Hp Laserjet Enterprise M855 M880 Flow Mfp Repair Manual 1 4br4o

LASERJET ENTERPRISE M855 LASERJET ENTERPRISE FLOW MFP M880 Repair Manual

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HP Color LaserJet Enterprise M855 and flow MFP M880 Repair Manual

Copyright and License

Trademark Credits

© 2013 Copyright Hewlett-Packard Development Company, L.P.

Microsoft®, Windows®, Windows® XP, and Windows Vista® are U.S. ed trademarks of Microsoft Corporation.

Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. The information contained herein is subject to change without notice. The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein. Part number: A2W77-90997 Edition 1, 11/2013

Conventions used in this guide TIP: Helpful hints or shortcuts. NOTE: Information that explains a concept or how to complete a task. IMPORTANT: CAUTION:

Information to help you avoid potential product error conditions.

Procedures that you should follow to avoid losing data or damaging the product.

WARNING! Alerts you to specific procedures that you must follow to avoid personal injury, catastrophic loss of data, or extensive damage to the product.

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Conventions used in this guide

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Table of contents

1 Removal and replacement ................................................................................................................................ 1 Removal and replacement strategy ...................................................................................................... 2 Considerations during removal and replacement ................................................................ 2 Required tools ...................................................................................................................... 3 Types of screws ................................................................................................................... 3 Service approach ................................................................................................................. 3 Before performing service .................................................................................................... 4 After performing service ....................................................................................................... 4 Parts removal order ............................................................................................................. 4 ed paper sizes and types ........................................................................................ 4 ed paper sizes for the input trays and duplexer ...................................... 5 ed paper types for the input trays and duplexer ..................................... 7 ed paper sizes for the finishing accessories ........................................... 9 ed paper types for the finishing accessories ........................................ 12 Customer-self repair assemblies ........................................................................................................ 14 Toner cartridge .................................................................................................................. 14 Imaging drum ..................................................................................................................... 15 Secondary transfer roller ................................................................................................... 16 Reinstall the secondary transfer roller ............................................................... 17 Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 .............................. 18 Intermediate transfer belt (ITB) .......................................................................................... 19 F .................................................................................................................................. 21 Switch back tray ................................................................................................................. 22 Formatter ........................................................................................................................... 23 Reinstall the formatter or install a replacement formatter ................................. 24 Hard-disk drive (HDD) or solid-state memory (SSM) ......................................................... 25 Identify the storage device ................................................................................ 25 Remove the HDD .............................................................................................. 26 Reinstall the HDD ............................................................................. 27 Remove the SSM .............................................................................................. 28 Reinstall the SSM ............................................................................. 29 Reinstall the product firmware ........................................................................... 30

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Memory DIMM ................................................................................................................... 32 Remove the memory DIMM .............................................................................. 32 Reinstall the memory DIMM .............................................................................. 33 Fax PCA (M880) ................................................................................................................ 35 Remove the fax PCA (M880) ............................................................................ 35 Document feeder mylar strip (M880) ................................................................................. 36 Install a replacement document feeder mylar strip (M880) ............................... 37 Document feeder white backing (M880) ............................................................................ 39 Install a replacement document feeder white backing (M880) .......................... 40 Background selector (M880) .............................................................................................. 44 Reinstall the background selector (M880) ......................................................... 46 Control assembly (M855) ......................................................................................... 47 Reinstall the control assembly (M855) .................................................... 52 Control assembly (M880) ......................................................................................... 53 Reinstall the control assembly (M880) .................................................... 57 Keyboard assembly (M880) ............................................................................................... 59 Remove the keyboard assembly (M880) .......................................................... 59 Reinstall the keyboard assembly (M880) .......................................................... 63 Pickup, feed, and separation rollers and pads ................................................................................... 67 Document-feeder roller (M880 only) .................................................................................. 68 Reinstall the document-feeder roller (M880 only) ............................................. 69 Document-feeder separation pad (M880 only) .................................................................. 70 Reinstall the document-feeder separation pad (M880 only) ............................. 72 Tray 1 rollers ...................................................................................................................... 75 Reinstall the Tray 1 rollers ................................................................................ 77 Tray 2, 1x500-sheet feeder, and 3x500-sheet feeder rollers ............................................. 78 Remove the Tray 2, 1x500-sheet feeder, and 3x500-sheet feeder rollers ........ 78 Reinstall the Tray 2, 1x500-sheet feeder, and 3x500-sheet feeder rollers ....... 79 High-capacity input (HCI) rollers ........................................................................................ 80 Remove the HCI rollers ..................................................................................... 80 Reinstall the HCI rollers .................................................................................... 81 Covers and doors ............................................................................................................................... 82 Location of major components ........................................................................................... 84 Scanner back cover (M880) ............................................................................................... 88 Scanner left cover (M880) ................................................................................................. 89 Remove the scanner left cover (M880) ............................................................. 89 Scanner right cover (M880) ............................................................................................... 90 Remove the scanner right cover (M880) ........................................................... 90 Scanner front cover (M880) ............................................................................................... 91 Remove the scanner front cover (M880) ........................................................... 91 Right upper rear cover (M855) ........................................................................................... 96

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Hardware integration pocket (HIP) cover (M855) .............................................................. 97 Hardware integration pocket (HIP) cover (M880) .............................................................. 98 Reinstall the HIP cover (M880) ....................................................................... 100 Face-down bin ................................................................................................................. 101 Reinstall the face-down bin ............................................................................. 102 Left rear cover .................................................................................................................. 104 Remove the left rear cover .............................................................................. 104 Switch back cover ............................................................................................................ 105 Lower right cover ............................................................................................................. 106 Rear upper rear cover (M880) ......................................................................................... 107 Right upper rear cover (M880) ......................................................................................... 108 Rear upper MFP cover (M880) ........................................................................................ 109 Reinstall the rear upper MFP cover (M880) .................................................... 110 Left upper rear cover and rear upper B cover (M880) ..................................................... 111 Remove the left upper rear cover and rear upper B cover (M880) ................. 111 Rear upper front cover (M880) ........................................................................................ 113 Remove the rear upper front cover (M880) ..................................................... 113 Front top cover ................................................................................................................. 115 Remove the front top cover ............................................................................. 115 Rear top cover (M855) ..................................................................................................... 116 Remove the rear top cover (M855) ................................................................. 116 Left cover ......................................................................................................................... 118 Remove the left cover ..................................................................................... 118 Right upper front cover (M855) ........................................................................................ 120 Remove the right upper front cover (M855) .................................................... 120 Right upper front cover (M880) ........................................................................................ 122 Remove the right upper front cover (M880) .................................................... 122 Right upper cover (M855) ................................................................................................ 124 Remove the right upper cover (M855) ............................................................ 124 Right door assembly ........................................................................................................ 129 Remove the right door assembly .................................................................... 129 Reinstall the right door assembly .................................................................... 132 Left front cover ................................................................................................................. 133 Remove the left front cover ............................................................................. 133 Install a replacement left front cover ............................................................... 136 Front door ........................................................................................................................ 137 Reinstall the front door .................................................................................... 141 Rear cover ....................................................................................................................... 143 Remove the rear cover .................................................................................... 143 Install a replacement rear cover ...................................................................... 144 Right rear cover ............................................................................................................... 146

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Remove the right rear cover ............................................................................ 146 Front inner cover .............................................................................................................. 147 Remove the front inner cover .......................................................................... 147 Reinstall the front inner cover ......................................................................... 148 Main assemblies ............................................................................................................................... 149 Location of major components ......................................................................................... 152 Document feeder assembly (M880) ................................................................................. 154 Remove the document feeder assembly (M880) ............................................ 154 Reinstall the document feeder assembly (M880) ............................................ 159 Scanner control board (SCB) (M880) .............................................................................. 160 Remove the SCB (M880) ................................................................................ 160 Scanner assembly (M880) ............................................................................................... 162 Remove the scanner assembly (M880) .......................................................... 162 Reinstall the scanner assembly (M880) .......................................................... 166 Interlock switch assembly ................................................................................................ 167 Remove the interlock switch assembly ........................................................... 167 Front-door open detection switch .................................................................................... 169 Remove the front-door open detection switch ................................................. 169 Reinstall the front-door-open detection switch ................................................ 171 Main switch assembly ...................................................................................................... 173 Remove the main switch assembly ................................................................. 173 Secondary transfer assembly .......................................................................................... 175 Remove the secondary transfer assembly ...................................................... 175 Reinstall the secondary transfer assembly ..................................................... 181 Multipurpose tray (Tray 1) drive assembly ....................................................................... 183 Remove the multipurpose tray (Tray 1) drive assembly .................................. 183 Multipurpose tray (Tray 1) guide assembly ...................................................................... 190 Remove the multipurpose tray guide assembly .............................................. 190 Tray 2 pickup unit ............................................................................................................ 191 Remove the Tray 2 pickup assembly .............................................................. 191 F home position sensor ............................................................................................ 192 Remove the f home position sensor ......................................................... 192 Reinstall the f home position sensor ........................................................ 193 Shutter gear holder assembly .......................................................................................... 194 Remove the shutter gear holder assembly ..................................................... 194 Reinstall the shutter gear holder assembly ..................................................... 196 F-edge area cooling fan FM10 (front) ....................................................................... 200 Remove the f-edge area cooling fan FM10 (front) ................................... 200 Reinstall the f-edge area cooling fan FM10 (front) ................................... 202 F-edge area cooling fan FM9 (rear) .......................................................................... 204 Remove the f-edge area cooling fan FM9 (rear) ...................................... 204

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Reinstall the f-edge area cooling fan FM9 (rear) ...................................... 205 F fan FM2 ................................................................................................................. 207 Remove the f fan FM2 .............................................................................. 207 Reinstall the f fan FM2 ............................................................................. 209 F fan duct .................................................................................................................. 211 Remove the f fan duct .............................................................................. 211 Reinstall the f fan duct .............................................................................. 213 Cartridge fan FM3 (yellow and magenta) ........................................................................ 214 Remove the cartridge fan FM3 (yellow and magenta) .................................... 214 Reinstall the cartridge fan FM3 (yellow and magenta) .................................... 216 Cartridge fan FM4 (cyan and black) ................................................................................ 218 Remove the cartridge fan FM4 (cyan and black) ............................................ 218 Reinstall the cartridge fan FM4 (cyan and black) ............................................ 220 Laser/scanner fan FM1 .................................................................................................... 222 Remove the laser/scanner fan FM1 ................................................................ 222 Reinstall the laser/scanner fan FM1 ................................................................ 224 Delivery fan FM8 .............................................................................................................. 226 Cartridge front area cooling fan FM7 ............................................................................... 228 Remove the cartridge front area cooling fan FM7 ........................................... 228 Reinstall the cartridge front area cooling fan FM7 .......................................... 229 Memory tag PCA ............................................................................................................. 230 Remove the memory tag PCA ........................................................................ 230 Reinstall the memory tag PCA and sheet-metal bracket ................................ 232 Image-drum motor ........................................................................................................... 233 Remove the image-drum motor ...................................................................... 233 F power supply ......................................................................................................... 235 Remove the f power supply ...................................................................... 235 Reinstall the f power supply ..................................................................... 236 Primary transfer-roller disengagement motor .................................................................. 238 Remove the primary transfer-roller disengagement motor .............................. 238 Intermediate transfer belt (ITB) alienation-drive assembly .............................................. 240 Remove the ITB alienation-drive assembly ..................................................... 240 F motor ..................................................................................................................... 242 Remove the f motor .................................................................................. 242 Intermediate transfer belt (ITB) motor .............................................................................. 243 Remove the ITB motor .................................................................................... 243 Toner-cartridge feed motor (black) .................................................................................. 244 Remove the toner-cartridge feed motor (black) .............................................. 244 Toner-cartridge feed motor (yellow, magenta, and cyan) ................................................ 245 Remove the toner-cartridge feed motor (yellow, magenta, and cyan) ............ 245 Environmental sensor ...................................................................................................... 247

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Remove the environmental sensor ................................................................. 247 Interconnect PCA (M855) ................................................................................................ 248 Remove the interconnect PCA (M855) ........................................................... 248 Reinstall the interconnect PCA (M855) ........................................................... 251 Interconnect PCA (M880) ................................................................................................ 252 Remove the interconnect PCA (M880) ........................................................... 252 Reinstall the interconnect PCA (M880) ........................................................... 254 Formatter case ................................................................................................................. 255 Remove the formatter case ............................................................................. 255 Reinstall the formatter case ............................................................................ 256 Formatter, formatter case, and interconnect board (ICB) ................................................ 257 Remove the formatter, formatter case, and ICB ............................................. 257 Reinstall the formatter, formatter case, and ICB ............................................. 259 High-voltage power supply (HVPS) B .............................................................................. 260 Remove the HVPS B ....................................................................................... 260 Reinstall the HVPS B ...................................................................................... 261 DC controller PCA ........................................................................................................... 263 Remove the DC controller PCA ...................................................................... 263 Color-plane registration (R) sensor assembly ............................................................ 264 Remove the R sensor assembly ................................................................ 264 Reinstall the R sensor assembly ................................................................ 267 Low-voltage power supply (LVPS) ................................................................................... 269 Remove the LVPS ........................................................................................... 269 High-voltage power supply (HVPS) A (first transfer) ....................................................... 272 Remove the HVPS A (first transfer) ................................................................ 272 Reinstall the HVPS A (first transfer) ................................................................ 274 Lifter-drive assembly ........................................................................................................ 276 Remove the lifter-drive assembly .................................................................... 276 Reinstall the lifter-drive assembly ................................................................... 278 Toner-cartridge drive assembly (yellow and magenta) .................................................... 280 Remove the toner-cartridge drive assembly (yellow and magenta) ................ 280 Reinstall the toner-cartridge drive assembly (yellow and magenta) ................ 281 Toner-cartridge drive assembly (cyan and black) ............................................................ 282 Remove the toner-cartridge drive assembly (cyan and black) ........................ 282 Reinstall the toner-cartridge drive assembly (cyan and black) ........................ 283 Cartridge interface PCA (cyan and black) ....................................................................... 284 Remove the cartridge interface PCA (cyan and black) ................................... 285 Cartridge interface PCA (yellow and magenta) ............................................................... 286 Remove the cartridge interface PCA (yellow and magenta) ........................... 287 Main drive assembly ........................................................................................................ 288 Remove the main drive assembly ................................................................... 289

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Reinstall the main drive assembly ................................................................... 290 Replace or reinstall the toner-cartridge drive assemblies or the main drive assembly .... 291 Replace the toner-cartridge drive assembly or the main drive assembly ........ 291 Reinstall the toner-cartridge drive assembly or the main drive assembly ....... 296 F drive assembly ....................................................................................................... 298 Remove the f drive assembly ................................................................... 298 Reinstall the f drive assembly .................................................................. 303 Scanner cover .................................................................................................................. 306 Remove the scanner cover ............................................................................. 306 Laser/scanner assembly (yellow and magenta) .............................................................. 307 Remove the laser/scanner assembly (yellow and magenta) ........................... 307 Reinstall the laser/scanner assembly (yellow and magenta) .......................... 311 Laser/scanner assembly (cyan and black) ...................................................................... 312 Remove the laser/scanner assembly (cyan and black) ................................... 312 Reinstall the laser/scanner assembly (cyan and black) .................................. 317 Duplex reverse assembly (M855) .................................................................................... 319 Remove the duplex reverse assembly (M855) ................................................ 319 Duplex reverse assembly (M880) .................................................................................... 320 Remove the duplex reverse assembly (M880) ................................................ 320 VOC fan (M855) ............................................................................................................... 321 Remove the VOC fan (M855) .......................................................................... 321 VOC fan (M880) ............................................................................................................... 323 Remove the VOC fan (M880) .......................................................................... 324 Face-down delivery assembly(M855) .............................................................................. 327 Remove the face-down delivery assembly (M855) ......................................... 327 Face-down delivery assembly (M880) ............................................................................. 332 Remove the face-down delivery assembly (M880) ......................................... 333 Face-down cover ............................................................................................................. 343 Remove the face-down cover ......................................................................... 344 Duplexing feed assembly ................................................................................................. 345 Reinstall the duplexing feed assembly ............................................................ 349 Multipurpose tray (Tray 1) pickup assembly .................................................................... 350 Remove the multipurpose tray (Tray 1) pickup assembly ............................... 350 Reinstall the multipurpose tray (Tray 1) pickup assembly ............................... 355 Input accessories ............................................................................................................................. 356 High-capacity input (HCI) feeder ..................................................................................... 357 Location of major components ........................................................................ 357 HCI right tray ................................................................................................... 360 HCI left tray ..................................................................................................... 361 HCI rear cover ................................................................................................. 362 HCI right lower cover ....................................................................................... 363

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Remove the HCI right lower cover .................................................. 363 HCI right tray pickup motor ............................................................................. 365 Remove the HCI right tray pickup motor ........................................ 365 HCI right tray pickup drive ............................................................................... 366 Remove the HCI right tray pickup drive .......................................... 366 HCI left tray pickup motor ................................................................................ 367 Remove the HCI left tray pickup motor ........................................... 367 HCI left tray pickup drive ................................................................................. 368 Remove the HCI left tray pickup drive ............................................ 368 HCI right tray lifter drive assembly .................................................................. 369 Remove the HCI right tray lifter drive assembly ............................. 369 HCI left tray lifter drive assembly .................................................................... 370 Remove the HCI left tray lifter drive assembly ............................... 370 HCI right tray media-level sensor assembly .................................................... 371 Remove the HCI right tray media-level sensor assembly ............... 371 HCI left tray media-level sensor assembly ...................................................... 372 Remove the HCI left tray media-level sensor assembly ................. 372 HCI right tray automatic close assembly ......................................................... 373 Remove the HCI right tray automatic close assembly .................... 373 HCI left tray automatic close assembly ........................................................... 374 Remove the HCI left tray automatic close assembly ...................... 374 HCI right tray pickup assembly ....................................................................... 375 Remove the HCI right tray pickup assembly .................................. 375 Reinstall the HCI right tray pickup assembly .................................. 376 HCI left tray pickup assembly .......................................................................... 377 Remove the HCI left tray pickup assembly ..................................... 377 Reinstall the HCI left tray pickup assembly .................................... 379 HCI merge assembly ....................................................................................... 380 Remove the HCI merge assembly .................................................. 380 Reinstall the HCI merge assembly ................................................. 381 HCI controller PCA .......................................................................................... 382 Remove the HCI controller PCA ..................................................... 382 1x500- and 3x500-sheet feeders ..................................................................................... 383 Location of major components ........................................................................ 383 1x500 and 3x500 rear cover ........................................................................... 387 1x500 and 3x500 right front cover ................................................................... 388 Remove the 1x500 and 3x500 right front cover .............................. 388 Reinstall the 1x500 and 3x500 right front cover ............................. 389 1x500 and 3x500 upper front face cover ......................................................... 390 Remove the 1x500 and 3x500 upper front face cover .................... 390 Reinstall the 1x500 and 3x500 upper front face cover ................... 391

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1x500 and 3x500 upper front cover ................................................................ 392 Remove the 1x500 and 3x500 right front cover .............................. 392 1x500 and 3x500 upper front left face cover ................................................... 395 Remove the 1x500 and 3x500 upper front left face cover .............. 395 1x500 storage box door .................................................................................. 396 Remove the 1x500 storage box door ............................................. 396 1x500 storage box ........................................................................................... 398 Remove the 1x500 storage box ...................................................... 398 1x500 and 3x500 right lower cover ................................................................. 400 Remove the 1x500 and 3x500 right lower cover ............................ 400 1x500 Tray 3 pickup assembly ........................................................................ 402 Remove the 1x500 Tray 3 pickup assembly ................................... 402 Reinstall the 1x500 Tray 3 pickup assembly .................................. 405 3x500 Tray 3 pickup assembly ........................................................................ 407 Remove the 3x500 Tray 3 pickup assembly ................................... 407 Reinstall the 3x500 Tray 3 pickup assembly .................................. 410 3x500 Tray 4 pickup assembly ........................................................................ 412 Remove the 3x500 Tray 4 pickup assembly ................................... 412 Reinstall the 3x500 Tray 4 pickup assembly .................................. 415 3x500 Tray 5 pickup assembly ........................................................................ 416 Remove the 3x500 Tray 5 pickup assembly ................................... 416 Reinstall the 3x500 Tray 5 pickup assembly .................................. 418 1x500 Tray 3 automatic close assembly ......................................................... 419 Remove the 1x500 Tray 3 automatic close assembly .................... 419 3x500 Tray 3, Tray 4, and Tray 5 automatic close assemblies ....................... 420 Remove the 3x500 Tray 3, Tray 4, and Tray 5 automatic close assemblies ...................................................................................... 420 1x500 Tray 3, 3x500 Tray 3, Tray 4, and Tray 5 pickup motors ..................... 422 Remove the 1x500 Tray 3, 3x500 Tray 3, Tray 4, and Tray 5 pickup motors ................................................................................. 422 1x500 and 3x500 controller PCA .................................................................... 424 Remove the HCI controller PCA ..................................................... 424 Shared input accessory covers and doors ....................................................................... 425 HCI, 1x500, and 3x500 left cover .................................................................... 425 Remove the HCI, 1x500, and 3x500 left cover ............................... 426 Reinstall the HCI, 1x500, and 3x500 left cover .............................. 427 HCI, 1x500, and 3x500 right door assembly ................................................... 428 Remove the HCI, 1x500, and 3x500 right door assembly .............. 428 HCI, 1x500, and 3x500 right rear cover .......................................................... 430 Remove the HCI, 1x500, and 3x500 right rear cover ..................... 430 Reinstall the HCI right rear cover ................................................... 432

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Intermediate paper transport unit (IPTU) .......................................................................................... 433 Location of major components ......................................................................................... 434 IPTU assembly ................................................................................................................ 437 IPTU rear cover ............................................................................................................... 439 Reinstall the IPTU rear cover .......................................................................... 440 IPTU driver PCA .............................................................................................................. 442 Remove the IPTU driver PCA ......................................................................... 442 IPTU finisher lock assembly ............................................................................................ 443 Remove the IPTU finisher lock assembly ....................................................... 443 IPTU fan assembly .......................................................................................................... 446 Remove the IPTU fan assembly ..................................................................... 446 IPTU side assembly ............................................................................................... 447 Remove the IPTU side assembly .......................................................... 447 Reinstall the IPTU side assembly .......................................................... 450 IPTU upper and lower guide assemblies ......................................................................... 451 Remove the IPTU upper and lower guide assemblies .................................... 451 Install a replacement IPTU upper guide assembly .......................................... 456 Finishing accessories ....................................................................................................................... 457 Identify the finishing accessories ..................................................................................... 458 Identifying finishing accessory covers and doors ............................................................ 460 Shared finishing accessory assemblies ........................................................................... 464 Top cover lock assembly ................................................................................. 466 Latch lower covers (front and rear) ................................................................. 468 Latch assembly ............................................................................................... 470 Remove the latch assembly ........................................................... 470 Open/closed stepped cover assembly ............................................................ 471 Upper stepped cover assembly ....................................................................... 472 Lower stepped cover assembly ....................................................................... 474 Remove the lower stepped cover assembly ................................... 474 Reinstall the lower stepped cover ................................................... 477 Top door assembly .......................................................................................... 478 Front door ........................................................................................................ 479 Remove the front door .................................................................... 479 Inner upper cover assembly ............................................................................ 480 Inner upper cover assembly (remove) ............................................ 481 Clutch assembly (front side) ............................................................................ 482 Remove the clutch assembly (front side) ....................................... 482 Sensor switch assembly .................................................................................. 483 Remove the sensor switch assembly ............................................. 483 Inner lower cover assembly ............................................................................ 486 Inner lower cover assembly (remove) ............................................ 488

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Front foot cover assembly ............................................................................... 490 Remove the front foot cover assembly ........................................... 490 Bin cable guide cover ...................................................................................... 492 Reinstall the bin cable guide cover ................................................. 495 Rear cover assembly ...................................................................................... 496 Remove the rear cover assembly ................................................... 496 Main controller PCA assembly ........................................................................ 498 Remove the main controller PCA assembly ................................... 498 Entrance upper guide assembly ...................................................................... 513 Remove the entrance upper guide assembly ................................. 513 Rear foot cover assembly ............................................................................... 516 Remove the rear foot cover assembly ............................................ 516 Stack wall upper assembly and upper wall guide assembly ........................... 518 Remove the stack wall upper assembly and upper wall guide assembly ........................................................................................ 518 Upper cross member assembly ...................................................................... 521 Remove the upper cross member assembly .................................. 521 Reinstall the upper cross member assembly .................................. 529 Paper feed drive assembly .............................................................................. 533 Remove the paper feed drive assembly ......................................... 533 Pressure roller assembly ................................................................................. 535 Remove the pressure roller assembly ............................................ 536 Stack upper bin and lower bin assemblies ...................................................... 540 Remove stack upper bin and lower bin assemblies ....................... 541 Reinstall the stack upper bin and lower bin assemblies ................. 544 Height wall assembly ...................................................................................... 546 Remove the height wall center assembly ....................................... 546 Reinstall the height wall assembly .................................................. 547 Paper face sensor and flag assembly ............................................................. 548 Remove the paper face sensor and flag assembly ........................ 548 Staple subassembly ........................................................................................ 553 Remove the staple subassembly .................................................... 553 Staple connecting cable assembly .................................................................. 556 Remove the staple connecting cable assembly ............................. 556 Staple assembly .............................................................................................. 558 Remove the staple assembly ......................................................... 558 Paper detect holder assembly ......................................................................... 562 Remove the paper detect holder assembly .................................... 562 Reinstall the paper detect holder assembly .................................... 563 Operation tray assembly ................................................................................. 564 Remove the operation tray assembly ............................................. 565

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Reinstall the operation tray assembly ............................................. 571 Swing guide assembly .................................................................................... 575 Remove the swing guide assembly ................................................ 576 Reinstall the swing guide assembly ................................................ 582 Return roller assembly .................................................................................... 586 Remove the return roller assembly ................................................. 587 Clutch assembly (rear side) ............................................................................ 588 Remove the clutch assembly (rear side) ........................................ 588 Stack ejection motor assembly ....................................................................... 591 Remove the stack ejection motor assembly ................................... 591 Press motor assembly ..................................................................................... 595 Remove the press motor assembly ................................................ 595 Common driver PCA assembly ....................................................................... 599 Remove the common controller PCA assembly ............................. 599 Interface cable assembly ................................................................................ 601 Remove the interface cable assembly ............................................ 601 Paper assembly ...................................................................................... 603 Remove the paper assembly ................................................. 603 Booklet maker accessory ................................................................................................. 607 Knob ................................................................................................................ 608 Saddle output bin assembly ............................................................................ 609 Reinstall the saddle output bin ....................................................... 610 Right cover assembly (BM PCA) ..................................................................... 611 Remove the right cover assembly (BM PCA) ................................. 611 Booklet maker controller PCA ......................................................................... 615 Remove the booklet maker controller PCA .................................... 615 Inner side plate assembly ............................................................................... 616 Remove the inner side plate assembly ........................................... 616 Before reinstalling the inner side plate assembly ........................... 620 Guide sensor assembly ................................................................................... 623 Remove the guide sensor assembly .............................................. 623 Guide motor assembly .................................................................................... 625 Remove the guide motor assembly ................................................ 625 Saddle motor assembly (SS and BM) ............................................................. 627 Remove the saddle motor assembly (SS and BM) ......................... 627 Saddle feed motor assembly ........................................................................... 629 Remove the saddle feed assembly ................................................ 629 Folding-motor mount assembly ....................................................................... 633 Remove the folding-motor mount assembly ................................... 633 Reinstall the folding-motor mount assembly ................................... 637 Delivery switch mount assembly ..................................................................... 638

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Remove the delivery switch mount assembly ................................. 638 Saddle stapler assembly ................................................................................. 641 Remove the saddle stapler assembly ............................................. 641 Lower left guide assembly ............................................................................... 643 Remove the lower left guide assembly ........................................... 643 Saddle delivery inner cover, front assembly ................................................... 645 Remove the saddle delivery inner cover, front assembly ............... 645 Saddle delivery inner cover, rear assembly .................................................... 647 Remove the saddle delivery inner cover, rear assembly ................ 647 Saddle guide assembly ................................................................................... 649 Remove the saddle guide assembly ............................................... 650 Reinstall the saddle guide assembly .............................................. 653 Saddle feed assembly ..................................................................................... 655 Remove the saddle feed assembly ................................................ 656 Reinstall the saddle feed assembly ................................................ 659 Saddle assembly ............................................................................................. 660 Remove the saddle assembly ........................................................ 661 Reinstall the saddle assembly ........................................................ 668 Upper delivery guide assembly ....................................................................... 669 Remove the upper delivery guide assembly ................................... 669 Saddle paper delivery assembly ..................................................................... 671 Remove the saddle paper delivery assembly ................................. 671 Reinstall the saddle paper delivery assembly ................................ 673 Saddle rear end sensor assembly ................................................................... 674 Remove the saddle rear end sensor assembly .............................. 675 Reinstall the saddle rear end sensor .............................................. 681 Booklet maker and stapler/stacker with hole punch accessories .................................... 682 Remove the punch front cover ........................................................................ 682 Punch lower front cover assembly .................................................................. 684 Remove the punch lower front cover assembly .............................. 684 Punch rear cover assembly ............................................................................. 686 Remove the punch rear cover assembly ........................................ 686 Punch controller PCA assembly ...................................................................... 687 Remove the punch controller PCA assembly ................................. 687 Reinstall the punch controller PCA assembly ................................. 687 Punch waste tray ............................................................................................. 688 Punch inner cover assembly ........................................................................... 689 Remove the punch inner cover assembly ...................................... 689 Punch top cover .............................................................................................. 691 Remove the punch top ................................................................... 691 Punch hole assembly ...................................................................................... 694

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Remove the punch hole assembly ................................................. 694 Reinstall the punch hole assembly ................................................. 699 Replace the punch hole assembly or the punch controller PCA assembly ..... 702 Set the punch hole assembly type .................................................. 702 Set the sensor adjustment values .................................................. 704 2 Parts and diagrams ....................................................................................................................................... 707 Order parts by authorized service providers .................................................................................... 708 Order parts, accessories, and supplies ........................................................................... 708 Related documentation and software .............................................................................. 708 Supplies part numbers ..................................................................................................... 708 Customer self-repair parts ............................................................................................... 709 Service replacement parts ............................................................................................... 711 Accessories ..................................................................................................................... 712 How to use the parts lists and diagrams .......................................................................................... 714 Assembly locations ........................................................................................................................... 715 Base product (no optional trays or accessories) .............................................................. 715 Stapler/stacker and booklet maker .................................................................................. 720 Stapler/stacker external assembly locator ...................................................... 722 Booklet maker ................................................................................................. 728 Intermediate paper transportation unit (IPTU) ................................................................. 734 1x500-sheet feeder .......................................................................................................... 738 3x500-sheet feeder .......................................................................................................... 740 High-capacity input (HCI) feeder ..................................................................................... 742 Document feeder and scanner assemblies (M880) .......................................................................... 748 Document feeder assemblies (M880) .............................................................................................. 750 Scanner assemblies (M880) ............................................................................................................. 754 Covers .............................................................................................................................................. 756 Right door assembly ......................................................................................................................... 760 Internal components ......................................................................................................................... 762 Internal components (1 of 6) ............................................................................................ 762 Internal components (2 of 6) ............................................................................................ 764 Internal components (3 of 6) ............................................................................................ 766 Internal components (4 of 6) ............................................................................................ 768 Internal components (5 of 6) ............................................................................................ 770 Internal components (6 of 6) ............................................................................................ 772 Intermediate paper transfer unit (IPTU) assemblies ......................................................................... 774 1x500-sheet feeder with stand (M855 only) covers .......................................................................... 776 1x500-sheet feeder with stand (M855 only) covers ......................................................... 776 1x500-sheet feeder with stand components .................................................................... 778 3x500-sheet feeder .......................................................................................................................... 780

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3x500-sheet feeder covers .............................................................................................. 780 3x500-sheet feeder components ..................................................................................... 782 High-capacity input (HCI) feeder ...................................................................................................... 784 Stapler stacker/booklet maker .......................................................................................................... 790 Stapler/stacker covers ..................................................................................................... 790 Booklet maker covers ...................................................................................................... 792 Finisher main body (1 of 3) .............................................................................................. 794 Finisher main body (2 of 3) .............................................................................................. 796 Finisher main body (3 of 3) .............................................................................................. 798 Stapler/stacker main body ............................................................................................... 800 Booklet maker main body ................................................................................................ 802 Booklet maker saddle assembly ...................................................................................... 804 Alphabetical parts list ....................................................................................................................... 808 Numerical parts list ........................................................................................................................... 825 Index ................................................................................................................................................................. 843

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List of tables

Table 1-1 ed paper sizes for the input trays and duplexer .................................................................... 5 Table 1-2 ed paper types ....................................................................................................................... 8 Table 1-3 ed paper sizes for the finishing accessories .......................................................................... 9 Table 1-4 ed paper types for the finishing accessories ....................................................................... 12 Table 1-5 M855 base product covers and doors (1 of 2) ................................................................................. 84 Table 1-6 M855 base product covers and doors (2 of 2) ................................................................................. 85 Table 1-7 M880 base product covers and doors (1 of 2) ................................................................................. 86 Table 1-8 M880 base product covers and doors (2 of 2) ................................................................................. 87 Table 1-9 Base product main assemblies (1 of 2) .......................................................................................... 152 Table 1-10 Base product main assemblies (2 of 2) ........................................................................................ 153 Table 1-11 External covers and doors ........................................................................................................... 357 Table 1-12 Main assemblies (1 of 2) .............................................................................................................. 358 Table 1-13 Main assemblies (2 of 2) .............................................................................................................. 359 Table 1-14 Printed circuit assembly (PCA) .................................................................................................... 359 Table 1-15 External covers and doors (1x500-sheet feeder) ......................................................................... 383 Table 1-16 External covers and doors (3x500-sheet feeder) ......................................................................... 384 Table 1-17 Main assemblies (1x500-sheet feeder) ........................................................................................ 385 Table 1-18 Main assemblies (3x500-sheet feeder) ........................................................................................ 385 Table 1-19 Printed circuit assembly (PCA) .................................................................................................... 386 Table 1-20 IPTU covers (1 of 2) ..................................................................................................................... 434 Table 1-21 IPTU covers (2 of 2) ..................................................................................................................... 435 Table 1-22 IPTU main assemblies ................................................................................................................. 435 Table 1-23 IPTU PCA ..................................................................................................................................... 436 Table 1-24 Stapler stacker covers and doors ................................................................................................ 460 Table 1-25 Stapler stacker with hole punch covers and doors ...................................................................... 461 Table 1-26 Booklet maker covers and doors ................................................................................................. 462 Table 1-27 Booklet maker with hole punch covers and doors ....................................................................... 463 Table 1-28 DIPSW settings ............................................................................................................................ 509 Table 1-29 Do not change these DIPSW settings .......................................................................................... 510 Table 1-30 LED601 and LED602 blinking patterns ........................................................................................ 703 Table 1-31 LED601 and LED602 blinking patterns ........................................................................................ 705 Table 2-1 Order parts, accessories, and supplies .......................................................................................... 708

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Table 2-2 Related documentation and software ............................................................................................ 708 Table 2-3 Supplies part numbers ................................................................................................................... 708 Table 2-4 Customer self-repair parts .............................................................................................................. 709 Table 2-5 Service replacement parts ............................................................................................................. 711 Table 2-6 M855 base product assembly locations (1 of 2) ............................................................................ 715 Table 2-7 M855 base product assembly locations (2 of 2) ............................................................................ 716 Table 2-8 M880 base product assembly locations (1 of 2) ............................................................................ 718 Table 2-9 M880 base product assembly locations (2 of 2) ............................................................................ 719 Table 2-10 Stapler/stacker and booklet maker main assemblies ................................................................... 720 Table 2-11 Stapler/stacker and booklet maker PCA ...................................................................................... 721 Table 2-12 Stapler/stacker external assembly locator ................................................................................... 722 Table 2-13 Stapler/stacker with hole puncher external assembly locator ...................................................... 723 Table 2-14 Staple stacker internal assembly locator ..................................................................................... 724 Table 2-15 Staple stacker with hole puncher internal assembly locator ........................................................ 725 Table 2-16 Staple stacker external assembly locator (door open) ................................................................. 726 Table 2-17 Staple stacker with hole puncher external assembly locator (door open) .................................... 727 Table 2-18 Booklet maker external assembly locator .................................................................................... 728 Table 2-19 Booklet maker with hole puncher external assembly locator ....................................................... 729 Table 2-20 Booklet maker internal assembly locator ..................................................................................... 730 Table 2-21 Booklet maker with hole puncher internal assembly locator ........................................................ 731 Table 2-22 Booklet maker external assembly locator (door open) ................................................................. 732 Table 2-23 Booklet maker with hole puncher external assembly locator (door open) ................................... 733 Table 2-24 IPTU external assembly locator (1 of 3) ....................................................................................... 734 Table 2-25 IPTU external assembly locator (2 of 3) ....................................................................................... 734 Table 2-26 IPTU external assembly locator (3 of 3) ....................................................................................... 735 Table 2-27 IPTU internal assembly locator (1 of 2) ........................................................................................ 736 Table 2-28 IPTU internal assembly locator (2 of 2) ........................................................................................ 736 Table 2-29 IPTU PCA ..................................................................................................................................... 737 Table 2-30 1x500-sheet feeder (1 of 2) .......................................................................................................... 738 Table 2-31 1x500-sheet feeder (2 of 2) .......................................................................................................... 739 Table 2-32 3x500-sheet feeder (1 of 2) .......................................................................................................... 740 Table 2-33 3x500-sheet feeder (2 of 2) .......................................................................................................... 741 Table 2-34 HCI feeder (1 of 6) ....................................................................................................................... 742 Table 2-35 HCI feeder (2 of 6) ....................................................................................................................... 743 Table 2-36 HCI feeder (3 of 6) ....................................................................................................................... 744 Table 2-37 HCI feeder (4 of 6) ....................................................................................................................... 745 Table 2-38 HCI feeder (5 of 6) ....................................................................................................................... 746 Table 2-39 HCI feeder (6 of 6) ....................................................................................................................... 746 Table 2-40 Document feeder and scanner assemblies (M880) ..................................................................... 749 Table 2-41 Document feeder assemblies (M880, 1 of 2) ............................................................................... 751 Table 2-42 Document feeder assemblies (M880, 2 of 2) ............................................................................... 753

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Table 2-43 Scanner assemblies (M880) ........................................................................................................ 755 Table 2-44 Covers (M855) ............................................................................................................................. 757 Table 2-45 Covers (M880) ............................................................................................................................. 759 Table 2-46 Right door assembly .................................................................................................................... 761 Table 2-47 Internal components (1 of 6) ........................................................................................................ 763 Table 2-48 Internal components (2 of 6) ........................................................................................................ 765 Table 2-49 Internal components (3 of 6) ........................................................................................................ 767 Table 2-50 Internal components (4 of 6) ........................................................................................................ 769 Table 2-51 Internal components (5 of 6) ........................................................................................................ 771 Table 2-52 Internal components (6 of 6) ........................................................................................................ 773 Table 2-53 Intermediate paper transfer unit (IPTU) assemblies .................................................................... 775 Table 2-54 1x500-sheet feeder with stand (M855 only) covers ..................................................................... 777 Table 2-55 1x500-sheet feeder with stand components ................................................................................ 779 Table 2-56 3x500-sheet feeder covers .......................................................................................................... 781 Table 2-57 3x500-sheet feeder components ................................................................................................. 783 Table 2-58 HCI feeder covers ........................................................................................................................ 785 Table 2-59 HCI feeder internal components (1 of 2) ...................................................................................... 787 Table 2-60 HCI feeder internal components (2 of 2) ...................................................................................... 789 Table 2-61 Stapler/stacker covers .................................................................................................................. 791 Table 2-62 Booklet maker covers ................................................................................................................... 793 Table 2-63 Finisher main body (1 of 3) .......................................................................................................... 795 Table 2-64 Finisher main body (2 of 3) .......................................................................................................... 797 Table 2-65 Finisher main body (3 of 3) .......................................................................................................... 799 Table 2-66 Stapler/stacker main body ............................................................................................................ 801 Table 2-67 Booklet maker main body ............................................................................................................. 803 Table 2-68 Booklet maker saddle assembly .................................................................................................. 807 Table 2-69 Alphabetical parts list ................................................................................................................... 808 Table 2-70 Numerical parts list ....................................................................................................................... 825

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List of figures

Figure 1-1 Screwdrivers ..................................................................................................................................... 3 Figure 1-2 Remove the toner cartridge ............................................................................................................ 14 Figure 1-3 Remove the image drum ................................................................................................................. 15 Figure 1-4 Remove the secondary transfer roller (1 of 2) ................................................................................ 16 Figure 1-5 Remove the secondary transfer roller (2 of 2) ................................................................................ 16 Figure 1-6 Reinstall the secondary transfer roller ............................................................................................ 17 Figure 1-7 Remove Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 ............................ 18 Figure 1-8 Remove the ITB (1 of 4) .................................................................................................................. 19 Figure 1-9 Remove the ITB (2 of 4) .................................................................................................................. 19 Figure 1-10 Remove the ITB (3 of 4) ................................................................................................................ 20 Figure 1-11 Remove the ITB (4 of 4) ................................................................................................................ 20 Figure 1-12 Remove the f (1 of 3) ............................................................................................................. 21 Figure 1-13 Remove the f (2 of 3) ............................................................................................................. 21 Figure 1-14 Remove the f (3 of 3) ............................................................................................................. 21 Figure 1-15 Remove the switch back tray ........................................................................................................ 22 Figure 1-16 Remove the formatter (1 of 2) ....................................................................................................... 23 Figure 1-17 Remove the formatter (2 of 2) ....................................................................................................... 23 Figure 1-18 Remove the HDD (1 of 2) ............................................................................................................. 26 Figure 1-19 Remove the HDD (2 of 2) ............................................................................................................. 26 Figure 1-20 Remove the SSM (1 of 2) ............................................................................................................. 28 Figure 1-21 Remove the SSM (2 of 2) ............................................................................................................. 28 Figure 1-22 Remove the memory DIMM (1 of 2) .............................................................................................. 32 Figure 1-23 Remove the memory DIMM (2 of 2) .............................................................................................. 32 Figure 1-24 Reinstall the memory DIMM .......................................................................................................... 33 Figure 1-25 Reinstall the memory DIMM .......................................................................................................... 33 Figure 1-26 Reinstall the memory DIMM .......................................................................................................... 34 Figure 1-27 Remove the fax PCA (M880; 1 of 2) ............................................................................................. 35 Figure 1-28 Remove the fax PCA (M880; 2 of 2) ............................................................................................. 35 Figure 1-29 Remove the document feeder mylar strip (M880; 1 of 4) ............................................................. 36 Figure 1-30 Remove the document feeder mylar strip (M880; 2 of 4) ............................................................. 36 Figure 1-31 Remove the document feeder mylar strip (M880; 3 of 4) ............................................................. 37 Figure 1-32 Remove the document feeder mylar strip (M880; 4 of 4) ............................................................. 37

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Figure 1-33 Install a replacement document feeder mylar strip (M880; 1 of 2) ................................................ 38 Figure 1-34 Install a replacement document feeder mylar strip (M880; 2 of 2) ................................................ 38 Figure 1-35 Remove the document feeder white backing (M880; 1 of 3) ........................................................ 39 Figure 1-36 Remove the document feeder white backing (M880; 2 of 3) ........................................................ 39 Figure 1-37 Remove the document feeder white backing (M880; 3 of 3) ........................................................ 40 Figure 1-38 Install a replacement document feeder white backing (M880; 1 of 6) .......................................... 40 Figure 1-39 Install a replacement document feeder white backing (M880; 2 of 6) .......................................... 41 Figure 1-40 Install a replacement document feeder white backing (M880; 3 of 6) .......................................... 41 Figure 1-41 Install a replacement document feeder white backing (M880; 4 of 6) .......................................... 42 Figure 1-42 Install a replacement document feeder white backing (M880; 5 of 6) .......................................... 42 Figure 1-43 Install a replacement document feeder white backing (M880; 6 of 6) .......................................... 43 Figure 1-44 Remove the background selector (M880; 1 of 4) .......................................................................... 44 Figure 1-45 Remove the background selector (M880; 2 of 4) .......................................................................... 44 Figure 1-46 Remove the background selector (M880; 3 of 4) .......................................................................... 45 Figure 1-47 Remove the background selector (M880; 4 of 4) .......................................................................... 45 Figure 1-48 Reinstall the background selector (M880) .................................................................................... 46 Figure 1-49 Remove the control assembly (M855; 1 of 10) ................................................................... 47 Figure 1-50 Remove the control assembly (M855; 2 of 10) ................................................................... 47 Figure 1-51 Remove the control assembly (M855; 3 of 10) ................................................................... 48 Figure 1-52 Remove the control assembly (M855; 4 of 10) ................................................................... 48 Figure 1-53 Remove the control assembly (M855; 5 of 10) ................................................................... 49 Figure 1-54 Remove the control assembly (M855; 6 of 10) ................................................................... 49 Figure 1-55 Remove the control assembly (M855; 7 of 10) ................................................................... 50 Figure 1-56 Remove the control assembly (M855; 8 of 10) ................................................................... 50 Figure 1-57 Remove the control assembly (M855; 9 of 10) ................................................................... 51 Figure 1-58 Remove the control assembly (M855; 10 of 10) ................................................................. 51 Figure 1-59 Reinstall the control (M855) ................................................................................................ 52 Figure 1-60 Remove the control assembly (M880; 1 of 8) ..................................................................... 53 Figure 1-61 Remove the control assembly (M880; 2 of 8) ..................................................................... 53 Figure 1-62 Remove the control assembly (M880; 3 of 8) ..................................................................... 54 Figure 1-63 Remove the control assembly (M880; 4 of 8) ..................................................................... 54 Figure 1-64 Remove the control assembly (M880; 5 of 8) ..................................................................... 55 Figure 1-65 Remove the control assembly (M880; 6 of 8) ..................................................................... 55 Figure 1-66 Remove the control assembly (M880; 7 of 8) ..................................................................... 56 Figure 1-67 Remove the control assembly (M880; 8 of 8) ..................................................................... 56 Figure 1-68 Reinstall the control assembly (M880; 1 of 3) ..................................................................... 57 Figure 1-69 Reinstall the control assembly (M880; 2 of 3) ..................................................................... 57 Figure 1-70 Reinstall the control assembly (M880; 3 of 3) ..................................................................... 58 Figure 1-71 Remove the keyboard assembly (M880; 1 of 7) ........................................................................... 59 Figure 1-72 Remove the keyboard assembly (M880; 2 of 7) ........................................................................... 60 Figure 1-73 Remove the keyboard assembly (M880; 3 of 7) ........................................................................... 60

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Figure 1-74 Remove the keyboard assembly (M880; 4 of 7) ........................................................................... 61 Figure 1-75 Remove the keyboard assembly (M880; 5 of 7) ........................................................................... 61 Figure 1-76 Remove the keyboard assembly (M880; 6 of 7) ........................................................................... 62 Figure 1-77 Remove the keyboard assembly (M880; 7 of 7) ........................................................................... 62 Figure 1-78 Reinstall the keyboard assembly (M880; 1 of 7) ........................................................................... 63 Figure 1-79 Reinstall the keyboard assembly (M880; 2 of 7) ........................................................................... 63 Figure 1-80 Reinstall the keyboard assembly (M880; 3 of 7) ........................................................................... 64 Figure 1-81 Reinstall the keyboard assembly (M880; 4 of 7) ........................................................................... 64 Figure 1-82 Reinstall the keyboard assembly (M880; 5 of 7) ........................................................................... 65 Figure 1-83 Reinstall the keyboard assembly (M880; 6 of 7) ........................................................................... 65 Figure 1-84 Reinstall the keyboard assembly (M880; 7 of 7) ........................................................................... 66 Figure 1-85 Remove the document-feeder roller (M880; 1 of 3) ...................................................................... 68 Figure 1-86 Remove the document-feeder roller (M880; 2 of 3) ...................................................................... 68 Figure 1-87 Remove the document-feeder roller (M880; 3 of 3) ...................................................................... 69 Figure 1-88 Reinstall the document-feeder roller (M880) ................................................................................ 69 Figure 1-89 Remove the document-feeder separation pad (M880; 1 of 4) ...................................................... 70 Figure 1-90 Remove the document-feeder separation pad (M880; 2 of 4) ...................................................... 70 Figure 1-91 Remove the document-feeder separation pad (M880; 3 of 4) ...................................................... 71 Figure 1-92 Remove the document-feeder separation pad (M880; 4 of 4) ...................................................... 71 Figure 1-93 Reinstall the document-feeder separation pad (M880; 1 of 5) ...................................................... 72 Figure 1-94 Reinstall the document-feeder separation pad (M880; 2 of 5) ...................................................... 72 Figure 1-95 Reinstall the document-feeder separation pad (M880; 3 of 5) ...................................................... 73 Figure 1-96 Reinstall the document-feeder separation pad (M880; 4 of 5) ...................................................... 73 Figure 1-97 Reinstall the document-feeder separation pad (M880; 5 of 5) ...................................................... 74 Figure 1-98 Remove the Tray 1 rollers (1 of 5) ................................................................................................ 75 Figure 1-99 Remove the Tray 1 rollers (2 of 5) ................................................................................................ 75 Figure 1-100 Remove the Tray 1 rollers (3 of 5) .............................................................................................. 76 Figure 1-101 Remove the Tray 1 rollers (4 of 5) .............................................................................................. 76 Figure 1-102 Remove the Tray 1 rollers (5 of 5) .............................................................................................. 76 Figure 1-103 Reinstall the Tray 1 rollers .......................................................................................................... 77 Figure 1-104 Remove the Tray 2, 1x500, and 3x500 rollers (1 of 2) ............................................................... 78 Figure 1-105 Remove the Tray 2, 1x500, and 3x500 rollers (2 of 2) ............................................................... 79 Figure 1-106 Reinstall the Tray 2, 1x500, and 3x500 rollers ........................................................................... 79 Figure 1-107 Remove the HCI rollers (1 of 2) .................................................................................................. 80 Figure 1-108 Remove the HCI rollers (2 of 2) .................................................................................................. 81 Figure 1-109 Reinstall the HCI rollers .............................................................................................................. 81 Figure 1-110 M855 base product covers and doors (1 of 2) ............................................................................ 84 Figure 1-111 M855 base product covers and doors (2 of 2) ............................................................................ 85 Figure 1-112 M880 base product covers and doors (1 of 2) ............................................................................ 86 Figure 1-113 M880 base product covers and doors (2 of 2) ............................................................................ 87 Figure 1-114 Remove the scanner back cover (M880; 1 of 2) ......................................................................... 88

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Figure 1-115 Remove the scanner back cover (M880; 2 of 2) ......................................................................... 88 Figure 1-116 Remove the scanner left cover (M880; 1 of 2) ............................................................................ 89 Figure 1-117 Remove the scanner left cover (M880; 2 of 2) ............................................................................ 89 Figure 1-118 Remove the scanner right cover (M880; 1 of 2) ......................................................................... 90 Figure 1-119 Remove the scanner right cover (M880; 2 of 2) ......................................................................... 90 Figure 1-120 Remove the scanner front cover (M880; 1 of 8) ......................................................................... 91 Figure 1-121 Remove the scanner front cover (M880; 2 of 8) ......................................................................... 92 Figure 1-122 Remove the scanner front cover (M880; 3 of 8) ......................................................................... 92 Figure 1-123 Remove the scanner front cover (M880; 4 of 8) ......................................................................... 93 Figure 1-124 Remove the scanner front cover (M880; 5 of 8) ......................................................................... 93 Figure 1-125 Remove the scanner front cover (M880; 6 of 8) ......................................................................... 94 Figure 1-126 Remove the scanner front cover (M880; 7 of 8) ......................................................................... 94 Figure 1-127 Remove the scanner front cover (M880; 8 of 8) ......................................................................... 95 Figure 1-128 Remove the right upper rear cover (M855) ................................................................................. 96 Figure 1-129 Remove the hardware integration pocket (HIP) cover (M855) ................................................... 97 Figure 1-130 Remove the HIP cover (M880; 1 of 3) ........................................................................................ 98 Figure 1-131 Remove the HIP cover (M880; 2 of 3) ........................................................................................ 98 Figure 1-132 Remove the HIP cover (M880; 3 of 3) ........................................................................................ 99 Figure 1-133 Reinstall the HIP cover (M880; 1 of 2) ...................................................................................... 100 Figure 1-134 Reinstall the HIP cover (M880; 2 of 2) ...................................................................................... 100 Figure 1-135 Remove the face-down bin (1 of 2) ........................................................................................... 101 Figure 1-136 Remove the face-down bin (2 of 2) ........................................................................................... 101 Figure 1-137 Reinstall the face-down bin (1 of 2) .......................................................................................... 102 Figure 1-138 Remove the face-down bin (2 of 2) ........................................................................................... 102 Figure 1-139 Correct installation of face-down bin. ........................................................................................ 103 Figure 1-140 Incorrect installation of face-down bin. ..................................................................................... 103 Figure 1-141 Remove the left rear cover (1 of 2) ........................................................................................... 104 Figure 1-142 Remove the left rear cover (2 of 2) ........................................................................................... 104 Figure 1-143 Remove the switch back cover (1 of 2) ..................................................................................... 105 Figure 1-144 Remove the switch back cover (2 of 2) ..................................................................................... 105 Figure 1-145 Remove the lower right cover (1 of 2) ....................................................................................... 106 Figure 1-146 Remove the lower right cover (2 of 2) ....................................................................................... 106 Figure 1-147 Remove the rear upper rear cover (M880; 1 of 2) .................................................................... 107 Figure 1-148 Remove the rear upper rear cover (M880; 2 of 2) .................................................................... 107 Figure 1-149 Remove the right upper rear cover (M880; 1 of 2) .................................................................... 108 Figure 1-150 Remove the right upper rear cover (M880; 2 of 2) .................................................................... 108 Figure 1-151 Remove the rear upper MFP cover (M880; 1 of 2) ................................................................... 109 Figure 1-152 Remove the rear upper MFP cover (M880; 2 of 2) ................................................................... 109 Figure 1-153 Reinstall the rear upper MFP cover (M880) .............................................................................. 110 Figure 1-154 Remove the left upper rear cover and rear upper B cover (M880; 1 of 3) ................................ 111 Figure 1-155 Remove the left upper rear cover and rear upper B cover (M880; 2 of 3) ................................ 112

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Figure 1-156 Remove the left upper rear cover and rear upper B cover (M880; 3 of 3) ................................ 112 Figure 1-157 Remove the rear upper front cover (M880; 1 of 2) ................................................................... 113 Figure 1-158 Remove the rear upper front cover (M880; 2 of 2) ................................................................... 114 Figure 1-159 Remove the front top cover (1 of 2) .......................................................................................... 115 Figure 1-160 Remove the front top cover (2 of 2) .......................................................................................... 115 Figure 1-161 Remove the rear top cover (M855; 1 of 3) ................................................................................ 116 Figure 1-162 Remove the rear top cover (M855; 2 of 3) ................................................................................ 117 Figure 1-163 Remove the rear top cover (M855; 3 of 3) ................................................................................ 117 Figure 1-164 Remove the left cover (1 of 2) ................................................................................................... 118 Figure 1-165 Remove the left cover (2 of 2) ................................................................................................... 119 Figure 1-166 Remove the right upper front cover (M855; 1 of 2) ................................................................... 120 Figure 1-167 Remove the right upper front cover (M855; 2 of 2) ................................................................... 121 Figure 1-168 Remove the right upper front cover (M880; 1 of 2) ................................................................... 122 Figure 1-169 Remove the right upper front cover (M880; 2 of 2) ................................................................... 123 Figure 1-170 Remove the right upper cover (M855; 1 of 9) ........................................................................... 124 Figure 1-171 Remove the right upper cover (M855; 2 of 9) ........................................................................... 125 Figure 1-172 Remove the right upper cover (M855; 3 of 9) ........................................................................... 125 Figure 1-173 Remove the right upper cover (M855; 4 of 9) ........................................................................... 126 Figure 1-174 Remove the right upper cover (M855; 5 of 9) ........................................................................... 126 Figure 1-175 Remove the right upper cover (M855; 6 of 9) ........................................................................... 127 Figure 1-176 Remove the right upper cover (M855; 7 of 9) ........................................................................... 127 Figure 1-177 Remove the right upper cover (M855; 8 of 9) ........................................................................... 128 Figure 1-178 Remove the right upper cover (M855; 9 of 9) ........................................................................... 128 Figure 1-179 Remove the right door assembly (1 of 7) .................................................................................. 129 Figure 1-180 Remove the right door assembly (2 of 7) .................................................................................. 129 Figure 1-181 Remove the right door assembly (3 of 7) .................................................................................. 130 Figure 1-182 Remove the right door assembly (4 of 7) .................................................................................. 130 Figure 1-183 Remove the right door assembly (5 of 7) .................................................................................. 131 Figure 1-184 Remove the right door assembly (6 of 7) .................................................................................. 131 Figure 1-185 Remove the right door assembly (7 of 7) .................................................................................. 132 Figure 1-186 Reinstall the right door assembly .............................................................................................. 132 Figure 1-187 Remove the left front cover (1 of 5) .......................................................................................... 133 Figure 1-188 Remove the left front cover (2 of 5) .......................................................................................... 134 Figure 1-189 Remove the left front cover (3 of 5) .......................................................................................... 134 Figure 1-190 Remove the left front cover (4 of 5) .......................................................................................... 135 Figure 1-191 Remove the left front cover (5 of 5) .......................................................................................... 135 Figure 1-192 Install a replacement left front cover ......................................................................................... 136 Figure 1-193 Remove the front door (1 of 9) .................................................................................................. 137 Figure 1-194 Remove the front door (2 of 9) .................................................................................................. 137 Figure 1-195 Remove the front door (3 of 9) .................................................................................................. 138 Figure 1-196 Remove the front door (4 of 9) .................................................................................................. 138

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Figure 1-197 Remove the front door (5 of 9) .................................................................................................. 139 Figure 1-198 Remove the front door (6 of 9) .................................................................................................. 139 Figure 1-199 Remove the front door (7 of 9) .................................................................................................. 140 Figure 1-200 Remove the front door (8 of 9) .................................................................................................. 140 Figure 1-201 Remove the front door (9 of 9) .................................................................................................. 141 Figure 1-202 Reinstall the front door (1 of 2) ................................................................................................. 141 Figure 1-203 Reinstall the front door (2 of 2) ................................................................................................. 142 Figure 1-204 Remove the rear cover (1 of 3) ................................................................................................. 143 Figure 1-205 Remove the rear cover (2 of 3) ................................................................................................. 143 Figure 1-206 Remove the rear cover (3 of 3) ................................................................................................. 144 Figure 1-207 Install a replacement rear cover (1 of 2) ................................................................................... 144 Figure 1-208 Install a replacement rear cover (2 of 2) ................................................................................... 145 Figure 1-209 Remove the right rear cover (1 of 2) ......................................................................................... 146 Figure 1-210 Remove the right rear cover (2 of 2) ......................................................................................... 146 Figure 1-211 Remove the front inner cover (1 of 2) ....................................................................................... 147 Figure 1-212 Remove the front inner cover (2 of 2) ....................................................................................... 148 Figure 1-213 Reinstall the front inner cover ................................................................................................... 148 Figure 1-214 Base product main assemblies (1 of 2) .................................................................................... 152 Figure 1-215 Base product main assemblies (2 of 2) .................................................................................... 153 Figure 1-216 Remove the document feeder assembly (M880; 1 of 9) ........................................................... 154 Figure 1-217 Remove the document feeder assembly (M880; 2 of 9) ........................................................... 155 Figure 1-218 Remove the document feeder assembly (M880; 3 of 9) ........................................................... 155 Figure 1-219 Remove the document feeder assembly (M880; 4 of 9) ........................................................... 156 Figure 1-220 Remove the document feeder assembly (M880; 5 of 9) ........................................................... 156 Figure 1-221 Remove the document feeder assembly (M880; 6 of 9) ........................................................... 157 Figure 1-222 Remove the document feeder assembly (M880; 7 of 9) ........................................................... 157 Figure 1-223 Remove the document feeder assembly (M880; 8 of 9) ........................................................... 158 Figure 1-224 Remove the document feeder assembly (M880; 9 of 9) ........................................................... 158 Figure 1-225 Remove the SCB (M880; 1 of 4) ............................................................................................... 160 Figure 1-226 Remove the SCB (M880; 2 of 4) ............................................................................................... 160 Figure 1-227 Remove the SCB (M880; 3 of 4) ............................................................................................... 161 Figure 1-228 Remove the SCB (M880; 4 of 4) ............................................................................................... 161 Figure 1-229 Remove the scanner assembly (M880; 1 of 7) ......................................................................... 162 Figure 1-230 Remove the scanner assembly (M880; 2 of 7) ......................................................................... 163 Figure 1-231 Remove the scanner assembly (M880; 3 of 7) ......................................................................... 163 Figure 1-232 Remove the scanner assembly (M880; 4 of 7) ......................................................................... 164 Figure 1-233 Remove the scanner assembly (M880; 5 of 7) ......................................................................... 164 Figure 1-234 Remove the scanner assembly (M880; 6 of 7) ......................................................................... 165 Figure 1-235 Remove the scanner assembly (M880; 7 of 7) ......................................................................... 165 Figure 1-236 Remove the interlock switch assembly (1 of 2) ........................................................................ 167 Figure 1-237 Remove the interlock switch assembly (2 of 2) ........................................................................ 168

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Figure 1-238 Remove the front-door open detection switch (1 of 4) .............................................................. 169 Figure 1-239 Remove the front-door open detection switch (2 of 4) .............................................................. 170 Figure 1-240 Remove the front-door open detection switch (3 of 4) .............................................................. 170 Figure 1-241 Remove the front-door open detection switch (4 of 4) .............................................................. 171 Figure 1-242 Reinstall the front-door-open detection switch (1 of 3) ............................................................. 171 Figure 1-243 Reinstall the front-door-open detection switch (2 of 3) ............................................................. 172 Figure 1-244 Reinstall the front-door-open detection switch (3 of 3) ............................................................. 172 Figure 1-245 Remove the main switch assembly (1 of 3) .............................................................................. 173 Figure 1-246 Remove the main switch assembly (2 of 3) .............................................................................. 174 Figure 1-247 Remove the main switch assembly (3 of 3) .............................................................................. 174 Figure 1-248 Remove the secondary transfer assembly (1 of 10) ................................................................. 175 Figure 1-249 Remove the secondary transfer assembly (2 of 10) ................................................................. 176 Figure 1-250 Remove the secondary transfer assembly (3 of 10) ................................................................. 176 Figure 1-251 Remove the secondary transfer assembly (4 of 10) ................................................................. 177 Figure 1-252 Remove the secondary transfer assembly (5 of 10) ................................................................. 177 Figure 1-253 Remove the secondary transfer assembly (6 of 10) ................................................................. 178 Figure 1-254 Remove the secondary transfer assembly (7 of 10) ................................................................. 178 Figure 1-255 Remove the secondary transfer assembly (8 of 10) ................................................................. 179 Figure 1-256 Remove the secondary transfer assembly (9 of 10) ................................................................. 180 Figure 1-257 Remove the secondary transfer assembly (10 of 10) ............................................................... 180 Figure 1-258 Reinstall the secondary transfer assembly (1 of 3) ................................................................... 181 Figure 1-259 Reinstall the secondary transfer assembly (2 of 3) ................................................................... 181 Figure 1-260 Reinstall the secondary transfer assembly (3 of 3) ................................................................... 182 Figure 1-261 Remove the multipurpose tray (Tray 1) drive assembly (1 of 13) ............................................. 183 Figure 1-262 Remove the multipurpose tray (Tray 1) drive assembly (2 of 13) ............................................. 184 Figure 1-263 Remove the multipurpose tray (Tray 1) drive assembly (3 of 13) ............................................. 184 Figure 1-264 Remove the multipurpose tray (Tray 1) drive assembly (4 of 13) ............................................. 185 Figure 1-265 Remove the multipurpose tray (Tray 1) drive assembly (5 of 13) ............................................. 185 Figure 1-266 Remove the multipurpose tray (Tray 1) drive assembly (6 of 13) ............................................. 186 Figure 1-267 Remove the multipurpose tray (Tray 1) drive assembly (7 of 13) ............................................. 186 Figure 1-268 Remove the multipurpose tray (Tray 1) drive assembly (8 of 13) ............................................. 187 Figure 1-269 Remove the multipurpose tray (Tray 1) drive assembly (9 of 13) ............................................. 187 Figure 1-270 Remove the multipurpose tray (Tray 1) drive assembly (10 of 13) ........................................... 188 Figure 1-271 Remove the multipurpose tray (Tray 1) drive assembly (11 of 13) ........................................... 188 Figure 1-272 Remove the multipurpose tray (Tray 1) drive assembly (12 of 13) ........................................... 189 Figure 1-273 Remove the multipurpose tray (Tray 1) drive assembly (13 of 13) ........................................... 189 Figure 1-274 Remove the multipurpose tray guide assembly ........................................................................ 190 Figure 1-275 Remove the Tray 2 pickup assembly ........................................................................................ 191 Figure 1-276 Remove the f home position sensor (1 of 3) ...................................................................... 192 Figure 1-277 Remove the f home position sensor (2 of 3) ...................................................................... 192 Figure 1-278 Remove the f home position sensor (3 of 3) ...................................................................... 193

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Figure 1-279 Reinstall the f home position sensor .................................................................................. 193 Figure 1-280 Remove the shutter gear holder assembly (1 of 5) ................................................................... 194 Figure 1-281 Remove the shutter gear holder assembly (2 of 5) ................................................................... 194 Figure 1-282 Remove the shutter gear holder assembly (3 of 5) ................................................................... 195 Figure 1-283 Remove the shutter gear holder assembly (4 of 5) ................................................................... 195 Figure 1-284 Remove the shutter gear holder assembly (5 of 5) ................................................................... 196 Figure 1-285 Reinstall the shutter gear holder assembly (1 of 6) .................................................................. 196 Figure 1-286 Reinstall the shutter gear holder assembly (2 of 6) .................................................................. 197 Figure 1-287 Reinstall the shutter gear holder assembly (3 of 6) .................................................................. 197 Figure 1-288 Reinstall the shutter gear holder assembly (4 of 6) .................................................................. 198 Figure 1-289 Reinstall the shutter gear holder assembly (5 of 6) .................................................................. 198 Figure 1-290 Reinstall the shutter gear holder assembly (6 of 6) .................................................................. 199 Figure 1-291 Remove the f-edge area cooling fan FM10 (front; 1 of 3) .................................................. 200 Figure 1-292 Remove the f-edge area cooling fan FM10 (front; 2 of 3) .................................................. 200 Figure 1-293 Remove the f-edge area cooling fan FM10 (front; 3 of 3) .................................................. 201 Figure 1-294 Reinstall the f-edge area cooling fan FM10 (front; 1 of 3) ................................................. 202 Figure 1-295 Reinstall the f-edge area cooling fan FM10 (front; 2 of 3) ................................................. 202 Figure 1-296 Reinstall the f-edge area cooling fan FM10 (front; 3 of 3) ................................................. 203 Figure 1-297 Remove the f-edge area cooling fan FM9 (rear; 1 of 3) ..................................................... 204 Figure 1-298 Remove the Remove the f-edge area cooling fan FM9 (rear; 2 of 3) ................................ 204 Figure 1-299 Remove the f-edge area cooling fan FM9 (rear; 3 of 3) ..................................................... 205 Figure 1-300 Reinstall the f-edge area cooling fan FM9 (rear; 1 of 3) .................................................... 205 Figure 1-301 Reinstall the f-edge area cooling fan FM9 (rear; 2 of 3) .................................................... 206 Figure 1-302 Reinstall the f-edge area cooling fan FM9 (rear; 3 of 3) .................................................... 206 Figure 1-303 Remove the f fan FM2 (1 of 5) ........................................................................................... 207 Figure 1-304 Remove the f fan FM2 (2 of 5) ........................................................................................... 207 Figure 1-305 Remove the f fan FM2 (3 of 5) ........................................................................................... 208 Figure 1-306 Remove the f fan FM2 (4 of 5) ........................................................................................... 208 Figure 1-307 Remove the f fan FM2 (5 of 5) ........................................................................................... 209 Figure 1-308 Reinstall the f fan FM2 (1 of 3) .......................................................................................... 209 Figure 1-309 Reinstall the f fan FM2 (2 of 3) .......................................................................................... 210 Figure 1-310 Reinstall the f fan FM2 (3 of 3) .......................................................................................... 210 Figure 1-311 Remove the f fan duct (1 of 3) ........................................................................................... 211 Figure 1-312 Remove the f fan duct (2 of 3) ........................................................................................... 212 Figure 1-313 Remove the f fan duct (3 of 3) ........................................................................................... 212 Figure 1-314 Reinstall the f fan duct ....................................................................................................... 213 Figure 1-315 Remove the cartridge fan FM3 (yellow and magenta; 1 of 5) ................................................... 214 Figure 1-316 Remove the cartridge fan FM3 (yellow and magenta; 2 of 5) ................................................... 214 Figure 1-317 Remove the cartridge fan FM3 (yellow and magenta; 3 of 5) ................................................... 215 Figure 1-318 Remove the cartridge fan FM3 (yellow and magenta; 4 of 5) ................................................... 215 Figure 1-319 Remove the cartridge fan FM3 (yellow and magenta; 5 of 5) ................................................... 216

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Figure 1-320 Reinstall the cartridge fan FM3 (yellow and magenta; 1 of 3) .................................................. 216 Figure 1-321 Reinstall the cartridge fan FM3 (yellow and magenta; 2 of 3) .................................................. 217 Figure 1-322 Reinstall the cartridge fan FM3 (yellow and magenta; 3 of 3) .................................................. 217 Figure 1-323 Remove the cartridge fan FM4 (cyan and black; 1 of 5) ........................................................... 218 Figure 1-324 Remove the cartridge fan FM4 (cyan and black; 2 of 5) ........................................................... 218 Figure 1-325 Remove the cartridge fan FM4 (cyan and black; 3 of 5) ........................................................... 219 Figure 1-326 Remove the cartridge fan FM4 (cyan and black; 4 of 5) ........................................................... 219 Figure 1-327 Remove the cartridge fan FM4 (cyan and black; 5 of 5) ........................................................... 220 Figure 1-328 Reinstall the cartridge fan FM4 (cyan and black; 1 of 2) .......................................................... 220 Figure 1-329 Reinstall the cartridge fan FM4 (cyan and black; 2 of 3) .......................................................... 221 Figure 1-330 Reinstall the cartridge fan FM4 (cyan and black; 3 of 3) .......................................................... 221 Figure 1-331 Remove the laser/scanner fan FM1 (1 of 4) ............................................................................. 222 Figure 1-332 Remove the laser/scanner fan FM1 (2 of 4) ............................................................................. 222 Figure 1-333 Remove the laser/scanner fan FM1 (3 of 4) ............................................................................. 223 Figure 1-334 Remove the laser/scanner fan FM1 (4 of 4) ............................................................................. 223 Figure 1-335 Reinstall the laser/scanner fan FM1 (1 of 3) ............................................................................. 224 Figure 1-336 Reinstall the laser/scanner fan FM1 (2 of 3) ............................................................................. 224 Figure 1-337 Reinstall the laser/scanner fan FM1 (3 of 3) ............................................................................. 225 Figure 1-338 Remove the delivery fan FM8 (1 of 3) ...................................................................................... 226 Figure 1-339 Remove the delivery fan FM8 (2 of 3) ...................................................................................... 226 Figure 1-340 Remove the delivery fan FM8 (3 of 3) ...................................................................................... 227 Figure 1-341 Remove the cartridge front area cooling fan FM7 (1 of 2) ........................................................ 228 Figure 1-342 Remove the cartridge front area cooling fan FM7 (2 of 2) ........................................................ 229 Figure 1-343 Reinstall the cartridge front area cooling fan FM7 .................................................................... 229 Figure 1-344 Remove the memory tag PCA (1 of 3) ...................................................................................... 230 Figure 1-345 Remove the memory tag PCA (2 of 3) ...................................................................................... 231 Figure 1-346 Remove the memory tag PCA (3 of 3) ...................................................................................... 231 Figure 1-347 Reinstall the memory tag PCA .................................................................................................. 232 Figure 1-348 Remove the image-drum motor (1 of 2) .................................................................................... 233 Figure 1-349 Remove the image-drum motor (2 of 2) .................................................................................... 234 Figure 1-350 Remove the f power supply (1 of 2) ................................................................................... 235 Figure 1-351 Remove the f power supply (2 of 2) ................................................................................... 236 Figure 1-352 Reinstall the f power supply (1 of 2) .................................................................................. 236 Figure 1-353 Reinstall the f power supply (2 of 2) .................................................................................. 237 Figure 1-354 Remove the primary transfer-roller disengagement motor (1 of 2) ........................................... 238 Figure 1-355 Remove the primary transfer-roller disengagement motor (2 of 2) ........................................... 239 Figure 1-356 Remove the ITB alienation drive assembly (1 of 2) .................................................................. 240 Figure 1-357 Remove the ITB alienation drive assembly (2 of 2) .................................................................. 241 Figure 1-358 Remove the f motor (1 of 2) ............................................................................................... 242 Figure 1-359 Remove the f motor (2 of 2) ............................................................................................... 242 Figure 1-360 Remove the ITB motor (1 of 2) ................................................................................................. 243

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Figure 1-361 Remove the ITB motor (2 of 2) ................................................................................................. 243 Figure 1-362 Remove the toner-cartridge feed motor (black; 1 of 2) ............................................................. 244 Figure 1-363 Remove the toner-cartridge feed motor (black; 2 of 2) ............................................................. 244 Figure 1-364 Remove the toner-cartridge feed motor (yellow, magenta, and cyan; 1 of 2) ........................... 245 Figure 1-365 Remove the toner-cartridge feed motor (yellow, magenta, and cyan; 2 of 2) ........................... 246 Figure 1-366 Remove the environmental sensor ........................................................................................... 247 Figure 1-367 Remove the interconnect PCA (M855; 1 of 4) .......................................................................... 248 Figure 1-368 Remove the interconnect PCA (M855; 2 of 4) .......................................................................... 249 Figure 1-369 Remove the interconnect PCA (M855; 3 of 4) .......................................................................... 249 Figure 1-370 Remove the interconnect PCA (M855; 4 of 4) .......................................................................... 250 Figure 1-371 Reinstall the interconnect PCA (M855) ..................................................................................... 251 Figure 1-372 Remove the interconnect PCA (M880; 1 of 4) .......................................................................... 252 Figure 1-373 Remove the interconnect PCA (M880; 2 of 4) .......................................................................... 253 Figure 1-374 Remove the interconnect PCA (M880; 3 of 4) .......................................................................... 253 Figure 1-375 Remove the interconnect PCA (M880; 4 of 4) .......................................................................... 254 Figure 1-376 Reinstall the interconnect PCA (M880) ..................................................................................... 254 Figure 1-377 Remove the formatter case (1 of 2) .......................................................................................... 255 Figure 1-378 Remove the formatter case (2 of 2) .......................................................................................... 256 Figure 1-379 Reinstall the formatter case ...................................................................................................... 256 Figure 1-380 Remove the formatter, formatter case, and ICB (1 of 4) ........................................................... 257 Figure 1-381 Remove the formatter, formatter case, and ICB (2 of 4) ........................................................... 258 Figure 1-382 Remove the formatter, formatter case, and ICB (3 of 4) ........................................................... 258 Figure 1-383 Remove the formatter, formatter case, and ICB (4 of 4) ........................................................... 259 Figure 1-384 Reinstall the formatter, formatter case, and ICB ....................................................................... 259 Figure 1-385 Remove the HVPS B (1 of 2) .................................................................................................... 260 Figure 1-386 Remove the HVPS B (2 of 2) .................................................................................................... 261 Figure 1-387 Reinstall the HVPS B (1 of 2) .................................................................................................... 261 Figure 1-388 Reinstall the HVPS B (2 of 2) .................................................................................................... 262 Figure 1-389 Remove the DC controller PCA ................................................................................................ 263 Figure 1-390 Remove the R sensor assembly (1 of 5) ............................................................................. 264 Figure 1-391 Remove the R sensor assembly (2 of 5) ............................................................................. 265 Figure 1-392 Remove the R sensor assembly (3 of 5) ............................................................................. 265 Figure 1-393 Remove the R sensor assembly (4 of 5) ............................................................................. 266 Figure 1-394 Remove the R sensor assembly (5 of 5) ............................................................................. 266 Figure 1-395 Reinstall the R sensor assembly (1 of 4) ............................................................................. 267 Figure 1-396 Reinstall the R sensor assembly (2 of 4) ............................................................................. 267 Figure 1-397 Reinstall the R sensor assembly (3 of 4) ............................................................................. 268 Figure 1-398 Reinstall the R sensor assembly (4 of 4) ............................................................................. 268 Figure 1-399 Remove the LVPS (1 of 5) ........................................................................................................ 269 Figure 1-400 Remove the LVPS (2 of 5) ........................................................................................................ 269 Figure 1-401 Remove the LVPS (3 of 5) ........................................................................................................ 270

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Figure 1-402 Remove the LVPS (4 of 5) ........................................................................................................ 270 Figure 1-403 Remove the LVPS (5 of 5) ........................................................................................................ 271 Figure 1-404 Remove the HVPS A (first transfer) (1 of 3 ............................................................................... 272 Figure 1-405 Remove the HVPS A (first transfer) (2 of 3) .............................................................................. 273 Figure 1-406 Remove the HVPS A (first transfer) (3 of 3) .............................................................................. 273 Figure 1-407 Reinstall the HVPS A (first transfer) (1 of 3) ............................................................................. 274 Figure 1-408 Reinstall the HVPS A (first transfer) (2 of 3) ............................................................................. 274 Figure 1-409 Reinstall the HVPS A (first transfer) (3 of 3) ............................................................................. 275 Figure 1-410 Remove the lifter-drive assembly (1 of 3) ................................................................................. 276 Figure 1-411 Remove the lifter-drive assembly (2 of 3) ................................................................................. 277 Figure 1-412 Remove the lifter-drive assembly (3 of 3) ................................................................................. 277 Figure 1-413 Unlocked position of the lifter-driver assembly (correct) ........................................................... 278 Figure 1-414 Locked position of the lifter-driver assembly (incorrect) ........................................................... 278 Figure 1-415 Unlocking the lifter-drive assembly ........................................................................................... 279 Figure 1-416 Remove the toner-cartridge drive assembly (yellow and magenta) .......................................... 280 Figure 1-417 Reinstall the toner-cartridge drive assembly (yellow and magenta) ......................................... 281 Figure 1-418 Remove the toner-cartridge drive assembly (cyan and black) .................................................. 283 Figure 1-419 Reinstall the toner-cartridge drive assembly (cyan and black) ................................................. 283 Figure 1-420 Remove the cartridge interface PCA (cyan and black) ............................................................. 285 Figure 1-421 Remove the cartridge interface PCA (yellow and magenta) ..................................................... 287 Figure 1-422 Remove the main drive assembly (1 of 2) ................................................................................ 289 Figure 1-423 Remove the main drive assembly (2 of 2) ................................................................................ 289 Figure 1-424 Reinstall the main drive assembly ............................................................................................ 290 Figure 1-425 Replace the toner-cartridge drive assembly or the main drive assembly (1 of 8) ..................... 291 Figure 1-426 Replace the toner-cartridge drive assembly or the main drive assembly (2 of 8) ..................... 292 Figure 1-427 Replace the toner-cartridge drive assembly or the main drive assembly (3 of 8) ..................... 292 Figure 1-428 Replace the toner-cartridge drive assembly or the main drive assembly (4 of 8) ..................... 293 Figure 1-429 Replace the toner-cartridge drive assembly or the main drive assembly (5 of 8) ..................... 293 Figure 1-430 Correct position of toner-cartridge drive assembly (6 of 8) ....................................................... 294 Figure 1-431 Incorrect position of toner-cartridge drive assembly (7 of 8) ..................................................... 294 Figure 1-432 Replace the toner-cartridge drive assembly or the main drive assembly (8 of 8) ..................... 295 Figure 1-433 Reinstall the toner-cartridge drive assembly or the main drive assembly (1 of 4) .................... 296 Figure 1-434 Reinstall the toner-cartridge drive assembly or the main drive assembly (2 of 4) .................... 296 Figure 1-435 Correct position of toner-cartridge drive assembly (3 of 4) ....................................................... 297 Figure 1-436 Incorrect position of toner-cartridge drive assembly (4 of 4) ..................................................... 297 Figure 1-437 Remove the f drive assembly (1 of 10) .............................................................................. 298 Figure 1-438 Remove the f drive assembly (2 of 10) .............................................................................. 299 Figure 1-439 Remove the f drive assembly (3 of 10) .............................................................................. 299 Figure 1-440 Remove the f drive assembly (4 of 10) .............................................................................. 300 Figure 1-441 Remove the f drive assembly (5 of 10) .............................................................................. 300 Figure 1-442 Remove the f drive assembly (6 of 10) .............................................................................. 301

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Figure 1-443 Remove the f drive assembly (7 of 10) .............................................................................. 301 Figure 1-444 Remove the f drive assembly (8 of 10) .............................................................................. 302 Figure 1-445 Remove the f drive assembly (9 of 10) .............................................................................. 302 Figure 1-446 Remove the f drive assembly (10 of 10) ............................................................................ 303 Figure 1-447 Reinstall the f drive assembly (1 of 4) ................................................................................ 303 Figure 1-448 Reinstall the f drive assembly (2 of 4) ................................................................................ 304 Figure 1-449 Reinstall the f drive assembly (3 of 4) ................................................................................ 304 Figure 1-450 Reinstall the f drive assembly (4 of 4) ................................................................................ 305 Figure 1-451 Remove the scanner cover ....................................................................................................... 306 Figure 1-452 Remove the laser/scanner assembly (yellow and magenta; 1 of 6) ......................................... 307 Figure 1-453 Remove the laser/scanner assembly (yellow and magenta; 2 of 6) ......................................... 308 Figure 1-454 Remove the laser/scanner assembly (yellow and magenta; 3 of 6) ......................................... 309 Figure 1-455 Remove the laser/scanner assembly (yellow and magenta; 4 of 6) ......................................... 309 Figure 1-456 Remove the laser/scanner assembly (yellow and magenta; 5 of 6) ......................................... 310 Figure 1-457 Remove the laser/scanner assembly (yellow and magenta; 6 of 6) ......................................... 310 Figure 1-458 Reinstall the laser/scanner assembly (yellow and magenta; 1 of 2) ......................................... 311 Figure 1-459 Reinstall the laser/scanner assembly (yellow and magenta; 2 of 2) ......................................... 311 Figure 1-460 Remove the laser/scanner assembly (cyan and black; 1 of 8) ................................................. 312 Figure 1-461 Remove the laser/scanner assembly (cyan and black; 2 of 8) ................................................. 313 Figure 1-462 Remove the laser/scanner assembly (cyan and black; 3 of 8) ................................................. 313 Figure 1-463 Remove the laser/scanner assembly (cyan and black; 4 of 8) ................................................. 314 Figure 1-464 Remove the laser/scanner assembly (cyan and black; 5 of 8) ................................................. 315 Figure 1-465 Remove the laser/scanner assembly (cyan and black; 6 of 8) ................................................. 315 Figure 1-466 Remove the laser/scanner assembly (cyan and black; 7 of 8) ................................................. 316 Figure 1-467 Remove the laser/scanner assembly (cyan and black; 8 of 8) ................................................. 316 Figure 1-468 Reinstall the laser/scanner assembly (cyan and black; 1 of 3) ................................................. 317 Figure 1-469 Reinstall the laser/scanner assembly (cyan and black; 2 of 3) ................................................. 317 Figure 1-470 Reinstall the laser/scanner assembly (cyan and black; 3 of 3) ................................................. 318 Figure 1-471 Remove the duplex reverse assembly (M855) ......................................................................... 319 Figure 1-472 Remove the duplex reverse assembly (M880) ......................................................................... 320 Figure 1-473 Remove the VOC fan (M855; 1 of 2) ........................................................................................ 321 Figure 1-474 Remove the VOC fan (M855; 2 of 2) ........................................................................................ 322 Figure 1-475 Remove the VOC fan (M880; 1 of 6) ........................................................................................ 324 Figure 1-476 Remove the VOC fan (M880; 2 of 6) ........................................................................................ 324 Figure 1-477 Remove the VOC fan (M880; 3 of 6) ........................................................................................ 325 Figure 1-478 Remove the VOC fan (M880; 4 of 6) ........................................................................................ 325 Figure 1-479 Remove the VOC fan (M880; 5 of 6) ........................................................................................ 326 Figure 1-480 Remove the VOC fan (M880; 6 of 6) ........................................................................................ 326 Figure 1-481 Remove the face-down delivery assembly (M855; 1 of 8) ........................................................ 327 Figure 1-482 Remove the face-down delivery assembly (M855; 2 of 8) ........................................................ 328 Figure 1-483 Remove the face-down delivery assembly (M855; 3 of 8) ........................................................ 328

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Figure 1-484 Remove the face-down delivery assembly (M855; 4 of 8) ........................................................ 329 Figure 1-485 Remove the face-down delivery assembly (M855; 5 of 8) ........................................................ 329 Figure 1-486 Remove the face-down delivery assembly (M855; 6 of 8) ........................................................ 330 Figure 1-487 Remove the face-down delivery assembly (M855; 7 of 8) ........................................................ 330 Figure 1-488 Remove the face-down delivery assembly (M855; 8 of 8) ........................................................ 331 Figure 1-489 Remove the face-down delivery assembly (M880; 1 of 19) ...................................................... 333 Figure 1-490 Remove the face-down delivery assembly (M880; 2 of 19) ...................................................... 333 Figure 1-491 Remove the face-down delivery assembly (M880; 3 of 19) ...................................................... 334 Figure 1-492 Remove the face-down delivery assembly (M880; 4 of 19) ...................................................... 334 Figure 1-493 Remove the face-down delivery assembly (M880; 5 of 19) ...................................................... 335 Figure 1-494 Remove the face-down delivery assembly (M880; 6 of 19) ...................................................... 335 Figure 1-495 Remove the face-down delivery assembly (M880; 7 of 19) ...................................................... 336 Figure 1-496 Remove the face-down delivery assembly (M880; 8 of 19) ...................................................... 336 Figure 1-497 Remove the face-down delivery assembly (M880; 9 of 19) ...................................................... 337 Figure 1-498 Remove the face-down delivery assembly (M880; 10 of 19) .................................................... 337 Figure 1-499 Remove the face-down delivery assembly (M880; 11 of 19) .................................................... 338 Figure 1-500 Remove the face-down delivery assembly (M880; 12 of 19) .................................................... 339 Figure 1-501 Remove the face-down delivery assembly (M880; 13 of 19) .................................................... 339 Figure 1-502 Remove the face-down delivery assembly (M880; 14 of 19) .................................................... 340 Figure 1-503 Remove the face-down delivery assembly (M880; 15 of 19) .................................................... 340 Figure 1-504 Remove the face-down delivery assembly (M880; 16 of 19) .................................................... 341 Figure 1-505 Remove the face-down delivery assembly (M880; 17 of 19) .................................................... 341 Figure 1-506 Remove the face-down delivery assembly (M880; 18 of 19) .................................................... 342 Figure 1-507 Remove the face-down delivery assembly (M880; 19 of 19) .................................................... 342 Figure 1-508 Remove face-down cover ......................................................................................................... 344 Figure 1-509 Remove the duplexing feed assembly (1 of 7) ......................................................................... 345 Figure 1-510 Remove the duplexing feed assembly (2 of 7) ......................................................................... 345 Figure 1-511 Remove the duplexing feed assembly (3 of 7) ......................................................................... 346 Figure 1-512 Remove the duplexing feed assembly (4 of 7) ......................................................................... 346 Figure 1-513 Remove the duplexing feed assembly (5 of 7) ......................................................................... 347 Figure 1-514 Remove the duplexing feed assembly (6 of 7) ......................................................................... 347 Figure 1-515 Remove the duplexing feed assembly (7 of 7) ......................................................................... 348 Figure 1-516 Remove the multipurpose tray (Tray 1) pickup assembly (1 of 10) .......................................... 350 Figure 1-517 Remove the multipurpose tray (Tray 1) pickup assembly (2 of 10) .......................................... 350 Figure 1-518 Remove the multipurpose tray (Tray 1) pickup assembly (3 of 10) .......................................... 351 Figure 1-519 Remove the multipurpose tray (Tray 1) pickup assembly (4 of 10) .......................................... 351 Figure 1-520 Remove the multipurpose tray (Tray 1) pickup assembly (5 of 10) .......................................... 352 Figure 1-521 Remove the multipurpose tray (Tray 1) pickup assembly (6 of 10) .......................................... 352 Figure 1-522 Remove the multipurpose tray (Tray 1) pickup assembly (7 of 10) .......................................... 353 Figure 1-523 Remove the multipurpose tray (Tray 1) pickup assembly (8 of 10) .......................................... 353 Figure 1-524 Remove the multipurpose tray (Tray 1) pickup assembly (9 of 10) .......................................... 354

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Figure 1-525 Remove the multipurpose tray (Tray 1) pickup assembly (10 of 10) ........................................ 354 Figure 1-526 Reinstall the multipurpose tray (Tray 1) pickup assembly ........................................................ 355 Figure 1-527 External covers and doors ........................................................................................................ 357 Figure 1-528 Main assemblies (1 of 2) ........................................................................................................... 358 Figure 1-529 Main assemblies (2 of 2) ........................................................................................................... 359 Figure 1-530 Printed circuit assembly (PCA) ................................................................................................. 359 Figure 1-531 Remove the HCI right tray ........................................................................................................ 360 Figure 1-532 Remove the HCI left tray ........................................................................................................... 361 Figure 1-533 Remove the HCI rear cover ...................................................................................................... 362 Figure 1-534 Remove the HCI right lower cover (1 of 2) ................................................................................ 363 Figure 1-535 Remove the HCI right lower cover (2 of 2) ................................................................................ 364 Figure 1-536 Remove the HCI right tray pickup motor ................................................................................... 365 Figure 1-537 Remove the HCI right tray pickup drive (1 of 2) ........................................................................ 366 Figure 1-538 Remove the HCI left tray pickup motor ..................................................................................... 367 Figure 1-539 Remove the HCI left tray pickup drive ...................................................................................... 368 Figure 1-540 Remove the HCI right tray lifter drive assembly ........................................................................ 369 Figure 1-541 Remove the HCI left tray lifter drive assembly .......................................................................... 370 Figure 1-542 Remove the HCI right tray media-level sensor assembly (1 of 2) ............................................ 371 Figure 1-543 Remove the HCI right tray media-level sensor assembly (2 of 2) ............................................ 371 Figure 1-544 Remove the HCI left tray media-level sensor assembly (1 of 2) ............................................... 372 Figure 1-545 Remove the HCI left tray media-level sensor assembly (2 of 2) ............................................... 372 Figure 1-546 Remove the HCI right tray automatic close assembly (1 of 2) .................................................. 373 Figure 1-547 Remove the HCI right tray automatic close assembly (2 of 2) .................................................. 373 Figure 1-548 Remove the HCI left tray automatic close assembly (1 of 2) .................................................... 374 Figure 1-549 Remove the HCI left tray automatic close assembly (2 of 2) .................................................... 374 Figure 1-550 Remove the HCI right tray pickup assembly (1 of 3) ................................................................ 375 Figure 1-551 Remove the HCI right tray pickup assembly (2 of 3) ................................................................ 375 Figure 1-552 Remove the HCI right tray pickup assembly (3 of 3) ................................................................ 376 Figure 1-553 Reinstall the HCI right tray pickup assembly ............................................................................ 376 Figure 1-554 Remove the HCI left tray pickup assembly (1 of 2) .................................................................. 377 Figure 1-555 Remove the HCI left tray pickup assembly (2 of 2) .................................................................. 378 Figure 1-556 Reinstall the HCI left tray pickup assembly (1 of 2) .................................................................. 379 Figure 1-557 Reinstall the HCI left tray pickup assembly (2 of 2) .................................................................. 379 Figure 1-558 Remove the HCI merge assembly (1 of 2) ................................................................................ 380 Figure 1-559 Remove the HCI merge assembly (2 of 2) ................................................................................ 381 Figure 1-560 Reinstall the HCI merge assembly ............................................................................................ 381 Figure 1-561 Remove the HCI controller PCA ............................................................................................... 382 Figure 1-562 External covers and doors (1x500-sheet feeder) ...................................................................... 383 Figure 1-563 External covers and doors (3x500-sheet feeder) ...................................................................... 384 Figure 1-564 Main assemblies (1x500-sheet feeder) ..................................................................................... 385 Figure 1-565 Main assemblies (3x500-sheet feeder) ..................................................................................... 385

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Figure 1-566 Printed circuit assembly (PCA) ................................................................................................. 386 Figure 1-567 Remove the 1x500 and 3x500 rear cover (1 of 2) .................................................................... 387 Figure 1-568 Remove the 1x500 and 3x500 rear cover (2 of 2) .................................................................... 387 Figure 1-569 Remove the 1x500 and 3x500 right front cover (1 of 2) ........................................................... 388 Figure 1-570 Remove the 1x500 and 3x500 right front cover (2 of 2) ........................................................... 389 Figure 1-571 Reinstall the 1x500 and 3x500 right front cover ....................................................................... 389 Figure 1-572 Remove the 1x500 and 3x500 upper front face cover .............................................................. 390 Figure 1-573 Reinstall the 1x500 and 3x500 upper front face cover ............................................................. 391 Figure 1-574 Remove the 1x500 and 3x500 upper front cover (1 of 4) ......................................................... 392 Figure 1-575 Remove the 1x500 and 3x500 upper front cover (2 of 4) ......................................................... 393 Figure 1-576 Remove the 1x500 and 3x500 upper front cover (3 of 4) ......................................................... 393 Figure 1-577 Remove the 1x500 and 3x500 upper front cover (4 of 4) ......................................................... 394 Figure 1-578 Remove the 1x500 and 3x500 upper front left face cover ........................................................ 395 Figure 1-579 Remove the 1x500 storage box door (1 of 3) ........................................................................... 396 Figure 1-580 Remove the 1x500 storage box door (2 of 3) ........................................................................... 396 Figure 1-581 Remove the 1x500 storage box door (3 of 3) ........................................................................... 397 Figure 1-582 Remove the 1x500 storage box (1 of 2) ................................................................................... 398 Figure 1-583 Remove the 1x500 storage box (2 of 2) ................................................................................... 399 Figure 1-584 Remove the 1x500 and 3x500 right lower cover (1 of 2) .......................................................... 400 Figure 1-585 Remove the 1x500 and 3x500 right lower cover (2 of 2) .......................................................... 401 Figure 1-586 Remove the 1x500 Tray 3 pickup assembly (1 of 5) ................................................................ 402 Figure 1-587 Remove the 1x500 Tray 3 pickup assembly (2 of 5) ................................................................ 402 Figure 1-588 Remove the 1x500 Tray 3 pickup assembly (3 of 5) ................................................................ 403 Figure 1-589 Remove the 1x500 Tray 3 pickup assembly (4 of 5) ................................................................ 403 Figure 1-590 Remove the 1x500 Tray 3 pickup assembly (5 of 5) ................................................................ 404 Figure 1-591 Reinstall the 1x500 Tray 3 pickup assembly (1 of 4) ................................................................ 405 Figure 1-592 Reinstall the 1x500 Tray 3 pickup assembly (2 of 4) ................................................................ 405 Figure 1-593 Reinstall the 1x500 Tray 3 pickup assembly (3 of 4) ................................................................ 406 Figure 1-594 Reinstall the 1x500 Tray 3 pickup assembly (4 of 4) ................................................................ 406 Figure 1-595 Remove the 3x500 Tray 3 pickup assembly (1 of 4) ................................................................ 407 Figure 1-596 Remove the 3x500 Tray 3 pickup assembly (2 of 4) ................................................................ 408 Figure 1-597 Remove the 3x500 Tray 3 pickup assembly (3 of 4) ................................................................ 408 Figure 1-598 Remove the 3x500 Tray 3 pickup assembly (4 of 4 .................................................................. 409 Figure 1-599 Reinstall the 3x500 Tray 3 pickup assembly (1 of 4) ................................................................ 410 Figure 1-600 Reinstall the 3x500 Tray 3 pickup assembly (2 of 4) ................................................................ 410 Figure 1-601 Reinstall the 3x500 Tray 3 pickup assembly (3 of 4) ................................................................ 411 Figure 1-602 Reinstall the 3x500 Tray 3 pickup assembly (4 of 4) ................................................................ 411 Figure 1-603 Remove the 3x500 Tray 4 pickup assembly (1 of 4) ................................................................ 412 Figure 1-604 Remove the 3x500 Tray 4 pickup assembly (2 of 4) ................................................................ 413 Figure 1-605 Remove the 3x500 Tray 4 pickup assembly (3 of 4) ................................................................ 413 Figure 1-606 Remove the 3x500 Tray 4 pickup assembly (4 of 4) ................................................................ 414

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Figure 1-607 Reinstall the 3x500 Tray 4 pickup assembly (1 of 2) ................................................................ 415 Figure 1-608 Reinstall the 3x500 Tray 4 pickup assembly (2 of 2) ................................................................ 415 Figure 1-609 Remove the 3x500 Tray 5 pickup assembly (1 of 3) ................................................................ 416 Figure 1-610 Remove the 3x500 Tray 5 pickup assembly (2 of 3) ................................................................ 417 Figure 1-611 Remove the 3x500 Tray 5 pickup assembly (3 of 3) ................................................................ 417 Figure 1-612 Reinstall the 3x500 Tray 5 pickup assembly (1 of 2) ................................................................ 418 Figure 1-613 Reinstall the 3x500 Tray 5 pickup assembly (2 of 2) ................................................................ 418 Figure 1-614 Remove the 1x500 Tray 3 automatic close assembly (1 of 2) .................................................. 419 Figure 1-615 Remove the 1x500 Tray 3 automatic close assembly (2 of 2) .................................................. 419 Figure 1-616 Remove the 3x500 Tray 3, Tray 4, and Tray 5 automatic close assemblies (1 of 2) ................ 420 Figure 1-617 Remove the 3x500 Tray 3, Tray 4, and Tray 5 automatic close assemblies (2 of 2) ................ 421 Figure 1-618 1x500 pickup motor location ..................................................................................................... 422 Figure 1-619 3x500 pickup motor locations ................................................................................................... 423 Figure 1-620 Remove the 1x500 Tray 3, 3x500 Tray 3, Tray 4, and Tray 5 pickup motors ........................... 423 Figure 1-621 Remove the HCI controller PCA ............................................................................................... 424 Figure 1-622 Remove the HCI, 1x500, and 3x500 left cover (1 of 2) ............................................................. 426 Figure 1-623 Remove the HCI, 1x500, and 3x500 left cover (2 of 2) ............................................................. 426 Figure 1-624 Reinstall the HCI, 1x500, and 3x500 left cover ......................................................................... 427 Figure 1-625 Remove the HCI, 1x500, and 3x500 right door assembly (1 of 3) ............................................ 428 Figure 1-626 Remove the HCI, 1x500, and 3x500 right door assembly (2 of 3) ............................................ 428 Figure 1-627 Remove the HCI, 1x500, and 3x500 right door assembly (3 of 3) ............................................ 429 Figure 1-628 Remove the HCI, 1x500, and 3x500 right rear cover (1 of 4) ................................................... 430 Figure 1-629 Remove the HCI, 1x500, and 3x500 right rear cover (2 of 4) ................................................... 430 Figure 1-630 Remove the HCI, 1x500, and 3x500 right rear cover (3 of 4) ................................................... 431 Figure 1-631 Remove the HCI, 1x500, and 3x500 right rear cover (4 of 4) ................................................... 431 Figure 1-632 Reinstall the HCI, 1x500, and 3x500 right rear cover ............................................................... 432 Figure 1-633 Correct placement of the IPTU for servicing ............................................................................. 433 Figure 1-634 Incorrect placement of the IPTU for servicing ........................................................................... 433 Figure 1-635 IPTU covers (1 of 2) .................................................................................................................. 434 Figure 1-636 IPTU covers (2 of 2) .................................................................................................................. 435 Figure 1-637 IPTU main assemblies .............................................................................................................. 435 Figure 1-638 IPTU PCA ................................................................................................................................. 436 Figure 1-639 Remove the IPTU (1 of 4) ......................................................................................................... 437 Figure 1-640 Remove the IPTU (2 of 4) ......................................................................................................... 437 Figure 1-641 Remove the IPTU (3 of 4) ......................................................................................................... 438 Figure 1-642 Remove the IPTU (4 of 4) ......................................................................................................... 438 Figure 1-643 Remove the IPTU rear cover (1 of 3) ........................................................................................ 439 Figure 1-644 Remove the IPTU rear cover (2 of 3) ........................................................................................ 439 Figure 1-645 Remove the IPTU rear cover (3 of 3) ........................................................................................ 440 Figure 1-646 Reinstall the IPTU rear cover (1 of 2) ....................................................................................... 440 Figure 1-647 Reinstall the IPTU rear cover (2 of 2) ....................................................................................... 441

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Figure 1-648 Remove the IPTU driver PCA (1 of 2) ....................................................................................... 442 Figure 1-649 Remove the IPTU driver PCA (2 of 2) ....................................................................................... 442 Figure 1-650 Remove the IPTU finisher lock assembly (1 of 5) ..................................................................... 443 Figure 1-651 Remove the IPTU finisher lock assembly (2 of 5) ..................................................................... 443 Figure 1-652 Remove the IPTU finisher lock assembly (3 of 5) ..................................................................... 444 Figure 1-653 Remove the IPTU finisher lock assembly (4 of 5) ..................................................................... 444 Figure 1-654 Remove the IPTU finisher lock assembly (5 of 5) ..................................................................... 445 Figure 1-655 Remove the IPTU fan assembly (1 of 2) ................................................................................... 446 Figure 1-656 Remove the IPTU fan assembly (2 of 2) ................................................................................... 446 Figure 1-657 Remove the IPTU side assembly (1 of 6) ....................................................................... 447 Figure 1-658 Remove the IPTU side assembly (2 of 6) ....................................................................... 448 Figure 1-659 Remove the IPTU side assembly (3 of 6) ....................................................................... 448 Figure 1-660 Remove the IPTU side assembly (4 of 6) ....................................................................... 449 Figure 1-661 Remove the IPTU side assembly (5 of 6) ....................................................................... 449 Figure 1-662 Remove the IPTU side assembly (6 of 6) ....................................................................... 450 Figure 1-663 Reinstall the IPTU side assembly ................................................................................... 450 Figure 1-664 Remove the IPTU upper and lower guide assemblies (1 of 9) ................................................. 451 Figure 1-665 Remove the IPTU upper and lower guide assemblies (2 of 9) ................................................. 451 Figure 1-666 Remove the IPTU upper and lower guide assemblies (3 of 9) ................................................. 452 Figure 1-667 Remove the IPTU upper and lower guide assemblies (4 of 9) ................................................. 452 Figure 1-668 Remove the IPTU upper and lower guide assemblies (5 of 9) ................................................. 453 Figure 1-669 Remove the IPTU upper and lower guide assemblies (6 of 9) ................................................. 453 Figure 1-670 Remove the IPTU upper and lower guide assemblies (7 of 9) ................................................. 454 Figure 1-671 Remove the IPTU upper and lower guide assemblies (8 of 9) ................................................. 455 Figure 1-672 Remove the IPTU upper and lower guide assemblies (9 of 9) ................................................. 455 Figure 1-673 Install a replacement IPTU upper guide assembly (1 of 2) ....................................................... 456 Figure 1-674 Install a replacement IPTU upper guide assembly (2 of 2) ....................................................... 456 Figure 1-675 Identify the BM finishing accessory .......................................................................................... 458 Figure 1-676 Identify the BMHP finishing accessory ..................................................................................... 458 Figure 1-677 Identify the SS finishing accessory ........................................................................................... 459 Figure 1-678 Identify the SSHP finishing accessory ...................................................................................... 459 Figure 1-679 Stapler stacker covers and doors ............................................................................................. 460 Figure 1-680 Stapler stacker with hole punch covers and doors ................................................................... 461 Figure 1-681 Booklet maker covers and doors .............................................................................................. 462 Figure 1-682 Booklet maker with hole punch covers and doors .................................................................... 463 Figure 1-683 Remove the top cover lock assembly (1 of 3) ........................................................................... 466 Figure 1-684 Remove the top cover lock assembly (2 of 3) ........................................................................... 466 Figure 1-685 Remove the top cover lock assembly (3 of 3) ........................................................................... 467 Figure 1-686 Remove the latch lower covers (front and rear; 1 of 3) ............................................................. 468 Figure 1-687 Remove the latch lower covers (front and rear; 2 of 3) ............................................................. 468 Figure 1-688 Remove the latch lower covers (front and rear; 3 of 3) ............................................................. 469

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Figure 1-689 Remove the latch assembly (1 of 2) ......................................................................................... 470 Figure 1-690 Remove the latch assembly (2 of 2) ......................................................................................... 470 Figure 1-691 Remove the open/close stepped cover assembly (1 of 2) ........................................................ 471 Figure 1-692 Remove the open/close stepped cover assembly (2 of 2) ........................................................ 471 Figure 1-693 Remove the upper stepped cover assembly (1 of 4) ................................................................ 472 Figure 1-694 Remove the upper stepped cover assembly (2 of 4) ................................................................ 472 Figure 1-695 Remove the upper stepped cover assembly (3 of 4) ................................................................ 473 Figure 1-696 Remove the upper stepped cover assembly (4 of 4) ................................................................ 473 Figure 1-697 Remove the lower stepped cover assembly (1 of 5) ................................................................. 474 Figure 1-698 Remove the lower stepped cover assembly (2 of 5) ................................................................. 475 Figure 1-699 Remove the lower stepped cover assembly (3 of 5) ................................................................. 475 Figure 1-700 Remove the lower stepped cover assembly (4 of 5) ................................................................. 476 Figure 1-701 Remove the lower stepped cover assembly (5 of 5) ................................................................. 476 Figure 1-702 Reinstall the lower stepped cover (1 of 2) ................................................................................ 477 Figure 1-703 Reinstall the lower stepped cover (2 of 2) ................................................................................ 477 Figure 1-704 Remove the top door assembly (1 of 2) .................................................................................... 478 Figure 1-705 Remove the top door assembly (2 of 2) .................................................................................... 478 Figure 1-706 Remove the front door (1 of 2) .................................................................................................. 479 Figure 1-707 Remove the front door (2 of 2) .................................................................................................. 479 Figure 1-708 Move the inner upper cover out of the way (1 of 2) .................................................................. 480 Figure 1-709 Move the inner upper cover out of the way (2 of 2) .................................................................. 480 Figure 1-710 Remove the inner upper cover assembly (1 of 2) ..................................................................... 481 Figure 1-711 Remove the inner upper cover assembly (2 of 2) ..................................................................... 481 Figure 1-712 Remove the clutch assembly (front side; 1 of 2) ....................................................................... 482 Figure 1-713 Remove the clutch assembly (front side; 2 of 2) ....................................................................... 482 Figure 1-714 Remove the sensor switch assembly (1 of 4) ........................................................................... 483 Figure 1-715 Remove the sensor switch assembly (2 of 4) ........................................................................... 484 Figure 1-716 Remove the sensor switch assembly (3 of 4) ........................................................................... 484 Figure 1-717 Remove the sensor switch assembly (4 of 4) ........................................................................... 485 Figure 1-718 Move the inner lower cover out of the way (1 of 4) ................................................................... 486 Figure 1-719 Move the inner lower cover out of the way (2 of 4) ................................................................... 486 Figure 1-720 Move the inner lower cover out of the way (3 of 4) ................................................................... 487 Figure 1-721 Move the inner lower cover out of the way (4 of 4) ................................................................... 487 Figure 1-722 Remove the inner lower cover assembly (1 of 4) ..................................................................... 488 Figure 1-723 Remove the inner lower cover assembly (2 of 4) ..................................................................... 488 Figure 1-724 Remove the inner lower cover assembly (2 of 4) ..................................................................... 489 Figure 1-725 Remove the inner lower cover assembly (4 of 4) ..................................................................... 489 Figure 1-726 Remove the front foot cover assembly (1 of 2) ......................................................................... 490 Figure 1-727 Remove the front foot cover assembly (2 of 2) ......................................................................... 491 Figure 1-728 Remove the bin cable guide cover (1 of 6) ............................................................................... 492 Figure 1-729 Remove the bin cable guide cover (2 of 6) ............................................................................... 492

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Figure 1-730 Remove the bin cable guide cover (3 of 6) ............................................................................... 493 Figure 1-731 Remove the bin cable guide cover (4 of 6) ............................................................................... 493 Figure 1-732 Remove the bin cable guide cover (5 of 6) ............................................................................... 494 Figure 1-733 Remove the bin cable guide cover (6 of 6) ............................................................................... 494 Figure 1-734 Bin cable guide cover correctly installed ................................................................................... 495 Figure 1-735 Bin cable guide cover incorrectly installed ................................................................................ 495 Figure 1-736 Remove the rear cover assembly (1 of 4) ................................................................................. 496 Figure 1-737 Remove the rear cover assembly (2 of 4) ................................................................................. 496 Figure 1-738 Remove the rear cover assembly (3 of 4) ................................................................................. 497 Figure 1-739 Remove the rear cover assembly (4 of 4) ................................................................................. 497 Figure 1-740 Remove the main controller PCA assembly (1 of 6) ................................................................. 498 Figure 1-741 Remove the main controller PCA assembly (2 of 6) ................................................................. 499 Figure 1-742 Remove the main controller PCA assembly (3 of 6) ................................................................. 499 Figure 1-743 Remove the main controller PCA assembly (4 of 6) ................................................................. 500 Figure 1-744 Remove the main controller PCA assembly (5 of 6) ................................................................. 500 Figure 1-745 Remove the main controller PCA assembly (6 of 6) ................................................................. 501 Figure 1-746 Install a replacement main controller PCA assembly ............................................................... 502 Figure 1-747 Main controller PCA switches ................................................................................................... 503 Figure 1-748 Booklet maker controller PCA switches .................................................................................... 504 Figure 1-749 DIPSW4 alignment settings ...................................................................................................... 504 Figure 1-750 DIPSW4 staple position settings ............................................................................................... 505 Figure 1-751 DIPSW folding position settings ................................................................................................ 506 Figure 1-752 Mark the paper .......................................................................................................................... 507 Figure 1-753 Folding position adjustment (1 of 3) .......................................................................................... 507 Figure 1-754 Folding position adjustment (2 of 3) .......................................................................................... 508 Figure 1-755 Folding position adjustment (3 of 3) .......................................................................................... 508 Figure 1-756 Positive and negative width adjustment .................................................................................... 509 Figure 1-757 Adjust the stitcher (1 of 6) ......................................................................................................... 510 Figure 1-758 Adjust the stitcher (2 of 6) ......................................................................................................... 510 Figure 1-759 Adjust the stitcher (3 of 6) ......................................................................................................... 511 Figure 1-760 Adjust the stitcher (4 of 6) ......................................................................................................... 511 Figure 1-761 Adjust the stitcher (5 of 6) ......................................................................................................... 511 Figure 1-762 Adjust the stitcher (6 of 6) ......................................................................................................... 512 Figure 1-763 Remove the entrance upper guide assembly (1 of 3) ............................................................... 513 Figure 1-764 Remove the entrance upper guide assembly (2 of 3) ............................................................... 514 Figure 1-765 Remove the entrance upper guide assembly (3 of 3) ............................................................... 515 Figure 1-766 Remove the rear foot cover assembly (1 of 2) .......................................................................... 516 Figure 1-767 Remove the rear foot cover assembly (2 of 2) .......................................................................... 517 Figure 1-768 Remove the stack wall upper assembly and upper wall guide assembly (1 of 5) ..................... 518 Figure 1-769 Remove the stack wall upper assembly and upper wall guide assembly (2 of 5) ..................... 519 Figure 1-770 Remove the stack wall upper assembly and upper wall guide assembly (3 of 5) ..................... 519

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Figure 1-771 Remove the stack wall upper assembly and upper wall guide assembly (4 of 5) ..................... 520 Figure 1-772 Remove the stack wall upper assembly and upper wall guide assembly (5 of 5) ..................... 520 Figure 1-773 Remove the upper cross member assembly (1 of 13) .............................................................. 521 Figure 1-774 Remove the upper cross member assembly (2 of 13) .............................................................. 522 Figure 1-775 Remove the upper cross member assembly (3 of 13) .............................................................. 522 Figure 1-776 Remove the upper cross member assembly (4 of 13) .............................................................. 523 Figure 1-777 Remove the upper cross member assembly (5 of 13) .............................................................. 523 Figure 1-778 Remove the upper cross member assembly (6 of 13) .............................................................. 524 Figure 1-779 Remove the upper cross member assembly (7 of 13) .............................................................. 524 Figure 1-780 Remove the upper cross member assembly (8 of 13) .............................................................. 525 Figure 1-781 Remove the upper cross member assembly (9 of 13) .............................................................. 525 Figure 1-782 Remove the upper cross member assembly (10 of 13) ............................................................ 526 Figure 1-783 Remove the upper cross member assembly (11 of 13) ............................................................ 526 Figure 1-784 Remove the upper cross member assembly (12 of 13) ............................................................ 527 Figure 1-785 Remove the upper cross member assembly (13 of 13) ............................................................ 528 Figure 1-786 Reinstall the upper cross member assembly (1 of 7) ............................................................... 529 Figure 1-787 Reinstall the upper cross member assembly (2 of 7) ............................................................... 529 Figure 1-788 Reinstall the upper cross member assembly (3 of 7) ............................................................... 530 Figure 1-789 Reinstall the upper cross member assembly (4 of 7) ............................................................... 530 Figure 1-790 Reinstall the upper cross member assembly (5 of 7) ............................................................... 531 Figure 1-791 Reinstall the upper cross member assembly (6 of 7) ............................................................... 531 Figure 1-792 Reinstall the upper cross member assembly (7 of 7) ............................................................... 532 Figure 1-793 Remove the paper feed drive assembly (1 of 2) ....................................................................... 533 Figure 1-794 Remove the paper feed drive assembly (2 of 2) ....................................................................... 534 Figure 1-795 Remove the pressure roller assembly (1 of 8) .......................................................................... 536 Figure 1-796 Remove the pressure roller assembly (2 of 8) .......................................................................... 536 Figure 1-797 Remove the pressure roller assembly (3 of 8) .......................................................................... 537 Figure 1-798 Remove the pressure roller assembly (4 of 8) .......................................................................... 537 Figure 1-799 Remove the pressure roller assembly (5 of 8) .......................................................................... 538 Figure 1-800 Remove the pressure roller assembly (6 of 8) .......................................................................... 538 Figure 1-801 Remove the pressure roller assembly (7 of 8) .......................................................................... 539 Figure 1-802 Remove the pressure roller assembly (8 of 8) .......................................................................... 539 Figure 1-803 Remove the stack upper bin and lower bin assemblies (1 of 5) ............................................... 541 Figure 1-804 Remove the stack upper bin and lower bin assemblies (2 of 5) ............................................... 542 Figure 1-805 Remove the stack upper bin and lower bin assemblies (3 of 5) ............................................... 542 Figure 1-806 Remove the stack upper bin and lower bin assemblies (4 of 5) ............................................... 543 Figure 1-807 Remove the stack upper bin and lower bin assemblies (5 of 5) ............................................... 543 Figure 1-808 Reinstall the stack wall upper assembly and upper wall guide assembly (1 of 2) .................... 544 Figure 1-809 Reinstall the stack wall upper assembly and upper wall guide assembly (2 of 2) .................... 545 Figure 1-810 Remove the height wall assembly (1 of 2) ................................................................................ 546 Figure 1-811 Remove the height wall assembly (2 of 2) ................................................................................ 547

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Figure 1-812 Reinstall the height wall assembly ............................................................................................ 547 Figure 1-813 Remove the paper face sensor and flag assembly (1 of 9) ...................................................... 548 Figure 1-814 Remove the paper face sensor and flag assembly (2 of 9) ...................................................... 549 Figure 1-815 Remove the paper face sensor and flag assembly (3 of 9) ...................................................... 549 Figure 1-816 Remove the paper face sensor and flag assembly (4 of 9) ...................................................... 550 Figure 1-817 Remove the paper face sensor and flag assembly (5 of 9) ...................................................... 550 Figure 1-818 Remove the paper face sensor and flag assembly (6 of 9) ...................................................... 551 Figure 1-819 Remove the paper face sensor and flag assembly (7 of 9) ...................................................... 551 Figure 1-820 Remove the paper face sensor and flag assembly (8 of 9) ...................................................... 552 Figure 1-821 Remove the paper face sensor and flag assembly (9 of 9) ...................................................... 552 Figure 1-822 Remove the staple subassembly (1 of 6) ................................................................................. 553 Figure 1-823 Remove the staple subassembly (2 of 6) ................................................................................. 553 Figure 1-824 Remove the staple subassembly (3 of 6) ................................................................................. 554 Figure 1-825 Remove the staple subassembly (4 of 6) ................................................................................. 554 Figure 1-826 Remove the staple subassembly (5 of 6) ................................................................................. 555 Figure 1-827 Remove the staple subassembly (6 of 6) ................................................................................. 555 Figure 1-828 Remove the staple connecting cable assembly (1 of 2) ........................................................... 556 Figure 1-829 Remove the staple connecting cable assembly (2 of 2) ........................................................... 557 Figure 1-830 Remove the staple assembly (1 of 7) ....................................................................................... 558 Figure 1-831 Remove the staple assembly (2 of 7) ....................................................................................... 559 Figure 1-832 Remove the staple assembly (3 of 7) ....................................................................................... 559 Figure 1-833 Remove the staple assembly (4 of 7) ....................................................................................... 560 Figure 1-834 Remove the staple assembly (5 of 7) ....................................................................................... 560 Figure 1-835 Remove the staple assembly (6 of 7) ....................................................................................... 561 Figure 1-836 Remove the staple assembly (7 of 7) ....................................................................................... 561 Figure 1-837 Remove the paper detect holder assembly .............................................................................. 562 Figure 1-838 Reinstall the paper detect holder assembly .............................................................................. 563 Figure 1-839 Identify the operation tray assembly ......................................................................................... 564 Figure 1-840 Remove the operation tray assembly (1 of 11) ......................................................................... 565 Figure 1-841 Remove the operation tray assembly (2 of 11) ......................................................................... 566 Figure 1-842 Remove the operation tray assembly (3 of 11) ......................................................................... 567 Figure 1-843 Remove the operation tray assembly (4 of 11) ......................................................................... 567 Figure 1-844 Remove the operation tray assembly (5 of 11) ......................................................................... 568 Figure 1-845 Remove the operation tray assembly (6 of 11) ......................................................................... 568 Figure 1-846 Remove the operation tray assembly (7 of 11) ......................................................................... 569 Figure 1-847 Remove the operation tray assembly (8 of 11) ......................................................................... 569 Figure 1-848 Remove the operation tray assembly (9 of 11) ......................................................................... 570 Figure 1-849 Remove the operation tray assembly (10 of 11) ....................................................................... 570 Figure 1-850 Remove the operation tray assembly (11 of 11) ....................................................................... 571 Figure 1-851 Reinstall the operation tray assembly (1 of 5) .......................................................................... 571 Figure 1-852 Reinstall the operation tray assembly (2 of 5) .......................................................................... 572

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Figure 1-853 Reinstall the operation tray assembly (3 of 5) .......................................................................... 572 Figure 1-854 Reinstall the operation tray assembly (4 of 5) .......................................................................... 573 Figure 1-855 Reinstall the operation tray assembly (5 of 5) .......................................................................... 574 Figure 1-856 Identify the operation tray assembly ......................................................................................... 575 Figure 1-857 Remove the swing guide assembly (1 of 12) ............................................................................ 576 Figure 1-858 Remove the swing guide assembly (2 of 12) ............................................................................ 576 Figure 1-859 Remove the swing guide assembly (3 of 12) ............................................................................ 577 Figure 1-860 Remove the swing guide assembly (4 of 12) ............................................................................ 577 Figure 1-861 Remove the swing guide assembly (5 of 12) ............................................................................ 578 Figure 1-862 Remove the swing guide assembly (6 of 12) ............................................................................ 578 Figure 1-863 Remove the swing guide assembly (7 of 12) ............................................................................ 579 Figure 1-864 Remove the swing guide assembly (8 of 12) ............................................................................ 579 Figure 1-865 Remove the swing guide assembly (9 of 12) ............................................................................ 580 Figure 1-866 Remove the swing guide assembly (10 of 12) .......................................................................... 580 Figure 1-867 Remove the swing guide assembly (11 of 12) .......................................................................... 581 Figure 1-868 Remove the swing guide assembly (12 of 12) .......................................................................... 581 Figure 1-869 Reinstall the swing guide assembly (1 of 7) ............................................................................. 582 Figure 1-870 Reinstall the swing guide assembly (2 of 7) ............................................................................. 582 Figure 1-871 Reinstall the swing guide assembly (3 of 7) ............................................................................. 583 Figure 1-872 Reinstall the swing guide assembly (4 of 7) ............................................................................. 583 Figure 1-873 Reinstall the swing guide assembly (5 of 7) ............................................................................. 584 Figure 1-874 Reinstall the swing guide assembly (6 of 7) ............................................................................. 584 Figure 1-875 Reinstall the swing guide assembly (7 of 7) ............................................................................. 585 Figure 1-876 Remove the return roller assembly (1 of 2) .............................................................................. 587 Figure 1-877 Remove the return roller assembly (2 of 2) .............................................................................. 587 Figure 1-878 Remove the clutch assembly (rear side; 1 of 6) ....................................................................... 588 Figure 1-879 Remove the clutch assembly (rear side; 2 of 6) ....................................................................... 588 Figure 1-880 Remove the clutch assembly (rear side; 3 of 6) ....................................................................... 589 Figure 1-881 Remove the clutch assembly (rear side; 4 of 6) ....................................................................... 589 Figure 1-882 Remove the clutch assembly (rear side; 5 of 6) ....................................................................... 590 Figure 1-883 Remove the clutch assembly (rear side; 6 of 6) ....................................................................... 590 Figure 1-884 Remove the stack ejection motor assembly (1 of 7) ................................................................. 591 Figure 1-885 Remove the stack ejection motor assembly (2 of 7) ................................................................. 591 Figure 1-886 Remove the stack ejection motor assembly (3 of 7) ................................................................. 592 Figure 1-887 Remove the stack ejection motor assembly (4 of 7) ................................................................. 592 Figure 1-888 Remove the stack ejection motor assembly (5 of 7) ................................................................. 593 Figure 1-889 Remove the stack ejection motor assembly (6 of 7) ................................................................. 593 Figure 1-890 Remove the stack ejection motor assembly (7 of 7) ................................................................. 594 Figure 1-891 Remove the press motor assembly (1 of 7) .............................................................................. 595 Figure 1-892 Remove the press motor assembly (2 of 7) .............................................................................. 595 Figure 1-893 Remove the press motor assembly (3 of 7) .............................................................................. 596

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Figure 1-894 Remove the press motor assembly (4 of 7) .............................................................................. 596 Figure 1-895 Remove the press motor assembly (5 of 7) .............................................................................. 597 Figure 1-896 Remove the press motor assembly (6 of 7) .............................................................................. 597 Figure 1-897 Remove the press motor assembly (7 of 7) .............................................................................. 598 Figure 1-898 Remove the common driver PCA assembly (1 of 2) ................................................................. 599 Figure 1-899 Remove the common driver PCA assembly (2 of 2) ................................................................. 600 Figure 1-900 Remove the interface cable assembly (1 of 3) ......................................................................... 601 Figure 1-901 Remove the interface cable assembly (2 of 3) ......................................................................... 601 Figure 1-902 Remove the interface cable assembly (3 of 3) ......................................................................... 602 Figure 1-903 Remove the paper assembly (1 of 6) ............................................................................... 603 Figure 1-904 Remove the paper assembly (2 of 6) ............................................................................... 604 Figure 1-905 Remove the paper assembly (3 of 6) ............................................................................... 604 Figure 1-906 Remove the paper assembly (4 of 6) ............................................................................... 605 Figure 1-907 Remove the paper assembly (5 of 6) ............................................................................... 605 Figure 1-908 Remove the paper assembly (6 of 6) ............................................................................... 606 Figure 1-909 Remove the knob ...................................................................................................................... 608 Figure 1-910 Remove the saddle output bin assembly (1 of 2) ..................................................................... 609 Figure 1-911 Remove the saddle output bin assembly (2 of 2) ..................................................................... 609 Figure 1-912 Reinstall the saddle output bin assembly ................................................................................. 610 Figure 1-913 Remove the right cover assembly (BM PCA; 1 of 7) ................................................................ 611 Figure 1-914 Remove the right cover assembly (BM PCA; 2 of 7) ................................................................ 612 Figure 1-915 Remove the right cover assembly (BM PCA; 3 of 7) ................................................................ 612 Figure 1-916 Remove the right cover assembly (BM PCA; 4 of 7) ................................................................ 613 Figure 1-917 Remove the right cover assembly (BM PCA; 5 of 7) ................................................................ 613 Figure 1-918 Remove the right cover assembly (BM PCA; 6 of 7) ................................................................ 614 Figure 1-919 Remove the right cover assembly (BM PCA; 7 of 7) ................................................................ 614 Figure 1-920 Remove the booklet maker controller PCA ............................................................................... 615 Figure 1-921 Remove the inner side plate assembly (1 of 8) ........................................................................ 616 Figure 1-922 Remove the inner side plate assembly (2 of 8) ........................................................................ 617 Figure 1-923 Remove the inner side plate assembly (3 of 8) ........................................................................ 617 Figure 1-924 Remove the inner side plate assembly (4 of 8) ........................................................................ 618 Figure 1-925 Remove the inner side plate assembly (5 of 8) ........................................................................ 618 Figure 1-926 Remove the inner side plate assembly (6 of 8) ........................................................................ 619 Figure 1-927 Remove the inner side plate assembly (7 of 8) ........................................................................ 619 Figure 1-928 Remove the inner side plate assembly (8 of 8) ........................................................................ 620 Figure 1-929 Inner plate assembly in the up position .................................................................................... 620 Figure 1-930 Inner plate assembly in the middle position .............................................................................. 621 Figure 1-931 Reinstall the inner side plate assembly (1 of 3) ........................................................................ 621 Figure 1-932 Reinstall the inner side plate assembly (2 of 3) ........................................................................ 622 Figure 1-933 Reinstall the inner side plate assembly (3 of 3) ........................................................................ 622 Figure 1-934 Remove the guide sensor assembly (1 of 4) ............................................................................ 623

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Figure 1-935 Remove the guide sensor assembly (2 of 4) ............................................................................ 623 Figure 1-936 Remove the guide sensor assembly (3 of 4) ............................................................................ 624 Figure 1-937 Remove the guide sensor assembly (4 of 4) ............................................................................ 624 Figure 1-938 Remove the guide motor assembly (1 of 3) .............................................................................. 625 Figure 1-939 Remove the guide motor assembly (2 of 3) .............................................................................. 626 Figure 1-940 Remove the guide motor assembly (3 of 3) .............................................................................. 626 Figure 1-941 Remove the saddle motor assembly (SS and BM; 1 of 3) ........................................................ 627 Figure 1-942 Remove the saddle motor assembly (SS and BM; 2 of 3) ........................................................ 627 Figure 1-943 Remove the saddle motor assembly (SS and BM; 3 of 3) ........................................................ 628 Figure 1-944 Remove the saddle feed motor assembly (1 of 6) .................................................................... 629 Figure 1-945 Remove the saddle feed motor assembly (2 of 6) .................................................................... 630 Figure 1-946 Remove the saddle feed motor assembly (3 of 6) .................................................................... 630 Figure 1-947 Remove the saddle feed motor assembly (4 of 6) .................................................................... 631 Figure 1-948 Remove the saddle feed motor assembly (5 of 6) .................................................................... 631 Figure 1-949 Remove the saddle feed motor assembly (6 of 6) .................................................................... 632 Figure 1-950 Remove the folding-motor mount assembly (1 of 6) ................................................................. 633 Figure 1-951 Remove the folding-motor mount assembly (2 of 6) ................................................................. 634 Figure 1-952 Remove the folding-motor mount assembly (3 of 6) ................................................................. 634 Figure 1-953 Remove the folding-motor mount assembly (4 of 6) ................................................................. 635 Figure 1-954 Remove the folding-motor mount assembly (5 of 6) ................................................................. 635 Figure 1-955 Remove the folding-motor mount assembly (6 of 6) ................................................................. 636 Figure 1-956 Reinstall the folding-motor mount assembly ............................................................................. 637 Figure 1-957 Remove the delivery switch mount assembly (1 of 4) .............................................................. 638 Figure 1-958 Remove the delivery switch mount assembly (2 of 4) .............................................................. 639 Figure 1-959 Remove the delivery switch mount assembly (4 of 4) .............................................................. 639 Figure 1-960 Remove the delivery switch mount assembly (4 of 4) .............................................................. 640 Figure 1-961 Remove the saddle stapler assembly (1 of 3) .......................................................................... 641 Figure 1-962 Remove the saddle stapler assembly (2 of 3) .......................................................................... 642 Figure 1-963 Remove the saddle stapler assembly (3 of 3) .......................................................................... 642 Figure 1-964 Remove the lower left guide assembly (1 of 3) ......................................................................... 643 Figure 1-965 Remove the lower left guide assembly (2 of 3) ......................................................................... 643 Figure 1-966 Remove the lower left guide assembly (3 of 3) ......................................................................... 644 Figure 1-967 Remove the saddle delivery inner cover, front assembly (1 of 3) ............................................. 645 Figure 1-968 Remove the saddle delivery inner cover, front assembly (2 of 3) ............................................. 645 Figure 1-969 Remove the saddle delivery inner cover, front assembly (3 of 3) ............................................. 646 Figure 1-970 Remove the saddle delivery inner cover, rear assembly (1 of 3) .............................................. 647 Figure 1-971 Remove the saddle delivery inner cover, rear assembly (2 of 3) .............................................. 647 Figure 1-972 Remove the saddle delivery inner cover, rear assembly (3 of 3) .............................................. 648 Figure 1-973 Remove the saddle guide assembly (1 of 5) ............................................................................ 650 Figure 1-974 Remove the saddle guide assembly (2 of 5) ............................................................................ 650 Figure 1-975 Remove the saddle guide assembly (3 of 5) ............................................................................ 651

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Figure 1-976 Remove the saddle guide assembly (4 of 5) ............................................................................ 651 Figure 1-977 Remove the saddle guide assembly (5 of 5) ............................................................................ 652 Figure 1-978 Reinstall the saddle guide assembly (1 of 4) ............................................................................ 653 Figure 1-979 Reinstall the saddle guide assembly (2 of 4) ............................................................................ 653 Figure 1-980 Reinstall the saddle guide assembly (3 of 4) ............................................................................ 654 Figure 1-981 Reinstall the saddle guide assembly (4 of 4) ............................................................................ 654 Figure 1-982 Remove the saddle feed assembly (1 of 7) .............................................................................. 656 Figure 1-983 Remove the saddle feed assembly (2 of 7) .............................................................................. 656 Figure 1-984 Remove the saddle feed assembly (3 of 7) .............................................................................. 657 Figure 1-985 Remove the saddle feed assembly (4 of 7) .............................................................................. 657 Figure 1-986 Remove the saddle feed assembly (5 of 7) .............................................................................. 658 Figure 1-987 Remove the saddle feed assembly (6 of 7) .............................................................................. 658 Figure 1-988 Remove the saddle feed assembly (7 of 7) .............................................................................. 659 Figure 1-989 Reinstall the saddle feed assembly .......................................................................................... 659 Figure 1-990 Remove the saddle assembly (1 of 13) .................................................................................... 661 Figure 1-991 Remove the saddle assembly (2 of 13) .................................................................................... 661 Figure 1-992 Remove the saddle assembly (3 of 13) .................................................................................... 662 Figure 1-993 Remove the saddle assembly (4 of 13) .................................................................................... 662 Figure 1-994 Remove the saddle assembly (5 of 13) .................................................................................... 663 Figure 1-995 Remove the saddle assembly (6 of 13) .................................................................................... 663 Figure 1-996 Remove the saddle assembly (7 of 13) .................................................................................... 664 Figure 1-997 Remove the saddle assembly (8 of 13) .................................................................................... 664 Figure 1-998 Remove the saddle assembly (9 of 13) .................................................................................... 665 Figure 1-999 Remove the saddle assembly (10 of 13) .................................................................................. 665 Figure 1-1000 Remove the saddle assembly (11 of 13) ................................................................................ 666 Figure 1-1001 Remove the saddle assembly (12 of 13) ................................................................................ 666 Figure 1-1002 Remove the saddle assembly (13 of 13) ................................................................................ 667 Figure 1-1003 Reinstall the saddle assembly ................................................................................................ 668 Figure 1-1004 Remove the upper delivery guide assembly (1 of 3) .............................................................. 669 Figure 1-1005 Remove the upper delivery guide assembly (2 of 3) .............................................................. 670 Figure 1-1006 Remove the upper delivery guide assembly (3 of 3) .............................................................. 670 Figure 1-1007 Remove the saddle paper delivery assembly (1 of 5) ............................................................. 671 Figure 1-1008 Remove the saddle paper delivery assembly (2 of 5) ............................................................. 671 Figure 1-1009 Remove the saddle paper delivery assembly (3 of 5) ............................................................. 672 Figure 1-1010 Remove the saddle paper delivery assembly (4 of 5) ............................................................. 672 Figure 1-1011 Remove the saddle paper delivery assembly (5 of 5) ............................................................. 673 Figure 1-1012 Reinstall the saddle paper delivery assembly ......................................................................... 673 Figure 1-1013 Remove the saddle rear end sensor assembly (1 of 10) ........................................................ 675 Figure 1-1014 Remove the saddle rear end sensor assembly (2 of 10) ........................................................ 675 Figure 1-1015 Remove the saddle rear end sensor assembly (3 of 10) ........................................................ 676 Figure 1-1016 Remove the saddle rear end sensor assembly (4 of 10) ........................................................ 677

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Figure 1-1017 Remove the saddle rear end sensor assembly (5 of 10) ........................................................ 678 Figure 1-1018 Remove the saddle rear end sensor assembly (6 of 10) ........................................................ 678 Figure 1-1019 Remove the saddle rear end sensor assembly (7 of 10) ........................................................ 679 Figure 1-1020 Remove the saddle rear end sensor assembly (8 of 10) ........................................................ 679 Figure 1-1021 Remove the saddle rear end sensor assembly (9 of 10) ........................................................ 680 Figure 1-1022 Remove the saddle rear end sensor assembly (10 of 10) ...................................................... 680 Figure 1-1023 Reinstall the saddle rear end sensor assembly (1 of 2) .......................................................... 681 Figure 1-1024 Reinstall the saddle rear end sensor assembly (2 of 2) .......................................................... 681 Figure 1-1025 Remove the punch front cover (1 of 2) ................................................................................... 682 Figure 1-1026 Remove the punch front cover (2 of 2) ................................................................................... 683 Figure 1-1027 Remove the punch lower front cover assembly (1 of 3) ......................................................... 684 Figure 1-1028 Remove the punch lower front cover assembly (2 of 3) ......................................................... 684 Figure 1-1029 Remove the punch lower front cover assembly (3 of 3) ......................................................... 685 Figure 1-1030 Remove the punch rear cover assembly (1 of 2) .................................................................... 686 Figure 1-1031 Remove the punch rear cover assembly (2 of 2) .................................................................... 686 Figure 1-1032 Remove the punch controller PCA assembly ......................................................................... 687 Figure 1-1033 Remove the punch waste tray ................................................................................................ 688 Figure 1-1034 Remove the punch inner cover assembly (1 of 4) .................................................................. 689 Figure 1-1035 Remove the punch inner cover assembly (2 of 4) .................................................................. 689 Figure 1-1036 Remove the punch inner cover assembly (3 of 4) .................................................................. 690 Figure 1-1037 Remove the punch inner cover assembly (4 of 4) .................................................................. 690 Figure 1-1038 Remove the punch top cover (1 of 6) ..................................................................................... 691 Figure 1-1039 Remove the punch top cover (2 of 6) ..................................................................................... 691 Figure 1-1040 Remove the punch top cover (3 of 6) ..................................................................................... 692 Figure 1-1041 Remove the punch top cover (4 of 6) ..................................................................................... 692 Figure 1-1042 Remove the punch top cover (5 of 6) ..................................................................................... 693 Figure 1-1043 Remove the punch top cover (6 of 6) ..................................................................................... 693 Figure 1-1044 Remove the punch hole assembly (1 of 8) ............................................................................. 694 Figure 1-1045 Remove the punch hole assembly (2 of 8) ............................................................................. 695 Figure 1-1046 Remove the punch hole assembly (3 of 8) ............................................................................. 695 Figure 1-1047 Remove the punch hole assembly (4 of 8) ............................................................................. 696 Figure 1-1048 Remove the punch hole assembly (5 of 8) ............................................................................. 696 Figure 1-1049 Remove the punch hole assembly (6 of 8) ............................................................................. 697 Figure 1-1050 Remove the punch hole assembly (7 of 8) ............................................................................. 697 Figure 1-1051 Remove the punch hole assembly (8 of 8) ............................................................................. 698 Figure 1-1052 Determine the punch hole skew ............................................................................................. 699 Figure 1-1053 Adjust the punch hole location ................................................................................................ 700 Figure 1-1054 Correct punch hole alignment ................................................................................................. 701 Figure 1-1055 Set the punch hole assembly type .......................................................................................... 702 Figure 1-1056 SW601 punch hole assembly type settings ............................................................................ 703 Figure 1-1057 SW601 sensor adjustment settings ........................................................................................ 703

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Figure 1-1058 Set the sensor adjustment values ........................................................................................... 704 Figure 1-1059 SW601 sensor adjustment settings ........................................................................................ 704 Figure 1-1060 SW601 sensor adjustment settings ........................................................................................ 705 Figure 2-1 M855 base product cover locations (1 of 2) .................................................................................. 715 Figure 2-2 M855 base product assembly locations (2 of 2) ........................................................................... 716 Figure 2-3 M880 base product assembly locations (1 of 2) ........................................................................... 718 Figure 2-4 M880 base product assembly locations ( 2 of 2) .......................................................................... 719 Figure 2-5 Stapler/stacker and booklet maker main assemblies ................................................................... 720 Figure 2-6 Stapler/stacker and booklet maker PCA ....................................................................................... 721 Figure 2-7 Stapler/stacker .............................................................................................................................. 722 Figure 2-8 Stapler/stacker with hole puncher external assembly locator ....................................................... 723 Figure 2-9 Staple stacker internal assembly locator ...................................................................................... 724 Figure 2-10 Staple stacker with hole puncher internal assembly locator ....................................................... 725 Figure 2-11 Staple stacker external assembly locator (door open) ................................................................ 726 Figure 2-12 Staple stacker with hole puncher external assembly locator (door open) .................................. 727 Figure 2-13 Booklet maker external assembly locator ................................................................................... 728 Figure 2-14 Booklet maker with hole puncher external assembly locator ...................................................... 729 Figure 2-15 Booklet maker internal assembly locator .................................................................................... 730 Figure 2-16 Booklet maker with hole puncher internal assembly locator ....................................................... 731 Figure 2-17 Booklet maker external assembly locator (door open) ............................................................... 732 Figure 2-18 Booklet maker with hole puncher external assembly locator (door open) .................................. 733 Figure 2-19 IPTU external assembly locator (1 of 3) ...................................................................................... 734 Figure 2-20 IPTU external assembly locator (2 of 3) ...................................................................................... 734 Figure 2-21 IPTU external assembly locator (3 of 3) ...................................................................................... 735 Figure 2-22 IPTU internal assembly locator (1 of 2) ....................................................................................... 736 Figure 2-23 IPTU internal assembly locator (2 of 2) ....................................................................................... 736 Figure 2-24 IPTU PCA ................................................................................................................................... 737 Figure 2-25 1x500-sheet feeder (1 of 2) ........................................................................................................ 738 Figure 2-26 1x500-sheet feeder (2 of 2) ........................................................................................................ 739 Figure 2-27 3x500-sheet feeder (1 of 2) ........................................................................................................ 740 Figure 2-28 3x500-sheet feeder (2 of 2) ........................................................................................................ 741 Figure 2-29 HCI feeder (1 of 6) ...................................................................................................................... 742 Figure 2-30 HCI feeder (2 of 6) ...................................................................................................................... 743 Figure 2-31 HCI feeder (3 of 6) ...................................................................................................................... 744 Figure 2-32 HCI feeder (4 of 6) ...................................................................................................................... 745 Figure 2-33 HCI feeder (5 of 6) ...................................................................................................................... 746 Figure 2-34 HCI feeder (6 of 6) ...................................................................................................................... 746 Figure 2-35 Document feeder and scanner assemblies (M880) .................................................................... 748 Figure 2-36 Document feeder assemblies (M880, 1 of 2) .............................................................................. 750 Figure 2-37 Document feeder assemblies (M880, 2 of 2) .............................................................................. 752 Figure 2-38 Scanner assemblies (M880) ....................................................................................................... 754

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Figure 2-39 Covers (M855) ............................................................................................................................ 756 Figure 2-40 Covers (M880) ............................................................................................................................ 758 Figure 2-41 Right door assembly ................................................................................................................... 760 Figure 2-42 Internal components (1 of 6) ....................................................................................................... 762 Figure 2-43 Internal components (2 of 6) ....................................................................................................... 764 Figure 2-44 Internal components (3 of 6) ....................................................................................................... 766 Figure 2-45 Internal components (4 of 6) ....................................................................................................... 768 Figure 2-46 Internal components (5 of 6) ....................................................................................................... 770 Figure 2-47 Internal components (6 of 6) ....................................................................................................... 772 Figure 2-48 Intermediate paper transfer unit (IPTU) assemblies ................................................................... 774 Figure 2-49 1x500-sheet feeder with stand (M855 only) covers .................................................................... 776 Figure 2-50 1x500-sheet feeder with stand components ............................................................................... 778 Figure 2-51 3x500-sheet feeder covers ......................................................................................................... 780 Figure 2-52 3x500-sheet feeder components ................................................................................................ 782 Figure 2-53 HCI feeder covers ....................................................................................................................... 784 Figure 2-54 HCI feeder internal components (1 of 2) ..................................................................................... 786 Figure 2-55 HCI feeder internal components (2 of 2) ..................................................................................... 788 Figure 2-56 Stapler/stacker covers ................................................................................................................ 790 Figure 2-57 Booklet maker covers ................................................................................................................. 792 Figure 2-58 Finisher main body (1 of 3) ......................................................................................................... 794 Figure 2-59 Finisher main body (2 of 3) ......................................................................................................... 796 Figure 2-60 Finisher main body (3 of 3) ......................................................................................................... 798 Figure 2-61 Stapler/stacker main body .......................................................................................................... 800 Figure 2-62 Booklet maker main body ........................................................................................................... 802 Figure 2-63 Booklet maker saddle assembly (1 of 3) ..................................................................................... 804 Figure 2-64 Booklet maker saddle assembly (2 of 3) ..................................................................................... 805 Figure 2-65 Booklet maker saddle assembly (3 of 3) ..................................................................................... 806

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Removal and replacement strategy

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Customer-self repair assemblies

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Pickup, feed, and separation rollers and pads

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Covers and doors

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Main assemblies

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Input accessories

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Intermediate paper transport unit (IPTU)

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Finishing accessories

1

Removal and replacement strategy Considerations during removal and replacement This chapter describes the removal and replacement of field-replaceable units (FRUs) only. Replacing FRUs is generally the reverse of removal. Notes are included to provide directions for difficult or critical replacement procedures. HP does not repairing individual subassemblies or troubleshooting to the PCA component level. WARNING! Never operate or service the product with the protective cover removed from the laser scanner assembly. The reflected beam, although invisible, can damage your eyes. WARNING! parts.

The sheet-metal parts can have sharp edges. Be careful when handling sheet-metal

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. If an ESD workstation or mat is not available, ground yourself by touching the sheet-metal chassis before touching an ESD-sensitive part. Protect the ESD-sensitive parts by placing them in ESD pouches when they are out of the product. CAUTION:

Do not bend or fold the flat cables during removal or installation.

NOTE: To install a self-tapping screw, first turn it counterclockwise to align it with the existing thread pattern, and then carefully turn it clockwise to tighten. Do not overtighten. If a self-tapping screw-hole becomes stripped, repair the screw-hole or replace the affected assembly. TIP: For clarity, some figures in this chapter show assemblies removed that are not required to be removed to service the product (for example, the M880 scanner and document feeder assemblies). The procedures in this manual are correct for your product.

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Required tools ●

#2 Phillips screwdriver with a magnetic tip and a 152-mm (6-in) shaft length NOTE:

For the best fit, use a JIS #2 Phillips screwdriver for the stapler/stacker.

●

Small, flat-blade screwdriver

●

Needle-nose pliers

●

ESD strap (if one is available)

●

Penlight

CAUTION: Always use a Phillips screwdriver (callout 1). Do not use a Pozidriv screwdriver (callout 2) or any motorized screwdriver. These can damage screws or screw threads. Figure 1-1 Screwdrivers

Types of screws WARNING! Make sure that assemblies are replaced with the correct screw type. Using the incorrect screw (for example, substituting a long screw for the correct shorter screw) can cause damage to the product or interfere with product operation. Do not intermix screws that are removed from one assembly with the screws that are removed from another assembly. For a complete list of screw types and part numbers, see the Parts chapter in the product repair manual.

Service approach The products described in this manual use a field repair strategy. Defective parts are diagnosed and replaced at the Field Replaceable Unit (FRU) assembly level. Repair normally begins by using the product internal diagnostics and the following two-step process: 1.

Isolate the problem to the major system (for example, the network or server, or the product).

2.

Troubleshoot the problem by using the procedures in the troubleshooting manual.

After you locate a faulty part, the product can usually be repaired at the assembly level by replacing FRUs. Some mechanical assemblies might need to be repaired at the subassembly level. HewlettPackard Company does not replacement of components on the printed circuit assembles. The replaces toner cartridges as they are depleted. Additional instructions about other replaceable parts are provided in this section.

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The product tracks the amount of use on the customer-replaceable supplies by keeping a page count. The product prompts the to replace certain items when a supply is depleted or a specific number of pages has been printed. Swapping toner cartridges between products might cause a misrepresentation of supply life values and is not recommended.

Before performing service WARNING! Turn the product off, wait 5 seconds, and then remove the power cord before attempting to service the product. If this warning is not followed, severe injury and damage to the product can result. The power must be on for certain functional checks during troubleshooting. However, the power supply should be disconnected during parts removal. 1.

Remove all paper.

2.

Place the product on an ESD mat (if available). If an ESD workstation or mat is not available, ground yourself by touching the sheet-metal chassis before touching an ESD-sensitive part.

3.

Remove the toner cartridges.

4.

Remove the imaging drums.

5.

Remove the trays.

After performing service 1.

Reinstall the toner cartridges.

2.

Reinstall the trays.

3.

Reinstall the imaging drums.

4.

Return all paper to the trays.

5.

Plug in the power cable and turn on the product.

6.

Perform print-quality tests by printing from a host computer, the scanner glass, and the document feeder.

Parts removal order If multiple components must be removed to gain access to an assembly, the first step of the removal procedure lists all of the components that must be removed to gain access to that assembly. Use these lists to determine which parts must be removed before removing other parts.

ed paper sizes and types If the product is experiencing assembly failure, use the tables in this section to that the customer is using media that meets HP specifications.

4

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ed paper sizes for the input trays and duplexer

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ed paper types for the input trays and duplexer

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ed paper sizes for the finishing accessories

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ed paper types for the finishing accessories

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ed paper sizes for the input trays and duplexer NOTE: To obtain the best results, select the correct paper size and type in the print driver before printing. Table 1-1 ed paper sizes for the input trays and duplexer Size and dimensions

Tray 1

Tray 2

3x500-sheet trays

3,500-sheet highcapacity trays

Automatic duplex printing

Letter 279 x 216 mm (11 x 8.5 in) Letter Rotated 216 x 279 mm (8.5 x 11 in) Legal 216 x 356 mm (8.5 x 14 in) Executive 267 x 184 mm (10.5 x 7.3 in) Statement 216 x 140 mm (8.5 x 5.5 in) Oficio (8.5 x 13) 216 x 330 mm (8.5 x 13 in) 11 x 17 279 x 432 mm (11 x 17 in) 12 x 18 305 x 457 mm (12 x 18 in) 3x5 76 x 127 mm (3 x 5 in) 4x6 101 x 152 mm (4 x 6 in) 5x7 127 x 178 mm (5 x 7 in) 5x8 127 x 203 mm (5 x 8 in) A3 297 x 420 mm (11.7 x 16.5 in) A4 297 x 210 mm (11.7 x 8.3 in)

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Table 1-1 ed paper sizes for the input trays and duplexer (continued) Size and dimensions

Tray 1

Tray 2

3x500-sheet trays

3,500-sheet highcapacity trays

Automatic duplex printing

A4 Rotated 210 x 297 mm (8.3 x 11.7) A5 148 x 210 mm (5.8 x 8.3 in) A6 105 x 148 mm (4.2 x 5.8 in) RA3 305 x 430 mm (12 x 17 in) RA4 215 x 305 mm (8.5 x 12 in) SRA3 320 x 450 mm (12.6 x 17.7 in) SRA4 225 x 320 mm (8.9 x 12.6 in) B4 (JIS) 257 x 364 mm (10.1 x 14.3 in) B5 (JIS) 257 x 182 mm (10.1 x 7.2 in) B6 (JIS) 128 x 182 mm (5.1 x 7.2 in) Oficio (216 x 340) 215.9 x 340 mm (8.5 x 13.4 in) 8K 270 x 390 mm 270 x 390 mm (10.6 x 15.4 in) 16K 195 x 270 mm 270 x 195 mm (10.6 x 7.7 in) 8K 260 x 368 mm 260 x 368 mm (10.2 x 14.5 in) 16K 184 x 260 mm 260 x 184 mm (10.2 x 7.2 in) 8K 273 x 394 mm 273 x 394 mm (10.8 x 16 in)

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Table 1-1 ed paper sizes for the input trays and duplexer (continued) Size and dimensions

Tray 1

Tray 2

3x500-sheet trays

3,500-sheet highcapacity trays

Automatic duplex printing

16K 197 x 273 mm 273 x 197 mm (10.8 x 7.8 in) D Postcard (JIS) 148 x 200 mm (5.8 x 7.9 in) Envelope #9 98 x 225 mm (3.9 x 8.9 in) Envelope #10 105 x 241 mm (4.1 x 9.5 in) Envelope Monarch 98 x 191 mm (3.9 x 7.5 in) Envelope B5 176 x 250 mm (6.9 x 9.8 in) Envelope C5 162 x 229 mm (6.4 x 9 in) Envelope C6 114 x 162 mm (4.5 x 6.4in) Envelope DL 110 x 220 mm (4.3 x 8.7 in) Custom 76 x 127 mm to 320 x 457 mm (3.0 x 5.0 in to 12.6 x 18.0 in) Custom 148 x 210 mm to 297 x 432 mm (5.9 x 8.3 in to 11.6 x 17 in) Custom 148 x 210 mm to 320 x 457 mm (5.9 x 8.3 in to 12.6 x 18.0 in) Custom 175 x 210 mm to 320 x 457 mm (6.9 x 8.3 in to 12.6 x 18.0 in)

ed paper types for the input trays and duplexer Tray 1, Tray 2, and the 3x500-sheet trays several types of paper in the following weight range: 60-220 g/m2 (16-58 lb).

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The 3,500-sheet high-capacity trays cut-sheet paper in the following weight range: 60-120 g/ m2 (16-32 lb). The automatic duplex printing unit s paper in the following weight range: 60-220 g/m2 (16-58 lb). NOTE: To obtain the best results, select the correct paper size and type in the print driver before printing. Table 1-2 ed paper types Paper type

Tray 1

Tray 2

3x500-sheet trays

3,500-sheet highcapacity trays

Automatic duplex printing

Cut-sheet paper Labels Transparencies Glossy paper Glossy film Photo paper Envelopes

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ed paper sizes for the finishing accessories NOTE: For paper dimensions, see ed paper sizes for the input trays and duplexer on page 5 Table 1-3 ed paper sizes for the finishing accessories Size

Stacking

Stacking

Staple

Staple

Hole punch

Hole punch

(Portrait)

(Landscape)

(Corner)

(Saddle)

2 holes

3–4 holes

Booklet

Letter Letter Short-edge feed Legal Executive Executive Short-edge feed Statement Oficio (8.5 x 13) 11 x 17 12 x 18 3x5 4x6 5x7 5x8 A3 A4 A4 Short-edge feed A5 A6 RA3 RA4 SRA3 SRA4 B4 (JIS) B5 (JIS)

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Table 1-3 ed paper sizes for the finishing accessories (continued) Size

Stacking

Stacking

Staple

Staple

Hole punch

Hole punch

(Portrait)

(Landscape)

(Corner)

(Saddle)

2 holes

3–4 holes

Booklet

B5 (JIS) Short-edge feed B6 (JIS) Oficio (216 x 340) 8K 270 x 390 mm 16K 195 x 270 mm 16K 195 x 270 mm Short-edge feed 8K 260 x 368 mm 16K 184 x 260 mm 16K 184 x 260 mm Short-edge feed 8K 273 x 394 mm 16K 197 x 273 mm 16K 197 x 273 mm Short-edge feed D Postcard (JIS) Envelope #9 Envelope #10 Envelope Monarch Envelope B5 Envelope C5 Envelope C6

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Table 1-3 ed paper sizes for the finishing accessories (continued) Size

Stacking

Stacking

Staple

Staple

Hole punch

Hole punch

(Portrait)

(Landscape)

(Corner)

(Saddle)

2 holes

3–4 holes

Booklet

Envelope DL Custom Dimensions vary

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ed paper types for the finishing accessories NOTE: The number of sheets that can be stapled or folded into booklets varies with the thickness and size of the paper. The numbers in the following table indicate the number of sheets ed for each feature. Pages through the hole punch unit one sheet at a time. Table 1-4 ed paper types for the finishing accessories Type

Stacking in bins 1 or 2

Staples, small sheets of paper

Staples, large sheets of paper

Plain

50

HP EcoSMART Lite

Hole punch

Booklets in bin 3 with one cover sheet

Booklets in bin 3 with no cover sheet

30

14

15

50

30

14

15

HP Matte 90g

44

22

9

10

Light 60-74g

50

30

14

15

Bond

50

30

9

10

Recycled

50

30

14

15

Intermediate 85-95g

50

30

5

6

HP Matte 120g

18

11

4

5

HP Soft Gloss 120g

8

8

4

5

HP Glossy 120g

8

8

4

5

Mid-Weight 96-110g

18

11

4

5

Heavy 111-130g

18

9

4

5

Mid-Weight Glossy 96-110g

8

8

4

5

Heavy Glossy 111-130g

8

8

4

5

HP Matte 150g

13

9

2

3

HP Glossy 150g

5

5

Extra Heavy 131-175g

12

16

2

3

Extra Heavy Glossy 131-175g HP Matte 200g HP Glossy 200g Cardstock 176-220g Card Glossy 176-220g

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Table 1-4 ed paper types for the finishing accessories (continued) Type

Stacking in bins 1 or 2

Staples, small sheets of paper

Staples, large sheets of paper

50

Preprinted

Hole punch

Booklets in bin 3 with one cover sheet

Booklets in bin 3 with no cover sheet

30

14

15

50

30

14

15

Prepunched

50

30

Colored

50

30

14

15

Rough

50

30

9

10

Heavy Rough

18

11

5

6

Color Transparency Labels Letterhead Envelope Heavy Envelope

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Customer-self repair assemblies Toner cartridge 1.

Open the front door.

2.

Grasp the handle of the toner cartridge, and then pull out to remove it. Figure 1-2 Remove the toner cartridge

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Imaging drum 1.

Open the front door.

2.

Grasp the handle at the front of the imaging drum, and then slide it out until the blue handle on the top is visible. Grasp the blue handle on the top, and then slide the imaging drum all the way out to remove it. CAUTION: Do not touch or scratch the green cylinder on the bottom of the drum. While the imaging drum is out of the product, cover the green cylinder with paper to protect it from light exposure. Figure 1-3 Remove the image drum

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Secondary transfer roller 1.

Open the right door.

2.

Lift the green handle on the transfer assembly, and then open the . Figure 1-4 Remove the secondary transfer roller (1 of 2)

3.

Remove the secondary transfer roller. Figure 1-5 Remove the secondary transfer roller (2 of 2)

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Reinstall the secondary transfer roller Align the secondary transfer roller with the slots in the product, and then push until it clicks into place. Figure 1-6 Reinstall the secondary transfer roller

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Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 Slide the tray open until it stops, and then lift up on the front of the tray to release it. Remove the tray. NOTE: Tray 2 is shown below. The procedure is the same for the 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5. Figure 1-7 Remove Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5

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Intermediate transfer belt (ITB) 1.

Open the right door. Figure 1-8 Remove the ITB (1 of 4)

2.

Lift the green handle on the transfer assembly, and then open the . Figure 1-9 Remove the ITB (2 of 4)

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19

3.

Raise the ITB levers. Figure 1-10 Remove the ITB (3 of 4)

4.

Remove the ITB. Figure 1-11 Remove the ITB (4 of 4)

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F WARNING! 1.

The f might be hot.

Open the right door. Figure 1-12 Remove the f (1 of 3)

2.

Rotate the two blue f handles toward the center of the f as shown below. Figure 1-13 Remove the f (2 of 3)

3.

Grasp the handles and slide the f toward the right door to remove it. Figure 1-14 Remove the f (3 of 3)

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Switch back tray Press and hold one button (callout 1) while pulling the switch back tray away from the product (callout 2) to remove it. NOTE: The M855 is shown below. The procedure is the same for the M880. Figure 1-15 Remove the switch back tray

2 1

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Formatter 1.

Loosen two screws. Figure 1-16 Remove the formatter (1 of 2)

2.

Grasp the screws, and then slide the formatter out of the product. Figure 1-17 Remove the formatter (2 of 2)

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23

Reinstall the formatter or install a replacement formatter 1.

Remove the following components from the existing formatter, and then reinstall them on the replacement formatter. NOTE: Not all of these components will be installed on the formatter---which components are installed depends on the product configuration. Identify the installed components, remove those components, and then install them on the replacement formatter.

2.

●

Hard-disk drive. See Remove the HDD on page 26.

●

Solid-state memory. See Remove the SSM on page 28.

●

Memory DIMM. See Memory DIMM on page 32.

●

Fax PCA. See Fax PCA (M880) on page 35.

Make sure that the formatter is seated completely when reinstalling it. To that the formatter is correctly installed, use the power switch to turn on the product power, and then observe the following functions of the LEDs on the formatter. ●

The heartbeat LED (callout 1) illuminates if the formatter is completely seated.

●

The connectivity LED (callout 2) indicates that the formatter is functioning correctly. ◦

While the product is initializing, the connectivity LED rapidly blinks, and then turns off.

◦

After the initialization sequence is complete, the connectivity LED slowly blinks continuously.

If the LEDs do not function correctly, see the LED diagnostics section in the product troubleshooting manual.

2 1

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Hard-disk drive (HDD) or solid-state memory (SSM) Before proceeding, remove the following assemblies: ●

Formatter. See Formatter on page 23.

Identify the storage device

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■

Hard-disk drive (HDD). See Remove the HDD on page 26.

■

Solid-state memory (SSM). See Remove the SSM on page 28.

Customer-self repair assemblies

25

Remove the HDD CAUTION: 1.

ESD sensitive assembly.

Disconnect two connectors (callout 1). CAUTION: To disconnect the black connector (callout 2), grasp the connector and pull upward. Do not pull on the cable to disconnect the connector. Figure 1-18 Remove the HDD (1 of 2)

1 2

2.

Release two tabs (callout 1), and then slide the HDD out and away from the plastic mounting bracket (callout 2) to remove it. Figure 1-19 Remove the HDD (2 of 2)

2

1

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Reinstall the HDD NOTE: If you are installing a replacement drive, you must reinstall the product firmware. See Reinstall the product firmware on page 30.

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27

Remove the SSM CAUTION: 1.

ESD sensitive assembly.

Disconnect two connectors (callout 1). CAUTION: To disconnect the black connector (callout 2), grasp the connector and pull upward. Do not pull on the cable to disconnect the connector. Figure 1-20 Remove the SSM (1 of 2)

1 2

2.

Release two tabs (callout 1), and then slide the solid state memory out and away from the plastic mounting bracket (callout 2) to remove it. Figure 1-21 Remove the SSM (2 of 2)

2 1

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Reinstall the SSM NOTE: If you are installing a replacement SSM, you must reinstall the product firmware. See Reinstall the product firmware on page 30.

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29

Reinstall the product firmware NOTE: If you are installing a replacement HDD or SSM, use the procedure below to reinstall the product firmware on the replacement drive. If you are removing the HHD or SSM so that it can be installed on a replacement formatter, you can skip this procedure. 1.

Locate the product Web site. ●

In the US: ◦

●

Go to www.hp.com//colorljM855 or www.hp.com//colorljflowMFPM880 .

Outside the US: ◦

Go to http://www.hp.com/

◦

Select your country/region.

◦

Select Product & Troubleshooting

◦

Enter the product name, and then select Search.

2.

Select Drivers, Software, and Firmware, and then select Cross operating system (BIOS, Firmware, Diagnostics, etc.).

3.

Locate the firmware , and then select .

4.

Copy the firmware upgrade file to the root directory of a USB flash drive. The firmware upgrade file has a .bdl extension.

5.

Insert the USB flash drive into the USB port on the product control .

6.

The following message displays on the control : Error: 99.09.63 Incorrect Disk. Touch the OK button to continue.

7.

Wait for the Pre-Boot menu to appear on the control display, and then touch the down arrow button to scroll to 3 . Touch the OK button to select it.

8.

Touch the down arrow

button to scroll to 6 Manage Disk. Touch the OK button to select it.

9.

Touch the down arrow

button to scroll to 4 Clear Disk PWD. Touch the OK button to select it.

10. The message Proceed with Requested Action displays. Touch the OK button to select it. 11. Touch the back

button to return to the Pre-Boot menu home screen.

12. Touch the down arrow

button to scroll to 3 . Touch the OK button to select it.

13. Touch the down arrow

button to scroll to 1 . Touch the OK button to select it.

14. Touch the down arrow

button to scroll to 3 USB Thumbdrive. Touch the OK button to select it.

15. Touch the down arrow button to scroll to the firmware upgrade file that you ed in step 4. Touch the OK button to select it. NOTE:

30

If no .bdl files are listed, try saving the file to a different USB flash drive.

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16. Wait while the file transfers. When the transfer is complete, the message Complete displays on the screen. 17. Turn the product off, remove the USB flash drive, and then turn the product on. Wait for several minutes while the product initializes.

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31

Memory DIMM Before proceeding, remove the following assemblies: ●

Formatter. See Formatter on page 23.

Remove the memory DIMM CAUTION: 1.

ESD sensitive assembly.

Release two clips. Figure 1-22 Remove the memory DIMM (1 of 2)

2.

Rotate the DIMM upward (callout 1), and then remove it (callout 2). Figure 1-23 Remove the memory DIMM (2 of 2)

1

2

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Reinstall the memory DIMM 1.

Align the notch (callout 1) on the DIMM with the tab (callout 2) on the connector. Figure 1-24 Reinstall the memory DIMM

1 2

2.

Slide the DIMM into the connector (callout 1), and then rotate the DIMM down, toward the formatter. (callout 2). Figure 1-25 Reinstall the memory DIMM

2

1

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Customer-self repair assemblies

33

3.

Make sure that the memory DIMM snaps into the holder. Figure 1-26 Reinstall the memory DIMM

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Fax PCA (M880) Before proceeding, remove the following assemblies: ●

Formatter. See Formatter on page 23.

Remove the fax PCA (M880) CAUTION: 1.

ESD sensitive assembly.

Rotate the connector end of the fax PCA up and away from the formatter to release it. Figure 1-27 Remove the fax PCA (M880; 1 of 2)

2.

Carefully remove the fax PCA from the formatter bracket. Figure 1-28 Remove the fax PCA (M880; 2 of 2)

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35

Document feeder mylar strip (M880) 1.

Open the document feeder cover. Figure 1-29 Remove the document feeder mylar strip (M880; 1 of 4)

2.

Locate the mylar strip. Figure 1-30 Remove the document feeder mylar strip (M880; 2 of 4)

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Chapter 1 Removal and replacement

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3.

Carefully remove the mylar strip. Figure 1-31 Remove the document feeder mylar strip (M880; 3 of 4)

4.

Use your finger to remove any adhesive that remains after removing the mylar strip. Figure 1-32 Remove the document feeder mylar strip (M880; 4 of 4)

Install a replacement document feeder mylar strip (M880) Use the following guidelines when you install the replacement mylar strip:

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1.

Skin oils on the mylar strip can cause paper pickup problems. Wash your hands before handling the replacement mylar strip.

2.

When handling the replacement mylar strip, do not touch the adhesive portion of the strip.

Customer-self repair assemblies

37

3.

Position the replacement mylar strip as shown, with the rounded corners on the strip facing the document tray. NOTE:

Make sure that the adhesive side of the guide is face down.

Figure 1-33 Install a replacement document feeder mylar strip (M880; 1 of 2)

4.

Press down firmly on the strip to adhere it to the product. Figure 1-34 Install a replacement document feeder mylar strip (M880; 2 of 2)

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Chapter 1 Removal and replacement

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Document feeder white backing (M880) 1.

Open the document feeder. Figure 1-35 Remove the document feeder white backing (M880; 1 of 3)

2.

Carefully remove the white backing. Figure 1-36 Remove the document feeder white backing (M880; 2 of 3)

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Customer-self repair assemblies

39

3.

Remove any rubber stoppers that might still be attached to the document feeder. Figure 1-37 Remove the document feeder white backing (M880; 3 of 3)

Install a replacement document feeder white backing (M880) 1.

Position the replacement white backing on the scanner glass. Carefully remove the protective backing from the rubber stoppers. CAUTION: Do not touch the exposed adhesive. Figure 1-38 Install a replacement document feeder white backing (M880; 1 of 6)

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Chapter 1 Removal and replacement

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2.

Make sure that the arrow on the replacement white backing is positioned in the upper-left corner of the scanner glass. Figure 1-39 Install a replacement document feeder white backing (M880; 2 of 6)

3.

Completely close the document feeder. Figure 1-40 Install a replacement document feeder white backing (M880; 3 of 6)

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Customer-self repair assemblies

41

4.

Firmly push down on the four corners of the document feeder to adhere the white backing to the document feeder. Figure 1-41 Install a replacement document feeder white backing (M880; 4 of 6)

5.

Carefully open the document feeder. Figure 1-42 Install a replacement document feeder white backing (M880; 5 of 6)

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Chapter 1 Removal and replacement

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6.

Firmly press on the white backing over the areas shown below to make sure that the rubber stoppers are completely adhered to the document feeder. Figure 1-43 Install a replacement document feeder white backing (M880; 6 of 6)

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43

Background selector (M880) 1.

Open the document-feeder door. Figure 1-44 Remove the background selector (M880; 1 of 4)

2.

Rotate the input tray up. Figure 1-45 Remove the background selector (M880; 2 of 4)

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3.

Release two tabs. Figure 1-46 Remove the background selector (M880; 3 of 4)

4.

Slide the background selector away from the product to remove it. Figure 1-47 Remove the background selector (M880; 4 of 4)

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Customer-self repair assemblies

45

Reinstall the background selector (M880) Push in on the background selector until the tabs snap into place. NOTE: If jams occur after the assembly is installed, make sure that the assembly is fully seated. Figure 1-48 Reinstall the background selector (M880)

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Chapter 1 Removal and replacement

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Control assembly (M855) 1.

Tilt the control up. Figure 1-49 Remove the control assembly (M855; 1 of 10)

2.

Release one tab. Figure 1-50 Remove the control assembly (M855; 2 of 10)

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47

3.

Remove the cover. Figure 1-51 Remove the control assembly (M855; 3 of 10)

4.

Release one blue locking latch. Figure 1-52 Remove the control assembly (M855; 4 of 10)

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5.

Rotate the back of the control up and away from the product. Figure 1-53 Remove the control assembly (M855; 5 of 10)

6.

Lift the control assembly up and off of the product. CAUTION: The control is still attached to the product by the control- cables. Do not attempt to completely remove the assembly. Figure 1-54 Remove the control assembly (M855; 6 of 10)

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Customer-self repair assemblies

49

7.

Tilt the control forward to access the control- connectors. Figure 1-55 Remove the control assembly (M855; 7 of 10)

8.

Remove one screw (callout 1), and then release one ground wire (callout 2). Figure 1-56 Remove the control assembly (M855; 8 of 10)

1

2

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9.

Disconnect two USB cables (callout 1), and then disconnect one connector (callout 2). Figure 1-57 Remove the control assembly (M855; 9 of 10)

2

1

10. Remove the control assembly. Figure 1-58 Remove the control assembly (M855; 10 of 10)

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51

Reinstall the control assembly (M855) Make sure that the USB cables (callout 1) are connected to the correct connectors. See the label (callout 2) next to the connectors. NOTE: One connector on the control is not used and remains empty. Figure 1-59 Reinstall the control (M855)

2

1

52

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Control assembly (M880) 1.

Tilt the control up. Figure 1-60 Remove the control assembly (M880; 1 of 8)

2.

Release one tab (callout 1), and then rotate the cover up (callout 2) to remove it. Figure 1-61 Remove the control assembly (M880; 2 of 8)

1 2

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Customer-self repair assemblies

53

3.

Slide the keyboard about halfway out of the product. Figure 1-62 Remove the control assembly (M880; 3 of 8)

4.

Disconnect two connectors. Figure 1-63 Remove the control assembly (M880; 4 of 8)

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5.

Remove one screw. TIP:

Use the edge of a coin to loosen the screw.

Figure 1-64 Remove the control assembly (M880; 5 of 8)

6.

Slide the keyboard tray all the way into the product. Figure 1-65 Remove the control assembly (M880; 6 of 8)

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55

7.

Slide the control toward the right door. Figure 1-66 Remove the control assembly (M880; 7 of 8)

8.

Slide the control toward the front of the product to remove it. Reinstallation tip If you are installing a replacement control assembly, remove the keyboard assembly so that it can be installed on the replacement control assembly. See Keyboard assembly (M880) on page 59. IMPORTANT: If a device is installed in the hardware integration pocket (HIP), remove the HIP cover. See Hardware integration pocket (HIP) cover (M880) on page 98. Remove the device and transfer it to the replacement control . Figure 1-67 Remove the control assembly (M880; 8 of 8)

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Chapter 1 Removal and replacement

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Reinstall the control assembly (M880) 1.

Insert the cable and wire harness (callout 1) into the opening at the back of the control (callout 2). Figure 1-68 Reinstall the control assembly (M880; 1 of 3)

2 1

2.

Insert the tabs on the control into the slots on the product. Figure 1-69 Reinstall the control assembly (M880; 2 of 3)

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Customer-self repair assemblies

57

3.

Slide the control toward the left door to secure it to the product. Figure 1-70 Reinstall the control assembly (M880; 3 of 3)

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Chapter 1 Removal and replacement

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Keyboard assembly (M880) Before proceeding, remove the following assemblies: ●

Control (M880). See Control assembly (M880) on page 53.

Remove the keyboard assembly (M880) 1.

Place the control on a flat surface. Figure 1-71 Remove the keyboard assembly (M880; 1 of 7)

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59

2.

Open the hinged latch to release the flat cable. CAUTION: This connector is a Zero Insertion Force (ZIF) connector that uses a hinged retainer to secure a flat cable. The hinged retainer must be opened to release the flat cable. CAUTION: Be careful. Do not dislodge the latch from the connector when opening it. Figure 1-72 Remove the keyboard assembly (M880; 2 of 7)

3.

Disconnect the flat cable. Figure 1-73 Remove the keyboard assembly (M880; 3 of 7)

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4.

Tilt the screen down until it lies flat. Figure 1-74 Remove the keyboard assembly (M880; 4 of 7)

5.

Slide the keyboard tray all of the way out of the control until it stops. Figure 1-75 Remove the keyboard assembly (M880; 5 of 7)

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6.

Turn the control face-down on the work surface. Figure 1-76 Remove the keyboard assembly (M880; 6 of 7)

7.

Release and hold two tabs (callout 1) while sliding the keyboard tray away from the control (callout 2) to remove it. Figure 1-77 Remove the keyboard assembly (M880; 7 of 7)

1

2

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Reinstall the keyboard assembly (M880) 1.

Turn the keyboard tray upside down, and then position the flat cable (callout 1) inside the tray cavity. Align the edges of the tray (callout 2) with the slots in the control (callout 3). Figure 1-78 Reinstall the keyboard assembly (M880; 1 of 7)

3 1 2

2.

Slide the keyboard tray all the way into the control . The tabs on the tray snap into place as it is installed. Figure 1-79 Reinstall the keyboard assembly (M880; 2 of 7)

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3.

Turn the control face-up. Figure 1-80 Reinstall the keyboard assembly (M880; 3 of 7)

4.

Tilt the screen up. Figure 1-81 Reinstall the keyboard assembly (M880; 4 of 7)

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5.

Open the hinged latch, and then position the flat cable in the connector. CAUTION: Be careful. Do not dislodge the latch from the connector when opening it. Figure 1-82 Reinstall the keyboard assembly (M880; 5 of 7)

6.

Carefully close the latch to lock the flat cable into position. CAUTION: This connector is a Zero Insertion Force (ZIF) connector that uses a hinged retainer to secure a flat cable. When the flat cable is reinstalled, fully insert the flat cable in the connector, and then close the hinged retainer to lock the flat cable into the connector and provide proper electrical . If the flat cable is not locked into the connector, no electrical will occur. CAUTION: Be careful. Do not dislodge the latch from the connector when closing it. Figure 1-83 Reinstall the keyboard assembly (M880; 6 of 7)

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7.

Lightly pull on the flat cable to that it is securely fastened in the connector. CAUTION: Be careful. Do not use your full force to pull on the flat cable. A light pull on the cable is sufficient to that it is securely fastened. Figure 1-84 Reinstall the keyboard assembly (M880; 7 of 7)

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Pickup, feed, and separation rollers and pads

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●

Document-feeder roller (M880 only)

●

Document-feeder separation pad (M880 only)

●

Tray 1 rollers

●

Tray 2, 1x500-sheet feeder, and 3x500-sheet feeder rollers

●

High-capacity input (HCI) rollers

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67

Document-feeder roller (M880 only) CAUTION: If you are replacing the roller, do not touch the surface of the replacement roller. Skin oils deposited on the roller might cause paper pickup problems. 1.

Open the document-feeder door. Figure 1-85 Remove the document-feeder roller (M880; 1 of 3)

2.

Release one tab, and then open the access door. Figure 1-86 Remove the document-feeder roller (M880; 2 of 3)

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3.

Slide the roller left, and then lift it up and out of the product. Figure 1-87 Remove the document-feeder roller (M880; 3 of 3)

Reinstall the document-feeder roller (M880 only) The roller assembly is keyed. When reinstalling the roller assembly, position the hex-shaped fitting on the shaft toward the rear of the product. Figure 1-88 Reinstall the document-feeder roller (M880)

IMPORTANT: When the roller is reinstalled, the access door must be fully closed. When you close the door, you should hear two audible clicks. If, after replacing the roller document feeder, a document feeder jam message appears on the control display, make sure that the access door is fully closed.

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Document-feeder separation pad (M880 only) CAUTION: If you are replacing the pad, do not touch the surface of the replacement pad. Skin oils deposited on the pad might cause paper pickup problems. 1.

Open the document-feeder door. Figure 1-89 Remove the document-feeder separation pad (M880; 1 of 4)

2.

Release one tab to open the access door. Figure 1-90 Remove the document-feeder separation pad (M880; 2 of 4)

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3.

The separation pad is spring-loaded and partially releases when the access door is opened. Figure 1-91 Remove the document-feeder separation pad (M880; 3 of 4)

4.

Lift the separation pad up and away from the product. CAUTION: If the spring becomes dislodged, securely reinstall it as shown below. Figure 1-92 Remove the document-feeder separation pad (M880; 4 of 4)

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Reinstall the document-feeder separation pad (M880 only) 1.

Release and hold the separation pad access door open. Figure 1-93 Reinstall the document-feeder separation pad (M880; 1 of 5)

2.

Align the pins on the separation pad with the mounting slots. Figure 1-94 Reinstall the document-feeder separation pad (M880; 2 of 5)

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3.

Carefully press down on the separation pad to compress the spring. Figure 1-95 Reinstall the document-feeder separation pad (M880; 3 of 5)

4.

Continue to press down on the separation pad, and then release the access door. Figure 1-96 Reinstall the document-feeder separation pad (M880; 4 of 5)

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73

5.

that the separation pad is correctly installed and that the access door is fully closed as shown below. Figure 1-97 Reinstall the document-feeder separation pad (M880; 5 of 5)

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Tray 1 rollers CAUTION: Do not touch the surface of the rollers. Skin oils deposited on the rollers might cause paper pickup problems. 1.

Open the right door.

2.

Release two hinge pins and then remove the paper-feed cover. Figure 1-98 Remove the Tray 1 rollers (1 of 5)

3.

Release one tab (callout 1), slide the multipurpose upper feed guide to the right to release it (callout 2), and then lift it away from the door to remove it (callout 3). Figure 1-99 Remove the Tray 1 rollers (2 of 5)

2

1 3

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75

4.

Remove one plastic clip. Figure 1-100 Remove the Tray 1 rollers (3 of 5)

5.

Remove the upper roller by sliding it to the right. Figure 1-101 Remove the Tray 1 rollers (4 of 5)

6.

Pinch and hold the tab at the end of the lower roller to release it, and then slide the roller to the right to release it from the metal shaft. Slide the roller down to remove it. Figure 1-102 Remove the Tray 1 rollers (5 of 5)

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Reinstall the Tray 1 rollers Position the tabs on the multipurpose upper feed guide in the slots in the right door, and then slide it to the left to secure it to the door. One tab will click into place when the guide is seated properly. Figure 1-103 Reinstall the Tray 1 rollers

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77

Tray 2, 1x500-sheet feeder, and 3x500-sheet feeder rollers Before proceeding, remove one or more of the following trays, depending upon which rollers you are replacing: ●

Tray 2. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 Tray 3 (1x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 3 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 4 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 5 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

CAUTION: Do not touch the surface of the rollers. Skin oils deposited on the rollers might cause paper pickup problems. NOTE: Tray 2 is shown in the figures below. The procedure is the same for all of the referenced trays.

Remove the Tray 2, 1x500-sheet feeder, and 3x500-sheet feeder rollers 1.

Remove the appropriate tray. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

2.

Locate the rollers on the right-hand side of the tray cavity. Figure 1-104 Remove the Tray 2, 1x500, and 3x500 rollers (1 of 2)

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3.

Grasp the plastic tab on the roller and then pull the roller off of the rod. Repeat the process for the other rollers. Figure 1-105 Remove the Tray 2, 1x500, and 3x500 rollers (2 of 2)

1

2

3

Reinstall the Tray 2, 1x500-sheet feeder, and 3x500-sheet feeder rollers Reinstall the rollers in the order shown below. Make sure that the rollers snap into place. Figure 1-106 Reinstall the Tray 2, 1x500, and 3x500 rollers

1

2

3

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High-capacity input (HCI) rollers Before proceeding, remove the following assemblies: ●

HCI right tray. See HCI right tray on page 360.

●

HCI left tray. See HCI left tray on page 361.

CAUTION: If you are replacing the rollers, do not touch the surface of the replacement rollers. Skin oils deposited on the rollers might cause paper pickup problems.

Remove the HCI rollers 1.

Locate the rollers inside the tray cavity. Figure 1-107 Remove the HCI rollers (1 of 2)

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2.

Pinch the tabs at the end of the rollers to release them, and then remove two rollers in the order shown below. NOTE:

One roller is not replaced.

Figure 1-108 Remove the HCI rollers (2 of 2)

1

3

2

Reinstall the HCI rollers Reinstall the rollers in the order shown below. Make sure that the rollers snap into place. Figure 1-109 Reinstall the HCI rollers

1

2

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81

Covers and doors TIP: For clarity, some figures in this chapter show assemblies removed that are not required to be removed to service the product (for example, the scanner and document feeder assemblies). The procedures in this manual are correct for your product.

82

●

Location of major components

●

Scanner back cover (M880)

●

Scanner left cover (M880)

●

Scanner right cover (M880)

●

Scanner front cover (M880)

●

Right upper rear cover (M855)

●

Hardware integration pocket (HIP) cover (M855)

●

Hardware integration pocket (HIP) cover (M880)

●

Face-down bin

●

Left rear cover

●

Switch back cover

●

Lower right cover

●

Rear upper rear cover (M880)

●

Right upper rear cover (M880)

●

Rear upper MFP cover (M880)

●

Left upper rear cover and rear upper B cover (M880)

●

Rear upper front cover (M880)

●

Front top cover

●

Rear top cover (M855)

●

Left cover

●

Right upper front cover (M855)

●

Right upper front cover (M880)

●

Right upper cover (M855)

●

Right door assembly

●

Left front cover

●

Front door

●

Rear cover

●

Right rear cover

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●

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83

Location of major components Figure 1-110 M855 base product covers and doors (1 of 2)

11

10 9 8

11

7

22

33 4

6 5

Table 1-5 M855 base product covers and doors (1 of 2)

84

Item

Description

Item

Description

1

Tray 1

7

Tray 2

2

Right door

8

Power switch

3

Switch back tray

9

Front door

4

Face-down bin

10

HIP cover

5

Power receptacle

11

USB insertion slot

6

Engine test button

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Figure 1-111 M855 base product covers and doors (2 of 2)

11 15

22

14

33

13 12 12

44

11 5

10 9

6

8

77 Table 1-6 M855 base product covers and doors (2 of 2)

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Item

Description

Item

Description

1

Right upper cover

9

Rear cover

2

Switch back cover

10

Rear top cover

3

Right door assembly

11

Right upper rear cover

4

Lower right cover

12

Front door assembly

5

Face-down bin

13

Left front cover

6

Left cover

14

Right upper front cover

7

Left rear cover

15

Front top cover

8

Right rear cover

Covers and doors

85

Figure 1-112 M880 base product covers and doors (1 of 2)

10

9 8

1

7

2

3 4

6 5

Table 1-7 M880 base product covers and doors (1 of 2)

86

Item1

Description

Item

Description

1

Tray 1

6

Engine test button

2

Right door

7

Tray 2

3

Switch back tray

8

Power switch

4

Face-down bin

9

Front door

5

Power receptacle

10

Rear upper MFP cover

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Figure 1-113 M880 base product covers and doors (2 of 2)

16

15

1

14 13 12

2

3

11

4

10 9 8 7

5 6

Table 1-8 M880 base product covers and doors (2 of 2)

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Item

Description

Item

Description

1

Switch back cover

9

Left upper rear cover

2

Right door assembly

10

Rear upper rear cover

3

Lower right cover

11

Right upper rear cover

4

Face-down bin

12

Front door assembly

5

Left cover

13

Left front cover

6

Left rear cover

14

Right upper front cover

7

Right rear cover

15

Front top cover

8

Rear cover

16

Rear upper front cover

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87

Scanner back cover (M880) 1.

Remove two screws. Figure 1-114 Remove the scanner back cover (M880; 1 of 2)

2.

Remove the cover. Figure 1-115 Remove the scanner back cover (M880; 2 of 2)

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Scanner left cover (M880) Before proceeding, remove the following assemblies: ●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

Remove the scanner left cover (M880) 1.

Remove two screws. Figure 1-116 Remove the scanner left cover (M880; 1 of 2)

2.

Slide the cover towards the rear of the product to release it, and then remove the cover. Figure 1-117 Remove the scanner left cover (M880; 2 of 2)

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Scanner right cover (M880) Before proceeding, remove the following assemblies: ●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

Remove the scanner right cover (M880) 1.

Remove two screws. Figure 1-118 Remove the scanner right cover (M880; 1 of 2)

2.

Slide the cover towards the rear of the product to remove it. Figure 1-119 Remove the scanner right cover (M880; 2 of 2)

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Scanner front cover (M880) Before proceeding, remove the following assemblies: ●

Hardware integration pocket (HIP) cover (M880). See Hardware integration pocket (HIP) cover (M880) on page 98.

●

Control assembly (M880). See Control assembly (M880) on page 53.

●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

●

Scanner left cover (M880). See Scanner left cover (M880) on page 89.

●

Scanner right cover (M880). See Scanner right cover (M880) on page 90.

Remove the scanner front cover (M880) 1.

Raise the document feeder to the open position. Figure 1-120 Remove the scanner front cover (M880; 1 of 8)

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91

2.

Release one tab (callout 1), and then remove the wire guide (callout 2). Figure 1-121 Remove the scanner front cover (M880; 2 of 8)

2

1

3.

Remove two screws. Figure 1-122 Remove the scanner front cover (M880; 3 of 8)

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4.

Remove one screw. Figure 1-123 Remove the scanner front cover (M880; 4 of 8)

5.

Remove two screws. Figure 1-124 Remove the scanner front cover (M880; 5 of 8)

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93

6.

Carefully flex the corner of the cover away from the scanner (callout 1), and then slightly rotate the bottom of the cover up and off of the scanner (callout 2). Figure 1-125 Remove the scanner front cover (M880; 6 of 8)

1 2

7.

Carefully flex the corner of the cover away from the scanner (callout 1), and then rotate the bottom of the cover up (callout 2). Figure 1-126 Remove the scanner front cover (M880; 7 of 8)

1

2

94

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8.

Continue to rotate the cover up and away from the product to remove it. Figure 1-127 Remove the scanner front cover (M880; 8 of 8)

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95

Right upper rear cover (M855) Remove two screws (callout 1), and then remove the cover (callout 2). Figure 1-128 Remove the right upper rear cover (M855)

2

1

96

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Hardware integration pocket (HIP) cover (M855) Use a small flat blade screwdriver to carefully release the cover, and then remove it. Figure 1-129 Remove the hardware integration pocket (HIP) cover (M855)

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97

Hardware integration pocket (HIP) cover (M880) 1.

Note the location of four tabs under the HIP cover. Figure 1-130 Remove the HIP cover (M880; 1 of 3)

2.

Release two tabs on the side of the HIP cover toward the control screen. Figure 1-131 Remove the HIP cover (M880; 2 of 3)

98

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3.

Remove the HIP cover. Figure 1-132 Remove the HIP cover (M880; 3 of 3)

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99

Reinstall the HIP cover (M880) 1.

Align the tabs (callout 1) on the cover with the slots in the product (callout 2). Figure 1-133 Reinstall the HIP cover (M880; 1 of 2)

1

2

2.

Lower the HIP cover until it snaps into place. Figure 1-134 Reinstall the HIP cover (M880; 2 of 2)

100 Chapter 1 Removal and replacement

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Face-down bin NOTE: The M855 is pictured in the figures below. The same face-down bin part is used on the M855 and the M880. On the M880, the face-down bin is located in the cavity under the scanner assembly. 1.

Remove two screws. Figure 1-135 Remove the face-down bin (1 of 2)

2.

Lift up, and then remove the face-down bin. Figure 1-136 Remove the face-down bin (2 of 2)

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Reinstall the face-down bin 1.

Make sure that the tabs (callout 1) on the bin are aligned with the slots (callout 2) in the product. Figure 1-137 Reinstall the face-down bin (1 of 2)

2

1

2.

Press downward and toward the right door (callout 1) to fully seat the tabs, and then lower the bin into position (callout 2). Figure 1-138 Remove the face-down bin (2 of 2)

2

1

102 Chapter 1 Removal and replacement

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3.

Check to make sure that the cover is installed correctly and that no tabs are visible. IMPORTANT:

Incorrect installation might cause paper jams.

NOTE: The scanner assembly on the M880 obscures the view of this portion of the face-down bin. Slide your fingers across the edge between the face-down bin and the product to make sure that all the tabs are seated properly. Figure 1-139 Correct installation of face-down bin.

Figure 1-140 Incorrect installation of face-down bin.

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Left rear cover Before proceeding, remove the following assemblies: ●

Intermediate paper transport unit (IPTU), if it is installed. See IPTU assembly on page 437.

Remove the left rear cover 1.

Remove one screw (callout 1). Figure 1-141 Remove the left rear cover (1 of 2)

1

2.

Release one tab (callout 1), and then remove the cover (callout 2). Figure 1-142 Remove the left rear cover (2 of 2)

1

2

104 Chapter 1 Removal and replacement

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Switch back cover 1.

Open the right door, and then remove two screws. Figure 1-143 Remove the switch back cover (1 of 2)

2.

Remove the cover (callout 1). Figure 1-144 Remove the switch back cover (2 of 2)

1

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Covers and doors 105

Lower right cover NOTE: If the Tray 2 is not already removed for servicing, remove it now. 1.

Remove one screw. Figure 1-145 Remove the lower right cover (1 of 2)

2.

Remove the cover (callout 1). Figure 1-146 Remove the lower right cover (2 of 2)

1

106 Chapter 1 Removal and replacement

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Rear upper rear cover (M880) 1.

Remove seven screws. Figure 1-147 Remove the rear upper rear cover (M880; 1 of 2)

2.

Remove the cover (callout 1). Figure 1-148 Remove the rear upper rear cover (M880; 2 of 2)

1

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Right upper rear cover (M880) 1.

Remove two screws. Figure 1-149 Remove the right upper rear cover (M880; 1 of 2)

2.

Remove the cover (callout 1). Figure 1-150 Remove the right upper rear cover (M880; 2 of 2)

1

108 Chapter 1 Removal and replacement

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Rear upper MFP cover (M880) 1.

Remove one screw (callout 1). Figure 1-151 Remove the rear upper MFP cover (M880; 1 of 2)

1

2.

Remove the cover. Figure 1-152 Remove the rear upper MFP cover (M880; 2 of 2)

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Covers and doors 109

Reinstall the rear upper MFP cover (M880) Install the tab (callout 1) on the cover into the slot (callout 2) on the product, and then lower the cover into place. Figure 1-153 Reinstall the rear upper MFP cover (M880)

1

2

110 Chapter 1 Removal and replacement

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Left upper rear cover and rear upper B cover (M880) Before proceeding, remove the following assemblies: ●

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

Rear upper MFP cover (M880). See Rear upper MFP cover (M880) on page 109.

NOTE: The figures below show the document feeder and scanner removed for clarity. It is not necessary to remove these parts before removing the left upper rear cover and rear upper B cover.

Remove the left upper rear cover and rear upper B cover (M880) 1.

Remove one screw. Figure 1-154 Remove the left upper rear cover and rear upper B cover (M880; 1 of 3)

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Covers and doors 111

2.

Remove the cover (callout 1). Figure 1-155 Remove the left upper rear cover and rear upper B cover (M880; 2 of 3)

1

3.

Remove one screw, and then separate the rear upper B cover from the left upper rear cover. Figure 1-156 Remove the left upper rear cover and rear upper B cover (M880; 3 of 3)

112 Chapter 1 Removal and replacement

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Rear upper front cover (M880) Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Rear upper MFP cover (M880). See Rear upper MFP cover (M880) on page 109.

●

Left upper rear cover (M880). See Left upper rear cover and rear upper B cover (M880) on page 111.

●

Document feeder (M880). See Document feeder assembly (M880) on page 154.

●

Scanner assembly (M880). See Scanner assembly (M880) on page 162.

Remove the rear upper front cover (M880) 1.

Release one tab. Figure 1-157 Remove the rear upper front cover (M880; 1 of 2)

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Covers and doors 113

2.

Slide the cover away from the product to remove it. Figure 1-158 Remove the rear upper front cover (M880; 2 of 2)

114 Chapter 1 Removal and replacement

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Front top cover Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

Remove the front top cover 1.

Remove one screw (callout 1). Figure 1-159 Remove the front top cover (1 of 2)

1

2.

Release one tab (callout 1), and then remove the cover. Figure 1-160 Remove the front top cover (2 of 2)

1

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Covers and doors 115

Rear top cover (M855) Before proceeding, remove the following assemblies: ●

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

Left rear cover. See Left rear cover on page 104.

Remove the rear top cover (M855) 1.

Remove one screw. Figure 1-161 Remove the rear top cover (M855; 1 of 3)

116 Chapter 1 Removal and replacement

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2.

Slide the cover away from the product to remove it. Figure 1-162 Remove the rear top cover (M855; 2 of 3)

3.

Optional step: If necessary, remove one screw, and then separate the cover assembly. Figure 1-163 Remove the rear top cover (M855; 3 of 3)

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Covers and doors 117

Left cover Before proceeding, remove the following assemblies: ●

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

Left rear cover. See Left rear cover on page 104.

Remove the left cover 1.

Remove two screws (callout 1). Figure 1-164 Remove the left cover (1 of 2)

1

118 Chapter 1 Removal and replacement

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2.

Slide the cover away from the product to remove it. Figure 1-165 Remove the left cover (2 of 2)

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Covers and doors 119

Right upper front cover (M855) Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Hardware integration pocket (HIP) cover (M855). See Hardware integration pocket (HIP) cover (M855) on page 97.

●

Control (M855). See Control assembly (M855) on page 47

●

Front top cover. See Front top cover on page 115.

Remove the right upper front cover (M855) 1.

Remove one screw. Figure 1-166 Remove the right upper front cover (M855; 1 of 2)

120 Chapter 1 Removal and replacement

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2.

Release two tabs, and then rotate the cover away from the product to remove it. NOTE: Do not remove the USB cable from the cover. Release the cable from the product, and then remove it with the cover. TIP:

Use the arrows embossed on the product to locate the tabs.

Figure 1-167 Remove the right upper front cover (M855; 2 of 2)

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Covers and doors 121

Right upper front cover (M880) Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Document feeder (M880). See Document feeder assembly (M880) on page 154.

●

Scanner assembly (M880). See Scanner assembly (M880) on page 162

●

Front top cover. See Front top cover on page 115.

Remove the right upper front cover (M880) 1.

Release two tabs, and then rotate the cover away from the product. TIP:

Use the arrows embossed on the product to locate the tabs.

Figure 1-168 Remove the right upper front cover (M880; 1 of 2)

122 Chapter 1 Removal and replacement

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2.

Remove the cover. Figure 1-169 Remove the right upper front cover (M880; 2 of 2)

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Covers and doors 123

Right upper cover (M855) Before proceeding, remove the following assemblies: ●

Optional: Switch back tray. See Switch back tray on page 22.

●

Control (M855). See Control assembly (M855) on page 47

●

Right upper rear cover (M855). See Right upper rear cover (M855) on page 96.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Switch back cover. See Switch back cover on page 105.

●

Front top cover. See Front top cover on page 115.

●

Rear top cover. See Rear top cover (M855) on page 116.

●

Right upper front cover (M855). See Right upper front cover (M855) on page 120.

Remove the right upper cover (M855) 1.

Release the wire harnesses from the guide (callout 1), and then remove one screw (callout 2). NOTE:

Release the control cables from the guides as needed.

Figure 1-170 Remove the right upper cover (M855; 1 of 9)

1

2

124 Chapter 1 Removal and replacement

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2.

Open the front door, remove one screw (callout 1), release one tab (callout 2), and then remove the delivery fan cover (callout 3). Figure 1-171 Remove the right upper cover (M855; 2 of 9)

2

1 3

3.

Remove one screw (callout 1), and then push up on the assembly to release two sheet-metal tabs (callout 2). Figure 1-172 Remove the right upper cover (M855; 3 of 9)

1

2

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Covers and doors 125

4.

From the rear side of the product, remove two screws. Figure 1-173 Remove the right upper cover (M855; 4 of 9)

5.

From the right-rear side of the product, release one tab. Figure 1-174 Remove the right upper cover (M855; 5 of 9)

126 Chapter 1 Removal and replacement

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6.

Carefully remove the cover assembly. CAUTION: Release the control cables from the guides as needed to remove the assembly. Make sure that the control- cables are correctly routed and are not pinched when the assembly is reinstalled. NOTE:

The cover is still attached to a sheet-metal bracket.

Figure 1-175 Remove the right upper cover (M855; 6 of 9)

7.

Optional step: To remove the cover from the sheet-metal bracket, remove two screws. Figure 1-176 Remove the right upper cover (M855; 7 of 9)

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Covers and doors 127

8.

Optional step: To remove the cover from the sheet-metal bracket, before proceeding, note the location of the six tabs that secure the right upper cover to the assembly. Figure 1-177 Remove the right upper cover (M855; 8 of 9)

9.

Optional step: To remove the cover from the sheet-metal bracket, release three tabs (callout 1), release three additional tabs (callout 2), and then separate the cover from the assembly. Figure 1-178 Remove the right upper cover (M855; 9 of 9)

1

2

128 Chapter 1 Removal and replacement

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Right door assembly Before proceeding, remove the following assemblies: ●

Switch back cover. See Switch back cover on page 105.

Remove the right door assembly 1.

Open the right door, and then remove one screw (callout 1). Figure 1-179 Remove the right door assembly (1 of 7)

1

2.

Slide the retainer arm and guide (callout 1) to the left to disengage it from the product. Figure 1-180 Remove the right door assembly (2 of 7)

1

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Covers and doors 129

3.

On the door assembly, remove two self-tapping screws (callout 1), release two tabs (callout 2), and then remove the motor cover (callout 3). Figure 1-181 Remove the right door assembly (3 of 7)

2

1

3

4.

Release the wire harness from the retainer (callout 1), disconnect three connectors (callout 2), and then release one wire tie (callout 3) . TIP: To release the wire tie (callout 3), push in on the tab, and then remove the wire tie from the door. Figure 1-182 Remove the right door assembly (4 of 7)

3

1

2

130 Chapter 1 Removal and replacement

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5.

Disconnect one connector (callout 1), and then release one wire tie (callout 2). TIP: To release the wire tie (callout 2), push in on the tab, and then remove the wire tie from the door. Figure 1-183 Remove the right door assembly (5 of 7)

1 2 6.

Remove one screw (callout 1), and then release the wire harness from the retainer (callout 2). Figure 1-184 Remove the right door assembly (6 of 7)

1

2

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Covers and doors 131

7.

Carefully lift up the door assembly to remove it. Figure 1-185 Remove the right door assembly (7 of 7)

Reinstall the right door assembly When reinstalling the retainer arm, make sure that the tabs on the arm (callout 1) are installed in the slots in the product (callout 2). Figure 1-186 Reinstall the right door assembly

2

132 Chapter 1 Removal and replacement

1

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Left front cover Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Front top cover. See Front top cover on page 115.

●

Left cover. See Left cover on page 118.

Remove the left front cover 1.

Open the front door

2.

At the left side of the door, rotate the end of the retaining strap until it aligns with the hole in the bracket, and then push the strap through the hole to release it. Figure 1-187 Remove the left front cover (1 of 5)

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Covers and doors 133

3.

Remove two screws. Figure 1-188 Remove the left front cover (2 of 5)

4.

At the front of the product near the power switch, remove one screw. Figure 1-189 Remove the left front cover (3 of 5)

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5.

At the top of the product, remove one screw (callout 1), and then release one tab (callout 2). Figure 1-190 Remove the left front cover (4 of 5)

2

1

6.

Rotate the edge of the cover near the front door away from the product to release three tabs, and then remove the cover. NOTE:

The front door must be open to remove the cover.

Figure 1-191 Remove the left front cover (5 of 5)

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Covers and doors 135

Install a replacement left front cover If a replacement cover is installed, release two tabs on each side of the clip (callout 1), and then remove the retaining strap (callout 2) from the discarded cover and install it on the replacement cover. Figure 1-192 Install a replacement left front cover

2

1

136 Chapter 1 Removal and replacement

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Front door 1.

Open the front door

2.

At the left side of the door, rotate the end of the retaining strap until it aligns with the hole in the bracket, and then push the strap through the hole to release it. Figure 1-193 Remove the front door (1 of 9)

3.

Remove two screws that fasten the two plastic rails to the door. Figure 1-194 Remove the front door (2 of 9)

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Covers and doors 137

4.

Use a small flat blade screwdriver to release a tab (callout 1), slightly raise the plastic rail (callout 2), and then slide the rail to the right (callout 3) to release and remove it. NOTE:

Repeat this step for the remaining rail.

Figure 1-195 Remove the front door (3 of 9)

3

2 1

5.

At the right side of the door, remove two screws. Figure 1-196 Remove the front door (4 of 9)

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6.

the interlock-switch arm (callout 1), and then remove the switch lever (callout 2). Figure 1-197 Remove the front door (5 of 9)

1

2 7.

Slide the interlock-switch arm to the right to release it. CAUTION: The interlock-switch arm is spring loaded. Firmly grasp the arm when it is removed to prevent it from retracting. Figure 1-198 Remove the front door (6 of 9)

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8.

At the right side of the door, remove two screws. NOTE:

the door.

Figure 1-199 Remove the front door (7 of 9)

9.

At the left side of the door, remove two screws. NOTE:

the door.

Figure 1-200 Remove the front door (8 of 9)

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10. Raise the door until it is about one-half of the way open (callout 1), push down on the door (callout 2) to release it, and then remove the door. Figure 1-201 Remove the front door (9 of 9)

2

1

Reinstall the front door 1.

When reinstalling the door, make sure that the pins (callout 1) on the door are positioned in the slots (callout 2) on the product. Figure 1-202 Reinstall the front door (1 of 2)

2

1

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2.

When reinstalling the rails, make sure that the pin (callout 1) on the inner door is positioned inside the slot (callout 2) on the rail before reinstalling the screws. Figure 1-203 Reinstall the front door (2 of 2)

1 2

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Rear cover Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

Remove the rear cover 1.

Remove two screws. Figure 1-204 Remove the rear cover (1 of 3)

2.

M880 only: Remove three screws. Figure 1-205 Remove the rear cover (2 of 3)

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3.

Remove twelve screws, and then remove the cover. Figure 1-206 Remove the rear cover (3 of 3)

Install a replacement rear cover If a replacement cover is installed, remove the f fan cover and the right rear cover, and then install them on the replacement cover. 1.

Release three tabs, and then remove the f fan cover. TIP:

Look for the arrows embossed on the cover to locate the tabs.

Figure 1-207 Install a replacement rear cover (1 of 2)

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2.

Remove two screws, and then separate the right rear cover from the rear cover. Figure 1-208 Install a replacement rear cover (2 of 2)

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Right rear cover Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the right rear cover 1.

Remove two screws, and then separate the right rear cover from the rear cover. Figure 1-209 Remove the right rear cover (1 of 2)

2.

Optional step: If necessary, remove one screw, and then separate the small upper cover from the right rear cover. Figure 1-210 Remove the right rear cover (2 of 2)

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Front inner cover Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Front top cover. See Front top cover on page 115.

●

Left cover. See Left cover on page 118.

●

Left front cover. See Left front cover on page 133.

●

Front door assembly. See Front door on page 137.

Remove the front inner cover 1.

Remove eight screws. Figure 1-211 Remove the front inner cover (1 of 2)

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2.

Release two tabs, and then remove the front inner cover. Figure 1-212 Remove the front inner cover (2 of 2)

Reinstall the front inner cover Make sure that the tabs (callout 1) on the cover are inserted in the slots (callout 2) in the product. Figure 1-213 Reinstall the front inner cover

2

1

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Main assemblies TIP: For clarity, some figures in this chapter show assemblies removed that are not required to be removed to service the product (for example, the scanner and document feeder assemblies). The procedures in this manual are correct for your product.

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Location of major components

●

Document feeder assembly (M880)

●

Scanner control board (SCB) (M880)

●

Scanner assembly (M880)

●

Interlock switch assembly

●

Front-door open detection switch

●

Main switch assembly

●

Secondary transfer assembly

●

Multipurpose tray (Tray 1) drive assembly

●

Multipurpose tray (Tray 1) guide assembly

●

Tray 2 pickup unit

●

F home position sensor

●

Shutter gear holder assembly

●

F-edge area cooling fan FM10 (front)

●

F-edge area cooling fan FM9 (rear)

●

F fan FM2

●

F fan duct

●

Cartridge fan FM3 (yellow and magenta)

●

Cartridge fan FM4 (cyan and black)

●

Laser/scanner fan FM1

●

Delivery fan FM8

●

Cartridge front area cooling fan FM7

●

Memory tag PCA

●

Image-drum motor

●

F power supply

●

Primary transfer-roller disengagement motor

●

Intermediate transfer belt (ITB) alienation-drive assembly

●

F motor

Main assemblies 149

●

Intermediate transfer belt (ITB) motor

●

Toner-cartridge feed motor (black)

●

Toner-cartridge feed motor (yellow, magenta, and cyan)

●

Environmental sensor

●

Interconnect PCA (M855)

●

Interconnect PCA (M880)

●

Formatter case

●

Formatter, formatter case, and interconnect board (ICB)

●

High-voltage power supply (HVPS) B

●

DC controller PCA

●

Color-plane registration (R) sensor assembly

●

Low-voltage power supply (LVPS)

●

High-voltage power supply (HVPS) A (first transfer)

●

Lifter-drive assembly

●

Toner-cartridge drive assembly (yellow and magenta)

●

Toner-cartridge drive assembly (cyan and black)

●

Cartridge interface PCA (cyan and black)

●

Cartridge interface PCA (yellow and magenta)

●

Main drive assembly

●

Replace or reinstall the toner-cartridge drive assemblies or the main drive assembly

●

F drive assembly

●

Scanner cover

●

Laser/scanner assembly (yellow and magenta)

●

Laser/scanner assembly (cyan and black)

●

Duplex reverse assembly (M855)

●

Duplex reverse assembly (M880)

●

VOC fan (M855)

●

VOC fan (M880)

●

Face-down delivery assembly(M855)

●

Face-down delivery assembly (M880)

●

Face-down cover

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Duplexing feed assembly

●

Multipurpose tray (Tray 1) pickup assembly

Main assemblies 151

Location of major components Figure 1-214 Base product main assemblies (1 of 2)

1 2

11

3 4

5 10

6 7 8 9

Table 1-9 Base product main assemblies (1 of 2) Item

Description

Item

Description

1

Face-down delivery assembly

7

F drive assembly

2

Low-voltage power supply (LVPS)

8

ITB alienation drive assembly

3

Secondary transfer (T2) assembly

9

F PCA

4

Multipurpose tray (Tray 1) drive assembly

10

Main drive assembly

5

Toner cartridge drive assembly (C/K)

11

Shutter gear holder assembly

6

Toner cartridge drive assembly (Y/M)

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Figure 1-215 Base product main assemblies (2 of 2)

1 5 2

4

3

Table 1-10 Base product main assemblies (2 of 2)

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Item

Description

Item

Description

1

Duplex reverse assembly

4

F home position sensor assembly

2

Duplexing feed assembly (assembly is attached to the right door)

5

Color-plane registration (R) sensor assembly

3

Multipurpose tray (Tray 1) pickup assembly (assembly is attached to the right door)

Main assemblies 153

Document feeder assembly (M880) Before proceeding, remove the following assemblies: ●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

Remove the document feeder assembly (M880) IMPORTANT: If you are installing a replacement ADF assembly, you must use the Service menu to set the Document feeder Kit Interval and ADF Count values to zero. See Reinstall the document feeder assembly (M880) on page 159. 1.

Disconnect two connectors (callout 1), and one flat cable (callout 2). Figure 1-216 Remove the document feeder assembly (M880; 1 of 9)

2

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2.

Remove one screw (callout 1) and the retainer. NOTE: The screw (callout 1) that secures the wire retainer is longer than other screws used in the product. Make sure that you use this screw when the retainer is reinstalled. Figure 1-217 Remove the document feeder assembly (M880; 2 of 9)

1

3.

Remove one screw (callout 1) to release one ground wire. Figure 1-218 Remove the document feeder assembly (M880; 3 of 9)

1

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4.

Remove two screws (callout 1) to release the document feeder hinges. NOTE: These screws (callout 1) are longer than other screws used in the product. Make sure that you use these screws when the document feeder assembly is reinstalled. Figure 1-219 Remove the document feeder assembly (M880; 4 of 9)

1

5.

Carefully push the document feeder wire harness and flat cable up through the opening in the scanner bezel. Reinstallation tip When the document feeder is reinstalled, make sure that the wire harness and flat cable are behind the scanner bezel, or the scanner back cover will not fit properly. Figure 1-220 Remove the document feeder assembly (M880; 5 of 9)

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6.

Raise the document feeder to the open position. Figure 1-221 Remove the document feeder assembly (M880; 6 of 9)

7.

Lift the document feeder up until it stops. Figure 1-222 Remove the document feeder assembly (M880; 7 of 9)

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8.

Tilt the assembly towards the rear of the product to release the hinges. Figure 1-223 Remove the document feeder assembly (M880; 8 of 9)

9.

Lift the assembly up and off of the product. Figure 1-224 Remove the document feeder assembly (M880; 9 of 9)

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Reinstall the document feeder assembly (M880) IMPORTANT: If a replacement document feeder is installed, you must follow the instructions below to reset the counter. Failure to follow these instructions might result in more frequent paper jams. NOTE: If a replacement document feeder or scanner assembly is installed, you must install a replacement white backing on the document feeder. See Document feeder white backing (M880) on page 39. Installing a replacement document feeder assembly If a replacement document feeder is installed, do the following:

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1.

From the Home screen on the control , scroll to and touch the Device Maintenance button.

2.

Open the Service menu.

3.

On the screen, select the Service Access Code option from the drop-down list.

4.

Enter the following service access code for this product: 11088013.

5.

Reset the following values: ●

Document Feeder Kit Interval; set to zero

●

ADF Count; set to zero

Main assemblies 159

Scanner control board (SCB) (M880) Before proceeding, remove the following assemblies: ●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

Remove the SCB (M880) 1.

Disconnect four wire harness connectors (callout 1), one inline connector (callout 2), two flat cables (callout 3), and one USB connector (callout 4). NOTE:

The scanner control board (SCB) fan connector does not need to be disconnected.

Figure 1-225 Remove the SCB (M880; 1 of 4)

2

3

4

1 2.

Release the wire harnesses from the retainer (callout 1). Figure 1-226 Remove the SCB (M880; 2 of 4)

1

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3.

Remove two screws (callout 1). Figure 1-227 Remove the SCB (M880; 3 of 4)

1

4.

Carefully remove the SCB. Reinstallation tip If you are installing a replacement SCB, make sure to remove the protective cover from the USB connector (callout 1) on the replacement SCB before installing it in the product. Figure 1-228 Remove the SCB (M880; 4 of 4)

1

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Scanner assembly (M880) WARNING! The scanner assembly weighs approximately 26.3 kg (58.0 lbs). HP recommends that two people lift the assembly off of the product. Before proceeding, remove the following assemblies: ●

Control assembly (M880). See Control assembly (M880) on page 53.

●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

●

Document feeder assembly (M880). See Document feeder assembly (M880) on page 154.

●

Scanner control board (M880). See Scanner control board (SCB) (M880) on page 160.

●

Rear upper MFP cover (M880). See Rear upper MFP cover (M880) on page 109.

●

Rear upper rear cover (M880). See Rear upper rear cover (M880) on page 107.

●

Right upper rear cover (M880). See Right upper rear cover (M880) on page 108.

Remove the scanner assembly (M880) IMPORTANT: If you are installing a replacement scanner assembly, you must use the Service menu to set the Flatbed Count value to zero. See Reinstall the scanner assembly (M880) on page 166. 1.

At the rear of the product, release the wire harness (callout 1) from the retainer (callout 2). Figure 1-229 Remove the scanner assembly (M880; 1 of 7)

1

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2.

Remove four screws (callout 1). Figure 1-230 Remove the scanner assembly (M880; 2 of 7)

1

3.

At the front of the product (where the control was removed), release one tab (callout 1), and then separate the wire guide from the product (callout 2). Figure 1-231 Remove the scanner assembly (M880; 3 of 7)

2 1

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4.

Release the USB cable and wire harness (callout 1) from the guide (callout 2), and then remove the guide. Figure 1-232 Remove the scanner assembly (M880; 4 of 7)

2

1

5.

Remove three screws (callout 1). Figure 1-233 Remove the scanner assembly (M880; 5 of 7)

1

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6.

Carefully place the USB cable and wire harness in the cavity below the control mounting bracket to keep them out of the way when the scanner is removed. Figure 1-234 Remove the scanner assembly (M880; 6 of 7)

7.

Carefully lift the scanner assembly up and off of the product. WARNING! The scanner assembly weighs approximately 26.3 kg (58.0 lbs). HP recommends that two people lift the assembly off of the product. Figure 1-235 Remove the scanner assembly (M880; 7 of 7)

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Reinstall the scanner assembly (M880) IMPORTANT: If a replacement scanner assembly is installed, you must follow the instructions below to reset the counter. Failure to follow these instructions might result in more frequent paper jams. NOTE: If a replacement document feeder or scanner assembly is installed, you must install a replacement white backing on the document feeder. See Document feeder white backing (M880) on page 39. Installing a replacement scanner assembly If a replacement scanner assembly is installed, do the following: 1.

From the Home screen on the control , scroll to and touch the Device Maintenance button.

2.

Open the Service menu.

3.

On the screen, select the Service Access Code option from the drop-down list.

4.

Enter the following service access code for this product: 11088013.

5.

Reset the following value: ●

Flatbed Count; set to zero

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Interlock switch assembly Before proceeding, remove the following assemblies: ●

Front door. See Front door on page 137.

●

Front inner cover. See Front inner cover on page 147.

Remove the interlock switch assembly If the toner cartridges have not already been removed for servicing the product, remove them now. 1.

Disconnect two connectors (callout 1), remove one screw (callout 2), and then remove the interlock switch assembly (callout 3). Figure 1-236 Remove the interlock switch assembly (1 of 2)

3

1

2

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2.

Release the wire harness from the retainer (callout 1), release two tabs (callout 2), and then remove the right-door open detection switch (callout 3) from the assembly. Figure 1-237 Remove the interlock switch assembly (2 of 2)

3

1 2

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Front-door open detection switch Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Front top cover. See Front top cover on page 115.

●

Left cover. See Left cover on page 118.

●

Left front cover. See Left front cover on page 133.

Remove the front-door open detection switch 1.

Carefully release the flag from the holders to remove it. Reinstallation tip Note how the spring at the right end of the flag shaft is installed. If the spring becomes dislodged while removing the flag, you must correctly reinstall it so that the flag will properly function. See Reinstall the front-door-open detection switch on page 171. Figure 1-238 Remove the front-door open detection switch (1 of 4)

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2.

Disconnect one connector (callout 1), and then remove one screw (callout 2). Figure 1-239 Remove the front-door open detection switch (2 of 4)

2

1

3.

Release one tab (callout 1), and then remove the switch holder (callout 2). Figure 1-240 Remove the front-door open detection switch (3 of 4)

2

1

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4.

Release two tabs (callout 1), and then remove the front-door open detection switch (callout 2) from the assembly. Figure 1-241 Remove the front-door open detection switch (4 of 4)

2

1

Reinstall the front-door-open detection switch 1.

When the flag is reinstalled, make sure that the lower end of the spring is behind the holder. Figure 1-242 Reinstall the front-door-open detection switch (1 of 3)

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2.

When the flag is reinstalled, make sure that the top end of the spring is correctly seated on the flag. Figure 1-243 Reinstall the front-door-open detection switch (2 of 3)

3.

that the switch (callout 1) moves to the up position when the flag is toggled to the door closed position (callout 2). Figure 1-244 Reinstall the front-door-open detection switch (3 of 3)

2

1

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Main switch assembly Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Front top cover. See Front top cover on page 115.

●

Left cover. See Left cover on page 118.

●

Left front cover. See Left front cover on page 133.

●

Front door assembly. See Front door on page 137.

●

Front inner cover. See Front inner cover on page 147.

Remove the main switch assembly If the toner cartridges have not already been removed for servicing the product, remove them now. 1.

Release the wire harness from one retainer (callout 1), and then from the guide (callout 2). Figure 1-245 Remove the main switch assembly (1 of 3)

1

2

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Main assemblies 173

2.

Release the wire harness from one guide (callout 1), and then disconnect one connector (callout 2). TIP:

It is easier to disconnect the connector if the harness is first released from the guide.

Figure 1-246 Remove the main switch assembly (2 of 3)

1 2

3.

Remove one screw (callout 1), release one tab (callout 2), and then slide the switch assembly upward (callout 3) to remove it. Figure 1-247 Remove the main switch assembly (3 of 3)

2 3

1

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Secondary transfer assembly Before proceeding, remove the following assemblies: ●

Secondary transfer roller. See Secondary transfer roller on page 16

●

Intermediate transfer belt. See Intermediate transfer belt (ITB) on page 19.

Remove the secondary transfer assembly 1.

Open the right door to access the assemblies in the following steps.

2.

Release two tabs (callout 1), and then lift up (callout 2) to remove the right ITB guide (callout 3). Figure 1-248 Remove the secondary transfer assembly (1 of 10)

2

3

1

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Main assemblies 175

3.

Remove one screw (callout 1), release one tab (callout 2), and then remove the left ITB guide (callout 3). Figure 1-249 Remove the secondary transfer assembly (2 of 10)

1

2 3

4.

Grasp the connector cover (callout 1), and then remove the cover by lifting up while releasing the tab (callout 2). TIP:

Use the arrow embossed on the cover to locate the tab.

Figure 1-250 Remove the secondary transfer assembly (3 of 10)

2

1

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5.

Push in on the red mark on the connector (callout 1), and then disconnect the connector. Figure 1-251 Remove the secondary transfer assembly (4 of 10)

1

6.

Release the wire harness from two cable retainers (callout 1). Figure 1-252 Remove the secondary transfer assembly (5 of 10)

1

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7.

Disconnect one connector (callout 1). Figure 1-253 Remove the secondary transfer assembly (6 of 10)

1

8.

Remove one white plastic retainer (callout 1). Figure 1-254 Remove the secondary transfer assembly (7 of 10)

1

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9.

Use a small flat-blade screwdriver to slide one black-plastic bushing away from the chassis (callout 1). TIP: After the assembly is removed later in this procedure, use the clip removed in the step above to secure the bushing to the shaft so it will not be lost.

Figure 1-255 Remove the secondary transfer assembly (8 of 10)

1

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Main assemblies 179

10. Press down on the black handle (callout 1), and then Insert a screwdriver into the hole (callout 2) on the Multipurpose tray (Tray 1) drive assembly to hold the black handle in place. TIP: Using this method to hold the black handle in place will allow you to use both hands to remove the assembly, and will also make reinstalling the assembly easier. Figure 1-256 Remove the secondary transfer assembly (9 of 10)

2 1

11. Carefully press the feed guide (callout 1) toward the back of the product. Grasp the secondary transfer assembly and slide it toward the left (callout 2) to release the shaft (callout 3), and then remove the assembly. NOTE: Handle the assembly carefully. The registration assembly tension springs and spring mounting blocks at each end of the secondary transfer assembly can be easily dislodged. See Figure 1-258 Reinstall the secondary transfer assembly (1 of 3) on page 181. Figure 1-257 Remove the secondary transfer assembly (10 of 10)

1

2

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Reinstall the secondary transfer assembly 1.

Before reinstalling the secondary transfer assembly, make sure that the registration assembly tension springs (callout 1) and spring mounting blocks (callout 2) at each end of the secondary transfer assembly are correctly positioned. NOTE:

The springs should be straight (as shown below), and not bent or curved.

Figure 1-258 Reinstall the secondary transfer assembly (1 of 3)

1

1

2

2

2.

Carefully turn the assembly over, and then make sure that the tabs on the spring mounting blocks are fully seated in the assembly sheet metal. NOTE: If the secondary transfer assembly is removed or replaced while servicing the product and a 13.B2.DD error message appears on the control- display, remove the assembly and make sure that the registration tension springs and spring mounting blocks are correctly installed. Figure 1-259 Reinstall the secondary transfer assembly (2 of 3)

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3.

When the secondary transfer assembly is reinstalled, make sure that the gear assembly (callout 1) is placed under the ITB rail (callout 2). NOTE: To make reinstalling the assembly easier, insert a screwdriver into the hole on the Multipurpose tray (Tray 1) drive assembly to hold the black handle in place. See Figure 1-256 Remove the secondary transfer assembly (9 of 10) on page 180. Figure 1-260 Reinstall the secondary transfer assembly (3 of 3)

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Multipurpose tray (Tray 1) drive assembly Before proceeding, remove the following assemblies: ●

Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 19.

●

F. See F on page 21.

●

Secondary transfer assembly. See Secondary transfer assembly on page 175.

Remove the multipurpose tray (Tray 1) drive assembly 1.

At the right side of the product, near the lower right corner of the right door, remove one small cover (callout 1). Figure 1-261 Remove the multipurpose tray (Tray 1) drive assembly (1 of 13)

1

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Main assemblies 183

2.

Remove one screw (callout 1). Figure 1-262 Remove the multipurpose tray (Tray 1) drive assembly (2 of 13)

1

3.

Open the right door, remove one screw (callout 1), and then remove the handle (callout 2). Figure 1-263 Remove the multipurpose tray (Tray 1) drive assembly (3 of 13)

1

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4.

Press down on the black handle (callout 1) to release it, and then pull it forward to remove it. NOTE:

The handle is spring loaded. Firmly grasp the handle when it is removed.

Figure 1-264 Remove the multipurpose tray (Tray 1) drive assembly (4 of 13)

1

5.

Open the right door, and then remove one screw (callout 1). Figure 1-265 Remove the multipurpose tray (Tray 1) drive assembly (5 of 13)

1

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6.

Slide the retainer arm and guide (callout 1) to the left to disengage it from the chassis. Figure 1-266 Remove the multipurpose tray (Tray 1) drive assembly (6 of 13)

1

7.

Remove two screws (callout 1), and then remove the right-inner cover (callout 2). Figure 1-267 Remove the multipurpose tray (Tray 1) drive assembly (7 of 13)

1

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8.

On the door assembly, remove two self-tapping screws (callout 1), release two tabs (callout 2), and then remove the motor cover (callout 3). Figure 1-268 Remove the multipurpose tray (Tray 1) drive assembly (8 of 13)

2

1

3

9.

Disconnect one connector (callout 1), and then release one wire tie (callout 2). TIP: To release the wire tie (callout 2), push in on the tab, and then remove the wire tie from the door. Figure 1-269 Remove the multipurpose tray (Tray 1) drive assembly (9 of 13)

1 2

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10. Remove one screw (callout 1), and then disconnect one connector (callout 2). Figure 1-270 Remove the multipurpose tray (Tray 1) drive assembly (10 of 13)

1

2

11. Release one wire tie (callout 1). TIP:

To release the wire tie, push in on the tab, and then remove the wire tie from the chassis.

Figure 1-271 Remove the multipurpose tray (Tray 1) drive assembly (11 of 13)

1

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12. Remove two screws (callout 1). Figure 1-272 Remove the multipurpose tray (Tray 1) drive assembly (12 of 13)

1

13. Use a small flat-blade screwdriver (callout 1) to carefully release the assembly and two sheetmetal tabs (callout 2), and then remove the assembly (callout 3). Figure 1-273 Remove the multipurpose tray (Tray 1) drive assembly (13 of 13)

1

3

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Multipurpose tray (Tray 1) guide assembly Before proceeding, remove the following assemblies: ●

Secondary transfer roller. See Secondary transfer roller on page 16

●

Intermediate transfer belt. See Intermediate transfer belt (ITB) on page 19.

●

F. See F on page 21.

●

Secondary transfer assembly. See Secondary transfer assembly on page 175.

●

Multipurpose tray (Tray 1) drive assembly. See Multipurpose tray (Tray 1) drive assembly on page 183.

Remove the multipurpose tray guide assembly Disconnect one connector (callout 1), release one wire retainer (callout 2), remove two screws (callout 3), and then remove the multipurpose-tray guide (Tray 1) assembly. Reinstallation tip reinstalled.

Make sure that the connector (callout 1) is securely in place when the assembly is

Figure 1-274 Remove the multipurpose tray guide assembly

3

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Tray 2 pickup unit Before proceeding, remove the following assemblies: ●

Secondary transfer roller. See Secondary transfer roller on page 16

●

Tray 2. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

Intermediate transfer belt. See Intermediate transfer belt (ITB) on page 19.

●

F. See F on page 21.

●

Secondary transfer assembly. See Secondary transfer assembly on page 175.

●

Multipurpose tray (Tray 1) drive assembly. See Multipurpose tray (Tray 1) drive assembly on page 183.

●

Multipurpose tray (Tray 1) guide assembly. See Multipurpose tray (Tray 1) guide assembly on page 190.

Remove the Tray 2 pickup assembly Disconnect one connector (callout 1), remove four screws (callout 2), and then remove the Tray 2 pickup assembly (callout 3). Figure 1-275 Remove the Tray 2 pickup assembly

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F home position sensor Before proceeding, remove the following assemblies: ●

F. See F on page 21.

Remove the f home position sensor 1.

Open the front door, remove one screw (callout 1), release one tab (callout 2), and then remove the delivery fan cover (callout 3). Figure 1-276 Remove the f home position sensor (1 of 3)

2

1

3

2.

Disconnect one connector (callout 1). Figure 1-277 Remove the f home position sensor (2 of 3)

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3.

Open the right door, remove one screw (callout 1), release one tab (callout 2), and then remove the sensor assembly (callout 3). CAUTION: As the assembly is removed, guide the wire harness through the opening in the chassis from the front of the product. Figure 1-278 Remove the f home position sensor (3 of 3)

1

2

3

Reinstall the f home position sensor As the assembly is reinstalled, guide the wire harness through the opening in the chassis to the front of the product, and then make sure that the tab on the sensor (callout 1) is installed in the opening (callout 2) in the chassis. Figure 1-279 Reinstall the f home position sensor

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Shutter gear holder assembly Before proceeding, remove the following assemblies: ●

F. See F on page 21.

Remove the shutter gear holder assembly 1.

Open the right door, remove one screw (callout 1), and then remove one gear (callout 2). Figure 1-280 Remove the shutter gear holder assembly (1 of 5)

1 2

2.

Slide the left shutter toward the back of the product to remove it. Figure 1-281 Remove the shutter gear holder assembly (2 of 5)

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3.

Slide the right shutter toward the front of the product to remove it. Figure 1-282 Remove the shutter gear holder assembly (3 of 5)

4.

Remove one gear (callout 1), remove two screws (callout 2), and then separate the gear assembly (callout 3) from the chassis. CAUTION: The assembly is still connected to the product by a wire harness. Do not attempt to completely remove the assembly. Figure 1-283 Remove the shutter gear holder assembly (4 of 5)

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5.

Disconnect two connectors. Figure 1-284 Remove the shutter gear holder assembly (5 of 5)

Reinstall the shutter gear holder assembly 1.

Align the round tabs (callout 1) on the back of the shutter gear holder assembly with the slots (callout 2) in the chassis. Figure 1-285 Reinstall the shutter gear holder assembly (1 of 6)

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2.

Note the location of the guides on the back of the shutters. Figure 1-286 Reinstall the shutter gear holder assembly (2 of 6)

3.

Make sure that the guides (callout 1) on the shutters align with the rails (callout 2) so that they slide freely. NOTE:

The left shutter is shown below. The procedure is the same for the right shutter.

Figure 1-287 Reinstall the shutter gear holder assembly (3 of 6)

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4.

When the white gear (callout 1) is reinstalled, position the gear back in the assembly so that the teeth on the white gear align with the teeth on the smaller gear (callout 2). Figure 1-288 Reinstall the shutter gear holder assembly (4 of 6)

2

1

5.

When replacing the black gear, make sure that the teeth on the black gear align with the teeth on the white gear (callout 1). Also make sure that the teeth on the shutters (callout 2) align with the teeth on the black gear. Figure 1-289 Reinstall the shutter gear holder assembly (5 of 6)

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6.

Make sure that the arrows on the shutters align with the notches in the gear. Figure 1-290 Reinstall the shutter gear holder assembly (6 of 6)

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F-edge area cooling fan FM10 (front) Before proceeding, remove the following assemblies: ●

F. See F on page 21.

●

Shutter gear holder assembly. See Shutter gear holder assembly on page 194.

Remove the f-edge area cooling fan FM10 (front) 1.

Release the wire harness from one retainer (callout 1), disconnect one connector (callout 2), and then remove two screws (callout 3). Figure 1-291 Remove the f-edge area cooling fan FM10 (front; 1 of 3)

1

3

2.

2

Rotate the top of the fan away from the chassis (callout 1), and then lift it up and away from the product (callout 2) to remove it. Figure 1-292 Remove the f-edge area cooling fan FM10 (front; 2 of 3)

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3.

To remove the fan from the holder, release one tab (callout 1) and then rotate the top of the fan (callout 2) out of the holder to remove it. Figure 1-293 Remove the f-edge area cooling fan FM10 (front; 3 of 3)

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Reinstall the f-edge area cooling fan FM10 (front) 1.

Make sure that the fan is oriented as shown below when reinstalling it in the holder. NOTE:

The label in the center of the fan should be facing inward, toward the holder.

Figure 1-294 Reinstall the f-edge area cooling fan FM10 (front; 1 of 3)

2.

The embossed arrows on the fan must point into the chassis and to the left (toward the wire harness) when the fan and holder are installed in the product. Figure 1-295 Reinstall the f-edge area cooling fan FM10 (front; 2 of 3)

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3.

When reinstalling the fan, make sure that the tab is installed first and that it fits behind the sheet metal (callout 1). Figure 1-296 Reinstall the f-edge area cooling fan FM10 (front; 3 of 3)

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F-edge area cooling fan FM9 (rear) Before proceeding, remove the following assemblies: ●

F. See F on page 21.

●

Shutter gear holder assembly. See Shutter gear holder assembly on page 194.

Remove the f-edge area cooling fan FM9 (rear) 1.

Release the wire harness from one retainer (callout 1), disconnect one connector (callout 2), and then remove two screws (callout 3). Figure 1-297 Remove the f-edge area cooling fan FM9 (rear; 1 of 3)

3 2

2.

1

Rotate the top of the fan away from the chassis (callout 1), and then lift it up and away from the product (callout 2) to remove it. Figure 1-298 Remove the Remove the f-edge area cooling fan FM9 (rear; 2 of 3)

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3.

To remove the fan from the holder, release one tab (callout 1) and then rotate the top of the fan out of the holder (callout 2) to remove it. Figure 1-299 Remove the f-edge area cooling fan FM9 (rear; 3 of 3)

2

1

Reinstall the f-edge area cooling fan FM9 (rear) 1.

Make sure that the fan is oriented as shown below when reinstalling it in the holder. NOTE:

The label in the center of the fan should be facing inward, toward the holder.

Figure 1-300 Reinstall the f-edge area cooling fan FM9 (rear; 1 of 3)

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2.

The embossed arrows on the fan must point into the chassis and to the left (away from the wire harness) when the fan and holder are installed in the product. Figure 1-301 Reinstall the f-edge area cooling fan FM9 (rear; 2 of 3)

3.

When reinstalling the left f cooling fan, make sure that the tab is installed first and that it fits behind the sheet metal (callout 1). Figure 1-302 Reinstall the f-edge area cooling fan FM9 (rear; 3 of 3)

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F fan FM2 Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the f fan FM2 1.

Locate the f fan (callout 1). Figure 1-303 Remove the f fan FM2 (1 of 5)

1 2.

Release the wire harness (callout 1) from the guides (callout 2). Figure 1-304 Remove the f fan FM2 (2 of 5)

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3.

Disconnect one connector (callout 1), and then rotate the fan assembly out and down (callout 2) to remove it. Figure 1-305 Remove the f fan FM2 (3 of 5)

2

1

4.

Disconnect one connector (callout 1) on the fan holder, and then release the wire harness (callout 2) from the guides. Figure 1-306 Remove the f fan FM2 (4 of 5)

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5.

Release three tabs (callout 1), and then rotate the f fan (callout 2) out of the fan holder. Figure 1-307 Remove the f fan FM2 (5 of 5)

2

1

Reinstall the f fan FM2 1.

Make sure that the fan is oriented as shown below when reinstalling it in the holder. NOTE:

The label in the center of the fan should be facing inward, toward the holder.

Figure 1-308 Reinstall the f fan FM2 (1 of 3)

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2.

The embossed arrows on the fan must point into the chassis and to the left (toward the wire harness) when the fan and holder are installed in the product. Figure 1-309 Reinstall the f fan FM2 (2 of 3)

3.

When reinstalling the f fan assembly, make sure that the tabs (callout 1) on the holder are installed in the slots (callout 2) on the chassis. Figure 1-310 Reinstall the f fan FM2 (3 of 3)

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F fan duct Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

F fan FM2. See F fan FM2 on page 207.

●

F motor. See F motor on page 242.

Remove the f fan duct 1.

Remove one screw (callout 1). Figure 1-311 Remove the f fan duct (1 of 3)

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2.

Release one tab (callout 1). Figure 1-312 Remove the f fan duct (2 of 3)

1

3.

Rotate the top of the f fan duct away from the product to remove it. Figure 1-313 Remove the f fan duct (3 of 3)

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Reinstall the f fan duct Insert the tab (callout 1) on the duct into the slot (callout 2) on the chassis before rotating the duct into position. Figure 1-314 Reinstall the f fan duct

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Cartridge fan FM3 (yellow and magenta) Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the cartridge fan FM3 (yellow and magenta) 1.

Locate the cartridge fan (yellow and magenta; callout 1). Figure 1-315 Remove the cartridge fan FM3 (yellow and magenta; 1 of 5)

1 2.

Disconnect one connector (callout 1), and then release the wire harnesses (callout 2) from the guides (callout 3). Figure 1-316 Remove the cartridge fan FM3 (yellow and magenta; 2 of 5)

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3.

Rotate the fan assembly to the right (callout 1), while pulling the assembly away from the product (callout 2) to remove it. Figure 1-317 Remove the cartridge fan FM3 (yellow and magenta; 3 of 5)

1

2

4.

Disconnect one connector (callout 1) on the fan holder, and then release the wire harness (callout 2) from the guides. Figure 1-318 Remove the cartridge fan FM3 (yellow and magenta; 4 of 5)

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5.

Release three tabs (callout 1), and then rotate the fan (callout 2) out of the fan holder. Figure 1-319 Remove the cartridge fan FM3 (yellow and magenta; 5 of 5)

2

1

Reinstall the cartridge fan FM3 (yellow and magenta) 1.

Make sure that the fan is oriented as shown below when reinstalling it in the holder. NOTE:

The label in the center of the fan should be facing outward, away from the holder.

Figure 1-320 Reinstall the cartridge fan FM3 (yellow and magenta; 1 of 3)

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2.

The embossed arrows on the fan must point away from the chassis and to the left (toward the wire harness) when the fan and holder are installed in the product. Figure 1-321 Reinstall the cartridge fan FM3 (yellow and magenta; 2 of 3)

3.

When reinstalling the cartridge fan (yellow and magenta) assembly, make sure that the tabs (callout 1) on the holder are installed in the slots (callout 2) on the product. Figure 1-322 Reinstall the cartridge fan FM3 (yellow and magenta; 3 of 3)

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Cartridge fan FM4 (cyan and black) Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the cartridge fan FM4 (cyan and black) 1.

Locate the cartridge fan (cyan and black; callout 1). Figure 1-323 Remove the cartridge fan FM4 (cyan and black; 1 of 5)

1 2.

Disconnect one connector (callout 1), and then release the wire harnesses (callout 2) from the guides (callout 3). Figure 1-324 Remove the cartridge fan FM4 (cyan and black; 2 of 5)

2

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3.

Rotate the fan assembly to the right (callout 1), while pulling the assembly away from the product (callout 2) to remove it. Figure 1-325 Remove the cartridge fan FM4 (cyan and black; 3 of 5)

1 2

4.

Disconnect one connector (callout 1) on the fan holder, and then release the wire harness (callout 2) from the guides. Figure 1-326 Remove the cartridge fan FM4 (cyan and black; 4 of 5)

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5.

Release three tabs (callout 1), and then rotate the fan (callout 2) out of the fan holder. Figure 1-327 Remove the cartridge fan FM4 (cyan and black; 5 of 5)

2

1

Reinstall the cartridge fan FM4 (cyan and black) 1.

Make sure that the fan is oriented as shown below when reinstalling it in the holder. NOTE:

The label in the center of the fan should be facing outward, away from the holder.

Figure 1-328 Reinstall the cartridge fan FM4 (cyan and black; 1 of 2)

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2.

The embossed arrows on the fan must point away from the chassis and to the left (toward the wire harness) when the fan and holder are installed in the product. Figure 1-329 Reinstall the cartridge fan FM4 (cyan and black; 2 of 3)

3.

When reinstalling the cartridge fan (cyan and black) assembly, make sure that the tabs (callout 1) on the holder are installed in the slots (callout 2) on the chassis. Figure 1-330 Reinstall the cartridge fan FM4 (cyan and black; 3 of 3)

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Main assemblies 221

Laser/scanner fan FM1 Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the laser/scanner fan FM1 1.

Locate the laser/scanner fan (callout 1). Figure 1-331 Remove the laser/scanner fan FM1 (1 of 4)

1 2.

Release two locking tabs, and then disconnect one connector (callout 1). Release one tab (callout 2). and then rotate the fan assembly to the right (callout 3) to remove it. Figure 1-332 Remove the laser/scanner fan FM1 (2 of 4)

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3.

Disconnect one connector (callout 1) on the fan holder, and then release the wire harness (callout 2) from the guides. Figure 1-333 Remove the laser/scanner fan FM1 (3 of 4)

2

1

4.

Release three tabs (callout 1), and then rotate the laser/scanner fan (callout 2) out of the fan holder. Figure 1-334 Remove the laser/scanner fan FM1 (4 of 4)

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Reinstall the laser/scanner fan FM1 1.

Make sure that the fan is oriented as shown below when reinstalling it in the holder. NOTE:

The label in the center of the fan should be facing inward, toward the holder.

Figure 1-335 Reinstall the laser/scanner fan FM1 (1 of 3)

2.

The embossed arrows on the fan must point into the chassis and to the left (toward the wire harness) when the fan and holder are installed in the product. Figure 1-336 Reinstall the laser/scanner fan FM1 (2 of 3)

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3.

When reinstalling the laser/scanner fan assembly, make sure that the tabs (callout 1) on the holder are installed in the slots (callout 2) on the chassis. Figure 1-337 Reinstall the laser/scanner fan FM1 (3 of 3)

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Delivery fan FM8 1.

Open the front door.

2.

Remove one screw (callout 1), release one tab (callout 2), and then remove the delivery fan cover (callout 3). Figure 1-338 Remove the delivery fan FM8 (1 of 3)

2

1

3

3.

Disconnect one connector (callout 1), release the wire harness from the retainer (callout 2), remove three screws (callout 3), release one tab (callout 4), and then remove the delivery fan holder (callout 5). Figure 1-339 Remove the delivery fan FM8 (2 of 3)

3 4

5

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4.

Release the wire harness from the guide (callout 1), release one tab (callout 2), and then remove the fan (callout 3). Figure 1-340 Remove the delivery fan FM8 (3 of 3)

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Main assemblies 227

Cartridge front area cooling fan FM7 Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Front top cover. See Front top cover on page 115.

●

Left front cover. See Left front cover on page 133.

Remove the cartridge front area cooling fan FM7 1.

Disconnect one connector (callout 1), and then release the wire harness from the retainer (callout 2). Figure 1-341 Remove the cartridge front area cooling fan FM7 (1 of 2)

2

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2.

Remove three screws (callout 1), and then remove the fan (callout 2). Figure 1-342 Remove the cartridge front area cooling fan FM7 (2 of 2)

2

1

Reinstall the cartridge front area cooling fan FM7 When the fan is reinstalled, make sure that the label (callout 1) on the fan is facing out and away from the chassis. Figure 1-343 Reinstall the cartridge front area cooling fan FM7

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Memory tag PCA CAUTION:

ESD sensitive assembly.

Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the memory tag PCA 1.

Disconnect two connectors (callout 1) on the motors above the memory tag PCA, and then disconnect 11 connectors (callout 2) on the memory tag PCA. Figure 1-344 Remove the memory tag PCA (1 of 3)

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2.

If you are removing the memory tag PCA to gain access to parts behind it, remove four screws (callout 1), and then remove the memory tag PCA and sheet-metal bracket. Figure 1-345 Remove the memory tag PCA (2 of 3)

1

3.

If you are replacing the memory tag PCA, remove four screws (callout 1), and then remove the memory tag PCA. Figure 1-346 Remove the memory tag PCA (3 of 3)

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Reinstall the memory tag PCA and sheet-metal bracket Make sure that the tab (callout 1) on the sheet-metal bracket is installed in the slot (callout 2) on the chassis. Figure 1-347 Reinstall the memory tag PCA

1

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Image-drum motor Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the image-drum motor NOTE: All four motors are the same part number. 1.

Locate the image-drum motors: yellow (callout 1), magenta (callout 2), cyan (callout 3), and black (callout 4). Figure 1-348 Remove the image-drum motor (1 of 2)

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Main assemblies 233

2.

Disconnect one connector (callout 1), remove four screws (callout 2), and then remove the image-drum motor NOTE: The following figure shows the magenta image-drum motor. The removal procedure is the same for all four motors. Figure 1-349 Remove the image-drum motor (2 of 2)

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F power supply CAUTION:

ESD sensitive assembly.

Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the f power supply 1.

Disconnect four connectors (callout 1), release the wire harnesses from one retainer (callout 2), and then remove two screws (callout 3). Figure 1-350 Remove the f power supply (1 of 2)

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2.

Rotate the top of the f power supply away from the chassis (callout 1), and then lift it up (callout 2) to remove it. Figure 1-351 Remove the f power supply (2 of 2)

1

2

Reinstall the f power supply 1.

Make sure that the tab (callout 1) on the f power supply is installed in the slot (callout 2) on the chassis. Figure 1-352 Reinstall the f power supply (1 of 2)

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2.

Make sure that the sheet-metal tab below the power connector is positioned as shown below. The tab should be outside of the sheet-metal frame. Figure 1-353 Reinstall the f power supply (2 of 2)

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Primary transfer-roller disengagement motor Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

F power supply. See F power supply on page 235.

Remove the primary transfer-roller disengagement motor 1.

Remove one screw (callout 1), and then remove the motor cover (callout 2). Figure 1-354 Remove the primary transfer-roller disengagement motor (1 of 2)

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2.

Disconnect one connector (callout 1), remove two screws (callout 2), and then remove the primary-transfer roller disengagement motor (callout 3). Figure 1-355 Remove the primary transfer-roller disengagement motor (2 of 2)

2 3

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Intermediate transfer belt (ITB) alienation-drive assembly Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

F power supply. See F power supply on page 235.

Remove the ITB alienation-drive assembly 1.

Remove one screw (callout 1), and then remove the motor cover (callout 2). Figure 1-356 Remove the ITB alienation drive assembly (1 of 2)

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2.

Release one retainer (callout 1), disconnect one connector (callout 2). Remove three screws (callout 3), and then remove the ITB alienation drive assembly (callout 4). Figure 1-357 Remove the ITB alienation drive assembly (2 of 2)

1

4

3

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F motor Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the f motor 1.

Locate the f motor (callout 1). Figure 1-358 Remove the f motor (1 of 2)

1

2.

Disconnect one connector (callout 1), remove three screws (callout 2), and then remove the f motor. Figure 1-359 Remove the f motor (2 of 2)

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Intermediate transfer belt (ITB) motor Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the ITB motor 1.

Locate the ITB motor (callout 1). Figure 1-360 Remove the ITB motor (1 of 2)

1

2.

Disconnect one connector (callout 1), remove three screws (callout 2), and then remove the ITB motor. Figure 1-361 Remove the ITB motor (2 of 2)

1

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Toner-cartridge feed motor (black) Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the toner-cartridge feed motor (black) 1.

Locate the toner-cartridge feed motor (black; callout 1). Figure 1-362 Remove the toner-cartridge feed motor (black; 1 of 2)

1

2.

Disconnect one connector (callout 1), remove two screws (callout 2), and then remove the tonercartridge feed motor (black). Figure 1-363 Remove the toner-cartridge feed motor (black; 2 of 2)

1

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Toner-cartridge feed motor (yellow, magenta, and cyan) Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the toner-cartridge feed motor (yellow, magenta, and cyan) 1.

Locate the toner-cartridge feed motor (yellow, magenta, and cyan; callout 1). Figure 1-364 Remove the toner-cartridge feed motor (yellow, magenta, and cyan; 1 of 2)

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2.

Disconnect one connector (callout 1), remove two screws (callout 2), and then remove the tonercartridge feed motor (yellow, magenta, and cyan). Reinstallation tip Connect the connector (callout 1) before reinstalling the screws (callout 2). Figure 1-365 Remove the toner-cartridge feed motor (yellow, magenta, and cyan; 2 of 2)

1

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Environmental sensor Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Left cover. See Left cover on page 118.

Remove the environmental sensor Disconnect one connector (callout 1). Release three tabs (callout 2), and then remove the environmental sensor (callout 3). Figure 1-366 Remove the environmental sensor

1

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Interconnect PCA (M855) CAUTION:

ESD sensitive assembly.

Before proceeding, remove the following assemblies: ●

Formatter. See Formatter on page 23.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Left cover. See Left cover on page 118.

Remove the interconnect PCA (M855) 1.

Disconnect four connectors. Figure 1-367 Remove the interconnect PCA (M855; 1 of 4)

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2.

Remove two screws (callout 1). Figure 1-368 Remove the interconnect PCA (M855; 2 of 4)

1

3.

Locate one retainer. Figure 1-369 Remove the interconnect PCA (M855; 3 of 4)

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4.

Squeeze the ends of the retainer together (callout 1) to release it, and then remove the retainer (callout 2). Figure 1-370 Remove the interconnect PCA (M855; 4 of 4)

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Reinstall the interconnect PCA (M855) Make sure that the slot (callout 1) on the interconnect PCA is installed over the tab (callout 2) on the chassis. NOTE: If the formatter was not removed prior to removing the interconnect PCA, remove it before attempting to reinstall the PCA. Figure 1-371 Reinstall the interconnect PCA (M855)

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Interconnect PCA (M880) CAUTION:

ESD sensitive assembly.

Before proceeding, remove the following assemblies: ●

Formatter. See Formatter on page 23.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Left cover. See Left cover on page 118.

Remove the interconnect PCA (M880) 1.

Disconnect two connectors (callout 1) on top of the interconnect PCA and three connectors (callout 2) on the side. NOTE: Use a small flat-blade screwdriver to press the tab and release one of the top connectors as shown below. Figure 1-372 Remove the interconnect PCA (M880; 1 of 4)

1

2

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2.

Remove two screws. Figure 1-373 Remove the interconnect PCA (M880; 2 of 4)

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3.

Locate one retainer. Figure 1-374 Remove the interconnect PCA (M880; 3 of 4)

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4.

Squeeze the ends of the retainer together (callout 1) to release it, and then remove the retainer (callout 2). Figure 1-375 Remove the interconnect PCA (M880; 4 of 4)

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Reinstall the interconnect PCA (M880) Make sure that the slot (callout 1) on the interconnect PCA is installed over the tab (callout 2) on the chassis. NOTE: If the formatter was not removed prior to removing the interconnect PCA, remove it before attempting to reinstall the PCA. Figure 1-376 Reinstall the interconnect PCA (M880)

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Formatter case Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Left cover. See Left cover on page 118.

●

Interconnect PCA (M855). See Interconnect PCA (M855) on page 248.

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Interconnect PCA (M880). See Interconnect PCA (M880) on page 252.

Remove the formatter case 1.

M880 only: Remove the cable from two retainers. Figure 1-377 Remove the formatter case (1 of 2)

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2.

Remove seven screws (callout 1), and then remove the formatter case. Figure 1-378 Remove the formatter case (2 of 2)

1

Reinstall the formatter case Make sure that the tab (callout 1) on the formatter case is installed in the slot (callout 2) on the chassis. Figure 1-379 Reinstall the formatter case

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Formatter, formatter case, and interconnect board (ICB) NOTE: This procedure can be used to gain access to the DC controller when removing the main drive assembly. Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Left cover. See Left cover on page 118.

Remove the formatter, formatter case, and ICB 1.

Remove the wire harness from one retainer (callout 1). M880 only: Remove the cable from two retainers (callout 2). Figure 1-380 Remove the formatter, formatter case, and ICB (1 of 4)

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2.

Disconnect four connectors (callout 1). M880 only: Disconnect one additional connector (callout 2) by pressing one tab while pulling up gently on the cable. NOTE: 2).

Use a small flat-blade screwdriver to press the tab and release the connector (callout

Figure 1-381 Remove the formatter, formatter case, and ICB (2 of 4)

2

1

3.

Remove seven screws (callout 1). Figure 1-382 Remove the formatter, formatter case, and ICB (3 of 4)

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4.

Lift up (callout 1) to release one hook (callout 2), and then remove the formatter, formatter case, and ICB. Figure 1-383 Remove the formatter, formatter case, and ICB (4 of 4)

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Reinstall the formatter, formatter case, and ICB Make sure that the hook on the formatter case is installed in the slot on the chassis. Figure 1-384 Reinstall the formatter, formatter case, and ICB

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High-voltage power supply (HVPS) B CAUTION:

ESD sensitive assembly.

Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Left cover. See Left cover on page 118.

Remove the HVPS B 1.

Disconnect two connectors (callout 1), and then remove one screw (callout 2). CAUTION: Use care when disconnecting the white plastic connector at the top of the PCA. It can be easily damaged. Figure 1-385 Remove the HVPS B (1 of 2)

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2.

Release six tabs (callout 1) and then remove the HVPS B. Figure 1-386 Remove the HVPS B (2 of 2)

1

Reinstall the HVPS B 1.

After the HVPS B is installed and all tabs are in place, locate the circular locator windows (callout 1) along the side of the HVPS B. Figure 1-387 Reinstall the HVPS B (1 of 2)

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2.

Make sure that the spring (callout 1) can be seen through the eight locator windows. If the spring cannot be seen, remove and reinstall the HVPS B. NOTE: No error message is displayed on the control if these springs are positioned incorrectly. Poor print quality will be the only indicator. Figure 1-388 Reinstall the HVPS B (2 of 2)

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DC controller PCA CAUTION:

ESD sensitive assembly.

Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Left cover. See Left cover on page 118.

●

Formatter case. See Formatter case on page 255.

Remove the DC controller PCA Disconnect all of the connectors on the DC controller PCA. Remove six screws (callout 1), and then remove the DC controller PCA. Figure 1-389 Remove the DC controller PCA

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Color-plane registration (R) sensor assembly Before proceeding, remove the following assemblies: ●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left cover. See Left cover on page 118.

●

Front top cover. See Front top cover on page 115.

●

Front door assembly. See Front door on page 137.

●

Left front cover. See Left front cover on page 133.

●

Front inner cover. See Front inner cover on page 147.

Remove the R sensor assembly 1.

Remove one screw (callout 1), and then remove the bracket (callout 2). Figure 1-390 Remove the R sensor assembly (1 of 5)

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Remove three screws (callout 1). Figure 1-391 Remove the R sensor assembly (2 of 5)

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3.

Slide the sheet-metal cover out of the product. Figure 1-392 Remove the R sensor assembly (3 of 5)

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4.

Disconnect two connectors inside the cartridge cavity. Figure 1-393 Remove the R sensor assembly (4 of 5)

5.

Lift the R sensor assembly up to release two hooks on the assembly from the metal rod. NOTE: One clip is located toward the front of the product, and the other clip is located toward the back of the product. Reinstallation tip Make sure that the clips are snapped into place when reinstalling the R sensor assembly. Figure 1-394 Remove the R sensor assembly (5 of 5)

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Reinstall the R sensor assembly 1.

Note the location of two springs (callout 1) on the R sensor assembly. When reinstalling the R sensor assembly, make sure that these springs are positioned between the R sensor assembly and the product chassis. Figure 1-395 Reinstall the R sensor assembly (1 of 4)

1

2.

After the R sensor assembly is reinstalled, look into the cavity where the ITB would be installed. Locate the spring pedestal (callout 1), and make sure that the R spring at the back right-hand corner is correctly positioned (callout 2). TIP: This spring can also be viewed by looking into the cavity where the black toner cartridge would be installed. Figure 1-396 Reinstall the R sensor assembly (2 of 4)

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3.

Make sure that the tabs (callout 1) on the sheet-metal cover are inserted into the slots (callout 2) inside the product. Figure 1-397 Reinstall the R sensor assembly (3 of 4)

2

4.

1

Make sure that the tab on the bracket (callout 1) is positioned in the slot in the chassis (callout 2). Figure 1-398 Reinstall the R sensor assembly (4 of 4)

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Low-voltage power supply (LVPS) Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

Remove the LVPS 1.

M880 only: Disconnect one connector (callout 1). Figure 1-399 Remove the LVPS (1 of 5)

1

2.

Disconnect four connectors (callout 1), and then release the wire harnesses from three retainers (callout 2). Figure 1-400 Remove the LVPS (2 of 5)

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3.

Remove three screws (callout 1). Figure 1-401 Remove the LVPS (3 of 5)

1

4.

Lift the LVPS up (callout 1), push in on the lower right side (callout 2), and then rotate the top of the LVPS away from the product (callout 3). Figure 1-402 Remove the LVPS (4 of 5)

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5.

Lift the LVPS up and out of the product Figure 1-403 Remove the LVPS (5 of 5)

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High-voltage power supply (HVPS) A (first transfer) CAUTION:

ESD sensitive assembly.

Before proceeding, remove the following assemblies: ●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

Low-voltage power supply (LVPS). See Low-voltage power supply (LVPS) on page 269.

Remove the HVPS A (first transfer) 1.

Disconnect one connector (callout 1), and then remove one screw (callout 2). Figure 1-404 Remove the HVPS A (first transfer) (1 of 3

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2.

Release seven tabs. TIP:

Release the corner tabs first.

Figure 1-405 Remove the HVPS A (first transfer) (2 of 3)

3.

Lift the HVPS A up and off of one retainer, and then remove it from the product. Figure 1-406 Remove the HVPS A (first transfer) (3 of 3)

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Reinstall the HVPS A (first transfer) 1.

Position the slot bordered in white on the HVPS A into the retainer on the chassis before engaging the clips. Figure 1-407 Reinstall the HVPS A (first transfer) (1 of 3)

2.

After the HVPS A is installed and all tabs are in place, locate the circular locator windows across the top of the HVPS A. Figure 1-408 Reinstall the HVPS A (first transfer) (2 of 3)

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3.

Make sure that the spring (callout 1) can be seen through the 32 locator windows. If the spring cannot be seen, remove and reinstall the HVPS A (first transfer). NOTE: No error message is displayed on the control if these springs are positioned incorrectly. Poor print quality will be the only indicator. Figure 1-409 Reinstall the HVPS A (first transfer) (3 of 3)

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Lifter-drive assembly Before proceeding, remove the following assemblies: ●

Tray 2. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

Low-voltage power supply (LVPS). See Low-voltage power supply (LVPS) on page 269.

●

High-voltage power supply (HVPS) A (first transfer). See High-voltage power supply (HVPS) A (first transfer) on page 272.

Remove the lifter-drive assembly 1.

Disconnect three connectors (callout 1). Figure 1-410 Remove the lifter-drive assembly (1 of 3)

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2.

Remove three screws (callout 1), and then release two tabs (callout 2). Figure 1-411 Remove the lifter-drive assembly (2 of 3)

1

2

3.

Remove the lifter-drive assembly through the Tray 2 cavity. Figure 1-412 Remove the lifter-drive assembly (3 of 3)

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Reinstall the lifter-drive assembly 1.

When reinstalling the lifter-drive assembly, make sure that the assembly is unlocked (callout 1). If the lifter is locked (callout 2), the lifter will not function properly. Figure 1-413 Unlocked position of the lifter-driver assembly (correct)

1

Figure 1-414 Locked position of the lifter-driver assembly (incorrect)

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2.

If the assembly is in the locked position (callout 2 above), use a small, flat-blade screwdriver to press on the spring-loaded metal plate and move it to the unlocked position. Figure 1-415 Unlocking the lifter-drive assembly

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Toner-cartridge drive assembly (yellow and magenta) Before proceeding, remove the following assemblies: ●

All four toner cartridges. See Toner cartridge on page 14.

●

All four imaging drums. See Imaging drum on page 15.

●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

Memory tag PCA. See Memory tag PCA on page 230.

●

F fan FM2. See F fan FM2 on page 207.

●

Cartridge fan FM3 (yellow and magenta). See Cartridge fan FM3 (yellow and magenta) on page 214.

●

Laser/scanner fan FM1. See Laser/scanner fan FM1 on page 222.

●

All four image drum motors. See Image-drum motor on page 233.

●

F motor. See F motor on page 242.

●

F fan duct. See F fan duct on page 211.

●

Toner-cartridge feed motor (yellow, magenta, and cyan). See Toner-cartridge feed motor (yellow, magenta, and cyan) on page 245.

Remove the toner-cartridge drive assembly (yellow and magenta) Disconnect one connector (callout 1), remove four screws (callout 2), and then remove the tonercartridge drive assembly (yellow and magenta; callout 3). NOTE: Two of the screws are longer than the other two. See the reinstallation instructions below. Figure 1-416 Remove the toner-cartridge drive assembly (yellow and magenta)

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Reinstall the toner-cartridge drive assembly (yellow and magenta) 1.

Follow the gear-alignment procedure when replacing or reinstalling the toner-cartridge drive assembly (yellow and magenta). See Replace or reinstall the toner-cartridge drive assemblies or the main drive assembly on page 291.

2.

After the gear-alignment procedure is complete, install the two longer screws in the top positions (callout 1), and then install the two shorter screws in the lower positions (callout 2). NOTE: Move the black locks on the main drive assembly to the right (unlocked position) in order to install the lower screws in the toner-cartridge drive assembly. Figure 1-417 Reinstall the toner-cartridge drive assembly (yellow and magenta)

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Toner-cartridge drive assembly (cyan and black) Before proceeding, remove the following assemblies: ●

All four toner cartridges. See Toner cartridge on page 14.

●

All four imaging drums. See Imaging drum on page 15.

●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

F fan FM2. See F fan FM2 on page 207.

●

F fan duct. See F fan duct on page 211.

●

Cartridge fan FM3 (yellow and magenta). See Cartridge fan FM3 (yellow and magenta) on page 214.

●

Cartridge fan FM4 (cyan and black). See Cartridge fan FM4 (cyan and black) on page 218.

●

Laser/scanner fan FM1. See Laser/scanner fan FM1 on page 222.

●

Memory tag PCA. See Memory tag PCA on page 230.

●

All four image drum motors. See Image-drum motor on page 233.

●

F motor. See F motor on page 242.

●

Toner-cartridge feed motor (black). See Toner-cartridge feed motor (black) on page 244.

●

Toner-cartridge feed motor (yellow, magenta, and cyan). See Toner-cartridge feed motor (yellow, magenta, and cyan) on page 245.

●

Toner-cartridge drive assembly (yellow and magenta). See Toner-cartridge drive assembly (yellow and magenta) on page 280.

Remove the toner-cartridge drive assembly (cyan and black) Disconnect one connector (callout 1), remove three screws (callout 2), and then remove the tonercartridge drive assembly (cyan and black; callout 3). NOTE: One of the screws is longer than the other two. See the reinstallation instructions below.

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Figure 1-418 Remove the toner-cartridge drive assembly (cyan and black)

1 3 2

Reinstall the toner-cartridge drive assembly (cyan and black) 1.

Follow the gear-alignment procedure when replacing or reinstalling the toner-cartridge drive assembly (cyan and black). See Replace or reinstall the toner-cartridge drive assemblies or the main drive assembly on page 291.

2.

After the gear-alignment procedure is complete, install the longer screw in the top position (callout 1), and then install the two shorter screws in the lower positions (callout 2). NOTE: Move the black locks on the main drive assembly to the right (unlocked position) in order to install the lower screws in the toner-cartridge drive assembly. Figure 1-419 Reinstall the toner-cartridge drive assembly (cyan and black)

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Cartridge interface PCA (cyan and black) CAUTION:

ESD sensitive assembly.

NOTE: This part is the same part number as the cartridge interface PCA (yellow and magenta). Before proceeding, remove the following assemblies: ●

All four toner cartridges. See Toner cartridge on page 14.

●

All four imaging drums. See Imaging drum on page 15.

●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

F fan FM2. See F fan FM2 on page 207.

●

F fan duct. See F fan duct on page 211.

●

Cartridge fan FM3 (yellow and magenta). See Cartridge fan FM3 (yellow and magenta) on page 214.

●

Cartridge fan FM4 (cyan and black). See Cartridge fan FM4 (cyan and black) on page 218.

●

Laser/scanner fan FM1. See Laser/scanner fan FM1 on page 222.

●

Memory tag PCA. See Memory tag PCA on page 230.

●

All four image drum motors. See Image-drum motor on page 233.

●

F motor. See F motor on page 242.

●

Toner-cartridge feed motor (black). See Toner-cartridge feed motor (black) on page 244.

●

Toner-cartridge feed motor (yellow, magenta, and cyan). See Toner-cartridge feed motor (yellow, magenta, and cyan) on page 245.

●

Toner-cartridge drive assembly (yellow and magenta). See Toner-cartridge drive assembly (yellow and magenta) on page 280.

●

Toner-cartridge drive assembly (cyan and black). See Toner-cartridge drive assembly (cyan and black) on page 282.

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Remove the cartridge interface PCA (cyan and black) Remove three screws (callout 1), release one tab (callout 2), and then remove the cartridge interface PCA (cyan and black; callout 3). NOTE: These screws have washers attached. Figure 1-420 Remove the cartridge interface PCA (cyan and black)

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Cartridge interface PCA (yellow and magenta) CAUTION:

ESD sensitive assembly.

NOTE: This part is the same part number as the cartridge interface PCA (cyan and black). Before proceeding, remove the following assemblies: ●

All four toner cartridges. See Toner cartridge on page 14.

●

All four imaging drums. See Imaging drum on page 15.

●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

F fan FM2. See F fan FM2 on page 207.

●

F fan duct. See F fan duct on page 211.

●

Cartridge fan FM4 (cyan and black). See Cartridge fan FM4 (cyan and black) on page 218.

●

Cartridge fan FM3 (yellow and magenta). See Cartridge fan FM3 (yellow and magenta) on page 214.

●

Laser/scanner fan FM1. See Laser/scanner fan FM1 on page 222.

●

Memory tag PCA. See Memory tag PCA on page 230.

●

All four image drum motors. See Image-drum motor on page 233.

●

F motor. See F motor on page 242.

●

Toner-cartridge feed motor (yellow, magenta, and cyan). See Toner-cartridge feed motor (yellow, magenta, and cyan) on page 245.

●

Toner-cartridge drive assembly (yellow and magenta). See Toner-cartridge drive assembly (yellow and magenta) on page 280.

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Remove the cartridge interface PCA (yellow and magenta) Remove three screws (callout 1), release one tab (callout 2), and then remove the cartridge interface PCA (yellow and magenta; callout 3). NOTE: These screws have washers attached. Figure 1-421 Remove the cartridge interface PCA (yellow and magenta)

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Main drive assembly Before proceeding, remove the following assemblies: ●

All four toner cartridges. See Toner cartridge on page 14.

●

Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 19.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Left rear cover. See Left rear cover on page 104.

●

Left cover. See Left cover on page 118.

●

Rear cover. See Rear cover on page 143.

●

F fan FM2. See F fan FM2 on page 207.

●

F fan duct. See F fan duct on page 211.

●

Cartridge fan FM3 (yellow and magenta). See Cartridge fan FM3 (yellow and magenta) on page 214.

●

Cartridge fan FM4 (cyan and black). See Cartridge fan FM4 (cyan and black) on page 218.

●

Laser/scanner fan FM1. See Laser/scanner fan FM1 on page 222.

●

Memory tag PCA. See Memory tag PCA on page 230.

●

All four image drum motors. See Image-drum motor on page 233.

●

F power supply. See F power supply on page 235.

●

Intermediate transfer belt (ITB) alienation-drive assembly. See Intermediate transfer belt (ITB) alienation-drive assembly on page 240.

●

F motor. See F motor on page 242.

●

Toner-cartridge feed motor (black). See Toner-cartridge feed motor (black) on page 244.

●

Toner-cartridge feed motor (yellow, magenta, and cyan). See Toner-cartridge feed motor (yellow, magenta, and cyan) on page 245.

●

Formatter, formatter case, and interconnect board (ICB). See Formatter, formatter case, and interconnect board (ICB) on page 257.

●

Low-voltage power supply (LVPS). See Low-voltage power supply (LVPS) on page 269.

●

High-voltage power supply (HVPS) A (first transfer). See High-voltage power supply (HVPS) A (first transfer) on page 272.

●

Toner-cartridge drive assembly (yellow and magenta). See Toner-cartridge drive assembly (yellow and magenta) on page 280.

●

Toner-cartridge drive assembly (cyan and black). See Toner-cartridge drive assembly (cyan and black) on page 282.

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Cartridge interface PCA (cyan and black). See Cartridge interface PCA (cyan and black) on page 284.

●

Cartridge interface PCA (yellow and magenta). See Cartridge interface PCA (yellow and magenta) on page 286.

Remove the main drive assembly 1.

Disconnect four connectors (J113, J138, J141, and J142; callout 1) on the DC Controller, and then release the wire harnesses from the guide (callout 2). Figure 1-422 Remove the main drive assembly (1 of 2)

2 1

2.

Remove 12 screws, and then remove the main drive assembly. CAUTION: Do not remove the six red screws around the main drive assembly. Removal of these screws will cause damage to the assembly. Figure 1-423 Remove the main drive assembly (2 of 2)

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Reinstall the main drive assembly 1.

Do not touch the LEDs (callout 1) or the bias connections (callout 2) on the back of the main drive assembly. Contamination of these parts by grease or oil might result in print quality problems. Figure 1-424 Reinstall the main drive assembly

1

2 2.

Follow the gear-alignment procedure when replacing or reinstalling the main drive assembly. See Replace or reinstall the toner-cartridge drive assemblies or the main drive assembly on page 291.

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Replace or reinstall the toner-cartridge drive assemblies or the main drive assembly When the toner-cartridge drive units or the main drive assembly are installed on the product, the gears inside these assemblies must be realigned to ensure correct operation of the product. The following procedures explain how to align the gears when replacing the part or reinstalling the part after service. ●

If you are replacing the toner-cartridge drive assembly or the main drive assembly, see Replace the toner-cartridge drive assembly or the main drive assembly on page 291

●

If you are reinstalling the current toner-cartridge drive assembly or the main drive assembly, see Reinstall the toner-cartridge drive assembly or the main drive assembly on page 296

Replace the toner-cartridge drive assembly or the main drive assembly This procedure correctly aligns the gears of the main drive assembly (callout 1) and the tonercartridge drive assembly(ies) (callout 2). Use the four pins (callout 3) supplied with the replacement units to align the gears. NOTE: The toner-cartridge drive assembly (black) is shown in the figure below. Figure 1-425 Replace the toner-cartridge drive assembly or the main drive assembly (1 of 8)

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1.

Reinstall the main drive assembly. Push the black locks (callout 1) to the left while rotating the top gears (callout 2) on the main drive assembly until they lock into position. The large holes (callout 3) should point to the right (3 o'clock position). Figure 1-426 Replace the toner-cartridge drive assembly or the main drive assembly (2 of 8)

2

3 1

2.

Insert the long alignment pins (callout 1) through the gears (callout 2) in the main drive assembly. Figure 1-427 Replace the toner-cartridge drive assembly or the main drive assembly (3 of 8)

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3.

On the toner-cartridge drive assembly, rotate the top gear (callout 1) clockwise until the arrows align (callout 2). Insert the two short pins (callout 3). Figure 1-428 Replace the toner-cartridge drive assembly or the main drive assembly (4 of 8)

1

3

2 4.

Install the toner-cartridge drive assembly (callout 1) over the long pins in the main drive assembly (callout 2). NOTE:

The toner-cartridge drive assembly (black) is shown in the figure below.

Figure 1-429 Replace the toner-cartridge drive assembly or the main drive assembly (5 of 8)

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5.

Check the installation of the toner-cartridge drive assembly. CAUTION: Make sure that the toner-cartridge drive assembly is installed correctly. The assembly should be flush against the chassis (callout 1). Incorrect installation (callout 2) will cause the product to function incorrectly. Figure 1-430 Correct position of toner-cartridge drive assembly (6 of 8)

1

Figure 1-431 Incorrect position of toner-cartridge drive assembly (7 of 8)

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6.

Remove the alignment pins (callout 1). NOTE:

The toner-cartridge drive assembly (black) is shown in the figure below.

Figure 1-432 Replace the toner-cartridge drive assembly or the main drive assembly (8 of 8)

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Reinstall the toner-cartridge drive assembly or the main drive assembly This procedure correctly aligns the gears of the main drive assembly and the toner-cartridge drive assembly(ies) without the use of alignment pins. 1.

Reinstall the main drive assembly. Push the black locks (callout 1) to the left while rotating the top gears (callout 2) on the main drive assembly until they lock into position. The large holes (callout 3) should point to the right (3 o'clock position). IMPORTANT: When reinstalling without the alignment pins, it is important to that the locks (callout 1) are engaged. Figure 1-433 Reinstall the toner-cartridge drive assembly or the main drive assembly (1 of 4)

2

3 1

2.

On the toner-cartridge drive assembly, rotate the top gear (callout 1) clockwise until the arrows align (callout 2). Figure 1-434 Reinstall the toner-cartridge drive assembly or the main drive assembly (2 of 4)

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3.

Carefully install the toner-cartridge drive assembly. NOTE: it.

4.

Be careful not to rotate the gears on the toner-cartridge drive assembly while installing

Check the installation of the toner-cartridge drive assembly. CAUTION: Make sure that the toner-cartridge drive assembly is installed correctly. The assembly should be flush against the chassis (callout 1). Incorrect installation (callout 2) will cause the product to function incorrectly. Figure 1-435 Correct position of toner-cartridge drive assembly (3 of 4)

1

Figure 1-436 Incorrect position of toner-cartridge drive assembly (4 of 4)

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F drive assembly Before proceeding, remove the following assemblies: ●

F. See F on page 21.

●

Left rear cover. See Left rear cover on page 104.

●

Rear cover. See Rear cover on page 143.

●

F motor. See F motor on page 242.

Remove the f drive assembly 1.

Disconnect two connectors (callout 1), release one wire harness from the retainer (callout 2), and then release the wire harnesses from the guide (callout 3). Figure 1-437 Remove the f drive assembly (1 of 10)

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2.

At the right-rear side of the product, remove one screw (callout 1). Figure 1-438 Remove the f drive assembly (2 of 10)

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3.

Open the right door, and then remove one screw. Figure 1-439 Remove the f drive assembly (3 of 10)

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4.

Slide the retainer arm and guide to the left to disengage it from the chassis. Figure 1-440 Remove the f drive assembly (4 of 10)

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5.

Remove one screw (callout 1), and then remove the handle (callout 2). Figure 1-441 Remove the f drive assembly (5 of 10)

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6.

Remove two screws (callout 1), and then remove the right inner cover (callout 2). Figure 1-442 Remove the f drive assembly (6 of 10)

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2

7.

Use a small flat-blade screwdriver to release one plastic pin (callout 1), and then slide the duct to the right (callout 2) to remove it. TIP:

Use the arrow embossed on the duct to locate the pin (callout 1).

Reinstallation tip Lift up on the pin when the duct is reinstalled. Figure 1-443 Remove the f drive assembly (7 of 10)

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8.

Remove one screw (callout 1), and then separate the f cover open detection sensor holder (callout 2) from the chassis. CAUTION: The holder is still attached to the product. Do not attempt to completely remove the holder. Separate it from the product, and move it out of the way. Figure 1-444 Remove the f drive assembly (8 of 10)

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9.

Remove four screws. Figure 1-445 Remove the f drive assembly (9 of 10)

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10. Remove the f drive assembly. Figure 1-446 Remove the f drive assembly (10 of 10)

Reinstall the f drive assembly 1.

Make sure that the wire harness is routed through the correct opening in the chassis when reinstalling the assembly. Figure 1-447 Reinstall the f drive assembly (1 of 4)

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2.

When reinstalling the f cover open detection sensor holder, make sure that the tab on the holder (callout 1) is installed in the opening in the chassis (callout 2). Figure 1-448 Reinstall the f drive assembly (2 of 4)

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3.

When reinstalling the duct, make sure that the tabs on the duct (callout 1) are installed in the slots in the chassis (callout 2). Figure 1-449 Reinstall the f drive assembly (3 of 4)

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4.

When reinstalling the retainer arm, make sure that the tabs on the arm (callout 1) are installed in the slots in the chassis (callout 2). Figure 1-450 Reinstall the f drive assembly (4 of 4)

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Scanner cover Before proceeding, remove the following assemblies: ●

Control assembly (M880). See Control assembly (M880) on page 53.

●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Switch back cover. See Switch back cover on page 105.

●

Right upper rear cover (M855). See Right upper rear cover (M855) on page 96.

●

Right upper rear cover (M880). See Right upper rear cover (M880) on page 108.

●

Front top cover. See Front top cover on page 115.

●

Rear top cover. See Rear top cover (M855) on page 116.

●

Document feeder assembly (M880). See Document feeder assembly (M880) on page 154.

●

Scanner assembly (M880). See Scanner assembly (M880) on page 162.

Remove the scanner cover Remove eight screws (callout 1) and then remove the scanner cover (callout 2). CAUTION:

Be careful. Do not drop any of the screws into the product.

Figure 1-451 Remove the scanner cover

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Laser/scanner assembly (yellow and magenta) Before proceeding, remove the following assemblies: ●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Switch back cover. See Switch back cover on page 105.

●

Right upper rear cover (M855). See Right upper rear cover (M855) on page 96.

●

Right upper rear cover (M880). See Right upper rear cover (M880) on page 108.

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Front top cover. See Front top cover on page 115.

●

Rear top cover. See Rear top cover (M855) on page 116.

●

Document feeder assembly (M880). See Document feeder assembly (M880) on page 154.

●

Scanner assembly (M880). See Scanner assembly (M880) on page 162.

●

Scanner cover. See Scanner cover on page 306.

Remove the laser/scanner assembly (yellow and magenta) 1.

Disconnect one connector (callout 1), release one tab (callout 2), and then slide the corner cover to the right (callout 3) to remove it. Figure 1-452 Remove the laser/scanner assembly (yellow and magenta; 1 of 6)

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2.

Disconnect two connectors. Figure 1-453 Remove the laser/scanner assembly (yellow and magenta; 2 of 6)

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3.

Remove three springs. Figure 1-454 Remove the laser/scanner assembly (yellow and magenta; 3 of 6)

TIP: Hold the spring in place with one hand while releasing it with needle-nose pliers in the other hand. Figure 1-455 Remove the laser/scanner assembly (yellow and magenta; 4 of 6)

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4.

Lift up on the edge of the assembly closest to the left door, and then slide the assembly toward the front of the product. Figure 1-456 Remove the laser/scanner assembly (yellow and magenta; 5 of 6)

5.

Rotate the left side of the assembly toward the left door (callout 1), and then slide the assembly toward the back of the product (callout 2) to remove it. Figure 1-457 Remove the laser/scanner assembly (yellow and magenta; 6 of 6)

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Reinstall the laser/scanner assembly (yellow and magenta) 1.

CAUTION: Use care when reinstalling the cables for the laser/scanner assemblies. The traces on the cable ends can be damaged when reinserted. Figure 1-458 Reinstall the laser/scanner assembly (yellow and magenta; 1 of 2)

2.

CAUTION: Make sure that the tabs on each side of the laser/scanner are fully seated. Figure 1-459 Reinstall the laser/scanner assembly (yellow and magenta; 2 of 2)

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Laser/scanner assembly (cyan and black) Before proceeding, remove the following assemblies: ●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Right upper rear cover (M855). See Right upper rear cover (M855) on page 96.

●

Right upper rear cover (M880). See Right upper rear cover (M880) on page 108.

●

Front top cover. See Front top cover on page 115.

●

Rear top cover. See Rear top cover (M855) on page 116.

●

Document feeder assembly (M880). See Document feeder assembly (M880) on page 154.

●

Scanner assembly (M880). See Scanner assembly (M880) on page 162.

●

Scanner cover. See Scanner cover on page 306.

Remove the laser/scanner assembly (cyan and black) 1.

Disconnect one connector (callout 1), release one tab (callout 2), and then slide the corner cover to the right (callout 3) to remove it. Figure 1-460 Remove the laser/scanner assembly (cyan and black; 1 of 8)

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2.

Disconnect two connectors (callout 1), and then remove one spring (callout 2). Figure 1-461 Remove the laser/scanner assembly (cyan and black; 2 of 8)

2

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3.

Press and hold one spring-loaded tab (callout 1), and then slide the sheet-metal bar toward the front door (callout 2) to release it. Figure 1-462 Remove the laser/scanner assembly (cyan and black; 3 of 8)

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4.

Lift up the edge of the laser/scanner assembly (yellow and magenta; callout 1), and then remove the bar (callout 2). Figure 1-463 Remove the laser/scanner assembly (cyan and black; 4 of 8)

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5.

Remove three springs. Figure 1-464 Remove the laser/scanner assembly (cyan and black; 5 of 8)

TIP: Hold the spring in place with one hand while releasing it with needle-nose pliers in the other hand. Figure 1-465 Remove the laser/scanner assembly (cyan and black; 6 of 8)

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6.

Lift up the edge of the laser/scanner assembly (yellow and magenta) (callout 1), and then slide the laser/scanner (cyan and black) to the right (callout 2). Figure 1-466 Remove the laser/scanner assembly (cyan and black; 7 of 8)

1

2

7.

Lift up the edge of the laser/scanner assembly (yellow and magenta), rotate the left side of the assembly towards the left door (callout 1), and then slide the assembly toward the back of the product (callout 2) to remove it. Figure 1-467 Remove the laser/scanner assembly (cyan and black; 8 of 8)

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Reinstall the laser/scanner assembly (cyan and black) 1.

CAUTION: Use care when reinstalling the cables for the laser/scanner assemblies. The traces on the cable ends can be damaged when reinserted. Figure 1-468 Reinstall the laser/scanner assembly (cyan and black; 1 of 3)

2.

When reinstalling the bar, install the hook on the bar in the slot in the chassis as shown below. Figure 1-469 Reinstall the laser/scanner assembly (cyan and black; 2 of 3)

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3.

Make sure that the spring on the laser/scanner assembly (yellow and magenta) is in place. Figure 1-470 Reinstall the laser/scanner assembly (cyan and black; 3 of 3)

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Duplex reverse assembly (M855) Before proceeding, remove the following assemblies: ●

Switch back cover. See Switch back cover on page 105.

Remove the duplex reverse assembly (M855) Disconnect four connectors (callout 1), remove two screws (callout 2), and then remove the duplex reverse assembly (callout 3). Figure 1-471 Remove the duplex reverse assembly (M855)

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Duplex reverse assembly (M880) Before proceeding, remove the following assemblies: ●

Switch back cover. See Switch back cover on page 105.

Remove the duplex reverse assembly (M880) Disconnect three connectors (callout 1), remove two screws (callout 2), and then remove the duplex reverse assembly (callout 3). Figure 1-472 Remove the duplex reverse assembly (M880)

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VOC fan (M855) Before proceeding, remove the following assemblies: ●

Switch back tray. See Switch back tray on page 22.

●

Control (M855). See Control assembly (M855) on page 47.

●

Right upper rear cover (M855). See Right upper rear cover (M855) on page 96.

●

Hardware integration pocket (HIP) cover (M855). See Hardware integration pocket (HIP) cover (M855) on page 97.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Switch back cover. See Switch back cover on page 105.

●

Right upper front cover (M855). See Right upper front cover (M855) on page 120.

●

Front top cover. See Front top cover on page 115.

●

Rear top cover. See Rear top cover (M855) on page 116.

●

Right upper cover (M855). See Right upper cover (M855) on page 124.

Remove the VOC fan (M855) 1.

At the top of the product, release the wire harness from the retainer (callout 1), and then disconnect one connector (callout 2). Figure 1-473 Remove the VOC fan (M855; 1 of 2)

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2.

Remove one screw (callout 1), and then remove the VOC fan (callout 2). Reinstallation tip When the fan is reinstalled, make sure that the tab on the bottom fits into the slot provided on the chassis. Figure 1-474 Remove the VOC fan (M855; 2 of 2)

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VOC fan (M880) Before proceeding, remove the following assemblies:

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Switch back tray. See Switch back tray on page 22.

●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Switch back cover. See Switch back cover on page 105.

●

Rear upper rear cover (M880). See Rear upper rear cover (M880) on page 107.

●

Right upper rear cover (M880). See Right upper rear cover (M880) on page 108.

●

Rear upper MFP cover (M880). See Rear upper MFP cover (M880) on page 109.

●

Left upper rear cover (M880). See Left upper rear cover and rear upper B cover (M880) on page 111.

●

Rear upper front cover. See Rear upper front cover (M880) on page 113.

●

Front top cover. See Front top cover on page 115.

●

Right upper front cover (M880). See Right upper front cover (M880) on page 122.

●

Document feeder assembly (M880). See Document feeder assembly (M880) on page 154.

●

Scanner assembly (M880). See Scanner assembly (M880) on page 162.

●

Duplex reverse assembly (M880). See Duplex reverse assembly (M880) on page 320.

Main assemblies 323

Remove the VOC fan (M880) 1.

Remove one screw. Figure 1-475 Remove the VOC fan (M880; 1 of 6)

2.

Remove one screw (callout 1), and then release one tab (callout 2). Figure 1-476 Remove the VOC fan (M880; 2 of 6)

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3.

Release one tab. Figure 1-477 Remove the VOC fan (M880; 3 of 6)

4.

Release four tabs (callout 1), and then remove the switch back inner cover (callout 2). Figure 1-478 Remove the VOC fan (M880; 4 of 6)

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5.

Remove one screw (callout 1), and then lift the VOC fan (callout 2) away from the product. CAUTION: The VOC fan is still attached to the product by a wire harness. Do not attempt to completely remove the VOC fan. Figure 1-479 Remove the VOC fan (M880; 5 of 6)

2

1

6.

Release the wire harness from the retainer (callout 1), and then disconnect one connector (callout 2) to remove the VOC fan. Reinstallation tip When the fan is reinstalled, make sure that the tab on the bottom fits into the slot provided on the chassis. Figure 1-480 Remove the VOC fan (M880; 6 of 6)

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Face-down delivery assembly(M855) Before proceeding, remove the following assemblies: ●

Switch back tray. See Switch back tray on page 22.

●

Control (M855). See Control assembly (M855) on page 47.

●

Right upper rear cover (M855). See Right upper rear cover (M855) on page 96.

●

Hardware integration pocket (HIP) cover (M855). See Hardware integration pocket (HIP) cover (M855) on page 97.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Switch back cover. See Switch back cover on page 105.

●

Right upper front cover (M855). See Right upper front cover (M855) on page 120.

●

Front top cover. See Front top cover on page 115.

●

Rear top cover. See Rear top cover (M855) on page 116.

●

Right upper cover (M855). See Right upper cover (M855) on page 124.

●

Duplex reverse assembly (M855). See Duplex reverse assembly (M855) on page 319.

Remove the face-down delivery assembly (M855) 1.

At the top of the product, disconnect one connector (callout 1), and then release the wire harness from the retainer (callout 2). Figure 1-481 Remove the face-down delivery assembly (M855; 1 of 8)

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2.

Remove one screw (callout 1), and then remove the VOC fan (callout 2). Reinstallation tip When the fan is reinstalled, make sure that the tab on the bottom fits into the slot provided on the chassis. Figure 1-482 Remove the face-down delivery assembly (M855; 2 of 8)

1

3.

2

Remove two screws. Figure 1-483 Remove the face-down delivery assembly (M855; 3 of 8)

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4.

Remove one screw. Figure 1-484 Remove the face-down delivery assembly (M855; 4 of 8)

5.

Release one tab (callout 1), and then remove one cover (callout 2). TIP:

Use the arrow embossed on the cover to locate the tab.

Figure 1-485 Remove the face-down delivery assembly (M855; 5 of 8)

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Main assemblies 329

6.

Remove two screws. Figure 1-486 Remove the face-down delivery assembly (M855; 6 of 8)

7.

Disconnect one connector. Figure 1-487 Remove the face-down delivery assembly (M855; 7 of 8)

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8.

Remove the assembly. Figure 1-488 Remove the face-down delivery assembly (M855; 8 of 8)

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Face-down delivery assembly (M880) Before proceeding, remove the following assemblies: ●

Switch back tray. See Switch back tray on page 22.

●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Switch back cover. See Switch back cover on page 105.

●

Rear upper rear cover (M880). See Rear upper rear cover (M880) on page 107.

●

Right upper rear cover (M880). See Right upper rear cover (M880) on page 108.

●

Rear upper MFP cover (M880). See Rear upper MFP cover (M880) on page 109.

●

Left upper rear cover (M880). See Left upper rear cover and rear upper B cover (M880) on page 111.

●

Rear upper front cover. See Rear upper front cover (M880) on page 113.

●

Front top cover. See Front top cover on page 115.

●

Right upper front cover (M880). See Right upper front cover (M880) on page 122.

●

Document feeder assembly (M880). See Document feeder assembly (M880) on page 154.

●

Scanner assembly (M880). See Scanner assembly (M880) on page 162.

●

Duplex reverse assembly (M880). See Duplex reverse assembly (M880) on page 320.

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Remove the face-down delivery assembly (M880) 1.

Remove one screw. Figure 1-489 Remove the face-down delivery assembly (M880; 1 of 19)

2.

Remove one screw (callout 1), and then release one tab (callout 2). Figure 1-490 Remove the face-down delivery assembly (M880; 2 of 19)

2

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3.

Release one tab. Figure 1-491 Remove the face-down delivery assembly (M880; 3 of 19)

4.

Release four tabs (callout 1), and then remove the switch back inner cover (callout 2). Figure 1-492 Remove the face-down delivery assembly (M880; 4 of 19)

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5.

Release the wire harness and USB cable from the guide (callout 1), and then release one tab (callout 2). Figure 1-493 Remove the face-down delivery assembly (M880; 5 of 19)

2

6.

1

Remove three screws. Figure 1-494 Remove the face-down delivery assembly (M880; 6 of 19)

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7.

Remove three screws. Figure 1-495 Remove the face-down delivery assembly (M880; 7 of 19)

8.

Release the wire harness from the retainers (callout 1), open two retainers (callout 2), and then release a second wire harness (callout 3) from the sheet-metal bracket. Figure 1-496 Remove the face-down delivery assembly (M880; 8 of 19)

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9.

Remove six screws. Figure 1-497 Remove the face-down delivery assembly (M880; 9 of 19)

10. Remove the sheet-metal bracket. Figure 1-498 Remove the face-down delivery assembly (M880; 10 of 19)

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11. Disconnect one connector (callout 1), and then release the wire harness from the retainer (callout 2). Figure 1-499 Remove the face-down delivery assembly (M880; 11 of 19)

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12. Remove one screw (callout 1), and then remove the VOC fan (callout 2). Figure 1-500 Remove the face-down delivery assembly (M880; 12 of 19)

1

2

Reinstallation tip When the fan is reinstalled, make sure that the tab (callout 1) on the fan fits into the slot (callout 2) on the chassis. Figure 1-501 Remove the face-down delivery assembly (M880; 13 of 19)

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13. Remove two screws. Figure 1-502 Remove the face-down delivery assembly (M880; 14 of 19)

14. Remove one screw. Figure 1-503 Remove the face-down delivery assembly (M880; 15 of 19)

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15. Release one tab (callout 1), and then remove one cover (callout 2). TIP:

Use the arrow embossed on the cover to locate the tab.

Figure 1-504 Remove the face-down delivery assembly (M880; 16 of 19)

1

2

16. Remove two screws. Figure 1-505 Remove the face-down delivery assembly (M880; 17 of 19)

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17. Disconnect one connector. Figure 1-506 Remove the face-down delivery assembly (M880; 18 of 19)

18. Remove the assembly. Figure 1-507 Remove the face-down delivery assembly (M880; 19 of 19)

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Face-down cover Before proceeding, remove the following assemblies:

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Switch back tray. See Switch back tray on page 22.

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Control assembly (M855). See Control assembly (M855) on page 47.

●

Control assembly (M880). See Control assembly (M880) on page 53.

●

Scanner back cover (M880). See Scanner back cover (M880) on page 88.

●

Right upper rear cover (M855). See Right upper rear cover (M855) on page 96.

●

Right upper rear cover (M880). See Right upper rear cover (M880) on page 108.

●

Remove one of the following, depending upon product configuration: ◦

Face-down bin. See Face-down bin on page 101.

◦

Intermediate paper transport unit (IPTU). See IPTU assembly on page 437.

●

Switch back cover. See Switch back cover on page 105.

●

Front top cover. See Front top cover on page 115.

●

Rear top cover. See Rear top cover (M855) on page 116.

●

Right upper front cover (M855). See Right upper front cover (M855) on page 120.

●

Right upper front cover (M880). See Right upper front cover (M880) on page 122.

●

Right upper cover (M855). See Right upper cover (M855) on page 124.

●

Document feeder assembly (M880). See Document feeder assembly (M880) on page 154.

●

Scanner assembly (M880). See Scanner assembly (M880) on page 162.

●

Scanner cover. See Scanner cover on page 306.

●

Duplex reverse assembly (M880). See Duplex reverse assembly (M880) on page 320.

●

Duplex reverse assembly (M855). See Duplex reverse assembly (M855) on page 319.

●

Face-down delivery assembly (M855). See Face-down delivery assembly(M855) on page 327.

●

Face-down delivery assembly (M880). See Face-down delivery assembly (M880) on page 332.

Main assemblies 343

Remove the face-down cover Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the facedown cover. Figure 1-508 Remove face-down cover

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Duplexing feed assembly IMPORTANT: If you are installing a replacement duplexing feed assembly, you must use the Service menu to set the New Duplex Roller item to Yes. See Reinstall the duplexing feed assembly on page 349. 1.

Open the right door.

2.

Release two hinge pins and then remove the paper-feed cover. Figure 1-509 Remove the duplexing feed assembly (1 of 7)

3.

Release one tab (callout 1), slide the multipurpose upper feed guide to the right to release it (callout 2), and then lift it away from the door (callout 3) to remove it. Figure 1-510 Remove the duplexing feed assembly (2 of 7)

2

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4.

On the right door assembly, remove two self-tapping screws (callout 1), release two tabs (callout 2), and then remove the motor cover (callout 3). Figure 1-511 Remove the duplexing feed assembly (3 of 7)

2

1

3

5.

Disconnect two connectors (callout 1), release the wire harnesses from two retainers (callout 2), and then remove one screw (callout 3). Figure 1-512 Remove the duplexing feed assembly (4 of 7)

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6.

Remove two screws. Figure 1-513 Remove the duplexing feed assembly (5 of 7)

7.

Remove two screws. Figure 1-514 Remove the duplexing feed assembly (6 of 7)

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8.

Remove the duplexing feed assembly (callout 1). Reinstallation tip When reinstalling the duplexing feed assembly, make sure that there are no gaps between the part and the door. Figure 1-515 Remove the duplexing feed assembly (7 of 7)

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Reinstall the duplexing feed assembly IMPORTANT: If a replacement duplexing feed assembly is installed, you must follow the instructions below to reset the counter. Failure to follow these instructions might result in more frequent paper jams. Installing a replacement duplexing feed assembly If a replacement duplexing feed assembly is installed, do the following: 1.

From the Home screen on the control , scroll to and touch the Device Maintenance button.

2.

Open the Service menu.

3.

On the screen, select the Service Access Code option from the drop-down list.

4.

Enter one of the following service access codes:

5.

●

M855: 11085513

●

M880: 11088013

Reset the following value: ●

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Main assemblies 349

Multipurpose tray (Tray 1) pickup assembly Before proceeding, remove the following assemblies: ●

Duplexing feed assembly. See Duplexing feed assembly on page 345

Remove the multipurpose tray (Tray 1) pickup assembly 1.

Open Tray 1, release two hinge pins (callout 1), and then remove the Tray 1 lower cover (callout 2). Figure 1-516 Remove the multipurpose tray (Tray 1) pickup assembly (1 of 10)

1

2 2.

Disconnect one connector (callout 1), and then remove one screw (callout 2) to release the ground wire. Figure 1-517 Remove the multipurpose tray (Tray 1) pickup assembly (2 of 10)

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3.

Remove two screws. Figure 1-518 Remove the multipurpose tray (Tray 1) pickup assembly (3 of 10)

4.

Remove one screw. Figure 1-519 Remove the multipurpose tray (Tray 1) pickup assembly (4 of 10)

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5.

Remove two screws. Figure 1-520 Remove the multipurpose tray (Tray 1) pickup assembly (5 of 10)

6.

Make sure that Tray 1 is open, and then pull downward to remove Tray 1 and the Tray 1 pickup assembly together. Figure 1-521 Remove the multipurpose tray (Tray 1) pickup assembly (6 of 10)

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7.

Disconnect one connector (callout 1), and then release the wire harness from the guide (callout 2). Figure 1-522 Remove the multipurpose tray (Tray 1) pickup assembly (7 of 10)

1 2

8.

Gently pull on one wire harness (callout 1) to bring the connector (callout 2) through the slot (callout 3). Figure 1-523 Remove the multipurpose tray (Tray 1) pickup assembly (8 of 10)

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Main assemblies 353

9.

Use a small flat-blade screwdriver to release the shaft at the left side of the tray, and then separate the tray and the pickup assembly. Figure 1-524 Remove the multipurpose tray (Tray 1) pickup assembly (9 of 10)

10. Remove Tray 1 from the pickup assembly. Figure 1-525 Remove the multipurpose tray (Tray 1) pickup assembly (10 of 10)

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Reinstall the multipurpose tray (Tray 1) pickup assembly Make sure that the wire harness is correctly installed when the assembly is reinstalled. Figure 1-526 Reinstall the multipurpose tray (Tray 1) pickup assembly

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Main assemblies 355

Input accessories This section includes information about the following topics: ●

High-capacity input (HCI) feeder

●

1x500- and 3x500-sheet feeders

●

Shared input accessory covers and doors

356 Chapter 1 Removal and replacement

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High-capacity input (HCI) feeder NOTE: Some of the procedures in this section require the product to be removed from the input accessory.

Location of major components Figure 1-527 External covers and doors

7

1

6

2

5 4

3

Table 1-11 External covers and doors

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Item

Description

Item

Description

1

Right door assembly

5

Right rear cover

2

Right lower cover

6

Right tray

3

Left cover

7

Left tray

4

Rear cover

Input accessories 357

Figure 1-528 Main assemblies (1 of 2)

1

2

3

Table 1-12 Main assemblies (1 of 2) Item

Description

Item

Description

1

Left tray pickup assembly

3

Merge assembly

2

Right tray pickup assembly

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Figure 1-529 Main assemblies (2 of 2)

1

2

8 7

3 4

6

5

Table 1-13 Main assemblies (2 of 2) Item

Description

Item

Description

1

Left tray pickup drive assembly

5

Right tray automatic close assembly

2

Right tray pickup drive assembly

6

Left tray automatic close assembly

3

Right tray media-level sensor assembly

7

Left tray lifter drive assembly

4

Right tray lifter drive assembly

8

Left tray media-level sensor assembly

Figure 1-530 Printed circuit assembly (PCA)

1

Table 1-14 Printed circuit assembly (PCA)

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Item

Description

1

HCI controller PCA

Item

Description

Input accessories 359

HCI right tray 1.

Open the right tray.

2.

Lower the tray release lever, and then remove the right tray. NOTE: When the tray is reinstalled, the release lever automatically returns to the locked position. Figure 1-531 Remove the HCI right tray

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HCI left tray 1.

Open the left tray.

2.

Lower the tray release lever, and then remove the left tray. NOTE: When the tray is reinstalled, the release lever automatically returns to the locked position. Figure 1-532 Remove the HCI left tray

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Input accessories 361

HCI rear cover Remove one screw (callout 1), and then slide the rear cover (callout 2) toward the left door to remove it (callout 3). Figure 1-533 Remove the HCI rear cover

2

1

3

362 Chapter 1 Removal and replacement

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HCI right lower cover Before proceeding, remove the following assemblies: ●

HCI rear cover. See HCI rear cover on page 362.

●

HCI, 1x500, and 3x500 right door assembly. See HCI, 1x500, and 3x500 right door assembly on page 428.

●

HCI, 1x500, and 3x500 right rear cover. See HCI, 1x500, and 3x500 right rear cover on page 430.

Remove the HCI right lower cover 1.

Open the right tray.

2.

Remove one screw (callout 1), and then remove the lock holder (callout 2). Figure 1-534 Remove the HCI right lower cover (1 of 2)

1

2

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Input accessories 363

3.

Remove two screws (callout 1), and then remove the HCI right lower cover (callout 2). Figure 1-535 Remove the HCI right lower cover (2 of 2)

1

2

364 Chapter 1 Removal and replacement

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HCI right tray pickup motor Before proceeding, remove the following assemblies: ●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI right tray pickup motor Disconnect one connector (callout 1), remove two screws (callout 2), and then remove the right tray pickup motor (callout 3). Figure 1-536 Remove the HCI right tray pickup motor

2

1

3

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Input accessories 365

HCI right tray pickup drive Before proceeding, remove the following assemblies: ●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI right tray pickup drive Disconnect one connector (callout 1), remove three screws (callout 2), and then remove the right tray pickup drive (callout 3). NOTE: If you are replacing the HCI right tray pickup drive, remove the HCI right tray pickup motor from the old part and move it to the replacement part. See HCI right tray pickup motor on page 365. Figure 1-537 Remove the HCI right tray pickup drive (1 of 2)

2

1

3

366 Chapter 1 Removal and replacement

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HCI left tray pickup motor Before proceeding, remove the following assemblies: ●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI left tray pickup motor Disconnect one connector (callout 1), remove two screws (callout 2), and then remove the left tray pickup motor (callout 3). Figure 1-538 Remove the HCI left tray pickup motor

2

1

3

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Input accessories 367

HCI left tray pickup drive Before proceeding, remove the following assemblies: HCI rear cover. See HCI rear cover on page 362.

●

Remove the HCI left tray pickup drive Disconnect one connector (callout 1), remove three screws (callout 2), and then remove the left tray pickup drive (callout 3). NOTE: If you are replacing the HCI left tray pickup drive, remove the HCI left tray pickup motor from the old part and move it to the replacement part. See HCI left tray pickup motor on page 367. Figure 1-539 Remove the HCI left tray pickup drive

2

1

3

368 Chapter 1 Removal and replacement

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HCI right tray lifter drive assembly Before proceeding, remove the following assemblies: ●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI right tray lifter drive assembly 1.

Open the HCI right tray.

2.

Disconnect one connector (callout 1), remove three screws (callout 2), and then lift the assembly up to remove it. Figure 1-540 Remove the HCI right tray lifter drive assembly

1

2

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Input accessories 369

HCI left tray lifter drive assembly Before proceeding, remove the following assemblies: ●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI left tray lifter drive assembly 1.

Open the HCI left tray.

2.

Disconnect one connector (callout 1), remove three screws (callout 2), and then lift the assembly up to remove it Figure 1-541 Remove the HCI left tray lifter drive assembly

1 2

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HCI right tray media-level sensor assembly Before proceeding, remove the following assemblies: ●

HCI right tray. See HCI right tray on page 360.

●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI right tray media-level sensor assembly 1.

Disconnect one connector. Figure 1-542 Remove the HCI right tray media-level sensor assembly (1 of 2)

2.

From inside the tray cavity, remove one screw, and then remove the assembly. Figure 1-543 Remove the HCI right tray media-level sensor assembly (2 of 2)

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Input accessories 371

HCI left tray media-level sensor assembly Before proceeding, remove the following assemblies: ●

HCI left tray. See HCI left tray on page 361.

●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI left tray media-level sensor assembly 1.

Disconnect one connector. Figure 1-544 Remove the HCI left tray media-level sensor assembly (1 of 2)

2.

From inside the tray cavity, remove one screw, and then remove the assembly. Figure 1-545 Remove the HCI left tray media-level sensor assembly (2 of 2)

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HCI right tray automatic close assembly Before proceeding, remove the following assemblies: ●

HCI right tray. See HCI right tray on page 360.

●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI right tray automatic close assembly 1.

Disconnect one connector. Figure 1-546 Remove the HCI right tray automatic close assembly (1 of 2)

2.

From inside the tray cavity, remove three screws, and then remove the assembly. Figure 1-547 Remove the HCI right tray automatic close assembly (2 of 2)

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Input accessories 373

HCI left tray automatic close assembly Before proceeding, remove the following assemblies: ●

HCI left tray. See HCI left tray on page 361.

●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI left tray automatic close assembly 1.

Disconnect one connector. Figure 1-548 Remove the HCI left tray automatic close assembly (1 of 2)

2.

From inside the tray cavity, remove three screws, and then remove the assembly. Figure 1-549 Remove the HCI left tray automatic close assembly (2 of 2)

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HCI right tray pickup assembly Before proceeding, remove the following assemblies: ●

HCI right tray. See HCI right tray on page 360.

●

HCI rear cover. See HCI rear cover on page 362.

●

HCI right tray pickup drive. See HCI right tray pickup drive on page 366.

Remove the HCI right tray pickup assembly 1.

Remove one screw (callout 1), and then remove the lock holder (callout 2). Figure 1-550 Remove the HCI right tray pickup assembly (1 of 3)

1

2

2.

Disconnect three connectors (callout 1), and then remove one screw (callout 2). Figure 1-551 Remove the HCI right tray pickup assembly (2 of 3)

2

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1

Input accessories 375

3.

Remove two screws (callout 1), and then remove the assembly (callout 2). TIP: For easier removal, lift up on the merge assembly flap, and then remove (or replace) the pickup assembly from the right side of the HCI chassis (rather than from inside the tray cavity). Figure 1-552 Remove the HCI right tray pickup assembly (3 of 3)

1

2

Reinstall the HCI right tray pickup assembly Make sure that the pins (callout 1) on the HCI right tray pickup assembly are inserted in the holes (callout 2) in the product. Figure 1-553 Reinstall the HCI right tray pickup assembly

1

376 Chapter 1 Removal and replacement

2

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HCI left tray pickup assembly Before proceeding, remove the following assemblies: ●

HCI right tray. See HCI right tray on page 360.

●

HCI left tray. See HCI left tray on page 361.

●

HCI rear cover. See HCI rear cover on page 362.

●

HCI left tray pickup drive. See HCI left tray pickup drive on page 368.

Remove the HCI left tray pickup assembly 1.

Disconnect three connectors (callout 1) and then remove one screw (callout 2). Figure 1-554 Remove the HCI left tray pickup assembly (1 of 2)

2

1

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Input accessories 377

2.

From inside the tray cavity, remove one screw (callout 1), and then remove the assembly (callout 2). TIP:

the assembly when removing the screw (callout 1) so that it does not fall.

Figure 1-555 Remove the HCI left tray pickup assembly (2 of 2)

1

2

378 Chapter 1 Removal and replacement

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Reinstall the HCI left tray pickup assembly Make sure that the pins (callout 1) on the HCI left tray pickup assembly are inserted in the holes (callout 2) in the product. Figure 1-556 Reinstall the HCI left tray pickup assembly (1 of 2)

1

Figure 1-557 Reinstall the HCI left tray pickup assembly (2 of 2)

2

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Input accessories 379

HCI merge assembly Before proceeding, remove the following assemblies: ●

HCI right tray. See HCI right tray on page 360.

●

HCI rear cover. See HCI rear cover on page 362.

●

HCI right tray pickup drive. See HCI right tray pickup drive on page 366.

●

HCI right tray pickup assembly. See HCI right tray pickup assembly on page 375.

●

HCI, 1x500, and 3x500 right door assembly. See HCI, 1x500, and 3x500 right door assembly on page 428.

Remove the HCI merge assembly 1.

Disconnect one connector. Figure 1-558 Remove the HCI merge assembly (1 of 2)

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2.

Remove two screws (callout 1), and then remove the assembly (callout 2). Figure 1-559 Remove the HCI merge assembly (2 of 2)

1

2

Reinstall the HCI merge assembly Make sure that the tabs on the merge assembly (callout 1) are installed in the slots (callout 2) in the product. Figure 1-560 Reinstall the HCI merge assembly

2 1

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Input accessories 381

HCI controller PCA Before proceeding, remove the following assemblies: ●

HCI rear cover. See HCI rear cover on page 362.

Remove the HCI controller PCA Disconnect all of the connectors on the HCI controller PCA, remove four screws (callout 1), release two standoffs (callout 2), and then remove the PCA. Figure 1-561 Remove the HCI controller PCA

2

1

382 Chapter 1 Removal and replacement

2

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1x500- and 3x500-sheet feeders NOTE: Some of the procedures in this section require the product to be removed from the input accessory.

Location of major components Figure 1-562 External covers and doors (1x500-sheet feeder)

8

1

7

2

6

5 4

3

Table 1-15 External covers and doors (1x500-sheet feeder)

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Item

Description

Item

Description

1

Right door

5

Right rear cover

2

Right lower cover

6

Right front cover

3

Left cover

7

Storage box door

4

Rear cover

8

Upper front cover

Input accessories 383

Figure 1-563 External covers and doors (3x500-sheet feeder)

7

1 2

6

5 4

3

Table 1-16 External covers and doors (3x500-sheet feeder) Item

Description

Item

Description

1

Right door

5

Right rear cover

2

Right lower cover

6

Right front cover

3

Left cover

7

Upper front cover

4

Rear cover

384 Chapter 1 Removal and replacement

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Figure 1-564 Main assemblies (1x500-sheet feeder)

1 2

Table 1-17 Main assemblies (1x500-sheet feeder) Item

Description

Item

Description

1

Tray 3 pickup assembly (1x500)

2

Storage box assembly

Figure 1-565 Main assemblies (3x500-sheet feeder)

1 2 3

Table 1-18 Main assemblies (3x500-sheet feeder)

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Item

Description

Item

Description

1

Tray 3 pickup assembly (3x500)

3

Tray 5 pickup assembly (3x500)

2

Tray 4 pickup assembly (3x500)

Input accessories 385

Figure 1-566 Printed circuit assembly (PCA)

1

Table 1-19 Printed circuit assembly (PCA) Item

Description

1

Controller PCA (1x500, 3x500)

386 Chapter 1 Removal and replacement

Item

Description

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1x500 and 3x500 rear cover 1.

Move the lock lever (callout 1) to the unlocked position. Release one tab (callout 2), and then remove the lock lever. Figure 1-567 Remove the 1x500 and 3x500 rear cover (1 of 2)

1

2

2.

Remove one screw (callout 1), and then slide the rear cover (callout 2) toward the left door (callout 3) to remove it. Figure 1-568 Remove the 1x500 and 3x500 rear cover (2 of 2)

2

3

1

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Input accessories 387

1x500 and 3x500 right front cover Before proceeding, remove the following assemblies: ●

1x500 Tray 3(1x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 3 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

Remove the 1x500 and 3x500 right front cover 1.

Remove one screw. Figure 1-569 Remove the 1x500 and 3x500 right front cover (1 of 2)

2.

Open the 1x500 and 3x500 right door.

3.

1x500 only: Open the 1x500 storage box door.

388 Chapter 1 Removal and replacement

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4.

Use a small, flat-blade screwdriver to release three tabs (callout 1), and then lift the right front cover (callout 2) away from the product. Figure 1-570 Remove the 1x500 and 3x500 right front cover (2 of 2)

1

2

Reinstall the 1x500 and 3x500 right front cover Make sure that the tab on the cover (callout 1) is positioned over the sheet-metal slot (callout 2) in the product. Figure 1-571 Reinstall the 1x500 and 3x500 right front cover

2 1

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Input accessories 389

1x500 and 3x500 upper front face cover Before proceeding, remove the following assemblies: ●

Tray 2. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 Tray 3 (1x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 3 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

Remove the 1x500 and 3x500 upper front face cover Release one tab (callout 1), and then slide the upper front face cover (callout 2) toward the right door to remove it (callout 3). Figure 1-572 Remove the 1x500 and 3x500 upper front face cover

1 3 2

390 Chapter 1 Removal and replacement

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Reinstall the 1x500 and 3x500 upper front face cover Make sure that the three tabs on the cover (callout 1) are positioned in the slots (callout 2) in the product. Figure 1-573 Reinstall the 1x500 and 3x500 upper front face cover

2

1

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Input accessories 391

1x500 and 3x500 upper front cover Before proceeding, remove the following assemblies: ●

Tray 2. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 Tray 3 (1x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 3 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

●

1x500 and 3x500 upper front face cover. See 1x500 and 3x500 upper front face cover on page 390.

Remove the 1x500 and 3x500 right front cover 1.

Remove two screws. Figure 1-574 Remove the 1x500 and 3x500 upper front cover (1 of 4)

392 Chapter 1 Removal and replacement

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2.

Remove one screw. TIP:

Use a Phillips-head screwdriver with a short shaft to remove this screw.

Figure 1-575 Remove the 1x500 and 3x500 upper front cover (2 of 4)

3.

Remove one screw. Figure 1-576 Remove the 1x500 and 3x500 upper front cover (3 of 4)

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Input accessories 393

4.

Lift up to remove the upper front cover (callout 1). Figure 1-577 Remove the 1x500 and 3x500 upper front cover (4 of 4)

1

394 Chapter 1 Removal and replacement

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1x500 and 3x500 upper front left face cover Before proceeding, remove the following assemblies: ●

Tray 2. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 Tray 3 (1x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 3 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

●

1x500 and 3x500 upper front face cover. See 1x500 and 3x500 upper front face cover on page 390.

●

1x500 and 3x500 upper front cover. See 1x500 and 3x500 upper front cover on page 392.

Remove the 1x500 and 3x500 upper front left face cover Remove one screw from the 1x500 and 3x500 upper front cover (callout 1), and then remove the upper front left face cover (callout 2). Figure 1-578 Remove the 1x500 and 3x500 upper front left face cover

2

1

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Input accessories 395

1x500 storage box door Before proceeding, remove the following assemblies: ●

1x500 Tray 3. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

Remove the 1x500 storage box door 1.

Press down on one tab to release the door hinge. Figure 1-579 Remove the 1x500 storage box door (1 of 3)

2.

Release the link arm (callout 1) from the slot (callout 2). Figure 1-580 Remove the 1x500 storage box door (2 of 3)

2

1

396 Chapter 1 Removal and replacement

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3.

If you are replacing the storage box door, remove the link arm (callout 1) from the slot on the door (callout 2) and install it on the replacement door. Figure 1-581 Remove the 1x500 storage box door (3 of 3)

2

1

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Input accessories 397

1x500 storage box Before proceeding, remove the following assemblies: ●

1x500 Tray 3 (1x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

●

1x500 storage box door (1x500 only). See 1x500 storage box door on page 396.

Remove the 1x500 storage box 1.

Remove two screws. Figure 1-582 Remove the 1x500 storage box (1 of 2)

398 Chapter 1 Removal and replacement

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2.

Remove one screw (callout 1) and then lift the storage box (callout 2) out of the printer to remove it. Figure 1-583 Remove the 1x500 storage box (2 of 2)

2

1

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Input accessories 399

1x500 and 3x500 right lower cover Before proceeding, remove the following assemblies: ●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

●

HCI, 1x500, and 3x500 right door assembly. See HCI, 1x500, and 3x500 right door assembly on page 428.

●

HCI, 1x500, and 3x500 right rear cover. See HCI, 1x500, and 3x500 right rear cover on page 430.

Remove the 1x500 and 3x500 right lower cover NOTE: The 1x500 right lower cover is shown below. The procedure is the same for the 3x500 right lower cover. 1.

Remove one screw (callout 1), and then remove the lock holder (callout 2). Figure 1-584 Remove the 1x500 and 3x500 right lower cover (1 of 2)

1

2

400 Chapter 1 Removal and replacement

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2.

Remove two screws (callout 1), and then remove the right lower cover (callout 2). Figure 1-585 Remove the 1x500 and 3x500 right lower cover (2 of 2)

1

2

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Input accessories 401

1x500 Tray 3 pickup assembly Before proceeding, remove the following assemblies: ●

1x500 Tray 3. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 rear cover. See 1x500 and 3x500 rear cover on page 387.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

Remove the 1x500 Tray 3 pickup assembly 1.

Remove one screw (callout 1), and then remove the lock holder (callout 2). Figure 1-586 Remove the 1x500 Tray 3 pickup assembly (1 of 5)

1

2

2.

Remove one screw (callout 1), and then remove the tray guide rail (callout 2). Figure 1-587 Remove the 1x500 Tray 3 pickup assembly (2 of 5)

1 2

402 Chapter 1 Removal and replacement

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3.

Disconnect three connectors (callout 1), and then remove one screw (callout 2). NOTE:

The connectors and screw are located on the back of the product.

Figure 1-588 Remove the 1x500 Tray 3 pickup assembly (3 of 5)

2

4.

1

Remove one screw (callout 1). Hold the tray pickup assembly (callout 2), and then slide it toward the front of the product (callout 3) to release it. NOTE:

The screw and tray pickup assembly are located on the right side of the product.

Figure 1-589 Remove the 1x500 Tray 3 pickup assembly (4 of 5)

1

2

3

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Input accessories 403

5.

Remove the tray pickup assembly. Figure 1-590 Remove the 1x500 Tray 3 pickup assembly (5 of 5)

404 Chapter 1 Removal and replacement

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Reinstall the 1x500 Tray 3 pickup assembly 1.

Make sure that the shaft on the tray pickup assembly (callout 1) is positioned in the hole (callout 2) in the product. NOTE:

Callout 2 shows the location of the hole from the back of the product.

Figure 1-591 Reinstall the 1x500 Tray 3 pickup assembly (1 of 4)

1

Figure 1-592 Reinstall the 1x500 Tray 3 pickup assembly (2 of 4)

2

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Input accessories 405

2.

If the gear (callout 1) or the roller (callout 2) fall off of the tray guide rail, make sure that they are reinstalled correctly Figure 1-593 Reinstall the 1x500 Tray 3 pickup assembly (3 of 4)

2

1

3.

Install the end of the tray guide rail (callout 1) into the slot in the product (callout 2). Figure 1-594 Reinstall the 1x500 Tray 3 pickup assembly (4 of 4)

2

406 Chapter 1 Removal and replacement

1

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3x500 Tray 3 pickup assembly Before proceeding, remove the following assemblies: ●

3x500 Tray 3. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 4. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 rear cover. See 1x500 and 3x500 rear cover on page 387.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

●

3x500 Tray 4 pickup assembly. See 3x500 Tray 4 pickup assembly on page 412.

Remove the 3x500 Tray 3 pickup assembly 1.

Remove one screw (callout 1), and then remove the tray guide rail (callout 2). Figure 1-595 Remove the 3x500 Tray 3 pickup assembly (1 of 4)

2

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1

Input accessories 407

2.

Disconnect three connectors (callout 1), and then remove one screw (callout 2). NOTE:

The connectors and screw are located on the back of the product.

Figure 1-596 Remove the 3x500 Tray 3 pickup assembly (2 of 4)

2

3.

1

Remove one screw (callout 1). Hold the tray pickup assembly (callout 2), and then slide it toward the front of the product (callout 3) to release it. NOTE:

The screw and tray pickup assembly are located on the right side of the product.

Figure 1-597 Remove the 3x500 Tray 3 pickup assembly (3 of 4)

1

2

3

408 Chapter 1 Removal and replacement

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4.

Remove the tray pickup assembly. Figure 1-598 Remove the 3x500 Tray 3 pickup assembly (4 of 4

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Input accessories 409

Reinstall the 3x500 Tray 3 pickup assembly 1.

Make sure that the shaft on the tray pickup assembly (callout 1) is positioned in the hole (callout 2) in the product. NOTE:

Callout 2 shows the location of the hole from the back of the product.

Figure 1-599 Reinstall the 3x500 Tray 3 pickup assembly (1 of 4)

1

Figure 1-600 Reinstall the 3x500 Tray 3 pickup assembly (2 of 4)

2

410 Chapter 1 Removal and replacement

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2.

If the gear (callout 1) or the roller (callout 2) fall off of the tray guide rail, make sure that they are reinstalled correctly Figure 1-601 Reinstall the 3x500 Tray 3 pickup assembly (3 of 4)

2

1

3.

Install the end of the tray guide rail (callout 1) into the slot in the product (callout 2). Figure 1-602 Reinstall the 3x500 Tray 3 pickup assembly (4 of 4)

2 1

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Input accessories 411

3x500 Tray 4 pickup assembly Before proceeding, remove the following assemblies: ●

3x500 Tray 4. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 rear cover. See 1x500 and 3x500 rear cover on page 387.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

Remove the 3x500 Tray 4 pickup assembly 1.

Remove one screw (callout 1), and then remove the lock holder (callout 2). Figure 1-603 Remove the 3x500 Tray 4 pickup assembly (1 of 4)

1 2

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2.

Disconnect three connectors (callout 1), and then remove one screw (callout 2). NOTE:

The connectors and screw are located on the back of the product.

Figure 1-604 Remove the 3x500 Tray 4 pickup assembly (2 of 4)

2

3.

1

Remove one screw (callout 1). Hold the tray pickup assembly (callout 2), and then slide it toward the front of the product (callout 3) to release it. NOTE:

The screw and tray pickup assembly are located on the right side of the product.

Figure 1-605 Remove the 3x500 Tray 4 pickup assembly (3 of 4)

1

2 3

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Input accessories 413

4.

Remove the tray pickup assembly. Figure 1-606 Remove the 3x500 Tray 4 pickup assembly (4 of 4)

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Reinstall the 3x500 Tray 4 pickup assembly Make sure that the shaft on the tray pickup assembly (callout 1) is positioned in the hole (callout 2) in the product. NOTE: Callout 2 shows the location of the hole from the back of the product. Figure 1-607 Reinstall the 3x500 Tray 4 pickup assembly (1 of 2)

1

Figure 1-608 Reinstall the 3x500 Tray 4 pickup assembly (2 of 2)

2

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Input accessories 415

3x500 Tray 5 pickup assembly Before proceeding, remove the following assemblies: ●

3x500 Tray 5. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 rear cover. See 1x500 and 3x500 rear cover on page 387.

●

1x500 and 3x500 right front cover. See 1x500 and 3x500 right front cover on page 388.

●

1x500 and 3x500 right lower cover. See 1x500 and 3x500 right lower cover on page 400.

●

HCI, 1x500, and 3x500 right door assembly. See HCI, 1x500, and 3x500 right door assembly on page 428.

●

HCI, 1x500, and 3x500 right rear cover. See HCI, 1x500, and 3x500 right rear cover on page 430.

Remove the 3x500 Tray 5 pickup assembly 1.

Disconnect three connectors (callout 1), and then remove one screw (callout 2). NOTE:

The connectors and screw are located on the back of the product.

Figure 1-609 Remove the 3x500 Tray 5 pickup assembly (1 of 3)

2

1

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2.

Remove one screw (callout 1). Hold the tray pickup assembly (callout 2), and then slide it toward the front of the product (callout 3) to release it. NOTE:

The screw and tray pickup assembly are located on the right side of the product.

Figure 1-610 Remove the 3x500 Tray 5 pickup assembly (2 of 3)

2

1

3

3.

Remove the tray pickup assembly. Figure 1-611 Remove the 3x500 Tray 5 pickup assembly (3 of 3)

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Input accessories 417

Reinstall the 3x500 Tray 5 pickup assembly Make sure that the shaft on the tray pickup assembly (callout 1) is positioned in the hole (callout 2) in the product. NOTE: Callout 2 shows the location of the hole from the back of the product. Figure 1-612 Reinstall the 3x500 Tray 5 pickup assembly (1 of 2)

1

Figure 1-613 Reinstall the 3x500 Tray 5 pickup assembly (2 of 2)

2

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1x500 Tray 3 automatic close assembly Before proceeding, remove the following assemblies: ●

1x500 Tray 3. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 rear cover. See 1x500 and 3x500 rear cover on page 387.

Remove the 1x500 Tray 3 automatic close assembly 1.

Disconnect two connectors on the back of the product. Figure 1-614 Remove the 1x500 Tray 3 automatic close assembly (1 of 2)

2.

From inside the tray cavity, remove three screws (callout 1), and then remove the automatic close assembly (callout 2). Figure 1-615 Remove the 1x500 Tray 3 automatic close assembly (2 of 2)

2

1

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Input accessories 419

3x500 Tray 3, Tray 4, and Tray 5 automatic close assemblies Before proceeding, remove the following assemblies: ●

3x500 Tray 3. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 4. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 5. See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

1x500 and 3x500 rear cover. See 1x500 and 3x500 rear cover on page 387.

Remove the 3x500 Tray 3, Tray 4, and Tray 5 automatic close assemblies NOTE: The 3x500 Tray 3 automatic close assembly is shown below. The procedure is the same for the 3x500 Tray 4 or Tray 5 automatic close assemblies. 1.

Disconnect two connectors on the back of the product. Figure 1-616 Remove the 3x500 Tray 3, Tray 4, and Tray 5 automatic close assemblies (1 of 2)

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2.

From inside the tray cavity, remove three screws (callout 1), and then remove the automatic close assembly (callout 2). Figure 1-617 Remove the 3x500 Tray 3, Tray 4, and Tray 5 automatic close assemblies (2 of 2)

2

1

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Input accessories 421

1x500 Tray 3, 3x500 Tray 3, Tray 4, and Tray 5 pickup motors Before proceeding, remove the following assemblies: ●

1x500 and 3x500 rear cover. See 1x500 and 3x500 rear cover on page 387.

Remove the 1x500 Tray 3, 3x500 Tray 3, Tray 4, and Tray 5 pickup motors 1.

Locate the pickup motors: ●

1x500 Tray 3 pickup motor (callout 1)

●

3x500 Tray 3 pickup motor (callout 2)

●

3x500 Tray 4 pickup motor (callout 3)

●

3x500 Tray 5 pickup motor (callout 4)

Figure 1-618 1x500 pickup motor location

1

422 Chapter 1 Removal and replacement

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Figure 1-619 3x500 pickup motor locations

2 3 4

2.

Disconnect one connector (callout 1), remove two screws (callout 2), and then remove the pickup motor (callout 3). NOTE: The 1x500 Tray 3 pickup motor is shown below. The procedure is the same for the 3x500 Tray 3, Tray 4, and Tray 5 pickup motors. Figure 1-620 Remove the 1x500 Tray 3, 3x500 Tray 3, Tray 4, and Tray 5 pickup motors

3 1

2

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Input accessories 423

1x500 and 3x500 controller PCA Before proceeding, remove the following assemblies: ●

1x500 and 3x500 rear cover. See 1x500 and 3x500 rear cover on page 387.

Remove the HCI controller PCA Disconnect all of the connectors on the 1x500 and 3x500 controller PCA, remove six screws (callout 1), release two standoffs (callout 2), and then remove the PCA. Figure 1-621 Remove the HCI controller PCA

2

2

424 Chapter 1 Removal and replacement

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Shared input accessory covers and doors HCI, 1x500, and 3x500 left cover Before proceeding, remove the following assemblies:

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3x500 Tray 3 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

3x500 Tray 4 (3x500 only). See Tray 2, 1x500 Tray 3, 3x500 Tray 3, 3x500 Tray 4, and 3x500 Tray 5 on page 18.

●

HCI left tray (HCI only). See HCI left tray on page 361.

●

HCI rear cover (HCI only). See HCI rear cover on page 362.

●

1x500 and 3x500 rear cover (1x500 and 3x500 only). See 1x500 and 3x500 rear cover on page 387.

●

1x500 and 3x500 right front cover (1x500 and 3x500 only). See 1x500 and 3x500 right front cover on page 388.

●

1x500 and 3x500 upper front face cover (1x500 and 3x500 only). See 1x500 and 3x500 upper front face cover on page 390.

●

1x500 and 3x500 upper front cover (1x500 and 3x500 only). See 1x500 and 3x500 upper front cover on page 392.

●

1x500 storage box door (1x500 only). See 1x500 storage box door on page 396.

●

1x500 storage box (1x500 only). See 1x500 storage box on page 398.

Input accessories 425

Remove the HCI, 1x500, and 3x500 left cover NOTE: The HCI is shown below. 1.

Remove one screw. Figure 1-622 Remove the HCI, 1x500, and 3x500 left cover (1 of 2)

2.

Pull out slightly on the back edge of the cover to release one tab (callout 1), and then slide the cover toward the front of the product (callout 2) to remove it. Figure 1-623 Remove the HCI, 1x500, and 3x500 left cover (2 of 2)

2

1

426 Chapter 1 Removal and replacement

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Reinstall the HCI, 1x500, and 3x500 left cover Make sure that the tabs (callout 1) on the cover are positioned in the slots (callout 2) in the product. Figure 1-624 Reinstall the HCI, 1x500, and 3x500 left cover

2

1

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Input accessories 427

HCI, 1x500, and 3x500 right door assembly Remove the HCI, 1x500, and 3x500 right door assembly 1.

Open the right door assembly. Release one tab (callout 1), and then remove one stopper (callout 2). Figure 1-625 Remove the HCI, 1x500, and 3x500 right door assembly (1 of 3)

2 1

2.

Remove one screw. Figure 1-626 Remove the HCI, 1x500, and 3x500 right door assembly (2 of 3)

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3.

Lift the door straight up to remove it. Figure 1-627 Remove the HCI, 1x500, and 3x500 right door assembly (3 of 3)

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Input accessories 429

HCI, 1x500, and 3x500 right rear cover Before proceeding, remove the following assemblies: ●

HCI rear cover (HCI only). See HCI rear cover on page 362.

●

1x500 and 3x500 rear cover (1x500 or 3x500 only). See 1x500 and 3x500 rear cover on page 387.

Remove the HCI, 1x500, and 3x500 right rear cover 1.

Remove one screw. Figure 1-628 Remove the HCI, 1x500, and 3x500 right rear cover (1 of 4)

2.

Note the location of the tab on the top of the cover. Figure 1-629 Remove the HCI, 1x500, and 3x500 right rear cover (2 of 4)

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3.

Use a small, flat-blade screwdriver to release one tab. Figure 1-630 Remove the HCI, 1x500, and 3x500 right rear cover (3 of 4)

4.

Remove the right rear cover. Figure 1-631 Remove the HCI, 1x500, and 3x500 right rear cover (4 of 4)

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Input accessories 431

Reinstall the HCI right rear cover Make sure that the tab on the cover (callout 1) is installed over the sheet-metal slot on the product (callout 2). Figure 1-632 Reinstall the HCI, 1x500, and 3x500 right rear cover

2 1

432 Chapter 1 Removal and replacement

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Intermediate paper transport unit (IPTU) CAUTION: To avoid damaging the intermediate paper transport unit (IPTU), place it on the edge of a work surface as shown below to service it. Figure 1-633 Correct placement of the IPTU for servicing

Figure 1-634 Incorrect placement of the IPTU for servicing

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Intermediate paper transport unit (IPTU) 433

Location of major components Figure 1-635 IPTU covers (1 of 2)

11 22

33

Table 1-20 IPTU covers (1 of 2) Item

Description

1

Side assembly

2

Upper guide assembly

3

Finisher lock assembly

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Figure 1-636 IPTU covers (2 of 2)

1

Table 1-21 IPTU covers (2 of 2) Item

Description

1

Rear cover

Figure 1-637 IPTU main assemblies

1

2

Table 1-22 IPTU main assemblies

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Item

Description

1

IPTU fan assembly

2

Lower guide assembly

Intermediate paper transport unit (IPTU) 435

Figure 1-638 IPTU PCA

1

Table 1-23 IPTU PCA Item

Description

1

IPTU driver PCA

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IPTU assembly 1.

Turn the product off.

2.

If a finishing accessory is attached, unplug the device from the printer. Figure 1-639 Remove the IPTU (1 of 4)

3.

Press the release button down and hold it down (callout 1) as you slide the finishing accessory away from the product (callout 2). Figure 1-640 Remove the IPTU (2 of 4)

1

2

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Intermediate paper transport unit (IPTU) 437

4.

Remove two screws. Figure 1-641 Remove the IPTU (3 of 4)

5.

Slide the IPTU away from the product to remove it. Figure 1-642 Remove the IPTU (4 of 4)

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IPTU rear cover 1.

Place the IPTU face-down, and then remove six screws. Reinstallation tip Three of these screws (callout 1) have washers attached. Make sure that these screws are reinstalled in the same locations. Figure 1-643 Remove the IPTU rear cover (1 of 3)

1

2.

Rotate the top edge of the cover away from the IPTU. Figure 1-644 Remove the IPTU rear cover (2 of 3)

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Intermediate paper transport unit (IPTU) 439

3.

Rotate the left edge of the cover away from the IPTU, and then remove the cover. Figure 1-645 Remove the IPTU rear cover (3 of 3)

Reinstall the IPTU rear cover 1.

Make sure that the slots in the cover are aligned with the tabs on the IPTU. Figure 1-646 Reinstall the IPTU rear cover (1 of 2)

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2.

Make sure that the indentations on the cover (callout 1) slide underneath the metal tabs (callout 2) on the IPTU. Figure 1-647 Reinstall the IPTU rear cover (2 of 2)

2

1

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Intermediate paper transport unit (IPTU) 441

IPTU driver PCA Before proceeding, remove the following assemblies: ●

IPTU rear cover. See IPTU rear cover on page 439.

Remove the IPTU driver PCA 1.

Disconnect seven connectors. Figure 1-648 Remove the IPTU driver PCA (1 of 2)

2.

Remove two screws (callout 1), release two tabs, and then remove the IPTU driver PCA (callout 3). Figure 1-649 Remove the IPTU driver PCA (2 of 2)

1

3 2

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IPTU finisher lock assembly Before proceeding, remove the following assemblies: ●

IPTU rear cover. See IPTU rear cover on page 439.

Remove the IPTU finisher lock assembly 1.

Place the IPTU face-down, and then locate the finisher lock assembly. Figure 1-650 Remove the IPTU finisher lock assembly (1 of 5)

2.

Remove two screws. Figure 1-651 Remove the IPTU finisher lock assembly (2 of 5)

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Intermediate paper transport unit (IPTU) 443

3.

Disconnect three connectors (callout 1) on the IPTU driver PCA, and then remove the wire harnesses from the guides (callout 2). Figure 1-652 Remove the IPTU finisher lock assembly (3 of 5)

1

2

4.

Remove two screws. Figure 1-653 Remove the IPTU finisher lock assembly (4 of 5)

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5.

Remove the IPFU finisher lock assembly. Figure 1-654 Remove the IPTU finisher lock assembly (5 of 5)

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Intermediate paper transport unit (IPTU) 445

IPTU fan assembly Before proceeding, remove the following assemblies: ●

IPTU rear cover. See IPTU rear cover on page 439.

Remove the IPTU fan assembly 1.

Disconnect one connector (callout 1), and then release the wire harness from the guide (callout 2). Figure 1-655 Remove the IPTU fan assembly (1 of 2)

2

1

2.

Remove four screws (callout 1), and then remove the fan assembly (callout 2). Figure 1-656 Remove the IPTU fan assembly (2 of 2)

2

1

446 Chapter 1 Removal and replacement

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IPTU side assembly Before proceeding, remove the following assemblies: ●

IPTU rear cover. See IPTU rear cover on page 439.

●

IPTU finisher lock assembly. See IPTU finisher lock assembly on page 443.

●

IPTU fan assembly. See IPTU fan assembly on page 446.

●

IPTU driver PCA. See IPTU driver PCA on page 442.

Remove the IPTU side assembly 1.

Disconnect one connector (callout 1), and then remove one wire tie (callout 2). TIP: To release the wire tie (callout 2), push in on the tab, and then remove the wire tie from the chassis. Figure 1-657 Remove the IPTU side assembly (1 of 6)

2

1

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Intermediate paper transport unit (IPTU) 447

2.

Remove two screws (callout 1), and then remove the right assist motor (callout 2). Figure 1-658 Remove the IPTU side assembly (2 of 6)

1

2

3.

Release one tab (callout 1), and then slide the gear retainer (callout 2) off of the shaft to remove it. Figure 1-659 Remove the IPTU side assembly (3 of 6)

1

448 Chapter 1 Removal and replacement

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4.

Remove one drive belt (callout 1), and then slide the drive gear (callout 2) off of the shaft to remove it. Figure 1-660 Remove the IPTU side assembly (4 of 6)

2

1

5.

Repeat the previous two steps for the remaining three gear retainers, drive belts, and drive gears. Figure 1-661 Remove the IPTU side assembly (5 of 6)

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Intermediate paper transport unit (IPTU) 449

6.

Remove five screws, and then remove the side assembly (callout 1). Figure 1-662 Remove the IPTU side assembly (6 of 6)

1

Reinstall the IPTU side assembly When the side assembly is reinstalled, make sure that the bushings on the four drive-gear shafts are correctly installed as shown below. Figure 1-663 Reinstall the IPTU side assembly

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IPTU upper and lower guide assemblies Before proceeding, remove the following assemblies: ●

IPTU rear cover. See IPTU rear cover on page 439.

Remove the IPTU upper and lower guide assemblies 1.

Turn the IPTU face-down, and then remove two screws. Figure 1-664 Remove the IPTU upper and lower guide assemblies (1 of 9)

2.

Turn the IPTU face-up, release two tabs (callout 1), and then remove two covers (callout 2). Figure 1-665 Remove the IPTU upper and lower guide assemblies (2 of 9)

1

2

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Intermediate paper transport unit (IPTU) 451

3.

Remove six screws. NOTE:

These are self-tapping screws.

Figure 1-666 Remove the IPTU upper and lower guide assemblies (3 of 9)

4.

Lift the upper guide away from the IPTU, and then locate one hinge. Figure 1-667 Remove the IPTU upper and lower guide assemblies (4 of 9)

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5.

Remove two screws from the rear of the IPTU. Figure 1-668 Remove the IPTU upper and lower guide assemblies (5 of 9)

6.

Flex the plastic cover (callout 1) to release the hinge (callout 2) from the slot (callout 3). Figure 1-669 Remove the IPTU upper and lower guide assemblies (6 of 9)

1 2 3

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Intermediate paper transport unit (IPTU) 453

7.

Lift the upper guide assembly (callout 1) until the screw (callout 2) in the hinge is visible. Remove the screw. NOTE: This screw is different from the other screws in the assembly. Make sure to reinstall this screw in the hinge.

Figure 1-670 Remove the IPTU upper and lower guide assemblies (7 of 9)

1 2

454 Chapter 1 Removal and replacement

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8.

Lift the upper guide assembly straight up to remove it. Figure 1-671 Remove the IPTU upper and lower guide assemblies (8 of 9)

9.

Locate the upper guide assembly (callout 1) and the lower guide assembly (callout 2). Figure 1-672 Remove the IPTU upper and lower guide assemblies (9 of 9)

1

2

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Intermediate paper transport unit (IPTU) 455

Install a replacement IPTU upper guide assembly If you are installing a replacement upper guide assembly, follow these steps to remove the left- and right-assist assemblies, and then install them on the replacement upper guide assembly 1.

Turn the upper guide assembly over to access the bottom of the assembly. Remove one screw (callout 1), and then remove the left-assist assembly (callout 2). Figure 1-673 Install a replacement IPTU upper guide assembly (1 of 2)

2

1

2.

Remove one screw (callout 1), and then remove the right-assist assembly (callout 2). Figure 1-674 Install a replacement IPTU upper guide assembly (2 of 2)

2

1

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Finishing accessories CAUTION: servicing.

Turn the product off and disconnect the finishing accessory from the product before

This section includes information about the following topics:

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Identify the finishing accessories

●

Identifying finishing accessory covers and doors

●

Shared finishing accessory assemblies

●

Booklet maker accessory

●

Booklet maker and stapler/stacker with hole punch accessories

Finishing accessories 457

Identify the finishing accessories ●

Booklet maker (BM) Includes booklet maker and stapler functions. Figure 1-675 Identify the BM finishing accessory

●

Booklet maker with hole punch (BMHP) Includes booklet maker and hole punch (2/3 or 2/4) functions. Figure 1-676 Identify the BMHP finishing accessory

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Stapler/stacker (SS) Includes stapler functions. Figure 1-677 Identify the SS finishing accessory

●

Stapler/stacker with hole punch (SSHP) Includes stapler and hole punch (2/3 or 2/4) functions. Figure 1-678 Identify the SSHP finishing accessory

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Finishing accessories 459

Identifying finishing accessory covers and doors Figure 1-679 Stapler stacker covers and doors

1 2 3

12 11 4

10

4

5 6

9 7 8 Table 1-24 Stapler stacker covers and doors Item

Description

Item

Description

1

Step lower cover

7

Front foot cover

2

Top door assembly

8

Rear foot cover

3

Latch assembly

9

Rear cover

4

Latch lower cover

10

Inner lower cover

5

Step top cover

11

Inner upper cover assembly

6

Open-close step cover

12

Front door assembly

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Figure 1-680 Stapler stacker with hole punch covers and doors

1 2 3 4

1717 16 15 14 13 12

5

6 7

11 10 8 9 Table 1-25 Stapler stacker with hole punch covers and doors

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Item

Description

Item

Description

1

Step lower cover

10

Rear cover

2

Top door assembly

11

Punch rear cover

3

Punch top cover

12

Punch lower cover

4

Latch assembly

13

Inner lower cover

5

Latch lower cover

14

Punch front cover

6

Step top cover

15

Punch inner cover

7

Open-close step cover

16

Inner upper cover assembly

8

Front foot cover

17

Front door assembly

9

Rear foot cover

Finishing accessories 461

Figure 1-681 Booklet maker covers and doors

1 2 3

12 11

4 10

5 6

9 7 8 Table 1-26 Booklet maker covers and doors Item

Description

Item

Description

1

Step lower cover

7

Front foot cover

2

Top door assembly

8

Rear foot cover

3

Latch assembly

9

Rear cover

4

Latch lower cover

10

Inner lower cover

5

Step top cover

11

Inner upper cover assembly

6

Open-close step cover

12

Front door assembly

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Figure 1-682 Booklet maker with hole punch covers and doors

1 2 17

3

16

4

15 14

5

13

6

12

7 11 10 8 9

Table 1-27 Booklet maker with hole punch covers and doors

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Item

Description

Item

Description

1

Step lower cover

10

Rear cover

2

Top door assembly

11

Punch rear cover

3

Punch top cover

12

Punch lower cover

4

Latch assembly

13

Inner lower cover

5

Latch lower cover

14

Punch front cover

6

Step top cover

15

Punch inner cover

7

Open-close step cover

16

Inner upper cover assembly

8

Front foot cover

17

Front door assembly

9

Rear foot cover

Finishing accessories 463

Shared finishing accessory assemblies The assemblies described in this section are found on each of the finishing accessories. ●

Top cover lock assembly

●

Latch lower covers (front and rear)

●

Latch assembly

●

Open/closed stepped cover assembly

●

Upper stepped cover assembly

●

Lower stepped cover assembly

●

Top door assembly

●

Front door

●

Inner upper cover assembly

●

Clutch assembly (front side)

●

Sensor switch assembly

●

Inner lower cover assembly

●

Front foot cover assembly

●

Bin cable guide cover

●

Rear cover assembly

●

Main controller PCA assembly

●

Entrance upper guide assembly

●

Rear foot cover assembly

●

Stack wall upper assembly and upper wall guide assembly

●

Upper cross member assembly

●

Paper feed drive assembly

●

Pressure roller assembly

●

Stack upper bin and lower bin assemblies

●

Height wall assembly

●

Paper face sensor and flag assembly

●

Staple subassembly

●

Staple connecting cable assembly

●

Staple assembly

●

Paper detect holder assembly

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Operation tray assembly

●

Swing guide assembly

●

Return roller assembly

●

Clutch assembly (rear side)

●

Stack ejection motor assembly

●

Press motor assembly

●

Common driver PCA assembly

●

Interface cable assembly

●

Paper assembly

Finishing accessories 465

Top cover lock assembly 1.

Open the top cover, carefully unsnap two spring loaded arms to release them from the latch shaft, and then move the cover out of the way. Figure 1-683 Remove the top cover lock assembly (1 of 3)

2.

Move the upper cover out of the way, release one lever (callout 1) which holds the entrance upper guide assembly in the open position, and then lower the guide assembly (callout 2) into the accessory. Figure 1-684 Remove the top cover lock assembly (2 of 3)

1

466 Chapter 1 Removal and replacement

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3.

Remove one screw (callout 1), and then remove the upper cover lock assembly (callout 2). Figure 1-685 Remove the top cover lock assembly (3 of 3)

1

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2

Finishing accessories 467

Latch lower covers (front and rear) NOTE: The cover shown in the following procedure is installed on a booklet maker with hole punch (BMHP) accessory, however the procedure is the same for all of the finishing accessories. 1.

Remove four screws. Figure 1-686 Remove the latch lower covers (front and rear; 1 of 3)

2.

Before proceeding, take note of the two locator pins on the back side of each cover. These are positioning pins and must be correctly installed to assure proper alignment of the covers when they are reinstalled. Figure 1-687 Remove the latch lower covers (front and rear; 2 of 3)

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3.

Remove the covers (callout 1) by moving the top of the cover outward to release the positioning pins (callout 2). TIP: As the cover is removed, you might need to reach behind the cover to release the two locator pins on the back side of the cover. Figure 1-688 Remove the latch lower covers (front and rear; 3 of 3)

1

2

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Finishing accessories 469

Latch assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

Remove the latch assembly 1.

Remove four screws. Figure 1-689 Remove the latch assembly (1 of 2)

2.

Lift the assembly straight up to release it (callout 1), and then rotate the assembly away from the paper path entrance (callout 2) to remove it. Figure 1-690 Remove the latch assembly (2 of 2)

2

1

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Open/closed stepped cover assembly 1.

Open the cover. Figure 1-691 Remove the open/close stepped cover assembly (1 of 2)

2.

Carefully push in on the cover hinge (callout 1) to release the hinge pin, lift the rear edge of the cover out and up (callout 2), and then slide the cover to the right (callout 3). Unlatch the left hinge of cover by swinging it out and up to remove cover (callout 4). Figure 1-692 Remove the open/close stepped cover assembly (2 of 2)

3 4

2 1

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Finishing accessories 471

Upper stepped cover assembly 1.

Use your finger to release one tab (callout 1), carefully pull up on the corner of the cover (callout 2), and then push in on the cover to release a second tab (callout 3). Figure 1-693 Remove the upper stepped cover assembly (1 of 4)

2

3

2.

1

Use your finger to release one tab (callout 1), carefully pull up on the opposite corner of the cover (callout 2), and then push in on the cover to release a second tab (callout 3). Figure 1-694 Remove the upper stepped cover assembly (2 of 4)

2

3 1

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3.

Rotate the edge of the cover nearest the stack bins (callout 1) up and away from the accessory. TIP: As you rotate the cover up, push in on the center of the cover (callout 2) to make it easier to remove. Figure 1-695 Remove the upper stepped cover assembly (3 of 4)

1 2 1

4.

Remove the cover. Figure 1-696 Remove the upper stepped cover assembly (4 of 4)

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Finishing accessories 473

Lower stepped cover assembly Before proceeding, remove the following assemblies: ●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

Remove the lower stepped cover assembly 1.

Remove two screws. NOTE: From the top of the accessory, look down into the lower stepped cover to locate these screws. Figure 1-697 Remove the lower stepped cover assembly (1 of 5)

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2.

Remove one screw (callout 1) from the rear cover. TIP: Removing this screw is necessary to release the rear cover from the lower stepped cover when it is removed. Figure 1-698 Remove the lower stepped cover assembly (2 of 5)

3.

Carefully flex the corner of the rear cover away from the accessory (callout 1), and then slightly lift up and push in (callout 2) on the lower stepped cover to release one tab. Figure 1-699 Remove the lower stepped cover assembly (3 of 5)

2

1

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Finishing accessories 475

4.

Rotate the edge of the cover nearest the stack bins up and away from the accessory. Figure 1-700 Remove the lower stepped cover assembly (4 of 5)

5.

Remove the cover. TIP: Lift and rotate the cover as shown below so that the cover will slide out from under the top door. Figure 1-701 Remove the lower stepped cover assembly (5 of 5)

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Reinstall the lower stepped cover When the cover is reinstalled, open the top cover and make sure that the slots in the cover are underneath the sheet-metal tabs on the chassis. Figure 1-702 Reinstall the lower stepped cover (1 of 2)

Figure 1-703 Reinstall the lower stepped cover (2 of 2)

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Finishing accessories 477

Top door assembly NOTE: The following figures show the top door assembly on the stapler/stacker with hole punch (SSHP) finishing accessory. This removal procedure is the same for all of the finishing accessories. 1.

Open the door, and then carefully unsnap two spring loaded arms to release them from the latch shaft. Figure 1-704 Remove the top door assembly (1 of 2)

2.

From the front of the finisher, slide the top door slightly towards the rear of the accessory until it stops (callout 1). Carefully press in on the front hinge to release the hinge from the bracket (callout 2), and then lift it out of the bracket (callout 3). Slide the top of the door towards the front of the accessory to release the rear hinge (callout 4) from the rear bracket to remove the door. Figure 1-705 Remove the top door assembly (2 of 2)

3

1

2

4

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Front door Remove the front door 1.

Open the front door.

2.

the door, and then remove one self tapping screw (callout 1) and the sheet-metal hinge (callout 2). TIP: To reinstall the self-tapping screw, first turn it counterclockwise (1/4 turn) to align it with the existing thread pattern, and then carefully turn it clockwise to tighten. Do not overtighten. Figure 1-706 Remove the front door (1 of 2)

1

2

3.

With the door slightly angled away from the accessory so that it will not interfere with other accessory covers, lift the door up and off of the bottom hinge to remove it. Figure 1-707 Remove the front door (2 of 2)

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Finishing accessories 479

Inner upper cover assembly TIP: If the cover needs to be moved out of the way to gain access to assemblies immediately behind the cover, use the following procedure. If the cover needs to be removed to service other assemblies on the accessory, go to Inner upper cover assembly (remove) on page 481. 1.

Open the front door.

2.

Remove four screws. Figure 1-708 Move the inner upper cover out of the way (1 of 2)

3.

Rotate the cover towards the front door to move it out of the way. CAUTION: To prevent damage to the cover, make sure that it does not bind on the upper front door hinge when you move it out of the way. Figure 1-709 Move the inner upper cover out of the way (2 of 2)

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Inner upper cover assembly (remove) Before proceeding, remove the following assemblies: ●

Front door. See Front door on page 479.

Remove the inner upper cover assembly The figures in this section show the stepped covers removed. You do not need to remove the stepped covers to remove the inner upper cover assembly. 1.

Remove four screws. Figure 1-710 Remove the inner upper cover assembly (1 of 2)

2.

Remove the cover. Figure 1-711 Remove the inner upper cover assembly (2 of 2)

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Clutch assembly (front side) Before proceeding, do the following: ●

Move the inner upper cover assembly. See Inner upper cover assembly on page 480.

Remove the clutch assembly (front side) 1.

Disconnect one connector (callout 1), and then release the wire harness from three retainers (callout 2). Figure 1-712 Remove the clutch assembly (front side; 1 of 2)

1

2

2.

Remove one e-ring (callout 1), and then slide the clutch off of the shaft to remove it. Figure 1-713 Remove the clutch assembly (front side; 2 of 2)

1

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Sensor switch assembly Before proceeding, do the following: ●

Move the inner upper cover assembly. See Inner upper cover assembly on page 480.

Remove the sensor switch assembly WARNING! Make sure that the accessory interface cable is disconnected from the product. Line voltage exists at the switch when the accessory interface cable is connected to the product—even if the product is power is turned off. 1.

Disconnect one connector (callout 1), and then release the wire harnesses from three retainers (callout 2). Figure 1-714 Remove the sensor switch assembly (1 of 4)

2

1

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Finishing accessories 483

2.

Use a small flat-blade screwdriver to disconnect one connector (callout 1). Figure 1-715 Remove the sensor switch assembly (2 of 4)

1

3.

Remove one screw. Figure 1-716 Remove the sensor switch assembly (3 of 4)

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4.

Remove the assembly. Figure 1-717 Remove the sensor switch assembly (4 of 4)

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Finishing accessories 485

Inner lower cover assembly TIP: If the cover needs to be moved out of the way to gain access to assemblies immediately behind the cover, use the following procedure. If the cover needs to be removed to service other assemblies on the accessory, go to Inner lower cover assembly (remove) on page 488. 1.

Open the front door.

2.

Move the inner upper cover out of the way. See Inner upper cover assembly on page 480.

3.

Do one of the following: ●

Booklet maker (BM) and booklet maker with hole punch (BMHP): Remove four screws. Figure 1-718 Move the inner lower cover out of the way (1 of 4)

●

Stapler/stacker (SS) and stapler/stacker with hole punch (SSHP): Remove four screws. Figure 1-719 Move the inner lower cover out of the way (2 of 4)

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4.

Booklet maker (BM) and booklet maker with hole punch (BMHP) only: Remove one screw (callout 1), and then remove the green knob (callout 2). Figure 1-720 Move the inner lower cover out of the way (3 of 4)

1

2

5.

Slide the cover toward the front door so that it will not interfere with the inner upper cover, and then rotate the cover towards the front door to move it out of the way. CAUTION: To prevent damage to the cover, make sure that it does not bind on the upper front door hinge when you move it out of the way. Figure 1-721 Move the inner lower cover out of the way (4 of 4)

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Finishing accessories 487

Inner lower cover assembly (remove) Before proceeding, remove the following assemblies: ●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

Remove the inner lower cover assembly 1.

Booklet maker (BM) and booklet maker with hole punch (BMHP) only: Remove one screw (callout 1), and then remove the green knob (callout 2). Figure 1-722 Remove the inner lower cover assembly (1 of 4)

1

2

2.

Do one of the following: ●

Booklet maker (BM) and booklet maker with hole punch (BMHP): Remove four screws. Figure 1-723 Remove the inner lower cover assembly (2 of 4)

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●

Stapler/stacker (SS) and stapler/stacker with hole punch (SSHP): Remove four screws. Figure 1-724 Remove the inner lower cover assembly (2 of 4)

3.

Remove the cover. Figure 1-725 Remove the inner lower cover assembly (4 of 4)

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Front foot cover assembly NOTE: The cover shown in the following procedure is installed on a booklet maker with hole punch (BMHP) accessory, however the procedure is the same for all of the finishing accessories. Before proceeding, remove the following assemblies: ●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Inner lower cover assembly. See Inner lower cover assembly on page 486.

Remove the front foot cover assembly 1.

Remove two screws. Figure 1-726 Remove the front foot cover assembly (1 of 2)

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2.

Slightly slide the cover to the left to release it, and then remove the cover. Figure 1-727 Remove the front foot cover assembly (2 of 2)

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Finishing accessories 491

Bin cable guide cover 1.

Use the figure below to locate the bin cable guide cover. Figure 1-728 Remove the bin cable guide cover (1 of 6)

2.

If the upper or lower stack bin prevents access to this cover, do the following: TIP: Push up on the bin to move it toward the top of the accessory. To move the bin down, use the following procedure to release the clutch. a.

the bin.

b.

Release the bin clutch located on the underside of the bin, and then lower the bin to access the cover. TIP: Use a small flat-blade screwdriver to slide the raised portion of the clutch toward the spring to release the clutch and lower the bin.

Figure 1-729 Remove the bin cable guide cover (2 of 6)

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3.

Use your fingers to reach in behind the cover, and then rotate the end of the cover—near the stack bin cables—away from the accessory to release two tabs. Figure 1-730 Remove the bin cable guide cover (3 of 6)

4.

Slide the cover towards the stack bins to release it. Figure 1-731 Remove the bin cable guide cover (4 of 6)

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5.

Remove the cover. Figure 1-732 Remove the bin cable guide cover (5 of 6)

6.

After the cover is removed, take note of the location of the two latching tabs (callout 1) and the two positioning tabs (callout 2). When the bin cable guide cover is reinstalled, these tabs must be correctly positioned so that the cover is correctly installed and the bin cables will not bind on the cover when the bins move up and down. Figure 1-733 Remove the bin cable guide cover (6 of 6)

1

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Reinstall the bin cable guide cover If the cover is not correctly installed, the bin cable guide cover can bind on the cover, which causes the upper and lower stack bins to not function correctly. If the bins cannot function correctly, a 66.60.32 error message appears on the control- display. Make sure that the cover correctly fits flush against the rear cover when it is correctly installed—there should not be a gap between the bin cable guide cover and the rear cover. Figure 1-734 Bin cable guide cover correctly installed

Figure 1-735 Bin cable guide cover incorrectly installed

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Finishing accessories 495

Rear cover assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

Remove the rear cover assembly 1.

Remove five screws. Figure 1-736 Remove the rear cover assembly (1 of 4)

2.

Open the top door assembly, and then lift up on the rear cover to release two tabs. Figure 1-737 Remove the rear cover assembly (2 of 4)

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3.

As the cover is removed, you might need to reach behind the latch cover, and then release two locator pins on the back side of the cover. Figure 1-738 Remove the rear cover assembly (3 of 4)

4.

Remove the cover. NOTE: As the cover is removed, carefully feed the interface cable through the hole provided in the cover. Figure 1-739 Remove the rear cover assembly (4 of 4)

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Main controller PCA assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the main controller PCA assembly CAUTION: 1.

ESD sensitive assembly.

Disconnect 22 of the connectors, and then release the wire harnesses from the guides. TIP: Releasing the wire harnesses from the guides first will make it easier to disconnect some of the connectors on the PCA. NOTE:

The following connectors are not used on the PCA:

●

Booklet maker: J25, J27, J28, and J32

●

Booklet maker with hole punch: J21, J25, J27, and J28

●

Stapler/stacker with hole punch: J12, J15, J25, J27, J28, and J30

●

Stapler/stacker: J9, J16, and J32

Figure 1-740 Remove the main controller PCA assembly (1 of 6)

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2.

Remove two screws (callout 1) to release two ground wires, and then release the wire harnesses from four retainers (callout 2). Figure 1-741 Remove the main controller PCA assembly (2 of 6)

1

2

3.

Release the wire harnesses from one retainer at the top of the sheet-metal PCA mounting bracket. Figure 1-742 Remove the main controller PCA assembly (3 of 6)

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Finishing accessories 499

4.

Remove four screws. Figure 1-743 Remove the main controller PCA assembly (4 of 6)

5.

Lift up on the main controller PCA assembly to release it, and then remove the assembly. Figure 1-744 Remove the main controller PCA assembly (5 of 6)

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6.

Optional step: Remove four screws, and then separate the main controller PCA from the sheetmetal mounting bracket. Figure 1-745 Remove the main controller PCA assembly (6 of 6)

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Finishing accessories 501

Install a replacement main controller PCA assembly The main controller PCA assembly includes a removable memory device that contains important calibration information for the accessory. Carefully remove this device—place a small flat blade screwdriver between the memory device and the socket, and then gently pry the device out of the socket—and then install it on the replacement PCA to retain the calibration information. CAUTION: When you install the memory device, the notch on the device and the notch on the socket must be aligned. If the memory device is not correctly installed, the device polarity will be reversed, which will damage the memory device. Figure 1-746 Install a replacement main controller PCA assembly

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Adjustments These adjustments are for the primary stapler unit for both the stapler stacker and booklet maker accessories. Test the finishing accessory functions after replacing the main controller PCA. If needed, use these procedures to make performance adjustments. Access the main controller switches ●

SW1, SW2, and SW3 (callout 1)

●

DIPSW4 (callout 2)

NOTE: DIPSW4 has eight electronic switches that can be configured in the ON or OFF position. The controller PCA is marked ON and OFF to show the current switch position. Figure 1-747 Main controller PCA switches

1

2

Access the saddle controller switches (BM only) ●

SW1 (callout 1)

●

DIPSW (callout 2)

NOTE: DIPSW has eight electronic switches that can be configure in the ON or OFF position. The controller PCA is marked ON and OFF to show the current switch position.

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Finishing accessories 503

Figure 1-748 Booklet maker controller PCA switches

1

2

Adjust the alignment position Perform this adjustment if the alignment position must be changed. 1.

Turn the product power off, and then disconnect the interface cable from the product.

2.

Access the main controller PCA, and then set DIPSW4 to one of the following: Figure 1-749 DIPSW4 alignment settings ON

ON

1 2 3 4 5 6 7 8 A4 paper

1 2 3 4 5 6 7 8 LTR paper

3.

Connect the interface cable to the product, and then turn the product power on.

4.

Press SW3 on the main controller PCA. When SW3 is pressed, the swing guide opens and the alignment plate moves to the prescribed position.

5.

Place ten sheets of A4 or LTR paper between the alignment plates and align them squarely against the stopper. NOTE: The object of this calibration is to adjust the plates so that they lightly and evenly touch the sides of the stacked paper.

6.

Press SW1 or SW2 on the main controller PCA and adjust the alignment plate against the paper. The adjustment range is -/+ 4.2 mm (0.165 in). ●

Pressing SW1 moves the alignment plate 0.42 mm (0.016 in) forward

●

Pressing SW2 moves the alignment plate 0.42 mm (0.016 in) backward

7.

When the adjustment is complete, remove the paper, and then press SW3 once to write the adjustment values to the memory device on the PCA.

8.

Return all of the switches on DIPSW4 to the OFF position.

9.

Turn the product power off, and then install the covers.

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Adjust the staple position Adjust the stapler position if the staple position must be changed. This adjustment sets the front and rear stitches with A4/A4R when the paper used for adjustment is AB type and with LTR/LTRR when the paper is INCH type. 1.

Turn the product power off, and then disconnect the interface cable from the product.

2.

Access the main controller PCA, and then set DIPSW4 according to paper/stitch position used for adjustment: Figure 1-750 DIPSW4 staple position settings ON

ON

1 2 3 4 5 6 7 8 A4/front stitch

1 2 3 4 5 6 7 8 A4/rear stitch ON

ON

1 2 3 4 5 6 7 8 A4R/front stitch

1 2 3 4 5 6 7 8 A4R/rear stitch ON

ON

1 2 3 4 5 6 7 8 LTR/front stitch

1 2 3 4 5 6 7 8 LTR/rear stitch ON

ON

1 2 3 4 5 6 7 8 LTRR/front stitch

1 2 3 4 5 6 7 8 LTRR/rear stitch

3.

Connect the interface cable to the product, and then turn the product power on.

4.

Press SW3 on the main controller PCA. When SW3 is pressed, the swing guide opens and the alignment plate moves to the prescribed position.

5.

Place two sheets paper between the alignment plates and align them squarely against the stopper, and then push the rear edge of the paper against the rear alignment plate. If the gap between the front alignment plate and front edge of the paper is 1 mm (0.039 in) or greater, adjust the plate alignment before continuing. See Adjust the alignment position on page 504.

6.

Press SW3 on the main controller PCA once to staple the paper. Remove the stapled paper and the staple position.

7.

Press SW3 on the main controller PCA once.

8.

If the staple position is correct, insert a sheet of paper between the aligning plates and align it against the stopper, push the far end edge of the paper to the rear aligning plate, press SW3 once (stapling action/store adjustment value), and then proceed to step 10.

9.

If the staple position is incorrect, press SW1 or SW2 on the main controller PCA to adjust the staple position. ●

Pressing SW1 moves the alignment plate 0.49 mm (0.019 in) forward

●

Pressing SW2 moves the alignment plate 0.49 mm (0.019 in) backward

10. Repeat step 4 and step 5 until the staple is in the correct position.

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11. Return all of the switches on DIPSW4 to the OFF position. 12. Turn the product power off, and then install the covers. Adjust the folding position to the stitch position (booklet maker only) Adjust the position of the booklet fold by changing the settings of bits six through eight of DIPSW on the booklet maker controller PCA to match the booklet stapling (stitching) position. If the booklet maker controller PCA has been replaced, be sure to set the new DIPSW so that the settings will be the same as those on the old DIPSW. Perform this adjustment if you must change the folding position. Set the DIPSW on the booklet maker controller PCA to match the stitching position (adjusting the distance over which the paper positioning plate is moved to the folding position from the stitching position). 1.

Turn the product power off, and then disconnect the interface cable from the product.

2.

Access the booklet maker controller PCA, and then set DIPSW. To establish a baseline for measurements, set bits 1 through 8 of DIPSW on the booklet maker controller PCA as follows: NOTE:

Do not change bit 5.

Figure 1-751 DIPSW folding position settings ON

1 2 3 4 5 6 7 8 Do not change bit 5.

3.

Do the following: ●

Open the front door and the paper-jam-access guide plate on the saddle guide assembly.

●

At the rear of the accessory, tape the actuator of the inlet-cover sensor (saddle guide assembly PI9) and inlet door switch (saddle guide assembly SW1) so that both sensor and switch remain activated. This simulates the saddle guide in the closed position throughout the adjustment procedure.

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4.

Using two sheets of A3 or 11 x 17 paper, mark the top of the paper as shown below. This is a reference mark to show a specific end of the paper. The mark just needs to be somewhere at one end of the paper as shown below. Figure 1-752 Mark the paper Mark

A3/11x17 paper

Insert direction

5.

Close the saddle guide assembly and the front door of the accessory. Reconnect the interface cable from the booklet maker to the product. Turn the product power on, and wait until the product is in a Ready state.

6.

Press SW1 on the booklet maker controller PCA to activate the feed motor (M1). You will need to press and hold down SW1 for three seconds or longer if 11 x 17 paper is used.

7.

Open the front door of the accessory, and then open saddle guide assembly (callout 1). Insert the two sheets of marked paper into the paper path (callout 2) leading to the folding unit and past the booklet stapler unit (callout 3). Push them in by hand until the front edge of the sheets push against the paper positioning plate. Figure 1-753 Folding position adjustment (1 of 3)

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Finishing accessories 507

8.

Opening the booklet jam access door. Figure 1-754 Folding position adjustment (2 of 3)

9.

that the paper is properly located against the paper positioning plate (callout 1). NOTE: It is important for the bottom of the sheets of paper to be squarely resting on the paper positioning plate for the adjustment to be accurate. Check that the paper is even along the four tabs on the plate. Figure 1-755 Folding position adjustment (3 of 3)

10. Close the saddle guide assembly. 11. Press SW1 on the booklet maker controller PCA. The saddle stitcher unit will "stitch" the sheets, and fold and deliver the stack automatically to the booklet output bin.

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12. Measure the distance (L) between the stitching position and the folding position. Then perform a positive-width adjustment or a negative-width adjustment to suit the relationship between the stitching position and the folding position. NOTE: If the L adjustment is significantly larger than what the adjustment allows, the most common cause is that the paper was not fully inserted and resting squarely on the paper position plate. ●

If the stitching position is above the folding position, perform a positive-width adjustment.

●

If the stitching position is below the folding position, perform a negative-width adjustment.

Figure 1-756 Positive and negative width adjustment Negative Width Adjustment

Mark

Folding position Stitching position

Unit: mm Example: If L is 1 mm, provide -1 mm.

Positive Width Adjustment

Mark

Stitching position Folding position

Unit: mm Example: If L is 0.5 mm, provide +0.5 mm.

13. Refer to the following tables, and then change the settings of bits 6 through 8 on DIPSW. Table 1-28 DIPSW settings DIPSW Bit settings

Setting 0.5 mm (0.019 in) units

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Bit 6

Bit 7

Bit 8

OFF

ON

ON

+3

OFF

ON

OFF

+2

OFF

OFF

ON

+1

OFF

OFF

OFF

0

ON

OFF

ON

-1

ON

ON

OFF

-2

ON

ON

ON

-3

ON

OFF

OFF

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Table 1-29 Do not change these DIPSW settings DIPSW Bit settings Bit 6

Bit 7

Bit 8

ON

OFF

OFF

14. When adjustment has been completed and the stitch staples are within the fold line, set DIPSW bits 1 to 4 (only) to OFF. 15. Remove the tape from the actuator arm of switch SW1 and PI9 on the rear frame of the accessory. Adjust the stitcher unit 1.

Open the front cover.

2.

Pull out the stitcher mount unit to the front. Pull the stitcher towards you and then pull up.

3.

Remove three screws (callout 1) and then remove the stitcher cover (callout 2). Figure 1-757 Adjust the stitcher (1 of 6)

1

2 4.

Remove the stitcher positioning tool (callout 1) from the back of the cover. Figure 1-758 Adjust the stitcher (2 of 6)

1

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5.

To adjust the front stitcher, remove the front guide plate (callout 1) and center guide plate (callout 2). To adjust the rear stitcher, remove the center guide plate (callout 2) and the rear guide plate (callout 3). TIP:

Remove one screw from each plate to remove the plates.

Figure 1-759 Adjust the stitcher (3 of 6)

3 6.

2

1

To adjust the front stitcher, loosen the two screws (callout 1) on the stitcher mount (callout 2). To adjust the rear stitcher, loosen the two screws (callout 3) on the stitcher mount. Figure 1-760 Adjust the stitcher (4 of 6)

3

1

2 7.

Insert the tool (callout 1) into the staple slot of the stitcher (callout 2). Figure 1-761 Adjust the stitcher (5 of 6)

1 2

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8.

Tilt the stitcher, and turn the stitcher gear (callout 1) to match the recess of the tool (callout 2) and the mount (callout 3) and then tighten the screws on the stitcher mount. Figure 1-762 Adjust the stitcher (6 of 6)

1 2

3

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Entrance upper guide assembly Before proceeding, remove the following assemblies: ●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Top door assembly. See Top door assembly on page 478.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

Remove the entrance upper guide assembly 1.

On the upper front chassis, remove one screw (callout 1) to release the ground wire (callout 2), and then release the wire harness from three retainers (callout 3). Figure 1-763 Remove the entrance upper guide assembly (1 of 3)

3

1 2

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Finishing accessories 513

2.

Disconnect one connector. Figure 1-764 Remove the entrance upper guide assembly (2 of 3)

3.

Do the following: a.

Remove one screw (callout 1), and then remove the door lock assembly (callout 2).

b.

Remove one screw (callout 3) to release the remove the ground wire (callout 4). TIP: Use a small Phillips-head screwdriver to remove this screw.

c.

Remove one screw (callout 5), and then remove the hinge pin (callout 6).

d.

Lift the assembly up (callout 7), and then slide it to the right (carefully remove the wire harness through the access hole in the chassis) to remove it (callout 8). NOTE: The figure below shows the entrance guide assembly in the BM accessory. The assembly in the SSHP accessory is considerably smaller (about one half the size shown), but the procedure is the same.

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Reinstallation tip Carefully guide the wire harness through the access hole in the chassis when you reinsert the entrance assembly. Figure 1-765 Remove the entrance upper guide assembly (3 of 3)

4

3

1

2

6 5

8 7

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Rear foot cover assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468. NOTE:

Only the rear latch lower cover needs to be removed.

●

Latch assembly assembly. See Latch assembly on page 470.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

For all models with a hole punch assembly installed: ◦

Punch lower front cover assembly. See Punch lower front cover assembly on page 684.

◦

Punch rear cover assembly. See Punch rear cover assembly on page 686.

Remove the rear foot cover assembly 1.

Remove one screw. Figure 1-766 Remove the rear foot cover assembly (1 of 2)

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2.

Slightly slide the cover to the right to release it, and then remove the cover. Figure 1-767 Remove the rear foot cover assembly (2 of 2)

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Stack wall upper assembly and upper wall guide assembly Before proceeding, remove the following assemblies: ●

Open/closed stepped cover. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover. See Upper stepped cover assembly on page 472.

●

Lower stepped cover. See Lower stepped cover assembly on page 474.

Remove the stack wall upper assembly and upper wall guide assembly 1.

If the upper stack bin is in the raised position do the following: a.

the bin.

b.

Release the bin clutch located on the underside of the bin, and then lower the bin to access the cover. TIP: Use a small flat-blade screwdriver to slide the raised portion of the clutch toward the spring to release the clutch and lower the bin.

c.

Lower the bin to access the stack wall upper cover.

Figure 1-768 Remove the stack wall upper assembly and upper wall guide assembly (1 of 5)

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2.

Remove four screws. Figure 1-769 Remove the stack wall upper assembly and upper wall guide assembly (2 of 5)

3.

Raise the upper wall guide, and then remove one screw. Figure 1-770 Remove the stack wall upper assembly and upper wall guide assembly (3 of 5)

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4.

Remove the cover. Figure 1-771 Remove the stack wall upper assembly and upper wall guide assembly (4 of 5)

5.

If necessary, separate the upper guide wall (callout 1) from the stack wall upper assembly (callout 2). Figure 1-772 Remove the stack wall upper assembly and upper wall guide assembly (5 of 5)

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Upper cross member assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Open/closed stepped cover. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover. See Upper stepped cover assembly on page 472.

●

Lower stepped cover. See Lower stepped cover assembly on page 474.

●

Top door assembly. See Top door assembly on page 478.

●

Front door. See Front door on page 479.

●

Inner upper cover. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover. See Rear cover assembly on page 496.

●

Stack wall upper cover. See Stack wall upper assembly and upper wall guide assembly on page 518.

Remove the upper cross member assembly 1.

At the top of the accessory, disconnect one connector (callout 1), and then release the wire harness from one retainer (callout 2). TIP: The connector is located near the two solenoids mounted at the middle of the cross member assembly. Figure 1-773 Remove the upper cross member assembly (1 of 13)

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Finishing accessories 521

2.

Release the wire harness from two retainers, and move it out of the way. Figure 1-774 Remove the upper cross member assembly (2 of 13)

3.

Remove one screw (callout 1), and then remove the sheet-metal bracket (callout 2). Figure 1-775 Remove the upper cross member assembly (3 of 13)

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4.

At the front of the accessory, disconnect four connectors (callout 1), and then remove the wire from the six wire retainers (callout 2). WARNING! Make sure that the accessory interface cable is disconnected from the product. Line voltage exists at the switch when the accessory interface cable is connected to the product —even if the product is power is turned off. TIP: Use a small flat-blade screwdriver to loosen, and then remove the large white-plastic connector on the front door detection switch. Figure 1-776 Remove the upper cross member assembly (4 of 13)

1

2

2

1 5.

1

2

Release two tabs (callout 1), and then remove two wire tie retainers. Figure 1-777 Remove the upper cross member assembly (5 of 13)

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6.

Remove one screw to release the ground wire. Figure 1-778 Remove the upper cross member assembly (6 of 13)

7.

Release two connectors (callout 1) and three inline connectors (callout 2). TIP: Use a small flat-blade screwdriver to loosen, and then remove the two large white-plastic connectors (callout 1). Figure 1-779 Remove the upper cross member assembly (7 of 13)

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8.

Release the wire harnesses from five retainers (callout 1) along the top of the assembly, and then release the wire harnesses from eleven retainers (callout 2) along the inside of the assembly. TIP:

Move the wire harnesses out of the way.

Figure 1-780 Remove the upper cross member assembly (8 of 13)

1

2 9.

Remove one screw (callout 1), and then remove the sheet-metal hinge bracket (callout 2). Figure 1-781 Remove the upper cross member assembly (9 of 13)

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10. Remove four screws. Figure 1-782 Remove the upper cross member assembly (10 of 13)

11. Remove one e-ring (callout 1), slide the gear shaft to the left (callout 2), remove one bushing (callout 3), and then move the gear shaft out of the way. CAUTION: Do not lose the bushing (callout 3). Figure 1-783 Remove the upper cross member assembly (11 of 13)

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2 3

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12. Carefully rotate the edge of the upper cross member assembly up (callout 1), the swing guide assembly (callout 2), and then separate the swing-pressure rack (callout 3) from the sheet-metal tab (callout 4). Figure 1-784 Remove the upper cross member assembly (12 of 13)

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13. Remove the assembly. CAUTION: The black plastic bracket (callout 1) along the front edge of the assembly and the spring (callout 2) underneath the assembly are not captive. Do not lose these parts when removing or handling the assembly.

1

2 Figure 1-785 Remove the upper cross member assembly (13 of 13)

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Reinstall the upper cross member assembly 1.

When the assembly is positioned in the accessory, make sure that the spring underneath the assembly is seated on the pedestal on the swing guide. Figure 1-786 Reinstall the upper cross member assembly (1 of 7)

2.

that the two pivot arms are positioned in front of the pins (callout 1), and that the locking bar is seated in the cradle (callout 2). Reinstallation tip If after the upper cross member assembly is removed and replaced the message 13.60.A1 Jam in Top Left Door appears on the control display (or in the event log) after the product power is turned on, the two pivot arms or the locking bar might not have been properly installed. Figure 1-787 Reinstall the upper cross member assembly (2 of 7)

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3.

Install the mounting screws to secure the assembly to the chassis. Recheck the spring underneath the assembly. that the spring is correctly positioned. Figure 1-788 Reinstall the upper cross member assembly (3 of 7)

4.

Recheck the locking bar underneath the assembly. that it is correctly positioned in the cradle. If it is not correctly positioned, slightly lift up the upper cross member assembly and reposition the locking bar in the cradle. TIP: If necessary, slightly loosen, but do not remove, the assembly mounting screws to allow the assembly to be lifted up. Make sure that you retighten the mounting screws. Figure 1-789 Reinstall the upper cross member assembly (4 of 7)

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5.

To reinstall the gear shaft right-side bushing, align the keyed portion of the bushing with the slot in the chassis mounting tab. Figure 1-790 Reinstall the upper cross member assembly (5 of 7)

6.

To reinstall the gear shaft left-side bushing, align the keyed portion of the bushing with the slot in the chassis (callout 1), and then install the e-ring (callout 2). Reinstallation tip If the e-ring slot on the gear shaft is not visible, make sure that the drive gear, clutch, and pin—on the drive gear side of the shaft—are correctly assembled. If necessary, see the following optional step to reassemble the gear-shaft-pin assembly. Figure 1-791 Reinstall the upper cross member assembly (6 of 7)

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7.

Optional step: Make sure that the clutch is correctly position on the gear—two tabs on the clutch engage two slots on the gear face—and that the pin is positioned in the slot on the end of the shaft. Reinstall the gear shaft left-side bushing, and then install the e-ring (callout 2). See Figure 1-791 Reinstall the upper cross member assembly (6 of 7) on page 531. Figure 1-792 Reinstall the upper cross member assembly (7 of 7)

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Paper feed drive assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Main controller PCA assembly. See Main controller PCA assembly on page 498.

Remove the paper feed drive assembly 1.

Disconnect one connector (callout 1) and then release two retainers (callout 2). Figure 1-793 Remove the paper feed drive assembly (1 of 2)

2

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2.

Remove three screws (callout 1), and then remove the paper feed drive assembly (callout 2). NOTE: As you remove the assembly, slip the drive belt located behind the assembly off of the drive gear. Do not lose the belt. Figure 1-794 Remove the paper feed drive assembly (2 of 2)

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Pressure roller assembly Before proceeding, remove the following assemblies:

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Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Top cover assembly. See Top door assembly on page 478.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Main controller PCA assembly. See Main controller PCA assembly on page 498.

●

Stack wall upper cover assembly. See Stack wall upper assembly and upper wall guide assembly on page 518.

●

Upper cross member assembly. See Upper cross member assembly on page 521.

Finishing accessories 535

Remove the pressure roller assembly NOTE: Some of the figures in this procedure show white plastic drive gears. The gears in the accessory are black plastic. However, this removal procedure is correct for this accessory. 1.

Disconnect one connector (callout 1) and then release two retainers (callout 2). Figure 1-795 Remove the pressure roller assembly (1 of 8)

2

1 2.

Remove three screws (callout 1), and then remove the paper feed motor assembly (callout 2). NOTE: As you remove the assembly, slip the drive belt located behind the assembly off of the drive gear. Do not lose the belt. Make sure that you connect the belt to the gear when the paper feed motor assembly is reinstalled. Figure 1-796 Remove the pressure roller assembly (2 of 8)

1

2

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3.

Rotate the outer gear until the square box on the face of the gear is facing down. This horizontally aligns the locking pin behind the gear, and lessens the possibility of the pin falling into the accessory when the gear is removed in the next step. NOTE:

The outer gear is shown removed in the figure below.

Figure 1-797 Remove the pressure roller assembly (3 of 8)

4.

Remove one e-ring (callout 1), one gear (callout 2), and one pin (callout 3) behind the gear. Reinstallation tip Use the horizontal pin alignment described above to reinstall the pin. Figure 1-798 Remove the pressure roller assembly (4 of 8)

1 2 3

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Finishing accessories 537

5.

Remove one e-ring (callout 1), one gear (callout 2), and one pin (callout 3) behind the gear. NOTE: Before proceeding, rotate the inner gear until the visible hole in the shaft (callout 4) is horizontal to prevent the locking pin behind the gear from falling out of the shaft. Reinstallation tip Use the horizontal pin alignment described above to reinstall the pin. Figure 1-799 Remove the pressure roller assembly (5 of 8)

1 2 3

4

6.

Remove the e-ring (callout 1) and then remove one bushing (callout 2). Figure 1-800 Remove the pressure roller assembly (6 of 8)

1 2

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7.

At the opposite side of the accessory, remove the e-ring (callout 1) and then remove one bushing (callout 2). Figure 1-801 Remove the pressure roller assembly (7 of 8)

1 2

8.

Grasp the plastic component (callout 1) in the middle of the assembly, lift it up to clear the metal bracket, and then slide the assembly to the rear to release the front of the shaft. Lift the pressure roller assembly out of the accessory to remove it. Reinstallation tip When the assembly is reinstalled, first position the rear of the shaft in the hole of the chassis. Figure 1-802 Remove the pressure roller assembly (8 of 8)

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Finishing accessories 539

Stack upper bin and lower bin assemblies Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Remove the following assemblies only if you need to remove the lower bin: ◦

Front door. See Front door on page 479.

◦

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Stack wall upper cover assembly. See Stack wall upper assembly and upper wall guide assembly on page 518.

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Remove stack upper bin and lower bin assemblies NOTE: The stack upper bin assembly and the stack lower bin assembly look identical, but are different. Do not reverse the locations of the bins when they are reinstalled. The upper bin assembly has two connectors and a ground wire at the end of the cable. The lower bin assembly has only one connector and a ground wire at the end of the cable. Also, the lower bin assembly has a coil around the end of the cable. 1.

Do the following: Stack upper bin assembly: Remove one screw (callout 1), and then remove the upper sheetmetal cable retainer (callout 2). Stack lower bin assembly: Remove one screw (callout 3), and then remove the lower sheetmetal cable retainer (callout 4). Figure 1-803 Remove the stack upper bin and lower bin assemblies (1 of 5)

1 2 3

4

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Finishing accessories 541

2.

Release the wire harnesses from two retainers, and then do the following: Stack upper bin assembly: Remove one ground screw (callout 1), and then disconnect two connectors (callout 2) on the controller PCA (J7 and J14). Stack lower bin assembly: Remove one ground screw (callout 3), and then disconnect one connector (callout 4) on the controller PCA (J8). Figure 1-804 Remove the stack upper bin and lower bin assemblies (2 of 5)

1 2 3 4

3.

Remove two screws (callout 1) and the sheet-metal stop brackets (callout 2). TIP:

The upper bin can be removed now.

Figure 1-805 Remove the stack upper bin and lower bin assemblies (3 of 5)

1

2

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4.

Lower bin assembly only: If you are removing the lower bin, remove one screw (callout 1), and then remove the sheet-metal stop bracket (callout 2). Figure 1-806 Remove the stack upper bin and lower bin assemblies (4 of 5)

1 2 5.

Carefully slide the bin up and off of the finishing accessory. Figure 1-807 Remove the stack upper bin and lower bin assemblies (5 of 5)

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Finishing accessories 543

Reinstall the stack upper bin and lower bin assemblies When the bins are reinstalled, use the following procedure to release the clutch and slide the bin down onto the accessory. CAUTION: If both of the bins are reinstalled, do not install the upper bin directly on top of the lower bin. Leave a vertical gap between the bins. If the bins are not separated, an error message will appear on the control- display, and the bins might be damaged when the product power is turned on. 1.

the bin.

2.

Release the bin clutch located on the underside of the bin, and then lower the bin to access the cover. TIP: Use a small flat-blade screwdriver to slide the raised portion of the clutch toward the spring to release the clutch and lower the bin. Figure 1-808 Reinstall the stack wall upper assembly and upper wall guide assembly (1 of 2)

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3.

The bins must be installed so that they are level from side to side so that they will not bind on the track. If after installing the bins they are not level from side to side, remove them, and then reinstall the bins. CAUTION: The bins might be damaged when they move up and down if they are not correctly installed. TIP:

Lower the installed bin down to the exit rollers to check for level installation.

Figure 1-809 Reinstall the stack wall upper assembly and upper wall guide assembly (2 of 2)

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Height wall assembly NOTE: This assembly is described in the parts chapter as the following: ●

Height wall lower assembly (stapler/stacker and stapler stacker with hole punch)

●

Height wall center assembly (booklet maker)

Before proceeding, remove the following assemblies: ●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Stack wall upper cover assembly. See Stack wall upper assembly and upper wall guide assembly on page 518.

●

Stack upper bin and lower bin assemblies. See Stack upper bin and lower bin assemblies on page 540.

Remove the height wall center assembly NOTE: The following figures show the height wall assembly on the stapler/stacker with hole punch finishing accessory. This removal procedure is the same for all of the finishing accessories. 1.

Remove ten screws. Figure 1-810 Remove the height wall assembly (1 of 2)

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2.

Remove the cover. Figure 1-811 Remove the height wall assembly (2 of 2)

Reinstall the height wall assembly Make sure that the black bracket is in the down position when the height wall assembly is reinstalled. If the bracket is in the up position when the assembly is reinstalled, the upper stack wall will not move up and down. Figure 1-812 Reinstall the height wall assembly

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Finishing accessories 547

Paper face sensor and flag assembly Before proceeding, remove the following assemblies: ●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Stack wall upper cover assembly. See Stack wall upper assembly and upper wall guide assembly on page 518.

●

Stack upper bin and lower bin assemblies. See Stack upper bin and lower bin assemblies on page 540.

●

Height wall assembly. See Height wall assembly on page 546.

Remove the paper face sensor and flag assembly 1.

From the output side of the accessory, note how the spring on the left end of the flag is installed. Figure 1-813 Remove the paper face sensor and flag assembly (1 of 9)

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2.

Disengage the bottom portion of the spring (callout 1) from the tab (callout 2) on the chassis. NOTE:

The figure below shows the spring disengaged.

Figure 1-814 Remove the paper face sensor and flag assembly (2 of 9)

1 2

3.

Carefully flex the middle of the flag shaft away from the accessory (callout 1), and then disengage the end of the shaft from the mounting hole in the chassis (callout 2). Figure 1-815 Remove the paper face sensor and flag assembly (3 of 9)

1

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Finishing accessories 549

4.

Remove the paper sensor flag. Figure 1-816 Remove the paper face sensor and flag assembly (4 of 9)

5.

Release one tab, and then release the wire tie retainer. Figure 1-817 Remove the paper face sensor and flag assembly (5 of 9)

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6.

Disconnect two connectors (callout 1), and then release the wire harnesses from five retainers (callout 2). Figure 1-818 Remove the paper face sensor and flag assembly (6 of 9)

2

1

7.

Remove two screws. Figure 1-819 Remove the paper face sensor and flag assembly (7 of 9)

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Finishing accessories 551

8.

At the rear of the accessory, remove one screw. Figure 1-820 Remove the paper face sensor and flag assembly (8 of 9)

9.

Remove the assembly. Figure 1-821 Remove the paper face sensor and flag assembly (9 of 9)

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Staple subassembly Before proceeding, do the following: ●

Move the inner upper cover assembly out of the way. See Inner upper cover assembly on page 480.

Remove the staple subassembly 1.

Remove one screw (callout 1), and then remove the protective cover (callout 2) Figure 1-822 Remove the staple subassembly (1 of 6)

1 2

2.

Disconnect two connectors (callout 1) on the PCA, and then disconnect one connector (callout 2) on the motor. Figure 1-823 Remove the staple subassembly (2 of 6)

1

2

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Finishing accessories 553

3.

Release one tab (callout 1), and then remove the sub staple PCA (callout 2). Figure 1-824 Remove the staple subassembly (3 of 6)

1

2

4.

Remove one screw. Figure 1-825 Remove the staple subassembly (4 of 6)

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5.

Slide the staple subassembly away from the staple subassembly motor to release the rear tabs of the assembly from the sheet-metal bracket. TIP: When you reinstall the staple subassembly, make sure that the rear tabs of the assembly engage the slots in the sheet-metal bracket. Figure 1-826 Remove the staple subassembly (5 of 6)

6.

Remove the staple subassembly. Figure 1-827 Remove the staple subassembly (6 of 6)

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Finishing accessories 555

Staple connecting cable assembly Before proceeding, remove the following assemblies: ●

Move the inner upper cover assembly out of the way. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Staple subassembly. See Staple subassembly on page 553.

Remove the staple connecting cable assembly 1.

Disconnect one connector. Figure 1-828 Remove the staple connecting cable assembly (1 of 2)

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2.

Release the cable from three retainers, and then remove the cable. Reinstallation tip When the cable is reinstalled, make sure that it is positioned correctly and will not be pulled tight at either end when the staple subassembly moves along the staple assembly. Align the black marks on the cable with the black marks on the chassis to place the cable in the correct position. Figure 1-829 Remove the staple connecting cable assembly (2 of 2)

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Finishing accessories 557

Staple assembly Before proceeding, remove the following assemblies: ●

Move the inner upper cover assembly out of the way. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Staple subassembly. See Staple subassembly on page 553.

Remove the staple assembly 1.

Remove two screws. NOTE:

These screws are located under the controller PCA at the rear side of the accessory.

Figure 1-830 Remove the staple assembly (1 of 7)

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2.

Carefully push the staple subassembly base into the accessory. Figure 1-831 Remove the staple assembly (2 of 7)

3.

Remove one screw (callout 1), and then remove the sheet-metal sensor cover (callout 2). Figure 1-832 Remove the staple assembly (3 of 7)

1

2

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Finishing accessories 559

4.

Release one sensor (callout 1), and then release one wire retainer (callout 2). To remove the sensor, use your finger to release the sensor tabs from the underside of the assembly. TIP: It is easier to release the entire retainer from the sheet-metal stapler assembly tray than to try to release the wire harness from the retainer. Figure 1-833 Remove the staple assembly (4 of 7)

2

1

5.

Carefully push the stapler assembly about one-half way into the accessory to release two tabs under the front edge of the assembly. Reinstallation tip Make sure that the two tabs are engaged in the slots in the chassis when the assembly is reinstalled. Figure 1-834 Remove the staple assembly (5 of 7)

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6.

Lift up the stapler assembly. Figure 1-835 Remove the staple assembly (6 of 7)

7.

Carefully slide the stapler assembly out of the accessory. TIP: You might have to move the staple assembly up and down, and rotate it right and left, as you slide it out of the accessory to completely remove it. Figure 1-836 Remove the staple assembly (7 of 7)

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Finishing accessories 561

Paper detect holder assembly Before proceeding, remove the following assemblies: ●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Stack wall upper cover. See Stack wall upper assembly and upper wall guide assembly on page 518.

●

Stack upper bin and lower bin assembly. See Stack upper bin and lower bin assemblies on page 540.

●

Height wall assembly. See Height wall assembly on page 546.

Remove the paper detect holder assembly To remove the paper detect assembly, start at one end, grip each snap fastener at the base, and gently pull them to remove one at a time. CAUTION: The assembly is very fragile. Grip the assembly by the snap fasteners (callout 1) and not by the arm. Figure 1-837 Remove the paper detect holder assembly

1

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Reinstall the paper detect holder assembly When reinstalling, the small tab (callout 1) on each snap fastener must be inserted into a hole (callout 2). The paper detect assembly (callout 3) will not work properly if the tabs are not installed correctly. Figure 1-838 Reinstall the paper detect holder assembly

2 1

3

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Finishing accessories 563

Operation tray assembly Before proceeding, remove the following assemblies: ●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Main controller PCA assembly. See Main controller PCA assembly on page 498.

●

Stack wall upper cover assembly. See Stack wall upper assembly and upper wall guide assembly on page 518.

●

Stack upper bin and lower bin assembly. See Stack upper bin and lower bin assemblies on page 540.

●

Height wall assembly. See Height wall assembly on page 546.

●

Paper detect holder assembly. See Paper detect holder assembly on page 562.

The following figure shows the operation tray assembly. Use this figure to identify the assembly in the accessory. Figure 1-839 Identify the operation tray assembly

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Remove the operation tray assembly NOTE: Some of the figures in this procedure show white plastic drive gears. The gears in the accessory are black plastic. However, this removal procedure is correct for this accessory. 1.

Remove one e-ring. Figure 1-840 Remove the operation tray assembly (1 of 11)

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Finishing accessories 565

2.

Carefully slide the gear and belt (callout 1) off of the shaft, and then remove the locking pin (callout 2). The locking pin behind the gear is not captive. Do not lose the pin when removing the gear and belt. TIP: Before removing the gear, rotate the gear until the lines on the gear face are vertical. This horizontally aligns the pin, and minimizes the possibility of it falling into the accessory when the gear is removed.

Figure 1-841 Remove the operation tray assembly (2 of 11)

1

2

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3.

Remove one e-ring. Figure 1-842 Remove the operation tray assembly (3 of 11)

4.

Remove one small-flat washer and one bearing. TIP:

It is easier to remove the washer and bearing by using a small flat-blade screwdriver.

Figure 1-843 Remove the operation tray assembly (4 of 11)

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Finishing accessories 567

5.

At the rear of the accessory, remove one e-ring (callout 1), and then slide the clutch (callout 2) off of the shaft to remove it. Figure 1-844 Remove the operation tray assembly (5 of 11)

1

2

6.

Slide the stack-delivery roller to the left (callout 1) to release the bearing (callout 2). CAUTION: Avoid touching the rollers on the assembly. Skin oils can cause paper handling problems. Figure 1-845 Remove the operation tray assembly (6 of 11)

1 2

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7.

Carefully slide the bearing down the slot in the chassis. Figure 1-846 Remove the operation tray assembly (7 of 11)

8.

Remove the stack-delivery roller. Figure 1-847 Remove the operation tray assembly (8 of 11)

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Finishing accessories 569

9.

Disconnect one connector (callout 1), and then release the wire harness from the guide (callout 2). Figure 1-848 Remove the operation tray assembly (9 of 11)

2

1

10. Remove two screws. Figure 1-849 Remove the operation tray assembly (10 of 11)

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11. Raise the swing guide assembly, and then remove the operation tray assembly. Figure 1-850 Remove the operation tray assembly (11 of 11)

Reinstall the operation tray assembly 1.

Before installing the operation tray assembly, make sure that the staple assembly is out of the way. Figure 1-851 Reinstall the operation tray assembly (1 of 5)

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Finishing accessories 571

2.

On the assembly, slide the joggers to the inside position. Figure 1-852 Reinstall the operation tray assembly (2 of 5)

3.

When the assembly is installed, do not damage the mylar sheets inside the accessory. Locate the plastic pin on the back side of the gear. Install the gear with this pin facing the chassis. Then rotate the shaft so the hole is horizontal. Insert the metal locking pin, and then place the belt on the gear and slide the gear on the shaft so that it aligns with the locking pin in the slots on the gear. Figure 1-853 Reinstall the operation tray assembly (3 of 5)

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4.

Before installing the drive gear, make sure that it will be positioned on the shaft with the whiteplastic pin on the back of the gear facing the chassis. Figure 1-854 Reinstall the operation tray assembly (4 of 5)

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Finishing accessories 573

5.

Rotate the shaft so that the locking pin hole is horizontal, install the locking pin (callout 1), place the belt on the gear, and then slide the gear onto the shaft (callout 2). TIP: Rotate the gear until the lines on the gear face are vertical so that the slot on the back side of the gear for the locking pin is horizontally aligned. When the gear is correctly installed on the shaft, the shaft should rotate when the gear is rotated —the gear should not freely rotate on the shaft.

Figure 1-855 Reinstall the operation tray assembly (5 of 5)

1

2

574 Chapter 1 Removal and replacement

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Swing guide assembly Before proceeding, remove the following assemblies: ●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Top door assembly. See Top door assembly on page 478.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Main controller PCA assembly. See Main controller PCA assembly on page 498.

●

Stack wall upper cover assembly. See Stack wall upper assembly and upper wall guide assembly on page 518.

●

Stack upper bin and lower bin assembly. See Stack upper bin and lower bin assemblies on page 540.

●

Height wall assembly. See Height wall assembly on page 546.

●

Paper detect holder assembly. See Paper detect holder assembly on page 562.

●

Operation tray assembly. See Operation tray assembly on page 564.

The following figure shows the swing guide assembly. Use this figure to identify the assembly in the accessory. Figure 1-856 Identify the operation tray assembly

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Finishing accessories 575

Remove the swing guide assembly 1.

Look inside the accessory where the operation tray assembly was removed. Locate and remove one e-ring. NOTE:

This e-ring is located on the inside rear wall of the chassis.

Figure 1-857 Remove the swing guide assembly (1 of 12)

2.

Slide the white-plastic bushing out of the holder. Figure 1-858 Remove the swing guide assembly (2 of 12)

576 Chapter 1 Removal and replacement

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3.

Release one belt (callout 1), and then move it out of the way. Figure 1-859 Remove the swing guide assembly (3 of 12)

1

4.

Remove one belt (callout 1). Figure 1-860 Remove the swing guide assembly (4 of 12)

1

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Finishing accessories 577

5.

Look inside the accessory where the operation tray assembly was removed. Locate and remove one e-ring. Slide the bushing out of the holder. NOTE:

This e-ring and bushing are located on the inside front wall of the chassis.

Figure 1-861 Remove the swing guide assembly (5 of 12)

6.

At the top of the accessory, disconnect one connector (callout 1), and then release the wire harness from one retainer (callout 2). TIP: Follow the wire harness to the swing guide assembly, and release two more retainers (not shown) on the front and bottom of the cross member assembly. Figure 1-862 Remove the swing guide assembly (6 of 12)

2

578 Chapter 1 Removal and replacement

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7.

At the rear of the accessory, remove one retainer pin (callout 1), and then slide the clutch (callout 2) and gear (callout 3) off the shaft to remove them. Figure 1-863 Remove the swing guide assembly (7 of 12)

2

3

1

8.

At the output side of the accessory, remove one e-ring (callout 1), slide the gear shaft to the left (callout 2), and then remove one bushing (callout 3). CAUTION: Do not lose the bushing (callout 3). Figure 1-864 Remove the swing guide assembly (8 of 12)

1 2

3

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Finishing accessories 579

9.

Remove the gear-shaft assembly. Figure 1-865 Remove the swing guide assembly (9 of 12)

10. At the top of the accessory, loosen, but do not remove, four screws on the upper cross member assembly. Figure 1-866 Remove the swing guide assembly (10 of 12)

580 Chapter 1 Removal and replacement

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11. Carefully lift up on the edge of the upper cross member assembly (callout 1), and then separate the black-plastic gear rack (callout 2) from the sheet-metal tab (callout 3). Figure 1-867 Remove the swing guide assembly (11 of 12)

2 1

3

12. Carefully remove the swing guide assembly. Figure 1-868 Remove the swing guide assembly (12 of 12)

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Finishing accessories 581

Reinstall the swing guide assembly 1.

After the swing guide is reinstalled, that the two pivot arms on the upper cross member are positioned in front of the pins (callout 1), and that the locking bar is seated in the cradle (callout 2). NOTE:

Do not forget to retighten the four upper cross member mounting screws.

Reinstallation tip If the swing guide assembly is removed and replaced and the message 13.60.A1 Jam in Top Left Door appears on the control display (or in the event log) after the product power is turned on, the two pivot arms or the locking bar might not have been properly installed. Figure 1-869 Reinstall the swing guide assembly (1 of 7)

2

1

2.

that the spring underneath the upper cross member assembly is correctly positioned. Figure 1-870 Reinstall the swing guide assembly (2 of 7)

582 Chapter 1 Removal and replacement

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3.

To reinstall the gear shaft right-side bushing, align the keyed portion of the bushing with the slot in the chassis mounting tab. Figure 1-871 Reinstall the swing guide assembly (3 of 7)

4.

To reinstall the gear shaft left-side bushing, align the keyed portion of the bushing with the slot in the chassis (callout 1), and then install the e-ring (callout 2). Figure 1-872 Reinstall the swing guide assembly (4 of 7)

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Finishing accessories 583

5.

Make sure that the clutch is correctly position on the gear—two tabs on the clutch engage two slots on the gear face—and that the pin is positioned in the slot on the end of the shaft. Figure 1-873 Reinstall the swing guide assembly (5 of 7)

6.

Recheck the locking bar underneath the upper cross member assembly. that it is correctly positioned in the cradle. If it is not correctly positioned, slightly lift up the upper cross member assembly and reposition the locking bar in the cradle. TIP: If necessary, slightly loosen, but do not remove, the assembly mounting screws to allow the assembly to be lifted up. Make sure that you retighten the mounting screws. Figure 1-874 Reinstall the swing guide assembly (6 of 7)

584 Chapter 1 Removal and replacement

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7.

Make sure that the drive belts are correctly installed. Figure 1-875 Reinstall the swing guide assembly (7 of 7)

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Finishing accessories 585

Return roller assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Top door assembly. See Top door assembly on page 478.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Main controller PCA assembly. See Main controller PCA assembly on page 498.

●

Stack wall upper cover assembly. See Stack wall upper assembly and upper wall guide assembly on page 518.

●

Stack upper bin and lower bin assembly. See Stack upper bin and lower bin assemblies on page 540.

●

Height wall assembly. See Height wall assembly on page 546.

●

Paper detect holder assembly. See Paper detect holder assembly on page 562.

●

Operation tray assembly. See Operation tray assembly on page 564.

●

Swing guide assembly. See Swing guide assembly on page 575.

586 Chapter 1 Removal and replacement

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Remove the return roller assembly 1.

Disconnect one connector (callout 1), release two wire retainers (callout 2), and then remove two screws (callout 3). TIP: To make removing the return roller assembly easier, push the stapler assembly all the way inside the accessory. Figure 1-876 Remove the return roller assembly (1 of 2)

2 3

1

2.

Remove the return roller assembly from the front side of the chassis. NOTE: TIP:

When you remove the assembly, use both hands to the return roller.

Do not damage the mylar sheet during removal or replacement.

Figure 1-877 Remove the return roller assembly (2 of 2)

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Finishing accessories 587

Clutch assembly (rear side) Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the clutch assembly (rear side) 1.

Remove one screw (callout 1), and then remove the upper sheet-metal cable retainer (callout 2). Remove one screw (callout 3), and then remove the lower sheet-metal cable retainer (callout 4). Figure 1-878 Remove the clutch assembly (rear side; 1 of 6)

1 2 3

4

2.

Disconnect eight connectors (callout 1), and then release the four wire harnesses from the retainer and guide (callout 2). Figure 1-879 Remove the clutch assembly (rear side; 2 of 6)

2

1

588 Chapter 1 Removal and replacement

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3.

Disconnect two connectors (callout 1), and then release the two wire harnesses from the retainers (callout 2). Figure 1-880 Remove the clutch assembly (rear side; 3 of 6)

1

2

4.

Remove four screws (callout 1), release the wire harness from one retainer (callout 2), and then slightly lift up on the controller PCA sheet-metal bracket (callout 3) to release it. Figure 1-881 Remove the clutch assembly (rear side; 4 of 6)

3

1 2

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Finishing accessories 589

5.

Carefully rotate the top of the controller PCA away from the chassis and then move it out of the way. NOTE: If needed, release additional wire harnesses from retainers to make it easier to rotate the PCA out of the way. Figure 1-882 Remove the clutch assembly (rear side; 5 of 6)

6.

Remove one e-ring (callout 1), and then slide the clutch off the shaft to remove it. Figure 1-883 Remove the clutch assembly (rear side; 6 of 6)

1

590 Chapter 1 Removal and replacement

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Stack ejection motor assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the stack ejection motor assembly 1.

Remove one screw (callout 1), and then remove the upper sheet-metal cable retainer (callout 2). Remove one screw (callout 3), and then remove the lower sheet-metal cable retainer (callout 4). Figure 1-884 Remove the stack ejection motor assembly (1 of 7)

1 2 3

4

2.

Disconnect eight connectors (callout 1), and then release the four wire harnesses from the retainer and guide (callout 2). Figure 1-885 Remove the stack ejection motor assembly (2 of 7)

2

1

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Finishing accessories 591

3.

Disconnect two connectors (callout 1), and then release the two wire harnesses from the retainers (callout 2). Figure 1-886 Remove the stack ejection motor assembly (3 of 7)

1

2

4.

Remove four screws (callout 1), release the wire harness from one retainer (callout 2), and then slightly lift up on the controller PCA sheet-metal bracket (callout 3) to release it. Figure 1-887 Remove the stack ejection motor assembly (4 of 7)

3

1 2

592 Chapter 1 Removal and replacement

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5.

Carefully rotate the top of the controller PCA away from the chassis and move it out of the way. NOTE: If needed, release additional wire harnesses from retainers to make it easier to rotate the PCA out of the way. Figure 1-888 Remove the stack ejection motor assembly (5 of 7)

6.

Remove three screws. Figure 1-889 Remove the stack ejection motor assembly (6 of 7)

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Finishing accessories 593

7.

Remove the motor and drive belt. CAUTION: The drive belt behind the motor is not captive. Do not lose the belt when the motor is removed. Reinstallation tip If you are installing a replacement motor, remove the wire harness (callout 1) and drive belt (callout 2) from the discarded motor, and then install them on the replacement motor. Figure 1-890 Remove the stack ejection motor assembly (7 of 7)

2

1

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Press motor assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the press motor assembly 1.

Remove one screw (callout 1), and then remove the upper sheet-metal cable retainer (callout 2). Remove one screw (callout 3), and then remove the lower sheet-metal cable retainer (callout 4). Figure 1-891 Remove the press motor assembly (1 of 7)

1 2 3

4

2.

Disconnect eight connectors (callout 1), and then release the four wire harnesses from the retainer and guide (callout 2). Figure 1-892 Remove the press motor assembly (2 of 7)

2

1

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Finishing accessories 595

3.

Disconnect two connectors (callout 1), and then release the two wire harnesses from the retainers (callout 2). Figure 1-893 Remove the press motor assembly (3 of 7)

1

2

4.

Remove four screws (callout 1), release the wire harness from one retainer (callout 2), and then slightly lift up on the controller assembly PCA sheet-metal bracket (callout 3) to release it. Figure 1-894 Remove the press motor assembly (4 of 7)

3

1 2

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5.

Carefully rotate the top of the controller PCA away from the chassis and move it out of the way. NOTE: If needed, release additional wire harnesses from retainers to make it easier to rotate the PCA out of the way. Figure 1-895 Remove the press motor assembly (5 of 7)

6.

the motor, and then remove three screws. Figure 1-896 Remove the press motor assembly (6 of 7)

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Finishing accessories 597

7.

Remove the motor. Reinstallation tip If you are installing a replacement motor, remove the wire harness (callout 1) from the discarded motor, and then install it on the replacement motor. Figure 1-897 Remove the press motor assembly (7 of 7)

1

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Common driver PCA assembly NOTE: Only the booklet maker and stapler stacker accessories have a common driver PCA. Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the common controller PCA assembly CAUTION:

ESD sensitive assembly.

NOTE: The following connectors are not used on the PCA: J804, and J805. 1.

Disconnect all of the connectors. Figure 1-898 Remove the common driver PCA assembly (1 of 2)

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Finishing accessories 599

2.

Remove one screw (callout 1), use a pair of needle-nose pliers to release two standoffs (callout 2), and then remove the PCA (callout 3). Figure 1-899 Remove the common driver PCA assembly (2 of 2)

3

2

1

600 Chapter 1 Removal and replacement

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Interface cable assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the interface cable assembly 1.

Disconnect two connectors on the main controller PCA (J11 and J29; callout 1), and then release the wire harness from the retainer (callout 2). Figure 1-900 Remove the interface cable assembly (1 of 3)

2

2.

1

Remove two screws. Figure 1-901 Remove the interface cable assembly (2 of 3)

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Finishing accessories 601

3.

Remove the assembly. Figure 1-902 Remove the interface cable assembly (3 of 3)

602 Chapter 1 Removal and replacement

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Paper assembly NOTE: This assembly is installed only on the stapler/stacker (SS) model. Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Latch assembly. See Latch assembly on page 470.

●

Front door. See Front door on page 479.

●

Inner upper cover. See Inner upper cover assembly on page 480.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

For all models with a hole punch assembly installed: ◦

Punch lower front cover assembly. See Punch lower front cover assembly on page 684.

◦

Punch rear cover assembly. See Punch rear cover assembly on page 686.

◦

Punch waste tray. See Punch waste tray on page 688.

◦

Punch inner cover assembly. See Punch inner cover assembly on page 689.

◦

Punch upper cover assembly. See Punch top cover on page 691.

◦

Punch hole assembly. See Punch hole assembly on page 694.

Remove the paper assembly 1.

Disconnect two in-line connectors (callout 1), and then release the wire harnesses from one retainer (callout 2). Figure 1-903 Remove the paper assembly (1 of 6)

2

1

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Finishing accessories 603

2.

Disconnect two connectors (callout 1), and then release the wire harnesses from one retainer (callout 2). Figure 1-904 Remove the paper assembly (2 of 6)

1

2

3.

Remove two screws. Figure 1-905 Remove the paper assembly (3 of 6)

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4.

Remove two screws. Figure 1-906 Remove the paper assembly (4 of 6)

5.

Remove two screws. TIP:

These screws are located under the assembly, near the saddle guide assembly.

Figure 1-907 Remove the paper assembly (5 of 6)

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Finishing accessories 605

6.

Lift the assembly up to release it (callout 1), and then remove the assembly (callout 2). Figure 1-908 Remove the paper assembly (6 of 6)

2

1

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Booklet maker accessory The assemblies described in this section are unique to the booklet-maker (BM) finishing accessory. For information about removing and replacing assemblies that are common to all of the finishing accessories, see Shared finishing accessory assemblies on page 464.

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Knob

●

Saddle output bin assembly

●

Right cover assembly (BM PCA)

●

Booklet maker controller PCA

●

Inner side plate assembly

●

Guide sensor assembly

●

Guide motor assembly

●

Saddle motor assembly (SS and BM)

●

Saddle feed motor assembly

●

Folding-motor mount assembly

●

Delivery switch mount assembly

●

Saddle stapler assembly

●

Lower left guide assembly

●

Saddle delivery inner cover, front assembly

●

Saddle delivery inner cover, rear assembly

●

Saddle guide assembly

●

Saddle feed assembly

●

Saddle assembly

●

Upper delivery guide assembly

●

Saddle paper delivery assembly

●

Saddle rear end sensor assembly

Finishing accessories 607

Knob Remove one screw (callout 1), and then remove the green knob (callout 2). Figure 1-909 Remove the knob

1

2

608 Chapter 1 Removal and replacement

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Saddle output bin assembly 1.

Carefully push in on the bin hinges to release the hinge pins, and then separate the bin from the finishing accessory. CAUTION: The saddle output bin is still connected to the finishing accessory by a wire harness. Do not attempt to completely remove the bin. TIP:

Use a small flat-blade screwdriver to push in on the bin hinges and release them.

Figure 1-910 Remove the saddle output bin assembly (1 of 2)

2.

Disconnect one in-line connector, and then remove the bin. Reinstallation tip Make sure that this connector is reconnected before you reinstall the assembly. Figure 1-911 Remove the saddle output bin assembly (2 of 2)

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Finishing accessories 609

Reinstall the saddle output bin The spring loaded arm above the saddle output bin assembly can be easily dislodged. Hold the arm out of the way when you position the assembly on the accessory. Make sure that the arm is intact when the assembly is installed. Figure 1-912 Reinstall the saddle output bin assembly

610 Chapter 1 Removal and replacement

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Right cover assembly (BM PCA) NOTE: For booklet maker (BM) models only. Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Latch assembly. See Latch assembly on page 470.

●

For all models with a hole punch assembly installed: ◦

Punch lower front cover assembly. See Punch lower front cover assembly on page 684.

◦

Punch rear cover assembly. See Punch rear cover assembly on page 686.

◦

Punch waste tray. See Punch waste tray on page 688.

◦

Punch inner cover assembly. See Punch inner cover assembly on page 689.

◦

Punch upper cover assembly. See Punch top cover on page 691.

◦

Punch hole assembly. See Punch hole assembly on page 694.

Remove the right cover assembly (BM PCA) 1.

Remove two screws. TIP: These screws fasten the rear sheet-metal bracket to the punch assembly. Use the hole provided in the chassis next to the punch controller PCA to gain access to these screws. Figure 1-913 Remove the right cover assembly (BM PCA; 1 of 7)

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Finishing accessories 611

2.

Slightly lift up on the punch hole assembly (callout 1), and then disengage the sheet-metal bracket (callout 2). NOTE: The punch hole assembly is still fastened to the accessory chassis, but you should be able to disengage the bracket. Figure 1-914 Remove the right cover assembly (BM PCA; 2 of 7)

2

1

3.

Remove two screws. Figure 1-915 Remove the right cover assembly (BM PCA; 3 of 7)

612 Chapter 1 Removal and replacement

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4.

Slightly lift up on the punch hole assembly (callout 1), and then disengage the sheet-metal bracket (callout 2). NOTE: The punch hole assembly is still fastened to the accessory chassis, but you should be able to disengage the bracket. Figure 1-916 Remove the right cover assembly (BM PCA; 4 of 7)

2 1

5.

Remove two screws (callout 1), and then remove the sheet-metal brackets (callout 2). Figure 1-917 Remove the right cover assembly (BM PCA; 5 of 7)

2

1

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Finishing accessories 613

6.

Remove seven screws. Figure 1-918 Remove the right cover assembly (BM PCA; 6 of 7)

7.

Remove the cover. Figure 1-919 Remove the right cover assembly (BM PCA; 7 of 7)

614 Chapter 1 Removal and replacement

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Booklet maker controller PCA Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Right cover assembly (BM PCA). See Right cover assembly (BM PCA) on page 611.

Remove the booklet maker controller PCA CAUTION:

ESD sensitive assembly.

Disconnect all of the connectors, remove four screws, and then remove the PCA. Figure 1-920 Remove the booklet maker controller PCA

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Finishing accessories 615

Inner side plate assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Right cover assembly (BM PCA). See Right cover assembly (BM PCA) on page 611.

●

Booklet maker controller PCA. See Booklet maker controller PCA on page 615.

Remove the inner side plate assembly 1.

Disconnect three connectors (callout 1), and then release the wire harnesses from two retainers (callout 2). Figure 1-921 Remove the inner side plate assembly (1 of 8)

2

1

616 Chapter 1 Removal and replacement

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2.

Remove two screws. Figure 1-922 Remove the inner side plate assembly (2 of 8)

3.

At the drive gear side of the accessory, remove two screws. TIP: Removing these screws loosens the tray under the assembly. When the tray is loose it can be slightly moved out of the way, which makes removing the inner side plate assembly easier. Figure 1-923 Remove the inner side plate assembly (3 of 8)

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Finishing accessories 617

4.

Disconnect one connector (callout 1), and move the wire harness out of the way. CAUTION: When you remove the assembly, do not allow the right end of the shaft on the assembly damage the sensor (callout 2). Reinstallation tip Make sure that you reconnect the sensor connector (callout 1) when the assembly is reinstalled. Figure 1-924 Remove the inner side plate assembly (4 of 8)

1

2

5.

Slide the left end of the assembly shaft forward in the mounting hole provided in the chassis. Figure 1-925 Remove the inner side plate assembly (5 of 8)

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6.

Slightly slide the assembly toward the left, and then rotate the right side of the shaft out of the hole in the chassis. Figure 1-926 Remove the inner side plate assembly (6 of 8)

7.

Continue to move the assembly toward the left until the right side of the shaft is past the chassis. CAUTION: Do not damage the sensor (callout 1) with the end of the shaft (callout 2) when the shaft is rotated out of the chassis. TIP: The assembly might feel stuck as you remove it. Continue to move the assembly left, and rotate the right end of the shaft out of the chassis. It might take some time to get the shaft out of the chassis. Figure 1-927 Remove the inner side plate assembly (7 of 8)

2

1

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Finishing accessories 619

8.

Carefully remove the assembly. Figure 1-928 Remove the inner side plate assembly (8 of 8)

Before reinstalling the inner side plate assembly To avoid damage to the assembly sensors, and to make reinstallation of the assembly easier, move the inner plate on the assembly to the middle of the inner plate assembly. After positioning the inner plate assembly, go to Reinstall the inner side plate assembly on page 621. Figure 1-929 Inner plate assembly in the up position

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Figure 1-930 Inner plate assembly in the middle position

Reinstall the inner side plate assembly 1.

Position the assembly in the chassis by aligning the sheet-metal fingers of the inner plate assembly (callout 1) with the slots (callout 2) in the saddle assembly. Figure 1-931 Reinstall the inner side plate assembly (1 of 3)

2

1

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Finishing accessories 621

2.

Slide the left end of the assembly shaft into the hole in the chassis. Figure 1-932 Reinstall the inner side plate assembly (2 of 3)

3.

Push down on the assembly (callout 1) while rotating (callout 2) the right end of the shaft into the chassis. CAUTION: Do not damage the sensor (callout 3) with the end of the shaft (callout 4) when the shaft is rotated into the chassis. TIP: The assembly might feel stuck as you install it. Continue to move the assembly left, and rotate the right end of the shaft into the chassis. It might take some time to get the shaft into the chassis. Figure 1-933 Reinstall the inner side plate assembly (3 of 3)

3 2

1

4

622 Chapter 1 Removal and replacement

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Guide sensor assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the guide sensor assembly NOTE: This assembly is the folding roller home position sensor. 1.

Disconnect one connector. Figure 1-934 Remove the guide sensor assembly (1 of 4)

2.

Release two tabs on the retainer, and the remove the retainer from the sheet-metal bracket. Figure 1-935 Remove the guide sensor assembly (2 of 4)

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Finishing accessories 623

3.

Remove one screw. Figure 1-936 Remove the guide sensor assembly (3 of 4)

4.

Remove the assembly. Figure 1-937 Remove the guide sensor assembly (4 of 4)

624 Chapter 1 Removal and replacement

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Guide motor assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the guide motor assembly 1.

Disconnect one connector (callout 1), and then release the wire harness from one retainer (callout 2). Figure 1-938 Remove the guide motor assembly (1 of 3)

1

2

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Finishing accessories 625

2.

Remove two screws. TIP: One screw is hidden behind the wire harnesses along the left side of the sheet-metal mounting bracket. Use a small flat-blade screwdriver to hold the wire harnesses out of the way to access this screw. Figure 1-939 Remove the guide motor assembly (2 of 3)

3.

Remove the assembly. Figure 1-940 Remove the guide motor assembly (3 of 3)

626 Chapter 1 Removal and replacement

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Saddle motor assembly (SS and BM) Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the saddle motor assembly (SS and BM) 1.

Disconnect one connector. Figure 1-941 Remove the saddle motor assembly (SS and BM; 1 of 3)

2.

Remove three screws. Figure 1-942 Remove the saddle motor assembly (SS and BM; 2 of 3)

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Finishing accessories 627

3.

Remove the motor. CAUTION: The drive belt behind the motor is not captive. Do not lose the belt when the motor is removed. Figure 1-943 Remove the saddle motor assembly (SS and BM; 3 of 3)

628 Chapter 1 Removal and replacement

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Saddle feed motor assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the saddle feed assembly 1.

Before beginning, note how the drive belt is routed over the gears and-tension arm. The belt will not be tensioned correctly if the belt is not routed properly when the assembly is reinstalled. Figure 1-944 Remove the saddle feed motor assembly (1 of 6)

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Finishing accessories 629

2.

Push down on the belt tension arm (callout 1), and then remove the timing belt from the motor drive gear. IMPORTANT: Note how the belt is routed over the gears and belt-tension arm before you disengage the belt. Figure 1-945 Remove the saddle feed motor assembly (2 of 6)

1

3.

Remove one plastic wire cable tie. CAUTION: Do not damage the wire harnesses when this cable tie is removed. Do not attempt to remove the connector at the motor end of the wire harness. This wire harness is soldered to the motor and cannot be removed. Figure 1-946 Remove the saddle feed motor assembly (3 of 6)

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4.

Disconnect one inline connector (callout 1), and then release the wire harness from one retainer (callout 2). Figure 1-947 Remove the saddle feed motor assembly (4 of 6)

1

2

5.

Remove two screws. Figure 1-948 Remove the saddle feed motor assembly (5 of 6)

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Finishing accessories 631

6.

Remove the assembly. Figure 1-949 Remove the saddle feed motor assembly (6 of 6)

632 Chapter 1 Removal and replacement

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Folding-motor mount assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Latch assembly. See Latch assembly on page 470.

●

Move the inner lower cover assembly out of the way. See Inner upper cover assembly on page 480.

●

Right cover assembly (BM PCA). See Right cover assembly (BM PCA) on page 611.

●

For all models with a hole punch assembly installed: ◦

Punch lower front cover assembly. See Punch lower front cover assembly on page 684.

◦

Punch rear cover assembly. See Punch rear cover assembly on page 686.

Remove the folding-motor mount assembly 1.

Disconnect one connector (callout 1), release two tabs on one retainer (callout 2), remove the retainer from the sheet-metal bracket, and then release the wire harness from one retainer (callout 3). Figure 1-950 Remove the folding-motor mount assembly (1 of 6)

2

3

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1

Finishing accessories 633

2.

Disconnect one connector (callout 1), release two tabs (one on each side; callout 2) of two retainers (callout 3), and then remove the retainers from the sheet-metal bracket. Figure 1-951 Remove the folding-motor mount assembly (2 of 6)

1

3

2

3.

Disconnect one inline connector (callout 1), and then release the wire harness from two retainers (callout 2). TIP: One of the retainers is on the back side of the sheet-metal bracket. Use a longbarrel flat-blade screwdriver to release a tab on the retainer to open it When the assembly is reinstalled, you might have to disconnect connectors on the controller PCA, or release wire harnesses from other retainers in order to gain enough slack in the wire harnesses to close the retainer latch. Figure 1-952 Remove the folding-motor mount assembly (3 of 6)

2

1

634 Chapter 1 Removal and replacement

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4.

Disconnect one inline connector (callout 1), and then release the wire harness from one retainer (callout 2). Figure 1-953 Remove the folding-motor mount assembly (4 of 6)

1

2

5.

Remove three screws. Figure 1-954 Remove the folding-motor mount assembly (5 of 6)

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Finishing accessories 635

6.

Remove the assembly. CAUTION: There are two keyed bushings on the gear shafts that fit into holes on the chassis (see Reinstall the folding-motor mount assembly on page 637). The bushings are not captive. Do not lose them when the assembly is removed. Figure 1-955 Remove the folding-motor mount assembly (6 of 6)

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Reinstall the folding-motor mount assembly Make sure that the two brass bushings (callout 1) are installed on the gear shafts, and that the keyed portion of the bushings are aligned with the associated large slots in the chassis mounting holes (callout 2). The sheet-metal mounting bracket must be tight up against the chassis before you install the mounting screws. Figure 1-956 Reinstall the folding-motor mount assembly

2

1

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Finishing accessories 637

Delivery switch mount assembly Before proceeding, do the following: ●

Move the inner upper cover assembly out of the way. See Inner upper cover assembly on page 480.

●

Move the inner lower cover assembly out of the way. See Inner lower cover assembly on page 486.

Remove the delivery switch mount assembly 1.

Open the lower booklet jam access door. Figure 1-957 Remove the delivery switch mount assembly (1 of 4)

638 Chapter 1 Removal and replacement

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2.

Release the wire harnesses from two retainers (callout 1), and then disconnect two inline connectors (callout 2). TIP: Releasing the wire harnesses from the retainers first makes it easier to disconnect the connectors. Figure 1-958 Remove the delivery switch mount assembly (2 of 4)

1

2

3.

Remove one screw. Figure 1-959 Remove the delivery switch mount assembly (4 of 4)

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Finishing accessories 639

4.

Remove the assembly. Figure 1-960 Remove the delivery switch mount assembly (4 of 4)

640 Chapter 1 Removal and replacement

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Saddle stapler assembly Before proceeding, do the following: ●

Move the inner upper cover assembly out of the way. See Inner upper cover assembly on page 480.

●

Move the inner lower cover assembly out of the way. See Inner lower cover assembly on page 486.

Remove the saddle stapler assembly 1.

Remove one e-ring. Figure 1-961 Remove the saddle stapler assembly (1 of 3)

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Finishing accessories 641

2.

Remove one shaft (callout 1), and then remove the white plastic wheel (callout 2). Reinstallation tip The wheel is asymmetric. The small diameter end of the wheel should face toward the saddle stapler assembly when it is reinstalled. Figure 1-962 Remove the saddle stapler assembly (2 of 3)

1

2

3.

Pull the assembly straight out of the saddle assembly to remove it. Reinstallation tip If you are installing a replacement assembly, remove the staple cartridges from the discarded saddle stapler assembly, and then install them in the replacement assembly. Figure 1-963 Remove the saddle stapler assembly (3 of 3)

642 Chapter 1 Removal and replacement

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Lower left guide assembly Before proceeding, remove the following assemblies: ●

Saddle output bin assembly. See Saddle output bin assembly on page 609.

Remove the lower left guide assembly 1.

Remove one screw. Figure 1-964 Remove the lower left guide assembly (1 of 3)

2.

Release two tabs, and then remove the cover. Figure 1-965 Remove the lower left guide assembly (2 of 3)

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Finishing accessories 643

3.

Remove the cover. Figure 1-966 Remove the lower left guide assembly (3 of 3)

644 Chapter 1 Removal and replacement

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Saddle delivery inner cover, front assembly Before proceeding, remove the following assemblies: ●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Inner lower cover assembly. See Inner lower cover assembly on page 486.

Remove the saddle delivery inner cover, front assembly 1.

Remove one screw. Figure 1-967 Remove the saddle delivery inner cover, front assembly (1 of 3)

2.

Slide the cover up to release two tabs. Figure 1-968 Remove the saddle delivery inner cover, front assembly (2 of 3)

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Finishing accessories 645

3.

Remove the cover. Figure 1-969 Remove the saddle delivery inner cover, front assembly (3 of 3)

646 Chapter 1 Removal and replacement

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Saddle delivery inner cover, rear assembly Before proceeding, remove the following assemblies: ●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

Remove the saddle delivery inner cover, rear assembly 1.

Remove one screw. Figure 1-970 Remove the saddle delivery inner cover, rear assembly (1 of 3)

2.

Slide the cover up to release two tabs. Figure 1-971 Remove the saddle delivery inner cover, rear assembly (2 of 3)

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Finishing accessories 647

3.

Remove the cover. Figure 1-972 Remove the saddle delivery inner cover, rear assembly (3 of 3)

648 Chapter 1 Removal and replacement

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Saddle guide assembly Before proceeding, remove the following assemblies:

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Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Latch assembly. See Latch assembly on page 470.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Inner lower cover assembly. See Inner lower cover assembly on page 486.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

For all models with a hole punch assembly installed: ◦

Punch waste tray. See Punch waste tray on page 688.

◦

Punch inner cover assembly. See Punch inner cover assembly on page 689.

◦

Punch upper cover assembly. See Punch top cover on page 691.

◦

Punch hole assembly. See Punch hole assembly on page 694.

●

Paper assembly. See Paper assembly on page 603.

●

Right cover assembly (BM PCA). See Right cover assembly (BM PCA) on page 611.

Finishing accessories 649

Remove the saddle guide assembly 1.

Remove one screw (callout 1), and then remove the sheet-metal bracket (callout 2). Figure 1-973 Remove the saddle guide assembly (1 of 5)

2

1 2.

Release the lever, and then open the saddle guide. Figure 1-974 Remove the saddle guide assembly (2 of 5)

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3.

Remove one screw (callout 1), and then remove the hinge pin retainer (callout 2). TIP: Slightly move the saddle guide assembly back and forth to make removing the hinge pin retainer easier. Figure 1-975 Remove the saddle guide assembly (3 of 5)

2

1 4.

Slightly rotate the left side of the assembly away from the saddle assembly (callout 1), and then slide it to the left (callout 2). NOTE:

There is a pin on the left side of the assembly that must clear the accessory chassis.

Figure 1-976 Remove the saddle guide assembly (4 of 5)

1

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Finishing accessories 651

5.

Remove the assembly. Figure 1-977 Remove the saddle guide assembly (5 of 5)

652 Chapter 1 Removal and replacement

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Reinstall the saddle guide assembly 1.

Slide the saddle stapler out of the accessory to avoid damage to the mylar strips on the saddle guide assembly when it is reinstalled. Figure 1-978 Reinstall the saddle guide assembly (1 of 4)

2.

When you reinstall the assembly, do not damage the mylar strips (callout 1) on the assembly. Figure 1-979 Reinstall the saddle guide assembly (2 of 4)

1

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Finishing accessories 653

3.

Make sure the shaft-end edge of the assembly, and the hinge-pin edge of the assembly, are behind the sheet-metal stoppers on the chassis. Figure 1-980 Reinstall the saddle guide assembly (3 of 4)

4.

Install the hinge pin retainer (callout 1), and then install one screw (callout 2) to secure the assembly. TIP: Slightly move the saddle guide assembly back and forth to make installing the hinge pin retainer easier. Figure 1-981 Reinstall the saddle guide assembly (4 of 4)

1

2

654 Chapter 1 Removal and replacement

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Saddle feed assembly Before proceeding, remove the following assemblies:

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Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Move the inner upper cover assembly out of the way. See Inner upper cover assembly on page 480.

●

Latch assembly. See Latch assembly on page 470.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

For all models with a hole punch assembly installed: ◦

Punch waste tray. See Punch waste tray on page 688.

◦

Punch inner cover assembly. See Punch inner cover assembly on page 689.

◦

Punch upper cover assembly. See Punch top cover on page 691.

◦

Punch hole assembly. See Punch hole assembly on page 694.

Finishing accessories 655

Remove the saddle feed assembly 1.

Open the top door and front door.

2.

Booklet maker only: Disconnect two connectors (callout 1), and then release the wire harness from one retainer (callout 2). Figure 1-982 Remove the saddle feed assembly (1 of 7)

1

2 3.

Booklet maker with hole punch only: Disconnect four connectors (callout 1), and then release the wire harness from three retainers (callout 2). Figure 1-983 Remove the saddle feed assembly (2 of 7)

1

2

656 Chapter 1 Removal and replacement

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4.

Disconnect two connectors (callout 1), and then release the wire harnesses from two retainers (callout 2). TIP: It is easier to disconnect the connectors if you first release the wire harnesses from the retainers. Figure 1-984 Remove the saddle feed assembly (3 of 7)

2

1 5.

Remove two screws. Figure 1-985 Remove the saddle feed assembly (4 of 7)

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Finishing accessories 657

6.

Below the saddle feed assembly near the left side of the saddle guide, remove two screws. Figure 1-986 Remove the saddle feed assembly (5 of 7)

7.

Remove two screws (callout 1), and then remove the sheet-metal bracket (callout 2). Figure 1-987 Remove the saddle feed assembly (6 of 7)

2

658 Chapter 1 Removal and replacement

1

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8.

Remove one screw (callout 1), grasp the top of the saddle feed assembly (callout 2), and then lift it up to remove it. Figure 1-988 Remove the saddle feed assembly (7 of 7)

1

2

Reinstall the saddle feed assembly Make sure that the bottom mounting tab on the saddle feed assembly is on the outside of the chassis —not on the inside—when it is installed. Figure 1-989 Reinstall the saddle feed assembly

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Finishing accessories 659

Saddle assembly NOTE: The saddle assembly is not an orderable service part. This removal procedure is for reference only. HP does not recommend removing the saddle assembly at this time. Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Latch assembly. See Latch assembly on page 470.

●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Inner lower cover assembly. See Inner lower cover assembly on page 486.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

For all models with a hole punch assembly installed: ◦

Punch lower front cover assembly. See Punch lower front cover assembly on page 684.

◦

Punch rear cover assembly. See Punch rear cover assembly on page 686.

◦

Punch waste tray. See Punch waste tray on page 688.

◦

Punch inner cover assembly. See Punch inner cover assembly on page 689.

◦

Punch upper cover assembly. See Punch top cover on page 691.

◦

Punch hole assembly. See Punch hole assembly on page 694.

●

Paper assembly. See Paper assembly on page 603.

●

Saddle output bin assembly. See Saddle output bin assembly on page 609.

●

Right cover assembly (BM PCA). See Right cover assembly (BM PCA) on page 611.

●

Saddle delivery inner cover, front assembly. See Saddle delivery inner cover, front assembly on page 645.

660 Chapter 1 Removal and replacement

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Remove the saddle assembly 1.

Release the wire harnesses from the two retainers. Figure 1-990 Remove the saddle assembly (1 of 13)

2.

Disconnect two in-line connectors (callout 1), and then release the wire harness from one retainer (callout 2). Figure 1-991 Remove the saddle assembly (2 of 13)

1

2

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Finishing accessories 661

3.

Disconnect one connector (callout 1) on the main controller PCA, and then release the wire harness from the guide (callout 2). Figure 1-992 Remove the saddle assembly (3 of 13)

1

2 4.

Release one tab (callout 1, one tab on each retainer) on two retainers to release them from the sheet-metal bracket. Figure 1-993 Remove the saddle assembly (4 of 13)

1

662 Chapter 1 Removal and replacement

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5.

Remove one spring on the jam access locking arm. Set the spring aside. CAUTION: The spring is not captive. Do not lose the spring when releasing it. Reinstallation tip Do not forget to reinstall this spring when the assembly is reinstalled, or a replacement assembly is installed. Figure 1-994 Remove the saddle assembly (5 of 13)

6.

Remove two screws. Figure 1-995 Remove the saddle assembly (6 of 13)

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Finishing accessories 663

7.

Remove one screw. Figure 1-996 Remove the saddle assembly (7 of 13)

8.

Remove the sheet-metal bracket. Figure 1-997 Remove the saddle assembly (8 of 13)

664 Chapter 1 Removal and replacement

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9.

Remove two screws. NOTE:

These two screws are located on the common controller PCA side of the accessory.

Figure 1-998 Remove the saddle assembly (9 of 13)

10. Open the jam access plate, and then remove two screws. Figure 1-999 Remove the saddle assembly (10 of 13)

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Finishing accessories 665

11. Remove one screw. NOTE:

This screw is located on the front side of the accessory.

Figure 1-1000 Remove the saddle assembly (11 of 13)

12. Slightly slide the saddle assembly away from the stack bin side of the accessory to release it. Figure 1-1001 Remove the saddle assembly (12 of 13)

666 Chapter 1 Removal and replacement

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13. Carefully rotate the top of the assembly away from the accessory (callout 1), and then lift the assembly up and out of the accessory (callout 2). CAUTION: The assembly is heavy. CAUTION: Do not grasp the assembly along the top edge (callout 3). Doing so can damage the mylar strip along the edge and cause paper jam problems when the assembly is reinstalled. Figure 1-1002 Remove the saddle assembly (13 of 13)

3 1

2

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Finishing accessories 667

Reinstall the saddle assembly Make sure that the two hooks on the bottom of the assembly (one shown) are correctly engaged with the chassis, and that the tabs on the rear saddle inner cover are in the slots in the chassis. IMPORTANT: Make sure that all of the assembly sheet-metal brackets that the accessory chassis are flush against the chassis to prevent paper jam problems after the assembly is reinstalled. Make sure that the drive belts are correctly installed and have not been dislodged when handling the assembly. Figure 1-1003 Reinstall the saddle assembly

668 Chapter 1 Removal and replacement

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Upper delivery guide assembly Before proceeding, remove the following assemblies: ●

Open/closed stepped cover assembly. See Open/closed stepped cover assembly on page 471.

●

Upper stepped cover assembly. See Upper stepped cover assembly on page 472.

●

Lower stepped cover assembly. See Lower stepped cover assembly on page 474.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Inner lower cover assembly. See Inner lower cover assembly on page 486.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

Stack wall upper cover assembly. See Stack wall upper assembly and upper wall guide assembly on page 518.

●

Stack upper bin and lower bin assemblies. See Stack upper bin and lower bin assemblies on page 540.

●

Height wall assembly. See Height wall assembly on page 546.

●

Saddle output bin assembly. See Saddle output bin assembly on page 609.

Remove the upper delivery guide assembly 1.

Open the upper delivery assembly door. Figure 1-1004 Remove the upper delivery guide assembly (1 of 3)

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Finishing accessories 669

2.

Remove four screws. NOTE: One screw is a ground wire connection. Make sure that you reconnect the ground wire when the assembly is reinstalled. Figure 1-1005 Remove the upper delivery guide assembly (2 of 3)

3.

Remove the assembly. Figure 1-1006 Remove the upper delivery guide assembly (3 of 3)

670 Chapter 1 Removal and replacement

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Saddle paper delivery assembly Before proceeding, remove the following assemblies: ●

Saddle output bin assembly. See Saddle output bin assembly on page 609.

Remove the saddle paper delivery assembly 1.

Disconnect one connector. Figure 1-1007 Remove the saddle paper delivery assembly (1 of 5)

2.

Open the upper delivery assembly door. Figure 1-1008 Remove the saddle paper delivery assembly (2 of 5)

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Finishing accessories 671

3.

At the bottom lower-right corner of the upper delivery assembly door, locate and then rotate the locking pin to the upright position. Figure 1-1009 Remove the saddle paper delivery assembly (3 of 5)

4.

Slide the locking pin to the left to remove it. Figure 1-1010 Remove the saddle paper delivery assembly (4 of 5)

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5.

Slightly rotate the right side of the assembly out and away from the accessory (callout 1), slide the to the right (callout 2) to release the left side hinge, and then remove the assembly. Figure 1-1011 Remove the saddle paper delivery assembly (5 of 5)

2

1

Reinstall the saddle paper delivery assembly When the assembly is reinstalled, make sure that the sheet-metal of the accessory chassis is positioned in the slot in the cover (callout 1), and that the locking pin is in the locked position—push the pin all of the way down until it snaps into the locked position (callout 2). Figure 1-1012 Reinstall the saddle paper delivery assembly

1

2

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Finishing accessories 673

Saddle rear end sensor assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Latch assembly. See Latch assembly on page 470.

●

Front door. See Front door on page 479.

●

Inner upper cover assembly. See Inner upper cover assembly on page 480.

●

Inner lower cover assembly. See Inner lower cover assembly on page 486.

●

Bin cable guide cover. See Bin cable guide cover on page 492.

●

Rear cover assembly. See Rear cover assembly on page 496.

●

For all models with a hole punch assembly installed: ◦

Punch lower front cover assembly. See Punch lower front cover assembly on page 684.

◦

Punch rear cover assembly. See Punch rear cover assembly on page 686.

◦

Punch waste tray. See Punch waste tray on page 688.

◦

Punch inner cover assembly. See Punch inner cover assembly on page 689.

◦

Punch upper cover assembly. See Punch top cover on page 691.

◦

Punch hole assembly. See Punch hole assembly on page 694.

●

Paper assembly. See Paper assembly on page 603.

●

Right cover assembly (BM PCA). See Right cover assembly (BM PCA) on page 611.

●

Saddle guide assembly. See Saddle guide assembly on page 649.

674 Chapter 1 Removal and replacement

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Remove the saddle rear end sensor assembly 1.

Remove one screw. Figure 1-1013 Remove the saddle rear end sensor assembly (1 of 10)

2.

Remove two screws (callout 1), and then move the sheet-metal plate (callout 2) out of the way. CAUTION: The sheet-metal plate (callout 2) is still attached to the accessory by a wire harness and two retainers. Do not attempt to completely remove the sheet-metal plate. Figure 1-1014 Remove the saddle rear end sensor assembly (2 of 10)

2

1

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Finishing accessories 675

3.

At the drive belt side of the accessory, remove one screw (callout 1), and then move the upperdeflector solenoid (callout 2) out of the way. CAUTION: The solenoid (callout 2) is still attached to the accessory by one wire harness. Do not attempt to completely remove the solenoid. NOTE:

The solenoid plunger (callout 3) slides out of the solenoid as it is removed.

Figure 1-1015 Remove the saddle rear end sensor assembly (3 of 10)

1

3 2

676 Chapter 1 Removal and replacement

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4.

Remove one spring (callout 1), release one tab (callout 2) on the white-plastic retainer, and then slide the retainer and upper-deflector solenoid plunger and retainer (callout 3) off of the deflector shaft. NOTE: clarity.

The figure below shows lower-deflector spring, retainer, and plunger assemblies for

Reinstallation tip When the solenoid is reinstalled, make sure that the plunger freely moves in and out of the base before you fasten the base to the chassis. Figure 1-1016 Remove the saddle rear end sensor assembly (4 of 10)

2

1 3

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Finishing accessories 677

5.

At the output side of the accessory, rotate the top of the upper-deflector down (callout 1), slide the deflector toward the right (callout 2), and then carefully rotate the left end of the deflector away from the chassis (callout 3). WARNING! The deflector shafts (at the left end and right end of the deflector) are fragile. Do not break either of the deflector shafts when removing the deflector. Figure 1-1017 Remove the saddle rear end sensor assembly (5 of 10)

1 3 2

6.

Slide the deflector to the left to remove it. Repeat the previous steps to remove the lower-deflector solenoid, spring, retainer, plunger, and lower-deflector assemblies. Reinstallation tip The upper- and lower-deflector shafts are not identical. Make sure that you install the correct deflector when they are reinstalled. See Reinstall the saddle rear end sensor on page 681. Figure 1-1018 Remove the saddle rear end sensor assembly (6 of 10)

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7.

Remove one screw. Figure 1-1019 Remove the saddle rear end sensor assembly (7 of 10)

8.

Lift up on the sensor assembly to release it from the saddle assembly chassis. CAUTION: The sensor assembly is till attached to the accessory by one wire harness. Do not attempt to completely remove the sensor assembly. Figure 1-1020 Remove the saddle rear end sensor assembly (8 of 10)

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Finishing accessories 679

9.

Turn the assembly over, and then disconnect one connector. Figure 1-1021 Remove the saddle rear end sensor assembly (9 of 10)

10. Remove the saddle rear end sensor assembly. Figure 1-1022 Remove the saddle rear end sensor assembly (10 of 10)

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Reinstall the saddle rear end sensor 1.

The upper-deflector (callout 1) and lower-deflector (callout 2) are not identical. Make sure that you install the correct deflector in the correct position when they are reinstalled. TIP: The lower-deflector (callout 2) can be identified by the small black-plastic tab (callout 3) near the right end of the shaft. Figure 1-1023 Reinstall the saddle rear end sensor assembly (1 of 2)

1

2

2.

3

When the lower-deflector is installed, the small black-plastic tab near the right end shaft must be positioned in the cutout portion of the chassis so that it will not bind when the deflector moves. Figure 1-1024 Reinstall the saddle rear end sensor assembly (2 of 2)

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Finishing accessories 681

Booklet maker and stapler/stacker with hole punch accessories The assemblies described in this section are unique to the stapler/stacker with hole punch (SSHP) or booklet maker with hole punch (BMHP) finishing accessories. For information about removing and replacing assemblies that are common to all of the finishing accessories, see Shared finishing accessory assemblies on page 464. ●

Remove the punch front cover

●

Punch lower front cover assembly

●

Punch rear cover assembly

●

Punch controller PCA assembly

●

Punch waste tray

●

Punch inner cover assembly

●

Punch top cover

●

Punch hole assembly

●

Replace the punch hole assembly or the punch controller PCA assembly

Remove the punch front cover 1.

Open the punch front cover, and then remove one screw. Figure 1-1025 Remove the punch front cover (1 of 2)

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2.

Release the hinge pin, and then remove the cover. Figure 1-1026 Remove the punch front cover (2 of 2)

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Finishing accessories 683

Punch lower front cover assembly Before proceeding, remove the following assemblies: ●

Latch lower cover assembly (front). See Latch lower covers (front and rear) on page 468.

Remove the punch lower front cover assembly 1.

Remove one screw (callout 1) on the right side of the cover (callout 2). Figure 1-1027 Remove the punch lower front cover assembly (1 of 3)

1 2

2.

Open the front door, and then release one tab (callout 1). Figure 1-1028 Remove the punch lower front cover assembly (2 of 3)

1

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3.

Slightly lift up on the cover to release it, and then remove the cover. Figure 1-1029 Remove the punch lower front cover assembly (3 of 3)

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Finishing accessories 685

Punch rear cover assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468. NOTE:

Only the lower latch cover rear needs to be removed.

Remove the punch rear cover assembly 1.

Remove one screw. Figure 1-1030 Remove the punch rear cover assembly (1 of 2)

2.

Slightly lift up on the cover to release it, and then remove the cover. Figure 1-1031 Remove the punch rear cover assembly (2 of 2)

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Punch controller PCA assembly Before proceeding, remove the following assemblies: ●

Punch rear cover assembly. See Punch rear cover assembly on page 686.

Remove the punch controller PCA assembly CAUTION:

ESD sensitive assembly.

Disconnect eight connectors, remove two screws (callout 1), release two standoffs (callout 2), and then remove the PCA. TIP: Releasing the wire harnesses from the retainers will make it easier to disconnect some of the connectors on the PCA. Figure 1-1032 Remove the punch controller PCA assembly

2

1 Reinstall the punch controller PCA assembly IMPORTANT: If you are installing a replacement punch hole assembly or punch controller PCA, you must set the punch hole assembly type and adjust sensor values on the punch controller PCA. See Replace the punch hole assembly or the punch controller PCA assembly on page 702.

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Finishing accessories 687

Punch waste tray Pull the punch waste tray straight out of the punch assembly to remove it. Figure 1-1033 Remove the punch waste tray

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Punch inner cover assembly Before proceeding, remove the following assemblies: ●

Latch lower cover assembly (front). See Latch lower covers (front and rear) on page 468.

●

Punch lower front cover assembly. See Punch lower front cover assembly on page 684.

●

Punch waste tray. See Punch waste tray on page 688.

Remove the punch inner cover assembly 1.

Raise the punch upper cover, and then open the front door. Figure 1-1034 Remove the punch inner cover assembly (1 of 4)

2.

Remove one screw. Figure 1-1035 Remove the punch inner cover assembly (2 of 4)

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Finishing accessories 689

3.

Close the punch door, and then remove two screws. Figure 1-1036 Remove the punch inner cover assembly (3 of 4)

4.

Remove the cover. Figure 1-1037 Remove the punch inner cover assembly (4 of 4)

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Punch top cover Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468. NOTE:

●

Only the lower latch cover rear needs to be removed.

Punch rear cover assembly. See Punch rear cover assembly on page 686.

Remove the punch top 1.

Remove one screw. Figure 1-1038 Remove the punch top cover (1 of 6)

2.

Open the punch door. Figure 1-1039 Remove the punch top cover (2 of 6)

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Finishing accessories 691

3.

Remove two screws. Reinstallation tip The mounting holes for these two screws are slotted. Use these screws to adjust the position of the cover when it is reinstalled if it strikes the punch assembly or does not align correctly with the accessory covers. Figure 1-1040 Remove the punch top cover (3 of 6)

4.

Slightly raise the front edge of the cover. Figure 1-1041 Remove the punch top cover (4 of 6)

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5.

Slide the cover towards the rear of the accessory to release it. Figure 1-1042 Remove the punch top cover (5 of 6)

6.

Remove the cover. Figure 1-1043 Remove the punch top cover (6 of 6)

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Finishing accessories 693

Punch hole assembly Before proceeding, remove the following assemblies: ●

Latch lower covers (front and rear). See Latch lower covers (front and rear) on page 468.

●

Latch assembly. See Latch assembly on page 470.

●

Punch lower front cover assembly. See Punch lower front cover assembly on page 684.

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Punch rear cover assembly. See Punch rear cover assembly on page 686.

●

Punch waste tray. See Punch waste tray on page 688.

●

Punch inner cover assembly. See Punch inner cover assembly on page 689.

●

Punch top cover. See Punch top cover on page 691.

Remove the punch hole assembly 1.

Disconnect three connectors (callout 1) on the controller PCA, and then release the wire harnesses from one retainer (callout 2). Figure 1-1044 Remove the punch hole assembly (1 of 8)

1 2

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2.

Remove two screws. TIP: These screws fasten the rear sheet-metal bracket to the punch assembly. Use the hole provided in the chassis next to the punch controller PCA to gain access to these screws. Figure 1-1045 Remove the punch hole assembly (2 of 8)

3.

Slightly lift up on the punch hole assembly (callout 1), and then disengage the sheet-metal bracket (callout 2). NOTE: The punch hole assembly is still fastened to the accessory chassis, but you should be able to disengage the bracket. Figure 1-1046 Remove the punch hole assembly (3 of 8)

2

1

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Finishing accessories 695

4.

Remove two screws. Figure 1-1047 Remove the punch hole assembly (4 of 8)

5.

Slightly lift up on the punch hole assembly (callout 1), and then disengage the sheet-metal bracket (callout 2). NOTE: The punch hole assembly is still fastened to the accessory chassis, but you should be able to disengage the bracket. Figure 1-1048 Remove the punch hole assembly (5 of 8)

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6.

Remove one screw. Figure 1-1049 Remove the punch hole assembly (6 of 8)

7.

Remove one screw. Figure 1-1050 Remove the punch hole assembly (7 of 8)

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Finishing accessories 697

8.

Lift the assembly up to release it, and then remove the assembly. Figure 1-1051 Remove the punch hole assembly (8 of 8)

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Reinstall the punch hole assembly IMPORTANT: If you are installing a replacement punch hole assembly or punch controller PCA, you must set the punch hole assembly type and adjust sensor values on the punch controller PCA. See Replace the punch hole assembly or the punch controller PCA assembly on page 702. Adjust the punch hole location Punch adjustment is required when the punch holes are misaligned. If necessary, use the procedure below to adjust the position of punched holes after reinstalling, or replacing, the punch hole assembly. Adjust the screw on the puncher assembly to correct the position of punch holes. NOTE: The rear side punch hole is in a fixed position. The adjustment is made by pivoting the middle and front side hole in relation to the fixed rear side hole until all of the holes are aligned. 1.

Identify in which direction the punched hole adjustment is required. The figure below shows the punched hole misaligned to the left. Figure 1-1052 Determine the punch hole skew

Rear side

Paper feed direction

Front side 2.

To adjust the skewed hole alignment, do the following. NOTE: This adjustment procedure only moves the front portion of the punch to move the front hole into alignment with the rear hole. a.

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Open the punch door and upper cover.

Finishing accessories 699

b.

Loosen the adjustment screw (callout 1), and then move the punch plate to the right or to the left as necessary to bring the front punched hole in alignment with the rear hole. Figure 1-1053 Adjust the punch hole location

1

c.

Tighten the adjustment screw. IMPORTANT: Fully tighten the adjustment screw after making each adjustment and before closing the upper cover to make sure that the punch position does not move.

d.

Close the punch door and upper cover.

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3.

Print five test pages and repeat the adjustment procedure above until all the holes are aligned on the page. The figure below shows a page with correctly aligned punch holes. NOTE: The 12 mm (.47 in) distance from the trailing edge of the paper is calculated in firmware and cannot be adjusted. Figure 1-1054 Correct punch hole alignment

Rear side

12 mm (+/- 1.5 mm) Paper feed direction

Front side 4.

After adjustment is completed, print 25 test pages and make sure that the punched hole alignment remains constant. NOTE: If some pages have skewed holes while others do not, the problem is a skew in the paper and not the punch.

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Finishing accessories 701

Replace the punch hole assembly or the punch controller PCA assembly The punch controller PCA assembly stores configuration information for the punch hole assembly. Every time the punch hole assembly or the punch controller PCA assembly is replaced, the following procedures must be performed to set the punch hole assembly type as well as adjust sensors in the assembly. Set the punch hole assembly type Two types of punch hole assemblies are available: the 2/3 punch hole assembly (part number A2W94-67901), or the 2/4 punch hole assembly (part number CZ999-67902). Refer to the part number on the replacement part to determine the type of assembly you are installing. Follow these steps to set the punch hole assembly type. 1.

Turn the product power off.

2.

Locate the switches and LEDs on the punch controller PCA. ●

SW601 (callout 1) NOTE: SW601 has four electronic switches that can be configure in the ON or OFF position. The punch controller PCA is marked ON and OFF to show the current switch position.

●

LED602 (callout 2)

●

LED601 (callout 3)

●

SW602 (callout 4)

●

SW603 (callout 5)

Figure 1-1055 Set the punch hole assembly type

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4 5

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3.

Set SW601 to the following: Figure 1-1056 SW601 punch hole assembly type settings

ON 1 2 3 4 4.

Turn the product power on.

5.

Press SW602 and observe the blinking pattern of LED601 and LED602. The table below explains the different blinking patterns. Table 1-30 LED601 and LED602 blinking patterns LED601

LED602

LED blinking pattern explanation

Blinking one time

Not applicable

Blinking two times

2/3 punch hole assembly selected

Blinking three times

2/4 punch hole assembly selected

Blinking alternately

Waiting for type setting completion

Not lit

Blinking steadily

Type setting completed

6.

Continue pressing SW602 until the blinking pattern matches the type of punch hole assembly you are installing. For example, if you are installing a 2/4 punch hole assembly (part number CZ999-67902), press SW602 until both LED601 and LED602 blink three times.

7.

Once the LEDs are blinking in the correct pattern, press SW603 to store the punch hole assembly type value in memory.

8.

Wait until LED601 is not lit and LED602 is blinking steadily to indicate the type setting is complete.

9.

Press either SW602 or SW603.

10. Wait until only LED602 is blinking. 11. Turn the product power off. 12. Return all of the switches on SW601 to the OFF position. Figure 1-1057 SW601 sensor adjustment settings

ON 1 2 3 4

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Finishing accessories 703

Set the sensor adjustment values Follow these steps to adjust the sensors on the punch controller PCA. 1.

Turn the product power off.

2.

Locate the switches and LEDs on the punch controller PCA. ●

SW601 (callout 1) NOTE: SW601 has four electronic switches that can be configure in the ON or OFF position. The punch controller PCA is marked ON and OFF to show the current switch position.

●

LED602 (callout 2)

●

LED601 (callout 3)

●

SW602 (callout 4)

●

SW603 (callout 5)

Figure 1-1058 Set the sensor adjustment values

2

3

1

3.

4 5

Set SW601 to the following: Figure 1-1059 SW601 sensor adjustment settings

ON 1 2 3 4 4.

Turn the product power on.

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5.

Press SW602 and observe the blinking pattern of LED601 and LED602. The table below explains the different blinking patterns. Table 1-31 LED601 and LED602 blinking patterns LED601

LED602

Solidly lit

Blinking steadily Blinking alternately

Not lit

Blinking steadily

LED blinking pattern explanation Adjusting sensors Waiting for adjustment completion Sensor adjustment completed

6.

Wait until LED601 is not lit and LED602 is blinking steadily to indicate sensor adjustment is complete.

7.

Press either SW602 or SW603.

8.

Wait until LED601 is not lit and LED602 is blinking steadily to indicate the sensor adjustment is complete.

9.

Turn the product power off.

10. Return all of the switches on SW601 to the OFF position. Figure 1-1060 SW601 sensor adjustment settings

ON 1 2 3 4

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