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4-5WorkCentre Pro 275 Family (CC232-WCP275F) REP 1.1Repairs/Adjustments

REP 1.1 Power and Control Assembly

Parts List on PL 1.10

Removal

WARNING

Switch off the electricity to the machine, GP 14. Disconnect the power cord from the

customer supply while performing tasks that do not need electricity. Electricity can

cause death or injury. Moving parts can cause injury.

WARNINGTake care during this procedure. Sharp edges may be present that can cause injury.

CAUTION

Ensure that E.S.D. procedures are observed during the removal and installation of the IOT

PWB and the NVM chip. Make a visual check to ensure that the pins are fully inserted, without

being damaged.

Use the appropriate tool to remove the NVM chip.

1. Pull out tray 1 and tray 2 approximately 100 mm (4 inches).

2. Disconnect accessories and the output device.

3. Remove the rear cover, PL 8.10 Item 1.

4. Remove the waste toner bottle door assembly, REP 9.1.

5. Figure 1. Disconnect the ground wires from the ground point.

Figure 1 Main frame ground point

2Remove the groundwires from the groundpoint

1Remove the nut

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4-6 WorkCentre Pro 275 Family (CC232-WCP275F)REP 1.1Repairs/Adjustments

6. Figure 2. Remove the cable ties and the ground connection.

Figure 2 Cable tie and ground connection

7. Figure 3. Remove the securing screw from the power and control assembly.

Figure 3 Power and control assembly

Remove cable tie

Ground connection

Cut cable tie

1Remove screw

2Move the power andcontrol assembly tothe left

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8. Figure 4. Disconnect PJ24 and all of the HT leads on the HVPS PWB.

Figure 4 HVPS PWB

9. Figure 5. Disconnect the indicated PJs connectors on the IOT PWB.

NOTE: PJ33 is only used on 65-75 ppm machines. PJ64 is only used on 45-75 ppm

machines. Refer to GP 9 for the IOT sparing strategy.

Figure 5 IOT PWB

10. Figure 6. Disconnect all of the PJs from the LVPS.

1Disconnect PJ24

2Disconnect all the HTleads on the HVPS PWB

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Figure 6 LVPS

11. Remove the power and control assembly.

Replacement

If a new LVPS and base module is installed with the HVPS and IOT PWB transferred from

the failed LVPS and base module then perform steps 1 to 3.

If a new power and control assembly complete with IOT PWB and NVM has been

installed then perform steps 1 to 4. If the NVM has not been corrupted, it can be transferred from the IOT PWB on the failed

power and control assembly and installed onto the new IOT PWB. This will retain the orig-

inal machine configuration and NVM data for the IOT.

Figure 7, Ensure that the NVM chip is installed with the notch at the bottom. Improper

installation can damage the NVM.

Install the new power and control assembly with the original NVM chip on the IOT PWB

and perform steps 1 to 3.

CAUTION

Ensure the HT leads are correctly connected. Do not connect the female spade connector

between the male spade connector and the outer casing of the HT leads.CAUTION

Do not trap the harnesses when the power and control assembly is installed.

Perform the following:

1. Figure 7. Ensure that the bypass tray ribbon cable is routed correctly.

Figure 7 Bypass tray ribbon cable

2. Check that PJ148 has not been disconnected on the Main Drive PWB.

3. Figure 8. Ensure that the nut on the ground connection is tightened to secure the ground

terminals.

4. Figure 8. Use a digital multimeter set to a resistance range. Verify that continuity exists

between the ground pin on PJ 21 and the frame ground connection.

PJ10 bypass tray ribbon cable

Bypass tray ribbon cable

Notch on NVM

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4-9WorkCentre Pro 275 Family (CC232-WCP275F) REP 1.1, REP 1.2Repairs/Adjustments

Figure 8 Ground check

5. Reconnect the power cord and switch on the machine, GP 14.

If necessary, reload the software set, GP 4. If the machine is fitted with a network control-

ler, the machine will automatically upgrade or downgrade the software when the machine

isswitched on.

NOTE: After the software reload has been completed, the machine resets and gives a

message Restoring Configuration Settings. Do not switch off the machine or intervene

during this NVM transformation process.

6. Check the machine serial number and the machine configuration, GP 15.

REP 1.2 Wiring Harness Repairs

Purpose

WARNING

Switch off the electricity to the machine, GP 14. Disconnect the power cord. Electricity

can cause death or injury. Moving parts can cause injury.

WARNING

Do not attempt any repairs to the power cord or safety ground harness/conductor.

NOTE: Safety ground connections use green/yellow cables, or green cables with a yellow

stripe or band.

NOTE: Refer to PL 31.20 for identification of different connectors and terminal types.

The following steps identify the relevant procedures for repairing the various connectors con-

tained within the copier.

1. If wiring is damaged, use connector splicing blocks from the appropriate repair kit, PL

31.20, PL 31.25 and PL 31.30, to repair damaged wiring.

2. The following harness assemblies are not repairable; install new parts: Any ribbon harness.

Image processing module / LVPS/IOT PWB harness, (32-55 ppm) PL 3.20 Item 14

or (65-75 ppm) PL 3.10 Item 14.

ROS data cable, (32-55 ppm) PL 3.20 Item 15, (65-75 ppm) PL 3.10 Item 15.

Image processing module / UI harness, (32-55 ppm) PL 3.20 Item 11, (65-75 ppm)

PL 3.10 Item 11.

Riser PWB/Power distribution PWB harness, (32-55 ppm) PL 3.20 Item 6, (65-75

ppm) PL 3.10 Item 6.

(32-55 ppm)Image processing module/CCD PWB harness PL 3.20 Item 9.

(65-75 ppm)Image processing module/scanner PWB harness PL 3.10 Item 9.

(32-55 ppm)Image processing module/scanner driver PWB, PL 3.20 Item 7.

(65-75 ppm)Power distribution PWB/scanner PWB harness, PL 3.10 Item 7.

3. The following connectors can be repaired by removing the faulty terminals and installing

new terminals:

Molex SL connectors - REP 1.3.

Male Hirose DF 1B connectors - REP 1.4.

AMP EI connectors - REP 1.5.

Hirose DF11 Connectors - REP 1.6.

AMP CT connectors - REP 1.7.

Main frame ground connection

Ground pin on PJ 21

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REP 1.3 Molex SL Connectors


Removal

WARNING




NOTE: Molex connectors have small black housings in single and double row form with minia-

ture square section pins and sockets.

1. If the damaged connector is located in the centre of a double row housing beneath the

latching clip, the latching prong will not be accessible to release the connector from the

housing. Therefore it will be necessary to disassemble the housing as shown in Figure 1.

Figure 1 Disassembling the connector.

2. Figure 2. Remove the terminal from the connector housing using the Molex extractor tool,

Table 1.

Figure 2 Removing the terminal.

3. Cut off the damaged terminal, then strip 3mm of insulation from the end of the wire.

Replacement

1. Table 1. Select the correct replacement terminal, and identify the appropriate crimp posi-

tions for the terminal. Refer to PL 31.20 Item 10, and PL 31.20 Item 13.

1Hold the wires from thebold row connector

2Attach the Molex connector

5

Pull out A row

4Pull out B row connector

3Bend the housing open

Table 1 Connector Information

Description part No. Extractor Crimp Tool Crimp Tool Jaw

Wire insulation

Molex SL female 713W00432 600T1825 600T913 B B

Molex SL male 713W00232 600T1825 600T913 B B

1Insert Molex tool

2Press prong flat

3Push terminal out of housingusing a male terminal from therepair kit

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2. Figure 3. Insert a male or female terminal into the appropriate position of the crimp tool

and close the tool just enough to hold the terminal.

Figure 3 Crimping the terminal.

3. Insert the wire fully into the terminal so that the stripped portion of the wire is within the

inner grip of the terminal. Close the crimp tool fully to make the crimp.

4. Figure 4. Insert the crimped terminal into the appropriate position of the crimp tool and

close the crimp tool, to fasten the insulation of the wire in the outer grip of the terminal.

Figure 4 Crimping the insulation grip.

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5. Figure 5. Check that the crimp is correctly made.

Figure 5 Inspecting the finished crimp.

6. Insert the replacement terminal into the connector housing.

7. If the repair was carried out on a double row connector that needed to be disassembled,

push both connectors into the housing taking care that the A connector is fitted on the

fastener side.

REP 1.4 Male Hirose DF1B Connectors

Parts List on PL 31.15 and PL 31.20

Removal

WARNING



cause death or injury. Moving parts can cause injury.1. Figure 1. Remove the damaged terminal from the housing.

Figure 1 Remove the terminal

2. Cut off the damaged terminal, then strip 3 mm of insulation from the end of the wire.

Replacement

CAUTION

There are different terminals for large gauge and small gauge wire (Table 1). Ensure that the

correct replacement terminal is used.

1. Table 1. Select the correct replacement terminal and identify the appropriate crimp posi-

tions for the terminal. Refer to PL 31.15 Item 4 and PL 31.20 Item 1.

Correct

Incorrect

Loose strands of wire

Crimp loose

Insulation in crimp Wire exposed

1Raise plastic tab with

suitable tool, torelease terminal

2Remove terminal fromhousing

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NOTE: These connectors can be repaired using either crimp terminals or pre-crimped ter-

minals with flying lead and butt connector, as required.

2. Figure 2. Insert the terminal into the appropriate position of the crimp tool and close the

tool just enough to hold the terminal.


3. Insert the wire fully into the terminal so that the stripped portion of the wire is within thelonger grip of the terminal and the insulation of the wire is within the cable grip of the ter-

minal. Close the crimp tool fully to make the crimp; check that the wire is firmly crimped in

the terminal.


close the crimp tool to firmly fasten the insulation of the wire in the cable grip of the termi-

nal.

Figure 3 Crimping the insulation grip.


Description Part No Extractor Crimp Tool Crimp Tool Jaw

Wire Insulation

Male socket, 20-22 AWG 915W00007 - 600T913 A B

Male socket, 24-28 AWG 915W00008 - 600T913 B C

Male socket with flying

lead (part of Kit)

600K37891 - 600T913 - -

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Figure 4 Inspecting the finished crimp.


REP 1.5 AMP EI Connectors


Removal

WARNING




NOTE: The male housings contain socket terminals, and the female housings contain pin ter-

minals.

1. Use the extractor tool, Table 1, to release the terminal from the housing. Refer to Figure 1

to identify the male housing and terminal type. Refer to Figure 2 to identify the female

housing and the terminal type.

Figure 1 Terminal removal; male housing.

Correct

Incorrect

Wire exposed

Insulation In crimp


crimp loose

1Depress prong torelease terminal


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Figure 2 Terminal removal; female housing.

2. Cut off the damaged terminal, then strip 3mm of insulation from the end of the wire.

Replacement

1. Table 1. Select the correct replacement terminal and identify the appropriate crimp posi-

tions for the terminal. Refer to PL 31.15 Item 1.

2. Figure 3. Insert the terminal into the appropriate position of the crimp tool and close the

tool enough to hold the terminal.


3. Insert the wire completely into the terminal, so that the stripped portion of the wire is in the

longer grip of the terminal. The insulation of the wire is within the cable grip of the termi-

nal. Close the crimp tool completely to make the crimp. Check that the wire is crimped

firmly in the terminal.


Description Part No Extractor Crimp Tool Crimp Tool JawWire Insulation

Male socket 115P60155 - 600T913 A B

Female pin 115P60182 Paper clip 600T913 A B

2Remove terminal from housing

1Insert a paper clip torelease prong

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close the crimp tool to firmly fasten the insulation of the wire in the cable grip of the termi-

nal.

Figure 4 Crimping the insulated grip.


Figure 5 Inspect the finished crimp


Correct

Incorrect

Wire exposed

Insulation in crimp

Crimp loose


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4-17WorkCentre Pro 275 Family (CC232-WCP275F) REP 1.6, REP 1.7Repairs/Adjustments

REP 1.6 Hirose DF11 Connectors


Removal

WARNING



cause death or injury. Moving parts can cause injury.NOTE: The male housing contains female terminals that cannot be crimped in the field; if a ter-

minal is damaged, install a new terminal with flying lead.

1. Figure 1. Remove the damaged terminal from the connector housing.

Figure 1 Terminal removed

2. Cut the damaged terminal off the wire.

Replacement

1. Insert the replacement terminal with flying lead into the connector housing. Refer to repair

kit PL 31.20 Item 7.

2. Use a butt connector to connect the flying lead to the original wire.

REP 1.7 AMP CT Connectors

Parts List on sPL 31.30

Removal

WARNING



cause death or injury. Moving parts can cause injury.CAUTION

Amp CT connectors use in-line adaptors to connect housings together. Ensure that the correct

adaptor is used for each in-line connection (Table 1). Do not attempt to disassemble or repair

the in-line adaptors.

NOTE: There are two types of CT connector: insulation displacement connector (IDC) or crimp

terminal. Repairing crimp terminal CT connectors is performed by installing individual replace-

ment terminals with flying leads, connected to the existing wiring with connector splicing blocks

(removal steps 2 and 3). Repairing IDC connectors is performed by installing a complete

replacement housing with wires already fitted, connected to the existing wiring with connector

splicing blocks (removal steps 4 and 5). The replacement procedure is only applicable to crimpterminal connectors.

1. Identify the terminal type. Go to step 2 for a housing containing crimp terminals, or go to

step 4 for a housing containing insulation displacement (IDC) terminals.

1Raise plastic tab with suitable tool, to release terminal


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2. Figure 1. Remove the damaged crimp terminal from the connector housing.

Figure 1 Terminal removal.

3. Cut the damaged crimp terminal off the wire.

4. IDC housings are repaired by installing a complete replacement housing with wires

already fitted, connected with connector splicing blocks to the existing wiring. Refer to

Table 1. Select the correct replacement connector.

5. Cut one wire from the faulty connector and then reconnect the wire to the appropriate fly-

ing lead on the replacement connector. Repeat this process for each wire in turn, until the

faulty connector has been fully disconnected and the replacement connector installed in

its place.

Replacement

1. Insert the replacement crimp terminal with flying lead into the connector housing. Refer to

Table 1.

2. Use a connector splicing block to connect the flying lead to the original wire.

1Raise plastic tab with suitable tool, to release terminal



Description Part No Extractor Crimp Tool Crimp Tool Jaw

Wire Insulation

IDC replacement con-

nector kit (contains 2, 3,

4 and 6 way connectorswith flying leads)

600K40640 - - - -

IDC replacement con-

nector kit (contains 7, 8,

9, 10, 11, 12, 14 and 15

way connectors with fly-

ing leads)

600K40650 - - - -

Crimp terminal with fly-

ing lead (part of Kit)

600K37901 - - - -

In-line adaptor kit (con-

tains 2, 3 & 6 way con-nectors)

600K90400 - - - -

In-line adaptor kit (con-

tains 4, 8 & 15 way con-

nectors)

600K90390 - - - -

REP 1 8 D I t l k S it h 2 Fi 2 R h i l k i h

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REP 1.8 Door Interlock Switch


Removal

WARNING



cause death or injury. Moving parts can cause injury.WARNING

Take care during this procedure. Sharp edges may be present that can cause injury.

1. Figure 1. Release the door interlock switch.

Figure 1 Releasing switch

2. Figure 2. Remove the interlock switch.

Figure 2 Removing switch

Replacement

Reverse the removal procedure to replace the door interlock switch.

1Insert a steel rule or feelergauge and push to release thecatch. Pull the switch forward

2Repeat step 1 to release theother side of the switch

1Rotate the body of theswitch to remove.

REP 1 9 LVPS and Base Mod le 2 Remove the HVPS IOT PWB and cover assembly from the old LVPS and base module

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REP 1.9 LVPS and Base Module


Removal

WARNING




WARNING


1. Remove the power and control assembly, REP 1.1.

2. Remove the HVPS, IOT PWB and cover assembly from the old LVPS and base module,

Figure 1.

Figure 1 Remove the HVPS, IOT PWB and cover

1Remove 2 screws

2Disconnect PJ27and PJ26

3Slide the HVPS, IOT PWB and cover assembly to the right, then remove.

3 Remove the output device harness from the old LVPS and base module Figure 2 Replacement

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3. Remove the output device harness from the old LVPS and base module, Figure 2.

Figure 2 Harness removal

Replacement

1. Remove the cover from the new LVPS and base module, Figure 3.

Figure 3 Remove the cover

2. Install the HVPS, IOT PWB and cover assembly onto the new LVPS and base module.

Secure with 2 screws. Refer to Figure 1.

CAUTION

Do not over tighten the hex head screws. The screws break very easily.

3. Install the output device harness onto the new LVPS and base module. Secure with the 2

hex head screws. Refer to Figure 2.

4. Re-install the power and control assembly, refer to REP 1.1.

1Remove 2 hex headscrews

2Remove the output deviceharness

1Remove 2 screws

2Slide the cover to the right, then remove.

REP 1 10 HVPS 2 Figure 1 Remove the HVPS

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REP 1.10 HVPS


Removal

WARNING




WARNING



2. Figure 1. Remove the HVPS.

Figure 1 Remove the HVPS

1Disconnect 6HT connectors

3Remove 2 screws

2Disconnect PJ55

4Remove the HVPS

Replacement

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Replacement

1. Reverse the removal procedure to replace the HVPS.

2. Figure 2. Ensure that the white plastic insulator underneath the HVPS is seated correctly

on the plastic clips.

Figure 2 HVPS insulator and push clips

3. Figure 3. Use a digital multimeter set to a resistance range. Verify that continuity exists

between the ground pin on PJ 21 and the frame ground connection.

Figure 3 Ground connection check

HVPS PWB location tabs

Plasticpushclips

Frame groundconnection

(32-55 ppm only)Ground pin on PJ21

(65-75 ppm only)Ground pin on PJ21

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REP 2.1 User Interface Assembly

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y

Parts List on (32-55 ppm) PL 2.15, (65-75 ppm) PL 2.10.

Removal

WARNING




CAUTION

Ensure that E.S.D. procedures are observed during the removal and installation of the user

interface assembly.

1. Open the front door, PL 8.10 Item 10.

2. Remove the user interface assembly, Figure 1.

Figure 1 User interface assembly

Replacement

1. The replacement is the reverse of the removal procedure. Refer to GP 6 before the

screws are installed to the user interface assembly.

2. If prompted, reload the software set, GP 4. The WorkCentre and WorkCentre Pro will

automatically upgrade or downgrade the software when the machine is switched on, GP

14.

1Remove 2 screws

2Disconnect PJ130and PJ81

REP 2.2 User Interface Touch Screen

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Removal

WARNING




CAUTION


interface touch screen.

1. Remove the user interface assembly, REP 2.1

2. Put the user interface assembly on a flat surface.

CAUTION

The cable clamp on JP3 is very fragile and only needs to be lifted slightly to release the Ribbon

Cable.

3. Remove the user interface touch screen, Figure 1.

Figure 1 Remove the touch screen

Replacement

The replacement is the reverse of the removal procedure. Refer to GP 6 before the screws are

installed to the user interface assembly

3Remove four screws

1Disconnect PJ6

2

Lift the cable clamp to release theribbon cable

REP 2.3 User Interface PWB

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Removal

WARNING




CAUTION


interface PWB.

1. Remove the user interface assembly, REP 2.1

2. Put the user interface assembly on a flat surface.

CAUTION

The cable clamp on JP3 is very fragile and only needs to be lifted slightly to release the Ribbon

Cable.

3. Remove the user interface PWB, Figure 1.

Figure 1 Remove user interface PWB

Replacement

The replacement is the reverse of the removal procedure. Refer to GP 6 before the screws are

installed to the user interface assembly

1

Lift the cable clamp to releasethe ribbon cable

2Disconnect PJ6

3Remove eightscrews

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REP 3.1 IOT PWB 2. Check the machine serial number and the machine configuration, GP 15.

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Removal

WARNING




CAUTION

Ensure that E.S.D. procedures are observed during the removal and installation of the IOT

PWB and the NVM chip. Make a visual check to ensure that the pins are fully inserted, without

being damaged.

Use the appropriate tool to remove the NVM chip


2. Figure 1, disconnect the PJs from the IOT PWB.

NOTE: 32-38 ppm IOT PWBs do not have PJ33 and PJ64.

3. Remove the IOT PWB (8 screws).

Replacement If a new IOT PWB and NVM has been installed, perform steps 1 and 2.

If the NVM has not been corrupted, it can be transferred from the failed IOT PWB and

installed onto the new IOT PWB. This will retain the original machine configuration and

NVM for the IOT.

Ensure that the NVM chip is installed with the notch at the bottom, Figure 1. Improper

installation can damage the NVM.

Install the new IOT PWB. Ensure the IOT PWB ground contact screw is tight and the

spade contact does not damage any components or tracks on the IOT PWB, Figure 2.

Ensure the contact faces are clean. Ensure the screw is bright plated and not black. Per-

form step 1.Perform the following:


If necessary, reload the software set, GP 4. If the machine is fitted with a network control-

ler, the machine will automatically upgrade or downgrade the software when the machine

is switched on.

NOTE: After the software reload has been completed, the machine resets and gives a

message Restoring Configuration Settings. Do not switch off the machine or intervene

during this NVM transformation process.

Figure 1 IOT PWB

Figure 2 IOT PWB ground contact

Notch at the bottomNVM

IOT PWB ground contact.

REP 3.2 Image Processing Module PWBs

P t Li t PL 3 10 PL 3 11 PL 3 15 d PL 3 20

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Parts List on PL 3.10, PL 3.11, PL 3.15 and PL 3.20

Removal

WARNING




1. Pull out the image processing module, (32-55 ppm) PL 3.20 Item 1 or (65-75 ppm) PL

3.10 Item 1.

NOTE: Do not perform steps 2 through 4 if you are only removing the firewire PWB or

riser PWB.

2. If installed, remove the foreign interface PWB, (32-55 ppm) PL 3.15 Item 4 or (65-75 ppm)

PL 3.11 Item 3 from the image processing PWB.

NOTE: Record the location of the EPC memory PWBs before their removal.

3. Remove the EPC memory PWBs, (32-55 ppm) PL 3.20 Item 12 or (65-75 ppm) PL 3.10

Item 12 from the image processing PWB.

4. Remove the software module from the image processing PWB, REP 3.3.5. Disconnect the PJs from the relevant PWBs:

Image processing PWB, (32-55 ppm) PL 3.20 Item 3 or (65-75 ppm) PL 3.10 Item 3.

Firewire PWB, (32-55 ppm) PL 3.15 Item 6 or (65-75 ppm) PL 3.11 Item 7.

Riser PWB, (32-55 ppm) PL 3.15 Item 3 or (65-75 ppm) PL 3.11 Item 6.

6. Remove the embedded fax module, firewire PWB, riser PWB or image processing PWB,

Figure 1.

NOTE: 1. Only perform steps 1 to 4 of the removal procedure shown in Figure 1 if an

embedded fax module is installed.

NOTE: 2. On 32-55 ppm machines, the firewire PWB is installed on the right of the riser

PWB, not on the left as shown in Figure 1. It is also secured by 3 screws, not 2 screws.

3

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Figure 1 Image processing module

Software module. EPC MemoryPWBs.

5Remove 2 screws (65-75ppm) or 3 screws (32-55ppm), then the firewire PWBfrom the riser PWB.See Note 2.

6Remove the riser PWB.

4Remove 1 screw, then the embedded fax modulefrom the riser PWB.

7(32-55 PPM) Remove 2 screws marked A.(65-75 PPM) Remove 4 screws.

8Remove 8 screws, thenthe image processingPWB.

1Loosen 1 screw.

2Release the corner of theembedded fax module fromthe fax clip.

3Slide the fax clip away fromthe embedded fax module.

32-55 ppm only

Replacement

1. (65-75 ppm)If installing a new firewire PWB, replace the mounting bracket with either the

REP 3.3 Image Processing PWB Software Module

Parts List on PL 3 10 and PL 3 20

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( pp ) g , p g

mounting bracket from the old firewire PWB, or install a new a mounting bracket, PL 3.11

Item 5. Refer to Figure 2.

2. Ensure the EPC memory PWBs are installed into the correct connectors on the image

processing PWB.

3. Connect the power cord and switch on the machine, GP 14.

Figure 2 Mounting bracket (65-75 ppm)


Removal

WARNING




NOTE: During this procedure, the most recently saved file on the MRD is required. If possible,

save the file from the faulty software module. Be aware that the file on the faulty software mod-

ule may be corrupt.

NOTE: If the machine does not behave as expected during this procedure, switch off the

machine, GP 14, then switch on the machine.

1. Switch off the machine, GP 14.

2. Pull out the image processing module, (32-55 ppm) PL 3.20 Item 1 or (65-75 ppm) PL

3.10 Item 1.

3. If installed, remove the embedded fax PWB, PL 20.10 Item 4.

4. If the machine has a finisher installed, remove the finisher then install a finisher bypass

harness, PL 26.10 Item 7. Refer to the relevant procedure:

REP 11.11-120 1K LCSS Removal.

REP 11.13-110 2K LCSS Undocking.

REP 11.19-130 HCSS Un-Docking.

REP 11.13-170 HCSS BM Un-Docking.

5. WC232-WCP275 Only.Perform the following:

a. Remove the Firewire PWB (32-55 ppm) PL 3.15 Item 6 or (65-75 ppm) PL 3.11 Item

7.

b. Disconnect the network controller power supply harness, PL 16.10 Item 2 from PJ17

on the Power and Control Module.

c. Disconnect the network controller - firewire cable, PL 16.10 Item 12 from the network

controller.

6. Remove the image processing PWB software module, Figure 1.

NOTE: Figure 1 does not show a riser PWB. The machine may have a riser PWB

installed.

2Install either the mounting bracketfrom the old firewire PWB or a

new mounting bracket.

1Remove the existing mountingbracket (2 screws).

5. When the restore is complete, close the NVM save and restore tool. The UI should now

display Ready to scan.

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Figure 1 Software module removal

Replacement

Perform the following:1. Install the new software module, refer to Figure 1.


NOTE: Some or all of the following messages will appear on the UI:

Ready to scan your job.

Install phase incomplete.

Check settings for Tray 1.

Machine speed configuration error, power down / ignore.

Local interface problem detected. Please switch the machine off / on.

3. Enter dC131. Select chain 3, location 03-001 then chain 8, location 08-001. Make sure

the speed of the machine is correct. If necessary, adjust the speed setting.

NOTE: These are protected NVM values. A password is required before they can be

changed. The password can be obtained via the normal escalation process.

4. Perform a NVM restore, refer to GP 5.

NOTE: The following warning may be displayed; The NVM you are trying to restore has

been generated from a different version set number.

Select Yes to continue.

6. CC232-CC275 Only.Reload the machine software, refer to GP 4.

NOTE: This will load the SCD on to the new software module and upgrade the software if

necessary.

7. WC232-WCP275 Only.Perform the following:

a. Switch off the machine, GP 14.

b. Install the firewire PWB. Connect the network controller - firewire cable and the net-work controller power supply harness.

c. Switch on the machine, GP 14.

NOTE: This will load the SCD on to the new software module and upgrade the soft-

ware if necessary.

8. If necessary, switch off the machine, GP 14. Install the finisher then the embedded fax

PWB. Switch on the machine, GP 14.

9. Check that the machine has the correct levels of software.

10. Press the Access button. Enter Pathway Options.

Select: Go to Tools / System Settings / Time and Date / Set Date and Time

a. Set Date: Follow the instructions on the screen to set the correct date.

b. Set Time: Select 12 Hour (AM / PM) or 24 Hour clock.

Follow the instructions on the screen to set the correct time.

c. Press Reboot to exit.

11. Complete the final actions, SCP 6.

1Release the 2 catches.

2Remove the soft-ware module.

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REP 4.1A Main Drive Module (32-55 ppm)




10 R th filt d d t PL 9 25 It 2

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4-35WorkCentre Pro 275 Family (CC232-WCP275F) REP 4.1ARepairs/Adjustments

Removal

WARNING




WARNING


1. Pull out fuser module approximately 100mm, (4 inches), PL 10.8 Item 1.

2. Drop down short paper path assembly, PL 10.20.

3. Remove the xerographic module, PL 9.20 Item 2, and place in a black bag.

4. Remove left hand cover, PL 8.10 Item 3.

5. Disconnect PJ93 and the bias lead on the developer module, Figure 1.

Figure 1 Developer module

6. Remove the two screws securing the developer module, REP 9.2.

7. Pull the developer module out approximately 100mm (4 inches).

10. Remove the ozone filter and duct, PL 9.25 Item 2.

11. Move the power and control assembly to the rear, Figure 2.

Figure 2 Power supply

CAUTION

Take care when removing PJ1 on the IOT PWB, the pins can be easily damaged.

12. Disconnect PJs on the power and control assembly, (32-38 ppm) Figure 3, (45-55 ppm)

Figure 4.

Disconnect bias leadDisconnect PJ93

1Remove screw

2Disconnect PJ24

3Move Power supply tothe rear

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4-36 WorkCentre Pro 275 Family (CC232-WCP275F)REP 4.1ARepairs/Adjustments

Figure 3 Power and control assembly Figure 4 Power and control assembly

13. Remove the main frame ground wire, 01A Ground Distribution RAP.

14. Remove the waste toner full sensor, REP 9.4.

15. Unclip the wiring harness from the retaining clip and position the harness away from the

drives module, Figure 5.

16. Disconnect PJ57 on the waste toner door switch, Figure 5.

Disconnect PJ35 Disconnect PJ1

DisconnectPJ25

Disconnect HT lead Cand G

DisconnectPJ18

Disconnect PJ2 Disconnect HTlead C and G

Disconnect PJ35and PJ64

DisconnectPJ25

Disconnect

PJ18

Disconnect PJ2

Disconnect PJ1

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Figure 5 Harness and door switch

17. Prepare to remove the main drive assembly, Figure 6.

Figure 6 Main drive module

18. Slide the assembly off the location dowels.

Replacement

Replacement is the reverse of the removal procedure.

CAUTION

Do not trap the harnesses when the main drives module is located onto the dowels.

Take care when reconnecting PJ1 on the IOT PWB, the pins can easily be damaged.


1. It is important that the short paper path assembly is held in the UP position before install-ing the main drives module, Figure 7.

2Disconnect PJ57

1Remove harnessfrom the retainingclip

2Remove 7 silver screwsmarked A

3Slide the assembly off thelocation dowels 1

Disconnect PJ147,PJ148 and PJ149

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Figure 7 Short paper path assembly

2. If a new main drives module is installed, check that the drive speed is correct. The 32-38

ppm modules have black drive gears, Figure 8. The 45-55 ppm modules have white drive

gears, Figure 9.

3. Lubricate the developer module support pin on the main drive module drives plate with

Plastislip grease, (32-35 ppm) Figure 8, (45-55 ppm) Figure 9.

Figure 8 Main drives module 32-38 ppm

Support the short paper path

Lubricate the support pin

32-38 ppm black gears.

Fuser drive gear

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Figure 9 Main drive module 45-55 ppm

4. Manually rotate the main drive motor to engage the drive between the drives plate and the

inverter transport before tightening up the seven mounting screws, Figure 6.

5. If a new drives module or developer drive gear is installed, reset the developer count to

zero in the HFSI feature screen. Refer to GP 17 High Frequency service Items.

Lubricate the support pin45-55 ppm white gears

Fuser drive gear

REP 4.1B Main Drive Module (65-75 ppm)


Removal



10. Remove the ozone filter and duct, PL 9.25 Item 2.

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4-40 WorkCentre Pro 275 Family (CC232-WCP275F)REP 4.1BRepairs/Adjustments

Removal

WARNING





1. Pull out fuser module approximately 100mm, (4 inches), PL 10.10 Item 1.

2. Drop down short paper path assembly, PL 10.20.

3. Remove the xerographic module, PL 9.20 Item 2, and place in a black bag.

4. Remove left hand cover, PL 8.10 Item 3.

5. Disconnect PJ93 and the bias lead on the developer module, Figure 1.

Figure 1 Developer module

6. Remove the two screws securing the developer module, REP 9.2.

7. Pull the developer module out approximately 100mm (4 inches).

11. Move the power and control assembly to the rear, Figure 2.

Figure 2 Power supply

CAUTION

Take care when removing PJ1 on the IOT PWB, the pins can be easily damaged.

12. Disconnect PJs on the power and control assembly, Figure 3.

Disconnect bias leadDisconnect PJ93

1Remove screw

2Disconnect PJ24

3Move Power supply tothe rear

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4-41WorkCentre Pro 275 Family (CC232-WCP275F) REP 4.1BRepairs/Adjustments

Figure 3 Power and control assembly

13. Remove the main frame ground wire, 01A Ground Distribution RAP.

14. Remove the waste toner full sensor, REP 9.4.

15. Unclip the wiring harness from the retaining clip and position the harness away from the

drives module, Figure 4.

16. Disconnect PJ57 on the waste toner door switch, Figure 4.

Figure 4 Harness and door switch

17. Prepare to remove the main drive assembly, Figure 5.

Disconnect PJ35,PJ64

Disconnect PJ1

DisconnectPJ25

Disconnect HT lead Cand G

DisconnectPJ18

Disconnect PJ2

2Disconnect PJ57

1Remove harnessfrom the retainingclip

Replacement


CAUTION

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Figure 5 Main drive module

18. Slide the assembly off the location dowels.

CAUTION

Do not trap the harnesses when the main drives module is located onto the dowels.

Take care when reconnecting PJ1 on the IOT PWB, the pins can easily be damaged.


1. It is important that the short paper path assembly is held in the UP position before install-

ing the main drives module, Figure 6.

Figure 6 Short paper path assembly

CAUTION

The belt tensioners are of the floating type, and are spring loaded. They should not be locked

down.

2. Lubricate the developer module support pin on the main drive module drives plate with

Plastislip grease, Figure 7.

2Remove 7 silver screwsmarked A

3Slide the assembly off thelocation dowels 1

Disconnect PJ147,PJ148 and PJ149

Support the short paper path

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Figure 7 Main drives module

3. Manually rotate the main drive motor to engage the drive between the drives plate and the

inverter transport before tightening up the seven mounting screws, Figure 5.

4. Rotate the jam clearance knob 4c and ensure that the registration shaft turns freely.

5. If a new drives module or developer drive gear is installed, reset the developer count to

zero in the HFSI feature screen. Refer to GP 17 High Frequency service Items.

Lubricate the support pin

REP 4.2A Main Drive PWB (32-55 ppm)


Removal

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WARNING






2. Remove the fly wheel (3 short screws), Figure 1.

Figure 1 Remove the fly wheel

3. Remove the main drive PWB, Figure 2.

Figure 2 Main drive PWB

Replacement


1Remove 3 short screws2

Remove the fly wheel

2Remove 6 blackscrews marked A

1Disconnect 7 PJsmarked B

3Remove main drive motor

REP 4.2B Main Drive PWB (65-75 ppm)


Removal

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WARNING





1. Remove the main drive module, REP 4.1B.

2. Remove the P/Js from the main drive PWB, Figure 1.

Figure 1 Disconnect the PJs

3. Remove the main drive PWB, Figure 2.

Figure 2 Main drive PWB

4. Remove the drives support bracket on the main drive module, Figure 3. Then remove the

drive belt and the main drive PWB,

2Disconnect PJ144

1Disconnect PJ146,PJ154 and PJ151.

Remove 4 screws

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Figure 3 Drives support bracket

Replacement


CAUTION


down.

1. Ensure that the drives bracket is located in the tabs on the drives plate, Figure 4. Then

secure the main drive PWB to the drives plate.

Figure 4 Main drive PWB location

2. Ensure that the support bracket on the main drive module is located correctly with the

drive shafts and the collar, Figure 5. Then secure the support bracket.

Figure 5 Main drive module support bracket

3. Before installing the main drive module turn the drive gears by hand to position the drive

belts correctly on the drive gears.

1Remove 6 screws2

Remove the support bracket

3Remove the maindrive PWB

1Ensure that the tabs are located in the bracket

Position the collar All three shaft are locatedcorrectly in the bracket

REP 4.3A Main Drive Belt and Drive Gears (32-55 ppm)


Removal

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WARNING





1. Remove the main drive module, REP 4.1A.

2. To remove the main drive belt, (32-38 ppm), refer to Figure 1.

To remove the main drive belt, (45-55 ppm), refer to Figure 2.

Figure 1 Main drive belt 32-38 ppm

Figure 2 Main drive belt 45-55 ppm

3. Refer to Figure 3, to remove the items that follow:

Fuser drive gear.

Registration transport drive gear.

Developer drive gear.

3Remove the drive belt

1

Remove the circlip andgear

2Slip the drive belt overthe pulley on the belttensioner

1Remove the circlip andgear

2Slip the drive belt over thepulley on the belt tensioner

3Remove the drive belt

Replacement

CAUTION

The spring loaded belt tensioner, Figure 1 is a floating type and should not be locked down.


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Figure 3 Remove the drive gears

p p

If a new developer drive gear is installed, reset the developer count to zero in the HFSI feature

screen. Refer to GP 17 High Frequency service Items.

1

Remove circlipand intermedi-ated drive gear.

2Remove the circlip and thefuser drive gear

Remove the circlip and theregistration transport drivegear

Remove the circlip andthe developer drivegear

REP 4.3B Main Drive Belts and Drive gears (65-75 ppm)


Removal

WARNING

Remove circlip, outputpaper path drive gearand the spring

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WARNING





1. Remove the main drive module, REP 4.1B.

2. Remove the drives support bracket, Figure 1.

Figure 1 Drives support bracket

3. Refer to Figure 2, to remove the following:

Main drive belt 2

Fuser drive gear

Output paper path drive gear

Intermediate drive gear

Figure 2 Remove drive belt 2

4. Refer to Figure 3, to remove the following:

Main drive belt 1

Developer drive gear

Registration drive gear

Figure 3 Remove drive belt 1

1Remove six screws

2Remove the supportbracket

1Remove circlip and intermediatedrive gear

2Remove drive belt 2

Remove circlip and fuser drivegear / pulley

1Remove drive belt 1

Remove circlip andregistration drive pulley

Remove circlip and developer

drive gear / pulley

Replacement


CAUTION

The belt tensioners are of the floating type and are spring loaded They should not be locked

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down.

1. Ensure that the support bracket on the main drive module is located correctly on the drive

shafts and the collar, Figure 4.

Figure 4 Main drive module support bracket

2. Turn the drive gears by hand to position the drive belts correctly on the drive gears and

tensioner rolls.

3. If a new developer drive gear is installed, reset the developer count to zero in the HFSI

feature screen. Refer to GP 17 High Frequency service Items.

Position the collar All three shaft are locatedcorrectly in the bracket

REP 4.4 Photoreceptor Drive Gear


Removal

WARNING

Replacement

Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the

screws.

NOTE: Turn the drive shaft, so that the dowel pin is horizontal then locate the drive gear onto

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WARNING





1. Remove rear cover, PL 8.10 Item 1.

CAUTION

When the drive gear is removed from the shaft, the dowel pin may drop onto the IOT PWB or

LVPS.

2. Remove the photoreceptor drive gear, Figure 1.

Figure 1 Photoreceptor drive gear

NOTE: Turn the drive shaft, so that the dowel pin is horizontal then locate the drive gear onto

the drive shaft.

1Remove three shortscrews and the flywheel

2Remove the screwand collar

3Remove the drive gearand the dowel pin

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REP 5.1 Top Cover Assembly


Removal

WARNING

3Remove the 2 latch pins.

4Remove the topcover assembly.

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1. Open the DADH top cover.2. Remove the DADH top cover assembly, Figure 1.

Figure 1 Top cover

Replacement

CAUTION

Be careful when the self tapping screw is installed into a plastic component, refer to GP 6.

The replacement is the reverse of the removal procedure. Make sure the latch pins are

installed correctly, refer to Figure 1.

1Disengage the hinges.

2Remove the screw andthe plastic bushing (frontand back).

Take note of the position oflatch pins.

REP 5.2 Top Access Cover Assembly


Removal

WARNING

Replacement

CAUTION


The replacement is the reverse of the removal procedure. Make sure the 2 springs on the idler

roll are in the correct position, Figure 2. Then install the top cover.

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1. Open the DADH top cover.2. If installed, remove the rear wall, PL 8.10 Item 6.

3. Remove the DADH rear cover, PL 5.10 Item 1.

4. Remove the DADH top cover assembly, REP 5.1.

5. Remove the DADH top access cover assembly, Figure 1.

Figure 1 Top access cover assembly

p , g p

Figure 2 Torsion springs

2Remove the screw andthe bracket.

3Remove the top access

cover assembly.

1Disconnect PJ191 andthe ground harness.

Takeaway idler roll

torsion spring

CVT idler roll torsionspring

REP 5.3 Feed Assembly


Removal

WARNING

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1. Open the DADH top cover.

2. If installed, remove the rear wall, PL 8.10 Item 6.


4. Remove the feed roll assembly, REP 5.14.

5. Remove the feed assembly, Figure 1.

Figure 1 Feed assembly

Replacement

CAUTION


The replacement is the reverse of the removal procedure.

2Remove 4 self tappingscrews marked A.

1Disengage the hinges.

4Release the harness.

3Disconnect PJ183, PJ184and PJ187.

5Disconnect the groundharness.

6Remove the feedassembly.

REP 5.4 Input Tray Assembly


Removal

WARNING


6Loosen the screw.

8Remove the inputtray assembly.

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1. Remove the DADH, REP 5.19.

2. Remove the feed assembly, REP 5.3.

NOTE: To release the tension of the drive belts, refer to ADJ 5.1.

3. Remove the input tray assembly, Figure 1.

Figure 1 Input tray assembly

Replacement

CAUTION


1. The replacement is the reverse of the removal procedure.

2. Perform the steps that follow:

The feed motor and the CVT motor, belt tension adjustment, ADJ 5.1.

DADH Width Guide Adjustment, ADJ 5.3.

3Release the tension and disengagethe drive belt.


5Disconnect PJ190.

2Disconnect the ground harness.

1

Release the tension on theCVT motor drive belt.

REP 5.5 Baffle Assembly


Removal

WARNING

S it h ff th l t i it t th hi GP 14 Di t th d f th

CAUTION

When the top access cover assembly, feed assembly, input tray assembly and CVT roll are

removed the DADH structure is weak. Do not lower the DADH in this configuration.

7. Carefully install the DADH frame on the machine. Secure the DADH with the two thumb-

screws.

CAUTION

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2. Remove the top access cover assembly, REP 5.2.


4. Remove the input tray assembly, REP 5.4.

5. Remove the CVT roll, REP 5.15.

6. Prepare to remove the baffle assembly, Figure 1.

Figure 1 Preparation

CAUTION

Be careful to prevent damage to the document pad when the document pad is removed from

the baffle assembly.

8. Slide the baffle assembly lower cover, Figure 2.

1Disconnect the link arm.

4Disconnect PJ189.

2Disconnect the groundharness.


DADH frame.2Disengage the hingepin.

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Figure 2 Lower cover

CAUTION

Take care removing the baffle assembly, do not damage the solenoid link arm.

9. Remove the baffle assembly, Figure 3.

Figure 3 Baffle assembly

Replacement

CAUTION


The replacement is the reverse of the removal procedure. Make sure the torsion springs and

harness are in the correct position, Figure 4.

1Carefully remove the left handend of the document pad from thebaffle assembly.

2Remove 2 screws.

4To help the removal of thebaffle assembly, slide thelower cover approximately40mm (1.5 inches) awayfrom the document pad.

3Disengage the lugs in the lowercover.

4Remove the baffleassembly.

Solenoid link arm.

1Feed the harness and

ground harness through theframe.

3Slide the tab throughslot in DADH frame.

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Figure 4 Torsion springs and harness

Torsion springs.

Route the harness.

REP 5.6 Takeaway Roll Assembly


Removal

WARNING


2Remove 2 E-clips.

White spacers.

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CAUTION

Disconnect the ground harness from the static eliminator before the input tray assembly lower

cover is removed.


3. Turn the input tray assembly upside down. Remove the input tray assembly lower cover

(6 self tapping screws), PL 5.35 Item 9.

NOTE: To release the tension of the drive belt on the feed motor, refer to ADJ 5.1.

4. Remove the takeaway roll assembly, Figure 1.

Figure 1 Takeaway roll assembly

Replacement

The replacement is the reverse of the removal procedure. Make sure the spacers and E-clips

are installed correctly, refer to Figure 1.

1Release the tension anddisengage the drive belt.

3Slide the bearing forward.

4Remove the takeaway rollassembly.

Black spacer.

REP 5.7 Duplex Solenoid


Removal

WARNING


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y , p





2. If installed, remove the rear wall, PL 8.10 Item 6.

3. Prepare to remove the drive assembly, Figure 1.

Figure 1 Drives assembly

NOTE: To release the tension on the drive belts, refer to ADJ 5.1.

4. Remove the drive assembly, Figure 2.

Figure 2 Drives assembly

5. Remove the duplex solenoid, Figure 3.


4Release the harnesses.

5Disconnect PJ186.

3Disconnect PJ203 andPJ204.

1Disconnect 3 groundharnesses.


1Release the tension anddisengage the drivebelts.

3Remove the drive assembly.

2Remove the screws.

3Disconnect PJ205.

1Disconnect the

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Figure 3 Duplex solenoid

Replacement

CAUTION

The screw that attaches the ground harness to the duplex solenoid is shorter than the other

screws. Do not use the incorrect screw.

CAUTION


1. The replacement is the reverse of the removal procedure. Make sure that the wiring is not

caught below the drive assembly.

2. Perform the DADH motor adjustment, ADJ 5.1.

4Disconnect the ground harness.

5Release the duplex sole-noid from the clips.

Disconnect thelink arm.

REP 5.8 Takeaway and CVT Sensor


Removal

WARNING


Replacement

CAUTION

Be careful when the self tapping screw is installed into plastic component, refer to GP 6

The replacement is the reverse of the removal procedure. Make sure the spring plate and idler

roll torsion springs are in the correct position. Also make sure that the CVT sensor actuator is

in the correct position below the CVT roll and the idler shaft. Refer to Figure 1 and Figure 2.

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1. Remove the DADH top cover assembly, REP 5.1.

2. Remove the takeaway or CVT sensor, Figure 1.

Figure 1 Takeaway and CVT sensors

Then install the top cover assembly,

Figure 2 Torsion springs

1Remove the screw.

CVT sensor.

Takeaway sensor.

2Disconnect the correct PJ. Remove thecorrect sensor.

Spring plate.

CVT idler rollshaft.

Takeaway idler rolltorsion spring

CVT idler roll torsionspring

REP 5.9 Length Detect Sensors


Removal

WARNING


c stomer s ppl hile performing tasks that do not need electricit Electricit can

Replacement

CAUTION



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1. Remove the input tray assembly, REP 5.4.CAUTION


cover is removed, refer to Figure 1.



3. Remove the length detect sensors, Figure 1.

Figure 1 Length detect sensors

Ground harness.See CAUTION.

2Disconnect the correct PJ. Removethe correct sensor.

Length sensor 1.

Length sensor 2.

1Remove the ground harnessand bracket.

REP 5.10 Registration Sensor


Removal

WARNING


customer supply while performing tasks that do not need electricity Electricity can

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1. Remove the DADH, top cover assembly, REP 5.1.

2. Remove the registration sensor, Figure 1.

Figure 1 Registration sensor

Replacement

CAUTION


The replacement is the reverse of the removal procedure. Make sure the torsion spring is

installed correctly, Figure 2.

Figure 2 Torsion spring

1Remove 2 screws. 2

Carefully release thetorsion spring.

3Remove the pre-scanidler roll.

4Remove the sensor assembly.

5Disconnect PJ192. Remove the registrationsensor

Torsion spring.

REP 5.11 Exit Sensor


Removal

WARNING


customer supply while performing tasks that do not need electricity Electricity can

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1. Raise the DADH.

CAUTION

Be careful to prevent damage to the document pad when the document pad is removed from

the baffle assembly.

2. Prepare to remove the exit sensor, Figure 1.


3. Remove the exit sensor, Figure 2.

1Carefully remove the left hand end of thedocument pad from the baffle assembly.

2Remove 2 screws.

3Disengage the lugs in the lowercover.

4Remove the lower cover.

1DisconnectPJ196. Removethe exit sensor.

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Figure 2 Exit sensor

Replacement

CAUTION



REP 5.12 DADH Counterbalance


Removal

WARNING



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WARNINGDo not remove the DADH while the DADH is lowered. In the lowered position the coun-terbalance springs are compressed and can cause injury when released.

WARNING



2. Put the DADH upside down on a solid flat surface.

NOTE: The counterbalances are different. Each counterbalance is marked L or R to indicate

left or right. The removal procedure for the two counterbalances is same.

3. Remove the correct counterbalance, right, PL 5.10 Item 2 (4 screws) or left, PL 5.10 Item

4 (4 screws).

Replacement

CAUTION


1. The replacement is the reverse of the removal procedure. Make sure the ground tags are

attached when the counterbalances are installed Figure 1.


DADH height adjustment, ADJ 5.2.

DADH skew adjustment, ADJ 5.5. Figure 1 Ground tags

The left counterbalanceground tag.

The right counterbalanceground tag.

REP 5.13 Exit Roll Assembly


Removal

WARNING



Replacement

CAUTION


The replacement is the reverse of the removal procedure. Make sure the spacers and E-clips

are installed correctly, refer to Figure 1.

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CAUTION





4. Remove the exit roll assembly, Figure 1.

Figure 1 Exit roll assembly

Ground harness.See CAUTION.

1Remove the exit rollassembly.

Black spacers.

E-clip.

REP 5.14 Feed Roll Assembly


Removal

WARNING



cause death or injury Moving parts can cause injury

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1. Open the DADH top cover.

2. Remove the DADH feed roll assembly, Figure 1.

Figure 1 Feed roll assembly

Replacement

1. The replacement is the reverse of the removal procedure. When the feed rolls are

installed, make sure the lowest roll, (retard roll), is position on the assembly as shown in

Figure 2.

2. If a new feed roll assembly is installed, select dC131 chain 5, location 05-001 and reset

the copy count to zero.

3. If a new feed roll assembly is installed, reset the DADH feed count to zero in the HFSI fea-

ture screen. Refer to GP 17 High Frequency Service Items.

1Completely raise the feedroll assembly (2 clicks).

2Raise the feed roll assemblycover.

3Remove the feed roll assem-bly.

NOTE: There are three rollers on thefeed roll cartridge.

If the lower feed roll does not come outwith feed roll assembly, then remove itseparately from the machine.

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Figure 2 Retard roll position

Retard rollKey

REP 5.15 Duplex Gate, CVT Roll and CVT Motor, Drive Belt


Removal

WARNING



cause death or injury Moving parts can cause injury

CAUTION

When the top access cover assembly, feed assembly, input tray assembly and CVT roll are

removed the DADH structure is weak. Do not lower the DADH in this configuration

4. Carefully install the DADH frame on the machine. Secure the DADH with the 2 thumb-

screws.

5. Disengage the back CVT roll bearing, Figure 2.

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NOTE: To release the tension of the drive belt for the CVT motor, refer to ADJ 5.1.

3. Remove the duplex gate. If the CVT roll is removed, disengage the CVT roll drive belt,

Figure 1.

Figure 1 Duplex gate

Figure 2 Bearing

6. Remove the CVT roll and CVT motor, drive belt, Figure 3.

1Lift out the duplex

gate.

2Release the tension and dis-engage the CVT roll drive belt.

1Compress the two ends ofthe bearing together.

2Push the bearing to disengage.

CVT roll.

White washer.

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Figure 3 CVT roll

Replacement

1. The replacement is the reverse of the removal procedure. Make sure the white washer is

installed correctly, Figure 4.

2. Perform the DADH CVT motor adjustment, refer to ADJ 5.1.

Figure 4 Replacement

1Remove the CVT roll.

2Remove the CVT motor drivebelt.

REP 5.16 Document Width Sensor


Removal

WARNING





2Disconnect PJ193

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j y g p j y



CAUTION




(8 screws), PL 5.35 Item 9.

4. Remove the document width sensor, Figure 1.

Figure 1 Document width sensor

Replacement

CAUTION


1. The replacement is the reverse of the removal procedure. Make sure the document width

sensor arm is attached correctly, refer to Figure 1.

2. Perform the DADH Width Guide Adjustment, ADJ 5.3.

Disconnect PJ193.

3Remove the document width sensor.

arm

Ground harness.

REP 5.17 Input Tray Static Eliminator


Removal

WARNING




Replacement

CAUTION



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CAUTION


cover is removed, refer to Figure 1



3. Remove the input tray static eliminators, Figure 1.

Figure 1 Static eliminators

1

Remove the correctstatic eliminator.

Ground harness.

REP 5.18 Exit Roll Idler


Removal

WARNING




2Lift out the exit roll idlers.

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1. Remove the baffle assembly lower cover, PL 5.30 Item 1.

2. Remove the baffle assembly, REP 5.5.

3. Prepare to remove the exit roll idlers, Figure 1.


4. Remove the exit roll idlers, Figure 2.

Figure 2 Exit roll idlers

Replacement

CAUTION


The replacement is the reverse of the removal procedure. Make sure the torsion spring and

document finger are installed correctly, refer to Figure 3.

1Release the link arm.

2Raise one end of the exit roll idler shaft, then releasethe lift bar.

3Remove the lift bar andlink arm.

1Carefully remove the tor-sion spring and the docu-ment finger.

3

Remove the 2 bearings.

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Figure 3 Torsion spring and document finger

Torsion spring.

Document finger.

REP 5.19 DADH Removal


Removal

WARNING




WARNING

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WARNING

Do not remove the DADH while the DADH is lowered. In the lowered position the coun-

terbalance springs are compressed and can cause injury when released.

WARNING


1. If installed, remove the rear wall, PL 8.10 Item 6 and the left rear wall bracket assembly,

PL8.10 Item 16.

2. Disconnect the communication/power cable, PL 5.10 Item 6 and the DADH ground har-

ness, PL 5.10 Item 11.

3. Raise the DADH.

WARNING

Use safe handling procedures when removing the module, GP 16. The module is heavy.

NOTE: The DADH weight is 13Kg (29lb.).

4. Remove the DADH from the machine, Figure 1.

Figure 1 DADH removal

Replacement

1. The replacement is the reverse of the removal procedure.

2. If a new DADH is installed, perform the steps that follow:

a. Attach the document pad, refer to ADJ 5.6.

b. DADH Width Guide Adjustment, ADJ 5.3.

c. Select dC131 chain 5, location 05-001. Reset the copy count to zero.

d. Reset the DADH feed count to zero in the HFSI feature screen. Refer to GP 17 High

Frequency Service Items.


DADH height adjustment, ADJ 5.2.

DADH skew adjustment, ADJ 5.5.

1Remove 2 thumbscrews.

2Remove the DADH.

REP 6.1 ROS


Removal

WARNING

Avoid exposure to laser beam. Invisible laser radiation.

Front Rear

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4-79WorkCentre P

04a Repairs

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