Xerox DocuPrint 4512/4512N Service Manual 720P59570Table of Contents Title Page Introduction... Organization ..... Service Call Procedures..... Printer Specifications ....... Parts Lists... Repair Procedures... General Procedures Wiring Data Repair Analysis Procedures.. Options. DocuPrint 4512/4512N Service Manual Introduction ‘The Xwtux 4512/4512N Service Mariual Is the primary document used for repairing and maintaining the 4512/4512N Laser Printer. This manual contains Service Call Procedures, Diagnostic Procedures, General information, Repair Analysis Procedures, Image Quality Analysis Procedures, Wiring Data, Parts Lists, and Options that will enable the Service Representative to repair 4512/4512N failures. ‘The DocuPrint 4512 is the base model. The 4512N is the base model with a customer ‘selectable network option installed. For the remainder of this service manual, we will consider them as a product line and refer to them as the 4512. ContentsOrganization ‘This manual is divided into eight sections. The title and description of each section of the manual is as follows: Section 1 - SERVICE CALL PROCEDURES This section is used to identify a suspected problem. t contains Call Flow, Initial Actions, and Final Actions. This part of the service manual should always be used to start the service call. Section 2 - PRINTER SPECIFICATIONS This section contains all the specifications for the 4512N printer. Section 3 - PARTS LISTS. This section contains illustrations of disassembled subsystems and a listing of the spared parts. Part names are listed in this section of the manual even if the part itself is not spared. All the parts that are spared will have the part number listed. Parts that are not spared will not have a number listed. Section 4- REPAIR PROCEDURES This section contains the instructions for removal, replacement, and adjustment of the spared parts. Section 5 - GENERAL PROCEDURES: This section contains diagnostic routines, printer setup procedures, and a listing of tools and supplies. Section 6 - WII ING DATA This section contains illustrations of the plugliack locations and the routing of power and signal cables. Section 7 - REPAIR ANALYSIS PROCEDURES. This section. repair failures in the printer. This section also ins the procedures necessary to ‘troubleshoot print quality problems. ‘Section 8 - OPTIONS: This section contains the instructions for installing, repairing, troubleshooting, and the parts lists for customer purchased options. vi DecuPrint 4612/4512N Service ManualRevision Control List Product Manwal Title Part Number 4512N Laser Printer | DocuPrint 4512N Service Manual ‘720P59570 Page | Date Page | Date Page| Date Page | Date Title 996 325 | 9196 443 | 9196 539 | «986 ii 9/96 326 | 9196 444 | 9796 540 | 9196 i 9/96 327 | 9196 445 | 9196 bt 9/96 iv 9/96 328 | (9/96 446 | 9/96 542 | 9196 v 9196 447 | 9996 S43 | (9196 vi 9/96 at 9/96 443 | 9196 544 | 9196 vii 9/96 42 9/96 449 | 9/96 545 | 996 9/96 43 9/96 450 | 9/96 546 | 9196 a4 9/96 547 | 9/96 14 9196 45 9/96 54 9/96 548 | 996, 12 9/96 46 9/96 52 9/96 13 9/96 a7 9/96 53 9/96 61 9/96 14 9/96 48 9/96 54 9/96 62 996 48 9/98 55 9/96 63 9/98 24 9196 410 | 9196 56 9/96 64 9/96 22 9196 att 9/96 57 9/96 65 9/96 23 | 9196 412 | 9/96 58 9/96 66 9/96 2d 9/96 413 | 9/96 59 9/96 67 9/96 25 9196 414 | 9/96 510 | 9/96 68 9/96 26 9196 415 | 9/96 St 9/96 69 9/96 9186 4te | 9/96 512 | 996 6-10 | 9/96 9196 417 | 9/96 513 | 9/96 61 9/96 418 | 9/96 514 | 9/96 612 | 9/96 a 996 419 | 9/96 B15 | 9/96 613 | 9/96 32 9/96 420 | 9/96 516 | 9/96 614 | 996 33 9/86 421 9/96 517 | 996 615 | 996 34 9196 422 | 9/96 51a | 9/96 616 | 996 35 9/96 423 | 9/96 519 | 996 617 | 9196 36 9/98 424 | 9/96 5:20 | 9/96 618 | 9196 37 9/96 425 | 9/96 521 | 9/96 619 | 9996 38 9/96 426 | 9/96 522 | 9/96 620 | 996 39 9/96 427 | 9/96 523 | 996 621 | 9196 310 | 9/96 428 | 9/96 524 | 9/96 622 | 9196 att 9/96 429 © | 9/96 625 | (9/96 312 | 9796 430 | 9/96 526 | 9/96 7A 9/96 313 | 9796 431 | 9/96 527 | 9196 72 9/96 314 | 9/96 432 | 9/96 528 | 9/96 73 9/96 315 | 9/96 433 | 9/96 529 | 9196 74 9/96 3-16 9/96 434 9/96 5-30 9196 75 9/96 317 | 9/96 435 | 9/96 5-31 9/96 76 9796 318 | 9/96 436 | 9/98 532 | 9/96 77 9/96 319 9/96 437 9/96 5-33 9196 78 9196 320 | 9/96 438 | 9/96 534 | 9196 79 9/96 321 9/96 439 | 9/96 535 | 9/96 740 | 9196 322 | 9/96 440 | 9/96 536 | 9/96 mt 9/96 323 | 9/96 441 9/96 537 | 9/96 72 | 9196 324 | 9/96 442 | 9/96 5-38 | 9196 713 | 996 DocuPrint 4512/4512N Service Manual Revision Control ListRevision Control List (continued) Product Manual Title Part Number 4512N Laser Printer DocuPrint 4512N Service Manual ‘720P59570 Page | Date Page | Date Page | Date Page | Date 714 9/96 78 9/96 7-16 9/96 9196 9/96 9/96 9/96 9/96 9/96 85 9/96 8-6 9/96 8-7 9/96 8-8 9/98 Comment 9/96 Address | 9/96 9/96 Revision Control List vit DocuPrint 4512/4512N Service ManualThis Service Manual contains information that applies to the Xerox DocuPrint 4512N Electronic Laser Printer. NOTICE This manual is for use by Xerox Technicians and Xerox trained technicians only. NOTICE While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox arising out of any inaccuracies: or omissions, All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product rained service personnel only. Xerox does not warrant or represent that such documentation is complete. Nor does Xerox represent or warrant that it wll notify or provide to such customer any future changes to this documentation. Customer's service of equipment, ‘or modules, components, or parts of such equipment may void any otherwise applicable Xerox warranties. ff Customer services such ‘equipment, modules, components, or parts ‘thereof, Customer releases Xerox from any and all liability for Customer's actions, and Customer agrees to indemnify, defend, and hold Xerox harmless from any third party claims which arise directly or indirectly from such service. Prepared by: Technical Literacy Xerox Document University P.O. Box 2000 Leesburg, VA. 20177-0198 Prepared for: Office Document Systems / Office Printing Business (ODS/OPB) Customer and Marketing Focus 701 South Aviation Blvd. EI Segundo, California 90245 Copyright 1996 by Xerox Corporation. Xerox, DocuPrint 4512N is a registered trademark of Xerox Corporation. Product Safety Copyright 1996 Xerox Corporation. All rights reserved. Copyright protection olaimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, ‘templates, icons, screen displays, looks, etc. Xerox, and all product names and product numbers mentioned in this publication are trademarks. ‘Adobe and PostScript are trademarks of Adobe ‘Systems Incorporated. PCL, HP LaserJet, and Intelifont are trademarks of Hewlett-Packard Company. IBM is a trademark of International Business Machines Corporation. Microsoft, Microsoft Windows, Microsoft Word, MS, and MS-DOS are trademarks of Microsoft Corporation. Univers is a trademark of Linotype ‘AG or its subsidiaries. WordPerfectis a trademark ‘of WordPerfect Corporation. Centronics is a trademark of Centronics Corporation. Macintosh and TrueType are trademarks of Apple Computer, Incorporated. All other product names are trademarks/tradenames of their respective owners. PCL and PCL Se are trademarks of Hewlett Packard Company. This printer contains an emulation of the Hewlett Packard PCL 5e ‘command language, recognizes HP PCL Se commands, and processes these commands in a ‘manner compatible with Hewlett Packard LaserJet printer products. DocuPrint 4512/4512N Service ManualWarning This equipment complies with the requirements in Part 15 of FCC rules for a ‘class A computing device. Operation of the equipment in a residential area may cause unacceptable interference to radio and TV reception, requiring the operator to take whatever steps are necessary to correct the interference. Electrostatic Discharge ‘This caution indicates that there are components which are sensitive to damage caused by electrostatic discharge. o CAUTION ‘Shock Hazard This symbol indicates the presence of potentially hazardous voltages. CLASS 1 LASER PRODUCT ‘The Xerox DocuPrint 4512N laser printer is. certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this is a class of laser product that does not emit hazardous laser radiation; this ts possible only because the laser beam is totally enclosed during all modes of customer operation. DocuPrint 4512/4512N Service Manual ‘The laser and output of the taser scanner unit produces a beam that, if looked into, could cause ‘eye damage. Service procedures must be followed exactly as written without change. When servicing the machine or laser module, follow the procedures specified in the manual and there will be no hazards from the laser. Laser (FDA): Any laser label visible to service must be reproduced in the service manual with location shown or indicated. Safe working procedures and clear warnings concerning precautions to avoid possible exposure must also be included. ‘The Laser contained in the DocuPrint 4812N meets the following standard: Laser class 3B, maximum SmW, wavelength 780nm. ‘The following LASER symbol will be displayed at the start of any procedure where possible exposure to the laser beam exists. Paton LUOKAN 1 LASERLAITE, KLASS 1 LASER APPARAT Product SafetyEach 4512N laser printer has the laser warning label on the Laser Assembly. The Laser Label is visible when the Upper Cover is removed... CAUTION seaeadseniceant “more monencc omer. VORSICHT sxesersasicrite erence nour Sern ADVARSEL. itsavsimittes eee VARNING siusisexausseicor edt VARO! sernirtahiiztieensbecete kone deems tm0s eR 006 ‘Swedish / Finnish Laser Safety ARO! - Avattaessa ja suojalukitus ohitettaessa oletalttina nakyméttSméillo lasersditeilylle. Ald katso sdteeseen, \VARNING! - Osynlig laserstralning niir denna del dr 8ppnad och sparren ar urkopplad. Betrakta ej strdien. FAL 008 9196 ia Product Safety DocuPrint 4512/4512N Service ManualSection 1 Service Call Procedures DocuPrint 4512/4512N Service Manual 14 Service Call Procedures1.1 Call Flow Diagram ‘The basic troubleshooting steps are outlined in the Call Flow Diagram (Figure 1.1). All service calls begin with initial Actions and end with Final Actions. Figure 1.1 Call Flow Diagram. Initial Actions General Procedures Service Call Procedures 12 DoeuPrint 4512/4512N Service Manual1.2 1.3 1 Initial Actions ‘Question the operator and verify the problem. ‘Check that the printer paper path is clear of foreign matter such as staples, paper clips, and, paper scraps. ‘After you have identified the problem symptom, check the following ites: + The printer is connected to a wall power outlet, and the outlet is supplying the correct volt- age. + The printer power cord is not frayed or broken. + The printer is correctly grounded. ‘+ The printer is in an appropriate operating environment, with no extremes of heat or humid- ity. The printer is not exposed to direct sunlight. + The printer is on a level and stable surface. Corrective Actions If the printer has an obvious failure or fault, you can go directly to the appropriate Repair Procedure (Section 4) or Repair Analysis Procedure (RAP) (Section 7) and begin corrective action. If the fault is not obvious, follow the Entry Level RAP (Section 7) to identify the problem and begin corrective action. After all corrective actions have been made, perform Final Actions. DocuPrint 4512/4512N Service Manual 18 Service Call Procedures.1.4 Final Actions 1 Run Test Prints to evaluate print quality. 2 Perform the Image Quality Checkout procedures in Section 7 to correct any print quality defects. 3. Correct any secondary problems (return to Corrective Actions, if necessary). 4 Reinstall the machine covers. 5 Clean the machine and the work area. 6 Ask the customer to send a print job to verity printer operation. 7 Provide operator training as required. 8 Close the call. 9196 Service Call Procedures 14 DocuPrint 4812/4612N Service ManualDocuPrint 4512/4512N Service Manual 2 Section 2 Printer Specifications 2.1 Electrical Specifications... 2.1.1 Power Sources and Consumption 2.1.2 Power On/Ott. 2.1.3 Power Saver.. 2.9 Paper Specifications... 2.9.1 Paper Tray Capacity / Sizes (Tables 2.6.12, 2.6.16, and 2.6.16)... 97962.9.2 Paper Limitations.. 28 2.10 Operating Language and EMmULAtION ..viemeuemesenreunnnne DB 2.11 Communication Interfaces. +8 Printer Specifications 22 DocuPrint 4512/4512N Service Manual2.1 Electrical Specifications 2.1.1 Power Sources and Consumption The Xerox 4512 printer is available with either a 110 or a 220 volt configuration. Line | Line Voltage | Frequency | Frequency | Running Power | Power Voltage | Tolerance Tolerance | Consumption Saver TROVAC | 90-192VAC | S6OHZ | 80-60H | S00 Walls Maxmum | 30 Walls zeojesq/240 | 198-264VAC | 50/60 Hz 50-60Hz | 500Wetts Maximum | SO Watts VAC 2.1.2 Power On/Off ‘The Xerox 4512 is switched ON by a power ON/OFF switch mounted on the rear of the printer. The Power cord is detachable and plugged into a three-wire grounded power socket. The printer powers down automatically when itis nut used for a period of ime (see Power Saver). 2.1.3 Power Saver ‘The Power Saver reduces power consumption automatically when the printer does not receive data for a Period of ime. User can set to delay times of 15, 30, or 45 minutes. 2.1.4 Laser Class 1 with a maximum output of 15 milliwatts for 0.1 microseconds. 2.2 Mechanical Specifications Unit Width’ Depth Height Weight ‘Motic ‘380mm ‘468 mn ‘330 rm 155 Kg SAE 13in, 18.4in 13i0 342 Ibs 9/96 DocuPrint 4512/4512N Service Manual 23 Printer Specifications2.3 Consumables Photoconductor/Drum cartridge * Life: — Max: 30,000 pages. — Median: = 24,000 pages (A4, Letter, 5% area coverage) — The cartridge is capable of producing a maximum of 30,000 prints without other detrimental cficots. — Storage Toner/developer kit months* from the manufacturing month. + Contents: — Toner/developer cartridge — Roller cleaner — Drum protect cover + Life: — Median - 12,000 pages (A4, Letter coverage 5% area coverage) — Storage life: 24 months* from the manufacturing month. * the storage life is specified under packed and sealed conditions. 2.4 Status Display/Controls ‘The printer's status is controlled and displayed by: 8 Front Panel Keys, four LED's, and a 16 character LCD display. 9196 Printer Specifications 24 DocuPrint 4512/4512N Service Manual2.5 Physical Location 19.4 in. 468 mm ao ‘The printer should be installed on a sturdy, smooth, level, and flat surface. There should be enough clearance, 8 (203 mm) inches clearance on the back and right side and a minimum of 4 (102 mm) inches (on the left side, around the printer to allow air circulation around the vents to prevent the printer from overheating, and also allow you to easily: + Open the front pane! + Remove any jammed paper + Change consumables 2.6 Functional Specifications Warm Up Time First Print Out Print Speed - ipm Resolution - dpi (impressions per minute) | (Dots per inch) ‘Under 60 seconds ‘Under 15 seconds | Simplex 12 ipm (A, Leter) '300 dpi 600 dpi Dupiex - Bim (A4, Lettor) switchable 996 DocuPrint 4512/4512N Service Manual 25 Printer Specifications2.7 Environment ‘Temperature | Humidity | Noise | Lever ‘Operating | 10° - 32°C 15-85% RH Standby - Under 48 0B Within 5° | 50? - 90°F Printing - Under 52 dB i | EPA mode - Under 44 dB ‘Shipping 10° - 40°C 10 - 90% RH = 2aR? 100° F Ome wreeee | weer Less than 0.1 L j | PPM ‘The printer must not be exposed to: + abrupt changes in temperature or humidity (near heater or air conditioning vent) + any condensation + direct sunlight + chemicals + vibration + extreme dust or smoke * poor ventilation 2.8 Options MEMORY/DRAM: Launch Configuration is 6MB (2MB onboard and a 4MB SIMM). Future configuration will be 4MB onboard memory. * With three available memory expansion slots, memory is expandable to SOMB in units of 1, 4, or ‘16MB (4 MB SIMMs and 16 MB SIMMs are available from Xerox » imms are industry standard 72-pin, 70-ns, 32 bit, no parity. Paper Cassette: + Universal Cassette + Envelope Cassette Postscript board: * PostScript Level 2 - includes 35 outline fonts Interface board: 9/96 26 Printer Specifications DoouPrint 4512/4512N Service Manual+ AppleTalk / RS-232C I/F board + Ethernet Gard + Token Ring Card 2.9 Paper Specifications Weight: The recommended standard paper type is Xerox DP, 20 Ib. (80 gsm). Range: = 60 to 90 GSM,16 - 24 Ibs. Cassette Duplex 60 to 196 GSM,16 - 36 Ibs. Manual Feed 2.9.1 Paper Tray Capacity / Sizes (Tables 2.9.1a, 2.9.1b, and 2.9.1¢) Table 2.9.12 Standard Tray Capacity Paper Type Capacity (Sheets) ‘$4, Loter, BS, Executive, Legal, & FOI0 250 Envelope Cassette 20 ‘Table 29.1b Paper Sizes Paper Type T Size Feed Source a BaT x TO rohes | 10x BT a Paper Tray oF Manual exer [Bex ines ex zremm Paper Tay oF Manual BS (ISO) | 6.93x 8.84 inches / 176 x 250mm Executive 7.25% 105 indhes/ 164 x 267 mm Foto 85x 1S nones 216 x80 mm Legal 8.5 x 14 inches / 216 x 386 mm arn 10 Envelope “9 O58 inhes [05x24 mm Envelope Tray or Manval ‘Monarch Envelope TXT renee 8x 19 mM Envelope Tray oF Marval DLEnwione | 489x866 inches) 10x 220mm Envelope Tray or Marval CS Envelope (698x802 inches / 162 x 229 mn Envelope Tray or Marval CORP Fim (ranaparenoy) ‘Aor Lair Manual Only ‘abel Paper ‘4 or Leer Envelope Tray oF Marval Wirimam Paper Size Bei x TOO | STI KT Manual Ory “Table 291¢ Output Tray Output | Paper Type Capacity (Sheets) Face Down Tray a 250 9196 DocuPrint 4512/4512N Service Manual a7 Printer Specifications2.9.2 Paper Limitations ‘The following are recommended for optimum performance: + Envelopes with peet-off adhesive strips or more than one fold-over flap to seal must have adhesives compatible with the heat and pressure of the printer's fusing process. + Avoid: — Paper with embossed lettering, perforations, or rough texture. — Papar to which color was added after the paper was made. — Printed forms whose ink is not for laser printing, ‘Most papers that meet the specifications above may be fed either automatically through the universal paper cassette/envelope cassette, or manually through the manual feed slot. Manual feeding, however, will be necessary for envelopes (if envelope cassette is not being used), transparency films, and some media that meet specifications but are not ideal for feeding from the Paper Cassette, e.9., paper that is either highly textured, thicker than normal for its weight, or unusually smooth. 2.10 Operating Language and Emulation The Xerox 4512 emulates: + Post Script Level 2 (optional) + PCL5e 2.11 Communication Interfaces ‘Standard Parallel - Conforms to IEEE STD 1284, December 2, 1994. Connector: Female 36-pin DDK 57LE-40360-730B (029) or equivalent. Optional Serial - Connector: Female 25-pin DDK 17LE-13250-28 (D4CK) or equivalent. LocalTalk - Connector: Female 8-pin TCS7189-01-201 or equivalent. Ethernet - Connector: BNC and R45. Token Ring - Connector: RJ45. Printer Specifications 28 DocuPrint 4512/4512N Service ManualSection 3 Parts Lists PL 1 Covers. PL 2 Frame 1 (1 of 4) PL 3 Frame 1 (2 of 4) PL 4 Frame 1 (3 of 4).. PL 5 Frame 1 (4 of 4).. PL 6 Frame 2 (1 of 2).. PL 7 Frame 2 (2 of 2).. PL & Transport Unit (1 of 2) PL 9 Transport Unit (2 of 2)... PL 12 Packing Material & Accessories... PL 13 Hardware... PL 14 Part Number Cross Reference. DocuPrint 4512/4512N Service Manual at Parts ListsPL 1 Covers tem Part Description » LED Cover {P/O Item 5} 2 Control Panel PWE {P/O item 5} 3) Key Panel {P/O item 5} 4) Control Panel Holder {P/O Item 5} 5) Front Panel Assembly {Includes Items 1, 2, 3, 4, 6, & F} 8) Front Gover Latch {P/O tem 5} D Earth Spring {P/O tte 9} 8) Roller Spring {P/O Item 9} 9) Duplex Access Cover {Includes Items 7, 8, 10, & 11} 10) Roller Shaft {P/O Item 3} 1) Rollers [P/O Item 9) 12) 120614740 Paper Exit Sensor Actuator 13) 48K56500 Upper Cover Includes items 14 and 15} 14) Upper Cover Cushion {P/O item 13} 18) Eject Button {P/O Item 13 and 17) 18) Rubber Foot {P/O Item 17) 17) Bottom Cover {includes Items 15, 16, 18, & 19} 18) Cassette Push Out Lever {P/O item 17} 19) Cassette Push Out Spring {P/O Item 17} 20) ‘Caution Label (220) 21) Class 1 Label (220V) 22) 891617370 French Language Overstick Label ‘A 183W28050 M3x10 Binding Head Tapping Screw B —183W36050 _M4x10 Pan Head Tapping Screw © -26E43680 —-M4x12 Binding Head Tapping Screw © —_153W27850 __M3x8 Pan Head (Cup) Tapping Sorew F 18327650 _M3x6 Binding Head Tapping Screw Parts Lists, a2 DocuPrint 4512/4512N Service Manual9196 a3 DocuPrint 4512/4512N Service ManualPL 2 Frame 1 (1 of 4) Item Part 1) 2) 22K63560 3) 6K17050 4) 130K56450 5) 6) 7) -7eA7810 8) 7&47820 9) SE12110 10) 1) 12) 7E47830 13) 14) 15) 16) 17) 18) 121E13210 19) weno 20) 120614570 21) 6008556 = 18327850 15328050 K ——_s5aw20752 X 35615251 Parts Lints Description Drive Bearings Paper Feed Roller ‘Transport Roller Registration Sensor Hamess Retaining Plate Bearing ‘Traneport Roller Goar Lower Paper Feed Gear Clutch Spring Clutch Steve Clutch Boss Upper Paper Feed Gear Eject Lever Eject Spring Earth Spring 31T Gear 397 Gear Registration Clutch Paper Empty Actuator Holder Paper Empty Actuator Cable Tie \M3x8 Binding Head Tapping Sorew M3x10 Binding Head Tapping Screw AMM E-Ring Grip Ring 1.9MM DocuPrint 4612/45 12N Service ManualParts Lists 996 35 DocuPrint 4512/4512N Service ManualPL3 Frame 1 (2 of 4) tem Part 1) 2) 3) 160K31850 4) 110807460 5) 8) 7 8) —809E01350 9) 120E14580 10) 160K31860 1) 12) 13) 747860 14) 747870 15) 18) 17) 18) 19) 20) 21) 22) 23) 28) 25) 26) A E H N P 153W28850 T s13w27651 Vv 252Wo2051 w 11327850 Parts Lists Description Core Harness Retainer Motor Driver PWB Safety Switch Safety Switch Spring Safety Switch Actuator Safety Switch Lever Size Detect Spring Size Detect Lever Cassette PWB Cable Clamp Hamess Shield 36T Gear ‘30T Gear Earth Plate Hamess Sheet Fuser Ground Wire Frame Earth Plate Main Drive Motor Assembly Earth Spring SAT/24T Gear Drive Spacer Brake Boss Drive Bracket Gear Hamess Retainer M3x10 Binding Head Tapping Screw M3xB Binding Head Tapping Screw M3x10 Binding Head Tapping Screw Grip Ring 5MM M3x16 Binding Head Tapping Screw M3x6 Pan Head Machine Screw ‘Washer 4.11Dx6,50Dx0.25 Thick 1M3xB Binding Head Tapping Screw 9/96 38 DocuPrint 4512/4512N Service ManuelParts Lists DocuPrint 4512/4512N Service ManualPL 4 Frame 1 (3 of 4) Item Part 1) 62K08340 2) 3) 4) 8) rene 6) 7 8) 9) 10) 1) 12) 13) 14) c E Parts Lists Description Laser Assembly Laser Cushion D Laser Cushion C Laser Cushion A Core Printer Controller PWB Guide Framo Unit (Thie includes No. 2,9) Cassette Push Out Lever Cassette Push Out Spring ‘Shield Bottom Piate Bottom Plate Tape Laser Cushion B Laser Cushion E Méx12 Binding Head Tapping Screw x8 Binding Head Tapping Screw 38 DocuPrint 4512/4512N Service Manual9196 38 DocuPrint 4512/4512N Service Manual Parts ListsPL5 Frame 1 (4 of 4) tem » 2) 3) 4) 5) 6) ”n 8) 9) Description Paper Guide Assembly Paper Guide Spring PF Sheet B, P/O item 16 Guide Sheet B {F/O Item 4) Paper Guide Assembly {Includes items 3, 5, & 6) PF Sheet A, P/O item 16, Guide Sheet A {P/O tlem 4} P/O item 16, Guide Sheet C {P/O item 4} Register Roller Bearing Register Roller Drive Bearings, 10) Spring for Developer Cartridge 1) Earth Sheet 12) wee Slide Sheet 13) 160K31840 Toner Sensor PWB 14) Earth Plate for Sensor 15) Drum Connect PWB 16) Drum Connector Shield Plato 17) Earth Tape 18) 101R90 Photoconductor / Drum Cartridge 19) 108R88 Developer Cartridge 15327850 M3x8 Binding Head Tapping Scrow 18327850 Mx Binding Head Tapping Screw 153W28050 M3x10 Binding Head Tapping Screw 354w20852 5MM E-Ring 954W20752 4MM E-Ring Rezem Parts Lists 3-10 DoouPrint 4512/4512N Service ManualParts Lists DocuPrint 4512/4512N Service ManualPL6 Frame 2 (1 of 2) tem Part » 2) 3) 4 5) 8) 127610740 747920 7E47910 747900 ‘31E08310 183128050 15327850 1gw27651 356W24251 26560270 35619251 15315650 Parts Lists Description Shutter Lever B ‘Shutter Spring A Shutter Lever A Laser Shutter Ground Wire Bottom Plate Tape Core ‘Toner Motor Hamess ‘Toner Motor ‘Toner Aim Spring 15T Gear 40T Gear 26T Gear Toner Am High Voltage Terminal A ‘Toner Motor Shield Plate High Voltage Terminal B High Voltage Terminal © High Voltage Terminal D Transport Stopper Spring Transport Stopper Duot Sheet Duct Case M3x10 Binding Head Tapping Screw M3xB Binding Head Tapping Screw M3xB Binding Head Tapping Screw Grip Ring 4MM ‘Shoulder Screw Grip Ring 25MM M2x5 Binding Head Tapping Screw 342 DoouPrint 4512/4512N Service Manual9/96 DocuPrint 4512/4512N Service Manual 313 Parts ListsPL 7 Frame 2 (2 of 2) ttem = Part a 2) 3) 6304840 4) 127E10750 5) 105K16270 105K16280 ©) aEa1920 y 8) 9) wane 30) 105K16260 n) 160K31870 12) 733W03660 7303642 13) 14) ie 16) 160K32530 17) t¢0K32820 18) 160K31910 19) 160K33020 s (26E46040 wo t13w2785t Al 26E60250 AU 26260280 Av 119629751 AW t13W2765% AX 13W27451 Parte Liste Description Earth Plate Shield Tape (Ozone Filter Fan Motor Low Voltage Power Supply Assembly, 110 VAC Low Voltage Power Supply Assembly, 220 VAC ‘Toner Density Control Knob Mesh Shield Plate Shield Plate A High Voltage Power Supply PWB ‘System Controller PWB 4MB SIMM 16 MB SIMM Fitter Case Fan Motor Sheet ‘Connector Protector Cap (36 pin) LocalTalk / Serial PWE, PostScript PWE Ethemet PWB Token Ring M4x6 Pan Head Machine Screw M3xB Binding Head Tapping Screw Thumb Screw ‘Thumb Screw 3x32 Pan Head Machine Screw M3x8 Pan Head Machine Screw ‘M3x4 Pan Head Machine Screw at4 DocuPrint 4512/4512N Service ManualParts Lists 9/96 35 DocuPrint 4512/4512N Service ManualPL 8 Transport Unit (1 of 2) tem » 2) 3) 4 5) 6) 7 8) 9) 10) n) 12) 13) 14) 15) AD Parts Liste Description Fuser Cover Label {P/O tem 14} Fuser Cover Spring Fulerum Shaft Pressure Plate Shaft (P/O Item 14} Pressure Plate (P/O Item 14) Fusing Cover {P/O item 14] Presoure Plate Spring Exit Guide Pressure Spring (P/O Item 15} Cleaner Pressure Spring R {P/O lem 15} ‘Cleaner Pressure Spring L {P/O Item 15} Delivery Guide Spring [P/O Item 15} Delivery Roller {P/O Item 15} Delivery Guide {P/O item 15} Fuser Cover {Includes items 1, 4, 5, 6, & AD} Exit Guide {Includes ltems 8 - 13, J, & AD} ‘SMM E-Ring {P/O ltem 15} ‘2MM E-Ring {P/O item 15} 346 DocuPrint 4512/4512N Service Manual14 {Includes ltems 1, 4, 5, 6, & AD) 15 (Includes Items 8-13, J, & AD) taro 9/96 DocuPrint 4512/4512N Service Manual a7 Parts ListsPL 9 Transport Unit (2 of 2) tem Part 1) 98E17240 ae 3) 22E20780 4) 117617460 5) 8) 7 8) 8) 10) ----- 11) 23614650 12) ta7kea210 13) 14) 15) 16) 17) 18) 49) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 82) 33) 34) 36) 36) 37) 38) 39) 40) 41) 42) Parts Lists, Description Paper Guide C Guide Rotter Guide Roller Collar ‘Transter Corotron Wire Caution Label ‘Transport Frame Assembly 31T oar Transport Gear B 31T ‘Transport Gear A 31T Gear Arm Spring Duplex Drive Belt Duplex Transport Motor Gear Arm Cable Tie AM Gear Arm Shaft AN Fiange 287 AP Pulley 287 Guide Arm R Guide Rolier Spring Cover Switch Spring Cover Switch Hinge Pin PS Roller Bearing PF Roller D Registration Pinch Roll Shaft Registration Pinch Rolls Pinch Roll Earth Spring Earth Spring Transfer Corotron Case ‘Spring inch Roll Spring Transfer Corotron Ci Paper Guide LO ‘Separator Electrode Separator Guide Guide Arm L Paper Guide Sheet Front Cooling Fan Fuser Front Paper Guide Transter Corotron Spring &N Transter Corotron Spring A Transter Corotron Electrode Holder Guide Roller Spring L —— AF Ag AH 348 Part 15327850 s54w20852 354w20752 26E300140 a5awe20as2 113w27650 15327650 ‘354w20552 2e1watist 11316051 ‘towe0est 15327850 Description M3x8 Binding Head Tapping ‘Screw ‘MM E-Ring 4MM E-Ring M2.6x6 Pan Head Tapping Serew 3MM E-Ring M3x6 Binding Head Tapping Screw M3x6 Pan Head Machine Screw 1.5MM E-Ring Washer 3.310x6.00Dx0.5 Thick M2x10 Sorew Max16 Screw M3x8 Pan Head Tapping Sorew DecuPrint 4512/4512N Service Manual11.013 9/96 DocuPrint 4512/4512N Service Manual 319 Parts Lists.PL 10 Fuser Assembly tem Part Description » Exit Roller 2) ‘Separator Paw! Holder 3) Flange 247 4) 24T Pulley 5) Fusing Earth Spring 8) Separator Paw! Spring ”n Scparator Paw! 8) Lamp Holder 9 Terminal B 10) Fusing Earth Wire 1) Heat Roll Bearing 12) Retaining Ring 13) Fuser Gear 32T 14) Pressure Bearing 15) Pressure Roller Spring 18) Pressure Roller Bearing 17) Pressure Roller 18) Heat Roller 19) Transfer Corotron Resistor 20) Base Piate 21) Heater Cover 22) Terminal A 23) Thermostat 24) Thermistor 25) Heater Hamess B (110 V) Heater Hamess B (220 V) 26) 126K07420 Heater Lamp, 110 VAC 128K07410 Heater Lamp, 220 VAC 27) wees Heater Hamess A (110 V) cesses Heater Hamess A (220 V) 28) 126K07440 Fuser Assembly, 110 VAC {Includes Items 1 - 27) 126K07430 Fuser Assembly, 220 VAC {includes Items 1 - 27} 183W28050 Screw 3x10 18327850 _M3x8 Pan Head (Cup) Tapping Screw 18327650 M3x6 Binding Head Tapping Screw 354W20752 4MM E-Ring 26E54360 4x8 Binding Head Tapping Screw 113W27550 _M3x4 Binding Head Tapping Screw 113W27650 _M3x6 Binding Head Tapping Screw 11327651 M3x6 Pan Head Machine Screw 11927451 M&x# Pan Head Machine Sorew REENEATO> Parte Lite 220 DecuPrint 4512/4512N Service Manual26 28 {Includes items 1-27} 12008 Parts Lists DocuPrint 4512/4512N Service ManualPL 11 Cassette tem Part Description 1) 109R320 Adjustable Cassette 2) 109321 «Envelope Cassette 9196 Parts Lists 322 AB12/4512N Service ManualParts Lists 9198 9-23 DocuPrint 4512/4512N Service ManualPL 12 Packing Material & Accessories er » 2) 3) 4) 5) 6) 7 8) 9) 10) 1) 12) 13) 1) 18) Part ‘94K03380 101F90 OK35110 695E32000 695E32010 695E32270 38E17250 695E31990 50E13150 106R88 42E01210 Parte Liste Description AC Cord Fuser Wiper Photoconductor / Drum Cartridge Manual Feed Tray {Includes Iter 5) Paper Guide {P/O ttem 4) ‘Cassette Fixing Cushion (Germany only) ‘Operation Manual Bottom Packing Cushion20 Packing Case (110V) Packing Case (220V) Delivery Guide Cover ‘Top Packing Cus Received Document Tray Extender Developer Cartridge BV Fixer Packing Cushion Corotron Wire Cleaner iB DocuPrint 4512/4512N Service ManualDocuPrint 4512/4512N Service Manual 9796 325 Parts ListsPL 13 Hardware Part 153W28050 153W36050 26E43680 153W27850 15327850 153W27650 163W27550 +153W28050 354w20852 ‘354W20752 26554360 ‘956W26251 15326850 26E300140 26Fa8040 11327651 364Ww20452 252W02051 113W27850 356W15251 ss6w2a261 113W27550 113027650 11327651 118328250 AD 35420452 AE 11327451 AF 153W27650 AG = 354W20552 AK 251W2115t AJ 26€60250 AK 26€60260 AM 113W16051 AN AP as BEEN KX E F 11328651 153W27850 26E60270 AT 356W19251 AU 28660280 AV 11329751 AW 11327651 Ax 11327451 AY 153W15650 Parts Lists Description M3x10 Binding Head Tapping Screw ‘4x10 Pan Head Tapping Sorew M4xt2 Binding Head Tapping Screw M3x8 Pan Head (Cup) Tapping Screw M3x8 Binding Head Tapping Screw M3x6 Binding Head Tapping Screw M3x5 Binding Head Tapping Screw 3x10 Binding Head Tapping Screw 5MM E-Ring 4M E-Ring M4x8 Binding Head Tapping Screw Grip Ring 5MM 3x16 Binding Head Tapping Screw M2.6x6 Pan Head Tapping Screw Max6 Pan Head Machine Screw M3x6 Pan Head Machine Screw 38MM E-Ring Washer 4.11Dx6.50Dx0.25 Thick M3xB Binding Head Tapping Screw Grip Ring 1.9MM Grip Ring 4mm ‘M3xd Binding Head Tapping Screw (M3x6 Binding Head Tapping Screw M3x6 Pan Head Machine Screw Max@ Pan Head (Cup) Tapping Screw 2MM E-Ring M3x4 Pan Head Machine Screw M3x6 Pan Head Machine Screw 1.5MM E-Ring ‘Washer 3.31D%6.00Dx0.5 Thick ‘Thumb Screw ‘Shoulder Screw ‘M2x10 Pan Head Machine Screw M3x16 Pan Head Machine Screw M3x8 Pan Head Tapping Sorew ‘Shoulder Screw Grip Ring 2.6MM ‘Thumb Screw Max32 Pan Head Machine Screw M3x6 Pan Head Machine Screw M3x4 Pan Head Machine Screw M2x5 Binding Head Tapping Screw 9196 3:26 DocuPrint 4612/4512N Serviee ManualPL 14 Part Number Cross Reference PartNumber = PL# 105K16280 PL7 Part Number PLe 106R88, PLS & PLI2 3661920 PL 4109R320 PLit 3642060 Pu tosra21 Put BE12110 Piz 11007460 PL 6k17040 Pus 110K09090 PLo 6K17050 Pa 117817460 Pls Te67810 Pe 120614570 Pe 747820 Pie 12014580 PLS 7E47830 PL2 120E14740 Pu 7E47840 PL2 121E13210 PL2 747850 Pl 128K07410 PLIO 747860 PL 126K07420 PLIO 747870 Ps 128K07490 PLIO 7E47880 PL3 126KO7440 PLIO 7647890 pis 127810740 PLs 7667900 PLB 12710750 PL7 7647910 Pie 127£10860 Pig 7647920 PLe 127K22200 PL 7667930 PLto 127k22210 Pio ‘7E47940 PLO 130K56450 PL2 (22E20780 PLO 130K56460 PLIO (22K53560 PL2 130K56470 PLIO eksa570 PLO to0K1020 Put (22K53580 PLs 160K31830, PLS 23614650 PLS 160K31840 PLB 31£08310 PLB 160K31850 PL 38617240 PLo 160K31860 PL (38E17250 PLI2 160K31870 PLT A2E01210 PLZ 180K31910 PLT 48K56490 PL 160K32520 PL 48K58500 Put 416032630 Pu 48K56510 PLI 160K33020 PLT ‘48K56520 PLB 600S556, PL2 50E13150 Purz 69531990 PLi2 50K35110 PLI2 695E32000 PLI2 53504840 PL7 695E32010 PLI2 54412960 PLS 695632270 PLIZ 54K12370 Pu 7sswoses2 PLT 62K08340 PL4 733W03660 PLT 94K03380 PLI2 (809E01350 PLS 101R80 PLS & PLIZ 180901360 PLo 105K16260 PL 891617370 PL 105K16270 PL7 9/96 Parts Lists 327 DocuPrint 4512/4512N Service ManualNotes 9/96 Parte Liste 328 DocuPrint 4512/4512N Service ManualSection 4 Repair Procedures REP 4.0 Overview. REP 4.1 Covers REP 4.1.1 Front Panel Assembly .. REP 4.1.2 Upper Cover... REP 4.1.3 Exit Guide Assembly/Fuser Cover Assembly... REP 4.1.4 Bottom Cover. REP 4.2 Paper Feed REP 4.2.1 Paper Size Detect Lever .. REP 4.2.2 Paper Empty Actuator .. REP 4.2.3 Paper Feed Clutch REP 4.2.4 Paper Feed Roller REP 4.3 Paper Transportation REP 4.3.1 Upper Transport Assembly REP 4.3.2 Duplex Drive Belts REP 4.3.3 Paper Exit Roller REP 4.3.4 Registration Clutch 9/96 ‘DocuPrint 4512/4512N Service Manual at Repair Procedures