Olivetti DR N17 Service Manual

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6HUYLFH 0DQXDO

Code: 687200Q-00

September, 1999

686680G Service Manual ii

PUBBLICATION ISSUED BY:

Olivetti Lexikon S.p.A.
Documentazione
77, Via Jervis - 10015 Ivrea (Italy)

Copyright © 1999, Olivetti
All rights reserved

Printed in Italy

687200Q Service Manual ii

This servi ce m anual contai ns inf ormation that
applies to the Network Laser Printers.

NOTICE

This manual is for use by Technicians and trained
technicians only.

NOTICE

While eve ry ca re has been ta ke n in the
preparation of this manual, no liability will be
accepted by arising out of any inaccuracies or
omissions.

All service documenta tio n is s upplied to external
custome rs fo r inf ormational purposes onl y.
Service d oc um entation is intended for us e by
certified, product-traine d s ervice personnel only.
Olive t ti does not wa rrant or represent that such
docume nt at ion is complete. N or does Olivett i
represent or w arrant that it will notif y or provide to
such customer any future changes to this
documentation. Customer’s service of equipment,
or modules , c om ponents, or parts of such
equipment may void any ot herwise app lic able
Olivetti warranties. If Customer services such
equipment, modules, co mponents, o r parts
thereof, C us t om er releases Olivetti from any and
all liability fo r C us t om er’s actions, and Custo m er
agrees to indemnify, defend, and hold Olivetti
harmless from any third party claims which arise
directly or indirectly from such service.

Copyrigh t 1998, 1999 Olivet t i C orporation.
All rights re s erv ed.

Copyright protection claimed includes all forms of
matte rs of c opyr ight able mate rial s and i nfor mati on
now allowed by statutory or judicial law or
hereinaft er granted, incl uding withou t limitation,
material generated from th e s of t w are programs
which are displayed on the screen such as styles,
templates, icons, screen displays, looks, etcetera.

Olivetti, DP N17 are trademarks or registered
trademarks of Olivetti

Centro nic s is a tr ademark of Ce nt ronics Data
Compu t er C orporation.

Hewlett Packard, LaserJet+, LaserJet 500+,
LaserJet Series II, DeskJet, 7475A and any other
Hewlett Packard prod uc t s m entioned in this
publicat ion are trademarks of Hewlet t Packard
Company.

Apple Talk is a re gi s tered trademark of Apple
Compu t er C orporation.

NOVELL is a registere d t rademark of N ov ell Inc.
PostScript is a registered tradema rk of Adobe

Corporation.

Warning

This equipment complies with the
requirements in Part 15 of FCC rules for a
class A computing device. Operation of the
equipment in a residential area may cause
unacceptable interference to radio and TV
reception, requiring the operator to take
whatever steps are n ecessary to co r r ect the
interfer en ce.

Electr os tatic Discha r g e

This caution indicates that there are components
which ar e s ensitive to damage caused by
electrostat ic di s c harge.

CAUTION

These components are susceptible
to electrostat ic discharge. Observe

all ESD procedures to avoid

damage

iii 687200Q

Shock Hazard

This symbol indicates the presence of potentially
hazardou s v oltages.

CLASS 1 LASER PRODUCT

The Laser Printers are cert if ied to comply w ith
Laser Product Performance Standards, set by the
U.S. Department of Health and Human Services,
as a Class 1 Laser Product. This means that this
is a class of las er product tha t do es not emit
hazardou s la s er radiation; this is possible only
because the las er beam is totally enclosed during
all modes of customer operation.

The las er and output of t he laser scanner unit
produces a beam that, if loo k ed into, could ca us e
eye dam ag e. Servic e pr oc edures must be
followed ex ac t ly as w rit t en w it hout chang e.

When servicing the machine or laser module,
follow the procedures specified in the manual and
there will b e no hazards from t he laser.

Laser (FDA): Any laser label visible to service
must be reproduced in the service ma nual with
location shown or indicat ed. Safe work ing
proce dures and clear warnings concerning
precauti ons t o av oid possibl e ex posure must als o
be included.

The following laser symbol will be displayed at the
start of any procedure where possible exposure to
the laser beam exists.

Each Network Laser Printer has two la ser warning
labels. Th e f irs t label is located on th e t op of the
Laser Unit. The second is located behind the
right-hand cover. These labels are visible w hen
the covers are remove d. See the illustrat ions on
the next page for the loca t ion of the labels.

wsm0-02

asm0-03g

WARNING
Invisible laser radiation when cover open and
interlocks defeated. Avoid exposure to beam.

VARO!
Avattaessa ja suojalukitus ohitettaessa olet
alttiina nakymattomalle lasersateilylle. Ala
katso sateeseen.

..

..

..

..

..

..

..

..

VARNING!
Osynlig laserstralning nar denna del ar oppnad
och sparren ar urkopplad. Betrakta ej stralen.

..

..

..

..

..

o

o

Laser Class 3B
780nm Wavelength
5mW Maximum

iv 687200Q

(1)

(2)

687200Q Service Manual v

The warn ing sticker illustrated below is affixed to the area identified with

(3)

.

(3)

vi 687200Q

This page int entionally blank .

xi 687200Q

Table of Contents
Title Page

Introduction.............................................xi

Organization ...........................................xii

Service Call Procedures.................... ...1-1

Printer Specifications ...........................2-1

Parts List................................................3-1

Repair/Adjustment Procedures ...........4-1

General Procedures/Information .........5-1

Wiring Data ............................................6-1

Repair Analysis Procedures.................7-1

500-Sheet Paper Feeder Option...........8-1

Offset Catch Tray (OCT) Option...........9-1

Duplex Module Option........................ 1 0-1

Envelope Feeder..................................11-1

Introduction

The

Network Laser Printe rs Service M anual

is the
primar y document used for repairing and
maintaining the Netw ork Laser Printers.

This manual contains Service Call Procedures ,
Diagnos t ic Procedures, General Information,
Repair Analysis Procedures, Copy Quality
Analysis Procedures, Wiring Data, and Parts List
informa t ion that will enab le t he Service
Representative to repair the Network Laser
Printers fa ilures.

vii

687200Q Service Manual xii

Organiz a tion

This manual is divided int o eleven secti ons . T he
title and description of each section of this service
manual is as follows:

Section 1 - Service Call Procedures

This section is used to iden t if y a suspected
problem. It contains Call Flow, Initial Actions, and
Final Actions. This part o f the service ma nual
should always be used to start the service call.

Section 2 - Printer Spec if ic ations

This section contains al l th e printer specif ic at ions
for the Netw ork Laser Printe rs .

Section 3 - Parts List

This section contains illustrations of disassembled
subsystems and a listing of the spared parts.

Section 4 - Repair/Adjustment Procedures

This section contains the instructions for removal,
replacement, and adjustment of the spared parts.

Section 5 - General Procedures/Information

This section contains di agnostic rout ines, printer
setup procedures, and a listing of tools and
supplies.

Section 6 - Wiring Data

This section contains illu s tr at ions of the plug/ jack
location s a nd t he routing of pow er and signal
cables.

Section 7 - Repair Analysis Proc edures (RAPS)

This section contains the procedures necessary to
repair failures in the print er. This sec tio n also
contains the procedures necessary to
troubles hoot copy quality problems.

Section 8 - 500-Sheet P ap er F eeder Option

This section contains Specifications, Parts List,
REPs, Wi ring Diagram s, Troub les hooting, an d
RAPs inf orm atio n for th e 500- Sheet Paper Feeder
option.

Section 9 - Offset Catch Tray (OCT) Option

This sec ti on contains Spe c if ic at ions, Parts Li st,
REPs, W iring Diagram s , Troubl es hooting, and
RAPs information for the OCT option.

Section 10 - Duplex Module Option

This sec ti on contains Spe c if ic at ions, Parts Li st,
REPs, W iring Diagram s , Troubl es hooting, and
RAPs in fo rm ation for the D uplex Module option.

Section 11 - Envelope Feeder Option

This sec ti on contains Spe c if ic at ions, Parts Li st,
REPs, W iring Diagram s , Troubl es hooting, and
RAPs in fo rm ation for the En velope Feed er option.

Conventions

This manual uses the following nam es and
acronym s interchangeably.

• The “Multi-Sheet Bypas s F eeder” (MBF ) is
also referred to as the “Front Tray.”

• “Trays” are also referred to as “cassettes.”

• The “Print Engine Controller” is also referred
to as the “MCU” or the “AMCU.”

• “Tray 1” is als o referred to as the “250 Sheet
Feeder” or “Main Tray.”

• “Offset Catch Tray” (OCT) is also referred to
as the “Offset Bin.”

• “Stack” or “stacker” are also referred to as
“Bin.”

viii

687200Q Service Manual 1-1

Section 1

Service Call Procedures

Call Flow Diagram ......................................................................... 1-3

Initial Actions................................................................................. 1-4

Corrective Actions......................................................................... 1-4

Final Actions..................................................................................1-4

687200Q Service Manual 1-2

687200Q Service Manual 1-3

1

1.1 Call Flow Diagram

The basic t roubleshooting s te ps are outlined in t he Call Flow Diagra m (F igure 1.1.1). All service ca lls
begin with Initial Actions and end with Final Actions.

Figure 1.1.1 C al l Flow D iag ra m

Initial Act ions

Corrective Actions

RAPsParts List Repair Procedures

Wiring Data General Procedures

Correct Any

Secondary Problems

Final Actions

Image Quality

1-4 687200Q

1.2 Initial Actions

1

Questio n th e operator and ver if y th e problem.

2

Chec k t hat the printer paper path is clear of forei gn matter suc h as s t aples, paper clips, and
paper scra ps.

3

After you have identif ied the problem sy m ptom, check the followin g it ems:

• The printer is connected to a wall power outlet, and the outlet is supplying the correct
voltage.

• The printer power cord is not frayed or broken.

• The printer is correctly grounded.

• The printer is in an appropriate operating environment, with no extremes of heat or
humidity.

• The printer is not exposed to direct sunlight.

• The sp ac e around the pr inter meets th e requirement s.

• The printer is on a level and sta ble su rface.

4

Perform

Corrective Actions.

1.3 Corrective Actions

1

If the print er has an obvious failure or fault, you can go direc t ly to th e appropri at e

Repair

Procedure

or

Repair Analysis Procedure (RAP)

and begi n c orrective action.

2

If the f a ult i s no t obviou s, f oll o w th e

Entry Level RAP

to ident i fy t he pr ob l em an d b egi n cor r ec ti v e

action. See Section 7.2 .1 .

3

After all corrective actions have been made, perform

Final Actions

. See Sec tio n 1.4.

1.4 Final Actions

1

Correct any se c ondary problems.

2

Reinstall the machine covers.

3

Clean the m ac hine

(Printer Cleaning)

and the wor k area.

4

Generate

System Con troller Test Prints

to evaluate print q uality.

5

Perform the

Image Qua lit y Ch ec k out

procedures in section 7 to cor rect an y print qu ality de fects .

6

Ask the customer to send a print job to verify printer operation.

7

Provide operator training as required.

8

Close the c all.

687200Q Service Manual 2-1

Section 2

Printer Specifications

Electrical Specifications ............................................................... 2-3

Mechanical Specifications............................................................2-3

Minimum Space Requirements .................................................... 2-4

Functional Specifications............................................................. 2-5

Paper Specifications ..................................................................... 2-6

Options........................................................................................... 2-8

2-2 687200Q

687200Q Service Manual 2-3

2

2.1 Electrical Specifications

The Netwo rk Laser Pr int ers are available in 220 volt con f iguration that ca n be used with th e power
sources as s how n in Table 2.1.1.

T ab le 2.1.1 Electrical Specifications

2.2 Mechanical Specifications

Table 2.2.1 Mechanical Specifications

Line Voltage Line Vo ltage

Tolerance

Frequency Frequency

Tolerance

Power

Consumption

110/115 VAC 90 - 132 VAC 50/60 Hz 47 - 63 Hz 580 Watts
220/240 VAC 198 - 264 VAC 50/60 Hz 47 - 63 Hz 670 Watts

Unit Width Depth Height Weight

Metric 442 mm 418 mm 294 mm 18.6 Kg

SAE 17.4 in. 16.5 in. 11.6 in. 40.9 lbs

2-4 687200Q

2.3 Minimum Space Requirements

CAUTIO N

Do not block the fan at t he t op rear left corner (E).

NOTE: The 500-Sheet Paper Feeder adds 4.8 inches (120 mm) to th e height of the printer; t he Offset

Catch Tray (OCT) adds 5. 2 inches (130 m m ).

Top View
A

2 inches (50 mm)

B

20 inches (508 mm)

C

2 inches (50 mm)

D

12 inches (305 mm)

SEC0201.PCX

687200Q Service Manual 2-5

2.4 Functional Specificati ons

• Printing M et hod: Xerographi c Proc ess

• Exposure method: Scanning Laser

• Fusing Method: Heat and Pressure

T ab le 2.4.1 Print Speed and Resolution

Table 2.4.2 Operating Environment

Mode P rint S pee d - ppm

(pages per mi nute)

Resolution - dpi

(dots per inch)

Simplex 17 ppm 1200 dpi

Duplex 13 ppm 1200 dpi

Temperature Humidity Altitude Noise Level

5o - 35o C

50

o

- 90o F

15 - 85% RH 0 - 3000 m

0 - 10,000 Ft.

Running 49.5 dB
Standby 35.0 dB

Within 5

o

2-6 687200Q

2.5 Paper Specifications

The recommended sta ndard paper type is 80 gsm.
Paper Weight Limita ti ons :

• Bond pape r - 16 to 28 lbs (60 to 10 5 gs m )

• Cardstock - 50 lbs (190 gsm)

Table 2.5.1 Paper Sizes

Paper Type Size

A4 8.27 x 11.69 inches

210 x 297 mm

Letter 8.5 x 11 inches

216 x 279 mm

B5 (ISO) 6.93 x 9.84 inches

176 x 250 mm

Executive 7.25 x 10.5 inches

184 x 267 mm

Folio 8.5 x 13 inches

216 x 330 mm

Legal 8.5 x 14 inches

216 x 356 mm

Commercial-10 Envelope 4.13 x 9.5 inches

105 x 241 mm

Monarch Envelope 3.87 x 7.5 inches

98 x 191 mm

DL Envelope 4.33 x 8.66 inches

110 x 220 mm

C5 Envelope 6.38 x 9.02 inches

162 x 229 mm
OHP Film (Transparency) A4 or Letter
Label Paper A4 or Letter

687200Q Service Manual 2-7

T ab le 2.5.2 Standard Tray Capacity

Table 2.5.3 MBF Tray Capacity

Table 2.5.4 Optional 500-Sheet Feeder

Paper Type Capacity

(Sheets)

Letter , B5, Executive, A5, Folio, and Legal 250

A4 230

OHP Film (transparency) 10

Label Paper 10

Paper Type Capacity

(Sheets)

A4, Letter, B5, Executive, Folio, and Legal 100

Monarch, Commercial-10, C5, and DL Envelopes 10

OHP Film (transparency) 30

Label Paper 30

Paper Type Capacity

(Sheets)

A4, Letter, Folio, and Legal 500

2-8 687200Q

2.6 Options

The customer can install the followi ng opti ons:

• Up to two 500- sh eet High Capac ity Paper Decks or Trays

• High Capacity Envelope Feeder

• SIMMs (RAM ) (sizes: 4, 8, 16, and 32mb)

• Flash SIMM (8mb)

• I/O PWBs — 10/100 BaseT, Token Ring

•Hard Drive

• 500 Sheet Offsetting Catch Tray

• Duplex Module

687200Q Service Manual 3-1

Section 3

Parts List

About the Parts List .........................................................................3-3

PL 1 Covers I ....................................................................................3-4

PL 2 Covers II ...................................................................................3-6

PL 3 Paper Tray ...............................................................................3-8

PL 4 Paper Transportation I ..........................................................3-10

PL 5 Paper Transportation II .........................................................3-12

PL 6 Paper Transportation III ........................................................3-14

PL 7 Fusing ....................................................................................3-16

PL 8 Paper Exit ..............................................................................3-18

PL 9 Drive and Xerographic Module ............................................3-20

PL 10 Electrical Module I (with Top Cover) ................................. 3-22

PL 11 Electrical Module II (with Chassis) ....................................3-24

PL 12 System Controller ...............................................................3-26

3-2 687200Q

687200Q Service Manual 3-3

About the Parts List

This section identifies a ll part numbers and the corre s ponding location of all spare d s ubsystem
compon ent s .

Using the Parts List:

1

Each item number in the part numb er lis t ing correspo nds to an item num ber in the relate d
illustration. Also, the part s in a given s ubsystem of the machine will be located in the same
illustration o r in a s eries of assoc iated illustrat ions.

2

The letters “C,” “E,” “KL,” and “S” in each illustration stand for a C-ring, an E-ring, a KL clip, and a
screw, respectively.

3

The diam ond symbol in each illustration indicates an as s embly with one or m ore compon ent s.

4

The notation “with X-Y” following an item name indicates an assembly is made up of components
X through Y. For example, “1... (w it h it em s 2-4)” means ite m 1 c onsists of the items 2, 3, and 4
within the s am e page.

3-4 687200Q

PL 1 Covers I

S

S

2

1

S

S

6

S

KL

S

3

5

S

S

S

4

S

S

SAS301FA

687200Q Service Manual 3-5

PL 1 Covers I

Item Part Description

1. 576491 Q R ear Cover

2. 576492 R System Controller Cover

3. 128905W Front Cover Assembly (exploded on PL 2)

4. 417194 F Le ft Front Cover

5. 576495 L Top Cover

6. 576496 M Right Cover

(*) Not available

3-6 687200Q

PL2 Covers II

wsm3-07

7

8

13

4

3

2

5

9

11

S

1

(with 2 ~ 11)

12

6

10

SAS302FE

687200Q Service Manual 3-7

PL 2 Covers II

Item Part Description

1. (*) Front Cover Assembly (with items 2-11)(See

NOTE

)

2. (*) Front Cover

3. (*) Tray Cover

4. (*) Tray Stopper

5. (*) Ho lder Guide

6. (*) Main Tray

7. (*) Tray Extender

8. 57 6498 X Catch Holder

9. (*) Envelope Front Harness (See

NOTE

)

10. (*) Inner Cover

11. (*) E Ring

12. (*) Harness Cover

13. (*) Cover Stopper

(*) Not available

NOTE: This ha rness an d s ix screw s loc ated on the Front Cover Ass em bly are not detachable.

3-8 687200Q

PL 3 Paper Tray

3

2

7

6

5

4

8

S

S

S

1 (with 2)

S

S

SAS303FB

687200Q Service Manual 3-9

PL 3 Paper Tray

Item Part Description

1. 576499 Y Paper Size Sensor Assembly (with item 2)

2. (*) Paper Size Harness

3. 57 6500 D 250-Sheet Tray

4. (*) Front Tray Rail

5. (*) Rear Tray Rail

6. 57 6501 S Tray Cover

7. (*) Right Rail Guide

8. (*) Left Rail Guide

(*) Not available

3-10 687200Q

PL 4 Paper Transportation I

687200Q Service Manual 3-11

PL 4 Paper Transportation I

Item Part Description

1. 576502 T Paper Handler Unit Asse m bly (with items 2-21 and PL 5 items 1-17 & 21)

2. 576503 U Registration Ro ll

3. 576504 V Reg is t rati on (Spring ) C lut c h

4. (*) Le ver Sprin g

5. (*) Le ver

6. 576505 W Front Tray (MBF) Roll

7. 576506 X 250-Sheet Feed Roll

8. 576507 Y Pinc h R oll

9. 576508 H Turn Pinch Roll

10. (*) Supporter

11. 576509 A Dup lex Pin c h R oll

12. 576510 W Registration Solenoid

13. 576511 K Tray 1 Solenoi d

14. 576512 L Front Tray (MBF) Solenoid

15. (*) Pinch Rol l Spring

16. (*) Turn Roll Spring

17. (*) Duplex Pinch Spring

18. (*) Front Tray (MBF) Gear

19. (*) Release Link

20. (*) Registration Bushing

21. (*) Pinch Reg is t rat ion Bushing

22. 576513 M Lower Support

23. 576514 N Gear (23T)

24. 576515 P Gear (42T)

25. (*) Turn Roll

(*) Not available

3-12 687200Q

PL 5 Paper Transportation II

S

S

S

S

S

SAS305FB

S

22

19

20

20

18

17

16

15

21

14

7

6

4

3

12

13

1

9

8

10

5

2 (with3~13)

11(with12~13)

687200Q Service Manual 3-13

PL 5 Paper Transportation II

Item Part Description

1. 57 6516 Q Envelope Harness

2. (*) Front Tray (MBF) Chute Asse m bly (with items 3-1 3)

3. (*) N/F Spring

4. 57 6517 R Retard

5. (*) Retard Sp ring

6. (*) Multi Holder

7. 57 6518 S No Paper Sensor

8. (*) Ri ght Spring

9. (*) Varistor

10. (*) Left Spr ing

11. (*) Tray Bo ttom Assembly (wit h it ems 12-13)

12. (*) Cam Roll

13. 576519 T Front Tray (MBF) No Paper Actuator

14. (*) Bottom C hut e

15. 576520 Y Registration Sensor

16. (*) Earth Bottom Spring

17. (*) Inlet Chut e

18. (*) Toner Holder S ensor (P/O item 23)

19. (*) Toner Sensor (P/ O it em 23)

20. (*) Toner Sensor 1 Spring (P/O it em 23)

21. (*) Paper Handler Harness

22. (*) Toner Sensor Harness

23. 41 7202 X Toner Sensor Kit (with items 18-20)

(*) Not available

3-14 687200Q

PL 6 Paper Transportation I II

2

S

S

S

S

1

1 (with 2)

S

SAS306FC

687200Q Service Manual 3-15

PL 6 Paper Transportation III

Item Part Description

1. 576524 Q BTR (Bias Transfer Roll) Chute Assembly (with item 2)

2. 57 6525 R BTR

3-16 687200Q

PL 7 Fusing

20

40

3

31

S

4

S

32

32

S

7

8

5

6

S

S

2

(with 3 ~ 12)

1

(with 2 ~ 40)

S

S

17

33

34

35

38

24

28

27

29

39

S

21

26

18

19

E

S

S

25

30

15

22

16

23

21

37

37

26

14

S

S

13

S

S

S

36

34

38

9

(with 10 ~ 12)

12

S

11

10

(with 11)

SAS307FA

687200Q Service Manual 3-17

PL 7 Fusing

Item Part Description

1. (*) Fuser Assembly (115v) (with items 2-40)
576526 J F us er Assembly (220v ) (w ith items 2-4 0)

2. (*) Top Cover Assembly

3. (*) Top Cover

4. (*) Thermostat

5. (*) Fu s e Plate

6. (*) Harness 1 Plate

7. (*) Harness 2 Plate

8. (*) Fuse

9. (*) Fu s e H arness

10. (*) Exit Harness Assembly

11. (*) Temperature Sensor

12. (*) Fuser Plug Connector

13. (*) Ear t h H Spring

14. (*) Diode Ground

15. (*) Right Frame

16. (*) Right Pressure Roll Lever

17. (*) Left Frame

18. (*) Drive Gear (15T)

19. (*) Exit Idle Gea r (12T)

20. (*) Left Press ure Roll Lever

21. (*) Pressure R oll Bearing

22. (*) Inlet Chut e

23. (*) Static Elim inator

24. (*) Lower Exit Ch ut e

25. (*) Decurl Roll

26. (*) Exit Bear ing

27. (*) Exit Photo Sensor

28. (*) Exit Actua t or

29. (*) Exit Actua t or Spring

30. (*) Pressure R oll

31. (*) Exit Chute

32. (*) Exit Spr ing

33. (*) Heat Roll

34. (*) Heat Roll Bearing

35. (*) Heat Roll Gear

36. (*) Quar t z H eater

37. (*) Pressure R oll Spring

38. (*) Roller Rin g

39. (*) Exit Sp ring

40. (*) Cable Tie

(*) Not available

3-18 687200Q

11

19

21

13

S

S

S

S

10

12

8

9

7

9

6

(with 7 ~ 13,18~21,23,24,25)

14

16

17

22

S

15

18

20

2

1

S

S

S

S

3

4

5

4

24

23

S

S

SAS308FB

25

PL 8 Paper Exit

687200Q Service Manual 3-19

PL 8 Paper Exit

Item Part Description

1. (*) Top Cover (Refer to PL1 item 5)

2. 57 6527 K Option Cover

3. 57 6528 U Exit Gear

4. 57 6529 V Exit Bearing

5. 41 7198 K Exit Roll

6. 57 6530 S Exit Assembly (with item s 7-13, 18-21, 23, 24)

7. 57 6531 P Middle Ro ll

8. (*) Exit Gear

9. (*) Exit Bearing

10. (*) Exit Gate

11. 57 6532 Q Exit Motor

12. (*) Direction Spring

13. 57 6533 R Rear Cover Sensor

14. 57 6534 J Stack Full Sensor

15. 576535 K Stack Full Actuator

16. (*) Eliminator

17. (*) Exit Earth Spr ing

18. 57 6536 L Pinch Exit Roll

19. 57 6537 M Pinch Middle Roll

20. (*) Pinch Exi t S pring

21. (*) Pinch Mid dle Spring

22. 57 6538 W Exit Harnes s

23. (*) Gear (26T)

24. (*) Gear (47W)

25. (*) Roll

(*) Not available

3-20 687200Q

PL 9 Drive and Xerographic Module

S

S

S

S

S

15

1

10

S

14

S

S

S

S

5 (with 6 ~ 9)

3

9

8

7

9

8

7

2 (with 3 , 4)

6

S

4

13

S

12

S

S

S

11

S

S

SAS309FC

687200Q Service Manual 3-21

PL 9 Drive and Xerographic Module

Item Part Description

1. (*) ROS Plate

2. (*) CRU Side Guide Assembly (with items 3-4)

3. (*) CRU Side Guide

4. (*) Spring

5. (*) CRU Top Guide Assembly (with items 6-9)

6. (*) CRU Top Guide

7. (*) Roller

8. (*) Arm

9. (*) Spring

10. (*) L Duc t

11. (*) S Duct

12. 5765 39 X Main Motor Assembly

13. 5765 40 C Drive

14. 5765 41 Z Laser Assembly

15. (*) EP C artridge

(*) Not available

3-22 687200Q

PL 10 Electrical Module I (with Top Cov er)

2

4

3

S

S

1

SAS310FB

5

687200Q Service Manual 3-23

PL 10 Electrical Module I (with Top Cover)

Item Part Description

1. 41 7190 P Control Panel (W / O Item 5)

2. 57 6543 T Fan Filter

3. 57 6544 U Fan

4. 576545 V Panel Harness

5. 41 7199 L C ontrol Panel Label

3-24 687200Q

PL 11 Electrical Module II (with Chassis)

19

2

S

S

S

S

S

S

S

S

S

9

11

12

18

14

13

1

7

S

S

S

20

23

20

22

21

17

16

16

15

(with 16)

20

20

s

s

s

s

s

s

s

10

8

3

4

5

6

SAS311FB

24

687200Q Service Manual 3-25

PL 11 Electrical Module II (with Chassis)

Item Part Description

1. 576546 W LV PS

2. 576547 X Print Engine C ontroller

3. 576548 G HVPS

4. 576549 H Fuser PWB

5. (*) HVPS Ch as s is

6. 576550 E No Paper A ctuator

7. (*) Earth Spring

8. 576551 T HVPS H arness

9. 576552 U SOS Harness

10. 576553 V OCT H arness

11. 576554 W Laser Har ness

12. 576555 X Tray Harness

13. (*) US Power Cord

14. (*) EC Power Cord

15. (*) Electric Box Chassis (with item 16)

16. (*) Rail Guide

17. (*) Bush

18. 576556 Y Feed Harness

19. (*) Back Panel

20. (*) Clamp

21. (*) Top Harness

22. (*) Motor Earth Spr ing

23. (*) Inlet Harness

24. 417200 H Main Switch Re pair Kit

(*) Not available

3-26 687200Q

3

2

6

4

5

1

PL 12 System Controller

687200Q Service Manual 3-27

PL 12 System Controller

Item Part Description

1. 12 9074 Y System C ontroller PW BA

2. (*) Memory SIMM

3. (*) Token Ring PWBA

4. (*) Hard Dr ive Ass embly

5. (*) Standoff Locking

6. (*) Standoff Post

(*) Not available

3-28 687200Q

CODE PAGE

CODE PAGE CODE PAGE

129074Y 26
417190P 22
417194F 4
417198K 20
417199L 22
417200H 24
417202X 12
576491Q 4
576492R 4
576495L 4
576496M 4
576498X 6
576499Y 8
576500D 8
576501S 8
576502T 10
576503U 10
576504V 10
576505W 10
576506X 10
576507Y 10
576508H 10
576509A 10
576510W 10
576511K 10
576512L 10
576513M 10
576514N 10
576515P 10
576516Q 12
576517R 12
576518S 12
576519T 12
576520Y 12
576524Q 14
576525R 14
576526J 16
576527K 20
576528U 20
576529V 20
576530S 20
576531P 20
576532Q 20
576533R 20
576534J 20
576535K 20
576536L 20
576538W 20
576538W 20
576539X 20
576540C 20
576541Z 20
576543T 22
576544U 22
576545V 22
576546W 24
576547X 24
576548G 24
576549H 24

576550E 24
576551T 24
576552U 24
576553V 24
576554W 24
576555X 24
576556Y 24

687200Q Service Manual 4-1

Section 4

Repair/Adjustment Procedures

Overview........................................................... .................................4-5

Notations in the REP Text....................................................... 4-6

Before You Start Any REP....................................................... 4-6

Covers I .............................................................................................4-7

Rear Cover ..............................................................................4-7

Left Cover................................................................................4-8

Harness Cover.........................................................................4-9

Front Cover Assembly...........................................................4-10

Left Front Cover.....................................................................4-11

Top Cover Assembly .............................................................4-12

Right Cover............................................................................4-13

Covers II ..........................................................................................4-14

Envelope Feeder (EF) Cover.................................................4-14

Inner Cover............................................................................4-15

Front Tray..............................................................................4-16

Front Tray Cover....................................................................4-17

Tray Extender........................................................................4-18

Paper Tray (Tray I).......................................................................... 4-19

Paper Size Sensor.................................................................4-19

Paper Transportation I ...................................................................4-20

Paper Handling Unit Assembly..............................................4-20

Feed Roll Assembly...............................................................4-21

Duplex Refeed Roll................................................................4-22

Front Tray Roll.......................................................................4-23

4-2 687200Q

Paper Transportation II ..................................................................4-24

Toner Sensor.........................................................................4-24

Inlet Chute Assembly.............................................................4-25

Registration Sensor...............................................................4-26

Front Tray Chute Assembly...................................................4-27

Tray Bottom...........................................................................4-28

Retard Assembly ...................................................................4-29

Multi Holder............................................................................4-30

Front Tray No Paper Actuator................................................4-31

No Paper Sensor...................................................................4-32

Bottom Chute.........................................................................4-33

Supporter............................................................................... 4-34

Pinch Roll Assembly..............................................................4-36

Turn Pinch Roll Assembly......................................................4-37

Registration Solenoid/Tray 1 Solenoid/

Front Tray Solenoid...............................................................4-38

Registration Clutch Assembly................................................4-39

Paper Transportation III .................................................................4-40

Bias Transfer Roll (BTR) Assembly.......................................4-40

BTR Chute Assembly ............................................................ 4-41

Fusing..............................................................................................4-42

Fuser Assembly (CRU).............................................. ......... ...4-42

Paper Exit........................................................................................ 4-43

Exit Roll Assembly.................................................................4-43

Middle Roll Assembly ............................................................ 4-44

Exit Gate................................................................................4-45

Exit Motor Assembly..............................................................4-46

Rear Cover Sensor................................................................4-47

Option Cover/Eliminator Assembly........................................4-48

Stack Full Sensor...................................................................4-49

Stack Full Actuator.................................................................4-50

Drive and Xerographic Modules....................................................4-51

Main Motor Assembly............................................................ 4-51

Drive Assembly ......................................................................4-52

Laser Assembly..................................................................... 4-53

Electrical Module I..........................................................................4-54

Control Panel Assembly........................................................4-54

Fan Assembly........................................................................4-55

687200Q Service Manual 4-3

Electrical Module II.........................................................................4-56

System Controller Chassis.................................................... 4-56

Low Voltage Power Supply (LVPS).......................................4-57

Print Engine Controller..................................... .......... ......... ...4-58

High Voltage Power Supply (HVPS)......................................4-59

Fuser PWB .................................... ........................................4-60

No Paper Actuator.................................................................4-61

Main Power Switch................................................................4-62

4-4 687200Q

687200Q Service Manual 4-5

4

4.1 Overview

This section contains Net w ork Laser Pr inters Repair Procedure s (REPs):

1) Covers I

2) Covers II

3) Paper Tray

4) Paper Transportation I

5) Paper Transportation II

6) Paper Transportation III

7) Fusing

8) Paper Exit

9) Drive Assembly and Xero graphic Modules

10) Electrical I

11) Electrical II

4-6 687200Q

4.1.1 Notations in the REP Text

Location s given in th e R EPs assum e you are facing the Contro l Panel with the following orientation:

Figure 4.1.1.1 Printer Orientation

The following notations apply:

• Arrows in the illus tra ti ons show direction of movement. Follow the num erical order if t he

arrows are numbered.

• The notation

screw (number, type, length of thread)

identifies individual screws.

• The notation

REP X.Y

in a REP step directs you to another REP to see how to perform a

rela t ed procedure.

• The notation

Figure X.Y

references the illustration co rresponding t o the REP you are

performing.

• A number followed by a pare nt hesis, e.g., 8), references the corres ponding REP st ep.

4.1.2 Before You Start Any REP

There are a number of ste ps you should follow

before

you begin any procedure:

1

If applicable, cancel pending jobs and take the pr inter offline.

2

Switch the printer main power OFF, a nd disconnect th e power cord from th e wa ll outlet.

3

Remove the EP Cartridge from the printer; and store it in a safe, dark place.

4

Do not use force t o remove or install printer components.

5

Use only th e s c rew size and type designated in the RE P. T he wrong screw could easily dam age
tapped holes.

6

Wear a wrist strap to dissipate static electricity, which may damage sensitive electronic parts.

7

See

Section 6, Wiring Diagrams,

for detailed wiring diagrams.

Left

Rear

Front

Right

687200Q Service Manual 4-7

4.2 Covers I

4.2.1 Rear Cover

Removal

1

Open the R ear Cover.

2

Remove the screw s ec uring the stopper to the Frame. (See Figure 4.2.1.1).

3

Press and unlatch the pivots on both ends of the R ear Cover and remove the c over.

Figure 4.2.1.1 Rear Cover Removal

Replacement

Perform the removal steps in reverse order.

.

sas401fa

4-8 687200Q

4.2.2 Left Cover

Removal

1

Remove the three screws securing the cover to the Frame. (See Figure 4.2.2.1.)

2

Pull the rear end of the cover to snap it off the Frame.

Figure 4.2.2.1 Left Cover Removal

Replacement

Perform the removal steps in reverse order.

.8

SAS402FB

687200Q Service Manual 4-9

4.2.3 Harness Cover

Removal

1

Open the Front Cover.

2

Press the latch on the left, and use a flat-slot screwdriver to free the latch on the right by slightly
lifting upward. (See Figure 4.2.3.1.)

NOTE: Notice the routing of the harness underneath the Harness Cover.

3

Remove the Harness Cover by pullin g it upw ard and out of the Front Cover Assembly.

Figure 4.2.3.1 Harness Cover Removal

Replacement

Perform the removal steps in reverse order.

sas403fa

4-10 687200Q

4.2.4 Front Cover Assembly

Removal

1

Open the Front Cover As s em bly.

2

Remove the Harness Cover (

REP 4.2.3 Harness Cover

).

3

Disconnect P/J 130.

4

Slide the C over Stopper to the left to fr ee it f rom t he Frame. (See Figure 4.2. 4.1.)

5

Remove the KL clip securing the cover to the printer.

6

Slide the Front Cover As se m bly to the right, and rem ove the as s embly.

Figure 4.2.4.1 Removing the Front Cover

Replacement

Perform the removal steps in reverse order.

sas404f

687200Q Service Manual 4-11

4.2.5 Left Front Cover

Removal

1

Open the Front Cover.

2

Remove the two sc rew s securing th e Front C over to th e Frame. (See Figure 4.2.5. 1).

3

Remove the Front Cover from the Top Cover Assembly by rotating the Front Cover and pulling it
towards you.

Figure 4.2.5.1 Left Front Cover Removal

Replacement

Perform the removal steps in reverse order.

sas405f

4-12 687200Q

4.2.6

Top Cover Assembly

Removal

1

Open the Front Cover As s em bly.

2

Remove the Left Cover (

REP 4.2.2 Left Cover

).

3

Remove the Left Front Cover (

REP 4.2.5 Left Front Cover

).

4

Remove the System Controller Chassis (

REP 4.12 .1 Sy s t em C ontroller Ch as s is

).

5

Disconnect the four connectors (P/Js 23, 24, 28, and 32) from the Print Engine Controller. (See
Figure 4.2.6.1.)

6

Remove the four screws securing the Top Cover.

NOTE: You must open th e R ear Cover to remove two of the four sc r ew s.

7

Remove the Wire Harness fr om the Wire Holder.

8

Lift upward and remove the Top Cover Asse m bly.

Figure 4.2.6.1 Top Cover Assembly Removal

Replacement

Perform the removal steps in reverse order.

wsm4-11

sas406fa

687200Q Service Manual 4-13

4.2.7 Right Cover

Removal

1

Open the Front Cover As s em bly.

2

Remove the Stopper securing the Front Cover Assembly to the Frame.

3

Open the R ear Cover Assembly.

4

Remove the screw s ec uring the St opper of the Rear Cover to the Frame, and remove the
Stopper.

5

Remove the Top Cover Assembly (

REP 4.2.6 Top Cover Assembly

).

6

Remove the two sc rew s securing th e R ight Cover to the Frame.

7

Unlatch th e hooks securing the Righ t Cover at t he top and botto m and remove the Righ t Cover.

8

Using a flat blade screwdriver, unlatch th e two hooks secu ring the top o f the Right Cover.

9

Unlatch th e t wo bot t om hooks and the rear hook. Pull th e R ight Cover out while biasing it down.

Figure 4.2.7.1 Right Cover Removal

Replacement

Perform the removal steps in reverse order.

SAS407F.CDR

sas407f

4-14 687200Q

4.3 Covers II

4.3.1 Envelope Feeder (EF) Cover

Removal

1

Press the top of the Front Tray Cover to release the latch and open the tray.

2

Open the EF C over by 90 degrees. (See Fig ure 4.3.1.1.)

3

Grasp the E F Cover and remove it by pulling to the left.

Figure 4.3.1.1 EF Cover Removal

Replacement

Perform the removal steps in reverse order.

SAS408F.CDR

SAS408FB

687200Q Service Manual 4-15

4.3.2 Inner Cover

Removal

1

Press the t op of the Front Tray Cover Ass embly to release t he latch and op en the tray.

2

Open the EF C over by 90 degrees. (See Fig ure 4.3.2.1.)

3

Release the latch on the top of the Inner Cover (1), pull the cover down (2) , an d th en remove the
cover by pulling it to the fr ont (3).

Figure 4.3.2.1 Inner Cover Removal

Replacement

Perform the removal steps in reverse order.

SAS409F.CDR

1

2

3

SAS409FB

EF Cove r

4-16 687200Q

4.3.3 Front Tray

Removal

1

Press the t op of the Front Tray Cover Ass embly to release t he latch and op en the tray.

2

Remove the Front Tray Cover (

REP 4.3.4 Front Tray Cover

).

3

Lift the front tray slightly and disengage the Tray Stopper Arm from the right side of the Front Tray
Cover Assembly. (See Figure 4.3.3 . 1. )

4

Press the s ides of the cover inward on both ends to flex the cover hinge pivots out of the holes.

5

Remove the Front Cover from the Front Tray Cover Assembly.

Figure 4.3.3.1 T ra y Cover Removal

Replacement

Perform the removal steps in reverse order.

SAS409F.CDR

SAS410FA

687200Q Service Manual 4-17

4.3.4 Front Tray Cover

Removal

1

Press the t op of the Front Tray Cover Ass embly to release t he latch and op en the tray.

2

Pull the Front Tray Cover out fully. (See Figure 4.3.4 . 1. )

3

Lift the Front Tray with your fingers to cl ear the stops on the Front Tray Cover; th en pull the Front
Tray Cover out of the Front Tray Cover Assembly. (See Figure 4.3.4.1.)

Figure 4.3.4.1 Front Tray Cover Removal

Replacement

Perform the removal steps in reverse order.

SAS411F.CDR

SAS411FC

4-18 687200Q

4.3.5 Tray Extender

Removal

1

Press the t op of the Front Tray Cover Ass embly to release t he latch and op en the Front Tray.

2

Pull the Front Tray out fully. (See F igure 4.3.5.1. )

3

Unlatch th e Tray Exte nder.

4

Bend the R ight Tray Cover su pporting rib towards the r ight, while bias ing the Tray Extender
towards the left so th at th e Tray Exte nder snaps out o f the rib of the Cover Tray.

Figure 4.3.5.1 Tray Extender Removal

Replacement

Perform the removal steps in reverse order.

SAS412F.CDR

SAS412FC

687200Q Service Manual 4-19

4.4 Paper Tray (Tray I)

4.4.1 Paper Size Sensor

Removal

1

Remove the Paper Tray.

2

Remove the Rear Cover (

REP 4.2.1 Rear Cover

).

3

Remove the Left Cover (

REP 4.2.2 Left Cover

).

4

Remove the Front Cover Assembly (

REP 4.2.4 Front Cov er Assembly

).

5

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

6

Remove the System Controller Chassis (

REP 4.12 .1 Sy s t em C ontroller Ch as s is

).

7

Disco nnect the Paper Size Sensor co nnector (P/J 135). (See Figure 4. 4.1.1.)

8

Press the round clip and the Paper Size Sensor As s em bly St op from the Sy stem Controlle r si de
to the paper tray side; then slide the Paper Size Sensor towards the front and remove it.

Figure 4.4.1.1 Paper Size Sensor Removal

Replacement

Perform the removal steps in reverse order.

SAS413F.CDR

P/J135

SAS414FA

4-20 687200Q

4.5 Paper Transportation I

4.5.1 Paper Handling Unit Assembly

Removal

1

Remove the Left Cover (

REP 4.2.2 Left Cover

).

2

Remove the Left Front Cover (

REP 4.2.5 Left Front Cover

).

3

Remove the Front Cover Assembly (

REP 4.2.4 Front Cov er Assembly

).

4

Remove the EP Cartridge.

5

Disco nnect th e three co nnectors (P16, P 17, and P27) from the LVPS. (See Figure 4.5.1.1. ) Then
remove the harness from th e c able c lamps.

6

Remove the four screws securing the Paper Handling Unit Assembly.

7

Carefully lift the Paper Handling Unit Assembly upward; then remove the Assembly.

Figure 4.5.1.1 Paper Handling Unit Assembly Removal

Replacement

Perform the removal steps in reverse order.

SAS415F.CDR

SAS415FC

687200Q Service Manual 4-21

4.5.2 Feed Roll Assembly

Removal

1

Remove the EP Cartridge.

2

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

3

Position the Paper Hand ling Unit Assembly on the gear sid e.

4

Slightly pu s h back the two release t abs on the Feed Ro ll As s embly while lifting the Feed Roll up
the s h aft.

5

Remove the Feed Roll Assembly by tilting and rotating the Assembly to one side.

Figure 4.5.2.1 Feed Roll Assembly Removal

Replacement

Perform the removal steps in reverse order

SAS416F

4-22 687200Q

4.5.3 Duplex Refeed Roll

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Position the Paper Hand ling Unit Assembly on the gear sid e.

3

Pull slight ly on t he l atch; then remove the Du plex Refeed Roll by lifting it upwa rd. (See Figure

4.5.3.1.)

NOTE: The Du plex Refeed Roll is locate d next to th e Feed Roll.

Figure 4.5.3.1 Duplex Refeed Roll Removal

Replacement

Perform the removal steps in reverse order.

SAS417F.CDR

SAS44_3F

687200Q Service Manual 4-23

4.5.4 Front Tray Roll

Removal

1

Open the Front Cover As s em bly.

2

Press the Bottom Tray Assembly down.

3

Pull slightly on the latch; then remove the Front Tray Roll by sliding it to the right. (See Figure

4.5.4.1.)

Figure 4.5.4.1 Front Tray Roll

Replacement

Perform the removal steps in reverse order.

SAS418F

4-24 687200Q

4.6 Paper Transportation II

4.6.1 Toner Sensor

Removal

NOTE: Caref ully note the routing of the wiring harnes s.

1

Pull the Toner Sen s or Assembly towards th e f ront from the rear wh ile lifting upward on the Toner
Sensor As s em bly.

2

Disconnect the connec t or f rom the Toner Sen s or (P137). (See Figure 4.6.1 .1 . )

3

Disengage the three clips, lifting up the Toner Sensor.

Figure 4.6.1.1 Toner Sensor Removal

Replacement

Perform the removal steps in reverse order.

SAS419F.CDR

sas419fa

687200Q Service Manual 4-25

4.6.2 Inlet Chute Assembly

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Free the Toner Sensor w ire harness f rom t he Inlet Chute As s em bly.

3

Remove the two sc rew s securing th e I nlet Chute Assembly. (The screw on the right was al ready
removed in step 1. )

4

Bias the Inlet Chute Assembly towards the right and slightly towards the rear in order to clear the
bosses at th e lef t si de of the Chute As sembly. Lift upwar d and remove the assem bly.

Figure 4.6.2.1 Inlet Chute Assembly Removal

Replacement

Perform the removal steps in reverse order.

SAS420F.CDR

sas420fa

4-26 687200Q

4.6.3 Registration Sensor

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Use a flat-slot screwdriver blade to unhook the front Sensor Registration clip. (See Figure

4.6.3.1.)

3

Inser t t he s c rew driver blade into the opening to un hook the rear Registration Sensor clip.

4

Disconnect P123 from t he R egistration Se nsor.

Figure 4.6.3.1 Registration Sensor Removal

Replacement

Perform the removal steps in reverse order.

SAS421F.CDR

SAS421F

687200Q Service Manual 4-27

4.6.4 Fr ont Tray Chute Assembly

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Remove the Inlet Chute Assembly (

REP 4.6.2 Inlet Chute Assembly

).

3

Remove the screw s ec uring the Front Tray Chute Ass embly on the right.

4

Bias the Fr ont Tray Chute Assembly towards the rig ht while pu lling upward, an d t hen remove the
assembly.

Figure 4.6.4.1 Front Tray Chute Assembly Removal

Replacement

1

Compress the Bottom Tray until it stops.

2

Perform the removal steps in reverse order.

SAS422F.CDR

SAS422FA

4-28 687200Q

4.6.5 Tray Bottom

Removal

1

Remove the Front Tray Chute Assembly (

REP 4.6.4 Front Tray Chute Assembly

).

2

Compress the Tray Bottom.

3

Compress the tab on the right limiting the Tray Bottom upward travel.

4

Raise the Tray Botto m to th e upright pos it ion and pull the r ight pivot out of pos it ion.

5

Remove the Tray Bottom by pulling the Tray Bottom away from the left pivot.

NOTE: Be careful not to lose the springs when the Tray Bottom is decompressed.

Figure 4.6.5.1 Tray Bottom Removal

Replacement

1

Compre ss t he Tray Bottom w ith th e springs in posit ion.

2

Perform the removal steps in reverse order.

SAS423F.CDR

sas423fa

687200Q Service Manual 4-29

4.6.6 Retard Assembly

Removal

1

Remove the Tray Bottom (

REP 4.6.5 Tray Bott om

).

2

Press the R et ard Assembly down to th e level plan e, an d remove the Assem bly by unc lipping it
from the Tray Bottom.

Figure 4.6.6.1 Retard Assembly Removal

Replacement

Perform the removal steps in reverse order.

SAS424F

sas424f

4-30 687200Q

4.6.7 Multi Holder

Removal

1

Remove the Tray Bottom (

REP 4.6.5 Tray Bott om

).

2

Pull the Multi Holder upward out of the Tray Bottom.

Figure 4.6.7.1 Multi Holder Removal

Replacement

Perform the removal steps in reverse order.

SAS425F

SAS425F

687200Q Service Manual 4-31

4.6.8 Fr ont Tray No Paper Actuator

Removal

1

Remove the Tray Bottom (

REP 4.6.5 Tray Bott om

).

2

Turn the Tray Bottom ups ide down, and p ull and remove the Front Tray No Paper Actuator out of
position .

Figure 4.6.8.1 Front Tray No Paper Actuator Removal

Replacement

Perform the removal steps in reverse order.

SAS426F.CDR

SAS426F

sas426f

4-32 687200Q

4.6.9 No Paper Sensor

Removal

1

Remove the Tray Bottom (

REP 4.6.5 Tray Bott om

).

2

Use a flat-slot screwdriver blade. From the underside of the Tray Bottom, unhook the front No
Paper Sensor cl ip.

3

Lift the loos ened No Paper Sensor by prying it wit h a screwdriver and dis engage the rear clips.

4

Disconnect the Sensor connector, and remove the No Paper Sensor.

Figure 4.6.9.1 No Paper Sensor Removal

Replacement

Perform the removal steps in reverse order.

SAS427F.CDR

SAS427F

687200Q Service Manual 4-33

4.6.10 Bottom Chute

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Remove the Registration Sensor (

REP 4.6.3 Registratio n Sensor

).

3

Remove the Front Tray Chute Assembly (

REP 4.6.4 Front Tray Chute Assembly

).

4

Pull out the wire harness from the junction connector (P/J 128) of the Toner Sensor.

5

Remove the screw s ec uring the Bottom Chute on the right .

6

Remove the screw securing the right supporter to the Bottom Chute.

7

Remove the Bott om C hute from the Paper H andling Unit A s s em bly.

Figure 4.6.10.1 Bottom Chute Removal

Replacement

Perform the removal steps in reverse order.

SAS428F.CDR

SAS428F

4-34 687200Q

4.6.11 Supporter

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Raise the Paper H andling Unit As s em bly approximately 90 degrees.

3

Remove the wire harnesses connected to the No Toner Sensor and the Registration Sensor
away from the Supporter.

4

Remove the Lever Spring (1).

5

Remove the three screws securing the Suppor ter to the Registration Plate as well as the screw
securi ng t he Supporter to the Bot t om C hute.

6

Use tweezers to release the latch up out of the Front Tray Gear shaf t , a nd pull off the Supporte r
alon g with the F ront Tray Gear (2).

CAUTION! The Registration Bushing (3) and the P/Registration Bushing (4) might fall off

simultaneously. Be careful not to lose them.

687200Q Service Manual 4-35

Figure 4.6.11.1 Supporter Removal

Replacement

Perform the removal steps in reverse order.

SAS429F.CDR

1

2

3

4

SAS429FA

4-36 687200Q

4.6.12 Pinch Roll Assembly

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Remove the Supporter (

REP 4.6.11 Supporter

).

3

Unclip the s pring from th e Registration P lat e.

4

Unlatch th e c lip securing t he Pinch Roll A ssembly to the Registration Plat e.

5

Remove the Pinch Roll Assembly with the Pinch Roll springs.

Figure 4.6.12.1 Pinch Roll Assembly Removal

Replacement

Perform the removal steps in reverse order.

SAS431F.CDR

SAS431F

A

687200Q Service Manual 4-37

4.6.13 Turn Pinch Roll Assembly

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Remove the Supporter (

REP 4.6.11 Supporter

).

3

Unhook the sp ring on the R egistration Plate side from the R elease Link.

4

Remove the Turn Pinch Roll Assembly with the Tur n Pinch Roll Spring.

Figure 4.6.13.1 Turn Pinch Roll Assembly Removal

Replacement

Perform the removal steps in reverse order.

SAS432F.CDR

SAS432F

sas423f

4-38 687200Q

4.6.14 Registration Solenoid/Tray 1 Solenoid/Front Tray Solenoid

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Remove the three screws securing the Registration Solenoid, Tray 1 Solenoid, and Front Tray
Solenoid.

3

Pull the thr ee Solenoids away from the Supporter with the wire harness.

NOTE: You can remove these three Solenoids separately at this point.

Figure 4.6.14.1 Registration Solenoid/Tray 1 Solenoid/Front Tray Solenoid Removal

Replacement

Perform the removal steps in reverse order.

SAS433F.CDR

SAS433F

687200Q Service Manual 4-39

4.6.15 Registration Clutch Assembly

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Remove the Supporter (

REP 4.6.11 Supporter

).

3

Remove the Registration Bushing. (See Fig ure 4.6.11.1. )

4

Use a flat-slot screwdriver blade to pry off th e E-ring.

5

Slide the Registration Clutch Assembly off together with the Idler Gear.

Figure 4.6.15.1 Registration Clutch Assembly Removal

Replacement

Perform the removal steps in reverse order.

SAS434F

4-40 687200Q

4.7 Paper Transportation III

4.7.1 Bias Transfer Roll (BTR) Assembly

Removal

1

Open the Front Cover As s em bly.

2

Remove the EP Cartridge.

WARNING! T o prevent contamination of the BTR, do not touch the f oam portion of the roll. Handle

the roll by the shaft extension on each end.

3

Use a slotted screwdriver to lift each end of the BTR Assembly upward, and remove the
Assembly.

Figure 4.7.1.1 BTR Assembly Removal

Replacement

Perform the removal steps in reverse order.

SAS435F.CDR

SAS435F

687200Q Service Manual 4-41

4.7.2 BTR Chute Assembly

Removal

1

Remove the Paper Handling Unit Assembly (

REP 4.5 . 1 Paper H andling Unit As s em bly

).

2

Remove the two sc rew s securing th e BT R Chute As se m bly. (See Figure 4.7. 2. 1. )

3

Remove the two sc rew s securing th e H VPS leads.

4

Remove the Duplex Module, if present.

5

Remove the Fuser Module (

REP 4.8.1 Fuser Assembly (CRU)

).

6

Remove the rear screw securing the BTR Chute Assembly to the Frame.

7

Lift the BTR C hute Assembly upw ard and remove it.

Figure 4.7.2.1 BTR Chute Assembly removal

Replacement

Perform the removal steps in reverse order.

SAS436F.CDR

Red

Pink

SAS436FC

4-42 687200Q

4.8 Fusing

4.8.1 Fuser Assembly (CRU)

Removal

1

Remove the Duplex Module, if instal led. (

REP 10.3.1 Duplex Module

.)

2

Remove the two Fus er Module anchor screws. (See F igure 4.8.1.1. )

3

Grasp the Fuser Assembly by the peach felt tabs on both ends; then remove the Fuser Assembly
by firmly p ulling it towards you.

Figure 4.8.1.1 Fuser Assembly (CRU) Removal.

Replacement

1

Perform the removal steps in reverse order.

2

If a new Fuser Assembly was installed, reset the Fuser Life Counter.

3

Turn on the printer power while simultaneo usly pressing th e

ONLINE (0)

and

MENU DOWN (5)

keys. When the counter is reset, a row of black boxes will ap pear on the LC D screen and you
may release th e keys.

SAS437F.CDR

SAS437F

687200Q Service Manual 4-43

4.9 Paper Exit

4.9.1 Exit Roll Assembly

Removal

1

Remove the Top Cover Assembly (

REP 4.2.6 Top Cover Assembly

).

2

Remove the Option Cover

(REP 4.9.6 Option Cover/Eliminator Assembly).

3

Remove the three screws securing the Eliminator Assembly and take off the Exit Assembly.

4

Turn the Top Cover Assembly over.

5

Disconnect P/J24 (Exit Motor) and P/J124 (Rear Cover Sensor).

6

Remove the four screws securing the Exit Roll Assembly to the back side of the Top Cover
Assembly, and remove the Exit Roll Ass embly from the Top Cover Assembly.

7

Pry of f the hook of the be arings from t he top face side of the Top Cover Assembly, and remove
the Exit Roll Assembly together with the two bearings.

8

Disengage the latch of the Gear and slide off the Gear and the two bearings together. (See
Figure 4.9.1.1.)

Figure 4.9.1.1 Exit Roll Assembly Removal

Replacement

Perform the rem oval steps in rev erse order.

SAS448F.CDR

SAS448F

4-44 687200Q

4.9.2 Middle Roll Assembly

Removal

1

Remove the Top Cover Assembly (

REP 4.2.6 Top Cover Assembly

).

2

Turn the Top Cover Assembly over.

3

Pull the locking tab on the gear t o unlatch the Gear from the Middle Roll Assembly.

4

Pull the Gea r away from th e M iddle Roll Asse m bly.

5

Unhook bot h bearings an d pull the Midd le R oll Assembly together with th e bearings away from
the Exi t Assembl y Frame.

NOTE: The M iddle Pinch Ro lls m ight fall off when you remove the Mi ddle Roll Assem bly.

Figure 4.9.2.1 Middle Roll Assembly Removal

Replacement

Perform the rem oval steps in rev erse order.

SAS449F.CDR

sas449fa

687200Q Service Manual 4-45

4.9.3 Exit Gate

Removal

1

Remove the Top Cover Assembly (

REP 4.2.6 Top Cover Assembly

).

2

Turn the Top Cover Assembly over.

3

Remove the four screws securing the Exit Assembly, and remove the Assembly from the Top
Cover Assembly.

4

Bend the Exit Gate to remove the Gate from the Exit Motor end of the Exit Assembly.

5

Unlatch th e s haft on the Direc t ion Spring side of the Exit G at e, an d remove the Gate an d
Direction Spring from the Exit Assembly.

6

Remove the Direction Spring from the Exit Gate.

Figure 4.9.3.1 Exit Gate Removal

Replacement

Perform the rem oval steps in rev erse order.

SAS450F.CDR

sas450fa

4-46 687200Q

4.9.4 Exit Motor Assembly

Removal

1

Remove the Top Cover Assembly (

REP 4.2.6 Top Cover Assembly

).

2

Turn the Top Cover Assembly over.

3

Disconnect P/J24 (Exit Motor).

4

Remove th e tw o s crews securing the Exit Motor Assembly, and pull the Exit Motor Ass embl y o u t.
(See Figure 4.9.4.1).

NOTE: Note the routing of the Exit Motor wir ing harn es s.

5

Remove the Exit Motor wiring harness from the Cover Assembly.

Figure 4.9.4.1 Exit Motor Assembly Removal

Replacement

Perform the rem oval steps in rev erse order.

SAS451F.CDR

SAS451F

687200Q Service Manual 4-47

4.9.5 Rear Cover Sensor

Removal

1

Remove the Top Cover Assembly (

REP 4.2.6 Top Cover Assembly

).

2

Turn the Top Cover Assembly over.

3

Unhook the R ear Cover Sensor clip by pressing it from th e rear of the Top Cover Ass em bly, and
remove the Rea r C over Se ns or. (See Figure 4.9.5.1 .)

4

Unplug th e R ear Cover Sensor co nnector, and remove the sens or.

Figure 4.9.5.1 Rear Cover Sensor Removal

Replacement

Perform the rem oval steps in rev erse order.

SAS452F.CDR

SAS452F

4-48 687200Q

4.9.6 Option Cover/Eliminator Assembly

Removal

1

Remove the Option Cover. (Press the two hooks of the Option Cover Plate from under the rear
part of the Top Cover Assembly.)

2

Remove the three screws.

3

Remove the Eliminator Assembly along with the Exit Earth Spring.

Figure 4.9.6.1 Option Cover/Eliminator Assembly Removal

Replacement

Perform the rem oval steps in rev erse order.

SAS454F.CDR

sas453f

687200Q Service Manual 4-49

4.9.7 Stack Full Sensor

Removal

1

Remove the Rear Option Cover Plate and the Elimi nator Assem bly. (

REP 4.9.6 Option C over/

Eliminator Assembly

.)

2

Use a flat-slot screwdriver blade to unhook the Stack F ull Sensor clip. (See F igure 4.9.7.1.)

3

Disconnect the connector, and remove the Stack Full Sensor.

Figure 4.9.7.1 Stack Full Sensor Removal

Replacement

Perform the rem oval steps in rev erse order.

SAS454FA

4-50 687200Q

4.9.8 Stack Full Actuator

Removal

1

Remove the Rear Option Cover Plate and the Elimi nator Assem bly. (

REP 4.9.6 Option C over/

Eliminator Assembly

.)

2

Lift the right end of the Stack Full Actuator upward, and remove the Actuator. (See Figure

4.9.8.1.)

Figure 4.9.8.1 Stack Full Actuator Removal

Replacement

Perform the removal steps in reverse order.

SAS455F.CDR

SAS455FA