Elite XL8 Service Manual

8/11/2019 Elite XL8 Service Manual

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GCCTECHNOLOGIES

Elite XL 8ppmService Manual

GCC Technologies209 Burlington RoadBedford, M A 01730-9143

phone:781-275-5800fax:781-275-1115e-mail:[email protected]:http:// www.gcctech.com

EliteXL

GCCTECHNOLOGIES

072.15668

Thi d t t d ith F M k 4 0 4


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Elite XL 8PPM Laser PrinterTable of Contents

Elite XL 8ppm Service Manual iii

1. About this manual

1.1 How this manual is organized . . . . . . . . . . . . . . . . . . . . . . . . 1-31.2 Symbols used in this manual. . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 Associated documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Toner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Fuser heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Class 1 laser product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Electrostatic discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2. Specifications

2.1 Basic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.4 Mechanical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Size and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Minimum space requirements . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.5 Functional specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Printing method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Fusing method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Print speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Poweron sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Maximum paper size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Maximum printing area . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Maximum paper held in output tray . . . . . . . . . . . . . . . . . . . . . 2-4

Roller Circumferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.6 Operating environment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Temperature & humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Altitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Horizontal bias. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Noise (excluding impulse noise) . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.7 Paper specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5


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Paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Available paper types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Standard paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Paper weight limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Available paper sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Paper type and dimensions (width X height in millimeters) . . . . . . . . . 2-6

Printing accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.8 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Customer replaceable options. . . . . . . . . . . . . . . . . . . . . . . . 2-7

Factory replaceable options . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.9 Material Safety Data Sheet (1&2) . . . . . . . . . . . . . . . . . . . . . . 2-9

3. Parts Lists

PL1 - Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

PL2 - Paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4PL3 - Paper transportation I . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

PL4 - Paper transportation II . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

PL5 - Fusing and paper exit . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

PL6 - Drive and xerographic module . . . . . . . . . . . . . . . . . . . . . . .3-16

PL7 - Electrical module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

PL8 - Optional feeder assembly (250 sheet feeder) . . . . . . . . . . . . . . . .3-22

PL9 - Optional feeder assembly (500 sheet feeder) . . . . . . . . . . . . . . . .3-24

4. Repair and Replacement Procedures (RRP)

Notations in the RRP text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

RRP1 - Covers

RRP 1.1 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

RRP 1.2 Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

RRP 1.3 Left Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

RRP 1.4 Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

RRP2 - Paper Feed

RRP 2.1 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

RRP 2.2 Feed Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

RRP 2.3 Turn Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

RRP 2.4 Feed Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

RRP 2.5 Feed Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

RRP 2.6 Turn Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22


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RRP 2.7 No-Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

RRP 2.8 Feeder PWB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

RRP 2.9 Size Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

RRP3 - Paper Transportation

RRP 3.1 Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

RRP 3.2 Registration Roll Assembly . . . . . . . . . . . . . . . . . . . . . . 4-32

RRP 3.3 Lower Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-34

RRP 3.4 BTR (Bias Transfer Roller) Assembly . . . . . . . . . . . . . . . . . 4-36

RRP 3.5.1 Front Transport Assembly without Harness. . . . . . . . . . . . . . 4-38

RRP 3.5.2 Front Transport Assembly with attached Harness. . . . . . . . . . .4-40

RRP 3.6 Retard Pad Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 4-42

RRP 3.7 Transport Chute Assembly . . . . . . . . . . . . . . . . . . . . . . 4-44

RRP 3.8 PickUp Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-46

RRP 3.9 PickUp Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48RRP 3.10 MSI (Multi-Purpose Feeder) No-Paper Sensor Assembly. . . . . . . 4-50

RRP 3.11 Bottom Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-52

RRP 3.12 Console Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

RRP 3.13 MSI (Multi-Purpose Feeder) Front Tray Assembly. . . . . . . . . . .4-56

RRP4 - Fuser and Paper Exit

RRP 4.1 Fuser Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-58

RRP 4.2 Pressure Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60

RRP 4.3 Exit Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

RRP 4.4 Exit Roll Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

RRP 4.5 Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66

RRP 4.6 Heat Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68

RRP 4.7 Fuser Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .4-70

RRP 4.8 Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72

RRP 4.9 Exit Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-74

RRP5 - Drive and Xerographic Modules

RRP 5.1 Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76

RRP 5.2 CRU (Toner Sensor) PWB. . . . . . . . . . . . . . . . . . . . . . .4-78

RRP 5.3 ROS (Optical Unit) Assembly. . . . . . . . . . . . . . . . . . . . .4-80

RRP 5.4 Toner Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . .4-84

RRP6 - Electrical Modules

RRP 6.1 ESS PWB (Main Controller Board) . . . . . . . . . . . . . . . . . .4-86


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RRP 6.1.1 Elite XL 030 / 040 Combo Board Installation . . . . . . . . . . . . .4-88

RRP 6.2 Electronics Box Cover. . . . . . . . . . . . . . . . . . . . . . . . .4-94

RRP 6.3.1 Earth Plate Assembly without attached harness . . . . . . . . . . .4-96

RRP 6.3.2 Earth Plate Assembly with attached harness. . . . . . . . . . . . .4-98

RRP 6.4 MCU PWB (Engine Control Board) . . . . . . . . . . . . . . . . . 4-100

RRP 6.5 HVPS (High Voltage Power Supply) Assembly . . . . . . . . . . . 4-102

RRP 6.6 LVPS (Low Voltage Power Supply) Assembly . . . . . . . . . . . 4-104

RRP 6.7 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108

RRP 6.8 Top Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . 4-110

RRP 6.9 ESS Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112

RRP 6.9.1 RAM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4-114

RRP 6.9.2 ROM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4-116

RRP 6.9.3 True Res Daughter Card . . . . . . . . . . . . . . . . . . . . . . 4-118

RRP 6.9.4 GCIO Ethernet Card . . . . . . . . . . . . . . . . . . . . . . . . 4-122

5. Principles of Operation

The Print Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Paper Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Function of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

3.1 Paper Feed (PL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

3.2 Paper Transportation I (PL3) . . . . . . . . . . . . . . . . . . . . . . . . .5-11

3.2 Paper Transportation II (PL4) . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

3.3 Fusing and Paper Exit (PL5) . . . . . . . . . . . . . . . . . . . . . . . . .5-15

3.4 Drive and Xerographic Modules (PL6) . . . . . . . . . . . . . . . . . . . .5-17

3.5 Electrical Module (PL7) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

6. General Procedures and Information

1. Printer operations

1.0 Service Test Page . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

1.1 The Type D0 Console Assembly . . . . . . . . . . . . . . . . . . . 6-7

1.2 Printer modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

1.3 Online Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

1.4 Printing Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

1.5 Diagnostics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . .6-11DG30 Print Counter . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

DG02 Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Output tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Fuser temperature. . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

Fuser temperature explained . . . . . . . . . . . . . . . . . . . . . 6-18


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DG07 Fuser Temp.Set. . . . . . . . . . . . . . . . . . . . . . . . .6-19

DG08 Fuser Temp . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

DG80 Solenoid Tray 0 . . . . . . . . . . . . . . . . . . . . . . . . .6-22

DG81 Solenoid Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . .6-23

DG86 Solenoid Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . .6-24

DG84 T Clutch Upper . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

DG85 T Clutch Lower . . . . . . . . . . . . . . . . . . . . . . . . .6-26

DG82 Regi Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27

DG90 Motor Main. . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

DG91 HVPS BCR-AC . . . . . . . . . . . . . . . . . . . . . . . . .6-29

DG92 HVPS Fan Fast . . . . . . . . . . . . . . . . . . . . . . . . .6-30

DG93 HVPS (Dev Bias) . . . . . . . . . . . . . . . . . . . . . . . . 6-31

DG94 HVPS (T.Roll ) . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

DG95 HVPS (T.Roll +). . . . . . . . . . . . . . . . . . . . . . . . . 6-33

DG96 HVPS (BCR-DC, Detack). . . . . . . . . . . . . . . . . . . . 6-34

DG00 Exit Diag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

DG00 Size Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

DG00 Check Sum . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

2. Fault and Status Codes

Fault and Status code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Printer conditions and responses for Fault /Status codes . . . . . . . . . . . . . 6-40

Modes When Fault/Status codes are displayed. . . . . . . . . . . . . . . . . . 6-43

3. Printer Controls

Paper sheet size selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44

Sheet feeder selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45

4. ROS (Optical Unit) Controls

Scanner motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47

The relationship between scanner motor speed and print resolution . . . . . . .6-47

ROS preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47

ROS reference values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48

5. Fuser Controls

Heater Rod control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49

Fuser Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49

Sheet-specific mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49


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Fuser temperature table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49

Fuser temperature code table . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49

6. Recovery and Cleaning routines

On-Recovery routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51

7. Paper transport timing errors

E4 paper jam timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52

E3 paper jam timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53

E2-1 paper jam timing (Early registration). . . . . . . . . . . . . . . . . . . . 6-54

E2-2 paper jam timing (Misfed paper) . . . . . . . . . . . . . . . . . . . . . . .6-55

8. P/J locator on MCU PWB (Engine Control Board)

P/J locator table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57

P/J locator diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-60

9. Connection and wiring diagrams

Master connection and wiring diagrams. . . . . . . . . . . . . . . . . . . . . .6-62

Component connection and wiring diagrams . . . . . . . . . . . . . . . . . . .6-63

Diagram blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

LVPS Assembly and MCU PWB wiring diagram . . . . . . . . . . . . . . . . .6-67

LVPS Assembly and MCU PWB . . . . . . . . . . . . . . . . . . . . . . . . .6-68

LVPS Assembly and the Fuser Assembly wiring diagram. . . . . . . . . . . . .6-69

LVPS Assembly and the Fuser Assembly . . . . . . . . . . . . . . . . . . . .6-70MCU PWB and the ROS Assembly wiring diagram . . . . . . . . . . . . . . . .6-71

MCU PWB and the ROS Assembly. . . . . . . . . . . . . . . . . . . . . . . .6-72

MCU PWB, Feeder PWB, Feeder PWB AUX, Feed Solenoid,

and the Turn Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-74

MCU PWB and the Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . .6-79

MCU PWB, HVPS, Earth Plate Assembly, Transportation

Chute Assembly, Front Frame Assembly, Fan & ESS Fan, Transport

Chute Assembly to BTR Assembly, Front Frame Assembly to Chute Fan . . . .6-80

MCU PWB, Exit Sensor, MSI Sensor, and the PickUp Solenoid. . . . . . . . .6-85

MCU PWB, Registration Sensor, Registration Clutch, and the Toner Sensor . . .6-86

MCU PWB, CRU Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-88

ESS PWB and the Console Assembly . . . . . . . . . . . . . . . . . . . . . .6-90

LVPS, ESS PWB, and the MCU PWB. . . . . . . . . . . . . . . . . . . . . . .6-92


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10. Printing accuracy

Lead edge registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-94

Side edge registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-95

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-96

Vertical accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-97

Horizontal accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-98

7. Fault Isolation Procedures

Fault isolation tables

Printer Troubleshooting Path . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Using Level 1 FIPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

2.1 Fault code U2/Service Error 10 . . . . . . . . . . . . . . . . . . . . 7-5

2.2 Fault code U6/Service Error 11 . . . . . . . . . . . . . . . . . . . . 7-6

2.3 Fault code XX/Service Error 12. . . . . . . . . . . . . . . . . . . . 7-72.4 Fault code U4/Service Error 13 . . . . . . . . . . . . . . . . . . . . 7-8

2.5 Fault code E5/Cover is Open . . . . . . . . . . . . . . . . . . . . .7-10

2.6 Fault code E4/Paper Exit Jam . . . . . . . . . . . . . . . . . . . . .7-11

2.7 Fault code E3/Paper Path Jam . . . . . . . . . . . . . . . . . . . .7-13

2.8 Fault code E2/Paper Feed Jam. . . . . . . . . . . . . . . . . . . .7-16

2.8.1 Fault code J3/Install Toner. . . . . . . . . . . . . . . . . . . . . . .7-20

2.9 Fault code P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

2.10 Fault code C3/Install Tray 1,2 . . . . . . . . . . . . . . . . . . . . .7-22

2.11 Fault code C5/Tray (1,2) (empty) . . . . . . . . . . . . . . . . . . .7-23

2.12 Fault code J5/Toner is Low . . . . . . . . . . . . . . . . . . . . . .7-25

2.13 Fault code CX. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

2.13.1 Service Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27

2.13.2 Bad Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29

Printer performance problems

2.14.1 Fault code J5 is not displayed/Toner is Low is not displayed . . . . .7-32

2.14.2 Inoperative printer . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33

2.14.3 Malfunctioning LCD. . . . . . . . . . . . . . . . . . . . . . . . . .7-36

2.14.4 Malfunctioning LED . . . . . . . . . . . . . . . . . . . . . . . . . .7-37

2.14.5 Inoperative key pad . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

2.14.6 Erratic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40

2.14.7 Inoperative Drive Assembly. . . . . . . . . . . . . . . . . . . . . .7-41


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Table of Contents

x Elite XL 8ppm Service Manual

Level 3 FIPs (Fault Isolation Procedures)

3.1 LVPS Assembly failure (+5VDC) . . . . . . . . . . . . . . . . . . .7-43

3.2 LVPS Assembly failure (+24VDC) . . . . . . . . . . . . . . . . . . .7-44

3.3 Scanner Assembly failure. . . . . . . . . . . . . . . . . . . . . . .7-45

3.4 ROS Assembly failure . . . . . . . . . . . . . . . . . . . . . . . . .7-46

3.5 Heater Rod failure . . . . . . . . . . . . . . . . . . . . . . . . . . .7-48

3.6 Thermistor failure . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50

3.7 Exit Sensor failure . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51

3.8 Registration Sensor failure . . . . . . . . . . . . . . . . . . . . . .7-52

3.9 MSI (Multi-Purpose Feeder) Sensor failure. . . . . . . . . . . . . .7-53

3.10 No-Paper Sensor failure. . . . . . . . . . . . . . . . . . . . . . . .7-54

3.11 LD Switch S101 failure . . . . . . . . . . . . . . . . . . . . . . . .7-56

3.12 CRU Switch S100 failure . . . . . . . . . . . . . . . . . . . . . . .7-57

3.13 Paper Size Switch failure . . . . . . . . . . . . . . . . . . . . . . .7-59

3.14 Registration Clutch failure . . . . . . . . . . . . . . . . . . . . . . .7-613.15 Pick-Up Solenoid failure. . . . . . . . . . . . . . . . . . . . . . . .7-62

3.16 Feed Solenoid failure . . . . . . . . . . . . . . . . . . . . . . . . . 7-63

3.17 Turn Solenoid failure . . . . . . . . . . . . . . . . . . . . . . . . .7-65

3.18 NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67

3.19 Drive Assembly failure. . . . . . . . . . . . . . . . . . . . . . . . .7-68

3.20 Fan failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71

3.21 Chute Fan failure . . . . . . . . . . . . . . . . . . . . . . . . . . .7-73

3.22 Toner Sensor failure . . . . . . . . . . . . . . . . . . . . . . . . . .7-75

3.23 HVPS BCR (DS) failure. . . . . . . . . . . . . . . . . . . . . . . .7-76

3.24 HVPS DB failure. . . . . . . . . . . . . . . . . . . . . . . . . . . .7-77

3.25 HVPS TR failure . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-78

3.26 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-79

Image Quality Problems

Troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . .7-83

4.1 Light prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-85

4.2 Blank prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87

4.3 Black prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-89

4.4 Vertical band deletions . . . . . . . . . . . . . . . . . . . . . . . .7-90

4.5 Vertical linear deletions . . . . . . . . . . . . . . . . . . . . . . . .7-91

4.6 Horizontal band deletions. . . . . . . . . . . . . . . . . . . . . . .7-92

4.7 Vertical streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-94

4.8 Horizontal streaks . . . . . . . . . . . . . . . . . . . . . . . . . . .7-96

4.9 Spot deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-98


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Elite XL 8ppm Service Manual xi

Table of Contents

4.10 Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-99

4.11 Residual image . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100

4.12 Dirty background . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101

4.13 Skewed image. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102

4.14 Damaged prints. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103

4.15 Unfused image . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104


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Table of Contents

xii Elite XL 8ppm Service Manual


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Elite XL 8ppm Service Manual 1 1

Section 1Introduction


1.1 How this manual is organized . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.2 Symbols used in this manual. . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 Associated documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Toner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Fuser heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Class 1 laser product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5


Electrostatic discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5



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1 2 Elite XL 8ppm Service Manual


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Introduction


This manual contains technical and service information for the Elite XL Laser Printer. Por-tions of this manual are copyrighted by Fuji Xerox Corporation (FX) and portions are copy-righted by GCC Technologies, Inc. (GCC). No portion may be copied or reproducedwithout the prior consent of FX and GCC.

1.1 How this manual is organized

This manual is divided into 8 sections:

Section 1. Introduction contains general information about this manual.

Section 2. Printer Specifications describes the specifications and options of the Elite XLLaser Printer.

Section 3. Parts Lists provides exploded drawings with part numbers of all the compo-nents.

Section 4. RRP explains standard removal and replacement procedures for all of themajor components.

Section 5. Printing Mechanism provides a basic Elite XL Laser Printer principles of oper-ation.

Section 6. General Procedures and Information lists general information, P/J locations,and wiring diagrams.

Section 7. Fault Isolation Procedures provides basic mechanical, electrical, and printquality troubleshooting procedures.

Section 8. Installation, Removal & Call Information describes general service actions.

1.2 Symbols used in this manual

WARNING: A Warning indicates an operating or maintenance procedure, practice,

or condition that, if not strictly observed, could result in injury or loss oflife.

CAUTION:

A Caution indicates an operating or maintenance procedure, practice, orcondition that, if not strictly observed, could result in damage to, ordestruction of, equipment.

NOTE: A Note indicates an operating or maintenance procedure, practice, or conditionthat is necessary to accomplish a task efficiently.

1.3 Associated documents

Users Manual

The user manual that describes how to operate and maintain the Elite XL Laser Printer.

!


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Introduction

1.4 Safety information

Follow these safety instructions to prevent accidents while servicing the Elite XL LaserPrinter. Always be aware of the potential dangers present when working with electrical ormechanical equipment.

Power supply

Before starting any service procedure, switch off the printer power and unplug the powercord from the wall outlet. If you must service the printer with power applied, be aware ofthe potential for electrical shock.

Electrical components

Hand crank to inspect sprockets and gears. Do not try to hand crank the printer while theMain Motor is running.

WARNING: This printer uses a laser as part of the printing process. The laser beamis a very powerful, straight, narrow beam of light that produces extremeheat at its focal point. The laser beam in the Elite XL is invisible.Although you cannot see the beam, it can cause severe damage. Directeye exposure to the laser beam may cause eye injury or blindness.

To avoid permanent eye damage, follow these directions:

Before starting any service procedure, switch off the printer power and unplug thepower cord from the wall outlet.

Do not disassemble the ROS Assembly.

Use caution when you are working around the ROS Assembly or you are performinglaser related repair procedures.

The Elite XL Laser Printer is equipped with two safety switches. The interlock switchesthe HVPS. The LD switches the Laser Diode.

Fuser Heat

The fuser assembly becomes very hot during the operation of the printer. Switch theprinter off for at least five minutes to allow the fusing rollers to cool before servicing thefuser assembly.

Toner Safety

Toner is a nontoxic powder composed of plastic, iron and a small amount of pigment.Clean skin and clothing by removing as much toner as possible with a dry tissue and thenwashing with cold water. DO NOT USE HOT WATER TO CLEAN TONER OFF CLOTH-ING BECAUSE IT WILL PERMANENTLY FUSE INTO THE CLOTHING.

Safety components

Make sure fuses, interlock switches, covers and panels are all functioning properly afteryou have reinstalled or replaced them.

!


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Introduction

Electrostatic Discharge

Whenever you work on or around the Elite XL, BE EXTREMELY CAUTIOUS OF ELEC-TROSTATIC DISCHARGE (ESD). ESD can cause mysterious, intermittent problems andcomplete failures on the logic components of the printer, so make sure you are working ina static-safe environment. An anti-static pad on the workbench and floor and a groundingwrist strap should be part of every technicians work area.

CLASS 1 LASER PRODUCT

LASER SAFETY:

This printer is certified as a Class 1 laser product under the U.S.Department of Health and Human Services (DHHS) Radiation Performance Standardaccording to the Radiation Control for Health and Safety Act of 1968. This means that theprinter does not emit hazardous radiation. Since radiation emitted inside the printer iscompletely confined within protective housings and external covers, the laser beam can-not escape from the machine during any phase of user operation. The Center for Devicesand Radiological Health (CDRH) of the U.S. Food and Drug Administration implementedregulations for laser products on August 1, 1976. These regulations apply to laser prod-ucts marketed in the United States. The label on the printer indicates compliance with theCDRH regulations and must be attached to the laser products marketed in the UnitedStates.

Caution

- Use of controls, adjustments, or performance of procedures other than thosespecified in this manual may result in hazardous radiation exposure.


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Introduction


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Section 2Specifications

2.1 Basic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.4 Mechanical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Size and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Minimum space requirements . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.5 Functional specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Printing method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Exposure method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Fusing method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Print speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Poweron sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Maximum paper size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Maximum printing area . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Maximum paper held in output tray . . . . . . . . . . . . . . . . . . . . . 2-4

Roller Circumferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.6 Operating environment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Temperature & humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Altitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Horizontal bias. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Noise (excluding impulse noise) . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.7 Paper specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Available paper types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Standard paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Paper weight limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Available paper sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Paper type and dimensions (width X height in millimeters) . . . . . . . . . 2-6

Printing accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.8 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Customer replaceable options. . . . . . . . . . . . . . . . . . . . . . . . 2-7

Factory replaceable options . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.9 Material Safety Data Sheet (1&2) . . . . . . . . . . . . . . . . . . . . . . 2-9


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Specifications

2 Specifications

2.1 Basic components

The Elite XL Laser Printer has four major components.

1. The Base Engine

2. The EP Cartridge (CRU)3. The Paper Feeder Assembly

4. The Paper Cassette

2.2 Electrical specifications

The Elite XL printer uses either a 110 or a 220 volt power source. Model 1 is referred toas the 110V model. Model 2 is referred to as the 220V model.

Model 1 110/115VAC (90132VAC) 50/60Hz (4763Hz)

Model 2 220/240VAC (198264VAC) 50/60Hz (4763Hz)

2.3 Power consumption

The maximum power consumption of the Elite XL Laser Printer (not including the Control-ler and associated components) is:

Model 1 450 watts or less

Model 2 600 watts or less

EP Cartridge

Paper Cassette

Base Engine

Paper Feeder Assembly


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Specifications

2.4 Mechanical specifications

Size & Weight

Excluding the EP Cartridge and the Controller.

Width (17.05 in

.2 in) 433

5.0 mm

Depth (22.05 in

.2 in) 560

5.0 mm

Height (10.5 in

.2 in) 267

5.0 mm

Weight (40.3 lbs

1.1lb) 18.3

0.5 Kg

Minimum Space Requirements

GCCTECHNO

LOGIES

EliteXL

608

H

WD

O n L in e C om m P ap er S er vi ce

On Line

Menu

ManualFeed

Form FeedContinue

Enter

CancelReset

Elite XL

GCCTECHNOLOGIES

9 inches(230mm)

7 inches(180mm)

2 inches(50mm)

12.5 inches(320mm)

8 inches (200mm)minimum overheadclearance.

200 mm minimumoverhead clearance.


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Specifications

2.5 Functional specifications

Printing method

Printing by the xerographic process.

Exposure method

Scanning by semiconductor laser beam.

Fusing method

Toner fusing by heat and pressure.

Print speed

The Elite XL Laser Printer has four print speeds (PPM=Pages Per Minute) during continu-ous feed of various paper sizes:

8.0 PPM Statement (LEF), POSTCARD, A5 (LEF), MONARCH, A4 (LEF), LETTER(LEF), B5 (LEF), EXECUTIVE (LEF)

6.0 PPM DL, C5, COM10, LETTER (SEF), A3(SEF)

5.0 PPM LEGAL 13, LEGAL 14, B4

4.3 PPM A3, LEDGER

Resolution

The Elite XL Laser Printer has the following native resolutions (in dots per inch).

8ppm: 600dpi, 800dpi

Poweron sequence

The time it takes the printer to go from PowerOn to Ready.

Within 120 seconds at room temperature of 20C and with nominal voltage applied.

Maximum paper size

Either LEDGER or A3 (11.7" x 17 = 297 mm x 431.8 mm).

Maximum printing area

4.0 millimeters in from all four sides of the paper.

Maximum paper held in output tray

200 sheets of A4 or A3 FX Standard Paper Type L.

Roller Circumference 8ppm

Drum: 3.70 (94mm)

Heat Roller: 2.49 (63.15mm)

Pressure Roller: 2.40 (61mm)BTR Roller: 2.28 (57.8mm)

Registration Roller: 2.00 (50.89mm)

CRU Bias Charge Roller: 1.75 (45mm)

CRU Magnet Roll: 1.94(50mm)


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Specifications

2.6 Operating environment

The Elite XL Laser Printer is designed to operate under the following environmental condi-tions:

Temperature & humidity

41~95

F 5~35

C / 15~80%RH

Altitude

0~8200ft (0~2500m)

Horizontal bias

Less than 5

off level

Noise (excluding impulse noise)

Machine Running: less than 48.5dB

PowerOn Sequence: less than 41.5dB

Machine in Standby: less than 35.0dB

2.7 Paper specifications

Paper feed

The Elite XL Laser Printer uses two types of paper feed.

1. Cassette Feed (there are three selections):

TABLOID/A3 UNIVERSAL is the standard cassette. It holds a maximum of 250sheets of FX Standard paper, in ten different paper sizes.

LETTER TRAY is an optional cassette. It holds a maximum of 500 sheets of stan-dard letter paper.

A4 TRAY is an optional cassette. It holds a maximum of 500 sheets of standard A4

paper. ENVELOPE TRAY is an optional cassette. It holds a maximum of 30 envelopes or

100 postcards.

2. Multipurpose Feeder (MSI)

The Front Tray Assembly, or Multipurpose Feeder, holds 50 sheets of standardpaper, five standard envelopes, 30 sheets of label stock, or 25 standard postcards.

Available paper types

Regular paper (cut sheets), specified envelopes, postcards, specified OHP films (trans-parencies), and specified labels.

The maximum amount of OHP films: Long Cassette (10), Short Cassette (10), MSI (30).

Standard paper

FX Standard Paper Type L (A3 and A4 sizes).

Paper weight limitations

For Paper Cassettes

Maximum: 60~105g/m2 (1628 lbs) Except 190g/m2 (50 lbs) for postcards

For MSI


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Specifications

Maximum: 60~135g/m2 (1636 lbs) Except 190g/m2 (50 lbs) for postcards

Available paper sizes

For the Tabloid/A3 Cassette:

INTERNATIONAL USA

A5 (LEF) Statement (LEF)

B5 (LEF) Executive (LEF)

A4 (LEF) Letter (LEF)

A4(SEF) A4 (LEF)

Legal 13 Legal 13

Legal 14 Legal 14

B4 Letter (SEF)

A3 B4

Letter (LEF) A3

Ledger Ledger

For the Letter Cassette:

INTERNATIONAL USA

A5 (LEF) Statement (LEF)

B5 (LEF) Executive (LEF)

A4 (LEF) A4 (LEF)

Letter (LEF) Letter (LEF)

A4 (SEF) Letter (SEF)

For the Envelope Cassette:

COM10, Monarch, Double Letter (DL), C5, and Official Postcard.

For the Multipurpose Feeder Assembly (MSI):

All recommended paper sizes, from envelope and postcard, to A4.

Paper type and dimensions (width X height in millimeters)

A3 11.69 in x 16.54 in (297.0 mm x 420.0 mm)

A4 8.27 in x 11.69 in (210.0 mm x 297.0 mm)

A5 5.87 in x 8.27 in (149.0 mm x 210.0 mm)

B4 10.12 in x 14.33 in (257.0 mm x 364.0 mm)

B5 7.17 in x 10.12 in (182.0 mm x 257.0 mm)

C5 6.38 in x 9.02 in (162.0 mm x 229.0 mm)


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Specifications

COM-10 4.13 in x 9.5 in (104.8 mm x 241.3 mm)

DL 4.33 in x 8.66 in (110.0 mm x 220.0 mm)

EXECUTIVE 7.25 in x 10.5 in (184.2 mm x 266.7 mm)

LEDGER 11 in x 17 in (279.4 mm x 431.8 mm)

LEGAL 13" 8.5 in x 13 in (215.9 mm x 330.2 mm)

LEGAL 14" 8.5 in x 14 in (215.9 mm x 355.6 mm)

LETTER 8.5 in x 11 in (215.9 mm x 279.4 mm)

MONARCH 3.87 in x 7.5 in (98.4 mm x 190.5 mm)

POSTCARD 3.94 in x 5.83 in (100.0 mm x 148.0 mm)

STATEMENT 5.51 in x 8.5 in (139.9 mm x 215.9 mm)

Printing accuracy

For more information, read How to Read Printing Accuracy

in Section 6 of this manual.

The Elite XL Laser Printer is designed to be accurate within the following print image

parameters: Lead Edge Registration:

2.0 mm

Side Edge Registration:

2.5 mm

Skew:

2.0 mm (at a width of 245 mm)

Vertical Accuracy:

1.3 mm (at a height of 210 mm)

Feeding Accuracy:

1.0 mm (at the height of 390 mm)

Horizontal Accuracy:

2.0 mm (at a width of 245 mm and a height of 390mm)

2.8 Options

Customer replaceable options

The customer has four paper feed options.

TABLOID/A3 UNIVERSAL TRAY is the standard cassette. It holds a maximum of250 sheets of standard paper, in ten different paper sizes.

LETTER TRAY is an optional cassette. It holds a maximum of 250 sheets of stan-dard paper, in five different paper sizes.

ENVELOPE TRAY is an optional cassette. It holds a maximum of 30 envelopes or100 postcards.

LOWER SHEET FEEDER is an optional second sheet feeder. The lower sheetfeeder is an accessory that attaches to the bottom of the Elite XL allowing you to

add additional paper trays. There are two different lower sheet feeders available forthe Elite XL: 250- and 500- sheet capacities.


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Specifications

As shown in the diagram below, you can extend the printers paper feeding capacity to550 or 800 sheets by using a combination of the standard sheet feeder, the multipurposefeeder and either the optional 250 sheet feeder or the optional 500 sheet feeder.

GCCTECHN

OLOGIES

EliteXL

608

Standard 250Sheet Feeder

Optional Paper Tray

Multipurpose Feeder

Optional 250 or 500Sheet Feeder

(MSI)


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Specifications

Section IV - Physical Data

May OccurWill Not Occur X

N.A.

Water, dry chemical, carbondioxide or foam.

Avoid inhalation of smoke. Wear protective clothing and self-containedbreathing apparatus.

Toner is a combustible powder. Like most organic materials in powderform, when dispersed in air, it can form explosive mixtures.

Section V - Fire and Explosion Data

Flash Point (Method Used):

Extinguishing Media:

Special Fire Fighting Procedures:

Fire and Explosion Hazards:

Flammable LEL: N.A.Limits UEL: N.A.

Stability:

Hazardous Decomposition Products:

Incompatibility (Materials to Avoid):

Products of combustion may be toxic. Avoid breathing smoke.

None known

Unstable:Stable: X

Hazardous:Polymerization:

Section VI - Reactivity Data

Respiratory Protection:Eye Protection:Protective Gear:Other:

Section VII - Special Protection Information

None required when used as intended in Xerox equipment.None required when used as intended in Xerox equipment.None required when used as intended in Xerox equipment.For use other than normal customer - operating procedures (such as in bulk toner

processing facilities), goggles and respirators may be required. For moreinformation, contact Xerox.

Section VIII - Special Precautions

Handling and Storage:

Conditions to Avoid:

None

Avoid prolonged inhalation of excessive dust.

For Spills or Leakage:

Waste Disposal Method:

Section IX - Spill, Leak, and Disposal ProceduresSweep up or vacuum spilled toner and carefully transfer into a sealable wastecontainer. Sweep slowly to minimize generation of dust during clean-up. If avacuum is used, the motor must be rated as dust tight. A conductive hose bondedto the machine should be used to reduce static buildup (See Section V). Residuecan be removed with soap and cold water. Garments may be washed or drycleaned, after removal of loose toner.

When disposed, this material is not a hazardous waste according to FederalRegulation 40 CFR 261. However, State and Local requirements may be morerestrictive. Therefore, consultation with the appropriate State and Local waste

disposal authorities is advised.

Section X - Transportation Information

DOT Proper Shipping Name:Hazard Classification: I.D. Number: N.A.

Not RegulatedN.A.

600E74160

Trade Name: Elite XL Toner Cartridge MSDS No. : OEM-5029

Appearance/Odor:Boiling Point:Solubility in Water:Evaporation Rate:Vapor Density (Air = 1):Volatile N.A. %(Wgt.)

Black powder / faint odorN.A.NegligibleN.A.N.A.N.A. %(Vol.)

Softening Range:Melting Point:Specific Gravity (H

2O = 1):

Vapor Pressure (mm Hg):pH =

N.D.N.D.~ 1.7g/ccN.A.N.A.

2.9 Material Safety Data Sheet


28/401


Specifications

Section II - Emergency and First Aid

Eyes:Skin:Inhalation:Ingestion:Primary Route of Entry:Symptoms of Overexposure:

Medical Conditions GenerallyAggrevated by Exposure:Additional Information

Section III - Toxicology and Health Information

This material has been evaluated by Xerox Corporation.

Oral LD50

:Dermal LD

50:

Inhalation LC50

:

Eye Irritation:Skin Sensitization:Skin Irritation:Human Patch:Mutagenicity:Carcinogens:Aquatic LC

50:

> 5 g/kg (rats) practically non-toxic.1

N.D.> 5 mg/l (rats, 4 hr exposure) practically non-toxic.1

> 20 mg/l (rats, calculated 1 hr exposure)non-poisonous, DOT.1

Not an irritant.1

Not an sensitizer.1

Not an irritant.1

Non-irritating, non-sensitizing,1

No mutagenicity detected in the Ames Assay.1

None present.> 1000 mg/l (fathead minnows).1

TLV:PEL:

STEL:Ceiling:XEL2:

10 mg/m3(total dust)15 mg/m3(total dust5 mg/m3(respirable dust)None establishedNone established2.5 mg/m3 (total dust)0.4 mg/m3(respirable dust)

Additional Information: In a Xerox sponsored chronic inhalation study in rats using a special test toner, therewere no lung changes at all in the lowest exposure level (1 mg/m3), the most relevant level to potential humanexposures. A very slight degree of fibrosis was noted in 25% of the animals at the middle exposure level (4mg/m3) while a slight degree of fibrosis was observed at the highest exposure level (16mg/m3) in all animals.These findings are attributed to lung overloading, a generic response to excessive amounts of any dustretained in the lungs for a prolonged interval. The special test toner was ten times more respirable thancommercially available Xerox toner to comply with EPA testing protocol and would not function properly inXerox equipment.1Based on testing similar xerographic toner materials. 2XEL - Xerox Exposure Limit

Form 58739 (10/84) STAR N.A. - Not Applicable N.E. - None Established N.D. - Not Determined

Flush with water.Wash with soap and water.Remove from exposure.Dilute stomach contents with several glasses of water.InhalationMinimal respiratory tract irritation may occur as with exposure to largeamounts of any non-toxic dust.

None when used as described by product literature.See Sections III, V and VII.

CAS No.

25767-47-91309-38-29003-07-0

67762-90-7

84179-66-8, 109125-50-0,and/or 109125-51-1

Section I - Product Identification

Trade Names/Synonyms: Elite XL Toner Cartridge Part No: 673K6400

Chemical Name: None

Ingredients

Toner:Styrene/acrylate polymer (50-60%)Iron oxide (40-50%)Polypropylene wax (1-5%)Hydrophobic silicon dioxide (


29/401


Section 3Parts Lists

PL1 - Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

PL2 - Paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

PL3 - Paper transportation I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

PL4 - Paper transportation II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

PL5 - Fusing and paper exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

PL6 - Drive and xerographic module . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

PL7 - Electrical module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

PL8 - Optional feeder assembly (250 sheet feeder) . . . . . . . . . . . . . . . . . . 3-22

PL9 - Optional feeder assembly (500 sheet feeder) . . . . . . . . . . . . . . . . . . 3-24

Using the Parts List

1. The numbers shown in each illustration correspond to the numbers in that illustration'sparts list. The notation PL 3. 5" refers to item 5 in Parts List 3.

2. The letters C, E, and S, shown in an illustration, stand for Cring, Ering, and Screw.

3. The notation 3~7 in the parts list indicates an assembly is made up of components 3through 7.

4. The symbol in the parts list indicates a part is an Recommended Part and is con-stantly stocked and readily available.


30/401


Parts List

PL1 Covers

Figure 1. Printer covers

GCCTECHN

OLOGIES

EliteXL

608

SS

S

S

2

3

4

S

S

6

7

SS

1

5

8


31/401


Parts List

PL1 Covers

1. TOP COVER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15457

2. EXTENT TRAY ASSEMBLY (Output Tray Assembly) . . . . . . . . . . . . . . . . . . . . . 15462

3. OPTION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15453

4. REAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15458

5. LEFT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15454

6. RIGHT COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15455

7. FONT CARD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

8. FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15456

ELITE XL 616 UNIQUE SPARE PARTS

1.TOP COVER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16066

2. EXTENT TRAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16068

3. OPTION COVER, 16PPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16070

8. FRONT COVER, 16PPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16072


32/401


Parts List

PL2 Paper feed

Figure 1. Paper feed components

1718

20

2

15

19

7

61234

8

13

21

9

1110

14

222324

27

7

9

s

ss

s

s

s

ss

s

s

s

s

s

1 (with 2 ~ 21)

5 (with 6,7)

16


33/401


Parts List

PL2 Paper feed

1. FEEDER ASSEMBLY 1 TRAY (with 2~21)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15452

2. FEEDER FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

3. FEED SOLENOID (also works with Elite 600) . . . . . . . . . . . . . . . . . . . . . . . . . 15311

4. TURN SOLENOID (also works with Elite 600) . . . . . . . . . . . . . . . . . . . . . . . . . 15312

5. FEED ROLL ASSEMBLY (with 6,7)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15430

6. FEED CLUTCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

7. FEED ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15299

8. TURN ROLL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15429

9. FEED BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15447

10. GEAR IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15434

11. GEAR OUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15435

12. GEAR FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15436

13. NOPAPER ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15477

14. SIZE SPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15441

15. FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15494

16. HARNESS ASSEMBLY OUT (J116~J115)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15317

17. FEEDER EARTH PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

18. FEED HOUSING L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15459

19. FEED HOUSING R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15461

20. FEEDER TIE PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16092

21. ACTUATOR LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15445

22. TABLOID/A3 250 SHEET TRAY (Option)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC15249

23. LETTER 500 SHEET TRAY

(Option)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC15362

24. ENVELOPE TRAY

(Option)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC15253

25. 2 TRAY CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

26. JOINT FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15309

27. HARNESS CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16084


34/401


Parts List

PL3 Paper transportation I

Figure 1. Paper transportation I components


35/401


Parts List

PL3 Paper transportation I

1. LINK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15446

2. C/B SPRING S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15438

3. C/B SPRING L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15439

4. SPRING LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15443

5. SHUTTER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15442

6. TRAY LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15444

7. TRAY LINK STUD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

8. RETARD PAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15448

9. RETARD SPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

10. EARTH WIRE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

11. REGI. ROLL ASSEMBLY (with 12~21)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15450

12. REGI. ROLL SUBASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

13. REGI. CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15482

14. REGI. SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15490

15. REGI. ACT BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

16. REGI. ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15478

17. REGI. SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

18. HARNESS ASSEMBLY PRE REGI. (J25

J120)

. . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

19. CONNECT BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

20. CONNECTOR 2P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

21. CONNECTOR 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

22. RESISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

23. LOWER CHUTE ASSEMBLY (with 24,25)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15465

24. LOWER CHUTE A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

25. LOWER CHUTE B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S


36/401


Parts List

PL4 Paper transportation II

Figure 1. Paper transportation II components


37/401


Parts List

PL4 Paper transportation II

1. FRONT COVER ASSEMBLY

(with 2~41)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15460

2. FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15456

3. MSI (Multipurpose Feeder) TRAY ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 15463

4. BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

5. FRONT FRAME ASSEMBLY (with 6~17)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

6. FRONT FRAME SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

7. FRONT COVER LATCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15428

8. LATCH SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

9. RELEASE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16076

10. PICK UP SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15484

11. PICK UP ROLL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15449

12. FEED BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15447

13. GEAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15432

14. WIRE ASSEMBLY FG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

15. HARNESS ASSEMBLY FAN (J

128

J129)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

16. CONNECTOR 2P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

17. CONNECTOR 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

18. TRANS. CHUTE ASSEMBLY (with 19~26)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15466

19. TRANS. CHUTE SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

20. BIAS PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

21. BTR ARM L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

22. BTR ARM R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

23. ARM SPRING L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

24. ARM SPRING R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

25. FAN PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

26. CHUTE FAN (Front Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15488

27. BTR ASSEMBLY (A4)

(with 28,29)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15451

28. BTR SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

29. INLET CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

30. BOTTOM PLATE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15469

31. NO PAPER SENSOR ASSEMBLY (with 32~35)(On MSI-Multipurpose Feeder Tray)

. . . 15491

32. MSI (Multipurpose Feeder) SENSOR HOLDER. . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

33. MSI SENSOR (may be labeled as MBF sensor)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

34. MSI ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

35. HARNESS ASSEMBLY N/P (J

23

J121)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S


38/401


Parts List

PL4 Paper transportation II continued

36. CONSOLE ASSEMBLY (Front Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15473

37. HARNESS ASSEMBLY CONSOLE (J

20

J124)

. . . . . . . . . . . . . . . . . . . . . . . . . . 16098

38. HARNESS ASSEMBLY P/H1 (J

16

J124, J119, J127, J

306

J128, J302, J304)

. . . . . . . . N/S

39. LINK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S40. HINGE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

41. CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

42. MSI EXTENSION TRAY (Multipurpose Feeder) . . . . . . . . . . . . . . . . . . . . . . . . . 16100


1. FRONT COVER ASSEMBLY, 16PPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16090

18. TRANSPORTATION CHUTE ASSEMBLY, 16PPM . . . . . . . . . . . . . . . . . . . . . . . 16078

38. HARNESS CONSOLE, 16PPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16099


39/401


Parts List


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Parts List

PL5 Fusing and paper exit

Figure 1.Fusing and paper exit components


41/401


Parts List

PL5 Fusing and paper exit

1. FUSER ASSEMBLY (with 2~28)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(110V) 15485

1. FUSER ASSEMBLY (with 2~28)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(220V) 15486

2. FUSER FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

3. FUSER COVER L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

4. FUSER COVER R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

5. SCREW COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

6. FUSER TOP COVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

7. FUSER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

8. HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

9. LAMP GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

10. FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

11. IN CONDUCTIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

12. THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

13. FUSER IDLER SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

14. GEAR IDLER FUSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

15. GEAR H/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

16. HEAT ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

18. H/R RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

19. H/R EARTH SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

20. ELIMINATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

21. P/R EARTH SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

22. PRESSURE ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

23. P/R BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

24. NIP SPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

25. NIP LEVER L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

26. NIP LEVER R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

27. FUSER INLET CHUTE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

28. EXIT CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

29. EXIT SPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

30. EXIT ROLL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

31. U BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

32. GEAR EXIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

33. EXIT SENSOR BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S


42/401


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Parts List


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Parts List

PL6 Drive and xerographic module

Figure 1. Drive and xerographic components


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Parts List

PL6 Drive and xerographic module

1. BASE FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

2. ROS ASSEMBLY (Optical Unit) (with 3

~

8)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15468

3. ROS SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

4. ROS GEAR SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15431

5. GEAR IDLE ROS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15433

6. BTR BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

7. PUSH LEVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

8. RING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

9. DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15437

10. CRU SENSOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15470

11. CRU SENSOR PWB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15493

12. CRU ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15479

13. CRU SENSOR SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15440

14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. ERASE LAMP HOLDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

16. TONER SENSOR ASSEMBLY (with 17,18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15492

17. TONER SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

18. TONER SENSOR HOLDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

19. TONER SENSOR SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21. TONER CARTRIDGE CRU (8ppm/16ppm) . . . . . . . . . . . . . . . . . . . . . . . . . . AC15616

22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELITE 616 UNIQUE SPARE PARTS

2. ROS ASSEMBLY, 16PPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15727

9. DRIVE ASSEMBLY, 16PPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15719

16. TONER SENSOR ASSEMBLY, 16PPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15732


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Parts List

(5)

31

30

20

28

18

16

10

6 11

4

9

12

7

3

5

34

1,2

15

8

32

13

23,24,25

38

19

33

21,22

29

17

44

40,41,42,43

26,27

39

39

14

3536

PL7 Electrical module

Figure 1. Electrical components


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Parts List

PL7 Electrical module

1. LVPS (LOW VOLTAGE POWER SUPPLY) ASSEMBLY (110volt). . . . . . . . . . . . 15475

2. LVPS (LOW VOLTAGE POWER SUPPLY) ASSEMBLY (220volt). . . . . . . . . . . . 15476

3. HVPS (HIGH VOLTAGE POWER SUPPLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15474

4. KNOB VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

5. MCU BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

6. MCU PWB (Engine Control Board). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15496

7. FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15487

8. EARTH PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

9. HARNESS ASSEMBLY ROS (J12

J112,J114)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

10. HARNESS ASSEMBLY SOS (J19

J113)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

11. HARNESS ASSEMBLY HVPS (J15

J111)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

12. HARNESS ASSEMBLY TRAY1 (J13

J115)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

13. HARNESS ASSEMBLY CRU (J18

J118,J130)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

14. HARNESS ASSEMBLY REGI. (J1

7

J26, J28, J123)

. . . . . . . . . . . . . . . . . . . . . . . . . N/S

15. SADDLE EDGE H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

16. BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

17. ESS HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15497

18. ELEC. COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

19. FAN BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

20. ESS PWB ASSEMBLY (See Section 9 for information) . . . . . . . . . . . . . . . . . . . . . N/S

(Parts 19~26 are called the CONTROL SUBSYSTEM)

21. RAM SIMM MODULE 6MB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1541822. RAM SIMM MODULE 12MB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15600

23. GCIO I ETHERTALK NETWORK CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15081

24. GCIO II ETHERTALK NETWORK CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15585

25. GCIO III ETHERTALK NETWORK CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15775

26. ROM SIMM PROGRAMMED (XL 608, 808, 1208). . . . . . . . . . . . . . . . . . . . . . . 15178

27. ROM SIMM PROGRAMMED (XL 408). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15650

28. REAR PANEL SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

29. SHIELD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

30. CONTROLLER SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1547131. SHIELD EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15472

32. POWER CORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10044

33. BLANKING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

34. CLAMP L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

35. TOP COVER INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S


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Parts List

36. TOP COVER INTERLOCK HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

37. GUIDE CARTRIDGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

38. FAN ESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15489

39. DUCT FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15464

40. XL 408 MAIN CONTROLLER (OLD BOARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1568941. XL 608 MAIN CONTROLLER (OLD BOARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15687

42. XL 808 MAIN CONTROLLER (OLD BOARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15691

43. XL 1208 MAIN CONTROLLER (OLD BOARD) . . . . . . . . . . . . . . . . . . . . . . . . . . 15693

44. XL 1208 TRUE RES DAUGHTER CARD (OLD BOARD) . . . . . . . . . . . . . . . . . . 15552

45. XL 1208 SUPERSIZE CONTROLLER (OLD BOARD) . . . . . . . . . . . . . . . . . . . . 15955

46. XL 616 MAIN CONTROLLER (OLD BOARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15806

ELITE XL 608 PROGRAMMED COMBO BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . 16292

ELITE XL 808 PROGRAMMED COMBO BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . 16294ELITE XL 616 PROGRAMMED COMBO BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . 16296

ELITE XL 1208 PROGRAMMED COMBO BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . 16298

ELITE XL 1208 SUPERSIZE PROGRAMMED COMBO BOARD . . . . . . . . . . . . . . . 16299

50-PIN SCSI CONNECTOR WITH INTERNAL CABLE. . . . . . . . . . . . . . . . . . . . . . . 16111


3. HVPS (HIGH VOLTAGE POWER SUPPLY) 16PPM . . . . . . . . . . . . . . . . . . . . . . 15728

6. MCU PWB (ENGINE CONTROL BOARD) 16PPM. . . . . . . . . . . . . . . . . . . . . . . 157337. FAN, 16PPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15731


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Parts List


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Parts List

PL8 Optional feeder assembly (250 sheet feeder)

Figure 1. Optional 250 Sheet Feeder


51/401


Parts List


1. 250 SHEET FEEDER ASSEMBLY TRAY2 (with 2~21, 25)

. . . . . . . . . . . . . . . . AC15255

2. FEEDER FRAME ASSEMBLY TRAY2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15452

3. FEED SOLENOID TRAY2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15313

(called the Feed Solenoid throughout this manual)

4. TURN SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15312

5. FEED ROLL ASSEMBLY (with 6,7)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15430

6. FEED CLUTCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

7. FEED ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15299

8. TURNROLL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15429

9. FEED BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15447

10. GEAR IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15434

11. GEAR OUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15435

12. GEAR FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1543613. NOPAPER ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15477

14. SIZE SPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15441

15. FEEDER PWB AUX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15495

16. FEEDER EARTH SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

17. FEEDER EARTH PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

18. FEED HOUSING L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15459

19. FEED HOUSING R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15461

20. FEEDER TIE PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16092

21. ACTUATOR LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1544522. TABLOID/A3 250 SHEET TRAY (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC15249

23. ENVELOPE TRAY (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC15253

24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27. HARNESS CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16084

28. HARNESS OPTION FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16088


52/401


Parts List


Figure 1. Optional 500 Sheet Feeder


53/401


Parts List


1. 500 SHEET FEEDER ASSEMBLY (with 2~20, 27, 28, and 29)

(Optional)

. . . . . . . . AC15366

2. FEEDER FRAME ASSEMBLY TRAY2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

3. FEED SOLENOID TRAY2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15311

(called the Feed Solenoid throughout this manual)

4. TURN SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15312

5. FEED ROLL ASSEMBLY 500 (with 6,7)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16082

6. FEED CLUTCH ASSEMBLY 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/S

7. FEED ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15299

8. TURNROLL ASSEMBLY 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16094

9. FEED BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15447

10. GEAR IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Elite XL8 Service Manual

Documents

Transcript of Elite XL8 Service Manual