Xerox N2125N - DocuPrint B/W Laser Printer Service Manual

Network Laser Printer Service Manual 721P52390 February 2000 This Service Manual contains information that applies to the DocuPrint N2125 Laser Printer. CAUTION These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage.

sensitive to damage caused by electrostatic discharge. Shock Hazard This symbol indicates the presence of potentially hazardous voltages. Fuser Hazard This symbol indicates the presence of extreme heat from the Fuser Assembly. Class 1 LASER Product The DocuPrint N2125 laser printer is certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this is a class of laser product that does not emit hazardous laser radiation; this is possible only because the laser beam is totally enclosed during all modes of customer operation. The laser and output of the laser scanner unit produces a beam that, if looked into, could cause eye damage. Service procedures must be followed exactly as written without change. When servicing the machine or laser module, follow the procedures specified in the manual and there will be no hazards from the laser. Laser (FDA): Any laser label visible to service must be reproduced in the service manual with location shown or indicated. Safe working procedures and clear warnings concerning precautions to avoid possible exposure must also be included. The Laser contained in the DocuPrint N2125 meets the following standard: Laser class 3B, maximum 5mW, wavelength 780nm. The following LASER symbol will be displayed at the start of any procedure where possible exposure to the laser beam exists. LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT CAUTION These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. FM_001 manuals4you.com manuals4you.com

02/2000 iv Initial Issue Table of Contents Title - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - iv Organization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Revision Control List - - - - - - - - - - - - - - - - - - - - - - - - - - viii Service Call Procedures - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Repair Analysis Procedures - - - - - - - - - - - - - - - - - - - - - 2-1 Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Image Quality Repair Procedures - - - - - - - - - - - - - - - - - 3-1 Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Repair/Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 General Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Wiring Data- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Introduction The DocuPrint N2125 Service Manual is the primary document used for repairing and maintaining the DocuPrint N2125 Laser Printer. This manual contains Service Call Procedures, Diagnostic Procedures, General Information, Repair Analysis Procedures, Image Quality Analysis Procedures, Wiring Data, and Parts Lists that will enable the Service Representative to repair DocuPrint N2125 failures.

each section of the manual is as follows: Section 1 - Service Call Procedures This section is used to identify a suspected problem. It contains Machine Orientation, Call Flow, Initial Actions, Corrective Actions, and Final Actions. This part of the service manual should always be used to start the service call. Section 2 - Repair Analysis Procedures This section is used to isolate and identify problems to a faulty component or subassembly. It contains the introduction, display message table, error code tables and the Repair Analysis Procedures (RAPs). Section 3 - Image Quality This section contains image quality repair procedures to assist in correcting image quality defects. These procedures provide defect samples and definitions to help identify the type of defect that exists, the test pattern to use, and actions required to correct the defects. Section 4 - Repair / Adjustment This section contains the instructions for removal, replacement, and adjustment of the spared parts within the machine. Section 5 - Parts Lists This section contains illustrations of disassembled subsystems and a listing of the spared parts. Part names are listed in this section of the manual even if the part itself is not spared. All the parts that are spared will have the part number listed. Parts that are not spared will not have a number listed. Section 6 - General Procedures This section includes the Operations Menu Map and the Service Mode Menu Map. It includes all unique service operations, supplemental tools and supplies. Section 7 - Wiring Data This section contains sensor, connector, and PWB location drawings; power distribution diagrams, interconect diagrams, interconnect diagrams and pin assignment information. This information is not specific to individual procedures but is provided for general reference. manuals4you.com manuals4you.com

02/2000 vi Initial Issue Terminology and Symbols The following is the terminology and symbols that are used in this manual for Warnings, Electrostatic Device or General Cautions, and Notes. Warning This equipment complies with the requirements in Part 15 of FCC rules for a class A computing device. Operation of the equipment in a residential area may cause unacceptable interference to radio and TV reception, requiring the operator to take whatever steps are necessary to correct the interference. Electrostatic Discharge The following symbols indicates that there are components which are sensitive to damage caused by electrostatic discharge. Shock Hazard This symbol indicates the presence of potentially hazardous voltages. Fuser Hazard This symbol indicates the presence of extreme heat from the Fuser Assembly. FM_001

DocuPrint N2125 02/2000 vii Initial Issue Laser Product Certification CAUTION Use of controls or adjustments other than those specified in this manual may result in an exposure to dangerous laser radiation. The DocuPrint N2125 is certified to comply with Laser Product Performance Standards set by the United States Department of Health and Human Services as a Class 1 product. This means that it is a laser product that does not emit dangerous laser radiation during any mode of customer operation. During servicing, the laser beam could cause eye damage if looked at directly. Service procedures must be followed exactly as written without change. CAUTION These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. manuals4you.com manuals4you.com

DocuPrint N2125 02/2000 viii Page Revision Page Revision Page Revision Page Revision Page Revision Page Revision Initial Issue Product: DocuPrint N2125 Laser Printer Title: Xerox DocuPrint N2125 Network Laser Printer Service Manual Part Number: 721P52390 Title - - - -2/2000 ii - - - - - - -2/2000 iii - - - - - -2/2000 iv - - - - - -2/2000 v- - - - - - -2/2000 vi - - - - - -2/2000 vii - - - - - -2/2000 viii- - - - - -2/2000 ix - - - - - -2/2000 x- - - - - - -2/2000 1-1 - - - - -2/2000 1-2 - - - - -2/2000 1-3 - - - - -2/2000 1-4 - - - - -2/2000 1-5 - - - - -2/2000 1-6 - - - - -2/2000 1-7 - - - - -2/2000 1-8 - - - - -2/2000 2-1 - - - - -2/2000 2-2 - - - - -2/2000 2-3 - - - - -2/2000 2-4 - - - - -2/2000 2-5 - - - - -2/2000 2-6 - - - - -2/2000 2-7 - - - - -2/2000 2-8 - - - - -2/2000 2-9 - - - - -2/2000 2-10 - - - -2/2000 2-11 - - - -2/2000 2-12 - - - -2/2000 2-13 - - - -2/2000 2-14 - - - -2/2000 2-15 - - - -2/2000 2-16 - - - - 2/2000 2-17 - - - - 2/2000 2-18 - - - - 2/2000 2-19 - - - - 2/2000 2-20 - - - - 2/2000 2-21 - - - - 2/2000 2-22 - - - - 2/2000 2-23 - - - - 2/2000 2-24 - - - - 2/2000 2-25 - - - - 2/2000 2-26 - - - - 2/2000 2-27 - - - - 2/2000 2-28 - - - - 2/2000 2-29 - - - - 2/2000 2-30 - - - - 2/2000 2-31 - - - - 2/2000 2-32 - - - - 2/2000 2-33 - - - - 2/2000 2-34 - - - - 2/2000 2-35 - - - - 2/2000 2-36 - - - - 2/2000 2-37 - - - - 2/2000 2-38 - - - - 2/2000 2-39 - - - - 2/2000 2-40 - - - - 2/2000 2-41 - - - - 2/2000 2-42 - - - - 2/2000 2-43 - - - - 2/2000 2-44 - - - - 2/2000 2-45 - - - - 2/2000 2-46 - - - - 2/2000 2-47 - - - - 2/2000 2-48 - - - - 2/2000 2-49 - - - - 2/2000 2-50 - - - - 2/2000 2-51 - - - - 2/2000 2-52 - - - - 2/2000 2-53 - - - - 2/2000 2-54 - - - - 2/2000 2-55 - - - - 2/2000 2-56 - - - - 2/2000 3-1 - - - - - 2/2000 3-2 - - - - - 2/2000 3-3 - - - - - 2/2000 3-4 - - - - - 2/2000 3-5 - - - - - 2/2000 3-6 - - - - - 2/2000 3-7 - - - - - 2/2000 3-8 - - - - - 2/2000 3-9 - - - - - 2/2000 3-10 - - - - 2/2000 3-11 - - - - 2/2000 3-12 - - - - 2/2000 3-13 - - - - 2/2000 3-14 - - - - 2/2000 3-15 - - - - 2/2000 3-16 - - - - 2/2000 3-17 - - - - 2/2000 3-18 - - - - 2/2000 3-19 - - - - 2/2000 3-20 - - - - 2/2000 3-21 - - - - 2/2000 3-22 - - - - 2/2000 3-23 - - - - 2/2000 3-24 - - - - 2/2000 3-25 - - - - 2/2000 3-26 - - - - 2/2000 4-1 - - - - - 2/2000 4-2- - - - - 2/2000 4-3- - - - - 2/2000 4-4- - - - - 2/2000 4-5- - - - - 2/2000 4-6- - - - - 2/2000 4-7- - - - - 2/2000 4-8- - - - - 2/2000 4-9- - - - - 2/2000 4-10- - - - 2/2000 4-11 - - - - 2/2000 4-12- - - - 2/2000 4-13- - - - 2/2000 4-14- - - - 2/2000 4-15- - - - 2/2000 4-16- - - - 2/2000 4-17- - - - 2/2000 4-18- - - - 2/2000 4-19- - - - 2/2000 4-20- - - - 2/2000 4-21- - - - 2/2000 4-22- - - - 2/2000 4-23- - - - 2/2000 4-24- - - - 2/2000 4-25- - - - 2/2000 4-26- - - - 2/2000 4-27- - - - 2/2000 4-28- - - - 2/2000 4-29- - - - 2/2000 4-30- - - - 2/2000 4-31- - - - 2/2000 4-32- - - - 2/2000 4-33- - - - 2/2000 4-34- - - - 2/2000 4-35- - - - 2/2000 4-36- - - - 2/2000 4-37- - - - 2/2000 4-38- - - - 2/2000 4-39- - - - 2/2000 4-40- - - - 2/2000 4-41- - - - 2/2000 4-42- - - - 2/2000 4-43- - - - 2/2000 4-44- - - - 2/2000 4-45- - - - 2/2000 4-46- - - - 2/2000 4-47- - - - 2/2000 4-48- - - - 2/2000 4-49- - - - 2/2000 4-50- - - - 2/2000 4-51- - - - 2/2000 4-52- - - - 2/2000 4-53- - - - 2/2000 4-54- - - - 2/2000 4-55- - - - 2/2000 4-56- - - - 2/2000 4-57- - - - 2/2000 4-58- - - - 2/2000 4-59- - - - 2/2000 4-60- - - - 2/2000 4-61- - - - 2/2000 4-62- - - - 2/2000 4-63- - - - 2/2000 4-64- - - - 2/2000 4-65- - - - 2/2000 4-66- - - - 2/2000 4-67- - - - 2/2000 4-68- - - - 2/2000 4-69- - - - 2/2000 4-70- - - - 2/2000 4-71- - - - 2/2000 4-72 - - - 2/2000 4-73 - - - 2/2000 4-74 - - - 2/2000 4-75 - - - 2/2000 4-76 - - - 2/2000 4-77 - - - 2/2000 4-78 - - - 2/2000 4-79 - - - 2/2000 4-80 - - - 2/2000 4-81 - - - 2/2000 4-82 - - - 2/2000 4-83 - - - 2/2000 4-84 - - - 2/2000 4-85 - - - 2/2000 4-86 - - - 2/2000 4-87 - - - 2/2000 4-88 - - - 2/2000 4-89 - - - 2/2000 4-90 - - - 2/2000 4-91 - - - 2/2000 4-92 - - - 2/2000 4-93 - - - 2/2000 4-94 - - - 2/2000 4-95 - - - 2/2000 4-96 - - - 2/2000 4-97 - - - 2/2000 4-98 - - - 2/2000 4-99 - - - 2/2000 4-100 - - 2/2000 4-101 - - 2/2000 4-102 - - 2/2000 4-103 - - 2/2000 4-104 - - 2/2000 4-105 - - 2/2000 4-106 - - 2/2000

DocuPrint N2125 02/2000 ix Initial Issue Page Revision Page Revision Page Revision Page Revision Page Revision Page Revision 4-107 - - -2/2000 4-108 - - -2/2000 4-109 - - -2/2000 4-110 - - -2/2000 4-111- - - -2/2000 4-112 - - -2/2000 4-113 - - -2/2000 4-114 - - -2/2000 4-115 - - -2/2000 4-116 - - -2/2000 5-1 - - - - -2/2000 5-2 - - - - -2/2000 5-3 - - - - -2/2000 5-4 - - - - -2/2000 5-5 - - - - -2/2000 5-6 - - - - -2/2000 5-7 - - - - -2/2000 5-8 - - - - -2/2000 5-9 - - - - -2/2000 5-10 - - - -2/2000 5-11 - - - -2/2000 5-12 - - - -2/2000 5-13 - - - -2/2000 5-14 - - - -2/2000 5-15 - - - -2/2000 5-16 - - - -2/2000 5-17 - - - -2/2000 5-18 - - - -2/2000 5-19 - - - -2/2000 5-20 - - - -2/2000 5-21 - - - -2/2000 5-22 - - - -2/2000 5-23 - - - -2/2000 5-24 - - - -2/2000 6-1 - - - - -2/2000 6-2 - - - - -2/2000 6-3 - - - - -2/2000 6-4 - - - - -2/2000 6-5 - - - - - 2/2000 6-6 - - - - - 2/2000 6-7 - - - - - 2/2000 6-8 - - - - - 2/2000 6-9 - - - - - 2/2000 6-10 - - - - 2/2000 6-11 - - - - 2/2000 6-12 - - - - 2/2000 6-13 - - - - 2/2000 6-14 - - - - 2/2000 6-15 - - - - 2/2000 6-16 - - - - 2/2000 6-17 - - - - 2/2000 6-18 - - - - 2/2000 6-19 - - - - 2/2000 6-20 - - - - 2/2000 6-21 - - - - 2/2000 6-22 - - - - 2/2000 6-23 - - - - 2/2000 6-24 - - - - 2/2000 6-25 - - - - 2/2000 6-26 - - - - 2/2000 6-27 - - - - 2/2000 6-28 - - - - 2/2000 6-29 - - - - 2/2000 6-30 - - - - 2/2000 6-31 - - - - 2/2000 6-32 - - - - 2/2000 6-33 - - - - 2/2000 6-34 - - - - 2/2000 6-35 - - - - 2/2000 6-36 - - - - 2/2000 6-37 - - - - 2/2000 6-38 - - - - 2/2000 6-39 - - - - 2/2000 6-40 - - - - 2/2000 6-41 - - - - 2/2000 6-42 - - - - 2/2000 6-43 - - - - 2/2000 6-44 - - - - 2/2000 6-45 - - - - 2/2000 6-46 - - - - 2/2000 6-47 - - - - 2/2000 6-48 - - - - 2/2000 6-49 - - - - 2/2000 6-50 - - - - 2/2000 6-51 - - - - 2/2000 6-52 - - - - 2/2000 6-53 - - - - 2/2000 6-54 - - - - 2/2000 6-55 - - - - 2/2000 6-56 - - - - 2/2000 6-57 - - - - 2/2000 6-58 - - - - 2/2000 6-59 - - - - 2/2000 6-60 - - - - 2/2000 7-1 - - - - - 2/2000 7-2 - - - - - 2/2000 7-3 - - - - - 2/2000 7-4 - - - - - 2/2000 7-5 - - - - - 2/2000 7-6 - - - - - 2/2000 7-7 - - - - - 2/2000 7-8 - - - - - 2/2000 7-9 - - - - - 2/2000 7-10 - - - - 2/2000 7-11 - - - - 2/2000 7-12 - - - - 2/2000 7-13 - - - - 2/2000 7-14 - - - - 2/2000 7-15 - - - - 2/2000 7-16 - - - - 2/2000 7-17 - - - - 2/2000 7-18 - - - - 2/2000 7-19 - - - - 2/2000 7-20 - - - - 2/2000 7-21 - - - - 2/2000 7-22 - - - - 2/2000 7-23 - - - - 2/2000 7-24- - - - 2/2000 7-25- - - - 2/2000 7-26- - - - 2/2000 7-27- - - - 2/2000 7-28- - - - 2/2000 7-29- - - - 2/2000 7-30- - - - 2/2000 7-31- - - - 2/2000 7-32- - - - 2/2000 7-33- - - - 2/2000 7-34- - - - 2/2000 7-35- - - - 2/2000 7-36- - - - 2/2000 manuals4you.com manuals4you.com

02/2000 x Page Revision Page Revision Page Revision Page Revision Page Revision Page Revision Initial Issue

Initial Issue 1 Service Call Procedures 1.0 Introduction................................................................................................................ 1-3 1.1 Machine Orientation .................................................................................................. 1-3 1.2 Call Flow.................................................................................................................... 1-4 1.3 Initial Actions ............................................................................................................. 1-5 1.4 Corrective Actions ..................................................................................................... 1-5 1.5 Final Actions.............................................................................................................. 1-7 manuals4you.com manuals4you.com

Initial Issue 1.0 Introduction The Service Call Procedures section is used to identify a suspected problem. This section con- tains Call Flow, Initial Actions, Corrective Actions, and Final Actions. Call Flow illustrates the normal activities and flow of a service call. Initial Actions are used to gather information regarding the performance of the machine and prepare the product for servicing. Corrective Actions are used to verify the normal operation of the machine. In the Y/N (Yes/No) steps of the corrective actions, a Yes response will lead you to the next step. A No response will indicate the next step to perform or will direct you to a Repair Analysis Procedure (RAP). RAPs will provide the instructions to isolate the faulty part or provide a list of suspect parts, when isolation is not appropriate. Wire harnesses are not included in the repair actions and problems with loose connections or damaged harnesses should be isolated using visual inspection and the wiring data in section 7. Final Actions are used to evaluate the total operation of the system and to identify the actions required to complete the service call. 1.1 Machine Orientation For servicing the DocuPrint N2125, all references to machine orientation are as illustrated in Figure 1. Figure 1 Machine Orientation manuals4you.com manuals4you.com

1.2 Call Flow The call flow diagram shows the relationship of actions during a typical service call Figure 1. The functions in Call Flow correspond to service manual sections as follows: Section 1 - Initial Actions, Corrective Actions, and Final Actions Section 2 - Status Indicator Repair Analysis Procedures (RAPs) Section 3 - Image Quality Repair Analysis Procedures (IQ RAPs) Section 4 - Repair / Adjustment (REPs) Section 5 - Parts Lists (PLs) Section 6 - General Procedures Section 7 - Wiring All service calls start with Initial Actions and all service calls end with Final Actions. Figure 1 Call Flow Diagram

Initial Issue 1.3 Initial Actions Initial Actions are used to gather information from the operator concerning problems at the local machine. Make note of symptoms, error messages, error codes or other information con- cerning the problem that the operator may provide. This information may help identify an inter- mittent or unusual problem. Procedure 1. Ensure that the power cord is connected to the wall outlet and to the machine. 2. Check for paper or other objects in the paper path. 3. Remove all paper from the output tray(s). 4. The Rear Cover and Front Cover are closed. 5. The paper is within specification and is loaded correctly in the Paper Tray(s). 6. Ask the operator to describe, or if possible, demonstrate the problem. 7. If the problem is the result of incorrect operator action, refer the operator to the User doc- umentation. NOTE: The printer has the capability of displaying error messages while in the online mode or in the diagnostic mode. The Fault History log will list the last 100 errors that have occurred. The three codes may be different in format, but you can use any one of the codes to access the Error Code Tables (Table 1 or Table 2) in section 2. The Error Code Tables will list the corrective actions or direct you to a RAP. 8. If an error message is displayed refer to the Error Code Tables (Table 1 or Table 2). 9. If possible, print the “Configuration Sheet”. To print the Configuration Sheet, press and release [1] or [5] until “Print Menu” is displayed. Then press and release [2] or [6] until “Config Sheet” is displayed. Press Enter [4] to print the sheet. If the sheet is blank, go to IQ RAP 2. 10. Have the customer determine that the configuration settings are correct. 11. If possible, print the “Fault History”. To print the “Fault History” press and release [1] or [5] until “Print Menu” is displayed. Then press and release [2] or [6] until “Fault History” is dis- played. Next, press Enter [4] to print the sheet. The Fault History will list the error codes and the meter count when the event happened. Use the Fault History to determine the fre- quency of a problem. Access the Error Code Tables (Table 1 or Table 2) and perform the corrective action as instructed. 12. If the Fault History can not be printed, the fault history can be displayed on the Control Panel. To display the “Fault History” press and release [1] or [5] until “Print Menu” is dis- played. Then press and release [2] or [6] until “Display Faults” is displayed. Next, press press [3] to display the last fault that occurred. Continue to press and release [3] to display the error codes in order from the newest to the oldest. Pressing and releasing the [4] key will display the codes in order from the oldest to the newest. The Display Faults will dis- play the error code and the meter count when the event happened. An example of the dis- play “E9-2 #820”, where E9-2 is the error code and #820 is the meter count. 13. Proceed to Corrective Actions. 1.4 Corrective Actions Procedure Ensure that the Initial Actions have been completed. Switch the main power off, wait 10 sec- onds, then switch the main power on. The Fuser Fan runs. Y N Perform RAP 2. If the DC power is correct, perform RAP 20. The Main Drive Motor runs for approximately 6 seconds, then stops. Y N Perform RAP 16. The Fuser Fan runs. Y N Perform RAP 20. In approximately 30 seconds, the LCD Panel will display “Power On” and the Power On Diag- nostic (POD) software “Version x.xxx”. The display is correct. Y N Perform RAP 25 The Control Panel will display a number of different screens as the Power On Diagnostics Completes Figure 1. The printer completes Power On Diagnostics and Ready is dis- played. Y N Perform RAP 25. Press [1] twice to select “Print Menu”, then press and release [2] until “Menu Map” is displayed. Press Enter [4] to print the “Menu Map”. “Processing Menu Map” is displayed, immediately fol- lowed by “Processing Tray #”. The display is correct. Y N Perform RAP 25/RAP 26. The Main Driver Motor runs. Y N Perform RAP 29. Paper is fed from the paper tray and is delivered to the output tray. Y N Perform RAP as specified by the Error Code / Message listed in Table 1 of section 2. The print contains readable text. Y N If the print is black or blank perform IQ RAP 10 or IQ RAP 2. If the text is garbled, Perform ()RAP A. The print quality of the Menu Map is acceptable. Y N Perform Image Quality Checkout. A manuals4you.com manuals4you.com

Enter Diagnostics and select “Print Menu”. Scroll to “Test Print”. Feed at least 5 test prints from all available trays to the Standard output tray (GP 2.5) for test print. Test prints were suc- cessfully delivered from each tray. Y N Perform RAP as specified by the Error Code / Message listed in Table 1 of section 2. If the Duplex Assembly is installed, run at least 5 duplexed prints (GP 2.5) for test print. If a Duplex Assembly is not installed, follow the “Y” path. The prints were delivered success- fully. Y N Perform RAP as specified by the Error Code / Message listed in Table 1 of section 2. If a Offset Catch Tray (OCT) is installed, run at least 5 prints to the OCT (GP 2.5) for test print. If an OCT is not installed, follow the “Y” path. Prints were successfully delivered to the OCT. Y N Perform RAP as specified by the Error Code / Message listed in Table 1 of section 2. Ensure that all normal printer conditions are set i.e. paper loaded, machine in Ready condition, internet cable connected. Have the customer send a document to the printer. The print is successful. Y N Try a sending a document from a different application. The print was successful. Y N There may be a problem with the print drivers. Have the customer contact Xerox Customer Support. There may be a problem with the application software. Have the customer contact Xerox Customer Support. Go to Final Actions. Figure 1 Power On Diagnostic Sequence A

Initial Issue 1.5 Final Actions Procedure 1. Switch the main power off. 2. Update the tag matrix as required. 3. Reinstall all the covers removed during the service call and complete all required adminis- trative tasks. 4. Clean the covers and ensure all labels are readable. 5. Switch the printer power on. If any of the customer selections were changed return them to the customer’s preferred settings. 6. Run final prints and verify image quality. For Image Quality problems, go to section 3 - Image Quality Checkout. 7. Clean the general area. 8. Communicate with the customer to inform them of actions taken and to ensure all prob- lems have been solved. manuals4you.com manuals4you.com

Initial Issue 2 Status Indicator Repair Analysis Procedures Introduction...................................................................................................................... 2-3 Measurements................................................................................................................. 2-3 Error Code Table Error Code Tables........................................................................................................... 2-5 Base Printer RAP 1 AC Power............................................................................................................. 2-11 RAP 2 DC Power............................................................................................................. 2-12 RAP 3 DC Power Loading............................................................................................... 2-13 RAP 4 Tray # Failure Power Off/On (C3)........................................................................ 2-14 RAP 5 Tray # Empty (C5)................................................................................................ 2-15 RAP 6 Remove Output From Std Bin (C5)...................................................................... 2-16 RAP 7 MBF Misfeed (E2)................................................................................................ 2-16 RAP 8 Paper Jam / Misfeed (E2) .................................................................................... 2-17 RAP 9 System Controller PWB ....................................................................................... 2-18 RAP 10 Paper Jam Open Front Cover (E3).................................................................... 2-18 RAP 11 Paper Jam / Exit (E4)......................................................................................... 2-19 RAP 12 Close Front Cvr/Close Rear Cvr (E5) ................................................................ 2-20 RAP 13 Install Print Cartridge (J3) .................................................................................. 2-21 RAP 14 Toner Low (J5)................................................................................................... 2-21 RAP 15 P1: Fuser Pause ................................................................................................ 2-22 RAP 16 Motor Failure Power Off/On (U1)....................................................................... 2-22 RAP 17 Laser Fail / Power Off/On (U2) .......................................................................... 2-23 RAP 18 Fuser Failure Power Off/On (U4)....................................................................... 2-24 RAP 19 IOT NVM Fail / Power Off/On (U6) .................................................................... 2-24 RAP 20 Fan Failure Power Off Now (U5)........................................................................ 2-25 RAP 21 Low Paper Tray #............................................................................................... 2-25 RAP 22 Paper Size Error ................................................................................................ 2-26 RAP 23 Low Toner Sensor Failure.................................................................................. 2-26 RAP 24 Inoperative Printer.............................................................................................. 2-27 RAP 25 Malfunctioning LCD/LED.................................................................................... 2-28 RAP 26 Inoperative Keypad............................................................................................ 2-29 RAP 27 Erratic Printer Operation .................................................................................... 2-29 RAP 28 Power Supply..................................................................................................... 2-30 RAP 29 Main Motor Assembly ........................................................................................ 2-31 RAP 30 Laser Assembly ................................................................................................. 2-32 RAP 31 Fuser Assembly ................................................................................................. 2-32 RAP 32 Registration Sensor ........................................................................................... 2-33 RAP 33 MBF No Paper Sensor....................................................................................... 2-34 RAP 34 Tray 1 No Paper Sensor .................................................................................... 2-34 RAP 35 Standard Bin Stack Full Sensor......................................................................... 2-35 RAP 36 Print Cartridge Sensor Assembly....................................................................... 2-35 RAP 37 Tray Motor Assembly Checkout Procedure ....................................................... 2-36 RAP 38 Registration Clutch............................................................................................. 2-36 RAP 39 Turn Roll Clutch Assembly................................................................................. 2-37 RAP 40 Tray 1 Feed Clutch ............................................................................................ 2-37 RAP 41 MBF Feed Solenoid ........................................................................................... 2-38 RAP 42 System Controller Isolation................................................................................ 2-38 RAP 43 HVPS Assembly................................................................................................. 2-39 RAP 44 Electrical Noise .................................................................................................. 2-39 RAP 45 DIMM 1 (0101)................................................................................................... 2-40 RAP 46 DIMM 2 (0102)................................................................................................... 2-41 RAP 47 DIMM 3 (0103)................................................................................................... 2-41 RAP 48 Exit Sensor......................................................................................................... 2-42 RAP 49 Exit Motor........................................................................................................... 2-42 RAP 50 Load MBF (C5) .................................................................................................. 2-43 RAP 51 Face Up Tray Open (E5).................................................................................... 2-43 500 Sheet Feeder RAP 52 Low Paper Tray 2 (or Tray 3) 550 Sheet Feeder............................................... 2-45 RAP 53 550 Sheet Feeder Feed Clutch.......................................................................... 2-45 RAP 54 550 Sheet Feeder Assembly Not Recognized................................................... 2-46 Duplex Unit RAP 55 Duplex Unit Fail or Removed (E9-1).................................................................. 2-47 RAP 56 Paper Jam Open Front Cover (E7).................................................................... 2-47 Offsetting Catch Tray RAP 57 Offset Jam Open Rear Cover (E6-X)................................................................. 2-49 RAP 58 OCT Assy Not Recognized................................................................................ 2-50 RAP 59 Remove Output From Offset Bin (C5)................................................................ 2-50 RAP 60 OCT Stack Full Sensor ...................................................................................... 2-51 RAP 61 OCT Offset Operation Not Performed................................................................ 2-51 Envelope Feeder RAP 62 Envelope Feeder Not Recognized..................................................................... 2-53 RAP 63 Envelope Feed Clutch........................................................................................ 2-53 RAP 64 Envelope No Paper Sensor ............................................................................... 2-54 RAP 65 Load Envelope (C5)........................................................................................... 2-54 RAP 66 Envelope Feeder Jam (E2)................................................................................ 2-55 manuals4you.com manuals4you.com

Initial Issue Introduction The Repair Analysis Procedures section is used to isolate and identify problems to a faulty component or subassembly. It contains the Introduction, display message table, error code table and the Repair Analysis Procedures (RAPs). Use the Error Code Tables when messages or error codes are displayed or printed in a report. The Repair Analysis Procedures (RAPs) are accessed from Section 1, system checks or addi- tional checks. There are two types of RAPs: Status Indicator (SI) RAPs, contained in this sec- tion, and Image Quality (IQ) RAPs, located in Section 3. RAPs will normally isolate a problem to a specific component or subassembly, excluding the wire harnesses. In the Y/N (Yes/No) steps of the RAPs, a Yes/No response will either lead you to the next step or will indicate a corrective action. When the indicated corrective action has been completed, go to Section 1 and restart the System Check to verify that the problem has been corrected. Measurements Power and signal grounds are connected to frame ground, therefore all circuit troubleshooting can be performed using the metal frame (chassis) as the grounding point. If more information is needed to locate connectors or test points, refer to section 7. Unless otherwise specified, the following voltage tolerances are used within this section: Table 1 Table 1 Voltage Measurements Stated Measured +3.3 VDC +3.0 to 3.6 VDC +5.0 VDC +4.8 to +5.2 VDC +24.0 VDC +21.6 to +26.4 VDC 0.0 VDC Less than +0.5 VDC manuals4you.com manuals4you.com

Status Indicator Repair Analysis Procedures Initial Issue Error Code Tables Table 1 Error Code Table General Info Control Panel Message Fault History Entry Diagnostic Message Error Description Action Tray 1 Failure Power Off/On C3-1E Tray 1 is not detected, motor failure, Stack Height Sensor Failure. Inspect and repair Tray 1 Go to RAP 4. Tray 2 Failure Power Off/On C3-2E Tray 2 is not detected, motor failure, Stack Height Sensor Failure. Inspect and repair Tray 2 Go to RAP 4. Tray 3 Failure Power Off/On C3-3E Tray 3 is not detected, motor failure, Stack Height Sensor Failure. Inspect and repair Tray 3 Go to RAP 4. Load Envelope No Fault Entry C5: EBF Add Paper Envelope is out of paper Load Paper into Envelope Go to RAP 65. Load MBF No Fault Entry C5:MBF Add Paper MBF is out of paper. Load paper into MBF Go to RAP 50. Remove Output from Off- set Bin No Fault Entry C5:OCT Tray Full 5 prints are delivered to the top tray after the OCT Full Stack Sensor is actuated. Empty OCT Tray Go to RAP 59. Remove Output from Std. Bin No Fault Entry C5: Top Tray Full Top Tray is declared full when 5 prints are delivered to the top tray after the Full Stack Sensor is actuated. Empty Top Tray Go to RAP 6. Tray 1 Empty No Fault Entry C5:Tray 1 Add Pap Tray 1 is out of paper Load paper into Tray 1 Go to Rap 5. Tray 2 Empty No Fault Entry C5:Tray 2 Add Pap Tray 2 is out of paper Load paper into Tray 2 Go to Rap 5. Tray 3 Empty No Fault Entry C5:Tray 3 Add Pap Tray 3 is out of paper Load paper into Tray 3 Go to Rap 5. Disk Error Format Disk D-1 N/A Hard Drive error was detected. Power Off/On Format Hard Drive Replace Hard Drive (PL 10.1) Replace System Controller PWB (REP 9.2). Format Failed Disk Locked D-2 N/A Cannot format disk, disk locked via PJL or SNMP Command. Customer Unlock Disk Replace Hard Disk (PL 10.1). Format Failed Disk Locked D-3 N/A Cannot put disk in factory default attempt to initialize disk after it is locked. Customer Unlock Disk Replace Hard Disk (PL 10.1). Tray 1 Feed Jam Tray 1 Jam - Open Tray 1 E2-01 E2-0: Feed Jam Paper arrives at Registration Sensor too early. Open Tray 1 Open Front Cover Clear Paper Path Go to RAP 8. Tray 2 Feed Jam Tray 2 Jam - Open Tray 2 E2-02 E2-0: Feed Jam Paper arrives at Registration Sensor too early. Open Tray 2 Open Front Cover Clear Paper Path Go to RAP 8. manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures Tray 3 Feed Jam Tray 3 Jam - Open Tray 3 E2-03 E2-0: Feed Jam Paper arrives at Registration Sensor too early. Open Tray 3 Open Front Cover Clear Paper Path Go to RAP 8. Envelope Feed Jam Envelope Feeder Jam/ Remove all Envelopes E2-0E E2-0: Feed Jam Paper arrives at Registration Sensor too early. Remove Envelope Feeder Open Front Cover Clear Paper Path Go to RAP 66. MBF Feed Jam MBF Jam - Remove All Paper E2-0M E2-0: Feed Jam Paper arrives at Registration Sensor too early. Open Front Cover Clear Paper Path Go to RAP 7. Envelope Feed Jam Envelope Feeder Jam/ Remove all Envelopes E2-1E E2-1: Feed Jam Paper does not arrive at Registration Sensor position within a specified time. Remove Envelope Feeder Open Front Cover Clear Paper Path Go to RAP 66 MBF Misfeed MBF Jam - Remove All Paper E2-1M E2-1: Feed Jam Paper does not arrive at Registration Sensor position within a specified time. Open Front Cover or Feeder Clear Paper Path Close the Cover Go to RAP 7. Tray 1 Misfeed Tray 1 Jam - Open Tray 1 E2-11 E2-1: Feed Jam Paper does not arrive at Registration Sensor position within a specified time. Open Tray 1 Open Front Cover Clear Paper Path Go to RAP 8 Tray 2 Misfeed with 550 Sheet Feeder installed as Tray 2 Tray 2 Jam - Open Tray 2 E2-12 E2-1: Feed Jam Paper does not arrive at Registration Sensor position within a specified time. Open Front Cover Open Tray 2 Clear Paper Path Go to RAP 8 Tray 3 Misfeed with 550 Sheet Feeder installed as Tray 3 Tray 3 Jam - Open Tray 3 E2-13 E2-1: Feed Jam Paper does not arrive at Registration Sensor position within a specified time. Open Tray 1 Open Front Cover Clear Paper Path Go to RAP 8 Paper Jam - Open Front Cover E3-1 E3-1: Reg. Jam Exit Sensor did not actuate within time after the Registration clutch is actuated. Open Front Cover Remove Print Cartridge Clear Paper Path Go to RAP 10 Paper Jam - Open Front Cover E3-2 E3-2: Reg. Jam 1. Registration Sensor did not deactu- ate within time after actuation of Reg- istration sensor. 2. Registration Sensor is actuated at power on. Open Front Cover Remove Print Cartridge Clear Paper Path Go to RAP 10 Exit Jam - Open Rear Cover E4-0 E4-0: Exit Jam Paper leaves Exit Sensor early. Open Rear Cover Clear Paper Path Go to RAP 11 Exit Jam 1 Exit Jam - Open Rear Cover E4-2 E4-2: Exit Jam 1. Paper late off Exit Sensor. 2. Exit Sensor on at power up. Open Rear Cover Clear Paper Path Go to RAP 11 Table 1 Error Code Table General Info Control Panel Message Fault History Entry Diagnostic Message Error Description Action

Status Indicator Repair Analysis Procedures Initial Issue Exit Jam 2 Exit Jam - Open Rear Cover E4-3 E4-3: Exit Jam Custom Paper late off Exit Sensor within a specified time from Registra- tion Sensor. Open Rear Cover Clear Paper Path Change Paper Setting in Cus- tom Mode to correct size. Go to RAP 11. Close Front Cvr Close Rear Cvr E5: FRNT/Rear Cover 1. Front cover interlock is open. 2. Rear cover interlock is open. Close Front Cover Close Rear Cover Go to RAP 12. E-5: Face Up Open Face Up Tray is open. Close Face Up Tray Check Actuator Check Sensor Go to RAP 51. Jam in the OCT Offset Jam - Open Rear Cover E6-1 E6-1: OCT Jam 1. Paper late to OCT Sensor. Open OCT Rear Door Clear Paper Path Open Printer Rear Cover Clear Paper Path Go to RAP 57 OCT Jam Offset Jam - Open Rear Cover E6-2 E6-2: OCT Jam Paper late off OCT Sensor. OCT Sensor on at Power On Open OCT Rear Door Clear Paper Path Go to RAP 57 Paper Jam - Open Front Cover E7-0 E7-0: Duplex Jam Paper arrives at Registration Sensor early from Duplex Sensor. Open Front Cover Clear Paper Path Go to RAP 56. Paper Jam - Open Rear Cover E7-1 E7-1: Duplex Jam Paper late to Duplex Sensor Open the Rear Cover Remove Duplex Unit Clear Paper Path Go to RAP 56. Duplex Jam 3 Paper Jam - Open Rear Cover E7-2 E7-2: Duplex Jam 1. Paper late off Duplex Sensor. 2. Duplex Sensor on at power up. Open Rear Cover Remove Duplex Unit Clear Paper Path Go to RAP 56. Duplex Jam 4 Paper Jam - Open Rear Cover E7-3 E7-3: Duplex Jam Paper late to Registration Sensor from Duplex Sensor. Open Rear Cover Remove Duplex Unit Clear Paper Path Go to RAP 56. Duplex Unit Fail or Removed E9-1 E9-1: Duplex Fail Duplex module removed while power is on. Reinstall Duplex Module Go to RAP 55. Offset Bin Fail Power Off/On E9-2 E9-2: OCT Fail OCT removed while power is on. Switch Power Off Remove and Reinstall OCT Switch Power On Go to RAP 58. Envelope Feeder Fail or Removed E9-E E9: EBF Unit Fail Envelope Feeder module removed while power on. Reinstall Envelope Feeder Go to RAP 62. Tray 2/3 Failure Power Off/On E11 E11: Tray 2/3 Fail Trays 2/3 disconnected after power on. Reinstall Trays 2/3 Go to RAP 54. Table 1 Error Code Table General Info Control Panel Message Fault History Entry Diagnostic Message Error Description Action manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures Paper Size Jam Open Rear Cover PSE-1 C5: Paper Size Error There is a conflict between the size of the paper, which is detected by the Size Switches, and the length of paper the printer detects by the length of time the Registration Sensor is actuated. Correct the mismatch Open Rear Cover Go to RAP 22. Install Print Cartridge J3: EP Cartridge 1. Print Cartridge is not installed 2. The installed Print Cartridge is not the correct one. Install the Print Cartridge, or replace with the correct Print Cartridge Go to RAP 13. Toner Low No Fault Entry J5:Toner Low Toner Low is detected after 10 prints while Toner Sensor is on. Replace Print Cartridge Go to RAP 14. Memory Failure Power Off/On ESS-M N/A Controller memory has failed (32 meg on board). Power Off/On Go to RAP 9. NV Memory Fail Power Off/On ESS-N N/A Controller NVM Failure. Power Off/On Go to RAP 9. Flash Error Format Flash FMF-1 N/A Flash Memory error found. Flash memory format required. Flash memory format required Go to RAP 9. Motor Failure Power Off/On U1 U1: Motor Fail Motor Fail signal is declared 1.3 sec- onds after start of Main Motor. Power Off and On Go to RAP 16. Laser Failure Power Off/On U2 U2: ROS Fail 1.Laser Signal intervals are longer than the Ready time interval 20 sec- onds after the start of Laser warm up. 2. The laser power does not reach the value in NVM when the laser diode is switched on after the start of Laser warm up. 3. Laser signal intervals become longer than the Fail time interval after Laser warm up is completed. Power Off and On Go to RAP 17. Fuser Failure Power Off/On U4 U4: Fuser Fail 1. Fuser temperature drops below the set temperature after the Fuser warm up is complete. 2. Fuser warm up does not complete within 110 seconds. 3. Thermistor circuit is detected to be open. 4. Fuser temperature rises above the set temperature. 5. Heat rod is on for 10 seconds when the Main Drive Motor is stopped, after the Fuser warm up is completed. Power Off and On Go to RAP 18. Fan Failure Power Off Now U5 U5: Fan Fail Printer Pause Main Fan has failed. Check the Main Fan Power Off and On Go to RAP 20 Table 1 Error Code Table General Info Control Panel Message Fault History Entry Diagnostic Message Error Description Action

Status Indicator Repair Analysis Procedures Initial Issue IOT NVM Fail Power Off/On U6 U6: NVM Fail 1. A read error is detected during power on. 2. A write error is detected during write to the Nonvolatile Memory. Power Off and On Replace Print Engine Control- ler PWB (REP 9.3). Table 1 Error Code Table General Info Control Panel Message Fault History Entry Diagnostic Message Error Description Action Table 2 System Controller Error Code Table Control Panel Message LED # blinks Followed by 1 sec. off Comment 0001 - System Controller 1 System Controller Board major failure. Go to RAP 42. 0001 - BASE RAM 1 System Controller Board RAM failure. Go to RAP 42. 0001 - BASE ROM 3 System Controller Board boot ROM. Go to RAP 42. 0001 - ASIC 4 System Controller Board ASIC failure. Go to RAP 42. 0001 - TIMER 4 System Controller Board Timer failure. Go to RAP 42. 0001 - PWPM 5 System Controller Board PWPM failure. Go to RAP 42. 0001 - DMA 5 System Controller DMA failure. Go to RAP 42. 0001 - COMM 6 System controller parallel port failure, USB port failure, E- Net Port Failure. Replace System Controller PWB (REP 9.2) 1000 - IOT 8 System Controller - IOT handshake failure. Remove and reinstall the System Controller PWB (REP 9.2). Replace the System Controller PWB (REP 9.2). Replace the Print Engine Controller PWB (REP 9.3). 0010 - DISK 9 Hard disk failure. Format Hard Disk (see Reset Menu - GP 4.1). Replace the Hard Disk (PL 10.1). Replace the System Controller PWB (REP 9.2). 0101 - DIMM1 10 DIMM board 1 failure. Go to RAP 45. 0102 - DIMM2 11 DIMM board 2 failure. Go to RAP 46. 0103 - DIMM3 12 DIMM board 3 failure. Go to RAP 47. 2000 - XIE RAM 15 System Controller Xerox Image Enhanced PWPM failure. Replace the System Controller PWB (REP 9.2). 2010 - XIE PWPM 15 System Controller Xerox Image Enhanced PWPM failure. Replace the System Controller PWB (REP 9.2). 2020 - XIE VDMA 15 System Controller Xerox Image Enhanced VDMA failure. Replace the System Controller PWB (REP 9.2). 3000 - Token Ring 3000 - Serial 3000 - E-Net (10 Base 2) 16 Replace the appropriate network card (PL 10.1). Replace System Controller PWB (REP 9.2). 5000 - Memory None Memory size not large enough to load the system software Download Data. Replace System Controller PWB (REP 9.2). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures

Initial Issue RAP 1 AC Power Initial Actions Disconnect the AC power cord from the wall outlet. WARNING Improper connection of the grounding conductor can result in the risk of electrical shock. The following must be observed: • Never use a ground adapter plug to connect the machine to a power source. • Never attempt any maintenance function which is not specifically called out in the service procedures. • Never remove any covers which are fastened with screws, unless so instructed in the service procedures. CAUTION If any of the voltage measurements are not as specified in the following steps, the cause must be corrected. Caution the customer NOT to connect the machine to the wall outlet. Advise the customer that a licensed electrician must correct the wiring. Do not attempt to correct the wir- ing yourself. If you later find the condition has not been corrected, inform your manager in writ- ing of the improper wiring. Procedure Perform one of the following line voltage checks: US, XCI, and AO (115 VAC) Figure 1. Perform the following: Measure the AC voltage between AC Line and Neutral, between AC Line and Ground, and between AC Neutral and Ground. The voltage between Line and Neutral and between Line and Ground is 90 to 140 VAC and the voltage between Neutral and Ground less than 3 VAC. Figure 1 US, XCI, and AO (115 VAC) Outlet. XL, UK and AO (220 VAC) Figure 2. Perform the following: Measure the AC voltage between Line and Neutral, between Line and Earth/Ground, and between Neutral and Earth/Ground. The voltage between Line and Neutral and between Line and Earth/Ground is 198 to 264 VAC and between Neutral and Earth/Ground is less than 3 VAC. Figure 2 XL, UK, and AO (220 VAC) Outlet. XL, Europe (220 VAC) Figure 3. Perform the following: Measure the AC voltage between the supply pins, then between a supply pin and earth, then between the other supply pin and earth. The voltage is 198 to 264 VAC between the supply pins and between one of the supply pins and earth. Between the other supply pin and earth is less than 3 VAC. Figure 3 XL, Europe (220 VAC) Outlet. The voltage measured is correct. Y N Inform the customer of insufficient voltage or improper wiring. Check the continuity through all connections of the power cord. The measurement is less than 10 ohms for each connection. Y N Replace the power cord (PL 10.1), as applicable. Perform RAP 2. manuals4you.com manuals4you.com

RAP 2 DC Power This procedure is used to troubleshoot the Low Voltage Power Supply. Procedure Perform RAP 1 before starting this RAP. If RAP 1 results are correct, switch the printer power off and disconnect the printer power. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Connect printer power. Switch the printer power on. Measure the voltage on the LVPS between P/J285 pins 1 and 2. The voltage matches the line voltage. Y N Repair/replace the AC Wire Assembly (PL 10.1). Measure the voltage between both sides of the Fuse F1 and frame ground. Both readings match the line voltage. Y N Switch the printer power off. Replace fuse F1 (125V - 10A / 250V - 3A). Switch the printer power on. Measure the voltage between both sides of the Fuse F1 and frame ground. Both readings match the line voltage. Y N Replace the LVPS (REP 9.5). Problem Solved. Measure the voltage between LVPS P/J281 pin 1 and frame ground. The voltage is +24VDC. Y N On the LVPS, measure the voltage between P/J284 pin 2 and frame ground. The voltage is +24VDC Y N Switch the printer power off. Disconnect printer power. Disconnect P/J 281. Connect printer power. Switch the printer power on. Measure the voltage between LVPS P/J 281 pin 1 and frame ground. The voltage is +24VDC. Y N Replace the LVPS (REP 9.5). Go to RAP 3. Measure the voltage between P/J 284 pin 1 and frame ground. The voltage is +24VDC. Y N Check the Front Cover. The Front Cover is closed and actuating the interlock switch. Y N Repair or replace the defective cover/interlock switch as necessary. Check the continuity through the interlock switch. Replace if necessary. Replace the LVPS (REP 9.5). Check the voltages listed in Table 1. All voltages in Table 1 are correct. Y N Go to RAP 3. Return to Initial Actions or to the procedure that sent you here. Table 1 Low Voltage Readings Red Lead Black Lead Voltage P/J281 pin 7 Frame Ground +5.0VDC P/J281 pin 10 Frame Ground +3.3VDC P/J281 pin 1 Frame Ground +24.0VDC A A

Initial Issue RAP 3 DC Power Loading Initial Actions Perform RAP 2 DC Power before starting this RAP. WARNING AC input voltages can be lethal. Use extreme care while checking the voltages on the LVPS. Disconnect the power cord while checking the continuity of fuses and while removing or reinstalling the components. Procedure Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect the following from the LVPS: • P/J281 (Print Engine Controller PWB) • P/J282 (System Controller PWB) • P/J283 (LVPS Fan) • Pn1 (5VDC Power Supply) Switch the printer power on and measure the voltages listed in Table 1 on the LVPS. All voltages are correct. Y N Replace the LVPS (REP 9.5). Switch the printer power off. Reconnect P/J281 to the LVPS. Switch the printer power on and measure the voltages listed in Table 1. All the voltages are correct Y N Switch the printer power off. Reconnect all the P/Js to the LVPS. Disconnect the following from the Print Engine Controller PWB: • P/J22 (Laser) • P/J21 (Laser, SOS) • P/J23 (Connector PWB) • P/J25 (Print Cartridge Sensor) • P/J32 (Exit Motor) • P29 (Main Motor) • P/J26 (HVPS PWB) • P/J27 (Exit Sensor) • P/J31 (Stack Full Sensor) • P/J33 (Size 1 PWB) • P/J34 (Duplex PWB) • P/J35 (OCT PWB) Switch the printer power on and measure the voltages listed in Table 1. All voltages are correct. Y N Replace the Print Engine Controller PWB (REP 9.3). Switch the printer power off. Reconnect P/J23. Switch the printer power on. Measure the voltages listed in Table 1. All the voltages are correct. Y N Disconnect the following from the Connector PWB: • P/J43 (Registration Sensor, Registration Clutch) • P/J42 (Toner Sensor) • P/J45 (Paper Set Sensor) • P/J44 (Pick Up Solenoid) • P/J41 (Envelope PWB) Switch the printer power on. Measure the voltages listed in Table 1. All the volt- ages are correct. Y N Replace the Connector PWB. Switch the printer power off. Reconnect one of the disconnected plugs. Switch the printer power on. Measure the voltages listed in Table 1. All the voltages are cor- rect. Y N Replace the component just connected to the Connector PWB. Repeat the step with the next disconnected plug. Switch the printer power off. Reconnect one of the disconnected plugs. Switch the printer power on. Measure the voltages listed in Table 1. All the voltages are correct. Y N Replace the component just connected to the Print Engine Controller PWB. Repeat the step with the next disconnected plug. Switch the printer power off. Reconnect one of the disconnected plugs. Switch the printer power on. Measure the voltages listed in Table 1. All the voltages are correct. Y N Replace the component just connected to the LVPS. Repeat the step with the next disconnected plug. Table 1 LVPS Red Lead Black Lead Voltage P/J281 pin 7 Frame Ground +5.0VDC P/J281 pin 10 Frame Ground +3.3VDC P/J281 pin 1 Frame Ground +24.0VDC A A manuals4you.com manuals4you.com

RAP 4 Tray # Failure Power Off/On (C3) Tray Assembly (Tray 1, Tray 2, or Tray 3) are not in place. Procedure Enter Diagnostics, run a test print from every tray (see section 6). The Error Code specifies Tray 2 or Tray 3. Y N Remove and reinstall Tray 1. Press key “0”. The C3 error code still appears. Y N Problem solved. Measure the voltage from the lower contact of the Paper Feeder Socket (P/J672) and frame ground. The voltage is +24VDC. Y N Measure the voltage from P/J33 pin 6 on the Print Engine Controller PWB and frame ground. The voltage is +24VDC. Y N Go to RAP 2. Switch off the printer power. Remove the Size Sensor Housing (REP 3.11). Measure continuity between the disconnected P/J33 pin 6 to P/J331 pin 12 on the Tray 1 Size PWB. There is continuity between the two pins. Y N Repair or replace Feeder Harness Assembly (PL 9.1). On the Tray 1 Size PWB, measure continuity between P/J331 pin 12 to P/J61 pin 1. There is continuity between the two pins. Y N Replace the Tray 1 Size PWB (REP 3.13). Check the wiring between P/J67 pin 5 on the Tray 1 Feeder PWB and the bottom pin on the Paper Feeder Socket (P/J672). If in good condition, replace the Tray 1 Feeder PWB (REP 3.9). On the paper tray, measure the resistance between the middle and bottom terminals on the Paper Feeder Socket. The resistance is 75 to 105 ohms. Y N Go to RAP 37 On the paper tray, measure the resistance between the top and bottom terminals on the Paper Feeder Socket. There is continuity (0 ohms) between the two pins. Y N Repair or replace the Paper Feeder Socket. Replace the following parts one at a time until the problem is resolved: • Stack Height Sensor (3.4) • Feeder PWB (3.9) • Size 1 PWB (3.13) • Print Engine Controller PWB (9.3) Remove and reinstall the Tray indicated. Press key “0”. The C3 error code still appears. Y N Problem solved. Exchange Tray 1 with the Tray generating the “C3” code. Run a test print from each tray. The error code now indicates a Tray 1 failure. Y N The error code indicates a Tray 2 failure. Y N Remove the Tray 3 from the paper feeder. Check the voltage between the lower ter- minal on the Paper Feeder Connector and frame ground. The voltage is +24VDC Y N Check the wiring harnesses between the Tray 2 Size PWB (P/J53) and the Tray 3 Size PWB (P/J54). Repair or replace if necessary. If the harnesses are in good condition, replace the Tray 3 Size PWB (REP 11.19) then the Tray 3 Feeder PWB (REP 11.9). Replace the following components, in order, until the problem is resolved: • Stack Height Sensor (REP 11.13) • Feeder PWB (REP 11.9) • Size PWB (REP 11.19) • Print Engine Controller PWB (REP 9.3). Remove the Tray 2 from the paper feeder. Check the voltage between the lower terminal on the Paper Feeder Connector and frame ground. The voltage is +24VDC Y N Check the wiring harnesses between the Tray 1 Size PWB (P/J51) and the Tray 2 Size PWB (P/J52). Repair or replace if necessary. If the harnesses are in good con- dition, replace the Tray 2 Size PWB (REP 11.19) then the Tray 2 Feeder PWB (REP 11.9). Replace the following components, in order, until the problem is resolved: • Stack Height Sensor (REP 11.13) • Feeder PWB (REP 11.9) • Size PWB (REP 11.19) • Print Engine Controller PWB (REP 9.3). Remove the Tray now occupying the Tray 1 position and continue with RAP 37. A A

Initial Issue RAP 5 Tray # Empty (C5) Procedure The problem appears when using Tray 2 or Tray 3. Y N Check the paper level in Tray 1. There is paper in Tray 1. Y N Load paper into Tray 1. Enter diagnostics and select Test Print. Run a test print from the Tray 1. The C5 error code reappears. Y N Return to Initial Actions and restart. Remove Tray 1 from the printer. Remove all paper from the tray. Reinsert Tray 1 into the printer. From the rear of the printer, watch the Tray 1 bottom plate. The Bottom Plate is raised fully and evenly. Y N Go to RAP 37. Remove Tray 1. Manually actuate the Tray 1 No Paper sensor. The No Paper Actuator moves smoothly. Y N Replace the Tray 1 No Paper Actuator (REP 3.3). Enter diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Manually actuate the Tray 1 No Paper Sensor. The number on the LCD increments each time you press and release the actuator. Y N Go to RAP 34. Replace the Print Engine Controller PWB (REP 9.3). Check the paper level in Tray 2/3. There is paper in the Tray. Y N Load paper into Tray 2/3. Enter diagnostics and select Test Print. Run a test print from Tray 2/3. The C5 error code reappears. Y N Return to Initial Actions and restart. Remove Tray 2/3 from the printer. Remove all paper from the tray. Reinsert the Tray into the printer. From the rear of the printer, watch the tray bottom plate. The Bottom Plate is raised fully and evenly. Y N Go to RAP 37. Remove Tray 2/3. Manually actuate the No Paper Sensor. The No Paper Actuator moves smoothly. Y N Replace the Tray 2/3 No Paper Actuator (REP 11.7). Enter diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Manually actuate the Tray 2/3 No Paper Sensor. The number on the LCD increments each time you press and release one of the actuators. Y N Replace in order; the Feeder PWB (REP 11.9) then the Size PWB (REP 11.19) for the problem feeder assembly. Replace the Print Engine Controller PWB (REP 9.3). A A manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 6 Remove Output From Std Bin (C5) Error code indicates the output tray is full. Procedure There is a paper stack in the standard bin actuating the stack full Sensor. Y N The paper is curled. Y N Lift and release the Stack Full Actuator a few times. The actuator moves freely. Y N Replace Stack Full Actuator (REP 6.8) or Stack Full Sensor (REP 6.6), as nec- essary. Enter diagnostics and select Component Test. Scroll to Sensor Input test. Manually actuate and deactuate the Stack Full Actuator. The number on the LCD incre- ments each time you lift and release the actuator (the count may have a short delay because of the sensor circuit). Y N Go to RAP 35. Replace Print Engine Controller PWB (REP 9.3). Replace paper in paper tray with fresh dry paper. Run test prints. The error code reap- pears. Y N Problem solved. Enter diagnostics and select Component Test. Scroll to Sensor Input test. Manually actu- ate and deactuate the Stack Full Actuator. The number on the LCD increments each time you lift and release the actuator (the count may have a short delay because of the sensor circuit). Y N Go to RAP 35. Replace Print Engine Controller PWB (REP 9.3). Remove the paper stack. RAP 7 MBF Misfeed (E2) Paper arrives early or late to the Registration Sensor. Procedure Switch the printer power off. Open the Front Cover. Check the MBF Chute for contamination or obstructions. The MBF is free of contamination, paper, or other obstructions. Y N Clean the MBF and remove the paper or obstruction. Check the MBF Feed Roll for contamination and wear. The feed roll is clean and in good condition. Y N Replace the MBF Feed Roll (REP 4.3). Enter Diagnostics and select Component Test. Scroll to Confirm MBF Feed Solenoid and press Enter [4]. You can hear the solenoid energize. Y N Go to RAP 41. Open the Front Cover and cheat the Front Cover Interlock. Scroll to Main Motor Operation and press Enter. The MBF drive gears rotate smoothly. Y N Check, repair, or replace the Drive Gear (PL 5.1), Main Drive Gear Assembly (REP 8.2), or Main Motor Assembly (REP 8.1) as necessary. Scroll to Confirm MBF Feed Solenoid and press Enter [4]. The Feed Roll Shaft rotates, the Pick-up Cams move and allow the Bottom Plate to contact the Feed Roll, and the Feed Roll Shaft stops after one complete revolution. Y N Remove the MBF Chute Assembly (REP 4.1) and repair of replace the components as necessary. Check the Registration Sensor (RAP 32). If the Registration Sensor is good, and the problem persists, replace the Print Engine Controller PWB (REP 9.3).

Initial Issue RAP 8 Paper Jam / Misfeed (E2) Paper arrives early or late to the Registration Sensor or is on the sensor at power up. Procedure Check the paper in all trays. Check for curled, damaged, or damp paper and for paper that is out of specification. The paper is in good condition and meets specification. Y N Replace with fresh dry paper that is within specifications. Check all paper paths for contamination, paper, or other obstructions. All paper paths are clean and free of obstructions. Y N Remove contamination or obstructions. Enter Diagnostics and select Test Print. Run five prints from every paper tray. The problem appears when printing from Tray 2 or 3. Y N Remove Tray 1 from the printer. Check the Nudger Roll, Feed Roll, and Retard Roll for contamination and wear. All rolls are clean and in good condition. Y N Clean or replace the Nudger, Feed or Retard Roll as necessary (REP 3.8/REP 2.1). Reinsert Tray 1 into the printer. From the rear of the printer, watch the Tray 1 Bottom Plate. The Bottom Plate is raised fully and evenly. Y N Go to RAP 37. From the rear of the printer, watch the paper feed as you run a test print from tray 1. The Nudger Roll and Feed Roll rotate. Y N Go to RAP 40. Paper is fed from the tray to the Turn Roll Assembly. Y N Replace the Nudger and Feed Rolls (REP 3.8). The Turn Roll Assembly moves the paper to the Registration Sensor. Y N Go to RAP 39. Go to RAP 32. Remove Tray 1. Check the paper chute at the front of the tray (the chute guides paper from Tray 2 to the Tray 1 turn rolls). Check for contamination, paper, or other obstructions. The chute is clean and free of obstructions. Y N Remove obstructions and clean chute. Replace paper tray if necessary (PL 2.1). The jams occur when feeding from tray 3. Y N Remove tray 2 and place the tray in feeder 1. Place tray 1 in feeder 2. Enter diagnostics and select Test Print. Run 20 to 25 test prints from tray 2. All prints completed sucess- fully. Y N Remove the tray currently in feeder 2. Check the Nudger and Feed Rolls in feeder 2 for contamination and wear. The Feed Rolls are clean and in good condition. Y N Replace the Feed Rolls (REP 11.11). Check the Tray 2 Turn Roll Assembly. Check for obstructions, contamination, or wear. The Turn Rolls are clean and in good condition. Y N Remove the obstruction, clean, or replace the Turn Roll Assembly (REP 11.8). Replace the Feeder PWB (REP 11.9). If the problem persists, replace the Size PWB (REP 11.19) then the Print Engine Controller (REP 9.3). The paper tray currently in feeder 1 appears to be defective. Perform RAP 37 to check the tray motor. If RAP 37 checks out correctly, check the paper tray for contamination, obstructions, broken or deformed parts. Replace the paper tray if necessary (PL 2.1). Remove Tray 1 and Tray 2. Check the paper chute at the front of both trays (the chute guides paper from Tray 3 to the Tray 2 turn rolls and from Tray 2 to the Tray 1 turn rolls). Check for con- tamination, paper, or other obstructions. The chute is clean and free of obstructions. Y N Remove obstructions and clean chute. Replace paper tray if necessary (PL 2.1). Replace Tray 2. Remove tray 3 and place the tray in feeder 1. Place tray 1 in feeder 3. Enter diagnostics and select Test Print. Run 20 to 25 test prints from tray 3. All prints completed successfully. Y N Remove the tray currently in feeder 3. Check the Nudger and Feed Rolls in feeder 3 for contamination and wear. The Feed Rolls are clean and in good condition. Y N Replace the Feed Rolls (REP 11.11). Check the Tray 3 Turn Roll Assembly. Check for obstructions, contamination, or wear. The Turn Rolls are clean and in good condition. Y N Remove the obstruction, clean, or replace the Turn Roll Assembly (REP 11.8). Replace the Feeder PWB (REP 11.9). If the problem persists, replace the Size PWB (REP 11.19) then the Print Engine Controller (REP 9.3). The paper tray currently in feeder 1 appears to be defective. Perform RAP 37 to check the tray motor. If RAP 37 checks out correctly, check the paper tray for contamination, obstructions, broken or deformed parts. Replace the paper tray if necessary (PL 2.1). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 9 System Controller PWB Procedure Switch the printer power off. Remove the Left Interface Cover (REP 1.1). Remove all options and host interface cables from the System Controller PWB. Switch the printer power on. The error code reappears. Y N Switch the printer power off. Reinstall one of the removed cables or options. Switch the printer power on. The error code reappears. Y N Repeat the step with the next option or cable. Replace the option just installed. Replace the System Controller PWB (REP 9.2). RAP 10 Paper Jam Open Front Cover (E3) Paper is late to the Exit Sensor, paper is late off the Registration Sensor or Registration Sensor is actuated at power on. Procedure Switch the printer power off. Open the Front Cover and remove the Print Cartridge. Check the printer for contamination, paper scraps, or other obstructions. The paper path is clean and free of obstructions. Y N Clean components and remove all obstructions. Open the Rear Cover. Remove the Duplex unit if installed. Open the Fuser Access Cover. Check for contamination, paper scraps, or other obstructions. The paper path is clean and free of obstructions. Y N Clean components and remove all obstructions. Rotate the Fuser Idler Gear. The Fuser Idler Gear rotates smoothly. Y N Replace the Fuser Assembly (REP 6.2). Check the paper in all trays. The paper loaded in the paper trays is damp, wrinkled, or damaged. Y N The paper size used is within specifications. Y N Replace with paper meeting size specifications. Close the Rear Cover. Cheat the Front Cover Interlock. Enter diagnostics and select Com- ponent Test. Scroll to Confirm Reg Clutch and press Enter. You can hear the Registra- tion Clutch energize. Y N Go to RAP 38. Scroll to Main Motor Operation and press Enter. The Registration Rolls rotate smoothly. Y N Repair or replace as necessary: the Registration Rolls (REP 5.6), Registration Clutch (REP 5.5), Main Drive Gear Assembly (REP 8.2), or Main Motor Assembly (REP 8.1). Perform RAP 32 to test the Registration Sensor. The Registration Sensor is working correctly. Y N Repair or replace the Registration Sensor as necessary (REP 5.4). Perform RAP 48 to test the Exit Sensor. The Exit Sensor is working correctly. Y N Replace the Fuser Assembly (REP 6.2). A B

Status Indicator Repair Analysis Procedures Initial Issue Select Test Print and Run test prints. When the error code appears, inspect the position of lead edge of the paper. The lead edge of the paper passes between the BTR and the Print Cartridge Drum. Y N Check for contamination or obstructions between the Registration Rolls and the Print Cartridge Drum. The Detack Saw is clean and free of contamination. Y N Clean the Detack Saw or Replace the Transport Chute Assembly (REP 6.1) Inspect paper path between Transport Chute Assembly and the Fuser Assembly. The paper passes through the Fuser Assembly. Y N Replace the Fuser Assembly (REP 6.2). Replace the Print Engine Controller PWB (REP 9.3). Replace with fresh, dry paper. RAP 11 Paper Jam / Exit (E4) There is a paper jam at the Exit Sensor. Procedure Check the paper in the paper trays. Ensure the paper is installed correctly and the end guide touches the rear of the paper stack. The paper is within specification. If Custom Mode is used, ensure the settings are correct. All settings are correct and the paper is within specifica- tion. Y N Install fresh paper that is within specification or correct settings. Check the paper path for contamination, paper, or other obstructions. The paper path is clean and free of obstructions. Y N Remove obstructions and clean components as necessary. Enter Diagnostics and select Test Print. Run 25 prints from Tray 1. When the error code is displayed, there is paper on the Exit Sensor. Y N Open the Rear Cover and the Fuser Access Cover. Check the Exit Sensor Actuator. The actuator moves freely and returns to the home position when released. Y N Repair actuator or replace the Fuser Assembly (REP 6.2). Enter diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Open the Fuser Access Cover and use a piece of paper to block and unblock the Exit Sensor. The number on the LCD increments each time you press and release the actuator. Y N Go to RAP 48. Replace Print Engine Controller PWB (REP 9.3). Open the Rear Cover and check the Face Up Chute Assembly for contamination or obstruc- tions. The chute assembly is clean and free of obstructions. Y N Clean of replace the Face Up Chute Assembly as necessary (PL 1.2). Select Component Test. Scroll to Exit Motor FWD and press Enter. The Exit Motor rotates. Y N Go to RAP 49. The Exit Rollers and Pinch Rollers (on the Rear Cover) rotate smoothly. Y N Replace the Exit Rollers or Gears as necessary (PL 7.1). Check the Fuser Assembly for obstructions or contamination. The Fuser is clean and free of obstructions. Y N Clean or replace the Fuser Assembly (REP 6.2), as necessary. A B A manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures Check the Transport Chute for contamination or obstructions. The Transport Chute is clean and free of obstructions. Y N Clean of replace the Transport Chute as necessary (REP 6.1). Replace the Print Engine Controller PWB (REP 9.3). RAP 12 Close Front Cvr/Close Rear Cvr (E5) The Front Cover / Rear Cover (Interlock Switch) is open. Procedure Open and close the Front Cover. Inspect the movement of the Interlock Switch. The actuator tab on the Front Cover presses down on the Interlock Switch lever. Y N Replace the Front Cover Assembly (PL 1.1). Open and close the Rear Cover. Inspect the movement of the Interlock Switch. The actuator tab on the Rear Cover presses down on the Interlock Switch lever. Y N Replace the Rear Cover Assembly (PL 1.3). Enter diagnostics and select Component Test. Scroll to Sensor Input test and press Enter [4]. Open and close the Rear Cover. The number on the LCD increments each time you open and close the Rear Cover. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), the Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J30 from the Print Engine Controller PWB. Measure the resistance between pins 1 and 2 on the discon- nected plug as you open and close the Rear Cover. There is continuity when the Rear Cover is closed and infinity when the Rear Cover is open. Y N Check the wiring between P/J30 and the Rear Cover Interlock Switch. Repair or replace the wiring or interlock switch (REP 9.10) as required. Replace the Print Engine Controller PWB (REP 9.3). Open and close the Front Cover. The number on the LCD increments each time you open and close the Front Cover. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), the Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J284 from the LVPS PWB. Measure the resistance between pins 1 and 2 on the disconnected plug as you open and close the Front Cover. There is continuity when the Front Cover is closed and infinity when the Front Cover is open. Y N Check the wiring between P/J284 and the Front Cover Interlock Switch. Repair or replace the wiring or interlock switch (REP 9.9) as required. Connect P/J284 to the LVPS. Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/J28 pin 1 and frame ground. The voltage is 24VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). A

Status Indicator Repair Analysis Procedures Initial Issue RAP 13 Install Print Cartridge (J3) The Print Cartridge is not in place or is installed incorrectly. Procedure Open the Front Cover and remove the Print Cartridge. Inspect the tab on the top left of the Print Cartridge that actuates the Print Cartridge Sensor Assembly. The tab on the Print Cartridge is intact. Y N Replace the Print Cartridge (PL 8.1). Press and release the Print Cartridge Sensor Assembly Actuator. The Print Cartridge Sen- sor Assembly Actuator lever moves smoothly. Y N Replace the Print Cartridge Sensor Assembly (REP 7.3). Enter diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Manually actuate the Print Cartridge Sensor Assembly Actuator. The number on the LCD increments each time you press and release the actuator. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), the Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Install the Print Cartridge. Leave the Front Cover open. Disconnect P/J25 from the Print Engine Controller PWB. Check for continuity between J21-4 and J25-3, and J25-2 and J25-1 as you insert and remove the Print Cartridge. There is continuity between J25-4 and J25-3, and J25-2 and J25-1 when you insert the cartridge and no continuity when you remove the cartridge. Y N The Print Cartridge is a Xerox N2125 Print Cartridge. Y N Replace Print Cartridge with a Xerox N2125 Print Cartridge (PL 8.1). Replace the Print Cartridge Sensor Assembly together with the harness (REP 7.4). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). RAP 14 Toner Low (J5) The Print Cartridge is in a low toner condition. Procedure Install a new Print Cartridge. The J5 Error Code still appears. Y N Problem solved. Remove the Front Cover (REP 1.6) and the Left Front Cover (REP 1.7). Cheat the Front Cover Interlock Switch. On the Connector PWB, check the voltage between P/J42 pin 4 and frame ground. The voltage is 0.0VDC with the print cartridge installed and 3.3VDC with the print cartridge removed. Y N Check the voltage between P/J42 pin 3 and pin 1. The voltage is 24VDC. Y N On the Connector PWB, check the voltage between P/J231 pin 11 and pin 12. The voltage is 24VDC. Y N Check the Connector Harness Assembly. If OK, replace the Print Engine Con- troller PWB (REP 9.3). Replace the Connector PWB (REP 9.7). Replace the Toner Sensor (REP 5.2). On the connector PWB, check the voltage between P/J231 pin 9 and frame ground. The volt- age is 0.0VDC with the print cartridge installed and 3.3VDC with the print cartridge removed. Y N Replace the Connector PWB (REP 9.7). Check the Connector Harness Assembly. If OK, replace the Print Engine Controller PWB (REP 9.3). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 15 P1: Fuser Pause Receiving PAUSE command from the Controller. Procedure Switch OFF the printer power. Remove the Fuser Assembly. Measure the resistance between pins A4 & A5 of P272 on the Fuser Assembly (Figure 1). The resistance reads between 7K ohms and 380K ohms (see NOTE). Y N Replace the Fuser Top Cover (REP 6.9). Replace the Print Engine Controller PWB (REP 9.3). NOTE: The resistance measured will be determined by the actual temperature of the Fuser when the test is made. The acceptable range is between 7K ohms and 380K ohms. Figure 1 Fuser Connector RAP 16 Motor Failure Power Off/On (U1) There is a problem with the Main Motor. Procedure Remove the Left Interface Cover (REP 1.1), the Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Open the Rear Cover and, if installed, remove the Duplex Assembly. Manually rotate the rotor of the Main Motor clockwise (as viewed from the left side of the printer). The rotor of the Motor rotates smoothly. Y N Open the Front Cover and remove Print Cartridge. Manually rotate the rotor of motor clockwise. The rotor of Main Motor rotates smoothly. Y N Remove the Fuser Assembly (REP 6.2). Manually rotate the rotor of the Motor clock- wise. The rotor of the Main Motor rotates smoothly. Y N Remove the Main Motor (REP 8.1). Manually rotate the rotor of the Motor clock- wise. The rotor of Main Motor rotates smoothly. Y N Replace the Main Motor (REP 8.1). Replace the Main Drive Gear Assembly (REP 8.2) Replace the Fuser Assembly (REP 6.2). Replace the Print Cartridge (PL 8.1). Open the Front Cover and remove the Print Cartridge. Rotate the Metal Registration Roll man- ually. The Metal and Rubber Registration Rolls rotate smoothly. Y N Replace the Registration Rolls (REP 5.6) or clutch (REP 5.5), as necessary. With the Front Cover open, cheat the Front Cover Interlock. Enter diagnostics and select Com- ponent Test. Run the Main Motor Operation. Visually inspect the Main Motor and Main Drive Gears. The Main Motor and drive gears run smoothly and all drive gears are in good condition. Y N Go to REP 8.1. With the Main Motor still running, select MBF Feed Solenoid. The MBF Feed Roll Assembly rotates smoothly. Y N Replace the MBF Feed Roll components as necessary (REP 4.2/REP 4.3). Scroll to Turn Roll Clutch and press Enter. All Turn Roll Shafts rotate smoothly. Y N Repair or replace the appropriate Turn Roll Assembly (REP 3.2/REP 11.8). Scroll to Reg Roll Clutch and press Enter. The Registration Roll rotate smoothly. Y N Repair or replace the Registration Rolls (REP 5.6) as necessary. A

Status Indicator Repair Analysis Procedures Initial Issue Remove the paper from all paper trays. Scroll to Tray 1 Feed Clutch and press Enter. The Main Motor continues to rotate smoothly. Y N Repair or replace the Tray 1 Feed Clutch or Feed Shaft (REP 3.6). The printer has a Tray 2. Y N Replace the Main Motor Assembly (REP 8.1). Scroll to Tray 2 Feed Clutch and press Enter. The Main Motor continues to rotate smoothly. Y N Repair or replace the Tray 2 Feed Clutch or Feed Shaft (REP 11.10). The printer has a Tray 3. Y N Replace the Main Motor Assembly (REP 8.1). Remove the paper from all paper trays. Scroll to Tray 3 Feed Clutch and press Enter. The Main Motor continues to rotate smoothly. Y N Repair or replace the Tray 3 Feed Clutch or Feed Shaft (REP 3.6). Go to RAP 29. RAP 17 Laser Fail / Power Off/On (U2) There is a problem with the Laser Assembly. Procedure Enter Diagnostics and select NVM Config (password 0734). Check the value for Print Resolu- tion and for Laser Power. The value for Resolution is “02” and for Laser Power is “8”. Y N Replace the Print Engine Controller PWB (REP 9.3). Select Component Test then ROS Motor. You can hear the Scanner Motor spin up. Y N Go to RAP 30. Switch the printer power off. Remove the Left Interface Cover (REP 1.1), the Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J21 from the Print Engine Control- ler PWB. Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P21-6 and frame ground. The voltage is +5.0 VDC. Y N On the Print Engine Controller PWB, check the voltage between P25 pin 4 and frame ground. The voltage is +5.0 VDC. Y N On the Print Engine Controller PWB, check the voltage between P28 pin 7 and frame ground. The voltage is +5.0 VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). On the Print Engine Controller PWB, check the voltage between P25 pin 3 and frame ground. The voltage is +5.0 VDC. Y N Go to RAP 13. Replace the Print Engine Controller PWB (REP 9.3). Go to RAP 30. A manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 18 Fuser Failure Power Off/On (U4) There is a problem with the Fuser Assembly. Procedure Switch the printer power off. Wait a few minutes, then switch the printer power on. The Error Code reappears. Y N Run 25 to 30 test prints. The Error code reappears. Y N Problem solved Go to RAP 31. Go to RAP 31. RAP 19 IOT NVM Fail / Power Off/On (U6) There is problem with Non-Volatile RAM. Procedure Switch the printer power off then on. The U6 Error Code appears. Y N To ensure that the problem is solved, switch the printer power off and on several times. The U6 Error Code reappears. Y N Problem Solved. Enter Diagnostics and select NVM Config (password 0734). It is possible to enter into the NVM Config. Y N Replace the Print Engine Controller PWB (REP 9.3). Check the NVM Data one by one referring to the NVM Table (Table 2) in section 6. The data is set properly. Y N The incorrect data is read only. Y N Set the data to the default value. Replace the Print Engine Controller PWB (REP 9.3). Go to RAP 44. Enter Diagnostics and select NVM Config (password 0734). It is possible to enter into the NVM Config. Y N Replace the Print Engine Controller PWB (REP 9.3). Check the NVM Data one by one referring to the NVM Table (Table 2) in section 6. The data is set properly. Y N The incorrect data is read only. Y N Set the data to the default value. Replace the Print Engine Controller PWB (REP 9.3). Go to RAP 44.

Status Indicator Repair Analysis Procedures Initial Issue RAP 20 Fan Failure Power Off Now (U5) The printer is detecting incorrect fan rotation. Procedure Switch the printer power off, then on. The Fan rotates when the main power is switched on. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and Left Plate Assembly (REP 1.11). Switch the printer power on. On the LVPS, check the voltage between P/J283 pin 1 and frame ground. The voltage is +19VDC. Y N Check the voltage between P/J281 pin 13 and frame ground. The voltage is +0.8VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the LVPS (REP 9.5). Replace the Fan Assembly (REP 9.1). Enter Diagnostics and select Component Test. Scroll to Fan Motor Hi and press Enter. The Fan rotates at high speed. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and Left Plate Assembly (REP 1.11). Switch the printer power on. Scroll to Fan Motor Hi and press Enter. On the LVPS, check the voltage between P/J283 pin 1 and frame ground. The voltage is +21.5VDC. Y N Press the Online [0] key. Check the voltage between P/J281 pin 11 and frame ground. Press the Enter key. The voltage changes from 0.8VDC to 0.0VDC when you press the Enter key. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the LVPS (REP 9.5). Replace the Fan Assembly (REP 9.1). Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and Left Plate Assembly (REP 1.11). Enter Diagnostics and select Component Test. On the LVPS, check the voltage between P/J283 pin 2 and frame ground. The voltage is less than 1.0VDC. Y N Replace the Fan Assembly (REP 9.1). Replace the Print Engine Controller PWB (REP 9.3). RAP 21 Low Paper Tray # Paper stack in the Paper Tray Assembly is below 50 ±30 sheets. Procedure Insert a full Tray Assembly in the affected position. The Error Message reappears. Y N Problem solved. Remove the affected tray Assembly. Push up the Low Paper Actuator manually and then release. The Low Paper Actuator moves smoothly. Y N Repair or replace the Low Paper Sensor Assembly (REP 3.5/REP 11.14). Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Press the Low Paper Actuator manually and then release. The LCD increments the counter each time you press and release the Actuator. Y N Check the wiring associated with the specific Low Paper Sensor. If ok, replace the Low Paper Sensor (REP 3.5/REP 11.14). Replace the Print Engine Controller PWB (REP 9.3). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 22 Paper Size Error There is a conflict between the size of paper the printer senses and the size of paper that is actually loaded. Procedure The problem appears when using Tray 1, 2, or 3. Y N Verify the size of paper currently in the MBF Tray. Enter the User Menus, select Tray Menu, then select MBF Size. The paper size displayed on the LCD matches the size actually in the MBF. Y N Set MBF size to the size of paper actually installed, then press Enter. Replace the Print Engine Controller PWB (REP 9.3). The paper size in the problem tray is within printer specifications. Y N Replace with paper that meets specifications. Check the side guides and the Paper Stack End Guide in the problem tray. All guides are properly set for the size of paper installed. Y N Properly set the guides. Check the size cam on the left side of the paper tray (Table 1). The cams are in good condi- tion (not broken) and move freely as the paper tray end guide is moved. Y N Replace the paper tray (PL 2.1/PL 11.1). Reinstall the paper tray. Enter Diagnostics and select Component Test. Scroll to Paper Tray Size Reading and press Enter to display MBF size. Press Enter repeatedly to scroll through each of the paper trays. The paper size displayed on the LCD matches the size of the paper actually loaded. Y N Replace the Tray Size PWB (REP 3.13/REP 11.19). Replace the Print Engine Controller PWB (REP 9.3). RAP 23 Low Toner Sensor Failure Low Toner is not displayed when the Print Cartridge appears to be empty. Procedure Run a Test Print. Inspect the print quality. The print is light. Y N Return to Initial Actions. Replace the Print Cartridge (PL 8.1). Run 5 test prints (Config Sheet or Demo Page) and inspect the print quality. The print quality meets specifications. Y N Go to IQ RAP 1. Open the Front Cover and cheat the Front Cover Interlock. Enter Diagnostics and select Com- ponent Test. Scroll to Sensor Input and press Enter [4]. Hold the Print Cartridge in position while you carefully push down then release the Toner Sensor. The number on the LCD incre- ments each time you pull down and release the Toner Sensor. Y N Switch the printer power off. Remove the Front Cover (REP 1.6) and the Left Front Cover (REP 1.7). Cheat the Front Cover Interlock Switch. Switch the printer power on. On the connector PWB, check the voltage between P/J42 pin 4 and frame ground. The voltage is 0.0VDC with the print cartridge installed and 3.3VDC with the print cartridge removed. Y N Check the voltage between P/J42 pin 3 and pin 1. The voltage is 24VDC. Y N On the Connector PWB, check the voltage between P/J231 pin 11 and pin 12. The voltage is 24VDC. Y N Check the Connector Harness Assembly. If OK, replace the Print Engine Controller PWB (REP 9.3). Replace the Connector PWB (REP 9.7). Replace the Toner Sensor (REP 5.2). On the connector PWB, check the voltage between P/J231 pin 9 and frame ground. The voltage is 0.0VDC with the print cartridge installed and 3.3VDC with the print car- tridge removed. Y N Replace the Connector PWB (REP 9.7). Check the Connector Harness Assembly. If OK, replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). Table 1 Paper Size Actuators Actuator Cam Extended B5 SEF A5 SEF 13" SEF 14" SEF 8.5" SEF A4 SEF Top X X Middle X X X Bottom X X X Forward Cam X

Initial Issue RAP 24 Inoperative Printer The main power cannot be switched on. Procedure Ensure the power cord is properly connected to the wall outlet and to the Power Receptacle of the printer. The problem still exists. Y N Problem solved. Perform RAP 1, then return here. RAP 1 indicated that correct AC voltage is being sup- plied to the printer. Y N Notify customer that the power is out of specification. Perform RAP 2, then return here. RAP 2 indicated that correct DC voltage is being sup- plied to the printer. Y N Rap 2 instructed you to replace a component. Y N Perform RAP 3. Replace component as necessary. On the System Controller PWB, check the voltage on P/J13 between pins 1 and 2. The volt- age is 3.3VDC. Y N Switch the printer power off. Disconnect P/J13 from the System Controller PWB. Switch the printer power on. Check the voltage between pins 1 and 2 on the disconnected plug. The voltage is 3.3VDC. Y N Replace the LVPS (REP 9.5). Switch the printer power off. Remove any options connected to the System Controller PWB. Reconnect P/J13 to the System Controller PWB. Switch the printer power on. Check the voltage on P/J13 between pins 1 and 2 (if there are no options installed, follow the No path). The voltage is 3.3VDC. Y N Replace the System Controller PWB (REP 9.2). Switch the printer power off. Reinstall the removed options one at a time, switching on the power and checking for 3.3VDC on P/J13 between pins 1 and 2 after each one is installed. Replace the option just installed when the voltage fails. On the System Controller PWB, check the voltage on P/J13 between pins 3 and 4. The volt- age is 5.0VDC. Y N Switch the printer power off. Disconnect P/J13 from the System Controller PWB. Switch the printer power on. Check the voltage between pins 3 and 4 on the disconnected plug. The voltage is 5.0VDC. Y N On the LVPS, check the voltage between P/J PN1 pin 1 and frame ground. The voltage is +24.0VDC. Y N Replace the LVPS (REP 9.5). Replace the System Controller +5.0VDC Power Supply (REP 9.4). Switch the printer power off. Remove any options connected to the System Controller PWB. Reconnect P/J13 to the System Controller PWB. Switch the printer power on. Check the voltage on P/J13 between pin 3 and frame ground (if there are no options installed, follow the No path). The voltage is 5.0VDC. Y N Replace the System Controller PWB (REP 9.2). Switch the printer power off. Reinstall the removed options one at a time, switching on the power and checking for 5.0VDC on P/J13 between pin 3 and frame ground after each one is installed. Replace the option just installed when the voltage fails. On the Print Engine Controller PWB, check the voltage between P/J28 pin 1 and frame ground, P/J28 pin 7 and frame ground, and P/J28 pin 10 and frame ground. The voltage on pin 1 is +24VDC, pin 7 is +5.0VDC, and pin 10 is 3.3VDC. All voltages are correct. Y N Replace the LVPS (REP 9.5). Replace the System Controller PWB (REP 9.2). If the problem persists, replace the Print Engine Controller PWB (REP 9.3). A A manuals4you.com manuals4you.com

RAP 25 Malfunctioning LCD/LED There is an erratic display on LCD/LED. Procedure Switch the printer power off. Remove any options connected to the System Controller PWB. Disconnect P/J18 from the System Controller PWB. Switch the printer power on. On the Sys- tem Controller PWB, check the following voltages between P/J18 and frame ground. All the voltages listed in the column “with P/J18 disconnected” are correct. Y N On the System Controller PWB, check the voltage on P/J13 between pins 1 and 2. The voltage is 3.3VDC. Y N Switch the printer power off. Disconnect P/J13 from the System Controller PWB. Switch the printer power on. Check the voltage between pins 1 and 2 on the discon- nected plug. The voltage is 3.3VDC. Y N On the LVPS, check the voltage on P/J282 between pins 1 and 2. The voltage is 3.3VDC. Y N Replace the LVPS (REP 9.5). Repair or replace the harness between the LVPS and the System Controller PWB (PL 10.1). Replace the System Controller PWB (REP 9.2). On the System Controller PWB, check the voltage on P/J13 between pins 3 and 4. The voltage is 5.0VDC. Y N Switch the printer power off. Disconnect P/J13 from the System Controller PWB. Switch the printer power on. Check the voltage between pins 3 and 4 on the discon- nected plug. The voltage is 5.0VDC. Y N On the LVPS, check the voltage between P/J PN1 pins 1 and 2. The voltage is 24.0VDC. Y N Replace the LVPS (REP 9.5). Replace the System Controller +5.0VDC Power Supply (REP 9.4). Replace the System Controller PWB (REP 9.2). Switch the printer power off. Reconnect P/J18 to the System Controller PWB. Switch the printer power on. Check the voltages between the pins listed in Table 1 and frame ground. All the voltages listed in the column “with P/J18 connected” are correct. Y N Replace the Control Panel Assembly (PL 1.1). Switch the printer power off. Reinstall the removed options one at a time, switching on the power and checking the voltages between the pins listed in Table 1 and frame ground after each component is installed. Replace the option just installed if the voltage fails. After all the options are reinstalled, the LCD display is still erratic. Y N Problem solved. Return to Initial Actions and restart. Replace the Control Panel Assembly (PL 1.1). If the problem persists, replace the System Controller PWB (REP 9.2). Switch the printer power off. Reconnect P/J18 to the System Controller PWB. Switch the printer power on. Check the voltages between the pins listed in Table 1 and frame ground. All the voltages listed in the column “with P/J18 connected” are correct. Y N Replace the Control Panel Assembly (PL 1.1). Switch the printer power off. Reinstall the removed options one at a time, switching on the power and checking the voltages between the pins listed in Table 1 and frame ground after each component is installed. Replace the option just installed if the voltage fails. After all the options are reinstalled, the LCD display is still erratic. Y N Problem solved. Return to Initial Actions and restart. Replace the Control Panel Assembly (PL 1.1). If the problem persists, replace the System Con- troller PWB (REP 9.2). Table 1 P18 With P/J18 Disconnected With P/J18 Connected Pin 1 3.3VDC 3.3VDC Pin 2 0.0VDC 0.0VDC Pin 3 1.4VDC 3.3VDC Pin 4 0.0VDC 0.0VDC Pin 5 3.3VDC 3.3VDC Pin 6 1.4VDC 3.3VDC Pin 7 3.3VDC 3.3VDC Pin 8 0.0VDC 3.3VDC A A B B C C

Status Indicator Repair Analysis Procedures Initial Issue RAP 26 Inoperative Keypad Control Panel is not operative. Procedure Enter Diagnostics and select the Component Test. Scroll to Sensor Input test and press Enter [4]. The printer enters the Diagnostic Mode to the Sensor Input Level. Y N Disconnect P/J18 on the System Controller PWB. Measure the voltages listed in Table 1 between P18 on the System Controller PWB and frame ground. All the voltages are correct. Y N Replace the System Controller PWB (REP 9.2). Disconnect P/J412 from the Control Panel. Measure continuity on all wires between P/ J412 and P/J18. All checks are good. Y N Replace the wiring harness (PL 1.1). Replace the Control Panel Assembly (PL 1.1). Keypad numbers (1-7) increment the counter. Keypad number [4] enters the test and (0) exits the test. Y N Replace the Control Panel Assembly (PL 1.1). Replace the System Controller PWB (REP 9.2). RAP 27 Erratic Printer Operation Procedure Disconnect all host cables. Enter diagnostics and select Test Print. Run 15 to 20 test prints. The printer generates test prints. Y N Switch the printer power off. Disconnect P/J PN1 from the LVPS Assembly. Switch the printer power on. Check the voltage between P/J281 pin 7 and frame ground. The volt- age is +5.0VDC. Y N Switch the printer power off and reconnect PN1. Go to RAP 28. Replace the Print Engine Controller PWB (REP 9.3). The problem still appears. Y N Problem solved. Go to RAP 44. The printer RESETS while generating test print. Y N Replace the Print Engine Controller PWB (REP 9.3). The problem still appears. Y N Problem solved Notify customer the cause of the trouble seems to be a communication problem between the host computer and the printer. The customer should contact Customer Support. Go to RAP 28. Table 1 Keypad Pin Voltage 1 3.3 VDC 2 0 VDC 3 1.4 VDC 4 0 VDC 5 3.3 VDC 6 1.4 VDC 7 3.3 VDC 8 0 VDC manuals4you.com manuals4you.com

RAP 28 Power Supply Procedure Switch the printer power off. Disconnect the power cord. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect the following from the LVPS: • P/J281 (Print Engine Controller PWB) (REP 9.3) • P/J282 (System Controller PWB)(REP 9.2) • P/J11(Fuser)(REP 6.2) • P/J283 (Main Fan)(REP 9.1) • P/J284(Front Interlock Switch)(REP 9.9) • P/JPN1 (5VDC Power Supply)(REP 9.4) Connect the power cord. Switch the printer power on and measure the voltages listed in Table 1 on the LVPS. All voltages are correct. Y N Replace the LVPS (REP 9.5). Switch the printer power off. Reconnect P/J281 to the LVPS. Switch the printer power on and measure the voltages listed in Table 1. All the voltages are correct. Y N Switch the printer power off. Reconnect all the P/Js to the LVPS. Disconnect the following from the Print Engine Controller PWB: • P/J35 (OCT PWB) (REP 10.7) • P/J34 (Duplex PWB) (REP 12.4) • P/J33 (Size 1 PWB) (REP 3.13) • P/J22 (Laser) (REP 7.4) • P/J21 (Laser) (REP 7.4) • P/J23 (Connector PWB) (REP 9.7) • P/J31 (Stack Full Sensor) (REP 6.6) • P/J30 (Rear Interlock Switch) (REP 9.10) • P/J25 (Print Cartridge Sensor) (REP 7.3) • P/J32 (Exit Motor) (REP 6.5) • P/J29 (Main Motor) (REP 8.1) • P/J26 (HVPS PWB) (REP 9.6) • P/J27 (Fuser Sensors) (REP 6.2) Switch the printer power on and measure the voltages listed in Table 1. All voltages are correct. Y N Replace the Print Engine Controller PWB (REP 9.3). Switch the printer power off. Reconnect one of the disconnected plugs. Switch the printer power on. Measure the voltages listed in Table 1. All the voltages are correct. Y N Replace the component just connected to the Print Engine Controller PWB. Repeat the step with the next disconnected plug. Switch the printer power off. Reconnect one of the disconnected plugs. Switch the printer power on. Measure the voltages listed in Table 1. All the voltages are correct. Y N Replace the component just connected to the LVPS. Repeat the step with the next disconnected plug. Table 1 LVPS Red Lead Black Lead Voltage P/J281 pin 7 Frame Ground +5.0VDC P/J281 pin 10 Frame Ground +3.3VDC P/J281 pin 1 Frame Ground +24.0VDC A A

Initial Issue RAP 29 Main Motor Assembly Procedure Enter Diagnostics and select the Component Test. Scroll to Main Motor Operation and press Enter. The Main Motor rotates. Y N Switch the printer power off. Remove the Left Interface Cover (1.1), Left Cover (1.2), and Left Plate Assembly (1.11). Ensure the Rear Cover is closed. Switch the printer power on. Measure the voltages listed in Table 1 on the Main Motor Assembly. All voltages are correct. Y N The voltages on pins 1, 2, and 3 are correct. Y N On the Print Engine Controller PWB, check the voltage between P/J28 pins 1, 2, and 3 and frame ground. All three readings are +24.0 VDC. Y N Replace the LVPS (REP 9.5). On the Print Engine Controller PWB, check the voltage between P/J30 pin 2 and frame ground. The voltage is 24VDC. Y N Check the wiring between the Print Engine Controller PWB and the Rear Interlock. Repair or replace the wiring or replace the Rear Interlock Switch (REP 9.10). Replace the Print Engine Controller PWB (REP 9.3). The voltage on pin 7 is correct. Y N On the Print Engine Controller PWB, check the voltage between P/J28 pin 7 and frame ground. The voltage is +5.0 VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). On the Print Engine Controller PWB, check the voltage between P/J28 pin 10 and frame ground. The voltage is 3.3 VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). Enter Diagnostics and select the Component Test. Scroll to Main Motor Operation. On the Print Engine Controller PWB, measure the voltage between P/J29 pin 7 and frame ground. Press the Enter key. The voltage drops from 5.0 VDC to 0.0 VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Main Motor Assembly (REP 8.1). Problem solved, return to Initial Actions and continue. Table 1 Main Motor Harness From To Voltage CN101 - Pin 1 Frame Ground +24.0 VDC CN101 - Pin 2 Frame Ground +24.0 VDC CN101 - Pin 3 Frame Ground +24.0 VDC CN101 - Pin 7 Frame Ground +5.0 VDC CN101 - Pin 8 Frame Ground +3.3 VDC A A B B C C manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 30 Laser Assembly Procedure Enter Diagnostics and select Component Test. Scroll to ROS Motor and press Enter. You can hear the ROS Motor spin up. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1) Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. Check the volt- age between P/J21 pin 10 on the Print Engine Controller PWB and frame ground. The voltage is 24.0 VDC. Y N Check the voltage between P/J28 pin 1 on the Print Engine Controller PWB and frame ground. The voltage is 24.0 VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). Enter Diagnostics and select Component Test. Scroll to ROS Motor Operation. Check the voltage between P/J21 pin 12 and frame ground. Press the Enter key. The voltage drops from 5.0 VDC to 0.0 VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Laser Assembly (REP 7.4). Switch the printer power off. Remove the Left Interface Cover (REP 1.1) Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. Check the voltage between P21 pin 6 and frame ground. The voltage is +5.0VDC. Y N Check the voltage between P/J28 pin 7 and frame ground. The voltage is +5.0VDC. Y N Replace the LVPS (REP 9.5). Check the voltage between P/J25 pin 3 and frame ground. The voltage is +5.0VDC. Y N Go to RAP 36. Replace the Print Engine Controller PWB (REP 9.3). Measure the voltage between P/J21 pin 9 and frame ground. The voltage is +5.0VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Laser Assembly (REP 7.4). RAP 31 Fuser Assembly Procedure WARNING If the printer has been switched on, the fuser may be hot. Switch the printer power off. Remove the Fuser Assembly (REP 6.2). Measure the resistance between pins A4 and A5 of P272 (Figure 1). The resistance is between 7K and 380K ohms (depending on the temperature of the fuser). Y N Replace the Fuser Top Cover (REP 6.9). Measure the resistance between pins 3 and 4 of P272 on the Fuser Assembly (Figure 1). The resistance is less than 5 ohms. Y N Remove the Fuser Heat Rod (REP 6.9). Measure the resistance of the Heat Rod. The resistance is less than 5 ohms. Y N Replace the Heat Rod (REP 6.9). Replace the Fuser Top Cover (REP 6.9). Figure 1 Fuser Connector (P272) Reinstall the Fuser Assembly. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J11 from the LVPS PWB. Check the resistance between P11 pin 1 and pin 2. There is less than 5 ohms resistance. Y N Repair or replace the Fuser Harness Assembly (REP 6.3). Reconnect P/J11 and disconnect P/J27. Measure the resistance between P/J27 pins 1 and 2 (Figure 1). The resistance is between 7K and 380K ohms (depending on the temperature of the fuser). Y N Repair or replace the Fuser Harness Assembly (REP 6.3). A

Status Indicator Repair Analysis Procedures Initial Issue Reconnect P/J27. Measure the voltage on the LVPS between P/J281 pin 12 and frame ground as you switch the printer power on. The voltage is 0.0VDC during fuser warm up, then changes to 2.8VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the LVPS (REP 9.5). RAP 32 Registration Sensor Procedure Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Actuate and deactuate the Registration Sensor. The number on the LCD increments each time you press and release the actuator. Y N The actuator moves freely and is in good condition (not broken or damaged). Y N Replace the Registration Actuator (REP 4.2). Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, measure the voltage between P/J23 pin 11 and frame ground. The voltage is +3.3VDC with the Registration Sensor deactuated and 0.0VDC with the Registration Sensor actuated. Y N Switch the printer power off. Remove the Left Front Cover (REP 1.7). Switch the printer power on. On the Connector PWB, measure the voltage between P/J43 pin 5 and frame ground. The voltage is +3.3VDC with the Registration Sensor deactu- ated and 0.0VDC with the Registration Sensor actuated. Y N Check the voltage between P/J43 pin 3 and frame ground. The voltage is 1.2VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Registration Sensor (REP 5.4). Replace the Connector PWB (REP 9.7). Replace the Print Engine Controller PWB (REP 9.3). It appears that the Registration Sensor is working correctly. If a problem persists, replace the Print Engine Controller PWB (REP 9.3). A manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 33 MBF No Paper Sensor Procedure Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Actuate and deactuate the MBF No Paper Sensor. The number on the LCD increments each time you press and release the actuator. Y N The actuator moves freely and is in good condition (not broken or damaged). Y N Replace the MBF No Paper Sensor Actuator (REP 4.5). Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, measure the voltage between P/J23 pin 14 and frame ground. The voltage is +3.3VDC with the MBF No Paper Sensor deactuated and 0.0VDC with the Sensor actuated. Y N Switch the printer power off. Remove the Left Front Cover (REP 1.7). Switch the printer power on. On the Connector PWB, measure the voltage between P/J45 pin 3 and frame ground. The voltage is +3.3VDC with the MBF No Paper Sensor deac- tuated and 0.0VDC with the Sensor actuated. Y N Check the voltage between P/J45 pin 1 and frame ground. The voltage is 1.2VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the MBF No Paper Sensor (REP 4.8). Replace the Connector PWB (REP 9.7). Replace the Print Engine Controller PWB (REP 9.3). It appears that the MBF No Paper Sensor is working correctly. If a problem persists, replace the Print Engine Controller PWB (REP 9.3). RAP 34 Tray 1 No Paper Sensor Procedure Remove Tray 1. Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Actuate and deactuate the Tray 1 No Paper Sensor Actuator. The number on the LCD increments each time you press and release the actuator. Y N Visually inspect the Tray 1 No Paper Sensor Actuator. The actuator moves freely and is in good condition (not broken or damaged). Y N Replace the Tray 1 No Paper Sensor Actuator (REP 3.3). Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, measure the voltage between P/J33 pin 2 and frame ground as you actuate and deactuate the No paper Sensor. The voltage is 3.3VDC with the sen- sor deactuated and 0.0VDC with the sensor actuated. Y N Check the voltage between P/J33 pin 8 and frame ground. The voltage 3.3VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Tray 1 Feeder PWB (REP 3.9). Replace the Print Engine Controller PWB (REP 9.3). It appears that the Tray 1 No Paper Sensor is working correctly. If a problem persists, replace the Print Engine Controller PWB (REP 9.3).

Status Indicator Repair Analysis Procedures Initial Issue RAP 35 Standard Bin Stack Full Sensor Procedure Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Actuate and deactuate the Stack Full Sensor Actuator. The number on the LCD increments each time you press and release the actuator. Y N Visually inspect the Stack Full Sensor Actuator. The actuator moves freely and is in good condition (not broken or damaged). Y N Replace the Stack Full Actuator (REP 6.8). Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and Left Plate (REP 1.11). Disconnect P/J31 from the Print Engine Controller PWB. Switch the printer power on. On the Print Engine Controller PWB, measure the voltage between P31 pin 1 and frame ground. The voltage is +3.3VDC. Y N On the Print Engine Controller PWB, measure the voltage between P/J28 pin 10 and frame ground. The voltage is +3.3VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). Switch the printer power off. Reconnect P/J31 to the Print Engine Controller PWB. Switch the printer power on. On the Print Engine Controller PWB, measure the voltage between P/J31 pin 3 and frame ground. There is +3.3VDC between P/J31 pin 3 and frame ground when the Stack Full Sensor is deactuated and 0.0VDC when actuated. Y N Replace the Stack Full Sensor (REP 6.6). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). RAP 36 Print Cartridge Sensor Assembly Procedure Open the Front Cover and remove the Print Cartridge. Inspect the tab on the top of the Print Cartridge that actuates the Print Cartridge Sensor Assembly. The tab on the Print Cartridge is intact. Y N Replace the Print Cartridge (PL 8.1). Press and release the Print Cartridge Sensor Assembly Actuator. The Print Cartridge Sen- sor Assembly Actuator lever moves smoothly. Y N Replace the Print Cartridge Sensor Assembly (REP 7.3). Enter diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Manually actuate the Print Cartridge Sensor Assembly Actuator. The number on the LCD increments each time you press and release the actuator. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and Left Plate Assembly (REP 1.11). Switch the printer power on. On the print Engine Controller PWB, check the voltage between P/J25 pin 4 and frame ground. The voltage is +5.0VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Check the voltage between P/J25 pin 3 and frame ground. Manually actuate and deactu- ate the Print Cartridge Sensor Assembly. The voltage is 0.0VDC with the Print Car- tridge Sensor Assembly deactuated and +5.0VDC with the sensor actuated. Y N Replace the Print Cartridge Sensor Assembly together with the harness (REP 7.3). Check the voltage between P/J25 pin 2 and frame ground. Manually actuate and deactu- ate the Print Cartridge Sensor Assembly. The voltage is 3.3VDC with the Print Car- tridge Sensor Assembly deactuated and 0.0VDC with the sensor actuated. Y N Replace the Print Cartridge Sensor Assembly together with the harness (REP 7.3). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 37 Tray Motor Assembly Checkout Procedure Procedure NOTE: Tray 1 interlocks the 24VDC supply to the Tray 1 Size PWB, Tray 1 Feeder PWB, Tray 2 and Tray 3. Tray 2 interlocks the 24VDC supply to the Tray 2 Size PWB, Tray 2 Feeder PWB, and Tray 3. Tray 3 interlocks the 24VDC supply to the Tray 3 Size PWB and the Tray 3 Feeder PWB. Switch the printer power off. Remove the Paper Tray to be tested. Switch the printer power on. Measure the voltage from the lower contact of the Paper Feeder Socket to frame ground. The voltage is +24 VDC. Y N Go to RAP 2. On the left side of the paper tray, measure the motor winding resistance from the middle con- tact to the lower contact of the Paper Feeder Connector. The resistance reading is between 110 - 130 ohms. Y N Disconnect J673 from the 3 pin Paper Feeder Connector. Measure resistance between pins 1 and 4. The resistance reading is between 110 - 130 ohms. Y N Replace the Motor Assembly (REP 2.4). Replace Paper Feeder Connector (PL 2.2). Check the Paper Tray for damage, contamination, binding, misalignment or obstruction. All components are clean, connected properly, aligned properly and without damage. Y N Repair/replace as necessary. Replace the Motor Assembly (REP 2.4). RAP 38 Registration Clutch Procedure Enter Diagnostics and select Component Test. Scroll to Confirm Reg. Clutch and press Enter. You can hear the Registration Clutch energize. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J23 on the Print Engine Con- troller PWB. Measure the resistance between pins 6 and 9 on the disconnected plug. The resistance is approximately 145 to 165 ohms. Y N Remove the Front Cover (REP 1.6) and the Left Front Cover (REP 1.7). Disconnect P/J43 from the Connector PWB. Measure the resistance between pins 1 and 2 on the disconnected plug. The resistance is approximately 145 to 165 ohms. Y N Replace the Registration Clutch (REP 5.5). Replace the Connector PWB (REP 9.7). Reconnect P/J23. Switch the printer power on. Check the voltage between P/J23 pin 6 and frame ground. The voltage is +24VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Enter Diagnostics and select Component Test. Scroll to Confirm Reg. Clutch. Check the voltage between P/J23 pin 9 and frame ground. Press Enter. The voltage drops from +24VDC to 0.0VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Registration Clutch (REP 5.5) Switch the printer power off. Open the Front Cover and remove the Print Cartridge. With the Front Cover open, cheat the Front Cover Interlock. Enter Diagnostics and select Component Test. Scroll to Main Motor and press Enter. Scroll to Confirm Reg. Clutch and press Enter. The Registration Rolls rotate smoothly without stalling or jerking. Y N Replace the Registration Clutch (REP 5.5) or Registration Rolls (REP 5.6). Problem Solved.

Status Indicator Repair Analysis Procedures Initial Issue RAP 39 Turn Roll Clutch Assembly Procedure Enter Diagnostics and select Component Test. Scroll to Turn Roll Clutch and press Enter. You can hear the Turn Roll Clutch energize. Y N Remove Tray 1. Check the voltage between the lower contact of the Paper Feeder Con- nector and frame ground The voltage is +24VDC. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/J33 pin 6 and frame ground. The voltage is +24VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Feeder PWB (REP 3.9). On the left side of the Paper Tray, measure the resistance between the upper and lower contacts on the Paper Feeder Connector. Their is continuity between the two con- tacts. Y N Replace the Paper Feeder Connector (REP 2.5). Switch the printer power off. Remove the Paper Feeder Assembly (REP 3.1). Disconnect P/J64 from the Feeder PWB. Measure the resistance between pins 1 and 2 on the discon- nected plug. Their is continuity between the two pins. Y N Replace the Turn Clutch Assembly (PL 3.1). Replace the Feeder PWB (REP 3.9). If the problem persists, replace the Size PWB (REP 3.13). Switch the printer power off. Remove the Front Cover (REP 1.6). Cheat the Front Cover Inter- lock Switch. Enter diagnostics and select Component Test. Scroll to Main Motor and press Enter. Scroll to Turn Roll Clutch and press Enter. The Turn Rolls rotate smoothly without stalling or jerking. Y N Replace the Turn Roll Assembly (REP 3.2). Replace the Turn Roll Clutch (REP 3.2). If the problem persists, replace the Print Engine Con- troller PWB (REP 9.3). RAP 40 Tray 1 Feed Clutch Procedure NOTE: Tray 1 interlocks the 24VDC supply to the Tray 1 Size PWB, Tray 1 Feeder PWB, Tray 2 and Tray 3. Tray 2 interlocks the 24VDC supply to the Tray 2 Size PWB, Tray 2 Feeder PWB, and Tray 3. Tray 3 interlocks the 24VDC supply to the Tray 3 Size PWB and the Tray 3 Feeder PWB. Enter Diagnostics and select Component Test. Scroll to Confirm Tray 1 Feed Clutch and press Enter. You can hear the Tray 1 Feed Clutch energize. Y N Remove Tray 1. Check the voltage between the lower contact of the Paper Feeder Con- nector and frame ground The voltage is +24VDC. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/J33 pin 6 and frame ground. The voltage is +24VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Feeder PWB (REP 3.9). On the left side of the Paper Tray, measure the resistance between the upper and lower contacts on the Paper Feeder Connector. Their is continuity between the two con- tacts. Y N Replace the Paper Feeder Connector (REP 2.5). Switch the printer power off. Remove the Paper Feeder Assembly (REP 3.1). Disconnect P/J65 from the Feeder PWB. Measure the resistance between pins 1 and 4 on the discon- nected plug. Their is continuity between the two pins. Y N Replace the Tray 1 Feed Clutch (REP 3.6). Replace the Feeder PWB (REP 3.9). If the problem persists, replace the Size PWB (REP 3.13). Replace the Tray 1 Feed Clutch (REP 3.6). If the problem persists, replace the Print Engine Controller PWB (REP 9.3). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 41 MBF Feed Solenoid Procedure Enter Diagnostics and select Component Test. Scroll to Confirm MBF Feed Solenoid and press Enter. You can hear the MBF Feed Solenoid energize. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J23 on the Print Engine Con- troller PWB. Measure the resistance between pins 6 and 12 on the disconnected plug. The resistance is approximately 75 to 95 ohms. Y N Remove the Front Cover (REP 1.6) and the Left Front Cover (REP 1.7). Disconnect P/J44 from the Connector PWB. Measure the resistance between pins 1 and 2 on the disconnected plug. The resistance is approximately 75 to 95 ohms. Y N Replace the MBF Feed Solenoid (REP 4.9). Replace the Connector PWB (REP 9.7). Reconnect P/J23. Switch the printer power on. Check the voltage between P/J23 pin 6 and frame ground. The voltage is +24VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Enter Diagnostics and select Component Test. Scroll to Confirm MBF Feed Solenoid. Check the voltage between P/J23 pin 12 and frame ground. Press Enter. The voltage drops from +24VDC to 0.0VDC when you press Enter. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the MBF Feed Solenoid (REP 4.9) Switch the printer power off. Open the Front Cover and remove the Print Cartridge. With the Front Cover open, cheat the Front Cover Interlock. Enter Diagnostics and select Component Test. Scroll to Main Motor and press Enter. Scroll to Confirm MBF Feed Solenoid and press Enter. The MBF Feed Rolls make one complete revolution then stop. Y N Replace the MBF Feed Solenoid (REP 4.9). The MBF Feed Solenoid appears to operate correctly. If the problem persists, replace the Print Engine Controller PWB (REP 9.3). RAP 42 System Controller Isolation Procedure Switch the printer power off. Disconnect all cables connected to the rear of the System Control- ler PWB. Remove the Left Interface Cover (REP 1.1). Remove all options from the System Controller PWB. Switch the printer power on. The printer boots up correctly and Ready is displayed on the Control Panel (if no options are installed, follow the No path). Y N Switch the printer power off. Remove then reinstall the System Controller PWB (REP 9.2) to reseat the connection with the Print Engine Controller PWB. Switch the printer power on. The printer boots up correctly and Ready is displayed on the Control Panel. Y N Replace the System Controller PWB (REP 9.2). Problem Solved. Switch the printer power off. Reinstall one of the removed options or cables. Switch the printer power on. The printer boots up correctly and Ready is displayed on the Control Panel. Y N Replace the option or cable just installed. Repeat the last step with the next option or cable until the problem is found.

Status Indicator Repair Analysis Procedures Initial Issue RAP 43 HVPS Assembly Procedure Open the Front Cover. Remove the Print Cartridge. Inspect all contacts on the Transport Chute Assembly and the terminals on the Print Cartridge. The terminals are in good condition and contacting properly when the cartridge is installed. Y N Replace the Transport Chute Assembly (REP 6.1) or the Print Cartridge (PL 8.1) as nec- essary. Cheat the Front Cover Interlock Switch. Enter Diagnostics and select Component Test. Scroll to each of the high voltage tests (Table 1). Measure the voltage between the contact listed and frame ground. Press the Enter Key. At least one of the voltages is correct. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/J26 pin 2 and frame ground. The voltage is +24VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the HVPS (REP 9.6). All the voltages are correct. Y N Replace the Print Engine Controller PWB (REP 9.3). Cheat the Front Cover Interlock Switch. Enter Diagnostics and select Component Test. Scroll to each of the high voltage tests (Table 1). Measure the voltage between the contact listed and frame ground. Press the Enter Key. All the voltages are correct. Y N Check the Transport Chute Assembly for proper installation. Check the HVPS har- ness for proper connection and for damage. If everything is OK, Replace the HVPS (REP 9.6) Problem Solved. Problem solved. RAP 44 Electrical Noise Procedure Check if there is other electrical equipment, such as electrical generators, radio transmitters, or devices using electrical motors, within ten feet of the printer. Shut off the other electrical equip- ment, or relocate the printer at least twenty feet away from other devices. The Electrical Noise problem is still present. Y N Problem solved. Check the AC wall outlet and power cord (see RAP 1). The AC wall outlet is correctly wired and grounded. Y N Inform the customer of insufficient voltage or improper wiring. A licensed electrician must correct the wiring. Open the Front Cover. Remove the Print Cartridge. Inspect all contacts on the Transport Chute Assembly and the terminals on the Print Cartridge. The terminals are in good condition and contacting properly when the cartridge is installed. Y N Replace the Transport Chute Assembly (REP 6.1) or the Print Cartridge (PL 8.1) as nec- essary. Remove the Left Interface Cover (REP 1.1). Inspect the grounding screw and wire connected to the Main Power Connector. The cable is grounded properly. Y N Attach the grounding screw properly. Replace the Print Cartridge (PL 8.1). The Electrical Noise problem is still present. Y N Problem solved. Remove the Fuser Assembly (REP 6.2). Remove the end covers (see REP 6.9). Inspect the cables of the Heater Rod. The cables are attached properly. Y N Attach the cables properly or replace the Fuser Assembly (REP 6.2). Disconnect the HVPS (P/J26) from the Print Engine Controller PWB. Run 20 Test Prints (the prints will be blank). The Test Prints run normally. Y N Replace the Print Engine Controller PWB (REP 9.3). The problem is still present. Y N Problem solved. Inspect all of the grounds in the printer. All the grounds are securely connected. Y N Repair the bad grounds. Replace the following components one at a time until the cause of the problem is found. • HVPS PWB Assembly (REP 9.6). • Print Engine Controller PWB (REP 9.3). Table 1 High Voltage Power Supply Readings High Voltage Test Contact Reading Charge Roll DC Rear Transport Chute Pin Contact -425 ±40 VDC Charge Roll AC Rear Transport Chute Pin Contact 1000 ± 100 VAC Dev Bias DC Front Transport Chute Pin Contact +7.3 ± 3 VDC Dev Bias AC Front Transport Chute Pin Contact 555 ± 55 VAC BTR - BTR Roll Bushing -81 ± 8 VDC BTR + BTR Roll Bushing 0 VDC Detack Saw Detack Saw -930 ± 100 VDC A manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures • Print Cartridge (PL 8.1). • Fuser Assembly (REP 6.2). Replace the HVPS PWB Assembly (REP 9.6). RAP 45 DIMM 1 (0101) Procedure Switch the printer power off. Remove the Left Interface Cover (REP 1.1). Remove the DIMM installed in Slot 1 (slot 1 is the middle DIMM slot). Switch the printer power on. The error code reappears. Y N Switch the printer power off. Install the removed DIMM in Slot 2 (bottom DIMM slot). Switch the printer power on. The error code reappears. Y N Switch the printer power off. Remove DIMM from Slot 2 (bottom DIMM slot) and install the DIMM in slot 1 (middle DIMM slot). Switch the printer power on. The error code reappears. Y N Attribute the problem to a poor connection between the DIMM and the System Controller PWB. Go to Initial Actions. Replace the System Controller PWB (REP 9.2). Replace the DIMM installed in slot 2 with a new DIMM (PL 10.1). Replace the System Controller PWB (REP 9.2). A

Status Indicator Repair Analysis Procedures Initial Issue RAP 46 DIMM 2 (0102) Procedure Switch the printer power off. Remove the Left Interface Cover (REP 1.1). Remove the DIMM installed in Slot 2 (slot 2 is the bottom DIMM slot). Switch the printer power on. The error code reappears. Y N Switch the printer power off. Install the removed DIMM in Slot 3 (top DIMM slot). Switch the printer power on. The error code reappears. Y N Switch the printer power off. Remove DIMM from Slot 3 (top DIMM slot) and install the DIMM in slot 2 (bottom DIMM slot). Switch the printer power on. The error code reappears. Y N Attribute the problem to a poor connection between the DIMM and the System Controller PWB. Go to Initial Actions. Replace the System Controller PWB (REP 9.2). Replace the DIMM installed in slot 3 with a new DIMM (PL 10.1). Replace the System Controller PWB (REP 9.2). RAP 47 DIMM 3 (0103) Procedure Switch the printer power off. Remove the Left Interface Cover (REP 1.1). Remove the DIMM installed in Slot 3 (slot 3 is the top DIMM slot). Switch the printer power on. The error code reappears. Y N Switch the printer power off. Install the removed DIMM in Slot 2 (bottom DIMM slot). Switch the printer power on. The error code reappears. Y N Switch the printer power off. Remove DIMM from Slot 2 (bottom DIMM slot) and install the DIMM in slot 3 (top DIMM slot). Switch the printer power on. The error code reappears. Y N Attribute the problem to a poor connection between the DIMM and the System Controller PWB. Go to Initial Actions. Replace the System Controller PWB (REP 9.2). Replace the DIMM installed in slot 2 with a new DIMM (PL 10.1). Replace the System Controller PWB (REP 9.2). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 48 Exit Sensor Procedure Open the printer Rear Cover. Remove the Duplex Module, if installed. Open the Fuser Access Cover and check the Exit Sensor Actuator. Check that the actuator moves smoothly and is not broken. Make sure the actuator flag blocks the Exit Sensor when the access cover is closed. The actuator is in good condition and moves smoothly. Y N Replace the Fuser Assembly (REP 6.2). Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter [4]. Open the rear cover and open the Fuser Access Cover. Use a folded piece of paper to block and unblock the Fuser Exit Sensor. The number on the LCD increments each time you block and unblock the sensor. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J27 from the Print Engine Controller PWB. Switch the printer power on. Check the voltage between P/J27 pin 3 and frame ground. The voltage is 3.3VDC. Y N Check the voltage between P/J28 pin 10 and frame ground. The voltage is 3.3VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). Switch the printer power off. Reconnect P/J27 to the Print Engine Controller PWB. Switch the printer power on. Measure the voltage between P/J27 pin 5 and frame ground as you block and unblock the Fuser Exit Sensor. The voltage is 3.3VDC when the Fuser Exit Sensor is blocked and 0.0VDC when unblocked. Y N Replace the Fuser Assembly (REP 6.2). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). RAP 49 Exit Motor Procedure Switch the printer power off. Open the Rear Cover and manually rotate the Exit Chute Assem- bly. The Exit Chute rotates without binding. Y N Remove the Exit Chute Assembly (REP 6.4). Repair or replace components as necessary (PL 7.1). Enter diagnostics and select Component Test. Scroll to Exit Motor Fwd Operation. Open the Rear Cover and cheat the Rear Cover Interlock. Press the Enter Key. The Exit Motor rotates. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J32 from the Print Engine Controller PWB. On the disconnected plug, check the resistance between pins 1 and 2, pins 1 and 3, pins 1 and 4, and between pins 1 and 5. All readings are 25 to 35 ohms. Y N Replace the Exit Motor (REP 6.5). Replace the Print Engine Controller PWB (REP 9.3). Press the [0] key to stop the test. Scroll to Exit Motor Rev H and press Enter. The Exit Motor runs in reverse at high speed. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J32 from the Print Engine Controller PWB. On the disconnected plug, check the resistance between pins 1 and 2, pins 1 and 3, pins 1 and 4, and between pins 1 and 5. All readings are 25 to 35 ohms. Y N Replace the Exit Motor (REP 6.5). Replace the Print Engine Controller PWB (REP 9.3). Press the [0] key to stop the test. Scroll to Exit Motor Rev L and press Enter. The Exit Motor runs in reverse at low speed. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Disconnect P/J32 from the Print Engine Controller PWB. On the disconnected plug, check the resistance between pins 1 and 2, pins 1 and 3, pins 1 and 4, and between pins 1 and 5. All readings are 25 to 35 ohms. Y N Replace the Exit Motor (REP 6.5). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3).

Status Indicator Repair Analysis Procedures Initial Issue RAP 50 Load MBF (C5) Procedure Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Actuate and deactuate the MBF No Paper Sensor. The number on the LCD increments each time you press and release the actuator. Y N The actuator moves freely and is in good condition (not broken or damaged). Y N Replace the MBF No Paper Sensor Actuator (REP 4.5). Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, measure the voltage between P/J23 pin 14 and frame ground. The voltage is +3.3VDC with the MBF No Paper Sensor deactuated and 0.0VDC with the Sensor actuated. Y N Switch the printer power off. Remove the Left Front Cover (REP 1.7). Switch the printer power on. On the Connector PWB, measure the voltage between P/J45 pin 3 and frame ground. The voltage is +3.3VDC with the MBF No Paper Sensor deac- tuated and 0.0VDC with the Sensor actuated. Y N Check the voltage between P/J45 pin 1 and frame ground. The voltage is 1.2VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the MBF No Paper Sensor (REP 4.8). Replace the Connector PWB (REP 9.7). Replace the Print Engine Controller PWB (REP 9.3). It appears that the MBF No Paper Sensor is working correctly. If a problem persists, replace the Print Engine Controller PWB (REP 9.3). RAP 51 Face Up Tray Open (E5) Procedure Open the Rear Cover. The printer has a Duplex Unit installed. Y N Replace the Print Engine Controller PWB (REP 9.3). Check the Face Up Tray Sensor Actuator on the Rear Cover. The actuator is in good condi- tion. Y N Replace the Rear Cover (REP 1.8). Cheat the Rear Cover Interlock. Enter diagnostics and select Component Test. Scroll to Sensor Input Test and press Enter. Use a piece of paper to block and unblock the Face Up Tray Sen- sor. The number on the LCD increments each time you block and unblock the sensor. Y N On the Face Up Tray Sensor, check the voltage between pin 1 (pin to the rear of the printer) and frame ground. The voltage is 0.0VDC with the sensor unblocked and 3.3VDC with the sensor blocked. Y N Check the voltage between pin 3 on the sensor and frame ground. The voltage is 1.2VDC. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/ J34 pin 11 and frame ground. The voltage is 1.2VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Check the wiring harnesses. If the harnesses are in good condition, replace the Duplex PWB (REP 12.4). Replace the Face Up Tray Sensor (REP 12.14). Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/J34 pin 11 and frame ground. The voltage is 0.0VDC with the sensor unblocked and 3.3VDC with the sensor blocked. Y N Check the wiring harnesses. If the harnesses are in good condition, replace the Duplex PWB (REP 12.4). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures

Status Indicator Repair Analysis Procedures Initial Issue RAP 52 Low Paper Tray 2 (or Tray 3) 550 Sheet Feeder Tray 2 and/or Tray 3 have low paper. Procedure Fill the affected paper tray with fresh paper. The Error Code is still displayed. Y N Problem solved. Remove the paper tray from affected Feeder Assembly. Manually push up and release the low paper actuator. The low paper actuator moves smoothly up and down. Y N Inspect the Low Paper Actuator. Repair or replace as required. Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Press and release the Low Paper Actuator. The number on the LCD increments each time you press and release the actuator. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/J33 pin 8 and frame ground. The voltage is 3.3VDC. Y N On the Print Engine Controller PWB, check the voltage between P/J28 pin 10 and frame ground. The voltage is 3.3VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). Enter diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. On the Print Engine Controller PWB, for Tray 2, check the voltage between P/J33 pin 9 and frame ground; for Tray 3, check the voltage between P/J33 pin 10 and frame ground. Check the voltage as you actuate the Low Paper Sensor. The voltage changes from 3.3VDC to 0.0VDC. Y N Replace the Low Paper Sensor (REP 11.14) for the affected tray. If the problem per- sists, replace the Feeder PWB (REP 11.9) then the Size PWB (REP 11.19). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). RAP 53 550 Sheet Feeder Feed Clutch The 550 Sheet Feeder is not feeding paper or not feeding paper at the correct time. Procedure Enter Diagnostics and select Component Test. Scroll to Confirm Tray 2 Feed Clutch or Confirm Tray 3 Feed Clutch and press Enter. You can hear the clutch energize. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Enter diagnostics and select Component Test. Scroll to Confirm Tray 2 Feed Clutch or Confirm Tray 3 Feed Clutch. On the Print Engine Controller PWB, for Tray 2, check the voltage between P/J33 pin 13 and frame ground; for Tray 3, check the voltage between P/J33 pin 14 and frame ground. The volt- age is +24VDC. Y N Remove the Sheet Feeder Drive Assembly (REP 11.6) for the affected feeder. Dis- connect P/J651 from the Feed Clutch. Measure the resistance between the two pins on the feed clutch. The resistance is 140 to 170 ohms. Y N Replace the Paper Feed Clutch (REP 11.10). Replace the Feeder PWB (REP 11.9). If the problem persists, replace the Size PWB (REP 11.19). Press the Enter key. The voltage drops from +24VDC to 0.0VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Replace the Paper Feed Clutch (REP 11.10). Remove the Sheet Feeder Drive Assembly (REP 11.6) for the affected feeder. Check the Paper Feed Rolls for contamination and wear. The Paper Feed Rolls are clean and in good condi- tion. Y N Replace the Paper Feed Rolls (REP 11.11). Check the Paper Feed Assembly for binding, obstructions, or contamination. The feed assem- bly is clean and in good condition. Y N Clean, repair, or replace as necessary (REP 11.12). If the problem persists, replace the following in order until the problem is found: • Print Engine Controller PWB (REP 9.3). • Feeder PWB (REP 11.9). • Size PWB (REP 11.19) • Paper Feed Clutch (REP 11.10). manuals4you.com manuals4you.com

RAP 54 550 Sheet Feeder Assembly Not Recognized Controller does not recognize the Feeder Assembly. Procedure Check the alignment of the printer to the 550 Sheet Feeder and the alignment of the top 550 Sheet Feeder to the second 550 Sheet Feeder, if installed. Ensure that the connectors are properly aligned and properly connected. All connectors are properly aligned and con- nected. Y N Reseat the feeders and printer to obtain proper alignment and connection. Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Con- troller PWB, check the voltage between P/J33 pin 13 and frame ground. The voltage is 24VDC. Y N On the Print Engine Controller PWB, check the voltage between P/J33 pin 6 and frame ground. The voltage is 24.0VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Remove Paper Tray 2. Check the voltage between the bottom terminal on the mating con- nector on the Tray 2 feeder and frame ground. The voltage is 24.0VDC. Y N Remove paper tray 1. Check the voltage between the bottom terminal on the mating connector on the Tray 1 feeder and frame ground. The voltage is 24.0VDC. Y N Replace the Tray 1 Size PWB (REP 3.13). If the problem persists, replace the Tray 1 Feeder PWB (REP 3.9). Check the resistance between the bottom and top terminals of the mating connector on paper tray 1. There is continuity between the two pins. Y N Replace the paper tray mating connector (PL 2.2). Check that the paper tray mating connector and the feeder mating connector are properly aligned when the tray 1 is inserted into the feeder. The mating connectors are properly connected when the paper tray is inserted. Y N Repair or replace components as necessary. Replace the Tray 1 Size PWB (REP 3.13). If the problem persists, replace the Tray 1 Feeder PWB (REP 3.9). Check the resistance between the bottom and top terminals of the mating connector on the paper tray 2. There is continuity between the two pins. Y N Replace the paper tray mating connector (PL 2.2). Check that the paper tray mating connector and the feeder mating connector are properly aligned when the tray is inserted into the feeder. The mating connectors are properly connected when the paper tray is inserted. Y N Repair or replace components as necessary. Replace the Tray 2 Size PWB (REP 11.19). If the problem persists, replace the Tray 2 Feeder PWB (REP 11.9). The printer has two optional 550 Sheet Feeders installed. Y N Replace the Printer Engine Controller PWB (REP 9.3). On the Print Engine Controller PWB, check the voltage between P/J33 pin 14 and frame ground. The voltage is 24.0VDC. Y N Remove Paper Tray 3. Check the voltage between the bottom terminal on the mating con- nector on the Tray 3 feeder and frame ground. The voltage is 24.0VDC. Y N Replace the Tray 3 Size PWB (REP 11.19). If the problem persists, replace the Tray 3 Feeder PWB (REP 11.9). Check the resistance between the bottom and top terminals of the mating connector on paper tray 3. There is continuity between the two pins. Y N Replace the paper tray mating connector (PL 2.2). Check that the paper tray mating connector and the feeder mating connector are properly aligned when the tray is inserted into the feeder. The mating connectors are properly connected when the paper tray is inserted. Y N Repair or replace components as necessary. Replace the Tray 3 Size PWB (REP 11.19). If the problem persists, replace the Tray 3 Feeder PWB (REP 11.9). Replace the Print Engine Controller PWB (REP 9.3). A A B B

Status Indicator Repair Analysis Procedures Initial Issue RAP 55 Duplex Unit Fail or Removed (E9-1) Duplex Unit was removed while power was on. Procedure Switch the printer power off. Remove and reinstall the Duplex Unit. Switch the printer power on. Run a Config Sheet. The Duplex Unit is listed on the Config Sheet. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/J34 pin 9 and frame ground. The voltage is 3.3VDC with the duplex Unit removed and 0.0VDC with the Duplex Unit installed. Y N Check the wiring harnesses. If in good condition, replace the Duplex PWB (REP 12.4). If the problem persists, replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). Problem Solved. RAP 56 Paper Jam Open Front Cover (E7) Paper is early to the Registration Sensor, paper is late to or late off the Registration Sensor, or the Registration Sensor is actuated at power on. Procedure Open the printer and check for paper or other obstructions in the paper path. Remove the Duplex Assembly and check the rear entrance chute to the Paper Handler. The printer is free of jammed paper, paper scraps, or other obstructions. Y N Clear all jammed paper, paper scraps, and obstructions from the printer. Check the Duplex Belt, Rollers, and gears. Check for contamination, wear, and obstructions. The Duplex rollers, gears, and belt are clean and in good condition. Y N Replace components or Duplex Assembly as necessary (REP 12.1). Reinstall the Duplex Assembly. Enter diagnostics and select Test Print. Run 15 to 20 duplex test prints. The error code reappears. Y N Problem solved. Select Component Test. Scroll to Duplex Motor Low and press Enter. Then scroll to Duplex Motor Hi and press Enter. You can hear the Duplex Motor run at both speeds. Y N Remove the Duplex Assembly then remove the Duplex Cover (REP 12.3). Disconnect P/ J38 from the Duplex PWB. Measure the resistance on the disconnected plug between pin 1 and pin 2; between pin 1 and pin 3; between pin 1 and pin 4; and between pin 1 and pin 5. All four readings are between 30 and 37 ohms. Y N Replace the Duplex Motor Assembly (REP 12.8). Replace the Duplex PWB (REP 12.4). If the problem persists, replace the Print Engine Controller PWB (REP 9.3). Press [0] for one second to stop all tests. Scroll to Sensor Input test and press Enter. Use a small strip of paper to actuate and deactuate the Duplex Transport Sensor. The number on the LCD increments each time you press and release the actuator. Y N Replace the Duplex Sensor Assembly (REP 12.13). If the problem persists, replace the Print Engine Controller PWB (REP 9.3). Perform RAP 32 to test the Registration Sensor. The Registration Sensor is working cor- rectly. Y N Replace the Registration Sensor (REP 5.4). Replace the Print Engine Controller PWB (REP 9.3). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures

Initial Issue RAP 57 Offset Jam Open Rear Cover (E6-X) Paper late to OCT sensor, paper late off OCT sensor, or paper on OCT sensor at power on. Procedure Open the printer Rear Cover and the OCT Rear Cover. Check for paper or other obstructions in the paper path. The printer if free of jammed paper, paper scraps, or other obstructions. Y N Clear all jammed paper, paper scraps, and obstructions from the printer and the OCT. Run 15 to 20 test prints, output to OCT. The error code reappears. Y N Problem Solved Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Open the OCT Rear Cover. Actuate and deactuate the OCT Exit Sensor Actuator. The num- ber on the LCD increments each time you press and release the actuator. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). On the Print Engine Controller PWB, check the voltage between P/J35 pin 7 and frame ground as you actuate and deactuate the OCT Exit Sensor Actuator. The voltage is 3.3VDC when deactuated and 0.0VDC when actuated. Y N Replace the OCT Exit Sensor (REP 10.11). If the problem persists, replace the OCT PWB (REP 10.7). Replace the Print Engine Controller PWB (REP 9.3). Exit Sensor Input test and scroll to OCT Motor Operation. Press Enter. The OCT Motor runs. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Enter diagnostics and select Component Test. Scroll to OCT Motor Operation. On the Print Engine Controller PWB, check the volt- age between P/J35 pin 6 and frame ground. Press Enter. The voltage drops from 3.3VDC to 0.5VDC when the Enter Key is pressed. Y N Replace the Print Engine Controller PWB (REP 9.3). Switch the printer power off. Remove the OCT from the printer (REP 10.1). Turn the OCT up side down. Disconnect P/J210 from the OCT PWB. Check the resistance between pins 1 and 4, pins 1 and 6, pins 2 and 3, and pins 2 and 5 on the disconnected plug. All read- ings are 70 ± 10 ohms. Y N Replace the OCT Motor (REP 10.8). Replace the OCT PWB (REP 10.7). Open the OCT Rear Cover. Check the OCT rollers. The OCT Rollers are rotating smoothly. Y N Repair or replace the OCT Rollers as necessary (REP 10.14/REP 10.15). Switch the printer power off. Remove the OCT (REP 10.1). Open the printer rear cover and check the movement of the Exit Gate. The Exit Gate moves freely in both directions when pressed and released. Y N Repair or replace the Exit Gate as necessary (REP 6.4). Reinstall the OCT. Each time the printers’ rear cover or front cover is opened and closed with power applied, the printer performs a reset. At the completion of the reset, the Exit Gate tog- gles between fully open and fully closed positions. Open the printer rear cover. Switch the printer power on. Cheat the Rear Cover Interlock and watch the Exit Gate at the end of reset. Remove then replace the Rear Cover Interlock cheater. The Exit Gate toggles at the com- pletion of each reset. Y N Replace the Direction Solenoid (REP 10.10). if the problem persists, Replace the OCT PWB (REP 10.7). Replace the OCT PWB (REP 10.7). If the problem persists, Replace the Print Engine Control- ler PWB (REP 9.3). A A manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 58 OCT Assy Not Recognized Procedure Switch the printer power off. Remove and reinstall the OCT. Switch the printer power on. Run a Config Sheet. The OCT is listed on the Config Sheet. Y N Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Remove the OCT from the printer. Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/ J35 pin 1 and frame ground. The voltage is 3.3VDC. Y N Replace the Print Engine Controller PWB (REP 9.3). Switch the printer power off. Properly install the OCT on the printer. Switch the printer power on. On the Print Engine Controller PWB, check the voltage between P/J35 pin 1 and frame ground. The voltage is 0.0VDC. Y N Replace the OCT PWB (REP 10.7). Replace the Print Engine Controller PWB (REP 9.3). Problem Solved. RAP 59 Remove Output From Offset Bin (C5) Error code indicates the output tray is full. Procedure There is a paper stack in the offset bin actuating the Stack Full Sensor. Y N The paper is curled. Y N Lift and release the Stack Full Actuator a few times. The actuator moves freely. Y N Replace Stack Full Actuator (REP 10.12) or Stack Full Sensor (REP 10.13), as necessary. Enter diagnostics and select Component Test. Scroll to Sensor Input test. Manually actuate and deactuate the Stack Full Actuator. The number on the LCD incre- ments each time you lift and release the actuator (the count may have a short delay because of the sensor circuit). Y N Go to RAP 60. Replace Print Engine Controller PWB (REP 9.3). Replace paper in paper tray with fresh dry paper. Run test prints. The error code reap- pears. Y N Problem solved. Enter diagnostics and select Component Test. Scroll to Sensor Input test. Manually actu- ate and deactuate the Stack Full Actuator. The number on the LCD increments each time you lift and release the actuator (the count may have a short delay because of the sensor circuit). Y N Go to RAP 60. Replace Print Engine Controller PWB (REP 9.3). Remove the paper stack.

Status Indicator Repair Analysis Procedures Initial Issue RAP 60 OCT Stack Full Sensor Procedure Enter Diagnostics and select Component Test. Scroll to Sensor Input test and press Enter. Actuate and deactuate the OCT Stack Full Sensor Actuator. The number on the LCD incre- ments each time you press and release the actuator. Y N Visually inspect the Stack Full Sensor Actuator. The actuator moves freely and is in good condition (not broken or damaged). Y N Replace the Stack Full Actuator (REP 10.12). Switch the printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and Left Plate (REP 1.11). Disconnect P/J35 from the Print Engine Controller PWB. Switch the printer power on. On the Print Engine Controller PWB, measure the voltage between P35 pin 2 and frame ground. The voltage is +3.3VDC. Y N On the Print Engine Controller PWB, measure the voltage between P/J28 pin 10 and frame ground. The voltage is +3.3VDC. Y N Replace the LVPS (REP 9.5). Replace the Print Engine Controller PWB (REP 9.3). Switch the printer power off. Reconnect P/J35 to the Print Engine Controller PWB. Switch the printer power on. On the Print Engine Controller PWB, measure the voltage between P/J35 pin 2 and frame ground. There is +3.3VDC between P/J35 pin 2 and frame ground when the Stack Full Sensor is deactuated and 0.0VDC when actuated. Y N Replace the Stack Full Sensor (REP 10.13). If the problem persists, replace the OCT PWB (REP 10.7). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). RAP 61 OCT Offset Operation Not Performed Procedure Manually move the Offset Assembly from one side to the other. The Offset Assembly moves smoothly. Y N Replace the Offset Assembly (REP 10.14). Enter Diagnostics and select Component Test. Scroll to OCT Offset Motor and press Enter [4]. The Offset Assembly shifts left then returns right. Y N Switch the printer power off. Remove the Inner Exit Chute Assembly (REP 10.6). Discon- nect P/J229 from the OCT PWB. On the disconnected plug, measure the resistance between pins 1 and 3, pins 1 and 5, pins 2 and 4, and between pins 2 and 6. The resis- tance is 245 to 265 ohms. Y N Replace the OCT Offset Motor (REP 10.17). Replace the OCT PWB (REP 10.7). If the problem persists, replace the Print Engine Con- troller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures

Status Indicator Repair Analysis Procedures Initial Issue RAP 62 Envelope Feeder Not Recognized Procedure Switch the Printer power off. Remove and reinstall the envelope feeder. Switch the Printer power on. Run a Config Sheet. The Envelope Feeder is listed on the Config Sheet. Y N Switch the Printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the Printer power on. Check the voltage on the Print Engine Controller PWB between P/J23 Pin 4 and frame ground. The voltage is 0.0VDC. Y N Switch the Printer power off. Remove the Envelope Feeder. Check for continuity between J418 Pin 3 (Envelope Connector Assembly) and P/J23 Pin 4 on the Print Engine Controller PWB. There is continuity between the two pins. Y N Remove the Front Cover (REP 1.6) and the Left Front Cover (REP 1.7). Check for continuity between P/J 41 Pin 6 on the Connector PWB and P/J 23 Pin 4. There is continuity between the two pins. Y N Check the Connector Harness Assembly for proper connection and for defective wires. Repair or replace if necessary. If Harness is in good con- dition, replace the Connector PWB (REP 9.7). Replace the Envelope Connector Assembly (REP 4.10). Replace the Envelope Feeder PWB (REP 13.3). Replace the Envelope Feeder PWB (REP 13.3). Problem solved. RAP 63 Envelope Feed Clutch Procedure Enter Diagnostics and select Component Test. Scroll to confirm EBF Clutch and press Enter. You can hear the clutch energize. Y N Switch Power Off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Enter Diagnostics and select Component Test. Scroll to confirm EBF Clutch. On the Print Engine Controller PWB, check voltage between P/J23 Pin 1 and frame ground. Press Enter. The voltage pulses from 0.0VDC to 3.3VDC then returns to 0.0VDC. Y N Check the voltage between P/J23 Pin 4 and frame ground. The voltage is 0.0VDC. Y N Go to RAP 62. Replace the Print Engine Controller PWB (REP 9.3). Remove the Envelope Feeder from the Printer. Remove the Bottom Cover (REP 13.1) and the Top Chute (REP 13.2). Disconnect P/J413 from the Envelope Feeder PWB. Measure the resistance between Pins 1 and 2 on the disconnected plug. The resistance is 170 to 190 ohms. Y N Replace the Envelope Feed Clutch (REP 13.12). Replace the Envelope Feeder PWB (REP 13.3). Check the Envelope Feed Belts for wear and contamination. Check for belts slipping. Repair or replace as necessary. If Belts are in good condition and not slipping replace the Envelope Feed Clutch (REP 13.12). manuals4you.com manuals4you.com

Initial Issue Status Indicator Repair Analysis Procedures RAP 64 Envelope No Paper Sensor Procedure Enter Diagnostics and select Component Test. Scroll to Sensor Input Test and press Enter. Press and release the Envelope Feeder No Paper Sensor Actuator. The number on the LCD increments each time you press and release the Actuator. Y N Switch the Printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the Printer power on. On the Print Engine Controller PWB check the voltage between P/J23 Pin 4 and the frame ground. The voltage is 0.0VDC. Y N Go to RAP RAP 62. Check the voltage between P/J23 Pin 3 and frame ground. The voltage is 3.3 with the Envelope Feeder No Paper Sensor de-actuated and 0.0VDC with the sensor actu- ated. Y N Switch the Printer power off and remove the Envelope Feeder. Check for continuity between J418 (Envelope Connector Assembly) and P/J23 Pin 3 on the Print Engine Controller PWB. There is continuity between the pins. Y N Remove the Front Cover (REP 1.6) and the Front Left Cover (REP 1.7). Check for continuity between P/J41 Pin 5 on the Connector PWB and P/J23 Pin 3 on the Print Engine Controller PWB. There is continuity between the two pins. Y N Check the Connector Harness Assembly for proper connection and for defective wires. Repair or replace if necessary. If Harness is in good con- dition, replace the Connector PWB (REP 9.7). Replace the Envelope Connector Assembly (REP 4.10). Replace the Envelope Feeder PWB (REP 13.3). If the problem persists, replace the Envelope Feeder No Paper Sensor (REP 13.10). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3). RAP 65 Load Envelope (C5) Procedure Enter Diagnostics and select Component Test. Scroll to Sensor Input Test and press Enter. Press and release the Envelope Feeder No Paper Sensor Actuator. The number on the LCD increments each time you press and release the Actuator. Y N Switch the Printer power off. Remove the Left Interface Cover (REP 1.1), Left Cover (REP 1.2), and the Left Plate Assembly (REP 1.11). Switch the Printer power on. On the Print Engine Controller PWB check the voltage between P/J23 Pin 4 and the frame ground. The voltage is 0.0VDC. Y N Go to RAP RAP 62. Check the voltage between P/J23 Pin 3 and frame ground. The voltage is 3.3 with the Envelope Feeder No Paper Sensor de-actuated and 0.0VDC with the sensor actu- ated. Y N Switch the Printer power off and remove the Envelope Feeder. Check for continuity between J418 (Envelope Connector Assembly) and P/J23 Pin 3 on the Print Engine Controller PWB. There is continuity between the pins. Y N Remove the Front Cover (REP 1.6) and the Front Left Cover (REP 1.7). Check for continuity between P/J41 Pin 5 on the Connector PWB and P/J23 Pin 3 on the Print Engine Controller PWB. There is continuity between the two pins. Y N Check the Connector Harness Assembly for proper connection and for defective wires. Repair or replace if necessary. If Harness is in good con- dition, replace the Connector PWB (REP 9.7). Replace the Envelope Connector Assembly (REP 4.10). Replace the Envelope Feeder PWB (REP 13.3). If the problem persists, replace the Envelope Feeder No Paper Sensor (REP 13.10). Replace the Print Engine Controller PWB (REP 9.3). Replace the Print Engine Controller PWB (REP 9.3).

Initial Issue RAP 66 Envelope Feeder Jam (E2) Envelopes early of late to the Registration Sensor. Procedure Remove all envelopes. Check the Envelope Feeder and Printer for contamination, paper scraps, or other obstructions. The printer and Envelope Feeder is clean and free of obstructions. Y N Clean feeder and remove all obstructions. Check the Feed Belts. Check for dirt or contamination on the top side and the under side of the belt. Both sides of the belt are clean. Y N Replace the Feed Belts (REP 13.17). Enter Diagnostics and select Component Test. Scroll to Confirm EBF Clutch and press Enter. You can hear the clutch energize. Y N Go to RAP 63. Scroll to Main Motor Operation and press Enter. Scroll to Confirm EBF Clutch. Watch the Feed Belts and Feed Rollers and press Enter. The Feed Belts and Feed Rollers all rotate. Y N Ensure the Envelope Feeder is installed properly and is contacting the printer drive gear. The Envelope Feeder is installed correctly. Y N Reinstall the Envelope Feeder correctly. Remove the Envelope Feeder and check the feeder drive gears. All gears are in good condition and operating properly. Y N Replace the gears as necessary (PL 12.2). Replace the Envelope Feed Clutch (REP 13.12). If the problem persists, Replace the Envelope Feeder PWB (REP 13.3). Perform RAP 32 to check the Registration Sensor. The Registration Sensor is operating correctly. Y N Replace the Registration Sensor (REP 5.4). Replace the Print Engine Controller PWB (REP 9.3). manuals4you.com manuals4you.com

Initial Issue 3 Image Quality Repair Analysis Procedures Introduction...................................................................................................................... 3-3 Measurements................................................................................................................. 3-3 Image Quality Defect Definitions..................................................................................... 3-4 Image Quality Checkout.................................................................................................. 3-5 Solid Area Density........................................................................................................... 3-6 Background ..................................................................................................................... 3-6 Deletions (Line, Band, Spots).......................................................................................... 3-7 Fusing.............................................................................................................................. 3-7 Resolution ....................................................................................................................... 3-8 Registration (Side to Side) .............................................................................................. 3-8 Registration (Lead Edge to Trail Edge)........................................................................... 3-9 Skew................................................................................................................................ 3-9 Skips / Smears ................................................................................................................ 3-10 Spots ............................................................................................................................... 3-10 Other Print Defects.......................................................................................................... 3-11 IQ RAP 1 Light (Undertoned) Prints................................................................................ 3-11 IQ RAP 2 Blank Prints..................................................................................................... 3-12 IQ RAP 3 Spots............................................................................................................... 3-13 IQ RAP 4 Horizontal Deletions........................................................................................ 3-14 IQ RAP 5 Vertical Deletions ............................................................................................ 3-15 IQ RAP 6 Spot Deletions................................................................................................. 3-16 IQ RAP 7 Vertical Streaks............................................................................................... 3-17 IQ RAP 8 Horizontal Streaks........................................................................................... 3-18 IQ RAP 9 Residual Image ............................................................................................... 3-19 IQ RAP 10 Black Prints ................................................................................................... 3-20 IQ RAP 11 Background................................................................................................... 3-21 IQ RAP 12 Uneven Density............................................................................................. 3-21 IQ RAP 13 Skewed Image .............................................................................................. 3-22 IQ RAP 14 Damaged Print .............................................................................................. 3-23 IQ RAP 15 Registration................................................................................................... 3-24 IQ RAP 16 Skips / Smears.............................................................................................. 3-25 IQ RAP 17 Unfused Image.............................................................................................. 3-25 IQ RAP 18 Resolution ..................................................................................................... 3-26 manuals4you.com manuals4you.com

Initial Issue Introduction This section contains image quality repair procedures to assist in correcting image quality defects. These procedures provide defect samples, definitions and specifications to help iden- tify the type of defect that exists, the test pattern to use, and actions required to correct the defects. The voltage tolerances for this section are listed in Table 1 under the topic Measurements. Throughout these procedures, the term “vertical” refers to the process direction (the direction paper travels through the printer); the term “horizontal” refers to the scanning direction (the direction the laser beam scans across the page). Cleaning procedures should always be performed before beginning any Print Quality Repair procedure. Be sure that the paper meets printer specifications. Changing the paper, or using paper from a previously unopened ream, will resolve many print quality issues. After resolving an image quality problem, return to Image Quality Checkout to verify that no other image quality defects exist. Sample reproductions of the various image quality patterns are included under Image Quality Specifications. Use the Image Quality RAPS to further diagnose machine problems. In the Y/N (Yes/No) steps of the RAPs, a Yes response will lead you to the next step. A No response will indicate a corrective action, or will direct you to another step. When the indicated corrective action has been completed, go to Section 1 and restart the Initial Actions to verify that the problem has been corrected. Measurements Power and signal grounds are connected to frame ground, therefore all circuit troubleshooting can be performed using the metal frame (chassis) as the grounding point. If more information is needed to locate connectors or test points, refer to section 7. Unless specified otherwise, the following voltage tolerances are used within this section: Table 1 Table 1 Voltage Measurements Stated Measured + 5.0 VDC + 4.8 VDC to + 5.2 VDC + 3.3 VDC + 3.0 VDC to + 3.6 VDC + 24.0 VDC + 21.6 VDC to + 26.4 VDC 0.0 VDC less than + 0.5 VDC manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Image Quality Defect Definitions The System Controller Test Print (Figure 1) is used to evaluate each of the print quality param- eters. Each area of the test pattern is used for a print quality parameter. The areas and the print quality parameters are listed in Image Quality Checkout. Table 1 Image Quality Defect Definitions Defect Definitions Go To: LIGHT PRINTS: The overall image density is too light. IQ RAP 1 BLANK PRINTS: Prints with no visible image. IQ RAP 2 SPOTS: There are spots of toner on the page. IQ RAP 3 HORIZONTAL DELETIONS: There are areas of the image that are extremely light or missing entirely. These areas run horizontally across the page in the direction of scanning. IQ RAP 4 VERTICAL DELETIONS: There are areas of the image that are extremely light or missing entirely. These areas run vertically along the page in the direction of paper movement. IQ RAP 5 SPOT DELETIONS: Solid areas are marked with irregular white areas. IQ RAP 6 VERTICAL STREAKS: Extraneous dark lines/bands in the process direction. IQ RAP 7 HORIZONTAL STREAKS: Extraneous dark lines/bands in the direction of scan. IQ RAP 8 RESIDUAL IMAGES: The image from a previous print, which was not removed during the cleaning process, has been developed on the current print. IQ RAP 9 BLACK PRINTS: The print is completely covered with toner and has no visi- ble image. IQ RAP 10 BACKGROUND: Uniform toner contamination in non image areas. Refer to the Background specification. IQ RAP 11 UNEVEN DENSITY: The text/line darkness and solid area density image var- ies across the print. IQ RAP 12 SKEWED IMAGE: Angular displacement of the image from its intended posi- tion on the print. Refer to the specification. IQ RAP 13 DAMAGED PRINTS: Creases, wrinkles, excessive curl, cuts, folds or embossed marks. IQ RAP 14 REGISTRATION (lead edge to trail edge): Displacement of the image, in the process direction, from its intended position on the print. (inboard to outboard): Displacement of the image, in the direction of scan, from its intended position on the print. IQ RAP 15 SKIPS / SMEARS: Skip-Loss or stretching of the image in bands across the process direction. Smear-The distortion of the image in bands across the process direction that cause it to appear to be blurred or compressed. IQ RAP 16 UNFUSED IMAGE: Part of or all of the image is unfused. Refer to the specifi- cation. IQ RAP 17 RESOLUTION: At 600 DPI, the two pixel lines and halftone patches cannot be reproduced clearly on the print. IQ RAP 18

Image Quality Repair Analysis Procedures Initial Issue Image Quality Checkout The System Controller Test Print is used to evaluate and ensure that the printed image meets the printer specifications. Use new paper, whenever possible, to check the image quality of prints. Make five (5) prints of the System Controller Test Print (Figure 1). Discard the first two prints and retain the remaining prints for image quality analysis. The Image quality Checkout is used to evaluate the following: 1. Resolution (2 places) (Figure 1) 2. Skips and Smears (4 places) (Figure 1) 3. Registration (1 place) (Figure 1) 4. Resolution and Uniformity (2 places) (Figure 1) 5. Solid Area Density (3 places) (Figure 1) 6. Half Tone Resolution (2 places). (Figure 1) Go to Solid Area Density. Figure 1 System Controller Test Print. manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Solid Area Density Procedure Ensure the printer is set for 600 dpi. Compare the solid areas on the System Controller Test Patterns with the Output Reference document (82P520) (Figure 1). The solid areas on the print are at the 1.20 density square on the scale or higher, and all the solid areas on any print differ in density less than one density square. Y N The solid area density is uniform. Y N Go to IQ RAP 12 Uneven Density. The prints are too faint. Y N The prints are black. Y N Go to IQ RAP 11 Background. Go to IQ RAP 10 Black Prints Go to IQ RAP 1 Light Prints The Solid Area Density is within specifications. Go to Background. Figure 1 Output Reference Document Background Procedure Compare the Test Prints with the Visual Scale (82P284). The worst background area on any print should be at, or below, area 3 on the rating guide (Figure 1). The print is at the area 3 or below. Y N The background is uniform. Y N Go to IQ RAP 12 Uneven Density. Go to IQ RAP 11 Background. The printed test patterns meet the Background specification. Go to Deletions. Figure 1 Rating Guide

Image Quality Repair Analysis Procedures Initial Issue Deletions (Line, Band, Spots) Procedure Inspect Test Prints for the presence of deletions (missing image). There should be no deletions with a diameter larger than 0.5 mm visible on test prints (Figure 1). There are deletions on the test prints. Y N Go to Fusing. There are vertical (in direction of paper movement) Line/Band deletions present. Y N There are Horizontal (in direction of scanning) Line/Band Deletions present. Y N There are Spot Deletions present. Y N Go to Fusing. Go to IQ RAP 6 Spot Deletions. Go to IQ RAP 4 Horizontal Deletions. Go to IQ RAP 5 Vertical Deletions. Figure 1 Line, Band, or Spot Deletions. Fusing Procedure NOTE: The operating environment of the printer is from 41° F (5° Celsius) at 15% relative humidity to 95° F (35° Celsius) at 85% relative humidity. The fusing performance of the printer will vary according to the environment. • A cold environment will affect the warm-up time. • The weight (lb. / gsm) of the paper or transparency will affect the fusing of prints. • High humidity will have an adverse affect on the fusing of prints. Check the fusing quality of the image of a System Controller Test Print (Figure 1). Rub the image three times with a soft cloth or tissue. The image should not lift off of the surface of the print. The fusing quality of the image meets the specification. Y N Go to IQ RAP 17 Unfused Image. Go to Resolution. Figure 1 Fusing Quality. manuals4you.com manuals4you.com

Resolution Procedure Refer to Figure 1. Observe the three image areas on several System Controller Test Patterns. Check the resolution of the images in each of the areas: Arrow 1 The two pixel vertical, horizontal and diagonal lines should be clear and continuous. The diag- onal lines might appear to be narrower than the others. Arrow 2 The text paragraphs should be roughly equal in density. Arrow 3 The half-tone patches adjacent to the solid blocks in the corners should be uniform in appear- ance. The three checks (arrows 1, 2, & 3) are within specification. Y N Go to IQ RAP 18 Resolution. The printed test patterns meet the Resolution specification. Go to the Registration (Side to Side). Figure 1 Resolution. Registration (Side to Side) Procedure Measure the registration on two consecutive System Controller Test Patterns. Fold the paper in half (side edge to side edge). Observe the fold line of the paper with reference to the cross hairs of the target, Figure 1. The fold is within +/- 2.0 mm of the target cross hairs (each line on the target is 1 mm). Y N Go to IQ RAP 15 Registration. The test prints meet the side to side registration specification. Go to Registration (Lead Edge to Trail Edge). Figure 1 Registration (Side to Side).

Image Quality Repair Analysis Procedures Initial Issue Registration (Lead Edge to Trail Edge) Procedure Measure the registration on two consecutive System Controller Test Patterns. Fold the paper in half (lead edge to Trail Edge). Observe the fold line of the paper with reference to the cross hairs of the target. The fold is within +/- 2.0 mm of the target cross hairs (each line on the target is 1 mm) (Figure 1). Y N Go to IQ RAP 15 Registration. The printed test patterns meet the lead edge to trail edge registration specification. Go to Skew. Figure 1 Registration (Lead Edge to Trail Edge). Skew Procedure Enter Diagnostics and select Test Print. Scroll to Print Pattern and press Enter [4]. Observe the test pattern. Measure the dimensions ‘A’ and ‘B’ (Figure 1) on two consecutive test patterns. The difference between ‘A’ and ‘B’ should be 1.5 mm or less. The skew on the test patterns meets the specification. Y N Go to IQ RAP 13 Skewed Image. The printed test patterns meet the Skew specification. Go to the Skips and Smears. Figure 1 Printer Engine Controller Test Pattern. manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Skips / Smears Procedure Enter Diagnostics and select Test Print. Scroll to Print Pattern and press Enter [4]. Inspect the ladder chart test pattern. The pattern should be free from skips and smears (Figure 1). The test prints are free from skips and smears. Y N Go to IQ RAP 16 Skips/Smears. Go to the Spots checkout Figure 1 Skips / Smears. Spots Procedure From the menu mode, run a Config Sheet. Inspect the print for spots (Figure 1). Within a 208 x 95 mm square: • There should be no spots larger than or equal to 0.5 mm visible on the prints. • There should be no more than 1 spot measuring between 0.4 mm and 0.5 mm visible on the print. • There should be no more than 16 spots measuring between 0.25 mm and 0.4 mm visible on the print. • Any spot measuring less than 0.25 mm is acceptable. The prints are free of spots or the spots that are visible fall within the acceptable range. Y N Go to IQ RAP 3 Spots. Go to Other Print Defects. Figure 1 Spots.

Image Quality Repair Analysis Procedures Initial Issue Other Print Defects Procedure Inspect the Test Patterns for other Print Defects. Test Prints are free of defects. Y N There are dark streaks present on the Test Prints. Y N There is a residual image (ghosts) on the Test Prints. Y N There is paper damage: wrinkles, creases, tears, etc. Y N The printer meets specifications. Go to Initial Actions Go to IQ RAP 14 Damaged Prints. Go to IQ RAP 9 Residual Image. Go to IQ RAP 7 / IQ RAP 8 Streaks. Go to Final Actions IQ RAP 1 Light (Undertoned) Prints The overall image density is too light (Figure 1). Figure 1 Light Prints Initial Actions • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Ensure there are no obstructions in the Laser path. Procedure Load fresh, dry paper. Run a test print. The image density meets specifications. Y N Install a new Print Cartridge. Run a test print. The image density meets specifications. Y N Remove the Print Cartridge. Inspect the Metal Grounding Contacts on the Print Car- tridge Side Guide. The Metal Grounding Contacts are intact and free of contam- ination. Y N Reform or clean the Metal Grounding Contacts, so they make better contact with the drum shaft, or replace the Print Cartridge Side Guide (REP 7.5). Check for the continuity between the Metal Grounding Contacts and the printer body frame. There is continuity between the Metal Grounding Contacts and the printer frame. Y N Replace the Print Cartridge Side Guide (REP 7.5). Inspect Laser beam path between the Laser Assembly and the Drum for obstruc- tions. The laser beam path is free of obstructions. A B manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Y N Clean the Laser window and remove any obstructions from the laser beam path. The BTR is intact and is free of contamination. Y N Replace the BTR (REP 7.1). Generate a Test Print and switch OFF the printer power halfway through the print cycle. Carefully remove the Print Cartridge and inspect the toner image on the drum just before the transfer area (BTR). The image on the drum is completely devel- oped with sharp, black, easily read areas. Y N Go to (RAP 43) Inspect the toner image on the drum immediately after the transfer area (BTR). The toner image on the drum is transferred completely to the paper. Y N Go to (RAP 43) Replace in order until the problem is solved: BTR Assembly (REP 7.1), Fuser Assembly (REP 6.2), HVPS PWB (REP 9.6), Laser Assembly (REP 7.4), LVPS Assembly (REP 9.5), Print Cartridge Side Guide (REP 7.5), Print Engine Controller PWB (REP 9.3), Chute Transport Assembly (REP 6.1). Go to RAP 23. Problem Solved. IQ RAP 2 Blank Prints No visible image anywhere on the output print (Figure 1). Figure 1 Blank Prints Initial Actions • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Ensure there are no obstructions in the Laser path. • Ensure the blank prints are not the result of multisheet feeds. Procedure Enter Diagnostics and select Test Print. Scroll to Print Pattern and press Enter [4]. Run five test prints. The test prints are blank. Y N Exit diagnostics and enter the Menu Mode. Print a Config Sheet. The prints are blank. Y N The problem appears to be with the host computer or the cables. If the problems per- sist, replace the System Controller PWB (REP 9.2). Remove and reseat the System Controller PWB. If the problems persist, replace the Sys- tem Controller PWB (REP 9.2). Install a new Print Cartridge. Run a test print. There is a normal image on the paper. Y N Remove the Print Cartridge. Inspect the Metal Grounding Contacts on the Print Cartridge Side Guide. The Metal Grounding Contacts are intact and is free of contamination. Y N Reform or clean the Metal Grounding Contacts, so they make better contact with the drum shaft, or replace the Print Cartridge Side Guide (REP 7.5). A B A B

Image Quality Repair Analysis Procedures Initial Issue Check for continuity between the Metal Grounding Contacts and the printer frame. There is continuity between the Grounding Contacts and the printer frame. Y N Replace the Print Cartridge Side Guide (REP 7.5). The BTR is intact and is free of contamination. Y N Replace the BTR Assembly (REP 7.1). Generate a Test Print and switch OFF the printer power halfway through the print cycle. Carefully remove the Print Cartridge and inspect the toner image on the drum just before the transfer area (BTR). The image on the drum is completely developed; with sharp, black, easily read areas. Y N Go to RAP 43. Replace in order until the problem is solved: HVPS PWB (REP 9.6), Laser Assembly (REP 7.4), BTR Assembly (REP 7.1), Print Engine Controller PWB (REP 9.3), LVPS PWB (REP 9.5), Print Cartridge Side Guide (REP 7.5). Problem solved. IQ RAP 3 Spots There are spots of toner randomly scattered on the page (Figure 1). Figure 1 Spots Initial Actions • Check that the paper supply is clean, dry and fresh (recycled paper may have spots). • Ensure there are no obstructions in the Laser path. • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Check that rollers and other components in the paper path are clean and unobstructed. Procedure Install a new Print Cartridge. Run a Test Print. The spots are gone. Y N Inspect the BTR Assembly for contamination and wear. The BTR is free of contamina- tion and wear. Y N Replace the BTR Assembly (REP 7.1). Generate a Test Print and switch OFF the printer power halfway through the print cycle. Carefully remove the Print Cartridge and inspect the toner image on the drum just before the transfer area (BTR). The image on the drum is completely developed; with sharp, black easily read areas and no spots. Y N Go to RAP 43. A B A B manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures WARNING If the printer has been switched on, the Fuser will be hot. Open the Rear Cover. Remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open fuser jam access cover. Rotate the fuser idler gear man- ually and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. Y N Replace the Fuser Assembly (REP 6.2). Replace the following, in order, until the defective component is found: BTR Assembly (REP 7.1), Fuser Assembly (REP 6.2), Chute Transport Assembly (REP 6.1), HVPS PWB (REP 9.6), Laser Assembly (REP 7.4), Print Engine Controller PWB (REP 9.3) Problem solved. IQ RAP 4 Horizontal Deletions A deletion is an area of the print where the image is missing or extremely light. Horizontal dele- tions extend across the page (Figure 1). Figure 1 Horizontal Deletions Initial Actions • Check that the paper supply is dry and fresh. • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Check that rollers and other components in the paper path are clean and unobstructed. Procedure Enter Diagnostics and select Test Print. Scroll to Print Pattern and press Enter [4]. Run five test prints. The test prints have horizontal deletions. Y N Exit diagnostics and enter the Menu Mode. Print a Config Sheet. The prints have hori- zontal deletions. Y N The problem appears to be with the host computer or the cables. If the problems per- sist, replace the System Controller PWB (REP 9.2). Remove and reseat the System Controller PWB. If the problems persist, replace the Sys- tem Controller PWB (REP 9.2). Load fresh, dry paper. Run a test print. The problem is still present. Y N Problem solved. Install a new Print Cartridge. The problem is still present. A B

Image Quality Repair Analysis Procedures Initial Issue Y N Problem solved. Inspect the BTR Assembly for contamination and wear. The BTR is free of contamination and wear. Y N Replace the BTR Assembly (REP 7.1). Generate a test print and switch OFF the printer power halfway through the print cycle. Care- fully remove the Print Cartridge and inspect the toner image on the drum just before the trans- fer area (BTR). The image on the drum is completely developed, with sharp, black, easily read areas and no horizontal deletions. Y N Go to RAP 43. Inspect the toner image on the drum immediately after the transfer area (BTR). The toner image on the drum was transferred to the paper. Y N Go to RAP 43. WARNING If the printer has been switched on, the Fuser will be hot. Warning: the Fuser may be hot. Open the Rear Cover and remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open the fuser jam access cover. Rotate the fuser idler gear manually and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. Y N Replace the Fuser Assembly (REP 6.2). Replace in order until the problem is solved: HVPS PWB (REP 9.6), Print Cartridge Side Guide (REP 7.5), BTR Assembly (REP 7.1), Chute Transport Assembly (REP 6.1), Laser Assembly (REP 7.4), Print Engine Controller PWB (REP 9.3), Fuser Assembly (REP 6.2), MBF Chute Assembly (REP 4.1), Registration Clutch (REP 5.5), Turn Roll Assembly (REP 11.8). IQ RAP 5 Vertical Deletions A deletion is an area of the print where the image is missing or extremely light. Vertical band deletions are deletions which extend down the page (Figure 1). Figure 1 Vertical Deletions Initial Actions • Check that the paper supply is dry and fresh. • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Ensure there are no obstructions in the Laser path. • Check that rollers and other components in the paper path are clean and unobstructed. Procedure Load fresh, dry paper. Run a test print. The problem is still present. Y N Problem solved. Install a new Print Cartridge. Run a test print. The problem is still present. Y N Problem solved. Inspect the laser beam path between the Laser Assembly and the Drum. The laser beam path is free of obstructions. Y N Remove any obstructions from the laser beam path. Inspect the paper path, between feed and exit, for contamination or obstructions. The paper path is free of obstructions. Y N Remove obstructions or contamination from the paper path. A manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Inspect the BTR Assembly for contamination and wear. The BTR is free of contamination and wear. Y N Replace the BTR Assembly (REP 7.1). WARNING If the printer has been switched on, the Fuser will be hot. Open the Rear Cover and remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open the fuser jam access cover. Rotate the fuser idler gear manu- ally and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. Y N Replace the Fuser Assembly (REP 6.2). Replace in order until the problem is solved: BTR Assembly (REP 7.1), Laser Assembly (REP 7.4), Fuser Assembly (REP 6.2), Print Engine Controller PWB (REP 9.3). IQ RAP 6 Spot Deletions Solid areas are marked with irregular white areas. Figure 1 Spot Deletions Initial Actions • Check that the paper supply is dry and fresh. • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. Procedure Load fresh, dry paper. Run a test print. The problem is still present. Y N Problem solved. Install a new Print Cartridge. Run a test print. The problem is still present. Y N Problem solved. Inspect the toner image on the drum immediately after the transfer area (BTR). The toner image on the drum transferred to the paper. Y N Replace the BTR Assembly (REP 7.1). WARNING If the printer has been switched on, the Fuser will be hot. Open the Rear Cover and remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open the fuser jam access cover. Rotate the fuser idler gear manu- ally and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. A

Image Quality Repair Analysis Procedures Initial Issue Y N Replace the Fuser Assembly (REP 6.2). Replace the following, in order, until the defective component is found: BTR Assembly (REP 7.1), Chute Transport Assembly (REP 6.1). IQ RAP 7 Vertical Streaks Extraneous dark lines/bands in the process direction (in the direction of paper travel) (Figure 1). Figure 1 Vertical Streaks Initial Actions • Check that the paper supply is dry and fresh. • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Check that the paper is within specifications. • Inspect the paper path, between feed and exit, for contamination or obstructions. Procedure Enter Diagnostics and select Test Print. Scroll to Print Pattern and press Enter [4]. Run five test prints. The test prints have vertical streaks. Y N Exit diagnostics and enter the Menu Mode. Print a Config Sheet. The prints have verti- cal streaks. Y N The problem appears to be with the host computer or the cables. If the problems per- sist, replace the System Controller PWB (REP 9.2). Remove and reseat the System Controller PWB. If the problems persist, replace the Sys- tem Controller PWB (REP 9.2). Install a new Print Cartridge. Run a Test Print. The vertical streaks are gone. Y N Inspect the laser beam path between the Laser Assembly and the Drum. The laser beam path is free of obstructions. A manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Y N Remove any obstructions from the laser beam path. Inspect the BTR Assembly for contamination and wear. The BTR is free of contamina- tion and wear. Y N Replace the BTR Assembly (REP 7.1). WARNING If the printer has been switched on, the Fuser will be hot. Open the Rear Cover. Remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open the fuser jam access cover. Rotate the fuser idler gear manually and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. Y N Replace the Fuser Assembly (REP 6.2). Go to RAP 44 Problem solved. IQ RAP 8 Horizontal Streaks There are black lines running horizontally across the page (at a right angle to the direction of paper travel) (Figure 1). Figure 1 Horizontal Streaks Initial Actions • Check that the paper supply is dry and fresh. • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. Procedure Enter Diagnostics and select Test Print. Scroll to Print Pattern and press Enter [4]. Run five test prints. The test prints have horizontal streaks. Y N Exit diagnostics and enter the Menu Mode. Print a Config Sheet. The prints have hori- zontal streaks. Y N The problem appears to be with the host computer or the cables. If the problems per- sist, replace the System Controller PWB (REP 9.2). Remove and reseat the System Controller PWB. If the problems persist, replace the Sys- tem Controller PWB (REP 9.2). Install a new Print Cartridge. Run a test print. The horizontal streaks are gone. Y N Remove the Print Cartridge. Inspect the Metal Grounding Contacts on the Print Cartridge Side Guide. The Metal Grounding Contacts are intact and is free of contamination. Y N Reform or clean the Metal Grounding Contacts, so it makes better contact with the drum shaft, or replace the Print Cartridge Side Guide (REP 7.5). A A B

Image Quality Repair Analysis Procedures Initial Issue Check for the continuity between the Metal Grounding Contacts and the printer body frame. There is continuity between the Grounding Contacts and the Printer Frame. Y N Replace the Print Cartridge Side Guide (REP 7.5). Inspect the BTR Assembly for contamination and wear. The BTR is free of contamina- tion and wear. Y N Replace the BTR Assembly (REP 7.1). Generate a Test Print and switch OFF the printer power halfway through print cycle. Care- fully remove the Print Cartridge and inspect the toner image on the Drum just before the transfer area (BTR). The image on the Drum is developed; with sharp, black, easily read areas and no horizontal streaks. Y N Go to RAP 43. Inspect the toner image on the Drum immediately after the transfer area (BTR). The toner image on the Drum was transferred to the paper along with any horizontal streaks. Y N Replace the BTR Assembly (REP 7.1). Open the Rear Cover. Remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open the fuser jam access cover. Rotate the fuser idler gear manually and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. Y N Replace the Fuser Assembly (REP 6.2). Go to RAP 44. Problem solved. IQ RAP 9 Residual Image The image from a previous print, which was not removed during the cleaning process, has been developed on the current print. Figure 1 Residual Image Initial Actions • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Verify the fuser temperature (NVM). Procedure Replace paper with fresh, dry paper. Run a test print. Residual images still appear. Y N Problem solved. Install a new Print Cartridge. Run a test print. The residual images still appear. Y N Problem solved. Inspect the BTR Assembly for contamination and wear. The BTR is free of contamination and wear. Y N Replace the BTR Assembly (REP 7.1). A B A manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures WARNING If the printer has been switched on, the Fuser will be hot. Open the Rear Cover. Remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open the fuser jam access cover. Rotate the fuser idler gear manually and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. Y N Clean or replace the Fuser Assembly (REP 6.2). Replace the following, in order, until the defective component is found: BTR Assembly (REP 7.1), Fuser Assembly (REP 6.2), HVPS PWB (REP 9.6), Print Cartridge Side Guide (REP 7.5). IQ RAP 10 Black Prints A totally black output print. There is toner on the paper with no visible image. Figure 1 Black Prints Initial Actions • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Ensure the machine covers are in place and fit well so no outside light can enter the machine. Procedure Install a new Print Cartridge. Run a Test Print. The print is normal. Y N Shield half of the window of the Laser Assembly. Run a Test Print. The print is half white and half black. Y N Go to RAP 44. Go to RAP 30. Problem solved. A

Image Quality Repair Analysis Procedures Initial Issue IQ RAP 11 Background There is toner contamination on all or part of the page. The contamination appears as a very light gray dusting (Figure 1). Figure 1 Background Initial Actions • Inspect the printer paper path for items such as staples, paper clips and paper scraps. • Check installation of the Print Cartridge. • Check that the Print Cartridge ground contact points are clean. • Ensure the machine covers are in place and fit well so no outside light can enter the machine. Procedure Install a new Print Cartridge (PL 8.1). Run a Test Print. The background is gone. Y N Generate a Test Print and switch OFF the printer power halfway through the print cycle. Carefully remove the Print Cartridge and inspect the toner image on the drum just before the transfer area (BTR). The undeveloped areas of the drum are clean and without background. Y N Go to RAP 43. Clean or replace the Fuser Assembly (REP 6.2). The background is gone. Y N Replace the following, in order, until the defective component is found: HVPS PWB (REP 9.6), Fuser Assembly (REP 6.2), Chute Transport Assembly (REP 6.1), Laser Assembly (REP 7.4), Print Cartridge Side Guide (REP 7.5), Print Engine Controller PWB (REP 9.3). Problem solved. Problem solved. IQ RAP 12 Uneven Density Image density varies within the page in either direction (Figure 1). Figure 1 Uneven Density Initial Actions • Load fresh dry paper. • Check that the correct Print Cartridge is properly installed and not empty. • Ensure that the machine is reasonably level. • Check to make sure the Laser path is clean and unobstructed. • Remove the Print Cartridge and check the Left and Right Guides for ware, contamination, obstructions, etc. • Clean the Laser window. Procedure Run a Test Print. The Test Print output image contains uneven print. Y N Go to Final Actions. Install a new Print Cartridge (PL 8.1). Run a Test Print. The Test Print output image con- tains uneven print. Y N Problem solved. Go to Initial Actions. Check the Bias Transfer Roll (BTR) for contamination, even spring pressure, and proper instal- lation. The BTR is in good condition (not contaminated) and properly installed. Y N Repair or replace the BTR Assembly (REP 7.1). Check the Fuser Assembly for worn parts and for contamination on the Fuser Roll or Pressure Roll. The Fuser Assembly is in good condition. manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Y N Replace the Fuser Assembly (REP 6.2). Panic stop the printer half way through the print cycle. Look at the image on the drum. The image on the drum has even density. Y N Replace the Laser Assembly (REP 7.4). Look at the print on the paper before the Fuser. The print on the paper has even density. Y N Replace the BTR (REP 7.1). Replace the Fuser Assembly (REP 6.2). IQ RAP 13 Skewed Image The image is not parallel to the edges of the print sheet (Figure 1). Figure 1 Skewed Image Initial Actions • Check the paper tray(s) installation and the paper in the tray(s). • Load fresh dry paper. • Paper meets specification. • Check the paper path for any obstructions or debris that might hamper the passage of the paper. • Ensure the Print Cartridge is properly installed. Procedure Run 5 test prints, single sided, from each paper tray. If the printer has a Duplex Assembly, run five duplexed prints from each tray. The skewed image appears only on duplexed prints. Y N The skewed image occurs on prints fed from all trays. Y N The skewed image occurs on prints fed from the MBF Tray. Y N The skewed image occurs on prints fed from Tray 1. Y N The skewed image occurs on prints fed from Tray 2. Y N • Check the Tray 3 Feed Rolls. Clean or replace if necessary. • Check the Tray 3 Retard Roll. Clean or replace if necessary. • Check the Nudger Roll. Clean or replace if necessary. • Check the Tray 3 Transport Rolls. Check for obstructions or con- tamination. Clean as necessary. • Check the feed chute between Tray 3 and Tray 2. Check for obstructions or contamination. Clean as necessary. A B C D E

Image Quality Repair Analysis Procedures Initial Issue • Check the Tray 2 Feed Rolls. Clean or replace if necessary. • Check the Tray 2 Retard Pad/Retard Roll. Clean or replace if neces- sary. • Check the Tray 2 Nudger Roll. Clean or replace if necessary. • Check the Tray 2 Transport Rolls. Check for obstructions or contami- nation. Clean as necessary. • Check the feed chute between Tray 2 and Tray 1. Check for obstruc- tions or contamination. Clean as necessary. • Check the Tray 1 Feed Rolls. Clean or replace if necessary. • Check the Tray 1 Nudger Roll. Clean or replace if necessary. • Check the Tray 1 Retard Roll. Clean or replace if necessary. • Check the feed chute between Tray 1 and the Registration Rolls. Check for obstructions or contamination. Clean as necessary. • Check the MBF Feed Rolls. Clean or replace if necessary. • Check the MBF Retard Pad. Clean or replace if necessary. • Check the MBF Guide. Check for obstructions or contamination. Clean or replace as necessary. • Check the Registration Sensor. Check actuation and for obstructions or con- tamination. Clean or replace as necessary. • Check the Registration Sensor. Check actuation and for obstructions or contamina- tion. Clean or replace as necessary. • Check the Registration Rolls. Clean or replace if necessary. • Check the BTR Roll and bearings. Clean or replace if necessary. • Check the Print Cartridge. Replace if necessary. • Check the Chute Transport Assembly. Check for obstructions or contamination. Clean or replace as necessary. • Check the Fuser Assembly. Check for worn parts or rolls. Check for obstructions or con- tamination. Clean or replace as necessary. • Check all rolls and drives in the Exit Assembly. Check for obstructions or contamination. Clean or replace as necessary. • Check the Duplex assembly. Check for worn parts or rolls. Check for obstructions or con- tamination. Clean or replace as necessary. • Check the chute between the Duplex Assembly and the Registration Rolls. Check for worn parts or rolls. Check for obstructions or contamination. Clean or replace as neces- sary. IQ RAP 14 Damaged Print The printed page comes out of the printer either wrinkled, creased, or torn (Figure 1). Figure 1 Damaged Print Initial Actions • Check that the paper supply is dry and fresh. • Check that rollers and other components in the paper path are clean and unobstructed. • Ensure that paper is within specification. Procedure Observe paper feed as you run a test print. The paper fed crooked. Y N Replace paper with fresh, dry standard paper. Run a Test Print. The paper is still dam- aged. Y N Problem solved. Open the Rear Cover. Remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open the fuser jam access cover. Rotate the fuser idler gear manually and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. Y N Clean or replace the Fuser Assembly (REP 6.2). Inspect the paper path between the feed tray and the exit tray for contamination or obstructions. The paper path is free of obstructions. Y N Remove obstructions or contamination from the paper path. Inspect all of the rolls along the paper path, between the feed tray and the exit tray, for contamination, wear or damage. The paper path rolls are free of contamination, wear, or damage. A B C D E A manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Y N Replace the damaged or worn roll. Install a new Print Cartridge. Run a Test Print. The print is still damaged. Y N Problem Solved. Replace the following, in order, until the defective component is found: Fuser Assembly (REP 6.2), Chute Transport Assembly (REP 6.1), BTR Assembly (REP 7.1), MBF Feed Roll Assembly (REP 4.2), Retard Pad Assembly (REP 4.7), Turn Roll Assembly (REP 11.8), Paper Feed Rolls (REP 11.11), Tray Assembly /REP 4.4). Go to IQ RAP 13. IQ RAP 15 Registration The image is not positioned correctly on the paper. It may be off in either the process direction or in the scan direction (Figure 1). Figure 1 Registration Initial Actions • Check to ensure that the paper is within specification. • Check that the paper supply is dry and fresh and loaded correctly. • Check that the Paper Tray guides are set correctly. • Check that rollers and other components in the paper path are clean and unobstructed. Procedure Run a test print. The Test Print output image is properly registered. Y N Perform the registration check (ADJ 1.1). The printer registration is set correctly. Y N Perform the registration procedure (ADJ 1.1). If misregistration occurs in the process direction, replace in sequence as necessary: Rub- ber Registration Rolls (REP 5.6), Registration Clutch (REP 5.5), Main Drive Gear Assem- bly (REP 8.2), Main Motor Assembly (REP 8.1), Registration Sensor (REP 5.4), Print Engine Controller PWB (REP 9.3), or System Controller PWB (REP 9.2). If misregistration occurs across the process direction, replace in sequence as necessary: Laser (REP 7.4), System Controller PWB (REP 9.2). Have the customer send another print job. The print image is properly registered. Y N Have the customer contact the Xerox Customer Support. Problem Solved. A

Image Quality Repair Analysis Procedures Initial Issue IQ RAP 16 Skips / Smears A disturbance of the image which lengthens or shortens the image in the process direction. A darkening across the process direction or a repeat of the image in the process direction (Figure 1). Figure 1 Skips / Smears Initial Actions • Check that the paper supply is dry and fresh. • Check to ensure that the paper is within specification. • Check the paper path for any obstructions or debris. Procedure Run a test print. The image has skips or smears. Y N Problem Solved. Check, clean, or replace as necessary in the following sequence: • Transport Chute Assembly (REP 6.1). • The Main Drive Gear components (REP 8.2). • The Fuser Assembly (REP 6.2). The defect still occurs. Y N Problem Solved. Replace the Print Cartridge (PL 8.1). IQ RAP 17 Unfused Image The printed image is not fully fused to the paper. The image rubs off easily (Figure 1). Figure 1 Unfused Image Initial Actions • Check to ensure that the paper is within specification. Procedure Replace the paper with fresh, dry paper from an unopened ream. Run a test print. The prob- lem is still present. Y N Problem solved. Refer to Nonvolatile Memory Setup Mode and check the Fuser setting. The NV code is set to the factory default value. Y N Set NV code to the factory default value. Run 25 test prints. The problem is still present. Y N Problem Solved. Increase the fuser temperature by one increment. The overall print density is within specification. Y N Go to IQ RAP 1 Open the Rear Cover. Remove the Fuser Assembly. Rotate the fuser idler gear manually and inspect the Heat Roll. Open the fuser jam access cover. Rotate the fuser idler gear manually and inspect the Pressure Roll. The Heat Roll and the Pressure Roll are free of scratches and contamination. manuals4you.com manuals4you.com

Initial Issue Image Quality Repair Analysis Procedures Y N Clean or replace the Fuser Assembly (REP 6.2). Open the fuser jam access cover. Rotate the fuser idler gear manually and inspect the contact between the Heat Roll and the Pressure Roll along the rotation. The Heat Roll and the Pres- sure Roll are contacting each other uniformly. Y N Replace the Fuser Assembly (REP 6.2). Replace the following, in order, until the defective component is found: Fuser Assembly (REP 6.2), Print Engine Controller PWB (REP 9.3), LVPS PWB (REP 9.5). IQ RAP 18 Resolution The two pixel lines and halftone patches cannot be reproduced clearly on the print. Initial Actions • Ensure that the print density is set to the default value. Procedure Install a new Print Cartridge (PL 8.1). Run the image quality test print. The Test Print output resolution is good. Y N Replace the following, in order, until the defective component is found: Laser Assembly (REP 7.4) then the HVPS PWB (REP 9.6). Problem Solved.

REP 1.1 Left Interface Cover Assembly.......................................................................... 4-5 REP 1.2 Left Cover ......................................................................................................... 4-5 REP 1.3 Option Cover..................................................................................................... 4-6 REP 1.4 Top Cover Assembly......................................................................................... 4-6 REP 1.5 Right Cover....................................................................................................... 4-7 REP 1.6 Front Cover Assembly ...................................................................................... 4-8 REP 1.7 Left Front Cover................................................................................................ 4-8 REP 1.8 Rear Cover Assembly....................................................................................... 4-9 REP 1.9 Rear Face Up Cover Assembly ........................................................................ 4-10 REP 1.10 Interlock Cover................................................................................................ 4-10 REP 1.11 Left Plate Assembly ........................................................................................ 4-11 REP 1.12 Plate Handle ................................................................................................... 4-11 Tray 1 REP 2.1 Retard Roll Assembly ....................................................................................... 4-13 REP 2.2 Friction Clutch Assembly .................................................................................. 4-14 REP 2.3 Retard Spring.................................................................................................... 4-15 REP 2.4 Motor Assembly ................................................................................................ 4-16 REP 2.5 Connector and Socket Guide............................................................................ 4-17 Paper Feed (Tray 1) REP 3.1 Paper Feeder.................................................................................................... 4-19 REP 3.2 Turn Roll Assembly........................................................................................... 4-19 REP 3.3 Tray 1 No Paper Actuator ................................................................................. 4-20 REP 3.4 Stack Height Sensor ......................................................................................... 4-21 REP 3.5 Low Paper Sensor ............................................................................................ 4-21 REP 3.6 Feed Clutch Assembly...................................................................................... 4-22 REP 3.7 Feeder Assembly.............................................................................................. 4-23 REP 3.8 Paper Feed Rolls .............................................................................................. 4-24 REP 3.9 Feeder PWB ..................................................................................................... 4-24 REP 3.10 Feeder Socket................................................................................................. 4-25 REP 3.11 Size Sensor Housing ...................................................................................... 4-26 REP 3.12 Size Sensor Actuators .................................................................................... 4-27 REP 3.13 Tray 1 Size PWB............................................................................................. 4-28 REP 3.14 Size Harness Assembly.................................................................................. 4-28 Paper Feed (MBF) REP 4.1 MBF Chute Assembly ....................................................................................... 4-29 REP 4.2 MBF Feed Roll Assembly ................................................................................. 4-29 REP 4.3 MBF Feed Roll.................................................................................................. 4-30 REP 4.4 Tray Bottom Assembly...................................................................................... 4-31 REP 4.5 MBF No Paper Actuator.................................................................................... 4-32 REP 4.6 Tray Pick Up ..................................................................................................... 4-32 REP 4.7 Retard Pad Assembly ....................................................................................... 4-33 REP 4.8 MBF No Paper Sensor...................................................................................... 4-33 REP 4.9 Pick Up Solenoid............................................................................................... 4-34 REP 4.10 Envelope Connector Assembly....................................................................... 4-35 Paper Transportation REP 5.1 Paper Handler Assembly .................................................................................. 4-37 REP 5.2 Toner Sensor .................................................................................................... 4-38 REP 5.3 Registration Actuator ........................................................................................ 4-39 REP 5.4 Registration Sensor .......................................................................................... 4-40 REP 5.5 Registration Clutch............................................................................................ 4-40 REP 5.6 Rubber Registration Roll................................................................................... 4-41 Exit Assembly and Fuser REP 6.1 Transport Chute Assembly ............................................................................... 4-43 REP 6.2 Fuser Assembly ................................................................................................ 4-43 REP 6.3 Fuser Harness Assembly.................................................................................. 4-44 REP 6.4 Exit Chute Assembly......................................................................................... 4-45 REP 6.5 Exit Motor Assembly ......................................................................................... 4-46 REP 6.6 Stack Full Sensor.............................................................................................. 4-46 REP 6.7 Mid 1 & Mid 2 Roll Assemblies ......................................................................... 4-47 REP 6.8 Stack Full Actuator............................................................................................ 4-49 REP 6.9 Fuser Upper Cover Assembly/ Heat Rod.......................................................... 4-50 Xerographics REP 7.1 BTR Assembly .................................................................................................. 4-51 REP 7.2 Print Cartridge Top Guide Assembly ................................................................ 4-51 REP 7.3 Print Cartridge Sensor Assembly...................................................................... 4-52 REP 7.4 Laser Assembly ................................................................................................ 4-53 REP 7.5 Print Cartridge Side Guide................................................................................ 4-53 Main Drive REP 8.1 Main Motor Assembly ....................................................................................... 4-55 REP 8.2 Main Drive Gear Assembly ............................................................................... 4-55 Electrical REP 9.1 Fan Assembly ................................................................................................... 4-57 REP 9.2 System Controller PWB .................................................................................... 4-57 REP 9.3 Print Engine Controller PWB............................................................................. 4-58 REP 9.4 5VDC PWB ....................................................................................................... 4-59 REP 9.5 LVPS PWB........................................................................................................ 4-60 REP 9.6 HVPS PWB....................................................................................................... 4-60 REP 9.7 Connector PWB ................................................................................................ 4-61 REP 9.8 Main Switch....................................................................................................... 4-62 REP 9.9 Front Interlock Switch Assembly....................................................................... 4-63 REP 9.10 Rear Interlock Switch Assembly ..................................................................... 4-63 REP 9.11 Offset Catch Tray Harness Assembly............................................................. 4-64 REP 9.12 Duplex Harness Assembly.............................................................................. 4-64 Offsetting Catch Tray (OCT) REP 10.1 Offset Catch Tray (OCT)................................................................................. 4-67 REP 10.2 Exit Tray Extension......................................................................................... 4-67 REP 10.3 Exit Tray.......................................................................................................... 4-68 manuals4you.com manuals4you.com