04a Repairs

July 2005
4-1 WorkCentre Pro 275 Family (CC232-WCP275F)

Repairs/Adjustments
4 Repairs/Adjustments
REPs 1 - Standby Power
REP 1.1 Power and Control Assembly ........................................................................... 4-5
REP 1.2 Wiring Harness Repairs.................................................................................... 4-9
REP 1.3 Molex SL Connectors ....................................................................................... 4-10
REP 1.4 Male Hirose DF1B Connectors ......................................................................... 4-12
REP 1.5 AMP EI Connectors .......................................................................................... 4-14
REP 1.6 Hirose DF11 Connectors .................................................................................. 4-17
REP 1.7 AMP CT Connectors......................................................................................... 4-17
REP 1.8 Door Interlock Switch........................................................................................ 4-19
REP 1.9 LVPS and Base Module.................................................................................... 4-20
REP 1.10 HVPS.............................................................................................................. 4-22
REPs 2 - User Interface
REP 2.1 User Interface Assembly................................................................................... 4-25
REP 2.2 User Interface Touch Screen............................................................................ 4-26
REP 2.3 User Interface PWB.......................................................................................... 4-27
REPs 3 - Machine Run Control
REP 3.1 IOT PWB........................................................................................................... 4-29
REP 3.2 Image Processing Module PWBs .................................................................... 4-30
REP 3.3 Image Processing PWB Software Module........................................................ 4-32
REPs 4 - Main Drives
REP 4.1A Main Drive Module (32-55 ppm)..................................................................... 4-35
REP 4.1B Main Drive Module (65-75 ppm)..................................................................... 4-40
REP 4.2A Main Drive PWB (32-55 ppm) ........................................................................ 4-44
REP 4.2B Main Drive PWB (65-75 ppm) ........................................................................ 4-45
REP 4.3A Main Drive Belt and Drive Gears (32-55 ppm) ............................................... 4-47
REP 4.3B Main Drive Belts and Drive gears (65-75 ppm) .............................................. 4-49
REP 4.4 Photoreceptor Drive Gear ................................................................................. 4-51
REPs 5 - DADH
REP 5.1 Top Cover Assembly ........................................................................................ 4-53
REP 5.2 Top Access Cover Assembly............................................................................ 4-54
REP 5.3 Feed Assembly................................................................................................. 4-55
REP 5.4 Input Tray Assembly......................................................................................... 4-56
REP 5.5 Baffle Assembly................................................................................................ 4-57
REP 5.6 Takeaway Roll Assembly.................................................................................. 4-60
REP 5.7 Duplex Solenoid................................................................................................ 4-61
REP 5.8 Takeaway and CVT Sensor.............................................................................. 4-63
REP 5.9 Length Detect Sensors ..................................................................................... 4-64
REP 5.10 Registration Sensor ........................................................................................ 4-65
REP 5.11 Exit Sensor ..................................................................................................... 4-66
REP 5.12 DADH Counterbalance ................................................................................... 4-68
REP 5.13 Exit Roll Assembly .......................................................................................... 4-69
REP 5.14 Feed Roll Assembly........................................................................................ 4-70
REP 5.15 Duplex Gate, CVT Roll and CVT Motor, Drive Belt ........................................ 4-72
REP 5.16 Document Width Sensor ................................................................................. 4-74
REP 5.17 Input Tray Static Eliminator............................................................................. 4-75
REP 5.18 Exit Roll Idler................................................................................................... 4-76
REP 5.19 DADH Removal............................................................................................... 4-78
REPs 6 - ROS
REP 6.1 ROS.................................................................................................................. 4-79
REPs 7 - Paper Supply
REP 7.1 Tray 1 and Tray 2 Removal .............................................................................. 4-81
REP 7.2 Tray 3 and Tray 4 Removal .............................................................................. 4-82
REP 7.3 Tray 3 and Tray 4 Elevator Motor ..................................................................... 4-84
REP 7.4 Tray 3 and Tray 4 Elevator Cables ................................................................... 4-85
REP 7.5 Bypass Tray and Left Hand Door Assembly..................................................... 4-87
REP 7.6 Tray 1 and Tray 2 Paper Guide Latch............................................................... 4-88
REP 7.7 Tray 3 and Tray 4 Limit and Stack Height Sensor ............................................ 4-91
REP 7.8 Tray 3 and Tray 4 Stack Limiter........................................................................ 4-92
REP 7.9 Tray 3 and Tray 4 Home Switch ....................................................................... 4-93
REP 7.10 HCF Control PWB........................................................................................... 4-95
REP 7.11 Tray 3 and Tray 4 Elevator Damper................................................................ 4-96
REP 7.12 Tray 1 and Tray 2 Paper Size Cams............................................................... 4-97
REPs 8 - Paper Transport
REP 8.1 Tray 1 and Tray 2 Paper Feed Assembly ......................................................... 4-99
REP 8.2 Tray 3 Paper Feed Assembly ........................................................................... 4-102
REP 8.3 Tray 4 Paper Feed Assembly ........................................................................... 4-104
REP 8.4 Registration Transport ...................................................................................... 4-106
REP 8.5 Registration Clutch............................................................................................ 4-108
REP 8.6 Registration Sensor and Wait Sensor............................................................... 4-110
REP 8.7 Duplex Transport .............................................................................................. 4-111
REP 8.8 Duplex Motor and Drive Belts ........................................................................... 4-112
REP 8.9 Bypass Tray Feed Solenoid.............................................................................. 4-113
REP 8.10 Tray 3 and Tray 4 Transport Motor ................................................................. 4-114
REP 8.11 Tray 3 and Tray 4 Transport Drive Gear......................................................... 4-115
REP 8.12 Tray 1 and Tray 2 Transport Drive Belt........................................................... 4-117
REP 8.13 Tray 3 Transport Assembly............................................................................. 4-118
REP 8.14 Tray 3 Feed Sensor Actuator.......................................................................... 4-119
REP 8.15 Tray 1 and Tray 2 Transport Roll Bearings..................................................... 4-120
REP 8.16 Tray 1 and Tray 2 Transport Rolls .................................................................. 4-123
REP 8.17 Tray 1 or Tray 2 Feed Sensor Actuator .......................................................... 4-124
REP 8.18 Tray 1 and Tray 2 Transport Motor ................................................................. 4-125
REP 8.19 Bypass Tray Feed Head ................................................................................. 4-126
REP 8.20 Bypass Tray Drive Gear.................................................................................. 4-129
REP 8.21 Bypass Tray Feed Roll.................................................................................... 4-130
REP 8.22A Bypass Tray Retard Pad (32-55 ppm).......................................................... 4-132
REP 8.22B Bypass Tray Retard Pad (65-75 ppm).......................................................... 4-134
REP 8.23 Bypass Tray Empty Sensor ............................................................................ 4-135
REP 8.24 Tray 1 Feed Sensor ........................................................................................ 4-136
July 2005
Repairs/Adjustments
REP 8.26 Drive Roll Assembly........................................................................................ 4-138
REP 8.27 Registration Transport Drive Belt.................................................................... 4-140
REP 8.29 Tray 3 Takeaway Roll Assembly .................................................................... 4-141
REP 8.30 Tray 3 Transport Roll Assembly ..................................................................... 4-144
REP 8.31 Tray 3 and Tray 4 Transport Roll .................................................................... 4-146
REP 8.32 Duplex Sensor ................................................................................................ 4-148
REPs 9 - Xerographics
REP 9.1 Waste Toner Bottle Assembly .......................................................................... 4-151
REP 9.2 Developer Assembly......................................................................................... 4-152
REP 9.3 Ozone Fan........................................................................................................ 4-153
REP 9.4 Waste Toner Full Sensor .................................................................................. 4-154
REP 9.5 Toner Dispense Module.................................................................................... 4-155
REP 9.6 Xerographic Module Latch................................................................................ 4-156
REP 9.7 Developer Paddle ............................................................................................. 4-159
REP 9.8 Transfer / Detack Harness................................................................................ 4-160
REP 9.9 Erase Lamp ...................................................................................................... 4-161
REP 9.10 Auger Damper ................................................................................................ 4-163
REPs 10 - Print Transport and Fusing
REP 10.1 Short Paper Path Assembly............................................................................ 4-167
REP 10.2 Inverter Assembly ........................................................................................... 4-169
REP 10.3 Inverter Motor ................................................................................................. 4-172
REP 10.4 Inverter Path Solenoid .................................................................................... 4-173
REP 10.5 Inverter Nip Solenoid ...................................................................................... 4-174
REP 10.6 Nip Roll Guide................................................................................................. 4-175
REP 10.7 Upper Baffle Assembly ................................................................................... 4-177
REP 10.8 Nip Split Shaft Assembly ................................................................................ 4-178
REP 10.9 Shaft Actuator ................................................................................................. 4-179
REP 10.10 Fuser Latch................................................................................................... 4-180
REP 10.11 Inverter Gate................................................................................................. 4-182
REP 10.12 Tri-Roll Shaft Assembly ................................................................................ 4-184
REP 10.13 Fuser Web Motor .......................................................................................... 4-186
REP 10.14 Exit Shaft Assembly...................................................................................... 4-188
REP 10.15 Intermediate Drive Belt ................................................................................. 4-189
REP 10.16 Fuser Exit Switch.......................................................................................... 4-193
REP 10.17 IOT Exit Sensor ............................................................................................ 4-195
REP 10.18 Inverter Output Guide Assembly................................................................... 4-197
REPs 11-110 - 2K LCSS
REP 11.1-110 2K LCSS Covers ..................................................................................... 4-199
REP 11.2-110 Input Drive Belt and Paper Entry Transport Motor .................................. 4-200
REP 11.3-110 Intermediate Paper Drive Belt ................................................................. 4-201
REP 11.4-110 Paper Output Drive Belt and Paper Transport Exit Motor ....................... 4-202
REP 11.5-110 Bin 1 Drive Belts ...................................................................................... 4-203
REP 11.6-110 Tamper Assembly.................................................................................... 4-206
REP 11.7-110 Hole Punch Unit, Motor and Sensors ...................................................... 4-207
REP 11.8-110 Stapler Traverse Assembly ..................................................................... 4-209
REP 11.9-110 Staple Head Unit ..................................................................................... 4-210
REP 11.10-110 Ejector Assembly Sensors..................................................................... 4-211
REP 11.11-110 Bin 1 Level Sensors............................................................................... 4-212
REP 11.12-110 Paddle Wheel Shaft Assembly .............................................................. 4-213
REP 11.13-110 2K LCSS Undocking.............................................................................. 4-216
REP 11.14-110 2K LCSS PWB....................................................................................... 4-217
REP 11.15-110 Entry Guide Cover ................................................................................. 4-218
REP 11.16-110 Docking Latch Assembly ....................................................................... 4-219
REP 11.17-110 Ejector Belt ............................................................................................ 4-220
REPs 11-120 - 1K LCSS
REP 11.1-120 1K LCSS Covers...................................................................................... 4-221
REP 11.2-120 Input Drive Belt and Transport Motor 1.................................................... 4-222
REP 11.3-120 1K LCSS Stability Foot ............................................................................ 4-223
REP 11.4-120 Paper Output Drive Belt and Transport Motor 2 ...................................... 4-223
REP 11.5-120 Bin 1 Drive Belts ...................................................................................... 4-224
REP 11.6-120 Tamper Assembly.................................................................................... 4-226
REP 11.7-120 Stapler Assembly and SH1 Paper Sensor............................................... 4-227
REP 11.8-120 Ejector Assembly and Sensors................................................................ 4-229
REP 11.9-120 Bin 1 Upper Level Sensor........................................................................ 4-230
REP 11.10-120 Paddle Wheel Shaft Assembly .............................................................. 4-231
REP 11.11-120 1K LCSS Removal ................................................................................. 4-234
REP 11.12-120 1K LCSS PWB....................................................................................... 4-235
REP 11.13-120 Entry Guide Cover ................................................................................. 4-236
REP 11.14-120 Docking Latch Assembly and Docking Interlock Switch ........................ 4-237
REP 11.15-120 Ejector Belt ............................................................................................ 4-238
REPs 11-130 - HCSS
REP 11.1-130 HCSS Covers .......................................................................................... 4-239
REP 11.2-130 Compiler Carriage Assembly................................................................... 4-240
REP 11.3-130 Staple Head Unit 1 Assembly and SH1 Paper Sensor ............................ 4-247
REP 11.4-130 Carriage PWB.......................................................................................... 4-250
REP 11.5-130 Bin 1 or Bin 2 Assembly........................................................................... 4-252
REP 11.6-130 Compiler Carriage Elevator Motor, Bracket and Bearing......................... 4-253
REP 11.7-130 Compiler Carriage Elevator Belts ............................................................ 4-255
REP 11.8-130 Elevator Belt Tensioner Springs .............................................................. 4-260
REP 11.9-130 HCSS Castors ......................................................................................... 4-261
REP 11.10-130 Hole Punch Motor and Coupling............................................................ 4-262
REP 11.11-130 Upper Paper Guide................................................................................ 4-263
REP 11.12-130 Diverter Gate and Solenoid ................................................................... 4-264
REP 11.13-130 Mylar Guide Assembly........................................................................... 4-266
REP 11.14-130 Vertical Transport Belts and Pre-compile Pulleys.................................. 4-273
REP 11.15-130 Vertical Transport Nip Rollers................................................................ 4-276
REP 11.16-130 Chad Full Bin Sensor, Actuator and Spring........................................... 4-276
REP 11.17-130 Transport Motor 1A, Motor Damper and Drive Belt ............................... 4-278
REP 11.18-130 Transport Motor 1B, Motor Damper and Drive Belt ............................... 4-279
REP 11.19-130 HCSS Un-Docking................................................................................. 4-280
REP 11.20-130 CC Ejector Motor Assembly and Ejector Home Sensor ........................ 4-281
REP 11.21-130 CC Paddle Roll Motor Assembly and Paddle Roll Home Sensor .......... 4-282
REP 11.22-130 CC Top Baffle Assembly........................................................................ 4-283
REP 11.23-130 Compiler Sensor .................................................................................... 4-285
REP 11.24-130 CC Entrance Baffle and Springs............................................................ 4-286
REP 11.25-130 Elevator belt drive pulleys...................................................................... 4-287
REP 11.26-130 CC Stapling Unit Traverse Motor........................................................... 4-288
REP 11.27-130 Transport Motor 2 and Motor Damper ................................................... 4-289
July 2005
Repairs/Adjustments
REP 11.28-130 CC Eject Roll Motor ............................................................................... 4-290
REP 11.29-130 CC Kicker Assembly.............................................................................. 4-291
REP 11.30-130 CC Tray Hold Solenoid Assembly ......................................................... 4-293
REP 11.31-130 CC Stapler Mount and Traverse Shaft Assembly.................................. 4-295
REP 11.32-130 CC Transport Shaft Assembly ............................................................... 4-297
REP 11.33-130 Docking Latch Components .................................................................. 4-299
REP 11.34-130 Compiler Carriage Belt Grips................................................................. 4-302
REP 11.35-130 Bin 1 or Bin 2 Offset Motor and Offset Sensor ...................................... 4-303
REP 11.36-130 Bin 1 or Bin 2 Elevator Motor and Bearing ............................................ 4-304
REP 11.37-130 Entry Sensor and Punch Position Sensor ............................................. 4-305
REP 11.38-130 2nd to Top Exit Sensor .......................................................................... 4-306
REP 11.39-130 CC Shutter............................................................................................. 4-307
REP 11.40-130 CC Nip Shaft Components .................................................................... 4-308
REP 11.41-130 CC Eject Housing Assembly.................................................................. 4-310
REPs 11-170 - HCSSBM
REP 11.1-170 HCSS BM Covers.................................................................................... 4-313
REP 11.2-170 Compiler Carriage Assembly................................................................... 4-315
REP 11.3-170 Staple Head Unit 1 Assembly and SH1 Paper Sensor ............................ 4-318
REP 11.4-170 Carriage PWB.......................................................................................... 4-321
REP 11.5-170 Bin 1 Assembly........................................................................................ 4-322
REP 11.6-170 HCSS BM Castors................................................................................... 4-323
REP 11.7-170 Hole Punch Motor and Coupling.............................................................. 4-325
REP 11.8-170 Upper Paper Guide.................................................................................. 4-326
REP 11.9-170 HCSS BM Upper Diverter Gate and Solenoid......................................... 4-327
REP 11.10-170 Chad Bin Full Sensor, Actuator and Spring........................................... 4-328
REP 11.11-170 Transport Motor 1A, Motor Damper and Drive Belt ............................... 4-330
REP 11.12-170 Transport Motor 1B Motor Damper and Drive Belt ................................ 4-331
REP 11.13-170 HCSS BM Un-Docking .......................................................................... 4-332
REP 11.14-170 BM Lower Diverter Solenoid.................................................................. 4-333
REP 11.15-170 BM Lower Diverter Gate........................................................................ 4-335
REP 11.16-170 BM Flapper and Flapper Roll Motor ...................................................... 4-337
REP 11.17-170 BM PWB................................................................................................ 4-338
REP 11.18-170 BM Crease Blade Motor ........................................................................ 4-340
REP 11.19-170 BM Crease Roll Motor ........................................................................... 4-342
REP 11.20-170 BM Backstop Motor Assembly............................................................... 4-343
REP 11.21-170 BM Backstop Assembly and BM Stack Hold Solenoids ........................ 4-344
REP 11.22-170 BM Entry Roll......................................................................................... 4-346
REP 11.23-170 BM Entry Sensor ................................................................................... 4-348
REP 11.24-170 BM Crease Roll Gate Motor .................................................................. 4-350
REP 11.25-170 BM Paper Path Transport Motor and Damper....................................... 4-350
REP 11.26-170 Back Stop Drive Assembly .................................................................... 4-351
REP 11.27-170 BM Staple Heads................................................................................... 4-353
REP 11.28-170 BM Stapler Bracket Assembly ............................................................... 4-355
REP 11.29-170 BM Conveyor Belts................................................................................ 4-359
REP 11.30-170 BM Tamper Assembly and Tamper 1 Motor.......................................... 4-361
REP 11.31-170 CC Ejector Motor Assembly and Ejector Home Sensor ........................ 4-363
REP 11.32-170 CC Paddle Roll Motor Assembly and Paddle Roll Home Sensor .......... 4-364
REP 11.33-170 CC Top Baffle Assembly ....................................................................... 4-365
REP 11.34-170 Compiler Sensor.................................................................................... 4-367
REP 11.35-170 CC Entrance Baffle and Springs............................................................ 4-368
REP 11.36-170 Crease Blade Assembly ........................................................................ 4-369
REP 11.37-170 CC Stapling Unit Traverse Motor........................................................... 4-372
REP 11.38-170 Transport Motor 2 and Motor Damper ................................................... 4-373
REP 11.39-170 CC Eject Roll Motor ............................................................................... 4-374
REP 11.40-170 CC Kicker Assembly.............................................................................. 4-375
REP 11.41-170 CC Tray Hold Solenoid Assembly ......................................................... 4-377
REP 11.42-170 CC Stapler Mount and Traverse Shaft Assembly.................................. 4-379
REP 11.43-170 CC Transport Shaft Assembly ............................................................... 4-381
REP 11.44-170 Docking Latch Components................................................................... 4-383
REP 11.45-170 Compiler Carriage Belt Grips................................................................. 4-386
REP 11.46-170 Bin 1 Offset Motor and Offset Sensor.................................................... 4-387
REP 11.47-170 Bin 1 Elevator Motor and Bearing.......................................................... 4-388
REP 11.48-170 Entry Sensor and Punch Position Sensor.............................................. 4-389
REP 11.49-170 2nd to Top Exit Sensor .......................................................................... 4-390
REP 11.50-170 BM Eject Sensor .................................................................................... 4-391
REP 11.51-170 BM Support Leg and Spring .................................................................. 4-391
REP 11.52-170 BM Crease Rolls, Gears, Clutch and Bearings...................................... 4-394
REP 11.53-170 CC Shutter and Springs......................................................................... 4-400
REP 11.54-170 CC Nip Shaft Components .................................................................... 4-401
REP 11.55-170 BM Pre-compile Pulley and Tyres ......................................................... 4-403
REP 11.56-170 BM Right Hand Cover............................................................................ 4-405
REP 11.57-170 CC Eject Housing Assembly.................................................................. 4-407
REP 11.58-170 BM Crease Nip Springs ......................................................................... 4-409
REP 11.59-170 Crease Roll Gate Assembly................................................................... 4-412
REP 11.60-170 BM Paper Guide Assembly.................................................................... 4-415
REP 11.61-170 BM Module............................................................................................. 4-417
REPS 12 - OCT
REP 12.1 OCT Fingers Install ......................................................................................... 4-425
REPs 14A - Scanner (32-55 ppm)
REP 14.1A Scanner (32-55 ppm).................................................................................... 4-427
REP 14.2A Exposure Lamp Inverter and Fuse (32-55 ppm)........................................... 4-429
REP 14.3A Document Size Sensors (32-55 ppm) .......................................................... 4-430
REP 14.4A DADH Closed Switch (32-55 ppm) ............................................................... 4-431
REP 14.5A Scanner PWB (32-55 ppm) .......................................................................... 4-432
REP 14.6A CVT Glass, Document Glass and CVT Ramp (32-55 ppm) ......................... 4-433
REP 14.7A Scan Carriage Home Sensor (32-55 ppm) ................................................... 4-434
REP 14.8A Input Module Angle Sensor (32-55 ppm)...................................................... 4-435
REP 14.9A Exposure Lamp (32-55 ppm)........................................................................ 4-436
REP 14.10A Scan Idler Pulleys (32-55 ppm) .................................................................. 4-437
REP 14.11A Scan Motor (32-55 ppm)............................................................................. 4-438
REPs 14B - Scanner (65-75 ppm)
REP 14.1B Scanner (65-75 ppm).................................................................................... 4-439
REP 14.2B Top Cover (65-75 ppm) ................................................................................ 4-441
REP 14.3B CVT Glass, CVT Ramp Assembly and Document Glass (65-75 ppm)......... 4-442
REP 14.4B Scan Carriage Home Sensor (65-75 ppm) ................................................... 4-443
REP 14.5B Scan Carriage Assembly (65-75 ppm) ......................................................... 4-444
REP 14.6B Scan Motor and Mounting (65-75 ppm)........................................................ 4-445
REP 14.7B Scan Cables (65-75 ppm)............................................................................. 4-446
REP 14.8B Scan Drive Belt (65-75 ppm) ........................................................................ 4-450
REP 14.9B Input Module Angle Sensor (65-75 ppm)...................................................... 4-451
July 2005
Repairs/Adjustments
REP 14.10B Exposure Lamp and Exposure Lamp Inverter (65-75 ppm) ....................... 4-452
REP 14.11B Exposure Lamp Ribbon Harness (65-75 ppm)........................................... 4-453
REP 14.12B Scanner PWB (65-75 ppm) ........................................................................ 4-455
REP 14.13B Scan Carriage Ribbon Cable (65-75 ppm) ................................................. 4-455
REP 14.14B Document Size Sensor 1 and Document Size Sensor 2 (65-75 ppm) ....... 4-456
REPs 16 - Network Controller
REP 16.1 Network Controller PWBs Access .................................................................. 4-459
REP 16.2 Network Controller Disk Drive......................................................................... 4-462
ADJs 3 - Registration
ADJ 3.1 Registration Setup............................................................................................. 4-463
ADJ 3.2 Magnification Adjustment .................................................................................. 4-463
ADJs 4 - Machine Lubrication
ADJ 4.1 Machine Lubrication .......................................................................................... 4-465
ADJs 5 - DADH
ADJ 5.1 DADH Drive Belt Adjustment............................................................................. 4-481
ADJ 5.2 DADH Height Adjustment .................................................................................. 4-482
ADJ 5.3 DADH Width Guide Adjustment ........................................................................ 4-484
ADJ 5.4 DADH Cleaning Procedure ............................................................................... 4-484
ADJ 5.5 DADH Registration Adjustment ......................................................................... 4-485
ADJ 5.6 DADH Document Pad ....................................................................................... 4-486
ADJs 6 - ROS
ADJ 6.1 ROS Window Cleaning Procedure.................................................................... 4-487
ADJ 6.2 ROS Cleaning Procedure.................................................................................. 4-488
ADJs 7 - Paper Trays
ADJ 7.1 Tray 3 and Tray 4 Paper Tray Guide Setting .................................................... 4-489
ADJs 8 - Paper Feed and Registration
ADJ 8.1 Transport Drive Belt .......................................................................................... 4-491
ADJ 8.2 Registration Setup............................................................................................. 4-491
ADJs 9 - Xerographics
ADJ 9.1 Corotron Cleaning ............................................................................................. 4-493
ADJ 9.2 Image Quality Adjustment Routine.................................................................... 4-493
ADJ 9.3 Developer Magnetic Seal Brush Adjustment ..................................................... 4-494
ADJ 9.4 Xerographics Cleaning...................................................................................... 4-496
ADJs 11-110 - 2K LCSS
ADJ 11.1-110 2K LCSS Bin 1 Level................................................................................ 4-497
ADJ 11.2-110 Machine to 2K LCSS Alignment ............................................................... 4-497
ADJ 11.3-110 Hole Punch Position................................................................................. 4-498
ADJs 11-120 - 1K LCSS
ADJ 11.1-120 1K LCSS Bin 1 Level................................................................................ 4-499
ADJs 11-130 - HCSS
ADJ 11.1-130 Machine to HCSS Alignment.................................................................... 4-501
ADJs 11-170 - HCSSBM
ADJ 11.1-170 Machine to HCSS BM Alignment ............................................................. 4-503
ADJ 11.3-170 Stapler Anvil Alignment ............................................................................ 4-505
ADJ 11.4-170 Crease Blade Position.............................................................................. 4-509
ADJ 11.5-170 Booklet Tamping ...................................................................................... 4-512
ADJ 11.6-170 Booklet Compiling Position....................................................................... 4-514
ADJ 11.7-170 Booklet Crease Position........................................................................... 4-517
ADJ 11.8-170 Booklet Staple Position ............................................................................ 4-517
ADJs 14A - Scanner
ADJ 14.1A Optics Cleaning Procedure (32-55 ppm)....................................................... 4-519
ADJs 14B - Scanner
ADJ 14.1B Optics Cleaning Procedure (65-75 ppm)....................................................... 4-521
ADJ 14.2B Scan Carriage Assembly (65-75 ppm) .......................................................... 4-522
ADJ 14.3B Scan Motor and Scanner Drive Belt (65-75 ppm) ......................................... 4-523
July 2005
4-5 WorkCentre Pro 275 Family (CC232-WCP275F) REP 1.1
Repairs/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.
WARNING
Take 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
2
Remove the ground
wires from the ground
point
1
Remove the nut
July 2005
Repairs/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
1
Remove screw
2
Move the power and
control assembly to
the left
July 2005
Repairs/Adjustments
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.
1
Disconnect PJ24
2
Disconnect all the HT
leads on the HVPS PWB
July 2005
Repairs/Adjustments
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
July 2005
4-9 WorkCentre Pro 275 Family (CC232-WCP275F) REP 1.1, REP 1.2
Repairs/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
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.
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
July 2005
Repairs/Adjustments
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.
1
Hold the wires from the
bold row connector
2
Attach the Molex connector
5
Pull out A row
4
Pull out B row connector
3
Bend 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
1
Insert Molex tool
2
Press prong flat
3
Push terminal out of housing
using a male terminal from the
repair kit
July 2005
Repairs/Adjustments
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.
July 2005
Repairs/Adjustments
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
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
1
Raise plastic tab with
suitable tool, to
release terminal
2
Remove terminal from
housing
July 2005
Repairs/Adjustments
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 the
longer 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 - -
July 2005
Repairs/Adjustments
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
1
Depress prong to
release terminal
2
housing
July 2005
Repairs/Adjustments
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.
Wire Insulation
Male socket 115P60155 - 600T913 A B
Female pin 115P60182 Paper clip 600T913 A B
2
Remove terminal from housing
1
Insert a paper clip to
release prong
July 2005
Repairs/Adjustments
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
July 2005
Repairs/Adjustments
REP 1.6 Hirose DF11 Connectors
Removal
WARNING
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
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 crimp
terminal 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.
1
Raise plastic tab with suitable tool, to release terminal
2
housing
July 2005
Repairs/Adjustments
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.
1
Raise plastic tab with suitable tool, to release terminal
2
housing
Wire Insulation
IDC replacement con-
nector kit (contains 2, 3,
4 and 6 way connectors
with 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 - - - -
July 2005
Repairs/Adjustments
REP 1.8 Door Interlock Switch
Removal
WARNING
WARNING
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.
1
Insert a steel rule or feeler
gauge and push to release the
catch. Pull the switch forward
2
Repeat step 1 to release the
other side of the switch
1
Rotate the body of the
switch to remove.
July 2005
Repairs/Adjustments
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
1
Remove 2 screws
2
Disconnect PJ27
and PJ26
3
Slide the HVPS, IOT PWB and cover assembly to the right, then remove.
July 2005
Repairs/Adjustments
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.
1
Remove 2 hex head
screws
2
Remove the output device
harness
1
Remove 2 screws
2
Slide the cover to the right, then remove.
July 2005
Repairs/Adjustments
REP 1.10 HVPS
Removal
WARNING
WARNING
2. Figure 1. Remove the HVPS.
Figure 1 Remove the HVPS
1
Disconnect 6
HT connectors
3
Remove 2 screws
2
Disconnect PJ55
4
Remove the HVPS
July 2005
Repairs/Adjustments
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
Plastic
push
clips
Frame ground
connection
(32-55 ppm only)
Ground pin on PJ21
(65-75 ppm only)
Ground pin on PJ21
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments

REP 2.1 User Interface Assembly
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.
1
Remove 2 screws
2
Disconnect PJ130
and PJ81
July 2005
Repairs/Adjustments
REP 2.2 User Interface Touch Screen
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
3
Remove four screws
1
Disconnect PJ6
2
Lift the cable clamp to release the
ribbon cable
July 2005
Repairs/Adjustments
REP 2.3 User Interface PWB
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 release
the ribbon cable
2
Disconnect PJ6
3
Remove eight
screws
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments

REP 3.1 IOT PWB
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.
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.
2. Check the machine serial number and the machine configuration, GP 15.
Figure 1 IOT PWB
Figure 2 IOT PWB ground contact
Notch at the bottom
NVM
IOT PWB ground contact.
July 2005
Repairs/Adjustments
REP 3.2 Image Processing Module PWBs
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.
July 2005
Repairs/Adjustments
Figure 1 Image processing module
Software module.
EPC Memory
PWBs.
5
Remove 2 screws (65-75
ppm) or 3 screws (32-55
ppm), then the firewire PWB
from the riser PWB.
See Note 2.
6
Remove the riser PWB.
4
Remove 1 screw, then the embedded fax module
from the riser PWB.
7
(32-55 PPM) Remove 2 screws marked A.
(65-75 PPM) Remove 4 screws.
8
Remove 8 screws, then
the image processing
PWB.
1
Loosen 1 screw.
2
Release the corner of the
embedded fax module from
the fax clip.
3
Slide the fax clip away from
the embedded fax module.
32-55 ppm only
July 2005
Repairs/Adjustments
Replacement
1. (65-75 ppm) If installing a new firewire PWB, replace the mounting bracket with either the
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)
REP 3.3 Image Processing PWB Software Module
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.
2
Install either the mounting bracket
from the old firewire PWB or a
new mounting bracket.
1
Remove the existing mounting
bracket (2 screws).
July 2005
Repairs/Adjustments
Figure 1 Software module removal
Replacement
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.
5. When the restore is complete, close the NVM save and restore tool. The UI should now
display Ready to scan.
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.
1
Release the 2 catches.
2
Remove the soft-
ware module.
July 2005
Repairs/Adjustments
July 2005
4-35 WorkCentre Pro 275 Family (CC232-WCP275F) REP 4.1A
Repairs/Adjustments

REP 4.1A Main Drive Module (32-55 ppm)
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 lead
Disconnect PJ93
1
Remove screw
2
Disconnect PJ24
3
Move Power supply to
the rear
July 2005
Repairs/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
Disconnect
PJ25
Disconnect HT lead C
and G
Disconnect
PJ18
Disconnect PJ2
Disconnect HT
lead C and G
Disconnect PJ35
and PJ64
Disconnect
PJ25
Disconnect
PJ18
Disconnect PJ2
Disconnect PJ1
July 2005
Repairs/Adjustments
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.
2
Disconnect PJ57
1
Remove harness
from the retaining
clip
2
Remove 7 silver screws
marked A
3
Slide the assembly off the
location dowels
1
Disconnect PJ147,
PJ148 and PJ149
July 2005
Repairs/Adjustments
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
July 2005
Repairs/Adjustments
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.
45-55 ppm white gears
Fuser drive gear
July 2005
4-40 WorkCentre Pro 275 Family (CC232-WCP275F) REP 4.1B
Repairs/Adjustments
REP 4.1B Main Drive Module (65-75 ppm)
Removal
WARNING
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.
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, Figure 3.
Disconnect bias lead
Disconnect PJ93
1
Remove screw
2
Disconnect PJ24
3
Move Power supply to
the rear
July 2005
Repairs/Adjustments
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
Disconnect
PJ25
Disconnect HT lead C
and G
Disconnect
PJ18
Disconnect PJ2
2
Disconnect PJ57
1
Remove harness
from the retaining
clip
July 2005
Repairs/Adjustments
Figure 5 Main drive module
18. Slide the assembly off the location dowels.
Replacement
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.
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.
2
Remove 7 silver screws
marked A
3
Slide the assembly off the
location dowels
1
Disconnect PJ147,
PJ148 and PJ149
Support the short paper path
July 2005
Repairs/Adjustments
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.
July 2005
Repairs/Adjustments
REP 4.2A Main Drive PWB (32-55 ppm)
Removal
WARNING
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
1
Remove 3 short screws
2
Remove the fly wheel
2
Remove 6 black
screws marked A
1
Disconnect 7 PJs
marked B
3
Remove main drive motor
July 2005
Repairs/Adjustments
REP 4.2B Main Drive PWB (65-75 ppm)
Removal
WARNING
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,
2
Disconnect PJ144
1
Disconnect PJ146,
PJ154 and PJ151.
Remove 4 screws
July 2005
Repairs/Adjustments
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.
1
Remove 6 screws
2
Remove the support bracket
3
Remove the main
drive PWB
1
Ensure that the tabs are located in the bracket
Position the collar
All three shaft are located
correctly in the bracket
July 2005
Repairs/Adjustments
REP 4.3A Main Drive Belt and Drive Gears (32-55 ppm)
Removal
WARNING
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.
3
Remove the drive belt
1
Remove the circlip and
gear
2
Slip the drive belt over
the pulley on the belt
tensioner
1
gear
2
Slip the drive belt over the
pulley on the belt tensioner
3
July 2005
Repairs/Adjustments
Figure 3 Remove the drive gears
Replacement
CAUTION
The spring loaded belt tensioner, Figure 1 is a floating type and should not be locked down.
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 circlip
and intermedi-
ated drive gear.
2
Remove the circlip and the
fuser drive gear
Remove the circlip and the
registration transport drive
gear
the developer drive
gear
July 2005
Repairs/Adjustments
REP 4.3B Main Drive Belts and Drive gears (65-75 ppm)
Removal
WARNING
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
1
Remove six screws
2
Remove the support
bracket
1
Remove circlip and intermediate
drive gear
2
Remove drive belt 2
Remove circlip and fuser drive
gear / pulley
Remove circlip, output
paper path drive gear
and the spring
1
Remove drive belt 1
Remove circlip and
registration drive pulley
Remove circlip and developer
drive gear / pulley
July 2005
Repairs/Adjustments
Replacement
CAUTION
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 located
correctly in the bracket
July 2005
Repairs/Adjustments
REP 4.4 Photoreceptor Drive Gear
Removal
WARNING
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
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
the drive shaft.
1
Remove three short
screws and the fly
wheel
2
Remove the screw
and collar
3
Remove the drive gear
and the dowel pin
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments
REP 5.1 Top Cover Assembly
Removal
WARNING
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.
1
Disengage the hinges.
2
Remove the screw and
the plastic bushing (front
and back).
3
Remove the 2 latch pins.
Take note of the position of
latch pins.
4
Remove the top
cover assembly.
July 2005
Repairs/Adjustments
REP 5.2 Top Access Cover Assembly
Removal
WARNING
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
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.
Figure 2 Torsion springs
2
the bracket.
3
Remove the top access
cover assembly.
1
Disconnect PJ191 and
the ground harness.
Takeaway idler roll
torsion spring
CVT idler roll torsion
spring
July 2005
Repairs/Adjustments
REP 5.3 Feed Assembly
Removal
WARNING
WARNING
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.
2
Remove 4 self tapping
screws marked A.
1
Disengage the hinges.
4
Release the harness.
3
Disconnect PJ183, PJ184
and PJ187.
5
Disconnect the ground
harness.
6
Remove the feed
assembly.
July 2005
Repairs/Adjustments
REP 5.4 Input Tray Assembly
Removal
WARNING
WARNING
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.
7
screws marked A.
3
Release the tension and disengage
the drive belt.
4
5
Disconnect PJ190.
2
Disconnect the ground harness.
6
Loosen the screw.
8
Remove the input
tray assembly.
1
Release the tension on the
CVT motor drive belt.
July 2005
Repairs/Adjustments
REP 5.5 Baffle Assembly
Removal
WARNING
WARNING
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
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
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.
1
Disconnect the link arm.
4
Disconnect PJ189.
2
harness.
3
July 2005
Repairs/Adjustments
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.
1
Carefully remove the left hand
end of the document pad from the
baffle assembly.
2
Remove 2 screws.
DADH frame.
4
To help the removal of the
baffle assembly, slide the
lower cover approximately
40mm (1.5 inches) away
from the document pad.
3
Disengage the lugs in the lower
cover.
2
Disengage the hinge
pin.
4
Remove the baffle
assembly.
Solenoid link arm.
1
Feed the harness and
ground harness through the
frame.
3
Slide the tab through
slot in DADH frame.
July 2005
Repairs/Adjustments
Figure 4 Torsion springs and harness
Torsion springs.
Route the harness.
July 2005
Repairs/Adjustments
REP 5.6 Takeaway Roll Assembly
Removal
WARNING
WARNING
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.
1
Release the tension and
disengage the drive belt.
3
Slide the bearing forward.
2
Remove 2 E-clips.
4
Remove the takeaway roll
assembly.
White spacers.
Black spacer.
July 2005
Repairs/Adjustments
REP 5.7 Duplex Solenoid
Removal
WARNING
WARNING
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.
2
screws marked A.
4
Release the harnesses.
5
Disconnect PJ186.
3
PJ204.
1
Disconnect 3 ground
harnesses.
2
1
Release the tension and
disengage the drive
belts.
3
Remove the drive assembly.
July 2005
Repairs/Adjustments
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.
2
Remove the screws.
4
Disconnect the ground harness.
3
Disconnect PJ205.
5
Release the duplex sole-
noid from the clips.
1
Disconnect the
link arm.
July 2005
Repairs/Adjustments
REP 5.8 Takeaway and CVT Sensor
Removal
WARNING
WARNING
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
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.
Then install the top cover assembly,
Figure 2 Torsion springs
1
Remove the screw.
CVT sensor.
Takeaway sensor.
2
Disconnect the correct PJ. Remove the
correct sensor.
Spring plate.
CVT idler roll
shaft.
Takeaway idler roll
torsion spring
CVT idler roll torsion
spring
July 2005
Repairs/Adjustments
REP 5.9 Length Detect Sensors
Removal
WARNING
CAUTION
cover is removed, refer to Figure 1.
3. Remove the length detect sensors, Figure 1.
Figure 1 Length detect sensors
Replacement
CAUTION
Ground harness.
See CAUTION.
2
Disconnect the correct PJ. Remove
the correct sensor.
Length sensor 1.
Length sensor 2.
1
Remove the ground harness
and bracket.
July 2005
Repairs/Adjustments
REP 5.10 Registration Sensor
Removal
WARNING
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
1
Remove 2 screws.
2
Carefully release the
torsion spring.
3
Remove the pre-scan
idler roll.
4
Remove the sensor assembly.
5
Disconnect PJ192. Remove the registration
sensor
Torsion spring.
July 2005
Repairs/Adjustments
REP 5.11 Exit Sensor
Removal
WARNING
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.
1
Carefully remove the left hand end of the
document pad from the baffle assembly.
2
Remove 2 screws.
3
Disengage the lugs in the lower
cover.
4
Remove the lower cover.
July 2005
Repairs/Adjustments
Figure 2 Exit sensor
Replacement
CAUTION
1
Disconnect
PJ196. Remove
the exit sensor.
July 2005
Repairs/Adjustments
REP 5.12 DADH Counterbalance
Removal
WARNING
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
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 counterbalance
ground tag.
The right counterbalance
ground tag.
July 2005
Repairs/Adjustments
REP 5.13 Exit Roll Assembly
Removal
WARNING
CAUTION
4. Remove the exit roll assembly, Figure 1.
Figure 1 Exit roll assembly
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.
Ground harness.
See CAUTION.
1
Remove the exit roll
assembly.
Black spacers.
E-clip.
July 2005
Repairs/Adjustments
REP 5.14 Feed Roll Assembly
Removal
WARNING
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.
1
Completely raise the feed
roll assembly (2 clicks).
2
Raise the feed roll assembly
cover.
3
Remove the feed roll assem-
bly.
NOTE: There are three rollers on the
feed roll cartridge.
If the lower feed roll does not come out
with feed roll assembly, then remove it
separately from the machine.
July 2005
Repairs/Adjustments
Figure 2 Retard roll position
Retard roll
Key
July 2005
Repairs/Adjustments
REP 5.15 Duplex Gate, CVT Roll and CVT Motor, Drive Belt
Removal
WARNING
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
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.
Figure 2 Bearing
6. Remove the CVT roll and CVT motor, drive belt, Figure 3.
1
Lift out the duplex
gate.
2
Release the tension and dis-
engage the CVT roll drive belt.
1
Compress the two ends of
the bearing together.
2
Push the bearing to disengage.
July 2005
Repairs/Adjustments
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
1
Remove the CVT roll.
2
Remove the CVT motor drive
belt.
CVT roll.
White washer.
July 2005
Repairs/Adjustments
REP 5.16 Document Width Sensor
Removal
WARNING
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.
1
2
Disconnect PJ193.
3
Remove the document width sensor.
arm
Ground harness.
July 2005
Repairs/Adjustments
REP 5.17 Input Tray Static Eliminator
Removal
WARNING
CAUTION
cover is removed, refer to Figure 1
3. Remove the input tray static eliminators, Figure 1.
Figure 1 Static eliminators
Replacement
CAUTION
1
Remove the correct
static eliminator.
Ground harness.
July 2005
Repairs/Adjustments
REP 5.18 Exit Roll Idler
Removal
WARNING
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.
1
Release the link arm.
2
Raise one end of the exit roll idler shaft, then release
the lift bar.
3
Remove the lift bar and
link arm.
1
Carefully remove the tor-
sion spring and the docu-
ment finger.
2
Lift out the exit roll idlers.
3
Remove the 2 bearings.
July 2005
Repairs/Adjustments
Figure 3 Torsion spring and document finger
Torsion spring.
Document finger.
July 2005
Repairs/Adjustments
REP 5.19 DADH Removal
Removal
WARNING
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,
PL 8.10 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.
1
Remove 2 thumbscrews.
2
Remove the DADH.
July 2005
Repairs/Adjustments
REP 6.1 ROS
Removal
WARNING
Avoid exposure to laser beam. Invisible laser radiation.
WARNING
WARNING
1. Remove the scanner, REP 14.1A Scanner (32-55 ppm) or REP 14.1B Scanner (65-75
ppm).
CAUTION
Take care not to damage the wiring at the rear of the ROS.
2. Figure 1, remove the ROS.
Figure 1 ROS removal
1
Remove screw
2
Slide the ROS to the rear to align
cut out. Lift the rear of the ROS.
See Caution
3
Slide the ROS to the rear to
clear the front dowels, then lift
up and out.
4
Disconnect the harnesses at
the ROS then remove the ROS
Front Rear
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the ROS.
CAUTION
Ensure that the harnesses are not damaged when the ROS is installed.
1. If installing a new ROS, ensure that the ROS is the correct speed for the machine:
A 32-38 ppm ROS has a serial number beginning with 35 or 36.
A 45-55 ppm ROS has a serial number beginning with 55 or 56.
A 65-75 ppm ROS has a serial number beginning with 75.
NOTE: Refer to Figure 2 for the location of the serial number.
2. Figure 2. Ensure that the harness is routed correctly.
Figure 2 ROS harness routing
3. Go to dC604 Registration Setup, check/adjust the registration.
4. Perform ADJ 9.2 Image Quality Adjustment Routine.
Serial number.
(Underneath)
Harness routing
July 2005
Repairs/Adjustments

REP 7.1 Tray 1 and Tray 2 Removal
Removal
WARNING
1. Remove the tray 1 or tray 2, Figure 1.
NOTE: The removal procedure for tray 1 and tray 2 is same.
Figure 1 Tray 1 and tray 2 removal
Replacement
Pull the tray
out and lift to
remove
Tray stop
Tray stop
July 2005
Repairs/Adjustments
REP 7.2 Tray 3 and Tray 4 Removal
Removal
WARNING
1. Remove the paper from the two trays.
2. Remove the right hand cover, PL 7.25 Item 2.
3. Remove the tray 3 and tray 4 front cover, Figure 1.
Figure 1 Tray 3 and tray 4 front covers removal
4. Remove the stops, Figure 2.
If Tray 4 needs to be removed then remove Tray 3 first.
If only Tray 3 is to be removed then do not remove the left hand stop.
Figure 2 Tray 3 and tray 4 rail stops
5. Lift and pull to remove the tray complete with the guide rails.
Replacement
The replacement is the reverse of the removal procedure. Refer to GP 6 when refitting the
screws to secure tray 3 and tray 4 front covers.
NOTE: When installing tray 3 or tray 4 ensure that the tray rails are located correctly in the
base of the HCF, Figure 3.
1
Remove 3 screws (tray 3)
3
Remove 2 screws (tray 4)
2
Use a small screw driver to remove the
front cover from tray 3
3
Remove left hand stop
(tray 4)
1
Remove right hand stop
(tray 3)
2
Remove centre stop
July 2005
Repairs/Adjustments
Figure 3 Location of the tray rails
Tray 4 rail location
Tray 3 rail location
July 2005
Repairs/Adjustments
REP 7.3 Tray 3 and Tray 4 Elevator Motor
Removal
WARNING
WARNING
1. Pull out tray 3 and tray 4.
2. Remove the network controller if installed, PL 16.10.
3. Remove the rear cover from the HCF, PL 7.25 Item 1.
4. Disconnect PJ395 or PJ397 elevator motor harness from the HCF control PWB,
5. Disconnect the harness from the low paper sensor on the elevator motor.
6. Remove the tray 3 or tray 4 elevator motor, Figure 1.
Figure 1 Elevator motor removal
Replacement
Tray 4 elevator motor
1
Remove the screw
Tray 3 elevator motor
2
Remove the elevator
motor
HCF control PWB
Low paper sen-
sor
Timing disc
July 2005
Repairs/Adjustments
REP 7.4 Tray 3 and Tray 4 Elevator Cables
Removal
WARNING
WARNING
NOTE: The elevator drives at the front and at the rear are similar for both trays.
1. Remove tray 3 or tray 4, REP 7.2.
2. Remove the cables from the front drive pulley, Figure 1.
Figure 1 Front elevator cable removal
3. Remove the pulley carrier and pass the cables through the base of the tray, Figure 2.
NOTE: Short cable over the outer pulley and the long cable over the inner pulley.
Figure 2 Remove front elevator cables
4. Remove the tray 3 rear elevator cable, Figure 3.
1
Remove E clip
2
Remove the short cable from the
drive pulley.
3
Remove the long cable from the
drive pulley.
Tray 4 drive shaft
Remove cables
Tray 3 drive shaft
Tray 4 pulley carrier
Tray 3 pulley
carrier
July 2005
Repairs/Adjustments
Figure 3 Tray 3 rear cable removal
5. Remove the tray 4 rear elevator cable, Figure 4.
Figure 4 Tray 4 rear cable removal
Replacement
Tray 3 front cables.
1. Thread the short cable over the inner groove on the pulley
2. Thread the long cable over the outer groove on the pulley.
Tray 3 rear cable.
Thread the medium length cable over the inner groove on the pulley.
Tray 4 front cables.
1. Thread the long cable over the inner groove on the pulley
2. Tread the short cable over the outer groove on the pulley.
Tray 4 rear cable.
Thread the medium length cable over the outer groove on the pulley.
1
Remove E-clip
5
Remove the cable from
the drive pulley.
4
Remove the drive
dog and cap
6
Pass cable through the
base of the tray
2
Remove the metal plate if
fitted
3
Remove the pulley
carrier
2
Remove the drive dog
and end cap
1
Remove E-clip
3
Remove the cable from
the drive pulley
6
Pass the cable through
the base of the tray
4
Remove 3 pulley carrier
5
Remove the metal plate if fitted
July 2005
Repairs/Adjustments
REP 7.5 Bypass Tray and Left Hand Door Assembly
Parts List on (32-55 ppm) PL 7.35, (65-75 ppm) PL 7.30
Removal
WARNING
WARNING
2. Remove the waste toner bottle and door, REP 9.1.
3. Remove the plastic cover from the feed assembly, PL 8.25 Item 1.
4. Prepare to remove the bypass tray, Figure 1.
5. Remove upper left hand cover, PL 8.10 Item 3.
6. Pull out the extender tray on the bypass tray.
7. Remove the bypass tray, Figure 2.
NOTE: Check that the point of the hinge pin has not damaged the ribbon cable.
Figure 2 Bypass tray hinge pin
Replacement
NOTE: When replacing the hinge pin do not damage the ribbon cable.
1
Disconnect PJ10
on the IOT PWB
2
Unclip the ribbon
cable
Left hand door
and bypass
tray
1
Remove the hinge pin
Ribbon cable
2
Remove the left door
and bypass tray
July 2005
Repairs/Adjustments
REP 7.6 Tray 1 and Tray 2 Paper Guide Latch
Removal
WARNING
1. Remove the paper and remove the tray, REP 7.1.
2. Unlock the side guide stop, Figure 1.
Figure 1 Unlock the side guide stop
3. Remove the side guide stop, Figure 2.
Figure 2 Remove the side guide stop
4. Slide the rear side guide assembly to the front of the tray.
5. Remove the side guide assembly, Figure 3.
Figure 3 Remove the side guide assembly
6. Remove the catch, Figure 4.
1
Press the two tabs together
2
Move the side guide stop to the
cut out
1
Align the tabs with the cut outs
in the tray base
2
Remove the side guide stop
1
Lift the tab with a small
screwdriver
2
Move the side guide assembly
and remove
July 2005
Repairs/Adjustments
Figure 4 Remove the catch
7. Remove the paper guide latch, Figure 5.
Figure 5 Remove the latch
Replacement
1. Locate the latch, Figure 6.
1
Press the tabs
together
2
Push the catch down
to remove
1
Use a small screwdriver to release
the tabs on both sides of the latch
2
Remove the latch
July 2005
Repairs/Adjustments
Figure 6 Locate the latch
2. Locate the side guide assembly in the base of the tray, Figure 7.
Figure 7 Locate the side guide assembly
1
Press the tabs together
2
Push the latch down until it
locks into position
1
Position the side guide assem-
bly over the cut outs
2
Press down on the two
tabs and slide to the rear
July 2005
Repairs/Adjustments
REP 7.7 Tray 3 and Tray 4 Limit and Stack Height Sensor
Removal
WARNING
WARNING
1. Pull out Tray 3 or tray 4, PL 7.15 Item 3.
2. Remove the network controller, PL 16.10.
4. Remove the required paper feed assembly:
Tray 3 paper feed assembly, REP 8.2.
Tray 4 paper feed assembly, REP 8.3.
5. Disconnect and remove the stack limit and height sensor, Figure 1.
Figure 1 Stack limit and height sensor
Replacement
Stack limit switch
Stack height sensor
July 2005
Repairs/Adjustments
REP 7.8 Tray 3 and Tray 4 Stack Limiter
Removal
WARNING
WARNING
1. Remove tray 3, REP 7.2.
2. Perform the following:
To remove the tray 3 stack limiter and bracket, Figure 1.
To remove the tray 4 stack limiter and bracket, Figure 2.
Figure 1 Tray 3 stack limiter and bracket
Figure 2 Tray 4 stack limiter and bracket
3. Remove the stack limiter from the bracket.
Replacement
1
Use a small screwdriver
to lift and hold the tab
2
Slide the bracket to the front
2
Slide the bracket to the front
1
Use a small screwdriver to press down the
tab to release the bracket
July 2005
Repairs/Adjustments
REP 7.9 Tray 3 and Tray 4 Home Switch
Removal
WARNING
WARNING
The removal procedure is the same for tray 3 and tray 4.
1. Pull out Tray 3 or Tray 4.
4. Remove the tray home switch and holder, Figure 1.
Figure 1 Tray home switch and holder
5. Remove the tray home switch, Figure 2.
Figure 2 Tray home switch
1
Remove screw
2
Lift and remove the
holder
1
Release harness
2
Press the tabs to release the
switch
3
Disconnect the har-
ness
July 2005
Repairs/Adjustments
Replacement
Ensure that the tabs on the switch holder locates correctly in the holes in the base, Figure 3.
Figure 3 Holder location
Tabs on the holder
Location holes in
the base
July 2005
Repairs/Adjustments
REP 7.10 HCF Control PWB
Removal
WARNING
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the HCF
Control PWB.
3. Remove the HCF Control PWB, Figure 1.
Figure 1 Remove the HCF control PWB
Replacement
After completing the replacement procedure, perform dC604 Registration Setup.
1
Disconnect all PJ
connectors
2
Remove the screw
3
Press the clip to
release the PWB
July 2005
Repairs/Adjustments
REP 7.11 Tray 3 and Tray 4 Elevator Damper
Removal
WARNING
WARNING
Take care during this procedure. Sharp edges may be present can cause injury.
1. Remove tray 3 or tray 4, REP 7.2.
2. To remove the damper from tray 3, Figure 1.
Figure 1 Tray 3 damper
3. To remove the damper from tray 4, Figure 2.
Figure 2 Tray 4 damper
Replacement
The replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screws.
1
Remove the screw
2
Lift and remove the
damper
1
Remove the screw
2
Lift and remove the damper
July 2005
Repairs/Adjustments
REP 7.12 Tray 1 and Tray 2 Paper Size Cams
Removal
WARNING
WARNING
1. Remove the output device.
3. Remove tray 1 or tray 2 leaf spring, Figure 1.
Figure 1 Remove the leaf springs
4. Remove the cams for tray 1 or tray 2, Figure 2.
NOTE: The cams are the same for tray 1 and for tray 2. The small cam is for the tray
home position and the larger cams are for the paper size position.
Figure 2 Remove the cams
Replacement
screws.
Remove the screw and leaf
spring for Tray 2
leaf spring for Tray 1.
1
Remove the tray home
cam
2
Remove the 4 paper
size cams
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments

REP 8.1 Tray 1 and Tray 2 Paper Feed Assembly
Removal
WARNING
WARNING
1. Remove tray 1 and tray 2.
3. Remove the waste toner bottle and door, REP 9.1.
4. Move the power and control assembly, Figure 1.
5. Remove the cover from the feed assembly, PL 8.25 Item 1.
CAUTION
Do not catch on the feed sensor actuators on the feed sensors when the feed assembly is
removed.
6. Remove tray 1 and 2 paper feed assembly, Figure 2.
Figure 2 Paper feed assembly
7. To remove tray 1 paper feed assembly, Figure 3.
1
Remove the screw
2
Move the power supply
to the left
1
Disconnect connectors
3
Remove 5 screws
2
Remove drive
belt
5
Disconnect PJ10 and unclip
the ribbon cable
6
Remove the feed
assembly
4
Disconnect connector
July 2005
Repairs/Adjustments
Figure 3 Remove tray 1 paper feed
8. To remove tray 2 paper feed assembly, Figure 4.
Figure 4 Remove tray 2 paper feed
1
Remove 3 screws
2
Disconnect PJ connector
at the rear of the socket
1
Remove 3 screws
2
Disconnect PJ connector
at the rear of the socket
July 2005
Repairs/Adjustments
Replacement
CAUTION
Take care not to catch the tray 1 paper feed sensor on the ground plate as the feed assembly
is installed, Figure 5.
1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screws.
2. Perform ADJ 8.1 Transport Drive Belt.
3. If a new feed roll assembly is installed, reset Tray 1 or Tray 2 Feeds count to zero in the
HFSI feature screen. Refer to GP 17 High Frequency service Items.
Figure 5 Paper feed sensor and ground plate
Paper feed sensor
Ground plate
July 2005
Repairs/Adjustments
REP 8.2 Tray 3 Paper Feed Assembly
Removal
WARNING
WARNING
1. Pull out tray 3.
4. Remove the paper feed assembly, Figure 1.
NOTE: Note the position of the blue flash on the ribbon cable when connected into
PJ399.
Figure 1 Tray 3 feed assembly
Replacement
screws.
1. Refer to the kit instructions and install the spacers on the paper feed assembly.
2. Slide the spacer to the end of the shaft, Figure 2.
Figure 2 Location of the spacer
3. Make sure that the feed assembly locates in the stack limiter bracket., Figure 3.
1
Disconnect 2 PJs.
3
Lift the tab and move the
feed assembly to the left
and remove.
2
Disconnect ribbon cable
from PJ 399
Position of the spacer
July 2005
Repairs/Adjustments
Figure 3 Locate the paper feeder assembly
4. Install the paper feed assembly and push the tray in slowly.
NOTE: Check that the tray does not touch the feed assembly.
5. Connect the ribbon cable and the PJs, Figure 1.
6. If a new feed roll assembly is installed, reset the Tray 3 Feeds count to zero in the HFSI
Locate the feeder into the stack
limit bracket
July 2005
Repairs/Adjustments
REP 8.3 Tray 4 Paper Feed Assembly
Removal
WARNING
WARNING
1. Pull out tray 4.
4. Prepare to remove the paper feeder, Figure 1.
5. Remove the paper feed assembly, Figure 2.
NOTE: Note the position of the blue flash on the ribbon cable when connected into
PJ391.
Figure 2 Tray 4 feed assembly
1
Remove 2 screws
2
Remove the cover
1
Disconnect ribbon
cable from PJ391
3
Lift tab and move the feed
assembly to the left and
remove
2
Disconnect 2 PJs
July 2005
Repairs/Adjustments
Replacement
screws.
1. Make sure that the feed assembly locates in the stack limiter bracket., Figure 3.
Figure 3 Install the paper feed assembly
2. Install the paper feed assembly and push the tray in slowly.
NOTE: Check that the tray does not touch the feed assembly.
3. Connect the ribbon cable and the PJs, Figure 2.
4. If a new feed roll assembly is installed, reset the Tray 4 Feeds count to zero in the HFSI
Locate the feeder into the stack
limit bracket
July 2005
Repairs/Adjustments
REP 8.4 Registration Transport
Removal
WARNING
WARNING
1. Remove the fuser module, PL 10.10 Item 1.
2. Remove the duplex assembly, REP 8.7.
3. Remove the xerographic module, PL 9.20 Item 2.
4. Remove the developer module, REP 9.2.
5. Remove the short paper path assembly, REP 10.1.
6. Open left hand door, PL 7.30 Item 2.
CAUTION
Figure 1. Do not damage the temperature/humidity PWB.
7. Prepare to remove the registration transport, Figure 1.
8. Remove the registration transport through the front of the machine, Figure 2.
1
Disconnect the harness
3
Disconnect bias
lead.
2
Remove the 2 screws and the retainer bracket
Temperature / Humidity
PWB
Ground wire
July 2005
Repairs/Adjustments
Figure 2 Transport removal
Replacement
screw to the retaining bracket.
CAUTION
Ensure that the locking foot is correctly located into the base. Refer to Figure 3.
2.
Figure 3 Transport location
3. Check that the ground wire is secured, Figure 1, when the retainer bracket is reinstalled.
4. Go to 01A Ground Distribution RAP. Check for continuity to ground between the registra-
tion drive shaft and the pre-registration drive shaft.
5. After completing the replacement procedure, perform the dC604 Registration Setup.
6. If a new Bias contact is installed, reset the Bias Foam count to zero in the HFSI feature
1
Move the frame to the front and lift to
unlock the transport from the base.
2
Remove the registration transport
through the front of the machine
July 2005
Repairs/Adjustments
REP 8.5 Registration Clutch
Removal
WARNING
WARNING
1. Remove the registration transport, REP 8.4.
2. Prepare to remove the clutch, Figure 1.
3. Remove the registration clutch, Figure 2.
Figure 2 Registration Clutch
1
2
Remove the harness
from the baffle
1
Remove E-clip on the
gear
2
Remove the E-clip
3
Remove the clutch and
gear together
July 2005
Repairs/Adjustments
Replacement
Check the following:
1. The clutch is located on the tang on the registration frame, Figure 3.
2. The clutch harness is correctly routed and secure, Figure 1.
3. Turn the jam clearance knob 4c to rotate the drive shaft. Ensure that the drive plate on the
clutch rotates without binding on the clutch body, Figure 3.
Figure 3 Clutch location
After completing the replacement procedure, perform the dC604 Registration Setup.
Locate the
clutch into the
tang
Clutch drive plate
Clutch body
July 2005
Repairs/Adjustments
REP 8.6 Registration Sensor and Wait Sensor
Removal
WARNING
WARNING
2. Remove the appropriate sensor, Figure 1.
Figure 1 Sensor location
Replacement
Wait sensor
Registration sensor
1
Disconnect harness
2
Release the sensor
and remove
July 2005
Repairs/Adjustments
REP 8.7 Duplex Transport
Removal
WARNING
WARNING
1. Remove the duplex transport, Figure 1.
Figure 1 Duplex transport removal
Replacement
screw to the duplex transport.
2. Go to 01A Ground Distribution RAP. Check the ground continuity of the duplex transport.
3. Check that the duplex transport is located correctly on the metal channel, Figure 2.
NOTE: Lift the left side of the transport to engage the support pin through the rear frame.
Figure 2 Duplex transport location
2
Pull the transport out by 75 mm
(3 inches) and disconnect the
harness
1
Remove screw.
3
Pull out and remove
the duplex transport
Metal channel.
Duplex transport
Duplex transport
July 2005
Repairs/Adjustments
REP 8.8 Duplex Motor and Drive Belts
Removal
WARNING
WARNING
1. Remove the duplex transport, REP 8.7.
NOTE: The duct on the duplex transport is only used on the 65 - 75 ppm machine.
2. Remove the motor and drive belts, Figure 1.
Figure 1 Duplex motor and drive belts
Replacement
2
Remove 2 screws
3
Remove motor
5
Remove drive belts
1
Disconnect the
motor harness
4
Remove E-clip
July 2005
Repairs/Adjustments
REP 8.9 Bypass Tray Feed Solenoid
Removal
WARNING
WARNING
1. Remove the bypass tray, REP 7.5.
2. Remove the bypass feed solenoid, Figure 1.
Figure 1 Bypass tray feed solenoid
Replacement
3
Remove 2 screws
2
Remove the spring
(top first)
1
Disconnect harness
4
Remove the solenoid
July 2005
Repairs/Adjustments
REP 8.10 Tray 3 and Tray 4 Transport Motor
Removal
WARNING
WARNING
2. Remove HCF rear cover, PL 7.25 Item 1.
3. Remove the Tray 3 and 4 transport motor, Figure 1.
Figure 1 Tray 3 and 4 transport motor
Replacement
screws.
2
Remove 2 screws
1
Disconnect motor
harness
3
Remove the motor
July 2005
Repairs/Adjustments
REP 8.11 Tray 3 and Tray 4 Transport Drive Gear
Removal
WARNING
WARNING
2. Remove the tray 3 and 4 transport motor, REP 8.10.
3. Remove the tray 3 and 4 transport motor bracket, Figure 1.
Figure 1 Tray 3 and 4 transport motor bracket
1
Remove 2 screws
2
Remove the bracket with the
drive gear and the drive belt
July 2005
Repairs/Adjustments
Replacement
CAUTION
The needle bearing in the drive gear can be damaged during removal / replacement. Care
must be taken when removing / replacing the drive gear onto the take away drive shaft.
1. Locate the drives belt onto the drive gear and the tray 3 transport drive coupling, Figure 2.
Figure 2 Transport drive gear
2. Check that the transport motor bracket is located on the stops on the HCF frame, Figure
3.
Figure 3 Transport motor bracket
Drive belt Tray 3 transport drive
coupling
Drive gear
Locate the bracket on the stops to
position the bracket correctly.
HCF frame
July 2005
Repairs/Adjustments
REP 8.12 Tray 1 and Tray 2 Transport Drive Belt
Removal
WARNING
WARNING
2. Remove waste toner bottle, PL 9.10 Item 1.
3. Remove the cover from the feed assembly, PL 8.25 Item 1.
4. Remove the transport drives belt, Figure 1.
Figure 1 Tray 1 and 2 drives belt
Replacement
1. Reverse the removal procedure to replace the transport drives belt.
1
Loosen screw
2
Remove drives belt
July 2005
Repairs/Adjustments
REP 8.13 Tray 3 Transport Assembly
Removal
WARNING
WARNING
CAUTION
Take care when removing tray 3 support bracket from its snap in mounting.
1. Remove tray 3 and tray 4 front covers, Figure 1.
Figure 1 Remove front covers
CAUTION
Take care to avoid damage to the tray 3 feed sensor flag at the rear of the tray, PL 7.15 Item 9.
2. Remove tray 3 transport assembly, Figure 2.
Figure 2 Tray 3 transport assembly
Replacement
screws.
1
Remove 2 screws
2
Remove 3 screws
Use a small screw driver to remove the
front cover from tray 3
1
Remove 2 screws
2
Apply pressure between
transport and tray
3
Press the rear lug over the post
4
Remove the transport
July 2005
Repairs/Adjustments
REP 8.14 Tray 3 Feed Sensor Actuator
Removal
WARNING
WARNING
1. Remove tray 3 transport assembly, REP 8.13.
2. Remove tray 3 feed sensor actuator, Figure 1.
NOTE: Make a note of how the spring is located.
Figure 1 Tray 3 feed sensor actuator
Replacement
CAUTION
Take care when locating the actuator spring, it can be easily deformed or broken
1
Remove the actuator
2
Remove actuator spring
July 2005
Repairs/Adjustments
REP 8.15 Tray 1 and Tray 2 Transport Roll Bearings
Removal
WARNING
WARNING
1. Remove tray 1 and tray 2, PL 7.10.
2. Perform the necessary actions:
Go to step 3 to remove tray 1 front bearing.
Go to step 4 to remove tray 2 front bearing.
Go to step 5 to remove tray 1 or tray 2 rear bearings.
a. Remove tray 1 tie bar. Figure 1,
Figure 1 Remove tray 1 tie bar
b. Remove tray 1 front bearing, Figure 2.
Figure 2 Remove tray 1 front bearing
1
Remove screw
2
Remove screw
3
Remove tie bar
Remove the bearing
July 2005
Repairs/Adjustments
4. Remove the front bearing in tray 2, Figure 3.
Figure 3 Remove tray 2 front bearing
a. Remove the rear cover, PL 8.10 Item 1.
b. Remove the waste toner bottle and door, REP 9.1.
c. Remove the cover from the paper feed assembly, PL 8.25 Item 1.
d. Prepare to remove the rear bearings, Figure 4.
2
Remove the bearing
1
Remove screw
2
Remove drive belt
3
Remove drive
gears
1
Loosen screw
July 2005
Repairs/Adjustments
e. Remove the rear bearing, Figure 5.
Figure 5 Rear bearing
Replacement
1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting
screws.
1
Remove bearing
July 2005
Repairs/Adjustments
REP 8.16 Tray 1 and Tray 2 Transport Rolls
Removal
WARNING
WARNING
1. Remove tray 1 and 2 paper feed assembly, REP 8.1.
2. Remove the front bearings, REP 8.15.
3. Remove the drive gear and shaft, Figure 1,
Figure 1 Rear drive gear and shaft
Replacement
Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting screws.
If a new transport roll is installed, reset the Tray 1 or Tray 2 trans count to zero in the HFSI fea-
ture screen. Refer to GP 17 High Frequency service Items.
1
Remove the clip and
drive gear
3
Remove the drive shaft
2
Remove the ground
plate
July 2005
Repairs/Adjustments
REP 8.17 Tray 1 or Tray 2 Feed Sensor Actuator
Removal
WARNING
WARNING
1. Remove paper tray 1 and tray 2, PL 7.10.
2. Remove tray 1 and 2 paper feed assembly, REP 8.1.
3. Remove the transport roll, REP 8.16.
4. Remove the feed sensor actuator, rear first, Figure 1.
NOTE: The spring can be easily damaged or lost.
Figure 1 Feed sensor actuator
Replacement
1
Remove the actuator
2
Remove the spring
July 2005
Repairs/Adjustments
REP 8.18 Tray 1 and Tray 2 Transport Motor
Removal
WARNING
WARNING
1. Remove tray 1 and tray 2 feed assembly, REP 8.1.
2. Remove tray 1 paper feed, Figure 1.
Figure 1 Tray 1 paper feed
3. Remove tray 1 and tray 2 transport motor, Figure 2.
Figure 2 Tray 1 and tray 2 transport motor
Replacement
screws.
1
Remove E-clip
and drive gear
2
Remove 3 screws
3
Disconnect PJ connector at the
rear of the black socket
4
Remove the tray 1
feed assembly
1
Remove 2 screws
2
Remove the
motor
July 2005
Repairs/Adjustments
REP 8.19 Bypass Tray Feed Head
Removal
WARNING
WARNING
2. Open left hand door and remove the spring from the feed solenoid, Figure 1.
Figure 1 Feed solenoid spring
3. Remove the cover from the feed head, Figure 2.
Figure 2 Feed head cover
1
Unclip and remove
the spring
1
Use a small screw driver to
release the cover
July 2005
Repairs/Adjustments
4. Remove ribbon cable from feed head, Figure 3.
Figure 3 Feed head ribbon cable
5. Remove the feed head, Figure 4.
Figure 4 Bypass tray feed head
Replacement
1. Replacement is the reverse of the removal procedure.
2. Before replacement of the feed head ensure that feed roll, pressure plate cam and drive
gear are correctly aligned, Figure 5.
1
Disconnect PJ
from the tray
empty sensor
2
Remove ribbon
cable
1
Press the tabs and lift the
feed head
Repeat the action at the
rear
2
Remove the
feed head
July 2005
Repairs/Adjustments
Figure 5 Component alignment
1
Position the flat
on the Feed roll
2
Position of the pressure
plate cam
3
Position of the tab on
the drive gear
4
Position of the nip rolls
July 2005
Repairs/Adjustments
REP 8.20 Bypass Tray Drive Gear
Removal
WARNING
WARNING
1. Remove the bypass tray feed head, REP 8.19.
2. Remove the bypass tray drive gear, Figure 1.
Figure 1 Drive gear removal
Replacement
2. Before replacement of the feed head ensure that feed roll, pressure plate cam and drive
gear are correctly aligned, Figure 2.
1
Hold feed roll to stop
shaft falling out
2
Lift the tab to remove the gear
2
plate cam
1
Position the flat
on the feed roll
3
the drive gear
4
July 2005
Repairs/Adjustments
REP 8.21 Bypass Tray Feed Roll
Removal
WARNING
WARNING
1. Open the left hand door, PL 7.30 Item 2.
2. The bypass tray pressure plate must be in the down position. Check that the solenoid
lever is engaged in the drive gear, Figure 1.
Figure 1 Engage drive gear
3. Remove the cover from the feed head, Figure 2.
Figure 2 Remove feed head cover
4. Remove the bypass tray feed roll, Figure 3.
Solenoid lever engaged
in the drive gear
1
release the cover
July 2005
Repairs/Adjustments
Figure 3 Remove the feed roll
Replacement
2. Check the feed head to ensure that the feed roll, pressure plate cam and drive gear are
correctly aligned, Figure 4,
3. If a new feed roll is installed, reset the Bypass feeds count to zero in the HFSI feature
1
Remove the KL clip
2
Remove nip roll
3
Remove feed roll
plate cam
Position the flat
on the feed roll
the drive gear
July 2005
Repairs/Adjustments
REP 8.22A Bypass Tray Retard Pad (32-55 ppm)
Removal
WARNING
WARNING
2. Prepare to remove the retard pad, Figure 1.
3. Remove the retard pad, Figure 2.
Figure 2 Remove the retard pad
2
Move the pad to the rear and allow
the pad to spring up
1
Release the pressure
plate tag to allow the
plate to spring up
1
Press the support arms to
release the retard pad
2
Remove the retard pad
July 2005
Repairs/Adjustments
Replacement
1. Ensure that the retard pad and pressure plate springs are correctly located, Figure 3.
Figure 3 Spring location
2. If a new retard pad is installed, reset the Bypass feeds count to zero in the HFSI feature
Pressure plate spring
Retard pad spring
July 2005
Repairs/Adjustments
REP 8.22B Bypass Tray Retard Pad (65-75 ppm)
Removal
WARNING
WARNING
2. Prepare to remove the retard pad, Figure 1.
3. Remove the retard pad, Figure 2.
Figure 2 Remove the retard pad
Replacement
If a new retard pad is installed, reset the Bypass feeds count to zero in the HFSI feature
1
Move the pad to the rear
and allow the pad to
spring up
1
Insert a screwdriver
between the pad and
holder and twist
2
Remove the retard pad
July 2005
Repairs/Adjustments
REP 8.23 Bypass Tray Empty Sensor
Removal
WARNING
WARNING
2. Remove the tray empty sensor, Figure 1.
Figure 1 Tray empty sensor
Replacement
1
Push down on the lug
to release the sensor
2
Remove the sensor
July 2005
Repairs/Adjustments
REP 8.24 Tray 1 Feed Sensor
Removal
WARNING
WARNING
1. Remove tray 1 and tray 2 feed head assembly up to step 6, REP 8.1.
2. Release the harness from the feed head assembly, Figure 1.
Figure 1 Release the harness
3. Release the feed sensor from the support bracket, Figure 2.
Figure 2 Release the sensor
4. Disconnect the cable harness and remove the feed sensor, Figure 3.
Figure 3 Remove the sensor
Replacement
1
Release the harness
from under the cable
clips
1
Press down on the lug to release
the sensor
2
Move the sensor
1
2
Remove the sensor
July 2005
Repairs/Adjustments
Removal
WARNING
WARNING
1. Remove the tray 2 paper feed assembly, REP 8.1.
2. Release the harness from the feed head assembly, Figure 1.
Figure 1 Release the cable harness
3. Release the feed sensor from the support bracket, Figure 2.
Figure 2 Release the sensor
4. Disconnect the cable harness and remove the feed sensor, Figure 3.
Figure 3 Remove the sensor
Replacement
1
Release the harness
from under the cable
clips
1
Press down on the lug to
release the sensor
2
Move the sensor
1
2
Remove the sensor
July 2005
Repairs/Adjustments
REP 8.26 Drive Roll Assembly
Removal
WARNING
WARNING
2. Remove the registration nip assembly, Figure 1.
Figure 1 Registration nip assembly
3. Remove the lower registration guide, Figure 2.
Figure 2 Lower bias guide
4. Remove the registration clutch, REP 8.27.
5. Remove the E-clips and bearing from the registration shaft, Figure 3.
Figure 3 E-clip and bearing
1
Remove jam clearance
knob
2
Remove screw
3
Press down and
slid to release
the nip assembly
1
Remove 2 screws
2
Remove the bias guide
1
Remove the E-clip and
bearing
2
Remove the E-clip, spring
washer and bearing
July 2005
Repairs/Adjustments
6. Remove the drive roll assembly, Figure 4.
Figure 4 Drive roll assembly
Replacement
Ensure that the ground strap is between the frame and the bearing. Figure 5.
Figure 5 Ground strap position
1
Remove the drive roll
assembly
Ground strap
Bearing
July 2005
Repairs/Adjustments
REP 8.27 Registration Transport Drive Belt
Removal
WARNING
WARNING
2. Remove the drive belt, Figure 1.
Figure 1 Drive belt
Replacement
1
July 2005
Repairs/Adjustments
Removal
WARNING
WARNING
1. Pull out Tray 3.
4. Remove tray 3 feed sensor, Figure 1.
Figure 1 Tray 3 feed sensor
Replacement
REP 8.29 Tray 3 Takeaway Roll Assembly
Removal
WARNING
WARNING
2. Remove the jam clearance door, Figure 1.
2
Press the tabs together
1
July 2005
Repairs/Adjustments
Figure 1 Remove the jam clearance door
3. Preparation to remove the transport roll assembly, Figure 2.
4. Remove the takeaway roll assembly, Figure 3.
1
Lift the jam clearance door
2
Push the tab to release the
door hinge
1
Remove the E-clip
2
Remove the drive gear and belt
July 2005
Repairs/Adjustments
Figure 3 Remove the takeaway shaft
5. Remove the idler roll and shaft, Figure 4.
Figure 4 Remove the idler roll and shaft
Replacement
Replacement is the reverse of the removal procedure. 2
Remove the E-clip
1
Remove the E-clip
3
Press the tabs and
push the bearing out
4
Remove the takeaway
shaft
1
Move the tabs to remove the idler rolls
and shaft
July 2005
Repairs/Adjustments
REP 8.30 Tray 3 Transport Roll Assembly
Removal
WARNING
WARNING
2. Remove the jam clearance door, Figure 1.
Figure 1 Remove the jam clearance door
1
Remove the coupling
3
Push the tab to release the
door hinge
2
Lift the jam clearance door
July 2005
Repairs/Adjustments
3. Preparation to remove the transport roll assembly, Figure 2.
4. Remove the transport roll assembly, Figure 3.
Figure 3 Remove the transport roll assembly
Replacement
1
Remove the E-clip
2
Remove the coupling
3
Remove the belt and
drive gear
1
Remove the E-clip
2
Remove the E-clip
3
Press the tabs and push
the bearing out
4
Remove the transport
roll assembly
July 2005
Repairs/Adjustments
REP 8.31 Tray 3 and Tray 4 Transport Roll
Removal
WARNING
WARNING
1. Remove tray 3 and tray 4 transport motor, REP 8.10.
2. Remove Tray 3 and tray 4 transport drive gear, REP 8.11.
3. Remove the left cover, PL 7.25 Item 2.
4. Remove paper tray 2, REP 7.1.
5. (32-55 ppm Only) Remove the ground plate, Figure 1.
Figure 1 Remove the ground plate (32-55 ppm only)
6. Remove tray 3, REP 7.2.
7. Remove the idler shaft assembly, Figure 2.
Figure 2 Remove the idler shaft assembly
1
Remove 2 screws
and the bracket
2
Remove the ground
plate
3
Remove the E-clip
1
Remove the springs
2
Remove the idler rolls, shaft and
bearings
July 2005
Repairs/Adjustments
8. Remove tray 3 and tray 4 transport roll, Figure 3.
Figure 3 Remove the transport roll
Replacement
screws.
1. Refer to Figure 4, to install the tray 3 and tray 4 transport roll.
Figure 4 Install the transport roll
2. (32-55 ppm Only) Ensure that the ground plate has contact with the transport roll shaft,
refer to Figure 1.
1
Press the rolls and slide the shaft
to the rear until it is released from
the front bearing
2
Slide the shaft to the front until it is
released from the rear bearing
1
Locate the shaft in the
bearing at the rear.
2
Press and slide the shaft
into the front bearing
Front bearing
July 2005
Repairs/Adjustments
3. If a new tray 3 and tray 4 transport roll is installed, reset the Tray 3 / 4 trans count to zero
in the HFSI feature screen. Refer to GP 17 High Frequency service Items.
REP 8.32 Duplex Sensor
Removal
WARNING
WARNING
NOTE: The duct on the duplex transport is only on the 65 - 75 ppm machine.
2. Remove the duplex sensor, Figure 1.
Figure 1 Duplex sensor
1
2
Press the lugs to release the
sensor
3
Remove the sensor
July 2005
Repairs/Adjustments
Replacement
If a new duplex sensor is installed, reset the Duplex sensor count to zero in the HFSI feature
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments

REP 9.1 Waste Toner Bottle Assembly
Removal
WARNING
cause death or injury.
WARNING
2. Remove the waste toner bottle and the waste toner door, Figure 1.
Figure 1 Waste toner door
Replacement
1
Open the waste toner door
2
Screw the cap onto the bottle
4
Press the ends of the strap together to
release the waste toner door
5
Depress the retaining clip on the
hinge block. Remove the waste
toner door
3
Remove the waste toner
bottle
July 2005
Repairs/Adjustments
REP 9.2 Developer Assembly
Removal
WARNING
WARNING
2. Disconnect PJ93 and the developer bias lead, Figure 1.
Figure 1 Developer bias leads
3. Remove the developer module, Figure 2.
Figure 2 Remove the developer assembly
Replacement
When replacing the original developer, perform step 2.
When installing new developer module, perform the following:
1. Follow the developer spares pack instruction sheet to prepare the developer module.
2. Lubricate the developer module support pins, ADJ 4.1.
3. Enter diagnostics, GP 1. Select dC131 location 09-271 developer age and reset to zero.
4. Perform the dC905 TC Sensor Calibration.
5. Perform ADJ 9.2 Image Quality Adjustment Routine.
6. (65-75 ppm only). Perform ADJ 9.3 Developer Magnetic Seal Brush Adjustment.
7. If a new developer assembly is installed, reset the Developer count to zero in the HFSI
1
Disconnect PJ93
2
Disconnect developer bias
lead
1
Turn the latch
2
Remove the xerographic module and
place in a black bag
3
Remove two screws and remove
the developer module
July 2005
Repairs/Adjustments
REP 9.3 Ozone Fan
Removal
WARNING
WARNING
2. Remove the waste toner bottle, REP 9.1.
3. Remove ozone filter and duct, PL 9.25 Item 2.
CAUTION
When the drive gear is removed, the drive pin may drop onto the IOT PWB or LVPS.
4. Remove the ozone fan, Figure 1.
Figure 1 Remove the ozone fan
Replacement
screws.
NOTE: Turn the drive shaft so that the dowel pin is horizontal then locate the drive gear onto
the shaft.
1
Remove three short
screws and the fly
wheel
2
Remove the collar
3
Remove the drive
gear
4
Remove 3 screws
5
Disconnect PJ 53 on the
photoreceptor motor
PWB and remove the fan
July 2005
Repairs/Adjustments
REP 9.4 Waste Toner Full Sensor
Removal
WARNING
WARNING
2. Remove the waste toner bottle, PL 9.10 Item 1.
3. Remove the waste toner full sensor, Figure 1.
Figure 1 Waste toner full sensor
Replacement
2
Disconnect PJ 48
4
Remove the sensor from
the black plastic housing
1
Remove the screw
3
Remove cable-ties
July 2005
Repairs/Adjustments
REP 9.5 Toner Dispense Module
Removal
WARNING
WARNING
1. Remove the developer assembly, REP 9.2.
2. Remove the toner cartridge.
3. Disconnect the harness PJ97 and PJ75 on the toner dispense module, Figure 1.
Figure 1 Disconnect the harness
4. Remove the securing screws from the toner dispense module, Figure 2.
Figure 2 Remove the securing screws
5. Remove the toner dispense module by sliding it of the developer assembly, Figure 3.
1
Disconnect harness PJ97
2
Disconnect harness PJ75
1
Remove 2 screws
Support guides
Harness
July 2005
Repairs/Adjustments
Figure 3 Remove the toner dispense module
Replacement
1. Ensure that the harnesses are routed under the support guides on the toner dispense
module, Figure 2.
2. If a new low toner sensor (32-55 ppm) PL 9.17 Item 5, (65-75 ppm) PL 9.15 Item 5 was
also installed with a new toner dispense module then perform dC905 TC Sensor Calibra-
tion.
REP 9.6 Xerographic Module Latch
Parts List on 32-38 ppm) PL 9.22, (45-75 ppm) PL 9.20
Removal
WARNING
WARNING
1. Remove the scanner:
REP 14.1A scanner 32-55 ppm.
REP 14.1B scanner 65-75 ppm.
2. Remove the developer assembly, REP 9.2.
3. Refer to REP 6.1 and move the ROS to the side, Figure 1.
Figure 1 Position the ROS
4. Remove the pivot plate to release the developer paddle, Figure 2.
Slide the module
ROS
July 2005
Repairs/Adjustments
NOTE: Observe where the spring is located on the tie bar and on the developer paddle.
Figure 2 Remove the pivot plate
WARNING
Take care when removing the latch. The latch contains a compressed spring, which can
cause injury when released.
5. Remove the screw from the latch, Figure 3.
Figure 3 Remove the latch
Replacement
Apply Plastislip grease, PL 26.10 Item 8, to the internal diameter of the bush on the frame (i.e.
the hole the pin fits into) prior to insertion.
Check the following, Figure 4.
1. The latch pin is correctly lined up with the flats on the latch plate.
2. The latch handle and the latch pin are correctly lined up.
3. When reinstalling the developer paddle into the pivot plate, check that the spring is cor-
rectly located on the tie bar and on the feature on the developer paddle, Figure 2.
1
Support the developer
paddle
Spring
2
Remove the
screw
3
Remove the pivot
plate
1
Remove the screw
2
Remove the latch
July 2005
Repairs/Adjustments
Figure 4 Latch alignment
Latch pin
Latch pin
Latch plate
Latch handle
July 2005
Repairs/Adjustments
REP 9.7 Developer Paddle
Removal
WARNING
WARNING
1. Remove the xerographic module latch, REP 9.6.
2. Remove the developer paddle, Figure 1.
Figure 1 Developer paddle
Replacement
1
Remove spring
2
Move the developer paddle
3
Release and remove
the developer paddle
July 2005
Repairs/Adjustments
REP 9.8 Transfer / Detack Harness
Removal
WARNING
WARNING
2. Remove the Transfer / Detack harness, Figure 1.
Figure 1 Transfer / detack harness
Replacement
1
Insert a screwdriver to flex the
frame
Tab on the harness terminal block
2
Push down on the harness
terminal block to release the
tab
July 2005
Repairs/Adjustments
REP 9.9 Erase Lamp
Removal
WARNING
WARNING
3. Remove the erase lamp support, Figure 1.
Figure 1 Erase lamp support
4. Remove the erase lamp, Figure 2.
Figure 2 Remove the erase lamp
Replacement
Check that the location posts on the erase lamp (Figure 2), location in the holes in the frame,
Figure 3.
1
Remove the screw
2
Pull out the erase
lamp support
1
Lift the tab at the end of the erase lamp
2
Slide the erase lamp out of
the support
Rear location posts
Front posts
July 2005
Repairs/Adjustments
Figure 3 Location holes
Erase lamp connector
Location holes
July 2005
Repairs/Adjustments
REP 9.10 Auger Damper
Removal
WARNING
WARNING
1. Cam off the developer module.
3. Remove the waste toner from the auger system at the front of the machine, Figure 1.
Figure 1 Auger system at the front
4. Remove the waste toner bottle assembly, REP 9.1.
5. Remove the waste toner from the shutter auger tube at the rear of the machine, Figure 2.
Figure 2 Shutter and waste toner auger
6. Remove the ozone filter and the duct, PL 9.25 Item 2.
7. Remove the waste toner full sensor up to step 3, REP 9.4.
8. Remove the shutter assembly and the support bracket, Figure 3.
1
Vacuum out the
auger system
Place the vacuum cleaner hose over the waste toner tube
and push the shutter to the open position.
July 2005
Repairs/Adjustments
Figure 3 Remove shutter assembly
9. Remove the auger damper, Figure 4.
Figure 4 Remove the auger damper
Replacement
1. Install the new auger damper, Figure 5.
1
Remove 4 screws
2
Disconnect PJ97
3
Remove the shut-
ter assembly and
bracket
Pull out the auger damper
July 2005
Repairs/Adjustments
NOTE: The auger damper is slightly longer than the auger spring.
Figure 5 Installing the insert
2. Ensure that the shutter assembly is positioned correctly on the support bracket.
3. Support the auger tube when locating the shutter assembly, and bracket onto the auger
tube, Figure 6.
Figure 6 Shutter and bracket position
1
Push and twist the auger damper until it
stops at the end of the auger tube.
1
Support the auger tube
2
Ensure that the shutter is
positioned correctly on the
bracket
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments

REP 10.1 Short Paper Path Assembly
Removal
WARNING
WARNING
1. Remove the fuser assembly, (32-55 ppm) PL 10.8 Item 1, (65-75 ppm) PL 10.10 Item 1.
3. Remove the xerographic module and place in a black bag, (32-38 ppm) PL 9.22 Item 2,
(45-75 ppm) PL 9.20 Item 2.
4. Remove the transfer / detack corotron, (32-38 ppm) PL 9.22 Item 8, (45-75 ppm) PL 9.20
Item 8.
5. Prepare the power and control module, Figure 1.
Figure 1 Prepare the power and control module
6. Remove the short paper path assembly, Figure 2.
Figure 2 Remove short paper path assembly
1
Remove securing
screw
2
Disconnect transfer
and detack lead
3
Move the module
to the rear
1
Remove screw
and ground lead
3
Disconnect vacuum
transport fan
2
Remove screw
4
Pass the HT leads
through the hole
July 2005
Repairs/Adjustments
Replacement
screws.
CAUTION
To ensure the transport hinge is located correctly, install the left hand screw first with the
ground lead then the right hand screw.
1. Check that the detack wire with the spiral wrap is routed correctly on the transport hinge,
Figure 3.
Figure 3 Spiral wrap location
2. Position the ground wire terminal in the left hand screw location on the hinge bracket and
position the spiral wrap on the detack wire, Figure 4.
3. When locating the hinge bracket to the frame make sure that the hinge is pushed fully
against the frame.
4. To ensure the transport hinge is located correctly, install the left hand screw first with the
ground wire then the right hand screw.
NOTE: Ensure that both ends of the ground lead are connected to the correct terminals.
Figure 4 Ground wire and spiral wrap
5. After completing the replacement procedure, check that the short paper path assembly
latches without excessive force.
Raise and lower the latch mechanism of the short paper path assembly, PL 10.20 Item 1,
to ensure that the transfer / detack corotron is parallel to the photoreceptor. If the move-
ment of raising the short paper path assembly is not smooth, check the action of the push
rod, PL 10.20 Item 13. Refer to REP 10.15 Step 5 for the removal of the push rod. Check
for burrs and rough edges on the push rod and the associated mechanism it operates.
Detack wire with spiral wrap
Transfer wire
Position of the ground wire
tag
Position of the spiral wrap
July 2005
Repairs/Adjustments
REP 10.2 Inverter Assembly
Removal
WARNING
WARNING
1. Remove the fuser assembly, (32-55 ppm) PL 10.8 Item 1, (65-75 ppm) PL 10.10 Item 1.
3. Remove the output device and the right hand cover, PL 8.10 Item 9.
5. Remove the inverter support, Figure 1.
Figure 1 Inverter support
6. Remove the tie bar. Figure 2.
Figure 2 Tie bar
1
Remove 2 screws
2
Rotate the inverter
support clockwise
to align both cut-
outs and remove
1
Remove 4 screws
marked A
2
Disconnect the harness on
inverter motor driver PWB
4
Disconnect
harness
3
Remove the tie bar
July 2005
Repairs/Adjustments
7. Lift the inverter frame and move to the front, Figure 3.
Figure 3 Move frame to the front
8. Remove the inverter assembly through the right hand side of the machine, Figure 4.
Figure 4 Remove Inverter assembly
1
Lift the frame out of the
base
2
Move the inverter assembly
1
Ensure the idler shafts at the rear
are clear, before turning the inverter
2
Remove the inverter
assembly
July 2005
Repairs/Adjustments
Replacement
Before installing the inverter assembly check the following:.
1. Check that the inverter motor harness is routed correctly. Make sure that the harness
does not get trapped between the inverter frame and the base, Figure 2.
2. That the solenoid harness connector is located at the rear of the inverter frame, Figure 5
Figure 5 Solenoid harness connector
3. That the nip roll guide is correctly located in the cut out at the front and rear of the inverter
frame, Figure 6.
Figure 6 Nip roll guide
4. Make sure that the two upper baffles are linked correctly. When the latch 3d4d is
released, the two baffles lift together.
screws.
NOTE: When the idler shafts are located, Figure 4. Rotate knob 3C clockwise to engage
the drives coupling between the inverter and the drives plate. This will also allow the
inverter to locate into the base of the machine, Figure 3.
6. If a new inverter assembly is installed, reset the Post Fuser count to zero in the HFSI fea-
ture screen. Refer to GP 17 High Frequency service Items.
Solenoid harness
connector
Nip roll guide located on
the inverter frame
July 2005
Repairs/Adjustments
REP 10.3 Inverter Motor
Removal
WARNING
WARNING
1. Remove the inverter assembly, REP 10.2.
2. Remove the inverter motor, Figure 1.
Figure 1 Inverter motor
Replacement
1
Remove 2 screws
2
Remove the inverter
motor
July 2005
Repairs/Adjustments
REP 10.4 Inverter Path Solenoid
Removal
WARNING
WARNING
2. Remove the diverter solenoid, Figure 1.
Figure 1 Inverter path solenoid
Replacement
screws.
1. Check that the solenoid harness connector is located at the rear of the inverter frame as
in Figure 1.
5
Remove 2 screws
1
Lift the upper baffle to vertical position
2
Remove 2 E-clips
4
Disconnect solenoid
harness
6
Remove the solenoid
3
Remove the shaft
and the baffle
July 2005
Repairs/Adjustments
REP 10.5 Inverter Nip Solenoid
Removal
WARNING
WARNING
2. Remove the inverter nip solenoid, Figure 1.
Figure 1 Inverter nip solenoid
Replacement
screws.
3
Remove the solenoid
2
Remove 2 screws
1
July 2005
Repairs/Adjustments
REP 10.6 Nip Roll Guide
Purpose
This procedure is used to repair the following:
Single exit nip roll, PL 10.11 Item 7 (65-75 ppm), PL 10.13 Item 7 (32-55 ppm).
Double exit nip rollPL 10.11 Item 8 (65-75 ppm), PL 10.13 Item 8 (32-55 ppm).
Nip roll guide, PL 10.11 Item 10 (65-75 ppm), PL 10.13 Item 10 (32-55 ppm).
Removal
WARNING
WARNING
3. Remove the tie bar, Figure 1.
Figure 1 Remove tie bar
1
Remove 4 screws
2
Disconnect harness from
3
Remove tie bar
July 2005
Repairs/Adjustments
4. Remove the nip roll guide, Figure 2.
Figure 2 Nip roll guide
5. Remove the following components from the nip roll guide as required:
IOT exit sensor.
Single exit nip roll.
Double exit nip roll.
Replacement
screws.
CAUTION
Check that the inverter path solenoid harness is not trapped between the nip roll guide and the
support bracket, Figure 3.
1. Ensure that the ground connection is secured by the nip roll guide front fixing screw.
Figure 3 Inverter path solenoid Harness
1
Remove screw
3
Disconnect the harness from the
exit sensor and from the nip roll
guide
4
Remove the nip roll
guide
2
Remove screw and move
the ground connection
clear
Harness
Nip roll guide
Support bracket
July 2005
Repairs/Adjustments
REP 10.7 Upper Baffle Assembly
Removal
WARNING
WARNING
2. Remove the upper baffle assembly, Figure 1.
Figure 1 Upper baffle assembly
Replacement
screws.
1. Check that the solenoid harness connector is located at the rear of the inverter frame,
refer to Figure 1.
1
Lift the upper baffle to vertical position
2
Remove 2 E-clips
3
Remove the shaft
and the baffle
Solenoid harness
connector
July 2005
Repairs/Adjustments
REP 10.8 Nip Split Shaft Assembly
Removal
WARNING
WARNING
Figure 1 Tie bar
4. Remove the nip split shaft assembly, Figure 2.
Figure 2 Nip split shaft assembly
1
Remove 4 screws
2
Disconnect harness on
inverter motor driver
PWB
3
Remove tie bar
1
Release both springs
2
Remove nip split
shaft assembly
July 2005
Repairs/Adjustments
Replacement
screws.
1. Check that both springs are positioned correctly, Figure 3.
Figure 3 Location of the spring
2. If a nip slit shaft assembly is installed, reset the nip split shaft count to zero in the HFSI
REP 10.9 Shaft Actuator
Removal
WARNING
WARNING
2. Remove the inverter nip solenoid, REP 10.5.
3. Remove the shaft actuator, Figure 1.
Figure 1 Shaft actuator
Spring position
1
Unclip both springs
2
Remove the shaft actuator
July 2005
Repairs/Adjustments
Replacement
screws.
NOTE: Check that both springs are positioned correctly, Figure 2.
Figure 2 Location of the spring
REP 10.10 Fuser Latch
Removal
WARNING
WARNING
2. Remove the scanner:
REP 14.1A Scanner (32-55 ppm)
REP 14.1B Scanner (65-75 ppm).
3. Refer to REP 6.1 and move the ROS to the side, Figure 1.
Figure 1 Move the ROS
Spring position
ROS
Fuser latch
July 2005
Repairs/Adjustments
WARNING
Take care when removing the latch. The latch contains a compressed spring, which can
cause injury when released.
4. Hold the fuser latch pin in position with a screw driver and remove the screw at the back
of the latch to release the fuser latch, latch pin and spring, Figure 2.
Figure 2 Remove the fuser latch
Replacement
screws.
NOTE: Ensure the latch stop is seated over the locator post on the machine frame, Figure 3.
Figure 3 Locate the latch stop
1
Remove screw
4
Remove latch and stop
3
Remove spring
2
Remove latch pin
Locator post
Screw
Fuser latch
Latch stop
Spring
Latch pin
July 2005
Repairs/Adjustments
REP 10.11 Inverter Gate
Removal
WARNING
WARNING
1. Remove the inverter path solenoid, REP 10.4.
2. Pull the pivot assembly latch (3a) forward.
3. Remove the tri-roll knob, Figure 1.
Figure 1 Tri-roll knob
CAUTION
Take care not break the inverter assembly bracket.
4. Carefully unlatch the inverter assembly bracket from the inverter assembly, Figure 2.
Figure 2 Inverter assembly support
release the clip on the tri-roll
knob
1
Remove
two
screws
2
Use a screw-
driver to
unlatch the clip
from the frame
July 2005
Repairs/Adjustments
5. Remove the inverter path solenoid link, Figure 3.
Figure 3 Inverter path solenoid link
6. Remove the inverter gate, Figure 4.
Figure 4 Inverter gate
Replacement
Re-install the remainder of the removed components. Replacement is the reverse of the
removal procedure. Refer to GP 6 before refitting the screws.
1
Use a screw driver
to remove the link
1
Rotate and then remove the inverter gate
July 2005
Repairs/Adjustments
REP 10.12 Tri-Roll Shaft Assembly
Removal
WARNING
WARNING
1. Remove the inverter gate, REP 10.11.
2. Remove the tri-roll bearing, Figure 1.
Figure 1 Tri-roll bearing
3. Remove the securing screw and tri-roll drive gear, Figure 2.
Figure 2 Tri-roll drive gear
1
Remove screw
2
Remove E-clip
3
Remove the
bearing
1
Remove the screw
2
Raise the tang to
remove the gear
July 2005
Repairs/Adjustments
4. Remove the tri-roll guide, Figure 3.
Figure 3 Tri-roll guide
5. Remove the tri-roll shaft, Figure 4.
NOTE: Note the orientation of the tri-roll shaft.
Figure 4 Tri-roll shaft
Replacement
1. Re-install the following components:
tri-roll shaft
tri-roll guide
tri-roll drive gear and securing screw
tri-roll bearing
inverter gate. Make sure that the inverter assembly support casing is installed cor-
rectly. Refer to the replacement procedure in REP 10.11.
screws.
2. If a new tri-roll shaft assembly is installed, reset the Post Fuser count to zero in the HFSI
1
Location stud
July 2005
Repairs/Adjustments
REP 10.13 Fuser Web Motor
Removal
WARNING
WARNING
1. Remove the main drive module, (32-55 ppm) REP 4.1A, (65-75 ppm) REP 4.2A.
2. Disconnect PJ 154 on the main drive PWB and remove the fuser web motor assembly,
(32-55 ppm) Figure 1, (65-75 ppm) Figure 2.
Figure 1 Drives module 32-55 ppm
Figure 2 Drives module 65-75 ppm
1
Remove 3 screws 2
Remove the fuser web
assembly
1
Remove 3 screws
2
Remove the fuser web assembly
July 2005
Repairs/Adjustments
3. Remove the fuser connector assembly from the fuser web motor assembly, Figure 3.
Figure 3 Fuser web motor assembly
Replacement
NOTE: There are two different configurations of fuser web motor, refer to the parts list. Both
types can be installed on all machine speed variations.
1
Remove 2 screws
2
Remove the fuser connector
assembly
July 2005
Repairs/Adjustments
REP 10.14 Exit Shaft Assembly
Removal
WARNING
WARNING
2. Remove the exit shaft assembly, (65-75 ppm) Figure 1, (32-55 ppm) Figure 2.
Figure 1 Exit shaft assembly 65-75 ppm
Figure 2 Exit shaft assembly 32-55 ppm
Replacement
1. Ensure that the bearings locate into the baffle guide and that the baffle guide is linked with
the upper baffle. This ensures that both baffles are lifted together when clearing a post
fuser jam.
1
bearing
2
Remove circlip, drive gear and
bearing
3
Remove the exit shaft
2
Remove circlip, drive gear and
bearing
3
Remove the exit shaft
1
Remove the circlip and bearing
July 2005
Repairs/Adjustments
REP 10.15 Intermediate Drive Belt
Removal
WARNING
WARNING
2. Release the transfer / detack corotron harness from the supports, Figure 1.
Figure 1 Transfer / detack corotron harness
3. Remove the securing screw to release the drives assembly, Figure 2.
1
Release the harness
1
Remove screw
Corotron carrier
Drives assembly
July 2005
Repairs/Adjustments
4. Remove the vacuum fan, Figure 3.
Figure 3 Remove vacuum fan
5. Remove the push rod, Figure 4.
Figure 4 Remove the push rod
1
Remove 2 screws
2
Remove the vacuum fan
1
Lift the drives
assembly up
2
Release the push rod
3
Remove the push rod
July 2005
Repairs/Adjustments
6. Remove the intermediate drive assembly, Figure 5.
Figure 5 Remove the drive assembly
7. Remove the intermediate drive belt, Figure 6.
Figure 6 Remove the drive belt
1
Lift the drive gear assembly
2
Move the drive gear assem-
bly to release the catch and
remove the assembly
1
Remove snap on washer
2
Remove drive belt
July 2005
Repairs/Adjustments
Replacement
Before installing the short paper path, check the following:
1. Ensure that the push rod is positioned behind the intermediate drive belt, Figure 7.
Figure 7 Push rod position
2. The transfer / detack HT leads are correctly positioned at the rear of the short paper path
assembly, Figure 1.
Push rod
Drive belt
July 2005
Repairs/Adjustments
REP 10.16 Fuser Exit Switch
Removal
WARNING
WARNING
WARNING
Do not touch the fuser while it is hot.
2. Remove the top cover from the fuser module, Figure 1.
Figure 1 Remove the top cover
3. Remove the upper paper guide assembly, Figure 2.
Figure 2 Remove the upper guide assembly
1
Remove 4 screws
2
Remove the top cover
2
Remove 2 screws
1
July 2005
Repairs/Adjustments
4. Release the harness and remove the fuser exit switch, Figure 3.
Figure 3 Remove the fuser exit switch
Replacement
screws.
1. On the 65-75 ppm machines. Make sure that the harness and the connector are routed
away from the spring, Figure 4.
Figure 4 Harness location 65-75 ppm
1
Remove the
screw
2
Release the harness
harness connector
Spring
Harness
July 2005
Repairs/Adjustments
REP 10.17 IOT Exit Sensor
Removal
WARNING
WARNING
1. Remove the output device.
Figure 1 Remove the tie bar
4. Release the nip roll guide, Figure 2.
Figure 2 Release the nip roll guide
1
Remove 4 screws
2
Disconnect the harness from the
3
Remove the tie bar
1
Remove two screws
2
Lift the guide to release
the nip roll guide
July 2005
Repairs/Adjustments
5. Remove the IOT exit sensor, Figure 3.
Figure 3 Remove the IOT sensor
Replacement
screws to the output guide.
CAUTION
Check that the inverter path solenoid harness is not caught between the nip roll guide and the
Figure 4 Inverter path solenoid harness
1
2
Press the lugs down to release
the IOT sensor
Inverter path solenoid harness
Nip roll guide
Support
bracket
July 2005
Repairs/Adjustments
REP 10.18 Inverter Output Guide Assembly
Removal
WARNING
WARNING
2. Release the nip roll guide, Figure 1.
Figure 1 Release nip roll guide
3. Remove the output guide, Figure 2.
Figure 2 Remove the output guide
2
Remove two screws
1
Disconnect the
harness
3
Lift the guide to release the nip
roll guide
2
Remove two screws
1
Remove two screws
3
Flex the side plates to release the
output guide
July 2005
Repairs/Adjustments
Replacement
screws.
CAUTION
Check that the inverter path solenoid harness is not caught between the nip roll guide and the
Figure 3 Inverter path solenoid harness
Nip roll guide
Support bracket
Inverter path solenoid
harness
July 2005
4-199 WorkCentre Pro 275 Family (CC232-WCP275F) REP 11.1-110
Repairs/Adjustments

REP 11.1-110 2K LCSS Covers
Parts List on PL 11.2.
Removal
WARNING
Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus-
tomer supply while performing tasks that do not need electricity. Electricity can cause
death or injury. Moving parts can cause injury.
WARNING
Remove the covers, Figure 1.
NOTE: Removing the top cover first will allow easy removal of the front and rear covers.
Figure 1 Removing the covers
Replacement
Reverse the removal procedure to replace the covers.
1
Open the exit cover,
remove two screws.
5
Remove two screws.
3
Open the front door,
remove four screws.
2
Remove the top
cover.
4
Remove the front door
cover assembly.
6
Remove the rear cover
assembly.
July 2005
Repairs/Adjustments
REP 11.2-110 Input Drive Belt and Paper Entry Transport
Motor
Removal
WARNING
WARNING
1. Remove the 2K LCSS rear cover, REP 11.1-110.
2. Remove the motor and drive belt, Figure 1.
Figure 1 Removing the drive belt
Replacement
1. Place the belt around the pulleys.
2. Install the motor screws, but do not tighten.
3. Install the spring
4. Rotate the shaft by hand to ensure the belt runs smoothly over the pulleys and allow the
spring to tension the belt.
5. Tighten the motor screws and re-connect the harness.
6. Install the 2K LCSS rear cover, REP 11.1-110.
2
Disconnect the
motor harness.
1
Remove
the
spring.
4
Remove
the drive
belt.
3
Remove 2 screws and motor
July 2005
Repairs/Adjustments
REP 11.3-110 Intermediate Paper Drive Belt
Removal
WARNING
WARNING
1. Remove the 2K LCSS rear cover REP 11.1-110.
2. Remove the intermediate paper drive belt, Figure 1.
Replacement
1. Lubricate the belt tensioner, refer to ADJ 4.1.
2. Install the belt tensioner, shoulder screw, washer and spring.
NOTE: The washer only fits over the threaded part of the shoulder screw.
3. Install the belt over the pulleys, ensuring that the belt is on all five pulleys.
2
Remove screw and move
the sensor bracket
assembly away.
3
Press down on the pulley
to loosen the belt tension.
4
Remove the drive belt.
1
Remove the spring,
shoulder screw and
washer.
July 2005
4-202 WorkCentre Pro 275 Family (CC232-WCP275F) REP 11.3-110, REP 11.4-110
Repairs/Adjustments
NOTE: Two of the pulleys are free to slide along the shaft. Ensure the belt is correctly
located on these pulleys.
4. Re-install the sensor bracket assembly and install the screw.
REP 11.4-110 Paper Output Drive Belt and Paper Transport
Exit Motor
Removal
WARNING
WARNING
2. Remove the intermediate drive belt, REP 11.3-110.
3. Remove the output drive belt and motor, Figure 1.
Replacement
1. Install the belt over the pulleys.
2. Install the motor pivot shouldered screw and fully tighten.
3. Install the two motor mounting bracket securing screws but do not tighten them.
4. Install the belt tensioner spring.
5. Rotate the belt by hand to allow the spring to tension the belt. Tighten the screws.
6. Install the intermediate drive belt, REP 11.3-110.
July 2005
Repairs/Adjustments
REP 11.5-110 Bin 1 Drive Belts
Removal
WARNING
WARNING
1. Remove the 2K LCSS front and rear covers, REP 11.1-110.
2. Remove the bin 1 drive belt (rear) Figure 1.
3
Support the motor
and remove three
screws.
4
Remove the
motor and
belt.
1
Disconnect the motor har-
ness from the main PWB.
2
Remove the
belt tensioner
spring.
July 2005
Repairs/Adjustments
NOTE: Keep all of the components removed as a set. The set of rear frame components
are different from the front frame set.
Figure 1 Bin 1 drive belt (rear)
3. Remove the bin 1 drive belt (front) Figure 2.
9
Remove 2 screws and
upper pulley.
2
Remove E-clip and bearing.
6
Remove 3 screws and
release the lower and middle
PWB standoffs, leaving the
PWB attached by only the top
standoff.
12
Remove 2 screws, lower
pulley and drive belt.
1
Disconnect PJ318.
3
Remove 3 screws, remove
bracket with motor.
4
Fully lower bin 1.
11
Remove screw and
remove the belt clamp.
5
Release the tensioner spring. 10
Disconnect PJ316 and release the belt
from behind the PWB and drive pulley.
7
Remove 2 screws
8
Move motor assembly to
the right
July 2005
Repairs/Adjustments
Figure 2 Bin 1 drive belt (front)
Replacement
NOTE: Ensure the correct set of components are used for each side of the 2K LCSS.
1. Reverse the removal procedure to replace the bin 1 drive belts.
NOTE: The bin 1 level can critically affect the overall stack registration. Refer to ADJ
11.1-110 if adjustment is necessary.
2. Install the front and rear covers REP 11.1-110.
1
If not already lowered, fully lower bin 1, refer
to figure 1.
2
Release the tensioner spring.
3
Remove two screws
and lower pulley.
5
Remove 2 screws, upper
pulley and drive belt.
4
Remove screw and
front belt clamp.
July 2005
Repairs/Adjustments
REP 11.6-110 Tamper Assembly
Removal
WARNING
WARNING
1. Remove the 2K LCSS covers REP 11.1-110.
2. Prepare to remove the tamper assembly Figure 1.
Figure 1 Preparing the tamper assembly
3. Figure 2, remove the tamper assembly.
Figure 2 Removing the tamper assembly
Replacement
Reverse the removal procedure to replace the tamper assembly.
1
Disconnect 3 sensor harnesses and
release the harnesses from the retainers.
3
Release the harness
from all retainers along
the tamper assembly.
2
Disconnect the tamper
motors harnesses.
4
Release the harness from the retainer
next to the paddle motor assembly, PL
11.8 Item 10
1
Remove 2 screws
2
Lift the tamper
assembly upwards
and remove from the
2K LCSS
July 2005
Repairs/Adjustments
NOTE: Ensure that the slots in the tamper assembly locate correctly in the 2K LCSS frame.
NOTE: Ensure the sensors are correctly located in the tamper assembly, they are easily mis-
located when being disconnected and re-connected to the harnesses.
NOTE: Ensure that all connectors in the harness over the tamper assembly are securely con-
nected.
REP 11.7-110 Hole Punch Unit, Motor and Sensors
Removal
WARNING
WARNING
1. Remove the 2K LCSS covers, REP 11.1-110.
2. Remove and empty the chad bin, PL 11.6 Item 4.
3. Remove the hole punch unit, motor assembly and sensors, Figure 1.
Replacement
1. Reverse the removal procedure to replace the hole punch unit, motor assembly and sen-
sors.
2. If necessary, perform ADJ 11.3-110 Hole Punch Position.
NOTE: When installing the hole punch motor assembly, ensure that the belt tensioner arm
does not get trapped behind the motor assembly plate.
NOTE: Refer to IQS 6 Copy / Print Defects for hole punch performance specifications.
July 2005
Repairs/Adjustments
Figure 1 Hole punch unit, motor and sensors
4
Remove screw securing the sensor bracket. Disconnect
the harnesses and remove the bracket assembly. Pinch
together the legs to remove the punch head home and
punch head present sensors.
3
Disconnect the
motor harness and
remove the hole
punch motor
assembly.
2
Remove two screws.
6
Remove screw and slide out the bracket.
5
Disconnect
the PJ.
7
Remove 2 screws,
remove sensors
and disconnect the
harnesses.
1
Remove the thumb
screw and slide out
the punch unit.
July 2005
Repairs/Adjustments
REP 11.8-110 Stapler Traverse Assembly
Removal
WARNING
WARNING
WARNING
Take care not to topple the 2K LCSS.
The 2K LCSS is unstable when un-docked from the machine.
Do not show the customer how to un-dock the 2K LCSS.
1. Un-dock the 2K LCSS, REP 11.13-110.
2. Remove the rear cover and front door cover assembly, REP 11.1-110.
3. Manually move the ejector, PL 11.18 fully to the right.
4. Figure 1, Disconnect the harness.
Figure 1 Harness disconnection
CAUTION
When removing and replacing the stapler traverse assembly, support the weight of the assem-
bly underneath the stapler and take care not to damage wiring.
5. Remove the stapler traverse assembly, Figure 2.
Figure 2 Removing the stapler traverse assembly
Replacement
1. Ensure the stapling traverse assembly is engaged on the front and rear locating dowels.
2. Reverse the removal procedure to replace the stapling unit.
1
Disconnect the
group of 5 connec-
tors.
NOTE. the entry
guide cover has been
omitted for clarity
2
Remove 2 screws.
SEE CAUTION
1
Remove
screw.
3
Remove the stapler
traverse assembly.
SEE CAUTION.
July 2005
Repairs/Adjustments
REP 11.9-110 Staple Head Unit
Removal
WARNING
WARNING
1. Remove the stapler traverse assembly, REP 11.8-110.
2. Place the stapler traverse unit upside-down
3. Remove the staple head unit from the stapling unit Figure 1.
Figure 1 Removing the staple head unit
Replacement
Reverse the removal procedure to replace the staple head unit.
3
Remove two screws and
remove the staple head unit.
1
Remove 2
screws, remove
stapler cover.
2
Disconnect the
harness
July 2005
Repairs/Adjustments
REP 11.10-110 Ejector Assembly Sensors
Removal
WARNING
WARNING
WARNING
1. Disconnect the two harnesses between the 2K LCSS and the machine.
2. Un-dock the 2K LCSS, REP 11.13-110 and move it away from the machine.
3. Ensure the stapling unit is at the home position.
4. If necessary, manually move the ejector to the left position.
5. Figure 1, remove the ejector assembly.
6. Remove the appropriate sensor by releasing the legs of the sensor and disconnecting the
harness.
Replacement
CAUTION
When installing the ejector assembly onto the 2K LCSS, ensure that the ejector fingers do not
damage the wiring to the staple head unit.
Reverse the removal procedure to replace the eject assembly or sensors.
Figure 1 Removing the ejector assembly
2
Remove 3 screws.
1
Disconnect 2 bulkhead
connectors.
3
Lower the ejector assembly,
disengage the dowels from the
mounting blocks and remove.
Ejector home
sensor Q11-320
Ejector out sensor
Q11-322
Ejector motor
encoder sensor.
Remove 2
screws and
cover to access
the sensor
July 2005
Repairs/Adjustments
REP 11.11-110 Bin 1 Level Sensors
Removal
WARNING
WARNING
1. Remove the ejector assembly, REP 11.10-110.
2. Remove the stacker level sensors Figure 1.
Figure 1 Removing the stacker level sensors
Replacement
Reverse the removal procedures to replace the bin 1 level sensors.
2
Disconnect 2 connectors.
1
Remove two screws
and harness retainers.
4
Release the sensors and
disconnect harnesses.
3
Remove 2
screws, remove
sensor support
assembly.
July 2005
Repairs/Adjustments
REP 11.12-110 Paddle Wheel Shaft Assembly
Removal
WARNING
WARNING
1. Remove the stapler traverse assembly, REP 11.8-110.
2. Remove the tamper assembly, REP 11.6-110.
3. Figure 1, remove the paddle motor assembly.
Figure 1 Paddle motor assembly
4. Figure 2, prepare the rear components.
1
Release harness
from retainer
2
Disconnect 2
harnesses
3
Remove 2
screws
4
Remove motor
assembly
July 2005
Repairs/Adjustments
Figure 2 Rear preparation
5. Figure 3, prepare the front components.
Figure 3 Front preparation
6. Ensure that the compiler ejector is in the home position (fully to the left).
7. Figure 4, remove the paddle wheel shaft assembly.
1
Remove E-clip
and flag
2
Remove gear
assembly
3
Remove E-clip
and bearing
4
Remove 3 screws
1
Remove E-clip
2
Release spring and remove
the switch actuator
3
Remove 2 screws
4
remove screw
5
and remove the switch
bracket
July 2005
Repairs/Adjustments
Figure 4 Paddle wheel shaft removal
Replacement
1. Install the paddle wheel shaft, ensure that the pin on the rear of the safety gate switch
cam, refer to Figure 3, locates in the safety gate. Install the front E-clip.
2. Install the output cover, refer to Figure 4, ensuring that the safety gate is aligned with the
slots in the output cover.
3. Install the rear bearing and E-clip.
4. Install the switch bracket, 1 screw, connect the harness, refer to Figure 3.
5. Install the gear assembly, refer to Figure 2, ensuring that it locates onto the large D flat.
6. Install the flag and E-clip, refer to Figure 2, ensuring that the flag locates on the small D
flat.
7. Figure 5, ensure the paddles and flag are correctly aligned, install the motor assembly,
refer to Figure 1.
Figure 5 Paddle alignment
8. Test the operation of the paddle roll, enter dC330, output code 11-025. When the code is
cancelled the paddles must stop with both rubber blades inside of the output cover. If nec-
essary, check that the gear assembly and flag are correctly located on the D flats.
1
Move the output
cover to the right
2
Slide shaft assembly
to the rear
3
Remove the
shaft assembly
1
Align paddles with the output cover
2
Ensure the
encoder flag is
within the sensor
July 2005
Repairs/Adjustments
REP 11.13-110 2K LCSS Undocking
Removal
WARNING
WARNING
WARNING
1. If necessary, disconnect the harnesses between the 2K LCSS and the machine.
2. Open the 2K LCSS front door.
3. Figure 1, release the 2K LCSS link bracket assembly.
Figure 1 2K LCSS link bracket assembly
Replacement
Line up the 2K LCSS latches to the machine apertures then push the two units firmly together
until they latch.
1
Press the latch block forward
to release both latches.
2
Roll the 2K LCSS away
from the machine.
July 2005
Repairs/Adjustments
REP 11.14-110 2K LCSS PWB
Parts List on PL 11.26 Item 1.
Removal
WARNING
WARNING
1. Remove the 2K LCSS rear cover assembly, REP 11.1-110.
2. Disconnect all harness connectors from the 2K LCSS PWB.
3. Remove the three screws and release the three standoffs securing the 2K LCSS PWB.
Replacement
NOTE: Before replacing the 2K LCSS rear cover assembly, perform 11F-110 2K LCSS PWB
DIP Switch Settings RAP.
Reverse the removal procedure to replace the 2K LCSS PWB.
July 2005
Repairs/Adjustments
REP 11.15-110 Entry Guide Cover
Parts List on PL 11.24 Item 5.
Removal
WARNING
WARNING
1. Remove the 2K LCSS front cover and 2K LCSS rear cover, REP 11.1-110.
2. Disconnect the harness to the entry sensor, PL 11.24 Item 3, at the rear frame.
3. Figure 1, remove the entry guide cover.
Replacement
Reverse the removal procedure to replace the entry guide cover.
Figure 1 Entry guide cover removal
1
Remove 2 screws
2
Remove 2 screws
3
Remove the cover
July 2005
Repairs/Adjustments
REP 11.16-110 Docking Latch Assembly
Removal
WARNING
WARNING
1. Remove the front and rear covers, REP 11.1-110.
2. Figure 1, prepare to remove the docking latch assembly.
Figure 1 Prepare to remove the latch.
3. Figure 2, remove the docking latch assembly.
Figure 2 Latch assembly removal.
Replacement
Reverse the removal procedure to replace the docking latch assembly.
CAUTION
Ensure that the front and rear harness are threaded through the flanged holes, refer to Figure
1 and Figure 2.
1
Disconnect P/J302
2
Remove 2 screws
Flanged hole
2
Disconnect
the switch
harness
1
Release the
harness
retainer
3
Remove 2
screws
Flanged
hole
4
Remove the latch assembly
July 2005
Repairs/Adjustments
REP 11.17-110 Ejector Belt
Removal
WARNING
WARNING
1. Remove the ejector assembly, refer to REP 11.10-110.
2. Figure 1, remove the ejector belt.
Figure 1 Remove the ejector belt
Replacement
The replacement is the reverse of the removal procedure. Ensure the ejector belt is correctly
engaged with the belt grip on the ejector assembly before the clip is reinstalled. Refer to Figure
1.
1
Remove the clip.
2
Remove the E-clip.
3
Remove the pulley
then the ejector belt.
Belt grip.
July 2005
Repairs/Adjustments

REP 11.1-120 1K LCSS Covers
Removal
WARNING
WARNING
Remove the covers, Figure 1.
NOTE: Removing the top cover first will allow easy removal of the front and rear covers.
Figure 1 Removing the covers
Replacement
Reverse the removal procedure to replace the covers.
1
Open the exit cover.
Remove two screws,
then the top cover.
2
Remove two screws,
then the rear cover.
3
Open the front door,
remove three screws.
4
Remove the front door
cover assembly.
July 2005
Repairs/Adjustments
REP 11.2-120 Input Drive Belt and Transport Motor 1
Removal
WARNING
WARNING
2. Remove transport motor 1 and the input drive belt, Figure 1.
Replacement
1. Place the belt around the pulleys.
NOTE: Ensure that the shoulder screw is installed in the correct position. Refer to Figure
1.
2. Install the motor screws, but do not tighten.
3. Install the spring.
4. Rotate the shaft by hand to ensure the belt runs smoothly over the pulleys and allow the
spring to tension the belt.
5. Tighten the motor screws and re-connect the harness.
1
Disconnect PJ17.
2
Remove the spring.
4
Remove the drive belt.
3
Remove 3 screws, then
transport motor 1.
Shoulder screw.
July 2005
Repairs/Adjustments
REP 11.3-120 1K LCSS Stability Foot
Removal
WARNING
1. Remove the 1K LCSS, REP 11.11-120.
2. Figure 1, remove the stability foot.
Figure 1 Removal
Replacement
Align the slots in the stability foot with the locating pins under the machine. Firmly push the sta-
bility foot into position.
REP 11.4-120 Paper Output Drive Belt and Transport Motor
2
Removal
WARNING
WARNING
1. Remove the 1K LCSS top cover and rear cover, REP 11.1-120.
2. Remove the intermediate drive belt, PL 11.118 Item 4.
3. Remove the paper output drive belt, Figure 1.
Figure 1 Removing the paper output drive belt
4. Remove transport motor 2, Figure 2.
1
Push down the rear locking
tab. Release the rear of the
stability foot.
2
Push down the front locking
tab. Remove the stability foot.
Locating pin
Locating pin
3
Remove the paper
output drive belt.
1
Loosen the screw.
2
Release the tension on
the paper output drive
belt. Re-tighten the
screw.
July 2005
Repairs/Adjustments
Figure 2 Removing transport motor 2
Replacement
NOTE: Rotate the paper output drive belt by hand to allow the spring to tension the belt.
Tighten the screw.
REP 11.5-120 Bin 1 Drive Belts
Removal
WARNING
WARNING
1. Enter dC330, code 11-032, bin 1 elevator motor down. Fully lower bin 1.
2. Open the 1K LCSS front door, PL 11.100 Item 4.
3. Switch off the machine.
4. Remove the 1K LCSS rear cover and front cover, REP 11.1-120.
NOTE: Keep all of the components removed as a set. The set of rear frame components
are different from the front frame set.
5. Prepare to remove the rear bin 1 drive belt, Figure 1.
2
Remove 2 screws.
3
Remove transport
motor 2.
1
Disconnect the
inline PJ.
July 2005
Repairs/Adjustments
6. Remove the rear bin 1 drive belt, Figure 2.
Figure 2 Bin 1 drive belt removal (rear)
7. Remove the bin 1 drive belt (front) Figure 3.
3
Remove the E-clip and
bearing.
2
Disconnect PJ6, PJ4, PJ1, PJ3 and
PJ12. Release the harnesses from
the 2 cable clamps.
4
Remove 3 screws
and 1 earth lead.
1
Release the tensioner spring.
5
Remove the bin 1
elevator motor and
bracket.
2
Remove 3 screws
marked A. Release 1
standoff.
3
Disconnect PJ.
1
Remove 2 screws then the lower pulley.
Standoff.
5
Remove 1 screw from the belt clamp.
Remove the belt.
4
Remove 2 screws then
the upper pulley.
July 2005
Repairs/Adjustments
Figure 3 Bin 1 drive belt (front)
Replacement
NOTE: Ensure the correct set of components are used for each side of the 1K LCSS.
1. Reverse the removal procedure to replace the bin 1 drive belts.
NOTE: Bin 1 level can critically affect the overall stack registration. Refer to ADJ 11.1-120
if adjustment is necessary.
REP 11.6-120 Tamper Assembly
Removal
WARNING
WARNING
1. Remove the 1K LCSS covers REP 11.1-120.
2. Prepare to remove the tamper assembly, Figure 1.
Figure 1 Preparing the tamper assembly
1
Release the tensioner
spring.
2
Remove two screws then
the lower pulley.
4
Remove screw and front
belt clamp. Remove the
belt.
3
Remove two screws
then the upper pul-
ley.
1
Disconnect 3 sensor harnesses
and release the harnesses from
the retainers.
3
Release the harness from all retainers
along the tamper assembly.
2
Disconnect the tamper
motors harnesses.
4
Release the harness from the
retainer next to the paddle
motor assembly, PL 11.104
Item 10.
July 2005
Repairs/Adjustments
Figure 2 Removing the tamper assembly
Replacement
Reverse the removal procedure to replace the tamper assembly.
NOTE: Ensure that the slots in the tamper assembly locate correctly in the 1K LCSS frame.
NOTE: Ensure the sensors are correctly located in the tamper assembly, they are easily mis-
located when being disconnected and re-connected to the harnesses.
NOTE: Ensure that all connectors in the harness over the tamper assembly are securely con-
nected.
REP 11.7-120 Stapler Assembly and SH1 Paper Sensor
Removal
WARNING
WARNING
1. Remove the 1K LCSS covers, REP 11.1-120.
2. Manually move the ejector, PL 11.114 fully to the right (out position).
3. Prepare to remove the staple head unit and mounting bracket, Figure 1.
CAUTION
When removing and replacing the stapler assembly, support the weight of the assembly under-
neath the stapler and take care not to damage wiring.
4. Remove the stapler assembly, Figure 2.
1
Remove 2 screws
2
Lift the tamper assembly upwards and
remove from the 1K LCSS.
2
Disconnect the bulk-
head connector.
1
Remove 2 screws.
July 2005
Repairs/Adjustments
Figure 2 Removal
CAUTION
When removing the SH1 paper sensor, do not damage the actuator for the SH1 cartridge sen-
sor, Figure 3.
5. Remove the SH1 paper sensor, Figure 3.
Figure 3 SH1 paper sensor removal
Replacement
Reverse the removal procedure to replace the staple head unit.
1
Remove 2 screws.
2
Remove the stapler assembly.
See CAUTION.
1
Disconnect the PJ.
2
Remove 3 screws.
SH1 cartridge
sensor actuator
3
Remove the SH1
paper sensor.
July 2005
Repairs/Adjustments
REP 11.8-120 Ejector Assembly and Sensors
Removal
WARNING
WARNING
1. If necessary, manually move the ejector to the right (out position).
2. Remove the docking latch, REP 11.14-120.
NOTE: Do not disconnect the docking interlock switch.
3. Figure 1, remove the ejector assembly.
Figure 1 Removing the ejector assembly
2
Remove 3 screws.
1
Disconnect 2 bulkhead
connectors.
3
Lower the ejector assembly,
disengage the dowels from the
mounting blocks and remove.
Ejector home
sensor Q11-320
Ejector out sensor
Q11-322
Ejector motor encoder sensor.
4
Remove 2 screws and
cover to access the sensor.
July 2005
Repairs/Adjustments
4. Remove the appropriate sensor by releasing the legs of the sensor and disconnecting the
harness.
Replacement
CAUTION
When installing the ejector assembly onto the 1K LCSS, ensure that the ejector fingers do not
damage the wiring to the staple head unit.
Reverse the removal procedure to replace the eject assembly or sensors.
REP 11.9-120 Bin 1 Upper Level Sensor
Removal
WARNING
WARNING
1. Remove the ejector assembly, REP 11.8-120.
2. Remove the bin 1 upper level sensor, Figure 1.
Figure 1 Removing the stacker level sensors
Replacement
Reverse the removal procedures to replace the bin 1 upper level sensor.
2
Remove two screws, then the
sensor support.
1
Disconnect the harness.
3
Unclip the sensor.
July 2005
Repairs/Adjustments
REP 11.10-120 Paddle Wheel Shaft Assembly
Removal
WARNING
WARNING
1. Remove the tamper assembly, REP 11.6-120.
2. Figure 1, remove the paddle motor assembly.
Figure 1 Paddle motor assembly
3. Figure 2, prepare the rear components.
2
Disconnect PJ.
3
Remove 2
screws
4
Remove motor
assembly.
1
Disconnect PJ14.
July 2005
Repairs/Adjustments
4. Figure 3, prepare the front components.
Figure 3 Front preparation
5. Ensure that the compiler ejector is fully to the left (home position).
6. Figure 4, remove the paddle wheel shaft assembly.
1
Remove E-clip and
flag.
2
Remove E-clip and bearing
3
Remove 3 screws
marked A.
1
Remove E-clip and bearing.
2
Remove 3 screws
marked A.
July 2005
Repairs/Adjustments
Figure 4 Paddle wheel shaft removal
Replacement
1. The replacement is the reverse of the removal procedure. Ensure the paddles and flag
are correctly aligned, refer to Figure 5.
Figure 5 Paddle alignment
2. Test the operation of the paddle roll, enter dC330, output code 11-025. When the code is
cancelled the paddles must stop with both rubber blades inside of the output cover. If nec-
essary, check that the gear assembly and flag are correctly located on the D flats.
1
Remove the output
cover.
2
Remove the shaft assembly.
1
Align paddles with the output cover.
2
Ensure the encoder flag is within the sensor.
July 2005
Repairs/Adjustments
REP 11.11-120 1K LCSS Removal
Removal
WARNING
WARNING
WARNING
Take care not to topple the LCSS. The LCSS is unstable when undocked from the
machine. Do not show the customer how to undock the LCSS.
WARNING
Use safe handling procedures when removing the module, GP 16. The module is heavy.
NOTE: The 1K LCSS weight is 21Kg (46lb).
1. Disconnect the harnesses between the 1K LCSS and the machine.
2. Remove the 1K LCSS bin 1, PL 11.100 Item 10.
3. Remove the 1K LCSS top cover, refer to REP 11.1-120.
4. Open the 1K LCSS front door.
5. Figure 1, prepare to remove the 1K LCSS.
Figure 1 1K LCSS link bracket assembly
6. Close the 1K LCSS front door.
1
Remove 2 thumb-
screws from under-
neath the 1K LCSS.
2
Pull the latch block forward to
release both latches.
July 2005
Repairs/Adjustments
7. Figure 2, remove the 1K LCSS.
Figure 2 1K LCSS removal
Replacement
The replacement is the reverse of the removal procedure. Ensure that the bottom bracket on
the 1K LCSS is located over the support pins. Line up the 1K LCSS latches to the machine
apertures then push the two units firmly together until they latch.
REP 11.12-120 1K LCSS PWB
Removal
WARNING
WARNING
2. Disconnect all harness connectors from the 1K LCSS PWB.
3. Remove the three screws and release the three standoffs securing the 1K LCSS PWB.
Replacement
Reverse the removal procedure to replace the 1K LCSS PWB. Before replacing the 1K LCSS
rear cover, perform the 11F-120 1K LCSS PWB DIP Switch Settings RAP.
1
Slide the 1K LCSS away from the
machine to disengage the latches and
bottom bracket.
2
Use the lifting handles to
remove the 1K LCSS from
the mounting bracket.
Docking latch (front
and rear)
Bottom bracket
Support pins (front and
rear)
July 2005
Repairs/Adjustments
REP 11.13-120 Entry Guide Cover
Removal
WARNING
WARNING
2. Remove the 1K LCSS front cover and rear cover, REP 11.1-120.
3. Figure 1, remove the entry guide cover.
Figure 1 Entry guide cover removal
Replacement
Reverse the removal procedure to replace the entry guide cover.
2
Remove 2 screws
3
Remove 2 screws
4
Remove the cover
1
Disconnect the
bulkhead connector
July 2005
Repairs/Adjustments
REP 11.14-120 Docking Latch Assembly and Docking
Interlock Switch
Removal
WARNING
WARNING
2. Figure 1, prepare to remove the docking latch assembly.
3. Figure 2, remove the docking latch assembly.
Figure 2 Latch assembly removal
4. Remove the sensor cover, PL 11.102 Item 1.
5. Release the docking interlock switch from the sensor cover.
Replacement
Reverse the removal procedure to replace the docking latch assembly.
CAUTION
Ensure that the harness is put through the flanged hole, refer to Figure 1.
1
Disconnect PJ6.
2
Release 2 harness retainers.
3
Pull the harness
through the flanged
hole.
4
Remove 2 screws
1
Release the harness
retainer
2
Remove 2 screws
3
Remove the latch
assembly
July 2005
Repairs/Adjustments
REP 11.15-120 Ejector Belt
Removal
WARNING
WARNING
1. Remove the ejector assembly, refer to REP 11.8-120.
2. Figure 1, remove the ejector belt.
Figure 1 Remove the ejector belt
Replacement
The replacement is the reverse of the removal procedure. Ensure the ejector belt is correctly
engaged with the belt grip on the ejector assembly before the clip is reinstalled. Refer to Figure
1.
1
Remove the clip.
2
Remove the E-clip.
3
Remove the pulley
then the ejector belt.
Belt grip.
.
July 2005
Repairs/Adjustments

REP 11.1-130 HCSS Covers
Removal
WARNING
customer supply, while performing tasks that do not need electricity. Electricity can
WARNING
NOTE: All major HCSS covers are dealt with in this procedure, only remove the covers listed in
the procedure that you are performing.
Figure 1, remove the top cover.
Figure 1 Top cover removal
Figure 2, remove the rear cover.
Figure 2 Rear cover removal
To remove the front door, remove the lower hinge pin and slide the door from the upper
pivot pin, refer to PL 11.30.
To remove the front cover, remove 6 screws, refer to PL 11.30.
To remove the hole punch access cover, remove 2 thumb screws, refer to PL 11.30.
To remove the upper left cover, remove two screws, refer to PL 11.30.
3
Disconnect PJ493
and PJ439
4
Remove the top cover.
2
Remove 2 screws
1
Pivot the top tray.
Remove 2 screws
2
Remove 4 screws
4
Remove the rear
cover
1
Remove the harness from
the retainer.
3
Remove one screw
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to install the HCSS covers.
NOTE: If the compiler carriage is in the fully raised position, the safety gate on the top cover
will need to be raised by hand when top cover is installed.
REP 11.2-130 Compiler Carriage Assembly
Removal
WARNING
WARNING
CAUTION
Do not remove the compiler carriage elevator motor worm wheel to move the compiler carriage
1. Cheat the front door interlock. Enter dC330 code 11-015, compiler carriage motor step
down and code 11-013, compiler carriage motor step up to move the compiler carriage to
the service position, Figure 1. If necessary, select stop to halt the compiler carriage in the
service position. Remove the interlock cheater and switch off the machine, GP 14.
Figure 1 Service position
2. Remove the HCSS top cover, rear cover, front door and front cover, REP 11.1-130.
3. Remove bin 0, PL 11.60 Item 15.
Jam clearance knob must align with lower screw
July 2005
Repairs/Adjustments
4. Remove bin 1, REP 11.5-130.
5. Figure 2, disconnect the harnesses.
Figure 2 Disconnect the carriage PWB
6. Move the stapler assembly inboard by about 75 mm (3 inches).
7. Figure 3, release the mylar guide.
Figure 3 Mylar guide release
8. Remove the compiler carriage support springs from the base of the HCSS. Figure 4,
install the compiler carriage supports.
2
Disconnect PJ401, PJ412, PJ411
and PJ410 from the carriage PWB
3
Disconnect the earth wire
1
Release the harnesses between the
HCSS PWB and carriage PWB from
the bridge
1
Release the tension of the mylar guide
2
Move the metal end of
the mylar guide
towards the front and
unhook from the hole
in the compiler car-
riage frame
3
Carefully allow the mylar
guide to be rolled upwards
by the spring
July 2005
Repairs/Adjustments
Figure 4 Compiler carriage supports
9. Figure 5, remove the clamp.
Figure 5 Clamp removal
10. Figure 6, release the compiler carriage assembly from the frame.
1
Hook top of the compiler
carriage supports into the
screw holes
2
Hook the bottom of the
compiler carriage sup-
ports under the black
plastic cross member
Remove screw and clamp
July 2005
Repairs/Adjustments
Figure 6 Releasing the carriage assembly
3
Push the carriage assembly towards the
front until the rear belt grip clears the rear
frame
1
rear until the front belt grip clears the front
frame
2
Pull the compiler carriage outside the
frame
4
Pull the compiler carriage outside
the frame
July 2005
Repairs/Adjustments
WARNING
Use safe handling procedures, GP 16 when removing the module. The module is heavy.
NOTE: The carriage assembly weighs approximately 5.5Kg (12lb).
CAUTION
Do not damage the compiler sensor, when removing the compiler carriage assembly.
11. Figure 7, remove the compiler carriage assembly.
Figure 7 Removing the compiler carriage assembly
3
Support the carriage assembly with one
hand and release the compiler carriage sup-
ports
4
Turn the assembly in an
anti-clockwise direction
and remove through the
frame
1
Pull the belt out of
the front belt grip
2
Pull the belt out of the
rear belt grip
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the compiler carriage assembly, referring to the fol-
lowing list:
1. Use the compiler carriage supports to support the compiler carriage during the replace-
ment.
2. Ensure that the compiler is aligned as shown in Figure 8.
Figure 8 Carriage alignment
3. If necessary the elevator belt tensioner springs can be repositioned, refer to REP 11.8-
130.
4. Remove the compiler carriage supports.
5. Figure 9, ensure the mylar guide is correctly located.
Top of both grips must align with
marks on the frame
Belt tensioner
springs must be 50
+/- 10 mm (2 +/- 0.5
inches) below the
bottom of the belt
grips
July 2005
Repairs/Adjustments
Figure 9 Mylar guide position
Incorrect
Mylar guide is outboard
of the compiler carriage
frame top
Incorrect
Mylar guide is inboard
frame top
Correct
Mylar guide is flush
with the compiler
carriage frame top
July 2005
Repairs/Adjustments
REP 11.3-130 Staple Head Unit 1 Assembly and SH1 Paper
Sensor
Removal
WARNING
1. Open the HCSS front door and cheat the front door interlock. Enter dC330 code 11-016 to
move the compiler carriage to the lowest position.
WARNING
2. Remove the top cover, REP 11.1-130.
Figure 1 Mylar guide
6. Figure 2, release the compiler input guide.
1
2
Move the metal end of
the mylar guide
towards the front and
unhook from the hole in
the compiler carriage
frame
3
Carefully allow the mylar
guide to be rolled upwards
4
Lay the mylar guide over the
input guide
July 2005
Repairs/Adjustments
Figure 2 Compiler input guide
7. Remove the staple head cover (one screw), PL 11.46 Item 12.
8. Disconnect the stapler harness from the compiler PWB at PJ414 and the ground connec-
tor, cut the tie wrap.
9. Figure 3, remove the compiler staple head assembly.
Figure 3 Staple head removal
10. Figure 4, remove the SH1 paper sensor.
1
Unhook spring
2
Remove 2
screws
3
Push guide to
the right
1
Remove
two
screws
2
Remove the
staple head
July 2005
Repairs/Adjustments
Figure 4 Sensor removal
11. Disconnect the harness from the staple head.
Replacement
Reverse the removal procedure to replace the staple head assembly.
1
Disconnect the
sensor harness
2
Press in both lugs
at one end and lift
the sensor at that
end
3
Press in both lugs at
the other end and lift
the sensor to remove
July 2005
Repairs/Adjustments
REP 11.4-130 Carriage PWB
Removal
WARNING
WARNING
1. Remove the HCSS top cover and rear cover, REP 11.1-130.
2. Figure 1, remove the harness cover and support.
Figure 1 Harness cover and support
3. Figure 2, remove the carriage PWB.
1
Un-clip the harness cover by
releasing the two latches
2
Cut two tie wraps, discon-
nect the harnesses and
release from the support
3
Remove screw and release
the support from the top
mounting
July 2005
Repairs/Adjustments
Figure 2 Carriage PWB removal
Replacement
Reverse the removal procedures to replace the carriage PWB. Ensure the harness cover
removed in Figure 1, is correctly installed so that it does not interfere with jam clearance latch
5d.
CAUTION
Figure 3. When securing the harness to the support, ensure that the harness cannot be dam-
aged when the compiler carriage moves between the upper and lower limits.
Figure 3 Harness position
1
Disconnect all con-
nectors on the PWB
2
Remove screw
3
Lift PWB from retainers
Harness must
clear this plate
Harness must
clear this support
July 2005
Repairs/Adjustments
REP 11.5-130 Bin 1 or Bin 2 Assembly
Removal
WARNING
NOTE: This procedure illustrates the procedure for the bin 1 assembly. The procedure for bin 2
is similar. The Bin 1 assembly must be removed before the bin 2 assembly.
WARNING
1. Remove the HCSS top cover, rear cover, front door and front cover, REP 11.1-130.
2. Release the harness to the appropriate bin from the harness support next to the HCSS
PWB.
3. Disconnect PJ416 and PJ424.
4. Figure 1, remove the bin assembly.
Replacement
Reverse the removal procedures to replace the bin 1 assembly.
Figure 1 Bin 1 assembly removal
1
Remove screw
3
Lift and remove the bin
assembly
2
Remove screw
July 2005
Repairs/Adjustments
REP 11.6-130 Compiler Carriage Elevator Motor, Bracket
and Bearing
Removal
WARNING
WARNING
1. Cheat the front door interlock. Enter dC330 code 11-015, compiler carriage motor step
down and code 11-013, compiler carriage motor step up, to move the compiler carriage to
the service position, Figure 1.
2. Remove the HCSS top cover and rear cover, REP 11.1-130.
3. Figure 2, install the compiler carriage supports.
Jam clearance knob must
align with lower screw
July 2005
Repairs/Adjustments
NOTE: The motor worm and wheel are greased, wear disposable gloves, PL 26.10 Item 10
during this step to avoid grease contamination.
4. Rotate the compiler carriage elevator motor worm by hand to release the tension on the
elevator belts
5. Remove the rear elevator belt tensioner spring, REP 11.8-130.
6. Figure 3, remove the compiler carriage elevator motor.
Figure 3 Motor and bracket removal
7. Figure 4, remove the motor from the bracket.
1
Hook the top of the compiler
screw holes
2
Hook the bottom of the com-
piler carriage supports
under the black plastic cross
member
NOTE: Bin 0 and bin
1 have been omitted
for clarity
1
Remove E-clip
2
Remove worm wheel
and E-clip behind the
worm wheel
3
5
Remove the motor
assembly and bearing
4
Remove 3 screws
NOTE: Bin 1 has
been omitted for clar-
ity
July 2005
Repairs/Adjustments
Figure 4 motor removal
Replacement
1. Reverse the removal procedure to replace the compiler carriage elevator motor and
bracket.
2. Install the rear elevator belt tensioning spring, REP 11.8-130.
REP 11.7-130 Compiler Carriage Elevator Belts
Removal
WARNING
WARNING
1. Figure 1, cheat the HCSS front door interlock. Enter dC330 code 11-015, compiler car-
riage motor step down and 11-013, compiler carriage motor step up, to move the compiler
carriage to the service position.
2. Remove the HCSS top cover, rear cover, front cover and front door, REP 11.1-130.
5. Figure 2, install the compiler carriage supports.
1
2
Remove 2 screws
3
Remove motor
Jam clearance knob must align with lower screw
July 2005
Repairs/Adjustments
6. Figure 3, remove the locking block.
Figure 3 Locking block removal
7. Figure 4, release the compiler carriage assembly from the frame.
1
Hook the top of the compiler
screw holes
2
Hook the bottom of the com-
piler carriage supports under
the black plastic cross mem-
ber
locking block
July 2005
Repairs/Adjustments
8. Figure 5, release the elevator belts from the carriage belt grips.
1
rear until the front belt grip clears the
front frame.
2
Pull the compiler carriage outside
the frame.
3
front until the rear belt grip clears the
rear frame.
4
frame.
July 2005
Repairs/Adjustments
Figure 5 Release the belts from the carriage
9. Remove the compiler carriage elevator motor, REP 11.6-130.
10. Figure 6, release the rear belts from the top pulley.
Figure 6 Releasing belts
11. Figure 7, remove the rear elevator belt.
1
Pull the belt out of
the front belt grip
2
Pull the belt out of the
rear belt grip
2
Slide the small belt off the pul-
ley and slowly release the ten-
sion to the mylar guide system.
Lay the mylar guide over the
input baffle
3
Slide the large belt off the pulley
1
Mark the position of the small
belt on the pulley
July 2005
Repairs/Adjustments
Figure 7 Elevator belt removal
12. Figure 8, remove the front elevator belt.
Figure 8 Releasing the belt
Replacement
1. Reverse the removal procedure to replace the compiler carriage elevator belts. Ensure
the small belt is returned to its original position on the pulley.
2. Tension the compiler carriage elevator belts, refer to REP 11.8-130.
2
Slide the belt off the pulley
and remove through the hole
in the frame
1
Remove the belt tensioner
spring
1
Remove 2 screws
2
Lift the shaft slightly and slide the belt
off the pulley and free from the frame
4
Remove the belt
from the top pulley.
3
Remove the belt
tensioner spring
July 2005
Repairs/Adjustments
REP 11.8-130 Elevator Belt Tensioner Springs
Removal
WARNING
WARNING
NOTE: This procedure illustrates the front elevator belt tensioner spring. The procedure for the
rear spring is identical.
1. Remove bin1, REP 11.5-130.
2. Figure 1, remove the spring.
Figure 1 Removing spring
Replacement
1. Figure 2, replace the spring.
Figure 2 Replacing spring
2. Install bin 1, REP 11.5-130.
1
Insert long nosed piers
through the spring
2
Twist the piers
to compress
the spring
3
Twist the spring
away from the belt
4
Release the tension
in the spring and
remove from the belt
1
Position one leg of spring on the belt
2
Insert long nosed pliers
through the spring
3
Twist the pliers
to compress
the spring
4
Hook the leg of
the spring over
the belt
5
Allow the spring to tension
the belt and remove the pliers
July 2005
Repairs/Adjustments
REP 11.9-130 HCSS Castors
Removal
WARNING
WARNING
1. Separate the HCSS from the machine, REP 11.19-130.
2. If removing the rear non-adjustable castor, remove the rear cover, REP 11.1-130.
3. Figure 1, remove a non-adjustable castor.
Figure 1 Removal of non-adjustable castors
4. Figure 2, remove or adjust an adjustable castor.
2
Remove the relevant
screw.
1
Place two reams of
paper at the front or
rear of the HCSS
July 2005
Repairs/Adjustments
Figure 2 Caster removal or adjustment
Replacement
Reverse the removal procedure to install the HCSS castors.
REP 11.10-130 Hole Punch Motor and Coupling
Parts List on PL 11.38, PL 11.36
Removal
WARNING
WARNING
1. Remove the HCSS top cover, HCSS rear cover and HCSS upper left cover, REP 11.1-
130.
2. Figure 1, remove the hole punch motor.
Figure 1 Hole punch motor removal
3. Remove the hole punch unit, PL 11.36 Item 12. Remove the hole punch motor coupling
by pulling from the shaft.
Replacement
Reverse the removal procedure to replace the hole punch motor.
1
Place two reams of paper at
the front or rear of the HCSS
2
Tilt the HCSS suffi-
ciently to slide the paper
reams under the base
3
To adjust the height of the
HCSS, rotate the hand wheel
in the appropriate direction.
To remove the castor,
unscrew in the direction of
the arrow
1
Remove two screws
2
Disconnect the harness and
remove the motor
July 2005
Repairs/Adjustments
NOTE: When replacing the hole punch motor coupling, unsure that it is located against the
shoulder on the shaft.
REP 11.11-130 Upper Paper Guide
Removal
WARNING
WARNING
2. Figure 1, remove the front and rear supports.
Figure 1 Removing supports
1
Remove 2 screws and rear support
2
Remove 2 screws and front support
July 2005
Repairs/Adjustments
3. Figure 2, Remove the upper paper guide.
Figure 2 Removing guide
Replacement
Reverse the removal procedure to replace the upper paper guide.
REP 11.12-130 Diverter Gate and Solenoid
Removal
WARNING
WARNING
1. Remove the HCSS top cover, rear cover upper left cover and front cover, REP 11.1-130.
2. Remove one screw and the diverter solenoid cover, PL 11.36 Item 2.
3. Remove the upper paper guide, REP 11.11-130.
4. Figure 1, prepare to remove the diverter gate.
1
Remove 4
screws
2
Release the guide from
the 4 locating features
and remove
July 2005
Repairs/Adjustments
5. Figure 2, remove the diverter gate.
Figure 2 Diverter gate removal
Replacement
Reverse the removal procedure to install the diverter gate.
3
Remove two bearings.
One at each end of the
shaft.
2
Remove the two E clips.
shaft.
1
Remove 2 screws, disconnect
the harness and remove the
solenoid.
3
Carefully bend the centre of the diverter gate upwards and
remove
2
Push the diverter gate fully to
the rear
1
Carefully push the
lever past the shaft
to rest against the
inner baffle
July 2005
Repairs/Adjustments
REP 11.13-130 Mylar Guide Assembly
Purpose
This procedure is used to repair the following parts:
Mylar guide reel, PL 11.40 Item 4.
Mylar guide torsion spring, PL 11.40 Item 5.
Mylar guide clamp, PL 11.40 Item 7.
Pulley gear, PL 11.40 Item 9.
Drive belt, PL 11.40 Item 10.
Shaft, PL 11.40 Item 15.
Mylar guide, PL 11.40 Item 16.
Removal
WARNING
1. Open the HCSS front door and cheat the front door interlock. Enter dC330 code 11-016 to
move the compiler carriage to the lowest position.
WARNING
2. Remove the HCSS top cover, rear cover and front door, REP 11.1-130.
4. Remove the bin 1 assembly, REP 11.5-130.
Figure 1 Release the mylar guide
7. Figure 2, loosen the belt tensioner.
1
2
Move the metal end
of the guide towards
the front or rear and
unhook from the
hole in the compiler
carriage frame
3
Carefully allow the mylar guide
to be rolled upwards by the
spring
July 2005
Repairs/Adjustments
Figure 2 Belt tensioner
8. Figure 3, remove the mylar guide reel bearings.
Figure 3 Bearing removal
9. Figure 4, remove the pulley/gear and drive belt.
1
Loosen screw 3 turns
1
2
July 2005
Repairs/Adjustments
Figure 4 Belt drive
10. Roll the mylar guide fully onto the guide reel.
11. Figure 5, remove the mylar guide reel assembly.
Figure 5 Guide reel assembly
12. Figure 6, remove the mylar guide, mylar guide clamp, torsion spring and gear.
1
Remove E-clip
3
Remove belt
2
Remove the pulley/gear
1
Push the assembly
to the rear
2
Remove the shaft
from the front hole
3
Remove the assembly
July 2005
Repairs/Adjustments
Figure 6 Mylar guide
13. Figure 7, Remove the shaft.
Figure 7 Shaft removal
Replacement
1. Re-assemble the mylar guide reel, shaft and end caps.
2. Figure 8, install the mylar guide and clamp.
1
Remove gear
and spring
2
Fully unwind the mylar guide
3
Remove 3 screws
4
Remove the mylar
guide clamp and
mylar guide
1
Remove E-clip and front cap
2
Remove E-clip and rear cap
3
Remove the
shaft from the
mylar guide reel
July 2005
Repairs/Adjustments
Figure 8 Mylar guide position
3. Roll the mylar guide fully onto the guide reel.
4. Figure 9, install the torsion spring and gear.
Figure 9 Spring location
5. Install the following components by reversing the removal procedure:
Mylar guide reel assembly.
Belt drive.
Mylar guide reel bearings.
6. Figure 10, set the position of the mylar guide to correctly tension the torsion spring.
1
Round hole must
be at the front of
the guide reel
2
Position the
clamp
3
Install 3
screws
1
Engage spring in
hook of guide reel
2
Slide the gear on the shaft and
engage spring in slot
July 2005
Repairs/Adjustments
Figure 10 Spring tension
7. Figure 11, Connect the mylar guide to the compiler carriage.
1
Slide the small belt off
the pulley
2
Rotate the mylar guide drum
using the belt until the free end
of the mylar guide aligns with
the step in the frame
3
Slide the small belt
on the pulley
July 2005
Repairs/Adjustments
Figure 11 Mylar guide attachment
8. Reverse the removal procedure to install the remainder of the components.
1
Hook the mylar
guide into the hole
in the compiler
carriage frame
2
Slide the hook to
the centre of the
carriage hole
Incorrect
Mylar guide is outboard
frame top
Incorrect
Mylar guide is inboard of
frame top
Correct
Mylar guide is flush with
frame top
July 2005
Repairs/Adjustments
REP 11.14-130 Vertical Transport Belts and Pre-compile
Pulleys
Removal
WARNING
WARNING
1. Remove the compiler carriage assembly, REP 11.2-130.
2. Lay the mylar guide over the input guide.
3. Figure 1, remove the drive pulley.
Figure 1 Belt removal
4. Figure 2, release the belts from the upper pre-compile pulleys.
1
Loosen screw
2
Slide tensioner
bracket fully upwards
3
Tighten screw
4
Remove the belt
from around the
drive pulley
5
Remove E-clip and
drive pulley
July 2005
Repairs/Adjustments
Figure 2 Release belts
5. Figure 3, remove the bracket.
Figure 3 bracket removal
6. Figure 4, remove the vertical transport belts.
1
Remove E-clip and
bearing at each end
of the shaft
2
Push shaft to the rear to release the belts
3
Slide belts off the
upper pulley
4
Rest the belts on
top of the frame
5
Remove the upper
pre-compile pulley
1
Use a hex driver to
remove 2 screws
2
Use a ratchet
wrench and 5.5mm
socket to remove 2
screws
3
Remove the bracket
July 2005
Repairs/Adjustments
Replacement
1. Install belts over the frame.
2. Re-locate the frame and install the bearing, washer, E-clip and 2 screws.
3. Place belts over the upper pre-compile pulleys, but between pre-compile lower pulleys.
4. Lift the upper shaft into position and install the bearing and E-clip.
5. Position the belts onto the lower pre-compile pulleys.
6. Reverse the removal procedure to replace the remainder of the removed components.
7. Tension the mylar guide, refer to REP 11.13-130.
2
Remove E-clip washer and
bearing from both ends of
the lower pre-compile pulley
shaft
1
Remove 2 screws
3
Pull frame rearward to
release from hook.
4
Lift the rear of the frame
5
Remove belts through the
gap under the frame
July 2005
Repairs/Adjustments
REP 11.15-130 Vertical Transport Nip Rollers
Removal
NOTE: The vertical transport contains eight identical nip rollers, the repair procedure is identi-
cal for all.
WARNING
WARNING
1. Open the HCSS front door.
2. Figure 1, Remove a vertical transport nip roller.
Figure 1 Roller removal
Replacement
Reverse the removal procedures to replace the vertical transport nip rollers.
REP 11.16-130 Chad Full Bin Sensor, Actuator and Spring
Removal
WARNING
WARNING
1. Remove the chad bin.
2. Separate the HCSS from the machine, REP 11.19-130.
3. Remove the HCSS top cover, rear cover, upper left cover, front door and front cover, REP
11.1-130
4. Figure 1, remove the cover.
Figure 1 Cover removal
5. Figure 2, remove the screws securing the docking bracket and the chad bin support.
1
Pinch the
legs together
2
Slide the nip roller
assembly partially out
3
Hold the spring
and remove
together with
the nip roller
assembly
2
Gently bend the cover to release the dowels
1
Remove two screws
July 2005
Repairs/Adjustments
Figure 2 Preparation for bracket removal
6. Figure 3, remove the chad bin support.
Figure 3 Chad bin support removal
7. Figure 4, remove the chad bin sensor and/or actuator.
1
Remove eight screws.
1
Lift the docking bracket to release the hooks
2
Lift the support to
release the hooks
July 2005
Repairs/Adjustments
Figure 4 Sensor/actuator removal
Replacement
Reverse the removal procedure to replace the chad bin sensor actuator and/or sensor.
NOTE: Ensure that the spring below the actuator is correctly located on the raised sections of
the actuator and chad bin support.
REP 11.17-130 Transport Motor 1A, Motor Damper and
Drive Belt
Removal
WARNING
WARNING
1. Remove the rear cover, REP 11.1-130
2. Figure 1, loosen the belt.
Figure 1 Loosening the belt
3. Figure 2, remove the belt.
1
Press the actuator pivots
through the chad bin support
3
from the sensor
4
Release the legs of the
sensor and remove
2
Remove the actuator
and spring
1
Loosen the belt tensioner screw, fully
loosen the belt, then tighten the screw
July 2005
Repairs/Adjustments
4. Disconnect the motor harness if necessary.
5. Remove 2 screws to remove the motor from the motor damper.
Replacement
1. Reverse the removal procedure to replace the drive belt.
2. Loosen the belt tensioner screw, allow the belt tensioner to tension the belt, then tighten
the belt tensioner screw.
REP 11.18-130 Transport Motor 1B, Motor Damper and
Drive Belt
Removal
WARNING
WARNING
1. Remove the rear cover, REP 11.1-130
1
Loosen
two
screws on
the motor
bracket
2
Slide the
motor and
bracket off
the screws
3
Remove
the belt
1
Loosen the belt tensioner screw,
fully. Loosen the belt, then
tighten the screw.
July 2005
Repairs/Adjustments
Replacement
REP 11.19-130 HCSS Un-Docking
Removal
CAUTION
Do not show the customer how to un-dock the HCSS.
1. Release the jam clearance latch and fully open the gap between the machine and the
HCSS.
2. Figure 1, move the HCSS away from the machine
Figure 1 Docking latch location
3. Disconnect the harnesses between the machine and the HCSS if necessary.
Replacement
Reverse the removal procedure to replace the HCSS.
2
Remove the pulley
1
Remove the
K-L clip
5
Remove the
drive belt from
the pulleys
3
Loosen two
screws on
the motor
bracket
4
Slide the
motor and
bracket
off the
screws
2
Roll the HCSS away
from the machine
1
Feel under the docking latch
bracket and release the docking
latch by pulling the lever forward
July 2005
Repairs/Adjustments
REP 11.20-130 CC Ejector Motor Assembly and Ejector
Home Sensor
Removal
WARNING
WARNING
2. Figure 1, remove the compiler carriage cross piece.
Figure 1 Removing the cross member
3. Figure 2, remove the ejector motor assembly and home sensor.
Figure 2 Removing the motor and sensor
Replacement
Reverse the removal procedure to replace the ejector motor assembly and home sensor.
1
Remove 1 screw
at either end of
the cross mem-
ber
2
Bend open the frame to release the
cross piece from the locating dowels
3
Release the
connecting rod
from the
crankshaft
1
Release the harness from
the retainers and disconnect
at the motor and sensor
2
Remove screw
3
Slide motor assembly
across and remove
4
Use a small screw-
driver to release the
sensor from the
July 2005
Repairs/Adjustments
REP 11.21-130 CC Paddle Roll Motor Assembly and Paddle
Roll Home Sensor
Removal
WARNING
WARNING
CAUTION
Do not loose the white plastic worm on the end of the motor spindle. It is a slide fit on the motor
spindle.
2. Figure 1, remove the motor assembly.
Figure 1 Motor assembly removal
3. Remove the motor, if necessary, by removing the remaining screw.
Drive lugs
Bearing
Worm
Shutter is shown
removed for clarity
1
Remove 2
screws
2
Lift the motor assembly and disengage the worm
from the bearing
3
Remove screw and
ground wire
4
Disconnect motor
harness and sensor
harness
July 2005
Repairs/Adjustments
4. Remove the sensor, if necessary, by releasing the sensor legs.
Replacement
1. If necessary, install the sensor and/or motor in the bracket.
2. Reconnect the ground wire and harnesses.
3. Ensure that the white plastic worm is fully located on the drive lugs of the motor, Figure 1.
4. Locate the motor assembly, ensuring that the nose of the white plastic worm is located in
the bearing in the frame, Figure 1, install the two securing screws.
5. Reinstall the top cover.
REP 11.22-130 CC Top Baffle Assembly
Purpose
This procedure is used to repair the following components:
Carriage top baffle, PL 11.47 Item 12.
Carriage top baffle return spring, PL 11.47 Item 13.
Top baffle idler, PL 11.47 Item 14.
Top baffle idler spring, PL 11.47 Item 15.
Removal
WARNING
WARNING
1. Remove the compiler carriage, REP 11.2-130.
2. Figure 1, remove the top baffle assembly
July 2005
Repairs/Adjustments
Figure 1 Removing the top baffle assembly
NOTE: If only new idlers and springs are being installed, it is easier to leave the carriage top
baffle return spring connected.
3. Figure 2, if required, remove the idlers and springs from the baffle.
Figure 2 Removing the idlers and springs
Replacement
Reverse the removal procedure to replace the top baffle assembly and components.
2
Use a flat bladed screwdriver to care-
fully move the baffle pivot out of the
frame
1
Loosen 2 screws,
2 turns each
3
Release the spring from
the baffle (see note)
1
Press down on the idler
2
Slide the idler from under the hooks
3
Hold the spring with a
small screwdriver,
remove the idler and
spring
July 2005
Repairs/Adjustments
REP 11.23-130 Compiler Sensor
Removal
WARNING
WARNING
2. Figure 1, improve the access to the area
Figure 1 Improving access
3. Figure 2, remove the sensor cover.
4. Release the sensor lugs from the mounting using a small screwdriver and disconnect the
sensor from the harness.
Replacement
Reverse the removal procedure to replace the compiler carriage entry sensor. Ensure the har-
ness cover removed in Figure 1, is correctly installed so that it does not interfere with jam clear-
ance latch 5d.
1
Remove the harness cover
by releasing the two legs
2
Open the top baffle.
Use adhesive tape to fix the top baffle in the open position.
1
Remove 2
screws
2
Slide the cover to the rear
to align with the notch
3
Remove the
cover
July 2005
Repairs/Adjustments
REP 11.24-130 CC Entrance Baffle and Springs
Removal
WARNING
WARNING
1. Remove the compiler sensor, REP 11.23-130.
2. Remove the carriage PWB from its mounting but do not disconnect any PJs from the
PWB, refer to REP 11.4-130.
3. Figure 1, remove the CC entrance baffle.
Figure 1 Removing the entrance baffle
Replacement
Reverse the removal procedure to replace the CC entrance baffle assembly.
1
Remove 2 entrance baffle
springs (1 each end)
3
Disconnect ground wire
4
Remove 4 screws
5
Remove the baffle assembly
2
Unhook spring
July 2005
Repairs/Adjustments
REP 11.25-130 Elevator belt drive pulleys
Removal
WARNING
WARNING
1. Remove the front and rear elevator belt tensioner spring, REP 11.8-130.
2. Remove the compiler carriage elevator motor and bracket, REP 11.6-130.
3. Figure 1, remove the lower carriage shaft.
Figure 1 Shaft removal
4. Figure 2, remove the elevator belt drive pulleys.
Figure 2 Pulley removal
Replacement
Reverse the removal procedure to replace the elevator belt drive pulleys
1
Remove 2 screws
2
Feed the shaft assembly
though the belt loops and
remove from the rear
1
Remove E-clip and pulley
2
Remove E-clip
and pulley
July 2005
Repairs/Adjustments
REP 11.26-130 CC Stapling Unit Traverse Motor
Removal
WARNING
WARNING
1. Remove the compiler PWB, REP 11.4-130.
2. Figure 1, remove the stapling unit traverse motor.
Figure 1 Motor removal
Replacement
Reverse the removal procedure to replace the stapling unit traverse motor.
NOTE: Ensure that the ground connector, Figure 1, is trapped between the motor flange and
the compiler frame.
1
Remove 2 screws
2
Remove
the motor
Ground
connector
July 2005
Repairs/Adjustments
REP 11.27-130 Transport Motor 2 and Motor Damper
Removal
WARNING
WARNING
1. Remove the carriage PWB, but only disconnect sufficient PWB connectors to allow
access to the motor screws, refer to REP 11.4-130.
2. Figure 1, remove transport motor 2.
3. Remove 2 nuts to separate the motor damper from the motor.
Replacement
1. Reverse the removal procedure to replace transport motor 2.
2. Ensure that the ground connector is secured with the lower motor screw, Figure 1.
3. Loosen the tensioner screw, allow the spring to tension the belt, then tighten the tensioner
screw, Figure 1.
1
Loosen screw,
move tensioner
fully upward,
tighten screw
2
Remove 2 screws
3
Remove the motor
Ground
connector
July 2005
Repairs/Adjustments
REP 11.28-130 CC Eject Roll Motor
Removal
WARNING
WARNING
2. Remove the carriage PWB, REP 11.4-130.
3. Figure 1, remove the CC eject roll motor.
Replacement
1. Reverse the removal procedure to replace the CC eject roll motor.
2. Ensure that the ground connector is secured with the lower motor nut, Figure 1.
1
Remove E-clip,
pulley and belt
2
Remove 3 nuts
3
Remove the motor
Ground
connector
July 2005
Repairs/Adjustments
REP 11.29-130 CC Kicker Assembly
Purpose
Kicker Solenoid, PL 11.49 Item 4.
Compiler carriage bin height sensor, PL 11.49 Item 5.
Compiler carriage 90% full sensor, PL 11.49 Item 5.
Return spring, PL 11.49 Item 16.
Kicker fingers, PL 11.49 Item 19.
Removal
WARNING
WARNING
2. Remove the rear tamper drive belt by pushing the belt from the motor pulley where there
is no flange.
3. Figure 1, remove the kicker assembly.
July 2005
Repairs/Adjustments
Figure 1 Removal
4. Figure 2, dismantle the components of the kicker assembly as necessary.
2
Disconnect the ground connector and 3
harnesses
3
Remove screw
4
Pivot the assembly to
improve access
5
Remove the E-clip,
slide the tamper shaft
to the rear
6
Remove the assembly,
being careful not to dam-
age the kicker fingers
1
Remove screw
July 2005
Repairs/Adjustments
Figure 2 Dismantling
Replacement
Reverse the removal procedure to replace the kicker assembly components.
REP 11.30-130 CC Tray Hold Solenoid Assembly
Removal
WARNING
WARNING
2. Figure 1, remove the tray hold solenoid.
Remove 2 screws to remove the solenoid,
release the spring from the plunger
Release the
legs to remove
a sensor
Carefully spring the frame
apart to remove the kicker
fingers and return spring
July 2005
Repairs/Adjustments
Figure 1 Solenoid removal
Replacement
CAUTION
Ensure the short and long screw are installed in the correct location, Figure 1.
Reverse the removal procedure to replace the tray hold solenoid assembly.
NOTE: Ensure that the solenoid is positioned on the locating dowels.
1
Disconnect harness
2
Remove 2 screws
Long screw with earth tag
Short screw
3
Remove solenoid and linkage
July 2005
Repairs/Adjustments
REP 11.31-130 CC Stapler Mount and Traverse Shaft
Assembly
Removal
WARNING
WARNING
2. Remove the staple head assembly, REP 11.3-130.
3. Remove the stapling unit traverse motor, REP 11.26-130.
4. Figure 1, remove the stapler mount and traverse shaft assembly.
July 2005
Repairs/Adjustments
Figure 1 Assembly removal
5. Unscrew the traverse shaft from the stapler mount.
Replacement
Reverse the removal procedure to replace the stapler mount and traverse shaft assembly.
1
Remove screw and
slide out shaft
2
Remove E-clip, gear and bearing
3
Remove E-clip
and bearing
4
Slide out the stapler
mount and traverse
shaft assembly
July 2005
Repairs/Adjustments
REP 11.32-130 CC Transport Shaft Assembly
Purpose
Transport shaft, PL 11.49 Item 8.
Transport shaft pulley, PL 11.49 Item 9.
Transport shaft kit, PL 11.49 Item 10.
Guide roller, PL 11.49 Item 11.
Compiler belt kit, PL 11.49 Item 12.
Feed chute, PL 11.49 Item 13.
Removal
WARNING
WARNING
1. Remove transport motor 2, REP 11.27-130.
2. Figure 1, prepare to remove the transport shaft assembly.
3. Figure 2, Remove the transport shaft assembly.
1
2
Remove 2 E-clips, pulley and bearing
July 2005
Repairs/Adjustments
Figure 2 Removal
4. Figure 3, dismantle the components of the transport shaft assembly.
Replacement
Reverse the removal procedure to replace the transport shaft assembly and components.
2
Remove 3
screws
1
Ensure stapler unit
is fully to the front
3
Hold the compiler tray down and
slide the transport shaft assembly
rearwards as far as possible
4
Pull the front of the shaft
past the stapler and
remove the assembly
1
Slide out the transport shaft
2
Wrap the belt
around the roller
and press the
roller out and
remove (2 places)
July 2005
Repairs/Adjustments
REP 11.33-130 Docking Latch Components
Purpose
This procedure is used to repair the following components
Docking Release latch, PL 11.34 Item 13.
Release bracket, PL 11.34 Item 11.
Docking interlock switch (S11-300A), PL 11.34 Item 3.
Docking pivot interlock switch (S11-300B), PL 11.34 Item 5.
Restraining cable, PL 11.34 Item 1.
Removal
WARNING
WARNING
1. Un-dock the HCSS from the machine, REP 11.19-130.
2. Figure 1, release the restraining cable.
Figure 1 Restraining cable
3. Figure 2, remove the docking latch bracket rear cover.
1
Release the latch, open
the bracket fully
3
If a new restraining
cable is being installed,
remove screw
4
Open the bracket
as far as possible
2
Remove screw
July 2005
Repairs/Adjustments
4. Figure 3, Remove the release bracket.
Figure 3 Release bracket
5. Figure 4, if necessary, remove the docking release latches.
1
Remove 2 screws
2
Release 2 dowels
from the holes
3
Remove
the cover
1
Snap the lower fitting
apart (2 places)
2
Twist the bracket
counterclockwise and
lift off the top dowel (2
places)
3
Disconnect the spring
and remove the bracket
July 2005
Repairs/Adjustments
Figure 4 Latch removal
6. Figure 5, if necessary, remove the docking interlock switch or the docking pivot interlock
switch.
Figure 5 Switches removal
Replacement
Reverse the removal procedure to replace the removed components.
1
Remove E-clip
(2 places)
2
Push out the
pin (2 places)
using a small
screwdriver 3
Remove the
latch (2 places)
and press together the
catches to remove the
docking interlock switch
remove 2 screws to remove the
docking pivot interlock switch
July 2005
Repairs/Adjustments
REP 11.34-130 Compiler Carriage Belt Grips
Removal
WARNING
WARNING
2. Figure 1, remove the compiler carriage belt grips.
Figure 1 Removing grips
Replacement
Reverse the removal procedure to replace the compiler carriage belt grips.
2
Remove 3 screws
1
Remove 3 screws and the front grip
3
Cut the cable tie and
remove the rear grip
July 2005
Repairs/Adjustments
REP 11.35-130 Bin 1 or Bin 2 Offset Motor and Offset
Sensor
Removal
WARNING
WARNING
1. Remove the bin 1 or bin 2 tray assembly by disconnecting the harness, removing the
thumbscrew and pulling the tray assembly off the support.
2. Figure 1, remove the bin lower support.
Figure 1 Support removal
3. Figure 2, remove the bin offset sensor and bin offset motor.
Figure 2 Component removal
Replacement
Reverse the removal procedure to replace the bin 1 or bin 2 offset motor and offset sensor.
NOTE: Ensure the peg of the gear/crank locates in the slot of the tray.
1
Remove 4 screws
2
Remove the bin lower support
1
Pinch the sensor legs together, remove the
sensor and disconnect the harness
2
Remove 1 E-clip
and gear/crank
3
Remove 1 E-clip
and the gear
4
Remove 2 screws
and the motor
5
Disconnect the motor
harness
July 2005
Repairs/Adjustments
REP 11.36-130 Bin 1 or Bin 2 Elevator Motor and Bearing
Removal
WARNING
WARNING
1. Remove the bin 1 or bin 2 tray assembly by disconnecting the harness, removing the
thumbscrew and pulling the tray assembly off the support.
2. Remove the rear cover, REP 11.1-130.
3. Figure 1, remove the elevator motor.
NOTE: The elevator motor worm and gears are greased, take care not to contaminate
other parts of the machine with the grease. Wear protective gloves if desired.
Replacement
Reverse the removal procedure to replace the bin 1 or bin 2 elevator motor.
1
Remove E-clip
and gear
2
Remove E-clip
and bearing
3
Remove 2
screws, slide
the motor down
4
Disconnect the
harness and
remove the motor
July 2005
Repairs/Adjustments
REP 11.37-130 Entry Sensor and Punch Position Sensor
Removal
WARNING
WARNING
1. Remove the rear cover and upper left cover, REP 11.1-130.
2. If installed, remove the hole punch unit, PL 11.36 Item 12.
3. Remove the lower left cover, PL 11.30 Item 22.
5. Figure 1, remove the sensor.
Replacement
Reverse the removal procedure to replace the entry sensor and punch position sensor.
1
Remove
3 screws
2
Move the front of the tie
bar to the right and
release the rear from the
dowels
3
Rotate the assembly
to access the screws
4
Remove screw and sensor,
disconnect the harness
July 2005
Repairs/Adjustments
REP 11.38-130 2nd to Top Exit Sensor
Removal
WARNING
WARNING
1. Remove the HCSS top cover, REP 11.1-130.
2. Figure 1, remove the 2nd to top exit sensor.
Replacement
Reverse the removal procedure to replace the 2nd to top exit sensor.
1
Remove screw
and securing
block.
2
Use a small screwdriver to release the
sensor legs.
3
Disconnect the sensor
harness and remove
the sensor.
July 2005
Repairs/Adjustments
REP 11.39-130 CC Shutter
Removal
WARNING
WARNING
1. Remove the CC eject housing assembly, REP 11.41-130.
2. Figure 1, remove the CC shutter.
Figure 1 Shutter removal
Replacement
Reverse the removal procedure to replace the CC shutter.
1
Remove the screw
2
Slide the shutter
to the front,
release the pin
from the rear
4
Un-snap the
middle fixings
5
Release the pin
from the front
and remove the
shutter
3
Unhook the springs
from the shutter
July 2005
Repairs/Adjustments
REP 11.40-130 CC Nip Shaft Components
Purpose
Nip roll, PL 11.48 Item 2.
Nip shaft, PL 11.48 Item 3.
Nip spring, PL 11.48 Item 4.
Removal
WARNING
WARNING
2. Figure 1, improve the access to the area.
3. Figure 2, remove the entrance baffle cover.
1
Remove the
harness cover
2
Open the top baffle and
fix in the open position
using adhesive tape
July 2005
Repairs/Adjustments
4. Figure 3, remove the nip shaft, nip springs and nip rolls.
Figure 3 Nip shaft removal
Replacement
Reverse the removal procedure to replace the nip shaft, nip springs and nip rolls.
1
Remove 2 screws
2
Slide the cover to the rear to align
with the notch
3
Remove the cover
1
Remove 2
springs
2
lift out the nip shaft with rolls
3
Slide the rolls off the shaft
July 2005
Repairs/Adjustments
REP 11.41-130 CC Eject Housing Assembly
Removal
WARNING
WARNING
2. Figure 1, remove the compiler carriage cross member
3. Figure 2, prepare to remove the CC eject housing assembly.
1
Remove 1 screw at either
end of the cross member
2
Bend open the frame to
release the cross member
3
Release the connecting
rod from the crankshaft
July 2005
Repairs/Adjustments
4. Figure 3, remove the CC eject housing assembly.
1
Remove 2 screws
marked A. Release
the harness clamp
3
Remove the
screw. Release the
ground connector
2
Disconnect the
motor and sensor
harnesses
4
Disconnect 2
ground terminals
5
Disconnect the sensor harness
July 2005
Repairs/Adjustments
Figure 3 Housing removal
Replacement
Reverse the removal procedure to replace the CC ejector housing assembly.
NOTE: Ensure that the front and rear pivot pins are located in the pivot holes
1
Use a flat blade screwdriver
to release the pivot pin from
the hole
2
Raise the front of the housing
carefully guiding the CC
shutter out of the track
3
Remove the CC ejector
housing assembly
July 2005
Repairs/Adjustments

REP 11.1-170 HCSS BM Covers
Removal
WARNING
WARNING
NOTE: All major HCSS BM covers are dealt with in this procedure, only remove the covers
listed in the procedure that you are performing.
Remove the HCSS BM covers as follows:
1. Figure 1, top cover removal.
2. Figure 2, rear cover removal.
4
Disconnect PJ493 and PJ439
5
Remove the top cover.
3
Remove 2 screws
2
Remove 2
screws
1
Fold the bin 0 pivot tray
and bin 0 base tray.
July 2005
Repairs/Adjustments
Figure 2 Rear cover removal
3. Front door removal; remove the lower hinge pin and slide the door from the upper pivot
pin, refer to PL 11.60.
4. Figure 3, front cover removal.
Figure 3 Front cover removal
5. Hole punch access cover removal, remove 2 thumb screws, refer to PL 11.60 Item 3.
6. Upper left cover removal, remove two screws, refer to PL 11.60 Item 1.
Replacement
Reverse the removal procedure to install the HCSS BM covers.
2
Remove 4
screws
4
Remove the rear cover
1
Remove the harness
from the retainer.
3
Remove one
screw
1
Remove screw
2
Remove 6 screws
3
Release the base of the
cover from the frame
July 2005
Repairs/Adjustments
REP 11.2-170 Compiler Carriage Assembly
Removal
WARNING
WARNING
1. Remove the top cover, rear cover, front door and front cover, REP 11.1-170.
3. Figure 1, disconnect the harnesses.
Figure 1 Disconnect the carriage PWB
3
Disconnect PJ401, PJ412,
PJ411 and PJ410 from the
carriage PWB
4
Disconnect the earth
wire
1
Release the harnesses
between the HCSS
PWB and carriage
PWB from the bridge
2
Cut 2 tie-wraps
July 2005
Repairs/Adjustments
4. Figure 2, move the stapler assembly inboard by about 75 mm (3 inches), by turning the
stapler traverse screw with a 5.5 mm nut driver.
Figure 2 Stapler transverse shaft
WARNING
NOTE: The carriage assembly weighs approximately 5.5Kg (12lb).
CAUTION
Do not damage the compiler sensor, when removing the compiler carriage assembly.
5. Figure 3, remove the locking block.
Figure 3 Locking block removal
6. Fully pull out the BM module, PL 11.65 Item 1.
Stapler transverse shaft
1
Remove the jam
clearance knob
2
Remove the support
3
Remove the clamp and support
July 2005
Repairs/Adjustments
7. Remove the BM support bracket, PL 11.68 Item 4. 8. Figure 4, release the compiler carriage assembly from the frame.
4
front until the rear belt grip clears the rear
frame
2
Push the carriage
assembly towards
the rear until the
front belt grip
clears the front
frame
3
Pull the compiler carriage
outside the frame
5
frame
1
Support the weight of the compiler
carriage, remove two screws
July 2005
Repairs/Adjustments
9. Figure 5, remove the compiler carriage assembly.
Figure 5 Removing the compiler carriage assembly
Replacement
Reverse the removal procedure to replace the compiler carriage assembly.
REP 11.3-170 Staple Head Unit 1 Assembly and SH1 Paper
Sensor
Removal
WARNING
WARNING
5. Figure 1, lower the front of the compiler carriage.
3
Remove the carriage.
1
Tilt the compiler carriage
clockwise.
2
Pull the front of the carriage
through the frame.
July 2005
Repairs/Adjustments
Figure 1 Carriage position
6. Figure 2, release the compiler input guide.
Figure 2 Compiler input guide
7. Remove the staple head cover (one screw).
8. Return the compiler carriage to the original position and secure with the two top screws.
9. Figure 3, remove the compiler staple head assembly.
1
Remove the front
support
2
Support the weight of
3
Remove 2 screws
4
Lower the front of the
carriage
1
Unhook spring
2
Remove 2
screws
3
Push guide to
the right
Stapler traverse shaft
July 2005
Repairs/Adjustments
10. Figure 4, remove the SH1 paper sensor.
11. Disconnect the harness from the staple head.
Replacement
Reverse the removal procedure to replace the staple head assembly.
2
Remove two
screws
3
Remove the
staple head
1
Rotate the stapler
traverse shaft to
align screws with
holes
Viewed from above
1
2
Press in both lugs at one
end and lift the sensor at
that end
3
Press in both lugs at the
other end and lift the
sensor to remove
July 2005
Repairs/Adjustments
REP 11.4-170 Carriage PWB
Removal
WARNING
WARNING
2. Figure 1, remove the harness cover and support.
Figure 1 Harness cover and support
3. Figure 2, remove the carriage PWB.
1
Un-clip the harness
cover by releasing the
two latches
2
Remove screw and release the
support from the top mounting
July 2005
Repairs/Adjustments
Figure 2 Carriage PWB removal
Replacement
Reverse the removal procedures to replace the carriage PWB. Ensure the harness cover
removed in Figure 1, is correctly installed so that it does not interfere with jam clearance latch
5d.
REP 11.5-170 Bin 1 Assembly
Removal
WARNING
WARNING
1. Remove the HCSS BM top cover, rear cover, front door and front infill cover, REP 11.1-
170.
2. Release the harness to bin 1 from the harness support next to the HCSS PWB.
3. Disconnect PJ416 and PJ424.
4. Figure 1, remove the bin assembly.
1
Disconnect all connectors
on the PWB
2
Remove
screw
3
Lift PWB from retainers
July 2005
Repairs/Adjustments
Figure 1 Bin 1 assembly removal
Replacement
Reverse the removal procedures to replace the bin 1 assembly.
REP 11.6-170 HCSS BM Castors
Removal
WARNING
WARNING
1. Un-dock the HCSS BM from the machine, REP 11.13-170.
2. If removing the rear non-adjustable castor, remove the rear cover, REP 11.1-170.
3. Figure 1, remove a non-adjustable castor.
1
Remove screw
3
Lift and remove the bin
assembly
2
Remove screw
July 2005
Repairs/Adjustments
Figure 1 Removal of non-adjustable castors
4. Figure 2, remove or adjust an adjustable castor.
Figure 2 Adjustable castor
Replacement
Reverse the removal procedure to install the HCSS BM castors.
2
Remove the screw.
1
Place two reams of
paper at the front or rear
of the HCSS BM
3
Remove the screw
1
Place two reams of paper at
the front or rear of the HCSS
BM
2
Tilt the HCSS BM sufficiently
to slide the paper reams
under the base
3
To adjust the height of the
HCSS BM, rotate the hand
wheel in the appropriate
direction. To remove the
castor, unscrew in the
direction of the arrow
July 2005
Repairs/Adjustments
REP 11.7-170 Hole Punch Motor and Coupling
Removal
WARNING
WARNING
1. Remove the HCSS BM top cover, rear cover and upper left cover, REP 11.1-170.
2. Figure 1, remove the hole punch motor, PL 11.70 Item 7.
Figure 1 Hole punch motor removal
3. Remove the hole punch unit, PL 11.66 Item 12. Remove the hole punch motor coupling
by pulling from the shaft.
Replacement
Reverse the removal procedure to install the hole punch motor.
NOTE: When replacing the hole punch motor coupling, ensure that it is located against the
shoulder on the shaft.
1
Remove two screws
2
Disconnect the harness from the motor
and remove the motor
July 2005
Repairs/Adjustments
REP 11.8-170 Upper Paper Guide
Removal
WARNING
WARNING
2. Figure 1, remove the front and rear supports.
Figure 1 Removing supports
3. Figure 2, Remove the upper paper guide.
Figure 2 Removing guide
Replacement
Reverse the removal procedure to replace the upper paper guide.
1
Remove 2 screws and rear support
2
Remove 2 screws and front support
1
Remove 4 screws
3
Release the guide
from the 4 locating
features and remove
2
Remove 2 screws
July 2005
Repairs/Adjustments
REP 11.9-170 HCSS BM Upper Diverter Gate and Solenoid
Removal
WARNING
WARNING
1. Remove the top cover, rear cover, front door, upper left cover and front infill cover, REP
11.1-170.
2. Remove the diverter solenoid cover, one screw.
4. Figure 1, prepare to remove the diverter gate.
3
Remove two bearings.
shaft.
2
Remove the two
E clips. One at
each end of the
shaft.
1
Remove 2 screws, dis-
connect the harness
and remove the sole-
noid
July 2005
Repairs/Adjustments
Figure 2 Diverter gate removal
Replacement
Reverse the removal procedure to install the diverter gate.
REP 11.10-170 Chad Bin Full Sensor, Actuator and Spring
Removal
WARNING
WARNING
1. Remove the chad bin.
2. Separate the HCSS BM from the machine, REP 11.13-170.
3. Remove the HCSS BM top cover, rear cover, upper left cover, front door and front infill
cover, REP 11.1-170.
4. Remove the front left cover, PL 11.30 Item 3.
5. Figure 1, remove the cover.
6. Figure 2, remove the screws securing the docking bracket and the chad bin support.
3
Carefully bend the centre of the diverter gate upwards and
remove
2
Push the diverter gate fully to
the rear
1
Carefully push the
lever past the shaft
to rest against the
inner baffle
2
Gently bend the cover to
release the dowels
1
Remove two
screws
July 2005
Repairs/Adjustments
Figure 2 Preparation for bracket removal
7. Remove the chad bin support.
Figure 3 Chad bin support removal
8. Figure 4, Remove the chad bin sensor and/or actuator.
Remove eight
screws.
1
Lift the docking bracket to
release the hooks
2
Lift the support to release the
hooks
July 2005
Repairs/Adjustments
Figure 4 Sensor/actuator removal
Replacement
Reverse the removal procedure to replace the chad bin sensor actuator and/or sensor.
NOTE: Ensure that the spring below the actuator is correctly located on the raised sections of
the actuator and chad bin support.
REP 11.11-170 Transport Motor 1A, Motor Damper and
Drive Belt
Removal
WARNING
WARNING
1
Press the actuator pivots through the chad bin
support
3
Disconnect the
harness from
the sensor
4
Release the legs of the
sensor and remove
2
Remove the actuator
and spring
Loosen the belt tensioner
screw, fully loosen the
belt, then tighten the
screw
July 2005
Repairs/Adjustments
Replacement
REP 11.12-170 Transport Motor 1B Motor Damper and
Drive Belt
Removal
WARNING
WARNING
1
Loosen two
screws on
the motor
bracket
2
Slide the
motor bracket
off the screws
3
Remove the
belt
Loosen the belt tensioner
screw, fully loosen the belt,
then tighten the screw.
July 2005
Repairs/Adjustments
4. Disconnect the motor harness if necessary
5. Remove 2 screws to remove the motor from the motor damper
Replacement
REP 11.13-170 HCSS BM Un-Docking
Removal
WARNING
WARNING
CAUTION
Do not show the customer how to un-dock the HCSS BM.
1. Release the jam clearance latch and fully open the gap between the machine and the
HCSS BM.
2. Figure 1, release the docking latch and move the HCSS BM away from the machine
2
Remove
the pulley
1
Remove
the K-L clip
5
Remove the
drive belt from
the pulleys
3
Loosen two
screws on the
motor bracket
4
Slide the motor
and bracket off
the screws
July 2005
Repairs/Adjustments
Figure 1 Docking latch location
3. Disconnect the harnesses between the machine and the HCSS BM if necessary.
Replacement
Reverse the removal procedure to replace the HCSS BM.
REP 11.14-170 BM Lower Diverter Solenoid
Removal
WARNING
WARNING
2. Figure 1, prepare to remove the lower diverter solenoid.
1
Feel under the docking latch
bracket and release the docking
latch lever by pulling it forward
2
Move the HCSS BM away
from the machine
July 2005
Repairs/Adjustments
Figure 1 Preparing to remove the solenoid
3. Figure 2, remove the solenoid plunger and spring.
Figure 2 Removing the plunger and spring
4. Figure 3, Remove the lower diverter solenoid.
1
Remove 2
screws
3
Remove
screw
4
Loosen
screw
2
Move motor
onto ledge
Pivot the solenoid upwards,
remove the plunger and spring
July 2005
Repairs/Adjustments
Figure 3 Removing the solenoid
Replacement
Reverse the removal procedure to replace the lower diverter solenoid.
REP 11.15-170 BM Lower Diverter Gate
Removal
WARNING
WARNING
1. Remove the top cover, rear cover and upper left cover, REP 11.1-170.
2. Remove the lower diverter solenoid, REP 11.14-170.
3. Figure 1, remove the vertical transport jam clearance door.
Figure 1 Removing the jam clearance door
4. Figure 2, remove the vertical transport baffle.
1
Ensure there is enough
slack in the harness to
move the solenoid to the
opening
2
Remove screw
3
Move the solenoid into the
opening and disconnect
the harness
1
Remove the KL-clip
2
Lift the door from the pivot holes and remove
July 2005
Repairs/Adjustments
Figure 2 Removing the baffle
Figure 3 Removing the diverter gate
Replacement
Reverse the removal procedure to replace the HCSS BM lower diverter gate.
1
Remove 4 screws
2
Remove the baffle
1
Remove 2 E-clips and 2 bearings
2
Remove the diverter gate
July 2005
Repairs/Adjustments
REP 11.16-170 BM Flapper and Flapper Roll Motor
Purpose
BM flapper, PL 11.80 Item 23.
BM flapper roll motor, PL 11.80 Item 28.
BM flapper roll home sensor, PL 11.80 Item 12.
Removal
WARNING
WARNING
1. Open the HCSS BM front door and fully pull out the BM module.
2. Figure 1, remove the BM flapper assembly.
Figure 1 Remove the BM flapper assembly
3. Figure 2, remove the BM flapper.
2
Disconnect PJ565 from the BM flapper roll
motor and PJ 587 from the BM flapper roll
home sensor.
3
Remove the BM flapper assembly.
1
Remove 4 screws and 2
ground wires.
July 2005
Repairs/Adjustments
Figure 2 BM flapper removal
4. Figure 3, remove the BM flapper roll motor and the BM flapper roll home sensor.
Figure 3 BM flapper removal
Replacement
REP 11.17-170 BM PWB
Removal
WARNING
WARNING
2. Figure 1, Remove the BM PWB.
1
Remove the E-clip and the
bearing.
2
Remove the
E-clip and the
bearing.
3
Remove the BM flapper.
2
Remove 2 screws and
the ground harness.
3
Remove the BM flapper roll motor.
Remove the worm gear.
1
Release the BM flapper
roll home sensor.
July 2005
Repairs/Adjustments
Figure 1 PWB removal
Replacement
CAUTION
Figure 1, ensure the BM harness and bin 2 harness are correctly positioned in the harness
retainers so that harnesses are not damaged when the BM is moved to the extremities of its
travel.
Reverse the removal procedures to replace the BM PWB.
1
Disconnect all PJs
3
If necessary, release harnesses
from the retainers to allow the
PWB to be removed
2
Remove 8 screws and
remove the PWB
BM harnesses
Harness retainers
Bin 2 harness
July 2005
Repairs/Adjustments
REP 11.18-170 BM Crease Blade Motor
Purpose
BM crease blade motor encoder sensor, PL 11.84 Item 1.
BM crease blade motor, PL 11.84 Item 3.
Motor encoder, PL 11.84 Item 4.
Bearing, PL 11.84 Item 7.
Crank, PL 11.84 Item 8.
Removal
WARNING
WARNING
2. Remove the crease blade knob (6d), PL 11.80 Item 4.
3. Remove the crease roll handle (6c), PL 11.80 Item 5.
4. Remove the BM front cover, PL 11.80 Item 3.
5. Remove the left frame plate, PL 11.82 Item 2.
6. Remove the motor cover, PL 11.84 Item 11. It is easier to remove the screw using an
open ended spanner, this means the removal of the BM PWB is not necessary.
7. Figure 1, remove the BM crease blade motor assembly.
July 2005
Repairs/Adjustments
Figure 1 Removing the motor assembly
8. Figure 2, remove the BM crease blade motor.
1
Remove 4 screws
2
Remove E-clip and bearing,
release the connecting rod
3
Remove circlip, rear crank
and bearing
4
Remove E-clip and bearing, release the connecting rod
5
Remove
circlip,
front
crank
and
bearing
7
Remove the motor
assembly from the frame
6
Disconnect the
motor harness
July 2005
Repairs/Adjustments
Figure 2 Removing the motor
Replacement
Reverse the removal procedure to replace the BM crease blade motor.
NOTE: Ensure that the mark on the crease blade knob aligns with the arrow on the front infill
cover when the crease blade is fully withdrawn.
REP 11.19-170 BM Crease Roll Motor
Removal
WARNING
WARNING
2. Remove 4 screws securing the BM PWB mounting plate to the frame, allow the PWB and
mounting plate to hang down, giving access to the BM crease roll motor.
1
Support the encoder
and slide out the shaft
2
Remove the encoder
3
Remove the sensor
from the bracket
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the BM crease roll motor.
REP 11.20-170 BM Backstop Motor Assembly
Purpose
Ground wire, PL 11.82 Item 3.
Motor damper, PL 11.82 Item 5.
BM backstop motor, PL 11.82 Item 6.
BM backstop drive belt, PL 11.82 Item 20.
Removal
WARNING
WARNING
2. Figure 1, remove the BM backstop motor.
1
Remove 3
screws
2
Remove the circlip
3
Disconnect
the motor
harness
5
Pull the motor
assembly off
the shaft
4
Remove the
encoder disc
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the BM backstop motor.
NOTE: Allow the spring to tension the drive belt while the screws are still loose, then tighten
the 4 screws.
REP 11.21-170 BM Backstop Assembly and BM Stack Hold
Solenoids
Removal
WARNING
WARNING
2. Figure 1, remove the belt clamp.
Figure 1 Belt clamp removal
2
Remove
4 screws
1
Remove
allen key
and spring
4
Free the motor pulley from the belt
and lift out the motor assembly
3
Disconnect the
motor harness
6
Remove 2 screws to release the motor
from the bracket, remove 2 screws to
remove the motor and ground wire from
the damper
5
Remove the belt
2
If necessary move the
backstop assembly by
hand to align with the
cutout.
3
Remove 2
screws
4
Remove the
belt clamp
1
Remove the allen
key from the storage
position
July 2005
Repairs/Adjustments
3. Figure 2, remove the backstop shaft.
Figure 2 Backstop shaft removal
4. Figure 3, remove the BM backstop assembly.
Figure 3 Backstop removal
5. Figure 4, remove the BM stack hold solenoids
1
Remove 2 allen screws
2
Remove the shaft support
3
Lower the shaft
through the backstop
assembly, tilt the
assembly to one side
and remove the shaft
upwards
1
Cut cable tie
and disconnect
harness
2
Cut cable tie
and disconnect
harness
3
Move the backstop
assembly to the centre
of the belt span
4
Rotate the backstop
assembly and remove
from behind the belt
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the BM backstop assembly.
NOTE: Return the allen key to the storage position inside the spring.
REP 11.22-170 BM Entry Roll
Purpose
BM entry roll pulley, PL 11.80 Item 14.
BM entry roll, PL 11.80 Item 15.
Removal
WARNING
WARNING
5. Figure 1, remove the BM Entry Roll.
1
Remove the nut and solenoid
2
Remove the nut and solenoid
July 2005
Repairs/Adjustments
Figure 1 Roll removal
Replacement
Reverse the removal procedure to replace the BM entry roll.
NOTE: Tension the drive belt by loosening then tightening the screw, Figure 1.
1
Remove E-clip, bearing,
pulley and belt.
2
Remove E-clip and
bearing.
3
Remove the
entry roll.
July 2005
Repairs/Adjustments
REP 11.23-170 BM Entry Sensor
Removal
WARNING
WARNING
5. Figure 1, remove the BM entry sensor.
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the BM entry sensor.
1
Remove 2 screws
3
Disconnect the
sensor harness
4
Remove the baffle
2
Remove 2 screws
5
Peel off the mylar strip
from between the legs of
the sensor and remove
the sensor.
July 2005
Repairs/Adjustments
REP 11.24-170 BM Crease Roll Gate Motor
Removal
WARNING
WARNING
2. Fully pull out the BM module.
3. Figure 1, remove the motor assembly
4. Remove 3 nuts to release the motor from the bracket.
Replacement
Reverse the removal procedure to replace the BM crease roll gate motor.
REP 11.25-170 BM Paper Path Transport Motor and
Damper
Removal
WARNING
WARNING
4. Remove 2 screws to remove the motor from the bracket.
5. Remove 2 screws to remove the motor from the damper.
Replacement
Reverse the removal procedure to replace the BM paper path transport motor.
1
Remove E-clip
and pulley
2
Cut tie-wraps
4
Disconnect the
motor harness
3
Remove 2
screws
5
Remove
the motor
assembly
1
2
Remove 2
screws
3
Remove the
motor assembly
July 2005
Repairs/Adjustments
REP 11.26-170 Back Stop Drive Assembly
Purpose
BM backstop link springs, PL 11.82 Item 8.
BM backstop link, PL 11.82 Item 9.
BM backstop drive shaft, PL 11.82 Item 18.
BM backstop belt, PL 11.82 Item 19.
BM back stop bearing, PL 11.82 Item 22.
BM back stop idler bracket, PL 11.82 Item 23.
Removal
WARNING
WARNING
5. Remove the LH frame plate, PL 11.82 Item 2.
6. Remove the BM tamper assembly, REP 11.30-170.
7. Remove the backstop motor assembly, REP 11.20-170.
8. Remove the backstop assembly, REP 11.21-170.
9. Remove the crease blade assembly, REP 11.36-170.
10. Figure 1, remove the BM backstop drive shaft and bearings.
Figure 1 Drive shaft removal
11. Figure 2, remove the backstop link.
2
Remove KL-clip
and pulley
1
Remove E-clip
and bearing
3
Remove KL-clip
and bearing
4
Remove the
drive shaft
July 2005
Repairs/Adjustments
Figure 2 Backstop link removal
12. Figure 3, remove the BM backstop idler bracket assembly.
Figure 3 Idler bracket assembly removal
13. Figure 4, remove the BM backstop belt.
1
Press down on the link and
release the front tensioner link
2
Press down on the link and
release the rear tensioner link
3
Remove the link
and two springs
1
Remove 2 screws
2
Remove the bracket
assembly and belt
July 2005
Repairs/Adjustments
Figure 4 Backstop belt removal
Replacement
Reverse the removal procedure to replace the removed components. Allow the BM backstop
belt to be tensioned correctly before the bracket assembly securing screws are tightened.
Refer to Figure 3.
REP 11.27-170 BM Staple Heads
Removal
WARNING
WARNING
2. Remove the relevant staple head cover, PL 11.88 Item 14.
3. Pull the stapler bracket handle, PL 11.88 Item 9. Open the staplers fully.
4. Figure 1, remove a staple head.
1
Remove KL-clip, tensioner
link and bearing
2
Slide the shaft
to one side
3
Remove the belt
July 2005
Repairs/Adjustments
Replacement
1. Reverse the removal procedure to replace the BM staple heads.
2. Perform ADJ 11.3-170, Stapler Anvil Alignment.
1
Remove 2 screws
using a 5.5mm
socket and
ratchet driver
2
Loosen 1 screw
using a 5.5mm
socket and ratchet
driver
3
Using a 5.5mm socket
and short extension fully
loosen the screw until the
staple head is released.
Leave the socket and
extension in position on
the screw
4
Disconnect the
stapler harness
and remove the
stapler
July 2005
Repairs/Adjustments
REP 11.28-170 BM Stapler Bracket Assembly
Purpose
This procedure is used to repair the following parts:
Front follower, PL 11.88 Item 1.
Actuator, PL 11.88 Item 2.
Rear follower, PL 11.88 Item 3.
Spring, PL 11.88 Item 4.
BM paper present sensor Q11-190, PL 11.88 Item 5.
Latch slide, PL 11.88 Item 6.
Staple bracket handle, PL 11.88 Item 9.
Stapler bracket assembly, PL 11.88 Item 10.
Torsion spring, PL 11.88 Item 11.
Bearing, PL 11.88 Item 12.
Spring, PL 11.88 Item 13.
BM stapler head carrier closed sensor Q11-421, PL 11.88 Item 18.
Lower shaft, PL 11.88 Item 19.
Upper shaft, PL 11.88 Item 20.
Removal
WARNING
WARNING
mounting plate to hang down, giving access to the BM staple head carrier closed sensor.
3. Figure 1, remove the BM staple head carrier closed sensor actuator.
Figure 1 Actuator removal
4. Temporarily attach the PWB mounting plate using only the top two screws.
9. Remove both staple head covers, PL 11.88 Item 14.
10. Figure 2, lower the stapler bracket.
1
Remove the
sensor
2
Remove
the KL-clip
3
Remove the
actuator
July 2005
Repairs/Adjustments
Figure 2 Lowering stapler bracket
11. Figure 3, remove the latch shaft.
1
Release the rear follower
from the slot using a
screwdriver
2
Pull the stapler bracket
handle to open the staplers
fully
July 2005
Repairs/Adjustments
Figure 3 Latch shaft removal
12. Figure 4, prepare to remove the BM stapler bracket assembly.
1
Remove KL-clip and pull shaft forward
50 mm (2 inches)
3
Compress the spring, remove
the rear follower and spring
2
Remove 2 E-clips
and the front follower
4
Push the shaft to the rear
to release the latch slide
5
Pull the shaft completely
to the rear to remove
July 2005
Repairs/Adjustments
13. Figure 5, remove the BM stapler bracket assembly.
1
Remove KL-clip
4
Release the spring
from the side frame
3
Remove 2 E-clips
6
Disconnect harnesses
and ground wire
5
Remove E-clip
2
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the BM stapler bracket assembly and components.
REP 11.29-170 BM Conveyor Belts
Removal
WARNING
WARNING
NOTE: The removal procedure illustrates how to remove the rear conveyor belt. The proce-
dure for the front conveyor belt is similar.
1. Remove bin 2 by disconnecting the harness, removing the thumb screw. then lift the bin
upwards to release.
2. Remove the BM bin 2 extension by aligning the pivot pins with the cutouts and snapping
the extension out of engagement.
3. Turn over bin 2 and remove the base pan, 3 screws.
4. Remove the BM bin 2 connector from the base pan, 1 screw.
5. Figure 1, remove the idler roller.
2
Remove the
bracket
assembly
from the front
1
Lever out
the bearing
using a
screwdriver
July 2005
Repairs/Adjustments
Figure 1 Idler roller removal
6. Figure 2, remove the BM conveyor belt.
Replacement
Reverse the removal procedure to replace the BM conveyor belts.
1
Remove E-clip
2
Push out shaft and
remove one bearing
3
Push the other bearing
though the frame to
remove the idler roller
1
Release belt from the drive pulley
2
Feed the belt through the cut-out to remove
July 2005
Repairs/Adjustments
REP 11.30-170 BM Tamper Assembly and Tamper 1 Motor
Purpose
BM tamper 1 motor, PL 11.81 Item 3.
BM rear tamper arm, PL 11.81 Item 5.
BM front tamper arm, PL 11.81 Item 6.
BM rear tamper rack, PL 11.81 Item 7.
BM front tamper rack, PL 11.81 Item 8.
BM rear tamper assembly, PL 11.81 Item 9.
BM front tamper assembly, PL 11.81 Item 10.
BM tamper gear, PL 11.81 Item 11.
BM tamper bracket, PL 11.81 Item 12.
BM tamper rack guide, PL 11.81 Item 13.
BM tamper guide plate, PL 11.81 Item 15.
BM rear tamper finger, PL 11.81 Item 16.
BM front tamper finger, PL 11.81 Item 17.
Removal
WARNING
WARNING
5. Remove the left frame plate, PL 11.82 Item 2.
Figure 1 Tamper assembly removal
7. Figure 2, remove the front and rear tamper assemblies. Also remove the tamper gear and
tamper motor.
3
Remove 2 screws
1
Remove the cover and
4
Remove 2 screws
and earth connector
6
Move the tampers to align with the
slots to release each tamper from
the slot
7
Remove the tamper
assembly
2
If necessary, remove 2
screws to remove the
motor
5
Remove 2 screws
July 2005
Repairs/Adjustments
Figure 2 Dismantling the tamper assembly
8. Figure 3, remove the tamper guide plate from each of the tamper assemblies.
Figure 3 Guide plate removal
Replacement
1. If the tamper racks were removed from the BM tamper rack guide, perform the following:
a. Align the guide tabs on both tamper racks with the slots in the BM tamper rack guide.
Refer to Figure 2.
b. Start both tamper racks into the BM tamper rack guide at the same time. Both
tamper racks must engage with the BM tamper gear simultaneously. To check that
the front and rear tampers are correctly aligned, perform the following:
Fully push in the tampers.
The distance between the end stop on each tamper and the ends of the BM
tamper rack guide should be equal. Refer to Figure 2.
If the distances are different by more than 1mm (0.040 inches). Perform again
step B.
2. Reverse the removal procedure to replace the BM tamper assembly and tamper 1 motor.
3. Perform ADJ 11.5-170 Booklet Tamping.
1
Pull out both tamper
assemblies
4
Remove
E-clip
2
Remove
4 screws
5
Remove
the gear
6
Remove 2 screws,
remove the motor
3
Remove the BM
tamper rack guide
Guide tab
Guide tab
End stop
End
stop
1
Remove
screw and
tamper finger
2
Remove the
guide plate
July 2005
Repairs/Adjustments
REP 11.31-170 CC Ejector Motor Assembly and Ejector
Home Sensor
Removal
WARNING
WARNING
2. Figure 1, remove the compiler carriage cross member.
3. Figure 2, remove the eject housing motor assembly and home sensor.
Figure 2 Removing the motor and sensor
Replacement
Reverse the removal procedure to replace the eject housing motor assembly and home sen-
sor.
1
Remove 1
screw at either
end of the cross
member
2
Bend open the frame to release the
cross member from the locating dowels
3
Release the
connecting rod
from the
crankshaft
1
Release the harness from the retainers
and disconnect at the motor and sensor
2
Remove screw
3
Slide motor assembly
across and remove
4
Release the sensor
from the bracket using
a small screwdriver
July 2005
Repairs/Adjustments
REP 11.32-170 CC Paddle Roll Motor Assembly and Paddle
Roll Home Sensor
Removal
WARNING
WARNING
CAUTION
Do not loose the white plastic worm on the end of the motor spindle. It is a slide fit on the motor
spindle.
3. Remove the motor, if necessary, by removing the remaining screw.
1
Remove 2
screws
2
Lift the motor assembly and disengage the worm from
the bearing
3
Remove screw
and ground wire
4
Disconnect motor
harness and sensor
harness
Drive lugs
Bearing
Worm
July 2005
Repairs/Adjustments
4. Remove the sensor, if necessary, by releasing the sensor legs.
Replacement
1. If necessary, install the sensor and/or motor in the bracket.
2. Reconnect the ground wire and harnesses.
3. Ensure that the white plastic worm is fully located on the drive lugs of the motor.
4. Locate the motor assembly, ensuring that the nose of the white plastic worm is located in
the bearing in the frame, install the two securing screws.
5. Reinstall the top cover.
REP 11.33-170 CC Top Baffle Assembly
Purpose
Carriage top baffle, PL 11.73 Item 12.
Carriage top baffle return spring, PL 11.73 Item 13.
Top baffle idler assembly, PL 11.73 Item 14.
Top baffle idler spring, PL 11.73 Item 15.
Removal
WARNING
WARNING
2. Figure 1, remove the top baffle assembly
July 2005
Repairs/Adjustments
Figure 1 Removing the top baffle assembly
NOTE: If only new idlers and springs are being installed, it is easier to leave the spring con-
nected.
3. Figure 2, if required, remove the idlers and springs from the baffle.
Figure 2 Removing the idlers and springs
Replacement
Reverse the removal procedure to replace the top baffle assembly and components.
2
Carefully lever the baffle pivot out of the
frame using a flat bladed screwdriver
1
Loosen 2 screws,
2 turns each
3
Release the spring from
the baffle (see note)
1
Press down on the idler
2
Slide the idler from under the hooks
3
Hold the spring with a
small screwdriver,
remove the idler and
spring
July 2005
Repairs/Adjustments
REP 11.34-170 Compiler Sensor
Removal
WARNING
WARNING
2. Figure 1, improve the access to the area
1
Remove the
harness cover
2
using adhesive tape.
1
Remove 2
screws
2
3
Remove the
cover
July 2005
Repairs/Adjustments
4. Release the sensor lugs from the mounting using a small screwdriver and disconnect the
sensor from the harness.
Replacement
Reverse the removal procedure to replace the compiler carriage entry sensor. Ensure the har-
ness cover removed in Figure 1, is correctly installed so that it does not interfere with jam clear-
ance latch 5d.
REP 11.35-170 CC Entrance Baffle and Springs
Removal
WARNING
WARNING
1. Remove the compiler carriage entry sensor, REP 11.34-170.
2. Refer to REP 11.4-170, remove the carriage PWB from its mounting but do not disconnect
any PJs from the PWB.
3. Figure 1, remove the CC entrance baffle.
July 2005
Repairs/Adjustments
Figure 1 Removing the entrance baffle
Replacement
Reverse the removal procedure to replace the CC entrance baffle.
REP 11.36-170 Crease Blade Assembly
Purpose
Connecting rod, PL 11.84 Item 9.
Crease blade assembly, PL 11.84 Item 13.
Crease blade support guide, PL 11.84 Item 14.
Removal
WARNING
WARNING
5. Figure 1, remove the crease blade.
1
Remove 2
springs
3
4
Remove 4 screws
5
Remove the baffle
2
Unhook spring
July 2005
Repairs/Adjustments
Figure 1 Crease blade removal
6. Figure 2, remove the front blade support.
Figure 2 Front support removal
7. Figure 3, remove the rear blade support.
2
Remove 4 screws
3
Manoeuvre the blade out from
under the front and rear supports
1
Remove 2
screws
1
Remove E-clip
2
Release the front
connecting rod
and bearing
3
Remove E-clip
4
Remove front
blade support
July 2005
Repairs/Adjustments
Figure 3 Rear support removal
CAUTION
Do not loosen the three red screws that surround the lower support guides
8. Figure 4, remove the support guides (4 places).
Figure 4 Support guide removal
Replacement
Reverse the removal procedure to replace the crease blade assembly
1
Remove E-clip
3
Remove E-clip
2
Release the rear
connecting rod
and bearing
4
Remove rear
blade support
1
Depress the centre
of the guide
2
Pull the guide outward to remove
Red screws -
see caution
July 2005
Repairs/Adjustments
REP 11.37-170 CC Stapling Unit Traverse Motor
Removal
WARNING
WARNING
2. Figure 1, remove the stapling unit traverse motor.
Replacement
Reverse the removal procedure to replace the stapling unit traverse motor.
NOTE: Ensure that the ground connector, Figure 1, is trapped between the motor flange and
the compiler frame.
1
Remove 2 screws
2
Remove
the motor
Ground
connector
July 2005
Repairs/Adjustments
REP 11.38-170 Transport Motor 2 and Motor Damper
Removal
WARNING
WARNING
2. Figure 1, remove transport motor 2.
3. Remove 2 nuts to separate the motor damper from the motor.
Replacement
1. Reverse the removal procedure to replace transport motor 2.
2. Ensure that the ground connector is secured with the lower motor screw, Figure 1.
3. Loosen the tensioner screw, allow the spring to tension the belt, then tighten the tensioner
screw, Figure 1.
1
Loosen screw,
move tensioner
fully upward,
tighten screw
2
Remove 3 nuts
3
Remove the motor
Ground
connector
July 2005
Repairs/Adjustments
REP 11.39-170 CC Eject Roll Motor
Removal
WARNING
WARNING
2. Figure 1, remove the CC eject roll motor.
Replacement
1. Reverse the removal procedure to replace the CC eject roll motor.
2. Ensure that the ground connector is secured with the lower motor nut, Figure 1.
1
Remove E-clip,
pulley and belt
2
Remove 3 nuts
3
Remove the motor
Ground
connector
July 2005
Repairs/Adjustments
REP 11.40-170 CC Kicker Assembly
Purpose
Kicker solenoid, PL 11.75 Item 4.
Compiler carriage bin height sensor, PL 11.75 Item 5.
Compiler sensor 90% full sensor, PL 11.75 Item 5.
Return spring, PL 11.75 Item 16.
Kicker fingers, PL 11.75 Item 19.
Removal
WARNING
WARNING
2. Remove the rear tamper drive belt by pushing the belt from the motor pulley where there
is no flange.
3. Figure 1, remove the kicker assembly.
July 2005
Repairs/Adjustments
Figure 1 Removal
4. Figure 2, dismantle the components of the kicker assembly as necessary.
2
connector and 3 har-
nesses
3
Remove screw
4
Pivot the assembly to improve access
5
Remove the E-clip,
slide the tamper
shaft to the rear
6
Remove the assembly, being
careful not to damage the kicker
fingers
1
Remove screw
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the kicker assembly components.
REP 11.41-170 CC Tray Hold Solenoid Assembly
Removal
WARNING
WARNING
2. Figure 1, remove the tray hold solenoid.
Remove 2 screws to remove the solenoid,
release the spring from the solenoid plunger
Release the
legs to remove
a sensor
Carefully spring the frame
apart to remove the kicker
fingers and return spring
July 2005
Repairs/Adjustments
Replacement
CAUTION
Ensure the short and long screw are installed in the correct location, Figure 1.
Reverse the removal procedure to replace the tray hold solenoid assembly.
NOTE: Ensure that the solenoid is positioned on the locating dowels.
1
Disconnect harness
2
Remove 2 screws
Long screw with earth tag
Short screw
3
Remove solenoid and linkage
July 2005
Repairs/Adjustments
REP 11.42-170 CC Stapler Mount and Traverse Shaft
Assembly
Removal
WARNING
WARNING
2. Remove the staple head assembly, REP 11.3-170.
3. Remove the stapling unit traverse motor, REP 11.38-170.
4. Figure 1, remove the stapler mount and traverse shaft assembly.
July 2005
Repairs/Adjustments
5. Unscrew the traverse shaft from the stapler mount.
Replacement
Reverse the removal procedure to replace the stapler mount and traverse shaft assembly.
1
Remove screw and
slide out shaft
2
Remove E-clip, gear and
bearing
3
4
Slide out the stapler
mount and traverse
shaft assembly
July 2005
Repairs/Adjustments
REP 11.43-170 CC Transport Shaft Assembly
Purpose
This procedure is used to repair the following components.
Transport shaft, PL 11.75 Item 8.
Transport shaft pulley, PL 11.75 Item 9.
Guide roller, PL 11.75 Item 11.
Compiler belt, PL 11.75 Item 12.
Feed chute, PL 11.75 Item 13.
Removal
WARNING
WARNING
1. Remove transport motor 2, REP 11.38-170.
2. Figure 1, prepare to remove the transport shaft assembly.
3. Figure 2, Remove the transport shaft assembly.
1
2
Remove 2 E-clips, pulley
and bearing
July 2005
Repairs/Adjustments
Figure 2 Removal
4. Figure 3, dismantle the components of the transport shaft assembly.
Replacement
Reverse the removal procedure to replace the transport shaft assembly and components.
2
Remove 3
screws
1
Ensure stapler unit
is fully to the front
3
Hold the compiler tray down and
slide the transport shaft assembly
rearwards as far as possible
4
Pull the front of the shaft
past the stapler and
remove the assembly
1
Slide out the transport shaft
2
Wrap the belt
around the roller
and press the
roller out and
remove (2 places)
July 2005
Repairs/Adjustments
REP 11.44-170 Docking Latch Components
Purpose
This procedure is used to repair the following components
Docking Release latch, PL 11.64 Item 13.
Release bracket, PL 11.64 Item 11.
Docking interlock switch (S11-300A), PL 11.64 Item 3.
Docking pivot interlock switch (S11-300B), PL 11.64 Item 5.
Restraining cable, PL 11.64 Item 1.
Removal
WARNING
WARNING
1. Un-dock the HCSS from the machine, REP 11.13-170.
2. Figure 1, release the restraining cable.
Figure 1 Restraining cable
3. Figure 2, remove the docking latch bracket rear cover.
1
Release the latch, open
the bracket fully
3
If a new restraining
cable is being installed,
remove screw
4
Open the bracket as
far as possible
2
Remove screw
July 2005
Repairs/Adjustments
4. Figure 3, Remove the release bracket.
Figure 3 Release bracket
5. Figure 4, if necessary, remove the docking release latches.
1
Remove 2 screws
2
Release 2 dowels
from the holes
3
Remove
the cover
1
Snap the lower fitting
apart (2 places)
2
Twist the bracket
counterclockwise
and lift off the top
dowel (2 places)
3
Disconnect the spring
and remove the bracket
Top dowel in two
places
July 2005
Repairs/Adjustments
Figure 4 Latch removal
6. Figure 5, if necessary, remove the docking interlock switch or the docking pivot interlock
switch.
Figure 5 Switches removal
Replacement
Reverse the removal procedure to replace the removed components.
1
Remove E-clip
(2 places)
2
Push out the
pin (2 places)
using a small
screwdriver
3
Remove the
latch (2 places)
and press together the
catches to remove the
docking interlock switch
remove 2 screws to remove the
docking pivot interlock switch
July 2005
Repairs/Adjustments
REP 11.45-170 Compiler Carriage Belt Grips
Removal
WARNING
WARNING
2. Figure 1, remove the compiler carriage belt grips.
Figure 1 Removing grips
Replacement
Reverse the removal procedure to replace the compiler carriage belt grips.
1
Remove 3 screws and the
front grip
2
Remove 3 screws
3
Cut the cable tie and
remove the rear grip
July 2005
Repairs/Adjustments
REP 11.46-170 Bin 1 Offset Motor and Offset Sensor
Removal
WARNING
WARNING
1. Remove the bin 1 assembly by disconnecting the harness, removing the thumbscrew and
pulling the tray assembly off the support.
2. Figure 1, remove the bin lower support.
Figure 1 Support removal
3. Figure 2, remove the bin offset sensor and bin offset motor.
Figure 2 Component removal
Replacement
Reverse the removal procedure to replace the bin 1 offset motor and offset sensor.
NOTE: Ensure the peg of the gear/crank locates in the slot of the tray.
1
Remove 4 screws
2
Remove the bin lower support
1
Pinch the sensor legs together, remove
the sensor and disconnect the harness
2
Remove E-clip
and gear/crank
3
Remove E-clip
and gear
4
Remove 2 screws
and motor
5
Disconnect the
motor harness
July 2005
Repairs/Adjustments
REP 11.47-170 Bin 1 Elevator Motor and Bearing
Removal
WARNING
WARNING
1. Remove the bin 1 assembly by disconnecting the harness, removing the thumbscrew and
pulling the tray assembly off the support.
3. Figure 1, remove the elevator motor.
NOTE: The elevator motor worm and gears are greased, take care not to contaminate
other parts of the machine with the grease. Wear protective gloves if desired.
Replacement
Reverse the removal procedure to replace the bin 1 elevator motor.
1
Remove E-clip
and gear
2
Remove E-clip
and bearing
3
Remove 2
screws, slide
the motor down
4
Disconnect the
harness and
remove the motor
July 2005
Repairs/Adjustments
REP 11.48-170 Entry Sensor and Punch Position Sensor
Removal
WARNING
WARNING
1. Remove the rear cover and upper left cover, REP 11.1-170.
2. Remove the hole punch unit, if installed.
3. Remove the lower left cover, PL 11.60 Item 23.
5. Figure 1, remove the sensor.
Replacement
Reverse the removal procedure to replace the entry sensor and punch position sensor.
1
Remove
3 screws
2
Move the front of the tie bar to
the right and release the rear
from the dowels
3
Rotate the assembly
to access the screws
4
Remove screw and sensor,
July 2005
Repairs/Adjustments
REP 11.49-170 2nd to Top Exit Sensor
Removal
WARNING
WARNING
1. Remove the HCSS top cover, REP 11.1-170.
2. Fold bin 0 to the left to give access to the top of the compiler carriage.
3. Figure 1, remove the 2nd to top exit sensor.
Replacement
Reverse the removal procedure to replace the 2nd to top exit sensor.
1
Remove screw and
securing block
2
Release the sensor legs
using a small screwdriver
3
and remove the sensor
July 2005
Repairs/Adjustments
REP 11.50-170 BM Eject Sensor
Removal
WARNING
WARNING
1. Remove the BM right hand cover, REP 11.56-170.
2. Remove the upper exit brush (3 screws), PL 11.88 Item 16.
3. Figure 1, remove the BM eject sensor.
Replacement
Reverse the removal procedure to replace the BM eject sensor.
REP 11.51-170 BM Support Leg and Spring
Removal
WARNING
WARNING
1. Remove the BM, front door, front cover and rear cover, REP 11.1-130.
2. Figure 1, remove screws from the rear.
4. Support the weight of the BM on a stack of paper approximately 2 reams high. Add or
remove paper from the stack to ensure that the stack supports the right side of the BM
module.
5. Figure 2, prepare to remove the right hand support rail.
1
Remove screw,
slide out sensor
2
Disconnect
the harness
and remove
the sensor
1
Remove 2 screws
July 2005
Repairs/Adjustments
6. Figure 3, remove the right hand support rail.
Figure 3 Rail removal
7. Figure 4, remove the BM support leg and spring.
1
Remove 4
screws
2
Remove
2 screws
1
Push the rail to the rear
to release the dowels
2
Rotate the rail clockwise to give access
to the inner base of the BM module
July 2005
Repairs/Adjustments
Figure 4 Leg and spring removal
Replacement
1. Install the support leg, spring and pin.
2. Figure 5, align the pin to accept the E-clip.
Figure 5 Pin alignment
3. Figure 6, insert the E-clip.
1
Remove the E-clip
using a small flat
screwdriver
2
Slide out the pin
3
Remove the support
leg and spring
1
Insert a small screw-
driver into the E-clip
groove
2
Slide the pin using the
screwdriver, so that the
screwdriver touches the
frame
3
Carefully remove
the screwdriver
July 2005
Repairs/Adjustments
Figure 6 E-clip insertion
4. Install the remainder of the removed components by reversing the removal procedure.
NOTE: Ensure that the 4 screws removed in step 1 of Figure 5 are tightened in exactly
the original position, by carefully aligning the screw head with the witness marks on the
frame.
REP 11.52-170 BM Crease Rolls, Gears, Clutch and
Bearings
Removal
WARNING
WARNING
2. Release the crease roll nip pressure by fully rotating the crease roll handle (6c) counter-
clockwise.
7. Remove the BM crease roll motor, REP 11.19-170, but do not disconnect the motor har-
ness or remove the motor from the mounting plate.
8. Figure 1, remove the rear bearings.
1
Attach the E-clip to
the tip of a magnetic
screwdriver
2
Slide the screwdriver and
E-clip along the frame.
Snap the E-clip into the
groove
July 2005
Repairs/Adjustments
Figure 1 Rear bearing removal
9. Temporarily attach the BM crease roll motor using only the top screw.
10. Temporarily attach the PWB mounting plate using only the top two screws.
12. Figure 2, prepare to remove the upper crease roll.
13. Figure 3, remove the upper crease roll.
1
Remove 2 circlips.
2
Remove 2 bearings.
1
Remove the circlip.
2
Remove the upper
crease roll gear.
3
Remove the upper
crease roll bearing.
July 2005
Repairs/Adjustments
Figure 3 Upper crease roll removal
14. Figure 4, remove the lower crease roll and clutch assembly.
Figure 4 Lower crease roll and clutch assembly removal
1
Slide the upper crease
roll to the rear, remove
from the front.
1
Pull the lower crease roll and
clutch assembly to the front to
release the bearing.
2
Slide the front of the lower
crease roll and clutch assem-
bly out of the slot.
3
Remove the lower crease roll
and clutch assembly.
July 2005
Repairs/Adjustments
Replacement
CAUTION
Do not remove the crease roll and clutch assembly if they are secure on the shaft.
1. Install the lower crease roll and clutch assembly and bearings.
2. Check if the lower crease roll gear and clutch assembly are secure on the shaft. If the
lower crease roll gear and clutch assembly wobble, perform the following:
a. Figure 5, remove the clutch.
Figure 5 Clutch removal
b. Figure 6, carefully identify the lower crease roll gear and clutch assembly compo-
nents. Reassemble the components on the lower crease roll shaft in sequence from
1 to 12. Ensure the following points are followed:
Components are orientated correctly as shown in Figure 6.
The shallow grooves in the bore of the gear face towards the rear and mate
with the teeth of the clutch plate installed on the shaft.
The deep grooves in the bore of the gear face towards the front and mate with
the teeth of the clutch plates subsequently installed on the shaft.
The spring retainer is installed over the end the shaft.
1
the retainer.
2
Remove the 9 nine
clutch plates and the
lower crease roll gear.
July 2005
Repairs/Adjustments
Figure 6 Clutch components
c. Figure 7, Ensure that the tabs of the outermost gear keyed clutch plate are not out-
side of the grooves in the gear.
Lower crease roll shaft
Bearing
Shaft keyed clutch
plate
Gear keyed clutch
plate
Shaft keyed clutch
plate
Gear keyed clutch
plate
Lower crease roll gear
(note the orientation)
Retainer (note the
orientation)
Screw
July 2005
Repairs/Adjustments
Figure 7 Outermost gear keyed clutch plate
d. Figure 8, ensure that the final shaft keyed clutch plate does not come off of the shaft
during installation.
Figure 8 Outermost gear keyed clutch plate
e. Tighten the screw on the front end of the shaft until it reaches a hard stop.
f. Check that the lower crease roll gear and clutch assembly is secure on the shaft. If
necessary, repeat steps A to D.
3. Install the remainder of the removed components by reversing the removal procedure.
Tabs
Grooves
Outermost gear
keyed clutch plate
Final shaft keyed
clutch plate
July 2005
Repairs/Adjustments
REP 11.53-170 CC Shutter and Springs
Removal
WARNING
WARNING
1. Remove the CC eject housing assembly, REP 11.57-170.
2. Figure 1, remove the CC shutter.
Figure 1 Shutter removal
Replacement
Reverse the removal procedure to replace the CC shutter.
1
Remove the
screw
2
Slide the shutter
to the front,
release the pin
from the rear
4
Un-snap the middle fixings
5
Release the pin
from the front
and remove the
shutter
3
Unhook the
springs from
the shutter
July 2005
Repairs/Adjustments
REP 11.54-170 CC Nip Shaft Components
Purpose
Removal
WARNING
WARNING
2. Figure 1, improve the access to the area.
1
Remove the harness
cover
2
using adhesive tape
July 2005
Repairs/Adjustments
4. Figure 3, remove the nip shaft, nip springs and nip rolls.
Figure 3 Nip shaft removal
Replacement
Reverse the removal procedure to replace the nip shaft, nip springs and nip rolls.
1
Remove 2 screws
2
3
Remove the
cover
1
Remove 2
springs
2
Lift out the nip shaft
with rolls
3
Slide the rolls off
the shaft
July 2005
Repairs/Adjustments
REP 11.55-170 BM Pre-compile Pulley and Tyres
Removal
WARNING
WARNING
2. Remove the drive pulley, PL 11.67 Item 2, refer to REP 11.12-170, figure 2.
3. Figure 1, remove the BM pre-compile pulley.
Figure 1 Pulley removal
4. Figure 2, remove the BM pre-compile tyres.
1
Remove E-clip
and bearing
2
Remove E-clip
and bearing
3
Push the pulley shaft to the rear and remove from the front
July 2005
Repairs/Adjustments
Figure 2 Tyre removal
Replacement
Reverse the removal procedure to replace the BM pre-compile pulley and tyres
Remove the tyres
from the pulley
July 2005
Repairs/Adjustments
REP 11.56-170 BM Right Hand Cover
Removal
WARNING
WARNING
2. Open the BM front door and fully pull out the BM module.
6. Figure 1, Prepare to remove the BM right hand cover.
July 2005
Repairs/Adjustments
7. Figure 2, remove the BM right hand cover.
1
Push the BM fully
home
2
Remove 3 screws
3
Fully pull out the
BM module
4
Remove 3 screws
July 2005
Repairs/Adjustments
Replacement
Reverse the removal procedure to replace the BM right hand cover.
REP 11.57-170 CC Eject Housing Assembly
Removal
WARNING
WARNING
2. Figure 1, remove the compiler carriage cross member
3. Figure 2, prepare to remove the CC eject housing assembly.
1
Lever the cover
free of the detents
2
Disconnect the
harness and
remove the cover
1
Remove 1 screw at
either end of the
cross member
2
Bend open the frame to
release the cross member
3
Release the connecting
rod from the crankshaft
July 2005
Repairs/Adjustments
4. Figure 3, remove the CC eject housing assembly.
1
Remove 2 screws
marked A, release
the harness clamp
3
Remove screw,
release the ground
connector
2
Disconnect
the motor
and sensor
harnesses
4
Disconnect 2 ground
terminals
5
July 2005
Repairs/Adjustments
Figure 3 Housing removal
Replacement
Reverse the removal procedure to replace the CC ejector housing assembly.
NOTE: Ensure that the front and rear pivot pins are located in the pivot holes
REP 11.58-170 BM Crease Nip Springs
Removal
WARNING
WARNING
1. Open the BM front door and fully pull out the BM.
2. Rotate the crease roll handle (6c) fully counterclockwise.
6. Figure 1, remove the front lower linkage.
1
Release the pivot pin from
the hole using a flat blade
screwdriver
2
Raise the front of the
housing carefully guiding
the CC shutter out of the
track
3
Remove the CC
ejector housing
assembly
July 2005
Repairs/Adjustments
Figure 1 Front linkage removal
7. Figure 2, remove the front spring.
Figure 2 Front spring removal
8. Remove the rear cover REP 11.1-170.
9. Fully push in the BM.
mounting plate to hang down, giving access to the rear nip spring and linkage.
11. Figure 3, remove the rear lower linkage.
1
Remove the
KL-clip
2
Slide the linkage off the shafts
3
Release the linkage from
the spring hook
1
Move the spring to the corner cutout
2
Flex the spring
slightly and slide out
of the hole
July 2005
Repairs/Adjustments
Figure 3 Rear linkage removal
12. Figure 4, remove the rear spring.
Figure 4 Rear spring removal
Replacement
Reverse the removal procedure to replace the BM crease roll nip front spring.
1
Remove the KL-clip
2
Remove the E-clip
3
Slide the linkage off
the shafts
4
Release the linkage
from the spring hook
1
Move the spring to
the corner cutout
2
Flex the spring slightly
and slide out of the hole
July 2005
Repairs/Adjustments
REP 11.59-170 Crease Roll Gate Assembly
Purpose
Crease roll gate rack gear, PL 11.87 Item 8.
Crease roll gate rack drive gear, PL 11.87 Item 13.
Crease roll gate rack, PL 11.87 Item 14.
Crease roll gate front guide, PL 11.87 Item 15.
Crease roll gate rear guide, PL 11.87 Item 16.
Crease roll gate, PL 11.87 Item 19.
Removal
WARNING
WARNING
1. Open the HCSS BM front door and fully pull out the BM.
6. Remove the crease roll gate motor, REP 11.24-170.
7. Figure 1, remove the crease roll gate rack drive gear and both crease roll gate rack gears.
Figure 1 Removing gears
8. Figure 2, Remove the front and rear crease roll gate racks.
1
Remove E-clip and 2 gears
2
Remove E-clip
and gear
July 2005
Repairs/Adjustments
Figure 2 Removing the racks
9. Figure 3, remove the crease roll gate.
Figure 3 Gate removal
10. Figure 4, remove the grease roll gate front guide.
1
Remove E-clip
and front rack
2
Remove E-clip
and rear rack
Twist the gate
to allow the
shaft to exit the
slot, then lift
out the gate
July 2005
Repairs/Adjustments
Figure 4 Front guide removal
11. Figure 5, remove the grease roll gate rear guide.
Figure 5 Rear guide removal
12. Loosen 3 screws to remove the crease roll gate shaft from the crease roll gate.
Replacement
Reverse the removal procedure to replace the crease roll gate assembly.
CAUTION
Ensure that the crease roll gate shaft is centrally located within the crease roll gate.
1
Remove two
screws
2
Remove screw
4
Remove
the guide
3
Hold the baffle
away from the
guide
1
Remove two screws
3
Hold the baffle
away from the
guide
4
Remove the
guide
2
Remove screw
July 2005
Repairs/Adjustments
REP 11.60-170 BM Paper Guide Assembly
Purpose
Paper guide, PL 11.80 Item 7.
NOTE: If only new nip components are being installed, the BM paper guide assembly
does not need to be removed.
Removal
WARNING
WARNING
1. Open the BM front door and fully pull out the BM.
2. Rotate the crease roll handle (6c) fully counterclockwise.
6. Figure 1, remove the front bearing.
Figure 1 Front bearing removal
7. Figure 2, remove the rear bearing.
1
Remove
the E-clip
2
Remove the bearing
July 2005
Repairs/Adjustments
Figure 2 Rear bearing movement
8. Figure 3, remove the BM paper guide assembly.
Figure 3 paper guide assembly removal
9. Figure 4, remove the components from the BM paper guide assembly.
1
Remove the
E-clip, then
the bearing.
1
Remove 4 screws. Discon-
nect the 2 ground harnesses.
2
Pivot the BM flapper assembly
down to rest on the crease
blade.
3
Lift out the BM paper
guide assembly.
July 2005
Repairs/Adjustments
Figure 4 Paper guide dismantling
Replacement
Reverse the removal procedure to replace the BM paper guide assembly.
REP 11.61-170 BM Module
Removal
WARNING
Mandatory safety warning. This procedure must be performed by two people. The mod-
ule is heavy.
WARNING
Do not undock the HCSSBM from the machine. The machine maintains the stability of
the HCSSBM.
WARNING
WARNING
1. Remove the BM rear cover, REP 11.1-170.
1
Release the nip
springs to
remove the nip
shaft and nip
rolls
2
Remove E-clip and
rear latch
3
Remove E-clip
and front latch
4
Carefully disengage
the spring legs from
the guide and
remove the shaft
assembly
July 2005
Repairs/Adjustments
2. Figure 1, disconnect PJ553 and PJ559 from the BM PWB.
Figure 1 Disconnect the PJs
3. Figure 2, disconnect the harness from bin 2.
Figure 2 Disconnect the harness
4. Open the BM front door, PL 11.60 Item 5.
1
PJ559.
2
Release the harness from the retainers.
1
Remove two screws.
2
Route the harness through the frame.
3
Disconnect the harness. Secure the
harness to the harness retainers.
July 2005
Repairs/Adjustments
5. Figure 3, prepare to remove the BM module.
6. Figure 4, prepare to remove the BM module.
7. Figure 5, Release the latches.
2
Make sure that the top of the paper
stack is level with the base of the BM
module.
1
Align approximately
two reams of paper
against the edge of the
HCSS BM.
1
Fully pull out the BM module.
2
Disconnect the ground har-
ness. Secure the harness to
the harness retainers.
July 2005
Repairs/Adjustments
Figure 5 Releasing the slides
WARNING
Use safe handling procedures, GP 16 when removing this module. The module is heavy.
CAUTION
Do not damage the BM front cover when the BM module is removed.
NOTE: The BM module weight is 23 Kg (50.6 lb.).
NOTE: The BM catch will spring to the rear when the BM module is removed. Refer to Figure
7.
8. Figure 6, remove the BM module.
1
Pull up the right side latch to
release the slide from the rail.
3
Push down the left side latch
to release the slide from the
rail.
2
Fully push in the slide.
4
Fully push in the
slide.
July 2005
Repairs/Adjustments
Figure 6 Remove the BM module
Replacement
CAUTION
Do not damage the harnesses when the BM module is installed. Ensure that the rails are cor-
rectly aligned with the slides.
1. Put the BM module on the paper stack in front of the HCSS BM.
2. Route the bin 2 harness and the ground harness to the rear of the HCSS BM.
3. If a new BM is to be installed, perform the following:
a. Unlatch the slides from the new BM module. Refer to Figure 5.
b. Install the new BM module onto the existing rails in the HCSS BM.
4. Figure 7, prepare to install the BM module.
1
Carefully remove the
BM module.
One person must lift the
BM module by the left side
cross member.
A second person must lift the
BM module by the booklet exit
slot.
July 2005
Repairs/Adjustments
Figure 7 Position of the catch
5. Reverse the removal procedure to replace the BM module.
CAUTION
Ensure the BM harness and bin 2 harness are correctly positioned in the harness retainers so
that harnesses are not damaged when the BM is moved to the extremities of its travel.
6. Perform the 11F-170 Booklet Quality RAP.
1
Hold the catch in the forward position.
2
Carefully push the BM module into the
HCSS BM until the catch is held under
the guide. Do not push the BM further
into HCSS BM.
Guide
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments
REP 12.1 OCT Fingers Install
Installation
WARNING
CAUTION
Do not install the OCT fingers on 65 ppm machines.
1. Remove the OCT, PL 12.10 Item 2.
CAUTION
Make sure that the OCT fingers are installed in the correct position. Each of the three fingers is
marked.
3. Install three OCT fingers on to the exit shaft assembly, Figure 1.
Figure 1 Finger install
4. Remove the fuser module (32-55 ppm) PL 10.8 Item 1 or (65-75 ppm) PL 10.10 Item 1.
5. Manually feed a sheet of A4 or 8.5 x 11 inch paper, long edge feed, through the paper
path, Figure 2.
NOTE: This is necessary to make sure that the OCT fingers are fully raised when the right
hand cover is installed.
Figure 2 Inserting paper
CAUTION
When the right cover is installed, make sure that the OCT fingers extend through the hole in
the right hand cover. Refer to Figure 3.
6. Install the right hand cover, Figure 3.
Finger 1
Finger 2
Finger 3
1
Release the jam clear-
ance handle 3d/4d.
2
Insert a sheet of paper
in to the paper path.
3
Rotate the jam clear-
ance handle 3c counter
clockwise.
July 2005
Repairs/Adjustments
Figure 3 Finger check
7. Remove the piece of paper from the paper path. Make sure that the OCT fingers fall freely
under their own weight.
8. Re-install the fuser then the OCT.
OCT fingers.
July 2005
Repairs/Adjustments

REP 14.1A Scanner (32-55 ppm)
Removal
WARNING
WARNING
1. Lock the scan carriage, Figure 1,.
3. Disconnect all harnesses that will prevent removal of the image processing PWB module,
then remove the image processing PWB module, PL 3.20 Item 1.
5. Remove the user interface, REP 2.1.
6. Remove the OCT, PL 12.10 Item 2, or perform the following:
REP 11.12-120 1K LCSS Removal.
REP 11.13-110 LCSS Undocking.
REP 11.13-170 HCSS BM Undocking.
7. Remove the left hand cover, PL 8.10 Item 3.
9. Remove the xerographic module. Put the module in a black bag.
WARNING
NOTE: The scanner weight is 16.5 kg (36lb.).
10. Figure 2. Stand at the rear of the machine and remove the scanner. Figure 1 Scan carriage locking
1
Remove the transport screw from the storage
position and lock the scan carriage.
Serial number
July 2005
Repairs/Adjustments
Figure 2 Scanner removal
Replacement
1. The replacement procedure is the reverse of the removal procedure. Observe the steps
that follow during replacement.
If a new scanner is installed, make sure that the scanner is the correct speed for the
machine. A 32 - 38 ppm scanner has a serial number that begins with 3. A 45 - 55
ppm scanner has a serial number that begins with 5. Refer to Figure 1 for the loca-
tion of the serial number.
Ensure that the receptacle on the base of the scanner is correctly installed onto the
tongue on the machine frame. Refer to Figure 2.
1
Remove 2 screws and 2 spacers
5
Remove the scanner
4
Raise the scanner and
release the harness from
beneath the scanner
3
Push the scanner towards
the rear of the machine
Tongue (2 positions)
Receptacle (2 positions)
2
Remove 1 screw and 1 spacer
July 2005
Repairs/Adjustments
REP 14.2A Exposure Lamp Inverter and Fuse (32-55 ppm)
Removal
WARNING
1. Remove the CVT glass and document glass, REP 14.6A.
2. Remove the exposure lamp inverter and fuse, Figure 1.
Figure 1 Inverter and fuse
Replacement
1. Reverse the removal procedure to replace the exposure lamp inverter and fuse.
2. When re-connecting the ribbon cable into PJ463, the blue band printed on the cable must
face to the left, when viewed as shown in Figure 1.
3. Figure 1, ensure the ribbon cable is folded correctly in the cable clamp. Engage two of the
cable clamp clips in the carriage holes. Bend the clamp to engage the third clip.
2
Place fingers under the carriage to hold
the cable clamp, then release the 3 clips
from above while pulling the clamp down
1
Remove 2 screws
4
Disconnect 2
connectors
5
Remove the inverter and
fuse
Fuse
PJ 464
PJ 463
3
Note the orientation
of the ribbon cable,
blue stripe to the left
July 2005
Repairs/Adjustments
REP 14.3A Document Size Sensors (32-55 ppm)
Removal
WARNING
WARNING
2. For document size sensor 2 only, remove the PWB cover - 3 screws, PL 14.25 Item 1.
3. Remove the document size sensor 1 and / or 2, Figure 1.
Figure 1 Document size sensor 1
NOTE: Figure 1 shows document size sensor 1. The fastening for the document size sen-
sor 2 is the same as for 1.
Replacement
1. Reverse the removal procedure to replace the document size 1 and 2 sensors.
2. Figure 2, when re-installing the PWB cover, PL 14.25 Item 1, ensure that the upper run of
scan cable does not get trapped in the cable anchor slot.
Figure 2 Correct position of the scan cable
1
Pinch the legs together to
release the sensor
2
Cable anchor slot
Scan cable upper run
July 2005
Repairs/Adjustments
REP 14.4A DADH Closed Switch (32-55 ppm)
Removal
WARNING
WARNING
2. Remove the user interface assembly, REP 2.1.
3. Remove the scanner top cover, PL 14.20 Item 3.
4. Remove the DADH closed switch, Figure 1.
Figure 1 DADH closed switch
Replacement
Reverse the removal procedure to replace the DADH closed switch.
1
Release the catch and disconnect
the bulkhead connector
2
Remove 2 screws
3
Remove the
switch
July 2005
Repairs/Adjustments
REP 14.5A Scanner PWB (32-55 ppm)
Removal
WARNING
WARNING
2. Remove the scanner PWB cover, PL 14.25 Item 1. Release the document size sensor
from the cover, REP 14.3A.
3. Remove the scanner PWB, Figure 1.
Figure 1 Scanner PWB
Replacement
1. Reverse the removal procedure to replace the scanner PWB.
2. When re-installing the PWB cover, PL 14.25 Item 1, ensure that the upper run of scan
cable does not get trapped in the cable anchor slot, Figure 2.
Figure 2 Correct position of the scan cable
3. When re-connecting the ribbon cable to PJ456 ensure that the blue band printed on the
cable faces the front of the machine.
1
Disconnect all
harnesses
2
Release 4 standoffs
3
Remove the scanner
PWB
Cable anchor slot
Scan cable upper run
July 2005
Repairs/Adjustments
REP 14.6A CVT Glass, Document Glass and CVT Ramp
(32-55 ppm)
Removal
WARNING
WARNING
CAUTION
Careless handling may separate the plastic CVT ramp from the document glass, if this hap-
pens, install a new document glass, PL 14.20 Item 5 and CVT ramp, PL 14.20 Item 13.
Contamination in the optics cavity can cause image quality defects. Do not allow the optics
cavity to become contaminated.
4. Remove the CVT glass and document glass, Figure 1.
Replacement
CAUTION
Careless handling may separate the plastic CVT ramp from the document glass, if this hap-
pens, install a new document glass, PL 14.20 Item 5 and CVT ramp, PL 14.20 Item 13.
1. Clean the underside of the CVT glass and document glass, ADJ 14.1A.
NOTE: Ensure that the CVT glass is installed as far to the right as possible.
NOTE: Ensure that the white stripes on both the CVT glass and the document glass, are
at the front of the machine and on the underside of the glass.
2. Reverse the removal procedure to replace the CVT glass and document glass.
3. Clean the upper side of the CVT glass and document glass, ADJ 14.1A
Figure 1 Document glass and CVT glass
1
Remove 2 screws
3
Lift off the document
glass and store carefully
2
Lift off the CVT glass
and store carefully
July 2005
Repairs/Adjustments
REP 14.7A Scan Carriage Home Sensor (32-55 ppm)
Removal
WARNING
WARNING
CAUTION
Do not remove the document glass.
Do not loosen the two screws securing the setting plate, shown in Figure 1.
4. Remove the scan carriage home sensor, Figure 1.
Figure 1 Scan carriage home sensor
Replacement
1. Reverse the removal procedure to replace the scan carriage home sensor.
2. Figure 1, when mounting the sensor, ensure that the location hole in the sensor mounting
plate is located over the dowel of the setting plate.
3. When replacing the scan carriage home sensor, ensure that the lugs are located in the
slot of the mounting plate before tightening the screw.
4. Ensure the adhesive tape is re-installed so that it entirely covers the aperture. If neces-
sary install new adhesive tape.
1
Peel back
the adhesive
tape
2
Remove screw and release the mounting plate to reveal
the sensor
4
and remove the sensor
3
Remove screw
DO NOT LOOSEN
THESE SCREWS
Setting
plate
Lugs
Dowel
Location hole
July 2005
Repairs/Adjustments
REP 14.8A Input Module Angle Sensor (32-55 ppm)
Removal
WARNING
WARNING
4. Remove the input module angle sensor, Figure 1.
Figure 1 Input module angle sensor
Replacement
1. Reverse the removal procedures to replace the input module angle sensor.
2. When replacing the input module angle sensor, ensure that the lugs on the sensor are
located in the slot of the frame before tightening the screw.
1
Remove screw
2
Depress the actuator
3
Disconnect the sensor from the harness
July 2005
Repairs/Adjustments
REP 14.9A Exposure Lamp (32-55 ppm)
Removal
WARNING
WARNING
2. Manually move the full rate carriage to align with the cut-outs in the frame.
3. Remove the exposure lamp with the end blocks, Figure 1.
Figure 1 Releasing lamp fasteners
4. Remove the end blocks from the exposure lamp, Figure 2.
Figure 2 Removing end blocks
Replacement
Reverse the removal procedure to replace the exposure lamp.
2
Press the catch and slide the
mounting block upwards at both
ends of the lamp
3
Release the mounting block
from the carriage at both
ends of the lamp and
remove the lamp with the
end blocks
1
Disconnect PJ464 through
the access hole and release
the lamp harness retainer
1
Slide the end block
from the lugs
2
Remove the end block from the
other end of the exposure lamp
July 2005
Repairs/Adjustments
REP 14.10A Scan Idler Pulleys (32-55 ppm)
Removal
WARNING
WARNING
2. Carefully move the full rate carriage to the left side of the scanner module.
3. Remove the scan idler pulleys, Figure 1.
NOTE: Figure 1 and Figure 2 show the rear scan idler pulley. The procedure for the front
scan idler pulley is similar.
Figure 1 Scan idler pulley removal
Replacement
1. Reverse the removal procedure to replace the scan idler pulleys. Install the scan idler pul-
leys, Figure 2.
Figure 2 Scan idler pulley replacement
1
Remove the
E-clip
2
Hold the tension in the cable and
slide the pulley off of the shaft
3
Maintain the tension in the cable and
remove the pulley from the cable loop
1
Maintain the tension in the
cable and place the pulley
in the cable loop
2
Slide the pulley onto the shaft
3
Install the E-clip
July 2005
Repairs/Adjustments
REP 14.11A Scan Motor (32-55 ppm)
Removal
WARNING
WARNING
2. Mark the position of the scan motor bracket, Figure 1.
Figure 1 Motor bracket position
3. Remove the scan motor and remove the weight (32-38 ppm only), Figure 2.
Replacement
1. Re-assemble the motor onto the bracket and fully tighten the screws.
2. Replace motor / bracket assembly into the optics cavity, engage the motor pulley with the
drive belt and install the two screws, but do not tighten.
3. Move the motor / bracket assembly to the right until the bracket aligns with the scribe line,
Figure 1, then fully tighten the screws.
4. Re-install the flywheel and tighten the 2 screws.
5. Re-install the CVT glass and document glass.
6. Ensure that the weight (32-38 ppm only) is fitted onto the new motor.
Scribe a line
1
Disconnect PJ456
2
Remove 2 screws
5
Remove 2 screws and remove
the motor from the bracket
4
Loosen 2 grub screws and remove
the flywheel
3
Remove the motor
and bracket
Weight (32-38
ppm only)
July 2005
Repairs/Adjustments

REP 14.1B Scanner (65-75 ppm)
Removal
WARNING
WARNING
1. Remove the OCT, PL 12.10 Item 2, or perform the following:
REP 11.13-110 LCSS Undocking
REP 11.19-130 HCSS Undocking
REP 11.13-170 HCSS BM Undocking
2. Figure 1. Lock the scan carriage.
5. Remove the user interface, REP 2.1.
6. Disconnect all harnesses that will prevent removal of the image processing PWB module,
then remove the image processing PWB module, PL 3.10 Item 1.
7. Remove the left hand cover, PL 8.10 Item 3.
9. Remove the xerographic module. Put the module in a black bag.
WARNING
NOTE: The scanner weight is 16.5 kg (36lb.).
10. Figure 2. Stand at the rear of the machine and remove the scanner.
Figure 1 Locking the scan carriage
Remove the transport screw from the storage
position and lock the scan carriage.
July 2005
Repairs/Adjustments
Figure 2 Scanner removal
Replacement
1. The replacement procedure is the reverse of the removal procedure. Ensure that the
receptacle on the base of the scanner is correctly installed onto the tongue on the
machine frame. Refer to Figure 2.
Screw and spacer
3
Push the scanner towards the
rear of the machine
5
Remove the scanner
1
2
(See also Detail A)
Tongue
Receptacle (2 positions)
Tongue
4
Raise the scanner and release the harness from
beneath the scanner
Detail A
July 2005
Repairs/Adjustments
REP 14.2B Top Cover (65-75 ppm)
Removal
WARNING
WARNING
2. Remove the user interface assembly, REP 2.1. It is not necessary to disconnect the PJ.
3. Figure 1, remove the top cover.
Replacement
1. The replacement procedure is the reverse of the removal procedure.
2. Perform ADJ 14.1B Optics Cleaning as necessary.
3
Remove
three
screws
2
Loosen three screws
4
Lift off the top cover
1
Remove one screw
July 2005
Repairs/Adjustments
REP 14.3B CVT Glass, CVT Ramp Assembly and
Document Glass (65-75 ppm)
Removal
WARNING
WARNING
CAUTION
Careless handling may separate the plastic CVT ramp assembly from the document glass. If
this happens, install a new document glass, PL 14.10 Item 5 and CVT ramp assembly, PL
14.10 Item 13.
Contamination of the optics cavity can cause image quality defects. Do not allow the optics
cavity to be contaminated.
1. Remove the top cover, REP 14.2B.
2. Figure 1, remove the CVT glass, document glass and CVT ramp assembly.
Figure 1 CVT glass and document glass assembly
Replacement
2. Ensure that the white AGC strips on the document glass and the CVT glass are at the
front and underside of the glass.
3. Perform ADJ 14.1B Optics Cleaning as necessary.
1
Remove 2 screws
2
Loosen 6 screws and rotate 6 glass clamps away
from the document glass
3
Remove the CVT glass, and
the document glass with the
CVT ramp assembly
July 2005
Repairs/Adjustments
REP 14.4B Scan Carriage Home Sensor (65-75 ppm)
Removal
WARNING
WARNING
1. Remove the scanner top cover, REP 14.2B.
CAUTION
Do not remove the document glass.
Do not loosen the two screws securing the setting plate, shown in Figure 1.
2. Figure 1, remove the scan carriage home sensor.
Figure 1 Scan carriage home sensor
Replacement
1. Install the sensor on to the sensor plate, ensuring the lugs locate correctly in the slot.
2. Re-connect the sensor.
3. Install the sensor plate. Ensure that the three locating lugs are correctly located in the
slots of the mounting plate.
4. The replacement of the removed components in the reverse of the removal procedure.
4
Remove the
sensor (1 screw)
3
Disconnect the sensor
1
Remove the
screw
2
Pull forward the sensor plate
Do not loosen
July 2005
Repairs/Adjustments
REP 14.5B Scan Carriage Assembly (65-75 ppm)
Removal
WARNING
WARNING
1. Remove the CVT glass and document glass, REP 14.3B.
CAUTION
When disconnecting the scan carriage ribbon cable, do not bend the connector pins.
2. Figure 1. Remove the scan carriage assembly.
Figure 1 Carriage removal
Replacement
1. Insert the exposure lamp ribbon cable through the securing clamp and the square hole.
2
Loosen 1 screw,
then slide out
the cable
1
Remove the PJ cover (2
screws) and disconnect the
scan carriage ribbon cable
4
Remove the scan carriage
3
Loosen 3 screws, then slide
out the cables
July 2005
4-445 WorkCentre Pro 275 Family (CC232-WCP275F) REP 14.5B, REP 14.6B
Repairs/Adjustments
2. Figure 2. Place the scan carriage centrally over the springs on the scan cables. Slide the
scan cables under the fixing tabs.
NOTE: Observe the spring position between the fixing tabs on the scan carriage assem-
bly.
Figure 2 Alignment of the scan carriage
3. Reconnect the scan carriage ribbon cable.
4. Reinstall the PJ cover.
5. Reconnect the exposure lamp ribbon cable. Ensure that the metal connections face
towards the PWB.
6. Close the exposure lamp ribbon harness securing clip.
7. Perform ADJ 14.2B Scan Carriage Adjustment.
8. Perform ADJ 14.1B Optics Cleaning Procedure.
REP 14.6B Scan Motor and Mounting (65-75 ppm)
Removal
WARNING
2. Remove the scanner motor cover, PL 14.16 Item 10, (2 screws).
3. Figure 1. Prepare to remove the motor.
4. Figure 2. Remove the motor and mounting. Note the orientation of the bracket and the
mounting.
Spring position
Fixing tab
Fixing tab
2
Remove 3 screws
1
Scribe round
the bracket
July 2005
Repairs/Adjustments
Figure 2 Motor and mounting
Replacement
2. Perform ADJ 14.3B Scanner Motor.
REP 14.7B Scan Cables (65-75 ppm)
Removal
WARNING
WARNING
1. Remove the scan carriage, REP 14.5B.
2. Remove the scan motor cover PL 14.16 Item 10, (2 screws).
3. Slide the cables off the pulleys or capstan.
4. Remove the springs and lift out the cables.
Replacement
1. Figure 1 shows the general arrangement of the scan cables, when correctly installed.
Figure 1 Scan cable arrangement
3
Remove the mount-
ing (2 screws)
2
Remove the bracket
(2 screws)
1
Release the wiring and
disconnect PJ 461.
(Press the top of the PJ)
6 turns on
each cable
Upper scan
cable
Lower scan cable
Note that the springs are in
the same relative position.
July 2005
Repairs/Adjustments
2. Figure 2. Prepare to install the lower scan cable.
NOTE: The lower scan cable is black and is longer than the upper scan cable.
NOTE: The anchor ball is not installed centrally on the scan cables.
NOTE: To assist in holding the scan cables in position, use adhesive tape.
Figure 2 Mount the lower scan cable on the capstan
3. Figure 3. Prepare to install the lower scan cable.
Figure 3 Installation of the lower scan cable
1
Wind three turns below the anchor
point on the capstan.
2
Install the anchor ball in the anchor
point
3
Use adhesive tape to secure the anchor ball in the anchor point
longer, black cable
short end
long end
1
Wind three turns above the
anchor point
2
Install the cable around the left, rear, lower pulley
3
Install the cable around the
right, rear, lower pulley
July 2005
Repairs/Adjustments
4. Figure 4. Prepare to install the upper scan cable.
NOTE: The anchor ball is not installed centrally on the scan cable.
Figure 4 Mount the upper scan cable on the capstan
5. Figure 5. Install the lower scan cable.
Figure 5 Installation of the upper scan cable
1
Wind three turns below the
anchor point on the capstan.
2
Install the anchor ball in the
anchor point
3
Use adhesive tape to secure the
anchor ball in the anchor point
long end
short end
1
Attach the spring to
the cable
3
Install the cable over the front,
right pulley
2
Install the cable around
the front, left pulley
July 2005
Repairs/Adjustments
1
Wind three turns above the
anchor point
1
Install the cable around the left
rear, upper pulley
July 2005
Repairs/Adjustments
8. Figure 8. Install the upper scan cable.
9. Remove the adhesive tape used to secure the anchor balls in the anchor points.
10. Reinstall the scan carriage, REP 14.5B.
11. Perform ADJ 14.2B scan carriage assembly.
12. Reinstall the CVT glass and document glass, REP 14.3B.
13. Reinstall the scanner top cover, REP 14.2B.
14. Reinstall the DADH, REP 5.19.
REP 14.8B Scan Drive Belt (65-75 ppm)
Removal
WARNING
WARNING
1. Remove the scan carriage assembly, REP 14.5B.
2. Remove the scan motor, REP 14.6B.
3. Secure the scan cables, Figure 1.
Figure 1 Scan cables and capstan
NOTE: When removing the scan cables from the pulleys, it is not necessary to lift out the
cables from the scanner.
4. Remove the scan cables from the pulleys, REP 14.7B.
5. Remove the scan drive belt, Figure 2.
2
Attach the spring to the cable.
5
Reinstall the circlip.
1
Lift off the right, rear
upper pulley (1 circlip).
3
Place the cable round the pulley.
4
Install the pulley on to the shaft.
1
Secure the scan cables to
the capstan
Insulation tape
July 2005
Repairs/Adjustments
Figure 2 Removal of the scan drive belt
Replacement
2. Perform ADJ 14.3B Scanner Motor.
REP 14.9B Input Module Angle Sensor (65-75 ppm)
Removal
WARNING
WARNING
2. Figure 1, remove the input module angle sensor.
Figure 1 Input module angle sensor
Replacement
1. Reverse the removal procedures to replace the input module angle sensor.
2. When replacing the input module angle sensor, ensure that the lugs on the sensor are
located in the slot of the frame before tightening the screw.
2
Carefully thread the scan drive belt over the scan cables.
Remove the scan drive belt.
1
Remove the scan drive
belt from the capstan
1
Remove one screw
2
Depress the actuator
3
Disconnect the sensor from
the harness and remove
July 2005
Repairs/Adjustments
REP 14.10B Exposure Lamp and Exposure Lamp Inverter
(65-75 ppm)
Removal
WARNING
WARNING
1. Remove the document glass, the CVT glass and the CVT ramp assembly, REP 14.3B.
CAUTION
The machine may have shims installed below each end of the exposure lamp. Do not loose the
shims when the exposure lamp is removed. The shims are installed to improve image quality.
Not all machines have shims installed.
2. Figure 1. Remove the exposure lamp.
Figure 1 Removal of the exposure lamp
3. Figure 2. Remove the exposure lamp inverter.
2
Remove screw
3
Remove the exposure
lamp.
3
Disconnect the exposure lamp harness
Shim
(see CAUTION)
1
Remove screw
Shim
(see CAUTION)
July 2005
Repairs/Adjustments
Figure 2 Removal of the exposure lamp inverter
Replacement
1. The replacement procedure is the reverse of the removal procedure. If the machine had
shims installed below the exposure lamp, make sure that they are replaced correctly, refer
to Figure 1.
2. Perform ADJ 14.1B Optics Cleaning.
REP 14.11B Exposure Lamp Ribbon Harness (65-75 ppm)
Removal
WARNING
WARNING
1. Remove the document glass, the CVT glass, and the CVT ramp assembly, REP 14.3B.
2. Remove the scanner PWB cover, PL 14.16 Item 9 (three screws).
3. Remove the scan carriage ribbon cable, PL 14.15 Item 4.
4. Figure 1. Remove the exposure lamp ribbon harness.
5. Remove the scan carriage ribbon cable felt securing strip.
2
Disconnect the exposure
lamp ribbon harness
1
Remove two screws
3
Remove the exposure lamp inverter
July 2005
Repairs/Adjustments
Figure 1 Removal
Replacement
1
If necessary, carefully
move the scan carriage
assembly to the left
2
Carefully move the
securing clip
5
Carefully thread the expo-
sure lamp ribbon harness
through the securing clips
4
Gently raise the
securing clip
3
Depress expo-
sure lamp rib-
bon harness
housing and
remove the
harness
July 2005
Repairs/Adjustments
REP 14.12B Scanner PWB (65-75 ppm)
Removal
WARNING
WARNING
2. Remove the scanner PWB cover, PL 14.16 Item 9.
3. Disconnect all of the harness connectors from the scanner PWB, PL 14.16 Item 8.
4. Remove four screws securing the scanner PWB.
5. Remove the scanner PWB.
Replacement
REP 14.13B Scan Carriage Ribbon Cable (65-75 ppm)
Removal
WARNING
WARNING
2. Remove the scanner PWB cover, PL 14.16 Item 9.
3. Prepare to remove the scan carriage ribbon cable, PL 14.15 Item 4.
4. Figure 1. Remove the scan carriage ribbon cable.
Figure 1 Removal of the scan carriage ribbon cable
5. Remove the felt protection strip from the scan carriage ribbon cable.
1
Remove the connector cover
2
Disconnect the scan
carriage ribbon cable
4
Disconnect the scan
5
Remove the scan
3
Release two harness
retainers
July 2005
Repairs/Adjustments
Replacement
CAUTION
Take care when replacing the scan carriage ribbon cable. The scan carriage ribbon cable is
easily damaged.
REP 14.14B Document Size Sensor 1 and Document Size
Sensor 2 (65-75 ppm)
Removal
WARNING
WARNING
2. Figure 1. Remove document size sensor 1 (Q14-315).
NOTE: The removal of document size sensor 1 (Q14-315) is shown. The removal of doc-
ument size sensor 2 (Q14-320) is identical.
Figure 1 Remove document size sensor 1 (Q14-315)
1
Disconnect the
harness
2
Remove 1 screw
3
Remove the document size sensor
July 2005
Repairs/Adjustments
Replacement
July 2005
Repairs/Adjustments
July 2005
Repairs/Adjustments

REP 16.1 Network Controller PWBs Access
Removal
WARNING
WARNING
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the PWB.
1. Remove the network controller, PL 16.10, from the rear of the machine.
2. Remove the screws securing the front cage, Figure 1.
Figure 1 Network controller
Remove 6 screws
July 2005
Repairs/Adjustments
3. Remove the front cage, Figure 2.
Figure 2 Removing the cage
4. Remove the relevant PWB, Figure 3.
Figure 3 Removing a PWB
Remove front cage
1
Remove the screw.
2
Remove the PWB
July 2005
Repairs/Adjustments
5. Network controller PWB location connections, Figure 4.
Figure 4 PWB locations
Replacement
PCI locations
Memory module location
July 2005
Repairs/Adjustments
REP 16.2 Network Controller Disk Drive
Removal
WARNING
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the disk
drive.
1. Remove the network controller, PL 16.10, from the rear of the machine.
2. Remove the front cage on the network controller, refer to REP 16.1.
3. Remove the network controller disk drive, Figure 1.
Figure 1 Disk drive
Replacement
1
Disconnect PJ 3
2
Disconnect PJ 5
3
Remove two screws
4
Lift and remove the
disk drive

04a Repairs

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July 2005

4-1 WorkCentre Pro 275 Family (CC232-WCP275F)

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