Xerox DocuPrint P1202 Service Manual Download

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Xerox DocuPrint P1202 Service Manual

4-1

Repair Procedures

Section 4

Repair Procedures

4.0 Overview.......................................................................................... 4-3

REP 4.1 Covers

REP 4.1.1 Multi-Purpose Feeder (MPF)........................................... 4-4

REP 4.1.2 Control Panel Harness Cover.......................................... 4-6

REP 4.1.3 Main Cover ...................................................................... 4-8

REP 4.2 Paper Feed

REP 4.2.1 Pick-Up Roll Assembly .................................................. 4-11

REP 4.3 Paper Transportation ........................................................... 4-14

REP 4.3.1 Fuser Exit Assembly...................................................... 4-14

REP 4.3.2 Paper Out Actuator, Paper Feed / Reg. Actuator, Paper
Size Actuator, and Exit Sensor Actuator......................................... 4-18

PREP 4.3.3 Cover Open Sensor .................................................... 4-19

REP 4.4 Fuser

REP 4.4.1 Fuser Assembly............................................................. 4-21

REP 4.4.2 Fuser Thermistor ........................................................... 4-25

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Summary of Contents for DocuPrint P1202

Page 1: ...XEROX Xerox DocuPrint P1202 Service Manual 720P15700 egl_421a www printcopy info w w w p r i n t c o p y i n f o ...

Page 2: ...Aviation Blvd El Segundo California 90245 Copyright 1998 by Xerox Corporation Xerox and DocuPrint P1202 are registered trademarks of Xerox Corporation Copyright 1998 Xerox Corporation All rights reserved Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted including without limitation m...

Page 3: ...is totally enclosed during all modes of customer operation The laser and output of the laser scanner unit produces a beam that if looked into could cause eye damage Service procedures must be followed exactly as written without change When servicing the machine or laser module follow the procedures specified in the manual and there will be no hazards from the laser Laser FDA Any laser label visibl...

Page 4: ... Xerox DocuPrint P1202 Service Manual The Laser Label is visible when the Top Cover is removed Figure 1 Figure 1 Laser Safety Label Laser Label Finland Laser Safety DP8_034 www printcopy info w w w p r i n t c o p y i n f o ...

Page 5: ...nual is the primary document used for repairing and maintaining the P1202 Laser Printers This manual contains Service Call Procedures Diagnostic Procedures General Information Repair Analysis Procedures Copy Quality Analysis Procedures Wiring Data and Parts Lists that will enable the Service Representative to repair P1202 failures NOTE In some of the DocuPrint P1202 documentation the Print Cartrid...

Page 6: ...sted in this section of the manual even if the part itself is not spared All the parts that are spared will have the part number listed Parts that are not spared will not have a number listed Section 4 REPAIR PROCEDURES This section contains the instructions for removal replacement and adjustment of the spared parts Section 5 GENERAL PROCEDURES This section contains diagnostic routines printer set...

Page 7: ...99 4 20 3 99 4 21 3 99 4 22 3 99 4 23 3 99 4 24 3 99 4 25 3 99 4 26 3 99 4 27 3 99 4 28 3 99 4 29 3 99 4 30 3 99 4 31 3 99 4 32 3 99 4 33 3 99 4 34 3 99 4 35 3 99 4 36 3 99 4 37 3 99 4 38 3 99 4 39 3 99 4 40 3 99 4 41 3 99 4 42 3 99 4 43 3 99 4 44 3 99 4 45 3 99 4 46 3 99 5 1 3 99 5 2 3 99 5 3 3 99 5 4 3 99 5 5 3 99 5 6 3 99 5 7 3 99 5 8 3 99 5 9 3 99 5 10 3 99 5 11 3 99 5 12 3 99 5 13 3 99 5 14 3...

Page 8: ...ii Xerox DocuPrint P1202 Service Manual Product Manual Title Part Number P1202 Laser Printer Xerox DocuPrint P1202 Service Manual 720P15700 Page Date Page Date Page Date Page Date www printcopy info w w w p r i n t c o p y i n f o ...

Page 9: ...Service Manual 1 1 Service Call Procedures Section 1 Service Call Procedures 1 1 1 Call Flow Diagram 1 2 1 2 Initial Actions 1 3 1 3 Corrective Actions 1 3 1 4 Final Actions 1 4 www printcopy info w w w p r i n t c o p y i n f o ...

Page 10: ...he Call Flow Diagram Figure 1 1 All service calls begin with Initial Actions and end with Final Actions Figure 1 1 Call Flow Diagram Initial Actions Corrective Actions RAPs Parts List Repair Procedures Wiring Data General Procedures Final Actions Correct Any Secondary Problems Image Quality www printcopy info w w w p r i n t c o p y i n f o ...

Page 11: ...inter is correctly grounded earthed The printer is in an appropriate operating environment with no extremes of heat humidity or dirt The printer is not exposed to direct sunlight The printer is on a level and stable surface 1 3 Corrective Actions 1 If the printer has an obvious failure or fault you can go directly to the appropriate Repair Procedure Section 4 or Repair Analysis Procedure RAP Secti...

Page 12: ...edures in section 7 to correct any print quality defects 3 Correct any secondary problems return to Corrective Actions if necessary 4 Reinstall the machine covers 5 Clean the machine and the work area 6 Ask the customer to send a print job to verify printer operation 7 Provide operator training as required 8 Close the call www printcopy info w w w p r i n t c o p y i n f o ...

Page 13: ...Power On Off 2 3 2 1 3 Power Saver 2 3 2 1 4 Mechanical 2 3 2 1 5 Consumables 2 3 2 2 Physical Location 2 4 2 3 Functional Specifications 2 4 2 4 Environment 2 5 2 5 Options 2 5 2 5 1 PostScript Simms 2 5 2 6 Paper Specifications 2 5 2 6 1 Paper limitations 2 6 2 7 Operating Language and Emulation 2 7 2 8 Communication Interfaces 2 7 www printcopy info w w w p r i n t c o p y i n f o ...

Page 14: ...3 99 Printer Specifications 2 2 Xerox DocuPrint P1202 Service Manual 2 9 Status Display Controls 2 8 www printcopy info w w w p r i n t c o p y i n f o ...

Page 15: ...eceive data for a period of time Power Saver is a menu selection in the Remote Control Panel RCP software which provides the user with the ability to control when the printer enters the power saver state The default value is 30 minutes In Power Save mode the power consumption is under 30 watts 2 1 4 Mechanical 2 1 5 Consumables PRINTER CARTRIDGE 6000 pages at 5 coverage more with use of the toner ...

Page 16: ...ve the paper in the front output tray allow air circulation around the vents to prevent the printer from overheating 2 3 Functional Specifications Warm Up Time First Print Out Print Speed ppm pages per minute Resolution dpi Dots per inch From Sleep mode to Standby mode under 45 seconds From Standby mode 20 seconds From Power save mode 30 seconds 12 ppm True 600 x 600 dpi RET of 1200 x 1200 egl_419...

Page 17: ...ard NOTE The PostScript SIMM is an option The customer is required to provide the PostScript SIMM 2 6 Paper Specifications Papers that meet the specifications may be fed either through the Multipurpose Paper Feeder or the Manual Single Sheet Feeder If you use thick paper from the RCP menu with a weight of more than 90 g m2 40lb or envelope you must insert paper into the Manual Single Sheet Feeder ...

Page 18: ... whose ink is not for laser printing Most papers that meet the above specifications may be fed either through the multisheet or the single sheet paper feeder Some media meets the specifications but is not ideal for feeding e g paper that is either highly textured thicker than normal for its weight or unusually smooth Paper types Size Input Source Capacity Tray 1 or 2 MPF Paper Letter 8 5 x 11 in L...

Page 19: ...ces NOTE IEEE 1284 EPP is not supported Parallel port Centronics IEEE P1284 compatible bi directional Nibble Byte and ECP Serial port RS 232C supports data transfer up to 11 52K bps Auto Interface Switching AIS when the serial interface is installed LocalTalk Macintosh Host Interface 230 4 bps SDLC FMO Coding RS 232C USB Universal Serial Bus port is standard with the P1202 printer www printcopy in...

Page 20: ...ilable for NT 4 0 change printer settings from the computer screen Remote Control Panel The Remote Control Panel RCP program allows you to view and change print settings for the following operating systems DOS Windows 3 1 Windows 95 Windows 98 and NT 4 0 Table 1 READY Green LED Steady On Online and Ready to Print Blinking Receiving data processing or printing Double blink every 2 or 3 seconds Wait...

Page 21: ...4 Laser Assembly Exit Assembly Print Cartridge 3 8 PL 5 Fuser Assembly 3 10 PL 6 Main Drive Assembly 3 12 PL 7 Systems Controller and Electronics 3 14 PL 8 Pickup Assembly Bottom View 3 16 PL 9 Paper Tray Upper 3 18 PL 10 Lower Paper Tray Frame and Paper Tray Option 3 20 Tools Kits and Expendables 3 22 www printcopy info w w w p r i n t c o p y i n f o ...

Page 22: ...Stacker Back Stop 4 Lever 5 Window LED PWB 6 Button Panel LED 7 Main Cover 8 120N00304 Multi Purpose Tray Empty Lever 9 Static Brush 10 Exit Lock 11 Exit Guide 12 3N00706 Exit Stopper 4 per order 13 2N01619 Exit Cover Assembly 14 Cover Opener Button 15 Systems Controller Cover 16 123N00186 LED Panel PWB 17 Panel Cap www printcopy info w w w p r i n t c o p y i n f o ...

Page 23: ...3 99 Xerox DocuPrint P1202 Service Manual 3 3 Parts Lists 16 17 1 9 10 11 12 13 12 10 7 14 15 2 6 5 4 3 8 egl_603c www printcopy info w w w p r i n t c o p y i n f o ...

Page 24: ...7 127N01006 DC Fan 8 110N00828 Off On Switch 9 113N00310 Left Transfer Holder Bracket 10 113N00311 Right Transfer Holder Bracket 11 22N01021 Transfer Roller 12 7N00776 Transfer Gear 13 Wire Shield 14 Systems Controller Shield 15 Simm Cover 16 130N00900 Cover Open Sensor 17 38N00284 Transfer Guide Bracket Assembly 18 130N00907 Thermistor Housing 19 007N00774 Multi purpose Tray Drive Bracket 20 140N...

Page 25: ...nual 3 5 Parts Lists 20 7 8 4 3 18 16 17 14 15 13 1 12 10 2 19 9 11 5 egl_602e 7 8 4 3 18 16 17 14 15 13 1 12 10 2 9 11 5 egl_602d 20 7 8 4 3 18 16 17 14 15 13 1 12 10 2 19 9 11 5 egl_602e www printcopy info w w w p r i n t c o p y i n f o ...

Page 26: ...ti Purpose Tray Assembly Includes items 2 4 2 Tray Cover 3 Output Tray 4 3N00706 Tray Stoppers 4 per order 5 22N01022 Multi Purpose Rack Assembly Includes items 6 11 6 Rack Frame 7 Rack Plate 8 Bracket Assembly 9 Solenoid 10 19N00433 Holder Pad Assembly 11 Paper Empty Sensor www printcopy info w w w p r i n t c o p y i n f o ...

Page 27: ...3 99 Xerox DocuPrint P1202 Service Manual 3 7 Parts Lists 7 11 6 5 1 2 4 4 3 9 8 10 egl_604d www printcopy info w w w p r i n t c o p y i n f o ...

Page 28: ... 1 113R00397 Print Cartridge No Cycling Campaign 113R00398 Print Cartridge Recycling Campaign 2 123N00185 Erase Lamp 3 122N00138 Laser Assembly 4 Fuser Guide 5 2N01618 Exit Housing Assembly Includes items 6 8 6 Exit Roll 7 Exit Roller 8 Exit Housing 9 7N00775 Exit Gear Bracket Assembly www printcopy info w w w p r i n t c o p y i n f o ...

Page 29: ...3 99 Xerox DocuPrint P1202 Service Manual 3 9 Parts Lists 5 4 6 7 8 2 1 9 egl_611d 3 www printcopy info w w w p r i n t c o p y i n f o ...

Page 30: ...user Assembly 110V Includes items 2 8 126N00090 Fuser Assembly 220V Includes items 2 8 2 130N00901 Thermostat 3 Fuser Harness 4 130N00902 Thermistor 5 122N00139 Halogen Lamp 110V 122N00140 Halogen Lamp 220V 6 Exit Roll 7 Pressure Roll 8 Heat Roll 9 126N00088 Exit Actuator www printcopy info w w w p r i n t c o p y i n f o ...

Page 31: ...3 99 Xerox DocuPrint P1202 Service Manual 3 11 Parts Lists 6 7 8 1 3 4 PLACES 4 9 5 4 PLACES 4 PLACES 2 egl_606e www printcopy info w w w p r i n t c o p y i n f o ...

Page 32: ...3 99 Parts Lists 3 12 Xerox Docuprint P1202 Service Manual PL 6 Main Drive Assembly Item Part Number Description 1 5N00619 Main Drive Assembly www printcopy info w w w p r i n t c o p y i n f o ...

Page 33: ...3 99 Xerox DocuPrint P1202 Service Manual 3 13 Parts Lists egl_605e 1 www printcopy info w w w p r i n t c o p y i n f o ...

Page 34: ...20V Includes Item 3 4 2 Engine PWB Frame 3 108N00398 Fuse 4 108N00397 Fuse 110V 108N00399 Fuse 220V 5 140N05246 Motor Drive PWB 6 SMPS Shield 7 140N05248 Systems Controller PWB 110V 140N05250 Systems Controller PWB 220V 8 Memory Simm 9 Postscript Simm Option 10 Serial Local Talk PWB Option 11 Harness to Engine Board 12 Harness to LED Panel Board www printcopy info w w w p r i n t c o p y i n f o ...

Page 35: ...3 99 Xerox DocuPrint P1202 Service Manual 3 15 Parts Lists 5 3 4 1 2 6 7 10 8 12 11 9 egl_612d www printcopy info w w w p r i n t c o p y i n f o ...

Page 36: ...bly Bottom View Item Part Number Description 1 130N00903 Feeder Assembly Includes Items 2 4 2 130N00904 Feeder Rubber 2 per order 3 130N00905 Feed Drive Roll 4 Pickup Gear 5 Base Bracket Right 6 Base Bracket Left 7 Ground Plate www printcopy info w w w p r i n t c o p y i n f o ...

Page 37: ...3 99 Xerox DocuPrint P1202 Service Manual 3 17 Parts Lists 2 3 4 1 6 7 egl_607d 5 www printcopy info w w w p r i n t c o p y i n f o ...

Page 38: ... Lists 3 18 Xerox Docuprint P1202 Service Manual PL 9 Paper Tray Upper Item Part Number Description 1 50N00278 Paper Tray Includes Item 2 2 38N00286 Paper Guide www printcopy info w w w p r i n t c o p y i n f o ...

Page 39: ...3 99 Xerox DocuPrint P1202 Service Manual 3 19 Parts Lists egl_608c 1 egl_608d 1 2 www printcopy info w w w p r i n t c o p y i n f o ...

Page 40: ...de 4 127N01007 Step Motor 5 152N01669 Core Harness 6 140N05249 Paper Tray Frame Main PWB 7 Feeder Pickup Assembly Includes Item 18 8 Left Frame Cover and Shield 9 Right Frame Cover 10 Rear Cover 11 Upper Frame 12 Lower Frame 13 Arm Actuator 14 Feeder Clutch Housing 15 Solenoid 16 Double Option Gear 17 Harness 18 Pickup Rubber 19 Paper Tray Includes Item 20 20 38N00286 Rear Guide www printcopy info...

Page 41: ...DocuPrint P1202 Service Manual 3 21 Parts Lists egl_609c 9 14 4 17 10 11 7 13 12 18 1 15 3 16 2 5 6 8 egl_609e 9 14 4 17 10 11 7 18 13 12 19 20 1 15 3 16 2 5 6 8 www printcopy info w w w p r i n t c o p y i n f o ...

Page 42: ...reated 2 600S04372 Cleaning Pads 3 35P02162 Cotton Swabs 4 99P03082 Disposable Gloves 5 99P03023 Disposable Plastic Bags 6 5P01737 Drop Cloth 7 43P00045 Film Remover 8 43P00048 Formula A Cleaner 9 63P00560 Glue Capsule 10 600S04653 Polyurethane Pads 11 35P03191 Towel heavy duty Supplies XL Xerox Item Part Number Description 1 8R90175 Cleaner 2 600S04372 Cleaning Pad Kit 3 8R90019 Cloth 4 43P00083 ...

Page 43: ...P 4 1 3 Main Cover 4 8 REP 4 2 Paper Feed REP 4 2 1 Pick Up Roll Assembly 4 11 REP 4 3 Paper Transportation 4 14 REP 4 3 1 Fuser Exit Assembly 4 14 REP 4 3 2 Paper Out Actuator Paper Feed Reg Actuator Paper Size Actuator and Exit Sensor Actuator 4 18 PREP 4 3 3 Cover Open Sensor 4 19 REP 4 4 Fuser REP 4 4 1 Fuser Assembly 4 21 REP 4 4 2 Fuser Thermistor 4 25 www printcopy info w w w p r i n t c o ...

Page 44: ...tridge 4 28 REP 4 5 2 Main Drive Motor Assembly 4 29 REP 4 5 3 Erase LampErase Lamp 4 31 REP 4 5 4 Transfer Roller 4 32 REP 4 5 5 DC Fan Motor 4 34 REP 4 6 Electrical Modules REP 4 6 1 Engine PWB 4 35 REP 4 6 2 System Controller PWB 4 40 REP 4 6 3 LSU Laser Assembly 4 42 REP 4 6 4 Replacing the ROM 4 44 www printcopy info w w w p r i n t c o p y i n f o ...

Page 45: ...s is the art number and is used by the developers for tracking and control of the art There are a number of steps you should follow each time before you begin a procedure 1 Do not use force to remove or install printer components 2 Use only the screw size and type designated in the REP The wrong screw could easily damage tapped holes 3 Wear a wrist strap to dissipate static electricity which may d...

Page 46: ...Manual REP 4 1 Covers REP 4 1 1 Multi Purpose Feeder MPF Removal 1 Switch the printer power off and disconnect the AC power cord 2 Open the MPF cover Figure 4 1 1a Figure 4 1 1a Opening the MPF Cover egl_322a www printcopy info w w w p r i n t c o p y i n f o ...

Page 47: ...ers Figure 4 1 1b 4 Hold the MPF cover at a 45 degree angle then remove Figure 4 1 1c Figure 4 1 1b Unlatching the MPF Cover Stopsl Figure 4 1 1c MPF Cover Removal Replacement 1 Assemble in reverse order 2 Verify proper operation egl 324a egl_323a www printcopy info w w w p r i n t c o p y i n f o ...

Page 48: ...r power off and disconnect the AC power cord 2 Press the cover open button and raise the Printer Cover Figure 4 1 2a 3 Remove the screw and unlatch the Control Panel Harness Cover Figure 4 1 2b Figure 4 1 2a Cover Open Button Figure 4 1 2b Removing the Panel Cap egls307a egl_314a www printcopy info w w w p r i n t c o p y i n f o ...

Page 49: ... Repair Procedures 4 Disconnect the data cable from the Panel Board Figure 4 1 2c Figure 4 1 2c Disconnecting Data Cable Replacement 1 Assemble in reverse order 2 Verify proper operation egl_316a www printcopy info w w w p r i n t c o p y i n f o ...

Page 50: ...ti Purpose Feeder REP 4 1 1 3 Remove the Controller Board REP 4 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Remove the two screws at the rear of the Main Cover Figure 4 1 3a Figure 4 1 3a Rear Screwsl 6 Open the printer cover and remove the two screws Figure 4 1 3b Figure 4 1 3b Front Screws egl_325a egl_327a www printcopy info w w w p r i n t c o p y i n f o ...

Page 51: ...in Cover Figure 4 1 3c Figure 4 1 3c Unlatch Front Ends 8 Slide the Main Cover upward off of the Printer Figure 4 1 3d NOTE Ensure that the Printer Power On Off Switch is in the Off position before removing the cover Figure 4 1 3d egl_329a egl_330a www printcopy info w w w p r i n t c o p y i n f o ...

Page 52: ...ing the cover push in the Paper Empty Actuator which is mounted on the Top Cover NOTE When reinstalling the Main Cover ensure that you have access to the System Controller connectors J3 and J4 1 Assemble in reverse order 2 Verify proper operation www printcopy info w w w p r i n t c o p y i n f o ...

Page 53: ...rtridge REP 4 5 1 4 Remove the System Controller PWB REP 4 6 2 5 Remove the Control Panel Harness Cover REP 4 1 2 6 Disconnect the Control Panel Harness from J1 on the Control Panel 7 Remove the Main Cover REP 4 1 3 8 Turn the Printer over so the buttom is facing upward 9 Remove the three scews from the left base bracket Figure 4 2 1a Figure 4 2 1a Left Base Bracket Removal egl_318a www printcopy ...

Page 54: ...Screw 11 Remove the two screws that secure the Pick Up Roll Assembly to the printer Figure 4 2 1c 12 Lift the Pick Up Roll upward and out of the printer Figure 4 2 1c Pick Up Roll Assembly Removal NOTE If the Pick Up Roll is to be replaced individually go to step 13 egl_320a egls319a www printcopy info w w w p r i n t c o p y i n f o ...

Page 55: ...the Pick Up Roll for wear replace as required Figure 4 2 1d Figure 4 2 1d Removing Pick up Roll Replacement 1 Assemble in reverse order 2 Verify proper operation egl_321a 1 Push Tab Up ward to remove the Pick up Roll 2 Remove Pick up Roll www printcopy info w w w p r i n t c o p y i n f o ...

Page 56: ...per Tray 2 Remove the Printer Cartridge REP 4 5 1 3 Remove the System Controller PWB REP 4 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Remove the Fuser Cover Figure 4 3 1a Figure 4 3 1a Exit Assembly Removal egl_331a www printcopy info w w w p r i n t c o p y i n f o ...

Page 57: ...e Manual 4 15 Repair Procedures 8 Remove the three screws from the Exit Idler Gear Assembly Figure 4 3 1b 9 Remove the Exit Gear Assembly Figure 4 3 1b Exit Idler Gear Removal egl_333a www printcopy info w w w p r i n t c o p y i n f o ...

Page 58: ... releasing the latches To remove such parts press the hook end of the latch away from the part to which it is latched 10 Remove the two screws from the Exit assembly and unlatch the two tabs Figure 4 3 1c Figure 4 3 1c Exit Assembly Removal NOTE If the Exit Roller Shaft is to be replaced individually go to step 10 egl_335a www printcopy info w w w p r i n t c o p y i n f o ...

Page 59: ...emove the circlips then remove the idler gears Use care not to break the gear shafts when removing the circlips 13 To replace the Exit Rollers lift the rollers out of the Exit Roller Holder 14 If the Exit Roller Holder or spring is to be replaced use care when removing and installing the holder The mounting pins can break off Replacement 1 Assemble in reverse order egl_334a www printcopy info w w ...

Page 60: ...rol Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Remove the Engine PWB REP 4 6 1 8 Remove the desired actuator by gently squeezing the sides of the actuator Figure 4 3 2a Figure 4 3 2a Paper Empty Sensor Removal Replacement 1 Assemble in reverse order 2 Verify proper operation 3 egl_427a Paper Feed Registratio...

Page 61: ...ove the Printer Cartridge REP 4 5 1 3 Remove the System Controller PWB REP 4 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Remove the ICU Shield Figure 4 3 3a Figure 4 3 3a ICU Shield Removal egl_387a www printcopy info w w w p r i n t c o p y i n f o ...

Page 62: ...vice Manual 8 Remove the two screws that secure the Cover Open Sensor to the frame Figure 4 3 2b Figure 4 3 3b 9 Remove the two screws that secure the Sensor to the holder Figure 4 3 5c egl_388a egl_389a www printcopy info w w w p r i n t c o p y i n f o ...

Page 63: ... 4 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Remove the three screws from the Exit Idler Gear Assembly Figure 4 4 1a Figure 4 4 1a 8 Remove the two screws that secure the Printer Engine PWB Cover Figure 4 4 1b Remove the cover Figure 4 4 1b Fuser Assembly egl_345a egl_347a www print...

Page 64: ...ctuator is located on the bottom of the Fuser near the printer s AC input wires Ensure that the actuator is not damaged as the Fuser is removed 10 Disconnect the harnesses from CN102 and CN4 on the Printer Engine PWB Figure 4 4 1c Figure 4 4 1c Exit Actuator Removal egl_346a Exit Actuator www printcopy info w w w p r i n t c o p y i n f o ...

Page 65: ...4 1d 12 Remove the Fuser Assembly Figure 4 4 1d Fuser Assembly To remove the Fuser Heat Rod 13 Remove the screw that secures the Heat Rod Terminal to the right end of the Fuser Assembly and slide the Heat Rod out of the Fuser Assembly Figure 4 4 1e Figure 4 4 1e Heat Rod Removal egl_348a egl_353a www printcopy info w w w p r i n t c o p y i n f o ...

Page 66: ...Heat Rod handle the Heat Rod only by the ends Do not touch the glass part of the Heat Rod Figure 4 4 1f 2 Install the Heat Rod and terminal Figure 4 4 1f Seating the Heat ARod 3 Reinstall the Fuser Assembly ensuring that the Exit Sensor Actuator is not damaged and has free movement 4 Complete the assembly in reverse order egl_354a www printcopy info w w w p r i n t c o p y i n f o ...

Page 67: ...REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Remove the Fuser Assembly REP 4 4 1 8 Remove the Thermistor wire harness from the three place holders Figure 4 4 2a Figure 4 4 2a Fuser Thermistor Removal 9 Remove the screw that secures the Thermistor to the Fuser Assembly Figure 4 4 2b 10 Remove the Thermistor Assembly Figure 4 4 2b ...

Page 68: ...ce Manual Replacement 1 Ensure that the Thermistor is properly seated when reinstalled Figure 4 4 2c Figure 4 4 2c Reinstalling the Thermistor 2 Assemble in reverse order 3 Verify proper operation egl_352a www printcopy info w w w p r i n t c o p y i n f o ...

Page 69: ... 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Remove the Fuser Assembly REP 4 4 1 8 Remove the two screws that secure the Thermostat to the Fuser Assembly Figure 4 4 3a Figure 4 4 3a Fuser Thermistor Removal Replacement 1 Assemble in reverse order 2 Verify proper operation egl_349a www...

Page 70: ...5 1a Ensure that your thumb does not interfere with the drum protection door Figure 4 5 1a Printer Cartridge Removal 3 Remove the Printer Cartridge by rotating it up and out of the printer 4 If the Printer Cartridge will be out for longer then a few minutes cover the Cartridge with several sheets of paper to protect it from light Replacement 1 Assemble in reverse order www printcopy info w w w p r...

Page 71: ...rtridge REP 4 5 1 3 Remove the System Controller PWB REP 4 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Disconnect the four connectors from the Motor Drive PWB Figure 4 5 2a Figure 4 5 2a Motor Drive Connector Removal egl_337a www printcopy info w w w p r i n t c o p y i n f o ...

Page 72: ...onnector from the Motor Drive PWB Figure 4 5 2b Figure 4 5 2b Motor Drive PWB and Gear Bracket Removal 10 Remove the three gold colored screws that secure the Main Drive Motor to the assembly and remove the Main Drive Motror assembly Figure 4 5 2c Figure 4 5 2c Main Drive Motor Removal Replacement 1 Assemble in reverse order 2 Verify proper operation egl_339a Connector egl_340a www printcopy info ...

Page 73: ...PWB REP 4 6 1 8 Remove the four screws that secure the Transfer Guide Figure 4 5 3a Remove the Transfer Guide 9 Disconnect the harness from CN1 on the Erase Lamp Assembly Figure 4 5 3b 10 Remove the two screws that secure the Erase Lamp Assembly and remove the assembly Figure 4 5 3b Erase Lamp Removal Replacement 1 Assemble in reverse order 2 When reinstalling the Printer Engine PWB on the base fr...

Page 74: ...ler PWB REP 4 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 NOTE Be careful not to touch the BTR roll with your hands 7 Using a flat head screw driver slowly lift up the right end of the BTR Roller as shown in Figure 4 5 4a Figure 4 5 4a BTR Roller Remova egl_309a www printcopy info w w w...

Page 75: ...ller out of the printer Figure 4 5 4b NOTE Ensure that the Gear on the right end of the BTR Roll is in place Figure 4 5 4b BTR Roll Removal Replacement 1 If installing a new Transfer Roller remove the gear from the old roller and place on the new roller 2 Assemble components in reverse order 3 Verify proper operation egl_308a www printcopy info w w w p r i n t c o p y i n f o ...

Page 76: ...r PWB REP 4 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Disconnect the DC Fan from CN2 on the Motor Drive PWB 8 Remove the DC Fan Motor Figure 4 5 5a Figure 4 5 5a DC Fan Motor Removal Replacement 1 Assemble in reverse order 2 Verify proper operation egl_338a www printcopy info w w w ...

Page 77: ...emove the System Controller PWB REP 4 6 2 3 Remove the Multi Purpose Feeder REP 4 1 1 4 Remove the Paper Tray 5 Remove the Main Cover REP 4 1 3 6 Remove the SMPS bracket Figure 4 6 1a Figure 4 6 1a Removing SMPS Bracket CAUTION These components are susceptible to electrostatic discharge Observe all ESD procedures to avoid damage egl_347a www printcopy info w w w p r i n t c o p y i n f o ...

Page 78: ...PWB Frame Figure 4 6 1b Figure 4 6 1b Removing Engine PWB Bracket 8 Turn the Printer over so the buttom is facing upward 9 Remove the six scews from the right and left base bracket Figure 4 6 1c Figure 4 6 1c Right and Left Base Bracket Removal egl_369a egl_370a www printcopy info w w w p r i n t c o p y i n f o ...

Page 79: ...dures 10 Remove the three screws securing the Image Control Unit ICU 4 6 1d Figure 4 6 1d Remove the ICU 11 Remove the ground screw from the Engine PWB frame 4 6 1e Figure 4 6 1e Removing the egl_371a egl_372a www printcopy info w w w p r i n t c o p y i n f o ...

Page 80: ...tom of the base frame 4 6 1f Figure 4 6 1f Engine PWB frame Removal 13 Press the plastic Tab back and gently lift up the Engine PWB 4 6 1g The PWB fits tightly on its locating pins It may be necessary to gently rock the PWB as you lift it Figure 4 6 1g Engine PWB Removal egl_373a egl_374a www printcopy info w w w p r i n t c o p y i n f o ...

Page 81: ...ugh to disconnect the Laser Harness from CN3 the Interface Harness from CN5 and the Main Drive from CN1 Remove the Engine PWB Figure 4 6 2h Figure 4 6 1h Engine PWB Removal Replacement 1 Assemble in reverse order 2 Verify proper operation egl_375a eps www printcopy info w w w p r i n t c o p y i n f o ...

Page 82: ...ntroller PWB 3 Press down on the tab Figure 4 6 3a and remove the SIMM Cover 4 Remove the screw that secures the metal shield and remove the shield Figure 4 6 2a Figure 4 6 2a SIMM Cover Shield Removal CAUTION These components are susceptible to electrostatic discharge Observe all ESD procedures to avoid damage egl_310a egl_312a SIMM Cover www printcopy info w w w p r i n t c o p y i n f o ...

Page 83: ...nter Figure 4 6 2b 7 Slide the System Controller out the rear of the printer Figure 4 6 2b Figure 4 6 2b System Controller Removal 8 If an Optional Serial PWB is installed and the System Controller PWB is being replaced remove the Optional Serial PWB and install it on the new System Controller PWB Replacement 1 Assemble in reverse order 2 Verify proper operation egl_311a egl_313 www printcopy info...

Page 84: ...the Printer Cartridge REP 4 5 1 3 Remove the System Controller PWB REP 4 6 2 4 Remove the Control Panel Harness Cover REP 4 1 2 5 Disconnect the Control Panel Harness from J1 on the Control Panel 6 Remove the Main Cover REP 4 1 3 7 Remove the Fuser Cover Figure 4 6 4a Figure 4 6 3aLaser Scanner Motor Harness egl_331a www printcopy info w w w p r i n t c o p y i n f o ...

Page 85: ...Scanner Motor Control PWB Figure 4 6 3b 9 Remove the three screws that secure the Laser Assembly to the printer frame Figure 4 6 3b Figure 4 6 3b Laser Assembly Removal Replacement 1 Clean the Laser window 1 Assemble in reverse order 2 Verify proper operation egl_332a www printcopy info w w w p r i n t c o p y i n f o ...

Page 86: ...he AC power cord 2 Press the cover open button and raise the printer front cover Figure 4 6 5a 3 Remove the Print Cartridge REP 4 5 1 Figure 4 6 4a Opening Printer Front Cover CAUTION These components are susceptible to electrostatic discharge Observe all ESD procedures to avoid damage egl_390a eps www printcopy info w w w p r i n t c o p y i n f o ...

Page 87: ...moval 5 Using an IC extractor remove the ROM Figure 4 6 4c Figure 4 6 4c Removing the ROM Replacement CAUTION When installing the ROM ensure that the notch on the ROM is in line with the notch on the socket 1 Assemble in reverse order 2 Verify proper operation egl_391a egl_392a www printcopy info w w w p r i n t c o p y i n f o ...

Page 88: ...3 99 Repair Procedures 4 46 Xerox DocuPrint P1202 Service Manual This Page Intentionally Left Blank www printcopy info w w w p r i n t c o p y i n f o ...

Page 89: ...inter Operations 5 5 5 2 1 Control Panel 5 5 5 2 2 Printer Modes 5 6 5 2 2 1 Ready Mode Online 5 6 5 2 2 2 Test Mode 5 6 5 2 3 Clearing Printer Memory 5 7 5 2 4 Print Cartridge Cleaning Procedure 5 7 5 3 Printer Software 5 7 5 3 1 Installing Software 5 8 5 3 1 1 Installing Printer Drivers 5 8 5 3 1 2 Installing Status Monitor and Remote Control Panel 5 9 5 3 2 The Status Monitor 5 9 5 3 3 Remote C...

Page 90: ...5 18 5 3 37 PostScript Tab 5 19 5 4 Diagnostic Control Unit DCU 5 20 5 4 1 Connecting the DCU 5 20 5 4 2 The DCU s Operating Modes 5 20 5 4 2 1 Status Mode 5 22 5 4 2 2 Diagnostic Mode 5 23 5 4 3 General Test Procedures 5 25 5 5 Engine Controller PWB 5 28 5 6 Installing Additional Memory 5 29 5 7 EPROM Update Procedure 5 31 5 8 Update Procedure 5 34 5 9 Abbreviations 5 36 www printcopy info w w w ...

Page 91: ...e printer through the ventilation slots Such objects may touch dangerous high voltage points causing electric shock a short circuit or a fire 5 Use only a grounded earthed power source If you are not sure of the type of power available consult your dealer or the local power company 6 Make sure no one can trip on the power cord or communication cable and that no weight is placed on them 7 Avoid tou...

Page 92: ...lled chemicals These can generate enough static charge to damage sensitive components 5 Do not remove a replacement component from its protective package until you are ready to install it Most replacement components are packaged with leads that are electrically shorted together by conductive foam aluminum foil or other conductive material 6 Immediately before removing the protective material from ...

Page 93: ...ol Panel The table below provides various LED conditions and describes their significance Indicator Description Error LED on There is no print cartridge The cover is open There is a paper jam if the Paper LED is on Other error condition Error LED blink Printer memory is insufficient for print job Paper LED on The paper tray is empty There is a paper jam if Error LED is also on Paper LED blink The ...

Page 94: ...inter is in Ready Mode the Ready LED on the Control Panel is lit When the Ready LED is blinking the printer is receiving processing data or printing When the Ready LED is OFF the printer is Offline 5 2 2 2 Test Mode In Test Mode the printer is able to print a one page configuration sheet Local Test Mode To initiate a printer self test and print a configuration sheet follow these steps 1 Make sure ...

Page 95: ... of the page The printer will produce one page Depending on the contamination the page may contain a heavy concentration of background More than one cleaning cycle may be required to remove contamination Replace Printer Cartridge if cleaning cycles do not resolve the print quality problem 5 3 Printer Software The customer has a choice of different software configurations depending upon their needs...

Page 96: ...Hardware Found dialog box click on the OK button then insert the Xerox DocuPrint P1202 CD ROM into your CD ROM drive 3 Using the Browse button select d win95 inf where d is your CD ROM drive letter then click OK Skip to Step 7 4 Insert the Xerox DocuPrint P1202 CD ROM into your CD ROM drive If window automatically runs the CD ROM skip to Step 7 5 Select Run from the Start menu 6 Type d setup exe o...

Page 97: ...from the Language Menu 6 From the Main Installation Menu select RCP SM 7 Follow the on screen instructions to complete the installation 5 3 2 Status Monitor NOTE The Status Monitor is not available with Windows NT 4 0 The Status Monitor program runs in background mode When selected the Status Monitor automatically displays messages from the printer on the computer screen whenever the printer s sta...

Page 98: ...there has excessive curl paper jams of this type will occur Paper jam near inside rear of printer The printer had a jam while feeding paper into the xerographic area To remedy the problem the user should open the cover remove the image cartridge and paper cleared Paper jam near front of printer The printer had a jam in the area from the fuser to face up stacker or fuser to face down stacker To rem...

Page 99: ... Select Program from the Start menu Select Xerox DocuPrint P1202 then Remote Control Panel from the drop down list Windows 3 1x Double click the Xerox RCP folder in Program Manager Double click the RCP SM icon The RCP window shown on the next page contains three main areas The top area is a series of tabs enabling the choice of any of five RCP views Total View Printer Page Font Quality and Test To...

Page 100: ...ral Procedures and Information 5 12 Xerox DocuPrint P1202 Service Manual Status Monitor Displays the current printer status Exit Closes the Remote Control Panel www printcopy info w w w p r i n t c o p y i n f o ...

Page 101: ...ow the printing is oriented on the page Top Margin sets the top margin of the print material Left Margin set the left margin of the print material Copies sets the number of copies printed for each page AUTO CR sets how the printer performs a carriage return Quality sets the printer resolution to either 300 or 600 dpi The higher the setting the sharper the clarity of printed characters and graphics...

Page 102: ...ner when printing The default value is OFF which provides 100 usage Auto Continue determines what action the printer should take when a manual feed print job is sent to the printer and there is no paper in the MSF If set to ON the printer will pick up the paper from Tray 1 after ten seconds Otherwise the printer will wait for you to load paper in the MSF Jam Recovery determines what action the pri...

Page 103: ...des the printer with information about the type of paper to be used for a print job If you use paper with a weight of more than 42lb 90 g m2 or an envelope set this to THICK and use the MSF s manual feed slot Density determines the overall density of the printed image Memory Enhancement mode makes the printer process more data by optimizing the memory When set to ON the complex data can be process...

Page 104: ...pacing if the handshaking protocol uses XON XOFF pacing When set to ON the printer send a continuous stream of XONs to the host computer to indicate that the serial port is ready to receive more data An XON is sent every second as long as no data is received across the serial port in the last second the last XON is accepted by the host computer and the printer is ready to receive data from the ser...

Page 105: ...otice and version level It also enables the printing of the following test documents Configuration Page prints the configuration sheet A list of the user default settings the installed options and the amount of printer memory available prints Demo Page prints the standard demonstration page sm5_006 egl_434a www printcopy info w w w p r i n t c o p y i n f o ...

Page 106: ...ed a scalable monospaced font Pitch refers to the num ber of fixed space characters in a horizontal inch of type Point Size sets the font point size only if you have selected a scalable typographic font Point size refers to the height of the characters in the font One point equals approximately 1 72 of an inch You can select point sizes from1 to 1008 in increments of 0 25 points Lines Per Page set...

Page 107: ...I The PS II tab shown above enables the following printer settings Use this tab to control the following printer feature only when the PostScript option is installed Font List prints the font list showing all the fonts available for PostScript sm5_006 egl_433a www printcopy info w w w p r i n t c o p y i n f o ...

Page 108: ... Cartridge Interlock Switch must be actuated to perform the DCU tests The Print Cartridge must be in place and the Front Cover closed or the interlock cheated to run the tests 8 Reconnect AC power and switch on the printer 5 4 2 The DCU s Operating Modes Operation of the DCU is simpler than it might appear from the variety of indicators and labels on the DCU s face see Figure 5 4 2a Only some of t...

Page 109: ... FOLIO PRINT START PRINT START 2 nd CASSETTE PRINT START MP TRAY FEED SENSOR 1 st OFF FEED SENSOR 2 ndON FEED SENSOR 2 nd ON PAPER OUT OPEN FUSER ERROR WARM UP LOW HEAT ERROR COVER OPEN ERROR OVER HEAT ERROR SLEEP MODE NO PAPER or NO CASSETTE PAPER JAM0 PAPER JAM1 PAPER JAM2 MPF PRINT MODE NO PAPER in MP TRAY LSU NOT READY GREEN MODE 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 BIAS1 LSU MOTOR ...

Page 110: ...ist of codes and status error parameters is in Table 5 4 3 on the following page If the problem is resolved without disconnecting power Status Mode removes the error code displayed and resumes normal operation If power is disconnected powering on once again causes Status Mode to repeat its status review until another problem is detected or the review is successfully completed Whenever Status Mode ...

Page 111: ...ressing three keys DOWN SHIFT and STOP at the time the printer is switched on If the printer is already connected and in the Status Mode it is necessary to switch off the printer hold down the three keys and switch on the printer When the DCU enters Diagnostic Mode the readout window displays 00 and all LEDs on the printer s Control Panel start to blink The Control Panel LEDs continue to blink as ...

Page 112: ...Service Manual The 00 readout is the Diagnostic Code for testing the main motor The UP and SHIFT DOWN keys are used to scroll the Diagnostic Code list up and down in the readout window to select other diagnostic tests www printcopy info w w w p r i n t c o p y i n f o ...

Page 113: ... SHIFT STOP The exceptions are tests 11 and 12 which are ended by switching off the printer What happens between starting and stopping a test varies according to the type of test The four voltage tests 01 04 require use of a multimeter and probes Test results are determined from the multimeter readings Column 3 Figure 5 4 5a illustrates the locations of the high voltage test points and Table 5 4 5...

Page 114: ...s For example consider test 08 the test of the Feed and Exit Sensors If the feed sensor circuit is working properly the unlabeled LED and only that LED will be lit when the Feed Sensor is actuated If either of the other two LEDs light or if the unlabeled LED fails to light the Feed Sensor circuit is not operating properly Three of the thirteen tests 04 05 and 10 are multiple tests After the first ...

Page 115: ...ode On Lit Lit Lit SHIFT STOP 06 Pick Up Solenoid Press ENTER Solenoid Activates Lit SHIFT STOP 07 Paper Out Sensor Press ENTER Remove Paper Lit SHIFT STOP 08 Feed Exit Sensor Press ENTER Actuate Feed Sensor Actuate Exit Sensor Lit Lit SHIFT STOP 09 Cover Open Sensor Press ENTER Actuate Sensor Deactuate Sensor Lit SHIFT STOP 10 Fuser Circuit Standby Heat Print Heat Overheating Press ENTER Press UP...

Page 116: ...e machine or installed correctly the printer will not operate Provides the control signals necessary to operate the laser Identifies the installation of a new Print Cartridge The Engine Controller PWB monitors four paper sensors Feed Sensor Located before the transfer process Senses if paper is feeding and starts the process of sending image data to the laser Exit Sensor The Exit Sensor is located...

Page 117: ...SIMM options to increase the printer memory up to a total of 36Mb All SIMMs are industry standard EDO 72 pin 32 bit memory no parity 60 ns or faster and are available in sizes of 4 8 16 or 32MB When the SIMM is installed the Controller PWB will automatically detect the memory and increase the printer buffer size To install an additional memory module 1 Switch off printer and disconnect the AC powe...

Page 118: ...dule is on the top Figure 5 6 0c Figure 5 6 0a 6 Hold the SIMM at a vertical 30 degree angle and firmly push it with your thumbs into the slot Push the module into the back of the slot to fully seat it Figure 5 6 0d Figure 5 6 0a 7 Rotate the module to the right until the clips on the edges of the slot snap click onto the module 8 Reinstall the Shield and the right side cover panel 9 Run a Status ...

Page 119: ...sconnect the AC power 2 Remove the right side cover panel by pressing the latch down and pulling it out and up Figure 5 7 0a Figure 5 7 0a Right Side Cover Removal 3 Remove the metal plate by removing the screw holding it in place 5 7 0b Figure 5 7 0a Shield Removal egl_412b egl_413b www printcopy info w w w p r i n t c o p y i n f o ...

Page 120: ...igure 5 7 0a Disconnecting J7 and J12 5 Remove the three screws securing the back plate of the System Controller PWB Figure 5 7 0d Figure 5 7 0a System Controller Removal 6 Slide the System Controller PWB from the printer and place it on a flat surface Discard the metal filler plate egl_416b J7 connector J12 Connector egl_417b www printcopy info w w w p r i n t c o p y i n f o ...

Page 121: ...stallation 8 Slide the controller board back into the printer and replace the three screws to secure it 9 Connect the two System Controller PWB connectors wire harnesses at J7 and J12 10 Replace the right side cover panels 11 Connect the serial interface cable 12 Have the user set the appropriate transmission speed in the RCP 13 Confirm the serial option setup for the printer matches the PC values...

Page 122: ...s letter or xerox a4 220 if default paper size is A4 rom XXX XXX represents the version level i e 103 for version 1 03 boot XXX XXX represents the version level i e 103 for version 1 03 The computer s parallel port should be assigned as standard LPT1 hex 378 before beginning the procedure Procedure 1 Unzip the files to a temporary directory 2 Make sure the printer is powered off and the parallel c...

Page 123: ...represents the version level i e 103 for version 1 03 This tests 115 VAC systems with a default for letter size paper OR At the C prompt type fprt xerox a4 XXX lpt1 XXX represents the A4letter size paper The ready LED should stay on 11 Switch off the printer and then switch it back on 12 Print a configuration sheet by holding the On Off line button down for about 5 seconds until all the LEDs are b...

Page 124: ...l Processing Unit neg negative DCU Diagnostic Control Unit OSC oscillator DMA Direct Memory Access PCU Printer Control Unit DMAC Direct Memory Access Controller PPM Pages Per Minute DOS Disk Operating System PRINT Print command DPI Dots Per Inch psync page synchronization DRAM Dynamic Random Access Memory pwr power DS Data Strobe RAM Random Access Memory DVM Digital Voltmeter READY Engine ready to...

Page 125: ... PWB 6 5 6 2 3 1 Engine PWB 6 7 6 2 4 Lower Feeder 6 8 6 3 Wiring Harness 6 9 6 3 1 Interface Harness 6 9 6 3 2 Laser Harness 6 10 6 3 3 Control Panel Harness 6 11 6 3 4 Motor Harness 6 12 6 3 5 DCU Connector 6 12 6 3 6 Thermistor 6 12 6 3 7 Heat Rod 6 12 6 3 8 AC Input 6 13 6 3 9 Lower Feeder Harness 6 13 6 3 10 Serial Port 6 13 6 4 PWB Layout 6 14 www printcopy info w w w p r i n t c o p y i n f...

Page 126: ...ng Data 6 2 Xerox DocuPrint P1202 Service Manual 6 4 1 System Controller PWB 6 14 6 4 2 Control Panel PWB 6 14 6 4 3 Engine PWB 6 15 6 4 4 Motor Drive PWB 6 16 www printcopy info w w w p r i n t c o p y i n f o ...

Page 127: ...ponents and how they are connected The circuit board layout section contains the circuit board layouts and the wiring connectors The circuit board illustrations show the locations of the connectors and any sensors located on the board Each connector has an arrow that indicates the position of pin one for that connector The wiring diagrams illustrate the wiring connections between the circuit board...

Page 128: ...T2 PA OUT4 PA OUT5 24V CLUTCH PAPER GND 5V PANEL BOARD CONTROLLER BOARD ENGINE BOARD MOTOR_BD FAN MOTOR MAIN MOTOR MP CLUTCH MP PAPER SECOND CASSET FEEDER LASER UNIT LSU MOTOR TONER SENSOR PTL_LAMP THERMISTOR THERMISTOR FUSER DCU CN 1 J 4 J 5 CN 101 CN 104 P S W AC INPUT CN 105 CN 105 CN 102 CN 5 CN 6 CN 4 CN 5 CN 2 CN 10 CN 12 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 129: ... 2 2 System Controller PWB System Controller PWB Parallel Interface Connector Control Panel PWB Printer Engine PWB SIMM Connector Serial Option PWB Interface Harness DCU Connector dp8_031 Control Panel Harness www printcopy info w w w p r i n t c o p y i n f o ...

Page 130: ...OCK TRIAC SMPS AC POWER VIDEO CONTROLLER MOTOR SUB B D VIDEO CONTROLLER INTERFACE FAN MP_CLUTCH MP_SENSOR COVER FEED P_EMPTY TONER EXIT MP_PAPER SCF_EMPTY MP_EMPTY AO A7 AS ADO AD7 ADO AD7 ADO AD7 DS AVREF 5V 24V POWER OFF 5V POWER OFF A8 A15 A15 AO A7 A8 A15 CHARGE SUPPLY BIAS TRANSFER NEGATIVE TRANSFER THVPWM BIASPWM THVREAD TIMER ACCOUNT 6 944MHZ EXTERNAL BUS INTERFACE A D CONVERTER egl_435a ww...

Page 131: ...in Drive Motor Thermistor Heat Rod Laser Diode Laser Motor Erase Lamp BTR Roll Printer Cartridge Supply MHV Charge Bias Not Used Lower Feeder Harness Motor Harness Interface Harness Laser Harness System Controller PWB dp8_030 Lower Feeder Connector www printcopy info w w w p r i n t c o p y i n f o ...

Page 132: ...uPrint P1202 Service Manual 6 2 4 Lower Feeder Lower Feeder PWB Drive Motor Feed Solenoid Meter will read approxmately 11 3 VDC Lower Feeder Harness Lower Feeder Printer Engine PWB www printcopy info w w w p r i n t c o p y i n f o ...

Page 133: ...l Name 1 23 CSBY 13 11 CMSG 2 24 EBSY 14 12 5 0 VDC 3 21 EXITPAPP 15 9 5 0 VDC 4 22 EMSG 16 10 5 0 VDC 5 19 PRINT 17 7 5 0 VDC 6 20 CCLK 18 8 GND 7 18 NC 19 5 GND 8 17 VDATA 20 6 GND 9 15 RADY 21 3 GND 10 16 PSYNC 22 4 GND 11 13 NC 23 1 DCU CLOCK 12 14 HSYNC 24 2 DCU DATA dp8_073 P3 to J3 System Controller PWB P5 to CN5 Printer Engine PWB www printcopy info w w w p r i n t c o p y i n f o ...

Page 134: ...D 5 P1 CN1 Laser Diode Pin 5 5 0 VDC 6 P1 CN1 Laser Diode Pin 6 HSYNC 7 P1 CN1 Laser Motor Pin 5 NC 8 P1 CN1 Laser Motor Pin 4 LREADY 9 P1 CN1 Laser Motor Pin 3 PMOTOR 10 P1 CN1 Laser Motor Pin 2 AGND 11 P1 CN1 Laser Motor Pin 1 24 0 VDC 12 P1 CN1 Erase Lamp Pin 2 5 0 VDC 13 P1 CN1 Erase Lamp Pin 1 ERASE LAMP dp8_074 P1 Erase Lamp P1 Laser Diode P1 Laser Motor P3 Printer Engine PWB www printcopy i...

Page 135: ...trol Panel Harness P4 to J4 Pin Number P1 to J1 Pin Numbers Signal Name 1 1 5 0 VDC 2 2 GND 3 3 READY LED 4 4 PAPER LED 5 5 MANUAL LED 6 6 ERROR LED 7 7 FRONT PANEL KEY dp8_076 P1 Control Panel P4 System Controller PWB www printcopy info w w w p r i n t c o p y i n f o ...

Page 136: ...or 6 3 7 Heat Rod P1 Pin Number Signal Name 1 24 0 VDC 2 24 0 VDC 3 MOTOR A 4 MOTOR B 5 MOTOR A 6 MOTOR B J6 Pin Number Signal Name 1 5 0 VDC 2 DCU DATA 3 DCU CLOCK 4 GND P4 Pin Number Signal Name 1 THERMISTOR 2 THERMISTOR P102 Pin Number Signal Name 1 LAMP 2 LAMP www printcopy info w w w p r i n t c o p y i n f o ...

Page 137: ...bers Lower Feeder PWB 1 Red 1 1 Red 2 Orange 5 2 Orange 3 Yellow 2 3 Yellow 4 Green 6 4 Green 5 Blue 3 5 Blue 6 Purple 7 6 Purple 7 White 4 7 White 8 Black 8 8 Black Serial Port Pin Number Purpose 1 Request to Send RTS 2 Transmit Data TXD 3 Receive Data RXD 4 Date Set Ready DSR 5 Ground GND 6 Data Terminal Ready 1 DTR1 7 Not Connected NC 8 Data Terminal Ready 1 DTR1 9 Not Connected NC www printcop...

Page 138: ...3 99 Wiring Data 6 14 Xerox DocuPrint P1202 Service Manual 6 4 PWB Layout 6 4 1 System Controller PWB 6 4 2 Control Panel PWB 1 egl_425a egl_423a www printcopy info w w w p r i n t c o p y i n f o ...

Page 139: ...3 99 Xerox DocuPrint P1202 Service Manual 6 15 Wiring Data 6 4 3 Engine PWB 6 4 4 Motor Drive PWB egl_424a egl_426a www printcopy info w w w p r i n t c o p y i n f o ...

Page 140: ...3 99 Wiring Data 6 16 Xerox DocuPrint P1202 Service Manual This Page Intentionally Left Blank www printcopy info w w w p r i n t c o p y i n f o ...

Page 141: ...P 7 3 RAP 7 3 Main Drive Motor 7 6 RAP 7 4 Control Panel 7 8 RAP 7 5 Paper Feed 7 9 RAP 7 6 Paper Jam 7 10 RAP 7 7 Printer Problem 7 11 RAP 7 8 Image Quality Problems 7 12 RAP 7 8 1 Image Quality Defect Definitions Causes and Solutions 7 12 RAP 7 9 Communications RAP 7 16 RAP 7 10 SIMM Check Out Procedure 7 17 www printcopy info w w w p r i n t c o p y i n f o ...

Page 142: ... J 2 In most cases the second P J pin in the notation is a Return RTN Frame Ground FG or Signal Ground SG 3 When a RAP tells you to take a voltage reading between P J X and P J Y with no pin numbers given refer to the Wiring and Connection Diagrams in Section 6 and take readings on ALL pins 4 Unless otherwise instructed by a RAP take all voltage readings with the Print Cartridge Front Cover Interl...

Page 143: ...nsure that all covers are properly closed 2 Connect the AC power The Main Drive Motor runs Y N Go to RAP 7 3 3 The Ready LED illuminates and all other LEDs are off Y N Go to RAP 7 4 4 The Main Drive Motor stops dependant upon PCU version motor can run for up to 60 seconds Y N Replace the Engine PWB PL 7 5 Wait for approximately 60 seconds The Ready LED remains illuminated and all other LEDs remain...

Page 144: ...ated Y N Replace the System Controller PWB PL 7 15 Press and hold the Front Panel Key until all four LEDs flash Release the key The manually fed page is printed correctly Y N Replace the Engine PWB PL 7 16 Ask the customer to enter the Remote Control Panel RCP select the Test Menu and print a Demo List The Demo List prints successfully Y N Go to RAP 7 9 17 Ask the customer to print a document from...

Page 145: ...Open or Missing Printer Cartridge Verify that the Printer Cartridge is properly installed Verify that the Front Cover is properly closed Verify that the printer cartridge front cover interlock actuator moves freely Replace the Engine PWB PL 5 Paper Jam 0 Go to RAP 7 6 Paper Jam 1 Go to RAP 7 6 Paper Jam 2 Go to RAP 7 6 Scanner Error LASER Replace the LASER Assembly PL 4 Fuser Error Replace the Fus...

Page 146: ...xt to the printer Cheat the Front Cover Interlock Reconnect the AC power The Main Drive Motor Assembly runs normally Y N Go to step 10 7 Disconnect the AC power Rotate the Pick Up Assembly gears The gears rotate freely Y N Check the gears for obstructions Repair or replace the Pick Up Assembly as necessary PL 8 8 Rotate the Fuser Drive Gears The Fuser Drive and Exit Drive Gears rotate freely Y N C...

Page 147: ...osed 1 to 9 seconds are correct Y N Replace the Engine PWB PL 7 13 Replace the Main Drive Motor Assembly PL 6 Table 7 3 Main Drive Motor Voltages Measure Voltage from CN1 Pin To Interlock Open Interlock Closed after 10 Seconds Interlock Closed 1 to 9 Seconds 3 Frame Ground 24 4 2 0 VDC 23 8 0 5 VDC 21 8 1 0 VDC 4 Frame Ground 24 4 2 0 VDC 23 8 0 5 VDC 21 8 1 0 VDC 5 Frame Ground 24 4 2 0 VDC 23 8 ...

Page 148: ... Y N Verify the System Controller PWB to Engine PWB Harness If harness is OK replace the Engine PWB PL 7 7 Replace the System Controller PWB PL 7 8 Use Table 7 4 to isolate the problem Table 7 4 Control Panel LEDs Control Panel LEDs Possible Cause Solution All four LEDs blink Defective Laser Defective Fuser Go to RAP 7 7 Error LED only is illuminated No Printer Cartridge Open Front Cover Defective...

Page 149: ...tuator Press and hold the Online Off line Button until all four LEDs blink Release the button Observe the Paper Feed Solenoid The solenoid energizes Y N Replace the Engine PWB PL 7 2 Observe the Pick Up Assembly The Pick Up Assembly rotates Y N Replace the Pick Up Assembly PL 8 3 Clean or replace as necessary the Pick Up Roll PL 8 the Pick Up Roll Assembly PL 8 www printcopy info w w w p r i n t c...

Page 150: ...per Jam 0 Paper Feed Registration Sensor or Sensor Actuator Use DCU test 08 to verify sensor If OK replace the Engine PWB PL 7 Paper Jam 01 Paper Feed Registration Sensor or Sensor Actuator Fuser Assembly Use DCU test 08 to verify sensor If OK replace the Engine PWB PL 7 Verify Fuser Assembly is operational Remove or replace as necessary PL 5 Inspect Exit Sensor Actuator Repair of replace as neces...

Page 151: ...he Engine PWB Measure the resistance between pins 1 and 2 on the disconnected plug The resistance is between 4K ohms and 200K ohms Y N Replace the Thermister PL 5 5 Replace the Engine PWB PL 7 6 Disconnect the AC power Remove the Laser Assembly and verify proper connection of both Laser harness connectors Both connectors are properly connected and the harnesses are undamaged Y N Properly connect r...

Page 152: ... necessary PL 4 BLACK PRINTS the print is completely covered with toner and has no visible image 1 Controller PWB 2 Incorrect charge voltage 3 Print Cartridge 4 Engine PWB 5 Laser on all the time 1 Using the DCU print a DCU test print If the test print is OK replace the Controller PWB If test print is black continue 2 Verify charge voltage output Charge voltage equals 1 3 KVDC 100 VDC If not repla...

Page 153: ...ve ground on Print Cartridge 3 Controller PWB 4 Incorrect high voltage output 5 Defective LASER 6 Transfer Roller pressure 7 Paper 1 Inspect cartridge for removal of seal tape 2 Verify Print Cartridge ground Check continuity between cartridge contact and the Controller PWB metal cover Ensure that the Print Cartridge ground contact is clean and undamaged 3 Using the DCU print a DCU test print If th...

Page 154: ...d or of a high rag content 3 Check Remote Control Panel print quality settings 4 Inspect clean replace Fuser Assembly as necessary PL 5 5 Replace the Engine PWB PL 7 STREAKS Extraneous dark lines bands in or across the process direction These are Engine defects not related to the Controller PWB or Host Data 1 Print Cartridge 2 Fuser Assembly 3 Transfer Roller 4 Contaminated paper path 1 Inspect dr...

Page 155: ...per transportation 2 Main Drive Motor Assembly 3 Fuser Assembly 4 Print Cartridge 1 Inspect paper transportation system for proper operation Replace worn parts 2 Inspect Main Drive Motor Assembly for damaged or worn gears Replace as necessary 3 Inspect clean replace Fuser Assembly as necessary PL 5 4 Replace Print Cartridge PL 4 Skewed Image Angular displacement of the image from its intended posi...

Page 156: ...etup parameters 6 Disconnect and reconnect the host interface cable from the serial interface port Inspect for any visual signs of damage to the cable Replace interface cable if necessary customer purchased item Have customer send a print job using another application 7 Remove and reinstall the serial PWB to ensure that it is properly installed Print a Configuration Sheet The configuration sheet i...

Page 157: ... 3 2 Return to the Entry Level RAP and continue 3 Replace the System Controller PWB PL 7 Print a configuration sheet The RAM size indicated on the Status Report matches the memory actually installed in the printer Y N Inform the customer that the SIMM appears defective or is not compatible with the printer A compatible SIMM is a 72 pin 50ns or faster no parity 4 Problem is resolved Return to the E...

Page 158: ...3 99 Repair Analysis Procedures RAP 7 18 Xerox DocuPrint P1202 Service Manual This Page is Intentionally Left Blank www printcopy info w w w p r i n t c o p y i n f o ...

Page 159: ...ss printed on the reverse side of this page if you send it by external mail add the necessary postage When folded these pages form an envelope Fold and include any marked up pages in the envelope and or write your comments below Name Job Title Date Employee No Location Code Publication Number Date and Revision of Publication Title of Publication 720P15700 3 99 Xerox DocuPrint P1202 Service Manual ...

Page 160: ...leted on the reverse side Before stapling please be sure that all information is completed on the reverse side Xerox Corporation PSD E Mail Stop ESM1 O58 701 S Aviation Blvd El Ssgundo CA 90245 ATTN P1202 Developers Add Necessary Postage www printcopy info w w w p r i n t c o p y i n f o ...

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