ColorQube 9200, 9300 Family Instructor Slides

Xerox ColorQube 9200/9300
New To Family Service Training
Page 1 June 2011

Module 1 – Course Introduction and Overview
Course Objectives
When you have completed the Xerox ColorQube Family Service
Training, you will be able to:
• Use the Service Documentation to locate faults and repair the
machine
• Identify major electrical and mechanical components
• Install additional hardware
• Be familiar with components that feed and transport paper through
the machine
• Identify the paper supply areas
• Answer questions about the operation of the machine
• Identify scanner and DADH components and describe their operation
• Identify the Solid Ink components and functions of the various CRUs
• Understand Diagnostic, Calibration and maintenance routines
Page 2 Version 3.0 - Nov 2011

Module 1 – Course Introduction and OverviewNew
Preliminary Information
Course prerequisites:
• General office printing, color, solid ink, color, scan & copy technologies, fax,
and ESD
Equipment (tools, safety equipment and lab equipment ):

• PWS and software
• USB memory device
• Microprobe tool (600T2177)
• Service tools for ColorQube machines
• Print and scan drivers
Course structure & map:

• 7 or 5 days – see Course Maps in Student Workbook
• Typical training module with work projects
• Lab partners

Module 1 – Course Introduction and Overview
Module Objectives
On completion of the Course Introduction and Overview module you will

understand and be able to describe:
• Safety practices and machine hazards for ColorQube products
• Acronyms and abbreviations that apply to ColorQube products

Module 2 - Product Overview
Module Objectives
• Name the main parts of the machine
• Remove and replace CRUs
• Name the various paper trays
• List the main features and options

Module 2 - Product Overview
Machine Configuration and Optional devices
PFP and HVF

PFP and OCT Office Finisher Booklet Maker
PPI
PFP with HVF Booklet Maker and PFP and HVF PFP, HVF and PPI
TriFolder

Module 2 - Product Overview New
Visual Differences
ColorQube 9200 Logo ColorQube 9300 Logo

Module 3 – Documentation and Support
Module Objectives
• Understand the structure and reference symbology
• Enter and exit Diagnostic mode
• Answer questions about documentation and diagnostics

Module 4 – Image Input Terminal
Module Objectives
• Identify Scanner and DADH components
• Describe the DADH sequence of operation
• Understand how the scan carriage assembly functions
• Perform common adjustment and repair procedures
• Understand diagnostic procedures for the scanner and DADH

Module 5 - Power, Control, and Ventilation
Introduction
Power, Control, and Ventilation Module Topics:
• Power Supply Unit
• Interlocks
• Printed Wiring Boards (PWBs) Part I
• Printed Wiring Boards (PWBs) Part II
• AC Heaters
• Cooling and Ventilation
• POST/PEST Errors
Work Projects:
• Locate the PWBs
• Monitor temperatures using dc335
• Abatement plenum removal
• Troubleshoot POST and PEST errors

Power, Control, and Ventilation
Module Objectives
Presentations: Student Activities:
• Complete Power, Control, and
Printed wiring boards Ventilation Module CBT lessons
AC heaters technical overview • Locate the PWBs
Cooling and ventilation system • Measure AC heater temperatures
overview (dc335)
• Remove/reinstall the Abatement
• POST/PEST technical overview Plenum
• Observe the normal power on
process – sounds, mechanical
functions, and POST LED activity
• Troubleshoot POST and PEST
faults

AC Heaters Technical Overview
Printheads: Reservoirs, Jetstack Left and Right

Umbilicals
Ink Melt Heaters
Ink Reservoir
Assembly
Registration/
Drum Preheat Assembly

Drum Heater Schematic
Line
Drum Heater Control:
• Relays in Power Supply
Unit control heater
configuration
• Elements in parallel for
110 Volt operation
• Elements in series for 220
Volt operation (as shown)
• Non-resettable Thermal Drum Drum
Cutouts protect heaters Drum
Heater #1 Drum
Heater #2
Heater #1 Heater #2
• Thermal Cutout Board
part of
Registration/Preheat Neutral
Assembly

Monitoring AC Heater Operation
Testing:
• Component - Printhead 1
• Heater - Reservoir
• Setpoint Mode - Ready
Setpoint
changed from
“Ready” to
“Off”
Setpoint
changed from
“Off” to
“Ready”
100 Seconds

Cooling and Ventilation
System Overview
Drum
Chassis Fan
Fan
(inside
Image
Processing
module)
Enclosur
e Fan
Abatement
Fan
Power
Supply Fan Marking
Unit Fan

Cooling and Ventilation
Abatement Plenum Installation
Incorrect Installation: Correct Installation:

Pin In Wrong Location Pin Between Alignment Features
Abatement Plenum

POST/PEST Technical Overview New
Power On Sequence
Phase 1: Power On Self Test
• Copy Controller and IME Controller both run POST
• LEDs report errors using a blink pattern
• 7-segment LED reports CQ 9300 controller
POST errors
Phase 2: Print Engine Self Test

• Copy Controller waits while IME Controller performs PEST
• “99” chain link codes indicate PEST failure
Phase 3: Mechanical Initialization

• Copy Controller - scanner and DADH
• IME Controller - paper feeders, finisher, and IOT
• Standard chain link codes report faults

ColorQube 9200 CBC/NC LED Locations
Flashing LEDs
Normally ON LEDs
Normally OFF LEDs
Note: For CR12, 14, 16, & 18, only one LED should be ON.
None of these LEDs are lit if the network cable is
disconnected.

ColorQube 9200 SBC LED Locations (Tag 006)
Flashing Normally ON LEDs
CR1 LEDs CR3
CR2 CR4
CR13
CR30
CR14
CR45 (only flashes
CR23
during HDD access)
CR24
CR39 (only flashes
when SIM card is CR35
(ON)
accessed)
Normally OFF LEDs
CR5
CR18
CR21
CR22
CR20/25/26
CR43

ColorQube 9300 Controller LED Locations
Flashing Normally ON LEDs
CR3 LEDs CR1
CR7 CR4
PJ14 Ethernet CR5
LEDS
CR8
CR9
CR12
Normally OFF LEDs

CR2
CR10 (unused)
CR11 (unused)
CR13 (unused)
CR14
CR24

POST/PEST Technical Overview
IME Controller POST LED Locations
Media Path Marking
Driver Board Unit
(below left (inside
scanner recessed
Rear Front LED
cable) area)
LED

Decoding IME Controller POST Errors
Flutter - Digit 1 Blinks - Pause - Digit 2 Blinks - Pause - Digit 3 Blinks - Flutter
12 3
PEST Errors
Hard Error – system
critical failure
• Attempt reboot
• “Call For Service” UI
message
• 99.xxx in all fault
logs
Soft Error – non-critical

failure Hard Errors
• Machine powers on
Soft Errors
• 99.xxx in PEST
Fault History only

Reading PEST Fault History
99.552 – most recent
Hard Error
99.000 – beginning of
PEST sequence
99.999 – delimits hard

errors from soft errors
99.520 – soft errors Hard Errors

are listed below hard
Soft Errors
errors

CBT Activity
The CBT lessons demonstrate:
• Basic function of the Power Supply Unit
• Location and function of Interlocks
• Location and function Printed Wiring Boards
• Location and function of each AC heater
• How the machine monitors heater temperatures
• Basic function and location of each fan
• Replacement tips for the Abatement Plenum
• Power on sequence overview
• POST and PEST error reporting
• POST and PEST error troubleshooting

Work Projects 1, 2, 3, and 4
Work Project 1 – Locate PWBs
• Locate and inspect the PWBs for this machine
Work Project 2 – Monitor Temperatures
• Use dc335 to record device temperatures
• Graph the Upper Umbilical temperature over time
Work Project 3 – Plenum Removal and Installation
• Remove and reinstall the Abatement Plenum
Work Project 4 – Observe Power On Sequence
• Observe normal POST LED blink activity
• Observe normal sounds and mechanical activity during power on

Troubleshooting Exercises
Wait for the Instructor to install faults into your machine.
Identify the location of the error code and RAP.
Use the RAP to locate and resolve the issue.

Session Review – AC Heaters, Cooling, and
Ventilation
How does the machine monitor the surface temperature of the drum?
How can technicians determine the expected temperature for specific

heaters?
The Drum Assembly is unable to reach its “Ready” setpoint mode

temperature. Before replacing the assembly, what troubleshooting steps
can you perform to isolate the problem?
What is the function of the Dust Abatement system?
How can you verify the Abatement Plenum is correctly installed?

Session Review – POST/PEST Errors
How can you identify the beginning of the 3-digit blink pattern for POST
errors?
Which LEDs blink POST error codes?
Which subsystems are being tested during PEST?
A 99.xxx chain link is logged in the PEST Fault History but is not logged
in the Last 40 Fault History or the Fault Counters. What does this tell
you about the error?
In dc123 Fault History, what is the meaning of the codes 99.000 and
99.999?

Module 6 – Paper Supply
Module Objectives
• Identify the Paper Supply areas
• Answer questions about the components
• Be aware of common repair procedures

Module 7 - Paper Feed and Registration
Introduction
Paper Feed and Registration Module Student Activities:
Topics: • Complete Paper Feed and
Registration Module CBT lessons
Registration/preheat assembly
• Observe the Tray 2 feed head
technical overview
• Complete the registration
adjustment (dc625)
• Test nip C (Optional)
• Clean the pre-transfix sensor
• Locate the confirm and vertical
jam sensors
• Remove and install the Tray 2/3
feed heads, horizontal paper
path, registration/preheat
assembly, bypass tray
components

Paper Feed and Registration
Module Objectives
• Complete Paper Feed and
• Paper feed technical overview
Registration Module CBT lessons
• Registration/preheat assembly
• Observe Tray 2 Feed Head
technical overview operation
• Paper transportation technical
• Complete the Registration
overview Adjustment (dc625)
• Paper path technical overview
• Test Nip C (Optional)
• Jam clearance technical overview
• Clean the Pre-Transfix Sensor
• Locate the Confirm and Vertical
Jam Sensors
• Remove and install the Tray 2 and
Tray 3 Feed Heads, Horizontal
Paper Path, Registration/Preheat
Assembly, and several Bypass
Tray components
Registration/Preheat Assembly Functions
The Registration/Preheat Assembly
performs two basic functions:
• Warms the media to improve ink transfer
from the drum to the paper.
• Aligns the leading edge (deskew) of the
media , and centers the sheet of media in
the paper path.
The Stance Sensor controls two key

functions:
• Opens the assembly when jams occur
• Switches between idlers based on media
size

Replaceable Parts
The assembly can be
replaced as a unit or repaired
using one of the following
service kits:
• Steering Roller Kit: Belt
Contains two rollers and Steering
s Rollers
two drive belts
• Air Pump Kit:
Contains two pump
assemblies
Air Pumps

Registration Calibration
Do not perform calibration if:
• Missing black jets
• Printheads not aligned Large black
Calibration Process: Edges used to area calibrates
detect “light to scan bar to dark
• Machine prints image
dark” and “dark output
• Duplex path inverts page
to light”
• Registration/Preheat scan
transitions
bar detects image
• L-shaped corner areas
compared to determine skew
• 30 pages required to adjust
all three sets of idler roller
positions

Testing Paper Path Nips
To troubleshoot paper feed issues
such as skewing, become familiar with
the normal force required to move
paper through the nips.
Example for testing Nip C:
1. Place strips of paper under both
rollers for Nip C.
2. Push the paper through with the nip
engaged. It should buckle.
3. Using dc330 Chain Link 082.007,
enable the Nip C Release
Solenoid.
4. Push the paper through with Nip C
disengaged. It should slide freely.

CBT Activity
The CBT lesson demonstrates:
• General function of the Registration/Preheat Assembly
• Process for achieving paper registration in the paper path
• The “Clean For Ink Smears” cleaning sequence

Work Projects 1 - 9
Work Project 1 – Remove Tray 1 Cassette Assembly
Work Project 2 – Registration Adjustment
Work Project 3 – Test Nip C (Optional)
Work Project 4 – Clean the Pre-Transfix Sensor
Work Project 5 – Remove Tray 2 Feed Head
Work Project 6 – Locate the Confirm and Vertical Jam Sensors
Work Project 7 – Remove the Horizontal Paper Path and
Registration/Preheat Assembly (Optional)
Work Project 8 – Locate Paper Path Components
Work Project 9 – Remove Bypass Tray Components

Troubleshooting Exercises
Wait for the Instructor to install a faults into your machine.
Use the service manual to identify the defect type and RAP
Use the RAP to locate and resolve the issue.

Session Review – Registration/Preheat Assembly
• How does the Registration/Preheat Assembly determine the skew and
position of the paper?
• What symptoms are likely to occur if the air system fails?
• How can you manually open the Registration/Preheat Assembly when it

is inside the machine?

Module 8 – Image Marking Engine
Introduction
Image Marking Engine Module lesson titles:
• System Overview, Safety, & Precautions
• What is an IME?
• Ink Delivery
• Printheads
• Printhead Purges
• IOD Sensor
• Drum Drive
• Drum Maintenance
• Transfix and Stripper Blade
• Print Process Summary
• Troubleshoot Image Quality Issues
• Jet Substitution
Work Projects include extensive use of service diagnostics, calibration
sequences, and repair procedures
Instructor-led session reviews highlight important concepts

Session 1 – Introduction
System Overview, Safety, and Precautions
Presentations:
• Image Marking Engine (IME) Overview
• Technology-specific safety and service precautions
Student Activities
• Safety & service precautions matching exercise

Session 1 – System Overview, Safety, and
Precautions
Image Marking Engine (IME) Overview
The Image Marking Engine:
• Melts ink sticks and delivers liquid ink to the printheads
• Generates ink images on the drum
• Transfers images to media
Major IME subsystems:

• Ink delivery
• Marking unit
• Ink on drum (IOD)
sensor
• Drum
• Drum maintenance
• Transfix and strip

Precautions
Hazards
Burn hazards – Ink spills – Cut hazard –
temperatures to hot, liquid ink drum stripper
115°C blade
Shock hazards – Oil spills – Pinching –

AC line voltages, cleaning unit drum drive,
410V drum drive printhead
power supply docking, and
transfix
loading

Precautions
Damage By Mishandling Components
Printhead Faceplate – Never touch or
attempt to clean
Printhead Faceplate Cover – Never
reuse
Printhead Flex Cables – Never touch
gold contacts Ink In
Hot Printheads – Never tilt, keep level Reservoirs
(see images)
Printhead Wiper Blades – Never touch
Drum – Never dent or scratch
Transfix Roller – Never drop, dent, or
scratch
Ink after tilting

Precautions
Work Project 1 - Matching Activity
This is a worksheet activity.
After completing the worksheet, wait for the instructor to review the
answers.

Precautions
Matching Activity Answers
1. Drum Drive Motor
Pinch hazard from closed loop servo feedback system.
2. Printheads
When tilted, melted ink leaks into adjacent reservoirs causing ink mixing.
3. Printhead Wipers, Printheads
Do not touch the Printhead Faceplate area and the wiper blades. Oil or debris that
contaminates the blades can block Printhead jets.
4. Cleaning Unit
Oil leaks can damage carpets, clothing, and furniture. Place on paper after
removal.
5. Printheads, Umbilicals, and Ink Reservoir
Spilled ink can cause burns, destroy internal parts, and damage carpets, clothing,
and furniture.
6. Drum Drive Motor
Wait 2.5 minutes after power down to fully discharge 410 V 3-Phase power source.
7. Printheads, Ink Reservoir, Ink Melt Heaters
Some exposed surfaces are hot enough to cause burns (up to 115 °C/239 °F).
8. Printheads, Ink Reservoir, Drum, Umbilicals , Regi/Preheat Assly, Ink Melt
Heaters
Contain line voltages. Unplug power cord to disconnect heaters from line voltage.

Precautions
Session Review
What parts contain oil or ink that can be spilled?
What unique solid ink technology parts must be handled carefully to avoid
physical damage?
Which part has a 3-phase power supply that must be discharged before
you unplug its power connection?

Ink Delivery, Printheads, and Printhead Purges
• Complete Marking Module CBT
Ink delivery subsystem functions lessons from “Introduction” to
Ink delivery system calibrations “Printhead Purges”
• Prime the Umbilicals (dc976)
Printhead subsystem overview
• Check the ink stick count (dc131)
• Printhead purge concept
• Remove/reinstall two Printheads
• Printhead purge system • Observe the Printhead purge and
components wipe sequences using dc965
• Service and calibration tips • Observe motions from Printhead
drive and calibration motors
(dc914)
• Perform Printhead calibrations
(dc972)
• Remove/reinstall the Ink Sticks,
Ink Loader, Ink Reservoir
Assembly, and Printheads

Session 2 – Ink Delivery Technical Overview
Subsystem Functions
The Subsystem includes the
following components:
• Ink Loader Assembly
Ink Loader
• Ink Melt Heaters Umbilical –
• Ink Reservoir Upper
• Umbilicals Carriage
Umbilical –
Lower
Carriage
Ink Melt
Heaters
Ink Reservoir

Reset Ink Stick Counter
The system tracks the number of ink sticks used so that it can display status
information for the ink supply.
You may need to reset the ink

stick count after repairing
the Ink Loader Assembly. Use
dc131 and NVM ID 420-01,
02, 03, and 04.
Follow these guidelines:
• Do not reset NVM values –

You reload the ink prior to power
on to a level within one ink stick
per color of the original level.
• Must reset NVM values – You need to power up the machine with more than a
one ink stick difference to the original level per color.

Priming the Umbilicals
When replacing an Umbilical,
prime it with ink before running Check Valve Unit
the Printhead cleaning cycle: (CVU)
• Boot into IME diagnostics to
prevent the system from
melting ink.
• Run dc976 to prime one or
both Umbilicals.
• Skipping this calibration can
force ink and air back into
the reservoir, causing Ink
Reservoir Assembly failure.

IME Diagnostics Mode
IME Diagnostics Mode places the IME Controller into service diagnostics mode
while the Copy Controller and UI operate in customer mode. IME Diagnostics is
used for service procedures (example: prime Umbilicals)
General characteristics include:
• Skips PEST during power on
• Disables IME functions until service diagnostics command is received
• Disables AC heaters and drum drive (no drum rotation)
• UI reports fault code 00.000 when no other faults exist
Booting into IME Diagnostics mode:

1. Turn off the power.
2. Open the Upper Left Door and Front Cover, and remove Waste Tray.
3. Turn on power. Wait 3-4 minutes until the UI prompts to close Front Cover.
4. Close the Upper Left Door, cheat the Front Cover interlock, and the install Waste
Tray.
5. Wait for UI to report fault code 00.000.

Session 2 – Service and Calibration Tips
Replacing Umbilicals Not Released Released
Insert screwdriver under

the yellow and black ink
couplers. Pushing on
the corners may
damage the coupler.
Pry up and release both

sides of Umbilical
connector.

Session 2 – Printheads Technical Overview
Subsystem Functions
Four Printheads:
• Upper Carriage - 2 and Upper X-axis Drive Motor
4
Stitch Motor Roll Motor
• Lower Carriage - 1 and
3
Each carriage contains:

• Stitch Motor
• Two Roll Motors
• X-axis Drive Motor
Lower X-axis Drive

Motor
Blending the Image
The Printheads are staggered so that each produces part of the image.
• How do the Roll

Motors help to
achieve calibration?
• What is the function

of the Stitch Motor?
• When are the X-Axis

Motor used?
Before Calibration
After Calibration

Printhead Electronics
Wave Amp Board
IME Controller
Marking Unit
Heater Board
Marking Unit
Driver Board

Session 2 – Service and Calibration Tips New
Remove & Reinstall Existing Printheads
Removing and reinstalling a Printhead can involve 30 to 55 minutes of
calibration, even if you do not replace any parts:
• To Avoid Full Calibration Requirements:

Remove and reinstall Printheads to their same locations (1, 2, 3, & 4)
• Calibration Required:
Remove and reinstall any of the Printheads to a new location
• To Save Time When Troubleshooting:

Avoid swapping Printheads to isolate problems
• Match Printhead Types to Ribbon Cables:

Original Printheads use white cables
Updated printheads use brown cables

Calibrations for New Printheads
At power on, automatic Printhead to drum spacing check:
• Prevents damage from making contact with a moving drum
• Warm up time plus check take ~20 minutes
Perform Printhead
Uniformity adjustment
(dc972) after replacement:
• One Printhead - 30
minute calibration
• All four Printheads - 55
minute calibration
• Select “Manual” and
Item #1 for most
calibrations
Do not select

Calibrations – Head to Head Uniformity
Head to Head
Uniformity matches
output intensity of the
four Printheads.
When adjusting:
• Scan multiple sets of
images, as required
• Always scan most
recent images
• Feed test images SEF
in direction of black
arrows

Calibrations – TRC Generation
Tonal Response Curve
(TRC) Generation sets
the dot size to achieve
consistent mid-tone
solid fills.
When adjusting:
• Scan multiple sets of
images, as required
• Always scan most
recent images
• Feed test images
SEF in direction of
black arrows

Factory Set Carriage Screws
Do not loosen, adjust,
or remove screws
marked in red.
Damage to the drum
will occur.
Both carriages have

corresponding sets of
screws for each
Printhead mount.

Printhead Cable Clips
Cable clips increase reliability of
the Printhead cable interface.
Lift the tab to release the clip.

Session 2 – Printhead Purges Technical
Overview
Why Purging Occurs
Weak Jet
Printhead purges optimize image quality
by correcting weak or missing jets.
What conditions can cause the system to
purge the Printheads?
Jet Test Page (2 per color) Missing Jet
Sputtering Jet

Overview
User-Initiated Fixes
Tools > Troubleshooting > Fix Image Quality menu.

Overview
User-Initiated Fixes – Advanced Routines
Advanced routines:
• Light Lines (Quick):
substitute missing jets
detected by the IOD
Sensor
• Light Lines (Full):
purge all four
Printheads, align
them, and substitute
missing jets
• Ink Smears:
clean the
Registration/Preheat
Assembly and paper
path

Overview
Automatic Light Lines Fix - Admin Control
NOT initiated directly by users.
Log in as admin to select
behavior:
• Intelligent Ready
determines when machine
is idle.
• System attempts to recover
missing jets during idle
“Automatic Maintenance
Cycle” (normally at night).
• Quick Fix – when ON, the
machine substitutes
missing jets.
• Full Fix – controls timing of
purges when machine is
idle.
Overview
Service Purges
Additional tools available to service:
• Use dc968 to purge individual Printheads
• Jet Test pages show jets by color and
number
• Label color shows jet status:
black, purple, red, or green

Overview
Printhead Purge Subsystem Components
Printhead purging involves a variety of components:
Horizontal Motion Motor Vertical Motion Motor
Purge Line
Printhead
Wiper Blades
Umbilicals Ink Reservoir Assembly Waste Tray

Overview
Low Pressure Assist Valve
Low Pressure Assist Valve reduces air
pressure applied to Printheads during
wipe sequence, stopping flow from jet
nozzles:
• Too little pressure:
wipers push waste ink
back into jet nozzles
• Too much pressure:
ink oozes out of jets
after Wiper Blade
passes by

Overview
Waste Tray Sensor
The Waste Tray Sensor serves
two important purposes: Reed Sensor
• Detects Waste Tray
installation
• Indicates when the Marking
Unit drawer is closed
There is no other sensor for the
Marking Unit drawer.
Caution: The sensor detects

the magnet when within 10
mm. To prevent the
Printheads from docking
unexpectedly, remove the Magnet
Front Door interlock cheater
BEFORE closing the Marking
Unit drawer.

Overview
Cleaning Page
The machine automatically generates
a “Cleaning Page”.
• What is the function of this page?
• Why are two pages required?
• What symptom would you see in
printed images after the purge
cycle if the system did NOT print a
Cleaning Page?

Overview
Ink Mixing
What has caused
the image quality
problem in this
example?

Session 2 – Ink Delivery, Printheads, & PH
Purges
CBT Activity
Complete the following CBT Lessons:
• Introduction
• What Is An IME?
• Ink Delivery
• Printheads – record Printhead Handling Exercise notes in your Student
Workbook (see Page 8-16 in Student Guide)
• Printhead Purges

Session 2 – Work Projects
Work Projects 2, 3, and 4
During disassembly work projects throughout this module, follow the
EDOC REPs!
Work Project 2 – Ink Delivery System Calibration

• Run dc976 Ink Delivery Fault Recovery and select “Lower Umbilical”
• Run dc131 to view the choices for resetting the ink stick levels
(NVM ID 420-01, 02, 03, and 04)
Work Project 3 – Printhead Replacement and Calibration

• Remove and reinstall Printheads 1 and 3
• Disconnect and reinstall both Umbilical ends from the lower carriage
• Run service diagnostics tests for Printhead systems
• Run the Printhead calibrations
Work Project 4 – Ink Delivery Component Removal

• Remove and reinstall the Ink Loader Assembly
• Remove and reinstall the Ink Reservoir Assembly

Session 2 – Session Review Questions
Ink Delivery, Printheads, and Printhead Purges
• Discuss observations from the “Printhead Handling Exercise”.
• What symptoms would you observe if the Air Pump Motor on the Ink Reservoir
Assembly has failed?
• How much cool down time is required to avoid ink spills?
• Under what conditions should you load partial ink sticks?
• How can you keep the machine from warming up at power on?
• How can you determine if the Upper and Lower Carriages are locked on
ColorQube 9200 products?
• What can happen if you tilt a hot Printhead?
• How can you quickly check a Printhead for correct mechanical installation?
• Why should you avoid swapping Printheads that have been removed?
• When does the system perform Automatic Jet Recovery activities?

IOD Sensor, Drum, Transfix, and Stripper Blades
• Complete CBT lessons “IOD
• Ink On Drum (IOD) Sensor Sensor”, “Drum Drive”, “Drum
functions Maintenance”, and “Transfix and
Stripper Blades”
• Typical IOD Sequence
• Test IOD Sensor functionality (dc914)
• Drum drive functions
• Remove/reinstall the IOD Sensor
• Drum maintenance system Assembly
functions • Clean the Rear Drum Fan Shroud
• Transfix drive and stripper blade • Manually unlock the Cleaning Unit
Camshaft
functions
• Test Cleaning Unit operation (dc959)
• Service precautions and tips
• Test the transfix system
(dc962/dc140)
• Clean the Transfix Stripper Blade
• Remove and install the Drum
Stripper Blade and the Drum
Assembly

Session 3 – IOD Sensor Technical Overview
Subsystem Functions
IOD Sensor detects images
printed on drum for calibration and
optimizing image quality:
• Head to head alignment
• Y runout
• Y dot position
• Detect and resolve missing jets
The sensor detects only missing
jets.
It CANNOT detect weak or
sputtering jets.
Weak Jet Sputtering Jet

IOD Sensor Components
Scan Bar
Mylar Shield
Encoder
Drive Motor
Drive Gear

ADC and IOD Sensor Concepts
Laser - ADC Solid Ink - IOD
Sensor samples Sensor samples
images images

IOD Sensor Scan Intervals
The UI reports, “Print Quality Maintenance in Progress … Please Wait”
when an IOD sequence is in process. In this mode the machine is unable
to generate prints or copies.
IOD sequences occur during:
• Power On
Check initial image quality
• Calibration
Detect test images
• Automatic Maintenance Cycle “idle” time
Check for missing jets and purge or substitute as needed
• Normal Operation
Every 500 prints

Typical IOD Sequence
Drum Maintenance
Calibrate
Clean Up Image
Correct
Acquire
Analyze

Fault Tolerant Mode
Service Codes on UI indicate
the machine has degraded
performance, including:
• IOD in degraded mode
• Y run out NVM reset
• Chronic jets detected
• PEST warnings exist
• Registration/Preheat
Assembly calibration
required
• Transfix cal NVRAM Reset
• Drum drive belt error
Always resolve Service Codes

when servicing machines.

IOD Sensor Service Tips
Service tips for the IOD Sensor Assembly:
• If using the protective drum cover, install it flat (no wrinkles or bubbles)
to avoid binding that damages the mylar IOD Sensor shield.
• Rotate the drum clockwise when removing it to avoid damaging the
mylar IOD Sensor shield and Drum Thermistors.
• Do not clean the IOD cover unless debris is hanging over it and
interferes with the scan bar.
• Never clean the scan bar using substances that leave a residue.
• Use the arrow for orientation and motion required for installation.
• If the IOD Assembly is wedged during installation, use a flat blade
screwdriver to pry it loose at the front sheet metal frame of the
assembly.
• To avoid oil spills do not tip the Cleaning Unit and place it on a sheet of
paper.

Session 3 – Drum Drive Technical Overview
Subsystem Functions
Examples of factors that affect drum Drum Pulley Release Lever
rotation speed (list is not exhaustive):
• Print quality modes Drum Belt
• Paper type
• Paper size.
During normal operation drum rotation

occurs:
• During the drum maintenance cycle
• To receive the ink during imaging Tension Spring
• To advance the paper during the
transfix process Drum Drive Motor
• To maintain even heat on the drum
(contains internal encoder)
surface Drum Encoder

Safety Issues
There are two safety issues involving the Drum Drive.
What are the issues and how can you protect yourself from injury?

Reset NVM Page Count
Use dc131 (NVM ID 492-70) to reset page count after drum replacement.

Cleaning the Drum
To clean ink from the drum (use one of top 3 first):
1. Allow automatic chase pages to clean the drum off.
2. Run chase pages from dc612.
3. Select "Clean for smears" from the customer Troubleshooting menu or service
diagnostics dc969.
4. Use an IPA/Water solution to clean the ink off.
5. Last resort - scrape ink off the drum using a dull plastic edge (credit card).
Use one of the above methods to fully clean after removing most ink.
Determine the reason for ink build up on the drum:

• Paper jam that was left overnight
• Cleaning Unit that is low on oil
• Possible Drum Stripper Blade damage
• Inspect/clean the IOD Sensor if there is ink contamination underneath the
drum and near the abatement plenum.

Session 3 – Drum Drive Technical Overview New
Drum Replacement Service Tips
Service tips for Drum removal: Guide Pin and Hole
• To avoid extensive rework, insert
the Stripper Baffle Frame guide pin
through the hole in the chassis.
• Wait 2.5 minutes after power down
to discharge the power supply.
• Handle the drum carefully to avoid
dents or scratches.
• Do not tip the Cleaning Unit. Place it
on a sheet of paper.
• ColorQube 9300 drums ship with a
drum removal kit – these parts are
built into ColorQube 9200
machines.

Session 3 – Drum Maintenance Technical
Overview New
Subsystem Functions
Typical Cleaning Unit life
expectancy: New Cleaning Unit
• 220K images for CQ9200
330K images for CQ9300
• A/A4 sheets of typical office media
• 11% ink coverage
• First unit has a shorter life
(typically 156K for ColorQube
9200) as the drum absorbs more
oil when new
Used Cleaning Unit
Built-in EEPROM tracks and stores
usage. To determine life remaining:
• Use UI - Machine Information >
Supplies > All Supplies
• Use service diagnostics (dc135)
• Access via CentreWare IS

Overview New
Compatibility
ColorQube 9200 and 9300
Cleaning Units are NOT
interchangeable:
• Mechanically the same
• Contain different oil
Installing wrong cleaning unit

generates an error message (see
image)
Oil, Drum Stripper Blade, and

Drum surface work in unison to
increase Cleaning Unit life
expectancy

Overview
Reporting Life Remaining Status
Cleaning Unit status reporting:
• 0 to 20 days Remaining:
Cleaning Unit will need replacing soon. Reorder now, DO NOT replace
until requested.
• 100 Pages Remaining:
Same message as above.
• 0 Pages Remaining:
Cleaning Unit needs to be replaced. Replace Cleaning Unit now to
resume operation.
“Snooze” mode extends life 6,000 pages (Cleaning Unit must be at end of
life):
• Log in as Admin
• Enter Tools / Device Settings
• Select “Enter Cleaning Unit Passcode” and enter 8651

Overview
Cleaning Unit Test Pages
Metering Blade
Timing Page
Oil Bar Page

Overview
Typical IQ Issues
Damaged Pixel
Metering Dropout
Blade (Voids)
Too Much Oil

Overview Drum Maintenance Service Tips
When removing the Cleaning
Unit:
• To prevent oil spills, avoid
tipping.
• Place the Cleaning Unit on a
surface that cannot be
damaged (i.e, sheets of paper)
to prevent oil stains.
• To clean excess oil from the
machine, refer to the service
manual. The oil pan holds up
to 1.3 liters of oil.
Oil Pan (Located Beneath Cleaning Unit)

Session 3 – Transfix/Blades Technical Overview
Transfix Function Review
Laser and solid ink machines use different methods for image transfer to
media.
Laser: Solid Ink:
Static charges Transfix roller
Fuser heat/pressure Similar to offset press

Transfix Drive Subsystem
Checking media thickness:
• Stop drum Transfix Motor (Front)
• Lower Transfix Roller against
drum
• Lift roller & advance paper
• Lower roller against media
• Begin transfixing
Compound Gear
Transfix Roller
Transfix Encoder Transfix Linkage (Front)

Transfix Load Values
Transfix load calibration:
• Factory values on labels for Transfix Motor (Front)
front and rear linkage
• Values stored in NVM (dc978)
NVM Values
Factory Labels (Front and Rear)

Transfix Stripper Blade
Transfix Stripper Blade prevents media from wrapping around roller:
• Mylar construction
• Constant contact with Transfix Roller Mylar Blade Touches Roller
• Requires cleaning
to remove paper dust
and ink accumulation
Transfix Stripper
Blade Assembly

Session 3 – Transfix/Blades Technical Overview New
Drum Stripper Blade Stripper Latch Sensor
The Drum Stripper Blade releases the

paper from the drum surface:
• Solenoid extends and retracts blade
for each page
• Routes paper toward the Exit Module
• Blade is extremely sharp!
Install protective Drum Stripper Blade
clip before handling. Drum Stripper
• ColorQube 9200 blade is yellow Blade
ColorQube 9300 blade is silver
• Never install the CQ 9300 Drum
Stripper Blade into CQ 9200 Stripper Blade Solenoid
machines – causes smudging

Service Precautions and Tips
Ground Wire
Install all ground straps.
Protect Transfix Roller from damage:

• Never scratch with a tool
• Never drop the roller
Remove excess grease from inner surface

of Transfix Roller Support before installing
the roller.
Important!
Install Drum Stripper Blade clip before
repairing the machine. Refer to service
manual for Drum Stripper Blade
procedures.
Clean the Transfix Stripper Blade to Roller Support

prevent paper jams and/or image quality
issues.
Session 3 – IOD Sensor, Drum, Transfix/Stripper
Blades
CBT Activity
Complete the following CBT Lessons:
• IOD Sensor
• Drum Drive
• Drum Maintenance
• Transfix and Stripper Blades

Work Projects 5, 6, 7, and 8
Work Project 5 – IOD Sensor Testing and Replacement
• Remove and reinstall the IOD Sensor Assembly
Work Project 6 – Observe and Test Drum Maintenance

• Check life remaining via the UI
• Observe Drum Maintenance Camshaft motion
• Manually lock and unlock camshaft
• Test Cleaning Unit
Work Project 7 – Transfix Service Procedures

• Test transfix system loading
• Clean the Transfix Stripper Blade
Work Project 8 – Drum Replacement

• Clean the Rear Drum Fan Shroud
• Remove and reinstall the Drum Assembly

IOD Sensor and Drum Drive
• What precautions apply when cleaning the IOD Sensor’s scan bar?
• What component can be easily damaged when removing and installing
the IOD Sensor?
• What parts may be damaged if you remove the drum cover incorrectly?
• How is the IOD Sensor similar to ADC sensors on laser machines?
• What is the primary source of debris that builds up inside the Rear Drum
Fan Shroud?
• Name four functions associated with drum rotation during normal
operation.

Drum Maintenance and Transfix/Stripper Blades
• How can you test the Cleaning Unit roller for oil saturation?
• How can you check the Cleaning Unit status?
• A UI message says to replace the Cleaning Unit soon but the machine still
makes copies and prints. Should you replace the Cleaning Unit now to avoid
image quality issues, or wait for the machine to detect the Cleaning Unit’s end
of life?
• Which of the following is most likely to cause serious injury: Drum Stripper
Blade or Transfix Stripper Blade?
• What failure will occur if the Drum Stripper Blade is constantly extended?
Constantly retracted?
• How do the Transfix Encoders determine the amount of load on each end of
the Transfix Roller?
• What image quality defect would you expect to see if you drop the Transfix
Roller?
• When installing the drum assembly into the machine, you are unable to seat it
properly. Name the three guide pins that must be seated when installing the
drum.
Print Process and Image Quality Troubleshooting
Presentations:
• Inkbots and the Solid Ink Print Process
• Print Process Variations
• Troubleshooting Tools and Concepts
Student Activities
• Complete CBT lessons “Print Process Summary” and “Troubleshoot
Image Quality Issues”
• Answer questions relating to the print process
• Generate test prints
• Practice troubleshooting (simulations and hard faults)

Session 4 – Print Process Summary
Inkbots and Solid Ink Printing - Classroom Activity 1
Watch and discuss the video located on the Training CD-
ROM:
• Look for events that relate to the solid ink print process.
• What solid ink print process steps are missing from this
video?

Print Process Summary CBT - Classroom Activity 2
As a group, view the CBT lesson, “Print Process Summary”:
• After viewing each step (1 – 7), discuss any questions student have
about the print process used by this machine.
• Complete all seven steps (Buttons 1 – 7):
– Image Processing
– System Readiness
– Drum Maintenance
– Media Transport
– Registration and Preheat
– Generate the Image
– Transfix and Exit

Print Process Variations
Several factors can vary the print process (not an exhaustive list):
• Burst Mode
• Envelopes
• Print Quality Mode
• Media Thickness Check
• Jet Substitution
The machine automatically performs functions to optimize output quality!

Session 4 – Troubleshooting Tools and
Concepts
Isolating the IOT
To isolate the IOT:
• Verify media is supported
• Eliminate environmental factors
– Ambient temperature
– Blocked air vents
– Relative humidity
– Excessive dust and debris inside the machine
• Print embedded pages to eliminate application software, IIT, or fax
• Generate output using different paper sources and output
destinations

Concepts
IME Only Test Print
To isolate IOT defects to the IME (print engine):
1. Turn the machine off.
2. Open the left MID door (not upper door).
3. Remove the waste tray.
4. Close the front door or insert an interlock
cheater.
5. Power up the machine. Look for “three
blink” pattern on the Marking Unit’s upper
red LED.
6. Close the left mid door, insert the waste tray
(keep front door closed or keep the cheater
in place).
7. An A or A4 sheet will be printed.

Concepts
Solid Ink vs. Laser
Key technology differences that apply to image quality troubleshooting:
• Image registration
• Image transfer
• Bonding images To media
• Environmental conditions
• Sensitivity to media surface texture
• Sensitivity to media color

Concepts
Terminology Differences
Xerographic terminology:
• Paper path direction = Process
• Cross-process = Scan or inboard-to-outboard
Solid Ink terminology:

• Paper path direction = Process or Y-axis
• Cross-process = across the drum or X-axis
The service manual uses "X-axis, Cross-process, Y-axis,

and Process" to describe test pattern characteristics,
components, and the movement of media within the
machine.

Concepts
Troubleshooting Tools – Customer Level
UI contains tools for customers who experience image quality issues:
• Fix Image Quality
• Paper Tips & Office Demo Pages
• Copying Guide/Scanning Guide

Concepts
Customer Jet Test Page
Customer Jet Test Pages provide key information:
• Color Bands - General health of all four
Printheads
• JSC (On, On) - Jet Substitution Configuration is
enabled for both customer setting and machine
setting.
• PC (On, On) - The Purge Configuration is set to
“purge at night/when idle” for both customer
setting and machine setting.
• All Four Printheads - S/N and the total number of
Intermittent, Chronic, and Masked jets (as defined
by the IOD information):
Example:
H4:<serial number>;W2;C3;M1 means Printhead 4
has two Intermittent (bad) jets, three Chronic jets,
and one Masked jet

Concepts
Troubleshooting Tools – Service Only
Primary service tools for resolving image quality issues:
• Service manual IQ RAPs - step-by-step procedures for specific
issues.
– IQ 1 isolates problems to scanner (IIT), DADH, fax, or print engine
(IOT)
– Table 1 cross-references symptoms to example images and RAPs
• Service Test Prints topic - visual examples and intended uses for
each service print.
• IME Only Test Print: isolate the Copy Controller from the IME.
• Component Test Routines: Service diagnostics “Diagnostics” tab.
• Calibration Routines: Service diagnostics “Adjustments” tab.
• Maintenance Routines: Service diagnostics “Maintenance” tab.

Concepts
Isolating Solid Ink IOT Subsystems
Techniques and observations for isolating solid ink IOT issues:
• If the defect involves random lines, are they dark or light?
• Does the defect appear in one section of the image or across the drum?
• Does the defect improve after running the purge sequence?
• After running a purge sequence, does each section of the waste tray
contain a normal amount of waste ink?
• Does the defect appear in solid fills or halftones only?
• Does the machine have a Service Code?
• Does the defect involve oil on the media?
• Does the issue involve smudges/smears or defects to the actual printed
image?
• Is the defect visible primarily in text and fine lines?
• Repeating defects appear at 9 inch intervals or only on alternate pages?

Session 4 – Troubleshooting Simulation
Image #1
Use IQ 1 Table 1 to
identify the correct IQ
1
RAPs and example
images.

Image #2
Use IQ 1 Table 1 to
identify the correct IQ 2
RAPs and example
images.
Hint:
In the left image, the
narrow lines in cyan, black,
and green are within
specification.
Focus on the groups of

lines visible in the
magenta, red, and blue.

Image #3
Use IQ 1 Table 1 to identify
the correct IQ RAPs and
example images.
3

Image #4
Use IQ 1 Table 1 to identify
example images. 4

Image #5
Use IQ 1 Table 1 to
identify the correct IQ
RAPs and example 5
images.
Hint:
The image is too grainy.

Image #6
Use IQ 1 Table 1 to identify 6
example images.

Session 4 – Troubleshoot Image Quality Issues
CBT Activity
The CBT presents common solid ink IQ issues, their relationship to
product technology, and associated troubleshooting techniques:
• IOT Adjustments
• Weak Or Missing Jets
• Ink Mixing and Ink Discoloration
• Smudges and Smears
• Wrinkling and Ghosting
• Cleaning Unit Oil Supply Issues
• Thermal Issues

Work Project 9
Work Project 9 – Test Prints
• Run dc612 to generate commonly used service test prints
(keep the pages for future reference)
• Print the IME Only test print

Session 4 – Fault Analysis and Repair
Troubleshooting Practice
Wait for the Instructor to install a fault into your machine.
Use the service manual to identify the defect type and IQ RAP.
Use the IQ RAP to locate and resolve the issue.

Print Process Summary
At what point during the print cycle does the machine perform a drum
maintenance cycle?
You see the same image quality defect when generating both prints and
copies. Based on your knowledge of the imaging process, which
subsystems (IIT, CBC, IOT, finisher, paper feeders) can you eliminate
based on this information?
If a customer says their machine is printing much slower than expected,

what is a likely cause?
Name two parameters checked by the system before imaging begins.

Image Quality Troubleshooting
What is the function of the IME only test print?
Why are laser machines more sensitive than solid ink machines to
humidity levels?
X-Axis and Y-Axis equate to which directions on the printed page?
The customer Jet Test Page contains the following information: H3:<serial
number>;W3;C5. What does this mean?
After running a Printhead purge sequence to resolve random light stripes,

one section of the Waste Tray contains almost no waste ink. How does
the waste ink volume relate to the light stripes issue?

Jet Substitution Objectives
Topics - Instructor Led Technical Overview
• Output quality maintenance
• Automatic maintenance cycles
• Jet substitution and print speed
• Using the Jet Test Pages to identify masked jets
• Manually masking jets
• Clearing manually masked jets
Work Projects
• Manually masking a jet
• Comparing print speed with and without masked jets

Session 5 – Technical Overview
Output Quality Maintenance
Missing Jet Detection:
• IOD sequences check
jets
• Performed about 6
times daily
Quick Fix:
• When selected, the
machine substitutes
missing jets using an
adjacent jet
• For 3 or more
consecutive missing
jets, only the 2 outer
jets will be substituted

Full Fix Settings
Full Fix settings control
when the machine purges
to clear missing jets
detected by the IOD
sensor:
• Eco Fix (default) - Fix
during next Automatic
Maintenance Cycle (i.e.,
idle time at night)
• Always Fix - Fix
immediately after
detection – results in
more purges
• Off - Purges will not
occur

Automatic Maintenance Cycles
When Eco Fix is selected,
Automatic Maintenance Number Of Missing Jets To Trigger Proactive Purge
Cycles include purge
Model Total Color Total Black Consecutive
sequences based on: Jets Jets Jets
• Model – 9201, 9202,
9201 Never Purge 2 OR 1 Pair
9203
• Color vs. Black missing
9202 6 OR 2 OR 1 Pair
jets
• Consecutive vs. single
9203 2 OR 1 OR 1 Pair
missing jets

Automatic Maintenance Cycles – Examples
Which of the following conditions will cause the machine to perform a
proactive purge during the next Automatic Maintenance Cycle?
• Model 9201 has 2 consecutive missing color jets
• Model 9202 has 5 missing, non-consecutive color jets
• Model 9203 has 1 missing color jet and one missing black jet

Session 5 – Technical Overview New
Freeze-Thaw Sequences
30-minute Freeze-Thaw Sequences:
• Performed if 3 regular warm purges fail to clear problem jets
• Only Model 9202/9203 and 9302/9303 machines perform freeze-
thaw sequences
• Freeze process can break loose debris that blocks jets
• Model 9201 and 9301 never perform freeze-thaw sequences

Chronic Jets
Machine labels jet as
“Chronic” after: Number Of Chronic Jets Before Sending UI Message
• Model 9201 – 3 Model Color Chronic Black Chronic

unsuccessful warm purges Message Message
• Model 9202/9203 – 3 9201 2 consecutive 1
unsuccessful warm purges
and freeze-thaw sequence 9202 Any 2 chronic jets 1
When chronic jet is detected:
• Machine masks the jet 9203 1 1
• Service Code and UI
message may be generated
(see table)

Session 5 – Technical Overview PH4 Jet 220
Affect on CQ 9200 Print Speed
PH1 Jet 1
Jet substitution only slows down
print speed when:
• Masked jet is needed for
imaging
AND
• Jet is located within A4, LEF
print zone (4.3 mm margin)
Unused Jets Outside Of Imaging Area
Unused Jets Printheads & Jets 4.3 mm Margin 5 mm Margin 9 mm Margin 20 mm

Margin
Unused Jets For PH1 – Jets 1 to … 40 42 54 87
Letter-Size Page PH4 – Jets 220 to …
176 178 166 133
Unused Jets For PH1 – Jets 1 to … 12 14 26 57

A4-Size Page
PH4 – Jets 220 to … 208 206 194 162

ColorQube 9200 Speed-Up Mode
Speed-up mode compensates for speed reduction caused by jet
substitution:
• Increases print speed for pages that DO NOT use masked jets
• Prints at the maximum Model 9203 speed for the selected Print Quality
Mode, regardless of the machine type
• Enabled if any jet is manually masked, OR the IOD Sensor detects a
missing jet within the A4 (with 4.3 mm margin) LEF print zone
Print Speeds With and Without Speed-Up Mode
Print Speed (ppm) - No Masked Print Speed (ppm) - Masked Jets (same for all models)
Jets
PQ Modes 9201 9202 9203 Non- Two consecutive Masked jet
consecutive masked jets used present but not
masked jet used used
Fast 60 70 85 53 38 85
Standard 50 60 70 41 30 70
Enhanced 38 45 50 28 20 50
Photo 30 30 40 22 15 40

ColorQube 9200 Speed-Up Mode – Example
Enhanced mode is selected on a Model 9201 machine. If a user
prints a 6 page document that requires the use of one masked jet on
pages 2 and 5 only, what is the approximate print speed for each of
the 6 pages?
Page 1 speed ____ Page 3 speed ____ Page 5 speed ____

Page 2 speed ____ Page 4 speed ____ Page 6 speed ____
Print Speeds With and Without Speed Up Mode
Jets
Fast 60 70 85 53 38 85
Standard 50 60 70 41 30 70
Enhanced 38 45 50 28 20 50
Photo 30 30 40 22 15 40

ColorQube 9200 Speed-Up Mode – Explanation
Two images are simultaneously created on the drum for each pair of
LEF pages within the same job. Therefore, the extra drum
revolutions needed to substitute jets on pages 2 and 5 also decrease
the print speed for pages 1 and 6.
Page 1 speed 28 ppm Page 3 speed 50 ppm Page 5 speed 28
ppm Page 2 speed 28 ppm Page 4 speed 50
ppm Page 6 speed 28 ppm
Print Speeds With and Without Speed Up Mode
Jets
Fast 60 70 85 53 38 85
Standard 50 60 70 41 30 70
Enhanced 38 45 50 28 20 50
Photo 30 30 40 22 15 40

ColorQube 9200 Speed-Up Mode – Conclusion
• When masked jet is NOT detected in the A4 (with 4.3 mm margin)
LEF print zone, all pages print at the rated Model speed
• When masked jet IS detected in the A4 (with 4.3 mm margin) LEF
print zone, pages that do not use the jet print at Model 9203 speed
• Print speed is further reduced if two consecutive jets are masked
Jet Substitution Summary
9201 9202 9203
Advertised Color 38 ppm 45 ppm 50 ppm
Speed
Average Blended Speed With Bad 42 44 48
Jets
Missing Black Jets To Trigger Proactive 2 2 1
Purge
Non-consecutive Missing Color Jets To Trigger Proactive Never Purge 6 2
Purge
Freeze-Thaw Recovery No Yes Yes
Speed-up Mode With Bad Jets Yes Yes N/A
Color Chronic Message on UI 2 consecutive Any 2 chronics Any 1 chronic
Black Chronic Message on UI Any 1 chronic Any 1 chronic Any 1 chronic
Service Action When IOD Sensor Detects Missing Jets Mask Mask 1st, Replace
replace PH for Printhead for
2 chronic jets any chronic jets

ColorQube 9300 Jet Substitution
Key differences from ColorQube 9200 products:
• Typically use SOFT substitution mode – requires less imaging time
• Use HARD substitution mode (same as CQ 9200) only when:
– Coverage exceeds 75%
– Less than 9 jets between substituted jets
– More than 21 substituted jets on four Printheads combined
• Use speed up mode only when hard substitution is required
• Apply speed up mode only until the machine achieves rated speed
• On average, ColorQube 9300 products will not print faster than
their rated speed

Customer Jet Test Pages
Condition of Printhead
Jets:
• W (Weak) - detected
missing jets that have
not been labeled as
“chronic”
• C (Chronic) - jets that
have been purged 3
times; includes freeze-
thaw cycle for Model
9202/9203 & 9302/9303
• M (Masked) - missing
jets for which jet
substitution is enabled
manually or by the
machine

Service Jet Test Pages
Condition of Printhead
Jets:
• Chart on right side of
page identifies number
and type of problem jets
• Purple Jet Label –
detected missing jets
that are NOT “chronic”
• Red Jet Label –
chronic jets
• Green Jet Label –
missing jets for which
jet substitution is
enabled manually

Jet Masking Limits
Use the following guidelines to determine if masking is
appropriate:
• It is possible to individually mask up to 40 jets per machine
• Cannot mask adjacent jets
• Follow 91-638-00 IOD Detects Chronic Jet Error RAP
• Model 9203 - Masking recommended in limited cases only
• Model 9201/9202 - Masking recommended unless an adjacent
jet has already been masked
• Additional ColorQube 9300 requirement - chronic jets are less
than 10 jets from another chronic or masked jet

Manually Masking Jets
To manually mask a jet:
• Enter Service Mode
• Select Adjustments tab
• Select dc131 NVM Read/Write
• Locate an unused link for
Chain 445, links 9-48
(value of 0)
• Enter a 5 digit number
using format HCJJJ:
– H=head number (1, 2, 3, 4)
– C=color (C=1, M=2, Y=3, K=4)
– J=jet number (i.e., 004, 036,
217)
• Select Write

Clearing Manually Masked Jets
To clear a manually masked
jet:
• Install a new Printhead
OR
• Select dc131 NVM
Read/Write
• Enter Chain 445 link 9
• Compare the desired jet
value to the NVM value
stored in that link
• Scroll through links 9-48
until you locate the desired
jet
• To clear the jet, enter 0
• Select Write
Work Project 10
Work Project 10 – Manually Mask a Jet
• Run dc131 to mask magenta jet 27 on Printhead 2
• Run dc968 to verify the mask

Jet Substitution
True or False - the machine always attempts to purge missing jets during the
Automatic Maintenance Cycle.
What is the definition of a chronic jet?
What information can you look for on the UI, Customer Jet Test Page, and
Service Jet Test Page to determine if the machine has a chronic jet?"
True or False - jet substitution slows down the overall print speed.
On a Service Jet Test Page the label for PH 1 cyan jet #24 is red and the label
for PH3 yellow jet #7 is purple. What is the status of these jets?
NVM ID 445 link 24 contains the value 33111. What printhead, color, and jet
number will be masked?

Module 9 – Software Upgrade, AltBoot and Fault
Histories
Module Objectives
• Use NVM Save and Restore, and Clone Machine routines to back-
up machine data
• Use the AltBoot procedure to upgrade/replace the existing software
• Locate and view the machine’s fault history

Histories
File Numbering & Naming
(PPP).(MMM).(YYY).(DDD).(RR) #.dlm:
• PPP - is the platform identifier – Discovery Platform
• MMM - is the machine identifier – ColorQube
• YYY - is the year of release
• DDD - is the day, in the year, of release
• RR - is the daily revision number
If the software version is 060.050.009.30823.dlm:

• PPP = 060 = Discovery platform
• MMM = 050 = ColorQube (9200 MBC – see next slide)
• YYY = 009 = 2009
• DDDRR = 30823 = 23rd revision released on the 308th day of 2009

Histories
Machine Identifiers
Three ColorQube machine identifiers (MMM):
• 050 = 9200 MBC (W/O Tag 006)
• 080 = 9200 SBC (W/Tag 006)
• 180 = 9300 software
Examples:
• 060.050.009.30823 = 9200 MBC software
• 060.080.009.30824 = 9200 SBC software
• 061.180.101.004101 = 9300 Launch software

Histories
AltBoot 8 vs. AltBoot 9
ColorQube 9200 MBC AltBoot Options:
• Using AltBoot 8:
– Upgrades Copy Controller and Network Controller only
– Following reboot, upgrades any additional SW modules
required for the software set
– Takes approximately 20 minutes
• Using AltBoot 9:
– Upgrades all machine SW modules and all connected
options, regardless of current SW versions
– Upgrades boot codes
– Takes approximately 35 minutes

Histories
AltBooting SBC Machines
ColorQube 9200 SBC AltBoot Tips:
• One AltBoot process available - no “8” or “9” options
• Machine Status button does not illuminate prompting you to press
“8” or “9”
• To begin the upgrade automatically:
– Insert the USB drive
– Power on the machine
• Placing a .dlm file in the “altboot” folder performs the same function
as launching an AltBoot 8 on MBC machines
• If an Altboot 9 equivelent is required on SBC machines, place a
unique “forced_upgrade” file into the “altboot” folder along with the
.dlm file

Histories
Common AltBoot Issues
Check the “Altboot” folder name spelling:
• No spaces or dashes are allowed (Not OK: alt boot, alt_boot)
• Lower- and upper-case letters are OK
Verify the correct .dlm file is placed in the AltBoot folder. You cannot:
• Use an MBC .dlm file on an SBC machine
• Use an SBC .dlm file on an MBC machine
Try using a different USB drive
Connect the USB drive to a port located directly on the NC or SBC
board

Histories
CBT Activity
The CBT presents procedures and tips for software upgrades, performing
altboots, and viewing fault histories:
• USB memory devices
• Good practices
• AltBoot
• Software upgrades via the network and USB
• Viewing fault histories and counters

Module 9 – Work Projects
Work Projects 1 & 2
Work Project 1 – Perform the Altboot procedure
• Refer to GP 4
• Perform NVM Save using dC361
• Perform Network Close process GP 17
Work Project 2 – Examine dC123 PEST Fault History

Module 10 – Offset Catch Tray and Office
Finisher
Module Objectives
• Identify various output devices
• Gain a general understanding of the interlocks, power requirements,
CRUs, control and sensors on the device

Work Projects 1, 2, & 3
Work Project 1 – Use Office Finisher
Work Project 2 – Remove components:

• Tamper assembly
• Ejector assembly
• Stapler Traverse assembly
Work Project 3 – Observe Offset Catch Tray operation

Module 11 – HVF, Booklet Maker, Tri-Folder and
PPI
Module Objectives
• Identify the various options and their features
• A general understanding of the interlocks, power requirements, CRUs,

control sequences and sensors

Work Projects 1, 2, 3, 4, & 5
Work Project 1 – Observe Buffer area operation
Work Project 2 – Remove components:

• Ejector assembly
• Front Tamper
• Rear Tamper
• Stapler Unit
Work Project 3 – Observe Booklet Maker operation
Work Project 4 – Observe Tri-Folder operation
Work Project 5 – Observe Post Process Inserter operation

Module 12 – Fax
Module Objectives
On completion of this module you will understand:

• Embedded Fax
• Server Fax
• LAN Fax

Work Projects 1, 2, & 3
Work Project 1 – Embedded Fax
Work Project 2 – Server Fax
Work Project 3 – LAN Fax

Module 13 – Maintenance
Module Objectives
On completion of this module you will be able to:

• Describe the ink sticks for different billing plans
• Demonstrate user maintenance
• Inform users about machine productivity and quality
• Identify maintenance checks
• Understand the service support available

Module 14 – ColorQube 9300 Service Differences
New
Module Objectives
On completion of this module you will be able

to:
• Describe the user-level
differences between
products
• Describe the service-level
differences between
products
• Resolve common ColorQube
service issues

Module 14 – Work Projects New
Work Projects 1, 2, 3, & 4
Work Project 1 – Use High Speed print quality mode
Work Project 2 – Print via the USB port
Work Project 3 – Locate the Tools UI folder
Work Project 4 – Locate unique ColorQube 9300 assemblies:

• Drum Stripper Blade
• Transfix Roller
• Upper Printhead Carriage Frame – no locking mechanism
• Single Board Controller – 7-segment LED

ColorQube 9200, 9300 Family Instructor Slides

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ColorQube 9200, 9300 Family Instructor Slides

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Xerox ColorQube 9200/9300

New To Family Service Training

Page 1 June 2011

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Equipment (tools, safety equipment and lab equipment ):

Course structure & map:

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On completion of the Course Introduction and Overview module you will

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PFP and HVF

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ColorQube 9200 Logo ColorQube 9300 Logo

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Printheads: Reservoirs, Jetstack Left and Right

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Incorrect Installation: Correct Installation:

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Phase 2: Print Engine Self Test

Phase 3: Mechanical Initialization

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Normally OFF LEDs

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Normally OFF LEDs

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Soft Error – non-critical

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99.999 – delimits hard

99.520 – soft errors Hard Errors

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Identify the location of the error code and RAP.

Use the RAP to locate and resolve the issue.

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How can technicians determine the expected temperature for specific

The Drum Assembly is unable to reach its “Ready” setpoint mode

What is the function of the Dust Abatement system?

How can you verify the Abatement Plenum is correctly installed?

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Which LEDs blink POST error codes?

Which subsystems are being tested during PEST?

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The Stance Sensor controls two key

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Use the RAP to locate and resolve the issue.

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• What symptoms are likely to occur if the air system fails?