XEROX DocuColor 2045/2060 service manal

DocuColor 2060 / 2045 e X X cellerate cellerate Service Manual

April 2002 701P37867

NOTICE While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox arising out of any inaccuracies or omissions. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that such documentation is complete. Nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer’s service of equipment, or modules, components, or parts of such equipment may void any otherwise applicable Xerox warranties. If Customer services such equipment, modules, components, or parts thereof, Customer releases Xerox from any and all liability for Customer’s actions, and Customer agrees to indemnify, defend, and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.

Prepared by: Xerox Corporation Global Knowledge and Language Services 780 Salt Road Webster, N.Y. 14580 Copyright 2001/ 2002 by Xerox Corporation. Xerox and all product names in this publication are registered trademarks of Xerox Corporation.

NOTICE While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox arising out of any inaccuracies or omissions. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that such documentation is complete. Nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer’s service of equipment, or modules, components, or parts of such equipment may void any otherwise applicable Xerox warranties. If Customer services such equipment, modules, components, or parts thereof, Customer releases Xerox from any and all liability for Customer’s actions, and Customer agrees to indemnify, defend, and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.

Prepared by: Xerox Corporation Global Knowledge and Language Services 780 Salt Road Webster, N.Y. 14580 Copyright 2001/ 2002 by Xerox Corporation. Xerox and all product names in this publication are registered trademarks of Xerox Corporation.

Table of Contents Section Title

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Tools and Cleaning Supplies. . . . . . . . . . . . . . . . . . . . . . . . . viii Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi DocuColor 2060 / 2045 Service Log Sheet. . . . . . . . . . . . . . . . Section Title

Section

How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fault Code Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Output Defect Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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DocuColor 2060 / 2045 eXcellerate Service Manual

III

Table of Contents

Introduction About This Manual This service manual is designed to aid the operator who has received DocuColor 2060 / 2045 eXcellerate training. The manual provides the information necessary to correct problems, or to make a decision to call the Customer Support Center or call for service No attempt should be made to perform repairs or adjustments that go beyond the scope of these service manuals. The information in this manual applies to the DocuColor 2060 / 2045. This section of the manual contains safety information, a listing of the tools and cleaning supplies that you will need, and a glossary of terms used in DocuColor DocuColor 2060 / 2045 training. The following is a short description of the six sections contained in each manual:

Section I - How To Use This Manual This section describes the types of problems you will be able to solve and when to use this manual. This section also describes when to leave the manual. A fault code is generated when the senses a problem. Only those codes for which you can take corrective actions have been listed in this manual. If your displays a fault code that is not in this manual, you must call for assistance.

The actions in each of the fault code procedures are arranged in the order of either the most probable cause of the problem, or ease of performance. Try the actions in the procedure one at a time until the problem is solved. If the procedure does not solve the problem, you will be directed to call for assistance. If you cannot resolve any problem in a reasonable amount of time, call for assistance.

Section 2 - Fault Code Procedures

Section 5 - Repair Procedures This section contains a parts list and the removal, replacement, and adjustment procedures for machine sub components.

Section 6 - General Procedures The General Procedures section contains procedures that provide support to the maintenance tasks, removal and replacement procedures, or corrective actions.

This section contains the procedures used to repair faults. This section is used when a fault code is displayed on the User Interface screen.

Section 3 - Output Defect Procedures This section contains the procedures used to correct defects in the machine output. This section assists you in identifying output defects by providing both descriptions, and in some cases, illustrations of defects. Once you have determined the type of defect, you can determine the appropriate correction procedure to use.

Section 4 - Preventive Maintenance This section describes the maintenance tasks that should be performed as preventive maintenance.

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Introduction

IV


Safety The following pages list safety procedures which must be followed at all times. These lists do not include all of the potential areas of concern, but they should stimulate your thought process and make you aware of safe working conditions. Always be safety conscious. For safety information, call 1-800-828-6571 (U.S. and Canada)

Chemical Safety

System Safety

•

When When work working ing with with liqu liquid id chemic chemicals als,, replace the cap immediately after pouring the chemicals.

•

Never Never teac teach h an anyon yone e an any y repai repair, r, adju adjuststment or maintenence procedure that you have learned during training.

•

Never Never use use a any ny chem chemica icall unles unless s speci specififically directed to do so.

•

Never Never attem attempt pt any any repa repair ir or proced procedure ure for which you have not been trained.

•

If poss possibl ible, e, stor store e all all chemi chemical cals s in met metal al cabinets. If a meta cabinet is not available, store the chemicals in a well ventilated area away from heat and bright light.

•

Never Never perfo perform rm a repair repair,, remov removal, al, or a replacement without following the appropriate service manual procedure exactly.

•

Never Never attem attempt pt any any repa repair ir for for whic which h there there is not a specific procedure.

•

Never Never use use any any una unauth uthori orized zed chemi chemical cals s on or in Xerox equipment.

•

•

Never Never put put chem chemica icals ls on on an any y comp compone onent nt that is hot or warm. Dangerous or explosive fumes could result.

When When you you have have ffini inishe shed d work work in in an area, area, immediately replace all panels and covers. Never leave them off while the machine is running.

•

•

Neve Neverr mix mix chem chemic ical als s of any any kin kind. d.

Do not not s set et tool tools s insid inside e the the machi machine. ne. If not not removed, they can damage the machine.

•

When When us using ing chemic chemicals als for cleani cleaning ng a any ny part of the machine, never pour them directly onto the part. Pour them directly onto a cleaning towel and then use the towel to clean the component.

•

Do not not plac place e your your eyes eyes in line line with with an any y action or force that is being applied. A slip of the hand or a tool failure could result in an eye injury.

•

•

Dispos Dispose e of any contam contamina inated ted cleani cleaning ng materials properly.

Alwa Always ys wea wearr eye eye prot protec ecti tion on whe when n directed to do so by the documentation.

•

•

Wear Wear plast plastic ic glov gloves es when wheneve everr it is is recomrecommended. This is especially true when handling chemicals such as Xerox Film Remover, Lens and Mirror Cleaner, and fuser shield.

Always Always allow allow adeq adequat uate e time time for the comcomponents or assemblies to cool before beginning repairs in areas that generate heat, such as the fuser.

•

Always Always ensure ensure that that the the light lighting ing is adeadequate before beginning repairs in any area of the machine.

Work Area Safety •

Paper Paper on the floor floor can can caus cause e you you to slip. slip. Pick up any paper immediately.

•

Never Never put put liqu liquids ids on o orr near near the the m mach achine ine..

•

Keep Keep all all ais aisle les s cle clear ar..

•

Avoid Avoid wea wearin ring g open open toe shoes. shoes. Shoes Shoes that cover your feet completely provide better protection against covers, components, and other objects that can drop or fall.

•

•

Put any used used parts parts secure securely ly in in the the box box or container that held the new part. Store the used in a safe area until it is returned to the service representative. Never Never leav leave e tools tools scatte scattered red around around the work area. Always put them away when you are finished with the repair work.

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V

Safety

•

Always use the right tool for the job, and use it in a safe manner.

•

Never move the machine, even if it is mounted on a mobility plate, or a rail .

•

Before performing maintenance, remove jewelry, and tuck in or remove neckties. Avoid loose fitting clothing that could get caught in the machine, and tie back long hair, if applicable.

•

Never put liquids or ashtrays on the machine.

•

Use caution whenever working around electrical connectors. Do not touch the connector pins.

•

Observe all procedures carefully when working in the machine.

•

Never disable machine interlocks.

•

Visually inspect the machine power cord and plug for any obvious physical damage at each service call. If a problem is identified, disable the machine, install the Safety Lockout Kit, and notify your service representative for support.

Symbols

Safeguard Labels Laser Danger Labels

WARNING This symbol indicates that personal injury is possible if you do not strictly follow the practice, procedure, condition, or statement that follows the symbol.

The following types of labels are located on the machine. For your protection, you should know that these labels indicate you are near a laser hazard However, when you see the labels, and the covers are on the laser , there are no hazards to you.

CAUTION This symbol indicates that machine damage is possible if you do not strictly follow the practice, procedure, condition, or statement that follows the symbol.

Laser Safety • •

Do not bypass interlocks when working in or around any equipment using a laser. Do not wear any jewelry or use any shiny tools or objects around a laser. Any shiny object can accidently reflect a laser beam into the eyes.

LASER This symbol is a reminder of the possible hazards that are associated with a laser.

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Safety

VI


Notices

Safety Lockout Kit

Warning and caution notices are located immediately before the step or procedure in which you should heed the notice.

WARNING Many of the service procedures you will be performing during your training will require the removal of power to the machine by removing the power cord from the outlet. Using The Safety Lockout Kit is mandatory whenever a service procedure calls for power to be switched off. Severe electrical shock may occur if these regulations are not followed. Follow this procedure when you use the Safety Lockout Kit:

WARNING Notices preceded with the word “Warning” and the warning symbol are put in the documentation to alert you to the fact that a potential for personal injury exists. Whenever this notice is present, take all precautions in accordance with the notice.

CAUTION Notices preceded with the word “Caution” and the caution symbol are put in the documentation to alert you to the fact that a potential for machine or parts damage exists. Whenever this notice is present, take all precautions in accordance with the notice.

1. Switch off the machine power. 2. Disconnect the Power Cord from the AC power outlet. 3. Attach Safety Lockout Kit to the Power Cord Plug. Note: There is a procedure for installing the Safety Lockout Kit in section 6 of this manual.

NOTE: Notes are put in the documentation to aid you in performing a procedure, or to add information to clarify a procedure. They do not imply a warning or a caution.

Whenever you are instructed to power down the equipment, make sure that NO possibility exists for someone else to turn power back on while you are servicing electrical components. If you are servicing machines with two or more power cords, you may need multiple Lockout/ Tagout kits.

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VII

Safety

Tools and Cleaning Supplies Tools

(not pictured)

The following tools are required for the removal and replacement procedures in this service manual: Safety Glasses Part # 6OOT563 (1 pair) Used for eye protection.

Straight Slot Pocket Screwdriver

5.5 mm Combo Wrench

600T40501

Magnetic Pick-up

600T41911

Black Protective Bag

95P2362

Safety Lockout Kit

600T1933

Test Pattern

600T40205 Kynar Dusting Pouch

Long Magnetic Metric nut driver 5.5mm

8R2909

Part Number: 82E13120

600T1988

Needle Nose Pliers

#1 Cross Slot Screwdriver

600T40901

499T356

6mm x 100mm Straight Slot Screwdriver

150mm Scale

600T1989

600T41503

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Tools and Cleaning Supplies

VIII


Cleaning Supplies The following supplies are required for the service procedures in this service manual:

WARNING

Oval Cleaning Brush Part # 600T41901

WARNING

Harmful vapors.

Avoid eye contact.

Anti Static Fluid (ADF) Part # 8R90273

Formula “A” Cleaner Part #43P48 General purpose cleaner for machine components, covers, etc.

Avoid breathing or contact with skin. Cotton Swabs Part #35P2162 Used to clean sensors.

Plastic Gloves WARNING Avoid eye contact. Lens and Mirror Cleaner Part #43P81 (non-ADF machines)

Drop Cloth Part # 35P1737 Used to protect floor or desk when working on machine components outside the machine.

Used to clean mirrors and Platen Glass.

Optics Cleaning Cloth (blue) WARNING

Part #499T90417

Part # 99P3024 (3 pair) Used to protect hands from cleaning solvents and fuser shield. Cleaning Cloth Part # 600S4372 (pack of 10) Used to clean surfaces sensitive to residue, such as the document glass. Can be used in heated areas. Can be used dry or damp.

Flammable Film Remover Part # 43P45 (Not available in RX) Used to remove silicone oil and dry ink from m/c components.

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IX


Ordering Supplies Check the supplies regularly and reorder supplies before the last item is used.

CAUTION: Do not use any supplies not approved by Xerox. You can damage the machine by using supplies other than those recommended. To order minimum quantities of all supply items except soft lint free towels, call 1-800822-5881, Monday through Friday, between 8:00 a.m. and 8:00 p.m. To order larger quantities of all supply items including soft lint free towels, call 1-800-8222200, Monday through Friday, between 8:00 a.m. and 5:00 p.m. Give the Xerox representative the following information: • Your Xerox customer number •

Your model name and number

•

Item description

•

Quantities of items required

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X


Glossary A A3 - Metric paper size, corresponding to 11 x 17” paper. A4 - Metric paper size, corresponding to 8.25 x 11.75” ARRF - Active Retard Roll Feeders. The Feeder Assemblies in this copier are called Active Retard Roll Feeders (ARRF). They get this name from the fact that the Retard Roller can rotate in the opposite direction to the Feed Roll.

ASG - Analog Screen Generator Auditron - An optional accessory device used to control and record copier usage. Autometer - An optional accessory device used to control and record copier usage.

B B5 - Metric paper size, corresponding to 5.5 x 8.5” paper. Background - The non-image areas of the copy have a visible dusting of dry ink.

CC - Charge corotron. Places a high voltage on the photoreceptor in order to permit oppositely-charged toner particles to stick to the image areas on the photoreceptor. CCD - Charged Coupled Device. An array of closely spaced capacitors that provides a mechanism for shifting electrical charges. In the IIT it is used in conjunction with photodiodes as a semiconductor device which coverts the light reflected off a document into electrical signals to obtain an electronic image.

ADF - Automatic Document Feeder. Automatically feeds, registers, and returns a stack of documents through a multisheet feeder.

Belt (photoreceptor) - Flexible, endless strip of photosensitive material used in the xerographic process. Serves the same purpose as a photoreceptor drum.

CCW - Counter Clock Wise

ADC - Automatic Density Control. Monitors density patches developed on the IBT Belt.

Black copy - The image area of the copy is entirely black.

ADH - Automatic Document Handler

Blank copy - The image area of the copy is entirely white (or non-imaged).

Copy cartridge - A customer replaceable unit containing the photoreceptor and (often) one or more corotrons.

ADJ - Adjustment AGC - Automatic Gain Control. Automatically sets the gain of the amplifier in the analog circuit which processes the CCD Color Image Sensor outputs. ALC - Auto Level Control. Adjusts the TRC based on the differenceof ROS intensity levels on the drum. Amp - Measure of electrical current. Area coverage - Amount of image on a page. Expressed in percent. Each copier has specifications for optimum performance from dry ink based on area coverage.

BPO - Bead Pick Off BSD - Block Schematic Diagram BTR - Bias Transfer Roll. Transfers the toner image from the Drum to the surface of the IBT Bypass - A chute, tray, or other assembly through which an operator may feed special copy paper, bypassing standard paper trays.

C

Change tag - A number that represents a modified or retrofitted configuration of the copier.

Corotron - A thin wire (possibly glasscoated) strung under high tension. Corotrons conduct a high voltage electrical field to the photoreceptor during the xerographic process. CPM - Copies Per Minute. C-POP - Color Patch on Paper CQ - Copy Quality CVA - Copy Volume Analyzer CW - Clock Wise

C - Represents the toner color Cyan in the C, M, Y, K color mode used in all color printers.

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XI

Glossary

D DADF - Duplexing Automatic Document Feeder. DCU - Diagnostic Control Unit Detack corotron - Places a high voltage on the photoreceptor in order to permit paper to separate from the photoreceptor during the xerographic process. Developer - Coarse powder that carries dry ink to the photoreceptor in the xerographic process. Developer module - A replaceable module containing the developer material. DFE - Digital Front End Diagnostic(s) program - Programs used by service engineers to troubleshoot machine and copy quality problems. DM - Duplex Module Dry ink or imager - Fine powder used to develop the image. Also called toner. Drum - See Photorecptor Duplex - Two-sided

E Edge Erase (lamp) - A lamp or electroluminescent strip that shines briefly on the photoreceptor between latent images to discharge the edge of an image area. EPC Print - Electronic Precollation Print ESD - Electrostatic Discharge. When a procedure has this warning, use caution when handling electronic components and assemblies.

ESV - Electrostatic Voltmeter. The surface of the Photoreceptor Drum is charged and the voltage level is measured during setups by the Electrostatic Voltmeter. Exposure lamp - One or more lamps under the platen that illuminate the original document during the exposure step of xerography.

F

GSM - Grams per square meter. It is a metric paper weight designation that is equivalent to US pounds.

H Half-rate (carriage) - Assembly that “carries” optical mirrors at half the rate of scan. HCF - High Capacity Feeder HCSS - High Capacity Stacker / Stapler

FCO(T) - First Copy Out (time). Time from pushing Start Print to when the copy arrives in the output tray or device. Foreign interface - Non-Xerox-made accessory, usually installed to control and record copier usage. F-Tra - Feeder Transports Full-rate (carriage) - Assembly that “carries” the exposure lamp and/or mirror at the rate of scan. Compare with half-rate carriage. Fuse - Melt (dry ink) into paper at high temperatures. Fuser roll - The heated roll that melts the dry ink onto the paper when pressed against the pressure roll.

G GFI - Ground Fault Interrupter. Provides protection against excessive leakage current to ground. GFP - Ground fault protector. Protects the copier (and operator) against shocks caused by AC leakage between the power source and the copier frame.

HDD - Hard Disk Drive HFSI - High Frequency Service Item. A maintenance procedure to clean or replace a component or assembly at a pre-determined interval. H-Tra - Horizontal Transport HVPS - High Voltage Power Supply. Supplies the high voltage to the corotron wires and other xerographic components. Hz - Hertz. Electrical cycles per second.

I I/B - Inboard. A term to indicate “toward the back of the machine”. IBT - Intermediate Transfer Belt. A flexible, conductive metallic belt that rotates against the surface of the Drum. The toner image on the Drum is transferred to the IBT. In the case of four color printing, the four color image is built on the IBT and then transferred to paper. IIT - Image Input Terminal. The Image Input Terminal (IIT) senses the image and converts it to digital information.

GP - General Procedure 04/02

Glossary

XII


Imager - Fine powder used to develop the image. Also called toner, dry ink.

tion of printing paper or placement of originals on a platen or feeding device.

OEM - Original equipment manufacturer.

Interimage (lamp) - A lamp or electroluminescent strip that shines briefly on the photoreceptor between latent images.

Light copy - The printed image is lighter than the original image.

OHP - Overhead Projector

IOT - Image Output Terminal.

LVPS - Low Voltage Power Supply. LVPS supplies the various DC voltage levels required by the machine.

IPM - Images per minute. IPS - Image Processing System. The Image Processing System (IPS) performs the color correction and the editing functions. ITracs - The automatic density check that is performed by the CPOP Sensors with a scanner installed. IQ - Image Quality

J J-Tra - Junction Transport

K K - Represents the toner color Black in the C, M, Y, K color mode used in all color printers. Kynar - A material that is user to lubricate the IBT Belt.

L LCD - Liquid Crystal Display. This assembly displays graphic operator information and allows the operator to enter information through the touch panel. LE - Leading edge of a sheet of paper as it travels through the paper path for processing LED - Light Emitting Diode. Used as visual indicators. LEF - Long Edge Feed. Refers to the orienta-

LUT - Look Up Table

M M - Represents the toner color Magenta in the C, M, Y, K color mode used in all color printers. Machine service log - The book or pages where the service engineer records service activity for the copier. Message - A message that appears on the control console display indicating a malfunction or need for other attention to the copier. Similar to status code. MOB - Marks on Belt

N NG - No Good. The result of a failed diagnostic routine. NOHAD module - 5015 product family. An optional accessory.... NVM - Non-volatile memory. Memory that retains information even when the copier is turned off or unplugged.

O O/B - Outboard. A term to indicate “toward the front of the machine”.

OGM - On Going Maintenence Optics - General term referring to the exposure lamp, lens, mirrors, reflectors used to expose and image the original document onto the photoreceptor.

P Photoreceptor - The light-sensitive drum or belt that is exposed to an original image, and is developed with dry ink or toner. Platen Glass - Where you register an original to make a copy. Found under a platen cover or document handling device. Power saver - Copier mode where energy consumption is reduced when there is no activity for a predetermined length of time. PPM - Prints per minute. P/N - Part Number POB - Paper on Belt P/R - Photoreceptor Preclean (or clean) corotron - Places a high voltage on the photoreceptor in order to permit residual toner to be loosened enough to be vacuumed or brushed off the photoreceptor. Pressure roll - The roll that presses copy paper against the fuser roll, melting the dry ink into the paper. PTC - Pretransfer Corotron. Helps in the transfer of the 4 layer image from the IBT Belt to paper.

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XIII

Glossary

PWB - Printed wiring board. The circuit boards used in controlling the machine processes

R R/E - Reduction / Enlargement. RAP - Repair Analysis Procedure RC Patch - Registration Control Patch. Helps to determine the proper writing angle of the ROS units. RegiCon - Registration Control Residual image - A “ghost” image on the copy or print. REP - Repair ROM - Read Only Memory ROS - Raster Output Scanner (laser). The Raster Output Scanner uses a diode laser to expose the photoreceptor with a raster image.

S SEF - Short Edge Feed. Refers to the orientation of printing paper or the placement of originals on a platen or feeding device. Skew - The image is misregistered unequally top to bottom or side to side. SMH - Special Materials Handler (Tray 3) SNR - Sensor Snubber - A (usually) triangular device, most often found in a paper cassette or tray, for the purpose of preventing more than one sheet of paper from entering the feed or registration area at one time. Spot - A small dot of dry ink on a copy or

U

print that is not part of the original image. Status code - An alphanumeric code that appears on the control console display indicating a malfunction or need for other attention to the copier. Similar to message.

UI - User Interface. The UI enables the operator to specify the quantity, orientation, magnification, color and other details of the output.

Status indicator - Alpha-numeric code or lamps that indicate the status of the copier.

V

Stripper fingers - Small, pointed devices that strip copy or print paper from the fuser or photoreceptor.

T Tag (change) - A number that represents a modified or retrofitted configuration of the copier or printer. TC - Transfer corotron. Places a high voltage on the photoreceptor in order to permit transfer of dry imager from the photoreceptor to copy paper. Threshold - Information normally attained through diagnostics indicating change interval for assemblies, components, or machine consumable. Toner - Fine powder used to develop the image. Also called dry ink or imager. Touch Panel - The Touch Panel is part of the LCD Assembly and contains the switches which sense when and where the operator touches the LCD display. Tracs - The automatic density check that is performed by the ADC sensors on the IBT. TRC - Tone Reproduction Curve. The function in image processing that adjusts the characteristic of output image density to input image density.

VAC - AC Voltage Vbias - Bias voltage applied to the Developer Housing. V Clean - Value of the cleaning field. The electrostatic voltage difference that causes toner particles to return to the developer roll from the background areas of the electrostatic latent image. VGS - Voltage Grid Set. Determines drum potential based on temperature and humidity V/H - Value “High”. Value of the elecrostatic discharge on the unexposed areas of a charged drum. V/M - Value “Mid”. Value of the elecrostatic discharge on the drum after the charged drum is exposed to an image area of 60% density for C, M, Y and 50% for K. V-Sel - Video Select

W Web - Material that wipes the Fuser Heat Roll of excess oil and toner debris.

Y Y - Represents the toner color Yellow in the C, M, Y, K color mode used in all color printers.

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Glossary

XIV


1. How To Use This Manual Section Contents

Page

When to use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Call Flow Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Obvious Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Status Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Output Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Initial Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Every Call Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . 1-6 Extended Maintenance Activities . . . . . . . . . . . . . . . . . . . . 1-7 Final Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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DocuColor 2060/2045 eXcellerate Service Manual

1-1

How To Use This Manual

When To Use This Manual

Call Flow Chart

There are four reasons to use this manual: •

An obvious problem, such as a broken component

•

A fault code

•

An output defect, such as image quality

•

Preventive maintenance

Initial Action Section 1

Preventive Maintenance Section 4

Fix the Problem

Call Flow Sequence Refer to the Call Flow Chart. This chart shows the correct sequence to follow each time service is performed on the machine. Follow this chart to ensure that the equipment maintains a high level of performance and reliability.

Output Defect Procedures Section 3

Initial Action: The first step in the Call Flow, found in Section 1. During this procedure you obtain additional information about the machine state to help in the problem diagnosis. And you are sent to Section 4, Preventive Maintenance, to determine if any HFSI items require attention. Also you are directed to perform Every Call Cleaning Procedures and Extended Mainte- nance Activities (if required). Fix the Problem: You will be directed to go to a specific area of the service manual to diagnose and repair the machine fault.

Repairs & Adjustments Section 5

Fault Code Procedures Section 2

Final Actions Section 1

Note: If you are unable to clear any problem within a reasonable time, you should call a Customer Service Engineer (CSE) for assistance. Final Actions: These actions, found in Section 1, will make sure that all machine features are operating to specification. You will also verify that the physical appearance of the machine is satisfactory and that the administrative tasks necessary to close out a service call are performed.

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1-3


Obvious Problem

Preventive Maintenance

If there is an obvious problem such as a broken or loose component, go to section 5 and repair the problem. Then, return to the Call Flow Chart in Section 1 and continue. If the part number or the repair procedure is not listed in section 5, the problem is beyond the scope of this manual and you must call for assistance.

By performing regular cleaning and replacement procedures, a high level of system reliability, productivity, and output quality can be expected. The maintenance tasks that you should perform on a regular basis are described in HFSI - section 4.

Status Code A status code is displayed on the User Interface when the machine senses a problem. Anytime a status code is displayed, service is required. This manual provides information that will help you perform the necessary service, or instruct you to call for assistance. When a status code is displayed, go to section 2 for the appropriate clearance procedure. Section 2 is in a table form. Column 1 lists the fault codes and column 2 lists the possible solutions. The solutions in each of the status codes is arranged in the order of either the most probable cause of the problem, or ease of performance. Try the actions one at a time until the problem is solved. If the solution is beyond the scope of this manual, you will be instructed to call for assistance. If a displayed status code is not listed in the table, call for assistance. If there is a component removal and replacement required, you will be sent to the appropriate procedure. If you cannot resolve any problem in a reasonable amount of time, call for assistance. Finally, if you are able to resolve the problem, return to the Call Flow Chart in Section 1 and continue.

Output Defects When you see an output defect (image quality), go to section 3 for the appropriate service procedure. Section 3 contains sample defects to assist you in determining the problem. Use the section contents page to locate the necessary procedure. If there is a component removal and replacement required, you will be sent to the appropriate procedure. Finally, if you are able to fix the image defect, return to the Call Flow Chart in Section 1 and continue.

04/02


1-4


Initial Actions

7.

Purpose

8. Exit the TKO Diagnostic Pathway.

The purpose of the Initial Action section of the Service Call Procedures is to determine the reason for the service call and to identify and organize the actions which must be performed.

9.

Procedure 1.

2.

Obtain from the operator, a description of the reason for the call. If possible, determine the nature of the job being run and the mode of operation of the system at the time the problem occurred. Also, ask the operator to describe any other problems that may have been observed. Inspect any rejected copies, if possible. Look for indications of excessive paper jams, such as wrinkles in the paper, images that are not fused, images that are skewed or are excessively misregistered. Try to identify the specific defects which caused the customer to reject the copy. Ensure that the task being attempted is within the capabilities of the machine.

3.

Record the billing meter readings on the Service Log.

4.

Enter the TKO Diagnostic Pathway, and determine what HFSI action is required based on the customer output volume. Refer to Section 4 Preventive Maintenance for detailed HFSI information. Record any items that require action.

Check the Service Log for any recent activities that are related to the problem that caused the service call or any secondary problem. If a Fault Code is displayed, go to the Fault Code Procedures in Section 2 to begin troubleshooting and return here after repairing the fault code.

NOTE: If a Fault Code is displayed while performing a diagnostic procedure, go to Section 2 Fault Code Entry Table and repair the fault. Return to Diagnostics and continue with the DC procedure that you were performing. 10. If the machine is configured as a printer-only , perform the image quality checkout procedure on page 3.2-6A. a.

If a problem is found , go to the Output Defect Procedures in Section 3 to begin troubleshooting and return here after repairing the problem.

b.

If a problem is not found, go to step 12.

11. If the machine is configured as a copier / printer , perform the image quality checkout procedures on 3.2-31 and 3.2-6A.

NOTE: The service strategy of the DocuColor 2060 /2045 Machine is to perform any High Frequency Service Item (HFSI) actions and Every Call Cleaning Procedures before attempting to repair any problems. Some problems will be corrected by this strategy without the need to diagnose them. The Call Flow RAP will be used for any remaining problems.

a.

If a problem is found , go to the Output Defect Procedures in Section 3 to begin troubleshooting and return here after repairing the problem.

b.

If a problem is not found, go to step 12.

12. Try to rerun the customer job(s) that exhibits the problem. a.

If a problem is observed, check to see if it only occurs on a particular job. If the problem occurs only on a particular job, verify that the job is being run correctly. If the problem occurs on more than one job, place a service call and then go to Final Actions .

b.

If a problem is not observed , go to Final Actions .

5. Perform any required HFSI activities. 6.

Perform Every Call Cleaning Procedures and Extended Maintenance Activities (if more than 50,000 impressions since last service call).

04/02


1-5


Every Call Cleaning Procedures

Fuser Assembly

These cleaning procedures are to be performed on every call or whenever a subsystem is accessed.

WARNING / CAUTION Do not use any solvents unless directed to do so by the Service Manual.

•

Clean the Fuser Belt Stripper Fingers (Sect. 5, Component Location Overview 3).

•

Clean the Fuser Exit Sensor with a dry cotton swab (REP 10.14).

•

Wipe off the Exit Transport Assembly (Sect. 5, Sensor Locations, Figure 13).

•

Check the level of the Fuser Oil and replenish if necessary. (GP 8)

Toner Tubes •

Vacuum the area around the Toner Cartridges (Sect. 5, Component Location Overview 1).

CAUTION Do not vacuum around or near sensors or PWBs (circuit boards) unless the vacuum cleaner is properly grounded. General Cleaning Use a dry lint-free cloth for all cleaning actions, unless directed otherwise. When a moistened cloth is used, wipe afterwards with a dry lint-free cloth, except when cleaning rolls.

Optics (Copier Only) •

Clean the Platen Glass (REP 6.3) with Lens and Mirror Cleaner and a dry lint-free cloth.

Paper Transport Module •

Clean the 2nd BTR Roll Assembly (REP 9.14).

•

Vacuum the Detack Corotron (REP 9.20).

•

Vacuum the Vacuum Transport Belts (Sect. 5, Component Location Overview 2).

•

Clean the four Vacuum Transport Sensors (REP 8.2) with a dry cotton swab.

IBT Belt Area •

Clean the MOB Sensor Assembly (REP 6.1) with a dry cotton swab.

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1-6


Extended Maintenance Activities (50,000 or more impressions)

Xerographic Area

•

These cleaning procedures must be performed in addition to the Every Call Cleaning activities, when there has been more than 50,000 impressions made since these Extended Maintenance Activities were last performed.

Clean all 4 ROS Windows. (REP 6.2)

IBT Belt Area

CAUTION After cleaning any roll, let it air-dry. Do not wipe it with a dry cloth.

CAUTION To access the reflective patch on the IBT Belt, move it only by rotating the flywheel attached to the IBT Belt Drive Motor.

Optics (Copier Only)

•

Clean the Belt Home Position Sensor 1/2 (REP 9.7 and REP 9.8) with a lint-free cloth.

•

•

Clean the IBT Reflective Patch (REP 9.9) with a dry lint-free cloth.

•

Clean the POB Jam Sensor (REP 9.21) with a dry cotton swab.

•

Clean the Mirrors (REP 6.5) with Lens and Mirror Cleaner and a dry lintfree cloth. Clean the White Reference Strip (REP 6.5) with a dry lint-free cloth only.

Fuser Assembly Paper Trays •

•

•

(Remove the Tray 3 Feed Assembly Cover) Clean all the rolls in the Feed Assembly (REP 7.1) with Film Remover and a water-moistened, lint-free cloth.

Clean the Inverter Path Sensor (Sect. 5, Sensor Locations, Fig. 11) and (if accessible) Exit Transport Path Sensor (Sect. 5, Sensor Locations, Fig. 13) with a dry cotton swab.

•

Clean the Tray 3 Pre-feed (REP 7.4), Feed Out (REP 7.5) and OHP Sensors (REP 7.6) with a dry cotton swab.

Clean the (Fuser) Cleaner Roll Assembly (REP 10.12) by scraping it, using a tool with a semi-sharp edge, such as a six-inch rule.

•

Clean the Finger Assembly-HR (REP 10.15) with a dry lint-free cloth.

Paper Transport Module •

Clean the two F-Transport Sensors with a dry cotton swab (Sect. 5, Sensor Locations, Fig. 1).

•

Clean the four J-Transport Sensors with a dry cotton swab (Sect. 5, Sensor Locations, Fig. 2 and 3).

•

Clean the Registration Out Sensor with a dry cotton swab (REP 8.7).

•

Clean the two Aligner Path Sensors with a dry cotton swab (REP 8.8).

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1-7


Final Actions Purpose The intent of this procedure is to be used as a guide to follow at the end of every service call.

Procedure

CAUTION When adding Fuser Oil, do not fill above the bottom of the neck on the Fuser Oil Reservoir.

CAUTION Fuser Oil is very slippery. Promptly clean up any oil that has spilled. See Section 4 for the proper c leaning procedures. 1.

Add Fuser Oil to fill the sump to the required level. (GP 8)

2.

Ensure that the exterior of the machine and the adjacent area are clean. Use a dry cloth or a cloth moistened with water to clean the machine. Do not use solvents.

3. Complete the Service Log. 4.

At the next Xerox service call, discuss any service activity you have performed with your Xerox service representative. This will ensure that the service representative understands what has been done to the machine and that may impact his or her service strategy.

04/02


1-8


2. Fault Code Procedures Page

6-277 thru 6-355. . . . . . . . . . . . . . . 2-16

8-180, 8-184 . . . . . . . . . . . . . . . . . . 2-24

Introduction . . . . . . . . . . . . . . . . . . . . 2-3

6-360, 6-361. . . . . . . . . . . . . . . . . . 2-16

8-190 thru 8-194 . . . . . . . . . . . . . . . 2-24

6-371 . . . . . . . . . . . . . . . . . . . . . . . 2-17

8-198 thru 8-310 . . . . . . . . . . . . . . . 2-24

6-372 thru 6-623. . . . . . . . . . . . . . . 2-17

8-311 . . . . . . . . . . . . . . . . . . . . . . . . 2-24

6-624 thru 6-626. . . . . . . . . . . . . . . 2-18

8-312 . . . . . . . . . . . . . . . . . . . . . . . . 2-25

6-627 thru 6-648. . . . . . . . . . . . . . . 2-18

8-601 . . . . . . . . . . . . . . . . . . . . . . . . 2-25

6-649 thru 6-651. . . . . . . . . . . . . . . 2-18

8-602 thru 8-604 . . . . . . . . . . . . . . . 2-24

6-652 thru 6-656. . . . . . . . . . . . . . . 2-18

8-605 . . . . . . . . . . . . . . . . . . . . . . . . 2-25

7-210 thru 7-284. . . . . . . . . . . . . . . 2-19

8-900 . . . . . . . . . . . . . . . . . . . . . . . . 2-26

7-285 . . . . . . . . . . . . . . . . . . . . . . . 2-19

9-105 . . . . . . . . . . . . . . . . . . . . . . . . 2-26

7-286 thru 7-340. . . . . . . . . . . . . . . 2-19

9-301 . . . . . . . . . . . . . . . . . . . . . . . . 2-26

7-510 thru 7-512. . . . . . . . . . . . . . . 2-20

9-330 thru 9-336 . . . . . . . . . . . . . . . 2-26

7-513 thru 7-518. . . . . . . . . . . . . . . 2-19

9-343, 9-344 . . . . . . . . . . . . . . . . . . 2-27

7-528 . . . . . . . . . . . . . . . . . . . . . . . 2-19

9-350 thru 9-357 . . . . . . . . . . . . . . . 2-27

7-600 . . . . . . . . . . . . . . . . . . . . . . . 2-20

9-358 . . . . . . . . . . . . . . . . . . . . . . . . 2-27

8-105, 8-110. . . . . . . . . . . . . . . . . . 2-21

9-360 . . . . . . . . . . . . . . . . . . . . . . . . 2-28

8-120 . . . . . . . . . . . . . . . . . . . . . . . 2-21

9-361 . . . . . . . . . . . . . . . . . . . . . . . . 2-28

8-122 . . . . . . . . . . . . . . . . . . . . . . . 2-22

9-362 . . . . . . . . . . . . . . . . . . . . . . . . 2-28

8-130 thru 8-144. . . . . . . . . . . . . . . 2-22

9-363 . . . . . . . . . . . . . . . . . . . . . . . . 2-29

8-146 . . . . . . . . . . . . . . . . . . . . . . . 2-22

9-375 . . . . . . . . . . . . . . . . . . . . . . . . 2-29

8-150 . . . . . . . . . . . . . . . . . . . . . . . 2-22

9-377 . . . . . . . . . . . . . . . . . . . . . . . . 2-29

8-154 . . . . . . . . . . . . . . . . . . . . . . . 2-23

9-402 thru 9-405 . . . . . . . . . . . . . . . 2-30

8-157 . . . . . . . . . . . . . . . . . . . . . . . 2-23

9-410 thru 9-421 . . . . . . . . . . . . . . . 2-30

8-160 . . . . . . . . . . . . . . . . . . . . . . . 2-23

9-500 . . . . . . . . . . . . . . . . . . . . . . . . 2-30

8-170 . . . . . . . . . . . . . . . . . . . . . . . 2-23

9-600 thru 9-603 . . . . . . . . . . . . . . . 2-30

Section Contents

Status Fault Codes Table 1. Status Code Entry Table . 2-4 1-300 thru 1-359 . . . . . . . . . . . . . . . . 2-4 2-310 thru 2-502 . . . . . . . . . . . . . . . . 2-4 3-312 thru 3-951 . . . . . . . . . . . . . . . . 2-5 3-504, 3-505 . . . . . . . . . . . . . . . . . . . 2-5 3-508, 3-516, 3-520. . . . . . . . . . . . . . 2-6 3-521, 3-522, 3-523. . . . . . . . . . . . . . 2-7 3-525, 3-526, 3-527. . . . . . . . . . . . . . 2-8 3-529 thru 3-532 . . . . . . . . . . . . . . . . 2-9 3-540 . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 3-541 thru 3-546 . . . . . . . . . . . . . . . 2-10 4-310 thru 4-607 . . . . . . . . . . . . . . . 2-11 5-110 . . . . . . . . . . . . . . . . . . . . . . . . 2-11 5-111 thru 5-113 . . . . . . . . . . . . . . . 2-12 5-115, 5-116 . . . . . . . . . . . . . . . . . . 2-13 5-195 . . . . . . . . . . . . . . . . . . . . . . . . 2-14 5-274, 5-275 . . . . . . . . . . . . . . . . . . 2-14 5-301, 5-501 . . . . . . . . . . . . . . . . . . 2-15 5-900 thru 5-902 . . . . . . . . . . . . . . . 2-15 5-903, 5-904 . . . . . . . . . . . . . . . . . . 2-16


04/02 2-1

Fault Code Procedures

9-604 thru 9-607 . . . . . . . . . . . . . . .2-31

10-385 thru 10-390 . . . . . . . . . . . . . 2-38

9-608 thru 9-615 . . . . . . . . . . . . . . .2-31

10-392 thru 10-394 . . . . . . . . . . . . . 2-39

9-618, 9-619. . . . . . . . . . . . . . . . . . .2-31

10-400. . . . . . . . . . . . . . . . . . . . . . . 2-39

9-624 thru 9-643 . . . . . . . . . . . . . . .2-31

10-401. . . . . . . . . . . . . . . . . . . . . . . 2-39

9-663 thru 9-666 . . . . . . . . . . . . . . .2-32

10-600. . . . . . . . . . . . . . . . . . . . . . . 2-39

9-670 thru 9-677 . . . . . . . . . . . . . . .2-32

12-295. . . . . . . . . . . . . . . . . . . . . . . 2-40

9-685, 9-686. . . . . . . . . . . . . . . . . . .2-32

12-500. . . . . . . . . . . . . . . . . . . . . . . 2-40

9-690 thru 9-693 . . . . . . . . . . . . . . .2-32 9-694 thru 9-697 . . . . . . . . . . . . . . .2-33 10-105, 10-106. . . . . . . . . . . . . . . . .2-33 10-110 . . . . . . . . . . . . . . . . . . . . . . .2-33 10-112 . . . . . . . . . . . . . . . . . . . . . . .2-34 10-120 . . . . . . . . . . . . . . . . . . . . . . .2-34 10-122 . . . . . . . . . . . . . . . . . . . . . . .2-34 10-123 . . . . . . . . . . . . . . . . . . . . . . .2-35 10-130 . . . . . . . . . . . . . . . . . . . . . . .2-35 10-132 . . . . . . . . . . . . . . . . . . . . . . .2-35 10-290 . . . . . . . . . . . . . . . . . . . . . . .2-36 10-310 . . . . . . . . . . . . . . . . . . . . . . .2-36 10-311 thru 10-313 . . . . . . . . . . . . .2-36 10-314 thru 10-316 . . . . . . . . . . . . .2-37 10-318 . . . . . . . . . . . . . . . . . . . . . . .2-37 10-319 . . . . . . . . . . . . . . . . . . . . . . .2-37 10-354 thru 10-367 . . . . . . . . . . . . .2-38 10-380 . . . . . . . . . . . . . . . . . . . . . . .2-38 10-382 . . . . . . . . . . . . . . . . . . . . . . .2-38


04/02 2-2


Introduction

Always Heed The Following Warning.....

This section contains status code procedures. Each procedure represents a status code, or group of status codes that may be displayed, indicating a problem. The status codes are numerical (e.g. 5-901), with the number to the left of the hyphen indicating the area of the machine and the remaining digit(s) indicating a particular fault to that area. Using the example of status code 5-901, the first number (5) indicates that the fault has occurred in the ADF (Automatic Document Feeder). A “10-106” code would indicate a duplex jam.

WARNING Switch off the Main Power Switch, and disconnect the Power Cord. Install Lockout tag. Failure to do so could result in severe electrical shock.

To access the correct procedure, use the section content page to locate the indicated status code and the appropriate page number. The Status Code Entry Table is composed of two columns. The left column contains the status code fault indicator. The right column includes a description of the fault and the actions to take in resolving the problem. The actions are the “most likely” suspects. In each case, if you try to resolve the fault and all attempts fail, you are directed to call for service. Always follow the Repair procedures carefully. Whenever directed, be sure to Switch off the Main Power Switch and disconnect the Power Cord.


04/02 2-3


Status Code Entry Table

Procedure Go to the Status Code Entry Table below

Status Code Entry Table Status Code

Description/Direction

1-300, 302, 303, 304, 308, 309, 350, 355, 356, 357, 358, 359

The Control Logic indicates a Standby Power failure.

2-310, 311, 340, 345, 500, 501, 502

The Control Logic indicates a User Interface failure.

Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-4


Status Code 3-312, 315, 317, 318, 340, 352, 356, 357, 360, 362, 365, 368, 379, 380, 381, 393, 394, 395, 396, 397, 500, 507, 509, 510, 519, 524, 590, 592, 593, 598, 950, 951 3-504

Description/Direction The Control Logic indicates a User Interface failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

The Control Logic indicates that the printing area is too small for both the image and the Color Bar. Initial Action: Clear the job. If the fault is declared again, power the machine OFF then ON. If the problem still exists: Place a service call.

3-505

The Control Logic indicates that, when selecting a small size, the whole image could not be printed on the paper. Initial Action: Select a smaller image size. Select a larger image size. If the fault is declared again, power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-5


Status Code


3-508

The Control Logic indicates that in the COPY or SCAN modes, the numbers of the image exceeds the count available to the system. Simplex = 1024, and Duplex= 2048. Initial Action: Reduce the number of copies or scans to within the designated limits. Power the machine OFF then ON, and repeat the job with a new copy/scan count. If the problem still exists: Place a service call.

3-516

The control logic indicates that when selecting Tray at the beginning of printing in the Auto Paper Supply (APS) mode, there was no selectable Tray (paper size, type, direction) available. Initial Action: Ensure that paper of the desired size, type and direction is in the tray. Ensure that the Paper Tray indicators are set correctly. If OK, power the machine OFF then ON. If the problem still exists: Place a service call.

3-520

The control logic indicates that all of the available (not broken) trays at the time of printing are at the Inhibit Setting. Initial Action: Use the following Tools Pathway: Machine Default 1\ Auto Tray Switching and try to release any inhibited tray. If OK, power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-6


Status Code 3-521

Description/Direction The Control Logic indicates that the paper sizes identified in the tray and the actual transported one are different. Initial Action: Use the following Tools Pathway: Machine Default 1\ Auto Tray Switching and ensure that Auto Tray Switching is enabled. Ensure that the End Guides are properly adjusted to the paper in the Tray. If OK, power the machine OFF then ON. If the problem still exists: Place a service call.

3-522

The Control Logic indicates that the paper types identified in the tray and the actual transported one are different. Initial Action: Use the following Tools Pathway: Machine Default 1\ Auto Tray Switching and ensure that Auto Tray Switching is enabled. Ensure that the End Guides are properly adjusted to the paper in the Tray. If OK, power the machine OFF then ON. If the problem still exists: Place a service call.

3-523

The Control Logic indicates that the designated number of images cannot be put into the Repeat Mode. Initial Action: Reduce the designated number of images and attempt to repeat the job. If the fault is declared again, power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-7


Status Code 3-525

Description/Direction The Control Logic indicates that magnification exceeded 400% in the Poster Mode. Initial Action: Clear the job and select a poster size that requires a magnification of 400% or less and attempt to repeat the job. If the fault is declared again, power the machine OFF then ON. If the problem still exists: Place a service call.

3-526

The Control Logic indicates a problem with Auto Rotation. Initial Action: Use the following Tools Pathway: Machine Default 2\ Auto Rotation, switch it off and attempt to resume the job. If the fault is declared again, power the machine OFF then ON. If the problem still exists: Place a service call.

3-527

The Control Logic indicates that the machine detects a Fast Scan problem in Reduction/Enlargement Mode. Initial Action: Select another magnification ratio, press the Confirmation button and continue the job. If the fault is declared again, power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-8


Status Code 3-529

Description/Direction The Control Logic indicates that the number of images exceeded the maximum allowable during copying or scanning. Initial Action: Start printing the job already scanned to recover the job. If the fault is declared again, cancel the job and power the machine OFF then ON. If the problem still exists: Place a service call.

3-530

The Control Logic indicates that scanning was completed but the image data did not get into the HDD. Initial Action: Cancel the job. If the fault code does not clear, power the machine OFF then ON. If the problem still exists: Place a service call.

3-531, 532

The Control Logic indicates that the NVM location used to handle the job is full. Initial Action: Cancel the job. If the fault code does not clear, power the machine OFF then ON. If the problem still exists: Place a service call.

3-540

The Control Logic indicates that the paper size supplied to the HCSS is different from what the HCSS is set to receive. Initial Action: Ensure that the paper trays for the HCSS are set to the correct size. Cancel the job. If the fault code does not clear, power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-9


Status Code


3-541, 542

The Control Logic indicates a discrepancy between the paper size(s) selected and that which the HCSS stapler is set to staple. Initial Action: Ensure that the paper size(s) and orientation selected for the job matches the paper size and orientation selected for the HCSS. Cancel the job. If the fault code does not clear, power the machine OFF then ON. If the problem still exists: Place a service call.

3-543

The Control Logic indicates that the number of sheet to be fed to the HCSS exceeds the maximum number that can be stapled. Initial Action: Ensure that the quantity of prints/copies does not exceed the recommended amount. Cancel the job. If the fault code does not clear, power the machine OFF then ON. If the problem still exists: Place a service call.

3-544, 545

The Control Logic indicates a problem with Power Off Recovery at Power On or HCSS failed to provide proof of delivery. Initial Action: Cancel the job. If the fault code does not clear, power the machine OFF then ON. If the problem still exists: Place a service call.

3-546

The Control Logic indicates a recovery problem occurred when exiting from Interrupt during a EPC-Print or DFE Print job. Initial Action: Cancel the job. If the fault code does not clear, power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-10


Status Code 4-310, 311, 318, 319, 320, 321, 322, 323, 324, 325, 326, 327, 328, 329, 330, 331, 332, 350, 351, 352, 353, 354, 355, 600, 601, 602, 603, 604, 605, 606, 607 5-110

Description/Direction The Control Logic indicates a Drives failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

The Control Logic indicates that the DADF Registration Sensor does not detect a document within the allowed time. Initial Action: Check the sensor for any object or material that may be blocking it. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

5-111

The Control Logic indicates that the document did not pass through the DADF Regi Sensor within the allowed time. Initial Action: Check the sensor for any object or material that may be blocking it. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-11


Status Code


5-112, 113

The Control Logic indicates that the document did not pass through the DADF Regi Sensor within the allowed time during document inversion. Initial Action: Check the transport area for jammed paper or paper fragments. Check the sensor for any object or material that may be blocking it. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

5-115

The Control Logic indicates that the DADF Exit Sensor did not detect a document within the time allowed. Initial Action: Check the sensor for any object or material that may be blocking it. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

5-116

The Control Logic indicates that the DADF Exit Sensor did not detect a document leaving it within the time allowed. Initial Action: Check the sensor for any object or material that may be blocking it. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-12


Status Code


5-195

The Control Logic indicates that a document of a different size from the first document was detected in the No Mix Mode. Initial Action: Ensure that the document stack is composed of all the same size documents, free of damage and within specification. If the problem remains: Follow any operator instructions, load a good set of fifty or less documents in the DADF, power the machine OFF then ON, then repeat the job. If the problem still exists: Place a service call.

5-274

The Control Logic indicates a problem with one or both DADF Size Sensors when a document is loaded at Power On. Initial Action: Follow any operator instructions, load a good set of fifty or less documents in the DADF, power the machine OFF then ON, then repeat the job. If the problem still exists: Place a service call.

5-275

The Control Logic indicates a RAM test failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-13


Status Code 5-301

Description/Direction The Control Logic indicates a problem with the DADF Top Cover Interlock circuits. Initial Action: Open the DADF Cover and check for causes which might prevent the front and rear Interlock Switches from actuating. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

5-501

The Control Logic indicates a “Re-set Original Pages” problem. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

5-900, 901

The Control Logic indicates the Document Sensor is in a static jam state. Initial Action: Check the sensor for any object or material that may be blocking it. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

5-902

The Control Logic indicates the Registration Sensor is in a static jam state. Initial Action: Check the sensor for any object or material that may be blocking it. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-14


Status Code 5-903

Description/Direction The Control Logic indicates the Exit Sensor is in a static jam state. Initial Action: Check the sensor for any object or material that may be blocking it. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

5-904

The Control Logic indicates a duplex-mode static jam. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

6-277, 300, 312, 320, 321, 330, 331, 340, 345, 355

The Control Logic indicates a Video Sync/Carriage Scan failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

6-360, 361

The Control Logic indicates a carriage position error. Initial Action: Check the Carriage Cable for contamination and clean it with a water-moistened lint-free cloth as required. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-15


Status Code 6-371

Description/Direction The Control Logic indicates a problem with the Exposure Lamp circuit. Initial Action: Check the White Reference border on the reverse side of the Platen Glass (REP 6.3) for contamination and clean it with Lens and Mirror Cleaner as required. Check the optical mirrors for contamination and clean with Film Remover and a water-moistened lint-free cloth as required. Replace the Exposure Lamp (REP 6.4). If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

6-372, 373, 374, 375, 377, 380, 381, 382, 383, 384, 385, 386, 387, 388, 389, 390, 391, 392, 393, 394, 395, 396, 397, 398, 399, 620, 621, 622, 623

The Control Logic indicates a ROS Subsystem/Video Cable/Skew Mirror Sensor failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists:


Place a service call.

04/02 2-16


Status Code 6-624, 625, 626

Description/Direction The Control Logic indicates a problem with A-1 C Patch detection. Initial Action: Ensure that the MOB Sensor (REP 6.1) has been cleaned with a dry cotton swab. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

6-627, 628, 629, 630, 631, 632, 633, 634, 635, 636, 637, 638, 639, 640, 641, 642, 643, 644, 645, 646, 647, 648

The Control Logic indicates a RC Patch Sample out-of-range failure.

6-649, 650, 651

The Control Logic indicates a problem with the reflective rate of one or more color(s).

Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

Initial Action: Ensure that the MOB Sensor (REP 6.1) has been cleaned with a dry cotton swab. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

6-652, 653, 654, 655, 656

The Control Logic indicates a Skew Displacement Value out-of-range failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-17


Status Code 7-210, 211, 212, 213, 214, 215, 216, 217, 281, 282, 283, 284 7-285

Description/Direction The Control Logic indicates a Paper Supply failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call. The Control Logic indicates that the OHP (Overhead Projector) Sensor has a problem with transparencies. Initial Action: Check the sensor for any object or material that may be blocking it. Ensure that the OHP Sensor (REP 7.6) has been cleaned with a dry cotton swab. Ensure that the transparency is within specifications and that is loaded with the positioning stripe, up, and towards the Feed Assembly. Ensure that the machine is in the Simplex Mode. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

7-286, 287, 288, 340

The Control Logic indicates a Paper Supply failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-18


Status Code 7-510, 511, 512

Description/Direction The Control Logic indicates that there is no paper loaded in the tray selected. Initial Action: Ensure that the tray is closed fully and not in a jam condition. Ensure that the tray attributes selected in Tools Modes match the paper loaded in the tray. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

7-513, 514, 515, 517, 518

The Control Logic indicates a Paper Supply failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

7-528

The Control Logic indicates that the OHP (Overhead Projector) Sensor has a problem with transparencies placed in Tray 3. Initial Action: Check the OHP Sensor for any object or material that may be blocking it. Ensure that the OHP Sensor (REP 7.6) has been cleaned. Ensure that the transparency is within specifications and that is loaded with the positioning stripe, up, and towards the Feed Assembly. Ensure that the machine is in the Simplex Mode. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-19


Status Code 7-600

Description/Direction The Control Logic indicates that paper did not reach the Takeaway Nip/Release Sensor within the allowed time. Initial Action: Check the sensor for any object or material that may be blocking it. Clean the Takeaway Release Sensor (REP 7.7) with a dry cotton swab. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

8-105, 110

The Control Logic indicates that paper did not reach the Tray 1 or Tray 2 Feedout Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Tray 1 Feed Rolls (REP 7.12) or Tray 2 Feed Rolls (REP 7.13) with Film Remover and a watermoistened lint-free cloth. Replace the Tray 1 Feed Rolls (REP 7.12) or Tray 2 Feed Rolls. (REP 7.13) If the problem still exists: Place a service call.

8-120

The Control Logic indicates that paper did not reach the Tray 3 Feedout Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Tray 3 Prefeed Sensor (REP 7.4) and the Tray 3 Feedout Sensor (REP 7.5) with a dry cotton swab. If the problem still exists: Place a service call.


04/02 2-20


Status Code 8-122

Description/Direction The Control Logic indicates that paper did not reach the Tray 3 Path Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Tray 3 Prefeed Sensor (REP 7.4) and the Tray 3 Path Sensor (Sect. 5, Fig. 6) with a dry cotton swab. If the problem still exists: Place a service call.

8-130, 136, 140, 144

The Control Logic indicates that paper did not reach the J-Transport Path Sensor 1, 3, or 4 within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the J-Transport Path Sensor 1, 3 (Sect. 5, Fig. 2), or 4 (Sect. 5, Fig. 3) with a dry cotton swab. If the problem still exists: Place a service call.

8-146

The Control Logic indicates that paper did not reach the J-Transport Path Sensor 4 within the allowed time. Initial Action: Check for any obstruction in the paper path. If the problem still exists: Place a service call.

8-150

The Control Logic indicates that paper did not reach the Aligner Path Sensor 1 within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Aligner Path Sensor 1 (REP 8.8) with a dry cotton swab. Clean the J-Transport Path Sensor 5 (Sect. 5, Fig. 3) with a dry cotton swab. If the problem still exists: Place a service call.


04/02 2-21


Status Code 8-154

Description/Direction The Control Logic indicates that paper did not reach the Aligner Path Sensor 3 within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Aligner Path Sensor 2 and 3 (REP 8.8) with a dry cotton swab. Clean the J-Transport Path Sensor 5 (Sect. 5, Fig. 3) with a dry cotton swab. If the problem still exists: Place a service call.

8-157

The Control Logic indicates that paper did not reach the H-Transport Path Sensor 8 within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the H-Transport Path Sensor 8 (REP 8.6) with a dry cotton swab. If the problem still exists: Place a service call.

8-160

The Control Logic indicates that paper did not reach the Registration Out Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Registration Out Sensor (REP 8.7) with a dry cotton swab. If the problem still exists: Place a service call.

8-170

The Control Logic indicates that paper did not reach the V-Transport Sensor 1 or 2 within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the V-Transport Sensor 1 and 2 (REP 8.2) with a dry cotton swab. If the problem still exists: Place a service call.


04/02 2-22


Status Code


8-180, 184

The Control Logic indicates that paper did not reach the J-Transport Duplex Path Sensor 1 or 3 within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the J-Transport Duplex Path Sensor 1 (Sect. 5, Fig. 4), or 3 (Sect. 5, Fig. 5) with a dry cotton swab. If the problem still exists: Place a service call.

8-190, 193. 194

The Control Logic indicates that paper did not reach the H-Transport Path Sensor 1, 4 or 5 within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the H-Transport Path Sensor 1, 4 or 5 (REP 8.5) with a dry cotton swab. If the problem still exists: Place a service call.

8-198, 199 301, 302, 310,

The Control Logic indicates a Paper Feed failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

8-311

The Control Logic indicates that the Registration Side Shift Motor failed to return to the Home Position. Initial Action: Check for any obstruction in the paper path. If the problem still exists: Place a service call.


04/02 2-23


Status Code 8-312

Description/Direction The Control Logic indicates a problem with the Belt Home Position Sensors. Initial Action: Clean the Belt Home Position Sensor 1 (REP 9.7), and 2 (REP 9.8) with a dry cotton swab. If the problem still exists: Place a service call.

8-601

The Control Logic indicates that the Registration Lift Up Motor failed to return to the Home Position. Initial Action: Check for any obstruction in the paper path. If the problem still exists: Place a service call.

8-602, 603, 604

The Control Logic indicates a problem with the Aligner Nip Release Motor 1, 2, or 3. Initial Action: Check for any obstruction in the paper path. Clean the Aligner Nip Release Home Sensor 1, 2, or 3 (REP 8.9) with a dry cotton swab. If the problem still exists: Place a service call.

8-605

The Control Logic indicates that the Registration Side Shift Sensor did not detect paper within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Registration Side Shift Sensor (REP 8.10) with a dry cotton swab. If the problem still exists: Place a service call.


04/02 2-24


Status Code 8-900

Description/Direction The Control Logic indicates that a static paper jam has occurred. Initial Action: Check the sensor in the area indicted by the User Interface for any object or material that may be blocking it and follow any operator instructions. Clean the sensor associated with the area indicated on the User Interface. If the problem remains: Power the machine OFF then ON. If the problem still exists: Place a service call.

9-105

The Control Logic indicates that the paper was not stripped from the IBT Belt. Initial Action: Ensure that the paper is within specifications. Ensure that paper is not tacked to the underside of the IBT Belt (REP 9.9) or stuck in the IBT Cleaner Assembly. (REP 9.5) Clean the POB Jam Sensor (REP 9.21) with a dry cotton swab. If the problem still exists: Place a service call.

9-301

The Control Logic indicates a Transfer Interlock failure. Initial Action: Ensure that the Transfer Drawer is closed and latched. Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-25


Status Code 9-330, 331, 332, 333, 335, 336

Description/Direction The Control Logic indicates a miscellaneous Toner delivery or collection problem. Initial Action: None Close out the call: Place a service call.

9-343, 344

The Control Logic indicates that the IBT Belt reached the home position too late or too early. Initial Action:

CAUTION To access the reflective patch on the IBT Belt, move it only by rotating the flywheel attached to the IBT Belt Drive Motor. Clean the reflective patch on the IBT Belt (REP 9.9) with a dry lint-free cloth. Clean the Belt Home Position Sensor 1 (REP 9.7) with a dry cotton swab. If the reflective patch is damaged or missing, replace the IBT Belt. (REP 9.9) If the problem still exists: Place a service call. 9-350, 351, 352, 353, 354, 355, 356, 357

The Control Logic indicates a problem with a Developer Motor or a Dispenser. Initial Action: None Close out the call: Place a service call.


04/02 2-26


Status Code 9-358

Description/Direction The Control Logic indicates that the 2nd BTR is not in the proper retract position. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

9-360

The Control Logic indicates that the Yellow VH Charge setup did not complete successfully. Initial Action: Power the machine OFF then ON. If the problem remains: Replace the Drum Assembly. (REP 9.1) Power the machine OFF then ON. If the problem still exists: Place a service call.

9-361

The Control Logic indicates that the Magenta VH Charge setup did not complete successfully. Initial Action: Power the machine OFF then ON. If the problem remains: Replace the Drum Assembly. (REP 9.1) Power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-27


Status Code 9-362

Description/Direction The Control Logic indicates that the Cyan VH Charge setup did not complete successfully. Initial Action: Power the machine OFF then ON. If the problem remains: Replace the Drum Assembly (REP 9.1). Power the machine OFF then ON. If the problem still exists: Place a service call.

9-363

The Control Logic indicates that the Black VH Charge setup did not complete successfully. Initial Action: Power the machine OFF then ON. If the problem remains: Replace the Drum Assembly. (REP 9.1) Power the machine OFF then ON. If the problem still exists: Place a service call.

9-375

The Control Logic indicates that the Waste Toner Bottle is improperly installed. Initial Action: Ensure that the Waste Toner Bottle (REP 9.22) is properly installed. Power the machine OFF then ON. If the problem still exists: Place a service call.


04/02 2-28


Status Code 9-377

Description/Direction The Control Logic indicates that the Waste Toner Bottle is full. Initial Action: Clean the Waste Bottle Full Sensor. (REP 9.22) Replace the Waste Toner Bottle. (REP 9.22) Power the machine OFF then ON. If the problem still exists: Place a service call.

9-402, 403, 404, 405

The Control Logic indicates that a Toner dispenser is almost empty. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still remains: Place a service call.

9-410, 411, 412, 413, 415, 416, 421

The Control Logic indicates a Toner supply, delivery, or collection problem. Initial Action: None Close out the call: Place a service call.

9-500

The Control Logic indicates that the 2nd BTR is near the end of life (HFSI Counter 9-841). Initial Action: Replace the 2nd BTR Roll Assembly. (REP 9.14) Reset the HSFI counter after replacement. If the problem still exists: Place a service call.


04/02 2-29


Status Code 9-600, 601, 602, 603

Description/Direction The Control Logic indicates that the high-density patch for yellow, magenta, cyan, or black is beyond the normal range. Initial Action: Clean all the ADC Sensors (REP 9.13) with a dry cotton swab. Power the machine OFF then ON. If the problem still exists: Place a service call.

9-604, 605, 606, 607

The Control Logic indicates that the low-density patch for yellow, magenta, cyan, or black is beyond the normal range. Initial Action: Clean all the ADC Sensors (REP 9.13) with a dry cotton swab. Power the machine OFF then ON. If the problem still exists: Place a service call.

9-608, 609, 610, 611, 612, 613, 614, 615

The Control Logic indicates a TC sensing or ADC function problem. Initial Action: Clean all the ADC Sensors (REP 9.13) with a dry cotton swab. Power the machine OFF then ON. If the problem still exists: Place a service call.

9-618, 619

The Control Logic indicates a temperature or humidity problem. Initial Action: None Close out the call: Place a service call.


04/02 2-30


Status Code


9-624, 625, 626, 627, 628, 629, 634, 635, 636, 637, 638, 639, 640, 641, 642, 643

The Control Logic indicates an electrostatic setup or ADC setup problem.

9-663, 664, 665, 666

The Control Logic indicates a problem with an ADC control signal.

Initial Action: Clean all the ADC Sensors (REP 9.13) with a dry cotton swab. Using the Diagnostic Control Unit (DCU), perform Max Setup. (ADJ 9.1) If the problem still remains: Place a service call. Initial Action: Clean all the ADC Sensors (REP 9.13) with a dry cotton swab. Using the Diagnostic Control Unit (DCU), perform Max Setup. (ADJ 9.1) If the problem still remains: Place a service call.

9-670, 671, 672, 673, 674, 675, 676, 677

The Control Logic indicates a problem with an ADC output signal. Initial Action: Using the Diagnostic Control Unit (DCU), perform Max Setup. (ADJ 9.1) If the problem still remains: Place a service call.


04/02 2-31


Status Code 9-685, 686

Description/Direction The Control Logic indicates a problem with an ADC control signal. Initial Action: If background is present, go to IQ 12 in Table 3 within Section 3. If background is not present: Clean all the ADC Sensors (REP 9.13) with a dry cotton swab. Clean the IBT Belt (REP 9.9) with a dry lint-free cloth. Using the Diagnostic Control Unit (DCU), perform Max Setup. (ADJ 9.1) If the problem still remains: Place a service call.

9-690, 691, 692, 693

The Control Logic indicates a problem with an ADC output signal. Initial Action: Using the Diagnostic Control Unit (DCU), perform Max Setup. (ADJ 9.1) If the problem still remains: Place a service call.

9-694, 695, 696, 697

The Control Logic indicates a problem with a Look-up-table (LUT) calculation. Initial Action: Using the Diagnostic Control Unit (DCU), perform Max Setup. (ADJ 9.1) If the problem still remains: Place a service call.


04/02 2-32


Status Code 10-105, 106

Description/Direction The Control Logic indicates that paper did not reach or leave the Fuser Exit Sensor within the allowed time. Initial Action:

Warning - Switch off the Power, disconnect the Power Cord, and apply the Lockout Tag. - Allow the Fuser to cool before performing this procedure. - Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. Check for any obstruction in the Vacuum Transport paper path. (REP 8.1) Clean the Fuser Exit Sensor (REP 10.14) with a dry cotton swab. Check that the Fuser Belt is not torn or contaminated with oil (if oily, wipe belt with dry lint-free cloth). (REP 10.2) If the problem still exists: Place a service call. 10-110

The Control Logic indicates that paper did not reach the Decurler Upper Path Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Decurler Upper Path Sensor (Sect. 5, Fig. 7) with a dry cotton swab. If the problem still exists: Place a service call.

10-112

The Control Logic indicates that paper did not reach the Decurler Lower Path Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Decurler Lower Path Sensor (Sect. 5, Fig. 8) with a dry cotton swab. If the problem still exists: Place a service call.


04/02 2-33


Status Code 10-120

Description/Direction The Control Logic indicates that paper did not reach the Entrance Path Sensor 1 within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Entrance Path Sensor 1 (Sect. 5, Fig. 10) with a dry cotton swab. Clean the Fuser Exit Roll (Sect. 5, Fig. 14) and the Inverter Assembly Rolls (Sect. 5, Figs. 11, 12) with Film Remover and a water-moistened lint-free cloth. If the problem still exists: Place a service call.

10-122

The Control Logic indicates that paper did not reach the Exit Transport Path Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Exit Transport Path Sensor (Sect. 5, Fig. 13) with a dry cotton swab. Clean the Decurler Drive Roll (Sect. 5, Fig. 9) with Film Remover and a water-moistened lint-free cloth. If the problem still exists: Place a service call.

10-123

The Control Logic indicates that paper did not leave the Exit Transport Path Sensor within the allowed time. Initial Action: Check for any obstruction in the inverter and exit paper path. Clean the Exit Transport Path Sensor (Sect. 5, Fig. 13) with a dry cotton swab. Clean the Exit Roll Assembly (Sect. 5, Fig. 14) and Inverter Roller (Sect. 5, Figs. 11, 12) with Film Remover and a water-moistened lint-free cloth. If the problem still exists: Place a service call.


04/02 2-34


Status Code 10-130

Description/Direction The Control Logic indicates that paper did not reach the Inverter Path Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Inverter Path Sensor (Sect. 5, Fig. 11) with a dry cotton swab. Clean the Exit Roll Assembly (Sect. 5, Fig. 14) with Film Remover and a water-moistened lint-free cloth. If the problem still exists: Place a service call.

10-132

The Control Logic indicates that paper did not reach the Inverter Duplex End Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Inverter Duplex End Sensor (Sect. 5, Fig. 12) with a dry cotton swab. Clean the Inverter Roller Assembly (Sect. 5, Figs. 11, 12) with Film Remover and a water-moistened lintfree cloth. If the problem still exists: Place a service call.

10-290

The Control Logic indicates that the decurler cam did not activate the Duplex Decurler Cam Position Sensor within the time allowed. Initial Action: Check for any obstruction in the paper path. If the problem still exists: Place a service call.

10-310

The Control Logic indicates a Fuser Belt tracking problem. Initial Action: None Close out the call: Place a service call.


04/02 2-35


Status Code 10-311, 312, 313

Description/Direction The Control Logic indicates a Fuser Belt latching problem. Initial Action: None Close out the call: Place a service call.

10-314, 315, 316

The Control Logic indicates a Fuser Belt tracking problem. Initial Action:

Warning - Switch off the Power, disconnect the Power Cord, and apply the Lockout Tag. - Allow the Fuser to cool before performing this procedure. - Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. Ensure that the spring finger of the Fuser Belt Position Sensor (Sect. 5, Component Location Overview 3. See also REP 10.2, Fig. 5 ) is riding on the outside edge of the belt. Clean the Fuser Walk Motor Sensor (REP 10.16) with a dry cotton swab. If the problem still exists: Place a service call. 10-318

The Control Logic indicates that the Fuser did not reach operating temperature in Standby. Initial Action: None Close out the call: Place a service call.


04/02 2-36


Status Code 10-319

Description/Direction The Control Logic indicates a problem with the Fuser Drive Motor. Initial Action: None Close out the call: Place a service call.

10-354, 355, 356, 357, 359, 360, 366, 367

The Control Logic indicates a Fuser control or overheat problem. Initial Action: None Close out the call: Place a service call.

10-380

The Control Logic indicates that the Fuser Oil is empty. Initial Action:

CAUTION When adding Fuser Oil, do not fill above the bottom of the neck on the Oil Bottle.

Add Fuser Oil to fill the Oil Bottle to the required level. (GP 8) If the problem still exists: Place a service call. 10-382

The Control Logic indicates that the Fuser Belt Web is empty. Initial Action: Ensure that the (Fuser) Web Material Assembly (REP 10.9) has been replaced. If the problem still exists: Place a service call.


04/02 2-37


Status Code 10-385, 386, 387, 388, 389, 390

Description/Direction The Control Logic indicates an External Heat Roll control or overheat problem. Initial Action: None Close out the call: Place a service call.

10-392, 393, 394

The Control Logic indicates an Inlet Roll control or overheat problem. Initial Action: None Close out the call: Place a service call.

10-400

The Control Logic indicates that the Fuser Oil is nearly empty. Initial Action:

CAUTION When adding Fuser Oil, do not fill above the bottom of the neck on the Oil Bottle.

Add Fuser Oil to fill the Oil Bottle to the required level. (GP 8) If the problem still exists: Place a service call. If the problem still exists: Place a service call.


04/02 2-38


Status Code


10-401

The Control Logic indicates that the Fuser Belt Web is nearly empty. Initial Action: Ensure that the (Fuser) Web Material Assembly (REP 10.9) has been replaced. If the problem still exists: Place a service call.

10-600

The Control Logic indicates that the decurler cam did not deactivate the Duplex Decurler Cam Position Sensor within the time allowed. Initial Action: Check for any obstruction in the paper path. If the problem still exists: Place a service call.

12-295

The Control Logic indicates a failure with the Offset Catch Tray. Initial Action: Clean the Offset Home Sensor (REP 8.11) with a dry cotton swab. If the problem still exists: Place a service call.

12-500

The Control Logic indicates a failure with the Stack Height detection function of Offset Catch Tray. Initial Action: None Close out the call: Place a service call.


04/02 2-39


3. Output Defect Procedures Section Contents

Page

Troubleshooting Introduction to Image Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1-2 Image Quality Evaluation Process. . . . 3.1-3

Image Quality Defect Samples 3.3.1 Introduction . . . . . . . . . . . . . . . . . 3.3-1 3.3.2 Image Quality Defect Samples . . 3.3-1 Figure 1 Bead Carryout, Single-Color Band (Faint). . . . . . . . . . . . . . . . . . . . . . . . . . 3.3-3

IQ 1 Troubleshooting Entry Procedure 3.1-4

Figure 2 Bead Carryout, Single-Color Band (Severe) . . . . . . . . . . . . . . . . . . . . . . . . 3.3-3

Image Quality Defect Definitions . . . . . 3.1-5

Figure 3 Corrupted Video Data . . . . . . 3.3-5

Table 1. Defects With Workarounds . . 3.1-9 Table 2. Defects With Signatures (Specific

Figure 4 Rainbow-Like Single or Multi-Color Bands. . . . . . . . . . . . . . . . . . . . . . . . . . 3.3-5

Characteristics) . . . . . . . . . . . . . . . . . 3.1-10

Figure 5 Water Stains . . . . . . . . . . . . . 3.3-7

Table 3. Defects With Less Specific Characteristics. . . . . . . . . . . . . . . . . . . . . . . . 3.1-13

Figure 6 Localized, Single-Color, Half Tone, Streak Deletion. . . . . . . . . . . . . . . . . . . 3.3-7

Table 4. Corrective Actions . . . . . . . . 3.1-19

Figure 7 Mottle (w/ Some Granularity) . 3.3-9

Image Quality Specifications

Figure 8 Toner Starvation Between Low Density / High Density Area . . . . . . . . . . . . 3.3-9

3.2.1 General Information . . . . . . . . . . 3.2-1

Figure 9 Image Slip . . . . . . . . . . . . . . 3.3-11

3.2.2 IOT Setup for Full Color Output Check. (with Modified Restore Chart).. . . . . . . 3.2-1

Figure 10 Mosaic . . . . . . . . . . . . . . . . 3.3-11

3.2.2.1 IOT Color Standards . . . . . . . . 3.2-4

Figure 12 Small Dark Dots on Text . . 3.3-13

3.2.5 DFE Test Patterns . . . . . . . . . . . 3.2-6

Figure 13 Newton Rings. . . . . . . . . . . 3.3-15

3.2.6 Copier Setup for Full Color Output Check. . . . . . . . . . . . . . . . . . . . . . . . . . 3.2-8

Figure 14 Start of Rib Marks . . . . . . . 3.3-15

3.2.6.1 Color Copier Specifications . . . 3.2-8

Figure 16 Water Marks. . . . . . . . . . . . 3.3-17

Figure 11 Vacant Characters . . . . . . . 3.3-13

Figure 15 Rib Marks. . . . . . . . . . . . . . 3.3-17


04/02 3.1-1

Output Defect Procedures

Introduction to Image Quality Troubleshooting This section of the Service Manual provides the information that is required for the correct evaluation of the image quality. It consists of the following parts: IQ 1 Image Defect Troubleshooting Procedure - This is where you begin whenever you are troubleshooting an image quality problem. There are two parts to IQ1: •

Analyze: Table 1, Defects with Workarounds, Table 2, Defects with Signatures (or Specific Characteristics) and Table 3, Defects with Less Specific Characteristics .

•

Resolution: Table 4, Corrective Actions is used to isolate the defect to either the specific cause or have you request service.

Image Defect Definition - Table A, Image Defect Definitions . This table can be used in conjunction with IQ 1 Image Quality Trouble- shooting Entry Procedure to better understand the characteristics of the defects in the Procedure.


04/02 3.1-2


Image Quality Evaluation

2. The Image Quality Defect Definition Table A contains details descriptions each image quality defect listed in Table 1 and 2.

Introduction

Section 3.2 provides information about image quality specifications/ standards.

Procedure All image quality parameters for the DocuColor 2060/2045 are evaluated using the following Test Patterns (TP): •

Reference TP

•

DFE-generated Modified Restore Chart

•

Copier Color TP, 82E13120

•

DCU Single-Color Halftone TP (GP 9)

Section 3.3 provides samples of image defects.

The first three patterns are used to evaluate most defects, while the last pattern is used on a case-by-case basis. Section 3.1 of this Service Manual provides the information that is required for the correct evaluation of image quality. It consists of: 1. The IQ 1 Image Defect Troubleshooting Entry Procedure. This procedure is comprised of the following: •

Table 1: Defects with Workarounds - This table defines defects and provides directions to minimized them.

•

Table 2: Defects with Signatures (or Specific Characteristics) - This table analyzes defects and provides directions to resolve them.

•

Table 3: Defects with Less Specific Characteristics - This table analyzes defects and provides directions to resolve them.

•

Table 4: Corrective Actions - You are sent here to minimize or resolve the defect identified in any of the other three tables. This table consists of two columns. The left column (Defect Name) and the right column (Corrective Action). The information under Corrective Action includes a description of the fault and the actions to take.


04/02 3.1-3


IQ 1 Image Quality Troubleshooting Entry Procedure This section of the Service Manual is used to diagnose and to repair image quality problems. The purpose of the Image Quality Troubleshooting Entry Procedure is to serve as the entrance vehicle into the Image Quality section. All Image Quality Procedures must be accessed through this Procedure.

3. Compare the defect to those listed on Table 3. (Refer to Image Defect Definitions -Table A and Defect Samples - Section 3.3) If there is a match, go to the corrective action indicated to perform repair actions that should resolve the defect. If there is no match, place a service call.

Initial Action •

Ensure that all HFSI items that are near or over threshold have been repaired. (reference Section 4)

•

Ensure that all of the Every Call Cleaning activities have been performed. (reference Section 1)

•

Ensure that the test pattern prints / copies made duringInitial Actions in Section 1, and any sample defect from the customer’s job, are available at this time to help identify the type of image quality defect the machine has.

•

Ensure that a good quality paper (Refer to Customer Documentation for recommended paper) is loaded and the Tray end Guides are properly set. If the problem persists, continue with this procedure.

Procedure 1. Compare the defect to those listed on Table 1. (Refer to Image Defect Definitions -Table A and Defect Samples - Section 3.3) These defects are “normal” for this product and require additional countermeasures. If there is a match, refer to the corrective action indicated to perform workarounds that should minimize the effects of the defect. If there is no match, go to step 2. 2. Compare the defect to those listed on Table 2. (Refer to Image Defect Definitions -Table A and Defect Samples - Section 3.3) These defects have easily recognizable “signatures” (that is, specific characteristics or conditions) and usually have only one known cause. If there is a match, refer to the corrective action indicated to perform the repair action(s) that should resolve the defect. If there is no match, go to step 3.


04/02 3.1-4


Image Quality Defect Definitions In the following pages, you will find Image Detect Definitions. This table can be used in conjunction with IQ 1 Image Quality Troubleshooting Entry Procedure to better understand the definitions of the detects in the Procedure. Image Defect

Definition

Background

Undesirable toner deposits on the print/copy. The toner deposits can be localized or may cover the entire print/copy. Depending on the density of the background, it is referred to as low, medium, high, or very high background. It may occur in all colors, single colors, or any combination of single colors.

Bands

The absence or low density of toner in desired image areas, or the presence of toner in undesired areas in the shape of a band. Bands are widths greater than 0.5 mm. Bands are generally uniform in shape from one end to the other, and can run in any direction on the print/copy.

Bead Carryout

Developer beads that are electrostatically attracted to the print/copy during the transfer process. Bead Carryout is characterized by a fine, loose grit on the surface of the print/copy. On this product, it looks like Mottle or low density. Bead Carryout is most noticeable in high density areas and usually does not affect all four colors at the same time.

Blurred or Fuzzy Image

Images that are not clear, or appear out of focus.

Color Balance, Poor

Colored areas of the print/copy that exhibit a change in hue, as opposed to a change in density. This is most often judged in the gray areas of the print/copy. Theoretically, a true gray can be produced with equal amounts of magenta, yellow and cyan toner. Therefore, a common example of poor color balance is a gray image that is reproduced with slightly more of one of those color toners. The result is a gray that appears to have a magenta, yellow or cyan hue, rather than true gray.

Contamination (Back Side or Side 2 of Print/Copy)

Toner deposit on the back side of a print/copy or on the second side of a two-sided print/copy.

Corrupted Video Data

A variety of image defects which occur when printing in the customer mode but do not occur when printing in the diagnostic mode.


04/02 3.1-5


Image Defect

Definition

Deletions

The undesirable absence of toner from the print/copy. This defect can show as white, light, or untrue colored areas on the print/copy. The most common example is a deletion caused by the “tenting” of paper from mishandling or moisture, or by dents or defects in the IBT.

Density High

A condition that results when too much toner of a single color or combination of colors is developed on the print/copy. This results in darker prints for the single color toner or the color that results from the combination of colors.

Density Low

A condition that results when too little toner of a single color or combination of colors is developed on print/copy. This results in lighter prints for the single-color toner or the color that results from the combination of color toners.

Density Uneven

The uneven development of toner on the print/copy from one area to another. Typically, this results in change in density from inboard to outboard and sometimes from lead edge to trail edge.

Fuser Oil Streaks or Globs

Lead edge to trail edge streaks or globs that show up first on transparencies or coated paper as low gloss streaks in solid areas. In severe cases, oil streaks can show up on paper as low density streaks or globs in large half tone areas.

Granularity

An image defect that causes solid areas to have a sandy appearance. Granularity is most noticeable in middle-density solid areas.

Grossly Shifted Color Plane

One or more color planes shifted by 1/2 inch or more from its normal position.

Hollow Characters

Small circular-shaped deletions within a character that can occur when the image density is low or a transparency is used.

Image Slip

Image disturbance just pr ior to fusing, usually in the form of a band, located along the lead edge of a print/copy.

Lines

The absence or low density of toner in desired image areas, or the presence of toner in undesired areas in the shape of a line. Lines are generally uniform in shape from one end to the other, and can run in any direction on the print/copy. Lines are defined as measuring less than 0.5 mm in width. (By contrast, streaks are generally shorter than lines and are of nonuniform width along their length. They may have a more ragged or fuzzy appearance than lines, and can run in any direction on the print/copy.)


04/02 3.1-6


Image Defect

Definition

Low Contrast Reproduction

The inability to adequately reproduce a low contrast image.

Marks (Rib and Water)

Uneven gloss on a fused print/copy which has a rib-like or water-mark appearance. They are caused by one or more of the following: incorrect pad force, incorrect pressure roll nip, or a low oil condition. The defects are unique to this product and examples are supplied in the Image Defect Samples sections of the Image Quality Supplement.

Misregistration (Color-toColor)

Multi-colored images that are not superimposed and should be. This can occur in the lead edge to trail edge or inboard to outboard direction.

Misregistration (System)

The alignment of the image to the edges of the print/copy paper. It is defined by lead and side edge registration, and lead and side edge skew.

Missing Colors

The loss of one of the color toners from the output print/copy. Depending on the original, this can result in missing areas of the image, or changes in the color balance of the print/copy.

Moire

Patterns on the image areas of the output copy that has the appearance of a screen or grid overlaying the image. It may be uniform or nonuniform in area or shape.

Mottle

Solid area, high density image areas that are reproduced with a surface that resembles marble.

Newton Rings

Repetitive, irregular-shaped marks that occur when making copies of glossy photographs. These marks are most noticeable in large low-density or highlight areas.

Offsetting, Fuser

The removal of toner from the print/copy by the fuser and the subsequent redeposition of that toner on another area of the same or other another print/copy. Removing toner from the image leaves the image rough and without gloss. The redeposited toner may appear as a duplicate image, partially shifted image, or lines and streaks.

Residual Image

A toner image that remains on the photoreceptor or IBT after cleaning. The next image is place on top of the residual image and both images are transferred to the next print/copy.

ROS Borders

Intentional lead edge, side edges, and trail edge deletions that make a border on the print/copy paper.

Solid Single-Color Print/ Copy

An image that is reproduced as solid black (or color) from lead edge to trail edge and from inboard to outboard. The ROS Border may or may not be visible.


04/02 3.1-7


Image Defect

Definition

Spots

Generally ci circular in in sh shape, th these de defects ca can be be ca caused by by a an n ab absence of of to toner in in a desired area, or a deposit of toner in an undesired area.

Text / Image Separation Errors

Mosaic: An image defect that can affect fine line ladders or low screen halftones. It causes closely spaced lines, low frequency halftones, and certain texts to have a blotchy appearance. Vacant Characters: An image defect that results when the center of a character is filled-in with a (200R) halftone screen while its outer border is made up of a (600L) text screen. Small Dark Dots on Text: An image defect that causes a localized area of a character in a text to look like it contains small dark dots.

Tone Tonerr Sta Starv rvat atio ion n

This This defe defect ct occu occurs rs at the the tra trans nsit itio ion n poi point nt betw betwee een n a high high dens densit ity y are area a and and a low low dens densit ity y area area of the same color. A localized area of the mag brush becomes “starved” for toner due to development fringe field effects. Starvation tends to worsen at low triboelectric levels (high toner concentration).

Unfu Unfuse sed d Pri Print nt/C /Cop opy y

The The Ton Toner er on the the pri print nt/c /cop opy y is is n not ot comp comple lete tely ly fuse fused. d.

Water ater Stai Stains ns

Unev Uneven en glos gloss s on on a fuse fused d pri print nt/c /cop opy y whi whic ch has has the the app appea eara ranc nce e of of a wate waterr sta stain in.. It It is is cau cause sed d by by one or more of the following: incorrect pad force, incorrect pressure roll nip, or a low oil condition. This defect is unique to this product and an example of it is supplied in the Image Defect Samples sections of the Image Quality Supplement.

Wrinkl Wrinkled ed Prin Print/C t/Copy opy

Creasi Creasing ng or folds folds on the print/ print/cop copy y in in the the lead lead to to trai traill edge edge direct direction ion,, or or clos closely ely spaced spaced ‘waves ‘waves’’ in the inboard to outboard direction.


04/02 3.1-8


Table 1. Defects With Workarounds Defect Name

Defect Samples

Defect Characteristics

Table 4 Reference

Moire

n/a

Description - Patterns on the image areas of the output copy that has the appearance of a screen or grid overlaying the image. It may be uniform or nonuniform in area or shape.

Go to IQ 31.

New Newton ton Ri Rings ngs

Fig. ig. 13 13

Des Descrip cripti tion on - R Rep epet etiitive tive,, irr irreg egul ular ar-s -sha hape ped d mar marks ks that that occur when making copies of glossy photographs. These marks are most noticeable in large low-density or highlight areas.

Go to IQ 32.

Text / Image Separation Errors

Fig. 10

Description - Mosaic: An image defect that can affect fine line ladders or low screen halftones. It causes closely spaced lines, low frequency halftones, and certain texts to have a blotchy appearance.

Go to IQ 33.

Fig. 11

Description - Vacant Characters: An image defect that results when the center of a character is filled-in with a (200R) halftone screen while its outer border is made up of a (600L) text screen. (Note: This level of detail is best observed with an eye loop.)

Fig. 12

Description - Small Dark Dots on Text: An image defect that causes a localized area of a character in a text to look like it contains small dark dots. (Note: This level of detail is best observed with an eye loop.)

n/a

Description - Ghost images (Negative) on the output copy after duplex prints.

Oil Ghosting


04/02 3.1-9

Replace the Fuser Belt Assembly (REP 10.2) with one that is packdated Sept. 2000 or later. Replace the IBT Belt. (REP 9.9)


Table 2. Defects With Signatures (Specific Characteristics) Defect

Interval

Isolation Technique

Component

Corrective Action

Lines, spot, marks only when using the scanner

Same area of each page

Deletion lilines (L (LE/TE)

Same ar ar ea ea of of ea each page

Deletions, lines, marks or spots

11x17: Every 4th page 8.5x11: LEF every 8th page

Lines or marks (LE/TE)

Random

Line or or ma ma rk rks (L (LE/TE)

12x18: 11” from OB edge

Fuser user Heat Heat Roll oll

Repl Replac ace e the the Heat Heat Roll oll (REP 10.3) Perform ADJ 10.1 Fuser Nip

Deletions, lines, marks, or spots

11x17: repeats every 264 mm

Drum

Replace the Drum Assembly (REP 9.1) Perform Max Setup (ADJ 9.1)


Using the DCU, make all four singlecolor halftone prints to isolate the problem color (GP 9).

Platen Glass

Clean Platen Glass

ROS ROS S Sea eall Gla Glas ss

Clea Clean n ROS ROS Seal eal Gla Glass ss (REP 6 2)

IBT Belt

Replace the IBT Belt (REP 9.9) Perform ADJ 9.3 Registration Control Setup Perform ADJ 9.1 Max Setup

Simplex job shows only on back side Vacuum Transport Duplex job show on both sides Belts

04/02 3.1-10

Vacuum the Vacuum Transport Belts (Section 5, Component Location Overview 2)


Table 2. Defects With Signatures (Specific Characteristics) Defect Deletions, lines, marks, or spots

Interval 11x17: repeats every 88 mm

Isolation Technique

Component

Corrective Action

Using GP1 Xerographic Hardstop procedure, look at the area of the IBT Belt before it reaches the 2nd BTR. Using the DCU, make all four singlecolor halftone prints to isolate the problem color (GP 9).

1st BTR

Replace the 1st BTR (REP 9.10) for the problem color. Perform ADJ 9.1 Max Setup.

If the defect is not present, the problem is 2nd BTR related. 2nd BTR or 2nd BTR Backup Roll

Replace the 2nd BTR (REP 9.14). Replace the 2nd BTR Backup Roll (REP 9.12). Perform ADJ 9.1 Max Setup.

Deleti Deletion, on, line line,, mark mark or spot spot

11x17: 11x17: repeats repeats every 204 mm

Fuse Fuserr Heat Heat Roll Roll

Repl Replac ace e the the Heat Heat Rol Roll (REP 10.3). Perform ADJ 10.1 Fuser Nip.

Image Slip/Smear (Defect Sample 9)

Located within 30 mm from LE

Dry Fuser Pad or Wick

Replace the Fuser Belt Assembly. (REP 10.2)

Fireworks or star-like deletion (no defect sample)

Random

1st BTR


Bands, Rainbow-like single or multi-color

Closely-spaced LE/ Using the DCU, make all four singleTE bands color halftone prints to isolate the problem color (GP 9).

Charge Corotron wire or screen

Replace the Charge Corotron and Screen (REP 9.2) for the problem color. Perform ADJ 9.1 Max Setup.



04/02 3.1-11


Table 2. Defects With Signatures (Specific Characteristics) Defect

Interval

Isolation Technique

Missing color

Entire area of every page


TE smear on side 1 of duplex job

Component

Corrective Action

DFE Cable

Reseat both ends of the cable between the DFE and the VSEL PWB (reference GP 6, Fig. 3) for the problem color.

Within 30 mm from TE

Paper/Paper Setting

Ensure that the gsm setting is correct. Flip the paper. Replace the paper.

TE smea smearr on on sim simpl plex ex job job

With Within in 30 mm from from TE

Paper/Paper Setting

Ensure that the gsm setting is correct. Flip the paper. Replace the paper.

Circular, tear-drop shaped deletions

Random

1st BTR




04/02 3.1-12


Table 3. Defects With Less Specific Characteristics Image Defect

Defect Sample

Printer Test Pattern Used

Printer Standards

Copier/Printer Test Pattern

Copier/Printer Standards

Table 4 Reference

Background

n/a

Modified Restore Chart

Non-Image areas of the prints should be free of background for any color.

Copier Color Test Pattern

Non-Image areas of the copy should be free of background for any color.

IQ 12

Bands

n/a


Acceptable to the customer on the customer’s job.



IQ 10




IQ 10





IQ 16

(Lead Edge to Trail Edge)

Optional: DC612, Halftone (overall)

Bands (Inboard to Outboard)

n/a


Bead Carryout

Fig. 1,

Solid SingleColor Print / Copy

n/a


The print should not be a single solid color.


The copy should not be a single solid color.

IQ 22

Blurred or Fuzzy Image

n/a





IQ 23

Color Balance, Poor

n/a

n/a

Color balance is obtained as a result of doing Max Setup.

n/a

Color balance is obtained as a result of doing Max Setup.

IQ 25

Optional: DC612, Halftone (overall)

Fig. 2


04/02 3.1-13



Defect Sample


Printer Standards



Table 4 Reference

Contamination, Back Side or Side 2 of Print/ Copy

n/a





IQ 26

Corrupted Video Data

Fig. 3


None allowed.


None allowed.

IQ 13

Deletions (Random)

n/a

DC612, Halftone (overall)

More than four random deletions greater than 1.0 mm or one A3 (11 x 17) print, or more than seven within a four-print run.


More than four random deletions greater than 1.0 mm or one A3 (11 x 17) print/copy, or more than seven within a four-print/ copy run.

IQ 15

Deletions (Single-color Streak)

Fig. 6





IQ 10

Density (High)

n/a


Nominal density is obtained as a result of doing Max Setup.



IQ 21

Density (Low)

n/a





IQ 20

Density (Uneven)

n/a


Inboard-to-outboard density is obtained as a result of doing Max Setup.


Inboard-to-outboard density is obtained as a result of doing Max Setup.

IQ 19

Fuser Oil Streaks

n/a





IQ 4


04/02 3.1-14



Defect Sample


Printer Standards



Table 4 Reference

Granularity

n/a


No worse than the granularity on the Reference Test Pattern.


No worse than the granularity on the Reference Test Pattern.

IQ 17

Grossly Shifted Color Plane

n/a


Color must not be shifted.


Color must not be shifted.

IQ 18

Hollow Characters

n/a





IQ 27

Image Slip

Fig. 9





IQ 5

Lines

n/a





IQ 10

Low Contrast Reproduction

n/a





IQ 19

Marks, Rib and Water

Figs. 14, 15, 16





IQ 6


04/02 3.1-15



Defect Sample


Printer Standards



Table 4 Reference

Misregistration (Colorto-Color)

n/a


The bottom edge of any horizontal line in one color should not protrude beyond the top edge of the adjoining colored line. The right hand side of any vertical line in one color should not protrude past the left hand side of the adjoining colored line.


The bottom edge of any horizontal line in one color should not protrude beyond the top edge of the adjoining colored line. The right hand side of any vertical line in one color should not protrude past the left hand side of the adjoining colored line.

IQ 29

Misregistration (System)

n/a


Lead/side edge registration and side edge skew must be checked and correct by a CST.


Lead/side edge registration and side edge skew must be checked and correct by a CST.

Place a service call

Missing Colors

n/a


None allowed.


None allowed.

IQ 14

Moire

n/a


n/a


Moire present in area H is acceptable; moire present in area I is unacceptable.

IQ 31

Mottle

Fig. 7


No worse than the mottle on the Reference Test Pattern.



IQ 24

Newton Rings

Fig. 13


n/a



IQ 32

Offsetting, Fuser

n/a


No noticeable offsetting.


No noticeable offsetting.

IQ 3

Residual Image

n/a


No noticeable residual image.


No noticeable residual image.

IQ 2


04/02 3.1-16



Defect Sample


Printer Standards



Table 4 Reference

ROS Borders

n/a


Lead/side/trail edge: 4 mm (all trays)


Lead/side/trail edge: 4 mm (all trays)

IQ 30

Spots, (Periodic or Random) Black or Color

n/a


There should be no random or repetitive spot greater than 0.5 mm; or more than 20 random spots between 0.2 to 0.5 mm on one A3 (11 x 17) print.


There should be no random or repetitive spot greater than 0.5 mm; or more than 20 random spots between 0.2 to 0.5 mm on one A3 (11 x 17) print/copy.

IQ 11

Spots, Periodic or Random) White

n/a


There should be no random or repetitive white spot greater than 0.5 mm; or more than 6 spots between 0.2 to 0.5 mm on one A3 (11 x 17) print.


There should be no random or repetitive white spot greater than 0.5 mm; or more than 6 spots between 0.2 to 0.5 mm on one A3 (11 x 17) print/ copy.

IQ 11

Smears

n/a





IQ 10

Streaks

Fig. 6





IQ 10

Text/Image Separation Errors Mosaic

Fig. 10


n/a



IQ 33


04/02 3.1-17



Defect Sample


Printer Standards



Table 4 Reference

Text/Image Separation Errors Vacant Characters

Fig. 11


n/a



IQ 33

Text/Image Separation Errors Small Dark Dots on Text

Fig. 12


n/a



IQ 33

Toner Starvation

Fig. 8





IQ 9

Unfused Print/Copy

n/a


None allowed.


None allowed.

IQ 7

Water Stains

Fig. 5





IQ 6

Wrinkled Print/Copy

n/a


None allowed.


None allowed.

IQ 8


04/02 3.1-18


Table 4. Corrective Actions

Defect Name IQ 2 Residual Image

Corrective Action This procedure is used when any noticeable residual image is present. Procedure: Using the DCU, make all four single-color halftone prints to isolate the problem color (GP 9). Classify your observation (choose step 1 or 2): 1. The problem is present in all four colors: Perform the GP1 xerographic Hardstop procedure. • If the defect is present on the IBT image, replace the IBT Cleaner Assembly. (REP 9.5) •

If the defect is not present on the IBT image, perform ADJ 10.1 Fuser Nip. If the problem still remains, replace all these parts at the same time (except the ones that might have been replaced already during this call): Heat Roll Assembly (REP 10.3) Fuser Belt Assembly (REP 10.2) (Heat Roll) Wick (REP 10.11) Donor Roll Assembly (REP 10.10) After replacing these parts, advance the web material manually to a clean area. (REP 10.9)

•

If the problem still exists: Place a service call.

2. The problem is present in a single color: Replace the Drum Assembly (REP 9.1) that exhibits the problem.


04/02 3.1-19



Defect Name IQ 3 Offsetting, Fuser

Corrective Action This procedure is used when any noticeable offsetting is present. Initial Action:

WARNING •

Switch Switc h off the Power, Power, discon disconnect nect the Power Power Cord, Cord, and apply apply the the Safety Lockou Lockoutt Kit (GP 7).

•

Allow the Fuser Fuser to cool befo before re perform performing ing this this procedu procedure. re.

•

Fuserr Oil is an eye Fuse eye irritant. irritant. Do Do not rub rub eyes eyes after handli handling ng Fuser Fuser Compo Components nents..

Cam open the Fuser Assembly (REP 10.1) and if excess Toner is present, attempt to clean excess Toner off the affected fuser components using the Fuser Subsystem Maintenance (in Section 1). Procedure: 1. Clean Clean or repl replace ace thes these e parts partsall all at the same time (except time (except the ones that might have been replaced already during this call): •

Heat Heat Rol Rolll Asse Assemb mbly ly (RE (REP P 10.3 10.3))

•

Fuse Fuserr Belt Belt Ass Assem embl bly y (REP (REP 10. 10.2) 2)

•

External External Heat Roll Roll (REP (REP 10.7) - Clean Clean only, only, using a water-m water-moiste oistened ned lint-free lint-free cloth. cloth.

•

(Hea (Heatt Rol Roll) l) Wic Wick k (RE (REP P 10.1 10.11) 1)

•

Dono Donorr Roll Roll Asse Assemb mbly ly (REP (REP 10. 10.10 10))

2. After cleaning or replacing a part, advance the web material manually to a clean area. (REP 10.9) If the problem still exists: Place a service call.


04/02 3.1-20



Defect Name IQ 4 Oil Streaks

Corrective Action This procedure is used when any noticeable oil streaks ar e present. Procedure: 1. Clean or replace all all these parts one at a time (except (except the ones that might have been replaced already during this call): •

Fuse Fuserr Belt Belt Ass Assem embl bly y (REP (REP 10. 10.2) 2)

•

External External Heat Roll Roll (REP (REP 10.7) - Clean Clean only, only, using a water-m water-moiste oistened ned lint-free lint-free cloth. cloth.

•

Dono Donorr Roll Roll Ass Assem embl bly y (REP (REP 10.1 10.10) 0)

2. After cleaning or replacing a part, advance the web material manually to a clean area. (REP 10.9) If the problem still exists: Place a service call. IQ 5 Image Slip

This procedure is used when there is an image disturbance problem just prior to fusing, usually in the form of a band located along the lead edge of a print/copy. Procedure: 1. Replace the Fuser Belt Assembly. (REP 10.2) If the problem still exists: Place a service call.


04/02 3.1-21



Defect Name

Corrective Action

IQ 6 Marks, Rib and Water

This procedure is used when there is an uneven gloss on a fused print/copy which has a rib-like or watermark appearance.

(Also known as Water Stains)

Initial Action:

WARNING •

Switch Switc h off the Power, Power, discon disconnect nect the Power Power Cord, Cord, and apply apply the the Safety Lockou Lockoutt Kit (GP 7).

•

Allow the Fuser Fuser to cool befo before re perform performing ing this this procedu procedure. re.

•

Fuserr Oil is an eye Fuse eye irritant. irritant. Do Do not rub rub eyes eyes after handli handling ng Fuser Fuser Compo Components nents..

Procedure:

CAUTION Before performing the Fuser Pad Spring adjustment, be sure to perform all prerequisite checks and actions exactly as indicated. 1. Perfor Perform m the the foll followi owing: ng: •

Fuser Fuser Pad Pad S Spri pring ng a adju djustm stment ent (ADJ (ADJ 10.2) 10.2)



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Defect Name IQ 7 Unfused Print/Copy

Corrective Action This procedure is used when fuser fixing is not within specifications. Initial Action: NOTE: This problem usually occurs because of lack of heat/pressure in the Fuser, or because of excess NOTE: This Toner on the print/copy. •

Ensure Ensure that the the correct correct paper paper weight weight has been selecte selected d for the paper being being used. used.

Procedure NOTE: Setting NOTE: Setting the nip width near the maximum allowed will provide the best fusing. 1. Perform Perform ADJ 10.1 10.1 Fuse Fuserr Nip. Nip. If the problem remains: Perform ADJ 9.1 Max Setup to ensure that the output density is not too high. If the problem still exists: Place a service call.


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Defect Name IQ 8 Wrinkles

Corrective Action The procedure is used when the print/copy contains wrinkles or closely spaced ‘waves’ which do not meet specification. Initial Action: Wrinkles (or waves) occur when there is non-uniform stress in the paper while it passes though the NOTE: Wrinkles NOTE: Fuser Assembly. These stresses can be caused by the following: paper type or condition (old paper is worse), uneven oil distribution inboard to outboard, differences in contact arc inboard to outboard, and the type of image density (dark solid area images, especially 2-sided prints are worse). • Ensure Ensure that the custom customer er is using a fresh fresh supply supply of print/copy print/copy paper. paper. Procedure: 1. (Refer to Detailed Maintenance Activities as required.) Check the HFSI status of the following fuser comcomponents: Heat Roll Assembly (100k) (REP 10.3); Donor Roll Assembly (100k) (REP 10.10); and Fuser Belt Assembly (300k) (REP 10.2). Replace any item that is near or over threshold. 2. Clean the following following components, unless they were replaced in step 1: Fuser Belt Assembly (REP (REP 10.2) and Donor Roll Assembly. (REP 10.10) If the problem remains: Perform ADJ 10.1 Fuser Nip. If the problem remains: Perform ADJ 9.1 Max Setup to ensure that the output density is not too high. If the problem still exists: Place a service call.

IQ 9 Toner Starvation

The procedure is used when a localized area of the mag brush becomes “starved” for toner due to development fringe field effects. (Starvation tends to worsen with high toner concentration.) Procedure. 1. Perform Perform ADJ 9.1 Max Max Setup Setup.. If the problem still exists: Place a service call.


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Defect Name IQ 10 Bands, Lines, Smears, Or Streaks

Corrective Action This Procedure is used when the lOT output image shows light or dark bands, lines, or streaks in the lead edge to trail edge direction. Initial Actions: •

Ensure that all HFSI items that are near or over threshold have been replaced.

•

If the problem only occurs in the copier mode, check for dark rings around the circumference of the Exposure Lamp in isolated areas. Replace the Lamp as required. (REP 6.4)

Procedure Using the DCU, make all four single-color halftone prints to isolate the problem color (GP 9). Classify your observation (choose step 1 or 2): 1. The problem is light bands, lines, smears, or streaks: NOTE: If the defect is present in all four colors, check for foreign materials contacting the IBT Belt at the area between the 1st BTR and the 2nd BTR. (Refer to IBT Belt REP 9.9) NOTE: If the defect is present in single color, perform these actions in the following order: •

Inspect the BPO Mag Roll (REP 9.4) for developer bead buildup and clean it as required.

•

Replace the Charge Corotron and Screen (REP 9.2) for the problem color.

•

Replace the 1st BTR (REP 9.10) for the problem color.

If the problem still exists: Place a service call. 2. The problem is dark bands, lines, smears, or streaks: NOTE: If the defect is present in all four colors, check for poor cleaning of the IBT Belt. Replace the Belt Cleaner Blade Assembly (REP 9.6) as required. NOTE: If the defect is present in single color, perform these actions in the following order: •

Clean the ROS Seal Glass (REP 6.2) for the problem color (continued on next page)


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Defect Name

Corrective Action

IQ 10 (Continued)

IQ 11 White, Black Or Colored Spots

•

Check the drum for the problem color for scratches or damage. Replace the Drum as required (REP 9.1). If the problem is poor cleaning, replace the Drum. (REP 9.1)

•

Check for foreign materials contacting the drum for the problem color at the area between charging and development.

•

Replace the Drum Assembly (REP 9.1) for the problem color.

This Procedure is used when the lOT output print/copy has white, black, or colored spots. Initial Actions •

For a copier-only problem, inspect and clean the Platen Glass. (REP 6.3)

•

For a two-sided only problem, inspect and vacuum the Vacuum Transport 1 and 2 Assembly. (REP 8.1)If the problem remains, inspect and clean the 2nd BTR Roll Assembly. (REP 9.14)

Procedure Using the DCU, make all four single-color halftone prints to isolate the problem color (GP 9). Classify your observation (choose step 1, 2 , or 3): 1. The problem is present only in black: •

Replace the Drum Assembly. (REP 9.1)

2. The problem is present in all four colors: •

Inspect, clean and/or replace the IBT Belt (REP 9.9) as required.

3. The problem is present in only one color: •

Replace the Developer Material (REP 9.19) for the problem color and perform Max Setup. (ADJ 9.1)



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Defect Name IQ 12 Background

Corrective Action This Procedure is used when the output image shows background greater than the specification. Initial Action: •

If this is a copier-only problem, ensure that the original is in good condition and that it is held flat against the Platen Glass. If the problem remains, clean the mirrors. (REP 6.5)

•

Ensure that all HFSI items (especially the developer material for all four colors) that are near or over threshold have been replaced.

Procedure: 1. Perform the GP1 xerographic Hardstop procedure. •

If background is present between the IBT Cleaner Assembly and the yellow Drum Assembly, replace the IBT Cleaner Assembly. (REP 9.5)

•

If background is present across the entire top surface of the IBT Belt, perform ADJ 9.1 Max Setup.

If the problem still exists: Place a service call. IQ 13 Corrupted Video Data

This Procedure is used for a printer-only image quality problem. Initial Action: Ensure that the cables between the DFE and the VSEL PWBs (reference GP 6, Fig. 1) are connected securely. Procedure: Place a service call.

IQ 14 Missing Colors

This Procedure is used when a variety of image defects occur when printing in the customer mode but do not occur when printing halftones using the Diagnostic Control Unit. (GP 9) Initial Action: Ensure that the cable between the DFE and the VSEL PWB (reference GP 6, Fig. 1) for the problem color is connected securely. Procedure: Place a service call.


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Defect Name IQ 15 Deletions (Random)

Corrective Action This Procedure is used when the output copy is experiencing deletions that are not shown in the Image Quality Defect Samples. Initial Actions: •

Load some new, dry 24 lb. 11X17/A3 Xerox Color Xpressions (XC), or 90 GSM Colotech + (XE) into each paper tray.

•

Ensure that the developer material for all four colors that are near or over threshold have been replaced.

Procedure: Using the DCU, make all four single-color halftone prints to isolate the problem color (GP 9). Classify your observation (choose step 1, 2, or 3): 1. The deletion occurs from only one tray in all colors : NOTE: For the problem tray, replace both components at the same time. •

(If accessible) Tray 1 Feed/Nudger Roll Assembly (REP 7.14) and the Tray 1 Retard Roll. (REP 7.15)

•

(If accessible) Tray 2 Feed/Nudger Roll Assembly (REP 7.14) and the Tray 2 Retard Roll. (REP 7.15)

•

Tray 3 Feed Roll Assembly (REP 7.10) and the Tray 3 Retard Roll. (REP 7.11)

2. The deletion occurs from all trays in one colors: •

Replace the 1st BTR (REP 9.10) for the problem color.

3. The deletion occurs from all trays in all colors: •

Replace the IBT Belt. (REP 9.9)

If the problem still exists: Place a service call. IQ 16 Bead Carry Out

This Procedure is used when the copy is experiencing bead carry out. This defect is felt as a fine grit on the surface of the copy Procedure: Place a service call.


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Defect Name IQ 17 Granularity

Corrective Action This Procedure is used when the output copy shows graininess, or a sandy, textured appearance. Initial Actions: NOTE: Paper outside the specified weight and quality range can increase graininess. Heavy weight papers are particularly susceptible. •


•


Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 18 Grossly Shifted Color Plane

This Procedure is used when one or more color planes are shifted by 1/2 inch or more from its normal position. Procedure: Place a service call.

IQ 19 Uneven Density

This Procedure is used when the IOT output image shows uneven density in the inboard-to-outboard direction. Initial Action: •


Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call.


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Defect Name IQ 20 Low Image Density

Corrective Action This Procedure is used when the final output image is noticeably low. Initial Actions: NOTE: Paper outside the specified weight and quality range can increase graininess. Heavy weight papers are particularly susceptible. •


•


Procedure: 1. Clean all the ADC Sensors (REP 9.13), then perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 21 High Image Density

This Procedure is used when the final output image is noticeably high. Initial Action: •


Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 22 IOT Solid Single-Color Print/Copy

The Procedure is used when the print/copy is a solid single color with no original image seen on the print/ copy. Procedure: 1. Replace the Drum Assembly (REP 9.1) that exhibits the problem. If the problem remains: Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call.


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Defect Name IQ 23 Blurred or Fuzzy Image

Corrective Action The Procedure is used when the image is not clear, or appears out of focus. Initial Actions: •


•


Procedure: Place a service call. IQ 24 Mottle

The Procedure is used when the output image has mottle or a mottle-like defect. Initial Actions: NOTE: Mottle can occur when using lower quality paper, paper which is not in specification for this machine (refer to the customers Materials Usage Guide and Recommended Paper List), paper that has a high moisture content, or a paper supply setting that does not match the paper that is installed in it. •

Replace the paper presently being used with new 24 lb. Xerox Color Xpressions (XC), or 90 GSM Colotech + (XE) paper and run test prints. Or, ensure that the customer has calibrated the DFE to match the type of paper being used. (Depending on what DFE is used in the system, refer the customer to the Fiery EX2000 Printer Guide, Chapters 16 and 18, or to the CSX Printing Guide, for detailed information.)

•

Ensure that the paper weight and type selected match the weight and type of the paper itself.

Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call.


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Defect Name IQ 25 Poor Color Balance

Corrective Action The Procedure is used when the gray areas of the print/copy appears to have a magenta, yellow or cyan hue, rather than true gray. Initial Actions: • •

Ensure that the system is properly calibrated and that the customer is using the 200 rotated dot screen. This is the only screen for which the color is balanced. When calibrating, use expert mode in the calibration screen to check that measured values of C, M, and Y are above or generally above the target values.If the measured values are well below the targets, perform the adjustment below.

Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 26 Back Side or Side Two Print/ Copy Contamination

The Procedure is used for Back Side and Side-Two print/copy contamination. Initial Action: •

Ensure that all paper transports (refer to REP 8.1, 8.5 and 8.6), including the 2nd BTR Roll Assembly (REP 9.14) are clean.

Procedure : Place a service call. IQ 27 Hollow Characters

This Procedure is used for small circular-shaped deletions with a character. Initial Action: •


Procedure: Place a service call.


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Defect Name IQ 28 Low Contrast Reproduction

Corrective Action This Procedure is used when the highlight image is wiped out or the density of highlight images is too low. Initial Actions: •


•


Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 29 Color-toColor Misregistration

This Procedure is used when multi-colored images are not superimposed. Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call.

IQ 30 ROS Borders

The Procedure is used when the intentional border deletions do not meet specification. Initial Action: •

Using the Tools Mode, select the tab labeled “Feature Defaults 1”; then choose “Edge / Center Erase” and the “Border Erase” option to set the uniform width of the border. If this dimension needs to be fine-tuned, select the “Edge / Center Erase” options to adjust the top, bottom, left, right, and center as required.

Procedure : Place a service call.


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Defect Name IQ 31 Moire

Corrective Action The Procedure is used when the halftone screen in the original interferes with the halftone screens being generated by the copier. Initial Actions: •

Select the tab labeled “Image Quality”; then choose “Original Type.” If either Auto Photo & Text or Photo is selected, ensure that the “Photo” option (not Halftone or xerographic Copy) is chosen.

• •

Change the orientation of the original by rotating it 90 degrees. Select the tab labeled “Image Quality”; then choose “Sharpness.” Ensure that the “Softest” option is chosen. • Reduce or enlarge the copy slightly (example, 95% or 105%). • Select the tab labeled “Image Quality”; then choose “Original Type.” Ensure that the “Maps” option is chosen.). Procedure : Place a service call. IQ 32 Newton Rings

The Procedure is used when a defect appears as repetitive, irregular-shaped marks that occur when making copies of glossy photographs. Initial Actions: • Clean the Platen Glass with Film Remover and water-moistened lint-free cloth. • Place a transparency between the photo and the Platen Glass. Procedure : Place a service call.


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Defect Name

Corrective Action

IQ 33 Text / Image Separation

The Procedure is used when using the Original Type options of Auto Photo and Text or Text, the copier attempts to discriminate between text and photo areas within the original. On occasion, a defect may appear where an area is classified incorrectly and text is treated as photo or vise-versa. Initial Actions: •

Select the tab labeled “Image Quality”; then choose “Original Type.” If either Auto Photo & Text or Photo is selected, ensure that the “Photo” option (not Halftone or xerographic Copy) is chosen. • Change the orientation of the original by rotating it 90 degrees. • Select the tab labeled “Image Quality”; then choose “Sharpness.” Ensure that the “Softest” option is chosen. • Reduce or enlarge the copy slightly (example, 95% or 105%). • Select the tab labeled “Image Quality”; then choose “Original Type.” Ensure that the “Maps” option is chosen. • Using the Tools Mode, select the tab labeled “Machine Defaults 2”; then choose “Auto Recognition” and “Text: Photo.” Depending on the type of separation problem your are having, you can try the following: For a problem with distorted text, select “Auto Photo & Text: Level 2 or 1”; for a problem with a photograph, select “Auto Photo & Text: Level 4 or 5.” Procedure : Place a service call.


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3.2.1 General Information The Image Quality Specification section contains the following subsections: •

3.2.2 IOT Setup for Full Color Output Check. This procedure is intended to be used to judge machine output for proper density, color balance and color fidelity.

•

3.2.5 DFE Test Page. This subsection illustrates the recommended DFE test pattern available for troubleshooting image quality.

•

3.2.6 Copier Setup for Full Color Output Check. This procedure is intended to be used to judge machine output for proper density, color balance, and color fidelity.

You will use the four subsections as described to assist you in troubleshooting image quality defects in the machine. These standards/specifications apply to prints made on recommended paper. Other paper may not allow the machine to perform within these standards / specifications. The standard recommendation for paper is to use 24 # Xerox Color Xpressions (USCO), or 90 GSM Colotech (XL). When performing 3.2.2 IOT Setup for Full-Color Output Check (With Modified Restore Chart), you will compare the designated areas on the Restore Pattern to the designated areas on the Reference Test Pattern as directed by the 3.2.2.1 IOT Color Standards. When performing 3.2.6 Copier Setup for Full-Color Output Check, you will compare copies of Test Pattern 82E13120 to the 3.2.6.1 Copier Color Specifications.

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3.2.2 IOT Setup For Full-Color Output Check (With Modified Restore Chart)

NOTE: A file can be downloaded directly (Direct) or sent to the Print or Hold queues. Files sent to the Print or Hold queue are spooled in the printer’s memory. Files sent to the Hold queue remain in memory until they are moved to the Print queue or are deleted. Choose the Hold Queue if you need to set the properties before printing. For setting properties, see the Printing Guide.

The following steps are used to set up the machine for the purpose of making DFE test pattern prints to judge output images for density, color balance, and color fidelity. 1.

Load 24# Xerox Color Xpressions 11” X 17” (USCO), or 90 GSM Colotech A3 (XL) paper (if available) in Tray 2.

g.

NOTE: For the Fiery EX2000, go to step 2. For the Creoscitex CSX2000, go to step 3. 2.

Using the Web Down Loader, download the file: Restore11x17.pdf or RestoreA3.pdf file on the Fiery EX2000 in order to make test prints. NOTE: See the xerox RIP Installation Worksheet for this installation to determine the designated client workstation. a.

Launch the Internet browser application on the designated client workstation. b. Insert the CD containing the “Restore11x17.pdf and RestoreA3.pdf” files. c. Enter the IP address of the Fiery EX2000 from the current Configuration page (see “To print a Configuration page from the Control Panel”.). NOTE: An alternative method is to get access is to use the DNS name. This name can be obtained from the network administrator. It is case-sensitive and must be entered exactly. d.

If a Log In dialog box appears, select Guest and click OK. (This box appears only if the administrator has set a password.) e. When the Fiery EX2000 home page appears, click to select WebDownloader. Then move the cursor over the buttons to display information about the selections. f. Select the destination.

Click “Browse” to search for the desired file. Then select this file and click “Open”. NOTE: The “Restore11x17.pdf and RestoreA3.pdf” files will be found on the CD inserted into the workstation.

h.

Click “Download” to produce a 200 dot screen print; label it and set it aside. i. After printing is completed, click “WebSpooler” and find the “Restore11x17.pdf or RestoreA3.pdf” file. j. Double-click this file and choose the “Image Quality” tab. k. Change the “Digital Press Mode” to “600 Line 90 deg fixed”. l. Click “OK”, then select “Job/Print” from the “herald” at the top of the page to produce a 600 line screen print; label it and set it aside. 3. Loading the file: Restore11x17.pdf or RestoreA3.pdf, on the Creoscitex CSX2000 in order to make test prints. a. Insert the CD containing the “Restore11x17.pdf and RestoreA3.pdf” files. b. Choose “Job\Import Job” at the top left corner of the screen. c. Navigate to the CD ROM, drive E, and click the “Restore11x17.pdf or RestoreA3.pdf" file. d. Set the “Virtual Printer" box to “PrintToStore". e. Click “Add to List” and then “Submit", when this button becomes available. NOTE: The submitted file will RIP, and then it will appear at the top of the “Storage” folder on the right side of the screen. f. g.

Double-click the stored file and a menu will appear. Click “Paper Stock” and choose the following: “Tabloid, paper, 81105, uncoated and Tray 2”. NOTE: Say “Yes” to any messages that might appear.

h. Select “Color” and then “Calibration”. i. Choose “None”. j. Choose “Screening Method” and then “Dot 200”.


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k.

Click “Submit” to produce a 200 dot screen print; label it and set it aside. l. Double-click the stored file again and a menu will appear. m. Click “Paper Stock” and ensure that the following are still selected: “Tabloid, paper, 81-105, uncoated and Tray 2”. NOTE: Say “Yes” to any messages that might appea r. n. o. p. q.

Select “Color” and then “Calibration”. Choose “None”. Choose “Screening Method” and then “Line 600”. Click “Submit” to produce a 600 line screen print; label it and set it aside. NOTE: When performing the following step, use the Modified Restore Chart printed with the 200 dot screen (except where indicated) when making com- parisons . 4.

Compare the designated areas on the Modified Restore Chart to the original Reference Test Pattern shipped with the machine. 5. Follow the directions under Table 1B “Checks to Perform” to ensure that the prints comply with the color standards.

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3.2.2.1 IOT Color Standards Table 1 - B 3.2.2.1 Color Standards - Test Patterns Used

CHECKS TO PERFORM

Background Granularity: Compare the black, magenta, and cyan (99%, 60% and 20%) patches near the center of the Modified Restore Chart to the identical patches on the Reference Test Pattern. Mottle: Compare the magenta, cyan, black and green (99% and 60%) patches near the center of the Modified Restore Chart to the identical patches on the Reference Test Pattern. Banding in Halftones: Check the horizontal portion of the “H” band Inboard-to-Outboard Color Density: Check one of the prints by folding it in the center and comparing the inboard side to the outboard side. Lines Streaks

TEST PRINT (AREA USED)

RECOMMENDED REPAIR CRITERION

Overall A

No obvious background under normal viewing conditions Worse than Reference Test Pattern

A (m,c,k) C (g)

Worse than Reference Test Pattern

B B

Not acceptable to the customer on the customer’s job Clearly visible imbalance

Overall Overall

Any visible unwanted line Not acceptable to the customer on the customer’s job

Spots (black or color): Check the black prints made at 20 Cin%, the 3C prints made at 20 Cin%, and the 3C print made at 60 Cin%. White Spots/Deletions/Debris Centered Deletions (DCDs): Check the black prints made at 20 Cin%, the 3C prints made at 20 Cin%, and the 3C print made at 60 Cin%.

Overall (DC612, 3-1) Overall (DC612, 3-1)

Residual Image: Check the black print and the 3C prints made at 20 Cin%. Color-to-Color Registration: Use the DFE Modified Restore Chart printed at 600 L to compare its color line pairs to the color line pairs on the Reference Test Pattern.

Overall (DC612, 3-1) D The bottom edge of any horizontal line in one color protrudes beyond (600 Line) the top edge of the adjoining colored line. The right hand side of any vertical line in one color protrudes past the left hand side of the adjoining colored line. Overall Toner should not smear when rubbed with moderate pressure. Overall Feels oily, has visible oil marks, or customer complaint

Unfused Print Excess Oil on Print Excessive Curl: Check made with sheet lying on a flat surface. Line Density: Use the DFE Modified Restore Chart printed at 600 L to compare the darkness of its fine (2 pixel) lines to the fine lines on the Reference Test Pattern. Line Width Uniformity (slow and fast scan): Use the DFE Modified Restore Chart printed at 600 L to compare its fine lines to the fine lines on the Reference Test Pattern.


Any random or repetitive spot greater than 0.5 mm; or more than 20 random spots between 0.2 to 0.5 mm on one A3 (11 x 17) print Any repetitive white spot or deletion greater than 0.5 mm; or more than 6 spots between 0.2 to 0.5 mm on one A3 (11 x 17) print More than four random spots/deletions/DCDs greater than 1.0 mm on one A3 (11 x 17) print, or more than seven within a four-print run Any noticeable residual image

Overall 13 mm maximum on all four corners E Worse than Reference Test Pattern (600 Line) E (600 Line)

Worse than Reference Test Pattern

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Figure 1 Modified Restore Chart

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3.2.5 DFE Test Pages This section shows the test pages that are available to assist in isolating defects caused by the DFE.

How to Run the EX2000 Test Page Figure 1 shows EX2000 Test Page. Instructions for running the EX2000 Test Page are located in the EX2000 Installation and Service Guide. This guide is a pdf file located on your E-DOC CD in the directory EFI_Docs. In order to access this file, perform the following steps: 1. Click on the Windows START button. 2. Select Run. 3. Type in the letter of your CD ROM drive followed by the path name, :\Vendor\EFI_Docs\I&SG.pdf.

Figure 1 DFE: EX2000 Test Page (LE is on right edge of image as shown)


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How to Run the XPS Test Pages Figure 2 and Figure 3 show the XPS Test Pages. Instructions for running theses test pages are located in the DocuColor 2060/2045 SPX Service Manual Supplement under GP9, Printing and Configuration Pages.

Figure 2 DFE: YMCK Test Page (LE on right edge) Figure 3 DFE: Complex Test Page (LE on right edge)

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3.2.6 Copier Setup For Full Color Output Check

3.2.6.1 Copier Color Specifications

The following steps are used to set up the machine for the purpose of making test pattern copies to judge the output image for color fidelity. This procedure should be used for judging Full Color output only.

Figure 1 illustrates Test Pattern 82E13120. Table 1 items A through I correspond to locations on the test pattern. These locations contain image data designed to test for different image specifications.

1.

3.2.6.1 Copier Color Specifications - Test Pattern Image Data Check Locations

Set the following Basic Feature option to the selection indicated: a. Output Color - Full Color 2. Set the following Image Quality options to the selections indicated: a. Original Type - Auto Photo & Text b. Lighter/Darker - Auto c. Color Balance - Off d. Chroma - Normal e. Sharpness - Normal 3. Place (Copier Color Test Pattern 82E13120) on the platen, load 24# Xerox Color Xpressions 11” X 17” (USCO), or 90 GSM Colotech A3 (XL) paper (if available) in Tray 2, and make a copy. 4. Refer to Color Specifications (3.2.6.1 Color Copier Specifications) to evaluate the copy of the test pattern.

AREA A

B C

D

E

F G H I


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CHECK PERFORMED Text Reproduction Check. Each of the seven sentences in this area are fully reproduced with no missing letters or portions of letters. The sentences are reproduced in Black, Cyan, Magenta, Yellow, Red, Green and Blue. Color Registration Check. The patterns in location B should be properly registered to provide Black, Red, Green and Blue lines. Inboard-to- Outboard Color Density Check. The density of both the low density and high density bands should be uniform from inboard to outboard. This can be tested by folding the copy in the center and comparing the inboard side of the copy to the outboard side of the copy at location C. Both the high density and low density locations should exhibit even inboard-to-outboard density. Color Gradation Check. This area should exhibit a decreasing density of each of the colors from 100% density to 5% density. In a properly adjusted machine, the 10% patches should be visible and the 5% patches should be barely visible or not visible on the test pattern copy (except for the bottom row). Routine Color Check. Location E represents three general tests for the machine to reproduce colors common to customer originals. Location A is a general skin tone test. Location B represents the color of grass or other common foliage. Location C represents the color of the sky. Photo Gradation Check. Location F is not used for any copy quality evaluation on this product. IIT Calibration Patches. These patches are scanned for IIT Calibration during the DC945 IIT Calibration portion of Max Setup. 100 Lines/Inch Image. A Moire defect will show on this image. Moire on a 100 Line/Inch image is within specification. 175 Lines/Inch Image. This image is used to test for Moire. Depending on the degree of the defect, moire seen on this image should be considered out of specification.

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Copier Color Test Pattern 82E13120

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3.3.1 Introduction

3.3.2 Image Defect Samples

This portion of the service manual contains Image Quality Defect Samples of signature defects produced on the DocuColor 2060/ 2045.

The following figures contain examples of signatures and their possible causes. Figure 1 Bead Carryout, Single-Color Band (Faint)

Important Note: Figure 2 Bead Carryout, Single-Color Band (Severe) The following Image Quality Defect Samples were printed on a DocuColor 2060 / 2045 and are intended to show the image defects but due to possible machine setup differences, they may not be fully representational of the original Image Quality Defect Samples. For the best representation of the Image Quality Defect Samples, it is recommended to view the electronic version of these sample in Section 3.3 of the Service Manual that is found on the DocuColor 2060 / 2045 eXcellerate EPSS CD.

Figure 3 Corrupted Video Data Figure 4 Rainbow-Like Single or Multi-Color Bands Figure 5 Water Stains Figure 6 Localized, Single-Color, Half Tone, Streak Deletion Figure 7 Mottle (With Some Granularity) Figure 8 Toner Starvation Between Low Density / High Density Area Figure 9 Image Slip Figure 10 Mosaic Figure 11 Vacant Characters Figure 12 Small Dark Dots on Text Figure 13 Newton Rings Figure 14 Start of Rib Marks Figure 15 Rib Marks Figure 16 Water Marks

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Image Quality Defect Samples

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Figure 1 Bead Carryout, Single-Color Band (Faint)

Figure 2 Bead Carryout, Single-Color Band (Severe)

CAUSE:

CAUSE:

Toner agglomerate or debris buildup between the magnetic roll and the drum, resulting in a faint, narrow band.

Toner agglomerate or debris buildup between the magnetic roll and the drum, resulting in a severe, narrow band. the drum is usually damaged in this case.

CORRECTIVE ACTION: CORRECTIVE ACTION: Go to IQ 16 of the Corrective Action Table in Section 3 Go to IQ 16 of the Corrective Action Table in Section 3

DocuColor 2060/2045

04/02 3.3-3




04/02 3.3-4

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 3 Corrupted Video Data

Figure 4 Rainbow-Like Single or Multi-Color Bands

CAUSE:

CAUSE:

This sample is one of a variety of image defects caused by a connection problem between the DFE and IOT.

Contaminated Charge Scorotron Wire. CORRECTIVE ACTION:

CORRECTIVE ACTION: Go to IQ 10 of the Corrective Action Table in Section 3 Go to IQ 13 of the Corrective Action Table in Section 3

DocuColor 2060/2045

04/02 3.3-5




04/02 3.3-6

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 5 Water Stains

Figure 6 Localized, Single-Color, Half Tone, Streak Deletion

CAUSE:

CAUSE:

Likely caused by incorrect fuser nip pressure.

BPO Mag Roll developer bead buildup. The drum is sometimes damaged in this case.


DocuColor 2060/2045

04/02 3.3-7




04/02 3.3-8

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 7 Mottle (With Some Granularity)

Figure 8 Toner Starvation Between Low Density and High Density Area

CAUSE:

CAUSE:

Damp or low quality paper, aged developer material, or low toner concentration.

A localized area of the magnetic brush becomes ‘starved’ for toner due to development fringe field effects.

CORRECTIVE ACTION:

CORRECTIVE ACTION:

Go to IQ 24 of the Corrective Action Table in Section 3


DocuColor 2060/2045

04/02 3.3-9




04/02 3.3-10

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 9 Image Slip

Figure 10 Mosaic (5x actual size)

CAUSE:

CAUSE:

Likely caused by problems associated with the Pad Wick and Sheet Pad.

Text / Image Separation errors in Text and Text / Photo modes.

CORRECTIVE ACTION:

CORRECTIVE ACTION:



DocuColor 2060/2045

04/02 3.3-11




04/02 3.3-12

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 11 Vacant Characters (5x actual size)

Figure 12 Small Dark Dots on Text (5x actual size)

CAUSE:

CAUSE:



CORRECTIVE ACTION:

CORRECTIVE ACTION:



DocuColor 2060/2045

04/02 3.3-13




04/02 3.3-14

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 13 Newton Rings (5x actual size)

Figure 14 Start of Rib Marks (1/3 actual size and enhanced for clarity)

CAUSE:

CAUSE:

Highly reflective surfaces on a glossy photograph.

They are caused by one or more of the following: Incorrect pad force, incorrect pressure roll nip, or a low oil condition.


DocuColor 2060/2045

04/02 3.3-15




04/02 3.3-16

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 15 Rib Marks (1/3 actual size and enhanced for clarity)

Figure 16 Water Marks (1/3 actual size and enhanced for clarity)

CAUSE:

CAUSE:



CORRECTIVE ACTION:

CORRECTIVE ACTION:



DocuColor 2060/2045

04/02 3.3-17




04/02 3.3-18

DocuColor 2060/2045

4. Preventive Maintenance Section Contents

Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 High Frequency Service Items (HFSI) . . . . . . . . . . . . . . . . 4-3


04/02 4-1


Introduction

Cleaning Procedures

Some parts or assemblies used in the DocuColor 2060 / 2045 should be cleaned or checked at regular intervals. The interval between the required maintenance is based on copy count. Because of different machine environments, varying amounts of machine use, and a variety of paper quality used, the interval between maintenance actions for a given maintenance item may vary from the suggested interval. Always clean any component in need of cleaning whenever it is made accessible during repair of the copier.

Purpose

The Cleaning Procedures, along with the High Frequency Service Items (HFSI), provide the necessary information to maintain the copier subsystems at a high level of reliability.

These cleaning procedures are to be performed at the Service Intervals specified in the Detailed Maintenance Activities. Procedure

WARNING / CAUTION Do not use any solvents unless directed to do so by the Service Manual. General Cleaning Use a dry lint free cloth or a lint free cloth moistened with water for all cleaning unless directed otherwise by the Service Manual. Wipe with a dry lint-free cloth if a moistened cloth is used. Optical Sensors Clean the sensors with a dry cotton swab or a dry lint-free cloth. Block Sensors Clean the sensors with a dry cotton swab. Platen Glass Use a lint-free cloth with Lens and Mirror Cleaner. All Machine Rolls Use a lint-free cloth moistened with water and Film Remover. Allow the Rolls to air dry. Do not wipe with a dry cloth. External Covers Use a lint-free cloth moistened with water. Do not use any solvents. Fuser Oil While wearing plastic gloves, wipe up as much of the spill as you can with a white cleaning cloth. Then use Film Remover and a white cleaning cloth to help breakdown the remaining Fuser Oil and repeat until the spill is completely cleaned.


04/02 4-2


High Frequency Service Items (HFSI)

Note: The HFSI Items that are Bolded are the eXcellerate items that will require service. All other items will be performed by a Xerox Cus- tomer Service Engineer.

Procedure Note: Refer to GP 3 and GP4 to perform the following tasks.

Table 1. DC135 HFSI List 1. Enter the TKO Diagnostic Pathway and select DC135 HSFI Counters. 2. Use this table to determine the action to be performed if any High Frequency Service Item (HFSI) counter is over threshold (indicated by a RED marker) or approaching the threshold (indicated by a yellow marker). Using the customer’s output volume numbers (high, medium, or low volume) and this machine’s history, evaluate which HFSI actions should be serviced at this time.

Chain Link No. No.

Note: If any HFSI Items are tagged yellow, for approaching Thresh- old, determine whether it is appropriate to perform a service procedure based on the Threshold Number and t he area of the machine you are working in. 3. Refer to Cleaning Procedures for detailed cleaning instructions. 4. Clear the code of each HFSI item that was performed on the service call.


04/02 4-3

REP Reference Threshold #

Item

004 004 004

810 (Suction Blower) Filter 811 Ozone Filter 812 (Dust Blower) Filter

100K 200K 200K

005

005

800 (Document Feed Chute) Feed Roll Kit / Nudger Roll Kit (Document Feed Chute) Retard Roll 801 DADF Platen Belt

006

800 Exposure Lamp

1000K ** Replace at every failure 2400K **

9.15 9.16 9.15

100K **

100K **

006

801 IIT Scan Count

007 007 007 007 007 007 007 007 007

800 801 802 803 804 805 806 807 808

Feed / Retard / Nudger Roll -Tray 1 Feed / Retard / Nudger Roll -Tray 2 Feed / Retard / Nudger Roll -Tray 3 Tray 1 Feed Assembly Tray 2 Feed Assembly Tray 3 Feed Assembly Tray 1 Takeaway Roller Assembly Tray 2 Takeaway Roller Assembly Tray 3 Takeaway Roller Assembly

300K 300K 300K 1500K 1500K 1500K 1500K 1500K 500K

008 008 008 008

801 802 803 810

F Transport Roller Assembly J-Transport Drive Roller Assembly 1 and 2 J-Transport Drive Roller Assembly 3 and 4 Paper Aligner Roll / Aligner Pad Assembly

3000K 3000K 3000K 1500K

6.4

7.13/14 7.13/4 7.9 7.11 7.11 7.9

7.7


Chain Link No. No. 008

008 008 008 008 008

008

008

008 008

008 008

Item

811 (Aligner Upper Chute) Registration Roll Assembly (Aligner Upper Chute) Registration Pinch Roll Assembly (Registration Size Shift Motor) Gear 81 2 A li gner Nip / Relea se M ot or 1 As se mbl y 813 Registration Motor and Gear (single) / Gear (dual) 830 Vacuum Transport Belt -Transport 1 831 Vacuum Transport Belt -Transport 2 840 (Inverter Roller Assembly - Left) Clutch (Entrance Swing Assembly) Gear (Entrance Swing Assembly) Entrance Transport Clutch 841 (Exit Transport Assembly) Pinch Roll (Swing Transport Assembly) Entrance Roller Assembly (Swing Transport Assembly) Gear (Inverter 2 Transport) Pinch Roll (Exit Transport Assembly) Out Put Roller 850 (Inverter Roller Assembly - Left) Inverter Roller (Inverter Roller Assembly - Right (1 of 2)) Pinch Roll (Inverter Roller Assembly - Right (2 of 2)) Roller Assembly, Pinch Roll Assembly (Inverter 1 Transport Assembly (1 of 2)) Duplex Roller Assembly (Entrance Chute Assembly) Pinch Roll 851 (Inverter Roller Assembly - Right) Gear (Exit Transport Assembly) Gear 860 (Horizontal Transport) Cross Roll Assembly (Horizontal Transport) Aligner Pan Assembly 870 Decurler Belt Kit 871 (Decurler Roll) Enter Roll Assembly (Decurler Roll) El. Roll Assembly (Enter Chute) Pinch Roll Assembly



Chain Link No. No.

3000K

1 50 0K 3000K

800 Developer (Y)

009

801 Developer (M)

009

802 Developer (C)

009

803 Developer (K)

009

804 BPO Trim (Y)

009 009

3000K

3000K

1500K 1500K

3000K 3000K

04/02 4-4

Item

009

009 3000K 3000K 1500K


BPO Assembly) 805 BPO Trim (M) BPO Assembly) 806 BPO Trim (C) BPO Assembly) 807 BPO Trim (K) BPO Assembly) Developer Assembly Developer Assembly Developer Assembly Developer Assembly BPO Assembly (Y) BPO Assembly (M)

(Clean the

512K 512K 512K 512K 1024K

9.19 9.19 9.19 9.19 9.4

(Clean the

1024K

9.4

(Clean the

1024K

9.4

(Clean the

1024K

9.4

009 009 009 009 009 009

808 809 810 811 812 813

Input Input Input Input

Shaft Shaft Shaft Shaft

(Y) (M) (C) (K)

009 009

814 BPO Assembly (C) 815 BPO Assembly (K)

009

820 Drum Assembly (Y)

100K

009

821 Drum Cycle (Y) (Reset counter only)

500K

009

822 Drum Assembly (M)

100K

009

823 Drum Cycle (M) (Reset counter only)

500K

009

824 Drum Assembly (C)

100K

009

825 Drum Cycle (C) (Reset counter only)

500K

009

826 Drum Assembly (K)

100K

009

827 Drum Cycle (K) (Reset counter only)

500K

009 009 009 009 009

828 829 840 841 842

200K 50K 100K 100K 100K

009

845 2nd BTR Trim (Reset counter only)

CC Filter (1-4) Waste Toner Bottle PTC Assembly (K) 2nd BTR Roll Assembly (Belt) Cleaner Blade Assembly

6144K 6144K 6144K 6144K 3000K 3000K 3000K 3000K

9.1 9.1 9.1 9.1 9.18 9.22 9.23 9.14 9.6

100K


Chain Link No. No.

009 009

Item


846 (Transfer Belt - Inner) Cleaning Roll 847 (Transfer Drawer) IBT Belt

800K 400K

009

848 IBT Belt (Cycle) (Reset counter only)

137K

009 009 009 009 009

849 850 851 852 853

400K 400K 400K 400K 400K

009 009

854 Helical Gear - 96T 855 Exit Chute Assembly

010 010 010 010 010

800 801 802 803 804

1st BTR Roll (Y,M,C,K) 2nd BTR Back Up Roll Assembly Belt Cleaner Brush Assembly Belt Cleaner Film Seal Assembly (1st BTR Roll) Bearing (1-4) / (2nd BTR Back Up Roll) Bearing

Heat Roll Fuser Belt (Fuser Belt) Sheet Pad (Fuser Belt) Pad Wick Assembly

(Fuser Web Assembly) Web Material Assembly

9.11 9.9 9.10 9.12 9.5 9.6 9.10 / 9.12

1000K 1000K

100K 100K 100K 100K 9,609,800

10.3

10.9

100K 100K

10.10 10.15

100K 300K 300K 500K

10.12 10.2 10.15

NOTE: This is not actual print

count. This counter displays print count x100. 010 010

010 010 010 010 010

806 Donor Roll Assembly 807 (Heat Roll Assembly) Finger Assembly / (Fuser Belt) Stripper Fingers (Clean Only) 808 Heat Roll Wick 809 Oil Filter 810 Belt Module 812 Finger Assembly - Heat Roll and Fuser Belt 813 Fuser Module


3000K

04/02 4-5


5. Repairs and Adjustments 7. Paper Supply

SECTION CONTENTS PARTS LIST Parts List (with Expected Life)..........................................................................

5-3

Component Locations Overview 1 Component Locations................................................................... Overview 2 IOT Module................................................................................... Overview 3 Fuser Assembly............................................................................

5-4 5-5 5-6

Sensor Locations Sensor Map ...................................................................................................... Sensor and Roll Assembly Locations ............................................................... Figure 1 F Transport Path Sensor 1 and 4 ................................................... Figure 2 J Transport (1) Path Sensor 1 and 3 .............................................. Figure 3 J Transport (2) Path Sensor 4 and 5 .............................................. Figure 4 J Transport (3) Duplex Path Sensor 1 ............................................ Figure 5 J Transport (3) Duplex Path Sensor 3 ............................................ Figure 6 Tray 3 Path Sensor......................................................................... Figure 7 Decurler Upper Path Sensor........................................................... Figure 8 Decurler Lower Path Sensor........................................................... Figure 9 Decurler Upper / Lower Exit Sensor............ ................................... Figure 10 Entrance Path Sensor 1 and 3........................................................ Figure 11 Inverter Path Sensor....................................................................... Figure 12 Inverter Duplex End / Duplex Path Sensor.............................. ....... Figure 13 Exit Transport Path Sensor............................................................. Figure 14 Exit Roll Assembly................................................... .......................

5-7 5-8 5-8 5-8 5-9 5-9 5-10 5-10 5-11 5-11 5-12 5-12 5-13 5-13 5-14 5-14

REPAIRS 4. Drives REP 4.1 Duplex Decurler Position Sensor Assembly.......................................

5-15

6. Imaging REP 6.1 MOB Sensor Cleaning (Marking On Belt)........................................... 5-16 REP 6.2 (Seal Glass) ROS Window Cleaning (Raster Output Scanner).......... 5-17 REP 6.3 Platen Glass Cleaning........................................................................ 5-20 REP 6.4 Exposure Lamp ................................................................ .................. 5-22 REP 6.5 Mirror Cleaning................. .................................................................. 5-24


REP 7.1 Tray 3 Feed Assembly....................................................................... REP 7.2 Tray 3 Stack Height Sensor Cleaning............. ................................... REP 7.3 Tray 3 No Paper Sensor Cleaning ..................................................... REP 7.4 Tray 3 Pre-feed Sensor Cleaning ...................................................... REP 7.5 Tray 3 Feed Out Sensor Cleaning..................................................... REP 7.6 OHP Sensor Cleaning (Overhead Projector)..................................... REP 7.7 Tray 3 Takeaway Roller Assembly .................................................... REP 7.8 Tray 3 Pinch Rolls................................................ .............................. REP 7.9 Tray 3 Feed Roll Assembly................................................................ REP 7.10 Tray 3 Retard Roll.......................................................... .................. REP 7.11 Tray 1 Feed Assembly..................................................................... REP 7.12 Tray 2 Feed Assembly..................................................................... REP 7.13 Tray 1 /2 Feed / Nudger Roll Assembly........................................... REP 7.14 Tray 1 /2 Retard Roll......................................... ...............................

8. Paper Transportation REP 8.1 Vacuum Transport 1 and 2 ................................................................ REP 8.2 Vacuum Transport 1 and 2 Paper Sensors Cleaning ........................ REP 8.3 Horizontal Transport 1 ....................................................................... REP 8.4 Horizontal Transport 2 ....................................................................... REP 8.5 Horizontal 1 Transport (5) Path Sensor 1, 3, and 4 Cleaning ............ REP 8.6 Horizontal 2 Transport (6) Path Sensor 5 and 8 Cleaning. ................ REP 8.7 Registration In / Out Sensors Cleaning.............................................. REP 8.8 Aligner Path Sensors Cleaning.......................................................... REP 8.9 Aligner / Nip Release Home Sensors Cleaning ................................. REP 8.10 Registration Side Shift Sensor Cleaning.......................................... REP 8.11 Offset Home / Offset Position Sensor Cleaning............. ..................

5-45 5-46 5-47 5-48 5-49 5-50 5-51 5-52 5-54 5-55 5-57

9. Xerographic7 REP 9.1 Drum Assembly.................................................................................. REP 9.2 Charge Corotron / Screen.......................................................... ........ REP 9.3 Xerographic Module................................................................... ........ REP 9.4 BPO Magnetic Roll Cleaning (Bead Pick Off )..................... .............. REP 9.5 Belt Cleaner Assembly / Cleaner Brush Assembly............................ REP 9.6 Belt Cleaner Blade Assembly / Film Seal Assembly.......................... REP 9.7 Belt Home Position Sensor 1 Cleaning............... ............................... REP 9.8 Belt Home Position Sensor 2 Cleaning............... ............................... REP 9.9 IBT Belt (Intermediate Transfer Belt) ................................................. REP 9.10 1st BTR (Bias Transfer Roll)............................................................ REP 9.11 IBT Inner Cleaner Brush.................................................................. REP 9.12 2nd BTR Back Up Roll Assembly .................................................... REP 9.13 ADC Sensor Assembly (Automatic Density Control) ....................... REP 9.14 2nd BTR Roll Assembly...................................................................

04/02 5-1

5-25 5-27 5-28 5-29 5-30 5-31 5-32 5-33 5-35 5-38 5-40 5-42 5-44 5-45

5-59 5-61 5-63 5-64 5-66 5-69 5-70 5-70 5-71 5-75 5-78 5-80 5-81 5-83

Repairs and Adjustments

REP 9.15 Suction Blower / Dirt Blower Filters .................................................. 5-86 REP 9.16 Ozone Filter............................ .......................................................... 5-88 REP 9.17 C-Pop Sensor / Exit Transport Sensor Cleaning.............................. 5-89 REP 9.18 C C Filter (Charge Corotron)..................................... ....................... 5-92 REP 9.19 Developer Replacement................................ ................................... 5-94 REP 9.20 Detack Corotron .................................................................... ........... 5-97 REP 9.21 POB Jam Sensor (Paper on Belt)..................................................... 5-99 REP 9.22 Waste Bottle / Waste Bottle Full Sensor Cleaning ........................... 5-101 REP 9.23 Pretransfer Corotron......................................................................... 5-103

ADJUSTMENTS

10. Fusing

NOTE: The procedures that are highlighted in GREEN are supported with a video that is found on the DocuColor 2060 / 2045 eXcellerate Training Support CD.

REP 10.1 Camming open the Fuser Assembly ................................................ 5-103 REP 10.2 Fuser Belt Assembly......................................................................... 5-106 REP 10.3 Heat Roll..................................................................... ...................... 5-109 REP 10.4 Heat Roll Main Heater Rod............................................................... 5-112 REP 10.5 Heat Roll Sub Heater Rod................................................................ 5-114 REP 10.6 Heat Roll Thermistor Cleaning ......................................................... 5-115 REP 10.7 External Heat Roll............................................................................. 5-116 REP 10.8 External Heat Roll Thermistor Cleaning ........................................... 5-119 REP 10.9 Fuser Web Assembly ............................................................ ........... 5-122 REP 10.10 Donor Roll Assembly........................................................... ........... 5-123 REP 10.11 Heat Roll Wick...................... .......................................................... 5-126 REP 10.12 Fuser Oil Filter................................. ............................................... 5-127 REP 10.13 External Heat Roll Latch Sensor Cleaning......... ............................ 5-128 REP 10.14 Fuser Exit Sensor Cleaning............................................................ 5-129 REP 10.15 Heat Roll Finger Assembly................................................. ............ 5-130 REP 10.16 Fuser Walk Sensor Cleaning.......................................................... 5-131

ADJ 9.1 Max Setup (v6.2.2) .......................................................... ................... ADJ 9.2 IBT Belt Learn Routine....... ................................................................ ADJ 9.3 Registration Control Setup ......................................................... ........ ADJ 10.1 Fuser Nip............... ................................................................... ........ ADJ 10.2 Pad Spring........................................................... .............................

5-133 5-141 5-142 5-142 5-144

33. Covers REP 13.1 IOT Upper Front Cover (Image Output Terminal)............................. 5-132


04/02 5-2


DocuColor 2060 / 2045 Parts with Expected Life

Part No.

Expected Life Range

DocuColor 2060 / 2045 Parts with Expected Life

Part No.

Expected Life Range

Doner Roll Assembly

1K59732

100K

(Tray 3) Retard Roll

59K13770

300K

(Transfer Drawer) IBT Belt

1R558

400K

2nd BTR Roll Assembly

59K14785

100K

(1st BTR Roll) Bearing

13E82150

400K

1st BTR Roll (Y, M, C, K)

59K14840

400K

(2nd BTR Back Up Roll) Bearing

13E85430

400K

(Tray 1&2) Feed / Nudger Roll Assembly

59K9561

300K

Drum Assembly (Y,M,C,K)

13R564

100K

(Tray 1&2) Retard Roll

59K9591

300K

(Fuser Belt) Stripper Finger

19E39751

100K

(Fuser Belt Assy) Frame and Rolls

1K76990

300K

(Fuser Belt) Sheet Pad

19E39781

100K

Fuser Belt

64K91310

100K

(Fuser Belt) Pad Kit

600K87490

300K

Waste Toner Bottle

93K92600

50K

(Fuser Belt) Finger Assembly

19K94521

500K

125K93001

100K

(Heat Roll) Finger Assembly

19K97030

500K

Pretransfer Corotron (K Drum Assembly)

(Belt) Cleaner Blade Assembly

33K93480

100K

Charge Assembly

125K93011

At Failure

Film Seal Assembly

35K81190

400K

Screen (Charge Grid) - Part of Charge Assembly

15E58380

At Failure

(Fuser Belt) Pad Wick Assembly

39K90571

100K

(Heat Roll) Wick

39K90580

100K

Web Material

5K82320

When required

(Belt Cleaner) Brush Assembly

42K91740

400K

Exposure Lamp

122E91760

At Failure

Oil Filter

53E92710

300K

CC (Fan) Filter 1-4

53K91480

200K

(Suction Blower) Filter

53K91590

100K

Ozone Filter

53K91600

200K

Heat Roll Assembly

59K10680

100K

(Tray 3) Feed / Nudger Roll Assembly

59K12560

300K

(Tray 3 Takeaway) Roll Assembly

59K12580

500K


04/02 5-3


Overview 1 Component Location User Interface With Control Panel

Toner Cartridges

DADF Output Module

On Board Tool Kit

Feeder Transport

Paper Tray 1 Duplex / Exit Transports Paper Tray 2

Horizontal Transport 2 Horizontal Transport 1 Junction Transports Paper Tray 3

(Special Materials Handling)


04/02 5-4


Overview 2

IOT Module

Xerographic Modules ( K, C, M, Y )

IBT Belt

Imaging

Development

Fuser Assembly

Transfer Drawer

Paper Handling Module

Vacuum Transports Belts Registration and Aligner Assembly


04/02 5-5


Overview 3

Fuser Assembly (cammed open)

Web Material Assembly

(Heat Roll) Finger Assembly Heat Roll

Fuser Belt Position Sensor Fuser Belt Assembly

(Fuser Belt) Finger Assembly

Inverter Transport Assembly


04/02 5-6


Sensor Location Map

Table 1 L1 #2 Tray Prefeed SNR S1 SMH Prefeed SNR D1 J-Tra Dup Path SNR #1 L2 #1 Tray Prefeed SNR S2 SMH Feed Out SNR D3 J-Tra Dup Path SNR #3 L3 Feed Out SNR #2 L4 Feed Out SNR #1 F1 F-Tra Path SNR #1 F2 Overhead Projector F4 F-Tra Path SNR #4

H5 H-Tra Path SNR #5 H8 H-Tra Path SNR #8

S3 SMH Path SNR J1 J3 J4 J5

J-Tra Path SNR #1 J-Tra Path SNR #3 J-Tra Path SNR #4 J-Tra Path SNR #5

A1 Aligner Path SNR #1 A2 Aligner Path SNR #2 A3 Aligner Path SNR #3 R1 Regi in SNR R2 Regi Out SNR


V1 V2 V3 V4

V-Tra SNR #1 V-Tra SNR #2 V-Tra SNR #3 V-Tra SNR #4

H1 H-Tra Path SNR #1 H3 H-Tra Path SNR #3

E1 Exit Ent SNR #1 E2 Exit Ent SNR #2

H4 H-Tra Path SNR #4

E3 E4 E5 E6 E7

i1 i4 i5 i6

Fuser Exit SNR Inv End SNR Inv Dup End SNR Inv Dup Path SNR

DEC Upper Path SNR DEC Upper Exit SNR DEC Lower Path SNR DEC Lower Exit SNR Exit SNR

B1 Belt H/P Sensor #1 B2 Belt H/P Sensor #2 B3 POB Jam Sensor

04/02 5-7


Sensor and Roll Assembly Locations Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14

F Transport Path Sensor 1 and 4 J Transport (1) Path Sensor 1 and 3 J Transport (2) Path Sensor 4 and 5 J Transport (3) Duplex Path Sensor 1 J Transport (3) Duplex Path Sensor 3 Tray 3 Path Sensor Decurler Upper Path Sensor Decurler Lower Path Sensor Decurler Upper / Lower Exit Sensor Entrance Path Sensor 1 and 3 Inverter Path Sensor Inverter Duplex End / Duplex Path Sensor Exit Transport Path Sensor Exit Roll Assembly

1

3

Figure 2 J Transport (1) Path Sensor 1 and 3 ( Handle 3a open )

1

( side view )

4 Figure 1 F Transport Path Sensor 1 and 4 ( Handle 2 open )


04/02 5-8


4 5

PS 1

Figure 4 J Transport (3) Duplex Path Sensor 1 (PS 1) Figure 3 J Transport (2) Path Sensor 4 and 5

( Handle 7a open )

( Handle 3b open )

( bottom view )

( bottom view )


04/02 5-9


PS 3

1 Figure 5 J Transport (3) Duplex Path Sensor 3 (PS 3)

Figure 6 Tray 3 Path Sensor (1)

( Handle 7b open )

( bottom view )

( side view )


04/02 5-10


1

1

Figure 8 Decurl er Lower Path Sensor (1)

Figure 7 Decur ler Upper Path Sensor (1)

( Handle 8d open )

( Handle 8c )

( side view )

( side view )


04/02 5-11


]

2

1

1 3

2

Figure 9 Decurler Upper Exit (1) / Lower Exit Sensors (2) Decurler Drive Roller Assembly (3) ( Handle 8a and 8b open ) Figure 10 Entrance Path Sensor 1 and 2

( top view ) ( Handle 8f open )

( bottom view )


04/02 5-12


2

1 1

2

3

3

2

Figure 11 Inverter Path Sensor (1) Inverter Roller Assemblies (2) Figure 12 Inverter Duplex End (1) / Duplex Path Sensor (2) Inverter Roller Assemblies (3)

( Handle 4c open )

( top view )

( Handle 8g open )

( side view )


04/02 5-13


1

1

Figure 13 Exi t Transport Path Sensor (1)

Figure 14 Exit Roll Assembly (1)

( Accessory and Offset Catch Tray removed )

( Handle 4c open )

( bottom view )

( top view )


04/02 5-14


REP 4.1 Duplex Decurler Position Sensor Cleaning

c. d.

Remove (1) screw and the sensor bracket. (Figure 2) Clean the sensor with a dry cotton swab.

Removal / Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove the Horizontal Transport 1 (REP 8.3). 2. Clean the Duplex Decurler Position Sensor. (Figure 1) a. Release the wire harness from the clamp. b. Disconnect J229.

C

A

Figure 2

Replacement NOTE: Upon replacement, ensure that the cut-out on the Sensor Assembly mates with the locking locating tab.

B

1. Replace in reverse order.

Figure 1


04/02 5-15


REP 6.1 MOB Sensor Cleaning

4. Clean the MOB Sensors. (Figure 2) a. Clean the MOB Sensors with a cotton swab.

Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the IOT Front Left Door. 2. Remove the Upper Inner Cover. 3. Access the MOB / ADC Sensor Bracket. (Figure 1) a. Disconnect P/J764. b. Remove the (2) screws and the (2) ground wires. c. Pull out the MOB / ADC Sensor Bracket.

A Figure 2

Replacement

B

CAUTION Upon replacement, ensure that the guide pins on the MOB Sensor are seated firmly in the MOB / ADC Sensor Assembly. NOTE: Clean the ADC Sensor before replacing the MOB / ADC Sensor Assembly. (REP 9.13)

A B


C

Figure 1


04/02 5-16


REP 6.2 ROS Window Cleaning (Seal Glass)

(Figure 2) is for illustration purposes to show the rectangular slot of the ROS Window Tool and the rectangular Tab on the end of the ROS Window. The Slot in the Tool is inserted over the Tab on the Window and rotated 90 degrees to remove the Window.

Introduction

1. ROS Window Tool

Note: The ROS Tool can be found in the onboard tool kit at the rear of the Paper Handling Module. (Figure 1) a. Remove (2) screws. b. Remove the Tool Kit Compartment Cover.

2. ROS Window 3. Tool Slot 4. Window Tab

1 3 B A 2 4 Figure 1

Figure 2


04/02 5-17


2. Insert the Removal Tool. (Figure 4) a. Lift up and lower the Window Access Cover. b. Insert the Removal Tool with the tool slot in a horizontal position. Very slightly rotate the tool back and forth until you feel the tool slip over the Tab on the window.

Removal / Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7)

CAUTION The ROS Window is very fragile and could be easily damaged. Be extra careful while removing or installing the window.

B

1. Access the ROS Window. (Figure 3) a. Loosen the (2) screws.

A

Figure 4

A

Figure 3


04/02 5-18


3. Remove the ROS Window. (Figure 5) a. Rotate the Removal Tool 90 degrees and pull out the ROS Window. b. Clean both sides of the ROS Window with a damp cloth.

Replacement

CAUTION Make sure the ROS Window is reinstalled correctly. There is an “UP” indication on the ROS Window moulding next to the window tab. (Figure 6)

A

Figure 6

Figure 5 1.


04/02 5-19

Replace in reverse order.


REP 6.3 Platen Glass Cleaning

3. Carefully clean both sides of the Platen Glass with film remover and a water moistened, lint free cloth.

Removal / Cleaning

4.

Clean the White Reference Strip. (Figure 2) a. Move the Half Rate and the Full Rate Carriages to the right. b. Clean the White Reference Strip, located on the underside of the Registration bar, with a dry cloth.


CAUTION When cleaning the Platen Glass, do not clean the White Reference Strip with solvents. This will damage the strip and lead to image quality problems. Wipe the Strip with a dry cloth.

A

B

1. Open the Platen Cover or DADF. 2. Remove the Platen Glass. (Figure 1) a. Remove the (2) screws. b. Remove the Right Side Plate. c. Remove the Platen Glass.

A Figure 2

B

C Figure 1


04/02 5-20


Replacement 1. Install the Platen Glass. (Figure 3) a. Position the Platen Glass under the clip in the upper left hand corner.

2. Make sure when securing the Platen Glass, it does not cover the metal positioning bracket or you could damage the Glass. (Figure 4)

Bracket

A

Figure 4 3. Position the Right Side Plate. 4. Tighten the (2) screws that secure the Right Side Plate while pressing the Plate to the left.

Figure 3


04/02 5-21


REP 6.4 Exposure Lamp

3.

Removal

Position the Full Rate Carriage to remove the Lamp. (Figure 1) a. Pull the Full-Rate Carriage to align with the large cut-out in the frame

NOTE: After replacing the Exposure Lamp, reset the HFSI counter (NVM 006-800).


CAUTION Avoid touching the exposure lamp with your bare hands during removal or installation. Oil from your hands will contaminate the surface of the lamp.

Figure 1

1. Open the Platen Cover or DADF. 2. Remove the Platen Glass. (REP 6.3)


A

04/02 5-22


4. Release the connector harness. (Figure 2) a. Disconnect the connector. b. Release the harness from the (2) retainers.

5. Remove the Exposure Lamp. (Figure 3) a. Remove the screw. b. Carefully remove the Exposure Lamp.

B

A B

A Figure 2

Figure 3

Replacement 1. Replace in reverse order.

NOTE: When replacing the Exposure lamp, position the outboard side first and then the inboard side.


04/02 5-23


REP 6.5 Mirror Cleaning

4.

Carefully clean the (2) mirrors on the Half Rate Carriage with a lint-free cloth and Lens and Mirror Cleaner. (Figure 1)

Cleaning


#1 CAUTION Avoid touching the exposure lamp with your bare hands during removal or installation. Oil from your hands will contaminate the surface of the lamp.

WARNING When cleaning, use extreme care to avoid coming in contact with metal frame edges.

#2

Figure 1

1. Open the Platen Cover or DADF. 2. Remove the Platen Glass. (REP 6.3) 3. Pull the Full Rate Carriage and the Half Rate Carriage to an access position.


04/02 5-24


5.

Carefully clean the (1) mirror on the Full Rate Carriage. (Figure 2) a. Clean the mirror on the Full Rate Carriage with lens and Mirror Cleaner.

REP 7.1 Tray 3 Feed Assembly Removal NOTE: After replacing the Tray 3 Feed Assembly, reset the HFSI counter (NVM 007-805).


A

1. Open Tray 3 to the service position. (GP 6) 2. Remove the Tray 3 Feeder Assembly Top Cover. (Figure 1) a. Loosen (2) Screws b. Slide the Top Cover to the left and remove.

Figure 2

A B A

Figure 1


04/02 5-25


3. Remove the Connector Sheild. (Figure 2) a. Loosen (1) screw and remove the sheild.

4. Remove the Tray 3 Feed Assembly. (Figure 3) a. Disconnect 2 connectors (P/J344, P/J345). b. Remove the (4) screws and lift the Tray 3 Feed Assembly to remove.

B B A

B Figure 2

A Figure 3


04/02 5-26


Replacement 1. When replacing the Tray 3 Feeder Assembly, make sure that the Connector Sheild and the right side Support Plate are secured on the Tray 3 frame studs. (Figure 4)

REP 7.2 Tray 3 Stack Height Sensor Cleaning Removal / Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open Tray 3 to the service position. (GP 6) 2. Remove the Tray 3 Feed Assembly. (REP 7.1) 3. Access the Stack Height Sensor. (Figure 1) a. Remove (4) screws.

Stud

Figure 4


A Figure 1


04/02 5-27


4.

REP 7.3 Tray 3 No Paper Sensor Cleaning

Clean / Remove the Stack Height Sensor. (Figure 2) a. If necessary, carefully unclip and remove the sensor for cleaning.

Removal

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open Tray 3 to the service position. (GP 6) 2. Remove the Tray 3 Feed Assembly. (REP 7.1) 3. Access the Stack Height Sensor. (Figure 1) a. Remove (4) screws.

A

Figure 2

Replacement 1. Clean the No Paper Sensor. (REP 7.3) 2. Replace in reverse order.

A Figure 1


04/02 5-28


REP 7.4 Tray 3 Pre-feed Sensor Cleaning

4. Remove the Stack Height Sensor. (Figure 2) a. If necessary, carefully unclip and remove the sensor for cleaning.

Removal / Cleaning

A

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open Tray 3 to the service position. (GP 6) 2. Remove the Top Cover. (Reference REP 7.1) 3. Remove the Tray 3 Pre-feed Sensor. (Figure 1) a. Remove (2) screws and the Tray 3 Pre-feed Sensor.

Figure 2

Replacement 1. Clean the Stack Height Sensor. (REP 7.2) 2. Replace in reverse order.

A

Figure 1


04/02 5-29


REP 7.5 Tray 3 Feed Out Sensor Cleaning

b. Clean the Pre-feed Sensor with a cotton swab. (Figure 2)

Removal / Cleaning

B

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open Tray 3 to the service position. (GP 6) 2. Remove the Top Cover. (Reference REP 7.1) 3. Remove the Feed-out Sensor. (Figure 1) a. Remove (1) screw. b. Clean the Sensor with a dry cotton swab.

B Figure 2

A


Figure 1



04/02 5-30


REP 7.6 OHP Sensor Cleaning

3. Remove the OHP Sensor. (Figure 2) a. Remove (1) screw and the Feed-out Sensor. b. Clean the Feed-out Sensor with a dry cotton swab.

Removal / Cleaning


A B

1. Open Tray 3 to the service position. (GP 6) 2. Remove the Top Cover. (Figure 1) a. Loosen (2) screws. b. Slide the Top Cover to the left and remove.

B Figure 2


A Figure 1


04/02 5-31


REP 7.7 Tray 3 Takeaway Roller Assembly

Removal

Cleaning

3. Remove the Connector Shield. (Figure 1) a. Loosen (1) screw. b. Lift and remove the Connector Shield.

NOTE: After replacing the Tray 3 Takeaway Roller Assembly, reset the HFSI counter (NVM 007-808).

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull Tray 3 out to the service position. (GP 6) 2. Clean the Takeaway Rolls. (Figure 1) a. Clean the Takeaway Rolls with film remover and a water moistened, lint free cloth

A

B

Figure 2

A

Figure 1


04/02 5-32


4.

Remove the Takeaway Roll Assembly. (Figure 1) a. Remove the C-clips and bearings at both ends of the Assembly. b. Remove the Takeaway Roll Assembly.

REP 7.8 Tray 3 Pinch Rolls Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull Tray 3 out to the service position. (GP 6) 2. Remove the Top Cover. (Figure 1) a. Loosen (2) screws. b. Slide the Top Cover to the left and remove.

A A

B

B Figure 3

Replacement NOTE: Ensure the Lip of the Bearings are both towards the Feed Rolls and the C-clips are to the inside of the bearings. When replacing the Connector Sheild, make sure it is secured on the frame stud at the bottom. 2. Replace in reverse order.

A

1.


04/02 5-33

Figure 1


3. Clean the Pinch Rolls. (Figure 2) a. Clean the Pinch Rolls with film remover and a water moistened, lint free cloth.

Removal 4. Remove the Pinch Rolls. (Figure 3) a. Remove the 2 Springs. b. Remove the E-clip for the Rear Cam Follower.

A A B

A

Figure 2 Figure 3


04/02 5-34


REP 7.9 Tray 3 Feed Roll Assembly

5. Remove the Pinch Roll Assembly. (Figure 4) a. Slide the Cam Follower to the left. b. Slide the Pinch Roll Assembly to the left and remove. c. Remove the E-clips from the shaft to remove the Pinch Rolls

Cleaning NOTE: After replacing the Tray 3 Feed Roll Assembly, reset the HFSI counter (NVM 007-802).

A

B WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull Tray 3 out to the service position. (GP 5) 2. Remove the Top Cover. (Figure 1) a. Loosen (2) screws. b. Slide the Top Cover to the left and remove.

Figure 4

B


A Figure 1


04/02 5-35


3. Access the Feed Rolls. (Figure 2) a. Lift up the left side of the Feed Roll Assembly

4.

Clean the Rolls with film remover and a water moistened, lint free cloth. (Figure 3) a. Nudger Rolls. b. Feed Rolls.

A

B A Figure 3 Figure 2


04/02 5-36


6. Remove the Feed Roll Assembly. (Figure 5) a. Bias the Feed Roll Assembly to the right and lift out.

Removal 5.

Remove the Pre-feed Sensor Assembly. (Figure 4) a. Remove the (2) screws. b. Lift up on the Pre-feed Sensor Assembly to remove. Do not disconnect the Assembly c. Remove the Bearing.

C

A

A B

Figure 5

Figure 4


04/02 5-37


Replacement

REP 7.10 Tray 3 Retard Roll

NOTE: When replacing the Pre-feed Sensor Assembly, make sure the Bearing Tab is in place in the bracket. (Figure 6)

Removal / Cleaning NOTE: After replacing the Tray 3 Retard Roll, reset the HFSI counter (NVM 007-802).

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull Tray 3 out to the service position. (GP 6) 2. Remove the Retard Roll Assembly. (Figure 1) a. Remove the (2) screws. b. Remove the Retard Roll Assembly by pulling out the left side first and releasing the bracket tab from the frame

Bearing Tab Figure 6

A

1.

Make sure the outboard part of the Feed Roll Assembly shaft goes in first. 2. Replace in reverse order.

B

Figure 1


04/02 5-38


3. Clean / Remove the Retard Rolls. (Figure 2) a. If cleaning is required, clean the Rolls with a towel dampened with water. b. If replacement is required, remove the E-ring. c. Bias the Rolls to the left and remove.

B

Replacement NOTE: When replacing the Retard Roll Assembly, place the Bracket Tab in the frame slot first, and angle the Assembly up into position. (Figure 3)

A

Bracket Tab

Figure 3 Figure 2


1.

04/02 5-39

Replace in reverse order.


REP 7.11 Tray 1 Feed Assembly

2.

Open the Left Hand Cover and open the Tray 1 Drawer. (Figure 1)

Removal NOTE: After replacing the Tray 1 Feed Assembly, reset the HFSI counter (NVM 007-803).

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Undock Tray 4 if equipped. (GP 10)

CAUTION Do not open the Tray 4 Paper Drawer when Tray 4 is in the undocked position. Figure 1


04/02 5-40


3.

Remove the Tray 1 Feed Assembly. (Figure 2) a. Remove the (1) screw. NOTE: To access Tray 2 components, remove the (1) screw and pivot the assembly out from the right.

4. Remove the Tray 1 Feed Assembly. (Figure 3) a. Disconnect P791A. b. Remove the K-clip. c. Remove the stud. d. Remove the Feed Assembly.

A

A C

D B Figure 2 Figure 3



04/02 5-41


REP 7.12 Tray 2 Feed Assembly

2.

Open the Left Hand Cover and open the Tray 2 Drawer. (Figure 1)

Removal NOTE: After replacing the Tray 2 Feed Assembly, reset the HFSI counter (NVM 007-804).

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1.

Undock Tray 4 if equipped. (GP 10)

CAUTION Do not open the Tray 4 Paper Drawer when Tray 4 is in the undocked position.


Figure 1

04/02 5-42


3.

Remove the Tray 2 Feed Assembly. (Figure 2) a. Remove the screw.

NOTE: To access Tray 2 components, remove the (1) screw and pivot the assembly out from the right.

4. Remove the Tray 2 Feed Assembly. (Figure 3) a. Disconnect P791B. b. Remove the K-clip. c. Remove the stud. d. Remove the Feed Assembly.

C B

A

D

A Figure 2

Figure 3



04/02 5-43


REP 7.13 Tray 1 / 2 Feed / Nudger Roll Assembly

4.

Removal NOTE: After replacing the Tray 1 / 2 Feed / Nudger Roll Assembly, reset the HFSI counter (NVM 007-800 for Tray 1 and NVM 007-801 for Tray 2).

Remove the Feed / Nudger Roll Assembly. (Figure 2) a. Pinch the (2) ends of the shaft inward. b. Lift the Feed Roll Assembly to remove.

NOTE: If cleaning is required, clean the Feed / Nudger Rolls with a towel dampened with water.


A

1. Undock Tray 4 if equipped (GP 10). 2. Open the Left Hand Cover and open the appropriate Drawer (Tray 1/2). 3. Access the Tray 1/2 Feed Assembly. (Figure 1) a. Remove the (1) screw for the appropriate tray. b. Pivot the Feed Assembly out of the machine from the right.

Tray

B

1 Figure 2


B

Tray

2 Figure 1


04/02 5-44


REP 7.14 Tray 1 / 2 Retard Roll

REP 8.1 Vacuum Transport 1 and 2

Removal / Cleaning

Removal

NOTE: After replacing the Tray 1 / 2 Retard Roll, reset the HFSI counter (NVM 007-800 for Tray 1 and NVM 007-801 for Tray 2).

NOTE: This procedure covers the removal of Vacuum Transport Assembly 1. The procedure to remove the Vacuum Transport Assembly 2 is the same with the exception of disconnecting P/J703B and P/J785B from Vacuum Transport Assembly 2.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. 2.

Remove the Tray 1 / 2 Feed / Nudger Roll Assembly. (REP 7.13) Remove the Tray 1 / 2 Retard Roll Assembly. (Figure 1) a. Push the ends of the Retard Roll Assembly into the bracket and remove. NOTE: If cleaning is required, clean the Retard Roll with a towel dampened with water.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Path Module to the service position. (GP 2) 2. Remove the Vacuum Transport. (Figure 1) a. Disconnect P/J703A and P/J785A from Vacuum Transport Assembly 1. b. Loosen the 3 screws securing the Vacuum Transport 1 to the Transport Drawer. Slide the Vacuum Transport 1 to the front of the machine and lift to remove.

A

B A B

B

A Figure 1 (bottom view)

Figure 1




04/02 5-45


REP 8.2 Vacuum Transport 1 and 2 Paper Sensor Cleaning

3. Clean the Paper Sensors. (Figure 2) a. Clean the Paper Sensors with a dry cotton swab

Cleaning


A

NOTE: For general cleaning, the Paper Sensors can be cleaned with cotton swab through the Guide Plate without removal of the vacuum transports (reference figure 1). If the Transport related Fault Code does not clear, proceed with the removal of the sensor for a thorough cleaning.

A

1. Remove the Vacuum Transport 1 and / or 2. (REP 8.1) 2. Cleaning the Paper Sensors. (Figure 1) a. Slide the Guard Plate open.

Figure 2

Replacement NOTE: When reinstalling Sensor Bracket, the position is not fixed. Ensure Bracket is biased properly to line up with opening of Plate.

A


Figure 1


04/02 5-46


REP 8.3 Horizontal Transport 1

Replacement

Removal

CAUTION Be careful not to damage the connectors when installing the Transport. Be sure the Wire Harness is routed correctly behind the spring. (Figure 2)

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the IOT Front Doors. 2. Remove the Horizontal Transport 1. (Figure 1) a. Remove the Connector Cover (1 screw), and disconnect P/J779 and P/J780. b. Remove the (2) screws securing the Horizontal Transport 1 to the frame.

Spring

CAUTION Be careful not to damage the connectors when removing the Transport. c. Remove the Horizontal Transport 1 by pulling the Transport forward.

Figure 2 1. Replace in reverse order.

A B B Figure 1


04/02 5-47


REP 8.4 Horizontal Transport 2 Removal

CAUTION Be Careful not to damage the Connectors when removing the Transport 2. c. Remove the Horizontal Transport 2 by pulling the Transport forward.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the IOT Front Doors. 2. Remove the Horizontal Transport 2. (Figure 1) a. Remove the Connector Cover (1 screw), and disconnect P/J788, P/J782, and P/J781. b. Remove the (2) screws securing the Horizontal Transport 2 to the frame.

A B B

Figure 1


04/02 5-48


REP 8.5 Horizontal 1 Transport (5) Path Sensor 1, 3, and 4

Replacement

CAUTION Be careful not to damage the connectors when installing the Transport. Be sure the Wire Harness is routed correctly behind the spring. (Figure 2)

Removal / Cleaning NOTE: This procedure covers the removal of the Horizontal Transport Path Sensor 1. The procedures for removing the Horizontal Transport Path Sen- sors 1, 3, and 4 are identical with the exception of disconnecting J221, J223, and J224 from the respective Sensor.

Spring


Remove the Horizontal 1 Transport (5) and note the position of the Path Sensors. (REP 8.3) (Figure 1)

Figure 2

Path Sensor 1


Path Sensor 2

Path Sensor 3 Figure 1


04/02 5-49


2. Clean Clean the the Path Path Sensor. Sensor. (Fig (Figure ure 2) 2) a. Remove the (1) screw and the cover. b. Slide the sensor out of the bracket and clean the sensor with a cotton swab.

REP 8.6 Horizontal 2 Transport (6) Path Sensor 5 and 8 Removal / Cleaning NOTE: This procedure covers the removal of Horizontal Transport Path Sensor 5. The procedures for removing the Horizontal Transport Path Sen- sors 8 is identical with the exception of disconnecting J225 or J228.

A

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove Horizon Horizontal tal 2 Transport Transport (6) and and note the positio position n of the Path Path sensors. (REP 8.4) (Figure 1)

B

Path Sensor 8

Path Sensor 5

Figure 2

Replacement NOTE: When installing the sensor, connect the connector before installing the sensor. 1. Rep Replac lace e in in reve reverse rse order. order.

Figure 1


04/02 5-50


REP 8.7 Registration In / Out Sensor Cleaning

2. Clean Clean the the Path Path Sensor. Sensor. (Fig (Figure ure 2) 2) a. Remove the (1) screw. b. Slide the sensor out of the bracket. c. Clean the sensor with a cotton swab.

Removal / Cleaning NOTE: This procedure covers the removal of the Registration In Sensor. The procedure for removing the Registration Out Sensor is identical with the exception of disconnecting P/J 108 from the Registration Out Sensor.

A

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Path Path Module Module to the the service service position. position. (GP 2) 2. Rem Remove ove the the Front Front Top Cover. Cover. (Fig (Figure ure 1) a. Remove (2) screws. b. Lift off the Front Top Cover.

B

B Figure 2

Replacement NOTE: When installing the sensor, connect the connector before installing the sensor.

A

1. Rep Replac lace e in in reve reverse rse order. order.

Figure 1


04/02 5-51


3. Clean Clean the the Path Path Sensor. Sensor. (Fig (Figure ure 2) 2) a. Remove the (2) screws b. Slide the sensors out of the brackets and clean with a cotton swab or dry lintless cloth.

REP 8.8 Aligner Path Sensor Cleaning Removal / Cleaning


A

1. Open the Paper Path Path Module Module to the the service service position. position. (GP 2) 2. Remove the Paper Paper Path Module Module Left Left Front Cover. (Figure (Figure 1) a. Remove (3) screws. Lift the 4a handle to access the front screws. b. Remove the Paper Path Module Left Front Cover.

B A

Figure 2

A

Replacement NOTE: When installing the sensor, connect the connector before installing the sensor.

A

1. Rep Replac lace e in in reve reverse rse order. order.

A

Figure 1


04/02 5-52


3. Note the position position of the (3) Aligner Aligner Path Path Sensors. Sensors. (Figure (Figure 2)

4. Clean the (3) Aligner Aligner Path Sensors. Sensors. (Figure (Figure 3) a. Remove the (1) screw. b. Slide the Sensor out of the bracket and clean with film remover and a water moistened, lint free cloth.

Sensors

2

A

B Figure 2 Figure 3



04/02 5-53


REP 8.9 Aligner Nip / Release Home Sensor Cleaning

3. Note the position position of the the (3) Aligner Aligner Nip / Release Release Home Home Sensors. Sensors. (Figure 2)

Removal / Cleaning

Sensors WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Path Path Module Module to the the service service position. position. (GP 2) 2. Remove the Paper Paper Path Module Module Left Left Front Cover. Cover. (Figure (Figure 1) 1) a. Remove (3) screws. Lift the 4a handle to access the front screws. b. Remove the Paper Path Module Left Front Cover.

Figure 2

A A A

Figure 1


04/02 5-54


4.

Clean the (3) Aligner Nip / Release Home Sensors. (Figure 3) a. Clean the (3) Aligner Nip / Release Home Sensors with a dry cotton swab.

REP 8.10 Registration Side Shift Sensor Cleaning Removal / Cleaning


2

1. 2.

A

Open the Paper Path Module to the service position. (GP 2) Remove the Paper Path Module Left Front Cover. (Figure 1) a. Remove (3) screws. b. Remove the Paper Path Module Left Front Cover.

A A

B A

Figure 3


A A Figure 1


04/02 5-55


3.

Remove the Side Shift Sensor Assembly. (Figure 2) a. Remove (1) screw. b. Carefully pull the Side Shift Sensor Assembly out of the Registration Aligner Assembly.

4. Clean the Side Shift Sensor. (Figure 3) a. Clean the Side Shift Sensor with a dry cotton swab.

A 2

B

A Figure 3


Figure 2


04/02 5-56


REP 8.11 Offset Home / Offset Position Sensor Cleaning

2. Remove the Tab Covers. (Figure 2) a. Remove the (2) screw. b. Lift off the (2) Tab Covers.

Cleaning


B A

1. Remove the Offset Catch Tray. (Figure 1) a. Disconnect the connector. b. Remove the (1) screw. c. Move the Offset Catch Tray to the right to release the Assembly from the frame and remove.

Figure 2

B

C

A

Figure 1


04/02 5-57


3. Release the Tabs. (Figure 3) a. Release the (2) Shaft Tabs but do not remove the Shafts.

4. 5.

Flip the Assembly Support over as it is still connected. Clean the Offset Home and Offset Position Sensors with a dry cotton swab. (Figure 4)

A

2

Sensors

Figure 3

Figure 4



04/02 5-58


REP 9.1 Drum Assembly

3.

Loosen the Xerographic Module screws. (Figure 2) a. completely loosen the (3) captive Xerographic Module screws.

Removal NOTE: All (4) Drum Assembly removal procedures are identical. NOTE: After replacing the Drum Assembly, reset the HFSI counter (NVM 009-820 for Drum Assembly (Y), 009-822 for Drum Assembly (M), 009-824 for Drum Assembly (C), and 009-826 for Drum Assembly (K).

A WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. 2.

Open the Front Doors and remove the Upper Inner Cover. (REP 13.1) a. Lift the green Handle (4) to lower the Paper Path Module and b. release the (2) Camming Levers for the IBT Module. (Figure 1)

Figure 2

B B

A

Figure 1


04/02 5-59


4. Pull the Xerographic Module out to the service position. (Figure 3) a. Pull out the bottom of the Handle. b. Using the Handle, pull the Xerographic Module out to the service position.

5. Remove the Drum Assembly. (Figure 4) a. Rotate the Drum Assembly Retaining Latch CCW and then pull it out of the Front Plate. b. Bias the Drum Assembly to the front of the Xerographic Module. c. Pull the Drum Assembly straight out from the Xerographic Module to remove it.

A

A B C Figure 3

Figure 4

CAUTION Do Not expose the Drum Assembly to light for more than one minute or Light Shock will occur. Place the Drum Assembly in a Black Protective Bag after removing it from the machine.

6. Immediately store the Drum Assembly in the black protective bag and ensure that the assembly is not stored with the Drum side down.

Replacement NOTE: Upon replacement, gently tighten the Drum support screws evenly, especially the Drum drive screw. This is too avoid binding the Xerographic Module. NOTE: Use the Kynar dusting pouch and lightly tap the length of the Drum to ensure the proper lubrication. 1. Replace in reverse order. 2. Perform Max Setup. (ADJ 9.1)


04/02 5-60


REP 9.2 Charge Corotron / Screen

1. Remove the Drum Assembly. (REP 9.1) 2. Remove the Charge Corotron Assembly. (Figure 1) a. Remove (1) screw. b. Remove the Charge Corotron Assembly.

Removal NOTE: All (4) Charge Corotron and Screen Assembly removal procedures are identical. NOTE: There is not an HFSI Counter for the Charge Corotron or Screen, so you must track your activities on your service log.

A

B

NOTE: The Charge Corotron and the Screen should be changed at the same time.


CAUTION Do Not expose the Drum Assembly to light for more than one minute or Light Shock will occur. Place the Drum Assembly in a Black Protective Bag when you are not performing any maintenance on it. Figure 1

WARNING Always wear eye protection when removing the Spring and the Charge Corotron Screen.


04/02 5-61


3. Remove the Charge Corotron Screen. (Figure 2)

Replacement 1. Install the Screen on the inboard side of the Drum Assembly. (Figure 3) a. Make sure the Screen is properly seated on the notch in the frame. (Figure 3)

a. Using a small flat blade screwdriver, carefully release the Spring that secures the Screen to the Drum Assembly. b. Carefully remove the Screen and avoid contact with the edges of the Screen.

A

B

A Figure 2 Figure 3


04/02 5-62


2.

Install the Screen on the outboard side of the Drum Assembly. (Figure 4). a. Hold the Screen through the slot in the Drum Assembly Frame. b. Attach the Spring through the slot in the Screen. c. Push the bottom of the Spring into the frame until it locks into position.

REP 9.3 Xerographic Module Removal NOTE: All (4) Xerographic Module removal procedures a re identical.


A

CAUTION The Xerographic Module is heavy. Use Caution when removing the Xerographic Module. 1.

B

Pull the Xerographic Module out to the service position. (Reference REP 9.1)

C

Figure 4


04/02 5-63


REP 9.4 BPO Magnetic Roll Assembly Cleaning

2. Remove the Xerographic Module. (Figure 1) a. Remove the Module while pressing in on the slide locks on both sides of the Module.

Removal / Cleaning NOTE: All (4) BPO Assembly removal procedures are identical. After cleaning a BPO Assembly, reset the HFSI counter (NVM 009-804 for BPO Assembly (Y), 009-805 for BPO Assembly (M), 009-806 for BPO Assembly (M), and 009-807 for BPO Assembly (K).


A 1.

Remove the appropriate Drum Assembly and place in a protective bag. (REP 9.1)

Figure 1

Replacement 1. Replace in reverse order. 2. Perform Max Setup (ADJ 9.1)


04/02 5-64


2. Remove the Pretransfer Corotron. (Figure 1) a. Remove (1) screw. b. Remove the Pretransfer Corotron.

3. Remove the BPO Assembly. (Figure 2) a. Remove (1) screw. b. Slide the BPO Assembly to the right to release the pin on the left side of the Assembly c. Remove the BPO Assembly. d. Vacuum out the BPO Assembly.

B

C A

B

Figure 1 (Bottom view of the Xerographic Module shown outside of the machine)

A

Figure 2 (Bottom view of the Xerographic Module shown outside of the machine)

Replacement 1. Make sure the BPO Assembly is seated correctly on the locating tab. 2. Replace in reverse order.


04/02 5-65


REP 9.5 IBT Belt Cleaner Assembly / Cleaner Brush Assembly

2. Locate the IBT Module Prop Rod. (Figure 1)

Removal / Cleaning NOTE: After replacing Cleaner Brush Assembly, reset the HFSI counters (NVM 009-851)


Prop Rod

Pull the IBT Module Drawer to the Service Position. (GP 2)

Figure 1


04/02 5-66


3.

Position the Prop Rod to help support the weight of the IBT Module. (Figure 2)

4. Remove the IBT Cleaner Assembly. (Figure 3) a. Disconnect J357. b. Loosen the screw securing the IBT Cleaner Assembly to the IBT Assembly. c. Slide the IBT Cleaner Assembly Forward to remove.

A B C Figure 2

Figure 3


04/02 5-67


4. If cleaning is required, vacuum out the brush area while turning the gear. (Figure 4)

5. If the removal of the Cleaner Brush Assembly is required, perform the following: (Figure 5) a. Remove the Belt Cleaner Blade and the Film Seal Assembly. (REP 9.6) b. Remove (4) screws (2 front and 2 rear) c. Lift up the on the front and rear pads to remove the Cleaner Brush Assembly.

Gear

C

B Brush Area

A Figure 4

B Figure 5

Replacement NOTE: Upon replacement, ensure that the Locating Pins engage the holes in the Rear IBT Assembly Frame. 1. Replace in reverse order.


04/02 5-68


REP 9.6 Belt Cleaner Blade / Film Seal Assembly

4.

Removal NOTE: After replacing the Cleaner Blade Assembly and the Film Seal Assembly, reset the HFSI counters (NVM 009-842 and 009-852).

Remove the Cleaner Blade Assembly. (Figure 1) a. Remove (2) screws. (front and rear) b. Remove the Cleaner Blade Assembly c. Remove (2) screws. (front and rear) d. Remove the Film Seal Assembly

A B

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. 2. 3.

Pull the IBT Module drawer to the Service Position. (GP 2) Raise the IBT Module to the Service Position. Remove the IBT Belt Cleaner Assembly. (REP 9.5)

C D Figure 1



04/02 5-69


REP 9.7 Belt Home Position Sensor 1 Cleaning

REP 9.8 Belt Home Position Sensor 2 Cleaning

Removal Removal WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull the IBT Module drawer to the Service Position. (GP 2) 2. Raise the IBT Module to the Service Position. 3. Remove the IBT Belt. (REP 9.9) 4. Cleaning the Belt Home Position Sensor 1 (Figure 1). a. Clean the Sensor.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. 2. 3. 4.

Pull the IBT Module drawer to the Service Position. (GP 2) Raise the IBT Assembly to the Service Position and install the prop rod. Remove the IBT Belt. (REP 9.9) Clean the Belt Home Position Sensor 2 (a). (Figure 1)

A

Figure 1

Replacement

Figure 1

NOTE: Clean the Belt Home Position Sensor 2 before replacing the IBT Belt. (REP 9.8)

Replacement NOTE: Clean the Belt Home Position Sensor 1 before replacing the IBT Belt. (REP 9.7)




04/02 5-70


REP 9.9 IBT Belt

3. Locate the IBT Module Prop Rod. (Figure 2)

Removal NOTE: After replacing the IBT Belt, reset the HFSI counter (NVM 009-847).


Pull the IBT Module drawer to the Service Position. (GP 2)

Prop Rod

CAUTION Failure to pull the IBT Module Drawer to the Service Position before raising the IBT Module will result in severe damage to the IBT Belt. 2.

Raise the IBT Module to the Service Position. (Figure 1) a. Grab the IBT Module Handle and lift. The IBT Module will lock into place.

Figure 2

A

Figure 1


04/02 5-71


4.

Position the Prop Rod to help support the weight of the IBT Module. (Figure 3)

5. Remove the IBT Cleaner Assembly. (REP 9.5) 6. Remove the POB Jam Sensor Assembly, and the Paper Guide Assembly. (Figure 4) a. Loosen (1) screw. b. Disconnect the Connector and release the harness from the clamp. c. Pull forward to remove the POB Jam Sensor Assembly. d. Loosen (1) screw and move the Paper Guide forward to remove.

B A

D

C Figure 3

Figure 4


04/02 5-72


7.

Release the tension on the IBT Belt (Figure 5). a. Release the tension on the IBT Belt by rotating the Tension Lever clockwise.

8. Remove the Prop Rod. 9. Remove the IBT Belt by pulling from both sides of the IBT Module. You may have to rotate the belt slightly in a clockwise manner. (Figure 6)

A

Figure 6 Figure 5 10. Place the IBT Belt in a safe place.

CAUTION The IBT is easily damaged, handle the belt with care. Oils from your hands may affect the image quality. Use plastic gloves when handling the belt, and place it on a clean flat surface.


04/02 5-73


1.

Replacement NOTE: Upon replacement, ensure that the Reflective Tape on the inside of the IBT Belt is toward the front of the machine. (Figure 7)

Before replacing the IBT Belt, clean the Belt Home Position Sensors 1 and 2. (REP 9.7 and 9.8)

CAUTION The IBT is easily damaged, handle the belt with care. Oils from your hands may affect the image quality. Use plastic gloves when handling the belt, and place it on a clean flat surface.

Reflective Tape

2.

Install the IBT Install Assist Tool. (Figure 8) a. Remove the Assist Tool from the IBT Module Storage Compartment b. Install the IBT Install Assist Tool with the flared edge towards the rear

Flared Edge

Figure 7

A

Figure 8


04/02 5-74


3. Install the IBT Belt over the Assist Tool. 4. When the IBT Belt is in position in the middle of the rolls, remove the IBT Belt Install Tool. 5. When you apply tension on the Belt, make sure there are no wrinkles. If there are, de-tension the Belt and adjust the Belt to the center of the rolls on both sides of the IBT Module. Slowly reapply tension. 6. Dust the IBT Belt using the Kynar Dusting Pouch once, along the width of the Belt. 7. Continue steps in reverse order. 8. When adding a new IBT Belt, enter diagnostics and select DC956 Belt Edge Learn Mode. If you are reinstalling the old one, go to the next step. 9. Perform Max Setup (ADJ 9.1)

REP 9.10 1st BTR (Bias Transfer Roll) and Bearing Removal NOTE: All (4) 1st Bias Transfer Roll removal procedures are identical. NOTE: After replacing the 1st BTR (1-4), reset the HFSI counter (NVM 009- 849).


CAUTION Failure to pull the IBT Module Drawer to the Service Position before raising the IBT Module will result in severe damage to the IBT Belt.

CAUTION Do not touch the foam part of the BTR. Handle the BTR by the metal shaft.

WARNING Always wear eye protection when removing the Spring and the Bearing. 1. Remove the IBT Belt. (REP 9.9) 2. Lower the IBT Assembly by raising it slightly and releasing the lever.


04/02 5-75


3.

Lift the rear end of the 1st BTR out of the spring loaded clamps, then remove the front end of the BTR out of the 1st BTR Housing. (Figure 1)

4. Remove the Bearing (Figure 2) a. While holding down the Bearing and the Spring, loosen the (1) screw. b. Tilt the Bearing Housing away from the Spring and Bearing. c. Lift out the Spring and the Bearing.

1st BTR

B

Figure 1

A Figure 2


04/02 5-76


2.

Replacement NOTE: Transfer the Plastic End Caps onto the new Bias Transfer Roll if they are not already on the new Roll. 1.

Compress the Spring and the Bearing into the Housing and tighten the (1) screw. Push down on the Bearing to see if it has been installed properly. (Figure 4)

Place the old spring on to the new bearing and position the assembly over the pin on the BTR Housing. (Figure 3)

Screw Pin Figure 4 Figure 3


04/02 5-77


3.

REP 9.11 IBT Inner Cleaner Brush

The 1st BTR Roll is not reversible. Install the Roll so that the end of the Roll with the longer shaft is at the front of the IBT Module and inserted first. (Figure 5)

Removal NOTE: After replacing the Inner Cleaner Brush, reset the HFSI counter (NVM 009-846).

Longer Shaft



Figure 5 4. Replace in reverse order. 5. Perform the Max Setup Adjustment. (ADJ 9.1)


04/02 5-78


1. Remove the IBT Belt. (REP 9.9) 2. Remove the IBT Inner Cleaner Brush. (Figure 1) a. Remove the K-clip securing the Cleaner Brush to the IBT Assy. b. Remove the Sprocket.

3. Lift the IBT Inner Cleaner Brush from the bottom and remove. (Figure 2)

A

Brush

B

Figure 2 Figure 1



04/02 5-79


REP 9.12 2nd BTR Back Up Roll Assembly

2.

Disconnect the (red) LVPS power connector (A) from the 2nd BTR Back Up Roll Assembly. (Figure 1)

Removal NOTE: After replacing the 2nd BTR Back Up Roll Assembly, reset the HFSI counter (NVM 009-850).

A WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7)


WARNING Avoid coming in contact with metal frame edges on the IBT Frame while performing this procedure.

Figure 1

1. Remove the IBT Belt. (REP 9.9)


04/02 5-80


3.

REP 9.13 ADC Sensor Cleaning

Remove the 2nd BTR Back Up Roll Assembly. (Figure 2) a. Remove the 3 screws securing the Support Plate.

Removal / Cleaning

NOTE: Support the 2nd BTR Back Up Roll Assembly while doing Step 3b. b. Remove the Support Plate securing the 2nd BTR Back Up Roll.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) NOTE: Both ADC Sensor Assembly removal procedures are identical.

A B

1. Remove the IOT Upper Front Cover. (GP2) 2. Access the MOB / ADC Sensor Bracket. (Figure 1) a. Disconnect P/J764. b. Remove the (2) screws and the (2) ground wires. c. Pull out the MOB / ADC Sensor Bracket.

A

B

Figure 2

Replacement

CAUTION Ensure that Ground Clips are contacting the inside Rear Frame.

B

NOTE: Secure the High Voltage Lead prior to installing Bracket.

C


A Figure 1


04/02 5-81


3. Remove the ADC Sensor. (Figure 2). a. Remove (3) screws and the ADC Sensor Assembly.

4. Clean the ADC Sensor. (Figure 3) a. Clean the ADC Sensor with a dry lint-free cloth or a dry cotton swab.

NOTE. The ADC Sensor remains connected.

A

A A Figure 3

Figure 2

Replacement NOTE: After cleaning the ADC Sensor, clean the MOB Sensor. (REP 6.1) 1. Replace in reverse order.


04/02 5-82


REP 9.14 2nd BTR Roll Assembly

3.

Disconnect the High Voltage Lead from the Detack Corotron. (Figure 2)

Removal / Cleaning NOTE: After replacing the 2nd BTR Roll Assembly, reset the HFSI counter (NVM 009-841).


Open the Paper Handling Module Drawer to the Service Position. (GP 2) 2. Remove (3) screws and the Paper Handling Module Drawer middle cover. (Figure 1)

Lead

Figure 2

2

Figure 1


04/02 5-83


4.

Remove the Detack Corotron (A) by pivoting it CCW, and lifting it out. (Figure 3)

5.

Remove the (2) screws securing the 2nd BTR Roll Assembly. a. Remove the (2) screws securing the 2nd BTR Roll Assembly to the Transfer Module Drawer. (Figure 4)

Note: If cleaning is required, use a lift-free cloth moistened with water.

A

A

Figure 3

Figure 4


04/02 5-84


6.

Push down on the Idler to release the 2nd BTR Assembly. (Figure 5)

7.

Idler

Remove the 2nd BTR Roll Assembly by pivoting it up and to the right of the bracket to remove it from the Paper Handling Module Drawer. (Figure 6)

Bracket

Figure 5

Figure 6


04/02 5-85


Replacement

REP 9.15 Suction Blower / Dust Blower Filters

NOTE: Make sure that the metal tab on the Detack Corotron engages the High Voltage Lead in the middle of the connector. (Figure 7)

Removal


Tab

NOTE: All (4) Filter removal procedures are identical and should be replaced at the same time.

NOTE: After replacing the Filters, reset the HFSI counter (NVM 004-810 for the Suction Blower Filter and 004-812 for the Dust Blower Filter).

1. Remove (6) screws and the Ecology Module Upper Rear Cover. (Figure 1)

1

Figure 7

1

1.

Before replacing it, carefully brush out the Detack Corotron as not to damage the coronode pins. 2. Replace in reverse order

1

Figure 1


04/02 5-86


2. Note the position of the Filter Assemblies. (Figure 2)

3. Remove the Air Intake Assembly by releasing the two clips (A) securing it in place, and rocking it upwards to free it of the Filter Assembly. (Figure 3)

Dust Blower Filters

A

Suction Blower Filters

Figure 2

Figure 3


04/02 5-87


REP 9.16 Ozone Filter

4. Remove the Filter. (Figure 4)

Removal NOTE: After replacing the Ozone Filter, reset the HFSI counter (NVM 004- 811).

Filter WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove (1) screw to access the Ozone Filter. (Figure 1)

1 Figure 4


Figure 1


04/02 5-88


REP 9.17 C-Pop Sensor / Exit Transport Path Sensor Cleaning

2. Remove the Ozone Filter. (Figure 2)

Removal


Filter

Remove the Top Cover on the Output Transport Module (OTM). (Figure 1) a. Open the OTM Front Door. b. Loosen the (2) Front Screws. c. Remove the (2) Rear Screws. d. Lift and Remove the OTM Top Cover.

C Figure 2

D


B A Figure 1


04/02 5-89


2.

Remove the Exit Transport Assembly. (Figure 2) a. Disconnect P/J 734 and 728. b. Remove (3) screws. c. Remove the Exit Transport Assembly.

3.

Clean the Exit Transport Path Sensor. (Figure 3) a. Remove (1) screw. b. Slide the Sensor out of the bracket. c. Clean the Path Sensor with a dry cloth or a cotton swab.

A

A B

C B

B

Figure 2 Figure 3


04/02 5-90


4. Disconnect J105. (Figure 4)

6.

Clean the (4) C-Pop Sensor windows inside the Assembly with a dry lint-free cloth. (Figure 6)

J 105

A Figure 4 5.

Remove the C-Pop Sensor Assembly. (Figure 5) a. Remove the (3) screws b. Remove the C-Pop Sensor Assembly

Figure 6

B

A Figure 5


04/02 5-91


7.

REP 9.18 CC Filter

Clean the (4) C-Pop Sensors (A) with a dry lint-free cloth. (Figure 7)

Removal NOTE: There is one HFSI Counter for all four CC Filters. Replace all (4) fCC Filters at the same time. After replacing the CC Filters (1-4), reset the HFSI counter (NVM 009-828).

A


Remove the Drum Assembly (REP 9.1). Be sure to place the Drum Assembly in the Black Protective Bag. 2. Remove the Xerographic Module (9.3)

Figure 7



04/02 5-92


3.

Disengage the Side Rail from the rear of the Xerographic Module but do not remove. (Figure 1) a. Remove (1) screw. b. Allow the Side Rail to drop but still connected to the front of the Xerographic module.

4. Remove the Duct. (Figure 2) a. Slide the Duct to the left to release the (2) pins and lift the Duct to remove.

B

A

A

Figure 2

Figure 1


04/02 5-93


5. Remove the CC Filter (Figure 3). a. Turn the Duct up-side-down to access the Filter. b. Remove the Filter by bending it slightly to release the Tabs at each end.

REP 9.19 Developer Replacement Removal NOTE: All four developer removal procedures are identical. NOTE: The funnel supplied is not used on this product. NOTE: After replacing the Developer, reset the HFSI counter (NVM 009- 800 for (Y), 009-801 for (M), 009-802 for (C) and 009-803 for (K)).

CC Filter

1. 2.

On the User Interface Control Panel, press the Access button. Enter the Tools Password (11111 as the default) on the key pad and select the Enter button on the UI screen. 3. Select TKO Pathway. 4. Open the Front Doors and remove the IOT Upper Front Cover. (REP 13.1)) 5. Lower the Paper Path Module and move the IBT Module Latching Handles to the unlocked position. 6. Place a drop cloth on the floor under the Developer Housing. 7. Select DC955 Exchange Developer Mode and then select Discharge Mode. The screen will direct you to perform the necessary steps.

Figure 3



04/02 5-94


8.

Attach the Recovery Bag around the Developer Assembly. (Figure 1) a. Carefully position the bag around the dump assembly.

9.

Pull the Discharge Shutter open for the color being replaced. (Figure 2)

A

Bag removed for clarity

Figure 1

9

Figure 2


04/02 5-95


10. Adjust the Recovery Bag. (Figure 3) a. Adjust the Recovery Bag so to bottom edge of the bag is caught on the rear of the Discharge Shutter. This action will prevent the possibility of the Recovery Bag getting caught up in the Developer Housing Gears.

Developer Replacement 1. Position the Developer Assembly Filler Guide. (Figure 4) a. Loosen the screw.

Gears

A A

Figure 4

Figure 3 11. Return to the User Interface, and select the appropriate color. 12. Review the screen to make sure all the steps have been performed and select Confirm. 13. Select the Start button on the UI Control Panel. 14. When the recovery cycle is complete, rerun the routine one more time. (step 11) 15. After completing the second recovery cycle, close the Discharge Shutter and remove the Recovery Bag.


04/02 5-96


REP 9.20 Detack Corotron

b. Pull the Toner Dispense Chute out until it clicks into place. (Figure 5)

Removal / Cleaning


Open the Paper Handling Module Drawer to the Service Position. (GP 2) 2. Remove (3) screws and the Paper Handling Module Drawer middle cover. (Figure 1)

B

2 Figure 5 2. 3. 4. 5. 6. 7. 8. 9. 10.

Close out of the existing screen and select the Replenish. Select the appropriate colors. Select Confirm and select the Start button on the UI Control Panel. Add developer while the routine is running. When finished, move the Filler Guide back to it original position and retighten screw. Raise the Camming Levers for the IBT Module. Raise the Paper Path Module. Reinstall the Upper Front Cover. Reset the HFSI counter(s). (GP 4) Perform the Max Setup Adjustment. (ADJ 9.1)


04/02 5-97

Figure 1


3.

Disconnect the High Voltage Lead from the Detack Corotron. (Figure 2)

4.

Remove the Detack Corotron (A) by pivoting it CCW, and lifting it out. (Figure 3)

Lead

A

Figure 2


Figure 3

04/02 5-98


REP 9.21 POB Jam Sensor Cleaning

Replacement 1.

If replacing the old Detack Corotron Assembly, carefully brush out the Detack Corotron as not to damage the coronade pins. 2. Make sure that the metal tab on the Detack Corotron engages the High Voltage Lead in the middle of the connector. (Figure 4)

Removal

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. 2.

Tab

Pull the IBT Module drawer to the Service Position. (GP 2) Raise the IBT Module to the Service Position. (Figure 1) a. Grab the IBT Module Handle and lift. The IBT Module will lock into place.

A Figure 4 3. Replace in reverse order. Figure 1


04/02 5-99


3. Remove the POB Jam Sensor Assembly. (Figure 2) a. Loosen (1) screw. b. Disconnect the Connector and release the harness from the clamp. c. Pull forward to remove the POB Jam Sensor Assembly.

4. Clean the POB Jam Sensor. (Figure 3) a. Clean the POB Jam Sensor with a dry cloth or a cotton swab.

4

B A

C Figure 3

Replacement 1. Replace in reverse order. Figure 2


04/02 5-100


REP 9.22 Waste Toner Bottle / Waste Bottle Full Sensor Cleaning

3.

Cleaning

To access the Waste Bottle Full Sensor. (Figure 1) a. Remove the Offset Catch Tray (refer to REP 8.11) or undock the Stacker Stapler or other accessory, is present. b. Pull open the Waste Toner Bottle Door. c. Remove the (6) screws and the Right Side Cover.

NOTE: After replacing the Waste Toner Bottle, reset the HFSI counter (NVM 009-829).

B WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7)

C

1.

Place a drop cloth under the Waste Bottle Door at the back of the Exit Module. 2. To access the Waste Bottle, open the Waste Bottle Door, lift out the Waste Bottle and cover the opening with the cap found on the side of the bottle. Vacuum out the door cavity and insert the new bottle. (reference Figure 1). Dispose of the Waste Toner Bottle according to Local Regulations.

Figure 1


04/02 5-101


4.

Note the position of the Waste Toner Bottle Full Sensor Assembly. (Figure 2)

5.

Clean the Waste Toner Bottle Full Sensor. (Figure 3). a. Clean the Waste Toner Bottle Full Sensor with a dry lint-free cloth.

4

A

Figure 2

Figure 3



04/02 5-102


REP 9.23 Pretransfer Corotron

REP 10.1 Camming Open the Fuser Assembly

Removal

Removal

NOTE: Although all 4 Xerographic Modules have a Pretransfer Corotron Assembly, only the K module has a corotron wire and only that assembly is replaced. NOTE: After replacing the Pretransfer Corotron Assembly, reset the HFSI counter (NVM 009-840).

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove the (K) Drum Assembly. (REP 9.1) 2. Remove the Pretransfer Corotron. (Figure 1) a. Remove the (1) screw. b. Remove the Pretransfer Corotron Assembly.


WARNING Allow the Fuser to cool before performing this procedure.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1.

B

Pull out the Transport Drawer to the service position. (GP 2)

A Figure 1

Replacement .1. Replace in reverse order.


04/02 5-103


2. Remove the Fuser Covers. (Figure 1) a. Remove the 4e Handle b. Remove (1) screw. c. Loosen (2) and the Front Cover. d. Remove the (2) screws and the Top Cover e. Loosen the (1) screw and the Rear Cover

3. Removing the Front Cam Screws. (Figure 2) a. Remove the collar screw first. b. Remove the second screw.

E

D

B

A

B

Figure 2

A C

C Figure 1


04/02 5-104


4. Removing the Rear Cam Screws. (Figure 3) a. Remove the collar screw first. b. Remove the second screw.

5. Lift open the Fuser Assembly. (Figure 4) a. Place your hands on both sides of the Fuser Assembly. b. Lift open the Fuser Assembly.

A

A

B A Figure 4 Figure 3


04/02 5-105


6.

Note the position of the cammed open Fuser Assembly (Figure 5)

REP 10.2 Fuser Belt Assembly Removal



Figure 5



WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Cam open the Fuser Assembly. (REP 10.1)

04/02 5-106


2.

Remove the Pressure Roll Finger Bracket. (Figure 1) a. Remove the screws (2).

3.

A

Disconnect the Front Inlet Roll Heater Rod and Inlet Roll Thermistor. (Figure 2) a. Disconnect J245 and release the wire from the clamp. (Front Heater Rod) b. Disconnect P133 and release the wire from the clamp. c. Release the Front Spring Roller Assembly.

A

C B Figure 1

Figure 2


04/02 5-107


4.

Disconnect the Rear Inlet Roll Heater Rod. (Figure 3) a. Disconnect P87 and release the wire from the clamps. b. Release the Rear Spring Roller Assembly.

5.

Reach under the Pad Assembly (A) with both hands and lift out the Fuser Belt Assembly. Note: You might consider putting on a pair of gloves to remove the Fuser Belt Assembly for there could be some residual Fuser Oil that you may come in contact with. (Figure 4)

A A A

B Figure 4 Figure 3


04/02 5-108


REP 10.3 Heat Roll

Replacement NOTE: Be careful not to bend the Fuser Belt Position Sensor Spring Finger during reinstallation. (Figure 5)

Removal NOTE: After replacing the Heat Roll, reset the HFSI counter (NVM 010- 800).


1 WARNING Allow the Fuser to cool before performing this procedure.

Spring Finger WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Cam open the Fuser Assembly. (REP 10.1) Figure 5

1.

When repositioning the Pressure Roll Stripper Finger Assembly, bias it away from the Fuser Belt Assembly. 2. Replace in reverse order.


04/02 5-109


2.

Disconnect P/Js and remove the Heat Rod Bracket. (Figure 1) a. Disconnect P/ J244 and P/ J243. b. Remove (1) screw and the Heater Rod Bracket.

3.

Disconnect P37 and P38 at the rear of Fuser Heater Rods. (Figure 2) a. Disconnect P/J 37 and P38. b. Release the wires from the clamp and the (2) brackets.

B B

A PJs

A Figure 1 Figure 2


04/02 5-110


4.

Carefully remove the Heat Roll Heat Rods (A) by gently pulling them out of the front of the Fuser Assembly. (Figure 3)

5.

Release the Front Heat Roll Retaining Bracket. (Figure 4) a. Loosen (1) the screw to allow the bracket to release from the frame tab. b. Rotate the bracket clockwise to release the Heat Roll.

B A

A

Figure 4

Figure 3


04/02 5-111


6.

Release the Rear Heat Roll Retaining Bracket. (Figure 5) a. Loosen (1) screw to allow the bracket to release from the frame tab. b. Rotate the bracket clockwise to release the Heat Roll.

REP 10. 4 Heat Roll Main Heater Rod Removal


A



B Figure 5 7.

Holding both ends of the Heater Roll, lift it out of the Fuser Assembly.

Replacement 1. Clean the Heat Roll Thermistors before replacing the Heat Roll. (REP 10.9) 2. Straighten out the Heat Rod wires on both ends. 3. While holding the Heat Roll vertically off the edge of your work surface, insert the Heat Rods until the connectors clear the other side. NOTE: The Heat Rods must be aligned properly in the Heat Roll. Ensure that the Heat Rods do not cross inside the roll. 4. Replace in reverse order.


04/02 5-112


2.

Disconnect the P/J and remove the Heat Rod Bracket. (Figure 1) a. Disconnect P/ J244. b. Remove (1) screw and the Heater Rod Bracket.

3.

Disconnect P37 at the rear of Fuser Heater Rods. (Figure 2) a. Disconnect P/J 37. b. Release the wire from the clamp and the (2) brackets. c. Gently pull the Main Heater Rod out of the front of the Fuser Assembly

B B

PJ 244

A

Figure 1 Figure 2

Replacement Note: Before inserting the Heater Rod, straighten out the connector and the wire and gently twist the Heater Rod as it is inserted into the Heat Roll. Make sure the 2 heater rods do not cross inside the Heat Roll. 1. Replace in reverse order.


04/02 5-113


REP 10.5 Heat Roll Sub Heater Rod

2.

Removal

Disconnect the P/J and remove the Heater Rod Bracket. (Figure 1) a. Disconnect P/ J243. b. Remove (1) screw and the Heater Rod Bracket.


B



PJ 243

Figure 1


04/02 5-114


3.

Disconnect P38 at the rear of Fuser Heater Rods. (Figure 2) a. Disconnect P/J 38. b. Release the wire from the clamp and the (2) brackets. c. Gently pull the Sub Heater Rod out of the front of the Fuser Assembly

REP 10.6 Heat Roll Thermistor Cleaning Removal


B WARNING Allow the Fuser to cool before performing this procedure.

A

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Cam open the Fuser Assembly. (REP 10.1) 2. Remove the Heat Roll. (REP 10.3)

Figure 2

Replacement Note: Before inserting the Heater Rod, straighten out the connector and the wire and gently twist the heat rod as it is inserted into the Heat Roll. Make sure the 2 heater rods do not cross inside the Heat Roll. 1. Replace in the reverse order.


04/02 5-115


3.

Clean the Fuser Heat Roll Thermistors with a cloth and film cleaner. (Figure 1) a. Control Thermistor b. Overheat Thermistor c. Sub Thermistor

REP 10.7 External Heat Roll Removal



B

A

C


Pull out the Transport Drawer to the service position.

Figure 1

Replacement 1. Replace in the reverse order.


04/02 5-116



3.

A

E

D

Open the External Heat Roll Assembly. (Figure 2) a. Remove the screws (4) and lift up on the External Frame Assembly. b. Flip the Assembly over in a counterclockwise manner.

B

A

B Figure 2

A C

C Figure 1


04/02 5-117


4.

Disconnect the External Heat Rod (front). (Figure 3) a. Disconnect J246 and remove the wire from the clamps. b. Remove the (1) screw and the bracket.

5.

Disconnect the External Heat Rod (rear). (Figure 4) a. Disconnect J88 and remove the wire from the clamp. b. Remove the (1) screw and the bracket.

A

B

B A Figure 3


Figure 4

04/02 5-118


6. Remove the External Heat Roll. (Figure 5) NOTE: Although Figure 5 shows the External Heat Roll without the Heat Rod, remove the Heat Roll with the Heat Rod in place. a. Lift the External Heat Roll out of the Assembly.

REP 10.8 External Heat Roll Thermistor Cleaning Removal


A




Figure 5

Replacement 1. Clean the External Heat Roll Thermistors before replacing the External Heat Roll. (REP 10.8) 2. Replace in reverse order


04/02 5-119



3.

A

E

D

Open the External Heat Roll Assembly. (Figure 2) a. Remove the screws (4) and lift up on the External Frame Assembly. b. Flip the Assembly over in a counterclockwise manner.

B

A

B Figure 2

A C

C Figure 1


04/02 5-120


4.

Remove the External Heat Roll Thermistors. (Figure 3) a. Remove the (1) screw for the Control Thermistor. b. Remove the (1) screw for the Overheat Thermistor.

A

5. Clean the thermistors. (Figure 4) a. Clean the thermistors with a cloth dampened with film cleaner

B

A

Figure 3 Figure 4



04/02 5-121


REP 10.9 Fuser Web Assembly Removal NOTE: After replacing the Fuser Web Assembly, reset the HFSI counter (NVM 010-804).

3. Remove the Fuser Web Assembly. (Figure 1) a. Remove the (2) screws. b. Rotate the Assembly from the top and pull the Web Assembly out.


1

A

2B

A 1


WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. 2.

Figure 1

Pull out the Transport Drawer to the service position. (GP 2) Open the Duplex Inverter (Handle 4) and the Fuser Exit Chute (Handle 4d).


04/02 5-122


Replacement 1. When replacing the Fuser Web Assembly, make sure to get both pins on each side into the frame rails before pivoting the Assembly up into the proper positon. (Figure 2)

REP 10.10 Fuser Donor Roll Assembly Removal NOTE: After replacing the Donor Roll Assembly, reset the HFSI counter (NVM 010-806).



WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components.

Pins

1.


Figure 2



04/02 5-123



3.

Remove the Fuser Donor Roll Assembly (front). (Figure 2) a. Remove the spring. b. Remove the K-clip and gear. c. Remove the K-clip and slide the bearing off of the shaft.

B A E

D

C B

A

Figure 2 (front)

C

C Figure 1


04/02 5-124


4.

Remove the Fuser Donor Roll Assembly (rear). (Figure 3) a. Remove the spring. b. Remove the clip and gear. c. Slide the bearing off of the shaft.

Replacement

CAUTION Installing the Fuser Donor Roll Assembly incorrectly will damage the Fuser resulting in paper jams or copy quality problems.

B

6.

Install the Donor Roll Assembly. (Figure 4) a. Ensure that the Metering Blade Assembly is in the position shown in the CORRECT Insert shown in Figure 4. b. As the Assembly is lowered into position, allow the Wick Plate Spring to guide the Metering Blade Assembly into the wick channel.

A C Figure 3 (rear) 5.

Lift both ends of the Donor Roll Assembly to remove it from the Fuser Assembly.

Correct Position

Incorrect Position Figure 4


04/02 5-125


REP 10.11 Heat Roll Wick

2. Remove the Fuser Wick. (Figure 1) a. Remove the screws (3). b. Slide the Fuser Wick under the Oiling Pipe and remove.

Removal NOTE: After replacing the Wick, reset the HFSI counter (NVM 010-808).



A WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. NOTE: You may want to wear a pair of gloves to perform this procedure. 1.

Figure 1


Remove the Fuser Donor Roll Assembly. (REP 10.10)


04/02 5-126


REP 10.12 Fuser Oil Filter

2. Remove the Fuser Oil Filter. (Figure 1) a. Remove the filter by lifting up on it.

Removal NOTE: After replacing the Fuser Belt, reset the HFSI counter (NVM 010- 809).

A WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7)


WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. Figure 1 Oil Filter (partially removed)

NOTE: You may want to wear a pair of gloves to perform this procedure. 1.

Remove the Fuser Heat Roll Wick. (REP 10.11)



04/02 5-127


REP 10.13 External Heat Roll Latch Sensor Cleaning

2.

Removal / Cleaning

Clean the Fuser External Heat Roll Latch Sensor. (Figure 1) a. Remove the screw. b. Remove the Sensor bracket, and clean the sensor with a cotton swab.



A B


Flip open the Fuser External Heat Roll Assembly but do not remove. (REP 10 7)

Figure 1



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REP 10.14 Fuser Exit Sensor Cleaning

3. Remove the Fuser Exit Sensor. (Figure 1) a. Remove the screw. b. Clean the Sensor with a cotton swab.

Removal / Cleaning


B WARNING Allow the Fuser to cool before performing this procedure.

A WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. 2.

Pull out the Transport Drawer to the service position. Open the Duplex Inverter (Handle 4) and the Fuser Exit Chute (Handle 4d). Figure 1



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REP 10.15 Heat Roll Finger Assembly

2.

Removal / Cleaning NOTE: After cleaning the Finger Assembly, reset the HFSI counter (NVM 010-807). After replacing the Finger Assembly, reset the HFSI counter (NVM 010-812).

Remove the Fuser Heat Roll Stripper Finger Assembly. (Figure 1) a. Remove the front and rear screws while holding onto the Assembly. b. Carefully remove / clean the Stripper Fingers to avoid damage to the Heat Roll and / or the Fuser Belt Assembly.


A


B WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1.

Remove the Fuser Web Material Assembly (REP 10.9). Figure 1



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REP 10.16 Fuser Walk Sensor

3. Clean the Fuser Walk Sensor. (Figure 1) a. Clean the Fuser Walk Sensor with a dry cotton swab.

Removal



WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. 2.

A

Pull out the Transport Drawer to the service position. Remove the Vacuum Transport Assembly #2. (REP 8.1) Figure 1



04/02 5-131


REP 13.1 IOT Upper Front Cover Removal

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the IOT Front Doors. 2. Remove the Upper Front Cover. (Figure 1) a. Remove (8) screws.

A

A A

Figure 1



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ADJ 9.1 Max Setup (v6.2.2)

3. Press the Accept Key to stop the toggle.

Purpose The purpose of this procedure is to optimize toner density levels and obtain consistent image quality.

DC 934 ADC / ADG Setup 4. Select (N)EXT and press the ACCEPT key.

NOTE: If a fault occurs during any procedure, Call for Service .

a.

The following message will be displayed: DC934 ADC AGC SETUP b. SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

NOTE: The following procedure is to be used with v6.2.2 Machine Software only.

Preliminary Actions

5.

1. Suspend printing at the DFE. 2. Make sure all covers are in place and all the doors are closed. 3. Fix all apparent Image Quality problems (Section 3) and check the Call Flow Procedure (Section 1). 4. Perform Every Call Cleaning Procedure. (Section 1) 5. Replace all HFSI Components at or near threshold. (GP 4) 6. Load 11 x 17 or A3, 24 lb. paper (Color Expressions or an equivalent) into Tray 2. 7. Run 30 prints of the of the DC612 Color Test Pattern List (Pro-Con Test Pattern 5-1) to stabilize Process Control.

a.

The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETE = 312 SECONDS

b. At the completion of the program, the following message will be displayed:

DC934 SET UP COMPLETE: VALUES OK SELECT: (N)EXT (V)IEW (B)ACK (Q)UIT DC 933 VH / VM Setup 6. Select (N)EXT and press the Accept key. a. The following message will be displayed: DC933 VH / VM SETUP SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

Max Setup Adjustment DC 930 Process Control Status 1. Enter the Diagnostic Mode using the DCU. (GP 6) 2. Select Max Setup in the Diagnostic Mode. a. The following message will appear: PLEASE WAIT NVM CHANGE IN PROGRESS

7. Select (S)TART, and press the ACCEPT key. a. The following message will be displayed: PLEASE WAIT, SET UP IN PROGRESS TIME TO COMPLETE = 285 SECONDS

b. When the NVM change is complete, the following message will appear and toggle between lines 2 and 3: DC 930 PROCON SWITCH JUDGE SWITCH STATUS: OK SELECT: (N)EXT (B)ACK (V)IEW (Q)UIT


Select (S)TART, and press the ACCEPT key.

04/02 5-133

b. At the completion of the program, the following message will be displayed: SET UP COMPLETE, VH / VM SETUP OK SELECT: (N)EXT (B)ACK (V)IEW (Q)UIT


DC 918 DC918 Hi Light ASG Bias Adjustment 8. Select (N)EXT and press the ACCEPT key. a. The following message will be displayed and toggle lines 2 and 3:

DC918 HI-LT. MAN. SETUP: IB / OB ASG BIAS SCREEN DESIGNATION = 300-0, TRAY 2 30 mm

DC918 HI-LT. MAN. SETUP: IB / OB ASG BIAS SELECT: (S)TART (N)EXT (B)ACK (Q)UIT 9. Press the ACCEPT key to stop the toggle. 10. Select (S)TART, and press the ACCEPT key. a. The following message will be displayed:

PLEASE WAIT, SETUP IN PROGRESS CHECK IB / OB DENSITY @ COMPLETION b. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern: IB / OB DENSITY OK? SELECT: (N)EXT (A)DJUST Outboard

Inboard

DC 918 Adjustment Check: Using the test print in the output tray, visually check the entire print and compare the side to side density 30 mm in from each side. The density of the inboard side of the print is fixed. The density of the OB side of the print is adjustable. (Figure 1)

Figure 1 c. If there is no difference IB to OB for all colors, select (N)ext and press the ACCEPT key and continue with step 11 of the Max Setup. d. If an adjustment to the OB density is required, select (A)DJUST and press the ACCEPT key. The following message will be displayed: (Note: you may want to write down the current values for reference)

DARKER = (DOWN), LIGHTER = (UP) Y = OXXX M = OXXX C = OXXX K = OXXX


04/02 5-134


b. Press the ACCEPT key to stop the toggle. c. Select (S)TART and press the ACCEPT key, the following message will be displayed:

Adjustment - Use the right and left arrow keys to select the color that need adjusting. - Use the up and down arrow keys to change the value (XXX). - A lower number will darken the outboard end of the selected color. - A higher number will lighten the outboard end of the selected color. e. Select (S)AVE, and press the ACCEPT key when you are finished with the required changes. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (S)TART (B)ACK

PLEASE WAIT, SETUP IN PROGRESS CHECK SQUARE DENSITY @ COMPLETION d. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern: 300 - 0 COMPLETE, SQUARE DENSITY OK? SELECT: (S)AVE (A)DJUST

DC918 Hi Light ASG Bias Adjustment (300 - 0)

f. Select (S)TART, and press the ACCEPT key. The following message will be displayed:

Check: For the 300 - 0 pattern, the C, M, Y, and K squares in the 9th row should be barely visible while the squares in the 8th row are clearly visible. (Figure 2)

PLEASE WAIT SETUP IN PROGRESS CHECK IB / OB @ COMPLETION g. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern:

IB / OB DENSITY OK? SELECT: (N)EXT (A)DJUST h. Repeat the check and / or adjustment until the IB / OB densities are balanced. 11. When the IB / OB density check is OK, the (N)ext key and the ACCEPT keys selected: a. The following message will be displayed and toggle between lines 2 and 3: DC918 HI - LT MAN SETUP: HI - LT ASG BIAS SCREEN DESIGNATION = 300 - 0 TRAY = 2 SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

Eighth Row Ninth Row

Figure 2


04/02 5-135


e. If the density is OK for all colors, select (S)ave and press the ACCEPT key and continue with step 11b of the Max Setup.

11B. Select (N)EXT and press the ACCEPT key. a. The following message will be displayed and toggle between line 2 and 3: DC918 HI - LT MAN SETUP: HI - LT ASG BIAS SCREEN DESIGNATION = 300 - 180 TRAY = 2 SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

f. If the density of any or all colors are not OK, select (A)djust and select the ACCEPT key. The following screen will be displayed: (Note: you may want to write down the current values for reference) DARKER = (UP), LIGHTER = (DOWN) Y = OXXX M = OXXX C = OXXX K = OXXX

b. Press the ACCEPT key to stop the toggle c. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS CHECK SQUARE - DENSITY @ COMPLETION

Adjustment - Use the right and left arrow keys to select the color that need adjusting. - Use the up and down arrow keys to change the value (XXX). - A higher number will darken the selected color. - A lower number will lighten the selected color. g. Select (S)AVE, and press the ACCEPT key when you are finished with the required changes. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

d. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern:

300 - 180 COMPLETE, SQUARE DENSITY OK? SELECT: (S)AVE (A)DJUST DC918 Hi Light ASG Bias Adjustment (300 - 180)

h. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT SETUP IN PROGRESS CHECK SQUARE DENSITY @ COMPLETION i. When all squares have meet the requirements in the Check procedure, Select (S)AVE, and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT


04/02 5-136

Check: For the 300 - 180 pattern, the C, M, Y, and K squares in the 9th row should be barely visible while the squares in the 8th row are clearly visible. (see figure 2) d. If the density is OK for all colors, select (S)ave and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT Select (N)ext and continue with step 11C of the Max Setup. e. If the density of any or all colors are not OK, select (A)djust and press the ACCEPT key. the following screen will be displayed: (Note: you may want to write down the current values for reference) DARKER = (UP), LIGHTER = (DOWN) Y = OXXX M = OXXX C = OXXX K = OXXX


b. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS CHECK SQUARE - DENSITY @ COMPLETION

Adjustment - Use the right and left arrow keys to select the color that need adjusting. - Use the up and down arrow keys to change the value (XXXX). - A higher number will darken the selected color. - A lower number will lighten the selected color. f. Select (S)AVE, and press the ACCEPT key when you are finished with the required changes. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

c. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern:

600 COMPLETE, SQUARE DENSITY OK? SELECT: (S)AVE (A)DJUST

DC918 Hi Light ASG Bias Adjustment (600)

g. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT SETUP IN PROGRESS CHECK SQUARE DENSITY @ COMPLETION h. When all squares have meet the requirements in the Check procedure, Select (S)AVE, and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT 11C. The following message will be displayed and toggle lines 2 and 3.

d. If the density is OK for all colors, select (S)ave and press the ACCEPT key. The following message will be displayed:

DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT Select (N)ext and continue with step 12 of the Max Setup. e. If the density of any or all colors are not OK, select (A)djust and press the ACCEPT key. The following screen will be displayed: (Note: you may want to write down the current values for reference)

DARKER = (UP), LIGHTER = (DOWN) Y = OXXX M = OXXX C = OXXX K = OXXX

DC918 HI - LT MAN SETUP: HI - LT ASG BIAS SCREEN DESIGNATION = 600 TRAY = 2 SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

Adjustment - Use the right and left arrow keys to select the color that need adjusting. - Use the up and down arrow keys to change the value (XXX). - A higher number will darken the selected color. - A lower number will lighten the selected color.

a. Press the ACCEPT key to stop the toggle.


Check: For the 600 pattern, the C, M, Y, and K squares in the 9th row should be barely visible while the squares in the 8th row are clearly visible. (see figure 2)

04/02 5-137


f. Select (S)AVE, and press the ACCEPT key when you are finished with the required changes. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

d. Select (N)EXT and press the ACCEPT key.

DC 922 TRC Control Setup 13. The following message will be displayed

g. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS CHECK SQUARE DENSITY @ COMPLETION h. When all squares have meet the requirements in the Check procedure, Select (S)AVE, and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT

DC 917 ALC / TRC Target Setup 12. The following message will be displayed:

a. Select (S)TART, and press the ACCEPT key. The following message will be displayed:

PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETE = 314 SECONDS b. At the completion of the routine, the following message will be displayed: DC922 TRC CNTRL COMPLETE SELECT: (S)TART AGAIN c. Press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETE - 314 SECONDS

DC917 ALC / TRC TARGET SET SELECT: (S)TART (N)EXT (Q)UIT a. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT SETUP IN PROGRESS SAVE VALUES AT SET UP COMPLETION b. At the completion of the routine, the following message will be displayed: DC917 SETUP COMPLETE, VALUES OK? SELECT (S)AVE c. Press the ACCEPT key. The following message will be displayed:

DC917 SAVE COMPLETE SELECT: (N)EXT (B)ACK (V)IEW (Q)UIT


DC922 TRC CONTROL: ASG SWITCHES ON SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

04/02 5-138

d. At the completion of the routine, the following message will be displayed and toggle, only if the machine needs the Tone Up / Tone Down Adjustment. If the Machine is within its specification, go to step (h).

DC922 TRC CNTRL COMPLETE: TONE UP / DN ?? SELECT: (A)DJUST (V)IEW (B)ACK (Q)UIT DC922 TRC COMPLETE: TONE UP / DN NG Y = ?? M = ?? C = ?? K = ?? e. Press the ACCEPT key to stop the toggle. f. Select (A)DJUST and press the ACCEPT key. At the completion of the routine, the following message will be displayed and toggle:


b. Press the ACCEPT key to stop the toggle. c. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT FOR CALIBRATION TO COMPLETE

Y = OK, PRINTS = XX M = OK, PRINTS = XX C = OK, PRINTS = XX K = OK, PRINTS = XX TONE UP / DOWN ADJUST SELECTED, TRAY 2 SELECT: (S)TART

d. At the completion of the routine, the following message will be displayed: CALIBRATION COMPLETE: REMOVE PAPER

g. Press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETE - 314 SECONDS h. At the completion of the routine, the following message will be displayed

DC922 TRC CNTRL COMPLETE: RADC OK? SELECT: (N)EXT (V)IEW (Q)UIT

e. Select (N)EXT and press the ACCEPT key. 16. The following message will be displayed and toggle: DC 945 IIT CALIBRATION: CCD CALIBRATION PLACE TEST PATTERN ON PLATEN TEST PATTERN ON PLATEN? SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

i. Select (N)EXT and press the ACCEPT key. 14. The following message will be displayed:

a. Place Test Pattern on the platen (reference figure 3). b. Press the ACCEPT key to stop the toggle. c. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT FOR CALIBRATION TO COMPLETE AT COMPLETION, REMOVE TEST PATTERN

DC922 TRC CNTRL COMPLETE: TONE UP / DN OK? SELECT: (N)EXT (V)IEW (Q)UIT a. If your machine configuration is for printer only, select (Q)UIT and press the ACCEPT key

b. If your machine is equipped with a scanner, select (N)EXT and press the ACCEPT key.

CALIBRATION COMPLETE

SELECT: (N)EXT (B)ACK (Q)UIT

DC 945 IIT Calibration

d. Select (N)EXT and press the ACCEPT key.

15. The following message will be displayed and toggle: DC 945 IIT CALIBRATION: WHITE REFERENCE PLACE PAPER ON PLATEN

DC 926 17. The following message will be displayed and toggle: DC 926 C-POP TRC CONTROL TOT REQUIRES 11X17 OR A3 PAPER

PAPER ON PLATEN? SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

SELECT: (S)TART (B)ACK (Q)UIT a. Place 10 sheets of 11x17, 24 lb. paper on the platen. (Color Expressions or equivalent)


04/02 5-139


a. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT FOR SETUP TO COMPLETE TIME TO COMPLETE - 330 SECONDS b. Upon completion, the following message will be displayed: DC TEST COMPLETE SELECT: (N)EXT c. Select (N)EXT and press the ACCEPT key. The following message will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT

a. The C, M, and Y in column 10 on the print should be well defined (visible). Magenta (M) should be better defined (darker) than C and Y. b. Fold the copy between the upper and lower gray-scale rows. c. Compare the gray scale on the copy to the gray scale on the 82E13120 test pattern, between the 60% column and the 30% column, on the Test Pattern. (Figure 3) NOTE : you may see a hue shift at 30% and below.

Copy

d. Select (E)XIT and press the ACCEPT key.

60%

Scanner Color Balance 18. Enter the Tools Mode, Tools Pathway and select the “More” tab. 19. Select Feature Defaults 1 and set the following to “0” or “Auto”: a. Lighten / Darken b. Color Balance (0) for C, M, Y, and K c. Color Shift (0) d. Chroma (0) Normal

30%

B

20. Exit Tools Mode and select the Features button to access the Copier Mode Screen (Ready for Scan to Print). Ensure that Color Expressions 24 lb. 11x17 / Colotech 90 gsm A3 paper is loaded in one of the paper trays. in the Copier Mode screen, select the following: a. Basic Features, Full Color and 100% Reduce / Enlarge. b. The Paper Tray with 11 x 17 loaded. b. Added Features, Image Shift, Set to No Shift, Save. c. Image Quality, Original Type. Set the Auto Photo & Text and Halftone, Save.

Test Pattern Figure 3

21. Place test pattern 82E13120 on the Platen, and make 2 copies. 22. Check the second copy. (Figure 3)


04/02 5-140


23. If an Adjustment is needed a. Select Tools Pathway Mode, Features Default 1, Color Balance. Use Density, Low and Med to bring in the grays. Select Close. b. Repeat Steps 21 through 22 until the copies match the test pattern c. Using the Image Quality Supplement, refer to the 3.2.2 IOT Setup for Full-Color Output Check (Without Modified Restore Chart) or to the 3.2.2 IOT Setup for Full-Color Output Check (With Modified Restore Chart) to confirm the IQ setup. 24. After completing the image quality setup, label the final output prints with the Machine Number, Date and Meter Count and place the prints in the Right Front Door Compartment for future reference.

ADJ 9.2 Belt Edge Learn Mode Purpose To ensure that the IBT belt is in it’s correct tracking position by establishing a profile table using the Belt Edge sensors. Procedure 1. Enter the DCU Diagnostics (GP 6). The following screen will be displayed: (1) BELT EDGE LEARN, (2) REGICON (3) MAX SETUP, (4) HALFTONE 2.

Select (1) BELT EDGE LEARN, and press the ACCEPT key. The following screen will be displayed:

DC 956 BELT EDGE LEARN MODE SELEECT: (S)TART (N)EXT 3.

Select (S)TART and press the ACCEPT key. The following screen will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETION = 100 SECONDS

4.

Upon completion of the routine, the following screen will be displayed and toggle between lines 2 and 3: DC956 SETUP COMPLETED EDGE PROFILE SUCCESSFUL SELECT (N)EXT

5. Press the ACCEPT key to stop the toggle. 6. Select (N)EXT and press the ACCEPT key. The following screen will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT 7. Select (E)XIT and press the ACCEPT key.


04/02 5-141


ADJ 9.3 RegiCon Sensor Check

ADJ 10.1 Fuser Nip

Purpose To determine the correct operation of the Registration Control Sensor by detecting any mis-registration of a cyan patch on the IBT belt as measured by the MOB sensor.

Purpose The purpose is to ensure that the proper pressure is applied to the print as it passes through the fuser.

Procedure 1. Enter the DCU Diagnostics (GP 6). The following screen will be displayed: (1) BELT EDGE LEARN, (2) REGICON (3) MAX SETUP, (4) HALFTONE 2.

Select (2) REGICON, and press the ACCEPT key. The following screen will be displayed:

DC 685 REGICON SETUP SELEECT: (S)TART (Q)UIT

Check 1. Enter DC701 Fuser Nip Measurement in the TKO Pathway. (GP 3) 2. Select a tray with either 8.5x11 (A4) or 11x17 (A3) 24lb (90gsm) paper. NOTE: For best results use Xerox Color Xpressions paper. 3.

Select Start.

NOTE: The print comes out upside down. Ensure that you mark the black side of the print Inboard and Outboard. 4.

Remove the print and mark the Inboard and Outboard side of the print.

NOTE: The Fuser Nip is located about the center of the print on the black side.

3.

Select (S)TART and press the ACCEPT key. The following screen will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETION = 100 SECONDS

5.

4.

Upon completion of the routine, the following screen will be displayed: DC685 SETUP COMPLETED SELECT (N)EXT

NOTE: Steps 5 and 6 are performed to stabilize the Fuser.

5.

7.

Select (N)EXT and press the ACCEPT key. The following screen will be displayed:

PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT

Select DC612 Color Test Pattern Print. Select Pattern 7 Color Reg. Run three prints. 6. Perform DC701 Fuser Nip Measurement two more times after waiting at least 30 seconds between each run and perform DC612 Pattern 7 Color Reg. between each nip check.

On the last of the Fuser Nip prints, measure 10mm in from the edge at the Fuser Nip on the Inboard and Outboard side. 8. If the Fuser Nip measurements do not meet the following specifications, perform the adjustment: • 4.1mm +/- .2mm Inboard • 4.2mm +/- .2mm Outboard

6. Select (E)XIT and press the ACCEPT key.


04/02 5-142


Adjustment 1. Pull out the Transport Drawer to the service position. 2. Open the Inverter Transport (handle 4c) and the Fuser Exit Chute Assembly (handle 4d). (Figure 1)

3.

Adjust the (2) screws (A) located through the hole in the P/R Finger Bracket: (Figure 2) • To increase the nip, turn both screws CW. • To decrease the nip, turn both screws CCW. NOTE: One full turn equals .5mm.

Fuser Exit Chute

A

A

Inverter Transport Figure 2 Figure 1


04/02 5-143


ADJ 10.2 Fuser Pad Spring

3.

Purpose The purpose is to adjust the Fuser Pad Spring to eliminate the problem of Rib Marks and Water Marks on the print or copy output. Prerequisite 1. Check all the 100K HFSI Counters. If any of the following items are over 80% threshold, replace them now. a. Sheet Pad - replace the Fuser Belt Assembly b. Pad (or Belt) Wick Assembly - replace the Fuser Belt Assembly c. Fuser Belt 2. Check all the 300K HFSI Counters. Adjustment 1. Remove the Web Material Assembly. (REP 10.9) 2. Cam open the Fuser Web Assembly. (REP 10.1)

Remove the Pressure Roll Finger Assembly. (Figure 1) a. Remove 2 screws

A

A

Figure 1


04/02 5-144


4.

Review the characteristics of the Pad Spring Adjustment Tool. (Figure 2)

6.

Position the Tool against the Pad Spring. You may need to adjust the Pad Spring CW or CCW to allow the Tool to be positioned correctly. (Figure 4)

Pin 1

Faces Inboard

Pin 2 Faces Outboard

Pin 3

Figure 2

5.

Observe the location of the 3 pins for the proper placement of Pad Spring Tool. (Figure 3)

Pin 2 Figure 4

Pin 3

Pin 1

Figure 3


04/02 5-145


7.

Adjust the Pad Screw so that the Pad Spring is equal to 42mm. (Figure 5) a. Rotate the adjustment screw slowly CW until it stops. b. Rotate the screw 1/4 revolution CCW (90 degrees) and remove the tool.

Checking for defects after adjusting the Pad Screws 1. Load 81-135 gsm coated two-sided paper in Tray # 3. (It is recommended that you use paper that is on the Recommended Papers List) 2. Ensure that all the tray settings are correct. 3. Print (10) simplex 40% K halftones (pattern 3-1) and check for defects. (refer to the DC 2060/45 Rib Mark / Water Mark Identification Document) If no defect is present, proceed to 4. If a defect is present, it is either case #1 or #2, go to the Adjustment for Rib Marks. (step 6) 4. Print (30) duplex 40% K halftones (pattern 3-1) and check for defects. Inspect both sides of the print but pay close attention to the second side. (refer to the DC 2060 / 2045 Rib Mark / Water Mark Identification Document) If no defect is present, proceed to 4. If a defect is present, it is either case #1 or #2, go to the Adjustment for Water Marks. (step 9) 5. Print (50) duplex 40% 4-color halftones. If no defects appear, the adjustment is complete. If a defect does appear, proceed to the Fine Tune Adjustment. (step 12) NOTE: The following steps are for the Adjustment for Rib Marks. 6. 7.

Adjust the inboard and outboard Pad Screws (1) full Turn CW. Perform the Fuser Nip Adjustment to ensure Pressure Roll Nip is still within specification. 8. Return to step 3. NOTE: The following steps are for the Adjustment for Water Marks. 9. Adjust the inboard and outboard Pad Screws (1) full Turn CCW. 10. Perform the Fuser Nip Adjustment to ensure Pressure Roll Nip is still within specification. 11. Return to step 4. Figure 5 8. 9.

NOTE: The following steps are for the Fine Tune Adjustment.

Perform the same procedure for the outboard Pad Spring. Install the Web Material Assembly and the Pressure Roll Stripper Finger Assembly. 10. Perform the Adjustment Procedure for the Fuser Nip.


12. This is a high stress case using the 40% 4-color halftones as a print sample (step 5) and might require a half or quarter turn of the Pad Screws. If you are directed here, use the same process but use half and quarter turns to eliminate the defect. You also would use the Fine Tune Adjustment if (1) full turns changes the defect from one to another.

04/02 5-146


6. General Procedures General Procedures GP 1 Xerographic Hard Stop ..................................................... 6-3 GP 2 Moving the Paper Path, IBT Module to the Service Position 6-4 GP 3 Entering Tools Mode and TKO Diagnostics on the UI...... 6-6 GP 4 Clearing and Changing HFSI Thresholds......................... 6-6 GP 5 Moving Tray 3 into the Service Position .......................... 6-7 GP 6 Diagnostic Control Unit (DCU) Operation ........................ 6-7 GP 7 Safety Lockout Kit Installation ......................................... 6-10 GP 8 Replenishing the Fuser Oil .............................................. 6-12 GP 9 Generating DCU Test Patterns ........................................ 6-13 GP 10 Undocking Tray 4 ........................................................ 6-14

Product Specifications General Information................................................................... 6-16 Product Specifications ............................................................... 6-16

Consumables Machine Consumables .............................................................. 6-18

Change Tag Information Change Tag Introduction ........................................................... 6-19


04/02 6-1

General Procedures

GP 1 Xerographic Hard Stop Purpose To stop the machine while it is in the xerographic process cycle to enable fault isolation of the xerographic components.

5. Move the IBT Belt in a clockwise direction by rotating the IBT Belt Drive Motor (CCW) by hand in order to see the image. (Figure 1) NOTE: Be sure to clear the machine of all the paper that has been fed.

Procedure 1. Select 10 prints / copies of the Test pattern that displayed the fault. 2. Press the Start Button on the UI Control Panel. 3. When the first print enters the Catch Tray or an Output Device, open the Right Front Door.

5

WARNING Switch OFF the power, disconnect the Power Cord, and apply the Safety Lockout Kit (see GP 7). 4. Extend the IBT Drawer out to the service position. (reference GP 2)


04/02 6-3

Figure 1

General Procedures

GP 2 Moving the Paper Path Module and IBT Module to the Service Position

2. Remove the Interlock Cover. (Figure 1) a. Loosen the screw. b. Remove the Cover

Purpose To enable access to the particular module for ease of service.

B

Procedure

A

WARNING Switch OFF the power, disconnect the Power Cord, and apply the Safety Lockout Kit (see GP 8). 1. Open the Front Doors and remove the Upper Inner Cover. NOTE: The Interlock Cover has to be removed when removing the IBT Module. This cover is a mechanical interlock for the IBT Module.

Figure 1

General Procedures

04/02 6-4


3. Unlatch the IBT Module (A) and /or the Paper Handling Module (B) and pull it out of the machine. Note the position of the Rail Release Latches. (Figure 2)

CAUTION Always unlatch the Paper Handling Module before pulling out the IBT Module.

4. To get the Assemblies into and out of the Service Position, perform the following: (Figure 3) a. To get the Assemblies into the Service Position: Use a small pointed tool, such as a screwdriver, push in through the hole while pulling out on the Assembly, to release the rail. Repeat for the other side and pull the Assembly out until it locks into place. b. To release the Assembly from the Service Position: Push in on the Rail Release Latch, while pushing in the Assembly. Repeat for the other side to push the Assembly into the machine.

A

A B A Figure 3

B B Figure 2


04/02 6-5

General Procedures

GP 3 Entering Tools Mode and TKO Diagnostics on the User Interface

GP 4 Clearing and Changing the HFSI Thresholds The HFSI Thresholds can be customized to reflect the operational requirements of each machine. Some may need to be lowered to ensure reliability, some may be raised to extend the life of that component.

Entering, and exiting the Tools Mode and TKO Diagnostics.

CAUTION Under no circumstances are you to enter the Auditron Administration Pathway when accessing Diagnostics. If you cannot enter the Diagnostic mode, contact the System Administrator for the current password. Procedure 1. Press the Access key on the UI Control Panel. The Password screen will open. 2. Using the 10-Key Pad, type the password and press Enter. The default password is five ones (11111). 3. Select the desired pathway. a. Tools Pathway b. TKO Pathway 4. To exit Diagnostics: • In the Tools Mode before selecting a pathway, touch the Cancel button. To exit while in a Tools Pathway, touch the Exit button. • In the TKO Pathway, at the Diagnostic Entry screen, touch the Complete button. At the Diagnostics Exit screen, press the Start button on the Control Panel.

General Procedures

Procedure 1. Press the Access button on the UI Control Panel. The Password screen will open. 2. Using the 10-Key Pad, type the password and press Enter. The default password is five ones (11111). 3. Select TKO Pathway 4. Select DC135 HFSI Counters and perform the following: a. To clear an existing HFSI counter: • Using the 10-Key Pad, enter the 4 digit Chain Link No. for the appropriate HFSI Counter. The HFSI Counter must be displayed on the screen to work. You cannot enter a HFSI Counter number that is not displayed. • Press the Clear All button on the Control Panel to reset the Current Life to "0". b. To set a new HFSI Threshold value: • Using the 10-Key Pad, enter the 4 digit Chain Link No. for the appropriate HFSI Counter. • Press the Correct button on the screen. • Using the 10-Key Pad, enter the new Spec Number value, and press the Start button on the Control Panel to lock in the value.

04/02 6-6


GP 5 Moving Tray 3 into the Service Position

GP 6 Diagnostic Control Unit (DCU) Operation

Procedure

Control Panel Description and Functionality

1. Open Tray 3. 2. Using a small pointed tool, such as a screwdriver, push in through the hole in the rail while pulling out on the Tray Assembly. Repeat on the other side, and pull the Assembly out until it locks into place. (see Figure 1) 3. To Release the Tray Assembly, push in on the Rail Release Latch while pushing in on the Assembly. Repeat on the other side, to push the Assembly into the machine. (see Figure 1)

The DCU’s control panel is made up of an LCD display, and (5) pressure sensitive switches. (Table 1) Table 1 Item

Left / Right Carats

Symbol

Description

<,>

Advances the display selection list to the right or left. They are used in conjunction with the Accept key. Scrolls the display that exceeds the two line LCD display capability. Also increments numerical values. Confirmation key, used to enter the current User selection. Capable of displaying two lines of text, provides User selection information.

Up / Down Carats /\ , \/

Latch

Hole Accept Key

LCD Display

N/A

Figure 1


04/02 6-7

General Procedures

Powering On the DCU 1.

Remove the protective tape from the 4 Velcro Tabs on the bottom of the DCU and position the DCU onto the Top Cover of the DocuColor 2060/2045 just to the right of the User Interface. (Figure 1)

2. Connect the Power Cord to the Power Supply but do not plug the assembly into a wall receptacle at this time. 3. Connect the Power Cord and the 25 pin connector end of the Interface Cable to the DCU (Figure 2)

Interface Cable

Power Cord

Figure 2 Figure 1

General Procedures

04/02 6-8


4. Connect the 9 pin DB Connector end of the Interface Cable to the IOT Diagnostic Port on the Electrical Module. (Figure 3)

1. Depress either the Up or Down Carat key or the Accept key to activate the DCU menu display. The following screen will appear: WELCOME CHOOSE ANOTHER LANGUAGE? SELECT: (N)O (Y)ES

2. Using the left or right carat key, make the proper selection. Select the ACCEPT key. The following screen will be displayed: PLEASE ENTER ACCESS CODE: 000 SELECT: (A)CCPT WHEN DONE

IOT Diag Port

3. Using the Up / Down carat keys to increment the values, and the Left / Right carat keys to move the cursor to the next position, enter the default access code 123. The following screen will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT

YMCK V-Sel Cables

4. Select (N)EXT to access the DCU diagnostic programs. The following screen will be displayed: (1) BELT EDGE LEARN, (2) REGICON (3) MAX SETUP, (4) HALF TONE

Figure 3

NOTE: The other plug of the interface cable is for future consid- erations of the DCU. 5. Plug the Power Supply into a standard wall receptacle. When this connection is made, the LCD display on the DCU will be backlit for approximately 15 seconds. The DCU will not accept any operator input until the LCD display backlight goes off.

Note the following: (1) BELT EDGE LEARN (Adjustment 9.2 found in section 5) (2) REGICON (Adjustment 9.3 found in section 5) (3) MAX SETUP (Adjustment 9.1 found in section 5) (4) HALF TONE (General Procedure 9 found in section 6) NOTE: When the DCU is running any of the four routines, the following message will be displayed on the machine’s User Inter- face; "Portable Service Workstation is in progress" NOTE: The machine must be in a "Ready to Print" state before you can run any of the DCU routines.


04/02 6-9

General Procedures

DCU Diagnostic Descriptions

GP 7 Safety Lockout Kit Installation

DC 612 Color Test Pattern Print

Purpose

Purpose

To ensure that the machine cannot be powered on, while any machine maintenance is being performed.

To provide internal Test Patterns that are used to help identify image quality problems. DC 685 Regicon Setup Purpose To calculate the correction amount and set up the Registration Control Sensor within the acceptable range. DC 951 Max Setup

Kit Contents 1. 2. 3. 4. 5.

Safety Lockout Tag Power Cord Lockout Stopper Circuit Breaker Lockout Stopper (not used) Padlock with 2 keys Instructions

Procedure

Purpose To ensure that the Xerographic Systems are set and operating at optimum levels.

1. Switch off the power to the machine and disconnect the power cord. 2. Place the Safety Lockout Tag onto the padlock. (Figure 1)

DC 956 Belt Edge Learn Purpose To ensure that the IBT Belt is in it’s correct tracking position by establishing a profile table using the Belt Edge Sensors.

Figure 1

General Procedures

04/02 6-10


3. Place the red lockout stopper onto the end of the electrical plug so the tab fits through the hole in the terminal. (Figure 2)

4. Attach the padlock to the electrical plug through the red stopper. (Figure 3)

Tab

Figure 3

Figure 2


04/02 6-11

General Procedures

GP 8 Replenishing the Fuser Oil

3. Open the Reservoir Cap by pulling the tab at the back of the cap forward. (Figure 1)

Procedure

WARNING Be aware that the Fuser area can be very hot when the machine has been in use.

Tab

WARNING Avoid eye contact with Fuser Oil. It may cause temporary eye discomfort. Wash eyes thoroughly with water.

WARNING Wipe up spillage completely as residue can be slippery. See Section 4 for the proper cleaning procedure. Figure 1

1. Open the Right Front Door. 2. Place a drop cloth on the floor under the Fuser area. Any oil spilled on the floor will make the floor very slippery. (See Section 4 for proper cleaning procedure)

General Procedures

04/02 6-12


4. Remove the cap from the bottle of Fuser Oil and replace it with the Filler Spout Cap. This cap was provided with the digital press at install.Contact your Xerox service representative if you cannot locate the Filler Spout Cap and need one. 5. Carefully insert the filler Spout into the opening of the Fuser Oil Reservoir and squeeze the bottle until the oil reaches the maximum fill level visible inside the reservoir. (Figure 2)

Maximum Fill Level

GP 9 Generating DCU Test Patterns Procedure 1. With the DCU powered up (GP 7), depress either the Up or Down Carat key or the Accept key to activate the DCU menu display. The following screen will appear: WELCOME CHOOSE ANOTHER LANGUAGE? SELECT: (N)O (Y)ES

2. Using the left or right carat key, make the proper selection. Select the ACCEPT key. The following screen will be displayed: PLEASE ENTER ACCESS CODE: 000 SELECT: (A)CCPT WHEN DONE 3. Using the Up / Down carat keys to increment the values, and the Left / Right carat keys to move the cursor to the next position, enter the default access code 123. The following screen will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT

Figure 2

6. Remove the Filler Cap from the bottle and place it on a piece of paper or cloth to drain. Place the original cap back on the bottle. 7. Close the Reservoir Cap ensuring it snaps into place. 8. Close the Right Front Door.


4. Select (N)EXT to access the DCU diagnostic programs. The following screen will be displayed: (1) BELT EDGE LEARN, (2) REGICON (3) MAX SETUP, (4) HALF TONE 5. Select (4) Half Tone. The following screen will be displayed: DC 612 COLOR TEST PATTERN PLEASE PLACE 11 X 17 PAPER ON THE PLATEN SELECT (N)EXT WHEN READY

04/02 6-13

General Procedures

6. Select the Accept Key to stop the toggle and select (N)EXT.The following screen will be displayed:

Purpose To access the left side of the Paper Feed Module for general maintenance and repair activity.

SCREEN = 200R, TRAY =2, PRINT = 4 PATTERN = 3-1 HALFTONE, Cin = 20% 7. Select the Accept Key to start the routine. The routine will run 1 print for each color. The sequence for the routines is CMYK and each color will be displayed on the second line as the routine progresses. The following screen will be displayed: PLEASE WAIT, SETUP IN PROGRESS RUNNING Y COLOR 8. When the printing routine is complete, the following screen will be displayed: PLEASE REMOVE 11 X 17 PAPER FROM THE PLATEN SELECT (N)EXT WHEN READY

GP 10 Undocking Tray 4

Procedure WARNING Switch OFF the power, disconnect the Power Cord, and apply the Safety Lockout Safety Lockout Kit (see GP 7).

WARNING / CAUTION The Tray 4 paper tray must be closed before undocking occurs. Also, do not open the Tray 4 paper tray while the assembly is undocked. This may cause the Tray 4 Assembly to t ip over.

9. Select (N)EXT to return to the main menu.

General Procedures

04/02 6-14


1. Remove the wheel chocks from the left side of Tray 4. 2. Disconnect the Ground Straps (Figure 1). a. Open the Right Front Door on Tray 4. b. Disconnect the front and rear Ground Strap.

3. Undock Tray 4. (Figure 2) a. Lift up on the handle b. Turn the handle clockwise (1/8th turn) c. Close the Front Right Door d. Roll Tray 4 to an appropriate area that will provide enough access to perform the desired activities.

B A

A

B B

Figure 1 Figure 2

Replacement 1. Roll Tray 4 into the proper docking position and make sure the docking pins on the lower right hand bracket are in alignment with the left side bracket on the Paper Feed Module. 2. Replace in reverse order. Note: When Tray 4 is in the docked position, make sure the handle is pushed down to ensure the proper locking engagement.


04/02 6-15

General Procedures

Product Specifications

Product Specifications

General Information

Physical Characteristics Without Accessories

Product Codes

Dimensions/Space Requirement (Figure 1) Table 1

Product

USA

Canada

Latin Xerox America Europe

DC 2045 DC 2060 Stacker/Stapler High Capacity Stacker High Capacity Feeder FFIU Module

PM9 PM7 VV1 UE6

PM9 PM7 VV1 UE6

PM9 PM7 VV1 UE6

PN0 PM7 VV1 UE6

LM4

LM4

LM4

LM4

RW3

RW3

RW3

RW3

For additional Space Requirements with accessories, refer to the DocuColor 2060 / 2045 Installation Planning Guide or the DocuColor 2060 / 2045 Service Documentation, Section 9, Space Requirements.

Figure 1 2060

/ 2045 Space Requirements

Table 1 Dimensions and Weights Dimensions

Width Depth Height Weight

General Procedures

04/02 6-16

US

92.3" 37.4" 55.6" 1874.25 lbs

Metric

2360 MM. 960 MM. 1408 MM. 850 Kg


Electrical Specifications

System Capability

POWER CONSUMPTION

WARMUP TIME • 7 minutes

• • •

Standby - 2.6 KVA maximum Run - 4.8 KVA maximum Install - 6 KVA

COPY SPEED First print out time • 16 seconds Print Rate (Prints / Minute) With very heavy or very light substrates, print speed must decrease to ensure image quality. With the DocuColor 2045/2065 Digital Press, the machine will always print at optimum speed in accordance to the substrate. The most popular substrates for this class of digital press are produced at the maximum speed available on each model. The 8.5 x 11 inch (A4) substrates, print speeds are:

Voltage (50/60 Hz) • •

Minimum: 200 Maximum 240

Environmental Specifications AUDIBLE NOISE Table 2 Audible Noise

Stand by Copy Cycle Full System Operation

Continuous Noise (dBa)

Impulse Noise (dBa)

49.5 64.0 72.0

N/A 72.2 72.0

Table 3 Print Per Minute

OZONE GENERATION •

Maximum 0.02 ppm

Heat Output • •

Operation: 12300 BTUs per hour, average Standby: 7936 BTUs per hour, average

Maximum Altitude

Substrate

Heavy Weight Light Weight (Mode 1) (Mode 2)

Auto Select (Mode 3)

17-21 lbs (64-80 g/m2) 22-28 lbs (81-105 g/m2) 29-36 lbs (106-135 g/m2) 37-40 lbs (136-150 g/m2) 41-59 lbs (151-220 g/m2) 60-74 lbs (221-280 g/m2) Transparencies

45 45 30 30 22.5 22.5 22.5

45 60 60 30 30 22.5 22.5

In Normal configuration: 6557 feet (2000 meters). For altitudes of 6580 to 9843 feet (2001 to 300 meters) field retrofits are acceptable.

Operating Temperatures • • • •

Minimum: 50o F (10o C) o

o

Maximum: 90 F (32 C) Minimum: 15% relative humidity Maximum: 85% relative humidity


45 60 60 30 30 22.5 22.5

NOTE: Tray Capacities are based on 24 lb. (90 gsm) Color Xpressions

Tray Capacity • • •

04/02 6-17

Trays 1 and 2: 550 sheets Tray 3: 2000 sheets Tray 4 (optional): 2500 sheets

General Procedures

Machine Consumables

NOTE: Each IOT will be shipped with one carton of each C, M, Y, and K toner, one carton of fuser agent, and one fuser agent spout. Customers will have the responsibility of adding fuser agent to the IOT. Purchase of the above items is COD specific and is determined by the marketing plan of the COD.

Table 1 Machine Consumables Supply Item

Dry Ink/Toner (Black) Dry Ink/Toner (Cyan) Dry Ink/Toner (Magenta) Dry Ink/Toner (Yellow) Developer (Black) Developer (Cyan) Developer (Magenta) Developer (Yellow) Fuser Agent Waste Dry Ink/Toner Container Paper

Supply Number Eastern Hemisphere

Supply Number Western Hemisphere

Supply Unit Shipped with digital press/ Reorder Quantity

Approximate Print Yield/ Carton (Full Color Prints)

6R90289

6R975

1

18K

6R90290

6R976

1

30K

6R90291

6R977

1

30K

6R90292

6R978

1

30K

5R90246

5R629

1

500K

5R90247

5R630

1

500K

5R90248

5R631

1

500K

5R90249

5R632

1

500K

8R4004 8R90352

8R3993 8R12662

1 1

50K 50K

ColorTech+

Brightwhite 94

General Procedures

NOTE: Developer replacement frequency is projected to be approximately 100,000 images when using 2060 / 2045 60 Base- line paper and other stocks with equivalent smoothness and structure. Replacement rates may be more frequent for opera- tions which use high percentages of coated stocks and/or larger then 8.5 x 11 inch (A4) size throughput, e.g. 11x17 (A3). NOTE: The toner yield projections are based on 7.5% area coverage per color (4 colors = 3.0% at standardized conditions on 8.5x11 inch (A4) 2060 / 2045 60 System Baseline paper. The actual yields vary greatly depending on color intensity, area coverage, paper stock and mode selected.

04/02 6-18


XEROX DocuColor 2045/2060 service manal

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