How To Replace A Hard Disk Drive
By Raymond Cote

   
In the Xerox 5090 family

( … Without Software or a Diagnostic Disk)

That may sound like an impossible task, but it can be done quite easily. A few techs and one self-maintainer have asked questions about replacing the hard disk drive in a 5090 copier. They thought you needed software and a diagnostic disk to accomplish this operation--not true.

Another myth I’ve encountered was based on the fact that the hard disk drive is “married” to the copier. Although that’s a true statement, there are work-arounds that the manufacturer won’t tell you about. What I discovered was when you replace a hard disk drive from a 5090, make sure the other copier has the same configuration. For example: If you have a 5690 with an interposer, you can’t use a hard disk drive from a 5390. The reason: The copier with the interposer has operational software information on the hard disk for the interposer, and the 5390 doesn’t. So, a simple swap isn’t going to work. You’ll actually need to do a complete format and reload the software from scratch.

There have been several concerns that have been brought to my attention concerning software for the Xerox 5090 family of copiers. I always recommend purchasing all software through Xerox Corp. for the best results. That way, you’re guaranteed fresh floppy disks with the latest version of the software for that particular product. All installation procedures/instructions are shipped with the software package. You’ll also need the diagnostic disk as well to enter diagnostics on the 5090 families of copiers. This little floppy disk is essential for having access to any diagnostic programs onboard the system. The best way to do a job is to have the right tools on hand at all times. Go to Xerox’s Website, www.xerox.com, for additional information on license and software issues.

 As the fleet of high-speed copiers continues to age, you’ll notice more of these copiers being sold at bargain prices through various Websites. Complete Xerox 5090s have been seen from time to time on eBay for about $1,000 or less. Most of them are working copiers, and owners are trying to sell them with the hope that someone can put them to use or strip them for parts.

I recently received the following information. The tech that sent in this tip was a technician with about 10 years’ experience working on this family of copiers. Read this procedure for educational purposes only.

Replacing the Seagate hard drive without software

It’s strongly recommended that you find the two floppy disks that come with the machine or make two floppy disks with the following information: Save critical data by using DC-325. The purpose of this information is to restore the copier information in such areas as NVM and HFSI. (Actually, it’s really not that critical because the HFSI information can be manually recorded on a piece of paper and entered manually later. And if there are any NVM values that need to be addressed, then they too can be recorded on a separate piece of paper.) The trick here is to save the information before the hard drive fails, because once it does, the information may be impossible to extract.

When your hard drive becomes brain dead and/or the copier won’t boot to the operators screen, it may be time to format the hard drive and reload the software. This is the first and possibly the best way to restore a 5090 hard disk drive. In some instances, formatting the hard disk drive might not work because of internal problems, and then it’s replacement time.

If you have the service diagnostic disk, then it should be a piece of cake. Follow the procedures in the service manual for a complete format and reloading of the software. If formatting the rigid disk doesn’t resolve the problem, you’ll need to replace it. However, if you have a spare (working) Seagate hard drive (part number 156K4090) that was recently harvested from another working 5090 copier (or similar copier), you may be in luck. Locate the two floppy disks with the saved data and keep them handy before you start. * NOTE: It’s been my experience, as a technician, hard drives don’t usually fail completely overnight. They’ll usually display some type of warning that all is not well, and the condition usually becomes increasingly worse over time. When you start noticing that the hard drive is having problems booting up to the operators screen, try saving the information in DC-325. Incidentally, these two floppy disks should be on hand and in the logbook of every machine. It’s highly recommended that you always have them on hand in the event of a hard drive failure. You never know when you might need them.

In the General Procedures section of the service manual, on page 6-110, read the procedure for the DC-325 “Save Critical Disk Files” to save all the information on a floppy disk. Then after you install the recovered hard drive from the other copier, you’ll have all the information ready to install in the new hard drive.

If you can enter the diagnostics, perform DC-352 “Park the Rigid Heads,” found on page 6-122 in the General Procedures section of the service manual.

WARNING!

Switch off the power and remove all

power cords from the wall.

Remove the rear UI base rear cover (2K8110) by loosening two 7mm screws located under the rear cover (near the two corners). Remove the UI card cage cover 4 – 7mm screws (PL5-C5) to gain access to the hard drive area. Remove the san core PWB (PL5-C5), 140K17196, and label all bus communication lines and connectors P/Js. Remove the video engine PWB (PL5-C5), 140K28021, and label all bus communication lines and connectors. Also remove the AIIOP PWB (PL5-C5), 140K50990, and label all the bus lines and connectors. (It’s interesting to note that when the above PWBs are removed, the cavity housing the hard drive is readily accessible, and techs with large hands will have plenty of room to operate.)

Disconnect the ground wire, ribbon cables, and plug to the hard drive assembly (PL5-C9), and remove the rigid disk drive, 156E4090, by removing the two 7mm nuts that hold the hard drive in place. Once the hard drive is removed, mark it with a felt tip marker to identify the one you removed. They’re identical, and it’s easy to get them confused.

Installing the hard disk drive

Now we’re ready to reverse the steps and install the new or newer hard disk drive in your copier. Carefully insert the hard disk drive into the cavity, and secure it with the two 7mm nuts. It’s important to use them because if the 5090 copier is ever moved to another location, the nuts will help keep the hard disk drive where it’s supposed to be. Otherwise, you’ll have a truly sparking surprise when you plug it into the power outlet. Connect all cables and connectors to the hard drive, and inspect your work as you go along.

Install all PWBs, and carefully connect all bus lines and ribbon connectors. Hopefully, you labeled them all, and they were all connected to the proper destinations. Remember, one mistake can cause you many hours of troubleshooting. Inspect your work once again, and if everything is properly connected, go for the gold and plug the machine in. Now is the time to cross your fingers and pray that you didn’t forget anything.

Have your diagnostic disk ready (700P98131) for the next step. Switch on the power and wait until the 8888888888s appear on the digital display. Insert the disk into the slot and wait for the copier to continue to boot up the information from the floppy disk. DC _ _ _ will appear on the digital display window. Use the C button and enter 326 (Restore Disk Files). Information that was previously saved using DC-325 from the floppies can now be installed in this copier. You can also use the Proof button to scroll through the DC routines on the disk. Once DC-326 is highlighted on the diagnostic panel, select Start. If “SAN1 EDN2” is displayed, press #1 on the key PWB. When SAN is displayed on the screen, press Start. This will start the loading of the information.

Eventually, you’ll get the message to “InS Floppy.” Insert the floppy disk #1 that was previously used to save the critical data. Press the start switch. DC-326 will start to restore the files from the floppy disk. Meanwhile, the display will show DC-326. When you get the message “DC-326 - - oo,” it’s telling you the files were restored to the rigid disk. When the information is successfully restored, press the stop button twice, and the copier will reboot. Remove the floppy disk, and save it in the secret compartment in the finisher with the logbook. If all the files were copied successfully, you won’t have to do the fine-tuning of registration and all the other little do-dads that are involved.

Fine-tuning without the diagnostic disk or software

My son, Brian, is a computer geek, and he reminded me that there’s usually a backdoor to most software applications. This copier is no exception. It’s interesting to note that if you don’t have the diagnostic disk or the software, all is not lost. And if the hard disk drive was installed properly, you can enter diagnostics the normal way (with the new hard disk drive) and go through the installation procedures outlined in the installation manual. Or, you can use the following DC procedures to “tweak” up the copier. Refer to the General Procedures section of the service manual. The information is also outlined in the Installation Guide as well.

DC-602 Image Trim Setup, page 6-134

DC-603 Magnification Setup, page 6-135

DC-604 Registration Setup, page 6-135

DC-605 Imaging Tests, page 6-136

DC-701 Fuser Setup, page 6-136

DC-702 Duplex Tray Setup and tests, page 6-138

DC-703 Registration Servo … Transfer (blade) Setup, page 6-140

When I swapped out a hard disk drive for the first time, I wasn’t sure what to expect. At first, I didn’t think it could be done without the diagnostic disk, and the customer’s software package was missing several disks. Clearly, it was an impossible task. In a way, I surprised myself when I used the hard drive from a cannibalized 5090 that was being stripped for parts. When I powered up the copier, it booted up to the operators screen and displayed “Ready” after it warmed up. When I programmed it to make copies, I was shocked when it delivered what I asked for. Oddly enough, the registration was almost perfect, and all I had to do was some fine-tuning in some of the DC programs mentioned in this article.

Sometimes when you’re truly expecting the worst case scenario, you get a boost in life by actually doing something that amazes you. This was one such event that I’ll always remember. Most of the time, I feel like a klutz when I do a routine service call that should only take an hour or so and it turns out to be a week from hell because of one little mistake I made or something I failed to do.

Once again, thanks to all the techs who have sent in their ideas and solutions. It’s good to know that the information is being used in the field. If you have something that you’d like to share with the field, please feel free to send it in.  I can be reached at www.VillageCopierNY@AOL.COM.