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HP PageWide Enterprise Color 556/ MFP 586 series - Output Bin Full &
Stuck Output Flap
c05331561 | For HP And Channel Partner Internal Use
Last Modified: 2016-11-14

Issue:
Customers report seeing a Output Bin Full message on control panel and the exit flap door stuck. This issue can occur when opening or
closing the door, or when turning on the printer, or printing.

Cause:
A bowed sheet metal frame causes the plastic cover to bow and interfere with the output flap. This prevents the output flap door from opening.

The output flap might be warped as well.

Serial number range for affected units:

CN65Kxxxxx

CN65Uxxxxx

CN666xxxxx

CN66Bxxxxx

CN66Dxxxxx

CN66Fxxxxx

CN66Lxxxxx

Solution:
Order part # D3Q24-67004 - SERVICE ASSEMBLY - Output Flap / Sensor Kit

The kit includes the following parts:

Figure : Output Flap Assembly

Figure : Shims

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Use the following instructions and recommendations to solve this issue.

1. Turn off the printer and unplug all the cables.

Remove scanner base cover

1. Insert a flat blade screwdriver tip into pocket as shown.

2. Rotate the screwdriver handle up to release the cover.

3. Carefully pull out the cover. It may be necessary to gently wiggle the left end of the cover to help it come loose.

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Remove the output cover.

1. Use a screwdriver to pry out the center of the output flap. Grab the flap with one finger so that the flap remains pulled outward after the
screwdriver is removed.

2. While continuing to pull out on the center of the flap, remove the right side of the flap by pressing in and sliding the retention pin out of its
holder.

Release the pressure on the cover so that the flap is flat again.

3. Hold cover at both ends as shown. Rotate the cover up about 45 degrees and slide the output door towards the rear to release the front pin.

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CAUTION:
Do not force the part out. It will come free easily when positioned at the 45 degree angle as shown in the images.

Install the shims.

1. The front/bottom edge of each paper tray has two small pads or shims stuck to them. The following picture shows the tray completely
removed from the printer but this is not necessary.

2. Pull out the main paper tray (Tray 2) so that you can locate a pad on the bottom of the tray. You should be able to feel them along the bottom
of the front edge.

Use a fingernail to carefully pry off the pad/shim. If possible, try to pull the existing double sided adhesive
off with the pad.

3. If more than half of the double sided adhesive came off with the pad, move to the next step.

If less than half of the adhesive has been saved, wipe off any small amount of adhesive left on the pad and apply a small piece of double
sided tape to the flat side of the pad, as shown above.

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4. Insert and rotate the tip of a flat blade screwdriver to pry up the plastic cover in the area shown in the following image.

The screwdriver handle can be placed back down on the output area of the printer so that both hands will be free for shim installation.

5. Carefully place the pad directly below the plastic rib next to the screwdriver tip as shown in the previous image.

If available, using tweezers or needle nose pliers can make this process easier.

6. Remove the flat blade screwdriver and ensure that the plastic rib rests on the shim, as shown. Carefully but firmly use the screwdriver to
press down to fully secure the adhesive/tape on both sides of the rib.

Replace the output door

1. Position the output door as shown, with the door rotated slightly up. The front side pin aligned with the hole, and the rear of the door pulled
slightly away.

Slide the front side pin into the hole. If the door does not slide easily, continue to slightly rotate and move the rear of the door until the pin
slides in.

Do NOT force the pin into the hole; it will slide in

when correctly positioned.

2. Flex the rear side of the part so that the rear pin can be inserted into the rear hole. Release the part when finished and make sure the door
can open and close freely.

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3. Check installation.


 
CAUTION:
Take care to not over-bend the plastic.

Replace the scanner bottom cover.

1. Position the scanner bottom cover by carefully lifting and inserting the left side of the part into the opening between the printer and the
scanner.

2. Using 2 hands secure the cover by squeezing upwards to engage the snaps.

Test

1. Print a test page to verify that the output door opens

and closes freely.

2. If the output door still has difficultly and does not open and close correctly, more plastic shims (Install shim) can be added on top of the first
shim.

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