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K Service Source
LaserWriter 8500
K Service Source
Overview
LaserWriter 8500
Overview
About This Overview - 1
About This Overview
This overview briefly describes the servicing issues of the LaserWriter 8500, especially those that distinguish it from earlier Apple laser printers.
360 Degree View
LaserWriter 8500 Basic Configuration
Overview
General - 2
General
The LaserWriter 8500 is a 600 dpi, 20 ppm monochrome laser printer that is capable of printing onto paper up to 13 x 20 inches in size. In its basic configuration, the printer has a capacity of 650 sheets, the standard cassette holding 500 sheets (as compared to the 250 typical in earlier printers), the multipurpose tray holding 150. There are several options available for the printer, including a duplexer unit (for two-sided printing), a 500sheet feeder, and an envelope cassette.
LaserWriter 8500 with Duplexer and Sheet Feeder
360 Degree View
Overview
Duplexer - 3
Duplexer
The duplexer is an inverted L-shaped feeder that mounts onto the upper rear of the printer. Once installed, all paper (even simplex) diverts into and exits from the duplexer. This is unlike the LaserWriter 12/640 PS, which employs a solenoid-actuated diverter controlled through software. The operative element in the LaserWriter 8500 is the exchange chute, located in the fuser assembly. The exchange chute is actuated (i.e. locked in place) during installation of the duplexer. After the first pass of a duplex page, the paper partially exits the duplexer delivery rollers. The rollers then reverse and the paper feeds back down through the duplexer and into the printer engine, in preparation for imaging of the second side. The paper then exits through the duplexer into the delivery tray.
Duplexer
Paper Path Through Duplexer
Overview
Paper Path - 4 The duplexer derives its power from the printer engine but has its own motor to generate mechanical drive.
Offset Function
The duplexer has a job separation feature that allows print jobs to be stacked offset (i.e. staggered left-to-right) in the delivery tray. Job separation is set in the Apple Printer Utility. Note: Due to cost considerations, the offset function has been incorporated into the duplexer instead of the printer engine. Offsetting and duplex printing are otherwise unrelated to one another. The offset motor in the duplexer generates the mechanical drive for offsetting paper.
Overview
Sheet Feeder - 5
Sheet Feeder
As with the LaserWriter 16/600 PS and LaserWriter 12/ 640 PS designs, the sheet feeder fits squarely beneath the printer to form a dual front-loading cassette arrangement. Unlike those models, however, you can stack two feeders beneath the printer, for a total auxiliary capacity of 1000 sheets. Also unlike those models, the sheet feeder and the engine use identical cassettes in the LaserWriter 8500. The sheet feeder derives its power and mechanical drive from the printer engine.
Sheet Feeder
Overview
Form Factor - 6
C
Form Factor
D B
A
To achieve a reasonably compact form factor, the tail end of the cassette has been designed to extend out from the engine footprint (A). Consequently, the pickup rollers feed from the insertion end of the cassette (B), similar to the LaserWriter II. This arrangement influences the architecture of the printer in the following ways. 1
Note: Diagram shows printer with long cassette and oversize (11 x 17 inch or A3) paper installed.
Printer Cross-Section
2
Because pickup occurs deep within the printer, all mechanical drive elements are arranged vertically along the rear (C), resulting in a simple C-shaped paper path. This vertical arrangement yields a compact, lowmaintenance gear train, consisting at its essence of one gear assembly driven by one central motor.
You can stack letter-sized paper on the multipurpose tray and shut the cover (D), thus hiding that paper from view inside a multipurpose "compartment."
Overview
A C B C
Form Factor - 7 3 The design of the cassette bottom plate (A) is new.
Below the plate, three springs provide upward pressure that forces the paper against the pickup rollers. (Only two of the springs are activated when the width guides (B) are set for narrower paper). In most printers, the bottom plate receives constant uniform pressure from the springs. As you insert the cassette, the paper snugly and passively presses against the pickup rollers.
With this printer, however, the bottom plate must stay down during insertion to avoid snagging. The springs are released, and the bottom plate elevated against the pickup rollers, only when the cassette is fully inserted. This spring release is actuated by a latch on each side of the cassette near the leading edge (C). See "Cassette" in the Basics chapter for more information.
Overview
Feed Long-Edge Feed (LEF) Feed Short-Edge Feed (SEF)
Paper Orientation - 8
Paper Orientation
The paper path is wide enough to print letter or A4 sized paper in long-edge feed (LEF) mode. LEF mode is recommended as it achieves the fastest 20 ppm throughput and optimizes duplex printing. Note: The cassette automatically senses paper orientation. The multipurpose tray does not. Printing in short-edge feed (SEF) mode from the multipurpose tray may produce undesirable results. Paper orientation and how best to load paper can be confusing, especially when talking with customers over the phone. It is further complicated when printing duplex jobs. Keep in mind the following tips: · Use the LEF and SEF terms when talking about how paper is loaded. These are the terms found in the user manual.
Overview
Paper Orientation - 9 · The terms "portrait" and "landscape" are best used only when talking about how a printed page is to be formatted. Remember that LEF mode, for example, can result in either a landscape or a portrait formatted page. · Load letterhead face-up. · As you stand facing the printer: the top of the page is on the left for LEF portrait, and on the near side for LEF landscape.
LEF Paper Orientation
Overview
Service Test Page - 10
Service Test Page
A service test page, sometimes called an engine test page, is a page whose description resides in firmware on the DC controller board. Successful printing of a service test page confirms the operation of the print engine. Of equal importance, if a print quality problem appearing on a normal page also appears on the service test page, the I/O controller board is proven good and should not be swapped. There are two ways to print a service test page on the LaserWriter 8500. 1 If the I/O board is installed, use a paper clip to press the test page button. This button is accessible through a small unmarked hole at the top of the I/O bracket.
Service Test Page Test Page Button
Note: Use this button liberally, both in person and when troubleshooting with customers on the phone. It is your
Overview
Test Page Jumper
Service Test Page - 11 first line of defense in isolating faults between the I/O board and printer engine.
2
If the I/O board and shield have been removed from the printer, you can print a service test page by jumpering the two pins of connector P23 on the DC controller board.
Overview
RAM Memory - 12
RAM Memory
The LaserWriter comes with 16 megabytes (MB) of RAM soldered onto the I/O controller board. There is one SIMM slot available for installing additional RAM. The following table lists the memory requirements and supported paper sizes for duplex printing and PhotoGrade.
16 MB 20 MB 24 MB 32 MB 48 MB Memory Letter, A4, B4, legal Letter, A3, A4, B4, legal, ledger Duplex Printing Letter, A4, B5 PhotoGrade No Use both features at once? Yes; up to letter and A4 Yes; up to legal Yes; up to B4 Yes; all supported paper sizes
Up to ledger and A3 Up to Japan Standard and Japan Larger All supported paper sizes
Letter, A3, A4, B4, legal, ledger Letter, A3, A4, B4, legal, ledger Letter, A3, A4, B4, legal, ledger
All supported paper sizes
Overview
SIMM Sizes and Speeds - 13
SIMM Sizes and Speeds
Size 4 MB SIMM 8 MB SIMM 16 MB SIMM* 32 MB SIMM* Configuration 1 M X 32 bit (one 4 MB bank) 2 M X 32 bit (two 4 MB banks) 4 M X 32 bit (one 16 MB bank) 8 M X 32 bit (two 16 MB banks) Speed 70 ns 70 ns 70 ns 70 ns or or or or less less less less Connector type 72-pin 72-pin 72-pin 72-pin
* Must have a 2 KB row (11 bit x 11 bit) refresh rate. 16 MB SIMMs with a 4 KB row (12 bit x 10 bit) refresh rate are not compatible with the printer.
Overview
Miscellaneous - 14
Miscellaneous
Full-Stack Sensor
When the delivery tray is full of paper, the printer stops accepting print jobs and the controller reports an error message to the host computer. Sensing of delivery tray capacity is done through the full-stack sensor located just above the delivery rollers. With a duplexer installed, the duplexer full-stack sensor assumes this function. The parts used in the duplexer actuator and the printer actuator are not interchangeable.
Actuator for Full-Stack Sensor
Other Sensors and Interlocks
All other sensors and interlocks are similar to previous printers and will be familiar to the experienced technician. See "Sensing System Locator" in the Basics chapter for a
Overview comprehensive diagram.
Miscellaneous - 15
There is also a mechanical interlock that disengages the fuser assembly drive train when the top cover is open (to facilitate removal of paper jams). See "Top Housing and Xerographics" in the Basics chapter.
Point-of-Sale (POS) Button
The Ready LED is also a button that actuates a microswitch on the status panel board. If you hold this LED during printer startup, the printer will enter the special POS state (or exit from POS if POS is currently enabled). You can also make these settings through the Printer Utility.
Demonstration Page
During POS state, the ready LED flashes two shades of green instead of the normal steady green. When you press the ready LED thereafter, a special demonstration page will print. While in POS state, the energy saving feature is
Overview
Miscellaneous - 16 disabled, but in all other ways, the printer is networkaware and will perform just as it does in ready state.
Voltage-Specific Parts
Four parts in the printer are available in both 110V and 220V versions: · · · · Power supply Fuser assembly Transport chute assembly DC controller board
Note: The DC controller board, though universal in previous printers, is not in the LaserWriter 8500.
The second version of this board satisfies European Economic Community requirements and has made possible some localization of controller board firmware (default paper size for the multipurpose tray, for example).
Overview
Miscellaneous - 17
Density Adjustment Dial
Density Adjustment
On the left side of the multipurpose tray compartment, there is a density adjustment dial. This dial changes the DC component of the development bias voltage supplied by the high-voltage power supply. The dial adjusts the threshold voltage, in effect changing the background density across the entire imageable page. A second method of density adjustment is through the Apple Printer Utility, which adjusts the laser power output. In effect, this adjusts the density of the printed pixels.
K Service Source
Basics
LaserWriter 8500
Basics
Function of Main Components - 1
Function of Main Components
This topic describes the function of the following components of the LaserWriter 8500. ·Cassette ·Cassette Feed Components ·Manual Feed Components ·Paper Transportation ·Fusing and Paper Exit ·Frame and Drive ·Top Cover and Xerographics ·Electrical
Cassette
Paper Width Guides
The paper width guides are adjusted left-to-right to accommodate different paper widths. They contact the left and right sides of the paper stack and hold the paper stack in place in the crosswise direction. The left and right snubbers (paper separating claws) at the leading edge of paper allow only one sheet of paper to be fed from the cassette into the printer. The snubbers move together with the paper width guides.
Pressure Plate Springs
Two pressure springs act against the bottom plate when paper width is less than 8.5 inches (216 mm). When the paper width is greater, additional forced is deemed necessary and a third pressure spring is released against the bottom plate. The mechanism that releases or contains the third spring is controlled by the paper width guides.
Bottom Plate Assembly Left Width Guide Size Cams Pressure Plate Springs
Right Width Guide
Paper End Guide
Basics
Function of Main Components - 2
Paper End Guide
The paper end guide can be adjusted front-to-rear to accommodate different paper lengths. It is in contact with the trailing edge of the paper stack.
When the paper end guide is adjusted, the size cams on the left side of the cassette rotate into a unique pattern of projections and gaps. When you insert the cassette, the position of the cams align with actuators that are housed in the printer's left cassette guide assembly. The actuators correspond to four microswitches on the cassette feed board.
Cassette Size Cam Size Cam
Size Actuator Size Switch Cassette Feed Board
Size Actuator Size Switch Cassette Feed Board
Cassette Latches
On each side near the leading edge of the cassette are two cassette latches. When the cassette is outside the printer, these latches hold the bottom plate down against the force of the pressure plate springs. As the cassette is inserted, the latches release and the bottom plate elevates.
Bottom Plate Assembly
Right Cassette Latch Cassette Bottom Plate Assembly
Cassette Guide (in Printer)
Basics
Function of Main Components - 3
Cassette Feed Components
Turn Clutch Cassette Feed Solenoid and Feed Gear
Cassette Feeder Board Cassette Paper-Present Sensor and Actuator
Cassette Feeder Board
The feeder board has the paper size microswitches (see previous topic) and serves as a relay board for the signals between the cassette feed and the DC controller board. This sensor detects the presence of paper in the cassette. When the feed solenoid is actuated, the feed gear is releases and turns to engage with the feed idler gear. The feed gear then begins to rotate, causing the pickup rollers to rotate. After one revolution, the feed gear disengages from the feed idler gear and is latched by the pawl of the feed solenoid. The turn clutch is an electromagnetic clutch that switches on and off the drive power to the lower and upper feed rollers. These rollers have an integral metal shaft/rubber roller design. Drive to the rollers is controlled by the turn clutch so that the rollers start feeding from the pickup area and stop feeding at the registration sensor.
Cassette Paper-Present Sensor and Actuator Cassette Feed Solenoid and Feed Gear
Turn Clutch
Lower and Upper Feed Rollers
When the engine receives a /PRFD signal from the controller, the engine stops feeding at the registration sensor and resumes when it receives a subsequent /START signal. If the / START signal is received before the paper reaches the registration position, the printer will feed the paper continuously without stopping the rotation of the feed rollers.
Pickup Rollers
Rotate and feeds one sheet of paper each time the cassette feed solenoid is actuated.
Basics
Function of Main Components - 4
Manual Feed Components
Toner Sensor Manual Feed Guide Tray
Manual Feed Sensor Assembly Manual Feed Paper-Present Sensor
Manual Feed Guide Tray
The manual feed guide tray is the pressure plate and width guide for manual feed paper. During standby the tray is held down by the pickup roller assembly cams. When the paper is about to feed, the cams move off the tray due to the rotation of the pickup roller assembly. The manual feed guide tray is therefore pressed up by the two pressure springs and the paper is pressed against the pickup roller. Part of the manual feed sensor assembly, this sensor detects the presence of paper in the manual feed compartment. Also part of the manual feed sensor assembly, this sensor detects low toner by responding to the magnetism of the toner in the cartridge.
Manual Feed Paper-Present Sensor
Toner Sensor
Basics
Function of Main Components - 5
Paper Transportation
Transfer Roller Assembly
Transport Chute Assembly
Transfer Roller Assembly
The transfer roller is in contact with the drum in the toner cartridge. The roller is driven by the drum gear so that the roller surface moves at the same speed as the drum surface.
The transfer roller applies a positive charge to the back side of the paper when the paper travels between the roller and the drum. The negatively charged toner image transfers from the drum surface to the front side of the paper because it is attracted by the positive charge on the back side of the paper.
Transport Chute Assembly
Transport Chute Assembly Photosensitive Drum Detack Saw Transfer Roller Registration Actuator Registration Sensor
Toner Cartridge
Rear Chute Assembly Pickup Roller
Rubber Registration Roller Metal Registration Roller
Separation Pad
Included in the transport chute assembly are the following components.
Pickup solenoid and pickup gear: When the pickup solenoid is actuated, the pickup gear is released and turned by the pulling force of the pickup spring to engage with the opposite gear in the main gear assembly. The pickup gear then begins to rotate, causing the pickup roller assembly to rotate. After one revolution, the pickup gear disengages from the opposite gear because of its sector-shaped cutout and is latched by the pawl of the feed
Pickup roller assembly: Consists of two pickup rollers, three core rollers, pickup cams, and the shaft. It rotates one turn each time the manual feed pickup solenoid is actuated, and feeds one sheet of paper from the manual feed compartment.
Basics solenoid.
Function of Main Components - 6
Rear chute assembly: Guides the paper fed from the cassette between the metal and rubber registration rollers. Metal registration roller and rubber registration roller: The rotation of these rollers is controlled by means of the registration clutch assembly so as to register the paper with the image on the drum. Registration sensor: Detects the arrival and departure of the paper at the registration position.
Separation pad assembly: Prevents extra sheets of paper from being fed by the friction between the paper and the rubber of the separation pad.
Transfer roller bearing: Applies the transfer voltage from the high-voltage power supply to the transfer roller assembly.
Detack saw: Imparts a negative charge to the back side of the paper, partially neutralizing the positive charges, so that the paper can peel off the drum.
Duplexer
The duplexer derives its mechanical drive from the duplex motor. The offset motor generates the lateral drive for job separation (left-to-right staggering of paper in the delivery tray).
Gear B Duplex Motor Duplexer Gear B
Offset Gear
Gear C Gear A Gear D Pulley Gear
Drive Belt
Pulley Gear
Basics
Function of Main Components - 7
Fusing and Paper Exit
Fuser Assembly Full Stack Sensor and Actuator Exit Sensor and Actuator
Thermostat
Temperature Sensor Assembly Pressure Roller
Thermal Fuse
Fuser Bulb (Inside Heat Roller)
The fuser assembly houses all components of fusing (the permanent fixing of toner to paper by means of heat and pressure), as well as components for paper delivery.
Heat Roller
The heat roller is a hollow metal tube that applies heat to the paper passing between it and the pressure roller. The heat is generated by the fuser bulb inside the heat roller. This heat melts the toner on the paper. The pressure roller is a solid, sponge rubber-coated metal shaft that presses the paper against the heat roller. The pressure helps bond the toner to the paper.
Pressure Roller
Heater Assembly
The heater assembly consists of the fuser bulb and the wiring and connectors attached to the ends of the bulb.
Temperature Sensor Assembly
The temperature sensor assembly is a thermistor whose resistance varies sharply with a change in temperature. This sensor is held in contact with the heat roller surface and monitors the temperature thereof. The signal from this sensor is used to maintain the temperature of the heat roller surface within the specified range by switching the power to the heater bulb on and off. The signal is also used for the first-stage overheat protection. The thermostat is part of the heater bulb circuit ad functions as the second-stage overheat
Thermostat
Basics
Function of Main Components - 8
protection. If the temperature sensor assembly fails to prevent a fuser overheat, the thermostat opens and power is cut to the heater bulb.
Thermal Fuse
Also a part of the heater bulb circuit, the thermal fuse functions as the third-stage overheat protection. If both the first and second stages fail to prevent a fuser overheat, the thermal fuse opens and power is cut to the heater bulb.
Heat Roller Diode
There is a negative charge that builds up on the heater bulb. This charge can disturb the toner image on the paper during fusing. The heat roller diode grounds this charge.
Full Stack Sensor
Full Stack Actuator Exit Sensor Exit Chute Roller To Duplexer Exchange Chute
Exit Actuator
Heat Roller Finger Heat Roller Pressure Roller
Fuser Assembly
Heat Roller Fingers
These fingers work in conjunction the non-stick coating of the heat roller to peel the leading edge of the paper from the roller. The exit sensor detects the arrival and departure of the paper on the delivery side of the heat roller. The full stack sensor detects when the delivery tray is full of paper. The installation of an optional duplexer locks the exchange chute into a position so that all paper is directed up into the duplexer.
Exit Sensor
Full Stack Sensor Exchange Chute
Basics
Function of Main Components - 9
Frame and Drive
Main Motor
Registration Clutch Assembly Main Gear Assembly
Paper-Handling Gear Assembly
Main Motor
Generates all the drive power for the printer and optional sheet feeder. Distributes drive power from the main motor to the fuser assembly, toner cartridge, paper handling gear assembly, registration clutch assembly, and pickup gear. Transfers the drive power from the main gear assembly to the feed idler gear and to a second gear within the main gear assembly.
Main Gear Assembly
Paper Handling Gear Assembly
Registration Clutch Assembly
An electromagnetic clutch that switches the drive power on and off to the two registration rollers at a specified time after the registration sensor has detected the arrival of the paper. This clutch actuates momentarily after the paper arrives at the registration rollers to allow the feed rollers to remove any skew induced during paper feed.
Basics
Function of Main Components - 10
Top Housing and Xerographics
Guide Arm and Fuser Guide Lever
Fuser Assembly
Fuser Guide Lever
Top Cover
Main Gear Assembly
Front
When the top cover opens, the fuser guide lever presses down on the floating idler gear at the top of the main gear assembly, thus disengaging the fuser assembly from the gear train. This makes removal of paper jams from the fuser much easier. When the top cover is closed, the floating idler gear springs upward to mate the fuser gearing to the main gear train.
Cartridge Sensor Assembly
Cartridge-Present Switch LD Switch
Cartridge Sensor Assembly
Toner Cartridge
Front
Cartridge-present switch: The signal from this switch stops printer operation when the toner cartridge is absent or the top cover is open.
The cartridge sensor assembly houses the two switches below.
Basics
Function of Main Components - 11
Laser-diode (LD) switch: This switch opens the laser diode circuit when the toner cartridge is absent or the top cover is open. The LD switch protects users against exposure to the laser light.
Toner Cartridge
Photosensitive drum: An aluminum cylinder with a surface coating of photoconductive material. The photoconductive coating holds an electrical charge, and allows the charge to flow through the thickness when exposed to light. Bias charge roller (BCR): Places a uniform electrical charge on the drum surface, erasing any charging patterns remaining from the previous cycle.
The toner cartridge consists of five major components.
Magnetic roller: Holds a thin layer of toner on its surface and transports it to the gap between the drum and the magnet roller. Toner is supplied to the magnetic roller by two agitators inside the toner compartment.
Charging and metering (CM) blade: Spreads a thin layer of toner on the magnetic roll and gives toner a negative charge. Cleaning blade: Scrapes the toner off the drum surface that is remaining after the transfer stage.
Laser/Scanner Assembly
Laser Diode Assembly M L L M L = Lens M = Mirror SOS = Start of Scan M M
Laser/Scanner Assembly SOS Board Photosensitive Drum
Front
Scanner Mirror
The laser/scanner assembly scans a light beam onto the surface of the photosensitive drum. This assembly consists of three major components: the laser diode, the scanning mirror, and the start-of-scan (SOS) board.
Basics
Function of Main Components - 12
Electrical
Fuser Access Cover Actuator Top Cover Actuator Fuser Cover Interlock Switch Top Cover Interlock Switch
Top Cover Interlock Switch
The top cover interlock switch is a safety switch that interrupts the supply of 24 VDC from the power supply to the DC controller board whenever the top cover is open. This switch also causes the power supply to interrupt AC line voltage to the fuser assembly. The switch is located inside the left cartridge guide and is actuated by the nylon tip at the end of the laser/scanner actuator rod. A safety switch that stops operation of the main motor, the laser/scanner assembly, and the fuser whenever the fuser access cover is open. The switch is located on the right side of the fuser access cover opening.
Fuser Cover Interlock Switch
Fan DC Controller Board High-Voltage Power Supply Print Density Adjustment Knob (Service Access Side) Power Supply
Fan
The fan exhausts the air inside the printer to prevent an excessive heat caused by the fuser assembly. There is one fan in the LaserWriter 8500.
Power Supply
The power supply produces regulated low DC voltages from AC power. The power supply also switches on and off the AC power to the fuser heater bulb. The main power switch is hard-wired to the power supply. The high-voltage power supply produces high voltage power for the charge and magnetic roller in the toner cartridge, the transfer roller, and the detack saw.
High-Voltage Power Supply
Basics
Function of Main Components - 13
DC Controller Board
The DC controller board controls all printer operations. It has the following six major functions. 1. Communicates with the I/O board. 2. Communicates with the optional duplexer.
3. Receives information from the printer sensors and switches. 4. Controls the laser/scanner, fuser, and main motor. 5. Controls the printing process.
6. Distributes DC power from the power supply to other printer components.
Print Density Adjustment Knob
This knob adjusts the print density by changing the DC component of the developing bias voltage supplied by the high-voltage power supply. Turning this knob clockwise increases the print density. Turning this knob counterclockwise decreases the print density.
Print Density Adjustment Knob (User Accessible Side)
Basics
Sensing System Locator (Printer Engine) - 14
Sensing System Locator (Printer Engine)
Cartridge Sensing and Laser/Scanner Interlock
Sensor: Cartridge Sensor Assembly (P/N 922-2811) Actuator: As the top cover closes, a tab on the toner cartridge presses an actuator in the cartridge sensor assembly. A B C D E (Fuser Assembly)
Full Stack Sensing (A) Exit Sensing (B)
Sensor: Part of Fuser Assembly Actuator: P/N 076-0653 Sensor/Actuator: Part of Fuser Assembly (Transport Chute Assembly)
Registration Sensing (C)
Sensor/Actuator: P/N 076-0652
(Manual Feed Sensor Assembly)
Toner Sensing (D)
Toner Sensor Assembly (P/N 922-2799) Sensor: P/N 922-2774 Acutator: P/N 922-2798
Manual Feed Paper-Present Sensing (E)
Fuser Cover Interlock
Actuator: As the fuser access cover (P/N 922-2757) closes, a tab on the cover presses the switch. Switch: P/N 922-2813
Top Cover Interlock
Actuator: As the top cover closes, the nylon tip of the laser/scanner actuator rod presses the switch. Switch: P/N 922-2812
Paper Size Sensing
Actuators: As cassette is inserted, size cams on cassette meet four size actuators on left cassette guide assembly (P/N 922-2773). Switches: Size actuators press microswitches on the cassette feeder board (P/N 922-2770).
Cassette Paper-Present Sensing
Actuator: P/N 922-2776 Sensor: P/N 922-2774
Basics
Sensing System Locator (Duplexer) - 15
Sensing System Locator (Duplexer)
Full Stack Sensor Full Stack Actuator (P/N 922-3038)
Duplex Paper-Pass Sensor (P/N 922-3037)
Duplexer Full Stack Actuator
Duplexer Full Stack Sensor Upper Cover Interlock Switch
Duplexer Upper Cover Duplexer Lower Cover Paper-Pass Sensor
Lower Cover Interlock Switch
Basics
Wiring Diagram - 16
Wiring Diagram
Paper-Pass Sensor Full Stack Sensor Offset Motor
P/J 192
Laser/Scanner LD Toner Cartridge
P/J 112
Layout of sheet feeder is identical to cassette feeder board.
Duplex Motor Interlock Switches
P/J 193 P/J 198 P/J 195
SOS MOT
P/J 113 P/J 114
P/J 196 P/J186
P/J 197
P/J12 P/J184 P/J187 DB CR DTS TR
Sheet Feeder
P/J 15 P207 P202
P/J206
Duplexer Board HVPS
P183 P/J 151
Duplexer
Main Motor
M P/J 16
Turn Clutch Cassette Feed Paper-Present Sensor
P/J204
Cassette Feeder Board
Cartridge-Present Sensor Manual Feed Sensor Assembly Toner Sensor Manual Feed PaperPresent Sensor Registration Sensor Registration Clutch Manual Feed Solenoid
P/J904
P/J 171
P/J 17 P201
P/J221
P/J922
P/J222
P/J 22
P/J 20
P/J205
P/J 203
Cassette Feed Solenoid P31
P/J937
P/J 134 P/J 132
P/J137
P18 P14 P17
P/J131
P/J 13
DC Controller Board
Actua Board l Layou t
P12
P/J 23
P16
P182
Duplex Interface Board
P/J P/J 190 180
P/J 18
P/J 19
P21 P11
P20
Fuser Cover Interlock Switch Exit Sensor Full Stack Sensor Temp. Sensor Heater Bulb Thermostat Thermal Fuse Fuser Assembly Power Switch Power Inlet
P/J 124 P/J 31 P/J 942 P/J 14 P/J412 P/J21 P/J11 P/J 142
I/O Board
P/J 411
P/J 421
Status Panel
Top Cover Interlock Switch
Fan
P/J 122
P/J127
P/J121 P/J 123
Power Supply
P/J 126
P13 P22 P19
Test Print
P/J135
P/J935
DC Controller Board
P15
P23
K Service Source
Specifications
LaserWriter 8500
Specifications
Engine - 1
Engine
Marking engine Laser
Fuji Xerox P880 laser-xerographic Type: Semiconductor laser diode Wavelength: 780 nanometers (nm) Output power: 5 milliwatts (mW) maximum
Specifications
Controller - 2
Controller
Microprocessor ROM RAM
AMD Am29040 30/60-MHz RISC microprocessor 8 megabytes (MB) of ROM (including 136 fonts) 16 MB of RAM (expandable to 48 MB). See "RAM Memory" in the Overview chapter for more information. 80C186 I/O processor 8 kilobytes (KB) parameter EEPROM
I/O processor EEPROM
Specifications
Ports - 3
Ports
General
LocalTalk port Parallel port AAUI Ethernet port with three protocols: EtherTalk Novell NetWare IPX (PSERVER or RPRINTER) TCP/IP (lpd) External Ethernet transceivers available for thin coaxial (10BASE-2) thick coaxial (10BASE-5) Ethernet twisted-pair cable (10BASE-T) can connect directly to a hub Two-position communication switch All ports and protocols simultaneously active (but only one Ethernet connector)
Specifications
Imaging - 4
Imaging
Resolution
600 dots per inch (dpi) resolution 600 dpi FinePrint (edge enhancement for text and line art) Enhanced 600 dpi grayscale imaging: Standard 85 lines/inch dithered halftone, 101 gray levels 106 lines/inch dithered halftone, 129 gray levels 141 lines/inch dithered halftone, 73 gray levels PhotoGrade (additional RAM may be required) 106 lines/inch halftone, 201 gray levels 141 lines/inch halftone, 257 gray levels 150 lines/inch halftone, 145 gray levels PostScript Level 3
Grayscale imaging
PostScript
Specifications
Imaging - 5 One hundred thirty-six PostScript fonts are provided with the printer, including such fonts as Albertus, Antique Olive, Apple Chancery, Arial, ITC Avant Garde ®, Bondoni, ITC Bookman ®, Carta, Chicago, Clarendon, CooperBlack, Copperplate, Coronet, Courier, Eurostile, Geneva, GillSans, Goudy, Helvetica, Helvetica Black, Helvetica Compressed, Helvetica Narrow, Hoefler Text, Joanna, LetterGothic, Lubalin Graph, Marigold, Monaco, MonaLisa, New Century Schoolbook, New York, Optima, Oxford, Palatino ®, StempelGaramond, Symbol, Tekton, Times, Univers, Univers Condensed, WingDings, ITC Zapf Chancery ®, and ITC Zapf Dingbats ®. Note: Actual speed depends on the images printed. One-sided: 20 pages per minute maximum using long-edge feed (LEF) U.S. letter or A4-size paper. Duplex: 13 pages per minute maximum using long-edge feed U.S. letter or A4-size paper. Envelopes--9.7 envelopes per minute maximum.
Printer fonts
Speed
Specifications
Life Expectancy - 6
Life Expectancy
Printer reliability (MTBF)
Average number of impressions between failure is 180,000 pages. (In duplex mode, a single sheet is considered to be two impressions.) Life expectancy is up to 14,000 pages when printing text documents with average page coverage (5% black). An example of a 5% black page coverage is a page consisting of double-spaced 14-point Courier type. Printing images and other graphics may shorten toner cartridge life expectancy.
Toner cartridge life expectancy
Specifications
Printing Materials - 7
Printing Materials
Paper types
16- to 28-pound laser-quality bond (60 to 105 g/m 2 ); up to 36-pound (135 g/m 2 ) stock when fed manually through the multipurpose tray. Accepts most textured and colored stock. Accepts medium-weight photocopier transparencies and labels. Envelopes can be printed from the multipurpose tray or from the optional envelope feeder. The paper used should not scorch, melt, transfer material, or release hazardous emissions when heated to 200° C (400° F) for 0.1 seconds.
Paper sizes and capacity
The paper cassette holds 500 sheets of 20-pound (75 g/m 2 ) paper. The multipurpose tray can hold up to 150 sheets of standard U.S. letter paper, and other paper sizes from postcard up to U.S. legal. An optional 500-sheet feeder and cassette is
Specifications
Printing Materials - 8 available. An envelope feeder that can automatically feed up to 50 envelopes is also available.
Standard 500-sheet cassette
Multipurpose tray
Paper Type U.S. Letter (LEF) U.S. Letter Small (LEF) A4 (LEF) A4 Small (LEF) A5 (LEF) Executive (LEF)
Paper Type U.S. Letter (LEF) U.S. Letter Small (LEF) Statement (LEF) Executive (LEF) A4 (LEF) A4 Small (LEF) A5 (LEF) B5 (LEF)
Size 8.5" x 11" (215.9 mm x 279.4 mm) 8.5" x 11" (215.9 mm x 279.4 mm) 8.27" x 11.69" (210 mm x 297 mm) 8.27" x 11.69" (210 mm x 297 mm) 5.84" x 8.26" (148 mm x 210 mm) 10.5" x 7.25" (266.7 mm x 184.2 mm)
Size 8.5" x 11" (215.9 mm x 279.4 mm) 8.5" x 11" (215.9 mm x 279.4 mm) 8.48" x 5.48" (215.9 mm x 139.7 mm) 10.5" x 7.25" (266.7 mm x 184.2 mm) 8.27" x 11.69" (210 mm x 297 mm) 8.27" x 11.69" (210 mm x 297 mm) 5.84" x 8.26" (148 mm x 210 mm) 7.17" x 10.12" (182 mm x 257 mm)
Specifications
B5 (LEF) Statement (LEF) U.S. Legal (SEF) U.S. Legal Small (SEF) Tabloid (SEF) A3 (SEF) Large (SEF) Large (SEF) Large (SEF) COM10 (SEF) Monarch (SEF) DL (SEF) C5 (SEF) Hagaki Postcard (SEF)
Printing Materials - 9
7.17" x 10.12" (182 mm x 257 mm) 8.48" x 5.48" (215.9 mm x 139.7 mm) 8.5" x 14" (215.9 mm x 355.6 mm) 8.5" x 14" (215.9 mm x 355.6 mm) 11" x 17" (279.4 mm x 431.8 mm) 11.69" x 16.54" (297 mm x 420.2 mm) 13" x 18" (330 mm x 457.2 mm) 13" x 18.5" (330 mm x 470 mm) 13" x 20" (330 mm x 508 mm) 4.125" x 9.5" (104.8 mm x 241.3 mm) 3.875" x 7.5" (98.4 mm x 190.5 mm) 4.33" x 8.66" (110 mm x 220 mm) 6.38" x 9.02" (162 mm x 229 mm) 3.94" x 5.83" (100 mm x 148 mm) 8-1/2" x 11" (215.9 mm x 279.4 mm) 8-1/2" x 11" (215.9 mm x 279.4 mm) 8.48" x 5.48" (215.9 mm x 139.7 mm) 10.5" x 7.25" (266.7 mm x 184.2 mm)
Optional 500-sheet A3 cassette
Paper Type Size U.S. Letter (LEF) U.S. Letter Small (LEF) Statement (LEF) Executive (LEF)
Specifications
A4 (LEF) A4 Small (LEF) A5 (LEF) B5 (LEF) U.S. Legal (SEF) Tabloid (SEF) A3 (SEF) Large (SEF) Large (SEF)
Printing Materials - 10
8.27" x 11.69" (210 mm x 297 mm) 8.27" x 11.69" (210 mm x 297 mm) 5.84" x 8.26" (148 mm x 210 mm) 7.17" x 10.12" (182 mm x 257 mm) 8.5" x 14" (215.9 mm x 355.6 mm) 11" x 17" (279.4 mm x 431.8 mm) 11.69" x 16.54" (297 mm x 420.2 mm) 13" x 18" (330 mm x 457.2 mm) 13" x 18.5" (330 mm x 470 mm)
Optional envelope sizes and weights
Optional duplex printing unit
Paper Type U.S. Letter (LEF) U.S. Letter Small (LEF) U.S. Legal (SEF)
Envelope Weight COM10 (SEF) Monarch (SEF) DL (SEF) C5 (SEF)
Size 8.5" x 11" (215.9 mm x 279.4 mm) 8.5" x 11" (215.9 mm x 279.4 mm) 8.5" x 14" (215.9 mm x 355.6 mm)
Size 24 lb 4.125" x 9.5" (104.8 mm x 241.3 mm) 24 lb 3.875" x 7.5" (98.4 mm x 190.5 mm) 80 g/m 2 110 mm x 220 mm 90 g/m2 162 mm x 229 mm
Specifications
U.S. Legal Small (SEF) A4 (LEF) A4 Small (LEF) B5 (LEF) Ledger (SEF) A3 (SEF)
Printing Materials - 11
8.5" x 14" (215.9 mm x 355.6 mm) 8.27" x 11.69" (210 mm x 297 mm) 8.27" x 11.69" (210 mm x 297 mm) 7.17" x 10.12" (182 mm x 257 mm) 11" x 17" (279.4 mm x 431.8 mm) 11.69" x 16.54" (297 mm x 420.2 mm)
Specifications
Dimensions - 12
Dimensions
Basic configuration (printer with A4 cassette)
Height: 16.2 in. (41.1 cm) Width: 23.2 in. (58.9 cm) Depth: 17.9 in. (45.5 cm)
Additional dimension when adding the duplexer Height: 2.9 in. (7.4 cm) Depth: 3.0 in. (7.6 cm)
Additional dimension when adding the sheet feeder and A3 universal cassette Height: 5.2 in. (13.2 cm) Depth: 5.9 in. (15.0 cm)
Additional dimension when adding the sheet feeder and letter/A4 universal cassette Height: 5.2 in. (13.2 cm)
Specifications
Dimensions - 13
Space requirements
About 7 in. or 18 cm Note: Vertical clearance is about 14 in. or 36 cm
About 6 in. or 15 cm
Exhaust Vent
About 1 in. or 2.5 cm
About 17 in. or 43 cm
Weight
Approximately 30 lb. (14 kg)
Specifications
Environmental - 14
Environmental
Operating
Temperature: 41° to 95° F (5° to 35° C) Humidity: 15 to 85 percent relative humidity noncondensing Altitude: 0 to 8200 feet (0 to 2500 meters)
Note: There is a varistor VR53 is in the upper left corner of the high-voltage power supply. Counter-clockwise adjustment of this varistor lowers the toner threshold and increases the maximum operating altitude.
Storage (toner cartridge) Storage (printer)
Temperature: 32° to 95° F (0° to 35° C) Humidity: 15 to 80 percent relative humidity noncondensing Temperature: 32° to 95° F (0° to 35° C) Humidity: 15 to 80 percent relative humidity noncondensing About 13 in. or 32 cm
Specifications
Environmental - 15 U.S. 90 to 132 VAC, 47 to 63 Hz 100 to 120 nominal voltage, 50 to 60 nominal Hz Europe and Australia 198 to 264 VAC, 47 to 63 Hz 220 to 240 nominal voltage, 50 to 60 nominal Hz
Voltage requirements
Important: There are four parts in the printer that are voltagespecific: the power supply, the fuser assembly, the transport chute assembly, and the DC controller board. Refer to the Parts chapter for more information.
Power consumption
Energy-saving mode 26 watts (W) Standby average 100/120 volts (V), approximately 125 W 220/240 V, approximately 120 W
Specifications
Environmental - 16 Operating average 110/120 V, approximately 390 W 220/240 V, approximately 370 W Maximum power consumption 120 V, approximately 840 W, 6.3 amperes (A) 240 V, approximately 860 W, 3.2 A
K Service Source
Take Apart
LaserWriter 8500
Take Apart
General - 1
General
Before you begin, perform the following procedures: · Switch off power and unplug the printer · Remove duplexer and/or sheet feeder (if applicable) · Remove cassette · Remove toner cartridge Before working on any printed circuit board, ground yourself and your equipment to an earth or building ground. Use a grounded conductive workbench mat and grounding wriststrap, and ground your equipment to the mat.
Take Apart
Fuser Access Cover - 2
Fuser Access Cover
Fuser Access Cover
No preliminary steps are required before you begin this procedure.
Take Apart 1
Fuser Access Cover - 3 Open the fuser access cover and shift it leftward to release its right hinge. Free the left hinge and remove the fuser access cover from the printer.
Fuser Cap
2
Fuser Access Cover
Note: The fuser cap is the part that you remove before installing a duplexer. The cap is a part of the fuser access cover (P/N 9222757).
Take Apart
= Location of Detent
Left Top Cover - 4
Left Top Cover
Before you begin, remove the fuser access cover. Note: The left top cover is held to the printer by two screws, a detent (on the cover's bottom edge, near where the three covers abut one another), and the status panel cable.
Left Top Cover
Take Apart
Left Top Cover Screw Status Panel
Left Top Cover - 5 1 2 Open the manual feed tray and the top cover.
Status Panel Cable
Detent
Screw
Left Top Cover (On Its Side)
3
Remove the two screws securing the left top cover to the printer frame (one along the rear and one inside the manual feed compartment).
Top Cover
4
Pull out slightly on the left top cover to release the detent and rest the cover on its side atop the chassis. Disconnect the status panel cable and remove the cover.
Take Apart
Left Top Cover - 6 Note: The status panel is not part of the left top cover, but is available separately as P/N 922-2767. Caution: With the left or right top covers removed, fingers are no longer fully protected from the closure of the top cover. Whenever possible, keep the top cover closed.
If you must work with the top cover open, however, first make sure that it is all the way up in the latched position. In addition, place a temporary support (a piece of folded cardboard, cloth, newspaper, etc.) in the space beneath the side flange of the top cover.
Temporary Support For Top Cover
Take Apart
Left Cover Assembly - 7
Left Cover Assembly
Left Cover Assembly
No preliminary steps are required before you begin this procedure.
Take Apart 1
Left Cover Assembly - 8 Loosen the two knurled captive screws securing the left cover assembly.
2
Left Cover Assembly
Slide the cover to the left to free its front edge and remove the cover from the printer.
Screw
Take Apart
Front Left Cover - 9
Front Left Cover
Before you begin, remove the following: · Left top cover · Left cover assembly
Front Left Cover
Take Apart 1
Front Left Cover - 10 Release the two tabs at the top of the front left cover and remove the cover from the printer frame.
Front Left Cover
Take Apart
Left Lower Cover - 11
Left Lower Cover
Before you begin, remove the left cover assembly.
Left Lower Cover
Take Apart 1
Left Lower Cover - 12 Remove the two screws securing the left lower cover and remove the cover from the printer frame.
Left Lower Cover
Take Apart
Right Top Cover - 13
Right Top Cover
Right Top Cover
Before you begin, remove the fuser access cover.
Take Apart
Right Top Cover
Right Top Cover - 14 1 2 Open the manual feed tray and the top cover.
3
Remove the two screws securing the right top cover to the printer frame (one along the rear and one inside the manual feed compartment). Lift the cover straight up and off the printer.
Take Apart
Right Top Cover - 15 Caution: With the left or right top covers removed, fingers are no longer fully protected from the closure of the top cover. Whenever possible, keep the top cover closed. If you must work with the top cover open, however, first make sure that it is all the way up in the latched position. In addition, place a temporary support (a piece of folded cardboard, cloth, newspaper, etc.) in the space beneath the side flange of the top cover.
Temporary Support For Top Cover
Take Apart
Right Cover - 16
Right Cover
Before you begin, remove the following: · Fuser access cover · Right top cover
Right Cover
Take Apart 1
Right Cover - 17 Remove the five screws that secure the right cover to the printer (two at the bottom, two along the rear edge, and one at the top).
Detent Edge
2
Release the detent edge of the cover (where the cover wraps around to meet the cassette guide) and remove the right cover from the printer.
Right Cover
Take Apart
Exit Cover - 18
Exit Cover
Exit Cover
Before you begin, remove the following: · Fuser access cover · Left top cover · Right top cover
Take Apart
Exit Cover
Exit Cover - 19 1 2 Close the top cover.
Remove the two screws securing the exit cover (one low at the right and one angled at the left).
Full Stack Actuator
Caution: In the following step, make sure to hold the full-stack actuator clear while you remove the cover. The actuator is exposed and very susceptible to damage. 3 Tilt the exit cover forward to clear the actuator and lift the cover from the printer.
Take Apart
Top Cover - 20
Top Cover
Top Cover
Before you begin, remove the following: · Fuser access cover · Left top cover · Right top cover · Exit cover 1 Open the top cover housing.
Caution: Make sure you have placed a temporary support underneath the top cover as described in the left top cover and right top cover topics.
Take Apart
Top Cover
Top Cover - 21 2 Remove the two screws securing the top cover to the housing (one on the left and one on the right outer face of the cover). Remove the temporary support and close the top cover.
3
4
Slide cover slightly forward and remove the cover from the frame.
Take Apart
Front Cover - 22
Front Cover
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · Right top cover · Right cover Note: The manual feed cover assembly and the front cover come off together.
Manual Feed Cover Assembly
Front Cover
Take Apart 1
Front Cover - 23 Remove the two screws securing the front cover to the chassis.
2
Lift out the manual feed cover assembly together with the front cover.
Note: Perform step 3 only if you are replacing a damaged front cover or manual feed cover. 3
Front Cover Manual Feed Cover Assembly
Flex one arm of the front cover to release the hinge and separate the front cover from the manual feed cover.
Take Apart
Turn-In Chute - 24
Turn-In Chute
No preliminary steps are required before you begin this procedure. 1 2
Turn-In Chute
Hold open the turn chute cover.
3
Flex the left side arm of the turn-in chute and remove its hinge hole from the boss on the left cassette guide assembly. Remove the turn-in chute from the cassette guide.
Turn Chute Cover
Boss
Take Apart
Turn Chute Cover - 25
Turn Chute Cover
Before you begin, remove the turn-in chute. 1 2 Hold the turn chute cover half open.
Turn Chute Cover
3
Using needle-nosed pliers, remove the two turn chute springs that are installed between the turn chute cover and the left and right cassette guide assemblies. Hold the turn chute cover completely open and slide to the left.
Take Apart 4
Turn Chute Cover - 26 Lift the rear of the printer and pull down the right side of the turn chute cover. Slide the turn chute cover to the right and remove it from the printer.
5
Turn Chute Cover
Take Apart
Fuser Assembly - 27
Fuser Assembly
Fuser Assembly Screw Screw
Before you begin, remove the fuser access cover. Caution: Let the fuser assembly cool before performing this procedure. 1 Loosen the four captive screws securing the fuser assembly to the printer.
Screw Screw
Take Apart 2
Handle Handle
Fuser Assembly - 28 Grip the fuser assembly by the two small handles at each end and lift the fuser from the printer.
Take Apart
I/O Board - 29
I/O Board
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover 1 Make a note of the position of the reset button on the I/O bracket.
Cables
Reset Button
I/O Board
2
Disconnect the two cables at the right side the board.
I/O Board with Shield
Take Apart
4 5 6 7
I/O Board - 30 3 Remove the eleven silver-colored screws that secure the I/O shield to the chassis (12 on the left, 3 below the fan, 4-7 at the top, 8, 9, and 11 on the right, and 10 at the bottom.) Pull the controller board with the intact shield from the printer.
11 2 3 8
4
1
9
10
Note: There may be some resistance from the receptacle connector on the blind side of the board (near the top, just left of center).
Take Apart
I/O Board - 31 Note: Peform the following steps only if you are replacing a defective I/O board. 5 Remove the screw at the bottom left corner of the I/O board.
I/O Bracket
I/O Board Screw (Step 5)
6
7
Screw Connector Screws
Remove the two screws and the six small I/O connector screws that secure the I/O bracket to the shield. Remove the I/O bracket. Remove the four remaining screws (step five removed the fifth) that secure the I/O board
8
Screw
Take Apart
I/O Board - 32 to the shield
Receptacle Connector
9
Remove the board, being careful to elevate the receptacle on the rear to clear the plate.
Metal Tabs
Backside of I/O Shield
Replacement Notes: · When replacing the I/O bracket, make sure that the three metal tabs slide in the cutouts in the shield. · Check the position of the reset button on the I/O bracket, and restore the setting if you have accidently changed it during this procedure.
Take Apart
Cassette Feeder Board - 33
Cassette Feeder Board
Before you begin, remove the following: · Left top cover · Left cover assembly · Front left cover · Left lower cover · I/O board
Cassette Feeder Board
Take Apart
Cassette Feeder Board Screw Screw
Cassette Feeder Board - 34 1 Disconnect the cable going into the left side of the board. Remove the four screws securing the cassette feeder board.
2
Cable Screw
Note: To loosen the bottom left screw, insert the screwdriver through the opening in the printer frame.
Screw
Take Apart
Disconnect Cables
Cassette Feeder Board - 35 3 Lift the board away from the printer and disconnect the two remaining cables.
4
Remove the cassette feeder board from the printer.
Take Apart
Duplex Interface Board - 36
Duplex Interface Board
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board
Duplex Interface Board
Take Apart
Screws
Duplex Interface Board - 37 1 Disconnect the cable on the rear face of the board.
2
Cable
Remove the two screws that secure the connector end of the board to the chassis frame.
Duplex Interface Board
Take Apart
Duplex Interface Board - 38 3 Pull out on the right end of the board to free the receptacle connector on the opposite side.
4
Slide the board to the right and remove it from the printer.
Take Apart
DC Controller Board
DC Controller Board - 39
DC Controller Board
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board · Duplex interface board
Take Apart
Screw Screw
DC Controller Board - 40 1 Disconnect all the cables going into the board.
Note: If you are replacing the DC controller board, perform step 2 and you are done. If all you need is access to a deeper part, go to step 3. 2 Remove the four screws that secure the controller board to the chassis (one at each corner of the board) and remove the board from the printer.
Screw Location for Board-Only Removal
Screw
Screw
Take Apart
Screw Screw
DC Controller Board - 41 Note: The following steps remove the DC controller board holder along with the board. Remove the cables from the cable clamps.
3 4
Remove the four screws that secure the controller board holder to the chassis (two along the top flange, one to the right of the density dial, and one below the left corner of the board).
Screw Location for Board and Holder Removal
Screw
Screw
Take Apart 5
DC Controller Board - 42 Remove the controller board and holder from the printer.
Removing Board and Holder
Take Apart
Fan
Fan - 43
Fan
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board 1
Remove the two lower screws that secure the fan to the chassis.
Take Apart
Ferrite Core
Fan - 44 2 Disconnect the fan cable from P/J122 on the power supply.
3
Open the cable clamp (near the density dial) and the ferrite core (near the fan), pull the fan cable free, and remove the fan from the printer.
Cable Clamp
P/J122
Take Apart
Power Supply - 45
Power Supply
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · Left lower cover · I/O board Note: The main power receptacle and switch (also known as the power inlet) is hard-wired to the power supply.
Power Inlet Power Supply
Take Apart 1
Power Supply - 46 Remove the screw securing the grounding wire to the chassis.
2
3
Grounding Screw Power Inlet Holder Screws Screw
Remove the three screws securing the power inlet holder and lift the holder up from the chassis. Remove the power cable from the two clamps.
Take Apart 4
Power Supply - 47 Remove the two brasscolored screws that secure the receptacle to the inlet holder and lift the holder from the power inlet.
Screw
Screw
Take Apart
Screw Power Supply Screw
Power Supply - 48 5 Disconnect all the cables going into the power supply. Replacement Note: Connector P127 is not used in this printer. The single wire orange cable goes into the P123 lead to the right of P127.
6
Remove the four screws securing the power supply to the chassis (two through the circuit board and two through the flange at the bottom).
Screw
Screw
Take Apart 7
Power Supply - 49 Shift the power supply slightly to the left, pivot the bottom upward to clear the chassis frame, and remove the power supply from the printer.
Take Apart
High-Voltage Power Supply
High-Voltage Power Supply - 50
High-Voltage Power Supply
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board · Duplex interface board · DC controller board (with holder)
Take Apart
Screw Screw
High-Voltage Power Supply - 51 1 Disconnect all the cables going into the highvoltage power supply. Remove the brasscolored screw in the center of the board.
2
3
Screw
Remove the four screws (one at each corner of the board) that secure the high-voltage power supply to the chassis.
Screw
Screw
Take Apart
High-Voltage Power Supply - 52 4 Holding the density dial with your finger, lift the high-voltage power supply from the printer.
Density Dial
Take Apart
High-Voltage Power Supply - 53 Replacement Note: Connector TR at the bottom of the high-voltage power supply goes in with the narrow edge facing outward. Failure to connect this properly will cut voltage flow to the transfer roller, resulting in very light overall print quality.
Connector TR
Take Apart
Main Motor
Main Motor - 54
Main Motor
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board · Duplex interface board
Take Apart
Screw
Main Motor - 55 1 Disconnect the motor cable at P16 from the DC controller board.
2
Remove the three screws (one through the flange at top, two through the flange at the bottom) that secure the main motor to the chassis.
Screw
Screw
P16
Take Apart 3
Main Motor - 56 Lift out the left side of the motor to clear the DC controller board holder and remove the motor from the printer.
Take Apart
Paper Handling Gear Assembly - 57
Paper Handling Gear Assembly
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board · Duplex interface board · DC controller board (with holder)
Paper Handling Gear Assembly
Take Apart
Screw Cable Screw
Paper Handling Gear Assembly - 58 1 Disconnect the cable going into the registration clutch assembly.
2
3
Free all the wires and cables from the clamp on the gear assembly.
Remove the three screws securing the gear assembly.
Screw
Take Apart
Paper Handling Gear Assembly - 59 4 Gently pull the gear assembly out of the printer.
Take Apart
Registration Clutch Assembly - 60
Registration Clutch Assembly
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board · Duplex interface board · DC controller board (with holder) · Paper handling gear assembly
Registration Clutch Assembly
Take Apart
Registration Clutch Assembly
Registration Clutch Assembly - 61 1 After removing the paper handling gear assembly, you can freely lift the registration clutch assembly out of the printer.
Take Apart
Turn Clutch - 62
Turn Clutch
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board
Turn Clutch
Take Apart
Armature and Teeth
Turn Clutch - 63 1 2 Disconnect the cable from the turn clutch.
Remove the E-ring securing the clutch and slide the clutch off the end of the feed roller shaft.
Replacement Note: Orient the clutch so that the chassis armature slips between the two teeth at the edge of the clutch.
Cable
E-Ring
Take Apart
Left Cassette Guide Assembly - 64
Left Cassette Guide Assembly
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · Left lower cover · Turn-in chute · Turn chute cover · I/O board · Power supply
Left Cassette Guide Assembly
Take Apart
Cables Screw
Left Cassette Guide Assembly - 65 1 Disconnect the cables from the cassette feeder board, pickup solenoid, and the turn clutch.
2
Remove the three screws on the outside face of the chassis that secure the cassette guide assembly to the chassis wall.
Screw Screw
Cable
Take Apart
Left Cassette Guide Assembly - 66 3 Remove the screw on the inside face of the cassette guide that secures the cassette guide assembly to the chassis wall. Free the turn clutch cable from the clamp.
4 5
Screw
Clamp
6
Using a flat blade screwdriver, push the three tabs at the bottom of the cassette guide, one by one, to release them from the printer frame. Tilt the cassette guide, pulling its bottom edge from the inside of the printer frame.
Take Apart
Left Cassette Guide Assembly - 67 7 Ensure that the three upper hooks of the cassette guide are released from the printer frame.
8
9
Push all harnesses on the cassette guide to free them from the printer frame. Remove the cassette guide from the printer frame.
Take Apart
Cassette Paper-Present Sensor - 68
Cassette PaperPresent Sensor
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · Turn-in chute · I/O board
J205
1
Swing the arm of the cassette paper-present actuator to the rear direction so that the actuator is away from the cassette paper-
Take Apart present sensor.
Cassette Paper-Present Sensor - 69
2 3
Open the turn chute cover.
Use a small flat blade screwdriver to release the hooks of the cassette paper-present sensor, located on the inside of the printer frame (work from the rear of the printer), from the left cassette guide assembly. Note: Do not move the cassette paper-present sensor away, since it is connected with the feeder harness. Disconnect P/J205 from the sensor. Remove the sensor.
4 5
Take Apart
Right Cassette Guide Assembly - 70
Right Cassette Guide Assembly
Before you begin, remove the following: · Fuser access cover · Right top cover · Right cover · Turn-in chute · Turn chute cover
Right Cassette Guide Assembly
Take Apart
Right Cassette Guide Assembly - 71 1 Remove the three screws securing the right cassette guide assembly.
Hook Hook
2
3
Tab Tab
Press the three tabs at the bottom of the cassette guide and release them from the printer frame. Tilt the cassette guide, pulling its bottom edge from the inside of the printer frame.
Hook
4
Tab Right Cassette Guide Assembly
Release the three upper hooks of the cassette guide from the frame and remove the cassette guide from the printer.
Take Apart
Cassette Paper-Present Actuator - 72
Cassette PaperPresent Actuator
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · Left lower cover · Turn-in chute · Turn chute cover · I/O board · Power supply · Left cassette guide assembly
Cassette Paper-Present Actuator
Take Apart
Cassette Paper-Present Actuator - 73 1 Push the shaft of the cassette paper-present actuator inward to release it from the outside collar.
Second
2
First
Release the far end of the actuator from its collar, slide the actuator to the right, and remove it from the printer.
Take Apart
Cassette Pickup Roller(s) - 74
Cassette Pickup Roller(s)
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · Turn-in chute · Turn chute cover · I/O board 1
Solenoid
Pickup Roller
Press down the armature of the cassette pickup solenoid to engage the feed gear with the feed idler gear.
Take Apart
Cassette Pickup Roller(s) - 75 2 Rotate the rotor of the main motor clockwise until the rubber surface of the pickup roller faces downward. Hold the pickup roller shaft firmly with one hand. With the other hand, pull the roller off the shaft.
Shaft
Pin
3
Motor
Replacement Note: Match up the pin inside the roller with the hole in the shaft, and press the pickup roller onto the shaft.
Take Apart
Cassette Pickup Solenoid - 76
Cassette Pickup Solenoid
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · I/O board
Cassette Pickup Solenoid
Take Apart
Cassette Pickup Solenoid - 77 1 Remove the spring that connects the feed core to the chassis armature. Note: This spring is a part of the spring kit (P/N 076-0647). Disconnect solenoid cable J204 from the left cassette guide assembly.
Feed Core
Feed Spring
2
3
J204
Chassis Armature
Remove the screw securing the cassette pickup solenoid to the chassis armature and remove the solenoid from the printer.
Cassette Pickup Solenoid
Take Apart
Lower Feed Roller - 78
Lower Feed Roller
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · Right top cover · Right cover · Turn-in chute · Turn chute cover · I/O board · Turn clutch
Lower Feed Roller
Take Apart 1
Lower Feed Roller - 79 On the gear end of the roller, remove the Ering securing the gear and slide the gear off the lower feed roller shaft. Slide the feed bearing off the roller shaft.
E-Ring Bearing
2 3
4
Lower Feed Roller Bearing Gear E-Ring
On the right side, remove the E-ring securing the feed bearing and slide the bearing off the shaft. Remove the lower feed roller shaft by freeing one end then the other from the chassis frame.
Take Apart
Upper Feed Roller
Upper Feed Roller - 80
Upper Feed Roller
Before you begin, remove the following: · Fuser access cover · Left top cover · Left cover assembly · Front left cover · Right top cover · Right cover · Turn-in chute · Turn chute cover · I/O board
Take Apart 1
Upper Feed Roller - 81 On the gear end of the roller, remove the Ering securing the gear and slide the gear off the feed roller shaft. Slide the feed bearing off the roller shaft.
E-Ring Bearing
2 3
4
Upper Feed Roller
On the right side, remove the E-ring securing the feed bearing and slide the bearing off the shaft. Remove the feed roller shaft by freeing one end then the other from the chassis frame.
Bearing Gear E-Ring
Take Apart
Top Cover Housing - 82
Top Cover Housing
Top Cover Housing
Before you begin, remove the following: · Fuser access cover · Left top cover · Right top cover · Left cover assembly · Exit cover · Top cover · Fuser assembly · I/O board
Take Apart
Screw
Top Cover Housing - 83 1 Using a small flat blade screwdriver, remove the ferrite core above and to the left of the DC controller board. Disconnect connectors P12 and P17 on the DC controller board. Remove the screw securing the grounding wire to the top of the chassis.
2
3
Ferrite Core
Connectors
Take Apart 4
Screw and Guide Arm Cover
Top Cover Housing - 84 Remove the screw and cable clamp located just behind the fan and remove the cables from the clamp. Snake the two cables disconnected in step 2 through the cable guide in the chassis. Remove the screw and the small black fuser guide arm cover.
5
6
Screw and Cable Clamp
Cable Guide
Take Apart
Hold-Open Shaft
Top Cover Housing - 85 7 While holding the top cover housing open, unseat the two torsion springs from the collars on the rear tie plate. Close the top cover. Remove the screw at each end of the hold-open shaft.
8 9
Rear Tie Plate Collar Spring Spring
Collar
Take Apart
Top Cover Housing - 86 10 Raise the top cover and release the two locking feet so that the cover rests directly on the chassis.
Left Locking Foot
Right Locking Foot
Take Apart
Top Cover Housing - 87 11 Lift the top cover housing from the printer frame.
Take Apart
Laser/Scanner Assembly - 88
Laser/Scanner Assembly
Laser/Scanner Assembly