Oki B6500 Service Manual
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Oki B6500 Service Manual

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Table of Contents

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Download this manual See also: Troubleshooting Manual, Reference Manual
Laser Printer
OKI B6500
Service Manual
060810A

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Summary of Contents for Oki B6500

  • Page 1 Laser Printer OKI B6500 Service Manual 060810A...
  • Page 2 This document is protected by copyright. It is not forgiven to photocopy or duplicate any part of this document in any form without previous permission in writing from Oki Data, Americas, Inc.

  • Page 3: About This Manual

    1. About This Manual This manual is a standard service manual containing information required for maintenance of this laser printer (standard specifications). 2. Cautions, Warnings and Notes Maintenance operations requiring special cautions or additional information for procedures in this manual are presented as "Warning", "Caution", or "Note", according to their nature. If instructions are not observed, death or serious injury may be caused.
  • Page 4 4. Safety To prevent possible accidents during maintenance activities, you must pay attention to the "Warning" and "Caution" information in this manual. Performing any dangerous operations, or procedures not included in this manual, should be avoided. Occasionally, it may be required to perform some procedures not covered by this manual. These procedures should be performed carefully, always giving attention to safety.
  • Page 5 4.2 Drive units When servicing gears or other drive units, be sure to turn them OFF and disconnect the power plug from the receptacle. Whenever possible, drive them manually. Never touch the gears or other moving parts while the printer is running. 4.3 High-temperature units When servicing high-temperature units (removal, replacement, adjustment, etc.), be sure to turn them OFF to prevent burns, injuries and an electrical hazard.
  • Page 6 4.4 Laser beams • Direct exposure to a laser beam can damage the eyes and cause blindness. • Never open a cover that has a laser warning label attached. • Before disassembling and reassembling this laser printer, be sure to turn the printer power OFF.
  • Page 7 4.5 Warning/caution labels Warning labels and caution labels are attached to this laser printer to prevent accidents. These labels should be clear and easy to read. Check the labels for any damage such as peeling or stains when servicing the printer. 4.5.1 Caution label for high-temperature units Hi Temp Label 4.5.2 Caution label for laser beams...
  • Page 8 5. Installation 5.1 Power source Do not plug too many leads into a single socket. Use a dedicated electric outlet and confirm that the power is within specifications. Connect the single power cord to an electric outlet capable of supplying more power than the maximum power consumption of this laser printer.
  • Page 9 5.4 Unpacking 5.4.1 Unpacking laser printer The printer must be carried horizontally with two or more persons. Extreme care must be taken to avoid personal injuries. Unpack the carton and confirm that the part numbers of the laser printer and all components are correct.
  • Page 10 5.4.3 Unpacking Option Face Up Tray Unpack the carton and confirm that the part numbers of the Face Up Tray and all components are correct. Ensure that all components are undamaged. JG0008AA 5.4.4 Unpacking Option 550 Paper Feeder Unpack the carton and confirm that the part numbers of the Option 550 Paper Feeder and all components are correct.
  • Page 11 5.5 Installation Procedures 5.5.1 Installing laser printer For details, refer to the Instruction Manual supplied with the main unit. When holding up the later printer, be sure to grasp the handles with both hands. Grasping a part other than the handles result in fall or damage of the laser printer. When holding up the later printer, bend your knees thoroughly to prevent lower back strain.
  • Page 12 5.5.2 Installing Option Duplex For details, refer to the Instruction Manual supplied with the main unit or Chapter 3 RRP 21.1 Option Duplex. Before the installation, turn off the power and plug off the power cord. 1) Unpack the Option Duplex, remove cushioning materials, and confirm that all attachments are available.
  • Page 13 5.5.4 Installing Option 550 Paper Feeder For details, refer to the Instruction Manual supplied with the main unit or Chapter 3 RRP 20.1 Option 550 Paper Feeder. Before the installation, turn off the power, plug off the power cord, and remove the paper tray from the laser printer.
  • Page 14 6. Dismantlement 6.1 Dismantlement procedures 6.1.1 Dismantling laser printer and option units For details, refer to the Instruction Manual or Chapter 3 Removal and Replacement Procedures. The dismantlement process is performed by following installation procedures in reverse sequence. When holding up the later printer, be sure to grasp the handles with both hands. Grasping a part other than the handles results in fall or damage of the laser printer.
  • Page 15 Chapter 1 Troubleshooting .....................1 - 1 Chapter 2 Diagnostics ....................1 - 1 Chapter 3 Removal and Replacement Procedures ............3 - 1 Chapter 4 Print Engine Plug/Jack Connector Locations..........1 - 1 Chapter 5 Parts List......................1 - 1 Chapter 6 Principles of Operation ..................1 - 1 Chapter 7 Wiring......................1 - 1 Chapter 8 Printer Specifications ..................1 - 1 Chapter 9 ESS Options ....................1 - 1...
  • Page 16 Blank Page...

  • Page 17: Table Of Contents

    Chapter 1 Troubleshooting Chapter 1 Troubleshooting CONTENTS Chapter 1 Troubleshooting .................... 1 - 1 1. Progressing with the Troubleshooting ................ 1 - 1 1.1 Troubleshooting Flow Chart......................1 - 1 1.2 Preparatory Requirements....................... 1 - 2 1.3 Cautions for Service Operations ...................... 1 - 3 1.4 Cautions for FIP Use........................
  • Page 18 Chapter 1 Troubleshooting Chapter 1 Troubleshooting CONTENTS FIP1.37 MOTOR ASSY EXIT ......................1 - 58 FIP1.38 CLUTCH REGI ........................1 - 59 FIP1.39 CLUTCH ASSY PH ....................... 1 - 60 FIP1.40 GUIDE TRAY LEFT ....................... 1 - 61 FIP1.41 HVPS/MCU ........................... 1 - 62 FIP1.42 Electrical Noise ........................
  • Page 19 Chapter 1 Troubleshooting Chapter 1 Troubleshooting CONTENTS FIP4.3 Low Paper in Tray/Tray 3, 4 ....................1 - 100 FIP4.4 No Recognition of Option 550 Paper Feeder ................ 1 - 101 FIP4.5 Inappropriate Option 550 Paper Feeder ................1 - 102 4.12 Level 2 FIP..........................

  • Page 20: Chapter 1 Troubleshooting

    Chapter 1 Troubleshooting Chapter 1 Troubleshooting CONTENTS Blank Page...

  • Page 21: Chapter 2 Diagnostics

    Chapter 1 Troubleshooting The FIP makes the assumption that the printer controller (PWBA ESS) is functioning normally. If the problem cannot be corrected by using the FIP, replace the printer controller with a new one and check for proper operation. Any OEM with unique specifications, or the direct control of any operation by the printer controller, may cause the operation to be different from the description in this manual.

  • Page 22: Preparatory Requirements

    Chapter 1 Troubleshooting 1.2 Preparatory Requirements Be sure to check the following items before beginning the troubleshooting procedures: Voltage of the power supply is within specifications (measure the voltage at the electric outlet). Power cord is free from breakage, short-circuit, disconnected wire, or incorrect connection. The laser printer is properly grounded.

  • Page 23: Cautions For Service Operations

    Chapter 1 Troubleshooting 1.3 Cautions for Service Operations When servicing the printer, be sure to remove the power cord from the power outlet except when absolutely necessary. Unless specifically indicated, whenever the printer power is ON, never touch any of the electrical components.

  • Page 24: Cautions For Fip Use

    Chapter 1 Troubleshooting 1.4 Cautions for FIP Use The FIP makes the assumption that the printer controller (PWBA ESS) is functioning normally. If the problem cannot be corrected by using the FIP, replace the printer controller with a new one and check for proper operation.
  • Page 25 Chapter 1 Troubleshooting 14) "Replacement" in the FIP indicates replacement of parts which are considered to be the source of trouble. These parts are sometimes components of assemblies containing them, or of a higher- level assembly. In such an instant, the higher-level assembly must be replaced. 15) In the FIP, the paper tray at the lower part of the printer is referred to as "Tray 1", and the second tray as "tray 2", and the first tray of Option 550 Paper Feeder as “Tray 3”, and the second tray as “Tray 4”.

  • Page 26: Level 1 Fip

    Chapter 1 Troubleshooting 2. Level 1 FIP 2.1 Level 1 FIP The level 1 FIP is the first step for problem resolution. The level 1 FIP isolates the presence of various troubles including error codes. The level 2 FIP provides a guide for proceeding with the troubleshooting.

  • Page 27: Error/Status Code List

    Chapter 1 Troubleshooting 2.3 Error/Status Code List For information about the following FIP items described in “FIP to be referenced” column in the following table, refer to the following: FIP1.1 through 45: Printer FIP2.1 through 11: Option Duplex FIP3.1 through 15: Option OCT FIP4.1 through 12: Option 550 Paper Feeder FIP to be Status Code...
  • Page 28 Chapter 1 Troubleshooting FIP to be Status Code Error Contents Error Description referenced - Paper size detected by the Paper Size Switch or set in the NVRAM does not STATUS 3-6 Paper Size Mismatch FIP1.12 match the paper length obtained from ON time of Regi Sensor at feeding.
  • Page 29 Chapter 1 Troubleshooting Contents of FIP to be Error Description referred Paper Jam/Exit -When the paper was not fed to Exit Sensor within the specified Exit Jam 1 FIP1.8 time. - When Exit Sensor turned ON in warming up. Paper Jam/Exit - When paper was not Exit Jam 2 fed to Exit Sensor within the specified FIP1.8...

  • Page 30: Level 2 Fip

    Chapter 1 Troubleshooting 3. Level 2 FIP 3.1 Level 2 FIP The Level 2 FIP is the diagnostic procedure to sort various troubles in addition to the error codes. When troubleshooting, executing the steps given in the FIP or checkout procedure allows you to quickly find the cause of a problem.

  • Page 31: Error Code Fip

    Chapter 1 Troubleshooting 4. Error Code FIP 4.1 Level 1 FIP FIP1.1 NVM Error Step Check Possible causes: HVPS/MCU (PL12.1.19) Does Error occur when the power is turned ON? Go to step 4. Go to step 2. Does Error still occur when the power is turned OFF Go to step 4.

  • Page 32: Fip1.2 Ros Error

    Chapter 1 Troubleshooting FIP1.2 ROS Error Step Check Possible causes: ROS ASSY (PL8.1.1) HVPS/MCU (PL12.1.19) EP CARTRIDGE HARNESS ASSY ROS (PL8.1.2) LVPS (PL12.1.5) Set NV03 and Checking NVRAM for data setup value. NV04 to factory Are the values of NV03 (resolution) and the value of setup, and then NV04 (Laser Diode output) set at the initial setup value Go to FIP1.26...

  • Page 33: Fip1.3 Fuser Error

    Chapter 1 Troubleshooting FIP1.3 Fuser Error Step Check Possible causes: FUSER ASSY (PL8.1.20) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) HARNESS ASSY FUSER (PL8.1.17) HARNESS ASSY LVPS (PL12.1.1) Checking the thermistor for operation. Does Error occur soon after the power is turned ON? Replace FUSER Go to FIP1.27 ASSY.

  • Page 34: Fip1.4 Fan Error

    Chapter 1 Troubleshooting FIP1.4 Fan Error Step Check Possible causes: FAN MAIN (PL1.1.14) FAN SUB (PL8.1.5) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking FAN MAIN for rotation (1). Go to step 2. Go to step 5. Does FAN MAIN rotate, when the power is turned ON? Checking FAN SUB for rotation (1).

  • Page 35: Fip1.5 Main Motor Error

    Chapter 1 Troubleshooting FIP1.5 Main Motor Error Step Check Possible causes: MAIN MOTOR (PL11.1.2) GEAR ASSY HOUSING (PL11.1.3) GEAR ASSY PLATE (PL11.1.10) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking MAIN MOTOR installation With tool Go to Reinstall obstruc- Are MAIN MOTOR, GEAR ASSY HOUSING and GEAR step 2.

  • Page 36: Fip1.6 Cover Error

    Chapter 1 Troubleshooting FIP1.6 Cover Error Step Check Possible causes: INTERLOCK S/W 24V (PL8.1.11) INTERLOCK S/W 5V (PL8.1.12) INTERLOCK S/W REAR (PL12.1.7) SWITCH I/L ASSY (PL1.1.11) COVER OPEN (PL1.1.2) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) With tool Go to step Checking COVER OPEN and COVER REAR 2.

  • Page 37: Fip1.7 Fip Paper Jam/Regi To Fuser

    Chapter 1 Troubleshooting FIP1.7 FIP Paper Jam/Regi to Fuser Step Check Possible causes: FUSER ASSY (PL8.1.20) HVPS/MCU (PL12.1.19) CLUTCH REGI (PL5.1.23) BTR ASSY (PL8.1.21) EP CARTRIDGE GEAR ASSY HOUSING (PL11.1.3) HARNESS ASSY FUSER (PL8.1.17) LVPS (PL12.1.5) 150 FEEDER ASSY (PL5.1.1) GUIDE ASSY CRU R (PL8.1.25) Replace the Checking the paper condition Is the paper in the tray...
  • Page 38 Chapter 1 Troubleshooting Step Check Checking HARNESS ASSY FUSER for continuity Warning; Start the operation after the FUSER ASSY Replace HAR- have cooled down. Go to step 11. NESS ASSY Disconnect P/J46 from LVPS. FUSER. Remove FUSER ASSY. (RRP8.8) Is there continuity between P/J46 and P/J4647? Checking the power to Exit Sensor Is the voltage across P/J46-3(+) and P/J46-4(-), 3.3 Go to step 13.
  • Page 39 Chapter 1 Troubleshooting Step Check Checking GLUTCH REGI for function Does CLUTCH REGI function appropriately? Go to FIP1.38 Go to step 21. Check using Chapter 2 Diagnostic [Regi. Roll Clutch CLUTCH REGI. Test]. Checking GEAR ASSY HOUSING operation (1) Remove EP CARTRIDGE. Replace HVPS/ Install COVER ASSY and close it.

  • Page 40: Fip1.8 Paper Jam/Exit

    Chapter 1 Troubleshooting FIP1.8 Paper Jam/Exit Step Check Possible causes: FUSER ASSY (PL8.1.20) HVPS/MCU (PL12.1.19) HARNESS ASSY FUSER (PL8.1.17) MOTOR ASSY EXIT (PL10.1.15) LVPS (PL12.1.5) ROLL PINCH EXIT (PL10.1.23) 500 EXIT ASSY (PL10.1.2) 150 PAPER CASSETTE (PL2.1.50) 550 PAPER CASSETTE (PL4.1.50) Replace the Checking the paper condition.
  • Page 41 Chapter 1 Troubleshooting Step Check Checking Exit Sensor for operation (2). Remove EP CARTRIDGE. Is the voltage across P/J46-5(+) and P/J46-4(-) on Go to step 14. Go to step 12. LVPS, 0VDC when Actuator Exit is pushed, and 3.3VDC when released? Checking the power to Exit Sensor.

  • Page 42: Fip1.9 Paper Jam/Tray To Regi

    Chapter 1 Troubleshooting FIP1.9 Paper Jam/Tray to Regi Step Check Possible causes: 150 FEEDER ASSY (PL5.1.1) 150 PAPER CASSETTE (PL2.1.50) SENSOR REGI (PL5.1.30) ACTUATOR B (PL5.1.17) CHUTE ASSY FDR1 (PL5.1.3) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) CHUTE ASSY FDR2 (PL7.1.21, PL20.2.2) CLUTCH ASSY PH (PL5.1.21, PL7.1.20, PL20.2.21) ROLL ASSY RETARD (PL2.1.2, PL4.1.2, PL20.3.2) CLUTCH PR-REGI (PL20.2.22) 550 FEEDER OPION (PL20.2.1)
  • Page 43 Chapter 1 Troubleshooting Step Check Checking CHUTE ASSY FDR1/2 (PL5.1.3, PL7.1.21) for operation Replace CHUTE Does each gear and roller of CHUTE ASSY FDR1/2 Go to step 11. ASSY FDR1/2. rotate smoothly? Turn each gear and roller with a finger to check. With tool Go to Checking a paper feeding tray Check if the paper...

  • Page 44: Fip1.10 Paper Jam/Misfeed

    Chapter 1 Troubleshooting FIP1.10 Paper Jam/Misfeed Step Check Possible causes: 150 FEEDER ASSY (PL5.1.1) 150 PAPER CASSETTE (PL2.1.50) SENSOR REGI (PL5.1.30) ACTUATOR B (PL5.1.17) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) CLUTCH REGI (PL5.1.23) CHUTE ASSY FDR1 (PL5.1.3) GEAR ASSY HOUSING (PL11.1.3) SENSOR NO PAPER (PL5.1.38, PL7.1.38, PL20.2.33) CHUTE ASSY FDR2 (PL7.1.21, PL20.2.2) PLATE ASSY BTM (PL2.1.10, PL4.1.10, PL20.3.10) ROLL ASSY RETARD (PL2.1.2, PL4.1.2, PL20.3.2)
  • Page 45 Chapter 1 Troubleshooting Step Check Checking paper position Remove EP CARTRIDGE. Go to FIP1.28 Go to step 8. Does the front end of paper touch ACTUATOR B of SENSOR REGI. SENSOR REGI? Checking ROLL ASSY RETARD Replace ROLL Is ROLL ASSY RETARD clean and installed correctly? ASSY RETARD.

  • Page 46: Fip1.11 Ep Cartridge

    Chapter 1 Troubleshooting FIP1.11 EP Cartridge Step Check Possible causes: HVPS/MCU (PL12.1.19) EP CARTRIDGE GUIDE ASSY CRU R (PL8.1.25) Checking EP CARTRIDGE (1) Replace EP CAR- Is the EP CARTRIDGE appropriate model? Go to step 2. TRIDGE. Remove the EP CARTRIDGE to check the model. Checking EP CARTRIDGE (2) Install the EP CARTRIDGE again.

  • Page 47: Fip1.12 Paper Size Error

    Chapter 1 Troubleshooting FIP1.12 Paper Size Error Step Check Possible causes: 150 FEEDER ASSY (PL5.1.1) 150 PAPER CASSETTE (PL2.1.50) SENSOR REGI (PL5.1.30) ACTUATOR B (PL5.1.17) HVPS/MCU (PL12.1.19) GUIDE TRAY LEFT (PL7.1.7) 550 FEEDER ASSY (PL7.1.10) 550 PAPER CASSETTE (PL4.1.50) Checking the paper size setup Replace the paper, Does the paper size in use match the size setup by Go to step 2.

  • Page 48: Fip1.13 No Tray/Tray 1, 2

    Chapter 1 Troubleshooting FIP1.13 No Tray/Tray 1, 2 Step Check Possible causes: GUIDE TRAY LEFT (PL7.1.7) 150 PAPER CASSETTE (PL2.1.50) HVPS/MCU (PL12.1.19) 550 PAPER CASSETTE (PL4.1.50) Go to FIP4.1 "No Does Error occur with Tray 3 or Tray 4? Go to step 2. Tray/Tray 3.4".

  • Page 49: Fip1.14 No Paper/Tray 1, 2

    Chapter 1 Troubleshooting FIP1.14 No Paper/Tray 1, 2 Step Check Possible causes: SENSOR NO PAPER (PL5.1.38, PL7.1.38) ACTUATOR NO PAPER (PL5.1.6, PL7.1.14) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) PLATE ASSY BTM (PL2.1.10, PL4.1.10) RACK BTM LOCK 550 (PL4.1.21) HOUSING BASE 550(PL4.1.44) Go to FIP4.2 "No Does Error Code indicate Tray 3 or Tray 4? Go to step 2.

  • Page 50: Fip1.15 Low Paper In Tray/Tray 2

    Chapter 1 Troubleshooting FIP1.15 Low Paper in Tray/Tray 2 Step Check Possible causes: SENSOR LOW PAPER (PL7.1.4) ACTUATOR LOW PAPER (PL7.1.5) PLATE ASSY BTM (PL4.1.10) HVPS/MCU (PL12.1.19) 550 PAPER CASSETTE (PL4.1.50) 550 FEEDER ASSY (PL7.1.10) Checking the sensor for operation Does Error still occur, after Paper Cassette filled with a Go to step 2.

  • Page 51: Fip1.16 Drum Life

    Chapter 1 Troubleshooting FIP1.16 Drum Life Step Check Possible causes: EP CARTRIDGE GUIDE ASSY CRU R (PL8.1.25) HVPS/MCU (PL12.1.19) Checking EP CARTRIDGE Does Error still occur, after installing a new EP CAR- Go to step 2. End of work TRIDGE? Checking GUIDE ASSY CRU R for continuity Replace HVPS/ Replace GUIDE...

  • Page 52: Fip1.17 Fuser Life

    Chapter 1 Troubleshooting FIP1.17 Fuser Life Step Check Possible causes: FUSER ASSY (PL8.1.20) HARNESS ASSY FUSER (PL8.1.17) HVPS/MCU (PL12.1.19) Checking FUSER ASSY Does Error still occur, after installing a new FUSER ASSY and sending RESET FUSER LIFE WARNING Replace HVPS/ command? MCU.

  • Page 53: Fip1.18 No Power

    Chapter 1 Troubleshooting FIP1.18 No Power Step Check Possible causes: POWER CORD (PL12.1.23) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) OPERATION PANEL (PL1.1.1) HARNESS ASSY PANEL (PL1.1.10) INTERLOCK S/W 24V (PL8.1.11) INTERLOCK S/W 5V (PL8.1.12) INTERLOCK S/W REAR (PL12.1.7) FAN MAIN (PL1.1.14) FAN SUB (PL8.1.5) ROS ASSY (PL8.1.1) FUSER ASSY (PL8.1.20) GEAR ASSY HOUSING (PL11.1.3)
  • Page 54 Chapter 1 Troubleshooting Step Check Checking CLUTCH REGI (PL5.1.23) Remove SHIELD PLATE HVPS (PL12.1.18). Go to FIP1.38 Disconnect P/J243. Go to step 8. CLUTCH REGI. Remove EP CARTRIDGE. Does FAN MAIN rotate, when the power is turned ON? Checking OPERATION PANEL Disconnect HARNESS ASSY PANEL from PWBA ESS.
  • Page 55 Chapter 1 Troubleshooting Step Check Checking FAN SUB Replace FAN SUB. (RRP8.2) Replace HVPS/ Remove EP CARTRIDGE. End of work MCU. (RRP12.10) Does the FAN SUB rotate, when the power is turned 1 – 35...

  • Page 56: Fip1.19 Lcd/Led Display Error

    Chapter 1 Troubleshooting FIP1.19 LCD/LED Display Error Step Check Possible causes: OPERATION PANEL (PL1.1.1) HARNESS ASSY PANEL (PL1.1.10) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking 3.3VDC power line Is the voltage across the Go to step 2. Go to step 4 harness of OPERATION PANEL, 3.3 VDC? Replace HAR- Checking OPERATION PANEL for continuity (1) Go to step 3.

  • Page 57: Fip1.20 Inoperative Keypad

    Chapter 1 Troubleshooting FIP1.20 Inoperative Keypad Step Check Possible causes: OPERATION PANEL (PL1.1.1) HARNESS ASSY PANEL (PL1.1.10) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking 3.3 VDC power line Is the voltage across the harness of OPERATION Go to step 2. Go to step 4. PANEL, 3.3 VDC? Replace HAR- Checking OPERATION PANEL for continuity (1)

  • Page 58: Fip1.21 Other Printer Error

    Chapter 1 Troubleshooting FIP1.21 Other Printer Error Step Check Possible causes: HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Run a test print. Is the printer able to test print? Go to step 4. Go to step 2. Check using Chapter 2 Diagnostic [TEST PATTERN MODE MENU].

  • Page 59: Fip1.22 Face Up Tray Error

    Chapter 1 Troubleshooting FIP1.22 Face Up Tray Error Step Check Possible causes: HVPS/MCU (PL12.1.19) SENSOR FACE UP OPEN (PL10.1.25) GATE FU (PL10.2.6) LEVER GATE FU (PL10.2.17) Checking Actuator for operation With tool Go to Does ACTUATOR FULL STACK in GATE FU move step 2.

  • Page 60: Fip1.23 Full Stack Error/500 Paper Exit

    Chapter 1 Troubleshooting FIP1.23 Full Stack Error/500 Paper Exit Step Check Possible causes: SENSOR FULL STACK (PL10.1.26) ACTUATOR FULL STACK (PL10.1.10) HVPS/MCU (PL12.1.19) Checking ACTUATOR FULL STACK for operation With tool Go to Replace ACTUA- Does ACTUATOR FULL STACK in paper feed out sec- step 2.

  • Page 61: Level 2 Fip

    Chapter 1 Troubleshooting 4.2 Level 2 FIP FIP1.24 LVPS Step Check Possible causes: LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) HARNESS ASSY LVPS (PL12.1.1) Checking LVPS (PL12.1.5) control power Remove SHIELD PLATE LVPS. (RRP12.1) Disconnect P/J41 from LVPS. Replace LVPS. Turn the power ON. Go to step 2.

  • Page 62: Fip1.25 Main Motor

    Chapter 1 Troubleshooting FIP1.25 MAIN MOTOR Step Check Possible causes: MAIN MOTOR (PL11.1.2) HARNESS ASSY LVPS (PL12.1.1) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking MAIN MOTOR Remove EP CARTRIDGE. Close COVER OPEN (PL1.1.2). Go to step 2. Go to step 3. Does MAIN MOTOR rotate, when the power is turned Check by rotation sound of MAIN MOTOR.

  • Page 63: Fip1.26 Ros Assy

    Chapter 1 Troubleshooting FIP1.26 ROS ASSY Step Check Possible causes: ROS ASSY (PL8.1.1) HARNESS ASSY ROS (PL8.1.2) INTERLOCK S/W 5V (PL8.1.12) HARNESS ASSY LVPS (PL12.1.1) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking the power to Laser Diode of ROS ASSY Remove COVER TOP ASSY (PL1.1.7). (RRP1.4) Disconnect P/J140 from ROS ASSY.
  • Page 64 Chapter 1 Troubleshooting Step Check Checking /ROSMOT ON signal of Scanner Motor Install EP CARTRIDGE. Close COVER OPEN (PL1.1.2). Go to step 11. Go to step 10. Is P/J13-3(+) and P/J13-2(-) on HVPS/MCU, 0 V just after when the power is turned ON, and 5VDC 10 sec- onds after stopping MAIN MOTOR? Checking HARNESS ASSY ROS for continuity Replace HVPS/...

  • Page 65: Fip1.27 Fuser Assy

    Chapter 1 Troubleshooting FIP1.27 FUSER ASSY Step Check Possible causes: FUSER ASSY (PL8.1.20) HVPS/MCU (PL12.1.19) INTERLOCK S/W 24V (PL8.1.11) HARNESS ASSY FUSER 100V/200V (PL8.1.17) HARNESS ASSY AC100V/200V (PL12.1.8) LVPS (PL12.1.5) HARNESS ASSY LVPS (PL12.1.1) Checking Heater circuit for continuity Remove SHIELD PLATE LVPS. (RRP12.1) Disconnect P/J47 from LVPS.
  • Page 66 Chapter 1 Troubleshooting Step Check Checking the resistance of Thermistor of Temperature Sensor Disconnect P/J46 from LVPS. Replace FUSER Go to step 8. Is the resistance between P/J46-6 and P/J46-7 and P/ ASSY. (RRP8.8) J46-1 and P/J46-2 about 480 k-ohm in the normal tem- perature (about 20 °C)? Checking after replacing HVPS/MCU Replace HVPS/MCU.

  • Page 67: Fip1.28 Sensor Regi

    Chapter 1 Troubleshooting FIP1.28 SENSOR REGI Step Check Possible causes: SENSOR REGI (PL5.1.30) ACTUATOR B (PL5.1.17) 150 FEEDER ASSY (PL5.1.1) HARNESS ASSY TRAY1 (PL5.1.37) HARNESS ASSY CHUTE (PL12.1.17) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking ACTUATOR B for operation and shape Remove 150 FEEDER ASSY. (RRP5.1) Does ACTUATOR B operate smoothly? Is the flag of ACTUATOR B formed normally to shield With tool Go to...
  • Page 68 Chapter 1 Troubleshooting Step Check Checking HARNESS ASSY TRAY1 for continuity Remove SENSOR REGI. (RRP5.7) Disconnect P/J245. Replace HAR- Is there continuity between Go to step 8. NESS ASSY P/J245-4 and P/J241-3? TRAY1. P/J245-5 and P/J241-2? P/J245-6 and P/J241-1? Checking HVPS/MCU for continuity Go to FIP1.24 Replace HVPS/ Disconnect P/J11 from HVPS/MCU.

  • Page 69: Fip1.29 Sensor No Paper

    Chapter 1 Troubleshooting FIP1.29 SENSOR NO PAPER Step Check Possible causes: SENSOR NO PAPER (PL5.1.38, PL7.1.38) ACTUATOR NO PAPER (PL5.1.6, PL7.1.14) 150 FEEDER ASSY (PL5.1.1) HARNESS ASSY TRAY1 (PL5.1.37) HARNESS ASSY TRAY2 (PL7.1.36) HARNESS ASSY CHUTE (PL12.1.17) HVPS/MCU (PL12.1.19) PLATE ASSY BTM (PL2.1.10, PL4.1.10) LVPS (PL12.1.5) 550 FEEDER ASSY (PL7.1.10) Checking ACTUATOR NO PAPER for shape and oper-...
  • Page 70 Chapter 1 Troubleshooting Step Check Checking HARNESS ASSY CHUTE for continuity Disconnect P/J24 from HVPS/MCU. Disconnect P/J245 and P/J248. Is there continuity between J24-6 and J245-13? Replace HAR- J24-7 and J245-12? Go to step 7. NESS ASSY J24-8 and J245-11? CHUTE.

  • Page 71: Fip1.30 Sensor Low Paper

    Chapter 1 Troubleshooting FIP1.30 SENSOR LOW PAPER Step Check Possible causes: SENSOR LOW PAPER (PL7.1.4) ACTUATOR LOW PAPER (PL7.1.5) PLATE ASSY BTM (PL4.1.10) HARNESS ASSY LOW1 (PL7.1.2) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking ACTUATOR LOW PAPER for operation Install Paper Cassette. Does ACTUATOR LOW PAPER operate smoothly, when PLATE ASSY BTP is pushed and released by the With tool Go to...

  • Page 72: Fip1.31 Sensor Toner

    Chapter 1 Troubleshooting FIP1.31 SENSOR TONER Step Check Possible causes: SENSOR TONER (PL5.1.46) SENSOR TONER ASSY (PL5.1.45) HARNESS ASSY TONER1 (PL5.1.50) HARNESS ASSY TONER2 (PL12.1.28) EP CARTRIDGE HVPS/MCU (PL12.1.19) Checking EP CARTRIDGE (1) Go to step 3. Go to step 2. Does sufficient toner in EP CARTRIDGE remain? Checking EP CARTRIDGE (2) Does the problem still occur, after replacing EP CAR-...

  • Page 73: Fip1.32 Interlock S/W 24V

    Chapter 1 Troubleshooting FIP1.32 INTERLOCK S/W 24V Step Check Possible causes: INTERLOCK S/W 24V (PL8.1.11) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking INTERLOCK S/W 24V Replace INTER- Disconnect P/J45 from LVPS. Go to FIP1.24 LOCK S/W 24V. Is P/J45-1 and P/J45-3 continuous, when INTERLOCK LVPS.

  • Page 74: Fip1.33 Interlock S/W 5V, Switch I/L Assy

    Chapter 1 Troubleshooting FIP1.33 INTERLOCK S/W 5V, SWITCH I/L ASSY Step Check Possible causes: INTERLOCK S/W 5V (PL8.1.12) SWITCH I/L ASSY (PL1.1.11) HARNESS ASSY ROS (PL8.1.2) HARNESS ASSY LVPS (PL12.1.1) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking INTERLOCK S/W 5VL Replace INTER- Remove INTERLOCK S/W 5VL.

  • Page 75: Fip1.34 Interlock S/W Rear

    Chapter 1 Troubleshooting FIP1.34 INTERLOCK S/W REAR Step Check Possible causes: INTERLOCK S/W REAR (PL12.1.7) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking INTERLOCK S/W REAR for continuity Replace INTER- Disconnect P/J44 from LVPS. Go to FIP1.24 LOCK S/W REAR. Is P/J44-1 and P/J44-3 continuous, when INTERLOCK LVPS.

  • Page 76: Fip1.35 Switch I/L Assy (Interlock S/W Front R)

    Chapter 1 Troubleshooting FIP1.35 SWITCH I/L ASSY (Interlock S/W Front R) Step Check Possible causes: SWITCH I/L ASSY (PL1.1.11) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking SWITCH I/L ASSY for continuity Disconnect P/J411. Replace SWITCH I/ Go to step 2. Is P/J411-1 and P/J411-2 continuous, when SWITCH I/ L ASSY.

  • Page 77: Fip1.36 Pwba Exit Motor

    Chapter 1 Troubleshooting FIP1.36 PWBA EXIT MOTOR Step Check Possible causes: PWBA EXIT MOTOR (PL12.1.4) HARNESS ASSY LVPS (PL12.1.1) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking HARNESS ASSY LVPS for continuity Disconnect P/J27, P/J10, P/J102 and P/J101 from Replace HAR- HARNESS ASSY LVPS. Go to step 2.

  • Page 78: Chapter 1 Troubleshooting Contents

    Chapter 1 Troubleshooting FIP1.37 MOTOR ASSY EXIT Step Check Possible causes: MOTOR ASSY EXIT (PL10.1.15) PWBA EXIT MOTOR (PL12.1.4) HARNESS ASSY LVPS (PL12.1.1) LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) Checking MOTOR ASSY EXIT for operation. Not using DIAG tool- End of work Go to step 3.

  • Page 79: Fip1.38 Clutch Regi

    Chapter 1 Troubleshooting FIP1.38 CLUTCH REGI Step Check Possible causes: CLUTCH REGI (PL5.1.23) HARNESS ASSY CHUTE (PL12.1.17) HARNESS ASSY TRAY1 (PL5.1.37) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking HARNESS ASSY CHUTE for continuity Disconnect P/J24 from HVPS/MCU. Replace HAR- Is there continuity between Go to step 2.

  • Page 80: Fip1.39 Clutch Assy Ph

    Chapter 1 Troubleshooting FIP1.39 CLUTCH ASSY PH Step Check Possible causes: CLUTCH ASSY PH (PL5.1.21, PL7.1.20) HARNESS ASSY TRAY1 (PL5.1.37) HARNESS ASSY TRAY2 (PL7.1.36) HARNESS ASSY CHUTE (PL12.1.17) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking HARNESS ASSY CHUTE for continuity Disconnect P/J24 from HVPS/MCU. Is there continuity between Replace HAR- J24-13 and J245-6?

  • Page 81: Fip1.40 Guide Tray Left

    Chapter 1 Troubleshooting FIP1.40 GUIDE TRAY LEFT Step Check Possible causes: GUIDE TRAY LEFT (PL7.1.7) HARNESS ASSY LVPS (PL12.1.1) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking HARNESS ASSY LVPS for continuity Disconnect P/J18 from HVPS/MCU. Replace HAR- Go to step 2. Disconnect P/J1821. NESS ASSY LVPS.

  • Page 82: Fip1.41 Hvps/Mcu

    Chapter 1 Troubleshooting FIP1.41 HVPS/MCU Step Check Possible causes: HVPS/MCU (PL12.1.19) GUIDE ASSY CRU R (PL8.1.25) EP CARTRIDGE HARNESS ASSY ANT (PL8.1.24) HARNESS ASSY LVPS (PL12.1.1) Checking the power by GUIDE ASSY CRU R Replace GUIDE Is GUIDE ASSY CRU R installed appropriately? ASSY CRU R.

  • Page 83: Fip1.42 Electrical Noise

    Chapter 1 Troubleshooting FIP1.42 Electrical Noise Step Check Possible causes: HVPS/MCU (PL12.1.19) GUIDE ASSY CRU R (PL8.1.25) FUSER ASSY (PL8.1.20) EP CARTRIDGE HARNESS ASSY ANT (PL8.1.24) HARNESS ASSY AC100V/200V (PL12.1.8) HARNESS ASSY LVPS (PL12.1.1) Option 550 Paper Feeder PWBA FEEDER 550 (PL20.1.34) PWBA DUPLEX (PL21.1.32) Checking a foreign noise...
  • Page 84 Chapter 1 Troubleshooting Step Check Checking PWB ground Remove SHIELD PLATE LVPS (PL12.1.3) and SHIELD PLATE HVPS (PL12.1.8). (RRP12.1, 12.9) Is the ground normal? Are screws for ground of the following PWBs firmly tightened? All screws of HVPS/MCU (PL12.1.19) All screws of LVPS (PL12.1.5) Restore the Go to step 9.

  • Page 85: Fip1.43 Motor Assy Exit

    Chapter 1 Troubleshooting FIP1.43 MOTOR ASSY EXIT Step Check Possible causes: MOTOR ASSY EXIT (PL10.1.15) HARNESS ASSY LVPS (PL12.1.1) PWBA EXIT MOTOR (PL12.1.4) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking MOTOR ASSY EXIT. Not using DIAG tool: Replace MOTOR ASSY EXIT End of work Go to step 3.

  • Page 86: Fip1.44 Sensor Face Up Open

    Chapter 1 Troubleshooting FIP1.44 SENSOR FACE UP OPEN Step Check Possible causes: SENSOR FACE UP OPEN (PL10.1.25) GATE FU (PL10.2.6) LEVER GATE FU (PL10.2.17) HARNESS ASSY EXIT SNR (PL10.1.27) HVPS/MCU (PL12.1.19) Checking GATE FU for operation Open COVER ASSY REAR 500. Move LEVER GATE FU up and down.

  • Page 87: Fip1.45 Sensor Full Stack

    Chapter 1 Troubleshooting FIP1.45 SENSOR FULL STACK Step Check Possible causes: SENSOR FULL STACK (PL10.1.26) ACTUATOR FULL STACK (PL10.1.10) HARNESS ASSY EXIT SNR (PL10.1.27) HVPS/MCU (PL12.1.19) Checking ACTUATOR FULL STACK Open COVER ASSY REAR 500. Move ACTUATOR FULL STACK with a finger. With tool Go to Replace ACTUA- Does ACTUATOR FULL STACK operate smoothly?
  • Page 88 Chapter 1 Troubleshooting Blank Page 1 – 68...

  • Page 89: Duplex Option

    Chapter 1 Troubleshooting Duplex Option 4.3 Error/Status Code List Status Code Error Contents Error Description FIP to be referred STATUS 3-1 STATUS 3-1 to 3-5 indicates STATUS 3-2 JAM by combination of Table STATUS 3-3 1-1. STATUS 3-4 STATUS 3-5 -Cover of Option Duplex is STATUS 17-3 Duplex Cover Open...

  • Page 90: Level 1 Fip

    Chapter 1 Troubleshooting 4.5 Level 1 FIP FIP2.1 Option Duplex Cover Error Step Check Possible causes: HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) HSG LOWER DUP (PL21.1.6) COVER HSG DUP (PL21.1.18) SWITCH DUPLEX (PL21.1.27) PWBA DUPLEX (PL21.1.32) Checking COVER HSG DUP With tool Go to step Replace HSG Open COVER HSG DUP.

  • Page 91: Fip2.2 Option Duplex Error

    Chapter 1 Troubleshooting FIP2.2 Option Duplex Error Step Check Possible causes: HVPS/MCU (PL12.1.19) PWBA DUPLEX (PL21.1.32) HARNESS ASSY DUP (PL21.1.7) Checking Option Duplex installation Go to FIP2.8 Does Error still occur, after removing Option Duplex End of work PWBA DUPLEX. once, reinstalling, and then turning the power ON? 1 –...

  • Page 92: Fip2.3 Paper Jam/Exit To Dup

    Chapter 1 Troubleshooting FIP2.3 Paper Jam/Exit to Dup Step Check Possible causes: HVPS/MCU (PL12.1.19) SENSOR DUP (PL21.1.34) ACTUATOR DUP (PL21.1.37) ROLL DUP (PL21.1.17) ROLL PINCH (PL21.1.4) MOTOR DUPLEX (PL21.1.29) Does Error occur, when the power is turned ON? Go to step 2. Go to step 4.

  • Page 93: Fip2.4 Paper Jam/Dup To Regi

    Chapter 1 Troubleshooting FIP2.4 Paper Jam/Dup to Regi Step Check Possible causes: HVPS/MCU (PL12.1.19) FDR1 AS SUB 150 A4 (PL5.1.2) SENSOR DUP (PL21.1.34) ACTUATOR DUP (PL21.1.37) ROLL DUP (PL21.1.17) ROLL PINCH (PL21.1.4) MOTOR DUPLEX (PL21.1.29) Checking Option Duplex installation Remove Option Duplex, and then reinstall. Go to step 2.

  • Page 94: Fip2.5 Paper Jam/Duplex Misfeed

    Chapter 1 Troubleshooting FIP2.5 Paper Jam/Duplex Misfeed Step Check Possible causes: FDR1 AS SUB 150 A4 (PL5.1.2) HVPS/MCU (PL12.1.19) ROLL DUP (PL21.1.17) ROLL PINCH (PL21.1.4) MOTOR DUPLEX (PL21.1.29) Checking Option Duplex installation Remove Option Duplex, and then reinstall. Go to step 2. End of work Does Error occur, when Test Printing a Duplex print? Reinstall FDR1 AS...

  • Page 95: Fip2.6 Paper Size Error/Duplex

    Chapter 1 Troubleshooting FIP2.6 Paper Size Error/Duplex Step Check Possible causes: HVPS/MCU (PL12.1.19) GUIDE TRAY LEFT (PL7.1.7) Go to step 2. Replace the paper. PWBA FEEDER 550 (PL20.1.34) Checking paper size Is the paper size capable for duplex printing? Checking the paper size setup Change the paper Does the paper size in use match the size set by Go to step 3.

  • Page 96: Fip2.7 No Recognition Of Option Duplex

    Chapter 1 Troubleshooting FIP2.7 No Recognition of Option Duplex Step Check Possible causes: HVPS/MCU (PL12.1.19) HARNESS ASSY LVPS (PL12.1.1) PWBA DUPLEX (PL21.1.32) HARNESS ASSY DUP (PL21.1.7) Checking Option Duplex detection signal (1) Remove PWBA DUPLEX. (RRP21.5) Remove HARNESS ASSY DUP. Connect J2750 of HARNESS ASSY DUP to P2750 of Go to step 4.

  • Page 97: Level 2 Fip

    Chapter 1 Troubleshooting 4.6 Level 2 FIP FIP2.8 PWBA DUPLEX Step Check Possible causes: PWBA DUPLEX (PL21.1.32) HARNESS ASSY DUP (PL21.1.7) HVPS/MCU (PL12.1.19) HARNESS ASSY LVPS (PL12.1.1) Checking HARNESS ASSY DUP for continuity Remove Option Duplex. Replace HAR- Go to step 2. Disconnect P/J50 from PWBA DUPLEX.

  • Page 98: Fip2.9 Motor Duplex

    Chapter 1 Troubleshooting FIP2.9 MOTOR DUPLEX Step Check Possible causes: MOTOR DUPLEX (PL21.1.29) PWBA DUPLEX (PL21.1.32) HARNESS ASSY DUP (PL21.1.7) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) HARNESS ASSY LVPS (PL12.1.1) Checking HARNESS ASSY DUP for continuity Remove Option Duplex. Replace HAR- Disconnect P/J50 from PWBA DUPLEX. Go to step 2.

  • Page 99: Fip2.10 Sensor Dup

    Chapter 1 Troubleshooting FIP2.10 SENSOR DUP Step Check Possible causes: SENSOR DUP (PL21.1.34) ACTUATOR DUP (PL21.1.37) HARNESS ASSY DUP SNR (PL21.1.35) PWBA DUPLEX (PL21.1.32) HARNESS ASSY DUP (PL21.1.7) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) HARNESS ASSY LVPS (PL12.1.1) Checking ACTUATOR DUP for operation Does ACTUATOR DUP operate smoothly? With tool Go to Replace ACTUA-...

  • Page 100: Fip2.11 Switch Duplex

    Chapter 1 Troubleshooting FIP2.11 SWITCH DUPLEX Step Check Possible causes: SWITCH DUPLEX (PL21.1.27) HARNESS ASSY LVPS (PL12.1.1) HARNESS ASSY DUP COVER (PL21.1.31) PWBA DUPLEX (PL21.1.32) HARNESS ASSY DUP (PL21.1.7) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking SWITCH DUPLEX for continuity Replace SWITCH Remove SWITCH DUPLEX.

  • Page 101: Oct Option

    Chapter 1 Troubleshooting OCT Option 4.7 Error/Status Code List FIP to be Status Code Error Contents Error Description referred STATUS 3-1 STATUS 3-2 STATUS 3-1 to 3-5 indicates JAM by combina- tion of Table 1-1. STATUS 3-3 STATUS 3-4 STATUS 3-5 STATUS 16-5 Full Stack (OCT) -Option OCT became Full Stack.

  • Page 102: Level 1 Fip

    Chapter 1 Troubleshooting 4.8 Level 1 FIP FIP3.1 Option OCT Cover Error Step Check Possible causes: HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) PWBA OCT (PL23.1.22) COVER REAR (PL23.1.4) COVER OCT (PL23.1.1) S/W REAR COVER (PL23.1.18) HARNESS ASSY REAR COVER (PL23.1.29) With tool Go to step Checking COVER REAR Replace Cover 2.

  • Page 103: Fip3.2 Option Oct Error

    Chapter 1 Troubleshooting FIP3.2 Option OCT Error Step Check Possible causes: HARNESS ASSY OCT1 (PL12.1.26) HVPS/MCU (PL12.1.19) PWBA OCT (PL23.1.22) HARNESS ASSY OCT2 (PL23.1.25) Checking Option OCT installation Go to FIP3.8 Remove Option OCT, reinstall and turn the power ON. End of work PWBA OCT.

  • Page 104: Fip3.3 Paper Jam/Exit To Oct

    Chapter 1 Troubleshooting FIP3.3 Paper Jam/Exit to OCT Step Check Possible causes: HVPS/MCU (PL12.1.19) SENSOR OCT (PL23.1.30) ACTUATOR OCT (PL23.1.31) ROLL OCT LOWER (PL23.1.16) ROLL OCT UPPER (PL23.1.36) ROLL PINCH (PL23.1.34) MOTOR ASSY OCT (PL23.1.6) Does Error occur, when the power is turned ON? Go to step 2.

  • Page 105: Fip3.4 Paper Jam/Oct

    Chapter 1 Troubleshooting FIP3.4 Paper Jam/OCT Step Check Possible causes: HVPS/MCU (PL12.1.19) SENSOR OCT (PL23.1.30) ACTUATOR OCT (PL23.1.31) ROLL OCT LOWER (PL23.1.16) ROLL OCT UPPER (PL23.1.36) ROLL PINCH (PL23.1.34) MOTOR ASSY OCT (PL23.1.6) Does Error occur, when the power is turned ON? Go to step 2.

  • Page 106: Fip3.5 Paper Size Error/Oct

    Chapter 1 Troubleshooting FIP3.5 Paper Size Error/OCT Step Check Possible causes: HVPS/MCU (PL12.1.19) GUIDE TRAY LEFT (PL7.1.7) PWBA FEEDER 550 (PL20.1.34) Checking the paper size setup Change the paper Does the size of paper in use match the size set by Go to step 2.

  • Page 107: Fip3.6 Full Stack Error/Oct

    Chapter 1 Troubleshooting FIP3.6 Full Stack Error/OCT Step Check Possible causes: Sensor Full Stack (0n PWBA OCT) HVPS/MCU (PL12.1.19) PWBA OCT (PL23.1.22) ACTUATOR FULL STACK (PL23.1.15) Checking ACTUATOR FULL STACK for operation With tool Go to Does ACTUATOR FULL STACK move smoothly, when Replace ACTUA- step 2.

  • Page 108: Fip3.7 No Recognition Of Option Oct

    Chapter 1 Troubleshooting FIP3.7 No Recognition of Option OCT Step Check Possible causes: HVPS/MCU (PL12.1.19) HARNESS ASSY OCT1 (PL12.1.26) PWBA OCT (PL23.1.22) HARNESS ASSY OCT2 (PL23.1.25) Checking Option OCT detection signal (1) Disconnect P/J70 on PWBA OCT. Go to step 5. Go to step 2.

  • Page 109: Level 2 Fip

    Chapter 1 Troubleshooting 4.9 Level 2 FIP FIP3.8 PWBA OCT Step Check Possible causes: PWBA OCT (PL23.1.22) HARNESS ASSY OCT1 (PL12.1.26) HARNESS ASSY OCT2 (PL23.1.25) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) Checking HARNESS ASSY OCT2 for continuity Remove Option OCT. (RRP23.1) Replace HAR- Disconnect P/J70 from PWBA OCT.

  • Page 110: Fip3.9 Motor Assy Oct

    Chapter 1 Troubleshooting FIP3.9 MOTOR ASSY OCT Step Check Possible causes: MOTOR ASSY OCT (PL23.1.6) PWBA OCT (PL23.1.22) HARNESS ASSY OCT MOT (PL23.1.46) HARNESS ASSY OCT2 (PL23.1.25) HVPS/MCU (PL12.1.19) HARNESS ASSY OCT1 (PL12.1.26) Checking HARNESS ASSY OCT MOT for continuity With tool Go to Replace HAR- Remove HARNESS ASSY OCT MOT.

  • Page 111: Fip3.10 Motor Assy Offset

    Chapter 1 Troubleshooting FIP3.10 MOTOR ASSY OFFSET Step Check Possible causes: MOTOR ASSY OFFSET (PL23.1.20) MOTOR ASSY OCT (PL23.1.6) PWBA OCT (PL23.1.22) HARNESS ASSY OCT2 (PL23.1.25) HVPS/MCU (PL12.1.19) HARNESS ASSY OCT1 (PL12.1.26) Checking MOTOR ASSY OFFSET Not using DIAG tool: Replace MOTOR ASSY OFF- End of work Go to step 4.

  • Page 112: Fip3.11 Solenoid Assy Gate

    Chapter 1 Troubleshooting FIP3.11 SOLENOID ASSY GATE Step Check Possible causes: SOLENOID ASSY GATE (PL23.1.27) P WBA OCT (PL23.1.22) HARNESS ASSY OCT2 (PL23.1.25) HVPS/MCU (PL12.1.19) HARNESS ASSY OCT1 (PL12.1.26) Checking SOLENOID ASSY GATE Not using DIAG tool: Replace SOLENOID ASSY GATE. End of work Go to step 4.

  • Page 113: Fip3.12 S/W Rear Cover

    Chapter 1 Troubleshooting FIP3.12 S/W REAR COVER Step Check Possible causes: S/W REAR COVER (PL23.1.18) HARNESS ASSY REAR COVER (PL23.1.29) PWBA OCT (PL23.1.22) HARNESS ASSY OCT2 (PL23.1.25) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) HARNESS ASSY OCT1 (PL12.1.26) Checking S/W REAR COVER for continuity (1) Remove S/W REAR COVER.

  • Page 114: Fip3.13 Sensor Oct

    Chapter 1 Troubleshooting FIP3.13 SENSOR OCT Step Check Possible causes: SENSOR OCT (PL23.1.30) ACTUATOR OCT (PL23.1.31) HARNESS ASSY OCT SNR (PL23.1.26) PWBA OCT (PL23.1.22) HARNESS ASSY OCT2 (PL23.1.25) HVPS/MCU (PL12.1.19) HARNESS ASSY OCT1 (PL12.1.26) Checking ACTUATOR OCT for operation Remove Option OCT. (RRP23.1) Open COVER REAR.

  • Page 115: Fip3.14 Sensor Full Stack (On Pwba Oct)

    Chapter 1 Troubleshooting FIP3.14 Sensor Full Stack (On PWBA OCT) Step Check Possible causes: Sensor Full Stack (Mounted on PWBA OCT) ACTUATOR FULL STACK (PL23.1.15) PWBA OCT (PL23.1.22) HARNESS ASSY OCT2 (PL23.1.25) HVPS/MCU (PL12.1.19) HARNESS ASSY OCT1 (PL12.1.26) Checking ACTUATOR FULL STACK for operation Remove Option OCT.

  • Page 116: Fip3.15 Sensor Offset (On Pwba Oct)

    Chapter 1 Troubleshooting FIP3.15 Sensor Offset (On PWBA OCT) Step Check Possible causes: Sensor Offset (Mounted on PWBA OCT) CHUTE OFFSET ASSY (PL23.1.35) PWBA OCT (PL23.1.22) HARNESS ASSY OCT2 (PL23.1.25) HVPS/MCU (PL12.1.19) HARNESS ASSY OCT1 (PL12.1.26) Checking the Actuator of CHUTE OFFSET for opera- tion Remove Option OCT.

  • Page 117: Paper Feeder Option

    Chapter 1 Troubleshooting 550 Paper Feeder Option 4.10 Error/Status Code List FIP to be Status Code Error Contents Error Description referred STATUS 1-5 Cassette Fail - Paper size is not specified. FIP4.1 STATUS 15-3 Near end of paper in Tray 4 - Remaining paper in Tray 4 became low.

  • Page 118: Fip4.1 No Tray/Tray 3, 4

    Chapter 1 Troubleshooting 4.11 Level 1 FIP FIP4.1 No Tray/Tray 3, 4 Step Check Possible causes: HVPS/MCU (PL12.1.19) OPT ASSY SIZE (PL20.1.8) Option 550 Paper Feeder 550 PAPER CASSETTE (PL20.3.50) Does Error still occur, after removing and reinstalling the 550 PAPER CASSETTE of Option 550 Paper Go to step 2.

  • Page 119: Fip4.2 No Paper/Tray 3, 4

    Chapter 1 Troubleshooting FIP4.2 No Paper/Tray 3, 4 Step Check Possible causes: HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) SENSOR NO PAPER (PL20.2.33) ACTUATOR NO PAPER (PL20.2.6) Option 550 Paper Feeder 550 PAPER CASSETTE (PL20.3.50) PLATE ASSY BTM (PL20.3.10) RACK BTM LOCK 550 (PL20.3.21) HOUSING BASE 550(PL20.3.44) Checking if there is any paper Is there any paper in Go to step 2.

  • Page 120: Fip4.3 Low Paper In Tray/Tray 3, 4

    Chapter 1 Troubleshooting FIP4.3 Low Paper in Tray/Tray 3, 4 Step Check Possible causes: HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) SENSOR LOW PAPER (PL20.1.30) ACTUATOR LOW PAPER (PL20.1.31) PLATE ASSY BTM (PL20.3.10) Option 550 Paper Feeder 550 PAPER CASSETTE (PL20.3.50) Checking the sensor for operation Does Error still occur, after 550 PAPER CASSETTE Go to step 2.

  • Page 121: Fip4.4 No Recognition Of Option 550 Paper Feeder

    Chapter 1 Troubleshooting FIP4.4 No Recognition of Option 550 Paper Feeder The description below is on the assumption that Option 550 Paper Feeder's are installed to Tray 3 and Tray 4. Step Check Possible causes: LVPS (PL12.1.5) HVPS/MCU (PL12.1.19) PWBA FEEDER 550 (PL20.1.34) HARNESS ASSY FDR2 (PL20.1.5) HARNESS ASSY FDR5 (PL20.1.26) Checking HARNESS ASSY FDR2 of Feeder equivalent...

  • Page 122: Fip4.5 Inappropriate Option 550 Paper Feeder

    Chapter 1 Troubleshooting FIP4.5 Inappropriate Option 550 Paper Feeder Step Check Possible causes: PWBA FEEDER 550 (PL20.1.34) Checking Option 550 Paper Feeder Go to FIP4.6, 4.7 Replace Option Is Option 550 Paper Feeder for correct JIGEN2 PWBA FEEDER 550 Paper Feeder installed? 550.

  • Page 123: Level 2 Fip

    Chapter 1 Troubleshooting 4.12 Level 2 FIP FIP4.6 PWBA FEEDER 550 It is stated here as Option 550 Paper Feeder is set as Tray 3. When it is set as Tray 4, refer to the statement in FIP2.21 PWBA FEEDER 550 for the circuit usage condition. Step Check Possible causes:...

  • Page 124: Fip4.7 Pwba Feeder 550

    Chapter 1 Troubleshooting FIP4.7 PWBA FEEDER 550 It is stated here as Option 550 Paper Feeder is set as Tray 4. When it is set as Tray 3, refer to the statement in FIP2.20 PWBA FEEDER 550 for the circuit usage condition. Step Check Possible causes:...

  • Page 125: Fip4.8 Sensor No Paper

    Chapter 1 Troubleshooting FIP4.8 SENSOR NO PAPER Step Check Possible causes: SENSOR NO PAPER (PL20.2.33) ACTUATOR NO PAPER (PL20.2.6) HARNESS ASSY CLSNR1 (PL20.2.31) HARNESS ASSY CLSNR2 (PL20.1.36) 550 PAPER CASSETTE (PL20.3.50) Option 550 Paper Feeder PWBA FEEDER 550 (PL20.1.34) HVPS/MCU (PL12.1.19) Checking ACTUATOR NO PAPER Remove Option 550 Paper Feeder.
  • Page 126 Chapter 1 Troubleshooting Step Check Checking HVPS/MCU for continuity Replace HVPS/ Disconnect P/J11 and P/J20 from HVPS/MCU. Go to step 7. MCU. (RRP12.10) Is there continuity between P11-16 and P20-5? Checking after replacing SENSOR NO PAPER (3) Replace HVPS/ Replace SENSOR NO PAPER. (RRP20.16) MCU.

  • Page 127: Fip4.9 Sensor Low Paper

    Chapter 1 Troubleshooting FIP4.9 SENSOR LOW PAPER Step Check Possible causes: SENSOR LOW PAPER (PL20.1.30) ACTUATOR LOW PAPER (PL20.1.31) HARNESS LOW PAPER (PL20.1.33) HARNESS ASSY FDR2 (PL20.1.5) Option 550 Paper Feeder 550 PAPER CASSETTE PWBA FEEDER 550 (PL20.1.34) PLATE ASSY BTM (PL20.3.10) HVPS/MCU (PL12.1.19) Checking ACTUATOR LOW PAPER Remove Option 550 Paper Feeder.

  • Page 128: Fip4.10 Opt Assy Size

    Chapter 1 Troubleshooting FIP4.10 OPT ASSY SIZE Step Check Possible causes: OPT ASSY SIZE (PL20.1.18) HARNESS ASSY SIZE FDR1 (PL20.1.19) HARNESS ASSY SIZE FDR2 (PL20.1.35) Option 550 Paper Feeder 550 PAPER CASSETTE PWBA FEEDER 550 (PL20.1.34) HVPS/MCU (PL12.1.19) Checking HARNESS ASSY SIZE FDR1 for continuity Replace HAR- Remove HARNESS ASSY SIZE FDR1.

  • Page 129: Fip4.11 Clutch Assy Ph

    Chapter 1 Troubleshooting FIP4.11 CLUTCH ASSY PH Step Check Possible causes: CLUTCH ASSY PH (PL20.2.21) Option 550 Paper Feeder 550 PAPER CASSETTE (PL20.3.50) PWBA FEEDER 550 (PL20.1.34) HARNESS ASSY CLSNR1 (PL20.2.31) HARNESS ASSY CLSNR2 (PL20.1.36) HARNESS ASSY FDR2 (PL20.1.5) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) HARNESS ASSY FDR1 (PL12.1.21) Checking HARNESS ASSY CLSNR1 for continuity...

  • Page 130: Fip4.12 Clutch Pr-Regi

    Chapter 1 Troubleshooting FIP4.12 CLUTCH PR-REGI Step Check Possible causes: CLUTCH PR-REGI (PL20.2.22) Option 550 Paper Feeder 550 PAPER CASSETTE (PL20.3.50) PWBA FEEDER 550 (PL20.1.34) HARNESS ASSY CLSNR1 (PL20.2.31) HARNESS ASSY CLSNR2 (PL20.1.36) HARNESS ASSY FDR2 (PL20.1.5) HVPS/MCU (PL12.1.19) LVPS (PL12.1.5) HARNESS ASSY FDR1 (PL12.1.21) Checking HARNESS ASSY CLSNR1 for continuity Replace HAR-...

  • Page 131: Image Quality Defects

    Chapter 1 Troubleshooting 5. Image Quality Defects 5.1 Entry Chart for Image Quality Troubleshooting Start Test Printing Is there a corresponding FIP? Carry out the corresponding troubleshooting. Troubleshoot The trouble is restored? The trouble is restored? It is assumed that the Printer Controller is functioning normally. By running a test print with the engine only, if the trouble is on the Printer Controller side or the engine side, diagnosis is simple, except those defects that are not able to be diagnosed by test print.
  • Page 132 Chapter 1 Troubleshooting When an image quality problem occurs, run a test print to clearly define the defect. Next, troubleshoot using the image quality FIP table accordingly. If the problem cannot be resolved using the image quality FIP, check again with the image quality FIP. Next, replace [ESS and possible causes] in order and check, and troubleshoot, using [Chapter 2 Diagnostic].

  • Page 133: Image Quality Fip

    Chapter 1 Troubleshooting 5.2 Image Quality FIP FIP- 1.P1 Faint Print Print defect The density of the image is entirely too faint. ESS and possible causes - EP CARTRIDGE - GUIDE ASSY CRU R (PL8.1.25) - BTR ASSY (PL8.1.21) - 150 FEEDER ASSY (PL5.1.1) - PWBA ESS (PL12.1.13) - ROS ASSY (PL8.1.1) - FUSER ASSY (PL8.1.20)
  • Page 134 Chapter 1 Troubleshooting Step Check Checking the image development process Operate Test Print, and turn off the power of the printer while printing. Remove the EP CARTRIDGE with care, and check the Go to FIP1.41 Go to step 8. toner image formed on the drum, right before the tran- HVPS/MCU.

  • Page 135: Fip- 1.P2 Blank Print (No Print)

    Chapter 1 Troubleshooting FIP- 1.P2 Blank print (No print) Print defect The entire paper is printed pure white. ESS and possible causes - EP CARTRIDGE - GUIDE ASSY CRU R (PL8.1.25) - BTR ASSY (PL8.1.21) - 150 FEEDER ASSY (PL5.1.1) - ROS ASSY (PL8.1.1) - PWBA ESS (PL12.1.13) - FUSER ASSY (PL8.1.20)
  • Page 136 Chapter 1 Troubleshooting Step Check Checking BTR ASSY Remove BTR ASSY. (RRP8.10) Replace BTR Check if any stains and/or wear on BTR ASSY. Are Go to step 6. ASSY. (RRP8.10) there any stains and/or wear on BTR? Checking the image development process Operate Test Print, and turn off the power of the printer while printing.

  • Page 137: Fip- 1.P3 Solid Black

    Chapter 1 Troubleshooting FIP- 1.P3 Solid Black Print defect The entire paper is printed jet-black. ESS and possible causes - EP CARTRIDGE - HVPS/MCU (PL12.1.19) - LVPS (PL12.1.5) - 150 FEEDER ASSY (PL5.1.1) - ROS ASSY (PL8.1.1) - PWBA ESS (PL12.1.13) - 550 FEEDER ASSY (PL7.1.10) Before commencing troubleshooting, check the paper transfer course.

  • Page 138: Fip- 1.P4 Vertical Blank Lines (White Stripes In Paper Transport Direction)

    Chapter 1 Troubleshooting FIP- 1.P4 Vertical blank lines (White stripes in paper transport direction) Print defect There are some extremely faint or completely non- printed parts. Those non-printed parts cover a wide area vertically, along the paper feed- ing direction. ESS and possible causes - EP CARTRIDGE - BTR ASSY (PL8.1.21)
  • Page 139 Chapter 1 Troubleshooting Step Check Checking Heat Roll and Pressure Roll Remove FUSER ASSY. (RRP8.8) Warning; Start the operation after the FUSER ASSY Go to step [ESS have cooled down. Replace FUSER and possible Turn the Gear HR with a finger, and check the Heat Roll ASSY.

  • Page 140: Fip- 1.P5 Horizontal Band Cross Out

    Chapter 1 Troubleshooting FIP- 1.P5 Horizontal band cross out Print defect There are some extremely faint or completely non- printed parts. Those non-printed parts cover a wide area horizontally, perpendicular to the paper feeding direction. ESS and possible causes - EP CARTRIDGE - HVPS/MCU (PL12.1.19) - GUIDE ASSY CRU R (PL8.1.25) - BTR ASSY (PL8.1.21)
  • Page 141 Chapter 1 Troubleshooting Step Check Checking the image transcribe process Check the toner image formed on the drum, right after Go to FIP1.41 the transcribe part (BTR). Go to step 7. HVPS/MCU. Is the toner image on the drum completely transcribed on the paper? Checking Drive Assy and GEAR ASSY HOUSING Replace Drive Assy and GEAR ASSY HOUSING.

  • Page 142: Fip- 1.P6 Vertical Stripes

    Chapter 1 Troubleshooting FIP- 1.P6 Vertical stripes Print defect There are vertical black stripes along the paper. ESS and possible causes - EP CARTRIDGE - HVPS/MCU (PL12.1.19) - GUIDE ASSY CRU R (PL8.1.25) - BTR ASSY (PL8.1.21) - 150 FEEDER ASSY (PL5.1.1) - ROS ASSY (PL8.1.1) - PWBA ESS (PL12.1.13) - 550 FEEDER ASSY (PL7.1.10)

  • Page 143: Fip- 1.P7 Horizontal Stripes

    Chapter 1 Troubleshooting FIP- 1.P7 Horizontal stripes Print defect There are horizontal black stripes along the paper. ESS and possible causes - EP CARTRIDGE - HVPS/MCU (PL12.1.19) - GUIDE ASSY CRU R (PL8.1.25) - BTR ASSY (PL8.1.21) - 150 FEEDER ASSY (PL5.1.1) - MAIN MOTOR (PL11.1.2) - GEAR ASSY HOUSING (PL11.1.3) - ROS ASSY (PL8.1.1)
  • Page 144 Chapter 1 Troubleshooting Step Check Restore or clean Checking Drum ground the Plate Earth, or Check the Plate Earth of GUIDE ASSY CRU R. Go to step 7. replace GUIDE Are there any stains or deformation on the Plate Earth? ASSY CRU R.

  • Page 145: Fip- 1.P8 Partial Deletion

    Chapter 1 Troubleshooting FIP- 1.P8 Partial Deletion Print defect There are some extremely faint or completely missing parts. Those missing parts are dotted in a limited area on the paper. ESS and possible causes - EP CARTRIDGE - HVPS/MCU (PL12.1.19) - BTR ASSY (PL8.1.21) - 150 FEEDER ASSY (PL5.1.1) - PWBA ESS (PL12.1.13)

  • Page 146: Fip- 1.P9 Spots

    Chapter 1 Troubleshooting FIP- 1.P9 Spots Print defect There are toner spots all over the paper disorderedly. ESS and possible causes - EP CARTRIDGE - HVPS/MCU (PL12.1.19) - BTR ASSY (PL8.1.21) - 150 FEEDER ASSY (PL5.1.1) - ROS ASSY (PL8.1.1) - GUIDE ASSY CRU R (PL8.1.25) - PWBA ESS (PL12.1.13) - 550 FEEDER ASSY (PL7.1.10)

  • Page 147: Fip- 1.P10 Ghosting

    Chapter 1 Troubleshooting FIP- 1.P10 Ghosting Print defect The ghost appears on the paper. The ghost may be the image of the previous page, or a part of the page currently printing. ESS and possible causes - EP CARTRIDGE - HVPS/MCU (PL12.1.19) - GUIDE ASSY CRU R (PL8.1.25) - Drive Assy - BTR ASSY (PL8.1.21)
  • Page 148 Chapter 1 Troubleshooting Step Check Checking Heat Roll and Pressure Roll Remove FUSER ASSY. (RRP8.8) Warning; Start the operation after the FUSER ASSY have cooled down. Replace FUSER Go to step 7. Turn the Gear HR with a finger, and check the Heat Roll ASSY.

  • Page 149: Fip- 1.P11 Background (Fog)

    Chapter 1 Troubleshooting FIP- 1.P11 Background (Fog) Print defect There is toner stain all over or a part of the page. The stain appears as very bright gray stain. ESS and possible causes - EP CARTRIDGE - BTR ASSY (PL8.1.21) - HVPS/MCU (PL12.1.19) - GUIDE ASSY CRU R (PL8.1.25) - ROS ASSY (PL8.1.1)

  • Page 150: Fip- 1.P12 Skew

    Chapter 1 Troubleshooting FIP- 1.P12 Skew Print defect The printed image is not paralleled with both sides of the paper. ESS and possible causes - EP CARTRIDGE - BTR ASSY (PL8.1.21) - 150 FEEDER ASSY (PL5.1.1) - FUSER ASSY (PL8.1.20) - Paper Cassette - PLATE ASSY BTM (PL2.1.10, PL4.1.10) - 150 Paper Feeder...

  • Page 151: Fip- 1.P13 Paper Damage

    Chapter 1 Troubleshooting FIP- 1.P13 Paper damage Print defect The paper comes out from the printer crumpled, folded or worn-out. ESS and possible causes - FUSER ASSY (PL8.1.20) - Heat Roll - Pressure Roll - PWBA ESS (PL12.1.13) - 150 FEEDER ASSY (PL5.1.1) - EP CARTRIDGE - BTR ASSY (PL8.1.21) - Paper Cassette...
  • Page 152 Chapter 1 Troubleshooting Step Check Checking EP CARTRIDGE Go to step [ESS Install a new EP CARTRIDGE. and possible End of work Carry out a test printing. Is the paper still damaged? causes]. 1 – 132...

  • Page 153: Fip- 1.P14 Unfused Image

    Chapter 1 Troubleshooting FIP- 1.P14 Unfused Image Print defect The printed image is not fixed on the paper properly. The image easily comes off when rubbed. ESS and possible causes - FUSER ASSY (PL8.1.20) - Heat Roll - Pressure Roll - PWBA ESS (PL12.1.13) - LVPS (PL12.1.5) Before commencing troubleshooting, check the paper transfer course.
  • Page 154 Chapter 1 Troubleshooting Step Check Checking FUSER ASSY Turn the gear of the Heater Roller with a finger. Go to step [ESS Replace FUSER Check the contact condition of Heat Roll and Pressure and possible ASSY. (RRP8.8) Roll when rotating. causes].

  • Page 155: Judgment Of Print Consistency

    Chapter 1 Troubleshooting 6. Judgment of Print Consistency It is stated here how to judge simply the main print consistency printing with the standard paper (letter size). Keep the paper packaged in the operating environment for 12 hours, and then use the paper just after it has been unpacked.

  • Page 156: Side Edge Registration

    Chapter 1 Troubleshooting 6.2 Side Edge Registration Measure the amount of shift from the ideal point 108.0 mm away from the left end at center of front and- back of the paper. Reference: less than +/-2.5 mm 1 – 136...

  • Page 157: Skew

    Chapter 1 Troubleshooting 6.3 Skew Measurement of the inclined paper feeding Measure the vertical distance of two points 190 mm away each other on the top horizontal line. Reference: less than +/-1.2 mm 1 – 137...

  • Page 158: Perpendicularity

    Chapter 1 Troubleshooting 6.4 Perpendicularity Measurement of the perpendicularity for suppressing inclines of ROS and OPC. Check the perpendicular line to the horizontal line to measure the horizontal distance at the point 114.5 mm away vertically from center of top horizontal line. Reference: less than +/-0.8 mm JG54A3AA 1 –...

  • Page 159: Parallelism

    Chapter 1 Troubleshooting 6.5 Parallelism The parallelism is difference of feeding speed between left and right sides of the paper. Measure the difference of length between two 234 mm long vertical lines 190 mm away each other. Reference: less than +/-1.2 mm 1 –...
  • Page 160 Chapter 1 Troubleshooting Blank Page 1 – 140...

  • Page 161: Preventive Maintenance

    Chapter 1 Troubleshooting 7. Preventive Maintenance When visiting the customer for a service call, perform the maintenance work to prevent any additional problems. Procedure for preventive maintenance 1) Check how the customer is using the machine. 2) Write down the cumulative print count. Use the cumulative print count as a guide of replacing periodic replacement parts.
  • Page 162 Chapter 1 Troubleshooting Blank Page 1 – 142...
  • Page 163 Chapter 2 Printer Diagnostics Chapter 2 Diagnostics CONTENTS Chapter 2 Diagnostics ....................2 - 1 1. Diagnostics ........................2 - 1 1.1 Overview ............................2 - 1 2. Entering Diagnostics ....................2 - 2 3. Main Menu........................2 - 3 3.1 Navigating through the Diagnostic Menus ..................2 - 3 3.2 Main Menu ............................
  • Page 164 Chapter 2 Printer Diagnostics Chapter 2 Diagnostics CONTENTS 11. Print Summary......................2 - 16...

  • Page 165: Chapter 2 Diagnostics

    Chapter 2 Diagnostics Chapter 2 Diagnostics 1. Diagnostics 1.1 Overview Diagnostics enable you to run various test on printer components. You can run motors forward and reverse and at different speeds, the actuation and de-actuation of sensors or switches, energize and de-energize solenoids, etc.

  • Page 166: Entering Diagnostics

    Chapter 2 Diagnostics 2. Entering Diagnostics To enter diagnostics, perform the following: 1. Switch the printer power OFF. 2. Press and hold both the “Menu” and “ ” buttons on the Operator Panel 3. Switch the printer power ON. 4. Continue to hold the “Menu” and “ ” buttons until “Initializing” is displayed on the LCD. 5.

  • Page 167: Main Menu

    Chapter 2 Diagnostics 3. Main Menu 3.1 Navigating through the Diagnostic Menus Four buttons are used to navigate through the diagnostic menus and sub-menus, ( , ). From the initial menu selection “Output Tests” (see 3.2), pressing the “ ” button moves down the menu to “Input Tests”...

  • Page 168: Output Tests

    Chapter 2 Diagnostics 4. Output Tests With “Output Tests” displayed on the LCD, pressing the “ ” button will enter the “Output Tests” menu and display the first menu selection. The complete Output Tests menu is displayed in the figure below. None of the menu selections in the Output Tests have sub-menus.

  • Page 169: Input Tests

    Chapter 2 Diagnostics 5. Input Tests Input tests are used to test cover interlocks, paper path sensors, paper size switches, etc., fuser tem- perature and ROM Checksum. With “Input Tests” displayed on the LCD, pressing the “ ” button will enter the “Input Tests” menu and display the first menu selection (Sensor Test).

  • Page 170: Alignment

    Chapter 2 Diagnostics 6. Alignment The image registration alignment allows each tray to be adjusted independently. Alignment routines are used to set “X” and “Y” values for the paper trays. With “Alignment” displayed on the LCD, pressing the “ ” button will enter the “Alignment” menu and display the first menu selection (Tray1 Y Adjust).

  • Page 171: Maintenance Info

    Chapter 2 Diagnostics 7. Maintenance Info Maintenance Info indicates the current count of the selected menu, the serial number of the printer, or resets the error log. With “Maintenance Info” displayed on the LCD, pressing the “ ” button will enter the Maintenance Info menu and display the first menu selection.

  • Page 172: Asset Tag

    Chapter 2 Diagnostics Using the “ “or “ “ buttons scroll through the possible choices that can be entered in each digit loca- tion. The choices are: ! " # $ % & ' ( ) * + , -. / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? @ A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ ` a b c d e f g h I j k l m n o p q r s t u v w x y z { | } ~ As you can see, numbers, letters, or symbols can be entered as part of the serial number.

  • Page 173: Operator Panel

    Chapter 2 Diagnostics 8. Operator Panel Operator Panel Menu enables the running of tests on Operator Panel. These tests include the LEDs, the LCD, and the Keys (buttons). With “Operator Panel” displayed on the LCD, pressing the “ ” button will enter the Operator Panel menu and display the first menu selection.

  • Page 174: Key Test

    Chapter 2 Diagnostics 8.3 Key Test The key test enables the testing of eight buttons on the operator panel. With Key Test displayed, press- ing the “ ” button will enter the key test. Opn: This indicates that a button is Open. As you press each button, the corresponding location will change to Cls indicating that button is closed.

  • Page 175: Test Print

    Chapter 2 Diagnostics 9. Test Print The Test Print Menu enables the running of five test prints, selecting the tray for the source paper, and selecting duplex or simplex. With “Test Print” displayed on the LCD, pressing the “ ” button will enter the Test print menu and dis- play the first menu selection.

  • Page 176: Engine Test Page

    Chapter 2 Diagnostics 9.3 Engine Test Page With “Engine Test Page” displayed on the LCD, pressing the “ ” button will print the Engine Test Page. 9.4 Grid Page With “Grid Page” displayed on the LCD, pressing the “ ” button will print the Grid Page. 2 - 12...

  • Page 177: Blank Page

    Chapter 2 Diagnostics 9.5 Blank Page With “Blank Page” displayed on the LCD, pressing the “ ” button will print a Blank Page. 9.6 Black Page With “Black Page” displayed on the LCD, pressing the “ ” button will print a page with a large black square.

  • Page 178: Test Page

    Chapter 2 Diagnostics 9.7 Test Page With “Test Page” displayed on the LCD, pressing the “ ” button will print the Test Page. 2 - 14...

  • Page 179: Flash Summary

    Chapter 2 Diagnostics 10. Flash Summary With ”Flash Summary” displayed on the LCD, pressing the “ ” button will print the Flash Summary (shown below). When the print completes, the display will remain at the Flash Summary Menu. This is an example of the Flash Summary Report 2 - 15...
  • Page 180 Chapter 2 Diagnostics 11. Print Summary With “Print Summary” displayed on the LCD, pressing the “ ” button will print the Print Summary (shown below). When the print completes, the display will remain at the Print Summary Menu. This is an example of the Print Summary Report 2 - 16...
  • Page 181 Chapter 3 Removal and Replacement Procedures (RRPs) Chapter 3 Removal and Replacement Procedures (RRPs) CONTENTS RRP1. COVERS......................3 - 4 RRP1.1 COVER REAR (PL 1.1) ......................3 - 4 RRP1.2 COVER RIGHT (PL 1.1)......................3 - 5 RRP1.3 COVER LEFT (PL 1.1) ......................3 - 6 RRP1.4 COVER TOP (PL 1.1), OPERATION PANEL (PL 1.1)..............
  • Page 182 Chapter 3 Removal and Replacement Procedures (RRPs) Chapter 3 Removal and Replacement Procedures (RRPs) CONTENTS RRP5.5 CLUTCH ASSEMBLY PH (PL 5.1.20)..................3 - 82 RRP5.6 SENSOR NO PAPER (PL 5.1.38)................... 3 - 84 RRP5.7 GUIDE TRAY RIGHT (PL 5.1) ....................3 - 86 RRP5.8 GUIDE TRAY LEFT (PL 7.1)....................
  • Page 183 Chapter 3 Removal and Replacement Procedures (RRPs) Chapter 3 Removal and Replacement Procedures (RRPs) CONTENTS RRP9. Electrical ......................3 - 147 RRP9.1 SHIELD PLATE LVPS (PL 9.1) ..................... 3 - 148 RRP9.2 PWBA EXIT MOTOR (PL 9.1.4).................... 3 - 149 RRP9.3 LVPS (PL 9.1.5) ........................3 - 150 RRP9.4 POWER SWITCH (PL 9.1.6), HARNESS ASSEMBLY AC100V/AC200V (PL 9.1.8) ...
  • Page 184 Chapter 3 Removal and Replacement Procedures (RRPs) Chapter 3 Removal and Replacement Procedures (RRPs) CONTENTS RRP12.3 COVER LEFT PLATE (PL12.1)................... 3 - 216 RRP12.4 OPT ASSY SIZE (PL12.1)....................3 - 217 RRP12.5 DRIVE ASSY OPT FDR (PL12.1) ..................3 - 218 RRP12.6 MOTOR FEEDER (PL12.1)....................

  • Page 185: Chapter 5 Parts List

    Chapter 3 Removal and Replacement Procedures (RRPs) Removal and Replacement Procedures Removal and Replacement Procedures (RRPs) Removal and replacement procedures are described for the 9 major sections of the parts listings, plus the 3 optional components. RRP 1 COVERS RRP 2 150 PAPER CASSETTE RRP 3 500 PAPER CASSETTE...
  • Page 186 Chapter 3 Removal and Replacement Procedures (RRPs) 1.2 Prohibited matter Do not remove the frame components shown in the figure below. Removing any of these components will make the laser printer go out of alignment. If the frame components are removed or their screws loosened by mistake, be sure to replace them again on a stable and firm horizontal work surface.
  • Page 187 Chapter 3 Removal and Replacement Procedures (RRPs) 1.4 Description of procedures "RRP X,Y "AAAAA" at the top of procedures represent the part name AAAAA are to be removed and replaced. "(PL X.Y.Z)" following the parts name in procedures represent that the parts are those of the plate (PL) "X.Y", item "Z"...

  • Page 188: Rrp1. Covers

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP1. COVERS RRP1.1 COVER REAR (PL 1.1) Removal Remove the 500 COVER REAR (PL 7.1) (RRP7.9) Remove the 5 screws (silver with flange, 8mm x 2, gold tapping, 8mm x 3) securing the COVER REAR to the printer (Figure 1).

  • Page 189: Rrp1.2 Cover Right (Pl 1.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP1.2 COVER RIGHT (PL 1.1) Removal Loosen the screw securing the COVER RIGHT to the rear side of the printer (Figure 1). Shift the COVER RIGHT in the direction of the arrow to release the 4 hooks, two below, one in front and one on rear, securing the cover to the printer.

  • Page 190: Rrp1.3 Cover Left (Pl 1.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP1.3 COVER LEFT (PL 1.1) Removal Remove the 500 COVER REAR (PL 7.1.21) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Shift the COVER LEFT in the direction of the arrow to release the 4 hooks, two below and two on rear, securing the cover to the printer (Figure 1).

  • Page 191: Rrp1.4 Cover Top (Pl 1.1), Operation Panel (Pl 1.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP1.4 COVER TOP (PL 1.1), OPERATION PANEL (PL 1.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1) Remove the 500 EXIT ASSEMBLY (PL 7.1) (RRP7.2).
  • Page 192 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the OPERATION PANEL to the COVER TOP, and secure it using the 2 hooks. Connect P/J1 of the OPERATION PANEL. Secure the harnesses with the 2 clamps on the OPERATION PANEL. Install the COVER TOP to the printer, and secure it to the COVER FRONT (PL 1.1) using the 2 hooks at the front of the COVER TOP.

  • Page 193: Rrp1.5 Cover Front (Pl 1.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP1.5 COVER FRONT (PL 1.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9) Remove the COVER REAR (PL 1.1) (RRP1.1) Remove the COVER LEFT (PL 1.1) (RRP1.3) Remove the COVER RIGHT (PL 1.1) (RRP1.2) Remove the COVER EXIT 500 (PL 1.1) (RRP7.1) Remove the 500 EXIT ASSEMBLY (PL 7.1) (RRP7.2).

  • Page 194: Rrp2. 150 Paper Cassette

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP2. 150 PAPER CASSETTE 3 - 10...

  • Page 195: Rrp2.1 Roll Assembly Retard (Pl 2.1.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP2.1 ROLL ASSEMBLY RETARD (PL 2.1.2) Removal Pull out the 150 PAPER CASSETTE from the printer. Release the hooks securing the HOLDER RETARD (PL 2.1) to the 150 PAPER CASSETTE using a screwdriver (Figure 1). Lift up the HOLDER RETARD in the direction of the arrow, and remove it.
  • Page 196 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the ROLL ASSEMBLY RETARD to the SHAFT RETARD (PL 2.1), and secure the ROLL ASSEMBLY RETARD with the hook. When installing, do not touch the roller surface of the ROLL ASSEMBLY RETARD. Be sure to install the hook of the ROLL ASSEMBLY RETARD in the groove of the SHAFT RETARD.

  • Page 197: Rrp2.2 Rack Size (Pl 2.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP2.2 RACK SIZE (PL 2.1) Removal Remove the COVER CST (PL 2.1) from the 150 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. Release the hooks securing the GEAR PINION (PL 2.1) to the HOUSING TOP 150 (PL 2.1), and remove the PINION GEAR (Figure 1).
  • Page 198 Chapter 3 Removal and Replacement Procedures (RRPs) Remove the 2 screws (gold tapping, 8mm) from both right and left side, as well as the 6 screws (gold tapping, 8mm) on the back, that secure the HOUSING TOP 150 (PL 2.1) to the HOUSING BASE 150 (PL 2.1) (Figure 2).
  • Page 199 Chapter 3 Removal and Replacement Procedures (RRPs) LINK SW SIZE 1 150 LINK SW SIZE 2 150 LINK SW SIZE 3 150 RACK SIZE (PL2.1.32) JG3009AA GUIDE END 150 JG3200AB Figure 3. Size Rack Replacement Put the hook of the tip of the RACK SIZE (PL 2.1) into the groove of the HOUSING EXTENSION 150, and turn it in the opposite direction of the arrow.
  • Page 200 Chapter 3 Removal and Replacement Procedures (RRPs) After tightening the screws, move the GUIDE ASSEMBLY END 150 back and forth, and make sure that the LINK SW SIZEs operate smoothly. While pressing down the hook of the HOUSING TOP 150, install the GUIDE ASSEMBLY SD R150 (PL 2.1) to the HOUSING TOP 150.

  • Page 201: Rrp2.3 Gear Sector (Pl 2.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP2.3 GEAR SECTOR (PL 2.1) Removal Remove the COVER CST (PL 2.1) from the 150 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. Release the hooks securing the GEAR PINION (PL 2.1) to the HOUSING TOP 150 (PL 2.1), and remove the GEAR PINION.
  • Page 202 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the GEAR SECTOR to the HOUSING EXTENSION 150 (PL 2.1) (Figure 1). Secure the GEAR SECTOR using the screw (black with flange, 8mm). Install the RACK SIZE 150 (PL 2.1) (RRP2.2). Install the COVER EXTENSION (PL 2.1) to the HOUSING EXTENSION 150 using the 4 screws (gold tapping, 6mm).
  • Page 203 Chapter 3 Removal and Replacement Procedures (RRPs) 10) With completely opened GUIDE ASSEMBLY SD L150 (PL 2.1) and GUIDE ASSEMBLY SD R150 (PL 2.1), install the GEAR PINION (PL 2.1) to the HOUSING TOP 150. When installing the GEAR PINION, make sure the GUIDE ASSEMBLY SD R150 and GUIDE ASSEMBLY SD L150 are completely opened.

  • Page 204: Rrp2.4 Guide Assembly End 150 (Pl 2.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP2.4 GUIDE ASSEMBLY END 150 (PL 2.1) Removal Remove the COVER CST (PL 2.1) from the 150 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. Release the hooks securing the GEAR PINION (PL 2.1) to the HOUSING TOP 150 (PL 2.1), and remove the GEAR PINION.
  • Page 205 Chapter 3 Removal and Replacement Procedures (RRPs) 11) Remove the RACK SIZE (PL 2.1) (RRP2.2). 12) Remove the GEAR SECTOR (PL 2.1) (RRP2.3). 13) Release the hooks securing the GUIDE ASSY END 150 to the HOUSING EXTENSION 150. Be careful handling the hooks of the GUIDE ASSY END150. They are fragile and could break if given excessive force.
  • Page 206 Chapter 3 Removal and Replacement Procedures (RRPs) When installing the GEAR PINION, make sure the GUIDE ASSEMBLY SD R150 and GUIDE ASSEMBLY SD L150 are completely opened. If not, the side register may be mis- aligned. 11) Install the COVER CST (PL 2.1) to the 150 PAPER CASSETTE. 3 - 22...

  • Page 207: Rrp2.5 Plate Assembly Btm (Pl 2.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP2.5 PLATE ASSEMBLY BTM (PL 2.1) Removal Remove the COVER CST (PL 2.1) from the 150 PAPER CASSETTE (Figure 1). Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go (Figure 1).
  • Page 208 Chapter 3 Removal and Replacement Procedures (RRPs) In the following steps, the GEAR PB L (PL 2.1), GEAR BTM DMP ONEWAY (PL 2.1) and GEAR BTM LOCK ONEWAY (PL 2.1) will be detached. Be careful not to lose these gears (Figure 2).
  • Page 209 Chapter 3 Removal and Replacement Procedures (RRPs) When installing the PLATE ASSEMBLY BTM, be sure to put 2 SPRING BTM UP 150s (PL 2.1) into the bosses on the back of the PLATE ASSEMBLY BTM (NOTE 1) (Figure 2). Be sure to put 2 claws on the top of the PLATE ASSEMBLY BTM under the hooks on the HOUSING TOP 150.(NOTE 2) (Figure 2).

  • Page 210: Rrp2.6 Gear Lever Lock (Pl 2.1.25), Lever Btm Lock (Pl 2.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP2.6 GEAR LEVER LOCK (PL 2.1.25), LEVER BTM LOCK (PL 2.1) Removal Remove the COVER CST (PL 2.1) from the 150 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. While pressing down the lock of the STOPPER GEAR (PL 2.1), release the lock of LEVER BTM LOCK (PL 2.1) to lift up the PLATE ASSEMBLY BTM (PL 2.1) (Figure 1).
  • Page 211 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement When installing, be sure to lift up the PLATE ASSEMBLY BTM. If the PLATE ASSEMBLY BTM is inclined, a paper skew or jam may occur. Check after the installation is completed. Put the SPRING STOPPER GEAR (PL 2.1) into the STOPPER GEAR (PL 2.1), and secure the STOPPER GEAR to the HOUSING BASE 150 (PL 2.1) using the 2 screws (gold tapping, 6mm).

  • Page 212: Rrp2.7 Handle Extension 150 (Pl 2.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP2.7 HANDLE EXTENSION 150 (PL 2.1) Removal Remove the COVER CST (PL2.1.1) from the 150 PAPER CASSETTE. Remove the 2 screws on the back side of the HANDLE EXTENSION 150 (PL 2.1) (Figure 1). Release the 5 hooks at the upper side and the 2 hooks at the lower side of the HANDLE EXTEN- SION 150 (PL 2.1), then, remove the HANDLE EXTENSION 150 (PL 2.1) from the HOUSING EXTENSION 150 (PL 2.1) (Figure 1).

  • Page 213: Rrp3. 550 Paper Cassette

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3. 550 PAPER CASSETTE 3 - 29...

  • Page 214: Rrp3.1 Roll Assembly Retard (Pl 3.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.1 ROLL ASSEMBLY RETARD (PL 3.1) Removal Pull out the 550 PAPER CASSETTE from the printer. Release the hooks securing the HOLDER RETARD (PL 3.1) to the 550 PAPER CASSETTE using a screwdriver (Figure 1). Lift up the HOLDER RETARD in the direction of the arrow, and remove it (Figure 1).
  • Page 215 Chapter 3 Removal and Replacement Procedures (RRPs) It is also possible to remove the ROLL ASSEMBLY RETARD by pushing the HOLDER RETARD down (Figure 2). G3209AA Figure 2. Holder Retard Replacement Install the ROLL ASSEMBLY RETARD to the SHAFT RETARD (PL 12.3), and secure the ROLL ASSEMBLY RETARD with the hook.

  • Page 216: Rrp3.2 Rack Size (Pl 4.1.40)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.2 RACK SIZE (PL 4.1.40) Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. Release the hooks securing the GEAR PINION (PL 12.3) to the HOUSING TOP 550 (PL 12.3), and remove the GEAR PINION (Figure 1).
  • Page 217 Chapter 3 Removal and Replacement Procedures (RRPs) Remove the 2 screws (gold tapping, 8mm) from both right and left sides, as well as the 6 screws (gold tapping, 8mm) on the back (Figure 2), that secure the HOUSING TOP 550 to the HOUSING BASE 550 (PL 3.1).
  • Page 218 Chapter 3 Removal and Replacement Procedures (RRPs) NOTE 1 RACK SIZE (PL4.1.40) (PL 3.1.40) JG3021AB GUIDE ASSY END 550 Figure 3. Size Rack Replacement Put the hook on top of the RACK SIZE into the groove of the HOUSING EXTENSION 550 (PL 3.1), and turn it in the opposite direction of the arrow.
  • Page 219 Chapter 3 Removal and Replacement Procedures (RRPs) LINK SW SIZE 2-550 (PL3.1.46) (PL4.1.46) LINK SW SIZE 1-550 LINK SW SIZE 3-550 PL 3.1 PL 3.1 (PL4.1.45) (PL4.1.47) JG3210AA Figure 4. Link Size Switches After tightening the screws, move the GUIDE ASSEMBLY END 550 back and forth, and make sure that the LINK SW SIZEs operate smoothly.

  • Page 220: Rrp3.3 Gear Sector (Pl 3.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.3 GEAR SECTOR (PL 3.1) Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. Release the hooks securing the GEAR PINION (PL 12.3) to the HOUSING TOP 550 (PL 12.3), and remove the GEAR PINION.
  • Page 221 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the GEAR SECTOR to the HOUSING EXTENSION 550 (PL 3.1). Secure the GEAR SECTOR using the screw (black with flange, 8mm). Install the RACK SIZE (PL 3.1) (RRP3.2). Install the COVER EXTENSION (PL 3.1) to the HOUSING EXTENSION 550 using the 4 screws (gold tapping, 6mm).
  • Page 222 Chapter 3 Removal and Replacement Procedures (RRPs) While pressing down the hook of the HOUSING TOP 550, install the GUIDE ASSEMBLY SD R550 (PL 12.3) to the HOUSING TOP 550. After installing, make sure that the 3 claws of the GUIDE ASSEMBLY SD R550 sit cor- rectly in the grooves of the HOUSING TOP 550.

  • Page 223: Rrp3.4 Guide Assembly End 550 (Pl 3.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.4 GUIDE ASSEMBLY END 550 (PL 3.1) Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. Release the hooks securing the GEAR PINION (PL 12.3) to the HOUSING TOP 550 (PL 12.3), and remove the GEAR PINION.
  • Page 224 Chapter 3 Removal and Replacement Procedures (RRPs) Release the 4 hooks of the HOUSING TOP 550, and remove the HOUSING TOP 550 together with the HOUSING EXTENSION 550 (PL 3.1) from the HOUSING BASE 550. Remove the 4 screws (gold tapping, 6mm) securing the COVER EXTENSION (PL 3.1) to the HOUSING EXTENSION 550.
  • Page 225 Chapter 3 Removal and Replacement Procedures (RRPs) Install the HOUSING EXTENSION 550 and HOUSING TOP 550 (PL 12.3) to the HOUSING BASE 550 while pushing the LINK SW SIZE1-550 (PL 3.1), LINK SW SIZE2-550 (PL 3.1) and LINK SW SIZE3-550 (PL 3.1) of the HOUSING BASE 550 outward (RRP3.2). Be sure to put 2 claws on the top of the PLATE ASSEMBLY BTM under the hooks on the HOUSING TOP 550.

  • Page 226: Rrp3.5 Plate Assembly Btm

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.5 PLATE ASSEMBLY BTM Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. Release the hooks securing the GEAR PINION (PL 12.3) to the HOUSING TOP 550 (PL 12.3), and remove the GEAR PINION (Figure 1).
  • Page 227 Chapter 3 Removal and Replacement Procedures (RRPs) Release the hook of the GEAR PB R (PL 3.1), and remove the GEAR PB R from the SHAFT PB (PL 3.1) (Figure 2). It is hard to remove GEAR PB R. When removing it, be careful not to break it (Figure 2). Disengage the GEAR PB L from the PLATE GEAR LOCK 550 while bending the HOUSING BASE 550 in the direction of the arrows.
  • Page 228 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Insert the SHAFT PB (PL 3.1) into the PLATE ASSEMBLY BTM, and insert the GEAR BTM DMP ONEWAY, GEAR PB L and GEAR BTM LOCK ONEWAY to the SHAFT PB. While disengaging the GEAR PB L, install the assembled PLATE ASSEMBLY BTM to the HOUS- ING TOP 550 (PL 12.3).
  • Page 229 Chapter 3 Removal and Replacement Procedures (RRPs) After installing, make sure that the 3 claws of the GUIDE ASSEMBLY SD R550 sit cor- rectly in the grooves of the HOUSING TOP 550 (NOTE 3) (Figure 1). While pressing down the hook of the HOUSING TOP 550, install the GUIDE ASSEMBLY SD L550 (PL 12.3) to the HOUSING TOP 550.

  • Page 230: Rrp3.6 Gear Lever Lock (Pl 3.1.26), Lever Btm Lock (Pl 3.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.6 GEAR LEVER LOCK (PL 3.1.26), LEVER BTM LOCK (PL 3.1) Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. While pressing down the lock of the STOPPER GEAR (PL 12.3), release the lock of LEVER BTM LOCK (PL 3.1) to lift up the PLATE ASSEMBLY BTM (PL 3.1).
  • Page 231 Chapter 3 Removal and Replacement Procedures (RRPs) When removing the STOPPER GEAR, be careful not to lose the SPRING STOPPER GEAR. Replacement When installing, be sure to lift up the PLATE ASSEMBLY BTM. If the PLATE ASSEMBLY BTM is inclined, a paper skew or jam may occur. Check after the installation is completed. Put the SPRING STOPPER GEAR (PL 3.1) into the STOPPER GEAR (PL 12.3), and secure the STOPPER GEAR to the HOUSING BASE 550 (PL 3.1) using the 2 screws (gold tapping, 6mm).
  • Page 232 Chapter 3 Removal and Replacement Procedures (RRPs) Be sure to install the hook of the GEAR PB R into the groove of the SHAFT PB. Install the PLATE GEAR LOCK 550 (PL 3.1) to the HOUSING BASE 550, and secure it with the hook.

  • Page 233: Rrp3.7 Handle Extension 550 (Pl 3.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.7 HANDLE EXTENSION 550 (PL 3.1) Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Remove the 2 screws on the back side of the HANDLE EXTENSION 550. Release the 5 hooks at the upper side and 2 hooks at the lower side of the HANDLE EXTENSION 550, then, remove the HANDLE EXTENSION 550 from the HOUSING EXTENSION 550 (PL 3.1) (Figure 1).

  • Page 234: Rrp3.8 Guide Indicator 3 (Pl 3.1.36)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.8 GUIDE INDICATOR 3 (PL 3.1.36) Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Remove the HANDLE EXTENSION 550 (PL 3.1) (RRP3.7). When removing the HANDLE EXTENSION 550, the LOW INDICATOR (PL 3.1) and LOW IND FRONT (PL 3.1) will be detached.

  • Page 235: Rrp3.9 Guide Indicator 2 (Pl 3.1.35)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.9 GUIDE INDICATOR 2 (PL 3.1.35) Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Release the lock of the LOCK EXTENSION, and pull out the cassette extension as far as it will go. Release the hooks securing the GEAR PINION (PL 12.3) to the HOUSING TOP 550 (PL 12.3), and remove the GEAR PINION (Figure 1).
  • Page 236 Chapter 3 Removal and Replacement Procedures (RRPs) Figure 2. Lever BTM Lock 11) Remove the GUIDE INDICATOR 1 (PL 3.1) from the hooks of the HOUSING TOP 550, and remove the SUPPORT GUIDE IND together with the GUIDE INDICATOR 1 and GUIDE INDICA- TOR 2 from the HOUSING TOP 550.
  • Page 237 Chapter 3 Removal and Replacement Procedures (RRPs) Install the SUPPORT GUIDE IND together with the GUIDE INDICATOR 1 and GUIDE INDICA- TOR 2 to the HOUSING TOP 550 (PL 12.3), and secure the GUIDE INDICATOR 1 using the 2 hooks of the HOUSING TOP 550. Slide the SUPPORT GUIDE IND (PL 3.1) along the groove of the HOUSING EXTENSION 550 to install, and assemble the HOUSING TOP 550 and HOUSING EXTENSION 550 into 1 unit.
  • Page 238 Chapter 3 Removal and Replacement Procedures (RRPs) When installing the GEAR PINION, make sure the GUIDE ASSEMBLY SD R550 and GUIDE ASSEMBLY SD L550 are completely opened. If not, the side register may be mis- aligned. 12) Install the COVER CST (PL 12.3) to the 550 PAPER CASSETTE. After assembling, make sure that the LOW IND FRONT moves up-and-down in conjunc- tion with the up-and-down movement of the PLATE ASSEMBLY BTM 3 - 54...

  • Page 239: Rrp3.10 Low Ind Front (Pl 3.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP3.10 LOW IND FRONT (PL 3.1) Removal Remove the COVER CST (PL 12.3) from the 550 PAPER CASSETTE. Remove the HANDLE EXTENSION 550 (PL 3.1) (RRP3.7). Turn the LOW INDICATOR (PL 3.1) by 90 degrees, and remove it together with the LOW IND FRONT from the HANDLE EXTENSION 550 (Figure 1).

  • Page 240: Rrp4. 150 Paper Feeder

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4. 150 paper Feeder 3 - 56...

  • Page 241: Rrp4.1 150 Feeder Assembly (Pl)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.1 150 FEEDER ASSEMBLY (PL 4.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the CHUTE TRANSFER (PL 6.1) together with the BTR ASSEMBLY (RRP6.9). Disconnect the connector (P/J245) of the HARNESS ASSEMBLY TRAY 1 (PL 4.1) from the HAR- NESS ASSEMBLY CHUTE (PL 9.1) (Figure 1).
  • Page 242 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement While lifting up the 150 FEEDER ASSEMBLY in the direction of the arrow (A), and install it to the printer. Then, put the bosses at right and left of the 150 FEEDER ASSEMBLY into the holes of the printer.

  • Page 243: Rrp4.2 Roll Assembly Nudger (Pl 4.1), Roll Assembly Feed (Pl 4.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.2 ROLL ASSEMBLY NUDGER (PL 4.1), ROLL ASSEMBLY FEED (PL 4.1) Removal Open the COVER OPEN (PL 1.1). Release the hook securing the ROLL ASSEMBLY NUDGER, and pull the ROLL ASSEMBLY NUDGER out from the SHAFT NUDGER (PL 4.1) (Figure 1). Release the hook securing the ROLL ASSEMBLY FEED, and pull the ROLL ASSEMBLY FEED out from the SHAFT FEED (PL 4.1) (Figure 1).

  • Page 244: Rrp4.3 Clutch Oneway Nudger (Pl 4.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.3 CLUTCH ONEWAY NUDGER (PL 4.1) Removal Open the COVER OPEN (PL 1.1). Remove the ROLL ASSEMBLY FEED (PL 4.1) (RRP4.2). When removing, do not touch the roller surface of the ROLL ASSEMBLY FEED. Pull out the CLUTCH ONEWAY FEED (PL 4.1) from the SHAFT FEED (PL 4.1) (Figure 1).

  • Page 245: Rrp4.4 Gear Nudger (Pl 4.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.4 GEAR NUDGER (PL 4.1) Removal Open the COVER OPEN (PL 1.1). While pressing down the boss of the HOLDER LEFT (PL 4.1) at the back of the 150 FEEDER ASSEMBLY, shift the HOLDER LEFT in the direction of the arrow to remove the 3 hooks (Figure Remove the HOLDER LEFT from the SUPPORT NUDGER (PL 12.3).
  • Page 246 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the GEAR NUDGER to the SHAFT NUDGER (PL 4.1), and secure the GEAR NUDGER with the hook. When installing, do not touch the roller surface of the ROLL ASSEMBLY NUDGER and GEAR NUDGER.

  • Page 247: Rrp4.5 Roll Regi Rubber (Pl 4.1.12)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.5 ROLL REGI RUBBER (PL 4.1.12) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER REAR (PL 1.1) (RRP1.1) Remove the CHUTE TRANSFER (PL 6.1) together with the BTR ASSEMBLY (RRP6.9). Remove the 150 FEEDER ASSEMBLY (PL 4.1) (RRP4.1).
  • Page 248 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Shift the ROLL REGI RUBBER in the opposite direction of the arrow, and install it to the 150 FEEDER ASSEMBLY. When installing, do not touch the roller surface of the ROLL REGI RUBBER. Install the ROLL REGI RUBBER so that its D-cut is positioned at the BEARING REGI RIGHT side.

  • Page 249: Rrp4.6 Clutch Assembly Ph (Pl 4.1.21), Clutch Regi (Pl 4.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.6 CLUTCH ASSEMBLY PH (PL 4.1.21), CLUTCH REGI (PL 4.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the CHUTE TRANSFER (PL 6.1) together with the BTR ASSEMBLY (RRP6.9).
  • Page 250 Chapter 3 Removal and Replacement Procedures (RRPs) When installing, make sure that the notch of the CLUTCH ASSEMBLY PH is combined with the boss of the CHUTE REGI. The harness of the CLUTCH ASY PH should be routed around the portion of the CHUTE REGI as shown (Figure 1).

  • Page 251: Rrp4.7 Sensor Regi (Pl 4.1.30)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.7 SENSOR REGI (PL 4.1.30) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Release the hooks securing the COVER SENSOR (PL 4.1), and remove the COVER SENSOR from the CHUTE ASSEMBLY REGI (Figure 1).

  • Page 252: Rrp4.8 Sensor No Paper (Pl 4.1.38)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.8 SENSOR NO PAPER (PL 4.1.38) Removal Open the COVER OPEN (PL 1.1). Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Lift up the 150 FEEDER ASSEMBLY a little, insert a screwdriver through the space left by the FUSER ASSEMBLY, and remove the screw (gold, 8mm) securing the HOLDER NO PAPER SEN- SOR (PL 4.1) (Figure 1).
  • Page 253 Chapter 3 Removal and Replacement Procedures (RRPs) Put the wires of the HARNESS ASSEMBLY TRAY 1 into the notch of the HOLDER NO PAPER SENSOR as shown (Figure 1). Insert a screwdriver through the space left by the FUSER ASSEMBLY, and install the HOLDER NO PAPER SENSOR to the 150 FEEDER ASSEMBLY using the screw (gold, 8mm).

  • Page 254: Rrp4.9 Sensor Toner (Pl 4.1.46)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.9 SENSOR TONER (PL 4.1.46) Removal Open the COVER OPEN (PL 1.1). Disconnect the connector (P/J220) of the SENSOR TONER from the HARNESS ASSEMBLY TONER 1 (PL 4.1) (Figure 1). Release the holdings of the harness of the SENSOR TONER from 2 clamps. Release 2 hooks of the HOLDER-D (PL 4.1), and remove the SENSOR TONER from the HOLDER-D by turning it in the direction of the arrow (Figure 1).

  • Page 255: Rrp4.10 Actuator No Paper (Pl 4.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP4.10 ACTUATOR NO PAPER (PL 4.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Place the printer down on its left side. Be careful not to scratch the cover, and do not drop the printer. Open the COVER OPEN (PL 1.1).
  • Page 256 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the HOLDER LEFT (PL 4.1) and ACTUATOR NO PAPER (PL 4.1) to the SUPPORT NUDGER (PL 12.2). Be sure to install the shafts on both ends of the ACTUATOR NO PAPER into the HOLDER LEFT and SUPPORT NUDGER.

  • Page 257: Rrp5. 550 Paper Feeder

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5. 550 Paper Feeder 3 - 73...

  • Page 258: Rrp5.1 550 Feeder Assembly (Pl)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.1 550 FEEDER ASSEMBLY (PL 5.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the CHUTE TRANSFER (PL 6.1) together with the BTR ASSEMBLY (RRP6.9). Remove the 150 FEEDER ASSEMBLY (PL 4.1) (RRP4.1).
  • Page 259 Chapter 3 Removal and Replacement Procedures (RRPs) Install the 550 FEEDER ASSEMBLY to the frame. Secure the CHUTE OUT (PL 5.1) to the frame using the 2 screws (silver with flange, and spring washer 8mm) (Figure 1). One of the screws that secure the CHUTE OUT to the frame is tightened together with the SPRING EARTH (PL 5.1.31).

  • Page 260: Rrp5.2 Roll Assembly Nudger (Pl 5.1), Roll Assembly Feed (Pl 5.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.2 ROLL ASSEMBLY NUDGER (PL 5.1), ROLL ASSEMBLY FEED (PL 5.1) Removal Open the COVER OPEN (PL 1.1) so that the removing operation can be checked visually. Remove Tray 1 and Tray 2 Paper Cassettes. Lift up the 150 FEEDER ASSEMBLY (PL 4.1).
  • Page 261 Chapter 3 Removal and Replacement Procedures (RRPs) When installing, do not touch the roller surface of the ROLL ASSEMBLY NUDGER and ROLL ASSEMBLY FEED. Install the ROLL ASSEMBLY NUDGER to the SHAFT NUDGER (PL 5.1), and secure the ROLL ASSEMBLY NUDGER with the hook. Be sure to install the hook of the ROLL ASSEMBLY NUDGER into the groove of the SHAFT NUDGER.

  • Page 262: Rrp5.3 Clutch Oneway Nudger (Pl 5.1.27)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.3 CLUTCH ONEWAY NUDGER (PL 5.1.27) Removal Open the COVER OPEN (PL 1.1) so that the removing operation can be checked visually. Remove the Paper Cassettes of the Tray 1 and Tray 2. Lift up the 150 FEEDER ASSEMBLY (PL 4.1).
  • Page 263 Chapter 3 Removal and Replacement Procedures (RRPs) Be sure to install the hook of the ROLL ASSEMBLY FEED into the groove of the SHAFT FEED. When installing, do not touch the roller surface of the ROLL ASSEMBLY FEED. Press the 150 FEEDER ASSEMBLY (PL 4.1) down so that it returns to the original position. Close the COVER OPEN (PL 1.1).

  • Page 264: Rrp5.4 Gear Nudger (Pl 5.1.18)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.4 GEAR NUDGER (PL 5.1.18) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Place the printer down on its left side. Be careful not to scratch the cover, and do not drop the printer. Open the COVER OPEN (PL 1.1).
  • Page 265 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the GEAR NUDGER to the SHAFT NUDGER (PL 5.1), and secure it with the hook. When installing, do not touch the roller surface of the GEAR NUDGER. Be sure to install the hook of the GEAR NUDGER into the groove of the SHAFT NUDGER.

  • Page 266: Rrp5.5 Clutch Assembly Ph (Pl 5.1.20)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.5 CLUTCH ASSEMBLY PH (PL 5.1.20) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the CHUTE TRANSFER (PL 6.1) together with the BTR ASSEMBLY (RRP6.9). Remove the 150 FEEDER ASSEMBLY (PL 4.1) (RRP4.1).
  • Page 267 Chapter 3 Removal and Replacement Procedures (RRPs) Be careful of the arranging of the harness of the CLUTCH ASSEMBLY PH. Install the PLATE TIE (PL 5.1) to the CHUTE OUT (PL 5.1) using the 6 screws (gold tapping, 8mm) (Figure 1). Install the 550 FEEDER ASSEMBLY (PL 5.1) (RRP5.1).

  • Page 268: Rrp5.6 Sensor No Paper (Pl 5.1.38)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.6 SENSOR NO PAPER (PL 5.1.38) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the CHUTE TRANSFER (PL 6.1) together with the BTR ASSEMBLY (RRP6.9). Remove the 150 FEEDER ASSEMBLY (PL 4.1) (RRP4.1).
  • Page 269 Chapter 3 Removal and Replacement Procedures (RRPs) Install the CHUTE TRANSFER (PL 6.1) (RRP6.9). Do not tighten the screw to the left side hole of the CHUTE TRANSFER. Install the COVER REAR (PL 1.1) (RRP1.1). There are 2 kinds of screws, make sure they are installed correctly. Install the FUSER ASSEMBLY (PL 6.1) (RRP6.8).

  • Page 270: Rrp5.7 Guide Tray Right (Pl 5.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.7 GUIDE TRAY RIGHT (PL 5.1) Removal Remove the EP CARTRIDGE and Paper Cassettes. Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3).
  • Page 271 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Shift the GUIDE TRAY RIGHT in the opposite direction of the arrow to install it to the frame, and secure it using the screw (silver, 6mm). When installing the GUIDE TRAY RIGHT, make sure the installing position of the PLATE CST LOCK (PL 5.1) is in the position shown (Figure 1) (NOTE).

  • Page 272: Rrp5.8 Guide Tray Left (Pl 7.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.8 GUIDE TRAY LEFT (PL 7.1) Removal Remove the EP CARTRIDGE and Paper Cassettes. Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3).
  • Page 273 Chapter 3 Removal and Replacement Procedures (RRPs) Connect the connector (P/J1821) of the GUIDE TRAY LEFT to the HARNESS ASSEMBLY LVPS (PL 9.1) (Figure 1). Return the printer to the normal use state. Install the COVER FRONT (PL 1.1) (RRP1.5). Install the COVER TOP (PL 1.1) (RRP1.4).

  • Page 274: Rrp5.9 Sensor Low Paper (Pl 5.1.4)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.9 SENSOR LOW PAPER (PL 5.1.4) Removal Remove the EP CARTRIDGE and Paper Cassettes. Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Place the printer down on its right side. Be careful not to scratch the cover, and do not drop the printer.

  • Page 275: Rrp5.10 Actuator No Paper (Pl 5.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP5.10 ACTUATOR NO PAPER (PL 5.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Place the printer down on its left side. Be careful not to scratch the cover, and do not drop the printer. Open the COVER OPEN (PL 1.1).
  • Page 276 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the HOLDER LEFT (PL 5.1) and ACTUATOR NO PAPER to the SUPPORT NUDGER (PL 5.1). Be sure to install the shafts on both ends of the ACTUATOR NO PAPER into the HOLDER LEFT and SUPPORT NUDGER.

  • Page 277: Rrp6. Xerographics

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6. Xerographics 3 - 93...

  • Page 278: Rrp6.1 Ros Assembly (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.1 ROS ASSEMBLY (PL 6.1) When performing the ROS ASSEMBLY removal and/or installation, be sure to perform the operation on a level and smooth work surface. If the operation is performed on a rough and/or inclined surface, the ROS ASSEMBLY will be out of alignment.
  • Page 279 Chapter 3 Removal and Replacement Procedures (RRPs) The printed circuit board on the ROS ASSEMBLY is fragile, therefore, be sure to hold it when disconnecting the connectors (Figure 1). 16) Remove the 4 screws (black with flange, 8mm) securing the ROS ASSEMBLY to the frame. Be careful not to drop or strike the ROS Assembly with any tools or other objects.

  • Page 280: Rrp6.2 Duct Front (Pl 6.1), Fan Sub (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.2 DUCT FRONT (PL 6.1), FAN SUB (PL 6.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).
  • Page 281 Chapter 3 Removal and Replacement Procedures (RRPs) Connect the connector (P/J270) of the FAN SUB to the HARNESS ASSEMBLY LVPS (PL 9.1). Install the COVER FRONT (PL 1.1) (RRP1.5). Install the COVER TOP (PL 1.1) (RRP1.4). Install the 500 EXIT ASSEMBLY (PL 7.1) (RRP7.2). Install the COVER EXIT 500 (PL 1.1) (RRP7.1).

  • Page 282: Rrp6.3 Shield Plate Ros (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.3 SHIELD PLATE ROS (PL 6.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).
  • Page 283 Chapter 3 Removal and Replacement Procedures (RRPs) Install the COVER EXIT 500 (PL 1.1) (RRP7.1). 10) Install the COVER RIGHT (PL 1.1) (RRP1.2). 11) Install the COVER LEFT (PL 1.1) (RRP1.3). 12) Install the COVER REAR (PL 1.1) (RRP1.1). There are 2 kinds of screws, make sure they are installed correctly. 13) Install the COVER REAR 500 (PL 7.1) (RRP7.9).

  • Page 284: Rrp6.4 Guide Cru Left (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.4 GUIDE CRU LEFT (PL 6.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).
  • Page 285 Chapter 3 Removal and Replacement Procedures (RRPs) 19) Disconnect the connector (P/J141) of the INTERLOCK S/W 5V from the HARNESS ASSEMBLY LVPS (PL 9.1) (Figure 1). 20) Disconnect the connector (P/J45) of the INTERLOCK S/W 24V from the LVPS (PL 9.1.5) (Figure 21) Disconnect the connectors (P/J46 and P/J47) of the HARNESS ASSEMBLY FUSER from the LVPS (Figure 1).
  • Page 286 Chapter 3 Removal and Replacement Procedures (RRPs) There are 2 kinds of screws, make sure they are installed correctly. 23) Install the COVER REAR 500 (PL 7.1) (RRP7.9). 3 - 102...

  • Page 287: Rrp6.5 Interlock S/W 24V, Interlock S/W 5V (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.5 INTERLOCK S/W 24V, INTERLOCK S/W 5V (PL 6.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2).
  • Page 288 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the INTERLOCK S/W 24V and INTERLOCK S/W 5V to the HOLDER I/L SW1 (PL 6.1) and secure them with hooks (Figure 1). Install the HOLDER I/L SW2 (PL 6.1) to the GUIDE CRU LEFT (PL 6.1) using the 2 screws (gold tapping, 6mm) (Figure 1).

  • Page 289: Rrp6.6 Lever Guide (Pl 6.1.14)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.6 LEVER GUIDE (PL 6.1.14) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2).
  • Page 290 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the LEVER GUIDE to the GUIDE CRU LEFT (PL 6.1) (Figure 1). Install the GUIDE SL (PL 6.1) to the GUIDE CRU LEFT. Install the SPACER SS (PL 6.1) to the GUIDE CRU LEFT. Install the SPRING SL (PL 6.1) to the GUIDE CRU LEFT.

  • Page 291: Rrp6.7 Harness Assembly Fuser (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.7 HARNESS ASSEMBLY FUSER (PL 6.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2).
  • Page 292 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the COVER GUIDE CRU (PL 6.1) together with the HARNESS ASSEMBLY FUSER to the GUIDE CRU LEFT (PL 6.1) (Figure 1). Install the GUIDE CRU LEFT (PL 6.1) (RRP6.4). When installing, make sure that the LEVER LINK (PL 6.1.29) is attached to the GUIDE CRU LEFT.

  • Page 293: Rrp6.8 Fuser Assembly (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.8 FUSER ASSEMBLY (PL 6.1) Removal Before performing the following procedures, make sure that the FUSER ASSEMBLY has cooled. Open the COVER REAR 500 (PL 7.1). Push down the LEVER FUSER LH (PL 6.1) and LEVER FUSER RH (PL 6.1) in the direction of the arrow to release the lock of the FUSER ASSEMBLY (Figure 1).

  • Page 294: Rrp6.9 Btr Assembly (Pl 6.1)]

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.9 BTR ASSEMBLY (PL 6.1)] Removal Open the COVER OPEN (PL 1.1). Pinch the hooks of both ends of the BTR ASSEMBLY, and remove it from the printer (Figure 1). Use extreme care in handling of the BTR ASSEMBLY, do not touch or damage the BTR surface.

  • Page 295: Rrp6.10 Chute Transfer (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.10 CHUTE TRANSFER (PL 6.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the BTR ASSEMBLY (PL 6.1) (RRP6.9). Release the hook of the CHUTE TRANSFER (Figure 1).

  • Page 296: Rrp6.11 Pwba Assembly Ant (Pl 6.1.23)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.11 PWBA ASSEMBLY ANT (PL 6.1.23) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2).
  • Page 297 Chapter 3 Removal and Replacement Procedures (RRPs) 11) Install the FUSER ASSEMBLY (PL 6.1) (RRP6.8). 12) Install the COVER REAR (PL 1.1) (RRP1.1). There are 2 kinds of screws, make sure they are installed correctly. 13) Install the COVER REAR 500 (PL 7.1) (RRP7.9). 14) Install the BTR ASSEMBLY (PL 6.1) (RRP6.9).

  • Page 298: Rrp6.12 Guide Assembly Cru R (Pl 6.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.12 GUIDE ASSEMBLY CRU R (PL 6.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2).
  • Page 299 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the GUIDE ASSEMBLY CRU R. Put the harness of the GUIDE ASSEMBLY CRU R to the hole of the frame (Figure 1). Install the GUIDE ASSEMBLY CRU R to the frame using the 3 screws (silver, 6mm) (Figure 1). Connect the connector (P/J15) of the HARNESS ASSEMBLY ANT to the HVPS/MCU (PL 9.1.19).

  • Page 300: Rrp6.13 Lever Link (Pl 6.1.29), Link Gear 3(Pl 6.1.30)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP6.13 LEVER LINK (PL 6.1.29), LINK GEAR 3(PL 6.1.30) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2).
  • Page 301 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Assemble the LEVER LINK and LINK GEAR 3 as shown in the figure, and install them to the GUIDE CRU LEFT (PL 6.1) (Figure 1). Install the COVER GUIDE CRU (PL 6.1) and HARNESS ASSEMBLY FUSER (PL 6.1) to the GUIDE CRU LEFT (RRP6.7).

  • Page 302: Rrp7. 500 Paper Exit

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7. 500 Paper Exit 3 - 118...
  • Page 303 Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.1 COVER EXIT 500 ( PL 1.1 Removal Open the COVER REAR 500 (PL 7.1). Remove the 2 screws securing the COVER EXIT 500, and remove from the printer (Figure 1). Figure 1. 500 Exit Cover Replacement Install the COVER EXIT 500 to the printer, and secure it with the 2 screws (Figure 1).

  • Page 304: Rrp7.2 500 Exit Assembly

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.2 500 EXIT ASSEMBLY Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).
  • Page 305 Chapter 3 Removal and Replacement Procedures (RRPs) Install the COVER RIGHT (PL 1.1) (RRP1.2). Install the COVER LEFT (PL 1.1) (RRP1.3). Install the COVER REAR (PL 1.1) (RRP1.1). There are 2 kinds of screws, make sure they are installed correctly. 10) Install the COVER REAR 500 (PL 7.1) (RRP7.9).

  • Page 306: Rrp7.3 Chute Up Exit, Chute Low Exit (Pl 7.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.3 CHUTE UP EXIT, CHUTE LOW EXIT (PL 7.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).
  • Page 307 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Remove the LINK GATE OCT (PL 7.1) assembled into the removed CHUTE UP EXIT (Figure 1). Secure the CHUTE UP EXIT to the CHUTE LOW EXIT using the 2 screws (gold tapping, 8mm) (Figure 1).

  • Page 308: Rrp7.4 Roll Exit (Pl 7.1.)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.4 ROLL EXIT (PL 7.1.) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).
  • Page 309 Chapter 3 Removal and Replacement Procedures (RRPs) Install the COVER LEFT (PL 1.1) (RRP1.3). Install the COVER REAR (PL 1.1) (RRP1.1). There are 2 kinds of screws, make sure they are installed correctly. Install the COVER REAR 500 (PL 7.1) (RRP7.9). 3 - 125...

  • Page 310: Rrp7.5 Motor Assembly Exit (Pl 7.1.15)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.5 MOTOR ASSEMBLY EXIT (PL 7.1.15) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).

  • Page 311: Rrp7.6 Sensor Face Up Open (Pl 7.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.6 SENSOR FACE UP OPEN (PL 7.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).

  • Page 312: Rrp7.7 Sensor Full Stack (Pl 7.1.26)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.7 SENSOR FULL STACK (PL 7.1.26) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).

  • Page 313: Rrp7.8 Actuator Full Stack (Pl 7.1.10)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.8 ACTUATOR FULL STACK (PL 7.1.10) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).

  • Page 314: Rrp7.9 Cover Rear 500 (Pl 7.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.9 COVER REAR 500 (PL 7.1) Removal Pinch the lever to release the lock, and open the COVER REAR 500 (Figure 1). Move the STOPPER FSR in the arrow direction to remove (Figure 1). Release the hook of the right side boss of the COVER REAR 500, and shift the COVER REAR 500 in the direction of the arrow to remove from the printer (Figure 1).

  • Page 315: Rrp7.10 Fuser Roll (Fu) (Pl 7.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.10 FUSER ROLL (FU) (PL 7.2) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the 5 screws (gold tapping, 8mm) securing the CHUTE LOW FU (PL 7.2) to the COVER REAR 500 (Figure 1). Release the hooks of the COVER REAR 550, and remove the CHUTE LOW FU from the COVER REAR 500 (Figure 1).

  • Page 316: Rrp7.11 Lever Gate Holder,Spring Lever Gate, Lever Gate Fu (Pl 7.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.11 LEVER GATE HOLDER,SPRING LEVER GATE, LEVER GATE FU (PL 7.2) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the 5 screws (gold tapping, 6mm) securing the CHUTE LOW FU (PL 7.2) to the COVER REAR 550.

  • Page 317: Rrp7.12 Lever Latch Left, Spring Latch Fu, Lever Latch Right (Pl 7.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.12 LEVER LATCH LEFT, SPRING LATCH FU, LEVER LATCH RIGHT (PL 7.2) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the 5 screws (gold tapping, 6mm) securing the CHUTE LOW FU (PL 7.2) to the COVER REAR 550.
  • Page 318 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the SPRING LATCH (PL 7.2) (Figure 1). Install the LEVER LATCH LEFT (PL 7.2) to PIPE LATCH FU (PL 7.2), then install them to CHUTE LOW FU (PL 7.2) (Figure 1). Install the LEVER LATCH RIGHT (PL 7.2) to PIPE LATCH FU (PL 7.2) (Figure 1).

  • Page 319: Rrp7.13 Roll Pinch Fuser, Spring Pinch Fuser (Pl 7.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.13 ROLL PINCH FUSER, SPRING PINCH FUSER (PL 7.2) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the 5 screws (gold tapping, 6mm) securing the CHUTE LOW FU (PL 7.2) to the COVER REAR 550.

  • Page 320: Rrp7.14 Gate Fuser (Pl 7.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.14 GATE FUSER (PL 7.2) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the 5 screws (gold tapping, 6mm) securing the CHUTE LOW FU (PL 7.2) to the COVER REAR 550. Release the hooks of the COVER REAR 550, and remove the CHUTE LOW FU from the COVER REAR 550.

  • Page 321: Rrp7.15 Gate Oct Exit (Pl 7.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP7.15 GATE OCT EXIT (PL 7.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).

  • Page 322: Rrp8. Frame & Drive

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP8. Frame & Drive 3 - 138...

  • Page 323: Rrp8.1 Motor Cover (Pl 8.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP8.1 MOTOR COVER (PL 8.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1PL 1.1) (RRP1.2).
  • Page 324 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the MOTOR COVER to the frame using the screw (silver, 6mm) (Figure 1). Install the harness connector of MAIN MOTOR(Figure 1). Install the SHIELD PLATE ROS (PL 6.1) (RRP6.3). Install the ROS ASSEMBLY (PL 6.1) (RRP6.1). Be careful not to drop or strike the ROS Assembly with any tools or other objects.

  • Page 325: Rrp8.2 Main Motor (Pl 8.1.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP8.2 MAIN MOTOR (PL 8.1.2) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2).
  • Page 326 Chapter 3 Removal and Replacement Procedures (RRPs) 13) Install the COVER RIGHT (PL 1.1) (RRP1.2). 14) Install the COVER LEFT (PL 1.1) (RRP1.3). 15) Install the FUSER ASSEMBLY (PL 6.1) (RRP6.8). 16) Install the COVER REAR (PL 1.1) (RRP1.1). There are 2 kinds of screws, make sure they are installed correctly. 17) Install the COVER REAR 500 (PL 7.1) (RRP7.9).

  • Page 327: Rrp8.3 Gear Assembly Housing (Pl 8.1.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP8.3 GEAR ASSEMBLY HOUSING (PL 8.1.3) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Release the holding of the HARNESS ASSEMBLY INTERLOCK2 and HARNESS ASSEMBLY LVPS from the clamps on the GEAR ASSEMBLY HOUSING.
  • Page 328 Chapter 3 Removal and Replacement Procedures (RRPs) Install the COVER LEFT (PL 1.1) (RRP1.3). Install the COVER REAR (PL 1.1) (RRP1.1). There are 2 kinds of screws, make sure they are installed correctly. Install the COVER REAR 500 (PL 7.1) (RRP7.9). 3 - 144...

  • Page 329: Rrp8.4 Gear Assembly Plate (Pl 8.1.10), Gear 9 (Pl 8.1.9)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP8.4 GEAR ASSEMBLY PLATE (PL 8.1.10), GEAR 9 (PL 8.1.9) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the FUSER ASSEMBLY (PL 6.1) (RRP6.8). Remove the COVER LEFT (PL 1.1) (RRP1.3).
  • Page 330 Chapter 3 Removal and Replacement Procedures (RRPs) Install the boss which is under the connector of HARNESS ASSEMBLY FUSER to the frame (Fig- ure 1). Install the GEAR ASSEMBLY PLATE to the frame using the 4 screws (silver, 6mm) (Figure 1). When installing, if the GEAR or the SPRING that are not fixed to the GEAR ASSEMBLY PLATE come off, re-install them in the direction shown in the figure.

  • Page 331: Rrp9. Electrical

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9. Electrical 3 - 147...

  • Page 332: Rrp9.1 Shield Plate Lvps (Pl 9.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.1 SHIELD PLATE LVPS (PL 9.1) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).

  • Page 333: Rrp9.2 Pwba Exit Motor (Pl 9.1.4)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.2 PWBA EXIT MOTOR (PL 9.1.4) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Disconnect the harnesses from the connectors (P/J101, P/J102 and P/J103) on the PWBA EXIT MOTOR (Figure 1).

  • Page 334: Rrp9.3 Lvps (Pl 9.1.5)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.3 LVPS (PL 9.1.5) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).
  • Page 335 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the LVPS to the frame using the 5 screws (silver, 6mm) (Figure 1). Connect the harness connectors to the connectors (P/J40, P/J41, P/J42, P/J43, P/J44, P/J45, P/ J46, P/J47 and P/J48) on the LVPS (Figure 1). Connect the connector of the harness LVPS to the connector (P/J101) on the PWBA EXIT MOTOR (PL 12.1.4) (Figure 1).

  • Page 336: Rrp9.4 Power Switch (Pl 9.1.6), Harness Assembly Ac100V/Ac200V (Pl 9.1.8)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.4 POWER SWITCH (PL 9.1.6), HARNESS ASSEMBLY AC100V/AC200V (PL 9.1.8) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2).
  • Page 337 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the POWER SWITCH to the frame (Figure 1). Install the HARNESS ASSEMBLY AC100V/AC200V to the hole at the rear of the frame (Figure 1). Secure the ground terminal of the HARNESS ASSEMBLY AC100V/AC200V to the frame using the screw (silver with toothed washer, 6mm) (Figure 1).

  • Page 338: Rrp9.5 Interlock S/W Rear (Pl 9.1.7)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.5 INTERLOCK S/W REAR (PL 9.1.7) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Remove the COVER LEFT (PL 1.1) (RRP1.3). Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the COVER EXIT 500 (PL 1.1) (RRP7.1).
  • Page 339 Chapter 3 Removal and Replacement Procedures (RRPs) When installing, pull the CHUTE EXIT FUSER lever. Install the COVER EXIT 500 (PL 1.1) (RRP7.1). Install the COVER RIGHT (PL 1.1) (RRP1.2). 10) Install the COVER LEFT (PL 1.1) (RRP1.3). 11) Install the COVER REAR (PL 1.1) (RRP1.1). There are 2 kinds of screws, make sure they are installed correctly.

  • Page 340: Rrp9.6 Fan Main (Pl 1.1.14)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.6 FAN MAIN (PL 1.1.14) Removal Remove the COVER REAR 500 (PL 7.1) (RRP7.9). Remove the COVER REAR (PL 1.1) (RRP1.1). Release the harness clamps of the FAN MAIN (Figure 1). Remove the 2 screws (silver tapping,8mm) securing the FAM MAIN to the COVER REAR, and remove the FAN MAIN (Figure 1).

  • Page 341: Rrp9.7 Shield Assembly Ess (Pl 9.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.7 SHIELD ASSEMBLY ESS (PL 9.1) Removal Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the 12 screws (silver, 6mm) securing the SHIELD ASSEMBLY ESS to the frame (Figure Remove the SHIELD ASSEMBLY ESS. Figure 1.

  • Page 342: Rrp9.8 Shield Assembly Window (Pl 9.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.8 SHIELD ASSEMBLY WINDOW (PL 9.1) Removal Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the 2 screws securing the SHIELD ASSEMBLY WINDOW to the frame (Figure 1). Remove the SHIELD ASSEMBLY WINDOW. Figure 1.

  • Page 343: Rrp9.9 Shield Plate Hvps (Pl 12.1.18)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.9 SHIELD PLATE HVPS (PL 12.1.18) Removal Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the SHIELD ASSEMBLY ESS (PL 9.1) (RRP9.7). Remove the 10 screws (silver, 6mm) securing the SHIELD PLATE HVPS to the frame (Figure 1). Remove the SHIELD PLATE HVPS.

  • Page 344: Rrp9.10 Hvps/Mcu (Pl 9.1.19)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP9.10 HVPS/MCU (PL 9.1.19) Removal Remove the COVER RIGHT (PL 1.1) (RRP1.2). Remove the SHIELD ASSEMBLY ESS (PL 9.1) (RRP9.7). Remove the SHIELD PLATE HVPS (PL 9.1) (RRP9.9). Remove the screw (silver, 6mm) securing the BRACKET HANDLE R (PL 9.1.12) to the frame. Remove the BRACKET HANDLE R from the frame.
  • Page 345 Chapter 3 Removal and Replacement Procedures (RRPs) Replace the BRACKET SHIELD HVPS (PL 9.1) to the frame and secure with 3 screws (silver, 6mm) (Figure 1). Reconnect the harness connectors: (P/J10, P/J11, P/J13, P/J14, P/J15, P/J16, P/J17, P/J18, P/ J20, P/J22, P/J24, P/J26, P/J 27, P/J 28, P/J29, P/J30, and P/J31) on the HVPS/MCU (Figure 1). Replace the BRACKET HANDLE R on the frame.
  • Page 346 Chapter 3 Removal and Replacement Procedures (RRPs) Duplex Option Description of procedure [RRP X.Y “AAAAA”] attached at the front of the procedure shows that the name of parts to be assembled/disassembled is “AAAAA”. “(PL X.Y.Z)” attached at the end of parts name in the procedure shows that the parts corresponds to the plate (PL) “X.Y”, item “Z”...

  • Page 347: Rrp10.Duplex Option

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.Duplex Option RRP10.1 Duplex Option Removal When removing the Duplex Option, be careful not to drop the Duplex unit. Loosen the 2 SCREW THUMBs (PL 10.1) securing the Duplex Option to the printer. Push up the LEVER LATCH RIGHT (PL 10.1), and release the hooks of the LEVER LATC RIGHT and LEVER LATCH LEFT (PL 10.1).
  • Page 348 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement When installing the Duplex Option, be careful not to drop the unit. Insert the 2 bottom hooks of the HSG LOWER DUP (PL 10.1) into the holes of the printer. When installing, be sure to install the bottom hooks of the Duplex Option into the holes of the printer.

  • Page 349: Rrp10.2 Hsg Upper Assy (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.2 HSG UPPER ASSY (PL10.1) Removal Remove the 4 screws (gold tapping, 8mm) securing the HSG UPPER ASSY to the Option Duplex. Remove the HSG UPPER ASSY from the COVER HSG DUP (PL 10.1). HSG UPPER ASSY (PL21.1.1) COVER HSG DUP...

  • Page 350: Rrp10.3 Hsg Lower Dup (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.3 HSG LOWER DUP (PL10.1) Removal Remove the COVER LEFT (PL 10.1). (RRP10.9) Remove the COVER RIGHT (PL 10.1). (RRP10.10) Disconnect the connector (P/J50) of the HARNESS ASSY DUP (PL 10.1) from the PWBA DUPLEX (PL 10.1).
  • Page 351 Chapter 3 Removal and Replacement Procedures (RRPs) MOTOR DUPLEX HARNESS ASSY DUP SNR HARNESS ASSY HARNESS ASSY DUP DUP EARTH J23615AA Replacement Install the HSG LOWER DUP to the COVER HSG DUP (PL 10.1) using the 2 SCREW HINGEs (PL 10.1). Install the SPRING DAMPER (PL 10.1) to the COVER HSG DUP using the SCREW TAPPING (PL 10.1).

  • Page 352: Rrp10.4 Cover Top (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.4 COVER TOP (PL10.1) Removal Remove the COVER RIGHT (PL 10.1). (RRP10.10) Remove the screw (gold tapping, 8mm) securing the COVER TOP to the COVER HSG DUP (PL 10.1). Shift the COVER TOP in the direction of the arrow to release the 4 hooks, and remove the COVER TOP from the COVER HSG DUP.

  • Page 353: Rrp10.5 Pwba Duplex (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.5 PWBA DUPLEX (PL10.1) Removal Remove the COVER LEFT (PL 10.1). (RRP10.9) Remove the COVER RIGHT (PL 10.1). (RRP10.10) Remove the COVER TOP (PL 10.1). (RRP10.4) Disconnect the harness connectors from the connectors (P/J50, P/J51, P/J52, P/J53 and P/J 54) on the PWBA DUPLEX.
  • Page 354 Chapter 3 Removal and Replacement Procedures (RRPs) When installing, be sure to fit the positioning holes on the COVER TOP to the bosses on the COVER HSG DUP. Install the COVER RIGHT (PL 10.1). (RRP10.10) When installing, be sure to fit the positioning holes on the COVER RIGHT to the bosses on the COVER HSG DUP.

  • Page 355: Rrp10.6 Cover Rear (Pl10.1), Fan Duplex (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.6 COVER REAR (PL10.1), FAN DUPLEX (PL10.1) Removal Remove the COVER RIGHT (PL 10.1). (RRP10.10) Remove the COVER TOP (PL 10.1). (RRP10.4) Disconnect the harness connector from the connector (P/J54) on the PWBA DUPLEX (PL 10.1).
  • Page 356 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement 1) Install the FAN DUPLEX to the COVER REAR using the 2 screws (gold tapping, 22mm). When installing, be sure to install the FAN DUPLEX so that the label is facing outside. Install the COVER REAR to the COVER HSG DUP using the 4 screws Secure the harness of the FAN DUPLEX to the hook on the COVER HSG DUP.

  • Page 357: Rrp10.7 Sensor Dup (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.7 SENSOR DUP (PL10.1) Removal Remove the COVER RIGHT (PL 10.1). (RRP10.10) Remove the COVER TOP (PL 10.1). (RRP10.4) Release the hooks of the SENSOR DUP, and remove it from the COVER HSG DUP (PL 10.1). Disconnect the connector (P/J530) of the HARNESS ASSY DUP SNR (PL 10.1) form the SEN- SOR DUP.

  • Page 358: Rrp10.8 Roll Dup (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.8 ROLL DUP (PL10.1) Removal Remove the COVER LEFT (PL 10.1). (RRP10.9) Remove the COVER RIGHT (PL 10.1). (RRP10.10) Remove the HSG UPPER ASSY (PL 10.1). (RRP10.2) Remove the HSG LOWER DUP (PL 10.1). (RRP10.3) Remove the 2 screws (gold tapping, 8mm) and the SCREW TAPPING (PL 10.1) securing the COVER DAMPER (PL 10.1) to the COVER HSG DUP (PL 10.1).
  • Page 359 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Move 3 ROLL DUPs in the opposite direction of the arrow, and install them to the BEARING DUP (PL 10.1) on the GEAR ROLL (PL 10.1) side To avoid contamination when installing the ROLL DUP, do not touch the rubber rollers. Put the BEARING DUP into the ROLL DUP on the opposite side of the GEAR ROLL, and insert it into the hole on the COVER HSG DUP (PL12.1.18), and then secure it with the hook.

  • Page 360: Rrp10.9 Cover Left (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.9 COVER LEFT (PL10.1) Removal Remove the 2 screws (gold tapping, 8mm) securing the COVER LEFT. Remove the COVER LEFT from the COVER HSG DUP (PL 10.1). COVER HSG DUP (PL21.1.18) COVER LEFT (PL21.1.25) J23609AA Replacement...

  • Page 361: Rrp10.10 Cover Right (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.10 COVER RIGHT (PL10.1) Removal Remove the 2 screws (gold tapping, 8mm) securing the COVER RIGHT. 2) Remove the COVER RIGHT from the COVER HSG DUP (PL 10.1). COVER HSG DUP (PL21.1.18) COVER RIGHT (PL21.1.41) J23610AA Replacement...

  • Page 362: Rrp10.11 Motor Duplex (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.11 MOTOR DUPLEX (PL10.1) Removal Remove the COVER LEFT (PL 10.1). (RRP10.9) Remove the COVER TOP (PL 10.1). (RRP10.4) Remove the PWBA DUPLEX (PL 10.1). (RRP10.5) Remove the screw (silver, 6mm) securing the HARNESS ASSY DUP EARTH (PL 10.1) Remove the 3 screws (gold tapping, 8mm) securing the BRACKET MOTOR (PL 10.1) to the COVER HSG DUP (PL 10.1).
  • Page 363 Chapter 3 Removal and Replacement Procedures (RRPs) MOTOR DUPLEX (PL21.1.29) HARNESS ASSY DUP EARTH (PL21.1.28) COVER HSG DUP (PL21.1.18) BRACKET MOTOR (PL21.1.26) SPRING LATCH (PL21.1.15) J23616AA Replacement Install the MOTOR DUPLEX to the BRACKET MOTOR using the 2 screws (gold, 6mm). When installing the MOTOR DUPLEX, be careful in the installing direction.
  • Page 364 Chapter 3 Removal and Replacement Procedures (RRPs) When installing, be careful in the installing direction. Install the COVER TOP (PL 10.1). (RRP10.4) When installing, be sure to fit the positioning holes on the COVER TOP to the bosses on the COVER HSG DUP. Install the COVER LEFT (PL 10.1).

  • Page 365: Rrp10.12 Switch Duplex (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.12 SWITCH DUPLEX (PL10.1) Removal Remove the COVER LEFT (PL 10.1). (RRP10.9) Remove the COVER TOP (PL 10.1). (RRP10.4) Remove the PWBA DUPLEX (PL 10.1). (RRP10.5) Remove the screw (silver, 6mm) securing the HARNESS ASSY DUP EARTH (PL 10.1). Remove the 3 screws (gold tapping, 8mm) securing the BRACKET MOTOR (PL 10.1) to the COVER HSG DUP (PL 10.1).
  • Page 366 Chapter 3 Removal and Replacement Procedures (RRPs) Connect the connector of the HARNESS ASSY DUP COVER (PL 10.1) to the connector (P/ J52) of the SWITCH DUPLEX. Install the BRACKET MOTOR to the COVER HSG DUP (PL 10.1) using the 3 screws (gold tapping, 8mm).

  • Page 367: Rrp10.13 Cover Harness (Pl10.1), Harness Assy Dup (Pl10.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP10.13 COVER HARNESS (PL10.1), HARNESS ASSY DUP (PL10.1) Removal Remove the COVER LEFT (PL 10.1). (RRP10.9) Remove the COVER RIGHT (PL 10.1). (RRP10.10) Remove the HSG LOWER DUP (PL 10.1). (RRP10.3) Remove the screw (gold tapping, 8mm) securing the COVER HARNESS R. Release the 2 hooks of the COVER HARNESS, and remove it from the HSG LOWER DUP.

  • Page 368: Rrp11.Oct Option

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.OCT Option RRP11.1 OCT Option Removal When removing the Option OCT, be careful not to drop the assembly. Loosen the 2 SCREW THUNBs (PL 11.1) securing the OCT to the printer. Lift up the OCT, and disconnect the connector (P/J3070) of the HARNESS ASSY OCT2 (PL 11.1) from the printer, Release the 2 hooks at the bottom side of the COVER OCT (PL 11.1) from the printer, and remove the OCT.
  • Page 369 Chapter 3 Removal and Replacement Procedures (RRPs) REAR VIEW SCREW THUMB (PL23.1.5) Option OCT HOOK JG3801AA Replacement When installing the OCT, be careful not to drop the assembly. Insert the 2 hooks at the bottom side of the COVER OCT (PL 11.1) into the holes of the printer,and place the Option OCT on the printer.
  • Page 370 Chapter 3 Removal and Replacement Procedures (RRPs) Fasten the Option OCT to the printer by tightening the 2 SCREW THUMBs (PL 11.1). The SCREW THUMB should be completely tightened to fasten the Option OCT. 3 - 186...

  • Page 371: Rrp11.2 Cover Rear (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.2 COVER REAR (PL11.1) Removal Move the COVER REAR in the direction of the arrows, and remove the bosses on both sides of the COVER REAR from the COVER OCT (PL 11.1), and then remove the COVER REAR. COVER REAR (PL23.1.4) BOSS...

  • Page 372: Rrp11.3 Tray Assy Oct (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.3 TRAY ASSY OCT (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the COVER OCT (PL 11.1). (RRP11.4) Remove the 2 screws (gold tapping, 8mm) on both sides securing the TRAY ASSY OCT to the removed COVER OCT, and remove the TRAY ASSY OCT from the COVER OCT.

  • Page 373: Rrp11.4 Cover Oct (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.4 COVER OCT (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the WEIGHT (PL 11.1). Remove the hinges on both sides of the FLAPPER L (PL 11.1) from the COVER OCT (PL 11.1).
  • Page 374 Chapter 3 Removal and Replacement Procedures (RRPs) WEIGHT (PL23.1.2) FLAPPER L (PL23.1.49) FLAPPER R (PL23.1.50) LINK (PL23.1.47) SHAFT FULL STACK ACTUATOR FULL STACK (PL23.1.48) (PL23.1.15) FLAPPER L JG3821AA JG3823AB HINGE (PL23.1.49) COVER OCT (PL23.1.1) JG3804AA Replacement Install the COVER OCT to the Option OCT. Secure the COVER OCT to the Option OCT using the 2 screws (gold tapping, 8mm) at the bot- tom.
  • Page 375 Chapter 3 Removal and Replacement Procedures (RRPs) Secure the COVER OCT to the Option OCT using the 2 screws (gold tapping, 8mm) at the rear. Install the LINK (PL 11.1) attached with the FLAPPER R (PL 11.1) to the ACTUATOR FULL STACK (PL 11.1) from under slanting direction, and install the hinges on both sides of the FLAPPER R to the COVER OCT.

  • Page 376: Rrp11.5 Cover Front (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.5 COVER FRONT (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the COVER OCT (PL 11.1). (RRP11.4) Remove the 3 screws (gold tapping, 8mm) securing the COVER FRONT to the Option OCT and remove the COVER FRONT.
  • Page 377 Chapter 3 Removal and Replacement Procedures (RRPs) GEAR CAM (PL23.1.28) COVER FRONT (PL23.1.45) JG3805AC CHUTE OFFSET (PL23.1.38) GEAR CAM (PL23.1.28) GEAR OF MOTOR ASSY OFFSET (PL23.1.20) JG3806AA Replacement Make sure that the GEAR CAM (PL 11.1) and the GEAR of the MOTOR ASSY OFFSET (PL 11.1) are engaged, and the boss of the GEAR CAM is in the groove of the CHUTE OFFSET (PL 11.1).
  • Page 378 Chapter 3 Removal and Replacement Procedures (RRPs) Install the COVER OCT (PL 11.1). (RRP11.4) Install the COVER REAR (PL 11.1). (RRP11.2) 3 - 194...

  • Page 379: Rrp11.6 Actuator Full Stack (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.6 ACTUATOR FULL STACK (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) 2) Remove the COVER OCT (PL 11.1). (RRP11.4) 3) After lifting up the flap of the ACTUATOR FULL STACK in the direction of the arrow (1), remove the hook first, and then move it in the direction of the arrow (2) to remove from the Option OCT.
  • Page 380 Chapter 3 Removal and Replacement Procedures (RRPs) HOOK FLAP ACTUATOR FULL STACK (PL23.1.15) JG3807AB ACTUATOR FULL STACK SHAFT FULL STACK JG3822AA Replacement Lift up the ACTUATOR FULL STACK in the direction of the arrow (1), and insert it to the hook. Move the ACTUATOR FULL STACK in the opposite direction of the arrow (2) to install.
  • Page 381 Chapter 3 Removal and Replacement Procedures (RRPs) When installing the ACTUATOR FULL STACK to the Option OCT, combine it with the SHAFT FULL STACK as shown in the figure. Install the COVER OCT (PL 11.1). (RRP11.4) Install the COVER REAR (PL 11.1). (RRP11.2) After installation, when the FLAPPER L is moved with a finger, make sure that the ACTU- ATOR FULL STACK moves together with the FLAPPER L.

  • Page 382: Rrp11.7 Pwba Oct (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.7 PWBA OCT (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the COVER OCT (PL 11.1). (RRP11.4) Remove the ACTATOR FULL STACK in order to prevent from breaking ACTUATOR FULL STACK (PL 11.1). Release the harness connected to the S/W REAR COVER (PL 11.1) from the clamp.
  • Page 383 Chapter 3 Removal and Replacement Procedures (RRPs) PWBA OCT (PL23.1.22) P/J74 SUPPORT OCT RIGHT (PL23.1.23) PWBA OCT BLOCK GUIDE GROOVES JG3825AA Replacement Install the PWBA OCT to the SUPPORT OCT RIGHT (PL 11.1) using the screw (silver, 6mm). Install the SUPPORT OCT RIGHT attached with the PWBA OCT to the Option OCT using 2 screws (gold tapping, 8mm).
  • Page 384 Chapter 3 Removal and Replacement Procedures (RRPs) Connect the harness connectors to the connectors (P/J70, P/J71, P/J72, P/J73, P/J74 and P/ J75) on the PWBA OCT. When connecting a harness connector, connect it by securing PWBA OCT with your hand. Secure the harness connected to the S/W REAR COVER (PL 11.1) using clamp.

  • Page 385: Rrp11.8 Motor Assy Offset (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.8 MOTOR ASSY OFFSET (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the COVER OCT (PL 11.1). (RRP11.4) Remove the PWBA OCT (PL 11.1). (RRP11.7) Remove the 2 screws (gold tapping, 8mm) securing the MOTOR ASSY OFFSET to the Option OCT.

  • Page 386: Rrp11.9 Solenoid Assy Gate (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.9 SOLENOID ASSY GATE (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the COVER OCT (PL 11.1). (RRP11.4) Remove the COVER FRONT (PL 11.1). (RRP11.5) Remove the PWBA OCT (PL 11.1). (RRP11.7) Remove the MOTOR ASSY OFSET (PL 11.1).

  • Page 387: Rrp11.10 Sensor Oct (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.10 SENSOR OCT (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP10.6) Remove the COVER OCT (PL 11.1). (RRP11.4) Remove the COVER FRONT (PL 11.1). (RRP11.5) Release the HARNESS ASSY OCT SNR (PL 11.1) from the hooks. Disconnect the connector (P/J730) of the HARNESS ASSY OCT SNR from the SENSOR OCT.
  • Page 388 Chapter 3 Removal and Replacement Procedures (RRPs) HOOKS SPRING ACTUATOR (PL23.1.32) HOUSING OCT (PL23.1.14) ACTUATOR OCT (PL23.1.31) HOOK HARNESS ASSY OCT SNR (PL23.1.26) JG3811AA SENSOR OCT ACTUATOR OCT SPRING ACTUATOR (PL23.1.30) (PL23.1.31) (PL23.1.32) HOUSING OCT (PL23.1.14) JG3813AA JG3812AA 3 - 204...
  • Page 389 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the SENSOR OCT to the HOUSING OCT (PL 11.1), and secure it with the hooks. Move the ACTUATOR OCT in the opposite direction of the arrows, and secure it with the hooks.

  • Page 390: Rrp11.11 Roll Oct Lower (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.11 ROLL OCT LOWER (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the COVER OCT (PL 11.1). (RRP11.4) Remove the 2 screws (gold tapping, 8mm, gold 6mm) securing the SUPPORT OCT LEFT (PL 11.1).
  • Page 391 Chapter 3 Removal and Replacement Procedures (RRPs) SUPPORT OCT LEFT (PL23.1.10) GEAR 19/37 (PL23.1.8) GEAR 19 (PL23.1.11) BRACKET MOTOR OCT (PL23.1.9) GEAR 19 (PL23.1.11) GEAR 45 (PL23.1.7) BEARING ROLL (PL23.1.13) ROLL OCT LOWER (PL23.1.16) BEARING ROLL (PL23.1.13) HOOK HOUSING OCT (PL23.1.14) HOOK JG3814AA...
  • Page 392 Chapter 3 Removal and Replacement Procedures (RRPs) When installing the GEAR 19, be careful in the installing direction. Install the BRACKET MOTOR OCT (PL 11.1) using the 2 screws (gold tapping, 8mm). Install the SUPPORT OCT LEFT using the 2 screws (gold tapping, 8mm, gold 6mm). Install the COVER OCT (PL 11.1).

  • Page 393: Rrp11.12 Roll Oct Upper (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.12 ROLL OCT UPPER (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the COVER OCT (PL 11.1). (RRP11.4) Remove the COVER FRONT (PL 11.1). (RRP11.5) Remove the GEAR CAM (PL 11.1). Remove the 2 screws (gold tapping, 8mm, gold 6mm) securing the SUPPORT OCT LEFT (PL 11.1).
  • Page 394 Chapter 3 Removal and Replacement Procedures (RRPs) C UTE OFFSET ASSY (PL23.1.35) OUSING OCT (PL23.1.14) BEARING OFFSET (PL23.1.12) SUPPORT OCT LEFT (PL23.1.10) GEAR 19/37 (PL23.1.8) GEAR 19 (PL23.1.11) BRACKET MOTOR OCT (PL23.1.9) GEAR 19 (PL23.1.11) GEAR 45 (PL23.1.7) JG3815AB 3 - 210...
  • Page 395 Chapter 3 Removal and Replacement Procedures (RRPs) ROLL OCT UPPER (PL23.1.36) BEARING ROLL (PL23.1.13) CHUTE OFFSET ASSY (PL23.1.35) JG3816AB Replacement Install the ROLL OCT UPPER to the CHUTE OFFSET ASSY (PL 11.1). Install the 2 BEARING ROLLs (PL 11.1) to the CHUTE OFFSET ASSY. Install the BEARING ROLL (PL 11.1) to the HOUSING OCT (PL 11.1).

  • Page 396: Rrp11.13 Motor Assy Oct (Pl11.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP11.13 MOTOR ASSY OCT (PL11.1) Removal Remove the COVER REAR (PL 11.1). (RRP11.2) Remove the COVER OCT (PL 11.1). (RRP11.4) Disconnect the connector of the MOTOR ASSY OCT from the HARNESS ASSY OCT MOT (PL 11.1).

  • Page 397: Rrp12.550 Paper Feeder Option

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.550 Paper Feeder Option RRP12.1 550 Paper Feeder Option Removal Remove the EP CARTRIDGE. Pull out the 250 PAPER CASSETTE or 550 PAPER CASSETTE from the 2nd tray of the printer. Remove the 550 PAPER CASSETTE from the Option 550 Paper Feeder. Remove 2 JOINT FEEDERs (PL 12.1) at the rear of the printer securing the printer and the Option 550 Paper Feeder.
  • Page 398 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Install the printer on the Option 550 Paper Feeder. When installing, align the holes and the bosses of the printer and Option 550 Paper Feeder, and fix them using 4 JOINT FEEDERs firmly. Secure the printer and Option 550 Paper Feeder using 2 JOINT FEEDERs (PL 12.1) inside the tray insertion space.

  • Page 399: Rrp12.2 Cover Right Plate (Pl12.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.2 COVER RIGHT PLATE (PL12.1) Removal Remove the screw (gold tapping, 8mm) securing the COVER RIGHT PLATE to the frame. Lift up the COVER RIGHT PLATE just above the boss of the FRAME CVR R550 (PL 12.1) a lit- tle to release.

  • Page 400: Rrp12.3 Cover Left Plate (Pl12.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.3 COVER LEFT PLATE (PL12.1) Removal Remove the 2 screws (gold tapping, 8mm) securing the EARTH PLATE (PL 12.1) to the frame. Remove the EARTH PLATE. Lift up the COVER LEFT PLATE just above the boss of the FRAME CVR L550 (PL 12.1) a little to release them.

  • Page 401: Rrp12.4 Opt Assy Size (Pl12.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.4 OPT ASSY SIZE (PL12.1) Removal Release the HARNESS ASSY SIZE FDR1 (PL 12.1) from the hooks of the FRAME CVR L550 (PL 12.1). Remove the 2 screws (gold tapping, 8mm) securing the OPT ASSY SIZE to the FRAME CVR L550.

  • Page 402: Rrp12.5 Drive Assy Opt Fdr (Pl12.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.5 DRIVE ASSY OPT FDR (PL12.1) Removal Remove the 550 FEEDER OPTION (PL 12.2). (RRP12.1) Remove the COVER LEFT PLATE (PL 12.1.3). (RRP12.3) Disconnect the connector (P/J820) of the MOTOR FEEDER (PL 12.1.17) attached to the DRIVE ASSY OPT FDR from the HARNESS ASSY FDR MOT (PL 12.1.37).
  • Page 403 Chapter 3 Removal and Replacement Procedures (RRPs) Install the 550 FEEDER OPTION (PL 12.2). (RRP12.1) 3 - 219...

  • Page 404: Rrp12.6 Motor Feeder (Pl12.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.6 MOTOR FEEDER (PL12.1) Removal Remove the 550 FEEDER OPTION (PL 12.2). (RRP12.1) Remove the COVER LEFT PLATE (PL 12.1.3). (RRP12.3) Remove the DRIVE ASSY OPT FDR (PL 12.1.8). (RRP12.5) Remove the 2 screws (gold, 6mm) securing the MOTOR FEEDER to the DRIVE ASSY OPT FDR.

  • Page 405: Rrp12.7 Sensor Low Paper (Pl12.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.7 SENSOR LOW PAPER (PL12.1) Removal Remove the COVER RIGHT PLATE (PL 12.1.1). (RRP12.2) Remove the 2 screws securing the HLD LOW PAPER ASSY (PL 12.1.29) to the FRAME CVR R550 (PL 12.1). Disconnect the connector (P/J810) of the HARNESS LOW PAPER (PL 12.1.33) from the SEN- SOR LOW PAPER of the HLD LOW PAPER ASSY.

  • Page 406: Rrp12.8 Pwba Feeder 550 (Pl12.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.8 PWBA FEEDER 550 (PL12.1) Removal Remove the COVER RIGHT PLATE (PL 12.1.1). (RRP12.2) Disconnect the harness connectors from the connectors (P/J80, P/J81, P/J82, P/J83, P/J84 and P/ J85) on the PWBA FEEDER 550. Remove the 2 screws (gold tapping, 8mm) securing the PWBA FEEDER 550 to the frame.
  • Page 407 Chapter 3 Removal and Replacement Procedures (RRPs) One of the screws that secure the PWBA FEEDER 550 is tightened together with the FRAME TOP ASSY. When installing, align the hole of the PWBA FEEDER 550 with the boss of the FRAME CVR R550.

  • Page 408: Rrp12.9 550 Feeder Option (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.9 550 FEEDER OPTION (PL12.2) Removal Remove the 5 screws (gold tapping, 8mm) securing the COVER RE550 (PL 12.1.25) to the frame. Remove the COVER RE550. Disconnect the connector (P/J855) of the HARNESS ASSY CLSNR1 (PL 12.1.31) from the HARNESS ASSY CLSNR2 (PL 12.1.36).
  • Page 409 Chapter 3 Removal and Replacement Procedures (RRPs) COVER RE550 (PL20.1.25) (SEE Note1) 550 FEEDER OPTION (PL20.2.1) CHUTE 550 LOWER (PL20.2.34) NOTE1) WHEN ASSEMBLING JG3510AA Replacement Install the CHUTE 550 LOWER (PL 12.2.34) to the 550 FEEDER OPTION using the 3 screws (silver, 6mm).
  • Page 410 Chapter 3 Removal and Replacement Procedures (RRPs) Connect the connector (P/J855) of the HARNESS ASSY CLSNR1 (PL 12.2.31) to the HAR- NESS ASSY CLSNR2 (PL 12.1.36). After connecting the connector, put the connector under the harness. 7)Install the COVER RE550 (PL 12.1.25) to the frame using the 5 screws (gold tapping, 8mm).

  • Page 411: Rrp12.10 Roll Assy Nudger (Pl12.2), Roll Assy Feed (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.10 ROLL ASSY NUDGER (PL12.2), ROLL ASSY FEED (PL12.2) Removal Release the hook securing the ROLL ASSY NUDGER, and pull it out from the SHAFT NUDGER (PL 12.2.9). Release the hook securing the ROLL ASSY FEED, and pull it out from the SHAFT FEED (PL 12.2.16).
  • Page 412 Chapter 3 Removal and Replacement Procedures (RRPs) When installing, do not hold the rubber rollers of the ROLL ASSY FEED. Install the ROLL ASSY NUDGER to the SHFT NUDGER (PL 12.2.9), and secure the ROLL ASSY NUDGER with the hook. Be sure to install the hook of the ROLL ASSY NUDGER into the groove of the SHAFT NUDGER.

  • Page 413: Rrp12.11 Clutch Oneway Nudger (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.11 CLUTCH ONEWAY NUDGER (PL12.2) Removal Remove the ROLL ASSY FEED (PL 12.2.12). (RRP12.10) Pull out the CLUTCH ONEWAY FEED (PL 12.2.13) from the SHAFT FEED (PL 12.2.16). Remove the E-ring securing the CLUTCH ONEWAY NUDGER to the SHAFT FEED. Pull out the CLUTCH ONEWAY NUDGER from the SHAFT FEED.

  • Page 414: Rrp12.12 Gear Nudger (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.12 GEAR NUDGER (PL12.2) Removal While lifting up the boss of the HOLDER LEFT (PL 12.2.5) at the back of the 550 FEEDER OPTION, shift the HOLDER LEFT in the direction of the arrow to remove the 3 hooks. Remove the HOLDER LEFT from the SUPPORT NUDGER (PL 12.2.4).
  • Page 415 Chapter 3 Removal and Replacement Procedures (RRPs) ROLL ASSY GEAR NUDGER (PL20.2.10) ROLL ASSY NUDGER (PL20.2.11) UNDER VIEW A (SEE DETAILED VIEW) SUPPORT NUDGER (PL20.2.4) LIFT UP (BOSS) ACTUATOR NO PAPER HOLDER LEFT (PL20.2.6) (PL20.2.5) DETAILED VIEW OF A HOLDER LEFT ACTUATOR NO PAPER HOOK...
  • Page 416 Chapter 3 Removal and Replacement Procedures (RRPs) Install the ACTUATOR NO PAPER (PL 12.2.6) and HOLDER LEFT (PL 12.2.5) to the SUP- PORT NUDGER (PL 12.2.4). Be sure to install the shafts on both ends of the ACTUATOR NO PAPER into the HOLDER LEFT and SUPPORT NUDGER.

  • Page 417: Rrp12.13 Roll Assy Turn (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.13 ROLL ASSY TURN (PL12.2) Removal Remove the 550 FEEDER OPTION (PL 12.2). (RRP12.1) Remove the CLUTCH PR-REGI (PL 12.2.22). (RRP12.15) Remove 2 E-rings on both ends of the ROLL ASSY TURN securing the BEARING FEEDER (PL 12.2.23).

  • Page 418: Rrp12.14 Clutch Assy Ph (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.14 CLUTCH ASSY PH (PL12.2) Removal Remove the 550 FEEDER OPTION (PL 12.2). (RRP12.1) Remove the 6 screws (gold taping, 8mm) securing the PLATE TIE (PL 12.2.29). Remove the PLATE TIE from the CHUTE OUT (PL 12.2.25). Disconnect the connector (P/J853) of the CLUTCH ASSY PH from the HARNESS ASSY CLSNR1 (PL 12.2.31).
  • Page 419 Chapter 3 Removal and Replacement Procedures (RRPs) Connect the connector (P/J853) of the CLUTCH ASSY PH to the HARNESS ASSY CLSNR1 (PL 12.2.31). After connecting the connector, put the connector into the space between two ribs of the CHUTE OUT (PL 12.2.25). Install the 550 FEEDER OPTION (PL 12.2).

  • Page 420: Rrp12.15 Clutch Pr-Regi (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.15 CLUTCH PR-REGI (PL12.2) Removal Remove the 550 FEEDER OPTION (PL 12.2). (RRP12.1) Remove the 6 screws (gold taping, 8mm) securing the PLATE TIE (PL 12.2.29). Remove the PLATE TIE from the CHUTE OUT (PL 12.2.25). Disconnect the connector (P/J854) of the CLUTCH PR-REGI from the HARNESS ASSY CLSNR1 (PL 12.2.31).

  • Page 421: Rrp12.16 Sensor No Paper (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.16 SENSOR NO PAPER (PL12.2) Removal Remove the screw securing the HOLDER NO PAPER SENSOR (PL 12.2.32). Remove the HOLDER NO PAPER SENSOR from the Option 550 Paper Feeder. Release the 2 hooks of the SENSOR NO PAPER, and remove the SENSOR NO PAPER from the HOLDER NO PAPER SENSOR.

  • Page 422: Rrp12.17 Roll Assy Retard (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.17 ROLL ASSY RETARD (PL12.2) Removal Pull out the 550 PAPER CASSETTE (PL 12.3) from the Option 550 Paper Feeder. Release the hooks securing the HOLDER RETARD (PL 12.3.5) to the 550 PAPER CASSETTE using a screwdriver or the like.
  • Page 423 Chapter 3 Removal and Replacement Procedures (RRPs) ROLL ASSY RETARD (PL20.3.2) FRICTION CLUTCH (PL20.3.3) HOOKS SPRING RETARD JG3518AA G3209AA Replacement Install the ROLL ASSY RETARD to the SHFT RETARD (PL 12.3.4), and secure the ROLL ASSY RETARD with the hook. When installing, do not hold the rubber rollers of the ROLL ASSY RETARD.
  • Page 424 Chapter 3 Removal and Replacement Procedures (RRPs) After installing, make sure the HOLDER RETARD comes back to the former position with the spring force of the SPRING RETARD (PL 12.3.6), when pushing down the HOLDER RETARD and then release the finger from it. Install the 550 PAPER CASSETTE to the Option 550 Paper Feeder.

  • Page 425: Rrp12.18 Rack Size (Pl12.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.18 RACK SIZE (PL12.3) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPER CASSETTE (PL 12.3.50). Release the lock of the LOCK EXTENSION, and draw out the cassette extension as far as it will go.
  • Page 426 Chapter 3 Removal and Replacement Procedures (RRPs) GEAR PINION HOOKS (PL20.3.12) GUIDE ASSY SD L550 (PL20.3.11) CLAWS GUIDE ASSY SD R550 (PL20.3.13) HOOK HOOK PLATE ASSY BTM HOOK CLAWS HOUSING TOP 550 WHEN ASSEMBLING HOUSING TOP550 CLAW JG3521AA GUIDE ASSY SD L550 3 - 242...
  • Page 427 Chapter 3 Removal and Replacement Procedures (RRPs) HOUSING BASE 550 (PL20.3.44) COVER EXTENSION (PL20.3.31) HOUSING TOP 550 (PL20.3.16) HOUSING EXTENSION 550 (PL20.3.42) HOOK JG3519AA 3 - 243...
  • Page 428 Chapter 3 Removal and Replacement Procedures (RRPs) NOTE 1 RACK SIZE (PL20.3.40) JG3520AB GUIDE ASSY END 550 LINK SW SIZE 2-550 (PL20.3.46) LINK SW SIZE 1-550 LINK SW SIZE 3-550 (PL20.3.45) (PL20.3.47) JG3541AA Replacement Put the hook on the tip of the RACK SIZE into the groove of the HOUSING EXTENSION 550 (PL 12.3.42), and turn it in the opposite direction of the arrow.
  • Page 429 Chapter 3 Removal and Replacement Procedures (RRPs) When installing the RACK SIZE, be sure to draw out the GUIDE ASSY END 550 (PL 12.3.43) as far as it will go.(NOTE 1). Install the COVER EXTENSION (PL 12.3.31) to the HOUSING EXTENSION 550 using the 4 screws (gold tapping, 6mm).
  • Page 430 Chapter 3 Removal and Replacement Procedures (RRPs) After assembling, make sure that the LOW IND FRONT moves up-and-down in conjunc- tion with the up-and-down movement of the PLATE ASSY BTM. 3 - 246...

  • Page 431: Rrp12.19 Gear Sector (Pl12.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.19 GEAR SECTOR (PL12.3) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPER CASSETTE (PL 12.3.50). Release the lock of the LOCK EXTENSION, and draw out the cassette extension as far as it will go.
  • Page 432 Chapter 3 Removal and Replacement Procedures (RRPs) GEAR SECTOR (PL20.3.39) HOUSING EXTENSION 550 (PL20.3.42) JG3522AA Replacement Install the GEAR SECTOR to the HOUSING EXTENSION 550 (PL 12.3.42). Secure the GEAR SECTOR using the screw (black with flange, 8mm). Install the RACK SIZE (PL 12.3.40). (RRP12.18) Install the COVER EXTENSION (PL 12.3.31) to the HOUSING EXTENSION 550 using the 4 screws (gold tapping, 6mm).
  • Page 433 Chapter 3 Removal and Replacement Procedures (RRPs) After tightening the screws, move the GUIDE ASSY END 550 back and forth, and make sure that the LINK SW SIZEs operate smoothly. 7)Insert the link lever of the GUIDE INDICATOR1 (PL 12.3.34) into the hole of the PLATE ASSY BTM.

  • Page 434: Rrp12.20 Guide Assy End 550 (Pl12.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.20 GUIDE ASSY END 550 (PL12.3) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPER CASSETTE (PL 12.3.50). Release the lock of the LOCK EXTENSION, and draw out the cassette extension as far as it will go.
  • Page 435 Chapter 3 Removal and Replacement Procedures (RRPs) HOOKS HOOKS HOUSING EXTENSION 550 (PL20.3.42) GUIDE ASSY END 550 (PL20.3.43) JG3523AA Replacement Secure the GUIDE ASSY END 550 to the HOUSING EXTENSION 550 (PL 12.3.42) using the 4 hooks. Install the GEAR SECTOR (PL 12.3.39). (RRP12.19) Install the RACK SIZE (PL 12.3.40).
  • Page 436 Chapter 3 Removal and Replacement Procedures (RRPs) After assembling the HOUSING TOP 550 with HOUSING BASE 550 using the 4 hooks, secure them using the 2 screws (gold tapping, 8mm) from both right and left sides, as well as the 6 screws (gold tapping, 8mm) on back.

  • Page 437: Rrp12.21 Plate Assy Btm (Pl12.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.21 PLATE ASSY BTM (PL12.3) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPER CASSETTE (PL 12.3.50). Release the lock of the LOCK EXTENSION, and draw out the cassette extension as far as it will go.
  • Page 438 Chapter 3 Removal and Replacement Procedures (RRPs) GEAR PINION HOOKS (PL20.3.12) GUIDE ASSY SD L550 (PL20.3.11) CLAWS GUIDE ASSY SD R550 (PL20.3.13) HOOK HOOK LEVER BTM LOCK (PL20.3.27) WHEN ASSEMBLING HOUSING TOP550 CLAW STOPPER GEAR GUIDE ASSY SD L550 (PL20.3.29) JG3524AA 3 - 254...
  • Page 439 Chapter 3 Removal and Replacement Procedures (RRPs) GEAR PB L (PL20.3.7) GEAR BTM DMP ONEWAY (PL20.3.8) SHAFT PB PLATE ASSY BTM (PL20.3.9) (PL20.3.10) GEAR BTM LOCK ONEWAY (PL20.3.15) SPRING BTM UP 550 (PL20.3.18) GEAR PB R (PL20.3.20) JG3525AB GUIDE INDICATOR 1 PLATE ASSY BTM (PL20.3.10) JG3536AA...
  • Page 440 Chapter 3 Removal and Replacement Procedures (RRPs) Replacement Insert the SHAFT PB (PL 12.3.9) into the PLATE ASSY BTM, and insert the GEAR BTM DMP ONEWAY, GEAR PB L and GEAR BTM LOCK ONEWAY to the SHAFT PB. While disengaging the GEAR PB L, install the assembled PLATE ASSY BTM to the HOUSING TOP 550 (PL 12.3.16).

  • Page 441: Rrp12.22 Gear Lever Lock (Pl12.3), Lever Btm Lock (Pl12.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.22 GEAR LEVER LOCK (PL12.3), LEVER BTM LOCK (PL12.3) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPER CASSETTE (PL 12.3.50). Release the lock of the LOCK EXTENSION, and draw out the cassette extension as far as it will go.
  • Page 442 Chapter 3 Removal and Replacement Procedures (RRPs) NOTE1) LEVER BTM LOCK STOPPER (PL20.3.27) GEAR PB R (PL20.3.20) STOPPER GEAR PLATE GEAR LOCK 550 (PL20.3.29) (PL20.3.19) RACK BTM LOCK 550 (PL20.3.21) GEAR BTM LOCK PINION (PL20.3.23) COVER BTM UP 550 (PL20.3.22) SEE NOTE2 SPRING BTM LOCK (PL20.3.24)
  • Page 443 Chapter 3 Removal and Replacement Procedures (RRPs) NOTE2 (REAR VIEW) WHEN ASSEMBLING STOPPER GEAR SPRING STOPPER GEAR JG3183AA RACK BTM LOCK 550 JG3542AA RACK BTM LOCK 550 Space JG3544AA Replacement When installing, be sure to lift up the PLATE ASSY BTM. If the PLATE ASSY BTM is inclined, a paper skew or jam may occur.
  • Page 444 Chapter 3 Removal and Replacement Procedures (RRPs) Put the SPRING STOPPER GEAR (PL 12.3.28) into the STOPPER GEAR (PL 12.3.29), and secure the STOPPER GEAR to the HOUSING BASE 550 (PL 12.3.44) using the 2 screws (gold tapping, 6mm). When installing the STOPPER GEAR, be careful not to lose the SPRING STOPPER GEAR.

  • Page 445: Rrp12.23 Handle Extension 550 (Pl12.1)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.23 HANDLE EXTENSION 550 (PL12.1) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPER CASSETTE (PL 12.3.50). Remove the 2 screws on the back side of the HANDLE EXTENSION 550 (PL 12.3.41). Release the 5 hooks at the upper side and the 2 hooks at the lower side of the HANDLE EXTENSION 550 (PL 12.3.41).

  • Page 446: Rrp12.24 Guide Indicator 3 (Pl12.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.24 GUIDE INDICATOR 3 (PL12.3) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPER CASSETTE (PL 12.3.50). Remove the HANDLE EXTENSION 550 (PL 12.3.41). (RRP12.23) When removing the HANDLE EXTENSION 550, the LOW INDICATOR (PL 12.3.37) and LOW IND FRONT (PL 12.3.38) will be detached.
  • Page 447 Chapter 3 Removal and Replacement Procedures (RRPs) Be sure to align the groove of the GUIDE INDICATOR 1 and the projection of the GUIDE INDICATOR 3. Insert the link lever of the GUIDE INDICATOR 1 (PL 12.3.34) to the hole of the PLATE ASSY BTM.

  • Page 448: Rrp12.25 Guide Indicator 2 (Pl12.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.25 GUIDE INDICATOR 2 (PL12.3) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPERE CASSETTE (PL 12.3.50). Release the lock of the LOCK EXTENSION, and draw out the cassette extension as far as it will go.
  • Page 449 Chapter 3 Removal and Replacement Procedures (RRPs) HOUSING BASE 550 HOUSING TOP 550 HOOKS GUIDE INDICATOR 1 (PL20.3.34) HOUSING EXTENSION 550 GUIDE INDICATOR 2 (PL20.3.35) SUPPORT GUIDE IND (PL20.3.32) JG3528AA Replacement Insert the GUIDE INDICATOR 2 into the hole of the GUIDE INDICATOR 1 (PL 12.3.34) from back.
  • Page 450 Chapter 3 Removal and Replacement Procedures (RRPs) After tightening the screws, move the GUIDE ASSY END 550 back and forth, and make sure that the LINK SW SIZEs operate smoothly. Insert the link lever of the GUIDE INDICATOR1 (PL 12.3.34) into the hole of the PLATE ASSY BTM.

  • Page 451: Rrp12.26 Low Ind Front (Pl12.3)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.26 LOW IND FRONT (PL12.3) Removal Remove the COVER CST (PL 12.3.1) from the 550 PAPER CASSETTE (PL 12.3.50). Remove the HANDLE EXTENSION 550 (PL 12.3.41). (RRP12.23) Turn the LOW INDICATOR (PL 12.3.37) by 90 degrees, and remove it together with the LOW IND FRONT from the HANDLE EXTENSION 550.
  • Page 452 Chapter 3 Removal and Replacement Procedures (RRPs) After assembling, make sure that the LOW IND FRONT moves up-and-down in conjunc- tion with the up-and-down movement of the PLATE ASSY BTM 3 - 268...

  • Page 453: Rrp12.27 Spring Earth Top (Pl12.2)

    Chapter 3 Removal and Replacement Procedures (RRPs) RRP12.27 SPRING EARTH TOP (PL12.2) Removal Remove the screw (silver, 6mm) securing the SPRING EARTH TOP to the FRAME TOP ASSY (PL 12.1.7). Remove the SPRING EARTH TOP. NOTE Replacement Put the tip of the SPRING EARTH TOP into the hole of the FRAME TOP ASSY (PL 12.1.7), and secure it using the screw (silver, 6mm).
  • Page 454 Chapter 3 Removal and Replacement Procedures (RRPs) Blank Page 3 - 270...
  • Page 455 Chapter 4 Plug/Jack(P/J) Connector Locations Chapter 4 Plug/Jack(P/J) Connector Locations CONTENTS Chapter 4 Print Engine Plug/Jack Connector Locations..........4 - 1 1. Connector [P (plug) / J (jack)]..................4 - 1 1.1 List of P/J ............................4 - 1 1.2 Print Engine P/J Diagram (1 of 2) ....................4 - 4 1.3 Print Engine P/J Diagram (2 of 2) ....................
  • Page 456 Chapter 4 Plug/Jack(P/J) Connector Locations Chapter 4 Plug/Jack(P/J) Connector Locations CONTENTS Blank Page...

  • Page 457: Chapter 4 Print Engine Plug/Jack Connector Locations

    Chapter 4 Plug/Jack(P/J) Connector Locations Chapter 4 Print Engine Plug/Jack Connector Locations 1. Connector [P (plug) / J (jack)] 1.1 List of P/J Coordinates Remarks G-104 Connects OPERATION PANEL and HARNESS ASSY PANEL B-111 Connects HARNESS ASSY LVPS and HVPS/MCU D-111 Connects HARNESS ASSY LVPS and HVPS/MCU E-111...
  • Page 458 Chapter 4 Plug/Jack(P/J) Connector Locations Coordinates Remarks A-108 Connects ROS ASSY and HARNESS ASSY ROS R-119 Connects HARNESS ASSY LVPS and INTERLOCK SW 5V M-121 Connects PWBA ASSY ANT and HARNESS ASSY ANT A-108 Connects ROS ASSY and HARNESS ASSY ROS A-107 Connects ROS ASSY and HARNESS ASSY ROS A-109...
  • Page 459 Chapter 4 Plug/Jack(P/J) Connector Locations Blank Page 4 – 3...

  • Page 460: Print Engine P/J Diagram (1 Of 2)

    Chapter 4 Plug/Jack(P/J) Connector Locations 1.2 Print Engine P/J Diagram (1 of 2) <Engine (FRONT)> 1821 2083 J24101AA 4 – 4...

  • Page 461: Print Engine P/J Diagram (2 Of 2)

    Chapter 4 Plug/Jack(P/J) Connector Locations 1.3 Print Engine P/J Diagram (2 of 2) <Engine (REAR)> 3070 4647 2750 J24102AA 4 – 5...

  • Page 462: Duplex Transport Option

    Chapter 4 Plug/Jack(P/J) Connector Locations Duplex Transport Option 2. Connector [P (plug) / J (jack)] 2.1 List of P/J Coordinates Remarks H-308 Connects HARNESS ASSY DUP and PWBA DUPLEX H-308 Connects MOTOR DUPLEX and PWBA DUPLEX H-308 Connects HARNESS ASSY DUP COVER and PWBA DUPLEX F-307 Connects HARNESS ASSY DUP SNR and PWBA DUPLEX F-307...

  • Page 463: Duplex Transport Option P/J Diagram

    Chapter 4 Plug/Jack(P/J) Connector Locations Duplex Transport Option P/J Diagram <Option Duplex> 2750 J24611AA 4 – 7...

  • Page 464: Oct Option

    Chapter 4 Plug/Jack(P/J) Connector Locations OCT Option 3. Connector [P (plug) / J (jack)] 3.1 List of P/J Coordinates Remarks J-407 Connects HARNESS ASSY OCT2 and PWBA OCT J-408 Connects MOTOR ASSY OCT and PWBA OCT J-407 Connects MOTOR ASSY OFFSET and PWBA OCT J-408 Connects HARNESS ASSY OCT SNR and PWBA OCT I-407...

  • Page 465: Oct Option P/J Diagram

    Chapter 4 Plug/Jack(P/J) Connector Locations OCT Option P/J Diagram <Option OCT> 3070 JG4801 4 – 9...

  • Page 466: Sheet Feeder

    Chapter 4 Plug/Jack(P/J) Connector Locations 550 Sheet Feeder 4. Connector [P (plug) / J (jack)] 4.1 List of P/J Coordinates Remarks I-208 Connects HARNESS ASSY SIZE FDR2 and PWBA FEEDER 550 H-208 Connects HARNESS LOW PAPER and PWBA FEEDER 550 H-208 Connects HARNESS ASSY FDR MOT and PWBA FEEDER 550 I-208...

  • Page 467: Sheet Feeder P/J Diagram

    Chapter 4 Plug/Jack(P/J) Connector Locations 550 Sheet Feeder P/J Diagram <Option 550 Feeder> 8483 2083 J24501AA 4 – 11...
  • Page 468 Chapter 4 Plug/Jack(P/J) Connector Locations Blank Page 4 – 12...
  • Page 469 Chapter 5 Parts Lists Chapter 5 Parts Lists CONTENTS Chapter 5 Parts List......................5 - 1 Engine ..........................5 - 1 Parts List.........................5 - 1 PL 1.1 Cover [Illustration] ....................5 - 2 PL 1.1 Cover [List] ......................5 - 3 PL 2.1 150 Paper Cassette [Illustration] .................5 - 4 PL 2.1 150 Paper Cassette [List] ..................5 - 5 PL 3.1 550 Paper Cassette [Illustration] .................5 - 6 PL 3.1 550 Paper Cassette [List] ..................5 - 7...
  • Page 470 Chapter 5 Parts Lists Chapter 5 Parts Lists CONTENTS Blank Page...

  • Page 471: Chapter 5 Parts List

    Chapter 5 Parts List Chapter 5 Parts List Engine Parts List Caution when using parts list: The Item Numbers in the illustrations have the corresponding Item Numbers in the list. The notation of PL "X.Y.Z" is composed of the plate (PL), item "X.Y", and parts "Z". The alphabet characters in the illustrations represent screws and clips as follows: "S": screw, "E": E-ring, "KL": KL clip, "C": C-ring, and "N": nut "...

  • Page 472: Pl 1.1 Cover [Illustration]

    Chapter 5 Parts List PL 1.1 COVER [ILLUSTRATION] 14 15 [Ref PL10.1] (J244) J25014AA 5 - 2...

  • Page 473: Pl 1.1 Cover [List]

    Chapter 5 Parts List PL 1.1 COVER [LIST] Item Parts name OPERATION PANEL (P1) COVER OPEN COVER REAR COVER RIGHT COVER FRONT COVER LEFT COVER TOP COVER STOPPER STOPPER OPEN HARNESS ASSY PANEL COVER EXIT 500 FAN MAIN 80 (J244) SEAL REAR FAN CLAMP 5 - 3...

  • Page 474: Pl 2.1 150 Paper Cassette [Illustration]

    Chapter 5 Parts List PL 2.1 150 PAPER CASSETTE [ILLUSTRATION] 50 (with 1-13,15-39) 21 22 26 25 JG5002AA 5 - 4...

  • Page 475: Pl 2.1 150 Paper Cassette [List]

    Chapter 5 Parts List PL 2.1 150 PAPER CASSETTE [LIST] Item Parts name COVER CST ROLL ASSY RETARD *1 FRICTION CLUTCH SHAFT RETARD HOLDER RETARD SPRING RETARD GEAR PB L GEAR BTM DMP ONEWAY SHAFT PB PLATE ASSY BTM GUIDE ASSY SD L150 GEAR PINION GUIDE ASSY SD R150 GEAR BTM LOCK ONEWAY...

  • Page 476: Pl 3.1 550 Paper Cassette [Illustration]

    Chapter 5 Parts List PL 3.1 550 PAPER CASSETTE [ILLUSTRATION] 50 (with 1-13,15-32,34-48,52,53) 27 26 JG5004AB 5 - 6...

  • Page 477: Pl 3.1 550 Paper Cassette [List]

    Chapter 5 Parts List PL 3.1 550 PAPER CASSETTE [LIST] Item Parts name Item Parts name COVER CST ROLL ASSY RETARD *1 FRICTION CLUTCH SHAFT RETARD HOLDER RETARD SPRING RETARD GEAR PB L GEAR BTM DMP ONEWAY SHAFT PB PLATE ASSY BTM GUIDE ASSY SD L550 GEAR PINION GUIDE ASSY SD R550...
  • Page 478 Chapter 5 Parts List HOUSING BASE 550 LINK SW SIZE1-550 LINK SW SIZE2-550 LINK SW SIZE3-550 LINK SW SIZE LOW 550 PAPER CASSETTE (with 1-13,15-32,34-48,52,53) STOPPER BASE R STOPPER BASE L *1: Periodical Replacement parts (per 200k print) 3sets [1] of PL3.1.2, PL5.1.19, 29 5 - 8...
  • Page 479 Chapter 5 Parts List Blank Page 5 - 9...

  • Page 480: Pl 4.1 150 Paper Feeder [Illustration]

    Chapter 5 Parts List PL 4.1 150 PAPER FEEDER [ILLUSTRATION] 1 (with 4-12,14-23,25-34, 37-44,46-52) 2 (with 4-10,12,14-20,22,25-28 31-34,40-42,46-50) 3 (Reference Only) (J220) (J240) (P220) (J22) (J245) (J241) 18 17 45 (with 46-50) 16 15 (P242) (P244) (P243) (J242) 33 32 51 32 (P241) (J243)

  • Page 481: Pl 4.1 150 Paper Feeder [List]

    Chapter 5 Parts List PL 4.1 150 PAPER FEEDER [LIST] Item Parts name 150 FEEDER ASSY (with 4-12,14-23,25-34,37-44,46-51) FDR1 AS SUB 150 A4 (with 4-10,12,14-20,22,25-28,31-34,40-42,46-50) CHUTE ASSY FDR1 (Reference Only) (with 4-10,14-20,40-42) SUPPORT NUDGER HOLDER LEFT ACTUATOR NO PAPER GEAR IDLER NUDGER HOLDER RIGHT SHAFT NUDGER 0 GEAR NUDGER...
  • Page 482 Chapter 5 Parts List SENSOR TONER (J220) HOLDER-D SPRING TONER SPRING TONER BOX HARNESS ASSY TONER 1 (J22-P220) GEAR REGI METAL WHITE *1: Periodical Replacement parts (per 200k print) 3sets [1] of PL4.1.11, 44, PL2.1.2 5 - 12...
  • Page 483 Chapter 5 Parts List Blank Page 5 - 13...

  • Page 484: Pl 5.1 550 Paper Feeder [Illustration]

    Chapter 5 Parts List PL 5.1 550 PAPER FEEDER [ILLUSTRATION] (J260) (J26) 21 (Reference Only) 10 (with 12-20,22-31,33-39) 7 (with 8,9) (J246) (P247) (J248) (J247) J25015AA 5 - 14...

  • Page 485: Pl 5.1 550 Paper Feeder [List]

    Chapter 5 Parts List PL 5.1 550 PAPER FEEDER [LIST] Item Parts name HARNESS ASSY LOW1 (J26-J260) GUIDE TRAY RIGHT SENSOR LOW PAPER (P260) ACTUATOR LOW PAPER PLATE CST LOCK GUIDE TRAY LEFT (with 8,9) COVER HARNESS SIZE LOCK CST L 550 FEEDER ASSY (with12-20,22-31,33-39) SUPPORT NUDGER HOLDER LEFT...

  • Page 486: Pl 6.1 Xero [Illustration]

    Chapter 5 Parts List PL 6.1 XERO [ILLUSTRATION] (J270) EP CARTRIDGE * (J170) (J140) (P131) (J160) (P141) (J31) (J15) (J16) (J13) (J14) (J17) (J150) (J45) 6 (with 7-15) 10 11 (J141) 25 (with 23,24) (J47) (J4647) (J46) J25016A 5 - 16...

  • Page 487: Pl 6.1 Xero [List]

    Chapter 5 Parts List PL 6.1 XERO [LIST] Item Parts name ROS ASSY 45-1200 (J131,P140,P160,P170) HARNESS ASSY ROS (J13,J14,J16,J17-P131,J140,P141,J160,J170) SHIELD PLATE ROS DUCT FRONT FAN SUB (J270) GUIDE ASSY CRU L 45 (with 7-15) GUIDE SL SPACER SS SPRING SL HOLDER I/L SW1 HARNESS ASSY INTERLOCK1 (J45) HARNESS ASSY INTERLOCK3 (J141)

  • Page 488: Pl 7.1 500 Paper Exit (1/2) [Illustration]

    Chapter 5 Parts List PL 7.1 500 PAPER EXIT (1/2) [ILLUSTRATION] 2 (with 4-7,10-13, 15-28,30) (J29) (J290) 30 23 (J291) 22 22 (J103) J25017AA 5 - 18...

  • Page 489: Pl 7.1 500 Paper Exit (1/2) [List]

    Chapter 5 Parts List PL 7.1 500 PAPER EXIT (1/2) [LIST] Item Parts name 500 EXIT ASSY (with4-7,10-13,15-28,30) CHUTE UP EXIT ELIMINATOR EXIT EARTH PLATE EXIT LINK GATE OCT ACTUATOR FULL STACK BEARING EXIT ROLL EXIT GEAR 21 MOTOR ASSY EXIT (J103) BRACKET MOTOR EXIT GEAR 16/49 GEAR 25-2...

  • Page 490: Pl 7.2 500 Paper Exit (2/2) & Option Face Up Tray [Illustration]

    Chapter 5 Parts List PL 7.2 500 PAPER EXIT (2/2) & OPTION FACE UP TRAY [ILLUSTRA- TION] 13 12 24 (with 25) OPTION G5702AB 5 - 20...

  • Page 491: Pl 7.2 500 Paper Exit (2/2) & Option Face Up Tray [List]

    Chapter 5 Parts List PL 7.2 500 PAPER EXIT (2/2) & OPTION FACE UP TRAY [LIST] Item Parts name CHUTE UP FU ROLL PINCH FU SPRING PINCH FU GATE FU CHUTE LOW FU LEVER LATCH LEFT PIPE LATCH FU SPRING LATCH FU LEVER LATCH RIGHT GEAR 21 BEARING EXIT...

  • Page 492: Pl 8.1 Frame & Drive [Illustration]

    Chapter 5 Parts List PL 8.1 FRAME & DRIVE [ILLUSTRATION] (J43) (J271) J25020AA 5 - 22...

  • Page 493: Pl 8.1 Frame & Drive [List]

    Chapter 5 Parts List PL 8.1 FRAME & DRIVE [LIST] Item Parts name MOTOR COVER MAIN MOTOR 45 (J43,J271) GEAR ASSY HOUSING SPRING RELEASE CLAMP-EDGE CLAMP-5V0 CLAMP-10V0 GEAR 9 GEAR ASSY PLATE FOOT GUIDE HARNESS R CLAMP-RWSH 5 - 23...

  • Page 494: Pl 9.1 Electrical [Illustration]

    Chapter 5 Parts List PL 9.1 ELECTRICAL [ILLUSTRATION] (J10) (J11) (J27) (J40) (J18) (J41) (P270) (J400) (J42) (P271) (J102) (PD2750A) (J1821A) (J20) (J22) (P3070) (P2083) (J24) (P221) (P245) (P248) (J30) (J44) (J48) (J480) J25018AA 5 - 24...

  • Page 495: Pl 9.1 Electrical [List]

    Chapter 5 Parts List PL 9.1 ELECTRICAL [LIST] Item Parts name HARNESS ASSY LVPS (J10,J11,J18,J27,J40,J41,J42,J102,P270,P271,J400,J1821A,PD2750A) PLATE TIE FRONT SHIELD PLATE LV J2 PWBA EXIT MOTOR LVPS POWER SWITCH INTERLOCK S/W REAR (J44) HARNESS ASSY AC IN (J48,J480) PANEL REAR BRACKET HANDLE R PWBA ESS SHIELD ASSY ESS SHIELD ASSY WINDOW...

  • Page 496: Options

    Chapter 5 Parts List OPTIONS PL 10.1 OPTION DUPLEX [ILLUSTRATION] 5 - 26...

  • Page 497: Pl 10.1 Option Duplex [List]

    Chapter 5 Parts List PL 10.1 OPTION DUPLEX [LIST] Item Parts name HSG UPPER ASSY (with 2-4) HSG UPPER DUP SPRING PINCH ROLL PINCH HSG LOWER DUP HARNESS ASSY DUP (J50-JD2750) EARTH ASSY PLATE COVER HARNESS SCREW THUMB SCREW HINGE COVER TOP LEVER LATCH RIGHT SHAFT LATCH...

  • Page 498: Pl 11.1 Option Oct [Illustration]

    Chapter 5 Parts List PL 11.1 OPTION OCT [ILLUSTRATION] (J71) (P710) (J710) 11 12 (J72) 11 13 (J740) (J75) (J74) (J730) (J73) (J70) (JD3070) (with 41-44, 35 (with 13,36-39) J25801AA 5 - 28...

  • Page 499: Pl 11.1 Option Oct [List]

    Chapter 5 Parts List PL 11.1 OPTION OCT [LIST] Item Parts name COVER OCT WEIGHT COVER REAR SCREW THUMB MOTOR ASSY OCT (J710) GEAR 45 GEAR 19/37 BRACKET MOTOR OCT SUPPORT OCT LEFT GEAR 19 BEARING OFFSET BEARING ROLL HOUSING OCT ACTUATOR FULL STACK ROLL OCT LOWER CHUTE INLET...
  • Page 500 Chapter 5 Parts List COVER FRONT HARNESS ASSY OCT MOT (J71-P710) LINK SHAFT FULLSTACK FLAPPER L FLAPPER R DAMPER ASSY TRAY L STOPPER DAMPER ASSY TRAY R 5 - 30...
  • Page 501 Chapter 5 Parts List Blank Page 5 - 31...

  • Page 502: Pl 12.1 Option 550 Paper Feeder (1/2) [Illustration]

    Chapter 5 Parts List PL 12.1 OPTION 550 PAPER FEEDER (1/2) [ILLUSTRATION] (JD2083) (J85) (J82) (P820) (J83) (J80) (P855) (P801) 29 (with 30-33) 8 (with 9-17) (J820) (J81) (J802) (J810) (J800) (P802) (J801) (J84) [Ref PL20.2.1] (PD8483) J25501AA 5 - 32...

  • Page 503: Pl 12.1 Option 550 Paper Feeder (1/2) [List]

    Chapter 5 Parts List PL 12.1 OPTION 550 PAPER FEEDER (1/2) [LIST] Item Parts name COVER RIGHT PLATE COVER FRONT COVER LEFT PLATE EARTH PLATE HARNESS ASSY FDR2 (J83-JD2083) SPRING EARTH TOP FRAME TOP ASSY DRIVE ASSY OPT FDR 45 (with 9-17) BRACKET ASSY FDR DRV 45 GEAR OPT FDR2 GEAR OPT FDR3...

  • Page 504: Pl 12.2 Option 550 Paper Feeder (2/2) [Illustration]

    Chapter 5 Parts List PL 12.2 OPTION 550 PAPER FEEDER (2/2) [ILLUSTRATION] 1 (with 4-23,25-34) 2 (Reference Only) 35 (with 4-10,14-20,23,25-28) 12 13 (J852) (J855) (P853) 32 33 (P854) (J853) (J854) J25502AA 5 - 34...

  • Page 505: Pl 12.2 Option 550 Paper Feeder (2/2) [List]

    Chapter 5 Parts List PL 12.2 OPTION 550 PAPER FEEDER (2/2) [LIST] Item Parts name 550 FEEDER OPTION (with4-23,25-34) CHUTE ASSY FDR2 (Reference Only) (with 4-10,15-20) SUPPORT NUDGER HOLDER LEFT ACTUATOR NO PAPER GEAR IDLER NUDGER HOLDER RIGHT SHAFT NUDGER GEAR NUDGER ROLL ASSY NUDGER *1 ROLL ASSY FEED *1...

  • Page 506: Pl 12.3 Option 550 Paper Cassette [Illustration]

    Chapter 5 Parts List PL 12.3 OPTION 550 PAPER CASSETTE [ILLUSTRATION] 50 (with 1-13,15-32,34-48,52,53) 27 26 JG5004AB 5 - 36...

  • Page 507: Pl 12.3 Option 550 Paper Cassette [List]

    Chapter 5 Parts List PL 12.3 OPTION 550 PAPER CASSETTE [LIST] Item Parts name COVER CST ROLL ASSY RETARD *1 FRICTION CLUTCH SHAFT RETARD HOLDER RETARD SPRING RETARD GEAR PB L GEAR BTM DMP ONEWAY SHAFT PB PLATE ASSY BTM GUIDE ASSY SD L550 GEAR PINION GUIDE ASSY SD R550...
  • Page 508 Chapter 5 Parts List LINK SW SIZE3-550 LINK SW SIZE LOW 550 PAPER CASSETTE (with 1-13,15-32,34-48,52,53) STOPPER BASE R STOPPER BASE L *1: Periodical Replacement parts (per 200k print) 3sets [1] of PL20.2.11,12,PL20.3.2 5 - 38...
  • Page 509 Chapter 6 Principles of Operation Chapter 6 Principles of Operation Contents Chapter 6 Principles of Operation ..................6 - 1 Engine ..........................6 - 1 1. Summary of Printing Process ..................6 - 1 2. Flow of Print Data ......................6 - 6 3. Driving Force Transmission Path ................6 - 7 3.1 MAIN MOTOR...........................
  • Page 510 Chapter 6 Principles of Operation Chapter 6 Principles of Operation Contents OCT Option ........................6 - 38 11. Driving Force Transmission Path ................6 - 38 11.1 MOTOR ASSY OCT ........................6 - 38 11.2 Gear Layout ..........................6 - 38 12.

  • Page 511: Chapter 6 Principles Of Operation

    Chapter 6 Principles of Operation Chapter 6 Principles of Operation Engine 1. Summary of Printing Process Electrophotography is used in the printer to print image on paper using a video signal sent from the PWBA ESS to the MCU of the HVPS/MCU. The electrophotography is composed of the following 7 steps: (1) Charging - Negative charges are uniformly distributed over the surface of the drum by Bias Charge Roll.
  • Page 512 Chapter 6 Principles of Operation Main components directly associated with the print process and transport of the paper are shown in the following figure. Components associated with print process: FUSER ASSY X-Port EP CARTRIDGE JG6102AA 6 – 2...
  • Page 513 Chapter 6 Principles of Operation Components associated with transport of paper: FUSER ASSY to Duplex Heat Roll Pressure Roll Drum EP CARTRIDGE ROS ASSY BTR ASSY Mag.Roll from Duplex from Option Feeder JG6103AA 6 – 3...
  • Page 514 Chapter 6 Principles of Operation In the exposure step, the surface of the drum negatively charged by the previous charging step is scanned by a thin laser beam. The light radiated from the laser diode of the ROS (Raster Output Scanner) scans the drum from one end to the other. The light passes via a rotating polygon mirror (12 facets) and also via a lens.
  • Page 515 Chapter 6 Principles of Operation In the cleaning step, the remaining toner is removed from the drum surface. The drum surface is prepared for the next cycle. The toner is scraped off the drum surface by a cleaning blade. The toner scraped off in the cleaning step is collected in a recovery toner compartment partitioned from unused toner.

  • Page 516: Flow Of Print Data

    Chapter 6 Principles of Operation 2. Flow of Print Data The NIC (Network Interface Card) of the printer connected with a network receives a packet signal in a bit stream from a client or server of the network, and decomposes the packet signal received next into a data format adapted for a layer from which the data is sent to the Controller.

  • Page 517: Driving Force Transmission Path

    Chapter 6 Principles of Operation 3. Driving Force Transmission Path 3.1 MAIN MOTOR The rotating force of the MAIN MOTOR is transmitted via gears in the GEAR ASSY HOUSING and via the GEAR ASSY PLATE to components that need mechanical driving force as shown in the following flow.

  • Page 518: Gear Layout

    Chapter 6 Principles of Operation 3.3 Gear Layout Drive path in EP CARTRIDGE: EP CARTRIDGE Gear 3 Gear 2 MAIN MOTOR JG6110AA Drive path in FEEDER ASSY: 150 FEEDER ASSY MAIN MOTOR 550 FEEDER ASSY Gear 15 Gear 5 CLUTCH ASSY PH Gear 13 CLUTCH ONEWAY NUDGER Gear 14...
  • Page 519 Chapter 6 Principles of Operation Drive path in CLUTCH REGI: MAIN MOTOR CLUTCH REGI Gear 18 Gear 17 Gear 5 Gear 15 Gear 14 Gear 13 JG6109AA Drive path in FUSER ASSY: FUSER ASSY Gear 8 Gear 7 Gear HR Gear 6 GEAR 9 Gear 5...
  • Page 520 Chapter 6 Principles of Operation Drive path in 500 Paper Exit & Option Face Up Tray: GEAR 25-2 GEAR21 ROLL EXIT GEAR 16/49 GEAR 25-1 500 Paper Exit GEAR21 ROLL FU MOTOR ASSY EXIT JG6112AA 6 – 10...

  • Page 521: Paper Transport

    Chapter 6 Principles of Operation 4. Paper Transport 4.1 Paper Transport Path The paper is supplied from the Tray1 and Tray 2 or the optional Tray3 and Tray 4, and is transported into the printer along the paper path shown below. 6 –...

  • Page 522: Layout Of Paper Transport Path

    Chapter 6 Principles of Operation 4.2 Layout of Paper Transport Path The following is a cross section of the JIGEN printer. Main components directly associated with the paper path and transport are shown here. Main components associated with transport of paper (when Option Duplex, Option 550 Feeder, Option OCT and 500 Paper Exit &...

  • Page 523: Actions Of Main Functional Components

    Chapter 6 Principles of Operation 5. Actions of Main Functional Components The functions of the main components of the JIGEN printer are described in the following sections: 5.1 Paper Cassette 5.2 Paper Feeder 5.3 Xero 5.4 Fuser 5.5 500 Paper Exit & Option Face Up Tray 5.6 Drive 5.7 Electrical 5.1 Paper Cassette...
  • Page 524 Chapter 6 Principles of Operation GUIDE ASSY L150 and GUIDE ASSY SD R150 The GUIDE ASSY SD R150 can be adjusted to different paper sizes by moving it to the left or right. The guides come into contact with the left and right edges of the paper and hold it in position.
  • Page 525 Chapter 6 Principles of Operation 150 Paper Cassette: PLATE ASSY BTM GUIDE ASSY SD L150 LEVER BTM LOCK STOPPER GEAR GUIDE ASSY SD R150 LOCK EXTENSION GUIDE ASSY END150 JG6117AA 550 Paper Cassette: PLATE ASSY BTM GUIDE ASSY SD L 550 LOCK EXTENSION LEVER BTM LOCK STOPPER GEAR...
  • Page 526 Chapter 6 Principles of Operation 5.2 Paper Feeder Since the Tray1 and Tray2 are functionally equivalent in terms of the Size Switch, ACTUATOR NO PAPER, and SENSOR NO PAPER, only the components of one tray are described here. Since the ACTUATOR LOW PAPER and SENSOR LOW PAPER are not installed in the Tray1, the description of these components applies to the Tray2 only.
  • Page 527 Chapter 6 Principles of Operation SENSOR LOW PAPER When paper is low in the Tray2 Paper Cassette, this is detected by the position of the ACTUATOR LOW PAPER and converted into an electrical signal. When the detection portion is shielded (i.e. paper is high), /LOW PAPER SNR ON signal is turned OFF.

  • Page 528: Xero

    Chapter 6 Principles of Operation 5.3 Xero EP CARTRIDGE The EP CARTRIDGE is also known as CRU (Customer Replaceable Unit), and is made up of the following five components. -Drum This is a cylinder of aluminum and coated with a photoconductive material. Because of this photoconductive coating layer, electric charges are retained on the surface in the dark, and electrical conduction occurs when exposed to light.
  • Page 529 Chapter 6 Principles of Operation BTR ASSY EP CARTRIDGE J26119AA 6 – 19...
  • Page 530 Chapter 6 Principles of Operation ROS ASSY The ROS (Raster Output Scanner) scans the surface of the drum with a laser beam. The ROS ASSY consists of the following three components, i.e., LD (Laser Diode) Assembly, Scanner Assembly, and SOS PWB. -LD Assembly The LD Assembly produces a laser beam.
  • Page 531 Chapter 6 Principles of Operation SOS PWB LD Assembly Scanner Assembly JG6121AA 6 – 21...

  • Page 532: Fuser

    Chapter 6 Principles of Operation 5.4 Fuser Heat Roll This is a hollow metal tube having a coated surface. This tube is heated by the inside Heater Rod. Heat is applied to the paper passing between this roll and the Pressure Roll.
  • Page 533 Chapter 6 Principles of Operation Exit Sensor Actuator Temperature Sensor Pressure Roll Heat Roll Thermostat Sensor J26122AA 6 – 23...

  • Page 534: Paper Exit & Option Face Up Tray

    Chapter 6 Principles of Operation 5.5 500 Paper Exit & Option Face Up Tray 500 Paper Exit is components for discharging the printed paper out of the printer. 500 Paper Exit enables Face-Up output to the Option Face Up Tray (mounted on the rear surface of the machine), and output to Option OCT as well as Face-Down output.
  • Page 535 Chapter 6 Principles of Operation 6 – 25...

  • Page 536: Drive

    Chapter 6 Principles of Operation 5.6 Drive GEAR ASSY HOUSING This housing is composed of gears for transmitting power from the MAIN MOTOR that drives the printer body to various portions of the printer. GEAR ASSY PLATE This transmits power from the MAIN MOTOR to the EP CARTRIDGE. LEVER LINK This connects and disconnects the power from the MAIN MOTOR to the FUSER ASSY.

  • Page 537: Electrical

    Chapter 6 Principles of Operation 5.7 Electrical INTERLOCK S/W 24V This safety switch cuts off a 24 VDC power supply from the LVPS to the HVPS MCU and MAIN MOTOR when the COVER OPEN is open. INTERLOCK S/W 5V This safety switch cuts off a 5 VDC power supply from the LVPS to the LD Assembly of the ROS ASSY when the COVER OPEN is open.
  • Page 538 Chapter 6 Principles of Operation INTERLOCK S/W 5V INTERLOCK S/W 24V INTERLOCK S/W REAR FAN MAIN PWBA EXIT MOTOR PWBA ESS LVPS HVPS/MCU FAN SUB J26125AA 6 – 28...

  • Page 539: Control

    Chapter 6 Principles of Operation 6. Control 6.1 Control of Paper Size 6.1.1 Cassette Feeding (Paper Cassette) The following table gives the states (ON(1) or OFF (0)) of the switches in the Size Switch, corresponding to the paper sizes of the Paper Cassette. The switches in the Size Switch are denoted by "SW1", "SW2", "SW3", and "SW4", respectively, from the front side.

  • Page 540: Ros Control

    Chapter 6 Principles of Operation 6.2 ROS Control 6.2.1 Rotation of Scanner Motor The control (ON/OFF) of the rotation of the Scanner Motor is performed as shown below according to the mode of operation. Mode of operation ON/OFF of rotation of Scanner Motor Standby state Kept OFF.

  • Page 541: Fuser Control

    Chapter 6 Principles of Operation 6.3 Fuser Control 6.3.1 Fuser Control The Halogen Lamp is controllably turned ON and OFF, based on the Fuser control temperature. At the start of warm-up and when the MAIN MOTOR is at rest, the standby temperature is taken as the Fuser control temperature.

  • Page 542: Schematic Diagram Of Safety System

    Chapter 6 Principles of Operation 7. Schematic Diagram of Safety System <FAN MAIN> <SWITCH DUPLEX> <FAN SUB> Option 550 Option 550 Option Option Feeder Feeder Duplex <PWBA <PWBA <PWBA <PWBA FEEDER550> FEEDER550> DUPLEX> OCT> SCANNER MOTOR ON, SCANNER MOTOR CLOCK <ROS ASSY>...

  • Page 543: Duplex Option

    Chapter 6 Principles of Operation Duplex Option 8. Driving Force Transmission Path 8.1 MOTOR DUPLEX The rotating force of the MOTOR DUPLEX is transmitted via various gears to components that need mechanical driving force as shown in the flow given below. MOTOR DUPLEX GEAR IDLE 57/37 GEAR IDLE 57/37...

  • Page 544: Paper Transport

    Chapter 6 Principles of Operation 9. Paper Transport 9.1 Paper Transport Path When the Option Duplex has been added, the paper is transported in the sequence given below. 6 – 34...

  • Page 545: Layout Of Paper Transport Path

    Chapter 6 Principles of Operation 9.2 Layout of Paper Transport Path Main components regarding the transport of the paper when the Option Duplex is installed are given below. ROLL PINCH ROLL OCT UPPER ROLL OCT LOWER ROLL PINCH FU ROLL PINCH OCT ROLL EXIT ROLL FU ROLL PINCH EXIT...

  • Page 546: Actions Of Main Functional Components

    Chapter 6 Principles of Operation 10. Actions of Main Functional Components The Option Duplex is available as an optional unit for JIGEN laser printer. Duplex printing is enabled by mounting this optional unit to the rear side of the base engine. SWITCH DUPLEX This switch detects that the HSG LOWER DUP and COVER HSG DUP are closed.
  • Page 547 Chapter 6 Principles of Operation SENSOR DUP ROLL DUP PWBA DUPLEX SWITCH DUPLEX MOTOR DUPLEX FAN DUPLEX J26615AA 6 – 37...

  • Page 548: Driving Force Transmission Path

    Chapter 6 Principles of Operation OCT Option 11. Driving Force Transmission Path 11.1 MOTOR ASSY OCT The rotating force of the MOTOR ASSY OCT is transmitted via various gears to components that need mechanical driving force as shown in the flow given below. 11.2 Gear Layout 6 –...

  • Page 549: Paper Transport

    Chapter 6 Principles of Operation 12. Paper Transport 12.1 Paper Transport Path When the Option OCT has been added, the paper is transported in the sequence given below. 6 – 39...

  • Page 550: Layout Of Paper Transport Path

    Chapter 6 Principles of Operation 12.2 Layout of Paper Transport Path Main components regarding the transport of the paper when the Option OCT is installed are given below. ROLL PINCH ROLL OCT UPPER ROLL OCT LOWER ROLL PINCH OCT ROLL PINCH FU ROLL EXIT ROLL FU ROLL PINCH EXIT...

  • Page 551: Actions Of Main Functional Components

    Chapter 6 Principles of Operation 13. Actions of Main Functional Components The Option OCT is available as an optional unit for JIGEN laser printer. Offset output is enabled by mounting this optional unit to the top of the 500 Paper Exit. MOTOR ASSY OCT This motor gives the driving force to the ROLL OCT LOWER and ROLL OCT UPPER, which transport the printed paper to the tray of the OCT.
  • Page 552 Chapter 6 Principles of Operation ROLL OCT UPPER MOTOR ASSY OCT S/W REAR COVER Sensor Full Stack OCT Sensor Offset PWBA OCT SENSOR OCT ROLL OCT LOWER MOTOR ASSY OFFSET CHUTE OFFSET ASSY SOLENOID ASSY GATE JG6815AB 6 – 42...

  • Page 553: Sheet Feeder Option

    Chapter 6 Principles of Operation 550 Sheet Feeder Option 14. Driving Force Transmission Path 14.1 MOTOR FEEDER The rotating force of the MOTOR FEEDER is transmitted via various gears to components that need mechanical driving force as shown in the flow given below. MOTOR FEEDER GEAR OPT FDR2 GEAR OPT FDR3...

  • Page 554: Paper Transport

    Chapter 6 Principles of Operation 15. Paper Transport 15.1 Paper Transport Path When the Option 550 Feeder has been added, the paper is transported in the sequence given below. 6 – 44...

  • Page 555: Layout Of Paper Transport Path

    Chapter 6 Principles of Operation 15.2 Layout of Paper Transport Path Main components regarding the transport of the paper when the Option 550 Feeder is installed are given below. ROLL PINCH ROLL OCT UPPER ROLL OCT LOWER ROLL PINCH FU ROLL PINCH OCT ROLL EXIT ROLL FU...

  • Page 556: Actions Of Main Functional Components

    Chapter 6 Principles of Operation 16. Actions of Main Functional Components The Option 550 Feeder is available as an optional feeder for JIGEN laser printer. The Paper Cassette installed in the optical feeder is identical in function with the standard Paper Cassette used by the base engine, and so the description of the Paper Cassette is omitted here.
  • Page 557 Chapter 6 Principles of Operation MOTOR FEEDER is transmitted to the ROLL ASSY via the CLUTCH PR-REGI. This conveys the paper into the printer together with ROLL PINCH TURN. PWBA FEEDER 550 A CPU is installed in the PWBA FEEDER 550. This CPU receives instructions from HVPS/MCU and from sensors and switches, and controls feeding operation in the Option 550 Feeder.
  • Page 558 Chapter 6 Principles of Operation Blank Page 6 – 48...

  • Page 559: Chapter 7 Wiring

    Chapter 7 Wiring Diagrams and Signal Information Chapter 7 Wiring Diagrams and Signal Information CONTENTS Chapter 7 Wiring Engine 1. Connection Wiring Diagram..................7 - 1 1.1 Symbols in the General Connection Wiring Diagram................ 7 - 1 1.2 General Wiring Diagram ........................7 - 3 2.
  • Page 560 Chapter 7 Wiring Diagrams and Signal Information Chapter 7 Wiring Diagrams and Signal Information CONTENTS Blank Page...

  • Page 561: Chapter 7 Wiring

    Chapter 7 Wiring Diagrams and Signal Information Chapter 7 Wiring Engine 1. Connection Wiring Diagram 1.1 Symbols in the General Connection Wiring Diagram The symbols in the general connection wiring diagram are described below. Symbols Description Represents an interconnection between parts using wiring harness or wire. Represents an interconnection which differs according to the specifications.
  • Page 562 Chapter 7 Wiring Diagrams and Signal Information Symbols Description Represents a functional part within a part, and indicates the name of the functional part. Represents a section in "2. Interconnection Wiring Diagram of Parts," and indi- cates its section No. Represents a screw for fixing wiring harness and a conductive member such as a plate spring.

  • Page 563: Chapter 7 Wiring Diagrams And Signal Information

    Chapter 7 Wiring Diagrams and Signal Information 1.2 General Wiring Diagram SENSOR HVPS FULL STACK P/J290 P/J29 /MCU PL10.1.26 PL12.1.19 SENSOR FACE UP OPEN P/J291 PL10.1.25 OPERATION PWBA ESS PANEL P/J28 P/J280 PL1.1.1 PL12.1.13 HARNESS ASSY P/J141 P/J14 INTERLOCK3 PL8.1.12 P/J400 FAN SUB P/J27...

  • Page 564: Interconnection Wiring Diagram Of Parts

    Chapter 7 Wiring Diagrams and Signal Information 2. Interconnection Wiring Diagram of Parts 2.1 Instructions for the Use of the Interconnection Wiring Diagram of Parts The symbols in the interconnection wiring diagram of parts are described below. Note that the description of general symbols is omitted. Symbols Description Represents an interconnection between parts using wiring harness or wire,...
  • Page 565 Chapter 7 Wiring Diagrams and Signal Information Symbols Description Indicates a return. Represents a connector. The connector and PIN Nos. are shown at the upper and lower parts respectively. "P,-" indicates the plug side of the connector. "J,>" indicates the jack side of the connector. Represents a connection terminal with a plate spring on the printed circuit board.

  • Page 566: Configuration Of The Interconnection Wiring Diagram Of Parts

    Chapter 7 Wiring Diagrams and Signal Information 2.2 Configuration of the Interconnection Wiring Diagram of Parts The interconnection wiring diagram is divided into 6 sections (1 - 6) indicating details of the interconnections of parts. 1 HARNESS ASSY INTERLOCK1, INTERLOCK S/W REAR, MAIN MOTOR 45, FAN SUB, MOTOR ASSY EXIT Connections of HARNESS ASSY INTERLOCK1 and INTERLOCK S/W REAR with LVPS Connections of MAIN MOTOR 45 with LVPS...
  • Page 567 Chapter 7 Wiring Diagrams and Signal Information 1 HARNESS ASSY INTERLOCK1, INTERLOCK S/W REAR, MAIN MOTOR 45, FAN SUB, MOTOR ASSY EXIT HARNESS ASSY LVPS(1/6) LVPS PL12.1.5 HVPS/ MCU PL12.1.1 P/J11 P/J41 PL12.1.19 MCU STBY 24V DC Power Save 1 Supply Power Save 2 P/J45...
  • Page 568 Chapter 7 Wiring Diagrams and Signal Information Signal line name Description /HEAT ON AC power-supply control signal for Heater Rod. Low: ON/High: OFF MOTOR ON Control signal for MAIN MOTOR 45. MOTOR ALM Monitor signal for MAIN MOTOR 45. Signal indicating that the rear cover is open. This signal goes High when the front or INTERLOCK AFT rear cover is open.
  • Page 569 Chapter 7 Wiring Diagrams and Signal Information 2 FUSER ASSY, POWER SWITCH HARNESS ASSY FUSER ASSY FUSER PL8.1.20 LVPS PL8.1.17 P/J46 P/J4647 PL12.1.5 P/J4249 STS 2 Pullup 3.3V / EXIT P/J4248 1 2 3 STS 1 P/J4247 (Secondary) Exit Sensor (Secondary) P.ROLL (Primary)
  • Page 570 Chapter 7 Wiring Diagrams and Signal Information 3 EP Cartridge, HOUSING ASSY BTR J2 HVPS/ MCU GUIDE ASSY CRU R EP CARTRIDGE PL 12.1.19 PL 8.1.25 Roll Drum Detack P/J 310 P/J 31 HOUSING ASSY BTR J2 HVPS PL 8.1.21 PWBA ASSY ANT P/J15 P/J150...
  • Page 571 Chapter 7 Wiring Diagrams and Signal Information 4 150 Paper Feeder, 250/550 Paper Feeder, FAN MAIN 80 GUIDE TRAY LEFT HVPS/ MCU HARNESS ASSY PL7.1.7 PL12.1.19 LVPS(6/6) P/J1821 P/J18 PL12.1.1 P/J180 Tray1 SW 4 SW Size1 SW 3 SW 2 SW 1 P/J210 Tray2...
  • Page 572 Chapter 7 Wiring Diagrams and Signal Information Signal line name Description /LOW-PAPER2 SNR Signal from SENSOR LOW PAPER. This signal goes Low when light is received. Signal from SENSOR NO PAPER of Tray2. This signal goes Low when light is /NO-PAPER2 SNR ON received.
  • Page 573 Chapter 7 Wiring Diagrams and Signal Information 5 ROS ASSY 45-1200, INTERLOCK S/W 5V, HARNESS ASSY INTERLOCK3 HARNESS ASSY HARNESS ASSY ROS LVPS(5/6) P/J141 P/J142 PL12.1.1 PL8.1.2 HARNESS ASSY INTERLOCK3 N.C. N.C. N.C. N.C. PL8.1.12 HVPS/ MCU PL12.1.19 ROS ASSY 45-1200 PL8.1.1 P/J14 P/J140...
  • Page 574 Chapter 7 Wiring Diagrams and Signal Information Signal line name Description /SOS SYNC signal generated by SOS Sensor. This signal commands start of each scan. /PCONT Sample / Hold circuit Low: Sampled (LD is forcibly lit up); High: Held Laser output control signal for determining or adjusting the current flowing through Vref Laser Diode.
  • Page 575 Chapter 7 Wiring Diagrams and Signal Information 6 500 Paper Exit HARNESS ASSY EXIT SNR PL10.1.27 HVPS/ P/J29 P/J290 SENSOR Pull Up 3.3V FULL STACK PL12.1.19 PL10.1.26 / FULLSTACK SNR ON P/J291 SENSOR Pull Up 3.3V FACE UP OPEN PL10.1.25 / FACE UP OPEN SNR ON Signal line name Description...

  • Page 576: Duplex Transport Option

    Chapter 7 Wiring Diagrams and Signal Information Duplex Transport Option 2.1 Connection Wiring Diagram HVPS/ PWBA DUPLEX PL21.1.32 FAN DUP J2 PL12.1.19 P/J54 PL21.1.33 P/J27 P/J2750 P/J50 SENSOR DUP P/J53 P/J530 PL21.1.34 SWITCH DUPLEX P/J52 P/J520 PL21.1.27 MOTOR DUPLEX P/J51 PL21.1.29 P/J56 P/J560...
  • Page 577 Chapter 7 Wiring Diagrams and Signal Information Option Duplex HARNESS HARNESS HVPS/ MCU PWBA DUPLEX ASSY LVPS ASSY DUP PL12.1.19 PL21.1.32 PL12.1.1 PL21.1.7 P/J27 P/J2750 P/J50 P/J54 FAN DUP J2 24V DC 24V DC PL21.1.33 24V RTN FAN ALARM 24V DC SENSOR DUP HARNESS ASSY 3.3V DC...

  • Page 578: Oct Option

    Chapter 7 Wiring Diagrams and Signal Information OCT Option 2.1 General Wiring Diagram HVPS/ MCU PWBA OCT PL23.1.22 PL12.1.19 MOTOR ASSY OCT P/J71 P/J710 PL23.1.6 P/J30 P/J3070 P/J70 MOTOR ASSY OFFSET P/J72 PL23.1.20 SOLENOID ASSY GATE P/J75 PL23.1.27 SENSOR OCT P/J73 P/J730 PL23.1.30...

  • Page 579: Configuration Of The Interconnection Wiring Diagram Of Parts

    Chapter 7 Wiring Diagrams and Signal Information 2.2 Configuration of the Interconnection Wiring Diagram of Parts Option OCT Connections of HVPS/MCU with PWBA OCT Connections of PWBA OCT with MOTOR ASSY OCT Connections of PWBA OCT with MOTOR ASSY OFFSET Connections of PWBA OCT with SOLENOID ASSY GATE Connections of PWBA OCT with SENSOR OCT Connections of PWBA OCT with S/W REAR COVER...
  • Page 580 Chapter 7 Wiring Diagrams and Signal Information Option OCT HARNESS ASSY HARNESS ASSY HARNESS ASSY OCT MOT OCT1 OCT2 PL23.1.46 PWBA OCT PL12.1.26 PL23.1.25 HVPS/ P/J71 P/J710 P/J30 P/J3070 P/J70 PL23.1.22 MOTOR 24V DC 24V DC ASSY OCT PL12.1.19 PL23.1.6 24V DC 3.3V DC P/J72...

  • Page 581: General Wiring Diagram

    Chapter 7 Wiring Diagrams and Signal Information 2.1 General Wiring Diagram HVPS/ MCU PWBA FEEDER 550 PL12.1.19 PL20.1.34 OPT ASSY SIZE P/J20 P/J2083 P/J83 P/J80 P/J801 P/J802 PL20.1.18 SENSOR LOW PAPER P/J81 P/J810 PL20.1.30 MOTOR ASSY OPT FDR 45 P/J82 P/J820 PL20.1.7 CLUTCH ASSY...

  • Page 582: Configuration Of The Interconnection Wiring Diagram Of Parts

    Chapter 7 Wiring Diagrams and Signal Information 2.2 Configuration of the Interconnection Wiring Diagram of Parts Option 550 Paper Feeder Connections of HVPS/MCU with PWBA FEEDER250 Connections of PWBA FEEDER550 with OPT ASSY SIZE Connections of PWBA FEEDER550 with SENSOR LOW PAPER Connections of PWBA FEEDER550 with MOTOR ASSY OPT FDR 45 Connections of PWBA FEEDER550 with CLUTCH ASSY PH Connections of PWBA FEEDER550 with CLUTCH PR-REGI...

  • Page 583: Option 550 Paper Feeder

    Chapter 7 Wiring Diagrams and Signal Information Option 550 Paper Feeder HARNESS HARNESS PWBA FEEDER 550 HARNESS HARNESS HVPS/MCU ASSY ASSY PL20.1.34 ASSY SIZE ASSY SIZE PL12.1.19 FDR1 FDR2 FDR 2 FDR 1 PL12.1.21 PL20.1.5 PL20.1.35 PL20.1.19 OPT ASSY P/J20 P/J2083 P/J83 P/J80...
  • Page 584 Chapter 7 Wiring Diagrams and Signal Information Blank Page 7 – 24...

  • Page 585: Chapter 8 Printer Specifications

    Chapter 8 Printer Specifications Chapter 8 Printer Specifications Contents Chapter 8 Printer Specifications Engine 1. Configuration of Printer....................8 - 1 1.1 Basic Configuration........................... 8 - 1 1.2 Engine Configuration with Options....................8 - 1 2. Electrical Properties.....................8 - 2 2.1 Power Source ........................... 8 - 2 2.1.1 For 120 VAC Printer........................
  • Page 586 Chapter 8 Printer Specifications Chapter 8 Printer Specifications Contents 4.3 Paper Output Tray .......................... 8 - 12 4.3.1 500 Sheet Face Down Output Tray ..................8 - 12 4.3.2 Face Up Output Tray (Option) ....................8 - 13 4.3.3 500 Sheet Offset Catch Tray (Option) ..................8 - 13 4.4 Printing Media ..........................

  • Page 587: Engine

    Chapter 8 Printer Specifications Chapter 8 Printer Specifications Engine 1. Configuration of Printer 1.1 Basic Configuration The basic printer consists of the print engine main unit, consumables (CRU), 150 Sheet Universal and 550 Sheet Universal Trays. JG8101AA 1.2 Engine Configuration with Options Functional configuration of this printer is shown below.

  • Page 588: Electrical Properties

    Chapter 8 Printer Specifications 2. Electrical Properties 2.1 Power Source Two types of power source as follows are available for this printer, which are selected according to the specifications. 2.1.1 For 120 VAC Printer Voltage Frequency Nominal Nominal 98VAC 120VAC 132VAC 47Hz 50/60Hz...

  • Page 589: Mechanical Properties

    Chapter 8 Printer Specifications 3. Mechanical Properties Dimensions shall be specified with nominal values including dimensional tolerances of +/- 5mm and +/- 0.5 kg. The dimensions shall not include any of the local projections including a lever and a handle. 3.1 Print Engine Size and Weight (REF) Configuration Depth (mm)

  • Page 590: Media Input Tray Size And Weight (Ref)

    Chapter 8 Printer Specifications 3.2 Media Input Tray Size and Weight (REF) Depth (mm) Width Height Weight Configuration Condition To Legal (mm) (mm) (kg) To A4/Letter Unpacked 283.7 390.6 449.2 50.4 1.60 150 Tray Packaged 487.0 375.0 157.0 Unpacked 283.7 394.6 453.2 85.6...

  • Page 591: Media Input Tray/Deck (Packaged In The Same Box), Size And Weight (Ref)

    Chapter 8 Printer Specifications 3.3 Media Input Tray/Deck (packaged in the same box), Size and Weight (REF) Depth (mm) Width Height Weight Configuration Condition To Legal (mm) (mm) (kg) To A4/Letter Unpacked 421.8 451.6 510.2 143.0 550 Input Tray Feeder Packaged 551.0 541.0...

  • Page 592: Duplex Unit Size And Weight

    Chapter 8 Printer Specifications 3.5 Duplex Unit Size and Weight Condition Width (mm) Depth (mm) Height (mm) Weight (kg) Unpacked 351.7 146.2 238.0 Packaged 454.0 322.0 237.0 J20009A 3.6 500 Sheet Offset Catch Tray Size and Weight Condition Width (mm) Depth (mm) Height (mm) Weight (kg)

  • Page 593: Face Up Tray Size And Weight (Ref)

    Chapter 8 Printer Specifications 3.7 Face Up Tray Size and Weight (REF) Condition Width (mm) Depth (mm) Height (mm) Weight (kg) Unpacked 162.6 89.4 (Installation) 320.6 0.25 Unpacked 169.6 43.0 (Simple) Packaged 360.0 200.0 95.0 JG8711AA 3.8 Minimum Space Requirements There must be sufficient space around the print engine for proper access, ventilation and operation.

  • Page 594: Specification

    Chapter 8 Printer Specifications 4. Specification 4.1 Base Print Engine Specification 4.1.1 Printing System Electro-photographic system (roller charging, single component magnetic toner development). 4.1.2 Exposure System Semiconductor laser beam scanning system. 4.1.3 Transfer System Roller transfer system. 4.1.4 Fixing System Thermal fusing system by a heated roller.

  • Page 595: Continuous Print Speed

    Chapter 8 Printer Specifications 4.1.8 Continuous Print Speed The following data are theoretical values for Input Trays 1,2,3 and 4. Simplex Simplex Thick Simplex Duplex Duplex Simplex/ Simplex Thick Stock Stock Mode3 Duplex Thick Stock Thick Stock Thick Stock Paper Size Thin Paper OHP Mode Mode1/...
  • Page 596 Chapter 8 Printer Specifications 3. Media Stack Capacity - Baseline paper: 150 sheets (Xerox 4200 20lb Letter / RX 80 A4: 3R91720 / Fuji Xerox P A4) - Other paper: Reference Media Stack Capacity - Standard paper: 17.5 mm maximum - Envelopes River series C5: 20 sheets (Max: 17.5mm) (Note 1) - Envelopes Columbian com10:...

  • Page 597: Auxiliary Paper Deck (Option)

    Chapter 8 Printer Specifications This tray shall automatically sense the following 7 paper sizes when the End Guide is properly adjusted. Type Size (mm x mm) Weight Letter SEF 215.9 x 279.4 Legal 14” SEF 215.9 x 355.6 Legal 13” SEF 215.9 x 330.2 Executive SEF 184.2 x 266.7...

  • Page 598: Duplex Unit (Option)

    Chapter 8 Printer Specifications 4.2.4 Duplex Unit (Option) This unit is capable of printing on both sides of the paper. 1. Media Size - Width: 88.9mm ~ 215.9mm - Length: 139.7mm ~ 355.6mm Type Size (mm x mm) Letter SEF 215.9 x 279.4 A4 SEF 210.0 x 297.0...

  • Page 599: Face Up Output Tray (Option)

    Chapter 8 Printer Specifications 4.3.2 Face Up Output Tray (Option) Under normal conditions (22 C, 55-60%RH), the print engine output tray has a capacity of 500 sheets of face-down output on the top cover, assuming the following paper. This applies to newly-opened paper which has been rested in the packaged condition for more than 12 hours in the operating environment.

  • Page 600: Ep Cartridge Specification

    Chapter 8 Printer Specifications 4.5 EP Cartridge Specification The EP Cartridge contains an OPC drum, a developing roller and blade, a primary charge roller, a drum cleaner, consumable memory device and the toner. The toner color shall be black. 4.5.1 EP Cartridge Life Three EP cartridges are available for the print engine.

  • Page 601: Environmental Specifications

    Chapter 8 Printer Specifications 5. Environmental Specifications 5.1 Installation and Storage Requirements 5.1.1 Print Engine Installation Requirements: Unpacked condition, an EP Cartridge installed. Condition C) Humidity (% RH) Altitude (m) Remarks Temperature ( Operating 5 - 35 15 - 85 0 - 3,500 non-condensing Non-operating...

  • Page 602: Pollution/Safety

    Chapter 8 Printer Specifications 5.7 Pollution/Safety The print engine shall meet the regulations (See Note 1). Under the normal operation, no smoke or fire shall be observed. Mis-use by an operator or power problems shall not cause fire. 1: See section for safety regulations. 5.8 Ozone Emission The print engine shall not emit more than 2.0 mg/h.

  • Page 603: Regulatory Agency Approvals

    Chapter 8 Printer Specifications 6. Regulatory Agency Approvals The print engine shall meet the following regulatory specifications. Printer configuration includes all paper handling options and a toner cartridge: Tray - OCT - Duplex - Face Up Tray 6.1 Safety Specifications 6.1.1 For 120V/240V Type - UL60950-1, 1 Edition by National Recognized Test Lab (NRTL)

  • Page 604: Reliability Specifications

    Chapter 8 Printer Specifications 7. Reliability Specifications The print engine shall meet the following specifications. 1. A single sheet shall be defined as two (2) impressions in the duplex mode. 2. Paper shall be flipped over if the feeding performance does not meet with face side. 7.1 MPBF (Mean Prints Between Failures) MPBF: 300,000 impressions.

  • Page 605: Ep Cartridge Life

    Chapter 8 Printer Specifications 7.3.3 EP Cartridge Life Three EP cartridges are available for the print engine. The 6K EP cartridge shall have an aver- age print life of 6,000 impressions on an average of 5% image coverage on Letter size paper. The 10K EP cartridge shall have an average of 10,000 impressions under the same conditions.

  • Page 606: Print Quality Specifications

    Chapter 8 Printer Specifications 8. Print Quality Specifications Specification values described below are the values within 95% in-spec rate. 8.1 Print Quality Evaluation and Guaranteed Conditions Print quality shall include print alignment, print density, uniformity, resolution and other items. Unless otherwise indicated, the following are the guaranteed conditions in simplex mode and in duplex mode.

  • Page 607: Chapter 9 Ess Options

    Chapter 9 ESS Options Chapter 9 Controller/ESS Options Contents Chapter 9 ESS Options 1. ESS Options ........................9 - 1 1.1 ESS Configuration ..........................9 - 1 2. Option Installation......................9 - 2 2.1 Installing the HDD ..........................9 - 2 2.2 Installing the CF ..........................9 - 3 2.3 Installing the Development Flash Card .....................
  • Page 608 Chapter 9 ESS Options Chapter 9 Controller/ESS Options Contents Blank Page...

  • Page 609: Chapter 9 Ess Options

    Chapter 9 ESS Options Chapter 9 ESS Options 1. ESS Options 1.1 ESS Configuration The ESS has several options that can be installed to enhance performance: a. Hard Drive (HDD) b. Compact Flash (CF) c. Development Flash Card d. Single In-line Memory Module (SIMM) Card e.

  • Page 610: Option Installation

    Chapter 9 ESS Options 2. Option Installation 2.1 Installing the HDD 1) Turn the printer power OFF and remove the power cord from the outlet. 2) Remove the COVER RIGHT (RRP1.2) (PL1.1.4) 3) Remove the SHIELD ASSY WINDOW (RRP12.8) (PL12.1.15) In the step that follows take care when seating the device.

  • Page 611: Installing The Cf

    Chapter 9 ESS Options 2.2 Installing the CF 1) Turn the printer power OFF and remove the power cord from the outlet. 2) Remove the COVER RIGHT (RRP1.2) (PL1.1.4). 3) Remove the SHIELD ASSY WINDOW (RRP12.8) (PL12.1.15). 4) Align the CF with the socket on the ESS PWB (See figure below). In the step that follows take care when seating the device.

  • Page 612: Installing The Development Flash Card

    Chapter 9 ESS Options 2.3 Installing the Development Flash Card 1) Turn the printer power OFF and remove the power cord from the outlet. 2) Remove the COVER RIGHT (RRP1.2) (PL1.1.4). 3) Remove the SHIELD ASSY WINDOW (RRP12.8) (PL12.1.15). 4) Align the Card with the socket on the ESS PWB (See figure below). In the step that follows take care when seating the device.

  • Page 613: Installing The Simm Card

    Chapter 9 ESS Options 2.4 Installing the SIMM Card 1) Turn the printer power OFF and remove the power cord from the outlet. 2) Remove the COVER RIGHT (RRP1.2) (PL1.1.4). 3) Remove the SHIELD ASSY WINDOW (RRP12.8) (PL12.1.15). 4) Release the latches on the SIMM Card socket (See figure below). In the step that follows take care when seating the device.
  • Page 614 Chapter 9 ESS Options 6) Seat the SIMM Card into the socket on the ESS. 7) Raise the latches on the SIMM Card socket firmly capturing the Card (See figure below). 8) Replace the SHIELD ASSY WINDOW. 9) Replace the COVER RIGHT. 10) Plug the power cord into the AC outlet and turn the printer power ON.

  • Page 615: Installing The Nic

    Chapter 9 ESS Options 2.5 Installing the NIC 1) Turn the printer power OFF and remove the power cord from the outlet. 2) Remove the COVER RIGHT (RRP1.2) (PL1.1.4). 3) Remove the SHIELD ASSY WINDOW (RRP12.8) (PL12.1.15). 4) Align the NIC with the socket on the ESS PWB (See figure below). In the step that follows take care when seating the device.
  • Page 616 Chapter 9 ESS Options Blank Page 9 - 8...

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