Page 1 Transmittal Page ............................Transmittal Page 03/2003 8850/ 510DP...
Page 2 Transmittal Page 03/2003 8850/ 510DP...
Page 3 Synergix Print System SPS 510dp printers. Photographs and illustration may show the external view of the 8850, however the procedure can also be done on the 510dp. Some of the covers may latch and open differently, but when opened the internal components are serviced in the same manner.
Page 4 Revised REP 7.1 Media Supply Drawer to add note that Drawers 2 and 3 are optional on 510dp. Revise REP 7.9 Media Drive Motor to add new Media Drive Chain reference for 8850 W/Tag 11 and 510dp. Revise REP 14.1Top Cover to show complete removal procedure and add 510dp differences.
Page 5 Title Pages ................Title Pages 03/2003 8850/ 510DP...
Page 6 Title Pages 03/2003 8850/ 510DP...
Page 7 OCUMENT OMPANY XEROX 8850/Wide Format System 510dp Printers Service Manual CAUTION Certain components in the 8850 Printer and SPS 510dp are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage. 701P39271 March, 2003...
Page 9: Table Of Contents
Introduction About this Manual ......................Organization ........................How to Use This Manual ....................Repair Analysis Procedures (RAPs) ................Repair / Adjustment Procedures ..................Reference Symbology..................... Introduction 03/2003 8850/ 510DP...
Page 10 Introduction 03/2003 8850/ 510DP...
Page 11: About This Manual
Section 1. - Service Call Procedures Procedures, Parts List, Diagnostic Procedures, Installation Procedures, Wiring Data and BSDs. This section contains the following: This manual will enable the Service Representative to repair the 8850 printer. • Call Flow Procedure • Initial Actions/ System Checks •...
Page 12: How To Use This Manual
Do not perform the remaining steps. Section 4. - Repair / Adjustment This section contains the repair and adjustment procedures for the 8850 Printer. Section 5. - Parts List This section contains the detailed Parts List for the 8850 Printer.
Page 13: Repair Analysis Procedures (Raps)
When the procedure or steps are not affected by a particular modification, they are identified with the statement, W/ O Tag/ MOD, followed by the modification number. The W/ O in the statement indicates that this step must be performed on units assembled without that specific modification. Introduction 03/2003 8850/ 510DP...
Page 14: Reference Symbology
Reference Symbology (Figure 1): The following symbols are used in this document: Figure 1 Reference Symbology (1 of 2) Introduction 03/2003 8850/ 510DP...
Page 15 (Figure 2): Reference Symbology, cont’d. Figure 2 Reference Symbology (2 of 2) Introduction 03/2003 8850/ 510DP...
Page 16 Introduction 03/2003 viii 8850/ 510DP...
Page 17 Initial Actions/Systems Checks ..................Print Defect Isolation Procedure ..................Workstation Checkout Procedure ................... Status Code Entry Chart ....................Message Display Entry Chart..................1-11 Maintenance Procedures ....................1-13 Callback .......................... 1-17 System Checkout / Final Action ..................1-17 Service Call Procedures 03/2003 8850/ 510DP...
Page 18 Service Call Procedures 03/2003 8850/ 510DP...
Page 19: Introduction
The Final Action is designed to ensure that the print is transported correctly and to ensure that image quality is within specification. Service Call Procedures 03/2003 Introduction 8850/ 510DP...
Page 20: Call Flow Procedure
System Checkout Offline menu: Reference the 8850/510dp Printer Operator Manual, Offline Setup Menu, Performing printer diagnostics, Viewing recent fault log to have the customer Perform the following: review the fault log.
Page 21: Print Defect Isolation Procedure
FRU (Field Replaceable Unit) Test in Section 2 of the Control- ler Service Manual. Otherwise, ask the customer to reload the print drivers. If the problem still exists, there could be a defective cable. Service Call Procedures 03/2003 Print Defect Isolation Procedure, Workstation 8850/ 510DP...
Page 22: Status Code Entry Chart
Media Registration Sen- PL 8.2 interchangeable. No RAP The Media Registration Sensor sor (A21Q1) PL 1.1 was detected to be actuated when • Main PWB (A3) the machine powered up. Service Call Procedures 03/2003 Status Code Entry Chart 8850/ 510DP...
Page 23 PL 1.1 • Main PWB (A3) machine powered up. This requires the Fuser exit area to be opened, and the media to be removed. Service Call Procedures 03/2003 Status Code Entry Chart 8850/ 510DP...
Page 24 + 5 VDC Bulk error signal detected • LVPS (A5), Connec- PL 1.1 • Main PWB (A3) No RP tors, wires, LL-02 8850 Firmware error • Main PWB (A3) This is a firmware problem. Press LL-24 Developer Bias error. • Check for damage on PL 1.3...
Page 25 No RAP 24 VDC Bulk power supply failure. • LVPS (A5) LL-51 Power On Self Test fault Replace Main PWB (A3) PL 1.1 No RAP The internal RAM failed POST. Service Call Procedures 03/2003 Status Code Entry Chart 8850/ 510DP...
Page 26 To reset: switch off, then on, the LL-89 This is a Firmware problem Main Power Switch. No RAP Press power off (0) then power on (1). If problem persists, reload the firmware. Service Call Procedures 03/2003 Status Code Entry Chart 1-10 8850/ 510DP...
Page 27: Message Display Entry Chart
Press power off (0), then power on (1). BRATE TONER SEN- calibrate when the If problem persists, go to J1-01 Under- code [0921-6] was toned Fault RAP. entered. Service Call Procedures 03/2003 Status Code Entry Chart, Message Display Entry 8850/ 510DP 1-11...
Page 28 C1-04, C2-04, C3-04 codes. sense media. 09 04 Automatic ESV Process Control Go to 09 04 Automatic ESV Setup Setup Failed, Condition system is unable Failed. to set Xerograph- Service Call Procedures 03/2003 Message Display Entry Chart 1-12 8850/ 510DP...
Page 29: Maintenance Procedures
Inspect Drum surface for deep scratches, chips or excessive wear. Replace print quality problems. Drum if damaged. Apply zinc stearate to the cleaning blade and Drum. *Note 2 Clean Drum surface with Xerox Film Remover if contaminated. Apply zinc stearate when surface is dry. As Required Check/clean cleaning blade.
Page 30 Check the stainless steel shield on the rear of the Detack aluminum chan- nel for a white powder. If a powder is present, replace the stainless shields. Service Call Procedures 03/2003 Maintenance Procedures 1-14 8850/ 510DP...
Page 31 TASK ENABLER Normal Call Check the cam for lubrication. To ensure correct Cutter operation. The Cutter will Place a light film of lubrication on the cam surface. not provide a straight cut. Service Call Procedures 03/2003 Maintenance Procedures 8850/ 510DP 1-15...
Page 32 To ensure correct air flow through machine, and to Check the Ozone Filter at 40K prints, clean or replace as required. Replace necessary. keep heat that is generated to a minimum. the Ozone Filter at 120K prints. Service Call Procedures 03/2003 Maintenance Procedures 1-16 8850/ 510DP...
Page 33: Callback
Figure 1 Recording the Print Count Readings Record all activities in the Service Log. Record the Print Count Readings on the Service Call Report. Give appropriate credit to the Customer. Service Call Procedures 03/2003 Callback, System Checkout / Final Action 8850/ 510DP 1-17...
Page 34 Service Call Procedures 03/2003 Callback, System Checkout / Final Action 1-18 8850/ 510DP...
Page 35 2-16 Other Faults OF-1 Control Panel RAP ....................2-17 OF-2 Power On Self Test (POST) RAP ................2-17 Generic RAPs Generic Clutch RAP ......................2-18 Generic Sensor RAP ....................... 2-18 Generic Switch RAP......................2-19 Status Indicator RAPs 03/2003 8850/ 510DP...
Page 36 Status Indicator RAPs 03/2003 8850/ 510DP...
Page 37 7.1, NOTE 2, and check the resistances of the windings of the Media Drive Motor (MOT1) The resistances of the windings of the Media Drive Motor (MOT1) are Replace the Media Drive Motor (MOT1), 7.2. Status Indicator RAPs 03/2003 C1-04/C2-04/C3-04 RAP 8850/ 510DP...
Page 38 J1-01 fault condition. Enter the code [0361] in order to exit the diagnostics mode. Figure 1 Location of Developer Drive Coupling The Developer Housing Auger and Drive Gears are rotating as the prints are being made. Status Indicator RAPs 03/2003 J1-01 Undertoned Fault RAP 8850/ 510DP...
Page 39 Replace the Main PWB, A3, PL 1.1. If the problem persists, enter the code [0926] to reset the Drive Gear NVM. Developer Housing Drive Gear Front Auger Drive Gear Figure 2 Developer Housing and Auger Drive Gears Status Indicator RAPs 03/2003 J1-01 Undertoned Fault RAP 8850/ 510DP...
Page 40 Clean the Grid. Replace NOTE: Severe arching the Charge Scorotron Assembly 9.9). will cause a crackling/ snapping sound in the area of the HVPS. Blue sparking may also be observed on the HVPS. Status Indicator RAPs 03/2003 LL-21 8850/ 510DP...
Page 41 Will cause a blank or light copy or partial image. Refer to PQ 6 Blank Prints / Partial Image 13 Light Image. Can also cause toner spotting or streaks on back side of copy if clean output is not working. Status Indicator RAPs 03/2003 LL-22 8850/ 510DP...
Page 42 Look for an excessive amount of developer material (beads) in the Developer area, media path, and corotrons. Remove the Developer Housing and clean any contamination on the Housing and in the area of the Housing. Clean the Registration Feed Baffle. Clean the BTR and BTR channel. Status Indicator RAPs 03/2003 LL-24 8850/ 510DP...
Page 43 9.1). There is damage to the Probe and/or Harness. Check for an open in the Charge Scorotron Grid circuit (BSD 9.1). Replace the Electrometer Probe and PWB 9.9). Clean/Repair the drum ground. Status Indicator RAPs 03/2003 LL-25 Charge Voltage V HIGH 8850/ 510DP...
Page 44 Check the continuity between Connector L and Connector 1, and between Con- nector N and Connector 2 on Filter Module (A10). The Filter Module has continuity. Replace Filter Module A10 1.3). Status Indicator RAPs 03/2003 LL-41, LL-45, LL-81 2-10 8850/ 510DP...
Page 45 Cartridge Drive Motor removed for clarity Rear Auger Drive Gear Developer Housing Drive Gear Front Auger Drive Gear Figure 1 Developer Housing and Auger Drive Gears Status Indicator RAPs 03/2003 LL-90 Overtoned Fault RAP 8850/ 510DP 2-11...
Page 46 Check for an open or short circuit to ground in the wire connected to A22Q1P1-3. If the wire is OK, replace the Toner Sensor A22Q1, 9.9. Run [9-21-6 Toner Sensor Calibra- tion. Replace the Main PWB, A3, PL 1.1. Status Indicator RAPs 03/2003 LL-90 Overtoned Fault RAP 2-12 8850/ 510DP...
Page 47 Connect the (+) meter lead to the Main PWB (A3) connector (A3P 601-16). Connect the (-) meter lead to (A3P 601-14), shown on BSD 9.1. There is (+) 24 VDC present. Status Indicator RAPs 03/2003 09 04 Automatic ESV Setup Failed, Condition X 8850/ 510DP 2-13...
Page 48 Check the harnesses between the AC Module Assembly (A1) and the Low Voltage Power Sup- plies for an open or short circuit. If okay, go to the 1.2 DC Power RAP. Status Indicator RAPs 03/2003 1.1 AC Power RAP 2-14 8850/ 510DP...
Page 49 Main PWB (A3). Refer to BSD 1.2 DC Power Generation when performing this procedure. The 8850/510dp Printer is equipped with a Ground Fault Protector (GFP) device that detects Initial Actions excessive current leakage to ground. If excessive leakage is detected, the device will remove all power to the printer.
Page 50 Check the wiring between Edge Fuser Thermistor (RT2) and Connector A1P 8 for a short cir- cuit. A short circuit is present. Replace the AC Module Assembly (A1)(PL 1.1). Repair the wiring, or replace the Edge Fuser Thermistor (RT2). Status Indicator RAPs 03/2003 Endless FUSER IS CALIBRATING Fault 2-16 8850/ 510DP...
Page 51 A32J1. Main PWB, A3, 1.1. There is an internal fault in the Control Panel or in the Main PWB A3. Status Indicator RAPs 03/2003 OF-1 Control Panel RAP, OF-2 Power On Self Test 8850/ 510DP 2-17...
Page 52 If the wiring is good, replace the Sensor. The Sensor and its circuit appear to be operating normally, check the adjustment or alignment of the Sensor. Figure 1 Clutch (Generic) Status Indicator RAPs 03/2003 Generic Clutch RAP, Generic Sensor RAP 2-18 8850/ 510DP...
Page 53 Replace the Switch (PL X.X) The switch and its circuit appear to be operating normally. check the adjustment or alignment of the switch. Figure 1 Switch (Generic) Status Indicator RAPs 03/2003 Generic Sensor RAP, Generic Switch RAP 8850/ 510DP 2-19...
Page 54 Status Indicator RAPs 03/2003 Generic Sensor RAP, Generic Switch RAP 2-20 8850/ 510DP...
Page 55 PQ 17A Smudge ......................3-18 PQ 18 Spots ........................3-19 PQ 19 Uneven Density....................3-19 PQ 20 Unfused Prints ..................... 3-20 PQ 21 Wrinkle/Crease ....................3-20 PQ 22 Offsetting......................3-21 PQ 23 Verticle Magnification ..................3-21 Print Quality 03/2003 8850/ 510DP...
Page 56 Print Quality 03/2003 8850/ 510DP...
Page 57: Print Quality Initialization Procedure
Section 2. CAUSES. Check that the Toner Concentration (TC) is calibrated correctly [9-21-4]. If the print quality defect is still present, go to the Print Defects in this section. Print Quality 03/2003 Print Quality Initialization Procedure, Print Defects 8850/ 510DP...
Page 58: Print Quality Definitions
This is the darkness and uniformity for a line. Misregistration This is when the distance from the lead edge of the image to the lead edge of the media is not within specification. Print Quality 03/2003 Print Quality Definitions 8850/ 510DP...
Page 59: Print Quality General Diagnostics
Solid Area Density (A) Uniformity This term refers to the image density of a totally black portions of the same print. (Figure 1) Use a wide roll of media and run test pattern Print Quality 03/2003 Print Quality General Diagnostics, Print Quality 8850/ 510DP...
Page 60 [9-55-5]. Select the image blocks and use the SIR 201.01 reference scale to measure the den- sity SPECIFICATION: Bond Media - No breaks in horizontal or vertical lines. Film - No breaks in lines. Print Quality 03/2003 Print Quality Specifications 8850/ 510DP...
Page 61 Linearity of lines refers to the straightness of the horizontal, vertical and diagonal lines. SPECIFICATION: Horizontal (D1) 812.8 mm +/- 4.0 mm (50 blocks) Vertical (D2) 975.4 mm +/- 5.0 mm (60 blocks) Print Quality 03/2003 Print Quality Specifications 8850/ 510DP...
Page 62 Cut Accuracy This is the dimension of variance from a true, horizontal cut. SPECIFICATION: +/- 4 mm Print Quality 03/2003 Print Quality Specifications 8850/ 510DP...
Page 63: Damaged Media
4. Wrinkle 4a. Damage or obstruction in 4a. Clear the media path of a. Bond media less than 20 lb may perform b. After all media checks, test with fresh Xerox This is damage that is proba- the media path. obstructions.
Page 64: Print Quality Raps
Receiver PWB and the LED Image Bar). 8. Photoreceptor Drive Motor Check at the Encoder is Encoder not installed or oper- installed correctly (REP 9.23). ating correctly. Replace the Encoder 9.1). Print Quality 03/2003 PQ 1, PQ 2 3-10 8850/ 510DP...
Page 65: Pq 3 Bands
8. Defective Detack Corotron. 8. Check / replace the installed Drum Encoder. installed correctly (REP 9.23) Detack Corotron. 8.3). Drum Drive Motor Replace the Encoder or Drum Drive Motor 9.1) Print Quality 03/2003 PQ 3, PQ 4 8850/ 510DP 3-11...
Page 66: Pq 5 Black Prints
LED, 5VDC, RS422, Signal Harness, Receiver PWB. 5. No Drum drive / defective 5. Refer to BSD 4.3 Drum. check for correct Drum drive. Replace the Drum (REP 9.3). Print Quality 03/2003 PQ 5, PQ 6 3-12 8850/ 510DP...
Page 67: Pq 7 Blurred Image
7. Fuser Heat Roll / Pressure 7. Determine and fix the Roll cause of the damage to the Rolls. Replace the rolls (REP 10.2, 10.8). 8. Defective Drum 8. Replace the Drum (REP 9.3). Print Quality 03/2003 PQ 7, PQ 8 8850/ 510DP 3-13...
Page 68: Pq 9 Deletions (Bands) (Non-Feed Direction)
7. BTR Spacing Rollers not 7. Check/ clean/ replace as damaged. Rolls. Replace the rolls (REP contacting Drum required 8.3). 10.2, 10.8). 8. Damaged Drum Drive 8. Replace the Drum Drive Encoder Motor 9.1) Print Quality 03/2003 PQ 9, PQ 10 3-14 8850/ 510DP...
Page 69: Pq 11 Deletions (Spots)
Roll is damaged. Could also Rolls. Replace the Roll(s) be caused by Incorrect Oiler (REP 10.2, 10.8) operation. 7. Defective Drum Replace the Drum (REP 9.3). Print Quality 03/2003 PQ 11, PQ 12 8850/ 510DP 3-15...
Page 70: Pq 13 Light Image
6. Defective Drum ground. 6. Ensure that the Drum is correctly grounded. 7. Defective Drum. 7. Replace the Drum (REP 9.3). 8. Developer Housing 8. Ensure the housing is latched securely. Print Quality 03/2003 PQ 13, PQ 14 3-16 8850/ 510DP...
Page 71: Pq 15 Residual Image
2. Defective Erase Bar 2. Refer to BSD 9.6 check the Erase Bar. Replace the lamp if necessary 9.2). 3. Contaminated Drum Replace the Drum (REP 9.3). 4. Incorrect vellum Print Quality 03/2003 PQ 15, PQ 16 8850/ 510DP 3-17...
Page 72: Pq 17 Smears
Drum Drum Buildup of devel- Push excess devel- oper material on the oper material back lower extrusion of into the housing. the developer hous- rubbing developed image on the Drum. Print Quality 03/2003 PQ 17, PQ 17A 3-18 8850/ 510DP...
Page 73: Pq 18 Spots
Drum evenly. Spacer Rolls on the Devel- oper Housing 9.10). 5B. Ensure that the housing is latched securely. 6. Defective Drum 6. Clean or replace the Drum (REP 9.3). Print Quality 03/2003 PQ 18, PQ 19 8850/ 510DP 3-19...
Page 74: Pq 20 Unfused Prints
5. Incorrect fuser temperature 5. Adjust Fuser Temperature (ADJ 10.1). Registration Rolls mis- Replace the rolls as aligned. required 8.2). 7. Exit Rolls damaged or mis- 7. Replace the Exit Rolls aligned 10.4) Print Quality 03/2003 PQ 20, PQ 21 3-20 8850/ 510DP...
Page 75: Pq 22 Offsetting
5. Damaged or contaminated 5. Clean or replace the Fuser Fuser Heat Roll Heat Roll (REP 10.2). 6. Damaged or contaminated 6. Clean or replace the Pres- Pressure Roll sure Roll (REP 10.8). Print Quality 03/2003 PQ 22, PQ 23 8850/ 510DP 3-21...
Page 76 Print Quality 03/2003 PQ 22, PQ 23 3-22 8850/ 510DP...
Page 77 4-55 ADJ 9.6 Augers ....................... 4-153 Xerographics ADJ 10.1 Fuser Temperature (NVM) ................4-154 ADJ 10.2 Fuser Drive Interlock Switch 8850 W/O Tag 8 ..........4-155 REP 9.1 Xerographic Module..................4-57 ADJ 10.3 Fuser Drive Motor.................... 4-156 REP 9.2 Drum Assembly ....................
Page 78 Repairs and Adjustments 03/2003 8850/ 510DP...
Page 79: Rep 3.1 Main Pwb (A3)
(Figure 1): Remove the Controller or (Figure 2): Remove the P193 Interface Cover. Lift out the Controller Disconnect connectors and set it on the floor A1P5 and J610 Figure 1 (8850) Removing the Controller Repairs and Adjustments 03/2003 REP 3.1 8850/ 510DP...
Page 80 PWB off the standoffs to remove the PWB Disconnect the Controller Communications Cable Figure 3 Removing the Main PWB (A3) Figure 2 Remove the Rear Cover (Figure 3): Remove the Main PWB.(A3) Repairs and Adjustments 03/2003 REP 3.1 8850/ 510DP...
Page 81: Rep 3.2 Xerographic High Voltage Power Supply (Hvps 1)
Replace the NVM Chip on the new Main PWB with the NVM Chip removed from the old Main PWB. Switch off the Main Power Switch. Disconnect the Power Cord. Check the Xerox Technical Service Bulletins (TSBs) or current bulletins to determine the Removal current version of software to be installed on the Main PWB.
Page 82 Grid wire Scorotron wire J2 HVPS Relay Cases Disconnect the BTR wire J5 Disconnect ground Disconnect the Disconnect wires Detack Corotron wire A25P1 Figure 1 Removing the Xerographic High Voltage Power Supply Repairs and Adjustments 03/2003 REP 3.2 8850/ 510DP...
Page 83: Rep 3.3 Sps 510Dp Control Panel
Figure 2 Reinstalling the Xerographic HVPS If a new Xerographic High Voltage Power Supply is being installed, perform the Electro- static Series 9.2. Disconnect the Connector Figure 1 Preparing to Remove the Control Panel Panel Repairs and Adjustments 03/2003 REP 3.2, REP 3.3 8850/ 510DP...
Page 84 Replacement The replacement is the reverse of the removal. Repairs and Adjustments 03/2003 REP 3.3 8850/ 510DP...
Page 85: Rep 7.1 Roll Media Supply Drawer
Open the Roll Media Supply Drawer that is to be removed. (Figure 1): Remove the Cover. Remove the Cover Remove the screws (one each side) Figure 1 Removing the Cover (Figure 2): Remove the Roll Media Supply Drawer. Repairs and Adjustments 03/2003 REP 7.1 8850/ 510DP...
Page 86: Rep 7.2 Rewind Gear And Rewind Internal Gear
Remove the roll of media. (Figure 1): Remove the Rewind Gear and the Rewind Internal Gear. Remove the Roll Media Supply Drawer Figure 2 Removing the Roll Media Supply Drawer Repairs and Adjustments 03/2003 REP 7.1, REP 7.2 4-10 8850/ 510DP...
Page 87: Rep 7.3 Roll Feed Pinch Rolls
Removal Open the Roll Media Supply Drawer. (Figure 1): Remove the Roll Feed Pinch Rolls. Remove the Rewind Remove the E-ring Internal Gear Figure 1 Removing the Rewind Gears Repairs and Adjustments 03/2003 REP 7.2, REP 7.3 8850/ 510DP 4-11...
Page 88: Rep 7.4 Roll Feed Drive Roll
(Figure 1): Remove the Roll Feed Drive Roll. Remove an E-ring from one end of the Roll Feed Pinch Roll Shaft to access the Pinch Rolls Figure 1 Removing the Roll Feed Pinch Rolls Repairs and Adjustments 03/2003 REP 7.3, REP 7.4 4-12 8850/ 510DP...
Page 89 Remove the bearing Remove the bearing Remove the E- ring Remove the E-Ring Remove the Roll Feed Drive Roll Figure 1 Removing the Roll Feed Drive Roll Repairs and Adjustments 03/2003 REP 7.4 8850/ 510DP 4-13...
Page 90: Rep 7.5 Feed Clutch
E-Ring Remove the chain Remove the E-Ring Move the Motor Bracket to Remove the sprocket relieve the tension on the chain Loosen the screws (2) Figure 1 Removing the Feed Clutch Repairs and Adjustments 03/2003 REP 7.5 4-14 8850/ 510DP...
Page 91: Rep 7.6 Rewind Clutch
Move the Motor Bracket to relieve the tension on the chain Remove the sprocket Loosen the screws (2) Remove the E-ring Figure 1 Removing the Rewind Clutch REP 7.7 Motion Sensor Repairs and Adjustments 03/2003 REP 7.6, REP 7.7 8850/ 510DP 4-15...
Page 92 Figure 2 Reinstalling the Encoder Disk Disconnect the connector Remove the Rewind Housing Remove the screws (3) Remove the Encoder Disk Figure 1 Removing the Motion Sensor Replacement Reinstall the Motion Sensor and the Rewind Housing. Repairs and Adjustments 03/2003 REP 7.7 4-16 8850/ 510DP...
Page 93: Rep 7.9 Roll Drive Motor
Remove the Replacement spring After installing the Roll Drive Motor, W/O Tag 11, allow the spring to adjust the chain tension then tighten the screws. 8850 W/Tag 11 and 510dp, adjust the Media Roll Drive Chain (ADJ Remove 7.1) the screws...
Page 94: Rep 7.10 Lower Media Roll Heater
Switch off the Main Power Switch. Disconnect the Power Cord. Removal Loosen the screws and open the Rear Door. Remove the screw Disconnect the connector Remove the Lower Media Roll Heater Figure 1 Removing the Lower Media Roll Heater Repairs and Adjustments 03/2003 REP 7.10 4-18 8850/ 510DP...
Page 95: Rep 7.11 Upper Media Roll Heater
Remove the screws (2) Slide the Media Roll and lift out the Upper Heater out from Heater Media Roll Heater and Guard Guard Figure 1 Removing the Upper Media Roll Heater Repairs and Adjustments 03/2003 REP 7.11 8850/ 510DP 4-19...
Page 96: Rep 7.12 Encoder Disk
Encoder Disk Align the open slot in the Encoder Disk with the opening in the housing Figure 2 Reinstalling the Encoder Disk Remove the Encoder Figure 1 Removing the Encoder Disk Repairs and Adjustments 03/2003 REP 7.12 4-20 8850/ 510DP...
Page 97: Rep 7.14 Sheet Feed Pinch Rolls
Step 2 Figure 2 Preparing to Remove the Upper Sheet Feed Housing Figure 1 Accessing the Fuser Module (Figure 2) Prepare to remove the Upper Sheet Feed Housing from the Fuser. Repairs and Adjustments 03/2003 REP 7.14 8850/ 510DP 4-21...
Page 98 Lower the Upper Sheet Feed Housing and pull to the left to remove the tabs from the right side frame Figure 3 Removing the Upper Sheet Feed Housing Figure 4 Removing the Pinch Roll Cover Repairs and Adjustments 03/2003 REP 7.14 4-22 8850/ 510DP...
Page 99 The replacement is the reverse of the removal. Ensure that the spring is applying pressure on the shaft. Remove the Rolls Remove the Shaft from the frame Figure 5 Removing the Pinch Rolls Repairs and Adjustments 03/2003 REP 7.14 8850/ 510DP 4-23...
Page 100 Repairs and Adjustments 03/2003 REP 7.14 4-24 8850/ 510DP...
Page 101: Rep 8.1 Lower Sheet Feed Assembly
Lower Sheet Feed Assembly Figure 2 Preparing the Lower Sheet Feed Assembly for Removal (Right Side) Remove the two mount screws Figure 1 Preparing the Lower Sheet Feed Assembly for Removal (Left Side) Repairs and Adjustments 03/2003 REP 8.1 8850/ 510DP 4-25...
Page 102 Figure 3 Removing the Lower Sheet Feed Assembly From the Printer Place the Lower Sheet Feed Assembly on a clean, flat surface. Replacement (Figure 4): Prepare the Lower Sheet Feed Assembly for reinstallation into the Printer. Repairs and Adjustments 03/2003 REP 8.1 4-26 8850/ 510DP...
Page 103 Reinstall the four screws that fasten the on printer floor plate and slide it Lower Sheet Feed Assembly to the inward Printer (two screws per side) Figure 5 Reinstalling the Lower Sheet Feed Assembly Repairs and Adjustments 03/2003 REP 8.1 8850/ 510DP 4-27...
Page 104 (Figure 6): Reconnect P/J A28J1 on the left side of the Lower Sheet Feed Assembly. P/J A28J1 Figure 6 Reconnecting P/J A28J1 Reinstall the Xerographic Module. Perform REP 8.1 Xerographic Module. Close the Printer Top Cover. Return the Printer to normal operation. Repairs and Adjustments 03/2003 REP 8.1 4-28 8850/ 510DP...
Page 105: Rep 8.2 Media Transport Module
(Figure 1): Open the Printer Front Cover (beneath the Control Panel) and release the spring tension on the Shaft Release Pin. Loosen the phillips screw slightly and rotate the bracket downward Figure 1 Releasing the Tension on the Shaft Release Pin Repairs and Adjustments 03/2003 REP 8.2 8850/ 510DP 4-29...
Page 106 Figure 2 Removing the Fuser Drive Gear from the Printer Figure 3 Disconnecting the Connectors (Figure 3): Remove the following connectors and ground strap from the left of the Media Transport Module (view from paper feed side of Printer). Repairs and Adjustments 03/2003 REP 8.2 4-30 8850/ 510DP...
Page 107 Shaft into the Shaft Release Pin, Release Pin compressing it Figure 5 Reinstalling the Media Transport Module (Figure 3): Reattach the connectors on the left side of the Media Transport Module. Reinstall the Fuser Drive Gear. Repairs and Adjustments 03/2003 REP 8.2 8850/ 510DP 4-31...
Page 108: Rep 8.3 Sheet Feed Sensor
Reinstall the Developer Module (if removed). Reinstall the Lower Sheet Feed Assembly. Return the Printer to normal operation. Figure 1 Removing the Vacuum Baffles Turn the Lower Sheet Feed Assembly over. Repairs and Adjustments 03/2003 REP 8.2, REP 8.3 4-32 8850/ 510DP...
Page 109: Rep 8.4 Stack Height Sensor
Disconnect P/J xxx the Lower Transport frame and remove Figure 2 Removing the Sheet Feed Sensor Allow Fuser Module Cover to drop downward Figure 1 Releasing the Fuser Drawer Latches Repairs and Adjustments 03/2003 REP 8.3, REP 8.4 8850/ 510DP 4-33...
Page 110 Remove the Spring Clip, then compress locking tabs and push Stack Height Sen- sor Assembly up through cutout in cover Figure 3 Removing the Stack Height Sensor Figure 2 Detaching the Stack Height Sensor Repairs and Adjustments 03/2003 REP 8.4 4-34 8850/ 510DP...
Page 111: Rep 8.5 Sheet Feed Drive Motor (Mot 1)
Figure 2 Removing the Sheet Feed Drive Motor Outline the current motor’s position on the Lower Transport Frame with a pencil Figure 1 Preparing the Sheet Feed Drive Motor for Removal Repairs and Adjustments 03/2003 REP 8.5 8850/ 510DP 4-35...
Page 112: Rep 8.6 Sheet Feed Drive Belt
Lower Transport Frame with a pencil Figure 1 Preparing to Remove the Sheet Feed Drive Belt (Figure 2): Turn the Lower Sheet Feed Assembly over and remove the Sheet Feed Drive Belt. Repairs and Adjustments 03/2003 REP 8.6 4-36 8850/ 510DP...
Page 113: Rep 8.7 Sheet Feed Drive Roll
Slide the gear off the shaft of the Sheet Feed Drive Roll Gear Figure 2 Removing the Sheet Drive Roll Gear Figure 1 Removing the Vacuum Baffles (Figure 2): Remove the Sheet Feed Drive Roll Gear. Repairs and Adjustments 03/2003 REP 8.7 8850/ 510DP 4-37...
Page 114 Remove the E-ring Remove the bearing Figure 4 Removing the Mounting Hardware from the Right Side Figure 3 Removing the Mounting Hardware from the Left Side Turn the Lower Sheet Feed Assembly over. Repairs and Adjustments 03/2003 REP 8.7 4-38 8850/ 510DP...
Page 115 Drive Motor Withdraw the opposite end from the Lower Sheet Feed Assembly first Figure 6 Removing the Sheet Drive Roll Figure 5 Preparing to Remove the Sheet Feed Drive Roll Repairs and Adjustments 03/2003 REP 8.7 8850/ 510DP 4-39...
Page 116: Rep 8.8 Media Registration Sensor
Disconnect the connector Lift the Baffle off the Media Transport Remove the five screws Module on Baffle Figure 1 Removing the Baffle Figure 1 Removing the Media Registration Sensor Repairs and Adjustments 03/2003 REP 8.8, REP 8.12 4-40 8850/ 510DP...
Page 117 Remove the two bearings (one at each end) Registration Support Assembly Figure 2 Rotating the Registration Support Assembly Figure 3 Removing the Registration Pinch Rolls Repairs and Adjustments 03/2003 REP 8.12 8850/ 510DP 4-41...
Page 118 (one each side) Reinstall the two outer E-rings (one each side) Registration Support Assembly Figure 5 Rotating the Registration Support Assembly Forward Figure 4 Reinstalling the Registration Pinch Roll Assembly Repairs and Adjustments 03/2003 REP 8.12 4-42 8850/ 510DP...
Page 119 Figure 6 Reinstalling the Springs Complete the reassembly of the Printer and perform the following: Fuser Temperature (NVM) 10.1. Vertical Magnification 8.1. Lead Edge Registration 8.2. Cut Length 8.3. Repairs and Adjustments 03/2003 REP 8.12 8850/ 510DP 4-43...
Page 120: Rep 8.13 Media Transport Drive Motor And Belt
Drive Belt Drive Motor Idler Pulley Disconnect M1P 1 from the Media Remove the three motor Transport Drive Motor mount screws Figure 1 Removing the Media Transport Drive Motor and Belt Repairs and Adjustments 03/2003 REP 8.13 4-44 8850/ 510DP...
Page 121: Rep 8.14 Cutter Home Sensor
Rotate the sensor downward and Disengage the two mount stubs remove it from the mount bracket Remove the wire from the mount clip Disconnect Q1P1 Figure 1 Removing the Cutter Home Sensor Repairs and Adjustments 03/2003 REP 8.14 8850/ 510DP 4-45...
Page 122: Rep 8.15 Media Exit Pinch Roll
REP 8.15 Media Exit Pinch Roll NOTE: There are two Media Exit Pinch Rolls on the 8850/510dp Printer. The removal pro- cedure is the same for both. Parts List on PL 14.2 WARNING Remove the retaining spring Remove the E-ring Switch off the Main Power Switch.
Page 123 Close the Fuser Module Drawer. Reinstall the Media Exit Pinch Roll into the Printer, ensuring that the washers and E-ring are correctly mounted. (Figure 4): Reinstall the Retaining Spring on the Media Exit Pinch Roll. Repairs and Adjustments 03/2003 REP 8.15 8850/ 510DP 4-47...
Page 124: Rep 8.16 Media Exit Drive Roll
Printer Figure 2 Removing the Upper Sheet Feed Housing Allow Fuser Module Cover to drop downward Figure 1 Releasing the Fuser Drawer Latches (Figure 2): Remove the Upper Sheet Feed Housing. Repairs and Adjustments 03/2003 REP 8.16 4-48 8850/ 510DP...
Page 125 Remove the E-ring Remove the Exit Roll Drive Gear and Drive Belt Figure 3 Removing the Fuser Exit Sensor Figure 4 Removing the Printer Right Side Hardware Repairs and Adjustments 03/2003 REP 8.16 8850/ 510DP 4-49...
Page 126 Drive Pulley & bearing Figure 5 Removing the Printer Left Side Hardware Remove the Media Exit Drive Roll from the Printer. Figure 6 Identifying the Right Side of Exit Drive Roll Shaft Repairs and Adjustments 03/2003 REP 8.16 4-50 8850/ 510DP...
Page 127 (Figure 8): Reinstall the Printer right side hardware. Reinstall the Upper Sheet Feed Housing. Swing closed the Fuser Module Front Cover. Close the Fuser Module Drawer. Return the Printer to normal operation. Repairs and Adjustments 03/2003 REP 8.16 8850/ 510DP 4-51...
Page 128: Rep 8.17 Registration Drive Roll
Remove the spring from the mount hooks on both sides of the Media Transport Module Figure 1 Pivoting Back the Registration Pinch Roller Extrusion (Figure 2): Remove the Front and Rear Media Shields. Repairs and Adjustments 03/2003 REP 8.17 4-52 8850/ 510DP...
Page 129 Figure 3 Removing the Detack Corotron and End Blocks port Assembly (Figure 4): Remove the Bias Transfer Roll (BTR) and BTR Extrusion from the Upper Figure 4 Removing the Bias Transfer Roll and BTR Extrusion Transport Assembly. Repairs and Adjustments 03/2003 REP 8.17 8850/ 510DP 4-53...
Page 130 Reinstall the two mount screws on each side. (Figure 6): Reinstall the Detack Corotron onto the Right and Left End Blocks prior to rein- stalling the Detack Corotron into the Upper Transport Assembly. Repairs and Adjustments 03/2003 REP 8.17 4-54 8850/ 510DP...
Page 131: Rep 8.18 Detack Corotron/Btr Extrusion
Remove the 2 Screws Figure 2 . Removing the Right Side Screws Figure 1 . Removing the Left Side Screws (Figure 2): Remove the Fthe two screws from the Right Side End Plate. Repairs and Adjustments 03/2003 REP 8.18 8850/ 510DP 4-55...
Page 132 (Figure 3): Remove the Detack Corotron and End Blocks from the Upper Transport Assembly. Rotate the Extrusion up to remove Figure 3 Removing the Detack Corotron/BTR Extrusion Replacement The replacement is the reverse of the Removal. Repairs and Adjustments 03/2003 REP 8.18 4-56 8850/ 510DP...
Page 133: Rep 9.1 Xerographic Module
(Figure 1): Lift the Printer Image Module. Lift Image Module to fully opened position Remove the ground strap from the frame Figure 1 Lifting the Image Module Figure 1 Removing the Xerographic Module Repairs and Adjustments 03/2003 REP 9.1, REP 9.2 8850/ 510DP 4-57...
Page 134 (Figure 3): Release the spring tension on the brackets located at either end of the Xero- graphic Module. Push bracket back to the horizontal position Figure 3 Releasing the Spring Tension on the Bracket Repairs and Adjustments 03/2003 REP 9.2 4-58 8850/ 510DP...
Page 135 Figure 4 Elevating the Xerographic Module to Service Position NOTE: In the following steps, the terms “Left” and “Right” describe machine locations as observed from the Roll Media Supply Drawer side of the Printer. Repairs and Adjustments 03/2003 REP 9.2 8850/ 510DP 4-59...
Page 136 Figure 6 Releasing the Bearing (Left Side) out of the Frame CAUTION In the following step avoid placing the Drum Assembly in areas where it may be accidentally knocked over or exposed to bright sunlight. Repairs and Adjustments 03/2003 REP 9.2 4-60 8850/ 510DP...
Page 137: Rep 9.3 Drum
(Figure 1): Carefully place the Drum Assembly, Gear Box down, in a safe place on the floor. Drum Assembly Gear Box Figure 8 Temporary Placement of the Drum Assembly Gear Box Figure 1 Temporary Placement of the Drum Assembly Repairs and Adjustments 03/2003 REP 9.2, REP 9.3 8850/ 510DP 4-61...
Page 138 If the Drum is being replaced, install a Cleaner Blade Kit (REP 9.4). Reassemble the Drum Assembly. Perform 4) Drum Cleaning Enhancement procedure. Reinstall the Drum Assembly. Perform the Electrostatic Series (ADJ 9.2). Repairs and Adjustments 03/2003 REP 9.3 4-62 8850/ 510DP...
Page 139: Rep 9.4 Cleaner Blade Kit
Use a vacuum cleaner to clean the channels and the areas where the new parts will be installed. Blade Retainer (3) Photoreceptor Seal Channel Cleaner Blade Figure 1 Removing the Cleaner Blade Repairs and Adjustments 03/2003 REP 9.4 8850/ 510DP 4-63...
Page 140 Install the first of the three Blade Retainers approximately one inch from the Xerographic Photoreceptor Module Frame, working to the left. Seal Blade Retainer (3) Cleaner Blade Figure 2 Installing the Cleaner Blade Kit Repairs and Adjustments 03/2003 REP 9.4 4-64 8850/ 510DP...
Page 141 Ensure that the seal is flush against the Xerographic Module Frame. Left-hand Seal Perform GP 4 Drum Cleaning Enhancement procedure. Photoreceptor Seal Cleaner Blade Blade Retainer (3) Figure 3 Installing the Cleaner Blade Kit Repairs and Adjustments 03/2003 REP 9.4 8850/ 510DP 4-65...
Page 142: Rep 9.5 Developer Module
(Figure 1): Remove the Toner Cartridge. Clean the toner from the holes in the dispense area and place a piece of tape Remove the Toner over the holes Dust Trap Figure 1 Removing the Toner Cartridge Repairs and Adjustments 03/2003 REP 9.5 4-66 8850/ 510DP...
Page 143 Slide the gear to the left Developer Module Clamp Bar (one each end) from the Printer Disconnect A22P1 8850 W/TAG 2 and SPS 510dp: Disconnect the Move the Gear Developer Heater Retainer into the groove on the gear Figure 2 Removing the Developer Module...
Page 144 Lift the Gear Module back in the Retainer Printer and push it to the left (drive side) Reconnect A22P1and 8850 W/TAG 2/SPS 510dp connect the developer heater Press tab and swing up Clamp Bar until it locks (one each end)
Page 145 Pull the plunger and then reinstall the Toner Cartridge Remove the tape Figure 4 Reinstalling the Toner Cartridge If new Developer Material has been installed, perform 8, Toner Control System Cali- bration. Repairs and Adjustments 03/2003 REP 9.5 8850/ 510DP 4-69...
Page 146: Rep 9.6 Cartridge Drive Motor
Figure 2 Removing the Cartridge Drive Motor from the Mounting Plate Ground Strap Disconnect P/J P1 (attached to motor) Figure 1 Removing the Cartridge Drive Motor (Figure 2): Remove the Cartridge Drive Motor from the Mounting Plate. Repairs and Adjustments 03/2003 REP 9.6 4-70 8850/ 510DP...
Page 147: Rep 9.7 Developer Material
Shield from under Shield the edge (full length) Figure 1 Removing the Sump Shield from the Developer Module NOTE: In the following step rotate the Developer Module away from the Magnetic Roll. Repairs and Adjustments 03/2003 REP 9.7 8850/ 510DP 4-71...
Page 148 If the factory setting of the augers is changed during the procedure, perform the adjustment procedure, Augers (ADJ 9.6). Magnetic Roll Rotate the gear counterclockwise Rotate the Developer Module Figure 2 Dumping the Developer Material Repairs and Adjustments 03/2003 REP 9.7 4-72 8850/ 510DP...
Page 149 CAUTION Ensure that the entire length of the tube on the Developer Module is clear of any developer. Using a vacuum cleaner, clean the housing where the Pressure Equalizer Tubes attach. Repairs and Adjustments 03/2003 REP 9.7 8850/ 510DP 4-73...
Page 150 Printer. Excessive rotation or lateral swaying of the module can cause the Devel- oper material to shift, resulting in diagnostic or image quality faults. (Figure 5): Reinstall the Pressure Equalizer Tubes. Repairs and Adjustments 03/2003 REP 9.7 4-74 8850/ 510DP...
Page 151 Reinstall the gear Reinstall the gear and the Grip Ring Reinstall the gear Reinstall the Pressure Equalizer Tube Retainer Reinstall the Pressure Equalizer Tube Figure 4 Reinstalling the Pressure Equalizer Tubes Repairs and Adjustments 03/2003 REP 9.7 8850/ 510DP 4-75...
Page 152 Figure 6 Reinstalling the Sump Shield in the Developer Module Rear Auger the non-drive side Reinstall the Air Filter on the back of the Developer Module (2 screws). Figure 5 Installing the Developer Material Repairs and Adjustments 03/2003 REP 9.7 4-76 8850/ 510DP...
Page 153 Top Shield Reinstall the screws (2) Reinstall the Top Shield Figure 7 Reinstalling the Top Shield (Figure 1): Reinstall the Sump Filter onto the Developer Module. Reinstall the Developer Module (REP 9.5). Repairs and Adjustments 03/2003 REP 9.7 8850/ 510DP 4-77...
Page 154 Figure 8 Reinstalling the Toner Cartridge Switch on the Printer and after warm-up, run diagnostic [9 - 21- 4] for sixty seconds. 10. Refer to Section 6 and perform GP 8 Toner Control System Calibration. Repairs and Adjustments 03/2003 REP 9.7 4-78 8850/ 510DP...
Page 155: Rep 9.8 Scorotron Pin Kit
Rotate the Image Module to the Service Position. (Figure 1): Remove the Scorotron Assembly from the Printer and place it on a flat surface. Remove the Scorotron Assembly Figure 1 Removing the Scorotron Assembly Repairs and Adjustments 03/2003 REP 9.8 8850/ 510DP 4-79...
Page 156 WARNING Remove the Torsion Springs from the End Blocks. Exercise extreme care when handling the Pin Array. It contains very sharp pins and can cause cuts or punctures if handled carelessly. Repairs and Adjustments 03/2003 REP 9.8 4-80 8850/ 510DP...
Page 157: Rep 9.9 Detack Corotron
Media Shields meet. This mark will prove helpful when reinstalling the shields. Plastic Media Shields (2) Place a pencil mark where the Media Shields meet Figure 1 Marking the Location of the Media Shields Repairs and Adjustments 03/2003 REP 9.8, REP 9.9 8850/ 510DP 4-81...
Page 158 Remove the voltage lead from and stretch the Pin Array to its the Left End Block maximum width Figure 3 Removing the Detack Corotron Set the Detack Corotron on a clean, flat surface. Repairs and Adjustments 03/2003 REP 9.9 4-82 8850/ 510DP...
Page 159 NOTE: (Figure 1): When reinstalling the Media Shields It may prove helpful to align the inner edge of each shield with the pencil mark drawn in Step 3 of the Removal Procedure. Repairs and Adjustments 03/2003 REP 9.9 8850/ 510DP 4-83...
Page 160: Rep 9.11 Toner Sensor
If a new Toner Sensor has been installed, perform GP 8 Toner Control System Calibra- tion. Perform the Electrostatic Series. Perform ADJ 9.2 Electrostatic Series. Repairs and Adjustments 03/2003 REP 9.11 4-84 8850/ 510DP...
Page 161: Rep 9.12 Toner Cartridge Home Sensor
(Figure 1): Remove the Toner Cartridge Home Sensor. Remove the Toner Cartridge Home Sensor from the threaded mount hole Straighten the wires Remove the wire from Disconnect P1 the fastener Figure 1 Removing the Toner Cartridge Home Sensor Repairs and Adjustments 03/2003 REP 9.12 8850/ 510DP 4-85...
Page 162 4 Reinstall the gear Position the tab at the bottom Reinstall the motor, the two Reinstall the E-ring mount screws and the Ground Wire Figure 2 Reinstalling the Cartridge Drive PLate Repairs and Adjustments 03/2003 REP 9.12 4-86 8850/ 510DP...
Page 163 (2), being careful not to drive the screws through the Top Shield Reinstall the Reinstall the Top Shield screws (2) Figure 3 Reinstalling the Top shield Reinstall the Developer Module (REP 9.5). Repairs and Adjustments 03/2003 REP 9.12 8850/ 510DP 4-87...
Page 164: Rep 9.13 Sump Shield
Remove the Top Shield Remove the Sump Shield from the Printer Remove the Sump Shield from under the edge (full length) Figure 1 Removing the Sump Shield from the Developer Module Repairs and Adjustments 03/2003 REP 9.13 4-88 8850/ 510DP...
Page 165 (Figure 2): Reinstall the Sump Shield on the Developer Module. Reinstall the Sump Shield under the edges on the housing Reinstall the Sump Shield Figure 2 Reinstalling the Sump Shield in the Developer Module Repairs and Adjustments 03/2003 REP 9.13 8850/ 510DP 4-89...
Page 166: Rep 9.14 Cartridge Drive Plate
Remove the two motor mount screws Remove the E-ring and gear Loosen the screws (2) Disconnect Remove the screws (2) Remove the Top Shield Figure 1 Removing the Cartridge Drive Plate Repairs and Adjustments 03/2003 REP 9.14 4-90 8850/ 510DP...
Page 167 4 Position the tab at the bottom Reinstall the gear and Reinstall the motor, the two E-ring mount screws and the Ground Wire Figure 2 Reinstalling the Cartridge Drive Plate Repairs and Adjustments 03/2003 REP 9.14 8850/ 510DP 4-91...
Page 168 Connect P1 careful not to drive the screws through the Top Shield Reinstall the Reinstall the Top Shield screws (2) Figure 3 Reinstalling the Top Shield Reinstall the Developer Module (REP 9.5). Repairs and Adjustments 03/2003 REP 9.14 4-92 8850/ 510DP...
Page 169: Rep 9.18 Pressure Equalizer Tubes
Remove the Pres- Remove the sure Equalizer Tube retainer Remove the Grip Remove the three Ring gears Remove the screw Remove the Pressure Equalizer Tube Figure 1 Removing the Pressure Equalizer Tubes Repairs and Adjustments 03/2003 REP 9.18 8850/ 510DP 4-93...
Page 170 Grip Ring gear Reinstall the Pres- sure Equalizer Tube Retainer Reinstall the Pres- sure Equalizer Tube Figure 2 Reinstalling the Pressure Equalizer Tubes Reinstall the Developer Module (REP 9.5). Repairs and Adjustments 03/2003 REP 9.18 4-94 8850/ 510DP...
Page 171: Rep 9.19 Roller Kit
Using pliers, pull out the pin Figure 1 Removing the Front and Rear Rollers Replacement Replace the roller and pin with parts from the kit. Repeat the procedure at the rear of the Image Module. Repairs and Adjustments 03/2003 REP 9.19 8850/ 510DP 4-95...
Page 172: Rep 9.20 Image Module
Remove the High Voltage Power Supply (REP 3.2). NOTE: In the following steps, cut cable ties as necessary in order to remove the harness. (Figure 1): (8850) Prepare to remove the Top Cover (Front). (510dp)j Remove the Control Panel (REP XX.x Repairs and Adjustments 03/2003 REP 9.20...
Page 173 Figure 2 Top Cover Interlock Plate Close the Developer Module Cover and lift off the Top Cover, being careful to disengage the small pin from the Interlock Plate. Open the Cutter Drawer. Repairs and Adjustments 03/2003 REP 9.20 8850/ 510DP 4-97...
Page 174 Figure 5 Pull the Video Cable through the Hole in Frame Release the Video Cable from the cable clamps Figure 4 Preparing the Video Cable for Removal Repairs and Adjustments 03/2003 REP 9.20 4-98 8850/ 510DP...
Page 175 Image Module Release the cable Figure 6 Preparing the Video Cable 13. (Figure 7): Disconnect A5P2 and prepare the harness for removal. Main PWB Figure 7 Preparing the Harness for Removal Repairs and Adjustments 03/2003 REP 9.20 8850/ 510DP 4-99...
Page 176 NOTE: Observe the way that the spring rests on the frame, underneath the cable clamp. This is how the reassembled parts must fit. 15. (Figure 9): Complete the removal preparation on the front area of the Image Module Assembly. Repairs and Adjustments 03/2003 REP 9.20 4-100 8850/ 510DP...
Page 177 Remove the bolt Figure 10 Preparing to Remove the Image Module Assembly (View looking at the Rear from the Right Side) 17. Lift out the Image Module Assembly / Pivot Bar combination. Repairs and Adjustments 03/2003 REP 9.20 8850/ 510DP 4-101...
Page 178: Rep 9.21 Erase Bar
(Figure 1): Remove the Erase Bar, located on the right side of the Xerographic Module. Remove the screw and slide the Erase Bar out of the Printer Figure 1 Removing the Erase Bar Repairs and Adjustments 03/2003 REP 9.21 4-102 8850/ 510DP...
Page 179: Rep 9.22 Bias Transfer Roll (Btr)
NOTE: The following procedure can be accomplished as shown, or it can be made easier by first removing the Xerographic Module (REP 9.1). (Figure 1): Remove the two Media Shields from the Printer. Plastic tabs Figure 1 Removing the two Media Shields Repairs and Adjustments 03/2003 REP 9.22 8850/ 510DP 4-103...
Page 180 NOTE: When reinstalling the Bias Trans- fer Roll ensure that the geared end of the BTR is located on the same side as the Drum Drive Motor Figure 2 Removing the Bias Transfer Roll (BTR) Repairs and Adjustments 03/2003 REP 9.22 4-104 8850/ 510DP...
Page 181: Rep 9.23 Drum Encoder Assembly
3): Release the spring tension on the brackets located at either end of the Xero- Lift Image Module to fully opened graphic Module. position Figure 1 Lifting the Image Module (Figure 2): Pull open the Fuser Drawer. Repairs and Adjustments 03/2003 REP 9.23 8850/ 510DP 4-105...
Page 182 Xerographic Module Figure 4 Elevating the Xerographic Module to Service Position Push bracket back to the horizontal position Figure 3 Releasing the Spring Tension on the Bracket Repairs and Adjustments 03/2003 REP 9.23 4-106 8850/ 510DP...
Page 183 Encoder. remove the Encoder Disconnect the connec- tor and pull Hub Slide- Lock out fully Lossen the Setscrews Figure 5 Removing the Drum Motor Cover (Figure 6): Remove the Encoder. Repairs and Adjustments 03/2003 REP 9.23 8850/ 510DP 4-107...
Page 184: Rep 9.24 Electrometer Probe (Esv 1)
After replacing the Drum Encoder Assembly, the following adjustments must be per- formed for bond, vellum, and film. ADJ 8.1 Vertical Magnification. ADJ 8.2 Lead Edge Registration ADJ 8.3 Cut Length Return the Printer to normal operation. Repairs and Adjustments 03/2003 REP 9.23, REP 9.24 4-108 8850/ 510DP...
Page 185: Rep 9.25 Ozone Filter (Sps 510Dp)
Figure 1 Removing the Top Rear Cap metal (Figure 2): Remove the ozone filter. Replacement Figure 2 Installing the Ozone Filter (Figure 3): Install the Ozone Filter Repairs and Adjustments 03/2003 REP 9.25 8850/ 510DP 4-109...
Page 186 Repairs and Adjustments 03/2003 REP 9.25 4-110 8850/ 510DP...
Page 187: Rep 10.1 Heat Rods, Edge (Hr 1) And Center (Hr 2)
Remove the rubber grommet from Carefully remove the two Heat Rods from the rubber grommet the Heat Rod Support Bracket Figure 2 Removing the Bracket (Left side) Figure 1 Accessing the Fuser Module Repairs and Adjustments 03/2003 REP 10.1 8850/ 510DP 4-111...
Page 188 Wear gloves or wrap a sheet of paper around the Heat Rod when handling the Heat Rod. Do not touch the glass section of the Heat Rod. Oil from fingers can cause damage to the Heat Rod. Repairs and Adjustments 03/2003 REP 10.1 4-112 8850/ 510DP...
Page 189 Fuser Assembly. Remove the Heat Rod Grommet from the Bracket Figure 5 Removing the Grommet from the Bracket Repairs and Adjustments 03/2003 REP 10.1 8850/ 510DP 4-113...
Page 190 11. Holding the rear fuser wires, push the rear fuser bracket to position the ceramic necks of the rods in the rear fuser grommet. 12. Fasten the rear fuser bracket to the Fuser Assembly. Repairs and Adjustments 03/2003 REP 10.1 4-114 8850/ 510DP...
Page 191: Rep 10.2 Fuser Heat Roll
Pull up on the handle and pull open the Fuser Module Drawer Remove the two right side screws Figure 2 Removing the Web Oiler Assembly Figure 1 Accessing the Fuser Module Remove the Heat Rods (REP 10.1). Repairs and Adjustments 03/2003 REP 10.2 8850/ 510DP 4-115...
Page 192 Figure 3 Preparing to Remove the Stripper Finger Assembly (Figure 4): While maintaining the pressure on the right side of the Stripper Finger Assem- bly, remove the assembly from the Printer. Repairs and Adjustments 03/2003 REP 10.2 4-116 8850/ 510DP...
Page 193 Latches and lower the Latching Cover Remove the Fuser Heat Roll Bearing Figure 6 Removing the Fuser Heat Roll Drive Gear and Bearing (right side) Figure 5 Releasing the Cover Laches Repairs and Adjustments 03/2003 REP 10.2 8850/ 510DP 4-117...
Page 194 NOTE: Do not pull the Heat Roll through the frame to remove. Only slide it enough to clear the frame then move in the opposite direction to remove. (Figure 8): Remove the Fuser Heat Roll. Repairs and Adjustments 03/2003 REP 10.2 4-118 8850/ 510DP...
Page 195: Rep 10.3 Web Oiler Assembly
Pressure Roll on the Fuser Heat Roll. Figure 1 Accessing the Fuser Module Ensure that there is a clean, flat surface on which to place the Web Oiler Assembly after it is removed. Repairs and Adjustments 03/2003 REP 10.2, REP 10.3 8850/ 510DP 4-119...
Page 196 10-31 Partial Web Oiler Parameters Reset - to reset the parameters for a partially used Web. Measure the diameter of the remaining web on the Supply Roll in millime- ters and enter this value. Repairs and Adjustments 03/2003 REP 10.3 4-120 8850/ 510DP...
Page 197: Rep 10.4 Stripper Fingers
Carefully remove the Stripper Finger of the Printer Assembly from the Printer and place it on a clean, flat surface Figure 1 Accessing the Stripper Finger Assembly Figure 2 Removing the Stripper Finger Assembly Repairs and Adjustments 03/2003 REP 10.4 8850/ 510DP 4-121...
Page 198: Rep 10.5 Web Oiler
Reinstall the Stripper Finger Assembly on the Printer. Reinstall the Web Oiler Assembly on the Printer. Close the Fuser Drawer Cover, and slide the Fuser Assembly back into the Printer. Return the Printer to normal operation. Repairs and Adjustments 03/2003 REP 10.4, REP 10.5 4-122 8850/ 510DP...
Page 199 Remove the Grip Ring from the Supply Roll Figure 1 Removing the Grip Ring Repairs and Adjustments 03/2003 REP 10.5 8850/ 510DP 4-123...
Page 200 NOTE: Be careful not to lose the Roll Take-up Spring when removing the Web Oiler. (Figure 4): Reinstall the Web Oiler. (Figure 3): Remove the Web Take up and Supply Rolls. Repairs and Adjustments 03/2003 REP 10.5 4-124 8850/ 510DP...
Page 201 Web by rotating the gear in the raised hub towards the frame direction shown Take up Pinch Sup- Figure 5 Reinstalling the Gear Roll Roll Figure 4 Reinstalling the Web Oiler Repairs and Adjustments 03/2003 REP 10.5 8850/ 510DP 4-125...
Page 202: Rep 10.6 Thermal Fuse (F1)
10-31 Partial Web Oiler Parameters Reset - to reset the parameters for a partially used Web. Measure the diameter of the remaining web on the Supply Roll in millime- ters and enter this value. Repairs and Adjustments 03/2003 REP 10.5, REP 10.6 4-126 8850/ 510DP...
Page 203 SEnsor Remove the Cover mal Fuse (F1) Figure 3 Removing the Thermal Fuse (F1) Remove the two screws, one at each end Figure 2 Accessing the Thermal Fuse (F1) Repairs and Adjustments 03/2003 REP 10.6 8850/ 510DP 4-127...
Page 204: Rep 10.7 Edge And Center Thermistors (Rt 2) And (Rt 3)
Figure 2 Accessing the Edge and Center Thermistors Figure 1 Accessing the Fuser Module Remove the Fuser Heat Roll (REP 10.2) (Figure 2): Access the Edge (RT 2) or Center (RT3) Thermistor. Repairs and Adjustments 03/2003 REP 10.7 4-128 8850/ 510DP...
Page 205: Rep 10.8 Pressure Roll
Pull up on the handle and pull open the Fuser Module Drawer. Remove the screw, disconnect the con- nector and remove the Thermistor Figure 3 Removing the Edge or Center Thermistor Figure 1 Accessing the Fuser Repairs and Adjustments 03/2003 REP 10.7, REP 10.8 8850/ 510DP 4-129...
Page 206 Support the Upper Sheet Feed Housing from screws falling while performing the Step 2 Figure 2 Removing the screws securing Upper Sheet Feed Housing (Figure 3): Remove the Upper Sheet Feed Housing. Repairs and Adjustments 03/2003 REP 10.8 4-130 8850/ 510DP...
Page 207 Remove the E-ring from the guide pin Figure 5 Removing the Pressure Roll from the Printer (Figure 6): Remove the Pressure Roll from the Shaft. Figure 4 Preparing to Remove the Pressure Roll Repairs and Adjustments 03/2003 REP 10.8 8850/ 510DP 4-131...
Page 208 Figure 6 Removing the Pressure Roll Bearing (Figure 7): Remove the Bearing from the Opposite end. Figure 7 Removing the Second Bearing Replacement (Figure 8): Install the Bearing in the new Pressure Roll. Repairs and Adjustments 03/2003 REP 10.8 4-132 8850/ 510DP...
Page 209 (Figure 9): Install the second Bearing. Support the Roll so that the Shaft remains in the bottom Bearing Figure 9 Installing the Second Bearing The replacement is the reverse of the removal. Repairs and Adjustments 03/2003 REP 10.8 8850/ 510DP 4-133...
Page 210: Rep 10.9 Fuser Exit Sensor (S2)
Pressure Roll Figure 10 Reinstalling the Spring Figure 1 Accessing the Fuser (Figure 2) and (Figure 3): Remove the Upper Sheet Feed Housing off the Fuser Repairs and Adjustments 03/2003 REP 10.8, REP 10.9 4-134 8850/ 510DP...
Page 211 Figure 3 Removing the Upper Sheet Feed Housing Figure 2 Removing the Screws Securing The Upper Sheet Feed Housing (Figure 3): Remove the Upper Sheet Feed Housing. Repairs and Adjustments 03/2003 REP 10.9 8850/ 510DP 4-135...
Page 212: Rep 10.11 Ac Module (A1)
Remove the Controller and the Rear Covers. Disconnect the connector Remove the Fuser Exit Sensor from the Housing Remove the Support Remove the Screw and Housing Spring Clip Figure 4 Removing the Fuser Exit Sensor Repairs and Adjustments 03/2003 REP 10.9, REP 10.11 4-136 8850/ 510DP...
Page 213 Loosen the screws, 2 on the one side and remove the Remove the AC Module two screws from the other side of the AC Module Figure 1 Removing the AC Module Repairs and Adjustments 03/2003 REP 10.11 8850/ 510DP 4-137...
Page 214 Repairs and Adjustments 03/2003 REP 10.11 4-138 8850/ 510DP...
Page 215: Rep 14.1 Top Cover
Switch off the Controller and the Printer Main Power Switches. Disconnect the Printer Power Cord. Removal (Figure 1): Open the Printer Rear Door. (8850) Loosen the 2 retaining screws (510dp) Release the Latch using the handle on the left side of the cover...
Page 216 Figure 3 Preparing to Remove the Top Cover (Front) Figure 4 Top Cover Interlock Plate Close the Developer Module Cover and lift off the Top Cover, being careful to disengage the small pin from the Interlock Plate. Repairs and Adjustments 03/2003 REP 14.1 4-140 8850/ 510DP...
Page 217 Pull the latch forward with the right slightly with the left hand hand Gently lower the Top Cover Figure 5 Lowering the Printer Top Cover Close and secure the Rear Door. Return the Printer to normal operation. Repairs and Adjustments 03/2003 REP 14.1 8850/ 510DP 4-141...
Page 218 Repairs and Adjustments 03/2003 REP 14.1 4-142 8850/ 510DP...
Page 219: Adj 3.2 Line Current Limit
Use the Next or Previous button to change the NOW setting. Press the Enter button in order to store the value in NVM. Press the Exit button two times. Table 2 Billing Type Selections Configuration FEET METRIC Repairs and Adjustments 03/2003 ADJ 3.2 8850/ 510DP 4-143...
Page 220: Adj 7.1 Media Roll Supply Drive Chain (510Dp, 8850 W/Tag 11)
The purpose is to adjust the media roll supply drive chain to ensure there is no delay in feeding the media. Introduction The 8850 must have Tag 11 which is a new mounting bracket for the Media Roll Drive Motor. Refer to the Change Tag Index for the kit number. Check Switch off the printer and unplug the power cord.
Page 221: Adj 8.1 Vertical Magnification
Perform the Check again. Figure 1 Checking the Vertical Magnification Adjustment (Figure 2): Enter code [0602] in order to adjust the Vertical Magnification. The following message will be displayed. Repairs and Adjustments 03/2003 ADJ 7.1 , ADJ 8.1 8850/ 510DP 4-145...
Page 222 Press the Enter button in order to store the value in NVM. Press the Exit button two times. Repeat the check for all the types of media used by the customer. Repairs and Adjustments 03/2003 ADJ 8.1 4-146 8850/ 510DP...
Page 223: Adj 8.2 Lead Edge Registration
Repeat the check for all the types of media used by the customer. Figure 1 Checking the Lead Edge Registration Adjustment (Figure 2): Enter code [0860] in order to adjust the Lead Edge Registration. The following message is displayed. Repairs and Adjustments 03/2003 ADJ 8.2 8850/ 510DP 4-147...
Page 224: Adj 8.3 Cut Length
Figure 1 Checking the Print Length (Figure 2): Enter code [0700] in order to adjust the Cut Length. Enter [1] to adjust. Figure 5 Print Length (Figure 6): Confirm the length adjustments. Repairs and Adjustments 03/2003 ADJ 8.3 4-148 8850/ 510DP...
Page 225: Adj 9.2 Electrostatic Series
(Figure 2): Wait for the process to complete. The following message will be displayed. Figure 2 Electrostatic Setup Complete Record the values for: V High, V Bias, and V Low in the 8850/510dp Service Log. Press the Exit button to exit the process.
Page 226: Adj 9.3 Image Density
This will affect the density of the output plots in [0955]. This step can also be done using the WebPMT with out affecting the output plots in [0955]. The adjustment will be done in the AccXES Controller. Repairs and Adjustments 03/2003 ADJ 9.3 4-150 8850/ 510DP...
Page 227: Adj 9.5 Toner Cartridge Home Sensor
(Figure 1): Ensure that the tip of the Toner Cartridge Home Sensor is 2.5 (+/- 0.5) mm from the plate. 2.5 +/- 0.5 mm Toner Cartridge Home Sensor Figure 1 Checking the Position of the Toner Cartridge Home Sensor Repairs and Adjustments 03/2003 ADJ 9.5 8850/ 510DP 4-151...
Page 228 (Figure 2): Adjust the Toner Cartridge Home Sensor to 2.5 (± 0.5) mm from the plate. 2.5 +/- 0.5 mm Straighten the wires and adjust the sensor Disconnect Q2 Remove the wires from the clamps (2 places) Figure 2 Adjusting the Toner Cartridge Home Sensor Repairs and Adjustments 03/2003 ADJ 9.5 4-152 8850/ 510DP...
Page 229: Adj 9.6 Augers
Rotate the Developer Auger until the flat on the auger flute is at the 7 Figure 1 Checking for the Correct Orientation of the Augers o’clock position Figure 2 Adjusting the Developer Auger Repairs and Adjustments 03/2003 ADJ 9.6 8850/ 510DP 4-153...
Page 230: Adj 10.1 Fuser Temperature (Nvm)
Press the Exit button two times. (Figure 3): Enter code [1062] in order to adjust the Fuser Temperature for vellum to 350. The following message is displayed. Figure 2 Vellum Temperature Set point Repairs and Adjustments 03/2003 ADJ 9.6, ADJ 10.1 4-154 8850/ 510DP...
Page 231: Adj 10.2 Fuser Drive Interlock Switch 8850 W/O Tag 8
Use the Previous button to decrease the Set Point, lowering the fusing temperature. ADJ 10.2 Fuser Drive Interlock Switch 8850 W/O Tag 8 Use the Next button to increase the Set Point, raising the fusing temperature. Adjustment Press the Enter button in order to store the value in NVM.
Page 232: Adj 10.3 Fuser Drive Motor
Figure 2 Performing the Adjustment Finger tighten the four nuts so that the Motor is against the frame and can just be moved Figure 1 Preparing the Fuser For Adjustment Repairs and Adjustments 03/2003 ADJ 10.2, ADJ 10.3 4-156 8850/ 510DP...
Page 233 Rotate the drive gear a quarter turn by spinning the Fuser Motor Shaft and repeat steps a and b again. Rotate the drive gear another quarter and repeat steps a and b. Repairs and Adjustments 03/2003 ADJ 10.3 8850/ 510DP 4-157...
Page 234 Repairs and Adjustments 03/2003 ADJ 10.3 4-158 8850/ 510DP...
Page 235 PL 14.2 Transport Latching Cover Components ............. 5-41 PL 1.3 DC Electrical Components................... PL 14.3 Front Door and Right Side Covers..............5-42 PL 1.4 Control Panel (8850).................... 5-10 PL 14.4 Developer Cover and Catch Tray ..............5-43 PL 1.5 Control Panel (510dp)..................
Page 236 Parts Lists 03/2003 8850/ 510DP...
Page 237: Overview
If a part or assembly has an associated repair or adjustment procedure, the procedure number will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3) Parts Lists 03/2003 Introduction 8850/ 510DP...
Page 238: Subsystem Information
Change Tag Index tells you which kit or piece parts you need. Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate number on the Tag matrix. Parts Lists 03/2003 Subsystem Information 8850/ 510DP...
Page 239: Symbology
(Figure 2). by the tag number within the circle (Figure 1). Information on the modification is in the Change Tag Index. Figure 2 Without Tag Symbol Figure 1 With Tag Symbol Parts Lists 03/2003 Symbology 8850/ 510DP...
Page 240 (Figure 3). Information on the modification is in the Change drawing was the configuration before being changed by the tag number within the circle Tag Index. (Figure 4). Figure 3 Entire Drawing With Tag Symbol Figure 4 Entire Drawing Without Tag Symbol Parts Lists 03/2003 Symbology 8850/ 510DP...
Page 241: 1.1 Electrical Control Components/Dc Power Generation
Power Supply (24V DC) (A5PS2) (P/O PL 1.1 Item – LVPS AC Power Harness (P/O 1.1 Item 105E15060 Power Supply (5V DC) (A5PS1) 160K73004 Main PWB (A3) (8850) (REP 3.1) – 960K10720 Main PWB (A3) (510dp) (REP 3.1) 101K42713 AC Module Assembly (A1)
Page 242: Intentionally Left Blank
Intentionally left blank Parts Lists 03/2003 8850/ 510DP...
Page 243: Pl 1.3 Dc Electrical Components
Charge Corotron Label (Red Arrow) (Not Spared) 105E15364 High Voltage Power Supply (A25PS1) (W/TAG 6) (REP 3.2, 9.2) 117K39571 Detack Corotron Harness 117K39582 Transfer Corotron Harness – Folder Enablement Harness (Not Spared) 101K44430 Filter Assembly 019E52800 Clamp Parts Lists 03/2003 PL 1.3 8850/ 510DP...
Page 244: 1.4 Control Panel (8850)
PL 1.4 Control Panel (8850) Item Part Description 101K26083 Control Panel 096E78252 Control Panel Label – ESD Insulator (P/O PL 1.4 Item – Display (P/O PL 1.4 Item – Control Console Housing (P/O 1.4 Item – Display Housing (P/O PL 1.4 Item...
Page 245: 1.5 Control Panel (510Dp)
PL 1.5 Control Panel (510dp) Item Part Description 101K48841 Control Panel Assembly (REP 3.3) – Control Panel (P/O PL 1.5 Item 892E94680 UI Label 892E94690 UI Button Label 162K23421 Control Console to Main PWB (A3) Parts Lists 03/2003 PL 1.5 8850/ 510DP 5-11...
Page 246: Pl 7.1 Roll Supply Feed Assembly
Drawer Cover 830E76230 Link 130E02271 Drawer Interlock Switch 010K01351 Slide 050K55060 Unsealed Roll Media Drawer Assembly (510dp) (REP 7.1) – 050K52841 Sealed Roll Media Drawer Assembly (8850) (REP 7.1) 162K28610 Jumper Harness Parts Lists 03/2003 PL 7.1 5-12 8850/ 510DP...
Page 247: Pl 7.2 Roll Supply Drives
7.7) 007E14610 Rewind Drive Gear (12T) 007K05760 Rewind Drive Assembly – Standoff (Not Spared) 126K07340 Lower Media Roll Heater (Roll 3) (REP 7.10) 809E46680 Motor Spring 604K16990 Motor Bracket Repair Kit (Tag Parts Lists 03/2003 PL 7.2 8850/ 510DP 5-13...
Page 248: 7.3 Roll Supply Drawer Components (Part 1 Of 4)
PL 7.1 Item – Drawer Frame (P/O PL 7.1 Item – LH Roll Lock (P/O PL 7.1 Item 003E17610 Roll Lock 009E27340 Roll Lock Spring 029E12930 Rewind Shaft 604K17800 Support Roller Kit Parts Lists 03/2003 PL 7.3 5-14 8850/ 510DP...
Page 249: 7.4 Roll Supply Drawer Components (Part 2 Of 4)
PL 7.1 Item – RH Roll Lock (P/O PL 7.1 Item 003E17610 Roll Lock 009E27340 Roll Lock Spring – RH Cradle Bracket (P/O PL 7.1 Item 029E14750 RH Support Pin 022E11540 Support Roller Parts Lists 03/2003 PL 7.4 8850/ 510DP 5-15...
Page 250: 7.5 Roll Supply Drawer Components (Part 3 Of 4)
Latch Pin – Supply Drawer Latch (P/O PL 7.1 Item 030K74790 Bracket 003K07581 Handle (8850) – 003E69900 Handle (510dp) 802K39390 Drawer Cover (8850) – 802K62260 Drawer Cover (510dp) 038K09190 Paper Guide 121E07680 Magnet – Handle (P/O PL 7.1 Item –...
Page 251: 7.6 Roll Supply Drawer Components (Part 4 Of 4)
PL 7.6 Roll Supply Drawer Components (Part 4 of 4) Item Part Description – Label (Media Load) (P/O PL 7.1 Item 052K03580 Roll Support Tube Assembly – Drawer Frame (P/O PL 7.1 Item Parts Lists 03/2003 PL 7.6 8850/ 510DP 5-17...
Page 252: Pl 7.7 Media Cutter Assembly
Media Cutter Assembly (A8) – Cutter Cover (Not Spared) – Bracket (Not Spared) 003E18781 Latch 010K01360 Media Cutter Slide 110E02640 Media Cutter Drawer Interlock Switch (S1) – Bracket (Not Spared) 011E04470 Cutter Interlock Actuator Lever Parts Lists 03/2003 PL 7.7 5-18 8850/ 510DP...
Page 253: Pl 7.8 Media Cutter Components
8.14) 423W57550 Drive Belt – Drive Pulley (34T) (P/O PL 7.7 Item 003E16521 Cutter Latch 009E27340 Latch Spring 127K26580 Cutter Drive Motor (MOT1) (ADJ 8.3) – Label (Hand Cut Caution) (Not Spared) Parts Lists 03/2003 PL 7.8 8850/ 510DP 5-19...
Page 254: Pl 8.1 Media Transport Module
PL 8.1 Media Transport Module Item Part Description 059K27831 Media Transport Module (REP 8.1, 8.1) 009E32510 Compression Spring 029K01111 Parts Lists 03/2003 PL 8.1 5-20 8850/ 510DP...
Page 255: 8.2 Media Registration Components (Part 1 Of 2)
023E23580 Registration Drive Belt (REP 8.13) 020E13603 Drive Motor Pulley (18T) 127K04293 Media Transport Drive Motor (MOT1) (REP 8.13, 8.1, 8.2) 022E11441 Idler 117K40140 Ground Strap 006K26701 Registration Drive Roll (REP 8.17) Parts Lists 03/2003 PL 8.2 8850/ 510DP 5-21...
Page 256: 8.3 Media Registration Components (Part 2 Of 2)
PL 8.1 Item 809E45020 Clip 006K26760 Bias Transfer Roll (REP 8.18) 030K73120 BTR Contact 019E07100 Cable Clip – Media Transport Frame (P/O PL 8.1 Item 055E49380 Left Media Shield 055E49390 Right Media Shield Parts Lists 03/2003 PL 8.3 5-22 8850/ 510DP...
Page 257: Pl 9.1 Xerographic Module Assembly
PL 9.1 Item – Cover (P/O PL 9.1 Item – Xerographic Module Assembly (Not Spared) (REP 9.1) 053E04750 Ozone Filter (510dp 9.25) – Encoder (P/O PL 9.1 Item (REP 9.23, 8.1) 604K13460 Encoder Kit Parts Lists 03/2003 PL 9.1 8850/ 510DP 5-23...
Page 258: Pl 9.2 Photoreceptor
– Xerographic Frame (P/O PL 9.1 Item 004E10130 Damper 013K03791 Non-Drive Bearing Assembly 115E11571 Contact – Non-Drive Bearing (P/O PL 9.2 Item 013E21510 Drive Bearing 117K40130 Ground Strap 035E64440 NOHAD Air Seal Parts Lists 03/2003 PL 9.2 5-24 8850/ 510DP...
Page 259: 9.3 Drum Cleaning (Part 1 Of 3)
9.3 Item – Cleaner Blade Retainer (P/O PL 9.1 Item 6,PL 9.3 Item 035K05790 Photoreceptor Seal – Cleaner Blade (P/O PL 9.1 Item 6,PL 9.3 Item (REP 9.4) 021K02160 Toner Exit Cap Parts Lists 03/2003 PL 9.3 8850/ 510DP 5-25...
Page 260: 9.4 Drum Cleaning (Part 2 Of 3)
PL 9.4 Drum Cleaning (Part 2 of 3) Item Part Description 094K00085 Waste Toner Auger 007E05221 Drum Drive Gear 023E01620 Auger Drive Belt 020E04350 Auger Pulley 013E00803 Auger Bearing – Xerographic Frame (P/O PL 9.1 Item 038K04860 Media Guide Parts Lists 03/2003 PL 9.4 5-26 8850/ 510DP...
Page 261: 9.5 Drum Cleaning (Part 3 Of 3)
PL 9.5 Drum Cleaning (Part 3 of 3) Item Part Description 035K05950 Toner Exit Seal 054E06533 Waste Toner/Developer Collection Tube 035K05941 Waste Bracket Seal – Bottle (Not Spared) Parts Lists 03/2003 PL 9.5 8850/ 510DP 5-27...
Page 262: Pl 9.6 Developer Module Assembly
Coupling Spring 007E15351 Drive Gear/Coupling 030K56160 Developer Support 050E20871 Bead Tray 030K56150 Developer Support 121K25992 Developer Module Assembly (W/ (REP 9.5, ADJ 9.3 9.6) – Clip (Not Spared) 016E16620 Bushing 126E02380 Heater (TAG Parts Lists 03/2003 PL 9.6 5-28 8850/ 510DP...
Page 263: 9.7 Developer Module Components (Part 1 Of 2)
055K13840 Top Shield – Developer Frame (P/O PL 9.6 Item 130K65900 Toner Sensor (REP 9.11, 9.3) 019E15551 Bias Clip 001E23080 Toner Strip 055K13830 Sump Shield (REP 9.13) 014E46450 Sensor Spacer 035E12210 Seal Parts Lists 03/2003 PL 9.7 8850/ 510DP 5-29...
Page 264: 9.8 Developer Module Components (Part 2 Of 2)
Seal – Roller (P/O PL 9.6 Item 035E64851 Seal – Cable Wrap (Not Spared) 604K12900 Seal Kit (6/Kit) 010E04190 Trickle Slide – 8850 Service Tools CD (Not Shown) (P/O PL 9.8 Item Parts Lists 03/2003 PL 9.8 5-30 8850/ 510DP...
Page 265: Pl 9.9 Image Module Assembly
PL 9.9 Item – ESV PWB Cover (Not Spared) 035E70260 Top Seal 035E66330 Strip Seal – Image Module Housing (P/O PL 9.9 Item 113K03041 ESV Extrusion 113E42081 Holder 962K00360 LED Bar Jumper Power Harness Parts Lists 03/2003 PL 9.9 8850/ 510DP 5-31...
Page 266: Pl 9.10 Toner Dust Control
053K04180 Toner Filter Assembly – Filter Cover (P/O PL 9.10 Item – Filter (P/O PL 9.10 Item 127E13650 Vacuum Fan 052E24241 Vacuum Tube 054K25000 Exhaust Duct – Toner Dust Trap (Not Spared) Parts Lists 03/2003 PL 9.10 5-32 8850/ 510DP...
Page 267: Two Roll Fuser
Fuser Motor (P/O PL 10.1 Item – Fuser Drive Gear (P/O PL 10.1 Item – Two Roll Fuser Assembly (Not Spared) 059K27880 Lower Sheet Feed Assembly (8850) (REP 8.1) – 055K34360 Lower Sheet Feed Assembly (510dp) (REP 8.1) 010K03380 Fuser Slide...
Page 268: 10.2 Fuser Components (Part 1 Of 4)
Fuser Heat Roll (REP 10.2) 122K02020 Center Heat Rod (HR2) (REP 10.1,ADJ 10.1) 122K02030 Edge Heat Rod (HR1) (REP 10.1,ADJ 10.1) 016E16200 Lamp Grommet 830E72250 Lamp Bracket (Non-Drive Side) 830E72260 Lamp Bracket (Drive Side) Parts Lists 03/2003 PL 10.2 5-34 8850/ 510DP...
Page 269: 10.3 Fuser Components (Part 2 Of 4)
962K02921 Fuser Harness Adapter 009E38060 Stripper Shaft Spring 962K00542 Fuser Harness 038K14960 Media Guide (TAG 604K12770 Stripper Repair Kit (TAG 4) (2/Kit) 604K04480 Entrance Guide Kit (10/Kit) 604K04470 Exit Guide Kit (10/Kit) Parts Lists 03/2003 PL 10.3 8850/ 510DP 5-35...
Page 270: 10.4 Fuser Components (Part 3 Of 4)
020E26340 Gear Pulley (30T) – Bearing (P/O PL 10.1 Item – Fuser Drive Interlock Switch (S30) (P/O PL 10.1 Item 604K12880 Wire Saddle Kit (6/Kit) (TAG 815E16870 Switch Plate 120P60583 Wire Saddle Parts Lists 03/2003 PL 10.4 5-36 8850/ 510DP...
Page 271: 10.5 Fuser (Web Oiler) Components (Part 4 Of 4)
– Roll Take-Up Spring (P/O PL 10.1 Item – Support (P/O PL 10.1 Item – Fuser Housing (P/O PL 10.1 Item 007E69390 Gear (16T) 007E69380 Gear (12T) 127E13610 Web Oiler Drive Motor Parts Lists 03/2003 PL 10.5 8850/ 510DP 5-37...
Page 272: 10.6 Upper Sheet Feed Components
PL 10.1 Item – Retainer Housing (P/O PL 10.1 Item – Sheet Feed Pinch Roll (P/O 10.1 Item (REP 7.14) – Shaft (P/O PL 10.1 Item – Spring (P/O PL 10.1 Item Parts Lists 03/2003 PL 10.6 5-38 8850/ 510DP...
Page 273: 10.7 Lower Sheet Feed Components
Sheet Feed Drive Motor (MOT1) (REP 8.5) – Sheet Feed Sensor (Q2) (P/O 10.1 Item (REP 8.3) – Wire Tie (P/O PL 10.1 Item 962K00630 Harness – Retainer (P/O PL 10.1 Item Parts Lists 03/2003 PL 10.7 8850/ 510DP 5-39...
Page 274: 14.1 Transport Latching Cover And Rear Door
(S29) 802K61140 Transport Latching Cover Assembly (510dp) – 802K40242 Transport Latching Cover Assembly (8850) (TAG 038K14990 Left Side Guide (8850) – 038K15460 Left Side Guide (510dp) 038K15000 Right Side Guide (8850) – 038K15470 Right Side Guide (510dp) 604K12740 Side Guide Kit...
Page 275: 14.2 Transport Latching Cover Components
Item Part Description 110K14080 Fuser Door Switch (TAG 892E95830 Label (Bypass Feed Widths) (510dp) – 892E50830 Label (Bypass Feed Widths) (8850) 115E01410 Static Eliminator – Fastener (P/O PL 14.1 Item 802K40210 Cover 003E67220 Latch Spring – Stack Height Switch (Q2) (P/O 14.1 Item...
Page 276: 14.3 Front Door And Right Side Covers
Right Side, Left Lower Cover (8850) – 802K61120 Right Side, Left Lower Cover (510dp) 048K47692 Right Side, Right Lower Cover 048K44401 Right Side, Right Cover 110E02640 Front Door Interlock Switch (S21) 003E13010 Keeper Parts Lists 03/2003 PL 14.3 5-42 8850/ 510DP...
Page 277: 14.4 Developer Cover And Catch Tray
PL 14.4 Developer Cover and Catch Tray Item Part Description 673K99610 Catch Tray Kit 673K99770 Support Kit 073E13352 Tray Support Kit 048E51410 Rear Developer Cover (8850) – 802E59040 Developer Cover (510dp) – Left Support (P/O PL 14.4 Item 004E21600 Bumper 019E55991 Support Clip –...
Page 278: 14.5 Top Cover And Catch Tray Brackets
Gasket (8850) – 035E64660 Gasket (510dp) 110K08970 Top Cover Interlock Switch (S26) 035E41150 Gasket 030K79860 Right Service Bracket (510p) – 030K57191 Right Service Bracket (8850) 030K57181 Left Service Bracket 055E38100 Shielding Pad Parts Lists 03/2003 PL 14.5 5-44 8850/ 510DP...
Page 279: 14.6 Covers (510Dp)
802E58520 Front Door Handle 802K60691 Rear Door 802K60711 Top Cover (REP 14.1) 035E71070 Seal Cover Airbox 035E70990 Door Seal 802E58490 Rear Top Cover 802K60750 False Front Cover – Control Panel (REP 3.3) Parts Lists 03/2003 PL 14.6 8850/ 510DP 5-45...
Page 280: Common Hardware
220W00650 Nut (M6) 112W27455 Screw (M4 X 12) 153W23452 Screw (M2.9 X 9.5) 251W22602 Flat Washer (No 10) 153W42353 Screw (M4 X 12) 153W17451 Screw (M4.2 X 9.5) 201W00455 Nut (M4 HEX) Parts Lists 03/2003 Common Hardware 5-46 8850/ 510DP...
Page 281: Part Number Index
PL 8.2 007E16330 PL 9.8 016E16200 PL 10.2 007E16341 PL 9.8 016E16620 PL 9.6 007E19071 PL 7.2 017K01120 PL 14.1 007E69360 PL 10.5 017K03820 PL 14.6 007E69370 PL 10.2 017K03831 PL 14.6 Parts Lists 03/2003 Part Number Index 8850/ 510DP 5-47...
Page 282 PL 9.2 026E11970 PL 8.2 035E64530 PL 10.3 026E57690 PL 9.9 035E64660 PL 14.5 028E07430 PL 7.8 035E64770 PL 10.1 028E07771 PL 9.6 035E64851 PL 9.8 028E14580 PL 10.5 035E66330 PL 9.9 Parts Lists 03/2003 Part Number Index 5-48 8850/ 510DP...
Page 283 PL 1.2 054K25000 PL 9.10 115E01410 PL 14.2 055K13830 PL 9.7 115E11571 PL 9.2 055K13840 PL 9.7 117E23750 PL 1.1 055K32730 PL 10.1 117E23751 PL 1.1 055K34360 PL 10.1 117K32480 PL 1.2 Parts Lists 03/2003 Part Number Index 8850/ 510DP 5-49...
Page 284 PL 14.4 130K66680 PL 10.2 802K60691 PL 14.6 130K66730 PL 7.8 802K60701 PL 14.6 142K01540 PL 1.2 802K60711 PL 14.6 152S05100 PL 1.1 802K60750 PL 14.6 152S05101 PL 1.1 802K61120 PL 14.3 Parts Lists 03/2003 Part Number Index 5-50 8850/ 510DP...
Page 285 PL 1.5 892E94690 PL 1.5 892E95830 PL 14.2 960K10720 PL 1.1 962K00360 PL 9.9 962K00542 PL 10.3 962K00630 PL 10.7 962K00640 PL 10.1 962K02830 PL 10.1 962K02921 PL 10.3 962K03180 PL 14.2 Parts Lists 03/2003 Part Number Index 8850/ 510DP 5-51...
Page 286 Parts Lists 03/2003 Part Number Index 5-52 8850/ 510DP...
Page 287 6-39 General Tools and Supplies (EO) ................... 6-40 Molex Connector Repair Procedure ................6-42 Product Specifications Product Specifications..................... 6-45 8850 Change Tag 8850 Change Tag Information ..................6-47 SPS 510dp Change Tag Information ................6-49 General Procedures 03/2003 8850/ 510DP...
Page 288 General Procedures 03/2003 8850/ 510DP...
Page 289: To Enter The Diagnostic Mode
The code entered will be displayed on the Control Panel. The test name will be in the bottom line of the display along with test feedback information. There also may be additional informa- tion displayed depending on the test being run. General Procedures 03/2003 To Enter The Diagnostic Mode 8850/ 510DP...
Page 290: To Exit The Diagnostic Mode
0 for low state and a 1 for high state. Press the Exit button to stop the diagnostic test. Press the Exit button again to clear the chain. General Procedures 03/2003 To Exit The Diagnostic Mode, Input Diagnostic Test 8850/ 510DP...
Page 291: Input Diagnostic Test Codes
Stack Height Sensor 1 is Full [0901] Toner Cartridge Home Sensor 0 is Active [0902] Drum Motor Stall Sensor 0 is Stalled [1005] Fuser Jam Switch 0 is Active General Procedures 03/2003 Input Diagnostic Test Codes, Output Diagnostic 8850/ 510DP...
Page 292: Output Diagnostic Test Codes
Bond, (2) Vellum, and (3) Film to select the feed rate for the media type loaded in the Media Drawer. To check the Rewind Clutch and reverse the Drive Motor, you must enter (4). The (4) is not displayed on the Control Panel display. General Procedures 03/2003 Output Diagnostic Test Codes, To Enter Multiple 8850/ 510DP...
Page 293: To Exit From Multiple Tests
This code is used to select the billing in meters or inches. EO: 1 = metric (meters) [0300] Jump 0. Restarts the IOT. [0301] Enter IOT Firmware Update Mode Download the latest software. General Procedures 03/2003 To Exit from Multiple Tests, Special Tests 8850/ 510DP...
Page 294 5]. Use two different pattern numbers Adjustment to see the LED bar change in code [0700] Cut Length Adjustment 600mm is ###mm [0921-5]. Go to ADJ 8.3 Cut Length. [0750] Adjust Heater on RH setpoint. 0-99 RH General Procedures 03/2003 Special Tests 8850/ 510DP...
Page 295 Oil Web. 50% means that 1/2 as much web is used. [1033] Advance Oil Web. Note: Very slow method on the 8850/ Used to tension the web correctly 510dp/510dp. when the oil assembly is removed Remove oil assembly and manually and reinstalled.
Page 296: Gp 1 Xerographic Hvps Checkout
Reference Table 1 and check that Vin is in specification. If okay continue. If not, check the wiring between A25P/J1 of the HVPS and A3P/J605. If the wiring is good, go to the DC Power RAP in Section 2. General Procedures 03/2003 GP 1 6-10 8850/ 510DP...
Page 297: Gp 2 Image On Drum (Panic Stop) Procedure
If the defect is visible on the developed image, the defect cause is related to the charge, procedure. the imaging or the developer. If the defect is not visible, the defect cause is related to the transfer or the fuser. Drum Drive Coupling General Procedures 03/2003 GP 2 8850/ 510DP 6-11...
Page 298: Gp 3 Drum Maintenance
Apply Film Remover to a clean polyurethane pad. (Figure 1): Wash the drum from end to end, using a circular motion. Minimum Pressure Polyurethane pad Figure 1 Washing the Drum General Procedures 03/2003 GP 3 6-12 8850/ 510DP...
Page 299: Gp 4 Drum Cleaning Enhancement
Controller. Go to the E7-01 RAP in the AccXES Controller Service Manual. Reinstall the drum assembly. If the test fails (1), replace the IOT Main PWB (REP 3.1). Rotate the Drum manually to clean off excess zinc stearate. General Procedures 03/2003 GP 4, GP 5 8850/ 510DP 6-13...
Page 300: Gp 7 Nvm Dump Of Adjustable Settings
No parity 9-21-3 V(LOW) • Data bits: 8 9-21-4 CP VOLTS. VOLTS Hold down the zero button on the 8850/510dp/510dp Printer Control Panel, and turn on 9-21-6 BIAS OFFSET VOLTS the Controller and the Printer. VOLTAGE General Procedures 03/2003 GP 7...
Page 301: Gp 8 Toner Control System Calibration
2): Estimate the humidity in the customer’s site then answer the question by entering 1 or 3 using the numeric key pad. The following message will be displayed. Figure 2 Confirming the Humidity Setup General Procedures 03/2003 GP 7, GP 8 8850/ 510DP 6-15...
Page 302 If the darkness square is not between 1.2 and 1.4, perform the adjustment again, starting at Step 2.. 10. Enter [0921-4] and make a record of the CONTROL POINT VOLTS and the RAW SEN- SOR VOLTS in the Printer Log Book. General Procedures 03/2003 GP 8 6-16 8850/ 510DP...
Page 303: Gp 9 Tone Down Procedure
Control Point. If the density is to light, decrease the Control Point in 0.2 volt increments until the density is within specification and allow the printer to operate at the new control point. General Procedures 03/2003 GP 9 8850/ 510DP 6-17...
Page 304 General Procedures 03/2003 GP 9 6-18 8850/ 510DP...
Page 305: System Configuration And Components
System Configuration and Components Purpose The purpose is to identify the components and module required to install the 8850 DS/SPS 510dp. Table 1 8850 DS/ SPS 510dp Components and Modules Synergix 8850 Digital Synergix 8850 Digital Solution with 2 inch/...
Page 306 Solution with 4 inch/ Description Part Number/Product Code Printer second second and SPS 510dp 8850 Tracing Paper Humidity Kit 98S04620/ GGV Synergix Scanner Compact Catch Tray 98S04457/ WP4 88XX Series Folder VPI 20 Ft. Shielded Cable 98K39960 VPI 50 Ft. Shielded Cable 98K39970 VPI 200 Ft.
Page 307: Installation Procedure
USO ONLY 220 VAC 20 AMP 115 VAC 20AMP NOTE: Except where specified, the install procedure is common to both the 8850 and the 10 D (A1)-D size prints (5 or 7 D (A1)-size prints per minute 510dp Printers. Photographs and illustration are mainly of the 8850.
Page 308 89” (222.5 cm) Front Rear 43.5” (108 cm) 36” (91.4cm) 129” 56.75” (328cm) (141.25 cm) 59.3” (150.6 cm Figure 3 8850 Minimum Space Requirements Figure 2 IOT Dimensions (Figure 3): Minimum Space Requirements. General Procedures 03/2003 Installation Procedure 6-22 8850/ 510DP...
Page 309 24.0 ” (61.0 cm) 36” 36” (91.4 cm) (91.4 cm) 77” (196cm) 36” (91.4 cm) 129” (328cm) Figure 4 510dp Minimum Floor Space Requirements General Procedures 03/2003 Installation Procedure 8850/ 510DP 6-23...
Page 310 NOTE: The Heat Lamps may not be in the Media Drawer. The Heat Lamps are being shipped in the Heat Roll on SPS 510dp and newer version of 8850 Printers. CAUTION When handling the Fuser Heat Rods, body oils must never contact the glass. Use a sheet of paper to support the glass during handling.
Page 311 Takeup Roll clockwise to remove any remaining slack in that roll Figure 8 Reinstalling the Web Oiler Assembly (Figure 9): Remove the shipping pads located near the ends of the image module. General Procedures 03/2003 Installation Procedure 8850/ 510DP 6-25...
Page 312 12. Lift open the developer module door, located on the top right side of the Printer. 13. Remove the toner cartridge from the developer module. General Procedures 03/2003 Installation Procedure 6-26 8850/ 510DP...
Page 313 Remove full length of sump shield to remove shield lip from under the front edge of the developer module Figure 11 Removing the sump shield General Procedures 03/2003 Installation Procedure 8850/ 510DP 6-27...
Page 314 Position the sump shield in the sump by rotating it around the plunger Figure 14 Disengaging the Developer Drive Figure 13 Reinstalling the sump shield General Procedures 03/2003 Installation Procedure 6-28 8850/ 510DP...
Page 315 Figure 15 Reinstalling the toner cartridge Figure 16 Completing the toner cartridge installation 21. Close the developer module cover. 22. Raise and hold the top cover while reinstalling the rear developer cover. General Procedures 03/2003 Installation Procedure 8850/ 510DP 6-29...
Page 316 NOTE: To ensure that the Printer frame is not twisted, use a level on both end frames to per- form the side-to-side level check. NOTE: Adjust the end that is farthest out of level first. General Procedures 03/2003 Installation Procedure 6-30 8850/ 510DP...
Page 317 Rotate the bolts to adjust Repeat Step 1 at the other Printer. the level of the Printer end of the Printer Figure 19 Adjusting the side-to-side level Figure 20 Adjusting the front-to-rear level of the Printer General Procedures 03/2003 Installation Procedure 8850/ 510DP 6-31...
Page 318 ): HFT Conroller: Install the P193 Interface Cover, then continue with Step 35. Figure 22 Installing the P193 Cover to Connect the HFT Controller 34. Refer to the appropriate AccXES Controller Service Manual, 8825. 8830. and 8850 Con- troller Installation to install the Controller.
Page 319 Controller serial number • Hardware address of the Ethernet Advanced Port 39. If the Printer is being installed as part of the 8850 DS/SPS 510dp, proceed to the Syn- ergix Scanner Service Manual, Section 6, Installation. Otherwise, continue on with the next step.
Page 320: Product Demonstration
10. Place a print of the Configuration Sheet inside the Front Door. 11. Record the following on the Printer Installation Quality Report card: • Print count readings, Meter A and Meter B • Printer serial number • Installation date • Comments General Procedures 03/2003 Installation Procedure, Product Demonstration 6-34 8850/ 510DP...
Page 321: Installation Checklist
16. Check the operator adjustments. Product Demonstration Checklist ON/OFF switch, Print Count Meter, and serial number plate. Control Console. Replacing the Toner Cartridge. Problem solving status codes. General Procedures 03/2003 Installation Checklist 8850/ 510DP 6-35...
Page 322 Disconnect the Controller ribbon cable from J307B on the Main PWB. Place the Controller in the Anti-static Bag, install the Top and Bottom End Caps, and place the assembly into the box. Secure the box with tape. General Procedures 03/2003 Removal Procedure 6-36 8850/ 510DP...
Page 323 19. Remove the Heat Rods (REP 10.1). Wrap in bubble pack. Tape cardboard to the entire length. Place in a Roll Media Supply Drawer. Secure the Roll Media Supply Drawer with tape General Procedures 03/2003 Removal Procedure 8850/ 510DP 6-37...
Page 324 21. Close the Fuser Drawer Cover. 22. Close the front door and the rear door. 23. Secure the front and rear doors with tape. 24. Secure the developer module door with tape. General Procedures 03/2003 Removal Procedure 6-38 8850/ 510DP...
Page 325: General Tools And Supplies (Naco)
20 lb. Roll Bond Media 22E630 Line Level 600T41510 Oil Tube (8 cc) 93E811 Round File, 6 inch 600T41801 Log Holder 600P293 Flat File, 6 inch 600T41802 Media Message 600P60017 General Procedures 03/2003 General Tools and Supplies (NACO) 8850/ 510DP 6-39...
Page 326: General Tools And Supplies (Eo)
600T1923 Test Leads (required for 600T2020) 600T1660 Electrometer 600T1620 Electrometer Probe Wing 600T1728 Table 2 Machine Consumable (EO) Machine Consumable (EO) Description Part Photoreceptor 1R535 Toner 6R989 General Procedures 03/2003 General Tools and Supplies (NACO), General Tools 6-40 8850/ 510DP...
Page 327 Grease Alvania No 2 600T90340 Silicone Grease 600T90429 Table 7 Nationalization Kits Nationalization Kits Generic Contents Part User Guide Ref. Only Safety Label (Non-English) Ref. Only Safety Label, Rails (Non-English) Ref. Only General Procedures 03/2003 General Tools and Supplies (EO) 8850/ 510DP 6-41...
Page 328: Molex Connector Repair Procedure
NOTE: Insert the Extractor Tab until the face of the tool is flush with the connector housing. ual module connec- module connectors from module connectors remain in tors are removed from the housing within the housing the housing Figure 1 Molex Extraction Tool Components General Procedures 03/2003 Molex Connector Repair Procedure 6-42 8850/ 510DP...
Page 329 (Terminal shown rotated 90 degrees) Insert the short Extractor Tab through the window in the module connector Terminal removal through the connector Figure 3 Removing the Terminal from the Connector General Procedures 03/2003 Molex Connector Repair Procedure 8850/ 510DP 6-43...
Page 330 Reinstall the terminal to the pin position from which it was removed. Reinstall the individual module connectors to the correct locations noted at the beginning of this procedure. Refer to Section 7 for detail of connector configuration. General Procedures 03/2003 Molex Connector Repair Procedure 6-44 8850/ 510DP...
Page 331: Product Specifications Product Specifications
(914 mm) (Figure 1): Printer front dimensions 129” (3277 mm) Figure 2 Printer Footprint 42.5” (1080 mm) 57” (1450 mm) Figure 1 Printer Front Dimensions Minimum Space Requirements (Figure 2): Printer footprint General Procedures 03/2003 Product Specifications 8850/ 510DP 6-45...
Page 332 Maximum Size 36” X 48 feet (914 mm X 12.2 m) Environmental Conditions 80 feet (24.4 m) Optional Temperature: Maximum 80°F (27°C) Minimum 60°F (10°C) Humidity: Maximum 80% Minimum 20% Maximum Elevation: 10,000 feet (3048 m) General Procedures 03/2003 Product Specifications 6-46 8850/ 510DP...
Page 333: 8850 Change Tag Information
Developer Heater PURPOSE: To control the temperature of the developer material to prevent a low tribo con- dition (Sleep Mode) in high humidity conditions. KIT NUMBER: 605K11690 REFERENCE: General Procedures 03/2003 8850 Change Tag Information, SPS 510dp Change 8850/ 510DP 6-47...
Page 334 The purpose is to provide an oiler end cap made of different material and add a hole in the Fuser frame to accommodate the lamp wiring KIT NUMBER: 604K12880 KIT NUMBER: REFERENCE: REFERENCE: PL 10.5 General Procedures 03/2003 SPS 510dp Change Tag Information, SPS 510dp 6-48 8850/ 510DP...
Page 335: Sps 510Dp Change Tag Information
R - Repair TAG: CLASS: USE: MFG SERIAL NUMBERS: NAME: 8850 TAGS PURPOSE: To indicate that all 8850 tags that are applicable are built into the SPS510dp. KIT NUMBER: REFERENCE: General Procedures 03/2003 SPS 510dp Change Tag Information 8850/ 510DP 6-49...
Page 336 General Procedures 03/2003 SPS 510dp Change Tag Information 6-50 8850/ 510DP...
Page 337 BSD 9.5 Drum Cleaning ....................7-54 BSD 9.6 Drum Discharging ..................... 7-56 BSD 9.7 Toner/Developer Dispense ................7-58 BSD 9.8 Corotron and Developer Bias Power ..............7-61 Fusing and Transportation BSD 10.1 Fuser Heat ..................... 7-63 Wiring Data 03/2003 8850/ 510DP...
Page 338 Wiring Data 03/2003 8850/ 510DP...
Page 339: How To Use Bsds
Diagnostic Code information to assist you in identifying the specific fault. NOTE: In the Block Schematic Diagrams that follow, FOR = Forever (unswitched), BULK = switched. Wiring Data 03/2003 How To Use BSDs 8850/ 510DP...
Page 340: Level 1 Bsd
Level 1 BSD Wiring Data 03/2003 Level 1 BSD 8850/ 510DP...
Page 341 Wiring Data 03/2003 Level 1 BSD 8850/ 510DP...
Page 342 Wiring Data 03/2003 Level 1 BSD 8850/ 510DP...
Page 343 Wiring Data 03/2003 Level 1 BSD 8850/ 510DP...
Page 344: Bsd 1.1 Main Power On (50 And 60 Hz)
BSD 1.1 Main Power On (50 and 60 HZ) Wiring Data 03/2003 BSD 1.1 8850/ 510DP...
Page 345 NOTE: 4: The Varistor has been added to provide additional electrical noise suppression. If it fails in a shorted condition, it will cause the Surge Voltage Protector to continually trip. A1A2P/J5 A1P/J8 A1P/J7 A1P/J3 Figure 1 AC MODULE Wiring Data 03/2003 BSD 1.1 8850/ 510DP...
Page 346: Bsd 1.2 Dc Power Generation (1 Of 3)
BSD 1.2 DC Power Generation (1 of 3) Wiring Data 03/2003 BSD 1.2 7-10 8850/ 510DP...
Page 347 MAIN PWB (A3) J619 - 1 12 VDC+24 VDC MAIN PWB (A3) J618 - 10 (FOR)+24 VDC MAIN PWB (A3) J618 - 12 (BULK) MAIN PWB (A3) J617 - 1 MAIN PWB (A3) J614 - 2 Wiring Data 03/2003 BSD 1.2 8850/ 510DP 7-11...
Page 348: Bsd 1.3 Interlock Monitoring (1 Of 4)
BSD 1.3 Interlock Monitoring (1 OF 4) Wiring Data 03/2003 BSD 1.3 7-12 8850/ 510DP...
Page 349 1.3 Interlock Monitoring (2 0F 4) Wiring Data 03/2003 BSD 1.3 8850/ 510DP 7-13...
Page 350 1.3 Interlock Monitoring (3 OF 4) Fuser Interlock Figure 1 Fuser Drawer Interlock Front Door Interlock Figure 2 Front Door Interlock Wiring Data 03/2003 BSD 1.3 7-14 8850/ 510DP...
Page 351 1.3 Interlock Monitoring (4 OF 4) CUTTER DRAWER INTERLOCK TOP COVER INTER- Figure 4 Cutter Drawer Interlock LOCK Figure 3 Top Cover Interlock Wiring Data 03/2003 BSD 1.3 8850/ 510DP 7-15...
Page 352: Bsd 1.4 Machine Cooling
BSD 1.4 Machine Cooling Wiring Data 03/2003 BSD 1.4 7-16 8850/ 510DP...
Page 353: Bsd 2.1 Mode Selection
BSD 2.1 Mode Selection Wiring Data 03/2003 BSD 2.1 8850/ 510DP 7-17...
Page 354 Wiring Data 03/2003 BSD 2.1 7-18 8850/ 510DP...
Page 355: Bsd 3.1 Machine Run Control
BSD 3.1 Machine Run Control Wiring Data 03/2003 BSD 3.1 8850/ 510DP 7-19...
Page 356 Wiring Data 03/2003 BSD 3.1 7-20 8850/ 510DP...
Page 357: Bsd 4.1 Fuser Heat Roll Drive
BSD 4.1 Fuser Heat Roll Drive Wiring Data 03/2003 BSD 4.1 8850/ 510DP 7-21...
Page 358: Bsd 4.2 Developer Drive
BSD 4.2 Developer Drive BSD 4.3 Drum Drive Wiring Data 03/2003 BSD 4.2, BSD 4.3 7-22 8850/ 510DP...
Page 359 Wiring Data 03/2003 BSD 4.3 8850/ 510DP 7-23...
Page 360: Bsd 6.1 Imaging Right Side
BSD 6.1 Imaging Right Side Wiring Data 03/2003 BSD 6.1 7-24 8850/ 510DP...
Page 361 Wiring Data 03/2003 BSD 6.1 8850/ 510DP 7-25...
Page 362 Wiring Data 03/2003 BSD 6.1 7-26 8850/ 510DP...
Page 363: Bsd 7.1 Media Drive
BSD 7.1 Media Drive Wiring Data 03/2003 BSD 7.1 8850/ 510DP 7-27...
Page 364 Wiring Data 03/2003 BSD 7.1 7-28 8850/ 510DP...
Page 365: Bsd 7.2 Media Feed, Roll 1
BSD 7.2 Media Feed, Roll 1 Wiring Data 03/2003 BSD 7.2 8850/ 510DP 7-29...
Page 366 Wiring Data 03/2003 BSD 7.2 7-30 8850/ 510DP...
Page 367: Bsd 7.3 Media Feed, Roll 2
BSD 7.3 Media Feed, Roll 2 Wiring Data 03/2003 BSD 7.3 8850/ 510DP 7-31...
Page 368 Wiring Data 03/2003 BSD 7.3 7-32 8850/ 510DP...
Page 369: Bsd 7.4 Media Feed, Roll 3
BSD 7.4 Media Feed, Roll 3 Wiring Data 03/2003 BSD 7.4 8850/ 510DP 7-33...
Page 370 Wiring Data 03/2003 BSD 7.4 7-34 8850/ 510DP...
Page 371: Bsd 7.5 Media Cutting
BSD 7.5 Media Cutting Wiring Data 03/2003 BSD 7.5 8850/ 510DP 7-35...
Page 372 Wiring Data 03/2003 BSD 7.5 7-36 8850/ 510DP...
Page 373: Bsd 8.1 Sheet Feed Registration And Transportation (1 Of 2)
BSD 8.1 Sheet Feed Registration and Transportation (1 of Wiring Data 03/2003 BSD 8.1 8850/ 510DP 7-37...
Page 374: Bsd 8.2 Media Registration And Transportation
BSD 8.2 Media Registration and Transportation Wiring Data 03/2003 BSD 8.1, BSD 8.2 7-38 8850/ 510DP...
Page 375 Wiring Data 03/2003 BSD 8.2 8850/ 510DP 7-39...
Page 376 Wiring Data 03/2003 BSD 8.2 7-40 8850/ 510DP...
Page 377 Wiring Data 03/2003 BSD 8.2 8850/ 510DP 7-41...
Page 378: Bsd 8.3 Print Transportation
BSD 8.3 Print Transportation Figure 1 Print Transportation (1 of 2) Wiring Data 03/2003 BSD 8.3 7-42 8850/ 510DP...
Page 379 Figure 2 Print Transportation (2 of 2) Wiring Data 03/2003 BSD 8.3 8850/ 510DP 7-43...
Page 380: Bsd 9.1 Charging
BSD 9.1 Charging Figure 1 Charging (1 of 2) Wiring Data 03/2003 BSD 9.1 7-44 8850/ 510DP...
Page 381 Figure 2 Charging (2 of 3) Wiring Data 03/2003 BSD 9.1 8850/ 510DP 7-45...
Page 382 Figure 3 Charging (3 of 3) Wiring Data 03/2003 BSD 9.1 7-46 8850/ 510DP...
Page 383: Bsd 9.2 Exposure
BSD 9.2 Exposure Figure 1 Exposure (1 of 1) Wiring Data 03/2003 BSD 9.2 8850/ 510DP 7-47...
Page 384: Bsd 9.3 Development
BSD 9.3 Development Figure 1 Development (1 of 4) Wiring Data 03/2003 BSD 9.3 7-48 8850/ 510DP...
Page 385 Figure 2 Development (2 of 4) Wiring Data 03/2003 BSD 9.3 8850/ 510DP 7-49...
Page 386 Figure 3 Development (3 of 4) Wiring Data 03/2003 BSD 9.3 7-50 8850/ 510DP...
Page 387 Figure 4 Development (4 of 4) Wiring Data 03/2003 BSD 9.3 8850/ 510DP 7-51...
Page 388: Bsd 9.4 Image Transfer And Media Stripping
BSD 9.4 Image Transfer and Media Stripping Figure 1 Image Transfer and Media Stripping (1 of 2) Wiring Data 03/2003 BSD 9.4 7-52 8850/ 510DP...
Page 389 Figure 2 Image Transfer and Media Stripping (2 of 2) Wiring Data 03/2003 BSD 9.4 8850/ 510DP 7-53...
Page 390: Bsd 9.5 Drum Cleaning
BSD 9.5 Drum Cleaning Figure 1 Drum Cleaning (1 of 2) Wiring Data 03/2003 BSD 9.5 7-54 8850/ 510DP...
Page 391 Figure 2 Drum Cleaning (2 of 2) Wiring Data 03/2003 BSD 9.5 8850/ 510DP 7-55...
Page 392: Bsd 9.6 Drum Discharging
BSD 9.6 Drum Discharging Figure 1 Drum Discharging (1 of 2) Wiring Data 03/2003 BSD 9.6 7-56 8850/ 510DP...
Page 393 Figure 2 Drum Discharging (2 of 2) Wiring Data 03/2003 BSD 9.6 8850/ 510DP 7-57...
Page 394: Bsd 9.7 Toner/Developer Dispense
BSD 9.7 Toner/Developer Dispense Figure 1 Toner/Developer Dispense (1 of 3) Wiring Data 03/2003 BSD 9.7 7-58 8850/ 510DP...
Page 395 Figure 2 Toner/Developer Dispense (2 of 3) Wiring Data 03/2003 BSD 9.7 8850/ 510DP 7-59...
Page 396 Figure 3 Toner/Developer Dispense (3 of 3) Wiring Data 03/2003 BSD 9.7 7-60 8850/ 510DP...
Page 397: Bsd 9.8 Corotron And Developer Bias Power
BSD 9.8 Corotron and Developer Bias Power Wiring Data 03/2003 BSD 9.8 8850/ 510DP 7-61...
Page 398 Wiring Data 03/2003 BSD 9.8 7-62 8850/ 510DP...
Page 399 BSD 10.1 Fuser Heat Figure 1 Fuser Heat (1 of 3) Wiring Data 03/2003 BSD 10.1 8850/ 510DP 7-63...
Page 400 Figure 2 Fuser Heat (2 of 3) Wiring Data 03/2003 BSD 10.1 7-64 8850/ 510DP...
Page 401 Figure 3 Fuser Heat (3 of 3) Wiring Data 03/2003 BSD 10.1 8850/ 510DP 7-65...
Page 402 BSD 10.2 Fuser Oil Dispensing Wiring Data 03/2003 BSD 10.2 7-66 8850/ 510DP...
Page 403 Figure 1 Fuser Oil Dispensing (2 of 2) Wiring Data 03/2003 BSD 10.2 8850/ 510DP 7-67...
Page 404 BSD 10.3 Fusing and Jam Detection Wiring Data 03/2003 BSD 10.3 7-68 8850/ 510DP...
Page 405 Wiring Data 03/2003 BSD 10.3 8850/ 510DP 7-69...
Page 406 Wiring Data 03/2003 BSD 10.3 7-70 8850/ 510DP...
Page 407 Wiring Data 03/2003 BSD 10.3 8850/ 510DP 7-71...
Page 408 Wiring Data 03/2003 BSD 10.3 7-72 8850/ 510DP...
Page 409 Toner Cartridge Drive Motor BSD 9.7 Figure 9 Supply A22P1/J1 Developer Assembly BSD 9.7 Figure 8 A3P606/J606 Main PWB to Developer Module Figure 4 A22Q1P1/J1 Toner Sensor BSD 9.7 Figure 10.1 A22Q1P1A/J1A Figure 12 Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-73...
Page 410 MOT2-1 and -2 Cooling Fan Motor BSD 1.4 Cutter Cover Interlock Switch BSD 1.3 Drawer 1 Reed Switch BSD 7.1 Drawer 2 Reed Switch BSD 7.1 Drawer 3 Reed Switch BSD 7.1 Wiring Data 03/2003 Plug/Jack List 7-74 8850/ 510DP...
Page 411 AC Power Module (A1) Exterior P/J 9 (Not visible in photograph) A1A2P/J5 P/J 8 P/J7 P/J 3 A1P5 Figure 1 AC Module (A1) Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-75...
Page 412 AC Power Module (A1) Interior (1 of 2) P/J 11 A1GFP1 A1FL1 A1S1 Figure 2 AC Module Interior Wiring Data 03/2003 Plug/Jack List 7-76 8850/ 510DP...
Page 413 AC Power Module (A1) Interior (2 of 2) Ground Fault Interrupt AC Receptacle Line Filter Main Power Switch (S1) Figure 3 AC Power Module (A1) Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-77...
Page 414 P/J 620 PJ 608 P/J 619 P/J609 P/J 618 J900 P/J 617 P/J612A P/J612 P/J 611 P/J 610 P/J 616 P/J 614 P/J 613 P/J 615 Figure 4 Main PWB Connectors (A3)j Wiring Data 03/2003 Plug/Jack List 7-78 8850/ 510DP...
Page 415 Low Voltage Power Supply (A5), Lower Frame Assembly Roll Feed Sensors (A0) A3J619A A0Q1P1/J1 A5PS1P1 A0Q3P1/J1 A0Q2P1/J1 Figure 5 LVPS and Roll Feed Sensors Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-79...
Page 416 Roll Feed (A7), Rear Lower Frame Assembly (A0) A0Q4P1/J1 A0L2P1/J1 A24P1/J1 A0L1P1/J1 A24P2/J2 A9P2/J2 A0L3P1/J1 A9P1/J1 A7P2/J2 A0Q5P1/J1 A0L4P1/J1 A7P1/J1 A0Q6P1/J1 A0L5P1/J1 A0L6P1/J1 Figure 6 Rear Lower Frame Assembly Media Roll Drives Wiring Data 03/2003 Plug/Jack List 7-80 8850/ 510DP...
Page 417 Cutter Motor (A8) A8M1P1/J1 A8Q1P1/J1 Figure 7 Cutter Motor (A8) Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-81...
Page 418 Fuser and Developer Drive (A20) and Vacuum Transport Fan (A0) A20M1P1/J1 Front Door Inter- A20M2P1 J1 (on lock Switch PWB) A0P/J3A A0P/J1A A0P/J2A A0B1P1/J1 Figure 8 Fuser/Developer Drives and Vacuum Transport Fan Wiring Data 03/2003 Plug/Jack List 7-82 8850/ 510DP...
Page 419 Media Transport (A21) A21P1/J1 Figure 9 Media Transport Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-83...
Page 420 Media Transport (A21) A21Q1P1/J1 MEDIA REGISTRATION SENSOR BIAS TRANSFER ROLL DETACK Figure 10 Media Transport Wiring Data 03/2003 Plug/Jack List 7-84 8850/ 510DP...
Page 421 Developer Module (A22) NOTE: A22Q1 and Q2 connectors are shown out of the harness channel for clarity. A22Q1P1/J1 A22P1/J1 Figure 11 Developer Right Side Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-85...
Page 422 A22M1P1/J1 A22Q2P1/J1 A22Q1P1A/J1A Figure 12 Toner Dispenser Motor Wiring Data 03/2003 Plug/Jack List 7-86 8850/ 510DP...
Page 423 Drum Drive Motor (A23) and ESV (A29) A31P1/J1 A20P2/J2 A23Q2P1/J1 A23M3P1/J1 Figure 13 Drum Drive Motor and ESV Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-87...
Page 424 Erase Bar (A23) A23P1J1 Figure 14 Erase Bar Connector Wiring Data 03/2003 Plug/Jack List 7-88 8850/ 510DP...
Page 425 High Voltage Power Supply (HVPS) (A25) A25J3 Scorotron Grid A25J4 Developer Bias A25J2 Charge A25J5 Bias Transfer Roll A25J6 Detack A25/J7 A25P1/J1 Figure 15 High Voltage Power Supply Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-89...
Page 426 Fuser Drawer (A27) A27HR2P1/J1 A27HR1J1/P1 A27RT3P1/J1 A27RT2P1/J1 THERMAL FUSE (F1) A27Q2P1 A27M1P1/ A27P3/J3 AQ27P2/J2 Figure 16 Fuser Assembly (A27) Wiring Data 03/2003 Plug/Jack List 7-90 8850/ 510DP...
Page 427 Fuser Drawer (A27) (continued) A27HR1P2/J2 A27HR2P2/J2 Figure 17 Fuser Left Side Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-91...
Page 428 Fuser Drawer (A27) (continued) A27P1/J1 Figure 18 Fuser Drawer Connector Wiring Data 03/2003 Plug/Jack List 7-92 8850/ 510DP...
Page 429 Fuser Drawer (A27) (continued) A27Q2P1/J1 AQ27Q1P1/J1 View of connector A27Q1P1/J1 is from under the Fuser Drawer with the Bottom Plate removed. Figure 19 Fuser Exit and Stack Height Sensors Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-93...
Page 430 Lower Sheet Feed Assembly(A28) A28M1P1/J1 A28Q1P1/J1 A28P1/J1 Figure 20 Lower Sheet Feed Assembly (A28) Wiring Data 03/2003 Plug/Jack List 7-94 8850/ 510DP...
Page 431 LED BAR (A29 and A30) A320P1 A30J2, A30J3 A29P4 A29P2 A29P3 A29P1 (beneath connectors) Figure 21 LED Bar and LED Jumper PWB (view through rear of Printer with Top Cover and Developer Cover raised) Wiring Data 03/2003 Plug/Jack List 8850/ 510DP 7-95...
Page 432 Control Panel (A32) A32P1/J1 A32P2/J2 Figure 22 Control Panel Connectors Wiring Data 03/2003 Plug/Jack List 7-96 8850/ 510DP...

This manual is also suitable for:

510dp

Xerox 8850 Service Manual

Introduction

1 Service Call Procedures

3 Print Quality

4 Repairs and Adjustments

5 Parts Lists

Overview

Parts Lists

Nohad

Image Module

Two Roll Fuser

Parts Lists

Covers

Common Hardware

6 General Procedures

General Procedures

Tools

Product Specifications Product Specifications

7 Wiring Data

Quick Links

Chapters

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Summary of Contents for Xerox 8850