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Repair Manual

1 Removal and replacement .............................................................................................................................. 1
Removal and replacement strategy ...................................................................................................................... 2
Introduction ......................................................................................................................................... 2
Required tools ..................................................................................................................................... 2
Types of screws ................................................................................................................................... 3
Service approach ................................................................................................................................................... 4
Before performing service .................................................................................................................. 4
After performing service ..................................................................................................................... 4
Parts removal order ............................................................................................................................ 4
Removal and replacement procedures ................................................................................................................. 5
Customer-replaceable parts ............................................................................................................... 5
Toner cartridge ................................................................................................................. 5
Input tray ........................................................................................................................... 6
Short-media extender ...................................................................................................... 7
Pickup roller ...................................................................................................................... 7
Separation pad ................................................................................................................ 10
Handset (M128fp model only) ........................................................................................ 11
Covers and external components ..................................................................................................... 12
Paper-delivery tray (output bin extension) ................................................................... 12
Left cover ........................................................................................................................ 13
Remove the left cover .................................................................................. 13
Scanner assembly ........................................................................................................... 14
Remove the scanner assembly .................................................................... 14
Cartridge door ................................................................................................................. 17
Remove the cartridge door .......................................................................... 17
Front cover and control-panel assembly ....................................................................... 19
Remove the front cover ............................................................................... 19
Remove the control-panel assembly ........................................................... 22
Right cover ...................................................................................................................... 24
Remove the right cover ................................................................................ 24
Top cover and image scanner lock ................................................................................. 27
Remove the top cover and image scanner lock ........................................... 27
Rear cover ....................................................................................................................... 29
Remove the rear cover ................................................................................. 29
Reinstall the rear cover ................................................................................ 30
Main assemblies ................................................................................................................................ 31
Transfer roller ................................................................................................................. 31
Left-side PCAs ................................................................................................................. 33
Wireless PCA (wireless models only) ........................................................... 35
Formatter PCA .............................................................................................. 37
Fax PCA (fax models only) ............................................................................ 42
Laser scanner assembly and cable ................................................................................. 43
Remove the laser scanner assembly and cable ........................................... 43
Motor PCA and motor ...................................................................................................... 45
Remove the motor PCA and motor .............................................................. 45
Engine controller PCA ..................................................................................................... 51
Remove the engine controller PCA .............................................................. 51
Reinstall the engine controller PCA ............................................................. 57
Fuser and delivery sensor PCA ....................................................................................... 60
Remove the fuser and delivery sensor PCA ................................................. 60
Reinstall the fuser ........................................................................................ 62
Pickup assembly and pickup sensor PCA ....................................................................... 64
Remove the pickup assembly and pickup sensor PCA ................................ 64
Reinstall tips for the grounding spring and lifting plate ............................. 66
Scanner and document feeder components .................................................................................... 69
Separate the scanner lid or document feeder from the scan base ............................... 69
Scanner components ...................................................................................................... 71
Scan bezel ..................................................................................................... 71
Scan drive system ........................................................................................ 73
Scan FFC cable .............................................................................................. 74
Scan motor ................................................................................................... 76
Scanner spring assembly ............................................................................. 78
Document feeder components ....................................................................................... 80
Document feeder (ADF) top cover ................................................................ 80
ADF core ........................................................................................................ 81
ADF separation pad ...................................................................................... 82
ADF inner tray ............................................................................................... 86
ADF input guides and gear ........................................................................... 86
ADF pre-pickup arm assembly ..................................................................... 89
2 Parts and diagrams ...................................................................................................................................... 91
Order parts by authorized service providers ...................................................................................................... 92
Order replacement parts ................................................................................................................... 92
Related documentation .................................................................................................................... 92
Supplies part numbers ...................................................................................................................... 92
Customer replaceable units (CRU) kit part numbers ........................................................................ 93
Whole-unit replacement part numbers ............................................................................................ 94
How to use the parts lists and diagrams ............................................................................................................. 95
Covers and external components ....................................................................................................................... 96
Internal assemblies ............................................................................................................................................. 98
Internal assemblies (1 of 3) .............................................................................................................. 98
Internal assemblies (2 of 3) ............................................................................................................ 100
Internal assemblies (3 of 3) ............................................................................................................ 102
Scanner and document feeder components ..................................................................................................... 104
Scanner lid, base models ................................................................................................................ 104
Scanner assembly, base models .................................................................................................... 106
Scan drive system, all models ........................................................................................................ 108
Scanner and document feeder assembly, fax models ................................................................... 110
Scanner assembly, fax models ....................................................................................................... 112
Document feeder assembly, fax models ........................................................................................ 114
Document feeder top cover, fax models ........................................................................................ 116
Document feeder core, fax models ................................................................................................ 118
Alphabetical parts list ....................................................................................................................................... 120
Numerical parts list ........................................................................................................................................... 124
Index ........................................................................................................................................................... 129
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