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Xerox 8855 Service Manual

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Xerox 8855

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Xerox 8855

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Page 1 Xerox 8855 Service Manual Xerox 8855...
Page 3 This manual replaces the 701P10270. Change Highlights: Corrections have been made based on feedback from Field Engineering and the field. Section 5: The parts lists for the 8855 IOT have been updated. Section 8A: Information added about the new 7399 Scanner Section 8A5: The parts lists for the 7396 Scanner have been updated.
Page 5 Xerox 8855 Printer Service Manual CAUTION Certain components in the 8855 are susceptible to damage from electrostatic discharge. Observe all ESD procedures in order to avoid component 701P15530 damage May 1999...
Page 6 Xerox service to the attention of the users of the 8855. documentation is intended for use by certified, product trained service personnel Federal Communications Commission radio only. Xerox does not warrant or represent frequency interference statement.
Page 7: Revision Control List
Revision Control List Product Title Part Number Date 8855 Printer Service Manual 701P15530 May 1999 Page Page Page Page Page Page Title 5/99 3-22 5/99 4-59 5/99 5/99 4-28 5/99 5-20 2/99 5/99 3-23 5/99 4-60 5/99 5/99 4-29 5/99...
Page 8 Page Page Page Page Page Page 7-18 5/99 8A 1-1 5/99 8A 5-1 5/99 8A 6-21 5/99 5-52 2/99 6-18 5/99 7-19 5/99 8A 1-2 5/99 8A 5-2 5/99 8A 6-22 5/99 5-53 2/99 6-19 5/99 5-54 2/99 6-20 5/99 7-20 5/99 8A 1-3...
Page 9 Page Page 8A 7-20 5/99 8B 5-1 2/99 8A 7-21 5/99 8B 5-2 2/99 8A 7-22 5/99 8B 5-3 2/99 8A 7-23 5/99 8B 5-4 2/99 8A 7-24 5/99 8B 5-5 2/99 8A 7-25 5/99 8B 5-6 2/99 8A 7-26 5/99 8B 5-7 2/99...
Page 10 Notes:...
Page 11: Table Of Contents
Section 3 Print Quality RAPs......3-1 Section 4 Repairs and Adjustments ....4-1 Section 5 Parts Lists ........5-1 Section 6 General Procedures ......6-1 ......Section 7 Wiring Data Section 8 Accessories: 7396/ 7399 Scanners ........8A 8855 Stacker ..........8B 5/99 Table of Contents 8855...
Page 12: Introduction
Service Section 2, component control code, and a BSD Procedures (RAPs) necessary to repair the Representative to repair the 8855. reference. faults. When using a RAP, always exit procedure when the fault is fixed. Do not Printer Maintenance Organization perform the remaining steps.
Page 13: Section 6 General Procedures
Procedures, General Information, which includes Product Specifications for the 8855. Section 7. - Wiring Data This section contains Plug/ Jack Location Index, Plug/ Jack Location Drawings, and the BSDs. Section 8. - Accessories This section contains the complete service documentation for the scanners and stacker.
Page 14 Notes: 5/99 8855...
Page 15: Service Call Procedures
Introduction ............1-2 Call Flow Diagram..........1-3 Initial Actions / System Checks ......1-4 Print Defect Isolation Procedure ......1-5 Status Code Entry Chart ........1-6 Subsystem Checks ..........1-13 System Checkout / Final Action ......1-16 5/99 Section Contents 8855...
Page 16: Introduction
Introduction Use the Service Call Procedure as maintenance guide when performing the service on the 8855 Printer. The procedure has been designed for use with the 8855 Service Manual. • Initial Actions / System Checks - This diagram is designed to identify and...
Page 17: Section 8 Of This Manual
DETERMINE WHICH PIECE OF EQUIPMENT NEEDS SERVICE SCANNER PROBLEM 8855 PROBLEM CONTROLLER STACKER PROBLEM 7336/7356/7396 PROBLEM REFER TO THE 8855 REFER TO THE REFER TO THE XEROX WORKSTATION DOCUMENTATION REFER TO SECTION 8 OF APPROPRIATE STACKER THIS MANUAL. SCANNER DOCUMENTATION IN...
Page 18: Initial Actions/System Checks
Go to Status Code Entry Chart Go to Print Defect Isolation Procedure Go to OF 1.1 Blank Indicator RAP in this section • SELECTION/ INDICATION PROBLEMS Go to OF 2.1 Selection/ Indication Go to Subsystem Checks. 5/99 Initial Actions/System Checks 8855...
Page 19: Print Defect Isolation Procedure
Procedure in Section 3 of the 7396 print parameters that the customer is using. Service manual. Perform GP1 or GP2 to confirm the problem. (Procedures located in Section 6 of this manual.) 5/99 Print Defect Isolation Procedure 8855...
Page 20: Status Code Entry Chart
1. Developer motor running signal remained high for 1 second after the developer motor was switched on. 2. Developer motor running signal remained low for 1 second after the developer motor was switched off. 5/99 Status Code Entry Chart 8855...
Page 21 2. The cutter blade did not reach the home within 0.8 seconds after the cutter motor was switched on. 3. The cutter blade did not reach the home position within 4 seconds after the main power was switched on. 5/99 Status Code Entry Chart 8855...
Page 22 DC controller PWB PL 10.3 Thermostat is open. E-41 Status Code E-41 displayed. Enter Service mode (4-F) and ensure that Key Card feature is set to 0. Cannot be cleared by cycling machine OFF and ON. 5/99 Status Code Entry Chart 8855...
Page 23 (Manual Feeder) 1. Paper is at the manual feed sensor while main power is switched on. Paper did not reach roll 1 paper set sensor within 2 seconds after the manual feed clutch was energized. 5/99 Status Code Entry Chart 8855...
Page 24 Fuser exit switch (LS 2) [1-2b] 10.5 PL 4.3 DC controller PWB PL 10.3 Excessive Buckle at Detack Area Paper did not reach the fuser exit switch within 3.9 seconds after the registration clutch was energized. 5/99 Status Code Entry Chart 8855 1-10...
Page 25 Roll 3 feed clock sensor drive belt out [1-26] PL 7.15 of position. Roll 3 paper set sensor did not detect paper. Paper set sensor (Q 3) PL 7.13 DC controller PWB PL 10.3 5/99 Status Code Entry Chart 8855 1-11...
Page 26 DC controller PWB PL 10.3 Bottom drawer is opened. U-04 Inner transport is open Inner transport set sensor (Q 24) [1-1C] 10.1 PL 6.4 DC controller PWB PL 10.3 Inner transport is not set. 5/99 Status Code Entry Chart 8855 1-12...
Page 27: Subsystem Checks
Magnetic Roller 656K feet Check Replace (200K metres) Developer Catch Check Clean the Registration Rolls, Tray and vacuum the Developer Catch Tray every service call. Drum Drive Clean Lubricate with Molybdenum Gears Grease (70P87) 5/99 Subsystem Checks 8855 1-13...
Page 28 Do not clean the Cleaner Inspect and replace if (20K metres) Check Blade with a cloth. If you necessary. vacuum the blade, reapply ® Kynar Cleaner Seal 65K feet Check Inspect and replace if (20K metres) necessary. 5/99 Subsystem Checks 8855 1-14...
Page 29 CHECK = Check, and if required, clean, replace, or adjust. = Must clean = Must replace Component Expected Life Every Cautions Descriptions Problem Indicators Call Feed Rolls Clean Clean with Film Remover Registration Clean Clean with Film Remover Rollers 5/99 Subsystem Checks 8855 1-15...
Page 30: System Checkout / Final Action
Service Meter B is reported under Total on the XSCR form. Billing Meter B reports linear feet / metres. To access Meter B, remove the two screws and lower the Control Panel Cover. 5/99 System Checkout / Final Action 8855 1-16...
Page 31: Repair Analysis Procedures (Raps)
2. Repair Analysis Procedures (RAPs) Section Contents TITLE PAGE STATUS INDICATORS E-01 Fuser Undertemperature....2-2 E-02 Fuser Overtemperature...... 2-4 J-12 Separator Jam ........2-5 OTHER FAULTS 1.1 Blank Indicator RAP ......2-6 2.1 Selection/Indication RAP ...... 2-7 5/99 Section Contents 8855...
Page 32 DC controller Check the wiring for an open (BSD 10.2). PWB as necessary (BSD 10.2). or short circuit. If the wiring is okay, replace the DC driver PWB (BSD 10.3). 5/99 E-01 Fuser Undertemperature RAP 8855...
Page 33 Check thermistor (RT 1) (BSD 10.3) and the wiring for an open or short circuit. Replace the thermistor, or replace the DC controller PWB as necessary (BSD 10.3). Replace the DC controller PWB (BSD 10.3). 5/99 8855 E-01 Fuser Undertemperature RAP...
Page 34 The resistance between J1 pins 1 and 3 is Infinite (open). Check the wiring to center SSR (SSR 1) for a short circuit. Replace the center SSR (SSR 1) or the DC driver PWB as required (BSD 10.3). 5/99 E-02 Fuser Overtemperature RAP 8855...
Page 35 Perform the following: • Clean the transfer (ED 2) and detack (ED 3) corotrons (BSD 9.4). • Clean and inspect the separation blower (BSD 10.1). • Clean and inspect the separation lamp (BSD 9.5). • 5/99 J-12 Separator Jam RAP 8855...
Page 36 Replace the AC terminal PWB (BSD 1.1). • LVPS 1 (BSD 1.2). • Replace the low voltage power supply Auxiliary PWB (BSD 1.4). • (LVPS 1) (BSD 1.2). Fuser relays (K 2) (BSD 10.3) and (K 3) (BSD 10.2). 5/99 1.1 Blank Indicator RAP 8855...
Page 37 For selection problems perform the following: Disconnect J211 at the DC controller PWB and check the wiring for an open circuit. Replace the indicator PWB or DC controller PWB as required (BSD 2.1). 5/99 OF 2.1 Selection / Indicator RAP 8855...
Page 38 Notes: 5/99 8855...
Page 39 PQ 13 Light Image ........3-19 PQ 14 Misregistration.........3-20 PQ 15 Residual Image .......3-21 PQ 16 Skewed Image ........3-21 PQ 17 Smears..........3-22 PQ 18 Spots ..........3-22 PQ 19 Uneven Density.......3-23 PQ 20 Unfused Prints.........3-23 PQ 21 Wrinkle ..........3-24 5/99 Section Contents 8855...
Page 40: Print Quality Initialization Procedure
Drum life (Refer to Section 1) Developer life (Refer to Section 1) Charge Scorotron wire height (ADJ 1.1.1) Transfer/ Detack wire height (ADJ 1.2.1) LED Print Head Strobe time [4-4] Developer Bias [4-H] Perform ADJ 4.4.3 Zener Tap Adjustment. 5/99 Print Quality Initialization Procedure 8855...
Page 41: Image Defects
Call Procedures in Section 1. If the defect is still present, continue with the Fuser Fix other PROBABLE CAUSES. This is a measure of how the toner particles adhere to the media as a result of the fusing process. 5/99 Image Quality Definitions 8855...
Page 42: Image Quality General Diagnostics
The following terms will be used when referring to prints made on the 8855. Resolution a. Process direction is in the media feed The uniformity or clarity of fine line detail.
Page 43: Image Quality Specifications
5.25 inches (133 mm) apart. Note: To adjust lead edge registration use Test Pattern 1 Diagnostic Program 4 (NVM), location [4-9]. Pattern 8 is used to produce various small patterns that are labeled 00 through 7F. 5/99 Image Quality Specifications 8855...
Page 44 2.0 lp/mm pressure. (Refer to density target on test pattern Cut Accuracy This is the dimension of variance from a true, horizontal cut. Non-Image Area Target SPECIFICATION: Test Pattern 1 (Density Target) +/- 2 mm 5/99 Image Quality Specifications 8855...
Page 45: Damaged Media Rap
Heat roller is damaged or contaminated. Replace the heat roller (REP 4.3.1). 5. Other Damage 5. If there are other defects that are on the print, go to the Media Handling Problems on the following pages. 5/99 Damaged Media RAP 8855...
Page 46: Media Handling Problems
Bond media under 20 lb may perform with For media transportation problems, use the less reliability than Xerox 20 lb. b. After all media checks, test with fresh Xerox following problem-solving approach. b. Other brands of media may have different media.
Page 47: Printer Check
(PL 1.5) are not damaged. 6. After completing the previous checks, run 6. If the problem still exists, look for an several prints with dry Xerox media to verify obstruction in the media path. that the problem is fixed or still exists. If the problem is fixed, perform the Final Actions.
Page 48: Pq 1 Background
4 for the developer bias and transfer corotron). 7. Concentration Sensor 7. Check the following: a. Toner Concentration (ADJ 3.1.1) Ensure that toner is feeding at proper intervals. Replace the Concentration Sensor (PL 3.2). 5/99 PQ 1 Background 8855 3-10...
Page 49: Pq 2 Bands
5. Check for foreign objects on the mag roll. 6. Developer life exceeded 6. Replace the developer as required. 7. Drum current Zener PWB 7. Refer to BSD 9.2 and check the drum current return Zener PWB for an open circuit. 5/99 PQ 2, Bands 8855 3-11...
Page 50: Pq 3 Bands
1. Cold solder joints on coils on the Filter PWB. 1. Replace the Filter PWB (PL 10.2). Also there may be no sealant securing the coils to the PWB. 5/99 PQ 3 Bands, PQ 3A Gray Bands 8855 3-12...
Page 51: Pq 4 Black Lines
The print is totally black with no image. 1. Defective charge scorotron 1. Clean or replace the charge scorotron wire (REP 1.1.1). 2. Charge control circuit 2. Refer to BSD 9.2. 5/99 PQ 4, PQ 5 Black Lines or Prints 8855 3-13...
Page 52: Pq 6 Blank Prints
4. Defective drum 4. Replace the drum (REP 1.4.1). 5. Process speed incorrect Enter [4-P] and ensure that the process speed matches the NVM chart on the Right Side Door. 5/99 PQ 6 Blank Prints 8855 3-14...
Page 53: Pq 7 Blurred Image
4. Defective registration roller 4. Replace as required (REP 6.8.1). 5. Dirty LED Spacing Rollers 5. Clean or replace as required. 5/99 PQ 7 Blurred Image 8855 3-15...
Page 54: Pq 8 Deletions (Bands)
7. Media Heater Switch set to H for on during 7. Enter diagnostic Mode 4 and adjust Media low humidity conditions. Heater Switch (4-o) as required. Under cold weather conditions, the switch should be set to L for off. 5/99 PQ 8 Deletions 8855 3-16...
Page 55: Pq 9 Deletions (Bands)
3. Check the mag roll for damage or binding. 4. The surface of the heat roller is damaged. 4. Determine and fix the cause of the damage to the heat roller. Replace the heat roller (REP 4.3.1). 5/99 PQ 9, PQ 10 Deletions 8855 3-17...
Page 56: Pq 11 Deletions (Spots)
1.2.1). Enter diagnostic mode 4 and check the transfer corotron settings. 3. Developer life exceeded 3. Replace the developer as required (5R594). 4. Contaminated drum stripper fingers 4. Clean the drum stripper finger (PL 1.5). 5/99 PQ 11 Deletions, PQ 12 Finger Marks 8855 3-18...
Page 57: Pq 13 Light Image
9. Check the following: a. Toner cartridge empty b. Toner cartridge is blocked. c. Toner supply sensor (BSD 9.6) 10. Defective Toner Concentration Sensor (PL 10. Perform Toner Concentration adjustment 3.2) (ADJ 3.1.1). 5/99 PQ 13 Light Images 8855 3-19...
Page 58: Pq 14 Misregistration
Replace the brake if required (REP 8.4.2). 5. Incorrect registration roller nip 5. Clean or replace the registration roller (REP 6.8.1). 6. Incorrectly loaded media 6. Instruct the operator on loading the media correctly. 5/99 PQ 14 Misregistration 8855 3-20...
Page 59: Pq 15 Residual Image
3. Incorrect registration roller nip 3. Clean or replace the registration roller (REP 6.8.1). 4. Roll 4 skew only Check for worn Idler Roll. Replace as required. Perform ADJ 7.8.5 5/99 PQ 15 Residual Image, PQ 16 Skewed Image 8855 3-21...
Page 60: Pq 17 Smears
3. Contaminated heat roller 3. Clean or replace the heat roller (REP 4.3.1). 4. Defective magnetic roll 4. Replace the magnetic roll (REP 3.4.1). 5. Contaminated fuser thermistors 5. Clean the thermistors (REP 4.7.2). 5/99 PQ 17 Smears, PQ 18 Spots 8855 3-22...
Page 61: Pq 19 Uneven Density
3. Incorrect fuser pressure 3. Perform Pressure Roller adjustment (ADJ 4.4.1). 4. Defective heat roller or pressure roller 4. Replace the heat roller (REP 4.3.1) or pressure roller (REP 4.4.1). 5/99 PQ 19 Uneven Density, PQ 20 Unfused Prints 8855 3-23...
Page 62: Pq 21 Wrinkle
7. Media Heater Switch set to H for on during 7. Enter diagnostic Mode 4 and adjust Media low humidity conditions. Heater Switch (4-o) as required. Under cold weather conditions, the switch should be set to L for off. 5/99 PQ 21 Wrinkle 8855 3-24...
Page 63: Section Contents
REP 7.7.1 Media Selection PWB 4-42 REP 6.8.1 Registration Rollers 4-31 REP 7.7.5 Feed Clutches (MC7, MC8) 4-42 REP 7.8.1 Upper Drawer Rails 4-43 REP 7.8.2 Middle Drawer Rails 4-44 REP 7.8.3 Lower Drawer Rails 4-45 5/99 Section Contents 8855...
Page 64 ADJ 7.8.1 Upper Drawer Rails 4-63 ADJ 7.8.2 Middle Drawer Rails 4-64 REP 9.1.3 Top Front Cover with ADJ 7.8.3 Lower Drawer Rails 4-65 7396 Scanner 4-53 ADJ 7.8.4 Cutter Home Position 4-66 ADJ 7.8.5 Roll 4 Idler Roll 4-69 5/99 Section Contents 8855...
Page 65 Attach the other ring connector to the spring at the outboard end. Outboard Outboard Pawls rep 1 Figure 2. Replacing the Charge Wire Inboard First Pawl Pawls Position rep 20S Figure 1. Replacing the Grid Wires 5/99 REP 1.1.1 8855...
Page 66 1. Clean the corotron housing and the wires with a water-dampened cloth. 2. (Figure 1): Replace the Corotron Wires. Ensure that the Corotron Wire is in the groove of the Adjusting Block (6 places) rep 3 Figure 1. Replacing the Corotron Wires 5/99 REP 1.2.1 8855...
Page 67 Cleaner Assembly, being careful to move the right side out first. Place the Cleaner Assembly on a flat surface. inst 5 Figure 2. Removing the Cleaner Assembly Fan Connector inst 4 Figure 1. Removing the Rear Upper Cover 5/99 REP 1.3.1 8855...
Page 68 Put the Stripper Finger Assembly in a safe place. Replacement 1. Apply Kynar Dusting Powder to the Drum. inst 8 Lock the Inner Transport Assembly Figure 4. Locking the Inner Transport Assembly inst 11 Figure 3. Removing the Stripper Finger Assembly 5/99 REP 1.3.1 8855...
Page 69 1. (Figure 2): During reassembly, ensure that the Guide Pipe fits snugly in the groove of the hub. Groove Guide Pipe Groove Collar Rep10 Rep11 Screw Figure 2. Reassembling the Drum Figure 1. Removing the Drum Assembly 5/99 REP 1.4.1 8855...
Page 70 Cover move the right side out first. Place the Cleaner Assembly on a flat surface. inst 5 inst 5 Figure 2. Removing the Cleaner Assembly Fan Connector inst 4 Figure 1. Removing the Rear Upper Cover 5/99 REP 2.1.1 8855...
Page 71 Kynar , to avoid damaging the blade. 4. Apply Kynar Dusting Powder to the entire surface of the drum. 5. Reinstall the Cleaner Assembly. rep 7 Figure 1. Tightening the Cleaning Blade Screws 5/99 REP 2.2.1 8855...
Page 72 5. Install the new developer, replace the Cover and reinstall the Developer Assembly. 6. Run diagnostic mode [8-0] five times to mix the developer. 7. Perform ADJ 3.1.1 Toner Concentration. Screw Lever rep 14 Figure 1. Preparing to remove the Developer Assembly 5/99 REP 3.1.1, 3.1.5 8855...
Page 73 Figure 1. Removing the Trimmer Bar 3. Place a sheet of paper on the floor and dump out the developer. 4. Remove the four screws, spacers, and the Cylinder Cover. 5. Remove the eleven screws and the Trimmer Bar. 5/99 REP 3.2.1, 3.3.1 8855 4-11...
Page 74 7. Remove the three screws and pull off the Mounting Bracket and the bearing. Spacing 36T Gear 8. Peel off the Side Seals (Both sides). E-ring Roller 9. Remove the Magnetic Roller. Rep17 Figure 1. Removing Developer Assembly Components (Left side) 5/99 REP 3.4.1 8855...
Page 75 3. Remove the two E-rings and the two collars. 4. Perform the Toner Concentration adjustment 4. Remove the two screws, disconnect the (ADJ 3.1.1). connectors, and remove the Mounting Bracket. 5. Remove the two screws and the solenoid. 5/99 REP 3.5.1, 3.5.2, 3.6.1 8855 4-13...
Page 76 4. Remove the screws and the Fuser Side Covers. Fuser Top Cover Rear Upper Cover Connectors Exit Cover Stop Bracket rep 24A Figure 2. Removing the Fuser Assembly Left Side Right Side Fuser Cover Fuser Cover rep23 Figure 1. Removing the Covers 5/99 REP 4.1.1 8855...
Page 77 3. Remove the screws and the Fuser Side Covers. Fuser Top Cover Rear Upper Cover Lamp Holder Heat Roller Plate rep 25 Figure 2. Removing the Heater Rods Left Side Right Side Fuser Cover Fuser Cover rep23 Figure 1. Removing the Covers 5/99 REP 4.2.1 8855 4-15...
Page 78 3. Remove the screws and the Fuser Side Covers. Fuser Top Cover Rear Upper Cover rep27 Exit Roller Assembly Figure 3. Removing the Exit Roller Assembly Left Side Right Side Fuser Cover Fuser Cover rep23 Figure 1. Removing the Covers 5/99 REP 4.3.1 8855...
Page 79 Ball Bearing Heat Bushing Heat Bushing Wavy Washer Wavy Washer Stop Ring Stop Ring rep 28 rep 28 Figure 4. Removing the Heat Roller Hardware Cover rep 29 Heat Roller Figure 5. Removing the Heat Roller 5/99 REP 4.3.1 8855 4-17...
Page 80 3. Remove the screws and the Fuser Side Covers. Fuser Top Cover Rear Upper Cover Exit Roller rep27 Assembly Figure 3. Removing the Exit Roller Assembly Left Side Right Side rep23 Fuser Cover Fuser Cover Figure 1. Removing the Covers 5/99 REP 4.4.1 8855...
Page 81 Pressure bushing. Roller. Bearing Bushing Pawl Pawl Pressure rep31 Roller C-ring Figure 5. Removing the Hardware Pressure Pressure Screw Roller Roller rep 30 Figure 4. Removing the Pressure Roller 5/99 REP 4.4.1 8855 4-19...
Page 82 Notes: 5/99 8855...
Page 83 Figure 1. Removing the Guide Plate Replacement Right Side Left Side Fuser rep23 Fuser Cover Cover 1. Ensure that the angle bracket is set to the fifth mark from the top. Figure 1. Removing the Covers 5/99 REP 4.5.1, 4.6.1 8855 4-21...
Page 84 Figure 2. Removing the Bracket Metering Blade has a small arrow underneath Arrow that points to cleaning Position edge. Figure 3. Side View of Holding Plate rep 34 and Metering Blade Figure 1. Removing Cover 5 5/99 REP 4.7.1 8855 4-22...
Page 85 1. Remove the Cleaner Assembly (REP 2.1.1). Harness clamp 2. (Figure 1): Loosen the four screws and remove Cover 5. Cover 5 Screws (Both sides) rep 35 Figure 2. Removing Bracket 1 rep 34 Figure 1. Removing Cover 5 5/99 REP 4.7.2 8855 4-23...
Page 86 Washer Locking Screw 6. Ensure that there is a slight movement to the rep38 assembly. Figure 1. Removing the Fixing Screw 7. Perform ADJ 7.8.4, Cutter Home Postion. 5/99 REP 5.1.1 8855 4-24...
Page 87 5. Replace the Paper Guide rep 45 6. Replace the Cutter Assembly (REP 5.1.1). Figure 2 Removing the Cutter Screws (4) Motor Cutter Motor Assembly rep 44 Figure 1. Removing the Cutter Motor Assembly 5/99 REP 5.2.1; 5.2.2 8855 4-25...
Page 88 11. At the rear of the machine, move the Frame rep52 assembly to the left, remove the bearing Right Side from the bracket, then remove the Inner Figure 1. Removing the Inner Transport Assembly Transport Assembly . 5/99 REP 6.1.1 8855 4-26...
Page 89 Guide Rail Inner Transport rep 46 Sensor Assembly Mounting Bracket rep 51a Figure 1. Removing the Cover Figure 1. Removing the Rail 5/99 REP 6.2.1, 6.2.5 8855 4-27...
Page 90 Loop Guide Wire around b. Follow the pattern shown. Center Screw and work c. Do not set the wire too tight or the Rail outward, towards the ends. Plates will bend. rep 5 Figure 1. Reinstalling the Guide Wires 5/99 REP 6.3.1 8855...
Page 91 4. Release the tabs and remove the Separation Figure 2. Removing the Counter Rollers Sensor. Tabs Paper Guide Separation Sensor rep 49 Figure 1. Removing the Paper Guide Mounting Bracket rep 48 Figure 1. Removing the Separation Sensor 5/99 REP 6.4.1, 6.5.1 8855 4-29...
Page 92 Vacuum Transport in order to disengage the Roller Shaft from the coupler. 3. Remove the Vacuum Transport. 4. Remove the Transport Belts from the Vacuum Transport. rep 51 Figure 1. Removing the Vacuum Transport Belts 5/99 REP 6.6.1 8855...
Page 93 7. Remove the Rollers as required. Replacement Rib 1 1. (Figure 2): Ensure that Rib 1 is flush as rep 53 shown at reassembly. Paper Guide Figure 1. Removing the Registration Rollers Rep54 Figure 2. Positioning Rib 1 5/99 REP 6.8.1 8855 4-31...
Page 94 Notes: 5/99 8855...
Page 95 Disconnect the Power Cord. Removal 1. (Figure 1): Remove four screws and the Manual Bypass Shelf. Manual Bypass Shelf Upper Drawer rep56 Figure 2. Removing the Upper Drawer rep55 Figure 1. Removing the Manual Bypass Tray 5/99 REP 7.1.1 8855 4-33...
Page 96 2. Remove the roll of paper. Drive Idler 3. Remove the screws (two per rail) that secure the Middle Drawer to the Rails. 4. Remove the Middle Drawer. Stopper rep70 Figure 1. Checking the Drive Idler Arm 5/99 REP 7.2.1 8855...
Page 97 3. (Figure 1): If the Drawer does not operate rep70 smoothly, ensure that the Stopper secured by the Drive Idler Arm moves smoothly. If it Figure 1. Checking the Drive Idler Arm does not, check and adjust the position of the rails. 5/99 REP 7.3.1 8855 4-35...
Page 98 Figure 3. Removing the Sensor 3. (Figure 1): Remove the two screws and remove the Pulse Plate Cover. Figure 2. Removing the Bracket Right Side Plate rep 57 Pulse Plate Cover Figure 1. Removing the Cover 5/99 REP 7.5.1 8855...
Page 99 3. (Figure 1): Remove the three screws and remove the Pulse Plate Cover. Sensor Connector rep82 Pulse Plate Cover Figure 3. Removing the Sensor rep81 Figure 2. Removing the Bracket Right Side Plate rep 80 Figure 1. Removing the Cover 5/99 REP 7.5.2 8855 4-37...
Page 100 1. Remove the Upper Drawer (REP 7.1.1). 2. (Figure 1): Remove the two screws from each side and remove the Cover. Roll Paper Size Sensor rep 61 Figure 2. Removing the Sensors Cover rep 60 Screws Figure 1. Removing the Cover 5/99 REP 7.6.1 8855...
Page 101 8. (Figure 2): Remove the screw remove the sensor, and disconnect the connector. Connector Bracket Rep71 Figure 1. Removing the Drawer Components Connector Sensor rep 72 Figure 2. Removing the Sensor 5/99 REP 7.6.2 8855 4-39...
Page 102 1. Pull out the Lower Drawer and remove the Figure 2. Removing the Sensor roll of paper. 2. (Figure 1): Remove the four screws from each side and remove the Cover. Cover rep 75 Figure 1. Removing the Cover 5/99 REP 7.6.3 8855...
Page 103 2. (Figure 1): Remove the screws from each Sensor. Disconnect the connector. side and remove the Cover. Sensor Cover Cover rep 60 Connector rep85 Figure 1. Removing the Cover Figure 3. Removing the Sensor rep 83 Figure 1. Removing the Cover 5/99 REP 7.6.4, 7.6.5 8855 4-41...
Page 104 Spool Guide. Figure 2. Disconnecting the Connector Spool Guide rep 68 rep62 Figure 1. Removing the Clutch 3. Release the wires from the cable clamps Figure 1. Removing the Spool Guide and disconnect the connector. 5/99 REP 7.7.1, 7.7.5 8855...
Page 105 Figure 2. Reinstalling the Rails 3. Reinstall the Upper Drawer. Magnetic Catch (2) 4. Perform the Upper Drawer Rail (ADJ 7.8.1) adjustment. Inner Toner Supply Cover Mechanism rep 65 Figure 1. Removing Inner Cover 1 5/99 REP 7.8.1 8855 4-43...
Page 106 5. (Figure 3): Remove the screws and the Rail Magnetic Mounting Brackets (both sides). Catch (2) Rail Mounting Rail Bracket Inner Cover rep 74 Toner Supply Mechanism Figure 3. Removing the Mounting Brackets rep 65 Figure 1. Removing Inner Cover 1 5/99 REP 7.8.2 8855...
Page 107 5. (Figure 3): Remove the screws and the Rail Guide Case Mounting Brackets (both sides). Rail Mounting Bracket Rail Inner Cover rep 79 Inner Cover 2 rep 77 Figure 3. Removing the Mounting Brackets Figure 1. Removing the Inner Covers 5/99 REP 7.8.3 8855 4-45...
Page 108 2. (Figure 1): Disconnect the connector for the clutch to be removed. Connector rep 68 Figure 2. Removing the Clutch CL3, CL4 CL1, CL2 rep 86 Figure 1. Disconnecting the Connectors 3. Remove the screws and the Clutch Mounting Bracket. 5/99 REP 8.1.1 8855...
Page 109 Shaft. e. Remove the two screws and one spring shaft and remove the Brake Mounting Bracket from the frame. Remove the washers and spacer from the Roller Shaft. rep 68 Figure 2. Removing the Clutch 5/99 REP 8.2.1 8855 4-47...
Page 110 3. (Figure 1): Loosen the two screws and remove the collar. 4. (Figure 2): Push the tab in the direction shown and pull the clutch off of the shaft. rep 68 Figure 2. Removing the Clutch 5/99 REP 8.3.1 8855...
Page 111 Armature Assembly from the Roller Shaft. Figure 1. Removing the Brake (CL9) 0.2 mm rep 90 c. Remove the three screws and remove the brake from the Brake Mounting Figure 2. Setting the Brake Gap Bracket. 5/99 REP 8.4.1 8855 4-49...
Page 112 Armature Assembly from the Roller Shaft. rep 88 Figure 1. Removing the Brake (CL10) 0.2 mm c. Remove the three screws and remove the brake from the Brake Mounting Bracket. Figure 2. Setting the Brake Gap 5/99 REP 8.4.2 8855...
Page 113 Sprocket 6. Remove the three screws and the mounting rep 93 bracket. Replacement Mounting Bracket 1. Set the sprocket 6 mm from the mounting bracket. Figure 1. Removing the Paper Feed Motor (MOT2) 5/99 REP 8.5.1 8855 4-51...
Page 114 8. Remove the Ozone Filter. Mounting Bracket Blower Stop Bracket Cover 2 Frame Cover 1 rep 64 Figure 1. Removing the Tray, Frames, and Cover Cover 1 Ozone Filter rep 95 Figure 2. Removing the Ozone Filter 5/99 REP 9.1.1 8855...
Page 115 Top Front Cover. the printer. • Remove the three screws securing the Stabilizer Bar to the 8855 and remove the Stabilizer Bar. 2. Place one Cover Access Tool on the top of each Side Fuser Covers.
Page 116 Notes: 5/99 8855...
Page 117 1. Remove the Charge Scorotron. 2. (Figure 1): Check that the height of the Charge Scorotron Wire (Dimension P) is as recorded on the label inside the Right Door (front and rear). rep2 Figure 1. Charge Scorotron Wire Height 5/99 ADJ 1.1.1 8855 4-55...
Page 118 Right Door (front and rear). 3. Check that the height of the Detack Corotron Wires (Dimensions S1 and S2) are as recorded on the label. rep4 Figure 1. Corotron Wire Heights 5/99 ADJ 1.2.1 8855 4-56...
Page 119 Set Lever of the Developer Assembly and turn it to the right. 12. Remove paper return transport to the up position. inst 96 13. Rotate the Toner Cartridge 180 TP502 (Control) TP501 (Analog) VR501 inst 97 Figure 1. Setting Toner Concentration 5/99 ADJ 3.1.1 8855 4-57...
Page 120 Drum and the rollers, perform the adjustment. rep12 5. If the shimstock stops at the nip, ensure the spacing rollers spin freely. If the spacing Figure 1. Setting the LED Print Head rollers do not spin freely, perform the adjustment. 5/99 ADJ 3.2.1 8855 4-58...
Page 121 5. Check the copy quality, and repeat Steps 2 – 5 until copy quality is within specification, as referenced in Section 3. Magnetic Roll Adjustment Screw Alignment Notches Figure 1. Correct placement of the Magnetic Roll Alignment Tool 5/99 ADJ 3.4.2 8855 4-59...
Page 122 The contact arc should be 10.5 mm +/- 1.5 mm. The center contact arc Figure 1. Pressure Roller Adjustment should be approximately 8 mm. This is due to the swelling at the end of the Pressure Roll. 5/99 ADJ 4.4.1 8855...
Page 123 Switch Main Circuit Breaker. Disconnect the Power Cord. NOTE: Some 8855 printers come with 2 bolded notches in the Fuser Adjustment Plates. It is Adjustment recommended that both of the Adjustment Plates be set inline with these notches (Adjustment 1).
Page 124 3. Press SW 701 to step to Diagnostic Program 2. 4. Enter [ 2- b]. 5. Surface potential should read approximately 640 VDC (alternating between 90 VDC). 6. If necessary, move the tap on the Zener Diode PWB and repeat the check. 5/99 ADJ 4.4.3 8855 4-62...
Page 125 8. Adjust the Rail Stop so that it securely rep 65 supports the rail and secure it. Be sure to secure all four stops. Figure 1. Removing the Inner Cover 9. Check that the Drawer operates smoothly. If not, repeat the adjustment. 5/99 ADJ 7.8.1 8855 4-63...
Page 126 8. Adjust the Rail Stop so that it securely supports the rail and secure it. Be sure to secure all four stops. rep 65 9. Check that the Drawer operates smoothly. If Figure 1. Removing the Inner Cover not, repeat the adjustment. 5/99 ADJ 7.8.2 8855...
Page 127 Magnetic Catches at the right side of the machine. Remove Inner Cover 1 and Inner Cover 2. Waste Toner Guide Case Inner Cover 1 Inner Cover 2 Rep77 Figure 1. Removing the Inner Covers 5/99 ADJ 7.8.3 8855 4-65...
Page 128: Adjustment Check
Cutter Assembly. Jigs (one round, one square) 7. (Figure 2): Install the square-shaped home Position Jig onto the studs at the end of the Cutter Assembly. rep 42a Studs Figure 2. Positioning the Home Position Jigs 5/99 ADJ 7.8.4 8855 4-66...
Page 129 Cutter is correctly adjusted, the color of this cut out should change from orange to green as the knob is rotated fully clockwise into the Home Position. rep 43a Figure 3. Location of Home Position Jigs, and positioning of Cutter Height Tool 5/99 ADJ 7.8.4 8855 4-67...
Page 130 9. Reinstall the Cutter Base Plate. 10. install the Cutter Assembly. 11. Verify Cutter performance by running a test print and observing that the cut is clean and the Cutter Handle rotates to the green spot. 5/99 ADJ 7.8.4 8855 4-68...
Page 131 Do not place any additional pressure on the bearing when tightening the screws. Screws 5. Reinstall the Idler Roll Adjustment Plate PLATE Cover and restore the printer to normal operation. Figure 1. Idler Roll Adjustment Plate Cover. 5/99 ADJ 7.8.5 8855 4-69...
Page 132 NOTES: 5/99 8855 4-70...
Page 133 PL 7.3 UPPER DRAWER COMPONENTS (PART 1 OF 4)..........5-36 PL 7.4 UPPER DRAWER COMPONENTS (PART 2 OF 4)..........5-37 PL 7.5 UPPER DRAWER COMPONENTS (PART 3 OF 4)..........5-38 PL 7.6 UPPER DRAWER COMPONENTS (PART 4 OF 4)..........5-39 Parts Lists 2/99 8855...
Page 134 Parts Lists 2/99 8855...
Page 135: Introduction
This index lists all the spared parts in the machine in numerical order. Each number is followed Without by a reference to the parts list on which the part may be found. Symbology Symbology used in the Parts List section is identified in the Symbology section. Parts Lists 2/99 Introduction 8855...
Page 136: 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 2/99 Subsystem Information 8855...
Page 137: 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 2/99 Symbology 8855...
Page 138 Tag number within the circle (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 2/99 Symbology 8855...
Page 139: 1.1 Xerographic Components
PL 1.1 XEROGRAPHIC COMPONENTS Item Part Description 144N44 DRUM (REP 1.3.1) 22N690 SPACING ROLLER (2/KIT) 130N677 LED PRINT HEAD (REP 3.2.1, ADJ 3.2.1) 125N32 CHARGE SCOROTRON ASSEMBLY 126N44 TRANSFER/DETACK COROTRON ASSEMBLY Parts Lists 2/99 PL 1.1 8855...
Page 140: 1.2 Drum Assembly
PART OF DRUM ASSEMBLY (REF: PL 1.1 item 1) – DRUM (P/O PL 1.2 item 1) (REP 1.4.1) 5N422 17N133 – GUIDE PIPE (P/O PL 1.2 item 1) 7N526 GEAR (180T) 20N281 DRUM DISK Parts Lists 2/99 PL 1.2 8855...
Page 141: 1.3 Charge Scorotron Assembly
BLOCK 1 117N1145 SCOROTRON WIRE (REP 1.1.1) 9N851 GRID SPRING (5/KIT) – HOUSING 1 (P/O PL 1.3 item 1) – STOPPER (P/O PL 1.3 item 1) – THUMB SCREW (P/O PL 1.3 item 26N461 SCREW Parts Lists 2/99 PL 1.3 8855...
Page 142: 1.4 Transfer/Detack Corotron Assembly
HOUSING (P/O PL 1.4 item 1) 91N423 GROUND 1 PLATE 91N424 GROUND 2 PLATE – COROTRON BASE (P/O PL 1.4 item 1) – SHIELD (P/O PL 1.4 item 1) – THUMB SCREW (P/O PL 1.4 item Parts Lists 2/99 PL 1.4 5-10 8855...
Page 143: 1.5 Stripper Fingers
PL 1.5 STRIPPER FINGERS Item Part Description 5N430 STRIPPER FINGER SHAFT 113N275 STRIPPER FINGER BRACKET 19N365 STRIPPER FINGER (4/KIT) – RIGHT SIDE FRAME (NOT SPARED) 1N249 CHARGE SCOROTRON RAIL Parts Lists 2/99 PL 1.5 8855 5-11...
Page 144: 2.1 Cleaning Assembly
PL 2.1 CLEANING ASSEMBLY Item Part Description 53N103 CLEANER ASSEMBLY (REP 2.1.1) Parts Lists 2/99 PL 2.1 5-12 8855...
Page 145: 2.2 Cleaning Components (Part 1 Of 2)
SIDE PLATE (P/O PL 2.2 item 1) 35N221 LEFT TONER SEAL 35N190 GUIDE SEAL 135N30 BEARING 54N30 DUCT 54N29 DUCT – SIDE PLATE (P/O PL 2.2 item 1) 35N203 RIGHT TONER SEAL 55N164 PLATE Parts Lists 2/99 PL 2.2 8855 5-13...
Page 146: 2.3 Cleaning Components (Part 2 Of 2)
STUD (NOT SPARED) – ACTUATOR (NOT SPARED) 9N796 SPRING – BRACKET (NOT SPARED) – RIGHT SIDE FRAME (NOT SPARED) – BRACKET (NOT SPARED) 110N726 TONER WASTE BOTTLE SWITCH (MS4) – LEFT SIDE FRAME (NOT SPARED) Parts Lists 2/99 PL 2.3 5-14 8855...
Page 147: 3.1 Developer And Toner Hopper Assemblies
PL 3.1 DEVELOPER AND TONER HOPPER ASSEMBLIES Item Part Description 2N1371 TONER CARTRIDGE SUPPORT 126N46 DEVELOPER ASSEMBLY (REP 3.1.1) 2N1356 COVER (D1) 2N1357 COVER (D2) 50N187 TONER HOPPER ASSEMBLY Parts Lists 2/99 PL 3.1 8855 5-15...
Page 148: 3.2 Developer Components (Part 1 Of 2)
BRACKET (P/O PL 3.2 item 1) 35N192 SEAL – UPPER PLATE (P/O PL 3.2 item 1) 13N268 GRIP RING 37N56 BLADE "A" – SIDE PLATE (P/O PL 3.2 item 1) 35E51340 LONG SEAL (W/TAG 17) Parts Lists 2/99 PL 3.2 5-16 8855...
Page 149: 3.3 Developer Components (Part 2 Of 2)
130N681 TONER SUPPLY SENSOR 35N197 SEAL 7N545 GEAR (18T) 5N432 SHAFT – BRACKET (P/O PL 3.3 item 1) 5N420 COLLAR 5N421 COUPLING 7N548 IDLER GEAR (32T) – COLLAR (P/O PL 3.3 item 1) Parts Lists 2/99 PL 3.3 8855 5-17...
Page 150: 3.4 Toner Hopper Assembly
5N424 TONER DISPENSE CLUTCH (CL11) – PIN (P/O PL 3.4 item 1) – SEAL (P/O PL 3.4 item 1) – BRACKET (P/O PL 3.4 item 1) – SHAFT (P/O PL 3.4 item 1) Parts Lists 2/99 PL 3.4 5-18 8855...
Page 151: 3.5 Developer Components
COLLAR (NOT SPARED) – BRACKET (NOT SPARED) – BOTTOM PLATE (NOT SPARED) – MOUNTING PLATE (NOT SPARED) – BRACKET (NOT SPARED) 5N410 COLLAR 9N794 SPRING – BRACKET (NOT SPARED) – ADAPTER (NOT SPARED) Parts Lists 2/99 PL 3.5 8855 5-19...
Page 152: 4.1 Fuser Assembly
PL 4.1 FUSER ASSEMBLY Item Part Description 2N1369 LEFT SIDE FUSER COVER 126N43 FUSER ASSEMBLY (REP 4.1.1) 2N1370 RIGHT SIDE FUSER COVER Parts Lists 2/99 PL 4.1 5-20 8855...
Page 153: 4.2 Fuser Components (Part 1 Of 5)
SIDE PLATE (P/O PL 4.2 item 1) – EDGE SADDLE (P/O PL 4.2 item – BEARING PLATE (P/O PL 4.2 item – DUCT (P/O PL 4.2 item 1) – BRACKET (P/O PL 4.2 item 1) Parts Lists 2/99 PL 4.2 8855 5-21...
Page 154: 4.3 Fuser Components (Part 2 Of 5)
SIDE PLATE (P/O PL 4.3 item 1) 5N416 COLLAR 13N271 BEARING 7N534 GEAR (40T) 117N1123 FUSER LAMP HARNESS 152N1540 SENSOR HARNESS – BRACKET (P/O PL 4.3 item 1) – BASE (P/O PL 4.3 item 1) Parts Lists 2/99 PL 4.3 5-22 8855...
Page 155: 4.4 Fuser Components (Part 3 Of 5)
RETAINING RING (P/O PL 4.4 item 91N421 SIDE PLATE – BASE (P/O PL 4.4 item 1) – BRACKET (P/O PL 4.4 item 1) 16N147 BUSHING – SIDE PLATE (P/O PL 4.4 item 1) 113N274 LAMP BRACKET Parts Lists 2/99 PL 4.4 8855 5-23...
Page 156: 4.5 Fuser Components (Part 4 Of 5)
BRACKET (P/O PL 4.5 item 1) – SIDE PLATE (P/O PL 4.5 item 1) 19N352 STRIPPER FINGER (15/KIT) 9N803 SPRING 113N276 HOLDER – FRAME (P/O PL 4.5 item 1) – SIDE PLATE (P/O PL 4.5 item 1) Parts Lists 2/99 PL 4.5 5-24 8855...
Page 157: 4.6 Fuser Components (Part 5 Of 5)
GUIDE PLATE (REP 4.5.1) – BRACKET (P/O PL 4.6 item 1) – SIDE PLATE (P/O PL 4.6 item 1) – PLATE (P/O PL 4.6 item 1) – FRAME (P/O PL 4.6 item 1) Parts Lists 2/99 PL 4.6 8855 5-25...
Page 158: 5.1 Cutter Assembly
PL 5.1 CUTTER ASSEMBLY Item Part Description 37N58 CUTTER ASSEMBLY (REP 5.1.1) Parts Lists 2/99 PL 5.1 5-26 8855...
Page 159: 5.2 Cutter Components (Part 1 Of 2)
OIL PAD ACTUATOR CAM (P/O PL 5.2 item 1) – OIL PAD BRACKET (P/O PL 5.2 item 1) – OIL PAD (P/O PL 5.2 item 1) – BUSHING (P/O PL 5.2 item 1) Parts Lists 2/99 PL 5.2 8855 5-27...
Page 160: 5.3 Cutter Components (Part 2 Of 2)
COVER (NOT SPARED) 13N267 ROLLER SHAFT BEARING – BRACKET (NOT SPARED) 26N438 FITTING SCREW 9N776 SPRING 5N415 COLLAR – RIGHT SIDE FRAME (NOT SPARED) – BEARING (NOT SPARED) 135N31 BEARING 29N147 11N357 LEVER 9N797 SPRING Parts Lists 2/99 PL 5.3 5-28 8855...
Page 161: 6.1 Inner Transport Assembly
PL 6.1 INNER TRANSPORT ASSEMBLY Item Part Description – INNER TRANSPORT ASSEMBLY (NOT SPARED) (REP 6.1.1) 9N792 GAS SPRING 28N187 WASHER – RETAINING RING (NOT SPARED) Parts Lists 2/99 PL 6.1 8855 5-29...
Page 162: 6.2 Inner Transport Components (Part 1 Of 3)
BEARING (P/O PL 6.2 item 1) – SHAFT (P/O PL 6.2 item 1) 7N531 GEAR (27T) 142N86 GASKET 142N85 GASKET 30N317 CONNECTOR BRACKET 116N163 CONNECTOR BLOCK – VACUUM TRANSPORT (P/O PL 6.2 item 2) Parts Lists 2/99 PL 6.2 5-30 8855...
Page 163: 6.3 Inner Transport Components (Part 2 Of 3)
1) 105N1096 HV POWER SUPPLY (PS3) 105N1097 HV POWER SUPPLY (PS2) 35N202 FELT STRIP – PAPER GUIDE (P/O PL 6.3 item 1) 121N290 ERASER PCB 5N452 SHAFT 9N793 LEAF SPRING 9N806 SPRING EXTENSION Parts Lists 2/99 PL 6.3 8855 5-31...
Page 164: 6.4 Inner Transport Components (Part 3 Of 3)
– PART OF INNER TRANSPORT ASSEMBLY (REF: PL 6.1 item 1) 38N208 PAPER GUIDE PLATE 14N329 SPACER 22N954 ROLLER 30N408 RH BRACKET 30N407 LH BRACKET – TRANSPORT FRAME (P/O PL 6.4 item 1) Parts Lists 2/99 PL 6.4 5-32 8855...
Page 165: 6.5 Registration And Paper Transport Rollers
LEAD TRANSLATION SENSOR (NOT SPARED) 7N510 GEAR (28T) 38N246 PAPER GUIDE PLATE 22N993 PAPER FEED ROLLER 22N685 PAPER TRANSPORT ROLLER SHAFT 91N425 RIGHT SIDE BRACKET – RIGHT SIDE FRAME (NOT SPARED) – BEARING (NOT SPARED) Parts Lists 2/99 PL 6.5 8855 5-33...
Page 166: 7.1 Drawer Assemblies
PL 7.1 DRAWER ASSEMBLIES Item Part Description 38N207 PAPER SHAFT ASSEMBLY – UPPER DRAWER ASSEMBLY (NOT SPARED)(REP 7.1.1) – MIDDLE DRAWER ASSEMBLY (NOT SPARED)(REP 7.2.1) – LOWER DRAWER ASSEMBLY (NOT SPARED)(REP 7.3.1) Parts Lists 2/99 PL 7.1 5-34 8855...
Page 167: 7.2 Paper Shaft Assembly
29N145 LEFT PIN 22N601 BRAKE – PLATE BRACKET (P/O PL 7.2 item – PLATE (P/O PL 7.2 item 1) – COUPLER (P/O PL 7.2 item 1) – KNOB (P/O PL 7.2 item 1) Parts Lists 2/99 PL 7.2 8855 5-35...
Page 168: 7.3 Upper Drawer Components (Part 1 Of 4)
BAND W/SNAP (P/O PL 7.3 item 1) – BLANK PAPER LABEL (P/O PL 7.3 item 1) – RIGHT SIDE PLATE (P/O PL 7.3 item 1) – ROLL PAPER CAUTION PLATE (P/O PL 7.3 item 1) 22N605 ROLLER SHAFT Parts Lists 2/99 PL 7.3 5-36 8855...
Page 169: 7.4 Upper Drawer Components (Part 2 Of 4)
LEAF SPRING – GROMMET (P/O PL 7.4 item 1) – PAPER GUIDE PLATE (P/O PL 7.4 item 1) – COVER (P/O PL 7.4 item 1) – RIGHT SIDE PLATE (P/O PL 7.4 item 1) Parts Lists 2/99 PL 7.4 8855 5-37...
Page 170: 7.5 Upper Drawer Components (Part 3 Of 4)
GEAR (36T) 28N195 THRUST WASHER 7N549 GEAR (30T) 91N415 BRACKET 20N268 PULLEY – COVER (P/O PL 7.5 item 1) 7N511 GEAR (30T) 9N777 SPRING 14N297 SPACER 31N136 TENSION ARM 7N514 GEAR (30T) 23N322 BELT Parts Lists 2/99 PL 7.5 5-38 8855...
Page 171: 7.6 Upper Drawer Components (Part 4 Of 4)
19N345 BRACKET – STOP PLATE (P/O PL 7.6 item 1) – ACTUATOR (P/O PL 7.6 item 1) 9N800 SPRING – SPACER (P/O PL 7.6 item 1) – BRACKET (P/O PL 7.6 item 1) Parts Lists 2/99 PL 7.6 8855 5-39...
Page 172: 7.7 Middle Drawer Components (Part 1 Of 4)
BLANK PAPER LABEL (P/O PL 7.7 item 1) 128N399 MEDIA SELECTION PWB (REP 7.7.1) – RIGHT SPOOL GUIDE (P/O PL 7.7 item 1) – RIGHT SIDE PLATE (P/O PL 7.7 item 1) 22N606 PAPER FEED ROLLER Parts Lists 2/99 PL 7.7 5-40 8855...
Page 173: 7.8 Middle Drawer Components (Part 2 Of 4)
PAPER GUIDE (P/O PL 7.8 item 1) – PAPER GUIDE (P/O PL 7.8 item 1) – RIGHT BRACKET (P/O PL 7.8 item – RIGHT SIDE PLATE (P/O PL 7.8 item 1) – PCB COVER (P/O PL 7.8 item 1) Parts Lists 2/99 PL 7.8 8855 5-41...
Page 174: 7.9 Middle Drawer Components (Part 3 Of 4)
BEARING (P/O PL 7.9 item 1) 20N269 PULLEY 14N297 SPACER 31N136 TENSION ARM 7N514 GEAR (30T) 23N322 BELT 7N511 GEAR (20T) 9N777 SPRING 91N415 BRACKET 20N268 PULLEY – COVER (P/O PL 7.9 item 1) Parts Lists 2/99 PL 7.9 5-42 8855...
Page 175: 7.10 Middle Drawer Components (Part 4 Of 4)
BRACKET (P/O PL 7.10 item 1) – SPACER (P/O PL 7.10 item 1) – PAPER FEEDER BRACKET (P/O PL 7.10 item 1) – BRACKET (P/O PL 7.10 item 1) – MIDDLE FEEDER HARNESS (P/O PL 7.10 item 1) Parts Lists 2/99 PL 7.10 8855 5-43...
Page 176: 7.11 Lower Drawer Components (Part 1 Of 5)
MEDIA SELECTION PWB (REP 7.7.1) – RIGHT SPOOL GUIDE (P/O PL 7.11 item 1) – BLANK PAPER LABEL (P/O PL 7.11 item 1) – BLANK PAPER LABEL (P/O PL 7.11 item 1) 19N345 HOOK 19N344 BRACKET Parts Lists 2/99 PL 7.11 5-44 8855...
Page 177: 7.12 Lower Drawer Components (Part 2 Of 5)
– GEAR (30T) (P/O PL 7.12 item 1) 29N180 22N957 ROLLER SHAFT 18N138 COUNTER ROLLER SHAFT ASSEMBLY – ROLLER (P/O PL 7.12 item 18) – COUNTER ROLLER SHAFT (P/O PL 7.12 item 18) Parts Lists 2/99 PL 7.12 8855 5-45...
Page 178: 7.13 Lower Drawer Components (Part 3 Of 5)
SPRING – BRACKET (P/O PL 7.13 item 1) – RIGHT SIDE PLATE (P/O PL 7.13 item 1) – REAR SENSOR BRACKET (P/O PL 7.13 item 1) – CLAMP (P/O PL 7.13 item 1) Parts Lists 2/99 PL 7.13 5-46 8855...
Page 179: 7.14 Lower Drawer Components (Part 4 Of 5)
GEAR (45T) 7N516 GEAR (20T) – DRIVE SHAFT SUPPORT BRACKET (P/O PL 7.14 item 1) – BEARING (P/O PL 7.14 item 1) 5N429 SHAFT 7N515 GEAR (30T) – COVER (P/O PL 7.14 item 1) Parts Lists 2/99 PL 7.14 8855 5-47...
Page 180: 7.15 Lower Drawer Components (Part 5 Of 5)
3N606 KNOB – BRACKET (P/O PL 7.15 item 1) – HARNESS (P/O PL 7.15 item 1) – GEAR (45T) (P/O PL 7.15 item 1) – SHAFT SUPPORT BRACKET (P/O PL 7.15 item 1) Parts Lists 2/99 PL 7.15 5-48 8855...
Page 181: 7.16 Paper Heater
PL 7.16 PAPER HEATER Item Part Description 126N40 PAPER HEATER (HTR4, HTR5) 126N41 PAPER HEATER (HTR3) – PAPER HEATER BRACKET (NOT SPARED) Parts Lists 2/99 PL 7.16 8855 5-49...
Page 182: 7.17 Left Side Drawer Rails
– MIDDLE RAIL BRACKET (NOT SPARED) 1N250 SLIDE – SLIDE BRACKET (NOT SPARED) – LOWER LEFT SIDE FRAME (NOT SPARED) 10N47 LOWER RAIL (REP 7.8.3, ADJ 7.8.3) – LOWER RAIL BRACKET (NOT SPARED) Parts Lists 2/99 PL 7.17 5-50 8855...
Page 183: 7.18 Right Side Drawer Rails
– MIDDLE RAIL BRACKET (NOT SPARED) 1N250 SLIDE – SLIDE BRACKET (NOT SPARED) – LOWER RIGHT SIDE FRAME (NOT SPARED) 10N47 LOWER RAIL (REP 7.8.3, ADJ 7.8.3) – LOWER RAIL BRACKET (NOT SPARED) Parts Lists 2/99 PL 7.18 8855 5-51...
Page 184: 8.1 Main Drive 1 (Part 1 Of 2)
ROLL 1 MANUAL FEED CLUTCH (CL1) (REP 8.1.1) ROLL 2 FEED CLUTCH (CL2) (REP 8.1.1) 7N520 GEAR (30T) 28N195 THRUST WASHER 6N838 TRANSMISSION SHAFT 7N504 GEAR (50T) 28N199 THRUST WASHER – SIDE PLATE (NOT SPARED) Parts Lists 2/99 PL 8.1 5-52 8855...
Page 185: 8.2 Main Drive 1 (Part 2 Of 2)
SIDE PLATE (NOT SPARED) 13N269 BEARING 5N404 COLLAR 7N554 SPROCKET (15T) 31N137 TENSION ARM – SPROCKET (15T) (NOT SPARED) 9N781 SPRING 7N551 SPROCKET (15T) 5N407 CLUTCH BRACKET 23N325 CHAIN – IDLER ARM (NOT SPARED) Parts Lists 2/99 PL 8.2 8855 5-53...
Page 186: 8.3 Main Drive
GEAR (50T) 13N271 BEARING (2/KIT) 7N529 GEAR (50T) 28N199 THRUST WASHER 5N406 CLUTCH BRACKET – HOLDER PLATE (NOT SPARED) 5N404 COLLAR 7N554 SPROCKET (15T) – EDGE SADDLE (NOT SPARED) – SIDE PLATE (NOT SPARED) Parts Lists 2/99 PL 8.3 5-54 8855...
Page 187: 8.4 Fuser Drive
– SHAFT (NOT SPARED) – EDGE SADDLE (NOT SPARED) 127N750 FUSER MOTOR (MOT6) – SIDE PLATE (NOT SPARED) – SHAFT (NOT SPARED) 28N195 THRUST WASHER 5N408 COLLAR 7N536 GEAR (24T) 7N749 GEAR (40T) Parts Lists 2/99 PL 8.4 8855 5-55...
Page 188: 8.5 Drum Drive
THRUST WASHER (NOT SPARED) 5N427 MID TRANSPORT FEED CLUTCH (CL6) (REP 8.3.1) 7N521 GEAR (50T) – LEFT SIDE FRAME (NOT SPARED) 74N23 BRACKET 7N516 GEAR (20T) 29N149 7N562 GEAR (26T) 13N268 RETAINING RING Parts Lists 2/99 PL 8.5 5-56 8855...
Page 189: 8.6 Drive Components
PL 8.6 DRIVE COMPONENTS Item Part Description – LEFT SIDE FRAME (NOT SPARED) 7N550 SPROCKET (15T) – PIVOT PIN (NOT SPARED) 91N416 PIN BRACKET 9N782 SPRING Parts Lists 2/99 PL 8.6 8855 5-57...
Page 190: Covers
TOP REAR COVER ASSEMBLY (NOT SPARED) 2N1353 TOP FRONT COVER 2N1418 LEFT SIDE COVER 74N20 SUPPORT BRACKET 74N21 CASTER BRACKET – SPRING WASHER (NOT SPARED) 17N134 ADJUSTER 17N132 CASTER 2N1417 RIGHT DOOR 2N1368 LOWER REAR COVER Parts Lists 2/99 PL 9.1 5-58 8855...
Page 191: 9.2 Upper And Front And Inner Covers
2N1366 LEFT FRONT COVER – INNER COVER (NOT SPARED) – INNER COVER (NOT SPARED) – WASTE TONER CARTRIDGE GUIDE (NOT SPARED) 11N356 LEVER 5N411 COLLAR 1N252 LEFT BASE – RIGHT BASE (NOT SPARED) Parts Lists 2/99 PL 9.2 8855 5-59...
Page 192: 9.3 Rail And Stop
Description – NUT PLATE (NOT SPARED) 110N726 RIGHT DOOR INTERLOCK SWITCH (MS1) – ACTUATOR (NOT SPARED) – SWITCH BRACKET (NOT SPARED) – RIGHT DOOR BRACKET (NOT SPARED) – RIGHT SIDE FRAME (NOT SPARED) Parts Lists 2/99 PL 9.3 5-60 8855...
Page 193: 10.1 Cross Flow Fans
PIN (NOT SPARED) 2N1354 TOP REAR COVER – FITTING PLATE (NOT SPARED) – BRACKET (NOT SPARED) – BRACKET (NOT SPARED) 9N787 GAS SPRING – BRACKET (NOT SPARED) – TOP REAR COVER ASSEMBLY (NOT SPARED) Parts Lists 2/99 PL 10.1 8855 5-61...
Page 194: 10.2 Electrical Components
53N100 OZONE FILTER (REP 9.1.1) – BRACKET (NOT SPARED) 109N211 DRAWER INTERLOCK SWITCH (DS3) 105N1099 DC POWER SUPPLY (LVPS1) 103N190 RESISTOR (R1) 127N749 LVPS1 COOLING FAN (FM1) – BRACKET (NOT SPARED) 16N148 BUSHING Parts Lists 2/99 PL 10.2 5-62 8855...
Page 195: 10.3 Electrical Components
BRACKET (NOT SPARED) 64N20 INDICATOR PLATE – RIGHT SIDE FRAME (NOT SPARED) – COLLAR (NOT SPARED) 140N4707 TONER CONTROL PWB – BUSHING (NOT SPARED) – BUSHING (NOT SPARED) 105N1104 DEVELOPER POWER SUPPLY 537E57010 E-PROM (F25F06) Parts Lists 2/99 PL 10.3 8855 5-63...
Page 196: 10.4 Electrical Components
SENSOR (Q22) – BRACKET (NOT SPARED) 127N752 CUTTER MOTOR (MOT3) (REP 5.2.1) 28N195 THRUST WASHER 127N751 PAPER FEED MOTOR (MOT2) (REP 8.5.1) – MOTOR BRACKET (NOT SPARED) 7N508 SPROCKET (20T) – BRACKET (NOT SPARED) Parts Lists 2/99 PL 10.4 5-64 8855...
Page 197: 10.5 Electrical Components
– ADAPTER PLATE (NOT SPARED) – BRACKET (NOT SPARED) 130N687 HUMIDITY SENSOR 110N726 LEFT COVER SWITCH (MS6) 160K60340 DEVELOPER MOTOR CONTROLLER PWB (W/TAG 17) 130N686 ELECTROMETER PWB (WITH PROBE) – BRACKET (NOT SPARED) Parts Lists 2/99 PL 10.5 8855 5-65...
Page 198: 11.1 Catch Trays
TRAY 1 50N189 TRAY 2 – BRACKET (NOT SPARED) – AUXILIARY POWER OUTLET (NOT SPARED) – PAPER HEATER SWITCH (NOT SPARED) 117K27001 POWER CORD – SUB-TRAY (NOT SPARED) 105N1197 TRANSMISSION PWB 105N1195 RECEIVING PWB Parts Lists 2/99 PL 11.1 5-66 8855...
Page 199: Part Number Index
PL 7.5 5N411 PL 9.2 PL 7.9 5N412 PL 3.2 PL 7.14 PL 3.5 7N512 PL 7.3 5N413 PL 7.3 PL 7.7 5N414 PL 8.4 PL 7.13 5N415 PL 5.3 7N513 PL 7.5 Parts Lists 2/99 Part Number Index 8855 5-67...
Page 200 PL 2.2 7N546 PL 7.5 9N789 PL 4.3 7N547 PL 4.3 9N790 PL 4.2 7N548 PL 3.3 9N792 PL 6.1 7N549 PL 7.5 9N793 PL 6.3 7N550 PL 8.6 9N794 PL 3.5 Parts Lists 2/99 Part Number Index 5-68 8855...
Page 201 PL 7.11 PL 8.2 19N345 PL 7.6 PL 8.3 PL 7.10 PL 8.5 PL 7.11 13N270 PL 3.2 19N346 PL 4.3 13N271 PL 2.2 19N347 PL 4.3 PL 4.3 19N348 PL 7.3 Parts Lists 2/99 Part Number Index 8855 5-69...
Page 202 PL 7.2 29N148 PL 8.5 22N957 PL 7.12 29N149 PL 8.5 22N993 PL 6.5 29N179 PL 5.2 23N322 PL 7.5 29N180 PL 7.12 PL 7.9 30N314 PL 10.4 PL 7.14 30N315 PL 6.5 Parts Lists 2/99 Part Number Index 5-70 8855...
Page 203 91N419 PL 4.6 47N14 PL 4.4 91N420 PL 4.3 47N15 PL 3.2 91N421 PL 4.4 PL 3.3 91N422 PL 4.3 50N187 PL 3.1 91N423 PL 1.4 50N188 PL 11.1 91N424 PL 1.4 Parts Lists 2/99 Part Number Index 8855 5-71...
Page 204 PL 1.3 128N398 PL 3.2 117N1122 PL 2.2 128N399 PL 7.3 117N1123 PL 4.3 PL 7.7 117N1145 PL 1.3 PL 7.11 117N1146 PL 1.4 128N436 PL 10.3 117K27001 PL 11.1 128N437 PL 10.3 Parts Lists 2/99 Part Number Index 5-72 8855...
Page 205 140N4709 PL 10.3 140N4710 PL 7.4 PL 7.7 140N4711 PL 10.2 140N4712 PL 10.2 140N4714 PL 10.3 140N4968 PL 10.3 142N84 PL 10.2 142N85 PL 6.2 142N86 PL 6.2 144N44 PL 1.1 Parts Lists 2/99 Part Number Index 8855 5-73...
Page 206 Parts Lists 2/99 Part Number Index 5-74 8855...
Page 207: General Procedures
........6-35 EDIA PECIFICATIONS ......6-35 LOOR PACE EQUIREMENTS SUPPLEMENTAL TOOLS AND SUPPLIES ........6-36 RINTER ONSUMABLES ............... 6-36 OOLS GENERAL PROCEDURES GP1 PLP S ........6-37 GP2 PLP P ......6-37 ORKS ..........6-38 HANGE NDEX 5/99 Diagnostics 8855...
Page 208: Diagnostics
SW 704 to step backward LED will display the letter J through the list. Exiting the Diagnostic Mode NOTE: The 8855 diagnostics cannot be exited by switching off the printer. To exit the diagnostic mode press and hold SW 701, then press SW 704.
Page 209 [1-0A] Page Blank Signal [1-19] [1-0b] Printer Busy Signal [1-1A] Cutter Home Position Sensor [1-0C] Registration Brake Clutch [1-1b] Overheat Thermostat [1-0d] Mid Transport Brake [1-1C] Inner Transport Set Sensor [1-0E] [1-1d] Roll 1 Feed Clock Sensor 5/99 Diagnostics 8855...
Page 210 Registration Sensor [1-37] Size Sensor 7 (not shown) [1-29] Roll 4 Feed Clock Sensor [1-38] Media Selection Data 2 [1-2A] Separation Sensor [1-39] Media Selection Data 3 [1-2b] Fuser Exit Switch [1-3A] Manual Feed Sensor [1-2C] [1-3b] 5/99 Diagnostics 8855...
Page 211 Fuser Motor Running [1-53] Side SSR [1-44] [1-54] Center SSR [1-45] Paper Feed Motor Running [1-55] [1-46] [1-56] [1-47] Drum Motor Running [1-57] HVPS 1 [1-48] Developer Bias On [1-58] [1-49] Paper Feed Motor On [1-59] [1-4A] 5/99 Diagnostics 8855...
Page 212 [1-63] Separation Blower [1-73] Roll 2 Feed Clutch [1-64] Paper Feed Motor Direction [1-74] Roll 3 Feed Clutch [1-65] [1-75] Roll 4 Feed Clutch [1-66] Drum Motor Direction [1-76] [1-67] [1-77] Paper Heaters [1-68] Toner Dispense Motor 5/99 Diagnostics 8855...
Page 213 Display Signal 4 [1-7E] Pressure Blowers High Speed [1-8d] Display Signal 5 [1-7F] Pressure Blowers Low Speed [1-8E] Display Signal 6 [1-80] [1-8F] Display Signal 7 [1-81] [1-90] [1-82] [1-91] [1-83] [1-92] [1-84] [1-93] [1-85] [1-94] [1-86] [1-95] 5/99 Diagnostics 8855...
Page 214 Output Data Bus 6 [1-A0] Switch Data 0 [1-AF] Output Data Bus 7 [1-A1] [1-b0] Input Data Bus 0 [1-A2] [1-b1] Input Data Bus 1 [1-A3] [1-b2] Input Data Bus 2 [1-A4] [1-b3] Input Data Bus 3 5/99 Diagnostics 8855...
Page 215 Code [1-b4] Input Data Bus 4 [1-b5] Input Data Bus 5 [1-b6] Input Data Bus 6 [1-b7] Input Data Bus 7 [1-b8] [1-b9] Paper Cut Signal [1-bA] Command Strobe Signal [1-bb] Print Signal [1-bC] [1-bd] [1-bE] [1-bF] 5/99 Diagnostics 8855...
Page 216 If the dashes are visible, but not blinking, the component is OFF. • If the dashes are blinking, the component is ON. Refer to the tables on pages 6-11 through 6-13 for a complete listing of available outputs. 5/99 Diagnostics 8855 6-10...
Page 217 [3-60] Erase Lamp [3-0b] Printer Busy Signal [3-52] [3-61] Separation Lamp [3-0C] Registration Brake Clutch [3-53] Center SSR [3-62] [3-0d] Mid Transport Brake [3-54] Side SSR [3-63] Separation Blower [3-0E] [3-55] [3-64] Paper Feed Motor Direction 5/99 Diagnostics 8855 6-11...
Page 218 Display Signal 5 [3-70] Registration Clutch [3-7F] Pressure Blowers (L) [3-8E] Display Signal 6 [3-71] Mid Transport Clutch [3-80] [3-8F] Display Signal 7 [3-72] Roll 1/Manual Feed Clutch [3-81] [3-90] [3-73] Roll 2 Feed Clutch [3-82] [3-91] 5/99 Diagnostics 8855 6-12...
Page 219 Code Description [3-92] [3-93] [3-94] [3-95] [3-96] [3-97] [3-98] Roll 1 Sensors Enabled [3-99] Roll 2 Sensors Enabled [3-9A] Roll 3 Sensors Enabled [3-9b] Roll 4 Sensors Enabled [3-9C] Digit Signal 4 [3-9d] [3-9E] [3-9F] 5/99 Diagnostics 8855 6-13...
Page 220 2. Connect meter leads to TP202 and GND to signal ON and OFF. read the DC voltage (Fig. 1). NOTE: SW 703 switches the +15 volt signal ON and OFF. SW 704 switches the +10 volt signal ON and OFF. 5/99 Diagnostics 8855 6-14...
Page 221 (A0, 30”, 34”, 36” in width). NOTE: As a general rule, increase fuser temperature to improve fusing, decrease fuser temperature to eliminate wrinkling of paper. 5/99 Diagnostics 8855 6-15...
Page 222 • 160 mms/s setting display: 4 P 1 6 0 • 120 mm/s setting display: 4 P 1 2 0 • 100 mm/s setting display 4 P 1 0 0 5/99 Diagnostics 8855 6-16...
Page 223 100º C. This adjustment changes fuser temperature of the center heat rod, and is used when printing small size sheets of tracing paper (less than 30 inches in width). Adjustment is the same as for [4-6]. 5/99 Diagnostics 8855 6-17...
Page 224 Adjustment is the same as for [4-d]. This adjustment changes fuser temperature of the side heat rod and is used with small prints of tracing paper less than 30 inches in width. Adjustment is the same as for [4-6]. 5/99 Diagnostics 8855 6-18...
Page 225 [4-A.1] [4-C.1] TR Corotron (Film 20%) value is decreased, the off-timing will be advanced. This adjustment changes the transfer corotron current when printing on film. Relative humidity is 20%. Adjustment is the same as for [4-A.1]. 5/99 Diagnostics 8855 6-19...
Page 226 For Metric Systems: Operate the external device. • 1 m/count • 4 P. 1: enable • 0.1 m/count • 4 P. 0: disable • /count • 0.1m /count For ANSI Systems: • 1 feet/count • 1 feet /count 5/99 Diagnostics 8855 6-20...
Page 227 6-1d Unused Code Description 6-0F Unused 6-1E Unused 6-00 Fuser temperature too low 6-10 Paper jam error 6-1F Unused 6-01 Fuser temperature too high 6-11 Out of paper error (Feeder 1) 6-02 Paper Feed Motor error 5/99 Diagnostics 8855 6-21...
Page 228 SC indicates that the paper will be cut when SW 703 is pressed. If SW 703 is not pressed, paper will be cut to the length set in Maximum Cut Length [4-3] (6 or 16 metres). 5/99 Diagnostics 8855 6-22...
Page 229: Factory Adjustment
Diagnostic mode will be the one displayed attribute. when exiting Diagnostics. Press SW 703 to step through the selections: • Positive • Negative • Positive Mirror • Negative Mirror NOTE: Ensure that selection is returned to 0 when test is complete. 5/99 Diagnostics 8855 6-23...
Page 230 Notes 5/99 8855 6-24...
Page 231: Inspecting The Shipment
Developer Assembly Cover. Paper Towels the Fuser Assembly (machine rear). • 12. Remove the screw and the Developer Drop Cloth Assembly Lock Bracket from the front of the Developer Assembly. 5/99 Installation 8855 6-25...
Page 232 Pulling out the Developer Assembly inst4 Fan Connector Figure 3. Removing the Rear Upper Cover inst5 Figure 4. Removing the Louvers 15. (Figure 4): Disconnect the Erase Lamp Connector and remove the wires from the cable clamp. 5/99 Installation 8855 6-26...
Page 233 Put the Stripper Finger Assembly in a safe place. d. Place the Cleaner Assembly on a flat surface. Left Right Side Side inst11 Figure 5. Removing the Stripper Finger Assembly 5/99 Installation 8855 6-27...
Page 234: Led Print Head
Lock the Inner (Both sides) Transport LED Print Head Assembly inst7 Figure 7. Locking the Inner Transport Assembly Figure 6. Installing the Pins NOTE: Connectors are inboard. 4. Connect all four connectors to the LED Print Head. 5/99 Installation 8855 6-28...
Page 235: Cleaner Assembly
Groove Assembly Install the Drum Assembly inst11a Figure 10. Reinstalling the Cleaner Assembly Square hole inst10 R-shaped hole Reinstall the Drum Figure 9. Reinstalling the Stripper Fingers Shaft Holder inst9 Figure 8. Installing the Drum Assembly 5/99 Installation 8855 6-29...
Page 236: Developer Assembly
4. Secure the Developer Assembly Cover the Down Lock and place the Inner Connect the with two screws. Transport Assembly operating Connectors position. 9. Reinstall the Charge Scorotron. 10. Reinstall the Rear Upper Cover. Figure 11. Reconnecting the Fan Connectors 5/99 Installation 8855 6-30...
Page 237: Toner Kit
Frame 1 move the cartridge back to the 12 o’clock position in preparation of verifying toner concentration during Final Checks. Right Fitting Plate Trays Inst13 Frame 2 Figure 12. Removing the Components 5/99 Installation 8855 6-31...
Page 238: Final Checks
• Jam clearance TP501 • (Analog) Verify customer requirements inst 97 Program 4 [ 4-h] for Trail Edge Blank. VR501 • Explain Billing Meter location and how to read the meters. Figure 13. Setting Toner Concentration 5/99 Installation 8855 6-32...
Page 239: Removal Procedure
13. Secure the Toner Waste Bottle and Preparing the Machine Removal Procedure Locking Arm with tape. 1. Turn off the 8855 and disconnect the Purpose 14. Secure the Toner Catch Tray with tape. Power Cord. The purpose is to repack the machine for 15.
Page 240 Notes: 5/99 Removal 8855 6-34...
Page 241: Product Specifications
Power Cord Length 13 feet, 20 Amp Environmental Conditions 65.5 in (1663 mm) Operating Range 153.5 in 38 in (3899 mm) 8855 65.5 in Relative Humidity 15% to 85% (965 mm) (1663 mm) Temperature 50°F to 85°F (10°C to 29°C) 49.5 in (1257 mm)
Page 242: Supplemental Tools And Supplies
Fuser Lubricating Grease 70N20 Toner (Unique XES Configuration Canister) 6R855 Tag Matrix Label 91P63536 Tools Density Tool 82P520 Developer Replacement Tool93N33 Cutter Home Position Jig 18N136 Phillips Screwdriver, 8” 600T2044 Shim Stock 600T41511 5/99 Supplemental Tools and Supplies 8855 6-36...
Page 243: General Procedures
DOS PlotWorks software by • X offset - No change running a test pattern through the 7336 sending known good files to the 8855 from the • Threshold - 145 scanner using the test diskette and a test PLP station.
Page 244: Change Tag Index
NAME: Threads Communications made: Cable M - Mandatory PURPOSE: Changes threads to match VPI cable. N - Not installed in the field KIT NUMBER: TBD O - Optional REFERENCE: R - Repair 5/99 Change Tag Index 8855 6-38...
Page 245 PURPOSE: Eliminates wires that short PURPOSE: A brush has been added to when 7396 is attached to the 8855. Also circuit because of excess force from the Developer Assembly to clean the Toner adds EME shields in 8855 to eliminate defective harness routing.
Page 246 Notes: 5/99 8855 6-40...
Page 247: Section Contents
7. Wiring Data Section Contents TITLE PAGE Plug/ Jack Location Index ......7-2 Plug/ Jack Location Drawing ......7-4 Block Schematic Drawings (BSDs) ..7-12 5/99 Section Contents 8855...
Page 248 J 71 J 105 J 21 J 72 J 106 J 22 J 73 J 107 J 24 J 74 J 108 J 25 J 76 J 121 J 26 J 77 J 122 J 27 5/99 Plug/Jack Location Index 8855...
Page 249 J 252D J 993 J 252F J 994 J 252P J 253D J 253F J 253P J 341A J 341C J 501 J 502 J 551 J 553 J 554 J 555 J 556 J 557 5/99 Plug/Jack Location Index 8855...
Page 250 Plug/Jack Location Drawings Figure 1: Top 5/99 Plug/ Jack Location Drawing 8855...
Page 251 Figure 2: Lower Rear 5/99 Plug/ Jack Location Drawing 8855...
Page 252 Figure 3: Lower Left 5/99 Plug/ Jack Location Drawing 8855...
Page 253 Figure 4: Upper Left 5/99 Plug/ Jack Location Drawing 8855...
Page 254 Figure 5: Rear View of Top Figure 6: Drawer 1 5/99 Plug/ Jack Location Drawing 8855...
Page 255 Figure 7: Drawer 2 5/99 Plug/ Jack Location Drawing 8855...
Page 256 Figure 8: Drawer 3 5/99 Plug/ Jack Location Drawing 8855 7-10...
Page 257 Figure 9: Right Side 5/99 Plug/ Jack Location Drawing 8855 7-11...
Page 258 SWITCH SWITCH SWITCH PL 10.4 PL 4.2 PL 4.2 AC TERMINAL J 15 J 15 STANDBY POWER BOARD NF 1 CHAIN 1 LEVEL 2 NOISE FILTER AC INTERLOCK SHEET 1 OF 4 RELAY 5/99 Chain 1 Standby Power 8855 7-12...
Page 259 AC TERMINAL THE VOLTAGE BETWEEN ACH 1 AND ACH 2 IS CHAIN 1 LEVEL 2 BOARD BETWEEN 220 AND 240 VAC. SHEET 2 OF 4 ACH 1 TB 152A ACH 2 TB 153A 5/99 Chain 1 Standby Power 8855 7-13...
Page 260 PL 10.3 +24 VDC J 203 [1-2F] U-01 U-02 [1-2E] [1-2d] U-03 DC COM Input Power Block STANDBY POWER Voltage Test Point Group Function CHAIN 1 LEVEL 2 +24 VDC SHEET 3 OF 4 5/99 Chain 1 Standby Power 8855 7-14...
Page 261: Machine Cooling
J 108-1 ACH 2 J 108-2 +24 VDC J 26-5 F123 -1/16 A 250 V STANDBY POWER +12 VDC J 25-1 CHAIN 1 LEVEL 2 DC COM J 25-4 SHEET 4 OF 4 5/99 Chain 1 Standby Power 8855 7-15...
Page 262 [3-8b] [3-8C] [3-8d] [3-8E] [3-8F] J 211 [3-98] [3-99] [3-9A] [3-9b] [3-9C] [1-A0] SW 701 SW 705 SW 702 SW 703 SW 704 MODE SELECTION CHAIN 2 LEVEL 2 SHEET 1 OF 1 5/99 Chain 2 Mode Selection 8855 7-16...
Page 263 E-18 Voltage Test Point Group Function +5 VDC J 24-8 +24 VDC J 24-6 +24 VDC K 4-5 +24 VDC MACHINE RUN CONTROL INTERLOCK CHAIN 3 LEVEL 2 SHEET 1 OF 2 5/99 Chain 3 Machine Run Control 8855 7-17...
Page 264: Machine Interface
I N F R A - R E D S I G N A L S P R O V I D E T H E C O M M U N I C A T I O N B E T W E E N T H E STACKER AND THE 8855. Input Power Block...
Page 265 NOTE: IMAGING TOP VIEW ACH 1 J 103-3 THE VOLTAGE BETWEEN ACH 1 AND ACH 2 IS CHAIN 6 LEVEL 2 ACH 2 J 104-3 BETWEEN 220 AND 240 VAC. SHEET 1 OF 1 5/99 Chain 6 Imaging 8855 7-19...
Page 266 J 94A 36 INCH SIZE PL 10.3 SENSOR +5 VDC PL 7.4 J 971A J 208 J 212 [3-98] LT BLU PAPER SUPPLY CHAIN 7 LEVEL 2 DC COM SHEET 1 OF 15 5/99 Chain 7 Paper Supply 8855 7-20...
Page 267 +5 VDC J 94B 36 INCH SIZE PL 10.3 SENSOR +5 VDC PL7.7 J 971B J 208 J 212 [3-99] LT BLU PAPER SUPPLY CHAIN 7 LEVEL 2 SHEET 2 OF 15 DC COM 5/99 8855 Chain 7 Paper Supply 7-21...
Page 268 J 94C 36 INCH SIZE PL 10.3 SENSOR +5 VDC PL 7.13 J 971C J 208 J 212 [3-9A] LT BLU DC COM PAPER SUPPLY CHAIN 7 LEVEL 2 SHEET 3 OF 15 5/99 Chain 7 Paper Supply 8855 7-22...
Page 269 +5 VDC 36 INCH SIZE PL 10.3 SENSOR +5 VDC PL 7.13 J 971D J 208 J 212 [3-9b] LT BLU DC COM PAPER SUPPLY CHAIN 7 LEVEL 2 SHEET 4 OF 15 5/99 8855 Chain 7 Paper Supply 7-23...
Page 270 AS THIS SIGNAL GOES FROM 0 VDC TO Voltage Test Point Group Function PAPER SUPPLY +8.2 VDC, THE DIRECTION OF ROTATION CHAIN 7 LEVEL 2 +24 VDC K 5-2 OF THE MOTOR CHANGES. SHEET 5 OF 15 INTERLOCK 5/99 Chain 7 Paper Supply 8855 7-24...
Page 271 ROLL 3 DRIVE 7.10 ROLL 4 DRIVE REGISTRATION DRIVE CL 1 ROLL1/ MANUAL FEED CLUTCH Input Power Block Voltage Test Point Group Function PAPER SUPPLY CHAIN 7 LEVEL 2 SHEET 6 OF 15 5/99 8855 Chain 7 Paper Supply 7-25...
Page 272 Input Power Block Q 13 Voltage Test Point Group Function PAPER SUPPLY ROLL 1 FEED CHAIN 7 LEVEL 2 NOTES: CLOCK SENSOR SHEET 7 OF 15 THIS SIGNAL IS A SERIES OF PULSES. 5/99 Chain 7 Paper Supply 8855 7-26...
Page 273 Input Power Block Q 14 Voltage Test Point Group Function PAPER SUPPLY ROLL 2 FEED CHAIN 7 LEVEL 2 NOTES: CLOCK SENSOR SHEET 8 OF 15 THIS SIGNAL IS A SERIES OF PULSES. 5/99 Chain 7 Paper Supply 8855 7-27...
Page 274 Input Power Block Q 15 Voltage Test Point Group Function PAPER SUPPLY ROLL 3 FEED CHAIN 7 LEVEL 2 NOTES: CLOCK SENSOR SHEET 9 OF 15 THIS SIGNAL IS A SERIES OF PULSES. 5/99 Chain 7 Paper Supply 8855 7-28...
Page 275 J 94 J 93 J 92 J 91 J 89 J 82 J 88 J 90 Input Power Block Voltage Test Point Group Function PAPER SUPPLY CHAIN 7 LEVEL 2 NOTES: SHEET 10 OF 15 THIS SIGNAL IS A SERIES OF PULSES. 5/99 Chain 7 Paper Supply 8855 7-29...
Page 276: Manual Sheet Feeding
P-05 J 68 +5 VDC J 207 J 207 [1-3A] J-05 +5 VDC DC COM Input Power Block Voltage Test Point Group Function PAPER SUPPLY CHAIN 7 LEVEL 2 SHEET 11 OF 15 5/99 Chain 7 Paper Supply 8855 7-30...
Page 277: Paper Feed
PL 8.5 MID-TRANSPORT J 44 J 557 ON (L) +24 VDC [3-0d] FEED CLUTCH +24 VDC Input Power Block PAPER SUPPLY Voltage Test Point Group Function CHAIN 7 LEVEL 2 SHEET 12 OF 15 5/99 Chain 7 Paper Supply 8855 7-31...
Page 278 CONTROLLER PWB Voltage Test Point Group Function + 5 VDC J 24-8 NOTES: PAPER SUPPLY +24 VDC K4-5 THIS SIGNAL IS A LOW GOING CHAIN 7 LEVEL 2 INTERLOCK PULSE. SHEET 13 OF 15 5/99 Chain 7 Paper Supply 8855 7-32...
Page 279 Voltage Test Point Group Function THE VOLTAGE BETWEEN ACH 1 AND ACH 2 IS BETWEEN 220 AND 240 VAC. +24 VDC J 25-2 PAPER SUPPLY CHAIN 7 LEVEL 2 SHEET 14 OF 15 5/99 Chain 7 Paper Supply 8855 7-33...
Page 280: Media Selection
J 72 J 972C PSEL-DG2 [3-9A] ROLL 4 MEDIA SELECTION PWB MATRIX PL 7.11 PL 7.12 J 971D J 751D J 972D PSEL-DG3 [3-9b] PAPER SUPPLY CHAIN 7 LEVEL 2 SHEET 15 OF 15 5/99 Chain 7 Paper Supply 8855 7-34...
Page 281 J 208 PAPER AT REGISTRATION +5 VDC SENSOR (L) +5 VDC [1-28] J-11 DC COM Input Power Block PAPER TRANSPORTATION Voltage Test Point Group Function CHAIN 8 LEVEL 2 SHEET 1 OF 1 5/99 Chain 8 Paper Transportation 8855 7-35...
Page 282: Drum Drive
AS THIS SIGNAL GOES FROM 0 VDC TO Input Power Block +8.2 VDC, THE DIRECTION OF ROTATION Voltage Test Point Group Function XEROGRAPHICS OF THE MOTOR CHANGES. CHAIN 9 LEVEL 2 +24 VDC K 5-2 SHEET 1 OF 7 INTERLOCK 5/99 Chain 9 Xerographics 8855 7-36...
Page 283 Group Function NOTES: XEROGRAPHICS THIS VOLTAGE GOES FROM +13 VDC TO +24 VDC J 24-6 CHAIN 9 LEVEL 2 +24 VDC K 4-5 0 VDC WHEN THE LAMP IS LIT. INTERLOCK SHEET 2 OF 7 5/99 Chain 9 Xerographics 8855 7-37...
Page 284 CONTROLLER PWB Input Power Block Voltage Test Point Group Function MOT 4 +24 VDC K 5-5 XEROGRAPHICS TOP VIEW INTERLOCK DEVELOPER +24 VDC K 5-2 CHAIN 9 LEVEL 2 MOTOR INTERLOCK SHEET 3 OF 7 5/99 Chain 9 Xerographics 8855 7-38...
Page 285 PL 6.3 J 25 ED 2 TRANSFER COROTRON +24 VDC DEVELOPED IMAGE PAPER TO TRANSFER Input Power Block XEROGRAPHICS Voltage Test Point Group Function CHAIN 9 LEVEL 2 SHEET 4 OF 7 +24 VDC 5/99 Chain 9 Xerographics 8855 7-39...
Page 286 Input Power Block NOTES: XEROGRAPHICS THIS VOLTAGE GOES FROM +13 VDC TO Voltage Test Point Group Function CHAIN 9 LEVEL 2 0 VDC WHEN THE LAMP IS ON. SHEET 5 OF 7 +24 VDC J 25-2 5/99 Chain 9 Xerographics 7-40 8855...
Page 287 J 33 J 13 SENSOR PL 3.3 J 559 L-01 TONER CONTROL PL 10.3 J 501 J 502 Input Power Block Voltage Test Point Group Function XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 6 OF 7 5/99 8855 Chain 9 Xerographics 7-41...
Page 288 CUSTOMER. ENTER [6-16] AND SWITCH THE H TO L USING SW702. TROUBLESHOOT THE ROOT CAUSE OR THE CODE WILL RETURN. Input Power Block Voltage Test Point Group Function XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 7 OF 7 5/99 Chain 9 Xerographics 7-42 8855...
Page 289 NOTES: Voltage Test Point Group Function FUSING THIS VOLTAGE GOES FROM +7 VDC TO 0 +24 VDC K 4-5 CHAIN 10 LEVEL 2 VDC WHEN THE BLOWER IS RUNNING. INTERLOCK SHEET 1 OF 5 5/99 Chain 10 Fusing 8855 7-43...
Page 290 J 26-4, 5 THE VOLTAGE BETWEEN ACH 1 AND ACH 2 IS FUSING ACH 1 TB 106-2 BETWEEN 220 AND 240 VAC. CHAIN 10 LEVEL 2 ACH 2 TB 107-2 SHEET 2 OF 5 5/99 Chain 10 Fusing 8855 7-44...
Page 291 J 26-4 NOTE: ACH 1 TB 104-1 FUSING THE VOLTAGE BETWEEN ACH 1 AND ACH 2 IS ACH 2 TB 105-1 CHAIN 10 LEVEL 2 BETWEEN 220 AND 240 VAC. SHEET 3 OF 5 5/99 Chain 10 Fusing 8855 7-45...
Page 292: Fuser Drive
Input Power Block Voltage Test Point Group Function THIS VOLTAGE GOES FROM +5 VDC TO 0 FUSING VDC WHEN THE MOTOR IS RUNNING. CHAIN 10 LEVEL 2 +24 VDC K 5-2 SHEET 4 OF 5 INTERLOCK 5/99 Chain 10 Fusing 8855 7-46...
Page 293 DC COM 10.4 EXIT DRIVE 10.4 COPY TO FUSER EXIT LS 2 FUSER EXIT SWITCH EXIT ROLL Input Power Block Voltage Test Point Group Function FUSING CHAIN 10 LEVEL 2 SHEET 5 OF 5 5/99 Chain 10 Fusing 8855 7-47...
Page 294 Notes: 5/99 Chain 10 Fusing 8855 7-48...
Page 295: Section Contents
1. Service Call Procedures Section Contents TITLE PAGE Service Call Procedures ....8A 1-2 Call Flow Diagram.......8A 1-3 Initial Actions / System Checks...8A 1-4 Image Defect Isolation Procedure ..8A 1-5 Status Code Entry Chart .....8A 1-6 System Checkout /Final Action ...8A 1-8 5/99 7396/7399 Scanners Section Contents...
Page 296 SERVICE CALL PROCEDURES System Checkout/Final Action The Service Call Procedures are designed to The purpose of this procedure is to make a Assist the Service Representative to identify record in the machine log book of the service scanner faults, perform necessary activities that were performed.
Page 297 Call Flow Diagram INITIAL ACTION/ SYSTEM CHECKS REPAIR ANALYSIS PROCEDURE HAS THERE BEEN MORE THAN 5 CUSTOMER WORK DAYS OR 3K FEET SINCE THE LAST SERVICE CALL? PERFORM THE MAINTENANCE PERFORM THE CALL BACK PROCEDURE FOR ALL PROCEDURE SUBSYSTEMS. PERFORM THE SYSTEM CHECKOUT / FINAL ACTION. 5/99 7396/7399 Scanners Call Flow Diagram...
Page 298: Status Indicator
Initial Actions/System Checks NOTE: You should have been directed here from the 8855 Call Flow Diagram because of a scanner problem 1. Ask the operator to describe the problem. 2. If a controller ia connected to the system, ask the operator to take the controller off-line.
Page 299 Image Defect Isolation Procedure Duplicate the Image Defect as follows : Print a Document (Test Print) from the Printer. Refer to the Printer Service Manual. Scan and Print the Document. Compare the Document to the Scanned Image . The Image Defect is on the Scanned Image only. Go to Scanner Image Quality, Section Go to the Printer Service Manual.
Page 300 Status Code Entry Chart NOTE: When an error occurs, the Error Indicator ( ) lights and the following Status Codes are displayed on the Zoom display. When an Error Message is displayed, press the 100% key to see the Error Code. Error Error Code Description...
Page 301 Error Error Code Description Components/Corrective Action BSD Ref PL Ref Message (100% Key (Zoom pressed) Display) E-JA. E-44 Document Jam Refer to BSD 5.3 Document Jam Refer to BSD 5.3 E-45 Document Jam Refer to BSD 5.3 E-46 E-47 Document Jam Refer to BSD 5.3 E-48 Document Jam...
Page 302: System Checkout/Final Action
System Checkout/Final Action Scan a document at 100%. Check document for image defects. Show scanned image to customer. 5/99 System Checkout/Final Action 7396/7399 Scanners 8A 1-8...
Page 303 2. Repair Analysis Procedures (RAPs) Section Contents TITLE PAGE Status Indicators C-00 CCD Reading Error ....8A 2-2 E-CE (E-17, E-18, E-19) CCD Connection Error ....8A 2-3 5/99 7396/7399 Scanners Section Contents 8A 2-1...
Page 304: Initial Action
C-00 CCD Reading Error This code is displayed when the CCD does not respond to a Document being fed. Initial Action Check that all cables shown on BSDs 6.2 and 6.3 are properly connected. Procedure The Platen Glass (PL 1.4) of the CCD Head and other parts of the CCD Head are free of dirt and scratches.
Page 305: Connection Error
E-CE (E-17, E-18, E-19) CCD Connection Error This code displayed when connection error is detected. Initial Action Check that cables between the Image Process PWB and the DC Controller PWB (BSD 6.3) are properly connected Procedure Check that +5 vdc is present at the DC Con- troller PWB and at the Image Process PWB (Refer to the +5 VDC Wirenet at the end of Section 8A 7) .
Page 306 Notes 5/99 7396/7399 Scanners 8A 2-4...
Page 307 3. Image Quality Section Contents TITLE PAGE Introduction ..........8A 3-2 Image Quality Samples Black Band (2-1/4 Inch Wide) .....8A 3-3 Black Bands or Lines ......8A 3-4 Stretched (Stream) Image ....8A 3-5 Image Quality RAPS IQ 1 Black Bands or Lines RAP..8A 3-6 IQ 2 White Bands or Lines RAP ..8A 3-7 IQ 3 Stretched (Stream) Image RAP........8A 3-8...
Page 308: Introduction
Introduction Image Quality RAPs Whenever an image quality problem is The Image Quality RAPs are located at the suspected in scanner, perform end of this Section. After you have determined Exposure Adjustment, 6.3.1, in Section 8A 4 of the definition that best describes the image this manual.
Page 309 5/99 7396/7399 Scanners Image Quality Samples 8A 3-3...
Page 310 5/99 Image Quality 7396/7399 Scanners 8A 3-4...
Page 311 5/99 7396/7399 Scanners Image Quality Samples 8A 3-5...
Page 312: Iq 1 Black Bands Or Lines Rap
IQ 1 Black Bands or Lines RAP Symptom / Checks Probable Cause Corrective Action Black band (2-1/4 inches wide) Faulty connection between CCD Segment and Visually inspect all connections. Repair as neces- Image Process PWB (BSD 6.2) sary. Defective CCD Head (BSD 6.2) Replace CCD Head (PL 1.4) Defective Image Process PWB (BSD 6.2) Replace Image Process PWB (PL 1.3...
Page 313: Iq 2 White Bands Or Lines Rap
IQ 2 White Bands or Lines RAP Symptom / Checks Probable Cause Corrective Action White Band or Line Platen Glass of CCD Head is scratched or dirty. Clean or replace Platen Glass (PL 1.4). Dirty Document Feed Rollers (BSD 5.3). Replace Document Feed Rollers (PL 1.5).
Page 314: Iq 3 Stretched (Stream) Image Rap
IQ 3 Stretched (Stream) Image RAP Symptom / Checks Probable Cause Corrective Action Stretched (Stream) Image. Slippage of Document Worn Document Feed Rollers. Replace Document Feed Roller (PL 1.5). that is being scanned. Improper tension of Feed Drive Belt. Adjust Feed Drive Belt Tension (PL 1.5). Slipping Drive Pulley.
Page 315 4. Repair/Adjustment Section Contents Adjustments Repairs ADJ 6.3.1 Exposure Adjustment....8A 4-15 REP 3.2.1 Upper Cover......8A 4-3 ADJ 6.3.2 Stamp Position.....8A 4-16 REP 3.2.2 Control Panel PWBs ....8A 4-4 REP 3.2.3 Document Sensors ....8A 4-5 REP 3.2.4 Floopy Drive (7399)....8A 4-6 REP 3.3.1 Document Shelf .....
Page 316 Notes: 5/99 7396/7399 Scanners 8A 4-2...
Page 317: Rep 3.2.1 Upper Cover
REP 3.2.1 Upper Cover Parts List on PL 1.1 Handle WARNING Upper Cover Disconnect the Power Cord. Removal 1. Open the Upper Unit Assembly. 2. (Figure 1): Remove the screw and the knob. 3. Remove the five screws from the front, and remove the handle.
Page 318: Rep 3.2.2 Control Panel Pwbs
REP 3.2.2 Control Panel PWBs Parts List on PL 1.1 WARNING Disconnect the Power Cord. Removal Upper Cover 1. Remove the Upper Cover (REP 3.2.1). 2. (Figure 1): Disconnect the connectors and remove Control Panel PWBs removing the 13 screws that secure the PWBs to the Interface Panel.
Page 319: Rep 3.2.3 Document Sensors
REP 3.2.3 Document Sensors Parts List on PL 1.6 WARNING Disconnect the Power Cord. Removal Sensors 1. Remove the Upper Cover (REP 3.2.1). 2. (Figure 1): Cut the black cable tie in order to loosen the harness to allow removal of the Sensor Bracket.
Page 320: Rep 3.2.4 Floopy Drive (7399)
REP 3.2.4 Floppy Drive (7399) Parts List on PL 1.4B WARNING Switch off the power. Disconnect the Power P/J CN1 Cord. Removal 1. Remove the Document Shelf (REP 3.3.1 (7399)). 2. Disconnect P/JCN1 and P/JCN2 from the rear of the Floppy Drive Assembly. NOTE: When removing the ribbon cable, note that the red wire is on the right hand side of the connector when plugged into the Floppy Drive.
Page 321: Rep 3.3.1 Document Shelf
REP 3.3.1 Document Shelf Document Shelf Parts List on PL 1.5 Rear corner WARNING Right Side Cover Disconnect the Power Cord. Removal 1. Raise the Upper Unit Assembly. 2. (Figure 1): Remove the two screws and the Left Side Cover. 3.
Page 322: Rep 3.3.2 Lower Unit Assembly
REP 3.3.2 Lower Unit Assembly PWBs Parts List on PL 1.2, 1.3, 1.4 WARNING Disconnect the Power Cord. LED DC Rear Cover Power Removal Supply 1. Remove the Document Shelf (REP 3.3.1). Upper Unit NOTE: Refer to Figure 1 to identify the PWB to Controller be removed.
Page 323: Rep 3.3.3 Dc Power Supply
REP 3.3.3 DC Power Supplies Parts List on PL 1.2 WARNING Disconnect the Power Cord. Scanner Rear Removal Cover (7399) 1. Remove the two screws and the Left Side Cover. 2. (Figure 1): Remove four screws, disconnect the connectors, and carefully lift out the DC Power Supply DCP1 from the left side.
Page 324: Rep 3.3.4 Ccd Head / Led
5. (Figure 2): In order to ensure correct belt REP 3.3.4 CCD Head / LED tension at reinstallation, make a scribe line (7396) Assembly on the frame in order to mark the position of the idler pulley. Parts List on PL 1.4 6.
Page 325 9. (Figure 3): Disconnect the connectors, 10. (Figure 4): Remove the CCD Head / LED remove the two screws at each end, and Assembly. remove the Front Roller Bracket Assembly. a. Perform REP 3.3.2 for the Image Process PWB. Front Roller b.
Page 326: Rep 3.3.4.1 Ccd Head
7. Remove the Bearing from the frame and 12. Lift and remove the front Document Roller REP 3.3.4.1 CCD Head (7399) remove it from the shaft. and bracket from the scanner. Assembly Parts List on PL 1.4B 8. Prepare to remove the Document Roller Bracket.
Page 327 16. Remove the rear Document Guide Plate 18. Lift the CCD Head Assembly up just enough Assembly (4 screws). to disconnect P/J875 on the lower Image Process PWB, and the in-line Thermostat connector, P/J30. 19. Remove the CCD Head Assembly from the scanner.
Page 328: Rep 3.3.5 Exposure Lamp (7399)
NOTE: It is not necessary to disconnect the Cooling Fan plug/jack at this time. REP 3.3.5 Exposure Lamp Replacement (7399) 7. Remove the Idler Bracket from the lower CAUTION frame drive. (PL1.5). Parts List on PL 1.4B Do not touch the new Exposure Lamp with 8.
Page 329: Adj 6.3.1 Exposure Adjustment
ADJ 6.3.1 Exposure Adjustment Purpose The purpose is to set the exposure for optimum print quality. Adjustment 1. Place the Standard White Strip (35N233) on the platen glass. 2. Enter the Service Mode. 3. Enter the Test Mode 5: Motor. 4.
Page 330: Adj 6.3.2 Stamp Position
ADJ 6.3.2 Stamp Position ( + ) ( - ) ( - ) ( + ) Purpose Stamp Stamp The purpose is to position the stamp per customer requirements. Backup Data No. 75 Backup Data No. 74 Adjustment ( - ) ( + ) 1.
Page 331 5 Parts Lists Introduction ........................Subsystem Information ....................Symbology ........................7396/99 SCANNER PL 1.1A FRAMES AND COVERS (PART 1 OF 2)............PL 1.1B FRAMES AND COVERS (PART 2 OF 2)............PL 1.2 LOWER FRAME ELECTRICAL COMPONENTS (PART 1 OF 3) ....... PL 1.3 LOWER FRAME ELECTRICAL COMPONENTS (PART 2 OF 3) .......
Page 332 Parts Lists 5/99 7396/99 SCANNER...
Page 333: Introduction
Table 2 Operating Companies Abbreviation Meaning Americas Operations USMG United States Marketing Operations United States Operations Xerox Canada Limited Xerox Europe Symbology Symbology used in the Parts List section is identified in the Symbology section. Parts Lists 5/99 Introduction 7396/99 SCANNER...
Page 334: Subsystem Information
Subsystem Information Use of the Term "Assembly" The term "assembly" will be used for items in the part number listing that include other itemized parts in the part number listing. When the word "assembly” is found in the part number listing, there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly.
Page 335: Symbology
Symbology A Tag number within a circle having a shaded bar and pointing to an item number shows that the configuration of the part shown is the configuration before the part was changed by the Tag A Tag number within a circle pointing to an item number shows that the part has been changed number within the circle (Figure 2).
Page 336 A Tag number within a circle with no apex shows that the entire drawing has been changed by A Tag number within a circle with no apex and having a shaded bar shows that the entire the Tag number within the circle (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.
Page 337: 1.1A Frames And Covers (Part 1 Of 2)
PL 1.1A FRAMES AND COVERS (PART 1 OF 2) Item Part Description 2N1442 UPPER COVER (7396) – 2N1626 UPPER COVER (7399) – USER INTERFACE PANEL (NOT SPARED) 107N326 LCD PWB 140N4938 CONTROL PANEL 2 PWB (7396) – 140N5268 CONTROL PANEL 2 PWB (7399) 140N4937 CONTROL PANEL 1 PWB –...
Page 338: 1.1B Frames And Covers (Part 2 Of 2)
PL 1.1B FRAMES AND COVERS (PART 2 OF 2) Item Part Description 50N286 CATCH TRAY (7399 ONLY) 50N287 CATCH TRAY EXTENSION (7399 ONLY) 73E11800 CATCH TRAY KIT (7396 ONLY) – CATCH TRAY (P/O PL 1.1B item 3) 50N288 GUIDE PLATE (7399 ONLY) 50N289 TRAY BASE (7399 ONLY) –...
Page 339: 1.2 Lower Frame Electrical Components (Part 1 Of 3)
PL 1.2 LOWER FRAME ELECTRICAL COMPONENTS (PART 1 OF 3) Item Part Description – PART OF LOWER UNIT ASSEMBLY (REF: PL 1.1A item 8) 127N908 FAN MOTOR 127N904 MOTOR CONTROL PWB (7396) – 140N5266 MOTOR CONTROL PWB (7399) – PWB BRACKET (P/O PL 1.2 item –...
Page 340: 1.3 Lower Frame Electrical Components (Part 2 Of 3)
PL 1.3 LOWER FRAME ELECTRICAL COMPONENTS (PART 2 OF 3) Item Part Description – PART OF LOWER UNIT ASSEMBLY (REF: PL 1.1A item 8) 140N4955 MEMORY PWB – PWB BRACKET (P/O PL 1.3 item 109N343 DC CONTROLLER PWB (7396) – 109N436 DC CONTROLLER PWB (7399) 142N114...
Page 341: 1.4A Lower Frame Electrical Components (Part 3 Of 3)
PL 1.4A LOWER FRAME ELECTRICAL COMPONENTS (PART 3 OF 3) Item Part Description – PART OF LOWER UNIT ASSEMBLY (7396 ONLY) (REF: PL 1.1A item 8) – PLATEN GLASS PLATE (P/O PL 1.4A item 5) – PLATEN GLASS PAD (P/O PL 1.4A item 5) 62N105 PLATEN GLASS...
Page 342: 1.4B Lower Frame Electrical Components (7399 Only)
PL 1.4B LOWER FRAME ELECTRICAL COMPONENTS (7399 ONLY) Item Part Description – PART OF LOWER UNIT ASSEMBLY (7399 ONLY) (REF: PL 1.1A item 8) 62N158 OPTICAL ASSEMBLY – PLATEN GLASS PLATE (P/O PL 1.4B item 2) – PLATEN GLASS PAD (P/O PL 1.4B item 2) 62N157 PLATEN GLASS...
Page 343: 1.5 Lower Frame Drives
PL 1.5 LOWER FRAME DRIVES Item Part Description – PART OF LOWER UNIT ASSEMBLY (REF: PL 1.1A item 8) 2N1512 DOCUMENT SHELF (7396) – 2N1625 DOCUMENT SHELF (7399) 142N118 PETP SHEET CR 142N116 PETP SHEET BR 142N115 PETP SHEET A 142N117 PETP SHEET BL 142N119...
Page 344: 1.6 Upper Frame Electrical Components
PL 1.6 UPPER FRAME ELECTRICAL COMPONENTS Item Part Description – PART OF UPPER UNIT ASSEMBLY (REF: PL 1.1A item 6) – GUIDE BRACKET (P/O PL 1.6 item – SENSOR BRACKET (P/O PL 1.6 item 1) 130N768 SENSOR – PLATE (P/O PL 1.6 item 1) –...
Page 345: 1.7 Upper Frame Drives
PL 1.7 UPPER FRAME DRIVES Item Part Description – PART OF UPPER UNIT ASSEMBLY (REF: PL 1.1A item 6) – FEED GUIDE PLATE "B" (P/O PL 1.7 item 1) 22N805 PLATEN ROLLER – UPPER LOCK SHAFT (P/O PL 1.7 item 1) –...
Page 346: Part Number Index
Part Number Index Table 1 Part Number Index Part Number Part List Table 1 Part Number Index 50N289 PL 1.1B Part Number Part List 57N8 PL 1.4B 2N1442 PL 1.1A 62N105 PL 1.4A 2N1443 PL 1.5 62N155 PL 1.5 2N1512 PL 1.5 62N157 PL 1.4B...
Page 347 Table 1 Part Number Index Part Number Part List 142N114 PL 1.3 142N115 PL 1.5 142N116 PL 1.5 142N117 PL 1.5 142N118 PL 1.5 142N119 PL 1.5 152N1600 PL 1.2 156N5 PL 1.4A PL 1.4B 156N6 PL 1.4A PL 1.4B 156N7 PL 1.4B 156N8...
Page 349: Section Contents
*1 Set Control Panel Defaults..8A 6-31 *2 Stamp Feature ......8A 6-31 *3 (Not Used) *4 (Not Used) *5 (Not Used) *6 Display 8855 Meter (Length)..8A 6-31 *7 (Not Used) *8 Auto Start (Enable/Disable) ..8A 6-31 *9 Display Scanner Meter (Length) ........8A 6-31...
Page 350: Service Mode
Service Mode Description of the Service Mode The service mode is used by the Service Representative to exercise various machine modes and to enter the Test Mode. Enter Service Mode Figure 1. Copy Mode Selected 1. Select the Copy Mode (Figure 1). 2.
Page 351: Test Mode
Test Mode Description of the Test Mode Enter the Test Mode Exit the Test Mode You must enter the Service Mode before entering the Test Mode. The Test Mode is Method A: Enter the Test Mode Method A: Exit the Test Mode used to perform the following tests: 1.
Page 352: Enter Test Mode
Test Mode 1: LED on zoom Paper preheat Description of test mode 1: LED on plain vellum bypass film paper tracing auto zoom set copy auto paper mode This test will automatically be performed for 1 plain vellum minute when the Test Mode is entered. This film paper tracing...
Page 353 Table 1. Test Mode 2 Testing Order Test Mode 2: LED shift Scan Mode Order Indicator Name / Icon Power Description of Test Mode 2: LED shift This test sequentially lights each LED in the Out of Roll Material order listed in Table 1. Print Mode When numeric display LEDs are lit, each Waste Toner Bottle Full...
Page 354 Stamping Position: Tens digit of Copy Number Magnification Ratio: 1% Refer to lighting order of seg- Refer to lighting order of seg- ments above. ments above Tone: line Sample Auto Zoom Magnification Ratio: 10% photo 1 Set Copy Auto Paper photo 2 Refer to lighting order of seg- Pre-Heat...
Page 355 Paper Deck 1 Paper Deck 3 Paper Deck 1 (Orange) Roll Material Size Roll Material Size Roll Material Type Units Digit Tens Digit Plain Paper Vellum Tracing plain vellum plain vellum film film paper tracing paper tracing Film plain vellum film paper tracing...
Page 356 Paper Deck 4 (Green) Roll Material Type Plain Paper Vellum Tracing Film plain vellum film paper tracing Paper Deck 4 (Orange) Roll Material Type Plain Paper Vellum Tracing Film plain vellum film paper tracing 190 Cut Mode Standard standard synchro mode 191 Cut Mode Synchro...
Page 357: Test Mode 3: Panel Key
Test Mode 3: Panel Key Table 1. Panel Key Being Tested Deck Selection Key Panel Key with Results Description of test mode 3: Panel Pressed Manual Feed Key Paper This test is used to confirm that each key on Pressed the control panel functions.
Page 358 Standard Cut Mode Key Synchro Cut Mode Key Reduce Key Paper Paper zoom plain vellum plain vellum film film bypass bypass paper tracing paper tracing mode plain vellum plain vellum reduce 100% enlarge film film paper tracing paper tracing plain vellum plain vellum...
Page 359 [ < ] Key (Threshold) Sample Key Set Copy Key Key Pressed xxxxxxx xxxxxx LED Lit preheat auto zoom set copy auto paper threshold Reset xxxxxxx xxxxxx preheat auto zoom set copy auto paper re-copy Reset sample re-copy Pressed sample [ >...
Page 360 Preheat Key Reset Key Re-copy Key Key Pressed " r " is Displayed on " r c " is Displayed on the Numeric Display the Numeric Display Pressed Pressed LED Lit preheat preheat xxxxxxx xxxxxx auto zoom set copy auto paper auto zoom set copy auto paper...
Page 361 * Key Start Key Menu [ < ] Key " A " is Displayed on xxxxxxx xxxxxx information the Numeric Display Pressed preheat auto zoom set copy auto paper Service Mode * Test Mode preheat 3: Panel Key Reset < auto zoom set copy auto paper...
Page 362 Menu (Enter) Key Leading Edge Key Mirror Image Key information information image line light Service Mode Service Mode photo 1 * Test Mode * Test Mode 3: Panel Key 3: Panel Key photo 2 return dark copy density menu menu shift leading edge trailing edge...
Page 363 Image Fix Key (Line/Photo 1/Photo 2) Stamp Angle Key Stamp Fix Key image stamp Pressed line light stamp photo 1 photo 2 dark input copy density input mirror negative angle position angle position Pressed Pressed Copy Density Key Stamp Position Key Stamp Input Key image stamp...
Page 364 Op Mode Key Ã scanner computer op. mode printer Pressed 5/99 Test Mode 3: Panel Key 7396/7399 Scanners 8A 6-16...
Page 365 This Page Intentionally Left Blank 5/99 7396/7399 Scanners Test Mode 4: Sensor 8A 6-17...
Page 366: Test Mode 4: Sensor
Test Mode 4: Sensor zoom Description of Test Mode 4: Sensor This test is used to confirm that each sensor functions when it is blocked by white, or light- mode colored, paper. reduce 100% enlarge Enter Test Mode 4 1. Enter the Service Mode. 2.
Page 367 Zoom Display with paper under sensor UPPER UNIT INTERLOCK SWITCH LED SCAN HEAD FEED ROLL FEED ROLL FEED ROLL 8.5" 11" 12" 17" 18" 22" 24" 30" 34" 36" 8.5" 9" 11" 12" 17" 18" ANSI ENGINEERING SIZE ANSI ARCHITECTURAL SIZE inch Figure 2.
Page 368: Test Mode 5: Motor
Test Mode 5: Motor Description of Test Mode 4: Motor This test is used for the Exposure Adjustmen 6.3.1 in Section 3 of this manual. Enter Test Mode 4 1. Enter the Service Mode. 2. Enter the Test Mode. 3. Press Stop/Eject (to skip Test Mode 1). 4.
Page 369: Test Mode 6: Original Feed
Test Mode 6: Original Feed Exit Test Mode 6 Press and hold the C key and press the Reset Description of Test Mode 6: Origi- key.. You will automatically exit the Test Mode nal Feed and the Service Mode. This test will feed an original at each of the three speeds: Reduce, Enlarge, or 100%.
Page 370: Test Print Mode
Test Print Mode This Mode is not implemented. Refer to the Printer Service Manual to make a print. 5/99 Test Print Mode 7396/7399 Scanners 8A 6-22...
Page 371 This Page Intentionally Left Blank 5/99 7396/7399 Scanners Backup Data Mode 8A 6-23...
Page 372: Backup Data Mode
Backup Data Mode information Description of Backup Data Mode This mode allows you to change the backup Service Mode * Backup Data data for the items listed in Table 1. Typical No. : Data: factory defaults are shown as [nn] in the Description column.
Page 373 18 7396 End of Image (Copy Mode) 39 - 98 42 7396 Scanner Setting (B) [19] 0 - 63 Table 1. Backup Data Description [79] 42 7399 Scanner Setting Default [19] 0 - 127 Description Range 18 7399 Image (Copy 40 - 100 (AE Prescan Enabled [42]) Single (0) or Dual Color [1]...
Page 374 69 Not Used 95 Reserved (7399) 70 Signal Cut Wait Data (Printer) [0] 0 - 150 96 Adjust the leading margin on im- 4 to 41 age shorter (7399) 71 Signal Cut Wait Data (Scanner) 30 - 100 97 Adjust the leading margin on im- 0 to 105 7396=[92], 7399=[86] age longer (7399)
Page 375: Mode Selection
Threshold and Contrast Level Mode Mode Selection Description Perform the following procedure to enter the Table 2. 7399 Threshold and Contrast Threshold Level Mode: This procedure allows you to customize the Default Values threshold and contrast levels for Photo 1, 1.
Page 376 Threshold Level Adjustment Contrast Level Adjustment information NOTE: The display will still indicate Thresh- Caution old. The Threshold Adjustment should Service mode Perform the following procedure to adjust the not be performed unless there are Threshold Contrast Level. severe Copy Quality problems. No.
Page 377: Automatic Exposure (Ae) Adjustment Mode
Table 2. 7399 AE Initial Values Automatic Exposure (AE) Ad- AE Level Adjustment justment Mode Perform the following procedure to adjust the Initial Value AE Comparison AE Level: Data Line Line/ph Photo Description 1. Using the < and > keys on the Threshold panel, select the AE Data to be adjusted.
Page 378: Red And Blue Threshold Adjustment Mode
Red and Blue Threshold Ad- justment Mode (7399) Figure 2. Image Panel Description Mode Selection This procedure allows you to customize the line light Perform the following procedure to enter the Red and Blue Threshold values for Line, Red and Blue Threshold adjustment mode. line/photo Line/Photo and Photo.
Page 379: Asterisk (*) Modes
For each of the following Asterisk Modes, first This mode is used to create stamps. Refer to This mode displays the 8855 copy count on enter the Service Mode. Press the * key and the 7396 Scanner Operator Manual for details.
Page 380: Jeweler's Screwdriver
Supplemental Tools and Sup- Test Pattern Kits plies AE Test Pattern 1N272 Install Kit 673K38501 Install Kit 673K38510 128 Mb SIMM Kit 673K38530 Tools Jeweler’s Screwdriver......600T2072 Holder Assembly (Support Blocks) (See Figure 1) ........19K4451 Shading Sheet (Standard white strip used for exposure setup)......35N233 Holder Assembly (Support Blocks)
Page 381: Installation
Scanner out of the box and placed it on top of hours after delivery in order to avoid 1.2) (DCP1 and DCP2). the 8855, along with the Installation Kit. Any damage to the CCD Head. discrepancies should be reported on the IQR 1.
Page 382 Connector In the next steps, optional memory is installed. This step is not necessary for 8. 7396 Only (Figure 5): Install the Memory the 7399 Scanner because it is shipped Kit onto the Memory PWB. 100V with the maximum 256 Mb memory. NOTE: Ensure that one SIMM is in the R Bank and the other is in the B Bank.
Page 383 128Mb Memory Installation 9. (Figure 4): Install two 64Mb SIMMs in location DM201 and DM203 and set the memory switches as shown. 256Mb Memory Installation 10. (Figure 5): Install four 64Mb SIMMs in location DM201, DM202, DM203, and DM204 and set the memory switches as shown.
Page 384 Assembly (2 blocks) which will be used to settings. Be sure to review the following above the Image Processor PWB. Record access the 8855 Top Front Cover. Refer to with the customer: the default settings on the Log Sheet for Section 6 of the 8855 Printer Service Manual •...
Page 385 The purpose is to enable mirror imaging when 8855 and remove the three screws the Rear Top Cover the four a 7396 Scanner is installed on the 8855 that secure the Stabilizer Bar to the screws Printer. The kit also provides shields to the 8855.
Page 386 4. (Figure 3): Install the Holder Assemblies 5. (Figure 4): Remove the three remaining 6. (Figure 5): Replace the Interface PWB. with the magnetic strips down. Move the screws, the Top Cover, and the Inner a. Disconnect the five P/J connectors on Scanner onto the Holder Assemblies so Shield.
Page 387 8. (Figure 6): Install the two earth brackets. 9. (Figure 7): Ensure that the earth brackets 10. Pull out the Upper Drawer and the Manual contact the LED. Bypass Shelf in order to provide easier a. Install the mounting bracket using the access to the area where the new earth holes between the J212 and J213 bracket is to be installed.
Page 388 13. (Figure 10): Install the gasket at the top of 14. Mark off Tag 12 on the 8855 Tag Matrix. NOTE: In the following step, the correct the Rear Cover to the dimensions shown. position can be verified by looking through the...
Page 389: General Service Notes
General Service Notes Removing Last Scan in Memory Replacing the DC Controller E- _._._._. on Information Display To remove the last scanned image from PROM If the Foot Switch accidentally gets stuck memory, perform the following. On the under the machine and is held actuated, the Purpose Numeric Keypad Panel (Figure 1): scanner will not function and the Information...
Page 390 4. Remove the EPROM from the DC Con- troller PWB position is labeled as U209. NOTE: Ensure that all electrostatic safe guards a followed for the next step. 5. Install the new EPROM. Ensure that the notch on the EPROM case (DIP) is aligned with the notch on the EPROM connector (DIP connector).
Page 391: Section Contents
7. Wiring Data Section Contents TITLE PAGE TITLE PAGE WIRENETS BSDs +5 VDC Wirenet........8A 7-36 LEVEL 1 BSD -12 VDC Wirenet.......8A 7-37 How to Use BSDs .......8A 7-3 +12 VDC Wirenet......8A 7-37 Level 1 BSD ........8A 7-4 +12 VDC LED Power Wirenet...8A 7-37 +24 VDC Wirenet......8A 7-38 STANDBY POWER Gnd Wirenet........8A 7-39...
Page 392 Notes: 5/99 7396/7399 Scanners 8A 7-2...
Page 393: How To Use Bsds
HOW TO USE BSDs Normally, you will be directed to a specific BSD from your Level 1 Entry Procedure. If you have a problem that is not identified in Level 1, then refer to the following Level 1 determine entry point troubleshooting.
Page 394: Level 1 Bsd
LEVEL 1 BSD (SHEET 1 OF 2) CHAIN 1 POWER DISTRIBUTION COOLING AIR 1.3 MACHINE AC POWER 1.1 MAIN 1.2 DC POWER COOLING SWITCHED POWER ON GENERATION +24 VDC +5 VDC DC POWER TO ALL CHAINS +12 VDC -12 VDC (7396) DC COM +12 VDC...
Page 395 LEVEL 1 BSD (SHEET 2 OF 2) CHAIN 5 DOCUMENT TRANSPORTATION DOCUMENT SIZE POSITIONED HAND FED DOCUMENT DETECTED DOCUMENT DOCUMENT DOCUMENT DOCUMENT AT EXIT DOCUMENT SIZE FEEDING RELEASE DETECTION CHAIN 4 DRIVES 4.1 SCANNER SCANNER DRIVE DRIVE FED DOCUMENT CHAIN 6 IMAGING SCANNED SENSED IMAGE...
Page 396 1.1 MAIN POWER ON (50 AND 60 HZ) (1 OF 2) WARNING DANGEROUS VOLTAGE. MAIN AC TERMINAL BOARD POWER PL 1.2 SWITCH (S1) F100 PL 1.4 15 AMPS J100 J101 F101 FILTERING 15 AMPS DC CONTROLLER PWB PL 1.3 TB101 CONTROL CONTROL +5 VDC...
Page 397 1.1 MAIN POWER ON (50 AND 60 HZ) (2 OF 2) J213 J214 J215 J205 J207 J204 J216 J203 J209/J218 J202 BOARD MATING CONNECTORS J201 J217 J102 F100 J100 J208 TB101 F101 J101 AC TERMINAL PWB (LOWER UNIT, REAR) J212 J211 (7399: LOCATED BEHIND INVERTER POWER...
Page 398 1.2 DC POWER GENERATION (1 OF 3) (7396) LED POWER SUPPLY PL 1.4 CN1A CN2A +12 VDC LED POWER +12 VDC POWER GND-O GND-P DC POWER SUPPLY (DCP1) PL 1.2 +5 VDC +12 VDC DC POWER TO ALL CHAINS +24 VDC REFER TO WIRENETS AT THE END OF MAIN DC SECTION 8A 7 FOR DC POWER...
Page 399 1.2 DC POWER GENERATION (2 OF 3) (7399) DC POWER SUPPLY (DCP1) PL 1.2 +5 VDC +12 VDC DC POWER TO -12 VDC ALL CHAINS MAIN DC POWER REFER TO WIRENETS AT THE END OF DC COM SECTION 8A 7 FOR DC POWER DISTRIBUTION FROM THE DC POWER SUPPLY (DCP1).
Page 400 Notes: 5/99 Chain 1 Standby Power 739/7399 Scanners 8A 7-10...
Page 401 1.2 DC POWER GENERATION (3 OF 3) 7399 INVERTER POWER SUPPLY DCP2 (LOWER UNIT, REAR) DC POWER SUPPLY DCP1 (LOWER UNIT, LEFT SIDE) 7396: LED POWER SUPPLY (LOWER UNIT, REAR) 5/99 7396/7399 Scanners Chain 1 Standby Power 8A 7-11...
Page 402 1.3 MACHINE COOLING (1 OF 3) (7399) INVERTER POWER SUPPLY DC POWER SUPPLY DCP1 COOLING FAN PL 1.2 MOT5 (7399) P/J61 PL 1.2 +12 VDC 12 VDC POWER COOLING AIR SUPPLY CONNECTION BLOCK +24 VDC +24 VDC POWER SUPPLY DC COM COOLING FAN MOT1 PL 1.2...
Page 403 1.3 MACHINE COOLING (2 OF 3) (7399) DC CONTROLLER PWB LAMP PL 1.2 COOLING FAN CONTROL MOT2 LOGIC PL 1.2 P/J31 J203 P203 COOLING AIR LAMP COOLING FAN MOT3 PL 1.2 P/J32 COOLING AIR J201 P201 LAMP COOLING FAN 3, 5 MOT4 PL 1.2 P/J33...
Page 404 Notes: 5/99 Chain 1 Standby Power 739/7399 Scanners 8A 7-14...
Page 405 1.3 MACHINE COOLING (3 OF 3) (7399) INVERTER POWER SUPPLY (7399) LAMP COOLING FAN COOLING FAN (7399) LAMP (7399) LAMP COOLING FAN COOLING FAN COOLING FAN COOLING FAN LOWER UNIT (COVER REMOVED) CN3, CN4 (TERMINAL BLOCKS) DC POWER SUPPLY DCP1 (LOWER UNIT, LEFT END) COOLING FAN (LOWER UNIT, RIGHT END,...
Page 406: 7396/ 7399 Scanners
2.1 MODE CONTROL (1 OF 2) UPPER UNIT CONTROL PWB PL 1.6 CONTROL PANEL CONTROL PANEL +5 VDC 2 PWB 1 PWB LCD PWB CONTROL PL 1.1 PL 1.1 30 WIRES 100 WIRES PL 1.1 LOGIC J711 P711 P702 J702 J701 P701 P213 J213...
Page 407 2.1 MODE CONTROL (2 OF 2) J214 J215 J216 J217 J218 J219 J213 J212 J211 UPPER UNIT CONTROL PWB CONTROL CONTROL PANEL 1 PWB PANEL 2 PWB AND LCD PWB UPPER UNIT (COVER REMOVED) 5/99 7396/7399 Scanners Chain 2 Mode Control 8A 7-17...
Page 408 4.1 SCANNER DRIVE (1 OF 2) DC CONTROLLER PWB MOTOR CONTROL PWB SCANNER DRIVE PL 1.3 PL 1.2 MOTOR MOT1 CONTROL CONTROL PL 1.2 LOGIC LOGIC J208 P208 P201 J201 DATA 0 P/J61 J203 P203 DATA 1 DATA 2 SCANNER DRIVE DATA 3 DATA 4...
Page 409 4.1 SCANNER DRIVE (2 OF 2) J213 J214 J215 J203 J202 J205 J207 J204 J216 J201 J203 J209/J218 J202 BOARD MATING CONNECTORS J201 MOTOR CONTROL PWB J217 LOWER UNIT RIGHT END (COVER REMOVED) J208 J212 J211 DC CONTROLLER PWB UPPER UNIT INTERLOCK SWITCH S1 SCANNER DRIVE MOTOR...
Page 410 POSITIONED 5.1 DOCUMENT RELEASE (1 OF 2) DOCUMENT DC CONTROLLER PWB UPPER UNIT CONTROL PWB PL 1.3 PL 1.6 CONTROL CONTROL LOGIC LOGIC J207 P207 P219 J219 FOOT SWITCH S2 DOCUMENT PL 1.4 RELEASE SOL1 P/J50 P202 J202 +24 VDC PL 1.6 P/J56 J212 P212...
Page 411 5.1 DOCUMENT RELEASE (2 OF 2) J214 J215 J216 J217 J218 J213 J214 J215 J219 J213 J212 J211 UPPER UNIT CONTROL PWB J205 J207 J216 J204 J203 UPPER UNIT J209/J218 J202 (COVER REMOVED) BOARD MATING DOCUMENT DOCUMENT CONNECTORS RELEASE RELEASE J201 SOL1 SOL3...
Page 412 5.2 DOCUMENT SIZE DETECTION (1 OF 2) UPPER UNIT CONTROL PWB DC CONTROLLER PL 1.6 +5 VDC PL 1.3 CONTROL SIZE 1 SENSOR (Q1) LOGIC CONTROL PL 1.7 P216 J216 LOGIC J219 P219 P207 J207 SIZE 2 SENSOR (Q2) +5 VDC PL 1.7 DOCUMENT SIZE...
Page 413 5.2 DOCUMENT SIZE DETECTION (2 OF 2) J213 J214 J215 J214 J215 J216 J217 J218 J205 J207 J219 J216 J204 J213 J212 J211 UPPER UNIT CONTROL PWB J203 J209/J218 J202 BOARD MATING CONNECTORS J201 J217 UPPER UNIT J208 (COVER REMOVED) SIZE SENSORS Q1 THROUGH Q5 REFER TO SECTION 6, GENERAL...
Page 414 5.3 DOCUMENT FEEDING (1 OF 2) UPPER UNIT CONTROL PWB DC CONTROLLER PL 1.6 DOCUMENT AT WAIT +5 VDC PL 1.3 CONTROL POSITION SENSOR (Q13) LOGIC CONTROL PL 1.7 P218 J218 LOGIC J219 P219 P207 J207 DOCUMENT IN POSITION SENSOR (Q12) +5 VDC PL 1.7 DOCUMENT...
Page 415 5.3 DOCUMENT FEEDING (2 OF 2) J213 J214 J215 REFER TO SECTION 6, GENERAL PROCEDURES, (TEST MODE 4) TO TEST THE SENSORS. J205 J207 J216 J204 J214 J215 J216 J217 J218 J203 J219 J213 J212 J209/J218 J211 J202 BOARD MATING CONNECTORS UPPER UNIT CONTROL PWB J201...
Page 416 6.1 EXPOSURE CONTROL (1 OF 3) (7396) EXPOSURE CONTROL PWB PL 1.5 ADJ 6.3.1 SENSED DOCUMENT DOCUMENT DOCUMENT DC CONTROLER PWB PL 1.3 SENSOR LEDS LEDS +5 VDC CONTROL LOGIC EXPOSURE P801 J801 J204 P204 DENSITY +24 VDC +24 VDC DC COM DC COM 5/99...
Page 417 6.1 EXPOSURE CONTROL (2 OF 3) (7399) SENSED DOCUMENT DOCUMENT DOCUMENT EXPOSURE CONTROL EXPOSURE LAMP PL 1.5 AUTO EXPOSURE SENSOR DC CONTROLLER PWB PL 1.3 ADJ 6.3.1 +24 VDC P/J37 J801 P801 P204 J204 CONTROL LAMP LOGIC P204 START EXPOSURE J204 DENSITY DC COM...
Page 418 Notes: 5/99 Chain 6 Imaging 7396/7399 Scanners 8A 7-28...
Page 419 6.1 EXPOSURE CONTROL (2 OF 2) J213 J214 J215 7399 INVERTER POWER SUPPLY DCP2 J205 J207 (LOWER UNIT, REAR) J216 J204 J801 EXPOSURE CONTROL PWB TS1 LAMP THERMOSTAT (7399) J203 J209/J218 J202 BOARD MATING CONNECTORS J201 J217 J208 LOWER UNIT J212 J211 (COVER REMOVED)
Page 420 6.2 SCANNING (1 OF 3) (7396) SCANNER DRIVE PRESSURE ROLL SCANNED DOCUMENT SENSED DOCUMENT CCD HEAD PL 1.4 FILTER/RELAY PWB IMAGE PROCESS PL 1.3 +12 VDC PL 1.3 P903 POWER P903 J903 J903 J001 P001 P863 J863 J002 P002 +24 VDC P904 J904 J003...
Page 421 6.2 SCANNING (2 OF 3) (7399) SCANNER DRIVE PRESSURE ROLL SENSED DOCUMENT SCANNED DOCUMENT SCANNED SHADING PWB IMAGE PL 1.3 CCD HEAD J861 P861 PL 1.4 4, 5, 6 P811 1, 2, 3 J863 P863 EXPOSURE FILTER +5 VDC LAMP PL 1.3 P818 DC COM...
Page 422 Notes: 5/99 Chain 6 Imaging 7396/7399 Scanners 8A 7-32...
Page 423 6.2 SCANNING (3 OF 3) J875 (BOTTOM) J016 J014 J012 J010 J008 J006 J004 J002 J863 J007 J005 J003 J015 J013 J011 J009 J001 SCAN HEAD ROTATED 90 DEGREES J862 (TOP) J876 (BOTTOM) CN1 AND CN2 J71 THROUGH J78 J864 (TOP) (HIDDEN INSIDE J874 (BOTTOM) SCAN HEAD)
Page 424 6.3 IMAGE DISTRIBUTION (1 OF 2) DC CONTROLLER PRINTER - B 37 WIRES SCANNED IMAGE J215 P215 PL 1.3 PROCESS IMAGE 32 WIRES PL 1.3 J873 P873 P211 J211 printer PRINTER - R 37 WIRES J214A P214A 20 WIRES printer 37 WIRES J874 P874...
Page 425 6.3 IMAGE DISTRIBUTION (2 OF 2) J875 J203 (BOTTOM) J863 DM201 S202 DM202 J862 (TOP) J876 (BOTTOM) J204 DM203 DM204 J864 (TOP) J874 (BOTTOM) J201 J873 (BOTTOM) J202 J861 (TOP) J871 (BOTTOM) S201 DS201 DS202 IMAGE PROCESS PWB MEMORY PWB LOWER UNIT (COVER REMOVED) 5/99...
Page 426: Vdc Wirenet
+5 VDC WIRENET DC POWER SUPPLY DCP1 +5 VDC DC CONTROLLER PWB +5 VDC P201 J201 POWER MEMORY PWB SUPPLY P201 J201 MOTOR CONTROL PWB UPPER UNIT CONTROL P202 J202 J60 P60 P211 J211 FLOPPY DISK (OPT.) IMAGE PROCESS PWB P871 J871 SHADING PWB P861...
Page 427: Vdc Wirenet
DC POWER SUPPLY -12 VDC WIRENET DCP1 -12 VDC FILTER/RELAY PWB CCD HEAD -12 VDC P901 J901 J902 P902 P801 J801 POWER FILTER SUPPLY +12 VDC WIRENET DC POWER SUPPLY DCP1 +12 VDC INVERTER POWER +12 VDC P/J61 SUPPLY COOLING POWER SUPPLY MOT5...
Page 428 +24 VDC WIRENET DC POWER SUPPLY DCP1 FILTER/RELAY PWB (7396) +24 VDC P904 J904 RELAY RY901 UPPER UNIT INTERLOCK SWITCH S1 +24 VDC P37 J37 P38 J38 POWER MOTOR CONTROL PWB SUPPLY UPPER UNIT CONTROL P202 J202 P60 J60 P211 J211 COOLING FAN P/J31 MOT1...
Page 429: Gnd Wirenet
GND WIRENET CCD HEAD FLOPPY DISK (OPT.) DC POWER SUPPLY DCP1 CN1 P1 FILTER/RELAY PWB J902 P902 P801 J801 P901 J901 SHADING PWB J861 P861 COOLING FAN IMAGE PROCESS PWB MOT1 J871 P871 COOLING FAN MOT2 MEMORY PWB COOLING FAN J201 P201 MOT3 AC TERMINAL...
Page 430 Notes: 5/99 Wirenets 7396/7399 Scanners 8A 7-40...
Page 431: Section Contents
4. Repair/Adjustment Section Contents Repairs REP 1.1.1 Upper Panel Assembly ..8B 4-2 REP 1.2.1 Drive Motor ......8B 4-2 REP 1.3.1 Timing Belt ......8B 4-3 REP 1.4.1 Left Cover ......8B 4-3 REP 1.5.1 Feedout Roller ...... 8B 4-4 REP 1.6.1 Feed-in Roller .......
Page 432: Rep 1.1.1 Upper Panel Assembly
Upper Panel Assembly (REP 1.1.1). 1. Move the stacker away from 8855. Note: There is a metal washer located under 2. Remove the Right Cover (PL 1.1). each of the black plastic washers in the 3. (Figure 1): Remove a screw and a Pivot.
Page 433: Rep 1.3.1 Timing Belt
Disconnect the Power Cord. Disconnect the Power Cord. Removal Removal 1. Move the stacker away from 8855. 1. Remove the Right Cover (PL 1.1). Left Cover 2. Remove the three screws that secure the 2. (Figure 1): Loosen the two screws securing Left Cover (PL 1.1).
Page 434: Rep 1.5.1 Feedout Roller
Left Cover. Figure 1. E-ring and Pulley Removal Removal 1. Move the stacker away from 8855. 1. Move the stacker away from 8855. 5. Remove another E-ring from the right end of 2. Remove the Timing Belt (REP 1.3.1).
Page 435: 8855 Stacker
Introduction ........................8B 5-3 Subsystem Information ....................8B 5-4 Symbology ........................8B 5-5 8855 STACKER PL 1.1 STACKER HOUSING AND COVERS ..............8B 5-7 PL 1.2 ELECTRICAL COMPONENTS ................8B 5-8 PL 1.3 ELECTRICAL AND DRIVE COMPONENTS ............8B 5-9 PL 1.4 DRIVE COMPONENTS ..................
Page 436 Parts Lists 2/99 8B 5-2 8855 STACKER...
Page 437 This index lists all the spared parts in the machine in numerical order. Each number is followed Without by a reference to the parts list on which the part may be found. Symbology Symbology used in the Parts List section is identified in the Symbology section. Parts Lists 2/99 Introduction 8855 STACKER 8B 5-3...
Page 438 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 2/99 Subsystem Information 8B 5-4 8855 STACKER...
Page 439 (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 2/99 Symbology 8855 STACKER 8B 5-5...
Page 440 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 2/99 Symbology 8B 5-6 8855 STACKER...
Page 441 INDICATION PWB 4N178 BUMPER 91N464 LEFT ADJUST PLATE 32N190 LOWER GUIDE PLATE 91N463 RIGHT ADJUST PLATE 2N1430 RIGHT COVER – STACKER UNIT ASSEMBLY (NOT SPARED) 117K26830 POWER CORD (GFI) 117P80447 POWER CORD Parts Lists 2/99 PL 1.1 8855 STACKER 8B 5-7...
Page 442 PWB COLLAR (P/O PL 1.2 item 1) 105N1197 TRANSMISSION PWB 105N1195 RECEIVING PWB – PWB COVER (P/O PL 1.2 item 1) 2N1432 TRANSPARENT COVER – ELECTRICAL FRONT COVER (P/O PL 1.2 item 1) Parts Lists 2/99 PL 1.2 8B 5-8 8855 STACKER...
Page 443 PARALLEL PIN 13N327 BEARING – PANEL (P/O PL 1.3 item 1) – ROLLER SHAFT (P/O PL 1.3 item 22N798 FEED-IN ROLLER (8/KIT) – RIGHT SIDE FRAME (P/O PL 1.3 item 1) Parts Lists 2/99 PL 1.3 8855 STACKER 8B 5-9...
Page 444 20N354 SPUR PULLEY 23N496 TIMING BELT 13N321 BEARING – SLIDER (P/O PL 1.4 item 1) – RIGHT SIDE FRAME (P/O PL 1.4 item 1) – PLATE (P/O PL 1.4 item 1) Parts Lists 2/99 PL 1.4 8B 5-10 8855 STACKER...
Page 445 1) 9N899 SPRING PLATE "B" 9N900 SPRING PLATE "A" – ROLLER SHAFT "A" (P/O PL 1.5 item 1) – ROLLER SHAFT "B" (P/O PL 1.5 item 1) 22N806 PINCH ROLLER (10/KIT) Parts Lists 2/99 PL 1.5 8855 STACKER 8B 5-11...
Page 446 PL 1.6 STACKER BASE AND CROSS BEAM Item Part Description 3N635 STOP BRACKET 4N179 CUSHION 26N457 THUMB SCREW – CROSS BEAM ASSEMBLY (NOT SPARED) – STACKER BASE FRAME (NOT SPARED) 26N458 ADJUSTABLE FOOT Parts Lists 2/99 PL 1.6 8B 5-12 8855 STACKER...
Page 447 SPRING (P/O PL 1.7 item 1) 3N679 HOOK – RELEASE SHAFT (P/O PL 1.7 item 3N634 HANDLE – BEARING (P/O PL 1.7 item 1) – CROSS BEAM FRAME (P/O PL 1.7 item 1) Parts Lists 2/99 PL 1.7 8855 STACKER 8B 5-13...
Page 448 20N354 PL 1.4 22N795 PL 1.3 22N796 PL 1.5 22N797 PL 1.3 22N798 PL 1.3 22N806 PL 1.5 23N496 PL 1.4 26N456 PL 1.4 26N457 PL 1.6 26N458 PL 1.6 Parts Lists 2/99 Part Number Index 8B 5-14 8855 STACKER...
Page 449 6. General Procedures Section Contents TITLE PAGE DIAGNOSTICS Component Test........8B 6-2 INSTALLATION Installation ..........8B 6-3 Removal ..........8B 6-6 Product Specifications ......8B 6-8 5/99 Stacker Section Contents 8B 6-1...
Page 450: Component Test
Component Test Note: Refer to REP 1.2.1 in Section 8B 4 and remove the Lower Guide Plate. Actuate the Interlock Switch in order to test the input and output components. The Paper Feed Motor and Fan require Interlocked +24 VDC. Interlocked +24 VDC develops the +5 VDC for the Reception and Transmission PWBs as well as the Paper Jam Sensor.
Page 451: Installation Installation
Procedure: 5. (Figure 3): Connect J 911 1. Switch off the 8855 power and disconnect Transmission PWB. the power cord. 6. (Figure 2): Install the Receiving PWB on the 2. (Figure 1): Remove the Catch Tray, Catch left bracket.
Page 452 9. (Figure 4): Install the Stop Brackets on the right and left sides of the 8855 rear side covers using the existing top two holes that were used to attach the Support Arms for the 30 sheet catch tray. Figure 5. Docking the Stacker...
Page 453 GFI Power Cord. 17. Ensure that Stacker operating 14. Plug in the 8855 Power Cord and the correctly. Stacker Power Cord. 15. Switch on the 8855 and the Stacker. green light on the Left Cover of the Stacker indicates that the power is on.
Page 454: Removal
Description Tape Bubble Pack Repack Box Procedure 1. Switch off the 8855 and the Stacker. 2. Unplug the power cords. 3. Place the Stacker Power Cord and GFI Power Cord in the repack box. Stop Bracket 4. (Figure 1): Remove the four Print Holders.
Page 455 Tray Brackets and the Stopper on the rear of the 8855. 17. Connect the power cord and switch on the 8855 power. 18. Ensure that the 8855 is working correctly. 19. Complete the call with FWSS. Install the Catch Tray...
Page 456: Product Specifications
Electrical Specifications Product Specifications Physical Characteristics Voltage Requirements Source voltage: 100 - 240 VAC Dimensions Current rating: 3 Amps Width: 34 inches (864 mm) Frequency: 50/ 60Hz 57.5 inches (1461 mm) (with paper supports extended) Power Consumption: 60 Watts Depth: 41 inches (1040 mm) Height: 28.5 inches (724 mm) Environmental Conditions...
Page 457 7. Wiring Data Section Contents TITLE PAGE Block Schematic Diagrams (BSDs)..8B 7-2 5/99 Stacker Section Contents 8B 7-1...
Page 458 Block Schematic Diagrams (BSDs) 12.1 AC/ DC Power PS 1 DC POWER MAIN INTERLOCK SUPPLY POWER SWITCH PL 1.2 SWITCH PL 1.3 RECEPTACLE PL 1.3 PL 1.3 +24 VDC CN 1 INTERLOCKED POWER 12.2, 12.3 CN 2 +24 VDC SUPPLY 12.2, 12.3 DC COM INDICATION...
Page 459 I N F R A - R E D S I G N A L S P R O V I D E T H E C O M M U N I C A T I O N B E T W E E N T H E Input Power Block STACKER AND THE 8855. Voltage Test Point...
Page 460 12.3 Copy Feed MOTOR DRIVER CONTROLLER MOT 1 PL 1.2 DRIVE MOTOR PL 1.2 PL 1.4 CONTROL J 253 CONTROL LOGIC LOGIC J 252 J 204 MOTOR START CLOCK LT BLU J 251 INTERLOCKED DC COM +24 VDC CONTROLLER CONTROLLER PL 1.2 PL 1.2 SENSOR...