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DocuColor 2060 / 2045 eXcellerate Service Manual

April 2002 701P37867

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

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

Table of Contents
Section Title Page

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

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

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Table of Contents

Introduction
About This Manual
This service manual is designed to aid the operator who has received DocuColor 2060 / 2045 eXcellerate training. The manual provides the information necessary to correct problems, or to make a decision to call the Customer Support Center or call for service No attempt should be made to perform repairs or adjustments that go beyond the scope of these service manuals. The information in this manual applies to the DocuColor 2060 / 2045. This section of the manual contains safety information, a listing of the tools and cleaning supplies that you will need, and a glossary of terms used in DocuColor 2060 / 2045 training. The following is a short description of the six sections contained in each manual: The actions in each of the fault code procedures are arranged in the order of either the most probable cause of the problem, or ease of performance. Try the actions in the procedure one at a time until the problem is solved. If the procedure does not solve the problem, you will be directed to call for assistance. If you cannot resolve any problem in a reasonable amount of time, call for assistance.

Section 5 - Repair Procedures


This section contains a parts list and the removal, replacement, and adjustment procedures for machine sub components.

Section 6 - General Procedures


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

Section 2 - Fault Code Procedures


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

Section 3 - Output Defect Procedures


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

Section I - How To Use This Manual


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

Section 4 - Preventive Maintenance


This section describes the maintenance tasks that should be performed as preventive maintenance.

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

Chemical Safety
When working with liquid chemicals, replace the cap immediately after pouring the chemicals. Never use any chemical unless specifically directed to do so. If possible, store all chemicals in metal cabinets. If a meta cabinet is not available, store the chemicals in a well ventilated area away from heat and bright light. Never use any unauthorized chemicals on or in Xerox equipment. Never put chemicals on any component that is hot or warm. Dangerous or explosive fumes could result. Never mix chemicals of any kind. When using chemicals for cleaning any part of the machine, never pour them directly onto the part. Pour them directly onto a cleaning towel and then use the towel to clean the component. Dispose of any contaminated cleaning materials properly. Wear plastic gloves whenever it is recommended. This is especially true when handling chemicals such as Xerox Film Remover, Lens and Mirror Cleaner, and fuser shield.

System Safety
Never teach anyone any repair, adjustment or maintenence procedure that you have learned during training. Never attempt any repair or procedure for which you have not been trained. Never perform a repair, removal, or a replacement without following the appropriate service manual procedure exactly. Never attempt any repair for which there is not a specific procedure. When you have finished work in an area, immediately replace all panels and covers. Never leave them off while the machine is running. Do not set tools inside the machine. If not removed, they can damage the machine. Do not place your eyes in line with any action or force that is being applied. A slip of the hand or a tool failure could result in an eye injury. Always wear eye protection when directed to do so by the documentation. Always allow adequate time for the components or assemblies to cool before beginning repairs in areas that generate heat, such as the fuser. Always ensure that the lighting is adequate before beginning repairs in any area of the machine.

Work Area Safety


Paper on the floor can cause you to slip. Pick up any paper immediately. Never put liquids on or near the machine. Keep all aisles clear. Avoid wearing open toe shoes. Shoes that cover your feet completely provide better protection against covers, components, and other objects that can drop or fall. Put any used parts securely in the box or container that held the new part. Store the used in a safe area until it is returned to the service representative. Never leave tools scattered around the work area. Always put them away when you are finished with the repair work.

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Safety

Always use the right tool for the job, and use it in a safe manner. Never move the machine, even if it is mounted on a mobility plate, or a rail . Before performing maintenance, remove jewelry, and tuck in or remove neckties. Avoid loose fitting clothing that could get caught in the machine, and tie back long hair, if applicable. Never put liquids or ashtrays on the machine. Use caution whenever working around electrical connectors. Do not touch the connector pins. Observe all procedures carefully when working in the machine. Never disable machine interlocks. Visually inspect the machine power cord and plug for any obvious physical damage at each service call. If a problem is identified, disable the machine, install the Safety Lockout Kit, and notify your service representative for support.

Symbols

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

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

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

Laser Safety
Do not bypass interlocks when working in or around any equipment using a laser. Do not wear any jewelry or use any shiny tools or objects around a laser. Any shiny object can accidently reflect a laser beam into the eyes. LASER This symbol is a reminder of the possible hazards that are associated with a laser.

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

Safety Lockout Kit

WARNING Many of the service procedures you will be performing during your training will require the removal of power to the machine by removing the power cord from the outlet. Using The Safety Lockout Kit is mandatory whenever a service procedure calls for power to be switched off. Severe electrical shock may occur if these regulations are not followed. Follow this procedure when you use the Safety Lockout Kit: 1. Switch off the machine power. 2. Disconnect the Power Cord from the AC power outlet. 3. Attach Safety Lockout Kit to the Power Cord Plug. Note: There is a procedure for installing the Safety Lockout Kit in section 6 of this manual. Whenever you are instructed to power down the equipment, make sure that NO possibility exists for someone else to turn power back on while you are servicing electrical components. If you are servicing machines with two or more power cords, you may need multiple Lockout/ Tagout kits.

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

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

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

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Safety

Tools and Cleaning Supplies


Tools
The following tools are required for the removal and replacement procedures in this service manual: Safety Glasses Straight Slot Pocket Screwdriver 600T40205 Kynar Dusting Pouch 8R2909 Part # 6OOT563 (1 pair) Used for eye protection. (not pictured) 5.5 mm Combo Wrench Magnetic Pick-up Black Protective Bag Safety Lockout Kit 600T40501 600T41911 95P2362 600T1933

Test Pattern

Long Magnetic Metric nut driver 5.5mm 600T1988

Part Number: 82E13120

#1 Cross Slot Screwdriver 499T356

Needle Nose Pliers 600T40901

6mm x 100mm Straight Slot Screwdriver 600T1989

150mm Scale 600T41503

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Cleaning Supplies
The following supplies are required for the service procedures in this service manual: Oval Cleaning Brush Part # 600T41901 WARNING Harmful vapors. Anti Static Fluid (ADF) Part # 8R90273 Avoid breathing or contact with skin. Cotton Swabs Part #35P2162 Used to clean sensors. WARNING Avoid eye contact. Formula A Cleaner Part #43P48 General purpose cleaner for machine components, covers, etc. Plastic Gloves WARNING Avoid eye contact. Drop Cloth Part # 35P1737 Used to protect floor or desk when working on machine components outside the machine. Lens and Mirror Cleaner Part #43P81 (non-ADF machines) Used to clean mirrors and Platen Glass. Part # 99P3024 (3 pair) Used to protect hands from cleaning solvents and fuser shield. Cleaning Cloth Part # 600S4372 (pack of 10) Used to clean surfaces sensitive to residue, such as the document glass. Can be used in heated areas. Can be used dry or damp.

Optics Cleaning Cloth (blue) WARNING Flammable Film Remover Part # 43P45 (Not available in RX) Used to remove silicone oil and dry ink from m/c components. Part #499T90417

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Tools and Cleaning Supplies

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

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

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Glossary
A
A3 - Metric paper size, corresponding to 11 x 17 paper. A4 - Metric paper size, corresponding to 8.25 x 11.75 ARRF - Active Retard Roll Feeders. The Feeder Assemblies in this copier are called Active Retard Roll Feeders (ARRF). They get this name from the fact that the Retard Roller can rotate in the opposite direction to the Feed Roll. ADF - Automatic Document Feeder. Automatically feeds, registers, and returns a stack of documents through a multisheet feeder. ADC - Automatic Density Control. Monitors density patches developed on the IBT Belt. ADH - Automatic Document Handler ADJ - Adjustment AGC - Automatic Gain Control. Automatically sets the gain of the amplifier in the analog circuit which processes the CCD Color Image Sensor outputs. ALC - Auto Level Control. Adjusts the TRC based on the differenceof ROS intensity levels on the drum. Amp - Measure of electrical current. Area coverage - Amount of image on a page. Expressed in percent. Each copier has specifications for optimum performance from dry ink based on area coverage. ASG - Analog Screen Generator Auditron - An optional accessory device used to control and record copier usage. Autometer - An optional accessory device used to control and record copier usage. CC - Charge corotron. Places a high voltage on the photoreceptor in order to permit oppositely-charged toner particles to stick to the image areas on the photoreceptor. CCD - Charged Coupled Device. An array of closely spaced capacitors that provides a mechanism for shifting electrical charges. In the IIT it is used in conjunction with photodiodes as a semiconductor device which coverts the light reflected off a document into electrical signals to obtain an electronic image. CCW - Counter Clock Wise Change tag - A number that represents a modified or retrofitted configuration of the copier. Copy cartridge - A customer replaceable unit containing the photoreceptor and (often) one or more corotrons. Corotron - A thin wire (possibly glasscoated) strung under high tension. Corotrons conduct a high voltage electrical field to the photoreceptor during the xerographic process. CPM - Copies Per Minute. C-POP - Color Patch on Paper CQ - Copy Quality CVA - Copy Volume Analyzer CW - Clock Wise

B
B5 - Metric paper size, corresponding to 5.5 x 8.5 paper. Background - The non-image areas of the copy have a visible dusting of dry ink. Belt (photoreceptor) - Flexible, endless strip of photosensitive material used in the xerographic process. Serves the same purpose as a photoreceptor drum. Black copy - The image area of the copy is entirely black. Blank copy - The image area of the copy is entirely white (or non-imaged). BPO - Bead Pick Off BSD - Block Schematic Diagram BTR - Bias Transfer Roll. Transfers the toner image from the Drum to the surface of the IBT Bypass - A chute, tray, or other assembly through which an operator may feed special copy paper, bypassing standard paper trays.

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

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Glossary

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

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

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

H
Half-rate (carriage) - Assembly that carries optical mirrors at half the rate of scan. HCF - High Capacity Feeder HCSS - High Capacity Stacker / Stapler HDD - Hard Disk Drive HFSI - High Frequency Service Item. A maintenance procedure to clean or replace a component or assembly at a pre-determined interval. H-Tra - Horizontal Transport HVPS - High Voltage Power Supply. Supplies the high voltage to the corotron wires and other xerographic components. Hz - Hertz. Electrical cycles per second.

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

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

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

G
GFI - Ground Fault Interrupter. Provides protection against excessive leakage current to ground. GFP - Ground fault protector. Protects the copier (and operator) against shocks caused by AC leakage between the power source and the copier frame. GP - General Procedure
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Imager - Fine powder used to develop the image. Also called toner, dry ink. Interimage (lamp) - A lamp or electroluminescent strip that shines briefly on the photoreceptor between latent images. IOT - Image Output Terminal. IPM - Images per minute. IPS - Image Processing System. The Image Processing System (IPS) performs the color correction and the editing functions. ITracs - The automatic density check that is performed by the CPOP Sensors with a scanner installed. IQ - Image Quality

tion of printing paper or placement of originals on a platen or feeding device. Light copy - The printed image is lighter than the original image. LUT - Look Up Table LVPS - Low Voltage Power Supply. LVPS supplies the various DC voltage levels required by the machine.

OEM - Original equipment manufacturer. OGM - On Going Maintenence OHP - Overhead Projector Optics - General term referring to the exposure lamp, lens, mirrors, reflectors used to expose and image the original document onto the photoreceptor.

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

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

J
J-Tra - Junction Transport

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

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

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

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

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Glossary

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

print that is not part of the original image. Status code - An alphanumeric code that appears on the control console display indicating a malfunction or need for other attention to the copier. Similar to message. Status indicator - Alpha-numeric code or lamps that indicate the status of the copier. Stripper fingers - Small, pointed devices that strip copy or print paper from the fuser or photoreceptor. VAC - AC Voltage

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

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

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

T
Tag (change) - A number that represents a modified or retrofitted configuration of the copier or printer. TC - Transfer corotron. Places a high voltage on the photoreceptor in order to permit transfer of dry imager from the photoreceptor to copy paper. Threshold - Information normally attained through diagnostics indicating change interval for assemblies, components, or machine consumable. Toner - Fine powder used to develop the image. Also called dry ink or imager. Touch Panel - The Touch Panel is part of the LCD Assembly and contains the switches which sense when and where the operator touches the LCD display. Tracs - The automatic density check that is performed by the ADC sensors on the IBT. TRC - Tone Reproduction Curve. The function in image processing that adjusts the characteristic of output image density to input image density.
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S
SEF - Short Edge Feed. Refers to the orientation of printing paper or the placement of originals on a platen or feeding device. Skew - The image is misregistered unequally top to bottom or side to side. SMH - Special Materials Handler (Tray 3) SNR - Sensor Snubber - A (usually) triangular device, most often found in a paper cassette or tray, for the purpose of preventing more than one sheet of paper from entering the feed or registration area at one time. Spot - A small dot of dry ink on a copy or

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

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

Glossary

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1. How To Use This Manual


Section Contents Page

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

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1-1

How To Use This Manual

When To Use This Manual


There are four reasons to use this manual: An obvious problem, such as a broken component A fault code An output defect, such as image quality Preventive maintenance

Call Flow Chart

Initial Action Section 1

Preventive Maintenance Section 4

Call Flow Sequence


Refer to the Call Flow Chart. This chart shows the correct sequence to follow each time service is performed on the machine. Follow this chart to ensure that the equipment maintains a high level of performance and reliability. Initial Action: The first step in the Call Flow, found in Section 1. During this procedure you obtain additional information about the machine state to help in the problem diagnosis. And you are sent to Section 4, Preventive Maintenance, to determine if any HFSI items require attention. Also you are directed to perform Every Call Cleaning Procedures and Extended Maintenance Activities (if required). Fix the Problem: You will be directed to go to a specific area of the service manual to diagnose and repair the machine fault.

Fix the Problem

Output Defect Procedures Section 3

Repairs & Adjustments Section 5

Fault Code Procedures Section 2

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

Final Actions Section 1

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How To Use This Manual

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

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

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

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

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How To Use This Manual

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DocuColor 2060/2045 eXcellerate Service Manual

Initial Actions
Purpose The purpose of the Initial Action section of the Service Call Procedures is to determine the reason for the service call and to identify and organize the actions which must be performed. Procedure 1. Obtain from the operator, a description of the reason for the call. If possible, determine the nature of the job being run and the mode of operation of the system at the time the problem occurred. Also, ask the operator to describe any other problems that may have been observed. 2. Inspect any rejected copies, if possible. Look for indications of excessive paper jams, such as wrinkles in the paper, images that are not fused, images that are skewed or are excessively misregistered. Try to identify the specific defects which caused the customer to reject the copy. Ensure that the task being attempted is within the capabilities of the machine. 3. Record the billing meter readings on the Service Log. 4. Enter the TKO Diagnostic Pathway, and determine what HFSI action is required based on the customer output volume. Refer to Section 4 Preventive Maintenance for detailed HFSI information. Record any items that require action.

7. Check the Service Log for any recent activities that are related to the problem that caused the service call or any secondary problem. 8. Exit the TKO Diagnostic Pathway. 9. If a Fault Code is displayed, go to the Fault Code Procedures in Section 2 to begin troubleshooting and return here after repairing the fault code.

NOTE: If a Fault Code is displayed while performing a diagnostic procedure, go to Section 2 Fault Code Entry Table and repair the fault. Return to Diagnostics and continue with the DC procedure that you were performing.
10. If the machine is configured as a printer-only, perform the image quality checkout procedure on page 3.2-6A. a. If a problem is found, go to the Output Defect Procedures in Section 3 to begin troubleshooting and return here after repairing the problem. b. If a problem is not found, go to step 12. 11. If the machine is configured as a copier / printer, perform the image quality checkout procedures on 3.2-31 and 3.2-6A. a. If a problem is found, go to the Output Defect Procedures in Section 3 to begin troubleshooting and return here after repairing the problem. b. If a problem is not found, go to step 12. 12. Try to rerun the customer job(s) that exhibits the problem. a. If a problem is observed, check to see if it only occurs on a particular job. If the problem occurs only on a particular job, verify that the job is being run correctly. If the problem occurs on more than one job, place a service call and then go to Final Actions. b. If a problem is not observed, go to Final Actions.

NOTE: The service strategy of the DocuColor 2060 /2045 Machine is to perform any High Frequency Service Item (HFSI) actions and Every Call Cleaning Procedures before attempting to repair any problems. Some problems will be corrected by this strategy without the need to diagnose them. The Call Flow RAP will be used for any remaining problems.
5. Perform any required HFSI activities. 6. Perform Every Call Cleaning Procedures and Extended Maintenance Activities (if more than 50,000 impressions since last service call).

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Every Call Cleaning Procedures


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

Fuser Assembly Clean the Fuser Belt Stripper Fingers (Sect. 5, Component Location Overview 3). Clean the Fuser Exit Sensor with a dry cotton swab (REP 10.14). Wipe off the Exit Transport Assembly (Sect. 5, Sensor Locations, Figure 13). Check the level of the Fuser Oil and replenish if necessary. (GP 8) Vacuum the area around the Toner Cartridges (Sect. 5, Component Location Overview 1).

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

Toner Tubes

CAUTION Do not vacuum around or near sensors or PWBs (circuit boards) unless the vacuum cleaner is properly grounded. General Cleaning Use a dry lint-free cloth for all cleaning actions, unless directed otherwise. When a moistened cloth is used, wipe afterwards with a dry lint-free cloth, except when cleaning rolls. Optics (Copier Only) Clean the Platen Glass (REP 6.3) with Lens and Mirror Cleaner and a dry lint-free cloth.

Paper Transport Module Clean the 2nd BTR Roll Assembly (REP 9.14). Vacuum the Detack Corotron (REP 9.20). Vacuum the Vacuum Transport Belts (Sect. 5, Component Location Overview 2). Clean the four Vacuum Transport Sensors (REP 8.2) with a dry cotton swab.

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

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Extended Maintenance Activities (50,000 or more impressions)


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

Xerographic Area

Clean all 4 ROS Windows. (REP 6.2)

IBT Belt Area

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

CAUTION To access the reflective patch on the IBT Belt, move it only by rotating the flywheel attached to the IBT Belt Drive Motor. Clean the Belt Home Position Sensor 1/2 (REP 9.7 and REP 9.8) with a lint-free cloth. Clean the IBT Reflective Patch (REP 9.9) with a dry lint-free cloth. Clean the POB Jam Sensor (REP 9.21) with a dry cotton swab.

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

Fuser Assembly Paper Trays (Remove the Tray 3 Feed Assembly Cover) Clean all the rolls in the Feed Assembly (REP 7.1) with Film Remover and a water-moistened, lint-free cloth. Clean the Tray 3 Pre-feed (REP 7.4), Feed Out (REP 7.5) and OHP Sensors (REP 7.6) with a dry cotton swab. Clean the Inverter Path Sensor (Sect. 5, Sensor Locations, Fig. 11) and (if accessible) Exit Transport Path Sensor (Sect. 5, Sensor Locations, Fig. 13) with a dry cotton swab. Clean the (Fuser) Cleaner Roll Assembly (REP 10.12) by scraping it, using a tool with a semi-sharp edge, such as a six-inch rule. Clean the Finger Assembly-HR (REP 10.15) with a dry lint-free cloth.

Paper Transport Module Clean the two F-Transport Sensors with a dry cotton swab (Sect. 5, Sensor Locations, Fig. 1). Clean the four J-Transport Sensors with a dry cotton swab (Sect. 5, Sensor Locations, Fig. 2 and 3). Clean the Registration Out Sensor with a dry cotton swab (REP 8.7). Clean the two Aligner Path Sensors with a dry cotton swab (REP 8.8).

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

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

CAUTION Fuser Oil is very slippery. Promptly clean up any oil that has spilled. See Section 4 for the proper cleaning procedures. 1. Add Fuser Oil to fill the sump to the required level. (GP 8) 2. Ensure that the exterior of the machine and the adjacent area are clean. Use a dry cloth or a cloth moistened with water to clean the machine. Do not use solvents. 3. Complete the Service Log. 4. At the next Xerox service call, discuss any service activity you have performed with your Xerox service representative. This will ensure that the service representative understands what has been done to the machine and that may impact his or her service strategy.

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2. Fault Code Procedures


Section Contents Page 6-277 thru 6-355. . . . . . . . . . . . . . . 2-16 6-360, 6-361. . . . . . . . . . . . . . . . . . 2-16 6-371 . . . . . . . . . . . . . . . . . . . . . . . 2-17 Status Fault Codes Table 1. Status Code Entry Table . 2-4 1-300 thru 1-359 . . . . . . . . . . . . . . . . 2-4 2-310 thru 2-502 . . . . . . . . . . . . . . . . 2-4 3-312 thru 3-951 . . . . . . . . . . . . . . . . 2-5 3-504, 3-505 . . . . . . . . . . . . . . . . . . . 2-5 3-508, 3-516, 3-520. . . . . . . . . . . . . . 2-6 3-521, 3-522, 3-523. . . . . . . . . . . . . . 2-7 3-525, 3-526, 3-527. . . . . . . . . . . . . . 2-8 3-529 thru 3-532 . . . . . . . . . . . . . . . . 2-9 3-540 . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 3-541 thru 3-546 . . . . . . . . . . . . . . . 2-10 4-310 thru 4-607 . . . . . . . . . . . . . . . 2-11 5-110 . . . . . . . . . . . . . . . . . . . . . . . . 2-11 5-111 thru 5-113 . . . . . . . . . . . . . . . 2-12 5-115, 5-116 . . . . . . . . . . . . . . . . . . 2-13 5-195 . . . . . . . . . . . . . . . . . . . . . . . . 2-14 5-274, 5-275 . . . . . . . . . . . . . . . . . . 2-14 5-301, 5-501 . . . . . . . . . . . . . . . . . . 2-15 5-900 thru 5-902 . . . . . . . . . . . . . . . 2-15 5-903, 5-904 . . . . . . . . . . . . . . . . . . 2-16 6-372 thru 6-623. . . . . . . . . . . . . . . 2-17 6-624 thru 6-626. . . . . . . . . . . . . . . 2-18 6-627 thru 6-648. . . . . . . . . . . . . . . 2-18 6-649 thru 6-651. . . . . . . . . . . . . . . 2-18 6-652 thru 6-656. . . . . . . . . . . . . . . 2-18 7-210 thru 7-284. . . . . . . . . . . . . . . 2-19 7-285 . . . . . . . . . . . . . . . . . . . . . . . 2-19 7-286 thru 7-340. . . . . . . . . . . . . . . 2-19 7-510 thru 7-512. . . . . . . . . . . . . . . 2-20 7-513 thru 7-518. . . . . . . . . . . . . . . 2-19 7-528 . . . . . . . . . . . . . . . . . . . . . . . 2-19 7-600 . . . . . . . . . . . . . . . . . . . . . . . 2-20 8-105, 8-110. . . . . . . . . . . . . . . . . . 2-21 8-120 . . . . . . . . . . . . . . . . . . . . . . . 2-21 8-122 . . . . . . . . . . . . . . . . . . . . . . . 2-22 8-130 thru 8-144. . . . . . . . . . . . . . . 2-22 8-146 . . . . . . . . . . . . . . . . . . . . . . . 2-22 8-150 . . . . . . . . . . . . . . . . . . . . . . . 2-22 8-154 . . . . . . . . . . . . . . . . . . . . . . . 2-23 8-157 . . . . . . . . . . . . . . . . . . . . . . . 2-23 8-160 . . . . . . . . . . . . . . . . . . . . . . . 2-23 8-170 . . . . . . . . . . . . . . . . . . . . . . . 2-23
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8-180, 8-184 . . . . . . . . . . . . . . . . . . 2-24 8-190 thru 8-194 . . . . . . . . . . . . . . . 2-24 8-198 thru 8-310 . . . . . . . . . . . . . . . 2-24 8-311 . . . . . . . . . . . . . . . . . . . . . . . . 2-24 8-312 . . . . . . . . . . . . . . . . . . . . . . . . 2-25 8-601 . . . . . . . . . . . . . . . . . . . . . . . . 2-25 8-602 thru 8-604 . . . . . . . . . . . . . . . 2-24 8-605 . . . . . . . . . . . . . . . . . . . . . . . . 2-25 8-900 . . . . . . . . . . . . . . . . . . . . . . . . 2-26 9-105 . . . . . . . . . . . . . . . . . . . . . . . . 2-26 9-301 . . . . . . . . . . . . . . . . . . . . . . . . 2-26 9-330 thru 9-336 . . . . . . . . . . . . . . . 2-26 9-343, 9-344 . . . . . . . . . . . . . . . . . . 2-27 9-350 thru 9-357 . . . . . . . . . . . . . . . 2-27 9-358 . . . . . . . . . . . . . . . . . . . . . . . . 2-27 9-360 . . . . . . . . . . . . . . . . . . . . . . . . 2-28 9-361 . . . . . . . . . . . . . . . . . . . . . . . . 2-28 9-362 . . . . . . . . . . . . . . . . . . . . . . . . 2-28 9-363 . . . . . . . . . . . . . . . . . . . . . . . . 2-29 9-375 . . . . . . . . . . . . . . . . . . . . . . . . 2-29 9-377 . . . . . . . . . . . . . . . . . . . . . . . . 2-29 9-402 thru 9-405 . . . . . . . . . . . . . . . 2-30 9-410 thru 9-421 . . . . . . . . . . . . . . . 2-30 9-500 . . . . . . . . . . . . . . . . . . . . . . . . 2-30 9-600 thru 9-603 . . . . . . . . . . . . . . . 2-30

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Fault Code Procedures

9-604 thru 9-607 . . . . . . . . . . . . . . .2-31 9-608 thru 9-615 . . . . . . . . . . . . . . .2-31 9-618, 9-619. . . . . . . . . . . . . . . . . . .2-31 9-624 thru 9-643 . . . . . . . . . . . . . . .2-31 9-663 thru 9-666 . . . . . . . . . . . . . . .2-32 9-670 thru 9-677 . . . . . . . . . . . . . . .2-32 9-685, 9-686. . . . . . . . . . . . . . . . . . .2-32 9-690 thru 9-693 . . . . . . . . . . . . . . .2-32 9-694 thru 9-697 . . . . . . . . . . . . . . .2-33 10-105, 10-106. . . . . . . . . . . . . . . . .2-33 10-110 . . . . . . . . . . . . . . . . . . . . . . .2-33 10-112 . . . . . . . . . . . . . . . . . . . . . . .2-34 10-120 . . . . . . . . . . . . . . . . . . . . . . .2-34 10-122 . . . . . . . . . . . . . . . . . . . . . . .2-34 10-123 . . . . . . . . . . . . . . . . . . . . . . .2-35 10-130 . . . . . . . . . . . . . . . . . . . . . . .2-35 10-132 . . . . . . . . . . . . . . . . . . . . . . .2-35 10-290 . . . . . . . . . . . . . . . . . . . . . . .2-36 10-310 . . . . . . . . . . . . . . . . . . . . . . .2-36 10-311 thru 10-313 . . . . . . . . . . . . .2-36 10-314 thru 10-316 . . . . . . . . . . . . .2-37 10-318 . . . . . . . . . . . . . . . . . . . . . . .2-37 10-319 . . . . . . . . . . . . . . . . . . . . . . .2-37 10-354 thru 10-367 . . . . . . . . . . . . .2-38 10-380 . . . . . . . . . . . . . . . . . . . . . . .2-38 10-382 . . . . . . . . . . . . . . . . . . . . . . .2-38

10-385 thru 10-390 . . . . . . . . . . . . . 2-38 10-392 thru 10-394 . . . . . . . . . . . . . 2-39 10-400. . . . . . . . . . . . . . . . . . . . . . . 2-39 10-401. . . . . . . . . . . . . . . . . . . . . . . 2-39 10-600. . . . . . . . . . . . . . . . . . . . . . . 2-39 12-295. . . . . . . . . . . . . . . . . . . . . . . 2-40 12-500. . . . . . . . . . . . . . . . . . . . . . . 2-40

Fault Code Procedures

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Introduction This section contains status code procedures. Each procedure represents a status code, or group of status codes that may be displayed, indicating a problem. The status codes are numerical (e.g. 5-901), with the number to the left of the hyphen indicating the area of the machine and the remaining digit(s) indicating a particular fault to that area. Using the example of status code 5-901, the first number (5) indicates that the fault has occurred in the ADF (Automatic Document Feeder). A 10-106 code would indicate a duplex jam. To access the correct procedure, use the section content page to locate the indicated status code and the appropriate page number. The Status Code Entry Table is composed of two columns. The left column contains the status code fault indicator. The right column includes a description of the fault and the actions to take in resolving the problem. The actions are the most likely suspects. In each case, if you try to resolve the fault and all attempts fail, you are directed to call for service. Always follow the Repair procedures carefully. Whenever directed, be sure to Switch off the Main Power Switch and disconnect the Power Cord.

Always Heed The Following Warning.....

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

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Fault Code Procedures

Status Code Entry Table

Procedure
Go to the Status Code Entry Table below

Status Code Entry Table


Status Code 1-300, 302, 303, 304, 308, 309, 350, 355, 356, 357, 358, 359 2-310, 311, 340, 345, 500, 501, 502 Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call. The Control Logic indicates a User Interface failure. Initial Action: Follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call. Description/Direction The Control Logic indicates a Standby Power failure.

Fault Code Procedures

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

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

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

3-505

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

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Fault Code Procedures

Status Code 3-508

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

3-516

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

3-520

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

Fault Code Procedures

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Status Code 3-521 Initial Action:

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

3-522

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

3-523

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

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Fault Code Procedures

Status Code 3-525 Initial Action:

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

3-526

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

3-527

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

Fault Code Procedures

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DocuColor 2060/2045 eXcellerate Service Manual

Status Code 3-529

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

3-530

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

3-531, 532

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

3-540

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

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Fault Code Procedures

Status Code 3-541, 542

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

3-543

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

3-544, 545

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

3-546

The Control Logic indicates a recovery problem occurred when exiting from Interrupt during a EPC-Print or DFE Print job. Initial Action: Cancel the job. If the fault code does not clear, power the machine OFF then ON. If the problem still exists: Place a service call. 04/02 2-10

Fault Code Procedures

DocuColor 2060/2045 eXcellerate Service Manual

Status Code 4-310, 311, 318, 319, 320, 321, 322, 323, 324, 325, 326, 327, 328, 329, 330, 331, 332, 350, 351, 352, 353, 354, 355, 600, 601, 602, 603, 604, 605, 606, 607 5-110 The Control Logic indicates a Drives failure. Initial Action:

Description/Direction

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

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

5-111

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

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Fault Code Procedures

Status Code 5-112, 113

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

5-115

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

5-116

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

Fault Code Procedures

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DocuColor 2060/2045 eXcellerate Service Manual

Status Code 5-195

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

5-274

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

5-275

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

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Fault Code Procedures

Status Code 5-301 Initial Action:

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

5-501

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

5-900, 901

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

5-902

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

Fault Code Procedures

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DocuColor 2060/2045 eXcellerate Service Manual

Status Code 5-903 Initial Action:

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

5-904

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

6-277, 300, 312, 320, 321, 330, 331, 340, 345, 355 6-360, 361

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

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Fault Code Procedures

Status Code 6-371 Initial Action:

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

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

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

Fault Code Procedures

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Status Code 6-624, 625, 626 Initial Action:

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

6-627, 628, 629, 630, 631, 632, 633, 634, 635, 636, 637, 638, 639, 640, 641, 642, 643, 644, 645, 646, 647, 648 6-649, 650, 651

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

The Control Logic indicates a problem with the reflective rate of one or more color(s). Initial Action: Ensure that the MOB Sensor (REP 6.1) has been cleaned with a dry cotton swab. If ok, follow any operator instructions and then power the machine OFF then ON. If the problem still exists: Place a service call.

6-652, 653, 654, 655, 656

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

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Fault Code Procedures

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

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

7-286, 287, 288, 340

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

Fault Code Procedures

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Status Code 7-510, 511, 512 Initial Action:

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

7-513, 514, 515, 517, 518

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

7-528

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

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Fault Code Procedures

Status Code 7-600 Initial Action:

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

8-105, 110

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

8-120

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

Fault Code Procedures

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Status Code 8-122 Initial Action:

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

8-130, 136, 140, 144

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

8-146

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

8-150

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

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Fault Code Procedures

Status Code 8-154 Initial Action:

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

8-157

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

8-160

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

8-170

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

Fault Code Procedures

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Status Code 8-180, 184

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

8-190, 193. 194

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

8-198, 199 301, 302, 310,

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

8-311

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

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Fault Code Procedures

Status Code 8-312 Initial Action:

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

8-601

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

8-602, 603, 604

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

8-605

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

Fault Code Procedures

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Status Code 8-900 Initial Action:

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

9-105

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

9-301

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

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Fault Code Procedures

Status Code 9-330, 331, 332, 333, 335, 336 Initial Action: None Close out the call: Place a service call. 9-343, 344

Description/Direction The Control Logic indicates a miscellaneous Toner delivery or collection problem.

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

CAUTION To access the reflective patch on the IBT Belt, move it only by rotating the flywheel attached to the IBT Belt Drive Motor. Clean the reflective patch on the IBT Belt (REP 9.9) with a dry lint-free cloth. Clean the Belt Home Position Sensor 1 (REP 9.7) with a dry cotton swab. If the reflective patch is damaged or missing, replace the IBT Belt. (REP 9.9) If the problem still exists: Place a service call. 9-350, 351, 352, 353, 354, 355, 356, 357 The Control Logic indicates a problem with a Developer Motor or a Dispenser. Initial Action: None Close out the call: Place a service call.

Fault Code Procedures

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Status Code 9-358 Initial Action:

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

9-360

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

9-361

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

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Fault Code Procedures

Status Code 9-362 Initial Action: Power the machine OFF then ON. If the problem remains:

Description/Direction The Control Logic indicates that the Cyan VH Charge setup did not complete successfully.

Replace the Drum Assembly (REP 9.1). Power the machine OFF then ON. If the problem still exists: Place a service call. 9-363 The Control Logic indicates that the Black VH Charge setup did not complete successfully. Initial Action: Power the machine OFF then ON. If the problem remains: Replace the Drum Assembly. (REP 9.1) Power the machine OFF then ON. If the problem still exists: Place a service call. 9-375 The Control Logic indicates that the Waste Toner Bottle is improperly installed. Initial Action: Ensure that the Waste Toner Bottle (REP 9.22) is properly installed. Power the machine OFF then ON. If the problem still exists: Place a service call.

Fault Code Procedures

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Status Code 9-377 Initial Action:

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

9-402, 403, 404, 405

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

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

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

9-500

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

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Fault Code Procedures

Status Code 9-600, 601, 602, 603

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

9-604, 605, 606, 607

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

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

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

9-618, 619

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

Fault Code Procedures

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Status Code 9-624, 625, 626, 627, 628, 629, 634, 635, 636, 637, 638, 639, 640, 641, 642, 643 9-663, 664, 665, 666 Initial Action:

Description/Direction The Control Logic indicates an electrostatic setup or ADC setup problem. Clean all the ADC Sensors (REP 9.13) with a dry cotton swab. Using the Diagnostic Control Unit (DCU), perform Max Setup. (ADJ 9.1) If the problem still remains: Place a service call. The Control Logic indicates a problem with an ADC control signal. Initial Action: Clean all the ADC Sensors (REP 9.13) with a dry cotton swab. Using the Diagnostic Control Unit (DCU), perform Max Setup. (ADJ 9.1) If the problem still remains: Place a service call.

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

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

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Fault Code Procedures

Status Code 9-685, 686 Initial Action:

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

9-690, 691, 692, 693

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

9-694, 695, 696, 697

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

Fault Code Procedures

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Status Code 10-105, 106 Initial Action:

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

Warning - Switch off the Power, disconnect the Power Cord, and apply the Lockout Tag. - Allow the Fuser to cool before performing this procedure. - Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. Check for any obstruction in the Vacuum Transport paper path. (REP 8.1) Clean the Fuser Exit Sensor (REP 10.14) with a dry cotton swab. Check that the Fuser Belt is not torn or contaminated with oil (if oily, wipe belt with dry lint-free cloth). (REP 10.2) If the problem still exists: Place a service call. 10-110 The Control Logic indicates that paper did not reach the Decurler Upper Path Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Decurler Upper Path Sensor (Sect. 5, Fig. 7) with a dry cotton swab. If the problem still exists: Place a service call. 10-112 The Control Logic indicates that paper did not reach the Decurler Lower Path Sensor within the allowed time. Initial Action: Check for any obstruction in the paper path. Clean the Decurler Lower Path Sensor (Sect. 5, Fig. 8) with a dry cotton swab. If the problem still exists: Place a service call.

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Fault Code Procedures

Status Code 10-120 Initial Action:

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

10-122

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

10-123

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

Fault Code Procedures

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Status Code 10-130 Initial Action:

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

10-132

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

10-290

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

10-310

The Control Logic indicates a Fuser Belt tracking problem. Initial Action: None Close out the call: Place a service call. 04/02 2-35

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Fault Code Procedures

Status Code 10-311, 312, 313 Initial Action: None Close out the call: Place a service call. 10-314, 315, 316

Description/Direction The Control Logic indicates a Fuser Belt latching problem.

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

Warning - Switch off the Power, disconnect the Power Cord, and apply the Lockout Tag. - Allow the Fuser to cool before performing this procedure. - Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. Ensure that the spring finger of the Fuser Belt Position Sensor (Sect. 5, Component Location Overview 3. See also REP 10.2, Fig. 5) is riding on the outside edge of the belt. Clean the Fuser Walk Motor Sensor (REP 10.16) with a dry cotton swab. If the problem still exists: Place a service call. 10-318 The Control Logic indicates that the Fuser did not reach operating temperature in Standby. Initial Action: None Close out the call: Place a service call.

Fault Code Procedures

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Status Code 10-319 Initial Action: None Close out the call: Place a service call. 10-354, 355, 356, 357, 359, 360, 366, 367 10-380

Description/Direction The Control Logic indicates a problem with the Fuser Drive Motor.

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

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

Add Fuser Oil to fill the Oil Bottle to the required level. (GP 8) If the problem still exists: Place a service call. 10-382 The Control Logic indicates that the Fuser Belt Web is empty. Initial Action: Ensure that the (Fuser) Web Material Assembly (REP 10.9) has been replaced. If the problem still exists: Place a service call.

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Fault Code Procedures

Status Code 10-385, 386, 387, 388, 389, 390 Initial Action: None Close out the call: Place a service call. 10-392, 393, 394

Description/Direction The Control Logic indicates an External Heat Roll control or overheat problem.

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

10-400

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

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

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

Fault Code Procedures

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Status Code 10-401 Initial Action:

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

10-600

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

12-295

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

12-500

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

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Fault Code Procedures

3. Output Defect Procedures


Section Contents
Troubleshooting Introduction to Image Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1-2 Image Quality Evaluation Process. . . . 3.1-3 IQ 1 Troubleshooting Entry Procedure 3.1-4 Image Quality Defect Definitions . . . . . 3.1-5 Table 1. Defects With Workarounds . . 3.1-9 Table 2. Defects With Signatures (Specific Characteristics) . . . . . . . . . . . . . . . . . 3.1-10 Table 3. Defects With Less Specific Characteristics. . . . . . . . . . . . . . . . . . . . . . . . 3.1-13 Table 4. Corrective Actions . . . . . . . . 3.1-19 Image Quality Specifications 3.2.1 General Information . . . . . . . . . . 3.2-1 3.2.2 IOT Setup for Full Color Output Check. (with Modified Restore Chart).. . . . . . . 3.2-1 3.2.2.1 IOT Color Standards . . . . . . . . 3.2-4 3.2.5 DFE Test Patterns . . . . . . . . . . . 3.2-6 3.2.6 Copier Setup for Full Color Output Check. . . . . . . . . . . . . . . . . . . . . . . . . . 3.2-8 3.2.6.1 Color Copier Specifications . . . 3.2-8

Page

Image Quality Defect Samples 3.3.1 Introduction . . . . . . . . . . . . . . . . . 3.3-1 3.3.2 Image Quality Defect Samples . . 3.3-1 Figure 1 Bead Carryout, Single-Color Band (Faint). . . . . . . . . . . . . . . . . . . . . . . . . . 3.3-3 Figure 2 Bead Carryout, Single-Color Band (Severe) . . . . . . . . . . . . . . . . . . . . . . . . 3.3-3 Figure 3 Corrupted Video Data . . . . . . 3.3-5 Figure 4 Rainbow-Like Single or Multi-Color Bands . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3-5 Figure 5 Water Stains . . . . . . . . . . . . . 3.3-7 Figure 6 Localized, Single-Color, Half Tone, Streak Deletion. . . . . . . . . . . . . . . . . . . 3.3-7 Figure 7 Mottle (w/ Some Granularity) . 3.3-9 Figure 8 Toner Starvation Between Low Density / High Density Area . . . . . . . . . . . . 3.3-9 Figure 9 Image Slip . . . . . . . . . . . . . . 3.3-11 Figure 10 Mosaic . . . . . . . . . . . . . . . . 3.3-11 Figure 11 Vacant Characters . . . . . . . 3.3-13 Figure 12 Small Dark Dots on Text . . 3.3-13 Figure 13 Newton Rings. . . . . . . . . . . 3.3-15 Figure 14 Start of Rib Marks . . . . . . . 3.3-15 Figure 15 Rib Marks. . . . . . . . . . . . . . 3.3-17 Figure 16 Water Marks. . . . . . . . . . . . 3.3-17

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Output Defect Procedures

Introduction to Image Quality Troubleshooting


This section of the Service Manual provides the information that is required for the correct evaluation of the image quality. It consists of the following parts: IQ 1 Image Defect Troubleshooting Procedure - This is where you begin whenever you are troubleshooting an image quality problem. There are two parts to IQ1: Analyze: Table 1, Defects with Workarounds, Table 2, Defects with Signatures (or Specific Characteristics) and Table 3, Defects with Less Specific Characteristics. Resolution: Table 4, Corrective Actions is used to isolate the defect to either the specific cause or have you request service.

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

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Image Quality Evaluation


Introduction Procedure All image quality parameters for the DocuColor 2060/2045 are evaluated using the following Test Patterns (TP): Reference TP DFE-generated Modified Restore Chart Copier Color TP, 82E13120 DCU Single-Color Halftone TP (GP 9)

2. The Image Quality Defect Definition Table A contains details descriptions each image quality defect listed in Table 1 and 2. Section 3.2 provides information about image quality specifications/ standards. Section 3.3 provides samples of image defects.

The first three patterns are used to evaluate most defects, while the last pattern is used on a case-by-case basis. Section 3.1 of this Service Manual provides the information that is required for the correct evaluation of image quality. It consists of: 1. The IQ 1 Image Defect Troubleshooting Entry Procedure. This procedure is comprised of the following: Table 1: Defects with Workarounds - This table defines defects and provides directions to minimized them. Table 2: Defects with Signatures (or Specific Characteristics) - This table analyzes defects and provides directions to resolve them. Table 3: Defects with Less Specific Characteristics - This table analyzes defects and provides directions to resolve them. Table 4: Corrective Actions - You are sent here to minimize or resolve the defect identified in any of the other three tables. This table consists of two columns. The left column (Defect Name) and the right column (Corrective Action). The information under Corrective Action includes a description of the fault and the actions to take.

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Output Defect Procedures

IQ 1 Image Quality Troubleshooting Entry Procedure


This section of the Service Manual is used to diagnose and to repair image quality problems. The purpose of the Image Quality Troubleshooting Entry Procedure is to serve as the entrance vehicle into the Image Quality section. All Image Quality Procedures must be accessed through this Procedure. Initial Action Ensure that all HFSI items that are near or over threshold have been repaired. (reference Section 4) Ensure that all of the Every Call Cleaning activities have been performed. (reference Section 1) Ensure that the test pattern prints / copies made during Initial Actions in Section 1, and any sample defect from the customers job, are available at this time to help identify the type of image quality defect the machine has. Ensure that a good quality paper (Refer to Customer Documentation for recommended paper) is loaded and the Tray end Guides are properly set. If the problem persists, continue with this procedure.

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

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

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DocuColor 2060/2045 eXcellerate Service Manual

Image Quality Defect Definitions


In the following pages, you will find Image Detect Definitions. This table can be used in conjunction with IQ 1 Image Quality Troubleshooting Entry Procedure to better understand the definitions of the detects in the Procedure. Image Defect Background Definition Undesirable toner deposits on the print/copy. The toner deposits can be localized or may cover the entire print/copy. Depending on the density of the background, it is referred to as low, medium, high, or very high background. It may occur in all colors, single colors, or any combination of single colors. The absence or low density of toner in desired image areas, or the presence of toner in undesired areas in the shape of a band. Bands are widths greater than 0.5 mm. Bands are generally uniform in shape from one end to the other, and can run in any direction on the print/copy. Developer beads that are electrostatically attracted to the print/copy during the transfer process. Bead Carryout is characterized by a fine, loose grit on the surface of the print/copy. On this product, it looks like Mottle or low density. Bead Carryout is most noticeable in high density areas and usually does not affect all four colors at the same time. Images that are not clear, or appear out of focus. Colored areas of the print/copy that exhibit a change in hue, as opposed to a change in density. This is most often judged in the gray areas of the print/copy. Theoretically, a true gray can be produced with equal amounts of magenta, yellow and cyan toner. Therefore, a common example of poor color balance is a gray image that is reproduced with slightly more of one of those color toners. The result is a gray that appears to have a magenta, yellow or cyan hue, rather than true gray. Toner deposit on the back side of a print/copy or on the second side of a two-sided print/copy. A variety of image defects which occur when printing in the customer mode but do not occur when printing in the diagnostic mode.

Bands

Bead Carryout

Blurred or Fuzzy Image Color Balance, Poor

Contamination (Back Side or Side 2 of Print/Copy) Corrupted Video Data

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Output Defect Procedures

Image Defect Deletions

Definition The undesirable absence of toner from the print/copy. This defect can show as white, light, or untrue colored areas on the print/copy. The most common example is a deletion caused by the tenting of paper from mishandling or moisture, or by dents or defects in the IBT. A condition that results when too much toner of a single color or combination of colors is developed on the print/copy. This results in darker prints for the single color toner or the color that results from the combination of colors. A condition that results when too little toner of a single color or combination of colors is developed on print/copy. This results in lighter prints for the single-color toner or the color that results from the combination of color toners. The uneven development of toner on the print/copy from one area to another. Typically, this results in change in density from inboard to outboard and sometimes from lead edge to trail edge. Lead edge to trail edge streaks or globs that show up first on transparencies or coated paper as low gloss streaks in solid areas. In severe cases, oil streaks can show up on paper as low density streaks or globs in large half tone areas. An image defect that causes solid areas to have a sandy appearance. Granularity is most noticeable in middle-density solid areas. One or more color planes shifted by 1/2 inch or more from its normal position. Small circular-shaped deletions within a character that can occur when the image density is low or a transparency is used. Image disturbance just prior to fusing, usually in the form of a band, located along the lead edge of a print/copy. The absence or low density of toner in desired image areas, or the presence of toner in undesired areas in the shape of a line. Lines are generally uniform in shape from one end to the other, and can run in any direction on the print/copy. Lines are defined as measuring less than 0.5 mm in width. (By contrast, streaks are generally shorter than lines and are of nonuniform width along their length. They may have a more ragged or fuzzy appearance than lines, and can run in any direction on the print/copy.)

Density High

Density Low

Density Uneven

Fuser Oil Streaks or Globs

Granularity Grossly Shifted Color Plane Hollow Characters Image Slip Lines

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Image Defect Low Contrast Reproduction Marks (Rib and Water)

Definition The inability to adequately reproduce a low contrast image. Uneven gloss on a fused print/copy which has a rib-like or water-mark appearance. They are caused by one or more of the following: incorrect pad force, incorrect pressure roll nip, or a low oil condition. The defects are unique to this product and examples are supplied in the Image Defect Samples sections of the Image Quality Supplement. Multi-colored images that are not superimposed and should be. This can occur in the lead edge to trail edge or inboard to outboard direction. The alignment of the image to the edges of the print/copy paper. It is defined by lead and side edge registration, and lead and side edge skew. The loss of one of the color toners from the output print/copy. Depending on the original, this can result in missing areas of the image, or changes in the color balance of the print/copy. Patterns on the image areas of the output copy that has the appearance of a screen or grid overlaying the image. It may be uniform or nonuniform in area or shape. Solid area, high density image areas that are reproduced with a surface that resembles marble. Repetitive, irregular-shaped marks that occur when making copies of glossy photographs. These marks are most noticeable in large low-density or highlight areas. The removal of toner from the print/copy by the fuser and the subsequent redeposition of that toner on another area of the same or other another print/copy. Removing toner from the image leaves the image rough and without gloss. The redeposited toner may appear as a duplicate image, partially shifted image, or lines and streaks. A toner image that remains on the photoreceptor or IBT after cleaning. The next image is place on top of the residual image and both images are transferred to the next print/copy. Intentional lead edge, side edges, and trail edge deletions that make a border on the print/copy paper. An image that is reproduced as solid black (or color) from lead edge to trail edge and from inboard to outboard. The ROS Border may or may not be visible.

Misregistration (Color-toColor) Misregistration (System) Missing Colors Moire Mottle Newton Rings Offsetting, Fuser

Residual Image ROS Borders Solid Single-Color Print/ Copy

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Output Defect Procedures

Image Defect Spots Text / Image Separation Errors

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

Toner Starvation

This defect occurs at the transition point between a high density area and a low density area of the same color. A localized area of the mag brush becomes starved for toner due to development fringe field effects. Starvation tends to worsen at low triboelectric levels (high toner concentration). The Toner on the print/copy is not completely fused. Uneven gloss on a fused print/copy which has the appearance of a water stain. It is caused by one or more of the following: incorrect pad force, incorrect pressure roll nip, or a low oil condition. This defect is unique to this product and an example of it is supplied in the Image Defect Samples sections of the Image Quality Supplement. Creasing or folds on the print/copy in the lead to trail edge direction, or closely spaced waves in the inboard to outboard direction.

Unfused Print/Copy Water Stains

Wrinkled Print/Copy

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DocuColor 2060/2045 eXcellerate Service Manual

Table 1. Defects With Workarounds Defect Name Moire Defect Samples n/a Defect Characteristics Description - Patterns on the image areas of the output copy that has the appearance of a screen or grid overlaying the image. It may be uniform or nonuniform in area or shape. Description - Repetitive, irregular-shaped marks that occur when making copies of glossy photographs. These marks are most noticeable in large low-density or highlight areas. Description - Mosaic: An image defect that can affect fine line ladders or low screen halftones. It causes closely spaced lines, low frequency halftones, and certain texts to have a blotchy appearance. Description - Vacant Characters: An image defect that results when the center of a character is filled-in with a (200R) halftone screen while its outer border is made up of a (600L) text screen. (Note: This level of detail is best observed with an eye loop.) Description - Small Dark Dots on Text: An image defect that causes a localized area of a character in a text to look like it contains small dark dots. (Note: This level of detail is best observed with an eye loop.) Description - Ghost images (Negative) on the output copy after duplex prints. Replace the Fuser Belt Assembly (REP 10.2) with one that is packdated Sept. 2000 or later. Replace the IBT Belt. (REP 9.9) Table 4 Reference Go to IQ 31.

Newton Rings

Fig. 13

Go to IQ 32.

Text / Image Separation Errors

Fig. 10

Go to IQ 33.

Fig. 11

Fig. 12

Oil Ghosting

n/a

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Output Defect Procedures

Table 2. Defects With Signatures (Specific Characteristics) Defect Lines, spot, marks only when using the scanner Deletion lines (LE/TE) Interval Same area of each page Same area of each page 11x17: Every 4th page 8.5x11: LEF every 8th page Using the DCU, make all four singlecolor halftone prints to isolate the problem color (GP 9). Isolation Technique Component Platen Glass ROS Seal Glass Corrective Action Clean Platen Glass Clean ROS Seal Glass (REP 6 2) Replace the IBT Belt (REP 9.9) Perform ADJ 9.3 Registration Control Setup Perform ADJ 9.1 Max Setup Vacuum the Vacuum Transport Belts (Section 5, Component Location Overview 2) Replace the Heat Roll (REP 10.3) Perform ADJ 10.1 Fuser Nip Replace the Drum Assembly (REP 9.1) Perform Max Setup (ADJ 9.1)

Deletions, lines, marks or spots

IBT Belt

Lines or marks (LE/TE)

Random

Simplex job shows only on back side Duplex job show on both sides

Vacuum Transport Belts

Line or marks (LE/TE)

12x18: 11 from OB edge

Fuser Heat Roll

Deletions, lines, marks, or spots

11x17: repeats every 264 mm

Drum

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DocuColor 2060/2045 eXcellerate Service Manual

Table 2. Defects With Signatures (Specific Characteristics) Defect Deletions, lines, marks, or spots Interval 11x17: repeats every 88 mm Isolation Technique Using GP1 Xerographic Hardstop procedure, look at the area of the IBT Belt before it reaches the 2nd BTR. Using the DCU, make all four singlecolor halftone prints to isolate the problem color (GP 9). If the defect is not present, the problem is 2nd BTR related. 2nd BTR or 2nd BTR Backup Roll Replace the 2nd BTR (REP 9.14). Replace the 2nd BTR Backup Roll (REP 9.12). Perform ADJ 9.1 Max Setup. Replace the Heat Roll (REP 10.3). Perform ADJ 10.1 Fuser Nip. Replace the Fuser Belt Assembly. (REP 10.2) Replace the 1st BTR (REP 9.10) for the problem color. Perform ADJ 9.1 Max Setup. Replace the Charge Corotron and Screen (REP 9.2) for the problem color. Perform ADJ 9.1 Max Setup. 1st BTR Replace the 1st BTR (REP 9.10) for the problem color. Perform ADJ 9.1 Max Setup. Component Corrective Action

Deletion, line, mark or spot

11x17: repeats every 204 mm

Fuser Heat Roll

Image Slip/Smear (Defect Sample 9) Fireworks or star-like deletion (no defect sample) Bands, Rainbow-like single or multi-color

Located within 30 mm from LE Random Using the DCU, make all four singlecolor halftone prints to isolate the problem color (GP 9). Using the DCU, make all four singlecolor halftone prints to isolate the problem color (GP 9).

Dry Fuser Pad or Wick 1st BTR

Closely-spaced LE/ TE bands

Charge Corotron wire or screen

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Output Defect Procedures

Table 2. Defects With Signatures (Specific Characteristics) Defect Missing color Interval Entire area of every page Isolation Technique Using the DCU, make all four singlecolor halftone prints to isolate the problem color (GP 9). Component DFE Cable Corrective Action Reseat both ends of the cable between the DFE and the VSEL PWB (reference GP 6, Fig. 3) for the problem color. Ensure that the gsm setting is correct. Flip the paper. Replace the paper. Ensure that the gsm setting is correct. Flip the paper. Replace the paper. Replace the 1st BTR (REP 9.8) for the problem color. Perform ADJ 9.1 Max Setup.

TE smear on side 1 of duplex job

Within 30 mm from TE

Paper/Paper Setting

TE smear on simplex job

Within 30 mm from TE

Paper/Paper Setting

Circular, tear-drop shaped deletions

Random

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

1st BTR

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Table 3. Defects With Less Specific Characteristics


Image Defect Defect Sample Printer Test Pattern Used Printer Standards Copier/Printer Test Pattern Copier/Printer Standards Table 4 Reference

Background

n/a

Modified Restore Chart Modified Restore Chart Optional: DC612, Halftone (overall)

Non-Image areas of the prints should be free of background for any color. Acceptable to the customer on the customers job.

Copier Color Test Pattern Copier Color Test Pattern

Non-Image areas of the copy should be free of background for any color. Acceptable to the customer on the customers job.

IQ 12

Bands (Lead Edge to Trail Edge) Bands (Inboard to Outboard)

n/a

IQ 10

n/a

Modified Restore Chart Optional: DC612, Halftone (overall)

Acceptable to the customer on the customers job.

Copier Color Test Pattern

Acceptable to the customer on the customers job.

IQ 10

Bead Carryout Solid SingleColor Print / Copy Blurred or Fuzzy Image Color Balance, Poor

Fig. 1, Fig. 2 n/a

Modified Restore Chart Modified Restore Chart

Acceptable to the customer on the customers job. The print should not be a single solid color.

Copier Color Test Pattern Copier Color Test Pattern

Acceptable to the customer on the customers job. The copy should not be a single solid color.

IQ 16

IQ 22

n/a

Modified Restore Chart n/a

Acceptable to the customer on the customers job. Color balance is obtained as a result of doing Max Setup.

Copier Color Test Pattern n/a

Acceptable to the customer on the customers job. Color balance is obtained as a result of doing Max Setup.

IQ 23

n/a

IQ 25

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Output Defect Procedures

Table 3. Defects With Less Specific Characteristics


Image Defect Defect Sample Printer Test Pattern Used Printer Standards Copier/Printer Test Pattern Copier/Printer Standards Table 4 Reference

Contamination, Back Side or Side 2 of Print/ Copy Corrupted Video Data Deletions (Random)

n/a

Modified Restore Chart

Acceptable to the customer on the customers job.

Copier Color Test Pattern

Acceptable to the customer on the customers job.

IQ 26

Fig. 3

Modified Restore Chart DC612, Halftone (overall)

None allowed.

Copier Color Test Pattern DC612, Halftone (overall)

None allowed.

IQ 13

n/a

More than four random deletions greater than 1.0 mm or one A3 (11 x 17) print, or more than seven within a four-print run. Acceptable to the customer on the customers job. Nominal density is obtained as a result of doing Max Setup. Nominal density is obtained as a result of doing Max Setup. Inboard-to-outboard density is obtained as a result of doing Max Setup. Acceptable to the customer on the customers job.

More than four random deletions greater than 1.0 mm or one A3 (11 x 17) print/copy, or more than seven within a four-print/ copy run. Acceptable to the customer on the customers job. Nominal density is obtained as a result of doing Max Setup. Nominal density is obtained as a result of doing Max Setup. Inboard-to-outboard density is obtained as a result of doing Max Setup. Acceptable to the customer on the customers job.

IQ 15

Deletions (Single-color Streak) Density (High) Density (Low)

Fig. 6

DC612, Halftone (overall) Modified Restore Chart Modified Restore Chart

DC612, Halftone (overall) Copier Color Test Pattern Copier Color Test Pattern

IQ 10

n/a

IQ 21

n/a

IQ 20

Density (Uneven) Fuser Oil Streaks

n/a

Modified Restore Chart Modified Restore Chart

Copier Color Test Pattern Copier Color Test Pattern

IQ 19

n/a

IQ 4

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Table 3. Defects With Less Specific Characteristics


Image Defect Defect Sample Printer Test Pattern Used Printer Standards Copier/Printer Test Pattern Copier/Printer Standards Table 4 Reference

Granularity

n/a

Modified Restore Chart Modified Restore Chart Modified Restore Chart Modified Restore Chart Modified Restore Chart Modified Restore Chart Modified Restore Chart

No worse than the granularity on the Reference Test Pattern. Color must not be shifted.

Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern

No worse than the granularity on the Reference Test Pattern. Color must not be shifted.

IQ 17

Grossly Shifted Color Plane Hollow Characters Image Slip

n/a

IQ 18

n/a

Acceptable to the customer on the customers job. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job.

Acceptable to the customer on the customers job. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job.

IQ 27

Fig. 9

IQ 5

Lines

n/a

IQ 10

Low Contrast Reproduction Marks, Rib and Water

n/a

IQ 19

Figs. 14, 15, 16

IQ 6

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Output Defect Procedures

Table 3. Defects With Less Specific Characteristics


Image Defect Defect Sample Printer Test Pattern Used Printer Standards Copier/Printer Test Pattern Copier/Printer Standards Table 4 Reference

Misregistration (Colorto-Color)

n/a

Modified Restore Chart

The bottom edge of any horizontal line in one color should not protrude beyond the top edge of the adjoining colored line. The right hand side of any vertical line in one color should not protrude past the left hand side of the adjoining colored line. Lead/side edge registration and side edge skew must be checked and correct by a CST. None allowed. n/a

Copier Color Test Pattern

The bottom edge of any horizontal line in one color should not protrude beyond the top edge of the adjoining colored line. The right hand side of any vertical line in one color should not protrude past the left hand side of the adjoining colored line. Lead/side edge registration and side edge skew must be checked and correct by a CST. None allowed. Moire present in area H is acceptable; moire present in area I is unacceptable. No worse than the mottle on the Reference Test Pattern. Acceptable to the customer on the customers job. No noticeable offsetting. No noticeable residual image.

IQ 29

Misregistration (System) Missing Colors Moire

n/a

Modified Restore Chart

Copier Color Test Pattern

Place a service call

n/a n/a

Modified Restore Chart Modified Restore Chart Modified Restore Chart Modified Restore Chart Modified Restore Chart Modified Restore Chart

Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern

IQ 14 IQ 31

Mottle

Fig. 7

No worse than the mottle on the Reference Test Pattern. n/a

IQ 24

Newton Rings Offsetting, Fuser Residual Image

Fig. 13

IQ 32

n/a n/a

No noticeable offsetting. No noticeable residual image.

IQ 3 IQ 2

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Table 3. Defects With Less Specific Characteristics


Image Defect Defect Sample Printer Test Pattern Used Printer Standards Copier/Printer Test Pattern Copier/Printer Standards Table 4 Reference

ROS Borders Spots, (Periodic or Random) Black or Color

n/a n/a

Modified Restore Chart Modified Restore Chart

Lead/side/trail edge: 4 mm (all trays) There should be no random or repetitive spot greater than 0.5 mm; or more than 20 random spots between 0.2 to 0.5 mm on one A3 (11 x 17) print. There should be no random or repetitive white spot greater than 0.5 mm; or more than 6 spots between 0.2 to 0.5 mm on one A3 (11 x 17) print. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job. n/a

Copier Color Test Pattern Copier Color Test Pattern

Lead/side/trail edge: 4 mm (all trays) There should be no random or repetitive spot greater than 0.5 mm; or more than 20 random spots between 0.2 to 0.5 mm on one A3 (11 x 17) print/copy. There should be no random or repetitive white spot greater than 0.5 mm; or more than 6 spots between 0.2 to 0.5 mm on one A3 (11 x 17) print/ copy. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job. Acceptable to the customer on the customers job.

IQ 30 IQ 11

Spots, Periodic or Random) White

n/a

DC612, Halftone (overall)

DC612, Halftone (overall)

IQ 11

Smears

n/a

Modified Restore Chart Modified Restore Chart Modified Restore Chart

Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern

IQ 10

Streaks

Fig. 6

IQ 10

Text/Image Separation Errors Mosaic

Fig. 10

IQ 33

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Output Defect Procedures

Table 3. Defects With Less Specific Characteristics


Image Defect Defect Sample Printer Test Pattern Used Printer Standards Copier/Printer Test Pattern Copier/Printer Standards Table 4 Reference

Text/Image Separation Errors Vacant Characters Text/Image Separation Errors Small Dark Dots on Text Toner Starvation Unfused Print/Copy Water Stains

Fig. 11

Modified Restore Chart

n/a

Copier Color Test Pattern

Acceptable to the customer on the customers job.

IQ 33

Fig. 12

Modified Restore Chart

n/a

Copier Color Test Pattern

Acceptable to the customer on the customers job.

IQ 33

Fig. 8

Modified Restore Chart Modified Restore Chart Modified Restore Chart Modified Restore Chart

No worse than the mottle on the Reference Test Pattern. None allowed. Acceptable to the customer on the customers job. None allowed.

Modified Restore Chart Copier Color Test Pattern Copier Color Test Pattern Copier Color Test Pattern

No worse than the mottle on the Reference Test Pattern. None allowed. Acceptable to the customer on the customers job. None allowed.

IQ 9

n/a Fig. 5

IQ 7 IQ 6

Wrinkled Print/Copy

n/a

IQ 8

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Table 4. Corrective Actions

Defect Name
IQ 2 Residual Image

Corrective Action
This procedure is used when any noticeable residual image is present. Procedure: Using the DCU, make all four single-color halftone prints to isolate the problem color (GP 9). Classify your observation (choose step 1 or 2): 1. The problem is present in all four colors: Perform the GP1 xerographic Hardstop procedure. If the defect is present on the IBT image, replace the IBT Cleaner Assembly. (REP 9.5) If the defect is not present on the IBT image, perform ADJ 10.1 Fuser Nip. If the problem still remains, replace all these parts at the same time (except the ones that might have been replaced already during this call): Heat Roll Assembly (REP 10.3) Fuser Belt Assembly (REP 10.2) (Heat Roll) Wick (REP 10.11) Donor Roll Assembly (REP 10.10) After replacing these parts, advance the web material manually to a clean area. (REP 10.9) If the problem still exists: Place a service call. 2. The problem is present in a single color: Replace the Drum Assembly (REP 9.1) that exhibits the problem.

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Output Defect Procedures

Table 4. Corrective Actions

Defect Name
IQ 3 Offsetting, Fuser

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

WARNING Switch off the Power, disconnect the Power Cord, and apply the Safety Lockout Kit (GP 7). Allow the Fuser to cool before performing this procedure. Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components.

Cam open the Fuser Assembly (REP 10.1) and if excess Toner is present, attempt to clean excess Toner off the affected fuser components using the Fuser Subsystem Maintenance (in Section 1). Procedure: 1. Clean or replace these parts all at the same time (except the ones that might have been replaced already during this call): Heat Roll Assembly (REP 10.3) Fuser Belt Assembly (REP 10.2) External Heat Roll (REP 10.7) - Clean only, using a water-moistened lint-free cloth. (Heat Roll) Wick (REP 10.11) Donor Roll Assembly (REP 10.10)

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

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Table 4. Corrective Actions

Defect Name
IQ 4 Oil Streaks

Corrective Action
This procedure is used when any noticeable oil streaks are present. Procedure: 1. Clean or replace all these parts one at a time (except the ones that might have been replaced already during this call): Fuser Belt Assembly (REP 10.2) External Heat Roll (REP 10.7) - Clean only, using a water-moistened lint-free cloth. Donor Roll Assembly (REP 10.10)

2. After cleaning or replacing a part, advance the web material manually to a clean area. (REP 10.9) If the problem still exists: Place a service call. IQ 5 Image Slip This procedure is used when there is an image disturbance problem just prior to fusing, usually in the form of a band located along the lead edge of a print/copy. Procedure: 1. Replace the Fuser Belt Assembly. (REP 10.2) If the problem still exists: Place a service call.

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Table 4. Corrective Actions

Defect Name
IQ 6 Marks, Rib and Water (Also known as Water Stains)

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

WARNING Switch off the Power, disconnect the Power Cord, and apply the Safety Lockout Kit (GP 7). Allow the Fuser to cool before performing this procedure. Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components.

Procedure:

CAUTION Before performing the Fuser Pad Spring adjustment, be sure to perform all prerequisite checks and actions exactly as indicated. 1. Perform the following: Fuser Pad Spring adjustment (ADJ 10.2) If the problem still exists: Place a service call.

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Table 4. Corrective Actions

Defect Name
IQ 7 Unfused Print/Copy

Corrective Action
This procedure is used when fuser fixing is not within specifications. Initial Action: NOTE: This problem usually occurs because of lack of heat/pressure in the Fuser, or because of excess Toner on the print/copy. Ensure that the correct paper weight has been selected for the paper being used. Procedure NOTE: Setting the nip width near the maximum allowed will provide the best fusing. 1. Perform ADJ 10.1 Fuser Nip. If the problem remains: Perform ADJ 9.1 Max Setup to ensure that the output density is not too high. If the problem still exists: Place a service call.

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Table 4. Corrective Actions

Defect Name
IQ 8 Wrinkles

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

IQ 9 Toner Starvation

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

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Table 4. Corrective Actions

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

Corrective Action
This Procedure is used when the lOT output image shows light or dark bands, lines, or streaks in the lead edge to trail edge direction. Initial Actions: Ensure that all HFSI items that are near or over threshold have been replaced. If the problem only occurs in the copier mode, check for dark rings around the circumference of the Exposure Lamp in isolated areas. Replace the Lamp as required. (REP 6.4)

Procedure Using the DCU, make all four single-color halftone prints to isolate the problem color (GP 9). Classify your observation (choose step 1 or 2): 1. The problem is light bands, lines, smears, or streaks: NOTE: If the defect is present in all four colors, check for foreign materials contacting the IBT Belt at the area between the 1st BTR and the 2nd BTR. (Refer to IBT Belt REP 9.9) NOTE: If the defect is present in single color, perform these actions in the following order: Inspect the BPO Mag Roll (REP 9.4) for developer bead buildup and clean it as required. Replace the Charge Corotron and Screen (REP 9.2) for the problem color. Replace the 1st BTR (REP 9.10) for the problem color.

If the problem still exists: Place a service call. 2. The problem is dark bands, lines, smears, or streaks: NOTE: If the defect is present in all four colors, check for poor cleaning of the IBT Belt. Replace the Belt Cleaner Blade Assembly (REP 9.6) as required. NOTE: If the defect is present in single color, perform these actions in the following order: Clean the ROS Seal Glass (REP 6.2) for the problem color (continued on next page)

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Output Defect Procedures

Table 4. Corrective Actions

Defect Name
IQ 10 (Continued) IQ 11 White, Black Or Colored Spots

Corrective Action
Check the drum for the problem color for scratches or damage. Replace the Drum as required (REP 9.1). If the problem is poor cleaning, replace the Drum. (REP 9.1) Check for foreign materials contacting the drum for the problem color at the area between charging and development. Replace the Drum Assembly (REP 9.1) for the problem color.

This Procedure is used when the lOT output print/copy has white, black, or colored spots. Initial Actions For a copier-only problem, inspect and clean the Platen Glass. (REP 6.3) For a two-sided only problem, inspect and vacuum the Vacuum Transport 1 and 2 Assembly. (REP 8.1) If the problem remains, inspect and clean the 2nd BTR Roll Assembly. (REP 9.14)

Procedure Using the DCU, make all four single-color halftone prints to isolate the problem color (GP 9). Classify your observation (choose step 1, 2 , or 3): 1. The problem is present only in black: Replace the Drum Assembly. (REP 9.1) Inspect, clean and/or replace the IBT Belt (REP 9.9) as required. Replace the Developer Material (REP 9.19) for the problem color and perform Max Setup. (ADJ 9.1) 2. The problem is present in all four colors: 3. The problem is present in only one color: If the problem still exists: Place a service call.

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Table 4. Corrective Actions

Defect Name
IQ 12 Background

Corrective Action
This Procedure is used when the output image shows background greater than the specification. Initial Action: If this is a copier-only problem, ensure that the original is in good condition and that it is held flat against the Platen Glass. If the problem remains, clean the mirrors. (REP 6.5) Ensure that all HFSI items (especially the developer material for all four colors) that are near or over threshold have been replaced.

Procedure: 1. Perform the GP1 xerographic Hardstop procedure. If background is present between the IBT Cleaner Assembly and the yellow Drum Assembly, replace the IBT Cleaner Assembly. (REP 9.5) If background is present across the entire top surface of the IBT Belt, perform ADJ 9.1 Max Setup.

If the problem still exists: Place a service call. IQ 13 Corrupted Video Data This Procedure is used for a printer-only image quality problem. Initial Action: Ensure that the cables between the DFE and the VSEL PWBs (reference GP 6, Fig. 1) are connected securely. Procedure: Place a service call. IQ 14 Missing Colors This Procedure is used when a variety of image defects occur when printing in the customer mode but do not occur when printing halftones using the Diagnostic Control Unit. (GP 9) Initial Action: Ensure that the cable between the DFE and the VSEL PWB (reference GP 6, Fig. 1) for the problem color is connected securely. Procedure: Place a service call. 04/02 3.1-27

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Output Defect Procedures

Table 4. Corrective Actions

Defect Name
IQ 15 Deletions (Random)

Corrective Action
This Procedure is used when the output copy is experiencing deletions that are not shown in the Image Quality Defect Samples. Initial Actions: Load some new, dry 24 lb. 11X17/A3 Xerox Color Xpressions (XC), or 90 GSM Colotech + (XE) into each paper tray. Ensure that the developer material for all four colors that are near or over threshold have been replaced.

Procedure: Using the DCU, make all four single-color halftone prints to isolate the problem color (GP 9). Classify your observation (choose step 1, 2, or 3): 1. The deletion occurs from only one tray in all colors: NOTE: For the problem tray, replace both components at the same time. (If accessible) Tray 1 Feed/Nudger Roll Assembly (REP 7.14) and the Tray 1 Retard Roll. (REP 7.15) (If accessible) Tray 2 Feed/Nudger Roll Assembly (REP 7.14) and the Tray 2 Retard Roll. (REP 7.15) Tray 3 Feed Roll Assembly (REP 7.10) and the Tray 3 Retard Roll. (REP 7.11) Replace the 1st BTR (REP 9.10) for the problem color. Replace the IBT Belt. (REP 9.9)

2. The deletion occurs from all trays in one colors: 3. The deletion occurs from all trays in all colors: If the problem still exists: Place a service call. IQ 16 Bead Carry Out This Procedure is used when the copy is experiencing bead carry out. This defect is felt as a fine grit on the surface of the copy Procedure: Place a service call.

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Table 4. Corrective Actions

Defect Name
IQ 17 Granularity

Corrective Action
This Procedure is used when the output copy shows graininess, or a sandy, textured appearance. Initial Actions: NOTE: Paper outside the specified weight and quality range can increase graininess. Heavy weight papers are particularly susceptible. Load some new, dry 24 lb. 11X17/A3 Xerox Color Xpressions (XC), or 90 GSM Colotech + (XE) into each paper tray. Ensure that all HFSI items that are near or over threshold have been replaced.

Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 18 Grossly Shifted Color Plane This Procedure is used when one or more color planes are shifted by 1/2 inch or more from its normal position. Procedure: Place a service call. IQ 19 Uneven Density This Procedure is used when the IOT output image shows uneven density in the inboard-to-outboard direction. Initial Action: Ensure that all HFSI items that are near or over threshold have been replaced. Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call.

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Table 4. Corrective Actions

Defect Name
IQ 20 Low Image Density

Corrective Action
This Procedure is used when the final output image is noticeably low. Initial Actions: NOTE: Paper outside the specified weight and quality range can increase graininess. Heavy weight papers are particularly susceptible. Load some new, dry 24 lb. 11X17/A3 Xerox Color Xpressions (XC), or 90 GSM Colotech + (XE) into each paper tray. Ensure that all HFSI items that are near or over threshold have been replaced.

Procedure: 1. Clean all the ADC Sensors (REP 9.13), then perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 21 High Image Density This Procedure is used when the final output image is noticeably high. Initial Action: Ensure that all HFSI items that are near or over threshold have been replaced. Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 22 IOT Solid Single-Color Print/Copy The Procedure is used when the print/copy is a solid single color with no original image seen on the print/ copy. Procedure: 1. Replace the Drum Assembly (REP 9.1) that exhibits the problem. If the problem remains: Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. 04/02 3.1-30

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Table 4. Corrective Actions

Defect Name
IQ 23 Blurred or Fuzzy Image

Corrective Action
The Procedure is used when the image is not clear, or appears out of focus. Initial Actions: Load some new, dry 24 lb. 11X17/A3 Xerox Color Xpressions (XC), or 90 GSM Colotech + (XE) into each paper tray. Ensure that all HFSI items that are near or over threshold have been replaced.

Procedure: Place a service call. IQ 24 Mottle The Procedure is used when the output image has mottle or a mottle-like defect. Initial Actions: NOTE: Mottle can occur when using lower quality paper, paper which is not in specification for this machine (refer to the customers Materials Usage Guide and Recommended Paper List), paper that has a high moisture content, or a paper supply setting that does not match the paper that is installed in it. Replace the paper presently being used with new 24 lb. Xerox Color Xpressions (XC), or 90 GSM Colotech + (XE) paper and run test prints. Or, ensure that the customer has calibrated the DFE to match the type of paper being used. (Depending on what DFE is used in the system, refer the customer to the Fiery EX2000 Printer Guide, Chapters 16 and 18, or to the CSX Printing Guide, for detailed information.) Ensure that the paper weight and type selected match the weight and type of the paper itself.

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

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Table 4. Corrective Actions

Defect Name
IQ 25 Poor Color Balance

Corrective Action
The Procedure is used when the gray areas of the print/copy appears to have a magenta, yellow or cyan hue, rather than true gray. Initial Actions: Ensure that the system is properly calibrated and that the customer is using the 200 rotated dot screen. This is the only screen for which the color is balanced. When calibrating, use expert mode in the calibration screen to check that measured values of C, M, and Y are above or generally above the target values. If the measured values are well below the targets, perform the adjustment below.

Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 26 Back Side or Side Two Print/ Copy Contamination The Procedure is used for Back Side and Side-Two print/copy contamination. Initial Action: Ensure that all paper transports (refer to REP 8.1, 8.5 and 8.6), including the 2nd BTR Roll Assembly (REP 9.14) are clean.

Procedure: Place a service call. IQ 27 Hollow Characters This Procedure is used for small circular-shaped deletions with a character. Initial Action: Ensure that all HFSI items that are near or over threshold have been replaced. Procedure: Place a service call.

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Table 4. Corrective Actions

Defect Name
IQ 28 Low Contrast Reproduction

Corrective Action
This Procedure is used when the highlight image is wiped out or the density of highlight images is too low. Initial Actions: Load some new, dry 24 lb. 11X17/A3 Xerox Color Xpressions (XC), or 90 GSM Colotech + (XE) into each paper tray. Ensure that all HFSI items that are near or over threshold have been replaced.

Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 29 Color-toColor Misregistration This Procedure is used when multi-colored images are not superimposed. Procedure: 1. Perform ADJ 9.1 Max Setup. If the problem still exists: Place a service call. IQ 30 ROS Borders The Procedure is used when the intentional border deletions do not meet specification. Initial Action: Using the Tools Mode, select the tab labeled Feature Defaults 1; then choose Edge / Center Erase and the Border Erase option to set the uniform width of the border. If this dimension needs to be fine-tuned, select the Edge / Center Erase options to adjust the top, bottom, left, right, and center as required.

Procedure: Place a service call.

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Table 4. Corrective Actions

Defect Name
IQ 31 Moire

Corrective Action
The Procedure is used when the halftone screen in the original interferes with the halftone screens being generated by the copier. Initial Actions: Select the tab labeled Image Quality; then choose Original Type. If either Auto Photo & Text or Photo is selected, ensure that the Photo option (not Halftone or xerographic Copy) is chosen. Change the orientation of the original by rotating it 90 degrees. Select the tab labeled Image Quality; then choose Sharpness. Ensure that the Softest option is chosen. Reduce or enlarge the copy slightly (example, 95% or 105%). Select the tab labeled Image Quality; then choose Original Type. Ensure that the Maps option is chosen.). Procedure: Place a service call.

IQ 32 Newton Rings

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

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Table 4. Corrective Actions

Defect Name
IQ 33 Text / Image Separation

Corrective Action
The Procedure is used when using the Original Type options of Auto Photo and Text or Text, the copier attempts to discriminate between text and photo areas within the original. On occasion, a defect may appear where an area is classified incorrectly and text is treated as photo or vise-versa. Initial Actions: Select the tab labeled Image Quality; then choose Original Type. If either Auto Photo & Text or Photo is selected, ensure that the Photo option (not Halftone or xerographic Copy) is chosen. Change the orientation of the original by rotating it 90 degrees. Select the tab labeled Image Quality; then choose Sharpness. Ensure that the Softest option is chosen. Reduce or enlarge the copy slightly (example, 95% or 105%). Select the tab labeled Image Quality; then choose Original Type. Ensure that the Maps option is chosen. Using the Tools Mode, select the tab labeled Machine Defaults 2; then choose Auto Recognition and Text: Photo. Depending on the type of separation problem your are having, you can try the following: For a problem with distorted text, select Auto Photo & Text: Level 2 or 1; for a problem with a photograph, select Auto Photo & Text: Level 4 or 5. Procedure: Place a service call.

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3.2.1 General Information


The Image Quality Specification section contains the following subsections: 3.2.2 IOT Setup for Full Color Output Check. This procedure is intended to be used to judge machine output for proper density, color balance and color fidelity.

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

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

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

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3.2.2 IOT Setup For Full-Color Output Check (With Modified Restore Chart)
The following steps are used to set up the machine for the purpose of making DFE test pattern prints to judge output images for density, color balance, and color fidelity. 1. Load 24# Xerox Color Xpressions 11 X 17 (USCO), or 90 GSM Colotech A3 (XL) paper (if available) in Tray 2. NOTE: For the Fiery EX2000, go to step 2. For the Creoscitex CSX2000, go to step 3. 2. Using the Web Down Loader, download the file: Restore11x17.pdf or RestoreA3.pdf file on the Fiery EX2000 in order to make test prints. NOTE: See the xerox RIP Installation Worksheet for this installation to determine the designated client workstation. a. Launch the Internet browser application on the designated client workstation. b. Insert the CD containing the Restore11x17.pdf and RestoreA3.pdf files. c. Enter the IP address of the Fiery EX2000 from the current Configuration page (see To print a Configuration page from the Control Panel.). NOTE: An alternative method is to get access is to use the DNS name. This name can be obtained from the network administrator. It is case-sensitive and must be entered exactly. d. If a Log In dialog box appears, select Guest and click OK. (This box appears only if the administrator has set a password.) e. When the Fiery EX2000 home page appears, click to select WebDownloader. Then move the cursor over the buttons to display information about the selections. f. Select the destination.

NOTE: A file can be downloaded directly (Direct) or sent to the Print or Hold queues. Files sent to the Print or Hold queue are spooled in the printers memory. Files sent to the Hold queue remain in memory until they are moved to the Print queue or are deleted. Choose the Hold Queue if you need to set the properties before printing. For setting properties, see the Printing Guide. g. Click Browse to search for the desired file. Then select this file and click Open. NOTE: The Restore11x17.pdf and RestoreA3.pdf files will be found on the CD inserted into the workstation. h. Click Download to produce a 200 dot screen print; label it and set it aside. i. After printing is completed, click WebSpooler and find the Restore11x17.pdf or RestoreA3.pdf file. j. Double-click this file and choose the Image Quality tab. k. Change the Digital Press Mode to 600 Line 90 deg fixed. l. Click OK, then select Job/Print from the herald at the top of the page to produce a 600 line screen print; label it and set it aside. 3. Loading the file: Restore11x17.pdf or RestoreA3.pdf, on the Creoscitex CSX2000 in order to make test prints. a. Insert the CD containing the Restore11x17.pdf and RestoreA3.pdf files. b. Choose Job\Import Job at the top left corner of the screen. c. Navigate to the CD ROM, drive E, and click the Restore11x17.pdf or RestoreA3.pdf" file. d. Set the Virtual Printer" box to PrintToStore". e. Click Add to List and then Submit", when this button becomes available. NOTE: The submitted file will RIP, and then it will appear at the top of the Storage folder on the right side of the screen. f. Double-click the stored file and a menu will appear. g. Click Paper Stock and choose the following: Tabloid, paper, 81105, uncoated and Tray 2. NOTE: Say Yes to any messages that might appear. h. Select Color and then Calibration. i. Choose None. j. Choose Screening Method and then Dot 200.
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Image Quality Specifications

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k.

Click Submit to produce a 200 dot screen print; label it and set it aside. l. Double-click the stored file again and a menu will appear. m. Click Paper Stock and ensure that the following are still selected: Tabloid, paper, 81-105, uncoated and Tray 2. NOTE: Say Yes to any messages that might appear. Select Color and then Calibration. Choose None. Choose Screening Method and then Line 600. Click Submit to produce a 600 line screen print; label it and set it aside. NOTE: When performing the following step, use the Modified Restore Chart printed with the 200 dot screen (except where indicated) when making comparisons. 4. Compare the designated areas on the Modified Restore Chart to the original Reference Test Pattern shipped with the machine. 5. Follow the directions under Table 1B Checks to Perform to ensure that the prints comply with the color standards. n. o. p. q.

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Image Quality Specifications

3.2.2.1 IOT Color Standards


Table 1 - B 3.2.2.1 Color Standards - Test Patterns Used TEST PRINT (AREA USED)

CHECKS TO PERFORM

RECOMMENDED REPAIR CRITERION

Background Overall No obvious background under normal viewing conditions Granularity: Compare the black, magenta, and cyan (99%, 60% and A Worse than Reference Test Pattern 20%) patches near the center of the Modified Restore Chart to the identical patches on the Reference Test Pattern. A (m,c,k) Worse than Reference Test Pattern Mottle: Compare the magenta, cyan, black and green (99% and 60%) C (g) patches near the center of the Modified Restore Chart to the identical patches on the Reference Test Pattern. Banding in Halftones: Check the horizontal portion of the H band B Not acceptable to the customer on the customers job Inboard-to-Outboard Color Density: Check one of the prints by folding it B Clearly visible imbalance in the center and comparing the inboard side to the outboard side. Lines Overall Any visible unwanted line Streaks Overall Not acceptable to the customer on the customers job Spots (black or color): Check the black prints made at 20 Cin%, the 3C Overall Any random or repetitive spot greater than 0.5 mm; or more than 20 prints made at 20 Cin%, and the 3C print made at 60 Cin%. (DC612, 3-1) random spots between 0.2 to 0.5 mm on one A3 (11 x 17) print White Spots/Deletions/Debris Centered Deletions (DCDs): Check the Overall Any repetitive white spot or deletion greater than 0.5 mm; or more than black prints made at 20 Cin%, the 3C prints made at 20 Cin%, and the (DC612, 3-1) 6 spots between 0.2 to 0.5 mm on one A3 (11 x 17) print 3C print made at 60 Cin%. More than four random spots/deletions/DCDs greater than 1.0 mm on one A3 (11 x 17) print, or more than seven within a four-print run Residual Image: Check the black print and the 3C prints made at 20 Overall Any noticeable residual image Cin%. (DC612, 3-1) Color-to-Color Registration: Use the DFE Modified Restore Chart D The bottom edge of any horizontal line in one color protrudes beyond printed at 600 L to compare its color line pairs to the color line pairs on (600 Line) the top edge of the adjoining colored line. The right hand side of any the Reference Test Pattern. vertical line in one color protrudes past the left hand side of the adjoining colored line. Unfused Print Overall Toner should not smear when rubbed with moderate pressure. Excess Oil on Print Overall Feels oily, has visible oil marks, or customer complaint Excessive Curl: Check made with sheet lying on a flat surface. Overall 13 mm maximum on all four corners Line Density: Use the DFE Modified Restore Chart printed at 600 L to E Worse than Reference Test Pattern compare the darkness of its fine (2 pixel) lines to the fine lines on the (600 Line) Reference Test Pattern. Line Width Uniformity (slow and fast scan): Use the DFE Modified E Worse than Reference Test Pattern Restore Chart printed at 600 L to compare its fine lines to the fine lines (600 Line) on the Reference Test Pattern.

Image Quality Specifications

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Lead Edge

Figure 1 Modified Restore Chart

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Image Quality Specifications

3.2.5 DFE Test Pages


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

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

Image Quality Specifications

04/02 3.2-6

DocuColor 2060/2045

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

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

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04/02 3.2-7

Image Quality Specifications

3.2.6 Copier Setup For Full Color Output Check


The following steps are used to set up the machine for the purpose of making test pattern copies to judge the output image for color fidelity. This procedure should be used for judging Full Color output only. 1. Set the following Basic Feature option to the selection indicated: a. Output Color - Full Color 2. Set the following Image Quality options to the selections indicated: a. Original Type - Auto Photo & Text b. Lighter/Darker - Auto c. Color Balance - Off d. Chroma - Normal e. Sharpness - Normal 3. Place (Copier Color Test Pattern 82E13120) on the platen, load 24# Xerox Color Xpressions 11 X 17 (USCO), or 90 GSM Colotech A3 (XL) paper (if available) in Tray 2, and make a copy. 4. Refer to Color Specifications (3.2.6.1 Color Copier Specifications) to evaluate the copy of the test pattern.

3.2.6.1 Copier Color Specifications


Figure 1 illustrates Test Pattern 82E13120. Table 1 items A through I correspond to locations on the test pattern. These locations contain image data designed to test for different image specifications.
3.2.6.1 Copier Color Specifications - Test Pattern Image Data Check Locations AREA A CHECK PERFORMED Text Reproduction Check. Each of the seven sentences in this area are fully reproduced with no missing letters or portions of letters. The sentences are reproduced in Black, Cyan, Magenta, Yellow, Red, Green and Blue. Color Registration Check. The patterns in location B should be properly registered to provide Black, Red, Green and Blue lines. Inboard-to-Outboard Color Density Check. The density of both the low density and high density bands should be uniform from inboard to outboard. This can be tested by folding the copy in the center and comparing the inboard side of the copy to the outboard side of the copy at location C. Both the high density and low density locations should exhibit even inboard-to-outboard density. Color Gradation Check. This area should exhibit a decreasing density of each of the colors from 100% density to 5% density. In a properly adjusted machine, the 10% patches should be visible and the 5% patches should be barely visible or not visible on the test pattern copy (except for the bottom row). Routine Color Check. Location E represents three general tests for the machine to reproduce colors common to customer originals. Location A is a general skin tone test. Location B represents the color of grass or other common foliage. Location C represents the color of the sky. Photo Gradation Check. Location F is not used for any copy quality evaluation on this product. IIT Calibration Patches. These patches are scanned for IIT Calibration during the DC945 IIT Calibration portion of Max Setup. 100 Lines/Inch Image. A Moire defect will show on this image. Moire on a 100 Line/Inch image is within specification. 175 Lines/Inch Image. This image is used to test for Moire. Depending on the degree of the defect, moire seen on this image should be considered out of specification.

B C

F G H I

Image Quality Specifications

04/02 3.2-8

DocuColor 2060/2045

Lead Edge

Copier Color Test Pattern 82E13120

DocuColor 2060/2045

04/02 3.2-9

Image Quality Specifications

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

3.3.2 Image Defect Samples


The following figures contain examples of signatures and their possible causes. Figure 1 Bead Carryout, Single-Color Band (Faint) Figure 2 Bead Carryout, Single-Color Band (Severe)

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

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

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Image Quality Defect Samples

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04/02 3.3-2

DocuColor 2060/2045

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

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

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

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

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

DocuColor 2060/2045

04/02 3.3-3

Image Quality Defect Samples

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04/02 3.3-4

DocuColor 2060/2045

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Figure 3 Corrupted Video Data

Figure 4 Rainbow-Like Single or Multi-Color Bands

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

CAUSE: Contaminated Charge Scorotron Wire. CORRECTIVE ACTION: Go to IQ 10 of the Corrective Action Table in Section 3

Go to IQ 13 of the Corrective Action Table in Section 3

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04/02 3.3-5

Image Quality Defect Samples

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04/02 3.3-6

DocuColor 2060/2045

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Figure 5 Water Stains

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

CAUSE: Likely caused by incorrect fuser nip pressure. CORRECTIVE ACTION:

CAUSE: BPO Mag Roll developer bead buildup. The drum is sometimes damaged in this case. CORRECTIVE ACTION:

Go to IQ 6 of the Corrective Action Table in Section 3 Go to IQ 10 of the Corrective Action Table in Section 3

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04/02 3.3-7

Image Quality Defect Samples

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04/02 3.3-8

DocuColor 2060/2045

Lead Edge

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Figure 7 Mottle (With Some Granularity)

Figure 8 Toner Starvation Between Low Density and High Density Area

CAUSE: Damp or low quality paper, aged developer material, or low toner concentration. CORRECTIVE ACTION: Go to IQ 24 of the Corrective Action Table in Section 3

CAUSE: A localized area of the magnetic brush becomes starved for toner due to development fringe field effects. CORRECTIVE ACTION: Go to IQ 9 of the Corrective Action Table in Section 3

DocuColor 2060/2045

04/02 3.3-9

Image Quality Defect Samples

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Image Quality Defect Samples

04/02 3.3-10

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 9 Image Slip

Figure 10 Mosaic (5x actual size)

CAUSE: Likely caused by problems associated with the Pad Wick and Sheet Pad. CORRECTIVE ACTION: Go to IQ 5 of the Corrective Action Table in Section 3

CAUSE: Text / Image Separation errors in Text and Text / Photo modes. CORRECTIVE ACTION: Go to IQ 33 of the Corrective Action Table in Section 3

DocuColor 2060/2045

04/02 3.3-11

Image Quality Defect Samples

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04/02 3.3-12

DocuColor 2060/2045

Lead Edge

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Figure 11 Vacant Characters (5x actual size)

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

CAUSE: Text / Image Separation errors in Text and Text / Photo modes. CORRECTIVE ACTION: Go to IQ 33 of the Corrective Action Table in Section 3

CAUSE: Text / Image Separation errors in Text and Text / Photo modes. CORRECTIVE ACTION: Go to IQ 33 of the Corrective Action Table in Section 3

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04/02 3.3-13

Image Quality Defect Samples

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Image Quality Defect Samples

04/02 3.3-14

DocuColor 2060/2045

Lead Edge

Lead Edge

Figure 13 Newton Rings (5x actual size)

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

CAUSE: Highly reflective surfaces on a glossy photograph. CORRECTIVE ACTION:

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

Go to IQ 32 of the Corrective Action Table in Section 3 Go to IQ 6 of the Corrective Action Table in Section 3

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04/02 3.3-15

Image Quality Defect Samples

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04/02 3.3-16

DocuColor 2060/2045

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Lead Edge

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

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

CAUSE: They are caused by one or more of the following: Incorrect pad force, incorrect pressure roll nip, or a low oil condition. CORRECTIVE ACTION: Go to IQ 6 of the Corrective Action Table in Section 3

CAUSE: They are caused by one or more of the following: Incorrect pad force, incorrect pressure roll nip, or a low oil condition. CORRECTIVE ACTION: Go to IQ 6 of the Corrective Action Table in Section 3

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04/02 3.3-17

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04/02 3.3-18

DocuColor 2060/2045

4. Preventive Maintenance
Section Contents Page

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

DocuColor 2060 / 2045 eXcellerate Service Manual

04/02 4-1

Preventive Maintenance

Introduction
Some parts or assemblies used in the DocuColor 2060 / 2045 should be cleaned or checked at regular intervals. The interval between the required maintenance is based on copy count. Because of different machine environments, varying amounts of machine use, and a variety of paper quality used, the interval between maintenance actions for a given maintenance item may vary from the suggested interval. Always clean any component in need of cleaning whenever it is made accessible during repair of the copier. The Cleaning Procedures, along with the High Frequency Service Items (HFSI), provide the necessary information to maintain the copier subsystems at a high level of reliability.

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

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

Preventive Maintenance

04/02 4-2

DocuColor 2060 / 2045 eXcellerate Service Manual

High Frequency Service Items (HFSI)


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

Note: The HFSI Items that are Bolded are the eXcellerate items that will require service. All other items will be performed by a Xerox Customer Service Engineer. Table 1. DC135 HFSI List

1. Enter the TKO Diagnostic Pathway and select DC135 HSFI Counters. 2. Use this table to determine the action to be performed if any High Frequency Service Item (HFSI) counter is over threshold (indicated by a RED marker) or approaching the threshold (indicated by a yellow marker). Using the customers output volume numbers (high, medium, or low volume) and this machines history, evaluate which HFSI actions should be serviced at this time. Note: If any HFSI Items are tagged yellow, for approaching Threshold, determine whether it is appropriate to perform a service procedure based on the Threshold Number and the area of the machine you are working in. 3. Refer to Cleaning Procedures for detailed cleaning instructions. 4. Clear the code of each HFSI item that was performed on the service call.

Chain Link No. No.

Item

REP Reference Threshold #

004 004 004


005

810 (Suction Blower) Filter 811 Ozone Filter 812 (Dust Blower) Filter
800 (Document Feed Chute) Feed Roll Kit / Nudger Roll Kit (Document Feed Chute) Retard Roll 801 DADF Platen Belt

100K 200K 200K


100K **

9.15 9.16 9.15

005

100K **

006

800 Exposure Lamp

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

6.4

006

801 IIT Scan Count

007 007 007 007 007 007 007 007 007


008 008 008 008

800 801 802 803 804 805 806 807 808


801 802 803 810

Feed / Retard / Nudger Roll -Tray 1 Feed / Retard / Nudger Roll -Tray 2 Feed / Retard / Nudger Roll -Tray 3 Tray 1 Feed Assembly Tray 2 Feed Assembly Tray 3 Feed Assembly Tray 1 Takeaway Roller Assembly Tray 2 Takeaway Roller Assembly Tray 3 Takeaway Roller Assembly
F Transport Roller Assembly J-Transport Drive Roller Assembly 1 and 2 J-Transport Drive Roller Assembly 3 and 4 Paper Aligner Roll / Aligner Pad Assembly

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


3000K 3000K 3000K 1500K

7.13/14 7.13/4 7.9 7.11 7.11 7.9

7.7

DocuColor 2060 / 2045 eXcellerate Service Manual

04/02 4-3

Preventive Maintenance

Chain Link No. No. 008

Item

REP Reference Threshold # 3000K

Chain Link No. No. 009 009 009 009 800 Developer (Y) 801 Developer (M) 802 Developer (C) 803 Developer (K) 804 BPO Trim (Y)

Item

REP Reference Threshold #

008 008 008 008 008

008

008

008 008

008 008

811 (Aligner Upper Chute) Registration Roll Assembly (Aligner Upper Chute) Registration Pinch Roll Assembly (Registration Size Shift Motor) Gear 812 Aligner Nip / Release Motor 1 Assembly 813 Registration Motor and Gear (single) / Gear (dual) 830 Vacuum Transport Belt -Transport 1 831 Vacuum Transport Belt -Transport 2 840 (Inverter Roller Assembly - Left) Clutch (Entrance Swing Assembly) Gear (Entrance Swing Assembly) Entrance Transport Clutch 841 (Exit Transport Assembly) Pinch Roll (Swing Transport Assembly) Entrance Roller Assembly (Swing Transport Assembly) Gear (Inverter 2 Transport) Pinch Roll (Exit Transport Assembly) Out Put Roller 850 (Inverter Roller Assembly - Left) Inverter Roller (Inverter Roller Assembly - Right (1 of 2)) Pinch Roll (Inverter Roller Assembly - Right (2 of 2)) Roller Assembly, Pinch Roll Assembly (Inverter 1 Transport Assembly (1 of 2)) Duplex Roller Assembly (Entrance Chute Assembly) Pinch Roll 851 (Inverter Roller Assembly - Right) Gear (Exit Transport Assembly) Gear 860 (Horizontal Transport) Cross Roll Assembly (Horizontal Transport) Aligner Pan Assembly 870 Decurler Belt Kit 871 (Decurler Roll) Enter Roll Assembly (Decurler Roll) El. Roll Assembly (Enter Chute) Pinch Roll Assembly

1500K 3000K 3000K 3000K 1500K

009 009 009 009 009 009 009 009 009 009 009 009

(Clean the (Clean the (Clean the (Clean the

512K 512K 512K 512K 1024K 1024K 1024K 1024K


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

9.19 9.19 9.19 9.19 9.4 9.4 9.4 9.4

BPO Assembly) 805 BPO Trim (M) BPO Assembly) 806 BPO Trim (C) BPO Assembly) 807 BPO Trim (K) BPO Assembly)
808 809 810 811 812 813 814 815

3000K

3000K

Developer Assembly Input Shaft (Y) Developer Assembly Input Shaft (M) Developer Assembly Input Shaft (C) Developer Assembly Input Shaft (K) BPO Assembly (Y) BPO Assembly (M) BPO Assembly (C) BPO Assembly (K)

009
009

820 Drum Assembly (Y)


821 Drum Cycle (Y) (Reset counter only)

100K
500K

9.1 9.1 9.1 9.1 9.18 9.22 9.23 9.14 9.6

009
009

822 Drum Assembly (M)


823 Drum Cycle (M) (Reset counter only)

100K
500K

009
1500K 1500K 009

824 Drum Assembly (C)


825 Drum Cycle (C) (Reset counter only)

100K
500K

009
009

826 Drum Assembly (K)


827 Drum Cycle (K) (Reset counter only)

100K
500K

3000K 3000K

009 009 009 009 009


009

828 829 840 841 842

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

200K 50K 100K 100K 100K


100K

845 2nd BTR Trim (Reset counter only)

Preventive Maintenance

04/02 4-4

DocuColor 2060 / 2045 eXcellerate Service Manual

Chain Link No. No.

Item

REP Reference Threshold #

009 009
009

846 (Transfer Belt - Inner) Cleaning Roll 847 (Transfer Drawer) IBT Belt
848 IBT Belt (Cycle) (Reset counter only)

800K 400K
137K

9.11 9.9 9.10 9.12 9.5 9.6 9.10 / 9.12

009 009 009 009 009


009 009

849 850 851 852 853

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

400K 400K 400K 400K 400K


1000K 1000K

854 Helical Gear - 96T 855 Exit Chute Assembly

010 010 010 010 010

800 801 802 803 804

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

(Fuser Web Assembly) Web Material Assembly


NOTE: This is not actual print

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

10.3

10.9

count. This counter displays print count x100.


010 010 806 Donor Roll Assembly 807 (Heat Roll Assembly) Finger Assembly / (Fuser Belt) Stripper Fingers (Clean Only) 808 Heat Roll Wick 809 Oil Filter 810 Belt Module 812 Finger Assembly - Heat Roll and Fuser Belt
813 Fuser Module

100K 100K

10.10 10.15

010 010 010 010


010

100K 300K 300K 500K


3000K

10.12 10.2 10.15

DocuColor 2060 / 2045 eXcellerate Service Manual

04/02 4-5

Preventive Maintenance

5. Repairs and Adjustments


7. Paper Supply

SECTION CONTENTS
PARTS LIST
Parts List (with Expected Life) .......................................................................... 5-3

Component Locations
Overview 1 Component Locations ................................................................... Overview 2 IOT Module ................................................................................... Overview 3 Fuser Assembly ............................................................................ 5-4 5-5 5-6

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

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

5-25 5-27 5-28 5-29 5-30 5-31 5-32 5-33 5-35 5-38 5-40 5-42 5-44 5-45 5-45 5-46 5-47 5-48 5-49 5-50 5-51 5-52 5-54 5-55 5-57 5-59 5-61 5-63 5-64 5-66 5-69 5-70 5-70 5-71 5-75 5-78 5-80 5-81 5-83

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

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

REPAIRS 4. Drives
REP 4.1 Duplex Decurler Position Sensor Assembly ....................................... 5-15 5-16 5-17 5-20 5-22 5-24

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

04/02

DocuColor 2060 / 2045 eXcellerate Service Manual

5-1

Repairs and Adjustments

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

ADJUSTMENTS
ADJ 9.1 Max Setup (v6.2.2) ............................................................................. ADJ 9.2 IBT Belt Learn Routine ....................................................................... ADJ 9.3 Registration Control Setup ................................................................. ADJ 10.1 Fuser Nip .......................................................................................... ADJ 10.2 Pad Spring........................................................................................ 5-133 5-141 5-142 5-142 5-144

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

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

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

Repairs and Adjustments

04/02
5-2

DocuColor 2060 / 2045 eXcellerate Service Manual

DocuColor 2060 / 2045 Parts with Expected Life

Part No.

Expected Life Range

DocuColor 2060 / 2045 Parts with Expected Life

Part No.

Expected Life Range

Doner Roll Assembly (Transfer Drawer) IBT Belt (1st BTR Roll) Bearing (2nd BTR Back Up Roll) Bearing Drum Assembly (Y,M,C,K) (Fuser Belt) Stripper Finger (Fuser Belt) Sheet Pad (Fuser Belt) Pad Kit (Fuser Belt) Finger Assembly (Heat Roll) Finger Assembly (Belt) Cleaner Blade Assembly Film Seal Assembly (Fuser Belt) Pad Wick Assembly (Heat Roll) Wick (Belt Cleaner) Brush Assembly Oil Filter CC (Fan) Filter 1-4 (Suction Blower) Filter Ozone Filter Heat Roll Assembly (Tray 3) Feed / Nudger Roll Assembly (Tray 3 Takeaway) Roll Assembly

1K59732 1R558 13E82150 13E85430 13R564 19E39751 19E39781 600K87490 19K94521 19K97030 33K93480 35K81190 39K90571 39K90580 42K91740 53E92710 53K91480 53K91590 53K91600 59K10680 59K12560 59K12580

100K 400K 400K 400K 100K 100K 100K 300K 500K 500K 100K 400K 100K 100K 400K 300K 200K 100K 200K 100K 300K 500K

(Tray 3) Retard Roll 2nd BTR Roll Assembly 1st BTR Roll (Y, M, C, K) (Tray 1&2) Feed / Nudger Roll Assembly (Tray 1&2) Retard Roll

59K13770 59K14785 59K14840 59K9561 59K9591

300K 100K 400K 300K 300K

(Fuser Belt Assy) Frame and Rolls Fuser Belt Waste Toner Bottle Pretransfer Corotron (K Drum Assembly) Charge Assembly Screen (Charge Grid) - Part of Charge Assembly Web Material

1K76990 64K91310 93K92600 125K93001

300K 100K 50K 100K

125K93011 15E58380

At Failure At Failure

5K82320

When required At Failure

Exposure Lamp

122E91760

Repairs and Adjustments

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Overview 1 Component Location User Interface With Control Panel DADF Output Module Toner Cartridges

On Board Tool Kit

Feeder Transport

Paper Tray 1 Duplex / Exit Transports Paper Tray 2

Horizontal Transport 2 Horizontal Transport 1 Junction Transports Paper Tray 3

(Special Materials Handling)

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Overview 2

IOT Module

Xerographic Modules
( K, C, M, Y )

Imaging

IBT Belt

Development

Fuser Assembly

Transfer Drawer

Paper Handling Module

Vacuum Transports Belts Registration and Aligner Assembly

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Overview 3

Fuser Assembly (cammed open)

Web Material Assembly

(Heat Roll) Finger Assembly Heat Roll

Fuser Belt Position Sensor


Fuser Belt Assembly

(Fuser Belt) Finger Assembly

Inverter Transport Assembly

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Sensor Location Map

Table 1
L1 L2 L3 L4 #2 Tray Prefeed SNR S1 SMH Prefeed SNR #1 Tray Prefeed SNR S2 SMH Feed Out SNR Feed Out SNR #2 S3 SMH Path SNR Feed Out SNR #1 J1 J-Tra Path SNR #1 F1 F-Tra Path SNR #1 J3 J-Tra Path SNR #3 F2 Overhead Projector J4 J-Tra Path SNR #4 F4 F-Tra Path SNR #4 J5 J-Tra Path SNR #5 D1 J-Tra Dup Path SNR #1 D3 J-Tra Dup Path SNR #3 A1 Aligner Path SNR #1 A2 Aligner Path SNR #2 A3 Aligner Path SNR #3 R1 Regi in SNR R2 Regi Out SNR H5 H-Tra Path SNR #5 H8 H-Tra Path SNR #8 V1 V2 V3 V4 V-Tra SNR #1 V-Tra SNR #2 V-Tra SNR #3 V-Tra SNR #4 H1 H-Tra Path SNR #1 H3 H-Tra Path SNR #3 H4 H-Tra Path SNR #4 i1 i4 i5 i6 Fuser Exit SNR Inv End SNR Inv Dup End SNR Inv Dup Path SNR E1 E2 E3 E4 E5 E6 E7 Exit Ent SNR #1 Exit Ent SNR #2 DEC Upper Path SNR DEC Upper Exit SNR DEC Lower Path SNR DEC Lower Exit SNR Exit SNR

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

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Sensor and Roll Assembly Locations


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

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

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

( side view )

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4 5 PS 1

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

( Handle 7a open ) ( bottom view )

( bottom view )

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PS 3

1
Figure 5 J Transport (3) Duplex Path Sensor 3 (PS 3) ( Handle 7b open ) Figure 6 Tray 3 Path Sensor (1)

( bottom view )

( side view )

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Figure 7 Decurler Upper Path Sensor (1) ( Handle 8c )

Figure 8 Decurler Lower Path Sensor (1) ( Handle 8d open )

( side view )

( side view )

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1 3

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

( top view )
( Handle 8f open )

( bottom view )

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2 1

Figure 11 Inverter Path Sensor (1) Inverter Roller Assemblies (2) ( Handle 4c open ) Figure 12 Inverter Duplex End (1) / Duplex Path Sensor (2) Inverter Roller Assemblies (3) ( Handle 8g open )

( top view )

( side view )

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Figure 13 Exit Transport Path Sensor (1) ( Accessory and Offset Catch Tray removed )

Figure 14 Exit Roll Assembly (1) ( Handle 4c open )

( bottom view )

( top view )

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REP 4.1 Duplex Decurler Position Sensor Cleaning


Removal / Cleaning

c. d.

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

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

Figure 2 Replacement NOTE: Upon replacement, ensure that the cut-out on the Sensor Assembly mates with the locking locating tab.

1. Replace in reverse order.

Figure 1

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REP 6.1 MOB Sensor Cleaning


Cleaning

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

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

CAUTION Upon replacement, ensure that the guide pins on the MOB Sensor are seated firmly in the MOB / ADC Sensor Assembly. NOTE: Clean the ADC Sensor before replacing the MOB / ADC Sensor Assembly. (REP 9.13) 1. Replace in reverse order.

A B C

Figure 1

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REP 6.2 ROS Window Cleaning (Seal Glass)


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

(Figure 2) is for illustration purposes to show the rectangular slot of the ROS Window Tool and the rectangular Tab on the end of the ROS Window. The Slot in the Tool is inserted over the Tab on the Window and rotated 90 degrees to remove the Window. 1. ROS Window Tool 2. ROS Window 3. Tool Slot 4. Window Tab

1 3 B A 2 4
Figure 1

Figure 2

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Removal / Cleaning

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

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

CAUTION The ROS Window is very fragile and could be easily damaged. Be extra careful while removing or installing the window. 1. Access the ROS Window. (Figure 3) a. Loosen the (2) screws.

Figure 4

Figure 3

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

Replacement

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

Figure 6

Figure 5 1. Replace in reverse order.

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REP 6.3 Platen Glass Cleaning


Removal / Cleaning

3. Carefully clean both sides of the Platen Glass with film remover and a water moistened, lint free cloth. 4. Clean the White Reference Strip. (Figure 2) a. Move the Half Rate and the Full Rate Carriages to the right. b. Clean the White Reference Strip, located on the underside of the Registration bar, with a dry cloth.

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

CAUTION When cleaning the Platen Glass, do not clean the White Reference Strip with solvents. This will damage the strip and lead to image quality problems. Wipe the Strip with a dry cloth. 1. Open the Platen Cover or DADF. 2. Remove the Platen Glass. (Figure 1) a. Remove the (2) screws. b. Remove the Right Side Plate. c. Remove the Platen Glass.

A
Figure 2

C
Figure 1

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

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

Bracket

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

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REP 6.4 Exposure Lamp


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

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

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

CAUTION Avoid touching the exposure lamp with your bare hands during removal or installation. Oil from your hands will contaminate the surface of the lamp. 1. Open the Platen Cover or DADF. 2. Remove the Platen Glass. (REP 6.3)

A
Figure 1

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

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

A B

A
Figure 2 Replacement 1. Replace in reverse order. Figure 3

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

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REP 6.5 Mirror Cleaning


Cleaning

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

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

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

#2

WARNING When cleaning, use extreme care to avoid coming in contact with metal frame edges. 1. Open the Platen Cover or DADF. 2. Remove the Platen Glass. (REP 6.3) 3. Pull the Full Rate Carriage and the Half Rate Carriage to an access position.

Figure 1

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

REP 7.1 Tray 3 Feed Assembly


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

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

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

Figure 2

A B A

Figure 1

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

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

B B A

B
Figure 2

A
Figure 3

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

REP 7.2 Tray 3 Stack Height Sensor Cleaning


Removal / Cleaning

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

Stud

Figure 4

2. Replace in reverse order.

A
Figure 1

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

REP 7.3 Tray 3 No Paper Sensor Cleaning


Removal

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

Figure 2

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

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

REP 7.4 Tray 3 Pre-feed Sensor Cleaning

Removal / Cleaning

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

Figure 2

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

Figure 1

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

REP 7.5 Tray 3 Feed Out Sensor Cleaning


Removal / Cleaning

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

B
Figure 2 Replacement 1. Replace in reverse order.

Figure 1

Replacement 1. Replace in reverse order. 04/02


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DocuColor 2060 / 2045 eXcellerate Service Manual

REP 7.6 OHP Sensor Cleaning


Removal / Cleaning

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

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

A B

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

B
Figure 2

A
Figure 1

Replacement 1. Replace in reverse order.

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REP 7.7 Tray 3 Takeaway Roller Assembly


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

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

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull Tray 3 out to the service position. (GP 6) 2. Clean the Takeaway Rolls. (Figure 1) a. Clean the Takeaway Rolls with film remover and a water moistened, lint free cloth

Figure 2

Figure 1

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4. Remove the Takeaway Roll Assembly. (Figure 1) a. Remove the C-clips and bearings at both ends of the Assembly. b. Remove the Takeaway Roll Assembly.

REP 7.8 Tray 3 Pinch Rolls


Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull Tray 3 out to the service position. (GP 6) 2. Remove the Top Cover. (Figure 1) a. Loosen (2) screws. b. Slide the Top Cover to the left and remove.

A A B

B
Figure 3

Replacement NOTE: Ensure the Lip of the Bearings are both towards the Feed Rolls and the C-clips are to the inside of the bearings. 1. When replacing the Connector Sheild, make sure it is secured on the frame stud at the bottom. 2. Replace in reverse order.

A
Figure 1

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3. Clean the Pinch Rolls. (Figure 2) a. Clean the Pinch Rolls with film remover and a water moistened, lint free cloth.

Removal 4. Remove the Pinch Rolls. (Figure 3) a. Remove the 2 Springs. b. Remove the E-clip for the Rear Cam Follower.

A A B A

Figure 2 Figure 3

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5. Remove the Pinch Roll Assembly. (Figure 4) a. Slide the Cam Follower to the left. b. Slide the Pinch Roll Assembly to the left and remove. c. Remove the E-clips from the shaft to remove the Pinch Rolls

REP 7.9 Tray 3 Feed Roll Assembly


Cleaning NOTE: After replacing the Tray 3 Feed Roll Assembly, reset the HFSI counter (NVM 007-802).

B
WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull Tray 3 out to the service position. (GP 5) 2. Remove the Top Cover. (Figure 1) a. Loosen (2) screws. b. Slide the Top Cover to the left and remove.

Figure 4

Replacement 1. Replace in reverse order.

A
Figure 1

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3. Access the Feed Rolls. (Figure 2) a. Lift up the left side of the Feed Roll Assembly

4. Clean the Rolls with film remover and a water moistened, lint free cloth. (Figure 3) a. Nudger Rolls. b. Feed Rolls.

B A
Figure 3 Figure 2

Repairs and Adjustments

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Removal 5. Remove the Pre-feed Sensor Assembly. (Figure 4) a. Remove the (2) screws. b. Lift up on the Pre-feed Sensor Assembly to remove. Do not disconnect the Assembly c. Remove the Bearing.

6. Remove the Feed Roll Assembly. (Figure 5) a. Bias the Feed Roll Assembly to the right and lift out.

A B
Figure 5

Figure 4

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Replacement NOTE: When replacing the Pre-feed Sensor Assembly, make sure the Bearing Tab is in place in the bracket. (Figure 6)

REP 7.10 Tray 3 Retard Roll


Removal / Cleaning NOTE: After replacing the Tray 3 Retard Roll, reset the HFSI counter (NVM 007-802).

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull Tray 3 out to the service position. (GP 6) 2. Remove the Retard Roll Assembly. (Figure 1) a. Remove the (2) screws. b. Remove the Retard Roll Assembly by pulling out the left side first and releasing the bracket tab from the frame

Bearing Tab
Figure 6 1. Make sure the outboard part of the Feed Roll Assembly shaft goes in first. 2. Replace in reverse order.

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DocuColor 2060 / 2045 eXcellerate Service Manual

3. Clean / Remove the Retard Rolls. (Figure 2) a. If cleaning is required, clean the Rolls with a towel dampened with water. b. If replacement is required, remove the E-ring. c. Bias the Rolls to the left and remove.

Replacement NOTE: When replacing the Retard Roll Assembly, place the Bracket Tab in the frame slot first, and angle the Assembly up into position. (Figure 3)

Bracket Tab

Figure 3 Figure 2 1. Replace in reverse order.

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REP 7.11 Tray 1 Feed Assembly


Removal NOTE: After replacing the Tray 1 Feed Assembly, reset the HFSI counter (NVM 007-803).

2. Open the Left Hand Cover and open the Tray 1 Drawer. (Figure 1)

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Undock Tray 4 if equipped. (GP 10)

CAUTION Do not open the Tray 4 Paper Drawer when Tray 4 is in the undocked position. Figure 1

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3. Remove the Tray 1 Feed Assembly. (Figure 2) a. Remove the (1) screw. NOTE: To access Tray 2 components, remove the (1) screw and pivot the assembly out from the right.

4. Remove the Tray 1 Feed Assembly. (Figure 3) a. Disconnect P791A. b. Remove the K-clip. c. Remove the stud. d. Remove the Feed Assembly.

A C

D B
Figure 2 Figure 3 Replacement 1. Replace in reverse order.

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REP 7.12 Tray 2 Feed Assembly


Removal NOTE: After replacing the Tray 2 Feed Assembly, reset the HFSI counter (NVM 007-804).

2.

Open the Left Hand Cover and open the Tray 2 Drawer. (Figure 1)

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7)
1. Undock Tray 4 if equipped. (GP 10)

CAUTION Do not open the Tray 4 Paper Drawer when Tray 4 is in the undocked position.

Figure 1

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3.

Remove the Tray 2 Feed Assembly. (Figure 2) a. Remove the screw.

NOTE: To access Tray 2 components, remove the (1) screw and pivot the assembly out from the right.

4. Remove the Tray 2 Feed Assembly. (Figure 3) a. Disconnect P791B. b. Remove the K-clip. c. Remove the stud. d. Remove the Feed Assembly.

C B

A
Figure 2

Figure 3 Replacement 1. Replace in reverse order.

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REP 7.13 Tray 1 / 2 Feed / Nudger Roll Assembly


Removal NOTE: After replacing the Tray 1 / 2 Feed / Nudger Roll Assembly, reset the HFSI counter (NVM 007-800 for Tray 1 and NVM 007-801 for Tray 2).

4. Remove the Feed / Nudger Roll Assembly. (Figure 2) a. Pinch the (2) ends of the shaft inward. b. Lift the Feed Roll Assembly to remove. NOTE: If cleaning is required, clean the Feed / Nudger Rolls with a towel dampened with water.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Undock Tray 4 if equipped (GP 10). 2. Open the Left Hand Cover and open the appropriate Drawer (Tray 1/2). 3. Access the Tray 1/2 Feed Assembly. (Figure 1) a. Remove the (1) screw for the appropriate tray. b. Pivot the Feed Assembly out of the machine from the right.

A B

Tray 1
Figure 2

Replacement 1. Replace in reverse order.

Tray 2
Figure 1

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REP 7.14 Tray 1 / 2 Retard Roll


Removal / Cleaning NOTE: After replacing the Tray 1 / 2 Retard Roll, reset the HFSI counter (NVM 007-800 for Tray 1 and NVM 007-801 for Tray 2).

REP 8.1 Vacuum Transport 1 and 2


Removal NOTE: This procedure covers the removal of Vacuum Transport Assembly 1. The procedure to remove the Vacuum Transport Assembly 2 is the same with the exception of disconnecting P/J703B and P/J785B from Vacuum Transport Assembly 2.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove the Tray 1 / 2 Feed / Nudger Roll Assembly. (REP 7.13) 2. Remove the Tray 1 / 2 Retard Roll Assembly. (Figure 1) a. Push the ends of the Retard Roll Assembly into the bracket and remove. NOTE: If cleaning is required, clean the Retard Roll with a towel dampened with water.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Path Module to the service position. (GP 2) 2. Remove the Vacuum Transport. (Figure 1) a. Disconnect P/J703A and P/J785A from Vacuum Transport Assembly 1. b. Loosen the 3 screws securing the Vacuum Transport 1 to the Transport Drawer. Slide the Vacuum Transport 1 to the front of the machine and lift to remove.

B A B

A
Figure 1 (bottom view) Replacement 1. Replace in reverse order. Replacement 1. Replace in reverse order.

Figure 1

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REP 8.2 Vacuum Transport 1 and 2 Paper Sensor Cleaning


Cleaning

3. Clean the Paper Sensors. (Figure 2) a. Clean the Paper Sensors with a dry cotton swab

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) NOTE: For general cleaning, the Paper Sensors can be cleaned with cotton swab through the Guide Plate without removal of the vacuum transports (reference figure 1). If the Transport related Fault Code does not clear, proceed with the removal of the sensor for a thorough cleaning. 1. Remove the Vacuum Transport 1 and / or 2. (REP 8.1) 2. Cleaning the Paper Sensors. (Figure 1) a. Slide the Guard Plate open.

Figure 2

Replacement

NOTE: When reinstalling Sensor Bracket, the position is not fixed. Ensure Bracket is biased properly to line up with opening of Plate. 1. Replace in reverse order.

Figure 1

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REP 8.3 Horizontal Transport 1


Removal

Replacement

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the IOT Front Doors. 2. Remove the Horizontal Transport 1. (Figure 1) a. Remove the Connector Cover (1 screw), and disconnect P/J779 and P/J780. b. Remove the (2) screws securing the Horizontal Transport 1 to the frame.

CAUTION Be careful not to damage the connectors when installing the Transport. Be sure the Wire Harness is routed correctly behind the spring. (Figure 2)

Spring

CAUTION Be careful not to damage the connectors when removing the Transport. c. Remove the Horizontal Transport 1 by pulling the Transport forward.

Figure 2 1. Replace in reverse order.

A B B
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REP 8.4 Horizontal Transport 2


Removal CAUTION Be Careful not to damage the Connectors when removing the Transport 2. c. Remove the Horizontal Transport 2 by pulling the Transport forward.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the IOT Front Doors. 2. Remove the Horizontal Transport 2. (Figure 1) a. Remove the Connector Cover (1 screw), and disconnect P/J788, P/J782, and P/J781. b. Remove the (2) screws securing the Horizontal Transport 2 to the frame.

A B B

Figure 1

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Replacement

REP 8.5 Horizontal 1 Transport (5) Path Sensor 1, 3, and 4


Removal / Cleaning NOTE: This procedure covers the removal of the Horizontal Transport Path Sensor 1. The procedures for removing the Horizontal Transport Path Sensors 1, 3, and 4 are identical with the exception of disconnecting J221, J223, and J224 from the respective Sensor.

CAUTION Be careful not to damage the connectors when installing the Transport. Be sure the Wire Harness is routed correctly behind the spring. (Figure 2)

Spring

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove the Horizontal 1 Transport (5) and note the position of the Path Sensors. (REP 8.3) (Figure 1)

Figure 2 1. Replace in reverse order. Path Sensor 2

Path Sensor 1

Path Sensor 3 Figure 1

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2. Clean the Path Sensor. (Figure 2) a. Remove the (1) screw and the cover. b. Slide the sensor out of the bracket and clean the sensor with a cotton swab.

REP 8.6 Horizontal 2 Transport (6) Path Sensor 5 and 8


Removal / Cleaning NOTE: This procedure covers the removal of Horizontal Transport Path Sensor 5. The procedures for removing the Horizontal Transport Path Sensors 8 is identical with the exception of disconnecting J225 or J228.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove Horizontal 2 Transport (6) and note the position of the Path sensors. (REP 8.4) (Figure 1)

Path Sensor 8

Path Sensor 5 Figure 2

Replacement NOTE: When installing the sensor, connect the connector before installing the sensor. 1. Replace in reverse order.

Figure 1

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2. Clean the Path Sensor. (Figure 2) a. Remove the (1) screw. b. Slide the sensor out of the bracket. c. Clean the sensor with a cotton swab.

REP 8.7 Registration In / Out Sensor Cleaning


Removal / Cleaning NOTE: This procedure covers the removal of the Registration In Sensor. The procedure for removing the Registration Out Sensor is identical with the exception of disconnecting P/J 108 from the Registration Out Sensor.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Path Module to the service position. (GP 2) 2. Remove the Front Top Cover. (Figure 1) a. Remove (2) screws. b. Lift off the Front Top Cover.

B
Figure 2

Replacement NOTE: When installing the sensor, connect the connector before installing the sensor. 1. Replace in reverse order.

Figure 1

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3. Clean the Path Sensor. (Figure 2) a. Remove the (2) screws b. Slide the sensors out of the brackets and clean with a cotton swab or dry lintless cloth.

REP 8.8 Aligner Path Sensor Cleaning


Removal / Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Path Module to the service position. (GP 2) 2. Remove the Paper Path Module Left Front Cover. (Figure 1) a. Remove (3) screws. Lift the 4a handle to access the front screws. b. Remove the Paper Path Module Left Front Cover.

B A

Figure 2 Replacement NOTE: When installing the sensor, connect the connector before installing the sensor. 1. Replace in reverse order.

A A A

Figure 1

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3. Note the position of the (3) Aligner Path Sensors. (Figure 2)

4. Clean the (3) Aligner Path Sensors. (Figure 3) a. Remove the (1) screw. b. Slide the Sensor out of the bracket and clean with film remover and a water moistened, lint free cloth.

Sensors

B
Figure 2 Figure 3 Replacement 1. Replace in reverse order.

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REP 8.9 Aligner Nip / Release Home Sensor Cleaning


Removal / Cleaning

3. Note the position of the (3) Aligner Nip / Release Home Sensors. (Figure 2)

Sensors
WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Path Module to the service position. (GP 2) 2. Remove the Paper Path Module Left Front Cover. (Figure 1) a. Remove (3) screws. Lift the 4a handle to access the front screws. b. Remove the Paper Path Module Left Front Cover.

Figure 2

A A A

Figure 1

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4. Clean the (3) Aligner Nip / Release Home Sensors. (Figure 3) a. Clean the (3) Aligner Nip / Release Home Sensors with a dry cotton swab.

REP 8.10 Registration Side Shift Sensor Cleaning


Removal / Cleaning

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

1. Open the Paper Path Module to the service position. (GP 2) 2. Remove the Paper Path Module Left Front Cover. (Figure 1) a. Remove (3) screws. b. Remove the Paper Path Module Left Front Cover.

A B A A A
Figure 1

Figure 3 Replacement 1. Replace in reverse order.

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3. Remove the Side Shift Sensor Assembly. (Figure 2) a. Remove (1) screw. b. Carefully pull the Side Shift Sensor Assembly out of the Registration Aligner Assembly.

4. Clean the Side Shift Sensor. (Figure 3) a. Clean the Side Shift Sensor with a dry cotton swab.

A
2

A
Figure 3 Replacement 1. Replace in reverse order. Figure 2

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REP 8.11 Offset Home / Offset Position Sensor Cleaning


Cleaning

2. Remove the Tab Covers. (Figure 2) a. Remove the (2) screw. b. Lift off the (2) Tab Covers.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove the Offset Catch Tray. (Figure 1) a. Disconnect the connector. b. Remove the (1) screw. c. Move the Offset Catch Tray to the right to release the Assembly from the frame and remove.

B A

Figure 2

B A

Figure 1

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3. Release the Tabs. (Figure 3) a. Release the (2) Shaft Tabs but do not remove the Shafts.

4. Flip the Assembly Support over as it is still connected. 5. Clean the Offset Home and Offset Position Sensors with a dry cotton swab. (Figure 4)

Sensors

Figure 3 Replacement 1. Replace in reverse order.

Figure 4

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REP 9.1 Drum Assembly


Removal NOTE: All (4) Drum Assembly removal procedures are identical. NOTE: After replacing the Drum Assembly, reset the HFSI counter (NVM 009-820 for Drum Assembly (Y), 009-822 for Drum Assembly (M), 009-824 for Drum Assembly (C), and 009-826 for Drum Assembly (K).

3. Loosen the Xerographic Module screws. (Figure 2) a. completely loosen the (3) captive Xerographic Module screws.

A
WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Front Doors and remove the Upper Inner Cover. (REP 13.1) 2. a. Lift the green Handle (4) to lower the Paper Path Module and b. release the (2) Camming Levers for the IBT Module. (Figure 1)

Figure 2

B B

Figure 1

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4. Pull the Xerographic Module out to the service position. (Figure 3) a. Pull out the bottom of the Handle. b. Using the Handle, pull the Xerographic Module out to the service position.

5. Remove the Drum Assembly. (Figure 4) a. Rotate the Drum Assembly Retaining Latch CCW and then pull it out of the Front Plate. b. Bias the Drum Assembly to the front of the Xerographic Module. c. Pull the Drum Assembly straight out from the Xerographic Module to remove it.

A B C
Figure 3

Figure 4 6. Immediately store the Drum Assembly in the black protective bag and ensure that the assembly is not stored with the Drum side down.

CAUTION Do Not expose the Drum Assembly to light for more than one minute or Light Shock will occur. Place the Drum Assembly in a Black Protective Bag after removing it from the machine.

Replacement NOTE: Upon replacement, gently tighten the Drum support screws evenly, especially the Drum drive screw. This is too avoid binding the Xerographic Module. NOTE: Use the Kynar dusting pouch and lightly tap the length of the Drum to ensure the proper lubrication. 1. Replace in reverse order. 2. Perform Max Setup. (ADJ 9.1)

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REP 9.2 Charge Corotron / Screen


Removal NOTE: All (4) Charge Corotron and Screen Assembly removal procedures are identical. NOTE: There is not an HFSI Counter for the Charge Corotron or Screen, so you must track your activities on your service log. NOTE: The Charge Corotron and the Screen should be changed at the same time.

1. Remove the Drum Assembly. (REP 9.1) 2. Remove the Charge Corotron Assembly. (Figure 1) a. Remove (1) screw. b. Remove the Charge Corotron Assembly.

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

CAUTION Do Not expose the Drum Assembly to light for more than one minute or Light Shock will occur. Place the Drum Assembly in a Black Protective Bag when you are not performing any maintenance on it.
Figure 1

WARNING Always wear eye protection when removing the Spring and the Charge Corotron Screen.

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3. Remove the Charge Corotron Screen. (Figure 2) a. Using a small flat blade screwdriver, carefully release the Spring that secures the Screen to the Drum Assembly. b. Carefully remove the Screen and avoid contact with the edges of the Screen.

Replacement 1. Install the Screen on the inboard side of the Drum Assembly. (Figure 3) a. Make sure the Screen is properly seated on the notch in the frame. (Figure 3)

B A
Figure 2 Figure 3

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2. Install the Screen on the outboard side of the Drum Assembly. (Figure 4). a. Hold the Screen through the slot in the Drum Assembly Frame. b. Attach the Spring through the slot in the Screen. c. Push the bottom of the Spring into the frame until it locks into position.

REP 9.3 Xerographic Module


Removal NOTE: All (4) Xerographic Module removal procedures are identical.

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

CAUTION The Xerographic Module is heavy. Use Caution when removing the Xerographic Module. 1. Pull the Xerographic Module out to the service position. (Reference REP 9.1)

Figure 4

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2. Remove the Xerographic Module. (Figure 1) a. Remove the Module while pressing in on the slide locks on both sides of the Module.

REP 9.4 BPO Magnetic Roll Assembly Cleaning


Removal / Cleaning NOTE: All (4) BPO Assembly removal procedures are identical. After cleaning a BPO Assembly, reset the HFSI counter (NVM 009-804 for BPO Assembly (Y), 009-805 for BPO Assembly (M), 009-806 for BPO Assembly (M), and 009-807 for BPO Assembly (K).

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

A
1. Remove the appropriate Drum Assembly and place in a protective bag. (REP 9.1)

Figure 1 Replacement 1. Replace in reverse order. 2. Perform Max Setup (ADJ 9.1)

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2. Remove the Pretransfer Corotron. (Figure 1) a. Remove (1) screw. b. Remove the Pretransfer Corotron.

3. Remove the BPO Assembly. (Figure 2) a. Remove (1) screw. b. Slide the BPO Assembly to the right to release the pin on the left side of the Assembly c. Remove the BPO Assembly. d. Vacuum out the BPO Assembly.

B
A

Figure 1 (Bottom view of the Xerographic Module shown outside of the machine)

B
Figure 2

(Bottom view of the Xerographic Module shown outside of the machine)

Replacement 1. Make sure the BPO Assembly is seated correctly on the locating tab. 2. Replace in reverse order.

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REP 9.5 IBT Belt Cleaner Assembly / Cleaner Brush Assembly


Removal / Cleaning NOTE: After replacing Cleaner Brush Assembly, reset the HFSI counters (NVM 009-851)

2. Locate the IBT Module Prop Rod. (Figure 1)

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull the IBT Module Drawer to the Service Position. (GP 2)

Prop Rod

Figure 1

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3. Position the Prop Rod to help support the weight of the IBT Module. (Figure 2)

4. Remove the IBT Cleaner Assembly. (Figure 3) a. Disconnect J357. b. Loosen the screw securing the IBT Cleaner Assembly to the IBT Assembly. c. Slide the IBT Cleaner Assembly Forward to remove.

A B C
Figure 2

Figure 3

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4. If cleaning is required, vacuum out the brush area while turning the gear. (Figure 4)

5. If the removal of the Cleaner Brush Assembly is required, perform the following: (Figure 5) a. Remove the Belt Cleaner Blade and the Film Seal Assembly. (REP 9.6) b. Remove (4) screws (2 front and 2 rear) c. Lift up the on the front and rear pads to remove the Cleaner Brush Assembly.

Gear

B
Brush Area

A
Figure 4

B
Figure 5 Replacement NOTE: Upon replacement, ensure that the Locating Pins engage the holes in the Rear IBT Assembly Frame. 1. Replace in reverse order.

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REP 9.6 Belt Cleaner Blade / Film Seal Assembly


Removal NOTE: After replacing the Cleaner Blade Assembly and the Film Seal Assembly, reset the HFSI counters (NVM 009-842 and 009-852).

4. Remove the Cleaner Blade Assembly. (Figure 1) a. Remove (2) screws. (front and rear) b. Remove the Cleaner Blade Assembly c. Remove (2) screws. (front and rear) d. Remove the Film Seal Assembly

A
WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull the IBT Module drawer to the Service Position. (GP 2) 2. Raise the IBT Module to the Service Position. 3. Remove the IBT Belt Cleaner Assembly. (REP 9.5)

C D
Figure 1 Replacement 1. Replace in reverse order.

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REP 9.7 Belt Home Position Sensor 1 Cleaning


Removal

REP 9.8 Belt Home Position Sensor 2 Cleaning


Removal

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull the IBT Module drawer to the Service Position. (GP 2) 2. Raise the IBT Module to the Service Position. 3. Remove the IBT Belt. (REP 9.9) 4. Cleaning the Belt Home Position Sensor 1 (Figure 1). a. Clean the Sensor.

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. 2. 3. 4. Pull the IBT Module drawer to the Service Position. (GP 2) Raise the IBT Assembly to the Service Position and install the prop rod. Remove the IBT Belt. (REP 9.9) Clean the Belt Home Position Sensor 2 (a). (Figure 1)

Figure 1 Replacement NOTE: Clean the Belt Home Position Sensor 2 before replacing the IBT Belt. (REP 9.8) 1. Replace in reverse order. Figure 1 Replacement NOTE: Clean the Belt Home Position Sensor 1 before replacing the IBT Belt. (REP 9.7) 1. Replace in reverse order.

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REP 9.9 IBT Belt


Removal NOTE: After replacing the IBT Belt, reset the HFSI counter (NVM 009-847).

3. Locate the IBT Module Prop Rod. (Figure 2)

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull the IBT Module drawer to the Service Position. (GP 2)

Prop Rod

CAUTION Failure to pull the IBT Module Drawer to the Service Position before raising the IBT Module will result in severe damage to the IBT Belt. 2. Raise the IBT Module to the Service Position. (Figure 1) a. Grab the IBT Module Handle and lift. The IBT Module will lock into place.

Figure 2

Figure 1

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4. Position the Prop Rod to help support the weight of the IBT Module. (Figure 3)

5. Remove the IBT Cleaner Assembly. (REP 9.5) 6. Remove the POB Jam Sensor Assembly, and the Paper Guide Assembly. (Figure 4) a. Loosen (1) screw. b. Disconnect the Connector and release the harness from the clamp. c. Pull forward to remove the POB Jam Sensor Assembly. d. Loosen (1) screw and move the Paper Guide forward to remove.

B D A

C
Figure 3

Figure 4

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7. Release the tension on the IBT Belt (Figure 5). a. Release the tension on the IBT Belt by rotating the Tension Lever clockwise.

8. Remove the Prop Rod. 9. Remove the IBT Belt by pulling from both sides of the IBT Module. You may have to rotate the belt slightly in a clockwise manner. (Figure 6)

Figure 6 Figure 5 10. Place the IBT Belt in a safe place. CAUTION The IBT is easily damaged, handle the belt with care. Oils from your hands may affect the image quality. Use plastic gloves when handling the belt, and place it on a clean flat surface.

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Replacement NOTE: Upon replacement, ensure that the Reflective Tape on the inside of the IBT Belt is toward the front of the machine. (Figure 7)

1. Before replacing the IBT Belt, clean the Belt Home Position Sensors 1 and 2. (REP 9.7 and 9.8)

Reflective Tape

CAUTION The IBT is easily damaged, handle the belt with care. Oils from your hands may affect the image quality. Use plastic gloves when handling the belt, and place it on a clean flat surface.

2. Install the IBT Install Assist Tool. (Figure 8) a. Remove the Assist Tool from the IBT Module Storage Compartment b. Install the IBT Install Assist Tool with the flared edge towards the rear

Flared Edge

Figure 7

Figure 8

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3. Install the IBT Belt over the Assist Tool. 4. When the IBT Belt is in position in the middle of the rolls, remove the IBT Belt Install Tool. 5. When you apply tension on the Belt, make sure there are no wrinkles. If there are, de-tension the Belt and adjust the Belt to the center of the rolls on both sides of the IBT Module. Slowly reapply tension. 6. Dust the IBT Belt using the Kynar Dusting Pouch once, along the width of the Belt. 7. Continue steps in reverse order. 8. When adding a new IBT Belt, enter diagnostics and select DC956 Belt Edge Learn Mode. If you are reinstalling the old one, go to the next step. 9. Perform Max Setup (ADJ 9.1)

REP 9.10 1st BTR (Bias Transfer Roll) and Bearing


Removal NOTE: All (4) 1st Bias Transfer Roll removal procedures are identical. NOTE: After replacing the 1st BTR (1-4), reset the HFSI counter (NVM 009849).

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

CAUTION Failure to pull the IBT Module Drawer to the Service Position before raising the IBT Module will result in severe damage to the IBT Belt.

CAUTION Do not touch the foam part of the BTR. Handle the BTR by the metal shaft.

WARNING Always wear eye protection when removing the Spring and the Bearing. 1. Remove the IBT Belt. (REP 9.9) 2. Lower the IBT Assembly by raising it slightly and releasing the lever.

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3. Lift the rear end of the 1st BTR out of the spring loaded clamps, then remove the front end of the BTR out of the 1st BTR Housing. (Figure 1)

4. Remove the Bearing (Figure 2) a. While holding down the Bearing and the Spring, loosen the (1) screw. b. Tilt the Bearing Housing away from the Spring and Bearing. c. Lift out the Spring and the Bearing.

1st BTR

Figure 1

A
Figure 2

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Replacement NOTE: Transfer the Plastic End Caps onto the new Bias Transfer Roll if they are not already on the new Roll. 1. Place the old spring on to the new bearing and position the assembly over the pin on the BTR Housing. (Figure 3)

2. Compress the Spring and the Bearing into the Housing and tighten the (1) screw. Push down on the Bearing to see if it has been installed properly. (Figure 4)

Screw Pin
Figure 4 Figure 3

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3. The 1st BTR Roll is not reversible. Install the Roll so that the end of the Roll with the longer shaft is at the front of the IBT Module and inserted first. (Figure 5)

REP 9.11 IBT Inner Cleaner Brush


Removal NOTE: After replacing the Inner Cleaner Brush, reset the HFSI counter (NVM 009-846).

Longer Shaft

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

CAUTION Failure to pull the IBT Module Drawer to the Service Position before raising the IBT Module will result in severe damage to the IBT Belt.

Figure 5 4. Replace in reverse order. 5. Perform the Max Setup Adjustment. (ADJ 9.1)

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1. Remove the IBT Belt. (REP 9.9) 2. Remove the IBT Inner Cleaner Brush. (Figure 1) a. Remove the K-clip securing the Cleaner Brush to the IBT Assy. b. Remove the Sprocket.

3. Lift the IBT Inner Cleaner Brush from the bottom and remove. (Figure 2)

A B

Brush

Figure 2 Figure 1 Replacement 1. Replace in reverse order.

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REP 9.12 2nd BTR Back Up Roll Assembly


Removal NOTE: After replacing the 2nd BTR Back Up Roll Assembly, reset the HFSI counter (NVM 009-850).

2. Disconnect the (red) LVPS power connector (A) from the 2nd BTR Back Up Roll Assembly. (Figure 1)

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

CAUTION Failure to pull the IBT Module Drawer to the Service Position before raising the IBT Module will result in severe damage to the IBT Belt.

WARNING Avoid coming in contact with metal frame edges on the IBT Frame while performing this procedure.

Figure 1

1. Remove the IBT Belt. (REP 9.9)

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3. Remove the 2nd BTR Back Up Roll Assembly. (Figure 2) a. Remove the 3 screws securing the Support Plate. NOTE: Support the 2nd BTR Back Up Roll Assembly while doing Step 3b. b. Remove the Support Plate securing the 2nd BTR Back Up Roll.

REP 9.13 ADC Sensor Cleaning


Removal / Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) NOTE: Both ADC Sensor Assembly removal procedures are identical.

A B A

1. Remove the IOT Upper Front Cover. (GP2) 2. Access the MOB / ADC Sensor Bracket. (Figure 1) a. Disconnect P/J764. b. Remove the (2) screws and the (2) ground wires. c. Pull out the MOB / ADC Sensor Bracket.

Figure 2 Replacement

CAUTION Ensure that Ground Clips are contacting the inside Rear Frame. NOTE: Secure the High Voltage Lead prior to installing Bracket. 1. Replace in reverse order.

B C A
Figure 1

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3. Remove the ADC Sensor. (Figure 2). a. Remove (3) screws and the ADC Sensor Assembly. NOTE. The ADC Sensor remains connected.

4. Clean the ADC Sensor. (Figure 3) a. Clean the ADC Sensor with a dry lint-free cloth or a dry cotton swab.

A A
Figure 2 Replacement NOTE: After cleaning the ADC Sensor, clean the MOB Sensor. (REP 6.1) 1. Replace in reverse order. Figure 3

Repairs and Adjustments

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REP 9.14 2nd BTR Roll Assembly


Removal / Cleaning NOTE: After replacing the 2nd BTR Roll Assembly, reset the HFSI counter (NVM 009-841).

3. Disconnect the High Voltage Lead from the Detack Corotron. (Figure 2)

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Handling Module Drawer to the Service Position. (GP 2) 2. Remove (3) screws and the Paper Handling Module Drawer middle cover. (Figure 1)

Lead

Figure 2

Figure 1

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4. Remove the Detack Corotron (A) by pivoting it CCW, and lifting it out. (Figure 3)

5. Remove the (2) screws securing the 2nd BTR Roll Assembly. a. Remove the (2) screws securing the 2nd BTR Roll Assembly to the Transfer Module Drawer. (Figure 4) Note: If cleaning is required, use a lift-free cloth moistened with water.

Figure 3

Figure 4

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6. Push down on the Idler to release the 2nd BTR Assembly. (Figure 5)

Idler

7. Remove the 2nd BTR Roll Assembly by pivoting it up and to the right of the bracket to remove it from the Paper Handling Module Drawer. (Figure 6)

Bracket

Figure 5

Figure 6

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Replacement NOTE: Make sure that the metal tab on the Detack Corotron engages the High Voltage Lead in the middle of the connector. (Figure 7)

REP 9.15 Suction Blower / Dust Blower Filters


Removal

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

Tab

NOTE: All (4) Filter removal procedures are identical and should be replaced at the same time.

NOTE: After replacing the Filters, reset the HFSI counter (NVM 004-810 for the Suction Blower Filter and 004-812 for the Dust Blower Filter).

1. Remove (6) screws and the Ecology Module Upper Rear Cover. (Figure 1)

1
Figure 7 1. Before replacing it, carefully brush out the Detack Corotron as not to damage the coronode pins. 2. Replace in reverse order

1 1

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2. Note the position of the Filter Assemblies. (Figure 2)

3. Remove the Air Intake Assembly by releasing the two clips (A) securing it in place, and rocking it upwards to free it of the Filter Assembly. (Figure 3)

Dust Blower Filters

Suction Blower Filters

Figure 2

Figure 3

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4. Remove the Filter. (Figure 4)

REP 9.16 Ozone Filter


Removal NOTE: After replacing the Ozone Filter, reset the HFSI counter (NVM 004811).

Filter
WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove (1) screw to access the Ozone Filter. (Figure 1)

1
Figure 4 Replacement 1. Replace in reverse order.

Figure 1

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2. Remove the Ozone Filter. (Figure 2)

REP 9.17 C-Pop Sensor / Exit Transport Path Sensor Cleaning


Removal

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove the Top Cover on the Output Transport Module (OTM). (Figure 1) a. Open the OTM Front Door. b. Loosen the (2) Front Screws. c. Remove the (2) Rear Screws. d. Lift and Remove the OTM Top Cover.

Filter

C
Figure 2 Replacement 1. Replace in reverse order.

B A
Figure 1

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2. Remove the Exit Transport Assembly. (Figure 2) a. Disconnect P/J 734 and 728. b. Remove (3) screws. c. Remove the Exit Transport Assembly.

3. Clean the Exit Transport Path Sensor. (Figure 3) a. Remove (1) screw. b. Slide the Sensor out of the bracket. c. Clean the Path Sensor with a dry cloth or a cotton swab.

A C B B

Figure 2 Figure 3

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4. Disconnect J105. (Figure 4)

6. Clean the (4) C-Pop Sensor windows inside the Assembly with a dry lint-free cloth. (Figure 6)

J 105

A
Figure 4 5. Remove the C-Pop Sensor Assembly. (Figure 5) a. Remove the (3) screws b. Remove the C-Pop Sensor Assembly

Figure 6

A
Figure 5

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7. Clean the (4) C-Pop Sensors (A) with a dry lint-free cloth. (Figure 7)

REP 9.18 CC Filter


Removal

NOTE: There is one HFSI Counter for all four CC Filters. Replace all (4) fCC Filters at the same time. After replacing the CC Filters (1-4), reset the HFSI counter (NVM 009-828).

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove the Drum Assembly (REP 9.1). Be sure to place the Drum Assembly in the Black Protective Bag. 2. Remove the Xerographic Module (9.3)

Figure 7 Replacement 1. Replace in reverse order.

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3. Disengage the Side Rail from the rear of the Xerographic Module but do not remove. (Figure 1) a. Remove (1) screw. b. Allow the Side Rail to drop but still connected to the front of the Xerographic module.

4. Remove the Duct. (Figure 2) a. Slide the Duct to the left to release the (2) pins and lift the Duct to remove.

Figure 2

Figure 1

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5. Remove the CC Filter (Figure 3). a. Turn the Duct up-side-down to access the Filter. b. Remove the Filter by bending it slightly to release the Tabs at each end.

REP 9.19 Developer Replacement


Removal NOTE: All four developer removal procedures are identical. NOTE: The funnel supplied is not used on this product. NOTE: After replacing the Developer, reset the HFSI counter (NVM 009800 for (Y), 009-801 for (M), 009-802 for (C) and 009-803 for (K)).

CC Filter

Figure 3 Replacement 1. Replace in reverse order.

1. On the User Interface Control Panel, press the Access button. 2. Enter the Tools Password (11111 as the default) on the key pad and select the Enter button on the UI screen. 3. Select TKO Pathway. 4. Open the Front Doors and remove the IOT Upper Front Cover. (REP 13.1)) 5. Lower the Paper Path Module and move the IBT Module Latching Handles to the unlocked position. 6. Place a drop cloth on the floor under the Developer Housing. 7. Select DC955 Exchange Developer Mode and then select Discharge Mode. The screen will direct you to perform the necessary steps.

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8. Attach the Recovery Bag around the Developer Assembly. (Figure 1) a. Carefully position the bag around the dump assembly.

9. Pull the Discharge Shutter open for the color being replaced. (Figure 2)

Bag removed for clarity

Figure 1

Figure 2

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10. Adjust the Recovery Bag. (Figure 3) a. Adjust the Recovery Bag so to bottom edge of the bag is caught on the rear of the Discharge Shutter. This action will prevent the possibility of the Recovery Bag getting caught up in the Developer Housing Gears.

Developer Replacement 1. Position the Developer Assembly Filler Guide. (Figure 4) a. Loosen the screw.

Gears

A A

Figure 4

Figure 3 11. Return to the User Interface, and select the appropriate color. 12. Review the screen to make sure all the steps have been performed and select Confirm. 13. Select the Start button on the UI Control Panel. 14. When the recovery cycle is complete, rerun the routine one more time. (step 11) 15. After completing the second recovery cycle, close the Discharge Shutter and remove the Recovery Bag.

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b. Pull the Toner Dispense Chute out until it clicks into place. (Figure 5)

REP 9.20 Detack Corotron


Removal / Cleaning

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the Paper Handling Module Drawer to the Service Position. (GP 2) 2. Remove (3) screws and the Paper Handling Module Drawer middle cover. (Figure 1)

2
Figure 5 2. 3. 4. 5. 6. 7. 8. 9. 10. Close out of the existing screen and select the Replenish. Select the appropriate colors. Select Confirm and select the Start button on the UI Control Panel. Add developer while the routine is running. When finished, move the Filler Guide back to it original position and retighten screw. Raise the Camming Levers for the IBT Module. Raise the Paper Path Module. Reinstall the Upper Front Cover. Reset the HFSI counter(s). (GP 4) Perform the Max Setup Adjustment. (ADJ 9.1)

Figure 1

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3. Disconnect the High Voltage Lead from the Detack Corotron. (Figure 2)

4. Remove the Detack Corotron (A) by pivoting it CCW, and lifting it out. (Figure 3)

Lead

Figure 2

Figure 3

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Replacement 1. If replacing the old Detack Corotron Assembly, carefully brush out the Detack Corotron as not to damage the coronade pins. 2. Make sure that the metal tab on the Detack Corotron engages the High Voltage Lead in the middle of the connector. (Figure 4)

REP 9.21 POB Jam Sensor Cleaning


Removal

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Pull the IBT Module drawer to the Service Position. (GP 2) 2. Raise the IBT Module to the Service Position. (Figure 1) a. Grab the IBT Module Handle and lift. The IBT Module will lock into place.

Tab

A
Figure 4 3. Replace in reverse order. Figure 1

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3. Remove the POB Jam Sensor Assembly. (Figure 2) a. Loosen (1) screw. b. Disconnect the Connector and release the harness from the clamp. c. Pull forward to remove the POB Jam Sensor Assembly.

4. Clean the POB Jam Sensor. (Figure 3) a. Clean the POB Jam Sensor with a dry cloth or a cotton swab.

B A

C
Figure 3 Replacement 1. Replace in reverse order. Figure 2

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REP 9.22 Waste Toner Bottle / Waste Bottle Full Sensor Cleaning

Cleaning NOTE: After replacing the Waste Toner Bottle, reset the HFSI counter (NVM 009-829).

3. To access the Waste Bottle Full Sensor. (Figure 1) a. Remove the Offset Catch Tray (refer to REP 8.11) or undock the Stacker Stapler or other accessory, is present. b. Pull open the Waste Toner Bottle Door. c. Remove the (6) screws and the Right Side Cover.

B
WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Place a drop cloth under the Waste Bottle Door at the back of the Exit Module. 2. To access the Waste Bottle, open the Waste Bottle Door, lift out the Waste Bottle and cover the opening with the cap found on the side of the bottle. Vacuum out the door cavity and insert the new bottle. (reference Figure 1). Dispose of the Waste Toner Bottle according to Local Regulations.

Figure 1

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4. Note the position of the Waste Toner Bottle Full Sensor Assembly. (Figure 2)

5. Clean the Waste Toner Bottle Full Sensor. (Figure 3). a. Clean the Waste Toner Bottle Full Sensor with a dry lint-free cloth.

Figure 2

Figure 3

Replacement 1. Replace in reverse order.

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REP 9.23 Pretransfer Corotron


Removal NOTE: Although all 4 Xerographic Modules have a Pretransfer Corotron Assembly, only the K module has a corotron wire and only that assembly is replaced. NOTE: After replacing the Pretransfer Corotron Assembly, reset the HFSI counter (NVM 009-840).

REP 10.1 Camming Open the Fuser Assembly


Removal

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

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Remove the (K) Drum Assembly. (REP 9.1) 2. Remove the Pretransfer Corotron. (Figure 1) a. Remove the (1) screw. b. Remove the Pretransfer Corotron Assembly.

WARNING Allow the Fuser to cool before performing this procedure.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Pull out the Transport Drawer to the service position. (GP 2)

B
Replacement .1. Replace in reverse order.

A
Figure 1

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2. Remove the Fuser Covers. (Figure 1) a. Remove the 4e Handle b. Remove (1) screw. c. Loosen (2) and the Front Cover. d. Remove the (2) screws and the Top Cover e. Loosen the (1) screw and the Rear Cover

3. Removing the Front Cam Screws. (Figure 2) a. Remove the collar screw first. b. Remove the second screw.

A
Figure 2

A C
C
Figure 1

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4. Removing the Rear Cam Screws. (Figure 3) a. Remove the collar screw first. b. Remove the second screw.

5. Lift open the Fuser Assembly. (Figure 4) a. Place your hands on both sides of the Fuser Assembly. b. Lift open the Fuser Assembly.

B A
Figure 4 Figure 3

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6. Note the position of the cammed open Fuser Assembly (Figure 5)

REP 10.2 Fuser Belt Assembly


Removal

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

WARNING Allow the Fuser to cool before performing this procedure.

Figure 5

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Cam open the Fuser Assembly. (REP 10.1)

Replacement 1. Replace in reverse order.

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2. Remove the Pressure Roll Finger Bracket. (Figure 1) a. Remove the screws (2).

3. Disconnect the Front Inlet Roll Heater Rod and Inlet Roll Thermistor. (Figure 2) a. Disconnect J245 and release the wire from the clamp. (Front Heater Rod) b. Disconnect P133 and release the wire from the clamp. c. Release the Front Spring Roller Assembly.

C B
Figure 1

Figure 2

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4. Disconnect the Rear Inlet Roll Heater Rod. (Figure 3) a. Disconnect P87 and release the wire from the clamps. b. Release the Rear Spring Roller Assembly.

5. Reach under the Pad Assembly (A) with both hands and lift out the Fuser Belt Assembly. Note: You might consider putting on a pair of gloves to remove the Fuser Belt Assembly for there could be some residual Fuser Oil that you may come in contact with. (Figure 4)

A A A

B
Figure 4 Figure 3

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Replacement NOTE: Be careful not to bend the Fuser Belt Position Sensor Spring Finger during reinstallation. (Figure 5)

REP 10.3 Heat Roll


Removal NOTE: After replacing the Heat Roll, reset the HFSI counter (NVM 010800).

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

1
WARNING Allow the Fuser to cool before performing this procedure.

Spring Finger
WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Cam open the Fuser Assembly. (REP 10.1)
Figure 5

1. When repositioning the Pressure Roll Stripper Finger Assembly, bias it away from the Fuser Belt Assembly. 2. Replace in reverse order.

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2. Disconnect P/Js and remove the Heat Rod Bracket. (Figure 1) a. Disconnect P/ J244 and P/ J243. b. Remove (1) screw and the Heater Rod Bracket.

3. Disconnect P37 and P38 at the rear of Fuser Heater Rods. (Figure 2) a. Disconnect P/J 37 and P38. b. Release the wires from the clamp and the (2) brackets.

B B

A
PJs

A
Figure 1 Figure 2

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4. Carefully remove the Heat Roll Heat Rods (A) by gently pulling them out of the front of the Fuser Assembly. (Figure 3)

5. Release the Front Heat Roll Retaining Bracket. (Figure 4) a. Loosen (1) the screw to allow the bracket to release from the frame tab. b. Rotate the bracket clockwise to release the Heat Roll.

B A

Figure 3

Figure 4

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6. Release the Rear Heat Roll Retaining Bracket. (Figure 5) a. Loosen (1) screw to allow the bracket to release from the frame tab. b. Rotate the bracket clockwise to release the Heat Roll.

REP 10. 4 Heat Roll Main Heater Rod


Removal

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

WARNING Allow the Fuser to cool before performing this procedure.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Cam open the Fuser Assembly. (REP 10.1)

B
Figure 5 7. Holding both ends of the Heater Roll, lift it out of the Fuser Assembly.

Replacement 1. Clean the Heat Roll Thermistors before replacing the Heat Roll. (REP 10.9) 2. Straighten out the Heat Rod wires on both ends. 3. While holding the Heat Roll vertically off the edge of your work surface, insert the Heat Rods until the connectors clear the other side. NOTE: The Heat Rods must be aligned properly in the Heat Roll. Ensure that the Heat Rods do not cross inside the roll. 4. Replace in reverse order.

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2. Disconnect the P/J and remove the Heat Rod Bracket. (Figure 1) a. Disconnect P/ J244. b. Remove (1) screw and the Heater Rod Bracket.

3. Disconnect P37 at the rear of Fuser Heater Rods. (Figure 2) a. Disconnect P/J 37. b. Release the wire from the clamp and the (2) brackets. c. Gently pull the Main Heater Rod out of the front of the Fuser Assembly

B B

PJ 244

A
Figure 1 Figure 2 Replacement Note: Before inserting the Heater Rod, straighten out the connector and the wire and gently twist the Heater Rod as it is inserted into the Heat Roll. Make sure the 2 heater rods do not cross inside the Heat Roll. 1. Replace in reverse order.

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REP 10.5 Heat Roll Sub Heater Rod


Removal

2. Disconnect the P/J and remove the Heater Rod Bracket. (Figure 1) a. Disconnect P/ J243. b. Remove (1) screw and the Heater Rod Bracket.

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

WARNING Allow the Fuser to cool before performing this procedure.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Cam open the Fuser Assembly. (REP 10.1)

PJ 243

Figure 1

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3. Disconnect P38 at the rear of Fuser Heater Rods. (Figure 2) a. Disconnect P/J 38. b. Release the wire from the clamp and the (2) brackets. c. Gently pull the Sub Heater Rod out of the front of the Fuser Assembly

REP 10.6 Heat Roll Thermistor Cleaning


Removal

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

B A
WARNING Allow the Fuser to cool before performing this procedure.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Cam open the Fuser Assembly. (REP 10.1) 2. Remove the Heat Roll. (REP 10.3)

Figure 2 Replacement Note: Before inserting the Heater Rod, straighten out the connector and the wire and gently twist the heat rod as it is inserted into the Heat Roll. Make sure the 2 heater rods do not cross inside the Heat Roll. 1. Replace in the reverse order.

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3. Clean the Fuser Heat Roll Thermistors with a cloth and film cleaner. (Figure 1) a. Control Thermistor b. Overheat Thermistor c. Sub Thermistor

REP 10.7 External Heat Roll


Removal

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

WARNING Allow the Fuser to cool before performing this procedure.

B A
Figure 1 Replacement 1. Replace in the reverse order.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Pull out the Transport Drawer to the service position.

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2. Remove the Fuser Covers. (Figure 1) a. Remove the 4e Handle b. Remove (1) screw. c. Loosen (2) and the Front Cover. d. Remove the (2) screws and the Top Cover e. Loosen the (1) screw and the Rear Cover

3. Open the External Heat Roll Assembly. (Figure 2) a. Remove the screws (4) and lift up on the External Frame Assembly. b. Flip the Assembly over in a counterclockwise manner.

A B A

A C
C
Figure 1

Figure 2

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4. Disconnect the External Heat Rod (front). (Figure 3) a. Disconnect J246 and remove the wire from the clamps. b. Remove the (1) screw and the bracket.

5. Disconnect the External Heat Rod (rear). (Figure 4) a. Disconnect J88 and remove the wire from the clamp. b. Remove the (1) screw and the bracket.

B B A
Figure 3 Figure 4

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6. Remove the External Heat Roll. (Figure 5) NOTE: Although Figure 5 shows the External Heat Roll without the Heat Rod, remove the Heat Roll with the Heat Rod in place. a. Lift the External Heat Roll out of the Assembly.

REP 10.8 External Heat Roll Thermistor Cleaning


Removal

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

WARNING Allow the Fuser to cool before performing this procedure.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Pull out the Transport Drawer to the service position.

Figure 5 Replacement 1. Clean the External Heat Roll Thermistors before replacing the External Heat Roll. (REP 10.8) 2. Replace in reverse order

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2. Remove the Fuser Covers. (Figure 1) a. Remove the 4e Handle b. Remove (1) screw. c. Loosen (2) and the Front Cover. d. Remove the (2) screws and the Top Cover e. Loosen the (1) screw and the Rear Cover

3. Open the External Heat Roll Assembly. (Figure 2) a. Remove the screws (4) and lift up on the External Frame Assembly. b. Flip the Assembly over in a counterclockwise manner.

A B A

A C
C
Figure 1

Figure 2

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4. Remove the External Heat Roll Thermistors. (Figure 3) a. Remove the (1) screw for the Control Thermistor. b. Remove the (1) screw for the Overheat Thermistor.

5. Clean the thermistors. (Figure 4) a. Clean the thermistors with a cloth dampened with film cleaner

Figure 3 Figure 4 Replacement 1. Replace in reverse order.

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REP 10.9 Fuser Web Assembly


Removal NOTE: After replacing the Fuser Web Assembly, reset the HFSI counter (NVM 010-804).

3. Remove the Fuser Web Assembly. (Figure 1) a. Remove the (2) screws. b. Rotate the Assembly from the top and pull the Web Assembly out.

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

1
WARNING Allow the Fuser to cool before performing this procedure.

2B

A
1

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Pull out the Transport Drawer to the service position. (GP 2) 2. Open the Duplex Inverter (Handle 4) and the Fuser Exit Chute (Handle 4d).

Figure 1

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Replacement 1. When replacing the Fuser Web Assembly, make sure to get both pins on each side into the frame rails before pivoting the Assembly up into the proper positon. (Figure 2)

REP 10.10 Fuser Donor Roll Assembly


Removal NOTE: After replacing the Donor Roll Assembly, reset the HFSI counter (NVM 010-806).

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

WARNING Allow the Fuser to cool before performing this procedure.

Pins

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Pull out the Transport Drawer to the service position.
Figure 2

2. Replace in reverse order.

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2. Remove the Fuser Covers. (Figure 1) a. Remove the 4e Handle b. Remove (1) screw. c. Loosen (2) and the Front Cover. d. Remove the (2) screws and the Top Cover e. Loosen the (1) screw and the Rear Cover

3. Remove the Fuser Donor Roll Assembly (front). (Figure 2) a. Remove the spring. b. Remove the K-clip and gear. c. Remove the K-clip and slide the bearing off of the shaft.

B A E

C
B

A C
C
Figure 1

Figure 2 (front)

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4. Remove the Fuser Donor Roll Assembly (rear). (Figure 3) a. Remove the spring. b. Remove the clip and gear. c. Slide the bearing off of the shaft.

Replacement

CAUTION Installing the Fuser Donor Roll Assembly incorrectly will damage the Fuser resulting in paper jams or copy quality problems. 6. Install the Donor Roll Assembly. (Figure 4) a. Ensure that the Metering Blade Assembly is in the position shown in the CORRECT Insert shown in Figure 4. b. As the Assembly is lowered into position, allow the Wick Plate Spring to guide the Metering Blade Assembly into the wick channel.

A C
Figure 3 (rear) 5. Lift both ends of the Donor Roll Assembly to remove it from the Fuser Assembly. Correct Position

Incorrect Position Figure 4

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REP 10.11 Heat Roll Wick


Removal NOTE: After replacing the Wick, reset the HFSI counter (NVM 010-808).

2. Remove the Fuser Wick. (Figure 1) a. Remove the screws (3). b. Slide the Fuser Wick under the Oiling Pipe and remove.

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

WARNING Allow the Fuser to cool before performing this procedure.

A
WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. NOTE: You may want to wear a pair of gloves to perform this procedure. 1. Remove the Fuser Donor Roll Assembly. (REP 10.10) Replacement 1. Replace in reverse order. Figure 1

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REP 10.12 Fuser Oil Filter


Removal NOTE: After replacing the Fuser Belt, reset the HFSI counter (NVM 010809).

2. Remove the Fuser Oil Filter. (Figure 1) a. Remove the filter by lifting up on it.

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

WARNING Allow the Fuser to cool before performing this procedure.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. NOTE: You may want to wear a pair of gloves to perform this procedure. 1. Remove the Fuser Heat Roll Wick. (REP 10.11) Figure 1 Oil Filter (partially removed) Replacement 1. Replace in reverse order.

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REP 10.13 External Heat Roll Latch Sensor Cleaning


Removal / Cleaning

2. Clean the Fuser External Heat Roll Latch Sensor. (Figure 1) a. Remove the screw. b. Remove the Sensor bracket, and clean the sensor with a cotton swab.

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

WARNING Allow the Fuser to cool before performing this procedure.

A B

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Flip open the Fuser External Heat Roll Assembly but do not remove. (REP 10 7)

Figure 1 Replacement 1. Replace in reverse order.

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REP 10.14 Fuser Exit Sensor Cleaning


Removal / Cleaning

3. Remove the Fuser Exit Sensor. (Figure 1) a. Remove the screw. b. Clean the Sensor with a cotton swab.

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

B
WARNING Allow the Fuser to cool before performing this procedure.

A
WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Pull out the Transport Drawer to the service position. 2. Open the Duplex Inverter (Handle 4) and the Fuser Exit Chute (Handle 4d). Figure 1 Replacement 1. Replace in reverse order.

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REP 10.15 Heat Roll Finger Assembly


Removal / Cleaning NOTE: After cleaning the Finger Assembly, reset the HFSI counter (NVM 010-807). After replacing the Finger Assembly, reset the HFSI counter (NVM 010-812).

2. Remove the Fuser Heat Roll Stripper Finger Assembly. (Figure 1) a. Remove the front and rear screws while holding onto the Assembly. b. Carefully remove / clean the Stripper Fingers to avoid damage to the Heat Roll and / or the Fuser Belt Assembly.

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

WARNING Allow the Fuser to cool before performing this procedure.

B
WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Remove the Fuser Web Material Assembly (REP 10.9). Figure 1 Replacement 1. Replace in reverse order.

Repairs and Adjustments

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REP 10.16 Fuser Walk Sensor


Removal

3. Clean the Fuser Walk Sensor. (Figure 1) a. Clean the Fuser Walk Sensor with a dry cotton swab.

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

WARNING Allow the Fuser to cool before performing this procedure.

WARNING Fuser Oil is an eye irritant. Do not rub eyes after handling Fuser Components. 1. Pull out the Transport Drawer to the service position. 2. Remove the Vacuum Transport Assembly #2. (REP 8.1) Figure 1 Replacement 1. Replace in reverse order.

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REP 13.1 IOT Upper Front Cover


Removal

WARNING Switch OFF the Power, disconnect the Power Cord, and apply the Safety Lockout Kit. (see GP 7) 1. Open the IOT Front Doors. 2. Remove the Upper Front Cover. (Figure 1) a. Remove (8) screws.

A A

Figure 1

Replacement 1. Replace in reverse order.

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ADJ 9.1 Max Setup (v6.2.2)


Purpose The purpose of this procedure is to optimize toner density levels and obtain consistent image quality. NOTE: If a fault occurs during any procedure, Call for Service. NOTE: The following procedure is to be used with v6.2.2 Machine Software only. Preliminary Actions 1. Suspend printing at the DFE. 2. Make sure all covers are in place and all the doors are closed. 3. Fix all apparent Image Quality problems (Section 3) and check the Call Flow Procedure (Section 1). 4. Perform Every Call Cleaning Procedure. (Section 1) 5. Replace all HFSI Components at or near threshold. (GP 4) 6. Load 11 x 17 or A3, 24 lb. paper (Color Expressions or an equivalent) into Tray 2. 7. Run 30 prints of the of the DC612 Color Test Pattern List (Pro-Con Test Pattern 5-1) to stabilize Process Control. Max Setup Adjustment DC 930 Process Control Status 1. Enter the Diagnostic Mode using the DCU. (GP 6) 2. Select Max Setup in the Diagnostic Mode. a. The following message will appear: PLEASE WAIT NVM CHANGE IN PROGRESS b. When the NVM change is complete, the following message will appear and toggle between lines 2 and 3: DC 930 PROCON SWITCH JUDGE SWITCH STATUS: OK SELECT: (N)EXT (B)ACK (V)IEW (Q)UIT

3. Press the Accept Key to stop the toggle.

DC 934 ADC / ADG Setup 4. Select (N)EXT and press the ACCEPT key.
a. The following message will be displayed: DC934 ADC AGC SETUP b. SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

5. Select (S)TART, and press the ACCEPT key. a. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETE = 312 SECONDS b. At the completion of the program, the following message will be displayed: DC934 SET UP COMPLETE: VALUES OK SELECT: (N)EXT (V)IEW (B)ACK (Q)UIT

DC 933 VH / VM Setup 6. Select (N)EXT and press the Accept key. a. The following message will be displayed: DC933 VH / VM SETUP SELECT: (S)TART (N)EXT (B)ACK (Q)UIT 7. Select (S)TART, and press the ACCEPT key. a. The following message will be displayed: PLEASE WAIT, SET UP IN PROGRESS TIME TO COMPLETE = 285 SECONDS b. At the completion of the program, the following message will be displayed: SET UP COMPLETE, VH / VM SETUP OK SELECT: (N)EXT (B)ACK (V)IEW (Q)UIT

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DC 918 DC918 Hi Light ASG Bias Adjustment 8. Select (N)EXT and press the ACCEPT key. a. The following message will be displayed and toggle lines 2 and 3: DC918 HI-LT. MAN. SETUP: IB / OB ASG BIAS SCREEN DESIGNATION = 300-0, TRAY 2 DC918 HI-LT. MAN. SETUP: IB / OB ASG BIAS SELECT: (S)TART (N)EXT (B)ACK (Q)UIT 9. Press the ACCEPT key to stop the toggle. 10. Select (S)TART, and press the ACCEPT key. a. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS CHECK IB / OB DENSITY @ COMPLETION b. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern: IB / OB DENSITY OK? SELECT: (N)EXT (A)DJUST DC 918 Adjustment Check: Using the test print in the output tray, visually check the entire print and compare the side to side density 30 mm in from each side. The density of the inboard side of the print is fixed. The density of the OB side of the print is adjustable. (Figure 1) Inboard Figure 1 c. If there is no difference IB to OB for all colors, select (N)ext and press the ACCEPT key and continue with step 11 of the Max Setup. d. If an adjustment to the OB density is required, select (A)DJUST and press the ACCEPT key. The following message will be displayed: (Note: you may want to write down the current values for reference) DARKER = (DOWN), LIGHTER = (UP) Y = OXXX M = OXXX C = OXXX K = OXXX Outboard 30 mm

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Adjustment - Use the right and left arrow keys to select the color that need adjusting. - Use the up and down arrow keys to change the value (XXX). - A lower number will darken the outboard end of the selected color. - A higher number will lighten the outboard end of the selected color. e. Select (S)AVE, and press the ACCEPT key when you are finished with the required changes. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (S)TART (B)ACK f. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT SETUP IN PROGRESS CHECK IB / OB @ COMPLETION g. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern: IB / OB DENSITY OK? SELECT: (N)EXT (A)DJUST h. Repeat the check and / or adjustment until the IB / OB densities are balanced. 11. When the IB / OB density check is OK, the (N)ext key and the ACCEPT keys selected: a. The following message will be displayed and toggle between lines 2 and 3: DC918 HI - LT MAN SETUP: HI - LT ASG BIAS SCREEN DESIGNATION = 300 - 0 TRAY = 2 SELECT: (S)TART (N)EXT (B)ACK (Q)UIT

b. Press the ACCEPT key to stop the toggle. c. Select (S)TART and press the ACCEPT key, the following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS CHECK SQUARE DENSITY @ COMPLETION d. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern: 300 - 0 COMPLETE, SQUARE DENSITY OK? SELECT: (S)AVE (A)DJUST DC918 Hi Light ASG Bias Adjustment (300 - 0) Check: For the 300 - 0 pattern, the C, M, Y, and K squares in the 9th row should be barely visible while the squares in the 8th row are clearly visible. (Figure 2)

Eighth Row Ninth Row

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e. If the density is OK for all colors, select (S)ave and press the ACCEPT key and continue with step 11b of the Max Setup. f. If the density of any or all colors are not OK, select (A)djust and select the ACCEPT key. The following screen will be displayed: (Note: you may want to write down the current values for reference) DARKER = (UP), LIGHTER = (DOWN) Y = OXXX M = OXXX C = OXXX K = OXXX Adjustment - Use the right and left arrow keys to select the color that need adjusting. - Use the up and down arrow keys to change the value (XXX). - A higher number will darken the selected color. - A lower number will lighten the selected color. g. Select (S)AVE, and press the ACCEPT key when you are finished with the required changes. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (S)TART (N)EXT (B)ACK (Q)UIT h. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT SETUP IN PROGRESS CHECK SQUARE DENSITY @ COMPLETION i. When all squares have meet the requirements in the Check procedure, Select (S)AVE, and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT

11B. Select (N)EXT and press the ACCEPT key. a. The following message will be displayed and toggle between line 2 and 3: DC918 HI - LT MAN SETUP: HI - LT ASG BIAS SCREEN DESIGNATION = 300 - 180 TRAY = 2 SELECT: (S)TART (N)EXT (B)ACK (Q)UIT b. Press the ACCEPT key to stop the toggle c. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS CHECK SQUARE - DENSITY @ COMPLETION d. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern: 300 - 180 COMPLETE, SQUARE DENSITY OK? SELECT: (S)AVE (A)DJUST DC918 Hi Light ASG Bias Adjustment (300 - 180) Check: For the 300 - 180 pattern, the C, M, Y, and K squares in the 9th row should be barely visible while the squares in the 8th row are clearly visible. (see figure 2) d. If the density is OK for all colors, select (S)ave and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT Select (N)ext and continue with step 11C of the Max Setup. e. If the density of any or all colors are not OK, select (A)djust and press the ACCEPT key. the following screen will be displayed: (Note: you may want to write down the current values for reference) DARKER = (UP), LIGHTER = (DOWN) Y = OXXX M = OXXX C = OXXX K = OXXX

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Adjustment - Use the right and left arrow keys to select the color that need adjusting. - Use the up and down arrow keys to change the value (XXXX). - A higher number will darken the selected color. - A lower number will lighten the selected color. f. Select (S)AVE, and press the ACCEPT key when you are finished with the required changes. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (S)TART (N)EXT (B)ACK (Q)UIT g. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT SETUP IN PROGRESS CHECK SQUARE DENSITY @ COMPLETION h. When all squares have meet the requirements in the Check procedure, Select (S)AVE, and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT 11C. The following message will be displayed and toggle lines 2 and 3. DC918 HI - LT MAN SETUP: HI - LT ASG BIAS SCREEN DESIGNATION = 600 TRAY = 2 SELECT: (S)TART (N)EXT (B)ACK (Q)UIT a. Press the ACCEPT key to stop the toggle.

b. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS CHECK SQUARE - DENSITY @ COMPLETION c. At the completion of the routine, the following message will be displayed and the machine will produce a test pattern: 600 COMPLETE, SQUARE DENSITY OK? SELECT: (S)AVE (A)DJUST

DC918 Hi Light ASG Bias Adjustment (600) Check: For the 600 pattern, the C, M, Y, and K squares in the 9th row should be barely visible while the squares in the 8th row are clearly visible. (see figure 2) d. If the density is OK for all colors, select (S)ave and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT Select (N)ext and continue with step 12 of the Max Setup. e. If the density of any or all colors are not OK, select (A)djust and press the ACCEPT key. The following screen will be displayed: (Note: you may want to write down the current values for reference) DARKER = (UP), LIGHTER = (DOWN) Y = OXXX M = OXXX C = OXXX K = OXXX Adjustment - Use the right and left arrow keys to select the color that need adjusting. - Use the up and down arrow keys to change the value (XXX). - A higher number will darken the selected color. - A lower number will lighten the selected color.

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f. Select (S)AVE, and press the ACCEPT key when you are finished with the required changes. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (S)TART (N)EXT (B)ACK (Q)UIT g. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS CHECK SQUARE DENSITY @ COMPLETION h. When all squares have meet the requirements in the Check procedure, Select (S)AVE, and press the ACCEPT key. The following message will be displayed: DC918 SAVE FUNCTION IS COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT DC 917 ALC / TRC Target Setup 12. The following message will be displayed: DC917 ALC / TRC TARGET SET SELECT: (S)TART (N)EXT (Q)UIT a. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT SETUP IN PROGRESS SAVE VALUES AT SET UP COMPLETION b. At the completion of the routine, the following message will be displayed: DC917 SETUP COMPLETE, VALUES OK? SELECT (S)AVE c. Press the ACCEPT key. The following message will be displayed: DC917 SAVE COMPLETE SELECT: (N)EXT (B)ACK (V)IEW (Q)UIT

d. Select (N)EXT and press the ACCEPT key.

DC 922 TRC Control Setup 13. The following message will be displayed DC922 TRC CONTROL: ASG SWITCHES ON SELECT: (S)TART (N)EXT (B)ACK (Q)UIT a. Select (S)TART, and press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETE = 314 SECONDS b. At the completion of the routine, the following message will be displayed: DC922 TRC CNTRL COMPLETE SELECT: (S)TART AGAIN c. Press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETE - 314 SECONDS d. At the completion of the routine, the following message will be displayed and toggle, only if the machine needs the Tone Up / Tone Down Adjustment. If the Machine is within its specification, go to step (h). DC922 TRC CNTRL COMPLETE: TONE UP / DN ?? SELECT: (A)DJUST (V)IEW (B)ACK (Q)UIT DC922 TRC COMPLETE: TONE UP / DN NG Y = ?? M = ?? C = ?? K = ?? e. Press the ACCEPT key to stop the toggle. f. Select (A)DJUST and press the ACCEPT key. At the completion of the routine, the following message will be displayed and toggle:

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Y = OK, PRINTS = XX C = OK, PRINTS = XX

M = OK, PRINTS = XX K = OK, PRINTS = XX

TONE UP / DOWN ADJUST SELECTED, TRAY 2 SELECT: (S)TART g. Press the ACCEPT key. The following message will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETE - 314 SECONDS h. At the completion of the routine, the following message will be displayed DC922 TRC CNTRL COMPLETE: RADC OK? SELECT: (N)EXT (V)IEW (Q)UIT i. Select (N)EXT and press the ACCEPT key. 14. The following message will be displayed: DC922 TRC CNTRL COMPLETE: TONE UP / DN OK? SELECT: (N)EXT (V)IEW (Q)UIT
a. If your machine configuration is for printer only, select (Q)UIT and press the ACCEPT key

b. Press the ACCEPT key to stop the toggle. c. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT FOR CALIBRATION TO COMPLETE d. At the completion of the routine, the following message will be displayed: CALIBRATION COMPLETE: REMOVE PAPER e. Select (N)EXT and press the ACCEPT key. 16. The following message will be displayed and toggle: DC 945 IIT CALIBRATION: CCD CALIBRATION PLACE TEST PATTERN ON PLATEN TEST PATTERN ON PLATEN? SELECT: (S)TART (N)EXT (B)ACK (Q)UIT a. Place Test Pattern on the platen (reference figure 3). b. Press the ACCEPT key to stop the toggle. c. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT FOR CALIBRATION TO COMPLETE AT COMPLETION, REMOVE TEST PATTERN CALIBRATION COMPLETE SELECT: (N)EXT (B)ACK (Q)UIT d. Select (N)EXT and press the ACCEPT key. DC 926 17. The following message will be displayed and toggle: DC 926 C-POP TRC CONTROL TOT REQUIRES 11X17 OR A3 PAPER SELECT: (S)TART (B)ACK (Q)UIT

b. If your machine is equipped with a scanner, select (N)EXT and press the ACCEPT key. DC 945 IIT Calibration 15. The following message will be displayed and toggle: DC 945 IIT CALIBRATION: WHITE REFERENCE PLACE PAPER ON PLATEN PAPER ON PLATEN? SELECT: (S)TART (N)EXT (B)ACK (Q)UIT a. Place 10 sheets of 11x17, 24 lb. paper on the platen. (Color Expressions or equivalent)

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a. Select (S)TART and press the ACCEPT key. The following message will be displayed: PLEASE WAIT FOR SETUP TO COMPLETE TIME TO COMPLETE - 330 SECONDS b. Upon completion, the following message will be displayed: DC TEST COMPLETE SELECT: (N)EXT c. Select (N)EXT and press the ACCEPT key. The following message will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT d. Select (E)XIT and press the ACCEPT key. Scanner Color Balance 18. Enter the Tools Mode, Tools Pathway and select the More tab. 19. Select Feature Defaults 1 and set the following to 0 or Auto: a. Lighten / Darken b. Color Balance (0) for C, M, Y, and K c. Color Shift (0) d. Chroma (0) Normal 20. Exit Tools Mode and select the Features button to access the Copier Mode Screen (Ready for Scan to Print). Ensure that Color Expressions 24 lb. 11x17 / Colotech 90 gsm A3 paper is loaded in one of the paper trays. in the Copier Mode screen, select the following: a. Basic Features, Full Color and 100% Reduce / Enlarge. b. The Paper Tray with 11 x 17 loaded. b. Added Features, Image Shift, Set to No Shift, Save. c. Image Quality, Original Type. Set the Auto Photo & Text and Halftone, Save. 21. Place test pattern 82E13120 on the Platen, and make 2 copies. 22. Check the second copy. (Figure 3)

a. The C, M, and Y in column 10 on the print should be well defined (visible). Magenta (M) should be better defined (darker) than C and Y. b. Fold the copy between the upper and lower gray-scale rows. c. Compare the gray scale on the copy to the gray scale on the 82E13120 test pattern, between the 60% column and the 30% column, on the Test Pattern. (Figure 3) NOTE: you may see a hue shift at 30% and below.

Copy

60% 30%

Test Pattern
Figure 3

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23. If an Adjustment is needed a. Select Tools Pathway Mode, Features Default 1, Color Balance. Use Density, Low and Med to bring in the grays. Select Close. b. Repeat Steps 21 through 22 until the copies match the test pattern c. Using the Image Quality Supplement, refer to the 3.2.2 IOT Setup for Full-Color Output Check (Without Modified Restore Chart) or to the 3.2.2 IOT Setup for Full-Color Output Check (With Modified Restore Chart) to confirm the IQ setup. 24. After completing the image quality setup, label the final output prints with the Machine Number, Date and Meter Count and place the prints in the Right Front Door Compartment for future reference.

ADJ 9.2 Belt Edge Learn Mode


Purpose To ensure that the IBT belt is in its correct tracking position by establishing a profile table using the Belt Edge sensors. Procedure 1. Enter the DCU Diagnostics (GP 6). The following screen will be displayed: (1) BELT EDGE LEARN, (2) REGICON (3) MAX SETUP, (4) HALFTONE 2. Select (1) BELT EDGE LEARN, and press the ACCEPT key. The following screen will be displayed: DC 956 BELT EDGE LEARN MODE SELEECT: (S)TART (N)EXT 3. Select (S)TART and press the ACCEPT key. The following screen will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETION = 100 SECONDS 4. Upon completion of the routine, the following screen will be displayed and toggle between lines 2 and 3: DC956 SETUP COMPLETED EDGE PROFILE SUCCESSFUL SELECT (N)EXT 5. Press the ACCEPT key to stop the toggle. 6. Select (N)EXT and press the ACCEPT key. The following screen will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT 7. Select (E)XIT and press the ACCEPT key.

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ADJ 9.3 RegiCon Sensor Check


Purpose To determine the correct operation of the Registration Control Sensor by detecting any mis-registration of a cyan patch on the IBT belt as measured by the MOB sensor. Procedure 1. Enter the DCU Diagnostics (GP 6). The following screen will be displayed: (1) BELT EDGE LEARN, (2) REGICON (3) MAX SETUP, (4) HALFTONE 2. Select (2) REGICON, and press the ACCEPT key. The following screen will be displayed: DC 685 REGICON SETUP SELEECT: (S)TART (Q)UIT 3. Select (S)TART and press the ACCEPT key. The following screen will be displayed: PLEASE WAIT, SETUP IN PROGRESS TIME TO COMPLETION = 100 SECONDS 4. Upon completion of the routine, the following screen will be displayed: DC685 SETUP COMPLETED SELECT (N)EXT 5. Select (N)EXT and press the ACCEPT key. The following screen will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT 6. Select (E)XIT and press the ACCEPT key.

ADJ 10.1 Fuser Nip


Purpose The purpose is to ensure that the proper pressure is applied to the print as it passes through the fuser. Check 1. Enter DC701 Fuser Nip Measurement in the TKO Pathway. (GP 3) 2. Select a tray with either 8.5x11 (A4) or 11x17 (A3) 24lb (90gsm) paper. NOTE: For best results use Xerox Color Xpressions paper. 3. Select Start. NOTE: The print comes out upside down. Ensure that you mark the black side of the print Inboard and Outboard. 4. Remove the print and mark the Inboard and Outboard side of the print. NOTE: The Fuser Nip is located about the center of the print on the black side. 5. Select DC612 Color Test Pattern Print. Select Pattern 7 Color Reg. Run three prints. 6. Perform DC701 Fuser Nip Measurement two more times after waiting at least 30 seconds between each run and perform DC612 Pattern 7 Color Reg. between each nip check. NOTE: Steps 5 and 6 are performed to stabilize the Fuser. 7. On the last of the Fuser Nip prints, measure 10mm in from the edge at the Fuser Nip on the Inboard and Outboard side. 8. If the Fuser Nip measurements do not meet the following specifications, perform the adjustment: 4.1mm +/- .2mm Inboard 4.2mm +/- .2mm Outboard

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Adjustment 1. Pull out the Transport Drawer to the service position. 2. Open the Inverter Transport (handle 4c) and the Fuser Exit Chute Assembly (handle 4d). (Figure 1)

3. Adjust the (2) screws (A) located through the hole in the P/R Finger Bracket: (Figure 2) To increase the nip, turn both screws CW. To decrease the nip, turn both screws CCW. NOTE: One full turn equals .5mm.

Fuser Exit Chute

Inverter Transport Figure 2 Figure 1

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ADJ 10.2 Fuser Pad Spring


Purpose The purpose is to adjust the Fuser Pad Spring to eliminate the problem of Rib Marks and Water Marks on the print or copy output. Prerequisite 1. Check all the 100K HFSI Counters. If any of the following items are over 80% threshold, replace them now. a. Sheet Pad - replace the Fuser Belt Assembly b. Pad (or Belt) Wick Assembly - replace the Fuser Belt Assembly c. Fuser Belt 2. Check all the 300K HFSI Counters. Adjustment 1. Remove the Web Material Assembly. (REP 10.9) 2. Cam open the Fuser Web Assembly. (REP 10.1)

3. Remove the Pressure Roll Finger Assembly. (Figure 1) a. Remove 2 screws

Figure 1

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4. Review the characteristics of the Pad Spring Adjustment Tool. (Figure 2)

6. Position the Tool against the Pad Spring. You may need to adjust the Pad Spring CW or CCW to allow the Tool to be positioned correctly. (Figure 4)

Faces Inboard

Pin 1 Pin 2

Faces Outboard

Pin 3

Figure 2

5. Observe the location of the 3 pins for the proper placement of Pad Spring Tool. (Figure 3)

Pin 2
Figure 4

Pin 3

Pin 1

Figure 3

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7. Adjust the Pad Screw so that the Pad Spring is equal to 42mm. (Figure 5) a. Rotate the adjustment screw slowly CW until it stops. b. Rotate the screw 1/4 revolution CCW (90 degrees) and remove the tool.

Checking for defects after adjusting the Pad Screws 1. Load 81-135 gsm coated two-sided paper in Tray # 3. (It is recommended that you use paper that is on the Recommended Papers List) 2. Ensure that all the tray settings are correct. 3. Print (10) simplex 40% K halftones (pattern 3-1) and check for defects. (refer to the DC 2060/45 Rib Mark / Water Mark Identification Document) If no defect is present, proceed to 4. If a defect is present, it is either case #1 or #2, go to the Adjustment for Rib Marks. (step 6) 4. Print (30) duplex 40% K halftones (pattern 3-1) and check for defects. Inspect both sides of the print but pay close attention to the second side. (refer to the DC 2060 / 2045 Rib Mark / Water Mark Identification Document) If no defect is present, proceed to 4. If a defect is present, it is either case #1 or #2, go to the Adjustment for Water Marks. (step 9) 5. Print (50) duplex 40% 4-color halftones. If no defects appear, the adjustment is complete. If a defect does appear, proceed to the Fine Tune Adjustment. (step 12) NOTE: The following steps are for the Adjustment for Rib Marks. 6. Adjust the inboard and outboard Pad Screws (1) full Turn CW. 7. Perform the Fuser Nip Adjustment to ensure Pressure Roll Nip is still within specification. 8. Return to step 3. NOTE: The following steps are for the Adjustment for Water Marks. 9. Adjust the inboard and outboard Pad Screws (1) full Turn CCW. 10. Perform the Fuser Nip Adjustment to ensure Pressure Roll Nip is still within specification. 11. Return to step 4.

Figure 5 8. Perform the same procedure for the outboard Pad Spring. 9. Install the Web Material Assembly and the Pressure Roll Stripper Finger Assembly. 10. Perform the Adjustment Procedure for the Fuser Nip.

NOTE: The following steps are for the Fine Tune Adjustment. 12. This is a high stress case using the 40% 4-color halftones as a print sample (step 5) and might require a half or quarter turn of the Pad Screws. If you are directed here, use the same process but use half and quarter turns to eliminate the defect. You also would use the Fine Tune Adjustment if (1) full turns changes the defect from one to another.

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6. General Procedures
General Procedures
GP 1 Xerographic Hard Stop ..................................................... 6-3 GP 2 Moving the Paper Path, IBT Module to the Service Position 6-4 GP 3 Entering Tools Mode and TKO Diagnostics on the UI...... 6-6 GP 4 Clearing and Changing HFSI Thresholds......................... 6-6 GP 5 Moving Tray 3 into the Service Position .......................... 6-7 GP 6 Diagnostic Control Unit (DCU) Operation ........................ 6-7 GP 7 Safety Lockout Kit Installation ......................................... 6-10 GP 8 Replenishing the Fuser Oil .............................................. 6-12 GP 9 Generating DCU Test Patterns ........................................ 6-13 GP 10 Undocking Tray 4 ........................................................ 6-14

Product Specifications
General Information ................................................................... 6-16 Product Specifications ............................................................... 6-16

Consumables
Machine Consumables .............................................................. 6-18

Change Tag Information


Change Tag Introduction ........................................................... 6-19

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GP 1 Xerographic Hard Stop


Purpose To stop the machine while it is in the xerographic process cycle to enable fault isolation of the xerographic components. Procedure 1. Select 10 prints / copies of the Test pattern that displayed the fault. 2. Press the Start Button on the UI Control Panel. 3. When the first print enters the Catch Tray or an Output Device, open the Right Front Door.

5. Move the IBT Belt in a clockwise direction by rotating the IBT Belt Drive Motor (CCW) by hand in order to see the image. (Figure 1) NOTE: Be sure to clear the machine of all the paper that has been fed.

WARNING Switch OFF the power, disconnect the Power Cord, and apply the Safety Lockout Kit (see GP 7). 4. Extend the IBT Drawer out to the service position. (reference GP 2)

Figure 1

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General Procedures

GP 2 Moving the Paper Path Module and IBT Module to the Service Position
Purpose To enable access to the particular module for ease of service. Procedure WARNING Switch OFF the power, disconnect the Power Cord, and apply the Safety Lockout Kit (see GP 8). 1. Open the Front Doors and remove the Upper Inner Cover. NOTE: The Interlock Cover has to be removed when removing the IBT Module. This cover is a mechanical interlock for the IBT Module.

2. Remove the Interlock Cover. (Figure 1) a. Loosen the screw. b. Remove the Cover

B A

Figure 1

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3. Unlatch the IBT Module (A) and /or the Paper Handling Module (B) and pull it out of the machine. Note the position of the Rail Release Latches. (Figure 2)

CAUTION Always unlatch the Paper Handling Module before pulling out the IBT Module.

4. To get the Assemblies into and out of the Service Position, perform the following: (Figure 3) a. To get the Assemblies into the Service Position: Use a small pointed tool, such as a screwdriver, push in through the hole while pulling out on the Assembly, to release the rail. Repeat for the other side and pull the Assembly out until it locks into place. b. To release the Assembly from the Service Position: Push in on the Rail Release Latch, while pushing in the Assembly. Repeat for the other side to push the Assembly into the machine.

A B A
Figure 3

B B
Figure 2

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GP 3 Entering Tools Mode and TKO Diagnostics on the User Interface


Entering, and exiting the Tools Mode and TKO Diagnostics.

GP 4 Clearing and Changing the HFSI Thresholds


The HFSI Thresholds can be customized to reflect the operational requirements of each machine. Some may need to be lowered to ensure reliability, some may be raised to extend the life of that component. Procedure 1. Press the Access button on the UI Control Panel. The Password screen will open. 2. Using the 10-Key Pad, type the password and press Enter. The default password is five ones (11111). 3. Select TKO Pathway 4. Select DC135 HFSI Counters and perform the following: a. To clear an existing HFSI counter: Using the 10-Key Pad, enter the 4 digit Chain Link No. for the appropriate HFSI Counter. The HFSI Counter must be displayed on the screen to work. You cannot enter a HFSI Counter number that is not displayed. Press the Clear All button on the Control Panel to reset the Current Life to "0". b. To set a new HFSI Threshold value: Using the 10-Key Pad, enter the 4 digit Chain Link No. for the appropriate HFSI Counter. Press the Correct button on the screen. Using the 10-Key Pad, enter the new Spec Number value, and press the Start button on the Control Panel to lock in the value.

CAUTION Under no circumstances are you to enter the Auditron Administration Pathway when accessing Diagnostics. If you cannot enter the Diagnostic mode, contact the System Administrator for the current password. Procedure 1. Press the Access key on the UI Control Panel. The Password screen will open. 2. Using the 10-Key Pad, type the password and press Enter. The default password is five ones (11111). 3. Select the desired pathway. a. Tools Pathway b. TKO Pathway 4. To exit Diagnostics: In the Tools Mode before selecting a pathway, touch the Cancel button. To exit while in a Tools Pathway, touch the Exit button. In the TKO Pathway, at the Diagnostic Entry screen, touch the Complete button. At the Diagnostics Exit screen, press the Start button on the Control Panel.

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GP 5 Moving Tray 3 into the Service Position

GP 6 Diagnostic Control Unit (DCU) Operation

Procedure
1. Open Tray 3. 2. Using a small pointed tool, such as a screwdriver, push in through the hole in the rail while pulling out on the Tray Assembly. Repeat on the other side, and pull the Assembly out until it locks into place. (see Figure 1) 3. To Release the Tray Assembly, push in on the Rail Release Latch while pushing in on the Assembly. Repeat on the other side, to push the Assembly into the machine. (see Figure 1)

Control Panel Description and Functionality


The DCUs control panel is made up of an LCD display, and (5) pressure sensitive switches. (Table 1)
Table 1 Item Symbol Description

Left / Right Carats

<,>

Up / Down Carats /\ , \/

Latch

Hole
Accept Key

LCD Display

N/A

Advances the display selection list to the right or left. They are used in conjunction with the Accept key. Scrolls the display that exceeds the two line LCD display capability. Also increments numerical values. Confirmation key, used to enter the current User selection. Capable of displaying two lines of text, provides User selection information.

Figure 1

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Powering On the DCU


1. Remove the protective tape from the 4 Velcro Tabs on the bottom of the DCU and position the DCU onto the Top Cover of the DocuColor 2060/2045 just to the right of the User Interface. (Figure 1)

2. Connect the Power Cord to the Power Supply but do not plug the assembly into a wall receptacle at this time. 3. Connect the Power Cord and the 25 pin connector end of the Interface Cable to the DCU (Figure 2)

Interface Cable

Power Cord

Figure 2 Figure 1

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4. Connect the 9 pin DB Connector end of the Interface Cable to the IOT Diagnostic Port on the Electrical Module. (Figure 3)

1. Depress either the Up or Down Carat key or the Accept key to activate the DCU menu display. The following screen will appear: WELCOME CHOOSE ANOTHER LANGUAGE? SELECT: (N)O (Y)ES

IOT Diag Port YMCK V-Sel Cables

2. Using the left or right carat key, make the proper selection. Select the ACCEPT key. The following screen will be displayed: PLEASE ENTER ACCESS CODE: 000 SELECT: (A)CCPT WHEN DONE 3. Using the Up / Down carat keys to increment the values, and the Left / Right carat keys to move the cursor to the next position, enter the default access code 123. The following screen will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT 4. Select (N)EXT to access the DCU diagnostic programs. The following screen will be displayed: (1) BELT EDGE LEARN, (2) REGICON (3) MAX SETUP, (4) HALF TONE Note the following: (1) BELT EDGE LEARN (Adjustment 9.2 found in section 5) (2) REGICON (Adjustment 9.3 found in section 5) (3) MAX SETUP (Adjustment 9.1 found in section 5) (4) HALF TONE (General Procedure 9 found in section 6) NOTE: When the DCU is running any of the four routines, the following message will be displayed on the machines User Interface; "Portable Service Workstation is in progress" NOTE: The machine must be in a "Ready to Print" state before you can run any of the DCU routines.

Figure 3

NOTE: The other plug of the interface cable is for future considerations of the DCU. 5. Plug the Power Supply into a standard wall receptacle. When this connection is made, the LCD display on the DCU will be backlit for approximately 15 seconds. The DCU will not accept any operator input until the LCD display backlight goes off.

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DCU Diagnostic Descriptions


DC 612 Color Test Pattern Print Purpose To provide internal Test Patterns that are used to help identify image quality problems. DC 685 Regicon Setup Purpose To calculate the correction amount and set up the Registration Control Sensor within the acceptable range. DC 951 Max Setup Purpose To ensure that the Xerographic Systems are set and operating at optimum levels. DC 956 Belt Edge Learn Purpose To ensure that the IBT Belt is in its correct tracking position by establishing a profile table using the Belt Edge Sensors.

GP 7 Safety Lockout Kit Installation


Purpose
To ensure that the machine cannot be powered on, while any machine maintenance is being performed.

Kit Contents
1. 2. 3. 4. 5. Safety Lockout Tag Power Cord Lockout Stopper Circuit Breaker Lockout Stopper (not used) Padlock with 2 keys Instructions

Procedure
1. Switch off the power to the machine and disconnect the power cord. 2. Place the Safety Lockout Tag onto the padlock. (Figure 1)

Figure 1
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3. Place the red lockout stopper onto the end of the electrical plug so the tab fits through the hole in the terminal. (Figure 2)

4. Attach the padlock to the electrical plug through the red stopper. (Figure 3)

Tab

Figure 3

Figure 2

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GP 8 Replenishing the Fuser Oil


Procedure

3. Open the Reservoir Cap by pulling the tab at the back of the cap forward. (Figure 1)

WARNING Be aware that the Fuser area can be very hot when the machine has been in use.

Tab

WARNING Avoid eye contact with Fuser Oil. It may cause temporary eye discomfort. Wash eyes thoroughly with water.

WARNING Wipe up spillage completely as residue can be slippery. See Section 4 for the proper cleaning procedure.
Figure 1

1. Open the Right Front Door. 2. Place a drop cloth on the floor under the Fuser area. Any oil spilled on the floor will make the floor very slippery. (See Section 4 for proper cleaning procedure)

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4. Remove the cap from the bottle of Fuser Oil and replace it with the Filler Spout Cap. This cap was provided with the digital press at install.Contact your Xerox service representative if you cannot locate the Filler Spout Cap and need one. 5. Carefully insert the filler Spout into the opening of the Fuser Oil Reservoir and squeeze the bottle until the oil reaches the maximum fill level visible inside the reservoir. (Figure 2)

GP 9 Generating DCU Test Patterns


Procedure
1. With the DCU powered up (GP 7), depress either the Up or Down Carat key or the Accept key to activate the DCU menu display. The following screen will appear: WELCOME CHOOSE ANOTHER LANGUAGE? SELECT: (N)O (Y)ES

Maximum Fill Level

2. Using the left or right carat key, make the proper selection. Select the ACCEPT key. The following screen will be displayed: PLEASE ENTER ACCESS CODE: 000 SELECT: (A)CCPT WHEN DONE 3. Using the Up / Down carat keys to increment the values, and the Left / Right carat keys to move the cursor to the next position, enter the default access code 123. The following screen will be displayed: PLEASE SELECT USER PROGRAM OR EXIT SELECT: (N)EXT (E)XIT

Figure 2

6. Remove the Filler Cap from the bottle and place it on a piece of paper or cloth to drain. Place the original cap back on the bottle. 7. Close the Reservoir Cap ensuring it snaps into place. 8. Close the Right Front Door.

4. Select (N)EXT to access the DCU diagnostic programs. The following screen will be displayed: (1) BELT EDGE LEARN, (2) REGICON (3) MAX SETUP, (4) HALF TONE 5. Select (4) Half Tone. The following screen will be displayed: DC 612 COLOR TEST PATTERN PLEASE PLACE 11 X 17 PAPER ON THE PLATEN SELECT (N)EXT WHEN READY

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6. Select the Accept Key to stop the toggle and select (N)EXT.The following screen will be displayed: SCREEN = 200R, TRAY =2, PRINT = 4 PATTERN = 3-1 HALFTONE, Cin = 20% 7. Select the Accept Key to start the routine. The routine will run 1 print for each color. The sequence for the routines is CMYK and each color will be displayed on the second line as the routine progresses. The following screen will be displayed: PLEASE WAIT, SETUP IN PROGRESS RUNNING Y COLOR 8. When the printing routine is complete, the following screen will be displayed: PLEASE REMOVE 11 X 17 PAPER FROM THE PLATEN SELECT (N)EXT WHEN READY 9. Select (N)EXT to return to the main menu.

GP 10 Undocking Tray 4
Purpose To access the left side of the Paper Feed Module for general maintenance and repair activity. Procedure WARNING Switch OFF the power, disconnect the Power Cord, and apply the Safety Lockout Safety Lockout Kit (see GP 7).

WARNING / CAUTION The Tray 4 paper tray must be closed before undocking occurs. Also, do not open the Tray 4 paper tray while the assembly is undocked. This may cause the Tray 4 Assembly to tip over.

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1. Remove the wheel chocks from the left side of Tray 4. 2. Disconnect the Ground Straps (Figure 1). a. Open the Right Front Door on Tray 4. b. Disconnect the front and rear Ground Strap.

3. Undock Tray 4. (Figure 2) a. Lift up on the handle b. Turn the handle clockwise (1/8th turn) c. Close the Front Right Door d. Roll Tray 4 to an appropriate area that will provide enough access to perform the desired activities.

B A B B A

Figure 1 Figure 2

Replacement 1. Roll Tray 4 into the proper docking position and make sure the docking pins on the lower right hand bracket are in alignment with the left side bracket on the Paper Feed Module. 2. Replace in reverse order. Note: When Tray 4 is in the docked position, make sure the handle is pushed down to ensure the proper locking engagement.

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Product Specifications
General Information
Product Codes
Table 1

Product Specifications
Physical Characteristics Without Accessories
Dimensions/Space Requirement (Figure 1) For additional Space Requirements with accessories, refer to the DocuColor 2060 / 2045 Installation Planning Guide or the DocuColor 2060 / 2045 Service Documentation, Section 9, Space Requirements.

Product DC 2045 DC 2060 Stacker/Stapler High Capacity Stacker High Capacity Feeder FFIU Module

USA PM9 PM7 VV1 UE6 LM4 RW3

Canada PM9 PM7 VV1 UE6 LM4 RW3

Latin America PM9 PM7 VV1 UE6 LM4 RW3

Xerox Europe PN0 PM7 VV1 UE6 LM4 RW3

Figure 1 2060

/ 2045 Space Requirements

Table 1 Dimensions and Weights


Dimensions US Metric

Width Depth Height Weight

92.3" 37.4" 55.6" 1874.25 lbs

2360 MM. 960 MM. 1408 MM. 850 Kg

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Electrical Specifications
POWER CONSUMPTION
Standby - 2.6 KVA maximum Run - 4.8 KVA maximum Install - 6 KVA Minimum: 200 Maximum 240

System Capability
WARMUP TIME 7 minutes COPY SPEED First print out time 16 seconds Print Rate (Prints / Minute) With very heavy or very light substrates, print speed must decrease to ensure image quality. With the DocuColor 2045/2065 Digital Press, the machine will always print at optimum speed in accordance to the substrate. The most popular substrates for this class of digital press are produced at the maximum speed available on each model. The 8.5 x 11 inch (A4) substrates, print speeds are:
Table 3 Print Per Minute
Substrate Heavy Weight Light Weight (Mode 1) (Mode 2) Auto Select (Mode 3)

Voltage (50/60 Hz)

Environmental Specifications AUDIBLE NOISE


Table 2 Audible Noise Continuous Noise (dBa) Impulse Noise (dBa)

Stand by Copy Cycle Full System Operation

49.5 64.0 72.0

N/A 72.2 72.0

OZONE GENERATION
Maximum 0.02 ppm Operation: 12300 BTUs per hour, average Standby: 7936 BTUs per hour, average

Heat Output

Maximum Altitude
In Normal configuration: 6557 feet (2000 meters). For altitudes of 6580 to 9843 feet (2001 to 300 meters) field retrofits are acceptable.

17-21 lbs (64-80 g/m2) 22-28 lbs (81-105 g/m2) 29-36 lbs (106-135 g/m2) 37-40 lbs (136-150 g/m2) 41-59 lbs (151-220 g/m2) 60-74 lbs (221-280 g/m2) Transparencies

45 45 30 30 22.5 22.5 22.5

45 60 60 30 30 22.5 22.5

45 60 60 30 30 22.5 22.5

NOTE: Tray Capacities are based on 24 lb. (90 gsm) Color Xpressions

Operating Temperatures
Minimum: 50o F (10o C) Maximum: 90o F (32o C) Minimum: 15% relative humidity Maximum: 85% relative humidity

Tray Capacity
Trays 1 and 2: 550 sheets Tray 3: 2000 sheets Tray 4 (optional): 2500 sheets

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Machine Consumables
Table 1 Machine Consumables Supply Item Supply Number Eastern Hemisphere Dry Ink/Toner (Black) Dry Ink/Toner (Cyan) Dry Ink/Toner (Magenta) Dry Ink/Toner (Yellow) Developer (Black) Developer (Cyan) Developer (Magenta) Developer (Yellow) Fuser Agent Waste Dry Ink/Toner Container Paper 6R90289 6R90290 6R90291 6R90292 5R90246 5R90247 5R90248 5R90249 8R4004 8R90352 Supply Number Western Hemisphere 6R975 6R976 6R977 6R978 5R629 5R630 5R631 5R632 8R3993 8R12662 Supply Unit Shipped with digital press/ Reorder Quantity 1 1 1 1 1 1 1 1 1 1 Approximate Print Yield/ Carton (Full Color Prints) 18K 30K 30K 30K 500K 500K 500K 500K 50K 50K

NOTE: Each IOT will be shipped with one carton of each C, M, Y, and K toner, one carton of fuser agent, and one fuser agent spout. Customers will have the responsibility of adding fuser agent to the IOT. Purchase of the above items is COD specific and is determined by the marketing plan of the COD. NOTE: Developer replacement frequency is projected to be approximately 100,000 images when using 2060 / 2045 60 Baseline paper and other stocks with equivalent smoothness and structure. Replacement rates may be more frequent for operations which use high percentages of coated stocks and/or larger then 8.5 x 11 inch (A4) size throughput, e.g. 11x17 (A3). NOTE: The toner yield projections are based on 7.5% area coverage per color (4 colors = 3.0% at standardized conditions on 8.5x11 inch (A4) 2060 / 2045 60 System Baseline paper. The actual yields vary greatly depending on color intensity, area coverage, paper stock and mode selected.

ColorTech+

Brightwhite 94

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Change Tag Introduction


Important modifications to the copier are identified by a tag number which is recorded on a tag matrix label attached to the inside of the IOT Left Front Door. This section describes all of the tags associated with the copier, as well as multinational applicability, classification codes, and permanent or temporary modification information.

Classification Codes
A tag number may be required to identify differences between parts that cannot be interchanged, or differences in diagnostic, repair, installation, or adjustment procedures. A tag number may also be required to identify the presence of optional hardware, special non-volatile memory programming, or whether mandatory modifications have been installed. Each tag number is given a classification code to identify the type of change that the tag has made. The classification codes and their descriptions are listed in the table below.
Table 1

Classification Code Description M N O R Mandatory tag. Tag not installed in the field. Optional tag. Repair Tag.

TAG: F-4
CLASS: M USE: All MFG SERIAL NUMBERS:N/A NAME: FFIU Module Modification PURPOSE:To upgrade the FFIU to version 305 software and enable fully functionality of the HCS, HCSS, and Tray 4 (HCF) KIT NUMBER:635K09310 PARTS LIST ON:PL 20.5

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