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4-204 Service Manual

7541-03x

8. Remove the two screws (G) securing the rear cover to the option feeder.

9. Remove the left and right drum stays (H).

10.Remove the clutch.

Table of Contents

Default Chapter3
- Table of Contents3
Notices and Safety Information13
- Safety Information15
Preface18
- Conventions18
General Information19
- Maintenance Approach19
- Models19
- Printer Configurations20
- Options and Features21
- Print Engine Specifications22
- Scan Fax and Copy Specifications29
- Tools Required for Service33
- Acronyms34
Diagnostic Information37
- Start37
  - Flatbed / ICC Card NVRAM38
  - Initial Check38
- POR (Power-On Reset) Sequence39
- Print Quality Issues40
- Black Page45
- No Print45
- Stain on Back of Page46
- Failure to Fuse46
- Stains on Edge of Page46
ADF & Scanner Print Quality47
- Image Quality Symptoms47
- Dark Image Quality (Using ADF or Scanner)47
- Vertical Lines (Process Direction Using the ADF)48
- Spots (Using Flatbed Scanner)48
- Skew (Using ADF)50
- Media Damage (Using ADF)51
- Black Page from Scanner52
Paper Jams53
- Clearing and Troubleshooting Paper Jams54
- Duplex Unit Service Check60
- Paper Path Service Checks60
- Paperfeed Unit Service Check63
- MPF Service Check64
- Clearing and Resolving Scanner Jams65
- ADF Paper Jam Service Check72
Error Codes74
- Abnormal Exit Motor74
- 990 XX Service75
- 976 XX Standard Network or Network Card X75
- Abnormal EEPROM75
- Service NCVRAM Mismatch75
- Service NV Failure75
- Service NVRAM Failure75
- Service Code CRC <Loc75
- Service System Board75
- Service NAND Failure75
- 959,XX Service Invalid Firmware75
- Service Memory Error75
- Service Emulation Error75
- Fax T30 Log Error Codes77
Service Checks81
- Black Printhead Error81
- Cyan Printhead Error81
- User Attendance Messages102
  - User Prompts102
  - User Attendance Messages (0-99)105
- Other Symptoms111
- Other Service Checks120
Diagnostic Aids133
- Understanding the Operator Panel and Menus133
- Configuration Menu141
- Diagnostics Mode150
- Theory of Operation161
Repair Information183
- Handling ESD-Sensitive Parts183
- Removal Procedures186
  - Arrangement of Removals in this Chapter186
- Cover Removals187
- Top Removals208
- Front Removals222
- Left Side Removals227
- Right Side Removals243
- Rear Removals255
- HVPS Removal293
- Waste Toner Sensor Removal294
Scanner Area Removals295
- ADF Assembly Removal295
- ADF Pick Roll Removal296
- ADF Separator Roll Removal297
- Flatbed Assembly Removal298
- Flatbed Front Cover299
- UICC Removal302
- Touchscreen Assembly Removal303
- ADF Relay Board304
- ICC Board305
- CCD Chassis306
- CCD Belt308
- Optical Paper Size Sensor309
- ADF Cable310
- ADF Motor Frame311
- ADF Solenoid314
- ADF Drive Clutch314
- ADF Input Tray315
- ADF Main Feeder316
- ADF Clutch319
- ADF Hinge319
- FB Hinge320
- Tray Paper Size Sensors320
- ADF Cover Open / ADF Pick Sensor324
- ADF Cover Open Sensor Actuator325
- Paper Present / Paper in Sensor326
- Paper Present Sensor Actuator327
- Paper in Sensor Actuator327
- Paper Path Sensor328
- Scan Sensor328
- Scan Sensor Actuator330
- Scan Sensor Cover (Not a Fru)331
- Duplex Timing Sensor334
- Duplex out (Scan Out) Sensor339
- Duplex out Sensor Actuator340
- Flatbed Cover Closed Sensor341
- Flatbed Upper Cover343
- Outer ADF Top Cover345
- Inner ADF Top Cover346
- ADF Relay Card Cover349
- Left ADF Cover349
- Right ADF Cover352
Duplex Unit Component Removals354
- Duplex Clutch Removal354
- Duplex Timing Belt Removal355
- Duplex Exit / MPF Sensor Removal355
- MPF Clutch Removal356
- MPF Tray Assembly Removal357
Paperfeed Unit Component Removals359
- Separating the MPF Tray and Main Tray Paperfeed Units359
- Paperfeed Unit Clutch Removal361
- Registration Sensor (MPF Tray) Removal361
- Registration Sensor Actuator Removal362
- Static Discharge Brush Removal362
- Torque Limiter Removal363
- Upper and Lower Registration Springs Removal363
Paperfeed Maintenance Kit Removals364
- Pick Roll Removal364
- Separator Roll Removal365
- Registration Roll Removal366
- MPF Roll Removal367
- MPF Pad Removal369
- Exit Guide (Paper Exit) Roll Removal372
- Option Paper Feed Removals378
- Adjustments387
Locations389
- Print Engine Cross Section389
- Flatbed / ADF Sensors391
- Option Feeder Locations423
Preventive Maintenance427
- Safety Inspection Guide427
- Lubrication Specifications427
- Scheduled Maintenance427
Parts Catalog429
- How to Use this Parts Catalog429
- Assembly 1: Covers430
- Assembly 2: Flatbed and ADF432
- Assembly 3: Flatbed434
- Assembly 4: ADF 1436
- Assembly 5: ADF 2438
- Assembly 6: Duplex Components 1440
- Assembly 7: Duplex Components 2442
- Assembly 8: Paper Exit444
- Assembly 9: Base 1446
- Assembly 10: Base 2448
- Assembly 11: Base 3450
- Assembly 12: Paper Feed452
- Assembly 13: Electrical 1454
- Assembly 14: Electrical 2456
- Assembly 15: Upper Assembly458
- Assembly 16: Printhead Controller Board Cables460
- Assembly 17: Paper Trays462
- Assembly 18: Fuser464
- Assembly 19: 550 Sheet Option Feeder Covers466
- Assembly 20: 550 Sheet Option Feeder Base468
- Assembly 21: 550 Sheet Option Feeder Paper Feed470
- Assembly 22: 550 Sheet Option Feeder Tray472
- Assembly 23: Maintenance Kits, Power Cords, and Options474
Index474
Part Number Index481

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