ColorQube 9300, 9301, 9302, 9303 Service Training Student Workbook

ColorQube® 9200/9300
Color Multi-Function Printer
Xerox ColorQube 9200/9300 Family

Service Training
Student Workbook
Xerox Internal-Use Only

ColorQube 9200/9300 Family
Service Training
Version 3.0 - Xerox Internal Use Only
November 2011
Xerox Corporation
Office Product Training and Information
26600 Parkway - Bldg. 60
M/S 7060-776
Wilsonville, OR 97070-1000
© 2011 Xerox Corporation. All rights reserved. XEROX®, XEROX and design® and
ColorQubeTM are trademarks of Xerox Corporation in the US and/or other countries.
Table of Contents
Preparation ...............................................................................Preparation-1
Service Training Student Sign Off Sheet .............................................................. Preparation-1
1 Course Introduction and Overview..............................................1-1

Course Introduction ............................................................................................................................1-1
Expectations and Roles......................................................................................................................1-1
Service Training Strategy................................................................................................................. 1-1
Instructor’s Responsibilities ............................................................................................................ 1-1
Course Objectives.................................................................................................................................1-2
Training Guide Conventions ............................................................................................................1-3
Course Prerequisites and Equipment............................................................................................1-3
Training Kit Contents......................................................................................................................... 1-4
Accessing Drivers ................................................................................................................................. 1-4
Course Map.............................................................................................................................................1-6
Training Modules................................................................................................................................. 1-7
Work Projects ........................................................................................................................................ 1-8
Lab Partners........................................................................................................................................... 1-9
Module 1 Overview - Begin Product Training Here.................................................................1-9
Module Objectives ...............................................................................................................................1-9
Technical Overview........................................................................................................................... 1-10
Work Projects ...................................................................................................................................... 1-10
Fault Analysis and Repair............................................................................................................... 1-14
Module 1 Quiz..................................................................................................................................... 1-14
Module Summary.............................................................................................................................. 1-15
2 Product Overview ...............................................................................2-1

Module Overview..................................................................................................................................2-1
Technical Overview..............................................................................................................................2-1
Machine Configuration......................................................................................................................2-1
Visual Differences Between ColorQube 9200 and 9300......................................................2-2
Machine Operation..............................................................................................................................2-2
Machine Installation...........................................................................................................................2-2
Work Projects .........................................................................................................................................2-3
Work Project 1 - User Interface Screens .................................................................................... 2-3
Work Project 2 - Copy ........................................................................................................................ 2-3
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Work Project 3 - Fax ........................................................................................................................... 2-4

Work Project 4 - Workflow Scanning........................................................................................... 2-5
Work Project 5 - Scan to E-mail ..................................................................................................... 2-5
Work Project 6 - Print......................................................................................................................... 2-5
Work Project 7 - Customer Maintenance .................................................................................. 2-6
Sign Off ................................................................................................................................................... 2-7
Module 2 Quiz ....................................................................................................................................... 2-8
Module Summary ................................................................................................................................ 2-9
3 Documentation and Support.........................................................3-1

Module Overview ................................................................................................................................. 3-1
Module Objectives............................................................................................................................... 3-1
Technical Overview ............................................................................................................................. 3-1
Diagnostics/Service Mode................................................................................................................ 3-2
Service Documentation - layout .................................................................................................... 3-2
Documentation - sections ................................................................................................................ 3-2
Service Manual vs. Eureka ................................................................................................................ 3-2
Work Projects......................................................................................................................................... 3-3
Work Project 1 ...................................................................................................................................... 3-3
Module 3 Quiz ....................................................................................................................................... 3-4
Module Summary ................................................................................................................................ 3-5
4 Image Input Terminal......................................................................4-1

Module Overview ................................................................................................................................. 4-1
Technical Overview ............................................................................................................................. 4-1
Work Projects......................................................................................................................................... 4-2
Registration Adjustment Series..................................................................................................... 4-2
Registration Series – Supplementary Information................................................................ 4-2
UI Diagnostics...................................................................................................................................... 4-2
Work Project 1 ...................................................................................................................................... 4-2
Work Project 2 ...................................................................................................................................... 4-3
Work Project 3 ...................................................................................................................................... 4-3
Fault Analysis and Repairs ............................................................................................................... 4-4
Module 4 Quiz ....................................................................................................................................... 4-5
Module Summary ................................................................................................................................ 4-6
5 Power, Control and Ventilation .....................................................5-1

Module Overview ................................................................................................................................. 5-1
Technical Overviews ........................................................................................................................... 5-2
AC Heaters Technical Overview..................................................................................................... 5-2
Cooling and Ventilation System Overview ............................................................................... 5-3
POST/PEST Technical Overview..................................................................................................... 5-4
Service CBT Activity ..........................................................................................................................5-10
Work Project 1 - Locate PWBs......................................................................................................5-11
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Work Project 2 - Monitor Temperatures ................................................................................. 5-11

Work Project 3 - Plenum Removal and Installation ........................................................... 5-12
Work Project 4 – Observe Power On Sequence .................................................................... 5-13
Fault Analysis and Repairs............................................................................................................. 5-14
Practice Work Problem #1 ............................................................................................................ 5-14
Practice Work Problem #9 ........................................................................................................... 5-16
Session Review.................................................................................................................................... 5-18
AC Heaters, Cooling, and Ventilation Session Review....................................................... 5-18
POST/PEST Errors Session Review.............................................................................................. 5-18
Module 5 Quiz..................................................................................................................................... 5-19
Module Summary.............................................................................................................................. 5-20
6 Paper Supply........................................................................................6-1
Module Overview..................................................................................................................................6-1
Technical Overview..............................................................................................................................6-1
Work Projects .........................................................................................................................................6-2
Work Project 1 ...................................................................................................................................... 6-2
Work Project 2 ...................................................................................................................................... 6-2
Sign Off ................................................................................................................................................... 6-2
Fault Analysis and Repairs................................................................................................................6-2
Module 6 Quiz........................................................................................................................................6-3
Module Summary.................................................................................................................................6-4
7 Paper Feed and Registration..........................................................7-1

Module Overview..................................................................................................................................7-1
Paper Feed ..............................................................................................................................................7-2
Service CBT Activity............................................................................................................................ 7-2
Registration/Preheat Assembly ......................................................................................................7-3
Technical Overview............................................................................................................................. 7-3
Paper Transportation, Paper Path, and Jam Clearance........................................................7-5
Work Projects .........................................................................................................................................7-5
Work Project 1 - Remove Tray 1 Cassette Assembly............................................................. 7-5
Work Project 2 (Optional) - Test Nip C ....................................................................................... 7-5
Work Project 3 - Clean the Pre-Transfix Sensor....................................................................... 7-6
Work Project 4 - Remove Tray 2 Feed Head............................................................................. 7-6
Work Project 5 - Locate the Confirm and Vertical Jam Sensors....................................... 7-6
Work Project 6 (Optional) - Remove the Horiz. Paper Path and Regi/Preheat Assembly
7-7
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Work Project 7 - Registration Adjustment ................................................................................ 7-7

Work Project 8 - Locate Paper Path Components.................................................................. 7-7
Work Project 9 - Remove Bypass Tray Components............................................................. 7-8
Sign Off .................................................................................................................................................. 7-8
Fault Analysis and Repairs ............................................................................................................... 7-8
Session Review...................................................................................................................................... 7-9
Module 7 Quiz ....................................................................................................................................... 7-9
Module Summary ..............................................................................................................................7-10
8 Image Marking Engine ....................................................................8-1

Module Overview ................................................................................................................................. 8-1
Session 1 - System Overview, Safety, & Precautions ............................................................. 8-2
Introduction .......................................................................................................................................... 8-2
IME Subsystems Overview............................................................................................................... 8-2
Safety and Service Precautions..................................................................................................... 8-3
Work Project 1 - Matching Activity .............................................................................................. 8-4
Session Review ..................................................................................................................................... 8-5
Session 2 - Ink Delivery, Printheads, and Printhead Purges................................................ 8-6
Introduction .......................................................................................................................................... 8-6
Ink Delivery Technical Overview ................................................................................................... 8-6
Printheads Technical Overview...................................................................................................... 8-9
Printhead Purges Technical Overview.......................................................................................8-12
Service CBT Activity..........................................................................................................................8-15
Work Project 2 - Ink Delivery System Calibration ................................................................8-17
Work Project 3 - Printhead Replacement and Calibration ...............................................8-18
Work Project 4 - Ink Delivery Component Removal............................................................8-20
Ink Delivery, Printheads, and Printhead Purges Session Review....................................8-21
Session 3 - IOD Sensor, Drum, Transfix, and Stripper Blades ..........................................8-23
Introduction ........................................................................................................................................8-23
IOD (Ink On Drum) Sensor Technical Overview....................................................................8-23
Drum Drive Technical Overview ..................................................................................................8-27
Drum Maintenance Technical Overview..................................................................................8-29
Transfix and Stripper Blades Technical Overview................................................................8-32
Work Project 5 - IOD Sensor Removal and Installation ....................................................8-36
Work Project 6 - Test Drum Maintenance System...............................................................8-36
Work Project 7 - Transfix Service Procedures.........................................................................8-37
Work Project 8 - Drum Replacement.........................................................................................8-38
IOD Sensor, Drum Drive & Maint., and Transfix/Stripper Blade Session Review ....8-39
Session 4 - Print Process and Image Quality Troubleshooting........................................8-41
Introduction ........................................................................................................................................8-41
Inkbots and Solid Ink Printing .....................................................................................................8-41
Troubleshooting Tools and Concepts .......................................................................................8-42
Troubleshooting Simulation .........................................................................................................8-48
Work Project 9 - Test Prints ...........................................................................................................8-49
Fault Analysis and Repairs ............................................................................................................8-50
Practice Work Problem #1 .............................................................................................................8-50
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Print Process and Image Quality Troubleshooting Session Review ............................. 8-52
Session 5 - Jet Substitution............................................................................................................ 8-53
Introduction ....................................................................................................................................... 8-53
Technical Overview.......................................................................................................................... 8-53
Work Project 10 - Manually Mask a Jet................................................................................... 8-61
Manual Jet Substitution Session Review ................................................................................ 8-62
Module 8 Quiz..................................................................................................................................... 8-63
Module Summary.............................................................................................................................. 8-65
9 Software Upgrade, AltBoot and Fault Histories .....................9-1

Module Overview..................................................................................................................................9-1
Technical Overview.............................................................................................................................9-2
Service CBT Activity.............................................................................................................................9-4
Work Projects .........................................................................................................................................9-4
Work Project 1 ...................................................................................................................................... 9-4
Work Project 2 ...................................................................................................................................... 9-4
Sign Off ................................................................................................................................................... 9-4
Fault Analysis .........................................................................................................................................9-5
Module 9 Quiz........................................................................................................................................9-6
Module Summary.................................................................................................................................9-7
10 Offset Catch Tray, Office Finisher............................................. 10-1

Module Overview............................................................................................................................... 10-1
Module Objectives ............................................................................................................................ 10-1
Technology Overview....................................................................................................................... 10-1
Work Projects ...................................................................................................................................... 10-1
Work Project 1 - Office Finisher .................................................................................................. 10-2
Work Project 2 - Office Finisher .................................................................................................. 10-2
Work Project 3 - Offset Catch Tray ........................................................................................... 10-2
Sign Off ................................................................................................................................................ 10-2
Fault Analysis and Repairs............................................................................................................. 10-3
Module 10 Quiz .................................................................................................................................. 10-4
Module Summary.............................................................................................................................. 10-5
11 HVF, BM, Tri-Folder and PPI........................................................ 11-1

Module Overview............................................................................................................................... 11-1
Module Objectives ............................................................................................................................ 11-1
Technology Overview....................................................................................................................... 11-1
Work Projects ..................................................................................................................................... 11-1
Work Project 1 - HVF....................................................................................................................... 11-1
Work Project 2 - HVF....................................................................................................................... 11-2
Work Project 3 - Booklet Maker .................................................................................................. 11-2
Work Project 4 - Tri-Folder ............................................................................................................ 11-3
Work Projects 5 - Post Process Inserter ................................................................................... 11-3
Sign Off ................................................................................................................................................ 11-4
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Fault Analysis and Repairs .............................................................................................................11-4

Module 11 Quiz...................................................................................................................................11-5
Module Summary ..............................................................................................................................11-6
12 Fax........................................................................................................ 12-1
Module Overview ...............................................................................................................................12-1
Module Objectives.............................................................................................................................12-1
Technology Overview.......................................................................................................................12-1
Work Projects......................................................................................................................................12-1
Work Project 1 - Embedded Fax..................................................................................................12-1
Work Project 2 - Server Fax ...........................................................................................................12-2
Work Project 3 - LAN Fax ...............................................................................................................12-2
Sign Off .................................................................................................................................................12-3
Fault Analysis ......................................................................................................................................12-3
Module 12 Quiz...................................................................................................................................12-4
Module Summary ..............................................................................................................................12-5
13 Maintenance .................................................................................... 13-1

Module Overview ...............................................................................................................................13-1
Work Projects......................................................................................................................................13-1
Work Project 1 ....................................................................................................................................13-1
Work Project 2 ....................................................................................................................................13-1
Sign Off .................................................................................................................................................13-2
Fault Analysis ......................................................................................................................................13-2
Module 13 Quiz...................................................................................................................................13-2
Module Summary ..............................................................................................................................13-3
14 ColorQube 9300 Service Diffs..................................................... 14-1

Module Overview ...............................................................................................................................14-1
Work Projects......................................................................................................................................14-1
Work Project 1 ....................................................................................................................................14-2
Work Project 2 ....................................................................................................................................14-2
Work Project 3 ....................................................................................................................................14-2
Work Project 4 ....................................................................................................................................14-2
Sign Off .................................................................................................................................................14-3
Fault Analysis ......................................................................................................................................14-4
Module 14 Quiz...................................................................................................................................14-4
Module Summary ..............................................................................................................................14-4
vi Version 3.0 - Xerox Internal Use Only Student Workbook

Preparation
Service Training Student Sign Off Sheet 0
Student Name:
Location:
Class Date:
Instructor:
Module Completed Instructor Initials

1. Introduction
2. Product Overview
3. Documentation and Support
4. Image Input Terminal
5. Power and Ventilation
6. Paper Supply
7. Paper Feed and Registration
8. Marking
9. Altboot, Software Upgrade, Fault Histories
10. Offset Catch Tray, Office Finisher
11. HVF, BM, Tri-folder and PPI
12. Fax
13. Maintenance Tasks
14. ColorQube 9300 Service Differences
Student Workbook Version 3.0 - Xerox Internal Use Only Preparation-1

Preparation-2 Version 3.0 - Xerox Internal Use Only Student Workbook

1 Course Introduction and
Overview
Course Introduction 0
Welcome to the Xerox ColorQube 9200/9300 Family Service Training
Programme!
You will be introduced to this new product over the next few days as
you complete the different portions of this training.
Through your Instructor, this first module will provide you with
information about the training facility you are attending as well as
an overview of the training program itself. This course was designed
to be similar to other Xerox Training Programs with plenty of hands-
on exercises, and opportunities for troubleshooting.
As you go through this training, relax and absorb the material. Don’t
hesitate to ask questions or get clarification if necessary.
Expectations and Roles 0
Service Training Strategy 0
• The Xerox ColorQube 9200/9300 Family Service Training course

is a combination of computer based training, Instructor led
presentation slides, and hands-on activities.
• The training course is designed to train all Students meeting the
minimum prerequisites.
Instructor’s Responsibilities 0
The responsibilities of the Instructor to the Students are:

• Deliver live instruction when necessary.
Student Workbook Version 3.0 - Xerox Internal Use Only 1-1

Course Introduction and Overview Xerox ColorQube 9200/9300 Family
• Assist you when you are having difficulty with the training
activities.
• Review your work.
• Provide additional resources when you need them.
• Track and evaluate your progress throughout the course
(sign-off sheets).
• Provide end-of-course feedback.
• Demonstrate and explain specific activities when
required.
• Misalign components and install practice faults in your
system for you to make certified adjustments.
• Provide you with any other assistance that will make your
learning easier. If at any time something is bothering you
that could affect your learning, be sure to discuss it with
your Instructor. Do not wait until you are about to leave to
get problems out in the open. The Instructor will assist
you whenever possible.
Course Objectives 0
When you have completed the Xerox ColorQube 9200/9300
Family Service Training you will be able to:
• Use the Service Documentation to locate required
information, diagnose faults, and perform Repair
procedures.
• Identify the major electrical and mechanical components
of the machine, including high and low voltage
generation and the mechanical drive system.
• Install additional hardware.
• Be familiar with the components that feed, transport, and
exit paper from the machine.
• Identify the various paper supply areas of the machine.
Identify supply components and perform common Repair
procedures in this subsystem.
• Answer questions about the sequence of operation for the
paper supply and feed components and understand the
paper path for a Simplex and Duplex copy or print job.
1-2 Version 3.0 - Xerox Internal Use Only Student Workbook

Xerox ColorQube 9200/9300 Family Course Introduction and Overview
• Identify the scanner and DADH components. Describe the

operating sequences for the document glass and DADH
• Identify the location and purpose of the Solid Ink process
components including the function and features of each
CRU.
• Understand how and when to use each diagnostic,
calibration, and maintenance routine.
Training Guide Conventions 0

Conventions are used within the course materials to identify
different types of information:
• Black text applies to the original ColorQube 9200 course
• Blue text identifies changes for ColorQube 9300 products
Course Prerequisites and Equipment 0

The prerequisites for the training course include the following:
• Introduction to Office Printing
• Color Fundamentals
• Solid Ink Technology
• Scan & Copy Fundamentals
• Fax Fundamentals
• ESD Handling techniques
You are required to have the following hardware and software
in addition to the course prerequisites, in order to service this
product:
• PWS with Windows 2000, or XP OS (upgraded memory
and Windows XP are required when using a Toshiba PWS)
• GSN version 9.0 or greater.
• Internet Explorer 5.5 or later version.
• Minimum of 500MB of disk space on the “C” drive
• Configured Network Interface Card (NIC)
• The cables and tools listed below are also required to
service this product. If you do not have these items, your
Instructor can provide them.

• Ethernet Crossover Cable (600T02252) - Used to connect

the PWS to the machine for printing
• USB Memory Device - used to perform Altboot system
installations and upgrades. This must be a USB memory
device approved by Xerox for 9200 Family use.
• Micro-probe Tool (600T2177) - used as an extension of
the standard meter probes in order to probe very small
connectors in the machine without damaging them
If you do not meet all of the prerequisites listed above, or if
you do not have the required hardware / software, discuss a
recovery plan with your Instructor. In rare cases, failure to
meet all of the requirements may mean taking this course at
a later date.
Training Kit Contents 0
Each Service Training Kit will contain the following items:

• Student Workbook hardcopy
• System Software
• Xerox ColorQube 9200 Student Training Program CD
• Xerox ColorQube 9200 EDOC or Service Manual
• Xerox ColorQube 9300 Service Differences Training
Program CD or access course via Learning@Xerox
• Xerox ColorQube 9300 Service Manual PDF or EDOC
• Service Test Pattern
• System Administrator CD
• Interactive User Guide CD
• Quick Reference Guide hardcopy
• Service Tools
- Drum Removal Wrench - T30 Torx wrench, provided
with replacement drum.
- Drum protector (part of 604K54931) - used to protect
the drum during removal and replacement.
Accessing Drivers 0
Drivers for the Xerox ColorQube 9200/9300 Family products

are available to download from Xerox.com. Follow the
instructions below to download the drivers:

1. Open your Internet browser.

2. Type in www.xerox.com in the Address field.
3. Select [Support and Drivers].
4. Ιn the Search field, enter the name of the product that
you have in the Training Center (i.e. Xerox ColorQube
9303) then select [Search].
5. Locate and download the specific driver you need for the
applicable Operating System, and desired Language.

Course Map 0
You may require more or less time than is estimated to
complete each module. You should be aware of the total time
spent in each module, as well as how much time is left to
complete the course
Each module in the course will direct you to perform the
applicable work projects and troubleshooting procedures in
order to successfully complete the training
Two Course Maps are shown which indicate New to Family,
and Differences programmes.
Table 1. Course Map - New to Family Course - 7 Days
Time to
Module complete Day
1 Course Introduction and Overview 1.0 hour Day 1
2 Product Overview 1.5 hours Day 1
3 Documentation and Support 0.5 hours Day 1
4 Image Input Terminal 3 hours Day 1
5 Power, Control and Ventilation 3.5 hours Day 2
6 Paper Supply 4 hours Day 2
7 Paper Feed and Registration 7.5 hours Day 3
8 Marking 1 7.5 hours Day 4
9 Software Upgrade, Altboot, Fault Histories 4 hours Day 6
10 Offset Catch Tray, Office Finisher 1 hours Day 6
11 HVF, BM, Tri-folder and PPI 2.5 hours Day 6
11 HVF, BM, Tri-folder and PPI (continued) 4 hours Day 7
12 Fax 1 hour Day 7
13 Maintenance Tasks 0.5 hours Day 7
14 ColorQube 9300 Service Differences 2.5 hours Day 7

Table 2. Course Map - Differences Course - 5 Days*
Time to
Module complete Day
1 Course Introduction and Overview 1.0 hour Day 1
2 Product Overview 1.5 hours Day 1
3 Documentation and Support 0.5 hours Day 1
4 Image Input Terminal 3 hours Day 1
5 Power, Control and Ventilation 2.5 hours Day 2
6 Paper Supply 1 hours Day 2
7 Paper Feed and Registration 4 hours Day 2
9 Software Upgrade, Altboot, Fault Histories 4 hours Day 5
10 Finishers 1 hour Day 5
11 Fax 1 hour Day 5
12 Maintenance Tasks 0.5 hours Day 5
13 ColorQube 9300 Service Differences 2.5 hours Day 5
* Refers to the differences from 5632 Family products.
Training Modules 0
• Each module contains the following activities:

- Module Objectives - May be presented by the
Instructor or provided within the CBT.
- Technical Overview - May be presented by Instructor
or provided within the CBT, or a combination of both.
- Work Projects - Hands-on activities with instructions
provided in the Student Workbook. Be prepared to
assist when requested. See below for more details.

- Fault Analysis and Repairs - Some modules include

practice troubleshooting exercises using Instructor-
installed faults. Fault Analysis is not referred to in the
course so you can vary when (or if) you ask the
Students to perform fault analysis exercises.
- Module Quiz - Some modules include quizzes to check
your understanding of the important concepts.
- Module Summary - Use this activity to ask/answer
questions and sign off module completion.
Work Projects 0
Work projects accompany the Xerox ColorQube 9200/9300

Family Service Training course. You will be directed to them
from the computer based training program.
• Do all the projects in the order listed and check off the
completed tasks.
• Your Instructor may wish to vary some of the work
projects so inform your Instructor before you start a
sequence of work projects.
• Return to the CBT training program when directed to do
so in the Student Workbook.
• Follow all procedures as written in the documentation.
• If you have any questions about the procedures ask your
Instructor or another Student.
• Be careful of sharp metal edges in the machine.
• Take care when unplugging and replacing plug jacks. Do
not force plugs or bend pins.
• Even when procedures are followed properly, things break.
If this happens notify the Instructor and look up the part
number in your documentation.
• Use E-doc or the Service Manual to assist in component
location.
• Do not replace a removed component unless instructed to
do so.
• At the end of each sequence of work projects you are
asked to obtain sign off from your Instructor. If the
Instructor is not available, continue with the next section,
and make sure you obtain sign off at the earliest
opportunity.

CAUTION: Be aware that there are different types of screws

in the machine. Machine screws go into metal threads and
self-tapping screws are for plastic. DO NOT OVER TIGHTEN
ANY SCREWS AND SPECIFICALLY THOSE THAT SECURE IN
PLASTIC. IF YOU DO STRIP THREADS THE COMPLETE
MACHINE MAY HAVE TO BE REPLACED.
Lab Partners 0
During this training event you may be paired up with a lab

partner. Please adhere to the following guidelines regarding
partners:
Cooperate with your partner about the pace of the training.
Some people are faster than others, while some people like to
take their time and absorb the material.
Work together to complete all work projects and
troubleshooting elements of the course. Avoid one person
doing all the work.
Instructors are available to address any problems that may
arise during the training course with regards to your working
arrangement as partners.
Module 1 Overview - Begin Product Training Here 0

By the end of this module you will understand and be able to
describe:
• Safety practices and machine hazards for ColorQube
products
Module Objectives 0
Given the resources available to you in the classroom, you will
be able to complete the module objectives.
 Refer to the Xerox ColorQube 9200 Service Training CBT,
and complete Module 1 Introduction.

Technical Overview 0
 Complete the entire Module 1 Introduction in the Service
Training CBT.
 Read the remaining pages in section 1 of the Student
Workbook.
Inform your Instructor once you have completed Module 1.
Work Projects 0
Review the following list to become familiar with acronyms
and abbreviations that are used in the Service
Documentation and the training materials for this course.
3TM 3 Tray Module (also TTM - Three Tray Module)
Abatement Air system to reduce head contamination
ADC Analogue to Digital Converter
ADC Sensor Automatic Density Control
A xerographic function analogous to the IOD Sensor
AIF Automated Information Forwarding (sends usage profile to Xerox)
AMPV Average Monthly Print Volume
AP Advanced Purge
BIST Built In Self Test - verifies basic functions (e.g. CPU)
Bit Depth 1 bit = Black or White
4 bit = 16 colours
8 bit = 256 colours
Bitmap fonts Pixels that form the shape of fonts. Created in specific sizes and
cannot be re-sized.
Burst Mode Copy mode when two A4/letter images are on the drum at the
same time
CAP Cold Abnormal Purge. Wax temperature too low for purging while
in standby, low power or sleep.
CBC Common Board Controller or Combined Board Controller
CC Copy Controller. Controller for Input and Output and some of
Image Path.
CCD Charge Coupled Device. Light sensitive device in scanner.
CCS Copy Control Software
CDI Common Device Interface
Chase Sheet Paper that is run through the machine to remove a partial image
from the drum
CIPS Common Image Path Software
CIS Contact Image Sense (related to Registration/Preheat assembly
scan bar)
CMM Colour Management Module - software application used for colour
conversion

CMO Critical, Major, Ordinary - problem rating system

CMS Colour Management System - helps provide colour consistency
CMY Cyan, Magenta, Yellow - subtractive primary colours
CMYK Cyan, Magenta, Yellow, Black
Cohesive Failure ink breakdown during transfix which produces part pixels
Colour An interaction of light, object and human eye. Consists of Hue,
Saturation and Lightness.
Colorimeter Device used for colour calibration
CP Cold Purge - normal power up
CPQD Customer-perceived Print Quality Defect
CRD Colour Rendering Dictionary - used to convert RGB to CMYK data
CU Cleaning Unit - provides cleaning and lubrication to drum.
CVU Check Valve Unit - prevents air and ink from flowing back into the
ink reservoir.
CWIS CentreWare Internet Services
CWM Continuously Weak or Missing Jets
DDB Drum Driver Board
Densitometer Photoelectric device that measures reflected light
DM Drum Module
DMO Developing Market Operations
DM Slime Accumulation of ink in the Drum Cleaning Unit.
DMU No longer used (Drum Maintenance Unit) - see CU.
Dosing Ink sent from the ink reservoir to print heads.
Dot Spread/Dot Gain The final size of an ink pixel after transfix.
Drooling Ink that has oozed from the print head
Duplex Dropout Loss of pixels on side 2
Embossing Outlines of the first printed side showing on the second side of a
duplex print.
ESP Encoded Skew and Process - deskew and registration functions
FLUSH Routine used to purge a contaminated ink reservoir.
Freckle/Freckling A pixel from a previous image showing on the next image.
FRU Field Replaceable Unit
FTTR Fast Time To Ready - allows paper to run through machine without
print head use
Gamut The colour range a device can produce.
GCR Grey Component Replacement - uses black to replace grey
produced from CMY
Ghosting A previous image seen on the current image
Gloss variance Variation in gloss - usually of duplex copies
H2H Head to Head alignment
HDD Hard Disk Drive
Head to Head Measures the relative intensity between heads at 100% coverage.
Uniformity
HFC Head Field Corrections (stored in NVM)
HFD Head Field Data (stored in NVM)
HM Head Maintenance
HSL Hue, Saturation and Lightness chart

HTD Head To Drum spacing

Hue colour or shade of colour
HVF High Volume Finisher
IIZ Inter Image Zone
IME Image Marking Engine
Ink Blocking Transference of image from one sheet to another, usually in the
output device
Ink Cooking Change in the ink colour due to ink remaining in a molten state for
extended periods. Usually caused by lack of machine use.
Ink Squeegee Ink smeared over page
IOD Ink On Drum sensor
IOP Ink On Paper
IPD Installation Preparation Document
IQ Image Quality
IUG Interactive User Guide
IWM Intermittent Weak or Missing jets
LCSS Low Capacity Stapler Stacker
LETO Lead Edge Time Out
Light Visible part of the electromagnetic spectrum
Lightness Brightness or darkness of an image
Low Power Mode Various components in the machine maintained at a low
temperature to save power (Print Head Jetstack, Print Head
Reservoir, Drum and Registration/Preheat assembly.
LPA Low Pressure Assist
LVPS Low Voltage Power Supply
Matting Matting is the reduction of gloss on the first printed side compared
with the second printed side
Metamerism Perceived colour changes under varying light sources
MFD Multi Function Device
Moire Undesirable dot patterns
Monochrome Black and White image containing white and shades of grey only.
MPB Media Path (paper path) Board
MR Melt Rate
MSI Multi-Sheet Inserter
MU Marking Unit
Mud Page Page of all colours to help clean the print head area. Now called a
Cleaning Page.
NA North America
NC Network Controller
NcCv Normally closed Check valve (in ink reservoir tank)
NoCv Normally open Check valve (in ink reservoir tank)
NRSB No Response to Start Button
ODIO On Demand Image Overwrite
Offsetting Ink or coloured regions transferred to the rear side of a print during
or after duplex printing
OHP Over-Head Projection (media)
OOM Out of Media

OOP Out of Paper or Out of Position

PCI Peripheral Component Interconnect - internal BUS within CBC
PCS Profile Connection Space - converts colour data as it moves from
one device to the next
PDB Power Distribution Board
PDM Post Drip Mass
PDT Product Design Team
PEST Print Engine Self Test - automated test that monitors current draws
PFP Paper Feed Platform
Pixel Picking The ability of the transfer system to transfer pixels from the drum
to the media
Pixel Sharing/ Method to hide missing jets
Borrowing
PLD Programmable Logic Device
PMC Problem Management Committee or Council
POP Plate on Plate - refers to Registration/Preheat assembly
POST Power On Self Test
PPI Post Process Inserter
PQ Print Quality
PTC Positive Temperature Coefficient - as heat rises, resistance rises and
current goes down
Registration and Pre Detects and corrects skew, and heats the paper to assist ink
Heat Assembly adhesion
Resolution Scan resolution defined in pixels (PPI or pixels per inch)
Reverse Text Text created by printing an ink field around the text letters
RGB Red, Green, Blue - primary additive colours
RIP Raster Image Processing - four separate Raster images are made
for each page of output, one for each colour (CMYK)
Roll Alignment of print heads
Roll Off Transfix roller rolling over trail edge
Roll On Transfix roller rolling over lead edge
Roller Ghosting Print quality defect caused by a contaminated transfix roller
Roving Jet Random missing jets
Runout Inconsistent concentricity of drum
SAG System Administrator Guide
SATA Serial data transmission for hard drives
Saturation Vividness or dullness of colour
SBC Single Board Controller - combined Controller and Network
Controller
Screen Frequency Distance between each line of pixels or dots in lines per inch (LPI)
SWFA Staggered Full Width Array
SIP Solid Ink Product or Scanner Image Processing PWBA
Sleep Mode Mode which keeps Print Heads, Printhead Reservoir and
Registration/Preheat assembly heaters at reduced temperature
Solid Fill Image condition where ink is at 100% coverage.
SOPM Scan Once Print Many -one scan to store the image data for
multiple prints

Stitch Front to back alignment of the printheads

TAR Take Away Roller
TBC Top Be Confirmed
TBD To Be Defined/Determined
TCO Total Cost of Operation
TEC Total Energy Consumption
TETO Trail Edge Time Out
TFD Time First Drip
TOF Transfix On Fly
Trapping Colour overlap used to cover small gaps where paper colour could
show through
TRC Tonal Response Curve - sets the dot size (drop mass) to achieve
consistent mid-tone solid fills
TTM Three Tray Module - also Time To Market
UCR Under Cover Removal
UI User Interface
USB Universal Serial Bus
Vector Fonts Fonts defined by lines that connect points to form characters.
Vector fonts can be resized without deterioration.
WAG Term used to define paper movement in the Registration/Preheat
assembly.
WAP Warm Auto Purge - automatic attempt to recover print head jets
WW World Wide
X Axis Cross process direction
XE Xerox Europe
Y Axis Process Direction
Z Axis Up and down movement or direction
Fault Analysis and Repair 0

There are no fault analysis and repair activities for Module 1.
Module 1 Quiz 0
There is no quiz for Module 1.

Module Summary 0
This module has provided an overview of the Xerox
ColorQube 9200/9300 Family Service Training Program. It
provided you with all of the necessary information regarding
the training center, its rules and guidelines as well as the
equipment you will use to complete this training.
Student and Instructor roles have been defined.
At this time, you should understand the structure of the
training course and the prerequisite knowledge, hardware,
and tools needed to proceed through this training event.
Review the objectives at the beginning of the module. If you
do not feel that you have completed all of the objectives
listed, review the materials for that objective, then discuss the
objective(s) with your Instructor.
Have your Instructor sign you off on Module 1.
______________________________ Instructor


2 Product Overview
Module Overview 0
This module will introduce you to the Xerox ColorQube 9200/9300
Family product and provide you with some basic information about
its configurations, installation specifications, features, and
capabilities.
Module Objectives 0
Given the resources available to you in the classroom, you will be
able to complete the module objectives.
 View the Introduction in Module 2 Product Overview in the
Service Training CBT, to identify the module objectives.
 Complete the entire Module 2 Product Overview in the Service
Training CBT.
Machine Configuration 0
As identified in Service Training CBT, the Xerox ColorQube 9200/
9300 Family is a full colour, multifunction machine providing
network and email features.

Product Overview Xerox ColorQube 9200/9300 Family
Visual Differences Between ColorQube 9200 and 9300 0

The logo located on the front door is the easiest way to
identify ColorQube 9200 and 9300 products. In genenal, the
machines are almost identical. They have the same UI and
exterior covers. They also use the same ink sticks, trays, and
finishers.
Throughout this course, differences between the two
products will be identified. The last Module, “ColorQube 9300
Service Differences”, provides a complete summary of the
user-level and service differences.
Machine Operation 0
During the work projects use the Customer Documentation to
identify the standard and optional features available.
Software options, described in the Interactive User Guide
(Overview>Software Options>Overview), are available for the
following.
• Job Flow Sheets
• EIP (Extensible Interface Platform)
• SMARTsend
• ScanFlowStore
Machine Installation 0
The Xerox ColorQube 9200/9300 Family is easily installed,
especially by experienced technicians. The installation
procedure is available in the install kit provided with the
machine.

Xerox ColorQube 9200/9300 Family Product Overview
Work Projects 0
In this module the source of information is the Embedded
Help screens from the UI, the customer documentation (IUG,
SAG and Quick User Guide) and the Xerox ColorQube 9200/
9300 Family with Booklet Maker Finisher.
Ask your Instructor for some A4/ 8.5x11 inch and A3/ 11x17
inch Demonstration Originals, or make some using a marker
pen and paper.
Although it is difficult to see the finisher functioning, it may
be of interest to cheat the interlock of the finisher front door
to observe the finisher running.
Refer to Embedded Help and the Quick Use Guide to perform
the following:
Work Project 1 - User Interface Screens 0
 Insert four originals into the DADH LEF.

• Select More under 'Copy Output' in Basic Copying tab.
• Select 1 or 2 Staples in Output Options screen.
• Select Save.
• Select 3 and press Start.
• Retrieve the output from the Stacker Tray.
Work Project 2 - Copy 0
 Load 6 single sided A4/ 8.5x11 inch documents into the

DADH. Note that the guides position the documents on the
centreline of the DADH. Make 3 sets of 1 to 2-sided copies
into the finisher.
• Keep one set of the copies to use as double sided test
documents.
Use one of the 2-sided sets to make 5 stapled sets as follows.
• Make 5 booklets or stapled sets. Watch the Professional
Finisher as the copies are made. Retrieve the output from
bin 2.
• Insert eight or ten originals into the document handler.
Follow the instructions and make 5 folded and stapled
booklets. Watch the compiler movement of the

Professional Finisher as the booklets are made. Retrieve

the output from bin 2 (the output is correct when each
image has been reduced and appears as one per page).
 Make 10 copies from the platen of an A3/ 11x17 inch
document using 50% reduction. Ensure that the page
orientation is maintained.
• Using an A3/ 11x17 inch document and the document
handler, make 3 single sided copies with Auto Reduction
selected. Maintain the document orientation and copy
onto A4/ 8.5x11 inch paper.
• Read the Image Quality section in the Quick User Guide.
Try some of the settings on the machine and observe the
effect.
• On the machine select some of the Additional Copy
Features described in the Quick Use Guide. Make copies
from the Quick User Guide to see the effect.
• Read the sections entitled Original Input and Image Shift
in the Quick User Guide. If you have some mixed size
documents available use them to practice with the input
options. Try the Image Shift feature to move the image
position on the copy.
• Read through the remainder of Section 3 of the Quick
User Guide to become familiar with the features detailed.
Practise on the machine any of the features covered so far
to test your understanding.
• Finally go to the machine and using the Help facility check
out copying help if you have not already done so.
Work Project 3 - Fax 0
 In this section, the Fax facilities of the machine are used to

conduct some basic Fax operations. Use the Quick User Guide
and the machine Help files for information.
• On the machine select the Basic Faxing tab and check the
options available. To view all the options available select
the feature to check out any further options.
• Use a document to send a Fax to another Fax machine, or
any Fax equipped Document Centre machine in your work
area. Check with your Instructor for the telephone number
if necessary.

• Review section 4 of the Quick User Guide for further

information about Fax features.
• Use the Help facilities on the machine to check
information available on Fax.
Work Project 4 - Workflow Scanning 0
 The Workflow Scanning feature allows an electronic file to be

created from a document. The electronic file can be filed or
faxed. If Workflow Scanning has been installed, a Workflow
Scanning tab will be available on the touch screen. If the
Workflow Scanning tab is not available, continue to Work
Project 5.
• Using the Control Panel touch screen select the Workflow
Scanning tab and More Scan Features tab to examine the
options available.
• Review the Workflow Scanning section in the Quick User
Guide.
• Scan a document to the default repository and then
access the scanned job in the repository from a PC in the
training room.
Work Project 5 - Scan to E-mail 0
 The Scan to E-mail feature enables an electronic file to be

sent to an E-mail address as an attachment. The electronic
file can be filed, faxed or distributed through email.
• If Scan to E-mail has been installed, an E-mail tab will be
available on the touch screen.
• Using the UI touch screen, select the E-mail tab and
examine the screen.
• Review the Scan to E-mail section in the Quick User Guide.
• Scan a document to a known E-mail address and then
access the E-mail from a PC in the training room.
Work Project 6 - Print 0
 Review the Print section in the Quick User Guide.

• If your machine is network connected, send a print from a

networked workstation to the machine. Check some of the
options from the CentreWare screen to customise your
print.
• Print a Configuration Report (if you have not already done
so). Locate the settings for TCP/IP on the report.
Work Project 7 - Customer Maintenance 0
Customer Maintenance consists of the replacement of the

various CRU assemblies, loading paper and staples, cleaning
activities and jam clearance. All activities are quick and
straightforward with no training or experience required.
 Loading paper
• Follow the instructions in the Interactive User Guide and
load paper into tray 1 or 2 and the HCF.
NOTE: It is critical that the top of the stack is BELOW the
maximum line. This is a common cause of paper jams.
 Login as a System Administrator
• Refer to the Interactive User Guide and open the section
’Resources’
• Press the ‘Machine Status’ button, then touch the ‘Tools’
tab.
• Read the overview and then access some of the options
that are available in the Tools pathway.
• Access some of the options that are available in the Tools
pathway (for example Machine Information, Supplies).
• Click on the link ‘Login as a System Administrator’ and
read the information.
• Click on the Home icon of the Interactive User Guide to
return to the home screen.
 CRU Removal and Replacement
Follow the instructions in the Interactive User Guide (IUG) to
remove or replace the:
• Solid Ink Sticks
• Cleaning Unit
• Staple cartridge
• DADH feed rollers

Sign Off 0
 Ask your Instructor to sign off these work projects. If you have
any questions ask your Instructor now.
If your Instructor is not available continue with the next
module.
______________________________ Instructor

Module 2 Quiz 0
Complete the Module 2 Quiz in the Service Training CBT. You
may use the machine or any of the documentation to assist
with your answers.
1 Which of the following are standard features of the Xerox

ColorQube 9200/9300 Family? Select any of the answers that
apply.
1. Copy, Scan and printing functions
2. DADH
3. Fax and LAN Fax
4. Colour User Interface
2 Which of these Paper Trays are standard? Select any of the

answers that apply.
1. Paper Feed Platform
2. Bypass Tray
3. Three Tray Module
4. All of the above
3 Which of the following correctly describes the output speed

of the ColorQube 9200 machine?
1. 30 to 70 prints per minute
2. 30 prints per minute
3. 30 to 85 prints per minute
4. 70 prints per minute
4 Which of the following output options are available for the

Xerox ColorQube 9200/9300 Family?
1. Offset Catch Tray
2. Low Capacity Stapler Sorter
3. High Volume Finisher with Booklet Maker
4. All of the above
5 What is the paper capacity (80gsm/20lb) of the HVF/BM

Stacker Tray when a Tri-Folder is installed?
1. 1000 sheets
2. 1500 sheets
3. 2000 sheets
4. 3000 sheets

Module Summary 5
In this module, you have:
 Viewed Module 2: Product Overview in the Service
Training CBT and used the customer documentation and
should be able to demonstrate your knowledge of
configurations, specifications, features, and capabilities.
 Review the objectives at the beginning of the module. If
you do not feel comfortable with your ability to perform
any objective, review the materials for that objective then
discuss the information with your Instructor.
 Inform your Instructor that you are ready to proceed to
the next module.
 Have your Instructor sign off Module 2.
______________________________ Instructor


3 Documentation and Support
Module Overview 0
This module will introduce you to the Service Documentation,
Diagnostic procedures, and Support material available on the Xerox
ColorQube 9200/9300 Family product.
Module Objectives 0
 View the Introduction of Documentation and Support in the
 This module reviews the service documentation and requires
several tasks to be completed.
 Xerox provides separate EDOC service manuals for ColorQube
9200 and ColorQube 9300 products. You will need to install both
EDOCs on your PWS to support these products. Check with your
instructor to determine which EDOC to use for this course.

Documentation and Support Xerox ColorQube 9200/9300 Family
Diagnostics/Service Mode 0
To enter Diagnostics/Service mode from power ON, ensure
the machine indicates READY on the UI. Press and hold the #
key, the * key and the STOP key. Enter the PIN 1991and touch
the ENTER button on the UI.
Service Documentation - layout 0

The Service Documentation is divided into sections. If you
have worked with Xerox documentation previously, the
presentation will be familiar to you. Wiring Data and a
Principles of Operation is included.
 Complete the Document Layout Module 3:
Documentation and Support in the Service Training CBT,
to identify the service manual layout.
Documentation - sections 0
 Complete the other sections within Module 3:
Documentation and Support in the Service Training CBT,
to identify the service manual and other documentation
support.
Service Manual vs. Eureka 0

The ColorQube service manuals contain detailed RAPs, REPs,
and service information designed to resolve the problems you
will encounter on these products. These manuals have been
updated frequently to incorporate field feedback. As a result,
the manuals work well - use them to diagnose and repair
machines.
Eureka supplements the service manual with practical hints
and tips. Although Eureka can provide helpful information,
use the service manual as your primary reference for
troubleshooting and repair procedures.
These products contain complex subsystems, so skipping the
service manual procedures can lead to incorrect diagnosis.

Xerox ColorQube 9200/9300 Family Documentation and Support
Work Projects 0
Work Project 1 0
 Enter Service Mode. Refer to General Procedures GP1 and

enter Service Mode.
 Refer to General Procedures dC361 to perform an NVM
backup.
 Exit Service Mode.
Sign Off 0
module.
______________________________ Instructor

Module 3 Quiz 0
with your answers.
1 What is the Part Number for the BM Backstop Motor?

1. 127K54710
2. 019K14160
3. 006K30790
4. 019E74451
2 The customer reports that the machine is making a squeaking

noise. What is the first action to take?
1. Lubricate relevant moving parts with a light mineral oil
2. Lubricate moving parts with silicone grease
3. Refer to OF1 Unusual Noise RAP
4. Inspect relevant areas for debris
3 What is the appropriate REP for cleaning the Drum Stripper

Blade?
1. REP 10.21
2. REP 10.6
3. GP14
4. The blade should not be cleaned
4 Select the correct IQ RAP for “oil on output” Image Quality

defects:
1. IQ 10
2. IQ 21
3. IQ 25
4. IQ 30
5 Which is the General Procedure for Software Update?

1. GP 2
2. GP 4
3. GP 6
4. GP 8

Xerox ColorQube 9200/9300 Family Documentation and Support
Module Summary 5
In this module, you have reviewed the Service Manual and
used it to find Service Call Procedures and Repair Analysis
Procedures.
you do not feel comfortable with you ability to perform
any objective, review the materials for that objective then
discuss the information with your Instructor.
the next module.
______________________________ Instructor


4 Image Input Terminal
Module Overview 0
This module provides an overview of the Image Input Terminal (IIT).
This Imaging Subsystem contains three major sections:
• The Image Input Terminal (IIT) scans the image on the
document and converts it to digital information.
• The User Interface (UI)
• The Duplex Automatic Document Handler (DADH)
Module Objectives 0
Given the resources available, you will be able to complete the
module objectives.
 View the Introduction in Module 4: Image Input Terminal in the
Complete the entire Module 4: Image Input Terminal in the Service
Training CBT.

Image Input Terminal Xerox ColorQube 9200/9300 Family
Work Projects 0
Registration Adjustment Series 0
There are no mechanical adjustments for either lead edge or

paper centre-line registration on this machine. The position of
the digital image on the drum is moved according to settings
stored in the NVM. The settings depend on the method of
scanning and the paper source and will compensate for any
registration errors.
Registration Series – Supplementary Information 0
The following are additional instructions to help set up the

registration series until confidence and experience are
established. The information is also available as described in
the dC608 dC609 procedures on the EDOC.
UI Diagnostics 0
The method of entry for UI diagnostics is slightly different

from normal diagnostic access. The procedure is to press and
hold the *, Dial Pause, and the # keys.
Work Project 1 0
 Release the scanner assembly.

• Power the machine down. It is not necessary to wait for
the machine to cool.
• Unplug the DADH, unscrew the thumbscrews and remove
the DADH. Put in a safe place.
• Remove the three cables connecting the scanner
assembly to the IOT.
• Open the Front Door
• Locate the two release catches under the UI, and while
squeezing them together with your forefingers, use your
thumbs to push the assembly to the rear. It may now be
lifted off.
NOTE: There is no requirement to lift the assembly away
completely - it is bulky and heavy.

Xerox ColorQube 9200/9300 Family Image Input Terminal
Work Project 2 0
 Remove the Document Glass.

• Refer to the Service Manual for instructions. Note that
there is one screw which is accessible only after pushing
the Scanner assembly to the rear and lifting up the left
side.
• Examine the LED scan lamps and diffusers, and the
SELFOC lens between them. Refer to the Service Manual
for cleaning instructions.
• Locate the following components, but do not attempt to
adjust or remove them:
- Paper Size Sensors
- Scanner Drive Motor, Capstan, drive cables
- DADH Closed Switch
- Scanner Driver PWBA
- The data cable from the scan carriage to the scanner
PWBA
- The white reference calibration strip
NOTE: The Scan Carriage is held against the underside of
the Document Glass by spring pressure, to maintain a
constant and precise distance from it.
DO NOT power up the machine with the Document Glass
removed - initialisation of the scanner will cause the Scan
Carriage to foul the Home Sensor and could cause the
sensor to fail.
• Replace the Document glass
• Replace the Scanner Assembly, and the DADH
• Reconnect all cables.
Work Project 3 0
 Refer to the Service Manual, and perform the following

activities on the DADH.
• Remove the DADH rear cover and locate the interlocks
and drives.
• Remove the outboard cover underneath the top DADH
cover.

• Open the Top Cover and push the Nudger Roll Motor
Actuator back and forth and observe the action of the
Nudger Roll and the Input Gates.
• Remove the DADH Nudger/Feed/Retard Roll CRU.
• Remove the DADH input tray. Remove the Input Tray
lower cover and observe the paper length and width
sensors.
• Re-assemble the DADH.
• Switch on the machine and observe the initialisation of
the scanner.
• Perform dC608 DADH Registration and dC609 Platen
Registration to calibrate the DADH.
• If you have not already done so, re-calibrate the UI touch
screen (by entering UI diagnostics).
• Load some documents and make copies to verify DADH
and scanner function.
Fault Analysis and Repairs 0

 Ask your Instructor for a practice fault, they will also provide a
problem statement.
Complete at least two practice faults and then ask for a
criterion fault.

Xerox ColorQube 9200/9300 Family Image Input Terminal
Module 4 Quiz 0
with your answers.
1 How is the size of the documents in the DADH detected?

1. Use of length sensors, setting of document width guides
and active length sensing .
2. Use of length sensors and document width guides.
3. Use of document present sensor and scanner document
size sensors.
4. The document size is not detected.
2 Select the correct statement below regarding TAG 007

document imaging (ColorQube 9200 only).
1. Imaging data is reflected from the document then passes
through the mirrored optical system and lens to the CCD .
2. Imaging data is reflected from the document and passes
through the SELFOC lens to the CCD.
3. Imaging data is reflected from the document and passes
through the SELFOC lens to the photosensor array.
4. Imaging data is reflected from the document then passes
through the mirrored optical system and lens to the
photosensor array.
3 What is the resolution of the photosensor array?

1. 300 dots per inch
4 What type of lamp is the scan lamp in the W/O TAG 007
scanner (ColorQube 9200 only)?
1. Cold cathode low pressure mercury vapour
2. Quartz halogen
3. Light Emitting Diode (LED)
4. Colour corrected fluorescent

5 Select the correct statement regarding scan drive.

1. The scan carriage is driven by a toothed belt and pulley
from the scan motor.
2. The scan carriage is driven by gears from the scan drive
motor.
3. The scan carriage is driven by gears to the capstan and
toothed belt to the scan carriage.
4. The scan carriage is driven by cables connected to the
capstan. The capstan is driven by a toothed belt and
pulley from the scan drive motor .
Module Summary 5
This concludes the Imaging module. In this module, you
became familiar with the Imaging process and procedures for
servicing and troubleshooting this part of the machine.
any objective, review the material for that objective. If
you are still not comfortable, discuss the information with
your Instructor.
the next module.
 Have your Instructor sign you off on Module 4.
______________________________ Instructor

5 Power, Control and
Ventilation
Module Overview 0
This module provides an overview of the Xerox ColorQube 9200/
9300 Family Power, Control and Ventilation. It covers the following
topics and work projects:
Topics - Instructor-led and CBT
• Power supply unit
• Interlocks
• Printed Wiring Boards (PWBs)
• 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
Module Objectives 0
• Presentations:
- Printed wiring boards
- AC heaters technical overview
- Cooling and ventilation system overview
- POST/PEST technical overview
During this session Students will:

Power, Control and Ventilation Xerox ColorQube 9200/9300 Family
• Complete the Power, Control, and Ventilation Module CBT

lessons.
• Locate many of the system PWBs.
• Measure several AC heater temperatures using dC335,
and monitor the temperature change after turning a
heater off.
• Remove and install the Abatement Plenum (damage to
the machine can occur if this part is improperly installed).
• Observe the normal power on process. This includes
normal sounds, mechanical functions, and POST LED
activity.
• Troubleshoot Instructor-installed POST and PEST faults.
Technical Overviews 0
AC Heaters Technical Overview 0
The machine contains six types of components that use AC

heaters. Each heater has a “setpoint”, which is the normal
operating temperature for the component. When the
machine is idle or in a sleep mode, the heaters are turned off
or operate at much lower temperatures.
• Printhead heaters (115°C/239°F): Each Printhead
contains a heater for the internal ink reservoirs and one
for each side of the Jetstack (left and right). The Jetstack
is constructed of several thin, metal plates that are etched
with small channels. When the plates are stacked and
bonded together, the etched surfaces create a network of
tiny passages that connect between the four reservoirs
and the 880 jets.
• Drum heater (55°C/131°F): Two individual heaters raise
the surface temperature of the imaging drum to its
operating temperature. Heat from the Printheads help to
maintain the drum temperature once it reaches operating
temperature. The Drum Heaters are on most of the time
for low-coverage prints and are off most of the time for
high coverage prints (>150% fill).
• Preheater (61°C/142°F): Metal plates preheat the media
prior to transfixing to improve ink transfer to the media.

Xerox ColorQube 9200/9300 Family Power, Control and Ventilation
• Ink melt heaters (120°C/248°F): Enabled for individual

colors when the level for that color is low in the Ink
Reservoir Assembly.
• Ink reservoir heaters (115°C/239°F): Two individual
heaters maintain liquid ink to supply the four Printheads.
• Umbilical heaters (105°C/221°F): Keeps the ink in the
liquid state as it travels from the Ink Reservoir Assembly to
the individual Printheads.
The Drum Heater operation depends on the machine’s AC
configuration.
• Relays in Power Supply Unit control heater configuration
• Elements for each heater are in parallel for 110 Volt
operation
• Elements in series for 220 Volt operation
• Non-resettable Thermal Cutouts protect from excessive
drum temperatures (board must be replaced)
• The Thermal Cutout Board is a subpart of the
Registration/Preheat Assembly
The Drum Heater is the only AC heater that switches modes
based on the power supply.
Service diagnostics test dC335 allows each AC heater to be
activated and monitored. You can enable individual heaters
and graph their temperature over time for given setpoints.
The example shows a graph for the Printhead 1 Reservoir
Heater. The “Ready” setpoint for this heater is 115°C.
In this first part of this graph, the Printhead 1 Reservoir
Heater Setpoint M ode has been changed from “Ready (115°
C) to “Off”. The graph shows the temperature decline over a
period of about 30 seconds. At the mid-point of the graphic,
the heater was set back to “Ready”. As a result, the
temperature increased to the operating level of 115° C.
NOTE: To change the scale of the graph, touch the center of
the UI.
Cooling and Ventilation System Overview 0
The IOT contains several fans for cooling and ventilation:

• Marking Unit Fan
• Power Supply Fan (part of the Power Supply Unit)

• Enclosure Fan
• Abatement Fan
• Drum Fan
• Chassis Fan (located in controller drawer)
The Marking Unit Fan, Power Supply Fan, Enclosure Fan, and
Chassis Fan are for general cooling.
The Drum Fan circulates air through the drum to maintain an
even surface temperature and to prevent overheating.
The Abatement Fan maintains air purity. It creates a vacuum
that removes paper dust and other debris that can
contaminate the Printhead jets.
If the Abatement Plenum is not seated properly, the Cleaning
Unit metering blade may not be able to move properly. If this
occurs, excessive oil can build up on the drum. In some cases
the oil sprays inside the machine as the drum rotates, causing
severe damage. The oil may leak out of the machine onto the
floor.
When installing the Abatement Plenum you cannot feel or
hear if it is correctly seated. Visually check to ensure the pin
on the rear of the machine is positioned between the two
alignment features on the plenum.
POST/PEST Technical Overview 0
The machine completes a 3-phase initialization process. The

Copy Controller and IME Controller must establish
communications to complete the process:
• Phase 1 – Power On Self Test or POST verifies function of
operating systems and basic communication
- Begins when power switch is turned on
- IME and Copy Controller perform POST
- Errors are reported using an LED blink pattern
- On ColorQube 9300 products, a 7-segment LED
reports controller POST errors
• Phase 2 – Print Engine Self Test or PEST begins after
POST to verify power supplies and general mechanical
health of the Image Marking Engine
- Copy Controller waits

- IME Controller checks for opens (no power draw when

device enabled), shorts (excessive power draw when
device enabled), and out-of-tolerance (low or high)
power draw conditions
- Errors reporting using 99-xxx-xx chain link
NOTE: A 321 blink code is normal when the Copy
Controller is waiting for the IME Controller to complete its
checks.
• Phase 3 – Mechanical initialization begins after PEST to
home components and start the warm up process.
- IME Controller notifies CBC when PEST ends
- Copy Controller initializes the scanner and DADH
- IME Controller initializes the paper feeders, finisher,
and IOT
- Errors reporting using standard runtime chain link xx-
xxx-xx (any number except “99”)
The Copy Controllers on ColorQube 9200 and 9300 products
use different methods to report boot up failures. Each board
contains several LEDs.

To troubleshoot power on failures involving the ColorQube

9200 CBC, refer to “OF 5 Boot Up Failure RAP”. It provides the
normal status of the CBC and NC LEDs - flashing, ON, OFF -
and how to interpret the LEDs when the system has failed.

ColorQube 9200 products with Tag 006 contain the Single

Board Controller (SBC). The SBC LEDs are in different
locations than the CBC/NC LEDs, but they serve the same
purpose. Refer to “OF 5 Boot Up Failure RAP” to interpret the
LEDs when the system has failed.

ColorQube 9300 Controllers contain a 7-segment LED, as well

as several LEDs on the board, to report system faults.
ColorQube 93xx
7-Segment LED
Use the “OF 16 POST Error RAP” to resolve faults reported by

the 7-segment LED. Use the “OF 5 Boot Up Failure RAP” to
interpret LEDs mounted directly on the board.
LEDs to report IME Controller POST errors are located on the
IME Controller (front of machine) and Media Path Driver
Board (rear panel). Only the red LED reports POST errors.

• Remove the Rear Cover to see the rear LED.

Remove “clip on” cover to see IME Controller LED.
• Red LEDs are normally dim when there is no error. They
light up only when reporting an error.
• Green LED turns on if the IME Controller is functioning.
• Both red LEDs (front and rear) report the same error code.
You only need to view one of them.
NOTE: The LED on the rear of the machine blinks the

POST error code only if the IME Controller can
communicate with the Media Path Driver Board.
Red LEDs blink a 3-digit error code to indicate POST failures:
• Begin counting when the LED flutters several rapid blinks.
• After the flutter, count up to nine blinks until there is a
pause, to determine the first digit of the error code.
• After the pause, count up to nine blinks until the next
pause, to determine the second digit.
• After the pause, count up to nine blinks until the next
flutter, to determine the third digit.
• The sequence loops continuously. You can begin counting
after each “flutter”.
PEST failures are categorized as Hard or Soft. The machine
logs a 99.xxx chain link for each, but responds differently:
• Hard Errors – Critical system errors

- IME Controller may reboot in an attempt to clear the

error
- “Call For Service” message displayed on the UI
- Chain link logged in the Fault Counter, Last 40 Fault
History, and PEST Fault History
• Soft Errors – Non-critical system errors
- Machine continues to power on (no error message on
the UI)
- Chain link logged in PEST Fault History only
NOTE: Other IME errors can occur that will shut the machine
down that are not chain 99, but they will NOT appear in the
PEST Fault History.
Within the dC123 PEST Fault History, error codes are
organized as follows:
• Hard errors are listed first (top of list) followed by soft
errors.
• The most recent error appears at the top of the list.
• The code 99.000 indicates the beginning of a PEST
sequence, such as when the machine is powered on.
• The code 99.999 is the delimiter between hard and soft
errors. Codes above 99.999 are hard errors and codes
below 99.999 in the list are soft errors.
Service CBT Activity 0

Complete the Power, Control, and Ventilation Module of the
Service Training CBT.
Power Supply Unit:
• Describe power input and subsequent power handling
• Locate the power supply unit
Interlocks:
• Power considerations when using interlocks
Printed Wiring Boards:
• Identify and locate all PWBs
• Describe function of PWBs and identify standard and
optional PWBs

AC Heaters:
• Location and function of each AC heater
• How the machine monitors heater temperatures
Cooling and Ventilation:
• Basic function and location of each fan
• Replacement tips for the Abatement Plenum
POST/PEST Errors:
• Power on sequence overview
• POST and PEST error reporting
• POST and PEST error troubleshooting
Work Project 1 - Locate PWBs 0
 Locate and inspect the following PWBs.

• Media path driver PWB
• Drum driver PWB
• Power distribution PWB
• Copy controller PWB
• Network Controller PWB (ColorQube 9200 w/o Tag 006)
• Embedded Fax PWB
• 3 Tray module PWB
Work Project 2 - Monitor Temperatures 0
During this work project you will run dC335 monitor and
record the following heater temperatures over time:
• Drum - front heater element
• Printhead 4 - left jetstack heater
• Lower umbilical
 Record the current temperature of three components:
1. Enter service diagnostics mode.
2. Select the Diagnostics tab and run Run dC335, “Heater
Monitor and Exerciser”.

3. From the UI, select the Components, Heaters, and

Setpoint Modes defined below. Record the current
temperature for all three heaters.
Component Heater Setpoint Mode Temperature
Drum Front Ready
Printhead 4 Left Jetstack Ready

Umbilical Lower Ready
 Use dC335 to observe temperature changes of the Upper

Umbilical Heater over time:
1. Configure dC335 to test the Upper Umbilical Heater at
the “Ready” setpoint (110° C).
2. Press “Graph” to begin the test.
3. After 15 seconds press “Stop”.
4. Change the Setpoint Mode to “Off”.
5. Press “Graph” to observe the temperature change over
time.
6. After 30 seconds press “Stop”.
7. Change the Setpoint Mode to “Ready”.
8. Press “Graph”. Watch the temperature return to 110° C.
9. Exit service diagnostics.
Work Project 3 - Plenum Removal and Installation 0
During this work project you will remove and reinstall the
Abatement Plenum. This work project contains a Checkpoint
that requires the Instructor’s signature to verify correct
installation of the Abatement Plenum.
 Remove the Abatement Plenum:
1. Remove the Cleaning Unit. To avoid oil spills, do not tip
the unit. Place the Cleaning Unit on a sheet a paper to
protect the customer’s environment.
2. Remove the Inner Skin. DO NOT install an interlock
cheater in the Front Door Interlock.
3. Reinstall the Cleaning Unit handle.
4. Remove the Abatement Plenum.
 Reinstall the Abatement Plenum. When installing the unit,
verify:

• The Abatement Plenum lines up correctly with the

Abatement Fan housing (rear of machine).
• The pin on the rear chassis is located between both
alignment features on the Abatement Plenum.
Instructor Signature: _____________________________
 Install a cheater for the Front Door Interlock.
Work Project 4 – Observe Power On Sequence 0
During this work project, Students will observe the normal

operation of the POST LEDs and listen to the normal power
on sequence.
 Observe the IME Controller POST LED during a normal power
on sequence:
1. Turn off the power.
2. Remove either the access cover to the Marking Unit (IME
Controller) or the Rear Cover to view one of the POST
LEDs.
3. Turn on the power and note the normal function of the
green and red LEDs:
Green LED Behavior: ____________________________
Red LED Behavior: ______________________________
 For ColorQube 9300 products, observe the 7-segment POST
LED during a normal power on sequence:
2. Locate the 7-segment LED on the rear panel.
3. Turn on the power and note the normal function of the
LED.
 Turn on the power and listen to the typical sounds. Try to
associate sounds with components during the normal power
on sequence:
2. If necessary, remove the Rear Cover and Inner Skin.
3. Install the Front Interlock Cheater.
4. Turn on the power and listen to the typical sounds. Try to
associate sounds with part of the machine.
5. with part of the machine.
NOTE: Repeat this process as time permits to become familiar
with the sounds and mechanical motions that occur during
power on.


This section involves troubleshooting exercises based on
Instructor-installed faults. After the Instructor installs a fault
in your machine, use the service manual and information
from this lesson to troubleshoot the image quality issue.
 Troubleshoot POST and PEST errors:
1. Wait for the Instructor to install a fault into your machine.
2. Use resources including the UI, POST LEDs and Fault
History to identify the error code.
3. Use the service manual to troubleshoot the error.
Practice Work Problem #1 0
Fill in the blanks to document your actions when resolving this

issue.
Location of fault code:

_________________________________________________ 0
RAP for this defect: ________________________________ 0
Troubleshooting steps:
_________________________________________________ 0
_________________________________________________
_________________________________________________

issue.

_________________________________________________ 0
_________________________________________________ 0
_________________________________________________
_________________________________________________


issue.

_________________________________________________ 0
_________________________________________________ 0
_________________________________________________
_________________________________________________

issue.

_________________________________________________ 0
_________________________________________________ 0
_________________________________________________
_________________________________________________

issue.

_________________________________________________ 0
_________________________________________________ 0
_________________________________________________

Statement: Machine will not power on.

Fault code:
_________________________________________________
_________________________________________________ 0
_________________________________________________
_________________________________________________
Statement: Unable to clear ‘The Front Door is open’

message.
Fault code:
_________________________________________________
_________________________________________________ 0
_________________________________________________
_________________________________________________
Statement: Unable to clear ‘The Top Left Side Door is open’

message.
Fault code:
_________________________________________________
_________________________________________________ 0
_________________________________________________
_________________________________________________
Statement: Unable to clear ‘The Front Door is open’

message.

Fault code:
_________________________________________________
_________________________________________________ 0
_________________________________________________
_________________________________________________

Session Review 0
AC Heaters, Cooling, and Ventilation Session Review 0
• 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?
POST/PEST Errors Session Review 0
• 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 5 Quiz 0
Complete the Module 5 quiz in the Service Training CBT. You
with your answers.
1 Under what circumstances should a customer with 115VAC

supply specify a 20 amp outlet?
1. All 50ppm machines require this supply
2. When the Bookletmaker and Trifolder are specified
3. When jobs with very high ink coverage and high
throughput are predicted
4. When the supply cable will not fit the socket
2 Why is there no High Voltage Power Supply?

1. The HVPS is embedded in the LVPS
2. Solid Ink machines do not need the high voltages required
by the Xerographic process .
3. The HVPS is only available for machines using a US
20amp supply
4. Actually, the HVPS is installed to the right of the LVPS
3 What hazards exist when the front door and its interlock are
open? Select any of the answers that apply.
1. 410V is present at the Drum Motor
2. AC line voltages
3. Hot surfaces
4. Molten ink
4 Where is the 3.3VDC supply generated? Select any of the

answers that apply.
1. In the LVPS
2. In the HVPS
3. On the Power Distribution PWB
4. On the Media Path Driver PWB
5 Which PWB controls the umbilical heaters?

1. The Media Path PWB
2. The Marking Unit Heater PWB
3. The Marking Unit Driver PWB
4. The Ink Path Heater PWB

Module Summary 5
This concludes the Power, Control and Ventilation work
projects module.
In this module, you became familiar with the Power, Control
and Ventilation process and procedures for servicing and
troubleshooting this part of the machine.
your Instructor.
the next module.
______________________________ Instructor

6 Paper Supply
Module Overview 0
This module provides an overview of the Xerox ColorQube 9200/
9300 Family Paper Supply.
The Xerox ColorQube 9200/9300 Family has three paper trays and a
bypass tray. A high capacity Paper Feed Platform (PFP) is available as
an option.
Module Objectives 0
 View the Introduction in Module 6 Paper Supply in the Service
Training CBT, to identify the module objectives.
 Complete the entire Module 6 Paper Supply in the Service
Training CBT.

Paper Supply Xerox ColorQube 9200/9300 Family
Work Projects 0
Work Project 1 0
 Remove the rear lower cover from the machine.

 Locate the Three Tray Module PWB. Locate the Tray 3
horizontal transport home switch, and the two sets of 5 paper
size switches/sensors for Tray 1 and 2.
 Remove Tray 1. Move the paper length and width guides to
observe the movement of the paper size actuators at the rear
of the trays.
 Reinstall tray 1.
Work Project 2 0
 Refer to SCP 4 Service Procedures, and GP3 General

Procedures in the Service Manual (EDOC) to enter dC135
CRU/HFSI location of your machine diagnostics.
 Reset the Tray 3 feed roll count.
Sign Off 0
module.
_______________________________________Instructor

 Ask your Instructor for a practice fault; they will also provide a
problem statement.
criterion fault.

Xerox ColorQube 9200/9300 Family Paper Supply
Module 6 Quiz 0
with your answers.
1 How is Tray 3 moved into the feed position?

1. Gears from the Main Motor
2. Springs elevate the stack
3. Gears from the Tray 3 elevator motor
4. Tray 3 elevator motor drives a cable and pulley system
2 Select the paper stock which cannot be fed.

1. Tabbed stock
2. Non-paper-backed transparencies
3. Paper-backed transparencies
4. Hole-punched stock
3 Select the capacity of the PFP with 75gsm/20lb paper.

1. 4000 sheets or 2000 sheets with A3/11x17” optional kit
4 What is the purpose of the Bypass Tray?

1. To feed stock such as pre-printed covers that bypass the
Imaging Engine
2. To feed stock that is too heavy or stiff to feed from other
trays
3. To feed special stock such as paper-backed transparencies
4. All of the above
5 What over-limit switches are fitted to the PFP? Select one of

the following answers.
1. An upper over-limit switch
2. A lower over-limit switch
3. Upper and Lower over-limit switches
4. No over-limit switches. The current increase when the
motor stalls signals the control logic to switch off the
motor.

Module Summary 5
This concludes the Paper Supply work projects module.
In this module, you became familiar with the Paper Supply
process and procedures for servicing and troubleshooting this
part of the machine.
your Instructor.
the next module.
______________________________ Instructor

Xerox ColorQube 9200/9300 Family Paper Supply


7 Paper Feed and Registration
Module Overview 0
In this module you will learn about the paper trays, how paper is fed
into the machine, and how the paper moves through the machine. It
covers a variety of subsystems and work projects, including:
Topics - Instructor Led and CBT
• Technical overview
• Paper feed - Trays 1 and 2
• Paper feed - Tray 3 (HCF)
• Paper feed - Tray 4 (Bypass Tray)
• Paper feed - Tray 5 (PFP)
• Registration/preheat assembly
• Paper transportation
• Paper path
• Jam clearance
Work Projects
• Observe the Tray 2 feed head
• Complete the registration adjustment (dC625)
• Test nip C
• Clean the pre-transfix sensor
• Remove and install the Tray 2/3 feed heads
• Locate the confirm and vertical jam sensors
• Remove and install the Horizontal Paper Path and registration/
preheat assembly
• Remove and install the bypass tray components

Paper Feed and Registration Xerox ColorQube 9200/9300 Family
Module Objectives 0
Given the resources available to you in the classroom, you will
be able complete the module objectives.
 View the Introduction in Module 7: Paper Feed and
Registration in the Service Training CBT, to identify the
module objectives.
• Complete the Paper Feed and Registration Module CBT
lessons.
• Observe the Tray 2 Feed Head operation.
• Use dC625 to complete the automated Registration
Adjustment.
• Test Nip C by inserting strips of paper and actuating the
Nip Release Solenoid. Nip C and other paper feed rollers
contain pairs of solenoid-controlled rolls that can cause
skew issues and other problems when failures occur.
• Clean the Pre-Transfix Sensor.
• Locate the Confirm and Vertical Jam Sensors (part of the
Vertical Transport).
• Remove and install the Tray 2 and Tray 3 Feed Heads,
Horizontal Paper Path, Registration/Preheat Assembly,
and several Bypass Tray components.
Paper Feed 0
 Complete the following Module 7: Paper Feed and

Registration sections of the Service CBT:
- Technical Overview
- Paper Feed - Trays 1 and 2
- Paper Feed - Tray 3 (HCF)
- Paper Feed - Tray 4 (Bypass Tray)
- Paper Feed - Tray 5 (PFP)
- Removal and Replacement

Xerox ColorQube 9200/9300 Family Paper Feed and Registration
Registration/Preheat Assembly 0
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 it in the paper path. There are no additional
adjustments to align registration when feeding from
various trays.
NOTE: This assembly also contains the drum thermal
cutout board. The thermal cutout opens if the drum
heater draws excessive current.
When paper jams occur at the preheater, the assembly
automatically opens, providing users access to clear the jam.
The assembly contains three sets of idlers. The machine
enables one set at a time, depending on the current media
size.
The assembly can be replaced as a unit or repaired using one
of the following service kits:
• Steering Roller Kit: Contains two rollers and two drive
belts
• Air Pump Kit: Contains two pump assemblies
A black image is printed as the registration calibration page.
To avoid failures of this calibration:
• Verify the machine has no missing black jets.
• If necessary, perform Printhead alignment.
NOTE: To avoid calibration issues, it is a good practice to
resolve weak/missing jets before beginning calibrations.
Calibration requires no intervention once you begin. The
machine generates about 30 pages because it calibrates each
set of paper feed idlers (wide, medium, and narrow stances).
The registration calibration follows this sequence:
1. The image is printed and transfixed.
2. The page is inverted via the duplex path and routed back
to the Registration/Preheat Assembly.

3. The scan bar detects the calibration page:

- The upper leading corner of media is detected as a
light to dark transition.
- The inner “L-shaped” edge is detected as dark to light
transition.
- The large black area calibrates the scan bar to dark
output.
- Skew is determined by comparing how the media
corner compares to the L-shaped area.
4. 30 pages feed through the machine to calibrate all three
sets of idler rollers.
Skew issues can be caused by Nip C, which has a Release
Solenoid (normally disengaged). To troubleshoot paper feed
issues through Nip C, you must become familiar with the
normal force required to move paper through both the front
and rear nips. When the Release Solenoid is engaged there
should be equal resistance from both nips. When the solenoid
is disengaged there should be little to no resistance from the
nips.
NOTE: The following process can be used when testing
any nip that uses a solenoid to open/close the nip.
Example process for testing Nip C:
1. Open the Upper Left Door and the Horizontal Paper Path.
2. Insert two strips of paper into the Horizontal Paper Path
and align one strip under each roller.
3. Close the Horizontal Paper Path.
4. To test the nip with the solenoid engaged, push each
paper strip into the Horizontal Paper Path. The paper
should buckle.
5. Enable the Nip C Release Solenoid (dC330 Chain Link
082.007).
6. Push each paper strip into the Horizontal Paper Path. The
paper should slide freely as the nip has been released.
 Complete the Module 7: Paper Feed and Registration -

Registration/Preheat Assembly section of the Service CBT.

Paper Transportation, Paper Path, and Jam Clearance 0

Paper Transportation section of the Service CBT.
Paper Path section of the Service CBT.
Jam Clearance section of the Service CBT.
Summary and Work Project sections of the Service CBT.
Work Projects 0
Work Project 1 - Remove Tray 1 Cassette Assembly 0
 Remove Tray 1 cassette assembly.

1. Put A4/8.5x11 inch paper into Tray 2 and make copies
from Tray 2.
2. Observe the action of the feed head when paper is fed
and observe the paper leaving the paper tray.
Work Project 2 (Optional) - Test Nip C 0
During this work project you will test Roller Nip C using the
technique described during the Instructor-led training.
 Test the normal force required to pull paper through Nip C:
2. Run dC330, “Component Control”.
3. Add the test for Chain Link 082.007 “Nip C Release
Solenoid”.
4. Open the Upper Left Door and the Horizontal Paper Path.
5. Insert two strips of paper into the Horizontal Paper Path
and align one strip under each roller for Nip C. The ends of
each paper strip should be accessible from the Upper Left
Door.

6. Reach into the Upper Left Door and push each paper strip
into the Horizontal Paper Path. The paper should buckle
because Nip C is engaged.
7. Pull the paper strips toward the Upper Left Door.
Approximately equal amounts of force should be required
to pull each strip.
8. Using dC330, disengage the Nip C Release Solenoid.
9. Push each paper strip into the Horizontal Paper Path. The
paper should slide freely.
NOTE: If either strip fails to slide freely, the Horizontal
Paper Path is defective.)
10. Close dC330 and exit service diagnostics.
Work Project 3 - Clean the Pre-Transfix Sensor 0
 To clean the Pre-Transfix Sensor:

1. Power the machine down.
2. Manually open the Registration and Preheat assembly
and check the warmth in this area. Note that this area is
automatically opened by the machine in the event of a
jam, to provide user access.
3. Refer to the service documentation REP 10.7 and remove

the hardware holding the Pre-Transfix Sensor. It is a
service activity to clean the Pre-Transfix Sensor
occasionally.
Work Project 4 - Remove Tray 2 Feed Head 0
 To remove the Tray 2 Feed Head:

1. Observe how the rolls are removed and replaced. These
rolls can be replaced without removing the feed assembly.
2. Observe how the sensors are removed and replaced.
3. Remove the Tray 3 feed head and observe its similarity to
Tray 2 feed head.
4. Replace both feed heads.
Work Project 5 - Locate the Confirm and Vertical Jam

Sensors 0
 To locate the Confirm and Vertical Jam Sensors:

1. Pull out the Marking Unit Service Drawer.

2. Consider how you would replace the Confirm and Vertical

Jam sensors without damaging the Print Heads.
3. Push in the Marking Unit Service Drawer and secure.
Work Project 6 (Optional) - Remove the Horiz. Paper Path

and Regi/Preheat Assembly 0
 To remove and reinstall the Horizontal Paper Path and

Registration/Preheat Assembly:
1. Remove the Horizontal Paper Path.
2. Remove the top cover (beware spring pressure within) and
identify the following components.
- The diverter gate solenoid and damper
- The nip solenoid
3. Remove the Registration/Preheat Assembly.
4. Reassemble and replace the Registration/Preheat
Assembly and Horizontal Paper Path.
Work Project 7 - Registration Adjustment 0
This work project includes steps for calibrating the paper path
registration.
 Complete the registration adjustment:
1. Enter service diagnostics and select dC625.
2. Verify one of the paper trays contains at least 30 A4/
Letter-size sheets.
3. Follow the on-screen instructions to complete the
adjustment procedure.
Work Project 8 - Locate Paper Path Components 0
 Power up the machine and locate the following components:

• HCF Feed
• Transport and Elevate Motors
• Tray 2 Elevate Motor and Drive Coupling
• Tray 1 Transport Motor
• Tray 1 feed sensor
• HCF feed sensor
• HCF Stack Height sensor
• Tray 3 feed sensor

• Tray 3 Horizontal Paper Path Jam Sensor

• Duplex End Sensor
Work Project 9 - Remove Bypass Tray Components 0
 To locate and remove Bypass Tray components:

1. Remove the Bypass Tray door.
2. Locate and remove the Bypass Feed roll.
3. Locate and remove the Retard Feed roll.
4. Replace both rolls and all remaining components.
5. Power on the machine.
Sign Off 0
module.
_______________________________________Instructor

problem statement.
criterion fault.

Session Review 0
• 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 7 Quiz 0
with your answers.
1 How do you access the PFP Nudger Roll?

1. Open the door
2. Undock the PFP
3. Remove the top cover
4. Undock the PFP and remove the top cover
2 Why is the second side of a duplex job TransFixed at half

speed?
1. To synchronise the paper feed with the drum revolutions
2. To minimise damage to the first side image
3. It isn’t, the second side is processed at full speed
4. To allow time for the drum, ink and paper to reach a
common temperature
3 How is the Registration and Pre-heat module opened for jam

clearance?
1. Handle 4b
2. Handle 4a
3. Automatically
4. Jams in this area are not customer-cleared
4 What two functions does the registration/pre-heat module

perform?
1. De-skew
2. Paper temperature control
3. Pre-condition the paper with release oil
4. Paper de-curl

5 How many drum revolutions for 75 dpi, and 600 dpi?

1. 75 dpi: 1, 600dpi: 10
2. 75 dpi: 2, 600dpi: 10
3. 75 dpi: 1, 600dpi: 8
4. 75 dpi: 1, 600dpi: 1
Module Summary 5
This concludes the Paper Feed and Registration module. In
this module, you became familiar with the Paper Feed and
Registration process and procedures for servicing and
your Instructor.
the next module.
______________________________ Instructor

8 Image Marking Engine
Module Overview 0
This module provides detailed information for servicing the Image
Marking Engine, or IME. It is divided into the following topics:
• System overview, safety and precautions
• What is an IME?
• Ink delivery
• Printheads
• Printhead purges
• Ink on drum (IOD) sensor
• Drum drive
• Drum maintenance
• Transfix and stripper blades
• Print process summary
• Troubleshoot image quality issues
• Jet substitution
The module is divided into five sessions, each containing work
projects and session reviews.
Session 1 Session 2 Session 3 Session 4 Session 5

System What Is An IOD Sensor Print Process Jet
Overview, IME? Summary Substitution
Safety and
Precautions
Ink Delivery Drum Drive Troubleshooting
Image Quality
Printheads Drum
Maintenance
Printhead Transfix and
Purges Stripper
Blades

Image Marking Engine Xerox ColorQube 9200/9300 Family
Session 1 - System Overview, Safety, & Precautions 0
Introduction 0
• Presentations:
- Image Marking Engine (IME) Overview
- Technology-specific safety and service precautions
During this session students will:
• Complete the Safety & Service Precautions matching
exercise.
IME Subsystems Overview 0
The Image Marking Engine, or IME:

• Melts ink sticks and delivers liquid ink to the printheads
• Generates the printed image on the drum
• Transfers ink images to media
The primary IME subsystems are:
• Ink delivery: Melts ink sticks and uses pressurized air to
pump the ink to the printheads. Also pumps pressurized
air to the Printheads during the purge process.
• Marking Unit: Contains four printheads and their
associated electronics and drive motors. This unit also
contains an air pump, two wiper blades, and two motors
that function together during the printhead purge process
(purging optimizes image quality).
• Ink on Drum (IOD) Sensor: Detects test images printed
on the drum, and checks for missing jets, to optimize
output quality.
• Drum: Receives the ink image from the printheads and
transports the paper during the transfix process.
• Drum Maintenance: Cleans the drum and coats it with
release agent (oil) before printing. The customer-
replaceable Cleaning Unit is responsible for the drum
maintenance functions.
• Transfix and Strip: Transfers the image from the drum to
the paper and routes the paper to the exit path.

Xerox ColorQube 9200/9300 Family Image Marking Engine
NOTE: The Registration/Preheat Assembly is often associated

with the IME, but has been covered earlier in this course.
Safety and Service Precautions 0
Before working on solid ink products, you must become

familiar with the technology-specific safety and service
precautions. Throughout the CBT for this module, the Inkbots
will demonstrate the hazards you will encounter on this
product.
Ink spills
The printheads, umbilicals, and ink reservoir contain hot,
liquid ink. They must be allowed to cool for 30 minutes.
Spilled ink can cause burns, destroy parts inside the machine,
and damage carpets, clothing, and furniture.
Oil spills
The Cleaning Unit contains a large reservoir of oil. If the
assembly is tipped, oil can leak out causing damage to
carpets, clothing, and furniture. Oil spills are also a slip hazard.
Cut Hazard
On this system, the Drum Stripper Blade that lifts the paper
off of the drum is very sharp. Always install the special Drum
Stripper Blade clip before touching or handling this part.
Pinch Hazards
Always keep fingers and tools away from the Drum Drive
system to avoid serious injuries. Its closed loop servo feedback
system drives the motor harder when it encounters resistance
(i.e., from thicker media), and therefore represents an
extremely dangerous pinch hazard.
Never place tools or fingers in the Transfix Drive gears
(exposed on front of machine with inner skin removed).
Printhead docking pins on front of machine can pinch when
Printheads move to print position (exposed on front of
machine with inner skin removed).
Handling components 0
• Do Not Touch Printhead Faceplate: never touch the
faceplate with hands, tools, paper, or clothing. Any
contact can permanently damage the Printhead jets.

• Never Clean Printhead Faceplate: Printheads must be

cleaned by purging only. Do not manually clean with
tools, fingernails, cloths, or any other item will destroy the
Printhead.
• Do Not Reuse Printhead Faceplate Covers: never reuse
the covers provided with new Printheads to protect
Printheads in the machine. Dust on the covers may plug
the Printhead jets.
• Never Touch Printhead Flex Cables: Do not to touch the
gold contacts on the Printhead flex cables. Oil from your
hands can degrade the drive signals.
• never Tilt Hot Printheads: When the Printheads are hot,
never tilt them beyond their approximate orientation in
the machine. Melted ink inside the Printhead can spill ink
or cause ink mixing from one reservoir to the next. The ink
travels through air passages around the white ink level
sensors, flowing toward the black reservoir.
• Do Not Touch Wiper Blades: Do not touch the Printhead
Wiper blades. Any contamination transferred to the wiper
blades will end up on the printhead faceplates, blocking
jets.
• Protect the Drum: Never scratch or bump the drum with
tools or other parts. Scratches and dents cause permanent
image quality problems. Remove jewelry to prevent
scratches.
• Protect the Transfix Roller: Never damage the rubber
transfix roller. Voids and dents on the roller cause
permanent image quality problems.
Work Project 1 - Matching Activity 0
Match devices from the list (A through H) to service issues in

the chart (1 through 8). Multiple answers may apply.
A. Cleaning Unit F. Printhead Wiper Blades
B. Drum G. Registration/Preheat Assembly
C. Drum Drive Motor H. Umbilicals
D. Ink Reservoir I. Ink Melt Heaters
E. Printheads

Devices Service Issue

(use letters)
1. Pinch hazard from closed loop servo feedback

system.
2. When tilted, melted ink leaks into adjacent
reservoirs causing ink mixing.
3. Do not touch. Contamination can block
Printhead jets.
4. Oil leaks can damage carpets, clothing, and
furniture.
5. Spilled ink from these devices can cause burns,
destroy parts inside the machine, and damage
carpets, clothing, and furniture.
6. Wait 2.5 minutes after power down to fully
discharge the lethal, 410 V 3-Phase power
source.
7. Exposed surfaces can cause burns.
8. Unplug the power cord to disconnect heaters
from AC line voltages.
Session Review 0
Several safety and service precautions for solid ink technology

DO NOT apply to most laser systems. You must learn how to
avoid:
• Damaging customer’s office: what parts contain oil or
ink that can be spilled?
• Damaging the machine: What unique solid ink
technology parts must be handled carefully to avoid
physical damage to the part?
• Causing injuries: Which part has a 3-phase power supply
that must be discharged before you unplug its power
supply wiring harness?

Session 2 - Ink Delivery, Printheads, and Printhead Purges 0
Introduction 0
• Presentations:
- Ink delivery subsystem functions.
- Ink delivery system calibrations.
- Printhead subsystem functions - includes the control
electronics, Roll, Stitch, X-axis Drive, and Carriage
Drive Select Motors.
- Printhead purge concept.
- Printhead purge subsystem components.
- Service and calibration tips.
• Complete the Marking Module CBT lessons from
“Introduction” to “Printhead Purges” (includes “Ink
Delivery”, “What Is An IME?”, and “Printheads”).
• Use dC976 to prime the Umbilicals and dC131 to check
the ink stick count.
• Remove both Printheads on the lower carriage.
• Use dC965 to observe purge/wipe sequences.
• Use dC914 to observe the Printhead drive and calibration
motors.
• Perform the Printhead Uniformity calibrations (dC972).
• Remove and reinstall the Ink Sticks, Ink Loader Assembly,
Ink Reservoir Assembly, and two Printheads.
Ink Delivery Technical Overview 0
The Ink Delivery Subsystem includes the following

components:
• Ink Loader Assembly: contains sensors that detect ink
sticks after they are loaded, determine the type of ink
stick (SKU), and determine the ink level. Also contains a
motorized belt drive system to transport the ink sticks to
the Ink Melt Assembly.
• Ink Melt Heaters: contains four AC heaters (CMYK) to
melt the ink sticks that are physically in contact with the
heaters. Ink drips from the Ink Melt Heaters into the Ink
Reservoir.

• Ink Reservoir: performs three primary functions: (1) AC

heater keeps the ink in liquid form, (2) series of solenoids
are actuated to direct melted ink through to the
umbilicals to the Printheads, and (3) an Air Pump Motor,
Accumulator, and Low Pressure Assist Valve generates
pressurized air for feeding ink and for the Printhead
cleaning process.
• Umbilicals: each Umbilical contains eight ink tubes, two
purge lines, two purge filters, and a Check Valve Unit
(CVU). Each feeds two Printheads: 2 & 4 on the upper
carriage and 1 & 3 on the lower carriage.
The system tracks the number of ink sticks used so that it can
display status information for the ink supply. Removing ink
sticks when the power is off can make the count inaccurate.
When this occurs, you can reset the ink stick counter.
Use the following guidelines to determine if the ink count
should be reset (using dC131):
• You replace part of the Ink Loader Assembly and reload
the ink prior to power on. If the ink level is within one ink
stick per color of the original level, there is no need to
reset the NVM values.
• If you replace part of the Ink Loader Assembly and need
to power up the machine with more than a one ink stick
difference to the original level per color:
- Remove all of the ink from the Ink Loader Assembly.
- Power up the machine.
- Run dC131 and enter NVM ID 420-01, 02, 03, and 04
to select the Ink Levels for cyan, magenta, yellow, and
black.
- To reset the NVM values, enter zero and press the
“Write” button for each color.
- Reload the ink sticks.
NOTE: This process also applies if the gas gauges
inaccurately show ink status due to corrupted NVM values.
When replacing an Umbilical, you must prime it with ink prior
to running the Printhead cleaning cycle. The calibration
routine is dC976.
When installing a new Umbilical, you must boot the machine
into IME diagnostics mode to prevent it from melting ink
BEFORE priming the Umbilicals.

Priming the Umbilical allows the Check Valve Unit (CVU) to

work properly. If not primed, ink will be forced back through
the CVU and plug the Ink Reservoir’s air routing system. This
destroys the Ink Reservoir Assembly.
IME Diagnostics is a special mode that places only the IME
Controller into service diagnostics mode for service
procedures such as priming the Umbilicals. In IME
Diagnostics mode the Copy Controller and UI operate in
customer mode.
Several characteristics of IME Diagnostics mode include:
• The machine skips PEST during power on
• The AC heaters are disabled
• The drum does not rotate
• In general, all IME functions are disabled until a service
diagnostics command enables them
• The UI displays fault code 00.000 when IME Diagnostics
are active and there are no other fault codes to report
A special process is required to boot the machine into IME
Diagnostics Mode:
1. Turn the power off.
2. Open the Upper Left Door.
3. Open the Front Cover (remove interlock cheater).
4. Remove the Waste Tray.
6. After 3-4 minutes the UI will display a message to close
the Front Cover. You should:
- Cheat the Front Cover interlock.
- Install the Waste Tray.
- Close the Upper Left Door.
The machine is now in IME Diagnostics mode. When the UI is
operational it will indicate fault code 00.000. You can now log
in to Service Diagnostics as per the normal process.
To prevent damage to the Umbilical when removing it:
• Use a screwdriver to pry up and release both sides of the
Umbilical’s Printhead connector. Pushing on the corners
may damage the coupler.
• To avoid damage, insert the screwdriver tip about 1 cm
from the edges of the Umbilical connector (under the
yellow and black ink couplers).

Printheads Technical Overview 0
The machine contains four Printheads, two each mounted on

upper and lower carriages:
• Upper Printheads are numbers 2 and 4
• Lower Printheads are numbers 1 and 3
Printhead numbers (1, 2, 3, & 4) are stamped on the carriage
directly next to each Printhead.
Each carriage contains a Stitch Motor, two Roll Motors, and
an X-axis Drive Motor. The machine has an Upper Carriage
and a Lower Carriage.
NOTE: The “Before Calibration” example has been
exaggerated to demonstrate how calibration combines the
output from the four Printheads. In reality, calibration moves
the Printheads very small distances to achieve a seamless
image.
The Printheads are staggered so that each produces part of
the image. To optimize image quality, the system blends the
output of each Printhead seamlessly into a single image.
• How do the Roll Motors help to achieve calibration?
• What is the function of the two Stitch Motors regarding
image calibration?
• The two X-axis Drive Motors move the entire Carriage
horizontally. When are these motors used?
NOTE: Printhead calibration is a very complex but critical
topic. It will be discussed several times during this module.
Several circuit boards combine to control the Printheads.
IME Controller: receives the image data (Low Voltage Data
Signal, or LVDS Video) from the system controller via an RJ-45
cable and routes it to the Waveamp Board. This board also
contains the NVM and flash memory for calibration values.
Waveamp Board: converts the LVDS Video to drive signals for
each piezo-electric crystal on the Printheads.
Marking Unit Heater Board: provides AC Heater drive signals
for the Printheads – one for the jetstack and one in the
reservoir – and both Umbilicals
Marking Unit Driver Board: produces motor drive signals for
the Printhead system:
• Cross-process, or X-axis drive

• Calibration motors for roll and stitch

• Carriage shipping restraint motors (not present in
ColorQube products)
• Carriage Drive Select Motor
• HM Vertical motion motor (wiper belts)
• HM Horizontal motion motor (wiper position)
NOTE: HM is an abbreviation for “Head Maintenance”. The
function of each motor will be covered by the CBT.
Removing and reinstalling a Printhead can involve 30 to 55
minutes of calibration, even if you do not replace any parts:
• To Avoid 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
When troubleshooting, avoid swapping Printheads to isolate
problems. The machine checks any Printhead that is installed
in a new location to verify it will not make contact with the
drum. That check takes 20 minutes including warm-up. Other
checks/calibrations will also be required including the full
Printhead Uniformity (dC972) series of adjustments.
Two types of Printheads are used in ColorQube 9200 and
9300 products. You can identify them by the ribbon cable
connector. Although the Printheads are interchangeable, you
must use the correct ribbon cables for each type of Printhead:
• Original Printheads require white cables
• Updated Printheads require brown cables
See the ColorQube 9300 Service Differences module for
details.
Each time you install a new Printhead, the following checks
and calibrations are required:
• At power on, the machine automatically verifies the new
Printhead will not make contact with the drum. The
machine’s thermals are used to perform this check, so the
machine must warm up to “Ready”. The check requires
about 20 minutes.
• Calibration is always required when installing a new
Printhead. If one Printhead is replaced, the calibration
takes about 30 minutes. Up to 55 minutes are required to

calibrate if all four Printheads are replaced. ColorQube

9300 Printhead calibration times are slightly less than
those shown for ColorQube 9200 products.
• Select “Manual” and “1 Printhead Replacement
Uniformity” to complete the calibration. Item #1 includes
steps 2-5 in order, but does not run Item #6.
CAUTION: Do not select Item #6, “Reset Head Uniformity
Data”. After running this reset, you will need to recalibrate the
Printheads.
The Printhead to Printhead Uniformity calibration requires
you to manually scan test patterns using the IIT. The
machine selects calibration values based on the scanned
images to match the output intensity of all four Printheads..
• You may need to scan multiple sets of images to achieve
calibration
• Scan the most recently printed images. The machine has
made adjustments and needs to analyze the most recent
images to determine if further adjustment is needed.
• Be sure to feed the test images SEF into the DADH as
directed by the large black arrows and in the order they
were printed. The calibration will fail if you feed the pages
in the wrong direction or the wrong order.
• When adjustment is required, large bands are visible
covering approximately ¼ of the page (corresponding to
one Printhead).
The Tonal Response Curve (TRC) Generation calibration also
requires you to manually scan test patterns using the IIT. The
machine sets the dot size (drop mass) to achieve consistent
mid-tone solid fills.
• You may need to scan multiple sets of images to achieve
calibration.
• Scan the most recently printed images. The machine has
made adjustments and needs to analyze the most recent
images to determine if further adjustment is needed.
• Be sure to feed the test images SEF into the DADH as
directed by the large black arrows. The calibration will
never complete if you feed the pages in the wrong
direction.

NOTE: Other automatic calibrations and output quality

maintenance functions use feedback from the Ink On
Drum (IOD) Sensor, but do not require you to manually
scan images. Refer to the next lesson for more
information.
Each carriage has factory set screws that should not be
loosened or removed by service. The screws marked in red on
this image are located behind the Printheads. Damage to the
drum will occur.
NOTE: Both carriages have corresponding sets of screws for
each Printhead mount.
Cable clips have been added to increase the reliability of
connections to the Printheads. Lift the metal tab to release
the clip and then slide it out of the way.
Printhead Purges Technical Overview 0
The system purges the Printheads to optimize image quality

by correcting weak or missing jets.
NOTE: If the IOD Sensor detects missing jets or calibration
issues, the system admin can dictate options for correcting
these issues. The IOD Sensor DOES NOT detect weak jets.
Purging takes time and consumes ink, but solves many image
quality issues. Users can initiate “fix” cycles using the Tools >
Troubleshooting > Fix Image Quality menu.
• Print Test Pages generates two pages that demonstrate
general print quality. The combined image area of the
two pages uses all jets from all four Printheads. Jet
numbers are not identified. Jets are interlaced for this
print.
• Light Lines performs a jet substitution cycle for missing
jets detected by the IOD Sensor. The IOD Sensor only
detects missing jets; not weak ones.
• Smears routes several sheets of paper through the paper
path to clean the Registration/Preheat Assembly.
• Advanced provides cleaning options (see next slide)
Select “Advanced” to access choices for cleaning:
• Light Lines (Quick) - Jet substitution for missing jets
detected by the IOD Sensor.

• Light Lines (Full) - Purges all four Printheads, performs an

alignment, and then substitutes any missing jets.
• Ink Smears - Cleans Registration/Preheat Assembly and
paper path.
Automatic Light Lines Fix controls warm purges and jet

substitution that are NOT initiated by direct user selection.
You must log in as the Administrator to access these controls.
Automatic Light Lines Fix capabilities use the system’s
Intelligent Ready function.
Intelligent Ready monitors customer usage patterns to
determine when the machine is idle and can perform an
Automatic Maintenance Cycle.
When customers enable Quick Fix, the machine automatically
substitutes missing jets until the next Automatic
Maintenance Cycle. The procedure takes less than a minute
to complete. The Full Fix choices control the timing of purges
during the Automatic Maintenance Cycles (normally at
night). Full Fix takes approximately 8 minutes to complete.
• Eco Fix performs purges based on the product type,
number and color of missing jets, and their location.
• Always Fix purges whenever a missing jet has been
detected, resulting in more frequent purges.
NOTE: Missing jets will be covered in more detail during
the Troubleshoot Image Quality Issues lesson.
Purging can clear problem jets and clear mixed inks from a
Printhead. Service technicians have access to more advanced
tools:
• Only technicians can choose to purge individual
Printheads.
• A “Jet Test” page is available from dC968 that identifies
each jet by color, number, and Printhead.
• Cyan 187 is a missing jet. The color of the jet label (red in
this example) indicates the following conditions:
- Black Label - Good jet.
- Purple Label - Bad jet detected by the IOD Sensor but
not yet labeled as “chronic”.
- Red Label - The machine has unsuccessfully
attempted to purge the jet 3 times and has labeled
the jet as “chronic”.

- Green Label - Jet substitution is manually enabled for

the jet.
NOTE: The jet label colors and jet substitution mode will
be covered later in this course.
Printhead purging (or cleaning) involves a variety of
components:
• Ink Reservoir's Air Pump Motor, Accumulator, and Low
Pressure Assist Valve: provide the pressurised air for
purging. Solenoids on the assembly direct the pressurised
air to purge lines located on the Umbilicals. The Low
Pressure Assist Valve controls how much air pressure is
delivered to the purge lines. (Internal parts of the Ink
Reservoir Assembly were covered in the Ink Delivery CBT.)
• Umbilicals: route ink to the Printheads. Also route
pressurised air from the Ink Reservoir, through purge lines,
to the Purge Filter. This filter prevents contaminants from
entering the Printhead.
• Carriage Drive Select Motor: moves the Printheads away
from the drum and positions them for cleaning.
• Printhead Wiper Blades: a belt-driven carriage system
positions and moves the Wiper Blades. Waste ink and
debris from the Printhead Faceplates drips into the Waste
Tray. Each wiper cleans an upper and lower printhead.
Horizontal Motion Motor positions the wipers horizontally
to align them with the upper and lower Printheads. The
Vertical Motion Motor moves the wipers vertically to wipe
the Printheads.
NOTE: Use the Marking Unit to locate the Wiper Blades and
both Motion Motors. Demonstrate how to move the wiper
blades manually by rotating the upper drive shaft (attaches
to both drive belts).
• Waste Tray: this removable tray collects the waste ink. A
locking system is enabled after cleaning to prevent users
from removing the tray when it contains liquid ink. After a
purge sequence the tray remains locked for approximately
1 minute.
CAUTION: To avoid spills, never try to remove the tray when
locked or empty the waste ink that is still in liquid form.
Why does the Ink Reservoir Assembly have a Low Pressure
Assist Valve, and what symptoms will occur if it fails?

• When the Low Pressure Assist Valve is enabled, the air

pump applies less air pressure to the Printheads.
• The reduced pressure stops ink flow from the jet nozzles,
allowing the wipe sequence to begin.
• Applying the correct amount of air pressure is critical to
successful Printhead cleaning.
• If the Low Pressure Assist Valve provides too much
pressure, ink oozes out of the jet nozzles after the Wiper
Blade passes by.
• If the air pressure is too low, waste ink can be drawn back
into the jet nozzles. Either condition results in ink mixing
and may cause weak or missing jets.
The Waste Tray Sensor serves two important purposes:
• Detects Waste Tray installation
• Indicates when the Marking Unit Service Drawer is closed
There is no other sensor for the Marking Unit Service Drawer.
CAUTION: The sensor detects the magnet when it is within
10 mm. To prevent the Printheads from docking
unexpectedly, remove the Front Door interlock cheater
BEFORE closing the Marking Unit Service Drawer.
To conclude the purge process, the machine automatically
generates a “Cleaning Page” (sometimes called ‘Mud Page’).
• What function do you think this page performs?
• Why are two pages required?
• What symptom would you expect to see in printed images
after the purge cycle if the system did NOT print a
Cleaning Page?
Complete the following Marking Module CBT lessons:

• Introduction
• What Is An IME?
• Ink Delivery
• Printheads
(use space below for Printhead Handling Exercise)
• Printhead Purges

Record your Printhead Handling Exercise notes here:

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These CBT lessons present the following information:

What Is An IME? An IME supports the following functions.
Ink Delivery:
• How the machine delivers ink sticks to the ink melt plates.
• Function of each sensor in the Ink Loader Assembly.
• How the machine detects an “ink out” condition.
• How the machine delivers ink from the Ink Reservoir to the
Printheads.
• Cool-down time needed to solidify ink in the Ink Reservoir
Assembly.
• Consequences of removing Umbilicals if the ink has not
solidified.
Printheads:
• Physical Printhead characteristics and signal connections.
• How the four Printheads work together to form an image
on the drum.
• Function of the Marking Unit motors used for positioning
the Printheads.
• Removal, installation, and special handling requirements.
• Printhead handling exercise.
Printhead Purges:
• Function of components used for Printhead purging
• Test pages associated with purge process
• Description of Wiper Blade chatter
Work Project 2 - Ink Delivery System Calibration 0
NOTE: During the disassembly work projects in this

module, be sure to follow the EDOC REPs!
During this work project, you will boot the machine into IME
Diagnostics mode, run dC976 to simulate the process for
priming an Umbilical, and use dC131 to view ink stick counts
in NVM.
NOTE: Do not actually reset the ink stick counts:
 Boot the machine into IME diagnostics (GP 1):
1. Turn the power off.

2. Open the Upper Left Door.

3. Open the Front Cover (remove interlock cheater).
4. Remove the Waste Tray.
5. Power on the machine. Note that it skips the normal PEST
tests.
6. Wait 3-4 minutes until the UI prompts you to close the
Front Cover.
7. Cheat the Front Cover interlock, install the Waste Tray.,
and close the Upper Left Door.
8. Wait for the UI to display fault code 000.000.
9. Log into service diagnostics as per the normal process.
 Run the Ink Delivery Fault Recovery sequence:
1. Touch the service diagnostics Maintenance tab.
2. Select dC976.
3. Select the “Lower Umbilical” (less time is required if you
select one item).
4. Press Start to begin the procedure.
NOTE: If the machine is hot when running this test, the
routine completes much faster than normal. If the
machine is cold, add 15 minutes to the completion time to
account for typical warm up.
 View and select the ink stick counts:
NOTE: See OF9 in Chapter 2 of the EDOC for more details.
1. Run dC131NVM Read/Write.
2. Enter NVM ID 420-01 and press the Read button to
display the cyan ink level.
3. Enter NVM ID 420-02, 03, and 04 and press the Read
button to display the remaining colors.
4. DO NOT RESET AT THIS TIME.
 DO NOT power down the machine. It should be hot for
Printhead removal during the next work project.
Work Project 3 - Printhead Replacement and Calibration 0
Tasks covered during this work project include Printhead

removal (both from lower carriage), handling hot Printheads,
removing the Umbilical ends from the metal carriage frame,
Printhead purges, and Printhead calibration.
This work project contains a Checkpoint that requires the
instructor’s signature:
• Correct handling of hot Printheads.

• Explain why to reinstall the Printheads in their original

locations.
 Remove Printheads 1 and 3:
1. Power down the machine (do NOT wait for the unit to cool
down).
2. Remove Printhead 1 from the lower carriage (REP 91.29)
and note its location for later installation.
3. Remove Printhead 3 from the lower carriage (REP 91.29)
and note its location.
NOTE: To avoid lengthy recalibration, be sure to note the
location of each Printhead (#1 and #3).
 Demonstrate to the instructor how to correctly handle hot
Printheads.
NOTE: Do not install the Printheads. Instead, proceed to
the next step (disconnect Umbilical connectors).
 Disconnect both Umbilical end connections (one each for
Printheads 1 and 3) from the lower carriage frame.
NOTE: Remove the umbilical end at the printhead not at

the ink reservoir. To practice removing an umbilical, pry
loose the umbilical end only. Do not disconnect the wiring
harnesses during this work project.
1. Refer to REP 91.31 for instructions.
2. Gently pry both Umbilical ends from the lower carriage.
3. Reinstall the Umbilical ends into the lower carriage frame.
4. Reinstall Printheads 1 and 3.
5. Close and fully seat the Marking Unit Service Drawer.
 Run service diagnostics tests for Printhead systems:
1. Power on the machine into IME Diagnostics mode (GP1).
2. Enter service diagnostics mode and touch the Diagnostics
tab.
3. Run dC967 to check the Printhead-to-Drum spacing.
4. After passing dC967, exit service diagnostics and reboot
the machine.
5. Enter service diagnostics mode and touch the Diagnostics
tab.
6. Run dC968 to determine the typical purge volume:
- Empty the waste tray.
- Select the Start button to begin the test sequence.
- Choose to purge all four Printheads.

- During the wipe sequence, check for excessive Wiper

Blade chatter (should not occur within the jet nozzle
area of the Printhead faceplates).
- After the purge completes, check the waste tray to
become familiar with the normal amount of waste ink
produced from a single purge.
7. Run dC330 to exercise the Printhead Calibration motors
(Marking Unit drawer pulled out). Test the following:
- 91-024: Printhead 1 Roll Motor
- 91-029: Printhead 1 Stitch Motor
- 91-030: Printhead 2 Stitch Motor
NOTE: When running motors of the same type (roll or
stitch), compare the range of motion for each motor.
When troubleshooting calibration issues, the motor with
the least range is most likely defective.
Run the Printhead Calibrations:
1. Power cycle the machine. This stabilizes the operating
system before running calibrations.
2. Run dC972, the full Printhead Uniformity suite:
3. Select “Manual”.
4. Select Printheads 1, 2, 3, and 4.
5. Select “1 Printhead Replacement Uniformity” to complete
the calibration (Item #1 includes steps 2-5 in order).
CAUTION: Item #6, “Reset Head Uniformity Data” resets the
calibration data to default values, requiring the calibration
sequence to be repeated. Use Item #6 only when instructed
by troubleshooting RAPs.
6. After completing the calibration, power off the machine.
Work Project 4 - Ink Delivery Component Removal 0
This work project contains a Checkpoint that requires the

instructor’s signature. Each student must correctly install an
Umbilical.
CAUTION: To avoid ink spills and damaged Printheads, use
caution when opening the Marking Unit and working near the
Printheads.
1. Remove the Ink Loader Assembly (REP 91.15).

NOTE: To avoid ink spills, the machine must be powered

off at least 30 minutes before proceeding.
2. Remove the Ink Reservoir Assembly (REP 91.20).
3. Reinstall the Ink Reservoir Assembly. When installing the
Umbilicals, verify:
- Cleanliness of mating surfaces between Umbilical and
Ink Reservoir Assembly.
- The gasket is in place between the Umbilical and Ink
Reservoir Assembly.
- Umbilical is fully seated onto both guide pins (use
mica insulator as a straight edge to check).
- Umbilicals are vertically aligned (straight up and
down).
- Tightness of both screws; ink will leak if under-
tightened.
- Installation of the mica insulator plates.
4. Reinstall the purge lines and use the orientation tabs to
verify installation.
5. Reinstall the remaining components.
6. Close and fully seat the Marking Unit service drawer.
NOTE: Be sure to power on the machine.
Ink Delivery, Printheads, and Printhead Purges Session

Review 0
Be prepared to discuss your answers for 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?

Session 3 - IOD Sensor, Drum, Transfix, and Stripper Blades0
Introduction 0
• Presentations:
- Ink On Drum (IOD) Sensor functions
- Typical IOD Sequence
- Drum drive functions
- Drum maintenance system functions
- Transfix drive and stripper blade functions
- Service precautions and tips
• Complete CBT lessons “IOD Sensor, “Drum Drive”, “Drum
Maintenance”, and “Transfix and Stripper Blades”.
• Test IOD Sensor functionality using dC914.
• Remove and install the IOD Sensor Assembly.
• Clean the Rear Drum Fan Shroud.
• Manually unlock the Cleaning Unit Camshaft Lock.
• Test the Cleaning Unit for typical operation (dC959).
• Test the transfix system using service diagnostics (dC962)
and manually (dC140).
• Clean the Transfix Stripper Blade.
• Remove and install the Drum Stripper Blade.
• Remove and install the Drum Assembly.
IOD (Ink On Drum) Sensor Technical Overview 0
The Ink On Drum, or IOD Sensor, is located directly below the

drum. It allows the system to detect images printed on the
drum. The sensor provides feedback regarding image quality,
making it possible to:
• Mechanically calibrate the four Printheads to function as
a single unit (head to head alignment)
• Calibrate Y runout (compensates for imperfections in
drum concentricity)
• Calibrate Y dot position (compensates for the varying
distances between Printhead jets and the drum surface)

• Detect and resolve missing jets (Light Lines Fix and Jet
Substitution modes)
The system requires a functional IOD Sensor to establish and
maintain image quality. The sensor detects only missing jets.
It CANNOT detect weak or sputtering jets.
The IOD Sensor has no replaceable parts. Its primary

components include:
• Scan Bar: Detects images printed on the drum.
• Mylar shield: Covers the Scan bar when not in use to
protect from contamination. When the Scan Bar is
positioned at either end of the assembly, the Scan Bar
tilts forward so it can scan the drum surface.
• Drive Motor and Encoder: Rotates in forward and reverse
directions to move the Scan Bar to the front or rear
scanning positions. An Encoder tracks the motor
revolutions to determine distance traveled. When the
Drive Motor is near the center of its travel the Scan Bar is
home (covered by the Mylar Shield).
• Drive Gear: Engages a pulley system to maintain tension
when positioning the Scan Bar.
Many technicians are familiar with the function of Automatic
Density Control (ADC) sensors in laser machines. The IOD
Sensor and ADC Sensor use similar processes to provide
closed loop feedback. They sample test images and provide
feedback that allows the system to calibrate image quality.
• Laser systems print toner images and use ADC Sensor
feedback to adjust toner density.
• This solid ink machine prints ink images on the drum and
uses IOD Sensor feedback to adjust Printhead position, jet
timing, and output intensity, and to detect missing jets.

The system performs IOD sequences during power on, when

running calibration sequences, when idle (Automatic
Maintenance Cycle), and during normal operation.
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 at the following times:
• Power On: The system verifies initial image quality.
• Calibration: Some of the Printhead calibration routines
use the IOD Sensor to detect test images and establish
calibration values.
• Automatic Maintenance Cycle “Idle” Time: The system
uses the IOD Sensor to check for missing jets and purge or
substitute as selected.
• Normal Operation: Every 500 prints the IOD Sensor
checks image quality. The drum is 30.5 cm (12 inches)
wide and the IOD Sensor scan bar is only 21.6 cm (8.5
inches) wide. Therefore, the system alternately checks
each end of the drum every 500 prints.
NOTE: Immediately after power on, the system performs
IOD Sensor sequences more frequently. This is necessary
to compensate for mechanical changes due to thermal
expansion.
A typical IOD sequence includes the following steps:
1. Drum Maintenance: The system oils the drum.
2. Calibrate: The IOD Sensor is positioned in the front or
rear position. It reads the bare surface of the drum with
and without illumination to establish “white” and “black”.
3. Image: The Printheads generate the test image on the
drum.
4. Acquire: As the drum rotates, the IOD Sensor scans the
image and sends the data to the IME Controller via the
Drum Driver Board.
5. Analyze: The acquired data is analyzed to determine
Printhead motor positions to optimize image quality.
6. Correct: The system sets the Printhead motors to the new
positions.
7. Cleanup: A drum maintenance cycle cleans the ink image
off of the drum.

If the machine is unable to complete a calibration sequence,

it continues to operate in a degraded “Fault Tolerant” mode. A
Service Code appears on the UI indicating the specific item,
or combination of items, that have failed. Most Service Codes
relate directly to the IOD Sensor detecting out-of-tolerance
image defects after a calibration sequence.
NOTE: Technicians should correct Service Codes when
they are present during service calls.
The machine logs Service Codes for the following conditions:
• IOD in Degraded Mode: Print quality is suboptimal - the
IOD Sensor may be working OK but has detected a
problem with the overall quality.
• Y Runout NVM Reset: The NVRAM got corrupted and
was reset to default - needs Y run out cal running.
• Chronic Jets Detected: Go to RAP for 91-638-00 (IOD
Detects Chronic Jet Error).
• Pest Warnings Exist: Check the PEST history for PEST
chain link errors.
• Registration/preheat Assembly Calibration Required:
The NVRAM got corrupted and was reset to default -
needs RaLPH cal running.
• Transfix cal NVRAM Reset: The NVRAM got corrupted
and was reset to default - needs transfix cal values
entering from labels on engine frame.
• Drum drive belt error: drum drive belt is damaged or
worn.
NOTE: Follow the Service Code RAP (OF section) in
Chapter 2 of service manual to resolve Service Codes.
When servicing a machine:
• Always check for Service Codes and resolve them as part
of the service visit, regardless of the original problem
description.
• If possible, ask the customer in advance what Service
Code is on the UI to determine parts you may need for
repairs.
Remember the following service tips for the IOD Sensor
Assembly:
• If using the protective drum cover, install it flat to avoid
binding that can damage the mylar IOD Sensor shield.

• Rotate the drum clockwise when removing the cover to

avoid damaging the mylar IOD Sensor shield and Drum
Thermistors.
• Unless debris is hanging over the IOD cover where it
interferes with the scan bar, cleaning is not
recommended.
• Cleaning the scan bar can cause damage if the cleaning
agent leaves a residue. You can try to carefully remove
pieces of ink, but do not clean using Isopropyl alcohol.
• The arrow etched into the metal end plate demonstrates
the orientation and motion required for installation.
• If the IOD Assembly is wedged during installation, use a
flatblade screwdriver to pry it loose at the front sheet
metal frame of the assembly.
• Do not tip the Cleaning Unit to avoid oil spills.
Drum Drive Technical Overview 0
The Drum Drive system rotates the drum at a variety of

speeds based on factors such as print quality modes, paper
type, and paper size. The drum rotates during the drum
maintenance cycle, to receive the ink during imaging, to
advance the paper during the transfix process, and to
maintain even heat on the drum surface during idle times. It
can also rotate for calibration and other maintenance tasks.
NOTE: Normally the drum rotates clockwise. For some
calibration routines it can also rotate counterclockwise.
The following components are used to rotate the drum:
• Drum Drive Motor: 410 V, three-phase motor that rotates
the drum via a drum drive belt. An internal encoder works
cooperatively with the drum encoder to verify drum
position.
• Tension Spring: Establishes the tension of the drum drive
belt.
• Tension Release Lever: Allows you to release the belt
tension for drive belt removal.
• Drum Encoder: Monitors the drum’s rotational position
and provides this information to the IME Controller via
the Drum Driver Board.

NOTE: Drum drive belts need frequent replacement. Since

the drum rotates constantly, the belt fails over a specific
time period, not based on the number of copies made.
NOTE: Drum assemblies for ColorQube 9200 and 9300
products are similar, but not identical. The ColorQube 9300
drum has a smoother surface.
You should already be familiar with two safety issues
involving the Drum Drive. What are the issues and how can
you protect yourself from injury?
As the drum wears, it consumes ink at different rates. Older
drums use less oil than new drums. Therefore, the machine’s
NVM tracks the number of pages generated on the drum, and
adjusts the oiling process as required to prevent image
quality issues.
After replacing the drum, technicians need to reset the NVM
using dC131 (NVM ID 492-70). Failure to reset the drum NVM
can result in duplex dropout image defects.
To clean ink from the drum. Use one of the top three first,
then try item four, and resort to item five only when
necessary:
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.
Remember that ink build up does NOT occur under normal
conditions. To avoid a repeat service call, determine the
reason for ink build up:
• Paper jam that was left overnight.
• Cleaning Unit that is low on oil or has a fault in its
actuation mechanism.
• Possible Drum Stripper Blade damage.
• Inspect/clean the IOD Sensor if there is ink contamination
underneath the drum and near the abatement plenum.
Several important service tips for drum replacement include:

• Be sure to insert the Stripper Baffle Frame guide pin

through the hole in the chassis during drum installation. If
this pin is not installed correctly, the machine jams at the
Drum Stripper Blade. You must completely remove the
drum assembly to seat the pin.
• Discharge the power supply for 2.5 minutes to avoid injury
when disconnecting the power cable from the Drum Drive
Motor.
• Handle the drum carefully to avoid scratches; damaged
surfaces will cause image quality defects.
• Take precautions to avoid oil spills when handling the
Cleaning Unit.
• ColorQube 9200 machines contain a plate and screw for
dislodging the Drum Pulley. To reduce cost, these parts are
not included in ColorQube 9300 machines. Instead, they
are packaged with replacement drum assemblies. After
replacing a ColorQube 9300 drum, technicians can either
leave the plate installed or remove it.
NOTE: The dC708 Drum Drive Control Test is no longer
recommended for testing ColorQube 9200 or 9300
products. It may return false results, causing unecessary
Drum Drive Motor replacements.
Drum Maintenance Technical Overview 0
The Cleaning Unit is a customer-replaceable item. Typical life

expectancy for ColorQube 9200 units is 220K images on 8.5 x
11 inch/A4 sheets of typical office media at 11% ink
coverage. ColorQube 9300 Cleaning Units have a life
expectancy of 330K images.
NOTE: Cleaning Units in new machines have a shorter life
expectancy (about 156K images for ColorQube 9200
products). As the drum wears, it absorbs less oil, increasing
the life expectancy of subsequent Cleaning Units.
Use the UI and CWIS (CentreWare Internet Services) to check
the remaining life.
The unit includes an EEPROM that tracks and stores actual
usage. The machine reads the EEPROM to determine the
remaining life.
The white roller surface gets marked by ink during normal use.
It does not stay white during normal usage.

ColorQube 9200 and 9300 Cleaning Units are mechanically

the same. The key difference is the type of oil they contain.
Installing the wrong unit generates an error message (see UI
message on image).
ColorQube 9300 products have a unique Drum Stripper Blade,
Drum, and Cleaning Unit. The Cleaning Unit oil works in
unison with the Drum Stripper Blade and Drum surface to
increase the life expectancy to 330K images.
Cleaning Unit status is available from the UI. Messages
prompt users when the unit is low and when it requires
replacement:
• Use Machine Information > Supplies > All Supplies to view
life remaining.
• When the Cleaning Unit reaches a predetermined number
of days remaining, it displays a warning message but the
machine continues printing (“Cleaning Unit will need
replacing soon. Reorder now, DO NOT replace until
requested.”).
- Customers can choose 0 to 20 days
- Number of days is calculated using the average
number of sheets printed each day over the past 10
days and the number of pages remaining based on
the IME firmware
• At 100 pages remaining, the UI displays “Cleaning Unit
will need replacing soon. Reorder now, DO NOT replace
until requested”, same as previous message.
• At zero pages remaining the Cleaning Unit must be
replaced to resume operation. The UI displays, “Cleaning
Unit needs to be replaced. Replace Cleaning Unit now.”
• In emergency situations, service technicians can use a
“snooze” mode to extend Cleaning Unit life by 6,000
pages. To do so:
- Log in as Admin.
- Enter Tools / Device Settings.
- Select "Enter Cleaning Unit Passcode" and enter 8651.
The UI selection "Enter Cleaning Unit Passcode" is only

displayed if the Cleaning Unit has reached end of life.
After placing the machine in snooze mode, replace the
Cleaning Unit as soon as possible.

Service diagnostics (dC959) includes three test pages for

checking Cleaning Unit operation. The lower “Oil Bar Chase”
button actually produces two test pages.
• Black Solid Fill page: Reveals non-uniform application of
oil. Look for missing pixels (voids or dropout) and non-
uniform gloss or matte-finish. Non-uniform oil coverage
can cause chatter marks from the blade or blotchy areas
caused by uneven oiling.
• Metering Blade Timing page: Reveals when the blade
makes contact with the drum. When working properly, the
page should contain a uniform pattern between the upper
and lower target lines. If the image appears outside the
target lines, either the blade is not being actuated at the
right time or it is not making contact with the drum.
• Oil Bar page: Reveals saturation of the oil roller. When
functioning properly, the oil bar (stain) on the test page
should be fairly uniform and consistent across the page.
Three typical image quality issues are shown.
• Black Solid Fill page: Missing pixels (voids or dropout)
caused by too much or not enough oil. This issue is most
easily visible in halftone regions printed on the second
side of duplex prints.
• Oil Bar Page: In this example the oil bar (stain) is too wide
indicating excessive oil. If the oil bar is missing or non-
uniform, not enough oil is being applied.
• Metering Blade Timing Page: In this example, the streak
outside the upper and lower target lines indicates a
damaged blade. The oil is not metered in that area of the
print (the blade fails to make contact with the drum).
NOTE: If the metering blade fails to make contact with
the drum, the entire page will be filled with the gray
pattern.
When removing the Cleaning Unit:
• Avoid tipping to prevent oil spills.
• The bottom of the Cleaning Unit might have a small
amount of oil (film). Place it on a surface that cannot be
damaged (i.e, sheets of paper).

• To clean excess oil from the machine, refer to the service

manual. Depending on the volume of oil, a few absorbent
towels may be sufficient. However, a special procedure
may be required because the oil pan holds up to 1.3 liters
of oil.
Transfix and Stripper Blades Technical Overview 0
The method used for image transfer is a major difference

between laser and solid ink machines.
• Laser printers transfer toner images to paper using static
charges, and then fuse the toner using heat and pressure.
• Can you explain how solid ink machines transfer ink from
the imaging drum to the paper?
The transfix drive subsystem includes the following
components:
• Transfix Roller: presses the paper against the drum to
achieve image transfer, generating several hundred
pounds per square inch. The leading edge of the paper is
positioned below the roller before the roller is lowered
against the drum.
NOTE: ColorQube 9200 and ColorQube 9300 Transfix
Rollers have different outer layers, which affect image
transfer properties. You will see the letter “T” etched into
the end of ColorQube 9300 Transfix Rollers. See the
ColorQube 9300 Service Differences module for details.
• Front and rear Transfix Motors: Control compound gears
at each end of the roller.
• Compound Gears & Transfix Linkage: Support and
control roller motion (front and rear).
• Transfix Encoders: Determine transfix flexure movement,
which equates to pressure against the drum. The system
varies the pressure based on media type (envelopes use
less pressure).
NOTE: The CBT demonstrates how the movement of the
compound gear equates to changes in roller position.
(Presentation slide images are shown in the fully loaded
position.)
Whenever media is added to a tray, the machine checks
media thickness before transfixing the next sheet:

1. The Transfix Roller is lowered against the drum (which is

stopped).
2. The machine lifts the roller and advances the leading
edge of the sheet just past the open transfix/drum nip.
3. The Transfix Roller is lowered again and then the drum
spins to begin transfixing. The machine determines media
thickness by comparing the encoder values when the
roller is against the drum and on the media.
The system must apply the correct transfix load pressure to
avoid wrinkling and media jams. The factory determines the
correct load value for the front and rear Transfix Linkage.
• A label on the front chassis shows the correct values.
• Use dC978 to check the current values and adjust when
making repairs.
NOTE: The NVM values must be changed when replacing
the Transfix Linkage.
The mylar Transfix Stripper Blade makes contact with the
Transfix Roller during transfixing. This blade prevents the
paper from sticking to the roller and wrapping around it.
Ink and paper dust can accumulate on this blade. Cleaning
resolves and/or prevents paper jams and image quality issues
associated with the dirty blade. Paper jams at this location
require a service call to resolve.
The Drum Stripper Blade is placed against the drum to
prevent the paper from sticking to the drum after transfixing.
The blade releases the paper and routes it toward the Exit
Module.
A solenoid lowers (activated) and raises (deactivated) the
blade for each printed page. The Stripper Latch Sensor,
located directly behind the front arm, detects the position of
the stripper gate lock arm so the system can detect lock
status.
WARNING: The Drum Stripper Blade is extremely
sharp! Install the protective Drum Stripper Blade
clip before handling.
ColorQube 9200 and ColorQube 9300 products use different
Drum Stripper Blades:
• ColorQube 9200 blades have a yellow, coated finish
• ColorQube 9300 blades have a silver, uncoated finish

Never install the CQ 9300 blade into CQ 9200 machines. It

causes smudging on printed pages.
NOTE: Under certain conditions, such as large runs of
high-coverage green prints on 80 gsm or thin media, the
CQ 9300 blade can cause image quality issues. The service
manual may direct you to install the CQ 9200 Drum
Stripper Blade to resolve these corner-case issues.
What will happen if you forget to attach the Transfix Roller
ground strap?
Remove excess grease from the Transfix Roller Support and
bearings before installing the roller. The grease can
contaminate the rubber roller surface when inserting it
through the support.
Protect the Transfix Roller surface from damage:
• Never scratch with a tool
• If removed, the Transfix Roller rolls easily. Secure the roller
to prevent it from rolling off of a table.
WARNING: Refer to service manual for Drum
Stripper Blade procedures.
Clean the Transfix Stripper Blade to prevent paper jams and/
or image quality issues.
Complete the following Marking Module CBT lessons:

• IOD Sensor
• Drum Drive
• Drum Maintenance
• Transfix and Stripper Blades
These CBT lessons present the following information:
IOD Sensor:
• Basic function of the IOD Sensor
• How the IOD Sensor detects images on the drum
• Replacement and installation instructions
• Calibration sequences and associated image quality
issues
Drum Drive:

• Basic function of the Drum Drive system

• Drum Drive Belt removal, cleaning, and installation
• Drum replacement tips
Drum Maintenance:
• Basic function of the Drum Maintenance system
• Usage factors that affect Cleaning Unit life expectancy
• Unlocking the Cleaning Unit Camshaft Lock
• Associating Cleaning Unit failure conditions to image
quality issues
Transfix and Stripper Blades:
• Components of the Transfix subsystem
• Drum Stripper Blade handling and installation
• Cleaning instructions for Transfix Stripper Blade and
Stripper Gate Baffle
• Common image quality issues associated with the
Transfix Roller and Drum Stripper Blade

Work Project 5 - IOD Sensor Removal and Installation 0
This work project contains one Checkpoint that requires your

instructor’s signature. Each student should demonstrate the
correct technique for removing and installing the IOD Sensor
Assembly.
 Remove and reinstall the IOD Assembly:
1. Power down the machine (do NOT wait for the unit to cool
down).
2. Open the Marking Unit service drawer.
3. Insert several sheets of paper between drum and IOD
sensor.
4. Remove the IOD Sensor Assembly (REP 91.22).
5. Reinstall IOD Sensor Assembly (leave Abatement Plenum
and Cleaning Unit out of machine).
6. Remove the sheets of paper.
7. Close the Marking Unit service drawer.
8. Install the Abatement Plenum and Cleaning Unit.
Work Project 6 - Test Drum Maintenance System 0
During this work project students will check the Cleaning Unit
life remaining, observe the Drum Maintenance camshaft,
unlock the Cleaning Unit Camshaft Lock, and test the
Cleaning Unit.
 Check the Cleaning Unit life remaining from user mode:
1. From user mode, press the Machine Status button.
2. Select the Supplies tab.
3. Select “All Supplies”.
 To observe the Drum Maintenance camshaft:
1. Locate the end of the camshaft located below the
Cleaning Unit (visible through a notch in the Cleaning
Unit housing).
2. Using a flashlight to see the camshaft, run a copy job
while observing the camshaft.
3. Note the positions of the camshaft during the drum
maintenance cycle (roller/blade home, roller against
drum, roller/blade against drum).
 To manually unlock the Cleaning Unit Camshaft Lock:

1. Remove the Cleaning Unit.

2. Move the lock mechanism to the locked and unlocked
positions. When locked, the camshaft cannot rotate.
 To test the Cleaning Unit:
1. Install the Cleaning Unit.
3. Touch the Diagnostics tab and choose dC959 Cleaning
Unit Exerciser.
4. Select the Self Test and check the UI for results.
5. Select the Full Speed Exerciser and Slow Speed Exerciser.
Verify the drum rotates during these tests.
6. Print the Black Solid Fill page and look for dropout
(missing pixels).
7. Print the Oil Bar Chase page and check the EDOC for
instructions to verify oil bar and blade timing (TP 20).
Work Project 7 - Transfix Service Procedures 0
This work project covers testing the Transfix Roller and

cleaning the Transfix Stripper Blade.
 Test the Transfix Roller:
2. Touch the Diagnostics tab and run dC962 Transfix Load
Test to become familiar with the automated process for
testing the transfix system.
 Manually test the transfix system:
1. Select dC140 Analog Monitor.
2. Select 010.012 Front Transfix Flexure Encoder.
3. Use a screwdriver to rotate the Front Transfix Motor shaft
to load and unload the roller.
4. Watch the mechanical movement of the Transfix Encoder
and Transfix Roller.
5. Watch the sensor value change as you load and unload
the system.
 Clean the Transfix Stripper Blade (PL 10.20 Item 14):
1. Refer to the service manual GP 27 (Machine Cleaning
Procedure).
2. Complete the procedure, taking care to avoid damaging
the mylar blade.
3. Install the Transfix Stripper Blade.

Work Project 8 - Drum Replacement 0
This work project covers Drum Assembly replacement and

cleaning the Rear Drum Fan Shroud.
Each student should install the Drum Stripper Blade clip and
remove the blade assembly.
This work project contains three Checkpoints that require the
Instructor’s signature:
• Correct use of the Drum Stripper Blade clip.
• Physical removal of the Drum Assembly
• Alignment with three guide pins on the machine frame
 Clean the Rear Drum Fan Shroud (PL 94.20 Item 5):
1. Refer to the service manual GP 27 (Machine Cleaning
Procedure).
2. Using a brush, clean the debris from the inner surfaces of
the shroud. This debris results from normal belt wear.
 Replace the Drum Assembly:
1. Using the service manual, remove the drum (REP 91.25).
As components are removed, place them in a clean area
where they are protected from damage.
2. Use the Drum Stripper Blade clip when removing the
Drum Stripper Blade.
3. Remove the Drum Assembly from the machine.
4. Remove the drum from the drum frame.

5. Attach the drum to the drum frame.
6. Reinstall the drum Assembly, including 3-4 screws, and
verify alignment with the three guide pins on the machine
frame (Exit Module removed).
7. Reassemble the machine.

8. Power on the machine to user mode.

9. Check the EDOC for required adjustments after Drum
Assembly installation.
NOTE: After completing this work project, power on the
machine to user mode.
IOD Sensor, Drum Drive & Maint., and Transfix/Stripper

Blade Session Review 0
• 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 will 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.
• 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
gouge 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.

Session 4 - Print Process and Image Quality

Troubleshooting 0
Introduction 0
• Presentations:
- Inkbots and the Solid Ink Print Process
- Print Process Variations
- Troubleshooting Tools and Concepts
• Complete CBT lessons “Print Process Summary” and
“Troubleshoot Image Quality Issues”
• Answer questions relating to the print process
• Generate test prints
• Practice troubleshooting
Inkbots and Solid Ink Printing 0
To begin this lesson, the instructor will play a video that

demonstrates some of the functions that take place during
the typical solid ink print process. As you watch this video:
• Look for events that relate to the solid ink print process.
• Identify solid ink print process steps are missing from the
video.
• Be prepared to discuss your observations.
The Instructor and students will view the Print Process
Summary CBT lesson as a group (Buttons 1 - 7).
After viewing each step of the print process, be prepared to
ask any remaining questions you have about the print process
used by this machine.
Several factors can vary the print process. It is not necessary
to memorize all of the conditions that can change the print
process, but it is helpful to know that variations do occur. Here
are several examples:

• Burst Mode: The machine prints two images on the drum.

This allows the machine to perform one drum
maintenance cycle for two images. The machine feeds
two sheets when transfixing. The Transfix Roller remains
against the drum when feeding the second sheet.
• Envelopes: The machine reduces the transfix load to
minimize wrinkling.
• Print Quality Mode: The machine rotates the drum
additional revolutions to increase the image resolution.
High resolution equates to more revolutions and fewer
pages per minute.
• Media Thickness Check: After the user opens a tray, the
machine automatically checks the media thickness next
time that tray is used. To do so, the machine prints the
image. The drum is stopped so the Transfix Roller can be
lowered directly against the drum (in a non-imaged area).
After raising the Transfix Roller, the media is fed to the
transfix position where the Transfix is lowered against it.
This process allows the machine to determine the media
thickness.
• Jet Substitution: If the machine has chronic missing jets,
and “Quick Fix” is enabled, the machine uses good jets in
place of the missing ones. This extra step can slows down
the print process for that page.
NOTE: When jet substitution is enabled, it only slows
down the machine if a jet is missing and is also required
for the current print in progress. See “Jet Substitution”
later in this training for more details.
Troubleshooting Tools and Concepts 0
The process for troubleshooting image quality issues always

begins by isolating the issue to an external cause or a system
component. This process is generally the same regardless of
the printing technology:
• Verify media is supported.
• Eliminate environmental factors:
- Ambient temperature: Low temperature may
increase pixel dropout and streakiness in solid fills.
- Blocked air vents: Lead to overheating and image
quality defects related to thermal issues.

- Relative humidity: Most likely to cause paper feed

issues but can also increase wrinkling.
- Excessive dust and debris: Can lead to poor jet
performance, smudges/smears on prints, and a variety
of other issues.
• Print embedded pages to eliminate application software,
input from the IIT, or fax.
• Generate output using different paper sources and output
destinations to eliminate paper path issues.
• If the image quality issue is still present after printing an
embedded page under the conditions listed above, you
have isolated the defect to the IOT.
Image quality defects can be caused by either the System
Controller (CBC/SBC) or the print engine systems in the IOT. If
necessary, an “IME Only Test Print” can be generated to
further isolate the controller from the IOT:
1. Turn the machine off.
2. Open the left mid door (not the upper door).
3. Remove the waste tray.
4. Close the front door or insert an interlock cheater.
5. Power up the machine. The upper red LED on the front of
the Marking Unit will begin to blink three times with a
slight pause between each set of three. This indicates the
IME is in its “IME test print” mode.
6. After the LED blink pattern begins, close the left mid door,
insert the waste tray (keep the front door closed or keep
the cheater in place). The IOT will enter standby/print
mode and generate the print as soon as it is able
(thermals up to temp and any errors resolved). You can tell
the IOT is getting ready because it slews the drum.
7. The machine prints an A or A4 sheet with CMYK bars.
NOTE: After printing the test page, the machine reboots
to customer mode. It performs POST and PEST and full
mech init.
Troubleshooting image quality on solid ink machines requires
a new approach because the machines generate images
using different technology. Here are some key differences
between solid ink and laser systems:
• Image Registration: Laser machines use the registration
roller to correct for skew and vary the laser scan position
to adjust for image registration on the page. Color laser
machines align color registration by adjusting the C, Y, M,
and K laser scan positions to align the four color planes.

This solid ink machine corrects for skew and page

registration using the Registration/Preheat Assembly.
Color registration is achieved through the Head to Head
alignment (dC972).
• Image Transfer: Solid ink printers are essentially an offset
press where the image transfers directly from the print
drum to the media. They have no bias voltages to change
print process parameters. Laser printers use static charges
to transfer toner. Print process parameters such as media
thickness and type cause the machine to vary bias
voltages and optimize toner transfer.
• Bonding Images To Media: Laser printers use a heated
roller to melt and press the toner into the media (fusing).
Solid ink printers preheat the paper and oil the drum
before image transfer. During the transfix process, a
pressure roller transfers the image to the media. The
media and drum temperatures, release agent (oil), and
transfix pressure can all affect image transfer and
adhesion.
• Environmental Conditions: Solid ink machines are less
sensitive to ambient temperature and humidity
conditions for image quality. High and low humidity
conditions are more likely to cause image quality issues
on laser machines because static charges transfer the
toner. (Humidity affects paper feed reliability on both
types of machines.)
• Sensitivity To Media Surface Texture: Solid ink machines
transfer the ink onto the surface of the media. In
comparison, laser machines fuse the toner into the media.
Therefore, imperfections on the media surface are more
likely to show through and degrade image quality on laser
machines. (This can be an issue with solid ink machines
too, causing graininess in the output).
• Sensitivity To Media Color: Color images look different
when printed on varying shades of media. However, laser
images are more sensitive to media color. As the toner is
fused to the paper, the color of the paper can change
colors within the image. Solid ink images (especially when
printed using high resolution) are impacted less by the
paper because the printed image lays on the surface of
the paper.

On laser machines process direction = paper path direction

and scan = laser scan direction, inboard to outboard, or cross
process direction.
This solid ink machine uses the following terminology for
image quality RAPs, test prints, and component names:
• Paper path direction = Process or Y-axis
• Cross-process = across the drum or X-axis
The term “scan” is not used within the solid ink imaging
process. This distinction is important because the service
manual uses the terms “X-axis, Cross-Process, Y-axis, and
Process” to describe test pattern characteristics, components,
and the movement of media within the machine.
The UI contains tools for customers who experience image
quality issues:
• Tools > Troubleshooting > Calibration > Fix Image
Quality: Use to launch automated sequences that resolve
banding and smears or to print test pages for evaluating
Printhead performance.
• Information Pages > Paper Tips Page: Indicates the
supported media.
• Information Pages > Office Demo Page: Use to check
general output quality.
• Information Pages > Copying Guide/Scanning Guide:
General instructions for using features.
Although the Customer Jet Test Page provides key
information at the bottom of each page (defined below), DO
NOT use the color bars on these pages to troubleshoot image
quality issues. Instead, use the embedded service test
patterns. They allow you to see individual printhead jets.
Customer Jet Test Pages provide the following:
• Color Bands: Printed using jet interlacing to show general
health of all four Printheads (two sheets are required to
use all of the jets; see “Max Right” and “Max Left” in page
footer).
• JSC (On, On): Jet Substitution Configuration is enabled
for both customer setting and machine setting (the
machine may override the customer setting temporarily if
the Quick Light Lines fix has been selected from the Tools-
>Fix Image Quality menu). After the next purge or
machine reboot the settings revert to customer settings.

When jet substitution is enabled, it only slows down the

machine if a jet is missing and is also required for the
current print in progress.
NOTE: “On, On” indicates JSC is enabled for customer
settings and machine settings.
• PC (On, On): The Purge Configuration is set to “purge at
night/when idle” for both customer setting and machine
setting. Same override rule applies. The purge here is jet
fix purge that will only occur if the machine needs to auto
recover intermittent weak/missing jets.
NOTE: “On, On” indicates PC is enabled for customer
settings and machine settings.
• All four Printheads: Serial number and the total number
of Intermittent (bad), Chronic, and Masked jets (as
defined by the IOD information).
Examples:
- H4:<serial number>;W2;C3;M1 means Printhead 4 has
two Intermittent (bad) jets, three Chronic jets, and
one Masked jet
- H1:<serial number>;W0;C0;M0 means Printhead 1 has
no Intermittent, Chronic, or Masked jets
Service tools for image quality issues:
• Service manual IQ RAPs: Step-by-step procedures based
on specific issues (see chapter 3 of service manual).
- Use IQ 1 to isolate problems to scanner (IIT), DADH,
fax, or print engine (IOT).
- Use Table 1, “Image Quality Symptoms” to cross-
reference symptoms to IQ RAPs. You must be able to
recognize specific types of defects to choose the
correct RAP.
- Use IQ 2 RAP and higher to troubleshoot specific
symptoms.
• Service Test Prints Topic: Descriptions of each service
print, including visual examples, intended uses (see
chapter 3 after the IQ RAPs).
• IME Only Test Print: Isolate the Copy Controller (CBC or
SBC) from the IME.
• Component Test Routines: Service diagnostics
“Diagnostics” tab. Check temperatures, Transfix load,
Cleaning Unit performance, Head to Drum spacing, Print
test patterns, Run Printhead maintenance cycles

• Calibration Routines: Service diagnostics “Adjustments”

tab. Document feeder registration, Registration/Preheat
Assembly calibration, Printhead calibration, Drum runout,
and Transfix values
• Maintenance Routines: Service diagnostics
“Maintenance” tab. You can perform a Head Purge on
individual Printheads. Clean Ink Smears is the same as the
customer procedure Machine Information > Tools >
Troubleshooting > Calibration >Fix Image Quality.
Xerographic technicians are familiar with common techniques
and observations that help to isolate problems within laser-
based IOTs to a component or subsystem.
• On a color laser machine, does the defect appear in one
color only or multiple colors?
• After hard stopping the machine while imaging, is the
defect visible in the toner image? (OPC, transfer belt, etc.)
• What direction on the page is the defect? (process or
cross-process)
• Check spacing between repeating defects to determine
defective part.
• Does the defect occur on one side of the page or both
sides?
Several new techniques and observations apply when
troubleshooting image quality defects on this machine.
• 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?

• Do repeating defects appear every 9 inches, or on every

other page regardless of page size?
Troubleshooting Simulation 0
Your Instructor will display a series of image quality issues. For

each visible defect, you should:
• Use Table 1Image Quality Symptoms (part of IQ 1Image
Quality Entry RAP) to determine the “image quality term”.
• Use Table 1Image Quality Symptoms to determine the
“IQ RAP”.
• Within the IQ RAP for each defect, locate the example
image and identify typical solutions.
Defect #1 Defect Term: __________________________
Defect #1 IQ RAP: ______________________________
Defect #1 Example Image: _______________________

Defect #2 IQ RAP: ______________________________

Defect #3 IQ RAP: ______________________________

Defect #4 IQ RAP: ______________________________

Defect #5 IQ RAP: ______________________________

Defect #6 IQ RAP: ______________________________

Complete the CBT lesson “Troubleshoot Image Quality

Issues”:
• IOT Adjustments
• Weak Or Missing Jets
• Ink Mixing
• Ink Discoloration
• Smudges and Smears
• Oily Prints
• Image Offset or Ghosting
• Wrinkling
Work Project 9 - Test Prints 0
Complete this work project to print service test pages.

 Run dC612 Print Test Pattern.
2. Touch the Diagnostics tab.
3. Select dC612, “Print Test Pattern”.
NOTE: Each student should generate copies of the following
pages for future reference:
• Initial Test Prints (used to evaluate image quality issues)
• Strip Test Page (tests drum stripper blade timing)
• Color Bands and Dithers Test Page
NOTE: Use the embedded service test pages instead of
the Customer Jet Test Page to troubleshoot image quality
issues.
 Print the “IME Only Test Print”:
1. Power down the machine.
2. Using the service manual (TP 25 IME Test Print), print the
“IME Only Test Print”. Save this page for future reference.
NOTE: Open the MID left door, not the upper left door, to
generate the IME Only Test Print.

NOTE: After purging using service diagnostics, this print

may show excessive ink mixing. The purge sequence does
not generate Cleaning Pages, so the jet nozzles will
contain waste ink.
This section involves troubleshooting exercises based on

Instructor-installed faults. After the Instructor installs a fault
in your machine, use the service manual and information
from this lesson to troubleshoot the image quality issue.
 Troubleshoot image quality issues:
1. Wait for the Instructor to install a fault into your machine.
2. Print the Customer Test Page to locate the image quality
defect.
3. Use the service manual to identify the defect type and IQ
RAP.
4. Use the IQ RAP to locate and resolve the issue.

image quality issue.
Symptom from IQ 1 Table 1 - Symptom Term:

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CAUTION: To avoid damage, turn off the machine BEFORE
making repairs.


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_________________________________________________ 0
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_________________________________________________

_________________________________________________
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Print Process and Image Quality Troubleshooting Session

Review 0
• 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/SBC, IOT,
finisher, paper feeders) can you eliminate based on this
information?
• If a customer says their machine is printing much slower
than expected, what are two likely causes?
• Name two print process parameters checked by the
system before imaging begins.
• 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;M0. 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?
Session 5 - Jet Substitution 0
Introduction 0
This training supplement provides information about the

output quality maintenance functions, including the process
for manually substituting a problem jet. It covers the
following topics and work projects:
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
NOTE: This presentation provides details for jet

substitution in ColorQube 9200 products. ColorQube 9300
products implement some aspects of jet substitution
differently. The primary differences have been highlighted.
On average, the machines perform IOD sequences 6 times
daily to detect missing jets and calibrate for stitch errors.
If a missing jet is detected:
• If Quick Fix (Jet substitution) feature is on (by default it is
on) and the jet is needed for an image, the machine
temporarily substitutes it using an adjacent jet on the
same Printhead to restore output quality.

• If 3 or more consecutive jets are missing the machine

cannot mask (substitute) all of the jets. However, it will
mask the two missing jets that have good neighboring
jets.
Full Fix settings control how the machine behaves after
detecting a missing jet:
• Eco Fix (default setting) – during the next Automatic
Maintenance Cycle (that happens during the night idle
time), the machine attempts to purge and clear missing
jets.
• Always Fix – the machine purges frequently because it
will not wait for the missing jet limits expected for purging
(example: 6 non-consecutive color jets for Model 9202).
• Off – purges will not occur.
Automatic Maintenance Cycles happen during the machine’s
night idle time to resolve issues such as missing jets. If the Full
Fix feature is set to Eco fix (the default setting), during the
next Automatic Maintenance Cycle the machine performs a
proactive purge to clear missing jets if:
• Model 9201 – any 2 black jets are missing, or any two
consecutive jets are missing (black or color). No purges are
attempted for non-consecutive, missing color jets.
• Model 9202 – any 6 color jets are missing, any 2 black
jets are missing, or any two consecutive jets are missing
(black or color).
• Model 9203 – any 2 color jets are missing, any black jet is
missing, or any two consecutive jets are missing (black or
color).
Number Of Missing Jets To Trigger Proactive Purge
Model Total Color Jets Total Black Jets Consecutive Jets
9201 Never Purge 2 OR 1 Pair
9202 6 OR 2 OR 1 Pair
9203 2 OR 1 OR 1 Pair
Practice Problem - Which of the following conditions will

cause the machine to perform a proactive purge during the
next Automatic Maintenance Cycle? (use chart)

• 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.
After 3 regular warm purges, if a problem jet has not cleared,

Model 9202/9203 and 9302/9303 machines perform a 30-
minute freeze-thaw sequence in a final attempt to clear the
jet. Freeze-thaw sequences take place during the Automatic
Maintenance Cycle sequence.
Freeze-thaw cycles cool and then rewarm the Printheads.
During the freeze process, debris that blocks a problem jet can
break loose. The next purge sequence clears the debris from
the Printhead.
Model 9201 and 9301 machines never perform freeze-thaw
sequences. They mark jets as chronic if 3 warm purges fail to
clear the jet.
After 3 unsuccessful attempts to clear a missing jet, including
the freeze-thaw sequence for Models 9202 and 9203:
• The machine labels the jet as “chronic” and will mask it.
• A Service Code with UI message will be triggered if the jet
is black. For color jets, the criteria for displaying the
message depends on the model:
- Model 9201 - 2 consecutive color jets
- Model 9202 - any 2 chronic color jets
- Model 9203 - any color jet
NOTE: Once a jet is labeled chronic, the machine will stop
purging to correct it. However, the machine will attempt to
purge for other non-chronic missing jets.
If the machine successfully detects a previously chronic jet at
a later time:
• The Service Code and UI message will be cleared.
• Masking will be disabled for the jet.
• The maintenance cycle counters for warm purges and
freeze-thaw will be reset.

Jet substitution affects print speed differently for ColorQube

9200 and ColorQube 9300 products. In general, you will
notice fewer speed ups and slow downs on ColorQube 9300
products.
On ColorQube 9200 machines, jet substitution can slow down
the print speed, but only when:
• The masked jet is needed for imaging.
• The jet is located within the A4, LEF print zone (4.3 mm
margin).
• On ColorQube 9200 products, the machine assumes any
jet within the A4, LEF print zone is needed for imaging.
The chart shows which jets are within the imaging area for
Letter/A4 pages (LEF) with 4.3 mm, 5 mm, 9 mm, and 20 mm
margins. The standard margin (for maximum printable area)
is 4.3 mm.
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
NOTE: Printhead 1 controls the front margin area

beginning with Jet 1 and counting up, depending on
margin width. Printhead 4 controls the back margin
beginning with Jet 220 and counting down.
On ColorQube 9200 products, if a masked jet exists in the A4
(with 4.3 mm margin) LEF print zone, a special speed-up
mode increases print speed for all pages that DO NOT use
masked jets.
Speed-up mode causes pages to print at the maximum Model
9203 speed for the selected Print Quality Mode, regardless of
the machine type.
Speed-up mode is enabled if:
• Any jet is manually masked.
• The IOD Sensor detects a missing jet within the A4 (with
4.3 mm margin) LEF print zone.

The following chart compares normal print speeds with the

speeds when masking is enabled:
Print Speeds With and Without Speed-Up Mode
Print Speed (ppm) - No Masked Jets Print Speed (ppm) - Masked Jets (same for all models)
PQ Modes 9201 9202 9203 Non-consecutive Two consecutive Masked jet present
masked jet used masked jets used but not 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
Enhanced mode is selected on a Model 9201 machine. If a

user prints a 6 page document that requires the use of a
masked jet on pages 2 and 5 only, what is the approximate
print speed for each of the 6 pages?
The machine generates the pages at the following speeds:
• Pages 1 and 2 - 28 ppm
Two images are simultaneously created on the drum for each
pair of LEF pages within the same job. In the above example,
extra drum revolutions will be required to mask the jet for
page 2, thus decreasing the Page 1 print speed. This principle
also applies to Pages 5 and 6.
NOTE: The machine disables speed-up mode if a jet is
unmasked manually or by the IOD Sensor.
Speed-up mode reduces impact of masked jets:
• When a 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 a masked jet is detected in the A4 (with 4.3 mm
margin) LEF print zone, the machine prints pages that do
not use the jet at maximum speed (i.e., at Model 9203
speed, which could be an added bonus).
• When a page uses masked jets, the speed for that page is
further reduced if two consecutive jets are masked

Refer to the chart for a summary of jet substitution on the

machine’s behavior.
Jet Substitution Summary
9201 9202 9203
Advertised Color Speed 38 ppm 45 ppm 50 ppm
Average Blended Speed With Bad Jets 42 44 48
Missing Black Jets To Trigger Proactive Purge 2 2 1
Non-consecutive Missing Color Jets To Trigger Proactive Purge Never Purge 6 2
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 any
2 chronic jets chronic jets
Jet substitution is used by ColorQube 9300 products, but

there are key differences from the ColorQube 9200
implementation.
ColorQube 9300 machines:
• Typically use a new “soft substitution” mode that
requires less imaging time when printing substituted jets.
• Use “hard substitution” mode (same as ColorQube 9200)
only when coverage for the affected color exceeds 75%,
there are less than 9 jets between substituted jets, or
more than 21 jets are substituted on all four printheads
combined.
• Use “speed up” mode only when hard substitution is
required - not needed for most substituted jets.
• Apply “speed up” mode only until the machine meets the
rated speed - on average ColorQube 9300 products will
not print faster than their rated speed.
The ColorQube 9300 Service Differences module covers this
topic in detail. It provides videos that explain the differences
between soft and hard jet substitution modes.
The Customer Jet Test Pages and Service Jet Test Pages each
provide information about masked jets. However, only the
Service pages allow you to determine the color and jet
number of the masked jet.
Information printed along the bottom of the Customer Jet
Test Page indicates jet status. In this example, Printhead 4
has 1 weak jet (W) and no chronic (C) or masked (M) jets.
Refer to the descriptions below for definitions of each status:
• W (weak) indicates the number of detected missing jets
that have not been labeled as “chronic”.

• C (chronic) indicates the number of missing jets that have

been purged 3 times, including a freeze-thaw cycle for
Modes 9202/9203 and 9302/9303.
• M (masked) indicates the number of missing jets for which
jet substitution is enabled either manually or by the
machine.
NOTE: The machine interlaces jets when printing this
page, so users will be unable to see missing jets by
examining the color bar image (they are masked using an
adjacent jet).
The Service Jet Test Page color codes the individual jet labels
to identify their status. A chart on right side of page indicates
the number and type of problem jets for both Printheads.
Refer to the status descriptions below for the purple, red, and
green jet labels:
• Purple jet number labels identify detected missing jets
that have NOT been labeled as “chronic” (same as Weak
on Customer Jet Test Page).
• Red jet number labels identify chronic jets (same as
Chronic on Customer Jet Test Page).
• Green jet number labels identify missing jets for which jet
substitution is enabled manually (same as Masked on
Customer Jet Test Page).
NOTE: Service Jet Test Pages print with NO jet interlacing.
Therefore, masked and missing jets will not generate color
bars (unless they are intermittent and begin to work
again).
When should the color bars be missing from this page?
• All jets attempt to print their corresponding color bar on
the Service Jet Test Page.
• Masked and chronic jets usually generate NO color bar.
• Jets that begin to work after being masked (intermittent)
may have a color bar even though their label is green.
• If the IOD Sensor has failed, it could report missing jets
incorrectly, causing them to be mislabeled.
Technicians can manually mask up to 40 individual jets to
improve output quality. However, you cannot manually mask
adjacent jets.

The EDOC RAP for chain link 91-638 specifies when to mask
jets. Note that the corrective action for repairing a chronic jet
differs by machine. Masking is recommended only in limited
cases to fix Model 9203 machines, while it is the first
corrective action for Model 9201 and 9202 machines unless
there is an adjacent masked jet.
NOTE: Service diagnostics will not allow you to mask two
consecutive jets.
The ColorQube 9300 RAP for 91-638 also has you verify that
chronic jets are less than 10 jets from another chronic or
masked jet.
To manually mask a jet:
1. Enter Service Mode, GP 1.
2. Select the Adjustments tab.
3. Select dC131 NVM Read/Write.
4. Locate an unused link that shows a value of 0 by entering
Chain 445, links 9-48.
Details
The NVM locations for manually masking jets are 445-9
through 445-48. When manually masking a jet, the
specific location to use is not important. However, if the
value in the location where you wish to enter a masking
value is anything other than 0, select another location in
the range (9 – 48) until you find one with a value of 0.
5. Mask jets by entering a 5 digit number which represents

the Printhead, color, and number of the jet to be masked
using the format “HCJJJ”:
• H=head number
• C=color (C=1, M=2, Y=3, K=4)
• JJJ=jet.
Jet numbers must be 3 digits – use zero to fill as necessary
(jet 4 is 004).
Example - To mask yellow jet 44 on printhead 2:

• Select an unused location in Chain Link 445.
• Enter 23044.
• Select write.
• Print the Service Jet Test Pages from dC968 to verify
the masked jet has a green label.

NOTE: Never manually mask jets the machine can fix

automatically. The machine can detect chronic jets and
will mask them if necessary. Reserve manual masking for
intermittent, weak, or sputtering jets the machine
CANNOT detect.
Identify the printhead, color, and jet number represented by
the 5-digit NVM ID values:
• NVM ID 12026: PH _____ Color ________ Jet # _____
The machine automatically resets the masked jet NVM values

on a Printhead after replacing it. However, if a masked jet
begins to work on a Printhead that remains in the machine,
you may need to clear the NVM for that jet.
Use the following process:
1. To locate a specific masked jet location in NVM (to clear
it), enter Chain 445 and select link number 9.
2. Compare the desired jet value to the NVM value. For
example, to locate the mask for yellow jet 44 on Printhead
2, look for “23044”.
3. If the value is 0 or a 5-digit value for another jet, scroll to
the next link (10) and select Read to determine the NVM
value. Continue cycling through links 9-48 until you locate
the desired jet. In this example, the mask for 23044 is
located in link 11.
4. To clear the jet, enter 0 and select write.
5. Print the Service Jet Test Pages from dC968 to verify the
jet label is not green (the label changes to black, purple, or
red depending on the jet status).
Work Project 10 - Manually Mask a Jet 0
During this work project students will mask a jet and verify
the it has been masked.
 Mask magenta jet 27 on Printhead 2:
1. Run service diagnostics and select Adjustments > dC131
NVM Read/Write.
2. Enter Chain 445.

3. Scroll through NVM locations 9-48 until you find a

location with a value of 0.
4. Enter the value for Printhead 2 Magenta jet 27 (22027).
5. Select Write to mask the jet.
 Verify Printhead 2 Magenta Jet 27 has been masked:
1. Run service diagnostics and select Maintenance > dC968
Head Purge.
2. Print the Service Jet Test Pages.
3. Verify the label for Printhead 2 Magenta Jet 27 is green.
Manual Jet Substitution Session Review 0
• 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 PH 3 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 8 Quiz 0
Complete the Module 8 quiz in the Service Training CBT. You
with your answers.
1 Which of the following parts are hot enough to cause burns?

(select all that apply)
1. Printhead
2. Umbilical
3. Transfix roller
4. Ink reservoir assembly
2 To avoid damaging the Ink Reservoir Assembly, which part

must be primed after replacement?
1. Either umbilical
2. Ink loader melt plate assembly
3. Ink loader assembly
4. Any printhead
3 Which of the following conditions causes the machine to

enter fault tolerance mode?
1. The machine draws too much power
2. The IOD sensor detects an imaging problem
3. A POST test has failed
4. The hard drive is full
4 What area of the machine should you clean periodically to

help prevent noisy operation and vibration issues?
1. Rear drum fan shroud
2. Transfix stripper blade
3. Cleaning unit metering blade
4. Registration/preheat assembly heating plates
5 What is the recommended procedure to test the Cleaning

Unit roller for oil saturation?
1. Perform a drum maintenance cycle and then check the
drum surface for oil.
2. Tilt the cleaning unit until oil is visible on the roller.
3. Print a test page and look for jagged lines.
4. Push on the roller with your fingertip .

6 Which part requires special handling to avoid severe cuts?

1. Transfix stripper blade
2. Drum stripper blade
3. Printhead wiper blade
4. Cleaning unit metering blade
7 What functions are detected by the Waste Tray Sensor?

Select any of the answers that apply.
1. Waste tray full
2. Marking unit closed
3. Waste tray installed
4. Cleaning unit installed
8 Which of the following can be detected by the IOD Sensor?

(select all that apply)
1. Missing jets
2. Weak jets
3. Sputtering jets
4. Intermittent jets
9 To correct X-stitch errors, run the adjustment for:

1. Head to head uniformity
2. TRC generation
3. Head to head alignment
4. Y dot position correction
10 After running the purge sequence you observe ink mixing.

Which of the following can cause this problem?
1. Wiper blade chatter
2. Dirty transfix stripper blade
3. Defective ink reservoir assembly heater
4. Too much oil applied by the cleaning unit

Module Summary 10
This concludes the Image Marking Engine module. In this
module, you became familiar with the safety and service
precautions unique to this product and solid ink technology.
You also studied each subsystem within the IME, learning the
most common repair procedures for each subsystem.
your instructor.
 Inform your instructor that you are ready to proceed to
the next module.
 Have your instructor sign you off on Module 8.
______________________________ Instructor


9 Software Upgrade, AltBoot
and Fault Histories
Module Overview 0
This module provides an overview of the various options for
installing and upgrading the machine’s software, and explores the
Fault Histories.
NOTE: Methods available for software upgrades depend on the
controller type. The ColorQube 9300 Service Differences module
provides additional details on software upgrades.
Module Objectives 0
able complete the module objectives.
 View the Introduction in Module 9: Software Upgrade, AltBoot
and Fault Histories in the Service Training CBT, to identify the
module objectives.
• Use the NVM Save and Restore routine, and the Clone Machine
routine, to back-up machine data
• Use the Altboot procedure to upgrade/replace the existing
software
• Locate and view the machine’s Fault History

Software Upgrade, AltBoot and Fault Histories Xerox ColorQube 9200/9300 Family
ColorQube .dlm files use the specific naming convention
outlined below:
(PPP).(MMM).(YYY).(DDD).(RR)#.dlm
In this naming convention:
• PPP - platform identifier - Discovery platform
• MMM - machine identifier - ColorQube
• YYY - year of release - (009 = 2009)
• DDD - day in the year of release - (308 = 308th day)
• RR - daily revision number (23 = 23rd revision on the
308th day in 2009)
Software versions use one of three machine identifiers
(MMM), based on the product nomenclature and controller
type:
• 050 = ColorQube 9200 MBC (w/o Tag 006)
• 080 = ColorQube 9200 SBC (with Tag 006)
• 180 = ColorQube 9300 Launch software
Study the following examples:
• 060.050.009.30823 is for the ColorQube 9200 with MBC
(w/o Tag 006)
• 060.080.009.30824 is for the ColorQube 9200 with SBC
(with Tag 006)
• 061.180.101.004101 is the ColorQube 9300 Launch
software
There are two AltBoot modes available to load software on
ColorQube 9200 MBC (w/o Tag 006) machines. Pressing the
“8” or “9” button on the printer’s Control Panel launches one
of the following upgrade processes:
• Press “8” to launch AltBoot 8:
- Upgrades Copy Controller and Network Controller only
- Following reboot, this process upgrades any additional
software modules required for the software set
- Takes approximately 20 minutes
• Press “9” to launch AltBoot 9:

Xerox ColorQube 9200/9300 Family Software Upgrade, AltBoot and Fault Histories
- Upgrades all machine software modules and all

connected options, regardless of current software
versions
- Upgrades boot codes
- Takes approximately 35 minutes
NOTE: If a fault occurs during a boot code upgrade (i.e.,
loss of power), the board containing the failed software
module must be replaced with a new board.
On ColorQube 9200 SBC (with Tag 006) machines, there is
just one AltBoot mode available to load software. Study the
following tips:
• Only 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 containing the .dlm files
- 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
If you have problems using AltBoot to load software, try the
following to resolve the issue:
• You must spell the “AltBoot” folder name correctly. No
spaces or dashes are allowed, but you can mix lower- and
upper-case letters.
• Be sure to select the correct .dlm file for your machine
and controller type, and place it in the “altboot” folder.
• Try using a different USB drive. Some machines will not
accept all types of USB drives.
• Connect the USB drive to another USB port. The length of
the USB cable, and other USB connections, can cause
problems. To avoid problems, use a USB port located on
the Network Controller PWB or the Single Board Controller
PWB.


 Complete the entire Module 9: Software Upgrade, AltBoot
and Fault Histories in the Service Training CBT.
Work Projects 0
Work Project 1 0
 Perform the AltBoot procedure to re-install the existing

software.
Refer to General Procedures GP4 in the Service Manual
(EDOC) which describes the procedure. During this procedure
you will prepare a USB Memory device, perform an NVM Save
and Restore (dC361) and also the Network Clone (GP17)
procedure.
NOTE: Use the current version of software, do not upgrade.
Work Project 2 0
 Examine dC123 PEST Fault History.

After you have completed this check, exit diagnostics and
return the machine to normal operational condition.
Sign Off 0
module.
_______________________________________Instructor

Fault Analysis 0
There is no fault analysis for Module 9.

Module 9 Quiz 0
with your answers.
1 Which process is used to re-install the current software?

1. Software Upgrade via USB
2. Software Upgrade via Network
3. Software Upgrade via PWS
4. Altboot
2 When do you need to save NVM settings?

1. Never
2. Every time software is upgraded or installed
3. When replacing the network controller PWB
4. When replacing the Image Processor PWB
3 Copying saved NVMs to USB fails - indicate 3 possible

reasons.
1. USB device is not Xerox approved
2. USB device has insufficient free space
3. USB device has incorrect directory structure
4. USB device is protected
4 Why will you not find Chain-Link 305-330 in the Service

Manual?
1. You must remove the “3” from the Link: 305-30
2. You must remove the “3” from the Chain: 05-330
3. You must add the Extension “00”: 305-330-00
4. “330” is invalid
5 What are the two most likely causes of failure of an AltBoot?

1. Incorrect key press
2. Key pressed at the wrong moment
3. Failure of the Network Controller hard disk
4. Communication failure between USB device and Network
Controller

Module Summary 5
This concludes the Software Upgrade, Altboot and Fault
Histories module. In this module, you became familiar with
the software installation and upgrade options, and with
deriving information from the Fault Histories.
your Instructor.
the next module.
______________________________ Instructor


10 Offset Catch Tray, Office
Finisher
Module Overview 0
This module provides an overview of the Offset Catch Tray and the
Office Finisher (LCSS) devices available with the Xerox ColorQube
9200/9300 Family.
Module Objectives 0
 View the Introduction in Module 10 Offset Catch Tray, Office
Finisher in the Service Training CBT, to identify the module
objectives.
Technology Overview 0
 Complete the entire Module 10 Offset Catch Tray, Office Finisher
in the Service Training CBT.
Work Projects 0
CAUTION: Do not lubricate machine parts unless instructed to do so
by Service Procedures. Machine performance can be severely
degraded by the application of lubricant to parts that are not
normally lubricated. Always refer to Service Documentation for
guidance.

Offset Catch Tray, Office Finisher Xerox ColorQube 9200/9300 Family
Work Project 1 - Office Finisher 0
 If you have not already done so, load five originals into the
document handler. Select various finishing options, 1 and 2
staples and hole punch and watch the copies being delivered
to the finisher. Note the way the copies are collected and
collated prior to stapling and how they are offset.
Work Project 2 - Office Finisher 0
 Perform the following actions.

• Remove the Tamper assembly,
• Remove the Ejector assembly,
• Remove the Stapler Traverse assembly
• Inspect the components and then replace them.
• Restore the machine to normal working order.
Work Project 3 - Offset Catch Tray 0
 If you have not already observed the Offset Catch Tray in

action:
• Power down, remove the Office Finisher and replace with
the Offset Catch Tray. Power up.
• Load five originals into the document handler. Note the
way the copies are collected and collated, and how they
are offset.
• Use the offline stapler to staple some of the sheets
together.
Sign Off 0
module.
_______________________________________Instructor

Xerox ColorQube 9200/9300 Family Offset Catch Tray, Office Finisher

Ask your Instructor for a practice fault, they will also provide a
problem statement.
NOTE: Complete at least two practice faults and then ask for
a criterion fault.

Module 10 Quiz 0
with your answers.
1 How does the Hole Punch recover from a Paper Jam?

1. Increase the torque of the Hole Punch Motor
2. Reverse the motor if increasing the torque was
unsuccessful
3. Automatic reverse
4. Purge the sheet to the Top Tray
2 What is the paper edge to hole centre tolerance?

1. 0.5 mm
2. 1.0 mm
3. 3.0 mm
4. 5.0 mm
3 Select 2 circumstances under which online stapling is

unavailable:
1. Output to Top Tray
2. Output to Catch Tray
3. Fewer than 3 sheets in the set
4. More than 50 sheets in the set
4 How may sets may be stapled when the Offset Catch Tray is
fitted?
1. Automatically using the Compiler Stapler
2. Manually using the Compiler Stapler
3. Manually using the Convenience Stapler (if fitted)
4. Not at all
5 What are the symptoms of the Diverter Solenoid failing to

actuate?
1. All output goes to the Stacker Tray
2. All output goes to the Top Tray
3. The Hole Punch repeatedly jams
4. Hole punching is unavailable

Xerox ColorQube 9200/9300 Family Offset Catch Tray, Office Finisher
Module Summary 5
This concludes the Offset Catch Tray and Office Finisher
module. In this module, you became familiar with these
output devices, and know the procedures for servicing and
troubleshooting them.
your Instructor.
the next module.
______________________________ Instructor


11 HVF, BM, Tri-Folder and PPI
Module Overview 0
This module provides an overview of the High Volume Finisher (HVF),
Booklet Maker (BM), the Tri-Folder and the Post Process Inserter
(PPI).
Module Objectives 0
 View the Introduction in Module 11: HVF, BM, Tri-Folder and PPI
in the Service Training CBT, to identify the module objectives.
 Complete the entire Module 11: HVF, BM, Tri-Folder and PPI in
the Service Training CBT.
Work Projects 0
CAUTION: Do not lubricate machine parts unless instructed to do so
by Service Procedures. Machine performance can be severely
degraded by the application of lubricant to parts that are not
normally lubricated. Always refer to Service Documentation for
guidance.
Work Project 1 - HVF 0
• Remove the Front Door and Rear Cover if you have not already
done so, and insert an interlock cheat.

HVF, BM, Tri-Folder and PPI Xerox ColorQube 9200/9300 Family
• Place a document in the DADH and make 3 copies single-

sided.
• With a flashlight, watch the copies stopping, then moving
through the buffer area immediately below and to the
right of handle 5b. Repeat this step until you have
observed the movement.
Work Project 2 - HVF 0
 Remove the following components from the HVF.

• Ejector Assembly
• Front Tamper
• Rear tamper
• Remove, inspect, and replace the Stapler Unit.
• Replace all previously removed components.
• Perform the Machine to HVF Alignment procedure, ADJ
12.1-171.
Work Project 3 - Booklet Maker 0
 • Remove, inspect, and replace a BM Staple Head.

• Remove, inspect, and replace the Crease Roll Motor.
Check the bearing is on the shaft before replacement.
• Perform the anvil adjustment procedure.
• Remove the Crease Blade and examine the Crease Blade
Drive mechanism.
• Replace the Crease Blade, and perform any adjustment
necessary as detailed in the Service Manual.
• Place 5 double-sided sheets in the DADH and scan 2-2
sided to make 10 stapled booklets. Observe the operation
of the 90% Full Sensor in the Output Tray.
• Repeat the exercise above but with the Output Tray flap
folded down. Note that the sensor is not activated in this
position.
• Verify the NVM settings on the BM label match the values
in dC131. This action verifies calibration.

Xerox ColorQube 9200/9300 Family HVF, BM, Tri-Folder and PPI
Work Project 4 - Tri-Folder 0
• Remove the Rear Cover and inspect the drive and

electrical connections between the HVF and the Tri-Folder.
Locate the two thumbscrews securing the two units
together.
• Remove the Tri-Folder drive belt and electrical
connections, and undock the Tri-folder. Examine the Entry
and Assist Gate Sensors.
• Remove, inspect, and replace the Assist Gate Solenoid.
You may need assistance when refitting the solenoid.
Consider how you would do this in the field without
assistance.
• Dock the Tri-Folder, remake the electrical connections, and
restore the drive belt. Place a document on the Document
Glass and make single sided copies, C- and Z-folded.
Observe how well or otherwise the stack forms in the
Output Tray. Thick or heavy stock may not stack well.
• Read the Tri-Folder Settings pages of the Service Manual
and adjust as necessary.
Work Projects 5 - Post Process Inserter 0
• If the PPI is fitted, undock it.

• Examine the electrical connector on the underside.
• Dock the PPI and ensure that it is securely latched.
• Put some stock in the PPI, marked with a large “F” for front
covers, and a large “B” for back covers. Ensure the
orientation is correct.
• Build a job using stock from the PPI for front and back
covers.
Print the job and check orientation of the covers stock.
Repeat this step until satisfied.
• Remove, examine, and replace the PPI Feed and Retard
Rolls.
• Inspect the three paper length sensors, and consider the
ease of replacement.

Sign Off 0
module.
_______________________________________Instructor

problem statement. Complete at least two practice faults and
then ask for a criterion fault.

Xerox ColorQube 9200/9300 Family HVF, BM, Tri-Folder and PPI
Module 11 Quiz 0
with your answers.
1 What are the symptoms if the Exit Diverter fails to actuate?

1. All output goes to the Top Tray
2. No output goes to the Top Tray
3. All output goes to the Booklet Maker
4. All output goes to the Tri-folder
2 What is the function of the Buffer?

1. Delays the first sheet of a set to allow time for the Exit
Diverter to operate
2. Holds the first of each pair of sheets so they may be
delivered together to the Compiler
3. Holds the first sheet of a set to allow the Compiler time to
complete the previous set
4. Delays each sheet to allow time for the ink to dry
3 What is the function of the Booklet Maker Backstop?

1. Enables unstapled booklets to be made
2. Enables booklets to be made with A3/11x17” stock
3. Reduces the risk of Stubbing
4. Positions the set for the Crease Blade
4 Why does the BM Output Tray flap fold down?

1. To reduce the footprint when not in use
2. To enable output to be collected in a bin
3. To disable the 90% Full Sensor if it fails
4. To reduce damage to pre-printed booklet covers
5 When creating C- and Z-folds, what is the function of the

Booklet Maker?
1. It makes the first fold, in the leading end of a Z-fold, and
the trailing end of a C-fold
2. It makes the first fold, in the trailing end of a Z-fold, and
the leading end of a C-fold
3. None - the Tri-folder makes both folds
4. Staples the sheets before folding

Module Summary 5
This concludes the HVF, BM, Tri-Folder and PPI module. In this
module, you became familiar with the HVF, BM, Tri-Folder and
PPI process and procedures for servicing and troubleshooting
this part of the machine.
your Instructor.
the next module.
______________________________ Instructor

12 Fax
Module Overview 0
This module provides an overview of the Fax operation.
Module Objectives 0
 View the Introduction in Module 12: Fax in the Service Training
CBT, to identify the module objectives.
NOTE: Early versions of the ColorQube 9301/9302/9303 Service
Differences from ColorQube 9200 CBT indicate the ColorQube
9300 fax module can be installed by users. Although the module
is easy to install, the installation strategy is determined by the
service organization in each region.
 Complete the entire Module 12: Fax in the Service Training CBT.
NOTE: ColorQube 9300 Fax modules are designed for easy
installation through a slot in the rear panel. Look for more
information on fax module differences in the ColorQube 9300
Service Differences module.
Work Projects 0
Work Project 1 - Embedded Fax 0
 • Install a Fax Module

Fax Xerox ColorQube 9200/9300 Family
• Follow the prompts of the Setup Wizard

• Find the Embedded Fax Setups screen in Tools
Check the options
Consider which options could be inadvertently
misconfigured
• Ensure the Confirmation Report is set to Always Print
• Fax a document to a known working Fax machine
Examine the Confirmation Report
• Fax a document to an adjacent telephone
Do not answer the telephone
Work Project 2 - Server Fax 0
 • Enable Server Fax on the UI

• Ensure that Confirmation Report is set to On.
• On the UI note that the Layout Adjustment screen
options differ from those for Embedded Fax
• Fax a document to a known working Fax machine
• Make a note of the current Server Settings
Change the Credentials Settings
• Send a Fax
• Restore the Credentials Settings and test for correct
operation
Work Project 3 - LAN Fax 0
 LAN Fax works with whichever Fax facility is configured on the

machine - either Embedded Fax or Server Fax.
• If you have not already done so, install a printer driver on
your workstation
• Create a short text document using any text editor or
word processor
• Send the document by selecting File, the Print
Select Fax from the Job Type drop-down.
Hit OK to send the document

Xerox ColorQube 9200/9300 Family Fax
• Ensure that the machine behaves normally if you Fax a

document from the DADH or Document Glass
Sign Off 0
module.
_______________________________________Instructor
Fault Analysis 0
There is no fault analysis for Module 12.

Module 12 Quiz 0
with your answers.
1 Where is the ColorQube 9200 Embedded Fax Module

installed?
1. On the Image Processing PWB
2. On the IME PWB
3. On the Network Controller PWB
4. Nowhere - Embedded Fax is a software option
2 How many lines can Embedded Fax support?

1. Many - it depends on the Fax Server configuration
2. 1 line
3. 1 or 2 lines
4. Each installed module provides 2 lines
3 How many lines can Server Fax support?

1. Many, depending upon Server configuration
2. Up to 2 per attached client machine
3. Up to 255 depending upon how many licences are
purchased
4. Both 1 and 3 above
4 What sort of memory is used by Embedded Fax?

1. DDR2
2. Compact Flash
3. Microdrive
4. Secure Digital (SD)
5 Select 3 advantages of Server Fax over Embedded Fax:

1. Server Fax enables colour Fax send/receive
2. Server Fax supports many telephone lines
3. Better telephone line utilisation
4. Server Fax transmits and receives more quickly

Xerox ColorQube 9200/9300 Family Fax
Module Summary 5
This concludes the Fax module. In this module, you became
familiar with the Fax process and procedures for servicing and
your Instructor.
the next module.
______________________________ Instructor


13 Maintenance
Module Overview 0
This module provides an overview of the various maintenance
activities the customer is expected to perform.
Module Objectives 0
Given all of the field resources available to you in the classroom, you
will be able complete the module objectives.
 View the Introduction in Module 13: Maintenance in the Service
Training CBT, to identify the module objectives.
 Complete the entire Module 13: Maintenance in the Service
Training CBT.
Work Projects 0
Work Project 1 0
 Empty the Waste Ink Tray and reset the Waste counter.
Work Project 2 0
 Look up Service Codes 4 and 36 in the Service Manual General

Procedures. Note that Code 36 represents 2 faults: Code 32 + Code 4.
Read the rectification instructions.

Maintenance Xerox ColorQube 9200/9300 Family
If any Service Code is shown on the machine, take the

necessary steps to rectify it.
Sign Off 0
_______________________________________Instructor
Fault Analysis 0
There is no Fault Analysis for this module.
Module 13 Quiz 0
There is no Module 13 Quiz.
Please continue to the Module Summary.

Xerox ColorQube 9200/9300 Family Maintenance
Module Summary 0
This concludes the Module 13, Maintenance. In this module
you became familiar with the maintenance activities required
to support this product.
your Instructor.
 Inform your Instructor that you have completed all the
ColorQube 9200 Student Training CBT content.
______________________________ Instructor

Maintenance Xerox ColorQube 9200/9300 Family

14 ColorQube 9300 Service Diffs
Module Overview 0
This module compares the ColorQube 9200 and ColorQube 9300
products, and provides scenarios that demonstrate common
ColorQube service activities.
Module Objectives 0
Given the resources available, and the ColorQube 9301/9302/9303
Service Differences from ColorQube 9200 CBT, you will be able
complete the module objectives.
 View the ColorQube 9300 Products CBT section to learn user-level
product differences.
 View the Service Updates CBT section to learn service-level
product differences.
 View the Service Tips CBT section to learn how to resolve
common ColorQube service issues.
 Complete the entire Module 14: ColorQube 9300 Service
Differences using the ColorQube 9301/9302/9303 Service
Differences from ColorQube 9200 CBT.
Work Projects 0
NOTE: Complete this work project if there is a ColorQube 9300
machine available to you.

ColorQube 9300 Service Diffs Xerox ColorQube 9200/9300 Family
Work Project 1 0
 The High Speed print quality mode is the default for Black
and White print jobs. Use this mode to optimize print speed.
• Install the PostScript printer driver.
• Send a print job and choose “Black and White” from the
Color Options tab.
• Display the Paper/Output tab and verify the print quality
mode is “High Speed”.
• Send the print job and note the speed.
Work Project 2 0
 The USB port on the left side cover allows users to access the
print and scan functions via a USB Flash Drive.
• Connect the USB Flash Drive to the left side cover USB
port.
• Follow the UI prompts to print files stored on the USB
Flash Drive.
Work Project 3 0
NOTE: PagePack billing is NOT used in North America.

Check with your training coordinator for information on
billing plans used in your region.
 The Tools UI folder provides access to the PagePack passcode,
low supply warning settings, and supply counter resets.
• Login as the Admin using “admin” and “1111”.
• Navigate the UI to locate the Supplies folder:
Tools > Device Settings > Supplies
• Explore the settings available.
NOTE: Settings for the PagePack Passcode will be
available ONLY if the machine is configured for PagePack
operation.
Work Project 4 0
 ColorQube 9300 products contain unique assemblies. Locate

and identify the following:

Xerox ColorQube 9200/9300 Family ColorQube 9300 Service Diffs
• Drum Stripper Blade - silver finish (not yellow)

• Transfix Roller - Letter “T” etched into metal
• Upper Printhead Carriage Frame - no motor, gears, or
locking pins in the carriage
• Single Board Controller - 7-segment LED for POST errors
Sign Off 0
_______________________________________Instructor

ColorQube 9300 Service Diffs Xerox ColorQube 9200/9300 Family
Fault Analysis 0
There is no Fault Analysis for this module.
Module 14 Quiz 0
There is no Module 14 Quiz. Instead, complete the “self-
check” questions for each CBT training section.
Please continue to the Module Summary.
Module Summary 0
This concludes Module 14, ColorQube 9300 Service
Differences. In this module you became familiar with the
primary differences between ColorQube 9200 and ColorQube
9300 products
your Instructor.
 Inform your Instructor that you have completed all the
ColorQube 9301/9302/9303 Service Differences from
ColorQube 9200 CBT content.
______________________________ Instructor

ColorQube 9300, 9301, 9302, 9303 Service Training Student Workbook

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Version 3.0 - Xerox Internal Use Only

Office Product Training and Information

26600 Parkway - Bldg. 60

1 Course Introduction and Overview..............................................1-1

2 Product Overview ...............................................................................2-1

Student Workbook Version 3.0 - Xerox Internal Use Only i

Work Project 3 - Fax ........................................................................................................................... 2-4

3 Documentation and Support.........................................................3-1

4 Image Input Terminal......................................................................4-1

5 Power, Control and Ventilation .....................................................5-1

ii Version 3.0 - Xerox Internal Use Only Student Workbook

Work Project 2 - Monitor Temperatures ................................................................................. 5-11

7 Paper Feed and Registration..........................................................7-1

Student Workbook Version 3.0 - Xerox Internal Use Only iii

Work Project 7 - Registration Adjustment ................................................................................ 7-7

8 Image Marking Engine ....................................................................8-1

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Practice Work Problem #5 ............................................................................................................ 8-52

9 Software Upgrade, AltBoot and Fault Histories .....................9-1

10 Offset Catch Tray, Office Finisher............................................. 10-1

11 HVF, BM, Tri-Folder and PPI........................................................ 11-1

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Fault Analysis and Repairs .............................................................................................................11-4

13 Maintenance .................................................................................... 13-1

14 ColorQube 9300 Service Diffs..................................................... 14-1

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Service Training Student Sign Off Sheet 0

Module Completed Instructor Initials

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Expectations and Roles 0

Service Training Strategy 0

• The Xerox ColorQube 9200/9300 Family Service Training course

The responsibilities of the Instructor to the Students are:

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• Identify the scanner and DADH components. Describe the

Training Guide Conventions 0

Course Prerequisites and Equipment 0

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• Ethernet Crossover Cable (600T02252) - Used to connect

Training Kit Contents 0

Each Service Training Kit will contain the following items:

Drivers for the Xerox ColorQube 9200/9300 Family products

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1. Open your Internet browser.

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Table 1. Course Map - New to Family Course - 7 Days

1 Course Introduction and Overview 1.0 hour Day 1

2 Product Overview 1.5 hours Day 1

3 Documentation and Support 0.5 hours Day 1

4 Image Input Terminal 3 hours Day 1

5 Power, Control and Ventilation 3.5 hours Day 2

6 Paper Supply 4 hours Day 2

7 Paper Feed and Registration 7.5 hours Day 3

8 Marking 1 7.5 hours Day 4

8 Marking 2 7.5 hours Day 5

9 Software Upgrade, Altboot, Fault Histories 4 hours Day 6

10 Offset Catch Tray, Office Finisher 1 hours Day 6

11 HVF, BM, Tri-folder and PPI 2.5 hours Day 6