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xii Service Manual

5041-030

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Table of Contents

Default Chapter3
- Table of Contents3
Notices and Safety Information11
- Safety Information13
Preface16
- Navigation Buttons16
- Change History17
- Conventions18
General Information19
- Maintenance Approach19
- Models19
- Printer Configurations20
- Options and Features21
- Printer Specifications22
- Tools Required for Service29
- Acronyms29
Diagnostic Information33
- Start33
  - Safety Feature Notice33
  - Initial Check34
- POR (Power-On Reset) Sequence35
- Print Quality Issues36
Paper Jams44
- Clearing and Troubleshooting Paper Jams45
- Duplex Unit Service Check51
- Paper Path Service Checks51
- Paperfeed Unit Service Check54
  - Mpf Service Check56
- Expansion Paper Feeder Service Check57
Error Codes58
- Abnormal Exit Motor58
- Abnormal EEPROM59
- Service NCVRAM Mismatch59
- Service NV Failure59
- Service NVRAM Failure59
- Service Code CRC <Loc59
- Service System Board59
- Service NAND Failure59
- 959,XX Service Invalid Firmware59
- Service Memory Error59
- Service Emulation Error59
- XX Standard Network or Network Card X60
- Service <Device60
- 991 XX Service61
- 990 XX Service61
1Xx / 9Xx Error Code Service Checks61
- Black Printhead Error61
- Cyan Printhead Error61
- Magenta Printhead Error61
- Yellow Printhead Error61
- Thermistor 1 Error62
- Thermistor 2 Error62
- Thermistor 3 Error63
- Belt Thermistor Error63
- Fuser - Fuser Heater Error64
- Power Switch Error64
- High Voltage Power Supply Error64
- Density Sensor Error65
- Abnormal Theta Sensor66
- Temperature Humidity Sensor Error67
- Drive Motor Error67
- Fuser / Paper Exit Motor Error67
- Tray1Error68
- Tray 3 Error68
- Tray 4 Error69
- Tray 5 Error70
- Fuser Fan Error70
- Power Supply Unit Fan Error71
- Main Unit Fan Error71
- Rear Fan Error71
- Steps before Starting the 9Yy Service Checks72
  - Collecting the History Information from the SE Menu72
  - Collecting the Firmware Logs (Fwdebug and Logs.tar.gz) from the SE Menu72
  - Collecting the Settings from the Menu Settings Page73
  - Collecting Information from the User73
  - System Software Error74
  - SDRAM R/W Error76
  - MDC Error76
  - CPU Error78
  - MDC Controller Error78
  - EEPROM Error78
  - 950.29-EPROM Mismatch Failure79
  - Service Invalid Firmware Error80
  - User Attendance Messages81
  - User Prompts81
  - User Attendance Messages (0-99)84
- Other Symptoms90
  - ON / off Switch Automatically Switching to the off Position Service Check91
- Other Service Checks92
  - Networking Service Check (ISP Install Needed)92
  - USB Port Service Check93
  - False Close Door Service Check94
  - Operator Panel Service Check94
  - Insert Tray Service Check95
  - Paper Skew Service Check95
  - Imaging Unit (Photo Developer) Missing Service Check96
  - Option Card Service Check96
  - Power Supply (Dead Machine) Service Check98
  - Printhead Service Check99
  - Transfer Belt up down Check99
  - Unable to Print from USB Thumb Drive Service Check100
  - Waste Toner Bottle Missing Service Check100
  - Wrong Paper Size Service Check - Tray1101
  - Wrong Paper Size Service Check - Tray2101
Diagnostic Aids103
- Understanding the Printer Operator Panel103
- Understanding the Homescreen Icons and Their Functions104
- Using the Touch-Screen Buttons105
- Other Touch-Screen Icons106
- Administrative Menus107
- Accessing the Service Menus108
- Configuration Menu109
  - Entering Config Menu109
  - Reset Separator Roll and Pick Assembly Counter110
  - Reset Maintenance Counter110
  - Reset Fuser Counter110
  - Reset Transfer Belt Counter110
  - Black Only Mode110
  - Print Quality Pages111
  - Fuser Speed111
  - Reports111
  - Color Trapping111
- Tray Insert Message111
- Size Sensing111
- Panel Menus111
- PPDS Emulation112
- Download Emuls112
- Demo Mode112
- Factory Defaults112
- Energy Conserve112
- Auto Align Adj112
- Color Alignment113
- Paper Prompts113
- Envelope Prompts114
- Action for Prompts114
- Jobs on Disk114
- Disk Encryption114
- Erase All Information on Disks114
- Font Sharpening114
- Wipe All Settings114
- Require Standby114
- LES Applications115
- Key Repeat Initial Delay115
- Key Repeat Rate115
- Clear Custom Status115
- USB Speed115
- USB Pnp115
- Automatically Display Error Screens115
- Exit Config Menu115
Diagnostics Mode116
- Entering Diagnostics Mode116
- Diagnostic Mode Menus116
- Print Tests118
  - Print Tests (Input Sources)118
  - Print Quality Pages118
- Hardware Tests118
- Device Tests121
- Input Tray Tests122
- Printer Setup122
- Reports124
- Event Log124
- Exit Diagnostics125
- Theory of Operation126
Repair Information145
- Handling ESD-Sensitive Parts145
  - RIP Board/Operator Panel Replacement146
  - Printhead Controller Board / Engine Board Replacement146
    - Esf Solutions Backup147
- Removal Procedures148
  - Arrangement of Removals in this Chapter148
- Cover Removals149
- Top Removals162
- Front Removals175
  - Transfer Belt CRU Removal175
- Transfer Belt Position Sensor Removal176
- Paper Size Sensor Removal177
- Photoconductor Lock Removal178
- Cassette Stopper Removal179
Left Side Removals180
- ISP Option Board Removal180
- Left EMI Shield Removal (Not a FRU)183
- Low Volt Power Supply Removal186
- Main Fan Removal187
- Power Supply Fan Removal189
- RIP Board Removal190
- Video Board Removal190
- Theta Sensor Removal192
- Density Sensor Removal193
- Main Switch Removal194
Right Side Removals195
- Fuser Removal195
- Handle Cover Removal196
- Duplex Removal197
- Paper Feed Unit Removal202
- Transfer Roll - CRU Removal203
Rear Removals204
- Drive Unit Removal204
- Drive Unit Motor C/M/Y/K Removal207
- Sub Drive Unit Removal208
- Door Interlock Switch Removal212
- Duplex Solenoid Removal213
- Fuser Entry Sensor Removal214
- Engine Board (MDCONT) Removal215
- Fuser Fan Removal215
- Fuser Exit Drive Unit Motor Removal216
- Papertray Lift Motor Removal217
- Toner Sensor Removal218
- Transfer Belt Motor Removal221
- Temperature and Humidity Sensor Removal222
- Rear Fan Removal222
- Sub Frame Unit Removal224
- Paper Size Switch Removal225
- Rear EMI Shield Removal- Not a FRU226
- Paper Feed Motor Removal230
- HVPS Removal231
- Waste Toner Sensor Removal232
Duplex Unit Component Removals233
- Duplex Clutch Removal233
- Duplex Timing Belt Removal234
- Duplex Exit / MPF Sensor Removal234
- MPF Clutch Removal235
- MPF Tray Assembly Removal236
Paperfeed Unit Component Removals238
- Separating the MPF Tray and Main Tray Paperfeed Units238
- Main Tray Paper Guide Removal239
- Multi-Purpose Feed Tray Paper Guide Removal241
- Paperfeed Unit Clutch Removal244
- Registration Sensor (MPF Tray) Removal245
- Registration Sensor Actuator Removal245
- Static Discharge Brush Removal246
- Torque Limiter Removal246
- Upper and Lower Registration Springs Removal246
Paperfeed Maintenance Kit Removals248
- Pick Roll Removal248
- Paperfeed Roll Removal248
- Separator Roll Removal249
- Registration Roll Removal250
- MPF Roll Removal251
- MPF Pad Removal253
- Exit Guide (Paper Exit) Roll Removal256
- Option Paper Feed Removals262
Locations271
- Exterior271
- Connector Values283
- Option Feeder Locations303
Preventive Maintenance307
- Safety Inspection Guide307
- Lubrication Specifications307
- Scheduled Maintenance308
Parts Catalog309
- How to Use this Parts Catalog309
- Assembly 1: Cover1310
- Assembly 2: Cover 2312
- Assembly 3: Duplex Components 1314
- Assembly 4: Duplex Components 2316
- Assembly 5: Paper Exit318
- Assembly 6: Base 1320
- Assembly 7: Base 2322
- Assembly 8: Base 3324
- Assembly 9: Paperfeed326
- Assembly 10: Electrical 1328
- Assembly 11: Electrical 2330
- Assembly 12: Upper Assembly332
- Assembly 13: Printhead Controller Board Cables334
- Assembly 14: Paper Trays336
- Assembly 15: Fuser338
- Assembly 16: 550 Sheet Option Feeder Covers340
- Assembly 17: 550 Sheet Option Feeder Base342
- Assembly 18: 550 Sheet Option Feeder Paperfeed344
- Assembly 19: 550 Sheet Option Feeder Tray346
- Assembly 20: Maintenance Kits, Power Cords, and Options348
Index348
Part Number Index355