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Workcentre 3210 Manual submited images

Workcentre 3210 Manual submited images

Xerox WorkCentre 7556 - MK ElectronicPL 21.12 Finisher Electrical Item Part Description 1 – Left Harness Guide (Not Spared) 2 – Right Harness Guide (Not Spared) 3 960K51453 Finisher PWB (REP 21.29) 4 – Finisher PWB Cover (Not Spared) 5 – Finisher PWB Cover (Not Spared) 6 962K38740 AC Inlet Harness 7 105E15200 Finisher LVPS 8 – LVPS Wire Harness (Not Spared) 9 – Screw (Not Spared) 10 960K31130 AC Filter 11 – Bracket (Not Spared) 12 962K67080 I/F Finisher Cable 13 – Harness Assembly (Not Spared) 14 – Harness Guide (Not Spared) 15 – Harness Guide (Not Spared) 16 – Connector Plate (Not Spared) 17 962K29160 Harness 18 960K04681 H-Transport PWB Initial Issue www MK-Electronic de 08/2010 5-119 Parts List WorkCentre 7556 Family Service Documentation PL 21.12PL 21.13 Finisher Harness Item Part Description 1 – Main Sensor Harness (Not Spared) 2 – Main Drive Harness (Not Spared) 3 – Interface Harness (Not Spared) 4 – Transport Entrance Sensor Harness (Not Spared) 5 – Buffer Sensor Harness (Not Spared) 6 – Top Exit Sensor Harness (Not Spared) 7 – Top Sensor Harness (Not Spared) 8 – Punch Drive Harness (Not Spared) 9 – Punch Sensor Harness (Not Spared) 10 – LVPS Harness (Not Spared) 11 962K58950 Interlock Harness 12 960K54831 Booklet PWB Parts List PL 21.13 www MK-Electronic de 08/2010 Initial Issue 5-120 WorkCentre 7556 Family Service DocumentationOverview Introduction .............28. HCF PL 28.1 HCF Unit ..........Subsystem Information Use of the TeA tag number within a circle with nPL 1.2 Control Panel/Platen Glass IPL 1.4 Control Panel (2 of 2) Item PL 1.6 Carriage Cable/Motor Item PaPL 1.8 IIT/IPS PWB Item Part DescriPL 2.1 LED Print Head (1 of 2) ItemPL 3.1 Drives (1 of 4) Item Part DePL 3.3A Drives (7525/7530/7535)(3 oPL 4.1 NOHAD Common Item Part DescrPL 4.2B NOHAD (7545, 7556)(1 of 3) PL 4.3B NOHAD (7545, 7556)(2 of 3) PL 4.4B NOHAD (7545, 7556)(3 of 3) PL 5.2 Development (2 of 2) Item PaPL 6.1 Transfer (1 of 2) Item Part PL 6.3 IBT Assembly (1 of 2) Item PPL 7.1 Fuser Item Part Description PL 8.2 Xerographic (2 of 2) Item PaPL 9.2 Tray 1/2 (2 of 2) Item Part PL 9.4 Tray 1 Feeder Assembly (1 ofPL 10.1 Three Tray Module Item PartPL 10.3 Tray 2 Feeder Assembly (1 oPL 10.5 Tray 3 Feeder Assembly (1 oPL 10.7 Tray 4 Feeder Assembly (1 oPL 10.9 Electrical Item Part DescriPL 10.13 Left Hand Cover Assembly IPL 11.1 Tray 2/3/4 Assembly Item PaPL 11.3 Tray 3 Item Part DescriptioPL 11.5 Tray 4 Paper Feed Item PartPL 11.7 Tray 2 Feeder (1 of 2) ItemPL 11.9 Tray 3 Feeder (1 of 2) ItemPL 28.5 HCF Feeder (2 of 3) Item PaPL 28.7 HCF Top Cover Unit Item ParPL 35.1 Single Board Controller (1 PL 51.1 DADF Accessory Item Part DePL 51.3 Base Frame Item Part DescriPL 51.5 DADF Drives (1 of 2) Item PPL 51.7 Front Belt Item Part DescriPL 51.9 Roll, Sensor Bracket Item PPL 51.11 Top Cover Item Part DescriPL 51.13 Registration Chute Item PaPL 51.15 Invert Chute Item Part DesPL 51.17 Sensor Bracket Item Part D extended embed settings WorkCentre Pro 35/45/55 Product Brochure (PDF, 564 KB) - XeroxXerox WorkCentre 3119 - MK ElectronicXerox WorkCentre PE 220 - MK ElectronicXerox WorkCentre 7132 - MK ElectronicXerox WorkCentre 3550 - MK ElectronicXerox WorkCentre 5225 / 5230 - MK ElectronicXerox WorkCentre Pro C3545 - MK ElectronicXerox Document WorkCentre 450c/450cp Service ... - MK ElectronicXerox Phaser 3635 - MK ElectronicXerox Workcentre 5700 Series5 Parts Lists - MK ElectronicXerox WorkCentre 5665WorkCentre 228 - Fuji XeroxXerox WorkCentre 4150 User GuideXerox WorkCentre 4150 User GuideWorkCentre 4150 - Fuji XeroxXerox® WorkCentre 3550 - Xerox Support and DriversScanFlowStore Easy and intuitive scanning on Xerox Workcentre ...Parts Lists - MK ElectronicXerox WorkCentre 4260 BrochureWorkCentre 228 - Fuji Xerox PrintersXerox WorkCentre® 5665 / 5675 / 5687 Multifunction System ...Colour Multifunction System: Colour Printing | Xerox WorkCentre ...ScanFlowStore Easy and intuitive scanning on a Xerox Workcentre ...Xerox® WorkCentre® 5135 / 5150 Multifunction ... - Gentechol.comXerox WorkCentre 6400 Brochure - Tap The WebScanFlowStore Easy and intuitive scanning on Xerox Workcentre 6400Xerox WorkCentre 4150 finalWorkCentre 7132 - XeroxXerox WorkCentre 5225 Brochure Loading... Loading... Loading...Magazine: Xerox WorkCentre 7556 - MK Electronic



Service Manual Septemper 2002 Fuji Xerox of Shanghai Limited NOTICE: All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service. Xerox Corporation Global Knowledge & Language Services 800 Phillips Road - Bldg. 845-17S Webster, New York 14580-9791 USA ©2001 Xerox Corporation. All rights reserved. Printed in the United States of America XEROX®, The Document Company®, the stylized X and the identifying product names and numbers herein are trademarks of XEROX CORPORATION. 701Pxxxxx Introduction About This Documentation .............................................................................................. Organization .................................................................................................................... How to Use This Documentation..................................................................................... Other Information ............................................................................................................ Reference Symbology ..................................................................................................... iii iii iv v vi WorkCentre Pro 420 9/02 i Introduction Introduction 9/02 ii WorkCentre Pro 420 About This Documentation Documentation Design and Purpose This Service Documentation contains diagnostic, repair, and maintenance information, which has been designed to assist the Service Representative in the isolation and repair of faults as well as maintenance of the Printer/Copier. This documentation assumes that the user is familiar with the electrical and mechanical standards that are commonly used throughout industry, as well as certain Xerox design and documentation conventions. This documentation also assumes that the user has successfully completed any required training and is familiar with the use of any special tools that are required to service this product. Organization This documentation is divided into six sections. In addition to the Introduction, the following sections are contained within this documentation. Section 1 - Service Call Procedures Section 2 - Status Indicator RAPs Section 3 - Image Quality RAPs Section 4 - Repair/Adjustment Procedures Section 5 - Parts List Section 6 - General Procedures/Information Section 7 - BSD A detailed description of the information contained within each section of the service documentation will be found in the following subsection. Applicability The diagnostic, repair, and adjustment procedures found in this documentation apply equally to all 50 Hz and 60 Hz machine versions. Some procedures, however, may be identified as being applicable to a specific version or machine configuration. Limitations This service documentation does not support specific electrical, mechanical, or operational considerations of any accessory device or machine modification not authorized by Xerox Corporation for this product. Service Documentation Revisions This service documentation may be subject to periodic revision in order to reflect any changes in electrical or mechanical hardware, as well as any possible additions or corrections necessary to ensure the technical accuracy of the documentation. Service Information (Yellow Pages - hardcopy only) When appropriate, service information in the form of yellow pages (for those with hard copy only) will be distributed and should be incorporated into their service documentation. Service information may include bulletin information, Tag and Kit information, page revisions, or current top problems relative to the repair and maintenance of the machine. Field Service Bulletins Field service information specifically applicable to the machine may occasionally be issued in the form of electronic or critical bulletins. Because bulletins contain important information, they should always be retained within this service documentation for quick reference. WorkCentre Pro 420 9/02 iii Introduction About This Documentation, Organization How to Use This Documentation Introduction This section provides the Service Representative with information pertaining to the organization and use of this service documentation, and includes the following supportive reference data: Reference Symbology Signal Nomenclature DC Voltage Range Specifications AC Voltage Range and Current Specifications Section 2: Status Indicator RAPs Section 2 of this documentation contains the Repair ysis Procedures (RAPs) necessary to repair all faults other than the image quality faults. The Service Representative will be referred to this section from some other section of this documentation during the service call. When a machine defect or fault has been resolved by using a RAP, the Service Representative should immediately return to the point in the service call from which section 2 was entered. There are two types of RAPs found in section 2. The first type is a RAP that is associated with the display of a status code or fault code in the RAP title. The second type is the Other Fault RAP. Other Fault RAPs are diagnostic procedures that are designed to address symptoms or problems that are not identified by, or associated with, a displayed status or fault code. Section 3: Image Quality RAPs Contains the Image Quality Repair ysis Procedures (IQ RAPs) that are used to diagnose image quality defect problems. The RAPs that are associated with image quality defect symptoms will contain the prefix “IQ” to differentiate them from other types of machine failure symptoms. Section 1: Service Call Procedures This section is used by the Service Representative as a structured process for determining the type and sequence of actions that are performed during a service call. The Service Call Procedures section is designed to assist in the effective recognition of machine symptoms and problems, as well as to provide instructions for the maintenance and corrective actions that are required to return the machine to the full operating condition. Section 1 of this service documentation is the entry level for all service calls. The Service Representative should begin each service call with the Initial Action procedure found in Section 1. The Service Call Procedures section is composed of five integral elements: Initial Action, System Checks, Subsystem Maintenance, Preventive Maintenance, and Final Action. The maintenance and diagnostic activities in this section may direct the Service representative to perform additional service activities found elsewhere in the documentation, such as RAPs, removal and replacement procedures, and adjustment procedures. The Initial Action procedure identifies certain required actions that are necessary to obtain a basic appraisal of machine operation at the start of the service call. The System Checks subsection is used to test the machine in order to confirm and define the problem areas. This subsection is used to assist the Service Representative in diagnosing the not readily apparent machine problems, or when there are conflicting or ambiguous symptoms present. It is important that this procedure be used in order to ensure that the correct symptom is being diagnosed. The Subsystem Maintenance subsection contains a specific activity procedure that must be performed on the service call. The Preventative Maintenance procedure contains a list of the cleaning and lubrication activities that are designed to extend and enhance the reliability and performance of the machine. The Final Action subsection is used to identify the actions necessary to clear the call with the Customer and to complete any administrative tasks that are associated with completing the service activity. Section 4: Repairs / Adjustment Procedures Contains all repair and adjustment procedures for the machine. Repairs (REPs) and adjustments (ADJ’s) are identified by the use of a standard chain prefix number. Section 5: Parts List Contains a list of spare parts for the machine. All parts list page reference numbers begin with the letters “PL”, followed by a prefix number, a decimal point, and a sequential number used within the subsystem. Section 6: General Procedures / Information Contains procedures and information of a general nature that apply to the machine. This section is divided into two basic parts.: General Procedures and General Information. The General Procedures subsection contains frequently used procedures that relate to the diagnosis, the setup, or the operation of the machine. The General Information subsection contains specific information that is pertinent to the operation of the machine, but will not be found in any other part of the service documentation. This information may include product codes, environmental operating data, installation space requirements, and paper and electrical specifications. This subsection may also contain information regarding supplemental tools and supplies, general service notes, a glossary of commonly used terms, and a Change Tag Index of authorized machine modifications and retrofits. Section 7: Wiring Data (Optional) Contains support information to assjst in the electrical diagnosis of machine problems. Introduction How to Use This Documentation 9/02 iv WorkCentre Pro 420 and Note statements Information relative to the completion of a task in a safe or thorough manner will be supplied in the form of a Caution.A Warning statement indicates an operating or maintenance procedure. practice. or condition that. The definition of a Caution. a Warning. or Note is as follows: Caution . practice. equipment. Warnings. These statements are found throughout the service documentation. Warning . Specific or Unique Terms. could result in personal injury or loss of life. WorkCentre Pro 420 9/02 v Introduction Other Information . contained elsewhere in this section.Other Information The Use of Caution. Warning. or a Note statement. or destruction of. Note . if not strictly observed. Warning. could result in damage to. Abbreviations. and Conventions A list of acronyms and abbreviations used in this service documentation will be found in the Reference Symbology subsection. Cautions. or condition that. These statements should be read before continuing to the next step in a procedure. The Use of Acronyms. Conventions The following bolding convention is used in this service documentation: Bolded numbers or words following the words “Press the” represent the actual keypad button on the Control Console. and Note statements appear before the steps to which they apply. The terms “dry ink” and “toner” are interchangeable.A Caution statement indicates an operating or maintenance procedure. practice. Specific Terms Test Pattern 82P524 (inch) and 82P523 (metric) will be referred to in this documentation as the Standard Test Pattern.A Note statement indicates an operating or maintenance problem. or condition that is necessary to accomplish a task efficiently. if not strictly observed.Reference Symbology Introduction to Reference Symbology This section describes and defines the various acronyms. Schematic Symbols These symbols represent various electrical and mechanical components or devices that are commonly found in Xerox equipment. Introduction Reference Symbology 9/02 vi WorkCentre Pro 420 . abbreviations. Table 1 lists the acronyms that are found in this service documentation that enable use of the documentation. adjustments. These specifications represent the expected range for AC (machine input power source) and DC (machine internal power supplies) voltages that are encountered during normal operation. Table 2 Wire Color Abbreviations Abbreviation BLK BLU BRN GRAY GRN G/Y ORN PINK RED VIO WHT YEL Y/G Wire Color black blue brown gray green green/yellow orange pink red violet white yellow yellow/green Abbreviations Table 2 lists the electrical wire colors that are identified in this service documentation and reflects the use of standardized abbreviations. Signal Nomenclature. and AC and DC power specifications. These symbols are included as an aid to understanding the representations used in the Circuit Diagrams (CD’s). reference symbols. Although some acronyms may be unique to this product. or other information that is important for successful diagnosis and repair. The following is a description of some of the terms found in this section: Table 1 General Acronyms Acronym AC ACH ACN AMP BSD BTU CD IQ DC ESD HFSI LED PL PWB RAP VAC VDC Definition Alternating Current Alternating Current High Alternating Current Neutral Ampere Block Schematic Diagram British Thermal Unit Circuit Diagram Image Quality Direct Current Electrostatic Discharge High Frequency Service Item Light Emitting Diode Parts List Printed Wiring Board Repair ysis Procedure Volts Alternating Current Volts Direct Current Acronyms Acronyms are used throughout this service documentation to denote common terminology. most acronyms used in this document are known throughout the service industry. The purpose of these symbols is to inform the Service Representative of procedures. AC and DC Voltage References The expected AC and DC voltage levels found in this machine are defined in this section. A complete list of all acronyms is in Section 6 Reference Symbols Reference symbols consist of various icons used in this documentation to denote supportive data that can be found in other sections of this documentation. Figure 3 Note Symbol Miscellaneous Symbols Descriptions of all commonly used graphic symbols are included to assist in diagnostics. LED Light Emitting Diode (LED) Figure 8 Triac Symbol Figure 4 Feedback Symbol Ground Machine ground symbol Figure 9 LED Symbol Motor Motor provides motive force WorkCentre Pro 420 9/02 vii Introduction Reference Symbology . The PL designation is Parts List.5 parts list. and parts lists. The symbols that refer to this supportive data are shown below.REFERENCE SYMBOLOGY Notes. Flag Symbol Indicates part of circuit referred to in RAP. Figure 7 LED Photo transistor Symbol Triac Triac switches AC power via Low Voltage Input. Figure 6 Connector Symbol Figure 2 PL Symbol Note Refers to notes. usually on same page. Feed Back Feedback signal. Blocked and unblocked light switches sensor off and on. adjustments. support the checklists and the RAP information. LED / Photo transistor Sensor Symbol identifies sensor used in document and paper path. Connector Plug / Jack Connector number and pin number Figure 5 Ground Symbol Figure 1 Flag Symbol Parts List The terminology in the figure below refers to the parts list that is located in section 5 of this Service Documentation. The number refers to the 8. Figure 15 With Tag Symbol Figure 12 Driver Symbol Laser Warning Solenoid Relay. WARNING Symbol is used to warn of possible eye damage from a laser beam if service procedures are not followed exactly as written. Figure 16 Laser Warning Symbol ESD Warning Figure 13 Relay. Figure 10 Motor Symbol Thermistor Thermistor Bead. used to sense temperature Symbol indicates that the entire page has not been modified by the tag number in the circle. or Solenoid. Observe ESD procedures to avoid component damage. or Solenoid Symbol CAUTION Symbol is used when components in the copier are susceptible to damage from electrostatic discharge. Clutch.Without Tag Change Symbol indicates that the area to which the triangle points has not been modified by the tag number in the circle. Figure 14 Without Tag Symbol With Tag Change Figure 11 Thermistor Symbol Driver Driver controls DC components. Symbol indicates that the area to which the triangle points has been modified by the tag number in the circle. Symbol indicates that the entire page has been modified by the tag number in the circle. Figure 17 ESD Caution Symbol Introduction Reference Symbology 9/02 viii WorkCentre Pro 420 . Clutch. could result in damage to. For example: MAIN MOTOR ON (L) +5 VDC 1. 3. DC Voltage Levels DC Voltages should be measured between the test point and the machine frame.4 VDC WorkCentre Pro 420 9/02 ix Introduction Reference Symbology . Table 4 Logic Voltage Levels Nominal Voltage +5 VDC +24 VDC Logic State Hi Lo Hi Lo Actual Voltage Ranges +2. Table 3 DC Voltage Levels Voltage +5 VDC +24 VDC Logic Voltage Levels Measurements of logic levels must be made with reference to the specified ground point.2 VDC 0. practice.0 VDC Specification +4.0 VDC to +0. Caution CAUTION A caution is used to alert the personnel to an operating or maintenance procedure.6 to +26.0 VDC to +25.0 VDC to +3.Warning Signal Nomenclature WARNING A warning is used to alert the personnel to an operating or maintenance procedure. if not strictly observed. or condition that. MAIN MOTOR ON= Signal Name (L) = Logic State when the signal is available in it’s named state. Table 3 shows the value of the voltages. The signal is named to imply the condition of the machine when the signal is available. or destruction of equipment.45 VDC +22. or condition that. if not strictly observed could result in injury or loss of life. unless some other point is referenced in a diagnostic procedure. unless instructed otherwise. In this case the signal is Lo when the Main Motor is energized.25 VDC +21.4 VDC to +5. 2.75 to +5.7 VDC 0. practice. +5 VDC= Logic level when the signal is Hi.Introduction Reference Symbology 9/02 x WorkCentre Pro 420 ...... 1-3 1-5 1-7 1-9 1-9 Call Flow Call Flow Procedure ........................................................................................ Subsystem Maintenance Periodic Maintenance..................... Status Codes / Other Faults Listing Status Codes / Other Faults Listing......................................................................... Maintenance Procedures ...................................................................... Initial Issue WorkCentre Pro 420 9/02 1-1 Service Call Procedures ..................................................................................................................1 Service Call Procedures Introduction Service Call Procedures...............................................................................................................Service Call Procedures 9/02 1-2 Initial Issue WorkCentre Pro 420 . Corrective Actions Schedule of periodic maintenance to do when copy count reaches specific quantity. This is designed to be used with printer/copier Service Documentation and is starting point for all service calls. Choices made based on machine symptom. Corrective Actions Steps to repair faults. – – Status Codes / Other Faults Listing List of status codes and other faults with descriptions. perform Final Actions.Service Call Procedures Use Service Call Procedures as a maintenance guide when performing any service on printer/ copier. • Final Actions Steps to verify machine operation and image quality. When all problems are repaired. Call Flow Procedure Identifies and classifies machine problems and refers to appropriate RAP for repair. Initial Issue WorkCentre Pro 420 9/02 1-3 Service Call Procedures Service Call Procedures . • • Initial Actions Steps to diagnose faults. Maintenance Procedures Tables of subsystem components to be maintained with suggested materials and procedures when that subsystem is repaired by direction from a RAP.Service Call Procedures Service Call Procedures 9/02 1-4 Initial Issue WorkCentre Pro 420 . go to Table 1 in this section. If machine is used as a printer perform following: • • • Verify that connections at rear of machine are secure. 8. go to Table 2 in this section. read following 2 items and respond as required. 1. ask Customer to demonstrate problem. Then go to Final Actions If less than 2000 copies have been made or if 20 days have not elapsed since last service call. If possible. If an obvious problem occurs. 8. If Fault History contains several faults with same status code. or if machine makes blank or unfused copies. go to Image Quality Diagnostics Overview in Image Quality Section.Call Flow Procedure Initial Actions On Telephone 1. Make a record of copy meter and Status Code. Reinstallation or Replacement information For other problems not listed above.5 x 11 inch (A4) documents into the ADF. If problem cannot be resolved over telephone. 5. and operating to specification. go to OF 14-1 PRINTER RAP in Section 2. 6. Check Service Log and Tag Matrix. Without ADF: Place Standard test pattern on the Document Glass. 13. 9. 2. 3. Load the document(s). Ask customer to run a print job to verify print operation. Give appropriate copy credits to Customer. Make copies. Make a record in Service Log of all necessary actions performed during service call. Continue with R/E button to display all most recent status codes. Corrective Actions 1. go to Periodic Maintenance in this section and perform actions listed after making repairs required in step 1. Ask Operator or Customer to describe problem. 3. Go to step 2 after responding to one or more of following items. Perform GP3 Main PWB [3–11] to generate Printer Test Pattern. Make 2 copies. Ask Customer to save copies or prints made when problem occurred. Call Customer and attempt to correct problem over telephone. Clear any jammed paper from machine. Also ask for any additional problems encountered with machine. repair as required and refer to Parts List as required for Removal. • • 2. Clean machine covers and area around machine. Exit Diagnostic Mode and make 4 copies of standard test pattern. wait 5 seconds. printer cable must be securely connected. or if 20 days have elapsed since last service call. If defects are present. Enter Diagnostic Mode. Read following 6 items and respond as required. Inspect sample copies provided by Customer. Proceed to Corrective Actions. and Tray 2 if present. If machine will not feed paper from all of paper trays. Enter [3–2] (GP 7 Status Code History ) and record most recent status code. If used as a network printer. 1. return to Corrective Actions and make necessary repairs. • If more than 2000 copies have been made since last service call. Provide operator training if required.5 x 11 inch (A4) documents into the ADF. If a new Drum Cartridge was installed in machine and problem continues. 12. Ensure image quality meets specifications in Section 3. 10. • Final Actions In this section you will make sure that machine is feeding paper correctly. ADF Only: Load two (2) 8. Show copies to operator or Customer. 6. 7. 2. give Customer your estimated time of arrival. The Service Log and Change Tag Matrix (behind front door) may contain information related to machine problem. – – • 9. Initial Issue WorkCentre Pro 420 9/02 1-5 Service Call Procedures Call Flow Procedure . Perform GP 2 Main PWB Generated Image [1–1] to generate ROS Test Pattern. check network connection. ADF Only: Load two (2) 8. After responding to one or more of previous items in step 1. You will also make sure that machine appearance is satisfactory and that administrative tasks necessary to close out a service call are performed. If an image defect occurs only in printing mode. 10. and ask Customer to store cartridge. Load the document(s). Make copies (if possible) using Tray 1. Check that space requirements and power requirements for machine are met. service this status code. If an image defect occurs in copying mode (printing mode not relevant at this point). Press 0 button to display secondary codes. 7. reinstall old Drum Cartridge in machine. and any jammed paper is removed. put 10 documents in the ADF. Make copies (if possible) using Tray 1 (and Tray 2 if present). Bypass Tray. Without ADF: Place Standard test pattern on the Document Glass. go to OF 14-1 PRINTER RAP. Place remaining copy with Service Log. or if a status code is displayed. ADF Only: Using the copies from the first run. Examine copies for obvious image quality defects. Switch off power. • • Select a tray. and then switch on power. Make a record of copy count meter in Service Log. If a status code is displayed on Control Panel. Update Change Tag Matrix as required. Also record any changes that were made to NVM. 3. • • • • • • 2. Put new Drum Cartridge in packaging. 4. 4. 11. making copies free of defects. go directly to Final Actions to complete service call. At Account 5.Service Call Procedures Call Flow Procedure 9/02 1-6 Initial Issue WorkCentre Pro 420 .E1 RAP ing Fuser Switch E2–1: Paper can not actuate in time OCT Exit Sensor after leaving Fuser Exit Switch E2–2: Paper can not deactuate in time OCT Exit Sensor after leaving Fuser Exit Switch E5–0: Front Door or Side Door is open E6–1: Tray 1 Door interlock is open E6–2: Tray 2 Door interlock is open J1–0: Toner level is low J3–0: Drum Cartridge not installed or incorrectly installed J4–1: Billing Counter missing or not installed correctly J4–2: Billing Counter is not a FXSL uniqueware J4–3: Billing Counter unit type Error J6–1: CRUM Communication Error J6–3: Billing Counter Communication Error J7–0: Drum Cartridge reached end of service life J8–0: Drum Cartridge not correct J9–1: CRUM is not a FXSL uniqueware L9–1: Current login account has no credits U1–0: Drive Module speed signal failure U2–2: The Exposure Lamp not lit or black white strip not sensed U3–0: Laser not detected U4–0: Previous U4 Status Code not cleared U4–1: Fuser overtemperature condition (425° F) is sensed U4–2: Fuser warm up failure occurred U4–3: Fuser warm up time exceeded E2-1 RAP E2-2 RAP E5 RAP E6 RAP E6 RAP J1 RAP J3 RAP J4-1 RAP J4-2 RAP J4-3 RAP J6-1 RAP J6-3 RAP J7 RAP J8 RAP J9-1 RAP L9-1 RAP U1 RAP U2 RAP U3 RAP U4 RAP U4 RAP U4 RAP U4 RAP A2–1: After constant-speed feed motor is energized. Document can not A2-1 RAP deactivate in time Document Registration Sensor A2–2: After constant-speed feed motor is energized. or Tray 2 communication failure U6–4: NVM signal failure U7: Control Panel communication from Main PWB failure U8: Control Panel communication to Main PWB failure U9–0: A HVPS output is shorted or overloaded. or carriages failure U2 RAP C4–3: Tray 1 fed paper actuated Registration Sensor too early after Tray C4-3 RAP 1 Takeaway Motor energized C4–4: Tray 2 fed paper actuated Registration Sensor too early after Tray C4-4 RAP 2 Takeaway Motor energized C4–5: Two-side fed paper did not actuate Registration Sensor in time C4–6: Two-side fed paper actuated Registration Sensor too early C5–0: The Tray 1 Paper Sensor not actuated C6–0: The Tray 2 Paper Sensor not actuated C7–0: The Tray 1 Interlock Switch not actuated C8–0: The Tray 2 Interlock Switch not actuated C9–0: Tray 1 fed paper did not actuate Tray 1 Feed Sensor in time E1–1: Paper did not actuate Fuser Switch in time after Registration Clutch energized E1–2: The paper did not de-actuate Registration Sensor in time after actuating Fuser Switch C4-5 RAP C4-6 RAP C5 RAP C6 RAP C7 RAP C8 RAP C9 RAP E1 RAP E1 RAP U5–0: The Fuser temperature dropped below minimum temperature for U5 RAP more than 5 seconds U5–1: AC input power problem U6–0: Printer control communication failure U6–1: Drum Cartridge.Status Codes / Other Faults Listing Table 1 Status Codes Entry Chart Status Code / Description A1–1: Document can not actuate Pre Regi. document can not A2-2 RAP actuate in time Document Exit Switch A2–3: Document can not deactivate in time Document Exit Switch after A2-3 RAP deactivating Document Registration Sensor A5–0: ADF Cover is open C1–0: Tray 1 fed paper did not actuate Tray 1 Takeaway Sensor in time after Tray 1 Feed Motor energized C2–0: Tray 2 fed paper did not actuate Tray 2 Takeaway Sensor in time after Tray 2 Feed Motor energized A5 RAP C1 RAP C2 RAP C3–0: Bypass fed paper did not actuate Registration Sensor in time after C3 RAP Bypass Feed Solenoid energized C3–1: Bypass fed paper actuated Registration Sensor too early after Bypass Feed Solenoid energized C4–0: Tray 1 fed paper did not deactuate Tray 1 Feed Sensor in time C4–1: Tray 1 fed paper did not actuate Registration Sensor in time C4–2: Tray 2 fed paper did not actuate Registration Sensor in time C3 RAP C4-0 RAP C4-1 RAP C4-2 RAP U2–1: Scan Home Sensor circuit. Sensor after Document Solenoid is energized A2–0: Document can not actuate Document Registration Sensor after actuating Document Presence Sensor Corrective Action A1-1 RAP A2 RAP Table 1 Status Codes Entry Chart Status Code / Description Corrective Action E1–5: The paper did not de-actuate Exit Sensor in time after de-actuat. or intermittent U5 RAP U6 RAP U6 RAP U6 RAP U7 RAP U8 RAP U9 RAP E1–3: The paper did not de-actuate Fuser Switch in time after deactuat. Scan Drive Motor.E1 RAP ing Registration Sensor E1–4: The paper did not actuate Exit Sensor in time after actuating Fuser Switch E1 RAP Initial Issue WorkCentre Pro 420 9/02 1-7 Service Call Procedures Status Codes / Other Faults Listing . or Tray 1.Table 2 Other Faults Entry Chart Other Fault Description Cooling Fan not operating Control Panel is blank Scanning problem Paper Tray problem Audible Noise / Odor problem Print problems Corrective Action OF 1-3 COOLING FAN RAP OF 2-1 BLANK DISPLAY RAP U2 RAP OF 7-1 PAPER TRAY RAP OF 16-1 NOISE or ODOR RAP OF 14-1 PRINTER RAP Copies/prints exit machine in non-standard or dam.OF 8-1 PAPER DAMAGE or STACKaged condition ING RAP Intermittent copier/printer operation Ground Checkout Diagnostics not available OF 16-2 GROUND RAP OF 16-2 GROUND RAP U2 RAP Service Call Procedures Status Codes / Other Faults Listing 9/02 1-8 Initial Issue WorkCentre Pro 420 . Clean top of Document Glass with Lens and Mirror cleaner and a Lint–Free Cloth. 7. Clean Registration Roll and Idler Roll • • • • Materials Film Remover/General Cleaning Solvent Lint–Free Cloth Film Remover/General Cleaning Solvent Lint–Free Cloth Initial Issue WorkCentre Pro 420 9/02 1-9 Service Call Procedures Periodic Maintenance. or an Image Quality RAP. Image Quality defects will occur if RIS Module is not vacuumed before reinstalling Document Glass. • • • Materials Lens and Mirror Cleaner Lint–Free Cloth Vacuum Cleaner Table 2 Paper Feed and Registration Subsystem Maintenance Procedures Perform this activity when given direction in Call Flow. whenever component is made accessible during repair of machine. 5. Make a copy to run Cooling Fan. a Status Code. NOTE: While performing a repair in a RAP. Clean any component that appears contaminated with dirt. When returning here after a repair. If fan is not operating go to OF 1-3 Cooling Fan RAP.11) and Bypass Retard Pad (PL 6. Procedure 1. b.1). Clean Bypass Feed Roll CAUTION Do not clean Retard Pad. 4. an Other Fault. Table 1 Optics Subsystem Maintenance Procedures Perform this activity whenever Document Glass (REP 6. Go to OF 16-2 Ground RAP and perform Ground Check. Do Copy Transportation and Fusing Maintenance Procedures (Table 4).12). Procedure Service following components as directed.4) (REP 10. Do Paper Feed and Registration Maintenance Procedures (Table 2). c.5) is completely removed. Maintenance Procedures This section contains a list of machine subsystem components to be maintained and suggested materials and procedures to be used.3) (REP 8. Maintenance Procedures . Do Document Feeder maintenance procedures (Table 5). Do Xerographic maintenance (Table 3). You will be referred here from Periodic Maintenance. Replace Fuser Module (PL 1. Clean Document Cover Pad with Lens and Mirror Cleaner and a Lint–Free Cloth.2) (REP 8. Perform GP 9 R. 6. 3. you may be directed to perform one or more following activities. 8. paper dust. CAUTION If bottom of Document Glass is cleaned.Periodic Maintenance Activities to perform if 2K copies or 20 days elapsed since last service call. skip what is already serviced. or dry imager. 2. Replace Bypass Feed Roll (PL 6. Every 125K copies: a. • • Vacuum Cleaner Clean Drum Cartridge contacts Lint–Free Cloth Film Remover/General Cleaning Solvent Table 4 Copy Transportation and Fusing Subsystem Maintenance Procedures Perform this activity when given direction in Call Flow or RAP’s Clean Fuser Roll Clean Exit Rollers. • • Film Remover/General Cleaning Solvent Heavy Duty Towel/Cleaning Cloth. Clean Registration Roll and Idler Roll. Clean any toner from Drum Cartridge. Clean Transfer/Detack Corotron housing with a soft brush. • Materials Cotton Swab Soft Brush Film Remover/General Cleaning Solvent Lint–Free Cloth Reg Roll • Reg Roll • • Reg Roll Contacts Figure 1 Registration Clean Transfer Roll Contact with a Lint–Free Cloth and Film Remover/ General Cleaning Solvent. Clean Transfer Detack contacts and corresponding contacts on HVPS with a Lint–Free Cloth and Film Remover/ General Cleaning Solvent.1). Materials Make 10 copies of a white document.• ton swab to remove • Toner.Table 2 Paper Feed and Registration Subsystem Maintenance Procedures Perform this activity when given direction in Call Flow. Service Call Procedures Maintenance Procedures 9/02 1-10 Initial Issue WorkCentre Pro 420 . • Clean Transfer/Detack • Corotron wire with a cot. Clean Registration Roll Contacts • • Materials Film Remover/General Cleaning Solvent Lint–Free Cloth Table 3 Xerographics Subsystem Maintenance Procedures Perform this activity when given direction in Call Flow. Reg Roll Transfer Detack Contacts Corotron Corotron Figure 2 Transfer • • Remove Drum Cartridge • (REP 9. If the bottom of CVT glass is contanimated. Output Roll. Output Pressure Roll. Remove offset Receiving Tray (REP 5. Film Remover/General Cleaning Solvent Lint-Free Cloth. do GP9 RIS/Mirror • cleaning. Clean CVT Roll • • Clean Exit Roll/Idler Roll • • CAUTION Image Quality defects will occur if machine is on and cleaning solutions are used on covers. Switch off machine before cleaning so that Cooling Fan is off. Cooling Fan may draw cleaning solution vapor into machine. gentle push • Roll. • Clean CVT glass pad. • • Materials Film Remover/General Cleaning Solvent Lint-Free Cloth. Exit Roll and • CVT Roll.3) to approach Feed Roll and gentle push Roll. Materials Formula A/All Purpose Cleaner Heavy Duty Towel/Cleaning Cloth Film Remover/General Cleaning Solvent Lint-Free Cloth. CVT Roll Exit Roll/Idler Roll Figure 3 Registration Initial Issue WorkCentre Pro 420 9/02 1-11 Service Call Procedures Maintenance Procedures . Table 6 Covers Subsystem Maintenance Procedures Perform this activity when given direction in Call Flow or RAP’s Clean covers as necessary.Table 5 Document Feeder (ADF) Subsystem Maintenance Procedures Perform this activity when given direction in Call Flow or RAP’s Clean Feed Roll. Film Remover/General Cleaning Solvent Lint-Free Cloth.Service Call Procedures Maintenance Procedures 9/02 1-12 Initial Issue WorkCentre Pro 420 ............................ U1 RAP .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. U9 RAP ............ U3 RAP ............................................................................................................................................ C6 RAP ........................... U6 RAP ................................................................ C2 RAP ................................................................................................................................................................................................................................................................................... OF 16-2 GROUND RAP.......................... OF 7-1 PAPER TRAY RAP.............................................................................. U8 RAP.................................................................................................................................................... J7 RAP .................................................................................................................................................................. U7............................... A2 RAP ............................................................................................................................2 Status Indicator RAP/Other Faults Status Indicator RAPs +5VDC POWER RAP.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... J6 RAP ................................................................................................................................................................................................................................................................. J8 RAP ................................................. C8 RAP .................................................... C9 RAP .................................................................................................................................................................. J6 RAP ................... C3 RAP ..... E2 RAP ........................................................................................................................................................ C7 RAP ........................................................... 2-3 2-3 2-4 2-8 2-11 2-12 2-14 2-16 2-18 2-19 2-20 2-21 2-22 2-23 2-27 2-31 2-32 2-32 2-33 2-33 2-33 2-33 2-34 2-35 2-36 2-38 2-40 2-42 2-43 2-44 2-46 2-47 2-48 2-51 2-54 2-58 2-60 2-62 2-64 2-66 Other Faults OF 1-1 CONTROL PANEL RAP .............................................................................................................. C4 RAP ............ J4 RAP ............................................................................................................................................................................................................................. J3 RAP ............................................................................................................................ U2 RAP ................ OF 2-1 BLANK DISPLAY RAP. C5 RAP ........... U4 RAP ................................................................................................................................................................................................................................ OF 1-2 MACHINE RUN RAP ............. Initial Issue WorkCentre Pro 420 9/02 2-1 Status Indicator RAP/Other Faults ........................................................................................................................................... OF 16-1 NOISE or ODOR RAP ............................................................................................................... OF 8-1 PAPER DAMAGE or STACKING RAP ......................................................... U5 RAP ............... J9 RAP .......................................................................................... E1 RAP ...... C1 RAP ......................... +24VDC POWER RAP.................................................................................................................................................................................................................................................................................................................. J1 RAP .......... OF 1-3 COOLING FAN RAP ........................................ OF 14-1 PRINTER RAP ................................... A1 RAP ..............................................................................................................Status Indicator RAP/Other Faults 9/02 2-2 Initial Issue WorkCentre Pro 420 . Replace POWER SUPPLY PWB Replace LVPS.+5VDC POWER RAP CR2 on MAIN PWB is turned on. Y N Reconnect MAIN PWB and LVPS. +24VDC POWER RAP The voltage between P/J102-(+) and GND(-) on MAIN PWB has +24VDC. Y N Check the voltage between ACN and ACH on POWER CORD. Initial Issue WorkCentre Pro 420 9/02 2-3 Status Indicator RAP/Other Faults A1 . Y N The voltage between P/J205-2 and P/J205-3 on LVPS has approximately 110/ 220VAC. check the customer's power supply. Y N Check the power cord. This connection is in good condition. Turn ON the power. Replace MAIN PWB. Check the voltage between P109-C9(+) and GND(-) on MAIN PWB. Y N Check the power cord. Replace MAIN PWB. Y N Turn OFF the power. Approximately 110/220VAC are measured. Turn ON the power. Y N The voltage between P/J205-2 and P/J205-3 on LVPS has approximately 110/ 220VAC. Approximately +5VDC is measured. Replace POWER SUPPLY PWB Replace LVPS. Check the Connection between P/J 109 on MAIN PWB and LVPS. Check the wire between MAIN PWB and the applicable component for an open circuit or poor contact by referring to BSD CHI. Check the wire between MAIN PWB and the applicable component for an open circuit or poor contact by referring to BSD CHI. Y N Turn OFF the power. Y N Check the Voltage between ACN and ACH on POWER CORD. check the customer's power supply. Approximately +24VDC is measured. If no problems are found. Check the connection between P/J 109 on MAIN PWB and LVPS. This connection is in good condition. Approximately 110/220VAC are measured. Y N Reconnect MAIN PWB and LVPS. Check the Voltage between P109-A31(+) and GND(-) on MAIN PWB. If no problems are found. Y N Remove ADF Rear Cover. Initial Actions • • • Ensure ADF hinges firmly lean against Top Cover. Procedure Remove ADF drive cover and offset catch tray. Y N The voltage between Pin 2(+) and GND(-) on Nudger Solenoid has +24VDC. The gentle push roll must rapidly moves down and up. Ensure ADF is securely closed. Y N Y N Y N Y N Y N Y N Y N Y N Y N Y N Y N Y N Y N Y N Status Indicator RAP/Other Faults A1 9/02 2-4 Initial Issue WorkCentre Pro 420 . Ensure offset catch tray is correctly installed if it was removed recently.A1 RAP A1–1: Document can not actuate Pre Regi Sensor after Document Solenoid is energized. Y N The voltage between Pin 1(+) and GND(-) on Nudger Solenoid has 0VDC. Repair as required. Enter [5-5] and turned ON. Observe the gentle push roll when switching on or off power source of machine. The voltage between P/J605-4(+) and GND(-) on ADF PWB has +24VDC. Check the wire between P/J103-10 on MAIN PWB and P/J603-10 on ADF PWB for an open circuit or poor contact.3VDC. Replace ADF PWB. Y N The voltage between Pin 2(+) and GND(-) on Document Feed Clutch has +24VDC. Check the wire between P/J103-2 on MAIN PWB and P/J603-21 on ADF PWB for an open circuit or poor contact. the voltage between P/J103-1(+) and GND(-) on MAIN PWB has approximately +1. the voltage between P/J601-2(+) and GND(-) on ADF PWB has approximately +10VDC. Enter[5-7] and press START button. Y N The voltage between P/J103-10(+) and GND(-) on MAIN PWB has +5VDC. When [5-1] is turned ON. Y N When [5-1] is turned ON. Y N When [5-1] is turned ON. When [5-1] is turned ON. Enter [5-9]. the voltage between P/J603-3(+) and GND(-) on ADF PWB has approximately +5VDC. the voltage between P/J103-3(+) and GND(-) on MAIN PWB has approximately +10VDC. Y N Replace MAIN PWB. When [5-1] is turned ON. Check the wire between P/J605-1 on ADF PWB and Pin 2 on Document Feed Clutch for an open circuit or poor contact. The voltage between P/J605-5(+) and GND(-) on ADF PWB has +24VDC Y N GO TO +24VDC Power FIP.B CVT Motor rotates. the voltage between P/J605-1(+) and GND(-) on ADF PWB has +24VDC. the voltage between P/J603-1(+) and GND(-) on ADF PWB has approximately +1. Y N When [5-1] is turned ON. the voltage between P/J603-2(+) and GND(-) on ADF PWB has approximately +10VDC. D C Initial Issue WorkCentre Pro 420 9/02 2-5 Status Indicator RAP/Other Faults A1 . the voltage between P/J603-3(+) and GND(-) on ADF PWB has approximately +5VDC. Y N When [5-7] is turned ON. Check the wire between P/J605-5 on ADF PWB and Pin 1 on Document Feed Clutch for an open circuit or poor contact. Y N Replace MAIN PWB.3VDC. Check wire between P/J103-1 on MAIN PWB and P/J603-1 on ADF PWB for an open circuit or poor contact. C Document Feed Clutch is energized. Y N The voltage between Pin 1(+) and GND(-) on Document Feed Clutch has 0VDC. Y N Replace MAIN PWB. Y N Replace MAIN PWB. Y N The Voltage between P/J602-1(+) and GND(-) on ADF PWB has +24VDC. The voltage between P/J603-10(+) and GND(-) on ADF PWB has +5VDC. Replace CVT MOTOR. Y N When [5-1] is turned ON. Y N Replace Nudger Solenoid. Check the wire between P/J103-3 on MAIN PWB and P/J603-3 on ADF PWB for an open circuit or poor contact. replace the Document Presence Sensor. replace Document Presence Sensor. If no problems are found. "1"(Low) is displayed. Manually rotate counter-clockwise CVT Roll ( opposite to normal direction) to check the rotation of Feed Rolls. If pre-input appears slow. clean or replace Feed Roll/Gentle push Roll. If the failure of A1 status code continues. Enter [5-7]. If no problems are found. Y N Check the circuit between Pin 2 on Document Presence Sensor and P/J103-18 on MAIN PWB for a short circuit. E Status Indicator RAP/Other Faults A1 9/02 2-6 Initial Issue WorkCentre Pro 420 . • • • Check for contamination and improper installation of the Sensor. repeat the test while observing document and drive. Remove the blank sheet of paper from the Sensor. Y N Block the Document Presence Sensor with a blank sheet of paper. Y N Go to +5VDC Power FIP. Y N Remove the connector of Document Presence Sensor. replace Document Presence Sensor. Enter [5-14] and press START button. If the failure of A1-1 Status Code continues. Check installation of the Sensor and the extraneous light diffraction. Repair as required. The voltage between Pin 1(+) and Pin 3(-) on Document Presence Sensor has +5VDC. enter [7] and press START button. "0"(High) is displayed. Y N The voltage between Pin 2(+) and GND(-) on Document Presence Sensor has +5VDC. Close ADF feed door. • Between P/J605-12 on ADF PWB and Pin 3 on Document Presence Sensor for an open circuit or poor contact. replace MAIN PWB. display should change between "0" and "1". Y N The voltage between P/J605-10(+) and P/J605-12(-) on ADF PWB has +5VDC. If document is stopped or blocked. If no problems are found. If no problems are found. replace MAIN PWB. When CVT MOTOR rotates. and Document Feed Roll is rotated. replace Document Feed Clutch. Check installation of the Sensor. E Document Feed Clutch is energized. The display should change to "0" (High). Y N Check the wire between Pin 2 on Document Presence Sensor and P/J103-18 on MAIN PWB for an open circuit or poor contact. • • Check CVT feed area for obstruction.D Use hand or paper to actuate or deactuate Document Presence Sensor. Check wire of the following: • Between P/J605-10 on ADF PWB and Pin 1 on Document Presence Sensor for an open circuit or poor contact. Enter [5-1] and press START button. put in a sheet of document in Document Feed Tray. Document Feed Clutch is energized. Y N Check the mechanical load of Document Feed Roll. Document should be fed and reach Document Exit Tray.Initial Issue WorkCentre Pro 420 9/02 2-7 Status Indicator RAP/Other Faults A1 . "1"(Low) is displayed. Use hand or paper to actuate or deactuate Document Registration Sensor. A2–1: After constant-speed feed motor is energized. Y N Check wire between Pin 2 on Document Registration Sensor and P/J103-17 on MAIN PWB for an open circuit or poor contact. Y N Replace MAIN PWB. Check installation of the Sensor. The voltage between Pin 1(+) and Pin 3(-) on Document Registration Sensor has +5VDC. When [5-1] is turned ON. Y N When [5-1] is turned ON. Y N When [5-1] is turned ON. document can not deactivate in time Document Registration Sensor.3VDC. Document should be fed and reach Document Exit Tray. Initial Actions Ensure CVT glass is faced steadily to the registration edge. If no problems are found. Y N The voltage between P/J609-1(+) and P/J609-3(-) on ADF PWB has +5VDC. If no problems are found. "0"(High) is displayed. Remove the blank sheet of paper from the Sensor. put in a sheet of document in Document Feed Tray. Y N Remove the connector of Document Registration Sensor. replace Document Registration Sensor. the voltage between P/J603-1(+) and GND(-) on ADF PWB has approximately +1. If no problems are found. Check wire between P/J103-2 on MAIN PWB and P/J603-2 on ADF PWB for an open circuit or poor contact. Ensure ADF hinges lean steadily against top cover. If no problems are found. Y N Replace MAIN PWB. Replace CVT MOTOR. repeat the test while observing document and drive. Y N Block the Document Registration Sensor with a blank sheet of paper. Check the wire between P/J103-1 on MAIN PWB and P/J603-1 on ADF PWB for an open circuit or poor contact. Y N Go to +5VDC Power FIP Check wire of the following: • Between P/J609-1 on ADF PWB and Pin 1 on Document Registration Sensor for an open circuit or poor contact. Y N Replace MAIN PWB. the voltage between P/J103-1(+) and GND(-) on MAIN PWB has approximately +1. Y N Check the circuit between Pin 2 on Document Registration Sensor and P/J10317 on MAIN PWB for a short circuit. clean GP9 RIS /reflector.A B C Check installation of the Sensor and the extraneous light diffraction. Procedure Enter [5-11]. replace Document Registration Sensor. Check CVT document transport area for obstruction. Enter [5-1] and press START button CVT Motor rotates. the voltage between P/J603-2(+) and GND(-) on ADF PWB has approximately +10VDC. Y N When [5-1] is turned ON. When [5-1] is turned ON. the voltage between P/J103-3(+) and GND(-) on MAIN PWB has approximately +10VDC. The display should change to "0"(High). If top cover is removed. Enter [5-14] and press START button. replace Document Registration Sensor. Y N The voltage between Pin 2(+) and GND(-) on Document Registration Sensor has +5VDC. Y N The voltage between P/J602-1(+) and GND(-) on ADF PWB has +24VDC. the voltage between P/J103-2(+) and GND(-) MAIN PWB has approximately +10VDC. Close ADF feed door. • Between P/J609-3 on ADF PWB and Pin 3 on Document Registration Sensor for an open circuit or poor contact. When [5-1] is turned ON. Check for contamination and improper installation of the Sensor.3VDC. If the failure of either A2-0 or A2-1 Status Code continues. the voltage between P/J601-2(+) and GND(-) on ADF PWB has approximately +10VDC. If document is stopped or blocked. A2 RAP A2–0: Document can not actuate Document Registration Sensor after actuating Document Presence Sensor. Check wire between P/J103-3 on MAIN PW and P/J603-3 on ADF PWB for an open circuit or poor contact. Ensure ADF feed door is securely closed. • • A A B Status Indicator RAP/Other Faults A2 9/02 2-8 Initial Issue WorkCentre Pro 420 . replace MAIN PWB. Y N When [5-1] is turned ON. the voltage between P/J603-3(+) and GND(-) on ADF PWB has approximately +5VDC. display should change between "0" and "1". replace MAIN B C PWB. Check wire between P/J103-2 on MAIN PWB and P/J603-21 on ADF PWB for an open circuit or poor contact. replace Document Exit Switch. Y N Check the circuit between Pin 1 on Document Exit Switch and P/J103-19 on MAIN PWB for a short circuit. the voltage between P/J103-3(+) and GND(-) on MAIN PWB has approximately +10VDC.A A2–2: After constant-speed feed motor is energized. Y N Remove the connector of Document Exit Switch. Y N Block the Document Exit Switch with a blank sheet of paper.3VDC. Remove the blank sheet of paper from the Sensor. the voltage between P/J103-2(+) and GND(-) on MAIN PWB has approximately +10VDC. Enter [5-1] and press START button.3VDC. Initial Actions Ensure CVT glass is faced steadily to the registration edge. put in a sheet of document in Document Feed Tray. document can not actuate in time Document Exit Switch. Check wire between Pin 2 on Document Exit Switch and P/J609-5 on ADF PWB for an open circuit or poor contact. When [5-1] is turned ON. Replace Document Exit Switch. The display should change to "0"(High). Y N When [5-1] is turned ON. If no problems are found. voltage between P/J601-2(+) and GND(-) on ADF PWB has approximately +10VDC. A2–3: Document can not deactivate in time Document Exit Switch after deactivating Document Registration Sensor. Y N Check wire between Pin 1 of Switch and P/J103-19 on MAIN PWB for an open circuit or a poor contact. If the failure of either A2-2 or A2-3 Status Code continues. Document should be fed and reach Document Exit Tray. Check wire between P/J103-3 on MAIN PWB and J603-3 on ADF PWB for an open circuit or poor contact. If document is stopped or blocked. Y N When [5-1] is turned ON. replace MAIN PWB. Procedure Enter [5-12]. replace ADF PWB. repeat the test while observing document and drive. • • A Initial Issue WorkCentre Pro 420 9/02 2-9 Status Indicator RAP/Other Faults A2 . Turned ON/OFF the Document Exit Switch with a blank sheet of paper. the voltage between J603-2(+) and GND(-) on ADF PWB has approximately +10VDC. Display should change between "0" and "1". When [5-1] is turned ON. Enter [5-14] and press START button. CVT Motor rotates. Y N Replace MAIN PWB. clean GP9 RIS /reflector. The display should change to "0"(High). If top cover is removed. Y N The voltage between P/J602-1(+) and GND(-) on ADF PWB has +24VDC. Y N When [5-1] is turned ON. Replace CVT MOTOR. Ensure ADF hinges lean steadily against top cover. If no problems are found. Y N The voltage between Pin 1(+) and GND(-) on Document Exit Switch has +5VDC. Ensure ADF feed door is securely closed. Check wire between P/J103-1 on MAIN PWB and P/J603-1 on ADF PWB for an open circuit or poor contact. Check Actuator for damage or breakage. Y N Replace MAIN PWB. If no problems are found. Close ADF feed door. Y N Replace Document Exit Switch. replace MAIN PWB. Check attachment of SWITCH. When [5-1] is turned ON. the voltage between P/J603-1(+) and GND(-) on ADF PWB has approximately +1. Y N When [5-1] is turned ON. Y N Replace MAIN PWB. The voltage between Pin 2(+) and GND(-) on Document Exit Switch has +5VDC. the voltage between P/J603-3(+) and GND(-) on ADF PWB has approximately +5VDC. Check CVT document transport area for obstruction. the voltage between P/J103-1(+) and GND(-) on MAIN PWB has approximately +1. "1"(Low) is displayed. Status Indicator RAP/Other Faults A2 9/02 2-10 Initial Issue WorkCentre Pro 420 . Y N Close ADF Cover. Procedure ADF Cover Interlock Switch is turned ON by hand. Replace ADF PWB. Check damage of ADF Interlock Switch Actuator and attachment of ADF Cover. The voltage between P/J605-2(+) and GND(-) on ADF PWB has +24VDC. The voltage between P/J603-15(+) and GND(-) on ADF PWB has +5VDC. Adjustment with ADF Cover and ADF Interlock Switch is poor. Y N Close ADF Cover. The voltage between P/J103-15(+) and GND(-) on MAIN PWB has +5VDC.A5–0: ADF Cover is open. If no problems are found. Y N The voltage between P/J602-1(+) and GND(-) on ADF PWB has +24VDC. Y N Check wire between P/J603-15 on ADF PWB and P/J103-15 on MAIN PWB for an open circuit or poor contact. Replace ADF PWB. Y N Replace MAIN PWB. A5-0 is gone off. The voltage P/J605-1(+) and GND(-) on ADF PWB has +24VDC. Check the wire between P/J605 on ADF PWB and ADF Cover Interlock Switch for an open circuit or poor contact. Y N Go to +24VDC Power FIP. replace ADF Cover Interlock Switch. Replace Tray 1 Feed Motor. Refer to label on paper tray and reinstall paper. Y N When [7-13] is turned ON.A C1 RAP C1–0: Tray 1 fed paper did not actuate Tray 1 Takeaway Sensor in time after Tray 1 feed motor is energized. Y N Block Tray 1 Takeaway Sensor with a blank sheet of paper. A Initial Issue WorkCentre Pro 420 9/02 2-11 Enter [7-7]. Y N Clear paper path and ensure no mechanical resistance. Replace Feed Roll and Retard Roll. replace Tray 1 Takeaway Sensor. Y N The voltage between Pin 1(+) and GND(-) on Tray 1 Takeaway Sensor has +5VDC. If no problems are found. Enter [7-11] and ON. the voltage between P/J403-1(+) and GND(-) on Tray 1 Control PWB has approximately +16VDC. replace Tray 1 Takeaway Sensor. Use hand or paper to actuate or deactuate Tray 1 Takeaway Sensor. Make a copy. Replace Tray 1 Control PWB. Enter [7-13]. Remove Tray 1. Y N Go to +24VDC Power RAP. Remove the blank sheet of paper. If Feed Rolls can not operate. Y N Make machine enter diagnostic state. Y N Go to +24VDC Power RAP. If no problems are found. Check installation of the Sensor and the extraneous light diffraction. The display should change to "0"(High). the voltage between P/J408-2(+) and GND(-) on Tray 1 Control PWB has +24VDC. Procedure Clear C1 status code. Feed rolls rotate. Y N When [7-11] is turned ON. replace Tray 1 Takeaway Sensor. Y N Check circuit between Pin 1 on Tray 1 Takeaway Sensor and P/J405-2 on Tray 1 Control PWB for a short circuit. Y N The voltage between P/J402-1(+) and GND(-) on Tray 1 Control PWB has +24VDC. Y N The operating sound of the Tray 1 Feed Motor is audible. Check Paper Guides are adjusted to the set paper size and properly laid. check and clean Feed Roll and Retard Roll to see if they are aging. Replace Tray 1 Feed Clutch. Tray 1 Feed Clutch is in good condition. If no problems are found replace Tray 1 Control PWB. The voltage between Pin 3(+) and Pin 2(-) on Tray 1 Takeaway Sensor has +5VDC. After C1. Y N The voltage between P/J408-1(+) and GND(-) on Tray 1 Control PWB has +24VDC. replace Tray 1 Control PWB. Y N Go to +5VDC Power FIP. Replace Tray 1 Control PWB. remove rear cover. Y N Check the voltage between Pin 1 on Tray 1 Takeaway Sensor and PWB P/J4052 on Tray 1 Control. Check the following: • Between P/J405-1 on Tray 1 Control PWB and Pin 3 on Tray 1 Takeaway Sensor for an open circuit or poor contact. replace Clutch. Check installation of the Sensor. Status Indicator RAP/Other Faults C1 . display should change between "0" and "1". Replace Tray 1 Control PWB. • Between P/J405-3 on Tray 1 Control PWB and Pin 2 on Tray 1 Takeaway Sensor for an open circuit or poor contact Check for contamination and improper installation of the Sensor. "0"(High) is displayed. Y N Remove connector of Tray 1 Takeaway Sensor. Paper is at the Takeaway roll. Repair as required. If no problems are found. Eliminate mechanical failure. press START button and check Feed rolls. Check Tray 1 Takeaway Sensor for mechanical failure. Y N The voltage between P/J405-1 (+) and P/J405-3(-) on Tray 1 Control PWB has +5VDC. If the failure of C1-0 Status Code continues. Y N The voltage between P/J402-1(+) and GND(-) on Tray 1 Control PWB has +24VDC. and open Tray 1 Access Door. Initial Actions • • Remove paper from tray and fan it to ensure edges are separated. "1"(Low) is displayed. Eliminate mechanical failure. Check Paper Guides are adjusted to the set paper size and properly laid. Y N The voltage between P/J402-1(+) and GND(-) on Tray 2 Control PWB has +24VDC. Y N The operating sound of the Tray 2 Feed Motor is audible. Replace Tray 2 Control PWB. Remove Tray 2. Replace Tray 2 Control PWB. Check installation of the Sensor. Y N When [7-14] is turned ON. replace Tray 2 Takeaway Sensor. If the failure of C1-0 Status Code continues. display should change between "0" and "1". Status Indicator RAP/Other Faults Initial Issue WorkCentre Pro 420 C2 . After C2. Use hand or paper to actuate or deactuate Tray 2 Takeaway Sensor. Tray 2 Feed Clutch is in good condition. A B 9/02 2-12 Replace Feed Roll and Retard Roll. press START button and check Feed rolls. Check installation of the Sensor and the extraneous light diffraction. Check for contamination and improper installation of the Sensor. If Feed Rolls can not operate. Replace Tray 2 Control PWB. replace Tray 2 Takeaway Sensor. The voltage between Pin 3(+) and Pin 2(-) on Tray 2 Takeaway Sensor has +5VDC. "1"(Low) is displayed. replace Tray 2 Takeaway Sensor. Y N The voltage between Pin 1(+) and GND(-) on Tray 2 Takeaway Sensor has +5VDC. The display should change to "0"(High) Y N Check circuit between Pin 1 on Tray 2 Takeaway Sensor and P/J405-2 on Tray 2 Control PWB for a short circuit. Y N When [7-12] is turned ON. If no problems are found. Procedure Clear C2 status code. Replace Tray 2 Feed Clutch. Y N Remove connector of Tray 2 Takeaway Sensor. Enter [7-14]. replace Clutch. Enter [7-12] and ON. If no problems are found. Y N Go to +24VDC Power RAP. Reinstall paper. Make a copy. the voltage between P/J403-1(+) and GND(-) on Tray 2 Control PWB has approximately +16VDC. replace Tray 2 Control PWB. Repair as required. Y N The voltage between P/J405-1 (+) and P/J405-3(-) on Tray 2 Control PWB has +5VDC. Y N Go to +5VDC Power FIP. check and clean Feed Roll and Retard Roll to see if they are aging. Refer to label on paper tray. Enter [7-8]. Y N Check the voltage between Pin 1 on Tray 2 Takeaway Sensor and PWB P/J4052 on Tray 2 Control. Initial Actions • • • Make a copy using Tray 1. B Y N Clear paper path and ensure no mechanical resistance. If no problems are found replace Tray 2 Control PWB. and open Tray 2 Access Door and Tray 1 Access Door. If no problems are found. the voltage between P/J408-2(+) and GND(-) on Tray 2 Control PWB has +24VDC. Y N Block Tray 2 Takeaway Sensor with a blank sheet of paper. to RAP Takeaway Tray 1 status code. Check Tray 2 Takeaway Sensor for mechanical failure. Y N The voltage between P/J408-1(+) and GND(-) on Tray 2 Control PWB has +24VDC. Feed rolls rotate. Remove paper from tray and fan it to ensure edges are separated. Check the following: • Between P/J405-1 on Tray 1 Control PWB and Pin 3 on Tray 2 Takeaway Sensor for an open circuit or poor contact. Replace Tray 2 Feed Motor. Y N Make machine enter diagnostic state. remove Rear Cover and Rear Cover of Tray 2.A C2 RAP C2–0: Tray 2 fed paper did not actuate Tray 2 Takeaway Sensor in time after Tray 2 Feed Motor energized. Remove the blank sheet of paper. Y N Go to +24VDC Power RAP. A sheet of paper is in Tray 2 Access Door. • Between P/J405-3 on Tray 1 Control PWB and Pin 2 on Tray 2 Takeaway Sensor for an open circuit or poor contact. If a status code is displayed. "0"(High) is displayed. Y N The voltage between P/J402-1(+) and GND(-) on Tray 2 Control PWB has +24VDC.Initial Issue WorkCentre Pro 420 9/02 2-13 Status Indicator RAP/Other Faults C2 .A C3 RAP C3–0: Bypass fed paper did not actuate IOT Registration Sensor in time after Bypass Feed Solenoid energized. Bypass feed sequence depends on Sector Gear Spring being in position shown. Bypass Feed Solenoid should be energized. Y N Lift Plate Cam is out of position. Bypass Feed Solenoid energizes. Bypass Feed Solenoid or Door Module. Check that 50 sheets fit under Bypass Feed Roll. In this position. Load 10 sheets of paper in Bypass Tray. Connect Bypass Feed Solenoid plug to P308 on PCM interface PWB. Check position of Paper Lift Plate. replace Sector Gear. Approximately +24 VDC is measured. Voltage should change from +0. replace MAIN PWB then. • Sector Gear Spring should be in position shown. Measure resistance (ohms) between two wires of Bypass Feed Solenoid plugs. Replace failed component if Sector Gear can be rotated clockwise without stopping. Ensure Slot is present. Initial Actions • • Turn paper so that topside faces down. Bypass Solenoid measures approximately 41 ohms or less. 50 sheets of paper fit. Lift Plate Cam Follower should be on high part of Lift Plate Cam. Ensure slot is present.1VDC to +6VDC. • Open Door Module. • Manually rotate Sector Gear counterclockwise. C3–1: Bypass fed paper actuated IOT Registration Sensor too early after Bypass Feed Solenoid energized. Procedure Select Bypass Tray and make a copy. unless Bypass Solenoid energizes. replace Door Module. Measure voltage at J311-10 on PCM interface PWB. Sector Gear Spring should be connected as shown and be free of damage. Copy is delivered and machine is ready. Sector Gear cannot be rotated clockwise (direction of normal operation). Observe Paper Lift Plate and make 10 copies. Perform or Check the following. Sector Gear is free of damage. If there is problem with Sector Gear. Check Paper Guides are adjusted to paper without pinching or squeezing paper. Paper Lift Plate lifts lead edge of paper up to Bypass Feed Roll before a C3 occurs. observe Bypass Feed Solenoid and press START button. Y N Replace LVPS first. Sector Gear Spring. Sector Gear Spring is connected as shown and is free of damage. Exchanging lead edge for trail edge will not be effective. Check Bypass Feed Solenoid. B Y N Reinstall Sector Gear Spring or replace Door Module. Check Sector Gear Spring condition and installation. If Sector Gear goes wrong. unless Bypass Solenoid energized. • Check Sector Gear for damage or breakage. Paper Lift Plate must lift lead edge of paper to Bypass Feed Roll to feed. • Open Door Module. C A Status Indicator RAP/Other Faults Initial Issue WorkCentre Pro 420 C3 . while holding Lift Plate Cam Follower away from Lift Plate Cam until cam follower is at position shown in figure 2. Y N Disconnect Bypass Feed Solenoid plug from P308 on PCM interface PWB. Measure voltage at P211-10 on PCM PWB and press START button. Y N Go to corresponding status code RAP. Select Bypass Tray. Enter [8-6] Actuator of IOT Regi Sensor is turned ON/OFF by hand. Gap should be enough for 50 sheets of 80 g/m2. • Open Door Module. B 9/02 2-14 Resistance should be approximately 41 ohms or less. Y N Replace Door Module. Replace LVPS. In this position Sector Gear cannot be rotated clockwise (direction of normal rotation). if no effects. • Check Sector Gear for damage or breakage. Y N Replace PCM interface PWB. • Enter [8-5]. Y N Problem is either Sector Gear. There must be a gap between Bypass Feed Rolls and Pad on Paper Lift Plate. Y N Replace Bypass Feed Solenoid. Go into diagnostic mode and enter [8-5]. Check machine operation after doing each item. • Ensure Retard Pad Spring pushes Retard pad up against bottom of Bypass Feed Roll as required . check the connection between MAIN PWB and LVPS. If the failure of either C3-0 or C3-1 Status Code continues. The voltage between Pin 2(+)and Pin 3(-) on IOT Regi Sensor has +5VDC. • Check for obstructions in Bypass Exit Guides. The display should change to "0"(High). • Check gear on Bypass Takeaway Roll Shaft. (Including PCM PWB) If no problems are found. Check wire of the following: • Between J306-2 on PCM PWB and Pin 2 on IOT Regi Sensor for an open circuit or poor contact. Initial Issue WorkCentre Pro 420 9/02 2-15 Status Indicator RAP/Other Faults C3 . (Including PCM PWB). Y N Block Sensor with a blank sheet of paper. If the problem persists. MAIN PWB in sequence. "1"(Low) is displayed. Check Actuator for damage. check the connection between MAIN PWB and LVPS. replace IOT Regi Sensor. Y N Remove the connector of IOT Regi Sensor.A problem here may also result in an E1 status code. Y N Check the wire Pin 1 on IOT Regi Sensor and P/J211-3 on LVPS for an open circuit or poor contact. Paper Lift Plate failed to lift stack in a previous check. If no problems are found. If no problems are found. Check installation of the Sensor. replace LVPS. If no problems are found.C The display should change between "0" and "1". Remove the blank sheet of paper from the Sensor. • Between J306-3 on PCM PWB and Pin 3 on IOT Regi Sensor for an open circuit or poor contact Check for contamination and improper installation of the Sensor. The display should change to "0"(High) Y N Check the circuit between Pin 2 on IOT Regi Sensor and P/J211-3 on LVPS for a short circuit. • Clean or replace Bypass Feed Roll. Check idlers that are driven by Bypass Takeaway Roll Shaft. replace IOT Regi Sensor. Y N The voltage between J306-2(+) and J306-3(-) on PCM PWB has +5VDC. Y N The voltage between Pin 1(+) and GND(-) on IOT Regi Sensor has +5VDC. replace IOT Regi Sensor. If the problem persists. Y N Go to +5VDC Power RAP. replace LVPS. Check installation of the Sensor and the extraneous light diffraction. Replace Bypass Drives Kit. MAIN PWB in sequence. Actuator of IOT Regi Sensor is turned ON/OFF by hand. The voltage between Pin 3(+) and Pin 2(-) on Tray 1 Takeaway Sensor has +5VDC. Y N Enter [7-7]. replace Tray 1 Takeaway Sensor. Check wire between J302-1 and P402-1. replace wires. D • Initial Actions • • • • Remove paper from tray and fan it to ensure edges are separated. C4-4. The display should change to "0"(High). enter [7-13] and press START button to actuate Tray 1 Feed Motor. Y N Go to +24VDC Power RAP. Approximately +16VDC is measured. Approximately +24VDC is measured. Replace Tray 1 Control PWB. C4-1. Remove the blank sheet of paper from the Sensor. A B C D Status Indicator RAP/Other Faults E 9/02 2-16 Initial Issue WorkCentre Pro 420 C4 . replace Tray 1 Control PWB. Procedure Switch off machine. replace Tray 1 Takeaway Sensor. "1"(Low) is displayed. C4-2. If no problems are found. Measure voltage between any pin on Feed Motor P403 and ground. C4-5 or C4-6 Status Code continues. Refer to label on paper tray and reinstall paper. enter [7-13] and press START. C4-6: Two-side fed paper actuated Registration Sensor too early. If there is damage. "0"(High) is displayed. Gear is free to rotate. Manually rotate gear for Tray 1 Feed Motor. C4-3: Tray 1 fed paper actuated Registration Sensor too early after Tray 1 Feed Motor is energized. Between P/J405-3 on Tray 1 Control PWB and Pin 2 on Tray 1 Takeaway Sensor for an open circuit or poor contact Check for contamination and improper installation of the Sensor. Make machine go into diagnostic mode. Y N Check the circuit between Pin 1 on Tray 1 Takeaway Sensor and P/J405-2 on Tray 1 Control PWB for a short circuit. Check circuit of Tray 1 Feed Motor. Y N Measure voltage at P402-1 on Tray 1 Control PWB. Check installation of the Sensor and the extraneous light diffraction. Check wire of the following: • Between P/J405-1 on Tray 1 Control PWB and Pin 3 on Tray 1 Takeaway Sensor for an open circuit or poor contact. Enter [8-6]. Switch on machine. C4-4: Tray 2 fed paper actuated Registration Sensor too early after Tray 2 Feed Motor is energized. Y N Remove the connector of Tray 1 Takeaway Sensor. Check installation of the Sensor. Check that Inner Guide of Tray 1 Access Door is correctly installed. If no problems are found. Replace Tray 1 Feed Motor. C4-2: Tray 2 fed paper did not actuate Registration Sensor in time. If no problems are found. Y N Check Takeaway Roll Gear Module for mechanical failure. Go into diagnostic mode. C4-1: Tray 1 fed paper did not actuate Registration Sensor in time. If no problems are found. C4-3. Machine is ready to copy. Y N Go to +5VDC Power FIP. Approximately +24VDC is measured Y N Measure voltage at J302-1 on PCM interface PWB. Y N Check the wire between Pin 1 on Tray 1 Takeaway Sensor and P/J405-2 on Tray 1 Control PWB for an open circuit or poor contact. Ensure no jammed paper in machine.A B C C4 RAP C4-0: Tray 1 fed paper did not deactuate in time. Y N The voltage between Pin 1(+) and GND(-) on Tray 1 Takeaway Sensor has +5VDC. C4-5: Two-side fed paper did not actuate Registration Sensor in time. replace Tray 1 Takeaway Sensor. Y N The voltage between P/J405-1(+) and P/J405-3(-) on Tray 1 Control PWB has +5VDC. Takeaway Rolls rotate. Y N Remove Rear Cover. Check that idler Roll Spring on Tray 1 Access Door pushes idler rolls against Takeaway Rolls. If the failure of either C4-0. Check Paper Guides are adjusted to the set paper size and properly laid. Block Tray 1 Takeaway Sensor with a blank sheet of paper. replace Tray 1 Control PWB. F Initial Issue WorkCentre Pro 420 9/02 2-17 Status Indicator RAP/Other Faults C4 . check the connection between MAIN PWB and LVPS. Manually rotate Tray 2 Feed Motor. If the failure of either C4-0. If no problems are found. Go into diagnostic mode. C4-5 or C4-6 Status Code continues. Y N Measure voltage at J302-1 on PCM interface PWB. Y N The voltage between Pin 1(+) and GND(-) on IOT Regi Sensor has +5VDC. C4-1. Y N Measure voltage at P402-1 on Tray 2 Control PWB. glue backed labels or other obstructions. C4-4. Y N Measure voltage at P402-1 on Tray 1 Control PWB.E The display should change between "0" and "1". Y N Check the circuit between Pin 1 on IOT Regi Sensor and P/J211-3 on LVPS (including PCM PWB) for a short circuit. Replace Takeaway Roll Gear. If no problems are found. check the connection between MAIN PWB and LVPS. replace LVPS. If the problem persists. If the problem persists. Approximately +24VDC is measured. replace IOT Regi Sensor. "1"(Low) is displayed. Check wire between Tray 2 P402-1 and Tray 1 P401-1. Check wire between J302-1 and P402-1. Check installation of the Sensor. replace wires. MAIN PWB in sequence. Check circuit of Tray 2 Feed Motor. Check installation of the Sensor and the extraneous light diffraction. Check for contamination and improper installation of the Sensor. F Takeaway Rolls rotate. Approximately +24 VDC is measured. Y N Go to +5VDC Power RAP. replace IOT Regi Sensor. Approximately +24 VDC is measured. The voltage between Pin 2(+) and Pin 3(-) on IOT Regi Sensor has +5VDC. glue backed labels or other obstructions. Check wire of the following: • Between J306-2 on PCM PWB and Pin 2 on IOT Regi Sensor for an open circuit or poor contact. If there is any damage. C4-3. If there is any damage. Tray 2 is installed. Gear is free to rotate. Y N Go to +24VDC RAP 1. If no problems are found. Y N The voltage between J306-2(+) and J306-3(-) on PCM PWB has +5VDC. Approximately +24VDC is measured. The display should change to "0"(High). Remove the blank sheet of paper from the Sensor. (Including PCM PWB). • Between J306-3 on PCM PWB and Pin 3 on IOT Regi Sensor for an open circuit or poor contact. Y N Measure voltage at P402-1 on Tray 2 Control PWB. Y N Check that Takeaway Roll Gear Module is free of mechanical failure. enter [7-14] and press START button to actuate Tray 2 Feed Motor. MAIN PWB in sequence. if any. Y N Block the Sensor with a blank sheet of paper. replace wires. Measure voltage at any pin of P403 on Tray 2 Control PWB. replace IOT Regi Sensor. Check that paper path is free of torn paper. Y N Remove the connector of IOT Regi Sensor. Replace Tray 2 Control PWB. Check Actuator for damage. Replace Tray 2 Feed Motor. Approximately +24VDC is measured. Y N Check the wire between Pin 1 on IOT Regi Sensor and P/J211-3 on LVPS for an open circuit or poor contact. If no problems are found. Replace Tray 1 Control PWB. Y N Ensure paper path is free of torn paper. The display should change to "0"(High). replace LVPS. C4-2. Y N Remove Rear Cover of Tray 2. replace Tray 1 Control PWB. If no problems are found. Check wire of the following: • Between P/J404-3 on Tray 1 Control PWB and Pin 3 on Tray 1 No Paper Sensor for an open circuit or poor contact.C5 RAP C5–0: Tray 1 No Paper Sensor is not actuated. go into diagnostic mode. Switch on power. The voltage between Pin 3(+) and Pin 2(-) on Tray 1 No Paper Sensor has +5VDC. If the problem persists. replace Tray 1 Control PWB. Repair as required. Display changes between "0" and "1". • Between P/J404-2 on Tray 1 Control PWB and Pin 2 on Tray 1 No Paper Sensor for an open circuit or poor contact. Status Indicator RAP/Other Faults C5 9/02 2-18 Initial Issue WorkCentre Pro 420 . Y N The voltage between P/J404-3(+) and P/J404-2(-) on Tray 1 Control PWB has +5VDC. Y N The voltage between Pin 1(+) and GND(-) on Tray 1 No Paper Sensor has +5VDC. Check for contamination and improper installation of the Sensor. Y N Go to +5VDC Power RAP. Check the installation position of no paper Sensor for any problem. Y N Check wire between Pin 1 on Tray 1 No Paper Sensor and P/J404-1 on Tray 1 Control PWB for an open circuit or poor contact. Manually handle the actuating arm of Tray 1 No Paper Sensor. If no problems are found. Procedure Remove Tray 1 module. enter [7-5] and press START button. replace Tray 1 No Paper Sensor. If no problems are found. replace MAIN PWB. Repair as required. replace Tray 1 Control PWB. replace Tray 2 Control PWB. If the problem persists. Check wire of the following: • Between P/J404-3 on Tray 2 Control PWB and Pin 3 on Tray 2 No Paper Sensor for an open circuit or poor contact. Check for contamination and improper installation of the Sensor. The voltage between Pin 3(+) and Pin2(-) on Tray 2 No Paper Sensor has +5VDC. Y N The voltage between Pin 1(+) and GND(-) on Tray 2 No Paper Sensor has +5VDC.C6 RAP C6–0: Tray 2 No Paper Sensor is not actuated. If no problems are found. Y N Check the wire Pin 1 on Tray 2 No Paper Sensor and J404-1 on Tray 2 Control PWB for an open circuit or poor contact. go into diagnostic mode. Y N Go to +5VDC Power RAP. Manually handle the actuating arm of Tray 2 No Paper Sensor. Switch on power. Display changes between "0" and "1". replace Tray 2 Control PWB. Y N The voltage between P/J404-3(+) and P/J404-2(-) on Tray 2 Control PWB has +5VDC. Procedure Remove Tray 2 module. replace Tray 2 No Paper Sensor. If the problem persists. If no problems are found. Initial Issue WorkCentre Pro 420 9/02 2-19 Status Indicator RAP/Other Faults C6 . • Between P/J404-2 on Tray 2 Control PWB and Pin 2 on Tray 2 No Paper Sensor for an open circuit or poor contact. enter [7-6] and press START button. replace Tray 1 Control PWB and MAIN PWB. If no problems are found. Check the installation position of no paper Sensor for any problem. Status Indicator RAP/Other Faults C7 9/02 2-20 Initial Issue WorkCentre Pro 420 . Replace Tray 1 Size Switch. The Actuator is in good condition. replace Tray 1 Control PWB. Check conductivity of the following: • Between Tray 1 Size Switch CN1-1 and Tray 1 Control PWB P/J406-1 • Between Tray 1 Size Switch CN1-2 and Tray 1 Control PWB P/J406-2 • Between Tray 1 Size Switch CN1-3 and Tray 1 Control PWB P/J406-3 • Between Tray 1 Size Switch CN1-4 and Tray 1 Control PWB P/J406-4 • Between Tray 1 Size Switch CN1-5 and Tray 1 Control PWB P/J406-5 The resistance is below 1 Ohm for all. Y N Check the open circuit or poor contact where the resistance is not below 1 Ohm. Check Tray 1 Paper Size Actuator. Y N Repair the Actuator. If the problem persists. Procedure Remove Tray1. and replace it if necessary.C7 RAP C7-0: Tray 1 Size Switch is not actuated. Procedure Remove Tray 2. Check Tray 2 Paper Size Actuator. replace Tray 2 Control PWB. Y N Check the open circuit or poor contact where the resistance is not below 1 Ohm. Initial Issue WorkCentre Pro 420 9/02 2-21 Status Indicator RAP/Other Faults C8 . If the problem persists. Check conductivity of the following: • Between Tray 2 Size Switch CN1-1 and Tray 2 Control PWB P/J406-1 • Between Tray 2 Size Switch CN1-2 and Tray 2 Control PWB P/J406-2 • Between Tray 2 Size Switch CN1-3 and Tray 2 Control PWB P/J406-3 • Between Tray 2 Size Switch CN1-4 and Tray 2 Control PWB P/J406-4 • Between Tray 2 Size Switch CN1-5 and Tray 2 Control PWB P/J406-5 The resistance is below 1 Ohm for all. and replace it if necessary. The Actuator is in good condition. Y N Repair the Actuator. Replace Tray 2 Size Switch.C8 RAP C8–0: Tray 2 Size Switch is not actuated. Y N Go to +24VDC Power RAP. Check wire of the following: • Between P/J405-1 on Tray 1 Control PWB and Pin 3 on Tray 1 Takeaway Sensor for an open circuit or poor contact. Replace Tray 2 Control PWB Enter [7-12] and press the START button. Tray 2 Feed Clutch is energized. Check installation of the Sensor. "0"(High) is displayed. Y N The voltage between P/J402-1(+) and GND(-) on Tray 2 Control PWB has +24VDC. • Remove paper from tray and fan it to ensure edges are separated. The voltage between Pin 3(+) and Pin 2(-) on Tray 1 Takeaway Sensor has +5VDC. Check for contamination and improper installation of the Sensor. "1"(Low) is displayed. B If the failure of C9-0 Status Code continues. If no problems are found. Y N Check the wire between Pin 1 on Tray 1 Takeaway Sensor and P/J405-2 on Tray 1 Control PWB for an open circuit or poor contact. Y N When [7-12] is turned ON?the voltage between P/J408-2(+) and GND(-) on Tray 2 Control PWB has 0VDC. Y N The voltage between P/J402-1(+) and GND(-) on Tray 2 Control PWB has +24VDC. display should change between "0" and "1". Y N Check the circuit between Pin 1 on Tray 1 Takeaway Sensor and J405-2 on Tray 1 Control PWB for a short circuit. The voltage between P/J408-1(+) and GND(-) on Tray 2 Control PWB has +24VDC. Check that Paper Guides are adjusted to the set paper size position and properly laid. Tray 2 Feed Motor rotates. Y N Block Tray 1 Takeaway Sensor with a blank sheet of paper. If no problems are found. • Check installation of the Sensor and the extraneous light diffraction. Y N Go to +24VDC Power RAP. Remove the blank sheet of paper from the Sensor. Use hand or paper to actuate or deactuate Tray 1 Takeaway Sensor. Y N The voltage between P/J405-1 (+) and P/J405-3(-) on Tray 1 Control PWB has +5VDC. Y N Go to +5VDC Power FIP. Y N Replace Tray 2 Control PWB. Enter [7-14] and Press the START button. If no problems are found. replace Tray 1 Takeaway Sensor. replace Tray 1 Takeaway Sensor. replace Tray 1 Takeaway Sensor. Replace Tray 2 Control PWB Replace Tray 2 Feed Clutch. Y N Remove the connector of Tray 1 Takeaway Sensor. replace Tray 1 Control PWB. Check the mechanical load of Tray 2 Feed Gear. replace Tray 1 Control PWB. • Between P/J405-3 on Tray 1 Control PWB and Pin 2 on Tray 1 Takeaway Sensor for an open circuit or poor contact. Y N The voltage between Pin 1(+) and GND(-) on Tray 1 Takeaway Sensor has +5VDC. If no problems are found. The display should change to "0"(High). A B Status Indicator RAP/Other Faults C9 9/02 2-22 Initial Issue WorkCentre Pro 420 . Procedure Enter [7-7].A C9 RAP C9–0: Tray 2 fed paper did not actuate Tray 1 Takeaway Sensor in time. Refer to label on paper tray and reinstall paper. Y N Remove Fuser Module. Registration Assembly is installed correctly. Y N Replace Fuser Module. The display should change. Replace Fuser Module. When [8-3] is turned ON. replace LVPS. When [8-3] is turned ON. the voltage between PCM PWB J311-8(+) and GND(-) has 0VDC. Y N Refer to BSD CH1. IOT Regi Clutch is energized Y N Enter [8-3] and ON. Y N Paper is stalled at Fuser Module. Manually rotate Drive Motor in a counterclockwise direction while observing Fuser Drives and rotation of visible portions of Fuser Rolls. Do following to verify operation of Registration Roll Drives. MAIN PWB in sequence. Corotron is correctly installed. Paper is stalled before entering Registration Assembly. • Push Registration Roll Assembly up and into operational position while partially closing Door Module. Turn ON/OFF Fuser Exit Switch by hand. Replace Registration Module. If no problems are found. Y N Check the connection between MAIN PWB and LVPS. While measuring resistance. replace Fuser Module. slowly open Door Module just enough to check position of lead edge of paper. The voltage between P/J305-1(+) and GND(-) on PCM PWB has +24VDC. Replace Registration Sensor. Resistance changes while actuating and de-actuating Fuser Exit Switch. Procedure Enter [10-6]. Replace IOT Regi Clutch. Check the wire of the following: • Between J203-1 on LVPS and J211A-2 on Fuse Module for an open circuit or poor contact. Measure resistance (ohms) between J211B-2 and 3 on Fuser Module. Y N Repair or replace components as required. Y N Repair as required. • Between J203-2 on LVPS and J211A-3 on Fuser Module for an open circuit or poor contact. check Front Intlk On +24VDC circuit to P/J305-1 on PCM PWB. • Remove Rear Cover. If no problems are found. Y N Repair as required. Drive of Fuser Module Drives appears to operate normally and without visual evidence of drive gear breakage or damage. Resistance should change from high resistance to less than 30 ohms to high resistance. the voltage between P/J305-4(+) and GND(-) on PCM PWB has +24VDC. actuate and deactuate Fuser Exit Switch. The voltage between P/J211-8(+) and GND(-)on LVPS has 0VDC. Verify any problem continues. Enter [8-3] and ON. MAIN PWB in sequence. Y N Remove Fuser Module. E1–3: Paper did not deactuate Fuser Exit Switch in time after de-actuating Registration Sensor.E1 RAP E1–1: Paper did not actuate Fuser Switch in time after Registration Clutch energized. Check that Pre Fuser Guide feels smooth and free of damage or has a condition that may stop paper movement.3. A Check installation of Registration Assembly. Run customer job and after E1 is displayed. Y N Check the wire between P/J211-8 on LVPS and J311-8 on PCM PWB for an open circuit or poor contact. Check installation of Transfer Detack Corotron. • Hold Registration Roll Assembly in this position and manually rotate Drive Motor in a counterclockwise direction while observing Registration Clutch Drive Gear and related drives. Registration Roll drives appear to operate normally and without visual evidence of drive gear breakage or damage. A Initial Issue WorkCentre Pro 420 9/02 2-23 Status Indicator RAP/Other Faults E1 . Y N Replace PCM PWB. Y N Repair or replace components as required. Check Actuator for damage. Paper is stalled before entering Registration Assembly. Procedure Enter [8-6] The actuator of IOT Regi Sensor is turned ON/OFF by hand. If no problems are found. Y N Remo Run customer job and after E1 is displayed. Remove the blank sheet of paper. If no problems are found. Registration Roll drives appear to operate normally and without visual evidence of drive gear breakage or damage. If the failure of E1-2 Status Code continues. Hold Registration Roll Assembly in this position and manually rotate Drive Motor in a counterclockwise direction while observing Registration Clutch Drive Gear and related drives. Y N Repair or replace components as required. Paper is stalled before entering Registration Assembly. slowly open Door Module just enough to check position of lead edge of paper. Check for contamination and improper installation of the Sensor. Y N Go to +5VDC Power RAP. "0"(High) is displayed. • Between P/J306-3 on PCM PWB and Pin 3 on IOT Regi Sensor for an open circuit or poor contact. Run customer job and after E1 is displayed. Y N Repair as required. Check the following: • Between on P/J306-2 PCM PWB and Pin 2 on IOT Regi Sensor for an open circuit or poor contact. Y N Block Sensor with a blank sheet of paper. Initial Issue 9/02 Y N WorkCentre Pro 420 2-24 Paper is stalled at Fuser Module. Y N Remove the connector of IOT Regi Sensor. check the connection between LVPS and MAIN PWB. Check installation of Registration Assembly. The display should change between "0" and "1". The voltage between Pin 2(+) and Pin 3(-) on IOT Regi Sensor has +5VDC. Check installation of Transfer Detack Corotron. Corotron is correctly installed. Drive of Fuser Module Drives appears to operate normally and without visual evidence of drive gear breakage or damage. replace LVPS. If problem continues. • Remove Rear Cover. replace LVPS. (Including PCM PWB) If no problems are found. MAIN PWB in sequence. Y N The voltage between Pin 1 on IOT Regi Sensor(+) and GND(-) has +5VDC. Do following to verify operation of Registration Roll Drives. Status Indicator RAP/Other Faults E1 Replace Registration Sensor. replace IOT Regi Sensor. Check installation of the Sensor. Y N Check the circuit between Pin 1 on IOT Regi Sensor and P/J211-3 on LVPS for a short circuit. Y N Repair or replace components as required. check the connection between MAIN PWB and LVPS. slowly open Door Module just enough to c . "1"(Low) is displayed. If a problem continues. MAIN PWB in sequence. Manually rotate Drive Motor in a counterclockwise direction while observing Fuser Drives and rotation of visible portions of Fuser Rolls. Y N Paper is stalled at Fuser Module. • • Push Registration Roll Assembly up and into operational position while partially closing Door Module. Verify any problem continues. Y N Remo Run customer job and after E1 is displayed. replace the IOT Regi Sensor. Y N Repair as required. replace Tray 1 Takeaway Sensor. Y N The voltage between P/J306-2(+) and P/J306-3(-) on PCM PWB has +5VDC. Check installation of the Sensor and the extraneous light diffraction. Y N Check wire between Pin on IOT Regi Sensor and P/J211-4 on LVPS for an open circuit or poor contact. Registration Assembly is installed correctly. (Including PCM PWB) If no problems are found.E1-2: Paper did not deactuate Registration Sensor in time after actuating Fuser Exit Switch. slowly open Door Module just enough to check position of lead edge of paper. The display should change to "0"(High). the voltage between P/J311-11(+) and GND(-) on PCM PWB has +24VDC. Y N The voltage between J307-1(+) and GND(-) on PCM PWB has +24VDC. MAIN PWB in sequence. replace LVPS. The operating sound of the Gate Select Solenoid is audible. Replace Gate Select Solenoid. Replace PCM PWB. Y N When [8-4] is turned ON.A Enter [8-4] and ON. If no problems are found. Y N When [8-4] is turned ON. Status Indicator RAP/Other Faults E1 9/02 2-26 Initial Issue WorkCentre Pro 420 . the voltage between P/J211-11(+) and GND(-) on LVPS has +24VDC. • A paper transportation failure due to foreign substance on the paper path. the voltage between P/J307-2(+) and GND(-) on PCM PWB has +24VDC. Check the following: • The drive transfer course from MAIN MOTOR to DOOR EXIT ROOL for no problem. Check the connection between MAIN PWB and LVPS. Check the wire between P/J211-11 on LVPS and P/J311-11 on PCM PWB for an open circuit or poor contact. Y N When [8-4] is turned ON. Y N Go to +24VDC Power RAP. the voltage between P/J603-9(+) and GND(-) on ADF PWB has 0VDC. Check installation of the Sensor and the extraneous light diffraction. Check wire of the following: • Between P/J608-1 on ADF PWB and Pin 1 on Copy Exit Sensor for an open circuit or poor contact. Y N The voltage between P/J103-8(+) and GND(-) on MAIN PWB has +0VDC. Y N The voltage between P/J608-1(+) and P/J306-3(-) on ADF PWB has +5VDC. E2-2: Paper can not deactuate in time OCT Exit Sensor after leaving Fuser Exit Switch. Y N Check the wire between Pin 2 on Copy Exit Sensor and P/J103-20 on MAIN PWB for an open circuit or poor contact. Replace PCM PWB. Check for contamination and improper installation of the Sensor. Y N Go to +24VDC Power RAP. If no problems are found. A Initial Issue WorkCentre Pro 420 A 9/02 2-27 B C Status Indicator RAP/Other Faults E2 . The Voltage between P/J603-8(+) and GND(-) on ADF PWB has 0VDC. Y N Go to +5VDC Power RAP. replace LVPS.E2 RAP E2-1: Paper can not actuate in time OCT Exit Sensor after leaving Fuser Exit Switch. Remove the blank sheet of paper from the Sensor. The voltage between Pin 1(+) and Pin 3(-) on Copy Exit Sensor has +5VDC. The display should change to "0"(High). MAIN PWB in sequence. Y N Remove the ADF Drive Cover. (Including ADF PWB) If no problems are found. the voltage between P/J211-11(+) and GND(-) on LVPS has +24VDC. Check Actuator for damage. Y N When [8-4] is turned ON. When [5-3] is turned ON. the voltage between J103-9(+) and GND(-) on MAIN PWB has 0VDC. This display should change to "0"(High). replace Copy Exit Sensor. Y N When [8-4] is turned ON. Procedure Enter [5-13]. Check the connection between MAIN PWB and LVPS. Y N Remove the connector of Copy Exit Sensor. Actuator of Copy Exit Sensor is turned ON/OFF by hand. Y N Replace MAIN PWB. Copy Exit Motor rotates. replace MAIN PWB. Check wire between J211-11 on LVPS and J311-11 on PCM PWB for an open circuit or poor contact. • Between P/J608-3 on ADF PWB and Pin 3 on Copy Exit Sensor for open circuit or poor contact. The display should change between "0" and "1". Y N Check the circuit between Pin 2 on Copy Exit Sensor and P/J103-20 on MAIN PWB for short circuit. Check installation of the Sensor. the voltage between P/J311-11(+) and GND(-) on PCM PWB has +24VDC. A Enter [8-4] and ON. Replace Gate Select Solenoid. replace MAIN PWB. Check wire between P/J103-9 on MAIN PWB and P/J603-9 on ADF PWB for an open circuit or poor contact. "1"(Low) is displayed. Y N When [5-3] is turned ON. Y N Block the Sensor with a blank sheet of paper. Y N The Voltage between P/J602-1(+) and GND(-) on ADF PWB has +24VDC. replace Copy Exit Sensor. The operating sound of the Gate Select Solenoid is audible. If no problems are found. Y N Replace MAIN PWB. The voltage between Pin 2(+) and GND(-) on Copy Exit Sensor has +5VDC. Y N When [8-4] is turned ON. Enter [5-3] and turned ON. (Including ADF PWB) If no problems are found. the voltage between P/J307-2(+) and GND(-) on PCM PWB has +24VDC. If no problems are found. If the failure of either E2-1 or E2-2 Status Code continues. replace the Copy Exit Sensor. Y N Go to +24VDC RAP. Y N The voltage between P/J307-1(+) and GND(-) on PCM PWB has +24VDC. replace ADF PWB. The voltage between P/J107-6(+) and GND(-) on MAIN PWB has +5VDC. Initial Actions Check damage of the L/H Interlock Switch Plate(2) by the side of L/H Door. Y N Check wire of the following: • Between P/J212-6 on LVPS and P/J312-6 on PCM PWB for an open circuit or poor contact • Between P/J212-7 on LVPS and P/J312-7 on PCM PWB for an open circuit or poor contact Close L/H Door. Check the wire between P/J103-7 on MAIN PWB and P/J603-7 on ADF PWB for an open circuit or poor contact. If no problems are found. Y N Check power code. Replace POWER SUPPLY PWB. The voltage between P/J107-9(+) and GND(-) on MAIN PWB has +24VDC.22VDC.B C D Check the wire between P/J103-8 on MAIN PWB and P/J603-8 on ADF PWB for an open circuit or poor contact. Replace LVPS. Y N The voltage between P/J103-7(+) and GND(-) on MAIN PWB has +0.22VDC. (Including L/H Door Interlock Switch) Check the wire between P/J312-10 on PCM PWB and P/J212-10 on LVPS for an open circuit or poor contact. Remove Rear Cover. and repair it if necessary. Procedure Cheat Front Door Interlock Switch. The voltage between P/J212-10(+) and GND(-) on LVPS has +24VDC. When [5-3] is turned ON. Y N Replace MAIN PWB. Y N Check the connection between MAIN PWB and LVPS. Y N Replace MAIN PWB. If no problems are found. check the customer's power supply. the voltage between P/J603-7(+) and GND(-) on ADF PWB has +0. MAIN PWB in sequence. Check Copy Exit Transmission for mechanical failure such as shaft being crooked. A Status Indicator RAP/Other Faults E2 9/02 2-28 Initial Issue WorkCentre Pro 420 . Replace Copy Exit Motor. Guides not smooth and clamping roll loose. The voltage between P/J212-6(+) and GND(-) on LVPS has +24VDC. If the problem persists. Y N Check the voltage between ACN and ACH of POWER CORD. Y N The voltage between P/J205-2 and P/J205-3 on LVPS has approximately 110/ 220VAC. Approximately 110/220VAC are measured. bearing loose. The voltage between P/J312-6(+) and GND(-) on PCM PWB has +24VDC. Repair as required. E5-0: Front and L/H Side Door Interlock is open. Y N Check the wire between Pin 1 and Pin 2 on PCM PWB for an open circuit or poor contact. Y N The voltage between J312-10(+) and GND(-) on PCM PWB has +24VDC. replace LVPS. and close L/H Door and Front Door. Check damage of Tray 1 Door Interlock Switch Actuator and attachment of Tray 1 L/H Cover. Y N Cheat Tray 1 Door Interlock Switch. • ADF • • • Top Cover Document Glass RIS Module E6-1: Tray 1 Door Interlock is open. Check the wire between Pin 2 on Tray 1 Door Interlock Switch and P/J407-2 on Tray 1 Control PWB for open circuit or poor contact. Y N Replace Tray 1 Door Interlock Switch. Procedure Enter [7-9] and press START button. Turn On the power. Y N Check the wire P/J107-9 on MAIN PWB and P/J807-9 on HVPS for an open circuit or poor contact. Tray 1 Door Interlock Switch is turned ON by hand. Initial Issue WorkCentre Pro 420 9/02 2-29 Status Indicator RAP/Other Faults E2 . The voltage between Pin 2(+) and GND(-) on Tray 1 Door Interlock Switch has +5VDC. If no problems are found. If no problems are found. Replace HVPS. replace Tray 1 Control PWB. Y N Check the wire between P/J807-6 on HVPS and P/J107-6 on MAIN PWB for an open circuit or poor contact. Adjustment with Tray 1 L/H Cover and Tray 1 Door Interlock Switch is poor. The voltage between J807-9(+) and GND(-) ON HVPS has +24VDC. The voltage between P/J807-6(+) and GND(-) on HVPS has +5VDC. Y N Check the wire between Pin 1 on Tray 1 Door Interlock Switch and P/J407-1 on Tray 1 Control PWB for an open circuit or poor contact.A Turn Off the power. replace Tray 1 Control PWB. The display should change from "1" to "0". The voltage between Pin 1(+) and GND(-) on Tray 1 Door Interlock Switch has +5VDC. Remove the following. The voltage between Pin 1(+) and GND(-) on Tray 2 Door Interlock Switch has +5VDC. replace Tray 2 Control PWB. Status Indicator RAP/Other Faults E2 9/02 2-30 Initial Issue WorkCentre Pro 420 . The voltage between Pin 2(+) and GND(-) on Tray 2 Door Interlock Switch has +5VDC. The display should change from "1" to "0". If no problems are found. replace Tray 2 Control PWB. Y N Cheat Tray 2 Door Interlock Switch. Y N Replace Tray 2 Door Interlock Switch. Tray 2 Door Interlock Switch is turned ON by hand. Check damage of Tray 2 Door Interlock Switch Actuator and attachment of Tray 2 L/H Cover. Adjustment with Tray 2 L/H Cover and Tray 2 Door Interlock Switch is poor. Check the wire between Pin 2 on Tray 2 Door Interlock Switch and P/J407-2 on Tray 2 Control PWB for open circuit or poor contact.E6-2: Tray 2 Door Interlock is open. Procedure Enter [7-10] and press START button. If no problems are found. Y N Check the wire between Pin 1 on Tray 2 Door Interlock Switch and P/J407-1 on Tray 2 Control PWB for an open circuit or poor contact. Measure voltage at P202-2 (+) on LVPS. Enough time must be allowed for toner to flow into Drum Cartridge. Initial Issue WorkCentre Pro 420 9/02 2-31 Status Indicator RAP/Other Faults J1 . remove Rear Cover. If machine was serviced or toner was added within 100 copies. If you cannot determine. Remove Top Cover. Remove ROS. Remove ADF. • Remove Drum Cartridge. Replace LVPS. Measure resistance (ohm) at P/J202-3 on LVPS. Remove Rear Cover. Remove Document Glass. Switch off machine. Resistance is 5 ohms or less. Switch on machine. repeat previous check. Remove RIS. Voltage changes between approximately +0. Display indication changes. Y N Replace MAIN PWB. Toner Bottle must be shaken according to instruction on bottle. Display should change between "0" and "1". Y N Replace LVPS. Y N Open Door Module. Connect black meter wire to MAIN PWB GND.1VDC and +5VDC. Procedure Check Toner Sensor. Measure voltage at P/J202-1 on LVPS. Approximately +24VDC is measured. Voltage changes from approximately +0. Measure voltage at golden finger at P/J109-A3 on MAIN PWB and LVPS while placing and removing pliers on Toner Sensor.J1 RAP J1-0: Toner level is low. • Enter [9-7].1VDC to +5VDC. Add toner. Y N Replace Toner Sensor. Carefully place pivot of pliers on raised part of Toner Sensor and remove pliers. Initial Actions • • Ensure Toner Bottle receiver on Drum Cartridge is clean and free of toner. Before adding toner. Place and remove pliers on and from Toner Sensor. Y N Replace LVPS. Switch on machine. Check that P/J202 on LVPS is connected. Procedure The J104 on MAIN PWB is firmly connected. Status Indicator RAP/Other Faults J4.J4 RAP J6 RAP J4-1: Billing Counter missing or not installed correctly. Replace MAIN PWB. Y N Go to +5VDC Power RAP. J4-2: Billing Counter is not a FXSL uniqueware. J4-3: Billing Counter unit type error. Replace wire harness of J104. J6-3: Billing Counter communication error. Y N The CR2 on MAIN PWB is turned on. Y N Connect it firmly. J6 9/02 2-32 Initial Issue WorkCentre Pro 420 . The voltage between P/J104-12(+) and GND(-) on MAIN PWB has +5VDC. Another J3 is displayed. Initial Issue WorkCentre Pro 420 9/02 2-33 Status Indicator RAP/Other Faults J3. Replacement should be made. Open Front Door. and does not impede movement of Drum Cartridge when Door Module is open. Ensure Drum Cartridge Interlock moves left when Door Module is open. J6-1: CRUM Communication Error J8-1: Incompatible CRUM detected J9-1: CRUM is not a FXSL uniqueware. Open Door Module. Install Drum Cartridge. replace Drum Cartridge. J9 . Check that harness between P/J 108 on MAIN PWB and P/J708 on CRUM are free of open circuit or damage. If Drum Cartridge does not lock into position. Repair as required. Ensure no misplaced objects are in Drum Cartridge opening. Y N If Drum Cartridge will not lock into position due to defect. J6. replace MAIN PWB. wait 5 seconds and switch on machine again. • • • • • Ensure corresponding CRUM Connector on machine back wall is free to move side-toside. Movement allows alignment when Drum Cartridge is installed. Reinstall another Drum Cartridge and another J3 is displayed. Drum Cartridge is securely installed and can be removed only after releasing Lock. Check wires for damage. Switch off machine. Check Drum Cartridge installation.J3 RAP J6 RAP J8 RAP J9 RAP J3-1: CRU missing or not installed correctly. Repair as required. J8. If no open circuit or damage exists. • Check that CRUM Connector on back of Drum Cartridge is secure and clean. Y N Return to Service Call Procedures in Section 1. Remove Rear Cover and check that P108 on MAIN PWB is connected. Y N Replace Drum Cartridge. Procedure Remove Drum Cartridge. Drum Cartridge is defective. replace MAIN PWB. Display indicated number of copies remaining on cartridge in thousands of copies. Status Indicator RAP/Other Faults J7 9/02 2-34 Initial Issue WorkCentre Pro 420 . Initial Actions Ensure Drum Cartridge is fully installed so that lick prevents removal. • Ensure CRUM connector on machine. Check that corresponding connector in machine is clean. enter diagnostic code [9-4]. located in opening for Drum Cartridge. Procedure Switch on machine. Then MAIN PWB is not responding to new cartridge. replace MAIN PWB. Remove Drum Cartridge and do the following: • Check that CRUM Connector is clean. Repair as required. is free to move slightly to allow correct alignment when Drum Cartridge is installed.J7 RAP J7-1: Drum Cartridge reached end of service life. Check that corresponding connector in machine is clean. Y N Replace Drum Cartridge. If problem continues. Y N Drum Cartridge was recently replaced by customer. Y N Install a new Drum Cartridge. Then J7 status code is correct. If J7 status code continues. Ensure Door Module closes securely. Repair as required. Reinstall Drum Cartridge. • If J7 status code problem continues. Ensure J708 is free to move slightly to allow correct alignment when Drum Cartridge is installed. A new Drum Cartridge was recently installed by customer. indicating no copies are available from cartridge. do the following: • Remove Drum Cartridge. • • • • Check that CRUM Connector is clean. Repair MAIN PWB. • Ensure Door Module closes securely. Reinstall Drum Cartridge. Display is "0". go into diagnostic mode. Manually handcrank Main Motor again. Y N Replace Drive Module. Less than 2 ohms is indicated. A B C Initial Issue WorkCentre Pro 420 9/02 2-35 Status Indicator RAP/Other Faults U1 . Main Motor operates. Y N Switch off machine. Switch on machine power. Connect black meter wire to MAIN PWB metal frame and red meter wire to Drive Module metal frame. If no problems are found. (Including PCM PWB). Manually rotate Main Drive Motor. Switch on machine. C Y N Check the connection between MAIN PWB and LVPS. Replace Drive Module. Main Drive Motor can be easily handcranked. When [4-1] is turned ON. the voltage between P/J211-2(+) and GND(-) on LVPS has less than +1VDC. replace LVPS. the voltage between CN1-4(+) and GND(-) on Main Motor has +5VDC. Y N Go to of 16-2 Ground RAP. • • Remove Fuser Module. Main Motor in sequence. Y N The voltage between P/J304-5(+) and GND(-) on PCM PWB has +24VDC. Reinstall Drum Cartridge. go into diagnostic mode. Y N Replace Drum Cartridge. Manually handcrank Main Motor again. Y N Check the wire between CN1-2 on Main Motor and P/J211-3 on LVPS for an open circuit or poor contact. Y N Refer to BSD CH1. Close Front and L/H Interlock. Reinstall Fuser Module. Main Motor in sequence. Manually handcrank Main Motor. the voltage between CN1-3(+) and GND(-) on Main Motor has less than +1VDC. When [4-1] is turned ON. Open Door Module. Check the wire between P/J304-5 on PCM PWB and CN1-1 on Main Motor for an open circuit or poor contact. observe Main Motor and press START button. Y N Do the following: • Remove Drum Cartridge. Y N When [4-1] is turned ON. Main Motor can be easily handcranked. The voltage between CN1-1(+) and GND(-) on Main Motor has +24VDC. Main Motor can be easily handcranked. If no problems are found. When [4-1] is turned ON. check Intlk On +24VDC circuit to P/J304-5 on PCM PWB. replace LVPS. Y N Replace Drive Module. Main Motor can be easily handcranked. Repair as required. Y N Replace Fuser Module.A B U1 RAP U1–0: Drive Module speed signal failure. Check Registration Clutch drives and Bypass drives for signs of visible wear or failure. Check the connection between MAIN PWB and LVPS.3. the voltage between P/J211-1(+) and GND(-) on LVPS has +5VDC. Procedure Remove Rear Cover. enter [4-1]. Check the wire between P/J211-1 on LVPS and CN1-4 on Main Motor for an open circuit or poor contact. Reassemble machine.1) (REP 6. Reference to possible noise will be made in RAP. Check Scan Home Sensor. Y N Measure voltage at Scan Home Sensor. • • • • Remove Rear Cover (REP 14.2) (REP 1.2).3) (REP 1. Remove Document Glass (REP 14.2) (REP 1. Connect black meter wire to MAIN PWB metal frame. Y N Switch off machine.2). Repair wires or replace RIS as required. Y N Switch on machine and measure voltage at four positions from P/J109A28(+) to P/J109-A31(+) on MAIN PWB. Raise RIS connector 3 mm so contacts can be visible (REP 14. U2 status code is displayed. Check Scan Home Sensor wires and RIS connections for visible damage. • • • Switch off machine. block and unblock Scan Home Sensor. Y N U2 status code is intermittent. Resistance should be less than 5 ohms. Tapping noise occurs. Voltage changes between approximately +5VDC and 0VDC.5). With red meter wire on pin 2. Disconnect RIS connector (Figure 3). replace MAIN PWB. Switch off machine. If RIS wires are good. Replace MAIN PWB. • • Remove Rear Cover (REP 14. Replace Main PWB (PL 1. Connect black meter wire on pin 1 and red meter wire on pin 3. Disconnect and reconnect RIS connector (Figure 3). A tapping noise occurs when Scan Home Sensor signal is failed to a low output.4).2). • • • • E Replace Main PWB (PL 1. • Switch off machine. Wait 10 seconds and switch on machine. Approximately +24 VDC is measured. Switch off machine. Voltage should change from less than +0. • Switch off machine.2).2). Remove ADF (REP 14. Actuate and deactuate Scan Home Sensor. Switch machine power and measure voltage at P105-40(+) on MAIN PWB. replace Imager Module. Carriages move. Procedure NOTE: Entry to this RAP may be from of 16-1 noise or odor. Y N Replace RIS Module (PL 2. Y N Replace LVPS (PL 1. or +24VDC failure.8VDC to +5VDC to less than +0.2). Switch on machine and measure voltage at P/J105-30 on MAIN PWB.1). and switch on machine.4). Y N Replace Scan Home Sensor. Remove Rear Cover (REP 14. Check sensor wires for an open circuit failure. Approximately +24VDC is measured. Connect black meter wire to MAIN PWB (Figure 3). Repair wires or replace RIS as required. If cables are tangled or loose.8VDC. Y N Scan Drive Motor or control failure. Raise RIS connector 3 mm so contacts are visible (Figure 3).A B C D U2 RAP U2–1: Scan Home Sensor circuit. Measure resistance between P/J105-40 and P/J105-38 (Figure 8). U2–2: Exposure Lamp not lit or black white strip not sensed. Switch on machine to test for a tapping noise and then switch off machine if noise is heard. Wait 20 seconds and press STOP button. incorrect mounting or other signs of failure. CAUTION Image Quality defects occur if mirrors in both carriages are not cleaned and RIS Module is not vacuumed before reinstalling Document Glass and ADF. Remove Rear Cover (REP 6. A B C D E Status Indicator RAP/Other Faults F 9/02 2-36 G Initial Issue WorkCentre Pro 420 U2 . Wait 10 seconds. Electrical check done on MAIN PWB before checking inside RIS module. If wires on RIS are good.1). replace MAIN PWB. Initial Actions Lift Document Cover and check cables. Scan Drive Motor. There should be +5VDC on pin 3. Y N U2 status code is displayed in previous check. Connect black meter wire to Main PWB metal frame. Go to Service Call Procedures in Section 1. Measure resistance between P/J105-38 and P/J105-36 (Figure 8). or carriages failure. • • • • • • • Switch off power. Connect red meter wire to P105-2 on MAIN PWB. Y N There is an open circuit in Scan Home Sensor of wires. Switch on machine and measure voltage at P105-2 on MAIN PWB. Y N Check Exposure Lamp circuit.2). There is problem with Exposure Lamp or Exposure Lamp power supply or there is problem with CCD circuit. There should be less than 5 ohms. Remove Rear Cover (REP 14.2). replace Imager Module (PL 2. Disconnect RIS connector (Figure 3). enter [6-1] and press START button.F G Voltage should change from approximately 0VDC to +5VDC to 0VDC within 12 seconds. Replace Exposure Lamp.5). If noise problem continues.1). Y N Measure voltage at pin 1 and pin 2. Remove Exposure Lamp to access power supply. Switch off machine and switch on machine while observing Exposure Lamp. Exposure Lamp illuminates within 12 seconds. Y N Replace Main PWB (PL 1. • • • Remove Document Glass (REP 6. Replace RIS Module.1) (REP 6. • • • • • Switch off machine. Connect red meter wire to white wire. Approximately +24 VDC is measured. Connect black meter wire to Main PWB metal frame. Y N Replace RIS Module. Y N Replace RIS Module. Switch off machine. Do the same check on other white wire at other end of Exposure Lamp. There should be +24 VDC with black meter wire to Fuser Module metal frame. Measure resistance at Blue Wire. There is +24VDC at pin 1 and pin 2. Y N Replace MAIN PWB. • Remove ADF. Replace Scan Home Sensor (PL 2. Initial Issue WorkCentre Pro 420 9/02 2-37 Status Indicator RAP/Other Faults U2 . Voltage changes from approximately 0VDC to +5VDC. Connect black meter wire to Main PWB metal frame. Check Scan Sensor input to Main PWB. +24 VDC is reaching RIS Module or U2-1 occurs.1). Replace Exposure Lamp power supply. Press STOP button.2) (REP 1. Go into diagnostic mode. There is +24 VDC on each white wire when START button is pressed. Do the same check on other Blue Wire at other end of Exposure Lamp Resistance should be less than 5 ohms. Raise ROS Connector (Figure 1) 3 mm so contacts are visible (Figure 1). Connect black meter wire to P/J106-5 on MAIN PWB and red meter wire to P/J106-7 on MAIN PWB (Figure 2). Switch on machine U3 status code problem continues.2). • • Disconnect and reconnect ROS Connector (Figure 1).2) (REP 6. Procedure Do the following: • Remove Rear Cover (REP 14.2). Y N Return to Service Call Procedures in Section 1. Approximately +5 VDC is measured. Replace ROS (PL 1.2) (REP 1.2). Status Indicator RAP/Other Faults U3 9/02 2-38 Initial Issue WorkCentre Pro 420 . (Figure 2). Y N Replace Main PWB (PL 1. Y N Replace Main PWB (PL 1.2) (REP 1.U3 RAP U3–0: Laser output not detected. Approximately +24 VDC is measured. Connect black meter wire to P/J106-11 on MAIN PWB and red meter wire on J106-10 MAIN PWB.3).Initial Issue WorkCentre Pro 420 9/02 2-39 Status Indicator RAP/Other Faults U3 . U4–3: Fuser maximum warm up in time is exceeded. If Flag 1 wire isn't repairable. Resistance is less than 5 ohms. d. Resistance check on Fuser Module Thermistor. Y N Replace LVPS (PL 1. Resistance should be between 7k and 10k ohms. 1. or Main PWB failure.4). Y N Replace LVPS (PL 1. Go to step 2. LVPS. replace LVPS and go to Step 2. c.4) • • • • Top Cover (REP 14. and verify normal fuser operation. 3. Make resistance check on Thermistor input circuit. or LVPS (Figure 5). 7.3) Procedure WARNING Personal injury may result from unauthorized service actions. Resistance is less than 5 ohms. Resistance should be less than 5 ohms.2) (REP 1. Make resistance check on ACH circuit to Fuser. Y N Replace LVPS (PL 1.4). Make resistance check on ACN and Triac circuit to Fuser. Resistance is greater than 10k ohms between ACN terminal of Power Cord Receptacle (Figure 2) and pin 6 of Frame Mounted Connector (Figure 1). CAUTION All of following steps are required to diagnose. Power Cord must not be reconnected until directed to do so. Measure resistance between ACH terminal of Power Cord Receptacle and pin 1 of Frame Mounted Connector. Remove following to check Thermistor wires. Measure resistance between ACH terminal of Power Cord Receptacle (Figure 2) and wire (Figure 5) at LVPS.A U4 RAP There is a problem with Fuser temperature control. fuse on LVPS (Figure 5). Remove Main PWB (REP 1. Press Switch On (Figure 2) on machine power switch. Resistance should be between 7k and 10k ohms between pins 2 and 3 of Frame Mounted Connector (Figure 1) . and make resistance checks on Thermistor circuit on LVPS.4) • • • • Top Cover (REP 14. b. 3.1). Move meter probe around while measuring pin 6 of Frame Mounted Connector to ensure contact is made with terminal inside hole. Resistance check on Fuser Module Thermostat and Heat Rod. Only spare part in Fuser Module is Heat Rod.2) and LVPS (REP 1.3 ) (REP 1. Remove Fuser Module (REP 10. Y N Thermistor wires (Figure 4). Repair Flag 1 wire. 2. Y N Ensure Switch On (Figure 2) is pressed on machine power switch and that probe was making contact with pin 1 of Frame Mounted Connector. 4. Measure resistance between ACN terminal of Power Cord Receptacle (Figure 2) and pin 6 of Frame Mounted Connector (Figure 1). Move meter probe around while measuring pin of Frame Mounted Connector to ensure contact is made with terminal inside hole.5) RIS Module (REP 6.3) (REP 1. Resistance check on ACH circuit to Fuser. Go to step 3. 2. repair. 9. Remove following to check Flag 1 wire. B There is a problem with Flag 1 wire (Figure 5). Regulator installed. Go to step 4. Resistance check on ACN and Triac circuit to Fuser.3) Check condition of wires from Frame Mounted Connector to LVPS. a.5) RIS Module (REP 6. • ADF (REP 14. C 9/02 2-40 Initial Issue WorkCentre Pro 420 A B Status Indicator RAP/Other Faults U4 . CAUTION A failed Fuser Module may result from doing service actions in RAP in a different order than provided. Go to step 4. • ADF (REP 14. 8.4). The circuit resistance should be less than 5 ohms. Make resistance check on Fuser Module Thermistor.1) ROS (REP 6.4). Leakage voltage measurement between ACH and ACN at Frame Mounted Connector. U4–2: A Fuser warm up failure occurred. Resistance check on Thermistor input circuit.2). U4–0: A previous U4 Status Code is not cleared. NOTE: U4 diagnostics are done with following checks in order shown: 1. Measure resistance between pins 2 and 3 of Frame Mounted Connector (Figure 1). Voltage shutdown verification at Frame Mounted Connector. 4.1) Document Glass (REP 6. 6. Disconnect Power Cord from machine. Replace Main PWB (PL 1. Resistance should be at least 10k ohms. This action completes circuit to be checked. U4–1: A Fuser over-temperature condition is sensed.3) (REP 1. 5.1) Document Glass (REP 6.1) ROS (REP 6. Regulated voltage measurement between ACH and ACN at Frame Mounted Connector. d. Resistance should be between 2k ohms and 300k ohms.2) (REP 1. After replacing LVPS. Measure resistance between pin 1 of Fuser Module Connector (Figure 1) and end of Fuser Heat Rod without an attached wire. Install Control Panel (REP 1. Y N A new Fuser Module is required (PL 1.3) (REP 1. A flashing 0 indicates control logic is ready to attempt fuser temperature control.5 – 4. or Fuser wiring failure. a. Y N A new Fuser Module is required. Move meter probes around to ensure contact is made with terminals inside holes. Do not install it at this time. Do not switch on machine power until directed to do so. A flashing 0 indicates control logic is ready to attempt fuser temperature control.5 – 10 ohms for a 220 volt machine. Replace Heat Rod. Next check requires observation of light from fuser heat rod. b. Go to Step 7 after replacing MAIN PWB. a. Clear U4 status code that was logged in previous check. voltage should be either 110 or 220 VAC. 7.1). Control logic should shut down 115 VAC or 220 VAC within this time.4). Check Heat Rod. 9.4). Position Fuser Module upside down so that Heat Rod terminals are accessible at ends of Heat Rod. Enter [10–1]. Fuser light alternates off and on within 40 seconds after it is visible. Prepare to measure regulated voltage on Frame connector. Voltage switches on fully because Control Logic responds to disconnected Thermistor as a cold fuser. Switch off machine if fuser heat rod is on for more than 40 seconds. Open interlocks will invalidate voltage check. Move meter probes around to ensure contact is made with terminals inside holes.4) (REP 10. Measure resistance between pins 1 and 6 on Fuser Module Connector (Figure 1). Then a low AC voltage reading is measured. Resistance should be between 2k ohms (hot fuser) and 300k ohms (cold fuser).1).5 – 10 ohms for a 220 volt machine. Y N Replace LVPS. Replace both Main PWB (PL 1.5 ohms for a 110 volt machine or 5. Clear U4 status code. Resistance should be either 1. With meter probes. Do not install it at this time.5 ohms for a 110 volt machine or 5. Switch off machine. Y N Replace LVPS. c. Continue to observe light from fuser heat rod and make a few copies. When machine is switched on. b. resistance should be either 1. Reassemble machine without Fuser Module. Observe area around fuser heat rod and switch on machine. Ensure Door Module and Front Door is closed as far as possible. press 0 key and press START button. Repeat Step 6 after replacing LVPS. Thermostat. 6. With meter probes prepare to measure voltage between pins 1 and 6 of Frame Mounted Connector. Switch off machine. Press and hold 0 key and switch on machine. Go to step 5. Switch on machine and measure voltage. go into diagnostic mode.1). c. Fuser heat rod power should alternate between on and off within 40 seconds after fuser heat rod illuminates. Continue measuring voltage for approximately 30 seconds. Install Fuser Module (REP 10. prepare to measure voltage between pins 1 and 6 of Frame Mounted Connector. press 0 key and press Start button. Switch on machine power.C Measure resistance between pins 2 and 3 on Fuser Module Connector (Figure 1). and after approximately 30 seconds or less changes to a lower value.1). Do not install it at this time. When machine is switched on. Y N You should have already switched off machine per previous CAUTION and instruction below. Switch off power. Resistance is less than 2 ohms. Do not install it at this time. voltage should be greater than 10VAC but less than 50VAC. D Initial Issue WorkCentre Pro 420 9/02 2-41 Status Indicator RAP/Other Faults U4 . Resistance is in this range. • • Remove Top Cover (REP 14.1).2) and LVPS PWB (PL 1. b. enter [10-1]. Make resistance check on Thermostat and Heat Rod on Fuser Module. 5.4) (REP 10. A new Fuser Module is required (PL 1. Go to step 6.5 – 4. Either Remove Control Panel (REP 1. Check leakage voltage at Frame Mounted Connector (Figure 1). If voltage is not in the range mentioned above. c. Fuser control is operating correctly with no load. If light from fuser heat rod continues to cycle off and on while making copies. Resistance is in this range. Voltage is either 110 VAC or 220 VAC between pins 1 and 6 of Frame Mounted Connector. a. d. Switch off machine if light from fuser heat rod does not alternate off and on within 40 seconds after light is first seen. Y N Check Thermostat before replacing Heat Rod. CAUTION Fuser Module will fail if light from fuser heat rod is visible for more than 50 seconds. replace MAIN PWB. fuser temperature regulation appears to be working. repeat check as stated above. • ADF (REP 14. Go to Step 6.1) or look through cooling vents on rear cover to see light from fuser heat rod. D 8. If voltage does not drop after 30 seconds. With meter probes on each Heat Rod terminal. Go to Step 6. replace MAIN PWB. Y N Heat Rod. Replace Power Cord (PL 1. Connect power cord. Y N Check customers power outlet for correct voltage. Y N Go to U4 RAP. Status Indicator RAP/Other Faults U5 9/02 2-42 Initial Issue WorkCentre Pro 420 . MAIN PWB in sequence. fans.U5 RAP U5–0: Fuser temperature dropped below specific temperature for more than 5 seconds.2). Appliances such as water heaters. If a problem continues. The voltage between J205-2 and J205-3 on LVPS has either 110VDC or 220VDC. (Including POWER SUPPLY PWB). replace LVPS. Voltage should be either 110VDC or 220VDC. If no problems are found. U5–1: Zero crossing signal is not present. and air conditions induce fluctuation in power that may result in a U5 Status Code. Disconnect power cord and measure voltage between ACH and CAN. Y N There is a problem with customers power outlet. Inform customer that service is required to restore power to power outlet. Switch on machine. Voltage measures 110 VAC or 220 VAC. Procedure Status code is U5–1. Y N Check circuit from Power Cord to LVPS. Check circuit where machine is connected. check connection between MAIN PWB and LVPS. clocks. dehumidifiers. Check the wire between J211-6 on LVPS and P311-6 on PCM PWB for an open circuit or poor contact. Replace PCM PWB. • • Connect black meter wire to P402-5 on Tray 1 Control PWB (Figure 4). If the U6-0 problem continues. Switch on machine. Procedure Status code is U6-1 Y N If status code is U6-4. Tray 1.1). Pull out and push in Drum Cartridge (REP 9. Replace PCM PWB. disconnect and reconnect Tray1 and Tray 2 harness. Resistance is less than 5 ohms.5). Disconnect and reconnect Tray 1 Tray 2 Harness. replace MAIN PWB. Y N Connect red meter wire to CN2-5 on PCM Interface PWB (Figure 3). C Y Initial Actions • • Switch off machine. Measure resistance (ohms) of Signal circuit. Y N • Switch off machine. If Tray 2 is present.2).A B U6 RAP U6-0: Printer control communication failure.2) (REP 8. U6-4: NVM signal failure. Resistance is less than 5 ohms. Connect black meter wire to P402 on Tray 1 Control PWB (Figure 4). Disconnect and reconnect Tray 1 Interface Harness (Figure 1). replace PCM PWB. U6-4 continues. When U6-1 occurs. Connect red meter wire to P/J109-A7 on Main PWB (Figure 6). Y N Connect red meter wire to P311-7 on PCM Interface PWB (Figure 3). Resistance is less than 5 ohms. Y N Connect red meter wire to CN2-4 on PCM Interface PWB (Figure 3). Resistance is less than 5 ohms. • • • • Switch off machine. • • Connect black meter wire to P402-2 on Tray 1 Control PWB (Figure 4). Resistance is less than 5 ohms.20). Y N Connect red meter wire to CN1-6 on PCM Interface PWB (Figure 3). Y N Then status code is U6-0. Open circuit failure in Signal or Clock circuit or internal communication failure in MAIN PWB. N Check the wire between P302-6 on PCM PWB and J402-6 on Tray 1 Control PWB for an open circuit or poor contact. If no problems are found.2) (REP 8. Y N Replace MAIN PWB.1).20). switch off machine and switch it on again. Replace MAIN PWB. Resistance is less than 5 ohms. Resistance is less than 5 ohms. Remove and reinstall Drum Cartridge (REP 9. Y N Connect red meter to P302-2 on PCM PWB. or Tray 2 communication failure. Check the wire between J212-8 on LVPS and P312-8 on PCM PWB for an open circuit or poor contact. Tray 1 Feed Motor also runs and jams paper in tray. Y N Check the wire between P302-5 on PWC PWB and J402-5 on Tray 1 Control PWB for an open circuit or poor contact. Open circuit failure in DC COM (Figure 2). Check the wire between J211-7 on LVPS and P311-7 on PCM PWB for an open circuit or poor contact. Connect red meter wire to P/J109-A5 on Main PWB (Figure 6). switch on machine again. • • • • • Remove Rear Cover (REP 14. wait 10 seconds. A B C Initial Issue WorkCentre Pro 420 9/02 2-43 Status Indicator RAP/Other Faults U6 . Resistance is less than 5 ohms. remove the Tray 2 Rear Cover (REP 14. Replace Tray 1 Control PWB (PL 4. U6-1 status code continues. Connect red meter wire to P312-8 or 9 on PCM Interface PWB (Figure 3). Replace Tray 1 Control PWB (PL 4. Measure resistance of Clock circuit. Remove the Tray 2 Rear Cover. Y N Check the wire between P302-2 on PCM PWB and J402-2 on Tray 1 Control PWB for an open circuit or poor contact. U6-1: Drum Cartridge. Y N Go to Service Call Procedures in Section 1.2) (REP 1. Harness is free of damage. Y N Replace Control Panel Harness (PL 3. replace Control Panel PWB (PL 4. Procedure Check Control Panel harness for damage. Go to OF 16–2 Ground RAP to check all machine grounds.U7. If U8 status code continues.4).1) (REP 1. U8 status code continues. replace Main PWB (PL 1. and verify machine operation. • Remove Document Cover (REP 14. U8 RAP U7: Control Panel communication from Main PWB failed. U8 9/02 2-44 Initial Issue WorkCentre Pro 420 . Status Indicator RAP/Other Faults U7. • • If U8 status code continues. U8: Control Panel communication to Main PWB failed.2) Return to Service Call Procedures in Section 1.1). Disconnect and reconnect Control Panel harness connectors. Y N Return to Service Call Procedures. Reassemble machine. Y N Repair as required (PL 3.1). • Remove Top Cover (REP 14. Machine is ready to copy.1).1). U8 .Initial Issue WorkCentre Pro 420 9/02 2-45 Status Indicator RAP/Other Faults U7. Remove Drum Cartridge (REP 9. Switch on machine. Replace Drum Cartridge. Make a few copies.U9 RAP U9-0: High Voltage Power Supply Error A HVPS output is shorted or overloaded. Y N Return to Service Call Procedures. replace Main PWB (PL 1. Switch on machine. Clean corresponding contacts on machine frame.1) (REP 9. Switch off machine. If U9 status code continues. A U9 Status Code is displayed after machine is switched on or while making copies. Y N Replace Transfer Detack Corotron (PL 5.2).1) and clean contacts on top of cartridge. A U9 status code is displayed. A Status Indicator RAP/Other Faults U9 9/02 2-46 Initial Issue WorkCentre Pro 420 .2) (REP 1.2). U9 Status Code is displayed after power up. • Clean Transfer Detack Corotron Contacts (Figure 1) at front end of Transfer Detack Corotron with film remover or cleaning solvent.1). Procedure NOTE: Possible cause of U9 is high voltage arcing at Transfer Detack Corotron or Drum Cartridge contacts.2). Switch off machine. Clean corresponding contacts on machine frame. Replace HVPS (PL 1. Remove Transfer Detack Corotron (REP 9. Do following: • Clean Transfer Detack Corotron with a dry brush. Remove Drum Cartridge (REP 9. • • Switch machine off and then on. Y N A J3 status code should be displayed if HVPS is functional.5).2) (REP 1.1). If a button does not respond. Disassemble Control Panel and replace buttons as required (PL 4.1). remove Control Panel (REP 1. Number keys should show number in display. Disassemble Control Panel and replace Control Panel PWB or buttons as required (PL 4.1).1). Your indication should be a display change for each key press. Press each key. Initial Issue WorkCentre Pro 420 9/02 2-47 Status Indicator RAP/Other Faults OF 1-1 CONTROL PANEL RAP . Y N Some illuminated indicators are visible. Diagnostics [2–2] is ready.OF 1-1 CONTROL PANEL RAP Control Panel problem Procedure Enter diagnostics [2–2]. remove Control Panel (REP 1. Y N Go to the OF 2-1 Blank Display and LVPS RAP. Check that buttons are free to actuate and deactuate. If any button actuation does not change display. Y N Replace Tray 1 Control PWB (PL 4. Disconnect and reconnect Tray 1 Tray 2 Harness. Figure 1 Paper Trays Machine Run Circuit Diagram Approximately +5 VDC is measured. Disconnect and reconnect Tray 1 Interface Harness (Figure 2). Perform following: • • • • • Machine run problem continues. Y N Connect red meter wire to CN1-5 on PCM Interface PWB (Figure 3). If Tray 2 is present. • • • Switch on machine. • Connect red meter wire to J3-3 on Tray 1 Control PWB (Figure 4).4).3) (REP 1.2). Resistance is 5 ohms or less. A Status Indicator RAP/Other Faults OF 1-2 MACHINE RUN RAP 9/02 2-48 Initial Issue WorkCentre Pro 420 . Check +5 VDC wire between Tray 1 Control PWB and machine (Figure 1). Replace PCM Interface PWB (PL 1. Switch off machine.2) (REP 8.2).OF 1-2 MACHINE RUN RAP Machine run problem. Switch on machine. Y N Replace Tray 1/Interface PWB Harness (PL 4. Y N Replace Tray 1 Control PWB (PL 4. Connect red meter wire to J2-3 on Tray 1 Control PWB (Figure 4).2) (REP 8. Approximately +5 VDC is measured. Y N Replace LVPS (PL 1. • • • Switch off machine. Connect red meter wire to CN1-11 on PCM Interface PWB (Figure 3).2) (REP 1. Replace LVPS (PL 1. Connect red meter wire to CN3-A09 on Main PWB (Figure 6). Check Control wire (Figure 1).3).3) (REP 1.2). Resistance is 5 ohms or less. Machine is equipped with Tray 2.2). Y N Replace Tray 1/Interface PWB Harness (PL 4. Connect black meter wire to J2-8 on Tray 1 Control PWB (Figure 4). Approximately +5 VDC is measured.3). Remove Rear Cover (REP 14. Connect red meter wire to J2-3 on Tray 2 Control PWB (Figure 4). Replace Tray 2 to Tray 1 Harness (PL 4. Approximately +5 VDC is measured. remove the Tray 2 Rear Cover (REP 14.4).20). Procedure If machine runs without making copy. Y N Return to service call procedures in Section 1. Check +5 VDC wire between Tray 1 Control PWB and Tray 2 Control PWB (Figure 1). A Connect red meter wire to CN2-1 on PCM Interface PWB (Figure 3). • Open circuit in +5 VDC or Data between Tray 1 Control PWB and Tray 2 Control PWB (Figure 1).2).2) (REP 1. check following: • Open circuit in Control or +5 VDC between Tray 1 Control PWB and PCM Interface PWB (Figure 1). Connect black meter wire to Main PWB metal frame. Y N Replace Tray 1/Interface PWB Harness (PL 4. Y N Replace PCM Interface PWB (PL 1.5).20). Y N Connect red meter wire to CN2-2 on PCM Interface PWB (Figure 3). Approximately +5 VDC is measured. Resistance is 5 ohms or less.Tray 1 Interface Harness Tray 1 Tray 2 Harness Figure 5 LVPS PWB Figure 2 Paper Tray Harness Figure 3 PCM Interface PWB Figure 4 Tray Control PWB Initial Issue WorkCentre Pro 420 9/02 2-49 Status Indicator RAP/Other Faults OF 1-2 MACHINE RUN RAP .Figure 6 Main PWB Status Indicator RAP/Other Faults OF 1-2 MACHINE RUN RAP 9/02 2-50 Initial Issue WorkCentre Pro 420 . Switch meter to DC voltage measurement. Connect black meter wire to Main PWB metal frame.4).2) (REP 1. Replace Cooling Fan (PL 1.2).2). Check for 9 VAC with red meter wire at CN1-9 on PCM Interface PWB (Figure 4). Y N Remove Rear Cover (REP 14.3). Y N Check for approximately +24 VDC at CN1-4 on PCM Interface PWB (Figure 4).OF 1-3 COOLING FAN RAP Cooling Fan problem NOTE: Cooling Fan operates at full speed while Main Drive Motor is energized and operates at reduced speed when machine is ready. Approximately +24 VDC is measured. and then voltage changes to approximately +0.2 VAC with red meter wire at CN3-A05 on Main PWB (Figure 3).4).2) (REP 1. Approximately +24 VDC is measured.2 VAC is measured. and then voltage changes to approximately +5 VDC after pressing Start.1 VDC after pressing Start. Check for +24 VDC at CN4-2 on PCM Interface PWB (Figure 4). Check that voltage changes to +0. Y N Replace LVPS (PL 1. Procedure Cooling Fan makes excessive noise. Y N Replace Cooling Fan (PL 1. Check for +24 VDC at CN4-1 on PCM Interface PWB (Figure 4). Approximately 2. Switch meter to DC voltage measurement.2). Replace PCM Interface PWB (PL 1. Replace Cooling Fan (PL 1. Approximately +24 VDC is measured.3) (REP 1. Check that voltage changes to +5 VDC after pressing Start to copy. Figure 1 Cooling Fan Motor Circuit Diagram Figure 2 LVPS PWB Initial Issue WorkCentre Pro 420 9/02 2-51 Status Indicator RAP/Other Faults OF 1-3 COOLING FAN RAP . Y N Replace LVPS (PL 1. Y N Replace Main PWB (PL 1.1 VDC after pressing Start to copy.3) (REP 1. Approximately 9 VAC is measured.2). Check for 2.2).Figure 3 Main PWB Figure 4 PCM Interface PWB Status Indicator RAP/Other Faults OF 1-3 COOLING FAN RAP 9/02 2-52 Initial Issue WorkCentre Pro 420 .Initial Issue WorkCentre Pro 420 9/02 2-53 Status Indicator RAP/Other Faults OF 1-3 COOLING FAN RAP . C12. Front Door Interlock. Y N Check customers power outlet for correct voltage.1). A blank display indicates a problem with one of following: • Customers power outlet • • • • • Power cord Input power circuit on LVPS Control Panel PWB and indicators +5 VDC to Control Panel +5 VDC on LVPS Figure 1 Power Cord at Machine End ACN Ground ACH NOTE: RAP verifies voltage to machine. Disconnect power cord from machine. or Main PWB do not control or regulate generation of +5 VDC.2). or C13 on the Main PWB (Figure 6). Replace Control Panel Harness (PL 3.3) (REP 1. replace Control Panel PWB (PL 4. Y N Remove Rear Cover (REP 14. Connect black meter wire to CN1-9 and red meter wIre to CN1-2 on the Main PWB (Figure 6).2) (REP 1. Door Module Interlock.OF 2-1 BLANK DISPLAY RAP Appropriate Control Panel indicators not illuminated. C4. go to RAP now. Y N There is a problem with customers power outlet. C11. Remove Top Cover (REP 14. Procedure NOTE: If Status Code is displayed. A Status Indicator RAP/Other Faults Figure 2 Control Panel +5 VDC and DC COM DC COM Data Port +5 VDC Data Port OF 2-1 BLANK DISPLAY RAP 9/02 2-54 Initial Issue WorkCentre Pro 420 . Voltage measures 110 VAC or 220 VAC. Press Switch On on Power Switch (Figure 3). or LVPS or Main PWB failure. Open Front Door. Approximately +5 VDC is measured. C3. A Replace Control Panel PWB (PL 4.2).4) Replace Main PWB (PL 1. Inform customer that service is required to restore power to power outlet. Check Control Panel Harness for visible damage. Approximately +5 VDC is measured. Then +5 VDC at Control Panel is checked followed by +5 VDC on LVPS.1) if required. Connect red meter wIre to CN3-C10. Replace Power Cord (PL 1.1). +5 VDC distribution failure. Approximately +5 VDC is measured. Y N Connect black meter wire to CN3-C2. Voltage measures 110 VAC or 220 VAC. or C5 on the Main PWB (Figure 6). Check for 110 VAC or 220 VAC at power cord between ACN and ACH (Figure 1).1). If not damaged. Y N Replace LVPS (PL 1. Connect black meter wire to DC COM test hole and red meter wIre to +5 VDC test hole (Figure 2).2).Power Cord Receptacle Power Switch Switch On Switch Off ACH Ground ACN Figure 3 Power Switch and Power Cord Receptacle Figure 5 LVPS PWB Figure 4 Control Panel Circuit Diagram Initial Issue WorkCentre Pro 420 9/02 2-55 Status Indicator RAP/Other Faults OF 2-1 BLANK DISPLAY RAP .Figure 6 Main PWB Status Indicator RAP/Other Faults OF 2-1 BLANK DISPLAY RAP 9/02 2-56 Initial Issue WorkCentre Pro 420 .Initial Issue WorkCentre Pro 420 9/02 2-57 Status Indicator RAP/Other Faults OF 2-1 BLANK DISPLAY RAP . Procedure Check inch or mm setting for paper trays: • Press and hold Paper Tray select button until lights flash on machine diagram. (PL 4. (PL 4. Y N While tray is in use. Y N Enter correct number. Problem is identified. Y N Call service support for assistance. Bypass Tray (PL 6.5).3) Check that Side Guide and End Guides are correctly positioned. Refer to Customer Programmable Options in Section 6. Go to C7 RAP for Tray 1 or C8 RAP for Tray 2.2). A 0 is displayed for inch paper size and 1 for metric paper size. Y N Two or more sheets of paper feed together. Go to C5 RAP for Tray 1 or C6 RAP for Tray 2.OF 7-1 PAPER TRAY RAP Paper tray problem. Y N Tray 2 can be selected on Control Panel. Remove Tray 2 Rear Cover (REP 14. Figure 1 LVPS PWB Status Indicator RAP/Other Faults OF 7-1 PAPER TRAY RAP 9/02 2-58 Initial Issue WorkCentre Pro 420 . • Enter 16 and press Start button. Tray 2. No indication when tray is empty. Correct number is displayed for machine usage. Tray problem is described in this RAP. it can be opened without declaring a status code. Attempt to repair problem with reference to parts lists: Tray 1. Check Tray 1 to Tray 2 Harness connections (PL 4.2).2). Y N Control logic should recognize when Tray 2 is installed after power is switched on.Figure 2 Main PWB Initial Issue WorkCentre Pro 420 9/02 2-59 Status Indicator RAP/Other Faults OF 7-1 PAPER TRAY RAP . Refer to label on paper tray.2). Long Edge Feed Back Edge Back Edge Lead Edge Paper Movement Output Tray end of machine Front Edge Front of Machine Figure 2 Paper Orientation Terms Trail Edge Lead Edge Paper Movement Output Tray end of Machine Trail Edge Short Edge Feed Procedure NOTE: If copy paper is wrinkled. or copies do not stack correctly in Exit Tray.7). Repair as required (PL 6. Paper stored for months in boxes or weeks in opened wrappers absorbs moisture and curls more than paper stored for shorter time before it is used. Check paper storage condition. There should be 1 to 2 mm movement when door is pushed to right and door moves left 1 to 2 mm when released. flip paper over. Ensure Side Guides (Figure 1) are adjusted to paper without pinching paper. if a lead edge tear occurs in Lead Edge (Figure 2) where Retard Pad (Figure 1) is positioned. go to IQ 16 Wrinkle RAP. Check Exit Transport components are in good condition. • • • Check that drive belt and drive gears are in good condition. Check Paper Guides are adjusted to paper without pinching or squeezing paper. When using Bypass Tray. Do following to Door Module.2). Reinstall paper. Repair as required (PL 6. • Check that Door Module Latches hold door securely closed. Ensure 50 or less sheets are loaded.OF 8-1 PAPER DAMAGE or STACKING RAP Paper exits machine damaged. Front Edge • Retard Pad Bypass Feed Roll Side Guides Figure 1 Bypass Tray Input Status Indicator RAP/Other Faults OF 8-1 PAPER DAMAGE or STACKING RAP 9/02 2-60 Initial Issue WorkCentre Pro 420 . Check mounting of Output Tray (REP 8. Check the following: • • • • Remove paper from tray and fan it to ensure edges are separated. Repair as required (PL 6.2).Initial Issue WorkCentre Pro 420 9/02 2-61 Status Indicator RAP/Other Faults OF 8-1 PAPER DAMAGE or STACKING RAP .4).1] Test Pattern Main PWB Print Components Figure 3 Main PWB Print Components Figure 1 Code Stop 9 Test Pattern Status Indicator RAP/Other Faults OF 14-1 PRINTER RAP 9/02 2-62 Initial Issue WorkCentre Pro 420 .4).2) (REP 1.2). Figure 2 Diagnostic Code [1 . There is an application problem with the PC. Discolored components are visible.2). Y N Replace Main PWB (PL 1.2) (REP 1. Remove Rear Cover (REP 14. Image is correct (Figure 1). Y N Repair as required (PL 1. Enter diagnostic [1-1]. Procedure Press and hold Stop button and press 9 button. Y N Check print connections to Main PWB are secure. Replace Main PWB (PL 1. Print connections are secure.4) or appropriate component such as NIC or USB components. Test print is produced. Image is correct (Figure 2).OF 14-1 PRINTER RAP Printed Image quality or printer function problem. Examine Main PWB for discolored components.2) (REP 1. Y N Replace Main PWB (PL 1.Initial Issue WorkCentre Pro 420 9/02 2-63 Status Indicator RAP/Other Faults OF 14-1 PRINTER RAP . Cooling Fan operates at slow speed when machine is ready.1). Manually raise Registration Assembly to engage drives. These components are checked last. Make several more copies. Install a jumper between pins 1 and 4 on Door Interface PWB (Figure 3). Close Front Door if it is open. Remove RIS (REP 6.4). Enter [4–1] and press Start button to operate drives. Noise continues. and 2 if equipped. Check if odor is strongest at Printer PWB.2) (REP 1.2) if it is determined that one of PWB’s is cause of odor. Remove Fuser Module (REP 10. incorrect mounting. Status Codes must be serviced before servicing Other Faults on these pages. Noise continues.3) (REP 1.1). A B Status Indicator RAP/Other Faults C 9/02 2-64 Initial Issue WorkCentre Pro 420 OF 16-1 NOISE or ODOR RAP . Observe carriages in RIS and then switch off and switch on machine. Y N Go to OF 1–3 Cooling Fan RAP.4). Press Start button to load 1. CAUTION Image Quality defects will occur if mirrors in both carriages are not cleaned and RIS Module is not vacuumed before reinstalling Document Glass.5). Do following to apply power to LVPS and Main PWB.4) (REP 9. NOTE: It is unusual that a continuous odor is caused by burning or overheated electrical components on LVPS. Lift Door Module slightly to enable this action.1). Press Start button. Remove Drum Cartridge (REP 9. Press Start button to operate drives. Y N Go to OF 1–3 Cooling Fan RAP. Cooling Fan operates. replace RIS Module (PL 1. Noise continues. Noise continues.1). • Enter Diagnostic Code [10–4] and press Start button. Connect a jumper between CN1–1 and CN1–4 on Door Interface PWB (Figure 3) . Odor occurs only when running special customer paper stock or labels. Scanning carriages in RIS module operate free of unusual noise. Ensure Front Door and Door Module remains closed during next diagnostic action. Fuser Module (PL 1. Y N Odor is strongest at Fuser Module. Ensure Front Door and Door Module remains closed during next diagnostic action. Procedure NOTE: If a Status Code is displayed during service call that is not clearable (assuming no jammed paper remains in machine. Y N Return to Service Call Procedures in Section 1. doors are closed. Y N Then problem is unusual odor. Refer to Supplemental Tools and Supplies in Section 6 for a lubricant. Remove Rear Cover (REP 14. If RIS Module noise continues. Check that [4–1] is still entered. Inspect fuser rolls for unidentified residue. Y N Replace Drum Cartridge under warranty (PL 1. or Main PWB without causing a fuse failure on LVPS and a blank display. Check that [4–1] is still entered. B • • Press 1 key to enter a 1.2) and operate machine.1). Y N Replace Fuser Module (PL 1. Your observation should be a blinking 1 to indicate 1 is loaded.A OF 16-1 NOISE or ODOR RAP There is a problem with how machine sounds. or machine is producing a burning.1). Y N Remove Document Glass (REP 6. Check PWB’s for odor. Odor is strongest at Main PWB. Y N Scan Home Sensor is failed low. Reinstall Drum Cartridge (REP 9.1). Y N Check PWB’s for signs of discoloration or excess heat. LVPS (PL 1. Check Scan Home Sensor wires and RIS connections for visible damage. a Check that unique paper stock or labels fits within specifications listed in Table 1 Copy Paper Specifications in Section 6. or other signs of failure. or other unusual odor. Inform customer how machine is expected to work with standard paper stock and labels. RIS Module (PL 1. is full). Exit Diagnostics. • Clean rails that support carriages. • • Ensure Front Door Interlock Switch is cheated or keep Front Door closed. If components appear good. • Apply a small quantity of lubricant to pulley shafts and ends of cable shafts. Carriages move to right and then to left free of excess noise. HVPS. Do following on RIS Module. Clean rolls with a dry cloth.1). Y N Make a copy and observe Cooling Fan at rear of machine. Reassemble machine and verify that RIS Module operates free of noise.4) or Main PWB (PL 1. Leave Door Module open. Problem is noise. Lubricate Registration Roll bearings (Figure 4). Make a copy while observing scanning carriages in RIS Module. • Press Switch On on Power Switch (Figure 1). Do following to lower fuser operating temperature. and Tray 1. Remove Fuser Module (REP 10. ozone. Carriages should move to right slightly and then to left without producing a tapping noise. If noise is heard before manually engaging Registration Assembly lubricate Drives Module (PL 3.C Y N Problem is in Door Module. Door Interface PWB There is a problem with Drives Module or Registration Assembly. Lubricate ends of drive shafts and gears with a minimal amount of oil (Table 1 Supplemental Tools and Supplies in Section 1). Power Cord Receptacle Power Switch Figure 3 Door Interface PWB Switch Off ACH Ground ACN Switch On Registration Clutch Drive Gear Registration Clutch Registration Roll Figure 1 Power Switch and Power Cord Receptacle Registration Sensor (under Reg Assy.1) (REP 4. If noise is heard when manually engaging Registration Assembly Lubricate ends of drive shafts and gears with a minimal amount of oil (Table 1 Supplemental Tools and Supplies in Section 1).) Figure 4 Registration Components Figure 2 LVPS PWB Initial Issue WorkCentre Pro 420 9/02 2-65 Status Indicator RAP/Other Faults OF 16-1 NOISE or ODOR RAP .1).3) (REP 1. ii.OF 16-2 GROUND RAP Ground Circuit problem that causes: • • • Intermittent abnormal machine operation Image quality problems Intermittent status codes Procedure NOTE: Figure 17 shows chassis or earth ground circuit for machine. iii. Meter should indicate less than 5 ohms. Open Door Module and connect other meter clip to Fuser Module Ground (Figure 1). Select lowest ohms scale. Attach clips to both meter wires and connect together. ii. Set up ohmmeter. b. i. Measure Fuser Module Ground. go to step 2. Check that Fuser Module Ground (Figure 1) is connected to Power Cord Receptacle ground (Figure 2). Go to step 1 for detailed information on checking machine grounds. a. Fuser Module Ground Wire WARNING Physical contact with power receptacle voltage at fuser may occur if both of following failures occur: • • There is an open circuit failure in Fuser Module Ground. Switch On Switch Off ACH Ground ACN Figure 2 Power Switch and Power Cord Receptacle c. Status Indicator RAP/Other Faults OF 16-2 GROUND RAP 9/02 2-66 Initial Issue WorkCentre Pro 420 . Less than 5 ohms is measured between any 2 positions in ground circuit. Disconnect Power Cord from Power Cord Receptacle at right side of machine (Figure 2). replace LVPS (PL 1. Select ohms on meter. Connect an meter clip to Ground pin (Figure 2). i.4). Power Switch Power Cord Receptacle Figure 1 Fuser Module Ground Wire Fuser Module metal frame will be at power receptacle voltage and machine may operate normally. If more than 5 ohms is measured. 1. iii. If less than 5 ohms is measured. There is a failure in Fuser Module and power receptacle voltage touches metal Fuser frame. Meter should indicate less than 1 ohm. d.3) (REP 1.4). Connect black meter wire to Main PWB metal frame. go to step 4. Connect red meter wire to Middle Ground Contact (Figure 4). go to step c. Screw HVPS Ground Middle Ground Contact Main PWB Metal Frame Figure 3 Main PWB Metal Frame Screw Figure 4 HVPS and Transfer Roll Ground Initial Issue WorkCentre Pro 420 9/02 2-67 Status Indicator RAP/Other Faults OF 16-2 GROUND RAP . do following: • • • Check that all 9 screws are installed in LVPS (REP 1. a. If less than 5 ohms is measured. go to step 3. c. Check Middle Ground Contact for Transfer Detack Corotron. c. replace LVPS at this time (PL 1. b.4) 3. If more than 5 ohms is measured.2). If screws are installed as described above. If less than 5 ohms is measured. a. b. If more than 5 ohms is measured. Remove Rear Cover (REP 14. Remove Right Cover (REP 14.3). check installation of Transfer Detack Contact Block (PL 1. check installation of HVPS (REP 1.5) and connection at HVPS Ground. Check that screw is installed in Main PWB Frame (Figure 3). Connect red meter wire to Main PWB Metal Frame. If more than 5 ohms is measured. Check that black meter wire is connected to Ground pin (Figure 2).2. Check Main PWB Metal Frame (Figure 3).2). Connect red meter wire to HVPS Ground (Figure 4). If less than 5 ohms is measured. If less than 5 ohms is measured.3). check wires from Registration Roll Assembly to connector for visible damage. Reg Roll Clip Reg Roll Clip Figure 5 Transfer Roll Clip Figure 7 Registration Roll Clip Middle Contact Figure 6 Transfer Roll Ground Pin 2 (green wire) ground wire Figure 8 Registration Roll Ground Connector Status Indicator RAP/Other Faults OF 16-2 GROUND RAP 9/02 2-68 Initial Issue WorkCentre Pro 420 . Check Registration Roll Ground.2).1) (REP 8.1) (REP 9.2) (REP 1. go to step 6. If less than 5 ohms is measured. Transfer Reg Roll Transfer Roll Clip Roll 5. Connect black meter wire to Main PWB metal frame. If less than 5 ohms is measured.4. do following: c. Connect red meter wire to Registration Roll Clip (Figure 7). If more than 5 ohms is measured. clean Transfer Roll Clip (refer to Table 3 in Maintenance Procedures in Section 1) If more than 5 ohms is measured again. Repair damage or replace Registration Assembly (PL 5. Connect red meter wire to Transfer Roll (Figure 5). go to step 5. b. Connect red meter wire to pin 2 Ground Wire (Figure 8) . a. replace Transfer Detack Corotron (PL 5. Connect black meter wire to Middle Contact (Figure 6).2). b. a. If more than 5 ohms is measured. Check Transfer Roll Ground. replace PCM Interface PWB (PL 1. If more than 5 ohms is measured. Connect red meter wire to Drum Cartridge Ground (Figure 10). If RIS Ground Wire is connected to RIS Ground Clip. replace LVPS (PL 1. continue with step c: c. If more than 5 ohms is measured. Connect red meter wire to metal RIS Frame (Figure 10).1). RIS Frame RIS Ground Wire Drum Cartridge Ground Figure 9 Drum Cartridge Ground Main PWB Metal Frame Figure 10 RIS Ground Initial Issue WorkCentre Pro 420 9/02 2-69 Status Indicator RAP/Other Faults OF 16-2 GROUND RAP . Check Drum Cartridge Ground a. 7. Check that RIS Ground Wire is connected to RIS Ground Clip (Figure 10). b. Check RIS Ground.6. If installation is good. go to step 7.2). If more than 5 ohms is measured. c.3) (REP 1. b. check installation of RIS (REP 6. Connect black meter wire to Main PWB metal frame (Figure 10). Remove Drum Cartridge (REP 9. If RIS Ground Clip is not present.1). a.5) and connection on Main PWB at CN7. If less than 5 ohms is measured. Connect black meter wire to Main PWB metal frame (Figure 10). replace RIS Ground Clip (PL 1.4). check installation of HVPS (REP 1. go to step 7. If less than 5 ohms is measured.2) j. a. replace Drive Module (PL 1. Check Paper Tray ground. continue with step c: c.4). replace PCM Interface PWB (PL 1. grounds checkout is complete. Connect red meter wire to CN2-6 on PCM Interface PWB (Figure 15). Loosen and retighten screws (2) on Tray 1 Control PWB. If Tray 2 is present continue with step g. If Tray 2 is not present grounds checkout is complete. ground checkout is complete. e. continue with step d. Loosen and retighten screws (2) on Tray 2 Control PWB.3).1) and clean hole in Fuser Module frame for Drive Module Ground. continue with step e. If less than 5 ohms is measured. continue with step j.2) (REP 1. Connect red meter wire to Drive Module metal frame.2). If more than 5 ohms is measured. replace Tray 1 Interface Harness (PL 4. h. Connect red meter wire to CN1-19 on PCM Interface PWB (Figure 15). If more than 5 ohms is measured. If more than 5 ohms is measured. b. If less than 5 ohms is measured. If less than 5 ohms is measured. Connect black meter wire to Main PWB Metal Frame (Figure 10). c. If more than 5 ohms is measured. f. b. If less than 5 ohms is measured. If more than 5 ohms is measured. If more than 5 ohms is measured. Remove Fuser Module (REP 10.8. replace Tray 1 Tray 2 Harness (PL 4.2). Connect red meter wire to J3-7on Tray 1 Control PWB (Figure 14). Connect red meter wire to J2-7 on Tray 1 Control PWB (Figure 14) . If more than 5 ohms is measured. If more than 5 ohms is measured.2) i. Clean Drive Module Ground (Figure 11) and reinstall Drive Module. Status Indicator RAP/Other Faults OF 16-2 GROUND RAP 9/02 2-70 Initial Issue WorkCentre Pro 420 . Connect red meter wire to Metal Paper Tray Frame of Tray 1 (Figure 12). If less than 5 ohms is measured. replace LVPS (PL 1. d.3) (REP 1. If less than 5 ohms is measured. g. continue with step f. a. continue with step c. If more than 5 ohms is measured. Repeat check. Connect red meter wire to J2-7on Tray 2 Control PWB. Repeat check. Check Drive Module ground. Tray 2 Metal Frame Figure 12 Paper Tray Ground X7 Tray 1 Metal Frame Figure 11 Drive Module Ground Drive Module Ground 9. If less than 5 ohms is measured. Connect black meter wire to Main PWB metal frame. replace Tray 1 Control PWB (PL 4. continue with step i. Connect black meter wire to X7 on Tray 1 Control PWB (Figure 12).Frame Ground for Tray 1 and Tray 2 Figure 15 PCM Interface PWB Initial Issue WorkCentre Pro 420 9/02 2-71 Status Indicator RAP/Other Faults OF 16-2 GROUND RAP .Figure 13 Tray 1 Tray 2 Ground Circuit X7 Tray 2 PJ Figure 16 LVPS PWB Figure 14 Tray Control PWB Paper Tray PJ 6 .Figure 17 Ground Circuit Paths Status Indicator RAP/Other Faults OF 16-2 GROUND RAP 9/02 2-72 Initial Issue WorkCentre Pro 420 ...................................................................................................Fuser................................................................................... IQ 9 Image Registration RAP ............ Spots ....................................................................................................................................................................................... IQ 12 Skips/Smears RAP .......................................... IQ 18 Other Image Defects RAP .............................................................................................................................................. IQ 2 Background (Uniform) RAP .................... Offsetting.............................................. IQ 4 Blank or No Image RAP ......................................................................................... IQ 1 Background Bands or Random Background RAP.................................................................................................................................. IQ 8 Lines / Streaks RAP ................................................................................................................................................................................................ IQ 3 Black Image RAP ............. Specifications ........................................................................................................................ Defects................................................................................ IQ 7 Image Density RAP ................................................................................................................................. Background .................................................................................................................... IQ 10 Residual Image/ Repeating Image / Offsetting RAP .................Drum Cartridge ............ IQ 15 Fusing RAP ................................................... 3-3 3-3 3-4 3-5 3-6 3-6 3-7 3-8 3-9 3-10 3-14 3-16 3-18 3-20 3-22 3-26 3-28 3-32 3-34 3-38 3-40 3-42 3-44 3-46 3-48 3-50 Initial Issue WorkCentre Pro 420 9/02 3-1 Image Quality ...................................3 Image Quality Image Quality Diagnostics ................................................................................................................ Image Properties................................. IQ 6 Deletions RAP ....................................................... IQ 16 Wrinkle RAP ........................................ IQ 13 Spots RAP........................................................................................................................................ IQ 5 Blurred Image RAP ................................................................................................................................................................. Paper Orientation Terms.................... Image Quality Diagnostics Overview ......................... IQ 11 Skew RAP ................................................................................................................................................................... Spots ............ IQ 17 Curl RAP ........................................................................... Image Quality Specification..........................Image Quality 9/02 3-2 Initial Issue WorkCentre Pro 420 . Transfer/Detack Corotron The most important service action for most Image Quality defects is Transfer/Detack Corotron cleaning. • • • Dirty corotron causes loss of image density and deletions in black image areas Dirty Transfer Roll Drives causes closely spaced bands of uneven density Poor Transfer Roll Ground causes background and image smear Image Quality Diagnostics Overview Benefits of Experience The following Image Quality service actions are required for best performance. Compare Image Quality problem with descriptions in this section. Drum Cartridge replacement is costly compared to cost of cleaning Transfer Detack area components and Document Glass. 2. This information enables shortest path to effective correction actions. Cleaning Transfer Detack Corotron.Image Quality Diagnostics Image quality includes imaged and non-imaged areas of paper. 3. Perform following Transfer/Detack Corotron cleaning actions on every service call. Transfer Roll Drives. Image Quality Diagnos- . Do not replace Drum Cartridge until all other service is done. Use a cotton swab wetted with Film Remover or General Cleaning Solvent to clean Transfer Wire (Figure 1). The information compiled here is extracted from IQ RAP's. 1. Learn this information to minimize time spent finding problem. and Transfer Roll Ground is most important image quality service action. Clean connection between clip and roll by sliding a single layer of heavy duty towel wetted with Film Remover or General Cleaning Solvent through connection to ensure a good electrical contact. Use a clean dry brush to remove excess toner from Transfer/Detack Corotron housing. Transfer Roll Ground Clip Transfer Roll Transfer Detack Corotron Corotron Figure 1 Transfer/Detack Corotron Initial Issue WorkCentre Pro 420 9/02 3-3 Image Quality Image Quality Diagnostics. then go to Image Quality RAP that best describes image problem. Check Transfer Roll Ground Clip (Figure 1) presses against Transfer Roll. If problem is not in this section. Then that value will flash. press 3 key and 6 key to enter a 36. Enter diagnostics [9-10]. If not. Image Quality Image Quality Diagnostics Overview. e. Reduce value by 1. Clean Transfer Corotron wire with a cotton swab wetted with Film Remover or General Cleaning Solvent. If default 37 is flashing. CORRECTIVE ACTION: Do not replace Drum Cartridge as first action. 4. continue. The background appears as spots of background or short strips of background. Verify if background problem is fixed. wait 10 seconds. Verify if background problem is fixed. If not. Background SYMPTOM: Background within 50 mm of lead edge of copy. Scale in millimeters 1.1 in Section 4 of Service Documentation and perform adjustment. b.Repeating Image Defects Image Defects that repeat at fixed intervals on copy can be measured and source identified. Verify if background problem is fixed. Verify if background problem is fixed. If not. Go to ADJ 9. Background 9/02 3-4 Initial Issue WorkCentre Pro 420 . default value. Press Stop button 5 times to exit diagnostics. continue. 2. continue.1). unless an adjustment was already made. Use Repeating Image Defects scale in Figure 2 to identify source of a repeating image defect. Your indication will be a steadily lit 36. Clean Transfer Corotron housing with a dry brush. 94 mm Drum 94 mm Fuser Pressure Roll 3.4) (REP 9. Switch off machine. Your indication will be a flashing 37. Your indication will be a flashing 36 or other value. Press Start button to load 36 or other value. Adjust Transfer Timing as follows. d. The specific usage of this scale follows with service actions required to service Top Problems. f. 21 mm Transfer Roll 46 mm Registration Roll 79 mm Fuser Roll Figure 2 Repeating Image Defects c. Replace Drum Cartridge (PL 1. If not. then switch on machine. all within 50 mm of lead edge of copy (Figure 1). a. continue. 2. Make 20 copies of white document. Spots or Strips of Background CORRECTIVE ACTION: Do not replace Drum Cartridge. If not. Replace Fuser Module (PL 1. 3. Clean spots from Fuser Roll (red roll) with a heavy duty towel wetted with Film Remover or General Cleaning Solvent. If not. Verify if spots problem is fixed. 1.Fuser SYMPTOM: Spots that repeat on copy and that are spaced at fixed intervals. 4. Approximately 79mm or 94mm spacing indicates a Fuser Problem.1). Spots .1). make another 20 copies. continue. continue. If spots problem reduces. Remove Fuser Module (REP 10. Scale in millimeters Figure 1 Spots or Strips of Background within 50 mm of Lead Edge of Copy 21 mm Transfer Roll 46 mm Registration Roll 79 mm Fuser Roll Figure 1 Repeating Image Defects 94 mm Drum 94 mm Fuser Pressure Roll Initial Issue WorkCentre Pro 420 9/02 3-5 Image Quality Background. The Repeating Image Defects scale in Figure 1 shows intervals for Spots and source. Do not replace Fuser Module as first action.4) (REP 10. Verify if spots problem is fixed.Fuser .Spots .1). Recreate offset problem with help of customer to verify image defect. Enter diagnostics [10-4].Drum Cartridge. Do not replace Fuser Module as first action. Remove Fuser Module (REP 10. or 3. Clean Offset image from Fuser Roll (red roll) with a heavy duty towel wetted with Film Remover or General Cleaning Solvent. continue. 3. Your indication will be a steadily lit 1. If not. make another 20 copies.1). Remove Drum Cartridge (REP 9. Press Start button to load 1. 2. Verify if offsetting problem is fixed. Press Stop button 5 times to exit diagnostics. a. Verify if Offsetting problem is fixed. exit diagnostics and go to step 3. Replace Drum Cartridge (PL 1.4) (REP 9. Perform following to reduce Fuser temperature. e.Drum Cartridge SYMPTOM: Spots that repeat on copy and that are spaced at fixed intervals. Replace Fuser Module (PL 1. If offset problem reduces. c. 94 mm spacing indicates a Drum Cartridge Problem. The Repeating Image Defects scale in Figure 1 shows a 79 mm interval for Fuser Roll Offsetting. The Repeating Image Defects scale in Figure 1 shows intervals for Spots and source. A long copy run may be required. 6. Verify if offsetting problem is fixed. 2. Verify if spots problem is fixed. 1. 2.Spots . continue. continue. If not. 1. If a flashing 1 is displayed.1). continue. 5. CORRECTIVE ACTION: Do not replace Drum Cartridge as first action. glue from labels transfers to Drum and creates Spots on copies.1). Make 20 copies of customers problem document. If not.4) (REP 10. Clean spots from Drum with a heavy duty towel wetted with Film Remover or General Cleaning Solvent. d. Scale in millimeters Rotate gear in direction shown to Rotate Drum Figure 2 Drum Rotation 21 mm Transfer Roll 46 mm Registration Roll 79 mm Fuser Roll Figure 1 Repeating Image Defects 94 mm Drum 94 mm Fuser Pressure Roll Image Quality Spots . 3. Scale in millimeters 21 mm Transfer Roll 46 mm Registration Roll 79 mm Fuser Roll Figure 1 Repeating Image Defects 94 mm Drum 94 mm Fuser Pressure Roll 4. If customer runs labels. Press 1 key to enter a 1. Offsetting 9/02 3-6 Initial Issue WorkCentre Pro 420 . CORRECTIVE ACTION: Do not replace Drum Cartridge. Your indication will be a flashing 1. Offsetting SYMPTOM: Images are picked up by Fuser Roll and re-transferred to copy at approximately 79 mm intervals. b. Rotate gear in direction shown to rotate drum (Figure 2). Your indication will be a flashing 1. If not. Image from front edge to back edge (Figure 1 Paper Orientation Terms) or lead edge to trail edge is not parallel to edges of copy.2 mm from lead edge of copy when feeding from Tray 2 or Bypass Tray (Figure 1 Test Pattern 82P524 inch/ 82P523 metric) (C). Blank Copy or Print Blank Copy or Print is a sheet of paper entirely without an image. or wrinkles: Refer to IQ 16 Wrinkle RAP to diagnose wrinkle or paper damage problems with copies or prints. Refer to IQ 4 Blank or No Image RAP to diagnose blank copy problems. No image should be visible within 4. Refer to IQ 3 Black Image RAP to diagnose black copy problems. or offsetting problems. Defects and Specifications contains definitions of both image property characteristics and also defective image characteristics. Back Edge Erase No image should be visible within 1mm of front edge or back edge. Paper Damage Paper Damage including folds.7 patch four times with a paper towel (twice lead edge to trail edge (Figure 1 Paper Orientation Terms) and twice front edge to back edge). Refer to IQ 5 Blurred Image RAP to diagnose resolution problems. The area of missing information is sharply defined. a ghosted image. Image Density Density is relative blackness between image and non-image areas. Specifications . there is a fusing problem. Image should be visible within 5 mm of front edge or back edge (Figure 1). Trail Edge Erase No image should be visible within 1mm of lead edge. nicks. Refer to IQ 1 Background Bands or Random Background RAP or IQ 2 Background (Uniform) RAP to diagnose background problems. A failure mode may be that Image darkness varies across copy. Registration. repeat image. Refer to IQ 15 Fusing RAP to diagnose Fusing problems. Resolution The uniformity or clarity of thin line detail. Refer to IQ 9 Image Registration RAP to diagnose registration or image position problems.5 mm of trail edge (Figure 1). Lead Edge Erase. Front Edge Erase. If image is easily wiped off paper or is easily removed by folding or leafing paper. The horizontal and vertical 3. The image must not smear (Figure 1 Test Pattern 82P524 inch/82P523 metric) (B). or an inverse or negative image. Image Position. Refer to IQ 10 Residual Image/ Repeating Image / Offsetting RAP to diagnose residual image. Refer to IQ 6 Deletions RAP to diagnose deletion problems. and 10 mm ±3. Black Copy or Print Black copy or print copy or print that is totally black with no white areas.3 mm from the centerline of the copy when feeding from Tray 2 or Bypass Tray (Figure 3). Defects. Residual Image. Refer to IQ 11 Skew RAP to diagnose skew problems. Defects. This is unlike deletions where image is not sharply defined or is not a clear image. Background Background is seen as darkness or dirtiness on non-image areas of copy.1 mm from the centerline of the copy (Figure 3) when feeding from Tray 1.8 mm for Tray 1 and 2. Refer to IQ 7 Image Density RAP to diagnose density problems Fuser Fix Fuser fix is a measure of how well toner particles adhere to paper as a result of fusing process. Centerline is shown in Figure 1 (I ). The image can either be a normal image. This defect is a result of failed paper transportation system components. Initial Issue WorkCentre Pro 420 9/02 3-7 Image Quality Image Properties.5 mm from lead edge of copy (Figure 1 Paper Orientation Terms) when feeding from Tray 1. Repeat Images. in repetitive areas.Image Properties. Skew Image is skewed on paper. Offsetting An image that is repeated on same sheet of paper or repeated on consecutive sheets. Gently rub .5 Lines per mm in Target arrays should be clearly visible (Figure 1 Test Pattern 82P524 inch/82P523 metric) (E). and ±3. or in bands from Lead Edge to Trail Edge or Front Edge to Back Edge (Figure 1 Paper Orientation Terms).0 mm for Tray 2 and Bypass Tray (Figure 1 Test Pattern 82P524 inch/82P523 metric) (C). Lead Edge Registration The 10 mm line on graduated mm scale must be 10 mm ±2. Part of image information is placed elsewhere on copy or it is completely missing. Deletions Deletion is an area where expected image information is lost. The area of deletion could be in one area of paper. Front-to-Back Registration The fold line of copy must be ±3. The difference between distance from lead edge of copy (Figure 1 Paper Orientation Terms) to each of two 10 mm outside graduation marks should not be more than 1. Size The distance from lead edge of image to lead edge of paper (Figure 1 Paper Orientation Terms) is not within specification. Specifications Image Quality Properties. Streaks Image defects that occur in direction of paper movement. Refer to IQ 16 Wrinkle RAP to diagnose wrinkle or paper damage problems. Refer to IQ 8 Lines / Streaks RAP to diagnose lines or streaks problems. Image 9/02 3-8 Initial Issue WorkCentre Pro 420 . Side A and Side B are used to evaluate image quality when compared to image quality specifications in this section.5 mm or smaller in diameter. Spots Image defects are 0.Smear Image defects in direction that is perpendicular to paper movement. Refer to IQ 18 Other Image Defects RAP to diagnose these image defects. Other Image Defects This is an image defect that is not described by any of previous Image Quality Properties or Defects. Figure 1 Test Pattern 82P524 inch/82P523 metric (Side A) Image Quality Image Properties. Refer to IQ 12 Skips/ Smears RAP to diagnose smear problems. Specifications. Image Quality Specification Test Pattern The primary test pattern used on this product is 82P524 (inch) or 82P523 (metric). Wrinkle Wrinkle is paper that is creased. Defects. Refer to IQ 13 Spots RAP to diagnose spots problems. Trail Edge Lead Edge Paper Movement Output Tray end of Machine Align corners and fold copy of Test Pattern Front Edge Figure 3 Folded Copy for Front to Back Registration Check Trail Edge Back Edge Front Edge Short Edge Feed Centerline Scale in millimeters 21 mm Transfer Roll 46 mm Registration Roll 79 mm Fuser Roll Figure 2 Repeating Image Defects 94 mm Drum 94 mm Fuser Pressure Roll Initial Issue WorkCentre Pro 420 9/02 3-9 Image Quality Paper Orientation . Fold Long Edge Feed Back Edge Back Edge Lead Edge Paper Movement Output Tray end of machine Front Edge Front of Machine Figure 1 Paper Orientation Terms Determining distance between defects could help isolate problems to a specific component. Figure 2 may help isolate cause of a repetitive defect.Paper Orientation Terms The terms used to describe areas of copy are shown in Figure 1.4) (REP 9. Connect Control Panel harness to Control Panel. Close Door Module. Rotate Drum (Figure 5) in direction shown. Remove Drum Cartridge (REP 9. 5. • • • • • Remove RIS (REP 6.1). a strip of LED’s. then switch on machine. – – – – Remove Drum Cartridge (REP 9. Trail Edge Lead Edge Paper Movement Output Tray end of Machine Trail Edge Short Edge Feed Figure 1 Background Bands Narrow Band Lead Edge to Trail Edge Light from red LED’s is visible from each hole in lamp. The image quality problem occurs only when using machine as a printer. Front Edge to Back Edge Narrow Band Procedure NOTE: If a status code is present. switch on machine. Press Start to energize Erase Lamp output and measure voltage (Figure 10). or A5 short edge feed paper. Verify Image Quality problem on machine. is located on top of space for Drum Cartridge (Figure 8).3).IQ 1 Background Bands or Random Background RAP Randomly distributed toner of varying density that appears grouped as bands.5 x 11 long edge feed. switch the feeding direction. Voltages are measured as specified in Figure 10. go to status code now. go to appropriate RAP now. Replace Drum Cartridge (PL 1. Front Edge Image Quality IQ 1 Background Bands or Random Background RAP 9/02 3-10 Initial Issue WorkCentre Pro 420 .5 x 8. Y N Do following to check Erase Lamp operating voltage. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Switch off machine.1). • • • If problem occurs with 8. wait 10 seconds. The lamp.1). wait 10 seconds.2). Perform following to check Erase Lamp.1). Y N Perform following until defect is fixed: • • Switch off machine. or ask customer if problem occurred when using machine as a copier or a printer or both. Y N Replace the HVPS (PL 1. Clean all Transfer Detack components (Table 3 in Maintenance Procedures in Section 1). Enter diagnostics [9-6] and ensure Front Door remains closed. Check Transfer Roll Ground Clip presses against Transfer Roll. Manually actuate Front Door Interlock Switch and view red light from Erase Lamp. A4 long edge feed. Enter [9-6] and press Start button to energize Erase Lamp.5 short edge feed. Disconnect Erase Lamp Plug (Figure 10). Long Edge Feed Back Edge Back Edge Lead Edge Paper Movement Output Tray end of machine Front Edge Front of Machine Figure 2 Paper Orientation Terms Go to OF 14-1 PRINTER RAP. Replace Erase Lamp (PL 1. Switch on machine. The bands may have well defines edges or edges with a gradient or spotted appearance.11] or Stop/9 Test Pattern Figure 4 Diagnostic Code [1 .1] Test Pattern Rotate gear in direction shown to Figure 5 Drum Rotation Figure 7 Random Background Initial Issue WorkCentre Pro 420 9/02 3-11 Image Quality IQ 1 Background Bands or Random Background .Registration Roll Transfer Roll Metal Shaft Transfer Detack Corotron Middle Contact Figure 3 Transfer Roll Registration Roll T/D contacts Figure 6 Diagnostic Code [3 .Initial Issue WorkCentre Pro 420 9/02 3-13 Image Quality IQ 1 Background Bands or Random Background . Verify Image Quality problem on machine. Replace Transfer/Detack Corotron if Transfer Roll does not move toward front after manually pushed to rear and released (PL 5. The default copy darker/copy lighter setting may be set to a lighter setting. Procedure NOTE: If a status code is present. • Check Grounding Tab at rear of Transfer Roll by pushing Transfer Roll to rear and observing it move to front.2) (REP 1. Registration Roll. or ask customer if problem occurred when using machine as a copier. The image quality problem occurs when using machine as a copier. Go to OF 14-1 PRINTER RAP. • Clean grounding tab at rear end of Transfer Roll. or as reported by customer.2). then switch on machine.A B Y N There is a problem with measurement technique or HVPS is defective. Y N Perform following to check Transfer Roll (Figure 1). replace HVPS (PL 1. Background is most noticeable in environments of low relative humidity. Push in Drum Cartridge and Connect Red lead of meter to clip. If measurement is correct. If customer copies gray or colored background documents. A B Image Quality IQ 2 Background (Uniform) RAP 9/02 3-14 Initial Issue WorkCentre Pro 420 . In some cases of background switching machine off and on may resolve problem when machine cycles up. IQ 2 Background (Uniform) RAP Randomly distributed toner of varying density that evenly cover part or all of paper. Clean Transfer Detack Corotron (Figure 1) (Maintenance Procedures in Section 1). wait 10 seconds. Recommend a humidifier be installed in area of machine. Manually hold black meter lead firmly against a screw for Top Cover. change background suppression to 1 or on (17 in Customer Programmable Options in Section 6).4) (REP 9. The background problem continues. Replace Drum Cartridge (PL 1. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. T/D contacts There is +370 VDC +/40 VDC while copy exits machine.1). Clean Registration Roll (Figure 1) (Table 2 in Section 1). Verify that RIS NVM settings are correct. Verify that measurement is correct.1) (REP 9. • Pull out Drum Cartridge slightly (REP 9. The background problem is temporarily corrected when a new Drum Cartridge is installed.1 and perform steps that identify and record RIS NVM values. Y N Return to Service Call Procedures in Section 1. • • • • Bend a Paper Clip as shown (Figure 2) and insert short end into hole for Bias Contact.5). Maintenance Procedures in Section 1). Use copy lighter or text selections. Manually actuate Front Door Interlock Switch (Figure 2) and make a copy while observing meter. Y N The background problem occurs only when colored documents are copied. Y N Ensure RIS values are correctly entered (REP 6. go to appropriate RAP now. Make a few copies. The RIS NVM values are correctly entered. Inform customer of change.1) (Figure 2). Registration Roll Transfer Roll Metal Shaft Transfer Detack Corotron Transfer Detack Corotron Middle Contact Figure 1 Transfer Roll. Y N Then background problem occurs when using machine only as a printer. Refer to REP 6. Environments with very low humidity like 15% relative humidity will impair machines ability to produce copies free of background. either now. approximately 1 mm of movement. Switch off machine. The humidity in machine environment is suspected to be very low or around 15% relative humidity. Make a copy. • Open Door Module. There should be approximately 390 VDC while a copy exits machine. Perform following to measure Bias Voltage of Drum Cartridge while making a copy.1). go to status code now.11] or Stop/9 Test Pattern Rotate gear in direction shown to Rotate Drum Figure 3 Drum Rotation Initial Issue WorkCentre Pro 420 9/02 3-15 Image Quality IQ 2 Background (Uniform) RAP .Paper Clip Interlock Switch Bias Contact (Right contact) Figure 2 Bias Contact Figure 4 Diagnostic Code [3 . This action allows time for a potential Main PWB recovery. Go to FInal Actions in Service Call Procedures (Maintenance Procedures in Section 1). then switch on machine. Y N Return to Service Call Procedures in Section 1. If problem continues. Y Initial Actions NOTE: If a status code is present. Y N Press and hold Stop button and then press the 9 button to generate a test print from Printer PWB (Figure 2). Y N There is a problem with RIS. The copies are available for inspection. Slide out Drum Cartridge and slide it back in. Switch off machine. Procedure Black copy results from following: • Drum charge problem/electrical contacts. go to appropriate RAP now. The HVPS was just removed. Y N Return to Service Call Procedures in Section 1. Reinstall Drum Cartridge. The HVPS must be removed and carefully reinstalled (REP 1. Make a copy. Verify machine operation.1) and clean contacts on top of cartridge. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Y N Then black image problem occurs when using machine only as a printer. • • Replace Drum Cartridge (PL 1. Y N Go to Call Flow Procedure in Section 1). Replace HVPS (PL 1. Go to OF 14-1 PRINTER RAP. either now.1). Y N Remove Drum Cartridge (REP 9. Figure 1 Diagnostic Code [1 . wait 10 seconds.2). go to status code RAP now.IQ 3 Black Image RAP The copy or print is totally black with no expected image visible. Check if HVPS was just serviced.2) (REP 1.5 mm wide. There are white borders around black copy. and enhances machine appearance. There may be narrow white borders at edges of paper.1). Close all covers/doors. Check edges (borders) of black copy. Switch on machine.5) This indicates that ROS erases charge on drum cartridge to perform edge fade-out and drum cartridge responds with no development in this area. Replace Drum Cartridge (PL 1. The black image problem is present. Also wipe corresponding contacts on HVPS PWB located above contacts on Drum Cartridge when it’s installed. The black image problem occurred again. Replace HVPS (PL 1.4) (REP 9.1] Test Pattern Image Quality IQ 3 Black Image RAP 9/02 3-16 Initial Issue WorkCentre Pro 420 . Also wipe corresponding contacts on HVPS PWB located above contacts on Drum Cartridge when its installed. HVPS failure/how to know/corrective action Verify Image Quality problem on machine. Inspect copies for narrow white borders at edges of paper. or ask customer if problem occurred when using machine as a copier. The black copy problem continues. provides a useful service to customer. reinstalled. Switch off machine. or as reported by customer. verify installation of RIS (REP 6.5). Make a copy.5).1).4) (REP 9. There are narrow white borders at edges of copy. The image quality problem occurs when using machine as a copier. Y N Check if black image copies reported by customer are available for inspection. Clean machine covers and Document Glass. Verify black copy image defect. If problem continues. Replace Main PWB (PL 1.2) (REP 1. replace RIS (PL 1. Reinstall Drum Cartridge. The black image problem is visible on test print. N Remove Drum Cartridge and clean contacts on top of cartridge.1). Run customer job to reproduce black image problem. 1 . or replaced. Verify machine operation.2) (REP 1.11] or Stop/9 Test Pattern Initial Issue WorkCentre Pro 420 9/02 3-17 Image Quality IQ 3 Black Image RAP .Figure 2 Diagnostic Code [3 . If problem continues.1). Verify blank copy image defect. Verify blank copy image defect. or as reported by customer. An open circuit in Bias Voltage for Drum Cartridge will cause this image defect. Y N Then blank image problem occurs when using machine only as a printer. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. machine. go to status code now. wait 10 seconds. Blank copy or no image results from following: • Development problem/no drum ground. verify installation of RIS (REP 6. Verify Image Quality problem on machine. go to appropriate RAP now. machine. If problem continues. Procedure NOTE: If a status code is present.1). Verify blank copy image defect. Verify blank copy image defect. machine. The blank image problem exists on test print. If problem continues. verify installation of RIS (REP 6.1). verify installation of RIS (REP 6. verify installation of RIS (REP 6.1). Verify blank copy image defect. machine. If problem continues. machine.1). Y N There is a problem with RIS. The image quality problem occurs when using machine as a copier. Go to OF 14-1 PRINTER RAP. Verify blank copy image defect. either now. There is a very light image on paper.1). Image Quality IQ 4 Blank or No Image RAP 9/02 3-18 Initial Issue WorkCentre Pro 420 . or ask customer if problem occurred when using machine as a copier.1). then switch on machine. Check example of image defect for a faint or very light image. verify installation of RIS (REP 6. If problem continues. then switch on machine. Y N Press and hold Stop button and then press the 9 button to generate a test print from Printer PWB (Figure 3). machine. verify installation of RIS (REP 6. If problem continues. If problem continues. Verify blank copy image defect. Switch off machine. verify installation of RIS (REP 6.IQ 4 Blank or No Image RAP This is a copy or print entirely without an image. no developer bias/how to know/corrective action Switch off machine. Verify blank copy image defect. wait 10 seconds. machine.Figure 3 Diagnostic Code [3 .11] or Stop/9 Test Pattern Initial Issue WorkCentre Pro 420 9/02 3-19 Image Quality IQ 4 Blank or No Image RAP . Procedure Blurred image results from following: • • Lateral charge conduction/how to know/corrective action Condensation caused by installing a machine from cold storage NOTE: If a status code is present. attempt to make it smooth with a file or fine emery cloth. If a nick or burr is found. Transfer Corotron Detack Corotron Figure 2 Pre-Fuser Guide. • Remove Fuser Module (REP 10.5 Lines per mm in resolution Targets should be clearly visible. The blurred image problem is visible on test print. Place Fuser Module upside down and metal guide is now visible above Fuser and Pressure Roll. A small nick or burr can cause a blurred image in a small area of copy as paper hits and skips past burr or nick. Press and hold Stop button and then press the 9 button to generate a test print from Printer PWB (Figure 1). If fresh paper reduces or eliminates occurrence of image blur. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Carefully clean following with a lint free cloth and Film Remover or General Cleaning Solvent. Check that Pre-Fuser Guide feels smooth and free of burrs. or a problem with RIS. – – – – Clean Transfer Corotron wire with a cotton swab and Film Remover or General Cleaning Solvent (Figure 2).1).1). Perform following to clean Transfer Detack Corotron (Figure 2). Return to Call Flow Procedure in Section 1. • Clean polished metal Pre Fuser Guide (Figure 2).11] or Stop/9 Test Pattern • Make copies of Side A of Test Pattern.5 mm lines per mm are clearly visible. Low relative humidity may cause what appears to be a blurred image and fresh paper has a normal moisture content. This guide is below Fuser Module. between them. The horizontal and vertical 3.IQ 5 Blurred Image RAP A blurred image can also be described as a fuzzy or grainy image. The 3. Wipe all Transfer Detack Corotron contacts at front end of corotron frame with a lint free cloth (Figure 2). causing paper to jump over burr. go to appropriate RAP now. Y N There may be low relative humidity. Check installation of Document Glass (REP 6. PreFuser Guide Figure 1 Diagnostic Code [3 . this is an indication that effects of low relative humidity may cause image blur again at some future time. • Load fresh paper. a problem with ROS. Check resolution targets. There is a problem with ROS or low relative humidity at machine site. Clean metal guide that is below Fuser and Pressure Roll of Fuser Module. Y N Check installation of RIS (REP 6.5). Ensure no lint from swab remains on corotron or corotron frame (Figure 2). Clean Detack Corotron with a dry brush (Figure 2). Transfer Detack Corotron Image Quality IQ 5 Blurred Image RAP 9/02 3-20 Initial Issue WorkCentre Pro 420 . go to status code now.Initial Issue WorkCentre Pro 420 9/02 3-21 Image Quality IQ 5 Blurred Image RAP . There is image missing near lead edge (Figure 1).1) to replace Exit Rollers. Initial Actions NOTE: If a status code is present. Initial Issue WorkCentre Pro 420 IQ 6 Deletions RAP . housing. Go to OF 14-1 PRINTER RAP. The deletion problem is visible on test print. Perform following: The deletion problem continues. – – – – Clean Transfer Corotron wire with a cotton swab and Film Remover or General Cleaning Solvent. Procedure An example of Vertical Deletions is shown in Figure 1. remove Fuser Module (REP 10. either now.2). Clean Detack Corotron with a dry brush. If not.1). Clean Detack Corotron with a dry brush. Use fresh paper and ensure that customer is storing paper correctly. If defect continues. contacts. IQ 6 Deletions RAP An area of image on copy that has no toner or a very faint image. Y N There is image missing near Trail Edge (Figure 2).4) (REP 9. Turn over paper in paper tray.3). go to appropriate RAP now. Perform following: • Clean Transfer Detack Corotron (Figure 7). Ensure no lint from swab remains on corotron or corotron frame (Figure 2). Fresh paper will also reduce effect of high or low humidity temporarily. The deletion may occur during image processing sequence on one of following actions: • Image output to drum (low toner) • • • • Image transfer to paper (dirty Transfer/Detack Corotron) Image fusing process (problem with fuser or pressure roll) Clean Transfer/Detack Corotron wire. replace RIS (PL 1. • Increase Transfer Off Timing (ADJ 9. If deletion continues.A B C D • Check Grounding Tab at rear of Transfer Roll by pushing Transfer Roll to rear and observing it move to front. Adjust Image Geometry (ADJ 8. Maintenance Procedures in Section 1). Clean Detack Corotron with a dry brush. A B C D Image Quality A 9/02 3-22 Verify that cleaning fixed defect. Wipe all Transfer / Detack Corotron contacts at front end of corotron frame with a lint free cloth.1) (REP 9. continue below. Wipe all Transfer Detack Corotron contacts at front end of corotron frame with a lint free cloth.1) (REP 8. Verify that cleaning fixed defect. • Open Door Module. Perform following: • Clean Transfer Detack Corotron (Figure 7). – Clean Transfer Corotron wire with a cotton swab and Film Remover or General Cleaning Solvent . Replace Drum Cartridge (PL 1. and HVPS contacts (Maintenance Procedures.3). continue below. Perform following to check Transfer Roll (Figure 7). Very low or very high humidity increases possibility of deletions. run 20 copies of a white document to correct problem. • • Clean grounding tab at rear end of Transfer Roll. approximately 1 mm of movement. Adjust Image Geometry (ADJ 8. Wipe all Transfer Detack Corotron contacts at front end of corotron frame with a lint free cloth. Section 1). Y N Perform GP 9 R. go to status code now. replace Door Module (PL 7. If not. Y N The Deletion appears as white lines solid areas near Trail Edge (Figure 2). If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1.1) (REP 6.1). continue below. If problem with deletions continues. Y N Return to Call Flow Procedure in Section 1. The image quality problem occurs when using machine as a copier.1). or as reported by customer. Ensure no lint from swab remains on corotron or corotron frame (Figure 7). or ask customer if problem occurred when using machine as a copier. Y N Verify Image Quality problem on machine.1) and clean entrance baffles on bottom of Fuser Module. – – – Ensure no lint from swab remains on corotron or corotron frame (Figure 7). Perform GP9. Y N Press and hold Stop button and then press the 9 button to generate a test print from Printer PWB (Figure 6). Verify that cleaning fixed defect. The Vertical Deletions on customer copy appear similar to Vertical Deletions in Figure 1. If not. Replace Transfer/Detack Corotron if Transfer Roll does not move toward front after manually pushed to rear and released (PL 5. If deletion continues. Clean Transfer Detack Corotron (Figure 7). Y N Then deletion problem occurs when using machine only as a printer. – – – – Clean Transfer Corotron wire with a cotton swab and Film Remover or General Cleaning Solvent. Perform service actions as directed.1). Check that contacts on both Drum Cartridge and machine frame are clean. • • Ensure customer knows how to add toner. Lead Edge Deletion Front Edge Figure 1 Deletions Rotate gear in direction shown to Rotate Drum Figure 3 Drum Rotation Initial Issue WorkCentre Pro 420 9/02 3-23 Image Quality IQ 6 Deletions RAP . The problem is one of following. Long Edge Feed Back Edge Back Edge Lead Edge Paper Movement Output Tray end of machine Front Edge Vertical Deletions Front of Machine Figure 2 Paper Orientation Terms Trail Edge Lead Edge Paper Movement Output Tray end of Machine Trail Edge Short Edge Feed If defect continues.1). Remove Drum Cartridge (REP 9.A • Adjust Transfer Off Timing (ADJ 9. run 20 copies of a white document to correct problem.11] or Stop/9 Test Pattern Figure 4 Bands of Deletions from LE/TE Registration Roll PreFuser Guide Transfer Corotron Transfer Roll Metal Shaft Detack Corotron Transfer Detack Corotron Middle Contact Figure 5 Transfer Roll / Registration Roll / T/D contacts Figure 7 Pre-Fuser Guide / Transfer / Detack Corotron Image Quality IQ 6 Deletions RAP 9/02 3-24 Initial Issue WorkCentre Pro 420 .Figure 6 Diagnostic Code [3 .Initial Issue WorkCentre Pro 420 9/02 3-25 Image Quality IQ 6 Deletions RAP . perform GP 9 R. Verify that RIS NVM settings are correct. Check that 18 in Customer Programmable Options in Section 6. Y N Ensure RIS values are correctly entered (REP 6. Clean Detack Corotron with a dry brush. Drum Voltage incorrect Development problems. • • • • Clean Transfer Corotron wire with a cotton swab and Film Remover or General Cleaning Solvent. If density problem continues. Y N There are areas of low density that appear as bands of low density that run from Lead Edge to Trail Edge (Figure 1) and have different widths Y N There is a single band of low density that runs from Lead Edge to Trail Edge and is toward either Back Edge or Front Edge (Figure 1). Clean Drum. The image quality problem occurs when using machine as a copier.1). then switch on machine. In these cases.A B Y N The density problem occurs in solid areas where image is uneven or of low density. Repeat action. especially if machine is operated in a very low copy rate. Perform following: Clean Transfer / Detack Corotron (Figure 4). Light image density on entire copy results when one of following occurs: • • • • • • • • • Drum light shock. Y N Remove Drum Cartridge (REP 9. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Replace Drum Cartridge (PL 1. Y N Then density problem occurs when using machine only as a printer. A B Image Quality Toner may be low. Initial Actions Very high humidity or very low humidity affects image density. Procedure NOTE: If a status code is present. or as reported by customer. Use fresh paper and ensure that customer is storing paper correctly. fatigue. or coating Drum Voltage incorrect Light path interference Development problems. Go to OF 14-1 PRINTER RAP. a new Drum Cartridge will temporarily improve image density until drum cartridge stabilizes to environment. or density is uneven. Refer to Maintenance Procedures in Section 1. Automatic Background Suppression may be turned on. specific areas have low density.1). Ensure no lint from swab remains on corotron or corotron frame. After exposure initialization make a few copies to check image density. The entire image area has low density. Verify Image Quality problem on machine.1). Refer to REP 6. Reinstall Drum Cartridge and make a few copies. then switch on machine.4) (REP 9. The density problem continues. Switch off machine. Check with customer to verify when last toner was added. If customer account environment is very high or low humidity. Add Toner if needed. CAUTION Image Quality defects will occur if mirrors in both carriages are not cleaned and RIS Module is not vacuumed before reinstalling Document Glass. is set to 0. Y N Return to Service Call Procedures in Section 1. IQ 7 Image Density RAP The entire image area has low density. fresh paper will improve image density. DRS non-uniformity Drum charge non-uniformity Erase non-uniformity Dark image density on entire copy results when one of following occurs: Light image density in some areas of copy result when one of following occurs: Switch off machine. either now. wait 10 seconds.1 and perform steps that identify and record RIS NVM values. IQ 7 Image Density RAP 9/02 3-26 Initial Issue WorkCentre Pro 420 . Y N The density problem occurs where image on copied document is pencil or is a light image. or ask customer if problem occurred when using machine as a copier. wait 10 seconds. The RIS NVM values are correctly entered. go to status code now. go to appropriate RAP now. Rotate Drum (Figure 3) in direction shown. Wipe all Transfer / Detack Corotron contacts at front end of corotron frame with a lint free cloth.1] Test Pattern Initial Issue WorkCentre Pro 420 9/02 3-27 Image Quality IQ 7 Image Density RAP .Long Edge Feed Back Edge Short Edge Feed Back Edge Lead Edge Paper Movement Output Tray end of machine Front Edge Front of Machine Figure 1 Paper Orientation Terms Trail Edge Lead Edge Paper Movement Output Tray end of Machine Trail Edge Rotate gear to Rotate Drum in direction shown Figure 3 Drum Rotation Front Edge Registration Roll Transfer Roll Metal Shaft Transfer Detack Corotron Middle Contact Figure 4 Transfer Roll / Registration Roll / T/D contacts Figure 2 Diagnostic Code [1 . The clip should push Transfer Roll back to front. Ensure trays are fully closed. Y N The specific image defect is short or broken lines. go to appropriate RAP now. near trail edge of copies (last 100 mm of copy). There is a problem with machine subsystem grounding. Perform following to reposition Document Pad. • Ensure Paper Guides in Paper Trays are adjusted to paper stack. replace Fuser Module (PL 1. Specification are in Lead Edge Registration and Front-to-Back Registration in Registration(front of Section 3). Check if lines or streaks are within a few millimeters of front edge or rear edge of copy (Figure 3 front edge and rear edge). Y N Place Side A of test pattern on Document Glass and make a few copies. Perform following to check Transfer Roll Clip. Y N Ensure Document Glass is clean. The registration is within specification. Y N Check orientation of lines or streaks on customers image defect example or make copies to verify image defect. The lines or streaks image defect is similar to example of Glitch Lines in Figure 8. Y N Then lines or streaks run in front edge to back edge direction or in both directions. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Perform Image Geometry (ADJ 8. Y N Go to OF 16-2 GROUND RAP. go to status code now. The customer document may be wrinkled at edge and a shadow is reproduced as a line. Make several copies to verify that Glitch Line image defect is repaired. Close Document Cover Open Document Cover and firmly press pad against Document Cover. Compare lines or streaks image defect on copies to example in Figure 8. Push Transfer Roll to rear and release it.2). IQ 8 Lines / Streaks RAP Black lines in white areas or white lines in dark areas (Figure 1). The line or streak image defect is visible on test print. Y N There is a line or streak that is approximately 79 mm from lead edge and may not appear on every copy. Make a copy of document pad (no document on document glass). Make a copy to verify line or streak is not visible. Replace Transfer/Detack Corotron if Transfer Roll does not move toward front when released (PL 5. There is a line next to lead edge. Ensure paper trays are set up correctly. The lines or streaks image defect occurs only when using machine as a printer. Y N One of following occurred: • The guides in paper trays aren’t adjusted correctly or paper trays aren’t fully closed. The lines or streaks run only in lead edge to trail edge direction (Figure 3 shows lead edge to trail edge direction). Place it on Document Glass against Registration Edge and centered in front to rear direction. A B C D Image Quality IQ 8 Lines / Streaks RAP .1). Initial Actions NOTE: If a status code is present. The Document Pad is misplaced. Perform following: • Ensure clip at rear end of Registration Roll (Figure 7) is firmly against Registration Roll shaft and is clean.1) (REP 9. If line or streak problem (approximately 79 mm from lead edge) continues. A 9/02 3-28 E F G Initial Issue WorkCentre Pro 420 • • Inform customer of these machine usage conditions. If there is more than 5 ohms. There should be less than 5 ohms. Some reduction or enlargement settings may reproduce edge of document on copy as a line. Y N Ensure Top Cover is installed correctly (REP 14. • • • There is a difference between paper size and customer document size. Clean connection by pulling a single layer of lint-free cloth treated with Film Remover or General Cleaning Solvent through connection. The Glitch Line image defect is repaired. • Measure resistance between metal frame of Fuser Module and metal part of Registration Roll Shaft. approximately 25 to 28 mm long. Turn over paper so that topside faces down. The line or streak image defect is repaired.3). Return to Call Flow Procedure in Section 1. Place Side A of test pattern on Document Glass and make a few copies.1). Clean clip by pulling a single layer of lint-free cloth treated with Film Remover or General Cleaning Solvent through connection. Procedure Find out if lines or streaks image defect occurs only when using machine as a printer. go to OF 16-2 GROUND RAP. The lines or streaks image defects are within a few millimeters of front edge or rear edge of copy. and run in direction of Paper Movement (Figure 3) Y N Press and hold Stop button and then press the 9 button to generate a test print (Figure 5).A B C D • • • • Pull off Document Pad.4) (REP 10. Check lead edge registration and front to back edge registration. Ensure clip at rear end of Transfer Roll (Figure 7) is firmly against Transfer Roll. approximately 1 mm of movement. • • • There is a difference between paper size and customer document size. Clean Detack Corotron with a dry brush (Figure 7). – – – – – Clean Transfer Corotron wire with a cotton swab and Film Remover or General Cleaning Solvent (Figure 7). The line or streak occurs during imaging. Figure 2 Diagnostic Code [1 . Some reduction or enlargement settings may reproduce edge of document on copy as a line. CAUTION Image Quality defects will occur if mirrors in both carriages are not cleaned and RIS Module is not vacuumed before reinstalling Document Glass.1) (REP 8. Remove Fuser Module (REP 10. Clean any lines or streaks with a lint free cloth (Figure 4). Go to OF 14-1 PRINTER RAP. Clean any lines or streaks with a lint free cloth. Ensure no lines or streaks are present on photoreceptor surface. Replace Door Module (PL 6. Ensure clip at rear end of Transfer Roll (Figure 7) is firmly against Transfer Roll and is clean.1). Perform GP 9 R. transfer.1). The customer document may be wrinkled at edge. Perform following: • Clean Transfer / Detack Corotron (Figure 7). • The Exit Rolls diameter is reduced by wear and sheet is disturbed in Fuser Module as it buckles. Figure 1 Black Lines Vertical Black Lines Vertical Black Streaks White Lines • Remove Drum Module (REP 9. Clean clip by pulling a single layer of lintfree cloth treated with Film Remover or General Cleaning Solvent through connection. Initial Issue WorkCentre Pro 420 9/02 3-29 Image Quality IQ 8 Lines / Streaks RAP .1] Test Pattern Inform customer of these machine usage conditions. Ensure no lint from swab remains on corotron or corotron frame (Figure 7). Then lines or streaks problem occurs when using machine only as a printer.1). Return to Call Flow Procedure in Section 1. Ensure paper trays are set up correctly. or fusing. Wipe all Transfer / Detack Corotron contacts at front end of corotron frame with a lint free cloth (Figure 7).A E F G Y N Then lines or streaks problem is caused by a RIS component. One of following occurred: • The guides in paper trays aren’t adjusted correctly or paper trays aren’t fully closed. Ensure no lines or streaks are present on Fuser Rolls.11] or Stop/9 Test Pattern Figure 3 Paper Orientation Terms Figure 4 Drum Rotation Figure 6 Transfer Roll / Registration Roll / T/D contacts Image Quality IQ 8 Lines / Streaks RAP 9/02 3-30 Initial Issue WorkCentre Pro 420 .Lead Edge Trail Edge Output Tray end of Figure 5 Diagnostic Code [3 .5) (PL 5. The Registration Roll remains stationary while rotating Registration Clutch Gear. The lead edge varies among copies. Fold Procedure A shorted or binding Registration Clutch (Figure 3) will cause image misregistration.3) (REP 8. Y N Go to E1 RAP to troubleshoot Registration Clutch circuit if clutch is energized. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Replace Registration Clutch (Figure 3) if it is binding (REP 8. replace Registration Clutch (REP 8.1). go to status code now. Replace Registration Clutch (REP 8. Open Door Module and manually rotate Registration Roll Gear. clutch is shorted or always energized or binding. Check if lead edge registration varies among copies. Y N Check installation of Registration Label.11). Ensure trays are fully closed. • Ensure Paper Guides in Paper Trays are adjusted to paper stack. Centerline Initial Actions NOTE: If a status code is present. Tray 2 (PL 4. Repair as required (PL 1.IQ 9 Image Registration RAP Image misplaced on paper. Tray 1 (PL 4. The Registration Roll should remain stationary. Bypass (PL 6. If Registration Roll rotates.5) (PL 5. The components are secure.2).5) (PL 5.3). Y N Repair as required.1) . Y N Do Image Geometry (ADJ 8.2). Check closing action of paper tray.1). Lead Edge Back Edge Front Edge Align corners and fold copy of Test Pattern Figure 1 Folded Copy for Front to Back Registration Check Long Edge Feed Back Edge Short Edge Feed Back Edge Trail Edge Paper Movement Output Tray end of machine Front Edge Front of Machine Figure 2 Paper Orientation Terms Lead Edge Paper Movement Output Tray end of Machine Trail Edge Front Edge Image Quality IQ 9 Image Registration RAP 9/02 3-32 Initial Issue WorkCentre Pro 420 . If a lead edge registration problem continues. Make 20 copies of Side A of Test Pattern from Tray 1. Problem is Lead Edge Registration (Figure 2). Check Bypass Feed Roll is securely installed. go to appropriate RAP now. Check Feed Rolls for Tray 1 (and Tray 2 if present) are securely installed.2).1). Repair as required (PL 4.Registration Clutch Figure 3 Registration Components Feed Assembly Actuator Figure 4 Feed Assembly Actuator Initial Issue WorkCentre Pro 420 9/02 3-33 Image Quality IQ 9 Image Registration RAP .1) (REP 9.3).1).3). • • • Close Door Module. Disconnect Erase Lamp Plug (Figure 7). Perform following to check Erase Lamp. Fuser removal not required. go to status code now.3). Maintenance ProcePL 1. Check components for wear or damage (PL 5.1). • • Clean Transfer Roll with Film Remover or General Cleaning Solvent and a lint free cloth. The lamp is located on top of space for Drum Cartridge. Y N Replace the HVPS (PL 1. Enter [9-6] and press Start button to energize Erase Lamp. • Clean grounding tab at rear end of Transfer Roll.3). Clean Registration Roll and Registration Idler Roll with film remover or cleaning Y N solvent and lint free cloth (Table 2 in Maintenance Procedures in Section 1). The image problem is still visible. If light is not visible from lamp. dures in Section 1). PL 1. Image Quality IQ 10 Residual Image/ Repeating Image / Offsetting 9/02 3-34 Initial Issue WorkCentre Pro 420 . Manually actuate Front Door Interlock Switch and view red light from Erase Lamp. Check components for wear or damage (PL 5. approximately 1 mm of movement. The distance is 94 mm. Procedure NOTE: If a status code is present. PL 1. Open Door Module and clean Fuser Exit Drive Roll (Figure 3). Light from red LED’s is visible from each hole in lamp. • Remove Drum Cartridge (REP 9. Measure distance between expected image and same position on residual or reverse image. PL 1. PL 1.IQ 10 Residual Image/ Repeating Image / Offsetting RAP An image that is repeated on same copy or consecutive copies. Replace Erase Lamp (PL 1. Make copies to check if image problem is still visible. Check Grounding Tab at rear of Transfer Roll by pushing Transfer Roll to rear and observing it move to front. Manually actuate Front Door Interlock Switch and view red light from Erase Lamp (Figure 5). replace Erase Lamp (PL 1. go to appropriate RAP now. Perform following to check Erase Lamp.1). Clean Registration Roll and Registration Idler Roll with film remover or cleaning solvent and lint free cloth (Table 2 in Maintenance Procedures in Section 1). Y N Clean Registration Roll Measure distance between expected image and same position on residual and Registration Idler Roll with film remover or cleaning solvent and lint free cloth (Table 2 in Maintenance Procedures in Section 1).3).3).2). Y N Measure distance between expected image and same position on residual image. Voltages are measured as specified in Figure 7. image. Replace Transfer/Detack Corotron if Transfer Roll does not move toward front after manually pushed to rear and released (PL 5. Enter [9-6] and press Start button to energize Erase Lamp.2).1). Return to Call Flow Procedure in Section 1. Check components for wear or damage (PL 5. The distance is approximately 79 mm. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Press Start to energize Erase Lamp output and measure voltage (Figure 10). • Remove Drum Cartridge (REP 9. The distance is 46 mm.3). The distance is 94 or 48 mm. Y N Perform following to check Transfer Roll (Figure 3). image. • Open Door Module.1). • • • Close Door Module.1). Connect Control Panel harness to Control Panel. Check components for wear or damage (PL 5. • • • • • Remove RIS (REP 6. Clean Transfer Detack Corotron (Figure 3) (Maintenance Procedures in Section 1). Clean Registration Roll and Registration Idler Roll with film remover or cleaning solvent and lint free cloth (Table 2 in Maintenance Procedures in Section 1).1). Y N Clean Registration Roll and Registration Idler Roll with film remover or cleaning Measure distance between expected image and same position on residual or reverse solvent and lint free cloth (Table 2 in Maintenance Procedures in Section 1). The residual or repeated image may appear as a very light negative or reverse image (Figure 1 residual image). Y N Do following to check Erase Lamp operating voltage. Enter diagnostics [9-6] and ensure Front Door remains closed. Check components for wear or damage (PL 5. Switch on machine.1).Shield Erase Lamp Plug Erase Lamp Plug Disconnected with [9-6] entered pin on off 1 0.2 VDC 1.2 VDC Figure 5 Erase Lamp Figure 7 Erase Lamp Output Voltage Check Figure 6 Erase Lamp Circuit Diagram Image Quality IQ 10 Residual Image/ Repeating Image / Offsetting 9/02 3-36 Initial Issue WorkCentre Pro 420 .2 VDC 1.2 VDC 2 24 VDC 24VDC 3 0.Initial Issue WorkCentre Pro 420 9/02 3-37 Image Quality IQ 10 Residual Image/ Repeating Image / Offsetting .1).15) (Tray 1 or 2). Figure 2 Transfer Roll / Registration Roll / T/D contacts Transfer Detack Corotron Middle Contact Transfer Roll Metal Shaft Procedure • Skis Paper Guides Figure 1 Skew Figure 3 Tray Components Image Quality IQ 11 Skew RAP 9/02 3-38 Initial Issue WorkCentre Pro 420 . go to appropriate RAP now.IQ 11 Skew RAP The image on copy or print is skewed to one side because paper is skewed or imaging process causes image to appear skewed (Figure 1).2). Clean Registration Roll and Registration Idler Roll with film remover or cleaning solvent and lint free cloth (Table 2 in Maintenance Procedures in Section 1). • • • • Remove paper from tray and fan it to ensure edges are separated. Refer to label on paper tray. go to status code now. Check installation of Registration Assembly (REP 8. Check mounting of Feed Rolls. Check components for wear or damage (PL 5. Repair as required (REP 8. Check Paper Guides are adjusted to paper without pinching or squeezing paper. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Registration Roll Initial Actions NOTE: If a status code is present. Reinstall paper.Initial Issue WorkCentre Pro 420 9/02 3-39 Image Quality IQ 11 Skew RAP . Y N • Ensure Transfer Roll gears are in place. Check that Pre Fuser Guide (Figure 4) is straight and secure. Clean Registration Roll and Registration Idler Roll with film remover or cleaning solvent and lint free cloth (Table 2 in Maintenance Procedures in Section 1). Repair if possible or replace Fuser Module (PL 1.4). and rotate freely. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1.1) (Table 3 in Maintenance Procedures in Section 1). go to appropriate RAP now. Long Edge Feed Back Edge Back Edge Lead Edge Paper Movement Output Tray end of machine Front Edge Front of Machine Figure 2 Paper Orientation Terms Trail Edge Lead Edge Paper Movement Output Tray end of Machine Trail Edge Short Edge Feed Front Edge Remove Fuser Module (REP 10. Skip or smear occurs approximately 40 . free of damage.1). clean. Repair or clean as required (PL 5. go to status code now. • • Clean Transfer Detack area components with film remover or cleaning solvent and lint free cloth (Table 3 in Maintenance Procedures in Section 1).70 mm from lead edge and may not appear on every copy or print. Transfer Reg Roll Transfer Roll Roll Contact Gears Reg Roll Contacts Transfer Detack Corotron Corotron Figure 3 Transfer Detack Area Components Figure 1 Skips and Smears Image Quality IQ 12 Skips/Smears RAP 9/02 3-40 Initial Issue WorkCentre Pro 420 .IQ 12 Skips/Smears RAP Procedure NOTE: If a status code is present.Pre Fuser Guide Transfer Corotron Detack Corotron Figure 4 Pre-Fuser Guide / Transfer / Detack Corotron Initial Issue WorkCentre Pro 420 9/02 3-41 Image Quality IQ 12 Skips/Smears RAP . Y N The distance is 94 mm (Figure 3).1).4) (REP 10. CAUTION Image Quality defects will occur if mirrors in both carriages are not cleaned and RIS Module is not vacuumed before reinstalling Document Glass. and re-transfers a light image to paper at 79 mm interval. Perform following to lower Fuser temperature: 1. Press Start button to load 1. In this case fuser reaches it’s highest operating temperatures. If spots problem continues. Spots that appear once on copy are on Document Glass or document. 2. glue on drum problem.4) (REP 9. If a flashing 1 is displayed. The spots problem occurs after running a steady series of small copy and/or print jobs or after running a long single copy/print run of 75 or more. Black Spots result from following: • • • Drum coating problem. 2. The spots repeat on copy. or 3. If spots problem is seen to diminish. or as reported by customer. Go to OF 14-1 PRINTER RAP. replace Fuser Module (PL 1. The image problem is still visible. damaged drum such as scratches problem/how to know/corrective action.A IQ 13 Spots RAP Circular dots or irregular shaped images on copy. Your indication will be a flashing 1. continue. Clean drum surface with a lint-free towel and Film Remover or General Cleaning Solvent (Supplemental Tools and Supplies in Section 6) and verify spots problem is fixed. The distance is approximately 79 mm. Y N Open Door Module and clean Fuser Exit Drive Roll (Figure 2). If spots problem continues. either now. The Fuser Roll may be damaged.1).1).1). 3. Check drum surface for spots. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Check with customer about machine usage. Press Stop button 5 times to exit diagnostics. Y N Then spots problem occurs when using machine only as a printer. 4. Ensure no lint from swab remains on corotron or corotron frame. • Clean Transfer Corotron wire with a cotton swab and Film Remover or General Cleaning Solvent. White Spots result from following: Verify Image Quality problem on machine. replace Drum Cartridge (PL 1. If spots problem continues. Make copies to check if image problem still exists. Your indication will be a steadily lit 1. or other problems that can’t be cleaned. damaged drum such as scratches problem/how to know/corrective action B Remove Drum Cartridge (REP 9. Measure distance between centers of repeating spots (Figure 3). may pick up toner from some images. White spots on black image or black spots on white image areas. Attempt to wipe spots off of red Fuser Roll with a lint-free towel and Film Remover or General Cleaning Solvent (Supplemental Tools and Supplies in Section 6). replace Fuser Module (PL 1. Make 20 copies of customers problem document to verify if spots problem is fixed.4) (REP 9. • • • A B Image Quality IQ 13 Spots RAP 9/02 3-42 Initial Issue WorkCentre Pro 420 . 5. nicks. The image quality problem occurs when using machine as a copier.1) and clean entire outside housing. attempt to clean drum surface with a lint free towel. There is a problem with one of following: • The Fuser Module may have picked up toner after running a steady series of small copy or print jobs or a long single copy/print run. replace Fuser Module (PL 1. use minimal Film Remover or General Cleaning Solvent on lint free towel (Supplemental Tools and Supplies in Section 6). Verify if spots problem is fixed. go to appropriate RAP now. Wipe all Transfer Detack Corotron contacts with a lint free cloth. go to status code now. If scratches or nicks are seen. or ask customer if problem occurred when using machine as a copier. Spots that repeat at fixed intervals (Figure 3) on copies are caused by Drum Cartridge.4). Make 20 copies of customers problem document. Y N Return to Call Flow Procedure in Section 1.4) (REP 10. “Fox Tracks” spots caused by toner leakage or incorrect toner metering • • Drum coating problem.1). replace Drum Cartridge (PL 1. or toner can’t be cleaned. Registration Roll. If spots remain. Procedure NOTE: If a status code is present. The Drum Cartridge may be defective in this case. run another 20 copies of an all white document. If silver colored spots are found. or Fuser Module. replace Drum Cartridge (PL 1. The Copy Cartridge incorrectly transferred excess toner to paper and Fuser Module picked up excess toner for re-translate to paper at 79 mm interval. Refer to Figure 1 for drum rotation direction. If not. Your indication will be a flashing 1. Inspect drum surface for spots. Y N Perform following: • Make 20 copies of an all white document. Enter diagnostics [10-4]. Y N Verify that top of Document Glass is clean. Inspect Fuser Roll for defects such as scratches. perform GP 9 R to clean bottom of Document Glass. Rotate gear to check drum surface (Figure 1 shows rotation direction). If not. Press 1 key to enter a 1. remove Drum Cartridge (REP 9. If black colored spots are found.4) (REP 9.1). If spots problem continues when manually placing documents on Document Glass. Clean Transfer Detack Corotron (Figure 2).1). Remove Fuser Module (REP 10. Otherwise continue below. Clean Detack Corotron with a dry brush.Rotate gear to Rotate Drum in direction shown Figure 1 Drum Rotation Fuser Switch Registration Roll Transfer Roll Metal Shaft Drive Roll Ground Wire Transfer Detack Corotron Middle Contact Figure 2 Fuser Module Scale in millimeters 21 mm Transfer Roll 46 mm Registration Roll 79 mm Fuser Roll Figure 3 Repeating Image Defects 94 mm Drum 94 mm Fuser Pressure Roll Initial Issue WorkCentre Pro 420 9/02 3-43 Image Quality IQ 13 Spots RAP .3) (REP 1.IQ 15 Fusing RAP Characters or image are easily wiped off. The most likely causes are listed before least likely causes. Refer to NVM Examine Modify Table in Section 6. go to OF 14-1 PRINTER RAP. A setting of 3 in [10 .4) (REP 10. Heavy weight paper may require higher temperature. Procedure NOTE: If a status code is present. Copies may be unfused before control console appears to loose power. Light weight paper may require lower temperature. Replace Fuser Module (PL 1.4] risks hot offsetting on long copy jobs. Do not use this setting if copy or print jobs are frequently 50 or more. Defective fuser heat roll or pressure roll LVPS failure Image Quality IQ 15 Fusing RAP 9/02 3-44 Initial Issue WorkCentre Pro 420 . If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. go to status code now. Damaged heat roll or pressure roll may result in small or large areas of unfused toner on paper. This indicates a LVPS problem. Ensure that fuser temperature is set correctly for customer paper that is used most frequently. Read all Possible Causes. Replace LVPS (PL 1. Three Fuser temperatures are available.4).1)). go to appropriate RAP now. Table 1 Possible Cause Damp Paper Incorrect fuser temperature Corrective Action Use fresh paper and ensure that customer is storing paper correctly. Then check machine for possible cause and perform Corrective Action. If image quality problem occurs while using machine only as a printer.Initial Issue WorkCentre Pro 420 9/02 3-45 Image Quality IQ 15 Fusing RAP .1). There should be no cuts or breaks in guide. PreFuser Guide Procedure NOTE: If a status code is present. Check Paper Trays for following: • Ensure Side Guides are secure and adjusted correctly to support paper. Check that Pre-Fuser Guide feels smooth and free of burrs. • Image Quality IQ 16 Wrinkle RAP 9/02 3-46 Initial Issue WorkCentre Pro 420 . Replace Fuser Module (PL 1. Section 1).2). go to appropriate RAP now. Y N Return to Call Flow Procedure in Section 1. • The conditions above are satisfied in paper trays. The wrinkle problem continues.4) (REP 10. Clean polished metal Pre Fuser Guide (Figure 2).IQ 16 Wrinkle RAP This is damage that is impressed on paper by fuser but is caused by condition of paper before it reaches fuser. Tray 1 (PL 4. If a nick or burr is found. Y N Return to Call Flow Procedure in Section 1. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. attempt to make it smooth with a file or fine emery cloth. Tray 2 (PL 4. Close Tray 1. go to status code now. • • Ensure Snubbers are secure and free of damage. causing paper to jump over burr.2).1) if wrinkle problem continues. Pull out tray to verify that corners of paper stack are under Snubbers. This guide is below Fuser Module. Examine rear guide for wear. The Tray must be fully closed to ensure reliable feeding and avoid jams or wrinkles due to skew. Check input and output guides and rollers for contamination. Push paper stack back down. Figure 1 Pre Fuser Guide The wrinkle problem continues. • Clean Registration Roll and Registration Idler Roll with film remover or cleaning solvent and lint free cloth (Table 2 in Maintenance Procedures in Section 1).1). Y N Repair as required. • • Remove Fuser Module (REP 10. A small nick or burr can cause a blurred image in a small area of copy as paper hits and skips past burr or nick. Check components for wear or damage (PL 5. Verify that paper stack pushes Snubbers up to their stop. Add fresh paper and verify machine operation. Clean as required (Table 4 in Maintenance Procedures. The Tray 1 elevator or Tray 2 Elevator (if present) must raise paper stack up against Snubbers when Tray is closed.Initial Issue WorkCentre Pro 420 9/02 3-47 Image Quality IQ 16 Wrinkle RAP . Good quality papers such as Xerox 4024 paper are recommended and they will typically produce reduced curl levels. We strongly recommend that open reams be carefully resealed in their wrapper in humid environments. Procedure NOTE: If a status code is present. A small amount of lead edge or trail edge curl is acceptable Read all Possible Causes. go to status code now. The amount of curl is greatly affected by moisture (water) content in paper.e. Additionally. by quality and also by type of paper being used. extended holiday weekends) in humid climates should be replaced with fresh paper. This will reduce moisture absorbed into paper from environment. go to appropriate RAP now. If an Other Fault is present as identified in Status Codes / Other Faults Listing in Section 1. Then check machine for possible cause and perform Corrective Action. go to OF 14-1 PRINTER RAP. Low cost papers and recycled paper can be expected to produce higher levels of curl. The most likely causes are listed before least likely causes. NOTE: Copy curl is caused by action of removing moisture out of paper as it is heated by rollers in copier to fuse toner. Table 1 Possible Cause Damp paper Corrective Action Use fresh paper and ensure curl Image Quality IQ 17 Curl RAP 9/02 3-48 Initial Issue WorkCentre Pro 420 . Paper moisture is another significant curl factor.IQ 17 Curl RAP This is a condition that is caused by a problem with fuser or copy paper. If image quality problem occurs while using machine only as a printer. paper left in paper tray over extended periods (i..18B Tray 1 Module with 2 Service Persons ...4 CVT Glass and Registration Edge ............................................................................... REP 10......................................................... REP 8.................................................................................................................................. REP 8............................................................................................................................................................................... REP 1................................................................................ REP 5....................................................................................4 ADF Nudger Solenlid (SOL 5).........................................5 ADF Feed Roll .............................................................25 Lift Upper Cover Interlock Switch......................1 Carriages ............24 Takeaway Sensor ........1 RIS Module ................................................................. REP 8..............................3 Registration Sensor ...................................................... REP 5..........................................................................................................................7 Exposure Lamp Power Supply .................19 Tray Control PWB...........13 Feed Motor.......1 Drum Cartridge ........................................ REP 14...............1 Top Cover ... REP 8................................. REP 8................ REP 8......................... REP 8......................18 Takeaway Roll Shaft....................9A Tray 2 Module with 1 Service Persons ......................................... REP 8...21 Exit Sensor...8 ADF Constant Velocity Transport (CVT) Motor (MOT 4) ......................6 Front Door................................................................18A Tray 1 Module with 1 Service Person. REP 6..........3 ROS Module ...................................................................................23 No Paper Sensor .................. REP 1............. REP 5. REP 1............................................2 Exposure Lamp...............2 Rear Cover........ REP 8................................................................................................................3 Right Cover ........................ Adjustments Imager ADJs ADJ 5.................................................15 Feed Roll.........................................................................1 ADF.............6 Registration Roll .............................. REP 8........................................ Tray 1 or Tray 2 .....9B Tray 2 Module with 2 Service Person...... REP 9...........................1 Control Panel ........................................................17 Document Exit Transport (Input Tray) ........... REP 5............................. REP 8............................................. REP 1...................................... REP 5.....................2 ADF Drivers Cover.....................................................................................................................1 Transfer Timing ............................................................................................13 ADF/DADF Access Door .............................. 4-59 4-60 4-64 4-65 4-66 4-67 4-68 4-71 4-72 4-73 4-74 4-76 4-77 4-78 4-79 4-81 4-82 4-83 4-84 4-85 4-86 4-87 4-88 4-89 4-90 4-93 4-95 4-97 4-98 4-99 4-100 4-101 Main Drives REP 4...3 PCM Interface PWB.2 Heat Rod...............................................3 Transfer Detack Corotron Wire ............................7 Output Tray ............................... REP 14.................................................................... Xerographic REP 9. REP 5........................... REP 1..........................................................4 Repairs / Adjustments Repairs Electrical REP 1.......................................... 4-103 4-105 4-106 4-107 Paper Feed and Registration REP 8............................................1 Door Module .... REP 8........................ REP 6...........................................................2 Registration Assembly .............5 Tray 2 Rear Cover ...7 Drum Cartridge Contact Support ...... Tray 1 or Tray 2................. REP 5.................... Tray 2...............................................................................................................................................................................................................................................................................................5 Document Glass ................................................................................................1 Main Drive Module.....................9 Document Registration Sensor (Q7)................................................ REP 1........................................8 Erase Lamp .............................. REP 8........... REP 5........................................................................................................16 ADF Copy Exit Motor (MOT 6)........................................................ Initial Issue WorkCentre Pro 420 9/02 4-1 Repairs / Adjustments ..........9 PCM Upper Frame...........................................10 Tray 1 or Tray 2 ................... 4-3 4-4 4-6 4-7 4-8 4-10 4-12 4-13 4-14 4-17 4-19 4-20 4-21 4-22 4-23 4-25 4-26 4-27 4-28 4-29 4-30 4-31 4-32 4-33 4-34 4-35 4-36 4-37 4-39 4-42 4-44 4-46 4-47 4-48 4-51 4-53 4-55 4-56 4-57 REP 8.................... REP 5.................................. Fuser REP 10...............................................6 Transfer Detack Contact Support .......... Xerographics ADJs ADJ 9.... REP 5................................................................................. Covers REP 14............................. REP 5.....................14 Takeaway Clutch...........................................................................................................................5 Registration Clutch ..................................16 Paper Size Cam...........20 Bypass Solenoid ............................. REP 8.......................................... REP 5..............8 Bypass Tray ................................ Imager REP 6.......... REP 9..............................6 ADF Retard Roll..............11 Document Feed (Takeaway Roll) Sensor (Q9). REP 1...........................................17 Takeaway Roll Shaft.......................................................1 Fuser Module .............2 Main PWB............................................................................................................................................................................... REP 1........................6 CCD Cleaning..... REP 8...........2 RIS Values.......... REP 5..................................... REP 5.......................... Tray 1............................................................................................................................... REP 8.........5 High Voltage Power Supply (HVPS)..........................10 Document Present Sensor (Q8) ............3 Offset Catch Tray....................................................................................................................................................................... REP 8.....................................................22 Duplex Module ............................................11 Bypass Feed Roll....................... ADJ 6.................................................................... REP 8.............................................................. REP 6..... REP 14............ REP 8.......... REP 8. Tray 1 or Tray 2 ..................................................................................4 Low Voltage Power Supply (LVPS) ... REP 8............2 Transfer Detack Corotron ........................................................................... ADJ 6.............................. REP 6............ Tray 1 or Tray 2 ..................................................................................................................................................................................................................................................................................... REP 8.................................................................... RREP 5...............................................................................................7 ADF PWB ............................................................ REP 5..........14 ADF Document Input Transport ......................................................... REP 5.................................................................. REP 8................................................................................................. REP 6................................................. REP 8.... REP 8.............................12 Bypass Retard Pad ..............15 ADF OCT Motor (MOT 7) ...................................... REP 6......................................................12 Document Exit Switch (S6) ....... REP 14........................................................................................................................1 Carriages .....Repairs / Adjustments 9/02 4-2 Initial Issue WorkCentre Pro 420 . 1 Remove Screws (3) Initial Issue WorkCentre Pro 420 9/02 4-3 Repairs / Adjustments REP 1.1 Control Panel Parts List on PL 3. CAUTION The Main PWB can be damaged by an electrostatic discharge. Turn over Top Cover and remove three (3) screws from underside of Control Panel.1). Remove Top Cover (REP 14. Remove ADF (REP 5. Disconnect Printer Cable and disconnect machine Power Cord. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6).1). Switch off machine power. 3.1 . 1. 2.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury.REP 1. WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Enter Diagnostic mode and record following. 4. Otherwise continue below.REP 1. Go to WARNING before step 2 if diagnostic mode cannot be entered. Enter Customer Programmable Options screen and record values listed there. a. Customer Programmable Options. 2. Disconnect Printer Cable and disconnect machine Power Cord. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6).2 9/02 4-4 Initial Issue WorkCentre Pro 420 .2 Removal 1.2 Main PWB Parts List on PL 1. go to WARNING before step 2 now. Refer to Section 6. Refer to Section 6. b.3). CAUTION The Main PWB can be damaged by an electrostatic discharge. Remove Rear Cover (REP 14. Remove Main PWB (Figure 1). Enter NVM Examine Modify Screen and record NVM values listed for this machine. Diagnostic Settings. If removing Main PWB for access to other components. 1 Disconnect (8) 2 3 Remove with small attached PWB Remove Screws (3) Figure 1 Removing Main PWB Repairs / Adjustments REP 1. 3.2) Remove Right Cover (REP 14. 3.2 . and Customer Option values. Reconnect Power Cord and switch on machine power. CRUM.Replacement 1. 2. Install Main PWB (reverse of steps in Figure 1). Initial Issue WorkCentre Pro 420 9/02 4-5 Repairs / Adjustments REP 1. Input previously recorded NVM.2).3 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Disconnect the two connectors P/J 211. CAUTION The Main PWB can be damaged by an electrostatic discharge. Disconnect Printer Cable and disconnect machine Power Cord. Switch off machine power. Remove PCM Interface PWB (Figure 1) 2 Remove Screws (3) 3 Remove with small attached PWB 1 Disconnect (7) Figure 1 Removing PCM Interface PWB Repairs / Adjustments REP 1.212 form LVPS. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6).REP 1. Remove Rear Cover (REP 14.3 9/02 4-6 Initial Issue WorkCentre Pro 420 .3 PCM Interface PWB Parts List on PL 1. 2. a. 1. b. Disconnect P/J 402 form Tray PWB. Remove Main PWB (REP 1. 204. Switch off machine power. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6).2). Disconnect connectors (7 . 4. (Figure 1). 5. Remove Rear Cover (REP 14. 211. Remove LVPS.3). Remove Acrews (7) form LVPS with a short .4 Low Voltage Power Supply (LVPS) Parts List on PL 1. Disconnect Printer Cable and disconnect machine Power Cord. 2.3 Removal WARNING Inadvertent operation could cause machine damage or personal injury. 212 on LVPS. b.2).REP 1. CAUTION Screw provides static ground for Main PWB. 206.handle Acrewdriver. 3. 1. Replacement NOTE: Install all Screws (7) after reinstalling LVPS. Remove Disconnect Figure 1 Removing LVPS Initial Issue WorkCentre Pro 420 9/02 4-7 Repairs / Adjustments REP 1. Remove LVPS (Figure 3). Figure 2 Installing Screws Installation 1 Make installation in revese order of the removal. a.4 .8) P/J 202. CAUTION The Main PWB can be damaged by an electrostatic discharge. Remove Right Cover (REP 14. 203. 205. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6). Disengage Spring from Tabs. Place Fuser Connector on ROS. 2.1). Switch off machine power. Remove RIS Module (REP 6.1).5 High Voltage Power Supply (HVPS) Parts List on PL 1.5 9/02 4-8 Initial Issue WorkCentre Pro 420 . Guides Ground Wire 9. Remove Ground Wire and Fuser Wires from Guides (Figure 1). 4. Remove CVT Glass (REP 6. Remove Top Cover (REP 14. 8. a.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Remove Fuser Connector from Slide-Contact Support (Figure 2). Remove Drum cartridge (REP 9. Remove Document Glass (REP 6.1). 6. b. c.1). CAUTION The Main PWB can be damaged by an electrostatic discharge. 5. 7.4).1). Disconnect Printer Cable and disconnect machine Power Cord. Remove ADF (REP 5. Lock Retainers (2) Fuser Connector SlideContact Support Spring Figure 2 Removing Fuser Connector from Slide Installation Figure 1 Removing Fuser Wires from Guides 1 Make installation in revese order of the removal. Press Lock down while sliding Fuser Connector to rear. 3.5). Remove Fuser Module (REP 10. Repairs / Adjustments REP 1. 1.REP 1.Initial Issue WorkCentre Pro 420 9/02 4-9 Repairs / Adjustments REP 1.5 . Remove Transfer Detack Contact Support (Figure 1).REP 1. 9. Pull up Support while checking Transfer Detack Contacts don’t hit frame. 3.6 Transfer Detack Contact Support Parts List on PL 1. 5. CAUTION The Main PWB can be damaged by an electrostatic discharge.1).5). Remove Drum cartridge (REP 9. c.1). 1.1).2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Disconnect Printer Cable and disconnect machine Power Cord. Remove RIS Module (REP 6. Remove HVPS (REP 1. Remove Document Glass (REP 6. Switch off machine power. Remove Screw. Remove Top Cover (REP 14.6 9/02 4-10 Initial Issue WorkCentre Pro 420 . Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6). Remove ADF (REP 5.1). Remove Fuser Module (REP 10. 4.1). Pull Springs out of sockets.5). 6.4). a. 2. Springs Screw Support Transfer Detack Contacts Figure 1 Removing Transfer Detack Contact Support Repairs / Adjustments REP 1. 7. Remove CVT Glass (REP 6. 8. b.Replacement NOTE: While installing Transfer Detack Contact Support keep Transfer Detack Contacts away from frame.6 . Reinstall Screw. Install springs in sockets as shown (Figure 2). Short White Wire Long White Wire Screw Black Wire Transfer Detack Contacts Figure 2 Removing Transfer Detack Contact Support Installation 1 Make installation in revese order of the removal. Initial Issue WorkCentre Pro 420 9/02 4-11 Repairs / Adjustments REP 1. 3. REP 9. 3.1). REP 9. 3.REP 1. REP 9.3 Removal WARNING Inadvertent operation could cause machine damage or personal injury.1).1). 3.1 Repairs / Adjustments REP 1. 3.1). 3.1). REP 9.1). Remove ADF (REP 5. 3. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6). REP 9. 3. 3.1). 3. 1.1).7 9/02 4-12 Initial Issue WorkCentre Pro 420 . CAUTION The Main PWB can be damaged by an electrostatic discharge.1). 3.1). Disconnect Printer Cable and disconnect machine Power Cord. 3.1). 3. Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( Remo Drum cartridge ( REP 9. 3. Switch off machine power. 2. REP 9. Remove Drum cartridge (REP 9. REP 9. REP 9.1).1).1). REP 9. REP 9.1). REP 9.7 Drum Cartridge Contact Support Parts List on PL 1. REP 9. REP 9.1). 6. Remove Drum cartridge (REP 9. Switch off machine powe. Guide Connector through hole and remove Erase Lamp.1).1). 2. c. From Drum Cartridge cavity disconnect Hinge Tabs (3).5). b.3 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Remove RIS Module (REP 6. Remove ADF (REP 14. Initial Issue WorkCentre Pro 420 9/02 4-13 Repairs / Adjustments REP 1. 8. Remove Erase Lamp (Figure 1). 3. 7. 9. rDisconnect Printer Cable and disconnect machine Power Cord. 1.8 Erase Lamp Parts List on PL 1.REP 1. CAUTION The Main PWB can be damaged by an electrostatic discharge. Push Locking Tabs (4) through holes. 5.4). Remove CVT Glass (REP 6. Hinge Tabs (3) Connector Locking Tabs (4) Figure 1 Removing Erase Lamp Installation 1 Make installation in revese order of the removal.5). Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6).1). Remove HVPS (REP 1. a.4). Remove Document Glass (REP 6. 4.8 . Remove Fuser Module (REP 10. Remove Top Cover (REP 14. Remove Fuser Module (REP 10. Remove CVT Glass (REP 6. 6. Remove Drum cartridge (REP 9. Remove Top Cover (REP 14.1).9 9/02 4-14 Initial Issue WorkCentre Pro 420 .5). 4.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Remove Document Glass (REP 6. 7.9 PCM Upper Frame Parts List on PL 1. Remove Fuser Wires and Ground Wire from Guides (Figure 1). 2. 9. Slide Lock Retainers (2) Fuser Connector Spring 10. 1. 5. Fuser Wires Guides Ground Wire Figure 2 Disengaging Fuser Connector Installation 1 Make installation in revese order of the removal.2). Remove ADF (REP 5. Remove Main PWB (REP 1.1).4). Disconnect Printer Cable. Remove RIS Module (REP 6.1). Switch off machine power and disconnect machine Power Cord. CAUTION The Main PWB can be damaged by an electrostatic discharge. 3.1).1). 8.REP 1. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6).3). Figure 1 Removing Fuser Wires from Guides Repairs / Adjustments REP 1. Remove PCM Interface PWB (REP 1.11. 1 Remove Screws (3) 3 Lift to Remove PCM 2 Remove Screws (3) Figure 3 Removing Upper PCM Frame Initial Issue WorkCentre Pro 420 9/02 4-15 Repairs / Adjustments REP 1. Remove PCM Upper Frame (Figure 3).9 .Repairs / Adjustments REP 1.9 9/02 4-16 Initial Issue WorkCentre Pro 420 .1 Main Drive Module Parts List on PL 1.1) if drive is not free Grasp to pull out to Remove Figure 1 Removing Drive Module Initial Issue WorkCentre Pro 420 9/02 4-17 Repairs / Adjustments REP 4. 1. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6).REP 4. Disconnect Printer Cable and disconnect machine Power Cord. Remove Main Drive Module (Figure 1). 2 Remove Screws (4) 3 1 Disconnect NOTE: Loosen rear Fuser mounting screw (REP 10. Remove Rear Cover (REP 14. 2.2). CAUTION The Main PWB can be damaged by an electrostatic discharge.1 .2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power.Repairs / Adjustments REP 4.1 9/02 4-18 Initial Issue WorkCentre Pro 420 . 1. NOTE: If the machine power is switched on while the ADF is removed. WARNING Put the ADF on the desk after it is remomed sothat the balancers will not press on ADF and the ADF frame will not be out of Shape.2). the Control Logic will enter a brief configuration process that results in the removal of ADF operability and control from the Main PWB. 3. If power is switched on before the ADF is installed. InstallatitF frame will not be out of Shape. 2.1 .REP 5. Figure 1 Disconnecting the Harness Connector Initial Issue WorkCentre Pro 420 9/02 4-19 Repairs / Adjustments REP 5. Disconnect the ADF Harness Connector from Main PWB (Figure 1). Remove the ADF (REP 14. The machine will behave like a Document Cover is present.1 ADF Parts List on PL 3. ADF operability can be restored by switching on the power after the ADF is connected. Switch off the machine power.1 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. Disconnect the Printer Cable connector and disconnect the machine Power Cord. a document cannot be sensed in the ADF. Replacement Reinstall the ADF/DADF. Lift the ADF/DADF to the full open position then remove the fixing screws on two balancers and remove the fixer on the right balancer. Remove the ADF/DADF Dives Cover (Figure 1). Open Feed Door.2 9/02 4-20 Initial Issue WorkCentre Pro 420 .2 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. b. c. Remove screws (3). Disconnect the Printer Cable connector and disconnect the machine Power Cord. Switch off the machine power. 1. Push in on the cover to disconnect the catch. 2 Remove Screws (4) Figure 1 Removing the ADF/DADF Drives Cover Repairs / Adjustments REP 5. Pull out and lift up the cover to remove it.2 ADF Drivers Cover Parts List on PL 3. a.REP 5. d. 4. Remove the Offset Cathe Tray Extension.2) Open the Access Door.3 . 2 1 Remove the screw (1) Rotate the tray to the right and pull. Remove the Offset Cathe Tray (Figure 1). ✶View Offset Catch Tray removal. 1. Disconnect the Printer Cable connector and disconnect the machine Power Cord.2 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. Initial Issue WorkCentre Pro 420 9/02 4-21 Repairs / Adjustments REP 5. 2. Access Door Figure 1 Removing the Offset Catch Tray Installation 1 Make installation in revese order of the removal.3 Offset Catch Tray Parts List on PL 3.REP 5. 3. Switch off the machine power. 3 Pull Corner forward and remove. Remove the ADF/DADF Drives Cover (REP 5. Disconnect the Printer Cable connector and disconnect the machine Power Cord. 1. Repairs / Adjustments REP 5.RREP 5.2 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury.3). 2. Switch off the machine power.4 ADF Nudger Solenlid (SOL 5) Parts List on PL 3. Remove the ADF Nudger Solenold (Figure 1). Remove the ADF Drives Cover (REP 5. 2 Spread the two locking tabs 3 1 Disconnect the connector Remove the ADF/DADF Nudger Solenoid Figure 1 Removing the ADF/DADF Nudger Solenoid Installation 1 Make installation in revese order of the removal.2).4 9/02 4-22 Initial Issue WorkCentre Pro 420 . Remove the Offset Catch Tray (REP 5. 3..5 9/02 4-24 Initial Issue WorkCentre Pro 420 . Figure 3 Feed Roll shaft engage the Solenoid Actuator Repairs / Adjustments REP 5.Feed Roll Shaft Solenoid Actuator is held up to receive the Feed Roll shaft. Repairs / Adjustments REP 5. Disconnect the Printer Cable connector and disconnect the machine Power Cord.REP 5.2). Remove the ADF Drives Cover (REP 5. 1. Switch off the machine power.7 9/02 4-26 Initial Issue WorkCentre Pro 420 . 1 Disconnect all connectors on the PWB 2 Push on the locking tab with a small screwdriver and remove the PWB ADF/DADF PWB Figure 1 Removing the ADF/DADF PWB Installation 1 Make installation in revese order of the removal. Remove the ADF PWB (Figure 1).7 ADF PWB Parts List on PL 3.2 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. 2.3 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. 3 Remove the screws (2) 1 Remove the screw (1) Figure 2 Removing the ADF/DADF CVT Motor Replacement NOTE: When installing the CVT Motor Assembly.3). Remove the ADF/DADF Document input Transport (REP 5. Remove the ADF/DADF Drives Cover (REP 5. 1. 3.14) is installed.ensure that the small end of the pulley is closest to the Front Plate. Disconnect the Printer Cable connector and disconnect the machine Power Cord. Install the screws (2) loosely so that the assembly can be moved to allow the belts to be installed.REP 5.8 . 4. 1 Remove screws (3) 3 Remove the CVT Motor 2 Disconnect belt 2 Remove the front plate. Remove the ADF/DADF Offset Catch Tray (REP 5. and Figure 2). NOTE: When installing the Front Plate. 2.2). NOTE: After the Document Input Transport (REP 5. 1 Figure 1 Removing the ADF/DADF CVT Drive front plate Make installation in revese order of the removal.8 ADF Constant Velocity Transport (CVT) Motor (MOT 4) Parts List on PL 3.adjust the CVT Motor assembly to remove the slack from the drive belts. Remove the ADF/DADF CVT Motor (Figure 1. drive belt and gear. Switch off the machine power. Initial Issue WorkCentre Pro 420 9/02 4-27 Repairs / Adjustments REP 5.14). Figure 1 Removing the Document Registration Sensor Installation 1 Make installation in revese order of the removal. 4.3 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. NOTE: The Document Registration Sensor has the actuator built into the sensor.14). Repairs / Adjustments REP 5.Check that the spring and actuator operates correctly whenever removing or replacing the Document Registration Sensor. Switch off the machine power. 3 Remove the sensor 1 Remove the screws (2) 2 Use a small screwdriver to unlock the locking tab. 2.9 9/02 4-28 Initial Issue WorkCentre Pro 420 . 5.9 Document Registration Sensor (Q7) Parts List on PL 3. Remove the Screws (2) and remove the metal bar. Remove the Offset Catch Tray (REP 5. Remove the Document Registration Sensor (Figure 1). 1. Remove the ADF Document input Transport (REP 5. Disconnect the Printer Cable connector and disconnect the machine Power Cord. 3.2).3). Remove the ADF Drives Cover (REP 5.REP 5.REP 5.10 Document Present Sensor (Q8) Parts List on PL 3. Switch off the machine power. 1. (2 screws and 2 springs) 2 Rotate the actuator until the paper path flag is in a vertical position.3). Figure 1 Removing the Document Present Sensor and Actuator Installation 1 Make installation in revese order of the removal. Remove the ADF Drives Cover (REP 5.2). Initial Issue WorkCentre Pro 420 9/02 4-29 Repairs / Adjustments REP 5. 1 Remove the CVT drive release. Remove the Offset Catch Tray (REP 5.2 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury.10 . 1. 3 Remove the Document Present Sensor by spreading the plastic latches and lifting the sensor. Remove the Document Present Sensor (Figure 1). then remove the actuator. 1. Disconnect the Printer Cable connector and disconnect the machine Power Cord. Repairs / Adjustments REP 5. 2 With a small screwdriver lift up on the sensor and remove it.2 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. Remove the Offset Catch Tray (REP 5. Disconnect the Printer Cable connector and disconnect the machine Power Cord.11 9/02 4-30 Initial Issue WorkCentre Pro 420 . 1 Swing the actuator away from the sensor. 1. Figure 1 Removing the Document Feed Sensor Installation 1 Make installation in revese order of the removal. Remove the Document Feed Sensor (Figure 1).REP 5. 1. 1.11 Document Feed (Takeaway Roll) Sensor (Q9) Parts List on PL 3.2). Remove the ADF Drivers Cover (REP 5.3). Switch off the machine power. Remove the Offset Catch Tray (REP 5.17).REP 5.12 Document Exit Switch (S6) Parts List on PL 3. Remove the ADF/DADF Document Input Transport (REP 5. 4.14). 3. Remove the Document Exit Switch (Figure 1). Document Feed Sensor 1 Use a small screwdriver to remove the Document feed Sensor. 1.2). Remove the Document Exit Transport (REP 5. Figure 1 Removing the Document Exit Switch Installation 1 Make installation in revese order of the removal.3). 2. Switch off the machine power. donot try to lift the Document Feed Sensor out by pulling on the actuator.12 . 2 Disconnect the connector. Remove the ADF/DADF Drivers Cover (REP 5.3 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. Initial Issue WorkCentre Pro 420 9/02 4-31 Repairs / Adjustments REP 5. Disconnect the Printer Cable connector and disconnect the machine Power Cord. NOTE: To prevent damage to the sensor. 5. Remove the ADF/DADF Drivers Cover (REP 5. Repairs / Adjustments REP 5.13 9/02 4-32 Initial Issue WorkCentre Pro 420 .13 ADF/DADF Access Door Parts List on PL 3.2). Switch off the machine power. Disconnect the Printer Cable connector and disconnect the machine Power Cord.REP 5. 1 Disconnect P/J 606 on the ADF PWB ADF/DADF Access Door 3 2 Remove the Access Door ground wire screw (1) Remove the wires from the routing channels 4 Remove the screw (1) under the hinge 5 Remove the Door Figure 1 Removing the Access Door Installation 1 Make installation in revese order of the removal.2 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. Remove the Access Door (Figure 1). 1. 2. 3. Loosen the screws (2) on the CVT Motor and slide the motor to the left to loosen the drive belts. Switch off the machine power. Remove the ADF Drivers Cover (REP 5. Disconnect P/J 605. Initial Issue WorkCentre Pro 420 9/02 4-33 Repairs / Adjustments REP 5. 2. Remove the left front screw (1). Remove the ADF Offset Catch Tray (REP 5. 608. Remove the left rear screw (Figure 2). g.14 . Use a small screwdriver to unlatch the Rear frame locking tab. Remove the belts from the pulleys. 1. Use a small screwdriver to unlatch the tab on the CVT Motor bracket then lift and remove the Document Input Transport.REP 5. Use a small screwdriver to unlatch the front frame locking tab. f. b.2). 610 on the ADF PWB. a. be sure that the clutch pulley properly engages the timing belt. Screw (1) Figure 1 Removing the Document Input Transport d. Disconnect the Printer Cable connector and disconnect the machine Power Cord. e. Remove the ADF Document Input Transport (Figure 1). c. Screw (1) CVT Motor Screws (2) Disconnect Input Transport Tab on the CVT Motor bracket Rear frame Locking Tab Figure 2 Removing the Document Input Transport Replacement NOTE: When reinstalling the Document Input Transport. Installation 1 Front frame Locking Tab Make installation in revese order of the removal.14 ADF Document Input Transport Parts List on PL 3.3).3 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. Remove the ADF/DADF Drives Cover (REP 5. Remove the ADF/DADF OCT Motor (Figure 1). Repairs / Adjustments REP 5. Open the ADF/DADF Left Door.15 ADF OCT Motor (MOT 7) Parts List on PL 3. 3. 3 Remove the OCT cam (it snaps into place). 2. Disconnect the Printer Cable connector and disconnect the machine Power Cord.15 9/02 4-34 Initial Issue WorkCentre Pro 420 . 1. 2 Remove Screws (2) 1 Disconnect the connector ADF/DADF Copy Exit Motor Figure 1 Removing the OCT Motor Installation 1 Make installation in revese order of the removal.REP 5. Switch off the machine power.2 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury.2). a. 2 Remove the Screws (2) 5 Remove the bracket and Motor 3 Remove the E-ring. Switch off the machine power. Replacement NOTE: When installing the Copy Exit Motor bracket. Initial Issue WorkCentre Pro 420 9/02 4-35 Repairs / Adjustments REP 5. Figure 2 Installing the ADF/DADF Copy Exit Motor bracked ADF/DADF Copy Exit Motor Access hole for screw.16 ADF Copy Exit Motor (MOT 6) Parts List on PL 3. Disconnect the Copy Exit Motor wiring harness from the ADF/DADF PWB. NOTE: Ensure that the OCT bushing is resting against the motor bracket and the bushing flange is not on top of the anti-rotation rib on the bracket.REP 5. (Figure 2).2) Remove the OCT Motor (REP 5. ensure that the bracket is properly installed on the locator pins. 2. Remove the Screws (2).3 Removal WARNING Inadvertent copier operation could cause machine damage or physical injury. Remove the ADF Drives Cover (REP 5. a. Disconnect the Printer Cable connector and disconnect the machine Power Cord. 3. b. Remove the ADF/DADF Copy Exit Motor. OCT shaft bushing Bracket locator pins (2) 4 Remove the OCT Cam Link.15) Remove the ADF Copy Exit Motor Bracket (Figure 1).16 . (1) Installation 1 Make installation in revese order of the removal. Figure 1 Removing the Copy Exit Motor Bracket 4. 1. 1 Remove the screw. Lift the ADF Copy Exit Motor from the bracket. 5. Disconnect Printer Cable and disconnect machine Power Cord.1 RIS Module Parts List on PL 2. CAUTION The Main PWB can be damaged by an electrostatic discharge. record NVM values indicated on label attached to top of RIS frame.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury.4). 4. 1.1). Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6). Remove Document Cover (REP 14. This product is certified to comply with Laser Product Performance Standards set by US Department of Health and Human Services as a Class 1 product. Initial Issue WorkCentre Pro 420 9/02 4-37 Repairs / Adjustments REP 6. During servicing.REP 6. Remove CVT glass and Registration mount (REP 6. NOTE: If RIS Module is being replaced. The laser warning symbol is repeated in specific service procedures where laser light exposure is possible. 3. This means that it is a laser product that does not emit laser radiation during any mode of customer operation. Remove Top Cover (REP 14. Remove Document Glass (REP 6.1 . Remove RIS Module (Figure 2) 1 Remove Screws (4) 2 3 Lift RIS to remove Figure 2 Removing RIS Lift Plug to Disconnect Figure 1 Laser Warning WARNING Use of controls or adjustments other than those specified in this documentation may result in an exposure to dangerous laser radiation. Service procedures must be followed exactly as written. laser beam could cause eye damage if looked at directly.5). Switch off machine power. 2.4). Refer to GP 9 R in Section 6. Clean and install Document Glass (REP 6. b. 7. Press START button to load value.1). 8. c. display flashes value when it is correctly loaded. Install Document Cover (REP 14. Reconnect machine power Cord and switch on machine power. Press Stop button 5 times to exit diagnostics.4). Use a crevice attachment to reach corners. CAUTION Do not use a brush attachment on vacuum cleaner.Replacement 1. Enter [14]. perform following to enter RIS calibration values: a. d. Press START button to load value. 3. Display flashes value when it is correctly loaded. record RIS Calibration Values for download after power up (Figure 3). g. Enter diagnostics [3-13]. h. Use number keys to enter Offset value that was previously recorded. RIS Calibration Values (Gain and Offset) 1 Install RIS on Pins (2) 3 Install Screw 2 Install screw 6 5 Install Screw Connect Plug 4 Install Screw Figure 3 Installing RIS 2. e. Repairs / Adjustments REP 6. f. 4. Brush may contaminate mirrors. 5. If a new RIS is installed. If a new RIS is installed. Install RIS Module (Figure 3).1 9/02 4-38 Initial Issue WorkCentre Pro 420 . 6. Use number keys to enter Gain value that was previously recorded. Press Stop button once to prepare for next entry. Install Top Cover (REP 14.5). Clean and vacuum entire area inside RIS. 6. Remove ADF (REP 5. Remove Document Glass (REP 6.1).5). Front Figure 1 Preparing to Remove Exposure Lamp Carriage Front Figure 3 Rotating Carriage Initial Issue WorkCentre Pro 420 9/02 4-39 Repairs / Adjustments REP 6.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury.REP 6. Rear end of Exposure Lamp Carriage 1 Remove screw (1) with Clamp 2 Remove Cable from Carriage 3 Repeat at other end 1 Move Exposure Lamp Carriage to this position 2 Remove Ribbon Cable from Guide Figure 2 Removing Cables from Exposure Lamp Carriage 7. Remove cables from Exposure Lamp Carriage (Figure 2). 3. 1. Prepare to remove Exposure Lamp Carriage (Figure 1). Remove Top Cover (REP 14. Disconnect Printer Cable. Rotate Exposure Lamp Carriage and remove it from within RIS (Figure 3).2 Exposure Lamp Parts List on PL 2. 4. Remove CVT Glass and Registration mount (REP 6. Switch off machine power and disconnect machine Power Cord. 5. 2.1).4).2 .2 9/02 4-40 Initial Issue WorkCentre Pro 420 . Mount 1 Push down Lock and slide Lamp to remove from mount 2 Position Lamp to engage tab 3 Engage Tab at other end 4 Check Lamp is locked into position 2 Disconnect 1 Connect Figure 4 Removing Lamp from Carriage Figure 5 Installing Lamp Repairs / Adjustments REP 6.8. Remove Exposure Lamp from Exposure Lamp Carriage (Figure 4). Replacement 1. Install Lamp (Figure 5).1). 8. Install Top Cover (REP 14. Refer to GP 9 R in Section 6.4).4). Install Document Cover (REP 14. 7. Initial Issue WorkCentre Pro 420 9/02 4-41 Repairs / Adjustments REP 6.1). Move both carriages to right end of RIS while checking Ribbon Cable Adjust Carriages (ADJ 6. Install Cable Clamps (Figure 6). 10. 2 Install Cable Clamp loosely 1 3 Install Cable Repeat for in cutout other end 5 Position Ribbon Cable as shown 4 Install Cable Clamp loosely at other end 6 Install Ribbon Cable in Guide Figure 6 Installing Front Cable Clamp 4. 3. Clean and vacuum entire area inside RIS.2 . 6. Install Document Glass (REP 6. Reinstall Carriage in RIS. Brush may contaminate mirrors. Use a crevice attachment to reach corners. 5. Install CVT Glass and Registration mount (REP 6.5).2. 9. 11. Reconnect machine Power Cord and switch on machine power. CAUTION Do not use a brush attachment on vacuum cleaner. Disconnect Printer Cable and disconnect machine Power Cord. Remove Document Glass (REP 6. 3. Electro Magnetic Emissions Clip Figure 2 Removing ROS Harness from Clip 9. 6. Open Front Door. 2. c. Service procedures must be followed exactly as written. This product is certified to comply with Laser Product Performance Standards set by US Department of Health and Human Services as a Class 1 product. 1 Remove Screws (3) 2 Lift ROS to Remove Figure 3 Removing ROS Module Repairs / Adjustments REP 6. Observe all ESD procedures to avoid component damage refer to GP 5 ESD Hookup Procedure (in Section 6). Switch off machine power. 7. Remove ADF (REP 5. laser beam could cause eye damage if looked at directly. Open Door Module. CAUTION Harness must pass through electro magnetic emission clip during reinstallation to prevent possible malfunction of customer electronic equipment. a. Remove Top Cover (REP 14. 8. During servicing.1).1). b.4). Disconnect Plug. 1.3 9/02 4-42 Initial Issue WorkCentre Pro 420 . 4. Figure 1 Laser Warning CAUTION The Main PWB can be damaged by an electrostatic discharge.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Plug Lock WARNING Use of controls or adjustments other than those specified in this documentation may result in an exposure to dangerous laser radiation. Remove CVT Glass (REP 6. Remove RIS Module (REP 6.1). This means that it is a laser product that does not emit laser radiation during any mode of customer operation. 5.REP 6. Remove ROS harness from electro magnetic emission clip (Figure 2). Remove wire harness from Electro Magnetic Emission Clip and then close Electro Magnetic Emission Clip. The laser warning symbol is repeated in specific service procedures where laser light exposure is possible.5).3 ROS Module Parts List on PL 1. Release Lock and open Electro Magnetic Emission Clip. Remove ROS Module (Figure 3). Initial Issue WorkCentre Pro 420 9/02 4-43 Repairs / Adjustments REP 6.3 .Replacement CAUTION Harness must pass through electro magnetic emission clip to prevent possible malfunction of other customer electronic equipment (Figure 4). 1 Connect Plug 2 Position harness in clip and close Figure 4 Installing ROS Harness in Clip Installation 1 Make installation in revese order of the removal. place a sheet of paper under the CVT glass to capture any paper dust that is caught between the CVT glass and the registration edge. Disconnect Printer Cable and disconnect machine Power Cord.1) CAUTION Image Quality defects occur if the White and Black Calibration Strip located under the Registration Edge has fingerprints. c.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury.1).4 CVT Glass and Registration Edge Parts List on PL 2. Clean and vacuum the inside area of the RIS Module. NOTE: Be sure to locate the 2 locating holes in the Registration Edge metal frame and place them directly over the 2 locating pins in the RIS frame. ADF euipped only: Remove the ADF (REP 5. Remove the Registration Edge. Remove the CVT Glass and store it in a safe place (Figure 1). Install the CVT Glass (Figure 2. Perform GP 9 RIS/Mirrors Cleaning. Repairs / Adjustments REP 6. and Figure 3). Mirrors Cleaning. Figure 1 Removing the CVT Glass and the Registration Edge RIS Module CVT Glass 1 Remove the screws (2) 2 Lift the Registrtion Edge off the RIS Module Replacement NOTE: Operation without the Registration Edge installed results in a U2 status code. CAUTION The CVT Glass is not attached to the Registration Edge. 1. b. Switch off the machine power and disconnect the machine Power Cord. Hold down the front end of the Registration Edge onto the locating pin and install the screw and tighten. Install the Document Glass if you removed it while servicing the machine. 6. Ensure That the CVT Glass and the White and Black Calibration Strip are clean. a. 3. Remove the Top Cover (REP 14. NOTE: When Removing the CVT glass. 5. or other contamination.4 9/02 4-44 Initial Issue WorkCentre Pro 420 . Install the Registration Edge (Figure 1). dirt smudges. 1. Ensure that the Calibration Strip is clean. Switch off machine power. Document Cover equipped only: Remove the Document Cover (REP 14. NOTE: The White and Black Calibration Strip is located on the underside of the Registration Edge. 2.REP 6. 4. Hold down the rear of the Registration Edge onto the locating pin and install the screw and tighten. 3. 2. Picking up the Registration Edge without removing the CVT Glass first may cause the CVT Glass to fall and break.4). Install the Top Cover (REP 14.1 4.1). If the thin strip of white foam. on the right side of the Registration Edge assembly. Initial Issue WorkCentre Pro 420 9/02 4-45 Repairs / Adjustments REP 6.4 . be sure that the glass is biased against the long grey foam on the left side of the Registration Edge assembly. Reconnect the machine Power Cord and restore the machine power.4) or the ADF (REP 5. and lower the Glass 3 When the CVT Glass is all the way down.1). is not in contact with the CVT Glass for the full length of the registration edge.Right side white Foam Seal Right side white Foam Seal 1 CVT Glass Install the CVT Glass at an angle to the left side foam seal Left side long gray Foam Seal 2 Registration Edge Push the CVT Glass into the left side long gray Foam Seal. 5. release the Glass and allow the left side long gray Foam Seal to push the CVT Glass against the Registration edge CVT Glass Registration Edge Assembly Left side long gray Foam Seal Figure 2 Installing the CVT Glass Figure 3 Installing the CVT Glass NOTE: When replacing the CVT glass. Reconnect the Document Cover (REP 14. 6. replace the Registration Edge PL 2. 1. 4. Install Top Cover (REP 14.REP 6. Lift Document Glass away from RIS Module CAUTION Do not use a brush attachment on vacuum cleaner. Clean and vacuum entire area inside RIS. Install ADF (REP 5. Switch off machine power and disconnect machine Power Cord. 1. Use a crevice attachment to reach corners. Remove Top Cover (REP 14. Replacement Repairs / Adjustments REP 6. 5. Reconnect machine Power Cord and switch on machine power. Check that Document glass is clean and install it. Refer to GP 9 R in Section 6.1). 2. Remove ADF (REP 5.1).5 Document Glass Parts List on PL 1.1).5 9/02 4-46 Initial Issue WorkCentre Pro 420 . Brush may contaminate mirrors. 3.1).1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. 3. Disconnect Printer Cable. 2. Any amount of contamination on CCD or lens will cause image quality problems (Figure 2).1). Initial Issue WorkCentre Pro 420 9/02 4-47 Repairs / Adjustments REP 6. Remove CCD cover (Figure 1). Reassemble in reverse order. Switch off machine power and disconnect machine Power Cord. 5.REP 6. 6. Lens and Mirror Cleaner and a lint free cloth remove any haze. CAUTION Figure 1 Removing CCD Cover Do not remove or loosen any screws in CCD area.4). Image Quality problems will result if CCD is not clean. Remove Top Cover (REP 14. Remove ADF (REP 5. 1. dust. CAUTION Do not perform this procedure unless directed to do so from Image Quality RAPs. CAUTION Check that surface of CCD and lens is clean. or lint from CCD and lens. Remove Document Glass (REP 6. Disconnect Printer Cable. CCD 1 2 Remove Remove Screws (3) Lens Figure 2 Cleaning CCD front glass 7. NOTE: Do not vacuum RIS with CCD cover removed.6 CCD Cleaning Clean WARNING Inadvertent operation could cause machine damage or personal injury. 3. With a cotton swab.1).6 . Remove CVT Glass and Registration mount (REP 6.5). 4. 2. Remove Exposure Lamp Power Supply (Figure 1).1). Switch off machine power and disconnect machine Power Cord. Remove Document Glass (REP 6. Disconnect Printer Cable. 2 Use small screwdriver to push out power supply 4 Use small screwdriver to push out power supply 1 Disconnect 3 Disconnect Figure 1 Removing Exposure Lamp Power Supply Repairs / Adjustments REP 6. 3. 6. 4. Remove CVT Glass and Registration mount (REP 6. Remove the Exposure Lamp (REP 6.7 Exposure Lamp Power Supply Parts List on PL 2.REP 6.2).1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. 2. Remove Top Cover (REP 14.4).5).1). Remove ADF (REP 5. 5.7 9/02 4-48 Initial Issue WorkCentre Pro 420 . 1. Install Top Cover (REP 14.4). Initial Issue WorkCentre Pro 420 9/02 4-49 Repairs / Adjustments REP 6. Clean and vacuum entire area inside RIS. Install Document Cover (REP 14. Install CVT Glass and Registration mount (REP 6.7 .4).5). 7. 5. Brush may contaminate mirrors. Install Exposure Lamp Power Supply. Use a crevice attachment to reach corners. 4.1). Refer to GP 9 R in Section 6.Replacement 1. 3. Reconnect machine Power Cord and switch on machine power. Install Document Glass (REP 6. CAUTION Do not use a brush attachment on vacuum cleaner. 2. 6.7 9/02 4-50 Initial Issue WorkCentre Pro 420 .Repairs / Adjustments REP 6. 2.1 Door Module Parts List on PL 6. Switch off machine power.REP 8.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Remove Rear Cover (REP 14. 3. Disconnect Printer Cable and disconnect machine Power Cord.1 . 1. Support Door Module while disconnecting Tethers (Figure 2). Open Door Module and disconnect P/J’s (3).2). 1 2 3 Remove Tether from Frame 4 5 Rotate to disengage and remove Figure 2 Disconnecting Tethers Figure 1 Disconnecting P/J’s Release Tether from other side Initial Issue WorkCentre Pro 420 9/02 4-51 Repairs / Adjustments REP 8.1 9/02 4-52 Initial Issue WorkCentre Pro 420 . Remove Door Module (Figure 3). 1 Loosen screw 2 Move Lock 3 4 Remove Door Module Figure 3 Removing Door Module Repeat for other side Repairs / Adjustments REP 8.4. Disconnect Printer Cable and disconnect machine Power Cord. Open Door Module. Disconnect Tether (Figure 2).2 Registration Assembly Parts List on PL 5. 2. Remove Rear Cover (REP 14. Disconnect Plugs (Figure 1).1 Removal WARNING Inadvertent operation could cause machine damage or personal injury.REP 8. 3. 4. 1. Rotate to disengage and remove Figure 2 Disconnecting Tether Figure 1 Disconnecting Plugs Initial Issue WorkCentre Pro 420 9/02 4-53 Repairs / Adjustments REP 8. Switch off machine power.2).2 . Remove Registration Assembly (Figure 3). 6. Lock Hinge Pin Figure 3 Removing Registration Assembly Repairs / Adjustments REP 8.2 9/02 4-54 Initial Issue WorkCentre Pro 420 . a.2). Push Lock to release Hinge Pin and lift front. Then remove Registration Assembly while feeding wires through hole.5. Remove Transfer Detack Corotron (REP 9.3 Registration Sensor Parts List on PL 5. Lock Tabs Plug Actuator Figure 1 Disconnecting Plugs 3. 1. 5.REP 8. Disconnect Plug. Disconnect Printer Cable and disconnect machine Power Cord. a. Figure 2 Removing Registration Sensor Initial Issue WorkCentre Pro 420 9/02 4-55 Repairs / Adjustments REP 8.2).1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. c. Open Door Module.2). 4. Push Tabs down. Pry up Lock to remove Lock. b. Disconnect Plugs (Figure 1). Remove Registration Assembly (REP 8.3 . d. Switch off machine power. 2. CAUTION Actuator damage may result from careless sensor removal. Remove Registration Sensor (Figure 2). Remove sensor while checking that Actuator remains undamaged. Remove Screws (2) and Rear Cover (REP 14.REP 8. Engage Stop with Tab.2). Close Door Module. b. 1. 2. 3. Tab Stop 3 Pull Clutch off shaft 2 Remove small lock ring 1 Disconnect Ground Wire Figure 2 Removing Registration Clutch Replacement Figure 1 Disconnecting Plugs 3. Disconnect Printer Cable and disconnect machine Power Cord. Reconnect machine power Cord and switch on machine. Install clutch (Figure 2). Disconnect Plugs (Figure 1).2). 1. 2. 4. Remove Screws (2) and Rear Cover (REP 14. 5. a. 4.2). c. Remove Registration Clutch (Figure 2).5 Registration Clutch Parts List on PL 5. Connect Ground Wire. Install lock ring. Remove Registration Assembly (REP 8. Switch off machine power.5 9/02 4-56 Initial Issue WorkCentre Pro 420 . Install Registration Assembly (REP 8. Open Door Module.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Repairs / Adjustments REP 8. Anti-rotation Tab Stop Lock Spring Figure 3 Removing Registration Roll Replacement NOTE: The bearing is equipped with two Anti-rotation Tabs. c. If one breaks during removal. Pull bearing out to remove it. d. Optional step: Remove bearing at other end of Registration Roll same way as in step b. Press Anti-rotation Tab with a small screwdriver so it can be moved past Stop and rotate bearing counterclockwise until Lock is visible. b. install bearing so other tab is employed. e.6 9/02 4-58 Initial Issue WorkCentre Pro 420 . Remove Registration Roll (Figure 3). Manually rotate shaft while removing it to assist removal.7. NOTE: Check that ground spring is pressing against Bronze bushing after installing it. Remove Spring. Repairs / Adjustments REP 8. a. Remove end of Registration Roll from frame and pull Registration Roll out of bearing at other end.REP 8.7 Output Tray Parts List on PL 6. Switch off machine power.3 Removal WARNING Inadvertent operation could cause machine damage or personal injury. 1. 1 Lift Tray 2 Bend hinge inward to disconnect Figure 1 Removing Output Tray Initial Issue WorkCentre Pro 420 9/02 4-59 Repairs / Adjustments REP 8. Disconnect Printer Cable and disconnect machine Power Cord.7 . Remove Output Tray (Figure 1). Switch off machine power.8 Bypass Tray Parts List on PL 6. (Figure 2). 3. These steps enable easier disassembly and reassembly. Remove Lower Guide (7). NOTE: Steps 3 and 4 are optional. 1. 4.3 Removal WARNING Inadvertent operation could cause machine damage or personal injury.1). Disconnect Printer Cable and disconnect machine Power Cord.REP 8. Remove Door Module (REP 8. Remove components (Figure 1).8 9/02 4-60 Initial Issue WorkCentre Pro 420 . 2. 3 Lift Guide enough to disengage locating pin 3 Remove Screws (7) 2 Remove Screws (3) 1 Open Bypass Tray 4 Lift to remove Upper Guide 2 Remove Springs (3) 1 Rotate Sector Gear 180 degrees counterclockwise Figure 1 Removing components 4 Lift and rotate Guide to move it past roller while holding Roller against cam Figure 2 Removing Lower Guide Repairs / Adjustments REP 8. Open Door Module. Install Bypass Tray in Door Module (Figure 4). Bend frame so Bypass Tray can be removed.8 . a. Replacement 1. b. Remove Bypass Tray (Figure 3). 2 Position Hinge Pin into Cutout. Remove Bend Figure 3 Removing Bypass Tray 1 Install Tray into opening 3 Open Tray. Close Bypass Tray so that it can be removed in direction shown.5. Check Hinge Pin in Cutout Figure 4 Installing Bypass Tray Initial Issue WorkCentre Pro 420 9/02 4-61 Repairs / Adjustments REP 8. Check other Hinge Pin. Rotate lower guide so Hole engages Pin on Door Module. Position Lower Guide against Door Flange as shown.2. 3. b. c.8 9/02 4-62 Initial Issue WorkCentre Pro 420 . Position Paper Stop and Bypass Retard Pad as shown during reassembly in step 2 to avoid C3 jams (Figure 5). Hold Retard Pad and Paper Stop in position shown (refer to step 2 required). Hole and Pin Paper Stop Bypass Retard Pad Figure 5 Positioning Paper Stop Lower Guide Retard Pad and Paper Stop Lower Guide Door Flange Figure 6 Installing Lower Guide Repairs / Adjustments REP 8. Install Lower Guide (Figure 6). a. Install lower guide screws (3). Reconnect machine power Cord and switch on machine. upper guide.1). springs (3). Springs (3) Screws (7) Screws (3) Figure 7 Installing Lower and Upper Guides 5. Initial Issue WorkCentre Pro 420 9/02 4-63 Repairs / Adjustments REP 8.8 .4. 6. screws (7) (Figure 7). Install Door Module (REP 8. a. c. a.2). 6.3). 5. If Tray 2 Module is secured to a wheeled stand.1).10).1). Remove machine from Tray 2 Module. Remove Document Glass (REP 6. Remove RIS Module (REP 6.1). Remove Tray 1 (REP 8. f. 4. Remove ROS Module (REP 6.9A Tray 2 Module with 1 Service Persons Parts List on PL 4.REP 8. Remove Rear Cover (REP 14. Remove Drum cartridge (REP 9. 2. 10. Remove Fuser Module (REP 10. Remove Tray 2 Module from Stand. Remove ADF (REP 5.4).1). Disconnect Printer Cable and disconnect machine Power Cord. Lift machine off of Tray 2 Module. Remove screw from frame at each corner of machine. b. Replacement NOTE: Manually push in screws (4) that secure machine to Tray 2 Module.9A 9/02 4-64 Initial Issue WorkCentre Pro 420 . e. 9.5). go to 9. 7. Switch off machine power. Open front door of stand and remove hardware that secures Tray 2 to stand. Repairs / Adjustments REP 8. Remove CVT Glass (REP 6. 3. d. Remove Top Cover (REP 14. 8. 1.1). Remove screw from frame at each corner of machine.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury.9B .9B Tray 2 Module with 2 Service Person Parts List on PL 4.REP 8. 1. If Tray 2 Module is secured to a wheeled stand. go to 2. a. Remove machine from Tray 2 Module. e. Remove Rear Cover (REP 14. Switch off machine power. Remove screws (4) at corners to remove Tray 2 Module from Stand. d. Remove screw from frame at each corner of machine. b. c. Replacement NOTE: Manually push in screws (4) that secure machine to Tray 2 Module. Disconnect Printer Cable and disconnect machine Power Cord. 2. Initial Issue WorkCentre Pro 420 9/02 4-65 Repairs / Adjustments REP 8. Lift machine off of Tray 2 Module.2). Pull out Tray 1 to access screws. Remove screw from frame at each corner of Tray 1.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. f. Disconnect Printer Cable and disconnect machine Power Cord. lift. 1. 2. Figure 1 Tray 1 / Tray 2 Removal Repairs / Adjustments REP 8. and pull out to remove Tray 1 or Tray 2 (Figure 1).10 9/02 4-66 Initial Issue WorkCentre Pro 420 .2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Pull out.10 Tray 1 or Tray 2 Parts List on PL 4. Switch off machine power.REP 8. Switch off copier and disconnect machine Power Cord. 2 1 Figure 1 Removing Bypass Feed Roll Initial Issue WorkCentre Pro 420 9/02 4-67 Repairs / Adjustments REP 8.11 Bypass Feed Roll Parts List on PL 6. Disconnect Printer Cable and disconnect machine Power Cord. 1.3 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Remove Bypass Feed Roll (Figure 1). Switch off machine power.REP 8.11 .2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. 2.12 Bypass Retard Pad Parts List on PL 6. 1. Remove Door Module (REP 8. 4. NOTE: Steps 3 and 4 are optional. Remove Screws (3) and Lower Guide (7). (Figure 2).REP 8. Remove components (Figure 1).12 9/02 4-68 Initial Issue WorkCentre Pro 420 . 3. Switch off machine power.1). Disconnect Printer Cable and disconnect machine Power Cord. 3 Lift Guide enough to disengage locating pin 3 Remove Screws (7) 4 Lift to remove Upper Guide 2 Remove Screws (3) 1 Open Bypass Tray 2 Remove Springs (3) 1 Rotate Sector Gear 180 degrees counterclockwise Figure 1 Removing components 4 Lift and rotate Guide to move it past roller while holding Roller against cam Figure 2 Removing Lower Guide Repairs / Adjustments REP 8. Open Door Module. These steps enable easier disassembly and reassembly. Replacement 1. Arms Paper Stop Bypass Retard Pad Figure 4 Positioning Paper Stop Figure 3 Removing Bypass Retard Pad Initial Issue WorkCentre Pro 420 9/02 4-69 Repairs / Adjustments REP 8. Position Paper Stop and Bypass Retard Pad as shown during reassembly in step 2 to avoid C3 jams (Figure 4).12 . Squeeze Arms together to remove Bypass Retard Pad (Figure 3).5. Position Lower Guide against Door Flange as shown. Install Door Module (REP 8. a.12 9/02 4-70 Initial Issue WorkCentre Pro 420 . springs (3). Install lower guide screws (3). Reconnect machine power Cord and switch on machine. Hold Retard Pad and Paper Stop in position shown (refer to step 1 required). Retard Pad and Figure 6 Installing Lower and Upper Guides 4. 3. and screws (7) (Figure 6). b. c. upper guide. Rotate lower guide so Hole engages Pin on Door Module.2. Lower Guide Figure 5 Installing Lower Guide Repairs / Adjustments REP 8. 5.1). Install Lower Guide (Figure 5). Remove the screws (2). 3. The way of removing Tray 1 or Tray 2 Feed Clutch is the same. Disconnect the connector P/J 408 on Tray and Tray 2 PWB separately. 4. Remove the stop of clutch and the clutch. Disconnect Mount Plate Figure 2 Disconnecting Feed Assembly 1 Operate in reverse order of the removal. Switch off machine power.14 9/02 4-72 Initial Issue WorkCentre Pro 420 .14 Takeaway Clutch. ensure that the concave of the clutch engages the mount plate. 1. 2. Tray 1 or Tray 2 Parts List on PL 4. Disconnect Printer Cable and disconnect machine Power Cord. Remove Rear Cover and Tray 2 Rear Cover.REP 8. Remove Screws (2) Figure 1 Disconnecting Feed Assembly Repairs / Adjustments REP 8.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Installation NOTE: When installing. 2. Remove Feed Roll assembly (Figure 1). Initial Issue WorkCentre Pro 420 9/02 4-73 Repairs / Adjustments REP 8. Remove Feed Roll assembly (Figure 2). b. Figure 2 Removing Feed Roll Installation 1 Operate in reverse order of the removal. Disconnect Printer Cable and disconnect machine Power Cord.REP 8. Remove Tray 1 and Tray 2. Tray 1 or Tray 2 Parts List on PL 4.15 . a. Switch off machine power. b. Figure 1 Removing Feed Roll Assembly 3. Remove Feed Roll assembly. Remove Feed Roll.15 Feed Roll.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Remove E-ring and bearing. a. Remove E-ring. 1. Install the Paper Size Cam. Switch off machine power.REP 8. a. Slide the tail guide to B4 (Tray 1-2) position to align the hole of fan-shaped plate with the hole of Tray. Insert locking pins.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Replacement Figure 1 Removing Tray 1 or Tray 2 Side Door Repairs / Adjustments REP 8. 2. Align the hole position of Size Cam with U-slot of Tray and make installation.16 Paper Size Cam Parts List on PL 4. b. 1.16 9/02 4-74 Initial Issue WorkCentre Pro 420 . Disconnect Printer Cable and disconnect machine Power Cord.Removal 1. 2. Remove Tray. Rmove Retard Roll assembly (Figure 1). a. b. c. Hold the bends at two ends. Press on the bends. Remove the Retard Roll Assembly. Figure 4 Removing Retard Roll Along with Clutch 4. Remove the Retard Roll. a. b. Push the bend toward the arrow. Poll out the shaft and remove the Retard Roll. Figure 3 Removing Retard Roll Assembly 3. Remove the Retard Roll along with the clutch. a. b. Hold the bends. Remove the Retard Roll along with the clutch. Figure 5 Removing Retard Roll Installation 1 Operate in reverse order of the removal. Initial Issue WorkCentre Pro 420 9/02 4-75 Repairs / Adjustments REP 8.16 REP 8.17 Takeaway Roll Shaft, Tray 1 Parts List on PL 4.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. 1. 2. 3. Remove machine from Tray 1 (REP 8.19A 2 person) or (REP 8.19B 1 person). Remove Takeaway Motor for Tray 1 (REP 8.14). Use a small screwdriver in location shown to pry Front Bearing away from tray frame and off of Takeaway Roll Shaft (Figure 1). Front Bearing Pry Here Figure 1 Removing Front Bearing 4. Remove Takeaway Roll Shaft. Repairs / Adjustments REP 8.17 9/02 4-76 Initial Issue WorkCentre Pro 420 REP 8.18 Takeaway Roll Shaft, Tray 2 Parts List on PL 4.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. 1. 2. 3. Remove machine from Tray 2 (REP 8.9A 1 person) or (REP 8.9B 2 person). Remove Takeaway Motor for Tray 2 (REP 8.14). Use a small screwdriver in location shown to pry Front Bearing away from tray frame and off of Takeaway Roll Shaft (Figure 1). Front Bearing Pry Here Figure 1 Removing Front Bearing 4. Remove Takeaway Roll Shaft. Initial Issue WorkCentre Pro 420 9/02 4-77 Repairs / Adjustments REP 8.18 REP 8.18A Tray 1 Module with 1 Service Person Parts List on PL 4.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. 1. 2. Remove ADF (REP 5.1). Remove Drum cartridge (REP 9.1). 3. 4. 5. 6. 7. 8. 9. Remove Output Tray (REP 8.7). Open Door Module. Remove Top Cover (REP 14.1). Remove Document Glass (REP 6.5). Remove CVT Glass (REP 6.4). Remove RIS Module (REP 6.1). Remove Fuser Module (REP 10.1). 10. Remove ROS Module (REP 6.3). 11. Remove machine from Tray 1 Module (Figure 1). 1 Remove Screws (2) 2 Remove Screw1 (1) 3 Remove Screw (1) 5 Remove machine from Tray 1 Module 4 Remove harness from channel Figure 1 Removing Machine from Tray 1 Module Repairs / Adjustments REP 8.18A 9/02 4-78 Initial Issue WorkCentre Pro 420 REP 8.18B Tray 1 Module with 2 Service Persons Parts List on PL 4.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. 1. Remove Output Tray (REP 8.7). 2. 3. 4. Remove Rear Cover (REP 14.2). Remove Right Cover (REP 14.3). Prepare to remove machine from Tray 1 Module (Figure 1). 1 Disconnect 3 Remove Screws (2) 2 Remove harness from channel Figure 1 Preparing to remove Tray 1 Module Initial Issue WorkCentre Pro 420 9/02 4-79 Repairs / Adjustments REP 8.18B 5. Continue to prepare to remove machine from Tray 1 Module (Figure 2). 4 1 Remove Screw (1) Remove Screw (1) 2 3 Raise Arm Disconnect Tether Figure 2 Removing Screws (2) 6. 7. Lift machine off of Tray 1 Module. Remove Tray 1 Module from Stand if required. a. Open front door of stand and remove hardware that secures Tray 2 to stand. Repairs / Adjustments REP 8.18B 9/02 4-80 Initial Issue WorkCentre Pro 420 Disconnect connectors (7). Tray 1 or Tray 2 Parts List on PL 4. a.REP 8. To remove Tray 2 Control PWB remove screws (2) and Tray 2 Rear Cover.19 .2 Removal WARNING Inadvertent operation could cause machine damage or personal injury.19 Tray Control PWB. 2. Remove Tray 1 or Tray 2 Control PWB (Figure 1). Switch off machine power. To remove Tray 1 Control PWB remove Rear Cover (REP 14. Disconnect Printer Cable and disconnect machine Power Cord. Initial Issue WorkCentre Pro 420 9/02 4-81 Repairs / Adjustments REP 8.2). Remove Acrews (2). Figure 1 Removing Tray 1 or Tray 2 Control PWB Installation 1 Operate in reverse order of the removal. 1. b. c. turn the indentation toward locking tab. Lossen screw in locking tab on Rear Side Door. Lossen rear Tether but not Upper Clip. Inner Guide shown removed for clarity Lock Figure 1 Wires Position in Clips Repairs / Adjustments REP 8. Use a small screwdriver to press the hood on rear shaft. 6.20 9/02 4-82 Initial Issue WorkCentre Pro 420 . 2.2 Removal NOTE: Ensure harness in Clips so wires not loose between PWB and Clips. then remove the belt pulley. Remove the spring of indented gear. Use a small screwdriver to press the hook on the belt pulley shaft. 5. 1. Remove Belt Mount Assembly.REP 8. Installation Operate in reverse order of the removal. 3. Open Door Module.20 Bypass Solenoid Parts List on PL 4. a. 1 Remove screws (2). Remove Bypass Solenoid. 4. then remove fan-shaped gear. Remove Reverse Solenoid. b. 7. then remove the shaft. 2.21 . Open Door Module. Installation 1 Operate in reverse order of the removal.REP 8. a Remove screw (1). 1. a Remove screw. 4. 5. 3. Remove Reverse Solenoid (Figure 1). Remove Exit Sensor Assembly (Figure 3). Remove Sensor from Exit Sensor Assembly.2 Replacement NOTE: Ensure harness in Clips so Wires not loose between PWB and Clip. 1 Remove the screw (1) 2 Remove the rotating door Reverse the electromagnet Figure 2 Wires Position in Clips PWB Don’t loosen the wire Cleat Figure 1 Wires Position in Clips Initial Issue WorkCentre Pro 420 9/02 4-83 Repairs / Adjustments REP 8. Remove Reverse Door (Figure 2).21 Exit Sensor Parts List on PL 6.REP 8. Switch off machine power.2 Replacement WARNING Inadvertent operation could cause machine damage or personal injury.22 Duplex Module Parts List on PL 6. Repairs / Adjustments REP 8.22 9/02 4-84 Initial Issue WorkCentre Pro 420 . Disconnect Printer Cable and disconnect machine Power Cord. Remove Screws (5) 1 Open the fasten hole and pull out the pin simultaneously Figure 2 Wires Position in Clips 2 Release the snap Figure 1 Wires Position in Clips 3 Remove Duplex Module. Lift latches (both sides). 1 2 Open Door Module.23 No Paper Sensor Parts List on PL 6. a. Disconnect Printer Cable and disconnect machine Power Cord. Switch off machine power. No Paper Sensor bracket Figure 1 Remove Sensor bracket Installation 1 Operate in reverse order of the removal. 2. Remove Sensor. Remove No Paper Sensor bracket.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. 1. Pull out.REP 8. b. c. Initial Issue WorkCentre Pro 420 9/02 4-85 Repairs / Adjustments REP 8. Remove No Paper Sensor (Figure 1). Remove Sensor mount plate. lift and pull out to Remove Tray 1 or Tray 2.23 . 1. Remove takeaway sensor bracket (Figure 1). Switch off machine power.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury.24 9/02 4-86 Initial Issue WorkCentre Pro 420 . b. Remove Sensor.24 Takeaway Sensor Parts List on PL 6. a.REP 8. lift and pull out to Remove Tray 1 or Tray 2. (FIgure 2) Takeaway Sensor bracket Takeaway Sensor Figure 2 Remove takeaway sensor Installation 1 Operate in reverse order of the removal. Remove takeaway sensor bracket. Disconnect Printer Cable and disconnect machine Power Cord. Pull out. 2. Figure 1 Remove takeaway sensor bracket Repairs / Adjustments REP 8. Use screwdriver stir up interlock switch stopper. a.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. 2. Figure 2 Remove interlock switch Figure 1 Remove interlock switch stopper Figure 1 Remove interlock switch stopper Initial Issue WorkCentre Pro 420 9/02 4-87 Repairs / Adjustments REP 8. Remove interlock switch.25 Lift Upper Cover Interlock Switch Parts List on PL 6.REP 8. Remove interlock switch (Figure 1).25 . 1. b. Disconnect Printer Cable and disconnect machine Power Cord.(FIgure 2) Interlock Switch stopper ) Figure 2 Remove interlock switch Installation 1 Operate in reverse order of the removal. Open lift upper cover.1 9/02 4-88 Initial Issue WorkCentre Pro 420 . c.4 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Place Drum Cartridge in a black bag. Remove Drum Cartridge. This results in image quality defects. Figure 1 Wires Position in Clips Repairs / Adjustments REP 9. b. Actuate orange release and pull out Drum Cartridge. Open Door Module. a. Switch off machine power. 1.REP 9. d. Disconnect Printer Cable and disconnect machine Power Cord. Use caution when Drum Cartridge is removed from machine. Open Front Door.1 Drum Cartridge Parts List on PL 1. CAUTION Drum Cartridge photoreceptor damage is likely if Drum Cartridge is handled carelessly. Lift Green Arm of Registration Assembly.2 . Green Arm Corotron Legs Springs (2) Figure 2 Installing Transfer Detack Corotron Legs Gray Locking Tabs 2. b. c.REP 9. Install Transfer Detack Corotron (Figure 2). Check springs under corotron. Check that both Springs are present. Install Corotron Legs into holes. 3. 1.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. a. Open Door Module. Close Door Module. Remove Transfer Detack Corotron (Figure 1). 2. b. a. Switch off machine power. Install front Gray Locking Tabs into front holes (removed in Figure 1) WARNING The sawtooth metal blade of Transfer Detack Corotron is sharp and could cause injury if handled carelessly. Push Gray Locking Tabs to rear to release corotron. Lower Green Arm and then remove corotron. Disconnect Printer Cable and disconnect machine Power Cord. Replacement 1.2 Transfer Detack Corotron Parts List on PL 5. Reconnect machine power Cord and switch on machine. c. Figure 1 Removing Transfer Detack Corotron Initial Issue WorkCentre Pro 420 9/02 4-89 Repairs / Adjustments REP 9. Reinstall Transfer Detack Corotron (REP 9. Install corotron wire (Figure 3). 4.3 . Slide Guard toward end (Figure 1). Use tools to install wire.2). 5. 6. 1. Install Spring on wire loop and install spring on clip (Figure 4). 2 Install wire on Post Figure 2 Installing Wire Loop End Figure 3 Installing Wire Spring End 3. 2.Replacement CAUTION Do not touch corotron wire. Initial Issue WorkCentre Pro 420 9/02 4-91 Repairs / Adjustments REP 9. Close Door Module. 7. Clip 1 Position wire under Guard. Reconnect machine power Cord and switch on machine. Reinstall Front End Guard (Figure 2).3 9/02 4-92 Initial Issue WorkCentre Pro 420 .Repairs / Adjustments REP 9.REP 10.1 Fuser Module Parts List on PL 1.4 Removal WARNING Skin burns may result from grasping hot areas of Fuser Module. If a hot Fuser Module must be removed, grasp Fuser Module by black plastic frame component, shown in figure (Figure 1). Damage to work surface may result if a hot Fuser Module is removed and positioned on an unprotected work surface. Place a hot fuser on ten sheets of paper. 1. 2. 3. Open Front Door. Open Door Module. Remove Fuser Module (Figure 1). a. b. c. d. Pull Paper Release outward until it latches into place. Remove Screw. Remove Screw. Remove Nut and Ground Wire. CAUTION If machine was making copies within 30 minutes, Fuser Module is hot. Grasp Fuser Module in areas shown and slide Fuser Module toward front of machine to clear tabs on Upper PCM Frame. e. f. Grasp Paper Release Handle to move Fuser Module toward front to release mounts. Pull outward to remove Fuser Module while removing Ground Wire from Fuser Module Frame. Paper Release Screw Screw Ground Wire Figure 1 Removing Fuser Module Initial Issue WorkCentre Pro 420 9/02 4-93 Repairs / Adjustments REP 10.1 Replacement 1. Install Fuser Module (Figure 2). a. Position Fuser module so Front Fuser Mount and Rear Fuser Mount are next to Molded Retainers. 2. Secure Fuser Module (Figure 3) a. b. Slide Fuser Module toward rear. Check that Mounts are behind Retainers. Install Screws (2). Rear Fuser Mount Molded Retainers Mount Mount Front Fuser Mount Retainer Retainer Screw Screw Figure 2 Installing Fuser Module Figure 3 Securing Fuser Module 3. 4. 5. Install Safety Ground Wire and install nut. Close Door Module. Reconnect machine power Cord and switch on machine. Repairs / Adjustments REP 10.1 9/02 4-94 Initial Issue WorkCentre Pro 420 REP 10.2 Heat Rod Parts List on PL 1.4 Removal WARNING Skin burns may result from grasping hot areas of Fuser Module. If a hot Fuser Module must be removed, grasp Fuser Module by black plastic frame component, shown in figure (Figure 1). Damage to work surface may result if a hot Fuser Module is removed and positioned on an unprotected work surface. Place a hot fuser on ten sheets of paper. 1. 2. 3. Remove Fuser Module (REP 10.1). Position Fuser Module upside down. Remove screws (2) (Figure 1). Remove Screw 4. Remove Heat Rod (Figure 2). Remove Screw Figure 2 Removing Heat Rod Replacement CAUTION Do not touch or handle surface of Heat Rod. Film Remover/General Cleaning Solvent and a lint free cloth can be used to clean surface of Heat Rod if necessary. CAUTION Do not flex or bend Heat Rod metal end tabs. One bend can destroy Heat Rod. 1. Figure 1 Removing Screws (2) 2. 3. Install Heat Rod without touching glass surface and install screws (2). Reinstall Fuser Module (REP 10.1). Reconnect machine power Cord and switch on machine. Initial Issue WorkCentre Pro 420 9/02 4-95 Repairs / Adjustments REP 10.2 Repairs / Adjustments REP 10.2 9/02 4-96 Initial Issue WorkCentre Pro 420 REP 14.1 Top Cover Parts List on PL 1.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. 1. 2. 3. 4. Remove Document Cover (REP 14.4). Open Door Module. Open Front Door. Remove Top Cover (Figure 1). 1 Remove Screws (4) 2 Lift Cover and Disconnect Harness Figure 1 Removing Top Cover Initial Issue WorkCentre Pro 420 9/02 4-97 Repairs / Adjustments REP 14.1 REP 14.2 Rear Cover Parts List on PL 7.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. CAUTION Broken connectors may result if Rear Cover moves down after screws are removed. 1. Support Rear Cover while removing screws (Figure 1). Screws (2) Figure 1 Removing Rear Cover Repairs / Adjustments REP 14.2 9/02 4-98 Initial Issue WorkCentre Pro 420 REP 14.3 Right Cover Parts List on PL 7.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. 1. Remove Right Cover. a. b. Open Front Door. Remove Screws (2) and Right Cover (Figure 1). Front Door Screws (2) Figure 1 Removing Right Cover. Initial Issue WorkCentre Pro 420 9/02 4-99 Repairs / Adjustments REP 14.3 REP 14.5 Tray 2 Rear Cover Parts List on PL 4.2 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. 1. Remove screws and cover (Figure 1). Screws (2) Figure 1 Removing Tray 2 Rear Cover Repairs / Adjustments REP 14.5 9/02 4-100 Initial Issue WorkCentre Pro 420 REP 14.6 Front Door Parts List on PL 7.1 Removal WARNING Inadvertent operation could cause machine damage or personal injury. Switch off machine power. Disconnect Printer Cable and disconnect machine Power Cord. 1. 2. Open Tray 1 50 mm. Push Lock right to release and to move right end of Front Door down (Figure 1). Move door left to release left hinge. Lock Figure 1 Removing Front Door Initial Issue WorkCentre Pro 420 9/02 4-101 Repairs / Adjustments REP 14.6 Repairs / Adjustments REP 14.6 9/02 4-102 Initial Issue WorkCentre Pro 420 ADJ 5.1 Carriages Purpose The purpose of this procedure is to ensure that Document is always in correct position when using ADF. NOTE: Only when skew is caused by ADF, can this adjustment be made. Check. 1. 2. 3. 4. 5. 6. 7. 8. 9. Switch on power. Ensure that Guide on the side of Input Tray has been adjusted to the size of document to be copied. Check any obstacle in Document Paper Path. Insert Test Pattern in ADF Document Input Tray. Check that the copy of Test Pattern is within ADF skew specifications (2). Cut two paper slips of 1x11 inch. Put a paper slip of 1x11 inch under Feed Roll Assembly. Use the second paper slip to actuate Document Exit Sensor, with actuating time enough to feed the first paper slip in between transport pulley and cross bar. Pull out the slip in between to text resistance. If no resistance is present, replace or clean Feed Roll, Cross Bar and Retard Pad on Input Tray. 10. To check that Takeaway Roll smoothly transport paper, put the paper slip obtained in 6 toward Input Stop Door (when standing facing right side of ADF, there it is left door). 11. Use the second paper slip to actuate Document Exist Sensor. When Document Feed Roll Assembly is in motion, push in the first paper slip until the Takeaway Roll input the slip by 1 inch. 12. Pull out the gripped slip to detemine the resistance. If no resistance is present, clean or replace Takeaway Roll (PL 3.2). 13. As for Rear Takeaway Roll, perform 10,11 and Y. 14. Tocheck that the pressure between Front CVT Cross Bar and Rear CVT Cross Bar is even, lift the front part of ADF. 15. Put a slip of paper under each roll to check that it is smoothly pulled. If it is not pulled properly, clean Cross Bar and CVT Board Roll. Check the state of spring on ends of Front and Rear CVT Cross Bar shafts. Replace if required. 16. Insert Test Pattern in ADF Document Transport Tray. 17. Check that the copy of Test Pattern is within ADF skew specifications (Figure 2). If skew is still present, make adjustment. (Figure 3) Initial Issue WorkCentre Pro 420 9/02 4-103 Repairs / Adjustments ADJ 5.1 1 9/02 4-104 Initial Issue WorkCentre Pro 420 .Repairs / Adjustments ADJ 5. Reconnect machine Power Cord and switch on machine power.ADJ 6. 6.5). Rear end shown. Initial Issue WorkCentre Pro 420 9/02 4-105 Repairs / Adjustments ADJ 6. Install Document Cover (REP 14.1 . Remove Document Glass (REP 6.1). Refer to GP 9 R in Section 6. Move Exposure Lamp Carriage to Right End. Install Top Cover (REP 14. 5.4). Right End Exposure Lamp Carriage Figure 2 Adjusting Carriages CAUTION Do not use a brush attachment on vacuum cleaner. Adjust Carriages (Figure 2). 4.2). 3. Install Document Glass (REP 6. Use a crevice attachment to reach corners. Switch off machine and disconnect machine power cord. a. • Image appears skewed (Figure 1). Adjustment NOTE: Adjust only if following occurs. Remove Top Cover (REP).1 Carriages Purpose Purpose is to align carriages to RIS Frame. Brush may contaminate mirrors. 2. Remove ADF (REP 5. Clean and vacuum entire area inside RIS. b. Remove CVT Glass (REP 6. c. 1. Screw Figure 1 Skewed Image • • • 1 2 3 4 5 6 Exposure Lamp replaced Exposure Lamp Power Supply replaced Direction to adjustment given in RAP. Hold Exposure Lamp Carriage tightly against Right End and tighten screws (2).4). Check the parallel degree of full-speed and half-speed Carriages.5). Loosen Screw at each end. Enter diagnostics [3-13].2 RIS Values Purpose Purpose is to load calibration value for RIS assembly in NVM. 6. Adjustment 1. 2. 3. Adjustment is required. Enter [14].1). 5.1). 2. 5. Repairs / Adjustments ADJ 6. RIS Values are on a label that is located on top of front RIS frame.2 9/02 4-106 Initial Issue WorkCentre Pro 420 . If values stored in NVM are same as values on label. Remove Top Cover (REP 14. Record value. Press Stop button once to prepare for next entry. Press Start button to load value. Press Stop button once to prepare for next entry. 6. This is RIS Offset Value stored in NVM.ADJ 6. Check 1. Reinstall Top Cover (REP 14. Enter [14]. Use number keys to enter RIS Gain value recorded in Check (from label that is located on top of front RIS frame). no change is required. 3. Use number keys to enter RIS Offset value recorded in Check (from label that is located on top of front RIS frame) Press Start button to load value. Press Stop button 5 times to exit diagnostics. Enter diagnostics [3-13]. Display flashes value when it is correctly loaded. Record value. If values are different. Display flashes value when it is correctly loaded. 4. 4. This is RIS Gain Value stored in NVM. Press Start button to load value. Make 4 copies of Side B of Test Pattern on 11”/A4 paper. Adjust [9–10] Transfer Off Timing. If problem is trail edge background.46 is best range of values.1 . 2. Output Tray end of machine Lead Edge Back Edge Trail Edge Paper Movement Direction Adjust [9–9] Transfer On Timing a. a. New value is displayed flashing. f.ADJ 9. Value is displayed flashing. Default value is 46. 37 . enter lower value by pressing number keys and pressing Start.1 Transfer Timing Purpose Purpose of this adjustment is to set on timing and off timing of Transfer Corotron. Front Edge Front of Machine Figure 1 Paper Orientation Terms Initial Issue WorkCentre Pro 420 9/02 4-107 Repairs / Adjustments ADJ 9. c. c. e. Value is displayed flashing. Long Edge Feed Adjustment 1. d. Enter diagnostic [9–10] and press Start. Exit diagnostics. b. Enter diagnostic [9–9] Press 4 key and then 0 key to enter 40. New value is displayed flashing. Exit diagnostics and make 4 copies of Side B of Test Pattern on 11”/A4 paper and go back to step c to adjust if required. b. enter 46 by pressing number keys and pressing Start. d. If problem is lead edge background.Repairs / Adjustments ADJ 9.1 9/02 4-108 Initial Issue WorkCentre Pro 420 ...............1 Tray 1/Tr ay 2 .......................................................................... Initial Issue WorkCentre Pro 420 9/02 5-1 Repairs / Adjustments ......................... Registration and Corotrons PL 5.......4 Tray (2of3) ................................3 Lower PCM Components....................................................................Overview Introduction ........... Part Number Index .........................................3 Tray (1of3) ..................................................... Control Console....................................................................... PL 4....................................................................... RIS Module.......................................................................................................2 Upper PCM Components......................................................................................................... 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-15 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-21 5-22 5-23 5-24 Imager PL 2...................................1 Registration And corotron .......2 ADF Module (2of2) ...................................................................................... Drum Cartridge ........................................................ Door Module PL 5.. Covers PL 7................................................................................................................................................................................................................... PL 6...................................................................................................................1 PCM Assembly............................................. PL 5........................................2 Door Components (1of2) .........................1 Control Panel Assembly ................. Control Panel PL 3.............2 Stand .............................................................................. Symbology ....................................................................................................................3 Door Components (2of2) ............................................. PL 8...........................................................1 Control Panel Components............. PL 1............1 Imager Components .......................................................................................................................................................... ..................... PL 8.............................................................. PL 7..................................1 Door ...................................................... PL 7....................................................... ....... PL 1......................................... 5-1 5-2 5-3 Parts Lists PCM PL 1........................... PL 5..................................................5 Tray (3of3) ............................................. .........1 Covers ........................... Subsystem Information ........................................................................................................................................... PL 5.........................................................................................................4 Fuser............................. Tray 1/Tray 2 PL 3............................................................ PL 1.....................................2 Tray Module.........................................................Repairs / Adjustments 9/02 5-2 Initial Issue WorkCentre Pro 420 . Symbology Symbology used in the Parts List section is identified in the Symbology section. (REP 5. Part Number Index This index lists all the spared parts in the machine in numerical order. Common Hardware The common hardware is listed in alphabetical order by the letter or letters used to identify each item in the part number listing and in the illustrations. Other Information Abbreviations Abbreviations are used in the parts lists and the exploded view illustrations to provide information in a limited amount of space. Service Procedure Referencing If a part or assembly has an associated repair or adjustment procedure. Dimensions are in millimeters unless otherwise identified. Electrical Connectors and Fasteners This section contains the illustrations and descriptions of the plugs. The following abbreviations are used in this manual: Table 1 Abbreviation A3 A4 A5 AD AWG EMI GB KB MB MM MOD NOHAD PL P/O R/E REF: SCSI W/ W/O Meaning 297 x 420 Millimeters 210 x 297 Millimeters 148 x 210 Millimeters Auto Duplex American Wire Gauge Electro Magnetic Induction Giga Byte Kilo Byte Mega Byte Millimeters Magneto Optical Drive Noise Ozone Heat Air Dirt Part List Part of Reduction/Enlargement Refer to Small Computer Systems Interface With Without Table 2 Operating Companies Abbreviation AO USMG USO XCL XE Meaning Americas Operations United States Marketing Operations United States Operations Xerox Canada Limited Xerox Europe Organization Parts Lists Each item number in the part number listing corresponds to an item number in the related illustration. ADJ 5.Introduction Overview The Parts List section identifies all part numbers and the corresponding location of all spared subsystem components.g. A part number listing of the connectors is included. Each number is followed by a reference to the parts list on which the part may be found. jacks. All the parts in a given subsystem of the machine will be located in the same illustration or in a series of associated illustrations. the procedure number will be listed at the end of the part description in the parts lists e.3) WorkCentre Pro 420 9/02 5-3 Parts List Introduction .1. and fasteners used in the machine. Tag The notation "W/Tag" in the parts description indicates that the part configuration has been updated. a part or assembly may be spared in two versions: with the Tag and without the Tag. but is not shown in the illustration. If the machine does not have a particular Tag and the only replacement part available is listed as "W/Tag. Whenever you install a Tag kit or all the piece parts that make up a Tag. Parts List Subsystem Information 9/02 5-4 WorkCentre Pro 420 . In those cases. The item number of the assembly or kit precedes the bracket. use whichever part is appropriate for the configuration of the machine on which the part is to be installed. The Change Tag Index tells you which kit or piece parts you need. When the word "assembly is found in the part number listing. Brackets A bracket is used when an assembly or kit is spared. the item numbers of the piece parts follow the bracket. Check the change Tag index in the General Information section of the Service Data for the name and purpose of the modification.Subsystem Information Use of the Term "Assembly" The term "assembly" will be used for items in the part number listing that include other itemized parts in the part number listing. there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly. In some cases. mark the appropriate number on the Tag matrix." install the Tag kit or all of the piece parts. A Tag number within a circle having a shaded bar and pointing to an item number shows that the configuration of the part shown is the configuration before the part was changed by the Tag number within the circle (Figure 2). Information on the modification is in the Change Tag Index. Figure 2 Without Tag Symbol Figure 1 With Tag Symbol WorkCentre Pro 420 9/02 5-5 Parts List Symbology .Symbology A Tag number within a circle pointing to an item number shows that the part has been changed by the tag number within the circle (Figure 1). Information on the modification is in the Change Tag Index. A tag number within a circle with no apex and having a shaded bar shows that the entire drawing was the configuration before being changed by the tag number within the circle (Figure 4).A tag number within a circle with no apex shows that the entire drawing has been changed by the tag number within the circle (Figure 3). Figure 3 Entire Drawing With Tag Symbol Figure 4 Entire Drawing Without Tag Symbol Parts List Symbology 9/02 5-6 WorkCentre Pro 420 . RIS Module.1) Top Cover Assembly (PR China) (REP 14.5) 420 Control Console (Metric)(220V) 420 Control Console (Inch)(110V) RIS Assembly (REP 6.1 .1) PCM Assembly (Not Spare) (REP 1.1) (Including 3-7) Top Cover Assembly (DMO) (REP 14. Control Console Item 1 2 – 3 4 5 – 6 7 8 9 10 11 Part – 802K53800 802K62090 802E51840 809E48410 802E95250 892E54181 – – 090E02520 101K48480 101K49020 801K13160 – Description ADF Assembly (REP 5.1) (Including 3-4. PL 1.1 PCM Assembly.1. 6-7) Copy Exit Baffle Leaf Spring Status Code Label Kit (English) Status Code Label Kit (Chinese) Top Cover Magnet Platen Glass (REP 6.9) WorkCentre Pro 420 9/02 5-5 Parts List PL 1.2) Cooling Fan (MOT) Transfer Detack Contact Support (REP 1.2 9/02 5-6 WorkCentre Pro 420 .2 Item 1) RIS Ground Spring Power Cord (110v) (DMO) Power Cord (220v) (DMO) Power Cord (220v) (Europe/Iran/Africa/Turkey/Arabia/R ussia) Power Cord (220v) (China) Power Cord (240v) (India/Hong Kong) Printer Cable – – 18 117E23652 117E23631 117E22910 Parts List PL 1.6) CRU Blocker Kit CRU Blocker (P/O PL 1.3) PCM Interface PWB (REP 1.3) Contact Spacer HVPS Repair Kit HVPS Mylar High Voltage Power Supply (HVPS) (PS2) (REP 1.1) Main PWB (REP 1.PL 1.5) Drive Module (MOT1) (REP 4.1 Item 9) ROS Module (REP 6.2 Item 12) Spring (P/O PL 1.2 Upper PCM Components Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 – – Part – 062K13011 160K96570 120E20080 604K17760 055E49173 105E15500 007K12173 960K10230 127K41250 014K07852 604K04040 – – – 809E45010 117E23661 117E10550 117E23621 Description Part of PCM Assembly (REF: PL 1.2 Item 12) PCM Upper Frame (P/O PL 1.3 Item 4) Toner Sensor Spring (P/O PL 1.3 Item 4) Wrase Lamp (LP1) (REP 1.3 .3 Lower PCM Components Item 1 2 – Part – 105E26600 105E15490 105E15680 3 4 5 6 7 8 9 10 11 12 13 14 15 16 160K96140 960K10030 – 962K16160 962K20650 – 115K02072 604K17750 130K66180 – 122K02330 – 604K17860 – – – Description Part of PCM Assembly (REF: PL1.4) LVPS (220V) (PS1) (REP 1.4) (China Mainland) LVPS (220V) (PS1) (REP 1.3 Item 13) Front Door Interlock Actuator Kit (P/O PL 1.7) Toner Sensor Kit Toner Sensor (P/O PL 1.1 Item 9) LVPS (110V) (PS1) (REP 1.3 Item 13) WorkCentre Pro 420 9/02 5-7 Parts List PL 1.PL 1.8) Crum Connector (Not Spared) Interlock Actuator Kit Spring (P/O PL 1.4) (DMO-WAST) Power Switch Board (220V) Power Switch Board (110V) DC Harness AC Harness (220V) AC Harness (110V) Conversion Socket Durm Cartridge Contact Support (REP 1.3 Item 13) PCM Lower Frame (P/O PL 1.PL 1.1) Fuser Module (220V) (REP 10.1) Toner Bottle Drum Cartridge (China Mainland) (REP 9.1) Drum Cartridge (DMO-East) (REP 9.4 9/02 5-8 WorkCentre Pro 420 .2) Heat Rod (220V) (REP 10.1) Drum Cartridge (DMO-Wast) (REP 9.1) Fuser Module (110V) (REP 10.1) Drum Cartridge (HongKong/Korea) (REP 9.1) Drum Cartridge (DMO-India) (REP 9.4 Fuser.1) Parts List PL 1. Drum Cartridge Item 1 – 2 – 3 4 – – – – Part 126E02101 126E02111 126K22680 126K00540 106R00280 113R00022 113R00023 113R00024 113R00025 113R00026 Description Heat Rod (110V) (REP 10.1 Item 3) Scan Home Sensor (Q2) WorkCentre Pro 420 9/02 5-9 Parts List PL 2.1 Imager Components Item 1 2 3 4 5 6 7 8 9 10 11 9 Part 090E02550 018K01250 – 122E02580 105K18490 – – – – – – 130E09310 Description CVT Glass (REP 6.1 Item 5) Front Power Supply (P/O PL 2.1 Item) Exposure Lamp (LP2) (REP 6.1 .7 PL 1.7) Rear Power Supply (P/O PL 2.2) Exposure Lamp Power Supply (SP3) (REP 6.4) Registration Guide Prat of Imager Assembly (REP 6.1 Item 5) Harness (P/O PL 2.1 Item 5) Harness (P/O PL 2.PL 2.1 Item 3) Imager House (P/O Item 3) Scan Driver Motor (MOT2) (P/O PL 2.10) Document Pre Registration Sensor (REP 5.13) Parts List PL 3.4) Document Present Sensor (REP 5.1 Item 1) Oct Output Tray Extension (P/O Item 1) Offset Catch Tray (Rep 6.1 9/02 5-10 WorkCentre Pro 420 .15) Document Feeder Housing Tray Extension Kit Copy Exit Guide ADF Access Door (REP 5.2) Feed Roll (REP 5.7) OCT Motor Bracket (MOT2) (P/O PL 3.1 Control Panel Components Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part – 050K54810 – – 022K60222 121K33560 107E94941 107E94941 – 160K96430 – 127K30560 – – 038K13220 802K53830 Description Part of ADF Module (REF: PL3.PL 3.11) Catch Tray Extension ADF Control PWB (REP 5.1 Item 3) OCT Motor (MOT2) (P/O PL 2.5) Document Nudger Solenoid (REP 5.1 Item 3) (REP 5.7 PL Item) ADF Driver Cover (REP 5.9) CVT Idler Spring Document Feeder Housing ADF Interface Cable Retard Roller (REP 5. ADJ 5.2 Item 1) Document Input Transport (P/L 3.2 Item 1) Copy/Print Exit Motor (REP 5.2 Item 1) Document Transport (Input Tray) (REP 5.2 Item 1) Baffle Passive Assembly (P/O PL 3.2 Item 1) Frame Stiffener (P/O PL 3.14.12) Registration Sensor (REP 5.2 Item 1) (REP 5.16) (P/O PL 3.2 Item 1) CVT Motor (REP) (P/O PL 3.14) Document Output Guide CVT Motor Bracket (P/O PL 3.14) Copy Exit Motor Bracket (P/O PL 3.6) 8 18 WorkCentre Pro 420 9/02 5-11 Parts List PL 3.2 .2 Item 1) Paper Guide (P/O PL 3.2 Item 1) Document Exit Switch (REP 5.PL 3.2 ADF Module (2of2) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part – – 121K25271 – 127K43940 001E76280 038K13331 – 127K43720 055K34430 – – 130K65042 130E09390 809E48730 – 962K16430 059K34770 Description Part of ADF Module (REF: PL 3.1) Document Feed Clutch (REP 5.1 Item 1) Control Panel Label (P/O PL 4.1 Item 4) Features Button (P/O PL 4.1 Item 4) Pagination Button (P/O PL 4.1 Item 4) Key Button (P/O PL 4.1 Item 4) Numeric Button (P/O PL 4.1 Item 4) Control Panel Harness (Not Spared) Control Panel PWB Parts List PL 4.1 Item 4) Single /Duplex Button (P/O PL 4.1 Item 1) Control Panel Top Cover (P/O PL 4.1 Item 4) Stop Clear Button (P/O PL 4.PL 4.1 Item 1) Control Panel Repair Kit Print Pause Resume Button (P/O PL 4.1 Item 4) Start Button (P/O PL 4.1 9/02 5-12 WorkCentre Pro 420 .1 Control Panel Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part – – – 604K17730 – – – – – – – – – 160K96350 Description Part of Control Panel Assembly (REP PL 1.19A REP 8.1 .9B) 2 097S50213 1 2 (EXPLODED ON PL 5.1 Tray 1/Tr ay 2 Item 1 Part – Description Tray 1 Module (REF: Item 2) (Note: Tray 1 Same As Tray 2.9A REP 8. Right Cover And Harness) (REP 8. Minus Rear Cover.PL 5.19B) Tray 2 Module (REP 8.2 ITEM 1) WorkCentre Pro 420 9/02 5-13 Parts List PL 5.23) No Paper Sensor Bracket Harness Take Away Sensor (REP 8.14) Bearing CIM Clutch Bracket Gear (T38/26) Harness Bracket No Paper Sensor Actuator No Paper Sensor (REP 8.2 9/02 5-14 WorkCentre Pro 420 .24) Take Away Sensor Bracket Harness Left Cover Interlock Switch Kit (REP 8.15) CIM Motor Bracket Gear (T51/15) Gear (T40/18) Gear (T37) Joint Assy Drive CIM Clutch (REP 8.3) Rear Cover (REP 14.2 Tray Module Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Part – 160K96420 110K14070 962K17460 127K43280 – 807E05500 007E66810 007E01240 011K02940 121K28300 413W77559 – 007E66820 – – 120E25110 130E82740 – – 130E82740 – – 604K18040 – – 007E60720 413W77559 120E25170 059K34020 809E48760 013E90840 – 604K18010 – 050K54370 – 802E53140 802E53130 Description CIM Module Tray 1 Control PWB Harness Paper Size Switch CIM Motor (REP 18.PL 5.25) (Include 25-26) Left Cover Interlock Bracket Left Cover Interlock Gear (T22) Bearing Take Away Sensor Actuator T/A Roller Spring Bearing Upper Feed Chute Left Cover Baffle Kit Left Cover Tray Tray Outline Border Right Cover (REP 14.2) 21 1{2~39 24{25~26 34 33 35 26 30 29 31 32 28 20 25 22 23 27 14 17 16 10 8 9 7 6 3 4 11 12 13 5 39 19 18 15 2 37 38 36 Parts List PL 5. 3 .3 Tray (1of3) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part – 050K54370 054E25140 059K21970 006K28430 – – – – 809E33160 031E10340 019K97497 – 059K21960 – 005K06110 – 809E49210 – Description Tray Assembly Feeder Assembly Chute Feed Roller Assembly (REP 8.17) Retard Housing Retard Roller Shaft Friction Clutch Retard Holder Spring Bearing WorkCentre Pro 420 9/02 5-15 Parts List PL 5.PL 5.15) Shaft Assembly Bearing Roller Earth Plate Screw Spring Holder Retard Holder Assembly (REP 8. 4 9/02 5-16 WorkCentre Pro 420 .16) End Guide Lock Screw Pin Cover Screw Screw Cover Earth Spring Latch Rear Latch Spring Front Latch Parts List PL 5.4 Tray (2of3) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part – – – 038E29640 038E29870 038E24300 809E14810 807E05440 007E55290 008E93921 – – 029E14970 – – – – 809E48590 – 003K17710 809E32960 003K17700 Description Housing Label Instruction Label Instruction (End Guide) End Guide Plate End Guide Guide Spring Gear Idler Gear Size Cam (REP 8.PL 5. PL 5.5 Tray (3of3) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part – 038E29630 038E29620 – 807E05430 807E05450 007E55261 – 809E34771 – – 011E14240 – – 809E38040 809E38050 – 809E48460 – – Description Bottom Flate Assembly (Upper) Side Baffle (Rear) Side Baffle (Front) Bottom Plate Rack Rack Pinion Guide Spring Spring Plate Cap Lever Label (Max) Label (OHP Max) Spring Spring Label (Size) Spring Latch Screw WorkCentre Pro 420 9/02 5-17 Parts List PL 5.5 . PL 6.1 Registration And corotron Item 1 2 3 4 5 6 7 8 9 10 11 12 Part 125K03930 125K03950 604K00570 – – – – 604K00580 – – 604K00590 604K00600 Description Registration Assembly (REP 8.2) Transfer Detack Corpotron (REP 9.2) Corotron Wire Kit (REP 9.3) Transfer Detack Corotron Wire (P/O PL 5.1 Item 2) Spring (P/O PL 6.1 Item) (P/O PL 5.1 Item 5) Transfer/Detack Corotron Support (P/O PL 5.1 Item 5) Registration Framework (P/O PL 5.1 Item 5) Registration Roller Kit (REP 8.6) Registration Roller (P/O PL 5.1 Item 8) (REP 8.6) Bearing (P/O PL 5.1 Item 8) Registration Clutch Kit (CL1) (REP 8.5) Registration Sensor Kit (Q1) (REP 8.6) Parts List PL 6.1 9/02 5-18 WorkCentre Pro 420 PL 7.1 Door Item 1 Part – Description Door Module (REP 8.1) WorkCentre Pro 420 9/02 5-19 Parts List PL 7.1 PL 7.2 Door Components (1of2) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Part – 006K28370 121E18780 – – – 130K83340 962K02671 – 604K04010 – – – – 008E07390 – 121E17524 – 604K04000 – – – – 604K04140 – – – – – – 019K06310 809E49500 – – – Description Part Of Door Module (REP PL 7.1 Item 1) Driver Gate (P/O PL 7.2 Item 1) Driver Gate Solenoid (P/O PL 7.2 Item 1) 24Belt (P/O PL 7.2 Item 1) Transport Gear (P/O PL 7.2 Item 1) Exit Transport (P/O PL 7.2 Item 1) Exit Sensor (Q3) (REP 8.21) Exit Sensor Harness (P/O PL 7.2 Item 1) Door Connector (P/O PL 7.2 Item 1) Door Gear Kit Sector Gear Spring (P/O PL 7.2 Item 7) Shaft (P/O PL 7.2 Item 7) Gear (18T/15T) (P/O PL 7.2 Item 7) Sector Gear (P/O PL 7.2 Item 7) Cam (P/O PL 7.2 Item 7) Gears and Housing (P/O PL 7.2 Item 7) Bypass Solenoid (SOL 4) (REP 8.23) Spring Door Latch Kit Door Latch (P/O PL 6.2 Item 15) Latch Shaft (P/O PL 6.2 Item 15) Door Handle (P/O PL 6.2 Item 15) Door Latch Spring (P/O PL 6.2 Item 15) Door Tether Kit Rear Tether (P/O PL 7.2 Item 20) Front Tether (P/O PL 7.2 Item 20) Hinge Lock (P/O PL 7.2 Item 1) Door (P/O PL 7.2 Item 1) Gear (T18) (P/O PL 7.2 Item 1) Bypass Retard Pad Kit (P/O PL 7.2 Item 1) Bypass Retard Pad (REP 8.12) Retard Pad Spring (P/O PL 7.2 Item 1) Spring Lower Guide Main Baffle (REP 8.22) Parts List PL 7.2 9/02 5-20 WorkCentre Pro 420 PL 7.3 Door Components (2of2) Item 1 2 3 4 5 6 7 8 Part – 050K53311 – 050K53451 – – – 059K28550 Description Part of Door Module (REP PL 7.1 Item 1) Side Output Tray (REP 8.7) Door (P/O PL 7.3 Item 1) Bypass Tray Kit (P/O PL 7.3 Item 1) (REP 8.8) Bypass Tray (P/O PL 7.3 Item 4) Bypass Tray Extensior (P/O PL 7.3 Item 4) Cover (P/O PL 7.3 Item 4) Bypass Feed Roller (REP 8.11) WorkCentre Pro 420 9/02 5-21 Parts List PL 7.3 PL 8.1 Covers Item 1 2 3 4 5 – 6 Part 802E51970 – 802E52200 001E73111 893E01350 893e01290 802K62460 Description Rear Cover (REP 14.2) Optics Locking Screw (Not Spared) Right Cover (REP 14.3) Front Door Tether J1/J7 Label (English) J1/J7 Label (Chinese) Front Door (REP 14.6) Parts List PL 8.1 9/02 5-22 WorkCentre Pro 420 PL 8.2 Stand Item 1 2 3 4 5 6 7 8 9 Part – – 604K04020 – – 017K00590 017E08790 802K39340 097S02556 Description Print/Copier (Not Spared) Stand Installation Screw (P/O PL 7.2) Stand Repair Kit Locator Registration (P/O PL 7.2 Item 3) Magnet (P/O PL 7.2 Item 3) Swivel Caster Rigid Caster Stand Door Stand WorkCentre Pro 420 9/02 5-23 Parts List PL 8.2 2 Part Number Index 9/02 5-24 WorkCentre Pro 420 .1 PL 1.3 PL 1.2 PL 1.1 PL 1.1 PL 1.1 PL 2.2 PL 3.2 PL 3.2 PL 3.1 PL 1.2 PL 5.4 PL 1.4 PL 2.3 PL 1.1 PL 4.1 PL 1.1 PL 5.1 PL 5.4 PL 1.1 PL 2.2 PL 4.2 PL 1.1 PL 3.2 PL 5.1 PL 3.1 PL 1.2 PL 5.1 PL 2.4 PL 1.2 PL 1.1 PL 3.1 PL 1.4 PL 1.3 PL 1.2 PL 5.2 PL 1.Part Number Index Part Number Table 1 Part Number Index Part Number 802K53800 802K62090 802E51840 809E48410 802E95250 892E54181 090E02520 101K48480 101K49020 801K13160 062K13011 160K96570 120E20080 604K17760 055E49173 105E15500 007K12173 960K10230 127K41250 014K07852 604K04040 809E45010 117E23652 117E22910 105K26600 105E15490 105E15680 160K96140 960K10030 962K16160 962K20650 115K02072 604K17750 130K66180 122K02330 604K17860 126E02101 126E02111 126K22680 Parts List Part List PL 1.2 PL 3.3 PL 1.2 PL 1.1 PL 3.1 PL 1.1 PL 3.1 PL 1.2 PL 1.3 PL 1.3 PL 1.3 PL 1.2 PL 3.1 PL 3.2 PL 1.4 PL 1.4 PL 1.2 PL 3.2 PL 3.2 PL 1.2 PL 1.3 PL 1.1 PL 3.3 PL 1.2 PL 1.2 PL 3.2 PL 3.2 PL 5.2 PL 1.1 PL 3.2 PL 3.1 PL 1.4 PL 1.3 PL 1.4 PL 1.2 PL 1.1 PL 2.2 PL 1.2 PL 1.1 PL 3.4 126K22540 106R00280 101R00022 101R00023 101R00024 101R00025 101R00026 090E02550 018K01250 122E02580 105K18490 130E09310 050K54810 022K60222 121K33560 107E94941 107E94941 160K96430 127K30560 038K13220 802K53830 121K25271 127K43940 001E76280 038K13331 127K43720 055K34430 130K65042 130E09390 809E48730 962K16430 059K34770 604K17730 160K96350 097S50213 160K96420 110K14070 962K17460 127K43280 807E05500 007E66810 Table 1 Part Number Index Part List PL 1.1 PL 3.3 PL 1.3 PL 1. 2 PL 7.1 PL 6.2 PL 5.5 PL 5.2 PL 6.2 PL 6.2 PL 7.5 PL 5.2 PL 7.4 PL 5.3 PL 5.2 PL 5.2 PL 5.2 PL 7.5 PL 6.5 PL 5.2 PL 5.3 PL 5.5 PL 5.5 PL 5.3 PL 5.2 PL 5.2 PL 5.2 PL 5.5 PL 5.2 PL 7.3 PL 5.3 Parts List WorkCentre Pro 420 9/02 5-25 Part Number Index .3 PL 6.2 PL 7.3 PL 5.4 PL 5.4 PL 5.2 PL 7.4 PL 5.2 PL 5.2 PL 7.Table 1 Part Number Index Part Number 007E1240 11K02940 121K28300 413W77559 007E66820 120E25110 130E82740 130E82740 604K18040 007E60720 413W77559 120E25170 059K34020 809E48760 013E90840 604K18010 50K54370 802E53140 802E53130 050K54390 054E25140 059K21970 006K28430 809E33160 031E10340 019K97497 059K21960 005K06110 809E49210 038E29640 038E29870 038E24300 809E14810 807E05440 007E55290 008E93921 029E14970 809E48590 003K17710 809E32960 003K17700 Part List PL 5.2 PL 6.5 PL 5.1 PL 6.2 PL 6.4 PL 5.3 PL 5.2 PL 5.2 PL 5.2 PL 5.3 PL 7.2 PL 7.2 PL 5.3 PL 7.2 PL 7.3 PL 5.4 Part Number 038E29630 038E29620 807E05430 807E05450 007E55261 809E34771 011E14240 809E38040 809E38050 125K03930 125K03950 604K00570 604K00580 604K00590 604K00600 055E49342 121E17523 130K83340 604K04000 604K04011 604K04141 604K04381 604K04390 962K02670 050K53311 050K53451 059K28550 006K28370 121E18780 130K83340 962K02671 604K04010 008E07390 121E17524 604K04000 604K04140 019K06310 809E49500 050K53311 050K53451 059K28550 Table 1 Part Number Index Part List PL 5.4 PL 5.4 PL 5.2 PL 5.1 PL 6.2 PL 6.4 PL 5.3 PL 5.2 PL 6.4 PL 5.2 PL 6.2 PL 6.4 PL 5.3 PL 5.2 PL 7.5 PL 5.2 PL 5.2 PL 5.3 PL 7.2 PL 5.3 PL 6.1 PL 6.3 PL 5.1 PL 6.4 PL 5.2 PL 5.1 PL 6.2 PL 5.2 PL 5.2 PL 6. 1 PL 8.Table 1 Part Number Index Part Number 802E51970 802E52200 001E73111 893E01350 893E01290 802K62460 604K04020 017K00590 017E08790 802K39340 097S02556 Part List PL 8.2 Parts List Part Number Index 9/02 5-26 WorkCentre Pro 420 .1 PL 8.1 PL 8.1 PL 8.1 PL 8.1 PL 8.2 PL 8.2 PL 8.2 PL 8.2 PL 8. ...................................................................... Diagnostic Programs............. Product Configurations. Component Codes ....................................................... Service Log ..................................... Supplemental Tools and Supplies..................................................................... Environmental Data and Requirements ....................................................................................................................................... Customer Accessed Data ........................... 6-3 6-4 6-5 6-6 6-7 6-8 6-12 6-13 6-15 6-15 6-16 6-16 6-17 6-17 6-18 6-18 6-19 6-21 6-23 General Information Space Requirements........................................................................................................................................................................................................... Diagnostic Settings .. Initial Issue WorkCentre Pro 420 9/02 6-1 General Procedures / Information .............................................................................................. Power Requirements.... Drum Cartridge Data ..................................................................................................................................................................................................... Hints and Tips ........................................................................................................................................................... Paper Specs........................... Toner Bottle / Drum Cartridge Yield ............................................................................................... Customer Programmable Options.......................................................................................................................................................................................................... Glossary of Terms.....................6 General Procedures / Information General Procedures Diagnostics..................... ........................................................................................................................................ General Procedures ............................................................................................................................................................................................................................ Product Specs............................................................................................................................................... General Procedures / Information 9/02 6-2 Initial Issue WorkCentre Pro 420 . Enter Diagnostic Mode Enter code number that is to left of hyphen (in table). Clear Diagnostic Code Press Stop/Clear button to clear diagnostic code. Components such as sensor or button require manual actuation to verify operation. Switching off power before Exposure Lamp Carriage stops moving may produce U2 status code or Scan Drive Motor noise when power is switched on. or solenoid will energize at this time. Wait 5 seconds. Press Stop button 3 times to enter another diagnostic code. Press and hold down 0 button. clutch. Enter Diagnostic Code 1. using number keys. Exit Diagnostic Mode Exit Diagnostic Mode using either of following: • • Press Stop/Clear button 5 times. 2.Diagnostics Enter Diagnostic Mode CAUTION Do not switch off power while Exposure Lamp Carriage moves to initialize. Secondary code identifies specific detail of area. Press Start button and 3 hyphens are displayed. 3. Enter Diagnostic Code. 1. Switch off machine. 2. Press Start button to energize an output component or to enable an input component to respond to manual actuation. 3. Press 0 button to display secondary status code when primary status code is flashing. primary code and secondary code. A C and number are displayed. Enter code number that is to right of hyphen (in table). Existing value is displayed flashing slowly. Initial Issue WorkCentre Pro 420 9/02 6-3 General Procedures / Information Diagnostics . Release 0 button after Control Panel indicators illuminate. Status Code A status code has two parts. Enter an NVM value 1. using number keys. or Switch off machine. 3. A Component such as motor. Use number keys to enter different value. switch on machine. Machine is in Diagnostic Mode and diagnostic code can be entered after control panel indicators go out. • • Primary code identifies area of machine and is displayed flashing slowly. and then switch on machine. Number is displayed. 2. Your indication will be new value is displayed flashing slowly. Press Start button to load value. Your indication will be value is displayed without flashing. 4. 7 Input Component Control Panel Buttons: Pressing button will change display and releasing button will change display.14 6-1 6-2 6-4 6-5 7 .16 6-3 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 8-6 9-7 10 . Start button is used to energize component and Stop button is used to de-energize component. Door Transport Interlock Switch and Front Door Interlock Switch Document Present Sensor ADF Feed Sensor ADF Registration Sensor Document Exit Sensor Copy Exit Sensor ADF Platen Sensor ADF Interlock Cover Scan Home Sensor CIM Paper Size Sensor ACIM Paper Size Sensor CIM Tray Out Switch ACIM Tray Out Switch CIM No Paper Sensor ACIM No Paper Sensor CIM Takeaway Sensor ACIM Takeaway Sensor Registration Sensor Toner Sensor (Front Door must be closed) Fuser Switch Side Exit Sensor Output Component Codes NOTE: There are no service actions in this table that are performed independently from direction given in Sections 2. 2-4 2 .d4 _ _ _) for 4 seconds.11 5 . or 4. 3. An Input Component Code is entered to check operation of sensor or switch.12 7 . 30 sec. General Procedures / Information Component Codes 9/02 6-4 Initial Issue WorkCentre Pro 420 .12 5 . 30 sec. After display clears for 1 second. 30 sec. 30 sec. ROS. 30 sec. An Output Component Control Code is entered to check operation of an output component such as clutch or motor.10 5 . or 4. 30 sec.11 7 . Time Out 3 . First 3 digits are displayed (d6.15 5 . 1 print 30 sec. Exposure Lamp Value (displays average pixel value No Timefor currently scanned image) out CIM Feed Clutch ACIM Feed Clutch CIM Takeaway Motor ACIM Takeaway Motor Registration Clutch Deflector Gate Solenoid Bypass Feed Solenoid HVPS/Main Drive Motor 30 sec.3 digit numbers are displayed for 6 digit print count.Main PWB. and paper path check Control Panel indicators NOTE: After entering Diagnostic Mode all Control Panel indicators illuminate temporarily.13 5 . Table 1 Input Component Codes Code 2-2 4-2 5-9 5 . 30 sec. Xerographic.11 4-1 5-1 5-2 5-3 5-5 5-6 5-7 5 . 30 sec. 30 sec. 30 sec. 30 sec.14 8-3 8-4 8-5 9-5 Scan Drive Motor (moves carriages to right and then No Timeto left) out ROS Polygon Motor 30 sec.d5.13 7 . 30 sec. Table 2 Output Component Codes Code 1-1 2-1 Output Component Internal Test Print .Component Codes Input Component Codes NOTE: There are no service actions in this table that are performed independently from direction given in Sections 2. Enter code for component. 30 sec. 3 remaining digits are displayed (_ _ _ d3. Manually actuate component while observing copy count display to verify operation. 30 sec.d1) Internal Test Print-Printer Main Drive Motor CVT Motor OCT Motor Copy Exit Motor ADF Nudge Solenoid ADF Interlock Alarm Document Feed Clutch ADF Simplex Feed Exposure Lamp 30 sec. 3.6 10 .d2. 3–9 NIC Reset Resets NIC to default settings NIC test print with configuration settings Generates test print.9 Erase Lamp Fuser Temperature Thermistor Temp value Cooling Fan (operates at low speed) Output Component Time Out 30 sec. Displays Software Revision ID for Main PWB 0 = No Tray 2 1 = Tray 2 Enabled NOTE: Automatically set when Tray 2 is installed.d1) Pressing Start button after entering this code resets NVM to default settings. starting at Main PWB. 3 remaining digits are displayed ( _ _ _ d3. Enter Code and press Start button.d5. 1. d6. d4. After display clears for 1 second. After display clears for 1 second.d4 _ _ _ ) for 4 seconds. 2. or 4.d2. Diagnostic Programs Table lists diagnostic codes for programs that are used to repair problems or provide information about machine condition or configuration. 3–10 NIC Test 3–11 Printer Internal Test Print 10 .Table 2 Output Component Codes Code 9-6 10 . to default value Initial Issue WorkCentre Pro 420 9/02 6-5 General Procedures / Information .d1) NOTE: Subtract Print Count from Total Copy/Print count to find Copy only count 2–4 Print Count 2 .3 10 . Press Stop/Clear button to clear display and enter another code or press Stop/Clear button again to exit diagnostics. Your indication is data is displayed. 3. 3–15 Reset Administra. 3 remaining digits are displayed (_ _ _ d3. d1 First 3 digits are displayed (d6.3 digit numbers are displayed for 6 digit print count.d4 _ _ _) for 4 seconds. going through ROS. d3. 3.Reset Administrator User Password in Multi User Electronic tor User Password Account mode.d5. d5. Most recent 10 status codes are displayed in sequence (GP 7 Status Code History ). or an output is produced. 2 . No Timeout 30 sec. Table 1 Diagnostic Programs Code 1–1 Name Main PWB Internal Test Print Total Page Count Description A test print is generated from Main PWB to verify that digital image path. is capable of producing specified image.10 Cooling Fan (operates at high speed) 2–3 3-1 3–2 3–3 3-5 NVM Initialize Status Code History Main PWB Software Revision ID Tray 2 3–12 Clear Fault History With this code entered. NOTE: There are no service actions in this table that are performed independently from direction given in Sections 2. 30 sec.3 digit numbers are displayed for 6 digit copy count. and ending at Drum Cartridge. d2. press Start button to clear fault history.d2. First 3 digits are displayed (d6. Enter Diagnostic Mode. (Image Geometry adjustment 1 of 7) 8 . 2. Enter Diagnostic Mode.5 mm.Life failure 3 . 3. NVM Initialize Inch/Millimeter Paper Size Pressing Start button after entering this code resets NVM to default settings.Warm up time exceeded limit Current Thermistor temperature Diagnostic Settings NOTE: There are no service actions in this table that are performed independently from direction given in Sections 2. 1 = Inch paper size 2 = Millimeter paper size Value noted on RIS Label (REP 6.Disables customer programmable power saver features and ride sets Fuser standby temp to 107ºC (245ºF) after 10 minutes of UI inactivity. Shipping screw.12 Adjust = +/.12 Adjust = +/. like code 2-6 Enter required number using number keypad.5 mm. Total CRUM count 0 .3 mm Each value changes image position on paper by 0. or 4. Moves carriages to right end of RIS. This indicates setting can be changed.24 Adjust = +/. Press Stop/Clear button to clear display and enter another code or press Stop/Clear button again to exit diagnostics. 1.3 mm Each value changes image position on paper by 0.1) Value noted on RIS Label (REP 6. stored in Tray 1. 4. (Image Geometry adjustment 2 of 7) Nominal = 12 (default) Range = 0 . Your indication is value is displayed without flashing. Your indication is value is displayed flashing. 3.13 RIS Gain value 3 . (Image Geometry adjustment 2 of 7) 3-1 3-6 3 . Press Start button to store new value. Enter Code and press Start button.10 Image to Paper Side Edge Registration General Procedures / Information Diagnostic Settings 9/02 6-6 Initial Issue WorkCentre Pro 420 .5 mm. (Image Geometry adjustment 3 of 7) Nominal = 6 (default) Range = 0 .3 mm ment Each value changes image position on paper by 0. can be installed through hole in Right Side Cover. 5.1 U4 reset 10 .Table 1 Diagnostic Programs Code 6-5 6-6 9-4 Name Exposure Lamp Value Scanner Park CRUM Count Description Displays Exposure Lamp value.Overtemperature Error 2 .0 .3 Thermistor Power Saver Over.Range = 0 . 1=Default setting.Fuser operation enabled 1 .3 mm Each value changes image position on paper by 0.1) Nominal = 6 (default) Range = 0 . Table 1 Diagnostic Settings Code 2-6 Name Description 10 .25 mm. A number is displayed flashing. enables customer programmable power saver features.14 RIS Offset value 8-7 Document Glass Lead Edge Registration 8-8 Document Glass Side Edge Registration 8-9 ADF Horizontal Nominal = 6 (default) registration Adjust.12 Adjustment = +/. 15 Trail Edge Deletion Nominal = 5 (default) Range = 0 .16 Duplex Horizontal Adjustment Normal = 12 (default) Range = 0 .13 Image to Paper Lead Edge Registration DMO Eest/ Sold / Hardstop not Mexico DMO West/ Sold / Hardstop Mexico HK/Korea Sold / Hardstop DMO India Sold / Hardstop 8 .4 0 is factory setting 0 .4 mm.10 Transfer off Timing Changes when Transfer de-energizes 9 .1 U4 reset 10 .11 Laser Output 10 .15 Adjust = +2. 3.24 Adjust = +/.4 Fuser Run Temperature 10 .11 ADF Vertical Registration Adjustment 8 .16 Adjustment = +/.191ºC (376ºF) (default) 3 . (Image Geometry adjustment of) EP is an Environmental Partner who contracts to return used Drum Cartridge for recycling.16 Adjust = +/.3 mm Each value changes image position on paper by 0.5 / -1.Fuser operation enabled 1 .12 Lead Edge Deletion 8 .8 Cooling Fan Initial Issue WorkCentre Pro 420 9/02 6-7 General Procedures / Information Drum Cartridge Data. (Image Geometry adjustment 7 of 7) Nominal = 8 (default) Range = 0 .25 mm. Table 1 Drum Cartridge Data MARKET Chinese Mailand SERVICE/USAGE Sold / Hardstop PART NUMBER 101R00022 101R00023 101R00024 101R00025 101R00026 8 .Overtemperature Error 2 .4 mm.186ºC (366ºF) 2 .25 mm. Nominal = 12 (default) Range = 0 .3 mm Each value changes image position on paper by 0.197ºC (386ºF) Duty Cycle in standby 30 (default) 9 . (Image Geometry adjustment 6 of 7) 8 . 9-9 Transfer on Timing Changes when Transfer energizes Adjustment range of 0 .Warm up time exceeded limit 1 .3 mm Each value changes image position on paper by 0.24 Adjustment = + / .3 mm Each value changes image position on paper by 0.Table 1 Diagnostic Settings Code Name Description Nominal = 8 (default) Range = 0 .2 mm Each value changes image position on paper by 0.2 mm.25 mm.14 Side Edge Deletion Nominal = 8 (default) Range = 0 . or 4. (Image Geometry adjustment 5 of 7) 8 .Life failure 3 .4 mm Each value changes image position on paper by 0. General Procedures .15 Adjust = +1 / . (Image Geometry adjustment 4 of 7) Drum Cartridge Data NOTE: There are no service actions in this table that are performed independently from direction given in Sections 2. or between drum and exit area. Large white or black squares in pattern measure approximately 10mm per side. Enter [1-1]. If GP2 image is good. After few seconds of cycle up time.General Procedures GP 1 Drum Cartridge Type This procedure uses appropriate intended Drum Cartridge to convert machine to different service plan. After few seconds of cycle up time. 4. Enter Diagnostics. A copy that is covered with image shown below indicates that image processing components under GP2 in Figure 2 are functional. problem is in Transfer/Detack Corotron GP 2 Main PWB Generated Image GP 2 verifies Main PWB image process function from ROS. If deletion is present. 2. Enter Diagnostic Code [ 9-1] and press Start button. Figure 2 will help identify suspect component. 3. If deletion is not present after running GP 8. Switch on machine. GP 2 can also be used to isolate cause of Deletions by opening Door Transport while copy is exiting. 5. check the following: If image defect occurs at drum. and GP 2 is good. problem is in RIS or components to right of RIS in Figure 2. 1 copy will be made with image shown in Figure 1 appearing on entire sheet of paper. To run GP2. If deletion is present. 1 copy will be made with image shown below appearing on entire sheet of paper.1). Press Start button. this also verifies following components: • • • • • • • • • Drum Cartridge Transfer/Detack Corotron Fusing Copy transportation RIS Mirror/Carriages Lens Exposure Lamp Document Glass Figure 2 GP 2. Remove Drum Cartridge (REP 9. Remove Drum Cartridge to examine drum for deletion. 2. General Procedures / Information General Procedures 9/02 6-8 Initial Issue WorkCentre Pro 420 . Switch off machine and install new or intended Drum Cartridge. GP 3. A copy that is covered with image shown below indicates that image processing components under GP 2 in Figure 2 are functional. 3. drum is defective. To perform GP2. Measured Repeating Image Defects Table 1 in Section 3 Figure 1 GP 2 Main PWB Generated Image If an image defect is present. Close Door Transport and switch on machine. enter [1–1] and press Start button to generate test pattern. If deletion is not present. perform following: 1. GP 8 and Measured Repeating Image Defects in Table 1. Large white or black squares in pattern measure approximately 10mm per side. perform GP 8. 1. perform following: 1. at least 1 test pattern will be delivered with an image similar to one shown (Figure 3). After 10 to 30 seconds of cycle up time. On rear of machine connect ESD prevention cable to Main PWB Metal Frame (Figure 5).GP3 Main PWB Printer Function Generated Image GP3 tests print processing function of Main PWB. Middle Terminal Figure 4 Connecting ESD Cable to Middle Terminal Figure 3 GP 3 Printer Generated Image Initial Issue WorkCentre Pro 420 9/02 6-9 General Procedures / Information General Procedures . To run GP3. 3. GP 5 ESD Hookup Procedure GP5 is used to identify location of connection points for ESD prevention cable. This test assumes GP2 Diagnostic Code [1-1] Test Pattern is good. This indicates that Printer is functional. Enter [3-11]. On right side of machine connect ESD prevention cable to Middle Terminal (Figure 4). Press Start button. 2. Enter Diagnostics. 1. and bottom of list is reached. Perform following to review status codes. NOTE: Status Code History cannot be corrupted or changed by incorrect keyboard entries while in [3–2]. indicating fault history is ready to start displaying status codes. Press reduction/enlargement down button to move viewing window down list. Enter [3–2] and press Start button. [3–12] can be used to clear status code history by entering code and pressing Start button. starting at top of list or 10. Press up button to move back up list.GP 7 Status Code History GP 7 is used to display 10 most recent status codes. FH is displayed. Main PWB Metal Frame Figure 5 Main PWB Metal Frame General Procedures / Information General Procedures 9/02 6-10 Initial Issue WorkCentre Pro 420 . Press 0 button to display secondary code. indicating all 10 codes were displayed. 4. 3. 2. However. Continue pressing R/E selection down button until End is displayed. 5. This will require several trial and error attempts. (REP5. Lens and Mirror Cleaner should form droplets on mirror. GP 8. image defect is cause by component to left of drum in Figure 6. 9. Measured Repeating Image Defects Table 1 in Section 3 Figure 6 GP 2. Before Lens and Mirror Cleaner evaporates.GP 8 Image on Drum GP 8 is used to isolate source of an image defect between drum and image output or drum and image input (Figure 6). Any dust particle is seen by optics as document image and reproduced according to characteristics of imaging process. 1. Vacuum inside of RIS. and begin to evaporate. Reinstall ADF. If image defect is visible.5). Clean Calibration Strip below Registration Edge with Lens and Mirror Cleaner (Table 1) and lint-free cloth. indicating correct amount was used. CAUTION Do not use a brush attachment on vacuum cleaner. If using customers document. 11. Clean other mirrors using same process. Soak finger-sized portion of dry towel with lens and mirror cleaner so that it is quite wet. 12. Swipe towel across mirror surface. gently swipe finger-sized portion of dry lintfree towel across mirror to remove remaining droplets.1) Remove Top Cover (REP 14. GP 3. Remove Drum Cartridge and examine image on drum for image defect. 14.1) and Document Glass (REP 6. If image defect is not visible on drum. 5. 6. 4. attempt to open Door Module when image defect is transferred to drum. 10. 13. Clean CVT Glass using same process. Reinstall CVT Glass. Perform GP 8 by opening Door Module as copy exits machine while running GP 2 or making copy using customers document. Align and confirm it on BO machine. Remove CVT glass.1). GP 9 RIS and Mirrors Cleaning GP 9 is used to identify specific process that yields best results in cleaning mirrors in RIS. Use a crevice attachment to reach corners. GP 11 Initial Issue WorkCentre Pro 420 9/02 6-11 General Procedures / Information General Procedures . Reinstall Top Cover (REP 14. Remove ADF module. Reinstall Document Glass (REP 6. 7. NOTE: Laser Optics are sensitive to smallest changes of reflectivity in light path and reproduce result on copies. 2. 3. CAUTION Image Quality defects will occur if RIS Module is not vacuumed before reinstalling Document Glass. 8.5). Brush may contaminate mirrors. defect is caused by component to right of drum in Figure 6 . Clean Document Glass using same process. 4.d5. Stop + 4 Stop + 5 Stop + 6 Stop + 7 No translation 2 . Customer Programmable 9/02 6-12 Initial Issue WorkCentre Pro 420 .d1) NOTE: Subtract Print Count from Total Copy/Print count to find Copy only count GP11 RIS Contamination Determines if image defect is caused by RIS contamination. • General Procedures / Information Customer Accessed Data. Enter 9 and press Start button.d2. is displayed for 4 seconds No translation NOTE: If Stop 2 value is 0. RIS is source of defect. Open Front Door and replace defective Drum Cartridge with new Drum Cartridge. Make a copy. Select reduction % if defect is near edge of paper. Image Quality is not acceptable and the Stop 2 value is higher than 0. In step 3. RIS is not source of defect. 5. Black line in white area White line in gray or black image Black band approximately 1 to 4 mm wide in gray image White band approximately 1 to 4 mm wide in gray image Measure position of image defect compared to any adjacent image. Enter Diagnostics.d4 _ _ _) for 4 seconds. 3 remaining digits are displayed (_ _ _ d3. Perform following to transfer data from old Drum Cartridge CRUM to new Drum Cartridge CRUM. 2. Failed Drum Cartridge must be installed. Shipping screw is stored in Tray 1 at left end of tray. 1. d4. • • Too much reduction and defect difficult to see. d5. d2. 2. Do GP 8 Image on Drum. defect will change position if caused by other xerographic parts or defect will not change position if RIS caused defect.GP10 Drum Cartridge Warranty A Xerox Drum Cartridge is failed if one of following exist: • • • Drum Cartridge causes excessive noise or vibration and Stop 2 value is more than 0. Xerox Drum Cartridge Warranty is expired. Customer Accessed Data Control Panel Accessed Data/Programs Table 1 Control Panel Data/Programs Function Printer RAM NIC Test Print Copies Remaining Displays Administrator’s or current Administrator User’s Remained copy count Machine Serial Number Software Level Configuration Total Copy/Print Count Key Press Description Stop + 0 Stop + 1 Stop + 2 Stop + 3 2 digit code displayed indicates Printer RAM in MB Test Print from NIC is generated and sent to Output Tray Percent of life remaining on Drum Cartridge. • If defect did not move compared to any adjacent image. Exit diagnostics.d4 _ _ _ ) for 4 seconds. enter 8 and press Start button.d5.3 digit numbers are displayed for 6 digit print count. Select enlargement % if defect is not near edge of paper • • 3. Not enough reduction and defect may not appear to change position compared to any adjacent image Too much enlargement and compared adjacent image may not be on paper Not enough enlargement possible defect may not appear to change position compared to any adjacent image If defect moved compared to any adjacent image. After display clears for 1 second. d3. After display clears for 1 second. RIS image defects are parallel to direction of paper movement and appear as follows: • • • • 1. d1 First 3 digits are displayed (d6. or toner can not be loaded. Press Start button to load CRUM data on new CRUM. CRUM data is now stored on Main PWB. Printer Test Print Stop + 9 RIS Carriage Park Stop + Pre. Press Clear to return carriage to home position. d6. in 5% increments. Print Count Stop + 8 2 . Do GP 9 RIS and Mirrors Cleaning.3 digit numbers are displayed for 6 digit copy count. or cartridge can not be installed and Stop 2 value is higher than 0 for any problem. Drum Cartridge does not lock in position. First 3 digits are displayed (d6. 3 remaining digits are displayed (_ _ _ d3. 3. Close Front Door.RIS Carriage moves to right end of RIS so that shipping set Mag screw can be installed.3 digit codes are displayed indicating revision level. Machine may continue to deliver acceptable image quality. 3 digit code displayed for Machine Hardware Configuration 2 .d1) Test Print from Printer is generated and sent to Output Tray.d2. 3 = 60 seconds before waiting print job will begin. 64% inch 3 = 70% metric. Table 1 Customer Programmable Options Feature Priority Paper Tray Program 10 Program Options 1=Tray 1 (default) 2=Tray 2 (selectable if Tray 2 installed) 3=Bypass Tray 0=no auto clear/auto clear ability disabled or off 1=20 seconds 2=30 seconds 3=60 seconds (default) 4=90 seconds 0=no low power/low power ability disabled or off (default) 1=5 minutes 2=20 minutes 3=60 minutes 4=120 minutes 5=240 minutes 0=5 minutes 1=20 minutes (default) 2=60 minutes 3=120 minutes 4=240 minutes Press Start to view current value Using number keys. Enter applicable value in Program Options column. These are not as reflective as 80 g/m or 20 lb. 2. Asterisk in table is default setting. metric R/E Copy Quality Table 1 Customer Programmable Options Program 15 Program Options 1 = Text Mode (default) 2 = Mixed Mode 3 = Photo Mode 0 = Inch (standard for 115 VAC) 1 = Metric (standard for 220 VAC) 0 = Off (default) 1 = On NOTE: Set to 1 to reduce toner consumption and background when copying very light weight documents or colored documents. 2 = 30 seconds required before waiting print job will begin (default). press Paper Tray Select button. 2. Your indication will be current selection is displayed flashing. not available to print. 129% inch 5 = 200% 0 = Off (default) 1 = On 0 = No Administrator User Mode (default) 1 = single Administrator User Mode 2 = Multi Administrator User Mode 16 17 Non Image Area Background Suppression To exit Customer Program Mode. Enter Program Number. Press Start button to store new selection. Copier Idle time out (Machine comes back to Print Module) 18 0 = off line. View current selection of any feature: 1. Your indication will be flashing machine mimic LED’s. 78% inch 4 = 141% metric. 4 = 90 seconds 5 = 120 seconds 6 = 180 seconds 0 = Darker 1 = Darkest 2 = Normal (default) 3 = Lighter 4 = Lightest 5 = Toner Saver 0 = 100% (default) 1 = 50% 2 = 82% metric. Display is blank) NOTE: Increases First Copy Out Time. Inch vs. Display shows --) NOTE: first Copy Output time increases.Customer Programmable Options User Program Mode allows user to select and modify various machine features. Change current selection: 1. Press Paper Tray select button for 4 seconds minimum. Feature Enter Customer Programmable Mode: 1. remains offline 1 = 0 seconds. Press Start button. Time-out to Power Saver (Fuser Temp Lowered. Reduction/Enlargement Preset 12 R/E Presets in % 20 13 Automatic Tray Switching (Same Size Setting) Set Start Machine Mode 21 27 14 Initial Issue WorkCentre Pro 420 9/02 6-13 General Procedures / Information Customer Programmable Options . white paper therefore non image areas of copies will be darker. enter any value between 50 and 200 and then press Start button 82% default for metric 64% default for inch Contrast Level 19 Auto Clear Time-out 11 Low Power Time-out (Fuser Off. First few millimeters of scanned document determines overall background suppression. Machine can immediately print after copy cycle down. General Procedures / Information Customer Programmable Options 9/02 6-14 Initial Issue WorkCentre Pro 420 . Space Requirements Space requirements for movable machine shown in Figure 1 and stationary machine shown in Figure 2. 500 Sheet paper tray (Tray 1) and 50 sheet Bypass Tray Auxiliary 500 sheet paper tray (Tray 2) Stand NIC or USB EPS Figure 1 Movable Machine Space Requirements Figure 2 Stationary Machine Space Requirements Initial Issue WorkCentre Pro 420 9/02 6-15 General Procedures / Information Space Requirements. Product Configurations .200% R/E with Document Cover. Product Configurations Table 1 Product Configurations • Machine • Accessories • • • 50 . 8.No paperbacked) Inkjet paper Inkjet transparencies Paperback transparencies Offset paper carbon paper Paper with irregular edges Vellum paper Embossed letterhead Paper with multipart forms Damaged or wrinkled paper Paper with staples or paper clips. 5.5”x11”. Table 1 Product Specifications Document Size: Document Glass R/E Capability: Metric R/E Capability: Inches Copy/Print Rate 5. 8. 215mmx315mm.5”x13”.5”.5”x11”. 100%.3 kg Stand: 46 lbs. A3. & 200% Variable Percentages: 50% to 200% Preset Percentages: 50%.Paper Specs.5” x 11” (A4) or 17 copies / minute 8. / 52-176 gsm 1 or 2-sided Tray 1: 500 sheets Tray 2: 500 sheets Output Tray 100 sheets maximum Yes 50 sheets Capacities 20 lb. Table 1 Paper Specifications Paper Trays 1 & 2 Paper Sizes 16k. / 60-90 gsm simplex Range: 16-32 lb. Predrilled Paper Output Tray Capacity First Copy Output Time Yes Yes (one sheet at a time) Warm Up Time Machine Weight Labels. 8. 5.5”x8. A3. 215mmx330mm. A4. 8. / 80 gsm) Optimum = 20 lb. 8. B4.4 kg Paper Weights Optimum = 20 lb.5” (A5) LEF to 11” x 17” SEF (A3) Variable Percentages: 50% to 200% Preset Percentages: 50%. No Transparencies (non. 141%. 215mmx330mm. No No No No No No No No No No No No No No No No No No No No No No General Procedures / Information Paper Specs.9 kg Tray 2: 14 lbs. B5.5”. Tray 1 less than 45 seconds 80 lb. 9/02 6-16 Initial Issue WorkCentre Pro 420 . 100%. 70%.5”x14” Product Specs. Product Specs.5” x 11” (A4): 6 seconds.5”x14” Bypass Tray A5.5” x 8. 8.5” x 11” (A4) 100 sheets maximum 8. (80 gsm) Letterhead. / 6.5”x13”. & 200% 20 copies / minute 8. / 20. 8k. A4. / 80 gsm Range = 16-24 lb.5”x8. A5. 78%. 11”x17”. 11”x17”. 215mmx315mm. / 36. 129%. 50F at 15% to 85% relative humidity maximum 32C . Standby Ready: 341 BTU/Hr. 47 to 53 Hz) Environmental Data and Requirements Ambient Temperature and Humidity requirement: • • • • • • • • Minimum: 10º C/50ºF at 15% humidity Maximum: 32º C/90ºF at 85% humidity Machine Running Maximum: 1537 BTU/Hr.90F at 15% to 85% relative humidity Power Consumption (5 minute average) • • • Machine Running: 1500 w (maximum) Power Saver: TBD Low Power: <70 w Heat Output (5 minute average) Temperature and Humidity Requirement Initial Issue WorkCentre Pro 420 9/02 6-17 General Procedures / Information Power Requirements. Low Power: 150 BTU/Hr. 57 to 63 Hz) 220 VAC (198 to 255 VAC.Power Requirements • • • Single phase (two wires plus ground) 110 VAC (104 to 127 VAC. Environmental Data and Re- . Power Saver: 198 BTU/Hr. minimum 10C . 4 23% Dense Text with Graphics 1.82P523 Figure 1 shows typical area coverage.000 copies/prints under warranty.000 3. Xerox Drum Cartridge yields 14. Toner Bottle yields approximately 5000 copies/prints at 6% area coverage.000 Table 2 Supplies Supply Name Toner Bottle Part Number PL 1.19P580 35P2162 8R90019 43P45 43P48 8R90175 43P78 8R90176 All .70P95 110V . Table 1 lists expected quantity.000 5.Toner Bottle / Drum Cartridge Yield Percent of printed area on document affects number of copies yielded from each Toner Bottle and each Drum Cartridge.43E550 35P3191 43P81 8R901784 600S4372 All .250 General Procedures / Information Supplemental Tools and Supplies 9/02 6-18 Initial Issue WorkCentre Pro 420 .4 Drum Cartridge PL 1. Other items that affect Toner Bottle yield are: • • • • • Size of documents being copied Background of document Whether or not Document Cover is open during copy operation Making two-sided copies.82P524 220V . or copies using Darker settings High humidity in machine environment Supplemental Tools and Supplies Tools Table 1 Tools Tool All Purpose Cleaner Antistatic Fluid Black Bag Bottom Pad Cotton Swab Cleaning Cloth Film Remover Formula A General Cleaning Solvent Grease Heavy-Duty Towels Lens and Mirror Cleaner Lint-Free Cloth Oil Test Pattern Part Number 8R90175 8R90273 95P2362 All . Supplies Figure 1 Area Coverage Table 1 Document Coverage 3% Minimal Text 5% Medium Text 11% Dense Text Expected Copies 10. CVT Glass. Diagnostic Paper Trays • Following actions increase paper feeding reliability from Tray 1 and Tray 2: – – • Adjust Paper Guides so that they touch paper stack without wrinkling or squeezing paper. Adjustment. Ensure no lint from swab remains on corotron or corotron frame. GP 9 R should be used anytime Document Glass (REP 6. Clean Registration Roll Clean Paper guides Clean Ground contact/electrical contacts Bypass Tray paper should be pushed fully into tray for reliable feeding. Clean Detack Corotron with dry brush.1) is removed. Assuming copier is producing unacceptable image quality. lint. White Calibration Strip. Image quality defects will result from dust. Wipe all Transfer Detack Corotron contacts at front end of corotron frame with lint free cloth. and Maintenance information. Image Quality Most Image Quality defects are serviced with thorough cleaning of following: • • • • • Top of Document Glass. CAUTION Drum Cartridge photoreceptor damage is likely if Drum Cartridge is handled carelessly. General Service Information NOTE: Following Hints and Tips are organized into Diagnostic. Removal and Replacement. NOTE: Removing Document Glass or RIS should be done only when this course of action is sure to result in effective repairs. This will cause side-to-side misregistration and E1 jams. located under Registration Edge. Use caution when Drum Cartridge is removed from machine. must be free of fingerprints and other contamination for optimum image quality. Closing tray forcefully may cause paper tray side guides misalignment. Service Call Highlights and General Service Information. good image produced with Diagnostic Code [1–1] indicates problem is in scanning optics components. Paper guides that guide paper from trays to image transfer area and then to Fuser Module. whenever these components are removed from machine. or other contaminants on any of optics components closest to document on document glass. Service Call Highlights Transfer components cleaning Transfer components cleaning: This service action is required to ensure image quality. Position of strip and position of Exposure Lamp are synchronized for accurate registration. CAUTION Image Quality defects will occur if RIS Module is not vacuumed before reinstalling Document Glass. Registration is set when machine is switched on and Exposure Lamp illuminates and scans Black/White Registration Strip (located under Registration Strip). Cleaning RIS and Document Glass before assembly. This results in image quality defects. Transfer/Detack Corotron including Corotron housing and ribs Drum Cartridge housing and ribs Fuser Exit Rolls and paper guides in Fuser Module. • • • • • • • Clean Transfer Corotron wire with cotton swab and Film Remover or General Cleaning Solvent. Initial Issue WorkCentre Pro 420 9/02 6-19 General Procedures / Information Hints and Tips .Hints and Tips Hints and Tips is presented in two sections. is required to avoid Image Quality defects. GP 2 Main PWB Generated Image can be used to verify ability of digital processing components to deliver an image to photoreceptor. Check Tray 1/Tray 2 Side Guides. With experience. Screw threads are cut in sheet metal or plastic frames first time screw is installed during manufacture.• • • • Narrow deletions that are sharply defined from top to bottom of copy may indicate contaminated mirrors. Side-to-side misregistration is most likely caused by mispositioned side guides in paper tray. switch on power may resolve some Image Quality defects. Neglecting to vacuum RIS prior to assembly will result in image quality defects after assembly. Correct direction to handcrank Main Drive Motor is counterclockwise while viewing motor from rear of machine. Drives • Noise like clicking sound at left end of machine could be Transfer Roll drive gears. wait 5 seconds. Maintenance Cleaning • • • GP 9 R should be used to clean any RIS mirror. They are located adjacent to rear end of Transfer Corotron. Apply mild insertion force while rotating screw back and forth in order to find previously cut screw threads. defect can be classified as digital problem or other. CAUTION Removal and Replacement NOTE: Machine is designed to use less tools for service than previous designs. Open Transport Door Assembly and check that Transfer Roll gears are secure and free of damage. Adjustment NOTE: Adjustments that are made during manufacture of machine do not require service during life of machine. or fusing subsystems. Fuser and Pressure Roll cleaning is done by making 20 copies of white document. causing rapid banging noise. xerographic. Skewed image can result from not pushing Paper Tray in all way. CAUTION Stripped threads will result when using firm hand grip on tools to tighten fasteners into plastic parts. Attempts to correct problem by changing manufacturing adjustments will make real cause of problem difficult to find. always attempt to service copying capability of machine before attempting to service printing capability. Refer to Removal and Replacement procedures until you are familiar with disassembly and reassembly of machine. continuing problem is responsibility of customer to resolve. • • Machine power can be switched on while Drive Assembly is removed. General Procedures / Information Hints and Tips 9/02 6-20 Initial Issue WorkCentre Pro 420 . • Printer If printing functions on machine are operational. Then use cotton swab dampened with film remover to wipe Transfer Corotron wire and shield. • • Poor image quality will result if Main Drive Motor is handcranked in wrong direction which causes cleaning blade to fold over. Before printing image quality diagnostics can be effective. Document Glass breakage may occur if edge of document glass hits frame member or hard point. Ensure no lint remains in Transfer/Detack Corotron assembly. A screw that is removed and replaced first time during service activities requires sensitivity while finding screw threads that were cut during manufacture. Use only your fingers to hold tools when tightening fasteners. Position of lead edge of jammed copy may indicate area in which to look for failed component or paper path obstruction Voltage Measurement • When making DC voltage measurements in 5 to 24 volt range. Digital image processing errors cause defects with unique characteristics when compared to defects caused by optical.5). Jams • RIS • A short circuit in signal wire will cause carriages to move to left and continue to drive left. Switch off power. machine must be known to be producing good copies. If an Image Defect is present. same measurement results can be expected with Black meter lead connected to metal frame component or DC Common circuit. Corotron cleaning should be done with brush on Detack Corotron. Excessive pressure on Transfer Corotron wire will stretch wire and cause image quality problems. Document Glass breakage may occur if edge of document glass hits frame member or hard point (REP 6. Electrostatic Set Up A Chip loaded with software identified by date or revision. Raster Output Scanner . Repair ysis Procedure for diagnosis of machine status codes and abnormal conditions Reduction/Enlargement refers to features selection or components that enable reduction or enlargement Repair Procedure for disassembly and reassembly of component on machine Raster Input Scanner . Machine converts AC power from power source to DC power.69 inches) x 420 millimeters (16. Solid Area Density Service Call Procedure Short Edge Feed An automatic process that is used to check Control Logic circuitry.For this product: includes optics/exposure components.27 inches) x 297 millimeters (11. converts it to digital data and then transmits it to ROS. because controller can read information and it can write information. Environmental Partner External Print Server Electrostatic Discharge. Name means that controller on PWB can only read information from ROM. scanning components and CCD. Electromagnetic Emissions are emitted from machine during normal operation and power of these emissions are reduced by machine design features. RIS Module scans image. but does not describe its function. to photoreceptor. og to Digital refers to conversion of signal Adjustment Procedure Binary digit. Controller or any other device cannot change values or send any software information to ROM. Advanced Customer Training: A course that teaches customers to perform some of service that is normally performed by Xerox Service Representative. with reference to definition of term LE Unscheduled Maintenance User Interface Universal Serial Bus With indicates machine condition where specified condition is present Without indicates machine condition where specified condition is not present Xerox Brazil Xerox Latin America General Procedures / Information Simplex Single sided copies Initial Issue WorkCentre Pro 420 9/02 6-21 Glossary of Terms . either 1 or 0. RAM is its accepted name.54 inches). A transfer of charge between bodies at different electrostatic potential. Digital Multimeter is generic name for meter that measures voltage. Single Inline Memory Module used to increase printing capacity Trail Edge of copy or print paper.Device that transfers digitally processed image.69 inches). A better name would be Read/Write Memory. current. using laser light. Charge Coupled Device (Photoelectric Converter) Circuit Diagram An Integrated Circuit (IC) (see Firmware) Customer Replaceable Unit Monitor Direct Current is type of power for machine components. Paper size 210 millimeters (8. representing an electrical state. or electrical resistance. Read Only Memory. A digital memory circuit from which information can be accessed or where software information can be stored. Ground Fault Device Ground High Frequency Service Item High Voltage Power Supply Hertz (Cycles per second) International Electro-technical Commission Image Quality 1000 copies Liquid Crystal Display Lead Edge of copy or print paper. A digital memory circuit that is designed to contain permanent software information. with reference to definition of term TE Light Emitting Diode Long Edge Feed Low Voltage Power Supply Multinational Network Interface Card ROS SAD SCP SEF Self Test SIMM TE UM UI USB W/ W/O XBRA XLA ROM RAP R/E REP RIS NVM OEM OGM PC PCM PL PO PWB PWS PJ RAM Description Non Volatile Memory Original equipment manufacturer On-going Maintenance Personal Computer Table 1 Power and Control Module also referred to as Electronic Control System Module Parts List Part of (Assembly Name) Printed Wiring Board Portable Workstation for Service Plug Jack (electrical connections) Random Access Memory device. Any fault that is detected during self-test is displayed by fault code or by LED’s on PWB.Glossary of Terms Term Table 1 Term A3 A4 AC ACT A/D ADJ Bit CCD CD Chip CRUM DC DMM EME EP EPS ESD ESU FIRMWARE GFD GND HFSI HVPS Hz IEC IQ KC LCD LE LED LEF LVPS MN NIC Description Paper size 297 millimeters (11. Alternating Current is type of current available at power source for machine. Table 1 Term XMEX Description Xerox Mexico General Procedures / Information Glossary of Terms 9/02 6-22 Initial Issue WorkCentre Pro 420 . Initial Issue WorkCentre Pro 420 9/02 6-23 General Procedures / Information Service Log .Service Log Make a two sided copy of this original document. Use the copy as the machine service log. Figure 1 Service Log General Procedures / Information Service Log 9/02 6-24 Initial Issue WorkCentre Pro 420 . Initial Issue WorkCentre Pro 420 9/02 6-25 General Procedures / Information Service Log . Figure 2 Service Log General Procedures / Information Service Log 9/02 6-26 Initial Issue WorkCentre Pro 420 . .........................................................................7-22 Chain 9 Marking ............................................................7-6 Chain 4 Start Power ...........................................................................................................................................................................................................................................................7-8 Chain 5 Document Transportation ........................7-14 Chain 7 Paper Supplying ......................................7-26 Chain 10 Fusing and Copy Transportation ............................................................................................................................................7-5 Chain 3 Machine Run Control.........................................................................7-9 Chain 6 Imaging ..............................................................Content Chain 1 Standby Power .........7-17 Chain 8 Paper Transportation .......................................................7-30 WorkCentre Pro 420 9/02 7-1 .......................................................................................................................................7-2 Chain 2 Mode Selection ............................. WorkCentre Pro 420 9/02 7-2 . WorkCentre Pro 420 9/02 7-3 . WorkCentre Pro 420 9/02 7-4 . WorkCentre Pro 420 9/02 7-5 . WorkCentre Pro 420 9/02 7-6 . WorkCentre Pro 420 9/02 7-7 . WorkCentre Pro 420 9/02 7-8 . WorkCentre Pro 420 9/02 7-9 . WorkCentre Pro 420 9/02 7-10 . WorkCentre Pro 420 9/02 7-11 . WorkCentre Pro 420 9/02 7-12 . WorkCentre Pro 420 9/02 7-13 . WorkCentre Pro 420 9/02 7-14 . WorkCentre Pro 420 9/02 7-15 . WorkCentre Pro 420 9/02 7-16 . WorkCentre Pro 420 9/02 7-17 . WorkCentre Pro 420 9/02 7-18 . WorkCentre Pro 420 9/02 7-19 . WorkCentre Pro 420 9/02 7-20 . WorkCentre Pro 420 9/02 7-21 . WorkCentre Pro 420 9/02 7-22 . WorkCentre Pro 420 9/02 7-23 . WorkCentre Pro 420 9/02 7-24 . WorkCentre Pro 420 9/02 7-25 . WorkCentre Pro 420 9/02 7-26 . WorkCentre Pro 420 9/02 7-27 . WorkCentre Pro 420 9/02 7-28 . WorkCentre Pro 420 9/02 7-29 . WorkCentre Pro 420 9/02 7-30 . WorkCentre Pro 420 9/02 7-31 . WorkCentre Pro 420 9/02 7-32 . WorkCentre Pro 420 9/02 7-33 . 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