Paper feeder ..........................................................................................................................197 Pickup/delivery sequence ...............................................................................................198 Paper jam detection ........................................................................................................199 6 Removal and replacement Chapter contents ...................................................................................................................201 Introduction ............................................................................................................................204 Removal and replacement strategy ................................................................................204 Repair notices .................................................................................................................204 Caution regarding electrostatic discharge (ESD) ...........................................................204 Required tools .................................................................................................................204 Types of screws ..............................................................................................................205 Supplies .................................................................................................................................207 Print cartridges and transfer unit ....................................................................................208 Covers ...................................................................................................................................209 Front door removal .........................................................................................................209 Left cover removal ..........................................................................................................210 Left front cover removal ..................................................................................................211 Right cover removal ........................................................................................................213 Top cover removal ..........................................................................................................214 Upper rear door removal ................................................................................................214 Rear cover removal ........................................................................................................215 Lower rear door (rear output bin) removal .....................................................................215 Tray 1 (multipurpose) removal .......................................................................................216 Main Assemblies ...................................................................................................................217 Transfer unit removal ......................................................................................................218 Print cartridge removal ...................................................................................................219 Fuser removal .................................................................................................................220 Face-down delivery assembly removal ..........................................................................221 Laser/scanner assembly removal ...................................................................................222 Image drive assembly removal .......................................................................................223 Developing engaging drive assembly removal ...............................................................225 Pick-up/feed assembly removal .....................................................................................225 Main assembly parts .............................................................................................................236 Tray 1 pick-up roller removal ..........................................................................................237 Tray 1 separation pad removal .......................................................................................237 Tray 2 pick-up roller removal ..........................................................................................238 Tray 2 separation pad removal .......................................................................................238 Secondary transfer charging roller removal ...................................................................239 Fuser sleeve unit removal ..............................................................................................239 Pressure roller removal ..................................................................................................239 Main thermistor/sub-thermistor removal .........................................................................239 Thermoswitch removal ...................................................................................................239 Feed guide unit removal .................................................................................................240 Swing guide removal, right .............................................................................................242 Swing guide removal, left ...............................................................................................245 Switches ................................................................................................................................250 Door Switch (SW1) removal ...........................................................................................250 Test print switch (SW1001) removal ..............................................................................251 Power switch (SW3001) removal ...................................................................................251 Sensors .................................................................................................................................252 Tray 1 (multipurpose tray) paper sensor (PS1) removal ................................................253 Tray 2 (cassette) paper sensor (PS2) removal ..............................................................253 Registration paper sensor (PS4) removal ......................................................................254 Media sensor (PS5) removal ..........................................................................................255 viii ENWW