DocuPrint C525 a Service Manual 1st Edition

DocuPrint C525 AService Manual 1st Edition

This service manual covers the following modelsFUJI XEROX Co. Ltd. Color Laser PrinterDocuPrint C525 A

Related MaterialsNo other related materials issued other than this service manual.

Confidentiality This service manual is issued intending use by

maintenance service personnel authorized by FUJI XEROX Co. Ltd. Copying, transferring or leasing this manual without prior consent by FUJI XEROX Co. Ltd. is prohibited.

When a page becomes irrelavant (e.g. superceded by a replacement page), destroy the page by burning or shredding it.

Handle with care to avoid loss or damage of the manual.

Revision and Modification InformationWhen design changes or revisions relating to this service manual occur, the overseas technical information or overseas service bulletin may be issued as supplementary information until such changes are accomodated in the updated version of this service manual.

CAUTION Important changes including revisions of spare part numbers and adjustment specifications must immediately be reflected on the respective pages of this service manual upon reception of such information.

Edited by: Fuji Xerox Co., Ltd. CS&S TSC SDEGKSP R&D Business Park Bldg 6A73-2-1, Sakado, Takatsu-ku, Kawasaki-shi, Kanagawa, JAPAN 213-8508TEL 044-812-7637

[XEROX] [The Document Company] are registered trademarks.

PRINTED IN JAPAN

DocuPrint C525 AService Manual 1st Edition Issued: January 2005

Company Name

Department Name

Telephone No.

Full Name Employee No. .

IntroductionGetting to know the Service ManualHow to use the Service ManualTerms and SymbolsAbbreviations

Chapter 1 Service Call Procedure

Chapter 2 Troubleshooting

Chapter 3 Image Quality Troubleshooting

Chapter 4 Disassembly/Assembly and Adjustment

Chapter 5 Parts List

Chapter 6 General

Chapter 7 Wiring Data

Chapter 8 Accessories

Chapter 9 BSD (Block Schematic Diagram) Not yet issued

Chapter 10 Machine Overview

Preface

PrefaceTable of ContentsTable of Contents1 Getting to know the Service Manual .............................................................. Preface-22 How to use the Service Manual ..................................................................... Preface-2

2.1 Contents of Manual ......................................................................................................Preface-22.2 Information on Updating ...............................................................................................Preface-3

3 Terms and Symbols ....................................................................................... Preface-44 Abbreviations ................................................................................................. Preface-5Preface-1

Introduction1. Getting to know the Service Manual1. Getting to know the Service ManualThis manual is used as the standard service manual for the DocuPrint C525 A.

Publication Comment SheetEnter any comments and/or corrections regarding the DocuPrint C525 A service manual into the Publication Comment Sheet, and send it to FX/CSS/IBS through the OpCo TS or CS department.

2. How to use the Service ManualThis manual describes the standard procedures for the servicing of the DocuPrint C525 A. Refer to Chapter 1 Service Call Procedure for efficient and effective servicing during maintenance calls.

2.1 Contents of Manual Hardware

This manual summarizes all technical information on the DocuPrint C525 A. Chapters

This manual is divided into ten chapters as described below.

Chapter 1 Service Call ProcedureThis chapter describes the general work and servicing procedures for the maintenance of the DocuPrint C525 A.

Chapter 2 TroubleshootingThis chapter describes the troubleshooting procedures other than image quality troubleshooting of the DocuPrint C525 A. It also describes how to use the diagnostics and some programs.

Chapter 3 Image Quality TroubleshootingThis chapter describes the image quality troubleshooting procedures of DocuPrint C525 A.

Chapter 4 Disassembly/Assembly and AdjustmentThis chapter describes the disassembly, assembly, adjustment and replacement procedures for components of the DocuPrint C525 A.

Chapter 5 Parts ListThis chapter contains spare parts list for DocuPrint C525 A.

Chapter 6 GeneralThis chapter contains the following general information on DocuPrint C525 A.6.1 Specifications6.2 Tools and Service Consumables6.3 Consumables6.4 Periodic Replacement Parts6.5 Installing the Printer6.6 Setting the Printer Environment6.7 Software Related Information

Chapter 7 Wiring DataThis chapter describes the wiring data of DocuPrint C525 A.7.1 Connectors [P (Plug)/J (Jack)]7.2 P/J Layout7.3 Connection Charts7.4 Connection Charts Between PartsPreface-2

Introduction2. How to use the Service ManualChapter 8 AccessoriesThis chapter provides information on accessories and options specific to DocuPrint C525 A.8.1 200/500 Sheet Feeder Installation Guide8.2 Duplex Unit Installation Guide

Chapter 9 BSD (Block Schematic Diagram) (Not yet issued)

Chapter 10 Machine OverviewThis chapter gives an overview of the functions of the main components of DocuPrint C525 A.

2.2 Information on UpdatingThis manual will be revised and sent to each customer engineer as specified below. Revisions must be incorporated correctly to keep the manual up-to-date.

Updating Procedure When the entire manual is revised, "1st Edition" on the front cover will be renewed to 1st Edition,

2nd Edition, 3rd Edition and so on. When this manual is partially revised, revisions will be sequentially indicated as Revision A,

Revision B, Revision C, etc. All revised pages will be marked accordingly with "Revision A", "Revision B", "Revision C" and so on.

Revision Sidebar When any paragraph, table or figure has been added or amended, a revision sidebar will be added to indicate where the revision was made.

If the same page is changed again due to a subsequent revision, revision sidebars associated with the previous revision(s) will be deleted.

(Example)Preface-3

Introduction3. Terms and Symbols3. Terms and SymbolsSpecific terms and symbols used in any particular chapter are described in the Preface for thatsection. The terms and symbols described here are used throughout this manual.

The terms and symbols used at the beginning of a text are defined as follows:DANGER Indicates an imminently hazardous situation, such as death or serious

injury if operators do not handle the machine correctly by disregarding the statement.

WARNING Indicates a potentially hazardous situation, such as death or serious injury if operators do not handle the machine correctly by disregarding the statement.

CAUTION Indicates a potentially hazardous situation, such as injury or property damage if operators do not handle the machine correctly by disregarding the statement.

INSTRUCTION Indicates that the printer or its components may be damaged if the instructed procedure is not strictly observed.

NOTE Used to emphasize the procedure, servicing, and regulation.

REFERENCE Used to describe the technical terminology and supplementary explanations.

OBJECTIVE Used to explain purpose of adjustment. REP : Indicates the disassembly/assembly procedure for reference. ADJ : Indicates the adjustment procedure for reference. PL : Indicates the parts list for reference. ASSY : Means Assembly.

Safety Critical Components (SCC)For the safety control of the Safety Critical Components and the components specified, follow the regulations regarding the Safety Critical Components set by Fuji Xerox Co., Ltd.Preface-4

Introduction4. AbbreviationsLED Light-emitting diodeLEF Long Edge FeedLH Left HandLV Low VoltageLVPS Low Voltage Power SupplyM Magenta

TR TransferVIO VioletWHT WhiteXERO XerographicY YellowYEL Yellow4. AbbreviationsAbbreviationsThis manual contains abbreviations that are specific to this manual, as well as general abbreviations, which include:

ADC Automatic Density ControlAG Analog GroundAPS Auto Paper SelectARC Auto Registration ControlASSY AssemblyATS Auto Tray SwitchingB BlackBCR Bias Charge RollBk BlackBLK BlackBLU BlueBRN BrownBTR Bias Transfer RollC CyanCLN CleanerCRU Customer Replaceable UnitCRUM CRU MoniterCTRG CartridgeDET Detoner RollDEVE. DeveloperDIAG. DiagnosticDISP Dispensedpi dots per inchDTS Detack SawDUP DuplexESB Electro Static BrushESS Electric SubsystemF FrontFEED, FDR FeederFIP Fault Isolation ProcedureGND GroundGRN GreenGRY GrayHT Half ToneHUM HumidityHVPS High Voltage Power SupplyICDC Image Count Dispense Control ID Image Density, or IdentificationIBT Intermediate Belt TransferINTL, INLK InterlockIOT Image Output TerminalK BlackL LeftL/H Left HandLD Laser diodeLDD Lightly Doped Drain

MAG Mag. RollMCU Machine Control UnitMOB Marks On BeltMOT MotorMSI Multi Sheet InserterN/P No PaperNVM Non Volatile MemoryOEM Original Equipment

ManufacuringOHP Overhead ProjectOP OperationOPC Organic Photo ConductorORN ORANGEPC Personal ComputerPCDC Pixel Count Dispense ControlPH Paper HandlingPHD Printer HeadPNK PinkPOP Paper On PhotoreceptorPPM Prints Per MinutePR,P/R ProcessPV Print VolumePWB(A) Printed Wiring Boad

(Assembly)R RightR RearR/H Right HandREF RefresherREGI. RegistrationRH Right HandROS Raster Output ScannerROT RotaryRTC Rubber Tube ChargerRTN ReturnSEF Short Edge FeedSG Signal GroundSMH Special Material HandlerSNR SensorSOL. SolenoidSOS Start Of ScanSTM Single Tray ModuleSW SwitchTEMP. TemperatureTM Tray ModuleTNER, TNR TonerTP ThermopilePreface-5

Chapter 1 Service Call Procedure

Chapter 1 Service Call ProcedureTable of ContentsTable of Contents1.1 Before Starting the Servicing ....................................................................................1-2

1.1.1 Safety ..................................................................................................................................... 1-21.1.2 Other Things to Note .............................................................................................................. 1-3

1.2 Servicing Call Procedure ..........................................................................................1-41.3 TRIM Servicing .........................................................................................................1-5

1.3.1 TRIM Servicing Procedure ..................................................................................................... 1-51.3.2 Machine Consumables and Periodic Replacement Parts ...................................................... 1-61.3.3 TRIM Check List ..................................................................................................................... 1-71-1

Chapter 1 Service Call Procedure1.1 Before Starting the Servicing1.1 Before Starting the Servicing

1.1.1 SafetyTo prevent any accident that may occur during maintenance servicing, any WARNING or CAUTION regarding the servicing must be strictly observed. Do not perform any hazardous operation.

1. Power SupplyTo prevent electrical shocks, burns, or injury, etc., be sure to switch OFF the machine and disconnect the plug before starting the maintenance servicing. If the machine has to be switched ON, such as when measuring the voltage, take extra care to prevent an electrical shock.

2. Drive AreaNever inspect or lubricate the drive area such as the gears during the machine operation.

3. Heavy PartsThe weight of the machine is 24.5kg. When moving the machine to ensure sufficient working space, take extra care to prevent back pain.

4. Safety DeviceSee that safety devices for preventing mechanical accidents, such as fuses, circuit breakers, interlock switches, etc., and those for protecting customers from injury, such as panels and covers, function properly. Modifications that hinder the function of any safety devices are strictly prohibited.

5. Installing and removing the partsThe edge of parts and covers may be sharp, take care not to touch them. If the oil gets onto your hand, wipe it off before getting on with the servicing. When removing parts or cables, do not pull them out by force but remove them slowly.

6. Specified ToolsFollow the instruction when a tool is specified.

7. Organic SolventsWhen using an organic solvent such as the Drum Cleaner or Machine Cleaner, pay attention to the following: Ensure good ventilation in the room to prevent too much intake of the solvent. Do not use heated solvent. Keep away from fire.

8. Cleaning the Toner and DeveloperAs the toner may cause a dust explosion, sweep the spilt toner into a waste container. When using a cleaner to clean the remaining toner, be sure to use the FX standard toner-proof cleaner and not a customer's cleaner. Also, as the developer also contains toner, exercise the same caution during cleaning.

9. ModificationsIf any modifications are deemed necessary for the printer, submit an Application for Approval ofModification prior to performing any work.

10.Other Safety PrecautionsFor safety, you should also pay attention to precautions other than the above 1 to 9 items. Follow the SAFE WORKING PRACTICES FOR ENGINEERS issued by FXAP EH and S (Environmental Health and Safety) to ensure greater safety during servicing,1-2

Chapter 1 Service Call Procedure1.1 Before Starting the Servicing1.1.2 Other Things to NotePay attention to the following when performing maintenance service to avoid wrong or redundant servicing:

1. Reference MaterialsBefore performing maintenance servicing, read all relevant technical materials such as SB, FTI, or FTO for a systematic approach.

2. DisassemblingMake sure to check the assembled condition before removing parts or disassembling the machine.

3. Installation/AdjustmentAfter the installation or adjustment is complete, check that no parts or tools are left inside or on the assemblies before using the machine.

4. Handling of parts/consumables replacedMake sure that the replaced parts or consumables as well as the packaging materials are collected back to the Service Center.

NOTE For the separation and processing methods for the collected items, refer to the Common Technical Information No. 2-138 for all machines.

If you have replaced the following consumables, affix the "U" sticker for the recyclable parts to behandled appropriately. Drum Cartridge Individual Color Toner CartridgeFor recyclable parts, fill the necessary items in the "U-TAG" and perform collection.

5. General precautions Take care not to disturb the customer's daily work. Place the drip cloth or paper on the customer's floor during work in the machine because

color toners may dirty the floor and are difficult to clean. Throw any trash generated during the maintenance service into the trash bag and bring them

to the servicing office. Record the service details and the consumables and parts replaced at visit in the Machine

Service Log.

DocuPrint C525 A weighs 24.5kg.Always have 2 or more people available to move the printer.Refer to the Installation Procedures for details.1-3

Chapter 1 Service Call Procedure1.2 Servicing Call Procedure1.2 Servicing Call Procedure

Initial Actions

1. Ask the operator(s) about the machine condition.2. Record the billing meter readings.3. Inspect any printing error, then check the machine.4. Check the Service Log.

UM Call

1. Troubleshoot on Level 1.2. Troubleshoot.3. Check the print quality using the test patterns on the machine.4. Feed paper from the respective trays and, if necessary, clean or replace the

Feed Roll.5. Repair all the secondary problems.6. Perform TRIM servicing.

SM Call

1. Check the print quality using the test patterns on the machine.2. Feed paper from the respective trays and, if necessary, clean or replace the

Feed Roll. 3. Repair all the secondary problems.4. Perform TRIM servicing.

Final Actions

1. Check overall operation/features.2. Check the machine exterior and consumables.3. Train the operator as required.4. Complete the Service Log and Service Report.5. Keep the print sample with the Service Log.1-4

Chapter 1 Service Call Procedure1.3 TRIM Servicing1.3 TRIM ServicingTRIM Servicing for DocuPrint C525 A is performed in all SM/UM to maintain the performance of the machine. Independent visits for TRIM Servicing does not take place.

1.3.1 TRIM Servicing Procedure1. Check overall operation before servicing

Make prints with a test pattern containing 20% color pattern for each color, gradation pattern and grid pattern.

1. 20% color pattern for each color: Checks for any scratches on the IBT Belt and Drum, and for fusing failure.

2. Gradation pattern : Checks for improper low-density reproducibility, color balance and fusing failure.

3. Grid pattern : Checks for color misalignment and fusing failure.

* Refer to Chapter 3 Image Quality Troubleshooting 3.4 Test Print on how to print test patterns.

2. Clean the interior of the machine Clean toner residues and paper powder etc. in the paper delivery system.

(Clean especially the operation section of the operator.)

3. Inspect parts that require periodic replacement (consumables) and replace them if necessary.

4. Safety Precautions Check the connection of the power plug and any damage on the cord and the plug.

5. Check the overall operation after servicing as follows: Check machine operation. Check the print quality. Check the billing meter reading.1-5

Chapter 1 Service Call Procedure1.3 TRIM Servicing1.3.2 Machine Consumables and Periodic Replacement Parts Check the total number of copies printed during TRIM Servicing before replacing the machine consumables.

Machine Consumables

* Use Conditions(*1) Color/BW Ratio = 2:1, Print Ratio = 5%(*2) Color/BW Ratio = 2:1, Print Ratio = 5%, Quantity printed at one time = 2 pages on average

Periodic Replacement Parts

* Use Conditions(*1) Color/BW Ratio = 2:1, Print Ratio = 5%, Quantity printed at one time = 2 pages on average(*2) Replace the Fuser Unit and the 2nd BTR Assy at the same time (whichever needs to be

replaced earlier)(*3) Replace Deve Assy K independently(*4) Replace Deve Assy Y, M and C at the same time (replace when whichever's life has expired)

Consumables Product Code LifeBlack Toner Cartridge CT200649 4KPV (*1)Cyan Toner Cartridge CT200650 4KPV (*1)Magenta Toner Cartridge CT200651 4KPV (*1)Yellow Toner Cartridge CT200652 4KPV (*1)Drum Cartridge CT350380 14KPV (*2)

Consumables Life (Life Warning Interval) RemarksFuser Unit 100KPV (99KPV)Deve Assy K 100KPV (99KPV)Deve Assy Y 67KPV (66KPV)Deve Assy M 67KPV (66KPV)Deve Assy C 67KPV (66KPV)2nd BTR Assy 100KPV (99KPV)1-6

Service Call Procedure1.3 TRIM Servicing

1-7

1.3.3 TRIM Check ListA --- Perform checking. Clean, replace, or supply if necessary.B --- Always perform cleaning and checking.C --- Always perform replacement service at the specified interval.* Refer to pages 3-5 on how to print test patterns.

CAUTION Do not touch the Drum, IBT Belt and 2nd BTR inside the Drum Cartridge directly with your hands.Do not use solvents such as Drum cleaner. (Time is required for recovery.)

No. Servicing Items Every time 100KDisassembly/Adjustment No. Service Details

1.1 Pre-servicing check (check the sound of the machine in operation) A Activate the machine and check that abnormal noise is not heard.

1.2 Pre-servicing check (print test patterns) A Print built-in test patterns and check the print quality. (Check the 20% color pattern for each color for density unevenness and image deletion. Check the Drum/IBT belt for damage, and the patterns for gradation recurrence and low density recurrence.)

2 Clean the interior of the machine (paper delivery system) Retard Roll A C Clean the paper dust and toner residue in the paper path and on the jam sensor. Clean especially the operation section of the operator. Check and clean the feed roll of the MSI.

3.1 Fuser Unit B C REP9.1 Check the H.Roll and P.Roll for scratches. Replace them if necessary.

3.2 2nd BTR Assy A C REP9.2 Check visually. Do not make direct contact.

4 Safety Precautions B

Make sure that the power plug is plugged in properly. Make sure that the power cords are not cracked and no wires are exposed. Make sure that no extension cord with insufficient capacity or power cord outside the specification for off-the-shelf power strips

is used. Make sure that no multiple power plugs are added to a single socket.

5.1 Post-servicing check (print quality) A Print built-in test patterns to confirm that the print quality satisfies the specification.

5.2 Post-servicing check (machine in operation) A Check the paper feed and check for abnormal noise.

5.3 Post-servicing check (meter) A Create the Service Log and Service Report.

Chapter 2 Troubleshooting

Chapter 2 TroubleshootingTable of ContentsTable of Contents2.1 Preface......................................................................................................................2-4

2.1.1 Fault repair flow ...................................................................................................................... 2-42.1.2 Installation check .................................................................................................................... 2-52.1.3 Things to take note when servicing ........................................................................................ 2-62.1.4 Things to take note when using FIP ....................................................................................... 2-72.1.5 Warm Up Operation Flow Chart at Power ON........................................................................ 2-9

2.2 Level 1 Troubleshooting..........................................................................................2-102.2.1 Level 1 FIP ........................................................................................................................... 2-102.2.2 FIP Flow ............................................................................................................................... 2-10

2.3 Level 2 Troubleshooting..........................................................................................2-112.3.1 Error/Status Code List (Paper Jam) ..................................................................................... 2-112.3.2 Error/Status Code List (Except Paper Jam) ......................................................................... 2-142.3.3 Error Code FIP ..................................................................................................................... 2-21FIP-1. 1 Y Toner Detached ............................................................................................................. 2-21FIP-1. 2 M Toner Detached ............................................................................................................ 2-22FIP-1. 3 C Toner Detached ............................................................................................................. 2-23FIP-1. 4 K Toner Detached ............................................................................................................. 2-24FIP-1. 5 XERO CRU Detached ....................................................................................................... 2-25FIP-1. 6 XERO Communication Error ............................................................................................. 2-26FIP-1. 7 XERO Verify Error ............................................................................................................. 2-28FIP-1. 8 XERO Imitation Error ........................................................................................................ 2-29FIP-1. 9 XERO ID Error .................................................................................................................. 2-30FIP-1. 10 Y Toner Communication Error ........................................................................................ 2-31FIP-1. 11 Y Toner Verify Error ........................................................................................................ 2-33FIP-1. 12 Y Toner Imitation Error .................................................................................................... 2-34FIP-1. 13 Y Toner ID Error .............................................................................................................. 2-35FIP-1. 14 M Toner Communication Error ........................................................................................ 2-36FIP-1. 15 M Toner Verify Error ........................................................................................................ 2-38FIP-1. 16 M Toner Imitation Error ................................................................................................... 2-39FIP-1. 17 M Toner ID Error ............................................................................................................. 2-40FIP-1. 18 C Toner Communication Error ........................................................................................ 2-41FIP-1. 19 C Toner Verify Error ........................................................................................................ 2-43FIP-1. 20 C Toner Imitation Error .................................................................................................... 2-45FIP-1. 21 C Toner ID Error .............................................................................................................. 2-46FIP-1. 22 K Toner Communication Error ........................................................................................ 2-47FIP-1. 23 K Toner Verify Error ........................................................................................................ 2-49FIP-1. 24 K Toner Imitation Error .................................................................................................... 2-50FIP-1. 25 K Toner ID Error .............................................................................................................. 2-51FIP-1. 26 Tray1 PSNR1 On Jam .................................................................................................... 2-52FIP-1. 27 MSI Regi On Jam ............................................................................................................ 2-56FIP-1. 28 Tray Regi On Jam ........................................................................................................... 2-59FIP-1. 29 Regi Off Jam ................................................................................................................... 2-62FIP-1. 30 Exit On Jam ..................................................................................................................... 2-65FIP-1. 31 BTR 2 Jam ...................................................................................................................... 2-70FIP-1. 32 OHP (lead) Jam .............................................................................................................. 2-75FIP-1. 34 Fuser In On Jam ............................................................................................................. 2-77FIP-1. 35 Exit Off Jam ..................................................................................................................... 2-81FIP-1. 36 Duplex Regi On Jam ....................................................................................................... 2-84FIP-1. 37 Duplex Out On Jam ......................................................................................................... 2-88FIP-1. 38 Duplex In On Jam ........................................................................................................... 2-90FIP-1. 39 Static Jam ....................................................................................................................... 2-93FIP-1. 40 Communication Error Feeder .......................................................................................... 2-94FIP-1. 41 Communication Error Duplex .......................................................................................... 2-96FIP-1. 42 PAGE Timeout ................................................................................................................ 2-972-1

Chapter 2 TroubleshootingTable of ContentsFIP-1. 43 NVRAM Error .................................................................................................................. 2-98FIP-1. 44 TR0 Failure ..................................................................................................................... 2-99FIP-1. 45 ROS Motor Failure ........................................................................................................ 2-101FIP-1. 46 Deve Home Position Sensor Error ................................................................................ 2-102FIP-1. 47 ADC Contamination ...................................................................................................... 2-103FIP-1. 48 High Density .................................................................................................................. 2-104FIP-1. 49 Low Density ................................................................................................................... 2-106FIP-1. 51 High Coverage .............................................................................................................. 2-108FIP-1. 52 BTR 2 Error ................................................................................................................... 2-109FIP-1. 53 BTR 2 Advance Error .................................................................................................... 2-111FIP-1. 54 Fuser Fail ...................................................................................................................... 2-113FIP-1. 55 Temp Sensor Error ........................................................................................................ 2-115FIP-1. 58 Humidity Sensor Error ................................................................................................... 2-116FIP-1. 59 Feed Motor Failure ........................................................................................................ 2-117FIP-1. 60 Duplex Motor Failure ..................................................................................................... 2-119FIP-1. 61 IBT CLN Fail .................................................................................................................. 2-122FIP-1. 62 Y Toner Life Over .......................................................................................................... 2-124FIP-1. 63 M Toner Life Over ......................................................................................................... 2-125FIP-1. 64 C Toner Life Over .......................................................................................................... 2-126FIP-1. 65 K Toner Life Over .......................................................................................................... 2-127FIP-1. 66 Waste Toner Bottle Life Over ........................................................................................ 2-128FIP-1. 68 Regi Cover Open (P/H Cover Open) ............................................................................. 2-129FIP-1. 69 2nd BTR Cover Open .................................................................................................... 2-130FIP-1. 70 Exit Cover Open ............................................................................................................ 2-131FIP-1. 71 Tray 1 Cover Open ........................................................................................................ 2-132FIP-1. 72 Duplex Cover Open ....................................................................................................... 2-134FIP-1. 73 Duplex Tray Open ......................................................................................................... 2-136FIP-1. 74 Front Cover Open ......................................................................................................... 2-137FIP-1. 75 Y Toner Life Warning .................................................................................................... 2-139FIP-1. 76 M Toner Life Warning .................................................................................................... 2-140FIP-1. 77 C Toner Life Warning .................................................................................................... 2-141FIP-1. 78 K Toner Life Warning .................................................................................................... 2-142FIP-1. 79 Toner Bottle Life Warning ............................................................................................. 2-143FIP-1. 80 Xero CRU Life Warning / Xero CRU Life2 .................................................................... 2-144FIP-1. 81 Electrical Noise ............................................................................................................. 2-145FIP-1. 82 ESS-Related Error ........................................................................................................ 2-1462.3.4 Abnormal Noise .................................................................................................................. 2-147

2.3.4.1 Abnormal Noise Troubleshooting Entry Chart .......................................................... 2-1472.3.5 Operation Table in Each Mode........................................................................................... 2-148FIP-1.N1 During Power ON .......................................................................................................... 2-148FIP-1.N2 During STANDBY .......................................................................................................... 2-149FIP-1.N3 During Printing (1 Sided) ............................................................................................... 2-150FIP-1.N4 During Printing (2 Sided) ............................................................................................... 2-152FIP-1.N5 During STANDBY .......................................................................................................... 2-155

2.4 How to use the Diag. (CE) Mode ..........................................................................2-1562.4.1 Explanation......................................................................................................................... 2-1562.4.2 Menu tree ........................................................................................................................... 2-1572.4.3 Function Items in CE Mode ................................................................................................ 2-1722.4.4 ESS Diag Details ................................................................................................................ 2-174

2.4.4.1 CodeROM Test ........................................................................................................ 2-1742.4.4.2 EEPROM Test .......................................................................................................... 2-1742.4.4.3 DRAM Test ............................................................................................................... 2-1742.4.4.4 CENTRONICS Test .................................................................................................. 2-1742.4.4.5 MAC+PHY Test ........................................................................................................ 2-1752.4.4.6 HAYATE Test ........................................................................................................... 2-1752.4.4.7 IOT Test ................................................................................................................... 2-1752.4.4.8 PANEL Test .............................................................................................................. 2-1762-2

Chapter 2 TroubleshootingTable of Contents2.4.4.9 All Test ..................................................................................................................... 2-1762.4.5 Other Diag./Settings ........................................................................................................... 2-177

2.4.5.1 Digital Input (DI) Test ............................................................................................... 2-1772.4.5.2 Digital Input Test Parameter Table ........................................................................... 2-1772.4.5.3 Digital Output (DO) Test ........................................................................................... 2-1782.4.5.4 Digital Output Test Parameter Table ........................................................................ 2-1782.4.5.5 NVM Access ............................................................................................................. 2-1802.4.5.6 Parameter Settings ................................................................................................... 2-1812.4.5.7 Installation Settings .................................................................................................. 2-181

2.4.6 Test Print ............................................................................................................................ 2-1822.4.6.1 Grid ........................................................................................................................... 2-1822.4.6.2 Grid 2 ........................................................................................................................ 2-1822.4.6.3 Density 20% Pattern ................................................................................................. 2-1822.4.6.4 Gradation Pattern ..................................................................................................... 2-182

2.5 Diag. by the Unit Alone .........................................................................................2-1832.5.1 Overview............................................................................................................................. 2-1832.5.2 Print Method ....................................................................................................................... 2-1832.5.3 Test Print Pattern................................................................................................................ 2-184

2.6 NVM List ...............................................................................................................2-1852-3

Chapter 2 Troubleshooting2.1 PrefaceNOTE This manual describes Fuji Xerox standard specifications and printer controllers in normal status.

2.1 PrefacePerform pre-check and verify the phenomenon, then use the FIP (Fault Isolation Procedure), "Diag. Operation", "Wiring Connection Charts", and "Operation Principles" to perform troubleshooting effectively.

2.1.1 Fault repair flowFaults are repaired in the following flow:

Check status and phenomenon

Perform pre-check

Start fault repair

Perform FIP

End

Check fault repair

Perform preventive maintenance

Chapter 7 Wiring DataChapter 10 Machine Overview

*Clean the Feed Roll. Check for any other problems.2-4

Chapter 2 Troubleshooting2.1 Preface2.1.2 Installation checkBefore troubleshooting, always check the following items.

1) The power supply voltage is within the specifications.

2) Check the power cord for damage, short-circuit, poor contact and improper connection.

3) The machine is properly grounded.

4) Avoid installing the machine at a place with high temperature, high humidity, low temperature, low humidity, or a place where the temperature will change drastically.

5) Avoid installing the machine near a water outlet, humidifier, heater or fire, dusty areas, or under the direct draft of an air-conditioner.

6) Avoid installing the machine in a place where volatile or flammable gas is generated.

7) Avoid installing the machine in a place exposed to direct sunlight.

8) Install the machine in a well-ventilated place.

9) Install the machine on a stable level surface.

10)Paper used must be within the specifications. (Standard paper is recommended.)

11)The machine must be properly handled.

12)The periodic replacement parts are replaced for every replacement sheet count.2-5

Chapter 2 Troubleshooting2.1 Preface2.1.3 Things to take note when servicing1) When servicing, always remove the power cord unless required otherwise.

WARNING When the power is turned ON, never touch a current-carrying part unless necessary.Also, as current is carried in the LVPS power switch/inlet even when the power is turned OFF, never touch the current-carrying part.

2) When the Interlock switch or security switch is turned ON with the covers removed and checking is carried out with the power turned ON, always remove the connector (P/J601) on the ROS ASSY.WARNING When the Interlock switch or security switch is turned ON with the

covers removed and checking is carried out with the power turned ON, always remove the connector (P/J601) on the ROS ASSY because laser light may be emitted from the ROS ASSY.

3) When the Interlock switch or security switch is turned ON with the covers removed and checking is carried out with the power turned ON, be careful of high voltage from the HVPS.WARNING When the Interlock switch or security switch is turned ON with the

covers removed and checking is carried out with the power turned ON, never touch the HVPS and high-voltage output parts because high voltage may be output from the HVPS.

4) Be careful not to burn yourself when touching a hot part.

5) When servicing, perform earthing for the service personnel with wrist bands etc. to remove static electricity from the body.2-6

Chapter 2 Troubleshooting2.1 Preface2.1.4 Things to take note when using FIP1) In the FIP, the printer controller (PWBA ESS) is assumed to be functioning properly.

Therefore, when a fault persists after troubleshooting, check by replacing with a functioning printer controller.If the fault persists, check by replacing in order the "Main Check Parts" and related parts in "Initial Check".

2) Before troubleshooting using the FIP, prepare functioning MCU, LV/HVPS, FUSER ASSY, and 2ND BTR ASSY, etc. as they may be needed to identify failures/faults.

3) During "Initial Check" in the FIP, do the checking at the level that can be easily carried out.

4) For "Initial Check" in the FIP, besides the "Main Check Parts", check also the parts that configure the main check parts as well as other related parts.

5) When servicing, always remove the power cord unless required otherwise.When the power cord is connected, never touch a current-carrying part unless necessary.

6) Descriptions related to connectors are expressed as follows:"P/J12" -> The connector (P/J12) is connected"P12" -> The plug side when the connector (P/J12) is disconnected (except when the connector is directly connected to the board)"J12" -> The jack side when the connector (P/J12) is disconnected (except when the connector is directly connected to the board)

7) In the FIP, "P/J1-2PIN P/J3-4PIN" means that the plus side of the instrument should be connected to "2PIN" of "P/J1" and the minus side to "4PIN" of "P/J3".

8) In the FIP, "P/J1P/J2" means that all the relevant pins between the "P/J1" and "P/J2" should be measured.

9) For voltage measurement in the FIP, "P/J1-2PIN P/J3-4PIN" means that the "P/J3-4PIN" at the rear and minus side is always AG [Analog Ground], SG [Signal Ground], or RTN [Return].Therefore, it is possible to connect the rear and minus side to another "AG", "SG", or "RTN" pin instead of "P/J3-4PIN" if the "AG", "SG", and "RTN" of both pins are conducting each other properly.However, care must be taken not to mess up "AG", "SG", and "RTN" because they are not at the same level.

10) A special tool must be used to measure the voltage of a small connector. Be careful when handling the tool as the edge of the tool is sharp.

11) When measuring a voltage, install the IBT ASSY, 2ND BTR ASSY and paper cassette and close the covers before turning ON the power to measure.

12) The numerical values described in the FIP are for reference only. Approximate values are considered to be the same.

13) Note that the parts that must be removed for checking specified in the FIP and their procedures are not described in the document.

14) "Replacement" in the FIP shows the parts that are considered to be the cause of the problem. Check by replacing the parts and the assembly parts (HIGH ASSY) that contains those parts.2-7

Chapter 2 Troubleshooting2.1 Preface15) In the FIP, the first feeding part using the paper cassette placed at the bottom of the machine is called "Tray 1" and the second part is called "Tray 2".

16) In the FIP, some procedures are separately described for each specification. Follow the instructions for your model to repair the faults.2-8

Chapter 2 Troubleshooting2.1 Preface2.1.5 Warm Up Operation Flow Chart at Power ONThe following shows the printer warm up operation flow (overview) from Power ON to Ready to Print.

Yes

Yes

No

No

No

Yes

No

Yes

Power ON

Ready (to print)

Fuser Warming Up(time-out in 45 sec)

Heater is red and hot.

Is Fuser Temp at power on lowerthan Fuser Temp Threshold?

Is there a certain difference or morebetween Environment SNR detected value at previous

print and the one at current print?

Are Cleaning and FuserWarming Up complete?

*1 : Rotary rotates 360 degrees+some at Home Position Correction; 720 at Procon Sequence.

*2 :ADC TC Correction corrects TC Target, based on Deve Housing driving time.

*3 :Procon Sequence performs ADC Patch creation and reading to adjust toner/image density.

If the ID Errors occur,go to: XERO: FIP 1.9 Y Toner: FIP 1.13 M Toner: FIP 1.17 C Toner: FIP 1.21 K Toner: FIP 1.25

If Fuser Fail occurs,go to FIP 1.54.

If Deve Home PositionSensor Error occurs,go to FIP 1.46.

Leg_Sec001_031FA

Are errors displayed? Resolve each error. (See Error/Status Codes List.)

CRUM Check & ADC TCTarget Value Correction (*2)

(16 sec)

Rotary Operation Check& Home Position Correction

(8 sec)

MOT ASSY ROT operates.(*1)

IBT Brush Motor operates.

BTR/IBT Cleaning(11 sec)

IBT Brush Motor operates.

Procon Sequence (*3)(30 sec or more)

MOT ASSY ROT operates. (*1)

If Deve Home PositionSensor Error occurs,go to FIP 1.46.

If IBT CLN Fail occurs,go to FIP 1.61.

A total of 37~840 sec(depending on the environment)2-9

Chapter 2 Troubleshooting2.2 Level 1 Troubleshooting2.2 Level 1 Troubleshooting

2.2.1 Level 1 FIPThe FIP is the first step in diagnosing a problem. The FIP helps to proceed with troubleshooting while checking for any error codes and other kinds of problems.

2.2.2 FIP Flow

Ask the operator about the problem.Did the operator operate the machine correctly?

Explain to the operator how to operate the machine correctly.

Is it an image quality problem?

Take note of the Jam code.Refer to the FIP to solve the problem.

Is it a jam problem?

Is an error message (error code) displayed on the Control Panel?

Refer to "Chapter 7 Wiring Data" to perform the appropriate troubleshooting.

Refer to "Chapter 3 Image Quality Troubleshooting" to repair the problem.

Ask the operator about the conditions when the jam occurred and toprint again in the same mode. Does the jam occur again?

Check the status of the customer's problem again and perform the preventive maintenance by referring to "Chapter 7 Wiring Data", Disassembly/Adjustment procedure, or information, etc.

Refer to the FIP to solve the problem.

NY

Y

Y

Y

N

N

N

Y N

Is the version of PWBA ESS and PWBA MCU the latest?

Is there abnormal noise?NY

Refer to "2.3.4 Abnormal Noise" and repair the problem.2-10

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting2.3 Level 2 Troubleshooting

2.3.1 Error/Status Code List (Paper Jam)

LCD Displayand Location of

OccurrenceError Details Error Description

FIP/Corrective

Action

Open Tray 1 & G Clear jam

(1)Tray1 PSNR1 On Jam The SENSOR T/R did not turn ON within the

specified time after SOLENOID FEED - ON. FIP-1 26

Open Cover EClear jam

OrOpen Unit DClear Area E

(2)

MSI Regi On Jam The SENSOR REGI did not turn ON within the specified time after SOLENOID PICK UP - ON. FIP-1 27

Open Cover GClear jam

(3)Tray Regi On Jam The SENSOR REGI did not turn ON within the

specified time after SENSOR T/R - ON. FIP-1 28

Leg_Sec001_020FA2-11

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingOpen Cover EClear jam


(3) (4)

Regi Off Jam The SENSOR REGI did not turn OFF within the specified time after CLUTCH ASSY REGI - ON. FIP-1 29

Open Cover AClear jam

OrOpen Unit D

Clear jam(4) (5)

Exit On JamThe Exit Sensor did not turn ON and the SENSOR FUSER IN was turned OFF within the specified time after CLUTCH ASSY REGI - ON.

FIP-1 30

Open Cover FClear jam

OrOpen Unit DClear Area F

(4) (5)

BTR 2 JamThe Exit Sensor did not turn ON and the SENSOR FUSER IN was turned ON within the specified time after CLUTCH ASSY REGI - ON.

FIP-1 31


OrOpen D and C

Clear jamOr

Load correctpaper in tray

(3)

OHP (lead) JamThe SENSOR OHP did not detect Transparency when Transparency setting is selected, or detected Transparency when Transparency setting is not selected.

FIP-1 32


(4)Fuser In On Jam

The SENSOR FUSER IN did not turn ON within the specified time after CLUTCH ASSY REGI - ON.

FIP-1 34

Open Cover AClear jam(4) (5) (6)

Exit Off Jam The Exit Sensor did not turn OFF within the specified time after SENSOR REGI - ON. FIP-1 35

Open C of D andcheck for paper

OrIf none

Clear Area E(8) (9) (3)

Duplex Regi On JamThe SENSOR REGI did not turn ON within the specified time after DUPLEX Load Signal (MCU).

FIP-1 36

Open D and CClear jam

(8)Duplex Out On Jam

The SENSOR LOW PATH did not turn ON within the specified time after SENSOR UPPER PATH - ON.

FIP-1 37

Open Unit DClear jam

(7)Duplex In On Jam

The SENSOR UPPER PATH did not turn ON within the specified time after Exit Sensor - OFF.

FIP-1 38



FIP/Corrective

Action2-12

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingOpen D and CClear jam

Static Jam(Remain at Dup Out)

The SENSOR LOW PATH was turned ON at Power ON or when the I/L was closed. (Static Jam)

FIP-1 39

Open Unit DClear jam

Static Jam(Remain at Dup In)

The SENSOR UPPER PATH was turned ON at Power ON or when the I/L was closed. (Static Jam)

Open Cover GClear jam

Static Jam(Remain at Tray Path 1)

The SENSOR T/R was turned ON at Power ON or when the I/L was closed. (Static Jam)

(No LCD Display) Static Jam(Remain at OHP)The SENSOR OHP was turned ON at Power ON or when the I/L was closed. (Static Jam)



Static Jam(Remain at Regi)

The SENSOR REGI was turned ON at Power ON or when the I/L was closed. (Static Jam)


OrOpen Unit DClear Area F

Static Jam(Remain at Fuser In)

The SENSOR FUSER IN was turned ON at Power ON or when the I/L was closed. (Static Jam)

Open Cover AClear jam

OrOpen Unit D

Clear jam

Static Jam(Remain at Exit)

The Exit Sensor was turned ON at Power ON or when the I/L was closed. (Static Jam)

Open Cover HClear jam IOT Tray Path2 JAM TrayPath2 Sensor JAM Detected

Remove jammed paper.

Open Tray 2 & HClear jam IOT Feeder2 JAM Tray2 Misfeed JAM Detected


Open Cover G, HClear jam

IOT Tray2 PSNR1 On JAM JAM Caused By Tray2 PSNR1 On




FIP/Corrective

Action2-13

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting2.3.2 Error/Status Code List (Except Paper Jam)

Status CodeOr LCD Display Error Details Error Description

FIP/Corrective

ActionLoad Yellow

Cartridge Y Toner DetachedThe yellow toner cartridge has not been installed. FIP-1 1

Load Magenta Cartridge M Toner Detached

The magenta toner cartridge has not been installed. FIP-1 2

Load Cyan Cartridge C Toner Detached

The cyan toner cartridge has not been installed. FIP-1 3

Load Black Cartridge K Toner Detached

The black toner cartridge has not been installed. FIP-1 4

Load Drum Cartridge XERO CRU Detached The drum cartridge has not been installed. FIP-1 5

Load Drum Cartridge

Xero Communication Error

A communication error occurred between the PWBA MCU and the ANTENNA ASSY (CRUM XERO).

FIP-1 6

009-361 Xero Verify Error Data write error occurred in the ANTENNA ASSY (CRUM XERO). FIP-1 7

009-366 Xero Imitation Error The drum cartridge with a different memory device has been installed. FIP-1 8

009-366 Xero ID Error The drum cartridge with different specifications has been installed. FIP-1 9

Load Yellow Cartridge

Y Toner Communication Error

A communication error occurred between the PWBA MCU and the ANTENNA CTRG (CRUM CTRIG).

FIP-1 10

009-364 Y Toner Verify Error Data write error occurred in the ANTENNA CTRG (CRUM CTRIG). FIP-1 11

009-369 Y Toner Imitation Error A yellow toner cartridge with a different memory device has been installed. FIP-1 12

009-369 Y Toner ID Error A yellow toner cartridge with different specifications has been installed. FIP-1 13

Load Magenta Cartridge

M Toner Communication Error


FIP-1 14

009-363 M Toner Verify Error Data write error occurred in the ANTENNA CTRG (CRUM CTRIG). FIP-1 15

009-368 M Toner Imitation Error A magenta toner cartridge with a different memory device has been installed. FIP-1 16

009-368 M Toner ID Error A magenta toner cartridge with different specifications has been installed. FIP-1 17

Load Cyan Cartridge

C Toner Communication Error


FIP-1 18

009-362 C Toner Verify Error Data write error occurred in the ANTENNA CTRG (CRUM CTRIG). FIP-1 19

009-367 C Toner Imitation Error A cyan toner cartridge with a different memory device has been installed. FIP-1 202-14

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting009-367 C Toner ID Error A cyan toner cartridge with different specifications has been installed. FIP-1 21

Load Black Cartridge

K Toner Communication Error


FIP-1 22

009-365 K Toner Verify Error Data write error occurred in the ANTENNA CTRG (CRUM CTRIG). FIP-1 23

009-370 K Toner Imitation Error A black toner cartridge with a different memory device has been installed. FIP-1 24

009-370 K Toner ID Error A black toner cartridge with different specifications has been installed. FIP-1 25

004-310 Communication Error FeederA communication error occurred between the PWBA MCU and the feeder. FIP-1 40

004-311 Communication Error DuplexA communication error occurred between the PWBA MCU and the Duplex. FIP-1 41

004-371 PAGE Timeout The PAGEC/PAGE signal was not received within 60s after PFA had been sent. FIP-1 42

003-356 NVRAM Error An error occurred in the NVRAM on the PWBA MCU. FIP-1 43

004-321 TR0 FailureThe PWBA MCU did not receive the output signals from the SENSOR TR-0 (TR0 Sensor) at the specified timing.

FIP-1 44

006-370 ROS Motor FailureThe PWBA MCU did not receive the output signals from the SOS Sensor in the ROS within the specified time.

FIP-1 45

004-332 Deve Home Position Sensor Error

The PWBA MCU did not receive the output signals from the Rotary Home Position Sensor within the specified time after the Rotary Developer had started rotation.

FIP-1 46

009-340 ADC Contamination An error occurred in the SENSOR ASSY ADC (ADC Sensor). FIP-1 47

009-341 High DensityThe output value from the SENSOR ASSY ADC (ADC Sensor) exceeds the specified value.

FIP-1 48

009-342 Low DensityThe output value from the SENSOR ASSY ADC (ADC Sensor) is below the specified value.

FIP-1 49

009-344 High Coverage The 500msec coverage for the lead edge of the image exceeds the limit. FIP-1 51

009-359 BTR 2 Error The inputs of the 2nd BTR Retract Sensor did not change during 2nd BTR initialization. FIP-1 52

009-358 BTR 2 Advance Error The 2nd BTR Retract Sensor did not turn ON within the specified time. FIP-1 53


FIP/Corrective

Action2-15

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting010-397 Fuser Fail

The Control Thermistor detected a temperature higher than the specified value. The Safety Thermistor detected a temperature higher than the specified value. The Control Thermistor does not detect READY within the specified time after the Main Lamp was turned ON during warm up. The Main Lamp was still lit ON after the specified time had passed since the Control Thermistor had detected READY. The Control Thermistor detected a temperature lower than the specified value after the specified time had passed since the Main Lamp turned ON during warm up. The FUSER ASSY latch lever has not been installed properly.

FIP-1 54

010-354 Temp Sensor ErrorThe SENSOR HUM & TEMP detected a temperature lower than -7 degrees Celsius or higher than 55 degrees Celsius.

FIP-1 55

004-324 Humidity Sensor Error The inputs from the SENSOR HUM & TEMP are out of the specifications. FIP-1 58

007-340 Feed Motor Failure The Feeder DRIVE ASSY FEED (Feed Motor) is not rotating at the specified speed. FIP-1 59

007-341 Duplex Motor FailureThe Duplex MOTOR ASSY DUP (Lower Roll Motor) or MOTOR ASSY DUP INV (Upper Roll Motor) are not rotating at the specified speed.

FIP-1 60

009-360 IBT CLN Fail The SENSOR IBT RETRACT cannot detect Advance/Retract of the CAM ASSY-IBT CL. FIP-1 61

Replace Yellow Cartridge Y Toner Life Over It is time to replace the yellow toner cartridge. FIP-1 62

Replace Magenta Cartridge M Toner Life Over

It is time to replace the magenta toner cartridge. FIP-1 63

Replace Cyan Cartridge C Toner Life Over It is time to replace the cyan toner cartridge. FIP-1 64

Replace Black Cartridge K Toner Life Over It is time to replace the black toner cartridge. FIP-1 65

Replace Drum Cartridge

Waste Toner Bottle Life Over It is time to replace the waste toner bottle. FIP-1 66

Close Cover E Regi Cover Open The CHUTE ASSY-REAR is open. FIP-1 68Close Cover F 2nd BTR Cover Open The CHUTE ASSY-FSR is open. FIP-1 69Close Cover A Exit Cover Open The COVER FUSER is open. FIP-1 70Close Cover G Tray 1 Cover Open The Tray 1 Cover is open. FIP-1 71Close Cover C Duplex Cover Open The Duplex Cover is open. FIP-1 72Close Unit D Duplex Tray Open The Duplex is open. FIP-1 73

Close FrontCover Front Cover Open The COVER FRONT ASSY U or COVER TOP is open. FIP-1 74


FIP/Corrective

Action2-16

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting- Y Toner Life Warning The yellow toner cartridge has reached the set toner supply time limit but it can still work. FIP-1 75

- M Toner Life Warning The magenta toner cartridge has reached the set toner supply time limit but it can still work. FIP-1 76

- C Toner Life Warning The cyan toner cartridge has reached the set toner supply time limit but it can still work. FIP-1 77

- K Toner Life Warning The black toner cartridge has reached the set toner supply time limit but it can still work. FIP-1 78

-

Toner Bottle Life Warning

The waste toner bottle is detected FULL by the SENSOR TNER FULL but can still work. FIP-1 79

- Xero CRU Life Warning The drum has exceeded its specified rotation count but it can still work.

FIP-1 80Replace Drum

Cartridge Xero CRU Life2The drum rotation count has exceeded the specified count.

Open Cover H IOT Cover Feeder2 Open The Feeder 2 Cover is open.Interlock is

close.016-300 ESS Data Cache Error CPU data cache error. FIP-1 82

016-301 ESS Instruction Cache Error CPU instruction cache error. FIP-1 82

016-302 ESS Illegal Exception CPU invalid exception. FIP-1 82

016-310 ESS FontROM Error (Main) Built-in Font ROM check sum error. FIP-1 82

016-311 ESS FontROM Error (Option) Option Font ROM check sum error. FIP-1 82016-312 ESS HD Failure Detected by an HDD error. FIP-1 82016-313 ASIC Failure TBD FIP-1 82

016-314 Reserved (VSYNC error) FIP-1 82

016-315 ESS On Baord RAM W/R Check Failure Detected at Intial On Baord RAM W/R Check. FIP-1 82

016-316 ESS DIMM Slot RAM W/R Check Failure Detected at Intial DIMM Slot RAM W/R Check. FIP-1 82

016-317 ESS ROM Check(Main) Failure Main Program ROM check sum error. FIP-1 82

016-318 ESS DIMM Slot RAM ErrorThis occurs when an unavailable DIMM is inserted in the DIMM Slot during initialization process at Power ON.

FIP-1 82

016-323 ESS NVRAM1 W/R Check Failure Detected by Master NVRAM W/R Check FIP-1 82

016-324 ESS NVRAM2 W/R Check Failure Detected by Secondary NVRAM W/R Check FIP-1 82

016-325 Reserved (for NVRAM3) FIP-1 82016-326 Reserved (for NVRAM4) FIP-1 82


FIP/Corrective

Action2-17

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting016-327 ESS NVRAM1 SIZE And ID Check FailureDetected by matching check of the system-required NVRAM size and the real size and of the ID to be recorded at the first Power ON.

FIP-1 82

016-328 Reserved (for NVRAM2) FIP-1 82016-340 On Board Network Communication Failure

Communication failure between the 1 CPU network and the ESS F/W. FIP-1 82

016-344On Board Network MAC Address Checksum Error

FIP-1 82

016-345On Board Network Ethernet BIST Parity/RAM R/W Error

FIP-1 82

016-346 On Board Network Internal Loopback Error FIP-1 82

016-351 Reserved FIP-1 82016-360 PCI Option#0 Fail PCI option 0 detection error. FIP-1 82016-361 PCI Option#1 Fail PCI option 1 detection error. FIP-1 82016-350 IEEE1284 Data Error Detected by the IEEE1284 controller. FIP-1 82

016-370 IOT-ESS Communication FailureCommunication failure between the IOT and ESS. FIP-1 82

016-355 USB Error (Spec only for DIAG) FIP-1 82

016-380MACPHY CHIP TEST Error (Spec only for DIAG)

FIP-1 82

016-381MACPHY INT LOOP TEST Error (Spec only for DIAG)

FIP-1 82

016-382MACPHY EXT LOOP TEST Error (Spec only for DIAG)

FIP-1 82

016-330 NIC-ESS Communication FailureCommunication failure between the NIC and ESS. FIP-1 82

016-331 NIC Flash ROM Boot Module Checksum Error FIP-1 82

016-332 NIC RAM R/W Test Error FIP-1 82

016-333NIC Flash ROM Application Module Checksum Error

FIP-1 82

016-334 NIC MAC Address Checksum Error FIP-1 82

016-335 NIC Ethernet BIST parity/RAM R/W Error FIP-1 82

016-336 NIC Internal Loopback Error FIP-1 82


FIP/Corrective

Action2-18

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting009-343 IOT PCDC Error PCDC error detected. Power OFF/ON

001-358 IOT Fan Error Fuser Fan Error Fuser detected. Power OFF/ON

001-360 IOT Fan Error Rear Fan Error Rear detected. Power OFF/ON

010-317 IOT Fuser Detached Fuser Detached detected. Power OFF/ON

Paper Tray Config Error Tray Configuration Error

Tray configuration error detected. (Includes all wrong configurations.)

Turn OFF the power, reset the tray and turn ON the

power.

009-371 IOT TONER ROTATE ERROR Rotation error during toner replacement.Cover is

open.

%sCheck paper

IOT Paper Size Mismatch Paper Size Mismatch detected.

Open/close the tray or

remove and reload paper

in Bypass Tray.

Load in %s%s %s No Suitable Paper

No paper is loaded in all existing trays during job standby or when the paper feed automatic selection is specified (All Tray Empty). When the paper feed automatic selection is specified, paper loaded in all existing trays do not match the setting (All Tray Size Mismatch). When a paper tray is specified, no paper is loaded in the specified tray (Specified Tray Empty). When a paper tray is specified, the paper size loaded in the specified tray is different (Specified Tray Size Mismatch).

-

Out of memory Press Set Memory Overflow

Press the Set button.

Disk is full Press Set Hard Disk Full


PDL Error Press Set PDL Error


Invalid job Press Set

Job Environment Violation A violation of the print conditions has occurred.


016-383 DOWNLOAD ID ERROR The download file ID is incorrect. Press the Set button.

016-384 DOWNLOAD RANGE ERRORThe write destination address during download is incorrect. Range check error.


016-385 DOWNLOAD HEADER ERRORThe download file header information is incorrect.



FIP/Corrective

Action2-19

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting016-386 DOWNLOAD CHECKSUM ERROR The download file check sum is incorrect.Press the Set

button.

016-387 DOWNLOAD FORMAT ERROR The download file format is incorrect.Press the Set

button.

016-388 DOWNLOAD INITIAL ERRORNIC activation in the download mode has failed when downloading the optional NIC.


016-389 DOWNLOAD INSERTION ERRORDownload was performed when the optional NIC was not installed.


016-390 DOWNLOAD COMM ERRORA communication error occurred when downloading the optional NIC.


016-391 DOWNLOAD PROTECT ERRORFW download was performed when FW update was prohibited by the panel settings.


016-392 DOWNLOAD DELETE ERROR Flash deletion error during download. FIP-1 82

016-393 DOWNLOAD WRITE ERROR Flash write error during download. FIP-1 82

016-394 DOWNLOAD VERIFY ERROR Flash verify error during download. FIP-1 82


FIP/Corrective

Action2-20

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting2.3.3 Error Code FIPFIP-1. 1 Y Toner Detached

Procedure Check Items Yes No

Parts considered to be the cause:TNR CRU Y (PL9.2.2)HOUSING ASSY-DEVE Y (PL9.2.6)ANTENNA CTRG (PL9.1.12)HARNESS ASSY MAIN (PL12.2.10)ANTENNA ASSY-CTRG (PL9.1.10)PWBA MCU (PL12.2.1)

1Check TNR CRU Y (Y Toner Cartridge) model nameIs a TNR CRU Y that complies with the specifications installed?

Go to Step 2.

Replace with a TNR CRU Y that complies

with the specifications.

2 Check installation of TNR CRU YIs the TNR CRU Y installed properly? Go to Step 3.Reinstall and go to Step 3.

3 Does the error persist after the power is turned ON/OFF several times? Go to Step 4. Completed.

4 Check installation of HOUSING ASSY-DEVE YIs the HOUSING ASSY-DEVE Y installed properly? Go to Step 5.Reinstall and go to Step 5.


6Check TNR CRU Y after replacementReplace the TNR CRU Y.When the power is turned ON, does the error occur again?

Go to Step 7. Completed.

7

Check operation of ANTENNA CTRGDisconnect P/J415 on the PWBA MCU and connect it again.When the power is turned ON, does the error occur again?

Go to Step 8. Go to Step 9.

8

Check HARNESS ASSY MAIN cablesDisconnect P/J415 on the PWBA MCU.Check the following. Are they conducting properly?J415-1 J106-2J415-2 J106-1

Go to Step 9.Repair the

open circuit or short circuit.

9Check HOUSING ASSY-DEVE Y after replacementReplace the HOUSING ASSY-DEVE Y. (REP9.6)When the power is turned ON, does the error occur again?


10

Check ANTENNA ASSY-CTRG or ANTENNA CTRG after replacementReplace the ANTENNA ASSY-CTRG or ANTENNA CTRG. (REP9.2)When the power is turned ON, does the error occur again?

Replace the PWBA MCU. (REP12.5)

Completed.2-21

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 2 M Toner Detached


Parts considered to be the cause:TNR CRU M (PL9.2.3)HOUSING ASSY-DEVE M (PL9.2.7)ANTENNA CTRG (PL9.1.12)HARNESS ASSY MAIN (PL12.2.10)ANTENNA ASSY-CTRG (PL9.1.10)PWBA MCU (PL12.2.1)

1Check TNR CRU M (M Toner Cartridge) model nameIs a TNR CRU M that complies with the specifications installed?

Go to Step 2.

Replace with a TNR CRU M that complies


2 Check installation of TNR CRU MIs the TNR CRU M installed properly? Go to Step 3.Reinstall and go to Step 3.


4 Check installation of HOUSING ASSY-DEVE MIs the HOUSING ASSY-DEVE M installed properly? Go to Step 5.Reinstall and go to Step 5.


6Check TNR CRU M after replacementReplace the TNR CRU M.When the power is turned ON, does the error occur again?


7



8




9Check HOUSING ASSY-DEVE M after replacementReplace the HOUSING ASSY-DEVE M. (REP9.6)When the power is turned ON, does the error occur again?


10



Completed.2-22

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 3 C Toner Detached


Parts considered to be the cause:TNR CRU C (PL9.2.4)HOUSING ASSY-DEVE C (PL9.2.8)ANTENNA CTRG (PL9.1.12)HARNESS ASSY MAIN (PL12.2.10)ANTENNA ASSY-CTRG (PL9.1.10)PWBA MCU (PL12.2.1)

1Check TNR CRU C (C Toner Cartridge) model nameIs a TNR CRU C that complies with the specifications installed?

Go to Step 2.

Replace with a TNR CRU C that complies


2 Check installation of TNR CRU CIs the TNR CRU C installed properly? Go to Step 3.Reinstall and go to Step 3.

3 Does the error persist after the power is turned ON/OFF several times? go to Step 4. Completed.

4 Check installation of HOUSING ASSY-DEVE CIs the HOUSING ASSY-DEVE C installed properly? Go to Step 5.Reinstall and go to Step 5.


6Check TNR CRU C after replacementReplace the TNR CRU C.When the power is turned ON, does the error occur again?


7



8

Check HARNESS ASSY MAIN cablesDisconnect the P/J415 on the PWBA MCU.Check the following. Are they conducting properly?J415-1 J106-2J415-2 J106-1



9Check HOUSING ASSY-DEVE C after replacementReplace the HOUSING ASSY-DEVE C. (REP9.6)When the power is turned ON, does the error occur again?


10



Completed.2-23

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 4 K Toner Detached


Parts considered to be the cause:TNR CRU K (PL9.2.1)HOUSING ASSY-DEVE K (PL9.2.5)ANTENNA CTRG (PL9.1.12)HARNESS ASSY MAIN (PL12.2.10)ANTENNA ASSY-CTRG (PL9.1.10)PWBA MCU (PL12.2.1)

1Check TNR CRU K (K Toner Cartridge) model nameIs a TNR CRU K that complies with the specifications installed?

Go to Step 2.

Replace with a TNR CRU C that complies


2 Check installation of TNR CRU KIs the TNR CRU K installed properly? Go to Step 3.Reinstall and go to Step 3.


4 Check installation of HOUSING ASSY-DEVE KIs the HOUSING ASSY-DEVE K installed properly? Go to Step 5.Reinstall and go to Step 5.


6Check TNR CRU K after replacementReplace the TNR CRU K.When the power is turned ON, does the error occur again?


7



8

Check HARNESS ASSY MAIN cablesDisconnect the P/J415 on the PWBA MCU.Check the following. Are they conducting properly?J415-1 J106-2J415-2 J106-1



9Check HOUSING ASSY-DEVE K after replacementReplace the HOUSING ASSY-DEVE K. (REP9.6)When the power is turned ON, does the error occur again?


10



Completed.2-24

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 5 XERO CRU Detached


Parts considered to be the cause:IBT ASSY (PL7.1.1)HARNESS-ASSY XERO (PL7.1.12)GUIDE CRU ASSY D (PL7.1.4) orANTENNA ASSY (PL7.1.10)PWBA MCU (PL12.2.1)

1Check IBT ASSY model nameIs a IBT ASSY that complies with the specifications installed?

Go to Step 2.

Replace with a IBT ASSY that complies with

the specifications.

2

Check installation of IBT ASSYRe-install the IBT ASSY.After the power is turned ON/OFF, does the error occur again?


3

Check operation of ANTENNA CTRGDisconnect the P/J416 on the PWBA MCU and connect it again.When the power is turned ON, does the error occur again?


4

Check HARNESS-ASSY XERO cablesDisconnect P/J416 on the PWBA MCU.Check the following. Are they conducting properly?J416-4 J109-2J416-5 J109-1

Go to Step 5.Replace the HARNESS-

ASSY XERO.

5Check IBT ASSY after replacementReplace the IBT ASSY.When the power is turned ON, does the error occur again?


6

Check GUIDE CRU ASSY D or ANTENNA ASSY after replacementReplace the GUIDE CRU ASSY D or ANTENNA ASSY. (REP7.2)When the power is turned ON, does the error occur again?


Completed.2-25

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 6 XERO Communication Error


Parts considered to be the cause:IBT ASSY (PL7.1.1)GUIDE CRU ASSY D (PL7.1.4) orANTENNA ASSY (PL7.1.10)HARNESS-ASSY XERO (PL7.1.12)PWBA MCU (PL12.2.1)LV/HVPS (PL12.2.3)


Go to Step 2.


the specifications.

2Check installation of IBT ASSYRe-install the IBT ASSY.When the power is turned ON, does the error occur again?




4 ANTENNA ASSY checkIs the ANTENNA ASSY dirty?

Clean the ANTENNA

ASSY and go to Step 5.

Go to Step 6.

5 When the power is turned ON, does the error occur again? Go to Step 6. Completed.

6



ASSY XERO.

7



8

Check power supply to PWBA MCUIs the following power supplied from the LV/HVPS to the PWBA MCU?J410-1 J410-2: 3.3 VDCJ410-3 J410-4: 5 VDCJ410-5/6 J410-7/8: 24 VDC


Go to Step 9.2-26

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting9

Check HARNESS ASSY MAIN cablesDisconnect P/J410 on the PWBA MCU and P/J502 on the LV/HVPS.Check the following. Are they conducting properly?J410-1 J502-1J410-2 J502-2J410-3 J502-3J410-4 J502-4J410-5 J502-5J410-6 J502-6J410-7 J502-7J410-8 J502-8

Replace the LV/HVPS. (REP12.6)

Repair the open circuit or short circuit.

Procedure Check Items Yes No2-27

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 7 XERO Verify Error


Parts considered to be the cause:IBT ASSY (PL7.1.1)GUIDE CRU ASSY D (PL7.1.4) orANTENNA ASSY (PL7.1.10)HARNESS-ASSY XERO (PL7.1.12)PWBA MCU (PL12.2.1)LV/HVPS (PL12.2.3)





3 ANTENNA ASSY checkIs the ANTENNA ASSY dirty?

Clean the ANTENNA

ASSY and go to Step 4.

Go to Step 5.


5



ASSY XERO.

6



7



Go to Step 8.

8



Repair the open circuit or short circuit.2-28

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 8 XERO Imitation Error


Parts considered to be the cause:IBT ASSY (PL7.1.1)PWBA MCU (PL12.2.1)HARNESS ASSY MAIN (PL12.2.10)LV/HVPS (PL12.2.3)


Go to Step 2.


the specifications.





4



Go to Step 5.

5




Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 9 XERO ID Error


Parts considered to be the cause:IBT ASSY (PL7.1.1)PWBA MCU (PL12.2.1)HARNESS ASSY MAIN (PL12.2.10)LV/HVPS (PL12.2.3)


Go to Step 2.


the specifications.



3


Replace the PWBA MCU.

(REP12.5)Go to Step 4.

4




Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 10 Y Toner Communication Error


Parts considered to be the cause:TNR CRU Y (PL9.2.2)ANTENNA ASSY-CTRG (PL9.1.10) orANTENNA CTRG (PL9.1.12)HARNESS ASSY MAIN (PL12.2.10)PWBA MCU (PL12.2.1)LV/HVPS (PL12.2.3)


Go to Step 2.



2Check installation of TNR CRU YReinstall the TNR CRU Y.When the power is turned ON, does the error occur again?




4 ANTENNA CTRG checkIs the ANTENNA CTRG dirty?

Clean the ANTENNA

CTRG and go to Step 5.

Go to Step 6.


6




7

Check ANTENNA ASSY-CTRG or ANTENNA CTRG after replacementReplace the ANTENNA ASSY-CTRG or ANTENNA CTRG. (REP9.2/REP9.3)When the power is turned ON, does the error occur again?


8



Go to Step 9.2-31

Chapter 2 Troubleshooting2.3 Level 2 Troubleshooting9



Repair the open circuit or short circuit.

Procedure Check Items Yes No2-32

Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 11 Y Toner Verify Error


Parts considered to be the cause:TNR CRU Y (PL9.2.2)ANTENNA ASSY-CTRG (PL9.1.10) orANTENNA CTRG (PL9.1.12)HARNESS ASSY MAIN (PL12.2.10)PWBA MCU (PL12.2.1)LV/HVPS (PL12.2.3)

1Check installation of TNR CRU Y (Y Toner Cartridge)Reinstall the TNR CRU Y.When the power is turned ON, does the error occur again?




3 ANTENNA CTRG checkIs the ANTENNA CTRG dirty?

Clean the ANTENNA

CTRG and go to Step 4.

Go to Step 5.


5




6

Check ANTENNA ASSY-CTRG or ANTENNA CTRG after replacementReplace the ANTENNA ASSY-CTRG or ANTENNA CTRG. (REP9.2/REP9.3)When the power is turned ON, does the error occur again?


7


Replace the PWBA MCU.

(REP12.5)Go to Step 8.

8




Chapter 2 Troubleshooting2.3 Level 2 TroubleshootingFIP-1. 12 Y Toner Imitation Error


Parts considered to be the cause:TNR CRU Y (PL9.2.2)PWBA MCU (PL12.2.1)HARNESS ASSY MAIN (PL12.2.10)LV/HVPS (PL12.2.3)


Go to Step 2.



2Check installation of TNR CRU YReinstall the TNR CRU Y.When the power is turned ON, does the error occur again?


3Check TNR CRU Y after replacementReplace the TNR CRU Y.When the

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