How to Remove and Replace the Second Pass Roller Assembly

How to remove the PIU (Paper Input Unit) from the printer and then disassemble it to remove and replace the Second Pass Roller assembly.

Follow the instructions in the order listed to remove the PIU from the printer and then remove and replace the Second Pass Roller assembly.

PIU removal instructions:
Remove Tray 2 and Tray 3. Remove both trays to prevent damage to the PIU plastic sensor flags.
Remove front cover
Remove the back cover.
Remove the Tray 1 pickup assembly.
Remove the right lower door assembly.
Remove four screws, see the figure below, call-out 1.
Slide the assembly out from the chassis approximately three inches, and unplug the connector inside the right end, see the figure below, call-out 2.
Continue sliding the assembly out of the chassis.

Figure 1: Paper Input Unit (PIU)

1 - Four screws

2 - Unplug connector

Disassembling the PIU

WARNING: The PIU has sharp metal edges; use caution in disassembly
Set the PIU on a flat surface with the printed circuit assembly (PCA) facing you, with Tray 2 and Tray 3 feed and separation rollers on the right.

Locate and identify the second-pass roller assembly (Figure 1) on the top of the PIU below the number three jam clearance plate. This is the plate with the number 3 on it.

Figure 2: Identifying the second-pass roller assembly

Detach the cable going from the top of the PCA to the clutch, which is attached to the left end of the second-pass roller assembly.

Loosen the PCA from the tabs that hold it to the side of the PIU, and remove one screw that holds the PCA in place. It is not necessary to loosen any other cables.

Removing E rings, clutch, and gear assembly
Use a small flat-bladed screwdriver to remove the E ring that holds the second-pass clutch and gear.

The clutch is prevented from rotating by a white arrow-shaped plastic part. Locate and remove this part by applying pressure to the rear of the part through the top of the PIU.

Remove the clutch and gear assembly.

Remove the E ring (Figure 2) and the gear that is to the right of the second-pass roller assembly.

Remove the E ring and the gear on the end of the second-pass roller assembly.

Figure 3: Removing the E ring and gear

Remove the E ring on the opposite end of the second-pass roller assembly (Figure 3).

Figure 4: Removing the E ring (on the opposite end)

Removing the second-pass roller assembly

NOTE: Replacement of the second-pass roller is done only as a repair to the PIU. If replacing the PIU, replacement of the second-pass roller assembly is not necessary.

Position the PIU with the PCA on the left and the second-pass roller assembly directly in front of you.

Slide the bushings off each end of the roller assembly.

Remove the roller assembly (Figure 4) by first sliding it to the left to clear the right side support, then lifting up and to the right.

Figure 5: Removing the roller assembly

Install the new roller assembly, and replace the components in the reverse order of removal.

Reinstall the PIU in the reverse order from the directions listed above.

After reassembly, run a paper path test for Trays 2, 3, 4, and 5, if applicable to verify repair.

© 2005 Hewlett-Packard