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HP LaserJet and Series Printers TWI Paper Pickup

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HP LaserJet and Series Printers TWI Paper Pickup Powered By Docstoc
					HP LaserJet 4200 and 4300 Series Printers - TWI,
Paper Pickup Assembly, 13.01, 13.02, 13.03, and
13.20 Errors Upon Initial Install
        ___________________________________________________


In this document:


           Tools required
           Parts required (part numbers are subject to change)
           CE Instructions
           Repair and replacement instructions


Introduction
This work instruction will provide information on troubleshooting paper jams errors that can occur
due to the following:

       a broken bushing or 18th gear on the feed roller shaft

       paper feed problems with trays and mechanical assemblies

       when the printer powers up to an error message, due to paper in its path or a paper path
        sensor signalling that there is a paper jam

Perform the following troubleshooting:

    1. Open the tray indicated by the message.
    2. Where is the leading edge of the paper?
    3. Ensure that the separation roller in the cassette tray is seated correctly and springs back
       into place. If the roller is bad, replace it. If the roller does not spring back into place,
       replace the tray.
    4. Clear all paper from the area. If necessary, remove the print cartridge, duplexer, trays,
       stacker, or stapler/stacker accessory.
    5. Open and close the top cover to clear the message.

                CAUTION: Ensure that all jammed paper is removed before closing the cover or
                tray.

    6. If the message persists, check for paper in the entire paper path.
            a. Perform the following troubleshooting with the Tray 1 (multi-purpose tray) 13.03
               errors:
                   i.  Open Tray 1.
                  ii.  Pull out the tray extension.
      iii.   Set the side guides to the correct width. Adjust the side guides so that
             they lightly touch the paper stack but do not bend the paper.
     iv.     Load paper in the tray. Make sure that the paper fits under the tabs and
             below the maximum-height indicators. If paper does not feed or if it only
             feeds in about 2 inches and stops, replace Tray 1 pickup assembly.

                     NOTE: Load paper with the front side facing up and the top,
                     short edge toward the printer.

b. Troubleshoot the 500-Sheet Paper Tray Configuration, replacing the tray if
   necessary.
      i.  Pinch the release that is located on the left guide and slide the side
          guides to the correct paper size. Refer to the following figure.
     ii.  Check left guide, ensuring that it is securely
          locked into place. Refer to the following figure.

             Figure 1: Paper tray guide in locked (in tray)
             and unlocked position (close-up view)




      iii.   Pinch the release that is located on the rear-paper guide and ensure that
             it is securely adjusted to the same paper size as the left guide.
     iv.     On the right side of the tray, turn the knob to
             Standard for LTR (letter), A4, LGL (legal), EXEC
             (executive), A5, or JIS B5 paper. Refer to the
             following figure.

                     NOTE: Turn the knob to Custom for supported custom paper
                     sizes.

             Figure 2: Knob location
               v.    Make sure that the stack is flat at all four corners and that the top of the
                     stack is below the maximum-height indicators.
               vi.   Check the feed/separation/pick rollers for wear, replacing if necessary.
        c. Troubleshoot the Feed Roller Assembly
                 i.  Remove tray.
                ii.  Tug on the feed/roller/feeder shaft, to the left, to see if the shaft falls out
                     of place.
               iii.  If the shaft falls out of place, replace the feed roller assembly bushing
                     and gear.
        d. If Tray 1, paper cassettes, rollers, and the feed roller assembly are ruled out,
            predict the Paper Feed Assembly, Registration Assembly, and Tray 2 Paper
            Pick-up Drive Assembly.
7. If the unit powers up to a 13.1 error message that cannot be cleared, perform the
   following troubleshooting:

             NOTE: This error can also be caused by the failure of the paper level sensor (PS
             107). If this sensor fails, the lifter motor does not rotate to lift the paper tray plate.
             This error can also occur if PS 101 senses paper installed in the tray, when the
             tray is empty.

         .   Open and close the cassette tray to verify that the paper level arm on the front
             cover of the tray is moving as the tray lifts. The dust cover, in the rear of the tray,
             can also be removed in order to observe the tray to see if it lifts into place. If the
                printer displays a READY status and the tray has not lifted, this would indicate that
                PS107 is not sensing the tray lift correctly. The printer will need to be replaced
                because this sensor cannot be replaced.
            a. Another way to check PS107 is to remove the cassette tray. Then press in on the
                paper size sensor springs on the right side of the printer opening. This should
                cause the lifter motor to activate and the lifter drive assembly gear should start
                moving until the paper pickup arm is pushed into the up position. When the paper
                pickup arm is in the up position this will shut off the lifter driver motor. If the lifter
                driver motor comes on, but does not shut off when the paper pickup arm is
                pushed into the up position, PS 107 is not working correctly. In both cases the
                printer will need to be replaced.
            b. To test the PS101 sensor, remove any paper from the paper cassette tray and
                then reinstall the tray. If the unit displays a READY status when the cassette tray
                is empty, this would indicate that PS101 is sensing paper in the tray incorrectly.
                This sensor cannot be replaced and the printer will need to be replaced.
    8. If a 13.20 error appears at power up after the entire paper path has been cleared of
       paper, perform the following steps:
             . Inspect paper path sensors PS102 and PS103 to verify that they are seated and
                moving correctly. PS102 is installed in the paper feed assembly.
            a. Verify that the flag and tension spring are seated correctly.
            b. If the paper feed assembly has been replaced, verify that the flag and spring
                were both moved from the old assembly to the new assembly.
            c. If unable to clear the error on the printer, and both PS102 and PS103 paper path
                flags appear to be working correctly, the printer will need to be replaced.

Tools required
Industry standard tools

        NOTE: Paper path tray sensors, PS102 and PS103, cannot be replaced as that would
        require frame separation.Also, the paper out (PS101) and stack position (PS107) sensors
        cannot be replaced, as that would also require frame separation. The paper path sensor
        flag for PS 102 can be replaced and is located on the paper feed assembly. If replacing
        the paper feed assembly, the PS102 flag and tension spring must be moved from the old
        assembly to the new assembly. If the flag and spring are not moved over to the new
        assembly, the unit will power up to a 13.20 error.

Parts required (part numbers are subject to change)

                                                                               Alternate part
      Part descriptions                          Part number
                                                                                  number
500-sheet tray                        RM1-0028-000CN                           Q2441-69001
                                      RU5-0045-000CN (Gear 18
                                      Tooth, Tray 2)
                                                                               n/a
                                      RU5-0088-000CN, Gear 18
Feed/Roller Assembly                  Tooth (Optional 500-sheet                n/a
                                      feeder)
                                                                               n/a
                                      RC1-0264-000CN, Bushing
                                      Feed Shaft
                                                                          Alternate part
         Part descriptions                    Part number
                                                                             number
Feed/Separation Roller (2
                                    RM1-0037-000CN                        n/a
each per tray)

                                    RM1-0036-000CN                        n/a
Pick Roller (1 each per tray)
Paper Feed Assembly                 RM1-0012-000CN                        n/a
Tray 2 Paper Pick-up Drive
                                    RM1-0034-000CN                        n/a
Assembly
Registration Assembly               RM1-0011-000CN*                       n/a
Tray 1 Pick Roller                  RL1-0019-000CN*                       n/a
Tray 1 Pickup Assembly              RM1-0004-000CN                        n/a
Spring, compression                 RC1-0213-000CN                        n/a
Paper Pick-up Arm (Feed
                                    RC1-0211-000CN                        n/a
Roller Plastic Housings)
Swing Plate                         RL1-0013-000CN                        n/a
23T Gear                            RC1-0371-000CN                        n/a

* denotes optional parts

    1. Open the tray indicated by the message.
    2. Where is the leading edge of the paper?
    3. Ensure that the separation roller in the tray springs back. If not, replace tray.
    4. Clear all paper from the area. If necessary, remove the print cartridge, duplexer, trays,
       stacker, or stapler/stacker accessory.
    5. Open and close the top cover to clear the message.
    6. If the message persists, check for paper in the entire paper path.

                 CAUTION: Ensure that all jammed paper is removed before closing the cover or
                 tray.

             a. Perform the following troubleshooting for Tray paper jam errors:
                   i.  Open Tray 1.
                  ii.  Pull out the tray extension.
                 iii.  Set the side guides to the correct width. Adjust the side guides so that
                       they lightly touch the paper stack but do not bend the paper.
                 iv.   Load paper in the tray. Make sure that the paper fits under the tabs and
                       below the maximum-height indicators. If problems occur with only Tray 1,
                       replace Tray 1 pickup assembly.

                                 NOTE: Load paper with the front side facing up and the top,
                                 short edge toward the printer.

             b. Troubleshoot the 500-Sheet Paper Tray Configuration, replacing the tray if
                necessary.
                   i.  Pinch the release that is located on the left guide and slide the side
                       guides to the correct paper size.
ii.    Check right and left guide, ensuring that it is
       securely snapped into the base of the tray. Refer
       to the following figure.

       Figure 3: Paper tray guide in locked (in tray)
       and unlocked position (close-up view)




iii.   Pinch the release that is located on the rear-paper guide, ensuring that it
       is adjusted to the correct paper size and is locked into place.
iv.    On the right side of the tray, turn the knob to
       Standard for LTR (letter), A4, LGL (legal), EXEC
       (executive), A5, or JIS B5 paper. Refer to the
       following figure.

               NOTE: Turn the knob to Custom for supported custom paper
               sizes.

       Figure 4: Knob location
      v.    Make sure that the stack is flat at all four corners and that the top of the
            stack is below the maximum-height indicators.
      vi.   Check the feed/separation/pick rollers for wear, replacing if necessary.
c. Remove the suspect paper tray (cassette) from the engine/feeder.
d. Try to slide the lifter, side to side, while on the gear train.
e. If the motor slides, then the issue is in fact the lifter motor
   support angle (tray lift motor mounted wrong). On the base unit,
   the sheet metal on the engine itself needs to be bent to a 90
   degree angle (see figure below). On the optional Tray 3 and Tray
   4, the sheet metal will need to be bent into a 90 degree angle on
   the sheet feeders. Follow the instructions in the Service Manual
   for more information about how to access the lifter motor support
   mount.

    Figure 5: Lifter motor support mount
f. If not, take the suspect paper tray (cassette) out.
g. Tug the feed roller/feeder shaft to the left.
h. If it falls out of place, the pick-up assembly is missing a bushing.
   Replace the Bushing Feed Shaft, and the Gear 18 Tooth for Tray
   2 if it was affected, and the Gear 18 Tooth for the Optional 500-
   sheet feeder if it was affected. Refer to the "Repair and
   replacement instructions" below for additional information.
i. If the feed roller/feeder shaft does not fall out, verify that none of the other trays
   are missing a bushing by removing the trays and tugging the feed roller/feeder
   shaft to the left.
j. If the feed roller/feeder shaft does not fall out, replace the tray with a new design
   tolerance failure counter measure tray, when available.

            NOTE: These new trays will be hard-rolled in GSO for replacement
            purposes. The hard roll cassette service part number has rolled from
            RM1-0028-000CN to RM1-0028-060CN.

            NOTE: A single digit in the 500-sheet feeder serial number indicates the
            countermeasure on the feeder. The counter-measured feeders are in the
            following ranges: CNCX100001 and higher or CNCX200001 and higher.
            The non-counter-measured feeders are in the following serial number
            ranges: CNBX1xxxxx or CNBX2xxxxx. The engine serial numbers
            associated with these countermeasures are as follows:

                    110V 4200 (China): CNDXxxxxxx
                    220V 4200 (China): CNFXxxxxxx
                    110V 4300 (China): CNDYxxxxxx
                    220V 4300 (China): CNFYxxxxxx
                    110V 4200 (CVI): USDNxxxxxx
                    220V 4200 (CVI): USFNxxxxxx

            NOTE: The differences in the new trays are:
                                Ribs have been added to the cassette main body to reduce the
                                 gap between the Cassette Main Body and the right guide.
                              The teeth of 14T Gear have been heightened by 0.3mm to
                                 ensure stable engagement between the cassette and the drive
                                 gears.
            k. If paper is stopping in or is not moving through the paper feed and registration
                area, and if the Tray 1 paper pickup assembly, paper cassettes, rollers, and feed
                roller assembly have been ruled out, replace the paper feed assembly, Tray 2
                paper pick-up drive assembly, and the registration assembly.
    7. If the unit powers up to a 13.1 error message that cannot be cleared, perform the
       following troubleshooting:

                 NOTE: This error can also be caused by the failure of the paper level sensor (PS
                 107). If this sensor fails, the lifter motor does not rotate to lift the paper tray plate.
                 This error can also occur if PS 101 senses paper installed in the tray, when the
                 tray is empty.

             .  Open and close the cassette tray to verify that the paper level arm on the front
                cover of the tray is moving as the tray lifts. The dust cover, in the rear of the tray,
                can also be removed in order to observe the tray to see if it lifts into place. If the
                printer displays a READY status and the tray has not lifted, this would indicate that
                PS107 is not sensing the tray lift correctly. The printer will need to be replaced
                because this sensor cannot be replaced.
            a. Another way to check PS107 is to remove the cassette tray. Then press in on the
                paper size sensor springs on the right side of the printer opening. This should
                cause the lifter motor to activate and the lifter drive assembly gear should start
                moving until the paper pickup arm is pushed into the up position. When the paper
                pickup arm is in the up position this will shut off the lifter driver motor. If the lifter
                driver motor comes on, but does not shut off when the paper pickup arm is
                pushed into the up position, PS 107 is not working correctly. In both cases the
                printer will need to be replaced.
            b. To test the PS101 sensor, remove any paper from the paper cassette tray and
                then reinstall the tray. If the unit displays a READY status when the cassette tray
                is empty, this would indicate that PS101 is sensing paper in the tray incorrectly.
                This sensor cannot be replaced and the printer will need to be replaced.
    8. If a 13.20 error appears at power up after the entire paper path has been cleared of
       paper, perform the following steps:
             . Inspect paper path sensors PS102 and PS103 to verify that they are seated and
                moving correctly. PS102 is installed in the paper feed assembly.
            a. Verify that the flag and tension spring are seated correctly.
            b. If the paper feed assembly has been replaced, verify that the flag and spring
                were both moved from the old assembly to the new assembly.
            c. If unable to clear the error on the printer, and both PS102 and PS103 paper path
                flags appear to be working correctly, the printer will need to be replaced.

Repair and replacement instructions
Refer to this section for repair information that is not documented in the Service Manual.


        1.0 - Repair and Replacement instructions for bushing feed shaft
                                                                               1.1 Follow the Service
Figure 6: Location of feed roller gear
                                                                               Manual instructions for
                                                                               removing the Tray 1
      1.0 - Repair and Replacement instructions for bushing feed shaft
                                                       pick-up gear assembly.
                                                       Once the gear
                                                       assembly is removed,
                                                       the feed roller gear is
                                                       exposed.

                                                       1.2. Once the gear
                                                       (shown in Figure 1,
                                                       center) has been
                                                       exposed, lift up the
                                                       little phalange
                                                       attaching the gear to
                                                       the feed roller shaft of
                                                       the while pulling away
                                                       from the chassis of the
                                                       printer.




Figure 7: Close-up of gear




                                                       1.3. Remove the
                                                       bushing from the
                                                       bushing feed shaft.
Figure 8: Location of bushing
                                                              NOTE: The
                                                              bushing may be
                                                              missing and/or
                                                              broken.
       1.0 - Repair and Replacement instructions for bushing feed shaft
                                                                          NOTE:
                                                                          Stop at
                                                                          this step
                                                                          to replace
                                                                          the gear
                                                                          and the
                                                                          bushing
                                                                          only. If the
                                                                          pick-up
                                                                          and feed
                                                                          roller
                                                                          assembly
                                                                          (inside the
                                                                          tray
                                                                          cavity)
                                                                          has to
                                                                          come
                                                                          apart,
                                                                          continue
                                                                          to Step
                                                                          1.4.
Figure 9: Outside view of feed roller shaft with bushing
and gear removed




                                                           1.4. The shaft will have
                                                           to be shifted to the left
                                                           to begin removal from
                                                           the chassis of the
                                                           printer.




                                                           1.5. Locate the feed
                                                           roller shaft (metallic
Figure 10: Internal location of feed roller shaft and
                                                           bar) and it's attached
plastic housing
                                                           black plastic housing
                                                           from within the chassis
                                                           of the printer.
       1.0 - Repair and Replacement instructions for bushing feed shaft




                                                          1.6. Grasp the feed
Figure 11: Left side alignment of feed roller shaft,
                                                          roller shaft and begin
during removal
                                                          guiding it to your left,
                                                          into a notch in the
                                                          opposite side of the
                                                          chassis. This allows the
                                                          right side of the shaft
                                                          to clear the opening
                                                          that it was previously
                                                          installed in.

                                                          Three parts are now
                                                          free to be removed.

                                                                Feed roller shaft
                                                                 and two gear
                                                                 assembly
                                                                 (comes out
                                                                 together)

                                                                Plastic housing
                                                                 for pick-up
                                                                 assembly

Figure 12: Chassis view with feed roller shaft, plastic
                                                                Compression
housing, and compression spring removed
                                                                 spring
       1.0 - Repair and Replacement instructions for bushing feed shaft




Figure 13: Inserting feed roller shaft into plastic
housing




                                                        1.7. Slide the feed
                                                        roller shaft into the
                                                        sleeve of the plastic
                                                        housing. While sliding
                                                        the shaft through,
                                                        ensure that the plastic
                                                        cut-out on the gear
                                                        assembly fits over the
                                                        locator peg on the
                                                        plastic housing.




                                                        1.8. Ensure that the
                                                        spring is snugly
                                                        secured by the bump
Figure 14: Spring to chassis alignment
                                                        protruding from the
                                                        sheet metal of the
                                                        chassis above the
                                                        paper sensor flap.
      1.0 - Repair and Replacement instructions for bushing feed shaft




                                                           1.9. With the spring in
Figure 15: Installing shaft, spring, and plastic housing   place, slide the shaft
                                                           through the plastic
                                                           housing and chassis of
                                                           the printer while
                                                           aligning the fin on the
                                                           back side of the plastic
                                                           housing with the tray
                                                           lift sensor shown in
                                                           Figure 10.

                                                           1.10. Install the
                                                           washer and the
                                                           bushing that were
                                                           previously installed on
                                                           the outside of the
                                                           chassis.

                                                           1.11. Refer to the
                                                           Service Manual for
                                                           additional instructions
                                                           regarding the
                                                           reassembly of the rest
                                                           of the printer.
2.0 - Repair and Replacement instructions for tray 1 paper-pickup assembly
                                                                   NOTE: Paper
Figure 16: Tray 1 pickup assembly (1 of 4)                         path tray
                                                                   sensors, PS102
                                                                   and PS103,
                                                                   cannot be
2.0 - Repair and Replacement instructions for tray 1 paper-pickup assembly
                                                              replaced as that
                                                              would require
                                                              frame
                                                              separation.Also,
                                                              the paper out
                                                              (PS101) and
                                                              stack position
                                                              (PS107)
                                                              sensors cannot
                                                              be replaced, as
                                                              that would also
                                                              require frame
                                                              separation. The
                                                              paper path
                                                              sensor flag for
                                                              PS 102 can be
                                                              replaced and is
                                                              located on the
                                                              paper feed
                                                              assembly. If
                                                              replacing the
                                                              paper feed
                                                              assembly, the
                                                              PS102 flag and
                                                              tension spring
                                                              must be moved
                                                              from the old
                                                              assembly to the
                                                              new assembly.
                                                              If the flag and
                                                              spring are not
                                                              moved over to
                                                              the new
                                                              assembly, the
                                                              unit will power
                                                              up to a 13.20
                                                              error.

                                                       2.1. Remove the
                                                       following assemblies:

                                                             Top, right-
                                                              side, and left-
                                                              side covers.

                                                             Tray 1.

                                                       2.2. Unplug the tray
                                                       1 pickup solenoid
                                                       connector and the
                                                       top-cover sensor
                                                       from the DC
2.0 - Repair and Replacement instructions for tray 1 paper-pickup assembly
                                                       controller PCA
                                                       (locations J79 and
                                                       J95; callout 1).

                                                       2.3. Unweave the
                                                       harnesses from the
                                                       wire guide (callout
                                                       2).

                                                              NOTE: It might
                                                              be necessary to
                                                              remove
                                                              additional wire-
                                                              harnesses from
                                                              the wire guide
                                                              to gain access
                                                              to the solenoid
                                                              and sensor
                                                              harnesses.
Figure 17: Tray 1 pickup assembly (2 of 4)


                                                       2.4. Remove three
                                                       screws (callout 3).

                                                       2.5. Depress the
                                                       pickup-gear-cover
                                                       upper retainer tab
                                                       (callout 4) to release
                                                       it.

                                                       2.6. Lift up on the
                                                       cover to release the
                                                       lower retaining tab
                                                       (not shown).

                                                       2.7. Remove the
                                                       cover.




                                                       2.8. Unplug the
                                                       pickup sensor
                                                       connector (callout
                                                       5).
Figure 18: Tray 1 pickup assembly (3 of 4)
                                                       2.9. Remove six
                                                       screws (callout 6).

                                                              NOTE: One of
2.0 - Repair and Replacement instructions for tray 1 paper-pickup assembly
                                                              the screws
                                                              (callout 7) on
                                                              the left side is
                                                              longer that the
                                                              others. Make
                                                              sure that this
                                                              screw is
                                                              replaced in the
                                                              same hole it is
                                                              removed from.
                                                              CAUTION:
                                                              Carefully thread
                                                              the solenoid
                                                              wire-harness
                                                              through the
                                                              hole provided in
                                                              the chassis.
                                                              When you
                                                              remove the
                                                              pickup
                                                              assembly, avoid
                                                              pinching the
                                                              pickup solenoid
                                                              wire-harness
                                                              between the
                                                              assembly and
                                                              the chassis.

Figure 19: Tray 1 pickup assembly (4 of 4)             2.10. Rotate the left
                                                       side of the assembly
                                                       away from the
                                                       chassis and then
                                                       slide the assembly to
                                                       the left to remove it.

                                                       2.11. Carefully feed
                                                       the pickup assembly
                                                       solenoid wire-
                                                       harness through the
                                                       opening in the
                                                       chassis as you
                                                       remove the
                                                       assembly.

                                                              NOTE: When
                                                              you install the
                                                              pickup
                                                              assembly, verify
                                                              that the
                                                              grounding
                                                              spring (located
                                                              on the right-side
Figure 20: Correct position of the Tray 1 pickup              of the assembly
2.0 - Repair and Replacement instructions for tray 1 paper-pickup assembly
assembly grounding spring                                     near the drive
                                                              gear) is
                                                              correctly
                                                              positioned
                                                              against the
                                                              dimple in the
                                                              chassis.