Section |
Page |
Copyright |
4 |
Warning Labels |
12 |
Safety Interlocks |
12 |
United States |
14 |
Canada |
14 |
European Union |
14 |
Contents |
17 |
General Information |
25 |
System Introduction and Overview |
26 |
System Features and Configurations |
27 |
Standard Configurations |
27 |
Front View |
28 |
Open View |
28 |
Side View with System Interfaces |
29 |
Back View |
29 |
Electronics Module |
30 |
Routine Maintenance Items and Consumables Life Expectancy |
31 |
Control Panel Layout |
32 |
Menu Map |
35 |
System Specifications |
36 |
Physical Dimensions and Clearances |
36 |
Print Engine (IOT) Functional Specifications |
37 |
System Electrical Specifications |
38 |
System Environmental Specifications |
38 |
Scanner/DADF (IIT) Specifications |
38 |
Tray and Media Specifications |
40 |
Duplex Automatic Document Feeder Guidelines |
41 |
Supported Envelopes |
43 |
Media Storage Guidelines |
43 |
Media that May Damage the System |
44 |
Media Skew Specification Print Engine (IOT) |
44 |
Media System Skew Specification (IIT/IOT) |
44 |
Theory of Operation |
45 |
System Overview |
46 |
System Summaries |
46 |
Image Input Terminal (IIT) |
47 |
Major Components of the DADF and Scanner |
47 |
Document Feeder Functions |
48 |
Document Feeder Paper Path and Imaging |
50 |
Copy/Scan Imaging |
50 |
Scanner Assembly Functions |
51 |
Scanner and Document Feeder Calibration |
52 |
Automatic Calibration |
52 |
Automatic DADF Calibration |
52 |
Automatic Scanner Calibration |
53 |
Manual Calibration |
53 |
System Electronics |
54 |
Exit Module (MEP) Board |
55 |
Scanner Power Supply |
55 |
Electronics Module |
55 |
Power Supply Diagram (Electronics Module) |
58 |
Image Output Terminal (IOT) Sub-Assemblies |
59 |
Sub-Assemblies of the IOT |
60 |
Paper Path and Paper Pick |
62 |
Paper Pick for Tray 1 |
62 |
Paper Pick for Trays 2 - 4 |
63 |
2-Sided (Duplex) Printing |
64 |
Sensor Locations |
65 |
System Motors, Solenoids, and Drive |
66 |
Process Drive |
67 |
Media Path Drive |
68 |
The Print Process |
69 |
Drum Preparation |
70 |
Printing |
70 |
Ink Loader |
71 |
Printhead |
72 |
Printhead Tilt |
75 |
Drum Assembly |
78 |
Transfix System |
80 |
Drum Maintenance System |
81 |
Purge System |
82 |
Transfixing and Exiting |
84 |
Transfix and Print Speeds |
88 |
Configuration Card Personality Parameters |
89 |
Error Messages and Codes |
93 |
Introduction |
94 |
Power-Up Error Messages and LED Codes |
95 |
BIST Error Reporting |
95 |
POST Error Reporting |
96 |
PEST Error Reporting |
99 |
Fault Code Error Message Troubleshooting |
100 |
Fault Code Error Reporting |
100 |
Interpreting Fault Codes |
100 |
1,000.4x Error - 525-Sheet Feeder Faults |
101 |
2,0XX.4x Error - I/O Circuit Board Fault |
102 |
2,0XX.6x Errors - I/O Board Program Faults |
102 |
3,0XX.6x - IPC Program Faults |
102 |
4,0XX.4x Errors - Process Control System Fault |
103 |
4,0XX.6x Process Control Software Fault |
105 |
5,0XX.4x Errors - Y-Axis Sub-System Fault |
106 |
5,0XX.6x Errors - Program Faults |
106 |
6,0XX.4x Errors - X-Axis Fault |
107 |
6,0XX.6x Errors - Program Faults |
107 |
7,0XX.4x Errors - Process Motor Gearbox Faults |
108 |
7,0XX.6x Errors - Program Faults |
111 |
8,0XX.xx Error - Wiper/Media Path Gearbox Faults |
112 |
8,0XX.6x Errors - Program Faults |
113 |
9,0XX.xx Errors - Ink Loader Faults |
114 |
9,009.44 and 900X.6x |
114 |
11,0XX.xx Errors - Electronics Module Interface Fault |
115 |
11,100.60 - Temperature Error |
116 |
12,000.60 Errors - Program Faults |
116 |
13,0XX.xx Errors - Thermal Faults |
116 |
13,000.6x Errors - Program Faults |
124 |
19,0XX.xx Errors - Printhead Calibration faults. |
125 |
19,0XX.6x - Errors |
125 |
21,000.69 Errors - Diagnostic Code Version Mismatch |
125 |
22,0XX.6x Errors - Jam Codes |
125 |
23,0XX.6x Errors - NVRAM Fault |
125 |
26,0XX.6x Errors - Printing Faults |
125 |
27,0XX.6x Errors - Profile Library |
126 |
29,0XX.6x Errors - Jam Manager |
126 |
31,0XX.4x Errors - Mechanical Initialization Jam |
126 |
31,0XX.6x Errors - Program Faults |
126 |
33,0XX.xx Errors - Tray Manager Device Faults |
127 |
34,0XX.xx Errors - Printhead NVRAM Faults |
127 |
36,000.40 Errors - Drum Maintenance Faults |
128 |
36,001.67 Errors |
128 |
37,0XX.xx Errors - PEST Faults |
129 |
39,0XX.xx Errors - Document Feeder / Scanner Unit Faults |
138 |
3-Digit Jam Codes |
141 |
Jam Code Definition Table |
142 |
General Troubleshooting |
159 |
Introduction |
160 |
Hidden Service Menu |
160 |
Service Diagnostics |
162 |
Service Diagnostics Menu Functions |
162 |
Important Information While Performing Service Diagnostics |
162 |
Entering Service Diagnostics |
163 |
From Customer Mode to Diagnostics: |
163 |
From System OFF to Diagnostics: |
163 |
Service Diagnostic Menu Definition Tables |
164 |
Service Diagnostic Print Engine Menu Functions |
169 |
Check Menu / Activators Definition Tables |
173 |
Check / Activators Menu |
173 |
Check Shafts Menu |
176 |
Check Fans Menu |
182 |
Check Heaters Menu |
183 |
Check Paper Path Menu |
185 |
Check Drive Menu |
193 |
Check Drum Menu |
198 |
Check Motors Menu |
203 |
Check Misc Menu |
206 |
System Power-Up Sequence |
212 |
Mechanical Initialization of the Print Engine |
213 |
Head Cleaning Cycle Performance |
215 |
Electrical Troubleshooting |
216 |
Electronics Module |
216 |
Document Feeder Lamp Does Not Turn ON |
217 |
Document Feeder Does Not Feed Media |
217 |
Scanner Scanhead Does Not Move |
218 |
Scanhead Motion is Not Smooth and Continuous |
218 |
Scanner Lamp Does Not Turn On |
218 |
Control Panel is Malfunctioning |
218 |
System Continuously Resets or Resets Unexpectedly |
219 |
Control Panel Is Blank and the PS and PE Indicators are Flashing an Error Code |
219 |
Exit Module (MEP) is Malfunctioning |
220 |
System Fails to Power-Up |
220 |
System Energy Star Mode Troubleshooting |
222 |
System Reports Missing Maintenance Kit |
223 |
System Reports Missing Waste Tray |
223 |
System Features Not Available |
223 |
525-Sheet Feeder Does Not Function |
224 |
Non-Specific Electronics Failure |
225 |
Verifying Scanner Power Supply Operation |
228 |
Verifying Power Supply Operation - Print Engine |
229 |
Measuring AC Power Supply Voltages |
230 |
Detecting condition of Fuse F2 and F3 |
230 |
Measuring DC Power Supply Voltages |
231 |
Ensuring Ground Integrity |
231 |
Testing Motor and Solenoid Resistances |
233 |
Paper Path and Media-Based Problems |
234 |
Media-Based Problems |
234 |
Paper-Pick Errors - Trays 2, 3, and 4 |
234 |
Paper-Pick Errors - Tray 1 |
235 |
Document Feeder Pick Problems |
235 |
Preheater and Transfix Jams |
235 |
Checking the Process and Media Path Drive |
236 |
Media Skews Passing Through the Paper Path |
236 |
Operating System and Application Problems |
237 |
Testing Communications Ports |
237 |
Ethernet Port Verification |
237 |
Ethernet Port Verification for Default Assigned IP Address 169.254.xxx.xxx |
238 |
USB Port Verification |
239 |
Network Problems |
239 |
To print an Event Log or Runtime Log: |
239 |
Obtaining Serial Back Channel Trace |
240 |
Image-Quality Troubleshooting |
241 |
Image-Quality Problems Overview |
242 |
Service Technician RIP Procedure |
243 |
Isolating a Copy/Scan Malfunction to the Scanner/DADF |
243 |
Before troubleshooting image-quality problems: |
243 |
DADF Image-Quality Problems |
244 |
Dark Streaks on the Copied Image |
244 |
Skewed Copy Image |
245 |
Copy Image is Lighter/Darker than the Original |
245 |
Fuzzy Text/Image |
246 |
Copied Image Colors Do Not Match the Original |
247 |
Scanner Image Quality Problems |
248 |
Dark Streaks on the Copied Image |
248 |
Copied Image is Skewed |
248 |
Copied Image is Lighter/Darker than the Original |
248 |
Copy Image Colors Do Not Match the Original |
249 |
Fuzzy Text/Image |
250 |
Diagnosing IOT (Print Engine) Print-Quality Problems |
251 |
Random Light Stripes |
252 |
Predominate Light Stripes |
253 |
Smudges or Smears |
254 |
The Printed Image Is Too Light or Too Dark |
255 |
No Image is Being Printed |
255 |
Color is Uneven or Color is Wrong |
256 |
Streaks or Lines Down the Print |
257 |
Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Transparencies |
259 |
There is ink on the White Portion of the Printed Page |
261 |
Fuzzy Text |
262 |
Poor Primary Color Fills |
264 |
Ghosting |
265 |
Poor Small Text Resolution |
266 |
Vertical Lines Appear Wavy |
267 |
Oil Streaks on Print |
268 |
Incomplete Image Transfer to Paper |
269 |
Ink Smears on First Printed Side of Duplex Print |
270 |
Repeating Print Defects on Print |
271 |
White Stripes (Pinstripes) |
272 |
Wrinkling |
273 |
Image is Offset or Cut-Off |
274 |
Poor Ink Adhesion, Poor Image Durability |
274 |
Analyzing Service Test Prints |
275 |
Test Print Examples |
275 |
1: Weak/Missing Jet |
275 |
2: X-Axis Motion (Drop Mass Evaluation) |
276 |
3: Color Bands, RGBK Dither |
276 |
4: Reverse Text |
277 |
5: Big Bands OHP |
278 |
6: Gray Fill, Dot Size Uniformity |
279 |
7: Manuf. Five Duplex GSF |
279 |
8: YMCKRGB Solid Fills |
280 |
9: Drum Seal |
280 |
10: Manuf. Paper Path |
280 |
11: Head-to-Drum Check |
281 |
12: Manuf X-Axis (Scanner) |
281 |
13-19: Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills |
282 |
20: OHP Color Bands |
282 |
21: Primary Solid Fills 10x |
283 |
22: Manuf. Skew Margins |
284 |
23: Manuf. Banding |
285 |
24: Head Roll |
285 |
25: Head Height |
285 |
26: X Dot Position |
285 |
27: Y Dot Position |
285 |
28: Chase Pages |
285 |
29: Oil Bar Chase |
285 |
30: Purge Efficiency |
285 |
31: Cleaning (Chase) Page |
286 |
Adjustments and Calibrations |
287 |
System Alignments and Adjustments |
288 |
Wiper Alignment |
288 |
Print Engine Component Home Positions and Indicators |
290 |
Homing the Printhead Wiper |
290 |
Homing the Head Tilt Gear |
291 |
When the Printhead Is NOT Installed |
291 |
Homing the Process Gear Drive Train |
294 |
Manual DADF to Scanner Calibration |
295 |
Starting the Calibration Procedure |
295 |
Scanner Platen Steps |
296 |
Document Feeder Steps |
297 |
Jet Substitution Mode |
298 |
Enabling Jet Substitution Mode |
298 |
Disabling Jet Substitution Mode |
299 |
Resetting NVRAM |
299 |
Cleaning and Maintenance |
301 |
Inspection |
302 |
System Self-Maintenance |
303 |
Printhead Maintenance Cycle (Eliminate Light Stripes) |
303 |
Paper Preheater Cleaning (Remove Print Smears) |
304 |
Transfix Roller Oiling |
304 |
Drum Cleaning - Chase Page |
304 |
Service Cleaning and Maintenance Procedures |
305 |
Supplies Required |
305 |
Cleaning for Print-Quality Problems |
306 |
Scan or Copy Print-Quality Problem |
306 |
Light Stripes or Missing Colors |
306 |
Ink Smears, Oil Spots, or Random Ink Streaks |
306 |
Media Jams and Paper Pick Cleaning Procedures |
307 |
Pick Roller Cleaning Methods |
307 |
Tray 1 Pick Rollers |
307 |
Cleaning the Drum Temperature Sensor |
308 |
Maintenance Kit |
309 |
Maintenance Kit Life |
309 |
Waste Tray |
309 |
Lubrication |
310 |
Service Parts Disassembly |
311 |
Overview |
312 |
Standard Orientation of the System |
312 |
General Notes on Disassembly |
313 |
Special Notes Regarding Screws Used in This Equipment. |
313 |
Notations in the Disassembly Text |
313 |
Image Input Terminal (DADF and Scanner) |
314 |
Duplex Automatic Document Feeder |
314 |
DADF Front Cover |
315 |
Scanner Assembly |
316 |
Control Panel |
317 |
Image Output Terminal (Print Engine) |
317 |
Covers |
318 |
Output Paper Tray Assembly |
318 |
Front Door / Tray 1 Assembly |
320 |
Right and Left Side Covers |
321 |
Rear Cover and EMI Shield |
322 |
Imaging |
323 |
Ink Loader Assembly |
323 |
Replacement Notes: |
323 |
Y-Axis Drum Belt, Y-Axis Tension Spring, and Y-Axis Motor Assembly |
324 |
Replacement Notes: |
325 |
Printhead Assembly, Right and Left Printhead Restraints |
326 |
Replacement Notes: |
331 |
X-Axis Bias Spring |
333 |
Replacement Note: |
333 |
Printhead Wiper |
334 |
Replacement Note: |
335 |
Media Release Blade (Stripper) Carriage Assembly and Transfix Roller |
336 |
Paper Preheater and Deskew Assembly |
337 |
Replacement Note: |
338 |
Duplex Roller |
339 |
Transfix Load Module |
340 |
Replacement Notes: |
343 |
Transfix Camshaft Assembly |
344 |
Drum Maintenance Camshaft Assembly |
345 |
Replacement Notes: |
345 |
Drum Maintenance Pivot Plate Assembly |
346 |
Drum Assembly |
347 |
Replacement Notes: |
348 |
Purge Pressure Pump |
351 |
Paper Path |
352 |
Exit Module Assembly (MEP) |
352 |
Replacement Note: |
354 |
Paper Guides |
354 |
Inner Simplex |
354 |
Replacement Note: |
354 |
Lower Inner Duplex |
354 |
Lower Exit-Guide Assembly with Strip Flag |
354 |
Upper Duplex Guide with Solenoid |
355 |
Replacement Notes: |
357 |
Take Away Roller |
358 |
Pick Assembly |
359 |
Replacement Note: |
360 |
Tray Lift Motor |
361 |
Replacement Note: |
361 |
Motors, Gears, Solenoids, Clutches, and Fans |
362 |
Media Drive Gearbox with Two Clutches and Solenoid |
362 |
Replacement Note: |
363 |
Tray 1 (MPT) Pick Solenoid |
364 |
Process Drive Motor and Gearbox |
365 |
Replacement Notes: |
366 |
X-Axis Motor Assembly |
367 |
Replacement Note: |
367 |
Head Tilt Compound Gear |
368 |
Replacement Notes: |
368 |
Electronics |
369 |
Scanner Power Supply |
369 |
Exit Module (MEP) Board |
370 |
Electronics Module |
371 |
Replacement Note: |
372 |
Back Frame and Printer Stabilizer |
373 |
Wave Amp Board |
375 |
Replacement Note: |
375 |
I/O Board |
376 |
Replacement Note: |
376 |
Drum Heater Relay Board |
377 |
Replacement Note: |
377 |
NVRAM Replacement |
378 |
Parts Lists |
379 |
Serial Number Format |
380 |
The serial number is coded as follows: |
380 |
Serial Number Example: |
380 |
Using the Parts List |
381 |
Covers |
382 |
Imaging |
384 |
Paper Path |
386 |
Motors, Gears, Solenoids, Clutches, Sensors, Fans and Backframe |
388 |
Electronics Module, Circuit Boards and Cables |
390 |
Sensors and Flags (Actuators) |
392 |
Xerox Supplies |
394 |
Wiring Diagrams |
397 |
Plug/Jack Locator Table |
398 |
Scanner/DADF Functional Diagrams |
401 |
Main Block Wiring Diagram |
402 |
Main Block Wiring Diagram (Continued) |
403 |
Scanner/Exit Module Power Supply and MEP (Exit Module) Board |
404 |
Right-Side Wiring Diagram |
405 |
Right-Side Wiring Diagram (Continued) |
406 |
Left-Side Wiring Diagram |
407 |
Left-Side Wiring Diagram (Continued) |
408 |
Inside Front Wiring Diagram |
409 |
Inside Top Wiring Diagram |
410 |
Inside Top Wiring Diagram (continued) |
411 |
Electronics Module |
412 |
Appendix |
413 |
Control Panel Menu Map |
414 |
Control Panel Menu Map -continued- |
415 |
Control Panel Menu Map -continued- |
416 |
Media Margin Specification Table |
417 |
Paper Weight Equivalence Table |
418 |