Lexmark Optra W810 Service Manual Download

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Repair Information

4-29

4023-001

Heater Lamp (H1) Removal

1. Remove the heater lamp cover. (See

“Heater Lamp Cover” on

page 4-28

2. Remove the heater lamp holder(front) (1). (1 screw)

3. Remove the earth (2). (1 screw)

4. Remove the gear assembly (3). (1 spring)

5. Remove the heater lamp cover(rear) (4). (2 screws)

6. Remove the heater lamp holder(rear) (5). (2 screws)

7. Remove the heater lamp(H1) (6). (1 screw)

Fusing Roller Thermistor (TH1) Removal

1. Remove the upper fusing roller.

2. Remove the fusing roller thermistor TH1 (1). (1 screw)

Summary of Contents for Optra W810

Page 1: ...ser Printer Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Start Diagnostics Manuals Menu ...

Page 2: ...sed to Lexmark International Inc Department D22 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase ...

Page 3: ...Transfer Section Release Section 1 9 Fusing Section 1 9 Cleaning Section 1 9 Paper Exit Section 1 10 General Flow for Printing Process 1 10 Paper Feed Section 1 11 Taking Up Paper Tray 1 1st Paper Cassette 1 11 Tray 1 Sensors 1 12 1st Cassette Tray 1 Paper Size Detection 1 15 Tray 2 2nd Paper Cassette 1 16 Taking up Paper Tray 2 2nd Paper Cassette 1 16 Tray 2 Sensors 1 18 Edge Guide and Trailing E...

Page 4: ...Door Interlock Switch S2 1 40 Duplex Unit Option 1 41 Parts Identification 1 41 Cross Sectional View 1 42 Switchback Mechanism 1 42 Transport and Duplex Paper Take Up Mechanism 1 43 Paper Deck 2500 Sheet LCC Option 1 45 Cross Sectional View 1 45 Vertical Transport Drive Mechanism 1 45 Paper Take Up Mechanism 1 47 Paper Take Up Retry Control 1 52 Paper Separating Mechanism 1 53 Paper Pressure Relea...

Page 5: ...lding Tray 1 77 Elevator Tray 1 78 Stapling Unit 1 80 Horizontal Transport Unit 1 81 Diagnostic Information 2 1 Service Error Codes 2 2 Operator Messages 2 7 Symptom Tables 2 29 Print Quality Symptom Table 2 29 Paper Feed Symptom Table 2 29 Other Printer Malfunction Symptom Table 2 31 LCC 2500 Sheet Tray 4 Symptom Table 2 32 Mailbox Symptom Table 2 32 Finisher Symptom Table 2 33 Printer Service Ch...

Page 6: ...ch Service Check 2 52 Finisher Service Checks 2 53 Finisher Power Service Check 2 53 Finisher Elevator Tray Service Check 993 2 53 Finisher Tray Drive Service Check 994 2 54 Finisher Shift Plate Drive Service Check 995 2 54 Finisher Paper Aligning Service Check 996 2 54 Finisher Stapler Drive Service Check 997 2 56 Finisher Paper Holding Tray Drive Service Check 998 2 56 Finisher Upper Entrance Se...

Page 7: ...edures 4 14 Pre disassembly 4 14 Outer Cover Removal 4 15 1st Cassette 250 Sheet Tray1 Paper Take Up Roller Removal 4 16 250 Sheet Cassette Tray 1 Paper Take Up Rolls Removal 4 16 250 Sheet Cassette Tray 1 Paper Take Up Rolls Cleaning 4 17 500 Sheet Cassette Tray 2 and 3 Vertical Transport Roller Rolls Cleaning 4 18 500 Sheet Cassette Tray 2 and 3 Paper Lifting Springs Replacement 4 18 500 Sheet C...

Page 8: ...al 4 44 CPM Power Supply Safety Switch and PWB L Removal 4 45 Power Unit Cooling Fan Motor M4 Removal 4 46 Ozone Fan Motor M8 and Ozone Filter Removal 4 47 1st Paper Cassette Tray 1 Paper Size Detecting Board Removal 4 48 Bottle Cover Sensor PC10 Removal 4 49 Agitating Motor M10 Removal 4 50 Main Hopper Motor M6 and Sub Hopper Motor M7 Removal 4 51 Transport Motor M2 Removal 4 52 Image Cartridge P...

Page 9: ...ll and Torque Limiter Assembly Removal 4 79 Paper Take Up Roll Cleaning 4 80 Feed Roll and Separator Roll Cleaning 4 80 Vertical Transport Roller Rolls Cleaning 4 81 Roll with a Torque Limiter Cleaning 4 81 Finisher Removal Procedures 4 82 External Covers Removal 4 82 Punch Unit Removal 4 84 Stapler Unit Disassembly 4 85 Rear Cable Removal 4 86 Front Cable Removal 4 88 Front Cable Installation 4 8...

Page 10: ... 5 24 Finisher Electrical Components 5 26 Finisher Main Board PWB A 5 28 Mailbox 5 29 External View Front When Connected To Printer 5 29 External View Rear When Connected To Printer 5 29 Mailbox External View Each Section 5 30 Mailbox Horizontal Transport Unit Cross Sectional View 5 30 Mailbox Horizontal Transport Unit Electrical Components 5 31 Mailbox Horizontal Transport Unit Mechanical Compone...

Page 11: ...r Deck Paper Tray A 7 70 Assembly 24 Paper Deck Paper Tray B 7 72 Assembly 25 Finisher Housing 7 74 Assembly 26 Finisher Frames 7 76 Assembly 27 Finisher Paper Transport A 7 80 Assembly 28 Finisher Paper Transport B 7 82 Assembly 29 Finisher Paper Aligning 7 86 Assembly 30 Finisher Assistance Tray 7 92 Assembly 31 Finisher Elevator Tray 7 96 Assembly 32 Finisher Punch Unit 7 100 Assembly 33 Finish...

Page 12: ...xii Service Manual 4023 001 ...

Page 13: ...Notices and Safety Information xiii 4023 001 Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown ...

Page 14: ...ervices 21 CFR Teil J für Laserprodukte der Klasse I 1 In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I der die Anforderungen der IEC International Electrotechnical Commission 60825 gemäß amtlicher Bestätigung erfüllt Laserprodukte der Klasse I gelten als unschädlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb 3b bei dem es sich um einen Galliumarsenlaser mit 5...

Page 15: ... di classe IIIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Avis...

Page 16: ...ssora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal a manutenção feita pelo utilizador ou condições de assistência prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I Voor de Verenigde Staten zijn deze eisen vastgelegd in DH...

Page 17: ...agtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder på bølgelængdeområdet 770 795 nanometer Lasersystemet og printeren er udformet således at mennesker aldrig udsættes for en laserstråling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Danish ...

Page 18: ...malle säteilylle kirjoittimen normaalin toiminnan käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä LUOKAN 1 LASERLAITE VAROITUS Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle KLASS 1 LASER APPARAT VARNING Om apparaten används på annat sätt än i denna bruksanvisni...

Page 19: ...tsätts för laserstrålning över Klass I nivå vid normal användning underhåll som utförs av användaren eller annan föreskriven serviceåtgärd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse I 1 laserprodukter og er i andre land godkjent som et Klasse I laserprodukt i samsvar med kravene i IEC 60825 Klasse I laserprodukter er ikke å betrakte som farlige...

Page 20: ...uctes làser de classe I no es consideren perillosos Aquesta impressora conté un làser de classe IIIb 3b d arseniür de gal li nominalment de 5 mil liwats i funciona a la regió de longitud d ona de 770 795 nanòmetres El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d un nivell de classe I durant una operació normal durant les tasq...

Page 21: ...Notices and Safety Information xxi 4023 001 Chinese Laser Notice Korean Laser Notice ...

Page 22: ...cing of this product Professional service personnel should understand this and take necessary precautions Consignes de Sécurité Ce produit a été conçu testé et approuvé pour respecter les normes strictes de sécurité globale lors de l utilisation de composants Lexmark spécifiques Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes Lexmark ne peut être tenu responsab...

Page 23: ...gehörigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen Die Wartungsinformationen für dieses...

Page 24: ... substituição As informações de segurança relativas a este produto destinam se a profissionais destes serviços e não devem ser utilizadas por outras pessoas Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários Informació de Seguretat Aquest producte està dis...

Page 25: ...Notices and Safety Information xxv 4023 001 El personal professional ha d estar ne assabentat i prendre les mesures convenients Chinese Korean ...

Page 26: ...xxvi Service Manual 4023 001 ...

Page 27: ...in the Repair Information chapter will help you identify parts After you complete the repair perform tests as needed to verify the repair Tools The removal and adjustment procedures described in this manual require the following tools and equipment Magnetic tip Phillips screwdrivers large and small Flat blade screwdrivers Analog volt ohmmeter a digital volt ohmmeter may also be used Needle nose pl...

Page 28: ...1 2 Service Manual 4023 001 Serial Number The serial number is located in the bottom left corner of the label illustrated below ...

Page 29: ...Area Network LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PICS Problem Isolation Charts PIXEL Picture Element POR Power On Reset POST Power On Self Test PQET Print Quality Enhancement Technology RIP Raster Image Processor ROS ...

Page 30: ...erator panel access for menus Universal Drawer 250 sheet 11x17 A3 letter legal A4 500 sheet input drawers Two 2 500 sheet input drawers 11x17 A3 letter legal A4 Copy collation Multiple copy collation in the printer RAM Dimensions 1 75 ft 535 mm Width x 2 06 ft 628 mm Depth x 1 40 ft 428 mm Height Printing system Electrostatic dry powdered imaging system Imaging cartridge Two component imaging cart...

Page 31: ...otoconductor OPC Cleaning system Blade system Separating system Paper separator Fusing system Heat roller fusing system Paper exit system Printer Face down 300 sheets maximum A4 C Letter C Mailbox 2000 sheets Finisher 2500 sheets 500 sheets standard bin 2000 sheets finisher bin Feature Description ...

Page 32: ...10BT 100BTx Ethernet 10BT 2 Ethernet 10BT 100BTx SCSI Coax twinax adapter for SCS B C Parallel connector Parallel USB A B C Paper handling 500 sheet input tray and drawer 2500 sheet input tray worldwide 2000 sheet mailbox 2500 sheet finisher 3 and 4 hole punching capability 5k stapling capacity A B C OptraImageTM Ethernet 10 100 SCSI scanner and fax A B C Supplies Photoconductor kit Toner cartridg...

Page 33: ...General Information 1 7 4023 001 Printer Options Parts Identification ...

Page 34: ...Exit Roller 12 Double Feed Sensor 2 Paper Exit Sensor PS3 13 Tray1 1st Paper Cassette 3 Lower Fusing Roller 14 1st Paper Cassette Near Empty Sensor PC5 4 Upper Fusing Roller Heater Lamp 15 1st Paper Cassette Empty Sensor PC4 5 Image Transfer Roller 16 ATDC Sensor 6 Synchronizing Roller 17 Sleeve Roller 7 Synchronizing Roller Sensor PC2 18 PC Drum Charger 8 Manual Unit 19 PC Drum 9 Tray2 2nd Paper ...

Page 35: ... laser diode in the printhead unit emits a laser beam The scanning beam creates an electrostatic latent image on the surface of the PC drum in the imaging cartridge Imaging Cartridge Charging Development Section The imaging cartridge consists of the charging section and development section The I C drive motor M1 drives the moving parts of the imaging cartridge Image Transfer Section Release Sectio...

Page 36: ...icking to the PC Drum Starting processing The I C imaging cartridge drive motor M1 starts turning Paper take up The transport motor M2 starts turning The paper take up solenoid turns on to feed paper Laser emission A laser beam is emitted at constant power Scanning the image data Paper feeding A laser beam scans the surface of the PC drum to produce a latent electrostatic image The sychronizing ro...

Page 37: ...m the 1st paper cassette 1 The transport motor M2 turns counterclockwise 2 The idle gear turns clockwise and the 1st cassette paper take up solenoid SL1 turns ON 3 The paper take up roller turns counterclockwise and paper is taken up 1 PC Drum 5 Synchronizing Roller 2 Image Transfer Roller 6 Paper Take Up Roller 3 Transport Motor M2 7 Paper 4 Synchronizing Roller Sensor PC2 ...

Page 38: ...t paper cassette in tray 1 1 1st Cassette Paper Near Empty Sensor PC5 5 Synchronizing Roller Sensor PC2 2 1st Cassette Set Sensor PC6 6 Double Feed Sensor 3 1st Cassette Paper Take up Solenoid SL1 7 Paper Take up Roller 4 Separator Pad 8 1st Paper Cassette Empty Sensor PC4 1 1st Cassette Set Sensor PC6 2 1st Paper Cassette ...

Page 39: ...C4 PC4 1 detects paper empty status of the 1st paper cassette 1st Cassette Tray 1 Paper Near Empty Sensor PC5 PC5 detects when the 1st cassette is near empty 1 1st Paper Cassette Empty Sensor PC4 2 Paper 1 1st Paper Cassette Near Empty Sensor PC5 2 Paper 3 Paper Lifting Plate ...

Page 40: ...per runs 10 mm or more double feeding may occur if the paper is taken up in the normal printing interval To avoid this the printer prolongs the printing intervals as long as the double feed sensor detects a double feed status This results in the reduction of the number of sheets fed per minute 1st Cassette Tray 1 Synchronizing Roller Sensor PC2 This sensor detects that the paper is fed inside the ...

Page 41: ... DIP switches are located on the 1st cassette paper size board PWB S1 The ON 1 OFF 2 settings of the length dip switches set the analog input voltage The input voltage and the normal input data from the width dip switch port determine paper size The precise paper size cannot be identified by detection and must be selected from the operation panel When no cassette is set all switches are set to off...

Page 42: ...te paper take up gear turns counterclockwise 4 The 1st cassette idle gear turns clockwise and the transport clutch CL1 turns ON 5 Power is transmitted to the 2nd paper cassette a The 2nd cassette paper take up solenoid SL21 turns ON b Paper take up roller turns counterclockwise c Paper is taken up 1 2nd Cassette Paper Empty Sensor PC22 4 2nd Cassette Right Door Detecting Sensor PC23 2 2nd Cassette...

Page 43: ... Information 1 17 4023 001 1 PC Drum 6 Paper 2 Image Transfer Roller 7 Paper Take up Roller 3 Transport Motor M2 8 Transport Clutch CL1 4 Synchronizing Roller Sensor PC2 9 Synchronizing Roller 5 Transport Gear ...

Page 44: ...ze indicated by the 2nd cassette paper size board PWB S2 S3 is also checked The length dip switch setting determines paper size 2nd Cassette Paper Empty Sensor PC22 PC22 detects the paper empty status of the 2nd paper cassette Paper empty status occurs when paper runs out in the 2nd paper cassette 1 2nd Cassette Paper Near Empty Sensor PC22 2 Paper ...

Page 45: ...nd cassette 2nd Cassette Right Door Detecting Sensor PC23 PC23 detects if the 2nd cassette right door is open or closed The right door is normally closed except when removing jammed paper 1 2nd Cassette Paper Near Empty Sensor PC25 3 Paper Lifting Plate 2 Paper 1 2nd Cassette Right Door Detecting Sensor PC23 2 Right Door ...

Page 46: ... trailing edge stop of the universal cassette slide to accommodate different paper sizes The edge guide and trailing edge stop of the fixed paper size cassette are attached in fixed positions Fixed Paper Size Cassette Paper Lifting Plate Two paper lifting springs in each cassette constantly raise the paper lifting plate ...

Page 47: ...cassette frame presses the cassette set switch on the back panel of the printer indicating the cassette is inserted The position of the rib on the cassette frame is different between the fixed paper size and universal cassette This lets the printer detect which cassette is inserted ...

Page 48: ...Near Empty Detection Height of the paper lifting plate determines paper near empty condition Since the amount of paper available during the take up sequence varies detection occurs when the paper take up roll is in the retracted position ...

Page 49: ...3 4023 001 Paper Empty Detection When the cassette runs out of paper the actuator of the paper empty sensor drops into the cutout of the paper lifting plate This exposes the sensor signaling that the cassette is out of paper ...

Page 50: ...l starts to turn the turning force transmits to the top sheet of paper The transmitted force overcomes the block of the fingers causing the top sheet of paper to ride over the fingers and feed out of the cassette into the printer The paper transport force obtained through friction with the top sheet of paper is weak and does not allow the second sheet of paper to ride over the block of the fingers...

Page 51: ... Roll Two paper take up rolls are mounted in both the fixed paper size cassette and universal cassette As the take up solenoid energizes the spring tension increases meshing the drive and clutch gear which transmits drive to the paper take up rolls ...

Page 52: ...oller to align the leading edge of the paper with the stopping synchronizing roller The leading edge of the paper slacks a little as shown in the figure The synchronizing clutch CL1 activates and the paper take up roller turns for a moment to securely feed the paper to the inside of the printer Paper Feeding 1 The transport motor M2 turns counterclockwise 2 The idle gear turns clockwise The synchr...

Page 53: ...ing roller feeds paper to the PC drum and transfer roller The PC drum and transfer roller pinch the paper and feed it to the fusing section 1 PC Drum 4 Synchronizing Clutch CL1 2 Image Transfer Roller 5 Paper 3 Transport Roller 6 Synchronizing Roller ...

Page 54: ...mage data The scanning laser beam scans the PC drum from left to right producing an electrostatic latent image on the surface of the PC drum Imaging Cartridge Charging Development Section The printer main body I C drive motor M1 transmits power to the gears of the imaging cartridge The I C drive motor M1 turns clockwise as viewed from the front of the printer ...

Page 55: ...ess toner from the PC Drum waste toner after transfer to the paper 6 Sheet erase Negatively charges the PC Drum to eliminate the remaining electric polarity after transfer to the paper 7 PC drum Charged roller that applies image to paper 8 Sleeve roller Transfers toner to the surface of the PC Drum via a rotating resin sleeve and then develops it 9 Screw Mixes toner and carrier inside the toner ho...

Page 56: ...he developer The ATDC sensor detects the ratio of toner to carrier and voltage controls the toner density The developer is then supplied to the sleeve roller The sleeve roller negatively charges the toner The toner adheres to the electrostatic latent image due to the reduced negative voltage in the image area The toner does not adhere to the area where the laser beam has not been applied This occu...

Page 57: ...General Information 1 31 4023 001 1 Laser Beam 4 ATDC Sensor 2 PC Drum 5 Screw 3 Sleeve Roller 6 Developer ...

Page 58: ...er evenly in the sub hopper The toner pushes upward on the toner detection plate The position of the toner detection plate indicates the amount of toner in the sub hopper A toner empty status occurs when the toner detection plate lowers enough for the lead switch to detect the plate However the lead switch is not activated when the toner supply motor stops or the bottle motor rotates When the sub ...

Page 59: ...ty status in the imaging cartridge occurs when the ATDC sensor detects a toner density ratio of toner to carrier below 10 When this occurs the appropriate toner density cannot be maintained The bottle motor and toner supply motor stop The toner empty status is recorded and will not reset until the toner cartridge is replaced ATDC Sensor The developer circulated by a screw passes over the ATDC sens...

Page 60: ...transfers the toner image on the surface of the PC Drum onto the paper Normally the paper separates from the PC drum without any outside interference When the paper fails to separate from the PC drum the separating claw releases the paper by force 1 PC Drum 2 Image Transfer Roller 3 Paper ...

Page 61: ...se light from the eraser lamp irradiates the PC drum eliminating the negative charge applied by the cleaning blade during PC drum cleaning This prevents black lines from being created on the front and rear ends and both sides of the image 1 Cleaning Blade 2 Optical Erase ...

Page 62: ...S1 and fusing roller heater lamp fuse TF1 are connected in series to the heater lamp H1 The heater lamp H1 heats when an AC voltage is applied Temperature Control Using The Thermistor The resistance of the thermistor TH1 attached to the upper fusing roller varies with temperatures When temperature rises the resistance of the thermistor TH1 decreases and vice versa Thermostat TS1 and Heater Lamp Fu...

Page 63: ...mperature Control The fusing section starts to warm up when the main switch turns ON Preliminary rotation occurs for 20 seconds when the temperature of the upper fusing roller reaches 170 C 338 F When the rotation stops the temperature of the upper fusing roller is approximately 200 C 392 F and warm up is complete Warm up takes approximately 1 minute Fusing PPM Control The sides of the fusing roll...

Page 64: ... exit roller and ejects printed side down out the top of the printer The transport motor M2 provides transmit power for feeding paper The paper exit sensor PC3 detects paper eject As paper passes through the sensor it presses the sensor arm until the sensor arm end engages with the photointerrupter 1 Paper Exit Sensor PC3 2 Paper ...

Page 65: ...ating fuse When the printer is turned ON the fuse is blown and the PC drum counter clears enabling detection of the image cartridge life When power is turned OFF the counter value is stored in the imaging cartridge EEPROM When power is turned ON the counter value is recalled from the imaging cartridge EEPROM to continue counting 1 Paper 6 Synchronizing Roller 2 Paper Exit Roller 7 Transport Motor ...

Page 66: ...imaging cartridge is replaced or jammed paper is removed With the door closed the projection of the right door presses the spring attached to the switch lever turning the switch ON When it is opened the lever of the switch is released turning the switch OFF 1 Right Door 3 Right Door Interlocks 2 Projection 4 Spring ...

Page 67: ...General Information 1 41 4023 001 Duplex Unit Option Parts Identification ...

Page 68: ...n the switchback motor reverses the rotational direction of the paper exit roller The one sided print then feeds into the duplex unit The drive of the switchback motor is transmitted through a gear train 1 Duplex Unit Transport Roller 1 3 Duplex Unit Transport Roller 2 2 Duplex Unit Transport Roll 1 4 Duplex Unit Transport Roll 2 ...

Page 69: ...hback motor drive Switchback Motor Control The switchback motor is a two phase stepping motor Transport and Duplex Paper Take Up Mechanism Transport and Duplex Paper Take Up Operation The transport and duplex paper take up operations are performed by two pairs of duplex unit transport rollers rolls and the manual feed paper take up roll of the printer The drive for these operations comes from the ...

Page 70: ...1 44 Service Manual 4023 001 Duplex Unit Transport Motor Control The duplex unit transport motor is a two phase stepping motor ...

Page 71: ...ransport motor HMOT The driving force of HMOT is transmitted via a gear train and registration clutch RCL to the vertical transport roller which feeds the paper from lift 1 or 2 to the printer Because of the long paper path from lift 2 skew tends to occur in the paper fed 1 Lift 2 5 Vertical Transport Roller 2 Paper Take Up Roll 2 6 Vertical Transport Roll 3 Lift 1 7 Feed Roll 4 Paper Take Up Roll...

Page 72: ...ms a loop in the paper between the separator roll and vertical transport roller Control of LCC Transport Motor HMOT The printer main engine board energizes and de energizes HMOT by sending signals to HMOT through the LCC paperdeck main board PWB A HMOT is a DC motor ...

Page 73: ... the last two sheets of paper The roll is mounted beneath paper take up roll 1 of lift 1 Paper take up roll 1 is active when paper is fed from lift 1 Both paper take up roll 1 and 2 activate to perform the paper take up sequence when paper feeds from lift 2 During this sequence paper empty sensor 1 PPS1 detects proper feed of paper through take up roll 1 The sheet of paper taken from lift 1 2 temp...

Page 74: ...and feeds a sheet of paper until the paper blocks paper standby position sensor S1 This serves as the standby position of the paper When the printer sends a paper take up signal the separator feed rolls and paper take up roll 1 transports the paper up to registration sensor RSEN After RSEN has been blocked the paper moves a ...

Page 75: ...sport roller unblocks paper standby position sensor S1 the subsequent sheet of paper is transported to the standby position and the LCC waits for the next paper take up signal Registration clutch RCL de energizes a given period of time after the trailing edge of the paper being taken up unblocks registration sensor RSEN The next paper take up signal transmits after the timer which starts when the ...

Page 76: ...per from lift 2 After the trailing edge of the last sheet of paper from Lift 1 unblocks paper empty sensor 1 PPS1 both paper take up roll 1 and 2 turn Paper take up roll 1 and 2 transports the sheet of paper until the paper blocks LCC take up sensor PPS0 Paper take up roll 1 transports the paper located at PPS0 until the paper blocks paper standby position sensor S1 This is the standby position of...

Page 77: ...er travels a little further to reach the vertical transport roller and form a registration loop before stopping The vertical transport roller transports the paper to the printer After the trailing edge of the paper transported by the vertical transport roller unblocks paper empty sensor 1 PPS1 paper take up roll 1 and 2 transport the subsequent sheet of paper until the subsequent sheet of paper bl...

Page 78: ...trailing edge of the paper being taken up unblocks registration sensor RSEN The next paper take up signal transmits after the timer which starts when the vertical transport roller rotates for the preceding sheet of paper runs out Paper Take Up Retry Control To minimize the occurrence of paper misfeed due to a slippery paper take up roll separator clutch BCL energizes again if a sheet of paper fail...

Page 79: ...r roll shaft It stops the separator roll when friction changes between the feed and separator rolls Paper Pressure Releasing Mechanism When LCC is pulled out the pressure release rail pushes the separator roll assembly downward releasing the pressure between the feed and separator roll The pressure release rail is located above the rail on the paper take up end ...

Page 80: ... paper take up roll upward releasing pressure between the paper and paper take up roll Edge Guides and Trailing Edge Stop The trailing edge stop screws into position not used for letter crosswise Edge guides slide into any position you want Whenever the positions of the edge guides and trailing edge stop change be sure to perform the paper size setting procedure See Paper Size Setting that follows...

Page 81: ...r crosswise After the positions of the edge guides and trailing edge stop change place the DIP switch keys on LCC main engine board PWB A in the corresponding positions according to the current paper size Note Positions 3 and 4 are not used SW1 Letter Crosswise A4 Crosswise 1 OFF ON 2 OFF OFF 3 OFF OFF 4 OFF OFF ...

Page 82: ...sor FRONT Lifting Mechanism When the LCC is slid into the printer the couplings engage The LCC lift up motor EMOT rotates forward and backward turning the one way gear and gear train to raise Lift 1 and Lift 2 respectively Lift 1 and 2 drive mechanisms each contain a one way gear When EMOT turns forward drive transmits to Lift 1 and when the motor turns backward drive transmits to Lift 2 ...

Page 83: ...k lift up sensor 1 LS1 EMOT de energizes and then energizes to start turning backward raising Lift 2 The paper stack causes the light blocking plate o the paper take up roll 2 assembly to block lift up sensor 2 LS2 EMOT de energizes Paper is consumed as print cycles run The paper take up roll gradually lowers unblocking the lift up Sensor EMOT energizes and the lift raises This lifts the paper sta...

Page 84: ...is unblocked while a paper take up sequence occurs with paper present on the lift 2 Lift 1 and 2 stops Lift up sensor is blocked The paper stack top level position is being corrected 3 LCC lift up motor EMOT energizes 4 Lift 1 and 2 descends LCC is slid out of the printer Lift 1 and 2 are lowered Note To absorb shocks that would otherwise be applied during the descent motion springs are loaded in ...

Page 85: ...sor indicating that the LCC paper deck is near empty Paper Empty Detection Paper empty sensor 1 PPS1 and paper empty sensor 2 PPS2 reflector type photosensors installed in the paper take up unit detect the paper empty condition When a paper empty condition is detected the corresponding message displays on the panel When Paper is Loaded The light from the LED of paper empty sensor 1 PPS1 or paper e...

Page 86: ...passage performance from being degraded by damp paper during highly humid conditions As long as the power cord is plugged in these heaters are kept ON at all times When Paper is Not Loaded The light from the LED of paper empty sensor 1 PPS1 or paper empty sensor 2 PPS2 does not reflect indicating there is no paper loaded in the LCC ...

Page 87: ...tion 1 61 4023 001 Mailbox Transport Option Parts Identification Horizontal Transport Unit Cross Sectional View 1 Paper Entrance Switching Mechanism 2 Upper Attachment 3 Transport Roller 4 Horizontal Unit Paper Sensor ...

Page 88: ...ated bin If the paper has not passed the PC1 or PWB C within a certain time after the printer paper exit sensor turns ON the paper has jammed inside the horizontal transport unit or at the entrance exit of the storage unit This results in a jam error Paper ejects from the horizontal transport unit The storage unit entrance roller then forwards the paper The subsequent paper path varies with the pa...

Page 89: ...ng solenoid SL1 energizes to swing the path switching guide upward and stop it when non sort tray transport position detecting sensor is blocked Mode other than Non Sort Paper entrance switching solenoid SL1 energizes to swing the path switching guide upward and stop it when finisher transport position detecting sensor is blocked ...

Page 90: ...the entrance If the entrance moves up and down when the horizontal transport unit is not attached to the printer properly the entrance may be damaged To prevent this a stopper is provided If the horizontal transport unit is not attached to the printer properly this stopper prevent the gears from engaging As a result drive force of the paper entrance transport motor M1 in the printer does not trans...

Page 91: ... paper path forcing the paper toward the 1st bin The paper then passes to the paper exit sensor exit roller and arrives in the 1st bin tray In mailbox mode if a bin other than 1st bin is designated the 1st bin switching deflector moves up causing the paper to move down toward the 2nd and subsequent bins For instance if the 2nd bin is designated the 2nd bin switching deflector moves down to close t...

Page 92: ...e of the 2nd Bin the light emits from the topside emitter of the PWB D2 3rd bin to the underside receiver of the PWB D1 2nd bin If paper is not present in the 2nd Bin the sensor turns ON indicating a paper empty If paper s is present the paper blocks the light keeping the sensor turned OFF Paper Full Detection Each bin contains a lever type switch When the height of the stacked papers exceeds a ce...

Page 93: ...orizontal transport unit moves up and all papers output through the horizontal transport unit into the 1st bin Mailbox Mode The entrance of the horizontal transport unit moves up and all papers output through the horizontal transport unit into the designated bin Any bins from the 1st to 10th bins can be assigned as dedicated bins ...

Page 94: ...ice Manual 4023 001 Finisher Option Parts Identification 1 1st Tray 6 Rear Cover 2 Upper Right Cover 7 Finisher Tray Cover 3 Misfeed Clearing Cover 8 Upper Rear Cover 4 Front Cover 9 Staple Door 5 Elevator Tray ...

Page 95: ...ng Mechanism 1st Tray Finisher Tray Path Switching Mechanism When the upper entrance switching solenoid energizes through PWM control the print exits into the 1st tray When the upper entrance switching solenoid de energizes the print exits toward the finisher tray ...

Page 96: ...ves the horizontal transport rollers and entrance roller which transports the print into the finisher 1st Tray Transport Mechanism Upper exit motor drives the 1st tray exit roller and transport roller to feed the print into the 1st tray The speed at which the print transports decelerates as it feeds into the 1st tray ...

Page 97: ...port unit M1 energizes to turn the horizontal transport rollers and entrance roller At the same time upper exit motor energizes to turn the transport roller The trailing edge of the print moves past the paper sensor of the horizontal transport unit After a given period of time the upper exit motor deenergizes to stop the transport roller The transport motor remains energized forming a loop in the ...

Page 98: ...ray and paper holding tray retract to let the processed print set stack drop onto the elevator tray CD Aligning Mechanism The CD aligning plate moves and the paddle rotates to press each print against the shift reference plate CD Aligning Plate The CD aligning motor rotates in the forward or backward direction turning the spiral shaft to move the CD aligning plate ...

Page 99: ...he CD aligning plate moves between the standby and aligning positions until the last print is aligned The CD aligning home position sensor detects the CD aligning plate home position This position serves as the reference point for movement of the CD aligning plate The standby position varies according to the paper size CD length The standby position is 8 5 mm away from the print end face ...

Page 100: ...addle moves the print which has been fed by the CD aligning plate toward the stapling corner The gear is normally locked by the torque limiter and when paddle motor turns forward the paddle lowers As the tension of the spring exceeds the force of the torque limiter the rotation of the motor transmits to the paddle through the gear train ...

Page 101: ...l taming motor turns forward and backward to lower and retract the curl tamer Shifting Mechanism A print set stack which has been aligned and stapled together transports to the non sort position or sort position The shift motor energizes turning the spiral shaft which moves the shift reference plate The shift sensor detects the home position of the shift reference plate The home position serves as...

Page 102: ...cting the tray The finisher tray motor turns forward to move the finisher tray to the home position and backward to retract the finisher tray Paper Trailing Edge Alignment As the finisher tray retracts the print set stack drops on the elevator tray The trailing edge of the print stack does not always rest flat on the elevator tray This causes the stack to curve upward To correct this the paper ali...

Page 103: ...w the processed print set stack to drop on the elevator tray The paper holding tray motor drives gears and belts which move the paper holding tray The tray is divided into four parts The retracted position of the tray varies according to the paper size The paper holding tray home position sensor detects the home position of the tray The home position serves as reference for retracting the paper ho...

Page 104: ...espectively Elevator Tray Stop Position Detection The elevator tray stops at the following positions Position Condition Detection Processing When a print or print set stack is fed into finisher The position at which elevator tray upper surface sensor PC8 activates Retracted Between two prints or print sets stacks Elevator tray position after lowering 55 mm from when PC8 activates Standby In standb...

Page 105: ...General Information 1 79 4023 001 ...

Page 106: ...le empty detecting sensor detects whether or not a staple sheet is in the staple cartridge When the number of staples left in the staple cartridge reaches approximately 40 a staple sheet empty condition occurs and displays on the printer operator panel If a staple sheet empty condition occurs during a stapling sequence it displays after the stapling sequence completes After a new staple cartridge ...

Page 107: ...General Information 1 81 4023 001 Horizontal Transport Unit The finisher horizontal transport unit is the same as the mailbox horizontal transport unit See page 1 64 ...

Page 108: ...1 82 Service Manual 4023 001 ...

Page 109: ...service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer Service error codes are indicated by a three digit error code If a service error code is displayed go to the Service Error Codes on page 2 2 User status messages provide information on the current status of the printer Ready is displayed on the first line of the displa...

Page 110: ...ain engine board PWB A 920 Fuser Error Indicates the fuser is below temperature when printing Go to the Fuser Temperature Low Service Check 920 922 on page 2 35 921 Fuser Past Maint Indicates the fuser is below temperature when printing and that the fuser life has been exceeded Have customer order new fuser maintenance kit 922 Fuser Error Fuser failed to reach standby temperature Go to the Fuser T...

Page 111: ... Finisher Ensure connectors are plugged in Check for damage to the gear train Ensure there is no overload Replace any damaged gears Replace the transport motor M1 Replace the PWB A finisher main board 936 Transport Motor Mailbox Go to Mailbox Transport Drive Service Check 935 on page 2 59 939 Controller Engine Communications Error The controller board and the engine board cannot communicate with o...

Page 112: ...ienced a CRC failure Replace the printer main engine board PWB A 955 956 957 959 System Board Indicates a processor ASIC or SRAM failure on the engine board Replace the printer main engine board PWB A 960 RAM Memory Error Indicates a memory error on the RIP controller board Replace the RIP controller board 961 RAM in Slot 1 J4 is Bad Ensure RAM is properly installed Replace RAM in Slot 1 If this d...

Page 113: ...ork Card is installed in slot x but cannot establish communications with it 978 Bad checksum while programming Network Card x Replace Network Card x 979 Flash parts failed while programming Network Card x 980 device Comm device mailbox finisher or LCC 2500 sheet paper drawer The engine is experiencing unreliable communications to the specified device Check cables Check control and system boards on...

Page 114: ... Elevator Tray Service Check 993 on page 2 53 994 Finisher Indicates finishing tray driver error Go to Finisher Tray Drive Service Check 994 on page 2 54 995 Finisher Indicates shift plate drive error Go to Finisher Shift Plate Drive Service Check 995 on page 2 54 996 Finisher Indicates arrangement bar drive error Go to Finisher Paper Aligning Service Check 996 on page 2 54 997 Finisher Indicates ...

Page 115: ...is open 1 Close cover A Check toner box cover open terminals and connector Replace if necessary 2 Replace printer main engine board PWB A if necessary Close Door D E Tray 2 D or tray 3 E is open Close to reset Check sensors PC 23 and connectors Replace if necessary Replace printer main engine board PWB A if necessary Close Door C The upper right door PC image cartridge is open Close the upper righ...

Page 116: ...and connectors Replace as necessary Note Replace the mailbox main board if necessary Close Cover M The finisher top cover is open Check switch S1 and connectors Replace as necessary Note Replace the finisher main board PWB A if necessary Close Cover N The finisher bin cover is open Check switch S7 and connectors Replace as necessary Note Replace the finisher main board PWB A if necessary Empty Box...

Page 117: ... is not ready to receive or process data This message displays when Stop is pressed during a print job Press Go to take the printer out of the not ready state Or to reset the printer Press Menu to access the Busy menu Select Reset Printer Performing Self Test The printer is running the normal series of start up tests after it is powered on When the tests are complete the printer returns to Ready N...

Page 118: ...e PC kit See operator manual Replace Toner Cartridge Toner cartridge is completely empty If the toner cartridge is not replaced when the warning is cleared the printer repeats this warning Replace toner cartridge See operator manual Replace Toner PC The toner cartridge and the photoconductor kit have been reported as near empty and near life If the photoconductor kit or toner cartridge is not repl...

Page 119: ...d Install new staples Check the connection between the stapler unit and the finisher stapler connector Replace the staple unit if necessary Staples Low The printer finishing device is low on staples Install new staples Check the connection between the stapler unit and the finisher stapler connector Replace the staple unit if necessary Tray 1 Missing Tray 2 Missing Tray 3 Missing Tray 4 Missing Tra...

Page 120: ...ut level reported by the bin is no longer full This warning is only available when the configure bins setting is set to Mailbox Check the tray bin full sensor and actuators Finisher standard bin PC12 Mailbox standard bin PWB B Bin1 PWB D1 Bin2 PWB D2 Bin3 PWB D3 Bin4 PWB D4 Bin5 PWB D5 Bin6 PWB D6 Bin7 PWB D7 Bin8 PWB D8 Bin9 PWB D9 Bin10 PWB C Tray 4 Low Tray 3 Low Tray 2 Low Tray 1 Low An input ...

Page 121: ...e Auto value After you set all link buff ers to Auto exit the printer menus to activate link buffer changes When Ready is dis played enable Resource Save in the Setup Menu and modify the link buffers again Press Go to clear the message The printer automatically disables Resource Save and continues 37 Insufficient Collation Area This message is displayed when the printer memory used to store pages ...

Page 122: ...t print or may not print correctly Cancel the print job Press Menu or Menu The Job Menu is dis played Press Menu or Menu until Cancel Job appears on the second line Press Select Reduce the complexity of the job Reduce the number of graphics or images on a page Delete unnecessary downloaded fonts or macros Change the Print Quality setting Install additional printer memory to avoid future Memory Ful...

Page 123: ... Press Select To avoid another Com plex Page error Set Page Protect On from the Setup Menu and re send the job Reduce the complexity of the page by using fewer fonts macros and graphics Install additional printer memory 50 PPDS Error See operator manual 51 Defective Flash The printer detects a defective flash during power on or during for mat and write to flash operations Press Go to clear the mes...

Page 124: ...u or Menu until Reset Printer appears on the second line Press Select 53 Unformatted Flash The printer detected an unformatted flash mem ory card during the power on process Flash operations are not allowed until the flash is formatted Try the following Format the flash mem ory card using Format Flash in the Tests Menu Send the data again If the error condition remains the flash mem ory card is de...

Page 125: ... the serial interface parameters protocol baud parity data bits are correct Press Go to clear the message and continue printing the job The print job may not print cor rectly Reset the printer Press Menu to access the Busy menu Select Reset Printer 54 Std Par ENA Connection Lost An external network adapter ENA that was once connected to the standard parallel port is no longer responding The printe...

Page 126: ...o the ENA and then resets 54 Ser x Fax Connection Lost See operator manual 54 Network x Software Error See operator manual 55 Insufficient Fax Buffer See operator manual 56 Serial Port x Disabled Data is sent to the printer across the serial port but the serial port is disabled When the serial error is displayed the reporting of other serial errors is sup pressed until the menus are entered or the...

Page 127: ...ed from the Parallel Buffer menu item Press Go to clear the message The printer discards the data sent to the parallel port Reset the printer Press Menu or Menu The Job Menu is displayed Press Menu or Menu until Reset Printer appears on the second line Press Select 58 Too Many Disks Installed You have installed more than one Hard Disk Option The Hard Disk Option can be installed only in connector ...

Page 128: ...nter was turned on Disk opera tions are not allowed until the disk is format ted Format the hard disk with the Format Disk setting in the Tests Menu Send the data again If the error condition remains the disk is defective and must be replaced Press Go to clear the message The disk is ignored and normal operation continues 70 79 INA errors These numbered mes sages are reserved for internal network ...

Page 129: ...thout a fourth tray for example may not have all three doors If sheets have been accumulated to be stapled when the jam is detected the printer alternately flashes the primary and secondary messages to indicate to the user that all accumulated sheets should not be removed during the jam clearance procedure Check paper sensor and actuator in tray 2 S3 tray 3 S3 tray 4 PPSO RSEN Go to Paper Feed Pic...

Page 130: ...5 202 Paper Jam Open Cover B Paper is jammed in the printer fuser Open the upper side door Open the fuser cover Check paper sensor and actuator for PC3 Replace the printer main engine board PWB A if necessary Go to Paper Feed Fuser Exit Service Check on page 2 46 231 Paper Jam Open Door G Paper is jammed in the duplex unit Open the duplex side door to access the jam area Check sensor and actuator ...

Page 131: ...41 Paper Jam Open Door C Paper is jammed around tray 1 Open side door C to access paper jam area If jam is not located by opening the side door open paper drawer 1 Check sensor and actuator for PC2 Replace the printer main engine board PWB A if necessary Go to Paper Feed Pickup Tray 1 250 Sheet Service Check on page 2 44 242 Paper Jam Open Door D Paper is jammed around tray 2 Open side door D to a...

Page 132: ...de doors open paper drawer 4 Note This message will not be displayed for the 2500 Sheet A4 drawer Check sensor and actuators for PPSO RSEN Replace the LCC main board PWB A if necessary Replace the printer main engine board PWB A if necessary Go to Paper Feed LCC 2500 Sheet Tray 4 Service Check on page 2 51 245 Paper Jam Open 500 Sheet Optional Tray 4 Door Paper is jammed around tray 5 Open tray 5 ...

Page 133: ...open LCC paper drawer Check sensors and actuators for PPSO RSEN and S1 Replace the LCC main board PWB A if necessary Replace the printer main engine board PWB A if necessary Go to Paper Feed LCC 2500 Sheet Tray 4 Service Check on page 2 51 251 Paper Jam Open Door C Paper is jammed in the vertical transport section Open tray 2 through 4 side doors doors D E F to access the paper jam Check paper sen...

Page 134: ...oors I J Paper is jammed in the eject option area Separate the mailbox from the printer Open doors I and J to access the jam area Go to Paper Feed Mailbox Service Check on page 2 48 280 Paper Jam Cover H Paper is jammed in the horizontal transport unit HTU Open the HTU cover to access the jam area Check horizontal transport sensors and actuators for PC1 PC2 Replace the printer main engine board PW...

Page 135: ... I J Paper is jammed in the transport of the mailbox Separate the mailbox from the printer Open doors I and J to access jam area Go to Paper Feed Mailbox Service Check on page 2 48 282 Paper Jam Open Cover N Paper is jammed in the finishing bin Open the finishing bin cover N to access jam area Clear all paper from the finishing bin Check horizontal transport sensors and actuators for PC1 PC2 If ne...

Page 136: ... Hori zontal Transport Ser vice Check on page 2 48 Paper Feed Finisher Service Check on page 2 50 284 Paper Jam Open Cover M Paper is jammed in the eject option area Open cover M to access jam area or Separate the finisher from the printer Check horizontal transport sensor and actuator for PC1 PC2 If necessary replace main board PWB A located in failing option Replace the printer main engine board...

Page 137: ...ensity Service Check on page 2 38 Foggy Background Go to Foggy Background Service Check on page 2 39 White Black Lines Go to White Black Lines Service Check on page 2 40 Offset Image Go to Offset Image Service Check on page 2 41 Blank Print Go to Blank Print Service Check on page 2 42 Reoccurring Marks Go to Image Space Table on page 2 43 Symptom Action Paper Jam in Pickup Tray 1 Go to Paper Feed ...

Page 138: ...zontal Transport Go to Paper Feed In Horizontal Transport Service Check on page 2 48 Paper Jam in Mailbox Go to Paper Feed Mailbox Service Check on page 2 48 Paper Jam in Finisher Go to Paper Feed Finisher Service Check on page 2 50 Paper Jam in LCC 2500 Sheet Go to Paper Feed LCC 2500 Sheet Tray 4 Service Check on page 2 51 Paper Jam or Malfunction of Hole Punch Go to Paper Feed Hole Punch Servic...

Page 139: ...chronizing Roll Registration Service Check on page 2 45 Operator Panel Does Not Operate Run LCD Hardware Test on page 3 5 and Button Test on page 3 6 If the display has diamonds on it or is blank and the printer PORs correctly replace the operator panel If problem persists replace the printer main engine board PWB A If the machine beeps 5 times and the screen remains blank or displays diamonds rep...

Page 140: ...ckup from Tray 4 Go to Paper Feed LCC 2500 Sheet Tray 4 Service Check on page 2 51 Paper Feed Problems Go to Paper Feed LCC 2500 Sheet Tray 4 Service Check on page 2 51 Paper Lift and Other Problems Go to Paper Deck 2500 Sheet LCC Option on page 1 45 Symptom Action No Power Go to Mailbox Power Service Check on page 2 58 Transport Drive Problems Go to Mailbox Transport Drive Service Check 935 on pa...

Page 141: ... Up or Down Go to Finisher Elevator Tray Service Check 993 on page 2 53 Shift Plate Fails to Move Go to Finisher Shift Plate Drive Service Check 995 on page 2 54 Paper Aligning Fails to Move Correctly Go to Finisher Paper Aligning Service Check 996 on page 2 54 Staple Drive Does Not Staple Go to Finisher Stapler Drive Service Check 997 on page 2 56 Holding Tray Fails to Drop Paper After Stapling G...

Page 142: ...the fuses are good check the power switch connector for continuity 4 Power Sup ply PU1 Fuser Frame Resistor Board PWB R Printer Main Engine Board PWB A If the fuses are not blown the listed parts may be bad Replace in the order given FRU Action 1 Thermistor Fuser The thermistor could be shorted Check and replace if necessary Check the fuser for damage If any thing other than the thermistor is dama...

Page 143: ...fuser unit 4 Printer Main Engine Board PWB A The printer main engine board PWB A may be defective Replace the main engine board FRU Action 1 Agitating Motor M10 The toner agitating motor may be defective allowing the toner to cake The caking prevents toner from being supplied to the main hopper Check agitating motor and replace as necessary 2 Toner Deflection Plate The toner sub hopper may be empt...

Page 144: ...U Action 1 Printhead Unit PH The printer may have improper laser exposure Replace the printhead unit 2 Fuser Frame Resistor Board PWB R1 Replace the fuser frame resistor board PWB R1 if necessary 3 Printer Main Engine Board PWB A Replace the printer main engine board PWB A if necessary ...

Page 145: ...ser Frame Resistor Board PWB R1 Printer Main Engine Board PWB A The printer may have poor image transfer Replace the listed parts in the order given as necessary FRU Action 1 Fuser Unit Check for dust toner or damage on the fusing roller Clean or replace as necessary 2 ImageTransfer Roller Check for dust toner or damage to the image transfer roller Clean or replace as necessary 3 Paper Path Clean ...

Page 146: ...Replace the toner cartridge 2 Imaging PC Cartridge Imaging PC cartridge may be at the end of life Replace the imaging PC cartridge 3 High Volt age Power Supply HV1 Fuser Frame Resistor Board PWB R1 Printer Main Engine Board PWB A The printer may have poor development Replace the listed parts in the given order as necessary ...

Page 147: ...maging PC Cartridge PC drum may have reached end of life Replace the imaging PC cartridge 2 High Volt age Power Supply HV1 Fuser Frame Resistor Board PWB R1 Printer Main Engine Board PWB A The printer may have poor development Replace the listed parts in the given order as necessary ...

Page 148: ...ion 1 Imaging PC Cartridge Check for scratches on the PC drum Replace the imaging PC cartridge 2 Printhead Unit Fuser Frame Resistor Board PWB R1 Printer Main Engine Board PWB A The printhead unit may be defective Replace the listed parts in the given order as necessary ...

Page 149: ... 001 Offset Image Service Check FRU Action 1 Fuser Unit Fusing roller may be damaged or worn out Replace the fusing unit 2 Imaging Transfer Roller Imaging transfer roller may be damaged or worn out Replace the imaging transfer roller ...

Page 150: ...m customer to replace imaging PC cartridge if at end of life 4 Printhead Unit Fuser Frame Resistor Board PWB R1 Printer Main Engine Board PWB A Exposure may be improper Replace the printhead unit Replace the listed parts in the order given as necessary 5 Imaging Transfer Roller HighVoltage Power Sup ply HV1 Fuser Frame Resistor Board PWB R Printer Main Engine Board PWB A Image transfer may be poor...

Page 151: ...ls If the defect is not repetitive the image cartridge PC IC may be defective If this does not resolve the problem replace the high voltage power supply HV1 See High Voltage Unit HV1 Removal on page 4 37 49 6 mm Sleeve Roller Imaging PC Cartridge 94 mm PC Drum 50 mm Image Transfer Roller Image Transfer Roller 62 8 mm Upper Fuser Roller Fuser Unit 93 5 mm Lower Fuser Roller ...

Page 152: ...printer main engine board PWB A If PJ13 is plugged in correctly and the solenoid still doesn t work replace the printer main engine board PWB A 3 Paper Take Up roller Ensure the paper take up roller is not damaged and replace if necessary 4 Paper Separator Pad Ensure the separator pad prevents a second sheet from being fed Replace if damaged FRU Action 1 Gears Ensure the main transport motor M2 tr...

Page 153: ...e not damaged and that they turn Replace any damaged or worn parts FRU Action 1 Transport Rollers Ensure paper is picked up normally Ensure the transport rollers are not damaged Replace as nec essary 2 Synchroniz ing Clutch CL1 Printer Main Engine Board PWB A Ensure the synchronizing clutch CL1 is turned on and paper is fed through the synchronizing roller If the synchronizing clutch CL1 is not tu...

Page 154: ...3 Gears Exit Roller Ensure the gear train and exit roller are not dam aged Replace as necessary 4 Fuser Frame Resistor Board PWB R1 Main Printer Engine Board PWB A Replace the listed parts in the given order as nec essary FRU Action 1 Paper Exit Roller Idler Lever Ensure the idler lever and gear are not damaged Replace if necessary 2 Paper Duplex Lever Ensure the duplex lever is not damaged Replac...

Page 155: ... 5 Duplex Transport Motor 2 M2 Ensure the gear and duplex transport motor 2 are not damaged Replace as necessary 6 Manual Feed Paper Take Up Clutch CL3 Ensure the manual feed paper take up clutch is working Replace if necessary FRU Action ...

Page 156: ...izontal transport roller Replace if necessary 4 Storage Unit Transport Motor M1 Ensure gear and motor M1 are not damaged Replace if necessary FRU Action 1 Transport Motor M1 Check for damage to gears and transport motor M1 Replace if necessary 2 Timing Belt Check for broken or damaged timing belts Replace as necessary 3 Entrance Roller Check entrance roller for damage Replace as necessary 4 1st Bi...

Page 157: ...t Bin Deflector Bin 2 9 Deflector Check deflector for damage Replace if damaged 6 Vertical Transport Roller Check vertical transport roller for damage Replace if damaged 7 Exit Roller Check exit roller for damage Replace if damaged FRU Action ...

Page 158: ...port Roll Check transport roller and roll for wear or damage Replace if necessary 4 Upper Entrance Switching Plate Lower Entrance Switching Plate Upper Exit Motor M2 Check upper entrance switching plate lower entrance switching plate upper exit motor M2 for wear or damage Replace if necessary 5 1st Tray Exit Roller 1st Tray Exit Roll Finisher Tray Exit Roller Finisher Tray Exit Roll Check rollers ...

Page 159: ...r present lift 1 empty 1 Paper Take Up Clutch 2 P2CL Paper Take Up Roll 2 LCC Trans port Motor Ensure paper take up clutch 2 turns on when paper is in lift 2 Replace if necessary Ensure paper take up roll 2 is not worn or damaged Replace if neces sary Replace the transport motor HMOT if neces sary 2 Paper Feed Roll Ensure the paper feed roll is not worn or damaged Replace as necessary 3 Separation...

Page 160: ...otor Ensure that the upper exit motor pulls paper into the punch assembly and stops while transport roll continues to turn Replace parts as necessary 3 Hole Punch Assembly Ensure that the electromagnetic clutch in the hole punch assembly moves the punch rods to cut holes Ensure the hole punch box is empty and push any tamped punch holes out of punch Replace the hole punch assembly if damaged 4 Tra...

Page 161: ...ltage is not present check the connectors and cable to the printer power supply unit PU1 Replace as necessary Check for 5 Vdc on connector PJ5A between pin 1 and ground and pin 3 and ground If voltage is not present check the connector on the printer main engine board PWB A Replace the printer main engine board PWB A if necessary If voltages are correct on PJ1 and PJ5A located on the finisher main...

Page 162: ... connectors are plugged in The finisher tray motor may be defective Replace if it fails to turn If problem persists replace the finisher main board PWB A FRU Action 1 Shift Plate Gears Belt The shift plate may be damaged Check for binds or damaged gears The drive belt may be broken Replace as necessary 2 Shift Plate Sensor PC6 The shift plate sensor PC6 may be defective Replace if necessary 3 Shif...

Page 163: ...s Gears Belt Check and replace any damaged parts 3 CD Aligning Motor M4 Ensure all connectors are plugged in Replace the motor if it fails to turn during POR 4 Finisher Main Board PWB A If problem persists replace the finisher main board PWB A FRU Action ...

Page 164: ...ists replace finisher main board PWB A 2 Stapler Unit If the stapler does not energize check for jammed staples or binds Replace parts as necessary Replace staple unit FRU Action 1 Paper Hold Tray Home Sensor PC9 Check the paper holding tray home sensor operation Replace if necessary 2 Paper Holding Tray Belt Guides Ensure the trays drive belt and guides are not damaged Replace if necessary 3 Pape...

Page 165: ...witching Solenoid SL1 Upper Switching Plate Finisher Main Board PWB A Paper entrance switch mechanism fails to operate correctly Check the upper entrance switching solenoid SL1 Check the path of the paper through the upper entrance switching plate If problem persists replace the finisher main board PWB A ...

Page 166: ...A Mailbox Main Board PWB A Check for the following voltages approximate on the mailbox main board PWB A 24 Vdc on connector PJ1 pin 1 to ground If no voltage is present check the main printer power supply PU1 connectors Replace the main printer power supply if necessary Check for 5 Vdc on connector PJ2 pin 1 to ground and pin 3 to ground If voltage is not present check the connectors on the main p...

Page 167: ...k bin deflector replace if damaged Refer to the following for solenoids and sensors tests Advanced Diagnostic Aids Menu Output Bin Feed Test on page 3 13 and Mailbox Sen sor Tests on page 3 18 Mailbox Internal Diagnostic Test on page 3 26 FRU Action 1 Drive Belts Drive Gears Emitter Wheel Sen sor Transport Motor M1 Ensure the connectors are plugged in Check the transport drive belts and gears for ...

Page 168: ...2 60 Service Manual 4023 001 ...

Page 169: ...the machine The printer performs the Power On Self Test 3 Release the buttons when Performing Self Test displays 4 Select Reset Printer to exit Diagnostics mode without a POR 5 Press EXIT DIAGNOSTICS to exit Diagnostics mode and POR the printer Diagnostics Mode Menu Structure The following is the Diagnostics mode menu structure The indented items are sub menus available under the main menu items w...

Page 170: ...Parallel 2 Wrap if available Parallel 3 Wrap if available Serial Wrap if available Serial 1 Wrap if available Serial 2 Wrap if available Serial 3 Wrap if available DUPLEX TESTS Quick Test Top Margin INPUT TRAY TESTS Feed Test OUTPUT BIN TESTS Feed Test Feed To All Bins FINISHER TESTS Staple Test BASE SENSOR TEST Engine LCC Finisher Mailbox ...

Page 171: ...est Clean Flash Test Defaults Page Count Perm Page Count View Tray Count Reset Tray Count Serial Number Configuration ID Edge to Edge Par S Strobe Adj Par 1 Strobe Adj Par 2 Strobe Adj Par 3 Strobe Adj Loop Adjustment ERROR LOG Display Log Clear Log EXIT DIAGNOSTICS ...

Page 172: ...onds horizontal lines used for skew adjustment the page count setting printer serial number code levels and print registration settings The power indicator also blinks while the page is printing When the quick test has successfully printed the panel returns to the prior level of the menu Diagnostics Print Tests Input Source Print Tests The diagnostic input source print tests may be used to verify ...

Page 173: ...age regardless of the duplex setting or the presence of the duplex unit Print Quality Pages 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select PRINT TESTS 3 Select Prt Quality Pgs The following message displays while printing Prt Quality Pgs Printing 4 Press Return to go back to Diagnostics mode main menu Hardware Tests LCD Hardware Test 1 Enter the Diagnostic mode See Diagnosti...

Page 174: ...ectly 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select HARDWARE TESTS 3 Select DRAM Memory Test The power indicator blinks indicating the test is in progress 4 Press Return Stop to exit the test P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F represents the number of tim...

Page 175: ...ses by 1 however if the test fails one of the following messages displays for approximately 3 seconds ROM Checksum Error ROM Burst Read Error Once the maximum pass count or fail count is reached the test stops with the power indicator on solid The final results display Parallel Wrap Test This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tes...

Page 176: ...t Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum cou...

Page 177: ...ace cable and install the wrap plug 2 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 3 Select HARDWARE TESTS 4 Select the appropriate Serial Wrap Test Serial Wrap Serial 1 Wrap Serial 2 Wrap or Serial 3 Wrap P F represent the same numbers for DRAM The power indicator blinks indicating the test is running 5 This test runs continuously unless canceled by pressing Return Stop ...

Page 178: ...rupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum count is reached the test stops The...

Page 179: ...elect Quick Test 4 Select Single or Continuous The following message displays while printing Quick Test Printing 5 Press Return or Stop to stop continuous print 6 Press Return to go back to Diagnostics mode main menu You have the option of printing one duplex page Single or continuously printing duplex pages until Return or Stop is pressed Continuous Note The duplex quick test page should be print...

Page 180: ...uring this test 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select INPUT TRAY TESTS 3 Select Feed Test 4 Open the lower front door to observe the paper path as media is being fed through the printer 5 Select input source Tray1 Tray2 Tray3 or Tray4 6 Select Single or Continuous The following message displays and the power indicator blinks input tray Feeding where input tray repre...

Page 181: ...iagnostic mode See Diagnostics Mode on page 3 1 2 Select OUTPUT BIN TESTS 3 Select Feed Test 4 Select output bin Standard Bin Output Bin 1 Output Bin 10 5 Select Single or Continuous The following message displays and the power indicator blinks output bin Feeding where output bin represents the output bin selected for the feed test 6 Press Return or Stop to stop continuous print The following mess...

Page 182: ...nter automatically diverts all output to Bin 1 No warning or message is posted when media is diverted 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select OUTPUT BIN TESTS 3 Select Feed To All Bins The following message displays and the power indicator blinks All Bin Test Feeding 4 Press Return or Stop to stop the test The following message displays All Bin Testing Cancelling 5 Pr...

Page 183: ...r returns to the original screen Base Printer Sensor Tests The base sensor test is used to determine whether or not the sensors located inside the printer are working correctly All sensor tests are contained under the same menu and they are separated into the following groups Engine Printer LCC 2500 Sheet Optional Paper Drawer Finisher Mailbox Each of these categories can be selected as a sub menu...

Page 184: ...ller 3 Take up 4 4 Take up 3 5 Take up 2 6 MP Paper Pos 7 Duplex Paper 8 Manual Take up 9 Bin 0 Full Note In the example above the Sync Roller MP Paper Pos and Bin 0 Full sensors are all open and the rest are closed LCC Sensor Tests 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select BASE SENSOR TEST 3 Select LCC The following message displays LCC 0001001 The binary number above ...

Page 185: ... the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select BASE SENSOR TEST 3 Select Finisher The following message displays Finisher 000111 10001001100 The binary number above is split into two segments The first segment top line contains six bits Starting from the left most bit the six bits correspond to the following sensors 1 Finisher Tray Exit 2 Tray 1 Exit 3 HTU Paper 4 Copy Set Detectin...

Page 186: ...or Retract 10 Self Priming 11 Paper Hold Retract 12 Paper Hold Home Mailbox Sensor Tests 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select BASE SENSOR TEST 3 Select Mailbox The following message displays Mailbox 000111 01101000100110 The binary number above is split into two segments The first segment top line contains six bits Starting from the left most bit the six bits corre...

Page 187: ...one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good the saved data is written back to the disk 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select DEVICE TESTS 3 Select Quick Disk Test The power indicator blinks while the test is in progress Quick Dis...

Page 188: ...lected Disk Test Clean BAD 000000 00 message displays The screen updates periodically indicating the percentage of test completed and the number of bad blocks found 5 The power indicator blinks during the test The test can be canceled anytime during the test by pressing Return Stop Once the test is complete the power indicator turns on solid and a message displays xxxx Bad Blocks yyyyyy Usable mes...

Page 189: ...d the power indicator turns on solid Flash Test Test Failed message displays if the test fails and the power indicator turns on solid 4 Press Go Return or Stop to return to the Device Tests menu Printer Setup Setting the Page Count 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select PRINTER SETUP 3 Select Page Count The following message displays Page Count 1234567 The left most ...

Page 190: ...or each installed tray Note Tray count cannot be modified from this menu 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select PRINTER SETUP 3 Select View Tray Count 4 Select tray in question The following message displays Tray X Count 1234567 5 Press Return to return to the View Tray Count menu Resetting the Per Tray Page Counters The Reset Tray Count menu lets you reset the page ...

Page 191: ...ee Diagnostics Mode on page 3 1 2 Select PRINTER SETUP 3 Select Configuration ID The left most digit blinks The blinking indicates which digit is ready for editing The following message displays Configuration ID 123456 4 Press Menu or Menu until the value you want displays 5 Press Select to move to the next digit 6 After entering the page count press Select and move to after the final digit and pr...

Page 192: ...e Diagnostics Mode on page 3 1 2 Select PRINTER SETUP 3 Select Loop Adjustment 4 Select Tray 1 Tray 2 4 or Duplex Feeder 5 Set the selected input source to one of the following Setting Displayed on Panel Engine Status Byte with bit 0 masked Small 0 0 mm 0x00 Small 1 0 mm 0x02 Small 1 9 mm 0x04 Small 2 9 mm 0x06 Small 3 8 mm 0x08 Small 4 8 mm 0x0A Big 0 0 mm 0x40 Big 1 0 mm 0x42 Big 1 9 mm 0x44 Big...

Page 193: ...vice messages are stored in the error log Viewing the Error Log 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select ERROR LOG 3 Select Display Log 4 Press Menu to move forward in the log 5 Press Menu to move backward in the log 6 Press Return or Stop to exit the error log Clearing the Error Log 1 Enter the Diagnostic mode See Diagnostics Mode on page 3 1 2 Select ERROR LOG 3 Sele...

Page 194: ...d checked alone Five LEDs are provided on the main board PWB A of the storage unit Operation of electrical and mechanical components such as sensors solenoids and motors can be checked by observing these LEDs Preparation Turn OFF the power to the printer disconnect the storage unit from the printer and then remove each cover from the storage unit as described in Storage Unit Cover Removals on page...

Page 195: ...e horizontal transport unit cable 28 pins This provides signal transfer between the printer and the storage unit Starting Test Mode The starting method varies according to how power is turned ON If the printer has not been powered ON turn ON the power switch on the printer while holding down S1 on the main board PWB A If the printer has already been powered ON press S3 for an instant while holding...

Page 196: ...ode initial display check Test Mode Name LED Display LED1 from left Check Contents Initial Display Check Checks the model installation of Storage Unit Horizontal Transport Unit Sensor Input Check Checks operation of each sensor Printer Model Setting Check Checks printer model setting Initial Operation Check Checks initial operation of the 10 Bin Mailbox Paper Size Input Check Checks paper size set...

Page 197: ...ter properly All the LEDs blink if there are no problems The sorter set switch S1 turns ON and LED3 blinks if the positioning pin on the printer is inserted into the hole on the storage unit properly LED Sensor Switch Code LED State 1 10 Bin Mailbox 2 Not used 3 Sorter Set Switch S1 Storage unit connected properly Storage unit not connected properly 4 Horizontal Unit Door Sensor PC4 Horizontal uni...

Page 198: ...ng order Mode Display Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Mode Display Group 1 LED Sensor Code LED State 1 Paper Exit Sensor Storage Unit PWB C Paper present No paper 2 Horizontal Unit Paper Sensor Horizontal Transport Unit PC1 Paper present No paper 3 Not used 4 Sorter Set Switch Storage Unit S1 Storage unit connected properly Storage unit not connected properly 5 Horizontal Unit Door...

Page 199: ...tion Paper path Non sort tray 4 Sort Bin Positioning Sensor Horizontal Transport Unit PC3 Entrance of Horizontal Unit is in upper position Paper path Horizontal Transport Unit 5 Non Sort Tray Paper Empty Sensor Horizontal Transport Unit PWB A PWB B No paper Paper present LED Sensor Code 1 Paper Empty Detecting Sensor 1st bin PWB B 2 Paper Empty Detecting Sensor 2nd bin PWB D1 3 Paper Empty Detecti...

Page 200: ... Detecting Sensor 6th bin PWB D5 2 Paper Empty Detecting Sensor 7th bin PWB D6 3 Paper Empty Detecting Sensor 8th bin PWB D7 4 Paper Empty Detecting Sensor 9th bin PWB D8 5 Paper Empty Detecting Sensor 10th bin PWB D9 LED Sensor Code 1 Paper Full Detecting Switch 1st bin PWB B 2 Paper Full Detecting Switch 2nd bin PWB D1 3 Paper Full Detecting Switch 3rd bin PWB D2 4 Paper Full Detecting Switch 4t...

Page 201: ...aper size Each time S2 is pressed the paper size switches as shown below When LEDs respond correctly the paper size setting can be made correctly from the printer The paper size will return to A4Y at the 9th depression LED Sensor Code 1 Paper Full Detecting Switch 6th bin PWB D5 2 Paper Full Detecting Switch 7th bin PWB D6 3 Paper Full Detecting Switch 8th bin PWB D7 4 Paper Full Detecting Switch ...

Page 202: ...peration repeats start and stop alternately To exit this mode press S1 while sorting operation is at stop To proceed to the next mode press S1 again after this mode is exited Solenoid Check This mode checks operation of each solenoid Each time S2 is pressed the solenoids turn ON sequentially one at a time When a solenoid turns ON that is the solenoid pin moves in the corresponding bin switching de...

Page 203: ...port unit moves down for duplex printing and moves up for single side printing The default is duplex printing Each time S2 is pressed the entrance moves up or down as shown Press S1 to exit this mode and return to initial display mode 6th 6th bin ON 7th 7th bin ON 8th 8th bin ON 9th 9th bin ON 10th all bins OFF Depression Paper Path 1st Moves up for Horizontal Transport Unit 2nd Moves down for Dup...

Page 204: ...3 36 Service Manual 4023 001 ...

Page 205: ... hot for a while after the printer stops running Always unplug connectors by holding the connector housing Be sure to use the fuse listed in the parts catalog Remember to install the ground wire or ground plate to ensure positive conduction Install the screw with a toothed washer in the right position at reassembly Handling the Printed Circuit Boards with MOS ICs The following precautions must be ...

Page 206: ...ing the IC directly with a multi meter use connectors on the board Never create a closed circuit across IC pins with a metal tool If it is necessary to touch the ICs and other electrical components on the board be sure to ground your body Image Cartridge PC I C Handling Precautions The following precautions must be observed when handling the image cartridge PC During Transportation Storage Use the...

Page 207: ...Repair Information 4 3 4023 001 Parts Not To Be Touched Any part where the mounting screws are painted red such as the printhead must not be removed disassembled or adjusted ...

Page 208: ...EGISTRATION from the Configuration Menu Group 4 Scroll to the margin you want and press Select See the following table 5 Scroll to the value you want and press Select A Quick Test page prints 6 Repeat margin adjustment until the registration gap d is the appropriate distance Margin Valid Range Top Margin 50 to 50 0 Tray 1 Left Mar 50 to 50 0 Tray 2 Left Mar 50 to 50 0 Tray 3 Left Mar 50 to 50 0 Tr...

Page 209: ...over interlock switch S2 up and down and tighten the screw at the position where the switch turns on Finisher Punch Hole Position Check Adjustment 1 Set the printer into the hole punch mode and make a print in the 1 1 setting 2 Fold the print in half and check to see if the punch holes are aligned deviation should be within 2 mm 3 If the holes are misaligned loosen the two screws that secure the p...

Page 210: ...4 6 Service Manual 4023 001 Solenoids and Sensors Adjustment ...

Page 211: ...Repair Information 4 7 4023 001 Upper Entrance Switching Solenoid SL1 1 Loosen the two screws 2 Move SL1 left and right so that dimension A measures 4 1 mm 3 Secure two screws ...

Page 212: ...he sensor with a sheet of paper 3 Measure the voltage on the print jack on PWB A 4 Turn VR counterclockwise until the voltage reads 4 3V or more 5 Remove the sheet of paper and check that the voltage is 0 8V or less Elevator tray empty sensor LED PWB E VR4 1st tray full detecting sensor LED PWB E VR7 Elevator tray empty sensor LED PWB E PJ16A 11B 1st tray full detecting sensor LED PWB E PJ16A 7B ...

Page 213: ... the stroke of the 1st bin switching solenoid as shown Check the Timing Belts Tension 1 Remove the storage unit rear cover 2 Check the tension of each timing belt Ensure any belt sag is within the specified range when the belt center is hand pushed with the listed force Check Point Force gf Sag 1 100 to 200 2 mm 2 200 to 300 2 mm ...

Page 214: ...present and extinguishes when there is no paper 2 Ensure that paper is not present in any bin and perform the following a Rotate VR to the full clockwise position and check that LED1 illuminates b Rotate VR counterclockwise slowly until LED1 starts to extinguish Record this position as position A If LED1 extinguishes at the full clockwise position record that position as position A 3 Place paper i...

Page 215: ...ull clockwise position and turn the printer ON 2 Start test mode and set the sensor input mode See Sensor Input Check on page 3 30 a Replaced Component b Sensor c Test Mode Sensor Input Check d VR PWB D1 1 Bin Empty Sensor Group 3 LED1 VR1 PWB D2 2 Bin Empty Sensor Group 3 LED2 VR2 PWB D3 3 Bin Empty Sensor Group 3 LED3 VR3 PWB D4 4 Bin Empty Sensor Group 3 LED4 VR4 PWB D5 5 Bin Empty Sensor Group...

Page 216: ...l clockwise position 9 When LED c illuminates record the position all the way to the right as position B 10 When the LED c goes off slowly turn VR d counterclockwise and record the position where LED illuminates as position B Resetting Maintenance Counters Resetting Hole Punch Counter When the hole punch box has been emptied the hole punch counter must be reset Perform the following to reset the c...

Page 217: ...d press Select The fuser page counter resets while the following message displays Resetting Fuser Count Resetting Transfer Counter When the transfer roll transfer mmkit is installed the transfer page counter must be reset 1 Turn the printer off 2 Press Select and Return as you turn the machine on 3 Select MAINT COUNTER from the Configuration Menu Group 4 Scroll to Reset Transfer and press Select T...

Page 218: ...al Procedures Pre disassembly 1 Remove the 1st cassette 1 2 Remove the 2nd cassette 2 3 Remove the 3rd cassette 3 4 Remove the toner cartridge 4 5 Raise the right cover release lever 7 and open the right cover 5 6 Remove the imaging cartridge 6 ...

Page 219: ...2 Remove the top cover 1 2 screws 3 Remove the front cover 2 2 screws Note When reinstalling the top and front cover securely insert the projections 3 4 of the covers into the appropriate cutouts of the printer frame 4 Remove the left cover 1 4 screws 5 Remove the harness cover 2 1 screw 6 Remove the rear cover 3 6 screws ...

Page 220: ...tte 2 Remove C clip 1 from end of rod 2 3 Remove C clip 3 4 Slide paper take up roller 4 to end of rod 2 5 Lift rod 2 and remove paper take up roller 4 250 Sheet Cassette Tray 1 Paper Take Up Rolls Removal 1 Remove the cassette from the upper drawer 2 Unlock the paper take up roll 1 and slide it off its shaft ...

Page 221: ...23 001 Note When installing the roll ensure it securely locks into place as illustrated 250 Sheet Cassette Tray 1 Paper Take Up Rolls Cleaning Clean the surface of the paper take up rolls with a soft cloth dampened with alcohol ...

Page 222: ...cal Transport Roller Rolls Cleaning Clean the surface of the vertical transport roller rolls with a soft cloth dampened with alcohol 500 Sheet Cassette Tray 2 and 3 Paper Lifting Springs Replacement Note The replacement springs are housed on the bottom of the cassette ...

Page 223: ...n 4 19 4023 001 1 Remove the cassette 2 Remove the two edge guide assemblies 1 2 screws each 3 Replace the springs 1 Note When installing the springs make sure both ends of the spring are properly secured as illustrated ...

Page 224: ...and optional tray 1 Remove the 2nd cassette 2 Turn the 2nd cassette over and remove the cover 1 2 screws 3 Remove the right PWB I assembly 2 1 screw 1 connector 4 Remove the left PWB I assembly 3 1 screw 1 connector 5 Remove the paper size detecting lever 1 and the left PWB S2 2 6 Remove the paper size detecting lever 1 and the right PWB S2 2 ...

Page 225: ...air Information 4 21 4023 001 Image Transfer Roller Removal 1 Raise the right cover release lever and open the right cover 2 Raise the pre image transfer guide plate 1 3 Remove the image transfer roller 2 ...

Page 226: ...move the I C thermistor TH2 1 screw 1 connector Image Transfer Unit Removal 1 Raise the right cover release lever and open the right cover 2 Remove two projections 2 and the image transfer unit 1 4 connectors Note Because the harness is short slightly raise the image transfer unit 1 and unplug the connector before attempting to remove the image transfer unit 1 ...

Page 227: ...3 001 Synchronizing Roller Sensor PC2 Removal 1 Remove the image transfer unit 1 See Image Transfer Unit Removal on page 4 22 2 From the back side of the image transfer unit 1 remove the synchronizing roller sensor PC2 2 2 screws ...

Page 228: ...Manual 4023 001 Pre transfer Guide Plate Register Plate PWB R2 Removal 1 Remove the image transfer roller See Image Transfer Unit Removal on page 4 22 2 Turn the imaging transfer unit over and remove PWB R2 2 screws ...

Page 229: ...g Roller Removal 1 Remove the image transfer unit See Image Transfer Unit Removal on page 4 22 2 Remove the paper dust remover 1 3 Remove two E ring and transport clutch 2 4 Remove the synchronizing roller 3 3 E rings 2 springs 4 bushings 2 gears ...

Page 230: ...oling Fan Motor M3 and I C Filter Removal 1 Remove the image transfer unit See Image Transfer Unit Removal on page 4 22 2 Remove the filter 1 3 Remove the filter fixing plate 2 2 screws 4 Remove the cooling fan motor M3 1 1 connector ...

Page 231: ...over 2 Loosen 2 screws and remove the fusing unit 1 Paper Exit Sensor PC3 and Actuator Removal 1 Remove the fusing unit See Fusing Unit Removal on page 4 27 2 Open the fusing unit cover 1 3 Compress projections and remove the paper exit sensor cover 2 4 Remove the paper exit sensor PC3 3 5 Remove the actuator 4 ...

Page 232: ...age 4 27 2 Remove the harness cover 1 1 screw 3 Remove the harness holder 2 2 screws 1 connector 4 Release one projection of the fusing unit cover and remove the heater lamp cover 3 2 screws Note The spring for opening and closing the fusing unit cover is removed when the heater lamp cover is removed ...

Page 233: ...p holder front 1 1 screw 3 Remove the earth 2 1 screw 4 Remove the gear assembly 3 1 spring 5 Remove the heater lamp cover rear 4 2 screws 6 Remove the heater lamp holder rear 5 2 screws 7 Remove the heater lamp H1 6 1 screw Fusing Roller Thermistor TH1 Removal 1 Remove the upper fusing roller 2 Remove the fusing roller thermistor TH1 1 1 screw ...

Page 234: ...4 30 Service Manual 4023 001 Fusing Roller Thermostat TS1 Removal 1 Remove the upper fusing roller 2 Remove the fusing roller thermostat TS1 1 2 screws ...

Page 235: ...l Sensor PC12 Removal 1 Remove the top cover 2 screws Note When reinstalling the top cover securely insert the projections of the cover into the appropriate cutouts of the printer frame 2 Remove the paper exit full sensor PC12 1 1 screw 1 connector ...

Page 236: ...ws Note When reinstalling the top cover securely insert the projections of the top cover into the appropriate cutouts of the printer frame 2 Raise the right cover release lever and open the right cover 3 Remove the imaging cartridge 4 Remove the eraser duct assembly 1 3 screws 1 connector ...

Page 237: ...Repair Information 4 33 4023 001 Erase Lamp LA1 Removal 1 Remove the eraser duct assembly See Eraser Duct Assembly Removal on page 4 32 2 Release three projections and remove the erase lamp LA1 1 ...

Page 238: ...34 Service Manual 4023 001 Fuser Frame Resistor Board PWB R1 Removal 1 Remove the eraser duct assembly See Eraser Duct Assembly Removal on page 4 32 2 Remove the cover 1 1 screw 3 Remove PWB R1 2 2 screws ...

Page 239: ...ette Paper Empty Sensor PC4 Removal 1 Remove the eraser duct assembly See Eraser Duct Assembly Removal on page 4 32 2 Remove the 1st cassette paper empty sensor assembly 1 1 screw 1 connector 3 Remove the 1st cassette paper empty sensor PC4 2 ...

Page 240: ...ce Manual 4023 001 Image Cartridge PC I C Cooling Fan Motor M9 Removal 1 Remove the eraser duct assembly See Eraser Duct Assembly Removal on page 4 32 2 Remove the I C cooling fan motor M9 1 2 screws 1 connector ...

Page 241: ...ge Unit HV1 Removal 1 Remove the I C Cooling Fan Motor M9 See Image Cartridge PC I C Cooling Fan Motor M9 Removal on page 4 36 2 Remove the high voltage unit cover 1 2 screws 1 connector 3 Remove the high voltage unit HV1 2 2 screws 5 connectors ...

Page 242: ... 2 screws Note When reinstalling the top cover securely insert the projections of the top cover into the appropriate cutouts of the printer frame 2 Remove the top cover of the main board reinforcement box cover 1 10 screws 3 Remove the top cover of the main board reinforcement box 2 6 screws ...

Page 243: ...Repair Information 4 39 4023 001 4 Remove PWB A 1 4 screws 5 Adjust image registration if necessary See Image Registration Adjustment on page 4 4 ...

Page 244: ...rinter Main Engine Board PWB A Removal on page 4 38 2 Remove the toner cartridge 3 Remove the rear cover 6 screws Note When reinstalling the rear cover securely insert the projections of the rear cover into the appropriate cutouts of the printer frame 4 Remove the left reinforcement plate 1 6 screws ...

Page 245: ...Repair Information 4 41 4023 001 5 Disconnect the harness 3 cord clamps and remove the handle 1 5 screws ...

Page 246: ...4 42 Service Manual 4023 001 6 Remove the printhead unit assembly 1 4 screws ...

Page 247: ...emoval 1 Remove the 1st cassette 2 Remove the front cover 2 screws Note When reinstalling the front cover securely insert the projections of the front cover into the appropriate cutouts of the printer frame 3 Remove the side switch S3 1 1 screw 4 connectors ...

Page 248: ...1 Power Supply Unit PU1 Removal 1 Remove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the left cover 4 screws 4 Remove the left reinforcement plate 6 screws 5 Remove the power supply base 1 3 screws 5 connectors ...

Page 249: ... 4 45 4023 001 6 Remove PU1 1 6 screws CPM Power Supply Safety Switch and PWB L Removal 1 Remove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove PWB L assembly 1 1 screw 4 Remove PWB L 2 1 screw 1 connector ...

Page 250: ...e Manual 4023 001 Power Unit Cooling Fan Motor M4 Removal 1 Remove the main board PWB A See Printer Main Engine Board PWB A Removal on page 4 38 2 Remove the power unit cooling fan motor M4 1 2 screws 1 connector ...

Page 251: ... and Ozone Filter Removal 1 Remove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the ozone filter assembly 4 1 screw 1 connector 4 Remove the ozone filter 1 5 Remove the ozone fan motor cover 2 2 screws 6 Remove the ozone fan motor M8 3 ...

Page 252: ... 1st Paper Cassette Tray 1 Paper Size Detecting Board Removal 1 Remove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the PWB S1 assembly 1 2 screws 1 connector 4 Remove the paper size detecting lever 2 and PWB S1 3 ...

Page 253: ...ion 4 49 4023 001 Bottle Cover Sensor PC10 Removal 1 Remove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the bottle cover sensor assembly 1 1 screw 1 connector 4 Remove the bottle cover sensor 2 PC10 ...

Page 254: ...e Manual 4023 001 Agitating Motor M10 Removal 1 Remove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the agitating motor assembly 1 2 screws 2 connectors 4 Remove the agitating motor M10 2 2 screws ...

Page 255: ...2 Remove the rear cover 6 screws 3 Compress the ends of both shafts and remove two gears 4 Remove the hopper motor assembly 1 2 screws 5 Remove the helical gear and shaft 2 1 E ring 6 Remove the main hopper motor M6 3 2 screws 7 Remove the helical gear and shaft 4 1 E ring 8 Remove the sub hopper motor M7 5 2 screws ...

Page 256: ...4 52 Service Manual 4023 001 Transport Motor M2 Removal 1 Remove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the transport motor M2 1 4 screws 1connector ...

Page 257: ... Remove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the right cartridge hopper cover 1 screw 4 Remove the cartridge hopper assembly 4 screws 2 connectors 5 Remove the cartridge hopper housing assembly 4 screws 6 Remove the I C drive motor M1 1 4 screws 1 connector ...

Page 258: ...toner cartridge 2 Remove the rear cover 6 screws 3 Remove the right cartridge hopper cover 1 screw 4 Remove the cartridge hopper assembly 4 screws 2 connectors 5 Remove the cartridge hopper housing assembly 4 screws 6 Remove the right door interlock switch S2 1 2 screws 2 connectors ...

Page 259: ...ove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the right cartridge hopper cover 1 screw 4 Remove the cartridge hopper assembly 4 screws 2 connectors 5 Remove the cartridge hopper housing assembly 4 screws 6 Remove the toner detecting read switch S4 1 2 screws ...

Page 260: ...4 56 Service Manual 4023 001 This page is intentionally blank ...

Page 261: ...e the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the right cartridge hopper cover 1 screw 4 Remove the cartridge hopper assembly 4 screws 2 connectors 5 Remove the cartridge hopper housing assembly 4 screws 6 Remove the 1st cassette paper near empty sensor PC5 1 1 screw 1 connector ...

Page 262: ...ove the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the right cartridge hopper cover 1 screw 4 Remove the cartridge hopper assembly 4 screws 2 connectors 5 Remove the cartridge hopper housing assembly 4 screws 6 Remove the 1st cassette set sensor PC6 1 1 connector ...

Page 263: ...e the toner cartridge 2 Remove the rear cover 6 screws 3 Remove the right cartridge hopper cover 1 screw 4 Remove the cartridge hopper assembly 4 screws 2 connectors 5 Remove the cartridge hopper housing assembly 4 screws 6 Remove the 1st cassette paper take up solenoid SL1 1 1 screw 1 connector ...

Page 264: ...tridge hopper cover 1 screw 4 Remove the cartridge hopper assembly 4 screws 2 connectors 5 Remove the cartridge hopper housing assembly 4 screws 6 Remove the 2nd cassette main board cover 1 1 screw 7 Remove the 2nd cassette unit 2 4 screws 4 fix plates 1 connector Note Place the printer body so that the left side is on the bottom when the 2nd cassette is removed ...

Page 265: ...Repair Information 4 61 4023 001 8 Remove the PWB H assembly 1 1 screw 1 connector 9 Remove the PWB H 2 1 screw ...

Page 266: ... Remove the rear cover 6 screws 3 Remove the right cartridge hopper cover 1 screw 4 Remove the cartridge hopper assembly 4 screws 2 connectors 5 Remove the cartridge hopper housing assembly 4 screws 6 Push and hold right projection and remove the 2nd cassette board cover 1 1 screw 7 Remove PWB A2 2 2 screws 2 connectors ...

Page 267: ...4 63 4023 001 500 Sheet Cassette Tray 2 and 3 Paper Take Up Roller Removal 1 Remove the 2nd cassette unit See Double Feed Detection Sensor Board PWB H Removal on page 4 60 2 Remove the 2nd cassette paper take up roller 1 ...

Page 268: ... Removal 1 Remove the 2nd cassette unit See Double Feed Detection Sensor Board PWB H Removal on page 4 60 2 Release 3 projections and remove the harness cover 1 3 Remove the 2nd cassette paper empty sensor cover 2 1 screw 1 connector 4 Remove the 2nd cassette paper empty sensor PC22 3 ...

Page 269: ...he 2nd cassette unit See Double Feed Detection Sensor Board PWB H Removal on page 4 60 2 Release 3 projections and remove the harness cover See 500 Sheet Cassette Tray 2 and 3 Paper Empty Sensor PC22 Removal on page 4 64 for illustration 3 Remove the 2nd cassette paper near empty sensor PC25 1 1 screw 1 connector ...

Page 270: ...eet Cassette Tray 2 and 3 Right Door Detecting Sensor PC23 Removal 1 Remove the 2nd cassette unit See Double Feed Detection Sensor Board PWB H Removal on page 4 60 2 Remove the 2nd cassette right door detecting sensor PC23 1 1 connector ...

Page 271: ...lenoid SL2 Removal 1 Remove the 2nd cassette unit See Double Feed Detection Sensor Board PWB H Removal on page 4 60 2 Unhook one side of the spring 1 3 Remove the 2nd cassette paper take up solenoid 2 1 screw 4 Remove the 2nd cassette paper take up solenoid SL2 3 1 screw 1 connector ...

Page 272: ...4 68 Service Manual 4023 001 Duplex Unit Removal Procedures Duplex Unit Removal 1 Remove the wiring cover 1 1 screw 2 Unplug the 2 connectors 3 Remove the duplex unit 1 2 screws ...

Page 273: ...Repair Information 4 69 4023 001 Duplex Unit Cleaning Wipe the surfaces of duplex unit transport roller 1 and 2 and duplex unit transport roll 1 and 2 clean with a soft cloth dampened with alcohol ...

Page 274: ...s Exterior Parts Removal Left Cover 1 Removal Remove 2 screws Front Cover 2 Removal Slide out the LCC and remove 3 screws Side Panel 3 Removal Open the side panel Right cover 4 removal Remove 2 screws Maintenance Panel 5 Removal Remove 1 screw Rear Cover 6 Removal Remove 4 screws ...

Page 275: ...Repair Information 4 71 4023 001 Paper Take Up Unit Removal 1 Remove the LCC 1 4 screws 2 Unplug 3 connectors and remove the harness from 5 cord clamps ...

Page 276: ...4 72 Service Manual 4023 001 3 Remove right cover 1 2 screws 4 Open the side panel 5 Remove paper take up unit 1 2 screws ...

Page 277: ...23 001 Paper Take Up Rolls Removal 1 Remove the paper take up unit See Paper Take Up Unit Removal on page 4 71 2 Unplug lift up sensor 1 and take up clutch 1 connectors of the right paper take up roll assembly 3 Unhook 2 springs ...

Page 278: ...23 001 4 Remove 1 screw and slide timing belt toward the clutch side Remove the right paper take up roll assembly 1 Note When mounting the right paper take up roll assembly fit the ends of the assembly into position as shown ...

Page 279: ...Repair Information 4 75 4023 001 5 Unplug lift up sensor 2 and take up clutch 2 connectors of the left paper take up roll assembly 6 Unhook 2 springs ...

Page 280: ...4 76 Service Manual 4023 001 7 Remove left paper take up roll assembly 1 1 screw Note When mounting the left paper take up roll assembly fit the ends of the assembly into position as shown ...

Page 281: ...Repair Information 4 77 4023 001 Note When mounting the paper take up roll assemblies fit the take up clutch into position as shown 8 Take the shaft 1 and paper take up roll 1 2 apart 1 C clip ...

Page 282: ...4 78 Service Manual 4023 001 Note When mounting paper take up roll 1 face the C clip as shown 9 Remove paper take up roll 2 1 2 C clips ...

Page 283: ...Information 4 79 4023 001 Feed Roll Separator Roll and Torque Limiter Assembly Removal 1 Open the side cover 2 Remove the separator roll and torque limiter assembly 1 1 C clip 3 Remove the feed roll 1 1 C clip ...

Page 284: ... the paper take up unit 2 Wipe the surface of paper take up roll 1 2 clean with a soft cloth dampened with alcohol Feed Roll and Separator Roll Cleaning 1 Open the side panel 2 Wipe the surface of the feed separator roll clean with a soft cloth dampened with alcohol ...

Page 285: ...e the paper take up unit 2 Wipe the surface of the vertical transport roller rolls clean with a soft cloth dampened with alcohol Roll with a Torque Limiter Cleaning 1 Slide out the LCC 2 Wipe the surface of the roll with a torque limiter clean with a soft cloth dampened with alcohol ...

Page 286: ... Left Cover 2 Removal 1 Remove the finisher tray cover 2 Remove 2 screws Upper Rear Cover 3 Removal 1 Open the misfeed clearing cover 2 Remove 3 screws Upper Right Cover 4 Removal 1 Open the misfeed clearing cover 2 Remove 2 screws Front Cover 5 Removal 1 Open the misfeed clearing cover 2 Remove the upper right cover 3 Remove 5 screws Rear Cover 6 Removal Remove 5 screws ...

Page 287: ...Repair Information 4 83 4023 001 ...

Page 288: ...4 84 Service Manual 4023 001 Punch Unit Removal 1 Remove punch unit 1 4 screws ...

Page 289: ...Repair Information 4 85 4023 001 Stapler Unit Disassembly 1 Remove handle 1 and cover 2 2 screws 2 Remove plate 3 2 screws 3 Remove guide 4 1 screw ...

Page 290: ...ce Manual 4023 001 Rear Cable Removal 1 Remove PWB A 1 6 screws 2 Remove the elevator motor M9 assembly 1 6 screws 2 C clips Note During the removal procedure support the elevator tray to prevent it from falling ...

Page 291: ...ormation 4 87 4023 001 3 Pull out the stapling unit 1 4 Remove the stapling unit base 2 4 screws 5 Unhook the cable 1 from the spring 2 6 Remove the ball 3 from the cable pulley 7 Unhook the cable 4 from the hook ...

Page 292: ...4 88 Service Manual 4023 001 Front Cable Removal 1 Unhook the cable 1 from the spring 2 2 Remove the ball 3 from the cable pulley 3 Unhook the cable from the hook ...

Page 293: ...the rear cable except the cable winding direction which is opposite 1 Hook the cable 1 on the hook 2 Wind the cable 1 around the pulley 3 Wind the cable counterclockwise and load the ball 2 into the cable pulley 4 With the elevator tray in the uppermost position wind the cable about five turns ...

Page 294: ...rest of the cable counterclockwise 6 With the elevator tray in the uppermost position wind the cable about 1 turn 7 Hook the cable 1 to the pulley 8 Hook the cable 2 to the spring 9 Pass the cable through the spring and secure it to the hook ...

Page 295: ...e Removing the rear cover lets you access the main board and transport motor Removing the front cover lets you access each solenoid Rear Cover 1 Removal Remove 6 screws Front Cover 2 Removal Remove 6 screws Top Cover 3 Removal 1 Remove rear cover 1 2 Remove front cover 2 3 Remove top cover 3 ...

Page 296: ...nit Cover Removal Warning Before removing the finisher or mailbox ensure that the horizontal transport unit is firmly supported or removed Failure to adhere will result in damage to the finisher or mailbox mounting brackets Remove rear cover 1 3 screws ...

Page 297: ...Locations 5 1 4023 001 5 Locations Printer with Options ...

Page 298: ...ter Lamp H1 is incorporated 15 2nd Cassette Paper Take up Roller 5 Paper Exit Roller 16 2nd Cassette Paper Empty Sensor PC22 6 Paper Exit Sensor PC3 17 2nd Cassette Paper Take up Solenoid SL21 7 Lower Fusing Roller 18 1st Cassette Paper Take up Roller 8 PC Drum 19 1st Cassette Paper Take up Solenoid SL1 9 Image Transfer Roller 20 1st Cassette Paper Empty Sensor PC4 10 Sleeve Roller 21 2nd Paper Ca...

Page 299: ...Locations 5 3 4023 001 Gear Roller Assignment Motors ...

Page 300: ...5 4 Service Manual 4023 001 Electrical Components ...

Page 301: ... PWB S1 1st Cassette Paper Size Detecting Board M9 I C Cooling Fan Motor PWB S2 2nd Cassette Paper Size Detecting Board M10 Agitating Motor S1 Power Switch PC2 Synchronizing Roller Sensor S2 Right Side Door Interlock Switch PC3 Paper Exit Sensor S3 Right Door Switch PC4 1st Cassette Paper Empty Sensor S4 Toner Detection Plate Read Switch PC5 1st Cassette Paper Near Empty Sensor S5 1st Cassette Pap...

Page 302: ...5 6 Service Manual 4023 001 Electrical Components cont ...

Page 303: ...e condition of the 2nd cassette side door When it is opened the sensor output is H PC25 2nd Cassette Paper Near Empty Sensor Detects paper near empty condition of the 2nd paper cassette Active L S1 Power Switch Turns power on and off S2 Right Door Interlock Switch Detects open close condition of the right door When it is closed the switch is ON S3 Right Door Switch Detects open close condition of ...

Page 304: ...5 8 Service Manual 4023 001 Printer Main Engine Board PWB A F1 Fuse 3A 125V F2 Fuse 3A 125V VR1 Factory setting do not touch ...

Page 305: ...Locations 5 9 4023 001 RIP Controller Card J1 Memory DIMM J13 Code DIMM J3 Memory DIMM J15 Riser Card J4 Memory DIMM U27 Hard Disk J10 Parallel Port ...

Page 306: ...5 10 Service Manual 4023 001 High Voltage Board HV1 Factory settings do not touch Power Unit PU1 F1 Fuse 10A 125V F2 Fuse 15A 250V All other Factory settings do not touch ...

Page 307: ...Locations 5 11 4023 001 Network Interface Card NIC Default setting of jumper posts ...

Page 308: ...5 12 Service Manual 4023 001 Paper Cassettes Fixed Paper Size Cassette Tray 1 only Universal Cassette Tray 2 3 and 500 Sheet Option ...

Page 309: ...Locations 5 13 4023 001 Cross Sectional View Fixed Paper Size Cassette Tray 1 only Universal Cassette Tray 2 3 and 500 Sheet Option ...

Page 310: ...m Paper Cassette Electrical Components Symbol Name Symbol Name PWB A Cassette Main Board S2 Side Cover Set Sensor PWB S Paper Size Detecting Board S3 Take Up Sensor SL1 Take Up Solenoid S4 Paper Empty Sensor S1 Cassette Set Switch S5 Paper Near Empty Sensor ...

Page 311: ...Locations 5 15 4023 001 Duplex Unit Parts Identification Duplex Cross Sectional View ...

Page 312: ...5 16 Service Manual 4023 001 Duplex Drive System ...

Page 313: ...ions 5 17 4023 001 Duplex Electrical Components Symbol Name PWB A Duplex Main Board M1 Switchback Motor M2 Duplex Unit Transport Motor S2 Duplex Unit Door Set Sensor PL1 Duplex Unit Transport Sensor in PWB A ...

Page 314: ...5 18 Service Manual 4023 001 Paper Deck Parts Identification 1 Lift 2 5 Separator Roll 2 Front Cover 6 Side Cover 3 Lift 1 7 Vertical Transport Rolls 4 Feed Roll ...

Page 315: ...Locations 5 19 4023 001 Paper Deck Cross Sectional View 1 Lift 2 5 Vertical Transport Roller 2 Paper Take Up Roll 2 6 Vertical Transport Roll 3 Lift 1 7 Feed Roll 4 Paper Take Up Roll 1 8 Separator Roll ...

Page 316: ...5 20 Service Manual 4023 001 Paper Deck Drive System ...

Page 317: ...r Empty Sensor 2 FRONT LCC Set Sensor PWB A LCC Main Board HMOT LCC Transport Motor RCL Registration Clutch LS1 Lift Up Sensor 1 RS1 Paper Near Empty Sensor 1 LS2 Lift Up Sensor 2 RS2 Paper Near Empty Sensor 2 P1CL Take Up Clutch 1 RSEN Registration Sensor P2CL Take Up Clutch 2 S1 Paper Standby Position Sensor PPS0 LCC Take Up Sensor SIDE Side Cover Set Sensor ...

Page 318: ...Service Manual 4023 001 Finisher Parts Identification 1 1st Tray 6 Rear Cover 2 Upper Right Cover 7 Finisher Tray Cover 3 Misfeed Clearing Cover 8 Upper Rear Cover 4 Front Cover 9 Staple Door 5 Elevator Tray ...

Page 319: ...nsport Rolls 3 1st Tray Exit Sensor PC1 11 Horizontal Transport Rollers 4 Upper Entrance Switching Plate 12 Lower Entrance Switching Plate 5 Transport Roll 13 Finisher Tray Exit Roller 6 Transport Roller 14 Elevator Tray Empty Sensor PQ PWB F 7 Entrance Roller 15 Finisher Tray Exit Roll 8 Entrance Roll 16 Finisher Tray Exit Sensor PC3 ...

Page 320: ...5 24 Service Manual 4023 001 Finisher Drive System ...

Page 321: ...Locations 5 25 4023 001 1 Paper Holding Tray Motor M10 5 CD Aligning Motor M4 2 Shift Motor M5 6 Finisher Tray Motor M8 3 Paddle Motor M6 7 Elevator Motor M9 4 Paper Curl Taming Motor M7 ...

Page 322: ...5 26 Service Manual 4023 001 Finisher Electrical Components ...

Page 323: ... PWB F Elevator Tray Empty Sensor PQ M9 Elevator Motor PWB F 1st Tray Full Detecting Sensor PQ M10 Paper Holding Tray Motor S1 Upper Cover Set Switch PC1 1st Tray Exit Sensor S2 Elevator Upper Limit Interlock Switch 1 PC2 Finisher Tray Home Position Sensor S3 Elevator Upper Limit Interlock Switch 2 PC3 Finisher Tray Exit Sensor S4 Staple Door Switch PC4 1st Tray Empty Sensor S5 Elevator Lower Limi...

Page 324: ...5 28 Service Manual 4023 001 Finisher Main Board PWB A ...

Page 325: ...Locations 5 29 4023 001 Mailbox External View Front When Connected To Printer External View Rear When Connected To Printer ...

Page 326: ...5 30 Service Manual 4023 001 Mailbox External View Each Section Mailbox Horizontal Transport Unit Cross Sectional View ...

Page 327: ... Horizontal Transport Unit Mechanical Components Symbol Name Solenoid PC1 Horizontal Unit Paper Sensor PC2 Non Sort Tray Positioning Sensor PC3 Sort Bin Positioning Sensor PC4 Horizontal Unit Door Sensor PWB A Non Sort Tray Paper Empty Sensor PQ PWB B Non Sort Tray Paper Empty Sensor LED ...

Page 328: ...t Cross Sectional View 1 Entrance Roller 2 1st Bin Switching Deflector 3 2nd Bin Switching Deflector 4 Vertical Transport Roller 5 Exit Roller 6 Paper Full Detecting Switch 7 Paper Empty Detecting Sensor Board 8 Bin Tray 1st to 10th bin from the top ...

Page 329: ... Empty Detecting Sensor Board 4th bin PWB D4 Paper Empty Detecting Sensor Board 5th bin PWB D5 Paper Empty Detecting Sensor Board 6th bin PWB D6 Paper Empty Detecting Sensor Board 7th bin PWB D7 Paper Empty Detecting Sensor Board 8th bin PWB D8 Paper Empty Detecting Sensor Board 9th bin PWB D9 Paper Empty Detecting Sensor Board 10th bin PWB C Paper Exit Sensor Board common to all bins S1 Sorter Se...

Page 330: ...5 34 Service Manual 4023 001 Mailbox Storage Unit Mechanical Components Mailbox Storage Unit Main Board PWB A ...

Page 331: ...Mkit none 250 000 Tray 1 250 Sheet Paper Take Up Roller Clean with a soft cloth dampened with alcohol Replaced at the time of trouble due to wear Second Cassette Tray 2 3 Take Up Roller Clean with a soft cloth dampened with alcohol Replaced at the time of trouble due to wear Duplex Transport Roll Transport Roller Clean with a soft cloth dampened with alcohol Replaced at the time of trouble due to ...

Page 332: ...limiter transport roll transport roller Clean with a soft cloth dampened with alcohol Replaced at the time of trouble due to wear Mailbox Finisher All rolls All rollers Clean with a soft cloth dampened with alcohol Replaced at the time of trouble due to wear Parts Cleaning Replacement Single Prints ...

Page 333: ... that the individual parts or the next higher assembly should be ordered NR Not Recommended in the Units column indicates that the part is procurable but not recommended for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted availability NS Not Shown in the Ref column indicates that the part is procurable ...

Page 334: ...Parts Catalog 7 2 4023 001 Assembly 1 Printer Housing ...

Page 335: ...r 9 12G2009 1 Handle 10 12G2010 1 Front Cover 11 12G2011 1 Label 12 12G2012 1 Cover 13 12G2013 1 Shield Plate 14 12G2014 1 Harness 15 12G2015 1 Harness 16 12G2016 1 Seal 17 12G2017 1 Cover 18 12G2018 1 Cover 19 12G2019 1 Tray 20 12G2020 1 Pressure Spring 21 12G2021 1 Cover 22 12G2022 1 Cover 23 12G3520 1 Operator Control Panel C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 E 1 Parts P...

Page 336: ...Parts Catalog 7 4 4023 001 Assembly 2 Printer Frames A ...

Page 337: ...Foot 12 12G2042 4 Holder 13 12G2043 1 Collar 14 12G2044 1 Bracket 15 12G2045 1 Harness 16 12G2046 1 Switch Power S1 Main SW 17 12G2047 1 Harness 18 12G2048 1 Bracket 19 12G2049 1 Switch SW Interlock S3 Right Side Door 20 12G2050 1 Guide Plate 21 12G2051 1 Harness 22 12G2052 1 Lever 23 12G2053 3 Retaining Ring 24 12G2054 1 Tension Spring 25 12G2055 1 Bracket 26 12G2056 3 Shaft 27 12G2057 1 Joint 28...

Page 338: ...Parts Catalog 7 6 4023 001 Assembly 2 cont Printer Frames A ...

Page 339: ... cont Printer Frames A Ref Part Number Units Description 2 34 12G2064 1 Label 35 12G2065 1 Bracket 36 12G2066 1 Bracket B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 E 1 Parts Packet 5 PN 12G3404 ...

Page 340: ...Parts Catalog 7 8 4023 001 Assembly 3 Printer Frames B ...

Page 341: ...0 12G2082 1 Tension Spring PF Door 11 12G2083 1 Holder 12 12G2084 1 Shutter 13 12G2085 1 Torsion Spring 14 12G2324 1 PW Board R PWB R2 Resistor Board 15 12G2086 1 Ground Plate 16 12G2087 1 Ground Plate 17 12G2088 1 Bracket 18 12G2089 1 Fan Motor M9 Image PC Cartridge 19 12G2090 1 Duct 20 12G2091 2 Seal 21 12G2092 1 Duct 22 12G2093 1 Seal 23 12G2094 1 Holder 24 12G2095 1 Seal 25 12G2096 1 Lamp Eras...

Page 342: ...Parts Catalog 7 10 4023 001 Assembly 3 cont Printer Frames B ...

Page 343: ...atalog 7 11 4023 001 Assembly 3 cont Printer Frames B Ref Part Number Units Description 3 B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 G 1 Parts Packet 7 PN 12G3406 ...

Page 344: ...Parts Catalog 7 12 4023 001 Assembly 4 Printer Hopper ...

Page 345: ... 1 Duct 13 12G2089 1 Fan Motor M8 Ozone 14 12G2117 1 Cover 15 12G3425 1 Transfer Ozone BM includes ozone filter and transfer unit 16 12G2119 1 Screw 17 12G2120 1 Set Plate 18 12G2121 1 Gear 39t 19 12G2122 1 Gear 45t 20 12G2123 1 Housing 21 12G2124 2 Bushing 22 12G2125 2 Gear 20t 23 12G2126 2 Shaft 24 12G2127 2 Worm Gear 25 12G2128 1 Bracket 26 12G2129 1 PWB Motor M7 sub hopper M6 main hopper 27 12...

Page 346: ...Parts Catalog 7 14 4023 001 Assembly 4 cont Printer Hopper ...

Page 347: ...r M10 Agitating Motor 44 12G2145 1 Mounting Plate 45 12G2146 1 Gear 16 20t 46 12G2147 1 Gear 16 60t 47 12G2148 1 Gear 25t 48 12G2149 1 Housing 49 12G2150 1 Terminal Cover A Toner Box 50 12G2151 1 Terminal Cover A Toner Box 51 12G2152 1 Shaft 52 12G2153 1 Lever 53 12G2154 1 Lock Lever 54 12G2155 1 Seal 55 12G2156 1 Durm 56 12G2157 2 Holder 57 12G2158 1 Bushing 58 12G2159 1 Torsion Spring 59 12G2160...

Page 348: ...Parts Catalog 7 16 4023 001 Assembly 5 Printer Fuser A ...

Page 349: ...er Exit 4 12G2175 1 Torsion Spring 5 12G2176 1 Actuator NS 12G2221 1 Fusing Unit 110V NS 12G2222 1 Fusing Unit 220V A 1 Parts Packet 1 PN 12G3400 B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 E 1 Parts Packet 5 PN 12G3404 G 1 Parts Packet 7 PN 12G3406 Note Illustrated parts that do not have a callout are for reference only ...

Page 350: ...Parts Catalog 7 18 4023 001 Assembly 6 Printer Fuser B ...

Page 351: ...or TH2 3 12G2255 1 Thermostat TS1 4 12G2256 1 Thermal Fuse TF1 5 12G2262 1 Heater 110V 5 12G2263 1 Heater 220V A 1 Parts Packet 1 PN 12G3400 B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 G 1 Parts Packet 7 PN 12G3406 I 1 Parts Packet 9 PN 12G3408 Note Illustrated parts that do not have a callout are for reference only ...

Page 352: ...Parts Catalog 7 20 4023 001 Assembly 7 Printer Manual Feed ...

Page 353: ...2G2286 1 Harness 13 12G2287 1 Ground Plate 14 12G2288 1 Cover Asm 15 12G2289 1 Lock Plate 16 12G2021 1 Cover 17 12G2290 1 Torsion Spring 18 12G2291 1 Hook 19 12G2292 2 Pressure Spring 20 12G2293 1 Ground Plate 21 12G2294 1 Bracket 22 12G2295 1 Harness 23 12G2296 2 Washer 24 12G2089 1 Fan Motor M3 Cooling 25 12G2297 1 Cushion 26 12G2298 1 Shaft 27 12G2299 1 Joint 28 12G2300 1 Gear 14t 29 12G2301 1 ...

Page 354: ...Parts Catalog 7 22 4023 001 Assembly 7 cont Printer Manual Feed ...

Page 355: ...lease Lever 37 12G2309 1 Cover 38 12G2310 1 Lever 39 12G2311 1 Cover 40 12G2312 1 Roller 41 12G2313 1 Guide 42 12G2190 1 Bushing 43 12G2314 4 Guide Bar 44 12G2315 4 Roll 45 12G2081 1 Photo Interrupter PC8 Manual Feed 46 12G2316 1 Actuator A 1 Parts Packet 1 PN 12G3400 B 1 Parts Packet 2 PN 12G3401 D 1 Parts Packet 4 PN 12G3403 E 1 Parts Packet 5 PN 12G3404 G 1 Parts Packet 7 PN 12G3406 ...

Page 356: ...Parts Catalog 7 24 4023 001 Assembly 8 Printer Transport ...

Page 357: ...age PC Cartridge 13 12G3425 1 Transfer Ozone BM includes transfer unit and ozone filter 14 12G2334 1 Conveyor Roller 15 12G2335 1 Conveyor Roller 16 12G2336 1 Cleaning Pad Asm 17 12G2337 2 Wave Washer 18 12G2338 1 Washer 19 12G2339 1 Actuator 20 12G2340 1 Pressure Spring 21 12G2341 1 Torsion Spring 22 12G2081 1 Photo Interrupter PC2 Timing 23 12G2342 1 Ground Plate 24 12G2343 1 Gear 13t 25 12G2344...

Page 358: ...Parts Catalog 7 26 4023 001 Assembly 9 Printer Electrical Components ...

Page 359: ... Power Supply 110V PU1 13 12G2366 1 Power Supply 220V PU1 below SN 1W856776 13 12G3457 1 Power Supply 220V PU1 above SN 1W856776 NS 12G3456 1 Power Supply Resistor 220V above SN 1W856776 14 12G2367 2 PWB Support 6 4h 15 12G2368 1 PWB Support 16 12G2369 1 Bracket 17 12G2370 1 Printhead Asm 18 12G2371 1 Bracket 19 1 IC PWB A Note Included on PWB A board only Order 12G2374 20 12G2373 2 Fuse 3A 21 12G...

Page 360: ...Parts Catalog 7 28 4023 001 Assembly 10 Printer Paper Take up ...

Page 361: ...1 12G2387 1 Harness 12 12G2388 1 Harness 13 12G2389 1 PWB HV1 High Voltage Power Supply 14 12G2390 1 Actuator 15 12G2081 1 Photo Interrupter PC4 Empty 16 12G2391 1 Cover 17 12G2392 2 Cover 18 12G2393 1 Shoulder Screw 19 12G2394 1 Rail 20 12G2395 1 Cover 21 12G2042 1 Holder 22 12G2041 1 Rubber Foot 23 12G2396 1 Lever 24 12G2397 1 Cover 25 12G2398 1 Bracket 26 12G2399 1 Terminal 27 12G2400 1 Harness...

Page 362: ...Parts Catalog 7 30 4023 001 Assembly 11 Printer Drive ...

Page 363: ... Motor M4 Power Unit Cooling 11 12G2414 1 Lever 12 12G2415 1 Motor M1 Image PC Cartridge 13 12G2416 1 Bracket 14 12G2417 1 Cover 15 12G2418 1 Harness 16 12G2419 1 Bracket 17 12G2042 2 Holder 18 12G2420 1 Bracket 19 12G2421 1 Ferrite Core 20 12G2422 1 Harness 21 12G2423 2 Bushing 22 12G2424 1 Bracket 23 12G2425 1 Harness 24 12G2426 2 Pin 25 12G2427 2 Gear 34t 26 12G2428 1 Lever 27 12G2429 1 Bracket...

Page 364: ...Parts Catalog 7 32 4023 001 Assembly 11 cont Printer Drive ...

Page 365: ...34 1 Power Cord Germany 42 11D0335 1 Power Cord Italy 42 11D0334 1 Power Cord Spain 42 11D0336 1 Power Cord Swiss French 42 11D0336 1 Power Cord Swiss German 42 11D0336 1 Power Cord Swiss Italian 42 11D0337 1 Power Cord U K 42 11D0338 1 Power Cord Israel 42 11D0339 1 Power Cord South Africa 42 11D0334 1 Power Cord Belgium 42 11D0330 1 Power Cord Argentina 42 11D0331 1 Power Cord Brazil 42 11D0332 ...

Page 366: ...Parts Catalog 7 34 4023 001 Assembly 12 Printer Paper Tray ...

Page 367: ... 12 12G2458 1 Friction Sheet 13 12G2459 1 Regulating Plate 14 12G2460 1 Label Max Level 15 12G2461 1 Regulating Plate 16 12G2462 1 Lifting Plate 17 12G2463 1 Width Scale 18 12G2464 2 Rack Gear 19 12G2465 1 Gear 20t 20 12G2466 1 Lever 21 12G2467 1 Regulating Plate 22 12G2468 1 Length Scale 23 12G2469 1 Label Paper Loading 24 12G2470 1 Cassette Body 25 12G2621 1 Handle 26 12G2472 1 Polyester Film 27...

Page 368: ...Parts Catalog 7 36 4023 001 Assembly 12 cont Printer Paper Tray ...

Page 369: ... 4023 001 Assembly 12 cont Printer Paper Tray Ref Part Number Units Description 12 34 12G2479 1 Lever 35 12G2480 1 Torsion Spring 36 12G2481 1 Label Paper Size D 1 Parts Packet 4 PN 12G3403 G 1 Parts Packet 7 PN 12G3406 ...

Page 370: ...Parts Catalog 7 38 4023 001 Assembly 13 500 Sheet Unit Housing ...

Page 371: ... 11 12G2538 1 PWB A Main Controller Board 12 12G2539 1 PWB Support 6 35h 13 12G2540 1 Harness 14 12G2541 1 Bracket 15 12G2542 4 Shoulder Screw 16 12G2543 1 Rubber Foot 17 12G2544 1 Holder 18 12G2545 1 Spring 19 12G2546 1 Bracket 20 12G2547 1 Bracket 21 12G2548 2 Pressure Spring 22 12G2549 2 Shoulder Screw 23 12G2550 2 Shoulder Screw 24 12G2551 1 Bracket 25 12G2552 2 Rubber Foot 26 12G2553 1 Bracke...

Page 372: ...Parts Catalog 7 40 4023 001 Assembly 13 cont 500 Sheet Unit Housing ...

Page 373: ...Parts Catalog 7 41 4023 001 Assembly 13 cont 500 Sheet Unit Housing Ref Part Number Units Description 13 B 1 Parts Packet 2 PN 12G3401 D 1 Parts Packet 4 PN 12G3403 E 1 Parts Packet 5 PN 12G3404 ...

Page 374: ...Parts Catalog 7 42 4023 001 Assembly 14 500 Sheet Unit Paper Take up ...

Page 375: ...568 1 Gear 31t 12 12G2569 1 Tension Spring 13 12G2081 4 Photo Interrupter PC22 PC23 PC25 14 12G2570 1 Bracket 15 12G2571 1 Solenoid SL1 Take up 16 12G2572 1 Bracket 17 12G2173 4 Stopper 18 12G2574 1 Gear 16 20t 19 12G2575 2 Gear 20t 20 12G2576 1 Gear 18t 21 12G2577 2 Bushing 22 12G2578 2 Gear 34t 23 12G2579 1 Harness 24 12G2580 1 Holder 25 12G2581 1 Bracket 26 12G2582 1 Lever 27 12G2583 1 Axle Pla...

Page 376: ...Parts Catalog 7 44 4023 001 Assembly 14 cont 500 Sheet Unit Paper Take up ...

Page 377: ...nits Description 14 34 12G2590 1 Collar 35 12G2591 1 Bracket 36 12G2592 1 Shaft 37 12G2593 1 Actuator 38 12G2594 1 Torsion Spring 39 12G3508 1 Guide Plate 40 12G2596 2 Guide A 1 Parts Packet 1 PN 12G3400 B 1 Parts Packet 2 PN 12G3401 D 1 Parts Packet 4 PN 12G3403 G 1 Parts Packet 7 PN 12G3406 ...

Page 378: ...Parts Catalog 7 46 4023 001 Assembly 15 500 Sheet Unit Paper Tray Unit A ...

Page 379: ...Paper Size 9 12G2605 1 Guide Plate 10 12G2606 1 Regulating Plate 11 12G2607 1 Lifting Plate 12 12G2608 1 Lifting Plate 13 12G2609 1 Pressure Spring 14 12G2610 1 Cassette Body 15 12G2611 1 Label Cassette 16 12G2612 2 Pressure Spring 17 12G2613 1 Gear 14t 18 12G2614 1 Shoulder Screw 19 12G2615 1 Regulating Plate 20 12G2616 1 Knob 21 12G2617 1 Pressure Spring 22 12G2618 1 Lever 23 12G2619 1 Shaft 24 ...

Page 380: ...Parts Catalog 7 48 4023 001 Assembly 16 500 Sheet Unit Paper Tray Unit B ...

Page 381: ...per 10 12G2631 1 Reinforce Plate 11 12G2632 1 Plate Spring 12 12G2633 2 Sheet 13 12G2634 1 Regulating Plate 14 12G2635 1 Terminal 15 12G2410 2 PWB I Paper Size Board 16 12G2636 2 Holder 17 12G2637 1 Terminal 18 12G2638 1 Cover 19 12G2639 1 Harness 20 12G2640 1 Reinforce Plate 21 12G2641 1 Plate 22 12G2642 1 Tension Spring 23 12G2643 1 Lever 24 12G2486 1 Wiring Saddle 5 2h 25 12G2487 2 Wiring Saddl...

Page 382: ...Parts Catalog 7 50 4023 001 Assembly 17 Printer Controller Card ...

Page 383: ...MB SIMM Code Controller Card 3 12G3521 1 Riser Card Controller Card 4 99A1757 1 2MB Flash DIMM 4 99A1758 1 4MB Flash DIMM 4 99A1759 1 8MB Flash DIMM 4 99A1774 1 16MB Flash DIMM 4 99A1752 1 4MB SDRAM DIMM 4 99A1753 1 8MB SDRAM DIMM 4 99A1754 1 16MB SDRAM DIMM 4 99A1755 1 32MB SDRAM DIMM 4 99A1756 1 64MB SDRAM DIMM NS 12C0805 2 Screw Parallel Port ...

Page 384: ...Parts Catalog 7 52 4023 001 Assembly 18 Duplex Unit ...

Page 385: ...2 12G2505 1 Seal 13 12G2190 4 Bushing 14 12G2506 2 Gear 20 T 15 12G2507 1 Tension Spring 16 12G2508 1 Lever 17 12G2509 1 Gear 12 40 T 18 12G2510 1 Axle Plate 19 12G2511 2 Motor M1 M2 Duplex Drive 20 12G2512 1 PWB A Duplex Control Board 21 12G2513 1 Plate 22 12G2514 2 Plate 23 12G2515 3 Gear 35 T 24 12G2516 2 Gear 24 T 25 12G2517 1 Gear 17 45 T 26 12G2518 1 Harness 27 12G2519 1 Holder 28 12G2520 4 ...

Page 386: ...Parts Catalog 7 54 4023 001 Assembly 18 cont Duplex Unit ...

Page 387: ...it Ref Part Number Units Description 18 34 12G2525 1 Cover 35 12G2526 1 Polyester Film 36 12G2527 1 Washer B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 E 1 Parts Packet 5 PN 12G3404 G 1 Parts Packet 7 PN 12G3406 ...

Page 388: ...Parts Catalog 7 56 4023 001 Assembly 19 Paper Deck Housing ...

Page 389: ...Bracket 9 12G2652 4 Shoulder Screw 10 12G2653 1 Ground Plate 11 12G2654 4 Bracket 12 12G2655 4 Handle 13 12G2656 1 Cover 14 12G2657 1 Rear Cover 15 12G2658 1 Polyester Film 16 12G2659 1 Holder 17 12G2660 1 Left Cover 18 12G2661 2 Cover 19 12G2662 1 Label Warning 20 12G2663 2 Regulating Plate 21 12G2664 2 Shoulder Screw 22 12G2042 4 Holder B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402...

Page 390: ...Parts Catalog 7 58 4023 001 Assembly 20 Paper Deck Paper Take up A ...

Page 391: ...nsion Spring 11 12G2675 1 Arm 12 12G2676 2 Stopper 13 12G2677 2 Bracket 14 12G2678 1 Ground Plate 15 12G2679 4 Bushing 16 12G2680 2 Photo Interrupter LS1 LS2 17 12G2681 2 Tension Spring 18 12G2682 2 Shaft 19 12G2683 2 Stopper Ring 20 12G2684 2 Shaft 21 12G2685 2 Arm 22 12G2686 2 Gear 26 T 23 12G2687 2 Shaft 24 12G2688 2 Pulley 20 T 25 12G2689 2 Tension Spring 26 12G2690 1 Timing Belt 27 12G2691 2 ...

Page 392: ...Parts Catalog 7 60 4023 001 Assembly 20 cont Paper Deck Paper Take up A ...

Page 393: ...Parts Catalog 7 61 4023 001 Assembly 20 cont Paper Deck Paper Take up A Ref Part Number Units Description 20 A 1 Parts Packet 1 PN 12G3400 G 1 Parts Packet 7 PN 12G3406 H 1 Parts Packet 8 PN 12G3407 ...

Page 394: ...Parts Catalog 7 62 4023 001 Assembly 21 Paper Deck Paper Take up B ...

Page 395: ... T 11 12G2708 2 Plate Spring 12 12G2709 1 Gear 26 T 13 12G2710 4 Bush 14 12G2711 1 Pulley 20 T 15 12G2664 4 Shoulder Screw 16 12G2712 1 Gear 20 T 17 12G2713 1 Shaft 18 12G2714 1 Clutch RCL Registration 19 12G2715 1 Bracket 20 12G2716 1 Clutch BCL Separation 21 12G2717 1 Shaft 22 12G2718 1 Pulley 18 T 23 12G2719 1 Timing Belt 24 12G2720 1 Gear 24 T 25 12G2721 1 Gear 20 35 T 26 12G2722 1 Pulley 14 T...

Page 396: ...Parts Catalog 7 64 4023 001 Assembly 21 cont Paper Deck Paper Take up B ...

Page 397: ...12G2731 1 Ply Gear 14 26 T 36 12G2732 1 Shaft 37 12G2733 1 Polyester Film 38 12G2734 1 Bracket 39 12G2735 1 Tension Spring 40 12G2736 1 Arbor Asm 41 12G2737 1 Roller Paper Take up 42 12G2738 1 Clutch 43 12G2683 2 Stopper Ring 44 12G2739 1 Frame 45 12G2740 1 Roller Paper Take up G 1 Parts Packet 7 PN 12G3406 H 1 Parts Packet 8 PN 12G3407 ...

Page 398: ...Parts Catalog 7 66 4023 001 Assembly 22 Paper Deck Drive ...

Page 399: ... 3 PWB Support 9 12G2752 2 Bracket 10 12G2753 1 Harness 11 12G2754 1 Harness 12 12G2755 1 Harness 13 12G2756 2 Pressure Spring 14 12G2757 2 Shaft 15 12G2758 2 Gear 16 32 T 16 12G2759 1 Gear 16 32 T 17 12G2806 4 Bush 18 12G2760 2 Gear 58 T 19 12G2761 1 Axle Plate 20 12G2679 4 Bushing 21 12G2762 1 Gear 72 T 22 12G2763 1 Gear 72 T 23 12G2764 2 Shaft 24 12G2765 1 Worm Gear 25 12G2766 1 Gear 16 32 T 26...

Page 400: ...Parts Catalog 7 68 4023 001 Assembly 22 cont Paper Deck Drive ...

Page 401: ...eck Drive Ref Part Number Units Description 22 32 12G2773 1 Bracket 33 12G2774 1 Harness 34 12G2775 1 Arbor 35 12G2776 2 Magnet Catch B 1 Parts Packet 2 PN 12G3401 G 1 Parts Packet 7 PN 12G3406 H 1 Parts Packet 8 PN 12G3407 I 1 Parts Packet 9 PN 12G3408 ...

Page 402: ...Parts Catalog 7 70 4023 001 Assembly 23 Paper Deck Paper Tray A ...

Page 403: ...5 12G2782 3 Shoulder Screw 6 12G2783 2 Polyester Film 7 12G2784 1 Holder 8 12G2664 2 Shoulder Screw 9 12G2785 2 Label Max Level 10 12G2786 1 Polyester Film 11 12G2787 1 Polyester Film 12 12G2788 1 Holder 13 12G2789 2 Regulating Plate 14 12G2790 1 Cassette Body 15 12G2791 1 Front Cover 16 12G2792 1 Label A4 16 12G2793 1 Label Letter 17 12G2794 1 Stopper H 1 Parts Packet 8 PN 12G3407 ...

Page 404: ...Parts Catalog 7 72 4023 001 Assembly 24 Paper Deck Paper Tray B ...

Page 405: ...10 12G2806 2 Bush 11 12G2807 2 Shaft 12 12G2808 2 Shaft 13 12G2809 1 Bracket 14 12G2810 2 Cam 15 12G2811 2 Holder 16 12G2812 1 Torsion Spring 17 12G2813 1 Torsion Spring 18 12G2814 2 Pulley 32 T 19 12G2815 2 Timing Belt 20 12G2816 2 Shaft 21 12G2817 2 Shaft 22 12G2818 5 Wiring Saddle 23 12G2819 6 Wiring Saddle 24 12G2820 4 Wiring Saddle 24 12G2821 5 Cord Clamp 25 12G2822 1 Edge Cover 25 12G2823 2 ...

Page 406: ...Parts Catalog 7 74 4023 001 Assembly 25 Finisher Housing ...

Page 407: ...046 2 Cover 14 12G3047 1 Left Cover lwr 15 12G3048 1 Front Cover 16 12G3049 1 Cover 17 12G3050 1 Right Cover upr 18 12G3051 1 Cover 19 12G3052 1 Knob 20 12G3053 1 Pressure Spring 21 12G2875 1 Rubber Strip 22 12G3054 1 Plate 23 12G3055 1 Rear Cover upr 24 12G3056 1 Label Position 24 12G3057 1 Label Position 24 12G3058 1 Label Position 25 12G3059 1 Label Position 25 12G3060 1 Label Position 25 12G30...

Page 408: ...Parts Catalog 7 76 4023 001 Assembly 26 Finisher Frames ...

Page 409: ...1 Cord Bushing 12 12G3071 1 Guide Plate 13 12G3072 1 Harness 14 12G3073 1 Harness 15 12G3074 1 IC PWB A IC3 16 12G3075 1 PWB A Control Board 17 12G3076 6 PWB Support 18 12G3077 4 PWB Support 12 7h 19 12G3078 1 Mounting Plate 20 12G3079 1 Harness 21 12G3080 1 Plate 22 12G3081 2 PWB E LED Board 23 12G3082 4 Collar 24 12G2859 2 Caster 25 12G3083 2 Mounting Plate 26 12G2858 2 Adjusting Bolt 27 12G3084...

Page 410: ...Parts Catalog 7 78 4023 001 Assembly 26 cont Finisher Frames ...

Page 411: ...ate 40 12G3091 1 Punch Trash Box 41 12G3092 1 Tape 42 12G3093 1 Mounting Plate 43 12G3094 1 Bracket 44 12G2068 1 Pin 45 12G3095 1 Plate Spring 46 12G3096 1 Bracket 47 12G3097 1 Microswitch S6 48 12G2960 1 Holder 49 12G3098 1 Bracket 50 12G3104 1 Magnet Catch 51 12G3099 2 Adjusting Bolt A 1 Parts Packet 1 PN 12G3400 C 1 Parts Packet 3 PN 12G3402 E 1 Parts Packet 5 PN 12G3404 F 1 Parts Packet 6 PN 1...

Page 412: ...Parts Catalog 7 80 4023 001 Assembly 27 Finisher Paper Transport A ...

Page 413: ...ring 11 12G3111 1 Plate Spring 12 12G2931 4 Roll 13 12G3112 1 Roll 14 12G3113 1 Polyester Film 15 12G3114 1 Neutralizing Brush 16 12G3115 1 Actuator 17 12G3116 1 Torsion Spring 18 12G3117 1 Guide Plate 19 12G3118 1 Arm 20 12G3119 1 Shaft 21 12G3120 1 Torsion Spring 22 12G3121 1 Cam 23 12G3122 1 Plate Spring 24 12G3123 1 Shoulder Screw 25 12G2173 1 Stopper B 1 Parts Packet 2 PN 12G3401 C 1 Parts Pa...

Page 414: ...Parts Catalog 7 82 4023 001 Assembly 28 Finisher Paper Transport B ...

Page 415: ...2 12G3133 1 Bracket 13 12G3134 1 Motor M2 Transport Upper Exit 14 12G3135 2 Shoulder Screw 15 12G3136 2 Shoulder Screw 16 12G3137 1 Guide 17 12G3138 1 Actuator 18 12G3139 1 Torsion Spring 19 12G3140 2 Plate Spring 20 12G3038 4 Cushion 21 12G3141 1 Torsion Spring 22 12G3142 1 Harness 23 12G3143 1 Bracket 24 12G2999 1 Photo Interrupter PC3 Finish Tray 25 12G3144 1 Roller 26 12G3145 2 Shaft 27 12G292...

Page 416: ...Parts Catalog 7 84 4023 001 Assembly 28 cont Finisher Paper Transport B ...

Page 417: ...r 39 12G3156 1 Gear 28t 40 12G3157 1 Gear 24t 41 12G3158 1 Ply Gear 19 28t 42 12G3159 1 Pulley 15t 43 12G3160 2 Pulley 19t 44 12G3161 3 Flange 45 12G3162 2 Arm 46 12G3163 2 Tension Spring 47 12G3164 1 Timing Belt 48 12G3165 1 Solenoid Transport SL1 49 12G3166 1 Bracket 50 12G3167 10 Roll B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 F 1 Parts Packet 6 PN 12G3405 G 1 Parts Packet 7 PN...

Page 418: ...Parts Catalog 7 86 4023 001 Assembly 29 Finisher Paper Aligning ...

Page 419: ...Photo Switch Top Position PC12 12 12G3178 1 Tension Spring 13 12G3179 1 Holder 14 12G3180 1 Bracket 15 12G3181 1 Arm 16 12G3182 1 Torsion Spring 17 12G3183 3 Gear 19t 18 12G3184 1 Paddle 19 12G3185 1 Actuator 20 12G3186 1 Actuator 21 12G3106 4 Photo Interrupter PC4 PC7 22 12G3187 1 Guide 23 12G2102 4 Stopper 24 12G3188 2 Bracket 25 12G3189 1 Timing Belt 26 12G3190 1 Motor Shift M5 27 12G3191 2 Fla...

Page 420: ...Parts Catalog 7 88 4023 001 Assembly 29 cont Finisher Paper Aligning ...

Page 421: ...ler 41 12G3202 1 Stopper 42 12G3203 1 Timing Belt 43 12G3204 1 Rail 44 12G3205 1 Neutralizing Brush 45 12G3065 1 PW Board F PWB F 46 12G3082 2 Collar 47 12G3038 2 Cushion 48 12G3206 1 PWB Motor Curl Control M7 49 12G3207 1 Bracket 50 12G3208 1 Shaft 51 12G3209 3 Lever 52 12G3210 1 Lever 53 12G3211 4 Cushion 54 12G3212 2 Arm 55 12G3213 1 Holder 56 12G3214 1 Shaft 57 12G3215 1 Torsion Spring 58 12G3...

Page 422: ...Parts Catalog 7 90 4023 001 Assembly 29 cont Finisher Paper Aligning ...

Page 423: ...nt Finishing Paper Aligning Ref Part Number Units Description 29 A 1 Parts Packet 1 PN 12G3400 C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 F 1 Parts Packet 6 PN 12G3405 G 1 Parts Packet 7 PN 12G3406 I 1 Parts Packet 9 PN 12G3408 ...

Page 424: ...Parts Catalog 7 92 4023 001 Assembly 30 Finisher Assistance Tray ...

Page 425: ...8 12G2971 2 Bushing 9 12G3228 1 Frame 10 12G3229 1 Frame 11 12G3230 1 Shaft 12 12G3231 2 Pulley 19t 13 12G3232 2 Holder 14 12G3233 1 Bracket 15 12G3234 4 Sub Tray 16 12G3235 2 Plate Nut 17 12G3236 18 Cushion 18 12G3237 16 Slider 19 12G3238 1 Reinforce Plate 20 12G3239 2 Bracket 21 12G3240 2 Pulley 19t 22 12G3161 2 Flange 23 12G3241 1 Rail 24 12G3242 1 Frame 25 12G3243 1 Plate 26 12G3244 1 Rail 27 ...

Page 426: ...Parts Catalog 7 94 4023 001 Assembly 30 cont Finisher Assistance Tray ...

Page 427: ... Assembly 30 cont Finisher Assistance Tray Ref Part Number Units Description 30 A 1 Parts Packet 1 PN 12G3400 C 1 Parts Packet 3 PN 12G3402 E 1 Parts Packet 5 PN 12G3404 F 1 Parts Packet 6 PN 12G3405 G 1 Parts Packet 7 PN 12G3406 ...

Page 428: ...Parts Catalog 7 96 4023 001 Assembly 31 Finisher Elevator Tray ...

Page 429: ...1 Timing Belt 12 12G3260 1 Bracket 13 12G3261 1 PWB Motor Elevator M9 14 12G3262 1 Shaft 15 12G3263 1 Pulley 29t 16 12G3264 2 Pulley 17 12G3265 1 Actuator 18 12G3266 3 Microswitch S2 S3 S5 19 12G3267 2 Tension Spring 20 12G3268 2 Wire 21 12G3269 2 Torsion Spring 22 12G3270 1 Bracket 23 12G3271 1 Bracket 24 12G3460 2 Photo Interrupter PC8 PC11 25 12G3272 1 Actuator 26 12G3273 2 Shaft 27 12G3274 4 B...

Page 430: ...Parts Catalog 7 98 4023 001 Assembly 31 cont Finisher Elevator Tray ...

Page 431: ...r Elevator Tray Ref Part Number Units Description 31 34 12G3281 1 Bracket 35 12G3282 1 Bracket 36 12G3283 1 Lever 37 12G2102 2 Stopper A 1 Parts Packet 1 PN 12G3400 C 1 Parts Packet 3 PN 12G3402 F 1 Parts Packet 6 PN 12G3405 G 1 Parts Packet 7 PN 12G3406 ...

Page 432: ...Parts Catalog 7 100 4023 001 Assembly 32 Finisher Punch Unit ...

Page 433: ... Bracket 12 12G3299 1 PWB motor M1 Transport 13 12G3300 1 Bracket 14 12G3301 1 Gear 22 38t 15 12G3302 1 Label Jam Removal 16 12G3303 1 Label Jam Removal 17 12G3304 1 Guide Plate 18 12G3305 1 Bracket 19 12G3306 1 Shaft 20 12G3307 1 Pressure Spring 21 12G3309 1 Punch Unit 3 hole 21 12G3310 1 Punch Unit 4 hole 22 12G3311 2 Knob 23 12G3312 2 Shoulder Screw A 1 Parts Packet 1 PN 12G3400 B 1 Parts Packe...

Page 434: ...Parts Catalog 7 102 4023 001 Assembly 33 Finisher Stapler Unit Finisher Tray ...

Page 435: ...val 10 12G3321 1 Cover 11 12G3322 1 Polyester Film 12 12G3323 1 Plate 13 12G3324 1 Stapler Unit 14 12G3325 1 Bracket 15 12G3326 1 Harness 16 12G3327 1 Guide 17 12G3328 2 Bushing 18 12G3329 3 Holder 19 12G3330 3 Belt 20 12G3331 3 Pulley 21 12G3332 3 Pulley 22 12G3333 3 Holder 23 12G3334 1 Pulley 18t 24 12G3335 1 Bracket 25 12G3336 1 Motor Finisher Tray M8 26 12G3337 1 Timing Belt 27 12G3226 1 Flang...

Page 436: ...Parts Catalog 7 104 4023 001 Assembly 33 cont Finisher Stapler Unit Finisher Tray ...

Page 437: ...Torsion Spring 45 12G3353 2 Rail 46 12G3038 2 Cushion 47 12G3354 2 Tension Spring 48 12G3355 1 Guide 49 12G2486 16 Wiring Saddle 5 2h 50 12G2487 2 Wiring Saddle 6 4h 51 12G3024 6 Wiring Saddle 16 8h 52 12G3356 22 Wiring Saddle 14 4h 53 12G2490 7 Edge Cover 8 5h 54 12G2491 4 Edge Cover 15 4h 54 12G2492 3 Edge Cover 25 0h 55 12G3027 16 Wiring Saddle 3 8h 56 12G3357 2 Cord Clamp 57 12G2102 1 Stopper ...

Page 438: ...Parts Catalog 7 106 4023 001 Assembly 34 Finisher Mailbox Horizontal Transfer A ...

Page 439: ...5 2 Magnet Catch 10 12G2976 1 Cover 11 12G2977 1 Handle 12 12G2978 2 Plate 13 12G2979 1 Rear Cover 14 12G2980 1 Cushion 15 12G2981 1 Guide Plate 16 12G2982 1 Lower Cover 17 12G2983 1 Shoulder Screw 18 12G2984 1 Lever 19 12G2985 4 Cushion 20 12G2986 1 Torsion Spring 21 12G2987 1 Guide Plate 22 12G2988 1 Guide Plate A 1 Parts Packet 1 PN 12G3400 C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12...

Page 440: ...Parts Catalog 7 108 4023 001 Assembly 35 Finisher Mailbox Horizontal Transfer B ...

Page 441: ...ing Belt 12 12G3003 1 Harness 13 12G3004 1 Bracket 14 12G3005 1 Bracket 15 12G2173 2 Stopper 16 12G3006 2 Photo Interrupter PC1 PC4 17 12G3007 1 Ply Gear 16 17t 18 12G3008 1 Shaft 19 12G3009 1 Frame 20 12G2053 1 Retaining Ring 21 12G3010 1 Actuator 22 12G3011 1 Cover 23 12G3012 1 Pin 24 12G3026 1 Torsion Spring 25 12G3013 1 Stopper 26 12G3014 2 Plate Spring 27 12G3015 1 Reinforce Plate 28 12G3016 ...

Page 442: ...Parts Catalog 7 110 4023 001 Assembly 35 cont Finisher Mailbox Horizontal Transfer B ...

Page 443: ...e 8 0h 36 12G3027 11 Wiring Saddle 3 8h Mailbox only 37 12G2488 5 Wiring Saddle 27h Mailbox only 38 12G3024 2 Wiring Saddle 16 8h Mailbox only 39 12G3025 1 Wiring Saddle 8 0h Mailbox only 40 12G2490 2 Edge Cover 8 5h Mailbox only C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 E 1 Parts Packet 5 PN 12G3404 G 1 Parts Packet 7 PN 12G3406 J 1 Parts Packet 10 PN 12G3409 ...

Page 444: ...Parts Catalog 7 112 4023 001 Assembly 36 Mailbox Housing ...

Page 445: ...2G2939 2 Shoulder Screw 8 12G2068 1 Pin 9 12G2834 1 Holder 10 12G2835 1 Polyester Film 11 12G2836 1 Front Cover 12 12G2837 1 Bin Rack 13 12G2838 2 Bracket 14 12G2839 1 PWB B Paper Exit Board 15 12G2840 2 Cover 16 12G2918 1 PWB D Paper Exit 17 12G2841 10 Neutralizing Brush 18 12G2842 10 Neutralizing Brush 19 12G2843 1 Label B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 J 1 Parts Packe...

Page 446: ...Parts Catalog 7 114 4023 001 Assembly 37 Mailbox Frames ...

Page 447: ...54 1 Harness 10 12G2855 1 Support Plate 11 12G2856 1 Bracket 12 12G2857 2 Foot 13 12G2858 2 Adjusting Bolt 14 12G2859 4 Caster 15 12G2860 1 Stop Plate 16 12G2861 1 Stop Plate 17 12G2862 1 Ground Plate 18 12G2863 2 Stopper 19 12G2864 2 Plate 20 12G2865 1 Pipe 21 12G2866 1 Label 22 12G2867 2 Label 23 12G2868 4 Plate 24 12G2869 2 Magnet 25 12G2870 2 Bracket 26 12G2871 1 Cover 27 12G2872 1 Ground Plat...

Page 448: ...Parts Catalog 7 116 4023 001 Assembly 37 cont Mailbox Frames ...

Page 449: ...37 cont Mailbox Frames Ref Part Number Units Description 37 A 1 Parts Packet 1 PN 12G3400 B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 G 1 Parts Packet 7 PN 12G3406 I 1 Parts Packet 9 PN 12G3408 J 1 Parts Packet 10 PN 12G3409 ...

Page 450: ...Parts Catalog 7 118 4023 001 Assembly 38 Mailbox Paper Transport A ...

Page 451: ...2889 1 Axle Plate 10 12G2890 1 Tension Spring 11 12G2891 2 Gear 17 T 12 12G2928 1 Gear 19 T 13 12G2892 2 Ball Bearing 14 12G2893 1 Roller 15 12G2894 1 Roller 16 12G2895 1 Guide 17 12G2896 1 Bushing 18 12G2897 1 Bracket 19 12G2898 1 Solenoid SL1 Non sort 20 12G2899 1 Stopper 21 12G2900 1 Tension Spring 22 12G2901 1 Holder 23 12G2902 1 Guide Plate 24 12G2903 1 Bracket 25 12G2904 1 Torsion Spring 26 ...

Page 452: ...Parts Catalog 7 120 4023 001 Assembly 38 cont Mailbox Paper Transport A ...

Page 453: ...Assembly 38 cont Mailbox Paper Transport A Ref Part Number Units Description 38 A 1 Parts Packet 1 PN 12G3400 B 1 Parts Packet 2 PN 12G3401 C 1 Parts Packet 3 PN 12G3402 G 1 Parts Packet 7 PN 12G3406 J 1 Parts Packet 10 PN 12G3409 ...

Page 454: ...Parts Catalog 7 122 4023 001 Assembly 39 Mailbox Paper Transport B ...

Page 455: ...4 12G2920 2 Gear 17t 5 12G2886 2 Gear 37t 6 12G2911 5 Shoulder Screw 7 12G2912 5 Guide 8 12G2907 8 Roll 9 12G2913 8 Plate Spring 10 12G2914 4 Bracket 11 12G2918 4 PW Board D PWB D1 PWB D4 12 12G2840 4 Cover 13 12G2915 1 Harness 14 12G2971 2 Bushing C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 G 1 Parts Packet 7 PN 12G3403 J 1 Parts Packet 10 PN 12G3409 ...

Page 456: ...Parts Catalog 7 124 4023 001 Assembly 40 Mailbox Paper Transport C ...

Page 457: ...2G2917 2 Bracket 5 12G2920 3 Gear 17t 6 12G2928 3 Gear 19t 7 12G2891 1 Gear 17t 8 12G2886 2 Gear 37t 9 12G2914 4 Bracket 10 12G2918 4 PW Board D PWB D6 PWB D9 11 12G2840 2 Cover 12 12G2915 1 Harness 13 12G2919 1 Harness 14 12G2912 4 Guide 15 12G2971 3 Bushing C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 G 1 Parts Packet 7 PN 12G3406 J 1 Parts Packet 10 PN 12G3409 ...

Page 458: ...Parts Catalog 7 126 4023 001 Assembly 41 Mailbox Paper Transport D ...

Page 459: ...922 4 Guide 6 12G2911 4 Shoulder Screw 7 12G2923 8 Shaft 8 12G2892 4 Ball Bearing 9 12G2924 16 Roll 10 12G2932 8 Plate Spring 11 12G2893 4 Roller 12 12G2971 4 Bushing 13 12G2899 4 Stopper 14 12G2935 4 Tension Spring 15 12G2901 4 Holder 16 12G2925 1 Solenoid Deflect SL2 17 12G2896 4 Bushing 18 12G2926 4 Guide C 1 Parts Packet 3 PN 12G3402 D 1 Parts Packet 4 PN 12G3403 G 1 Parts Packet 7 PN 12G3406 ...

Page 460: ...Parts Catalog 7 128 4023 001 Assembly 42 Mailbox Paper Transport E ...

Page 461: ...5 Shoulder Screw 10 12G2923 10 Shaft 11 12G2892 5 Ball Bearing 12 12G2931 12 Roll 13 12G2932 10 Plate Spring 14 12G2893 5 Roller 15 12G2971 5 Bushing 16 12G2933 1 Bushing 17 12G2934 1 Solenoid Deflect SL3 18 12G2901 4 Holder 19 12G2935 4 Tension Spring 20 12G2899 4 Stopper 21 12G2896 4 Bushing 22 12G2926 2 Guide 23 12G2936 3 Guide 24 12G2937 6 Plate Spring C 1 Parts Packet 3 PN 12G3402 D 1 Parts P...

Page 462: ...Parts Catalog 7 130 4023 001 Assembly 43 Mailbox Drive ...

Page 463: ... 12G2950 1 Harness 13 12G2951 1 Cord Bushing 14 12G2952 1 Harness 15 12G2953 1 Harness 16 12G2954 1 Fuse 0 5A 17 12G2955 1 PWB A Main Drive Board 18 12G2956 2 PWB Support 9 53h 19 12G2957 4 PWB Support 9 53h 20 12G2958 1 Bracket 21 12G2959 1 Microswitch Power S1 22 12G2960 1 Holder 23 12G2961 1 Bracket 24 12G2872 1 Ground Plate 25 12G2873 1 Magnet Catch 26 12G2962 1 Motor Asm Transport M1 27 12G29...

Page 464: ...Parts Catalog 7 132 4023 001 Assembly 44 Optional Features No illustration ...

Page 465: ...Fuser 110V MMKit 12G3420 1 Fuser 220V MMKit 99A0459 1 Hard Disk 11G0610 1 Cable Hard Disk 99A0422 1 Ethernet 10BaseT and 10Base2 99A0467 1 Parallel Port Adapter 99A0424 1 Infrared Adapter 99A0545 1 Serial Interface Adapter 12G3522 1 Printer Field Return Packaging 12G3543 1 TIFF Image Quick SIMM 99A1088 1 Prescribe Code SIMM 12G3426 1 IPDS and SCS TNe SIMM 99A1127 1 Barcode SIMM ...

Page 466: ...7 134 Service Manual 4023 001 ...

Page 467: ...clearing the error log 3 25 cooling fan motor M3 and I C filter removal 4 26 CPM power supply safety switch and PWB L removal 4 45 D default settings 3 26 diagnostic aids 3 1 diagnostic information 2 1 diagnostics mode 3 1 diagnostics mode menu structure 3 1 diagnostics mode tests 3 4 base printer sensors tests 3 15 defaults 3 26 device tests 3 19 diagnostics print tests 3 4 disk test clean 3 20 d...

Page 468: ... 84 rear cable 4 86 stapler unit disassembly 4 85 finisher sensor tests 3 17 finisher service checks 2 53 elevator tray 2 53 paper aligning 2 54 paper holding tray drive 2 56 power 2 53 shift plate drive 2 54 stapler drive 2 56 tray drive 2 54 upper entrance 2 57 1st cassette tray1 paper near empty sensor PC5 removal 4 57 1st cassette tray1 paper take up solenoid SL1 removal 4 59 1st cassette tray...

Page 469: ...C I C thermistor TH2 removal 4 22 image space table 2 43 image transfer roller removal 4 21 image transfer section 1 34 image transfer unit removal 4 22 imaging cartridge 1 28 input source print tests 3 4 input tray feed test 3 12 L LCC sensor tests 3 16 LCD hardware test 3 5 M mailbox cross sectional view 5 32 electrical components 5 33 external view each section 5 30 external view front 5 29 ext...

Page 470: ...val procedures 4 70 exterior parts 4 70 feed roll and separator roll 4 80 feed roll separator roll and torque limiter assembly 4 79 paper take up roll cleaning 4 80 paper take up rolls 4 73 paper take up unit 4 71 roll with a torque limiter cleaning 4 81 vertical transport roller rolls 4 81 paper exit full sensor PC12 removal 4 31 paper exit section 1 38 paper exit sensor PC3 and actuator removal ...

Page 471: ... 38 printhead unit assembly PH 4 40 right door interlock switch S2 4 54 right door switch S3 4 43 synchronizing roller removal 4 25 synchronizing roller sensor PC2 4 23 toner detecting read switch S4 4 55 transport motor M2 4 52 1st cassette tray1 paper near empty sensor PC5 4 57 1st cassette tray1 paper take up solenoid SL1 4 59 1st cassette tray1 set sensor PC6 4 58 1st cassette paper empty sens...

Page 472: ...ther printer malfunction 2 31 paper feed 2 29 print quality 2 29 synchronizing roller removal 4 25 synchronizing roller sensor PC2 removal 4 23 T toner detecting read switch S4 removal 4 55 toner feed service check 2 35 tools 1 1 transport motor M2 removal 4 52 tray 1 paper near empty sensor PC5 removal 4 57 paper size detecting board removal 4 48 paper take up roller removal 4 16 paper take up ro...

Page 473: ...e counters 3 22 Part Numbers 11D0328 7 33 11D0329 7 33 11D0330 7 33 11D0331 7 33 11D0332 7 33 11D0333 7 33 11D0334 7 33 11D0335 7 33 11D0336 7 33 11D0337 7 33 11D0338 7 33 11D0339 7 33 11G0610 7 133 11G3523 7 51 12C0805 7 51 12G2001 7 3 12G2002 7 3 12G2003 7 3 12G2004 7 3 12G2005 7 3 12G2006 7 3 12G2007 7 3 12G2008 7 3 12G2009 7 3 12G2010 7 3 12G2011 7 3 12G2012 7 3 12G2013 7 3 12G2014 7 3 12G2015...

Page 474: ...2G2097 7 9 12G2098 7 9 12G2099 7 9 12G2100 7 9 12G2101 7 9 12G2102 7 9 7 15 7 53 7 87 7 93 7 99 7 105 12G2105 7 13 12G2106 7 13 12G2107 7 13 12G2108 7 13 12G2109 7 13 12G2110 7 13 12G2111 7 13 12G2112 7 13 12G2113 7 13 12G2114 7 13 12G2115 7 13 12G2116 7 13 12G2117 7 13 12G2119 7 13 7 109 12G2120 7 13 12G2121 7 13 12G2122 7 13 12G2123 7 13 12G2124 7 13 12G2125 7 13 12G2126 7 13 12G2127 7 13 12G212...

Page 475: ...7 21 12G2296 7 21 12G2297 7 21 12G2298 7 21 12G2299 7 21 12G2300 7 21 12G2301 7 21 12G2302 7 21 12G2303 7 21 12G2304 7 21 12G2305 7 23 12G2306 7 23 12G2307 7 23 12G2308 7 23 12G2309 7 23 12G2310 7 23 12G2311 7 23 12G2312 7 23 12G2313 7 23 12G2314 7 23 12G2315 7 23 12G2316 7 23 12G2321 7 25 12G2322 7 25 12G2323 7 25 12G2324 7 9 7 25 12G2325 7 25 12G2326 7 25 12G2327 7 25 12G2328 7 25 12G2329 7 25 1...

Page 476: ...29 12G2398 7 29 12G2399 7 29 12G2400 7 29 12G2401 7 29 12G2402 7 29 12G2404 7 31 12G2405 7 31 12G2406 7 31 12G2407 7 31 12G2408 7 31 12G2409 7 31 12G2410 7 31 7 49 12G2411 7 31 12G2412 7 31 12G2413 7 31 12G2414 7 31 12G2415 7 31 12G2416 7 31 12G2417 7 31 12G2418 7 31 12G2419 7 31 12G2420 7 31 12G2421 7 31 12G2422 7 31 12G2423 7 31 12G2424 7 31 12G2425 7 31 12G2426 7 31 12G2427 7 31 12G2428 7 31 12...

Page 477: ...12G2502 7 53 12G2503 7 53 12G2504 7 53 12G2505 7 53 12G2506 7 53 12G2507 7 53 12G2508 7 53 12G2509 7 53 12G2510 7 53 12G2511 7 53 12G2512 7 53 12G2513 7 53 12G2514 7 53 12G2515 7 53 12G2516 7 53 12G2517 7 53 12G2518 7 53 12G2519 7 53 12G2520 7 53 12G2521 7 53 12G2523 7 53 12G2524 7 53 12G2525 7 55 12G2526 7 55 12G2527 7 55 12G2528 7 39 12G2529 7 39 12G2530 7 39 12G2531 7 39 12G2532 7 39 12G2533 7 ...

Page 478: ...1 7 47 12G2603 7 47 12G2604 7 47 12G2605 7 47 12G2606 7 47 12G2607 7 47 12G2608 7 47 12G2609 7 47 12G2610 7 47 12G2611 7 47 12G2612 7 47 12G2613 7 47 12G2614 7 47 12G2615 7 47 12G2616 7 47 12G2617 7 47 12G2618 7 47 12G2619 7 47 12G2620 7 47 12G2621 7 35 7 47 7 71 12G2622 7 49 12G2623 7 49 12G2624 7 49 12G2625 7 49 12G2626 7 49 12G2627 7 49 12G2629 7 49 12G2630 7 49 12G2631 7 49 12G2632 7 49 12G263...

Page 479: ... 12G2697 7 59 12G2700 7 63 12G2701 7 63 12G2702 7 63 12G2703 7 63 12G2704 7 63 12G2705 7 63 12G2706 7 63 12G2707 7 63 12G2708 7 63 12G2709 7 63 12G2710 7 63 12G2711 7 63 12G2712 7 63 12G2713 7 63 12G2714 7 63 12G2715 7 63 12G2716 7 63 12G2717 7 63 12G2718 7 63 12G2719 7 63 12G2720 7 63 12G2721 7 63 12G2722 7 63 12G2723 7 63 12G2724 7 63 12G2725 7 63 12G2726 7 63 12G2727 7 63 12G2728 7 63 12G2729 7...

Page 480: ...73 12G2805 7 73 12G2806 7 67 7 73 12G2807 7 73 12G2808 7 73 12G2809 7 73 12G2810 7 73 12G2811 7 73 12G2812 7 73 12G2813 7 73 12G2814 7 73 12G2815 7 73 12G2816 7 73 12G2817 7 73 12G2818 7 73 12G2819 7 73 12G2820 7 73 12G2821 7 73 12G2822 7 73 12G2823 7 73 12G2824 7 73 12G2828 7 113 12G2829 7 113 12G2830 7 113 12G2831 7 113 12G2832 7 113 12G2833 7 113 12G2834 7 77 7 113 12G2835 7 113 12G2836 7 113 1...

Page 481: ...12G2907 7 81 7 119 7 123 12G2908 7 119 12G2911 7 83 7 123 7 125 7 127 7 129 12G2912 7 123 7 125 12G2913 7 123 12G2914 7 123 7 125 12G2915 7 123 7 125 12G2916 7 123 7 125 12G2917 7 123 7 125 12G2918 7 113 7 123 7 125 12G2919 7 125 12G2920 7 119 7 123 7 125 7 127 7 129 12G2921 7 127 12G2922 7 127 7 129 12G2923 7 127 7 129 12G2924 7 83 7 127 7 129 12G2925 7 127 12G2926 7 127 7 129 12G2927 7 129 12G29...

Page 482: ...7 109 12G3003 7 109 12G3004 7 109 12G3005 7 109 12G3006 7 109 12G3007 7 109 12G3008 7 109 12G3009 7 109 12G3010 7 109 12G3011 7 109 12G3012 7 109 12G3013 7 109 12G3014 7 109 12G3015 7 109 12G3016 7 109 12G3017 7 109 12G3018 7 109 12G3019 7 109 12G3020 7 109 12G3021 7 109 12G3024 7 105 7 111 12G3025 7 111 12G3026 7 109 12G3027 7 105 7 111 12G3034 7 75 12G3035 7 75 12G3036 7 75 12G3037 7 75 12G3038 ...

Page 483: ...7 7 81 12G3108 7 81 12G3109 7 81 12G3110 7 81 12G3111 7 81 12G3112 7 81 12G3113 7 81 12G3114 7 81 12G3115 7 81 12G3116 7 81 12G3117 7 81 12G3118 7 81 12G3119 7 81 12G3120 7 81 12G3121 7 81 12G3122 7 81 12G3123 7 81 12G3124 7 83 12G3125 7 83 12G3126 7 83 12G3127 7 83 12G3128 7 83 12G3129 7 83 12G3130 7 83 12G3131 7 83 12G3132 7 83 12G3133 7 83 12G3134 7 83 12G3135 7 83 12G3136 7 83 12G3137 7 83 12G...

Page 484: ...202 7 89 12G3203 7 89 12G3204 7 89 12G3205 7 89 12G3206 7 89 12G3207 7 89 12G3208 7 89 12G3209 7 89 12G3210 7 89 12G3211 7 89 12G3212 7 89 12G3213 7 89 12G3214 7 89 12G3215 7 89 12G3216 7 89 12G3217 7 89 12G3218 7 89 12G3219 7 89 12G3223 7 93 12G3224 7 93 12G3225 7 93 12G3226 7 93 7 103 12G3227 7 93 12G3228 7 93 12G3229 7 93 12G3230 7 93 12G3231 7 93 12G3232 7 93 12G3233 7 93 12G3234 7 93 12G3235 ...

Page 485: ...01 12G3306 7 101 12G3307 7 101 12G3309 7 101 12G3310 7 101 12G3311 7 101 12G3312 7 101 12G3313 7 103 12G3314 7 103 12G3315 7 103 12G3316 7 103 12G3317 7 103 12G3318 7 103 12G3319 7 103 12G3320 7 103 12G3321 7 103 12G3322 7 103 12G3323 7 103 12G3324 7 103 12G3325 7 103 12G3326 7 103 12G3327 7 103 12G3328 7 103 12G3329 7 103 12G3330 7 103 12G3331 7 103 12G3332 7 103 12G3333 7 103 12G3334 7 103 12G33...

Page 486: ...G3458 7 27 12G3460 7 97 12G3507 7 87 12G3508 7 45 12G3509 7 47 12G3520 7 3 12G3521 7 51 12G3522 7 133 12G3543 7 133 99A0420 7 133 99A0421 7 133 99A0422 7 133 99A0424 7 133 99A0459 7 133 99A0467 7 133 99A0545 7 133 99A1088 7 133 99A1127 7 133 99A1752 7 51 99A1753 7 51 99A1754 7 51 99A1755 7 51 99A1756 7 51 99A1757 7 51 99A1758 7 51 99A1759 7 51 99A1774 7 51 ...

Page 487: ...Optra W810 Main Printer Wiring Diagram ...

Page 488: ...Optra W810 Finisher Wiring Diagram ...

Page 489: ...Optra W810 Mailbox Wiring Diagram ...

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