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Bravo 4200 Series Disc Publisher Service Manual 

2017 

20.3 

Unhook spring from frame. Pull up on post on left side of maintenance sled while pushing in on right 
side to pop sled out of frame. 

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20.4 

Instructions for modifying old versions of maintenance sled. Snip off plastic tabs and ridges indicated. 
Clean any excess ink. Discard and do not replace foam pad. 

Before 

After 

Summary of Contents for Bravo 4202

Page 1: ...Service Manual for Bravo 4200 Series Disc Publisher 2017 All rights reserved 04 27 17...

Page 2: ...ray 11 07 Power Resistor 13 08 Encoder Wheel Sensor 15 09 Encoder Wheel 17 10 Drive Mount 18 11 Power Supply 20 12 Drive Fan 22 13 Drives 24 14 Maintenance Felt 26 15 Maintenance Fan 27 16 Encoder Str...

Page 3: ...nment Sensor 44 2017 All rights reserved 23 Carrier Flex PC 47 24 Picker 51 25 Picker Motor 55 26 Picker Board Flex Cables 56 27 Arm Board 58 28 Solenoid 61 29 Drive Alignment 63 30 Troubleshooting 66...

Page 4: ...3 1 Cover 1 1 Loosen 4 screws securing back of cover 1 2 Remove 3 screws securing front of cover Slide picker and carrier to middle of printer Bravo 4200 Series Disc Publisher Service Manual 2017...

Page 5: ...4200 Series Disc Publisher Service Manual 2017 1 3 Unplug cable from control panel on underside of cover While lifting cover off of printer reach in and unplug blue LED board cable from mainboard Remo...

Page 6: ...Control Panel 2 1 Remove cover page 3 Remove 3 screws securing control panel After replacing control panel press buttons to verify they click properly Bravo 4200 Series Disc Publisher Service Manual 2...

Page 7: ...6 3 Blue LED Board 3 1 Remove cover page 3 Remove 2 screws securing blue LED board Unplug cable from end of board Bravo 4200 Series Disc Publisher Service Manual 2017...

Page 8: ...rews securing cover plate Remove plate Bravo 4200 Series Disc Publisher Service Manual 2017 4 2 Unplug any sata cables from hub For 2 drive units keep track of which cable is plugged into which port R...

Page 9: ...blisher Service Manual 2017 4 3 When replacing hub be sure pins properly plug into connectors on mainboard Plug any sata cables back in If locations of drives in dual drive units need to be reset cons...

Page 10: ...ainboard 5 1 Remove USB3 hub page 07 Unplug all cables and flex cables from mainboard Bravo 4200 Series Disc Publisher Service Manual 2017 5 2 Remove 4 screws securing mainboard Lift mainboard out of...

Page 11: ...4 When replacing mainboard make sure hole in corner is resting on small post before replacing 4 screws Attach USB3 hub and plug in all cables and flex cables Be sure to plug carrier and feed motors i...

Page 12: ...09 Remove 2 screws securing print tray guide to print tray Lift guide up off of tray leave attached to belt Bravo 4200 Series Disc Publisher Service Manual 2017 6 2 Lift back end of print tray slight...

Page 13: ...12 Bravo 4200 Series Disc Publisher Service Manual 2017 6 3 Remove screw securing front tray guide Lift guide out of base 6 4 Pull print tray out of printer...

Page 14: ...r resistor cable to power supply cable Unplug power resistor from mainboard Bravo 4200 Series Disc Publisher Service Manual 2017 7 2 While holding resistor mount bracket with fingers or needle nose pl...

Page 15: ...14 Bravo 4200 Series Disc Publisher Service Manual 2017 7 3 Remove 2 screws securing power resistor to resistor mount bracket Replace resistor...

Page 16: ...5 8 Encoder Wheel Sensor 8 1 Cut tie wrap securing cables Unplug encoder wheel sensor from mainboard Bravo 4200 Series Disc Publisher Service Manual 2017 8 2 Remove 2 screws securing sensor to bracket...

Page 17: ...16 Bravo 4200 Series Disc Publisher Service Manual 2017 8 3 When replacing sensor be sure encoder wheel is centered in slot...

Page 18: ...heel off of gear Clean area with alcohol before adhering new encoder wheel Bravo 4200 Series Disc Publisher Service Manual 2017 9 2 Be sure replaced encoder wheel is centered in sensor slot Clean enco...

Page 19: ...printer up Remove 6 screws securing drive mount base plate to base Bravo 4200 Series Disc Publisher Service Manual 2017 10 2 Tip drive mount forward Align slot on drive mount base plate with tab on r...

Page 20: ...Bravo 4200 Series Disc Publisher Service Manual 2017 10 3 Unplug all cables from back of drive s to detach drive mount from printer In 2 drive units keep track of which sata cable goes with which dri...

Page 21: ...1 Remove drive mount page 18 Unplug power supply from mainboard Cut tie wraps securing power supply cable Bravo 4200 Series Disc Publisher Service Manual 2017 11 2 Remove 5 screws securing power suppl...

Page 22: ...al 2017 11 3 Lift power supply out of printer Pull drive power cable out through opening on bottom of base 11 4 When replacing power supply route drive power cable to underside of printer Be sure it i...

Page 23: ...1 Remove drive mount page 18 Cut tie wrap securing fan and sata cables Unplug drive fan from mainboard Bravo 4200 Series Disc Publisher Service Manual 2017 12 2 Remove 2 screws securing fan to inside...

Page 24: ...Bravo 4200 Series Disc Publisher Service Manual 2017 12 3 Tip printer up and remove drive fan pulling cable out through opening on base When replacing fan be sure cable is oriented to lower left as sh...

Page 25: ...screws securing drive s to be replaced Bravo 4200 Series Disc Publisher Service Manual 2017 13 2 Slide drive s out from the front Slide new drive into bracket and secure with 4 screws use front set o...

Page 26: ...25 Bravo 4200 Series Disc Publisher Service Manual 2017 13 3 Use side cutters to snip off 4 small tabs on inside of new drive s After installing new drives consult Drive Alignment page 63...

Page 27: ...nce felt cover Remove old maintenance felt pads wear gloves to avoid ink on fingers Bravo 4200 Series Disc Publisher Service Manual 2017 14 2 Stack new set of maintenance felt pads into base in sequen...

Page 28: ...200 Series Disc Publisher Service Manual 2017 15 2 Remove maintenance felt page 26 Remove 2 screws securing fan mount bracket Remove fan pulling cable out through opening When replacing fan and bracke...

Page 29: ...ring from tab Bravo 4200 Series Disc Publisher Service Manual 2017 16 2 Pull left end of encoder strip off of tab first Then rotate other end of strip 90 to remove from flared end of right tab 2nd pic...

Page 30: ...ravo 4200 Series Disc Publisher Service Manual 2017 16 3 Be sure new encoder strip is routed through sensor slot on back of carrier Clean encoder strip with alcohol after handling Through Slot Behind...

Page 31: ...17 Carrier Drive Motor 17 1 Cut tie wrap securing cables Unplug carrier drive motor from mainboard Bravo 4200 Series Disc Publisher Service Manual 2017 17 2 Loosen screw securing carrier belt tension...

Page 32: ...8 driver securing carrier drive motor to carrier frame Remove motor 17 4 When installing new carrier drive motor be sure to include spacer between motor and carrier frame Loop belt around motor pulley...

Page 33: ...32 18 Carrier Frame 18 1 Unplug cables and flex cables indicated from mainboard Bravo 4200 Series Disc Publisher Service Manual 2017 18 2 Remove 2 screws indicated from back of carrier frame...

Page 34: ...33 Bravo 4200 Series Disc Publisher Service Manual 2017 18 3 Remove 2 screws indicated from back of carrier frame Remove control panel cable from wire saddle 18 4 Loosen screw on belt tensioner...

Page 35: ...e pressing in on belt tensioner to add slack pull belt off of pulley on tray drive shaft Remove 2 screws indicated from carrier frame R R Re e em m mo o ov v ve e e B B Be e el llt t t 18 6 Remove scr...

Page 36: ...elt around tray drive shaft before retightening belt tensioner Some early versions required different washers between carrier frame and base If one or more washer s was included be sure to place them...

Page 37: ...emove retaining ring from shaft Bravo 4200 Series Disc Publisher Service Manual 2017 R R Ri iin n ng g g 19 2 Pull tray drive shaft out of carrier frame When replacing shaft be sure bearing is located...

Page 38: ...017 19 3 Remove 2 screws T8 driver securing feed drive motor to bracket Remove motor 19 4 When replacing tray drive shaft be sure encoder wheel is centered in sensor slot If necessary remove encoder w...

Page 39: ...g from shaft Bravo 4200 Series Disc Publisher Service Manual 2017 R R Ri iin n ng g g 20 2 Pull tray drive shaft out of carrier frame When replacing shaft be sure bearing is located on outside of carr...

Page 40: ...left side of maintenance sled while pushing in on right side to pop sled out of frame P P Pu u us s sh h h P P Pu u ul lll ll 20 4 Instructions for modifying old versions of maintenance sled Snip off...

Page 41: ...aft Bravo 4200 Series Disc Publisher Service Manual 2017 21 2 Pull tray drive shaft partially out of carrier frame When replacing shaft be sure bearing is located on outside of carrier frame washer is...

Page 42: ...Publisher Service Manual 2017 21 3 Remove screws from each end of carrier shaft 21 4 Unplug both carrier flex cables from mainboard Press in on tab on flex holder to remove from carrier frame Pull fle...

Page 43: ...lisher Service Manual 2017 21 5 Loosen screw on belt tensioner Pull belt off of tensioner and carrier motor 21 6 Press down slightly on encoder fence to pull it out of sensor slot and route behind car...

Page 44: ...arrier are properly captured on top edge of carrier frame Press carrier shaft back into frame tightening both screws at the same time to prevent it from spinning Be sure flex cable is straight with fr...

Page 45: ...Bravo 4200 Series Disc Publisher Service Manual 2017 22 2 Press up on corner of lower capture lever just enough to access screw indicated do not completely remove lever Loosen screw with T8 driver do...

Page 46: ...4200 Series Disc Publisher Service Manual 2017 22 3 Slightly pry both frames apart just enough to pull alignment sensor wires out from tab P P Pr r ry y y 22 4 Remove screw securing quad sensor carrie...

Page 47: ...alignment sensor 22 6 When reassembling carrier be sure to snap end of quad sensor carrier bracket onto tab on frame before replacing screw Be sure to route alignment sensor wires behind tab before re...

Page 48: ...age 40 Remove 3 screws indicated 23 2 Press up on lower capture lever to detach from unit Lift lever off of unit pulling belt through opening Save small spring that falls out P P Pr r re e es s ss s s...

Page 49: ...r out of quad sensor carrier bracket Press sensor from new carrier flex pc into bracket until it snaps into place Be sure sensor is snapped properly in place so that both tiny round tabs are in notche...

Page 50: ...o tab on frame before replacing screw Be sure to route alignment sensor wires behind tab before replacing 4 screws securing both frames together Be sure bottom corners of carrier flex pc are pinched b...

Page 51: ...lever back into place while removing tweezers Spring should remain captured between parts Be sure spring is centered and sitting straight up and down S S Sp p pr r ri iin n ng g g 23 8 Measure out 4 1...

Page 52: ...ft R R Ri iin n ng g g 24 2 Pull tray drive shaft partially out of carrier frame When replacing shaft be sure bearing is located on outside of carrier frame washer is behind retaining ring and encoder...

Page 53: ...es Disc Publisher Service Manual 2017 24 3 Remove screws from each end of carrier shaft 24 4 Unplug picker flex cable from mainboard Peel flex cable off of double sided tape and route out through slot...

Page 54: ...o 4200 Series Disc Publisher Service Manual 2017 24 5 Loosen screw on belt tensioner do not remove belt 24 6 Pull out on right end of carrier shaft to pop it out of frame Slide picker off of shaft and...

Page 55: ...edge of carrier frame Press carrier shaft back into frame tightening both screws at the same time to prevent it from spinning Replace both pieces of double sided tape and be sure flex cable is paralle...

Page 56: ...nual 2017 25 2 Plug new picker motor into board through opening on plate and route cable into notch 1st pic Twist motor around once to take up excess cable slack before placing motor down into opening...

Page 57: ...d Flex Cables 26 1 Remove picker motor and picker side cover plate page 55 Unplug flex cable from arm board Bravo 4200 Series Disc Publisher Service Manual 2017 26 2 Remove 3 screws securing picker bo...

Page 58: ...r Service Manual 2017 26 3 When replacing picker board or flex cable s route flex cable s through slots on board as shown Be sure flex cable s are plugged into port s in correct orientation S S Sl llo...

Page 59: ...picker page 51 Unplug flex cable from arm board Bravo 4200 Series Disc Publisher Service Manual 2017 27 2 Press tab on sensor flag bracket out and up past edge of arm board to remove it from picker ar...

Page 60: ...Unplug solenoid cable from arm board Remove screw and washer securing arm board Pry out on edge of arm board to pop it out of picker arm P P Pr r ry y y 27 4 Before installing new arm board apply str...

Page 61: ...tom end of board into slot on picker arm then press top end into location Secure with screw and washer Connect solenoid and flex cable T T Ta a ab b b P P Pr r re e es s ss s s 27 6 Replace sensor fla...

Page 62: ...Solenoid 28 1 Remove arm board page 58 Pry pick finger cover off of tabs and remove Bravo 4200 Series Disc Publisher Service Manual 2017 28 2 Unhook spring from picker arm and pick finger P P Pr r ry...

Page 63: ...avo 4200 Series Disc Publisher Service Manual 2017 28 3 Remove 2 screws securing solenoid Remove solenoid pulling cable out through opening 28 4 When replacing solenoid route one cable behind post as...

Page 64: ...r top and bottom and verify proper drive opens If not click on Reset Drive Locations and follow prompts otherwise click Close Bravo 4200 Series Disc Publisher Service Manual 2017 29 2 Place a disc int...

Page 65: ...top drive tray 2nd pic Observe position of drive tray in relation to hovering disc Determine if drive needs to move forwards or backwards to center disc in tray 29 4 Turn screw clockwise to move driv...

Page 66: ...tray in relation to hovering disc Determine if drive needs to move forwards or backwards to center disc in tray 29 6 Drive adjustment screw is below cover but can still be accessed by a screwdriver co...

Page 67: ...s Error 2 0x02 Error2 3 0x03 Error3 0 0x02 Carrier flex PC page 47 J2 mainboard No carrier print tray solenoid or picker Control panel blinks Error 128 0x80 Error2 0 0x00 Error3 0 0x80 Picker board or...

Page 68: ...place in print tray moves to home position Arm board or sensor flag bracket page 58 Erratic carrier and picker movements before eventually grabbing disc Sensor on picker board page 56 Does not recogni...

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