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Printhead removal, installation, and adjustment

The instructions below will assist you in removing the printhead, installing the printhead, adjusting the registration (black), and aligning the color planes of the printer.

Verifying the printhead

Before you begin, you can verify that the printhead is the failing FRU by following this procedure:

1. Turn the printer off, and remove the power cord from the outlet. Remove all cords and cables from the printer before beginning.

2. Place the printer on a corner of a work area so the front and back can be accessed.

Section Page

Verifying the printhead 1

Removing the printhead 3

Installing and coarse aligning the printhead 11

Aligning the printhead 14

Dual diode alignment 14

Registration (black) 15

Color alignment (cyan, yellow, and magenta)

15

CAUTION—POTENTIAL INJURY:

The printer weight is greater than 32 kg (70 lb), and requires three or more trained personnel to lift it safety.

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3. Remove the system board shield:a. Open the system board shield door, and remove six screws (A) from the system board shield.

a. Swing the shield open about an inch, and slide the shield to the left to remove the shield.

A (27S2839)

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4. Carefully unplug the printhead cables (B) from the system board, and carefully connect the cables from the new printhead to the system board. Use the packaging that came with the printhead FRU to prop up the printhead.

5. Connect the power cord to the outlet and to the printer. Reconnect any cords.6. Turn on the printer, and check for the error message:

• If the error still appears, replace the system board.• If the error no longer appears, replace the printhead.

Removing the printhead

1. Turn the printer off.2. Disconnect the power cord from the electrical outlet and from the printer.

CAUTION—Possible eye damage.

Do not look at the printhead laser while it is turned on. Always point the printhead laser down into the packaging as shown. The laser can cause damage to your eyesight or the eyesight of others.

B

CAUTION

Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.

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3. Remove the rear upper cover:a. Open the system board shield door, and remove three screws (A).

b. Pull the left side out, and then remove the system board shield door to remove the rear upper cover.

A (88A0213)

1

2

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4. Remove the system board shield:a. Open the system board shield door, and remove six screws (A) from the system board shield.

a. Swing the shield open about an inch, and slide the shield to the left to remove the shield.

A (27S2839)

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5. Remove the scanner rear cover and the system board upper shield:a. Remove the four screws (A) and screw (B).

b. Tilt the cover up and pull to remove it.c. Remove four screws (B) to remove the system board upper shield.

A (88A0232)

B (88A0323)

B (88A0232)

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6. Use a screwdriver to pry up the bottom of the AIO option cover, and pull to remove it.Note: If you have any output options installed, then the AIO option cover is already removed. Remove the output options and HTU redrive unit instead.

7. Remove the printhead access cover and AIO rear scanner cover:a. Remove three screws (A), and lift to remove the prinhtead access cover.

A (88A0323)

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8. Remove the AIO rear scanner cover:a. Remove the screw (A) from the rear of the printer.

b. Pivot the AIO rear scanner cover forward, and then slide to remove it.

A (88A0322)

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9. Disconnect the three printhead cables (A) from the system board, and feed the cables through the slot in the system board cage.

A

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10. Remove six screws (B) from the brackets, and remove the brackets.

c. Tilt the printhead forward and lift to remove it.

B (10J3568)

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Installing and coarse aligning the printhead

1. Place the printhead into the printer angled forward, sliding the adjustment screws into the slots in the printer frame.

2. Lower the back of the printhead until the post on the back right corner drops into the hole in the printer frame.

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3. Route the three printhead cables (A) through the frame, and then connect them to the system board.Warning: Be careful reconnecting the printhead ribbon cables. Flat ribbon cables can easily be damaged and should be connected gently by hand.

4. Slide the left side of the printhead toward the back of the printer until the bottom of the coarse alignment screw (B) stops against the ridge in the printer frame.

5. Attach the three mounting brackets loosely to the printhead.Note: Do not tighten the six screws in the mounting brackets yet. The printhead needs to be able to move as you align it.

A

B

Enter Diagnostics mode: press and hold and , turn on the printer, and release the buttons when the splash screen appears.From the Diagnostics menu, navigate to:

REGISTRATION > Quick TestAn alignment page prints.Note: If you cannot see the triangles on the top of the test page, go to “Top Margin” on page 15, and adjust the top margin until the traingles are visible.

9. Use a flat-blade screwdriver to adjust the coarse alignment screw (C) until the triangles on the sheet are parallel to the edges of the paper. Turning the screw clockwise moves the left triangles lower and the right triangles higher (tilts the printed image to the left on the page).

10. Reprint the alignment page and continue adjusting the screw until the black plane is aligned.11. Once the black plane is aligned, tighten the screws in the right two printhead brackets (D), and then turn the coarse

alignment screw a half turn counterclockwise.12. Attach the front bracket, and tighten the screws (E).

13. Reprint the alignment page, and adjust the screw if necessary.

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Aligning the printhead

There is one printhead that houses the four color planes. The black plane is aligned to the printer, and the color planes are aligned to black. After you install the printhead and adjust the coarse alignment with the alignment screws, use the Diagnostic menu to fine tune the alignment.

Dual diode alignment1. From the Diagnostics menu, navigate to:

DUAL DIODE ADJUST > Diode Alignment PageAn alignment test page prints.If the alignment is correct, the color bars on the page should look solid in the middle (between 1 and -1) with white lines starting to form near the top and bottom of each bar.

2. If the solid color area of a bar is above 1 or below -1, then adjust the Dual Diode value for that color. Enter the number nearest the center of the solid color area to adjust it. Example: The solid color area on the following test page is closer to -4 than 0. Enter -4 for the value to adjust the position of the solid color area back toward 0.

3. Reprint the alignment page and make adjustments as needed until you are satisfied with the alignment.

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Registration (black)

Top Margin

1. From the Diagnostic menu, navigate to:REGISTRATION > Quick Test

An alignment test page prints.

2. Select Top Margin.3. Adjust the values to move the top alignment marks to the top edge of the page.

• Increasing the value moves the alignment marks toward the edge of the page.• Decreasing the value moves the alignment marks away from the edge of the page.

4. Reprint the test page and make adjustments as needed until you are satisfied with the alignment.

Bottom Margin

1. Select Bottom Margin. 2. Adjust the bottom margin until the points of the bottom margin alignment marks are visible and touching the edge of

the paper.• Increasing the value moves the alignment marks toward the edge of the page.• Decreasing the value moves the alignment marks away from the edge of the page.

3. Reprint the test page and make adjustments as needed until you are satisfied with the alignment.

Left Margin

1. Select Left Margin. 2. Adjust the left margin until the points of the left alignment marks touch the edge of the page.

• Increasing the value moves the alignment marks toward the edge of the page.• Decreasing the value moves the alignment marks away from the edge of the page.

3. Reprint the test page and make adjustments as needed until you are satisfied with the alignment.

Right Margin

1. Select Right Margin. 2. Adjust the right margin until the points of the left alignment marks touch the edge of the page.

• Increasing the value moves the alignment marks toward the edge of the page.• Decreasing the value moves the alignment marks away from the edge of the page.

3. Reprint the test page and make adjustments as needed until you are satisfied with the alignment.4. When the registration is complete, proceed to the color alignment.

Color alignment (cyan, yellow, and magenta)1. Open the front access door, and remove the cyan and magenta toner cartridges.2. Locate the “Color skew adjustment tool” page that came with these instructions.

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To use the skew tool, punch a screwdriver through the center of the wheel. Using a mark on the screwdriver handle as a point of reference, turn the paper until 0 lines up with your mark.

3. From the Diagnostic menu, navigate to:ALIGNMENT MENU > Yellow > Quick Test

Two alignment pages print. The first page is for adjusting the Skew and Top Margin, and the second page is for the Left Margin and Right Margin. For now you just need the Skew instructions on the first page.

4. Holding the skew wheel with the 0 at the mark on your screwdriver, place the screwdriver in the yellow adjustment screw (E) next to the yellow cartridge, and then turn the screwdriver to the number indicated on the alignment page—clockwise for a positive number, counterclockwise for a negative number.

5. Replace all the cartridges, and then reprint the test page and continue adjusting the screw until you are satisfied with the Skew alignment.

6. Repeat steps 3 through 5 to adjust the Skew for cyan and magenta (selecting Cyan and Magenta from the Alignment menu).Note: Do not move on to the Top Margin settings until the Skew A and B values are within +/-1 of 0.

7. From the Diagnostic menu, navigate to:ALIGNMENT MENU > Yellow > Top Margin

8. Set Top Margin to 0, and save the value.9. Do the same for Linearity.

It is important to set the values to 0 before continuing.10. From the Yellow menu, select Quick Test to reprint the alignment pages.

Two pages print. The first page is for adjusting the Skew and Top Margin, and the second page is for the Left Margin and Right Margin.

11. Follow the instructions on the pages to adjust the Top Margin, Left Margin, and Right Margin.Reprint the Quick Test pages and make adjustments as needed until you are satisfied with the alignment.

E

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12. From the Yellow menu, navigate to:Linearity > Quick Test

A test page similar to the following prints:

If the Linearity alignment is correct, the gray stripe near the center of each color on the test page should be within the 12 to -12 range.

13. If the gray stripe extends above 12 or below -12 where it crosses the Left, Center, or Right line, then adjust the Left Adjustment, Center Adjustment, or Right Adjustment for that color. Enter the number closest to where the gray stripe crosses the line.Example: The gray stripe on the following test page extends up to around 16 near the Center line. From the Yellow Linearity menu, enter 16 for the Center Adjustment value to move the gray stripe back toward 0.

14. Repeat the color alignment process for Cyan and Magenta.15. When all the color planes are aligned, replace the toner cartridges, and close the front access door.16. Replace the printhead access cover:

a. Slide the cover into position until the tabs on the right edge latch.b. Replace the three screws.

17. Replace the AIO rear scanner cover:a. Slide the AIO rear scanner cover into place.b. Replace the screw from the rear of the printer.

18. Replace the AIO option cover or the output options and HTU redrive unit.19. Replace the system board shields:

a. Replace the four screws to fasten the system board upper shield.b. Place the left side of the system board shield into position, and then swing the shield closed.c. Replace the four screws.

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20. Replace the scanner rear cover:a. Fit the cover into position with the ADF unit assembly cables in the notches.b. Replace the four screws.

21. Replace the rear upper cover.a. Fit the system board shield door post into the rear upper cover.b. Place the cover and door into position.c. Replace the three screws.