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4-116 Service Manual

5041-030

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10. Remove the screw (H) that fastens the roller holder to the paper exit unit frame.

11. Pull the roller holder back and away from the paper exit unit.

12. Repeat steps 9 thru 11 for the remaining rollers.

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