Primera Bravo 4202 User manual

Service Manual for Bravo 4200 Series Disc Publisher
©2017 All rights reserved
04/27/17

1
©2017 All rights reserved
01 Cover
03
02 Control Panel
05
03 Blue LED Board
06
04 USB3 Hub
07
05 Mainboard
09
06 Print Tray
11
07 Power Resistor
13
08 Encoder Wheel Sensor
15
09 Encoder Wheel
17
10 Drive Mount
18
11 Power Supply
20
12 Drive Fan
22
13 Drives
24
14 Maintenance Felt
26
15 Maintenance Fan
27
16 Encoder Strip
28
17 Carrier Drive Motor
30
18 Carrier Frame
32
19 Feed Drive Motor
36
20 Maintenance Sled
38
21 Carrier
40
04/27/17

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22 Alignment Sensor
44
©2017 All rights reserved
23 Carrier Flex PC
47
24 Picker
51
25 Picker Motor
55
26 Picker Board & Flex Cables
56
27 Arm Board
58
28 Solenoid
61
29 Drive Alignment
63
30 Troubleshooting
66
04/27/17

3
1 ▪Cover
1.1
Loosen 4 screws securing back of cover.
1.2
Remove 3 screws securing front of cover. Slide picker and carrier to middle of printer.
Bravo 4200 Series Disc Publisher Service Manual
2017

4
Bravo 4200 Series Disc Publisher Service Manual
2017
1.3
Unplug cable from control panel on underside of cover. While lifting cover off of printer,
reach in and unplug blue LED board cable from mainboard. Remove cover.

5
2 ▪Control Panel
2.1
Remove cover (page 3). Remove 3 screws securing control panel. After replacing control
panel, press buttons to verify they click properly.
Bravo 4200 Series Disc Publisher Service Manual
2017

6
3 ▪Blue LED Board
3.1
Remove cover (page 3). Remove 2 screws securing blue LED board. Unplug cable from end of
board.
Bravo 4200 Series Disc Publisher Service Manual
2017

7
4 ▪USB3 Hub
4.1
Remove 2 screws securing cover plate. Remove plate.
Bravo 4200 Series Disc Publisher Service Manual
2017
4.2
Unplug any sata cables from hub. For 2 drive units, keep track of which cable is plugged into
which port. Remove 3 screws securing hub.

8
Bravo 4200 Series Disc Publisher Service Manual
2017
4.3
When replacing hub, be sure pins properly plug into connectors on mainboard. Plug any sata cables
back in. If locations of drives in dual drive units need to be reset consult Drive Alignment (page 63).

9
5 ▪Mainboard
5.1
Remove USB3 hub (page 07). Unplug all cables and flex cables from mainboard.
Bravo 4200 Series Disc Publisher Service Manual
2017
5.2
Remove 4 screws securing mainboard. Lift mainboard out of unit.

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Bravo 4200 Series Disc Publisher Service Manual
2017
5.3
Remove 2 screws securing static brush to mainboard. Remove 3 standoffs. Secure static brush and
standoffs to new mainboard.
5.4
When replacing mainboard, make sure hole in corner is resting on small post before replacing 4
screws. Attach USB3 hub and plug in all cables and flex cables. Be sure to plug carrier and feed
motors into correct location. Drive and maintenance fans can be plugged into either location.
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6 ▪Print Tray
6.1
Remove mainboard (page 09). Remove 2 screws securing print tray guide to print tray. Lift guide up
off of tray (leave attached to belt).
Bravo 4200 Series Disc Publisher Service Manual
2017
6.2
Lift back end of print tray slightly and pull back against rear cover plate.

12
Bravo 4200 Series Disc Publisher Service Manual
2017
6.3
Remove screw securing front tray guide. Lift guide out of base.
6.4
Pull print tray out of printer.

13
7 ▪Power Resistor
7.1
Cut tie wrap securing power resistor cable to power supply cable. Unplug power resistor from
mainboard.
Bravo 4200 Series Disc Publisher Service Manual
2017
7.2
While holding resistor mount bracket with fingers or needle-nose pliers, remove 2 screws securing to
rear cover plate.

14
Bravo 4200 Series Disc Publisher Service Manual
2017
7.3
Remove 2 screws securing power resistor to resistor mount bracket. Replace resistor.

15
8 ▪Encoder Wheel Sensor
8.1
Cut tie wrap securing cables. Unplug encoder wheel sensor from mainboard.
Bravo 4200 Series Disc Publisher Service Manual
2017
8.2
Remove 2 screws securing sensor to bracket.

16
Bravo 4200 Series Disc Publisher Service Manual
2017
8.3
When replacing sensor, be sure encoder wheel is centered in slot.

17
9 ▪Encoder Wheel
9.1
Peel encoder wheel off of gear. Clean area with alcohol before adhering new encoder wheel.
Bravo 4200 Series Disc Publisher Service Manual
2017
9.2
Be sure replaced encoder wheel is centered in sensor slot. Clean encoder wheel with alcohol after
handling.

18
10 ▪Drive Mount
10.1
Tip printer up. Remove 6 screws securing drive mount base plate to base.
Bravo 4200 Series Disc Publisher Service Manual
2017
10.2
Tip drive mount forward. Align slot on drive mount base plate with tab on rear cover plate and
remove.

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Bravo 4200 Series Disc Publisher Service Manual
2017
10.3
Unplug all cables from back of drive(s) to detach drive mount from printer. In 2 drive units, keep
track of which sata cable goes with which drive.