HP LaserJet MFP M725 Repair Manual

LASERJET ENTERPRISE MFP M725

Repair Manual

M725zM725dn M725f M725z+

HP LaserJet Enterprise MFP M725

Repair Manual

Copyright and License

Trademark Credits

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

Reproduction, adaptation, or translation
without prior written permission is
prohibited, except as allowed under the
copyright laws.

The information contained herein is subject
to change without notice.

The only warranties for HP products and
services are set forth in the express warranty
statements accompanying such products and
services. Nothing herein should be
construed as constituting an additional
warranty. HP shall not be liable for technical
or editorial errors or omissions contained
herein.

Part number: CF066-90988

Edition 1, 03/2013

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

Conventions used in this guide

TIP: Tips provide helpful hints or shortcuts.

NOTE: Notes provide important information to explain a concept or to complete a task.

CAUTION: Cautions indicate procedures that you should follow to avoid losing data or damaging

the product.

WARNING! Warnings alert you to specific procedures that you should follow to avoid personal

injury, catastrophic loss of data, or extensive damage to the product.

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iv Conventions used in this guide ENWW

Table of contents

1 Removal and replacement ................................................................................................ 1

Removal and replacement strategy ............................................................................................. 2

Introduction .............................................................................................................. 2

Required tools ........................................................................................................... 3

Types of screws ........................................................................................................ 3

Service approach ...................................................................................................... 3

Before performing service .......................................................................................... 4

After performing service ............................................................................................. 4

Parts removal order ................................................................................................... 4

Pickup rollers ........................................................................................................................... 5

Tray 1 (multipurpose tray) pickup roller ........................................................................ 5

Reinstall the Tray 1 (multipurpose tray) pickup roller ....................................... 6

Tray 2 and Tray 3 pickup rollers ................................................................................. 7

Tray 4, Tray 5, and Tray 6 pickup and feed rollers ....................................................... 9

High capacity input feeder (HCI) pickup, feed, and separation rollers ............................ 11

Document feeder pickup and feed roller assembly ....................................................... 13

Separation pads and rollers .................................................................................................... 15

Tray 1 separation pad assembly ............................................................................... 15

Tray 2 and Tray 3 separation rollers .......................................................................... 16

Tray 4, 5, and 6 separation rollers ............................................................................ 17

Document feeder separation pad .............................................................................. 18

Reinstall the document feeder separation pad .............................................. 19

Covers and doors .................................................................................................................. 21

Front cover ............................................................................................................. 21

Right rear cover ...................................................................................................... 22

Left door ................................................................................................................ 23

Rear cover ............................................................................................................. 24

Front left lower cover ............................................................................................... 25

Front right lower cover ............................................................................................. 26

Face-down cover ..................................................................................................... 27

Tray 1 (multipurpose tray) cover ................................................................................ 28

Right door .............................................................................................................. 29

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Reinstall the right door .............................................................................. 30

Left handle cover ..................................................................................................... 31

Left inner lower cover .............................................................................................. 32

Left inner rear cover ................................................................................................. 33

Left inner front cover ................................................................................................ 35

Right handle cover .................................................................................................. 37

Face-down side cover .............................................................................................. 38

Front upper cover .................................................................................................... 39

Top rear outer cover ................................................................................................ 40

Output upper cover ................................................................................................. 41

Top rear inner cover ................................................................................................ 42

Left inner front upper cover ....................................................................................... 43

Left inner rear upper cover ....................................................................................... 44

Main assemblies .................................................................................................................... 45

Duplexer or duplex cover ......................................................................................... 46

Fuser ..................................................................................................................... 48

Control panel assembly ........................................................................................... 49

Paper delivery assembly .......................................................................................... 50

Install a replacement paper delivery assembly ............................................. 52

Registration assembly .............................................................................................. 54

Transfer roller ......................................................................................................... 57

Paper feed assembly ............................................................................................... 58

Laser scanner ......................................................................................................... 62

Toner cartridge door ............................................................................................... 64

Formatter cage assembly .......................................................................................... 69

Upper cassette pickup assembly ................................................................................ 70

Lower cassette pickup assembly ................................................................................ 73

Lifter drive assembly ................................................................................................ 75

Main drive assembly ............................................................................................... 77

Fuser drive assembly ............................................................................................... 81

Reinstall the fuser drive assembly ................................................................ 82

Switches ............................................................................................................................... 84

Power switch assembly ............................................................................................ 85

Left door interlock switch .......................................................................................... 86

Cartridge door interlock switch ................................................................................. 89

Cartridge door open detection switch ........................................................................ 91

Upper cassette media end switch .............................................................................. 93

Lower cassette media end switch ............................................................................... 94

Sensors ................................................................................................................................. 96

Environment sensor .................................................................................................. 98

Cartridge presence sensor ........................................................................................ 99

vi ENWW

Right door sensor .................................................................................................. 100

Motors, fans, and clutches ..................................................................................................... 103

Fuser motor .......................................................................................................... 105

Rear fan ............................................................................................................... 106

Front fan .............................................................................................................. 108

Fuser fan .............................................................................................................. 109

Upper cassette pickup clutch ................................................................................... 110

Lower cassette pickup clutch ................................................................................... 112

Printed circuit-board assemblies (PCAs) ................................................................................... 114

Formatter PCA ...................................................................................................... 114

High-voltage power supply ..................................................................................... 115

DC controller PCA ................................................................................................. 118

Low-voltage power supply assembly ........................................................................ 119

Dual in-line memory module ................................................................................... 122

Reinstall the Dual in-line memory module ................................................... 123

Fax PCA .............................................................................................................. 125

Miscellaneous parts .............................................................................................................. 126

Hard disk ............................................................................................................. 126

Trays .................................................................................................................................. 128

1x500-sheet paper feeder assembly ........................................................................ 128

1x500 rear cover ................................................................................... 128

1x500 left cover .................................................................................... 129

1x500 right-front cover ........................................................................... 131

1x500 front-upper cover ......................................................................... 132

1x500 right door ................................................................................... 133

1x500 right-lower cover .......................................................................... 135

1x500 pickup assembly .......................................................................... 136

1x500 lifter-drive assembly ..................................................................... 139

1x500 pickup motor ............................................................................... 140

1x500 driver PCA .................................................................................. 141

1x500 or 3x500-sheet paper feeder (optional accessory) .......................................... 142

Paper deck rear cover ............................................................................ 142

Paper deck left cover .............................................................................. 143

Paper deck front-lower cover ................................................................... 144

Paper deck right and left cassette rails ...................................................... 145

Paper deck right-corner cover .................................................................. 146

Paper deck front-upper cover ................................................................... 147

Paper deck right-door assembly ............................................................... 148

Paper deck right-lower cover 1 ................................................................ 150

Paper deck right-lower cover 2 ................................................................ 151

Paper deck left-lower cover ...................................................................... 152

ENWW vii

Paper deck rear-lower cover .................................................................... 153

Paper deck controller PCAs ..................................................................... 154

Paper deck lifter-drive assembly ............................................................... 155

Paper deck pickup motor ........................................................................ 156

Paper deck pickup assembly .................................................................... 157

Input devices ....................................................................................................................... 159

High capacity input (HCI) feeder ............................................................................. 159

HCI right tray ......................................................................................... 159

HCI left tray ........................................................................................... 160

HCI left cover ........................................................................................ 161

HCI left lower cover ................................................................................ 162

HCI rear cover ....................................................................................... 163

HCI right door ....................................................................................... 164

HCI right front cover ............................................................................... 165

HCI right center cover and right rear cover ................................................ 166

HCI right lower cover ............................................................................. 168

HCI rear lower cover .............................................................................. 169

HCI left tray lifter drive ............................................................................ 170

HCI right tray lifter drive ......................................................................... 171

HCI left tray pickup drive ........................................................................ 172

HCI right tray pickup drive ...................................................................... 173

HCI controller PCA ................................................................................. 174

HCI left tray automatic close assembly ...................................................... 175

HCI right tray automatic close assembly .................................................... 176

HCI left tray pickup assembly ................................................................... 178

HCI right tray pickup assembly ................................................................ 180

HCI merge assembly .............................................................................. 182

Output devices .................................................................................................................... 184

Stapler/stacker (stapler models only) ....................................................................... 184

Stapler/stacker left door ......................................................................... 184

Stapler/stacker left cover ........................................................................ 186

Stapler/stacker rear cover ....................................................................... 190

Stapler/stacker stapler door .................................................................... 191

Stapler/stacker jogger upper cover .......................................................... 192

Stapler/stacker stapler cover ................................................................... 193

Stapler/stacker left rear cover .................................................................. 195

Stapler/stacker right rear cover ............................................................... 196

Stapler/stacker output bin assembly ......................................................... 197

Stapler/stacker rear inner cover ............................................................... 198

Stapler/stacker stack cover ..................................................................... 199

Stapler/stacker stapler assembly .............................................................. 200

viii ENWW

Stapler/stacker paper feed assembly ........................................................ 201

Stapler/stacker alignment assembly .......................................................... 203

Stapler/stacker controller PCA ................................................................. 210

Stapler/stacker assembly ........................................................................ 211

Document feeder .................................................................................................................. 214

Document feeder assembly ..................................................................................... 214

Install a replacement document feeder assembly ........................................ 216

Document feeder cable cover ................................................................................. 217

Document feeder hinge .......................................................................................... 218

Document feeder mylar strips .................................................................................. 219

Install replacement document feeder mylar strips ........................................ 220

Document feeder foam reflector .............................................................................. 221

Install a replacement document feeder foam reflector .................................. 222

Document feeder tray extender ............................................................................... 227

Document feeder front cover ................................................................................... 229

Document feeder hatch cover ................................................................................. 233

Document feeder paper present sensor .................................................................... 234

Document feeder input tray bottom cover ................................................................. 235

Document feeder width-adjust sensor, paper-long and paper-short sensors ................... 236

Document feeder roller cover .................................................................................. 239

Document feeder rear cover ................................................................................... 241

Document feeder open sensor and flag .................................................................... 243

Reinstall the document feeder open sensor and flag .................................... 245

Scanner .............................................................................................................................. 246

Scanner controller board (SCB) assembly ................................................................. 246

Scanner assembly ................................................................................................. 248

Install a replacement scanner assembly ..................................................... 250

Scanner right cover ............................................................................................... 251

Scanner left cover ................................................................................................. 252

Scanner front cover ............................................................................................... 253

Reinstall the scanner front cover ............................................................... 254

Image scanner memory board ................................................................................ 255

Installing a replacement SCB and image scanner memory board ................. 257

2 Parts and diagrams ...................................................................................................... 259

Order parts by authorized service providers ............................................................................ 260

Related documentation and software ....................................................................... 260

Supplies part numbers ........................................................................................... 260

Customer self repair orderable parts ........................................................................ 261

Accessories part numbers ....................................................................................... 263

How to use the parts lists and diagrams .................................................................................. 265

ENWW ix

Fasteners used in this product ................................................................................................ 265

Assembly locations ............................................................................................................... 266

Base product (no optional trays or accessories) ......................................................... 266

Optional 500-sheet paper feeder (accessory) ........................................................... 267

Optional 1x500-sheet paper deck (accessory) .......................................................... 268

Optional 3x500-sheet paper deck (accessory) .......................................................... 269

High capacity input (HCI) paper deck ...................................................................... 270

Duplexer .............................................................................................................. 271

Optional stapler/stacker ........................................................................................ 272

Document feeder, control panel, and scanner whole units ......................................................... 274

Document feeder assemblies .................................................................................................. 276

Scanner assemblies .............................................................................................................. 278

Scanner controller board (SCB) .............................................................................................. 280

Print engine ......................................................................................................................... 282

External covers and panels ..................................................................................... 282

Internal components (1 of 4) ................................................................................... 284

Internal components (2 of 4) ................................................................................... 286

Internal components (3 of 4) ................................................................................... 288

Internal components (4 of 4) ................................................................................... 290

500-sheet paper feeder (Tray 4) ............................................................................................ 292

500-sheet paper feeder (Tray 4) covers .................................................................... 292

500-sheet paper feeder (Tray 4) components ............................................................ 294

1x500 and 3x500 paper deck .............................................................................................. 296

1x500 and 3x500 paper deck covers ..................................................................... 296

1x500 paper deck components .............................................................................. 298

3x500 paper deck components .............................................................................. 300

High capacity input (HCI) feeder ............................................................................................ 302

HCI covers ........................................................................................................... 302

HCI components (1 of 2) ........................................................................................ 304

HCI components (2 of 2) ........................................................................................ 306

Stapler/stacker assembly ...................................................................................................... 308

Stapler/stacker covers ........................................................................................... 308

Stapler/stacker components ................................................................................... 310

Alphabetical parts list ........................................................................................................... 312

Numerical parts list .............................................................................................................. 324

Index ............................................................................................................................... 337

x ENWW

List of tables

Table 1-1 Switch locations ................................................................................................................... 84

Table 1-2 Sensor locations ................................................................................................................... 96

Table 1-3 Motor locations .................................................................................................................. 103

Table 1-4 Fan locations ..................................................................................................................... 104

Table 1-5 Clutch locations .................................................................................................................. 104

Table 2-1 Order parts, accessories, and supplies .................................................................................. 260

Table 2-2 Related documentation and software .................................................................................... 260

Table 2-3 Supplies part numbers ......................................................................................................... 260

Table 2-4 Orderable parts ................................................................................................................. 261

Table 2-5 Accessories part numbers .................................................................................................... 263

Table 2-6 Common fasteners ............................................................................................................. 265

Table 2-7 Optional 500-sheet paper feeder (accessory) ......................................................................... 267

Table 2-8 Optional 1x500-sheet paper deck (accessory) ....................................................................... 268

Table 2-9 Optional 3x500-sheet paper deck (accessory) ....................................................................... 269

Table 2-10 High capacity input (HCI) paper deck ................................................................................. 270

Table 2-11 Duplexer ......................................................................................................................... 271

Table 2-12 Optional stapler/stacker (accessory) ................................................................................... 272

Table 2-13 Document feeder, control panel, and scanner whole units ..................................................... 275

Table 2-14 Document feeder assemblies .............................................................................................. 277

Table 2-15 Scanner assemblies .......................................................................................................... 279

Table 2-16 Scanner controller board (SCB) assembly ............................................................................ 281

Table 2-17 External covers and panels ................................................................................................ 283

Table 2-18 Internal components (1 of 4) ............................................................................................. 285

Table 2-19 Internal components (2 of 4) .............................................................................................. 287

Table 2-20 Internal components (3 of 4) .............................................................................................. 289

Table 2-21 Internal components (4 of 4) .............................................................................................. 291

Table 2-22 500-sheet paper feeder (Tray 4) covers ............................................................................... 293

Table 2-23 500-sheet paper feeder (Tray 4) components ....................................................................... 295

Table 2-24 1x500 and 3x500 paper deck covers ................................................................................ 297

Table 2-25 1x500 paper deck components ......................................................................................... 299

Table 2-26 3x500 paper deck

Table 2-27 HCI covers ...................................................................................................................... 303

components ......................................................................................... 301

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Table 2-28 HCI components (1 of 2) ................................................................................................... 305

Table 2-29 HCI components (2 of 2) ................................................................................................... 307

Table 2-30 Stapler/stacker covers ...................................................................................................... 309

Table 2-31 Stapler/stacker components ............................................................................................... 311

Table 2-32 Alphabetical parts list ....................................................................................................... 312

Table 2-33 Numerical parts list ........................................................................................................... 324

xii ENWW

List of figures

Figure 1-1 Screwdrivers ......................................................................................................................... 3

Figure 1-2 Remove the Tray 1 (multipurpose tray) pickup roller ................................................................... 5

Figure 1-3 Reinstall the Tray 1 (multipurpose tray) pickup roller (1 of 2) ....................................................... 6

Figure 1-4 Reinstall the Tray 1 (multipurpose tray) pickup roller (2 of 2) ....................................................... 6

Figure 1-5 Remove the Tray 2 and Tray 3 pickup rollers (1 of 2) ................................................................. 7

Figure 1-6 Remove the Tray 2 and Tray 3 pickup rollers (2 of 2) ................................................................. 8

Figure 1-7 Remove the 1x500 or 3x500 rollers (1 of 2) ............................................................................ 9

Figure 1-8 Remove the 1x500 or 3x500 rollers (2 of 2) .......................................................................... 10

Figure 1-9 Remove the high capacity input feeder pickup, feed, and separation rollers (1 of 4) .................... 11

Figure 1-10 Remove the high capacity input feeder pickup, feed, and separation rollers (2 of 4) .................. 11

Figure 1-11 Remove the high capacity input feeder pickup, feed, and separation rollers (3 of 4) .................. 12

Figure 1-12 Remove the high capacity input feeder pickup, feed, and separation rollers (4 of 4) .................. 12

Figure 1-13 Remove the document feeder pickup and feed roller assembly (1 of 3) ..................................... 13

Figure 1-14 Remove the document feeder pickup and feed roller assembly (2 of 3) ..................................... 13

Figure 1-15 Remove the document feeder pickup and feed roller assembly (3 of 3) ..................................... 14

Figure 1-16 Remove the Tray 1 separation pad assembly (1 of 2) ............................................................. 15

Figure 1-17 Remove the Tray 1 separation pad assembly (2 of 2) ............................................................. 15

Figure 1-18 Remove the Tray 2 and Tray 3 separation rollers ................................................................... 16

Figure 1-19 Remove the 1x500 or 3x500 rollers (1 of 2) ........................................................................ 17

Figure 1-20 Remove the 1x500 or 3x500 rollers (2 of 2) ........................................................................ 17

Figure 1-21 Remove the document feeder separation pad (1 of 3) ............................................................ 18

Figure 1-22 Remove the document feeder separation pad (2 of 3) ............................................................ 18

Figure 1-23 Remove the document feeder separation pad (3 of 3) ............................................................ 19

Figure 1-24 Reinstall the document feeder separation pad (1 of 2) ............................................................ 19

Figure 1-25 Reinstall the document feeder separation pad (2 of 2) ............................................................ 20

Figure 1-26 Remove the front cover (1 of 2) ........................................................................................... 21

Figure 1-27 Remove the front cover (2 of 2) ........................................................................................... 21

Figure 1-28 Remove the right rear cover ................................................................................................ 22

Figure 1-29 Remove the left door (1 of 2) .............................................................................................. 23

Figure 1-30 Remove the left door (2 of 2) .............................................................................................. 23

Figure 1-31 Remove the rear cover (1 of 2) ......

Figure 1-32 Remove the rear cover (2 of 2) ............................................................................................ 24

...................................................................................... 24

ENWW xiii

Figure 1-33 Remove the front left lower cover ......................................................................................... 25

Figure 1-34 Remove the front right lower cover ....................................................................................... 26

Figure 1-35 Remove the face-down cover .............................................................................................. 27

Figure 1-36 Remove the Tray 1 (multipurpose tray) cover (1 of 2) ............................................................. 28

Figure 1-37 Remove the Tray 1 (multipurpose tray) cover (2 of 2) ............................................................. 28

Figure 1-38 Remove the right door (1 of 2) ............................................................................................ 29

Figure 1-39 Remove the right door (2 of 2) ............................................................................................ 29

Figure 1-40 Reinstall the right door ....................................................................................................... 30

Figure 1-41 Remove the left handle cover .............................................................................................. 31

Figure 1-42 Remove the left inner lower cover ........................................................................................ 32

Figure 1-43 Remove the left inner rear cover (1 of 2) ............................................................................... 33

Figure 1-44 Remove the left inner rear cover (2 of 2) ............................................................................... 34

Figure 1-45 Remove the left inner front cover (1 of 2) .............................................................................. 35

Figure 1-46 Remove the left inner front cover (2 of 2) .............................................................................. 36

Figure 1-47 Remove the right handle cover ............................................................................................ 37

Figure 1-48 Remove the face-down side cover ........................................................................................ 38

Figure 1-49 Remove the front upper cover .............................................................................................. 39

Figure 1-50 Remove the top rear outer cover .......................................................................................... 40

Figure 1-51 Remove the output upper cover (1 of 2) ................................................................................ 41

Figure 1-52 Remove the output upper cover (2 of 2) ................................................................................ 41

Figure 1-53 Remove the top rear inner cover .......................................................................................... 42

Figure 1-54 Remove the left inner front upper cover ................................................................................ 43

Figure 1-55 Remove the left inner rear upper cover ................................................................................. 44

Figure 1-56 Remove the duplexer (1 of 2) .............................................................................................. 46

Figure 1-57 Remove the duplexer (2 of 2) .............................................................................................. 46

Figure 1-58 Remove the duplex cover .................................................................................................... 47

Figure 1-59 Remove the duplex cover .................................................................................................... 47

Figure 1-60 Remove the fuser ............................................................................................................... 48

Figure 1-61 Remove the control panel (1 of 2) ........................................................................................ 49

Figure 1-62 Remove the control panel (2 of 2) ........................................................................................ 49

Figure 1-63 Remove the paper delivery assembly (1 of 2) ........................................................................ 50

Figure 1-64 Remove the paper delivery assembly (2 of 2) ........................................................................ 51

Figure 1-65 Install a rep

Figure 1-66 Install a replacement paper delivery assembly (2 of 3) ........................................................... 52

Figure 1-67 Install a replacement paper delivery assembly (3 of 3) ........................................................... 53

Figure 1-68 Registration assembly left screw .......................................................................................... 54

Figure 1-69 Registration assembly right screw ........................................................................................ 54

Figure 1-70 Remove the registration assembly (1 of 2) ............................................................................ 55

Figure 1-71 Remove the registration assembly (2 of 2) ............................................................................ 55

Figure 1-72 Reinstalling the registration assembly ................................................................................... 56

Figure 1-73 Remove the transfer roller ................................................................................................... 57

lacement paper delivery assembly (1 of 3) ........................................................... 52

xiv ENWW

Figure 1-74 Remove the paper feed assembly (1 of 4) ............................................................................. 58

Figure 1-75 Remove the paper feed assembly (2 of 4) ............................................................................. 58

Figure 1-76 Remove the paper feed assembly (3 of 4) ............................................................................. 59

Figure 1-77 Reinstall the connector cover ............................................................................................... 59

Figure 1-78 Remove the paper feed assembly (4 of 4) ............................................................................. 60

Figure 1-79 Reinstall the paper feed assembly (1 of 2) ............................................................................ 60

Figure 1-80 Reinstall the paper feed assembly (2 of 2) ............................................................................ 61

Figure 1-81 Remove the laser scanner (1 of 3) ....................................................................................... 62

Figure 1-82 Remove the laser scanner (2 of 3) ....................................................................................... 62

Figure 1-83 Remove the laser scanner (3 of 3) ....................................................................................... 63

Figure 1-84 Remove the toner cartridge door (1 of 6) .............................................................................. 64

Figure 1-85 Remove the toner cartridge door (2 of 6) .............................................................................. 65

Figure 1-86 Remove the toner cartridge door (3 of 6) .............................................................................. 65

Figure 1-87 Remove the toner cartridge door (4 of 6) .............................................................................. 66

Figure 1-88 Remove the toner cartridge door (5 of 6) .............................................................................. 66

Figure 1-89 Remove the toner cartridge door (6 of 6) .............................................................................. 67

Figure 1-90 Reinstall the cartridge door assembly (1 of 2) ....................................................................... 67

Figure 1-91 Reinstall the cartridge door assembly (2 of 2) ....................................................................... 68

Figure 1-92 Remove the formatter cage (1 of 2) ...................................................................................... 69

Figure 1-93 Remove the formatter cage (2 of 2) ...................................................................................... 69

Figure 1-94 Remove the upper cassette pickup assembly (1 of 4) .............................................................. 70

Figure 1-95 Remove the upper cassette pickup assembly (2 of 4) .............................................................. 71

Figure 1-96 Remove the upper cassette pickup assembly (3 of 4) .............................................................. 71

Figure 1-97 Remove the upper cassette pickup assembly (4 of 4) .............................................................. 72

Figure 1-98 Remove the lower cassette pickup assembly (1 of 3) .............................................................. 73

Figure 1-99 Remove the lower cassette pickup assembly (2 of 3) .............................................................. 74

Figure 1-100 Remove the lower cassette pickup assembly (3 of 3) ............................................................ 74

Figure 1-101 Remove the lifter driver assembly (1 of 2) ........................................................................... 75

Figure 1-102 Remove the lifter driver assembly (2 of 2) ........................................................................... 76

Figure 1-103 Remove the main drive assembly (1 of 7) ........................................................................... 77

Figure 1-104 Remove the main drive assembly (2 of 7) ........................................................................... 77

Figure 1-105 Remove the main drive assembly (3 of 7) ........................................................................... 78

Figure 1-106 Remove th

Figure 1-107 Remove the main drive assembly (5 of 7) ........................................................................... 79

Figure 1-108 Remove the main drive assembly (6 of 7) ........................................................................... 79

Figure 1-109 Remove the main drive assembly (7 of 7) ........................................................................... 80

Figure 1-110 Reinstall the main drive assembly ...................................................................................... 80

Figure 1-111 Remove the fuser drive assembly (1 of 3) ............................................................................ 81

Figure 1-112 Remove the fuser drive assembly (2 of 3) ............................................................................ 81

Figure 1-113 Remove the fuser drive assembly (3 of 3) ............................................................................ 82

Figure 1-114 Reinstall the fuser drive assembly (1 of 3) ........................................................................... 82

e main drive assembly (4 of 7) ........................................................................... 78

ENWW xv

Figure 1-115 Reinstall the fuser drive assembly (2 of 3) ........................................................................... 83

Figure 1-116 Reinstall the fuser drive assembly (3 of 3) ........................................................................... 83

Figure 1-117 Switch locations .............................................................................................................. 84

Figure 1-118 Remove the power switch assembly ................................................................................... 85

Figure 1-119 Remove the left door interlock switch (1 of 4) ...................................................................... 86

Figure 1-120 Remove the left door interlock switch (2 of 4) ...................................................................... 86

Figure 1-121 Remove the left door interlock switch (3 of 4) ...................................................................... 87

Figure 1-122 Reinstall the left door lever ................................................................................................ 87

Figure 1-123 Remove the left door interlock switch (4 of 4) ...................................................................... 88

Figure 1-124 Remove the cartridge door interlock switch (1 of 4) ............................................................. 89

Figure 1-125 Remove the cartridge door interlock switch (2 of 4) ............................................................. 89

Figure 1-126 Remove the cartridge door interlock switch (3 of 4) ............................................................. 90

Figure 1-127 Remove the cartridge door interlock switch (4 of 4) ............................................................. 90

Figure 1-128 Remove the cartridge door open detection switch (1 of 3) .................................................... 91

Figure 1-129 Remove the cartridge door open detection switch (2 of 3) .................................................... 91

Figure 1-130 Remove the cartridge door open detection switch (3 of 3) .................................................... 92

Figure 1-131 Remove the upper cassette media end switch ...................................................................... 93

Figure 1-132 Remove the lower cassette media end switch (1 of 3) ........................................................... 94

Figure 1-133 Remove the lower cassette media end switch (2 of 3) ........................................................... 94

Figure 1-134 Remove the lower cassette media end switch (3 of 3) ........................................................... 95

Figure 1-135 Sensor locations .............................................................................................................. 96

Figure 1-136 Remove the environment sensor ......................................................................................... 98

Figure 1-137 Remove the cartridge presence sensor ............................................................................... 99

Figure 1-138 Remove the right door sensor (1 of 4) .............................................................................. 100

Figure 1-139 Remove the right door sensor (2 of 4) .............................................................................. 101

Figure 1-140 Remove the right door sensor (3 of 4) .............................................................................. 101

Figure 1-141 Remove the right door sensor (4 of 4) .............................................................................. 102

Figure 1-142 Motor locations ............................................................................................................. 103

Figure 1-143 Fan locations ................................................................................................................ 104

Figure 1-144 Clutch locations ............................................................................................................. 104

Figure 1-145 Remove the fus

Figure 1-146 Remove the rear fan (1 of 3) ........................................................................................... 106

Figure 1-147 Remove the rear fan (2 of 3) ........................................................................................... 106

Figure 1-148 Remove the rear fan (3 of 3) ........................................................................................... 107

Figure 1-149 Reinstall the rear fan ...................................................................................................... 107

Figure 1-150 Remove the front fan ...................................................................................................... 108

Figure 1-151 Reinstall the front fan ..................................................................................................... 108

Figure 1-152 Remove the fuser fan ...................................................................................................... 109

Figure 1-153 Reinstall the fuser fan ..................................................................................................... 109

Figure 1-154 Remove the upper cassette pickup assembly (1 of 2) .......................................................... 110

Figure 1-155 Remove the upper cassette pickup assembly (2 of 2) .......................................................... 111

er motor .................................................................................................. 105

xvi ENWW

Figure 1-156 Remove the lower cassette pickup assembly (1 of 2) .......................................................... 112

Figure 1-157 Remove the lower cassette pickup assembly (2 of 2) .......................................................... 113

Figure 1-158 Remove the formatter (1 of 2) .......................................................................................... 114

Figure 1-159 Remove the formatter (2 of 2) .......................................................................................... 114

Figure 1-160 Remove the high-voltage power supply assembly (1 of 5) ................................................... 115

Figure 1-161 Remove the high-voltage power supply assembly (2 of 5) ................................................... 116

Figure 1-162 Remove the high-voltage power supply assembly (3 of 5) ................................................... 116

Figure 1-163 Remove the high-voltage power supply assembly (4 of 5) ................................................... 117

Figure 1-164 Remove the high-voltage power supply assembly (5 of 5) ................................................... 117

Figure 1-165 Remove the DC controller PCA ........................................................................................ 118

Figure 1-166 Remove the low-voltage power supply assembly (1 of 5) .................................................... 119

Figure 1-167 Remove the low-voltage power supply assembly (2 of 5) .................................................... 119

Figure 1-168 Remove the low-voltage power supply assembly (3 of 5) .................................................... 120

Figure 1-169 Remove the low-voltage power supply assembly (4 of 5) .................................................... 120

Figure 1-170 Remove the low-voltage power supply assembly (5 of 5) .................................................... 121

Figure 1-171 Remove the DIMM (1 of 3) ............................................................................................. 122

Figure 1-172 Remove the DIMM (2 of 3) ............................................................................................. 122

Figure 1-173 Remove the DIMM (3 of 3) ............................................................................................. 123

Figure 1-174 Reinstall the DIMM (1 of 3) ............................................................................................. 123

Figure 1-175 Reinstall the DIMM (2 of 3) ............................................................................................. 124

Figure 1-176 Reinstall the DIMM (3 of 3) ............................................................................................. 124

Figure 1-177 Remove the fax PCA (1 of 2) .......................................................................................... 125

Figure 1-178 Remove the fax PCA (2 of 2) .......................................................................................... 125

Figure 1-179 Remove the hard disk (1 of 3) ......................................................................................... 126

Figure 1-180 Remove the hard disk (2 of 3) ......................................................................................... 126

Figure 1-181 Remove the hard disk (3 of 3) ......................................................................................... 127

Figure 1-182 Remove the 1x500 rear cover ......................................................................................... 128

Figure 1-183 Remove the 1x500 left cover (1 of 2) ............................................................................... 129

Figure 1-184 Remove the 1x500 left cover (2 of 2) ............................................................................... 129

Figure 1-185 Remove the 1x500 right-front cover ................................................................................. 131

Figure 1-186 Remove the 1x500 front-upper cover ............................................................................... 132

Figure 1-187 Remove the 1x500 right door (1 of 3) .............................................................................. 133

Figure 1-188 Remove the 1x500 right door (2

Figure 1-189 Remove the 1x500 right door (3 of 3) .............................................................................. 134

Figure 1-190 Remove the 1x500 right-lower cover ................................................................................ 135

Figure 1-191 Remove the 1x500 pickup assembly (1 of 4) .................................................................... 136

Figure 1-192 Remove the 1x500 pickup assembly (2 of 4) .................................................................... 136

Figure 1-193 Remove the 1x500 pickup assembly (3 of 4) .................................................................... 137

Figure 1-194 Remove the 1x500 pickup assembly (4 of 4) .................................................................... 137

Figure 1-195 Remove the 1x500 lifter-drive assembly (1 of 2) ................................................................ 139

Figure 1-196 Remove the 1x500 lifter-drive assembly (2 of 2) ................................................................ 139

of 3) .............................................................................. 133

ENWW xvii

Figure 1-197 Remove the 1x500 pickup motor ..................................................................................... 140

Figure 1-198 Remove the 1x500 driver PCA ........................................................................................ 141

Figure 1-199 Remove the 3x500 rear cover ......................................................................................... 142

Figure 1-200 Remove the 3x500 left cover (1 of 2) ............................................................................... 143

Figure 1-201 Remove the 3x500 left cover (2 of 2) ............................................................................... 143

Figure 1-202 Remove the 3x500 front-lower cover ................................................................................ 144

Figure 1-203 Remove the 3x500 right and left cassette rails .................................................................. 145

Figure 1-204 Remove the 3x500 right-corner cover .............................................................................. 146

Figure 1-205 Remove the 3x500 front-upper cover ............................................................................... 147

Figure 1-206 Remove the 3x500 right-door assembly (1 of 3) ................................................................ 148

Figure 1-207 Remove the 3x500 right-door assembly (2 of 3) ................................................................ 148

Figure 1-208 Remove the 3x500 right-door assembly (3 of 3) ................................................................ 149

Figure 1-209 Remove the 3x500 right-lower cover 1 ............................................................................. 150

Figure 1-210 Remove the 3x500 right-lower cover 2 ............................................................................. 151

Figure 1-211 Remove the 3x500 left-lower cover .................................................................................. 152

Figure 1-212 Remove the 3x500 rear-lower cover ................................................................................ 153

Figure 1-213 Remove the 3x500 paper deck controller PCA .................................................................. 154

Figure 1-214 Remove the 3x500 paper deck lifter-drive assembly (1 of 2) ............................................... 155

Figure 1-215 Remove the 3x500 paper deck lifter-drive assembly (2 of 2) ............................................... 155

Figure 1-216 Remove the 3x500 paper deck pickup motor .................................................................... 156

Figure 1-217 Remove the 3x500 paper deck pickup assembly (1 of 3) ................................................... 157

Figure 1-218 Remove the 3x500 paper deck pickup assembly (2 of 3) ................................................... 158

Figure 1-219 Remove the 3x500 paper deck pickup assembly (3 of 3) ................................................... 158

Figure 1-220 Remove the HCI right tray ............................................................................................... 159

Figure 1-221 Remove the HCI left tray ................................................................................................. 160

Figure 1-222 Remove the HCI left cover (1 of 2) ................................................................................... 161

Figure 1-223 Remove the HCI left cover (2 of 2) ................................................................................... 161

Figure 1-224 Remove the HCI left lower cover ...................................................................................... 162

Figure 1-225 Remove the HCI rear cover ............................................................................................. 163

Figure 1-226 Remove the HCI right door ............................................................................................. 164

Figure 1-227 HCI right door link detail ................................................................................................ 164

Figure 1-228 Remove the HCI right fron

Figure 1-229 Remove the HCI right front cover (2 of 2) ......................................................................... 165

Figure 1-230 Remove the HCI right center cover and right rear cover (1 of 2) .......................................... 166

Figure 1-231 Remove the HCI right center cover and right rear cover (1 of 2) .......................................... 167

Figure 1-232 Remove the HCI right lower cover ................................................................................... 168

Figure 1-233 Remove the HCI rear lower cover .................................................................................... 169

Figure 1-234 Remove the HCI left tray lifter drive .................................................................................. 170

Figure 1-235 Remove the HCI right tray lifter drive ................................................................................ 171

Figure 1-236 Remove the HCI left tray pickup drive (1 of 2) ................................................................... 172

Figure 1-237 Remove the HCI left tray pickup drive (2 of 2) ................................................................... 172

t cover (1 of 2) ......................................................................... 165

xviii ENWW

Figure 1-238 Remove the HCI right tray pickup drive (1 of 2) ................................................................. 173

Figure 1-239 Remove the HCI right tray pickup drive (2 of 2) ................................................................. 173

Figure 1-240 Remove the HCI controller PCA ....................................................................................... 174

Figure 1-241 Remove the HCI left tray automatic close assembly (1 of 2) ................................................. 175

Figure 1-242 Remove the HCI left tray automatic close assembly (2 of 2) ................................................. 175

Figure 1-243 Remove the HCI right tray automatic close assembly (1 of 2) .............................................. 176

Figure 1-244 Remove the HCI right tray automatic close assembly (2 of 2) .............................................. 177

Figure 1-245 Remove the HCI left tray pickup assembly (1 of 2) ............................................................. 178

Figure 1-246 Remove the HCI left tray pickup assembly (2 of 2) ............................................................. 179

Figure 1-247 Remove the HCI right tray pickup assembly (1 of 2) ........................................................... 180

Figure 1-248 Remove the HCI right tray pickup assembly (2 of 2) ........................................................... 181

Figure 1-249 Remove the HCI merge assembly (1 of 2) ......................................................................... 182

Figure 1-250 Remove the HCI merge assembly (2 of 2) ......................................................................... 183

Figure 1-251 Remove the stapler/stacker left door (1 of 3) .................................................................... 184

Figure 1-252 Remove the stapler/stacker left door (2 of 3) .................................................................... 184

Figure 1-253 Remove the stapler/stacker left door (3 of 3) .................................................................... 185

Figure 1-254 Remove the stapler/stacker assembly (1 of 5) ................................................................... 186

Figure 1-255 Remove the stapler/stacker assembly (2 of 5) ................................................................... 187

Figure 1-256 Remove the stapler/stacker assembly (3 of 5) ................................................................... 187

Figure 1-257 Remove the stapler/stacker assembly (4 of 5) ................................................................... 188

Figure 1-258 Remove the stapler/stacker assembly (5 of 5) ................................................................... 188

Figure 1-259 Remove the stapler/stacker left cover ............................................................................... 189

Figure 1-260 Remove the stapler/stacker rear cover ............................................................................. 190

Figure 1-261 Remove the stapler front door ......................................................................................... 191

Figure 1-262 Remove the stapler/stacker jogger upper cover ................................................................. 192

Figure 1-263 Remove the stapler cover (1 of 2) .................................................................................... 193

Figure 1-264 Remove the stapler cover (2 of 2) .................................................................................... 194

Figure 1-265 Remove the stapler/stacker left rear cover ........................................................................ 195

Figure 1-266 Remove the stapler/stacker right rear cover ...................................................................... 196

Figure 1-267 Remove the stapler/stacker output bin assembly ................................................................ 197

Figure 1-268 Stapler/stacker output bin assembly tab locations ............................................................. 197

Figure 1-269 Remove the stapler/stacker rear inner cover (1 of 2) .......................................................... 198

Figure 1-270 Remove the stap

Figure 1-271 Remove the stapler/stacker stack cover ............................................................................ 199

Figure 1-272 Remove the stapler/stacker stapler assembly .................................................................... 200

Figure 1-273 Remove the stapler/stacker paper feed assembly (1 of 2) ................................................... 201

Figure 1-274 Remove the stapler/stacker paper feed assembly (2 of 2) ................................................... 202

Figure 1-275 Remove the stapler/stacker alignment assembly (1 of 7) .................................................... 203

Figure 1-276 Remove the stapler/stacker alignment assembly (2 of 7) .................................................... 204

Figure 1-277 Remove the stapler/stacker alignment assembly (3 of 7) .................................................... 204

Figure 1-278 Remove the stapler/stacker alignment assembly (4 of 7) .................................................... 205

ler/stacker rear inner cover (2 of 2) .......................................................... 198

ENWW xix

Figure 1-279 Remove the stapler/stacker alignment assembly (5 of 7) .................................................... 205

Figure 1-280 Remove the stapler/stacker alignment assembly (6 of 7) .................................................... 206

Figure 1-281 Remove the stapler/stacker alignment assembly (7 of 7) .................................................... 207

Figure 1-282 Stapler/stacker alignment assembly hook detail ................................................................ 207

Figure 1-283 Stapler/stacker alignment assembly tab ........................................................................... 208

Figure 1-284 Stapler/stacker alignment assembly chassis slot ................................................................ 208

Figure 1-285 Install the stapler/stacker alignment assembly (1 of 2) ........................................................ 209

Figure 1-286 Install the stapler/stacker alignment assembly (2 of 2) ........................................................ 209

Figure 1-287 Remove the stapler/stacker controller PCA ....................................................................... 210

Figure 1-288 Remove the stapler/stacker assembly (1 of 5) ................................................................... 211

Figure 1-289 Remove the stapler/stacker assembly (2 of 5) ................................................................... 212

Figure 1-290 Remove the stapler/stacker assembly (3 of 5) ................................................................... 212

Figure 1-291 Remove the stapler/stacker assembly (4 of 5) ................................................................... 213

Figure 1-292 Remove the stapler/stacker assembly (5 of 5) ................................................................... 213

Figure 1-293 Remove the document feeder (1 of 3) ............................................................................... 214

Figure 1-294 Remove the document feeder (2 of 3) ............................................................................... 215

Figure 1-295 Remove the document feeder (3 of 3) ............................................................................... 215

Figure 1-296 Remove the document feeder cable cover ......................................................................... 217

Figure 1-297 Remove the document feeder hinge (1 of 2) ...................................................................... 218

Figure 1-298 Remove the document feeder hinge (2 of 2) ...................................................................... 218

Figure 1-299 Remove the document feeder mylar strips (1 of 3) .............................................................. 219

Figure 1-300 Remove the document feeder mylar strips (2 of 3) .............................................................. 219

Figure 1-301 Remove the document feeder mylar strips (3 of 3) .............................................................. 220

Figure 1-302 Remove the document feeder foam reflector (1 of 3) .......................................................... 221

Figure 1-303 Remove the document feeder foam reflector (2 of 3) .......................................................... 221

Figure 1-304 Remove the document feeder foam reflector (3 of 3) .......................................................... 222

Figure 1-305 Install a replacement document feeder foam reflector (1 of 8) ............................................. 222

Figure 1-306 Install a replacement document feeder foam reflector (2 of 8) ............................................. 223

Figure 1-307 Install a replacement document feeder foam reflector (3 of 8) ............................................. 223

Figure 1-308 Install a replacement document feeder foam reflector (4 of 8) ............................................. 224

Figure 1-309 Install a

Figure 1-310 Install a replacement document feeder foam reflector (6 of 6) ............................................. 225

Figure 1-311 Install a replacement document feeder foam reflector (7 of 8) ............................................. 225

Figure 1-312 Install a replacement document feeder foam reflector (8 of 8) ............................................. 226

Figure 1-313 Remove the document feeder tray extender (1 of 3) ........................................................... 227

Figure 1-314 Remove the document feeder tray extender (2 of 3) ........................................................... 227

Figure 1-315 Remove the document feeder tray extender (3 of 3) ........................................................... 228

Figure 1-316 Remove the document feeder front cover (1 of 8) ............................................................... 229

Figure 1-317 Remove the document feeder front cover (2 of 8) ............................................................... 229

Figure 1-318 Remove the document feeder front cover (3 of 8) ............................................................... 230

Figure 1-319 Remove the document feeder front cover (4 of 8) ............................................................... 230

replacement document feeder foam reflector (5 of 8) ............................................. 224

xx ENWW

Figure 1-320 Remove the document feeder front cover (5 of 8) ............................................................... 231

Figure 1-321 Remove the document feeder front cover (6 of 8) ............................................................... 231

Figure 1-322 Remove the document feeder front cover (7 of 8) ............................................................... 232

Figure 1-323 Remove the document feeder front cover (8 of 8) ............................................................... 232

Figure 1-324 Remove the document feeder hatch cover (1 of 2) ............................................................. 233

Figure 1-325 Remove the document feeder hatch cover (2 of 2) ............................................................. 233

Figure 1-326 Remove the document feeder paper present sensor (1 of 2) ................................................ 234

Figure 1-327 Remove the document feeder paper present sensor (2 of 2) ................................................ 234

Figure 1-328 Remove the document feeder input tray bottom cover ......................................................... 235

Figure 1-329 Remove the document feeder width-adjust sensor, paper-short and paper-long sensors ........... 236

Figure 1-330 Remove the document feeder width sensor ........................................................................ 237

Figure 1-331 Remove the document feeder paper-short sensor ............................................................... 237

Figure 1-332 Remove the document feeder paper-long sensor ................................................................ 238

Figure 1-333 Remove the document feeder roller cover (1 of 4) .............................................................. 239

Figure 1-334 Remove the document feeder roller cover (2 of 4) .............................................................. 239

Figure 1-335 Remove the document feeder roller cover (3 of 4) .............................................................. 240

Figure 1-336 Remove the document feeder roller cover (4 of 4) .............................................................. 240

Figure 1-337 Remove the document feeder rear cover (1 of 4) ............................................................... 241

Figure 1-338 Remove the document feeder rear cover (2 of 4) ............................................................... 241

Figure 1-339 Remove the document feeder rear cover (3 of 4) ............................................................... 242

Figure 1-340 Remove the document feeder rear cover (4 of 4) ............................................................... 242

Figure 1-341 Remove the document feeder open sensor and flag (1 of 4) ................................................ 243

Figure 1-342 Remove the document feeder open sensor and flag (2 of 4) ................................................ 243

Figure 1-343 Remove the document feeder open sensor and flag (3 of 4) ................................................ 244

Figure 1-344 Remove the document feeder open sensor and flag (4 of 4) ................................................ 244

Figure 1-345 Reinstall the document feeder open sensor and flag ........................................................... 245

Figure 1-346 Remove the SCB (1 of 3) ................................................................................................ 246

Figure 1-347 Remove the SCB (2 of 3) ................................................................................................ 246

Figure 1-348 Remove the SCB (3 of 3) ................................................................................................ 247

Figure 1-349 Remove the scanner (1 of 3) ........................................................................................... 248

Figure 1-350 Remove the scanner (2 of 3) ........................................................................................... 248

Figure 1-351 Remove the scanne

Figure 1-352 Reinstall the scanner ...................................................................................................... 250

Figure 1-353 Remove the scanner right cover (1 of 2) ........................................................................... 251

Figure 1-354 Remove the scanner right cover (2 of 2) ........................................................................... 251

Figure 1-355 Remove the scanner left cover (1 of 2) ............................................................................. 252

Figure 1-356 Remove the scanner left cover (2 of 2) ............................................................................. 252

Figure 1-357 Remove the scanner front cover (1 of 3) ........................................................................... 253

Figure 1-358 Remove the scanner front cover (2 of 3) ........................................................................... 253

Figure 1-359 Remove the scanner front cover (3 of 3) ........................................................................... 254

Figure 1-360 Reinstall the scanner front cover ...................................................................................... 254

r (3 of 3) ........................................................................................... 249

ENWW xxi

Figure 1-361 Remove the image scanner memory board (1 of 3) ............................................................ 255

Figure 1-362 Remove the image scanner memory board (2 of 3) ............................................................ 255

Figure 1-363 Remove the image scanner memory board (3 of 3) ............................................................ 256

Figure 2-1 Base product (no optional trays or accessories) ..................................................................... 266

Figure 2-2 Optional 500-sheet paper feeder (accessory) ........................................................................ 267

Figure 2-3 Optional 1x500-sheet paper deck (accessory) ...................................................................... 268

Figure 2-4 Optional 3x500-sheet paper deck (accessory) ...................................................................... 269

Figure 2-5 High capacity input (HCI) paper deck .................................................................................. 270

Figure 2-6 Duplexer .......................................................................................................................... 271

Figure 2-7 Optional stapler/stacker .................................................................................................... 272

Figure 2-8 Document feeder, control panel, and scanner whole units ...................................................... 274

Figure 2-9 Document feeder assemblies ............................................................................................... 276

Figure 2-10 Scanner assemblies ......................................................................................................... 278

Figure 2-11 Scanner controller board (SCB) ......................................................................................... 280

Figure 2-12 External covers and panels ............................................................................................... 282

Figure 2-13 Internal components (1 of 4) ............................................................................................. 284

Figure 2-14 Internal components (2 of 4) ............................................................................................. 286

Figure 2-15 Internal components (3 of 4) ............................................................................................. 288

Figure 2-16 Internal components (4 of 4) ............................................................................................. 290

Figure 2-17 500-sheet paper feeder (Tray 4) covers .............................................................................. 292

Figure 2-18 500-sheet paper feeder (Tray 4) components ...................................................................... 294

Figure 2-19 1x500 and 3x500 paper deck covers ............................................................................... 296

Figure 2-20 1x500 paper deck components ........................................................................................ 298

Figure 2-21 3x500 paper deck components ........................................................................................ 300

Figure 2-22 HCI covers ..................................................................................................................... 302

Figure 2-23 HCI components (1 of 2) .................................................................................................. 304

Figure 2-24 HCI components (2 of 2) .................................................................................................. 306

Figure 2-25 Stapler/stacker covers ..................................................................................................... 308

Figure 2-26 Stapler/stacker components .............................................................................................. 310

xxii ENWW

1 Removal and replacement

Removal and replacement strategy

●

Pickup rollers

●

Separation pads and rollers

●

Covers and doors

●

Main assemblies

●

Switches

●

Sensors

●

Motors, fans, and clutches

●

Printed circuit-board assemblies (PCAs)

●

Miscellaneous parts

●

Trays

●

Input devices

●

Output devices

●

Document feeder

●

Scanner

●

ENWW 1

Removal and replacement strategy

Introduction

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 support repairing individual subassemblies or troubleshooting to the 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.

The user replaces toner cartridges when they reach the end of life.

Swapping toner cartridges between products might cause a misrepresentation of supply life values and
is not recommended.

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
an ESD-sensitive part.

before

touching

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 flexible cables (FFCs) during removal or installation.

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

parts.

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 might 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.

2 Chapter 1 Removal and replacement ENWW

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 components 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
component with the screws that are removed from another component.

For a complete list of screw types and part numbers, see the Parts chapter.

Service approach

The HP LaserJet Enterprise MFP M725 uses 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 chapter.

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 support replacement of components on the printed circuit assembles.

ENWW

Removal and replacement strategy

3

Before performing service

WARNING! Turn the product off, wait 5 seconds, and then remove the power cord before

attempting to service the product.

product can result.

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

3. Remove the toner cartridge.

4. Remove the trays.

The power must be on for certain functional checks during troubleshooting.

After performing service

1. Reinstall the toner cartridge.

2. Reinstall the trays.

3. Return all paper to the trays.

4. Plug in the power cable and turn on the product.

If this warning is not followed, severe injury and damage to the

before

touching an ESD-sensitive part.

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.

4 Chapter 1 Removal and replacement ENWW

Pickup rollers

Instructions about other user-replaceable parts are provided in this section.

The product tracks the amount of use on the customer-replaceable supplies by keeping a page count.
The product prompts the user to replace certain items when a supply is depleted or a specific number of
pages have been printed.

CAUTION: Do not touch the roller surface unless you are replacing the roller. Skin oils on the roller

can cause paper pickup problems.

NOTE: Replace all of the rollers at the same time.

Tray 1 (multipurpose tray) pickup roller

●

Tray 2 and Tray 3 pickup rollers

●

Tray 4, Tray 5, and Tray 6 pickup and feed rollers

●

High capacity input feeder (HCI) pickup, feed, and separation rollers

●

Document feeder pickup and feed roller assembly

●

Tray 1 (multipurpose tray) pickup roller

1. Open the toner cartridge door.

2. Release tabs (callout 1), rotate the top of the roller away from the product, and then remove the

pickup roller (callout 2).

Figure 1-2 Remove the Tray 1 (multipurpose tray) pickup roller

1

2

ENWW

Pickup rollers

5

Reinstall the Tray 1 (multipurpose tray) pickup roller

1. Align the pins (callout 1) on the roller body with the slots in the holder.

Figure 1-3 Reinstall the Tray 1 (multipurpose tray) pickup roller (1 of 2)

1

2. Rotate the roller into the holder. Make sure that the tabs on the roller body snap into the holder.

Figure 1-4 Reinstall the Tray 1 (multipurpose tray) pickup roller (2 of 2)

6 Chapter 1 Removal and replacement ENWW

Tray 2 and Tray 3 pickup rollers

CAUTION: Do not touch the roller surface unless you are replacing the roller. Skin oils on the roller

can cause paper pickup problems.

NOTE: The same removal procedures apply to the Tray 2 pickup roller and Tray 3 pickup roller.

TIP: When removing the roller assembly, take note of the position and orientation of the roller shaft

so that the assembly can be correctly reinstalled.

1. Remove the trays.

2. From the front of the product, on the right side of the tray cavity, rotate the stopper (callout 1)

down.

Figure 1-5 Remove the Tray 2 and Tray 3 pickup rollers (1 of 2)

1

ENWW

Pickup rollers

7

3. Push the pickup roller (callout 1) in the direction indicated to remove it.

Figure 1-6 Remove the Tray 2 and Tray 3 pickup rollers (2 of 2)

1

8 Chapter 1 Removal and replacement ENWW

Tray 4, Tray 5, and Tray 6 pickup and feed rollers

CAUTION: Do not touch the roller surface unless you are replacing the roller. Skin oils on the roller

can cause paper pickup problems.

NOTE: The same removal procedures apply to the 1x500-sheet tray, the 1x500-sheet tray stand, and

the 3x500-sheet tray stand.

1. Remove the tray from the product, and then locate the rollers on the right-hand side of the tray

cavity.

Figure 1-7 Remove the 1x500 or 3x500 rollers (1 of 2)

ENWW

Pickup rollers

9

2. Release three tabs, and then pull the rollers in the direction indicated.

Reinstallation tip When you reinstall the rollers, make sure that the rollers snap into place.

Figure 1-8 Remove the 1x500 or 3x500 rollers (2 of 2)

10 Chapter 1 Removal and replacement ENWW

High capacity input feeder (HCI) pickup, feed, and separation rollers

CAUTION: Do not touch the roller surface unless you are replacing the roller. Skin oils on the roller

can cause paper pickup problems.

1. Open the high capacity right tray. Lower the tray release lever (callout 1) and then remove the

right tray (callout 2).

Figure 1-9 Remove the high capacity input feeder pickup, feed, and separation rollers (1 of 4)

1

2

2. Open the high capacity left tray. Lower the tray release lever (callout 1) and then remove the left

tray (callout 2).

Figure 1-10 Remove the high capacity input feeder pickup, feed, and separation rollers (2 of 4)

1

2

ENWW

Pickup rollers

11

3. Look up into the tray cavity and locate the rollers.

Figure 1-11 Remove the high capacity input feeder pickup, feed, and separation rollers (3 of 4)

4. Release three tabs, and then pull the rollers in the direction of the arrow. Repeat this step for

remaining rollers.

Figure 1-12 Remove the high capacity input feeder pickup, feed, and separation rollers (4 of 4)

12 Chapter 1 Removal and replacement ENWW

Document feeder pickup and feed roller assembly

CAUTION: Do not touch the roller surface unless you are replacing the roller. Skin oils on the roller

can cause paper pickup problems.

NOTE: Always replace the document feeder separation pad and pickup and feed roller assembly at

the same time.

1. Open the document feeder cover and locate the document feeder pickup and feed roller

assembly.

Figure 1-13 Remove the document feeder pickup and feed roller assembly (1 of 3)

2. Release one tab (callout 1) to open the assembly cover.

Figure 1-14 Remove the document feeder pickup and feed roller assembly (2 of 3)

1

ENWW

Pickup rollers

13

3. Push the roller assembly toward the front of the product, and then pull the assembly away from the

document feeder.

Figure 1-15 Remove the document feeder pickup and feed roller assembly (3 of 3)

14 Chapter 1 Removal and replacement ENWW

Separation pads and rollers

Tray 1 separation pad assembly

CAUTION: Do not touch the pad surface unless you are replacing the assembly. Skin oils on the pad

can cause paper pickup problems.

1. Open Tray 1.

2. Release two hinge pins (callout 1) on the Tray 1 cover assembly.

Figure 1-16 Remove the Tray 1 separation pad assembly (1 of 2)

1

3. Remove one screw (callout 1), and then remove the separation pad assembly (callout 2).

Figure 1-17 Remove the Tray 1 separation pad assembly (2 of 2)

2

1

ENWW

Separation pads and rollers

15

Tray 2 and Tray 3 separation rollers

CAUTION: Do not touch the roller surface unless you are replacing the roller. Skin oils on the roller

can cause paper pickup problems.

NOTE: The same removal procedures apply to the Tray 2 separation roller and Tray 3 separation

roller.

1. Remove the tray.

2. On the right side of the tray, remove two screws (callout 1), and then remove the roller assembly

(callout 2).

Figure 1-18 Remove the Tray 2 and Tray 3 separation rollers

1

2

16 Chapter 1 Removal and replacement ENWW

Tray 4, 5, and 6 separation rollers

CAUTION: Do not touch the roller surface unless you are replacing the roller. Skin oils on the roller

can cause paper pickup problems.

TIP: You do not have to separate the product from the feeder to remove these rollers.

1. Remove the tray from the product, and then locate the rollers on the right-hand side of the tray

cavity.

Figure 1-19 Remove the 1x500 or 3x500 rollers (1 of 2)

2. Release three tabs, and then pull the rollers in the direction indicated.

Reinstallation tip When you reinstall the rollers, make sure that the rollers snap into place.

Figure 1-20 Remove the 1x500 or 3x500 rollers (2 of 2)

ENWW

Separation pads and rollers

17

Document feeder separation pad

CAUTION: Do not touch the pad surface unless you are replacing the assembly. Skin oils on the pad

can cause paper pickup problems.

NOTE: Replace the separation pad and rollers at the same time.

1. Open the document feeder cover and locate the document feeder separation pad.

Figure 1-21 Remove the document feeder separation pad (1 of 3)

2. Press the tab (callout 1) toward the separation pad.

Figure 1-22 Remove the document feeder separation pad (2 of 3)

1

18 Chapter 1 Removal and replacement ENWW

3. Rotate the separation pad assembly up and away from the document feeder, and then remove the

assembly.

CAUTION: The spring underneath the separation pad is not captive. Do not lose the spring.

Figure 1-23 Remove the document feeder separation pad (3 of 3)

Reinstall the document feeder separation pad

When the replacement separation pad assembly is installed, verify the following.

1. When the replacement separation pad assembly is installed, make sure that the spring is seated

on the spring pedestal (callout 1) under the separation pad.

Figure 1-24 Reinstall the document feeder separation pad (1 of 2)

1

ENWW

Separation pads and rollers

19

2. Position the two tabs (callout 1) on the assembly in the holes provided in the document feeder

chassis.

Figure 1-25 Reinstall the document feeder separation pad (2 of 2)

1

20 Chapter 1 Removal and replacement ENWW

Covers and doors

Front cover

1. Remove Tray 2 and Tray 3, and open the toner cartridge door.

2. Remove three screws (callout 1).

Figure 1-26 Remove the front cover (1 of 2)

1

3. Pull the right side of the cover (callout 1) away from the product, and then release the tab

(callout 2) on the left side of the cover to remove the cover.

Figure 1-27 Remove the front cover (2 of 2)

1

2

ENWW

Covers and doors

21

Right rear cover

1. Open the toner cartridge door.

2. Remove one screw (callout 1), and then lift the right rear cover (callout 2) away from the product.

Figure 1-28 Remove the right rear cover

2

1

22 Chapter 1 Removal and replacement ENWW

Left door

1. Remove the duplex unit or the duplex cover. See Duplexer or duplex cover on page 46.

2. Open the left door, and then lift up on the retainer arm (callout 1) to release it from the door

assembly (callout 2).

Figure 1-29 Remove the left door (1 of 2)

1

2

3. Pull the left side of the assembly (callout 1) away from the product, release the pin on the right

side of the assembly, and then remove the door assembly.

Figure 1-30 Remove the left door (2 of 2)

1

ENWW

Covers and doors

23

Rear cover

1. On the rear side of the product, insert a small screwdriver (or a paper clip) into the tab slot

(callout 1) to release a hidden tab, and then slide the rear pocket cover (callout 2) in the direction
indicated to remove the cover.

Figure 1-31 Remove the rear cover (1 of 2)

2

1

2. Remove two screws (callout 1), and then slide the rear cover in the direction indicated to remove

the cover from the product.

Reinstallation tip During reinstallation, make sure that all cables are correctly positioned and

not pinched against metal parts of the chassis when you slide the rear cover into place.

Figure 1-32 Remove the rear cover (2 of 2)

1

24 Chapter 1 Removal and replacement ENWW

Front left lower cover

1. Remove the following components or assemblies:

Tray 2 and Tray 3.

●

Front cover. See

●

2. At the front of the product, remove one screw (callout 1), and then remove the cover (callout 2)

from the product.

Figure 1-33 Remove the front left lower cover

Front cover on page 21.

1

2

ENWW

Covers and doors

25

Front right lower cover

1. Remove the following components or assemblies:

Tray 2 and Tray 3.

●

Front cover. See

●

NOTE: If optional trays are installed, release the tray lock below the front right lower cover. Pull

Tray 4 out, and then rotate the blue lock lever to the right.

2. Remove one screw (callout 1), release one tab (callout 2), and then remove the cover (callout 3)

from the product.

Figure 1-34 Remove the front right lower cover

Front cover on page 21.

1

3

2

26 Chapter 1 Removal and replacement ENWW

Face-down cover

1. Open the toner cartridge door.

2. At the front of the product, remove one screw (callout 1), release one tab (callout 2) at the back of

the metal rail under the cover, and then lift the left side of the cover to release three tabs on the
rear side (callout 3) of the cover to remove the cover from the product.

NOTE: It might be easier to remove this cover if the stapler/stacker output bin is removed first.

See

Stapler/stacker output bin assembly on page 197.

Reinstallation tip When you reinstall the face-down cover, make sure that the three tabs

(callout 3) are properly inserted in the paper delivery assembly.

Figure 1-35 Remove the face-down cover

1

3

2

ENWW

Covers and doors

27

Tray 1 (multipurpose tray) cover

1. Remove the right rear cover. See Right rear cover on page 22.

2. Open Tray 1.

3. Inside Tray 1 release two pins (callout 1).

Figure 1-36 Remove the Tray 1 (multipurpose tray) cover (1 of 2)

1

4. Raise the cover to a half-closed position, pull the right side hinge slot (callout 1) away from the

hinge pin (callout 2), and then remove the cover (callout 3) from the product.

Figure 1-37 Remove the Tray 1 (multipurpose tray) cover (2 of 2)

2

3

1

28 Chapter 1 Removal and replacement ENWW

Right door

1. Remove the right rear cover. See Right rear cover on page 22.

2. On the right side of the product, remove two screws (callout 1).

Figure 1-38 Remove the right door (1 of 2)

1

3. Open the right door (callout 1), move it slightly toward the front of the product, and then release

the door retainer arm (callout 2) to remove the right door.

Figure 1-39 Remove the right door (2 of 2)

2

1

ENWW

Covers and doors

29

Reinstall the right door

Make sure that you correctly position the spring (callout 1) inside the metal chassis (callout 2) when you
reinstall the right door.

Figure 1-40 Reinstall the right door

2

1

30 Chapter 1 Removal and replacement ENWW

Left handle cover

1. Remove the rear cover. See Rear cover on page 24.

2. Release one tab (callout 1), and then slide the cover (callout 2) in the direction indicated to

remove it from the product.

Figure 1-41 Remove the left handle cover

1 2

ENWW

Covers and doors

31

Left inner lower cover

1. Remove the left door. See Left door on page 23.

2. Remove one screw (callout 1), release one tab (callout 2), and then slide the left inner lower cover

(callout 3) in the direction indicated to remove it from the product.

Figure 1-42 Remove the left inner lower cover

1

2

3

32 Chapter 1 Removal and replacement ENWW

Left inner rear cover

1. Remove the following components or assemblies:

Left door. See

●

Rear cover. See

●

Left inner lower cover. See

●

Fuser. See

●

2. Release two tabs (callout 1).

Figure 1-43 Remove the left inner rear cover (1 of 2)

Left door on page 23.

Rear cover on page 24.

Left inner lower cover on page 32.

Fuser on page 48.

1

ENWW

Covers and doors

33

3. Slide the left inner rear cover (callout 1) in the direction indicated to remove the cover from the

product.

Figure 1-44 Remove the left inner rear cover (2 of 2)

1

34 Chapter 1 Removal and replacement ENWW

Left inner front cover

1. Remove the following components or assemblies:

Front cover. See

●

Left door. See

●

Front left lower cover. See

●

Left inner lower cover. See

●

Fuser. See

●

2. On the left side of the product, release one tab (callout 1).

Figure 1-45 Remove the left inner front cover (1 of 2)

Front cover on page 21.

Left door on page 23.

Front left lower cover on page 25.

Left inner lower cover on page 32.

Fuser on page 48.

1

ENWW

Covers and doors

35

3. Inside the product, slide the cover (callout 1) out to remove it from the product.

Figure 1-46 Remove the left inner front cover (2 of 2)

1

36 Chapter 1 Removal and replacement ENWW

Right handle cover

1. Remove the following components or assemblies:

Front cover. See

●

Right rear cover. See

●

Front right lower cover. See

●

Tray 1 cover. See

●

Right door. See

●

2. On the right side of the product, remove one screw (callout 1), release two tabs (callout 2), and

then pull the top of the cover (callout 3) to remove it from the product.

Reinstallation tip You might have to move the cover up and down during reinstallation to

make sure that it is correctly aligned and snaps into place.

Figure 1-47 Remove the right handle cover

Front cover on page 21.

Right rear cover on page 22.

Front right lower cover on page 26.

Tray 1 (multipurpose tray) cover on page 28.

Right door on page 29.

3

1

2

ENWW

Covers and doors

37

Face-down side cover

1. Remove the following components or assemblies:

Front cover. See

●

Face-down cover. See

●

Front upper cover. See .

●

2. On the left side at the front of the product, release one tab (callout 1), and then remove the cover

(callout 2) from the product.

Figure 1-48 Remove the face-down side cover

Front cover on page 21.

Face-down cover on page 27.

Front upper cover on page 39.

2

1

38 Chapter 1 Removal and replacement ENWW

Front upper cover

1. Remove the front cover. See Front cover on page 21.

2. On the front side of the product, release two tabs (callout 1), and then remove the cover (callout 2)

from the product.

Figure 1-49 Remove the front upper cover

2

1

ENWW

Covers and doors

39

Top rear outer cover

1. Remove the rear cover. See Rear cover on page 24.

2. On the rear side of the product, remove one screw (callout 1), and then remove the cover

(callout 2) from the product.

Figure 1-50 Remove the top rear outer cover

2

1

40 Chapter 1 Removal and replacement ENWW

Output upper cover

1. If the product includes a stapler/stacker, remove the stapler/stacker. See Stapler/stacker assembly

on page 211.

2. Open the left door.

3. From the right side of the product, release two tabs (callout 1), and then remove the cover

(callout 2) from the product.

Figure 1-51 Remove the output upper cover (1 of 2)

2

1

The figure below shows the location of the tabs (callout 1).

Figure 1-52 Remove the output upper cover (2 of 2)

1

ENWW

Covers and doors

41

Top rear inner cover

1. Remove the following components or assemblies:

Right rear cover. See

●

Rear pocket cover. See step 1 of

●

Face-down cover. See

●

Output upper cover. See

●

Stapler/stacker (if it is installed). See

●

2. On the rear side of the product, release one tab (callout 1), and then slide the cover (callout 2) in

the direction indicated to remove it from the product.

Figure 1-53 Remove the top rear inner cover

Right rear cover on page 22.

Rear cover on page 24.

Face-down cover on page 27.

Output upper cover on page 41.

Stapler/stacker assembly on page 211.

2

1

42 Chapter 1 Removal and replacement ENWW

Left inner front upper cover

1. Remove the following components or assemblies:

Front cover. See

●

Front upper cover. See

●

Output upper cover. See

●

Stapler-stacker (if it is installed). See

●

2. On the front side of the product, release one tab (callout 1), and then slide the cover (callout 2) in

the direction indicated to remove it from the product.

Figure 1-54 Remove the left inner front upper cover

Front cover on page 21.

Front upper cover on page 39.

Output upper cover on page 41.

Stapler/stacker assembly on page 211.

2

1

ENWW

Covers and doors

43

Left inner rear upper cover

1. Remove the following components or assemblies:

Rear cover. See

●

Top rear outer cover. See

●

Stapler-stacker (if it is installed). See

●

2. On the rear side of the product, release one tab (callout 1), and then slide the cover (callout 2) in

the direction indicated to remove it from the product.

Figure 1-55 Remove the left inner rear upper cover

Rear cover on page 24.

Top rear outer cover on page 40.

Stapler/stacker assembly on page 211.

1 2

44 Chapter 1 Removal and replacement ENWW

Main assemblies

Duplexer or duplex cover

●

Fuser

●

Control panel assembly

●

Paper delivery assembly

●

Registration assembly

●

Transfer roller

●

Paper feed assembly

●

Laser scanner

●

Toner cartridge door

●

Formatter cage assembly

●

Upper cassette pickup assembly

●

Lower cassette pickup assembly

●

Lifter drive assembly

●

Main drive assembly

●

Fuser drive assembly

●

ENWW

Main assemblies

45

Duplexer or duplex cover

Remove the duplexer

NOTE: If the product is equipped with a duplexer, complete the following steps.

1. At the left side of the product, pull out the duplexer until it stops.

Figure 1-56 Remove the duplexer (1 of 2)

2. Lift up the duplexer and slightly pull it toward you to remove it.

Figure 1-57 Remove the duplexer (2 of 2)

46 Chapter 1 Removal and replacement ENWW

Remove the duplexer cover

NOTE: If the product does not have a duplexer, complete the following steps.

1. On the left side of the product, place a finger in the notch (callout 1) at the bottom of the cover.

Figure 1-58 Remove the duplex cover

1

2. Pull the cover (callout 1) in the direction indicated to remove it from the product.

Figure 1-59 Remove the duplex cover

1

ENWW

Main assemblies

47

Fuser

1. Remove the following components or assemblies:

Left door. See

●

Duplexer or duplexer access cover. See

●

2. Turn the two latches (callout 1) in the direction indicated, and then pull the fuser (callout 2) straight

out to remove it from the product.

NOTE: On the right side latch, you must reach behind the fuser door retainer to gain access to

the latch.

Figure 1-60 Remove the fuser

Left door on page 23.

Duplexer or duplex cover on page 46.

2

1

48 Chapter 1 Removal and replacement ENWW

Control panel assembly

1. On the front side of the product, tilt the control panel up away from the product, remove two

thumb-screws (callout 1), and then slide the control panel away from the product.

Figure 1-61 Remove the control panel (1 of 2)

1

2. On the underside of the control panel, disconnect two connectors (callout 1) to remove the control

panel from the product.

Figure 1-62 Remove the control panel (2 of 2)

1

ENWW

Main assemblies

49

Paper delivery assembly

1. Remove the following components or assemblies:

Face-down cover. See

●

Fuser. See

●

2. At the top of the product near the left side, disconnect one connector (callout 1).

Figure 1-63 Remove the paper delivery assembly (1 of 2)

Fuser on page 48.

Face-down cover on page 27.

1

50 Chapter 1 Removal and replacement ENWW

3. Remove four screws (callout 1), and then pull the paper delivery assembly (callout 2) straight out to

remove it from the product.

CAUTION: When holding the paper delivery assembly, do not touch the static eliminators.

Figure 1-64 Remove the paper delivery assembly (2 of 2)

1

2

ENWW

Main assemblies

51

Install a replacement paper delivery assembly

If you are replacing the paper delivery assembly, remove the output upper cover, link, and lever, and
then install them on the replacement assembly.

1. Release two tabs (callout 1), and then remove the output upper cover (callout 2).

Figure 1-65 Install a replacement paper delivery assembly (1 of 3)

1

2

2. Release one tab (callout 1).

Figure 1-66 Install a replacement paper delivery assembly (2 of 3)

1

52 Chapter 1 Removal and replacement ENWW

3. Remove the link (callout 1) and the lever (callout 2).

Figure 1-67 Install a replacement paper delivery assembly (3 of 3)

2

1

ENWW

Main assemblies

53

Registration assembly

1. Open the toner cartridge door.

2. Before proceeding, use the following two figures to locate the left and right registration mounting

screws.

Figure 1-68 Registration assembly left screw

Figure 1-69 Registration assembly right screw

54 Chapter 1 Removal and replacement ENWW

3. From the right side of the product, remove two screws (callout 1).

Figure 1-70 Remove the registration assembly (1 of 2)

1

4. Carefully pull the registration assembly (callout 1) out of the product.

Figure 1-71 Remove the registration assembly (2 of 2)

ENWW

1

Reinstallation tip When reassembling the registration assembly, make sure that the hooks (callout1)

on the rear side of assembly are seated in the slits (callout 2) on both sides. See the following figure.

Main assemblies

55

Figure 1-72 Reinstalling the registration assembly

121

1

2

56 Chapter 1 Removal and replacement ENWW

Transfer roller

1. Open the toner cartridge door.

2. On the right end of the roller, pull up on the tab (callout 1) to loosen the roller (callout 2), and then

remove the roller from the product.

Figure 1-73 Remove the transfer roller

1

2

ENWW

Main assemblies

57

Paper feed assembly

1. Remove the following components or assemblies:

Fuser. See

●

Registration assembly. See

●

Transfer roller. See

●

2. On the right side of the product, release one tab (callout 1).

Figure 1-74 Remove the paper feed assembly (1 of 4)

Fuser on page 48.

Registration assembly on page 54.

Transfer roller on page 57.

1

3. Hold up the right side of the paper feed assembly (callout 1).

Figure 1-75 Remove the paper feed assembly (2 of 4)

1

58 Chapter 1 Removal and replacement ENWW

4. Beneath the paper feed assembly (callout 1), remove the connector cover (callout 2) by pulling the

rear part of the cover up and toward you to release the front part of the cover.

Figure 1-76 Remove the paper feed assembly (3 of 4)

2

1

Reinstallation tip When reinstalling the connector cover, insert the front side (callout 1) first,

and then press down on the rear end (callout 2) of the cover to snap it in place.

Figure 1-77 Reinstall the connector cover

2

1

ENWW

Main assemblies

59

5. Slide the paper feed assembly (callout 1) in the direction indicated to remove it from the product.

Figure 1-78 Remove the paper feed assembly (4 of 4)

1

Reinstallation tip When reinstalling the paper feed assembly, turn the shutter (callout 1) frontward

so that the high-voltage power supply assembly (callout 2) is not damaged.

Figure 1-79 Reinstall the paper feed assembly (1 of 2)

1

2

Reinstallation tip When reinstalling the paper feed assembly, make sure that the pins (callout 1)

on the rear side of the paper feed assembly are seated in the grooves on the high-voltage power supply
assembly. The following figure shows the view from the left side of the product.

60 Chapter 1 Removal and replacement ENWW

Figure 1-80 Reinstall the paper feed assembly (2 of 2)

1

ENWW

Main assemblies

61

Laser scanner

1. Remove the face-down cover. See Face-down cover on page 27.

2. Remove the foam anti-static pad (callout 1) from the laser scanner.

Figure 1-81 Remove the laser scanner (1 of 3)

1

3. Disconnect one flat flexible cable (callout 1) and two connectors (callout 2), and then release the

cables from the cable guides (callout 3).

Figure 1-82 Remove the laser scanner (2 of 3)

3

1

2

62 Chapter 1 Removal and replacement ENWW

4. Remove four screws (callout 1), and then remove the laser scanner (callout 2) from the product.

NOTE: If the stapler-stacker is installed, you will need a 38 mm (1.5 in) short-shaft screwdriver

with a magnetic-tip to remove the screws. Or you can remove the stapler/stacker output bin. See

Stapler/stacker output bin assembly on page 197.

Figure 1-83 Remove the laser scanner (3 of 3)

2

1

ENWW

Main assemblies

63

Toner cartridge door

1. Remove the following components or assemblies:

Front cover. See

●

Right rear cover. See

●

Tray 1 (multipurpose tray) cover. See

●

Right door. See

●

2. Open the toner cartridge door.

3. Inside the door, use needle-nose pliers to release one tab (callout 1), and then release the link arm

(callout 2).

Figure 1-84 Remove the toner cartridge door (1 of 6)

Front cover on page 21.

Right rear cover on page 22.

Tray 1 (multipurpose tray) cover on page 28.

Right door on page 29.

2

1

64 Chapter 1 Removal and replacement ENWW

4. Release one tab (callout 1), and then remove the pin (callout 2) from the door linkage.

CAUTION: Be careful not to break the tab off of the pin.

Figure 1-85 Remove the toner cartridge door (2 of 6)

2

1

5. To the right of the door, disconnect two connectors (callout 1), and then release the cables

(callout 2) from the cable guide.

Figure 1-86 Remove the toner cartridge door (3 of 6)

1

2

ENWW

Main assemblies

65

6. While partially closing the cartridge door (callout 1), pull the link arm (callout 2) in the direction

indicated and release it from the notch in the cartridge door.

Figure 1-87 Remove the toner cartridge door (4 of 6)

1

2

7. Remove four screws (callout 1).

Figure 1-88 Remove the toner cartridge door (5 of 6)

1

66 Chapter 1 Removal and replacement ENWW

8. Slide the cartridge door assembly (callout 1) in the direction indicated to remove it from the

product.

Figure 1-89 Remove the toner cartridge door (6 of 6)

1

Reinstallation tip When reinstalling the cartridge door, insert the pin (callout 1) pointing as shown

in the following figure while the cartridge door is open.

Figure 1-90 Reinstall the cartridge door assembly (1 of 2)

1

Reinstallation tip When reinstalling the cartridge door, wind the cable (callout 1) around the cable

guide counter-clockwise and run through the groove (callout 2) before connecting it as shown in the
following figure.

ENWW

Main assemblies

67

Figure 1-91 Reinstall the cartridge door assembly (2 of 2)

2

1

68 Chapter 1 Removal and replacement ENWW

Formatter cage assembly

1. Remove the following components or assemblies:

Rear cover. See

●

Formatter. See

●

2. On the rear side of the product, disconnect two connectors (callout 1), one flat flexible cable

(callout 2), and then five connectors at the top of the assembly (callout 3).

Figure 1-92 Remove the formatter cage (1 of 2)

Rear cover on page 24.

Formatter PCA on page 114.

3

1

2

3. Remove three screws (callout 1), and then lift up the bottom of the formatter cage (callout 2) to

remove it from the product.

Figure 1-93 Remove the formatter cage (2 of 2)

1

2

ENWW

Main assemblies

69

Upper cassette pickup assembly

1. Remove the following components or assemblies:

Front cover. See

●

Right rear cover. See

●

Rear cover. See

●

Tray 1 (multipurpose tray) cover. See

●

Right door. See

●

Toner cartridge door. See

●

Formatter cage. See

●

2. Remove three screws (callout 1), and then remove the gear assembly (callout 2).

Figure 1-94 Remove the upper cassette pickup assembly (1 of 4)

Front cover on page 21.

Right rear cover on page 22.

Rear cover on page 24.

Tray 1 (multipurpose tray) cover on page 28.

Right door on page 29.

Toner cartridge door on page 64.

Formatter cage assembly on page 69.

1

2

70 Chapter 1 Removal and replacement ENWW

3. Disconnect two connectors (callout 1), release the cables (callout 2) from the cable guide, remove

the C-clip (callout 3) from the clutch shaft, and then pull the upper cassette pickup clutch (callout 4)
to remove it from the product.

Figure 1-95 Remove the upper cassette pickup assembly (2 of 4)

1

3

4

2

4. Release one tab (callout 1), and then remove the gear cover (callout 2).

Figure 1-96 Remove the upper cassette pickup assembly (3 of 4)

1

2

ENWW

Main assemblies

71

5. Remove four screws (callout 1), and then pull the upper cassette pickup assembly (callout 2) to

remove it from the product.

Figure 1-97 Remove the upper cassette pickup assembly (4 of 4)

1

2

72 Chapter 1 Removal and replacement ENWW

Lower cassette pickup assembly

1. Remove the following components or assemblies:

Right rear cover. See

●

Rear cover. See

●

Tray 1 (multipurpose tray) cover. See

●

Right door. See

●

Formatter cage. See

●

2. Remove three screws (callout 1), and then remove the gear assembly (callout 2).

Figure 1-98 Remove the lower cassette pickup assembly (1 of 3)

Right rear cover on page 22.

Rear cover on page 24.

Tray 1 (multipurpose tray) cover on page 28.

Right door on page 29.

Formatter cage assembly on page 69.

1

2

ENWW

Main assemblies

73

3. Disconnect two connectors (callout 1) (J43), release the cables (callout 2) from the cable guide,

remove the C-clip (callout 3) from the clutch shaft, and then pull the lower cassette pickup clutch
(callout 4) to remove it from the product.

Figure 1-99 Remove the lower cassette pickup assembly (2 of 3)

1

2

3

4

4. Remove four screws (callout 1), and then pull the lower cassette pickup assembly (callout 2) to

remove it from the product.

Figure 1-100 Remove the lower cassette pickup assembly (3 of 3)

1

2

74 Chapter 1 Removal and replacement ENWW

Lifter drive assembly

1. Remove the following components or assemblies:

Rear cover. See

●

Formatter cage. See

●

Low-voltage power supply. See

●

2. Disconnect three connectors (callout 1), and then release the cables (callout 2) from the cable

guide.

Figure 1-101 Remove the lifter driver assembly (1 of 2)

Rear cover on page 24.

Formatter cage assembly on page 69.

Low-voltage power supply assembly on page 119.

1

2

ENWW

Main assemblies

75

3. Remove four screws (callout 1), and then remove the lifter drive assembly (callout 2) from the

product.

Figure 1-102 Remove the lifter driver assembly (2 of 2)

1

2

76 Chapter 1 Removal and replacement ENWW