Primera Bravo 4202 Service Manual
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Primera Bravo 4202 Service Manual

4200 series
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Service Manual for Bravo 4200 Series Disc Publisher
04/27/17
©2017 All rights reserved

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Questions and answers

Malcolm Conlon
April 8, 2025

Good Day 4202 series - Pick up arm picks up DVD after imaging but will not release onto printer tray. Makes a continuous grinding sound. A light tape rests the arm release the DVD. Must repeat process every time. Is this a repairable issue.

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1 comments:
Mr. Anderson
May 14, 2025

Yes, the pick-up arm issue is repairable. If the arm picks up the DVD but does not release it and makes a grinding sound, possible causes include a faulty solenoid, a problem with the arm board or sensor flag bracket, or an issue with the sensor on the picker board. These components can be accessed and replaced based on the service manual instructions.

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Summary of Contents for Primera Bravo 4202

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

  • Page 2: Table Of Contents

    Cover Control Panel Blue LED Board USB3 Hub Mainboard Print Tray Power Resistor Encoder Wheel Sensor Encoder Wheel Drive Mount Power Supply Drive Fan Drives Maintenance Felt Maintenance Fan Encoder Strip Carrier Drive Motor Carrier Frame Feed Drive Motor Maintenance Sled Carrier 04/27/17 ©2017 All rights reserved...
  • Page 3 Alignment Sensor Carrier Flex PC Picker Picker Motor Picker Board & Flex Cables Arm Board Solenoid Drive Alignment Troubleshooting 04/27/17 ©2017 All rights reserved...

  • Page 4: Cover

    2017 Bravo 4200 Series Disc Publisher Service Manual 1 ▪ Cover Loosen 4 screws securing back of cover. Remove 3 screws securing front of cover. Slide picker and carrier to middle of printer.
  • Page 5 Bravo 4200 Series Disc Publisher Service Manual 2017 Unplug cable from control panel on underside of cover. While lifting cover off of printer, reach in and unplug blue LED board cable from mainboard. Remove cover.

  • Page 6: Control Panel

    2017 Bravo 4200 Series Disc Publisher Service Manual 2 ▪ Control Panel Remove cover (page 3). Remove 3 screws securing control panel. After replacing control panel, press buttons to verify they click properly.

  • Page 7: Blue Led Board

    2017 Bravo 4200 Series Disc Publisher Service Manual 3 ▪ Blue LED Board Remove cover (page 3). Remove 2 screws securing blue LED board. Unplug cable from end of board.

  • Page 8: Usb3 Hub

    2017 Bravo 4200 Series Disc Publisher Service Manual 4 ▪ USB3 Hub Remove 2 screws securing cover plate. Remove plate. Unplug any sata cables from hub. For 2 drive units, keep track of which cable is plugged into which port. Remove 3 screws securing hub.
  • Page 9 Bravo 4200 Series Disc Publisher Service Manual 2017 When replacing hub, be sure pins properly plug into connectors on mainboard. Plug any sata cables back in. If locations of drives in dual drive units need to be reset consult Drive Alignment (page 63).

  • Page 10: Mainboard

    2017 Bravo 4200 Series Disc Publisher Service Manual 5 ▪ Mainboard Remove USB3 hub (page 07). Unplug all cables and flex cables from mainboard. Remove 4 screws securing mainboard. Lift mainboard out of unit.
  • Page 11 Bravo 4200 Series Disc Publisher Service Manual 2017 Remove 2 screws securing static brush to mainboard. Remove 3 standoffs. Secure static brush and standoffs to new mainboard. When replacing mainboard, make sure hole in corner is resting on small post before replacing 4 screws.

  • Page 12: Print Tray

    2017 Bravo 4200 Series Disc Publisher Service Manual 6 ▪ Print Tray Remove mainboard (page 09). Remove 2 screws securing print tray guide to print tray. Lift guide up off of tray (leave attached to belt). Lift back end of print tray slightly and pull back against rear cover plate.
  • Page 13 Bravo 4200 Series Disc Publisher Service Manual 2017 Remove screw securing front tray guide. Lift guide out of base. Pull print tray out of printer.

  • Page 14: Power Resistor

    2017 Bravo 4200 Series Disc Publisher Service Manual 7 ▪ Power Resistor Cut tie wrap securing power resistor cable to power supply cable. Unplug power resistor from mainboard. While holding resistor mount bracket with fingers or needle-nose pliers, remove 2 screws securing to rear cover plate.
  • Page 15 Bravo 4200 Series Disc Publisher Service Manual 2017 Remove 2 screws securing power resistor to resistor mount bracket. Replace resistor.

  • Page 16: Encoder Wheel Sensor

    2017 Bravo 4200 Series Disc Publisher Service Manual 8 ▪ Encoder Wheel Sensor Cut tie wrap securing cables. Unplug encoder wheel sensor from mainboard. Remove 2 screws securing sensor to bracket.
  • Page 17 Bravo 4200 Series Disc Publisher Service Manual 2017 When replacing sensor, be sure encoder wheel is centered in slot.

  • Page 18: Encoder Wheel

    2017 Bravo 4200 Series Disc Publisher Service Manual 9 ▪ Encoder Wheel Peel encoder wheel off of gear. Clean area with alcohol before adhering new encoder wheel. Be sure replaced encoder wheel is centered in sensor slot. Clean encoder wheel with alcohol after handling.

  • Page 19: Drive Mount

    2017 Bravo 4200 Series Disc Publisher Service Manual 10 ▪ Drive Mount 10.1 Tip printer up. Remove 6 screws securing drive mount base plate to base. 10.2 Tip drive mount forward. Align slot on drive mount base plate with tab on rear cover plate and remove.
  • Page 20 Bravo 4200 Series Disc Publisher Service Manual 2017 10.3 Unplug all cables from back of drive(s) to detach drive mount from printer. In 2 drive units, keep track of which sata cable goes with which drive.

  • Page 21: Power Supply

    2017 Bravo 4200 Series Disc Publisher Service Manual 11 ▪ Power Supply 11.1 Remove drive mount (page 18). Unplug power supply from mainboard. Cut tie wraps securing power supply cable. 11.2 Remove 5 screws securing power supply to rear cover plate.
  • Page 22 Bravo 4200 Series Disc Publisher Service Manual 2017 11.3 Lift power supply out of printer. Pull drive power cable out through opening on bottom of base. 11.4 When replacing power supply route drive power cable to underside of printer. Be sure it is not pinched beneath or on side of power supply.

  • Page 23: Drive Fan

    2017 Bravo 4200 Series Disc Publisher Service Manual 12 ▪ Drive Fan 12.1 Remove drive mount (page 18). Cut tie wrap securing fan and sata cables. Unplug drive fan from mainboard. 12.2 Remove 2 screws securing fan to inside of rear cover plate.
  • Page 24 Bravo 4200 Series Disc Publisher Service Manual 2017 12.3 Tip printer up and remove drive fan, pulling cable out through opening on base. When replacing fan, be sure cable is oriented to lower left as shown.

  • Page 25: Drives

    2017 Bravo 4200 Series Disc Publisher Service Manual 13 ▪ Drives 13.1 Remove drive mount (page 18). Remove 4 screws securing drive(s) to be replaced. 13.2 Slide drive(s) out from the front. Slide new drive into bracket and secure with 4 screws (use front set of holes).
  • Page 26 Bravo 4200 Series Disc Publisher Service Manual 2017 13.3 Use side-cutters to snip off 4 small tabs on inside of new drive(s). After installing new drives consult Drive Alignment (page 63).

  • Page 27: Maintenance Felt

    2017 Bravo 4200 Series Disc Publisher Service Manual 14 ▪ Maintenance Felt 14.1 Remove drive mount (page 18). Remove 4 screws securing maintenance felt cover. Remove old maintenance felt pads (wear gloves to avoid ink on fingers). 14.2 Stack new set of maintenance felt pads into base in sequence and orientation shown (1 on bottom, 7 on top).

  • Page 28: Maintenance Fan

    2017 Bravo 4200 Series Disc Publisher Service Manual 15 ▪ Maintenance Fan 15.1 Cut tie wrap securing fan and sata cables. Unplug maintenance fan from mainboard. 15.2 Remove maintenance felt (page 26). Remove 2 screws securing fan mount bracket. Remove fan, pulling cable out through opening.

  • Page 29: Encoder Strip

    2017 Bravo 4200 Series Disc Publisher Service Manual 16 ▪ Encoder Strip 16.1 Unhook encoder fence spring from tab. 16.2 Pull left end of encoder strip off of tab first. Then rotate other end of strip 90° to remove from flared end of right tab (2 pic).
  • Page 30 Bravo 4200 Series Disc Publisher Service Manual 2017 16.3 Be sure new encoder strip is routed through sensor slot on back of carrier. Clean encoder strip with alcohol after handling. Through Slot Behind Slot...

  • Page 31: Carrier Drive Motor

    2017 Bravo 4200 Series Disc Publisher Service Manual 17 ▪ Carrier Drive Motor 17.1 Cut tie wrap securing cables. Unplug carrier drive motor from mainboard. 17.2 Loosen screw securing carrier belt tensioner.
  • Page 32 Bravo 4200 Series Disc Publisher Service Manual 2017 17.3 Remove 2 screws (T8 driver) securing carrier drive motor to carrier frame. Remove motor. 17.4 When installing new carrier drive motor be sure to include spacer between motor and carrier frame. Loop belt around motor pulley and retighten screw on carrier belt tensioner.

  • Page 33: Carrier Frame

    2017 Bravo 4200 Series Disc Publisher Service Manual 18 ▪ Carrier Frame 18.1 Unplug cables and flex cables indicated from mainboard. 18.2 Remove 2 screws indicated from back of carrier frame.
  • Page 34 Bravo 4200 Series Disc Publisher Service Manual 2017 18.3 Remove 2 screws indicated from back of carrier frame. Remove control panel cable from wire saddle. 18.4 Loosen screw on belt tensioner.
  • Page 35 Bravo 4200 Series Disc Publisher Service Manual 2017 18.5 While pressing in on belt tensioner to add slack, pull belt off of pulley on tray drive shaft. Remove 2 screws indicated from carrier frame. 18.6 Remove screw indicated from carrier frame. Lift carrier frame off of printer.
  • Page 36 Bravo 4200 Series Disc Publisher Service Manual 2017 18.7 When replacing carrier frame, be sure it is properly seated in all slot and posts on base before securing screws. Loop belt around tray drive shaft before retightening belt tensioner. Some early versions required different washers between carrier frame and base.

  • Page 37: Feed Drive Motor

    2017 Bravo 4200 Series Disc Publisher Service Manual 19 ▪ Feed Drive Motor 19.1 Remove carrier frame (page 32). Remove screw (T8 drive) and washer from end of tray drive shaft. Pull pulley off of end of shaft. Remove retaining ring from shaft. 19.2 Pull tray drive shaft out of carrier frame.
  • Page 38 Bravo 4200 Series Disc Publisher Service Manual 2017 19.3 Remove 2 screws (T8 driver) securing feed drive motor to bracket. Remove motor. 19.4 When replacing tray drive shaft, be sure encoder wheel is centered in sensor slot. If necessary, remove encoder wheel sensor and re-secure with encoder wheel in slot.

  • Page 39: Maintenance Sled

    2017 Bravo 4200 Series Disc Publisher Service Manual 20 ▪ Maintenance Sled 20.1 Remove screw (T8 driver) and washer from end of tray drive shaft. Pull pulley and belt off of end of shaft. Remove retaining ring from shaft. 20.2 Pull tray drive shaft out of carrier frame.
  • Page 40 Bravo 4200 Series Disc Publisher Service Manual 2017 20.3 Unhook spring from frame. Pull up on post on left side of maintenance sled while pushing in on right side to pop sled out of frame. 20.4 Instructions for modifying old versions of maintenance sled. Snip off plastic tabs and ridges indicated. Clean any excess ink.

  • Page 41: Carrier

    2017 Bravo 4200 Series Disc Publisher Service Manual 21 ▪ Carrier 21.1 Remove screw (T8 driver) and washer from end of tray drive shaft. Pull pulley and belt off of end of shaft. Remove retaining ring from shaft. 21.2 Pull tray drive shaft partially out of carrier frame. When replacing shaft, be sure bearing is located on outside of carrier frame, washer is behind retaining ring and encoder wheel is in sensor slot (2 pic).
  • Page 42 Bravo 4200 Series Disc Publisher Service Manual 2017 21.3 Remove screws from each end of carrier shaft. 21.4 Unplug both carrier flex cables from mainboard. Press in on tab on flex holder to remove from carrier frame. Pull flex cables out through frame.
  • Page 43 Bravo 4200 Series Disc Publisher Service Manual 2017 21.5 Loosen screw on belt tensioner. Pull belt off of tensioner and carrier motor. 21.6 Press down slightly on encoder fence to pull it out of sensor slot and route behind carrier. Through Slot Behind Slot...
  • Page 44 Bravo 4200 Series Disc Publisher Service Manual 2017 21.7 Pull out on right end of carrier shaft to pop it out of frame. Slide carrier off of shaft and remove. 21.8 When replacing carrier, be sure picker and carrier are properly captured on top edge of carrier frame.

  • Page 45: Alignment Sensor

    2017 Bravo 4200 Series Disc Publisher Service Manual 22 ▪ Alignment Sensor 22.1 Remove carrier from unit (page 40). Remove 2 screws indicated. 22.2 Press up on corner of lower capture lever just enough to access screw indicated (do not completely remove lever).
  • Page 46 Bravo 4200 Series Disc Publisher Service Manual 2017 22.3 Slightly pry both frames apart just enough to pull alignment sensor wires out from tab. 22.4 Remove screw securing quad sensor carrier bracket.
  • Page 47 Bravo 4200 Series Disc Publisher Service Manual 2017 22.5 Unplug alignment sensor from carrier flex pc. Connect new alignment sensor. 22.6 When reassembling carrier be sure to snap end of quad sensor carrier bracket onto tab on frame before replacing screw. Be sure to route alignment sensor wires behind tab before replacing 2 screws and retightening 1 screw.

  • Page 48: Carrier Flex Pc

    Bravo 4200 Series Disc Publisher Service Manual 2017 23 ▪ Carrier Flex PC 23.1 Remove carrier from unit (page 40). Remove 3 screws indicated. 23.2 Press up on lower capture lever to detach from unit. Lift lever off of unit, pulling belt through opening.
  • Page 49 Bravo 4200 Series Disc Publisher Service Manual 2017 23.3 Remove screw securing quad sensor carrier bracket. Remove 2 screws (T8 driver). As both frames separate, lift carrier flex pc out of assembly. 23.4 Use a small flathead screwdriver to pry and pop sensor out of quad sensor carrier bracket. Press sensor from new carrier flex pc into bracket until it snaps into place.
  • Page 50 Bravo 4200 Series Disc Publisher Service Manual 2017 23.5 Fold and crease carrier flex pc in locations shown. Place holes onto tiny tabs on bracket. Plug alignment sensor in. Place new carrier flex pc into frame. 23.6 When reassembling carrier be sure to snap end of quad sensor carrier bracket onto tab on frame before replacing screw.
  • Page 51 Bravo 4200 Series Disc Publisher Service Manual 2017 23.7 Gripping spring with tweezers, slide it in between lower capture lever and carrier base. Hold spring in center and snap lower capture lever back into place while removing tweezers. Spring should remain captured between parts.

  • Page 52: Picker

    Bravo 4200 Series Disc Publisher Service Manual 2017 24 ▪ Picker 24.1 Remove screw (T8 driver) and washer from end of tray drive shaft. Pull pulley and belt off of end of shaft. Remove retaining ring from shaft. 24.2 Pull tray drive shaft partially out of carrier frame. When replacing shaft, be sure bearing is located on outside of carrier frame, washer is behind retaining ring and encoder wheel is in sensor slot (2 pic).
  • Page 53 Bravo 4200 Series Disc Publisher Service Manual 2017 24.3 Remove screws from each end of carrier shaft. 24.4 Unplug picker flex cable from mainboard. Peel flex cable off of double-sided tape and route out through slot on carrier frame.
  • Page 54 Bravo 4200 Series Disc Publisher Service Manual 2017 24.5 Loosen screw on belt tensioner (do not remove belt). 24.6 Pull out on right end of carrier shaft to pop it out of frame. Slide picker off of shaft and remove.
  • Page 55 Bravo 4200 Series Disc Publisher Service Manual 2017 24.7 When replacing picker, be sure picker and carrier are properly captured on top edge of carrier frame. Press carrier shaft back into frame, tightening both screws at the same time to prevent it from spinning.

  • Page 56: Picker Motor

    Bravo 4200 Series Disc Publisher Service Manual 2017 25 ▪ Picker Motor 25.1 Remove 4 screws securing picker motor and picker side cover plate. Unplug picker motor from picker board and remove. 25.2 Plug new picker motor into board through opening on plate and route cable into notch (1 pic).

  • Page 57: Picker Board & Flex Cables

    Bravo 4200 Series Disc Publisher Service Manual 2017 26 ▪ Picker Board & Flex Cables 26.1 Remove picker motor and picker side cover plate (page 55). Unplug flex cable from arm board. 26.2 Remove 3 screws securing picker board. Remove board.
  • Page 58 Bravo 4200 Series Disc Publisher Service Manual 2017 26.3 When replacing picker board or flex cable(s), route flex cable(s) through slots on board as shown. Be sure flex cable(s) are plugged into port(s) in correct orientation.

  • Page 59: Arm Board

    Bravo 4200 Series Disc Publisher Service Manual 2017 27 ▪ Arm Board 27.1 Remove picker (page 51). Unplug flex cable from arm board. 27.2 Press tab on sensor flag bracket out and up past edge of arm board to remove it from picker arm.
  • Page 60 Bravo 4200 Series Disc Publisher Service Manual 2017 27.3 Unplug solenoid cable from arm board. Remove screw and washer securing arm board. Pry out on edge of arm board to pop it out of picker arm. 27.4 Before installing new arm board, apply stripe of thick tape near sensor as shown.
  • Page 61 Bravo 4200 Series Disc Publisher Service Manual 2017 27.5 When replacing arm board, hook tab on bottom end of board into slot on picker arm then press top end into location. Secure with screw and washer. Connect solenoid and flex cable. 27.6 Replace sensor flag bracket.

  • Page 62: Solenoid

    Bravo 4200 Series Disc Publisher Service Manual 2017 28 ▪ Solenoid 28.1 Remove arm board (page 58). Pry pick finger cover off of tabs and remove. 28.2 Unhook spring from picker arm and pick finger.
  • Page 63 Bravo 4200 Series Disc Publisher Service Manual 2017 28.3 Remove 2 screws securing solenoid. Remove solenoid, pulling cable out through opening. 28.4 When replacing solenoid route one cable behind post, as shown.

  • Page 64: Drive Alignment

    Bravo 4200 Series Disc Publisher Service Manual 2017 29 ▪ Drive Alignment 29.1 After replacing drive(s), verify they are set in correct location. Open PTPublisher. Click on Tools>Set Drives in Publisher. Click on Open/Close Drive buttons for top and bottom and verify proper drive opens.
  • Page 65 Bravo 4200 Series Disc Publisher Service Manual 2017 29.3 Set Position Offsets to Top Drive and click Set and Move To. Picker will lower disc into top drive tray pic). Observe position of drive tray in relation to hovering disc. Determine if drive needs to move forwards or backwards to center disc in tray.
  • Page 66 Bravo 4200 Series Disc Publisher Service Manual 2017 29.5 Set Position Offsets to Bottom Drive and click Set and Move To. Picker will lower disc into bottom drive tray (2 pic). Observe position of drive tray in relation to hovering disc. Determine if drive needs to move forwards or backwards to center disc in tray.

  • Page 67: Troubleshooting

    Bravo 4200 Series Disc Publisher Service Manual 2017 30 ▪ Troubleshooting Install ink cartridge before initialization. Error codes are displayed in Bravo4200 Production Tool. Symptoms During Initialization Possible Solution No carrier or print tray movement (solenoid Carrier drive motor (page 30) clicks and picker moves twice) J10 (mainboard) Control panel blinks...
  • Page 68 Bravo 4200 Series Disc Publisher Service Manual 2017 30 ▪ Troubleshooting Symptoms During Operation Possible Solution Picker drops down onto discs in bins multiple Solenoid (page 61) times but does not grab disc Picker grabs disc but does not place in print Arm board or sensor flag bracket (page 58) tray, moves to home position Erratic carrier and picker movements before...

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