Canon Parts

Distributor of
the Year

INSIDE THIS ISSUE

■ NEW OPTRA SE 3455 PARTS
■ 4000 BOARD REMOVAL
■ FEBRUARY TRAINING ADDED
JANUARY 2000, VOLUME EIGHT, NUMBER 12
 PRODUCT

NEW OPTRA SE 3455 PRODUCTS

HOT ROLL, MAINTENANCE KIT IN STOCK NOW
PARTS NOW! carries the hot roll
for the Lexmark Optra SE 3455, as
well as the maintenance kit for that
printer.
The kit contains the fuser
S N O W! (with empty cleaning wand
PART
ar k Elite and an alternate fuser sole-
3455 Hot Roll (99A0832)
x m
is a Le
noid), the charge roll (with
trib utor two plastic tools), transfer
Dis
Parts roll assembly, and three pick Call PARTS NOW! today at 608-
276-8688 to order.
rollers.

3455 Maintenance Kit

(99A0823)

A. Fuser
A
D B. Cleaning Wand
C. Solenoid
C D. Charge Roll+Tools
B E. Transfer Roll Assy.
D F. Pick Rollers

FEBRUARY/MARCH 2000 TRAINING SCHEDULE

for prices and more information go to the internet: [Link]/PRODSERV/[Link]
FEB 14 OPTRA S/4059S FEB 28 EX 4/4+/5
FEB 15 4000/4050 FEB 29 2100
FEB 16 WX 5SI/8000 & 8100 MAR 1 NX IIISI/4SI
FEB 17 COLOR 4500, DAY 1 MAR 2 WX 5SI/8000 & 8100
FEB 18 COLOR 4500, DAY 2 MAR 3 COLOR 5
 TECHNICAL

WALKTHROUGH
4000/4050 ENGINE CONTROLLER REMOVAL
BY DENNIS KOSTERMAN
RESEARCH & DEVELOPMENT

In any laser printer, the DC con-

troller board is a prime suspect when-
ever there is a problem, since it con-
trols all printer functions. This is espe-
cially true in printers like the 4000
and 4050, in which the DC controller
and power supplies are combined into
one assembly, the engine controller
board.
This assembly can be difficult to
remove and re-install. PARTS NOW!
routinely receives boards for repair or
exchange that have been damaged by
improper removal or installation. This
article will give step-by-step instruc- ing Tray 1 (the multi-purpose tray)
tions on how to replace your engine and the Rear Output Bin, to pro-
controller board, and will also indicate vide better access to the covers.
common mistakes. Much of this infor- 1. REAR RIGHT SIDE COVER. This
mation is available in multiple sections is the easiest cover to remove.
of the HP 4000/4050 service manual. Grasp its rear edge and pull to the
We offer the same information in more rear.
convenient, linear format, with some
2. TOP COVER. The manual says to
of our own observations added.
remove the control panel first,
TOOLS YOU WILL NEED: a Phillips but this is not necessary.
screwdriver, a small needle-nose pli-
a. Remove Toner Cartridge (make
ers, and, perhaps, a small slotted
sure to cover it or put it in a
screwdriver.
dark place, so the drum is not
A. REMOVE COVERS. Start by open- exposed to light).
 TECHNICAL

4000/4050 ENGINE CONTROLLER REMOVAL

b. Detach the Toner Cartridge
Drive Arm from the cover by
pinching the hinge with a nee-
dle-nose pliers.
c. Remove four screws (two in
front, under the lid, and two in
the rear).
d. “Squeeze” the right front side of PLATE A. REMOVE FUSER
the Top Cover and/or use a care to clear the power switch
small flat-blade screwdriver to rod.
release the tab inside the small
5. REAR OUTPUT BIN. Bend/bow
rectangular hole.
the piece enough to pop one of
e. The cover should now lift off. the hinges out of its hole, and
CAUTIONS: then rotate the bin upward and
slide the other hinge out of its
(1) Hold in place the Output
hole.
Assembly (in the rear of the
printer) while lifting the cover B. It is convenient at this point to
off; remove the fuser.

(2) As you remove the cover, reach 1. First remove the duplexer, or, if
underneath and unplug the rib- there is no duplexer, the left and
bon cable from the display. right Duplex Connector Covers,
which are identifiable by plastic
The remaining covers are easier.
arrows. Grasp each connector
3. LEFT SIDE COVER. Release the cover by its bottom edge and pull
latch (on top, about 1/3 of the
way in from the rear of the print-
er) and catches (in front) and lift
the cover up and away from the
printer.
4. FRONT RIGHT SIDE COVER.
Release the latch (top center) and
lift the cover up and away, taking
PLATE B. UNPLUG CONNECTOR
 up).
PLATE C.
2. Then loosen the two captive ENVELOPE
screws (see Plate A) and pull the
FEEDER CON-
fuser out.
NECTOR
C. FORMATTER. In order to remove COVER, WITH
the engine controller, you will have
SCREW HOLE
to separate the Engine Module (the
INDICATED
upper part of the printer) from the
Paper Feed Module (lower part). module together.
But before we can do this, there is
one more assembly to remove—the a. One of these is a black, self-tap-
formatter. The formatter cage ping screw located just below
assembly is located in the rear cor- and behind the fan on the fan
ner, motor side of the printer, and side of the printer.
PA
RTS N
is held in place by five screws, all b. The other two are long OW!
located around the edges (two on black screws in the front offers
repair
the fan side, two on the motor side, of the printer, one on and e s
xchan
and one on top). each side of the Tray 1 on thi ges
Input Assembly (to access s board
1. Remove these five screws and .
slide the cage toward the rear of the one on the motor side,
the printer to remove it. you will have to flip down or
remove the Envelope Feeder
2. Then remove the formatter pan Connector Cover—(see Plate C).
(held in by seven screws—four
black self-tapping screws and 2. Once these screws are removed,
three silver machine screws). you should be able to lift the
Engine Module off of the Paper
D. SEPARATE ENGINE MODULE Feed Module (see Plate D) and
FROM PAPER FEED MODULE. In turn it upside-down.
the cavity behind where the for-
matter cage & pan were, you will
see three connectors (see Plate B)
plugged into the lower half of the
printer (the paper feed module).
1. Unplug the largest and rearmost
of these. Now we need only
remove the three screws that hold
the engine module and paper feed PLATE D. SEPARATION
 TECHNICAL

4000/4050 ENGINE CONTROLLER REMOVAL

E. Now we are ready to remove the
Engine Controller board.
1. There are two cables coming into
the board from the “fan” side—
one from the fan itself, and one
from the Tray 1 paper sensor (see
Plate E). Carefully unplug these
cables, pulling straight out (one of
PLATE E. SPRING (CENTER) & 2 CABLES
the most common problems we
see is broken solder joints on these removed, the parts fall off the board,
connectors, caused by twisting or and indeed, we get many boards that
pulling the cables in different are missing parts (especially the small
directions while unplugging them). metal plate to which the toner car-
HEADQUARTERS: tridge grounding spring connects; this
3517 W. Beltline Hwy. 2. Also on the “Fan” side is a spring,
metal plate is not available separately,
Madison, WI 53713 hooked into a notch on a metal
and needs to remain with the board)
(608) 276-8688 plate attached to the board; dis-
(800) 886-6688 (see Plate G). You should, however,
connect the spring from the notch
FAX (608) 276-9593 keep the large metal plate that you just
(see Plate E). On the other side,
removed. This is not considered part of
SOUTHEAST BRANCH: disconnect the power switch rod
the board, and a new board will not
1085 SW 15th Ave. #5 from the power switch.
include one of these.
Delray Beach, FL 33444
3. The Engine Controller Board is
(561) 279-9280 4. At this point, you should be able to
(800) RG1-0939
held in place by seven screws (see
lift up the fan side of the board to
FAX (561) 279-9122 Plate F): four black self-tapping
access the connectors. There are
screws (three in front, and one in
URL 11 connectors that need to be
[Link]
the rear, fan side, and three silver
unplugged, all on cables coming in
M3 screws, all in the rear, motor
from the motor side of the board.
side—two of these are recessed.
As before, unplug these carefully,
Now you can remove the large
pulling straight out. Two of these
metal plate that covers the board.
connectors (the two with the
VERY IMPORTANT: do not remove any largest wires going to them—one
more screws after this. Any more has black and white wires; the
screws that you see are holding parts other has blue and orange wires)
onto the board—if these screws are require special care, because they
 have release tabs that must be
depressed to release the connec-
tor. We see many boards with
these connectors broken (because
people tried to unplug them with-
out pressing the tabs). Do not
unplug J31 or J71, which go to
the black plastic bracket attached
to the back of the board—this
bracket is part of the board, and
should remain with it. The black
plastic cable router in the center PLATE F. REMOVE 7 SCREWS
of the board should also remain
lems that we see.
with the board.
2. Don’t forget to replace the large
4. Once these connectors have been
metal plate before screwing the
unplugged, you can lift the board
board down (there are two tabs
out of the machine, and you’re
on the front of the plate that hook
done with removal.
into cutouts on the board).
F. To install a new board, simply
3. Also, don’t forget to reconnect the
reverse the above process. There
power switch rod (you won’t be
are a few things to look out for,
able to turn the printer on) and
though.
the toner cartridge grounding
1. On the front of the board is a spring (you will get light print
small notch which aligns with a with a gray background). We test
plastic rib on the body block (see hundreds of these boards here,
Plate H). When seating the board,
this notch may not line up prop-
erly with the rib (because of ten-
sion from all the cables plugged
into the board), so you may have
to work it into place. This is not
at all hard to do, but it’s impor-
tant—if the board is screwed
down without this notch properly
aligned, the plastic rib will press
on the board and crack it. This is
one of the most common prob- PLATE G. DON’T REMOVE SCREW
 TECHNICAL

and we occasionally forget these

things. And it’s no fun to have to
go through this whole process
again.
4. Finally, don’t forget to reconnect
the control panel and Toner
Cartridge Drive Arm when you’re
putting the Top Cover back on.
G. Once you have completed the
installation, you may have to adjust
the top page margin. This is done PLATE H. NOTCH & RIB
by adjusting a potentiometer on the
motor side of the machine, just
Cover).
behind the fan and the engine test
button (this potentiometer is not 1. Run an engine test and inspect
accessible with all the covers on, so the margins. The top and bottom
you will have to make this adjust- should be about the same. To
ment before installing the Left Side move the image down (i.e., make
the top margin larger), turn the
pot clockwise; to reduce the top
margin, turn the pot counter-
clockwise.
2. Once this adjustment is done,
install the Left Side Cover and
the printer should be “good to
go”.

Service Today
Editor: Robert Reinke
Director: Dan Olszewski
With Assistance this month from Steve Geishirt
KEEP THE CIRCLED PARTS ATTACHED WHEN and Dennis Kosterman. Past Service Today articles
YOU REMOVE THE ENGINE CONTROLLER are available at [Link]
 REPAIR &
RG5-0512-000R paper control pca, 4 33471-60004R formatter, IIP
RG5-0513-000R hvps, 4 33471-60007R dual i/o assy, IIP
RG5-0531-000R power supply, 4/4 plus/5 33481-60001R formatter

EXCHANGES RG5-0877-000R
RG5-0879-000R
input assy, 4 plus
fusing assy, 4 plus/1260
RG1-1591-000R
RG1-1597-000R
dc controller
HV power supply
RG5-0886-000R paper output assy, 4 plus RG1-1604-000R density pca
RG5-0966-000R dc controller, 4 plus, 5 RG1-1782-000R power supply
RG5-0969-000R hv power supply, 4 plus, 5 RG1-1788-000R fusing assembly
RG5-1933-000R power supply, 4/4 plus, 5 RG1-1792-000R pickup assy

RAPID TURN- RG5-2189-000R

RG5-2195-000R
output assy, 5
paper input repair, 5
RG1-1909-000R power supply

AROUND ● AX ENGINE REPAIR

5L & COMPATIBLES
● SX ENGINE REPAIR
II/III/IID/IIID
& COMPATIBLES
HP LASERJETS & RG5-2000-000R
RG5-2023-000R
scanner
dc controller RG0-0050-000R laser scanner

COMPATIBLES C3942-67902R formatter RG1-0710-000R

RG1-0718-000R
dc controller, II
paper control pca
● BX ENGINE REPAIR RG1-0931-000R paper pickup assy
● HP 4000 REPAIR RG1-0932-000R registration assy
RG5-2661-000R fusing assembly
4V & COMPATIBLES
C3143-67901R formatter RG1-0936-000R high voltage power supply
RG5-3693-000R engine cont. board RG1-0939-000R fusing assy
RG5-1435-000R high voltage power supply
C4118-37908R formatter RG1-0939-000GR fusing assy, gold
RG5-1557-000R fusing assy
RG5-2641-000R laser scanner RG5-2041-000R laser scanner RG1-0945-000R delivery assy
RH3-2150-000R power supply RG1-0951-000R dc power supply
● WX ENGINE REPAIR RG5-1559-000R dc controller RG1-1278-000R dc controller, IID
5SI & COMPATIBLES RG5-1584-000R paper guide RG1-1310/2007R dc power supply, IID/IIID
C3168-67902R formatter RG5-2044-000R hvps assy RG1-1326-000R reg. assy, IID/IIID
RG5-1852-000R paper pickup assy RG1-1340-000R lower pickup assy
RG5-1863-000R fusing assy ● NX ENGINE REPAIR RG1-1394-000R dc power supply
RG5-1880-000R pickup assy IIISI/4SI & COMPATIBLES RG1-1944-000R dc controller, IIID
RG5-1844-000R dc controller 33491-60143R formatter, older RG1-1969-000R dc controller, III
RG5-1895-000R laser scanner
33491-60160R formatter, newer RG1-1970-000R dc controller, IIID
C2009 69001R formatter, 4Si RG1-1975-000R dc power supply
● VX ENGINE REPAIR C2061A-R duplex assy RG1-2007-000R power supply, IIID
5P/6P & COMPATIBLES RG5-0021-000R laser scanner, IIISi RG1-2702-000R power supply, III
C3151-67901R formatter, 5P RG5-0025-000R input (+parts)
RG1-2706-000R dc controller, III
RG5-1700-000R fusing assy, 5P RG5-0046-000R fusing assy, IIISi
RG9-0205-000R ac power module, II
RG5-2800-000R fusing assy, 6P RG5-0067-000R delivery cov. assy
RG5-1780-000R laser scanner, 5P RG9-0319-000R ac power module, III
RG5-0076-000R hvps, IIISi
RG5-2848-000R laser scanner, 6P RG9-0749-000R ac power module, III
RG5-0085-000R dcps, IIISi
RG5-1798-000R dc controller, 5P
RG5-0089-000R dc controller, IIISi
RG5-2826-000R dc controller, 6P RG5-0153-000R laser scanner, 4Si

● EX ENGINE REPAIR
G5-0095-000R
RG5-0381-000R
acpm, IIISi
job offset assy LEXMARK
4/4 PLUS/5 & COMPATIBLES RG5-0842-000R dc controller, 4Si New exchanges are available for most
C2002-67901R formatter, 4 RG5-0161-000R reg. assy, IIISi Lexmark printers on the following parts
C2038-67901R formatter, 4 plus RG5-0166-000R ac power module
fuser power supply
C2041-67901R formatter, 4MP RG5-0168-000R dc power supply, 4Si
printhead assy lvps
C3919-67901R formatter, 5 RG5-0170-000R hvps, 4Si
RG5-0449-000R laser scanner, 4 scanner video controller pcb
RG5-0627-000R dc controller, 4Si
RG5-0451-000R paper feed assy, 4 hvps network cards
RG5-0454-000R fusing assy, 4 rip board cassette assy
● LX ENGINE REPAIR
RG5-0456-000R output assy, 4 controller board
IIP/IIP PLUS/IIIP & COMPATI-
RG5-0511-000R/
RG5-0903-000R laser scanner, 4 plus, 5 BLES
RG5-1078-000R dc controller, 4/860 C2008-69001R formatter, IIP plus
SALES STAFF
MANAGEMENT

Bob Allport Gonzo Casas Dan Cassidy Doug Damon Beau Davis Bruce Davis
Ed Abel
Ext. 158 Ext. 109 Ext. 113 Ext. 140 Ext. 111 Ext. 110
Ext. 136
Dan Olszewski
CEO

Roy Divine Burton Edwards Virgil Grenia Dave Gress Vito Griseta Barney Gugel Darrel Hayner
Ext. 166 Ext. 106 Ext. 182 Ext. 151 Ext. 165 Ext. 180 Fl Ext. 304
Wayne Tougas
Southeast Branch Mgr.

Traci Hertzler Richard Jordan Teresa Kelly Tim Kohl Julie Krauth Joe Lalley Rick Maharajh
Ext. 116 Ext. 155 Ext. 179 Ext. 117 Ext. 122 Ext. 162 Fl. Ext. 309
Roxanne Wenzel
Sales Manager

Noel Mahoney Mike Meinholz Sheila Power Tim Ritschard Kyle Rudolph Rich Russell Kas Schafer
Ext. 169 Ext. 172 Ext. 118 Ext. 147 Ext. 170 Ext. 157 Ext. 159

Cal Seelig Paul Seibold Matt Sickler Terry Sipple Mike Tilley Ken Wagner Chad Wiggen
Ext. 102 Ext. 145 Ext. 218 Fl. Ext. 305 Ext. 142 Ext. 134 Ext. 220

INK JET SALES

Brenda Barbian Tiffany McMahon

Ext. 149 Dan Wilson Joey Zingale
Ext. 185
Ext. 127 Ext. 184
 PARTS NOW!
POLICY ■ C. RESTOCKING FEE
1. The restocking fee is 20% or $25.00,
whichever is greater.
a. In cases not involving PARTS NOW! LLC
error
RMA - RETURN MERCHANDISE AUTHORIZATION b. If non-defective product is not returned
■ A. THE RMA# MUST ACCOMPANY RETURNS. within 5 days.
An RMA number assigned by a sales represen- ■ D. MISCELLANEOUS
tative must be put on the outside and inside of 1. Any product returned without an RMA
your returned product package for adequate number will be refused.
identification. Product returned without a valid 2. Manuals, printheads and special order
RMA# will be refused at the PARTS NOW! LLC items are not returnable.
dock. Place the enclosed label on the outside of
3. PARTS NOW! LLC is not responsible for
the package and print the RMA# on the pack-
damages incurred in transit.
ing slip. This is the customer’s responsibility.
4. Damaged product is the shipping carrier’s
■ B. RMA# DURATION. responsibility.
The customer’s RMA# is valid only for 30 cal-
5. Customer is responsible for return ship-
endar days from the date issued.
ping.
RETURNS/EXCHANGES 6. All product must be returned within 30
■ A. RESTRICTIONS. days.
Product returns must be: 1) repairable (no PARTS NOW! WARRANTY PERIOD
alterations or physical damage); 2) have a valid ■ A. NEW PRODUCT
RMA# and; 3) be an exact equivalent of the Original Manufacturer Warranty
part shipped out and; (4) be received by PARTS
NOW! prior to the RMA expiration date of 30 ■ B. FACTORY REFURBISHED PRODUCT:
calendar days from the date issued. Original Manufacturer Warranty
■ C. REFURBISHED PRODUCT
■ B. RETURN PROCESS.
1. Part Repair—6 months
When PARTS NOW! LLC receives the product
a. Fusing Assemblies
return, PARTS NOW! LLC will inspect it to
b. Mechanical Assemblies: Input, Output,
confirm that it is 1) the correct part and; 2)
Delivery etc.
eligible for product return. If not, then PARTS
c. Electronics: I/Os, DC Controllers, Power
NOW! LLC will have the option of: 1)returning
Supplies etc.
it with an explanation or; 2) providing no
2. Printers
refund for items received after 30 days.
a. As is: Guaranteed working on arrival
■ C. REIMBURSEMENT. b. PARTS NOW! LLC Refurbished-90 days.
HEADQUARTERS:
Upon inspection and acceptance of returned The printer you receive should be mechani-
product, PARTS NOW! LLC will credit the cally sound and operational. We will replace or 3517 W. Beltline Hwy.
account of the open account customer. If the repair, at our discretion, the part or parts that Madison, WI 53713
customer is non-open account, PARTS NOW! fail during the 90-day warranty period. This is
a limited warranty and does not cover minor (608) 276-8688
LLC will send a refund check.
cosmetic defects, such as blemishes, scratches, (800) 886-6688
WARRANTY RETURNS
and color defects. FAX (608) 276-9593
■ A. PROPER RETURNS
[Link] being returned to PARTS NOW! Upon arrival, inspect the package for damage
LLC. due to defect or PARTS NOW! LLC and refuse it if you feel the printer may be
damaged as a result of shipping. If you accept SOUTHEAST BRANCH:
error must be returned with:
the printer and later discover apparent ship- 1085 SW 15th Ave. #5
a. A valid RMA number (legible on outside ping damage, a claim should be made with the
of packaging) carrier. Delray Beach, FL 33444
b. Copy of the Original Invoice Your first step to make a warranty claim (561) 279-9280
c. Original packaging (if new) would be to call our tech support and give a (800) RG1-0939
d. Reason for return description so we can take the appropriate
steps to get you back up and running. FAX (561) 279-9122
■ B. INTERNAL WARRANTY PROCEDURE
1. PARTS NOW! LLC will, at the company’s RESPONSIBILITY FOR DAMAGE
■ A. PARTS NOW! LLC is not responsible for URL
option, select one of the following: [Link]
a. Replace the product damages incurred in transit. The shipping car-
b. Repair the product rier is responsible for such damage.
c. Credit the invoiced amount of the prod- ■ B. PARTS NOW! LLC does not issue RMA#s
uct (if not replaceable due to lack of for products damaged due to shipping. PARTS
inventory) NOW! LLC will place a new order for the cus-
tomer while the carrier is processing the cus-
tomer’s claim.
 ● A Lexmark Elite Parts Distributor
● Wholesale printer parts
● Exchanges on all Major Components
● Service Manuals
offers a Full
Range of 1-800-886-6688
Lexmark
Solutions

Bulk Rate
U.S. Postage
PAID
Madison, WI
Permit No. 367

JANUARY 2000, VOLUME EIGHT, NUMBER 12

SERVICE TODAY
3517 W. Beltline Hwy., Madison, WI 53713
(608) 276-8688 Fax: (608) 276-9593
(800) 886-6688 SOUTHEAST: (800) RG1-0939
URL: [Link]

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