Manual Dp180 - Serv - Man

Transmittal Page
Product Title Part Number
DocuPrint 180F Service Manual 720P16290
Status Date
Revision November 2000
This is a complete revision of the DocuPrint 180F Service Manual.

This Service Documentation supersedes all other releases.
THIS PAGE INTENTIONALLY LEFT BLANK
THE DOCUMENT COMPANY
XEROX
DocuPrint 180F Service Manual
720P16290
November 2000
WARNING
Prepared by:
This equipment generates, uses and can radiate radio frequency energy, and if not
installed and used in accordance with the instructions documentation, may cause
Xerox Corporation
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ence when operated in a commercial environment. Operation of this equipment in a
residential area is likely to cause interference in which case the user, at his own
© 1999, 2000 by Xerox Corporation. All rights reserved. Xerox ® and all identifying numbers
expense, will be required to correct the interference.
used in connection with the Xerox products mentioned in this publication are trademarks of the
Xerox Corporation.
All service documentation is supplied to Xerox external customers for informational purposes
only. Xerox service documentation is intended for use by certified, product-trained service per-
sonnel only. Xerox does not warrant or represent that it will notify or provide to such customer
any future change to this documentation. Customer performed service of equipment, or mod-
ules, components, or parts of such equipment may affect whether Xerox is responsible to fix
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Introduction
About this Manual ........................................................................................................... 3
Organization and Use of the Manual............................................................................... 3
Reference Symbology..................................................................................................... 6
Glossary of Terms........................................................................................................... 10
Revision 11/00 Introduction

DocuPrint 180F Service Manual 1
Introduction 11/00 Revision
2 DocuPrint 180F Service Manual
About this Manual Organization and Use of the Manual
The Service Manual is part of the multinational documentation system for the printer. When Organization Overview
used in conjunction with the Service Data, this manual will help in the isolation and repair of The Service Manual is comprised of the following primary Sections:
faults that may occur in the printer.
Introduction
The service manual contains information that applies to USCO, XL, and XCL printers. USCO
references normally apply to XCL as well. If USCO and XCL are different, the specific USO
Section 1: Service Call Procedures
information has a "USO Only" note, and the specific XCL information will be shown as "XCL
only." All "XL" references apply to Xerox Limited 50 Hz Printing Systems. Section 2: Status Indicator RAPs
Service Manual Revision Section 3: Print Quality RAPs
The service manual will be updated as the printer changes or as problem areas are identified.
Section 4: Repairs/Adjustment Procedures
Publication Comment Sheet Section 5: Parts List
A Publication Comment Sheet (PCS) is provided at the end of the Service Manual. The PCS Section 6: General Procedures/Information
allows field users to communicate information regarding the Service Documentation to MC
Section 7: Wiring Data
Service Information (yellow pages)
Section 8: Installation Manual or Procedures
Service Information pages are inserted in the back of the Service Manual. Service Information
is made of information considered temporary in nature. This information will be incorpo- Section 9 & 10: Accessories or Other important additional information.
rated into procedures if appropriate, or removed when the situation no longer applies. Included
are Bulletins, Tag and Kit information, current top problems, and other temporary information.
Organization Descriptions
Introduction
The Introduction contains information pertaining to the organization of the Service Manual:
Reference Symbology, Voltage Tolerances, Relay Cross References, and a Glossary of Terms
that are used in the documentation.
Section 1: SERVICE CALL PROCEDURES
This section contains procedures that determine what actions are to be taken during a service
call on the Printing System and in what sequence they are to be completed. This is the entry
level for all service calls.
The Call Flow Procedure is intended to provide an orderly approach to the entire call.
Inital Action identifies the recommended steps for getting an overview of the machine condi-
tion.
Corrective Action describes the recommended process for diagnosing and repairing the fail-
ure.
Scheduled Maintenance identifies the cleaning and replacement of items according to the
Service Manual intervals.
Final Action describes what precautions are recommended to ensure that the machine is in
the best possile condition when the call is completed.
Preliminary Working Document 0/0/00 Section Name

No Product Name Assigned ?-3 About this Manual, Organization and Use of the
System Fault Analysis creates an orderly process for diagnosing the cause of the failue when This section contains Plug/Jack locational drawings and Wirenet diagram of the power distribu-
it may not be apparent, or when there are conflicting or ambiguous symptoms. It is important tion networks in the Printing System. Individual wire networks are shown in the Circuit Dia-
that this procedure be used in order to ensure that the correct symptom is being diagnosed. grams contained in Section 2. Wirenets are not generated for signal wires without a wire
number. The use of the Circuit Diagram is required when tracing signal wiring. This section
The Non-Repeatable Diagnostics section is intended to provide process steps toward diag- also contains Block Schematic Diagrams for the Printing System.
nosing problems that are not occuring frequently enough to diagnose using the more traditional
procedures. Warnings and Cautions
Hazards are present when replacing some components. When directed to the repair proce-
Section 2: STATUS INDICATOR RAPs dure in the Service Documentation, be sure to follow all Warnings and Cautions. Their defini-
tions are as follows
This section contains the Repair Analysis Procedures (RAPs) and Circuit Diagrams (CDs) that
are used to diagnose fault codes and faults that do not generate other fault codes.
WARNING
The following information pertains to the RAP and CD numbering: A Warning is used whenever an operating or maintenance procedure, practice, condi-
tion, or statement could result in personal injury if not strictly observed.
• The RAP/CD number is identical to the Fault Code that is generated by the machine, with CAUTION
the exception that the RAP/CD does not carry the leading 0 (0X-XX) that is displayed by A Caution is used whenever an operating or maintenance procedure, practice, condition, or
the machine. statement could result in machine damage if not strictly observed.
• The first digit or pair of digits in a RAP/CD number identify the functional area to which the Voltage Specifications
Fault Code refers.
• 200 series Fault Codes (XX-200) refer to timing faults, and 300 series Fault Codes (XX- Table 1 Logic Voltages
300) refer to communication and synchronization faults.
Voltage Tolerance
• RAP/CDs numbered 600 and 700 (XX-600 and XX-700) are assigned by Service Educa-
tion. The Machine software cannot identify these failures, and therefore cannot assign a DC Com 0.0 to +0.8 VDC
fault code. +5 VDC H = +5.05 to +5.25 VDC
Section 3: PRINT QUALITY RAPs L = 0.0 to +0.8 VDC
+12 VDC H = +11.3 to +12.7 VDC
This section contains the RAPs and CDs and other diagnostic aids for troubleshooting Xero- L = 0.0 to +0.8 VDC
graphic print defect problems. RAPs associated with print defect symptoms all contain the pre-
+15 VDC H = +14.25 to +15.75 VDC
fix "PQ" to differentiate them from the rest of the failure symptoms (PQ9-xxx). If a Xerographic
fault code (9-xxx) is present, diagnostics of that failure should be done using the appropriate L = 0.0 to +0.8 VDC
RAP in the Status Indicator RAPs section. The section also contains print quality specifications -15 VDC H = -14.25 to -15.75 VDC
and print defect samples L = 0.0 to +0.8 VDC
+24 VDC H = +21.6 to +25.5 VDC
Section 4: REPAIRS/ADJUSTMENT PROCEDURES
L = +0.0 to +0.8 VDC
This section contains the repair/adjustment procedures for the Printing System. +34 VDC H = +33.5 to +35.5 VDC
L = 0.0 to +0.8 VDC
Section 5: PARTS LIST -34 VDC (H) -33.5 to -35.5 VDC
L = 0.0 to +0.8 VDC
Section 6: GENERAL PROCEDURES/INFORMATION
This section contains text versions of the dC (Diagnostic Programs) found on the IOT Monitor AC Voltage Specifications
screen. If one of the dC routines does not seem clear when using the IOT Monitor, refer to the
text to clarify the procedure.
The section also contains special checkout procedures and Generic RAPs which are used to
troubleshoot sensors, solenoids, and relays.
Section 7: WIRING DATA
Section Name 0/0/00 Preliminary Working Document

Organization and Use of the Manual ?-4 No Product Name Assigned
Measurements of AC Voltage can be made to the frame of the machine on 60Hz machines,
unless another reference is specified in a diagnostic procedure. On 50Hz machines, all mea-
surements of 220/230/240 VAC should be made with respect to ACN. All references to 115
VAC on circuit diagrams and BSDs are measured with respect to AC Return.
Table 2 AC Voltage Specifications - USMG and XCI

Service Line-to-Neutral Line-to-Line
Single Phase 103-107 VAC 207-253 VAC
Three Phase 103-127 VAC 179-219 VAC
Table 3 AC Voltage Specifications - XL

Service Phase-to-Neutral Phase-to-Phase
WYE 220 VAC 198-242 VAC 342-418 VAC
WYE 230 VAC 207-253 VAC 358-438 VAC
WYE 240 VAC 216-264 VAC 373-457 VAC
DELTA 220 VAC 198-242 VAC
Table 4 Autotransformer AC Voltage Specification - XL

Service AC Power-AC Ret
WYE 103-127 VAC
DELTA 103-127 VAC

No Product Name Assigned ?-5 Organization and Use of the Manual
Reference Symbology

?-6 No Product Name Assigned
Figure 1 Reference Symbology

No Product Name Assigned ?-7
Figure 2 Parts List Symbology

Figure 3 TAG/MOD

Glossary of Terms Table 1 Glossary of Terms
Glossary of Terms Term Definition

Concurrent Means the "time overlap" that can be achieved when two or
The Glossary contains terms and phrases that are used throughout the Service Documenta- more activities can be performed at the same time. For exam-
tion. ple, an activity concurrent with the print process would be
binding, because the two activities overlap in time giving the
Table 1 Glossary of Terms operator additional free (productive) time.
Term Definition CPU Central Processing Unit: The location in a computer where
data are processed.
A3 Paper size 297 millimetres (11.69 inches) x 420 millimetres
(16.54 inches). CRT Cathode Ray Tube (picture tube)
A4 Paper size 210 millimetres (8.27 inches) x 297 millimetres CRT Monitor The CRT and the high voltage video electronics
(11.69 inches). D/A Digital to Analog
ACT Advanced Customer Training: A course that teaches custom- Dash Symbol (MICR unique) The Dash is sometimes used as seperator
ers to perform some of the service normally performed by a within the On-Us Field.
CSE. Dead Cycle One or more of the machine drive motors are running; the
A/D Analog to Digital machine is not making prints or there is a component ener-
ADA Analog to Digital and Digital to Analog gized in Standby.
ADA PWB Analog to Digital and Digital to Analog PWD: Fifteen A/D Default Preset values in NVM or preset selections on the IOT Monitor
inputs, 12 D/A outputs, and 8 digital outputs. This board con- Screen
verts digital signals to analog information and vise versa. Diagnostics Hardware or software that monitors or improves the integrity
Amount Symbol The two amount symbols tell the reader/sorter that the num- of the control system. The service documentation is also con-
bers between the symbols are the amount of the check. sidered diagnostics.
AMAT Active MATrix: Material used to make the photoreceptor. DIO Digital Input/Output
Applications Layer One of a series of seven layers designed into the UI Core and DIO PWB Digital Input/Output PWB: Sixteen inputs from switches or
Video Engine PWB that determine what is displayed on the sensors. 16 DC output drivers, and local bus interface cir-
CRT by the Video Engine. cuitry.
APPS APPlications Software: The programs used by the processor DSS Density Sample Sensor: The IRD (Infra-Red Densitometer)
to perform specific tasks. E13B A specific font used for MICR characters. The E13B MICR
AUX Auxiliary font consists of numbers and symbols used to print in the
AZAP All Zones, All Paper Clear Band area of a check.
B4 Paper size 257 millimetres (10.12 inches) x 364 millimetres EPROM Erasable Programmable Read-Only Memory: A ROM that can
(14.33 inches). be erased and then programmed again with new software.
BCR Bar Code Reader ESV Electrostatic Voltmeter
Bit BInary digiT, either 1 or 0, representing an electrical state. Firmware The Integrated Circuits (chips) on a PWB
Boot The process of loading the operating system software to RAM Floppy Disk A plastic or mylar disk, coated with magnetic oxide, used to
store computer information. The floppy disk for the System
from a mass memory storage device.
Controller is a 5 1/4 inch flexible disk.
Bus An electrical connection that allows data flow in two directions
at the same time. Hardware The mechanical and electronic parts that make up a computer
or machine.
Byte A combination of eight bits representing the letters, numbers,
and symbols in a microprocessor. HFSI High Frequency Service Items
Chip An Integrated Circuit (IC) I/O Controller The Input/Output Controller: Acts as an interface between the
CPU and the devices used for inputs and outputs. The I/O
Clear Band A 5/8" wide strip running along the bottom of a MICR docu-
Controller translates the information so that the receiving
ment from left to right.
device (CPU or I/O device) understands it.
IC An Integrated Circuit is a micro circuit that contains hundreds
of electrical components. It is also known as a chip.

Table 1 Glossary of Terms Table 1 Glossary of Terms
Term Definition Term Definition
IFS Inverter/Feeder Stacker On-Us Symbol A symbol that tells the reader/sorter that the next few num-
Input Information from a source to a computer bers identify what account number and financial institution the
check is drawn on.
IOP Input/Output Processor: A PWB which connects to the local
bus and contains a microprocessor. OS The Operating System contains the guidelines on how all
IRD Infared Densitometer, also known as a DSS (density Sample components in the processor communicate. It provides the
Sensor) instructions to the CPU, which control the flow of information
among the computer components.
KC Kilo or 1000 prints
Output Moving the information from the computer to a destination
LE Lead Edge
OZAC Ozone and AC. A system in which the AC leads from the
LED Light Emitting Diode
High Voltage Output Module are routed inside the ozone
LEF Long Edge Feed ducts. This is done in order to minimize the possibility of the
Local Bus A high speed, serial transmission line connecting a Core PWB AC arcing to the machine frames.
with I/O PWBs. Parallel Transmission The transmission of information, one byte at a time, over mul-
LVPS Low Voltage Power Supply tiple electrically parallel wires
Mass Memory Storage A device used to store software information in a form directly PHM Paper Handling Module.
Device readable by the processor, but external to it. In the Siena PHN Paper Handling Node
Printer, the mass memory storage device is the rigid disk.
POPO Power Off/Power On
MEBJ Mean Events Between Jams
Print Defect Those defects that are xerographic and/or cosmetic related
MPBJ Mean Prints Between Jams is the mathematical average (dark horizontal bands, streaks, smears, gloss, etc.)
number of prints between jams.
PQ Print Quality
MIB The Marking/Imaging Buffer: A buffer on a circuit board in the
PQE Print Quality Evaluation
Marking/Imaging area that is used in analog to digital conver-
sions. Program A sequence of instructions that the CPU reads and interprets
to carry out tasks, such as mathematic, logic, and control
Micro-processor The CPU in one Integrated Circuit (IC) that controls all hard-
functions.
ware, such as ROM (Read Only Memory) and RAM (Random
Access Memory) devices. PROM Programmable Read Only Memory: ROMs that contain soft-
ware information and cannot be erased and reprogrammed.
MICR Magnetic Ink Character Recognition
PWB Printed Wiring Board
MIM Marketing/Imaging Module
PWBA Printed Wiring Board Assembly
MIN Marketing/Imaging Node
Queued Fault Active faults which need to be cleared. Some queued faults
Node A control system with a Core PWB (the main intelligence of
will not appear to the customer unless that feature is selected.
the node) and other PWBs, and I/O processors that depend
Range Fault NVM logged conditions which provide a warning of an
on the Core PWB. The I/O processor PWBs control the low-
est level of interface to the machine hardware. The Core approaching fault or of an existing fault which is not obvious to
PWB communicates with the I/O processor PWBs over a the customer.
shared line called a local bus. A node may also contain a Job RAM Random Access Memory device: A digital memory circuit
Manager Core PWB which has responsibility for high level from which information can be accessed or where software
machine control over a number of base machine core PWBs. information can be stored. RAM is its accepted name, but
The core PWBs communicate over a shared line called a Sys- does not describe its function. A better name would be the
tem Bus. Read and the Write Memory, because the controller can read
NOHAD Noise, Ozone, Heat, Air, Dirt the information and it can write the information.
NVM Non-Volatile Memory: A RAM (Random Access Memory) RCC Remote Controller Chip: Sixteen digital inputs and 16 digital
device that stores information as long as a DC voltage is outputs used to drive remote digital I/O. This chip is used on
the DIO.
applied.
Rigid Disk A metal or plastic disk coated with magnetic oxide for informa-
tion storage. It is a mass memory storage device.

Table 1 Glossary of Terms
Term Definition
ROM Read Only Memory device: A digital memory circuit designed
to contain permanent software information. The name means
that the controller on the PWB can only read the information
from the ROM. The controller or any other device cannot
change the values or write any software information to the
ROM. Most of the memory for the machine is in ROM.
SAN System Administrator Node
SCP Service Call Procedures
SEF Short Edge Feed
Self-test An automatic process used to check the Control Logic cir-
cuitry. Any fault detected during self-test is displayed by a
fault code or by LEDs on the PWBs.
Serial Transmission The transmission of microprocessor information, one bit at a
time, on a single wire
SLC A Shared Line Controller is a large scale integrated device
that contains an SLR and SLT.
SLR Shared Lint Receiver is one of the functional blocks within the
SLC.
SLT Shared Line Transmitter is one of the functional blocks within
the SLC.
Soft Failure A software error or an intermittent hardware failure
Software The programs (specified instructions) that inform the proces-
sor how to process information.
SPI Spots Per Inch (a print quality parameter)
System Bus A shared Line used by a Serial Transmission channel for high
level communications between nodes.
TE Trail Edge
Transit Symbol There are always two transit symbols in a MICR line. They
tell the reader/sorter that the numbers between these symbols
identify the institution upon which the check drawn.
TVCF Top Vacum Corrugated Feeder
VSAD Vertical Solid Area Deletion
WDT Watch Dog Timer: Monitors a processor for normal operation.
The processor is assumed to be operating normally as long
as it refreshes (clears) the WDT periodically.
XIC Xerox Initiated Call: A service call that is not placed by a cus-
tomer, but by Xerox or the CSE for the purpose of visiting the
machine to observe operation, installing a retrofit, performing
scheduled maintenance, etc.
3 Pitch Mode The number of impressions that can be placed on the photo-
receptor when printing onto paper that is wider than 9 inches.
7 Pitch Mode The number of impressions that can be placed on the photo-
receptor when printing onto paper that is 9 inches wide or
less.

1. Service Call Procedures
Call Flow PHN DIO PWB #2 Inputs/Outputs................................................................................... 1-46
0-1 Initial Action RAP ...................................................................................................... 1-3 PHN DIO PWB #3 Inputs/Outputs................................................................................... 1-46
0-2 Corrective Action RAP .............................................................................................. 1-4 PHN DIO PWB #6 Inputs/Outputs................................................................................... 1-47
0-3 Scheduled Maintenance Action RAP ........................................................................ 1-4 PHN Registration Servo PWB Inputs/Outputs................................................................. 1-47
0-4 Final Action RAP....................................................................................................... 1-5 Printer Group Fault Tables Purpose And Procedure....................................................... 1-48
Initial Action Paper Handling PHM Group Fault Tables

Initial Action Procedure ................................................................................................... 1-7 Paper Handling PHM Group Fault Tables....................................................................... 1-49
Maintenance Hints .......................................................................................................... 1-9 Paper Handling PHM Group Fault Table (2 of 4) ............................................................ 1-50
HFSI TABLES ................................................................................................................. 1-10 Paper Handling PHM Group Fault Table (3 of 4) ............................................................ 1-51
Paper Handling PHM Group Fault Table (4 of 4) ............................................................ 1-52
System Checks
System Fault Analysis Procedures ................................................................................. 1-15 Xerographics Group Fault Tables
Printer Entry Procedure................................................................................................... 1-16 Xerographics Group Fault Table (1 of 4)........................................................................ 1-53
Printer Power Entry Procedure ....................................................................................... 1-18 Xerographics Group Fault Table (2 of 4)........................................................................ 1-54
Print Damage Entry Procedure ....................................................................................... 1-18 Xerographics Group Fault Table (3 of 4)......................................................................... 1-55
UIM Boot Entry Procedure .............................................................................................. 1-19 Xerographics Group Fault Table (4 of 4)......................................................................... 1-56
Print Defect Entry Procedure .......................................................................................... 1-19 Run Control Group Fault Tables ..................................................................................... 1-57
Jam/Fault Code Entry Procedure.................................................................................... 1-20
Power/All Other Faults Group Fault Tables
Functional Checks Power/All Other Faults Group Fault Table (1 of 4) .......................................................... 1-60
Corrective Action for the DP180...................................................................................... 1-21 Power/All Other Faults Group Fault Table (2 of 4) .......................................................... 1-61
Power/All Other Faults Group Fault Table (3 of 4) .......................................................... 1-62
Physical Checks Power/All Other Faults Group Fault Table (4 of 4) .......................................................... 1-63
Print Paper Diagnostics................................................................................................... 1-23 Printer Fault Code Tables Purpose And Procedure ........................................................ 1-64
1 NRD Fault Code Tables ............................................................................................... 1-66
Subsystem Maintenance
Every Call Activities......................................................................................................... 1-27
Subsystem Checks ......................................................................................................... 1-28
Non-Repeatable Diagnostics 7 NRD Fault Code Tables ............................................................................................... 1-79
Non-Repeatable Problem Entry Procedure..................................................................... 1-31 8 NRD Fault Code Tables ............................................................................................... 1-83
Printer Electrical Noise Procedure .................................................................................. 1-34 9 NRD Fault Code Tables ............................................................................................... 1-94
Part 1: 9-XXX Fault Code Procedures ............................................................................ 1-35 10 NRD Fault Code Tables ............................................................................................. 1-105
Part 2: Electrical NODE Procedures ............................................................................... 1-38 11 NRD Fault Code Tables ............................................................................................. 1-111
Part 3: 06-XXX Fault Code Procedure ............................................................................ 1-39 DC140 Analog Display Diagnostic Procedure................................................................. 1-120
Part 4: Defeature Isolation Procedure............................................................................. 1-39 DC909 P/R Belt Seam And Xerographic Test................................................................. 1-127
Features Bypass Tables ................................................................................................ 1-40 DC951 Auto Xerographic Setup ...................................................................................... 1-133
NRD General Information And Diagnostic Hints ............................................................. 1-137
Inputs and Outputs Tables FSM PHM Fault Code Sensor Location Diagram............................................................ 1-142
FSN DIO PWB # 1A Inputs ............................................................................................. 1-41 Inverter Feeder Stacker DC226 Timing Interval Graphs ................................................. 1-144
FSN DIO PWB # 1 Outputs............................................................................................. 1-41 Printer DC726 Timing Interval Graphs ............................................................................ 1-150
FSN DIO PWB # 2 Inputs/Outputs .................................................................................. 1-42 Final Action...................................................................................................................... 1-158
FSN DIO PWB # 3 Inputs/Outputs .................................................................................. 1-42
FSN Stepper PWB A Inputs/Outputs .............................................................................. 1-43
MIN ADA PWB #1 Inputs/Outputs................................................................................... 1-43
MIN ADA PWB #2 Inputs/Outputs................................................................................... 1-44
MIN DIO PWB Inputs/Outputs......................................................................................... 1-44
PHN DIO PWB #1 Inputs/Outputs................................................................................... 1-45
Revision 11/00 Service Call Procedures

DocuPrint 180F Service Manual 1-1
Service Call Procedures 11/00 Revision
1-2 DocuPrint 180F Service Manual
0-1 Initial Action RAP 7. Print the PPR Log and run print samples. Review the data and prioritize the Actions and
Activities. A brief review of this information will help structure the Service Call by providing
The purpose of the Initial Action RAP is to help the Service Representative organize the ser-
a summary of the System problems which need to be corrected.
vice call. The Service Rep will use the System Status Information, Printer Performance Report
(PPR) and input from the Customer to accomplish this objective. 8. If this is a Scheduled Maintenance visit, go to the 0-3 Scheduled Maintenance Action
RAP, otherwise go to the 0-2 Corrective Action RAP.
Initial Actions
• If questions exist regarding the Initial Action RAP, go to the Initial Action Procedure for a
detailed description of each step.
NOTE: For Third Party Technicians, refer to GP 1000 Diagnostic Programs And Procedures for
work-around if the diagnostic routine mentioned in the documentation is not located on the
screen.
Procedure
1. Question the Customer for details about the system malfunction and service call. If possi-
ble, obtain information about the problem, the job configuration, the mode-of-entry opera-
tion and any other problems that may be occurring. Verify the primary reason for the call.
a. Primary Activity:
The Customer problem description. Within the Printer, this activity also includes:
• Examining Fault History Files
• Going to the HFSI TABLES and performing all due HFSI
• Repairing queued faults for the related subsystem
b. Secondary Activity:
All activities not related to the reported reason for the call. Within the Printer, this
activity also includes:
• All unrelated Fault History Files
• Going to the HFSI TABLES and performing all due HFSI
• Queued Faults
• Range Faults
2. Confirm by duplicating the problem with the Customer. If possible, verify the reported
problem by running the system in order to duplicate the problem. Ask the Customer to
demonstrate the problem. Enter the Service Mode at the Printer. Enter [Fault List]
Icons and record all Fault Codes prior to clearing any Faults.
3. If the Call is a Print Quality problem, inspect the rejected print and determine the cause of
the rejection by the Customer.
4. (IPS) Ensure that the Customer varies the system off-line (Job Integrity). Ensure that the
system is off-line and that no pages are left on the disk or in memory to be printed (have
the Customer ensure Job Integrity.
5. Verify that the System has booted properly and is capable of entering and displaying com-
mands.
6. Enter Service Mode at the Controller. Perform the Administration tasks:
• Obtain the Serial Number and the Initial Meter Reading
• Review previous Call Information and Status
• Verify/Record Diagnostic Locking Licensing String
• Record the Initial Meter "A" count to establish proper service billing credits during
Final Actions. The Serial Number must be verified to ensure service is rendered on
the correct Machine.

No Product Name Assigned ?-3 0-1 Initial Action RAP
0-2 Corrective Action RAP 0-3 Scheduled Maintenance Action RAP
The purpose of the Corrective Action RAP is to correct problems that were identified in the Ini- Procedure
tial Action RAP. 1. Store the PPR Printouts in the Machine Log Book. Reset the PPR upon completion.
Select the Service Mode Function.
Procedure 2. Enter the Printer Service Mode.
1. Primary Activity:
• Perform Scheduled Maintenance activities or go to the HFSI TABLES and perform-
• Go to the System Fault Analysis Procedures. ing all due HFSI activities as required.
• Repair the Primary Problem as identified by the Customer. • Perform Subsystem Checks for all the subsystems that were serviced.
• As required, perform all the related Subsystem tasks. • Investigate and perform Corrective Actions as required after review of the following:
NOTE: The performance of the following Secondary Activities at this time should be a. Queued Faults
negotiated with the Customer. Otherwise record the required action in the Machine Log b. Shutdown Information
Book. Perform the Secondary Activity at the next scheduled maintenance. c. Range Faults
2. Secondary Activity: • Perform previously recorded Secondary Activities.
• Repair any secondary problems that would prevent the Printer from running. • Perform Every Call Activities.
• Verify other Customer reported problems. 3. Reset the HFSI dC107 Counter (as required).
• Verify problems that may generate a UM prior to the next scheduled maintenance 4. Using dC101, save the "Set Up Parameters" to the Floppy Disk and store with the
call. Machine Log Book.
3. Perform Every Call Activities. Reset the HFSI dC107 Counters as required. 5. Select [Service Mode Exit] on the Printer Initial Actions screen. Exit the Service Mode at
4. Confirm that the Problems are corrected by exercising the area of the System which was the Controller and return to the Operator mode.
repaired. 6. Go to the 0-4 Final Action RAP.
5. If in the Printer Service Mode, select [Service Mode Exit] on the Printer Initial and Final
Call actions screen. Exit the Service Mode at the Controller and return the System to the
Operator Level.
6. Print samples using the Largest size paper available:
• TRAY I-10 Dimensional (Duplex) (DIM.PS)
• TRAY 2-10 White Dustings (DUST.PS)
• TRAY 3-10 Halftone (HALF.PS)
• TRAY 4-10 Xerographic (XEROX.PS)
7. Go to 0-4 Final Action RAP after all Corrective Actions are complete.

0-2 Corrective Action RAP, 0-3 Scheduled Mainte- ?-4 No Product Name Assigned
0-4 Final Action RAP
The purpose of the Final Action RAP is to provide the activities to be taken to complete the call
properly.
Procedure
NOTE: Ensure that the Service Mode is exited before beginning this procedure.
1. Run Verify. This is a Verification Test of the system Controller and Printer interface and
proper Printer operation.
2. If the Printer was serviced, "Reset Printer Fault History".
• Record the "Meter A" reading and use this to calculate Billing Meter Credits for the
Customer.
• Close the Call Closure screen, (LPS).
3. Return to Administer level for NPS, Log Level 2, or the Main windows for IPS.
4. Run a Customer job (cause of initial action if possible). Verify that the reported problem
was corrected by having the Customer run an appropriate job in order to duplicate the ini-
tial problem
5. Make all Final Entries to the Machine Log Book. If this is a MICR Machine, complete the
MICR Image Quality Analysis Procedure, PQ 9-639, and store with the Machine Log
Book.
6. Check the Customer supply inventory. Provide order if supplies are needed, inform the
Customer and information if necessary.
7. Close the call with the Work Support Center.

No Product Name Assigned ?-5 0-4 Final Action RAP
0-4 Final Action RAP ?-6 No Product Name Assigned
Initial Action Procedure Scheduled Maintenance -With this strategy the Service Representative will perfom all of
the primary activities related to the Customer description of the reason for the call. Sec-
PURPOSE ondary activities are to be performed at a time convenient for the Customer.
The purpose of the Initial Action section of the Service Call Procedures is to help the Service If the analysis of call and fault histories indicate a high potential for another UM before the
Representative organize the service call. The Service Representative will use the Initial Call next scheduled call, the problem must corrected before leaving the account.
Action, Info screen, (which provides a summary of the condition of the system), and input
Software Revision Level: Identifies the current software level resident in the machine.
from the Customer to accomplish this objective.
6. Determine if any of the information is related to the description of the problem. For exam-
ple, HFSI due could contribute to the problem. The subsystem which is likely to be the
PROCEDURE cause of the primary problem may be out of threshold range, see Table 1-1. There also
1. Obtain from the Customer a description of the reason for the call and, if possible, obtain may be Range Faults which could be related to the primary problem.
information on the nature of the job being run and mode of operation of the system at the
Make a note of secondary activities required.
time of the problem. Also, ask the Customer to describe any other problems that may be
Run the machine, if necessary, to verify the problem or ask the Customer to demonstrate
occuring.
the problem.
• Inspect any rejected prints, if possible. Look for indications of excessive paper jams,
such as wrinkles in the paper, unfused images, skewed images, excessive misregis- NOTE: Record the Queued faults on a sheet of paper in case you need to reference to them
tration. Try to identify the specific defects which caused the Customer to reject the during Corrective Action.
print.
a. Queued Faults: These are active faults in the system which need to be cleared.
• For MICR defects only, ensure that there is no printing on the second side oth the
Some Queued Faults will not appear in the Customer status handler unless that fea-
print in the Clear Band Area, and ensure that the MICR line is properly formatted.
ture is selected. Remember that there may be more of these faults than are dis-
NOTE: If the Customer reports an Odor problem, go to 4-707 RAP. played in the Initial screen. The total number of Queued Faults is shown in the Info
area of the screen and the faults not listed will be displayed when the listed faults are
• Primary Activities: Are all activities related to the Customer description of the rea- cleared.
son for the call. Primary activities include the repair for the reason for the call, Fault
In the event of the following Queued Faults the information displayed in the Shut-
History files for the related module, HFSI due for the related chain, Queued Faults
down Information may not be valid.
for the related chain, and all print quality defects identified by the Customer.
03-201 thru 03-205 are EDN to other Node Communication Faults
• Secondary Activities: Are all activities not related to the Customer description of
the reason for the call. This includes all unrelated Fault History Files, HFSI due, 03-372 thru 03-375 are Node Internal Failure
Queued Faults and Range Faults. 03-380 thru 03-385 are Download Failure
09-201 fault code
NOTE: For Third Party Technicians, refer to GP 1000, Diagnostic Programs and Proce-
dures, for work-arounds if the diagnostic routine mentioned in the documentation is not Go to the System Fault Analysis Procedures to repair all of the listed Queued Faults.
located on the UI Screen. If any of the listed Queued Faults were repaired using the System Fault Analysis
Procedure, it is necessary to select [Update Data] for accurate screen information.
2. Enter Diagnostics at Printer by selecting [Tools]. If the selection can not be selected, go Return to this step to continue. All Queued Faults should be cleared or repaired in
to the System Fault Analysis Procedures to repair, then return to step 3 of this procedure. order to totally restore the system to its full operating condion.
3. Note the reading on meter A. Select [CALL SERVICE] and verify that the Serial Number If the Customer description for the call is a fault code and all of the listed Queued
matches the number on the screen. Faults have been repaired, then the first 2 digits of the fault code define the primary
Select [SERVICE] and enter the Diagnostic Access Code. Select [Enter][SCP] to gain activities. For example, if the fault code is an 10-101, all HFSI, Queued Faults, and
access to the Service Call Procedure Dialogue. Range Faults that start with a 10 are primary activities. The Faults screen History
Files containing the fault code is also a primary activity. Determine the Faults
4. Initial Call Actions: Study the Initial Call Actions screen. The information on this screen
will help to structure the service call by providing a summary of the system problems screen History Files primary activity by viewing the Top 15 Actual.
which need to be corrected. b. Shutdown Information: Examine the Shutdown Information for an area shutdown
Depending upon the type of the problem, some of the SCP activities may not be needed. rate that is over threshold, (Table 1). If any area is a potential secondary activity,
refer to the Faults file. Review Top 15 Actual to find the specific fault codes that are
5. Account Information: This Information provides the Serial Number of the machine, Total
contributing to the shutdown rate.
Print Count and the Software Revision Level.
Serial Number -As mentioned in step 3, the serial number must be verified to ensure that Table 1 Shutdown Information Thresholds
service is rendered on the correct machine.
AREA THRESHOLD NOTE
Total Print Count -Are the total prints for billing. Total Print Counter, counts up to
999,999,999, rolls over, and repeats. It is an independent counter. Xero. 4 Fault 2
Comm. 2 Fault 2

No Product Name Assigned ?-7 Initial Action Procedure
Table 1 Shutdown Information Thresholds Almost Jam: Is to be used in conjunction with the RAPS to identify problem associ-
ated with wear and slippage.
AREA THRESHOLD NOTE
If an over threshold value is in the same area as the primary cause of the call, then
Other 6 Fault 2 isolate the cause of the problem by using information from:
Total Shutdown 2000 MEBJ 1 Rate • Top 15 Faults/Jams display
• Last 50 Shutdowns display
NOTE: 1. As the rates increase, the performance of the machine is improving. As the
rates go down, the performance of the machine is degrading. Diagnosis is indicated c. High Frequency Service Items (HFSIs) Due: These are HFSIs which have
exceeded predetermined limits and are therefore in need of service. Remember that
when the rate for the Area is equal to or less than the established threshold
there may be more of these items than are displayed in the Initial screen. The total
NOTE: 2. As the number of faults increase, the performance of the machine is wors-
number of HFSI is shown in the Info area of the screen, and the ulist-ordereded
ening. As the number of faults decrease, the performance of the machine is improv-
items will be displayed when the listed items are cleared. To review the HFSI, select
ing. Diagnosis is indicated when the rate for the Area is equal to or greater than the
HFSI, select HFSI screen.
established threshold.
On the HFSI screen, HFSIs that have reached "threshold" or "almost threshold" will
(Step b, continued) Compare these threshold values to the rates displayed on the
have either a Red or Yellow arrow pointing to the count on the item.
Initial Call Actions screen for each area. Initially, for new installs, the thresholds
provided should be used to determine when in-depth diagnosis of an area is The Red arrow iluminates when the item has actually reached, or exceeded, the ser-
vice interval. When the red arrow is illuminated, the item is shown in "HFSI due" on
required.
the Initial screen.
For example, if the threshold for the Inverter Feeder Stacker is 10,000 and SCP for I
F/S displays 7,000, enter the top 15 for I F/S and review the jams data. If the module The Yellow arrow illuminates when an item is within approximately 100k counts of
rate of 7,000 was caused by one jam, no action is required. If the rate was caused by the established service interval. The Yellow arrow alerts the Service Representative
to an impending part or parts replacement, allowing for spares and SM planning.
more than one jam in the same area, evaluation of the area is justified. if so, the area
should be reviewed completely in order to ensure all problems are identified. HFSIs due in the same area as the primary cause of call are primary activities.
When the area is operating at optimum for a specific machine, a standard level of Contained in the FA file is additional HFSI info on the task required when the HFSI
performance can be established over a series of service calls. These rates than screen indicates a clean, replace, or lube action is due.
become the expected performance for that machine and should be entered as the The next table lists the HFSI counters letters explanation.
threshold values. Variable factors, such as paper type, transparencies and labels,
Customer errors and general machine environment will affect expected machine Table 2 HFSI Counters Letters
performance. Letter Explanation
If the over threshold value is not in the primary area of service, search for the cause
C Clean
as a secondary activity and continue to diagnose the primary cause of the call.
L Lube
Total Shutdown Rate MEBJ (Mean Events Between Jams) The Total Shutdown
Rate equals Prints since last call divided by the number of shutdowns since last call. R Replace/Repair
The total shutdown rate is used as an overall indicator of machine performance. RO Rotated
The Last 50 lists the most current faults at the top of the first column. The print count,
at the time a fault is declared is recorded next to each fault. The Last 50 display Range Faults
records the primary cause of a shutdown in print. Secondary or coast faults are not
Range Faults are NVM logged conditions that indicated degraded machine opera-
recorded. With the exception of 03 code no shutdowns are recorded in standby.
tion (something going to happen or has already occurred). These conditions, if not
The Last 50 Shutdowns are used: corrected, may appear as other faults.
• To verify the primary reason for the call The purpose is to provide a warning of an approaching fault, or of an existing fault
• To identify possible problems not observed by the Customer which is not obvious to the Customer, so that corrective action can be taken to pre-
• To display grouped faults, combination faults, and/or random faults vent machine shutdown from occurring. These conditions will not show up as a Cus-
tomer status code.
• To view codes to identify time related groups.
Range Faults alert the Service Representative to an impending part or parts replace-
The Top 15 display arranges the area data in a specific sequence. For the sequence
starts with the worst MEBJ and MEBJ at the top. Xerox, Comm, and Other Faults, ment, allowing for spares and call planning.
the sequence starts with the largest number of faults at the top. Range Faults in the same area as the primary cause of call are primary activities.
Top 15 Faults/Jams: These are used to identify what has contributed to the fre- Any other Range Faults are secondary activities.
quency of module faults/jams.

Initial Action Procedure ?-8 No Product Name Assigned
NOTE: For step 7, if unable to make prints, go to the System Fault Analysis Procedures. Maintenance Hints
NOTE: Save prints for inspection during Level 1 - System Fault Analysis diagnostics examina- PROCEDURE
tion. The items in Table 1 are service actions that should not be performed when servicing the var-
7. After the print samples have been made, go to the Corrective Action for the DP180 sec- ious subsystems within the machine.
tion.
Table 1 Service actions that SHOULD NOT be performed
SUBSYSTEM SERVICE ACTION
All Unless directed, do not lubricate any components in the
Machine.
Xerographics Do not wash the PR Belt.
Do not wash the Dicorotrons.
Do not vacuum the Density Sample Sensor.
Panels Do not clean the outside panels with any substance other
than Formula A and water.
Fuser Do not touch the glass of the Heat Rod.
Do not use film remover to clean the Fuser and the Pressure
Rolls.

No Product Name Assigned ?-9 Initial Action Procedure, Maintenance Hints
HFSI TABLES The following HFSI intervals are recommended initial values. The CSE has the ability to mod-
ify these intervals as needed to address unique Customer requirements.
PROCEDURE
The following High Frequency Service Items are serviced in 1M increments. The items in each Items identified with a * signify the items contained in SM Kit 1. SM Kit 1 is Part Number
group, Table 1 and Table 2, should reach the indicated intervals (1M/2M) at about the same 600K25793.
time since they all depend on total impressions made rather than any special mode of opera-
tion. Items identified with a ** signify the items contained in SM Kit 2. SM Kit 2 is Part Number
600K25814.
NOTE: If an item fails before its scheduled service interval, service the item and reset the HFSI
counter, but keep the item on the same service schedule with the other items in the same
group.
The additional HFSI activities in Table 3 and Table 4 will be performed during SM as required
based on individual HFSI counter values. In the comments column for each HFSI counter is
additional information on the tasks required when an HFSI is due for service.
Table 1 1M SM HFSI Activities

CODE ITEM INTERVAL ACTION PARTS LIST COMMENTS
01-801 Cleaner Filter * / ** 1000K Replace PL 9.21 Before installing the new Filter Bag and Toner Cooling Filter, vacuum any
loose toner from the enclosure base and machine frame.
01-802 LVPS Filters * / ** 500K Replace PL 1.10 Do not vacuum the filters. Ensure the LVPS fans are not turning when
replacing the filters.
03-803 Toner Cooling Filter * 1000K Replace PL 4.7 Inspect for leaks in and around the Toner Dispenser Housing and repair
/ ** as required.
08-818 System Cleaning 1000K Clean Vacuum any loose toner and paper dust visible to the Customer from the
entire IOT (Processor, Inverter Feeder/Stacker, and Feeder/Stacker
modules), including all paper path Static Ground Brushes. Clean the
Xerographic sensors and paper handling sensors with a cleaning pad
(600S1276). Vacuum any contamination from the Controller ESS Card
Cage Cooling Air Filter. If the contaminates cannot be vacuumed,
replace the Air Filter. Inspect all areas for wear and loose hardware.
09-803 Transfer Assist Blade 1000K Replace PL 9.11 Ensure the adhesive securing the End Tab is fully intact and the Tab is at
4000K (W/ 3 Layer Blade) 90 degrees to the blade. Check the solenoids and linkage for freedom of
movement. Check for the presence of a special Customized TAB before
replacement. Ensure the blade is seated properly by viewing with a
flashlight.
09-809 POP Sensor 500K Clean Do not vacuum; clean with a cotton towel.
09-815 Dicorotron Shields 500K Clean Clean the Dicorotron shields by wiping them with a clean, dry towel
(35P3191) only. Inspect for discoloration when cleaning. White or yellow
deposits over 25% of the shield surface is reason to replace the shield.
Detack and Preclean Shields especially are prone to these deposits. If
deposits are found, check them for poor OZAC connectors, and look for
evidence of poor connections (e.g., arcing, discoloration).

HFSI TABLES ?-10 No Product Name Assigned
09-822 Preclean Dicorotron 1000K Replace PL 9.10 Do not touch or attempt to clean the glass coated wire! Touching or
attempting to clean can cause the glass to crack. These cracks may
not be visible and the dicorotron must be replaced. Touch and clean
only the sides of the dicorotron. During scheduled dicorotron replace-
ment, inspect the OZAC connectors, looking for evidence of poor con-
nections (e.g., arcing, discoloration). Perform the dC951 Xerographic
Setup routine (ADJ 9-3). NOTE: After installing known good Dicorotrons,
do not remove Dicorotrons to clean the Dicorotron wire. Use "chopped"
Dicorotron (125K1450) in the Preclean position.
09-824 Detack Dicorotron 1000K Replace PL 9.10 See Notes for 09-822.
09-825 Developer 1000K (w/o MICR) Replace Do not perform a Dump and Thump procedure during a routine scheuled
600K (W/MICR) Developer replacement. Perform the procedure only when the Developer
is contaminated (e.g., cleaner droppings are in the developer). Vacuum
the developer seals, Developer Catch Tray and clean any loose toner
from the Developer roll gears. Inspect the Developer Rolls 1 and 2 for
wear or smooth surfaces. Perform the dC951 Xerographic Setup routine
(ADJ 9-3).
10-801 Metering Blade 1000K Rotate/ Replace PL 10.7 Clean the paper residue from bottom of the Sump, and remember to
replace wick and Fuser Agent Filter when rotating or replacing the Blade.
Inspect for Fuser Agent leaks. Ensure the proper Blade positioning.
Check the new Blade edge for nicks. Place a notch in the used Blade
edge. Ensure there is full length contact arc between the fuser and donor
rolls. Ensure the donor roll loading arms are not bent.
10-802 Wick and Agent Filter 1000K Replace PL 10.7 PL 10.8 Clean the paper residue from bottom of the Sump. Ensure the proper
*/** clamp positioning. Purge Fuser Agent Line of air bubbles via dC330 (i.e.,
energize Fuser Solenoid Pump). Inspect for Fuser Agent Leaks. Install
automotive-type clamp (Part #: 419W1250) to replace the crimped brass
tube at the end of the hose to the Sump, if necessary. Ensure there is full
length contact arc between the fuser and donor rolls. Ensure the donor
roll loading arms are not bent.
10-814 Metering Assembly 1000K Clean Clean the Sump. Ensure there is full length contact arc between the
fuser and donor rolls. Ensure the donor roll loading arms are not bent.
Inspect for Fuser Agent Leaks. Check the Bearing Seats for wear.

08-816 Registration Cross 2000K Replace PL 8.7 Verify that the Upper Transport Baffle is seated properly, not damaged or
Rolls ** deformed. (W/TAG P-267) Two (2) Cross Roll Kits are required to
replace the four (4) Cross Rolls.
09-801 Cleaner Brush & 2000K Replace PL 9.24 Before replacing the Brush and Blades, vacuum any loose toner from the
Blades ** housing, and clean the Flicker Bar. If the discarded Cleaner Blades have
fused toner adhering to the lead edge, inspect the Upper and Lower
Detoning Rolls for loss of anodized coating. Ensure correct reinstallation
of the white plastic Auger channels. Vacuum the new Cleaner Brush
before replacement.

No Product Name Assigned ?-11 HFSI TABLES
09-805 Post-Cleaner Blade 2000K Replace PL 9.26 Lubricate the blade with the toner impregnated cloth, provided with the
(Spots Blades) Kit. Perform the Post-Cleaner Blade (Spots Blade) Contact Adjustment
(ADJ 9-16 ) if the discarded Blade shows an uneven wear pattern and/or
the P/R Belt shows evidence of scratches. Verify the Spots Blade is
installed correctly; backwards will trap excessive debris.
09-820 Charge 1 Dicorotron 2000K Replace PL 9.10 Do not touch or attempt to clean the glass coated wire! Touching or
attempting to clean the wire can cause the glass to crack. These
cracks may not be visible and the Dicorotron must be replaced.
Touch & clean only the sides of the dicorotrons. During scheduled
dicorotron replacement, inspect the OZAC connectors, looking for evi-
dence of poor connections (e.g., arcing, discoloration). Perform the
dC951 Xerographic Set Up routine (ADJ 9-3). NOTE: After installing
known good Dicorotrons, do not remove Dicorotrons to clean the
Dicorotron wire. Use "chopped" Dicorotron (125K1450) in the Preclean
position.
09-823 Transfer Dicorotron 2000K Replace PL 9.10 See Notes for 09-820.
09-826 Cleaner housing, 2000K Clean Remove the Brush, Blades, Flicker Bar and Filter Bag. Thoroughly vac-
manifold and hose uum the Cleaner Housing and gear train. Pull (vacuum) any loose toner
through hose at Filter Bag.
10-815 Prefuser Transport 2000K Clean Clean the transport base. Check the manifold plate for warp and air
vacuum holes leaks.(i.e., gasket, manifold cracks, etc.) Ensure that the vacuum holes
are clear of debris. NOTE: Prefuser Transport Belts are replaced every
6000K prints.
Table 3 HFSI Activities Less Than 2M

03-802 Cooling Fan / Particu- 2000K (with P-314) Replace PL 9.8 Vacuum any contamination from Cooling Fan Housing + grill.
late Filter (DP 180MX 1500K (W/O P-314) PL 4.8
Only)
10-805 Prefuser and Fuser 750K Clean Clean the Q1009 sensor and mirror with a cleaning pad and Lens & Mir-
Jam Sensors ror Cleaner, 43P81. Clean the Q1010 sensor with cotton swabs and
Lens & Mirror Cleaner, 43P81. Inspect for Fuser Agent Leaks.
10-806 Pressure Roll / Strip- 1500K, 750K (w/MICR) Replace/ Clean PL 10.4 and PL 10.5 Inspect for Fuser Agent leaks; inspect Fuser Gears for tooth wear and
per Finger "fretting". Ensure that the Metering and Donor Rolls are seated properly
by ensuring that the arms are not bent and are in the locked position.
Ensure a full length contact arc is evident between the fuser and donor
rolls.
Table 4 HFSI Activities Greater Than 2M

08-802 Tray 1 Feed Belt 1000K (Tray 1 Feeds) Replace PL 7.10 Visually check the Takeaway Rolls for any wear, any damage or contam-
ination. Clean the Takeaway Rolls with Film Remover, and clean the
Stack Relief sensors with a cleaning pad (600S1276). Check/adjust
Feed Belt tension if required, Check the Tray 1 Drive Coupling for bind-
ing; lubricate with Lubriplate (70P31) as required.

08-804 Tray 2 Feed Belt 1000K (Tray 2 Feeds) Replace PL 7.10 Visually check the Takeaway Rolls for any wear, any damage or contam-
ination. Clean the Takeaway Rolls with Film Remover, and clean the
Stack Relief sensors with a cleaning pad (600S1276). Check/adjust
Feed Belt tension if required, Check the Tray 2 Drive Coupling for bind-
ing; lubricate with Lubriplate (70P31) as required.
08-810-X Tray X Blower O Ring 15000K (Tray X Feeds) Replace PL 8.14 No additional actions are required.
Drive Belt
03-801 Printer Monitor Filters 3000K (Imps.) Replace PL 2.3 No additional actions are required.
09-821 Charge 2 Dicorotron 3000K (Imps.) Replace PL 9.10 Do not touch or attempt to clean the glass coated wire! Touching or
attempting to clean can cause the glass to crack. These cracks may
not be visible and the dicorotron must be replaced. Touch and clean
only the sides of the dicorotron. During scheduled dicorotron replace-
ment, inspect the OZAC connectors, looking for evidence of poor con-
nections (e.g., arcing, discoloration). Perform the dC951 Xerographic
Set Up routine (ADJ 9-3). NOTE: After installing known good
Dicorotrons, do not remove Dicorotrons to clean the Dicorotron wire. Use
"chopped" Dicorotron (125K1450) in the Preclean position.
08-808 Vertical Transport 3000K (Tray 1 +Tray 2 Replace PL 8.1 Check the drive coupling wear element, magnetic skis, and the switch
Belts +Duplex Feeds) actuator for damage.
08-817 Registration Servo 3000K (Imps.) Clean Clean with film remover. Run dC703 to optimize Dynamic Width mea-
Shaft Rolls surement counter.
10-812 Metering Roll 3000K (Sheets Thru Replace PL 10.7 Inspect for Fuser Agent leaks; inspect Fuser Gears for tooth wear and
Fuser) "fretting". Ensure that the Metering and Donor Rolls are seated properly.
Check the Metering Donor Roll and Metering Blade for nicks. Check the
Bearing Seats for wear. Check metering roll bearing seats for wear.
09-806 P/R Drive Coupling 4000K (Imps.) Clean/Lube Lubricate with Moly Grease, 70E120. See Rollovers (PC 3676, RO
177643) in the Service Information Section for additional information on
the lubricant and a tool for its application. Inspect the Drive Dogs for
wear.
09-808 Cleaner Flicker Bar 4000K Replace PL 9.24 Vacuum the Top Manifold Assembly.
09-827 Developer Drive Cou- 4000K (Imps.) Clean/Lube Lubricate with Moly Grease, 70E120 (PL 25.1). See Rollovers (PC 3676,
pling and Gears/Tray RO 177643) in the Service Information Section for additional information
1 & 2 Drive Couplings on the lubricant and a tool for its application. Inspect the Drive Dogs and
the Developer Drive Coupling Gears for wear.
10-816 Fuser/Pre-Fuser 4000K (Imps.) Clean/Lube Lubricate with Moly Grease, 70E120 (PL 25.1). See Rollovers (PC 3676,
Drive Couplings RO 177643) in the Service Information Section for additional information
on the lubricant and a tool for its application. Inspect the Drive Dogs for
wear.
09-XXX Dicorotron shield 5000K Replace PL 9.10 Replace the Dicorotron shield assembly for all Dicorotrons
assy
10-811 Prefuser Transport 6000K Replace PL 8.9 Clean the Transport base. Ensure that the vacuum holes are clear of
Belts debris. Replace the Transport Belts. Clean and lubricate the Drive Cou-
pling with Lubriplate (70P31).
09-802 Agitator Spring 7850K (PR Belt Rev's) Replace PL 9.23 Inspect for impacted toner and clean channels as required.

No Product Name Assigned ?-13 HFSI TABLES
09-830 Developer Bead 4200K (Imps) Replace PL 9.17 Vacuum loose debris and toner deposits on Developer seals, Catch Tray
Carry Out Seal and Developer gears.
Ensure the Seal substrate material is not rubbing on Roll 1 or Roll 2.
Trim substrate material as required.
10-803 Donor Roll 8000K Replace PL 10.8 Inspect for Fuser Agent leaks; inspect Fuser Gears for tooth wear and
"fretting". Ensure that the Metering and Donor Rolls are seated properly
by ensuring that the arms are not bent and are in the locked position.
Ensure a full length contact arc is evident between the fuser and donor
rolls.
08-806-X Tray X Feed Belt 15000K (Tray X Feeds) Replace PL 8.13 Check the Feeder Drive Coupling Wear Element for signs of wear or
damage.
11-802-X Disk Stepper Motor 15000K (Sheets Entering Replace PL 11.30 Ensure correct Drive Shaft coupling alignment.
Coupling Stacker X)
09-807 Cleaner Blower O- 10,000K Replace PL 9.20 Inspect the blower pulley for toner buildup in grooves, and clean as
Ring Drive Belts required.
10-813 Decurler Belts 15000K (Sheets Thru Replace PL 10.12 Inspect bearing on shafts, repair as required. Ensure the Decurler Sen-
Fuser) sor is adjusted fully ccw. Inspect the Decurler Sensor for missing or weak
spring.

A
System Fault Analysis Procedures Go to the Jam/Fault Code Entry Procedure.
Initial Actions
1. Enter this procedure only from the Call Flow Procedure.
2. Review the Maintenance Hints in the Initial Action Section to become aware of the service
action that should not be performed.
3. Make Sure all the power cords are connected and power is available. Ensure that all the
ELCI circuit breakers are in the On position.
Procedure
Question the operator to determine the failure symptoms. If this is an Online system, (IPS)
request that the operator vary the system offline. The problem reported has a fault code or
status message associated with the printer.
Y N
The problem reported Boot error message associated with the System Controller.
Y N
There is an obvious Print Quality defect with the delivered prints.
Y N
There is a problem observed or that is reported by the Customer and is
related to the printer.
Y N
The System Controller and all peripherals are operational and Ser-
vice Mode can be entered.
Y N
Go to the System Fault Analysis Procedure in the DP NPS Service
Manual or DP IPS Service Manual.
Observe the PPR and return to 0-2 Corrective Action RAP in the Call Flow
Procedures.
The problem reported is an Odor problem.

Y N
Go to the Printer Entry Procedure.
Go to 4-707 RAP.
The defect is related to the image location (Skew, Registration, or magnifica-

tion).
Y N
Run DIM.PS, 10 Prints. Observe the prints and identify the defect. Enter Printer
Service Mode, and go to the PQ 9-601, Printer Image Quality Entry RAP.
Enter Printer Service Mode, and go to the PQ 9-601, Printer Image Quality Entry
RAP.
Go to the System Fault Analysis Procedure in the DP NPS Service Manual or DP IPS
Service Manual.
The problem is associated with a fault code.

Y N
Go to the Printer Entry Procedure in Printer Fault Analysis Procedures.
A
No Product Name Assigned ?-15 System Fault Analysis Procedures
A B C D E F G H I J K
Printer Entry Procedure Y N
There is a problem with the
Procedure prints stacking in the stacker.
Enter UI Lockout, and Printer Service Mode. A Fault Code is declared. Y N
Y N Go to the NRD 1, Non-
The reported problem can be repeated on the System. Repeatable Problem Entry
Y N Procedure to isolate the
Go to the Non-Repeatable Problem Entry Procedure, Section 1. problem.
Ensure the Printer Main Power Switch is on and the Local Remote Switch is in the Go to 11-600, Poor Stacking
Remote position. Ensure that all circuit breakers are on. The Printer UI Monitor is com- Quality RAP.
pletely black (not illuminating).
Y N Go to 10-607, Unable to Type on
The problem occurred while doing a Printer software upgrade. Prints RAP.
Y N
There is a Floppy Disk problem. Go to the Print Defect Entry Procedure.
Y N
The Printer UI Monitor screen has Icons. Go to the Print Damage Entry Procedure.
Y N
Go to the UIM Boot Entry Procedure. Go to the 4-702, Processor Drive Noise RAP or 11-
712, Inverter/Stacker Noise RAP.
The "Not Ready Please Wait: Fuser warming up" or "READY" mes-
sage appears on the screen. The unfused prints exhibit lead edge-to-trail edge
Y N streaks.
Go to 3-700, the Printer Boot RAP. Y N
Go to the 10-608, Dry Ink Not Fixed RAP.
All "On-Screen" selections can be made.
Y N Go to the 10-605, Lead Edge-To-Trail Edge Streaks RAP.
Go to 2-700, the Printer UI Entry Procedure.
Go to the OF-3, Machine Failure With No Fault Code RAP.
The printer UI Monitor has one or more of the following problems: 1)
Color, distortion, 2) Missing information, 3) 7-segment display, 4) Go to the OF-2, Diagnostics RAP.
Hard buttons, 5) Audio tone.
Y N Go to the 2-700, Printer UI Entry Procedure.
The problem is with a status message.
Y N Go to the 3-701, Floppy Disk Drive Failure RAP.
There is a Dead Cycle problem (One or more of the
machine drive motors are running or a component that Go to the 3-703, Software Upgrade Problem RAP.
does not work and no fault code or message is displayed.
Y N The top LED on the EDN is off.
There is an unfused print problem. Y N
Y N The problem occurred while doing a Printer software upgrade.
There is an audible noise or odor problem. Y N
Y N There is a Floppy Disk problem.
The print is being damaged. Y N
Y N The Printer UI Monitor screen has Icons.
There is a print defect Quality problem. Y N
Y N Go to the UIM Boot Entry Procedure.
There is a "cannot type on prints"
problem. The "Not Ready Please Wait: Fuser warming up" or "READY" mes-
sage appears on the screen.
A B C D E F G H I J K A L M N
Printer Entry Procedure ?-16 No Product Name Assigned
A L M N A L M N O P Q
Y N Y N
Go to 3-700, the Printer Boot RAP. Go to the 10-608, Dry Ink Not Fixed RAP.
All "On-Screen" selections can be made. Go to the 10-605, Lead Edge-To-Trail Edge Streaks RAP.
Y N
Go to 2-700, the Printer UI Entry Procedure. Go to the OF-3, Machine Failure With No Fault Code RAP.
The printer UI Monitor has one or more of the following problems: 1) Go to the OF-2, Diagnostics RAP or System Checks in the DP IPS or
Color, distortion, 2) Missing information, 3) 7-segment display, 4) DP NPS.
Hard buttons, 5) Audio tone.
Y N Go to the 2-700, Printer UI Entry Procedure.
The problem is with a status message.
Y N Go to the 3-701, Floppy Disk Drive Failure RAP.
There is a Dead Cycle problem (One or more of the
machine drive motors are running or a component that Go to the 3-703, Software Upgrade Problem RAP.
does not work and no fault code or message is displayed).
Y N Go to the Printer Power Entry Procedure.
There is an unfused print problem.
Y N Go to the Jam/Fault Code Entry Procedure.
There is an audible noise or odor problem.
Y N
This print is being damaged.
Y N
There is a print defect or a MICR Quality
problem.
Y N
There is a "cannot type on prints"
problem.
Y N
There is a problem with the
prints stacking in the stacker.
Y N
Go to the NRD 1, Non-
Repeatable Problem Entry
Procedure to isolate the
problem.
Go to 11-600, Poor Stacking

Quality RAP.
Go to 10-607, Unable to Type on

Prints RAP.
Go to the Print Defect Entry Procedure.
Go to the Print Damage Entry Procedure.
Go to the 4-702, Processor Drive Noise RAP or 11-

712, Inverter/Stacker Noise RAP.
The unfused prints exhibit lead edge-to-trail edge

streaks.
A L M N O P Q
No Product Name Assigned ?-17 Printer Entry Procedure
Printer Power Entry Procedure Print Damage Entry Procedure
Initial Actions Procedure
Ensure the Printer is connected to the power source and that power is available. The printed sheet is wrinkled.
Y N
Procedure Refer to Panic Stop Procedure in the General Procedures. Stop the machine. Examine
the prints throughout the machine. The damage is occurring at the fuser.
The ELCI/RCD device is tripped.
Y N
Y N
The damage is occurring somewhere in the PHM other than the fuser.
On the line Interface Module, Circuit Breaker: CB 101 (60Hz), CB 104 (50Hz), or CB
Y N
105 (50Hz), is switched off.
The print damage is in the stacker. Go to the 11-600, Poor Stacking Quality
Y N
RAP.
Go to the 1-713, +5 VDC RAP.
Go to the 8-705, PHM Print Damage RAP.

Reset the circuit breaker. The circuit breaker switches off again.
Y N
Go to the 10-701, Bent Corners RAP.
Return to the Call Flow, 0-1 Initial Action RAP (Initial Actions).
Go to the 10-603, Wrinkle RAP.

Go to the 1-721, (60Hz), or 1-724 (50Hz), Circuit Breakers Switching Off RAP.
Reset the ELCI/RCD. The ELCI/RCD trips again.

Y N
Return to the Call Flow, 0-1 Initial Action RAP (Initial Actions).
Go to the 1-731 RAP.

Printer Power Entry Procedure, Print Damage Entry ?-18 No Product Name Assigned
UIM Boot Entry Procedure Print Defect Entry Procedure
Procedure Procedure
Switch off the Printer, wait 30 seconds, (some systems may require a full 2 minute wait), The defect is dark horizontal bands/streaks seen only on blank inserts or covers.
and switch on the Printer. The screen is displaying vertical or horizontal lines.. Y N
Y N Refer to Panic Stop Procedure in the General Procedures. Stop the machine. Examine
30 seconds after powering on the Printer, the UI screen is illuminated (lit) with pic- the prints. The defect is Fuser related (lead edge smear, print gloss, lead edge-to-
ture (1 or 2 on screen). trail edge smear).
Y N Y N
Go to the 2-700, Printer UI Entry Procedure. Go to the PQ 9-601, Printer Image Quality Entry RAP.
60 seconds after Power on, only "X__-XX-__X" is displayed on the 7-segment dis- Go to the appropriate RAP:
play. • 10-601, Fuser Lead Edge Smear RAP.
Y N • 10-602, Fuser Print Gloss RAP.
The 7-segment display is alternating "8888888888" and "0000000000".
• 10-605, Lead Edge to Trail Edge Streaks (Unfuser Prints) RAP.
Y N
• 10-607, Unable to Type on Prints RAP.
The 7-segment display illuminated at some point during the boot process.
Y N
Go to the 2-700, Printer UI Entry Procedure. Go to the PQ 9-611, Dark Streaks/Scratches/Bands RAP.
Go to the 3-224, RAP.
Go to the 2-700, Printer UI Entry Procedure.

No Product Name Assigned ?-19 UIM Boot Entry Procedure, Print Defect Entry Pro-
A B
Jam/Fault Code Entry Procedure The fault code is a 3-XXX code.
Y N
Procedure Does the fault code support the primary activity.
Enter Printer Service Mode. Circuit Breaker CB 102 or CB 103 is switched off. (60Hz Y N
machine only). Treat this fault code as a secondary activity. Go to the NRD1, Non-Repeatable
Y N Problem Entry Procedure in Section 1, to identify and troubleshoot the primary
A fault code was in the queue during the Initial Action. problem.
Y N
Go to the Non-Repeatable Problem Entry Procedure. The problem is always present, or can be made to occur frequently enough to
diagnose.
A single fault code is in the queue. Y N
Y N Go to the NRD1, Non-Repeatable Problem Entry Procedure in Section 1, to
The multiple fault codes include a 9-201. troubleshoot the problem.
Y N
The fault codes include 6-250 or 6-251. Go to the appropriate RAP or FA screen.
Y N
The multiple fault codes include one or more 9-203, 9-213, 9-215, or Press R. Allow 60 seconds for the system to reset. Select [dC], then [SCP]. The fault
9-32X codes. code(s) are cleared from the queue.
Y N Y N
The multiple fault codes include one or more 3-XXX (any chain Go to the RAP or FA screen for the first 3-XXX fault code in the queue.
3) codes.
Y N Go to the 3-730, Intermittent Entry RAP.
The primary problem is always present, or can be made to
occur frequently enough to diagnose. Go to 1-721, Circuit Breakers Switching Off RAP.
Y N
Go to the NRD1, Non-Repeatable Problem Entry Proce-
dure in Section 1, to troubleshoot the problem.
Go to the appropriate RAP.
Press R. Allow 60 seconds for the system to reset. Select [dC], then
[SCP]. The fault code(s) are cleared from the queue.
Y N
Go to the RAP or FA screen for the first 3-XXX fault code in the
queue.
Go to the 3-730, Intermittent Entry RAP.
The fault codes alternate between any combination of any of the fol-
lowing codes: 9-325, 9-326, 9-327, and 9-329.
Y N
The codes repeat after resetting.
Y N
Go to the Printer Electrical Noise Procedure in NRD, Section 1.
Go to the 9-328.
Go to the 6-250/251.

A B
Jam/Fault Code Entry Procedure ?-20 No Product Name Assigned
Corrective Action for the DP180
PURPOSE
The purpose of the Corrective Action section is to repair any problems that were identified in
the Initial Action section.
PROCEDURE
1. Go to System Fault Analysis Procedures to troubleshoot/repair the primary problem. Per-
form all primary activities.
NOTE: If the problem solution is not identified within 1 hour after starting diagnostics,
escalate the call.
a. Range Faults - Investigate the primary Range Faults. Repair as required.

b. Subsystem Checks/HFSIs due - Perform the Subsystem Checks and go to the
HFSI TABLES and perform all due HFSI in the primary subsystem.
• Subsystem Checks shall be done only when the problem is in that subsystem.
For example, if the problem was for Fuser misstrips, perform the Fuser Sub-
system Checks.
• Contained in the FA file is additional HFSI Info on the task required when the
HFSI screen indicates a clean, replace, or lube action is due.
• Every Call Activity - If greater than 100K prints or five Customer working days
since the last call, perform the Every Call Activities.
• If the account is under situational or scheduled maintenance, go to step 3.
2. SECONDARY ACTIVITY
NOTE: If determined that any identified secondary activity could potentially cause a prob-
lem, discuss with the Customer the secondary service actions you would perform and
how long they would take. If the Customer approves, perform the secondary activities. If
the Customer requires the use of the machine, schedule a time to return and perform the
secondary activities. If scheduled maintenance option is in effect, perform the secondary
activities at the next scheduled maintenance.
a. Shutdown Information - To achieve longer intervals between calls, perform a brief

investigation of the recent Shutdown Information to identify any problem that could
drive an earlier than expected call back.
b. Range Faults - If other Range Faults have been detected, perform corrective
actions as required.
c. HFSI - go to the HFSI TABLES and perform all the secondary HFSI due.
d. Print Quality - Inspect the prints for Print Quality/MICR Quality perform corrective
actions as required.
NOTE: If you determine that any identified secondary activity could potentially cause
a UM call, repair before leaving the account.
3. Verify that problems are corrected by exercising the area of the system which was
repaired.
4. After all corrective actions are complete, go to the Final Action section.

No Product Name Assigned ?-21 Corrective Action for the DP180
Corrective Action for the DP180 ?-22 No Product Name Assigned
Print Paper Diagnostics If unsuccessful, then try another ream of the same stock.
If unsuccessful, then try different stock.
PROCEDURE
Check Customer's paper supply. Curl is usually due to a high moisture content. Cus-
Use the following suggestions for diagnosing paper-related problems that are causing jams or
tomer should avoid using paper that has acclimated to a moist environment, particu-
IQ problems.
larly if reams are opened. Also, some paper as received from the supplier may
contain excessive moisture. Also, with short grained stock, it may be difficult-to-
Run a few single and double sided prints to the Sample Tray. Check the prints for curl, fluff,
impossible to decurl adequately.
etc. If one of the symptoms is present, refer to the following table and use the procedures indi-
cated for that problem (number in the parenthesis next to the paper condition symptom). If unsuccessful, then the job may have to be split into smaller segments to reduce
the number of prints placed in the Sample Tray or Stacker Bins.
Prints can be examined during a job by using the Proof button to deliver single sample prints b. Prints Curl across the Process Direction
to the Sample Tray. To check prints in the Stacker Modules the Stop button can be used. Adjust the decurler to induce a small amount of curl in the process direction to
oppose and overcome the cross curl.
The Operator Guide also contains additional helpful information about paper-related problems. If unsuccessful, repeat the checks used to diagnose "Curled Prints in the Process
Direction."
Table 1 PRINT PAPER DIAGNOSTICS
2. Fluffy Prints: This is a condition where the thickness of a paper stack will be significantly
PROBLEM PAPER CONDITION thicker than normal. The paper may exhibit a cockeled or wavy appearance. This type of
paper defect will stress bin and sample tray capacity.
Jams entering Duplex Inverter Edge Reinforced paper (9)
Try turning stock over. This will normally not fix the problem but may reduce the stack
Curled Print (1)
height somewhat.
Fluffy Print (2)
If unsuccessful, then try another ream of the same stock.
8-901, 902, 904-1, 904-2 jams Operator selection mismatch of size or type
If unsuccessful, then try different stock.
Operator changed paper size or type with job
Check Customer's paper supply. Curl is usually due to a high moisture content. Customer
incomplete
should avoid using paper that has acclimated to a moist environment, particularly if reams
Shingled multifeed (3) are opened. Also, some paper as received from the supplier may contain excessive mois-
Dog eared print paper (4) ture.
Skewed sheets (12) If unsuccessful, then the job may have to be split into smaller segments to reduce the
Jams entering Stacker Bins when bins are Curled Print (1) number of prints placed in the Sample Tray or Stacker Bins.
nearing full 3. Shingled multifeed: Two sheets overlap so that the sheet width is detected as too long
Fluffy Print (2) or as a trail edge late jam.
Multifeeds Poorly cut/drilled stock (7) Check stock for defective cutting, edge welding, or interlocking drilled holes.
Fuser misstrips Curled Stock (5) Try fanning the edges of the stock to be sure that edges and/or drilled holes are not inter-
Photoreceptor misstrips Curled Stock (5) locking sheet to sheet.
Transfer deletions Moist Stock (6) If successful, instruct the operator on when and how to do this.
Debris Centered deletions Paper debris or poorly cut/drilled stock (7) If unsuccessful, then check the feeder.
Spots on prints Paper debris (7) 4. Dog Ears: (Folded corners)
Smear with preprinted forms Preprinted forms (8) Look for obstructions in the paper path.
Paper jams at decurler, top transport inter- Light weight paper curl (10) If none found, then check the feeder.
face, or in the top transport using light weight If no improvement after checking the feeder and path to the point of dog ears, then try
paper another type of stock.
5. Curled stock (curl in the ream before printing)
1. Curled Prints: Refer to the Curl Limit Figure 1 for recommended Curl Limits. Try another ream of the same stock
a. Curled Prints in the Process Direction If unsuccessful, then try a different stock.
Press "STOP", wait until the printer cycles down then Adjust the Decurler. Check Check Customer's paper supply. Curl is usually due to a high moisture content. Customer
the effect of different decurler setting on the curl. should avoid using paper that has acclimated to a moist environment, particularly if reams
If unsuccessful, then try turning stock over. Try decurler adjustment if improvement are opened. Also, some paper as received from the supplier may contain excessive mois-
was seen. ture.

No Product Name Assigned ?-23 Print Paper Diagnostics
6. Moist stock: (Paper with excessive moisture content)
Try another ream of the same stock
If unsuccessful, then try a different stock
Check Customer's paper supply. Curl is usually due to a high moisture content. Customer
should avoid using paper that has acclimated to a moist environment, particularly if reams
are opened. Also, some paper as received from the supplier may contain excessive mois-
ture.
7. Debris: Most commonly from poorly cut and/or drilled stock or stock produced in a dusty
environment.
Check for cutting and or drilling debris
If present, try another stock.
If unsuccessful, then the debris is not coming from the paper.
If problem was the stock, then point out to the Customer that the stock is defective and
results with that stock cannot be improved.
8. Preprinted prints
Be sure stock printing does not line up with Tray 1 or 2 Feed Head.
Be sure stock has thoroughly dried ink. Fresh offset prints may present a smear problem
if not cured for a day or longer.
9. Edge reinforced stock
This stock can cause jams if entering the Duplex tray with the edge reinforcement facing
up. Load stock in Feed Trays 1 and/or 2 so reinforcement faces down.
10. Away from Image (AI) curl with light weight paper
Light weight paper is especially prone to jam at the top transport or top transport -
decurler interface if curled significantly in the AI direction. Adjust to achieve less AI curl.
Refer to "Curled Prints."
11. Up Curl with light weight paper
Adjust to achieve curl between flat and down. Refer to "Curled Prints."
12. Skewed sheets
Check from the feeder through the registration transport for any obstructions which may
be causing skew.
Check that the edge guides in the supply tray are set correctly.

Print Paper Diagnostics ?-24 No Product Name Assigned
Figure 1 60 HZ Curl Measurements

No Product Name Assigned ?-25 Print Paper Diagnostics
Print Paper Diagnostics ?-26 No Product Name Assigned
Every Call Activities PROCEDURE
The Every Call Activities (see Table 1 Every Call Activities) should be performed on every ser-
vice call. However, it is not necessary to perform the Every Call Activities, if less than 50K
prints since the last call.
Table 1 Every Call Activities

SUBSYSTEM ACTIVITY NOTES
Tray 3/4/5/6 Verify Stack Height Sensor, Q735 actuator not damaged (bent or broken). (PL 7.16)
Development Check for excess Developer Beads in the Catch Tray. It is normal to find a small quantity of beads (a tablespoon or less in Go to PQ 9-616, Development RAP
a normal 150K interval between UIM calls), mainly at the Tray ends. Empty the Developer Beads Catch Tray. and/or PQ 9-631, Bead Carryout RAP.
Photoreceptor Module 1. Clean the Air Dam Seal of the Stripper Finger Assembly. 1. Use dry cloth 35P3191.
Area 2. Clean the POP Sensor. 2. Use dry cloth 35P3191.
3. Check for dry ink buildup. 3. Clean and repair cause for buildup.
4. Inspect the Lamps for burnt out segments. 4. Repair as required.
Fuser 1. Check for Fuser Agent leaks and spillage.
2. Fill the Fuser Agent reservoir.
3. Visually check the condition of the Fuser, Donor and Pressure Rolls. 3. Replace as required:
a. Fuser Roll (PL 10.7)
b. Donor Roll (PL 10.9)
c. Pressure Roll (PL 10.4)
Subsystem Checks PROCEDURE

Subsystem Checks (Table 1 MIM System Checks) and (Table 2 PHN System Checks) shall be
done when the primary repair is in that subsystem. For example, if the primary reason for the
call was for Fuser Mis-strips, perform the Fuser Subsystem Checks.
Table 1 MIM System Checks

Fuser 1. Check the Reservoir (PL 10.1), Pan (PL 10.1) and Fuser Entrance Baffle (PL 10.4) under the Pressure Roll for Fuser 1. Replace as required. Fill the Reser-
Agent leaks. voir.
2. Check the Pressure and Fuser Rolls for excessive Agent and for proper Agent level in the Reservoir. 2. Go to 10-702, Fuser Air System
3. Clean the Fuser Entrance Baffle channel on each end that directs the Agent back to the Reservoir. Checkout RAP.
4. Inspect the Fuser Roll Idler and the input gears for tooth wear; replace as required. Listen for excessive gear noise with
the Rolls cammed in. Replace the gears if they are noisy.
5. Ensure that the Metering/Donor Rolls are seated properly.
6. Clean the Fuser Jam Sensor, Q1010, (PL 10.6) and the Prefuser Sensor, Q1009, ().
7. Clean the surface of the Airknife Manifold and ensure that the air holes are open.
8. Enter Printer dC330. Select [10], [Compressor].Verify that the Fuser air pressure is 20 +/- 1 PSI.
9. Visually inspect the Fuser, Donor and Pressure Rolls for evidence of early failure.
Cleaning 1. Check the Cleaner for toner buildup after cleaning. 1. Go toPQ 9-617, Cleaner RAP.
2. If the Cleaner fails by binding, suspect the Cleaner Drive Bracket (rear of the Machine) failed. Replace the bracket if 2. Replace the developer after perform-
bent or twisted. ing (REP 9-4), Dump and Thump.
3. Check the Photoreceptor for fine scratches in the process direction. If present, check for causes. 3. Replace the P/R (PL 9.1) if the
4. Clean the toner from the machine drives (rear of the Machine). scratches print. Go toPQ 9-604 to
determine cause of scratches.

No Product Name Assigned ?-27 Every Call Activities
Table 1 MIM System Checks
Development 1. Check the ends of the Developer Rolls for caked dry ink and developer. 1. Symptom of excess heat.
2. Check the Drive coupling freedom. 2. Lube/repair as required (PL 9.14).
3. Check the dirt seals and air baffles traces of any escaping dry ink, toner and/or developer. 3. Repair as required (PL 9.15).
4. Empty the Developer Bead Catch Tray.
5. Clean the dirt seals, the entrance and the exit lips and the Manifold surface.
Charge/Transfer/Erase Clean the Dicorotron Shields.
Belt Module 1. Check the operation of the Cleaner Zone Roll mechanism and the Belt Module latch.
2. Clean the Pretransfer and Precharge Erase Lamps. Replace the lamps if any of the individual LEDs do not light. 2. Pretransfer Erase Lamps (PL 9.3)
3. Clean the DSS and the Belt Hole Sensor (Q901). Precharge Erase Lamps (PL 9.4)
4. Clean the POP Sensor (Q904) and the Waste Bottle Full Sensor (Q901).
5. Check the condition of the Photoreceptor ground strip and ground brushes.
6. Check for dry ink and toner buildup patterns.
7. Clean loose dry ink from the Photoreceptor edge guides. If dry ink is fused to the edge guide, replace the edge guide. 7. Edge Guide (PL 9.5)

Subsystem Checks ?-28 No Product Name Assigned
Table 2 PHM System Checks
Tray 1 and Tray 2 Feed- 1. Check the entrance guide for wear or contamination. 1. (PL 7.13)
ers 2. Check the takeaway rolls for wear, any damage or contamination. 2. (PL 7.10)
3. Clean the Feed Belts, Retard Rolls, #1 Takeaway Roll Sensor (Q811), #1 Stack Relief Sensor (Q812), #2 Takeaway 3. (PL 7.13)
Roll Sensor (Q821) and #2 Stack Relief Sensor (Q822).
Retard Roll Brake (PL 7.13)
NOTE: If a print lead edge shears or for excessive multifeeds, replace the Retard Roll and Brake.
Tray 3/4 Check the Tray Latch operation. Press the Tray release button and ensure that the Tray can be opened when the READY
TO OPEN light switch is lit. Close the Tray and ensure that the Latch engages.
2. Check the O-ring drive for any wear, stretch or cracks.
Registration Transport Verify that the Lower Transport Baffle is seated properly.
Vertical Transport 1. Check the Drive Coupling wear element, magnetic skis and the switch actuator for wear.
2. Check and clean the Transport Belts.
Top Transport 1. Check the Drive and Idler Rolls for any wear or contamination.
2. Check the Static Brushes for wear, adjustment or any damage.
3. Check the Jam Sensor Actuators (Q1011 and Q1012) for damage.
General Check and clean the Friction Drive Elements and Sensors area for excessive paper dust.

No Product Name Assigned ?-29 Subsystem Checks
Subsystem Checks ?-30 No Product Name Assigned
Non-Repeatable Problem Entry Procedure NOTE: Do not use the Single Standout displayed on the Printer and Controller Fault History
Summary frames. Refer to the NRD General Information And Diagnostic Hints section for
PROCEDURE details on determining a single standout.
Use the following procedure to determine the corrective action to isolate/repair non-repeatable
problems. If the problem is repeatable, go to the hard failure RAPs in the Service Dialog or the Print Subsystems
Service Manual (Section 2 or 3). 1. Paper Handling Jams over threshold
a. For single standout fault codes, go to the appropriate Chain Fault Code Table.
Initial Action:
b. For no single standout fault codes, go to the Paper Handling PHM Group Fault
Tables.
For PQ related non-repeatable problems, go to the PQ 9-601 System PQ Entry Level RAP in
2. Feeder Stacker Jams over threshold
Section 3.
a. For single standout fault codes, go to the 11 NRD Fault Code Tables.
NOTE: Intermittent problems can be operator or account related due to different job types, b. For no single standout fault codes, go to the FSM Group Fault Tables.
varying operator skill levels, or changing environmental factors. For detailed list of possible 3. Xerographic Faults over threshold
environmental factors and interrogation procedures, go to NRD General Information And Diag-
a. 6 and 9 fault codes are listed, go to the Printer Electrical Noise Procedure.
nostic Hints. Continue through this procedure until confident that the Non-repeatable problem
b. For single standout fault codes, go to the appropriate 6 NRD Fault Code Tables or 9
has been corrected.
NRD Fault Code Tables.
Question the Operator c. For no single standout fault codes, go to the Xerographics Group Fault Table (1 of 4.
Obtain as much information as possible on the job being run when the non-repeatable prob- 4. Run Control Faults over threshold
lem(s) occurred. a. For single standout fault codes, go to the appropriate 3 NRD Fault Code Tables.
b. For no single standout fault codes, go to the Run Control Group Fault Tables.
Environmental factors 5. All Other Faults over threshold
Take into account any possible environmental factors that might be contributing to the problem.
a. For single standout fault codes, go to the appropriate Chain Fault Code Table.
b. For no single standout fault codes, go to the Power/All Other Faults Group Fault
Overdue HFSIs Table (1 of 4).
Select [SCP] HFSIs in the Service Dialog and perform if due.
For additional SCP fault history analysis hints, go to the NRD General Information And Diag-
nostic Hints section for the following specific information:
The Operator is complaining of excessive Process Optimization
occurrences (i.e.., frequent “Adjusting Print Quality Messages”) – Definition of a Single Standout fault code
Go to 9-203, 9-213. – Using the Fault History data, i.e., Last 50 Shutdowns, Almost Jams, and Range Faults
– Using the Timing and Bypass Routines
1. View the SCP scorecard Fault History threshold displayers to determine if any subsystem
– dC226 and dC726 Timing graphs
threshold is > 100%.
– Miscounting Almost Jam Counters
2. If a subsystem threshold is >100%, check for a Single Standout Fault Code in each sub-
system Top 15 Jams (or Faults) list. – Using the Controller NRDs
– PHM and FSM Fault Code/Sensor Location Diagrams
NOTE: Specific information on Group Fault Table/Fault Code Table usage (which may include
the running of stress tests/functional tests) can be found in the following sections; check the
NRD Section Contents for the appropriate page number:
– Printer Group Fault Table Usage

– Printer Fault Code Table Usage
– Controller Fault Code Table Usage
Go to the appropriate Fault Code Table or Group Fault Table as defined in the following para-
graphs.

No Product Name Assigned ?-31 Non-Repeatable Problem Entry Procedure
Figure 1 Non-Repeatable Diagnostics Flow Diagram.

Non-Repeatable Problem Entry Procedure ?-32 No Product Name Assigned
Figure 2 Non-Repeatable Diagnostics Flow Diagram.

No Product Name Assigned ?-33 Non-Repeatable Problem Entry Procedure
Printer Electrical Noise Procedure c. Check the routing of the harnesses in and around the Compressor and the rear of
the Electrical Module.
PURPOSE 2. If 6-xxx faults are NOT being declared or if the previous step has been completed, per-
The purpose of this NRD Procedure is to assist in the isolation of the cause of electrical noise form steps a, b, c, and d to determine which part of this procedure to go to:
in the Printer to a specific subsystem area or component.
NOTE: Before beginning the 9-xxx procedure, enter dC314 and ensure that all the Dicorotron
NOTE: While performing this procedure, remember that the cause of the fault or faults is prob- Power Supply calibrations are correct.
ably electrical noise. Question the operator to determine if the fault or faults can be isolated to
a. If one of the 9-201, 9-203, 9-213, 9-215, or 9-3XX fault codes are occurring, go to
a specific operational phase (start-up, print, cycle-down, etc.) and/or operation (PHN, MIN, or
the appropriate 9-XXX Fault Code Procedure in Part 1: 9-XXX Fault Code Proce-
FSN) of the machine.
dures of this NRD.
If crashes and/or shutdowns have been occurring, check the SCP Printer Shutdown History b. If the faults are related to a PHN, MIN, or FSN node, go to the appropriate Electrical
(Last 50 Faults), and the Xerographics Top 15 Faults to determine if 9-201, 9-203, 9-213, 9- Node Procedure in Part 2: Electrical NODE Procedures . If no problem is found, con-
215, 9-3xx, or 6-xxx faults have been occurring. If 3-xxx and 6-xxx fault codes are occurring tinue to step c.
about the same time as the 9-xxx fault, there is a strong possibility that it is the result of an arc- c. If 6-xxx fault codes are occurring, go to the 6-xxx Fault Code Procedure in Part 3:
ing or an electrical noise problem. 06-XXX Fault Code Procedure. If no problem is found, continue to Part 4: Defeature
Isolation Procedure.
If the 3-xxx faults can be reset, the problem probably is not a PWB failure.
d. For all other faults, go to the Defective Isolation Procedure in Part 4: Defeature Isola-
tion Procedure.
General Troubleshooting Hints:
If it is suspected that more than one Dicorotron or Ozac connector is arcing, remove all
dicorotrons, and reinstall them one at a time to see if the fault can be recreated. Multiple arcing
is not uncommon.
When replacing a Dicorotron or Ozac connector, check the mating connector for signs of arc-
ing, wear, contamination, and looseness.
Loose, intermittent or arcing connections on AC Motors or components can cause electrical

noise to be introduced into the system and result in false shutdowns (e.g. cooling fans, main
drive motors, vent fans).
The purpose of this procedure is to identify known causes of false 6-xxx fault codes being
declared by electrical noise.
The purpose of this procedure is to allow running the Printer with selected functions turned off.
It is expected that when the output generating the noise is turned off, the noise also will be
turned off.
Use this procedure to disable outputs by using dC131 and other dC routines.
PROCEDURE
NOTE: The ROS components are prone to electrical noise generated by other components in
the Printer. Some of the following checks ensure that the latest electrical noise resistant com-
ponents have been added to the system. Others ensure that the most likely electrical noise
generators in the Printer are not causing the false fault codes.
1. If 6-xxx faults are being declared, perform the following steps to ensure that the latest
electrical noise resistant components have been added to the system:
a. Inspect for 9-201 faults. Components associated with 9-201 faults can cause false 6
ROS faults. Ensure that all repairs have been made to eliminate the 9-201 faults.
b. Check that the routing of the OZAC high voltage wiring is correct (PL 9.4).

Printer Electrical Noise Procedure ?-34 No Product Name Assigned
Part 1: 9-XXX Fault Code Procedures
Table 1 Part 1: 9-XXX Fault Code Procedures
Code Procedures
9-201 The most common causes of 9-201 faults are as follows:
- Cracked dicorotron wire glass coating
- Dicorotron contamination
- Contamination by conductive brush fibers
1. Perform the following steps:
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing.
- Inspect the Ozac connectors and the dicorotron connectors for the following symptoms:
- A yellow, gray or light brown film (most common)
- Cracks on the connectors
- Pitting on the AC Dicorotron connectors
- Inspect the Ozac ducts where they pass near the machine frame. It is possible for the wires inside the duct to arc to the frame (discoloration of the tube
will be noticeable).
- Inspect the Dicorotrons for cracked glass, very excessive contamination, or for brush fibers on the wire or at the end blocks.
- Inspect for proper P/J mating at the Ozac and HVAC PWB connectors.
- Inspect the HVAC Output Module. Remove the module, and look for signs of arcing at the output lead or between the resistor and frame.
2. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. High suspect causes are
the Cleaner and Developer subsystems.
3. If the above efforts have not corrected the problem, replace the HVAC PWB or the HV Output Module one at a time. (An intermittent component is sus-
pected.
4. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.
BSD 9.1 (Sheet 1) 5. 9-201 faults have been caused by broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the
fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll.
9-203 A true 9-203 fault indicates that the Photoreceptor is at end of life. As a general guideline, PR belts with less than 500K copies on them should not be at
end of life. There are other causes that can trigger the fault code.
The most common causes of 9-203 faults are as follows:
Charging system problems
- Incorrect dicorotron height. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7 and ADJ 9-6 )
- Process Control feedback problems
- Incorrect ESV spacing. Check/adjust the ESV Height adjustment (ADJ 9-12 ).
- Stray light
- Ensure that all inner and outer covers are installed correctly.
The most common electrical causes of 9-203 faults are as follows:
- Poor or faulty Ozac connectors
- Poor Dicorotron connectors
- System electrical noise
1. Check the PR Belt for physical damage, delamination of the belt seam, and ground strip damage. If any is noted find and repair the cause of the damage
before replacing the PR Belt.
2. Perform the following:
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing.

No Product Name Assigned ?-35 Part 1: 9-XXX Fault Code Procedures
Code Procedures
- Cracks in the connectors
- Inspect for proper P/J mating at the Ozac and HVPS connectors. Ensure that the connections to the HVDC PWB are correct and tight. If the above efforts
have not corrected the problem, replace the HVDC PWB. (An intermittent PWB is suspected.)
3. Enter dC140 [Dicorotron Values]. In Standby, if any Dicorotron value is greater than 0.3 VDC replace the HVDC PWB (PL 1.7 ).
4. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. The high suspect causes
are the Cleaner and Developer subsystems.
BSD 9.4 (Sheet 1) 5. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.
9-213 The most common cause of 9-213 faults is incorrect ESV spacing.
- Check/adjust the ESV Height Adjustment (ADJ 9-12 ).
The most common electrical causes of 9-213 faults are as follows:
- Poor PR grounding
- Poor Dicorotron connectors
- High voltage PWB connector problems
- Loss of ESV signal or faulty ESV
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and a hotspot.
- Inspect the Ozac connectors and dicorotron connectors for the following:
- Loose, missing, or broken fibers on the PR Ground Brush
- Vacuum the belt module, the PR Ground Brush (replace if necessary), and the surrounding area
- Inspect Ozac contacts for arcing and reseat all Dicorotrons.
- Inspect for proper P/J mating at Ozac and HVPS connectors.
2. Enter dC140 [Dicorotron Values]. In Standby, if any Dicorotron value is greater than 0.3 VDC replace the HVDC PWB (PL 1.7 ).
the Cleaner and Developer subsystems. If developer beads are noted outside the Developer Housing check the developer drive gears for wear.
4. 9-201 faults have been caused by broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the
fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll.
5. Go to PQ 9-619, ESV RAP in Section 3, IQ.
6. Look for a loss of the +24 VDC, ESV components failure, or an ADA PWB problem.
7. If the problem has not been resolved, replace the ESV assembly.
BSD 9.4 (Sheet 1) 8. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.
9-212 9-215 Intermittent electrical noise induced on the DSS signal line can cause a false 9-212.
The most common electrical causes of 9-212 and / or 9-215 faults are as follows:
- Loose dicorotron connectors
- Poor or missing PR ground brush

Part 1: 9-XXX Fault Code Procedures ?-36 No Product Name Assigned
Code Procedures
1. Perform the following:
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and hotspots.
- A yellow, gray or light brown film
- Loose, missing, or broken fibers on the PR Ground Brush
- Vacuum the belt module, the PR Ground Brush (replace if necessary), and the surrounding area.
- Inspect the Dicorotrons for frosted glass, excessive contamination of the glass coated wire or the end block.
2. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. The high suspect causes
are the Cleaner and Developer subsystems.
3. If the above efforts have not corrected the problem, replace the DSS (an intermittent DSS is suspected).
BSD 9.5 4. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.
9-32X 9-330 The most common electrical causes for 9-32X and 9-330 (current out of range) faults are as follows:
- Poor or dirty connections of the Dicorotron shields causing current or voltage out of range conditions
- Loose, intermittent, or faulty high voltage connections between the supply PWB and the dicorotron shield connector
- Either arcing Dicorotrons shield contact connectors or Dicorotron contact arcing, causing excessive contamination of the dicorotron shield, and a frosted
appearance of the Dicorotron wire glass coating
- Poor seating of plug/jacks to the HVAC and HVDC PWB connectors
- Ensure that the HVDC PWB is installed correctly, the harness is connected properly, and that the quarter-turn screws are secured.
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and hotspots.
- A yellow, gray or light brown film
- Pitting on the AC Dicorotron connector
- Inspect the Dicorotrons for frosted glass and for excessive contamination of the glass coated wire or the end block.
- Inspect all HVPS connectors for proper P/J mating.
the Cleaner and Developer subsystems.
BSD 9.1 and BSD 9.2 3. If the problem has not been resolved, replace the HVDC PWB (An intermittent HVDC PWB is suspected.)
Part 2: Electrical NODE Procedures

Table 1 Part 2: Electrical NODE Procedures
Node Procedures
MIN The most common causes of non-repeatable electrical noise in the MIN are:
- Poorly seated Dicorotrons
- Poor Dicorotron and Ozac connectors
-- Inspect the connectors for a yellow or light brown (most common) or gray film, or cracks
-- Inspect the Dicorotrons for excessive contamination from conductive fibers or from cracked glass coating on the wires
-- Inspect for proper mating of the Ozac connectors and the correct mating of HVAC and HVDC connectors

No Product Name Assigned ?-37 Part 1: 9-XXX Fault Code Procedures
Table 1 Part 2: Electrical NODE Procedures
Node Procedures
-- Inspect for arcing between the Charge 1 and 2 Dicorotron connectors and the backside of the HVPS Card Cage. Remove the back covers and swing out
the card cage. The arcing occurs on the inside half of the metal card cage panel. Look for discolored metal and replace the Dicorotron connectors as
required.
-- Inspect for cuts in or belts rubbing on the Ozac tubes, wires, and connectors
-- Inspect the Ozac tubes for leaks, discoloration, and other signs of arcing
- An intermittent Core PWB, which can cause 3-203 faults. Before replacing any Core PWB for an intermittent fault, attempt to reseat the Local Bus, Shared
Lines, and the Power and Identification connectors. Also inspect for any spreading (marginally touching) contacts.
- Excessive developer or toner contamination in the Xerographic area. Find and repair the cause of the contamination. The high suspect causes are the
Cleaner and Developer subsystems.
- Developer beads or conductive fibers in the dicorotrons. Arcing can occur when a new cleaner brush is installed. The new brush may have loose conduc-
tive fibers and should be vacuumed prior to installation.
- HVDC wires (red) out of the HVPS Card Cage that are pinched and/or shorted to machine frame.
- Loose, missing, or broken fibers on the PR Ground Brush. 9-201 and 9-32x faults can occur when the brush fibers get into the Dicorotrons.
- Poor PR belt Ground Brush contact. The brush must make good contact to the PR.
- Poor harness routing may cause ESV faults. Avoid wrapping or routing the ESV Probe or harness near AC harnesses.
- Broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device
area are installed correctly, especially the ground wire that attaches to the Metering Roll.
- Check the HVAC Output Module output cables for arcing to a metal bracket near the cable.
PHN The most common causes of non-repeatable electrical noise in the PHN are:
- An intermittent Core PWB, which can cause 3-204 faults. Before replacing any Core PWB for an intermittent fault, attempt to reseat the Local Bus, Shared
Lines, and the Power and Identification connectors.
- Broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device
area are installed correctly, especially the ground wire that attaches to the Metering Roll. Also inspect for any spreading (marginally touching) contacts.
FSN The most common causes of non-repeatable electrical noise in the FSN are:
- Static problems
- Poor or missing machine grounds, including the strapping between the modules
- Poorly routed Shared Communication Lines. The cables may be shorted intermittently or bent to the point that the line shield becomes intermittent.
- An intermittent +24 VDC Stacker interlock circuit can cause crashes. Check the Printer Fault History (Last 50 faults) for +24 VDC failures at or near the
same time as the FSN faults. Troubleshoot as required.
- An intermittent Core PWB, which can cause 3-205 faults. Before replacing any Core PWB for an intermittent, try reseating the local bus, shared line, and
the power and identification connectors. Also inspect for any spreading (marginally touching) connector contacts.
Part 3: 06-XXX Fault Code Procedure

PROCEDURE
1. The purpose of this procedure is to identify known causes of false 6-XXX fault codes
being declared by electrical noise.
Listed below are known causes of false 6-XXX fault codes. It does not contain all causes,
only those that have been identified to date. Any AC Motor or component with loose, inter-
mittent or arcing contacts can cause electrical noise to be introduced into the system and
result in false 06-XXX fault codes.
2. Check the following components:
a. Faulty UI Power Supply generating electrical noise

Part 3: 06-XXX Fault Code Procedure, Part 4: Defea- ?-38 No Product Name Assigned
b. Cavity Cooling Fan P/J loose or arcing contacts Part 4: Defeature Isolation Procedure
c. Loose ground wires in the Fuser Metering Roll assembly & Transfer Assist Device
areas.
PROCEDURE
1. The purpose of this procedure is to allow running the Printer with selected functions
d. The HVAC Output Module output cables for arcing to a metal bracket near the cable.
turned off. It is expected that when the output generating the noise is turned off, the noise
e. Motor and capacitors in Feeder/Stacker loose connectors improper fastening or arc- also will be turned off.
ing contacts.
Use this procedure to disable outputs by using dC131 and other dC routines.
3. If no problem is found, continue to Part 4: Defeature Isolation Procedure.
NOTE: Use extreme care when making the changes in NVM. Ensure that the correct Node is
selected and that a record is made of all NVM values that are being changed prior to the
change. This will enable the locations to be reset to their original values after the troubleshoot-
ing is complete. Ensure that all values changed during troubleshooting are reset back to their
original values prior to completion of the service call.
Refer to the appropriate level Software dC131 Table (Section 6, General Procedures, in the
Service Manual) for current Data default values.
2. Refer to the Features Bypass chart. Functions can be bypassed by changing the values
for the appropriate address. To enable or disable a function, add or subtract the value in
the table, from the value found in that address in dC131.
Run the machine with the disabled feature in an attempt to determine if the fault also has
been disabled. It may be helpful to disable more than one function at a time. If the cause
of the electrical noise can be isolated to a specific Node, go to Part 2: Electrical NODE
Procedures, and perform the activities listed.
Disconnect inputs or outputs as required in an attempt to isolate the cause of the fault or
noise. Use care when disconnecting the wires. An intermittent connection may occur,
which can cause more problems than were originally present. Also, be sure to use the
Molex Pin Extractor, when appropriate, to avoid damaging the wires or connectors.
3. If the non-repeatable fault or noise can be isolated to a specific PWB, use the PWB Input/
Output tables to isolate the cause of the fault to a specific component or its associated
wiring. Refer to the appropriate PWB Input/Output chart.

No Product Name Assigned ?-39 Part 3: 06-XXX Fault Code Procedure, Part 4: Defea-
Features Bypass Tables
Table 1 MIN Features Bypass
Address 128 64 32 16 8 4 2 1 Defaults
124 Enable Closed Enable Toner Con- Enable Charge Enable Rest Recov- Enable PGEN Enable TC Setup Enable ROS Enable Electro- 255
Loop trol Control (ESV) ery Setup Setup static Setup
125 Enable RDR Analy- Enable VLD ROS Enable RDR Fault Enable Variable Enable Pixel Enable Video Enable Pattern 252
sis Position (Preci- Length Counting Generator
sion Patch)
176 Enable PIDC Col- Enable Walk PGEN Enable Declare Enable MIN 00
lection Fault Occurrence Log-
ging
178 Disable SOB Sen- Disable 50 Hz 00
sor Phase Detection
179 Disable ARC Simu- Disable HVPS Fault Disable HV Disable HVAC Disable PDIC 01
lation at Power Up Detection controller
466 Enable Dual Lamp Enable Hi-C Fuser Enable MIN 24V Enable Digital P- Enable MICR Enable PR unifor- Enable Speed Up 219
Fuser Roll detection Gen materials mity Features 223 (MICR)
Table 2 PHN Features Bypass

176 Enable Patch Print Enable copy Disable Dynamic Enable hole jump Disable 14 Trans- Disable Multi Bar 00
counter to count by Paper Width Faults Disable 9" Paper fer Assist Blade Code SBA retry
1
178 Enable Mis Reg 00
Detection
179 Enable TAB setup 00
value usage after
08-226
250 Disable Initializa- 00
tion of Transfer
Assist Blade
251 Disable 14” Trans- Disable 13” Trans- Disable 12” Trans- Disable 11” 00
fer Blade Solenoid fer Blade Solenoid fer Blade Solenoid Transfer Blade
Solenoid
Table 3 EDN Features Bypass

222 Enable Duplex 01
262 Enable FSN Fixture Enable Variable Enable JB5 Paper Enable 7x10 Paper Enable Large Enable MICR 64
Internal Image RDR Handling Handling Paper 66 (MICR)
488 ROS Type Image ROS Type Image 00
Enhancement Enhancement

Features Bypass Tables ?-40 No Product Name Assigned
FSN DIO PWB # 1A Inputs FSN DIO PWB # 1 Outputs
Table 1 FSN DIO PWB # 1A Inputs Table 1 FSN DIO PWB # 1 Outputs
Signal LED Signal Signal Output
Description Conn Signal TP Rtn Conn Conn LED TP BSD Description Conn TP Conn Volt BSD
Stacker A Stack J7-18 TS 12 J7-17 TS 11 J7-16 11.7 Back Tamper Clutch J2-11 TS 43 J2-12 +24VDC 11.6
Height Sensor Front Tamper Clutch J2-09 TS 52 J2-10 +24VDC 11.6
J7-15 TS 10 J7-14 TS 09 J7-13 Stacker Main Drive Start Relay J2-07 TS 44 J2-08 +24VDC 11.3
Back Tamper Posi- J7-12 TS 08 J7-11 TS 07 J7-10 11.8 J2-05 TS 53 J2-06 +5VDC 11.3
tion Sensor
J2-01 TS J2-02
Front Tamper Posi- J7-09 TS 06 J7-08 TS 05 J7-07 11.8
Stacker Main Drive Run Relay J2-03 TS 45 J2-04
tion Sensor
J3-01 TS 42 J3-02
Container Size J7-03 TS 02 J7-02 TS 01 J7-01 11.8
Switch-A J3-03 TS 50 J3-04
Container Size J7-06 TS 04 J7-05 TS 03 J7-04 11.8 Stacker Ready to UNLOAD Indica- J3-19 TS 46 J3-20 +5VDC 11.7
tor
Switch-B
Stacker In Use Indicator J3-17 TS 47 J3-18 +5VDC 11.7
Container Size J7-24 TS 16 J7-23 TS 15 J7-22 11.8
Switch-C Stacker Please Wait Indicator J3-15 TS 39 J3-16 +5VDC 11.7
Disk Lead Edge Sen- J7-21 TS 14 J7-20 TS 13 J7-19 11.5 J3-13 TS 48 J3-14
sor Stacker Elevator Motor Up J3-11 TS 40 J3-12 +5VDC 11.7
Drawer In Switch J6-04 TS 17 J6-05 TS 27 J6-06 11.7 Stacker Elevator Motor Down J3-09 TS 49 J3-10 +5VDC 11.7
Elevator Down Sen- J6-21 TS 28 J6-20 TS 18 J6-19 11.7 Back Tamper Motor J3-07 TS 51 J3-08 +5VDC 11.6
sor Front Tamper Motor J3-05 TS 41 J3-06 +5VDC 11.6
Bin Unload Button J6-24 TS 21 J6-23 TS 20 J6-22 11.7
Stacker Empty Sen- J6-27 TS 24 J6-26 TS 30 J6-25 11.7
sor
Stacker Elevator J6-30 TS 32 J6-29 TS 31 J6-28 11.7
Motor Encoder Sen-
sor
Main Pallet Latch J6-07 TS 19 J6-08 TS 29 J6-09 11.7
Sensor
Disk Sheet Sensor J6-10 TS 22 J6-11 TS 23 J6-12 11.5
A3 Trail Edge Sensor J6-13 TS 25 J6-14 TS 26 J6-15 11.5

No Product Name Assigned ?-41 FSN DIO PWB # 1A Inputs, FSN DIO PWB # 1 Out-
FSN DIO PWB # 2 Inputs/Outputs FSN DIO PWB # 3 Inputs/Outputs
Table 1 FSN DIO PWB # 2 Inputs Table 1 FSN DIO PWB # 3 Inputs
Signal Signal LED Signal Signal LED
Description Conn TP Conn LED TP Rtn Description Conn TP Conn LED TP Rtn BSD
HCT Stack Height Sensor J7-18 TS 12 J7-17 TS 11 J7-16 Horiz X-Port Sensor J7-18 TS 12 J7-17 TS 11 J7-16
J7-15 TS 10 J7-14 TS 09 J7-13 Turn Baffle Sensor J7-15 TS 10 J7-14 TS 09 J7-13
J7-12 TS 08 J7-11 TS 07 J7-10 Purge Tray Jam Sensor J7-12 TS 08 J7-11 TS 07 J7-10
HCT Position Sensor J7-09 TS 06 J7-08 TS 05 J7-07 Vertical X-port Sensor J7-09 TS 06 J7-08 TS 05 J7-07
[LED drive used for S13B] J7-03 TS 02 J7-02 TS 01 J7-01 Bypass X-port Sensor J7-03 TS 02 J7-02 TS 01 J7-01 11.4
HCT Length Sensor A J7-06 TS 04 J7-05 TS 03 J7-04 Back Offset Encoder Sensor J7-06 TS 04 J7-05 TS 03 J7-04
HCT Length Sensor B J7-24 TS 16 J7-23 TS 15 J7-22 J7-21 TS 14 J7-20 TS 13 J7-19
HCT Close Switch J7-21 TS 14 J7-20 TS 13 J7-19 Stacker Top Cover Intlk Switch J6-04 TS 17 J6-05 TS 27 J6-06 1.4
J6-04 TS 17 J6-05 TS 27 J6-06 Stacker Left Door Intlk Switch J6-21 TS 28 J6-20 TS 18 J6-19 1.4
HCT Unlock Switch J6-21 TS 28 J6-20 TS 18 J6-19 Vertical X-port Door Intlk Switch J6-24 TS 21 J6-23 TS 20 J6-22 1.4
HCT Width Sensor J6-24 TS 21 J6-23 TS 20 J6-22 Horiz X-port Door Interlock J6-27 TS 24 J6-26 TS 30 J6-25 1.4
J6-27 TS 24 J6-26 TS 30 J6-25 Switch
Feed Sensor Q857 J6-30 TS 32 J6-29 TS 31 J6-28 LVPS 24 V SENSE J6-30 TS 32 J6-29 TS 31 J6-28 TBD
J6-07 TS 19 J6-08 TS 29 J6-09 Stacker Right Door Intlk Switch J6-07 TS 19 J6-08 TS 29 J6-09 1.4
J6-10 TS 22 J6-11 TS 23 J6-12 J6-10 TS 22 J6-11 TS 23 J6-12
HCT Tray Down / Low Paper Sensors J6-13 TS 25 J6-14 TS 26 J6-15 Feeder Stacker Interlock Bypass J6-13 TS 25 J6-14 TS 26 J6-15 1.4
Switch
Table 2 FSN DIO PWB #2 Outputs
Table 2 FSN DIO PWB #3 Outputs
Signal
Description Conn Signal TP Rtn Conn Volt Signal Signal Output
Description Conn TP Conn Volt BSD
J2-11 TS 43 J2-12
Feeder Main Drive Start Relay J2-11 TS 43 J2-12
J2-09 TS 52 J2-10
J2-07 TS 44 J2-08 J2-09 TS 52 J2-10
J2-05 TS 53 J2-06 J2-07 TS 44 J2-08
J2-01 TS J2-02 HCF Horz. Jam Clearance Light J2-05 TS 53 J2-06
J2-03 TS 45 J2-04 Over Size Nip Release Solenoid J2-01 TS J2-02
Release Solenoid J3-01 TS 42 J3-02 +24VDC Bypass X-port Gate Solenoid J2-03 TS 45 J2-04 +24VDC 11.4
Feed Clutch J3-03 TS 50 J3-04 +24VDC Feeder Main Drive Run Relay J3-01 TS 42 J3-02
Tray Capacity Control Line 0 J3-19 TS 46 J3-20 +5VDC J3-03 TS 50 J3-04
Elevator Motor Up J3-11 TS 40 J3-12 +5VDC J3-13 TS 48 J3-14
Elevator Motor Down J3-09 TS 49 J3-10 +5VDC J3-11 TS 40 J3-12
J3-07 TS 51 J3-08 +5VDC J3-09 TS 49 J3-10
Blower Motor J3-05 TS 41 J3-06 +5VDC J3-07 TS 51 J3-08

J3-05 TS 41 J3-06

FSN DIO PWB # 2 Inputs/Outputs, FSN DIO PWB # 3 ?-42 No Product Name Assigned
FSN Stepper PWB A Inputs/Outputs MIN ADA PWB #1 Inputs/Outputs
Table 1 FSN Stepper PWB A Inputs Table 1 MIN ADA PWB #1 Inputs
Signal Signal LED Signal Signal Rtn
Description Conn TP Conn LED TP Rtn BSD Description Conn TP Conn Rtn TP Shield BSD
Disk Home Sensor J3-04 TS 14 J3-05 TS 16 J3-06 11.5 ESV Monitor J6-3 TS21 J6-4 TS22 --- 9.4
Right Guide Home Sensor J3-07 TS 04 J3-08 TS 06 J3-09 11.6 Coronode AC Voltage Monitor J6-7 TS27 J6-8 TS28 --- 9.1 (2)
Back Guide Home Sensor J3-10 TS 05 J3-11 TS 02 J3-12 11.6 Upper Detoning Roll Voltage J6-9 TS30 J6-10 TS31 --- 9.1
J3-13 TS 03 J3-14 TS 13 J3-15 Monitor
J3-21 TS 17 J3-20 TS 11 J3-19 Lower Detoning Roll Voltage J6-11 TS33 J6-12 TS34 --- 9.1 (1)
J3-24 TS 10 J3-23 TS 07 J3-22 Monitor
J3-27 TS 12 J3-26 TS 01 J3-25 Cleaner Brush Voltage Monitor J6-13 TS47 J6-14 TS48 J6-15 9.1 (1)
J3-30 TS 15 J3-29 TS 08 J3-28 Fuser Voltage Line Monitor J6-17 TS35 J6-16 TS36 --- 10.1 (1)
Metering Roll Temperature Con- J6-19 TS37 J6-18 TS38 --- 10.1 (1)
Table 2 FSN Stepper PWB A Outputs trol
Fuser Temperature Control J6-21 TS39 J6-20 TS40 --- 10.1 (1)
Signal Signal
Description Conn TP Rtn Volt BSD Coronode AC Current Monitor J6-23 TS41 J6-22 TS42 --- 9.1 (2)
DSS Monitor J7-1 TS51 J7-2 TS52 J7-3 9.5
Disk Motor Coil A J2-01 TS 27 J2-03 +24VDC 11.5
Disk Motor Coil B J2-02 TS 26 J2-03 +24VDC 11.5
Table 2 MIN ADA PWB #1 Outputs
Disk Motor Coil C J2-05 TS 23 J2-04 +24VDC 11.5
Signal Signal Rtn
Disk Motor Coil D J2-06 TS 22 J2-04 +24VDC 11.5
Description Conn TP Conn Rtn TP BSD
Right Guide Position Motor Coil A J2-07 TS 25 J2-09 +24VDC 11.6
Coronode AC Voltage Control J5-2 TS2 J5-1 TS56 9.1 (2)
Right Guide Position Motor Coil B J2-08 TS 19 J2-09 +24VDC 11.6
Lower Detoning Roll Voltage Control J5-4 TS3 J5-3 TS56 9.1 (1)
Right Guide Position Motor Coil C J3-11 TS 21 J3-10 +24VDC 11.6
Cleaner Brush Voltage Control J5-6 TS1 J5-5 TS56 9.1 (1)
Right Guide Position Motor Coil D J3-12 TS 20 J3-10 +24VDC 11.6
Upper Detoning Roll Voltage Control J5-8 TS4 J5-7 TS56 9.1 (1)
Back Guide Position Motor Coil A J3-13 TS 32 J3-15 +24VDC 11.6
Back Guide Position Motor Coil B J3-14 TS 31 J3-15 +24VDC 11.6
Back Guide Position Motor Coil C J3-17 TS 29 J3-16 +24VDC 11.6
Signal Signal Input Output Input
Back Guide Position Motor Coil D J3-18 TS 28 J3-16 +24VDC 11.6 Description Conn TP Conn Volt TP BSD
Toner Thumper Solenoid J4-1 TS32 J4-2 +24 TS58 9.6
Start Relay On J4-3 TS29 J4-4 +24 TS58 4.1 (1)
Run Relay On J4-5 TS26 J4-4 +24 TS58 4.1 (1)
HVAC Arc Test J4-9 TS20 J4-10 --- --- 9.1 (1)
HVAC Enable J4-13 TS16 J4-14 --- --- 9.1 (1)
DSS Enable J4-17 TS10 --- --- --- 9.5
DSS Calibrate J4-19 TS8 --- --- --- 9.5

No Product Name Assigned ?-43 FSN Stepper PWB A Inputs/Outputs, MIN ADA PWB
MIN ADA PWB #2 Inputs/Outputs MIN DIO PWB Inputs/Outputs
Table 1 MIN ADA PWB #2 Inputs Table 1 MIN DIO PWB Inputs
Signal Signal Rtn Signal LED
Description Conn TP Conn Rtn TP Shield BSD Description Conn Signal TP Rtn Conn Conn LED TP BSD
Dev Rolls 1 & 2 Voltage Monitor J6-1 TS18 J6-2 TS19 --- 9.2 (3) Paper at POP Sensor J6-4 TS17 J6-6 J6-5 TS27 9.7 (1)
Preclean Voltage Monitor J6-3 TS21 J6-4 TS22 --- 9.2 (1) HVAC Arc Detected J6-7 TS19 J6-9 --- --- 9.1 (1)
Preclean Current Monitor J6-5 TS24 J6-6 TS25 --- 9.2 (1) Low Toner Sensor J6-10 TS22 J6-12 1TB4 --- 9.6
Charge 2 Current Monitor J6-7 TS27 J6-8 TS28 --- 9.2 (1) Ozone Vacuum Switch J6-13 TS25 J6-15 --- --- 9.8
Charge 2 Voltage Monitor J6-9 TS30 J6-10 TS31 --- 9.2 (1) Waster Bottle Full Sen- J6-24 TS21 J6-22 J6-23 TS20 9.7 (1)
Transfer Voltage Monitor J6-11 TS33 J6-12 TS34 --- 9.2 (1) sor
Charge 1 Voltage Monitor J6-17 TS35 J6-16 TS36 --- 9.2 (1) DSS Diagnostic Moni- J6-27 TS24 J6-25 --- --- ---
tor
Charge 1 Current Monitor J6-19 TS37 J6-18 TS38 --- 9.2 (1)
Patch Generator Diag- J6-30 TS32 J6-28 --- --- ---
Dev Roll 3 Voltage Monitor J6-21 TS39 J6-20 TS40 --- 9.2 (3)
nostic Monitor
Detack Current Monitor J6-23 TS41 J6-22 TS42 --- 9.2 (1)
Release Agent Low J7-3 TS2 J7-1 J7-2 TS1 P10.4
Transfer Current Monitor J6-25 TS43 J6-24 TS44 --- 9.2 (1) Switch
50 Hz Phases Correct J7-9 TS6 J7-7 J7-8 TS5 1.7
Belt Hole Sensor J6-9 TS15 J6-7 J6-8 TS14 9.3
Signal Signal Input Input Input Machine Clock Pulse J6-3 TS11 TS22 --- --- 4.3
Description Conn TP Conn Volt TP BSD
Patch Enable J4-9 TS20 J4-10 +5 TS60 9.4 Table 2 MIN DIO PWB Outputs
Discharge Lamps On J4-11 TS17 1TB4 +24 --- 9.7 (2) Signal Input
Fuser Relay On J4-13 TS16 J4-14 +5 TS60 P10.1 Description Conn Signal TP Conn Input Volt Input TP BSD
(1)
Page Sync J2-1 TS54 J2-2 --- --- 6.6 (3)
Metering Roll Heater On J4-15 TS13 J4-16 +5 TS60 P10.1
Registration Sync J2-3 TS45 J2-4 --- --- 4.4
(1)
Pulse
Patch Generator High J2-5 TS53 J2-6 --- --- 9.5
ESV Reset J2-11 TS43 J2-12 --- --- 9.4
Signal Signal Rtn
Prefuser Vacuum Motor J3-15 TS39 J3-16 +5 TS35 10.2 (1)
Description Conn TP Conn Rtn TP BSD
Toner Motor J3-17 TS47 J3-18 +5 TS35 9.6
PGEN Reference J5-2 TS2 J5-1 TS56 9.5
Detack Current Control J5-12 TS9 J5-11 TS56 9.2 (1)
Dev Rolls 1 & 2 Voltage Control J5-14 TS11 TS13 TS56 9.2(3)
Charge 2 Current Control J5-16 TS14 J5-15 TS56 9.2 (1)
Dev Roll 3 Voltage Control J5-18 TS5 J5-17 TS56 9.2 (3)
Transfer Current Control J5-20 TS7 J5-19 TS56 9.2 (1)
Charge 2 Voltage Control J5-22 TS12 J5-21 TS56 9.2 (1) )
Preclean Current Control J5-24 TS15 J5-23 TS56 9.2 (1)

MIN ADA PWB #2 Inputs/Outputs, MIN DIO PWB In- ?-44 No Product Name Assigned
PHN DIO PWB #1 Inputs/Outputs Table 2 PHN DIO PWB #1 Outputs
Signal Signal Input Input
Table 1 PHN DIO PWB #1 Inputs Description Conn TP Conn Volt Input TP BSD
Signal Signal Rtn LED Capacity Bit 1 J3-9 TS49 J3-10 +5 TS35 7.1C (4)
Description Conn TP Conn Conn LED TP BSD Capacity Bit 0 J3-11 TS40 J3-10 +5 TS35 7.1C (4)
Tray 1
Unlock Switch J7-3 TS2 J7-1 --- --- 7.1B (3)
Stack Height Sensor J7-6 TS4 J7-4 J7-5 TS3 7.1B (3)
Down/Low Paper Sensor J7-9 TS6 J7-7 J7-8 TS5 7.1B (3)
Interlock Switch J7-12 TS8 J7-10 --- --- 7.1B (1)
Paper Length B Sensor J7-15 TS10 J7-7 J7-14 TS9 7.1B (2)
Stack Relief Sensor J7-18 TS12 J7-4 J7-17 TS11 TBD
Takeaway Roll Sensor J7-21 TS14 J7-4 J7-20 TS13 TBD
Paper Length A Sensor J7-24 TS16 J7-7 J7-23 TS15 7.1B (2)
Tray 2
Paper Length A Sensor J6-4 TS17 J6-25 J6-5 TS27 7.1C (2)
Stack Height Sensor J6-7 TS19 J6-9 J6-8 TS29 7.1C (3)
Stack Relief Sensor J6-10 TS22 J6-9 J6-11 TS23 TBD
Takeaway Roll Sensor J6-13 TS25 J6-9 J6-14 TS26 TBD
Paper Length B Sensor J6-21 TS28 J6-25 J6-20 TS18 7.1C (2)
Interlock Switch J6-24 TS21 J6-22 --- --- 7.1C (1)
Down/Low Paper Sensor J6-27 TS24 J6-25 J6-26 TS30 7.1C (3)
Unlock Switch J6-30 TS32 J6-28 --- --- 7.1C (3)
Table 2 PHN DIO PWB #1 Outputs

Signal Signal Input Input
Description Conn TP Conn Volt Input TP BSD
Tray 1
Stack Relief Solenoid J2-1 TS54 J2-2 +24 TS34 TBD
Elevator Motor Down J2-9 TS52 J2-10 +5 TS33 7.1B (1)
Elevator Motor Up J2-11 TS43 J2-10 +5 TS33 7.1B (1)
Feed Clutch J3-1 TS42 J2-2 +24 TS34 TBD
Capacity Bit 3 J3-13 TS48 J3-18 +5 TS35 7.1B (4)
Tray 2
Stack Relief Solenoid J2-3 TS45 J2-4 +24 TS34 TBD
Elevator Motor Down J2-5 TS53 J2-6 +5 TS33 7.1C (1)
Elevator Motor Up J2-7 TS44 J2-6 +5 TS33 7.1C (1)
Feed Clutch J3-3 TS50 J2-4 +24 TS34 8.1C (1)
Capacity Bit 3 J3-5 TS41 J3-10 +5 TS35 7.1C (4)
Capacity Bit 2 J3-7 TS51 J3-10 +5 TS35 7.1C (4)

No Product Name Assigned ?-45 PHN DIO PWB #1 Inputs/Outputs
PHN DIO PWB #2 Inputs/Outputs PHN DIO PWB #3 Inputs/Outputs
Table 1 PHN DIO PWB #2 Inputs Table 1 PHN DIO PWB #3 Inputs
Signal Signal Rtn LED Signal Signal Rtn LED
Description Conn TP Conn Conn LED TP BSD Description Conn TP Conn Conn LED TP BSD
Decurler Jam Sensor J6-4 TS17 J6-6 J6-5 TS27 10.7 (2) Tray 3 Down /Low Paper Sensor J6-13 TS25 J6-15 J6-14 TS26 7.1A (1) &
Vertical Transport Sensor J6-7 TS19 J6-9 J6-8 TS29 TBD 4
Left Door Intlk Switch J6-10 TS22 J6-12 J6-11 TS23 1.4 Tray 3 Unlock Switch J6-21 TS28 J6-19 --- --- 7.1A (4)
Processor Intlk Bypass J6-13 TS25 J6-15 --- --- 1.4 Tray 3 Width Sensor J6-24 TS21 J6-22 J6-23 TS20 7.1A (2)
Switch Tray 3 Open Sensor J6-27 TS24 J6-25 J6-26 TS30 7.1A (3)
Right Door Intlk Switch J6-21 TS28 J6-19 J6-20 TS18 1.4 Tray 3 Feed Sensor J6-30 TS32 J6-28 J6-29 TS31 TBD
Fuser Jam Sensor J6-24 TS21 J6-22 J6-23 TS20 10.7 (1) Tray 3 Transport Sensor J7-3 TS2 J7-1 J7-2 TS1 TBD
Prefuser Jam Sensor J6-27 TS24 J6-25 J6-26 TS30 10.2 (2) Tray 3 Length Sensor A J7-6 TS4 J7-4 J7-5 TS3 7.1A (2)
Top Cover Intlk Switch J6-30 TS32 J6-28 J6-29 TS31 1.4 Tray 3 Position C Sensor J7-9 TS6 J6-15 J7-8 TS5 7.1A (1)
Top Transport Jam Sensor J7-3 TS2 J7-1 J7-2 TS1 10.7 (2) Tray 3 Position B Sensor J7-12 TS8 J7-13 J7-11 TS7 7.1A (1)
Printer Intlk Sensor J7-6 TS4 J7-4 --- --- 1.3 Tray 3 Position A Sensor J7-15 TS10 J7-13 J7-14 TS9 7.1A (1)
Transfer Blade Sensor J7-9 TS6 J7-7 J7-8 TS5 9.2A Tray 3 Stack Height Sensor J7-18 TS12 J7-16 J7-17 TS11 7.1A (4)
Fuser Interlock Switch J7-12 TS8 J7-10 J7-11 TS7 1.4 Tray 3 Closed Switch J7-21 TS14 J7-19 --- --- 7.1A (3)
Fuser Cam Out Sensor J7-15 TS10 J7-13 J7-14 TS9 P10.3 Tray 3 Length Sensor B J7-24 TS16 J7-22 J7-23 TS15 7.1A (2)
Fuser Cam In Sensor J7-18 TS12 J7-16 J7-17 TS11 P10.3
Sheet at Cross Roll Sensor J7-21 TS14 J7-19 J7-20 TS13 TBD Table 2 PHN DIO PWB #3 Outputs
Registration Transport Sen- J7-24 TS16 J7-22 --- --- TBD Signal Signal Input Input Input
sor Description Conn TP Conn Volt TP BSD
Tray 3 Release Solenoid J3-1 TS42 J3-2 +24 TS36 7.1A (3)
Table 2 PHN DIO PWB #2 Outputs
Tray 3 Feed Clutch J3-3 TS50 J3-4 +24 TS36 TBD
Signal Signal Input Input Tray 3 Drive and Blower Motors J3-7 TS51 J3-6 +5 TS35 TBD
Description Conn TP Input Conn Volt TP BSD
Tray 3 Elevator Motor Down J3-9 TS49 J3-10 +5 TS35 7.1A (4)
24 VDC Enable J2-5 TS53 J2-6 +10 TS33 1.3A (1) Tray 3 Elevator Motor Up J3-11 TS40 J3-12 +5 TS35 7.1A (4)5
Cross Roll Motor On J2-9 TS52 J2-10 +5 TS33 TBD Capacity Bit 3 J3-13 TS48 J3-20 +5 TS35 7.1A (4)
Camming Motor On J2-11 TS43 2TB4-12 +5 TS33 10.3 Capacity Bit 2 J3-15 TS39 J3-20 +5 TS35 7.1A (4)
Right Cross Roll Solenoid J3-1 TS42 J3-2 +24 TS36 TBD Capacity Bit 1 J3-17 TS47 J3-20 +5 TS35 7.1A (4)
Intlk
Capacity Bit 0 J3-19 TS46 J3-20 +5 TS35 7.1A (4)
Left Cross Roll Solenoid J3-3 TS50 J3-4 +24 TS36 TBD
Intlk
Not In Use J3-5 TS41 J3-6 +24 TS35 ---
Agent Pump Solenoid J3-7 TS51 J3-8 +24 TS35 10.4
Duplex Gate Solenoid J3-9 TS49 J3-10 +24 TS48 10.7 (1)
Vertical Transport Clutch J3-11 TS40 J3-12 +24 TS35 TBD8.3
Air Knife Solenoid J3-13 TS48 J3-14 +24 TS35 10.6 (2)

PHN DIO PWB #2 Inputs/Outputs, PHN DIO PWB #3 ?-46 No Product Name Assigned
PHN DIO PWB #6 Inputs/Outputs PHN Registration Servo PWB Inputs/Outputs
Table 1 PHN DIO PWB #6 Inputs Table 1 PHN Registration Servo PWB Inputs
Signal Signal Rtn LED Signal Signal LED Shield
Description Conn TP Conn Comm LED TP BSD Description Conn TP Rtn Conn Conn Conn BSD
Duplex Inverter Position Sensor J7-9 TS6 J7-7 J7-8 TS5 TBD Registration Sync J4-8 TS4 --- --- J4-9 TBD
Duplex Inverter Exit Sensor J7-21 TS14 J7-19 J7-20 TS38 TBD Machine Clock Sensor J4-13 TS7 J4-14 --- J4-15 TBD
Registration Transport Sensor J4-20 TS3 J4-21 J4-19 J4-22 TBD
Table 2 PHN DIO PWB #6 Outputs Registration Transport Servo J4-28 TS8 J4-29 J4-27 --- TBD
Signal Signal Input Input Encoder
Description Conn TP Input Conn Volt TP BSD
Duplex Over Size Nip Release J2-1 TS54 J2-2 +24 TS36 TBD Table 2 PHN Registration Servo PWB Outputs
Solenoid Signal Signal Shield Grd
Not In Use J2-3 TS45 J2-4 --- --- --- Description Conn TP Conn Conn BSD
Transfer 4 Solenoid J2-5 TS53 2TB2-15 +24 --- 9.2A Registration Servo Motor Low J2-1 TS18 --- J4-29 TBD
Transfer 3 Solenoid J2-7 TS44 2TB2-15 +24 --- 9.2A Registration Servo Motor High J2-3 TS16 --- J4-29 TBD
Transfer 2 Solenoid J2-9 TS52 2TB2-15 +24 --- 9.2A Machine Clock to PHN J4-10 TS14 J4-11 --- 4.3
Transfer 1 Solenoid J2-11 TS43 2TB2-15 +24 --- 9.2A Registration Sensor to DIO J4-16 TS9 --- J4-17 TBD
Duplex Inverter Forward Clutch J3-1 TS42 J3-2 +24 TS36 TBD Registration Sync J4-23 TS6 --- J4-24 4.4
Duplex Inverter Reverse Clutch J3-3 TS50 J3-4 +24 TS36 TBD Machine Clock to MIN J4-25 TS14 J4-26 --- 4.3

No Product Name Assigned ?-47 PHN DIO PWB #6 Inputs/Outputs, PHN Registration
Printer Group Fault Tables Purpose And Procedure NOTE: Use the Functional Groups to help identify the group pattern or functional area of the
machine that is malfunctioning.
PURPOSE
The Group Fault Tables are used to determine fault code patterns when a subsystem is over
threshold; and, there is a non-repeatable fault code listed in the SCP Top 15 and/or Shutdown
History Last 50 Faults but, there is no Single Standout fault code.
PROCEDURE
1. This section contains the following Printer Group Fault Tables (GFT):
a. Paper Handling (PHM) - 08-1XX, 10-1XX, 09-1XX fault codes.
b. Feeder Stacker (FSM) 8-XXX, 11-XXX fault codes.
c. Xerographic - 6-XXX, 9-2XX, 9-3XX, 10-2XX fault codes.
d. Run Control - 3 fault codes.
e. Power/All Other Faults - 1, 4, 7-2XX, 8-3XX, 12-2XX fault codes. The order of the
subsystem GFTs in this section is the same as the order of the SCP Fault History
frames.
2. Listed in the Group Fault Tables are fault codes with problems (Components/Adjust-
ments) that can cause that fault (Refer to Group Fault Table Example).
The top of the Group Fault Table lists the functional group associated with specific fault
codes.
3. View the first row of Xs.
4. Determine whether this group of codes closely matches the patterns seen in the Top 15.
a. If it matches, go to the Components/Adjustments column.
b. If a specific component or adjustment is listed, troubleshoot that component or per-
form that adjustment first.
c. If the problem is not resolved, go to the NRD listed in the component/ adjustment
column.
d. If a specific component or adjustment is not listed, go to the referenced NRD.
e. If there is not a match, continue to the next row and again determine whether this
group of codes closely matches the patterns seen in the SCP screens. Continue
evaluating the rows until a pattern can be determined. If a match still cannot be
made, for 1XX jam codes, go to the Fault Code/Sensor Location Diagrams and
check for a common suspected faulty sensor.
Table 1 Group Fault Table Example

Functional Groups Fusing
Paper Handling (PHM) Components

10-101 10-102 10-104 10-201 10-202
Adjustments
Failed fuser relay (10-202 NRD) X X X
Pressure roll needs replacing (10-102 X
NRD)
Compressor problems (10-102 NRD) X X X
Prefuser Transport Problems (10-101 NRD) X X X X
Dirty/failed/fuser thermistor (10-201 NRD) X X X X

Printer Group Fault Tables Purpose And Procedure ?-48 No Product Name Assigned
Paper Handling PHM Group Fault Tables VT- Vertical Transport
Abbreviations:
VT (D)- Vertical Transport (Duplex)
SR- Stacker Relief
Table 1 Paper Handling (PHM) Group Fault Table (1 of 4)

SR
Functional Groups VT Paper Feed Paper Transport Duplex Inverter
TAR
Paper Handling (PHM) Components 8-111 8- 8-112 8- 8-113 8-

8-115 8-XXX 8-XXX 8-XXX 8-XXX 8-144 8-145 8-146 8-147
Adjustments 121 122 123
Q711 (721) Stack Height/Adj (8-111 NRD) X X X X X X
Q714 (724) Down/Low Paper/Adj (8-111 X X X
NRD)
Q812 (821) Stack Relief (8-111 NRD) X X X
Q811 (822) TAR (8-112 NRD) X X X
Q841 Duplex Sheet Sensor (8-145 NRD) X
Q842 Duplex TAR Sensor (8-145 NRD) X X X X
CL841, 842 Inverter Gear Box Assembly X X X X
(8-145 NRD)
Duplex Gate (8-145 NRD) X
SOL851 Nip Release Solenoid (8-145 X
NRD)
Duplex Inverter Turn Roll (8-145 NRD) X X X X
Duplex Inverter Exit Roll (8-144 NRD) X X X X
Q851 Vertical Transport Sensor (8-115 X X X
NRD)
Q861 Registration Transport Sensor (8-
152 NRD)
Q871 Cross Roll Sensor (8-152 NRD)
SOL811 (821) Stack Relief Solenoid (8- X X
111 NRD)
SOL861 (862) Cross Roll Solenoids (8-
151 NRD)
Feed Clutch (Respective Tray) (8-xxx X X X X X X X
NRD for respective tray)
PR stalling/slipping (8-151 NRD)

No Product Name Assigned ?-49 Paper Handling PHM Group Fault Tables
Paper Handling PHM Group Fault Table (2 of 4) VT- Vertical Transport
SR- Stacker Relief

Table 1 (PHM) Group Fault Tables (2 of 4)

Functional Groups VT (D) VT* Reg Transport Duplex Position Sheet Width

8-149 8-151 8-152 8-XXX 8-155 8-170 8-171 8-172 8-173
Q711 (721) Stack Height/Adj (8-111 NRD)
Q714 (724) Down/Low Paper/Adj (8-111
NRD)
Q811 (821) Stack Relief (8-111 NRD)
Q812 (822) TAR (8-112 NRD)
841 Duplex Inverter Position Sensor (8- X X X X
145 NRD)
Q842 Duplex Inverter Exit Sensor (8-145
NRD)
CL841, 842 Inverter Gear Box Assembly X X X X
(8-145 NRD)
Duplex Gate (8-145 NRD) X X X
SOL851 Nip Release Solenoid (8-145 X X
NRD)
Duplex Inverter Turn Roll (8-145 NRD) X X X X
Duplex Inverter Exit Roll (8-144 NRD) X X X X
Q851 Vertical Transport Sensor (8-115 X X X
NRD)
Q861 Registration Transport Sensor (8- X X X X X X
152 NRD)
Q871 Cross Roll Sensor (8-152 NRD) X X X
SOL811 (821) Stack Relief Solenoid (8-
111 NRD)
SOL861 (862) Cross Roll Solenoids (8- X X X X X X X
151 NRD)
Feed Clutch (Respective Tray) (8-xxx
NRD for respective tray)
PR stalling/slipping (also 8-903, 10-102, X X X X
and prints may be smeared.)

Paper Handling PHM Group Fault Table (2 of 4) ?-50 No Product Name Assigned
SR- Stacker Relief


Functional Groups SR TAR VT Paper Feed Paper Transport Duplex Inverter

8-115 8-XXX 8-XXX 8-XXX 8-XXX 8-144 8-145 8-146 8-147
Retard Roll (Tray1/Tray2) (8-111 NRD) X X X
Passive Latch Failure (8-111 NRD) X X X
Skew/Damage X X X X
Auto Latch Adj (Tray 1/Tray 2) (8-111 X X X
NRD)
Elevator Position (BSDs 7.1 A, B, C
(Sheet 2))
Feed Clutch Belt (Tray 1/Tray2) (8-111 X X X
NRD)
Feed Head Setup Series (Tray1/Tray2) X X X
(8-111 NRD)
Feeder Drive Adj (Tray 1/Tray2) (8-111 X X
NRD)
Lock/Latch Assembly (Tray 1/2/3) (8-111 X X X X X
NRD)
Takeaway Shaft Endplay (Tray 1/Tray 2) X X
(8-111 NRD)
PHM Drive Belt Tension (7-238 NRD) X X
Pretransfer Baffle (8-155 NRD)
Reg Transport Upper Baffles (8-152 X
NRD)
dC703 Paper Width Timing (8-302 NRD)

No Product Name Assigned ?-51 Paper Handling PHM Group Fault Table (3 of 4)
SR- Stacker Relief


Functional Groups VT (D) VT* Reg Transport Duplex Position Sheet Width

8-149 8-151 8-152 8-XXX 8-155 8-170 8-171 8-172 8-173
Retard Roll (Tray1/Tray2) (8-111 NRD)
Passive Latch Failure (8-111 NRD)
Skew/Damage (8-131 NRD) X X X X X X
Air System Checkout (Tray 3) (8-131
NRD)
Auto Latch Adj (Tray 1/Tray 2) (8-111
NRD)
Elevator Position (BSDs 7.1 A, B, C
(Sheet 2))
Feed Clutch Belt (Tray 1/Tray2) (8-111
NRD)
Feed Head Setup Series (Tray 1/Tray 2)
(8-111 NRD)
Feeder Drive Adj (Tray 1/Tray2) (8-111
NRD)
Lock/Latch Assembly (Tray 1/2/3) (8-111 X
NRD)
Takeaway Shaft Endplay (Tray 1/Tray 2)
(8-111 NRD)
PHM Drive Belt Tension (7-238 NRD)
Pretransfer Baffle (8-155 NRD) X
Reg Transport Upper Baffles (8-152 X X
NRD)
dC703 Paper Width Timing (8-302 NRD) X X X X X X X

Paper Handling PHM Group Fault Table (4 of 4) ?-52 No Product Name Assigned
Xerographics Group Fault Table (1 of 4)
Table 1 Xerographics Group Fault Table (1 of 4)
Functional Groups Stripping Dicors/Process Control/PR Timing/Environment Developer Cleaner
Xerographic Components 9-101 9- 9-203 9- 9-220 9-

9-201 9-202 9-211 9-212 9-215 9-221 9-320 9-321 9-322 9-323 9-324
ESV (9-203 NRD) X
DSS (9-203 NRD) X X
ACV AT 210/245 (9-202 X X
NRD)
Charge Dicors (9-202 NRD) X X
Toner passed the cleaner (9- X X X X
202 NRD)
Dicors/connectors (OZAC) (9- X X X X
201 NRD)
PreTransfer Lamp (9-203 X X
NRD)
Patch generator (9-203 NRD) X X
Discharge Lamp/PS (9-203 X
NRD)
Light leaks (9-203 NRD) X X A
Stray light (9-203 NRD) X
Electrical noise (Electrical X X X X X X X
Noise Procedure)
Ground Brush (9-201 NRD) X X
Photoreceptor ground (9-203 X X X
NRD)
High dark decay (9-203 NRD) X
Overtoned (9-202 NRD) X X X
Scratched Photoreceptor (9- X X
203 NRD)
Xero setup prep not per- X
formed (9-203 NRD)
ROS (9-203 NRD) X X X

No Product Name Assigned ?-53 Xerographics Group Fault Table (1 of 4
Functional Groups Dicorotrons Process Control
Xerographic Components
9-325 9-326 9-327 9-328 9-329 9-330 9-331 9-332 9-352 9-354 9-355
Adjustments
ESV (9-203 NRD) X X
DSS (9-203 NRD) X
ACV AT 210/245 (9-202 NRD) X X
Charge Dicors (9-202 NRD) X X
Toner passed the cleaner (9-202 X X X X
NRD)
Dicors/connectors (OZAC) (9-201 X X X X X X X X X X
NRD)
PreTransfer Lamp (9-203 NRD) X X X
Patch generator (9-203 NRD) X X X
Discharge Lamp/PS (9-203 NRD) X X X X
Light leaks (9-203 NRD) X X X X
Stray light (9-203 NRD) X
Electrical noise (Electrical Noise X X X X X X X X X X X
Procedure)
Ground Brush (9-201 NRD) X X X
Photoreceptor ground (9-203 NRD) X X X
High dark decay (9-203 NRD) X
Overtoned (9-202 NRD) X X X
Scratched Photoreceptor (9-203 X X X X
NRD)
Xero setup prep not performed (9- X X
203 NRD)
ROS (9-203 NRD) X

Xerographics Group Fault Table (2 of 4) ?-54 No Product Name Assigned
Functional Groups Stripping Dicors/Process Control/PR Timing/Environment Developer Cleaner
Xerographic Components 9-101 9- 9-203 9- 9-220 9-

9-201 9-202 9-211 9-212 9-215 9-221 9-320 9-321 9-322 9-323 9-324
+5 Volts (9-215 NRD) X
+15 Volts (9-201 NRD) X X X X X X
+24 Volts (9-215 NRD) X
MIB PWB (9-203 NRD) X X X
MIN DIO PWB (9-201 NRD) X X X X X X
MIN ADA PWB #1 (9-201 X X X X X X X
NRD)
MIN ADA PWB #2 (9-202 X X X X
NRD)
MIN Stepper PWB (9-203 X
NRD)
MIN AC Remote PWB #1 (9- X
215 NRD)
HVDC PWB (9-101 NRD) X X X X X X
HVAC PWB (9-201 NRD) X X X X X X
HVAC Output Module (9-201 X X X
NRD)
HV Arc (9-101 NRD) X X X X X X X
115 VAC (9-215 NRD) X
Drawer Roll up cable (9-101 X X X X X
NRD)
Developer/toner system (9- X
203 NRD)
Photoreceptor drives (9-220 X
NRD)
Cleaner system (9-203 NRD) X X X X X

No Product Name Assigned ?-55 Xerographics Group Fault Table (3 of 4)
Functional Groups Dicorotrons Process Control
Xerographic Components
9-325 9-326 9-327 9-328 9-329 9-330 9-331 9-332 9-352 9-354 9-355 9-356 9-358
Adjustments
+5 Volts (9-215 NRD) X X X
+15 Volts (9-201 NRD) X X X X X X X X X X X
+24 Volts (9-215 NRD) X X X X
MIB PWB (9-203 NRD) X
MIN DIO PWB (9-201 NRD) X X X
MIN ADA PWB #1 (9-201 NRD) X X X X X
MIN ADA PWB #2 (9-202 NRD) X X X X X X X X X
MIN Stepper PWB (9-203 NRD)
MIN AC Remote PWB #1 (9- X X
215 NRD)
HVDC PWB (9-101 NRD) X X X X X X X X
HVAC PWB (9-201 NRD)
HVAC Output module (9-201 X X X X X
NRD)
HV Arc (9-101 NRD) X X X X X X X X X X
115 VAC (9-215 NRD) X X X
Drawer Roll up cable (9-101
NRD)
Developer/toner system (9-203 X X X X
NRD)
Photoreceptor drives (9-220 X
NRD)
Cleaner system (9-203 NRD) X X X X X

Xerographics Group Fault Table (4 of 4) ?-56 No Product Name Assigned
Run Control Group Fault Tables
Table 1 Chain 1 Fault Codes
Code Description/Reference Procedures
NOTE: View the Top 15 and Shutdown History in [SCP] [Printer Fault History] to determine which 3-xxx fault category to
access in the following Group Fault Table.
3-2xx Communications Faults 1. If the fault code is 3-201, 3-23, 3-204, or 3-205, enter dC303 [EDN]. Decrease the System Bus Delay Interval to one-half of its
present value. Go to the Printer Electrical Noise Procedure, and perform the checks.
2. Check for a poor intermittent electrical connection:
An intermittent fault can also be caused by poor electrical connections. It can be isolated by using the CD that contains the function
which controls the area of the Printer that is producing the problem.
-Pull on the wires and shake the connectors in order to induce the fault.
-Check the wiring and the plug and jack connectors for loose, bent, or corroded pins. Removing the pins without using the extracting
tool is a common cause of loose or failed pins.
-Check for areas where the wiring may be rubbing on other parts and shorting.
-Check for connectors that do not mate properly.
-Check the voltage and ground sources for the proper levels.
-Check the wiring, connectors, and components close to the problem area for any signs of arcing.
3. Check for electrical intermittent noise:
An intermittent fault that is caused by electrical noise usually is one of two types, random or event related. Try to determine the type.
Try to determine the exact mode of operation the system is in when the fault occurs and run the system in that mode.
Completely Random:
-If the fault cannot be isolated to a specific function within the Printer, refer to the Shutdown History information and look for multiple
occurrences of fault codes that may locate the fault within a certain function and use the NRD Fault Code Table to troubleshoot the
fault.
Specific Events Related:
-If the fault has a consistent pattern, try to relate the pattern to events in the Printer, then eliminate as many functions as possible to
isolate a specific event.
-When the cause of the intermittent is isolated to a specific function, go to that functional area and check the grounding straps within
that function.
CAUTION
Do not exchange an EDN Core PWB from one Printer with an EDN Core PWB from another Printer, unless you perform an EDN ini-
tialization (dC323).
System Procedure: Electrical Noise If it is possible, exchange the suspected PWB with another PWB of the same type. If the problem follows the PWB to the new loca-
tion, replace the PWB. If the problem does not follow the PWB, replace the communication bus cables.
BSD 3.1, BSD 3.2, BSD 3.3, BSD 3.3A, 4. If the above procedures were followed and the problem continues, and if the suspected PWB has not yet been replaced. replace
BSD 3.3B, BSD 3.3C, BSD 3.4, BSD the suspected PWB now.
3.4A, BSD 3.4B
3-370 to 3-376 3- Internal Error Faults 1. Check for electrical intermittent noise:
377 3-378
Completely Random:
occurrences of fault codes that may locate the fault within a certain function.

No Product Name Assigned ?-57 Run Control Group Fault Tables
-Use the NRD Fault Code Table to troubleshoot the fault.
-When the cause of the intermittent is isolated to a specific function, go to that function area and check the grounding straps within
that function.
2. Go to the Printer Electrical Noise Procedure, and perform the checks.
3. If the above procedures were followed and the problem continues, and if the suspected PWB has not yet been replaced, then
replace the suspected PWB now.
4. Ensure that the latest release of software is loaded. If the problem continues, look for related fault codes.
NOTE: A related fault code is a fault which is associated with other faults by time stamp.
-Enter [Print/display SIL Log]. View the Printer Shutdown History (last 50 shutdowns) to determine if there are any other fault codes
listed which have occurred within 10 seconds of 3-370 to 3-375, 3-377 and 3-378.
-If there are other fault codes listed within 10 seconds of the 3-370 to 3-375, 3-377 and 3-378 go to the NRD for that fault.
-If there are not any other faults listed within 10 seconds of the 3-370 to 3-375, 3-377 and 3-378 faults, check the Software Release
Document to see if the problem has been identified and if there is a recommended work-around process. If the problem persists, call
the Customer Support Center for additional software support information.
System Procedure: Electrical Noise NOTE: If a software problem is found, a Software Problem Action Report (SPAR) is required.
3-380 to 3-385 3- Download Faults 1. CAUTION: Do not exchange an EDN Core PWB from one Printer with an EDN Core PWB from another Printer.
387
Exchange as follows the suspected generic Core PWB with another generic Core PWB:
-PHN Core PWB and MIN Core PWB (Termination Jumpers, J2, on Norm pin 1)
-PHN Core PWB (Termination Jumper, J2, on Norm pin 1) and FSN Core PWB (Termination Jumper, J2, on Test pin 3)
If the problem follows the Core PWB to the new location, replace the Core PWB.
2. Go to the Printer Electrical Noise Procedure and perform the checks.
3. Check for electrical intermittent noise:
Completely Random:
occurrences of fault codes that may locate the fault within a certain function.
-Use the NRD Fault Code Table to troubleshoot the fault.
System Procedure: Electrical Noise -When the cause of the intermittent is isolated to a specific function, go to that function area and check the grounding straps within
that function.
3-340 3-341 Turnaround Faults Turnaround Tests (3-340 and 3-341) are only executed at Printer power-up. Turnaround Tests may only fail some of the time.
1. Enter dC303 [MIN Turnaround Test].
If there are Signal Names highlighted, go to the respective CD and check the wiring and connectors.
-If there are no Signal Names highlighted, or a problem is not found in the previous step: Check all the wires and connectors that are
listed for the PWB that is failing.
2. Replace the following components in the order given:

Run Control Group Fault Tables ?-58 No Product Name Assigned
-PWB failing the Turnaround Test (MIN ADA PWB #1 for fault 3-340, MIN ADA PWB #2 for fault 3-341) (PL 1.8)
-Associated wire in the +24 VDC harness (Wiring Data)
-Printer LVPS (PL 1.9)
3-362 3-370 to 3- Control Software faults These faults are caused by software errors that may be related to Printer hardware problems.
377
-If there are other fault codes listed within 10 seconds of the 3-xxx fault, go to the NRD for that fault.
-If there are not any other faults listed within 10 seconds of the 3-xxx fault, check the Software Release Document to see if the prob-
lem has been identified and if there is a recommended work-around process.
If the problem persists, call the Customer Support Center for additional software support information.
NOTE: If a software problem is found, a Software Problem Action Report (SPAR) is required.
-378 System Controller TBD
3-390 to 3-393 UIM Rigid Disk Faults TBD

No Product Name Assigned ?-59 Run Control Group Fault Tables
Run Control Group Fault Tables ?-60 No Product Name Assigned
Power/All Other Faults Group Fault Table (1 of 4)
Table 1 Power/All Other Faults (1 of 4)
Functional Groups Interlock Power COM* Machine Clock Reg Sync Reg Xpt
PRINTER FAILURES 1-220 1-121 3-415 3-254 4-201 4-203 4-202 4-210 4-211 4-213 4-212 8-310
24 volt intermittent (open) (1-220 NRD) X X X
24 volt intermittent (short) (1-220 NRD) X X
24 volt missing (open) (1-220 NRD) X
24 volt crowbar (short) (1-220 NRD) X
24 volt enable harness (1-220 NRD) X
LVPS K103 (34V) (1-220 NRD) X
LVPS K104 (24V) (1-220 NRD) X
LVPS Control PWB (1-mod LVPS) (1-220 NRD) X
PHN DIO #2 (1-220 NRD) X X X
PHN DIO #2 ID conn (J5) (1-220 NRD) X X 241, 242
Static Discharge at Fuser grounds (1-220 NRD) X X 242
Power Line surges (3-250 NRD) X
Ass. local Node SCL/Conn(3-415 NRD) X X X
24 v Supply lines to Inductive loads X X

No Product Name Assigned ?-61 Power/All Other Faults Group Fault Table (1 of 4)
Functional Groups Dicorotrons Process Control Fuser Temp Fuser Camming FSN 24V
10-204 10-
11-250 PRINTER FAILURES 9-201 9-212 9-213 9-220 9-32X 10-203 10-205 10-216 12-217 11-250
206
24 volt intermittent (open) (1-220 NRD) X X X X X
24 volt intermittent (short) (1-220 NRD) X X X X
24 volt missing (open) (1-220 NRD) X X X X
24 volt crowbar (short) (1-220 NRD) X X
24 volt enable harness (1-220 NRD) X X X X
LVPS K103 (34V) (1-220 NRD) X X
LVPS K104 (24V) (1-220 NRD) X X X X
LVPS Control PWB (1-mod LVPS) (1-220 NRD) X X X X
PHN DIO #2 (1-220 NRD) X X
PHN DIO #2 ID conn (J5) (1-220 NRD) X X X X
Static Discharge at Fuser grounds (1-220 NRD) X
Power Line surges (3-250 NRD) X
Ass. local Node SCL/Conn(3-415 NRD) X
24 v Supply lines to Inductive loads X X X

Power/All Other Faults Group Fault Table (2 of 4) ?-62 No Product Name Assigned
Functional Groups Interlock Power COM* Machine Clock Reg Sync Reg Xpt
4-201 4-211 4-
PRINTER FAILURES 1-220 1-121 3-415 3-254 4-202 4-210 4-212 8-310
4-203 213
HVAC/HVDC PWBs/harness (3-250 NRD) X MIN PHN
HV ARC (3-250 NRD) X MIN PHN
+ 5 VDC/return (3-415 NRD) X X
PR drawer connector (BSD 4.3 X X
Machine encoder/clock/harness (4-201 NRD) X
Binding drives/driven component (BSD 12.10) X
Main Drive motor (4-201 NRD) X
PR drive coupling misalign/wear (4-201 NRD) X X
PR drive belt (4-201 NRD) X
+15 VDC/return (open/short) (4-201 NRD) X
-15 VDC/return (open/short) (4-201 NRD) X
Intermittent 115 VAC open(4-201 NRD) X
34 VDC/return (open/short) (9-201 NRD)
PR Drawer Roll Up cable

No Product Name Assigned ?-63 Power/All Other Faults Group Fault Table (3 of 4)
Functional Groups Dicorotrons/Process Control Fuser Temp Fuser Camming FSN 24V
10-204 10-
11-250 PRINTER FAILURES 9-201 9-212 9-213 9-220 9-32X 10-203 10-205 10-216 12-217 11-250
206
HVAC/HVDC PWBs/harness (3-250 NRD) X X
HV ARC (3-250 NRD) X X
+5 VDC/return (3-415 NRD) X
PR drawer connector (BSD 4.3) X
Machine encoder/clock/harness (4-201 NRD) X
Binding drives/driven component (BSD 12.10) X
Main Drive motor (4-201 NRD)
PR drive coupling misalign / wear (4-201 NRD) X
PR drive belt (4-201 NRD) X
+15 VDC / return (open/short) (4-201 NRD) X X X X X X
-15 VDC / return (open/short) (4-201 NRD) X X X X X
Intermittent 115 VAC open (4-201 NRD) X X
34 VDC / return (open/short) (9-201 NRD) X X
PR Drawer Roll Up cable X X X

Power/All Other Faults Group Fault Table (4 of 4) ?-64 No Product Name Assigned
Printer Fault Code Tables Purpose And Procedure
PURPOSE
These tables consist of fault code-specific procedures, which are intended to be used when
there is a non-repeatable fault code related problem in the Printer Module and the fault code is
a Single Standout code listed at the top of the SCP Printer Fault History Top 15 Jams/Faults
frame.
PROCEDURE
1. Access the appropriate NRD procedure based on the specific fault code.
2. Perform the steps in the procedure using the BSD as a reference and run the appropriate
stress test identified below.
Stress tests and Functional tests
1. The purpose of a stress test is to induce a failure to occur (if a subsystem is operating
marginally) or verify that a problem has been fixed properly.
2. The purpose of a functional test is to utilize the common/unique hardware to determine,
for example, whether a problem is common to all 3 - 6 paper trays or is unique to only one
(or two) of the trays.
Paper Handling
1. Use normal 20 lb. paper when running the timing interval routines to compare the graphs
with those in the NRD General Information and Diagnostic Hints section.
2. Use light weight or heavy weight paper to induce a failure.
3. Run paper from each of the paper trays to determine whether the problem is unique to a
tray. If it is not, then the problem is probably in one of the paper transport areas.
4. Use Printer dC606 (select Dark Dusting) to run dark lead edge prints to stress the Fuser
area.
Xerographics
1. Run dC910 in High Stress mode.

No Product Name Assigned ?-65 Printer Fault Code Tables
Figure 1 Fault Code Table Example

Printer Fault Code Tables ?-66 No Product Name Assigned
1 NRD Fault Code Tables
1-210 Processor Left Door Interlock Switch S106 was opened in 1. Measure the voltages of the sensor portion of the Processor Left Door Interlock Switch, Processor Right Door
the Print mode. Interlock Switch, or Processor Top Cover Interlock Switch. If a voltage is out of specification, replace the appro-
priate switch (PL 4.3, and PL 4.5).
1-211 Processor Right Door Interlock Switch S105 was opened in 2. Check the following components: - The Switch Connectors for loose installation, - The Switch Actuator
the Print mode. adjustments (PL 4.3), - Door/Cover for proper latching, - Wiring from the Switches to the PHN DIO PWB #2.
1-212 Processor Top Cover Interlock Switch S104 was opened in 3. Check/replace the following components, in the order given: - The appropriate Switch (PL 4.3, and PL 4.5), -
the Print mode. The appropriate Switch Connectors (PL 4.3, and PL 4.5), - PHN DIO PWB #2
1-221 The +24 VDC Sense Circuit of the Processor Interlock Sys-
tem indicates that the Processor Left Door, Right Door, and
Top Cover are closed, but the +5 VDC Status Switches indi-
cate that one of them is open.
Other dCs:330[1-4] BSD 1.4
-211 Go to the 1-210 NRD
-212 Go to the 1-210 NRD
1-214 Fuser Interlock Switch S101 was opened in the Print mode. 1. Measure the voltages of the sensor portion of the Fuser Interlock Switch. If a voltage is out of specification,
replace the switch (PL 10.1).
2. Check the Switch Connector for loose installation, the Switch Actuator alignment, Fuser Drawer for proper
latching, Wiring from the Switch to the PHN DIO PWB #2.
3. Check/replace the following components, in the order given:
The Fuser Interlock Switch (PL 10.1)
The Switch Connector (PL 10.1)
Other dCs: 330[1-4] BSD 1.4 PHN DIO PWB #2
1-220 Occurs when a failure in the Processor interlock system is
detected. The +5 VDC status switches indicate that the Pro-
cessor Left Door, Right door, and Top Cover are closed and
the +24 VDC sense circuit indicates that one of them is
open.
This fault can also occur if one of the following conditions
exists: +24 VDC from the LVPS has been interrupted due to
a P03 fault (Power Interrupt Mode). A short circuit in the +24
volt distribution has caused the LVPS to switch off the +24
VDC Output PWBs. The 24 VDC Enable signal which
enables the +24 VDC sections of the LVPS is lost due to a
hardware failure. The +24 VDC section of the LVPS has
failed.
10-216 Indicates that the Camming Motor MOT1004 failed to oper-
ate when commanded to do so. This fault code will cause
the Printer to enter the Power Interrupt mode and will dis-
able the +24 VDC section of the LVPS. A loss of +24 VDC
from the LVPS will declare a false 10-216 upon Power-Up.

No Product Name Assigned ?-67 1 NRD Fault Code Tables
11-250-1 11-250-2 Occurs when there is a failure detected in the Finisher inter-
lock system. The +5 VDC status switches indicate that all of
the Finisher covers and doors are closed and the +24 VDC
sense circuit indicates that a Finisher cover or door is open.
1. This procedure is divided into two categories:
- Type I, which only requires a [Reset] to clear the fault
- Type 11, which requires a Printer Power Off/Power On to clear the fault.
2. The following problems could cause a Type I ([Reset]) fault:
- A software/ hardware interaction problem. If this is a software/hardware interaction problem, the 1-220 fault will
only be in the [All Other Faults] Top 15 Faults.
- Talk to the operator about how they are clearing the fault. If they are not aware of the fault and have never
pressed [Reset] to recover, then this is a timing problem with an interlock switch and the LVPS. The Printer Shut-
down History [Last 50 Shutdowns] could be filled with 1-220 faults.
There is nothing you can do to correct this condition. The system is detecting and logging these faults, but they
are transparent to the operator.
- If the operator is clearing the fault, continue the procedure.
- Misaligned Interlock Switches; Check the interlock switches for correct adjustment (ADJ 4-1, ADJ 4-3).
3. Use dC 330 to determine if this is the problem. Electrical noise causing PHN DIO #2 to go off line (3-242)
momentarily: This could happen with any of the following noise induced faults:
- 9-32X, 9-21, 203, etc. Go to Printer Electrical Noise Procedure.
- An intermittent open on the Processor Interlock Sense line from the LVPS to PHN DIO#2; Go to BSDs 1.3D
(Figure 4) and BSD 1.4 and check the circuit for intermittent connections.
4. A Type II (PO/PO) fault is caused by an intermittent short in the +24 VDC distribution or an intermittent LVPS.
- Check the LEDs on the LVPS before clearing the fault to determine which LED is on. Use the +24 VDC Distri-
bution Wirenet for the appropriate LED position to troubleshoot the short.
- Check the Printer Fault History for faults which occurred at the same time as 1-220.
- Troubleshoot the wiring of the components associated with those faults first, if they are in the appropriate
wirenet. The following is a list of areas where harnesses have shorted to frame in the past:
- Transfer Assist area
- Thumper Solenoid
- Main DC harness along the Inverter Feeder/Stacker frame where the rear covers may hit or rub.
- Pinch point near the MIN Compressor.
NOTE: Jumpers can be added to the machine that will allow overriding the 24 VDC Enable signal and the 24
VDC Under Voltage Disable signal. If the LVPS senses an over current condition, the DC Output PWB with the
over current condition will shut down its 24 VDC output, regardless of the jumpers. The jumpers will keep the
other 24 VDC sections of the LVPS on while you try to determine the root cause of the problem.
CAUTION: These jumpers are diagnostic tools only. Do not leave them in the machine when you leave the
account.
5. Connect a jumper between TS53 and TS37 on the PHN DIO PWB #2 to override the 24 VDC Enable signal.
6. Connect a jumper between TH15 and TH14 on the LVPS to override the 24 VDC Under Voltage Disable sig-
nal.
7. Run the system with the jumpers installed. When the machine shuts down

1 NRD Fault Code Tables ?-68 No Product Name Assigned
8. First check the LVPS to see which LED is lit. Then check the Queued Faults to see if there are other new
faults occurring at the same time.
Other dCs: 330[1-4] BSD 1.4 9. Use this information along with the Wirenets and BSDs to troubleshoot the problem. Use dC 330 to energize
components in the area of the Printer where you suspect the problem is occurring.
06-367 Insufficient air flow through the Printer Card Cage. 1. Check the Card Cage for obstructions, dirt, or debris that may inhibit air flow through the Card Cage.
2. Check the wiring to the Printer Card Cage Fans for intermittent connections.
3. Replace the following components, in the given order:
- SLB/RDR PWB (PL 1.11)
BSD 1.6 - Card Cage Backplane (PL 1.11)
06-353 ROS LVPS output voltages are out of range. 1. Go to the ROS +36 VDC and -5.2 VDC wirenets (Figure 58) and check the circuits for intermittent short cir-
cuits.
- ROS LVPS (PL 1.11)
- Pixel PWB (PL 1.11)
06-358 +/-15 VDC outputs from the Printer LVPS to the Pixel PWB 1. Go to the +15 VDC Figure 45 and -15 VDC Figure 46 wirenets and check the circuits for intermittent connec-
are out of range. tions.
- Pixel PWB (PL 1.11)

3-201 EDN Core PWB cannot communicate with all other nodes. 1. If the P3-2xx fault only occurs during Print, and the fault code can be reset, go to the Printer Electrical Noise
Procedure. If the problem is not resolved by the Electrical Noise Procedure, proceed to step 2.
3-202 S/R Service Manual description
3-203 MIN Core PWB failed to acknowledge a message from 2. Enter dC303. Decrease the System Bus Delay Interval to one half its current value for System Bus Communi-
another Core PWB. cation faults.
3-204 PHN Core PWB failed to acknowledge a message from - Flex the System Communications Cables while observing the diagnostic routine. If a fault can be induced,
another Core PWB. replace the communications cable related to the failure.
3-205 FSN Core PWB failed to acknowledge a message from - Pull on the wires and shake the connectors to try to induce the fault. If a fault can be induced repair/replace the
another Core PWB. wire or connector related to the failure.
Hints: A particular failure can be identified to be either a Communications or a Power/PWB related type problem.
While monitoring the dC303 routine:
- If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus
Line that do not also go off line, the problem is related to the specific PWB or the power/connections/wiring to
the PWB.
Line that also go off line, the problem is related to a communication/cable/connector to the PWB.
3. Reseat the Communications, Power, and Identification connectors for the suspected PWB.
4. If it is possible, exchange the suspected PWB with another PWB of the same type. If the problem follows the
PWB to the new location, replace the PWB. If the problem does not follow the PWB, replace the communication
bus cables.
System Procedure: Electrical Noise BSD 3.1, BSD 3.2, 5. If all of the above procedures were followed and the problem continues, and if the suspected PWB was not
BSD 3.3, BSD 3.3A, BSD 3.3B, BSD 3.3C, BSD 3.4, BSD yet replaced, replace the suspected PWB now.
3.4A, BSD 3.4B
3-413 MIN Core PWB cannot communicate with any board on its 1. If the 3-413 or 3-2xx fault only occurs during Print, and the fault code can be reset, go to the Printer Electrical
Local Bus. Noise Procedure. If the problem is not resolved by the Electrical Noise Procedure, proceed to step 2.
3-231 MIN Core PWB cannot communicate with the MIN DIO 2. Enter dC303. Increase the Background Checksum Rate for Local Bus Communication faults.
PWB.
3-232 MIN Core PWB cannot communicate with the MIN ADA - Flex the System Communications Cables while observing the diagnostic routine. If a fault can be induced,
PWB #1. replace the communications cable related to the failure.
3-233 MIN Core PWB cannot communicate with the MIN ADA - Pull on the wires and shake the connectors to try to induce the fault. If a fault can be induced repair / replace
PWB #2. the wire or connector related to the failure.
3-234 MIN Core PWB cannot communicate with the SLB/RDR Hints: A particular failure can be identified to be either a Communications or a Power/ PWB related type prob-
PWB. lem.
3. While monitoring the dC303 routine:
the PWB.

bus cables.
3.4A, BSD 3.4B
3-241 PHN Core PWB cannot communicate with the PHN DIO 1. For Fault Code 3-241, check the Fuser ground wiring.
PWB #1.
3-242 PHN Core PWB cannot communicate with the PHN DIO 2. If the 3-415 or 3-2xx fault only occurs during Print, and the fault code can be reset, go to the Printer Electrical
PWB #2. Noise Procedure. If the problem is not resolved by the Electrical Noise Procedure, proceed to step 2.
3-245 PHN Core PWB cannot communicate with the PHN DIO 3. Enter dC303. Increase the Background Checksum Rate for Local Bus Communication faults.
PWB #5.
3-246 PHN Core PWB cannot communicate with the PHN DIO - Flex the System Communications Cables while observing the diagnostic routine. If a fault can be induced,
PWB #6. replace the communications cable related to the failure.
3-247 PHN Core PWB cannot communicate with the PHN Regis- - Pull on the wires and shake the connectors to try to induce the fault. If a fault can be induced repair/replace the
tration Servo PWB. wire or connector related to the failure.
3-414 PHN Core PWB cannot communicate with any board on its Hints: A particular failure can be identified to be either a Communications or a Power/ PWB related type prob-
Local Bus. lem. While monitoring the dC303 routine:
-If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus
the PWB.
bus cables.
6. If all of the above procedures were followed and the problem continues, and if the suspected PWB was not
yet replaced, replace the suspected PWB now.
System Procedure: Electrical Noise BSD 3.1, BSD 3.2, BSD
3.3, BSD 3.3A, BSD 3.3B, BSD 3.3C, BSD 3.4, BSD 3.4A,
BSD 3.4B
3-415 FSN Core PWB cannot communicate with any board on its 1. For Fault Code 3-252, check the grounding for the Finisher Bins Door.
Local Bus.
3-251 FSN Core PWB cannot communicate with the FSN DIO 2. If the 3-415 or 3-2xx fault only occurs during Print, and the fault code can be reset, go to the Printer Electrical
PWB #1. Noise Procedure. If the problem is not resolved by the Electrical Noise Procedure, proceed to step 2.
3-252 FSN Core PWB cannot communicate with the FSN DIO 3. Enter dC303.
PWB #2.
3-253 FSN Core PWB cannot communicate with the FSN DIO - Increase the Background Checksum Rate for Local Bus Communication faults.
PWB #3.
3-254 FSN Core PWB cannot communicate with the Stepper - Flex the System Communications Cables while observing the diagnostic routine. If a fault can be induced,
PWB. replace the communications cable related to the failure.
3-255 FSN DIO #4 is off line - Pull on the wires and shake the connectors to try to induce the fault. If a fault can be induced repair / replace
the wire or connector related to the failure.

3-256 FSN DIO #5 is off line Hints: A particular failure can be identified to be either a Communications or a Power / PWB related type prob-
lem. While monitoring the dC303 routine:
3-257 FSN DIO #6 is off line - If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus
the PWB.
3-258 FSN Stepper PWB #2 is off line - If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus
bus cables.
3.4A, BSD 3.4B
3-412 UIM can not talk to any Node on Local Bus
3-225 UIM Communication problem with Video Engine PWB
3-224 Video Engine PWB Communication problem with the UIM
3-223 CP-IOP is unable to communicate with the Touch Screen
3-221 UIM communication problem with CP-IOP PWB
3-208 EDN HDLC Transmitter/Receiver failed selftest or the Con- 1. This fault is only logged since it detects communication problems with the Controller from the Printer side of
troller failed to acknowledge a message sent by the Printer. the communications link.
RAP: 3-208 2. Enter OSDS and check SIL Log
3-340 MIN ADA PWB #1 Turnaround test has failed. 1. Enter dC303 [MIN Turnaround Test]. Look for a connector which is highlighted and go to the associated CD
and check the wiring for a short circuit to ground.
3-341 MIN ADA PWB #2 Turnaround test has failed. 2. Replace the respective ADA PWB (PL 1.8).
3-342 SLB/RDR PWB to Pixel PWB Turnaround test has failed. 1. Check the PWB and Backplane Connectors for loose, bent, or corroded pins. Reseat the SLB/RDR and the
Pixel PWBs.
3-343 SLB/RDR PWB to ROS Turnaround test has failed. 2. Check the Power and ROS Connectors on the Backplane for loose, bent, or corroded pins.
3-344 SLB/RDR PWB to EPMD PWB Turnaround test has failed. 3. Replace the SLB/RDR PWB and the respective PWB associated with the particular fault code (PL 1.11).
3-345 FSN Stepper #1 turnaround failure
3-346 FSN Stepper #2 turnaround failure
3-361 EDN Core PWB Battery has failed 1. Replace the EDN Core PWB (PL 1.11).
NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to ensure that the NVM Setup Param-
eters are saved.
2. Replace the LVPS (PL 1.9).
3-362 EDN NVM not initialized
3-370 SLB / RDR PWB internal failure. 1. Check the PWB and Backplane Connectors for loose, bent, or corroded pins. Reseat the SLB/RDR PWB.
2. Replace the SLB/RDR PWB (PL 1.11).
3-371 EDN Core PWB internal failure. 1. Perform the Electrical Noise Procedure.
3-372 UIM problem requiring software reset caused by hardware 2. Check the PWB and Backplane Connectors for loose, bent, or corroded pins.
3. Replace the EDN Core PWB (PL 1.11). Note: Perform the EDN Core PWB Replacement Procedure (REP 1-
13) to ensure the NVM Setup Parameters are saved.

4. Enter SCP [Printer Fault History]. Examine the Printer Shutdown History. If there are any other fault codes
listed within 10 seconds of the 3-37x fault, go to the respective NRD Procedure for the other faults listed.
System Procedure: Electrical Noise BSD 3.1
3-373 MIN Core PWB internal failure. 1. Perform the Printer Electrical Noise Procedure.
3-374 PHN Core PWB internal failure. 2. Check the PWB Connectors for loose, bent, or corroded pins.
3-375 FSN Core PWB internal failure. 3. Replace the respective Core PWB MIN Core PWB (PL 1.8) , PHN Core PWB (PL 1.4) , F5N Core PWB (PL
1.16).
NOTE: A suspect Core PWB may be swapped with another Core PWB and if the problem follows the PWB, the
PWB is defective.
listed within 10 seconds of the 3-37x fault, go to the respective NRD Procedure for the other faults listed.
3-377 Video Engine PWB problem requiring software reset 1. Enter CTM. Select [CTM Diagnostics] [Boot Test] [Continuous] [Continue]. Allow 3 cycles to complete. If a
fault code is displayed, go to the respective NRD. Ensure that there is not a disk utilization problem.
3-378 PHN received incorrect software control message. 2. Ensure that the latest release of software is loaded on the machine.
listed within 10 seconds of the 3-300 to 334, 3-360, 3-363, 3-365, 3-378 faults, go to the respective NRD Proce-
dure for the other faults listed.
4. These faults are related to job specific type software problems. Try to recreate the failure by running the same
job that the customer was running when the failure occurred.
If a specific failure mode can be identified, check the Software Release Document to see if the problem has
been identified and if there is a recommended work-around process. If the problem is not identified in the Soft-
ware Release Document, call the Customer Support Center for additional software support information.
System Procedure: Electrical Noise BSD 3.2, BSD 3.3,
BSD 3.4
3-380 UIN Core PWB Boot ROM download failure. 1. Enter SCP [Controller Fault History]. Look for related faults, C16-201 or C16-375. If any of these faults are
also occurring, go to the respective NRD.
3-381 EDN Core PWB download failure. 2. Replace the EDN Core PWB (PL 1.11) NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-
13) to ensure that the NVM Setup Parameters are saved.
3-382 UIM Core PWB download failure 1. Enter SCP [Controller Fault History]. Look for Disk related faults, C17-323, 324, 325, 327, or 328. If any of
these faults are also occurring, go to the respective NRD.
3-383 MIN Core PWB download failure. 2. Replace the respective Core PWB (PL 1.8) , PHN Core PWB (PL 1.4) , FSN Core PWB (PL 1.16).
3-384 PHN Core PWB download failure.
3-385 FSN Core PWB download failure. NOTE: A suspect Core PWB may be swapped with another Core PWB and if the problem follows the PWB, the
PWB is defective.
3-387 Video Engine PWB download failure.
3-390 UIM Core PWB Rigid Disk access fault.
3-391 UIM Core PWB Rigid Disk access fault
3-393 Video Engine Rigid Disk access fault
3-392 Video Engine detected a Rigid Disk failure.
3-401 EDN System Bus Communication failure
3-402 EDN Communication problem with the UIM
3-403 System Communication problem with the MIN
3-404 System Communication problem with the PHN Transient

3-405 System Communication problem with the FSN
3-461 EDN problem requiring software reset caused by noise. 1. Perform the Specific Related Checks above for the associated fault, then continue with this procedure.
3-462 UMI problem requiring software reset caused by noise. 2. Ensure that the latest release of software is loaded on the machine.
3-463 MIN problem requiring software reset caused by noise 3. Enter SCP [Printer Fault History]. Examine the Printer Shutdown History. If there are any other fault codes
listed within 10 seconds of the 334, 3-360, 3-363, 3-365, 3-378 faults, go to the respective NRD Procedure for
the other faults listed.
3-464 PHN problem requiring software reset caused by noise 4. These faults are related to job specific type software problems. Try to recreate the failure by running the same
job that the customer was running when the failure occurred.
3-465 FSN problem requiring software reset caused by noise If a specific failure mode can be identified, check the Software Release Document to see if the problem has
been identified and if there is a recommended work-around process. If the problem is not identified in the Soft-
ware Release Document, call the Customer Support Center for additional software information.
3-471 EDN problem requiring software reset (Software)
3-472 UIM problem requiring software reset (Software)
3-473 MIN problem requiring software reset (Software)
3-474 PHN problem requiring software reset (Software)
3-475 FSN problem requiring software reset (Software)
3-480 Too many segments in the queue
3-482 EDN received an unexpected stacker delivery signal
3-483 Stacker delivery routine made 2 requests for a segment
3-485 ESS print response late or not received by IOT
3-492 MIN Main Drive enable response timeout
3-494 PHN received a bad segment from the job manager

4-201 Indicates a Main Drive acceleration fault at Start Print. 1. Check the wiring from the Machine Clock Sensor Q401 to the PHN Registration Servo PWB for intermittent
connections.
4-202 Indicates a Main Drive acceleration fault (too many clock 2. Check the wiring from the PHN Registration Servo PWB to the MIN Core PWB for intermittent connections.
counts).
4-203 Indicates a Main Drive acceleration fault (too few clock 3. Check the wiring from the PHN Registration Servo PWB to the PHN Core PWB for intermittent connections.
counts).
4-210 Indicates that the Machine Clock Signal is missing at the 4. Check the following components:
PHN Core PWB.
- Photoreceptor drive components for binding (PL 4.17
- Main drive components for binding (PL 4.18)
5. Replace the following components, in the order given:
- Machine Clock Sensor Q401 (PL 9.3)
- PHN Registration Servo PWB (PL 1.5)
- PHN Core PWB (PL 1.5)
- MIN Core PWB (PL 1.5)
BSD 4.3
4-202 Go to the 4-201 NRD.
4-203 Go to the 4-201 NRD.
-210 Go to the 4-201 NRD.
4-211 Indicates that the Registration Sync Signal is missing at the 1. Check the wiring from the MIN DIO PWB #1 to the PHN Registration Servo PWB for intermittent connections.
PHN Core PWB.
4-212 Indicates that the Registration Sync Signal is missing at the 2. Check the wiring from the PHN Registration Servo PWB to the PHN Core PWB for intermittent connections.
PHN Core PWB.
4-213 Indicates that the Registration Sync Signal arrived unex- 3. Go to Printer Electrical Noise Procedure and check for electrical noise.
pectedly at the PHN Core PWB.
4. Replace the following components, in the order given:
- MIN DIO PWB #1 (PL 1.8)
- PHN Registration Servo PWB (PL 1.5)
- PHN Core PWB (PL 1.8)
Other dCs:330[1-4] BSD 4.4
4-220 Indicates that the three phases of AC power entering the 1. Check the wiring from the 3 Phase Detection PWB to the MIN DIO PWB for intermittent connections.
machine are not connected in the correct configuration (50
Hz only).
- 3 Phase Detection PWB (PL 1.1)
- MIN DIO PWB (PL 1.8)
BSD 1.7

6-250/251 6-250 indicates that a Continue of Scan signal was missing 1. Enter SCP [Printer Fault History]. If Fault Codes 6-350, 6-354, 6-355, 6-356, 6-359 or 6-365 are occurring at
6-251 indicates that a End of Scan signal was missing the same timestamp as the 6-250 and/or the 6-251 faults, go to the appropriate NRD associated with the other
fault codes first.
2. Depending on the frequency of the problem, dC330 [6] may indicate when the problem has been repaired.
Enter dC330 [6]. Select [Laser Write]. Press the Continue button. The SOS Missing and EOS Missing Input sig-
nals should toggle from L to H. Leave [Laser Write] energized for a few minutes, and check the input counters
for an increase greater than 1. An increase above 1 indicates a loss of the SOS and/or EOS Missing signals.
- Video cables for damage or poor connections
- Wires and connectors to the ROS LVPS for damage or poor connections
3. Enter dC910 [High Stress]. Select [Continue]. If any of the Dicorotrons are arcing, replace it (PL 9.10 and PL
9.11).
4. Check for electrical noise due to arcing.
For 6-250 faults only:
- SOS PWB (PL 6.1)
For 6-251 faults only:
- SOS PWB (PL 6.1)
For 6-250 and/or P6-251 faults:
- Pixel Clock PWB (PL 1.11)
- ROS Assembly (PL 6.1)
System Procedure: Electrical Noise BSD 6.7 (Sheet 2)
6-252/253 Indicates that the an extra SOS or EOS signal was gener- 1. Enter SCP [Fault History]. If fault codes 6-350, 6-354, 6-355, 6-356, 6-359 or 6-365 are occurring at the same
ated within the nominal timing for SOS or EOS timestamp as the 6-252 and/or 6-253 faults, go to the appropriate NRD associated with the other fault codes
first.
- Video cables for damage or poor connections
- Wires and connectors to the ROS LVPS for damage or poor connections
3. Enter dC910 [High Stress]. Select [Continue]. If any of the Dicorotrons are arcing, replace it (PL 9.10 and PL
9.11).
For 6-252 fault only:
- SOS PWB (PL 6.1)
For 6-253 fault only:
- EOS PWB (PL 6.1)
For 6-252 and/or 6-253 faults:

6-351 Indicates that the Voltage Controlled Oscillator was out of 1. Enter SCP [Printer Fault History]. If Fault Codes 6-250 and/or 6-251 are occurring at the same timestamp as
range the 6-352 faults, go to the 6-250/251 NRD first.
Enter dC330 [6]. Select [Laser Write]. Press the Continue button. The Voltage Controlled Oscillator Input signal
should toggle from L to H. Leave [Laser Write] energized for a few minutes and check the input counter for an
increase greater than 1. An increase above 1 indicates a loss of the Voltage Controlled Oscillator Input signal.
- Polygon Motor (PL 6.1)
6-352 Indicates that the SLB/RDR Byte Clock signal was missing 1. Enter SCP [Printer Fault History]. If Fault Codes 6-250 and/or 6-251 are occurring at the same timestamp as
the 6-351 faults, go to the 6-250/251 NRD first.
Enter dC330 [6]. Select [Laser Write]. Press the Continue button. The SLB/RDR Byte Clock signal should toggle
from L to H. Leave [Laser Write] energized for a few minutes, & check the input counter for an increase greater
than 1. An increase above 1 indicates a loss of the SLB/RDR Byte Clock signal.
System Procedure: Electrical Noise BSD 6.7 (Sheet 3) - SLB/RDR PWB (PL 1.11)
6-353 Indicates that one or more of the voltages supplied by the Remove the following in the order given. Monitor for the restoration of the missing voltage. Replace the compo-
ROS LVPS is missing. The absence of the voltages is nent which dragged down the missing voltage.
detected by monitoring LVPS MON is on (L), a 6-353 Fault is • Pixel PWB (PL 1.11)
declared. • SLB/RDR PWB (PL 1.11)
• ROS LVPS PWB (PL 1.11)
• The cable between J114 on the Card Cage to the ROS
• Various ROS PWBs (PL 6.1)
• The Backplane (PL 1.11)
6-354 Indicates that one or more of the Polygon Motor Phase(s) 1. Depending on the frequency of the problem, dC330 [6] may indicate when the problem has been repaired.
were missing Enter dC330 [6]. Check the Motor Driver Output signal counter for a few minutes. An increase above 0 indicates
a loss of the Motor Driver Output signal.
- Polygon Motor (PL 6.1)
- CRCM PWB (PL 6.1)
6-355 Indicates that the +5 VDC was missing on the SOS PWB. 1. Enter SCP [Printer Fault History]. If the two fault codes are occurring, check the circuit from P/J205-15 & 7 on
the Distribution PWB back towards the +5 VDC source voltage. If only one fault code is occurring, continue with
step 2.

2. For 6-355 faults, check the circuit from TH10 on the Distribution PWB thru the SOS PWB to the SLB/RDR
PWB. If no problem is found, replace the following components in the order given:
- SOS PWB (PL 6.1)
- CRCM PWB (PL 6.1)
3. Check the Ground wire on the Metering Roll for proper connection.
6-356 Indicates that the +5 VDC was missing on the EOS PWB. 4. For 6-356 faults, check the circuit from TH10 on the Distribution PWB thru the EOS PWB to the SLB/RDR
PWB. If no problem is found, replace the following components in the order given:
- EOS PWB (PL 6.1)
- CRCM PWB (PL 6.1)
6-358 TBD
6-364 Indicates that the Scan Beam Intensity was out of range 1. Enter SCP [Printer Fault History]. If Fault Codes 6-250 and/or 6-251 are occurring at the same timestamp as
the 6-364 faults, go to the 6-250/251 NRD first.
2. Check for electrical noise due to arcing.
3. Perform the following steps to check for a possible Beam 1 to Beam 2 mismatch at an Exposure Intensity set
to 0:
- Enter dC606 ROS Intensity Test and set the Exposure Value to 0.
- Read and record the values for SOS and EOS with the Exposure Value at 0.
- If the difference between Beam 1 and Beam 2 values is greater than 1 VDC, perform the actions in Step 6.
4. Perform the following steps to check the for a possible Beam 1 to Beam 2 mismatch at Exposure Intensity set
to 128:
- Enter dC606 ROS Intensity Test and set the Exposure Intensity to 128.
- Evaluate the difference between the SOS and EOS values.
5. Perform the following steps to check the for a possible Beam 1 to Beam 2 mismatch at Exposure Intensity set
to 255:
- Enter dC606 ROS Intensity Test and set the Exposure Intensity to 255.
- Evaluate the difference between the SOS and EOS values.
- EOS PWB (PL 6.1)
- SOS PWB (PL 6.1)
6-366 Polygon Motor fault (other than AC output) (IOT) TBD
6-367 Card Cage Overtemp TBD

6-701 Fault Code 6-701 is used to troubleshoot ROS related prob- 1. Replace the following in the order given:
lems that can cause non-repeatable Xerographic faults
- MIN ADA PWB #2 (PL 1.8)
- MIB PWB (PL 1.8)

7-211 Indicates that the Tray 1 Elevator was late to actuate the 1. Measure the voltages of the Stack Height Sensor (PL 7.1) and Down/Low Paper Sensor (PL 7.4). If a voltage
Stack Height Sensor Q711 or indexed on more than 2 con- is out of specification, replace the appropriate sensor.
secutive feeds
7-212 Indicates that the Tray 1 Elevator was late to the Tray 1 2. Check the resistance of the Interlock Switch (PL 7.9), Elevator Up Limit Switch (PL 7.6), and Elevator Down
Down/Low Paper Switch Q714 Limit Switch (PL 7.4). Replace as required.
3. Ensure that tag 171 is installed.
4. The Elevator Motor may be overheating. After the motor cools, the overheat sensor automatically will reset,
and the motor will work properly until it overheats again. Enter dC330 [7B]. Drive the Elevator Motor up and
down to check if it overheats. Also check for binding, wear or damage to the motor and the drives.
5. Check the following components/adjustments:
- Passive Latches for damage and for holding the tray in the locked position during operation.
- Lock Arm for binding on the frame pin, wear or damage
- Feed Head for binding and for seized bearings or harness interference
- Interlock Switch Actuator for damage, binding or wear
- Interlock Switch Actuator Spring for bends or breaks
- Interlock Switch Bracket for bends or looseness
- Drive belts or pulleys for damage
- Drive belt tensions
- Elevator for binding, wear or damage
- Lock Assembly adjustment (ADJ 7-10)
- Paper Feed Setup Series adjustment (ADJ 7-9)
- Elevator Drive Belt Tension adjustment (ADJ 7-11)
BSD 7.1B (Sheet 1, 3)
7-214 Indicates that the Tray 1 Interlock Switch S710 opened in 1. Check the resistance of the Interlock Switch (PL 7.9). Replace as required.
print
- Passive Latches for damage and for holding the tray in the locked position during operation
Other dCs: 330 [7B] BSD 7.1B (Sheet 1)
7-221 Indicates that the Tray 2 Elevator was late to actuate the 1. Measure the voltages of the Stack Height Sensor (PL 7.1) and Down/Low Paper Sensor (PL 7.4). If a voltage
Stack Height Sensor Q721 or indexed on more than 2 con- is out of specification, replace the appropriate sensor.
secutive feeds.

7-222 Indicates that the Tray 2 Elevator was late to the Tray 2 2. Check the resistance of the Interlock Switch (PL 7.9), Elevator Up Limit Switch (PL 7.6), and Elevator Down
Down/Low Paper Switch Q724 Limit Switch (PL 7.4). Replace as required.
4 . The Elevator Motor may be overheating. After the motor cools, the overheat sensor automatically will reset,
and the motor will work properly until it overheats again. Enter dC330 [7B]. Drive the Elevator Motor up and
down to check if it overheats. Also check for binding, wear, or damage to the motor and the drives.
- Feed Head for binding and for seized bearings or harness interference
BSD 7.1C (Sheet 1, 3)
7-224 Indicates that the Tray 2 Interlock Switch S720 opened in 1. Check the resistance of the Interlock Switch (PL 7.9). Replace as required.
print
Other dCs: 330 [7B] BSD 7.1C (SHEET1)
7-241-1 7-241-2 Indicates that the Tray 3/4 Elevator failed to move up to the 1. Measure the voltages of the Stack Height Sensor (PL 7.16), Down/Low Paper Sensor (PL 7.17), If a voltage is
feed position out of specification, replace the appropriate sensor.
2. Check the resistance of the Closed Switch (PL 7.14) and Overtravel Switch (PL 7.17). Replace as required.
7-244-1 724-2 Indicates that the Tray 3/4 Elevator failed to move down to 3. The Elevator Motor may be overheating. After the motor cools, the overheat sensor automatically will reset,
the Position A Sensor Q732 or the Tray 3 Down Sensor and the motor will work properly until it overheats again. Enter dC330 [7A]. Drive the Elevator Motor up and
Q737 was not made down to check if it overheats. Also check for binding, wear, or damage to the motor and the drives.
- Stack Height Sensor for proper mounting, bent or broken actuator
- Switch actuators for damage, binding or wear

- Lead Screw Bearings for seizure
- Stack Height adjustment (ADJ 7-31)
- Paper Plate adjustment (ADJ 7-31)
- Low Paper Sensor adjustment (ADJ 7-33)
BSD 7.1A (Sheet 1, 4)
7-248-1 7-248-2 Indicates that the Tray 3/4 Closed Switch S730 detected the 1. Check the resistance of the Closed Switch (PL 7.14). Replace as required.
tray unlatched in print
- Latch Arm for binding, wear or damage
- Release solenoid for burrs, wear or binding
- Tray 3 Latch Assembly adjustment (ADJ 7-32)
3. If the problem continues, go to the 7-241 NRD. If no problem is found, return here and continue.
4. Replace the Tray 3 Release Solenoid (PL 7.17)
Other dCs: 330 [7A] BSD 7.1A (Sheet 3)
7-250-1 7-250-2 Indicates that the Tray 3/4 Vertical Transport Door Interlock TBD
Opened in print
7-701 Used to troubleshoot non-repeatable Tray 1 Capacity Board 1. Check the resistance of the Tray Unlock Switch (PL 7.3). Replace as required.
problems
- Tray Unlock Switch for binding in the bezel
- Tray Unlock button for damage or wear
- Wire harness and connectors for pinched wires, or damage
3. Replace the Tray 1 Capacity PWB (PL 7.3).
Other dCs: 330 [7B] BSD 7.1B (Sheet 4)
7-702 Used to troubleshoot non-repeatable Tray 2 Capacity Board 1. Check the resistance of the Tray Unlock Switch (PL 7.3). Replace as required.
problems
- Wire harness and connectors for pinched wires, or damage
Other dCs: 330 [7B] BSD 7.1C (Sheet 4)
7-703 Used to troubleshoot non-repeatable Tray 3 Capacity Board 1. Measure the voltages of the HCT Position Sensor. If a voltage is out of specification, replace the sensor (PL
problems 7.17).
2. Check the resistance of the Tray Unlock Switch (PL 7.15). Replace as required.

- Wire harness and connectors for pinched wires or damage
Other dCs: 330 [7A] BSD 7.1A (Sheet 5)
7-704 Used to troubleshoot non-repeatable Tray 3 Unlatch prob- 1. Enter dC330 [7A]. Select [Tray 3 Release]. While observing the Release Solenoid, alternately press the Con-
lems tinue and Stop buttons. Check for binding or interference.
Release Solenoid, plunger, and linkage for damage, binding, wear or interference
Latch foot falls down and rests on the top of the pin
HCT Latch assembly adjustment (ADJ 7-32)
BSD 7.1A (Sheet 3)

8-100 8-101 Indicates that the Lead edge jam at Tray 3/4 lower Pre-Reg- 1. Inspect the Q850 and Q854 sensors for damage, dirt or obstructions.
istration Transport Sensor
2. Check to paper damage or dog ears. If present, go to the high capacity feeders, NRD 8-193.
3. Check all drive rolls, belts, and belt tensions.
4. Check the Preregistration idler roll clearance adj. (ADJ 8-11).
5. Check the FS/M to Printer alignment.
6. Ensure that the 8-100, 8-101 RAP has been followed.
8-102 8-103 Indicates that the Trail edge jam at Tray 3/4 Lower Pre-Reg- 1. Inspect the Q850 sensor for damage, dirt or obstructions.
istration Sensor.
2. Check for paper damage or dog-ears. If present faults are mostly induced by the high capacity feeders. Go to
8-705, Paper Damage RAP.
3. Check all drive rolls, pulleys, belts, and belt tensions.
4. Check the Preregistration Idler Rail clearance adjustment (ADJ 8-11).
5. Check the FSM to Printer Alignment.
6. Ensure that 8-102, 8-103 has been followed
8-104 8-105 Indicates that the Tray 3 or 4 Lead Edge was late to the 1. Measure the voltages of the Cross Roll (PL 8.6) and Registration Transport (PL 8.4) Sensor. If a voltage is out
Registration Transport Sensor Q8 61 from the Tray 3 or 4 of specification, replace the appropriate Sensor
Transport Sensor Q832 (A3/A4)
2. Ensure that tag 97 is installed. Check the Upper Left and Right Baffle adjustment (ADJ 8-11).
3. Enter dC330 [8] [Cycle Outputs], select [Cross Roll Left], and press the Continue. If the solenoid becomes
sluggish or intermittent as it warms up. replace it (PL 8.3). Perform the same checks on the [Cross Roll Right]
solenoid (PL 8.3).
4. Enter SCP [Printer Fault History]. If 8-180, 8-182 or 8-904 faults are occurring, go to the 8-182 NRD and
perform the checks indicated. These faults indicate a possible Tray 3 multifeed problem. go to 8-196 NRD. If 8-
193 fault occurs check the 8-193 NRD, no problem is found, return here and continue.
5. Enter dC726 [16. 8-153], [Timing Graphs], and press Continue. If there are feed variations or operation is
out of specified range, check the following components/adjustments:
- Paper stock skewing on the registration transport
- Paper stock catching on the registration edge
- Cross roll idler lift fingers for binding and correct position
- Tray 3 or 4 transport idler nips for proper seating
6. If the lead edge of the sheets of paper are catching or skewing on the lower turn baffles, install Finisher tag
61.
7. Check the level of the IF/S to PHM
8. If the sheets are snagging on the registration edge entrance chute or are skewing in the paper path, go to the
8-706 NRD PHM Misregistration and Skew Checkout. If no problem is found, return here and continue.
9. If jam occurs only in 3-pitch mode check the Tray 3 oversize nip release solenoid (Sol852) adjustment (ADJ 8-
13)
- Registration Transport/components and turn Baffle are installed correctly and not damaged worn, or binding
(PL 8.3)

- Lower Registration Baffle for proper seating
- Upper Tight Baffle for bows or damage
- Obstructions in the paper path (i.e., hardware, wires, paper, etc.)
- Turn Baffle for bows or damage
- Left and Right Cross Roll assemblies for wear, damage, or binding (PL 8.7)
- Cross Roll assembly drive rolls for damage, debonding, or flat spots (PL 8.7)
- Cross Roll assemblies and Drives for worn belts, binding, or damage (PL 8.7)
- Registration Edge for damage, grooves, and proper seating (PL 8.4)
- Servo Drive Rolls and idlers for wear, damage, or binding (PL 8.4)
- Preregistration Jam clearance baffle for damage and proper seating adjustment (ADJ 8-10)
- IF/S Preregistration baffle adjustment (ADJ 7-10)
- IF/S Preregistration idler roller clearance adjustment (ADJ 8-11)
- IF/S Preregistration drive roll for wear or contamination
- IF/S Preregistration idler spring for damage, stretching or missing
- Tray 3 or 4 Transport and components for wear, damage, or binding
- Tray 3 or 4 Blower O-ring for wear, damage or stretch
- Tray 3 or 4 Lock assembly adjustment (ADJ 7-10)
11. There is a possibility that the fault is related to components in the Registration Controller Servo area. Go to
the 8-302 NRD procedure, If no problem is found, return here and continue.
Other dCs:727 - Left and right Cross Roll assemblies (PL 8.4)
BSD 8.4 - Registration Edge (PL 8.4)
8-111 Indicates the Tray 1 LE was late to the Stack Relief Sensor 1. Measure the voltages of the Stack Height Sensor (PL 7.1 Down/Low Paper Sensor (PL 7.4), and Stack Relief
Q812 Sensor (PL 7.3). If a voltage is out of specification, replace the appropriate sensor.
2. Enter dC726 [1. 8-112] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a
specified range, check the following components/adjustments:
- Feed Clutch for wear, binding, or slippage
- Feed Belt Pulley or Feed Belt Idler one way clutch for binding
- Drive belts and idlers that are loose, worn, or damaged
- Tube Shaft & Feeder Drive Coupling for binding or wear of the D shaft & drive
- Takeaway Shaft Endplay adjustment (ADJ 7-1)
- Tray 1 Feeder Drive adjustment (ADJ 4-20)
- Feed Clutch Belt adjustment (ADJ 7-0)
3. If available, run 110 lb stock thru the system as a stress test.
4. Check/perform the following adjustments:
- Paper Feed Setup Series (ADJ 7-9)
- Length Guide Tension (ADJ 7-5)
- Tray Down/Low Paper Sensor (ADJ 7-2)
5. Perform the 8-701 NRD Friction Retard Checkout. If no problem is found, return here and continue.
6. Replace the Feed Clutch (PL 7.12)

Other dCs: 727 BSD: TBD
8-112 Indicates that the Tray 1 LE was late to the Takeaway Roll 1. Measure the voltages of the Takeaway Roll Sensor (PL 7.13) and Stack Relief Sensor (PL 7.13). If a voltage
Sensor Q811 is out of specification, replace the appropriate sensor.
- Feed Clutch for wear, binding, or slippage (PL 7.12)
- Feed Belt Pulley or Idler One-Way Clutch for binding
- Takeaway Roll Idler one way clutch for binding or slippage
3. If available, run 110 lb. stock thru the system as a stress test.
- Lock Assembly (ADJ 7-10)
- Feed Clutch Belt (ADJ 7-0)
8-113 Indicates that the Tray 1 TE was late off the Takeaway Roll 1. Measure the voltages of the Takeaway Roll Sensor (PL 7.13) and Stack Relief Sensor (PL 7.13). If a voltage
2. Enter dC726 [2.8-113] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a
- Takeaway Roll Drive and Idler for binding, wear or contamination
- Vertical Transport Drive Coupling and Drive Coupling Insert for wear or damage (PL 8.1)
- Nip missing in the Takeaway Roll area
- Feed Belt for wear or contamination
- Idler Springs for wear or out of position
- Vertical Transport for slippage, binding or wear
- Magnetic Strips for proper position or contamination
- Urethane sleeve for bonding to Takeaway Roll (PL 7.13)
- Takeaway Drive Roll area for wear, contamination, or obstructions (PL 7.13)

- PHM Drive Belt Tension adjustment (ADJ 4-17)
- Vertical Transport Drive Pulley and Belt for wear, damage or slippage (PL 8.1)
- Vertical Transport for binding & wear (PL 8.1)
- Vertical Transport Belts (PL 8.1)
- Feeder Assembly (PL 7.10)
6. Perform the 8-701 NRD Friction Retard Checkout.
Other dCs: 330 [8], 727 BSD: TBD
8-115 Indicates that the Tray 1 LE was late to the Vertical Trans- 1. Measure the voltages Vertical Transport Sensor. If a voltage is out of specification, replace the sensor (PL
port Sensor Q851 8.1).
- Takeaway Drive Roll area for wear, contamination, or obstructions (PL)
- Vertical Transport Clutch (PL 4.18)
Other dCs: 330 [8], 727 BSD: TBD Takeaway Roll (PL 7.13)
8-121 Indicates that the Tray 2 LE was late to the Stack Relief 1. Measure the voltages of the Stack Height Sensor (PL 7.1), Down/Low Paper Sensor (PL 7.4), and Stack
Sensor Q822 Relief Sensor (PL 7.13). If a voltage is out of specification, replace the appropriate sensor.
2. If the tray is opening during print, install Tag 171.
- Feed Clutch for wear, binding, or slippage
- Feed Belt Pulley or Feed Belt Idler one way clutch for binding

4. If available, run 110 lb stock thru the system as a stress test.
8-122 Indicates that the Tray 2 TE was late to the Takeaway Roll 1. Measure the voltages of the Takeaway Roll Sensor (PL 7.13) and Stack Relief Sensor (PL 7.13). If a voltage
- Feed Belt Pulley or Idler One-Way Clutch for binding
- Takeaway Roll Idler one way clutch for binding or slippage
8-123 Indicates that the Tray 2 TE was late off the Takeaway Roll 1. Measure the voltages of the Takeaway Roll Sensor (PL 7.13) and Stack Relief Sensor (PL 7.13). If a voltage
2. Enter dC726 [8-123] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a
- Nip missing in the Takeaway Roll area
- Feed Belt for wear or contamination
- Idler Springs for wear or out of position

- Urethane sleeve for bonding to Takeaway Roll (PL 7.10)
- Takeaway Drive Roll area for wear, contamination, or obstructions (PL 7.10 )
- Vertical Transport Drive Pulley and Belt for wear, damage or slippage (PL 8.1)
5. Replace the Feeder Assembly (PL 7.10)
6. Perform the 8-701 NRD Friction Retard Checkout.
8-144 Indicates that the Duplex LE was late to Vertical Transport 1. Measure the voltages of the Duplex TAR Sensor (PL 10.19) and Vertical Transport Sensor (PL 8.1). If a volt-
Sensor Q851 age is out of specification, replace the appropriate sensor.
2. Enter SCP [Printer Fault History]. If 8-146 faults are indicated, the problem is most likely in the Duplex area. If
8-146 faults are not indicated or Tray 1 and 2 faults are indicated, the problem is most likely in the Vertical Trans-
port area. If 8-145 and 8-146 faults are indicated, check the input drives to the Duplex Inverter Assembly.
- Flexible Coupling and D Shaft for damage (PL 8.1)
- Drive Coupling, Coupling Insert, and Drive Pulley for damage (PL 8.1)
- Upper and Lower Shafts for binding
- Input drives to the Duplex Inverter Assembly
- Belts, Shafts and Bearings for damage, slippage or wear
- Vertical Transport Clutch drive belt and idler for damage or wear
- Vertical Transport Clutch for slippage, wear or damage (PL 4.18)
- Vertical Transport Lower Shaft & Belts for damage or wear
- Magnetic Strips for the correct operating position and damage
5. If the output prints are damaged, go to the 8-705 NRD PHM Print Damage Checkout. If no problem is found,
return here and continue.
6. Perform the 8-156 and 8-145 NRDs for other possible causes of this problem. If no problem is found, return
here and continue.
7. Replace the Vertical Transport Clutch (PL 4.18)
Other dCs: 330 [8], 726, 727 BSD: TBD

8-145 Indicates that the Duplex LE was late to the Duplex TAR 1. Enter SCP [Printer Fault History]. If 8-171 faults are indicated, go to the 8-171 NRD. If no problem is found,
Sensor Q842 (A4) return here and continue. If 8-144 and 8-146 faults are indicated, check the input drives to the Duplex Inverter
Assembly.
2. Measure the voltages of the Duplex Inverter Exit Sensor (PL 10.19). If a voltage is out of specification, replace
the sensor.
3. Enter dC726 [29. 8-145 & 147] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is
- Dual Drive Rolls and Shafts for wear, contamination, or binding (PL 10.19)
- Forward Reverse Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20)
- Exit Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20)
- Inverter Exit Sensor actuator for damage or breakage
- Foil tape under the Inverter Position Sensor on the lower baffle for dirt, damage or missing
- Inverter Drag Brake for wear, binding, or free spinning (PL 10.22)
- One Way Clutch for slippage or binding (PL 10.22)
- Jam Clearance Baffles for proper latching
- Input drives to the Duplex Inverter Assembly and Inverter Gear Box Assembly
- Inverter Drive Coupling for wear or damage (PL)
- Duplex Gate Fingers (PL 10.21) for interference, bends or damage
- Torsion Springs (PL 10.21) for damage or stretch
- 5. Check/adjust the Duplex Timing (10-14). Perform this check several times, & if the check is varying by
greater than 10mm, replace the Inverter Gear Box Assembly (PL 10.22).
- One Way Clutch and Dual Drive Roll Shaft (PL 10.22, PL 10.19)
- Inverter Drag Brake/Idler Bracket (PL 10.22)
Other dCs: 330 [8], 727 BSD: TBD Inverter Gear Box Assembly (PL 10.22)
8-146 Indicates that the Duplex TE was late off the Duplex TAR 1. Measure the voltages of the Duplex Inverter Exit Sensor (PL 10.14). If a voltage is out of specification, replace
Sensor Q842 (A4) the sensor.
2. Enter SCP [Printer Fault History]. If 8-144 and 8-145 faults are indicated, check the input drives to the Duplex
Inverter Assembly.
3. Enter dC726 [30. 8-146] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is out of
- Wear Element Coupling (PL 10.19)

- Exit Drive Rolls, Shafts and latching blocks for wear, contamination, or binding (PL 10.19)
- Compression Springs on the Lower Baffle Latches for damage (PL 10.22)
- Wear Element Coupling (PL 10.19)
8-147 Indicates that the Duplex LE was late to the Duplex TARS 1. Enter SCP [Printer Fault History]. If 8-171 faults are indicated, go to the 8-171 NRD. If no problem is found,
sensor Q842 (A3) return here and continue. If 8-146 and 8-149 faults are indicated, check the input drives to the Duplex Inverter
Assembly.
2. Measure the voltages of the Duplex Inverter Exit Sensor (PL). If a voltage is out of specification, replace the
sensor.
3. Enter dC726 [29. 8-145 & 147] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is
- Inverter Exit Sensor actuator for damage or breakage
- Foil tape under the Inverter Position Sensor on the lower baffle for dirt, damage or missing
- Inverter Drag Brake for wear, binding, or free spinning (PL 10.22)
- Input drives to the Duplex Inverter Assembly and Inverter Gear Box Assembly
- Inverter Drive Coupling for wear or damage (PL)
- Duplex Gate Fingers (PL 10.21) for interference, bends or damage
- Torsion Springs (PL 10.21) for damage or stretch
5. Check/adjust the Duplex Timing (ADJ 10-14). Perform this check several times, & if the check is varying by
greater than 10mm, replace the Inverter Gear Box Assembly (PL 10.22).
- Inverter Drag Brake/Idler Bracket (PL 10.22)
- Inverter Gear Box Assembly (PL 10.22)
8-149 Indicates that the Duplex LE was late to the Vertical Trans- 1. Measure the voltages of the Duplex TAR Sensor (PL) and Vertical Transport Sensor (PL 8.1). If a voltage is
port Sensor Q851 (A3) out of specification, replace the appropriate sensor.
2. Enter SCP [Printer Fault History]. If 8-146 faults are indicated, the problem- is most likely in the Duplex
Inverter area. If 8-147 and 8-146 faults are indicated, check the input drives to the Duplex Inverter Assembly.

- Flexible Coupling and D Shaft for damage (PL 8.1)
- Drive Coupling, Coupling Insert, and Drive Pulley for damage (PL 8.1)
- Upper and Lower Shafts for binding
- Input drives to the Duplex Inverter Assembly
- Belts, Shafts and Bearings for damage, slippage or wear
- Vertical Transport Clutch drive belt and idler for damage or wear
- Vertical Transport Clutch for slippage, wear or damage (PL 4.18)
- Vertical Transport Lower Shaft & Belts for damage or wear
- Magnetic Strips for the correct operating position and damage
5. If the output prints are damaged, go to the 8-705 NRD PHM Print Damage Checkout. If no problem is found,
return here and continue.
6. Perform the 8-156 and 8-147 NRDs for other possible causes of this problem. If no problem is found, return
here and continue.
7. Replace the Vertical Transport Clutch (PL 4.18)
8-151 Indicates that the TE was late off the Vertical Transport Sen- 1. Measure the voltages of the Vertical Transport Sensor (PL 8.1). If a voltage is out of specification, replace the
sor Q851 sensor.
- Vertical Transport Belts for position and wear (PL 8.1)
- Vertical Transport Upper and Lower Shaft assembly for binding
- Vertical Transport Assembly for wear, damage, or slippage (PL 8.1)
- Vertical Transport Drive Coupling or Drive Coupling Insert for wear or damage (PL 8.1)
3. Enter dC726 [18. 8-151] [Timing Graphs]. If known, program dC726 to run using the paper tray that the cus-
tomer is having problems with. Select [Continue]. If there are feed variations or operation is out of specified
range, check the following components/adjustments:
- Multifed sheets
- Paper stock catching on the Registration Edge
- Check the Registration Edge for damage or grooves
- Cross Roll Drives for wear or contamination
- Nip Release Solenoid Assembly for binding, overheating or damage
4. If the sheets are snagging on the Registration Edge entrance chute, or skewing in the paper path, go to the 8-
706 NRD PHM Misregistration and Skew Checkout. If no problem is found, return here and continue.
5. Enter SCP [Printer Fault History]. If 8-152, 8-153, or 8-154 faults are indicated, go to the appropriate NRD and
perform the checks indicated. If no problem is found, return here and continue.
- Vertical Transport Belts and Drives for wear, damage, or slippage (PL 8.1)
- Vertical Transport Drive Belts for wear, damage or slippage
- Vertical Transport Magnetic Strips for the correct position or damage
- Vertical Transport Clutch for binding, wear, or damage (PL 4.18)
- Vertical Transport Magnetic Strips for the correct position or damage (PL 8.2)

- Registration Transport for correct installation and damage (PL 8.3)
- Turn Baffle for seating on inboard pin, spring on baffle and damage (PL 8.4)
- Nip Release Solenoid Assembly for binding, overheat or damage (PL 8.5)
- Nip Release Solenoid Assembly adjustment (ADJ 8-6)
- Vertical Transport Clutch (PL 4.18)
Other dCs: 330 [8], 727 BSD 8.3
8-152 Indicates that the LE was late to the Registration Transport 1. Measure the voltages of the Vertical Transport (PL 8.1), Cross Roll (PL 8.5) and Registration Transport (PL
Sensor Q861 from the Vertical Transport Sensor Q851 (A4) 8.5) Sensors. If a voltage is out of specification, replace the sensor.
2. Enter dC330 [8] [Cycle Outputs]. Select [Cross Roll Left]. Press the Continue button. If the solenoid becomes
sluggish or intermittent as it warms up, replace it (PL 8.5). Perform the same checks on the [Cross Roll Right]
and [Nip Release] solenoids (PL 8.10).
3. If available, run 110 lb. and 16 lb. stock thru the system as a stress test.
- Paper Stock skewing on the Registration Transport
- Cross Roll Idler Lift Fingers for binding and correct position
5. If the sheets are snagging on the Registration Edge entrance chute, or skewing in the paper path, go to the 8-
706 NRD PHM Misregistration and Skew Checkout. If no problem is found, return here and continue.
6. If the problem only occurs when the operator is using transparencies, enter SCP [Printer Fault History]. If 8-
204 faults are occurring, go to the 8-204 NRD and perform the checks indicated. If no problem is found, return
here and continue. Verify that the Registration Transport Sensor can be actuated by the transparencies, and
clean the Registration Transport and Cross Roll Sensors.
7. Enter SCP [Printer Fault History]. If 8-151 faults are indicated, the problem is most likely with the Vertical
Transport components.
- Left and Right Cross Roll Assemblies for wear, damage, or binding (PL 8.5)
- Vertical Transport Belts and Drives for wear, damage, or slippage (PL 8.1)
- Vertical Transport Clutch for binding, wear, or damage (PL 4.18)
- Vertical Transport Magnetic Strips for the correct position or damage (PL 8.2)
- Cross Roll Assembly drive rolls for damage, debonding, or flat spots (PL 8.7)
- Cross Roll Assemblies and Drives for worn belts, binding, or damage (PL 8.7)
- Registration Transport, Registration Transport components, and Turn Baffle for correct installation, damage,
wear or binding (PL 8.3)
- Servo Drive Rolls for wear, damage, or binding (PL 8.4)
- Nip Release Solenoid Assembly for binding, overheat or damage (PL 8.5)
- Nip Release Solenoid Assembly adjustment (ADJ 8-6)

- Left and Right Cross Roll Assemblies (PL 8.5)
- Registration Edge (PL 8.4)
Other dCs:727 10. There is a possibility that the fault is related to components in the Registration Controller Servo area. Go to
the 8-302 NRD procedure. If no problem is found, return here and continue.
BSD : TBD
8-155 Indicates that the TE was late off the Registration Transport 1. Measure the voltages of the Registration Transport (PL 8.4) and Cross Roll (PL 8.5) Sensors. If a voltage is
Sensor Q861 out of specification, replace the appropriate sensor.
2. Enter SCP [Printer Fault History]. If 8-196 faults are occurring, go to the 8-196 NRD and perform the checks
indicated. If no problem is found, return here and continue.
- Paper stock skewing on the Registration Transport
- Vertical Transport Idler Nips for proper seating
4. If the sheets are skewing in the paper path or misregistered, go to the 8-706 NRD PHM Misregistration and
Skew Checkout. If no problem is found, return here and continue.
- Registration Transport Upper Baffle for damage or bowing.
- Registration Transport and associated components for the correct installation and damage (PL 8.3)
- Servo Drive Rolls and Idlers for damage, contamination, slippage or binding
- Cross Rolls and Assemblies for binding, damage, or contamination (PL 8.5)
- Pretransfer Lift Block for the correct position or damage (PL 8.8)
- Pretransfer Baffle for the correct position or damage (PL 8.8)
- Mylar Transport Strip between the Registration Transport and the Pretransfer Baffle for proper seating or
damage (PL 8.4)
6. Check the Registration Transport Upper Baffle adjustment (ADJ 8-0).
- Cross Roll Idler Lift Assembly (PL 8.5)
System Procedure: Electrical Noise Registration Edge (PL 8.4 )
Other dCs: 330 [8],727 8. There is a possibility that the fault is related to components in the Registration Controller Servo area. Go to
the 8-302 NRD procedure. If no problem is found, return here and continue.
BSD: TBD

9-101 Indicates a POP jam in A4 mode 1. Enter SCP [Printer Fault History]. If 9-201, 9-327, 9-328 or 9-329 faults are occurring at the same timestamp
as the 9-101 or 9-102 faults, go to the NRD associated with the other fault codes first.
9-102 Indicates a POP jam in A3 mode 2. Measure the voltages of the POP Sensor Q904. If any voltage is out of specification, replace the sensor (PL).
3. Enter dC314 and ensure that the proper HVDC Calibration values have been entered for the DTAC$$SI and
TRANS$$SI values.
4. Enter dC140 [Dicorotron Values]. Select [Continue]. Check the Detack Current Monitor display. If the value is
greater than the Detack Current Control display, clean the Dicorotron connectors and clean/replace the Detack
Dicorotron & Shield (PL 9.10).
- Transition Baffle for damage or burrs
- Pretransfer Baffle for damage and the correct operating position
- Prefuser Transport for damage and the correct operating position
- PR Stripper Fingers for damage and the correct operating position
- Stripper Fingers (PL 9.3)
- Detack Dicorotron and Shield (PL 9.11)
- HVDC PWB (PL 1.7)
BSD 9.7 (Sheet 1) NOTE: 9-101/102 faults can be caused by the condition of the paper stock (e.g., high humidity, old paper, etc.).
9-201 Indicates that a high voltage power supply arc was detected 1. Enter dC910 [High Stress]. Select [Continue]. Run the machine several times, and observe the Dicorotrons
for arcing. Replace as required (PL 9.10, PL 9.11).
2. Check the PR Ground Brush for loose, missing, or broken fibers. If a problem is found, replace the PR Ground
Brush (PL 9.7) and all Dicorotrons (PL 9.10, PL 9.11). Vacuum the Xerographic area to remove any dislodged
fibers.
3. Check the following components for signs of arcing, cracks, pitting, contamination, open circuits, etc.:
- Ozac tube and connectors
- HVDC Cables and connections
- HVAC Output Module & connections
- Dicorotrons and Dicorotron pins, sockets, and connectors
- All Dicorotrons and Shields (PL 9.10, PL 9.11)
- HVAC Output Module (PL 1.7)
- HVAC PWB (PL 1.7)
5. The following list contains the infrequent causes of 9-201 faults:
- Intermittent loss of +/- 15 VDC or + 34 VDC to the HVAC PWB
- Pinched wires or open grounds in the Transfer Assist Device
- Intermittent contact in the Drawer Roll Up Ribbon Cable (PL 9.1)
- Broken ground wires in the Fuser Metering Assembly

System Procedure: Electrical Noise Other dCs: 140, 951
BSD 9.1 (Sheet 1)
9-202 Indicates that the AC Coronode Voltage Set point is out-of- 1. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7, (ADJ 9-6).
range
2. Ensure that the Cleaner Zone Roll and bearings are in their operating positions and are not damaged.
- Ozac system and connectors
- Dicorotrons and Dicorotron pins, sockets, connectors, and shields
4. Enter dC140 [Dicorotron Values]. Select [Continue]. Use the dC140 Diagnostic Table in this section as a refer-
ence. If any value is out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no
problem is found, return here and continue.
5. Enter dC951 [Xerographic] Option] [Setup Initialization with Fault Masking]. Select [Continue]. If any value in
the Setup & Initialization part of dC951 is out-of-range, go to the dC951 Xerographic Setup Routine Procedure in
this section. If no problem is found, return here and continue.
- All the Charge Dicorotrons and Shields (PL 9.10)
- HVDC PWB (PL 1.7)
- HVAC PWB (PL 1.7)
BSD 9.1 (Sheet 2)
9-203 Indicates that the Photoreceptor has reached its end of life 1. Check the PR Ground Brush for loose, missing or broken fibers. If a problem is found, replace the PR Ground
Brush (PL 9.7) and all the Dicorotrons (PL 9.10, PL 9.11). Vacuum the Xerographic area to remove the dis-
lodged fibers.
9-213 Indicates that the ESV has failed 2. Check/adjust the ESV Height (ADJ 9-12), Charge Dicorotron Height and Balance (ADJ 7-9) and ROS Correc-
tion Factor (ADJ 6-3) adjustments.
3. Check the dC131 [MIN] locations 260 (ESV Adjust) and 285 (Patch Location).
4. Ensure that the ROS Assembly is positioned correctly in the rails and is not skewed.
5. Ensure that the Charge Zone Rolls and bearings are in their operating positions and are not damaged.
- Dicorotrons and Dicorotron pins, sockets, connectors and shields.
7. Enter dC314 and ensure that the proper HVDC and HVAC Calibration values have been entered.
8. Enter dC140. While dC140 is running open the processor front doors. If any Dicorotron value is greater than
0.3 VDC after 30 seconds, replace the HVDC PWB (PL 1.7)
9. Enter dC140 [Dicorotron Values]. Select [Continue]. If any Dicorotron Shield Voltage is greater than 9.5,
replace the appropriate Dicorotron and Shield (PL 9.10, PL 9.11).

10. Rerun dC140. Use the dC140 Diagnostic Table in this section as a reference. If any value is out-of-range, go
to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and con-
tinue.
11. Enter dC951 [Xerographic Options] [Setup Initialization with Fault Masking]. Select [Continue]. If any value in
the Setup & Initialization part of dC951 is out-of-range, go to the DC951 Auto Xerographic Setup in this section.
If no problem is found, return here and continue.
12. Perform the following IQ RAPs: PQ 9-618 (PR Ground), PQ 9-619 (ESV), PQ 9-621 (Patch Generator), PQ
9-624 Precharge/Pretransfer Lamps), PQ 9-621 (Patch Gen/Patch Integrity), and PQ 9-633 (dC912 PR Unifor-
mity). If no problem is found, return here and continue.
- PR Belt (PL 9.1), HVAC PWB (PL 1.7)
- All the Charge Dicorotrons and Shields (PL 9.10), HVAC Output Module (PL 1.7)
- ESV Assembly (PL 1.7), MIB PWB (PL 1.8)
- HVDC PWB (PL 1.7), MIN DIO PWB (PL 1.8)
System Procedure: Electrical Noise Other dCs: 99 BSD 9.4 14. If the problem continues, go to the 6-701 NRD. The ROS generates the patch used in process control and
could be related to this problem.
9-211 Indicates that the Patch Generator has failed 1. Replace the following components in the order given:
Patch Generator (PL 9.10)
MIN DIO PWB (PL 1.8)
BSD 9.5 MIB PWB (PL 1.8)
9-212 Indicates that the DSS has failed 1. Check the PR Ground Brush for loose, missing or broken fibers. If a problem is found, replace the PR Ground
Brush (PL 9.7) and all the Dicorotrons (PL 9.10). Vacuum the Xerographic area to remove dislodged fibers.
2. Check/adjust the ROS Correction Factor adjustment (ADJ 6-3).
3. Check the Xerographic area of the Printer for an excessive buildup of dirt. If any is found, locate and repair the
cause of the dirt. The Cleaner and Developer subsystems may be causing the dirt.
- Dicorotrons and Dicorotron pins, sockets, connectors and shields
5. Check for broken or loose ground wires in Fuser Metering Roll assembly & Transfer Assist Device.
6. Perform the PQ 9-619 ESV & PQ 9-618 PR Ground RAPs. If no problem is found, return here and continue.
- DSS (PL 9.7)
MIN DIO PWB (PL 1.8)
9-213 Go to the 9-203 NRD.
9-215 Indicates that the Toner Dispenser has failed 1. Check the PR Ground Brush for loose, missing or broken fibers. If a problem is found, replace the PR Ground
Brush (PL 9.7) and all the Dicorotrons (PL 9.10, PL 9.11). Vacuum the Xerographic area to remove dislodged
fibers.

2. Clean the DSS, ESV, and Patch Generator with a clean, soft, lint free cloth (anti-static solution, 8R90275, may
be used on the DSS). Check the Xerographic area of the Printer for an excessive buildup of dirt. If any is found,
locate and repair the cause of the dirt. The Cleaner and Developer subsystems may be causing the dirt.
3. Check the dC 131 locations 260 (ESV Adjust) and 285 (Patch Location) are at the values shown in the appro-
priate level Software Table (Section 6, General Procedures, in the Service Manual).
4. Enter dC330 [9]. Select [PreClean/PrexTransfer Lamps]. Press the [Continue ] button. If all segments of the
Precharge Erase and Pretransfer Lamps do not light, replace the lamp (PL 9.3, PL 9.4).
5. Select [Toner Thumper]. Press the Continue button. If the Toner Thumper Solenoid does not energize, go to
the BSD, and check the circuit. If no problem is found, replace the Toner Thumper Solenoid (PL 9.19).
- Dicorotrons and Dicorotron pins, sockets, connectors, and shields
- Developer Housing and associated components for proper mechanical condition (rollers, gears, auger, bear-
ings, couplings, etc.)
- Developer Gears for wear or noise (PL 9.14)
- Input drives to the Developer Housing for wear, slippage, etc.
- Developer Housing for clogged dry ink
- Cross Mixer Baffle operation
- ROS Correction Factor adjustment (ADJ 6-3)
- Toner Thumper Solenoid adjustment (ADJ 9-0)
8. Perform the following IQ RAPs: PQ 9-616 (Development) and PQ 9-620 DSS. If no problem is found, return
here and continue.
- MIN AC Remote PWB (PL 1.7), Toner Thumper Solenoid (PL 9.19)
- Toner Dispenser Motor (PL 9.19), MIN ADA PWB #1 (PL 1.7)
- MIN DIO PWB (PL 1.8), Low Toner Sensor (PL 9.19)
- MIB PWB (PL 1.8), Precharge and Pretransfer Erase Lamps (PL 9.3, PL 9.4)
- Patch Generator (PL 9.10), Discharge Lamps Power Supply (PL 9.4)
9-220 Indicates that the time between belt holes is too long 1. Measure the voltages of the Belt Hole Sensor and LED. If any voltage is out of specification, replace the sen-
sor and/or LED (PL 9.7).
9-222 Indicates that the time between belt holes is too short 2. Enter dC912 [Timing Test]. Select [Continue]. Check the display for random numbers that are far from the oth-
ers. If any are observed, replace the Machine Clock Sensor (PL 9.3).
- PR Module and Drawer for proper seating
- PR Belt for damage. If damage is found, check the Developer Housing and Cleaner Housing for foreign parti-
cles. Also check the condition of the Ground Brush.
- PR Module condition (rolls, bearings, shafts, etc.)

- Machine Clock Sensor for looseness
- PR Module Input Drives
- Cleaner Module, Developer Housing, or Machine Drives for binding
- P/J300 for rubbing on drives
- Belt Hole Sensor and LED (PL 9.7)
- Photoreceptor (PL 9.1)
- MIN Core PWB (PL 9.7)
Other dCs: 330 [9] BSD 9.3 Photoreceptor Module (PL 9.1)
9-221 Indicates an ozone blower air flow failure. 1. Check the Ozone Vacuum Switch for intermittent operation.
- Air flow blockage in the duct
- Ozone Vacuum Switch for binding
- Ozone Blower Motor for binding
- Ozone Vacuum Switch (PL 9.9)
- Ozone Blower Capacitor (PL 9.8)
- Ozone Blower Motor (PL 9.9)
Other dCs: 330 [9] MIN DIO PWB (PL 1.8)
9-222 Go to the 9-220 NRD
9-320 Indicates that the Developer Rolls 1 & 2 bias voltage was 1. Check the following components:
out-of-range
- Developer Zone Roll Adjustment (ADJ 9-1)
- Developer Housing for intermittent short circuits
- Developer Housing for broken, damaged, or missing contact points (PL 9.15)
- Developer Drive Assembly for separation, wobble, or scrapes (PL 9.14)
2. Enter dC140 [DC Bias Values]. Select [Continue]. Use the dC140 Diagnostic Table in this section as a refer-
ence. If any of the displayed Dev Rolls 1 & 2 Voltage values are out-of-range, go to the DC140 Analog Display
Diagnostic Procedure in this section. If no problem is found, return here and continue.
- Developer Drive Assembly (PL 9.14)
- HVDC PWB (PL 1.7)
- HVAC PWB (PL 1.7)
System Procedure: Electrical Noise BSD 9.2 (Sheet 3) MIN ADA PWB #1 (PL 1.7)
9-321 Indicates that the Developer Roll 3 bias voltage is out-of- 1. Check the following components:
range
- Developer Zone Roll Adjustment (ADJ 9-1)
- Developer Housing for intermittent short circuits
- Developer Housing for broken, damaged, or missing contact points (PL 9.15)
- Developer Drive Assembly for separation, wobble, or scrapes (PL 9.14)

2. Enter dC140 [DC Bias Values]. Select [Continue]. Using the dC140 Diagnostic Table in this section as a refer-
ence. If any of the displayed Dev Roll 3 Voltage values are out-of-range, go to the DC140 Analog Display Diag-
nostic Procedure in this section. If no problem is found, return here and continue.
- Developer Drive Assembly (PL 9.14)
- HVDC PWB (PL 1.7)
9-322 Indicates that the cleaner voltage is out-of-range 1. Check the following components:
- Cleaner Assembly for intermittent short circuits
- Photoreceptor Tension Rolls/Springs for proper actuation
- Photoreceptor Tension adjustment (ADJ 9-11)
ence. If any of the displayed Cleaner Brush Voltage values are out-of-range, go to the DC140 Analog Display
Diagnostic Procedure in this section. If no problem is found, return here and continue.
- HVAC PWB (PL 1.7)
- HVDC PWB (PL 1.7)
9-323 Indicates that the UDTR voltage is out-of-range 1. Check the Cleaner Assembly for intermittent short circuits
ence. If any of the displayed Upper Detoning Roll Voltage values are out-of-range, go to the DC140 Analog Dis-
play Diagnostic Procedure in this section. If no problem is found, return here and continue.
- HVAC PWB (PL 1.7)
9-324 Indicates that the LDTR voltage is out-of-range 1. Check the Cleaner Assembly for intermittent short circuits
ence. If any of the displayed Lower Detoning Roll Voltage values are out-of-range, go to the DC140 Analog Dis-
play Diagnostic Procedure in this section. If no problem is found, return here and continue.
- HVAC PWB (PL 1.7)
9-325 Indicates that the Charge 2 voltage is out-of-range 1. Enter SCP [Printer Fault History]. If Fault Codes 9-326, 9-327, 9-328 and/or 9-329 are occurring at the same
timestamp as the 9-325 faults, there is a problem with the HVAC circuit, which is shared by all these dicorotrons.
If no problem is found with the circuit, replace the following components in the order given:
- HVAC PWB (PL 1.7)
2. Check the Charge Dicorotron Height and Balance adjustment (ADJ 9-7, ADJ 9-6)
3. Check the following components for loose connections, contamination, arcing, discoloration, etc.:
- Dicorotrons and connectors
- Ozac System and connectors

- HVDC and HVAC Cables
4 . Enter dC140. Select [Continue]. Using the dC140 Diagnostic Table in this section as a reference, if either of
the displayed Charge 1, or 2 Voltage or Current values are out-of-range, go to the DC140 Analog Display Diag-
nostic Procedure in this section. If no problem is found, return here and continue.
- HVDC PWB (PL 1.7)
9-326 Indicates that the Transfer current is out-of-range 1. Enter SCP [Printer Fault History]. If Fault Codes 9-325, 9-327, 9-328 and/or 9-329 are occurring at the same
- HVAC PWB (PL 1.7)
3. Enter dC140. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the
displayed Transfer Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Pro-
cedure in this section. If no problem is found, return here and continue.
- Transfer Dicorotron and Shield (PL 9.11)
- HVDC PWB (PL 1.7)
9-327 Indicates that the Detack current is out-of-range 1. Enter SCP [Printer Fault History]. If Fault Codes 9-325, 9-326, P9-328 and/or 9-329 are occurring at the same
- HVAC PWB (PL 1.7)
displayed Detack Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Proce-
dure in this section. If no problem is found, return here and continue.
- Detack Dicorotron and Shield (PL 9.11)
- HVDC PWB (PL 1.7)

9-328 Indicates that the Preclean current is out-of-range 1. Enter SCP [Printer Fault History]. If Fault Codes 9-325, 9-326, 9-327 and/or 9-329 are occurring at the same
- HVAC PWB (PL 1.7)
displayed Preclean Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Pro-
cedure in this section. If no problem is found, return here and continue.
- Preclean Dicorotron and Shield (PL 9.11)
- HVDC PWB (PL 1.7)
9-329 Indicates that the AC Voltage is out-of-range 1. Enter SCP [Printer Fault History]. If Fault Codes 9-325, 9-326, 9-327 and/or 9-328 are occurring at the same
- HVAC PWB (PL 1.7)
displayed Coronode AC Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic
Procedure in this section. If no problem is found, return here and continue.
- HVAC PWB (PL 1.7)
9-330 Indicates that the Charge 2 AC shield current is out-of-range 1. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7 & ADJ 9-6).
3. Enter dC99. Select [Continue]. If either of the Charge 1, or 2 Control values are out-of-range, go to the dC99
Routine Procedure in this section. If no problem is found, return here and continue.

4. Enter dC140. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If either of the
displayed Charge 1, or 2 Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic
Procedure in this section. If no problem is found, return here and continue.
- 2HVDC PWB (PL 1.7)
9-332 Indicates that the Printer failed to complete a cycle in con- 1. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7 & ADJ 9-6).
vergence after a power up
- Cleaner Zone Roll for proper engagement and operation
- PR Ground Strip and Ground Brush for damage, contamination, and wear
3. Perform the Xerographic Setup adjustment (ADJ 9-3). If any value is out-of-range during dC951, go to the
DC951 Auto Xerographic Setup in this section. If no problem is found, return here and continue.
4. If excessive dirt was found in the Xerographic area during the Xerographic Setup adjustment, locate and
repair the cause of the dirt.
5. Replace all the Charge Dicorotrons and Shields (PL 9.10).
6. Perform the PQ 9-601 Print Image Quality Entry Level RAP.
9-353 Indicates that the Printer failed to converge contrast in 1. Enter SCP [Printer Fault History]. If Fault Code 9-203 or 9-213 are occurring at the same timestamp as the 9-
dC951 353 faults, go to the 9-203 NRD.
2. Perform the ROS Low Correction Factor (ADJ 6-3) and Xerographic Set-up adjustments (ADJ 9-3). If any
value is out-of-range during dC951, go to the DC951 Auto Xerographic Setup in this section. If no problem is
found, return here and continue.
repair the cause of the dirt. The Developer and Cleaner subsystems are high suspects for causes of dirt.
4. The problem may be related to a non-uniform PR Belt. Enter dC912 [Uniformity Test]. Select [Continue]. If any
of the displayed values are out-of-range, replace the PR Belt (PL 9.10).
5. Perform the PQ 9-633 dC912 PR Uniformity RAP. If no problem is found, return here and continue.
6. If the problem continues, go to the 6-701 NRD. The ROS generates the patch used in process control and
9-354 Indicates that the Printer failed to set toner concentration in 1. Perform the Xerographic Set-up adjustment (ADJ 9-1). If any value is out-of-range, during dC951, go to the
dC951 DC951 Auto Xerographic Setup in this section. If no problem is found, return here and continue.
3. Perform the following PQ RAPs: PQ 9-617 Cleaner and PQ 9-621, Patch Gen/Patch Integrity RAP. If no prob-
lem is found, return here and continue.
BSD 9.5 4. If the problem continues, replace the DSS (PL 9.7).
9-355 Indicates that the printer failed to set the patch generator in 1. Perform the Xerographic Setup adjustment (ADJ 9-1). If any value is out-of-range, during dC951, go to the
dC951 DC951 Auto Xerographic Setup in this section. If no problem is found, return here and continue.
3. Enter dC330 [9] [Patch GEN High]. Press the Continue button. Use a mirror to observe the Patch Generator
LEDs. If all four LEDs are not lit, replace the Patch Generator (PL 9.10).

4. Perform the PQ 9-624 Precharge/Pretransfer Lamps RAP. If no problem is found, return here and continue.
- Patch Generator (PL 9.10)
- MIB PWB (PL 1.8)
BSD 9.5 MIN ADA PWB #2 (PL 1.7)
9-704 Used to troubleshoot the non-repeatable problems with the 1. Check the following components:
Toner Filter Blower Motor
- Toner Filter Blower O-rings for wear and damage (PL 9.20)
- Toner Filter Blower Motor for binding or resistance
2. Replace the following components; Toner Filter Blower Motor MOT905 (PL 9.20)
Other dCs: 330 [9] Toner Filter Blower Motor Capacitor C902 (PL 9.20)
9-705 Used to troubleshoot the non-repeatable problems with the 1. Check the MIM Cooling Fan for binding or resistance.
MIM Cooling Fan
2. Replace the MIM Cooling Fan MOT107 (PL 4.9)
BSD 1.6
8-902 Indicates a Tray 2 dynamic width error (first sheet is too long 1. Check the dC131 [PHN] locations 220 (A4 Almost Jam Value) and 222 (A4 Jam Value).
or short)
2. Measure the voltages of the Length A and Length B Sensors (PL 7.2). If a voltage is out of specification,
replace the sensor.
3. Enter dC330 [8] [Cycle Outputs]. Select [Cross Roll Left]. Press the Continue button. If the solenoid becomes
sluggish or intermittent as it warms up, replace it (PL 8.5)
4. Enter dC703 [Paper Width Timing Setup] [Printer Options] [Tray 2] [Printer Options]. Select [Continue].
Check/adjust the Average Error. If the problem still occurs after the adjustment or if the adjustment cannot be
achieved, continue with this procedure.
5. Ensure SCP [Printer Fault History]. If 8-123 or 8-155 faults are indicated, go to the 8-123 NRD. If no problem
is found, return here and continue.
6. Enter dC726 [21. 8-901, 2, 3] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is
- Paper stock skewing on the Registration Transport
- Vertical Transport Double Nip for proper seating
- Length Guide and Cam for damage or wear (PL 7.2)
- Left Cross Roll Solenoid for binding or damage (PL 8.5)
- Length Guide Position and Tension adjustment (ADJ 7-4, ADJ 7-5)
- Vertical Transport Magnetic Strips for proper position and damage
- Servo Drive Rolls and Idlers for wear, damage, or contamination
- Jam Clearance Baffles for proper seating and damage
- Registration Transport Sensor lens for damage

8. If the following problems are present, go to the appropriate NRD. If no problem is found, return here and con-
tinue.
- Damaged prints (Go to the 8-705 NRD)
- Mutifed sheets (Go to the 8-123 NRD)
- Misregistered or skewed sheets (Go to the 8-706 NRD)
9. Perform the 8-302 NRD for other possible causes of this problem. If no problem is found, return here and con-
tinue.
- Registration Transport Sensor (PL 8.4)
BSD: TBD - Left Cross Roll Solenoid (PL 8.5)

10-101 Print LE was late to the Prefuser Sensor Q1010 after it 1. Enter dC726. Select [22. 10-101], [Timing Graphs], [Continue]. When the test is complete, inspect the timing data
arrived at the Registration Sensor Q1009. for Normal, Late, or Random distribution. Perform the checks below which relate to the type of distribution identified
in the timing graph.
Late Distribution:
- Prefuser Transport for vacuum leaks (PL 8.9)
- Damaged or contaminated Prefuser Transport Drive Belts (PL 8.9)
- Binding Prefuser Transport Bearings (PL 8.9)
- Worn Prefuser Transport Drive Coupling (PL 4.16)
- Obstructed Prefuser Transport Manifold holes
- Prefuser Drive System for worn or misadjusted components (PL 4.16)
Normal or Random Distribution:
- Measure the voltage of the Registration Sensor Q861 (PL 8.4) and Prefuser Sensor Q1009. If a voltage is out of
specification replace the appropriate sensor, (PL 8.9).
2. For Misregistration or Skew, go to the 8-706 NRD.
3. For Print Jams Before the Prefuser Transport perform the following checks:
- Obstructions in the sheet path
- Condition of paper
- Operation and condition of the Transfer and Detack Dicorotrons (PL 9.11)
- Condition of the Pretransfer Baffle (PL 8.8)
- Condition of the Stripper Finger Assembly (PL 9.3)
- Condition and operation of the Transfer Assist Blade (PL 9.11)
Other dCs: 330[10], 727 BSD 10.2 - Condition of the Detack Paper Guide (PL 9.11)
10-102 Print LE was late to the Fuser Sensor Q1010 after it arrived 1. Ensure paper is loaded properly and does not have excessive curl. For duplex mode operation, check the
at the Prefuser Sensor Q1009. Decurler Exit Baffle adjustment (ADJ 10-8).
10-104 Print LE was late to the Decurler Sensor Q1011 after it 2. Perform the following stress test to increase the frequency of the failure.
arrived at the Fuser Sensor Q1010.
For 10-102 faults, enter dC726 Select [23. 10-102], [Timing Graphs], [Continue]. Run the same paper that the cus-
tomer was having problems with to aid in identification of the faulty component. If a fault cannot be induced, view the
Histogram timing data. If random distribution is detected, check the following components:
- Check the Fuser Drive Coupling for damage and ensure that it is lubricated (PL 4.17)
- Replace the Prefuser Sensor Q1009 and Fuser Sensor Q1010 (PL 8.9 and PL 10.6).
- For 10-104 faults, enter dC726 Select [24. 10-104], [Timing Graphs], [Continue]. Run the same paper that the
customer was having problems with to aid in identification of the faulty component. If a fault cannot be induced, view
the Histogram timing data. If random distribution is detected, check the following components:
- Check the Fuser Drive Coupling for damage and ensure that it is lubricated (PL 4.17)
- Replace the Fuser Sensor Q1010 and Decurler Sensor Q1011 (PL 10.6 and PL 10.17).
Identify the symptom below that relates to the failure.
- Skew/misregistration/wrinkles (severe)/dog ears (other than Fuser area)
- Go to the 8-706 NRD.
Multifeeds.

- Ask the operator which paper tray was used when the jam occurred and go to the 8-701 NRD to perform the
actions for the related paper tray.
Fuser jams/wraps/dog ears toward the Fuser Roll
- Ensure that Printer Tag 195 is installed.
- Perform the Air Knife Manifold adjustment (ADJ 10-4).
- Perform the Air Knife Pressure and MIM Compressor Air Pressure adjustments (ADJ 10-4).
- Perform the following air pressure checks:
- If the pressure is below 18 PSI during Printer operation (not puffing), enter dC330[10]. Select [MIM Compressor].
Use the Processor Air System Checkout Diagram to check the Air System for leaks.
If there is no pressure drop at puff, check the following components
- Air Knife Solenoid for proper operation
- Air Knife holes for contamination ion or clogging
- Air Lines for obstructions, kinks, or damage
- Check/replace the Moisture Trap Air Filter (PL 10.11).
- Perform the Fuser Roll Temperature adjustment (ADJ 10-4).
- Ensure that the following PHN NVM Locations (Air Knife Settings) are correct. Use the appropriate level Software
dC 131 Table (Section 6, General Procedures, in the Service Manual):
- 180
- 181
- 182
- 183
Check the following components:
- Fuser Agent Pump PHN NVM location 188 is at the value shown in the appropriate level Software dC 131 Table
(Section 6, General Procedures, in the Service Manual)
- Fuser Agent Pump (PL 10.9)
- Fuser Agent Lines for damage, kinks, or clogging.
- Fuser Agent Filter (PL 10.9)
- Fuser Wick (PL 10.8)
- Metering Blade for contamination or wear (PL 10.8)
- Metering Roll (PL 10.8) for binding bearings. Note: If bearings are bound, check the Donor Roll Loading Arms for
damage.
- Donor Roll (PL 10.9) for gouging or chunking.
- Pressure Roll and Donor Roll (Contact Arc) adjustments (ADJ 10-2).
Jams/wraps/dog ears toward the Pressure Roll
- If the air pressure is 22 PSI or more, especially with lightweight paper, perform the MIM Compressor Air Pressure
adjustment (ADJ 10-5).
- Perform the Stripper Finger Baffle ADJ 10-15 and Air Knife Manifold adjustments ADJ 10-4.
- Check for a contaminated Static Brush (PL 11.26).
- Bias the Static Brush as close to the Pressure Roll as possible without contacting the Pressure Roll.
Dark lead edge jams
- Check the setting of Lead Edge Suppression.

- Go to the third bullet on the previous page and perform the checks.
Overtoning Jams
- Go to the PQ 9-610 High Image Darkness RAP, Service Manual Section 3IQ.
Morning jams
Jams entering the Decurler (for 10-104 Faults only)
- Perform the Air Knife Pressure ADJ 10-5 and Vacuum Manifold adjustments (ADJ 10-4).
- Check for damaged or contaminated Decurler Belts (PL 10.13).
- Check for binding or worn Decurler Drive Belts or Pulleys (PL 10.13).
- Replace the Decurler Clutch (PL 10.13)
No telltales or indications.
- Measure the voltages of the Prefuser Sensor Q1009 (PHN DIO #2, TS24 (+), TS37(-)) and Fuser Sensor Q1010
(PHN DIO #2, TS21(+), TS37(-)). If there is NOT +0.5 VDC or less, clean or replace the appropriate sensor (PL 8.9
and PL 10.6).
- Check the Fuser Drive Coupling for damage and ensure that it is not binding on the shaft (PL 4.17). Lubricate the
shaft to allow free movement in and out along the shaft.
- Check the Photoreceptor Drive Coupling for damage and ensure that it is not binding on the shaft (PL 4.17). Lubri-
cate the shaft to allow free movement in and out along the shaft. Ensure that the Photoreceptor is not slipping or
stalling on the Photoreceptor Drive Rolls.
- Check the Prefuser Transport for belt slippage and clogged holes.
- Check the Prefuser Vacuum Motor for proper operation.
- Perform the following adjustments:
- Fuser Latch Assembly, Fuser Left and Right Drawer Slide (ADJ 10-12)
- Air Knife Manifold (ADJ 10-4)
- Air Knife Pressure (ADJ 10-5)
- Donor Roll ADJ 10-13 and Pressure Roll (Contact Arc), (ADJ 10-2).
- MIM Compressor Air Pressure (ADJ 10-5)
- Stripper Finger Baffle (ADJ 10-15)
- Pressure Roll (Contact Arc), (ADJ 10-2)
- Vacuum Manifold ( ADJ 10-4)
Other dCs: 330[10], 727 BSD 10.2, BSD 10.5, BSD 10.6,
BSD 10.7
10-105 10-106 Print TE was late to leave the Decurler Sensor. 1. Enter dC726. Select [25. 10-105&106], [Timing Graphs]. Run 100 sheets of the heaviest print paper the customer
has available to the Top Tray. When the test is complete, inspect the timing data for Normal, Late, or Random distri-
bution. Perform the checks below which relate to the type of distribution identified in the timing graph.
Late Distribution:
- Top Transport Slip Clutch (PL 10.15)
- Decurler and Top Transport Belts for proper tension or wear
- Decurler and Top Transport drives and pulleys
- Decurler Sensor adjustment (ADJ 10-10)
- Decurler Sensor adjustment (ADJ 10-10)

- Decurler Exit Baffle adjustment (ADJ 10-8)
- Measure the voltage of the Decurler Sensor Q1009. If the voltage is out of specification replace the sensor (PL
8.9).
- Obstructions in the paper path
- Damaged paper path components
- Loose or worn belts or pulleys in the Decurler Transport Drives (PL 10.13)
- Loose or worn belts or pulleys in the Top Transport Drives (PL 10.15)
- Ensure that all Top Transport Rolls and Idlers are clean and properly seated and that all springs are properly
installed.
2. Print Damage
Other dCs: 330[10], 727 BSD 10.7 Go to the 8-705 NRD.
10-107 Print LE was late to the Top Transport Sensor after it arrived 1. Enter dC726. Select [26. 10-107], [Timing Graphs]. Run 100 sheets of the heaviest print paper the customer has
at the Decurler Sensor. available to the Top Tray. When the test is complete, inspect the timing data for Normal, Late, or Random distribu-
tion. Perform the checks below which relate to the type of distribution identified in the timing graph.
Late Distribution:
- Decurler and Top Transport Sensor Actuators for binding
- Measure the voltage of the Top Transport Sensor Q1012. If the voltage is out of specification replace the sensor
(PL 10.17).
- Loose or worn belts or pulleys in the Top Transport Drives (PL 10.15)
installed.
2. Print Damage
Other dCs: 330[10], 727 BSD 10.7 Go to the 8-705 NRD.
10-108 10-109 Print TE was late to leave the Top Transport Sensor. 1. Enter dC726. Select [27. 10-18, 9 &10], [Timing Graphs]. Run 100 sheets of the heaviest print paper the customer
10-110 has available to the Top Tray. When the timing diagnostic test is complete, inspect the timing data for Normal, Late,
or Random distribution. Perform the checks below which relate to the type of distribution identified in the timing
graph.
Late Distribution:
- Top Transport Idlers and Rolls for binding or wear
- Top Transport drives, belts, and pulleys for wear or slipping
- Measure the voltage of the Top Transport Sensor Q1012. If the voltage is out of specification replace the sensor
(PL 10.17).
- Duplex Gate adjustment (ADJ 10-9)

- Decurler Setting
- Worn or dirty Top Transport Rolls (PL 10.15)
- Worn or damaged Top Transport Drive System components (PL 10.14 and PL 10.18)
- Worn or damaged Top Transport pulleys or belts
installed.
2. Print Damage; Go to the 8-705 NRD.
Other dCs: 727 BSD 10.7 3. Manually actuate and deactuate the Duplex Gate. If the Duplex gate does not move freely, repair or replace it (PL
10.15). Enter dC330 [10] [Cycle Outputs]. Select [Duplex Gate Solenoid]. Press the Continue button. If the solenoid
Continues to become sluggish or intermittent as it warms up, replace it (PL 10.16).
10-111 Go to 10-105 NRD
10-112 Go to 10-101 NRD
10-201 Fuser did not reach operating temperature within 7 minutes; 1. Inspect the Fuser Roll Thermistor and Metering Roll Thermistor for debris or damage and ensure that they are
No change (decrease) in Fuser Thermistor resistance for 3 making proper contact.
minutes; No change (decrease) in Thermistor resistance
within 10 second after clearing fault code 10-204
2. Measure the resistance of the Fuser Roll Thermistor and Metering Roll Thermistor. If 2 Megohms at room temper-
ature, or 8.5 to 11K ohms is not measured, replace the defective thermistor (PL 10.4 and PL 10.7).
3. Perform the Fuser Roll Thermostat and Metering Roll Thermostat adjustments (ADJ 10-0 and ADJ 10-1).
4. Enter dC701 [Temperature Setups] and check the Fuser Roll Temperature (ADJ 10-6).
5. Replace the Fuser Relay K1002 (PL 1.2).
- Fuser Heat Rod (PL 10.7)
- MIN ADA PWB#1 (PL 1.8)
- MIB PWB (PL 1.8)
- Wiring and connectors
BSD 10.1
10-202 Fuser has reached a temperature of 435 degrees F (over- 1. Inspect the Fuser Roll Thermistor and Metering Roll Thermistor for debris or damage and ensure that they are
temp). making proper contact.
2. Measure the resistance of the Fuser Roll Thermistor and Metering Roll Thermistor. If 2 Megohms at room temper-
ature, or 8.5 to 11K ohms is not measured, replace the defective thermistor (PL 10.4 and PL 10.8).
3. Perform the Fuser Roll Thermostat and Metering Roll Thermostat adjustments (ADJ 10-0 and ADJ 10-1).
4. Enter dC701 [Temperature Setups] and check the Fuser Roll Temperature (ADJ 10-6).
5. Replace the Fuser Relay K1002 (PL 1.2).
- Fuser Heat Rod (PL 10.7)
- MIB PWB (PL 1.8)
- Wiring and connectors
System Fault Group: Other dCs: BSD 10.1

0-203 Voltage to the Fuser is less than 170 VAC 1. Enter dC140 [Fuser Values]. Select [Continue] and check the Fuser Line Voltage. If the Fuser Line Voltage is low,
check the Input Line Voltage for a low condition. If OK, replace the MIN ADA PWB #1 (PL 1.8).
10-204 Go to 10-201 NRD
10-205 Go to 10-201 NRD
10-206 Go to 10-201 NRD
10-210 Metering Roll has not reached a temperature of 250 degrees 1. Inspect the Metering Roll Thermistor for debris or damage and ensure that it is making proper contact.
F within 7 minutes of Continue up; Metering Roll tempera-
ture is below 250 degrees F in Print (under-temperature)
2. Measure the resistance of the Metering Roll Thermistor. If 2 Megohms at room temperature, or 8.5 to 11K ohms is
not measured, replace the defective thermistor (PL 10.4 and PL 10.8).
3. Perform the Metering Roll Thermostat adjustment (ADJ 10-1).
4. Enter dC701 [Temperature Setups] and check the Metering Roll Temperature (ADJ 10-7).
BSD 10.1
10-211 Go to 10-210 NRD
10-212 Cam-in Sensor (left) was unblocked during print. 1. Check the Camming Flag for debris or damage.
10-217 Cam-in Sensor (left) was unblocked during Printer initializa- 2. Measure the voltage of the Cam-in Sensor Q1002. If the voltage is out of specification replace the sensor, (PL
tion. 10.5).
Other dCs: 330[10] BSD 10.5
10-213 Cam-out Sensor (right) was unblocked during print. 1. Check the Camming Flag for debris or damage.
10-218 Cam-out Sensor (right) was unblocked during Printer initial- 2. Measure the voltage of the Cam-out Sensor Q1003. If the voltage is out of specification replace the sensor, (PL
ization. 10.5).
10-214 Camming Motor failed to stop during cam-in while in print. 1. Check the Camming Flag for debris or damage.
10-215 Camming Motor failed to stop during cam-out while in print. 2. Check the Camming Motor Brake Release Lever to ensure that it is not actuated by wiring, Ozac Tubes, etc.,
while in the normal operating position.
10-219 Camming Motor failed to stop during cam-out at Printer ini- 3. Measure the voltage of the Cam-in Sensor Q1002 and the Cam-out Sensor Q1003. If the voltages are out of
tialization. specification replace the appropriate sensor, (PL 10.5).
10-216 Camming Motor failed to operate when commanded to do 1. Check the Camming Flag for debris or damage.
so.
2. Measure the voltage of the Cam-in Sensor Q1002. If the voltage is out of specification replace the sensor, (PL
10.5).
- Camming Motor Brake (PL 10.3)
- Camming Motor Coupling for loose set screws, damage or wear.
Other dCs: 330[10] BSD 10.3, BSD 10.5
10-217 Go to the 10-212 NRD
10-218 Go to the 10-213 NRD
10-219 Go to the 10-214 NRD

11-100 The sheet arrived unexpectedly at the Inverter Entrance
Sensor Q1101. This fault will be declared when a sheet is
detected at Q1101 in print, and PHN has not informed the
FSN that a sheet is on the way.
- Sheet Path for obstruction
- Process Duplex Gate for physical damage (PL 10.15)
Other dCs: 330 [10], 226 - Inverter Entrance Sensor for loose wires (PL 11.24)
BSD 11.2 2. Enter SCP [Fault]. If Fault Code 10-106 or 10-108 is displayed, go to the appropriate NRD.
11-102 11-103 Indicates that the lead edge of the print delivered from the 1. Measure the voltages of the Inverter Entrance Sensor. If a voltage is out of specification, replace the sensor (PL
Printer Top Transport Sensor, Q1012, did not arrive at the 11.24)
Inverter Entrance Sensor, Q1155, within 560 ms.
2. Enter dC226. Select [1. 11-102] and press the Continue button. If any feed variations or operation is out of spec-
ified range, check the following components:
- Drive Rolls for wear or obstruction (PL 10.14)
- Idler Rolls for the correct rotation (PL 10.14)
- Idler Spring for the proper mounting (PL 10.14)
3. If the sheets that enter the Inverter are misregistered, skewed, damaged, torn, nicked, or dog eared. go to the 8-
705, Fault Code Tables.
Other dCs: 330 [10], 227 4. Enter SCP [Fault]. If fault code 10-108 is displayed, go to the appropriate NRD.
BSD 11.2 5. Enter dC726. Select [54. 10-108] and press the Continue Button. If a Random distribution is displayed when the
timing diagnostic test is complete, check the Top Transport Drives for loose or worn drive belts.
11-104 Indicates that the trail edge of a print arrived 520 ms (3 1. Measure the voltages of the Inverter Entrance Sensor. If any of the voltages are out of specification, replace the
pitch) or 300 ms (7 pitch) late at the Inverter Entrance Sen- sensor (PL 11.24)
sor, Q1155. When this fault is declared, the sensor is
unblocked.
11-105 Indicates that the trail edge of a print arrived 520 ms (3 2. Enter dC226. Select [2. 11-104],and press the Continue Button. If any feed variations or operation is out of spec-
pitch) or 300 ms (7 pitch) late at the Inverter Entrance Sen- ified range, check the following components:
sor, Q1155. When this fault is declared, the sensor is
blocked.
- Active and Passive Gates for binding or obstructions (PL 11.23) (Duplex only)
- Gate Pivot for binding (PL 11.23)
- Solenoid Link and Spring for the proper mounting (PL 11.24)
- Drive Rolls for wear or obstruction (PL 10.14)
3. Enter dC330 [10]. Select [Inverter Gate], [Cycle Mode]. Press the Continue button, and wait five minutes to
ensure that the Inverter Gate Solenoid is hot. Press the Stop button.
4. Enter dC106. Select [Stacker A] ], and run a duplex job. If the sheet stops at the Inverter Gate, replace the
Inverter Gate Solenoid (PL 11.24).
5. Check the following for the Top/Middle/Bottom Shaft Drive components:

- Inverter Drive Belt and Top/Middle/Bottom Drive Rolls for wear or damage (PL 11.23)
6. Enter dC726. Select [2.11-104], and press the Continue Button. If a random distribution is displayed when the
timing diagnostic test is complete, check the Top Transport Drives for loose or worn drive belts.
BSD 11.2 7. Check the Inverter Drive motor to ensure proper operation and the compatibility of the motors and transport 50 or
60 Hz.
11-106 Indicates that the lead edge of an inverted print arrived ear-
lier than 350ms at the Post Inverter Sensor, Q1156, from the
Inverter Entrance Sensor, Q1155. The duplex print missed
the Inverter Gate.
11-107 Indicates that the lead edge of an inverted print from the
Inverter Entrance Sensor, Q1155, arrived early at the Sam-
ple Tray Sensor, Q1157. The print missed the Inverter Gate.
1. Check the following paper path components:
- Inverter Gate area for obstructions
- Inverter Gate Spring for damage (PL 11.24)
- Inverter Gate Solenoid plunger for binding (PL 11.24)
2. Check the Inverter Gate to ensure that it pivots freely thru the full range of travel (PL 11.24).
3. Inspect the gate and paper path for obstructions or damage. (PL 11.24)
4. Enter dC330, [10], [Inverter Gate], [Cycle Mode], and press the Continue Button actuate the gate solenoid.
After 5 minutes cycle the solenoid and check for sluggish operation or lack of travel. If so replace the gate solenoid
(PL 11.24)
5. Check the Sample Tray sensor for damage or loose connections (PL 11.26).
6. Check the Inverter Gate Solenoid adjustment (ADJ 11-1).
11-108 11-109 Indicates that the lead edge of a print delivered from the 1. Check the Inverter Gate for binding if okay, enter dC330 [10]. Select [Inverter Gate], [Cycle], & [Mode]. Press
Inverter Entrance Sensor, Q1155, did not arrive at the Post the Continue Button and wait five minutes to ensure that the Inverter Gate Solenoid is hot. Press [Stop] button.
Inverter Sensor, Q1156, within the specified time. Enter dC106 and run a duplex job. If the sheet stops at the Inverter Gate, replace the Inverter Gate Solenoid (PL
11.24).
2. Enter dC226. Select [3. 11-108], and press the Continue Button. If any feed variations or operation is out of spec-
ified range, check the following components:
- Inverter Gate for binding or obstructions (PL 11.24)
- Inverter Gate Bearing for damage or binding (PL 11.24)
- Top and bottom Hinge adjustment (ADJ 11-4)
- Link for damage or any missing parts (PL 11.24)
- Return Spring for damage (PL 11.24)
3. Measure the voltages of the Post Inverter Sensor. If a voltage is out of specification, replace the sensor (PL 11.2)
- Inverter Gate adjustment (ADJ 11-1)
- Inverter Output Baffle (ADJ 11-3)
- Passive Gate for straightness and that it is seated properly when pivot assembly is closed (PL 11.25)
Other dCs: 227 - Pivot assembly alignment (ADJ 11-7)
- Ensure that all parts are 50 or 60 Hz compatible

BSD 11.2 5. Enter dC226. Select [3. 11-108], and Press the Continue Button. If a random distribution is displayed when the
timing diagnostic test is complete, check the Inverter Drives for loose or worn drive belts.
11-110 Indicates that the trail edge of a print did not arrive at the 1. Check to ensure that the baffles are closed securely.
Post Inverter Sensor, Q1156, within 520ms (3 pitch) or
300ms (7 pitch) after the lead edge of the print arrived at the
sensor.
2. Check the Post Inverter sensor Q1156 for actuator damage or sluggish operation.(PL 11.2)
3. Inspect the registration rolls for damage or wear (PL 11.22) and check Gap setting (ADJ 11-1)
4. Inspect or drive roll idlers and ensure that they are contacting the drive rolls (PL 11.22).
5. Check the Preregistration drive belt for damage and Retension the belt.(PL 11.22)
11-112 Indicates that the lead edge of the print delivered from the 1. Check paper path for obstruction, nicks or burrs.
Post Inverter Sensor, Q1156, did not arrive at the Prestacker
Sensor, Q1158, within 440ms. When this fault is declared
the Prestacker Sensor is unblocked.
2. Check and adjust as necessary the registration corrugator roll adjustment.
3. Ensure that the Post-Inverter nip release solenoid is operating properly if in the 3-pitch mode. Exercise solenoid in
the dC330. Feed paper and ensure that they cycle once per pitch and release properly.
4. Perform nip relief rolls adjustment.
11-114 Indicates that the trail edge of a print did not arrive at the TBS
Prestacker Sensor, Q1158, within 520 ms (3 pitch) or 300
ms (7 pitch) after the lead edge of the print arrived at the
sensor. The valid destination for the sheet is beyond Stacker
A.
11-116 Indicates that the lead edge of a print delivered from the 1. Check the sample tray gate for proper operation.
Inverter Entrance Sensor, Q1155, did not arrive at the Sam-
ple Tray Sensor, Q1157, within 280ms for non-inverted
sheets and 720ms (7 pitch) or 950ms (3 pitch) for inverted
sheets. When this fault is declared, the sensor is unblocked.
2. Exercise gate in dC330. Ensure that the solenoid is cycling and releasing properly.
3. Perform the sample tray adjustment (ADJ 11-8).
11-117 Indicates that the lead edge of a print delivered from the TBS
Inverter Entrance Sensor, Q1155, did not arrive at the Sam-
ple Tray Sensor, Q1157, within 280ms for non-inverted
sheets and 720ms (7 pitch) or 950ms (3 pitch) for inverted
sheets. When this fault is declared, the sensor is blocked.
Sample Tray Sensor, Q1157, within 520ms (3 pitch) or
300ms (7 pitch) after the lead edge of the sheet arrived at
the sensor. When the fault is declared, the sensor is
unblocked.
Sample Tray Sensor, Q1157, within 520ms (3 pitch) or
300ms (7 pitch) after the lead edge of the sheet arrived at
the sensor. When the fault is declared, the sensor is
blocked.

11-120 Indicates that an unexpected sheet arrived at the Sample TBS
Tray.
11-130-1&2 Indicates that the lead edge of a print was detected at the 1. Check operation of Stacker Bypass gate. Energize gate solenoid to ensure that the solenoid is releasing properly
Disk Sheet Sensor, Q1106A, when it was not expected. and gate closes fully.
2. Perform gate setup and adjustment
3. If problem persist, disconnect solenoid and determine if problem goes away. If it does perform circuit diagnostic
XXX.
4. Energize solenoid and allow it to heat up for 5 minutes, if solenoid does not release or seems sluggish, replace it.
11-131-1 indicates that the lead edge of print did not arrive at the Disk
Sheet Sensor, Q1106A, within 260ms after the Prestacker
Sensor, Q1158 sensed the lead edge. When this fault is
declared, the Prestacker Sensor is unblocked and the Disk
Sheet Sensor is unblocked.
11-132-1 indicates that the lead edge of print did not arrive at the Disk
Sheet Sensor, Q1106A, within 260ms after the Prestacker
declared, the Prestacker Sensor is blocked and the Disk
Sheet Sensor is unblocked.
1. Check the bypass gate adjustment (ADJ 11-11) out of adjustment. Gate can cause LE damage as sheet catches
on gate.
2. Turn on solenoid in dC330 for 3 minutes operate in cycle mode and check for sluggish operation.
3. Check for excessive curl in stackers. Check for sheets catching on entrance baffles. Adjust decurler to reduce curl
and try flipping paper in the feeders.
4. Check disk entrance nip drive belt and pulleys for wear or damage. Re-tension belt.(PL 11.11)
5. Block the Disk Chute Sensor with sheet of paper and measure voltage at TP. If voltage is less than (TBS), replace
sensor.
6. Check baffle and drive rolls for damage, burrs, or obstructions (PL 11.11).
11-131-2 Indicates that the lead edge of print did not arrive at the Disk
Sheet Sensor, Q1106B, within 330ms after the Bypass
Transport Sensor, Q1107A sensed the lead edge. When this
fault is declared, the Bypass Transport Sensor is unblocked
and the Disk Sheet Sensor is unblocked.
11-132-2 Indicates that the lead edge of print did not arrive at the Disk
Sheet Sensor, Q1106B, within 330ms after the Bypass
1. Check the bypass gate adjustment (ADJ 11-11) out of adjustment. Gate can cause LE damage as sheet catches
on gate.
2. Turn on solenoid in dC330 for 3 minutes operate in cycle mode and check for sluggish operation.
3. Check for excessive curl in stackers. Check for sheets catching on entrance baffles. Adjust decurler to reduce curl
and try flipping paper in the feeders.
4. Check disk entrance nip drive belt and pulleys for wear or damage. Re-tension belt.
5. Block the Disk Chute Sensor with sheet of paper and measure voltage at TP. If voltage is less than (TBS), replace
sensor.

6. Check baffle and drive rolls for damage, burrs, or obstructions.
11-133-1&2 indicates that the lead edge of print did not arrive at the Disk TBS
Sheet Sensor, Q1106A/B, within 260 ms after the Prestacker
declared, the Prestacker Sensor is unblocked and the Disk
Sheet Sensor is blocked.
11-133-1&2 indicates that the lead edge of print did not arrive at the Disk TBS
Sheet Sensor, Q1106A/B, within 330ms after the Bypass
11-138-1&2 indicates that the lead edge of the print delivered from the TBS
Prestacker Sensor, Q1158, did not arrive at the Bypass
Transport Sensor, Q1107A, within 1000ms.
11-140-1&2 indicates that the trail edge of the print did not arrive at the TBS
Bypass Transport Sensor, Q1107A/B, within 325ms (7 pitch)
or 600 ms (3 pitch) after the lead edge of the print arrived at
the Bypass Transport Sensor. When the fault is declared the
Bypass Transport Sensor is blocked. The valid destination
for this print is beyond Stacker A.
Bypass Transport Sensor, Q1107A/B, within 325ms (7 pitch)
or 600 ms (3 pitch) after the lead edge of the print arrived at
the Bypass Transport Sensor. When the fault is declared the
Bypass Transport Sensor is unblocked. The valid destina-
tion for this sheet is beyond Stacker A.
Stacker A Bypass Transport Sensor, Q1107A/B, did not
arrive at the Stacker B Purge Transport Sensor, Q1164,
within 450ms. When the fault is declared, the Stacker B
Purge Transport Sensor is unblocked and the Stacker A
tion for the print is the Purge Tray.
Purge Transport Sensor is unblocked and the Stacker A
Bypass Transport Sensor is blocked. The valid destination
for the print is the Purge Tray.
Purge Transport Sensor is blocked and the Stacker A
tion for the print is the Purge Tray.

Purge Transport Sensor, Q1164, within 350ms (7 pitch) or
670ms (3 pitch) after the lead edge of the print arrived at the
Purge Transport Sensor. The valid destination for this print is
the Purge Tray.
11-146-1&2 Indicates that the lead edge of a print did not arrive at the 1. Check the Disk Home Sensor adjustment (ADJ 11-25)
11-147-1&2 Disk Lead Edge Sensor, Q1166A/B, within 300ms after the
lead edge of the print actuated the Disk Sheet Sensor,
Q1106A/B. This fault only occurs in the 7 pitch mode.
2. Check the Disk Entrance Gate adjustment (ADJ 11-26). These two checks are important if sheets are missing the
disk.
- Check Disk entrance nip for slipping, nipforce or binding.
3. If lead edge damage is apparent on the sheets, check the bypass gate adjustment (ADJ 11-11).
4. Check Q1166 sensor voltage at the test point while holding a sheet of paper at approx. 10mm from the sensor. If
the voltage is less than (TBS), replace the sensor.
5. Check bypass transport alignment (ADJ 10-10). Adjust if necessary.
11-148-1&2 Indicates that the trail edge of a print did not actuate the 1. Check sensor Q1166 part number to ensure that it is not reversed with Q1167.
Disk Lead Edge Sensor, Q1166A/B, within 123ms of the
lead edge of the print actuating the sensor. When the fault is
declared, the sensor is blocked.
This fault is only declared in the 7 pitch mode.
11-149-1&2 Indicates that the trail edge of a print did not actuate the TBS
Disk Lead Edge Sensor, Q1166A/B, within 130ms of the
lead edge of the print actuating the sensor. When the fault is
declared, the sensor is unblocked.
This fault is only declared in the 7 pitch mode.
11-150-1&2 indicates that the trail edge of a print did not arrive at the A3 1. Check the stack height sensor adjustment (ADJ 11-27).
Trail Edge Sensor, Q1167A/B, within 800ms after the trail
edge was detected at the Disk Lead Edge Sensor, Q1166A/
B.
- Check the Trail Edge Right Guide adjustment (ADJ 11-27)
2. Inspect the sheets for any damage or wrinkles that could prevent the sheets from stacking properly.
3. Check the trail edge assist belts for proper operation. Ensure that the belts are not slipping on drive rolls. Clean as
required.
4. Check Q1167 sensor voltage at the TP while holding a sheet of paper at approx. 10mm from sensor. If voltage is
less than (TBS), replace sensor.
5. Check paper stocks. High humidity and/or lightweight stocks can cause problems. Switch to heavier paper if pos-
sible.
11-200 Indicates that the Inverter Front Door Interlock Switch, TBS
S1153, opened with the High Capacity Feeder 3 or Stacker
A Main Drive Motor on.

11-220-1&2 Indicates that the Elevator failed to leave the home position TBS
(max down). The Stacker Elevator Down Sensor, Q1135A/B,
failed to deactuate within 500ms after the UP winding of the
Elevator Motor, MOT1106A/B, was energized to raise the
Elevator.
11-221-1&2 Indicates that the Stacker Elevator Down Sensor, Q1135A/ 1. Check the Stacker elevator motor for loose connection.
B, failed to actuate within 413 cumulative encoder pulses
after the Down winding of the Stacker Elevator Motor,
MOT1106A/B, was energized to lower the Elevator.
2. Check the encoder sensor voltage at the test point. If voltage is less than (TBS), replace sensor. Ensure that the
sensor is not blocked by encoder flag.
3. Check the capacitor cxx connections.
4. Check the lead screw belt tension. Check the belt for damage.
5. Check the stacker elevator tray level. Level as required.
11-222-1&2 Indicates that there were no encoder pulses received from 1. Check the Stacker elevator motor for loose connection.
the Stacker Elevator Encoder Sensor, Q1124A/B, with the
Stacker Elevator Motor, MOT1106A/B, activated. The fault
code can result when the motor is activated in either the up
or down mode.
2. Check the encoder sensor voltage at the test point. If voltage is less than (TBS), replace sensor. Ensure that the
sensor is not blocked by encoder flag.
3. Check the capacitor cxx connections.
4. Check the lead screw belt tension. Check the belt for damage.
5. Check the stacker elevator tray level. Level as required.
11-223-1&2 The Stacker Elevator failed to interrupt the Stack Height TBS
Sensor, Q1122, within 28 sec. after the Stacker Elevator
Motor, MOT1106, was energized to drive the elevator up/
down.
11-224-1&2 Indicates that the Stacker Module Top Cover was sensed TBS
open while Stacker A was in use.
11-228-1&2 Indicates that the Stacker Left Door Interlock Switch, TBS
S1163A/B, deactuated with print in process to the Stacker
bin.
11-229-1&2 Indicates that the Stacker Right Door Interlock Switch, TBS
S1138A/B, deactuated with a print in process to the Stacker
bin.
11-230-1&2 Indicates that the Disk Home Sensor, Q1121A/B, was TBS
unblocked during a run without a disk cycle. The Disk Step-
per failed to maintain the home position.
11-231-1&2 Indicates that there were no transitions in (26 steps w/o FS 1. Check the disk home position adjustment (ADJ 11-25).
Tag 5) or (117 steps w/ FS Tag 5) seen on the Disk Home
Sensor, Q1121A/B. There were too many steps required to
find the disk home position.
2. Check the disk Entrance gate adjustment (ADJ 11-26).

3. Check if the bottom of the disk is touching the stack after the shutdown. Check the stack height adjustment (ADJ
11-27).
4. Check the disk home sensor at the test point. Ensure that the flag is not blocking the sensor. If the voltage is less
than (TBS) replace the sensor.
5. Check the motor coupling. Tighten as required.
11-232-1&2 Indicates that the Right Guide Home Sensor, Q1132A/B, - Check the home sensor, slides, coil cord.
remained blocked after 100 steps of the Right Guide Motor,
MOT1105A/B.
- Check for loose connections
11-233-1&2 Indicates that the Right Guide Home Sensor, Q1132A/B, 1. Run the right guide in dC203. Check for smooth motion. Observe the coil cord and check if it is hanging up or in
remained unblocked after 2600 steps (7 pitch) or 100 steps any way preventing the guide from reaching home. If so, replace the cord.
(3 pitch) of the Right Guide Motor, MOT1105A.
- Slides may be jammed
2. As the guide moves, check the home sensor and flag for any interference. Ensure that the flag crosses the sen-
sor.
3. Inspect the stepper motor and sensor connections.
4. Inspect the guide for any obstructions or anything that could prevent the guide form reaching home.
11-237-1&2 Indicates that the Back Guide Home Sensor, Q1133A/B, -. Check for correct Belt Tension.
remained blocked after 100 steps of the Back Guide Motor,
MOT1105A/B.
- Check the guide squareness adjustment (ADJ 11-33)
- Check the Home sensor
- Check the Back Guide Motor for binding or intermittent operation
11-238-1&2 Indicates that the Back Guide Home Sensor, Q1133A/B, 1. Check the stepper motor belt tension. Ensure that it is not too tight. Adjust as necessary.
remained unblocked after 2600 steps (7 pitch) or 100 steps
(3 pitch) of the Back Guide Motor, MOT1105A/B.
2. Check the back guide squareness adjustment (ADJ 11-33).
3. Run the guide back and forth in dC203, observe if the guide is binding and check for any obstructions (PL 11.7).
4. Inspect the guide harnessing. Ensure that the harness is properly routed and do not interfere with guide move-
ment.
5. Check the home sensor voltage at the test point. If voltage is below (TBS), replace.
6. Inspect the guide for damaged lead screws (PL 11.7).
11-242-1&2 Indicates that there was a Front Tamper positioning failure 1. Inspect front offset assembly for binding linkages, broken or missing parts (PL 11.8).
after the second attempt to extend or retract the Front
Tamper Fingers. The Front Tamper Clutch actuated without
the Front Tamper Position Sensor, Q1135A/B, transitioning
within 200ms.
2. Inspect offset housing for broken plastic shaft snap-in features
3. Check clutch sensor flag and ensure that it does not hit the retract sensor.
4. Check the retract sensor voltage at the test point make sure the sensor is unblocked if voltage is less than (TBS),
replace sensor.
5. Ensure that the front tamper motor coupling is not loose or skipping.
6. Check the rear guide position via dC203 ensure that the guides are not set too tight.

7. Cycle the Fingers via dC203. Ensure that the clutch does not move more than 1/2 revolution. Replace clutch if it
does.
11-244-1&2 Indicates that there was a Back Tamper positioning failure 1. Inspect front offset assembly for binding linkages, broken or missing parts (PL 11.8).
after the second attempt to extend or retract the Back
Tamper Fingers. The Back Tamper Clutch actuated without
the Back Tamper Position Sensor, Q1134A/B, transitioning
within 100ms.
2. Inspect offset housing for broken plastic shaft snap-in features
3. Check clutch sensor flag and ensure that it does not hit the retract sensor.
4. Check the retract sensor voltage at the test point make sure the sensor is unblocked if voltage is less than (TBS),
replace sensor.
5. Ensure that the front tamper drive belt is properly tensioned and not skipping or damaged.
6. Check the rear guide position via dC203 ensure that the guides are not set too tight.
7. Cycle the Fingers via dC203. Ensure that the clutch does not move more than 1/2 revolution. Replace clutch if it
does.
11-250-2 Indicates that a loss of +24 VDC has been detected in the TBS
Feeder/Stacker module. The Printer will enter the Power
Interrupt mode when this fault occurs.
11-270-2 Indicates that a stray print arrived at the Purge Transport TBS
Sensor, Q1164B, unexpectedly. This fault is logged in NVM
only.

DC140 Analog Display Diagnostic Procedure PROCEDURE
PURPOSE NOTE: The ranges given in the table are only valid during a normal (Print Darkness 5) print run
and with a Photoreceptor that has less than 500K prints on it. If the Printer is in a Power Up
NOTE: Prior to performing any of these procedures, ensure that all the appropriate service call Convergence cycle, some dC140 values may not be within the ranges specified. If possible,
procedures have been completed (e.g., Initial Action, RAPs, NRDs, HFSIs due). wait for the Power Up Convergence cycle to complete.
Use this procedure when isolating the causes of an out-of-range value in dC140.
1. Make a print of the frames provided at the end of the dC140 section to record the dis-
played values.
General Troubleshooting Information
2. Enter dC140 [Dicorotron Values]. Select Continue. Check the values returned for any out-
of-range readings. (Refer to the dC140 Diagnostic Table)
NOTE: Read this section completely before beginning the procedure.
3. Select [DC Bias Values]. Select Continue. Check the values returned for any out-of-range
If any out-of-range values are noted, use the information given below, and the procedures and readings. (Refer to the dC140 Diagnostic Table)
references provided in the table to troubleshoot.
4. If any value is out-of-range ensure that the correct dC314 power supply calibration value
has been entered.
When using the fault code references, use the appropriate diagnostic procedure.
5. If a value is still out-of-range, replace any Dicorotrons and Shields associated with that
value (PL 9.10 and PL 9.11).
If excessive developer or toner contamination is noted in the Xerographic area, find and repair
the cause of the contamination. The Cleaner and Developer subsystems are high suspect 6. If any Control value is out-of-range, ensure that the appropriate NVM locations have the
causes. correct values.
7. If any Monitor value is out-of-range, check the following voltages:
A Monitor value depends on its corresponding Control value being correct. a. + and - 15 VDC +/- 0.25 VDC is present at the HVAC and HVDC PWBs (referenced
to DC Common on the PWB being checked)
The Control and Monitor values for each corresponding input/output should be within +/- 0.2
b. + and - 34 VDC +/- 1.0 VDC is present at the HVAC and HVDC PWBs (referenced to
VDC of each other.
DC Common on the PWB being checked)
c. 48 KHz is present and stable at the HVDC PWB (2.5 to 9 VAC)
The Required and Actual voltages in the [DC Bias Values] portion of dC140 should be within +/
- 5 VDC for their respective outputs. Also, the values for the Cleaner Brush, and the Lower and d. 24 KHz is present and stable at the HVAC PWB (2.5 to 9 VAC)
Upper Detoning Rollers may be as much as 30 VDC lower than the real voltages at the 8. Use the PQ RAP references as additional sources of information to fix the out-of-range
Cleaner. problem.
Table 1 dC140 Diagnostic

Parameter Range Procedures References Purpose
Coronode AC 8.0 to 9.8 VDC 1. Check the dC131 [MIN] locations BSD 9.1 (Sheet 2) Fault Code: 9-202, 9- This signal provides the control point voltage to the HVAC PWB. The
Voltage Control 146 (Dicor AC Voltage Reference) 328, 9-329 dC314: COR$$ACV IQ RAP: actual value of this signal is determined during Power Up Convergence
and 223 (Dicorotron AC Target). 9-626 or the Initialization portion of dC951 (ACV Setpoint).
Coronode AC 8.0 to 9.8 VDC BSD 9.1 (Sheet 2) Fault Code: 9-202, 09- This is the signal returned to the ADA PWB that informs the control logic
Voltage Monitor 328, 9-329 dC314: COR##ACV IQ RAP: about the AC Coronode voltage being produced. This value should be
9-626 within +/- 0.2 VDC of the Control Point.
Coronode AC 2.0 to 4.8 VDC BSD 9.1 (Sheet 2) dC314: COR##ACI IQ This is the signal returned to the ADA PWB that informs the control logic
Current Monitor RAP: 9-626 about the AC Coronode current being produced for the applied level of
the AC Coronode voltage. This parameter is neither controlled or moni-
tored for fault detection.
Charge 2 Voltage 3.4 to 4.6 VDC BSD 9.2 (Sheet 1) Fault Code: 9-203, 9- This signal provides the control point voltage to the HVDC PWB for the
Control 213, 9-325 dC314: CHG2$$SV IQ RAP: required shield bias of the Charge 2 Dicorotron. This value is also the ini-
9-626 tial charge voltage required on the PR Belt. Its value is dependent upon
the amount of Dark Decay and Dark Dusting Target voltage required.

No Product Name Assigned ?-121 DC140 Analog Display Diagnostic Procedure
Charge 2 Voltage 3.4 to 4.6 VDC BSD 9.2 (Sheet 1) Fault Code: 9-203, 9- This is the signal returned to the ADA PWB that informs the control logic
Monitor 213, 9-325 dC314: CHG2##SV IQ RAP: about the amount of Charge 2 shield bias being produced. This value
9-626 should be within +/- 0.2 VDC of the Control Point. The actual voltage that
corresponds to the monitor is displayed in dC909.
Charge 1 Voltage 3.2 to 5.3 VDC BSD 9.2 (Sheet 1) dC314: CHG1##SV IQ This is the signal returned to the ADA PWB that informs the control logic
Monitor RAP: 9-626 about the amount of Charge 1 shield bias being produced. This parame-
ter is not monitored for fault detection. The actual voltage that corre-
sponds to the monitor is displayed in dC909.
Charge 2 Current 0 to 0.2 VDC BSD 9.2 (Sheet 1) Fault Code: 9-203, 9- This signal provides the control point voltage to the HVDC PWB required
Control 213 dC314: CHG2$$SI IQ RAP: 9-626 for the Charge 2 shield current. The required shield current is dependent
on the potential difference between the Charge 2 shield bias and the PR
Belt charge. If a potential difference is measured, the HVDC PWB will
increase/decrease the Charge 1 shield bias until the potential between
the PR Belt and the Charge 2 shield is equal.
Charge 2 Current 0 to 0.2 VDC BSD 9.2 (Sheet 1) Fault Code: 9-203, 9- This is the signal returned to the ADA PWB that informs the control logic
Monitor 213, 9-330 dC314: CHG2##SI IQ RAP: 9- about the amount of Charge 2 shield current being produced. This value
626 should be within +/- 0.2 VDC of the Control Point. The actual voltage that
corresponds to the monitor is displayed in dC909.
Charge 1 Current 2.5 to 5.5 VDC BSD 9.2 (Sheet 1) dC314: CHG1##SI IQ This is the signal returned to the ADA PWB that informs the control logic
Monitor RAP: 9-626 about the amount of Charge 1 shield current being produced. There is no
corresponding control point or ault detection for this parameter. The
actual voltage that corresponds to the monitor is displayed in dC909.
Transfer Current 3.4 to 4.3 VDC 1. Check the dC131 [MIN] location BSD 9.2 (Sheet 1) Fault Code: 9-326 This signal provides the control point voltage to the HVDC PWB required
Control 210 (Transfer Shield Current Normal). dC314: TRAN$$SI IQ RAP: 9-626 for the Transfer shield current.
Transfer Current 3.4 to 4.3 VDC BSD 9.2 (Sheet 1) Fault Code: 9-326 This is the signal returned to the ADA PWB that informs the control logic
Monitor dC314: TRAN##SI IQ RAP: 9-626 about the amount of Transfer shield current being produced. This value
should be within +/- 0.2 VDC of the Control Point.
Transfer Voltage 6.0 to 8.5 VDC BSD 9.2 (Sheet 1) dC314: TRAN##SV IQ This is the signal returned to the ADA PWB that informs the control logic
Monitor RAP: 9-626 about the amount of Transfer shield bias being produced. This parameter
is not monitored for fault detection.
Detack Current 3.4 to 5.6 VDC 1. Check the dC131 [MIN] location BSD 9.2 (Sheet 1) Fault Code: 9-327 This signal provides the control point voltage to the HVDC PWB required
Control 202 (Detack Shield Current Refer- dC314: DTAC$$SI IQ RAP: 9-626 for the Detack shield current.
ence).
Detack Current 3.4 to 5.6 VDC BSD 9.2 (Sheet 1) Fault Code: 9-327 This is the signal returned to the ADA PWB that informs the control logic
Monitor dC314: DTAC##SI IQ RAP: 9-626 about the amount of Detack shield current being produced. This value
Detack Voltage 3.4 to 5.6 VDC BSD 9.2 (Sheet 1) dC314: DTAC##SV IQ This is the signal returned to the ADA PWB that informs the control logic
Monitor RAP: 9-626 about the amount of Detack shield bias being produced. This parameter
is not monitored for fault detection.
Preclean Cur- 5.9 to 6.7 VDC 1. Check the dC131 [MIN] location BSD 9.2 (Sheet 1) Fault Code: 9-328 This signal provides the control point voltage to the HVDC PWB required
rent Control 204 (Preclean Shield Current Refer- dC314: PCLN$$SI IQ RAP: 9-626 for the Preclean shield current.
ence).
Preclean Cur- 5.9 to 6.7 VDC BSD 9.2 (Sheet 1) Fault Code: 9-328 This is the signal returned to the ADA PWB that informs the control logic
rent Monitor dC314: PCLN##SI IQ RAP: 9-626 about the amount of Preclean shield current being produced. This value

DC140 Analog Display Diagnostic Procedure ?-122 No Product Name Assigned
Preclean Volt- 5.3 to 9.9 VDC BSD 9.2 (Sheet 1) dC314: PCLN##SV IQ This is the signal returned to the ADA PWB that informs the control logic
age Monitor RAP: 9-626 about the amount of Preclean shield bias being produced. This parame-
ter is not monitored for fault detection.
Dev Rolls 1 & 2 4.0 to 7.5 VDC 1. Check the dC131 [MIN] location BSD 9.2 (Sheet 3) Fault Code: 9-320 This signal provides the control point voltage to the HVDC PWB needed
Voltage Control 217 (Developer Rolls 1 & 2 Unit Ref- dC314: DEV1$$BV IQ RAP: 9-616 for the Developer Rolls 1 and 2 Bias voltage. This bias voltage changes,
erence). based on print mode. In standard mode, the specification for this bias is
130 volts more negative than the background voltage.
Dev Rolls 1 & 2 160 to 300 VDC 1. Check the dC131 [MIN] location BSD 9.2 (Sheet 3) Fault Code: 9-320 This is the corresponding voltage required by the Control Point.
Voltage Required 217 (Developer Rolls 1 & 2 Unit Ref- dC314: DEV1$$BV IQ RAP: 9-616
erence).
Dev Rolls 1 & 2 4..0 to 7.5 VDC BSD 9.2 (Sheet 3) Fault Code: 9-320 This is the signal returned to the ADA PWB that informs the control logic
Voltage Monitor dC314: DEV1##VM IQ RAP: 9-616 about the amount of Developer Rolls 1 and 2 Bias voltage being pro-
duced. This value should be within +/- 0.2 VDC of the Control Point.
Dev Rolls 1 & 2 160 to 300 VDC BSD 9.2 (Sheet 3) Fault Code: 9-320 This is the actual voltage being produced at the Developer Rolls 1 and 2.
Voltage Actual dC314: DEV1##VM IQ RAP: 9-616 This value should be within 5 VDC of the Required voltage. The value
also is displayed in dC909.
Dev Roll 3 Volt- 5.0 to 9.5 VDC 1. Check the dC131 [MIN] location BSD 9.2 (Sheet 3) Fault Code: 9-321 This signal provides the control point voltage to the HVDC PWB needed
age Control 218 (Developer Roll 3 Unit Refer- dC314: DEV2$$BV IQ RAP: 9-616 for the Developer Roll 3 Bias voltage. This bias voltage changes, based
ence). on print mode. In standard mode, the specification for this bias is 30 volts
more negative than the Developer Rolls 1 and 2 voltage.
Dev Roll 3 Volt- 200 to 380 VDC 1. Check the dC131 [MIN] location BSD 9.2 (Sheet 3) Fault Code: 9-321 This is the corresponding voltage required by the Control Point.
age Required 218 (Developer Roll 3 Unit Refer- dC314: DEV2$$BV IQ RAP: 9-616
ence).
Dev Roll 3 Volt- 5.0 to 9.5 VDC BSD 9.2 (Sheet 3) Fault Code: 9-321 This is the signal returned to the ADA PWB that informs the control logic
age Monitor dC314: DEV2##VM IQ RAP: 9-616 about the amount of Developer Roll 3 Bias voltage being produced. This
value should be within +/- 0.2 VDC of the Control Point.
Dev Roll 3 Volt- 200 to 380 VDC BSD 9.2 (Sheet 3) Fault Code: 9-321 This is the actual voltage being produced at the Developer Roll 3. This
age Actual dC314: DEV2##VM IQ RAP: 9-616 value should be within 5 VDC of the Required voltage. The value also is
displayed in dC909.
Cleaner Brush 5.5 to 6.3 VDC 1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-322 This signal provides the control point voltage to the HVDC PWB needed
Voltage Control 200 (Cleaner Bias Reference for Nor- dC314: CLNR$$BV IQ RAP: 9-617 for the Cleaner Brush Bias voltage.
mal mode).
Cleaner Brush 223 to 249 VDC 1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-322 This is the corresponding voltage required by the Control Point.
Voltage Required 200 (Cleaner Bias Reference for Nor- dC314: CLNR$$BV IQ RAP: 9-617
mal mode).
Cleaner Brush 5.5 to 6.3 VDC BSD 9.1 (Sheet 1) Fault Code: 9-322 This is the signal returned to the ADA PWB that informs the control logic
Voltage Monitor dC314: CLNR##VM IQ RAP: 9-617 about the amount of Cleaner Brush Bias voltage being produced. This
value should be within +/- 0.2 VDC of the Control Point.
Cleaner Brush 223 to 249 VDC BSD 9.1 (Sheet 1) Fault Code: 9-322 This is the actual voltage being produced at the Cleaner Brush. This
Voltage Actual dC314: CLNR##VM IQ RAP: 9-617 value should be within 5 VDC of the Required voltage. This voltage may
be as much as 30 VDC lower than the real voltage at the Cleaner Brush.
Lower Detoning 5.3 to 6.1 VDC 1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-324 This signal provides the control point voltage to the HVDC PWB needed
Roll Voltage 208 (Waste Bias Reference for Dead dC314: WAST$$BV IQ RAP: 9-617 for the Lower Detoning Roll.
Control Cycle mode).

Lower Detoning 539 to 601 VDC 1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-324 This is the corresponding voltage required by the Control Point. During
Roll Voltage 208 (Waste Bias Reference for Dead dC314: WAST$$BV IQ RAP: 9-617 normal operation, the Lower Detoning Roll requirement is 600 VDC mea-
Required Cycle mode). sured, with respect to the Cleaner Brush.
Lower Detoning 5.3 to 6.1 VDC BSD 9.1 (Sheet 1) Fault Code: 9-324 This is the signal returned to the ADA PWB that informs the control logic
Roll Voltage dC314: WAST##VM IQ RAP: 9-617 about the amount of Lower Detoning Roll Bias voltage being produced.
Monitor This value should be within +/- 0.2 VDC of the Control Point.
Lower Detoning 539 to 601 VDC BSD 9.1 (Sheet 1) Fault Code: 9-324 This is the actual voltage being produced at the Lower Detoning Roll.
Roll Voltage dC314: WAST##VM IQ RAP: 9-617 This value should be within 5 VDC of the Required voltage. This voltage
Actual may be as much as 30 VDC lower than the real voltage at the Lower
Detoning Roll.
Upper Detoning 5.9 to 6.7 VDC 1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-323 This signal provides the control point voltage to the HVDC PWB needed
Roll Voltage 206 (Reclaim Bias Reference for Nor- dC314: RCLM$$BV IQ RAP: 9-617 for the Upper Detoning Roll.
Control mal mode).
Upper Detoning 359 to 396 VDC 1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-323 This is the corresponding voltage required by the Control Point. During
Roll Voltage 206 (Reclaim Bias Reference for Nor- dC314: RCLM$$BV IQ RAP: 9-617 normal operation, the Upper Detoning Roll requirement is -400 VDC
Required mal mode). measured, with respect to the Cleaner Brush.
Upper Detoning 5.9 to 6.7 VDC BSD 9.1 (Sheet 1) Fault Code: 9-323 This is the signal returned to the ADA PWB that informs the control logic
Roll Voltage dC314: RCLM##VM IQ RAP: 9-617 about the amount of Upper Detoning Roll Bias voltage being produced.
Monitor This value should be within +/- 0.2 VDC of the Control Point.
Upper Detoning 359 to 396 VDC BSD 9.1 (Sheet 1) Fault Code: 9-323 This is the actual voltage being produced at the Upper Detoning Roll.
Roll Voltage dC314: RCLM##VM IQ RAP: 9-617 This value should be within 5 VDC of the Required voltage. This voltage
Actual may be as much as 30 VDC lower than the real voltage at the Upper
Detoning Roll.

Figure 1 dC140 Analog Display Dicorotron Values

Figure 2 dC140 Analog Display DC Bias Values

Figure 3 dC140 Analog Display Fuser Values

DC909 P/R Belt Seam And Xerographic Test 2. Enter dC909. Select Continue. Check the values returned for any out-of-range readings.
(Refer to the dC909 Diagnostic Table)
PURPOSE 3. Select [ESV-DSS Test]. Select Continue. Check the values returned for any out-of-range
NOTE: Prior to performing any of these procedures, ensure that all appropriate service call readings. (Refer to the dC909 Diagnostic Table, Table 1 and Figure 2)
procedures have been completed (e.g., Initial Action, RAPs, NRDs, HFSIs due). 4. If any 09-3XX faults occur use the following procedure to mask them, and rerun dC909:
Use this procedure when isolating the causes of an out-of-range value in dC909. a. Enter dC131 [MIN]. Enter location 179. Note and record the present value. Change
the value to 164.
General Troubleshooting Information b. Enter dC909. Select [Continue]. Check the values returned for any out-of-range
readings. (Refer to the dC909 Diagnostic Table, Table 1 and Figure 1).
NOTE: Read this section completely before beginning the procedure. c. Select [ESV - DSS Test] Select Continue. Check the values returned for any out-of-
range readings (refer to the dC909 Diagnostic Table, Table 1 and Figure 2).
If any out-of-range values are noted, use the information given below, and the procedures and
references provided in the table to troubleshoot. NOTE: Ignore any other fault codes that may occur. Also be sure to reset the value
in dC131 [MIN] location 179 to its original value before continuing.
If excessive developer or toner contamination is noted in the Xerographic area, find and repair
the cause of the contamination. The Cleaner and Developer subsystems are suspect causes. 5. If a value is out-of-range, replace any Dicorotrons and Shields associated with that value
(PL 9.10 & PL 9.11).
When using the fault code references, use the appropriate diagnostic procedure. 6. If any value is out-of-range, ensure that the correct dC314 power supply calibration value
has been entered.
PROCEDURE 7. Use the PQ RAP references as additional sources of information to fix the out-of-range
problem.
NOTE: The ranges given in the table are only valid during a normal (NORMAL) print run and
with a Photoreceptor that has less than 500K prints on it. If the Printer is in a Power Up Con-
vergence cycle, some dC909 values may not be within the ranges specified. If possible, wait
for the Power Up Convergence cycle to complete.
1. Enter dC909 section to record the displayed values.

Charge Ratio 55 to 75 Check the dC131 [MIN] loca- BSD 9.10 (sheet 2) Fault Code: 9-202 This is a ratio of the Charge 1 Current divided by the Charge 1 Voltage. The level of
tion 223 (Dicorotron AC Tar- PQ RAP: 9-626 the Coronode AC Voltage determines this ratio. The ratio increases as the coronode
get) voltage increases.
Charge 1 (V) 1300 to 2100 BSD 9.10 (SHEET 1) dC314: This is the amount of shield voltage placed on the Charge 1 Dicorotron by the HVDC
VDC / 2000 to CHGO##SV PQ RAP: 9-626 PWB. This voltage is the amount needed to charge the PR Belt to a voltage equal to
3000 VDC W the Charge 2 Voltage. The monitor voltage for this output is displayed in dC140.
MICR
Charge 1 (uA) 75 to 155 ua / BSD 9.10 (SHEET 1) dC314: This is the amount of Charge 1 shield current. This current is a result of the Charge 1
125 to 250 ua CHGO##S1 PQ RAP: 9-626 Shield voltage applied to the dicorotron and the AC Voltage on the coronode. The
W MICR monitor voltage for this input is displayed in dC140.
Charge 2 (V) 750 to 950 VDC BSD 9.10 (SHEET 1) dC314: This is the amount of shield voltage placed on the Charge 2 Dicorotron by the HVDC
/ 850 to 1000 CHGO##S FAULT CODE:9-203, 9-213, PWB. This voltage is the initial charge that is placed on the PR Belt to obtain the cor-
VDC W MICR 9-325 PQ RAP: 9-626 rect Dark Dusting target voltage, and is based on the Dark Decay voltage. The control
logic always assumes that the initial charge on the PR Belt is equal to the Charge 2
Shield voltage. The monitor voltage for this output is displayed in dC140.

DC909 P/R Belt Seam And Xerographic Test ?-128 No Product Name Assigned
Charge 2 (uA) -5 to 5 ua BSD 9.10 (SHEET 1) dC314: This is the amount of shield current flow from the Charge 2 Dicorotron. This current is
CHGO##SI Fault Code:9-203, 9-213 a result of the potential difference between the Charge 2 Shield voltage and the
PQ RAP: 9-616 charge placed on the PR Belt by the Charge 1 Dicorotron. If any current is detected,
the HVDC PWB controls the Charge 1 Shield voltage to bring the current back to 0
ua. When this current is 0 ua, the control logic knows that the charge on the belt is
equal to the Charge 2 Shield voltage. The monitor voltage for this output is displayed
in dC140.
Dev Rolls 1 & 2 185 to 285 VDC Check The dC131 [MIN] loca- BSD 9.3 dC314: DEV1$$BV Fault This is the voltage applied to the Developer Rolls 1 and 2. There is a specification for
(V) tion 217 (Developer rolls 1 Code:9-230 PQ RAP: 9-616 this voltage in each print mode. These specifications are set automatically during
and 2 Unit) dC951. This value also is displayed in dC140.
Dev Roll 3 (V) 235 to 335 VDC Check The dC131 [MIN] loca- BSD 9.3 dC314: DEV2$$BV Fault This is the voltage applied to the Developer Roll 3. There is a specification for this
tion 218 (Developer roll 3 Unit Code:9-231 PQ RAP: 9-616 voltage in each print mode. These specifications are set automatically during dC951.
Reference) This value also is displayed in dC140.
ESV Target (V) 700 to 800 VDC BSD 9.9 (Sheet 1) Fault Code:9-203, 9- This is the expected ESV reading on the next patch (ID Zone 2,4 and 6), based on
/ 800 to 900 213 PQ RAP: 9-619 the Charge 2 Shield voltage. The value depends on the Dark Dusting, Dark Decay,
VDC W MICR and Charge 2 Voltages.
Dark Dusting 670 to 770 VDC BSD 9.9 Fault Code:9-203, 9-213 PQ This is the target voltage of the latent image on the PR Belt, when the image arrives
/ 800 to 900 RAP: 9-616 at developer roll #1. This is the voltage the control logic is trying to maintain, based on
VDC W MICR the Dark Decay voltage. The High and Low contrast voltages are based on this value
and the Exposure Setpoint. This value for each print mode is setup during dC951.
Dark Decay 50 to 150 VDC BSD 9.9 Fault Code:9-203, 9-213 PQ This value is the loss of charge between the Charge 2 Dicorotron and the ESV. The
RAP: 9-601 total dark decay is equal to the Charge 2 Voltage minus the ESV Target Voltage times
(1.4). Then, Charge 2 Voltage is adjusted by subtracting the Dark Decay from the
Charge 2 Voltage, and comparing it to the Dark Dusting.
Exposure Set- 72 to 182 Check the dC131 [MIN] loca- BSD 6.2 (Sheet 2) Fault Code: 6-357, 6- This is a digital value that represents the amount of ROS exposure intensity. This
point tions 152 (Printer Scan Detec- 363, 6-364 value is calculated during dC951. The High and Low contrast voltages are based on
tion Calibration Normal) and this value and the Dark Dusting.
153 (Printer Scan Detection
Calibration Print Darkness 1).
The range given for this
parameter is with a normal
ROS. If the power output from
the ROS is low, this value can
be as high as 240. If the sys-
tem is meeting PQ specifica-
tions, a higher value is not
considered a problem and the
ROS assembly should not be
replaced.
PGEN Refer- 1.2 to 2.2 VDC / BSD 9.9 (SHEET 1) Fault Code: 9-211 This is the reference voltage applied to the Patch Generator to control its output
ence 1.6 to 2.6 VDC PQ RAP: 9-621 intensity: the higher the number, the brighter the Generator. The Patch Generator will
W MICR not switch on unless this value is at least 1.0 VDC. This value is calculated during
dC951 to ensure that the patch is always developed at approximately -300 volts.
Thus any changes measured by the DSS of the developed patch must be due to the
toner concentration. This value varies with each print mode.

No Product Name Assigned ?-129 DC909 P/R Belt Seam And Xerographic Test
ESV ID Zone 50 to 170 VDC / BSD:9.9 Fault Code: 9-213 PQ RAP: This is the background voltage reading, after exposure by the ROS.
Clean Frames 100 to 200 VDC 9-619
(1, 3, 5) W/ MICR
ESV ID Zone 700 to 800 VDC BSD:9.9 Fault Code: 9-213 PQ RAP: This is the charged patch values. This reading, along with the DSS readings in the
Patch Frames / 850 to 950 9-619 Patch Frames is used for Charge Control and Toner Concentration Control by the
(2, 4, 6) VDC W/ MICR control logic. This value should be about the same as the ESV Target Voltage.
ESV Test Pat- 150 to 250 VDC BSD:9.9 Fault Code: 9-213 PQ RAP: This is the reading by the ESV of the 0.2 density area block of the resident xero-
tern Position #1 / 200 to 300 9-619 graphic test pattern printer during dC909. The magnitude of the individual voltage is
VDC W/ MICR not important; however, the magnitude of the voltage compared to the other 4 ESV
Test Pattern Positions is important.
ESV Test Pat- 50 to 170 VDC / BSD:9.9 Fault Code: 9-213 PQ RAP: This is the reading by the ESV of the background area block of the resident xero-
tern Position #2 100 to 200 VDC 9-619 graphic test pattern printer during dC909. The magnitude of the individual voltage is
W/ MICR not important; however, the magnitude of the voltage compared to the other 4 ESV
DSS ID Zone 85 to 105 BSD:9.9 (SHEET 2) Fault Code 9-215 This is the reflectance of the developed patch after exposure by the Patch Generator.
Patch Frames PQ RAP: 9-620, 9-621 This reading along with the ESV readings in the Patch Frames, is used for Charge
(2, 4, 6) Control and Toner Concentration Control by the control logic. As toner concentration
increases, the patch gets darker, and the DSS reading decreases.
DSS Test Pat- 190 to 240 BSD 9.9 (Sheet 2) Fault Code 9-215 PQ This is the reading by the DSS of the 0.2 density area block of the resident xero-
tern Position #1 RAP 621 graphic test pattern printer during dC909.
DSS Test Pat- 210 to 270 / 218 BSD:9.9 (SHEET 2) Fault Code 9-215 This is the reading by the DSS of the background area after exposure by the ROS.
tern Position #2 to 246 W/ MICR PQ RAP: 9-620
DSS Test Pat- 55 to 70 BSD 9.5 Fault Code 9-215 PQ RAP: 9- This is the reading by the DSS of the 1.2 density area block of the resident xero-
tern Position #3 620 graphic test pattern printer during dC909.
DSS Test Pat- 190 to 240 / 150 BSD:9.9 (SHEET 2) Fault Cod 9-215 This is the reading by the DSS of the 0.35 density area block of the resident xero-
tern Position #4 to 200 W/ MICR PQ RAP: 9-620 graphic test pattern printer during dC909.
DSS Test Pat- 120 to 180 BSD:9.9 (SHEET 2) Fault Cod 9-215 This is the reading by the DSS of the 0.7 density area block of the resident Xero-
tern Position #5 PQ RAP: 9-620 graphic Test Pattern printer during dC909.
Toner Dispens- % Duty Cycle BSD:9.7 & 9.9 Fault Code 9-215 PQ This is the command for the toner dispenser motor, based on the DSS readings. For
ing <100 RAP: 9-620 a DSS reading less than 78, the command is off; between 78 and 81, the command is
(MICR 105) duty-cycle; between 82 and 88, the command is on; two consecutive readings higher
than 88, the command is on, and the Printer enters the dead cycle mode. The Printer
must return to the duty-cycle range within 18 PR Belt revolutions, after entering the
dead cycle mode.

ESV Reading 0 to 6 VDC Check the dC131 [MIN] loca- BSD:9.9 Fault Code 9-213 PQ RAP: 9- This is the voltage read by the ESV as calculated by the control logic based on the
tion 260 (ESV Adjustment) 619 ESV Monitor input voltage.
ESV Monitor 0.8 to 1.2 VDC BSD:9.9 Fault Code 9-213 PQ RAP: 9- This is the actual input voltage from the ESV to the control logic, used to calculate the
619 ESV Reading. This is the value of an uncharged PR Belt. This value is used through-
out print jobs to determine the charge on the PR Belt.
ESV Offset -5 to 5 / -8 to Perform the dC912 PR Unifor- BSD:9.9 Fault Code 9-203, 9-213 PQ This reading is the difference between the average of three readings in ID Zones #2
(Control Patch +8 W MICR mity check RAP: 9-619 and the total P/R image average. The offset values from Patch #2, 4 and #6 are used
#2) by the control logic prior to making changes to the charge value. These offsets are
needed, due to small variations in the PR Belt surface. Large variations from reading
to reading indicate that something is wrong.
(Control Patch +8 W MICR mity check RAP: 9-619 and the total P/R image average. The offset values from Patch #2,4 and #6 are used
(Control Patch +8 W MICR mity check RAP: 9-619 and the total P/R image average. The offset values from Patch #2, 4 and #6 are used
DSS Reading 218 to 246 Check the dC131 [MIN] loca- BSD:9.9 Fault Cod 9-212 PQ RAP: 9- This value is the DSS reading of a clean belt. It is used by the DSS to adjust its inter-
tion 259 (DSS Adjustment) 620 nal gain. A value of 255 indicates that the DSS calibrated itself to a contaminated
Photoreceptor Belt.

Figure 1 dC909 Xerographic Patch Test

Figure 2 dC909 ESV - DSS Test

DC951 Auto Xerographic Setup If excessive toner or developer contamination is noted in the Xerographic area, find and repair
the cause of the contamination. The Cleaner and Developer subsystems are suspect causes.
PURPOSE
When using the fault code references, use the appropriate diagnostic procedure.
NOTE: Prior to performing any of these procedures, ensure that all appropriate service call
procedures have been completed (e.g., Initial Action, RAPs, NRDs, HFSIs due).
PROCEDURE
Use this procedure when isolating the causes of an out-of-range value in dC951.
1. Enter dC951 [Xero]. Select Continue. Check the values returned for any out of range
readings. (Refer to the dC951 Diagnostic Table)
General Troubleshooting Information
2. If a value is out of range, replace any Dicorotrons and Shields associated with that range
(PL 9.10, PL 9.11).
NOTE: Read this section completely before beginning the procedure.
3. If any value is out of range, ensure that the correct dC314 power supply calibration value
If any out of range values are noted, use the information given below, and the procedures and has been entered.
references provided in the table to troubleshoot.
4. Use the PQ RAP references as additional sources of information to fix the out-of-range
problem.

ESV Monitor 22 to 35 1. Replace the 2 Charge BSD 9.9 Fault Code: 9- This is the digital value of the ESV Monitor voltage displayed in dC909. This value is for an
Dicorotrons and Shields (PL). 213 PQ RAP: 9-619 uncharged PR Belt. During normal operation the control logic uses this value to determine the
charge on the PR Belt.
2. Check the Charge Dicorotron
Height and Balance adjustment (9-6
& 9-7).
3. Reseat the HVAC & HVDC con-
nectors.
4. Check the Ozac system, HVDC
cables and Dicorotrons for opens,
loose connections, contamination,
and arcing.
DSS Calibration 218 to 246 1. Check the ground wire to the PR BSD 9.10 (SHEET 3) This is the DSS measurement of a clean patch. It is used to adjust the internal gain of the DSS to
Module from the PR Drawer. Fault Code: 9-212 PQ produce 9.0 VDC input voltage to the control logic.
RAP: 9-620
2. Check the wires from the MIN
DIO PWB to the DSS. Ensure that
the wires are not rubbing on the
frame above the processor com-
pressor.
3. If there is dirt on the Photorecep-
tor or DSS, Go to the PQ 9-601
RAP.
ACV Setpoint 210 to 247 1. Replace the 2 Charge BSD 9.10 (SHEET 3) This is a calculated value of the amount of AC voltage that is applied to each of the five dicorotrons.
Dicorotrons and Shields (PL 9.10 Fault Code: 9-202 PQ If this value is too high, there is the possibility of AC arcs. Also, controlling the shield currents may
RAP: 9-626 be difficult, because a small change in voltage results in a large change of current. If this value is
too low, the DC voltages may arc or the power supply may not be able to obtain the required shield
current.
2. Check the Charge Dicorotron
Height and Balance adjustment
(9-6 & 9-7).

DC951 Auto Xerographic Setup ?-134 No Product Name Assigned
3. Check the Ozac system, HVDC
cables and Dicorotrons for opens,
loose connections, contamination,
and arcing.
ACV Slope 95 +/- 3 BSD 9.10 (SHEET 3) PQ This is the ratio of the Charge 1 shield current divided by the Charge 1 shield voltage. This is used
RAP: 9-626 to determine when the AC Coronode voltage is at a nominal value for the correct operation.
ESV Offset ID -8 to 8 1. Perform the dC912 PR Uniformity BSD 9.9 (SHEET 2) Fault This reading is the difference between the average of three readings in ID Zones #2 and the aver-
Control Patch 2 check. Code: 9-203, 9-213 PQ age. The offset values from Patch #2 and #6 are used by the control logic prior to making the
RAP: 9-619 changes to the charge value. These offsets are needed, due to small variations in the PR Belt sur-
face. Large variations from reading to reading indicate that something is wrong.

Control Patch 4 check. Code: 9-203, 9-213 PQ age . The offset values from Patch #2 and #6 are used by the control logic prior to making the
Control Patch 6 check. Code: 9-203, 9-213 PQ age . The offset values from Patch #2 and #6 are used by the control logic prior to making the
High Charge 10 to 30 BSD 9.9 (SHEET 2) Fault This is one of two dark decay parameters measured during dC951. It, along with the Low Charge
Dark Decay Code: 9- 203, 9-213 PQ Dark Decay will be used to calculate the Dark Decay Intercept. It is measured, using a different
RAP: 9-620 value for the Charge 2 shield voltage than is used for the Low Charge Dark Decay.
Low Charge 8 to 28 BSD 9.9 (SHEET 2) Fault This is one of two dark decay parameters measured during dC951. It, along with the High Charge
Dark Decay Code: 9-203, 9-213 PQ Dark Decay will be used to calculate the Dark Decay Intercept. It is measured, using a different
RAP: 9-620 value for the Charge 2 shield voltage than is used for the High Charge Dark Decay.
Dark Decay 0 to 35 BSD 9.9 (SHEET 2) Fault This is the value calculated from the High and Low Charge Dark Decay values. It, along with the
Intercept Code: 9-203, 9-213 PQ ESV reading of the patch are used to determine the Charge 2 shield voltage and when to declare a
RAP: 9-620 9-203 fault due to a high Dark Decay.
Charge 2 Set- 99 to 159 BSD 9.10 (SHEET 1) This is the Charge 2 Shield Voltage used in setting up the High and Low Density Contrast in the
point (PD 5) Print Darkness 4 mode.
Exposure Set- 27 to 228 1. Check dC131 [MIN] locations 152 BSD 6.2 (Sheet 2) Fault This is the background voltage of the PR Belt after it has been charged and then exposed by the
point (PD 5) (Printer Scan Detection Calibration Code: 6-357, 6-363, 6- ROS Assembly in the Print Darkness 4 mode. This is one of the values used in determining the
Normal) and 153 (Printer Scan 364 appearance of a print for the various Print Darkness modes.
Detection Calibration Print Dark-
ness 1).
High Density 116 +/- 2 1. Check the dC131 [MIN] locations BSD 9.9 Fault Code: 9- This value is equal to the ESV reading of a solid patch, created by the ROS, minus the ESV reading
Contrast (PD 5) 223 (Dicorotron AC Target), 225 203, 9-213 PQ RAP: 9- of the background area, created by an exposed area of the belt in the Print Darkness 4 mode. This
(ESV Calibration factor), and 260 633 is one of the values used to determine the appearance of a print for the various Print Darkness
(ESV Adjust). modes.
Low Density 32 +/- 1 1. Check the dC131 [MIN] locations BSD 9.9 Fault Code: 9- This value is equal to the ESV reading of a 0.35 density patch, created by the ROS, operating in the
Contrast (PD 5) 223 (Dicorotron AC Target), 225 203, 9-213 PQ RAP: 9- ROS Patch Exposure mode, minus the ESV reading of the background area, created by an
(ESV Calibration factor), and 260 633 exposed area of the belt in the Print Darkness 4 mode. This is one of the values used to determine
(ESV Adjust). the appearance of a print for the various Print Darkness modes.

No Product Name Assigned ?-135 DC951 Auto Xerographic Setup
Charge 2 Set- 74 to 134 BSD 9.10 (SHEET 1) This is the Charge 2 Shield Voltage used in setting up the High and Low Density Contrast in the
point (PD 1) Print Darkness 1 mode.
Exposure Set- 54 to 255 1. Check the dC131 [MIN] locations BSD 6.2 (Sheet 2) Fault This is the background voltage of the PR Belt after it has been charged and then exposed by the
point (PD 1) 152 (Printer Scan Detection Cali- Code: 6-357, 6-363, 6- ROS Assembly in the Print Darkness 1 mode. This is one of the values used to determine the
bration Normal) and 153 (Printer 364 appearance of a print for various Print Darkness modes.
Scan Detection Calibration Print
Darkness 1).
High Density 100 +/- 2 1. Check the dC131 [MIN] locations BSD 9.9 Fault Code: 9- This value is equal to the ESV reading of a solid patch, created by the ROS, minus the ESV reading
Contrast (PD 1) 223 (Dicorotron AC Target), 225 203, 9-213 PQ RAP: 9- of the background area, created by an exposed area of the belt in the Print Darkness 1 mode. This
(ESV Calibration factor), and 260 633 is one of the values used to determine the appearance of a print for various Print Darkness modes.
(ESV Adjust).
Low Density 32 +/- 1 1. Check the dC131 [MIN] locations BSD 9.9 (SHEET 2) Fault This value is equal to the ESV reading of a 0.35 density patch created by the ROS operating in the
Contrast (PD 1) 223 (Dicorotron AC Target), 225 Code: 9-203, 9-213 PQ ROS Patch Exposure mode, minus the ESV reading of the background area created by an
(ESV Calibration factor), and 260 RAP: 9-633 exposed area of the belt in the Print Darkness 1 mode. This is one of the values used in determin-
(ESV Adjust). ing the appearance of a print for the various Print Darkness modes.
Average ESV 77 to 81 BSD 9.9 Fault Code: 9- This is the average of 14 measurements of the PR Belt. This reading is a contrast measurement
213 PQ RAP: 9-619 between the charge voltage and the background voltage.
Average DSS 86 +/- 1 BSD 9.9 (SHEET 2) Fault This is the average of 12 measurements of the dark band area of the PR Belt by the DSS. This
(MICR 86 Code: 9-212 PQ RAP: 9- value is used by the control logic to make decisions.
+/- 1) 620
PGEN Refer- DSS 90 BSD 9.9 (SHEET 1) Fault This is calibration of the output density of the Patch Generator so that the DSS reading of a devel-
ence (MICR 88) Code: 9-211 PQ RAP: 9- oped patch is 78 with the charge voltage at normal level. This calibration is important to the control
621 logic for controlling the Toner Dispenser Motor.
Toner Dispense N/A BSD 9.7, BSD 9.9 Fault With the developer voltage set to 120 volts above the background voltage, the Patch Generator
Code: 9-215 PQ RAP: 9- switched off and the charge adjusted to create a known, fixed development voltage of -300 volts.
616 The control logic controls the Toner Dispenser Motor to add, then depletes the toner until the DSS
reading of a developed image is within specification.

DC951 Auto Xerographic Setup ?-136 No Product Name Assigned
Figure 1 dC951 Xerographic Setup

No Product Name Assigned ?-137 DC951 Auto Xerographic Setup
NRD General Information And Diagnostic Hints a. Length of the run
b. Special selections
PURPOSE
c. Specific Paper Tray causing the problem
This section provides additional information that can help to characterize and isolate the NRD
d. Sensors have been jam bypassed
problem. The following information is intended to provide additional aid in the troubleshooting
of non-repeatable procedure. e. Exception programming
f. Image complexity: halftones, halftones and text, photos
NRD Strategy 2. If possible, instruct the Operator to set up and run the job.
Figure 1 depicts the major contents of Section NRD and the overall NRD diagnostic strategy 3. The following list is designed to aid in gathering the related information.
that should be utilized when troubleshooting the non-repeatable problems. This diagram is a a. For multiple machine placements, the problem occurs on more than one machine.
simplification of the detailed NRD entry flowchart at the beginning of Section NRD.
b. For multiple machine placements, the problem occurs at the same time of day, or
only during one work period.
NRD1 Non-Repeatable Problem Entry Procedure c. The problem is related to the skill level of the operator.
This procedure should be utilized to evaluate the SCP fault history data. Characterize the prob-
d. The Operator has gained access to the service mode.
lem into one of following categories, and go to the appropriate job aid.
e. The problem was preceded by excessively long standby time.
1. For Printer/Controller; If the fault code is a single standout (at the top of the Top 15 list in f. Non-Xerox supplies are being used.
the SCP subsystem frame, and has at least 5 counts); then, go to the appropriate Fault g. The problem is related to thruput material (size, weight, smoothness, curl, etc.).
Code Table NRD procedure, based on the single standout fault code. h. The problem is related to the last service call.
2. For Printer; If there is no single standout fault code, then, determine if there are 6/9 fault i. The problem is related to the operation of other equipment in the Customer Repro-
codes, which would indicate an electrical noise problem. If there are, then, go to the graphics Department (CRD).
Printer Electrical Noise Procedure.
j. The problem is related to account environmental factors (air conditioning, lights,
3. For Printer; If there is no single standout and no combination of 06/9 fault codes, go to the etc.).
Group Fault Tables to determine if there is a specific group fault pattern.
k. The problem is related to a specific job or image.
4. For Controller; To Be Documented
Electrical Noise Procedure
This procedure should be used to isolate the root cause of the electrical noise problem in the
system. This procedure also contains tables of all the PWB analog Inputs & Outputs in the
Printer, their test points, and BSD references.
Fault Code Tables

The appropriate fault code table should be accessed, if the problem has been characterized as
a single standout or almost jam problem. The specific fault code table and its supporting BSD
& diagnostic tools should be utilized to diagnose the root cause of the non-repeatable fault
code. These procedures are designed to be used in conjunction with the BSD and other dCs,
and, consequently, will require some deductive analysis as part of the diagnostic troubleshoot-
ing.
Group Fault Tables

These tables should be accessed only if there is no single standout and there are no 9 and/or
6 fault codes. If the SCP fault history is reviewed and there is a match, then, go to the appropri-
ate Fault Code Table or BSD to determine the specific root cause.
Operator Interrogation
Obtain as much information as possible on the job being run when the intermittent problem
occurred.
1. Investigate the following contributors:

NRD General Information And Diagnostic Hints ?-138 No Product Name Assigned
Figure 1 NRD Strategy Diagram (T7505A)

No Product Name Assigned ?-139 NRD General Information And Diagnostic Hints
Environmental Factors NOTE: Do not use the Single Standout displayed on the Printer and Controller Fault History
Summary frames. Refer to the following information to determine a single standout.
The following is a list of environmental conditions that have been known to cause or aggravate
intermittent machine problems. Single Standout Fault Code (Printer/Controller)
1. Select [SCP], [Tab 1], and the appropriate subsystem history, [Fault Summary]. The Top
NOTE: Ensure that the temperature in the room does not exceed 90° F (34° C) and that proper
15 and Single Standout Fault Codes for each subsystem are displayed on a single
ventilation exists at the rear of the machine. If the room temperature exceeds 90°F, or ventila-
screen. The following is the criteria used by the system for determining/declaring a Single
tion is blocked at the rear of the machine, instruct the customer to take corrective actions which
Standout Fault Code.
could include additional air conditioning or installation of the Vent Kit. Failure to correct the
overtemperature condition can result in erratic Controller operation, including an increased a. A Single Standout Fault must have at least 5 counts against it.
occurrence of Controller process optimization. b. Only one fault code is listed in the Top 15 Faults*
1. Investigate if the CRD exhibits one of the following conditions: c. The first fault code listed in the Top 15 Faults comprises at least 40% of the total
faults and no other fault code listed comprises more than 20% of the total faults.
a. Machine is exposed to temperature and humidity extremes (loading dock or old
buildings), causing a condensation on internal components. d. If the interval between service calls is relatively small (25K prints), a subsystem
may be over threshold and yet no action is required. The prints or scans
b. Machine is exposed to temperature and humidity extremes, causing the excessive
between calls may be too low to calculate an accurate rate.
static buildup, any sticking transport belts, or possible thermal overloads of motors
and power supplies. NOTE: The percentages are only a guideline.
c. Machine could be exposed to any direct or reflected sunlight causing the print quality
Example:
or touch screen problems.
d. Machine is subjected to air currents that affect the top tray stacking. Table 1 Percentage
2. Investigate the possibility of contamination within the CRD.
Code Faults
a. Contamination from other machines, such as offset powder from presses or cutting
10-102 12
oil from milling machines, can affect print quality and paper handling, and can clog
filters on electronic components. 10-104 4
b. Contamination can result from other external sources, such as spray glues or any 10-105 2
aerosol or atomized spray, floor sweeping compound, thruput material, and proximity 8-145 2
to heating and/or air conditioning units. 8-146 2
3. Investigate the machine for proper grounding and for external EMI/RFI.
a. Improper earth ground in some accounts, especially in old buildings, will cause peri- For this example, 10-102 is a Single Standout Fault Code because it comprises more than
odic process optimizations. 40% of the total faults (12/22).
b. Improper operating electrical equipment on the same electrical service or in the
same location (flickering lights due to a failing lamp ballast, etc.) can create intermit- Multiple Standout Fault Codes within a Subsystem
tent shutdowns. Two or more fault codes listed in the Top 15 Faults combined comprise at least 50% of total
Using the Fault History Data faults and individually at least 20% of the total faults.
Top 15 Faults
NOTE: The percentages are only a guideline.
The Top 15 Faults are prioritized by the fault code with the most counts at the top of the list.
Go to the Specific Subsystem Group Fault Table.
Top 15 Jams
Example:
The Top 15 Jams are prioritized by the fault code with the worst jam rate at the top of the list.
Table 2 Percentage
Categorizing Top 15 Faults Code Faults

10-102 12
Check for one of the following patterns of fault codes listed in the Top 15 Faults.
10-104 8
10-105 6
8-145 2
8-146 2

Table 2 Percentage Table 3
Code Faults Area Threshold
8-171 2 FSM jams xx
Xerographics xx
10-102, 10-104 & 10-105 comprise 81% (26/32 total faults) the total faults listed and individu- Printer Run Control xx
ally account for at least 20% of the total faults (10-102, 37%; 10-104, 25% & 10-105, 19%). For
Printer All Other xx
this example, the next step in troubleshooting would be to go to the Paper Handling PHM
Group Fault Tables. Also, for Multiple Standout Faults, if the fault codes are jam-related Controller faults xx
(1XXs), check the Fault Code/Sensor Location Diagrams, which identify the sensors and the
fault codes associated with each. Fault Code Troubleshooting Order
"Dominant" Fault Codes
Multiple Printer Subsystems Over Threshold
If more than one Printer subsystem is overthreshold, use the Fault Code Troubleshooting As explained in the SFA 1 Entry Level Procedure, it is important that certain fault codes are
Order strategy (refer to the last column on this page) in determining which subsystem to trou- troubleshot first. At the system level, Controller problems (i.e. power, control, communications
bleshoot first (e.g., subsystems that have 1 codes should be troubleshot before the sub- problems) should be troubleshot before Printer and Scanner problems. These are fault codes
systems that have 9 codes or 12 codes.) Once the appropriate subsystem has been identified, that have priority ("dominant" over other faults). Specifically within the Printer, the following 9
determine within that subsystem if there is a Single Standout, Multiple Standout, or no Stand- fault codes should be troubleshot next after power (1) and communication (3) faults: 9-201,
out. Troubleshoot and continue on to the other subsystems until confident that the problem has 203, 213, 320, 322, 328 and 9-329.
been resolved.
Shutdown History
No Standout Fault Code The Shutdown Histories list the most recent shutdown fault at the top of the first column. The
If there is no Single Standout or Multiple Fault Code listed in the Top 15, in addition to the time at which each fault occurred is recorded next to each fault. Only the primary cause of a
Group Fault Tables and the Fault Code/Sensor Location Diagrams, perform the following shutdown is recorded. Secondary (e.g. coast faults) are not recorded.
checks:
1. The Shutdown Histories are used:
1. Last 50 Shutdown History for the appropriate subsystem. Check the timestamps. Shut- a. To verify the primary reason for the call.
downs may indicate an operator trying to use a specific feature unsuccessfully (Paper b. To identify possible problems not observed by the customer.
Trays, Binder, etc.). Question the Operator about this possibility.
c. To display grouped faults, combination faults, and/or random faults.
2. Top 15 Last 4 Call information for the subsystem.
d. To identify time related groups of fault codes.
NOTE: The following descriptions of Last 4 Call previous MPBJ rate histories describe possi- Almost Jams (Printer only)
ble failure contributors. Almost Jam information is used to identify problems associated with mechanical component
3. A sudden change to a poor MPBJ rate indicates that the non-repeatable problem has wear and slippage. However, this data should only be accessed if the MPBJ is bad and the
occurred since the last call. During diagnostics and operator questioning, look for a Customer is still complaining, but there is no Single Standout or Group Fault pattern. The fol-
recently changed item that may have caused the failure. lowing information is for general troubleshooting; however, the information in the specific NRD
should be used as the primary job aid.
4. A progressive MPBJ rate indicates degradation that a part within the area addressed by
the specific code is gradually moving out of specification due to contamination, wear, etc.
1. Review Top 15 Jams (Actual) and Almost Jams screens to identify one of the jam rate
5. A poor previous MPBJ rate reflects that one of the two conditions listed above have
conditions identified below, and continue with step c.
existed prior to this service call. Determine if this condition is the result of operator activi-
a. A current MPBJ rate for one of the codes that is worse than the rates for the other
ties, environmental conditions, or was not addressed on prior calls.
codes.
Fault History Over Threshold b. A previous MPBJ rate for one code that shows gradual degradation of jam rate over
The following table lists the criteria for determining over threshold conditions for various sub- a period of time.
systems.
c. An Almost Jam code that displays the worst current MPBJ rate.
d. An Almost Jam code that displays a previous MPBJ rate that is worse than the other
Table 3
codes.
Area Threshold
2. Review MPBJ Almost Jams for the appropriate code and perform one of the following
PHM jams xx steps for the appropriate interval:

No Product Name Assigned ?-141 NRD General Information And Diagnostic Hints
a. For Printer, perform dC726/dC226, if the rate is less than 500. Observe timing for Using the Timing Routines (Printer dC226, Printer dC726)
intervals that are unstable, out of specification, etc.
The timing routines can assist in identifying the components that may be causing timing to
b. If the rate is greater than 500, go to step c. degrade. Degraded times for various events may be an indication of components that are sub-
3. Attempt to create the failure by stressing the suspected failure area and/ or component. ject to wear or damage and which may cause intermittent jams.
a. Use paper stock (i.e. 16 lb, 14 inch) that provides appropriate paper handling stress.
In order to stress test the suspect area, use lightweight or 14 inch paper (or use component
b. Attempt to accelerate the failure rate by repeatedly exercising the suspected compo-
control to heat up the suspect component) to induce the failure. Otherwise, it may appear that
nent in dC330. Perform the same activity for each suspected component.
the problem has corrected itself.
Miscounting Almost Jam Counters
The following Almost Jam counters are not recording properly: 8-145, 146, 147, 155, 171; 11- For 11-1xx, 10-1xx, and 08-1xx fault codes, perform the appropriate dC Timing Diagnostics
110, 114, 119. Do not troubleshoot an Almost Jam problem for these codes strictly based on a routine (Printer dC226, Printer dC726.
very high count.
Timing graph intervals:
Range Faults 1. Random distribution is indicated by data that is not centered around a normal bell shaped
Range Faults are NVM logged conditions that indicate degraded machine operation (some- curve. Associated failures include intermittent slipping components or intermittent sen-
thing going to happen or has already occurred). These conditions, if not corrected, may sors.
appear as other faults. The purpose is to provide a warning of an approaching fault, or of an 2. Late distribution is indicated by data shifted to the right of the normal range. Associated
existing fault which is not obvious to the customer, so that corrective action can be taken to failures include worn components or the sticking sensor actuators.
prevent machine shutdown from occurring. These conditions will not show up as a customer
3. Early distribution, is indicated by data shifted to the left of the normal range. Associated
fault code. Go to the appropriate NRD in the Fault Code Table section.
failures include the sticking sensor actuators. (continued)
4. No graph (data does not fill in the histogram even though the routine is running) usually is
SCP Printer Subsystem Groups and Group Fault Tables caused by a sensor being left bypassed (dC227/727) or the wrong mode or paper stock
The SCP Printer Fault History Diagnostic Frames consist of 6 major frames, each of which has being used.
an associated Group Fault Table (GFT), plus a frame for Range Faults. Printer Fault Summary
displays all the Printer subsystems on one screen with the Top 15 and Single Standout Fault
Using the Jam Bypass Routines (Printer dC727, dC227)
Codes listed for each. If the jam is occurring frequently enough or can be induced by running a stress test, use the
Jam Bypass routine to determine whether the problem is sensor-related. The jam bypass rou-
1. The Paper Handling Jams frame displays the Top 15 jam-related 1XX fault codes for the tines can be used to bypass a suspected faulty sensor. For jams that occur frequently enough
Paper Feed area (8-1XX codes), Print Transportation and Fusing area (10-1XX codes) (e.g., not hard failures, but can be repeated every 500 prints or less) run the machine with the
and the POP sensor area (9-1XX codes). suspected sensor bypassed.
The associated GFT is the PHM GFT.
If the jam does NOT re-occur, check the sensor circuitry (voltages) before adjusting/replacing
2. The Stacker Jams frame displays the Top 15 jam-related 1XX fault codes for the Finish-
the sensor.
ing Paper Path area (11-1XX codes).
The associated GFT is the FSM GFT. If the jam does still occur, suspect a mechanical-related failure. Check for the appropriate
3. The Xerographic Faults frame displays the Top 15 fault codes for the ROS area (6 switch or sensor for a binding actuator.
codes), Xerographic area (9-2XX, 3XX codes), and Fuser area (10-2XX codes).
The associated GFT is the Xerographic GFT. Suspected Dirty Sensor Problems
4. The Run Control frame displays the Top 15 fault codes for the Run Control area (3 Once it has been determined that the sensor is electrically functioning OK, then it can be
codes). cleaned. Otherwise, cleaning it first may mask the problem. After cleaning the sensor, measure
The associated GFT is the Run Control GFT. the voltage to check for marginal operation. Also, the cause of the dirt/contamination should be
determined and corrected.
5. The All Other Faults frame displays the Top 15 fault codes for the Standby Power area
(1 codes), Start Print Power (4 codes), and the other following areas: Paper Supply Tim-
Refer to the Generic Sensor RAP GP 6-2 in Section 6, for the LED voltage specifications.
ing (7-2XX codes), Paper Feed Timing (8-2XX codes), Reg Servo Controller (8-3XX
codes), and Finishing Timing, interlocks, temperature (11-2XX codes).
The associated GFT is the Power/All Other Faults GFT.
Frequent Process Optimization occurring
Go to the Controller Rollover Procedure.
6. The Range Faults frame displays the Top 15 for the following fault codes:
8-2XX, 10-2XX codes

Using information in the Printer NRD FCTs FSM PHM Fault Code Sensor Location Diagram
There are three major types of service actions for most of the Printer NRD procedures.
Table 1 Paper Handling Sensors
1. Checking Sensor Description BSD Fault Code
Perform the first step(s) that can be done in a short amount of time with a limited need for
Q811 Tray 1 Take Away Roll Sensor 8-112
analysis or fault isolation (i.e. sensor voltage checks, making the visual checks, collecting
the operator information, and running the dC diagnostic routines that may be able to Q812 Tray 1 Stack Relief Sensor 8-111
repeat the symptom). Q821 Tray 2 Take Away Roll Sensor 8-122, 8-123
2. Testing Q822 Tray 2 Stack Force Relief Sensor 8-121
a. Select one of the following descriptions that best describes the results of running the Q857 Tray 3/4 Feed Sensor 8-180 To 8-183
diagnostic routine. Q841 Duplex Sheet Sensor 8-170 To 8-173
b. If a diagnostic routine runs and consistently detects a fault code, go to the appropri- Q842 Duplex Take Away Roll Sensor 8-145 To 8-147
ate RAP, not the NRD procedure. Since the fault code can be made repeatable, the
Q851 Vertical Transport Sensor 8-113, 8-115, 8-144, 8-149, 8-151
RAP will offer superior fault isolation techniques and information.
Q852 Tray 3/4 Vertical Transport Sensor 8-184 To 8-187
c. If a diagnostic routine runs and eventually detects a fault code, go to the appropriate
NRD procedure. Q853 Tray 3/4 Turn Baffle Sensor 8-164 To 8-167, 8-188 To 8-190
d. Use the timing dC routines and other exercisers which run the system in a continu- Q854 Tray 3/4 Horizontal Transport Sen- 8-168, 8-169, 8-197, 8-198
ous mode of operation since these type of routines can better indicate or detect non- sor
repeatable problems. Q850 PreRegistration Transport Sensor 8-100 To 8-103
3. Repair/replace/adjust Q861 Registration Transport Sensor 8-152, 8-155, 8-156, 8-91 To 8-196
Identify specific symptoms (conditions) telltales by inspecting, observing, and evaluating Q904 POP Sensor 9-101, 9-102
the specified components (i.e. for wear, contamination, defects, etc.). Repair/replace/ Q1009 Prefuser Sensor 10-101, 10-112
adjust as required. Q1010 Post Fuser Sensor 10-102
Q1011 Decurler Sensor 10-104 To 10-106
Q1012 Top Transport Switch 10-107 To 10-110
Q1106 Disk Sheet Sensor 11.5 11-130 To 11-133
Q1107 Bypass Transport Sensor 11.4 11-138, 11-140, 11-141
Q1155 Inverter Entrance Sensor 11.2 11-102, 11-104, 11-105
Q1156 Post Inverter Sensor 11.4 11-106, 11-108, 11-110
Q1157 Sample Tray Sensor 11.2 11-107, 11-116 To 11-120
Q1158 Prestacker Sensor 11.4 11-112, 11-114
Q1164 Purge Transport Sensor 11.4 11-142 To 11-145
Q1166 Disk Lead Edge Sensor 11.5 11-146 To 11-149
Q1167 A3 Trail Edge Sensor 11.5 11-150

No Product Name Assigned ?-143 NRD General Information And Diagnostic Hints,
Figure 1 FSM/PHM Fault Code/Sensor Location Diagram

FSM PHM Fault Code Sensor Location Diagram ?-144 No Product Name Assigned
Inverter Feeder Stacker DC226 Timing Interval Graphs
Figure 1 Inverter/Feeded/Stacker dC226 Graph Interval Normal Distribution Examples

No Product Name Assigned ?-145 Inverter Feeder Stacker DC226 Timing Interval
Figure 2 Inverter/Feeded/Stacker dC226 Graph Interval Normal Distribution Examples (T3708A)

Inverter Feeder Stacker DC226 Timing Interval ?-146 No Product Name Assigned



Figure 6 Printer Bypass Transport Module dC226 Timing Graph Interval Normal Distribution Examples (3851A)

Printer DC726 Timing Interval Graphs
Figure 1 Printer dC726 Timing Graph Interval Normal Distribution Examples

No Product Name Assigned ?-151 Printer DC726 Timing Interval Graphs
Figure 2 Printer dC726 Timing Graph Interval Normal Distribution Examples (T7515A)

Printer DC726 Timing Interval Graphs ?-152 No Product Name Assigned



Figure 6 dC726 Printer Timing Graph Interval Normal Distribution Examples (T3704A)



Final Action Table 1 CALL CLOSURE SCREEN CHOICES
PURPOSE STATUS OF CALL CAUSE OF CALL
The purpose of the Final Action is to provide the steps which need to be taken to properly com- Print Quality Other
plete a call. Print Handling Jams
Print Handling Damage
PROCEDURE Scheduled Maintenance
NOTE: Ensure UI LOCKOUT MODE is exited before beginning this procedure. Bar Code Reader
Continuation Call
1. Run Verify. This is a verification test of the System Controller and Printer interface. Verify
will exercise all operations of the system. Individual IG test patterns and the number of Key Operator
prints can be selected in this mode. Logic Problem
Select "Call Closure Screen" on the UI Monitor. Unknown Problem
NOTE: The following is a recommended Procedure. Modify the procedure as required to Other Problem
match customer applications.
A different Service Representative returning to complete an "incomplete" call may
address problems that had already been repaired on the original call.
Should the call be "completed" without a problem being repaired, the new fault his-
tory will continue to show that a problem exists; problems will not go away because a
call is "completed."
It is recommended that any time a call is left "incomplete," a machine log book entry
is made to document machine status.
2. If the Printer was serviced, perform the following:
– "Back up the Printer NVM at the Printer Rigid Disk" this should be done at the Sys-
tem UI Monitor.
– Reset the Printer Fault History counters at the System UI Monitor
3. Record the final billing meter "A." The final billing meter reading should be used to calcu-
late credit for the customer.
4. [Enter Call Status] and [Cause of Call] at the System UI. There are causes from which
to choose (Table 1). Choosing one of these selections will cause the choice to appear on
the Initial Call Action screen of the next call under Cause of Last Call.
5. Return to OS Log Level 1.
6. Update the Tag Matrix, if a retrofit has been installed.
7. Enter information into the Machine Log Book. Information pertinent to a "incomplete" call
and other problems relevant to the call.
8. Clean the panels and work area before leaving.
9. Check the Customer inventory of supplies.
Table 1 CALL CLOSURE SCREEN CHOICES

STATUS OF CALL CAUSE OF CALL
Completed Print Quality Image Density
Incomplete--Parts Print Quality Background
Incomplete--Customer Print Quality Deletions
Incomplete Unresolved Print Quality Spots
Incomplete Other Print Quality Fusing
Print Quality MICR

No Product Name Assigned ?-159 Final Action
2. Status Indicator RAPS
1. Standby Power 2-708 Hard Buttons RAP................................................................................................. 2-106
1-210 RAP....................................................................................................................... 2-7 2-710 Horizontal And Vertical Sync RAP ........................................................................ 2-108
1-211 RAP....................................................................................................................... 2-7 2-713 Raster (Illuminated Screen) RAP .......................................................................... 2-110
1-212 RAP....................................................................................................................... 2-8 2-716 Touch Screen Icons RAP...................................................................................... 2-112
1-214 RAP....................................................................................................................... 2-8 2-718 7-Segment Digital Display RAP ............................................................................ 2-115
1-220 RAP....................................................................................................................... 2-10
1-221 RAP....................................................................................................................... 2-13
3. Machine Run Control
3-201 RAP....................................................................................................................... 2-117
1-700 AC Input Power (60 Hz) RAP................................................................................ 2-16
3-202 RAP....................................................................................................................... 2-122
1-701 AC Standby Power RAP (60HZ ONLY) ................................................................ 2-20
3-203 RAP....................................................................................................................... 2-127
1-702 AC Interlock Power RAP (60HZ ONLY) ................................................................ 2-22
3-204 RAP....................................................................................................................... 2-132
1-703 AC Switched On Power RAP (60HZ ONLY) ......................................................... 2-24
3-205 RAP....................................................................................................................... 2-137
1-704-1 Inverter/Stacker A Standby AC Power RAP (60HZ ONLY) ............................... 2-27
3-206 RAP....................................................................................................................... 2-142
1-704-2 Stacker B Standby AC Power RAP (60HZ ONLY) ............................................ 2-31
3-207 RAP....................................................................................................................... 2-148
1-705-1 Feeder (Tray 3) Standby AC Power RAP (60HZ ONLY) ................................... 2-33
3-208 RAP....................................................................................................................... 2-154
1-705-2 Feeder (Tray 4) Standby AC Power RAP (60HZ ONLY) ................................... 2-37
3-221 RAP....................................................................................................................... 2-157
1-707 AC Input Power RAP (50HZ WYE) ....................................................................... 2-40
3-223 RAP....................................................................................................................... 2-160
1-707AC Input Power RAP (50HZ DELTA)..................................................................... 2-42
3-224 RAP....................................................................................................................... 2-163
1-708 AC Standby Power RAP (50HZ WYE And DELTA) .............................................. 2-44
3-225 RAP....................................................................................................................... 2-167
1-709 AC Interlocked Power RAP (50HZ)....................................................................... 2-46
3-231 RAP....................................................................................................................... 2-171
1-710 AC Switched On Power RAP (50HZ) .................................................................... 2-48
3-232 RAP....................................................................................................................... 2-175
1-711-1 Inverter/Stacker A Standby AC Power (50HZ) .................................................. 2-51
3-233 RAP....................................................................................................................... 2-180
1-711-2 Stacker B Standby AC Power RAP (50HZ) ....................................................... 2-55
3-234 RAP....................................................................................................................... 2-184
1-712-1 Feeder (Tray 3) Standby AC Power RAP (50HZ) .............................................. 2-57
3-241 RAP....................................................................................................................... 2-188
1-712-2 Feeder (Tray 4) Standby AC Power RAP (50HZ) .............................................. 2-61
3-242 RAP....................................................................................................................... 2-194
1-713 +5 VDC RAP ......................................................................................................... 2-64
3-245 RAP....................................................................................................................... 2-199
1-714 +12 VDC RAP ....................................................................................................... 2-67
3-246 RAP....................................................................................................................... 2-204
1-715 +15 VDC RAP ....................................................................................................... 2-69
3-247 RAP....................................................................................................................... 2-209
1-716 -15 VDC RAP ........................................................................................................ 2-71
3-251 RAP....................................................................................................................... 2-213
1-717 +24,+34,-34 VDC RAP.......................................................................................... 2-73
3-252 RAP....................................................................................................................... 2-218
1-718 DC Power Corrective Actions RAP ....................................................................... 2-77
3-253 RAP....................................................................................................................... 2-223
1-719 Feeder/Stacker #2 24 VDC RAP .......................................................................... 2-79
3-254 RAP....................................................................................................................... 2-228
1-720 Processor Interlock Bypass Switch RAP .............................................................. 2-81
3-255 RAP....................................................................................................................... 2-233
1-721 Circuit Breakers Switching Off RAP (60HZ).......................................................... 2-83
3-256 RAP....................................................................................................................... 2-238
1-722 Paper Path Service Lamp RAP............................................................................. 2-84
3-257 RAP....................................................................................................................... 2-243
1-723 Convenience Outlet RAP (50HZ And 60HZ)......................................................... 2-86
3-258 RAP....................................................................................................................... 2-248
1-724 Circuit Breakers Switching Off RAP (50HZ).......................................................... 2-89
3-261 RAP....................................................................................................................... 2-253
1-726 RAP - ELCI/RCD Switching Off (Equipment Leakage Circuit Interrupter (60 Hz) / Residual
3-262 RAP....................................................................................................................... 2-259
Current Device (50 Hz) RAP ........................................................................................... 2-90
3-263 RAP....................................................................................................................... 2-265
1-731 RAP....................................................................................................................... 2-91
3-264 RAP....................................................................................................................... 2-271
2. Printer UI 3-265 RAP....................................................................................................................... 2-277
2-700 Printer UI Entry Procedure.................................................................................... 2-95 3-266 RAP....................................................................................................................... 2-283
2-701 Audio Tone RAP ................................................................................................... 2-96 3-267 RAP....................................................................................................................... 2-288
2-702 Blank 7-Segment Digital Display/Illuminated Screen RAP ................................... 2-98 3-268 RAP....................................................................................................................... 2-293
2-703 Brightness Control RAP ........................................................................................ 2-100 3-272 RAP....................................................................................................................... 2-298
2-705 CRT Color RAP..................................................................................................... 2-102 3-340 RAP....................................................................................................................... 2-301
2-706 Dark Screen RAP.................................................................................................. 2-104 3-341 RAP....................................................................................................................... 2-301
3-342 RAP....................................................................................................................... 2-302
Revision 11/00 Status Indicator Raps

3-343 RAP....................................................................................................................... 2-303 3-473 RAP....................................................................................................................... 2-383
3-344 RAP....................................................................................................................... 2-303 3-474 RAP....................................................................................................................... 2-384
3-345 RAP....................................................................................................................... 2-304 3-475 RAP....................................................................................................................... 2-384
3-346 RAP....................................................................................................................... 2-304 3-476 RAP....................................................................................................................... 2-385
3-347 RAP....................................................................................................................... 2-305 3-477 RAP....................................................................................................................... 2-385
3-348 RAP....................................................................................................................... 2-305 3-480 RAP....................................................................................................................... 2-386
3-361 RAP....................................................................................................................... 2-306 3-482 RAP....................................................................................................................... 2-386
3-362 RAP....................................................................................................................... 2-306 3-483 RAP....................................................................................................................... 2-387
3-370 RAP....................................................................................................................... 2-307 3-485 RAP....................................................................................................................... 2-387
3-371 RAP....................................................................................................................... 2-307 3-492 RAP....................................................................................................................... 2-388
3-372 RAP....................................................................................................................... 2-308 3-494 RAP....................................................................................................................... 2-388
3-373 RAP....................................................................................................................... 2-308 3-700 Printer Boot RAP................................................................................................... 2-389
3-374 RAP....................................................................................................................... 2-309 3-701 Floppy Disk Drive Failure RAP.............................................................................. 2-391
3-375 RAP....................................................................................................................... 2-309 3-702 System Bus Bad PWB Isolation RAP.................................................................... 2-391
3-376 RAP....................................................................................................................... 2-310 3-703 Software Upgrade Problem RAP .......................................................................... 2-397
3-377 RAP....................................................................................................................... 2-310 3-730 Intermittent Entry RAP .......................................................................................... 2-398
3-378 RAP....................................................................................................................... 2-311 3-731 Intermittent Communication RAP.......................................................................... 2-398
3-379 RAP....................................................................................................................... 2-311 3-732 Intermittent Internal Error RAP.............................................................................. 2-399
3-380 RAP....................................................................................................................... 2-312 3-733 Intermittent Download RAP................................................................................... 2-400
3-381 RAP....................................................................................................................... 2-312 3-734 Intermittent Rigid Disk RAP................................................................................... 2-400
3-382 RAP....................................................................................................................... 2-313 3-735 Intermittent Turnaround RAP ................................................................................ 2-401
3-383 RAP....................................................................................................................... 2-313 3-737 Intermittent Hardware Related Software Fault RAP.............................................. 2-401
3-384 RAP....................................................................................................................... 2-314 3-738 Intermittent Crash/No Fault Code RAP ................................................................. 2-402
3-385 RAP....................................................................................................................... 2-314 3-750 PWB Drawings Section ......................................................................................... 2-403
3-386 RAP....................................................................................................................... 2-315
3-387 RAP....................................................................................................................... 2-315 4. Print Power
3-389 RAP....................................................................................................................... 2-316 4-201 RAP....................................................................................................................... 2-421
3-390 RAP....................................................................................................................... 2-316 4-202 RAP....................................................................................................................... 2-425
3-391, 3-393 RAP ........................................................................................................... 2-317 4-203 RAP....................................................................................................................... 2-427
3-392 RAP....................................................................................................................... 2-318 4-210 RAP....................................................................................................................... 2-430
3-401 RAP....................................................................................................................... 2-318 4-211, 4-213 RAP............................................................................................................ 2-432
3-402 RAP....................................................................................................................... 2-324 4-212 RAP....................................................................................................................... 2-434
3-403 RAP....................................................................................................................... 2-329 4-220 RAP....................................................................................................................... 2-436
3-404 RAP....................................................................................................................... 2-334 4-221 RAP....................................................................................................................... 2-438
3-405 RAP....................................................................................................................... 2-339 4-700 Main Drive RAP (60HZ) ........................................................................................ 2-440
3-406 RAP....................................................................................................................... 2-344 4-701 Main Drive RAP (50HZ WYE) ............................................................................... 2-442
3-407 RAP....................................................................................................................... 2-350 4-701 Main Drive RAP (50HZ DELTA)............................................................................ 2-446
3-408 RAP....................................................................................................................... 2-356 4-702 Printer Drives Noise RAP...................................................................................... 2-450
3-412 RAP....................................................................................................................... 2-357 4-703 Print Power Rap (60HZ)........................................................................................ 2-453
3-413 RAP....................................................................................................................... 2-361 4-704 Print Power Rap (50HZ)........................................................................................ 2-455
3-414 RAP....................................................................................................................... 2-365 4-705 60HZ Fuser/Developer Drive Motor RAP.............................................................. 2-457
3-415 RAP....................................................................................................................... 2-369 4-706 50HZ Fuser/Developer Drive Motor RAP.............................................................. 2-460
3-416 RAP....................................................................................................................... 2-374 4-707 ODOR RAP ........................................................................................................... 2-462
3-461 RAP....................................................................................................................... 2-379 4-708 (50 Hz) Soft Start RAP .......................................................................................... 2-462
3-462 RAP....................................................................................................................... 2-379 6. ROS
3-463 RAP....................................................................................................................... 2-380
6-202 RAP....................................................................................................................... 2-465
3-464 RAP....................................................................................................................... 2-380 6-203 RAP....................................................................................................................... 2-469
3-465 RAP....................................................................................................................... 2-381 6-213 RAP....................................................................................................................... 2-472
3-466 RAP....................................................................................................................... 2-381
6-214 RAP....................................................................................................................... 2-475
3-467 RAP....................................................................................................................... 2-382 6-215 RAP....................................................................................................................... 2-478
3-471 RAP....................................................................................................................... 2-382
6-232 RAP....................................................................................................................... 2-481
3-472 RAP....................................................................................................................... 2-383
Status Indicator Raps 11/00 Revision

6-233 RAP....................................................................................................................... 2-484 8-151 RAP....................................................................................................................... 2-615
6-234 RAP....................................................................................................................... 2-488 8-152 RAP....................................................................................................................... 2-618
6-236 RAP....................................................................................................................... 2-491 8-155 RAP....................................................................................................................... 2-623
6-237 RAP....................................................................................................................... 2-494 8-156 RAP....................................................................................................................... 2-625
6-240 RAP....................................................................................................................... 2-497 8-164, 8-165 RAP............................................................................................................ 2-627
6-250/251 RAP................................................................................................................ 2-500 8-166, 8-167 RAP............................................................................................................ 2-629
6-252/253 RAP................................................................................................................ 2-504 8-168, 8-169 RAP............................................................................................................ 2-631
6-330 RAP....................................................................................................................... 2-508 8-170 RAP....................................................................................................................... 2-633
6-331 RAP....................................................................................................................... 2-511 8-171 RAP....................................................................................................................... 2-635
6-351 RAP....................................................................................................................... 2-513 8-172, 8-173 RAP............................................................................................................ 2-637
6-352 RAP....................................................................................................................... 2-516 8-179 RAP....................................................................................................................... 2-639
6-353 RAP....................................................................................................................... 2-519 8-180, 8-181 RAP............................................................................................................ 2-641
6-354 RAP....................................................................................................................... 2-522 8-182, 8-183 RAP............................................................................................................ 2-644
6-355 RAP....................................................................................................................... 2-525 8-184, 8-185 RAP............................................................................................................ 2-647
6-356 RAP....................................................................................................................... 2-528 8-186, 8-187 RAP............................................................................................................ 2-649
6-358 RAP....................................................................................................................... 2-531 8-188, 8-189 RAP............................................................................................................ 2-651
6-360 RAP....................................................................................................................... 2-534 8-190 RAP....................................................................................................................... 2-653
6-364 RAP....................................................................................................................... 2-537 8-191, 8-194 RAP............................................................................................................ 2-655
6-366 RAP....................................................................................................................... 2-541 8-192, 8-195 RAP............................................................................................................ 2-658
6-367 RAP....................................................................................................................... 2-544 8-193, 8-196 RAP............................................................................................................ 2-661
6-701 RAP....................................................................................................................... 2-546 8-197, 8-198 RAP............................................................................................................ 2-664
8-203 RAP....................................................................................................................... 2-666
7. Paper Supply 8-204 RAP....................................................................................................................... 2-666
7-211, 7-212 RAP ........................................................................................................... 2-549 8-210 RAP....................................................................................................................... 2-667
7-214 RAP....................................................................................................................... 2-550 8-211 RAP....................................................................................................................... 2-667
7-221, 7-222 RAP ........................................................................................................... 2-553 8-212 RAP....................................................................................................................... 2-668
7-224 RAP....................................................................................................................... 2-554 8-213 RAP....................................................................................................................... 2-668
7-241, 7-244 RAP ........................................................................................................... 2-557 8-216, 8-218 RAP............................................................................................................ 2-669
7-248 RAP....................................................................................................................... 2-561 8-217 RAP....................................................................................................................... 2-670
7-250 RAP....................................................................................................................... 2-563 8-225 RAP....................................................................................................................... 2-671
7-251 RAP....................................................................................................................... 2-564 8-226, 8-227 RAP............................................................................................................ 2-672
7-701 Tray 1 Capacity PWB Failure RAP ....................................................................... 2-566 8-302 RAP....................................................................................................................... 2-675
7-702 Tray 2 Capacity PWB Failure................................................................................ 2-569 8-310, 8-312 RAP............................................................................................................ 2-678
7-703 HCT Capacity PWB Failure .................................................................................. 2-572 8-700 Registration Servo Tests RAP .............................................................................. 2-680
7-704 HCT Unlatch RAP ................................................................................................. 2-575 8-701 Friction Retard Checkout RAP .............................................................................. 2-680
8. Paper Feed 8-704 Noise Diagnostics RAP ......................................................................................... 2-681
8-705 Paper Damage RAP.............................................................................................. 2-682
8-100, 8-101 RAP ........................................................................................................... 2-577
8-102, 8-103 RAP ........................................................................................................... 2-579 8-706 Misregistration And Skew RAP ............................................................................. 2-683
8-104, 8-105 RAP ........................................................................................................... 2-581 8-707 Tray 3/4 Air System RAP ...................................................................................... 2-685
8-708 Feeder Main Drive Motor RAP .............................................................................. 2-688
8-111 RAP....................................................................................................................... 2-586
8-112 RAP....................................................................................................................... 2-589 8-709 Cross Roll Motor RAP ........................................................................................... 2-691
8-113 RAP....................................................................................................................... 2-592 8-901 RAP....................................................................................................................... 2-693
8-902 RAP....................................................................................................................... 2-695
8-115 RAP....................................................................................................................... 2-594
8-121 RAP....................................................................................................................... 2-596 8-904 RAP....................................................................................................................... 2-697
8-122 RAP....................................................................................................................... 2-599 8-904-5 RAP.................................................................................................................... 2-699
8-999 RAP....................................................................................................................... 2-701
8-123 RAP....................................................................................................................... 2-602
8-144 RAP....................................................................................................................... 2-604 9. Xerographic
8-145 RAP....................................................................................................................... 2-607 9-101, 9-102 RAP............................................................................................................ 2-705
8-146 RAP....................................................................................................................... 2-609 9-201 RAP....................................................................................................................... 2-707
8-147 RAP....................................................................................................................... 2-611 9-202 RAP....................................................................................................................... 2-711
8-149 RAP....................................................................................................................... 2-613 9-203, 9-213 RAP............................................................................................................ 2-713

9-211 RAP....................................................................................................................... 2-718 10-216 RAP..................................................................................................................... 2-839
9-212 RAP....................................................................................................................... 2-720 10-601 Fuser Lead Edge Smear RAP............................................................................. 2-843
9-215 RAP....................................................................................................................... 2-724 10-602 Fuser Print Gloss RAP ........................................................................................ 2-843
9-220, 9-222 RAP ........................................................................................................... 2-729 10-603 Wrinkle RAP........................................................................................................ 2-844
9-221 RAP....................................................................................................................... 2-732 10-604 Fuser Agent On Print RAP .................................................................................. 2-846
9-320 RAP....................................................................................................................... 2-734 10-605 Lead Edge To Trail Edge Streaks (Unfused Print) RAP ..................................... 2-846
9-321 RAP....................................................................................................................... 2-739 10-606 Dry Ink Spots On Prints/Spot Deletions RAP...................................................... 2-847
9-322 RAP....................................................................................................................... 2-741 10-607 Unable to Type on Prints RAP ............................................................................ 2-847
9-323 RAP....................................................................................................................... 2-743 10-608 Dry Ink Not Fixed RAP ........................................................................................ 2-848
9-324 RAP....................................................................................................................... 2-745 10-701 Bent Corners RAP............................................................................................... 2-849
9-325 RAP....................................................................................................................... 2-747 10-702 Fuser Air System Checkout ................................................................................ 2-851
9-326 RAP....................................................................................................................... 2-749 10-703 (60HZ) Compressor Motor RAP.......................................................................... 2-854
9-327 RAP....................................................................................................................... 2-751 10-703 (50HZ) Compressor Motor RAP.......................................................................... 2-856
9-328 RAP....................................................................................................................... 2-753 10-704 Bleed-Off Solenoid RAP...................................................................................... 2-858
9-329 RAP....................................................................................................................... 2-756 10-705 Low Fuser Agent Level RAP ............................................................................... 2-860
9-330 RAP....................................................................................................................... 2-758 10-706 (60HZ) Prefuser Vacuum Motor RAP.................................................................. 2-862
9-332 RAP....................................................................................................................... 2-760 10-706 (50HZ) Prefuser Vacuum Motor RAP.................................................................. 2-864
9-353 RAP....................................................................................................................... 2-760 10-707 (60HZ) Camming Motor RAP .............................................................................. 2-866
9-354 RAP....................................................................................................................... 2-763 10-707 (50HZ) Camming Motor RAP .............................................................................. 2-869
9-355 RAP....................................................................................................................... 2-765 10-708 Fuser Agent Dispense RAP ................................................................................ 2-872
9-356 RAP....................................................................................................................... 2-768 10-709 MIB PWB RAP .................................................................................................... 2-874
9-360 RAP....................................................................................................................... 2-768 10-710 Camming Motor Runs Continuously RAP ........................................................... 2-876
9-361 RAP....................................................................................................................... 2-769 10-711 RAP..................................................................................................................... 2-878
9-702 Dry Ink Level Low Message RAP ......................................................................... 2-770 10-714 RAP..................................................................................................................... 2-883
9-703 Replace the Waste Bottle Message RAP ............................................................. 2-772
9-704 Toner Filter Blower Motor RAP ............................................................................. 2-774 11. Inverter/Stacker
9-705 MIN Cooling Fan RAP........................................................................................... 2-776 11-100 RAP..................................................................................................................... 2-889
9-706 Power.................................................................................................................... 2-778 11-102 RAP..................................................................................................................... 2-892
11-104, 11-105 RAP........................................................................................................ 2-895
10. Print Transportation Fusing 11-106 RAP..................................................................................................................... 2-898
10-101 RAP..................................................................................................................... 2-781 11-107 RAP..................................................................................................................... 2-900
10-102 RAP..................................................................................................................... 2-783 11-108 RAP..................................................................................................................... 2-902
10-104 RAP..................................................................................................................... 2-788 11-110 RAP..................................................................................................................... 2-905
10-105 RAP..................................................................................................................... 2-790 11-112 RAP..................................................................................................................... 2-907
10-106 RAP..................................................................................................................... 2-792 11-114 RAP..................................................................................................................... 2-910
10-107 RAP..................................................................................................................... 2-794 11-116, 11-117 RAP........................................................................................................ 2-912
10-108, 10-109 RAP ....................................................................................................... 2-797 11-118, 11-119 RAP........................................................................................................ 2-915
10-110 RAP..................................................................................................................... 2-800 11-130 RAP..................................................................................................................... 2-917
10-111 RAP..................................................................................................................... 2-803 11-131-1, 11-132-1, 11-133-1 RAP................................................................................. 2-920
10-112 RAP..................................................................................................................... 2-805 11-131-2, 11-132-2, 11-133-2 RAP................................................................................. 2-923
10-201 RAP..................................................................................................................... 2-807 11-131-3, 11-132-3, 11-133-3 RAP................................................................................. 2-927
10-202 RAP..................................................................................................................... 2-811 11-131-4, 11-132-4, 11-133-4 RAP................................................................................. 2-930
10-203 (60HZ) RAP ........................................................................................................ 2-816 11-138, 11-139 RAP........................................................................................................ 2-933
10-203 (50HZ) RAP ........................................................................................................ 2-818 11-140, 11-141 RAP........................................................................................................ 2-937
10-204, 10-206 RAP ....................................................................................................... 2-820 11-142-2, 11-143-2, 11-144-2 RAP................................................................................. 2-940
10-205 RAP..................................................................................................................... 2-824 11-142-3, 11-143-3, 11-144-3 RAP................................................................................. 2-944
10-210 (60HZ) RAP ........................................................................................................ 2-826 11-142-4, 11-143-4, 11-144-4 RAP................................................................................. 2-948
10-210 (50HZ) RAP ........................................................................................................ 2-830 11-145-2 RAP.................................................................................................................. 2-952
10-211 RAP..................................................................................................................... 2-834 11-145-3 RAP.................................................................................................................. 2-955
10-212, 10-217 RAP ....................................................................................................... 2-836 11-145-4 RAP.................................................................................................................. 2-958
10-213, 10-218 RAP ....................................................................................................... 2-836 11-146, 11-147 RAP........................................................................................................ 2-961
10-214, 10-215, 10-219 RAP .......................................................................................... 2-837 11-148, 11-149 RAP........................................................................................................ 2-964

11-150 RAP..................................................................................................................... 2-966 13-203 RAP..................................................................................................................... 2-1055
11-200 RAP..................................................................................................................... 2-968 13-205 RAP..................................................................................................................... 2-1057
11-220 RAP..................................................................................................................... 2-970 13-206 RAP..................................................................................................................... 2-1061
11-221 RAP..................................................................................................................... 2-972 13-207 RAP..................................................................................................................... 2-1061
11-222 RAP..................................................................................................................... 2-974 13-208 RAP..................................................................................................................... 2-1062
11-223 RAP..................................................................................................................... 2-978 13-700 Transition Module Main Drive Motor, MOT1301 RAP......................................... 2-1062
11-224 RAP..................................................................................................................... 2-980
11-228, 11-229 RAP ....................................................................................................... 2-982
11-231 RAP..................................................................................................................... 2-984
11-232, 11-233 RAP ....................................................................................................... 2-986
11-237, 11-238 RAP ....................................................................................................... 2-988
11-242 RAP..................................................................................................................... 2-990
11-244 RAP..................................................................................................................... 2-992
11-250-1 RAP ................................................................................................................. 2-994
11-250-2 RAP ................................................................................................................. 2-996
11-250-3 RAP ................................................................................................................. 2-998
11-250-4 RAP ................................................................................................................. 2-1000
11-270-2 RAP ................................................................................................................. 2-1002
11-600 Poor Stacking Quality RAP ................................................................................. 2-1004
11-601 Sloppy Set, Side-To-Side RAP ........................................................................... 2-1006
11-602 Sloppy Set, Skewed Sheets RAP ....................................................................... 2-1006
11-603 Sloppy Set, Front-To-BacK RAP......................................................................... 2-1007
11-604 Bottom Sheet Misregistration RAP ..................................................................... 2-1007
11-605 Clumped Registration, Top Of Set RAP.............................................................. 2-1008
11-606 Shingled Set/Stack RAP ..................................................................................... 2-1008
11-607 Sloppy Set, Curled Prints RAP ........................................................................... 2-1009
11-608 Random Misregistration RAP.............................................................................. 2-1009
11-609 Rolled Or Folded Prints RAP 8.5X11 OR A4 ...................................................... 2-1010
11-610 Rolled Or Folded Prints RAP 11X17 OR A3 ....................................................... 2-1010
11-611 Sloppy Set, Elevator Too Low RAP .................................................................... 2-1011
11-612 Poor Stacking Quality (7X10 Paper) RAP........................................................... 2-1011
11-700 Disk Motor, MOT1103 RAP ................................................................................ 2-1012
11-701 Back Guide Motor, MOT1104 RAP ..................................................................... 2-1015
11-702 Right Guide Motor, MOT1105 RAP .................................................................... 2-1017
11-703 Stacker Elevator Motor, MOT1106 RAP ............................................................. 2-1019
11-704 Front Tamper Motor, MOT1107, And Right Guide Tamper Motor, MOT1113 RAP 2-
1023
11-705 Back Tamper Motor, MOT1108 RAP .................................................................. 2-1025
11-706 Stacker Main Drive Motor, MOT1110 RAP ......................................................... 2-1027
11-707 Inverter Drive Motor, MOT1111 RAP .................................................................. 2-1030
11-708 Inverter Main Drive Motor, MOT1112 RAP ......................................................... 2-1032
11-709 Interlock Bypass Switch RAP.............................................................................. 2-1035
11-710 Container Sensing RAP ...................................................................................... 2-1037
11-711 Stacker Attention Light RAP ............................................................................... 2-1040
11-712 Inverter/Stacker Noise RAP ................................................................................ 2-1042
11-713 Stacker Control Panel RAP................................................................................. 2-1045
11-901-X Purge Tray Is Not Available RAP .................................................................... 2-1047
13. Transition Module

13-131 RAP..................................................................................................................... 2-1049
13-132 RAP..................................................................................................................... 2-1051
13-201 RAP..................................................................................................................... 2-1053

1-210 RAP 1-211 RAP
Fault Code, 1-210, occurs when the Printer Left Door Interlock Switch, S106, opens while in Fault Code, 1-211, occurs when the Printer Right Door Interlock Switch, S105, opens while in
Print Mode. Print Mode.
Procedure NOTE: A Circuit Diagram is not normally needed for this fault due to the conditions under
which it is declared. The 1-220 Circuit Diagram may be used as a reference.
NOTE: A Circuit Diagram is not normally needed for this fault due to the conditions under
which it is declared. The 1-220 Circuit Diagram may be used as a reference. Procedure
Ensure that the Printer Right Door is closed. Enter dC330. The Right Door INTLK SW dis-
Ensure that the Printer Left Door is closed. Enter dC330. The Left Door INTLK SW display
play indicates L.
indicates L.
Y N
Y N
Open the Printer Right Door. Manually actuate S105 several times. The Right Door
Open the Printer Left Door. Manually actuate the S106 several times. The Left Door
INTLK SW display toggles from H to L.
Y N
Y N
Replace the Printer Right Door Interlock Switch, S105 (PL 4.3).
Replace the Printer Left Door Interlock Switch, S106 (PL 4.3).
Check the following:

• Interlock Actuator adjustment for the Printer Right Door (ADJ 4-3).
• Interlock Actuator adjustment on the Printer Left Door (ADJ 4-3).
• Printer Right Door Latch adjustment (ADJ 4-1).
• The door is closing properly.
Check that the Printer Right Door closes properly. If the problem continues, replace the Printer
Check that the Printer Left Door closes properly. If the problem continues, replace the Printer
Right Door Interlock Switch, S105 (PL 4.3).
Left Door Interlock Switch, S106 (PL 4.3).

No Product Name Assigned ?-7 1-210, 1-211
1-212 RAP 1-214 RAP
Fault Code, 1-212, occurs when the Printer Right Top Cover Interlock Switch, S104, opens Fault code, 1-214, occurs when the Fuser Interlock Switch, S1001, is deactuated while in print
while in Print Mode. mode.
NOTE: A Circuit Diagram is not normally needed for this fault due to the conditions under Procedure
which it is declared. The 1-220 Circuit Diagram may be used as a reference.
Ensure that the Fuser Drawer is latched in the printer. Enter dC330 [10]. The Fuser INTLK
Procedure SW display indicates L.
Y N
Ensure that the Printer Right Top Cover is closed. Enter dC330. The Top Cover INTLK SW
Open the Fuser Drawer. Manually actuate the Fuser Interlock Switch. The display
display indicates L.
changes from H to L.
Y N
Y N
Open the Printer Right Top Cover. Manually actuate S104 several times. The Top Cover
Go to Flag 1. Check the circuit of the Fuser Interlock Switch (GP 6-2), (PL 10.1).
Y N
Replace the Printer Right Top Cover Interlock Switch, S104 (PL 4.5).
• (ADJ 10-13) Fuser Latch Assembly adjustment
Check the following: • (ADJ 10-12) Left and Right Drawer Slide adjustment
• Interlock Actuator adjustment for the Printer Right Top Cover (ADJ 4-3) • Alignment of the interlock actuator to the switch.
• Printer Right Top Cover Latch adjustment (ADJ 4-0)
Open and close the Fuser Drawer several times and check for intermittent operation of the
Check that the Printer Right Top Cover closes properly. If the problem continues, replace the Fuser INTLK SW display.
Printer Right Top Cover Interlock Switch, S104 (PL 4.5). Check the following:
• (ADJ 10-13) Fuser Latch Assembly adjustment
• (ADJ 10-12) Left and Right Drawer Slide adjustment
• Alignment of the interlock actuator to the switch.

1-212, 1-214 ?-8 No Product Name Assigned
Figure 1 1-214 Circuit Diagram (701005)

No Product Name Assigned ?-9 1-214
1-220 RAP Y N
Go to Flag 4. Check the 24 VDC side of the printer interlocks from 2TB1-1 to J354-10 at
Fault code, 1-220, occurs when a failure in the printer interlock system is detected. The 5 VDC the LVPS for an open circuit.
status switches indicate that the Printer Left Door, Right Door, and Top Cover are closed, and
the 24 VDC sense circuit indicates that one of them is open. This fault may also be caused by +24 VDC is measured between TH13 (+) and TH14 (-) on the LVPS.
a loss of +24 VDC due to any one of the following reasons: Y N
Go to Flag 8 and check for an open circuit. If OK, switch off the Printer and interchange
1. A +24 VDC failure occurs in the LVPS. the 24 VDC LVPS Relay, K104, with the 34 VDC LVPS Relay, K103. Switch on the Printer,
2. A short circuit in +24 VDC distribution caused the LVPS go into current limit. and wait for the printer to reach a ready condition. +24 VDC is measured between TH13
(+) and TH14 (-) on the LVPS.
3. The Printer has been put into the Power Interrupt mode due to a 3-XXX communications
fault. Y N
Replace the DC Output B PWB located in POS 8 of the LVPS (PL 1.10). If the prob-
4. There is a hardware failure between the control system and the LVPS.
lem continues, replace the Control PWB located in POS 11 of the LVPS (PL 1.10).
Initial Actions
• Check the adjustments for Printer Right Top Cover Latch (ADJ 4-0) and the Printer Right Switch off the Printer. Return the relays to their original locations. Replace the 24 VDC
Door Latch (ADJ 4-1) and also the Interlock Actuator adjustments (ADJ 4-3) for the LVPS Relay, (PL 1.10).
Printer Right Top Cover, Printer Right Door, and Printer Left Door.
• Check for loose or disconnected connectors at the three Printer Interlock switches. +5 VDC is measured at the TH23 test stake on the LVPS.
Y N
Procedure Remove connector, P394, from the PHN DIO PWB 2. Connect a jumper from TS37 to
Ensure that all the cover doors are closed. Enter dC330. The Printer INTLK Sense display TS4. The Printer INTLK Sense display changes from H to L.
indicates an H. Y N
Y N Replace the PHN DIO PWB 2 (PL 1.4).
Open the Printer Right Door. The Right Door INTLK SW display changes from L to H.
Y N Go to Flag 5. Check the wires for an open circuit.
Go to Flag 1. Check the circuit of the Right Door Interlock Switch (GP 6-2).
Enter dC330. Deselect [LVPS 24VDC]. Select [LVPS 24VDC]. Observe the 34 VDC LVPS
Open the Printer Left Door. The Left Door INTLK SW display changes from L to H. Relay, K103. Press the Start button. K103 actuates.
Y N Y N
Go to Flag 2. Check the circuit of the Left Door Interlock (GP 6-2). Replace the 24 VDC LVPS Relay, K104 (PL 1.10).
Open the Printer Right Top Cover. The Top Cover INTLK SW display changes from L Replace the 34 VDC Interlock Relay, K103, (PL 1.10). If the problem continues, replace the
to H. Control PWB located in POS 11 of the LVPS (PL 1.10).
Y N
Go to Flag 3. Check the circuit of the Top Cover Interlock Switch (GP 6-2, General
Procedures).
Go to the 1-720 Printer Interlock Bypass Switch RAP.
+24 VDC is measured at 2TB1-1.

Y N
+24 VDC is measured between TH12 (+) and TH14 (-) on the LVPS.
Y N
Go to the 1-717 +24 VDC RAP.
Go to Flag 6. Check wire 540 for an open circuit.
+24 VDC is measured between 2TB1-1 (+) and 2TB2-1 (-).

Y N
Ensure that all cover doors are closed. +24 VDC is measured at P354-10.

1-220 ?-10 No Product Name Assigned


A B C D
1-221 RAP Go to Flag 5. Check the wires for a short circuit. If OK, replace the 35 VDC
Interlock Relay, K103 and the 24 VDC Interlock Relay, K104 (PL 1.10).
Fault code, 1-221, occurs when a failure in the printer interlock system is detected. The 24
VDC sense circuit indicates that the Printer Left Door, Right Door, and Top Cover are closed, Go to the 1-720, Printer Interlock Bypass Switch RAP.
and the 5 VDC status switches indicate that one of them is open. When the fault occurs, the
printer will go into the Power Interrupt mode. Replace the Processor Right Door Interlock Switch (PL 4.3).
NOTE: If the fault occurs after closing the Printer Right Front Door, is intermittent and can be Insert a cheater into the Printer Right Door Interlock Switch. Press the Continue button. Open
cleared, vibration of the door upon switch actuation could be the cause. Go to the last step of the Printer Left Door. The Printer INTLK Sense display toggles from L to H.
the RAP for further actions. Y N
Replace the Printer Left Door Interlock Switch (PL 4.3).
Procedure
Ensure that all the cover doors are closed and that the printer interlocks are NOT bypassed. Remove the cheater. Close the Printer Left Door and the Printer Right Door. Press the Con-
Enter dC330. Select [LVPS 24v]. Press the Continue button. The Left Door INTLK SW dis- tinue button. Open the Printer Right Top Cover. The Printer INTLK Sense display toggles
play indicates L. from L to H.
Y N Y N
Go to Flag 2. Check the circuit of Left Door Interlock Switch (GP 6-2, General Proce- Replace the Printer Right Top Cover Interlock Switch (PL 4.3).
dures).
The interlocks appear to be OK. The problem may be intermittent. Check the following:
The Right Door INTLK SW display indicates L. • The Interlock actuator adjustments (ADJ 4-3) for the Printer Left Door, Right Door, and
Y N Right Top Cover.
Go to Flag 1. Check the circuit of the Right Door Interlock Switch (GP 6-2, General Proce- • Printer Right Top Cover Latch (ADJ 4-0) and the Printer Right Door Latch (ADJ 4-1)
dures). adjustments.
• Loose wires or connectors at all three Printer Interlock switches or the Printer Interlock
The Top Cover INTLK SW display indicates L.
Bypass Switch.
Y N
Go to Flag 3. Check the circuit of the Printer Right Top Cover Interlock Switch (GP 6-2,
General Procedures).
The Printer INTLK Bypass SW indicates L.

Y N
Monitor the Printer INTLK Sense display. Open the Printer Right Door.
NOTE: There is a two second delay between the switch deactuation and the toggling of the
Printer INTLK Sense.
The Printer INTLK Sense toggles from L to H.

Y N
Insert a cheater into the Printer Right Door Interlock switch. Open the Printer Left Door.
The Printer INTLK Sense toggles from L to H.
Y N
The fault originally occurred with the printer interlocks bypassed.
Y N
Remove the cheater key and close the Printer Right and Left Front doors.
Remove connector, P394, from the PHN DIO PWB 2. The Printer INTLK
Sense display changes from L to H.
Y N
Replace the PHN DIO PWB 2 (PL 1.4).
A B C D


A
1-700 AC Input Power (60 Hz) RAP Y N
This machine is wired for a dual cord configuration.
1-700 RAP is used when a problem exists in the AC Input Power Circuitry. Y N
The Line-To-Line voltage is measured from CB101-C to CB103-C.
Initial Actions Y N
• If any Circuit Breakers have been switching off automatically, go to RAP 1-721. Go to Flag 3. Check the wiring from CB103-C to TB101 for an open circuit.
• Ensure that the correct line voltage is available at the Wall Outlet (see Table 1).
The Line-To-Line voltage is measured from CB101-C to CB103-A.
Y N
Table 1 Voltage Specifications Go to Flag 3. Check the wiring from CB103-A to TB101 for an open circuit.
SERVICE MEASUREMENT RANGE
This RAP was entered from RAP 1-703.
Single Phase Line-to-Neutral 105-127 VAC
Y N
Single Phase Line-to-Line 210-254 VAC
115 VAC is measured from CB103-A to terminal 2 of the Convenience
Three Phase Line-to-Neutral 105-127 VAC Outlet, P111.
Three Phase Line-to-Line 182-220 VAC Y N
Go to Flag 4. Check the wires into and out of the Line Filter for an
open circuit. Remove the Line Filter, if necessary. If the wires are OK,
replace the LIne Filter, FL101 (PL 1.1).
• Ensure that the Fuser Power Circuit Breaker, CB102, and Main Power Circuit Breaker,
CB101 and CB103, are switched OFF.
115 VAC is measured between TB1-1 and P1-35, P1-10, and P1-25.
• Ensure that the Circuit Breakers on the ELCI/RCD Chassis (on the rear of the machine) Y N
are switched ON. Go to Flag 6. Check the wire going to the pin of P1 (where 115 VAC
WARNING was not available) for an open circuit.
Use caution when making the voltage measurements and always disconnect the Power
Cords when it is necessary to work inside the Line Interface Module. AC power is 115 VAC is measured between TB1-1 and P1-24, P1-28, P1-34, P1-7
present in the Line Interface Module whenever the Power Cords are plugged into the and P1-21.
Y N
Wall Outlet.
Go to Flag 7. Check the wire going to the pin of P1 (where 115 VAC
Procedure was not available) for an open circuit.
Remove the left rear panel and remove the cover from the Input Terminal Block, TB101. Refer
to Table 1 above. Check the Line-To-Line and Line-To-Neutral voltages on the terminal block. The AC input power is OK. Check the wiring and connectors for loose con-
The voltages are correct. nections.
Y N
Check the following components: Replace the Main Power Circuit Breaker, CB103 (PL 1.3).
• Wall Outlet for proper voltage
• Power Cord and ELCI/RCD Chassis for an open line (PL 1.14) The Line-To-Line voltage is measured from CB103-C to CB103-A.
• TB101 for proper connections Y N
Go to Flag 8. Check the wiring from CB103 to TB101 for an open circuit.
The Line-To-Line voltage is measured from CB102-A to CB102-C.
Y N This RAP was entered from RAP 1-703.
Go to Flag 1. Check the wiring from CB102 to TB101 for an open circuit. Y N
115 VAC is measured from CB103-A to terminal 2 of the Convenience Out-
This RAP was entered from RAP P10-203. let, P111.
Y N Y N
Go to Flag 11. Check the wires into and out of the Line Filter for an open
The Line-To-Line voltage is measured from CB101-A to CB101-C.
Y N circuit. Remove the Line Filter, if necessary. If the wires are OK, replace
Go to Flag 2. Check the wiring from CB101 to TB101 for an open circuit. the Line Filter (PL 1.1).
This RAP was entered from RAPs 1-701 or P1-703. 115 VAC is measured between TB1-1 and P1-35, P1-10, and P1-15.
A A B C
A B C
Y N
Go to Flag 9. Check the wire going to the pin of P1 (where 115 VDC was
not available) for an open circuit.
115 VAC is measured between TB1-1 and P1-24, P1-28, P1-34, P1-7, and
P1-21.
Y N
Go to Flag 10 Check the wire going to the pin of P1 (where 115 VAC was
not available) for an open circuit.
AC input power is OK. Check the wiring and connectors for loose connections.
Replace the Main Power Circuit Breaker, CB103 (PL 1.3).
Replace the Fuser Power Circuit Breaker, CB102 (PL 1.3).

Figure 1 1-700 Sing;e Power Cord Circuit Diagram

Figure 2 1-700 Dual Power Cord Circuit Diagram

A
1-701 AC Standby Power RAP (60HZ ONLY) Y N
Go to the 1-700, AC Input Power RAP.
The AC Standby Power RAP is used to help diagnose problems with AC Standby Power. AC
Standby Power is controlled by the Power On Relay which is energized as soon as +24 VDC is Go to Flag 3. Check the wires for an open circuit.
available from the LVPS. The Power On Relay supplies AC Power to the Main Drive Run
Relay, Compressor Relay, Interlock Relay, Camming Relay, Tray 1 and 2 Elevator Motors, The line-to-line voltage is measured between terminals 7 and 8 of the Power On Relay,
Inverter/Stacker Interlock Relay, and the Feeder Interlock Relay. K101.
Y N
Initial Actions +24 VDC is measured between terminals A and B of K101.
Y N
WARNING +24 VDC is measured between 1TB4-A and 1TB4-B.
AC power is present in the Line Interface Module and the AC Distribution Panel when- Y N
ever the printer power cord is plugged into the service outlet. +24 VDC is measured between TH12 (+) and TH14 (-) on the LVPS.
Perform the following: Y N
Go to the 1-717, +24, +34, and -34 VDC RAP.
• Ensure that the Main Power and the Fuser Power Circuit Breakers are switched on.
• Ensure that the printer Local/Remote Power Switch is switched to Local. Check wire 1028 for an open circuit.
• Ensure that the cover doors are closed or that the processor interlocks are bypassed.
Go to Flag 4. Check the wires for an open circuit.
Table 1 Voltage Specifications
Replace the Power On Relay, K101 (PL 1.3).
Single Phase Line-to-Neutral 105 to 127 VAC The line-to-line voltage is measured between terminals 5 and 6 of the Power On Relay,
K101.
Single Phase Line-to-Line 210 to 254 VAC
Y N
Three Phase Line-to-Neutral 105 to 127 VAC
Replace the Power On Relay, K101 (PL 1.3).
Three Phase Line-to-Line 182 to 220 VAC
115 VAC is measured at 2A7TB3-1.
Procedure Y N
The line-to-line voltage is measured between terminals 1 and 2 of the Power On Relay,
K101.
Y N
Y N
The line-to-line voltage is measured between terminals B and D of the Main Power
Circuit Breaker, CB101.
Y N
Y N
115 VAC is measured terminal 1 of K101.
Y N
115 VAC is measured between 2A7TB2-17 and 2A7TB2-10.
Go to Flag 1. Check wire 7A for an open circuit.
Y N
Go to the Wirenets Section (Wiring Data) and check wire 3 for an open circuit. If OK, go to
Go to Flag 2. Check wire 12A for an open circuit.
the 1-700, AC Input Power RAP.
The line-to-line voltage is measured between terminals 3 and 4 of the Power On Relay,
Go to Flag 8 and 9. Check the wires for an open circuit.
K101.
Y N
115 VAC is measured at terminal B of the Main Power Circuit Breaker, CB103.
Y N
115 VAC is measured at terminal D of the Main Power Circuit Breaker CB103.
A

1-702 AC Interlock Power RAP (60HZ ONLY) Y N
The AC Interlock Power RAP will help diagnose problems with printer AC Power that is con-
trolled by the door interlocks. AC Interlocked Power supplies the Cross Roll Motor and the 115 VAC is measured between 2A7TB1-10 and 2A7TB1-17
Toner Dispenser Motor. Y N
Go to Flag 5. Check wire 3F for an open circuit.
Initial Actions
WARNING
AC power is present in the Line Interface Module and the AC Distribution Panel when-
ever the Printer power cord is plugged into the service outlet.
Perform the following:
• Ensure that all covers are closed or that the Processor Interlocks are bypassed.
• Ensure that the Main Power Circuit Breaker CB101 is on.
Procedure
115 VAC is measured at terminal block, 2A7TB1-2.
Y N
Go to the 1-701, Standby Power RAP.
115 VAC is measured at terminal 7 of the Interlock Relay, K102.

Y N
Go to Flag 1. Check the wire for an open circuit.
115 VAC is measured at terminal 8 of K102.

Y N

Y N
Y N
+24 VDC is measured between terminals A (+) and B (-) of K102.
Y N
+24 VDC is measured between test points TH13 (+) and TH14 (-) of the
LVPS.
Y N
Replace the Interlock Relay, K102 (PL 1.6).

Y N


A
1-703 AC Switched On Power RAP (60HZ ONLY) Switch the Local/Remote Switch, S102, to the Local position. The Power On LED on the
Power Input PWB of the LVPS is still OFF.
The AC Switched On Power RAP will help diagnose problems with printer AC Power that is Y N
controlled by the System Power Switch on the System Controller, the Local/Remote Power +12 VDC is measured between terminals 1 and 2 of the Power Control Relay, K108.
Switch, and the Main Power Switch on the printer. AC Switched On Power supplies AC Power Y N
to the LVPS, ROS LVPS, Print Power Relay, and the Printer UI Video Display. Go to Flag 3 and check the wires for an open circuit.
Initial Actions Replace the Power Control Relay, K108 (PL 1.6).
WARNING The line-to-line voltage is measured between terminals B and D of the Main Power Cir-
AC power is present in the Line Interface Module and at the AC Distribution Panel when- cuit Breaker, CB101.
ever the printer power cord is plugged into the service outlet. Y N
Perform the following: Go to the 1-700, AC Input Power RAP.
• Ensure that the Main Power and the Fuser Power Circuit Breakers are switched on. The line-to-line voltage is measured between P395-1 and P395-12 at the LVPS.
• Ensure that the system power is on, that the Local/Remote Power Switch, S102, is in the Y N
remote position, and that the Printer Main Power Switch, S101, is on. The line-to-line voltage is measured between terminals 6 and 4 of the LVPS AC
Relay, K105.
Table 1 Voltage Specifications Y N
Single Phase Line-to-Neutral 105 to 127 VAC The line-to-line voltage is measured between terminals 3 and 1 of the K105.
Single Phase Line-to-Line 210 to 254 VAC Y N
115 VAC is measured between terminals A and B of K105.
Three Phase Line-to-Neutral 105 to 127 VAC
Y N
Three Phase Line-to-Line 182 to 220 VAC
Y N
Procedure Go to Flag 4. Check wire 7A for an open circuit.
The Power On LED on the Power Input PWB, located in the LVPS is OFF.
Y N 115 VAC is measured between terminal 5 of K105 and 2A7TB2-11.
Y N
The LED was ON. Switch the Local/Remote Power Switch, S102, to the Local position.
Switch off the System Power. The Power On LED on the Power Input PWB, located in Go to the Wirenets (Wiring Data) and check the ACN wire 3 for an open
the LVPS is still ON. circuit.
Y N
Go to Flag 8. Check the wires and the Local/Remote Power Switch for an open cir- 115 VAC is measured between terminal 5 of K105 and terminal B of K105.
cuit (PL 2.4). Y N
Go to Flag 5. Check wire 3HH for an open circuit.
The line-to-line voltage is measured between P395-1 and P395-12 on the LVPS.
Y N 115 VAC is measured at terminal 3 of the Power Control Relay, K108.
Y N
Return to the first step of this RAP and answer YES to BOTH the initial statement
AND to the second statement. (This is necessary because Power On LED on the Go to Flag 6. Check wire 7B for an open circuit.
LVPS is only a reliable indicator if it is not lit. One phase of AC Power is missing and
Go to Flag 7. Check the wires and the Main Power Switch, S101, for an open
the LED is still lit).
circuit (PL 4.3).
115 VAC is measured at 1TB1-1.
Replace the LVPS AC Relay, K105 (PL 1.6).
Y N
Go to Flag 10. Check the wires for an open circuit. Check all wires and connections for an
intermittent circuit. Switch off the system power and the Printer Main Power. Disconnect the power cords. Replace
the Power Input PWB of the LVPS (PL 1.10).
A
NOTE: Switch the Local/Remote switch, S102, to the Remote position when repair is
complete.
Figure 1 1-703 Circuit Diagram (7105)Continued on the next page.......


A B C D
1-704-1 Inverter/Stacker A Standby AC Power RAP (60HZ Y N
Go to the +24 VDC Distribution Wirenets, Figure 41 and check wires
ONLY) 63A and 65A for an open circuit.
The Inverter/Stacker A Standby Power RAP is used to help diagnose problems with AC Power
that is controlled by the Inverter/Stacker Interlock Relay in Module A. The Inverter/Stacker +24 VDC is measured at terminal 2 of the Feeder/Stacker Top Cover
Interlock Relay supplies AC Power to the Inverter Main Drive Motor, Front Tamper Motor, Back Interlock Switch, S1137.
Y N
Tamper Motor, Right Guide Tamper Motor, Stacker Elevator Relay, Inverter Motor, and the
Stacker Drive Motor. Go to Flag 7. Check wires 67D, 67A, and 63K for an open circuit. If
the wires are OK, replace the Inverter Front Door Interlock Switch,
S1153 (PL 4.11).
Procedure
If the problem occurs only when the Interlocks are bypassed, go to the second Procedure Go to Flag 8. Check the wires #70D, 70C, and 70A for an open circuit. If
labeled Interlock Bypass Problem later in this RAP. the wires are OK, replace the Feeder/Stacker Top Cover Interlock Switch,
WARNING S1137 (PL 4.12).
ever the printer power cord is plugged into the service outlet. Go to Flag 9. Check the wire for an open circuit.
Less than 10 VAC is measured between 2A7TB3-10 and the printer frame.
Y N Replace the Inverter/Stacker Interlock Relay, K111 (K1) (PL 1.19).
Go to the Wirenets Section (Wiring Data). Check wires 3D and 3A for an open circuit. If
OK, go to the 1-700, AC Input Power RAP. Replace the Inverter/Stacker Interlock Relay, K111 (K1) (PL 1.19).
115 VAC is measured at terminal 7 of K111 (K1).

115 VAC is measured 2A7TB3-2.
Y N Y N
Go to the 1-701, AC Standby Power RAP. Replace the Inverter/Stacker Interlock Relay, K111 (K1) (PL 1.19).
115 VAC is measured at 2A7TB3-5. Less than 1.0 VAC is measured between terminals 6 and 9 of K111 (K1).
Y N Y N
Replace the Inverter/Stacker Interlock Relay, K111 (K1) (PL 1.19).
Go to the 1-701, AC Standby Power RAP.
Remove the Inverter/Stacker Interlock Relay, K111 (K1). 115 VAC is measured between ter- Less than 10 VAC is measured between A-TB5-7 and Printer frame.
Y N
minals 5 and 6 of the K111 (K1) socket.
115 VAC is measured between terminals 4 and 6 of K111 (K1).
115 VAC is measured A-TB4-10.
Y N
Go to Flag 1. Check the wires for an open circuit. Y N
115 VAC is measured between A-TB4-5.
115 VAC is measured between terminals 4 and 6 of K111 (K1). Y N
Y N
Check the wires and connections for an intermittent circuit.
Re-install K111 (K1). 115 VAC is measured at terminal 8 of K111 (K1). Procedure
Y N INTERLOCK BYPASS PROBLEM
115 VAC is measured terminal 7 of K111 (K1). Bypass the interlocks. +24 VDC is measured between terminals A (+) and B (-) of K111
Y N (K1).
+24 VDC is measured between terminals A (+) and B (-) of K111 (K1). Y N
Y N +24 VDC is measured at terminal 1 of the Interlock Bypass Switch, S1152 (the side
+24 VDC is measured at terminal A of K111 (K1). where wire 63N is connected).
Y N Y N
+24 VDC is measured between side B (+) and side A (-) of A-TB7. Go to Flag 10. Check the wire for an open circuit.
A B C D E F
No Product Name Assigned ?-27 1-704-1
E F
+24 VDC is measured at terminal 1 of the Interlock Bypass Switch, S1152 (the side
where wire 71A is connected).
Y N
Replace the Interlock Bypass Switch, S1152 (PL 4.13).
Go to Flag 11. Check the wires for an open circuit. If OK, replace the Diode, CR4 (PL
24.5).

1-704-1 ?-28 No Product Name Assigned
Figure 1 1-704-1 Circuit Diagram (7106)Continued on the next page.......

Figure 2 1-704-1 Circuit Diagram (7133)

A B C D E
1-704-2 Stacker B Standby AC Power RAP (60HZ ONLY) +24 VDC is measured at terminal 2 of the Feeder/Stacker Top Cover
Interlock Switch, S1137.
The Stacker B Standby AC Power RAP is used to help diagnose problems with AC Power that Y N
is controlled by the Stacker Interlock Relay in Module B. The Stacker Interlock Relay supplies Go to Flag 7. Check wires 78H, and 78D for an open circuit.
AC Power to the Stacker Elevator Relay, Stacker Main Drive Motor, and the Tamper Motors.
Go to Flag 8. Check wires 70D, 70C, and 70A for an open circuit. If the
Procedure wires are OK, replace the Feeder/Stacker Top Cover Interlock Switch,
If the problem occurs only when the interlocks are bypassed, go to the second Procedure S1137 (PL 4.12).
labeled Interlock Bypass Problem later in this RAP.
WARNING
AC power is present in the Line Interface Module and the AC Distribution Panel when- Replace the Stacker B Interlock Relay, K111 (K1) (PL 1.19).
ever the printer power cord is plugged into the service outlet.
Less than 10 VAC is measured at A-TB1-12. 115 VAC is measured at terminal 7 of K111 (K1).
Y N Y N
Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP. Replace the Stacker B Interlock Relay, K111 (K1) (PL 1.19).
115 VAC is measured at A-TB1-8. Less than 1.0 VAC is measured between terminals 6 and 9 of K111 (K1).
Y N Y N
Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP. Replace the Stacker B Interlock Relay, K111 (K1) (PL 1.19).
115 VAC is measured at A-TB1-4. Less than 10 VAC is measured between B-TB5-7 and the Printer frame.
Y N Y N
Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP. Go to Flag 4. Check the wires for an open circuit.
Remove the Stacker B Interlock Relay K111 (K1). 115 VAC is measured between terminals 115 VAC is measured at B-TB4-10.
5 and 6 of K111 (K1). Y N
Y N 115 VAC is measured at B-TB4-5.
115 VAC is measured between terminals 4 and 6 of K111 (K1). Procedure
Bypass the interlocks. +24 VDC is measured between terminals A (+) and B (-) of K111
(K1).
Re-install K11 (K1). 115 VAC is measured at terminal 8 of K111 (K1). Y N
Y N
115 VAC is measured at terminal 7 of K111 (K1). where wire 78J is connected).
Y N Y N
+24 VDC is measured between terminals A (+) and B (-) of K111 (K1).
Y N
+24 VDC is measured at terminal A of K111 (K1). +24 VDC is measured at terminal 1 of the Interlock Bypass Switch, S1152 (the side
Y N
+24 VDC is measured between side A (+) and side B (-) of B-TB7. Y N
Y N Replace the Interlock Bypass Switch, S1152 (PL 4.13).
Go to the +24 VDC Distribution Wirenets and check wires 78A and
82A for an open circuit. Go to Flag 11. Check the wires for an open circuit. If OK, replace the Diode, CR4 (PL
24.5).
A B C D E F
F
Check the wires and connectors for an intermittent circuit.

A B C D E
1-705-1 Feeder (Tray 3) Standby AC Power RAP (60HZ +24 VDC is measured at terminal 2 of the Horizontal Transport Door
ONLY) Y N
Go to Flag 7. Check wires 67C, 67A, and 63A for an open circuit. If
The Feeder Standby AC Power RAP is used to help diagnose problems with AC Power con-
trolled by the Feeder Interlock Relay in Module A. The Feeder Interlock Relay supplies AC OK, replace the Inverter Front Door Interlock Switch, S1153 (PL
Power to the Feeder Drive Motor, Tray 3 Blower Motor, Tray 3 Elevator Motor, and the Feeder 4.11).
Drive Run Relay.
+24 VDC is measured at terminal 2 of the Vertical Transport Door
Procedure Y N
If the problem occurs only with the Interlocks bypassed, go to the second Procedure labeled Go to Flag 8. Check the wire for an open circuit. If OK, replace the
Interlock Bypass Problem later in this RAP. Horizontal Transport Door Interlock Switch, S1120 (PL 4.13).
WARNING
AC Power is present in the Line Interface Module and the AC Distribution Panel when- Go to Flag 9. Check the wires for an open circuit. If OK, replace the Verti-
ever the printer power cord is plugged into the service outlet. cal Transport Door Interlock Switch, S1118 (PL 4.13).
115 VAC is measured terminal 5 of the Main Drive Run Relay, K402.
Y N Go to Flag 10. Check the wire for an open circuit
Replace the Feeder Interlock Relay, K112 (K2) (PL 1.19).
Less than 10 VAC is measured at 2A7TB1-6.
Y N Replace the Feeder Interlock Relay, K112 (K2) (PL 1.19).
Go to the Wirenets (Wiring Data) and check wire 4 and 4C for an open circuit. If OK, go to
the 1-700, AC Input Power RAP. 115 VAC is measured at terminal 8 of K112 (K2).
Y N
Remove the Feeder Interlock Relay, K112 (K2). 115 VAC is measured between terminals 4
and 6 of K112 (K2).
Y N Less than 1.0 VAC is measured between terminals 6 and 9 of K112 (K2).
Y N
115 VAC is measured at A-TB3-2.
Y N 115 VAC is measured at A-TB3-13.
Re-install K112 (K2). 115 VAC is measured at terminal 7 of K112 (K2).
Y N Less than 10 VAC is measured at A-TB3-6.
Y N
Y N Go to Flag 4. Check the wire for an open circuit.
Y N
+24 VDC is measured at terminal A of K112 (K2). Procedure
+24 VDC is measured between side B (+) and side A (-) of A-TB7. Bypass the interlocks. +24 VDC is measured between terminals A (+) and B (-) of K112
Y N (K2).
Go to the 24 VDC Distribution Wirenets (Wiring Data), and check Y N
wires 63A and 65A for an open circuit. +24 VDC is measured at terminal 1 of the Interlock Bypass Switch, S1152 (the side
where wire 63N is connected).
A B C D E F
F
Y N
Y N
24.5).
Check the wires and connections for an open circuit.

Figure 1 1-705 Circuit Diagram (7107)Continued on the next page......


A B C D
1-705-2 Feeder (Tray 4) Standby AC Power RAP (60HZ Y N
Go to the 24 VDC Distribution Wirenets (Wiring Data), and check
ONLY) wires 78A and 82A for an open circuit.
The Feeder Standby AC Power RAP is used to help diagnose problems with AC Power con-
trolled by the Feeder Interlock Relay in Module B. The Feeder Interlock Relay supplies AC +24 VDC is measured at terminal 2 of the Horizontal Transport Door
Power to the Feeder Drive Motor, Tray 4 Blower Motor, Tray 4 Elevator Motor, and the Feeder Interlock Switch, S1120.
Y N
Drive Run Relay.
Go to Flag 7. Check wires 78D and 78F for an open circuit.
Procedure +24 VDC is measured at terminal 2 of the Vertical Transport Door
If the problem occurs only with the Interlocks bypassed, go the part of this procedure called Interlock Switch, S1118.
INTERLOCK BYPASS PROBLEM. Y N
WARNING Go to Flag 8. Check the wire for an open circuit. If OK, replace the
AC Power is present in the Line Interface Module whenever the printer power cord is Horizontal Transport Door Interlock Switch, S1120 (PL 4.13).
plugged into the service outlet.
Go to Flag 9. Check the wires for an open circuit. If OK, replace the Verti-
Y N cal Transport Door Interlock Switch, S1118 (PL 4.13).
Go to the 1-705-1, Feeder Standby AC Power RAP.
Go to Flag 10. Check the wire for an open circuit
Less than 10 VAC is measured at A-TB2-11.
Y N
Go to the 1-705-1, Feeder Standby AC Power RAP. Y N
Remove the Feeder Interlock Relay, K112 (K2). 115 VAC is measured between terminals 4
and 6 of K112 (K2). Less than 1.0 VAC is measured between terminals 6 and 9 of K112 (K2).
Y N Y N
Y N
Go to Flag 1. Check the wires for an open circuit. 115 VAC is measured at B-TB3-2.
Y N
Go to Flag 2. Check the wires for an open circuit. Go to Flag 5. Check the wires for an open circuit.
115 VAC is measured at B-TB3-13.

Y N Y N
Go to Flag 3. Check the wires for an open circuit. Go to Flag 6. Check the wires for an open circuit.
Re-install K112 (K2). 115 VAC is measured at terminal 7 of K112 (K2). Less than 10 VAC is measured at B-TB3-6.
Y N Y N
Y N
+24 VDC is measured between terminals A (+) and B (-) of K112 (K2). Check the wires and connections for an intermittent circuit.
INTERLOCK BYPASS PROBLEM
Y N
+24 VDC is measured at terminal A of K112 (K2). Bypass the interlocks. +24 VDC is measured between terminals A (+) and B (-) of K112
Y N (K2).
+24 VDC is measured between side A (+) and side B (-) of B-TB7. Y N
where wire 63N is connected).
A B C D E
E
Y N
Y N
24.5).
Check the wires and connectors for an intermittent condition.


A
1-707 AC Input Power RAP (50HZ WYE) The phase-to-neutral voltage is measured between terminals A and G of CB104.
Y N
The AC Input Power RAP will help diagnose problems with AC Power from the service outlet, The phase-to-neutral voltage is measured between terminals 1 and 4 of the Input
Power Cord, Line Filter, and Circuit Breakers. Terminal Block, TB101.
Y N
Initial Actions Disconnect the printer Power Cord. Check the Power Cord. Repair or replace the
Power Cord (PL 1.14).
WARNING
Use caution when making the voltage measurements and always disconnect the Printer Disconnect the Printer Power Cord. Remove the Line Interface Module (REP 1-2). Go to
power when working inside the Line Interface Module. AC power is present in the Line Flag 1. Check the wires into and out of the Line Filter, FL101. If they are OK, replace the
Interface Module whenever the power cord is connected to the service power. Line Filter, FL101 (PL 1.1).
The phase-to-neutral voltage is measured between terminals B and H, D and H, and F
• Ensure that the proper line voltage is available at the service power source (See Table 1). and H of the Main Power Circuit Breaker, CB104.
• Ensure that the circuit breakers are on. Y N
• Ensure that connector J268 is fully connected at the rear of the Line Interface Module.
The phase-to-neutral voltage is measured between terminal S of the Earth Leakage

Breaker, CB105, and terminal H of CB104.
SERVICE MEASUREMENT RANGE Y N
220 V Phase-to-Neutral 198 to 242 VAC Go to Flag 2. Check wire 8A for an open circuit.
230 V Phase-to-Neutral 207 to 253 VAC
The phase-to-neutral voltage is measured between terminals S and T of CB105.
240 V Phase-to-Neutral 216 to 264 VAC Y N
Procedure
The phase-to-neutral voltage is measured between terminals E and G of the Main Power The phase-to-neutral voltage is measured between terminals R and T of CB105.
Y N
Y N Go to Flag 4. Check wire 6 for an open circuit.
The phase-to-neutral voltage is measured between terminals 3 and 4 of the Input
The phase-to-neutral voltage is measured between terminals U and W and terminals V
Terminal Block, TB101.
Y N and W of CB105.
Disconnect the Printer Power Cord. Check the power cord. Repair or replace the Y N
Replace the Earth Leakage Breaker, CB105 (PL 1.2).
Disconnect the Printer Power Cord. Remove the Line Interface Module (REP 1-2). Go to The phase-to-neutral voltage is measured between P5-2 and P5-1.
Y N
Flag 1. Check the wires into and out of the Line Filter, FL101. If they are OK, replace the
Line Filter, FL101 (PL 1.1). Go to Flag 5. Check the wires for an open circuit.
The phase-to-neutral voltage is measured between P5-2 and P1-21.

The phase-to-neutral voltage is measured between terminals C and G of the Main Power
Circuit Breaker, CB104. Y N
Y N The phase-to-neutral voltage is measured between P5-2 and P1-35.
Y N
The phase-to-neutral voltage is measured between terminals 2 and 4 of the Input
Terminal Block, TB101. Go to Flag 8. Check the wires for an open circuit.
Y N
Go to Flag 9. Check wire 4J for an open circuit.
Disconnect the Printer Power Cord. Check the Power Cord. Repair or replace the
Disconnect the Printer Power Cord. Remove the Line Interface Module (REP 1-2). Go to
Line Filter, FL101 (PL 1.1).
A
Figure 1 1-707 Circuit Diagram (50Hz Wye) (7112)

A
1-707AC Input Power RAP (50HZ DELTA) The phase-to-phase voltage is measured between terminals B and F and terminals B
and D of the Main Power Circuit Breaker, CB104.
The AC Input Power RAP will help diagnose problems with AC Power from the service outlet, Y N
Power Cord, Line Filter, and Circuit Breakers. Replace the Main Power Circuit Breaker, CB104 (PL 1.2).
Initial Actions The phase-to-phase voltage is measured between terminal S of the Earth Leakage
Breaker, CB105, and terminal D of CB104.
WARNING Y N
Use caution when making the voltage measurements, and always disconnect the printer Go to Flag 2. Check wire 8A for an open circuit.
power when working inside the Line Interface Module. AC power is present in the Line
Interface Module whenever the power cord is connected to the service power. The phase-to-phase voltage is measured between terminals S and T of CB105.
• Ensure that the proper line voltage is available at the service power source (See Table 1).
• Ensure that the circuit breakers are on. The phase-to-phase voltage is measured between terminals R and T of CB105.
Y N
• Ensure that J268/P1 on the back of the Line Interface Module is fully connected.
The phase-to-phase voltage is measured between terminals U and W and terminals V
SERVICE MEASUREMENT RANGE and W of CB105.
220 V Phase-to-Phase 198 to 242 VAC Y N
Replace the Earth Leakage Breaker, CB105 (PL 1.2).
230 V Phase-to-Phase 207 to 253 VAC
240 V Phase-to-Phase 216 to 264 VAC The phase-to-phase voltage is measured between P5-2 and P5-1.
Y N
Procedure Go to Flag 5 and Flag 7. Check the wires for an open circuit.
The phase-to-phase voltage is measured between terminals C and E of the Main Power
115 VAC is measured between terminals P5-4 and P5-3.
Y N Y N
The phase-to-phase voltage is measured between terminals 2 and 3 of the Input Replace the Autotransformer, T101 (PL 1.1).
Disconnect the printer Power Cord. Check the power cord. Repair or replace the
Disconnect the printer Power Cord. Remove the Line Interface Module (REP 1-2). Go to
The phase-to-phase voltage is measured between terminals A and C of the Main Power
Y N
The phase-to-phase voltage is measured between terminals 1 and 2 of the Input
Y N
Disconnect the printer Power Cord. Check the Power Cord. Repair or replace the
Disconnect the printer Power Cord. Remove the Line Interface Module (REP 1-2). Go to
A
Figure 1 1-707 Circuit Diagram (50Hz Delta) (7113)

A B C
1-708 AC Standby Power RAP (50HZ WYE And DELTA) Go to Flag 3. Check the wires for an open circuit.
The AC Standby Power RAP is used to help diagnose problems with AC Standby Power. AC Replace the Power On Relay, K101 (PL 1.2).
Standby Power is controlled by the Power On Relay which is energized as soon as +24 VDC is
available from the LVPS. The Power On Relay supplies AC Power to the Compressor Relay, 115 VAC is measured between 2A7TB1-8 and 2A7TB1-2.
Interlock Relay, and the IFS Power Relay. Y N
Initial Actions
AC Standby Power is OK. Check the wires and connectors for an intermittent condition.
WARNING
ever the power cord is connected to the service power.
• Ensure that the Main Power Circuit Breaker and the Earth Leakage Breaker are on.
• Ensure that the cover doors are closed or that the interlocks are bypassed.
Procedure
NOTE: Whenever measuring 115 VAC in this procedure, 105 to 127 VAC is the acceptable
range.
115 VAC is measured between terminals 3 and 4 of the Power On Relay, K101.
Y N
115 VAC is measured between P5-3 and P5-4 (output connector of the Autotrans-
former, T101).
Y N
115 VAC is measured between terminals 7 and 8 of K101.

Y N
+24 VDC is measured between terminals A and B of K101.
Y N
+24 VDC is measured at terminal A of K101.
Y N
+24 VDC is measured 1TB4-1A.
Y N
Y N
Go to the 1-717, +24, +34, and -34 VDC RAP.
Go to the Wirenets Section (Wiring Data) and check wire 1028 for an open
circuit.
+24 VDC is measured between 1TB4-1A (+) and 1TB4-1B (-).

Y N
Go to the Wirenets Section (Wiring Data) and check wire 1029 for an open cir-
cuit.
A B C
Figure 1 1-708 Circuit Diagram (50Hz Wye) (7114)

A B C
1-709 AC Interlocked Power RAP (50HZ) Replace the Interlock Relay, K102 (PL 1.5).
The AC Interlock Power RAP will help diagnose problems with printer AC Power that is con- Replace the Interlock Relay, K102 (PL 1.5).
trolled by the door interlocks. AC Interlocked Power supplies the Cross Roll Motor and the
Toner Dispenser Motor. 115 VAC is measured between terminals 9 and 7 of K102.
Y N
Initial Actions Replace the Interlock Relay, K102 (PL 1.5).
WARNING Check the wires to the AC Remote PWB's.
AC power is present in the Line Interface Module and at the AC Distribution Panel when-
ever the power cord is connected to the service power.
• Ensure that the Main Power Circuit Breaker and the Earth Leakage Breaker are on.
• Ensure that all covers are closed or that the interlocks are bypassed.
Procedure
range.
115 VAC is measured between terminals 6 and 5 of the Interlock Relay, K102.
Y N
115 VAC is measured between terminal 7 and 8 of the Power On Relay, K101.
Y N
Go to the 1-708, Standby Power Rap.
115 VAC is measured between terminal 6 of K102 and 2A7TB1-8.

Y N
Go to Flag 1 and Flag 2. Check the wires for an open circuit.
Go to Flag 6. Check wire 51CC for an open circuit.

Y N
Go to Flag 5. Check wire 51EE for an open circuit.

Y N
Y N
Y N
Y N

Y N
A B C

A
1-710 AC Switched On Power RAP (50HZ) Switch the Local/Remote Power Switch to the Local position. The Power On LED on the
LVPS is still OFF.
The AC Switched On Power RAP will help diagnose problems with printer AC Power that is Y N
controlled by the System Power Switch on the System Controller, Local/Remote Power Switch, +12 VDC is measured between terminals 1 and 2 of K108.
and the Main Power Switch on the Printer. AC Switched On Power supplies AC Power to the Y N
LVPS, ROS LVPS, Print Power Relay, and the Printer UI Video Display. Go to Flag 16. Check the wires for an open circuit.
Initial Actions Go to Flag 2. Check wire #54B for an open circuit. If OK, replace the Power Control Relay,
K108 (PL 1.5).
WARNING
AC power is present in the Line Interface Module and at the AC Distribution Panel when- The phase-to-neutral voltage (Wye) or the phase-to-phase voltage (Delta) is measured
ever the power cord is connected to the service power. between terminals 1 and 3 of the LVPS Power Relay, K105.
The phase-to-neutral voltage (Wye) or the phase-to-phase voltage (Delta) is mea-
• Ensure that the Main Power Circuit Breaker and the Earth Leakage Breaker are on. sured between terminals U and W of the Earth Leakage Breaker, CB105.
• Ensure that the system power is on, that the Local/Remote Power Switch, S102 is in the Y N
remote position, and that the Main Power Switch, S101 is on. Go to the 1-707, AC Input Power RAP.
Procedure Go to Flag 1. Check the wires for an open circuit.
The Power On LED, on the Power Input PWB of the LVPS is OFF.
Y N (Delta only, Wye go on to next step) The phase-to-phase voltage is measured between ter-
The LED was ON. Switch the Local/Remote Power Switch to the Local position. Switch off minal K105-3 and 2A7TB3-10.
the System Power. The Power On LED on the LVPS is still ON. Y N
Y N Go to Flag 1. Check the wires for an open circuit. If OK, go to the 1-707, AC Input Power
Go to Flag 8. Check the wires and the Local/Remote Power Switch for an open cir- RAP (Delta).
cuit (PL 2.4).
The phase-to-neutral voltage (Wye) or the phase-to-phase voltage (Delta) is measured
115 VAC is measured between 1TB1-1 and 1TB1-7. between terminals 4 and 6 of K105.
Y N Y N
115 VAC is measured between terminals 4 and 6 of the ROS Power Relay, 115 VAC is measured between terminals A and B of K105.
K109. Y N
Y N 115 VAC is measured between 2A7TB1-3 and 2A7TB1-14.
Go to Flag 14 and Flag 15. Check for an open circuit. If OK, go to the 1-707, AC
115 VAC is measured between terminals 7 and 9 of the ROS Power Relay, Input Power RAP.
K109.
Y N 115 VAC is measured between 2A7TB1-3 and 2A7TB1-17.
115 VAC is measured between terminals A and B of K109. Y N
Y N Go to Flag 3. Check the wires and the Main Power Switch, S101 (PL 4.3) for an
Go to Flag 6. Check wires 52HH and 65A for an open circuit. open circuit.
Replace the ROS Power Relay, K109 (PL 1.5). Go to Flag 9. Check wires 52EE and 65 for an open circuit.
115 VAC is measured between 2A7TB4-14 and 2A7TB4-4. Replace the LVPS Power Relay, K105 (PL 1.5).
Y N
Go to Flag 7. Check wires 25 and 13 for an open circuit. The phase-to-neutral voltage (Wye) or the phase-to-phase voltage (Delta) is measured
between P395-1 and P395-12.
Go to Flag 11 and Flag 12. Check the wires for an open circuit. Y N
AC Switched on Power is OK. If the problem continues, check the wires and connectors for an
intermittent condition.
A
Figure 1 1-710 Circuit Diagram (7100)Continued on the next page.......


A
1-711-1 Inverter/Stacker A Standby AC Power (50HZ) Y N
Go to Flag 14. Check the wires for an open circuit. If OK, go to the 1-708, AC
The Inverter/Stacker A Standby Power RAP is used to help diagnose problems with AC Power Standby Power Rap.
that is controlled by the Inverter/Stacker Interlock Relay in Module A. The Inverter/Stacker
Interlock Relay supplies AC Power to the Inverter Main Drive Motor, Front Tamper Motor, Back 115 VAC is measured between terminals 7 and 6 of K107.
Tamper Motor, Trail Edge Tamper Motor, Stacker Elevator Relay, Inverter Motor, and the Y N
Stacker Drive Motor. Replace the IFS Power Relay, K107 (PL 1.5).
Initial Actions 115 VAC is measured between A-TB1-7 and A-TB1-11.

Y N
WARNING Go to Flag 18. Check the wires for an open circuit.
AC power is present in the Line Interface Module and at the AC Distribution Panel when-
ever the power cord is connected to the service power. Go to Flag 2. Check the wire for an open circuit.
115 VAC is measured between terminal 4 and 6 of K111 (K1).
• Ensure that the cover doors are closed. Y N
Procedure 115 VAC is measured between 2A7TB1-1 and 2A7TB1-7.
Y N
NOTE: Ensure that the voltage is in the acceptable range of 105 to 127 VAC whenever check- Go to the 1-708, Standby AC Power Rap.
ing for 115 VAC.
115 VAC is measured between terminals 1 and 2 of the IFS Power Relay, K107.
115 VAC is measured between terminals 5 and 6 of the Inverter/Stacker Interlock Relay,
Y N
K111 (K1).
Y N
115 VAC is measured between terminals 4 and 6 of the Inverter/Stacker Interlock
Relay, K111 (K1).
Y N
Y N
Replace the IFS Power Relay, K107 (PL 1.5).
Y N
115 VAC is measured between A-TB1-3 and A-TB1-11.
Go to the 1-708, Standby AC Power RAP.
Y N
Y N
Y N
Y N
Y N
Y N
Y N
+24 VDC is measured at terminal A of K111 (K1).
Y N
+24 VDC is measured between side B (+) and side A (-) of A-TB7.
Y N
Y N
65A for an open circuit.

+24 VDC is measured at terminal 2 of the Feeder/Stacker Top Cover
A B C D E
B C D E
Y N
Go to Flag 7. Check wires 67D, 67A, and 63K for an open circuit. If
the wires are OK, replace the Inverter Front Door Interlock Switch,
S1153 (PL 4.11).
Go to Flag 8. Check the wires 70D, 70C, and 70A for an open circuit. If the
wires are OK, replace the Feeder/Stacker Top Cover Interlock Switch,
S1137 (PL 4.12).
Bypass the interlocks. +24 VDC is measured between terminals A (+) and B (-) of
K111 (K1).
Y N
+24 VDC is measured at terminal 1 of the Interlock Bypass Switch, S1152
(the side where wire 63N is connected).
Y N

(the side where wire 71A is connected).
Y N
Go to Flag 11. Check the wires for an open circuit. If OK, replace the Diode,
CR4 (PL 24.5).

Y N

Y N
Y N

Y N
The Inverter/Stacker Standby AC Power is OK. Check all wires and connectors for an intermit-
tent circuit.

Figure 1 1-711-1 Circuit Diagram (7101)Continued on the next page......


A B C D E
1-711-2 Stacker B Standby AC Power RAP (50HZ) Go to Flag 8. Check wires 70D, 70C, and 70A for an open circuit. If the
wires are OK, replace the Feeder/Stacker Top Cover Interlock Switch,
The Stacker B Standby AC Power RAP is used to help diagnose problems with AC Power that S1137 (PL 4.12).
is controlled by the Stacker Interlock Relay in Module B. The Stacker Interlock Relay supplies
AC Power to the Stacker Elevator Relay, Stacker Main Drive Motor, and the Tamper Motors. Go to Flag 9. Check the wire for an open circuit.
Procedure Bypass the interlocks. +24 VDC is measured between terminals A (+) and B (-) of
K111 (K1).
WARNING Y N
AC power is present in the Line Interface Module whenever the power cord is connected +24 VDC is measured at terminal 1 of the Interlock Bypass Switch, S1152
to the service power. (the side where wire 78J is connected).
NOTE: Whenever measuring 115 VAC in this procedure, 105 to 127 VAC is an acceptable Y N
range.
115 VAC is measured between A-TB1-4 and A-TB1-12. +24 VDC is measured at terminal 1 of the Interlock Bypass Switch, S1152
Y N (the side where wire 71A is connected).
Go to the 1-711-1 Inverter/Stacker A Standby AC Power RAP. Y N
Y N Go to Flag 11. Check the wires for an open circuit. If OK, replace the Diode,
Go to the 1-711-1 Inverter/Stacker A Standby AC Power RAP. CR4 (PL 24.5).
115 VAC is measured between terminals 5 and 6 of the Stacker B Interlock Relay, K111 Replace the Stacker B Interlock Relay, K111 (K1) (PL 1.19).
(K1).
Y N Replace the Stacker B Interlock Relay, K111 (K1) (PL 1.19).
Y N 115 VAC is measured between terminals 7 and 9 of K111 (K1).
Replace the Stacker B Interlock Relay, K111 (K1) (PL 1.19).
115 VAC is measured between B-TB4-10 and B-TB5-7.
115 VAC is measured between terminals 4 and 6 of K111 (K1). Y N
Y N 115 VAC is measured between B-TB4-5 and B-TB5-7.
Y N 115 VAC is measured between B-TB4-5 and B-TB5-7.
+24 VDC is measured between terminals A (+) and B (-) of K111 (K1). Y N
Y N Check the wires and connections for an intermittent circuit.
+24 VDC is measured between side A (+) and side B (-) of B-TB7.
Y N
+24 VDC is measured at terminal 2 of the Feeder/Stacker Top Cover

Y N
Go to Flag 7. Check wires 78H, and 78D for an open circuit.
A B C D E

A B C
1-712-1 Feeder (Tray 3) Standby AC Power RAP (50HZ) Go to Flag 1. Check the wires for an open circuit.
The Feeder Standby AC Power RAP is used to help diagnose problems with AC Power con- 115 VAC is measured between terminals 4 and 3 of the IFS Power Relay, K107.
trolled by the Feeder Interlock Relay in Module A. The Feeder Interlock Relay supplies AC Y N
Power to the Feeder Drive Motor, Tray 3 Blower Motor, Tray 3 Elevator Motor, and the Feeder 115 VAC is measured between 2A7TB1-1 and 2A7TB1-7.
Drive Run Relay. Y N
Go to the 1-708, Standby Power RAP.
Initial Actions
WARNING
AC power is present in the Line Interface Module and at the AC Distribution Panel when- 115 VAC is measured between terminals 8 and 7 of K107.
ever the power cord is connected to the service power. Y N
Perform the following: Replace the IFS Power Relay, K107 (PL 1.5).
• Ensure that the cover doors are closed or that the interlocks are bypassed. Go to Flag 2. Check the wires for an open circuit.
Procedure
NOTE: Whenever measuring for 115 VAC in this procedure, 105 to 127 VAC is the acceptable Y N
range. 115 VAC is measured between terminal 3 of K107 and 2A7TB1-7.
Y N
115 VAC is measured between terminals 4 and 6 of the Feeder Interlock Relay, K112 (K2).
Go to Flag 15. Check the wires for an open circuit. If OK, go to the 1-708, Standby
Y N
AC Power RAP.
Y N
Y N
Y N
Go to the 1-708, Standby AC Power RAP.
Y N
Enter the [Power Interrupt] mode. Disconnect P412 from J1 on the FSN AC Remote PWB #3.
Exit the Power Interrupt mode.
115 VAC is measured between terminals 3 and 2 of K107. NOTE: P412 is disconnected to avoid inaccurate voltage readings due to possible alternate
Y N return paths. Reconnect P412 to J1 when the procedure is complete.
Go to Flag 15. Check the wires for an open circuit. If OK, go to the 1-708,
Standby AC Power RAP.
Y N
115 VAC is measured between terminals 8 and 6 of K107. 115 VAC is measured between terminals 8 and 9 of K112 (K2).
Y N
Y N
115 VAC is measured between terminals 7 and 6 of K107. +24 VDC is measured between terminals A (+) and B (-) of K112 (K2).
Y N Y N
+24 VDC is measured between terminals A and B of K107.
Y N Y N
Go to Flag 16 and Flag 17. Check the wires for an open circuit. +24 VDC is measured between side B (+) and side A (-) of A-TB7.
Y N
Replace the IFS Power Relay, K107 (PL 1.5). Go to the 24 VDC Distribution Wirenets (Wiring Data), and check
wires 63A and 65A for an open circuit.
+24 VDC is measured at terminal 2 of the Horizontal Transport Door
Y N
A B C D E F G
D E F G H
Y N Feeder Standby AC Power is OK. Check all wires and connections for intermittent circuits.
Go to Flag 7. Check wires 67C, 67A, and 63A for an open circuit. If
OK, replace the Inverter Front Door Interlock Switch, S1153 (PL
4.11).

Y N
Go to Flag 8. Check the wire for an open circuit. If OK, replace the
Horizontal Transport Door Interlock Switch, S1120 (PL 4.13).
cal Transport Door Interlock Switch, S1118 (PL 4.13).
K112 (K2).
Y N
Y N

Y N
CR3 (PL 24.5).

Y N

Y N
Y N

Y N
H
Figure 1 1-712-1 Circuit Diagram (7116)Continued on the next page.......


A B
1-712-2 Feeder (Tray 4) Standby AC Power RAP (50HZ) Y N
+24 VDC is measured at terminal A of K112B (K2).
The Feeder Standby AC Power RAP is used to help diagnose problems with AC Power con- Y N
trolled by the Feeder Interlock Relay in Module B. The Feeder Interlock Relay supplies AC +24 VDC is measured between side A (+) and side B (-) of B-TB7.
Power to the Feeder Drive Motor, Tray 4 Blower Motor, Tray 4 Elevator Motor, and the Feeder Y N
Drive Run Relay. Go to the 24 VDC Distribution Wirenets (Wiring Data), and check
wires 78A and 82A for an open circuit.
Initial Actions
+24 VDC is measured at terminal 2 of the Horizontal Transport Door
WARNING Interlock Switch, S1120.
AC power is present in the Line Interface Module and at the AC Distribution Panel when- Y N
ever the power cord is connected to the service power. Go to Flag 7. Check wires 78D and 78F for an open circuit.
• Ensure that the cover doors are closed or that the interlocks are bypassed. Interlock Switch, S1118.
Procedure Y N
Go to Flag 8. Check the wire for an open circuit. If OK, replace the
NOTE: Whenever measuring 115 VAC in this procedure, 105 to 127 VAC is the acceptable Horizontal Transport Door Interlock Switch, S1120 (PL 4.13).
range.
cal Transport Door Interlock Switch, S1118 (PL 4.13).
Y N

Y N
K112B (K2).
Y N
115 VAC is measured between terminals 4 and 6 of the Feeder Interlock Relay, K112B
(K2).
Y N
Y N
115 VAC is measured between terminals 5 and 6 of K112B (K2).
Y N
Y N
115 VAC is measured between terminals 5 and 6 of K112B (K2).

Y N
CR3 (PL 24.5).
Replace the Feeder Interlock Relay, K112B (K2) (PL 1.19).
Enter the [Power Interrupt] mode. Disconnect P412 from J1 on the FSN AC Remote PWB #3.
Exit the Power Interrupt mode.
Replace the Feeder Interlock Relay, K112B (K2) (PL 1.19).
NOTE: Disconnecting of P412 is necessary to prevent erroneous voltage readings due to alter-
nate return paths. Reconnect P412 when this procedure is complete. 115 VAC is measured between terminals 8 and 9 of K112B (K2).
Y N
115 VAC is measured between terminals 7 and 9 of K112B (K2). Replace the Feeder Interlock Relay, K112B (K2) (PL 1.19).
Y N
115 VAC is measured between terminals 8 and 9 of K112B (K2). 115 VAC is measured between B-TB3-2 and B-TB3-6.
Y N Y N
+24 VDC is measured between terminals A (+) and B (-) of K112B (K2). 115 VAC is measured between B-TB3-13 and B-TB3-6.
A B C
C
Y N
115 VAC is measured between B-TB3-13 and B-TB3-6.

Y N


A B C
1-713 +5 VDC RAP Go to the 1-718, DC Power Corrective Actions RAP, step 1.
The 1-713 RAP is designed to aid in troubleshooting any problems with the +5 VDC circuitry of The red LED on the PWB located at POS 3 is off.
the Printer LVPS and related wiring. Y N
Switch off the Printer. Disconnect J251 and J315 from the LVPS. Switch on the
Initial Actions Printer. The red LED located on the PWB at POS 3 is off.
Y N
WARNING Replace the DC Output A PWB located at POS 3 (PL 1.10).
When replacing PWBs, wait 5 minutes with the power off before removing any covers
from the LVPS. Switch off the Printer. Monitor the voltage between TH-3 (+) and TH-8 (-). Reconnect
CAUTION J251 to the LVPS. Switch on the Printer. +4.95 to 5.35 VDC is measured between
Do not install the LVPS with any of its covers removed. Damage may result due to incorrect air- TH-3 (+) and TH-8 (-).
flow in the supply. Y N
Do not attempt to replace fuses on PWBs that have blown. An open fuse is an indication of a Go to the 1-718, DC Power Corrective Actions RAP, step 2.
problem with the PWB.
Go to the 1-718, DC Power Corrective Actions RAP, step 3.
Never run the LVPS without the air filters installed. Conductive fibers from anti-static brushes
are known to cause the LVPS to fail.
The red LED on the PWB located at POS 4 is on. Switch off the Printer. Disconnect 4221
Perform the following: from the LVPS. Switch on the Printer. The red LED on the PWB located at POS 4 is off.
Y N
• Ensure that all cover doors are closed. Replace the DC Output PWB located at POS 4 (PL 1.10).
• Remove all jumper wires when the procedure is complete.
Procedure Go to the 1-718, DC Power Corrective Actions RAP, step 4.
NOTE: If an over-current condition (short circuit) exists, the power must be switched off and Measure the voltage between the following test holes on the LVPS:
the short circuit corrected or disconnected before the LVPS will reset. • TH-2 (+) and TH-8 (-)
The Power On LED (green) located on the Power Input PWB (POS 1) is lit. • TH-3 (+) and TH-8 (-)
Y N • TH-4 (+) and TH-8 (-)
The line-to-line voltage (60Hz), the phase-to-neutral voltage (50Hz Wye), or the +4.95 to 5.35 VDC is measured at all three test points.
phase-to-phase voltage (50Hz Delta) is measured between P395-1 and P395-12. Y N
Y N Switch off the Printer. Connect a jumper wire between TH-9 and TH-8 on the LVPS. Wait
Go to the 1-703, AC Switched On Power RAP (60Hz) or 1-710, AC Switched On 15 seconds. Switch on the Printer. Measure the voltage between TH-2 (+) and TH-8 (-),
Power RAP (50Hz). TH-3 (+) and TH-8 (-), and TH-4 (+) and TH-8 (-). +4.95 to 5.35 VDC is measured at all
three test points.
Replace the Power Input PWB (PL 1.10). Y N
Less than 4.95 VDC is measured at all three test points.
The line-to-line voltage (60Hz), the phase-to-neutral voltage (50Hz Wye), or the phase-to- Y N
phase voltage (50Hz Delta) is measured between P395-1 and P395-12. The voltage at TH-2 is OK.
Y N Y N
Go to the 1-703, AC Switched On Power RAP (60Hz) or 1-710 AC, Switched On Power Switch off the Printer. Disconnect J503 from the LVPS. Switch on the
RAP (50Hz). Printer. +4.95 to 5.35 VDC is measured between TH-2 (+) and TH-8 (-).
Y N
All of the red LEDS on the PWB's located in POS 2, 3, and 4 are off. Replace the DC Output A PWB located in POS 2 (PL 1.10).
Y N
The red LED on the PWB located at POS 2 is off. Go to the 1-718, DC Power Corrective Actions RAP, step 5.
Y N
Switch off the Printer. Disconnect J503 from the LVPS. Switch on the Printer. The The voltage at TH-3 is OK.
red LED located on the PWB at POS 2 is off. Y N
Y N Switch off the Printer. Disconnect J315, J298 and J251 from the LVPS.
Replace the DC Output A PWB located at POS 2 (PL 1.10). Switch on the Printer. +4.95 to 5.35 VDC is measured between TH-3 (+)
and TH-8 (-).
A B C D E F G
D E F G D E H I
Y N Y N
Replace the DC Output A PWB located at POS 3 of the LVPS (PL Go to the 1-710, AC Switched On Power RAP.
1.10).
Switch off the Printer. Monitor the voltage between TH-3 (+) and TH-8 (-).
Reconnect J251 to the LVPS. Switch on the Printer. +4.95 to 5.35 VDC is 115 VAC is measured at 2A7TB2-1.
measured between TH-3 (+) and TH-8 (-). Y N
Y N Go to the 1-703, AC Switched On Power RAP.
115 VAC is measured at P395-10.
Switch off the Printer. Monitor the voltage between TH-3 (+) and TH-8 (-). Y N
Reconnect P315 to the LVPS. Switch on the Printer. +4.95 to 5.35 VDC is Go to Flag 1. Check the wires for an open circuit.
measured between TH-3 (+) and TH-8 (-).
Y N Go to the ACN Distribution Wirenet (Wiring Data) and check wire 3KK for an
Go to the 1-718, DC Power Corrective Actions RAP, step 7. open circuit.
Go to the 1-718, DC Power Corrective Actions RAP, step 10. Check that the LVPS Cooling Fans are not blocked. Check the filters and ensure that
they are not contaminated. Switch off the Printer and allow 5 min for the LVPS to
The voltage at TH-4 is out of specification. Switch off the Printer. Disconnect cool. Switch on the Printer. Less than 2 VDC is measured between TH-1 and TH-
4221 from the LVPS. Switch on the Printer. 4.95 to 5.35 VDC is measured 8 on the LVPS.
between TH-4 (+) and TH-8 (-) on the LVPS. Y N
Y N The LVPS should now be working properly. Return to the beginning of the RAP
Replace the DC Output A PWB located at POS 4 in the LVPS (PL 1.10). to verify that it is OK. If the problem continues, replace the LVPS (PL 1.9).
Go to the 1-718, DC Power Corrective Actions RAP, step 8. Replace the Control PWB (PL 1.10). If the problem continues, replace the LVPS (PL
1.9).
The line-to-line voltage (60Hz), the phase-to-neutral voltage (50Hz Wye), or the
phase-to-phase voltage (50Hz Delta) is measured between P395-1 and P395- Replace the Control PWB (PL 1.10). If the problem continues, replace the LVPS (PL 1.9).
12.
Y N +9 to 13 VDC is measured between TH-21 (+) and TH-8 (-) on the LVPS.
Go to the 1-703, AC Switched On Power RAP (60Hz) or 1-710, AC Switched Y N
On Power RAP (50Hz). Switch off the Printer. Disconnect J505 and J298 from the LVPS. Switch on the Printer.
+9 to 13 VDC is measured between TH-21 and TH-8 on the LVPS.
Less than 2 VDC is measured between TH-1 and TH-8 on the LVPS. Y N
Y N Replace the Control PWB (PL 1.10).
Replace the Control PWB (PL 1.10). If the problem continues, replace the
LVPS (PL 1.9). Switch off the Printer. Reconnect J298 to the LVPS. Switch on the Printer. +9 to 13 VDC
is measured between TH-21 and TH-8 on the LVPS.
The LVPS Cooling Fans are operating correctly. Y N
Y N A short circuit exists in the power normal wiring of J298-5. Use the Power Normal
Less than 103 VAC is measured between P395-3 and P395-10. Distribution Wirenet (WIRING DATA) to isolate a short circuit in the wiring (J298-5,
Y N wire 1031).
Check that the LVPS Cooling Fans are not blocked. Check the filters and
ensure that they are not contaminated. If they look OK, replace the Power A short circuit exists in the power normal wiring of J505. Use the Power Normal Distribu-
Input PWB (PL 1.10). If the problem continues, replace the LVPS (PL 1.9). tion Wirenet (WIRING DATA) to isolate a short circuit in the wiring (J505-6, wire 1231 or
J505-7, wire 1220).
NOTE: The LVPS may be in an overheat condition. The Printer power
must be switched off to reset the LVPS.
+5 VDC is operating normally. The problem may be intermittent. Go to the Non-Repeatable
The machine is a 60Hz version. Problem Entry Procedure NRD1 (Service Call Procedures).
Y N
D E H I

1-714 +12 VDC RAP
The 1-714 RAP is designed to aid in troubleshooting problems with the +12 VDC circuitry.
Initial Actions
WARNING
When replacing PWBs, wait 5 minutes with power off before removing any covers from
the LVPS.
CAUTION
Do not install the LVPS with any of its covers removed. Damage may result due to incorrect air-
flow in the supply.
Do not attempt to replace fuses on PWBs that have blown. An open fuse is an indication of a
• Ensure that all cover doors are closed.

• Remove all jumper wires when procedure is complete.
Procedure
NOTE: If an over-current condition (short circuit) exists, the power must be switched off and
the short circuit corrected or disconnected before the LVPS will reset.
The amber LED on the PWB located in POS 2 is off.

Y N
Switch off the Printer. Disconnect P505 from the LVPS. Switch on the Printer. The amber
LED on the PWB located in POS 2 is off.
Y N
Replace the DC Output A PWB located in POS 2 (PL 1.10).
A short circuit exists in the wiring from J505-1 (wire #533). Use the +12 VDC Distribution
Wirenet (WIRING DATA) to isolate the cause of the short circuit.
NOTE: A faulty Hard Disk Drive has been known to cause reduced 12 VDC output.
+11.3 to 12.7 VDC is measured between TH-5 (+) and TH-8 (-) on the LVPS.
Y N
+12 VDC is OK. The problem may be intermittent. Go to the Non-Repeatable Problem Entry
Procedure NRD1 (Service Call Procedures).


A
1-715 +15 VDC RAP Y N
A short circuit exists in the wiring from J298. Switch off the Printer. Reconnect all the
The 1-715 RAP is designed to aid in the troubleshooting of the +15 VDC Printer LVPS circuitry LVPS connectors. Use the +15 VDC Distribution Wirenets (WIRING DATA) and look
and its related wiring. for the J298-16, wire #1009K. With the Printer power off, systematically disconnect
branch loads and observe the amber LED after switching on the power. When the
Initial Actions LED does not glow, the short circuit has been disconnected from the LVPS. Use this
technique until the problem has been isolated to a wire, PWB, or a component.
WARNING
When replacing PWBs, wait 5 minutes with power off before removing any covers from A short circuit exists in the wiring from J505. Switch off the Printer. Reconnect all the
the LVPS. LVPS connectors. Use the +15 VDC Distribution Wirenets (WIRING DATA) and look for
CAUTION the J505-3, wire #526. With the Printer power off, systematically disconnect branch loads
Do not install the LVPS with any of its covers removed. Damage may result due to incorrect air- and observe the amber LED after switching on the power. When the LED does not glow,
flow in the supply. the short circuit has been disconnected from the LVPS. Use this technique until the prob-
Do not attempt to replace fuses on PWBs that have blown. An open fuse is an indication of a lem has been isolated to a wire, PWB, or a component.
+14.15 to 15.85 VDC is measured between TH-6 (+) and TH-8 (-) on the LVPS.
Y N
+15 VDC IS OK. The problem may be intermittent. Go to the Non-Repeatable Problem Entry
• Ensure that all cover doors are closed. Procedure NRD1 (Service Call Procedures).
• Remove all jumper wires when procedure is complete.
Procedure
The amber LED on the PWB located in POS 3 of the LVPS is off.
Y N
Switch off the Printer. Disconnect J315, J298, and J505, from the LVPS. Switch on the
Printer. The amber LED on the PWB located in POS 3 is off.
Y N
A short circuit exists in the harness or a load. Switch off the Printer and reconnect J315 to
the LVPS. Switch on the Printer. The amber LED on the PWB located in POS 3 is off.
Y N
A short circuit exists in the wiring from J315. Switch off the Printer. Reconnect all the
LVPS connectors. Use the +15 VDC Distribution Wirenets (WIRING DATA) and look
for the J315-9 Wire #529. With the Printer power off, systematically disconnect
branch loads and observe the amber LED after switching on the power. When the
LED does not glow, the short circuit has been disconnected from the LVPS. Use this
technique until the problem has been isolated to a wire, PWB, or a component.
Switch off the Printer. Reconnect J298 to the LVPS. Switch on the Printer. The amber
LED on the PWB located at POS 3 is off.
A

A
1-716 -15 VDC RAP Y N
A short exists in the wiring from J298. Switch off the Printer. Reconnect J298 to the
The 1-716 RAP is designed to aid in troubleshooting problems with the Printer LVPS -15 VDC LVPS. Use the -15 VDC Distribution Wirenets (WIRING DATA) and look for J298-18
circuitry and related wiring. wire #1010J. With the Printer power off, systematically disconnect branch loads and
observe the amber LED after switching on the printer power. When the LED does not
Initial Actions glow, the short circuit has been disconnected from the LVPS. Use this technique until
the problem has been isolated to a wire, a PWB, or a component.
WARNING
When replacing PWBs, wait 5 minutes with power off before removing any covers from A short exists in the wiring from J505. Switch off the Printer. Reconnect J505 to the LVPS.
the LVPS. Use the -15 VDC Distribution Wirenets (WIRING DATA) and look for J505-4 wire 527.
CAUTION With the Printer power off, systematically disconnect branch loads and observe the amber
Do not install the LVPS with any of its covers removed. Damage may result due to incorrect air- LED after switching on the printer power. When the LED does not glow, the short circuit
flow in the supply. has been disconnected from the LVPS. Use this technique until the problem has been iso-
Do not attempt to replace fuses on PWBs that have blown. An open fuse is an indication of a lated to a wire, a PWB, or a component.
-14.15 to -15.85 VDC is measured between TH-7 (+) and TH-8 (-) on the LVPS.
Y N
-15 VDC IS OK. The problem may be intermittent. Go to the Non-Repeatable Problem Entry
• Ensure that all cover doors are closed. Procedure NRD1 (Service Call Procedures).
• Remove all the jumper wires when the procedure is complete.
Procedure
The amber LED on the PWB located in POS 4 is off.

Y N
Switch off the Printer. Disconnect J315, J298, and J505 from the LVPS. Switch on the
Printer. The amber LED on the PWB located in POS 4 is off.
Y N
A short circuit exists in the harness or a load. Switch off the Printer. Reconnect J315 to
the LVPS. Switch on the Printer. The amber LED on the PWB located at POS 4 is off.
Y N
A short exists in the wiring from J315. Switch off the Printer. Reconnect J315 to the
LVPS. Use the -15 VDC Distribution Wirenets (WIRING DATA) and look for J315-12
wire #530. With the power off, systematically disconnect branch loads and observe
the amber LED after switching on the power. When the LED does not glow, the short
circuit has been disconnected from the LVPS. Use this technique until the problem
has been isolated to a wire, a PWB, or a component.
Switch off the Printer. Reconnect J298 to the LVPS. Switch on the Printer. The amber
LED on the PWB located at POS 4 is off.
A

A B
1-717 +24,+34,-34 VDC RAP Y N
Switch off the Printer. Remove all jumper wires. Replace the DC Output B PWB
The 1-717 RAP is designed to help troubleshoot problems with the +24, +34, and -34 VDC cir- located in POS 5 (PL 1.10). If the problem continues, replace the Control PWB
cuitry. This includes the Printer LVPS and short circuits in the wiring or loads which cause the (PL 1.10).
LVPS to shut down.
Initial Actions
Perform the following: The LED on the PWB located in POS 6 is off.
Y N
The LED on the PWB located in POS 6 is on. Switch off the Printer. Disconnect J431
• Ensure that the Printer Cover Doors are closed.
from the LVPS. Connect a jumper wire between TS53 and TS37 on the PHN DIO
• Ensure that the Printer Interlocks are not bypassed. If they were, isolating 24 v short cir-
PWB 2. Switch on the Printer. +22.5 to 25.5 VDC is measured between TH11 (+)
cuits would be more difficult.
and TH14 (-) of the LVPS.
• Ensure that a communications problem is not causing 24VDC to turn off. Use dC 303 to Y N
check the status of the system bus and the local buses. Switch off the Printer. Remove all jumper wires. Replace the DC Output B PWB
located in POS 6 (PL 1.10). If the problem continues, replace the Control PWB
NOTE: 24 VDC is not available from the LVPS until the machine self test/system download is
complete. A jumper wire is sometimes used in the procedure to offset this delay period or to (PL 1.10).
bypass possible hardware problems.
the short circuit corrected or disconnected before the LVPS will reset. The LED on the PWB located in POS 7 is off.
Y N
NOTE: When using the Wirenets to check for a short circuit, check the queued faults for a
fault(s) that may relate to one of the components in the wirenet, and begin with the wiring for
and J315 from the LVPS. Connect a jumper wire between TS53 and TS37 on the
those components first.
PHN DIO PWB 2. Switch on the Printer. +22.5 to 25.5 VDC is measured between
NOTE: Remove all jumpers when the procedure is complete. TH12 (+) and TH14 (-) of the LVPS.
Y N
Procedure Switch off the Printer. Remove all jumper wires. Replace the DC Output B PWB
WARNING located in POS 7 (PL 1.10). If the problem continues, replace the Control PWB
(PL 1.10).
When replacing PWBs, wait 5 minutes with power off before removing any covers from
the LVPS.
Switch off the Printer. Reconnect J315 to the LVPS. Switch on the Printer. +22.5 to
CAUTION 25.5 VDC is measured between TH12 (+) and TH14 (-) of the LVPS.
Do not install the LVPS with any of its covers removed. Damage may result due to incorrect air- Y N
flow in the supply. Go to the 1-718, DC Power Corrective Actions RAP, step 12.
Do not attempt to replace fuses on PWBs that have blown. An open fuse is an indication of a
problem with the PWB. Go to the 1-718, DC Power Corrective Actions RAP, step 13.
are known to cause the LVPS to fail. The LED on the PWB located in POS 8 is off.
Y N
All of the LEDs located on the PWB's located in POS 5, 6, 7, 8, 9, and 10 are off. (Answer
No if any of these LEDs are on).
from the LVPS. Remove wire 510 at from connector J315-7 and reconnect J315 to
Y N
the LVPS. Connect a jumper wire between TS53 and TS37 on the PHN DIO PWB 2.
The LED on the PWB located in POS 5 is off.
Switch on the Printer. +22.5 to 25.5 VDC is measured between TH13 (+) and
Y N
TH14 (-) on the LVPS.
Y N
from the LVPS. Connect a jumper wire between TS 53 and TS 37 on the PHN DIO
Switch off the Printer. Remove all jumper wires. Replace the DC Output B PWB
PWB 2. Switch on the Printer. +22.5 to 25.5 VDC is measured between TH 10 (+)
and TH 14 (-).
(PL 1.10).
A B A C D
A C D E F G
Switch off the Printer. Reinsert wire 510 into J315-7 and reconnect J315 to the Y N
LVPS. Switch on the Printer. +22.5 to 25.5 VDC is measured between TH13 (+) Switch off the Printer. Disconnect J431 and J298 from the LVPS. Connect
and TH14 (-) on the LVPS. a jumper wire between TS 53 and TS 37 on the PHN DIO PWB 2. Switch
Y N on the Printer. +22.5 to 25.5 VDC is measured between TH 10 (+) and
Go to the 1-718, DC Power Corrective Actions RAP, step 14. TH 14 (-) on the LVPS.
Y N
Go to the 1-718, DC Power Corrective Actions RAP, step 15. Switch off the Printer. Remove all jumper wires. Replace the DC Out-
put B PWB located at POS 5 in the LVPS (PL 1.10).
The LED on the PWB located in POS 9 is off.
Y N Switch off the Printer. Keep the jumper wire on PHN DIO PWB 2. Recon-
The LED on the PWB located in POS 9 is on. Switch off the Printer. Disconnect J298 nect J431 to the LVPS. Switch on the Printer. +22.5 to 25.5 VDC is mea-
from the LVPS. Connect a jumper wire between TS53 and TS37 on the PHN DIO sured between TH 10 (+) and TH 14 (-) on the LVPS.
PWB 2. Switch on the Printer. +33.5 to 35.5 VDC is measured between TH16 (+) Y N
and TH18 (-) on the LVPS. Go to the 1-718, DC Power Corrective Actions RAP, step 18.
Y N
Switch off the Printer. Remove all jumper wires. Replace the DC Output B PWB Go to the 1-718, DC Power Corrective Actions RAP, step 19.
(PL 1.10). +22.5 to 25.5 VDC was measured at TH 11.
Y N
Go to the 1-718, DC Power Corrective Actions RAP, step 16. Switch off the Printer. Disconnect J431 from the LVPS. Connect a jumper
wire between TS 53 and TS 37 on the PHN DIO PWB 2. Switch on the
The LED on the PWB located in POS 10 is on. Switch off the Printer. Disconnect J298 Printer. +22.5 to 25.5 VDC is measured between TH 11 (+) and TH 14 (-
from the LVPS. Connect a jumper wire between TS53 and TS37 on the PHN DIO PWB 2. ) on the LVPS.
Switch on the Printer. -33.5 to 35.5 VDC is measured between TH17 (+) and TH18 (-) Y N
on the LVPS. Replace the DC Output B PWB located at POS 6 in the LVPS (PL
Y N 1.10).
Switch off the Printer. Remove all jumper wires. Replace the DC Output PWB
located in POS 10 (PL 1.10). If the problem continues, replace the Control PWB (PL Go to the 1-718, DC Power Corrective Actions RAP, step 20.
1.10).
+22.5 to 25.5 VDC was not measured at TH 12. Switch off the Printer. Discon-
Go to the 1-718, DC Power Corrective Actions RAP, step 17. nect J315 and J298 from the LVPS. Connect a jumper wire between TS 53 and
TS 37 on the PHN DIO PWB 2. Switch on the Printer. +22.5 to 25.5 VDC is
Measure the voltage between the following test holes on the LVPS: measured between TH 12 (+) and TH 14 (-) on the LVPS.
• TH 10 (+) and TH 14 (-) Y N
• TH 11 (+) and TH 14 (-) Switch off the Printer. Remove all jumper wires. Replace the DC Output B
• TH 12 (+) and TH 14 (-) PWB located at POS 7 in the LVPS (PL 1.10).
+22.5 to 25.5 VDC is measured at all three test points.

Switch off the Printer. Keep the jumper wire on PHN DIO PWB 2. Reconnect
Y N
J315 to the LVPS. Switch on the Printer. +22.5 to 25.5 VDC is measured
Switch off the Printer. Connect a jumper wire between TH 15 (+) and TH 14 (-) on the
between TH 12 (+) and TH 14 (-) on the LVPS.
LVPS. Switch on the Printer. Wait for four minutes to ensure time for +24 volts to be
Y N
enabled. Measure the voltage between the following test holes on the LVPS:
• TH 10 (+) and TH 14 (-)
• TH 11 (+) and TH 14 (-) Go to the 1-718, DC Power Corrective Actions RAP, step 22.
• TH 12 (+) and TH 14 (-)
+22.5 to 25.5 VDC is measured at all three test points. Remove the jumper wire from TH 15 and TH 14. .3 to 1 VDC is measured between
Y N TH 24 (+) and TH 8 (-) on the LVPS.
Less than +22.5 VDC is measured at all three test points. Y N
Y N Connect a jumper wire between TS 53 and TS 37 on the PHN DIO PWB 2.
+22.5 VDC is measured at two of the three test points. +22.5 VDC was mea- +22.5 to 25.5 VDC is measured between TH 10 (+) and TH 14 (-) on the
sured at TH 10. LVPS.
E F G E F H
E F H I
Y N Y N
Go to Flag 2. Check the wire for an open or short circuit. If OK, replace the Switch off the Printer and remove all jumper wires. Replace the DC Output B PWB
Control PWB (PL 1.10). located at POS 8 (PL 1.10). If the problem continues, replace the Control PWB (PL
1.10).
Remove the jumper wire. The Low Voltage Power Supply is OK. The machine
control system may have gone into Power Interrupt Mode due to a Fuser line Switch off the Printer. Return the relays to their original positions. Replace the 24 VDC
voltage or Fuser camming fault, interlock fault, or communications fault. If any Interlock Relay, K104 (PL 1.10).
of these fault codes are occurring, go to the associated RAP. If the machine is
not in Power Interrupt mode, replace the PHN DIO PWB 2 (PL 1.10). +33.5 to 35.5 VDC is measured between TH 16 (+) and TH 18 (-) on the LVPS.
Y N
Switch off the Printer and remove all jumper wires. Replace the Control PWB (PL Switch off the Printer. Interchange the 34 VDC Interlock Relay, K103, located in the LVPS
1.10). (marked K2 inside the LVPS), and the Interlock Relay, K102, located on the AC Distribu-
tion Panel. Connect a jumper wire between TS53 and TS37 on the PHN DIO PWB 2.
+22.5 to 25.5 VDC is measured between TH 13 (+) and TH 14 (-). Switch on the Printer. +33.5 to 35.5VDC is measured between TH 16 (+) and TH 18 (-)
Y N on the LVPS.
Switch off the Printer. Disconnect J298 and J315 from the LVPS. Do not remove the Y N
jumper from the LVPS. Connect another jumper wire between TS53 and TS37 on Switch off the Printer and remove all jumper wires. Replace the DC Output B PWB
the PHN DIO PWB 2. Switch on the Printer. +22.5 to 25.5 VDC is measured located in POS 9 (PL 1.10). If the problem continues, replace the Control PWB (PL
between TH 13 (+) and TH 14 (-) on the LVPS. 1.10).
Y N
Switch off the Printer. Interchange the 24 VDC Interlock Relay, K104 (marked Switch off the Printer. Return the relays to their original positions. Replace the 34 VDC
K1 inside the LVPS) and the 34 VDC Interlock Relay, K103 (marked K2 inside Interlock Relay, K103 (PL 1.10).
the LVPS). Switch on the Printer. +22.5 to 25.5 VDC is measured between
TH 13 (+) and TH 14 (-) on the LVPS. -33.5 to -35.5 VDC is measured between TH-17 (+) and TH-18 (-) on the LVPS.
Y N Y N
Switch off the Printer and remove all jumper wires. Replace the DC Output Switch off the Printer. Interchange the 34 VDC Interlock Relay, K103, located in the LVPS
B PWB located at POS 8 (PL 1.10). If the problem continues, replace the (marked K2 inside the LVPS), and the Interlock Relay, K102 located on the AC Distribu-
Control PWB (PL 1.10). tion Panel. Connect a jumper wire from TS53 to TS37 on the PHN DIO PWB 2. Switch on
the Printer. -33.5 to -35.5 VDC is measured between TH 17 (+) and TH 18 (-) on the
Switch off the Printer. Return the relays to their original positions. Replace the LVPS.
24 VDC Interlock Relay, K104 (PL 1.10). Remove all jumper wires. Y N
Switch off the Printer and remove all jumper wires. Replace the DC Output B PWB
Switch off the Printer. Reconnect J315 to the LVPS. Keep the jumper wire on PHN located in POS 10 (PL 1.10).
DIO PWB 2. Switch on the Printer. +22.5 to 25.5 VDC is measured between TH 13
(+) and TH 14 (-) on the LVPS. Switch off the Printer. Return the relays to their original positions. Replace the 34 VDC
Y N Interlock Relay, K103 (PL 1.10).
The LVPS is operating erratically.
Go to the 1-718, DC Power Corrective Actions RAP, step 24. Y N
The LVPS appears to be OK. The problem may be intermittent. An intermittent short cir-
Switch off the Printer and remove all jumper wires. Replace the Control PWB (PL 1.10). If cuit that puts the LVPS into an over-current shutdown can be reset if the printer is pow-
the problem continues, replace the LVPS (PL 1.10). ered off/on. Try to repeat the failure mode and relate it to a printer event or particular run
mode. For more information on intermittent faults, go to the Non-Repeatable Problem
+22.5 to 25.5 VDC is measured between TH 13 (+) and TH 14 (-). Entry Procedure (Service Call Procedures).
Y N
Switch off the Printer. Interchange the 24 VDC Interlock Relay, K104 (marked K1 inside Check the LVPS PWB's for proper seating. All PWB's are seated properly.
the LVPS) and the 34 VDC Interlock Relay, K103 (marked K2 inside the LVPS). Connect a Y N
jumper wire between TS53 and TS37 on the PHN DIO PWB 2. Switch on the Printer. Reseat any PWB's as necessary.
+22.5 to 25.5 VDC is measured between TH 13 (+) and TH 14 (-) on the LVPS.
Monitor the AC input voltage between P395-1 and P395-12. The AC input voltage is stable
and in specification.
I
J
Y N Replace the Control PWB (PL 1.10). If the supply still operates erratically, replace the LVPS
Go to the 1-700 AC Input Power Rap (60Hz) or the 1-707 AC Input Power Rap (50Hz). (PL 1.9).
J

1-718 DC Power Corrective Actions RAP 8. A short circuit exists at the output of connector 4221/J430-1. Use the 5 VDC Distribution
Wirenets (WIRING DATA) to isolate the short circuit (wire #81T). Switch off the Printer.
Procedure Reconnect J430 to the LVPS. With the Printer power off, systematically disconnect
branch loads and then with the Printer power on, measure the voltage between TH 4 and
NOTE: Ensure all cables, plugs/jacks are connected before performing this procedure. TH 8. 5 VDC will be available when the short circuit is disconnected from the LVPS. Use
1. A short circuit exists in the 5 VDC wiring at the output of connector J503. Switch off the this technique to isolate the problem to a wire, a PWB, or a component.
Printer and reconnect J503 to the LVPS. Use the 5 VDC Distribution Wirenet (WIRING 9. A short circuit exists in the output wiring of connector 4222/J431-7. Use the 24 VDC Dis-
DATA) to isolate the wiring of J503-1 or J503-2 for a short circuit (wire 1255 and 1257). tribution Wirenets (Wiring Data) to further isolate the cause of the short circuit (wire 63A).
With the Printer power off, systematically disconnect branch loads and then with the Keep a jumper wire connected between TS53 and TS37 on the PHN DIO PWB 2. With
Printer power on, measure the voltage between TH 2 (+) and TH 8 (-). 5 VDC will be avail- the Printer power off, systematically disconnect branch loads and measure the voltage
able when the short circuit has been disconnected from the LVPS. Use this technique to between TH10 and TH14 after switching on the power. When the voltage is present, the
isolate the problem to a wire, a PWB, or a component. short circuit has been disconnected from the LVPS. Use this technique until the problem
2. A short circuit exists from the wiring of J251-4, wire 525, or J251-2, wire 532. Switch off has been isolated to a wire, a PWB, or a component. Remove all jumper wires when com-
plete.
the Printer. Reconnect J251 to the LVPS. Use the 5 VDC Distribution Wirenets (WIRING
DATA) to further isolate the short circuit. With the Printer power off, systematically discon- 10. A short circuit exists from the wiring of J298-13, wire 1024. Switch off the Printer. Recon-
nect branch loads and then with the Printer power on, measure the voltage between TH 2 nect J298 to the LVPS. Use the 5 VDC Distribution Wirenets (WIRING DATA) to further
(+) and TH 8 (-). 5 VDC will be available when the short circuit has been disconnected isolate the short circuit. With the Printer power off, systematically disconnect branch loads
from the LVPS. Use this technique to isolate the problem to a wire, a PWB, or a compo- and measure the voltage between TH 3 (+) and TH 8 (-) after switching on the power. +5
nent. VDC will be available when the short circuit has been disconnected from the LVPS. Use
3. A short circuit exists from the wiring of J315-1, wire 538. Switch off the Printer. Reconnect this technique to isolate the a wire, a PWB, or a component.
J315 to the LVPS. Use the 5 VDC Distribution Wirenets (WIRING DATA) to further isolate 11. A short circuit exists in the output wiring from connector 4222/J431-12. Use the +24 VDC
the short circuit. With the Printer power off, systematically disconnect branch loads and Distribution Wirenets (Wiring Data) to isolate the short circuit (wire 64A). Keep a jumper
then with the Printer power on, measure the voltage between TH 3 and TH 8. 5 VDC will wire connected to TS53 and TS37 on the PHN DIO PWB 2. With the Printer power off,
be available when the short circuit has been disconnected from the LVPS. Use this tech- systematically disconnect branch loads and measure the voltage between TH11 and
nique to isolate the problem to a wire, a PWB, or a component. TH14 after switching on the Printer power. When the voltage is measured, the short circuit
4. A short circuit exists at the output of connector 4221/J430-1. Use the 5 VDC Distribution has been disconnected from the LVPS. Use this technique until the problem has been iso-
Wirenets (WIRING DATA) to isolate the short circuit (wire 81T). Switch off the Printer. lated to a wire, a PWB, or a component. Remove all jumper wires when complete.
Reconnect J430 to the LVPS. With the Printer power off, systematically disconnect 12. A short circuit exists in the wiring from P315. Switch off the Printer. Reconnect J298 to the
branch loads and then with Printer power on, measure the voltage between TH 4 (+) and LVPS. Use the +24 VDC Distribution Wirenets (Wiring Data) to further isolate the problem
TH 8 (-). 5 VDC will be available when the short circuit is disconnected from the LVPS. (pin J315-10, wire 540). Keep a jumper wire connected to TS53 and TS37 on the PHN
Use this technique to isolate the problem to a wire, a PWB, or a component. DIO PWB 2. With the Printer power off, systematically disconnect branch loads and mea-
sure the voltage between TH12 and TH14 after switching on the power. When the voltage
5. A short circuit exists in the 5 VDC wiring at the output of connector J503. Switch off the
Printer and reconnect J503 to the LVPS. Use the 5 VDC Distribution Wirenet (WIRING is measured, the short circuit has been disconnected from the LVPS. Use this technique
DATA) to isolate the wiring of J503-1 or J503-2 for a short circuit (wire 1255 and 1257). until the problem has been isolated to a wire, a PWB, or a component. Remove all jumper
wires when complete.
With the Printer power off, systematically disconnect branch loads and then with the
Printer power on, measure the voltage between TH 2 (+) and TH 8 (-). 5 VDC will be avail- 13. A short circuit exists in the wiring from J298. Switch off the Printer. Reconnect P298 to the
able when the short circuit has been disconnected from the LVPS. Use this technique to LVPS. Use the +24 VDC Distribution Wirenets (Wiring Data) to further isolate the problem
isolate the problem to a wire, a PWB, or a component. (pin J298-6, wire 1028). Keep a jumper wire connected to TS53 and TS37 on the PHN
DIO PWB 2. With the Printer power off, systematically disconnect branch loads and mea-
6. A short circuit exists from the wiring of J251-4, wire 1026, or J251-2, wire 1024. Use the 5
VDC Distribution Wirenets (WIRING DATA) to further isolate the short circuit. With the sure the voltage between TH12 and TH14 after switching on the power. When the voltage
Printer power off, systematically disconnect branch loads and then with the Printer power is measured, the short circuit has been disconnected from the LVPS. Use this technique
until the problem has been isolated to a wire, a PWB, or a component. Remove all jumper
on, measure the voltage between TH 3 and TH 8. 5 VDC will be available when the short
circuit has been disconnected from the LVPS. Use this technique to isolate the problem to wires when complete.
a wire, a PWB, or a component. 14. A short circuit exists in the wiring from J315. Use the +24 Interlock VDC Distribution
7. A short circuit exists from the wiring of J315-1, wire #538. Switch off the Printer. Recon- Wirenets (Wiring Data) to further isolate the problem (J315-7, wire 510). Keep a jumper
wire connected to TS53 and TS37 on the PHN DIO PWB 2. With the Printer power off,
nect J315 to the LVPS. Use the 5 VDC Distribution Wirenets (WIRING DATA) to further
isolate the short circuit. With the Printer power off, systematically disconnect branch loads systematically disconnect branch loads and measure the voltage between TH13 and
TH14 after switching on the power. When the voltage is measured, the short circuit has
and then with the Printer power on, measure the voltage between TH 3 and TH 8. 5 VDC
will be available when the short circuit has been disconnected from the LVPS. Use this been disconnected from the LVPS. Use this technique until the problem has been isolated
technique to isolate the a wire, a PWB, or a component. to a wire, a PWB, or a component. Remove all jumper wires when complete.

15. A short circuit exists in the wiring from J298. Switch off the Printer. Reconnect J298 to the 21. A short circuit exists in the output wiring from connector J315 (wire 540). Switch off the
LVPS. Use the +24 Interlock VDC Distribution Wirenets (Wiring Data) to further isolate the Printer. Reconnect J298 to the LVPS. Use the 24 VDC Distribution Wirenets (Wiring Data)
problem (J298-4, wire 1021 or J298-7, wire 1021B). Keep a jumper wire connected to to further isolate the cause of the short circuit. Keep a jumper wire connected to TS53 and
TS53 and TS37 on the PHN DIO PWB 2. With the Printer power on, systematically dis- TS37 on the PHN DIO PWB 2. With the Printer power off, systematically disconnect
connect branch loads and measure the voltage between TH13 and TH14 after switching branch loads and measure the voltage between TH-12 (+) and TH-14 (-) after switching
on the power. When the voltage is measured, the short circuit has been disconnected on the Printer power. When 24 VDC is available, the short circuit has been disconnected
from the LVPS. Use this technique until the problem has been isolated to a wire, a PWB, from the LVPS. Use this technique until the problem has been isolated to a wire, a PWB,
or a component. Remove all jumper wires when complete. or component. Remove all jumper wires when complete.
16. A short circuit exists in the wiring from J298-1 (wire 1018A). Switch off the Printer. Recon- 22. A short circuit exists in the output wiring from connector J298-6 (wire 1028). Switch off the
nect J298 to the LVPS. Use the +34 VDC Distribution Wirenets (Wiring Data) to further Printer. Reconnect J298 to the LVPS. Use the 24 VDC Distribution Wirenets (Wiring Data)
isolate the problem. Keep a jumper wire connected to TS53 and TS37 on the PHN DIO to further isolate the cause of the short circuit. Keep a jumper wire connected to TS53 and
PWB 2. With the Printer power off, systematically disconnect branch loads and measure TS37 on the PHN DIO PWB 2. With the Printer power off, systematically disconnect
the voltage between TH16 and TH18 after switching on the power. When the voltage is branch loads and measure the voltage between TH-12 (+) and TH-14 (-) after switching
measured, the short circuit has been disconnected from the LVPS. Use this technique on the Printer power. When 24 VDC is available, the short circuit has been disconnected
until the problem has been isolated to a wire, a PWB, or a component. Remove all jumper from the LVPS. Use this technique until the problem has been isolated to a wire, a PWB,
wires when complete. or component. Remove all jumper wires when complete.
17. A short circuit exists in the wiring from J298-3 (wire 1020). Use the -34 VDC Distribution 23. A short circuit exists in the output wiring from connector J315-7 (wire 510). Switch off the
Wirenets (Wiring Data) to further isolate the problem. Switch off the Printer. Reconnect Printer. Do not remove the jumper wire from the LVPS. Reconnect J298 to the LVPS. Use
J298 to the LVPS. Keep a jumper wire connected to TS53 and TS37 on the PHN DIO the 24 VDC Distribution Wirenets (Wiring Data) to further isolate the cause of the short
PWB 2. With the Printer power off, systematically disconnect branch loads and measure circuit. Keep a jumper wire connected to the PHN DIO PWB 2. With the Printer power off,
the voltage after switching on the power. When the voltage is measured, the short circuit systematically disconnect branch loads and measure the voltage between TH-13 (+) and
has been disconnected from the LVPS. Use this technique until the problem has been iso- TH-14 (-) after switching on the Printer power. When 24 VDC is available, the short circuit
lated to a wire, a PWB, or a component. Remove all jumper wires when complete. has been disconnected from the LVPS. Use this technique until the problem has been iso-
18. A short circuit exists in the output wiring from connector 4222/J431-7. Switch off the lated to a wire, a PWB, or component. Remove all jumper wires when complete.
printer power. Reconnect J298 to the LVPS. Use the 24 VDC Distribution Wirenets (WIR- 24. A short circuit exists in the output wiring from connector J298-7 (wire 1021B). Switch off
ING DATA) to further isolate the cause of the short circuit (wire 63A). Keep a jumper wire the Printer. Do not remove the jumper wire from the LVPS. Reconnect J298 to the LVPS.
connected to TS53 and TS37 on the PHN DIO PWB 2. With the Printer power off, system- Use the 24 VDC Distribution Wirenets (Wiring Data) to further isolate the cause of the
atically disconnect branch loads and measure the voltage between TH-10 (+) and TH-14 short circuit. Keep the jumper wire connected to TS53 and TS37 on the PHN DIO PWB 2.
(-) after switching on the printer power. When 24 VDC is available, the short circuit has With the Printer power off, systematically disconnect branch loads and measure the volt-
been disconnected from the LVPS. Use this technique until the problem has been isolated age between TH-13 (+) and TH-14 (-) after switching on the Printer power. When 24 VDC
to a wire, a PWB, or component. Remove all jumper wires when complete. is available, the short circuit has been disconnected from the LVPS. Use this technique
19. A short circuit exists from the wiring of J298-9, wire 1015A. Switch off the Printer. Recon- until the problem has been isolated to a wire, a PWB, or component. Remove all jumper
nect J298 to the LVPS. Use the 24 VDC Distribution Wirenets (WIRING DATA) to further wires when complete.
isolate the cause of the short circuit. Keep a jumper wire connected to TS53 and TS37 on
the PHN DIO PWB 2. With the Printer power on, systematically disconnect branch loads
and measure the voltage between TH-10 (+) and TH-14 (-) after switching on the printer
power. When 24 VDC is available, the short circuit has been disconnected from the LVPS.
Use this technique until the problem has been isolated to a wire, a PWB, or component.
Remove all jumper wires when complete.
20. A short circuit exists in the output wiring from connector 4222/J431-12 (wire 86J). Switch
off the Printer. Use the 24 VDC Distribution Wirenets (Wiring Data) to further isolate the
cause of the short circuit. Keep a jumper wire connected to TS53 and TS37 on the PHN
DIO PWB 2. With the Printer power off, systematically disconnect branch loads and mea-
sure the voltage between TH-11 (+) and TH-14 (-) after switching on the Printer power.
When 24 VDC is available, the short circuit has been disconnected from the LVPS. Use
this technique until the problem has been isolated to a wire, a PWB, or component.
Remove all jumper wires when complete.

A B C
1-719 Feeder/Stacker #2 24 VDC RAP A short circuit exists at the output of connector P4081. Go to the +24 VDC Distribu-
tion Wirenets (Wiring Data) and locate wires 86A,87A,88A,89A, and 90A. Switch off
Initial Actions the Printer and isolate the short circuit by disconnecting these branch loads until the
short circuit is removed from the LVPS. Then work left to right to further isolate the
CAUTION
problem. Look for loose wires and pinched harnesses.
Always switch off the printer power before disconnecting and reconnecting any connector on
the Feeder/Stacker LVPS.
Replace the Feeder/Stacker LVPS (PL 1.20).
Ensure that all connectors on the Feeder/Stacker LVPS are properly connected and seated.
+24 VDC is measured between P4080-4 (+) and P4080-14 (-).
NOTE: For the Feeder/Stacker LVPS to recover from a short circuit on the +24 VDC output, Y N
the AC power must be switched off. Switch off the Printer. Disconnect P4080 and P4081 from the Feeder/Stacker LVPS.
NOTE: When instructed to reconnect connectors one at a time and monitor a voltage, always Switch on the Printer. +24 VDC is measured between J138-4 (+) and J138-14 (-) on the
LVPS.
switch the printer off and on for each connector.
Y N
NOTE: The red LED on the Feeder/Stacker LVPS provides status of the +5 VDC output of the Go to Flag 1. Check the wires for an open circuit. Repair as necessary, then replace
supply which is not used. the Feeder/Stacker 24 VDC LVPS (PL 1.20). Ensure that the 24 LVPS Cooling Fan
operates when the new LVPS is installed. If not, replace the 24 VDC LVPS Cooling
Procedure Fan (PL 1.20).
The green LED on the Feeder/Stacker LVPS is lit. (Answer no if it is flashing).
Y N Switch off the Printer. Reconnect P4080 to the Feeder/Stacker LVPS. Switch on the
115 VAC is measured between B-TB2-5 and B-TB2-12. Printer. +24 VDC is measured between P4080-4 (+) and P4080-14 (-) on the LVPS.
Y N Y N
Go to the 1-705-2 RAP (60Hz) or 1-712-2 RAP (50Hz). A short circuit exists at the output of connector P4080. Go to the +24 VDC Distribu-
tion Wirenets (Wiring Data) and locate wires 79A,78A, and 81A. Switch off the
115 VAC is measured between P4084-1 and P4084-3. Printer and isolate the short circuit by disconnecting these branch loads until the
Y N short circuit is removed from the LVPS. Then work left to right to further isolate the
Go to Flag 2. Check the wires for an open circuit. problem. Look for loose wires and pinched harnesses.
+24 VDC is measured between P4080-4 (+) and P4080-14 (-). A short circuit exists at the output of connector P4081. Go to the +24 VDC Distribution
Y N Wirenets (Wiring Data) and locate wires 86A,87A,88A,89A, and 90A. Switch off the
Switch off the Printer. Disconnect P4080 and P4081 from the Feeder/Stacker LVPS. Printer and isolate the short circuit by disconnecting these branch loads until the short cir-
Switch on the Printer. +24 VDC is measured between J138-4 (+) and J138-14 (-) cuit is removed from the LVPS. Then work left to right to further isolate the problem. Look
on the LVPS. for loose wires and pinched harnesses.
Y N
Go to Flag 1. Check the wires for an open circuit. Repair as necessary, then The Feeder/Stacker LVPS Cooling Fan, MOT108, is operating properly.
replace the Feeder/Stacker 24 VDC LVPS (PL 1.20). Ensure that the 24 LVPS Y N
Cooling Fan operates when the new LVPS is installed. If not, replace the 24 +24 VDC is measured between P4083-1 (+) and P4083-2 (-).
VDC LVPS Cooling Fan (PL 1.20). Y N
Go to Flag 1. Check wires 78K, 78A, 82F and 82A for an open circuit.
Switch off the Printer. Reconnect P4080 to the Feeder/Stacker LVPS. Switch on the
Printer. +24 VDC is measured between P4080-4 (+) and P4080-14 (-) on the Replace the Feeder/Stacker LVPS Cooling Fan, MOT108 (PL 1.20).
LVPS.
Y N The Feeder/Stacker LVPS is OK. Check the connectors and harnesses for an intermittent con-
A short circuit exists at the output of connector P4080. Go to the +24 VDC Dis- dition.
tribution Wirenets (Wiring Data) and locate wires 79A,78A, and 81A. Switch off
the Printer and isolate the short circuit by disconnecting these branch loads
until the short circuit is removed from the LVPS. Then work left to right to further
isolate the problem. Look for loose wires and pinched harnesses.
A B C

A
1-720 Processor Interlock Bypass Switch RAP Continuity is measured between terminals 1A and 1B of S103.
Y N
Initial Actions Replace the Processor Interlock Bypass Switch, S103 (PL 1.15).
Ensure that the cover doors are closed and that the interlocks are not bypassed.
The Processor Interlock Bypass Switch is operating correctly. Check the wires and connectors
for an intermittent condition.
Procedure
Enter dC330. The Processor INTLK Bypass SW display indicates an L.
Y N
Connect a jumper lead between TS 25 and TS 37 on the PHN DIO PWB 2. The Proces-
sor INTLK Bypass display indicates an L.
Y N
Replace the PHN DIO PWB 2 (PL 1.4).
Disconnect P383 from the Processor Interlock Bypass Switch, S103. Continuity is mea-
sured between terminal 2A and terminal 2B on S103.
Y N
Replace the Processor Interlock Bypass Switch, S103 (PL 1.15).
The Processor INTLK Sense display indicates an L.

Y N
Open the Processor Right Front Door and insert a cheater into the Processor Interlock Bypass
Switch, S103. The Processor INTLK Bypass SW display indicates an H.
Y N
Disconnect P383 from S103. An open circuit is measured between terminal 2A and
terminal 2B.
Y N
Go to Flag 1 and check for a short circuit. If it is OK, replace the PHN DIO PWB 2 (PL
1.4).
The Processor INTLK Sense display indicates an L.

Y N
+24 VDC is measured at P383-3A.
Y N
Continuity is measured between terminal 3A and Terminal 3B of S103.

Y N
+24 VDC is measured at P383-1A.

Y N
A

A B
1-721 Circuit Breakers Switching Off RAP (60HZ) NOTE: If CB103 is switching off when the Main Drives turn on, go to the 4-201 RAP.
Check for a short circuit on the output side of the Power On Relay, K101. Disconnect one
Initial Actions branch at a time from terminals 7 and 8 of K101 to help isolate to Phase A or B and to the
WARNING Main Drive Relay or the Inverter Feeder/Stacker. Be careful not to let the terminals touch
AC power is present in the Line Interface Module and at the AC Distribution Panel when- any metal surfaces. Use the 115 VAC Distribution Wirenets (WIRING DATA) for reference.
ever the power cord(s) are plugged in to the wall outlet. If OK, replace the Main Power Circuit Breaker, CB103 (PL 1.3).
Plug the Printer Power Cord into the wall outlet. Reset CB101. CB101 remains on.
• For 50 Hz machines, go to the 1-724. Y N
Disconnect the Printer power. Check the wiring from CB101 to the Power On Relay, K101,
• Ensure that the Power Cord is unplugged.
and to the Local/Remote Power Switch, S101 for a short circuit. Use the 115 VAC Distri-
• Ensure that the System power is off. bution Wirenets (WIRING DATA) for reference.
• Ensure that the Local/Remote Power Switch is in the remote position.
• Check the Line Interface Module and the AC Distribution Panel for pinched wires, frayed Switch on the Printer power. CB101 remains on for a minimum of 15 seconds.
harnesses, and loose pins and terminals. Y N
Switch off the Printer power. Reset CB101. Disconnect P395 from the LVPS AC Input
Procedure Module. Switch on the Printer power. CB101 remains on.
A Circuit Breaker switching off is usually caused by a short circuit of AC power to machine Y N
frame. The best method for locating the short circuit is to isolate it from the source voltage Use the 115 VAC Distribution Wirenets (WIRING DATA) to check for a short circuit in
using a process of elimination. This RAP will help isolate the main branches of AC power. Fur- the wiring from the LVPS AC Power Relay, K105 to P395. If OK, replace the Main
ther troubleshooting may be necessary working left to right through the AC Distribution Power Circuit Breaker, CB101 (PL 1.3).
Wirenets, disconnecting the branch loads from the source, along with careful inspection of the
wiring looking for pinched or damaged wires. The Fuser Power Circuit Breaker, CB102, is Check the wiring of P395 for a short circuit. If OK, replace the LVPS Power Input PWB
staying on and the Main Power Circuit Breakers, CB101 or CB103, have been switching (PL 1.10).
off.
Y N A possible short circuit exists at the output side of the Power On Relay, K101, which causes
Plug the Power Cord in to the wall outlet. Reset CB102. CB102 remains on. the circuit breaker to switch off at initialization or during a particular run mode. Use the 115
Y N VAC Distribution Wirenets (WIRING DATA) and isolate the output side of K101. If OK, replace
Go to the 115 VAC Distribution Wirenets (WIRING DATA). Check for a short circuit the Main Power Circuit Breaker, CB101 (PL 1.3).
between CB102 and the Fuser Power Relay, K1001.
A possible short circuit exists in the fuser AC wiring beyond K1001, which is energized
during initialization. Unplug the Printer Power Cord. Go to the 115 VAC Distribution
Wirenets (WIRING DATA). Check for a short circuit on the output side of K1001. If no
short circuit can be found, replace the Fuser Power Circuit Breaker, CB102 (PL 1.3).
The Main Power Circuit Breaker, CB103, is staying on and the Main Power Circuit
Breaker CB101 has been switching off.
Y N
Plug the Power Cord into the wall outlet. Reset CB103. CB103 remains on.
Y N
Go to the 115 VAC Distribution Wirenets (WIRING DATA). Check for a short circuit
between CB103 and the Power On Relay, K101.
Switch on the Printer power. CB103 switches off during initialization.

Y N
Isolate the switching off of CB103 with a particular run mode or feature. Use the 115
VAC Distribution Wirenets (WIRING DATA) to isolate the area of a possible short cir-
cuit. If OK, replace the Main Power Circuit Breaker, CB103 (PL 1.3).
A B
1-722 Paper Path Service Lamp RAP
Procedure
+24 VDC is measured between test point TH12 (+) and test point TH14 (-) on the LVPS.
Y N
Go to the 1-717, +24, +/- 34 VDC RAP.
Open the Processor Right Front Door. +24 VDC is measured at P354-20 (+) and test point
TH14 (-) on the LVPS.
Y N
Replace the 24V LVPS Interlock Relay, K104 (PL 1.10).
Go to Flag 1. Check the wires for an open circuit. If OK, replace the Paper Path Service Lamp,
DS101 (PL 8.8).


1-723 Convenience Outlet RAP (50HZ And 60HZ)
Initial Actions
• Troubleshoot all other power problems first.

• Ensure that the Main Power Switch is Off and that all Circuit Breakers are on.
Procedure
The Printer is a 50Hz version.
Y N
115 VAC is measured between terminal 1 and ground of the Convenience Outlet,
P111.
Y N
115 VAC is measured at terminal 5 of the LVPS AC Relay, K105.
Y N

Y N
Replace the LVPS AC Relay, K105 (PL 1.6).
Go to Flag 2. Check the wire for an open circuit. If OK, check the ground wire to the
Convenience Outlet.

• Flag 6 for an open circuit
• Flag 4 and Flag 5 for an open circuit
• Continuity between terminals 2 and 5 of the LVPS Power Relay, K105 (PL 1.6)
• Convenience Outlet for damage or broken terminals



A B
1-724 Circuit Breakers Switching Off RAP (50HZ) Switch off the Printer power. Disconnect P395 from the LVPS. Reset CB105. Switch on
the Printer power. CB105 switches off.
Initial Actions Y N
Replace the LVPS Power Input PWB (PL 1.10).
WARNING
AC power is present in the Line Interface Module and at the AC Distribution Panel when- Go to the AC Power Distribution Wirenets (50Hz) (WIRING DATA) and check the wiring
ever the power cord is plugged in to the wall outlet. for a short circuit.
Disconnect P5 from the Autotransformer, T101. Reset CB105. CB105 switches off.
• Ensure that the all Printer Power is disconnected. Y N
• Ensure that the Main Power Circuit Breaker and the Earth Leakage Breaker are on. Use the AC Power Distribution Wirenets (50Hz) (WIRING DATA) and isolate the
• Ensure that the System power is off. Autotransformer loads and check for a short circuit.
• Ensure that the Local/Remote Power Switch is in the remote position.

Go to AC Power Distribution Wirenets (50Hz) (WIRING DATA) and check wire #7, 7A, 12, 12A,
• Check the Line Interface Module and AC Distribution Panel for pinched wires, frayed har- 12B, 12C, 12D, 12E, and wire #55 for a short circuit.
nesses, and for loose pins and terminals.
Procedure
A Circuit Breaker switching off is usually caused by a short circuit of AC Power to the machine
frame or other machine wiring. The best method for locating the short circuit is to isolate it from
the source voltage using a process of elimination. This RAP will help isolate the main branches
of AC power, but further troubleshooting may be necessary working left to right through the AC
Power Distribution Wirenets, disconnecting the branch loads from the source, along with care-
ful inspection of the wiring looking for pinched or damaged wires. The Earth Leakage
Breaker, CB105, is switching off.
Y N
The Main Power Circuit Breaker, CB104, is switching off. Connect the Printer to the ser-
vice power. CB104 immediately resets.
Y N
Switch on the printer power. CB104 switches off during initialization.
Y N
CB104 switches off while the printer is running. Try to relate printer events with
the switching off of CB104. Use the AC Power Distribution Wirenets (50Hz)
(WIRING DATA) for reference.
Use AC Power Distribution Wirenets (50Hz) (WIRING DATA) to isolate to the output
of K1001 or K101.
Go to the AC Power Distribution Wirenets (50Hz) (WIRING DATA) and check the wires all
the wires that are connected to CB104 for a short circuit.
Connect the Printer to the service power. CB105 switches off.

Y N
Switch on the Printer power. CB105 switches off.
Y N
CB105 switches off during initialization.
Y N
Go to the AC Power Distribution Wirenets (50Hz) (WIRING DATA) and isolate
the output sides of relays K101, K107, K102, and K106 for a short circuit. If OK,
replace the Earth Leakage Breaker, CB105 (PL 1.2).
Try to relate the switching off of CB105 to a particular run mode or event.
A B
A B
1-726 RAP - ELCI/RCD Switching Off (Equipment Leakage Y N
Refer to the 115 VAC Distribution Wirenets and inspect for a short circuit.
Circuit Interrupter (60 Hz) / Residual Current Device (50 Hz)
RAP Check the wiring to the circuit breakers for a short circuit. If the wiring checks OK,
replace the ELCI (PL 1.14).
1-726 RAP is used when a problem exists with the ELCI/RCD or associated circuitry.
The ELCI on the Main Power Cord is tripped.
Initial Actions Y N
• Ensure that the Printer Power Cord is unplugged. The ELCI on the Auxiliary Power Cord is tripped.
Y N
Procedure Refer to the 115 VAC Distribution Wirenets and inspect for a short circuit.
WARNING
Use caution when making the voltage measurements and always disconnect the Printer Replace the Auxiliary ELCI (PL 1.14).
Power Cord(s) when it is necessary to work inside the Line Interface Module. AC Power
is present in the Line Interface Module whenever the Printer Power Cord(s) is plugged Switch off the Printer circuit breakers. Reset the ELCI. The ELCI trips.
into the Wall Outlet. Y N
The ELCI/RCD device will trip if excessive leakage current to ground (earth) is detected. The Refer to the 115 VAC Distribution Wirenets and inspect for a short circuit.
best method of locating the leakage current path is to isolate it from the source voltage using
Check the wiring to the circuit breakers for a short circuit. If the wiring checks OK, replace
the process of elimination. This RAP will help isolate the main branches of AC power. Further
troubleshooting may be necessary, working left to right through the AC Power Distribution the ELCI (PL 1.14).
Wirenets, disconnecting the loads from the source and carefully inspecting for pinched or dam-
Plug the Printer Power Cord into the Wall Outlet. Reset the RCD. The RCD switches off.
aged wires.
This is a 50 Hz system. Y N
Y N Switch on the Printer. The RCD trips.
Y N
The Printer has multiple power cords.
Y N The RCD trips during INITIALIZATION.
Plug the Printer Power Cord into the Wall Outlet. Reset the ELCI. The ELCI Y N
switches off.
Y N
Switch on the Printer. The ELCI trips. Isolate the reason that the RCD trips to a particular event or feature. Unplug the
Printer Power Cord. Refer to the 115 VAC Distribution Wirenets and inspect for a
Y N
The ELCI trips during INITIALIZATION. short circuit.
Y N If OK, replace the RCD (PL 1.14).
Refer to the 115 VAC Distribution Wirenets and inspect for a short cir-
cuit. Switch off the Printer. Disconnect P395 from the LVPS. Reset the RCD. Switch on the
Printer. The RCD trips.
Y N
Isolate the reason that the ELCI trips to a particular event or feature.
Unplug the Printer Power Cord. Refer to the 115 VAC Distribution Check the wiring of P395 for a short circuit. If OK, replace the LVPS (PL 1.10).
Wirenets and inspect for a short circuit.
If OK, replace the ELCI (PL 1.14).
Switch off the Printer. Disconnect P395 from the LVPS. Reset the ELCI. Switch Switch off the Printer circuit breakers. Reset the RCD. The RCD trips.
Y N
on the Printer. The ELCI trips.
Y N Disconnect P5 from Autotransformer, T101. Reset the RCD. Switch on the Circuit Break-
Check the wiring of P395 for a short circuit. If OK, replace the LVPS (PL ers. Switch on the Printer. The RCD trips.
Y N
1.10).
Refer to the 115 VAC Distribution Wirenets and inspect for a short circuit in the loads
Refer to the 115 VAC Distribution Wirenets and inspect for a short circuit. to the Autotransformer.
Switch off the Printer circuit breakers. Reset the ELCI. The ELCI trips. Refer to the 115 VAC Distribution Wirenets and inspect for a short circuit.
A B C
C
Check the wiring to the circuit breakers for a short circuit. If the wiring checks OK, replace the 1-731 RAP
RCD (PL 1.14).
This RAP is intended to help locate faults in the AC Standby Power Distribution circuits, which
produce 8 ma maximum leakage current from AC or ACN to GND.
Some Printers may be equipped with an additional safety feature, an Equipment Leakage Cir-
cuit Interrupter (ELCI) or Residual Current Device (RCD). The ELCI/RCD will interrupt the AC
power to the machine if excessive leakage current to ground is detected. This device is custom
designed to meet Xerox requirements and will trip at leakage currents in excess of 8 ma.
A symptom indicating that the ELCI/RCD has switched on is electrical power to the printer
appears to be off, even though the Main Power Switch is switched on and the power outlet to
the printer is operational.
Initial Actions
• Check the position of the Main Power Switch.
• Check the power at the wall outlet. If power is not available at the outlet, ask the customer
to call for service to restore power.
• Locate the ELCI/RCD(s) at the rear of the machine.
Procedure
This is a 50 Hz machine.
Y N
Plug the power cord into the wall outlet. The ELCI/RCD switches off.
Y N
Switch on the machine. The ELCI/RCD switches off.
Y N
The ELCI/RCD switches off during initialization.
Y N
Continue to observe the operation of the machine. If the ELCI/RCD does
not switch off, end the service call. If the ELCI/RCD switches off, go to the
AC Power Distribution Wirenets (60 Hz). Check the output circuits of
relays K101, K102, K105, K107 and K108 for a short circuit. If OK, replace
the ELCI/RCD (PL 1.14).
Isolate the reason that the ELCI/RCD switches off to a specific mode or event.
Switch off the machine. Disconnect connector P395 from the LVPS. Reset the ELCI/
RCD. Switch on the machine. The ELCI/RCD switches off.
Y N
Replace the Position 1 Input PWB, and the Position 11 Control PWB (PL 1.10).
Go to the AC Power Distribution Wirenets (60 Hz) and check the wiring for a short
circuit (0 ohms to 20 kohms).
Switch off the circuit breakers. Reset the ELCI/RCD. The ELCI/RCD switches off.
Y N
If the LED remains on, there is a leakage current problem in the IOT. Go to the AC
Power Distribution Wirenets (60 Hz) and check the wiring for a short circuit (0 ohms
to 20 kohms).
A B
A B
If the LED turns off, there is a current overload problem in the IOT. Check the wiring to the
circuit breakers for a short circuit (0 ohms to 20 kohms). If the wiring is good, replace the
ELCI/RCD (PL 1.14).
Plug the power cord into the wall outlet. The ELCI/RCD switches off.
Y N
Y N
The ELCI/RCD switches off during initialization.
Y N
Continue to observe the operation of the machine. If the ELCI/RCD does not
switch off, end the service call. If the ELCI/RCD switches off, go to the AC
Power Distribution Wirenets (50 Hz). Check the output circuits of relays K101,
K102, K105, K107 and K108 for a short circuit. If OK, replace the ELCI/RCD
(PL 1.14).
Isolate the reason that the ELCI/RCD switches off to a specific mode or event.
Switch off the machine. Disconnect connector P395 from the LVPS. Reset the ELCI/RCD.
Y N
Replace the Position 1 Input PWB, and the Position 11 Control PWB (PL 1.10).
Go to the AC Power Distribution Wirenets (50 Hz) and check the wiring for a short circuit
(0 ohms to 20 kohms).
Switch off the circuit breakers. Reset the ELCI/RCD. The ELCI/RCD switches off.
Y N
Disconnect connector P5 from the Autotransformer, T101. Reset the ELCI/RCD. Switch
on the circuit breakers. Switch on the power to the machine. The ELCI/RCD switches
off.
Y N
Go to the AC Power Distribution Wirenets (50 Hz). Isolate the loads of the Autotrans-
former, and check the wiring for a short circuit (0 ohms to 20 kohms.)
Go to the AC Power Distribution Wirenets (50 Hz) and check the wiring for a short circuit
(0 ohms to 20 kohms).
Check the wiring to the circuit breakers for a short circuit (0 ohms to 20 kohms). If the wiring is
good, replace the ELCI/RCD (PL 1.14).


2-700 Printer UI Entry Procedure Table 1 PRINTER UI ENTRY TABLE
PROBLEM DEFINITION/RAP
Procedure
Touch Screen Icons Some or all of the Icons displayed on the screen can not be
The table contains an explanation of different Printer UI problems and reference to the proper
selected. Go to the 2-716 RAP.
RAP for diagnostics.
Vertical Line (Linearity) The length of the picture is incorrect. Replace the Video Dis-
play Assembly (PL 2.1).
Table 1 PRINTER UI ENTRY TABLE
7-Segment Digital Display The UI screen has a picture and some or all of the segments
PROBLEM DEFINITION/RAP
on the 7-Segment Digital Display are not functioning. Go to
Audio Tone There is a constant or a lack of an audio tone. Go to the the 2-718 RAP. The Printer UI Screen has no picture and
2-701 RAP. some or all of the segments on the 7-Segment Digital Dis-
Blank 7-Segment Digital Dis- No characters have been displayed on the 7-Segment play are not functioning. Go to the 2-702 RAP.
play with Illuminated Screen Digital Display. The Printer UI Screen is illuminated Printer UI Cooling Fan Fail- One or both of the Printer UI Cooling Fans is not operational.
(screen is lit) with no picture. Go to the 2-702 RAP. ure Go to the 2-706 RAP.
Brightness Control The Brightness Control is very faint or not functioning.
Picture is not focused. Go to the 2-703 RAP.
CRT Color There is a missing primary color (red, green, blue) or the
wrong color. Go to the 2-705 RAP.
Dark Screen The Printer UI Screen is not illuminated (black screen,
no picture visible) and characters may or may not be
displayed in the 7-Segment Digital Display. Go to the 2-
706 RAP.
Diagonal Bright Red, Green, All Video is there but overdriven. Replace the Video Engine
or Blue Lines PWB (PL 2.2).
Foldover The Picture displayed is compressed (Vertically or Horizon-
tally). Replace the Video Display Assembly (PL 2.1)
Hard Buttons Some of or all of the Hard Buttons are not functioning. Go to
the 2-708 RAP.
Horizontal Line (Linearity) The width of the picture is incorrect. Replace the Video Dis-
play Assembly (PL 2.1).
Horizontal and Vertical Sync There is a distorted, flickering, jittering, rolling, or rippling pic-
ture (blinks off and on, jumping, small thin stripes moving
across, up, down and/or through the picture). Go to the 2-
710 RAP.
Information Displayed Screen information or characters are missing. The display on
the screen is observed in only a portion of the screen. For
example the text is displayed incorrectly, the picture is dis-
played incorrectly, or large/small rectangular areas are dis-
played incorrectly on the screen. Go to the 3-390 RAP.
Raster (illuminated screen) The Printer UI Screen is illuminated (screen is lit) with no pic-
ture and 7-Segment Digital Display is operative. Go to the 2-
713 RAP.
Retrace Lines A pattern is left by the CRT beam when returning from the
end of one line to the start of the next. It can be seen as
white diagonal lines over the screen when the brightness
control is set at maximum. Replace the Video Display
Assembly (PL 2.1).
Skewed Picture The picture tilted to one side or the other. Replace the Video
Display Assembly (PL 2.1).

2-701 Audio Tone RAP
There is constant or lack of audio tone.
Initial Actions
Ensure that the Audio Tone volume is adjusted to a value greater than 8 for Alert Tone, and
Touch Tone. To adjust select [Tools], [Tones] in the Customer Mode.
Procedure
WARNING
High AC Voltage is present at the Video Display Assembly when the Printer UI Interlock
Switch is actuated. Do not cheat or bypass the Printer UI Interlock Switch. AC voltage is
not required for this procedure.
The Audio Tone is constantly beeping.
Y N
+15 VDC is measured between TH6 (+) and TH4 (-) on the CP IOP PWB.
Y N
Y N
Go to Flag 1. Check wires 1206D and 1205C for an open or a short circuit. Repair as
required.
Switch off the printer power. Ensure that the Control Panel PWB + Ribbon Cable is con-
nected and properly seated at the CP IOP PWB. Using the 200 ohm scale, 8 ohms +/-
2 ohms is measured between TH22 and TH23 on the CP IOP PWB.
Y N
Disconnect the Ribbon Cable from J4 at the CP IOP PWB. Ensure that pins 33 and
34 are not broken or bent. If pins 33 and 34 are OK, replace the Control Panel PWB
(PL 2.2)
Replace the CP IOP PWB (PL 2.1)
Check the ribbon cable between the Control Panel PWB and the CP IOP PWB for damage.
Ensure that there is not a short circuit to frame. If a short circuit is found, replace the Control
Panel PWB (PL 2.2)

Figure 1 2-701 Circuit Diagram (7200C).

2-702 Blank 7-Segment Digital Display/Illuminated Screen
RAP
The 7-Segment Digital Display is blank. The Printer UI Screen is illuminated with no picture.
Procedure
The +5 VDC LED, CR1, on the Video Engine PWB is lit.
Y N
+5 VDC is measured between TH6 (+) and TH7 (-) on the Video Engine PWB.
Y N
Y N
Go to Flag 1. Ensure that there is not an open circuit in the wires from the LVPS to
the Video Engine PWB. Ensure that +5 VDC is measured at both sides of the DC
EMI Filter. If the input voltage is OK, and there is no +5 VDC at the output, replace
the DC EMI Filter (PL 2.3). If the wires and the filter are OK, replace the Video
Engine PWB (PL 2.2).
Go to the 3-224 RAP. (Note): The +5 VDC LED, CR1, on the Video Engine PWB is bad.
The Power Normal LED, CR2, on the Video Engine PWB is lit.
Y N
+9 to +13 VDC is measured between TH8 (+) and TH7 (-) on the Video Engine PWB.
Y N
Disconnect the connector J505 from the LVPS. +9 to +13 VDC is measured
between TH21 (+) and TH8 (-) on the LVPS.
Y N
Go to Flag 2. Check wires 1230 and 1231. If the wiring is OK, replace the Video
Engine PWB (PL 2.2).
Go to the 3-224 RAP. (Note): The Power Normal LED, CR2, on the Video Engine PWB is
bad.


2-703 Brightness Control RAP
The Brightness Control does not function properly. The Printer UI Screen may be too bright or
too dim.
Initial Actions
WARNING
High AC Voltage is present at the Video Display Assembly if the Printer UI Interlock
Switch is actuated. Do not cheat or bypass the Printer UI Interlock Switch.
• The Video Display Cover must be in place in order to perform the first step.
• Ensure that the connector to the Brightness Control Pot, R202, are properly connected.
Procedure
Enter dC304. Observe the squares under the words Black, Red, Green, and Blue on the
screen. The color of each square is correctly identified by the color name above that
square.
Y N
Remove the Video Display Cover. +15 VDC is measured between TH9 (+) and TH7 (-)
on the Video Engine PWB.
Y N
Go to Flag 2. Check the wire 1206J for an open circuit.
Replace the Video Engine PWB (PL 2.2).
Remove the Video Display Cover. Disconnect the connector from the Brightness Control Pot.
Connect the meter between pins 1 and 2 of the Brightness Control Pot. Turn the Pot fully coun-
terclockwise then clockwise. Using the 2K scale, the resistance reading goes from 0 to 2K
ohms +/- 10%.
Y N
Replace the Brightness Control Pot (PL 2.1).
Connect the meter between pins 2 and 3 of the Brightness Control Pot. Turn the Pot fully coun-
terclockwise then clockwise. The resistance reading goes from 2K to 0 ohms +/- 10%.
Y N
Replace the Brightness Control Pot (PL 2.1).
Go to Flag 1. Check the wires, 1250, 1251, and 1252. The wiring is OK.
Y N
Repair the wiring problem.
+15 VDC is measured between TH9 (+) and TH7 (-) on the Video Engine PWB.
Y N
Go to Flag 2. Check the wire 1206J for an open circuit.
Replace the Video Display Assembly (PL 2.1).

Figure 1 2-703 Circuit Diagram (7202C)

A B
2-705 CRT Color RAP At the Video Engine PWB, disconnect the Red, Blue, and Green cables. Connect the Blue
cable to the Green plug at the Video Engine PWB. Actuate the Printer UI Interlock
There is a missing primary color. The Printer UI Screen displays the wrong color. Switch. The Printer UI Screen is Blue.
Y N
Initial Actions Deactuate the Printer UI Interlock Switch. Reconnect the Red, Blue, and Green
cables at the Video Engine PWB. At the Video Display Assembly disconnect Red,
WARNING Blue, and Green cables. Connect the Blue cable to the Green plug at Video Display
High AC Voltage is present at the Video Display Assembly when the Printer UI Interlock Assembly. Actuate the Printer UI Interlock Switch. The Printer UI Screen is Green.
is actuated. Do not bypass the Printer UI Interlock Switch. Only actuate the Printer UI Y N
Interlock Switch as directed by this procedure. Replace the Blue cable (PL 2.1).
Remove the Video Display Cover.
Perform the following: Replace the Video Display Assembly (PL 2.1).
Procedure Replace the Video Engine PWB (PL 2.2).
Actuate the Printer UI Interlock Switch. Enter dC304. There is a Red square displayed
There is a Green square displayed under the word Green.
under the word Red.
Y N
Y N
The Red, Blue, and Green cables are connected in the correct position at the Video
Deactuate the Printer UI Interlock Switch. Ensure that the Red, Blue, and Green cables
Engine PWB and the Video Display Assembly.
are located in the correct position at the Video Engine PWB and the Video Display
Y N
Assembly. The Video Cables are connected properly.
Connect the cables to match the cable colors with the marking on the Video Display
Y N
Assembly and Video Engine PWB (R=Red, B=Blue, and G=Green).
At the Video Engine PWB, disconnect the Red, Blue, and Green cables. Connect the
Green cable to the Red plug at Video Engine PWB. Actuate the Printer UI Interlock
At the Video Engine PWB, disconnect the Red, Blue, and Green cables. Connect the Red
Switch. The Printer UI Screen is Green.
cable to the Green plug on the Video Engine PWB. Actuate the Printer UI Interlock
Y N
Switch. The Printer UI Screen is Red.
Deactuate the Printer UI Interlock Switch. Reconnect the Red, Blue, and Green
Y N
cables at the Video Engine PWB. At the Video Display Assembly disconnect the
Deactuate the Printer UI Interlock Switch. Reconnect the Red, Blue, and Green
Blue and Green cables. Connect the Green cable to the Red plug at the Video Dis-
cables at the Video Engine PWB. At the Video Display Assembly disconnect the
play Assembly. Actuate the Printer UI Interlock Switch. The Printer UI Screen is
Red, Blue, and Green cables. Connect the Red cable to the Blue plug at the Video
Red.
Display Assembly. Actuate the Printer UI Interlock Switch. The Printer UI Screen is
Y N
Blue.
Replace the Green cable (PL 2.1).
Y N
Replace the Red cable (PL 2.1).


The Video Display Color is operating correctly. If problems continue, go to the 2-700, Printer UI
Entry RAP.
There is a Blue square displayed under the word Blue.
Y N
Deactuate the Printer UI Interlock Switch. The Red, Blue, and Green cables are con-
nected in the correct position at the Video Engine PWB and the Video Display
Assembly.
Y N
A B

A
2-706 Dark Screen RAP The +5 VDC LED, CR1, and the Power Normal LED, CR2, on the Video Engine PWB are
both illuminated.
The Printer UI Screen is not illuminated (dark screen) or the Printer UI Cooling Fans are not Y N
on. The 7-Segment Digit displays may or may not display characters. Go to the 2-702, Blank 7-segment Digital Display/ Illuminated Screen RAP.
Procedure Ensure that the Video Sync Cable is connected properly at Video Engine PWB and the Video
Display Assembly. Ensure the Brightness Control Pot is fully clockwise. Actuate the Printer UI
WARNING Interlock Switch for five to ten seconds and observe the Printer UI Screen. The screen has
High Voltage is present at the Video Display Assembly when the Printer UI Interlock Raster (the screen is illuminated).
Switch is actuated. Actuate the Printer UI Interlock Switch only as directed by this pro- Y N
cedure. Disconnect the Printer UI Power Cord at the receptacle. Measure the voltage between the
Both Printer UI Cooling Fans are on. white wire (+) from P514-1 and the black wire from P514-2 at the receptacle openings.
Y N Actuate the Printer UI Interlock Switch long enough to measure the AC voltage. 115 VAC
Both Printer UI Cooling Fans are off. is measured at the Printer UI Power Cord receptacle.
Y N Y N
There is a problem with one of the Printer UI Cooling Fans. Go to Flag 3. Check the Check the Printer UI Interlock Switch for failure. Switch off the printer power. Discon-
circuit of the cooling fan that is off. Ensure that wires 1244 and 1243 from the EMI nect wire 1242 from the interlock switch. With the interlock switch actuated, 0
Filter to the fan do not have an open circuit. If the wires are OK, replace the Printer ohms are measured between pin 3 and 4.
UI Cooling Fan (PL 2.3). Y N
Replace the Printer UI Interlock Switch, S201, (PL 2.1).
115 VAC is measured between J599-2 (+) and J599-1 (-).
Y N Go to Flag 4. Check wires 1243C, 1242, and 1244D for an open circuit.
Go to the 1-703 (60HZ) or go to the 1-710 (50HZ).
Disconnect the Video Sync Cable at Video Engine PWB. Measure the following voltage
WARNING on the PWB. 3 +/-.5 VDC or greater is measured between the Video Sync Cable
AC Power is present in the Printer UI Card Cage whenever the printer power cord(s) inside pin (+) and outer cap (-).
are connected and the printer power switch is on. Use care when working in this Y N
Replace the Video Engine PWB (PL 2.2)
area.
Switch off the printer power. Access the AC EMI Filter. Remove the UIM Core PWB and
Check and replace if necessary.
the Video Engine PWB. Switch on the printer power. 115 VAC is measured between A
• The Video Sync Cable (PL 2.1)
and B at the AC EMI Filter.
• The Video Display Assembly (PL 2.1).
Y N
Go to Flag 1. Check wires 1234A and 1233A for an open circuit.
Go to the 2-713, Raster RAP.
115 VAC is measured between C and D at the AC EMI Filter.
Y N
Replace the AC EMI Filter (PL 2.3).
Go to Flag 2. Ensure that wires 1244 and 1243 do not have an open circuit. Check the
position of all the wires in 6TB3.
Remove the Printer UI Cover. Ensure that the Printer UI Power Cord is plugged in and properly
positioned. Manually actuate the Printer UI Interlock Switch for five to ten seconds and observe
the Printer UI Screen. There is a dark screen problem.
Y N
Position the Printer UI Interlock Switch within the slots in the mounting bracket to achieve
actuation when the housing cover is in place. Add a piece of stick-on foam in the switch
area of the housing cover if required. Ensure that the Printer UI Cover is properly
installed.
A

2-708 Hard Buttons RAP WARNING
Some or all of the Control Panel Hard Buttons are not functioning.
Procedure Disconnect plug P719. Place the leads of the multimeter between respective pins, identified
The Diagnostic Mode can be entered. above, at the back of the P719 ribbon cable connector. Do not press the button at this time.
Y N An open circuit is measured.
There is a problem selecting a Touch Screen Icon. Y N
Y N Replace the Control Panel PWB (PL 2.2).
Replace the Control Panel PWB (PL 2.2). If the problem continues, replace the CP
IOP PWB (PL 2.1). Press the hard button being tested. A short circuit is measured.
Y N
Go to the 2-716, Touch Screen Icon RAP. Replace the Control Panel PWB (PL 2.2).
Enter dC305. Select [Keyboard] [Test]. When a button is actuated, the image of that button is The Control Panel PWB is OK, replace the CP IOP PWB (PL 2.1).
highlighted black on the Keyboard Test display. Do not actuate any buttons at this time.
Observe the keyboard represented on the screen. One or more of the buttons is high-
lighted black all the time.
Y N
One or more buttons is flashing black.
Y N
Press each of the hard buttons to highlight the image of the associated button on the
Keyboard Test Screen. Test all the Hard Buttons. Two or more images of buttons
are highlighted black on the test screen when only one button is pressed.
Y N
The respective images are highlighted black as the hard button is
pressed.
Y N
There is an open circuit. Go to the Control Panel Checkout at the end of
this RAP to check the circuit for the hard button in question.
The hard buttons are functioning correctly. If problems continue with the Printer
UI, go to the 2-700, Printer UI Entry RAP.
There is a short circuit in one of the select row signals. Go to the Control Panel
Checkout at the end of this RAP to check the circuit for the hard button in question.
There is a short circuit. Go to the Control Panel Checkout at the end of this RAP to check
the circuit for the hard button in question.
There is a short circuit in a select COL signal. Go to the Control Panel Checkout at the end of
this RAP to check the circuit for the hard button in question.
Control Panel Checkout
• Remove the Printer UI Housing Cover and base rear cover.
• Ensure that the ribbon cable is not damaged. Check for damaged pins at J4 of the CP
IOP PWB.
1). Go to Flag 1. Locate the hard button to be checked in the circuit diagram.
2). Go to Flag 2. Determine the Select Row for that button.
3). Go to Flag 3. Determine the Select Col for that button.
(Example: Button 5 has P719-1 (Select Row 0) and P719-10 (Select Col 4).


2-710 Horizontal And Vertical Sync RAP
The picture is distorted, flickering, jittering, rolling, or rippling. The picture blinks on and off,
jumps, or small thin stripes move across, up, down, and or through the picture.
Initial Actions
WARNING
Switch is actuated. Do not cheat or bypass the Printer UI Interlock Switch. Actuate the
Printer UI Interlock Switch only as directed in this procedure.
• Remove the Printer UI Cover.

• Ensure that the Video Sync Cable is connected properly at Video Engine PWB and the
Video Display Assembly.
Procedure
Disconnect the Video Sync Cable at the Video Display Assembly. + 3 VDC +/-.5 VDC is mea-
sured between TH1 (+) and TH5 (-) on the Video Engine PWB.
Y N
Disconnect the Video Sync and Blue Cables at the Video Engine PWB and the Video Display
Assembly. Connect the Blue Cable to the Video Sync plug on Video Engine PWB and the
Video Display Assembly. Actuate the Printer UI Interlock Switch for five seconds. The Printer
UI Screen displays a stable picture.
Y N
Restore the cables to their original positions. Replace the Video Display Assembly (PL
2.1).
Restore the Blue Cable to the original position. Replace the Video Sync Cable (PL 2.1).


2-713 Raster (Illuminated Screen) RAP
The UI Screen is illuminated with no picture. The 7-Segment display may or may not be opera-
tive.
Initial Actions
WARNING
• Remove the Video Display Cover and the Printer UI Base cover.
• Ensure that the Video Sync, Red, Blue, and Green Video Cables are connected at Video
Engine PWB and the Video Display Assembly.
Procedure
LED, CR4, on the Video Engine PWB is blinking.
Y N
+15 VDC is measured between TH9 (+) to TH7 (-) on the Video Engine PWB.
Y N
Y N
Go to the 1-715, +15 VDC RAP
Go to Flag 1. Check wires 1206J and 1205F for an open circuit. Check wire 1206J for a
short circuit to frame. If the wiring is OK, replace the Video Engine PWB (PL 2.2).
The Power Normal LED, CR2, on the Video Engine PWB is On.
Y N
Go to the 2-702, Blank 7-Segment Digital Display / Illuminated Screen RAP.
+3 VDC +/-.5 VDC is measured between the TH1 (+) and the TH5 (-) on the Video Engine
PWB.
Y N
+1 VDC or greater is measured between TH2 (+) and TH5 (-) on the Video Engine PWB.
Y N


A B
2-716 Touch Screen Icons RAP • The CP IOP PWB connector J3 for broken or bent pins.
• The Touch Screen PWB connector J1 for broken or bent pins.
Fault Code, 2-716, indicates that the UIM Core PWB cannot communicate with the CP IOP
• If OK, replace the Touch Screen PWB (PL 2.2). If problem continues, replace
PWB. This fault may prevent use of the Touch Screen and Control Panel. The CP IOP has
the CP IOP (PL 2.1).
failed to respond to a polling message from the UIM Controller Support Chip (CSC). The UIM
CSC poll of the CP IOP occurs approximately every 50 microseconds. When polled by the
Reseat the Inner Bezel, if the problem continues replace the Inner Bezel (PL 2.2).
UIM, the CP IOP must respond with an acknowledge message or an input update. The cause
of this fault could be a failure of the CP IOP PWB, failure of the UIM Local Bus cabling, or fail-
Enter dC305, [Touch Screen]. dC305 can be entered.
ure of the UIM Core PWB. This fault will cause the machine to go into the Power Interrupt
Y N
mode and will disable the +24 VDC section of the Low Voltage Power Supply.
Remove the Inner Bezel from the front of the Printer UI Screen. dC305 can be entered.
Y N
Some or all of the icons displayed on the screen can not be selected.
• The Ribbon Cable for an open circuit.
Initial Actions • The CP IOP PWB connector J3 for broken or bent pins.
WARNING • The Touch Screen PWB connector J1 for broken or bent pins.
High AC Voltage is present at the Video Display Assembly when the Printer UI Interlock • If OK, replace the Touch Screen PWB (PL 2.2). If problem continues, replace
Switch is actuated. Do not cheat or bypass the Printer UI Interlock Switch unless the CP IOP (PL 2.1).
directed to do so by this procedure.
Perform the following: Reseat the Inner Bezel, if the problem continues, replace the Inner Bezel (PL 2.2).
• Ensure that the Touch Screen Inner Bezel is clean, not obstructed, and properly seated. Press Continue. Two adjacent beams are bad.
• Ensure that the Touch Screen PWB is properly seated in Bezel. Y N
• Reseat the Ribbon Cable at J3 on CP IOP PWB and ensure that the ribbon cable is prop- Seven or more beams are bad.
Y N
erly seated.
NOTE: If the Touch Screen problem appears to be an intermittent fault or the Icons are • The Ribbon Cable for an open circuit.
responding slowly, go to the Intermittent Beam Procedure on this page. • The CP IOP PWB connector J3 for broken or bent pins.
Procedure • The Touch Screen PWB connector J1 for broken or bent pins.
The SERVICE Mode can be entered. • If OK, replace the CP IOP (PL 2.1).
Y N
Any of the Touch Screen Icons can be selected. -15 VDC is measured between TH3 (+) and TH4 (-) on the CP IOP PWB.
Y N Y N
-15 VDC is measured between 6TB2-7 (+) and 6TB1-2 (-).
Remove the Printer UI Cover. -15 VDC is measured between TH3 (+) and TH4 (-)
on the CP IOP PWB. Y N
Y N Go to the 1-716, -15 VDC RAP.
-15 VDC is measured between 6TB2-7 (+) and 6TB1-2 (-).
Y N Go to Flag 1. Check wires, 1205C and 1207D. If the wiring is OK, replace the CP
Go to the 1-716, -15 VDC RAP. IOP PWB (PL 2.1).
Go to Flag 1. Check wires, 1205C and 1207D for an open or short circuit. If the Replace the Touch Screen PWB (PL 2.2). If the problem continues, replace the CPIOP
wiring is OK, replace the CP IOP PWB (PL 2.1). PWB (PL 2.1).
Replace the Touch Screen PWB (PL 2.2). If problem continues, replace the CP IOP Check the following:
(PL 2.1). • The Ribbon Cable for an open circuit.
• The CP IOP PWB connector J3 for broken or bent pins.
Remove the Inner Bezel from the front of the Printer UI Screen. The [SERVICE] mode • The Touch Screen PWB connector J1 for broken or bent pins.
can be entered. • If OK, replace the Touch Screen PWB (PL 2.2).
Y N
INTERMITTENT BEAM PROCEDURE
• The Ribbon Cable for an open circuit.
A B
An intermittent beam is one that has not failed long enough to be detected in dC305 Touch
Screen Test. When intermittent beams occur the touch panel coordinate scanning system is
unable to provide valid responses to touches. This will sometimes appear as though the touch
panel is "locked up"; in some cases, the icon will not be the one selected by the touch system.
An intermittent beam can usually be suspected when the touch panel appears locked up and
no system fault has been declared.
ACTION
• Clean the Inner Bezel
• Remove the Inner Bezel. Clean the light emitting diodes and phototransistors on the
Touch Screen PWB.
• If the Inner Bezel and the light emitting diodes and phototransistors on the Touch Screen
PWB have been cleaned and the touch system is OK with the Inner Bezel in place, the
problem has been corrected.
• If the touch system works without the Inner Bezel, replace the Touch Screen Inner Bezel,
(PL 2.2).
• If the cleaning process did not correct the problem, replace the Touch Screen PWB, (PL
2.2).


2-718 7-Segment Digital Display RAP
The UI Screen has a picture, and all or some of the 7-Segment Displays are not functioning.
Initial Actions
WARNING
Procedure
Select [SCP]. All Digit Displays should be off. The same segment is on in each of the 10
Digit Displays.
Y N
Enter dC305. Select [Keyboard] [Tests]. All ten Digit Displays should display 8s. There
is a problem with the same segment(s) in each of the ten Digit Displays.
Y N
There is a problem with one specific Digit Display.
Y N
The Digit Displays are operating correctly. If the operator has identified an inter-
mittent problem, remove the Video Display Cover. Check the Control Panel
PWB Ribbon Cable for cuts or creases that may have damaged wires. Check
J4 of the CP IOP PWB for broken or bent pins. If the problem continues,
replace the CP IOP PWB. Continued problems, replace the Control Panel PWB
(PL 2.4).
Go to Flag 2. Identify the SEL line for the Digit Display with a problem. Measure from
P719 to the respective Test Hole on the Control Panel PWB. Check for an open cir-
cuit or a short circuit to frame. Check the ribbon cable for damage. If a problem is
identified, replace the Control Panel PWB (PL 2.2). If the Control Panel PWB and
Ribbon Cable are OK, replace the CP IOP PWB (PL 2.1).
Check the Control Panel PWB Ribbon Cable for damage. Disconnect P719 from the CP
IOP PWB. Go to Flag 1. Ensure that continuity exists from the test holes (TH15 through
TH21) at the Control Panel PWB to the respective pins at P719 for each SEG line. If the
Ribbon Cable is OK, replace the CP IOP PWB (PL 2.1). If the problem continues replace
the Control Panel PWB (PL 2.2).
Check the Control Panel PWB Ribbon Cable for damage. Go to Flag 1. Disconnect P719 from
the CP IOP PWB. Ensure that each test hole (TH15 through TH21) at the Control Panel PWB
does not have a short circuit to frame. If the Ribbon Cable is OK, replace the CP IOP PWB (PL
2.1). If the problem continues replace the Control Panel PWB (PL 2.2).


A B C D E
3-201 RAP Replace the System Bus cable between the UIM Core and the FSN Core
PWBs (PL 2.2)
Fault Code, 3-201, indicates that the EDN Core PWB cannot communicate with any PWB on
its System Bus. During system boot, the Boot ROM on the EDN Core PWB causes a message Reconnect the cable, P701/J4. Disconnect the System Bus Cable, P700/J3, at
to be sent on the system bus to itself. If the message is not detected by the EDN system bus the UIM Core PWB. Voltage is greater than +3.5 VDC at the CONNECTOR,
receiver, this fault is declared. The cause of this fault could be a failure of any one of the five J3, ON the UIM Core PWB between inside wire (+) and the outside base (-).
Core PWBs in the system bus cabling that could prevent system bus communication, or any Y N
bad or incorrect termination of the system bus. This fault will cause the machine to go into the Replace the UIM Core PWB (PL 2.2)
Power Interrupt mode and will disable the +24 VDC section of the Low Voltage Power Supply.
Replace the System Bus cable between the PHN Core PWB and the UIM Core
Initial Actions PWB (PL 2.2)
Reconnect the cable, P350/J3. Disconnect the System Bus cable, J361/J4, at the
• Switch off the printer and wait 15 seconds. Switch on the power in order to force a Self- PHN Core PWB. Voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON
Test. If Fault Code, 3-201, does not occur, the problem has been corrected. the PHN Core PWB, between the inside wire (+) and the outside base (-).
Y N
• Inspect all connectors on the EDN Core PWB for loose or improperly mated connectors.
Replace the PHN Core PWB (PL 1.4)
• If this fault is can be cleared but continues to occur, go to the 3-731, Intermittent Commu-
nications RAP. Replace the System Bus cable between the MIN Core PWB and the PHN Core PWB
• Check that the System Bus connectors are connected properly by referring to the System (PL 1.8)
Bus Cable Connections Table located at the end of this RAP.
• Check that the Shared Line Termination Jumper on the Core PWBs are properly posi- Reconnect the cable, P230/J3. Disconnect the System Bus cable, J224/J4, at the MIN
tioned by referring to the Core Termination Jumper Table located at the end of this RAP. Core PWB. Voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the MIN
Core PWB, between the inside wire (+) and the outside base (-).
Procedure Y N
NOTE: Check the System Bus cable connectors for bent pins when making any voltage mea- Replace the MIN Core PWB (PL 1.8)
surements on the System Bus cable.
Replace the System Bus cable between the MIN Core PWB and the Backplane for the
Disconnect the System Bus cable, P224/J105, at the Backplane for the EDN Core PWB. Volt- EDN Core PWB (PL 1.8)
age is greater than +3.5 VDC at the CABLE between the inside wire (+) and the outside
shield (-). Check for the following:
Y N • Bent pins at the system bus connector, J105, on the Backplane.
Reconnect the cable, P224/J105. Disconnect the System Bus cable, P230/J3, at the MIN
• Bent pins in the EDN Core PWB connectors.
Core PWB. Voltage is greater than +3.5 VDC at the CABLE between the inside wire
(+) and the outside shield (-). If OK, replace the EDN Core PWB (PL 1.11)
Y N NOTE: Perform the replacement procedure for the EDN Core PWB (REP 1-13) to ensure sav-
Reconnect the cable, P230/J3. Disconnect the System Bus cable, P350/J3, at the ing the NVM Setup Parameters.
PHN Core PWB. Voltage is greater than +3.5 VDC at the CABLE between the
inside wire (+) and the outside shield (-). If the problem continues, go to the 3-702, System Bus Bad PWB Isolation RAP.
Y N
Reconnect the cable, P350/J3. Disconnect the System Bus cable, P701/J4, at
the UIM Core PWB. Voltage is greater than +3.5 VDC at the CABLE Table 1 SYSTEM BUS CABLE CONNECTIONS TABLE
between the inside wire (+) and the outside shield (-). FROM PWB CONN TO PWB CONN
Y N
Reconnect the cable, P701/J4. Disconnect the System Bus cable, 4402 at UIM Core J4/P701 FSN Core J3/4402
the FSN Core PWB. Voltage is greater than +3.5 VDC at the CONNEC- UIM Core J3/P700 PHN Core J3/P350
TOR, J3, ON the FSN Core PWB, between the inside wire (+) and the PHN Core J4/P361 MIN Core J3/P230
outside base (-). MIN Core J4/J224 EDN Core J105/P224
Y N
Replace the FSN Core PWB (PL 1.17)
A B C D E
Table 2 CORE TERMINATION JUMPER TABLE
PWB JUMPER POSITION
UIM Core (J5) Pin 1 (NORM) & Pin 2
FSN Core (J2) Pin 3 (TEST) & Pin 2
PHN Core (J2) Pin 1 (NORM) & Pin 2
MIN Core (J2) Pin 1 (NORM) & Pin 2
Figure 1 EDN Core PWB / MIN Core PWB Circuit Diagram

Figure 2 PHN Core PWB / UIM Core PWB Circuit Diagram

Figure 3 FSN Core PWB Circuit Diagram

Figure 4 PWB Location Drawing
3-202 RAP

A B
Replace the UIM Core PWB (PL 2.3)
Fault Code, 3-202, indicates that the EDN Core PWB cannot communicate with the UIM Core
PWB. The UIM has failed to acknowledge a receipt of a message from the EDN Core PWB.
Reconnect the System Bus cable, P700/J3. Disconnect the System Bus cable, P224/J105, at
This message could be an operational message or a communication check message (poll)
the Printer Backplane for the EDN Core PWB. The voltage is greater than +3.5 VDC at the
sent by the EDN. The polling message is transmitted at least once every 12 seconds (adjust-
CABLE, between the inside wire (+) and the outside shield (-).
able in service mode). A crash file is stored on the Rigid Disk/SMSD and can be accessed with
Y N
diagnostic floppy utility dC 350. This fault will cause the machine go into the Power Interrupt
Reconnect the cable, P224/J105. Disconnect the System Bus cable, P230/J3, at the MIN
Core PWB. The voltage is greater than +3.5 VDC at the CABLE between the inside
wire (+) and the outside shield (-).
Initial Actions Y N
Perform the following: Reconnect the cable, P230/J3. Disconnect the System Bus cable, P350/J3, on the
PHN Core PWB. The voltage is greater than +3.5 VDC at the CABLE between
• If screen icons will not respond, check for reversed Bus cables J4 and J6 on the UIM Core the inside wire (+) and the outside shield (-).
PWB. Y N
• Visually inspect all connectors on the UIM Core PWB for loose or improperly mated con- Replace the System Bus cable between the PHN Core PWB and the UIM Core
nectors. PWB (PL 2.2)
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi-
cations RAP. Reconnect the System Bus cable, P350/J3. Disconnect the System Bus cable, J361/
J4, on the PHN Core PWB. The voltage is greater than +3.5 VDC at the CON-
• If the Top 15 Control System faults show a history of this or other 3-20X faults perform the
NECTOR, J4, ON the PHN Core PWB between the inside wire (+) and the out-
diagnostic floppy program dC350, Save Crash Data Files (General Procedures), and
side base (-).
record the crash codes and the meter A reading. Elevate the call to obtain assistance
Y N
analyzing the data.
Procedure
Disconnect the System Bus cable, P700/J3, at the UIM Core PWB. Replace the System Bus cable between the PHN Core and the MIN Core PWB (PL
1.8)
NOTE: Check the System Bus cable connectors for bent pins when making any voltage mea-
Reconnect the System Bus cable, P230/J3. Disconnect the System Bus cable, J224/J4,
The voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the UIM Core PWB on the MIN Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4,
between the inside wire (+) and the outside base (-). ON the MIN Core PWB between the inside wire (+) and the outside base (-).
Y N Y N
Reconnect the cable, P700/J3. Disconnect the System Bus cable, P701/J4, at the UIM Replace the MIN Core PWB (PL 1.8)
Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside
wire (+) and the outside shield (-). Replace the System Bus cable between the MIN Core PWB and the Printer Backplane
Y N (PL 1.8)
Reconnect the cable, P701/J4. Disconnect the System Bus cable, 4402/J3, at the
FSN Core PWB #1. The voltage is greater than +3.5 VDC at the CONNECTOR, Replace the EDN Core PWB (PL 1.11)
J3, ON the FSN Core PWB #1 between the inside wire (+) and the outside base
(-). Table 1 CORE TERMINATION JUMPER TABLE
Y N PWB JUMPER POSITION
Reconnect the System Bus cable, 4402/J3. Check the Shared Line Termination
Jumper, J2, on the FSN Core PWB #1 for a proper connection. The jumper
should be on pins 2 and 3 (TEST). The jumper is positioned properly. FSN Core (J2) Pin 3 (TEST) & Pin 2
Y N PHN Core (J2) Pin 1 (NORM) & Pin 2
Make the proper termination. MIN Core (J2) Pin 1 (NORM) & Pin 2
Replace the FSN Core PWB #1 (PL 1.17)
Replace the System Bus cable between the UIM Core PWB and the FSN Core PWB
#1 (PL 2.2)
A B



3-203 RAP

A
Y N
Fault Code, 3-203, indicates that the MIN Core PWB has failed to acknowledge receipt of a
message from another system node. This message could be an operational message from any Reconnect the cable, P700/J3. Disconnect the System Bus cable, 4402/J3, at the
system node or a communication check (poll) sent by the EDN Core PWB. The polling mes- FSN Core PWB #1. The voltage is greater than +3.5 VDC at the CONNECTOR,
J3, ON the FSN Core PWB #1 between the inside wire (+) and the outside base
sage is transmitted at least once every 12 seconds (adjustable in the service mode). A crash
file is stored on the Rigid Disk/SMSD and can be accessed with Diagnostic Floppy Utility dC (-).
350. This fault will cause the printer to go into the Power Interrupt mode and will disable the Y N
Reconnect the cable, 4402/J3. Check the Shared Line Termination Jumper, J2,
+24 VDC section of the Low Voltage Power Supply.
on the FSN Core PWB #1, and determine if it is properly connected. The
jumper should be between pins 2 and 3. The terminator is positioned prop-
Initial Actions erly.
hay que revizar los cables de comunicacion Make the proper termination.
• Visually inspect all connectors on the MIN Core PWB for loose or improperly mated con-
nectors. que estan en la min core ubicada al lado Replace the FSN Core PWB #1 (PL 1.17)
• izquierdo
If this fault can be cleared but
cations RAP.
inferior
continues to occur, delIntermittent
go to the 3-731, equipo estos cuando
Communi- hay
Reconnect the cable, 4402/J3. Disconnect the System Bus cable, P701/J4, at the
• If the Top 15 Control Systemmal contacto
faults show bloquean
a history of this laperform
or other 3-20X faults phnthecore y daUIMcodigo
Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between
diagnostic floppy program dC350, Save Crash Data Files (General Procedures), and the inside wire (+) and the outside shield (-).
record the crash codes and 03_203
the meter A reading. Elevate the call to obtain assistance Y N
analyzing the data. Replace the System Bus cable between the UIM Core PWB and the FSN Core
PWB #1 (PL 2.2)
Procedure
The Power Normal LED, CR1, on the MIN Core PWB is lit. Replace the UIM Core PWB (PL 2.2)
Y N
+5.0 VDC is measured between TH23 (+) and TH22 (-) on the MIN Core PWB. Reconnect the cable, P700/J3. Disconnect the System Bus cable, P350/J3, at the PHN
Y N Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside
Go to the +5 VDC wirenet Figure 30 (WIRING DATA), and check the wires, 1000A wire (+) and the outside shield (-).
and 1024, for an open circuit. If the wires are good, replace the MIN Core PWB (PL Y N
1.8) Replace the System Bus cable between the PHN Core PWB and the UIM Core PWB
(PL 2.2)
Replace the MIN Core PWB (PL 1.8)
Reconnect the cable, P350/J3. Disconnect the System Bus cable, J361/J4, at the PHN
Check the Identification Connector, P244/J5, on the MIN Core PWB to make sure that the cor- Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the
rect pins are connected and that the pins which are connected together have continuity. Refer PHN Core PWB, between the inside wire (+) and the outside base (-).
to the MIN CORE PWB Identification Connector Table. The connector is wired properly. Y N
Y N Replace the PHN Core PWB (PL 1.4)
Rewire or repair the connector to the proper termination.
Replace the System Bus cable between the PHN Core PWB and the MIN Core PWB (PL
Disconnect the System Bus cable, P230/J3, from the MIN Core PWB. 1.8)
surements on the System Bus cable. Reconnect the cable, P230/J3. Disconnect the System Bus Cable, J224/J4, at the MIN Core
PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the MIN Core
The Voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+) and the PWB, between the inside wire (+) and the outside base (-).
outside shield (-). Y N
Y N Reconnect the System Bus cable, J224/J4. Check the Shared Line Termination Jumper,
Reconnect the cable, P230/J3. Disconnect the System Bus cable, P700/J3, at the UIM J2, on the MIN Core PWB, in order to determine if it is properly connected. The jumper
Core PWB. The Voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the should be on pin 1 (NORM) and pin 2. The termination jumper is positioned correctly.
UIM Core PWB, between the inside wire (+) and the outside base (-). Y N
Make the proper termination.
A B
B C
Reconnect the cable, J224/J4. Disconnect the System Bus cable, P224/J105, at the Printer Replace the MIN Core PWB (PL 1.8)
Backplane for the EDN Core PWB. The voltage is greater than +3.5 VDC at the CABLE,
between the inside wire (+) and the outside shield (-). Table 1 MIN CORE PWB IDENTIFICATION CONNECTOR TABLE
Y N
PWB CONN PIN LOCATION
Replace the System Bus cable between the MIN Core PWB and the Printer Backplane for
the EDN Core PWB (PL 1.8) MIN Core P244/J5 Pin 1 & Pin 9 (connected)
Pin 2 & Pin 10 (connected)
Pin 3 & Pin 11 (not connected)
C



3-204 RAP

A
Y N
Fault Code, 3-204, indicates that the PHN Core PWB failed to acknowledge a receipt of a mes-
sage from another system node. This message could be an operational message from any Reconnect the cable, P350/J3. Disconnect the System Bus cable, P700/J3, at the
system node or a communication check (poll) sent by the EDN Core PWB. The polling mes- UIM Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3,
ON the UIM Core PWB, between the inside wire (+) and the outside base (-).
sage is transmitted at least once every 12 seconds (adjustable in the service mode). A crash
file is stored on the Rigid Disk/SMSD and can be accessed with diagnostic floppy utility dC Y N
350. This fault will cause the printer to go into the Power Interrupt mode and will disable the Reconnect the cable, P700/J3. Disconnect the System Bus cable, 4402/J3, at
the FSN Core PWB #1. The voltage is greater than +3.5 VDC at the CON-
+24 VDC section of the Low Voltage Power Supply.
NECTOR, J3, ON the UIM Core PWB, between the inside wire (+) and the
outside base(-).
Initial Actions Y N
Perform the following: Check the Shared Line Termination Jumper, J2, on the FSN Core PWB
#1, in order to determine if it is properly connected. The jumper should be
• Visually inspect all connectors on the PHN Core PWB for loose or improperly mated con- on pin 3 (TEST) and pin 2. The termination jumper is positioned cor-
nectors. rectly.
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Y N
cations RAP. Make the proper termination.
• Check the Queued faults for a 3-203. If present, go to that RAP.
• If the Top 15 Control System faults show a history of this or other 3-20X faults perform the +5.0 VDC is measured between TH23 (+) and TH22 (-) ON the FSN
Core PWB.
Diagnostic Floppy Program dC350, Save Crash Data Files (General Procedures), and
record the crash codes and the meter A reading. Elevate the call to obtain assistance Y N
analyzing the data. Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the
wires, 61A and 61J, for an open circuit. If the wires are good, replace
Procedure the FSN Core PWB #1. (PL 1.17)
The Power Normal LED, CR1, on the PHN Core PWB is lit.
Y N Replace the FSN Core PWB (PL 1.17)
+5.0 VDC is measured between TS23 (+) to TS22 (-) ON the PHN Core PWB.
Y N Reconnect the cable, 4402/J3. Disconnect the System Bus cable,P701/J4, at
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the wires, 532 and the UIM Core PWB. The voltage is greater than +3.5 VDC at the CABLE,
538, for an open circuit. If the wires are good, replace the PHN Core PWB (PL 1.4) between the inside wire (+) and the outside shield (-).
Y N
Replace the PHN Core PWB (PL 1.4) Replace the System Bus cable between the UIM Core PWB and the FSN
Core PWB #1 (PL 2.2)
Check the Identification Connector, P372/J5, on the PHN Core PWB in order to make sure that
the correct pins are connected and that the pins which are connected together have continuity. Replace the UIM Core PWB (PL 2.2)
Refer to the PHN CORE PWB Identification Connector Table located at the end of this RAP.
The connector is wired properly. Replace the System Bus cable between the UIM Core PWB and the PHN Core PWB
Y N (PL 1.4)
Disconnect the System Bus cable, J361/J4, at the PHN Core PWB.
Reconnect the cable, J361/J4. Disconnect the System Bus cable, P230/J3, on the MIN Core
PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
and the outside shield (-).
The Voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the PHN Core PWB Y N
between the inside wire (+) and the outside base (-). Replace the System Bus cable between the MIN Core PWB and the PHN Core PWB (PL
Y N 1.8)
Reconnect the cable, J361/J4. Disconnect the System Bus cable, P350/J3, at the PHN
Core PWB. The voltage is greater than +3.5 VDC at the CABLE between the inside Reconnect the cable, P230/J3. Disconnect the System Bus cable, J224/J4, on the MIN Core
wire (+) and the outside shield (-). PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, on the MIN Core
PWB, between the inside wire (+) and the outside base (-).
Y N
A B
B
Reconnect the cable, J224/J4. Disconnect the System Bus cable, P224/J105, on the Printer
Backplane for the EDN Core PWB. The voltage is greater than +3.5 VDC at the CABLE,
between the inside wire (+) and the outside shield (-). Table 1 PHN CORE PWB IDENTIFICATION CONNECTOR TABLE
Y N
PWB Conn Pin Location
Replace the System Bus cable between the MIN Core PWB and the Printer Backplane
(PL 1.11) PHN Core P372/J5 Pin 1 & Pin 9 (not connected)
Reconnect the cable, P224/J105. Replace the PHN Core PWB (PL 1.4) Pin 3 & Pin 11 (connected)




3-205 RAP NOTE: Check the System Bus cable connectors for bent pins when making any voltage mea-
Fault Code, 3-205, indicates that the FSN Core PWB #1 has failed to acknowledge a receipt of
a message from another system node. This message could be an operational message from Voltage is greater than +3.5 VDC at the connector, J3, ON the FSN Core PWB #1,
between the inside wire (+) and the outside base (-).
any system node or a communication check (poll) sent by the EDN Core PWB. The polling
message is transmitted at least once every 12 seconds (adjustable in service mode). A crash Y N
file is stored on the Rigid Disk/SMSD and can be accessed with Diagnostic Floppy Utility dC Check the Shared Line termination jumper, J2, on the FSN Core PWB #1, to determine if
it is properly connected. The jumper should be on pin 3 (TEST) and pin 2. The jumper is
350. This fault will cause the printer to go into the Power Interrupt mode and will disable the
+24 VDC section of the Low Voltage Power Supply. positioned correctly.
Y N
Initial Actions
Perform the following: Replace the FSN Core PWB #1 (PL 1.17)
• If screen icons will not respond, check for reversed Bus cables J4 and J6 on the UIM Core Reconnect the cable, 4402/J3. Disconnect the System Bus Cable, P701/J4 on the UIM Core
PWB. PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
• Inspect all connectors on the FSN Core PWB #1 for loose or improperly mated connec- and the outside shield (-).
tors. Y N
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Replace the System Bus cable from the UIM Core PWB to the FSN Core PWB #1 (PL
cations RAP. 2.2)
• If the Top 15 Control System faults show a history of this or other 3-20X faults, perform
the diagnostic floppy program dC350, Save Crash Data Files (General Procedures), and Reconnect the cable, P701/J4. Disconnect the System Bus cable, P700/J3, on the UIM Core
PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the UIM Core
record the crash codes and the meter A reading. Escalate the call to obtain assistance
analyzing the data. PWB, between the inside wire (+) and the outside base (-).
Y N
• Inspect all connectors on the MIN Core PWB, PHN Core PWB, and the UIM Core PWB
for loose or improperly mated connectors.
Procedure Reconnect the cable, P700/J3. Disconnect the System Bus cable, P350/J3, on the PHN Core
The Power Normal LED, CR1, on the FSN Core PWB #1 is lit. PWB. The voltage is greater than +3.5 VDC, at the CABLE, between the inside wire (+)
Y N and the outside shield (-).
+5.0 VDC is measured between TH23 (+) and TH22 (-) ON the FSN Core PWB #1. Y N
Y N Replace the System Bus cable from the UIM Core PWB and the PHN Core PWB (PL 2.3)
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the wires, 61A and
61J, for an open circuit. If the wires are good, replace the FSN Core PWB #1 (PL Reconnect the cable, P350/J3. Disconnect the System Bus cable, J361/J4, on the PHN Core
1.17) PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the PHN Core
Replace the FSN Core PWB (PL 1.17) Y N
Check the Identification Connector, P4056/J5, on the FSN Core PWB #1 in order to make sure
that the correct pins are connected and that the pins which are connected together have conti- Reconnect the cable, J361/J4. Disconnect the System Bus cable, P230/J3, on the MIN Core
nuity. Refer to the FSN CORE PWB #1 Identification Connector Table located at the end of this PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
RAP. The connector is wired properly. and the outside shield (-).
Y N Y N
Rewire or repair the connector to the proper termination. Replace the System Bus cable between the MIN Core PWB and the PHN Core PWB (PL
1.4)
Check the Termination Connector, J5, on the UIM Core PWB, in order to make sure that the
correct pins are connected and that they have continuity. The connector should be on pins 1 Reconnect the cable, P230/J3. Disconnect the System Bus cable, J224/J4, on the MIN Core
and 2. The termination connector is wired properly. PWB. The voltage is greater than +3.5 VDC at the connector, J4, ON the MIN Core PWB,
Y N between the inside wire (+) and the outside base (-).
Rewire or repair the connector. Y N
Disconnect the System Bus cable, 4402/J3, from the FSN Core PWB #1.
A
A B
Reconnect the cable, J224/J4. Disconnect the System Bus cable, P224/J105, at the Back- Replace the FSN Core PWB #1 (PL 1.17)
plane, for the EDN Core PWB. The voltage is greater than +3.5 VDC at the CABLE,
between the inside wire (+) and the outside shield (-). Table 1 FSN CORE PWB #1 Identification Connector Table
Y N
Replace the System Bus cable between the Backplane and the MIN Core PWB (PL 1.8)
FSN Core #1 4056/J5 Pin 1 & Pin 9 (connected)
B




A
3-206 RAP Disconnect the System Bus cable, 4092/J3, from the FSN Core PWB #2.
Fault Code, 3-206, indicates that the FSN Core PWB #2 has failed to acknowledge a receipt of NOTE: Check the System Bus cable connectors for bent pins when making any voltage mea-
a message from another system node. This message could be an operational message from surements on the System Bus cable.
any system node or a communication check (poll) sent by the EDN Core PWB. The polling Voltage is greater than +3.5 VDC at the connector, J3, ON the FSN Core PWB #2,
message is transmitted at least once every 12 seconds (adjustable in service mode). A crash between the inside wire (+) and the outside base (-).
file is stored on the Rigid Disk/SMSD and can be accessed with Diagnostic Floppy Utility dC Y N
350. This fault will cause the printer to go into the Power Interrupt mode and will disable the Check the Shared Line termination jumper, J2, on the FSN Core PWB #2, to determine if
+24 VDC section of the Low Voltage Power Supply. it is properly connected. The jumper should be on pin 3 (TEST) and pin 2. The jumper is
positioned correctly.
Initial Actions Y N
Perform the following: Make the proper termination.
• If screen icons will not respond, check for reversed Bus cables J4 and J6 on the UIM Core Replace the FSN Core PWB #2 (PL 1.17)
PWB.
• Inspect all connectors on the FSN Core PWB #2 for loose or improperly mated connec- Reconnect the cable 4092/J3. Disconnect the System Bus cable, 4091/J4, from the FSN Core
PWB #1. Voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+) and
tors.
the outside base (-).
• Ensure that J2 is properly terminated on the FSN Core PWB #2.
Y N
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Replace the System Bus cable from the FSN Core PWB #2 to the FSN Core PWB #1 (PL
cations RAP. 1.17)
the diagnostic floppy program dC350, Save Crash Data Files (General Procedures), and Reconnect the cable 4091/J4. Disconnect the System Bus Cable, 4402/J3 on the FSN Core
record the crash codes and the meter A reading. Escalate the call to obtain assistance PWB #. The voltage is greater than 3.5 VDC at the CONNECTOR, J3 ON the FSN Core
analyzing the data. PWB #1.
• Inspect all connectors on the MIN Core PWB, PHN Core PWB, FSN #1 Core PWB, and Y N
the UIM Core PWB for loose or improperly mated connectors. Replace the FSN Core PWB #1 (PL 1.17).
Procedure Reconnect the cable, 4402/J3. Disconnect the System Bus Cable, P701/J4 on the UIM Core
The Power Normal LED, CR1, on the FSN Core PWB #2 is lit. PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
+5.0 VDC is measured between TH23 (+) and TH22 (-) ON the FSN Core PWB #2. Y N
Y N Replace the System Bus cable from the UIM Core PWB to the FSN Core PWB #1 (PL
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the wires, 61A and 2.2)
61K, for an open circuit. If the wires are good, replace the FSN Core PWB #2 (PL
1.17) Reconnect the cable, P701/J4. Disconnect the System Bus cable, P700/J3, on the UIM Core
Replace the FSN Core PWB #2 (PL 1.17) PWB, between the inside wire (+) and the outside base (-).
Y N
Check the Identification Connector, P4056/J5, on the FSN Core PWB #2 in order to make sure Replace the UIM Core PWB (PL 2.2)
that the correct pins are connected and that the pins which are connected together have conti-
nuity. Refer to the FSN CORE PWB #2 Identification Connector Table located at the end of this Reconnect the cable, P700/J3. Disconnect the System Bus cable, P350/J3, on the PHN Core
RAP. The connector is wired properly. PWB. The voltage is greater than +3.5 VDC, at the CABLE, between the inside wire (+)
Rewire or repair the connector to the proper termination. Y N
Replace the System Bus cable from the UIM Core PWB and the PHN Core PWB (PL 2.2)
correct pins are connected and that they have continuity. The connector should be on pins 1 Reconnect the cable, P350/J3. Disconnect the System Bus cable, J361/J4, on the PHN Core
and 2. The termination connector is wired properly. PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the PHN Core
Y N PWB, between the inside wire (+) and the outside base (-).
Rewire or repair the connector.
Y N Replace the PHN Core PWB (PL 1.4)
A
Y N
Replace the System Bus cable between the MIN Core PWB and the PHN Core PWB (PL
1.8)
Reconnect the cable, P230/J3. Disconnect the System Bus cable, J224/J4, on the MIN Core
PWB. The voltage is greater than +3.5 VDC at the connector, J4, ON the MIN Core PWB,
Y N
Reconnect the cable, J224/J4. Disconnect the System Bus cable, P224/J105, at the Back-
between the inside wire (+) and the outside shield (-).
Y N
Table 1 FSN CORE PWB #2 Identification Connector Table

FSN Core #2 4116/J5 Pin 1 & Pin 9 (not connected)





3-207 RAP NOTE: Check the System Bus cable connectors for bent pins when making any voltage mea-
Fault Code, 3-207, indicates that the TMN Core PWB has failed to acknowledge a receipt of a
message from another system node. This message could be an operational message from any Voltage is greater than +3.5 VDC at the connector, J3, ON the TMN Core PWB, between
the inside wire (+) and the outside base (-).
system node or a communication check (poll) sent by the EDN Core PWB. The polling mes-
sage is transmitted at least once every 12 seconds (adjustable in service mode). A crash file is Y N
stored on the Rigid Disk/SMSD and can be accessed with Diagnostic Floppy Utility dC 350. Check the Shared Line termination jumper, J2, on the TMN Core PWB, to determine if it is
properly connected. The jumper should be on pin 3 (TEST) and pin 2. The jumper is
This fault will cause the printer to go into the Power Interrupt mode and will disable the +24
VDC section of the Low Voltage Power Supply. positioned correctly.
Y N
Initial Actions
Perform the following: Replace the TMN Core PWB (PL 1.19)
• If screen icons will not respond, check for reversed Bus cables J4 and J6 on the UIM Core Reconnect the cable, P819/J3. Disconnect the System Bus Cable, P818 from the F/S interface
PWB. bracket. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
• Visually inspect all connectors on the TMN Core PWB for loose or improperly mated con- and the outside shield (-).
nectors. Y N
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Replace the System Bus Cable between the F/S interface bracket and the TMN Core
cations RAP. PWB (PL 1.19)
the diagnostic floppy program dC350, Save Crash Data Files (General Procedures), and Reconnect the System Bus Cable, P818 to the F/S interface bracket. Disconnect the System
Bus Cable, P827 from the F/S interface bracket. The voltage is greater than +3.5 VDC at the
record the crash codes and the meter A reading. Escalate the call to obtain assistance
analyzing the data. CABLE, between the inside wire (+) and the outside shield (-).
Y N
• Visually inspect all connectors on the MIN Core PWB, PHN Core PWB, FSN Core PWB,
Replace the System Bus Cable between the F/S interface brackets (PL 1.19).
and the UIM Core PWB for loose or improperly mated connectors.
Procedure Reconnect the cable, P827. Disconnect the System Bus Cable, P829/J4 on the FSN Core
The Power Normal LED, CR1, on the TMN Core PWB is lit. PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
+5.0 VDC is measured between TS23 (+) and TS22 (-) ON the TMN Core PWB #1. Y N
Y N Replace the System Bus cable from the F/S interface bracket and the FSN Core PWB (PL
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the wires, 59D and 1.19)
60D, for an open circuit. If the wires are good, replace the TMN Core PWB (PL 1.19)
Reconnect the cable, P829/J4. Disconnect the System Bus Cable, P4402/J3, on the FSN Core
Replace the TMN Core PWB (PL 1.19) PWB. The voltage is greater than +3.5VDC at the CONNECTOR, J3, on the FSN Core
Check the Identification Connector, P817/J5, on the TMN Core PWB in order to make sure that Y N
the correct pins are connected and that the pins which are connected together have continuity. Replace the FSN Core PWB (PL 1.17)
Refer to the TMN CORE PWB Identification Connector Table located at the end of this RAP.
The connector is wired properly. Reconnect the Cable 4402/J3. Disconnect the System Bus Cable, P701/J4, on the UIM Core
Y N PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
Rewire or repair the connector to the proper termination. and the outside shield (-).
Y N
Check the Termination Connector, J5, on the UIM Core PWB, in order to make sure that the Replace the System Bus Cable from the UIM Core PWB and the FSN Core PWB (PL
correct pins are connected and that they have continuity. The connector should be on pins 1 1.17)
and 2. The termination connector is wired properly.
Y N Reconnect the cable, P701/J4. Disconnect the System Bus cable, P700/J3, on the UIM Core
Rewire or repair the connector. PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the UIM Core
Disconnect the System Bus cable, P819/J3, from the TMN Core PWB. Y N
A
A
Reconnect the cable, P700/J3. Disconnect the System Bus cable, P350/J3, on the PHN Core
PWB. The voltage is greater than +3.5 VDC, at the CABLE, between the inside wire (+)
Y N
Reconnect the cable, P350/J3. Disconnect the System Bus cable, J361/J4, on the PHN Core
PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the PHN Core
Y N
Y N
1.4)
Y N
Y N
Table 1 TMN CORE PWB Identification Connector Table

TMN Core PWB P817/J5 Pin 1 & Pin 9 (connected)



Figure 3 FSN Core PWB / TMN Core PWB Circuit Diagram


A B C
3-208 RAP Check the HDLC diagnostic LED on the EDN Core PWB. The HDLC diagnostic
LED is off.
Fault code, 3-208, indicates that the System Controller did not acknowledge receipt of either a Y N
data layer or client layer operational message from the EDN Core PWB, has disconnected The LED was on. Replace the EDN Core PWB (PL 1.11)
from the Printer, or has failed to establish data or client layer communications within either 4
minutes at initial power up or within 1 second of the Printer requesting client layer initialization. NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to
This fault may also be caused by an intermittent or bad HDLC System Controller/Printer Inter- ensure saving the NVM Setup Parameters.
face cable, or a software problem between the System Controller and the Printer. Check for the following:
• Connector J25 on the Backplane for bent pins.
Procedure • Printer System Interface cable for damage, loose connections, or open circuits.
Ensure that the latest releases of software are loaded on both the System Controller and the If the problem continues, replace the EDN Core PWB (PL 1.11)
Printer.
Ensure that the Service Mode is entered at the System Controller. (IPS) Verify the System off NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to ensure
line. (NPS) Halt the System or reboot the System Controller. The System Controller will then saving the NVM Setup Parameters.
attempt to establish communications with the Printer. The System Controller establishes
Enter dC106. Press the Continue button. The printer runs the job.
communications with the Printer.
Y N
Y N
Take an occurrence log on the Printer and go to the System Fault Analysis Proce-
Enter dC606. Select 10 prints. Press the Continue button. If the prints are made and
dures Operator Mode and disregard the printer fault code that was declared. If the
there is no print quality defect present the problem has been resolved. If the is a print
problem continues fault code, 3-208, may be the result of an internal software error
quality defect go to the PQ 9-601 Print Quality Entry RAP. If another fault code is dis-
in the System Controller. Contact the CSSC for instructions. A request may be made
played go to the RAP for the fault that is displayed. If the prints were not made and no
to perform the IOT Trace print out routine at the System Controller (General Proce-
fault code is declared continue with this RAP.
dures) with a request for some of the most important parameters from the data
Power off the system. Wait 20 seconds and power the system on. When the Printer
dump. If CSSC cannot be reached, perform the IOT Trace routine if possible and
begins to initialize and the paper tray lights come on, note if communications has been
contact CSSC at the first opportunity. If the rollover or occurrence of this fault is
established with the printer. Communications has been established.
application specific, ensure that all information and data related with the customers
Y N
unique application are noted for CSSC, and that the occurrence log has been taken
# +5 VDC is measured between P115-1 (+) and P115-2 (-) at the Printer Card
on the Printer.
Cage Backplane.
Y N
The problem has been resolved.
+5 VDC is available at P115-1 of the Printer Card Cage Backplane.
Y N
Enter dC106. Press the Continue button. The System Controller continuously rolls over
Go to the +5 VDC Distribution Wirenets (Wiring Data) and check wire
or continuously displays "Press Continue to begin printing" upon trying to start a sam-
#532 for an open circuit.
ple job.
Y N
Check the wire #531 for an open.
Power off the system. Wait 20 seconds and power the system on. When the Printer
begins to initialize and the paper tray lights come on, note if communications has been
+9 to +13 VDC (Power Normal) is measured between P113-5 (+) and P113-6 (-)
established with the printer. Communications has been established.
at the Printer Card Cage Backplane.
Y N
Y N
+9 to +13 VDC is measured between TH21 (+) and TH8 (-) at the LVPS.
Cage Backplane.
Y N
Y N
+5 VDC is available at P115-1 of the Printer Card Cage Backplane.
Y N
Go to the Wirenets (Wiring Data) and check wire #1031 for an open circuit.
Go to the +5 VDC Distribution Wirenets (Wiring Data) and check wire
-5.2 VDC is measured between P114-3 (+) and P114-4 (-) at the Printer Card
Cage Backplane.
Y N
Go to the 6-353.
Y N +9 to +13 VDC is measured between TH21 (+) and TH8 (-) at the LVPS.
A B C D E
D E F G
Y N Y N
Go to the 1-713 +5 VDC RAP. Go to the +5 VDC Distribution Wirenets (Wiring Data) and check wire
Cage Backplane. +9 to +13 VDC (Power Normal) is measured between P113-5 (+) and P113-6 (-)
Y N at the Printer Card Cage Backplane.
Go to the 6-353. Y N
Check the HDLC diagnostic LED on the EDN Core PWB. The HDLC diagnostic Y N
LED is off. Go to the 1-713 +5 VDC RAP.
Y N
The LED was on. Replace the EDN Core PWB (PL 1.11) Go to the Wirenets (Wiring Data) and check wire #1031 for an open circuit.
NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to
ensure saving the NVM Setup Parameters.
Cage Backplane.
Check for the following: Y N
• Connector J25 on the Backplane for bent pins. Go to the 6-353.
• Printer System Interface cable for damage, loose connections, or open circuits.
Check the HDLC diagnostic LED on the EDN Core PWB. The HDLC diagnostic
If the problem continues, replace the EDN Core PWB (PL 1.11)
LED is off.
NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to ensure Y N
saving the NVM Setup Parameters. The LED was on. Replace the EDN Core PWB (PL 1.11)
Attempt to run a Print Sample (DIM.PS). The sample job runs. NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to
Y N ensure saving the NVM Setup Parameters.
Take an occurrence log on the Printer and go to the System Controller RAP associ-
Check for the following:
ated with this type of problem. If the problem continues fault code, 3-208, may be the
result of an internal software error in the System Controller. Contact CSSC for
instructions. A request may be made to perform the IOT Trace print out routine at the
System Controller (General Procedures) with a request for some of the most impor- If the problem continues, replace the EDN Core PWB (PL 1.11)
tant parameters from the data dump. If CSSC cannot be reached, perform the IOT
NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to ensure
Trace routine if possible and contact CSSC at the first opportunity. If the rollover or
saving the NVM Setup Parameters.
occurrence of this fault is application specific, ensure that all information and data
related with the customers unique application are noted for CSSC, and that the Attempt to run a Print Sample (DIM.PS). The sample job runs.
occurrence log has been taken on the Printer. Y N
Take an occurrence log on the Printer and go to the System Controller RAP associ-
The problem has been resolved. ated with this type of problem. If the problem continues fault code, 3-208, may be the
result of an internal software error in the System Controller. Contact CSSC for
If the system did not roll over, but displayed "Press Continue to resume printing", then Reboot instructions. A request may be made to perform the IOT Trace print out routine at the
the System. The system Controller establishes communications with the Printer. System Controller (General Procedures) with a request for some of the most impor-
Y N tant parameters from the data dump. If CSSC cannot be reached, perform the IOT
Power off the system. Wait 20 seconds and power the system on. When the Printer Trace routine if possible and contact CSSC at the first opportunity. If the rollover or
begins to initialize and the paper tray lights come on, note if communications has been occurrence of this fault is application specific, ensure that all information and data
established with the printer. Communications has been established. related with the customers unique application are noted for CSSC, and that the
Y N occurrence log has been taken on the Printer.
Cage Backplane. The problem has been resolved.
Y N
+5 VDC is available at P115-1 of the Printer Card Cage Backplane. Exit Service Mode at the Printer and return to Operator Mode.
Attempt to run a Print Sample (DIM.PS). The system runs the job.
F G F
F H
Y N Y N
Power off the system. Wait 20 seconds and power the system on. When the Printer Take an occurrence log on the Printer and go to the System Controller RAP associ-
begins to initialize and the paper tray lights come on, note if communications has been ated with this type of problem. If the problem continues fault code, 3-208, may be the
established with the printer. Communications has been established. result of an internal software error in the System Controller. Contact CSSC for
Y N instructions. A request may be made to perform the IOT Trace print out routine at the
# +5 VDC is measured between P115-1 (+) and P115-2 (-) at the Printer Card System Controller (General Procedures) with a request for some of the most impor-
Cage Backplane. tant parameters from the data dump. If CSSC cannot be reached, perform the IOT
Y N Trace routine if possible and contact CSSC at the first opportunity. If the rollover or
+5 VDC is available at P115-1 of the Printer Card Cage Backplane. occurrence of this fault is application specific, ensure that all information and data
Y N related with the customers unique application are noted for CSSC, and that the
Go to the +5 VDC Distribution Wirenets (Wiring Data) and check wire occurrence log has been taken on the Printer.
Y N
P2113/J111 P114
Y N
Cage Backplane.
P/J120
Y N
Go to the 6-353.
Check the HDLC diagnostic LED on the EDN Core PWB. The HDLC diagnostic
LED is off.
Y N
The LED was on. Replace the EDN Core PWB (PL 1.11)
NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to
ensure saving the NVM Setup Parameters.

P/J115
• Printer System Interface cable for damage, loose connections, or open circuits. P213/J113
P102/J101 P2112/J112
NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to ensure
PRINTER CARD P2102/J102
Enter dC106. Press the Continue button. The printer runs the job. CAGE BACKPLANE
H
3-221 RAP
Fault Code, 3-221, indicates that the UIM Core PWB cannot communicate with the CP IOP
PWB. This fault may prevent use of the Touch Screen and Control Panel. The CP IOP has
failed to respond to a polling message from the UIM Controller Support Chip (CSC). The UIM
CSC poll of the CP IOP occurs approximately every 50 microseconds. When polled by the
UIM, the CP IOP must respond with an acknowledge message or an input update. The cause
of this fault could be a failure of the CP IOP PWB, failure of the UIM Local Bus cabling, or fail-
ure of the UIM Core PWB. This fault will cause the machine to go into the Power Interrupt
Initial Actions
If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communications
RAP.
Procedure
NOTE: Check the Local Bus cables connectors for bent pins when making any voltage mea-
surements on the local cable.
Disconnect the Local Bus cable, P703/J6, from the UIM Core PWB. The voltage is
greater than +3.5 VDC measured at the CABLE between the inside wire (+) and the out-
side shield (-).
Y N
Reconnect the cable, P703/J6. Disconnect the Local Bus cable, P704/J2, from the CP
IOP PWB. The voltage is greater than +3.5 VDC at the connector, J2, ON the CP IOP
PWB between the inside wire (+) and the outside base (-).
Y N
+5.0 VDC is measured between TH5 (+) and TH4 (-) ON the CP IOP PWB.
Y N
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the wires,
1200 and 1201, for an open circuit. If the wires are good, replace the CP IOP
PWB (PL 2.2)
Replace the Local Bus cable between the UIM Core PWB and the CP IOP PWB (PL 2.2)

If the problem continues, replace the UIM Core PWB (PL 2.2)
If the problem continues, go to the 3-223.

Figure 1 3-221/223 Circuit Diagram (7324)

Figure 2 3-221/223 PWB Location

3-223 RAP
Fault Code, 3-223, indicates that the CP IOP PWB cannot communicate with the Touch Screen
PWB. This fault may prevent use of the Touch Screen. The Touch Screen either failed to
acknowledge a message from the CP IOP PWB, failed to read data from the CP IOP PWB, or
failed self-test. This fault will cause the machine to go into the Power Interrupt mode and will
disable the +24 VDC section of the Low Voltage Power Supply.
Initial Actions
RAP.
Procedure
Replace the ribbon cable between the CP IOP PWB and the Touch Screen PWB (PL 2.2)
If problem continues, replace the CP IOP PWB (PL 2.2)
If problem continues, replace the Touch Screen PWB (PL 2.3)


Figure 2 3-221/223 PWB Location
3-224 RAP

Fault Code, 3-224, indicates that the Video Engine PWB cannot communicate with the UIM
Core PWB. This fault cannot be displayed in the current design and will appear on the CRT as
a "3" or an alternating "1" and "2". This fault will cause the machine to go into the Power Inter-
rupt mode and will disable the +24 VDC section of the Low Voltage Power Supply.
Initial Actions
RAP.
Procedure
+5.0 VDC is measure between TH5 (+) and TH10 (-) ON the UIM Core PWB.
Y N
Power Normal LED, CR 10, ON the UIM Core PWB is lit.
Y N
Check the power connector, P506/J2, on the UIM Core PWB for broken wires or bad
pin connections on pins 1, 2, 6, 8, and 10. Also make sure that the connector is
seated properly. Refer to the WIRING DATA for +5 VDC power distribution and
Power Normal distribution for the UIM Core PWB.
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the wires, 1212, 1213,
1214, 1218, and 1255, for an open circuit. If the wires are good, replace the UIM Core
PWB (PL 2.2)
Power Normal LED, CR 10, ON the UIM Core PWB is lit.

Y N
Go to the Power Normal distribution wirenet (WIRING DATA) and check the wire 1220 for
an open circuit. If the wire is good, replace the UIM Core PWB (PL 2.2)

If the problem continues, go to the 3-702, System Bus Bad PWB Isolation RAP.

Figure 1 3-224/225 Circuit Diagram


Figure 3 3-224/225 PWB Location Drawing

A B
3-225 RAP Power Normal LED, CR10, on the Video Engine PWB is lit.
Y N
Fault Code, 3-225, indicates that the UIM Core PWB cannot communicate with the Video Go to the Power Normal distribution wirenet, Figure 30, (WIRING DATA) and check
Engine PWB. The Video Engine PWB has failed to respond to a polling message from UIM or the wire 1231 for an open circuit. If the wire is good, replace the Video Engine PWB
has failed to acknowledge receipt of an operational message from the UIM Core PWB. The (PL 2.2)
polling message is sent at least once every 12 seconds, and two consecutive polls must fail to
be acknowledged before the fault is declared. This fault will cause the machine to go into the Replace the ribbon cable between the UIM Core PWB and the Video Engine PWB (PL
Power Interrupt mode and will disable the +24 VDC section of the Low Voltage Power Supply. 2.3)
If the problem continues, replace the Video Engine PWB (PL 2.2)
This fault may result in the following sequence of events: If the problem continues, replace the UIM Core PWB (PL 2.2)
1) Fault Code, 3-225, is shown on the Digital Display, and the CRT is illuminated with no pic- Go to the 3-386.
ture.
2) Fault Code, 3-225, is shown on the Digital Display, and the CRT has a "1" displayed.
3) Fault Code, 3-225, is shown on the Digital Display, and the CRT has a "2" displayed.
4) The Digital Display is blank (no characters), and the CRT is illuminated with no picture.
5) Normal power-up sequence is now displayed on the CRT and Digital Display.
6) The normal initial screen is now displayed.
7) 20 seconds after the normal initial screen is displayed, Fault Code, 3-225, is declared on the
CRT.
Initial Actions
• Check the air filters on the Low Voltage Power Supply.

cations RAP.
Procedure
The CRT displays an alternating blank screen and a "1".
Y N
+5.0 VDC is measured between TH6 (+) and TH7 (-) ON the Video Engine PWB.
Y N
Power Normal LED, CR10, ON the Video Engine PWB is lit.
Y N
Check the power connector, P507/J6, on the Video Engine PWB for broken
wires or bad pin connections on pins 1, 2, 8, and 10. Also make sure that the
connector is seated properly. Refer to the WIRING DATA section for +5 VDC
power distribution and Power Normal distribution wirenets for the Video Engine
PWB.
Go to the +5 VDC power distribution wirenet, Figure 57, (WIRING DATA) and check
wires 1223, 1224, 1228, and 1257, for an open circuit. If the wires are good, replace
the Video Engine PWB (PL 2.3)
A B


Figure 3 3-224/225 PWB Location Drawing

A B C
3-231 RAP Y N
Replace the Local Bus cable between the Backplane and the MIN DIO
Fault Code, 3-231, indicates that the MIN Core PWB cannot communicate with the MIN DIO PWB (PL 1.8)
PWB. The MIN DIO has failed to respond to a polling message from the MIN Core PWB. This
polling occurs approximately every 200 microseconds and the MIN DIO must respond with an Replace the MIN DIO PWB (PL 1.8)
acknowledge message or an input update. When the fault is declared, the Printer will hard stop
cycle down. This fault will cause the machine to go into the Power Interrupt mode will and dis- Reconnect the cable, P227/J5. Disconnect the Local Bus cable, J227/J3, at the MIN
able the +24 VDC section of the Low Voltage Power Supply. ADA PWB #2. Voltage is greater than +3.5 VDC at the CABLE between the
inside wire (+) and the outside shield (-).
Initial Actions Y N
Perform the following: Replace the Local Bus cable between the MIN DIO PWB and the MIN ADA
PWB #2 (PL 1.8)
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica-
tion faults present, 3-201/202/203/204/205, go to these RAPs. Reconnect the cable, J227/J3. Disconnect the Local Bus cable, P228/J2, at the MIN
ADA PWB #2. Voltage is greater than +3.5 VDC at the CONNECTOR, J2, ON the
MIN ADA PWB #2 between the inside wire (+) and the outside base (-).
cations RAP.
Y N
Procedure Replace the MIN ADA PWB #2 (PL 1.8)
Check the Queued Faults on the [SCP] screen. Fault Code, 3-232, is present.
Y N Replace the MIN DIO PWB (PL 1.8)
Fault Code, 3-233, is present.
Y N Go to the 3-233 RAP.
Check the Identification Connector, P249/J6, on the MIN DIO PWB to make sure
that the correct pins are connected and that the pins which are connected together Go to the 3-232 RAP.
have continuity. Refer to the MIN DIO PWB Identification Connector Table located at
the end of this RAP. The connector is wired properly. Table 1 MIN DIO PWB IDENTIFICATION CONNECTOR TABLE
Y N PWB CONN PIN LOCATION
DIO #1 P249/J6 Pin 1 & Pin 16 (connected)
+ 5.0 VDC is measured between TS38 (+) and TS37 (-) ON the MIN DIO PWB. Pin 2 & Pin 17 (connected)
Y N Pin 3 & Pin 18 (connected)
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the wire,
1000D, for an open circuit. If the wire is good, replace the MIN DIO PWB (PL
1.8)
Disconnect the Local Bus cable, P227/J5, at the MIN DIO PWB. Voltage is greater
than +3.5 VDC at the CONNECTOR, J5, ON the MIN DIO PWB between the
inside wire (+) and the outside base (-).
Y N
Reconnect the cable, P227/J5. Disconnect the Local Bus cable, P226/J108, at
the Backplane, for the MIN SLB/RDR PWB. Voltage is greater than +3.5 VDC
at the CONNECTOR, J108, ON the Backplane, between the inside wire (+)
and the outside base (-).
Y N
Replace the MIN SLB/RDR PWB (PL 1.11)
Reconnect the cable, P226/J108. Disconnect the Local Bus cable, J226/J4, at
the MIN DIO PWB. Voltage is greater than +3.5 VDC at the CABLE between
the inside wire (+) and the outside shield (-).
A B C
Figure 1 3-231/232/233/234 Circuit Diagram


Figure 3 3-231/232/233/234 PWB Location Drawing

A B
3-232 RAP Y N
Fault Code, 3-232, indicates that the MIN Core PWB cannot communicate with the MIN ADA the Backplane for the MIN SLB/RDR PWB. Voltage is greater than +3.5 VDC
PWB #1. The MIN ADA #1 failed to respond to a polling message from the MIN Core PWB. at the CONNECTOR, J108, ON the Backplane between the inside wire (+)
This polling occurs approximately every 200 microseconds and the MIN ADA #1 must respond and the outside base (-).
with an acknowledge message or an input update. When the fault occurs, the Printer will hard Y N
stop cycle down. This fault will cause the machine to go into the Power Interrupt mode and Replace the MIN SLB/RDR PWB (PL 1.11)
will disable the +24 VDC section of the Low Voltage Power Supply.
Initial Actions the MIN DIO PWB. Voltage is greater than +3.5 VDC at the CABLE between
Perform the following: the inside wire (+) and the outside shield (-).
Y N
Replace the Local Bus cable between the Backplane PWB and the MIN
tion faults present, 3-201/202/203/204/205, go to these RAPs. DIO PWB (PL 1.8)
Replace the MIN DIO PWB (PL 1.8)
cations RAP.
• Ensure that connector P256 is securely mounted to the rear frame of the Printer and that Reconnect the cable, P227/J5. Disconnect the Local Bus cable, J227/J3, at the MIN
connector J256 is making good electrical contact with P256 and not producing electrical ADA PWB #2. Voltage is greater than +3.5 VDC at the CABLE between the
noise. inside wire (+) and the outside shield (-).
Procedure Y N
Replace the Local Bus cable between the MIN ADA PWB #2 and MIN DIO
Check the Identification Connector, P206/J7, on the MIN ADA PWB #1 to make sure that the
correct pins are connected and that the pins which are connected together have continuity. PWB (PL 1.8)
Refer to the MIN ADA PWB #1 Identification Connector Table located at the end of this RAP.
Replace the MIN ADA PWB #2 (PL 1.8)
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea-
surements on the Local Bus cable. Reconnect the cable, P228/J2. Disconnect the Local Bus cable, J228/J3, at the MIN ADA
PWB #1. Voltage is greater than +3.5 VDC at the CABLE between the inside wire (+)
The connector is wired properly.
Y N
Y N
Replace the Local Bus cable between the MIN ADA PWB #1 and the MIN ADA PWB
#2 (PL 1.8)
+ 5.0 VDC is measured between TS54 (+) and TS56 (-) ON the MIN ADA PWB #1.
Y N
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA) and check the wire, 1000K, for an
open circuit. If the wire is good, replace the MIN ADA PWB #1 (PL 1.8)
Reconnect the cable, P225/J2. Disconnect the Local Bus cable, J225/J7, at the MIN Core
PWB. Voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
Disconnect the Local Bus cable, P225/J2, at the MIN ADA PWB #1. Voltage is greater than
outside shield (-).
+3.5 VDC at the CONNECTOR, J2, ON the MIN ADA PWB #1 between the inside wire (+)
Y N
Replace the Local Bus cable between the MIN Core PWB and the MIN ADA PWB #1 (PL
Y N
1.8)
Reconnect the cable, P225/J2. Disconnect the Local Bus cable, P228/J2, at the MIN ADA
PWB #2. Voltage is greater than +3.5 VDC at the CONNECTOR, J2, ON the MIN ADA
PWB #2 between the inside wire (+) and the outside base (-).
If the problem continues, replace the MIN Core PWB (PL 1.8)
Y N
If the problem continues, check the Identification Connector, P207/J7, on the MIN ADA PWB
Reconnect the cable, J228/J2. Disconnect the Local Bus cable, P227/J5, at the MIN
#2, and P249/J6, on the MIN DIO PWB. Ensure that the connectors are wired according to
DIO PWB. Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
their respective Identification Connector Table. If both connectors are wired correctly replace
MIN DIO PWB between the inside wire (+) and the outside base (-).
the MIN ADA PWB #2. The MIN ADA PWB #2 Identification Connector Table is located at the
end of the 3-233 RAP and the MIN DIO PWB Identification Connector Table is located at the
end of the 3-231 RAP.
A B
NOTE: Check the wires and the connectors for intermittent connections, poor crimps, etc. It
may be helpful to pull on the wires and shake the connectors to check for loose or intermittent
operation.
Table 1 MIN ADA PWB #1 IDENTIFICATION CONNECTOR TABLE

ADA #1 P206/J7 Pin 6 & Pin 14 (not connected)



3-233 RAP

A B C D
Fault Code, 3-233, indicates that the MIN Core PWB cannot communicate with the MIN ADA
PWB #2. The MIN ADA #2 failed to respond to a polling message from the MIN Core PWB. the MIN DIO PWB. Voltage is greater than +3.5 VDC at the CABLE between
This polling occurs approximately every 200 microseconds and the MIN ADA #2 must respond the inside wire (+) and the outside shield (-).
Y N
with an acknowledge message or an input update. When the fault occurs, the Printer will hard
stop cycle down. This fault will cause the machine to go into the Power Interrupt mode will Replace the Local Bus cable between the Backplane and the MIN DIO
and disable the +24 VDC section of the Low Voltage Power Supply. PWB (PL 1.8)

Initial Actions
Perform the following: Reconnect the cable, P227/J5. Disconnect the Local Bus cable, J227/J3, at the MIN
ADA PWB #2. Voltage is greater than +3.5 VDC at the CABLE between the
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- inside wire (+) and the outside shield (-).
tion faults present, 3-201/202/203/204/205, go to these RAPs. Y N
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Replace the Local Bus cable between the MIN ADA PWB #2 and MIN DIO
cations RAP. PWB (PL 1.8)
Procedure
Check the Queued Faults on the [SCP] screen.
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- Reconnect the cable, P228/J2. Disconnect the Local Bus cable, J228/J3, at the MIN ADA
surements on the Local Bus cable. PWB #1. Voltage is greater than +3.5 VDC at the CABLE between the inside wire (+)
Fault Code, 3-232, is present. Y N
Y N Replace the Local Bus cable between the MIN ADA PWB #1 and the MIN ADA PWB
Check the Identification Connector, P207/J7, on the MIN ADA PWB #2 to make sure that #2 (PL 1.8)
the correct pins are connected and that the pins which are connected together have con-
tinuity. Refer to the MIN ADA PWB #2 Identification Connector Table located at the end of Reconnect the cable, J228/J3. Disconnect the Local Bus cable, P225/J2, at the MIN ADA
this RAP. The connector is wired properly. PWB #1. Voltage is greater than +3.5 VDC at the CONNECTOR, J2, ON the MIN ADA
Y N PWB #1 between the inside wire (+) and the outside base (-).
+ 5.0 VDC is measured between TS54 (+) and TS56 (-) ON the MIN ADA PWB #2.
Y N Replace the MIN ADA PWB #2 (PL 1.8)
Go to the +5.0 VDC wirenet, Figure 33, (WIRING DATA) and check the wire, 1000M, If the problem continues, check the Identification Connector, P249/J6, on the MIN DIO
for an open circuit. If the wire is good, replace the MIN ADA PWB #2 (PL 1.8) PWB, and the connector P206/J7 on the MIN ADA PWB #1. Ensure that the connectors
are wired according to their respective Identification Connector Table. The MIN DIO Iden-
Disconnect the Local Bus cable, P228/J2, at the MIN ADA PWB #2. Voltage is greater tification Connector Table is located at the end of the 3-231 RAP, and the MIN ADA PWB
than +3.5 VDC at the CONNECTOR, J2, ON the MIN ADA PWB #2 between the inside #1 Identification Connector Table is located at the end of the 3-232 RAP.
wire (+) and the outside base (-).
Y N NOTE: Check the wires and the connectors for intermittent connections, poor crimps, etc.
Reconnect the cable, P228/J2. Disconnect the Local Bus cable, P227/J5, at the MIN It may be helpful to pull on the wires and shake the connectors to check for loose or inter-
DIO PWB. Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the mittent operation.
Y N
Table 1 MIN ADA PWB #2 IDENTIFICATION CONNECTOR TABLE
the Backplane, for the MIN SLB/RDR PWB. Voltage is greater than +3.5 VDC
at the CONNECTOR, J108, ON the Backplane between the inside wire (+) PWB CONN PIN LOCATION
and the outside base (-). ADA #2 P207/J7 Pin 6 & Pin 14 (connected)
Y N
A B C D


3-234 RAP

A B
Switch off the Printer. Remove the EPMD PWB and the Pixel PWB from the Printer Card
Fault Code, 3-234, indicates that the MIN Core PWB cannot communicate with the MIN SLB/
RDR PWB. The MIN SLB/RDR failed to respond to a polling message from the MIN Core Cage Backplane. Ensure that the AC input connector, P248/J1 to the ROS LVPS is con-
PWB. This polling occurs approximately every 200 microseconds and the MIN SLB/RDR must nected. Switch on the Printer power. The Diagnostic LED ON the MIN SLB/RDR PWB
is flashing.
respond with an acknowledge message or an input update. When the fault occurs, the Printer
will hard stop cycle down. This fault will cause the machine to go into the Power Interrupt Y N
mode and will disable the +24 VDC section of the Low Voltage Power Supply. The Diagnostic LED ON the MIN SLB/RDR PWB is on.
Y N
Initial Actions
Perform the following: This indicates that the MIN SLB/RDR PWB is OK. Switch off the Printer. Re-install
the EPMD PWB. Switch on the printer. The Diagnostic LED ON the MIN SLB/RDR
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- PWB is flashing.
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- The Diagnostic LED ON the MIN SLB/RDR PWB is on.
cations RAP. Y N
• Verify that EDN location 262 is set to the correct value. Replace the MIN SLB/RDR PWB (PL 1.11)
• For MICR Machines, ensure that the LSLB PWB is installed (PL 1.11).
This indicates that the EPMD PWB is OK. Replace the Pixel PWB (PL 1.11)
Procedure
Check the Queued Faults on the [SCP] screen. Replace the EPMD PWB (PL 1.11)
surements on the Local Bus cable.
Fault Codes, 3-232, 3-233, or 3-231 are also present. Fault Code, 3-232, is present.
Y N Y N
The Diagnostic LED on the SLB/RDR PWB is flashing. Fault Code, 3-233, is present.
Y N Y N
Disconnect the Local Bus cable, P226/J108, at the Printer Card Cage Backplane, for Go to RAP 3-231.
the MIN SLB/RDR PWB. The voltage is greater than +3.5 VDC at the CONNEC-
TOR, J108, at the Printer Card Cage Backplane, between the inside wire (+) Go to RAP 3-233.
Y N Go to RAP 3-232.
Reconnect the cable, P226/J108. Disconnect the Local Bus cable, J226/J4, at the
MIN DIO PWB. The voltage is greater than +3.5 VDC at the CABLE, between the
Y N
Replace the Local Bus cable between the MIN DIO PWB and the Printer Card
Cage Backplane (PL 1.8)
Reconnect the cable, J226/J4. Disconnect the Local Bus cable, P227/J5, at the MIN
DIO PWB. Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
Y N
A B


3-241 RAP

A
Y N
Fault Code, 3-241, indicates that the PHN Core PWB cannot communicate with the PHN DIO
PWB #1. The PHN DIO #1 has failed to respond to a polling message from the PHN Core Reconnect the cable, P359/J5. Disconnect the Local Bus cable, P360/J3, at the
PWB. This polling occurs approximately every 250 microseconds and the PHN DIO PWB #1 PHN Registration Servo PWB. Voltage is greater than +3.5 VDC at the CONNEC-
TOR, J3, ON the PHN Registration PWB, between the inside wire (+) and the
must respond with an acknowledge message or an input update. If the fault is temporary, the
PHN will constantly attempt to bring the DIO back on line. If this is successful during printing, outside base (-).
and no applications declared shutdown causing fault is detected, the top 15 fault count for 3- Y N
+5.0 VDC is measured between TS13 (+) and TS12 (-) ON the PHN Regis-
241 will be incremented, the fault is logged in the last 50, and printing will continue. (This is
done only once for each print to prevent filling the last 50). If a shutdown causing fault occurs tration Servo PWB.
and the PHN DIO PWB #1 is still off-line when shutdown is complete, 3-241 will appear with Y N
Go to the +5.0 VDC wirenet (WIRING DATA) and check the wire, 525, for
the shutdown causing fault in the UIM fault list and the Last 50 screen. This fault will cause the
machine to go into the Power Interrupt mode and will disable the +24 VDC section of the Low an open circuit. If the wire is good, replace the PHN Registration Servo
Voltage Power Supply. PWB (PL 1.4)
Replace the PHN Registration Servo PWB (PL 1.4)

Initial Actions
Perform the following: Reconnect the cable, P360/J3. Disconnect the Local Bus cable, 4417/J4, at the PHN
DIO PWB #5. Voltage is greater than +3.5 VDC measured at the CABLE
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- between the inside wire (+) and the outside shield (-).
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Replace the Local Bus cable between the PHN DIO PWB #5 and the PHN Reg-
cations RAP. istration Servo PHN PWB (PL 1.16)
• Ensure that the fuser ground wires are connected. There have been reported cases of
random 3-241 and 3-xxx faults being caused when the ground wires on the Fuser Meter- Reconnect the cable, 4417/J4. Disconnect the Local Bus cable, 4416/J5, at the PHN
ing Assembly become disconnected. Be sure to check the ground wire that is connected DIO PWB #5. Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
to the Metering Roll. PHN DIO PWB #5 between the inside wire (+) and the outside base (-).
Y N
Procedure Replace the PHN DIO PWB #5 (PL 1.16)
Check the Identification Connector, P336/J6, on the PHN DIO PWB #1 to make sure that the
correct pins are connected and that the pins which are connected together have continuity. Reconnect the cable, 4416/J5. Disconnect the Local Bus cable, J360/J4, at the PHN
Refer to the PHN DIO PWB #1 Identification Connector Table located at the end of this RAP. DIO PWB #6. Voltage is greater than +3.5 VDC measured at the CABLE
The connector is wired properly. between the inside wire (+) and the outside shield (-).
Y N Y N
Rewire or repair the connector to the proper termination. Replace the Local Bus cable between the PHN DIO PWB #4 and the PHN DIO
PWB #5 (PL 1.4)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the PHN DIO PWB #1.
Y N Replace the PHN DIO PWB #6 (PL 1.4)
Go to the +5 VDC wirenet, Figure 31, (WIRING DATA) and check the wire, 501, for an
open circuit. If the wire is good, replace the PHN DIO PWB #1 (PL 1.4) Reconnect the cable, P359/J5. Disconnect the Local Bus cable, J359/J4, at the PHN DIO
PWB #2. Voltage is greater than +3.5 VDC measured at the CABLE between the
Disconnect the Local Bus cable, P357/J5, at the PHN DIO PWB #1. inside wire (+) and the outside shield (-).
NOTE: Check the Local Bus cable connectors for bent pins when making voltage measure- Y N
ments on the Local Bus cable. Replace the Local Bus cable between the PHN DIO PWB #2 and the PHN DIO PWB
#6 (PL 1.4)
Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PHN DIO PWB #1
between the inside wire (+) and the outside base (-). Reconnect the cable, J359/J4. Disconnect the Local Bus cable, P358/J5, at the PHN DIO
Y N PWB #2. Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PHN DIO
Reconnect the cable, P357/J5. Disconnect the Local Bus cable, P359/J5, at the PHN DIO PWB #2 between the inside wire (+) and the outside base (-).
PWB #6. Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PHN DIO Y N
PWB #6 between the inside wire (+) and the outside base (-). Replace the PHN DIO PWB #2 (PL 1.4)
A A B
A B
Reconnect the cable, P358/J5. Disconnect the Local Bus cable, J358/J4, at the PHN DIO
PWB #1. Voltage is greater than +3.5 VDC measured at the CABLE between the
Y N
Replace the Local Bus cable between the PHN DIO PWB #1 and the PHN DIO PWB
#2 (PL 1.4)
Replace the PHN DIO PWB #1 (PL 1.4)
Reconnect the cable, P357/J5. Disconnect the Local Bus cable, J357/J7 at the PHN Core
PWB. Voltage is greater than +3.5 VDC measured at the CABLE between the inside wire
(+) and the outside shield (-).
Y N
Replace the Local Bus cable between the PHN Core PWB and the PHN DIO PWB #1 (PL
1.4)

If the problem continues, replace the PHN Core PWB (PL 1.4)
If the problem continues, check the Identification Connector, P387/J6, on the PHN DIO PWB
#2 and, P363/J6, on the PHN DIO PWB #6 and, 4015/J6, on the PHN DIO PWB #5. Ensure
that the connectors are wired according to their respective Identification Connector Table. THE
PHN DIO PWB #2 Identification Connector Table is located at the end of the 3-242 RAP, and
the PHN DIO PWB #6 Identification Connector Table is located at the end of the 3-246 RAP,
and the PHN DIO PWB # 5 Identification Connector Table is located at the end of the 3-245
RAP.

NOTE: Check the wires and the connectors for intermittent connections, poor crimps, etc. It
may be helpful to pull on the wires and shake the connectors to check for loose or intermittent
operation.
Table 1 PHN DIO PWB #1 IDENTIFICATION CONNECTOR TABLE

DIO #1 P336/J6 Pin 1 & Pin 16 (connected)

Figure 1 3-241/242/245/246/247 Circuit Diagram


Figure 3 3-241/242/245/246/247 PWB Location Drawing

A B
3-242 RAP Y N
Reconnect the cable, P359/J5. Disconnect the Local Bus cable, P360/J3, at the
Fault Code, 3-242, indicates that the PHN Core PWB cannot communicate with the PHN DIO PHN Registration Servo PWB. The voltage is greater than +3.5 VDC at the
PWB #2. The PHN DIO PWB #2 has failed to respond to a polling message from the PHN Core CONNECTOR, J3, ON the PHN Registration PWB between the inside wire
PWB. This polling occurs approximately every 250 microseconds and the DIO must respond (+) and the outside base (-).
with an acknowledge message or an input update. When the fault occurs, the printer will hard Y N
stop cycle down. Since this PWB controls the 24 Volt Enable signal, the fault will cause the +5.0 VDC is measured between TS13 (+) and TS12 (-) on the PHN
printer to go into the Power Interrupt mode and will disable the +24 VDC section of the Low Registration Servo PWB.
Voltage Power Supply. If an applications declared shutdown causing fault occurs and the PHN Y N
DIO PWB #2 is still off-line when the cycle down is complete, the 3-242 fault will appear with Go to the +5.0 VDC wirenet (WIRING DATA) and check the wire,
the shutdown causing fault in the Queued fault list and the Last 50 screen. 525, for an open circuit. If the wire is good, replace the PHN Regis-
tration Servo PWB (PL 1.4)
Initial Actions
Perform the following: Replace the PHN Registration Servo PWB (PL 1.4)
Reconnect the cable, P360/J3. Disconnect the Local Bus cable, 4417/J4, at the
• Check [SCP] Queued Faults. If there are any System Bus Communication faults
present, 3-201/202/203/204/205, go to these RAPs. PHN DIO PWB #5. The voltage is greater than +3.5 VDC at the CABLE
• If this fault can be cleared but continues to occur, go to the 3-731 Intermittent Communi-
Y N
cations RAP.
Replace the Local Bus cable between the PHN DIO PWB #5 and the PHN
Procedure Registration Servo PWB (PL 1.16)
Switch off the Printer and wait for fifteen seconds. Switch on the Printer. Check the Queued
Faults on the [SCP] screen. Fault Code, 3-241, is present. Reconnect the cable, 4417/J4. Disconnect the Local Bus cable, 4416/J5, at the
Y N PHN DIO PWB #5. The voltage is greater than +3.5 VDC at the CONNEC-
Check the Identification Connector, P387/J6, on the PHN DIO PWB #2, to make sure that TOR, J5, ON the PHN DIO PWB #5 between the inside wire (+) and the out-
the correct pins are connected and that the pins which are connected together have con- side base (-).
tinuity. Refer to the PHN DIO PWB #2 Identification Connector Table located at the end of Y N
this RAP. The connector is wired properly. Replace the PHN DIO PWB #5 (PL 1.16)
Y N
Rewire or repair the connector to the proper termination. Reconnect the cable, 4416/J5. Disconnect the Local Bus cable, J360/J4, at the
PHN DIO PWB #6. The voltage is greater than +3.5 VDC at the CABLE
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the PHN DIO PWB #2. between the inside wire (+) and the outside shield (-).
Y N Y N
Go to the +5 VDC wirenet, Figure 31, (WIRING DATA) and check the wire, 512, for Replace the Local Bus cable between the PHN DIO PWB #6 and the PHN
an open circuit. If the wire is good, replace the PHN DIO PWB #2 (PL 1.4) DIO PWB #5 (PL 1.4)
Disconnect the Local Bus cable, P358/J5, at the PHN DIO PWB #2. Replace the PHN DIO PWB #6 (PL 1.4)
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage Reconnect the cable, P359/J5. Disconnect the Local Bus cable, J359/J4, at the PHN
measurements on the Local Bus cable. DIO PWB #2. The voltage is greater than +3.5 VDC at the CABLE, between the
The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PHN DIO PWB inside wire (+) and the outside shield (-).
#2 between the inside wire (+) and the outside base (-). Y N
Replace the Local Bus cable between the PHN DIO PWB #2 and the PHN DIO
Y N
Reconnect the cable, P358/J5. Disconnect the Local Bus cable, P359/J5, at the PWB #6 (PL 1.4)
PHN DIO PWB #6. The voltage is greater than +3.5 VDC at the CONNECTOR,
J5, ON the PHN DIO PWB #6 between the inside wire (+) and the outside base
(-).
Reconnect the cable, P358/J5. Disconnect the Local Bus cable, J358/J4, at the PHN DIO
PWB #1. The voltage is greater than +3.5 VDC at the CABLE, between the inside
A B A
A
Y N
Replace the Local Bus cable between the PHN DIO PWB #1 and the PHN DIO PWB
#2 (PL 1.4)
Reconnect the cable, J358/J4. Disconnect the Local Bus cable, P357/J5, at the PHN DIO
PWB #1. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PHN
DIO PWB #1 between the inside wire (+) and the outside base (-).
Y N
Check the Identification Connector, P363/J6, on the PHN DIO PWB #6 4015/J6, on the
PHN DIO PWB #5, and P336/J6, on the PHN DIO PWB #1. Ensure that the connectors
are wired according to their respective Identification Connector Table. THE PHN DIO
PWB #1 Identification Connector Table is located at the end of the 3-241 RAP, the PHN
DIO PWB #6 Identification Connector Table is located at the end of the 3-246 RAP, and
the PHN DIO PWB # 5 Identification Connector Table is located at the end of the 3-245
RAP.
NOTE: Check the wires and the connectors for intermittent connections, poor crimps, etc.
It may be helpful to pull on the wires and shake the connectors to check for loose or inter-
mittent operation.
If all three identification connectors are wired correctly replace the PHN DIO PWB #2 (PL
1.4)
Table 1 PHN DIO #2 Identification Connector Table

DIO #2 P387/J6 Pin 1 & Pin 16 (not connected)




A B C
3-245 RAP Replace the Local Bus cable between the PHN Registration Servo PWB and the
PHN DIO PWB #5 (PL 1.16)
Fault Code, 3-245, indicates that the PHN Core PWB cannot communicate with the PHN DIO
PWB #5. The PHN DIO PWB #5 failed to respond to a polling message from the PHN Core Replace the PHN DIO PWB #5 (PL 1.16)
PWB. This polling occurs approximately every 250 microseconds and the DIO must respond
with an acknowledge message or an input update. When the fault occurs, the printer will hard Reconnect the Local Bus cable, P4416/J5. Disconnect the Local Bus cable, J360/J4, on the
stop cycle down. If an applications declared shutdown causing fault occurs and the PHN DIO PHN DIO PWB #6. The voltage is greater than +3.5 VDC at the CABLE, J360, between the
PWB #5 is still off-line when the cycle down is complete, the 3-245 will appear with the shut- inside wire (+) and the outside shield (-).
down causing fault in the Queued fault list and the Last 50 screen. This fault will cause the Y N
machine to go into the Power Interrupt mode and will disable the +24 VDC section of the Low Replace the Local Bus cable between the PHN DIO PWB #6 and the PHN DIO PWB #5
Voltage Power Supply. (PL 1.16)
Initial Actions Reconnect the Local Bus cable, J360/J4. Disconnect the Local Bus cable, P359/J5, on the
Perform the following: PHN DIO PWB #6. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
PHN DIO PWB #6 between the inside wire (+) and the outside base (-).
Y N
tion faults present, 3-201/202/203/204/205, go to these RAPs. Replace the PHN DIO PWB #6 (PL 1.4)
Reconnect the Local Bus cable, P359/J5. Disconnect the Local Bus cable, J359/J4, on the
cations RAP.
PHN DIO PWB #2. The voltage is greater than +3.5 VDC at the CABLE, between the
Procedure inside wire (+) and the outside shield (-).
+5 VDC is measured between TS38 (+) and TS37 (-) ON the PHN DIO PWB #5. Y N
Y N Replace the Local Bus cable between the PHN DIO PWB #6 and the PHN DIO PWB #2
Go to the +5.0 VDC Distribution wirenet, Figure 34, (WIRING DATA) and check the wire (PL 1.4)
61F for an open circuit. If the wire is good, replace the PHN DIO PWB #5 (PL 1.16)
Reconnect the Local Bus cable, J359/J4. Disconnect the Local Bus cable, P358/J5, on the
Disconnect the Local Bus cable, P4416/J5, on the PHN DIO PWB #5. PHN DIO PWB #2. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
PHN DIO PWB #2 between the inside wire (+) and the outside base (-).
ments on the Local Bus cable. Replace the PHN DIO PWB #2 (PL 1.4)
The voltage is greater than +3.5 VDC measured at the CONNECTOR, J5, ON the PHN DIO
PWB #5 between the inside wire (+) and the outside base (-). Reconnect the Local Bus cable, P358/J5. Disconnect the Local Bus cable, J358/J4, on the
Y N PHN DIO PWB #1. The voltage is greater than +3.5 VDC at the CABLE, between the
Reconnect the Local Bus cable, P4416/J5. Disconnect the Local Bus cable, P4417/J4, on
the PHN DIO PWB #5. The voltage is greater than +3.5 VDC at the CABLE, between Y N
the inside wire (+) and the outside shield (-). Replace the Local Bus cable between the PHN DIO PWB #1 and the PHN DIO PWB #2
(PL 1.4)
Y N
PHN Registration Servo PWB. The voltage is greater than +3.5 VDC at the CON- Reconnect the Local Bus cable, J358/J4. Disconnect the Local Bus cable, P357/J5, on the
PHN DIO PWB #1. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
NECTOR, J3, ON the PHN Registration Servo PWB between the inside wire (+)
and the outside base (-). PHN DIO PWB #1 between the inside wire (+) and the outside base (-).
Y N Y N
+5 VDC is measured between TS13 (+) and TS12 (-) on the PHN Registra-
tion Servo PWB.
Y N Reconnect the Local Bus cable, P357/J5. Disconnect the Local Bus cable, J357/J7, on the
PHN Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside
Go to the +5 VDC Distribution Wirenets (Wiring Data) and check the wire
#525 for an open circuit. wire (+) and the outside shield (-).
Y N
Replace the PHN Registration Servo PWB (PL 1.4) Replace the Local Bus cable between the PHN Core PWB and the PHN DIO PWB #1 (PL
1.4)
A B C D
D
Refer to the table and ensure that the Identification connector is wired the same as described
in the table and that all connections are being made. If OK, replace the PHN DIO PWB #5 (PL
1.4)
Table 1 PHN DIO PWB #5 IDENTIFICATION CONNECTOR TABLE

DIO #5 4087/J6 Pin 1 & Pin 16 (connected)




A B C
3-246 RAP Y N
+5.0 VDC is measured between TS13 (+) and TS12 (-) on the PHN
Fault Code, 3-246, indicates that the PHN Core PWB cannot communicate with the PHN DIO Registration Servo PWB.
PWB #6. The PHN DIO PWB #6 failed to respond to a polling message from the PHN Core Y N
PWB. This polling occurs approximately every 250 microseconds and the DIO must respond Go to the +5.0 VDC wirenet, Figure 31, (WIRING DATA) and check
with an acknowledge message or an input update. When the fault occurs, the printer will hard the wire, 525, for an open circuit. If the wire is good, replace the PHN
stop cycle down. If an applications declared shutdown causing fault occurs and the PHN DIO Registration Servo PWB (PL 1.4)
PWB #6 is still off-line when the cycle down is complete, the 3-246 will appear with the shut-
down causing fault in the Queued fault list and the Last 50 screen. This fault will cause the Replace the PHN Registration Servo PWB (PL 1.4)
machine to go into the Power Interrupt mode and will disable the +24 VDC section of the Low
Voltage Power Supply. Reconnect the cable, P360/J3. Disconnect the Local Bus cable, 4417/J4, at the
PHN DIO PWB #5. The voltage is greater than +3.5 VDC at the CABLE,
Initial Actions between the inside wire (+) and the outside shield (-).
Replace the Local Bus cable between the PHN DIO PWB #5 and the PHN
Registration Servo PWB (PL 1.16)
tion faults present, 3-201/202/203/204/205, go to these RAPs.
Reconnect the cable, 4417/J4. Disconnect the Local Bus cable, 4416/J5, at the
PHN DIO PWB #5. The voltage is greater than +3.5 VDC at the CONNEC-
cations RAP.
TOR, J5, ON the PHN DIO PWB #5 between the inside wire (+) and the out-
Procedure side base (-).
Check the Queued Faults on the [SCP] screen. Fault Code, 3-241, is present. Y N
Fault Code, 3-242, is present.
Y N Reconnect the cable, 4416/J5. Disconnect the Local Bus cable, J360/J4, at the
Check the Identification Connector, P363/J6, on the PHN DIO PWB #6 to make sure PHN DIO PWB #6. The voltage is greater than +3.5 VDC at the CABLE,
that the correct pins are connected and that the pins which are connected together between the inside wire (+) and the outside shield (-).
have continuity. Refer to the PHN DIO PWB #6 Identification Connector Table Y N
located at the end of this RAP. The connector is wired properly. Replace the Local Bus cable between the PHN DIO PWB #6 and the PHN
Y N DIO PWB #5 (PL 1.4)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the PHN DIO PWB #6.
Y N Reconnect the cable, P359/J5. Disconnect the Local Bus cable, J359/J4, at the PHN
Go to the +5 VDC wirenet, Figure 31, (WIRING DATA) and check the unnum- DIO PWB #2. The voltage is greater than +3.5 VDC at the CABLE, between the
bered orange wire that connects the PHN DIO PWB #6 to 2TB4, for an open inside wire (+) and the outside shield (-).
circuit. If the wire is good, replace the PHN DIO PWB #6 (PL 1.4) Y N
Replace the Local Bus cable between the PHN DIO PWB #2 and the PHN DIO
Disconnect the Local Bus cable, P359/J5, at the PHN DIO PWB #6. PWB #6 (PL 1.4)
NOTE: Check the Local Bus cable connectors for bent pins when making voltage Reconnect the cable, J359/J4. Disconnect the Local Bus cable, P358/J5, at the PHN
measurements on the Local Bus cable. DIO PWB #2. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON
the PHN DIO PWB #2 between the inside wire (+) and the outside base (-).
The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PHN DIO
PWB #6 between the inside wire (+) and the outside base (-). Y N
PHN Registration Servo PWB. The voltage is greater than +3.5 VDC at the Replace the PHN DIO PWB #6 (PL 1.4)
CONNECTOR, J3, ON the PHN Registration PWB between the inside wire If the problem continues, check the Identification Connector, 4015/J6, on the PHN
(+) and the outside base (-). DIO PWB #5. Ensure that the connector is wired according to the PHN DIO PWB #5
Identification Connector Table located at the end of the 3-245 RAP.
A B C A B
A B
NOTE: Check the wires and the connectors for intermittent connections, poor
crimps, etc. It may be helpful to pull on the wires and shake the connectors to check
for loose or intermittent operation
Table 1 PHN DIO PWB #6 Identification Connector Table

DIO #6 P363/J6 Pin 1 & Pin 16 (not connected)




A
3-247 RAP Y N
Fault Code, 3-247, indicates that the PHN Core PWB cannot communicate with the PHN Reg-
istration Servo PWB. The PHN Registration Servo PWB failed to respond to a polling message Replace the PHN Registration Servo PWB (PL 1.4)
from the PHN Core PWB. This polling occurs approximately every 250 microseconds and the
Registration Servo PWB must respond with an acknowledge message or an input update. Fault Code, 3-241, is present.
When the fault occurs, the printer will hard stop cycle down. If an applications declared shut- Y N
down causing fault occurs and the PHN Registration Servo PWB is still off-line when the cycle Fault Code, 3-242, is present.
down is complete, the 3-247 will appear with the shutdown causing fault in the Queued fault list Y N
and the Last 50 screen. This fault will cause the machine to go into the Power Interrupt mode Fault Code, 3-245, is present.
and will disable the +24 VDC section of the Low Voltage Power Supply. Y N
Go to RAP 3-246.
Initial Actions
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- Go to RAP 3-245.
tion faults present, 3-201/202/203/204/205, go to these RAPs.
Go to RAP 3-242.
cations RAP.
Go to RAP 3-241.
NOTE: For the location of any PWB referred to in this RAP go to the PWB Location Drawing,
Figure 2, found in the 3-750 PWB Drawings Section RAP.
Procedure
Check the Queued Faults on the [SCP] screen. Fault Codes, 3-241, 3-242, 3-245, or 3-246
are also present.
Y N
+5.0 VDC is measured between TS13 (+) and TS12 (-) ON the PHN Registration
Servo PWB.
Y N
Go to the +5.0 VDC wirenet, Figure 31, (WIRING DATA) and check the wire, 525, for
an open circuit. If the wire is good, replace the PHN Registration Servo PWB (PL
1.4)
Disconnect the Local Bus cable, P360/J3, at the PHN Registration Servo PWB.
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage
measurements on the Local Bus cable.
The voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the PHN Registra-
tion Servo PWB between the inside wire (+) and the outside base (-).
Y N
Reconnect the cable, P360/J3. Disconnect the Local Bus cable, 4417/J4, at the PHN DIO
PWB #5. The voltage is greater than +3.5 VDC measured at the CABLE between the
Y N
Replace the Local Bus cable between the PHN DIO PWB #5 and the PHN Registra-
tion Servo PWB (PL 1.16)
Reconnect the cable, 4417/J4. Disconnect the Local Bus cable, 4416/J5, at the PHN DIO
PWB #5. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PHN
DIO PWB #5 between the inside wire (+) and the outside base (-).
A



A
3-251 RAP Disconnect the Local Bus cable, P4081/J5, at the FSN DIO PWB #1A. The Voltage is greater
than +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #1A between the inside
Fault Code, 3-251, indicates that the FSN Core PWB cannot communicate with the FSN DIO wire (+) and the outside base (-).
PWB #1A. The FSN DIO PWB #1A has failed to respond to a polling message from the FSN Y N
Core PWB. This polling occurs approximately every 400 microseconds and the FSN DIO PWB Reconnect the cable, P4081/J5. Disconnect the Local Bus cable, P4081/J5, at the FSN
#1A must respond with an acknowledge message or an input update. If the fault is temporary, DIO PWB #1B. The Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
the FSN will constantly attempt to bring the DIO back on line. If this is successful during print- FSN DIO PWB #1B between the inside wire (+) and the outside base (-).
ing, and no applications declared shutdown causing fault is detected, the top 15 fault count for Y N
3-251 will be incremented, the fault is logged in the last 50, and printing will continue. (This is Reconnect the cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, at the
done only once for each print run to prevent filling the last 50 fault screen). If a shutdown caus- FSN Stepper PWB B. The Voltage is greater than +3.5 VDC at the CONNECTOR,
ing fault occurs and the FSN DIO PWB #1A is still off-line when shutdown is complete, 3-251 J4, ON the FSN Stepper PWB B between the inside wire (+) and the outside
will appear with the shutdown causing fault in the Queued fault list and the Last 50 screen. This base (-).
fault will cause the machine to go into the Power Interrupt mode and will disable the +24 VDC Y N
section of the Low Voltage Power Supply. +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper
PWB B.
Initial Actions Y N
Perform the following: Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T,
and 61A for an open circuit.
tion faults present, 3-201/202/203/204/205, go to these RAPs. Replace the FSN Stepper PWB B (PL 1.18)
• Check the Queued Faults on the [SCP] screen. If fault Code, 3-415, is present, go to the
Reconnect the cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on the
3-415.
FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CONNECTOR,
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- J5, ON the FSN DIO PWB #3B between the inside wire (+) and the outside base
cations RAP. (-).
• Ensure that the identification jumper connector, located on Feeder Stacker B, J4057, is Y N
not plugged into P4057. Reconnect the cable, P4085/54. Disconnect the Local Bus cable, J4086/J4, on
• Ensure that the FSN Stepper PWB A is not terminated (jumper should be on pins 1 and 2 the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CABLE
on J5) and that the FSN Stepper PWB B is terminated (jumper should be on pins 2 and 3 between the inside wire (+) and the outside shield (-).
on J5). Y N
Replace the Local Bus cable between the FSN DIO PWB #3B and the
• Ensure that connector P256 is securely mounted to the rear frame of the Printer and that
connector J256 is making good electrical contact with P256 and not producing electrical FSN Stepper PWB B (PL 1.18)
noise.
Replace the FSN DIO PWB #3B (PL 1.18)
surements on the Local Bus cable. Reconnect the cable, P4085/J5. Disconnect the Local Bus cable, P4083/J5, on the
FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CONNECTOR,
J5, ON the FSN DIO PWB #2B between the inside wire (+) and the outside base
found in the 3-750 PWB Drawings Section RAP
(-).
Procedure Y N
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable,
Check the Identification Connector, P4064/J6, on the FSN DIO PWB #1A to make sure that the
J4084/J4, on the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC
correct pins are connected and that the pins which are connected together have continuity.
at the CABLE between the inside wire (+) and the outside shield (-).
Refer to the FSN DIO PWB #1A Identification Connector Table located at the end of this RAP.
Y N
Y N
FSN DIO PWB #3B (PL 1.18)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #1A.
Y N
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61L, and 61A,
J4, on the FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at the
for an open circuit. If the wires are good, replace the FSN DIO PWB #1A (PL 1.18)
CABLE between the inside wire (+) and the outside shield (-).
A B C
B C B D
Y N Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/J4, on
Replace the Local Bus cable between the FSN DIO PWB #1B and the FSN the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC at the CABLE between
DIO PWB #2B (PL 1.18) the inside wire (+) and the outside shield (-).
Y N
Replace the FSN DIO PWB #2B (PL 1.18) Replace the Local Bus cable between the FSN DIO PWB #1A and the FSN DIO
PWB #2A (PL 1.18)
the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CONNECTOR, Replace the FSN DIO PWB #1A (PL 1.18)
J4, ON the FSN Stepper PWB A between the inside wire (+) and the outside base (-).
Y N Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4080/J7, at the
Reconnect the cable P4087/J4. Disconnect the Local Bus cable, J4088/J6, on the FSN Core PWB. Voltage is greater than +3.5 VDC at the CABLE, between the inside wire
FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CABLE (+) and the outside shield (-).
between the inside wire (+) and the outside shield (-). Y N
Y N Replace the Local Bus cable between the FSN Core PWB and the FSN DIO PWB #1A
Reconnect the cable, J4088/J6. Disconnect the Local Bus cable, P4089/P4090, (PL 1.18)
which connects the Local Bus of the #1 F/S Module to the Local Bus of the #2
F/S Module. The voltage is greater than +3.5 VDC at P4090 between the The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB between the inside
inside wire (+) and the outside shield (-). wire (+) and the outside base (-).
Y N Y N
Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #1A.
(PL 1.16) Y N
Go to the +5 VDC Distribution Wirenets, Figure 34, (Wiring Data) and check wires
Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL #61J, and 61A, for an open circuit.
1.18)
Replace the FSN Stepper PWB A (PL 1.18)
The problem is intermittent. Replace the following components one at a time until the problem
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on is resolved. Local Bus cable between the FSN Core PWB and the FSN DIO PWB #1A (PL
the FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CONNECTOR, 1.18)
J5, ON the FSN DIO PWB #3A between the inside wire (+) and the outside base (-).
Y N Table 1 FSN DIO PWB #1 Identification Connector Table
Reconnect the Local Bus cable P4085/J5. Disconnect the Local Bus cable, J4086/
J4, on the FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the
CABLE between the inside wire (+) and the outside shield (-). DIO #1A 4064/J6 Pin 1 & Pin 16 (connected)
Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Pin 3 & Pin 18 (connected)
Stepper PWB A (PL 1.18)
Replace the FSN DIO PWB #3A (PL 1.18)
the FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CONNECTOR,
J5, ON the FSN DIO PWB #2A between the inside wire (+) and the outside base (-).
Y N
Y N
Replace the Local Bus cable between the FSN DIO PWB #2A and the FSN
DIO PWB #3A (PL 1.18)

B D
Figure 1 3-251/252/253/254/255/256/257/258 Circuit Diagram


Figure 3 3-251/252/253/254/255/256/257/258 PWB Location Drawing
3-252 RAP

A
Y N
Fault Code, 3-252, indicates that the FSN Core PWB cannot communicate with the FSN DIO
PWB #2A. The FSN DIO #2A has failed to respond to a polling message from the FSN Core Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, P4081/J5, at
PWB. This polling occurs approximately every 400 microseconds and the FSN DIO PWB #2A the FSN DIO PWB #1B. The Voltage is greater than +3.5 VDC at the CONNECTOR,
J5, ON the FSN DIO PWB #1B between the inside wire (+) and the outside base (-).
must respond with an acknowledge message or an input update. If the fault is temporary, the
FSN will constantly attempt to bring the DIO back on line. If this is successful during printing, Y N
and no applications declared shutdown causing fault is detected, the top 15 fault count for 3- Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/
J4, at the FSN Stepper PWB B. The Voltage is greater than +3.5 VDC at the
252 will be incremented, the fault is logged in the last 50, and printing will continue. (This is
done only once for each print run to prevent filling the last 50). If a shutdown causing fault CONNECTOR, J4, ON the FSN Stepper PWB B between the inside wire (+) and
occurs and the FSN DIO PWB #2A is still off-line when shutdown is complete, 3-252 will the outside base (-).
Y N
appear with the shutdown causing fault in the Queued fault list and the Last 50 screen. This
fault will cause the machine to go into the Power Interrupt mode and will disable the +24 VDC +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper
section of the Low Voltage Power Supply. PWB B.
Y N
Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T,
Initial Actions and 61A, for an open circuit.
Replace the FSN Stepper PWB B (PL 1.18)
• Check the Queued Faults on the [SCP] screen. If there are any System Bus Communi-
cation faults present, 3-201/202/203/204/205, go to these RAPs. Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/
• Check the Queued Faults on the [SCP] screen. If fault Code 3-415 or 3-251 are present, J5, on the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CON-
go to the 3-415 RAP or the 3-251 RAP. NECTOR, J5, ON the FSN DIO PWB #3B between the inside wire (+) and the
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- outside base (-).
cations RAP. Y N
• Ensure that the Identification Jumper connector, J4057, located on F/S B is not plugged Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable,
into P4057.
• Ensure that the FSN Stepper PWB A ia not terminated (pins 1 and 2 should be connected
Y N
on J5) and that the FSN Stepper PWB B is terminated (pins 2 and 3 should be connected
on J5).
FSN Stepper PWB B (PL 1.18)
surements on the Local Bus cable. Replace the FSN DIO PWB #3B (PL 1.18)
NOTE: For the location of any PWB referred to in this RAP go to the PWB Location Drawing, Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, P4083/
found in the 3-750 PWB Drawings Section RAP. J5 on the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CON-
NECTOR, J5, ON the FSN DIO PWB #2B between the inside wire (+) and the
Procedure outside base (-).
Check the Identification Connector, P4066/J6, on the FSN DIO PWB #2A to make sure that the Y N
correct pins are connected and that the pins which are connected together have continuity. Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable,
Refer to the FSN DIO PWB #2A Identification Connector Table located at the end of this RAP. J4084/J4, on the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC
The connector is wired properly. at the CABLE between the inside wire (+) and the outside shield (-).
Y N Y N
Rewire or repair the connector to the proper termination. Replace the Local Bus cable between the FSN DIO PWB #2B and the
Y N Replace the FSN DIO PWB #2B (PL 1.18)
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61P, and 61A,
for an open circuit. If the wires are good, replace the FSN DIO PWB #2A (PL 1.18) Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/
Disconnect the Local Bus cable, P4083/J5, at the FSN DIO PWB #2A. The Voltage is greater CABLE between the inside wire (+) and the outside shield (-).
than +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #2A between the inside Y N
wire (+) and the outside base (-). Replace the Local Bus cable between the FSN DIO PWB #1B and the FSN
DIO PWB #2B (PL 1.18)
A B C
B C
Replace the FSN DIO PWB #1B (PL 1.18) Y N
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, on J4, on the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC at the
the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CONNECTOR, CABLE, between the inside wire (+) and the outside shield (-).
J4, ON the FSN Stepper PWB A between the inside wire (+) and the outside base (-). Y N
Y N Replace the Local Bus cable between the FSN DIO PWB #1A and the FSN
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4088/ DIO PWB #2A (PL 1.18)
J6, on the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the
CABLE between the inside wire (+) and the outside shield (-). Replace the FSN DIO PWB #1A (PL 1.18)
Y N
Reconnect the Local Bus cable, J4408/J6. Disconnect the Local Bus cable, Replace the Local Bus cable between the FSN CORE PWB and the FSN DIO PWB #1A
P4089/P4090, which connects the Local Bus of the #1 F/S Module to the Local (PL 1.18)
Bus of the #2 F/S Module. The voltage is greater than +3.5 VDC at P4090
between the inside wire (+) and the outside shield (-). The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB between the inside
Y N wire (+) and the outside base (-).
Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 Y N
(PL 1.16) +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB.
Y N
Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL Go to the +5 VDC Distribution Wirenets, Figure 34, (Wiring Data) and check wires
1.16) #61J, and 61A, for an open circuit.
Replace the FSN Stepper PWB A (PL 1.18) Replace the FSN Core PWB (PL 1.17)
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on The problem is intermittent. Replace the following components one at a time until the problem
the FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CONNECTOR, is resolved. Local Bus cable between the FSN DIO PWB #2A and the FSN DIO PWB #1A (PL
J5, ON the FSN DIO PWB #3A between the inside wire (+) and the outside base (-). 1.18)
Y N
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4086/ Table 1 FSN DIO PWB #2 Identification Connector Table
Y N DIO #2A 4066/J6 Pin 1 & Pin 16 (not connected)
Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Pin 2 & Pin 17 (connected)
Stepper PWB A (PL 1.18) Pin 3 & Pin 18 (connected)
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on
the FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CABLE between
Y N
Replace the Local Bus cable between the FSN DIO PWB #2A and the FSN DIO
PWB #3A (PL 1.18)
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4080/J7, at the
FSN Core PWB #1A. Voltage is greater than +3.5 VDC at the CABLE, between the inside
Y N
Reconnect the Local Bus cable, J4080/J7. Disconnect the Local Bus cable, P4081/J5, on
J5, ON the FSN DIO PWB #1A between the inside wire (+) and the outside shield (-).




3-253 RAP Y N
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, P4081/J5, at
Fault Code, 3-253, indicates that the FSN Core PWB cannot communicate with the FSN DIO the FSN DIO PWB #1B. The Voltage is greater than +3.5 VDC at the CONNECTOR,
PWB #3A. The FSN DIO #3A has failed to respond to a polling message from the FSN Core J5, ON the FSN DIO PWB #1B between the inside wire (+) and the outside base (-).
PWB. This polling occurs approximately every 400 microseconds and the FSN DIO PWB #3A Y N
must respond with an acknowledge message or an input update. If the fault is temporary, the Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/
FSN will constantly attempt to bring the DIO back on line. If this is successful during printing, J4, at the FSN Stepper PWB B. The Voltage is greater than +3.5 VDC at the
and no applications declared shutdown causing fault is detected, the top 15 fault count for 3- CONNECTOR, J4, ON the FSN Stepper PWB B between the inside wire (+) and
253 will be incremented, the fault is logged in the last 50, and printing will continue. (This is the outside base (-).
done only once for each print to prevent filling the last 50). If a shutdown causing fault occurs Y N
and the FSN DIO PWB #3 is still off-line when shutdown is complete, 3-253 will appear with the +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper
shutdown causing fault in the UIM fault list and the Last 50 screen. This fault will cause the PWB B.
machine to go into the Power Interrupt mode and will disable the +24 VDC section of the Low Y N
Voltage Power Supply. Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T
Initial Actions
Perform the following: Replace the FSN Stepper PWB B (PL 1.18)
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/
tion faults present, 3-201/202/203/204/205, go to these RAPs. J5, on the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CON-
NECTOR, J5, ON the FSN DIO PWB #3B between the inside wire (+) and the
• Check the Queued Faults on the [SCP] screen. If fault Code 3-415, 3-251, or 3-252 are
outside base (-).
present, go to the 3-415, 3-251, or 3-252 RAP.
Y N
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable,
cations RAP. J4086/J4, on the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC
• Ensure that the identification jumper connector, J4057, is not plugged into P4057. at the CABLE between the inside wire (+) and the outside shield (-).
• Ensure that the FSN Stepper PWB A ia not terminated (pins 1 and 2 connected on J5) Y N
and that the FSN Stepper PWB B is terminated (pins 2 and 3 connected on J5). Replace the Local Bus cable between the FSN DIO PWB #3B and the
FSN Stepper PWB B (PL 1.18)
surements on the Local Bus cable. Replace the FSN DIO PWB #3B (PL 1.18)
found in the 3-750 PWB Drawings Section RAP.
J5, on the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CON-
Procedure NECTOR, J5, ON the FSN DIO PWB #2B between the inside wire (+) and the
Check the Identification Connector, P4069/J6, on the FSN DIO PWB #3A to make sure that the outside base (-).
Y N
Refer to the FSN DIO PWB #3A Identification Connector Table. The connector is wired Reconnect the Local Bus cable P4083/J5. Disconnect the Local Bus cable,
properly. J4084/J4, on the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC
Y N
Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61W, and Replace the FSN DIO PWB #2B (PL 1.18)
61A, for an open circuit. If the wires are good, replace the FSN DIO PWB #3A (PL 1.18)
Disconnect the Local Bus cable, P4085/J5, at the FSN DIO PWB #3A. The Voltage is greater J4, on the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the
than +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #3A between the inside
wire (+) and the outside base (-). Y N
Replace the Local Bus cable between the FSN DIO PWB #1B and the FSN
A B C
A B C D
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, on J4, on the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC at the
the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CONNECTOR, CABLE, between the inside wire (+) and the outside shield (-).
J4, ON the FSN Stepper PWB A between the inside wire (+) and the outside base (-). Y N
Reconnect the local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4088/ DIO PWB #2A (PL 1.18)
J6, on the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the
CABLE between the inside wire (+) and the outside shield (-). Replace the FSN DIO PWB #1A (PL 1.18)
Y N
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, Replace the Local Bus cable between the FSN CORE PWB and the FSN DIO PWB #1A
P4089/P4090, which connects the Local Bus of the #1 F/S Module to the Local (PL 1.18)
Bus of the #2 F/S Module. The voltage is greater than +3.5 VDC at P4090
between the inside wire (+) and the outside shield (-). The voltage is greater than +3.5 VDC at the CONNECTOR, J7, ON the FSN Core PWB
Y N between the inside wire (+) and the outside base (-).
Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 Y N
(PL 1.16) +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB.
Y N
Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL Go to the +5 VDC Distribution Wirenets (Wiring Data) and check wires #61J and 61A
1.16) for an open circuit.
Replace the FSN Stepper PWB A (PL 1.18) Replace the FSN Core PWB (PL 1.17)
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on The problem is intermittent. Replace the following components one at a time until the problem
the FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CABLE between is resolved. FSN DIO PWB #2A (PL 1.18)
Y N Table 1 FSN DIO PWB #3 IDENTIFICATION CONNECTOR TABLE
Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Stepper
PWB A (PL 1.18)
DIO #3A 4069/J6 Pin 1 & Pin 16 (connected)
Replace the FSN DIO PWB #3A (PL 1.18) Pin 2 & Pin 17 (not connected)
FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CABLE between the
Y N
Replace the Local Bus cable between the FSN DIO PWB #2A and the FSN DIO PWB
#3A (PL 1.18)
FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
FSN DIO PWB #2A between the inside wire (+) and the outside shield (-).
Y N
FSN Core PWB. Voltage is greater than +3.5 VDC at the CABLE, between the inside wire
Y N
D



A
3-254 RAP Disconnect the Local Bus cable, P4087/J4, at the FSN Stepper PWB A. The Voltage is
greater than +3.5 VDC at the CONNECTOR, J4, ON the FSN Stepper PWB A between the
Fault Code, 3-254, indicates that the FSN Core PWB cannot communicate with the FSN Step- inside wire (+) and the outside base (-).
per PWB A. The FSN Stepper PWB A has failed to respond to a polling message from the FSN Y N
Core PWB. This polling occurs approximately every 400 microseconds, and the FSN Stepper Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4087/J4, at
PWB A must respond with an acknowledge message or an input update. If the fault is tempo- the Stepper PWB B. The Voltage is greater than +3.5 VDC at the CONNECTOR, J4,
rary, the FSN Core PWB will constantly attempt to bring the Stepper back on line. If this is suc- ON the FSN Stepper PWB B between the inside wire (+) and the outside base (-).
cessful during printing, and no fault that could cause a shutdown as a result of an application Y N
declaration is detected, then the top 15 fault count will be incremented, the fault will be logged +5 VDC is measured between TS33 (+) and TS9 (-) on the FSN Stepper PWB B.
in the last 50, and printing will continue. This is done only once for each print run to prevent fill- Y N
ing the last 50 screen. If a shutdown causing fault occurs and the FSN Stepper PWB A is still Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T, and
off-line when the shutdown is complete, 3-254 will appear with the shutdown causing fault in 61A, for an open circuit.
the Queued fault list and the Last 50 screen. This fault will cause the machine to go into the
Power Interrupt mode and will disable the +24 VDC section of the Low Voltage Power Supply. Replace the FSN Stepper PWB B (PL 1.18)
Initial Actions Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on
Perform the following: the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CONNECTOR,
Y N
tion faults present, 3-201/202/203/204/205, go to those RAPs. Reconnect the Local bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/
• Check the Queued Faults on the [SCP] screen. If fault Codes 3-415, 3-251, 3-252 or 3-
253 are present, go to those RAPs.
Y N
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Replace the Local Bus cable between the FSN DIO PWB #3B and the FSN
cations RAP. Stepper PWB B (PL 1.18)
• Ensure that the identification jumper connector, J4057, is not plugged into P4057 on F/S
B. Replace the FSN DIO PWB #3B (PL 1.18)
• Ensure that the FSN Stepper PWB A is not terminated (pins 1 and 2 should be connected
on J5) and that the FSN Stepper PWB B is terminated (pins 2 and 3 should be connected Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, P4083/J5, on
on J5). the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CONNECTOR,
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- Y N
surements on the Local Bus cable. Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4084/
Y N
Procedure Replace the Local Bus cable between the FSN DIO PWB #2B and the FSN
Check the Identification Connector, P4072/J3, on the FSN Stepper PWB A to make sure that DIO PWB #3B (PL 1.18)
the correct pins are connected and that the pins which are connected together have continuity.
Refer to the FSN Stepper PWB A Identification Connector Table (located at the end of this
RAP). The connector is wired properly.
Y N Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, P4081/J5, on
the FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at the CONNECTOR,
J5, ON the FSN DIO PWB #1B between the inside wire (+) and the outside shield (-).
+5.0 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB A. Y N
Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires 61T, and 61A, J4, on the FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at the
for an open circuit. If the wires are good, replace the FSN Stepper PWB A (PL 1.18) CABLE between the inside wire (+) and the outside shield (-).
Y N
A B C D
B C D E
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4088/J6, on J4, on the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC at the
the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CABLE CABLE, between the inside wire (+) and the outside shield (-).
between the inside wire (+) and the outside base (-). Y N
Reconnect the Local Bus cable, J4008. Disconnect the Local Bus cable, P4089/ DIO PWB #2A (PL 1.18)
P4090, which connects the Local Bus of the #1 F/S Module to the Local Bus of the
#2 F/S Module. The voltage is greater than +3.5 VDC at P4090 between the Replace the FSN DIO PWB #1A (PL 1.18)
Y N Replace the Local Bus cable between the FSN CORE PWB and the FSN DIO PWB #1A
Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 (PL (PL 1.18)
1.16)
The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB between the inside
Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL 1.16) wire (+) and the outside base (-).
Y N
Replace the FSN Stepper PWB A (PL 1.18) +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB.
Y N
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on the Go to the +5 VDC Distribution Wirenets, Figure 34, (Wiring Data) and check wires
FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CABLE between the #61J, and 61A, for an open circuit.
Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Stepper PWB
A (PL 1.18) The problem is intermittent. Replace the following components one at a time until the problem
is resolved. All local bus cables one at. Start with the cable between the FSN Stepper PWB A
Reconnect the Local Bus cable, J4086/J4. Disconnect the Local Bus cable, P4085/J5, on the and work back toward the FSN Core PWB. If the problem continues replace the following
FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PWBs in the following order one at a time until the problem is resolved. FSN Stepper PWB #1A
FSN DIO PWB #3A between the inside wire (+) and the outside shield (-). (PL 1.18)
Y N
Replace the FSN DIO PWB #3A (PL 1.18) Table 1 FSN STEPPER PWB A IDENTIFICATION CONNECTOR TABLE
FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CABLE between the STEPPER A 4072/J3 Pin 1 & Pin 16 (not connected)
inside wire (+) and the outside shield (-). Pin 2 & Pin 17 (not connected)
#3A (PL 1.18)
Y N
Reconnect the Local bus cable, P4083/J5. Disconnect the Local Bus cable, J4080/J7, at the
Y N
E



A
3-255 RAP Disconnect the Local Bus cable, P4081/J5, at the FSN DIO PWB #1B. The Voltage is greater
than +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #1B between the inside
PWB #1B. The FSN DIO #1B has failed to respond to a polling message from the FSN Core Y N
PWB. This polling occurs approximately every 400 microseconds, and the FSN DIO PWB #1B Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, at
must respond with an acknowledge message or an input update. If the fault is temporary, the the FSN Stepper PWB B. The Voltage is greater than +3.5 VDC at the CONNECTOR,
FSN will constantly attempt to bring the DIO back on line. If this is successful during printing, J4, ON the FSN Stepper PWB B between the inside wire (+) and the outside base (-).
and no fault that could cause a shutdown as a result of an applications declaration is detected, Y N
then the top 15 fault count for fault code, 3-255, will be incremented, the fault will be logged in +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB B.
the last 50, and printing will continue. This is done only once for each print cycle to prevent fill- Y N
ing the last 50 screen. If a shutdown causing fault occurs and the FSN DIO PWB #1B is still off- Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T, and
line when the shutdown is complete, fault code, 3-255, will appear with the shutdown causing 61A, for an open circuit.
fault in the Queued fault list and the Last 50 screen. This fault will cause the machine to go into
the Power Interrupt mode and will disable the +24 VDC section of the Low Voltage Power Replace the FSN Stepper PWB B (PL 1.18)
Supply.
Initial Actions the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CONNECTOR,
Perform the following: J5, ON the FSN DIO PWB #3 between the inside wire (+) and the outside base (-).
Y N
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4086/
tion faults present, 3-201/202/203/204/205, go to those RAPs. J4, on the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the
• Check the Queued Faults on the [SCP] screen. If fault Code 3-415, 3-251, 3-252, 3-253
Y N
or 3-254 are present, go to those RAP.
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Stepper PWB B (PL 1.18)
cations RAP.
• Ensure that the identification jumper connector, J4057, is not plugged into P4057. Replace the FSN DIO PWB #3B (PL 1.18)
• Ensure that the FSN Stepper PWB A is not terminated (pins 1 and 2 should be connected Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, P4083/
on J5) and that the FSN Stepper PWB B is terminated (pins 2 and 3 should be connected J5, on the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CON-
on J5). NECTOR, J5, ON the FSN DIO PWB #2B between the inside wire (+) and the
outside base (-).
surements on the Local Bus cable. Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable,
Y N
Procedure Replace the Local Bus cable between the FSN DIO PWB #2B and the
Check the Identification Connector, P4064/J6, on the FSN DIO PWB #1B to make sure that the FSN DIO PWB #3B (PL 1.18)
Refer to the FSN DIO PWB #1B Identification Connector Table (located at the end of this
Y N Reconnect the Local bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #1B. Y N
Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires 61L, and 61A, DIO PWB #2B (PL 1.18)
for an open circuit. If the wires are good, replace the FSN DIO PWB #1B (PL 1.18)
A
B C B C
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, 8J4088/J6, between the inside wire (+) and the outside base (-).
on the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CABLE
B B
B B D
Y N Y N
Reconnect the Local bus cable, J4088/J6. Disconnect the Local Bus cable, P4089/ Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable,
P4090, which connects the Local Bus of the #1 F/S Module to the Local Bus of the J4082/J4, on the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC
#2 F/S Module. The voltage is greater than +3.5 VDCat P4090 between the at the CABLE, between the inside wire (+) and the outside shield (-).
inside wire (+) and the outside shield (-). Y N
Y N Replace the Local Bus cable between the FSN DIO PWB #1A and the
Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 (PL FSN DIO PWB #2A (PL 1.18)
1.18)
Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL 1.18)
Replace the Local Bus cable between the FSN CORE PWB A and the FSN DIO
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4087/J4, on PWB #1A (PL 1.18)
the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at t he CONNECTOR,
J4, ON the FSN Stepper PWB A between the inside wire (+) and the outside shield (- Disconnect the Local Bus cable, J4080/J7 at the FSN Core PWB. The voltage is
). greater than +3.5 VDC at J7, ON the FSN Core PWB A between the inside wire (+)
Y N and the outside base (-).
Replace the FSN Stepper PWB A (PL 1.18) Y N
+5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB A.
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on Y N
the FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CABLE between Go to the +5 VDC Distribution Wirenets, Figure 34, (Wiring Data) and check
the inside wire (+) and the outside shield (-). wires #61J, and 61A, for an open circuit.
Y N
Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Stepper Replace the FSN Core PWB A (PL 1.17)
PWB A (PL 1.18)
The problem is intermittent. Replace the following components one at a time until the
Reconnect the Local Bus cable, J4086/J4. Disconnect the Local Bus cable, P4085/J5, on problem is resolved. The local Bus cables, one at a time, until the problem has been
the FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CONNECTOR, resolved. Start with the cable between the FSN DIO PWB #1B and FSN Stepper PWB A
J5, ON the FSN DIO PWB 3A between the inside wire(+) and the outside shield (-). (PL 1.16)
Y N
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on Table 1 FSN DIO PWB #1B IDENTIFICATION CONNECTOR TABLE
the FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CABLE between
DIO #1B 4064/J6 Pin 1 & Pin 16 (connected) (has continuity)
Y N Pin 2 & Pin 17 (connected) (has continuity)
Replace the Local Bus cable between the FSN DIO PWB #2A and the FSN DIO Pin 3 & Pin 18 (connected) (has wires, no continu-
PWB #3A (PL 1.18) ity)
P/J4057 disconnected
Reconnect the Local Bus cable, J4084/J4. Disconnect the Local Bus cable, P4083/J5,on
Y N
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4080/J7, at
the FSN Core PWB A. Voltage is greater than +3.5 VDC at the CABLE, between the
Y N
Reconnect the Local Bus cable, J4080/J7. Disconnect the Local Bus cable, P4081/
J5, on the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC at the CON-
NECTOR, J5, ON the FSN DIO PWB #1A between the inside wire (+) and the
outside shield (-).
B D



A
PWB #2B. The FSN DIO #5 has failed to respond to a polling message from the FSN Core Y N
PWB. This polling occurs approximately every 400 microseconds and the FSN DIO PWB #2B Reconnect the Local Bus cable, P4083/J5 at FSN DIO PWB #2B. Disconnect the Local
must respond with an acknowledge message or an input update. If the fault is temporary, the Bus cable, P4087/J4, at the Stepper PWB B. The Voltage is greater than +3.5 VDC at
FSN will constantly attempt to bring the DIO back on line. If this is successful during printing, the CONNECTOR, J4, ON the FSN Stepper PWB B between the inside wire (+) and
and no applications declared shutdown causing fault is detected, the top 15 fault count for 3- the outside base (-).
256 will be incremented, the fault is logged in the last 50, and printing will continue. (This is Y N
done only once for each print run to prevent filling the last 50). If a shutdown causing fault +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB B.
occurs and the FSN DIO PWB #2B is still off-line when shutdown is complete, 3-256 will Y N
appear with the shutdown causing fault in the UIM fault list and the Last 50 screen. This fault Go to the +5 VDC Distribution wirenets and check wires #61T and 61A for an
will cause the machine to go into the Power Interrupt mode and will disable the +24 VDC sec- open circuit.
tion of the Low Voltage Power Supply.
Initial Actions
Perform the following: Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on
the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CONNECTOR,
• Check the Queued Faults on the [SCP] screen. If fault Code 3-415, 3-251, 3-252, 3-253,
3-254 or 3-255 are present, go to that RAP.
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Y N
cations RAP. Replace the Local Bus cable between the FSN DIO PWB #3B and the FSN
• Ensure that the identification jumper connector, J4057, is not plugged into P4057 on F/S Stepper PWB B (PL 1.18)
B.
• Ensure that the FSN Stepper PWB A is not terminated (pins 1 and 2 should be connected Replace the FSN DIO PWB #3B (PL 1.18)
on J5). Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on
the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CABLE between
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- the inside wire (+) and the outside base (-).
surements on the Local Bus cable. Y N
Replace the Local Bus cable between the FSN DIO PWB #2B and the FSN DIO
PWB #3B (PL 1.18)
Procedure Replace the FSN DIO PWB #2B (PL 1.18)

Check the Identification Connector, P4066/J6, on the FSN DIO PWB #2B to make sure that the
correct pins are connected and that the pins which are connected together have continuity. Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/J4, on the
FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at the CABLE between the
Refer to the FSN DIO PWB #2B Identification Connector Table. The connector is wired
properly. inside wire (+) and the outside shield (-).
Y N Y N
Replace the Local Bus cable between the FSN DIO PWB #1B and the FSN DIO PWB
#2B (PL 1.18)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #2B.
Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61P, and 61A, FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
for an open circuit. If the wires are good, replace the FSN DIO PWB #2B (PL 1.18) FSN DIO PWB #1B between the inside wire (+) and the outside base (-).
Y N
A B
B C
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4088/J6, on the Y N
FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CABLE between the Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4082/
inside wire (+) and the outside base (-). J4, on the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC at the
Y N CABLE, between the inside wire (+) and the outside shield (-).
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4089/ Y N
P4090, which connects the Local Bus of the #1 I F/S Module to the Local Bus of the #2 F/ Replace the Local Bus cable between the FSN DIO PWB #1A and the FSN
S Module. The voltage is greater than +3.5 VDC at P4090 between the inside wire (+) DIO PWB #2A (PL 1.18)
Y N Replace the FSN DIO PWB #1A (PL 1.18)
Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 (PL 1.18)
Replace the Local Bus cable between the FSN CORE PWB A and the FSN DIO PWB
Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL 1.18) #1A (PL 1.17)
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4087/J4, on the The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB A between the inside
FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the COONECTOR, J4, ON wire (+) and the outside base (-).
the FSN Stepper PWB A between the inside wire (+) and the outside shield (-). Y N
Y N +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB A.
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on the #61J and 61A for an open circuit.
inside wire (+) and the outside shield (-). Replace the FSN Core PWB A (PL 1.17)
Y N
Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Stepper PWB The problem is intermittent. Replace the following components one at a time until the problem
A (PL 1.18) is resolved. FSN DIO PWB #2B (PL 1.18)
Reconnect the Local Bus cable, J4086/J4. Disconnect the Local Bus cable, P4085/J5, on the Table 1 FSN DIO PWB #2B IDENTIFICATION CONNECTOR TABLE
FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CONNECTOR, J5,
Y N DIO #2B 4066/J6 Pin 1 & Pin 16 (not connected) No wires
Replace the FSN DIO PWB #3A (PL 1.18) Pin 2 & Pin 17 (connected) Has continuity
Pin 3 & Pin 18 (not connected) Wires (--) no continuity
Y N
#3A (PL 1.18)
Y N
FSN Core PWB A. Voltage is greater than +3.5 VDC at the CABLE, between the inside
Y N
C



A
PWB #3B. The FSN DIO #3B has failed to respond to a polling message from the FSN Core Y N
PWB. This polling occurs approximately every 400 microseconds and the FSN DIO PWB #3B Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, P4087/J4, at
must respond with an acknowledge message or an input update. If the fault is temporary, the the Stepper PWB B. The Voltage is greater than +3.5 VDC at the CONNECTOR, J4,
FSN will constantly attempt to bring the DIO back on line. If this is successful during printing, ON the FSN Stepper PWB B between the inside wire (+) and the outside base (-).
and no applications declared shutdown causing fault is detected, the top 15 fault count for 3- Y N
257 will be incremented, the fault is logged in the last 50, and printing will continue. (This is +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB B.
done only once for each print run to prevent filling the last 50). If a shutdown causing fault Y N
occurs and the FSN DIO PWB #3B is still off-line when shutdown is complete, 3-257 will Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T and
appear with the shutdown causing fault in the UIM fault list and the Last 50 screen. This fault 61A for an open circuit.
will cause the machine to go into the Power Interrupt mode and will disable the +24 VDC sec-
tion of the Low Voltage Power Supply. Replace the FSN Stepper PWB B (PL 1.18)
Initial Actions Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on
Perform the following: the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CABLE between
Y N
tion faults present, 3-201/202/203/204/205, go to these RAPs. Replace the Local Bus cable between the FSN DIO PWB #3B and the FSN Stepper
PWB B (PL 1.18)
3-254, 3-255 or 3-256 are present, go to that RAP.
cations RAP. Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on the
• Ensure that the identification jumper connector, J4057, is not plugged into P4057 on F/S FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CABLE between the
B. inside wire (+) and the outside base (-).
• Ensure that the FSN Stepper PWB A ia not terminated (pins 1 and 2 should be connected Y N
on J5) and that the FSN Stepper PWB B is terminated (pins 2 and 3 should be connected Replace the Local Bus cable between the FSN DIO PWB #2B and the FSN DIO PWB
on J5). #3B (PL 1.18)
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- Reconnect the Local Bus cable, J4084/J4. Disconnect the Local Bus cable, P4083/J5, on the
surements on the Local Bus cable. FSN DIO PWB #2B. The Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
FSN DIO PWB #2B between the inside wire (+) and the outside base (-).
Y N
Procedure
Check the Identification Connector, P4069/J6, on the FSN DIO PWB #3B to make sure that the Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/J4, on the
correct pins are connected and that the pins which are connected together have continuity. FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at the CABLE between the
Refer to the FSN DIO PWB #3B Identification Connector Table. The connector is wired
properly. Y N
Y N Replace the Local Bus cable between the FSN DIO PWB #1B and the FSN DIO PWB
#2B (PL 1.18)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #2B. Reconnect the Local Bus cable, J4082/J4. Disconnect the Local Bus cable, P4081/J5, on the
FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61W, and FSN DIO PWB #1B between the inside wire (+) and the outside base (-).
61A, for an open circuit. If the wires are good, replace the FSN DIO PWB #3B (PL 1.18) Y N
A B
B C
FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CABLE between the Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4082/
inside wire (+) and the outside base (-). J4, on the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC at the
Y N CABLE, between the inside wire (+) and the outside shield (-).
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4089/ Y N
P4090, which connects the Local Bus of the #1 F/S Module to the Local Bus of the #2 F/S Replace the Local Bus cable between the FSN DIO PWB #1A and the FSN
Module. The voltage is greater than +3.5 VDC at P4090 between the inside wire (+) DIO PWB #2A (PL 1.18)
Y N Replace the FSN DIO PWB #1A (PL 1.18)
Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 (PL 1.18)
Replace the Local Bus cable between the FSN CORE PWB and the FSN DIO PWB #1A
Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL 1.18) (PL 1.17)
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4087/J4, on the The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB between the inside
FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON wire (+) and the outside base (-).
the FSN Stepper PWB A between the inside wire (+) and the outside shield (-). Y N
Y N +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB.
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on the #61J and 61A for an open circuit.
inside wire (+) and the outside shield (-). Replace the FSN Core PWB (PL 1.17)
Y N
Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Stepper PWB The problem is intermittent. Replace the following components one at a time until the problem
A (PL 1.18) is resolved. FSN DIO PWB #3B (PL 1.18)
Reconnect the Local Bus cable, J4086/J4. Disconnect the Local Bus cable, P4085/J5, on the Table 1 FSN DIO PWB #3B IDENTIFICATION CONNECTOR TABLE
FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CONNECTOR, J5,
Y N DIO #3B 4069/J6 Pin 1 & Pin 16 (connected) Continuity
Replace the FSN DIO PWB #3A (PL 1.18) Pin 2 & Pin 17 (not connected) No Wires
Pin 3 & Pin 18 (not connected) Has Wires, No Continuity
Y N DIO #2B 4066/J6 Pin 1 & Pin 16 (not connected) No wires
#3A (PL 1.18)
Y N
Y N
C


3-258 RAP

A
Fault Code, 3-258, indicates that the FSN Core PWB cannot communicate with the FSN Step-
per PWB B. The FSN Stepper PWB B has failed to respond to a polling message from the FSN
Core PWB. This polling occurs approximately every 400 microseconds and the FSN Stepper Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on the
PWB B must respond with an acknowledge message or an input update. If the fault is tempo-
rary, the FSN will constantly attempt to bring the Stepper back on line. If this is successful dur- inside wire (+) and the outside shield (-).
ing printing, and no fault that could cause a shutdown as a result of an applications declaration Y N
Replace the Local Bus cable between the FSN DIO PWB #3B and the FSN Stepper PWB
is detected, then the top 15 fault count for fault code,3-258, will be incremented, the fault will
be logged in the last 50, and printing will continue. This is done only once for each print run to B (PL 1.18)
prevent filling the last 50 screen. If a shutdown causing fault occurs and the FSN Stepper PWB
B is still off-line when the shutdown is complete, fault code, 3-258, will appear with the shut-
down causing fault in the Queued fault list and the Last 50 screen. This fault will cause the FSN DIO PWB #3B. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, on the
machine to go into the Power Interrupt mode and will disable the +24 VDC section of the Low FSN DIO PWB #3B between the inside wire (+) and the outside shield (-).
Y N
Voltage Power Supply.
Initial Actions Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on the
Perform the following: FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CABLE between the
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- Y N
tion faults present, 3-201/202/203/204/205, go to those RAPs. Replace the Local Bus cable between the FSN DIO PWB #2B and the FSN DIO PWB
• Check the Queued Faults on the [SCP] screen. If fault Code 3-415, 3-251, 3-252, 3-253, #3B (PL 1.18)
3-254, 3-255, 3-256 or 3-257 are present, go to those RAPs.
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- Reconnect the Local Bus cable, J4084/J4. Disconnect the Local Bus cable, P4083/J5, on the
cations RAP. FSN DIO PWB #2B. The Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
FSN DIO PWB #2B between the inside wire (+) and the outside base (-).
• Ensure that the identification jumper connector, J4057, is not plugged into P4057 on F/S
B. Y N
• Ensure that the FSN Stepper PWB A ia not terminated (pins 1 and 2 should be connected
on J5).
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- inside wire (+) and the outside shield (-).
Replace the Local Bus cable between the FSN DIO PWB #1B and the FSN DIO PWB
NOTE: For the location of any PWB referred to in this RAP go to the PWB Location Drawing, #2B (PL 1.18)
Procedure FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
Check the Identification Connector, P4072/J3, on the FSN Stepper PWB B to make sure that FSN DIO PWB #1B between the inside wire (+) and the outside base (-).
the correct pins are connected and that the pins which are connected together have continuity. Y N
Refer to the FSN Stepper PWB B Identification Connector Table (located at the end of this Replace the FSN DIO PWB #1B (PL 1.18)
Y N Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4088/J6, on the
Rewire or repair the connector to the proper termination. FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CABLE between the
Disconnect the Local Bus cable, P4087/J4, at the FSN Stepper PWB B. The Voltage is Y N
greater than +3.5 VDC at the CONNECTOR, J4, ON the FSN Stepper PWB B between the Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4089/
inside wire (+) and the outside base (-). P4090, which connects the Local Bus of the #1 F/S Module to the Local Bus of the #2 F/S
Y N Module. The voltage is greater than +3.5 VDC at P4090 between the inside wire (+)
+5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB B. and the outside shield (-).
Y N Y N
Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T, and 61A, Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 (PL 1.18)
for an open circuit.
A
B
Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL 1.18) Replace the Local Bus cable between the FSN Core PWB and the FSN DIO PWB #1A
(PL 1.16)
FSN Stepper PWB A. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB between the inside
the FSN Stepper PWB A between the inside wire (+) and the outside shield (-). wire (+) and the outside base (-).
Y N Y N
Replace the FSN Stepper PWB A (PL 1.18) +5 VDC is measured between TS23 (+) and TS22 (-) on the FSN Core PWB.
Y N
FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CABLE between the #61J, and 61A, for an open circuit.
Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Stepper PWB
A (PL 1.18) The problem is intermittent. Replace the following components one at a time until the problem
is resolved. The local Bus lines one at a time starting with the line between the FSN Stepper
Reconnect the Local Bus cable, J4086/J4. Disconnect the Local Bus cable, P4085/J5, on the PWB B and the FSN DIO PWB #3B and work back to the FSN Core PWB. If the problem con-
FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, tinues replace the PWBs in the following order one at a time until the problem is resolved. FSN
between the inside wire between the FSN Stepper PWB #1A and (+) and the outside Stepper PWB B (PL 1.18)
shield (-).
Y N Table 1 FSN STEPPER PWB B IDENTIFICATION CONNECTOR TABLE
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on the STEPPER B 4072/J3 Pin 1 & Pin 16 (not connected)
FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CABLE between the Pin 2 & Pin 17 (not connected)
inside wire (+) and the outside shield (-). Pin 3 & Pin 18 (connected)
Y N
#3A (PL 1.18)
Y N
Y N
Y N
Y N
B



A
3-261 RAP Disconnect the Local Bus cable, P4081/J5, at the FSN DIO PWB #1C. The Voltage is greater
than +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #1C between the inside
Fault Code, 3-261, indicates that the FSN Core PWB #2 cannot communicate with the FSN wire (+) and the outside base (-).
DIO PWB #1C. The FSN DIO PWB #1C has failed to respond to a polling message from the Y N
FSN Core PWB #2. This polling occurs approximately every 400 microseconds and the FSN Reconnect the cable, P4081/J5. Disconnect the Local Bus cable, P4081/J5, at the FSN
DIO PWB #1C must respond with an acknowledge message or an input update. If the fault is DIO PWB #1D. The Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
temporary, the FSN will constantly attempt to bring the DIO back on line. If this is successful FSN DIO PWB #1D between the inside wire (+) and the outside base (-).
during printing, and no applications declared shutdown causing fault is detected, the TOP 15 Y N
fault count for 3-261 will be incremented, the fault is logged in the LAST 50, and printing will Reconnect the cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, at the
continue. This is done only once for each print run to prevent filling the last 50 fault screen. If a FSN Stepper PWB D. The Voltage is greater than +3.5 VDC at the CONNECTOR,
shutdown causing fault occurs and the FSN DIO PWB #1C is still off-line when shutdown is J4, ON the FSN Stepper PWB D between the inside wire (+) and the outside
complete, 3-261 will appear with the shutdown causing fault in the Queued fault list and the base (-).
Last 50 screen. This fault will cause the machine to go into the Power Interrupt mode and will Y N
disable the +24 VDC section of the Low Voltage Power Supply. +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper
PWB D.
Initial Actions Y N
Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T,
Replace the FSN Stepper PWB D (PL 1.18)
tion faults present, 3-201/202/203/204/205/206/207, go to these RAPs.
• Check the Queued Faults on the [SCP] screen. If fault Code, 3-416, is present, go to the Reconnect the cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on the
3-416.
FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the CONNECTOR,
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- J5, ON the FSN DIO PWB #3D between the inside wire (+) and the outside base
cations RAP. (-).
• If this is a four module system, ensure that the Identification Jumper Connector, located Y N
on Feeder Stackers B and D, J4057, is not plugged into P4057. Reconnect the cable, P4085/J5. Disconnect the Local Bus cable, J4086/J4, on
• If this is four module system, ensure that the FSN Stepper PWB A and C is not terminated the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the CABLE
(jumper should be on pins 1 and 2 on J5) and that the FSN Stepper PWB B and D are ter- between the inside wire (+) and the outside shield (-).
minated (jumper should be on pins 2 and 3 on J5). Y N
Replace the Local Bus cable between the FSN DIO PWB #3D and the
• If this is a three module system, ensure that the Identification Jumper Connector, P/
FSN Stepper PWB D (PL 1.18)
J4057, located on Feeder Stacker C is connected.
• If this is three module system, ensure that the FSN Stepper PWB B and C are terminated Replace the FSN DIO PWB #3D (PL 1.18)
(jumper should be on pins 2 and 3 on J5).
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- Reconnect the cable, P4085/J5. Disconnect the Local Bus cable, P4083/J5, on the
surements on the Local Bus cable. FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the CONNECTOR,
J5, ON the FSN DIO PWB #2D between the inside wire (+) and the outside base
Procedure (-).
Check the Identification Connector, P4064/J6, on the FSN DIO PWB #1C to make sure that the Y N
correct pins are connected and that the pins which are connected together have continuity. Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable,
Refer to the FSN DIO PWB #1C Identification Connector Table located at the end of this RAP. J4084/J4, on the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC
The connector is wired properly. at the CABLE between the inside wire (+) and the outside shield (-).
Y N Y N
Rewire or repair the connector to the proper termination. Replace the Local Bus cable between the FSN DIO PWB #2D and the
FSN DIO PWB #3D (PL 1.18)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #1C.
Y N Replace the FSN DIO PWB #2D (PL 1.18)
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61L, and 61A,
for an open circuit. If the wires are good, replace the FSN DIO PWB #1C (PL 1.18) Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/
J4, on the FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the
A B C
B C B D
Y N Y N
Replace the Local Bus cable between the FSN DIO PWB #1D and the FSN Replace the Local Bus cable between the FSN DIO PWB #2C and the FSN
DIO PWB #2D (PL 1.18) DIO PWB #3C (PL 1.18)
Replace the FSN DIO PWB #1D (PL 1.18) Replace the FSN DIO PWB #2C (PL 1.18)
****** IF THIS IS A THREE MODULE SYSTEM GO THE THREE MODULE SUPPLE- Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/J4, on
MENT AT THE END OF THIS RAP. IF THIS IS A FOUR MODULE SYSTEM CONTINUE the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the CABLE between
WITH THE NEXT STATEMENT. ****** the inside wire (+) and the outside shield (-).
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, on Y N
the FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CONNECTOR, Replace the Local Bus cable between the FSN DIO PWB #1C and the FSN DIO
J4, ON the FSN Stepper PWB C between the inside wire (+) and the outside base (-). PWB #2C (PL 1.18)
Y N
Reconnect the cable P4087/J4. Disconnect the Local Bus cable, J4088/J6, on the Replace the FSN DIO PWB #1C (PL 1.18)
FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CABLE
between the inside wire (+) and the outside shield (-). Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4093/J7, at the
Y N FSN Core #2 PWB. Voltage is greater than +3.5 VDC at the CABLE, between the inside
Reconnect the cable, J4088/J6. Disconnect the Local Bus cable, P4089/P4090, wire (+) and the outside shield (-).
which connects the Local Bus of the #1 F/S Module to the Local Bus of the #2 Y N
F/S Module. The voltage is greater than +3.5 VDC at P4090 between the Reconnect the Local Bus Cable J4093/J7. Disconnect the Local Bus cable, P4090, which
inside wire (+) and the outside shield (-). connects the Local Bus of the #2 F/S Module to the FSN DIO PWB #1C. The voltage is
Y N greater than +3.5 VDC at the CABLE between the inside wire (+) and the outside
Replace the Local Bus cable between the FSN DIO PWB #1D and P4090 shield (-).
(PL 1.18) Y N
Replace the Local Bus cable between the FSN DIO PWB #1C and P4090 (PL 1.18)
Replace the Local Bus cable between the FSN Stepper PWB C and P4089 (PL
1.18) Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, P4090, which
connects the Local Bus of the #1 F/S Module to the Local Bus of the #2 F/S Module. The
Replace the FSN Stepper PWB C (PL 1.18) voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
outside shield (-).
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on Y N
the FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CONNECTOR, #(12/93) N - Replace the Local Bus Cable between the #1 F/S and the #2 F/S (PL
J5, ON the FSN DIO PWB #3C between the inside wire (+) and the outside base (-). 1.18)
Y N
Reconnect the Local Bus cable P4085/J5. Disconnect the Local Bus cable, J4086/ Replace the Local Bus Cable between the FSN Core PWB #2 and the connector P4089
J4, on the FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the (PL 1.17)
Y N The voltage is greater than +3.5 VDC at J7, ON the FSN Core #2 PWB between the inside
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN wire (+) and the outside base (-).
Stepper PWB C (PL 1.18) Y N
+5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #2.
Replace the FSN DIO PWB #3C (PL 1.18) Y N
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, P4083/J5, on #61J, and 61A, for an open circuit.
the FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CONNECTOR,
J5, ON the FSN DIO PWB #2C between the inside wire (+) and the outside base (-). Replace the FSN Core #2 PWB (PL 1.17)
Y N
J4, on the FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the
B D E
E
The problem is intermittent. Replace the following components one at a time until the problem Y N
is resolved. Local Bus cable between the FSN Core #2 PWB and the FSN DIO PWB #1C (PL Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4084/J4, on
1.18) the FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CABLE between
Table 1 FSN DIO PWB #1C Identification Connector Table Y N
Replace the Local Bus cable between the FSN DIO PWB #2C and the FSN DIO
PWB #3C (PL 1.18)
DIO #1C 4064/J6 Pin 1 & Pin 16 (connected)
Pin 2 & Pin 17 (connected) Replace the FSN DIO PWB #2C (PL 1.18)
FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the CABLE between the
**************THREE MODULE SUPPLEMENT **************
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, on the
Y N
FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON
Replace the Local Bus cable between the FSN DIO PWB #1C and the FSN DIO PWB
the FSN Stepper PWB C between the inside wire (+) and the outside base (-).
#2C (PL 1.18)
Y N
Reconnect the cable P4087/J4. Disconnect the Local Bus cable, J4088/J6, on the FSN
Replace the FSN DIO PWB #1C (PL 1.18)
Stepper PWB C. The voltage is greater than +3.5 VDC at the CABLE between the
Y N
Reconnect the cable, J4088/J6. Disconnect the Local Bus cable, P4089/P4090,
which connects the Local Bus of the #1 F/S Module to the Local Bus of the #2 F/S
Module. The voltage is greater than +3.5 VDC at P4090 between the inside wire
Y N
Replace the Local Bus cable between the FSN DIO PWB #1D and P4090 (PL
1.18)
Replace the Local Bus cable between the FSN Stepper PWB C and P4089 (PL 1.18)
Replace the FSN Stepper PWB C (PL 1.18)
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
FSN DIO PWB #3C between the inside wire (+) and the outside base (-).
Y N
Reconnect the Local Bus cable P4085/J5. Disconnect the Local Bus cable, J4086/J4, on
the FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CABLE between
Y N
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN Stepper
PWB C (PL 1.18)




A
DIO PWB #2C. The FSN DIO #2C has failed to respond to a polling message from the FSN Y N
Core PWB #2. This polling occurs approximately every 400 microseconds and the FSN DIO ********If this is a three module system, go to the THREE MODULE SYSTEM PROCE-
PWB #2C must respond with an acknowledge message or an input update. If the fault is tem- DURE at the end of this RAP. If this is a FOUR MODULE SYSTEM continue with the next
porary, the FSN Core PWB #2 will constantly attempt to bring the DIO back on line. If this is statement.********
successful during printing, and no applications declared shutdown causing fault is detected, Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, P4081/J5, at
the TOP 15 fault count for 3-262 will be incremented, the fault is logged in the LAST 50, and the FSN DIO PWB #1D. The Voltage is greater than +3.5 VDC at the CONNECTOR,
printing will continue. (This is done only once for each print run to prevent filling the LAST 50). J5, ON the FSN DIO PWB #1D between the inside wire (+) and the outside base (-).
If a shutdown causing fault occurs and the FSN DIO PWB #2C is still off-line when shutdown is Y N
complete, 3-262 will appear with the shutdown causing fault in the Queued fault list and the Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/
Last 50 screen. This fault will cause the machine to go into the Power Interrupt mode and will J4, at the FSN Stepper PWB D. The Voltage is greater than +3.5 VDC at the
disable the +24 VDC section of the Low Voltage Power Supply. CONNECTOR, J4, ON the FSN Stepper PWB D between the inside wire (+) and
Initial Actions Y N
Perform the following: +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper
PWB D.
Y N
• Check the Queued Faults on the [SCP] screen. If there are any System Bus Communi-
cation faults present, 3-201/202/203/204/205/206/207, go to these RAPs. Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T,
and 61A, for an open circuit.
• Check the Queued Faults on the [SCP] screen. If fault Code 3-416 or 3-261 are present,
go to that RAP.
cations RAP. Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/
• If this is a four module system, ensure that the identification jumper connectors, located J5, on the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the CON-
on Feeder Stackers B and D, J4057, are not plugged into P4057. NECTOR, J5, ON the FSN DIO PWB #3D between the inside wire (+) and the
• If this is a three module system, ensure that the identification jumper connector, located outside base (-).
on the Feeder Stacker C is connected. Y N
• If this is four module system, ensure that the FSN Stepper PWB A and C are not termi-
J4086/J4, on the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC
nated (jumper should be on pins 1 and 2 on J5) and that the FSN Stepper PWB B and D
are terminated (jumper should be on pins 2 and 3 on J5).
Y N
• If this is a three module system, ensure that the FSN Stepper PWBs B and C are termi- Replace the Local Bus cable between the FSN DIO PWB #3D and the
nated (jumper should be on pins 2 and 3 on J5) and that FSN Stepper PWB A is not termi-
nated (jumper should be on pins 1 and 2 on J5).
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- Replace the FSN DIO PWB #3D (PL 1.18)
Procedure J5 on the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the CON-
Check the Identification Connector, P4066/J6, on the FSN DIO PWB #2C to make sure that the NECTOR, J5, ON the FSN DIO PWB #2D between the inside wire (+) and the
correct pins are connected and that the pins which are connected together have continuity. outside base (-).
Refer to the FSN DIO PWB #2C Identification Connector Table located at the end of this RAP, Y N
but before the THREE MODULE supplement. The connector is wired properly. Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable,
Y N J4084/J4, on the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC
Rewire or repair the connector to the proper termination. at the CABLE between the inside wire (+) and the outside shield (-).
Y N
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #2C. Replace the Local Bus cable between the FSN DIO PWB #2D and the
Y N FSN DIO PWB #3D (PL 1.18)
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61P, and 61A,
for an open circuit. If the wires are good, replace the FSN DIO PWB #2C (PL 1.18) Replace the FSN DIO PWB #2D (PL 1.18)
A B C D
B C D B
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/ Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4093/J7, at the
J4, on the FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the FSN Core PWB #2. Voltage is greater than +3.5 VDC at the CABLE, between the inside
CABLE between the inside wire (+) and the outside shield (-). wire (+) and the outside shield (-).
Y N Y N
Replace the Local Bus cable between the FSN DIO PWB #1D and the FSN Reconnect the Local Bus cable, J4093/J7. Disconnect the Local Bus cable, P4081/J5, on
DIO PWB #2D (PL 1.18) the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the CONNECTOR,
J5, ON the FSN DIO PWB #1C between the inside wire (+) and the outside shield (-).
Replace the FSN DIO PWB #1D (PL 1.18) Y N
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, on J4, on the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the
the FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CONNECTOR, CABLE, between the inside wire (+) and the outside shield (-).
J4, ON the FSN Stepper PWB C between the inside wire (+) and the outside base (-). Y N
Y N Replace the Local Bus cable between the FSN DIO PWB #1C and the FSN
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4088/ DIO PWB #2C (PL 1.18)
J6, on the FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the
CABLE between the inside wire (+) and the outside shield (-). Replace the FSN DIO PWB #1C (PL 1.18)
Y N
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, Disconnect the Local Bus cable, P4090, which connects the Local Bus of the #2 F/S Mod-
P4090, which connects the Local Bus of the #3 F/S Module to the Local Bus of ule to the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the CABLE
the #4 F/S Module. The voltage is greater than +3.5 VDC at P4090 between between the inside wire (+) and the outside shield (-).
the inside wire (+) and the outside shield (-). Y N
Y N Replace the Local Bus cable between the FSN DIO PWB #1C and P4090 (PL 1.18)
Replace the Local Bus cable between the FSN DIO PWB #1D and P4090
(PL 1.18) Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, P4090, which
Replace the Local Bus cable between the FSN Stepper PWB C and P4089 (PL voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
1.18) outside shield (-).
Y N
Replace the FSN Stepper PWB C (PL 1.18) Replace the Local Bus Cable between the #1 F/S and the #2 F/S (PL 1.18)
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, J4093/J7, at the
the FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CONNECTOR, FSN Core PWB #2. The voltage is greater than +3.5 VDC at the CABLE between the
J5, ON the FSN DIO PWB #3C between the inside wire (+) and the outside base (-). inside wire (+) and the outside shield (-).
Y N Y N
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4086/ Replace the Local Bus Cable between the FSN Core PWB #2 and the connector
J4, on the FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the P4089 (PL 1.18)
Y N The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB #2 between the inside
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN wire (+) and the outside base (-).
Stepper PWB C (PL 1.18) Y N
+5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #2.
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on #61J, and 61A, for an open circuit.
the inside wire (+) and the outside shield (-). Replace the FSN Core PWB #2 (PL 1.18)
Y N
Replace the Local Bus cable between the FSN DIO PWB #2C and the FSN DIO
PWB #3C (PL 1.18)
B E
E
is resolved. Local Bus cable between the FSN DIO PWB #2C and the FSN DIO PWB #1C (PL
1.18)
Table 1 FSN DIO PWB #2C Identification Connector Table

DIO #2C 4066/J6 Pin 1 & Pin 16 (not connected)
***********THREE MODULE SUPPLEMENT************

Y N
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4086/J4, on
Y N
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN Stepper
PWB C (PL 1.18)
Y N
#3C (PL 1.18)




A
DIO PWB #3C. The FSN DIO #3C has failed to respond to a polling message from the FSN Y N
Core PWB#2. This polling occurs approximately every 400 microseconds and the FSN DIO ******* If this is a three module system go the THREE MODULE SUPPLEMENT at the
PWB #3C must respond with an acknowledge message or an input update. If the fault is tem- end of this RAP. If this is a FOUR MODULE SYSTEM continue with the next statement.
porary, the FSN will constantly attempt to bring the DIO back on line. If this is successful during *******
printing, and no applications declared shutdown causing fault is detected, the TOP 15 fault Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, P4081/J5, at
count for 3-263 will be incremented, the fault is logged in the LAST 50, and printing will con- the FSN DIO PWB #1D. The Voltage is greater than +3.5 VDC at the CONNECTOR,
tinue. (This is done only once for each print to prevent filling the LAST 50). If a shutdown caus- J5, ON the FSN DIO PWB #1D between the inside wire (+) and the outside base (-).
ing fault occurs and the FSN DIO PWB #3C is still off-line when shutdown is complete, 3-263 Y N
will appear with the shutdown causing fault in the UIM fault list and the LAST 50 screen. This Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/
fault will cause the machine to go into the Power Interrupt mode and will disable the +24 VDC J4, at the FSN Stepper PWB D. The Voltage is greater than +3.5 VDC at the
section of the Low Voltage Power Supply. CONNECTOR, J4, ON the FSN Stepper PWB D between the inside wire (+) and
Initial Actions Y N
Perform the following: +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper
PWB D.
Y N
tion faults present, 3-201/202/203/204/205/206/207, go to these RAPs. Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T
• Check the Queued Faults on the [SCP] screen. If fault Code 3-416, 3-261, or 3-262 are
present, go to that RAP.
cations RAP. Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/
• If this is a four module system, ensure that the identification jumper connectors, located J5, on the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the CON-
on Feeder Stackers B and D, J4057, are not plugged into P4057. NECTOR, J5, ON the FSN DIO PWB #3D between the inside wire (+) and the
• If this is a three module system, ensure that the identification jumper connector, located outside base (-).
on the Feeder Stacker C is connected. Y N
J4086/J4, on the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC
nated (jumper should be on pins 1 and 2 on J5) and that the FSN Stepper PWB B and D
Y N
• If this is a three module system, ensure that the FSN Stepper PWBs B and C are termi- Replace the Local Bus cable between the FSN DIO PWB #3D and the
nated (jumper should be on pins 2 and 3 on J5) and that FSN Stepper PWB A is not termi-
nated (jumper should be on pins 1 and 2 on J5).
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- Replace the FSN DIO PWB #3D (PL 1.18)
Procedure J5, on the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the CON-
Check the Identification Connector, P4069/J6, on the FSN DIO PWB #3C to make sure that the NECTOR, J5, ON the FSN DIO PWB #2D between the inside wire (+) and the
correct pins are connected and that the pins which are connected together have continuity. outside base (-).
Refer to the FSN DIO PWB #3C Identification Connector Table. The connector is wired Y N
properly. Reconnect the Local Bus cable P4083/J5. Disconnect the Local Bus cable,
Y N J4084/J4, on the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC
Rewire or repair the connector to the proper termination. at the CABLE between the inside wire (+) and the outside shield (-).
Y N
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #3C. Replace the Local Bus cable between the FSN DIO PWB #2D and the
Y N FSN DIO PWB #3D (PL 1.18)
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61W, and
61A, for an open circuit. If the wires are good, replace the FSN DIO PWB #3C (PL 1.18) Replace the FSN DIO PWB #2D (PL 1.18)
A B C D
B C D E
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/ Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4093/J7, at the
J4, on the FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the FSN Core PWB#2. Voltage is greater than +3.5 VDC at the CABLE, between the inside
CABLE between the inside wire (+) and the outside shield (-). wire (+) and the outside shield (-).
Y N Y N
Replace the Local Bus cable between the FSN DIO PWB #1D and the FSN Reconnect the Local Bus cable, J4093/J7. Disconnect the Local Bus cable, P4081/J5, on
DIO PWB #2D (PL 1.18) the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the CONNECTOR,
Replace the FSN DIO PWB #1D (PL 1.18) Y N
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, P4087/J4, on J4, on the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the
the FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CONNECTOR, CABLE, between the inside wire (+) and the outside shield (-).
J4, ON the FSN Stepper PWB C between the inside wire (+) and the outside base (-). Y N
Reconnect the local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4088/ DIO PWB #2C (PL 1.18)
J6, on the FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the
CABLE between the inside wire (+) and the outside shield (-). Replace the FSN DIO PWB #1C (PL 1.18)
Y N
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, Disconnect the Local Bus cable, P4090, which connects the Local Bus of the #2 F/S Mod-
P4090, which connects the Local Bus of the #3 F/S Module to the Local Bus of ule to the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the CABLE
the #4 F/S Module. The voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the outside shield (-).
between the inside wire (+) and the outside shield (-). Y N
Y N Replace the Local Bus cable between the FSN DIO PWB #1C and P4090 (PL 1.18)
Replace the Local Bus cable between the FSN DIO PWB #1D and P4090
(PL 1.18) Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, P4090, which
Replace the Local Bus cable between the FSN Stepper PWB C and P4089 (PL voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
1.18) outside shield (-).
Y N
Replace the FSN Stepper PWB C (PL 1.18) Replace the Local Bus Cable between the #1 F/S and the #2 F/S (PL 1.18)
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, J4093/J7, at the
the FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CABLE between FSN Core PWB #2. The voltage is greater than +3.5 VDC at the CABLE between the
the inside wire (+) and the outside shield (-). inside wire (+) and the outside shield (-).
Y N Y N
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN Stepper Replace the Local Bus Cable between the FSN Core PWB #2 and the connector
PWB C (PL 1.18) P4089 (PL 1.18)
Replace the FSN DIO PWB #3C (PL 1.18) The voltage is greater than +3.5 VDC at the CONNECTOR, J7, ON the FSN Core PWB #2
FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CABLE between the +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #2.
Y N Go to the +5 VDC Distribution Wirenets, Figure 34, (Wiring Data) and check wires
Replace the Local Bus cable between the FSN DIO PWB #2C and the FSN DIO PWB #61J and 61A for an open circuit.
#3C (PL 1.18)
FSN DIO PWB #2C between the inside wire (+) and the outside shield (-).
Y N
E F
F
is resolved. FSN DIO PWB #2C (PL 1.18)
Table 1 FSN DIO PWB #3C IDENTIFICATION CONNECTOR TABLE

DIO #3C 4069/J6 Pin 1 & Pin 16 (connected)
************ THREE MODULE SUPPLEMENT ************

Y N
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN Stepper PWB
C (PL 1.18)




3-264 RAP Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires 61T, and 61A,
Fault Code, 3-264, indicates that the FSN Core PWB #2 cannot communicate with the FSN for an open circuit. If the wires are good, replace the FSN Stepper PWB C (PL 1.18)
Stepper PWB C. The FSN Stepper PWB C has failed to respond to a polling message from the
FSN Core PWB #2. This polling occurs approximately every 400 microseconds, and the FSN Disconnect the Local Bus cable, P4087/J4, at the FSN Stepper PWB C. The Voltage is
Stepper PWB C must respond with an acknowledge message or an input update. If the fault is greater than +3.5 VDC at the CONNECTOR, J4, ON the FSN Stepper PWB C between the
temporary, the FSN Core PWB #2 will constantly attempt to bring the Stepper back on line. If inside wire (+) and the outside base (-).
this is successful during printing, and no fault that could cause a shutdown as a result of an Y N
application declaration is detected, then the TOP 15 fault count will be incremented, the fault ******* If this is a three module system go the THREE MODULE SUPPLEMENT at the
will be logged in the LAST 50, and printing will continue. This is done only once for each print end of this RAP. If this is a FOUR MODULE SYSTEM continue with the next statement.
run to prevent filling the LAST 50 screen. If a shutdown causing fault occurs and the FSN Step- ********
per PWB C is still off-line when the shutdown is complete, 3-264 will appear with the shutdown Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4087/J4, at
causing fault in the Queued fault list and the LAST 50 screen. This fault will cause the machine the Stepper PWB D. The Voltage is greater than +3.5 VDC at the CONNECTOR, J4,
to go into the Power Interrupt mode and will disable the +24 VDC section of the Low Voltage ON the FSN Stepper PWB D between the inside wire (+) and the outside base (-).
Power Supply. Y N
+5 VDC is measured between TS33 (+) and TS9 (-) on the FSN Stepper PWB D.
Initial Actions Y N
Perform the following: Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T, and
61A, for an open circuit.
tion faults present, 3-201/202/203/204/205/206/207, go to those RAPs. Replace the FSN Stepper PWB D (PL 1.18)
• Check the Queued Faults on the [SCP] screen. If fault Codes 3-416, 3-261, 3-262 or 3-
263 are present, go to those RAPs.
the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the CONNECTOR,
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- J5, ON the FSN DIO PWB #3D between the inside wire (+) and the outside base (-).
cations RAP. Y N
• If this is a four module system, ensure that the identification jumper connectors, located Reconnect the Local bus cable, P4085/J5. Disconnect the Local Bus cable, J4086/
on Feeder Stackers B and D, J4057, are not plugged into P4057. J4, on the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the
• If this is a three module system, ensure that the identification jumper connector, located CABLE between the inside wire (+) and the outside shield (-).
on the Inverter Feeder Stacker and Feeder Stacker C is connected. Y N
Replace the Local Bus cable between the FSN DIO PWB #3D and the FSN
nated (jumper should be on pins 1 and 2 on J5) and that the FSN Stepper PWB B and D Stepper PWB D (PL 1.18)
Replace the FSN DIO PWB #3D (PL 1.18)
• If this is a one or three module system, ensure that the FSN Stepper PWBs B and C are
terminated (jumper should be on pins 2 and 3 on J5) and that FSN Stepper PWB A is not
terminated (jumper should be on pins 1 and 2 on J5).
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- J5, ON the FSN DIO PWB #2D between the inside wire (+) and the outside base (-).
Procedure J4, on the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the
Check the Identification Connector, P4072/J3, on the FSN Stepper PWB C to make sure that CABLE between the inside wire (+) and the outside shield (-).
the correct pins are connected and that the pins which are connected together have continuity. Y N
Refer to the FSN Stepper PWB C Identification Connector Table (located at the end of this Replace the Local Bus cable between the FSN DIO PWB #2D and the FSN
RAP). The connector is wired properly. DIO PWB #3D (PL 1.18)
Y N
Rewire or repair the connector to the proper termination. Replace the FSN DIO PWB #2D (PL 1.18)
+5.0 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB C. Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, P4081/J5, on
J5, ON the FSN DIO PWB #1D between the inside wire (+) and the outside shield (-).
A
A B
Y N Reconnect the Local bus cable, P4083/J5. Disconnect the Local Bus cable, J4093/J7, at the
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4082/ FSN Core PWB #2. Voltage is greater than +3.5 VDC at the CABLE, between the inside
J4, on the FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the wire (+) and the outside shield (-).
CABLE between the inside wire (+) and the outside shield (-). Y N
Y N Reconnect the Local Bus cable, J4093/J7. Disconnect the Local Bus cable, P4081/J5, on
Replace the Local Bus cable between the FSN DIO PWB #1D and the FSN the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the CONNECTOR,
DIO PWB #2D (PL 1.18) J5, ON the FSN DIO PWB #1C between the inside wire (+) and the outside shield (-).
Y N
Replace the FSN DIO PWB #1D (PL 1.18) Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4082/
Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4088/J6, on CABLE, between the inside wire (+) and the outside shield (-).
the FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CABLE Y N
between the inside wire (+) and the outside base (-). Replace the Local Bus cable between the FSN DIO PWB #1C and the FSN
Y N DIO PWB #2C (PL 1.18)
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4090,
which connects the Local Bus of the #3 F/S Module to the Local Bus of the #4 F/S Replace the FSN DIO PWB #1C (PL 1.18)
Module. The voltage is greater than +3.5 VDC at the CABLE between the inside
wire (+) and the outside shield (-). Reconnect the Local Bus cable, J4093/J7. Disconnect the Local Bus cable, P4090, which
Y N connects the Local Bus of the #2 F/S Module to the FSN DIO PWB #1C. The voltage is
Replace the Local Bus cable between the FSN DIO PWB #1D and P4090 (PL greater than +3.5 VDC at the CABLE between the inside wire (+) and the outside
1.18) shield (-).
Y N
Replace the Local Bus cable between the FSN Stepper PWB C and P4089 (PL 1.18) Replace the Local Bus cable between the FSN DIO PWB #1C and P4090 (PL 1.18)
Replace the FSN Stepper PWB C (PL 1.18) Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, P4090, which
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on the voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CABLE between the outside shield (-).
Y N Replace the Local Bus Cable between the #1 F/S and the #2 F/S (PL 1.18)
C (PL 1.18) Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, J4093/J7, at the
FSN Core PWB #2. The voltage is greater than +3.5 VDC at the CABLE between the
Reconnect the Local Bus cable, J4086/J4. Disconnect the Local Bus cable, P4085/J5, on the inside wire (+) and the outside shield (-).
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the Y N
FSN DIO PWB #3C between the inside wire (+) and the outside shield (-). Replace the Local Bus Cable between the FSN Core PWB #2 and the connector
Y N P4089 (PL 1.18)
The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB #2 between the inside
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on the wire (+) and the outside base (-).
FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CABLE between the Y N
inside wire (+) and the outside shield (-). +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #2.
Y N Y N
Replace the Local Bus cable between the FSN DIO PWB #2C and the FSN DIO PWB Go to the +5 VDC Distribution Wirenets, Figure 34, (Wiring Data) and check wires
#3C (PL 1.18) #61J, and 61A, for an open circuit.
Reconnect the Local Bus cable, J4084/J4. Disconnect the Local Bus cable, P4083/J5, on the Replace the FSN Core PWB #2 (PL 1.17)
Y N
B C
C
is resolved. All local bus cables one at. Start with the cable between the FSN Stepper PWB C
and work back toward the FSN Core PWB #2. If the problem continues replace the following
PWBs in the following order one at a time until the problem is resolved. FSN Stepper PWB C
(PL 1.18)
Table 1 FSN STEPPER PWB C IDENTIFICATION CONNECTOR TABLE

STEPPER C 4072/J3 Pin 1 & Pin 16 (not connected)
************** THREE MODULE SUPPLEMENT **************

Y N
C (PL 1.18)




3-265 RAP Y N
Fault Code, 3-265, indicates that the FSN Core PWB #2 cannot communicate with the FSN the FSN Stepper PWB D. The Voltage is greater than +3.5 VDC at the CONNECTOR,
DIO PWB #1D. The FSN DIO #1D has failed to respond to a polling message from the FSN J4, ON the FSN Stepper PWB D between the inside wire (+) and the outside base (-).
Core PWB #2. This polling occurs approximately every 400 microseconds, and the FSN DIO Y N
PWB #1D must respond with an acknowledge message or an input update. If the fault is tem- +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB D.
porary, the FSN CORE PWB #2 will constantly attempt to bring the DIO back on line. If this is Y N
successful during printing, and no fault that could cause a shutdown as a result of an applica- Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T, and
tions deceleration is detected, then the TOP 15 fault count for fault code, 3-265, will be incre- 61A, for an open circuit.
mented, the fault will be logged in the LAST 50, and printing will continue. This is done only
once for each print cycle to prevent filling the LAST 50 screen. If a shutdown causing fault Replace the FSN Stepper PWB D (PL 1.18)
occurs and the FSN DIO PWB #1D is still off-line when the shutdown is complete, fault code, 3-
265, will appear with the shutdown causing fault in the Queued fault list and the LAST 50 Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on
screen. This fault will cause the machine to go into the Power Interrupt mode and will disable the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the CONNECTOR,
the +24 VDC section of the Low Voltage Power Supply. J5, ON the FSN DIO PWB #3 between the inside wire (+) and the outside base (-).
Y N
Initial Actions Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4086/
Perform the following: J4, on the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- Y N
tion faults present, 3-201/202/203/204/205/206/207, go to those RAPs. Replace the Local Bus cable between the FSN DIO PWB #3D and the FSN
Stepper PWB D (PL 1.18)
• Check the Queued Faults on the [SCP] screen. If fault Code 3-416, 3-261, 3-262, 3-263
or 3-264 are present, go to those RAP.
cations RAP. Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, P4083/J5, on
• Ensure that the identification jumper connectors, located on Feeder Stackers B and D, the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the CONNECTOR,
J4057, are not plugged into P4057. J5, ON the FSN DIO PWB #2D between the inside wire (+) and the outside base (-).
• Ensure that the FSN Stepper PWB A and C are not terminated (jumper should be on pins Y N
1 and 2 on J5) and that the FSN Stepper PWB B and D are terminated (jumper should be Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4084/
on pins 2 and 3 on J5). J4, on the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the
surements on the Local Bus cable. Replace the Local Bus cable between the FSN DIO PWB #2D and the FSN
DIO PWB #3D (PL 1.18)
Procedure
Check the Identification Connector, P4064/J6, on the FSN DIO PWB #1D to make sure that the Replace the FSN DIO PWB #2D (PL 1.18)
Refer to the FSN DIO PWB #1D Identification Connector Table (located at the end of this Reconnect the Local bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/J4, on
RAP). The connector is wired properly. the FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the CABLE between
Y N the inside wire (+) and the outside shield (-).
Replace the Local Bus cable between the FSN DIO PWB #1D and the FSN DIO
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #1D. PWB #2D (PL 1.18)
Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires 61L, and 61A, Replace the FSN DIO PWB #1D (PL 1.18)
for an open circuit. If the wires are good, replace the FSN DIO PWB #1D (PL 1.18)
Disconnect the Local Bus cable, P4081/J5, at the FSN DIO PWB #1D. The Voltage is greater FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CABLE between the
than +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #1D between the inside inside wire (+) and the outside base (-).

A
Y N Y N
Reconnect the Local bus cable, J4088/J6. Disconnect the Local Bus cable, P4090, which Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4082/
connects the Local Bus of the #3 F/S Module to the Local Bus of the #4 F/S Module. The J4, on the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at the
voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the CABLE, between the inside wire (+) and the outside shield (-).
Replace the Local Bus cable between the FSN DIO PWB #1D and P4090 (PL 1.18) DIO PWB #2C (PL 1.18)
Replace the Local Bus cable between the FSN Stepper PWB C and P4089 (PL 1.18) Replace the FSN DIO PWB #1C (PL 1.18)
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4087/J4, on the Reconnect the Local Bus cable, J4093/J7. Disconnect the Local Bus cable, P4090, which
FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON connects the Local Bus of the #2 F/S Module to the FSN DIO PWB #1C. The voltage is
the FSN Stepper PWB C between the inside wire (+) and the outside shield (-). greater than +3.5 VDC at the CABLE between the inside wire (+) and the outside
Y N shield (-).
Replace the FSN Stepper PWB C (PL 1.18) Y N
Replace the Local Bus cable between the FSN DIO PWB #1C and P4090 (PL 1.18)
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CABLE between the Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, P4090, which
inside wire (+) and the outside shield (-). connects the Local Bus of the #1 F/S Module to the Local Bus of the #2 F/S Module. The
Y N voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN Stepper PWB outside shield (-).
C (PL 1.18) Y N
Replace the Local Bus Cable between the #1 F/S and the #2 F/S (PL 1.18)
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, J4093/J7, at the
FSN DIO PWB 3C between the inside wire(+) and the outside shield (-). FSN Core PWB #2. The voltage is greater than +3.5 VDC at the CABLE between the
Y N inside wire (+) and the outside shield (-).
Replace the Local Bus Cable between the FSN Core PWB #2 and the connector
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on the P4089 (PL 1.18)
inside wire (+) and the outside shield (-). The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB #2 between the inside
Y N wire (+) and the outside base (-).
Replace the Local Bus cable between the FSN DIO PWB #2C and the FSN DIO PWB Y N
#3C (PL 1.18) +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #2.
Y N
Reconnect the Local Bus cable, J4084/J4. Disconnect the Local Bus cable, P4083/J5,on the Go to the +5 VDC Distribution Wirenets, Figure 34, (Wiring Data) and check wires
FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the #61J, and 61A, for an open circuit.
Y N Replace the FSN Core PWB #2 (PL 1.17)
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4093/J7, at the is resolved. The local Bus cables, one at a time, until the problem has been resolved. Start with
FSN Core PWB #2. Voltage is greater than +3.5 VDC at the CABLE, between the inside the cable between the FSN DIO PWB #1D and FSN Stepper PWB C (PL 1.18)
Y N Table 1 FSN DIO PWB #1D IDENTIFICATION CONNECTOR TABLE
J5, ON the FSN DIO PWB #1C between the inside wire (+) and the outside shield (-). DIO #1D 4064/J6 Pin 1 & Pin 16 (connected)
A
Table 1 FSN DIO PWB #1D IDENTIFICATION CONNECTOR TABLE




3-266 RAP Y N
Reconnect the Local Bus cable, P4083/J5 at FSN DIO PWB #2D. Disconnect the Local
Fault Code, 3-266, indicates that the FSN Core PWB #2 cannot communicate with the FSN Bus cable, P4087/J4, at the Stepper PWB D. The Voltage is greater than +3.5 VDC at
DIO PWB #2D. The FSN DIO #2D has failed to respond to a polling message from the FSN the CONNECTOR, J4, ON the FSN Stepper PWB D between the inside wire (+) and
Core PWB #2. This polling occurs approximately every 400 microseconds and the FSN DIO the outside base (-).
PWB #2D must respond with an acknowledge message or an input update. If the fault is tem- Y N
porary, the FSN Core PWB #2 will constantly attempt to bring the DIO back on line. If this is +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB D.
successful during printing, and no applications declared shutdown causing fault is detected, Y N
the TOP 15 fault count for 3-266 will be incremented, the fault is logged in the LAST 50, and Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T and
printing will continue. (This is done only once for each print run to prevent filling the LAST 50). 61A for an open circuit.
If a shutdown causing fault occurs and the FSN DIO PWB #2D is still off-line when shutdown is
complete, 3-266 will appear with the shutdown causing fault in the UIM fault list and the LAST Replace the FSN Stepper PWB D (PL 1.18)
50 screen. This fault will cause the machine to go into the Power Interrupt mode and will dis-
able the +24 VDC section of the Low Voltage Power Supply. Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, P4085/J5, on
Initial Actions J5, ON the FSN DIO PWB #3D between the inside wire (+) and the outside base (-).
J4, on the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the
tion faults present, 3-201/202/203/204/205/206/207, go to these RAPs. CABLE between the inside wire (+) and the outside shield (-).
Y N
3-264 or 3-265 are present, go to that RAP.
Stepper PWB D (PL 1.18)
cations RAP. Replace the FSN DIO PWB #3D (PL 1.18)
• Ensure that the identification jumper connectors, located on Feeder Stackers B and D,
J4057, are not plugged into P4057. Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on
• Ensure that the FSN Stepper PWB A and C are not terminated (jumper should be on pins the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the CABLE between
1 and 2 on J5) and that the FSN Stepper PWB B and D are terminated (jumper should be the inside wire (+) and the outside base (-).
on pins 2 and 3 on J5). Y N
Replace the Local Bus cable between the FSN DIO PWB #2D and the FSN DIO
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- PWB #3D (PL 1.18)
Procedure
Check the Identification Connector, P4066/J6, on the FSN DIO PWB #2D to make sure that the Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/J4, on the
correct pins are connected and that the pins which are connected together have continuity. FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the CABLE between the
Refer to the FSN DIO PWB #2D Identification Connector Table. The connector is wired inside wire (+) and the outside shield (-).
properly. Y N
Y N Replace the Local Bus cable between the FSN DIO PWB #1D and the FSN DIO PWB
Rewire or repair the connector to the proper termination. #2D (PL 1.18)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #2D. Reconnect the Local Bus cable, J4082/J4. Disconnect the Local Bus cable, P4081/J5, on the
Y N FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61P, and 61A, FSN DIO PWB #1D between the inside wire (+) and the outside base (-).
for an open circuit. If the wires are good, replace the FSN DIO PWB #2D (PL 1.18) Y N
Disconnect the Local Bus cable, P4083/J5, at the FSN DIO PWB #2D. The Voltage is greater
than +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #2D between the inside Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4088/J6, on the
wire (+) and the outside base (-). FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CABLE between the

A
Y N Y N
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4090, which Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4082/
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4087/J4, on the Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, P4090, which
FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CONECTOR, J4, ON the connects the Local Bus of the #1 F/S Module to the Local Bus of the #2 F/S Module. The
FSN Stepper PWB C between the inside wire (+) and the outside shield (-). voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
Y N outside shield (-).
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CABLE between the Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, J4093/J7, at the
inside wire (+) and the outside shield (-). FSN Core PWB #2. The voltage is greater than +3.5 VDC at the CABLE between the
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN Stepper PWB Y N
C (PL 1.18) Replace the Local Bus Cable between the FSN Core PWB #2 and the connector
P4089 (PL 1.18)
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB #2 between the inside
between the inside wire (+) and the outside shield (-). wire (+) and the outside base (-).
Y N Y N
Replace the FSN DIO PWB #3C (PL 1.18) +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #2.
Y N
FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CABLE between the #61K and 61A for an open circuit.
#3C (PL 1.18) The problem is intermittent. Replace the following components one at a time until the problem
is resolved. FSN DIO PWB #2D (PL 1.18)
FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the Table 1 FSN DIO PWB #2D IDENTIFICATION CONNECTOR TABLE
Y N
Replace the FSN DIO PWB #2C (PL 1.18) DIO #2D 4066/J6 Pin 1 & Pin 16 (not connected)
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4093/J7, at the Pin 3 & Pin 18 (connected)
FSN Core PWB #2. Voltage is greater than +3.5 VDC at the CABLE, between the inside
Y N
A



3-267 RAP Y N
Fault Code, 3-267, indicates that the FSN Core PWB #2 cannot communicate with the FSN the Stepper PWB D. The Voltage is greater than +3.5 VDC at the CONNECTOR, J4,
DIO PWB #3D. The FSN DIO #3D has failed to respond to a polling message from the FSN ON the FSN Stepper PWB D between the inside wire (+) and the outside base (-).
Core PWB #2. This polling occurs approximately every 400 microseconds and the FSN DIO Y N
PWB #3D must respond with an acknowledge message or an input update. If the fault is tem- +5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB D.
porary, the FSN Core PWB #2 will constantly attempt to bring the DIO back on line. If this is Y N
successful during printing, and no applications declared shutdown causing fault is detected, Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T and
the TOP 15 fault count for 3-267 will be incremented, the fault is logged in the LAST 50, and 61A for an open circuit.
printing will continue. (This is done only once for each print run to prevent filling the LAST 50).
If a shutdown causing fault occurs and the FSN DIO PWB #3D is still off-line when shutdown is Replace the FSN Stepper PWB D (PL 1.18)
complete, 3-267 will appear with the shutdown causing fault in the UIM fault list and the LAST
50 screen. This fault will cause the machine to go into the Power Interrupt mode and will dis- Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on
able the +24 VDC section of the Low Voltage Power Supply. the FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the CABLE between
Initial Actions Y N
Perform the following: Replace the Local Bus cable between the FSN DIO PWB #3D and the FSN Stepper
PWB D (PL 1.18)
tion faults present, 3-201/202/203/204/205/206/207, go to these RAPs. Replace the FSN DIO PWB #3D (PL 1.18)
3-254, 3-255 or 3-256 are present, go to that RAP.
FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the CABLE between the
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- inside wire (+) and the outside base (-).
cations RAP. Y N
• Ensure that the identification jumper connectors, located on Feeder Stackers B and D, Replace the Local Bus cable between the FSN DIO PWB #2D and the FSN DIO PWB
J4057, are not plugged into P4057. #3D (PL 1.18)
• Ensure that the FSN Stepper PWB A and C are not terminated (jumper should be on pins
1 and 2 on J5) and that the FSN Stepper PWB B and D are terminated (jumper should be Reconnect the Local Bus cable, J4084/J4. Disconnect the Local Bus cable, P4083/J5, on the
on pins 2 and 3 on J5). FSN DIO PWB #2D. The Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
FSN DIO PWB #2D between the inside wire (+) and the outside base (-).
surements on the Local Bus cable. Replace the FSN DIO PWB #2D (PL 1.18)
Procedure Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/J4, on the
Check the Identification Connector, P4069/J6, on the FSN DIO PWB #3D to make sure that the FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the CABLE between the
correct pins are connected and that the pins which are connected together have continuity. inside wire (+) and the outside shield (-).
Refer to the FSN DIO PWB #3D Identification Connector Table. The connector is wired Y N
properly. Replace the Local Bus cable between the FSN DIO PWB #1D and the FSN DIO PWB
Y N #2D (PL 1.18)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the FSN DIO PWB #3D. FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
Y N FSN DIO PWB #1D between the inside wire (+) and the outside base (-).
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61W, and Y N
61A, for an open circuit. If the wires are good, replace the FSN DIO PWB #3D (PL 1.18) Replace the FSN DIO PWB #1D (PL 1.18)
Disconnect the Local Bus cable, P4085/J5, at the FSN DIO PWB #3D. The Voltage is greater Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4088/J6, on the
than +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #3D between the inside FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CABLE between the
wire (+) and the outside base (-). inside wire (+) and the outside base (-).

A
Y N Y N
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4090, which Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4082/
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4087/J4, on the Reconnect the Local Bus Cable P4081/J5. Disconnect the Local Bus cable, P4090, which
FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON connects the Local Bus of the #1 F/S Module to the Local Bus of the #2 F/S Module. The
the FSN Stepper PWB C between the inside wire (+) and the outside shield (-). voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CABLE between the Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, J4093/J7, at the
inside wire (+) and the outside shield (-). FSN Core PWB #2. The voltage is greater than +3.5 VDC at the CABLE between the
C (PL 1.18) Replace the Local Bus Cable between the FSN Core PWB #2 and the connector
P4089 (PL 1.18)
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB #2 between the inside
between the inside wire (+) and the outside shield (-). wire (+) and the outside base (-).
Y N Y N
Replace the FSN DIO PWB #3C (PL 1.18) +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #2.
Y N
FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CABLE between the #61K and 61A for an open circuit.
#3C (PL 1.18) The problem is intermittent. Replace the following components one at a time until the problem
is resolved. FSN DIO PWB #3D (PL 1.18)
FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the Table 1 FSN DIO PWB #3D IDENTIFICATION CONNECTOR TABLE
Y N
Replace the FSN DIO PWB #2C (PL 1.18) DIO #3D 4069/J6 Pin 1 & Pin 16 (connected)
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4093/J7, at the Pin 3 & Pin 18 (not connected)
Y N
A



A B
3-268 RAP Replace the FSN Stepper PWB D (PL 1.18)
Fault Code, 3-268, indicates that the FSN Core PWB #2 cannot communicate with the FSN Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on the
Stepper PWB D. The FSN Stepper PWB D has failed to respond to a polling message from the FSN DIO PWB #3DD. The voltage is greater than +3.5 VDC at the CABLE between the
FSN Core PWB #2. This polling occurs approximately every 400 microseconds and the FSN inside wire (+) and the outside shield (-).
Stepper PWB D must respond with an acknowledge message or an input update. If the fault is Y N
temporary, the FSN Core PWB #2 will constantly attempt to bring the Stepper back on line. If Replace the Local Bus cable between the FSN DIO PWB #3D and the FSN Stepper PWB
this is successful during printing, and no fault that could cause a shutdown as a result of an D (PL 1.18)
applications declaration is detected, then the TOP 15 fault count for fault code,3-268, will be
incremented, the fault will be logged in the LAST 50, and printing will continue. This is done Reconnect the Local Bus cable, J4086/J4. Disconnect the Local Bus cable, P4085/J5, on the
only once for each print run to prevent filling the LAST 50 screen. If a shutdown causing fault FSN DIO PWB #3D. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, on the
occurs and the FSN Stepper PWB D is still off-line when the shutdown is complete, fault code, FSN DIO PWB #3D between the inside wire (+) and the outside shield (-).
3-268, will appear with the shutdown causing fault in the Queued fault list and the LAST 50 Y N
screen. This fault will cause the machine to go into the Power Interrupt mode and will disable Replace the FSN DIO PWB #3D (PL 1.18)
the +24 VDC section of the Low Voltage Power Supply.
Initial Actions FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at the CABLE between the
Perform the following: inside wire (+) and the outside base (-).
Y N
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- Replace the Local Bus cable between the FSN DIO PWB #2D and the FSN DIO PWB
tion faults present, 3-201/202/203/204/205/206/207, go to those RAPs. #3D (PL 1.18)
3-264, 3-265, 3-266 or 3-267 are present, go to those RAPs.
FSN DIO PWB #2D. The Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
• If this fault can be cleared but continues to occur, go to the 3-731, Intermittent Communi- FSN DIO PWB #2D between the inside wire (+) and the outside base (-).
cations RAP. Y N
• Ensure that the identification jumper connectors, located on Feeder Stackers B and D, Replace the FSN DIO PWB #2D (PL 1.18)
J4057, are not plugged into P4057.
• Ensure that the FSN Stepper PWB A and C are not terminated (jumper should be on pins Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4082/J4, on the
1 and 2 on J5) and that the FSN Stepper PWB B and D are terminated (jumper should be FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the CABLE between the
on pins 2 and 3 on J5). inside wire (+) and the outside shield (-).
Y N
NOTE: Check the Local Bus cable connectors for bent pins when making any voltage mea- Replace the Local Bus cable between the FSN DIO PWB #1D and the FSN DIO PWB
surements on the Local Bus cable. #2D (PL 1.18)
Procedure Reconnect the Local Bus cable, J4082/J4. Disconnect the Local Bus cable, P4081/J5, on the
Check the Identification Connector, P4072/J3, on the FSN Stepper PWB D to make sure that FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
the correct pins are connected and that the pins which are connected together have continuity. FSN DIO PWB #1D between the inside wire (+) and the outside base (-).
Refer to the FSN Stepper PWB D Identification Connector Table (located at the end of this Y N
RAP). The connector is wired properly. Replace the FSN DIO PWB #1D (PL 1.18)
Y N
Rewire or repair the connector to the proper termination. Reconnect the Local Bus cable, P4081/J5. Disconnect the Local Bus cable, J4088/J6, on the
FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CABLE between the
Disconnect the Local Bus cable, P4087/J4, at the FSN Stepper PWB D. The Voltage is inside wire (+) and the outside base (-).
greater than +3.5 VDC at the CONNECTOR, J4, ON the FSN Stepper PWB D between the Y N
inside wire (+) and the outside base (-). Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4090, which
Y N connects the Local Bus of the #3 F/S Module to the Local Bus of the #4 F/S Module. The
+5 VDC is measured between TS33 (+) and TS9 (-) ON the FSN Stepper PWB D. voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
Go to the +5 VDC Distribution wirenets, Figure 34, and check wires #61T, and 61A, Y N
for an open circuit. Replace the Local Bus cable between the FSN DIO PWB #1D and P4090 (PL 1.18)
A B C D
C D E F
Replace the Local Bus cable between the FSN Stepper PWB C and P4089 (PL 1.18) Reconnect the Local Bus Cable P4081/J5. Disconnect the Local Bus cable, P4090, which
Reconnect the Local Bus cable, J4088/J6. Disconnect the Local Bus cable, P4087/J4, on the voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
FSN Stepper PWB C. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON outside shield (-).
the FSN Stepper PWB C between the inside wire (+) and the outside shield (-). Y N
Y N Replace the Local Bus Cable between the #1 F/S and the #2 F/S (PL 1.18)
Reconnect the Local Bus Cable P4090. Disconnect the Local Bus cable, J4093/J7, at the
Reconnect the Local Bus cable, P4087/J4. Disconnect the Local Bus cable, J4086/J4, on the FSN Core PWB #2. The voltage is greater than +3.5 VDC at the CABLE between the
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and the outside shield (-).
Y N Replace the Local Bus Cable between the FSN Core PWB #2 and the connector
Replace the Local Bus cable between the FSN DIO PWB #3C and the FSN Stepper PWB P4089 (PL 1.18)
C (PL 1.18)
The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB #2 between the inside
Reconnect the Local Bus cable, J4086/J4. Disconnect the Local Bus cable, P4085/J5, on the wire (+) and the outside base (-).
FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, Y N
between the inside wire between the FSN Stepper PWB C and (+) and the outside shield +5 VDC is measured between TS23 (+) and TS22 (-) on the FSN Core PWB #2.
(-). Y N
Y N Go to the +5 VDC Distribution Wirenets, Figure 34, (Wiring Data) and check wires
Replace the FSN DIO PWB #3C (PL 1.18) #61K, and 61A, for an open circuit.
Reconnect the Local Bus cable, P4085/J5. Disconnect the Local Bus cable, J4084/J4, on the Replace the FSN Core PWB #2 (PL 1.17)
inside wire (+) and the outside shield (-). The problem is intermittent. Replace the following components one at a time until the problem
Y N is resolved. The local Bus lines one at a time starting with the line between the FSN Stepper
Replace the Local Bus cable between the FSN DIO PWB #2C and the FSN DIO PWB PWB D and the FSN DIO PWB #3D and work back to the FSN Core PWB #2. If the problem
#3C (PL 1.18) continues replace the PWBs in the following order one at a time until the problem is resolved.
FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the Table 1 FSN STEPPER PWB D IDENTIFICATION CONNECTOR TABLE
Y N
Replace the FSN DIO PWB #2C (PL 1.18) STEPPER D 4072/J3 Pin 1 & Pin 16 (not connected)
Reconnect the Local Bus cable, P4083/J5. Disconnect the Local Bus cable, J4093/J7, at the Pin 3 & Pin 18 (connected)
Y N
Y N
Y N
Replace the Local Bus cable between the FSN DIO PWB #1C and the FSN
DIO PWB #2C (PL 1.18)
E F



A B
3-272 RAP Y N
Go to the +5.0 VDC wirenet, Figure 63, (WIRING DATA) and check the wires,
Fault Code, 3-272, indicates that the TMN Core PWB cannot communicate with the TMN DIO 59J and 60H, for an open circuit. If the wires are ok, replace the Terminator
PWB. The TMN DIO has failed to respond to a polling message from the TMN Core PWB. This PWB (PL 1.19)
polling occurs approximately every 250 microseconds and the TMN DIO PWB must respond
with an acknowledge message or an input update. If the fault is temporary, the TMN will con- Replace the Terminator PWB (PL 1.19).
stantly attempt to bring the DIO back on line. If this is successful during printing, and no appli-
cations declared shutdown causing fault is detected, the top 15 fault count for 3-272 will be Reconnect the cable, P823/J2. Disconnect the Local Bus cable, J822/J4, at the TMN DIO
incremented, the fault is logged in the last 50, and printing will continue. This is done only once PWB. Voltage is greater than +3.5 VDC measured at the CABLE between the inside
for each print to prevent filling the last 50. If a shutdown causing fault occurs and the TMN DIO wire (+) and the outside shield (-).
PWB is still off-line when shutdown is complete, 3-272 will appear with the shutdown causing Y N
fault in the UIM fault list and the Last 50 screen. This fault will cause the machine to go into the Replace the Local Bus cable between the TMN DIO PWB and the Terminator PWB
Power Interrupt mode and will disable the +24 VDC section of the Low Voltage Power Supply. (PL 1.19)
Initial Actions Replace the TMN DIO PWB (PL 1.19)

Reconnect the cable, P821/J5. Disconnect the Local Bus cable, J820/J7 at the TMN Core
• Check the Queued Faults on the [SCP] screen. If there are any system bus communica- PWB. Voltage is greater than +3.5 VDC measured at the CABLE between the inside wire
tion faults present, 3-201/202/203/204/205/207, go to these RAPs.
Y N
Replace the Local Bus cable between the TMN Core PWB and the TMN DIO PWB (PL
cations RAP.
1.19)
Procedure
Check the Identification Connector, P811/J6, on the TMN DIO PWB to make sure that the cor- Replace the TMN DIO PWB (PL 1.19)
rect pins are connected and that the pins which are connected together have continuity. Refer If the problem continues, replace the TMN Core PWB (PL 1.19)
to the TMN DIO PWB Identification Connector Table located at the end of this RAP. The con-
nector is wired properly. Table 1 TMN DIO PWB IDENTIFICATION CONNECTOR TABLE
Y N PWB CONN PIN LOCATION
DIO P811/J6 Pin 1 & Pin 16 (connected)
+5.0 VDC is measured between TS38 (+) and TS37 (-) ON the TMN DIO PWB. Pin 2 & Pin 17 (connected)
Go to the +5 VDC wirenet, Figure 63, (WIRING DATA) and check the wire, 59F, for an
open circuit. If the wire is good, replace the TMN DIO PWB (PL 1.19). Reconnect the
Local Bus cables.
Disconnect the Local Bus cable, P821/J5, at the TMN DIO PWB.
NOTE: Check the Local Bus cable connectors for bent pins when making voltage measure-
ments on the Local Bus cable.
Voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the TMN DIO PWB between
the inside wire (+) and the outside base (-).
Y N
Reconnect the cable, P821/J5. Disconnect the Local Bus cable, P823/J2, at the Termina-
tor PWB. Voltage is greater than +3.5 VDC at the CONNECTOR ON the Terminator
PWB between the inside wire (+) and the outside base (-).
Y N
+5.0 VDC is measured between J1-1 (+) and J1-3 (-) ON the Terminator PWB.
A B

Figure 2 PWB Component Location

3-340 RAP 3-341 RAP
Fault Code, 3-340, indicates that the MIN ADA PWB #1 turnaround test has failed. This fault Fault Code, 3-341, indicates that the MIN ADA PWB #2 turnaround test has failed. This fault
will cause the machine to go into the Energy Saver mode and will disable the +24 VDC section will cause the machine to go into the Energy Saver mode and will disable the +24 VDC section
of the Low Voltage Power Supply. of the Low Voltage Power Supply.
Procedure Procedure
Select dC303, [Turnaround Test]. Determine which connector number is highlighted on a red Select dC303, [Turnaround Test]. Determine which connector number is highlighted on a red
background, on the screen, under the MIN ADA PWB #1 list. background, on the screen, under the MIN ADA PWB #2 list.
Check the wire for a short circuit to ground. Locate the appropriate connector in the MIN ADA Check the wire for a short circuit to ground. Locate the appropriate connector in the MIN ADA
PWB #1 Output Signals Table and go to the associated CD (Circuit Diagram) as reference. PWB #2 Output Signals Table and go to the associated CD (Circuit Diagram) as reference.
The wire is good. The wire is good.
Y N Y N
Replace or repair the wire. Replace or repair the wire.
The short circuit may have damaged the MIN ADA PWB #1. If the fault continues to occur, The short circuit may have damaged the MIN ADA #2. If the fault continues to occur,
replace the MIN ADA PWB #1 (PL 1.8) replace the MIN ADA PWB #2 (PL 1.8)
Replace the MIN ADA PWB #1 (PL 1.8) Replace the MIN ADA PWB #2 (PL 1.8)
Table 1 MIN ADA PWB #1 Output Signals Table Table 1 MIN ADA PWB #2 Output Signals Table
CONNECTOR SIGNAL NAME TEST STAKE CD REF CONNECTOR SIGNAL NAME TEST STAKE CD REF
J5-1 DC Com TS56 9-329 J5-1 DC Com TS56 9-355
J5-2 COR$$ACV TS2 9-329 J5-2 PGEN$$REF TS2 9-355
J5-3 DC Com TS56 9-324 J5-3 DC Com TS56 -
J5-4 LDTR$$BV TS3 9-324 J5-4 LAMP$$REF TS3 -
J5-6 CLNR$$BV TS1 9-322 J5-12 DTAC$$SI TS9 9-327
J5-8 UDTR$$BV TS4 9-323 J5-14 DEV1$$BV TS11 9-320
J5-11 DC Com TS56 - J5-15 DC Com TS56 9-330
J5-12 CHGO$$REF TS9 - J5-16 CH2$$SI TS14 9-330
J5-14 SCR$$REF TS11 PQ 9-631 J5-17 DC Com TS56 9-321
J5-15 DC Com TS56 PQ 9-631 J5-18 DEV2$$BV TS5 9-321
J4-1 Toner Thumper Solenoid (L) +24 TS32 9-702 J5-19 DC Com TS56 9-326
VDC J5-20 TRAN$$SI TS7 9-326
J4-2 +24 VDC TS58 9-702 J5-21 DC Com TS56 9-325
J4-3 Start Relay On (L) +24 VDC TS29 4-700 J5-22 CHG2$$SV TS12 9-325
J4-4 +24 VDC INTLK TS58 4-700 J5-23 DC Com TS56 9-328
J4-5 Run Relay On (L) +24 VDC TS26 4-700 J5-24 PCLN$$SI TS15 9-328
J4-9 ARC TEST TS20 9-201 J4-1 Top Edge PR Erase TS32 PQ 9-622
J4-13 HVPS$ENB TS16 9-329 J4-3 Top Edge Copy Erase TS29 PQ 9-622
J4-5 ID Patch Seg Low TS26 PQ 9-622
J4-7 ID Front/Rear Segments TS23 PQ 9-622
J4-9 ID Patch Seg Normal TS20 PQ 9-622
J4-11 MLMP$ENB TS17 PQ 9-624

Table 1 MIN ADA PWB #2 Output Signals Table 3-342 RAP
CONNECTOR SIGNAL NAME TEST STAKE CD REF
Fault code, 3-342, indicates a turnaround test failure from the MIN SLB/RDR PWB to the Pixel
J4-13 Fuser Relay On (L) +5 VDC TS16 10-202 PWB. This fault will cause the Printer to go into the Power Interrupt mode and will disable the
J4-14 +5 VDC TS60 10-202 +24 VDC section of the LVPS.
J4-15 Metering Roll Heater On (L) +5 TS13 10-210
VDC Procedure
J4-16 +5 VDC TS60 10-210 Switch off the Printer Circuit Breakers. Disconnect all printer power. Remove the Pixel PWB
from the Printer Card Cage Backplane. Ensure the AC Input connector to the ROS LVPS,
P284/J1 is reconnected. Switch on the Printer power. Fault code 3-342 is still present.
Y N
Replace the Pixel PWB (PL 1.11)

3-343 RAP 3-344 RAP
Fault code, 3-343, indicates a turnaround test failure from the MIN SLB/RDR PWB to the ROS. Fault code, 3-344, indicates a turnaround test failure from the MIN SLB/RDR PWB to the Pixel
This fault will cause the Printer to go into the Power Interrupt mode and will disable the +24 PWB. This fault will cause the Printer to go into the Power Interrupt mode and will disable the
VDC section of the LVPS. +24 VDC section of the LVPS.
Procedure Procedure
Switch off the Printer Circuit Breakers. Disconnect all printer power. Disconnect P2113/J111 Switch off the Printer Circuit Breakers. Disconnect all Printer power. Remove the EPMD PWB
from the Printer Card Cage Backplane. Switch on the Printer power. Fault code 3-343 is still from the Printer Card Cage Backplane. Ensure that the AC Input connector to the ROS LVPS,
present. P284/J1, is reconnected. Switch on Printer power. Fault code 3-344 is still present.
Y N Y N
Check the wiring from the SLB/RDR PWB to the RCM PWB. Inspect the harness and the Replace the Pixel PWB (PL 1.11)
connectors for intermittent connections.
Replace the SLB/RDR PWB (PL 1.11)
+15 VDC is measured on P113-1 at the Printer Backplane.
Y N
Y N
Go to the +15 VDC Distribution Wirenets, Figure 46, (Wiring Data) and check wire #1033
-15 VDC is measured at P113-3 at the Printer Backplane.

Y N
-15 VDC is measured between TH7 (+) and TH8 (-) on the LVPS.
Y N
Go to the 1-716 -15 VDC RAP.
Go to the -15 VDC Distribution Wirenets, Figure 46, (Wiring Data) and check wire #1035

3-345 RAP 3-346 RAP
Fault Code, 3-345, indicates that the FSN Stepper PWB A turnaround test has failed. This fault Fault Code, 3-346, indicates that the FSN Stepper PWB B turnaround test has failed. This fault
may cause the machine to go into the Energy Saver mode and disable the +24 VDC section of may cause the machine to go into the Energy Saver mode and disable the +24 VDC section of
the Low Voltage Power Supply. the Low Voltage Power Supply.
Procedure Procedure
background, on the screen, under the FSN Stepper PWB A list. background, on the screen, under the FSN Stepper PWB B list.
Check the wire for a short circuit to ground. Locate the appropriate connector in the FSN Check the wire for a short circuit to ground. Locate the appropriate connector in the FSN
STEPPER PWB A OUTPUT SIGNALS TABLE and go to the associated CD (Circuit Diagram) STEPPER PWB B OUTPUT SIGNALS TABLE and go to the associated CD (Circuit Diagram)
as reference. The wire is good. as reference. The wire is good.
Y N Y N
The short circuit may have damaged the FSN Stepper PWB A. If the fault continues to The short circuit may have damaged the FSN Stepper PWB B. If the fault continues to
occur, replace the FSN Stepper PWB A (PL 1.16) occur, replace the FSN Stepper PWB B (PL 1.16)
Replace the FSN Stepper PWB A (PL 1.16) Replace the FSN Stepper PWB B (PL 1.16)
Table 1 FSN STEPPER PWB A OUTPUT SIGNALS TABLE Table 1 FSN STEPPER PWB B OUTPUT SIGNALS TABLE
CONN ECTOR SIGNAL NAME TEST STAKE CD REF CONNECTOR SIGNAL NAME TEST STAKE CD REF
J2-1 Disk Motor A TS27 11-700 J2-1 Disk Motor A TS27 11-700
J2-2 Disk Motor B TS26 11-700 J2-2 Disk Motor B TS26 11-700
J2-5 Disk Motor C TS23 11-700 J2-5 Disk Motor C TS23 11-700
J2-6 Disk Motor D TS22 11-700 J2-6 Disk Motor D TS22 11-700
J2-7 Right Guide A TS25 11-702 J2-7 Right Guide A TS25 11-702
J2-8 Right Guide B TS19 11-702 J2-8 Right Guide B TS19 11-702
J2-11 Right Guide C TS21 11-702 J2-11 Right Guide C TS21 11-702
J2-12 Right Guide D TS20 11-702 J2-12 Right Guide D TS20 11-702
J2-13 Back Guide A TS32 11-701 J2-13 Back Guide A TS32 11-701
J2-14 Back Guide B TS31 11-701 J2-14 Back Guide B TS31 11-701
J2-17 Back Guide C TS29 11-701 J2-17 Back Guide C TS29 11-701
J2-18 Back Guide D TS28 11-701 J2-18 Back Guide D TS28 11-701

3-347 RAP 3-348 RAP
Fault Code, 3-347, indicates that the FSN Stepper PWB C turnaround test has failed. This fault Fault Code, 3-348, indicates that the FSN Stepper PWB D turnaround test has failed. This fault
may cause the machine to go into the Energy Saver mode and disable the +24 VDC section of may cause the machine to go into the Energy Saver mode and disable the +24 VDC section of
the Low Voltage Power Supply. the Low Voltage Power Supply.
Procedure Procedure
background, on the screen, under the FSN Stepper PWB C list. background, on the screen, under the FSN Stepper PWB D list.
Check the wire for a short circuit to ground. Locate the appropriate connector in the FSN Check the wire for a short circuit to ground. Locate the appropriate connector in the FSN
STEPPER PWB C OUTPUT SIGNALS TABLE and go to the associated CD (Circuit Diagram) STEPPER PWB D OUTPUT SIGNALS TABLE and go to the associated CD (Circuit Diagram)
as reference. The wire is good. as reference. The wire is good.
Y N Y N
The short circuit may have damaged the FSN Stepper PWB C. If the fault continues to The short circuit may have damaged the FSN Stepper PWB D. If the fault continues to
occur, replace the FSN Stepper PWB C (PL 1.18) occur, replace the FSN Stepper PWB D (PL 1.18)
Replace the FSN Stepper PWB C (PL 1.18) Replace the FSN Stepper PWB D (PL 1.18)
Table 1 FSN STEPPER PWB C OUTPUT SIGNALS TABLE Table 1 FSN STEPPER PWB D OUTPUT SIGNALS TABLE
CONNECTOR SIGNAL NAME TEST STAKE CD REF CONNECTOR SIGNAL NAME TEST STAKE CD REF
J2-1 Disk Motor A TS27 11-700 J2-1 Disk Motor A TS27 11-700
J2-2 Disk Motor B TS26 11-700 J2-2 Disk Motor B TS26 11-700
J2-5 Disk Motor C TS23 11-700 J2-5 Disk Motor C TS23 11-700
J2-6 Disk Motor D TS22 11-700 J2-6 Disk Motor D TS22 11-700
J2-7 Right Guide A TS25 11-702 J2-7 Right Guide A TS25 11-702
J2-8 Right Guide B TS19 11-702 J2-8 Right Guide B TS19 11-702
J2-11 Right Guide C TS21 11-702 J2-11 Right Guide C TS21 11-702
J2-12 Right Guide D TS20 11-702 J2-12 Right Guide D TS20 11-702
J2-13 Back Guide A TS32 11-701 J2-13 Back Guide A TS32 11-701
J2-14 Back Guide B TS31 11-701 J2-14 Back Guide B TS31 11-701
J2-17 Back Guide C TS29 11-701 J2-17 Back Guide C TS29 11-701
J2-18 Back Guide D TS28 11-701 J2-18 Back Guide D TS28 11-701

3-361 RAP 3-362 RAP
Fault Code, 3-361, indicates that the EDN Core PWB battery has failed. This fault will cause Fault Code, 3-362, indicates that the NVM values on the EDN Core PWB are not valid. This
the machine to go into the Energy Saver mode and disable the +24 VDC section of the Low fault will cause the machine to go into the Energy Saver mode and disable the +24 VDC sec-
Voltage Power Supply. tion of the Low Voltage Power Supply.
Procedure Initial Actions

Replace the EDN Core PWB (PL 1.11) Get the Temporary License String entitled (180LPS_Temp90_diag) from XDSS or TSC prior to
initializing the EDN Node. Read the CAUTION below before proceeding.
NOTE: Perform the replacement procedure for the EDN Core PWB (REP 1-13) to ensure sav-
ing the NVM Setup Parameters. CAUTION
Initializing the EDN Node will cause the IOT to lose its serial number data. Because the Value
Added License (180LPS_VAE_Diag) is locked on to the IOT Serial Number, the CSE will not
be able to enter the dc105 program to reset the serial number data.
Procedure
Select dC131, [EDN], [Initialize Selected Node].
Call TSC or XDSS to obtain the temporary license string. It is not locked into the Machine
Serial Number.
Select dC105, [Processor serial number and service telephone number]. The serial num-
ber in NVM must agree with the machine serial number otherwise the Restore Setup Parame-
ters procedure will not work.
Select dC101. Perform the Restore Setup procedure.
NOTE: All current Top 15 fault screens, all current HFSI counters, all current counters in
dC107, all counters on the SCP Entry screen and Billing counters are reset to zero. This infor-
mation resides in NVM and is therefore invalid when 03-362 faults are declared.

3-370 RAP 3-371 RAP
Fault code, 3-370, indicates an internal failure in the SLB/RDR PWB. This fault will cause the Fault Code, 3-371, indicates a potential hardware problem was detected on the EDN Core
printer to go into the Power Interrupt mode and disable the +24 VDC section of the LVPS. PWB that required the EDN to perform a software reset. When the fault occurs, a crash file is
stored on the Rigid Disk/SMSD. This fault will cause the machine to go into Energy Saver dur-
Initial Actions ing Operator modes, or Power Interrupt during diagnostic mode. Both modes disable the+24
VDC section of the Low Voltage Power Supply.
• If these Fault Codes have occurred when the operator was running a job, he/she should Initial Actions
have already followed the directions on the screen and to have selected the [CLEAR Perform the following:
ALL] and to have continued the job.
• Ensure that the SLB/RDR Firmware chip is installed correctly. • If fault code 3-381 is present in the Queued Faults on the [SCP] screen, go to 3-381.
• If the fault continues to occur, the operator should abort the job and start over again. • Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
order to force a Self-Test and a system node download. If Fault Code, 3-371, does not
• For MICR Machines, ensure that the LSLB PWB is installed (PL 1.11).
occur, the problem is corrected.
Procedure • If the fault can be cleared but continues to occur, go to the 3-732 Intermittent Internal
Ensure that the latest release of software is loaded on the machine. If the problem continues, Error RAP.
look for related fault codes.
• If power off and power on does not help, replace the EDN Core PWB (PL 1.11)
NOTE: A related fault code is a fault which is associated with other faults by copy count.
Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault ing the NVM Setup Parameters.
codes listed which have occurred within 15 copy counts of 3-370. There are other faults
listed within 15 copy counts of 3-370.
Procedure
Y N Ensure that the latest release of software is loaded on the System Controller and the Printer. If
Replace the MIN SLB/RDR PWB (PL 1.11) the problem continues, look for related fault codes.
NOTE: A related fault code is a fault which is associated with other faults by the number of
Go to the appropriate RAP for the other fault codes listed within 15 copy counts. prints that have been made (within 25 prints of the fault).
Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault
codes listed which have occurred within 25 prints of 3-371. There are other faults listed
within 25 prints of 3-371.
Y N
Go to RAP 3-201.
If the problem continues, fault code 3-371 may be the result of an unusual condition not
detected as a software or noise error (3-471 or 3-461). Call the hot line for instructions. A
request may be made to perform a dC350, Save Crash Data Files, routine (General Pro-
cedures). If Field Engineering cannot be reached, perform the dC 350 routine and contact
Field Engineering at the first opportunity.
Go to the appropriate RAP for the other fault codes listed within 15 copy counts.
If the problem continues, go to the 3-732, Intermittent Internal Error RAP.
3-372 RAP Initial Actions
Fault Code, 3-372, indicates a potential hardware problem was detected on the UIM Core
PWB that required the UIM to perform a software reset. When the fault occurs, a crash file is
• Switch off the Printer power, via the Printer Main Power Switch, S102. Wait 15 seconds,
stored on the rigid disk. This fault will cause the printer to go into the Energy Saver mode dur-
switch on the power in order to force a Self-Test and a system node download. If Fault
ing Operator modes of operation or into the Power Interrupt mode during diagnostic mode of
Code, 3-372, does not occur, the problem is corrected.
operation. Both modes disable the +24 VDC section of the Low Voltage Power Supply.
• If the fault is clearable but continues to occur, go to the 3-732 Intermittent Internal Error
RAP.
• If power on and power off, does not help, replace the UIM Core PWB (PL 2.2). Reconnect the System Bus and Local Bus Cables.

Procedure 3-373 RAP
Ensure that the latest release of software is loaded on the System Controller and the Printer. If
Fault Code, 3-373, indicates a potential hardware problem was detected on the MIN Core
the problem continues, look for related fault codes.
PWB that required the MIN to perform a software reset. When the fault occurs, a crash file is
NOTE: A related fault code is a fault which is associated with other faults by the number of stored on the rigid disk. This fault will cause the printer to go into the Energy Saver mode dur-
prints that have been made (within 25 prints of the fault). ing Operator modes of operation or into the Power Interrupt mode during diagnostic mode of
Initial Actions
Y N Perform the following:
If the problem continues, fault code 3-372 may be the result of an unusual condition not • If Fault Code, 3-383, is present in the Queued Faults on the [SCP] screen, go to the 3-
detected as a software or noise error (3-472 or 3-462). Call the hot line for instructions. A 383 RAP.
request may be made to perform a dC350, Save Crash Data Files, routine (General Pro- • Switch off the printer power via the Main Power Switch, S102. Wait 15 seconds, switch on
cedures). If Field Engineering cannot be reached, perform the dC 350 routine and contact the printer power in order to force a Self-Test and a system node download. If Fault Code,
Field Engineering at the first opportunity. 3-373, does not occur, the problem is corrected.
• When replacing a photoreceptor, the movement of the machine clock encoder may cause
Go to the appropriate RAP for the other fault codes listed within 25 print counts. this fault. If this is the case, no corrective action is required.
• If this fault is clearable but continues to occur, go to the 3-732, Intermittent Internal Error
RAP.
• If power on and power off does not help, replace the MIN Core PWB (PL 1.8)
Procedure
Ensure that the latest release of software is loaded on the System Controller and on the
Printer. If the problem continues, look for related fault codes.
NOTE: A related fault code is a fault which is associated with other faults by print count (within
25 prints).
codes listed which have occurred within 25 print counts of 3-373. There are other faults
listed within 25 print counts of 3-373.
Y N
Go to RAP 3-203. If the problem continues, fault code, 3-373, may be the result of an
unusual condition not detected as a software or noise error (3-473 or 3-463). Call the hot
line for instructions. A request may be made to perform a dC350, Save Crash Data Files,
routine (General Procedures). If Field Engineering cannot be reached perform the dC350
routine and contact Field Engineering at the first opportunity.
Go to the appropriate RAP for the other fault codes listed within 25 print counts.
If the problem continues, go to the 3-732 Intermittent Internal Error RAP.
3-374 RAP • If Fault Code, 3-384, is present in the Queued Faults on the [SCP] screen, go to RAP 3-
384.
Fault Code, 3-374, indicates a potential hardware problem was detected on the PHN Core • Switch off the printer power, via the Printer Main Power Switch, S102. Wait 15 seconds,
PWB that required the PHN to perform a software reset. When the fault occurs, a crash file is switch on the printer power in order to force a Self-Test and a system node download. If
stored on the rigid disk. This fault will cause the printer to go into the Energy Saver mode dur- Fault Code, 3-374, does not occur, the problem is corrected.
ing Operator modes of operation or into the Power Interrupt mode during diagnostic mode of • If this fault is clearable but continues to occur, go to the 3-732, INTERMITTENT INTER-
operation. Both modes disable the +24 VDC section of the Low Voltage Power Supply. NAL ERROR RAP.
• If power on and power off does not help, replace the PHN Core PWB (PL 1.4). Reconnect
Initial Actions the System Bus cable and the Local Bus cable.

Procedure 3-375 RAP
Ensure that the latest release of software is loaded on the System Controller and on the
Fault Code, 3-375, indicates a potential hardware problem was detected on the FSN Core
PWB that required the FSN to perform a software reset. When the fault occurs, a crash file is
NOTE: A related fault code is a fault which is associated with other faults by print count (within stored on the rigid disk. This fault will cause the printer to go into the Energy Saver mode dur-
25 prints). ing Operator modes of operation or into the Power Interrupt mode during diagnostic mode of
Initial Actions
Y N Perform the following:
Go to RAP 3-204. If the problem continues, fault code, 3-374, may be the result of an
unusual condition not detected as a software or noise error (3-474 or 3-464). Call the hot • If Fault Code, 3-385, is present in the Queued Faults on the [SCP] screen, go to RAP 3-
line for instructions. A request may be made to perform a dC350, Save Crash Data Files, 385.
routine (General Procedures). If Field Engineering cannot be reached perform the dC 350 • Switch off the Printer power via the Printer Main Power Switch, S102. Wait 15 seconds,
routine and contact Field Engineering at the first opportunity. switch on the Printer power in order to force a Self-Test and a system node download. If
Fault Code, 3-375, does not occur, the problem is corrected.
Go to the appropriate RAP for the other fault codes listed within 25 print counts. • If this fault is clearable but continues to occur, go to the 3-732, Intermittent Internal Error
If the problem continues, go to the 3-732 Intermittent Internal Error RAP. RAP.
• If power on and power off does not help, check the FSN local bus cables for a short cir-
cuit. If OK, replace the FSN Core PWB (PL 1.16). Reconnect the System Bus cable and
the Local Bus cable.
Procedure
25 print counts).
Y N
Go to RAP 3-205. If the problem continues, fault Code, 3-375, may be the result of an
routine (General Procedures). If Field Engineering cannot be reached perform the dC 350
Go to the 3-732 Intermittent Internal Error RAP.
Fault Code, 3-376, indicates a potential hardware problem was detected on the FSN Core
PWB #2 that required the FSN Core PWB #2 to perform a software reset. When the fault
• If Fault Code, 3-386, is present in the Queued Faults on the [SCP] screen, go to RAP 3-
occurs, a crash file is stored on the Rigid Disk/SMSD. This fault will cause the printer to go into
386.
the Energy Saver mode during Operator modes of operation or into the Power Interrupt
• Switch off the Printer power via the Printer Main Power Switch, S102. Wait 15 seconds,
mode during diagnostic mode of operation. Both modes disable the +24 VDC section of the
switch on the Printer power in order to force a Self-Test and a system node download. If
Low Voltage Power Supply.
• If this fault is clearable but continues to occur, go to the 3-732, Intermittent Internal Error
RAP.

• If power on and power off does not help, check the FSN local bus cables for a short cir- 3-377 RAP
cuit. If OK, replace the FSN Core PWB #2 (PL 1.18). Reconnect the System Bus cable
and the Local Bus cable. Fault Code, 3-377, indicates a failure in the Video Engine PWB internal board. This fault may
Procedure cause the machine to go into the Energy Saver mode and disable the +24 VDC section of the
Low Voltage Power Supply.
Initial Actions
NOTE: A related fault code is a fault which is associated with other faults by print count (within Perform the following:
25 print counts).
• Switch off the power, wait 15 seconds, switch on the power in order to force a Self-Test
and a system node download. If Fault Code, 3-377, does not occur, the problem is cor-
rected.
Y N • If this fault is clearable but continues to occur, go to the 3-732, Intermittent Internal Error
Go to RAP 3-206. If the problem continues, fault Code, 3-376, may be the result of an RAP.
unusual condition not detected as a software or noise error (3-476 or 3-466). Call the hot • If power on and power off does not help, replace the Video Engine PWB (PL 2.2)
line for instructions. A request may be made to perform a dC350, Save Crash Data Files, Procedure
Ensure that the latest release of software is loaded on the machine. If the problem continues,
look for related fault codes.
Go to the appropriate RAP for the other fault codes listed within 25 print counts. NOTE: A related fault code is a fault which is associated with other faults by copy count.
codes listed which have occurred within 15 copy counts of 3-377. There are other faults
listed within 15 copy counts of 3-377.
Y N
Fault Code, 3-377, is the result of an internal software error. If this software problem has
not been identified on the System Software Problem Set, located in the Software Release
Documentation, make a field service report, through SPAR, to engineering. Where possi-
ble perform a Save Current Selections (General Procedures) routine to copy the job
parameters that consistently cause the fault. Also when possible perform an IOT Trace
Log Dump (General Procedures) (This procedure must be performed within minutes after
the malfunction). The probability that engineering will be able to reproduce and thus
resolve these problems are greatly enhanced if these diskettes are received.
Go to the appropriate RAP for the other fault codes listed within 15 copy counts.

3-378 RAP 3-379 RAP
Fault code, 3-378, indicates that the System Controller detected a problem that required it to Fault Code, 3-379, indicates a potential hardware problem was detected on the TMN Core
perform a software reset by transmitting a Meta Reset signal to the printer. The receipt of this PWB that required the TMN to perform a software reset. When the fault occurs, a crash file is
signal causes the printer to perform a Video Loss Purge cycle down. This fault must generally stored on the rigid disk. This fault will cause the printer to go into the Energy Saver mode dur-
be serviced at the System Controller, but the printer may have induced the occurrence of the ing Operator modes of operation or into the Power Interrupt mode during diagnostic mode of
fault code. operation. Both modes disable the +24 VDC section of the Low Voltage Power Supply.

Ensure that the latest releases of software are loaded on the System Controller and the Printer. Perform the following:
If the problem continues, look for related fault codes or messages at both the System Control-
ler and the Printer UI and/or question the customer regarding any unique or stress types of • If Fault Code, 3-389, is present in the Queued Faults on the [SCP] screen, go to 3-389.
applications that have been running. • Switch off the Printer power via the Printer Main Power Switch, S102. Wait 15 seconds,
NOTE: A related fault code is a fault which is associated with other faults by print count. switch on the Printer power in order to force a Self-Test and a system node download. If
Select [SCP] [Last 50]. View the Last 50 shutdowns to determine if there are any other fault • If this fault is clearable but continues to occur, go to the 3-732, Intermittent Internal Error
codes listed which have occurred within 25 prints of 3-378. There have been other faults RAP.
listed within 25 prints of 3-378.
• If power on and power off does not help, check the TMN local bus cables for a short cir-
Y N
cuit. If OK, replace the TMN Core PWB (PL 1.19). Reconnect the System Bus cable and
Go to the System Fault Analysis Procedure in the DP IPS and DP NPS Service Manuals.
the Local Bus cable.
If the problem continues, fault code 3-378 may be the result of an internal software error
in the System Controller. Call the hotline for instructions. A request may be made to per- Procedure
form the IOT Trace routine at the System Controller (General Procedures) with a request Ensure that the latest release of software is loaded on the System Controller and the Printer. If
for some of the most important parameters from the data dump. If Field Engineering can- the problem continues, look for related fault codes.
not be reached, perform the IOT Trace routine and contact Field Engineering at the first
opportunity. If the rollover or occurrence of this fault is application specific, ensure that all
25 print counts).
information and data related with the customers unique application is noted for the Field
Engineer. Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault
Go to the appropriate RAP for the fault codes listed within 25 prints. listed within 25 print counts of 3-379.
Y N
Go to RAP 3-207. If the problem continues, Fault Code, 3-379, may be the result of an
3-380 RAP If power off and power on does not help, switch off the Printer power. Disconnect the two Sys-
tem Bus cables, P700/J3 and P701/J4, on the UIM Core PWB and move the Termination
Fault Code, 3-380, indicates a download failure for the UIM Core PWB Boot ROM. This fault is Jumper, J5, on the UIM Core PWB to the pin 3 (TEST) and pin 2 position. Switch on the Printer
shown on the digital display as alternating "8888888888" and "0000000000". This fault will power. The problem continues to occur.
cause the machine to go into the Power Interrupt mode and disable the +24 VDC section of Y N
the Low Voltage Power Supply. Go to the 3-702, System Bus Bad PWB Isolation RAP.
Procedure Reconnect the two System Bus cables and move the Termination Jumper back to pin 1
(NORM) and pin 2 position of the UIM Core PWB. Go to RAP 3-390.
Switch off the Printer power, wait 15 seconds, then switch on the power in order to force a Self-
Test and a system node download.

3-381 RAP 3-382 RAP
Fault code, 3-381, indicates an EDN Core PWB download failure. This fault will cause the Fault Code, 3-382, indicates a download failure in the UIM Core PWB. This fault will cause the
Printer to go into the Energy Saver mode and disable the +24 VDC section of the LVPS. machine to go into the Energy Saver mode and disable the +24 VDC section of the Low Volt-
age Power Supply.
Procedure
Switch the Printer power off, then on, to force a Self-test and a system node download. If Procedure
power off and on does not help, switch off the Printer power. Disconnect the System Bus cable, Switch off the Printer power, wait 15 seconds, switch on the power in order to force a Self-Test
P224/J105 at the Printer Card Cage Backplane. Switch on the Printer power. The problem is and a system node download. If Fault Code, 3-382, does not occur, the problem is corrected.
still present.
Y N If the problem continues, replace the UIM Core PWB (PL 2.2).
Reconnect the System Bus cable, P224/J105. Go to RAP 3-702.
Reconnect the System Bus cable, P224/J105. Go to RAP 3-375.
3-383 RAP 3-384 RAP

Fault Code, 3-383, indicates a download failure in the MIN Core PWB. This fault will cause the Fault Code, 3-384, indicates a download failure in the PHN Core PWB. This fault will cause the
machine to go into the Energy Saver mode and disable the +24 VDC section of the Low Volt- machine to go into the Energy Saver mode and disable the +24 VDC section of the Low Volt-
age Power Supply. age Power Supply.
Procedure Procedure
Switch off the Printer power, wait 15 seconds, switch on the power in order to force a Self-Test Switch off the Printer power, wait 15 seconds, switch on the power in order to force a Self-Test
and a system node download. If Fault Code, 3-383, does not occur, the problem is corrected. and a system node download. If Fault Code, 3-384, does not occur, the problem is corrected.
If the problem continues, switch off the power. Exchange the MIN Core PWB with the PHN If the problem continues, switch off the power. Exchange the PHN Core PWB with the MIN
Core PWB. Switch on the power. Check the Queued Faults on the [SCP] screen. Fault Core PWB. Switch on the power. Check the Queued Faults on the [SCP] screen. Fault
Code, 3-383, is present. Code, 3-384, is present.
Y N Y N
Fault Code, 3-384, is present. Fault Code, 3-383, is present.
Y N Y N
The problem is corrected. The problem is corrected.
Replace the PWB which is now in the PHN Core PWB position (PL 1.4) Replace the PWB which is now in the MIN Core PWB position (PL 1.8)
Go to the 3-390 RAP. Go to RAP 3-390.

3-385 RAP 3-386 RAP
Fault Code, 3-385, indicates a download failure in the FSN Core PWB #1. This fault will cause Fault Code, 3-386, indicates a download failure in the FSN Core PWB #2. This fault will cause
the machine to go into the Energy Saver mode and disable the +24 VDC section of the Low the machine to go into the Energy Saver mode and disable the +24 VDC section of the Low
Voltage Power Supply. Voltage Power Supply.
Procedure Procedure
Switch off the Printer power, wait 15 seconds, switch on the power in order to force a Self-Test Switch off the Printer power, wait 15 seconds, switch on the power in order to force a Self-Test
and a system node download. If Fault Code, 3-385, does not occur, the problem is corrected. and a system node download. If Fault Code, 3-386, does not occur, the problem is corrected.
If the problem continues, switch off the Printer power. Exchange the FSN Core PWB #1 with If the problem continues, switch off the Printer power. Exchange the FSN Core PWB #1 with
the PHN Core PWB. Switch on the Printer power. Check the Queued Faults on the [SCP] the FSN Core PWB #2. Switch on the Printer power. Check the Queued Faults on the [SCP]
screen. Fault Code, 3-385, is present. screen. Fault Code, 3-386, is present.
Y N Y N
Fault Code, 3-384, is present. Fault Code, 3-385, is present.
Y N Y N
The problem is corrected. The problem is corrected.
Replace the PWB which is now in the PHN Core PWB position (PL 1.4) Replace the PWB which is now in the FSN Core PWB #1 position (PL 1.18)
Go to the 3-390 RAP. Go to RAP 3-390.

3-387 RAP 3-389 RAP
Fault Code, 3-387, indicates a download failure of the Video Engine PWB. This fault is dis- Fault Code, 3-389, indicates a download failure in the TMN Core PWB. This fault will cause the
played on the CRT as an alternating "1" and a "blank screen". This fault may cause the printer to go into the Energy Saver mode and disable the +24 VDC section of the Low Voltage
machine to go into the Energy Saver mode and disable the +24 VDC section of the Low Volt- Power Supply.
age Power Supply.
Procedure
Procedure Switch off the Printer power, wait 15 seconds, switch on the power in order to force a Self-Test
The 7-Segment display shows alternating "8888888888" and "0000000000" or and a system node download. If Fault Code, 3-389, does not occur, the problem is corrected.
"8888888888" and "----------". If the problem continues, switch off the Printer power. Exchange the TMN Core PWB with the
Y N PHN Core PWB. Switch on the Printer power. Check the Queued Faults on the [SCP] screen.
+5.0 VDC is measured between TH6 (+) and TH7 (-) on the Video Engine PWB. Fault Code, 3-389, is present.
Y N Y N
Go to the +5 VDC wirenet, Figure 30, (WIRING DATA), and check the wires, 1223, Fault Code, 3-384, is present.
1224, 1228, and 1257, for an open circuit. If the wires are good, replace the Video Y N
Engine PWB (PL 2.2) The problem is corrected.
Power Normal LED, CR10, on the Video Engine PWB is lit. Replace the PWB which is now in the PHN Core PWB position (PL 1.4)
Y N
Go to the +12 VDC Power Normal signal wirenet, Figure 57, (WIRING DATA), and Go to the RAP 3-390.
check the wire, 1231, for an open circuit. If the wire is good, replace the Video
Engine PWB (PL 2.2)
Replace the ribbon cable between the UIM Core PWB and the Video Engine PWB (PL
2.3)
If problem continues, go to the 3-390.
Go to RAPs 3-380 and 3-381.

3-390 RAP If the problem continues, Run dC 357. At the completion of the dC357 routine a code
will be generated on the seven segment display. Follow the instructions for the code
Fault Code, 3-390, indicates that the UIM Core PWB detected a Rigid Disk/SMSD failure. This obtained that are included in the dC357 routine.
fault will cause the machine to go into the Energy Saver mode and will disable the +24 VDC If the problem continues perform the following:
section of the Low Voltage Power Supply. Switch off power. Check to ensure that none of the wires in the neck of the UI have
become worn and are shorting to the frame or each other.
Initial Actions If the problem continues escalate the call to obtain assistance.
• (W/ Tag U-17 and U-20)
Ensure that pin 1 of the 40 pin ribbon cable of the Rigid Disk/SMSD is connected to pin 1
dC 325, save critical files
of the corresponding connector on the UIM Core PWB.
dC 322, Rigid Disk/SMSD formatter
NOTE: Pin 1 on the Ribbon Cable is indicated by the colored stripe. A full software upgrade
dC 326, Restore Critical Disk files
Pin 1 is closest to the DC power connector of the Rigid Disk/SMSD.
• Voltage is +12.0 VDC from pin 1 (+) to pin 2 (-) of connector P515, at the Rigid Disk/
(W/O Tag U-17). Ensure that pin 1 of the two ribbon cables of the Rigid Disk Drive (34 and SMSD.
20 pin ribbon cables) are connected to pin 1 of their corresponding connectors on the UIM Y N
Core PWB. Voltage is +12 VDC from TH5 (+) to TH8 (-) on the LVPS.
Y N
Procedure Go to the 1-714 +12 VDC RAP.
Load and run the diagnostic program dC 350, General Procedures. The seven segment dis-
play stops with an error before displaying a crash code. Go to the +12 VDC Wirenet, Figure 57, (WIRING DATA), and check the wire, 1211D, for
Y N an open circuit.
Error codes 22 xx xx xx are displayed while scrolling through the error codes.
Y N Voltage is +5.0 VDC from pin 4 (+) to pin 3 (-) of the connector P515, at the Rigid Disk/
Voltage is +12.0 VDC from pin 1 (+) to pin 2 (-) of connector P515, at the Rigid SMSD.
Disk. Y N
Y N Go to the +5 VDC Wirenet, Figure 30, (WIRING DATA), and check the wire, 1209, for an
Voltage is +12 VDC from TH5 (+) to TH8 (-) on the LVPS. open circuit.
Y N
Go to the 1-714 +12 VDC LVPS RAP. Switch off the power. Replace the Ribbon Cable (34 pin ribbon cable w/o Tag U-17) between
the Rigid Disk/SMSD and the UIM Core PWB (PL 2.2)
Go to the +12 VDC Wirenet, Figure 57, (WIRING DATA), and check the wire, If the problem continues, switch off power and disconnect and then reconnect the Local Bus
1211D, for an open circuit. cable between the UIM Core PWB and the CPIOP PWB.
(W/O Tag U-17)). If the problems continues, switch off the power and replace the Ribbon Cable
Voltage is +5.0 VDC from pin 4 (+) to pin 3 (-) of the connector P515, at the (20 pin), between the Rigid Disk and the UIM Core PWB (PL 2.3).
Rigid Disk. If the problem continues, switch off the power and replace the UIM Core PWB (PL 2.3)
Y N If the problem continues, run dC350. At the completion of the dC357 routine a code will be
Go to the +5 VDC Wirenet, Figure 30, (WIRING DATA), and check the wire, generated on the seven segment display. Follow the instructions for the code obtained that are
1209, for an open circuit. included in the dC 357 routine, General Procedures.
If the problem continues switch off power. Check to ensure that none of the wires in the neck of
Switch off the power. Replace the Ribbon Cable (34 pin ribbon cable w/o Tag U-17) the UI have become worn and are shorting to the frame or each other.
between the Rigid Disk/SMSD and the UIM Core PWB (PL 2.2) If the problem continues escalate the call to obtain assistance.
(W/O Tag U-17). If the problems continues, switch off the power and replace the Rib-
bon Cable (20 pin), between the Rigid Disk and the UIM Core PWB (PL 2.3).
If the problem continues, switch off power and disconnect and then reconnect the
Local Bus cable between the UIM Core PWB and the CPIOP PWB.
If the problem continues, switch off the power and replace the Ribbon Cable (20
wires) between the Rigid Disk and the UIM Core PWB (PL 2.3)
If the problem continues, switch off the power and replace the UIM Core PWB (PL
2.2). Reconnect the System Bus and Local Bus cables.

3-390, 3-391, 3-393 ?-314 No Product Name Assigned
3-391, 3-393 RAP 3-392 RAP
Fault Code, 3-391, indicates that the UIM Core PWB detected a Rigid Disk access failure. This Fault Code, 3-392, indicates that the Video Engine PWB detected a Rigid Disk/SMSD failure.
fault may cause the machine to go into the Energy Saver mode and disable the +24 VDC sec- This fault may cause the machine to go into the Energy Saver mode and disable the +24 VDC
tion of the Low Voltage Power Supply. section of the Low Voltage Power Supply.
Fault Code, 3-393, indicates that the Video Engine PWB detected a Rigid Disk access failure. Procedure
This fault may cause the machine to go into the Power Interrupt mode and disable the +24 Go to the 3-390 RAP.
Procedure
Replace the ribbon cable between the UIM Core PWB and the Video Engine PWB (PL 2.2)
If the problem continues, replace the UIM Core PWB (PL 2.2)

3-401 RAP Reconnect the cable, P700/J3. Disconnect the System Bus Cable, P701/J4, at
the UIM Core PWB. Voltage is greater than +3.5 VDC at the CABLE
Fault Code, 3-401, indicates that the EDN Core PWB temporarily could not communicate with between the inside wire (+) and the outside shield (-).
any other node on the system bus. During system boot, the Boot ROM on the EDN Core PWB Y N
causes a message to be sent on the system bus to itself. If the message is not detected by the Replace the UIM Core PWB (PL 2.3)
EDN system bus receiver this fault is declared. The cause of this fault could be a failure of any
one of the five Core PWBs, in the system bus cabling that could prevent system bus communi- Replace the System Bus cable between the PHN Core PWB and the UIM Core
cation, or by any bad or incorrect termination of the system bus. This fault is only logged in PWB (PL 2.3)
NVM.
Reconnect the cable, P350/J3. Disconnect the System Bus cable, J361/J4, at the
Initial Actions PHN Core PWB. Voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON
Perform the following: the PHN Core PWB, between the inside wire (+) and the outside base (-).
Y N
• Visually inspect all connectors on the EDN Core PWB for loose or improperly mated con- Replace the PHN Core PWB (PL 1.4)
nectors.
Replace the System Bus cable between the MIN Core PWB and the PHN Core PWB
• If this fault is clearable but continues to occur, go to the 3-731, Intermittent Communica-
(PL 1.4).
tions RAP.
• Check that the System Bus connectors are connected properly by referring to the System Reconnect the cable, P230/J3. Disconnect the System Bus cable, J224/J4, at the MIN
Bus Cable Connections Table. Core PWB. Voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the MIN
• Check that the Shared Line Termination Jumper on the Core PWBs are properly posi- Core PWB, between the inside wire (+) and the outside base (-).
tioned by referring to the Core Termination Jumper Table. Y N
Procedure Replace the MIN Core PWB (PL 1.8)
NOTE: Check the System Bus cable connectors for bent pins when making any voltage mea- Replace the System Bus cable between the MIN Core PWB and the Backplane for the
surements on the System Bus cable. EDN Core PWB (PL 1.11)
Disconnect the System Bus cable, P224/J105, at the Backplane for the EDN Core PWB. Volt-
age is greater than +3.5 VDC at the CABLE between the inside wire (+) and the outside
• Bent pins at the system bus connector, J105, on the Backplane.
shield (-).
Y N • Bent pins in the EDN Core PWB connectors.
Reconnect the cable, P224/J105. Disconnect the System Bus cable, P230/J3, at the MIN If OK, replace the EDN Core PWB (PL 1.11)
Core PWB. Voltage is greater than +3.5 VDC at the CABLE between the inside wire
ing the NVM Setup Parameters.
Y N
Reconnect the cable, P230/J3. Disconnect the System Bus cable, P350/J3, at the If the problem continues, go to the 3-702, System Bus Bad PWB Isolation RAP.
PHN Core PWB. Voltage is greater than +3.5 VDC at the CABLE between the
Y N Table 1 System Bus Cable Connections Table
Reconnect the cable, P350/J3. Disconnect the System Bus cable, P700/J3, at
FROM PWB CONN TO PWB CONN
the UIM Core PWB. Voltage is greater than +3.5 VDC at the CABLE
between the inside wire (+) and the outside shield (-). UIM Core J4/P701 FSN Core J3/4402
Y N UIM Core J3/P700 PHN Core J3/P350
Reconnect the cable, P700/J3. Disconnect the System Bus cable, 4402/ PHN Core J4/P361 MIN Core J3/P230
J3, at the FSN Core PWB. Voltage is greater than +3.5 VDC at the
MIN Core J4/J224 EDN Core J105/P224
CONNECTOR, J3, ON the FSN Core PWB, between the inside wire (+)
Table 2 Core Termination Jumper Table
Y N
Replace the FSN Core PWB (PL 1.16) PWB JUMPER POSITION
Replace the System Bus cable between the UIM Core and the FSN Core
PWB (PL 1.16) FSN Core (J2) Pin 3 (TEST) & Pin 2
A B
A B
Table 2 Core Termination Jumper Table
PWB JUMPER POSITION
PHN Core (J2) Pin 1 (NORM) & Pin 2
MIN Core (J2) Pin 1 (NORM) & Pin 2

A B C D
A B C D


3-402 RAP Reconnect the System Bus cable at P700/J3. Disconnect the System Bus cable at P224/J105
at the Printer Backplane. The voltage is greater than +3.5 VDC at the CABLE, between the
Fault Code, 3-402, indicates that the EDN Core PWB temporarily could not communicate with inside wire (+) and the outside shield (-).
the UIM Core PWB. The UIM has failed to acknowledge a receipt from the EDN Core PWB. Y N
This message could be an operational message or a communication check message (poll) Reconnect the cable P224/J105. Disconnect the System Bus cable at P230/J3 at the MIN
sent by the EDN. The polling message is transmitted at least once every 12 seconds (adjust- Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside
able in service mode). A crash file is stored on the Rigid Disk/SMSD and can be accessed with wire (+) and the outside shield (-).
diagnostic floppy utility dC350. This fault is logged in NVM only. Y N
Reconnect the cable P230/J3. Disconnect the System Bus cable at P350/J3 on the
Initial Actions PHN Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between
Perform the following: the inside wire (+) and the outside shield (-).
Y N
Replace the System Bus cable between the PHN Core PWB and the UIM Core
• If screen icons will not respond, check for reversed Bus cables J4 and J6 on the UIM Core
PWB. PWB (PL 2.3)
• Visually inspect all connectors on the UIM Core PWB for loose or improperly mated con-
Reconnect the System Bus cable at P350/J3. Disconnect the System Bus cable at
nectors.
J361/J4 on the PHN Core PWB. The voltage is greater than +3.5 VDC at the
• If this fault is clearable but continues to occur, go to the 3-731, Intermittent Communica- CONNECTOR, J4, ON the PHN Core PWB between the inside wire (+) and the
tions RAP. outside base (-).
• If the Top 15 Control System faults show a history of this or other 3-20X faults perform the Y N
diagnostic floppy program dC 350, Save Crash Data Files (General Procedures), and Replace the PHN Core PWB (PL 1.4)
analyzing the data. Replace the System Bus cable between the PHN Core PWB and the MIN Core PWB
Procedure (PL 1.8)
NOTE: Check the System Bus cable connectors for bent pins when making voltage measure- Reconnect the System Bus cable P230/J3. Disconnect the System Bus cable J224/J4 on
ments on the System Bus cable. the MIN Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4,
ON the MIN Core PWB between the inside wire (+) and the outside base (-).
Disconnect the System Bus cable P700/J3, at the UIM Core PWB. The voltage is greater
Y N
than +3.5 VDC at the CONNECTOR, J3, ON the UIM Core PWB between the inside wire
(+) and the outside base (-).
Y N
Reconnect the cable at P700/J3. Disconnect the System Bus cable, P701/J4 at the UIM
(PL 1.11)
Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside
Y N
Reconnect the cable P701/J4. Disconnect then System Bus cable, 4402/J3 at the
Table 1 CORE TERMINATION JUMPER TABLE
FSN Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3,
ON the FSN Core PWB between the inside wire (+) and the outside base (-). PWB JUMPER POSITION
Y N UIM Core (J5) Pin 1 (NORM) & Pin 2
Reconnect the System Bus cable at 4402/J3. Check the Shared Line Termina-
FSN Core (J2) Pin 3 (TEST) & Pin 2
tion Jumper, J2, on the FSN Core PWB for a proper connection. The jumper
should be on pins 2 and 3 (TEST). The jumper is positioned properly. PHN Core (J2) Pin 1 (NORM) & Pin 2
Y N MIN Core (J2) Pin 1 (NORM) & Pin 2
Replace the System Bus cable between the UIM Core PWB and the FSN Core PWB
(PL 1.16)



A
A

3-403 RAP Y N
Reconnect the cable, 4402/J3. Check the Shared Line Termination Jumper, J2,
Fault Code, 3-403, indicates that the MIN Core PWB has temporarily failed to acknowledge on the FSN Core PWB, and determine if it is properly connected. The jumper
receipt of a message from another system node. This message could be an operational mes- should be between pins 2 and 3. The terminator is positioned properly.
sage from any system node or a communication check (poll) sent by the EDN Core PWB. The Y N
polling message is transmitted at least once every 12 seconds (adjustable in the service Make the proper termination.
mode). A crash file is stored on the Rigid Disk/SMSD and can be accessed with diagnostic
floppy utility dC350. This fault is logged in NVM only. Replace the FSN Core PWB (PL 1.16)
Initial Actions Reconnect the cable, 4402/J3. Disconnect the System Bus cable, P701/J4, at the
Perform the following: UIM Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between
Y N
• Visually inspect all connectors on the MIN Core PWB for loose or improperly mated con-
nectors. Replace the System Bus cable between the UIM Core PWB and the FSN Core
PWB (PL 1.16)
tions RAP.
• If the Top 15 Control System faults show a history of this or other 3-20X faults perform the
diagnostic floppy program dC 350, Save Crash Data Files (General Procedures), and Reconnect the cable, P700/J3. Disconnect the System Bus cable, P350/J3, at the PHN
record the crash codes and the meter A reading. Elevate the call to obtain assistance Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside
analyzing the data. wire (+) and the outside shield (-).
Procedure Y N
The Power Normal LED, CR1, ON the MIN Core PWB is lit. Replace the System Bus cable between the PHN Core PWB and the UIM Core PWB
Y N (PL 2.3)
+5.0 VDC is measured between TH23 (+) and TH22 (-) ON the MIN Core PWB.
Y N Reconnect the cable, P350/J3. Disconnect the System Bus cable, J361/J4, at the PHN
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA), and check the wires, 1000A Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the
PHN Core PWB, between the inside wire (+) and the outside base (-).
and 1024, for an open circuit. If the wires are good, replace the MIN Core PWB (PL
1.8) Y N
Replace the System Bus cable between the PHN Core PWB and the MIN Core PWB (PL
Check the Identification Connector, P244/J5, on the MIN Core PWB to make sure that the cor- 1.8)
rect pins are connected and that the pins which are connected together have continuity. Refer
to the MIN CORE PWB IDENTIFICATION CONNECTOR TABLE. The connector is wired Reconnect the cable, P230/J3. Disconnect the System Bus Cable, J224/J4, at the MIN Core
properly. PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the MIN Core
Y N
Reconnect the System Bus cable at J224/J4. Check the Shared Line Termination Jumper,
J2, on the MIN Core PWB, in order to determine if it is properly connected. The jumper
NOTE: Check the System Bus cable connectors for bent pins when making voltage measure-
ments on the System Bus cable. should be on pin 1 (NORM) and pin 2. The termination jumper is positioned correctly.
Y N
Disconnect the System Bus cable, P230/J3, from the MIN Core PWB. The Voltage is greater Make the proper termination.
than +3.5 VDC at the CABLE, between the inside wire (+) and the outside shield (-).
Y N Replace the MIN Core PWB (PL 1.8)
Reconnect the cable, P230/J3. Disconnect the System Bus cable, P700/J3, at the UIM
Core PWB. The Voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the Reconnect the cable, J224/J4. Disconnect the System Bus cable, P224/J105, at the Printer
UIM Core PWB, between the inside wire (+) and the outside base (-). Backplane. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire
Y N (+) and the outside shield (-).
Reconnect the cable, P700/J3. Disconnect the System Bus cable, 4402/J3 at the Y N
FSN Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3, Replace the System Bus cable between the MIN Core PWB and the Printer Backplane
ON the FSN Core PWB between the inside wire (+) and the outside base (-). (PL 1.11)

Replace the MIN Core PWB (PL 1.8) Table 1 MIN CORE PWB IDENTIFICATION CONNECTOR TABLE
Table 1 MIN CORE PWB IDENTIFICATION CONNECTOR TABLE
MIN Core P244/J5 Pin 1 & Pin 9 (connected)


A B
A B C
C
3-404 RAP

Y N
Fault Code, 3-404, indicates that the PHN Core PWB temporarily failed to acknowledge a
receipt of a message from another system node. This message could be an operational mes- Reconnect the cable, P700/J3. Disconnect the System Bus cable, 4402/J3, at
sage from any system node or a communication check (poll) sent by the EDN Core PWB. The the FSN Core PWB. The voltage is greater than +3.5 VDC at the CONNEC-
TOR, J3, between the inside wire (+) and the outside base(-).
polling message is transmitted at least once every 12 seconds (adjustable in the service
mode). A crash file is stored on the Rigid Disk/SMSD and can be accessed with diagnostic Y N
floppy utility dC350. This fault is logged in NVM only. Check the Shared Line Termination Jumper, J2, on the FSN Core PWB, in
order to determine if it is properly connected. The jumper should be on pin
3 (TEST) and pin 2. The termination jumper is positioned correctly.
Initial Actions Y N
Perform the following: Make the proper termination.
• Visually inspect all connectors on the PHN Core PWB for loose or improperly mated con- +5.0 VDC is measured between TH23 (+) and TH22 (-) ON the FSN
nectors. Core PWB.
• If this fault is clearable but continues to occur, go to the 3-731, Intermittent Communica- Y N
tions RAP. Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and wires,
• Check the Queued faults for a 3-203. If present, go to the 3-203 RAP. 61A and 61J for an open circuit. If wires are OK, replace the FSN
• If the Top 15 Control System faults show a history of this or other 3-20X faults perform the Core PWB. (PL 1.16)
diagnostic floppy program dC 350, Save Crash Data Files (General Procedures), and
analyzing the data.
Reconnect the cable, 4402/J3. Disconnect the System Bus cable at P701/J4, at
Procedure the UIM Core PWB. The voltage is greater than +3.5 VDC at the CABLE,
The Power Normal LED, CR1, ON the PHN Core PWB is lit. between the inside wire (+) and the outside shield (-).
Y N Y N
+5.0 VDC is measured between TS23 (+) to TS22 (-) ON the PHN Core PWB. Replace the System Bus cable between the UIM Core PWB and the FSN
Y N Core PWB (PL 1.16)
Go to the +5 VDC wirenet, Figure 31, (WIRING DATA) and check the wires, 532 and
538, for an open circuit. If wires are OK, replace the PHN Core PWB (PL 1.4) Replace the UIM Core PWB (PL 2.3)
Replace the PHN Core PWB (PL 1.4) Replace the System Bus cable between the UIM Core PWB and the PHN Core PWB
(PL 1.4)
Check the Identification Connector, P372/J5, on the PHN Core PWB to ensure the correct pins
are connected and the pins that are connected together have continuity. Refer to the PHN Replace the PHN Core PWB (PL 1.4)
CORE PWB IDENTIFICATION CONNECTOR TABLE. The connector is wired properly.
Y N Reconnect the cable, J361/J4. Disconnect the System Bus cable P230/J3, on the MIN Core
Rewire or repair the connector to the proper termination. PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
NOTE: Check the System Bus cable connectors for bent pins when making voltage measure- Y N
ments on the System Bus cable. Replace the System Bus cable between the MIN Core PWB and the PHN Core PWB (PL
1.4)
Disconnect the System Bus cable, J361/J4, at the PHN Core PWB. The Voltage is greater
than +3.5 VDC at the CONNECTOR, J4, between the inside wire (+) and the outside base
Reconnect the cable at P230/J3. Disconnect the System Bus cable at J224/J4 on the MIN
(-).
Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, between the
Y N
Reconnect the cable, J361/J4. Disconnect the System Bus cable, P350/J3, at the PHN
Y N
Core PWB. The voltage is greater than +3.5 VDC at the CABLE between the inside
Y N
Reconnect the cable, J224/J4. Disconnect the System Bus cable P224/J105 on the Printer
Reconnect the cable, P350/J3. Disconnect the System Bus cable, P700/J3, at the
Backplane. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire
UIM Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3,

Y N Reconnect the cable P224/J105. Replace the PHN Core PWB (PL 1.4)
(PL 1.11) Table 1 PHN CORE PWB IDENTIFICATION CONNECTOR TABLE
PHN Core P372/J5 Pin 1 & Pin 9 (not connected)


A
A B
B C
3-405 RAP

NOTE: Check the System Bus cable connectors for bent pins when making voltage measure-
Fault Code, 3-405, indicates that the FSN Core PWB #1 has temporarily failed to acknowledge
a receipt of a message from another system node. This message could be an operational mes- ments on the System Bus cable.
sage from any system node or a communication check (poll) sent by the EDN Core PWB. The Voltage is greater than +3.5 VDC at the CONNNECTOR, J3, ON the FSN Core PWB
polling message is transmitted at least once every 12 seconds (adjustable in the service between the inside wire (+) and the outside base (-).
floppy utility dC350. This fault is logged in NVM only. Check the Shared Line termination jumper, J2, on the FSN Core PWB, to determine if it is
Initial Actions positioned correctly.
PWB. Replace the FSN Core PWB (PL 1.16)
• Visually inspect all connectors on the FSN Core PWB for loose or improperly mated con-
nectors. Reconnect the cable, 4402/J3. Disconnect the System Bus Cable, P701/J4 on the UIM Core
PWB. The voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and
the outside shield (-).
tions RAP.
Y N
• If the Top 15 Control System faults show a history of this or other 3-20X faults perform the Replace the System Bus cable from the UIM Core PWB to the FSN Core PWB (PL 1.16)
record the crash codes and the meter A reading. Elevate the call to obtain assistance Reconnect the cable, P701/J4. Disconnect the System Bus cable, P700/J3, on the UIM Core
analyzing the data. PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the UIM Core
• Visually inspect all connectors on the MIN Core PWB, PHN Core PWB, and the UIM Core PWB between the inside wire (+) and the outside base (-).
PWB for loose or improperly mated connectors. Y N
Procedure Replace the UIM Core PWB (PL 2.3)
The Power Normal LED, CR1, ON the FSN Core PWB is lit.
Reconnect the cable at P700/J3. Disconnect the System Bus cable at P350/J3, on the PHN
Y N
Core PWB. The voltage is greater than +3.5 VDC, at the CABLE, between the inside wire
+5.0 VDC is measured between TH23 (+) and TH22 (-) ON the FSN Core PWB.
Y N
Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61A and
61J, for an open circuit. If the wires are good, replace the FSN Core PWB (PL 1.16)
PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, on the PHN Core
Check the Identification Connector, P4056/J5, on the FSN Core PWB in order to make sure
Y N
that the correct pins are connected and that the pins which are connected together have conti-
nuity. Refer to the FSN CORE PWB IDENTIFICATION CONNECTOR TABLE. The connec-
tor is wired properly.
Reconnect the cable at J361/J4. Disconnect the System Bus cable at P230/J3, on the MIN
Y N
Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire
Y N
correct pins are connected and that they have continuity. The connector should be on pins 1
1.4)
Y N
Reconnect the cable at P230/J3. Disconnect the System Bus cable at J224/J4, on the MIN
Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the MIN
Core PWB between the inside wire (+) and the outside base (-).
Disconnect the System Bus cable, 4402/J3, from the FSN Core PWB.
Y N

Reconnect the cable at J224/J4. Disconnect the System Bus cable P224/J105 at the Back- Replace the FSN Core PWB (PL 1.16)
between the inside wire (+) and the outside shield (-). Table 1 FSN CORE PWB IDENTIFICATION CONNECTOR TABLE
Y N
FSN Core 4056/J5 Pin 1 & Pin 9 (connected)


A
A B
3-406 RAP

Y N
Fault Code, 3-406, indicates that the FSN Core PWB #2 has temporarily failed to acknowledge
a receipt of a message from another system node. This message could be an operational mes- Check the Shared Line termination jumper, J2, on the FSN Core PWB #2, to determine if
sage from any system node or a communication check (poll) sent by the EDN Core PWB. The it is properly connected. The jumper should be on pin 3 (TEST) and pin 2. The jumper is
positioned correctly.
polling message is transmitted at least once every 12 seconds (adjustable in the service
floppy utility dC350. This fault is logged in NVM only. Make the proper termination.

Initial Actions
Perform the following: Reconnect the System Bus cable, 4092/J3. Disconnect the System Bus Cable, 4091/J4, from
the FSN Core PWB #1. Voltage is greater than +3.5 VDC at the cable between the inside
• If screen icons will not respond, check for reversed Bus cables J4 and J6 on the UIM Core wire (+) and the outside base (-).
PWB. Y N
• Visually inspect all connectors on the FSN Core PWB #2 for loose or improperly mated Replace the System Bus Cable from the FSN Core PWB #2 to the FSN Core PWB #2 (PL
connectors. 1.18)
tions RAP. Reconnect the cable 4091/J4. Disconnect the System Bus CABLE 4402/J3 on the FSN Core
• If the Top 15 Control System faults show a history of this or other 3-20X faults perform the PWB #1. The voltage is greater than 3.5 VDC at the CONNECTOR, J3 ON the FSN Core
PWB #1.
record the crash codes and the meter A reading. Elevate the call to obtain assistance Y N
analyzing the data. Replace the FSN Core PWB #1 (PL 1.18)
• Visually inspect all connectors on the MIN Core PWB, PHN Core PWB, UIM Core PWB,
Reconnect the cable, 4402/J3. Disconnect the System Bus Cable, P701/J4 on the UIM Core
FSN Core PWB #1, and the FSN Core PWB #2 for loose or improperly mated connectors.
PWB. The voltage is greater than +3.5 VDC at the CABLE between the inside wire (+) and
Procedure the outside shield (-).
The Power Normal LED, CR1, ON the FSN Core PWB #2 is lit. Y N
Y N Replace the System Bus cable from the UIM Core PWB to the FSN Core PWB (PL 1.18)
+5.0 VDC is measured between TH23 (+) and TH22 (-) ON the FSN Core PWB #2.
Y N Reconnect the cable, P701/J4. Disconnect the System Bus cable, P700/J3, on the UIM Core
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 61A and PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J3, ON the UIM Core
61K, for an open circuit. If the wires are good, replace the FSN Core PWB #2 (PL PWB between the inside wire (+) and the outside base (-).
1.18) Y N
Reconnect the cable at P700/J3. Disconnect the System Bus cable at P350/J3, on the PHN
Check the Identification Connector, P4056/J5, on the FSN Core PWB #2 in order to make sure Core PWB. The voltage is greater than +3.5 VDC, at the CABLE, between the inside wire
that the correct pins are connected and that the pins which are connected together have conti- (+) and the outside shield (-).
nuity. Refer to the FSN CORE PWB #2 IDENTIFICATION CONNECTOR TABLE. The con- Y N
nector is wired properly. Replace the System Bus cable from the UIM Core PWB and the PHN Core PWB (PL 1.4)
Y N
Rewire or repair the connector to the proper termination. Reconnect the cable, P350/J3. Disconnect the System Bus cable, J361/J4, on the PHN Core
PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, on the PHN Core
Check the Termination Connector, J5, on the UIM Core PWB, in order to make sure that the PWB, between the inside wire (+) and the outside base (-).
correct pins are connected and that they have continuity. The connector should be on pins 1 Y N
and 2. The termination connector is wired properly. Replace the PHN Core PWB (PL 1.8)
Y N
Rewire or repair the connector. Reconnect the cable at J361/J4. Disconnect the System Bus cable at P230/J3, on the MIN
Core PWB. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire
Disconnect the System Bus cable, 4092/J3, from the FSN Core PWB #2. Voltage is greater (+) and the outside shield (-).
than +3.5 VDC at the CONNECTOR, J3, ON the FSN Core PWB #2 between the inside Y N
wire (+) and the outside base (-). Replace the System Bus cable between the MIN Core PWB and the PHN Core PWB (PL
1.4)

Reconnect the cable at P230/J3. Disconnect the System Bus cable at J224/J4, on the MIN Replace the FSN Core PWB #2 (PL 1.18)
Core PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the MIN
Core PWB between the inside wire (+) and the outside base (-). Table 1 FSN CORE PWB #2 IDENTIFICATION CONNECTOR TABLE
Y N
FSN Core 4056/J5 Pin 1 & Pin 9 (not connected)
Reconnect the cable at J224/J4. Disconnect the System Bus cable P224/J105 at the Back- Pin 2 & Pin 10 (connected)
plane, for the EDN Core PWB. The voltage is greater than +3.5 VDC at the CABLE, Pin 3 & Pin 11 (connected)
Y N


A
A
3-407 RAP

Fault Code, 3-407, indicates that the TMN Core PWB has temporarily failed to acknowledge a
receipt of a message from another system node. This message could be an operational mes- surements on the System Bus cable.
sage from any system node or a communication check (poll) sent by the EDN Core PWB. The Voltage is greater than +3.5 VDC at the connector, J3, ON the TMN Core PWB, between
polling message is transmitted at least once every 12 seconds (adjustable in the service the inside wire (+) and the outside base (-).
floppy utility dC350. This fault is logged in NVM only. Check the Shared Line termination jumper, J2, on the TMN Core PWB, to determine if it is
Initial Actions positioned correctly.
PWB. Replace the TMN Core PWB (PL 1.19).
• Visually inspect all connectors on the TMN Core PWB for loose or improperly mated con-
nectors. Reconnect the cable, P819/J3. Disconnect the System Bus Cable, P818 from the F/S interface
bracket. The voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+)
tions RAP.
Y N
• If the Top 15 Control System faults show a history of this or other 3-20X faults perform the Replace the System Bus Cable between the F/S interface bracket and the TMN Core
diagnostic floppy program dC 350, Save Crash Data Files (General Procedures), and PWB (PL 1.19)
analyzing the data. Reconnect the System Bus Cable, P818 to the F/S interface bracket. Disconnect the System
• Visually inspect all connectors on the MIN Core PWB, PHN Core PWB, FSN Core PWB, Bus Cable, P827 from the F/S interface bracket. The voltage is greater than +3.5 VDC at the
and the UIM Core PWB for loose or improperly mated connectors. CABLE, between the inside wire (+) and the outside shield (-).
Procedure Y N
Replace the System Bus Cable between the F/S interface brackets. (PL 1.19)
The Power Normal LED, CR1, on the TMN Core PWB is lit.
Y N
Reconnect the cable, P827. Disconnect the System Bus Cable, P829/J4 on the FSN Core
+5.0 VDC is measured between TS23 (+) and TS22 (-) ON the TMN Core PWB #1.
Y N
Go to the +5 VDC wirenet, Figure 34, (WIRING DATA) and check the wires, 59D and
Y N
60D, for an open circuit. If the wires are good, replace the TMN Core PWB (PL 1.19)
Replace the System Bus cable from the F/S interface bracket and the FSN Core PWB (PL
1.19)
Replace the TMN Core PWB (PL 1.19)
Reconnect the cable, P829/J4. Disconnect the System Bus Cable, P4402/J3, on the FSN Core
Check the Identification Connector, P817/J5, on the TMN Core PWB in order to make sure that
PWB. The voltage is greater than +3.5VDC at the CONNECTOR, J3, on the FSN Core
the correct pins are connected and that the pins which are connected together have continuity.
Refer to the TMN CORE PWB Identification Connector Table located at the end of this RAP.
Y N
Y N
Reconnect the Cable 4402/J3. Disconnect the System Bus Cable, P701/J4, on the UIM Core
correct pins are connected and that they have continuity. The connector should be on pins 1
Y N
Replace the System Bus Cable from the UIM Core PWB and the FSN Core PWB (PL
Y N
1.16)
Reconnect the cable, P701/J4. Disconnect the System Bus cable, P700/J3, on the UIM Core
Disconnect the System Bus cable, P819/J3, from the TMN Core PWB.
Y N

Reconnect the cable, P700/J3. Disconnect the System Bus cable, P350/J3, on the PHN Core
PWB. The voltage is greater than +3.5 VDC, at the CABLE, between the inside wire (+)
Y N
PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J4, ON the PHN Core
Y N
Y N
1.4)
Y N
Y N
Table 1 TMN CORE PWB Identification Connector Table

TMN Core PWB P817/J5 Pin 1 & Pin 9 (connected)



Figure 3 FSN Core PWB / TMN Core PWB Circuit Diagram
A
A

3-408 RAP
Fault code, 3-408, indicates that the System Controller temporarily did not acknowledge
receipt of either a data layer or client layer operational message from the EDN Core PWB, has
disconnected from the Printer, or has failed to establish data or client layer communications
within either 4 minutes at initial power up or within 1 second of the Printer requesting client
layer initialization. This fault may also be caused by an intermittent or bad HDLC System Con-
troller/Printer Interface cable.
Procedure
+5 VDC is measured between P115-1 (+) and P116-1 (-) at the Printer Card Cage Back-
plane.
Y N
Go to the +5 VDC Distribution Wirenets, Figure 32, (Wiring Data) and check wire #532 for
an open circuit.
+9 to +13 VDC (Power Normal) is measured between P113-5 (+) and P113-6 (-) at the
Printer Card Cage Backplane.
Y N
Y N
-5.2 VDC is measured between P114-3 (+) and P114-4 (-) at the Printer Card Cage Back-
plane.
Y N
Check the HDLC diagnostic LED on the EDN Core PWB. The HDLC diagnostic LED is OFF.
Y N
The LED was ON. Replace the EDN Core PWB (PL 1.11)
NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to ensure sav-

NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to ensure saving the
NVM Setup Parameters.

3-412 RAP
Fault Code, 3-412, indicates that the UIM Core PWB could not talk to any PWB on its Local
Bus. During system boot, the Boot ROM on the UIM Core PWB causes a message to be sent
on the local bus to itself. When the message is not detected by the UIM local bus receiver this
fault is declared. This fault could be caused by a failure of any of the local bus PWBs or in the
local bus cabling that could prevent local bus communication.
Initial Actions
If this fault is clearable but continues to occur, go to the 3-731, Intermittent Communications
RAP.
Procedure
Disconnect the Local Bus cable, J703/J6, from the UIM Core PWB. Voltage is greater than
+3.5 VDC measured at the CABLE between the inside wire (+) and the outside shield (-).
Y N
Disconnect the Local Bus cable, P704/J2, from the CP IOP PWB. Voltage is greater
than +3.5 VDC at the CONNECTOR, J2, ON the CP IOP PWB between the inside wire
(+) and the outside base (-).
Y N
+5.0 VDC is measured between TH5 (+) and TH4 (-) ON the CP IOP PWB.
Y N
Go to the +5.0 VDC Wirenet, Figure 30, (WIRING DATA) and check the wires,
1200 and 1201, for an open circuit. If the wires are good, replace the CP IOP
PWB (PL 2.3)
Check both Local Bus cables for an open circuit or a short circuit between the UIM Core
PWB and the CP IOP PWB (PL 2.3)

Figure 1 3-412 Circuit Diagram

Figure 2 3-412 PWB Location Drawing

3-413 RAP

Reconnect the cable, P228/J2. Disconnect the Local Bus cable, J228/J3, at the MIN ADA
Fault Code, 3-413, indicates that the MIN Core PWB could not communicate with any PWB on
its Local Bus. During system boot, the Boot ROM on the MIN Core PWB causes a message to PWB #1. The voltage is greater than +3.5 VDC measured at the CABLE between the
be sent on the local bus to itself. When the message is not detected by the MIN local bus inside wire (+) and the outside shield (-).
Y N
receiver this fault is declared. This fault could be caused by a failure of any of the local bus
PWBs or in the local bus cabling that could prevent local bus communication. Replace the Local Bus cable between the MIN ADA PWB #1 and the MIN ADA PWB
#2 (PL 1.8)
Initial Actions Reconnect the cable, J228/J3. Disconnect the Local Bus cable, P225/J2, at the MIN ADA
If this fault is clearable but continues to occur, go to the 3-731, Intermittent Communications PWB #1. The voltage is greater than 4.0 VDC at the CONNECTOR, J2, ON the MIN
RAP. ADA PWB #1 between the inside wire (+) and the outside base (-).
Y N
Procedure Replace the MIN ADA PWB #1 (PL 1.8)
Replace the Local Bus cable between the MIN ADA PWB #1 and the MIN Core PWB (PL
1.8)
Disconnect the Local Bus cable, J225/J7, at the MIN Core PWB. The voltage is greater than
+3.5 VDC measured at the CABLE between the inside wire (+) and the outside shield (-). Replace the MIN Core PWB (PL 1.8)
Y N
Reconnect the cable, J225/J7. Disconnect the Local Bus cable, J227/J3, at the MIN ADA
PWB #2. The voltage is greater than +3.5 VDC measured at the CABLE between the
Y N
Reconnect the cable, J227/J3. Disconnect the Local Bus cable, P226/J108, at the
MIN SLB/RDR PWB. The voltage is greater than +3.5 VDC at the CONNECTOR,
J108, ON the MIN SLB/RDR PWB between the inside wire (+) and the outside
base (-).
Y N
Reconnect the cable, P226/J4. Disconnect the Local Bus cable, P227/J5, at the MIN
DIO PWB. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the
Y N
Reconnect the cable, P227/J5. Disconnect the Local Bus cable, J226/J4, of the
MIN DIO PWB. The voltage is greater than +3.5 VDC measured at the
Y N
Replace the Local Bus cable between the MIN DIO PWB and the MIN
SLB/RDR PWB (PL 1.11)
Replace the Local Bus cable between the MIN ADA PWB #2 and the MIN DIO PWB
(PL 1.8)
Reconnect the cable, J227/J3. Disconnect the Local Bus cable, P228/J2, at the MIN ADA
PWB #2. The voltage is greater than +3.5 VDC at the CONNECTOR, J2, ON the MIN
ADA PWB #2 between the inside wire (+) and the outside base (-).
Y N




A B
3-414 RAP Y N
Fault Code, 3-414, indicates that the PHN Core PWB could not communicate with any PWB on
its Local Bus. During system boot, the Boot ROM on the PHN Core PWB causes a message to Replace the Local Bus cable between the PHN DIO PWB #6 and the PHN DIO
be sent on the local bus to itself. When the message is not detected by the PHN local bus PWB #5 (PL 1.16)
receiver this fault is declared. This fault could be caused by a failure of any of the local bus
PWBs or in the local bus cabling that could prevent local bus communication. Reconnect the cable, J360/J4. Disconnect the Local Bus cable, P359/J5, at the PHN
DIO PWB #6. The voltage is greater than 4.0 VDC at the CONNECTOR, J5, ON
Initial Actions the PHN DIO PWB #6 between the inside wire (+) and the outside base (-).
Y N
tions RAP. Replace the PHN DIO PWB #6 (PL 1.4)
Procedure Replace the Local Bus cable between the PHN DIO PWB #2 and the PHN DIO PWB
NOTE: Check the Local Bus cable connectors for bent pins when making voltage measure- #6 (PL 1.4)
Reconnect the cable, J359/J4. Disconnect the Local Bus cable, J358/J4, at the PHN DIO
Disconnect the Local Bus cable, J357/J7, at the PHN Core PWB. The voltage is greater than PWB #1. The voltage is greater than +3.5 VDC measured at the CABLE between the
+3.5 VDC measured at the CABLE between the inside wire (+) and the outside shield (-). inside wire (+) and the outside shield (-).
Y N Y N
Reconnect the cable, J357/J7. Disconnect the Local Bus cable, J359/J4, at the PHN DIO Reconnect the cable, J358/J4. Disconnect the Local Bus cable, P358/J5, at the PHN
PWB #2. The voltage is greater than +3.5 VDC measured at the CABLE between the DIO PWB #2. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON
inside wire (+) and the outside shield (-). the PHN DIO PWB #2 between the inside wire (+) and the outside base (-).
Y N Y N
Reconnect the cable, J359/J4. Disconnect the Local Bus cable, 4417/J4, at the PHN Replace the PHN DIO PWB #2 (PL 1.4)
DIO PWB #5. The voltage is greater than +3.5 VDC measured at the CABLE
between the inside wire (+) and the outside shield (-). Replace the Local Bus cable between the PHN DIO PWB #1 and the PHN DIO PWB
Y N #2 (PL 1.4)
Reconnect the cable, 4417/J4. Disconnect the Local Bus cable, P360/J3, at the
PHN Registration Servo PWB. The voltage is greater than +3.5 VDC at the Reconnect the cable, J358/J4. Disconnect the Local Bus cable, P357/J5, at the PHN DIO
CONNECTOR,J3, ON the PHN Registration Servo PWB between the inside PWB #1. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON the PHN
wire (+) and the outside base (-). DIO PWB #1 between the inside wire (+) and the outside base (-).
Y N Y N
+5.0 VDC is measured between TS13 (+) and TS12 (-) on the PHN Replace the PHN DIO PWB #1 (PL 1.4)
Registration Servo PWB.
Y N Replace the Local Bus cable between the PHN DIO PWB #1 and the PHN Core PWB (PL
Go to the +5.0 VDC Wirenet, Figure 31, (WIRING DATA) and check 1.4)
the wire, 525, for an open circuit. If the wire is good, replace the PHN
Registration Servo PWB (PL 1.4) Replace the PHN Core PWB (PL 1.4)
Replace the Local Bus cable between the PHN Registration Servo PWB and
the PHN DIO PWB #5 (PL 1.16)
Reconnect the cable, 4417/J4. Disconnect the Local Bus cable, J360/J4, at the PHN
DIO PWB #6. The voltage is greater than +3.5 VDC measured at the CABLE
Y N
Reconnect the cable, J360/J4. Disconnect the Local Bus cable, 4416/J5, at the
PHN DIO PWB #5. The voltage is greater than +3.5 VDC at the CONNEC-
TOR, J5, ON the PHN DIO PWB #5 between the inside wire (+) and the out-
side base (-).
A B



A B C
3-415 RAP Y N
Disconnect the Local Bus cable at J4084/J4 on the FSN DIO PWB #2B. The volt-
Fault Code, 3-415, indicates that the FSN Core PWB could not communicate with any PWB on age is greater than +3.5 VDC at the CABLE between the inside wire (+) and the
its Local Bus. During system boot, the Boot ROM on the FSN Core PWB causes a message to outside shield (-).
be sent on the local bus to itself. When the message is not detected by the FSN local bus Y N
receiver this fault is declared. This fault could be caused by a failure of any of the local bus Replace the Local Bus cable between the FSN DIO PWB #2B and the FSN
PWBs or in the local bus cabling that could prevent local bus communication. DIO PWB #3B (PL 1.16)
Initial Actions Replace the FSN DIO PWB #2B (PL 1.16)
RAP. Reconnect the cable at P4083/J5 on the FSN DIO PWB #2B. Disconnect the Local Bus
cable at P4081/J5 on the FSN DIO PWB #1B. The voltage is greater than +3.5 VDC at
the CONNECTOR, J5, ON the FSN DIO PWB #1B between the inside wire (+) and the
Procedure outside shield (-).
ments on the Local Bus cable. Reconnect the cable at P4081/J5 on the FSN DIO PWB #1B. Disconnect the Local
Bus cable at J4082/J4 on the FSN DIO PWB #1B. The voltage is greater than
Disconnect the Local Bus cable, P4087/J4, at the FSN Stepper PWB A. The Voltage is +3.5 VDC at the CABLE between the inside wire (+) and the outside shield (-).
greater than +3.5 VDC at the CONNECTOR, J4, ON the FSN Stepper PWB A between the Y N
inside wire (+) and the outside base (-). Replace the Local Bus cable between the FSN DIO PWB #1B and the FSN
Y N DIO PWB #2B (PL 1.16)
Reconnect the cable, P4087/J4 at FSN Stepper PWB A. Disconnect the Local Bus cable,
P4187/J4, at the Stepper PWB B. The Voltage is greater than +3.5 VDC at the CON- Replace the FSN DIO PWB #1B (PL 1.16)
NECTOR, J4, ON the FSN Stepper PWB B between the inside wire (+) and the out-
side base (-). Reconnect the cable at P4081/J5 on the FSN DIO PWB #1B. Disconnect the Local Bus
Y N cable at J4088/J6 on the FSN Stepper PWB A. The voltage is greater than +3.5 VDC at
+5 VDC is measured between TS33 (+) and TS9 (-) on the FSN Stepper PWB B. the CABLE between the inside wire (+) and the outside base (-).
Y N Y N
Go to the +5 VDC Distribution wirenets, Figure 34, and check wires 61T and Disconnect the Local Bus cable at P4089/P4090 which connects the Local Bus of
61A for an open circuit. the F/S Module A to the Local Bus of the F/S Module B. The voltage is greater
than +3.5 VDC at P4090 between the inside wire (+) and the outside shield (-).
Replace the FSN Stepper PWB B (PL 1.16) Y N
Replace the Local Bus cable between the FSN DIO PWB #1B and P4090 (PL
Reconnect the Local Bus cable to P4187/J4 on the FSN Stepper PWB A. Disconnect the 1.16)
Local Bus cable at P4085/J5 on the FSN DIO PWB #3B. The voltage is greater than
+3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #3B between the inside Replace the Local Bus cable between the FSN Stepper PWB A and P4089 (PL 1.16)
Y N Replace the FSN Stepper PWB A (PL 1.16)
Disconnect the Local Bus cable at J4086/J4 on the FSN DIO PWB #3B. The volt-
age is greater than +3.5 VDC at the CABLE between the inside wire (+) and the Reconnect the Local Bus cable to P4087/J4 on the FSN Stepper PWB A. Disconnect the Local
outside shield (-). Bus cable at J4086/J4 on the FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at
Y N the CABLE between the inside wire (+) and the outside shield (-).
Replace the Local Bus cable between the FSN DIO PWB #3B and the FSN Y N
Stepper PWB B (PL 1.16) Replace the Local Bus cable between the FSN DIO PWB #3A and the FSN Stepper PWB
A (PL 1.16)
Reconnect the Local Bus cable to J4086/J4 on the FSN DIO PWB #3A. Disconnect the Local
Reconnect the cable at P4085/J5 at the FSN DIO PWB #3B. Disconnect the Local Bus Bus cable at P4085/J5 on the FSN DIO PWB #3A. The voltage is greater than +3.5 VDC at
cable at P4083/J5 on the FSN DIO PWB #2B. The voltage is greater than +3.5 VDC at the CONNECTOR, J5, ON FSN DIO PWB #3A between the inside wire (+) and the outside
the CONNECTOR, J5, ON the FSN DIO PWB #2B between the inside wire (+) and the shield (-).
outside base (-). Y N
A B C
Reconnect the cable at P4085/J5 at the FSN DIO PWB #3A. Disconnect the Local Bus cable at
J4084/J4 on the FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CABLE
Y N
#3A (PL 1.16)
Reconnect the cable at J4084/J4 at the FSN DIO PWB #2A. Disconnect the Local Bus cable at
P4083/J5 on the FSN DIO PWB #2A. The voltage is greater than +3.5 VDC at the CON-
NECTOR, J5, ON the FSN DIO PWB #2A between the inside wire (+) and the outside
shield (-).
Y N
Reconnect the cable, P4083/J5. Disconnect the Local Bus cable, J4080/J7, at the FSN Core
PWB A. Voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+) and
Y N
Reconnect the cable at J4080/J7 on the FSN Core PWB A. Disconnect the Local Bus
cable at P4081/J5 on the FSN DIO PWB #1A. The voltage is greater than +3.5 VDC at
the CONNECTOR, J5, ON the FSN DIO PWB #1A between the inside wire (+) and the
outside shield (-).
Y N
Reconnect the cable, P4081/J5 on the FSN DIO PWB #1A. Disconnect the Local
Bus cable at J4082/J4 on the FSN DIO PWB #1A. The voltage is greater than
+3.5 VDC at the CABLE, between the inside wire (+) and the outside shield (-).
Y N
Replace the Local Bus cable between the FSN Core PWB A and the FSN DIO PWB #1A
(PL 1.16)
The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB A between the inside
Y N
+5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB A.
Y N
61J and 61A for an open circuit.
Replace the FSN Core PWB A (PL 1.16)
The problem is an intermittent one. Go to the 3-731, Intermittent Communications RAP.



A
A B
B
3-416 RAP Reconnect the Local Bus cable to P4087/J4 on the FSN Stepper PWB D. Disconnect the
Local Bus cable at P4085/J5 on the FSN DIO PWB #3D. The voltage is greater than
Fault Code, 3-416, indicates that the FSN Core PWB #2 could not communicate with any PWB +3.5 VDC at the CONNECTOR, J5, ON the FSN DIO PWB #3D between the inside
on its Local Bus. During system boot, the Boot ROM on the FSN Core PWB #2 causes a mes- wire (+) and the outside base (-).
sage to be sent on the local bus to itself. When the message is not detected by the FSN local Y N
bus receiver this fault is declared. This fault could be caused by a failure of any of the local bus Reconnect the cable at P4085/J5 at the FSN DIO PWB#3 Disconnect the Local Bus
PWBs or in the local bus cabling that could prevent local bus communication. cable at J4086/J4 on the FSN DIO PWB #3D. The voltage is greater than +3.5
VDC at the CABLE between the inside wire (+) and the outside shield (-).
Initial Actions Y N
RAP. Stepper PWB D (PL 1.18)

• If this is a four module system, ensure that the Identification Jumper Connector, located
on Feeder Stackers B and D, J4057, is not plugged into P4057.
Reconnect the cable at P4085/J5 at the FSN DIO PWB #3D. Disconnect the Local Bus
• If this is four module system, ensure that the FSN Stepper PWB C is not terminated
cable at P4083/J5 on the FSN DIO PWB #2D. The voltage is greater than +3.5 VDC at
(jumper should be on pins 1 and 2 on J5) and that the FSN Stepper PWB D is terminated
the CONNECTOR, J5, ON the FSN DIO PWB #2D between the inside wire (+) and the
(jumper should be on pins 2 and 3 on J5).
outside base (-).
• If this is a three module system, ensure that the Identification Jumper Connector, P/ Y N
J4057, located on Feeder Stacker C is connected. Reconnect the cable at P4083/J5 on the FSN DIO PWB #2D. Disconnect the Local
• If this is three module system, ensure that the FSN Stepper PWB C is terminated (jumper Bus cable at J4084/J4 on the FSN DIO PWB #2D. The voltage is greater than
should be on pins 2 and 3 on J5). +3.5 VDC at the CABLE between the inside wire (+) and the outside shield (-).
Procedure Y N
NOTE: Check the Local Bus cable connectors for bent pins when making voltage measure- DIO PWB #3D (PL 1.18)
Disconnect the Local Bus cable, P4087/J4, at the FSN Stepper PWB C. The Voltage is
greater than +3.5 VDC at the CONNECTOR, J4, ON the FSN Stepper PWB C between the
Reconnect the cable at P4083/J5 on the FSN DIO PWB #2D. Disconnect the Local Bus
cable at P4081/J5 on the FSN DIO PWB #1D. The voltage is greater than +3.5 VDC at
Y N
the CONNECTOR, J5, ON the FSN DIO PWB #1D between the inside wire (+) and the
This is a four module system.
outside shield (-).
Y N
Y N
+5 VDC is measured between TS33 (+) and TS9 (-) on the FSN Stepper PWB C.
Reconnect the cable at P4081/J5 on the FSN DIO PWB #1D. Disconnect the Local
Y N
Bus cable at J4082/J4 on the FSN DIO PWB #1D. The voltage is greater than
Go to the +5 VDC Distribution wirenets, Figure 34, and check wires 61T and
+3.5 VDC at the CABLE between the inside wire (+) and the outside shield (-).
61N for an open circuit.
Y N
Replace the FSN Stepper PWB C (PL 1.18).
DIO PWB #2D (PL 1.18)
Reconnect the cable, P4087/J4 at FSN Stepper PWB C. Disconnect the Local Bus cable,
P4087/J4, at the Stepper PWB D. The Voltage is greater than +3.5 VDC at the CON-
NECTOR, J4, ON the FSN Stepper PWB D between the inside wire (+) and the out-
Reconnect the cable at P4081/J5 on the FSN DIO PWB #1D. Disconnect the Local Bus
side base (-).
cable at J4088/J6 on the FSN Stepper PWB C. The voltage is greater than +3.5 VDC
Y N
at the CABLE between the inside wire (+) and the outside base (-).
+5 VDC is measured between TS33 (+) and TS9 (-) on the FSN Stepper PWB D.
Y N
Y N
Reconnect the cable J4088/J6. Disconnect the Local Bus cable at P4089/P4090
Go to the +5 VDC Distribution wirenets, Figure 34, and check wires 61T and
which connects the Local Bus of the F/S Module C to the Local Bus of the F/S Mod-
ule D. The voltage is greater than +3.5 VDC at P4090 between the inside wire

Y N Replace the FSN DIO PWB #1C (PL 1.18)
Replace the Local Bus cable between the FSN DIO PWB #1D and P4090 (PL
1.18) Reconnect the cable P4081/J5 on the FSN DIO PWB #1C. Disconnect the local bus cable
P4090 at the interface connector on module C. The voltage is greater than 3.5VDC at
Replace the Local Bus cable between the FSN Stepper PWB C and P4089 (PL 1.18) the Cable, between the inside wire (+) and the outside shield (-).
Y N
Replace the FSN Stepper PWB C (PL 1.18) Replace the Local Bus cable between the FSN DIO PWB #1C and the interface con-
nector (PL 1.18).
Reconnect the cable to P4087/J4 on the FSN Stepper PWB C. Disconnect the Local Bus cable
at J4086/J4 on the FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CABLE Reconnect the cable P4090 at the interface connector. Disconnect the Local Bus cable
between the inside wire (+) and the outside shield (-). P4090 at the interface connector to module B. The voltage is greater than 3.5VDC at
Y N the Cable, between the inside wire (+) and the outside shield (-).
C (PL 1.18) Replace the Local Bus cable between the two interface connectors on modules B
and C (PL 1.18)
Reconnect the cable to J4086/J4 on the FSN DIO PWB #3C. Disconnect the Local Bus cable
at P4085/J5 on the FSN DIO PWB #3C. The voltage is greater than +3.5 VDC at the CON- Replace the Local Bus cable between the FSN Core PWB #2 and the interface connector
NECTOR, J5, ON FSN DIO PWB #3C between the inside wire (+) and the outside shield (- (PL 1.18)
).
Y N The voltage is greater than +3.5 VDC at J7, ON the FSN Core PWB #2 between the inside
Replace the FSN DIO PWB #3C (PL 1.18) wire (+) and the outside base (-).
Y N
Reconnect the cable at P4085/J5 at the FSN DIO PWB #3C. Disconnect the Local Bus cable +5 VDC is measured between TS23 (+) and TS22 (-) ON the FSN Core PWB #2.
at J4084/J4 on the FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CABLE Y N
between the inside wire (+) and the outside shield (-). Go to the +5 VDC Distribution Wirenets (Wiring Data) and check wires 61K and 62F
Y N for an open circuit.
#3A (PL 1.18) Replace the FSN Core PWB #2 (PL 1.18)
Reconnect the cable at J4084/J4 at the FSN DIO PWB #2C. Disconnect the Local Bus cable at The problem is an intermittent one. Go to the 3-731, Intermittent Communications RAP.
P4083/J5 on the FSN DIO PWB #2C. The voltage is greater than +3.5 VDC at the CON-
NECTOR, J5, ON the FSN DIO PWB #2C between the inside wire (+) and the outside
shield (-).
Y N
Reconnect the cable, P4083/J5. Disconnect the Local Bus cable, J4093/J7, at the FSN Core
PWB #2. Voltage is greater than +3.5 VDC at the CABLE, between the inside wire (+) and
Y N
Reconnect the cable at J4093/J7 on the FSN Core PWB #2. Disconnect the Local Bus
cable at P4081/J5 on the FSN DIO PWB #1C. The voltage is greater than +3.5 VDC at
the CONNECTOR, J5, ON the FSN DIO PWB #1C between the inside wire (+) and the
outside shield (-).
Y N
Reconnect the cable, P4081/J5 on the FSN DIO PWB #1C. Disconnect the Local
Bus cable at J4082/J4 on the FSN DIO PWB #1C. The voltage is greater than
+3.5 VDC at the CABLE, between the inside wire (+) and the outside shield (-).
Y N
Replace the Local Bus cable between the FSN DIO PWB #1C and the FSN
DIO PWB #2C (PL 1.18)



A B
3-461 RAP
A B A C
A C D E F
Fault Code, 3-461, indicates that a potential noise problem was detected on the EDN Core 3-462 RAP
PWB that required a software reset. When the fault occurs, a crash file is stored on the rigid
Fault Code, 3-462, indicates that a potential noise problem was detected on the UIM Core
disk. This fault will cause the printer to go into Energy Saver mode during Operator modes or
PWB that required a software reset. When the fault occurs, a crash file will be stored on the
into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC section
rigid disk. This fault will cause the printer to go into Energy Saver mode during Operator
of the Low Voltage Power Supply.
modes or into Power Interrupt mode during diagnostic mode. Both modes disable the +24
Initial Actions
Perform the following: Initial Actions
• If fault code 3-381 is present in the Queued Faults on the [SCP] screen, go to the 3-381 Perform the following:
RAP.
• Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
• If the fault is clearable but continues to occur, go to the Printer Electrical Noise Procedure
• If the fault is clearable but continues to occur, go to the Printer Electrical Noise Procedure
(Service Call Procedures).
NRD3 (Service Call Procedures).
• If power on and power off, does not help, replace the UIM Core PWB (PL 2.3)
• If power on and power off does not help, replace the EDN Core PWB (PL 1.11)
Procedure
NOTE: Perform the replacement procedure for the EDN Core PWB (REP 1-13) to ensure sav- Ensure that the latest release of software is loaded on the System Controller and the Printer. If
ing the NVM Setup Parameters. the problem continues, look for related fault codes.
Procedure NOTE: A related fault code is a fault which is associated with other faults by the number of
Ensure that the latest release of software is loaded on the System Controller and the Printer. If prints that have been made (within 25 prints of the fault).
NOTE: A related fault code is a fault which is associated with other faults by the number of codes listed which have occurred within 25 prints of 3-462. There are other faults listed
prints that have been made (within 25 prints of the fault). within 25 prints of 3-462.
Y N
detected as a hardware or software error (3-372 or 3-472). Call the hot line for instruc-
tions. A request may be made to perform a dC350, Save Crash Data Files, routine (Gen-
Y N
eral Procedures). If Field Engineering cannot be reached, perform the dC 350 routine and
contact Field Engineering at the first opportunity.
D E F
3-463 RAP 3-464 RAP
Fault Code, 3-463, indicates that a potential noise problem was detected on the MIN Core Fault Code, 3-464, indicates that a potential noise problem was detected on the PHN Core
PWB that required a software reset. When the fault occurs, a crash file is stored on the rigid PWB that required a software reset. When the fault occurs, a crash file is stored on the rigid
disk. This fault will cause the printer to go into Energy Saver mode during Operator modes or disk. This fault will cause the printer to go into Energy Saver mode during Operator modes or
into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC section into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC section
Initial Actions Initial Actions

Perform the following: Perform the following:
• If fault code 3-383 is present in the Queued Faults [SCP] screen, go to the 3-383 RAP. • If fault code 3-384 is present in the Queued Faults [SCP] screen, go to the 3-384 RAP.
• Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in • Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
order to force a Self-Test and a system node download. If Fault Code, 3-463, does not order to force a Self-Test and a system node download. If Fault Code, 3-464, does not
occur, the problem is corrected. occur, the problem is corrected.
• When replacing a Photoreceptor, the movement of the machine clock encoder may cause • If the fault is clearable but continues to occur, go to the NDR3 Electrical Noise RAP (Ser-
this fault. If this is the case, no corrective action is required. vice Call Procedures).
• If the fault is clearable but continues to occur, go to the Printer Electrical Noise Procedure • If power on and power off, does not help, replace the PHN Core PWB (PL 1.4)
(Service Call Procedures). Procedure
• If power on and power off, does not help, replace the MIN Core PWB (PL 1.8) Ensure that the latest release of software is loaded on the System Controller and the Printer. If
Procedure the problem continues, look for related fault codes.
prints that have been made (within 25 prints of the fault).
Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault within 25 prints of 3-464.
codes listed which have occurred within 25 prints of 3-463. There are other faults listed Y N
within 25 prints of 3-463. If the problem continues, fault code 3-464 may be the result of an unusual condition not
Y N detected as a hardware or software error (3-374 or 3-474). Call the hot line for instruc-
If the problem continues, fault code 3-463 may be the result of an unusual condition not tions. A request may be made to perform a dC350, Save Crash Data Files, routine (Gen-
detected as a hardware or software error (3-373 or 3-473). Call the hot line for instruc- eral Procedures). If Field Engineering cannot be reached, perform the dC 350 routine and
tions. A request may be made to perform a dC350, Save Crash Data Files, routine (Gen- contact Field Engineering at the first opportunity.
contact Field Engineering at the first opportunity. Go to the appropriate RAP for the other fault codes listed within 25 print counts.

3-465 RAP 3-466 RAP
Fault Code, 3-465, indicates that a potential noise problem was detected on the FSN Core Fault Code, 3-466, indicates that a potential noise problem was detected on the FSN Core
PWB that required a software reset. When the fault occurs, a crash file is stored on the rigid PWB #2 that required a software reset. When the fault occurs, a crash file is stored on the rigid
disk. This fault will cause the printer to go into Energy Saver mode during Operator modes or disk. This fault will cause the printer to go into Energy Saver mode during Operator modes or
into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC section into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC section

• If fault code 3-385 is present in the Queued Faults [SCP] screen, go to the 3-385 RAP. • If fault code 3-386 is present in the Queued Faults [SCP] screen, go to the 3-386 RAP.
• Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in • Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
order to force a Self-Test and a system node download. If Fault Code, 3-465, does not order to force a Self-Test and a system node download. If Fault Code, 3-466, does not
occur, the problem is corrected. occur, the problem is corrected.
• If the fault is clearable but continues to occur, go to the Printer Electrical Noise Procedure • If the fault is clearable but continues to occur, go to the Printer Electrical Noise Procedure
NRD3 (Service Call Procedures). NRD3 (Service Call Procedures).
• If power on and power off, does not help, replace the FSN Core PWB (PL 1.16) • If power on and power off, does not help, replace the FSN Core PWB #2 (PL 1.18)
Procedure Procedure
Ensure that the latest release of software is loaded on the System Controller and the Printer. If Ensure that the latest release of software is loaded on the System Controller and the Printer. If
the problem continues, look for related fault codes. the problem continues, look for related fault codes.
NOTE: A related fault code is a fault which is associated with other faults by the number of NOTE: A related fault code is a fault which is associated with other faults by the number of
prints that have been made (within 25 prints of the fault). prints that have been made (within 25 prints of the fault).
Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault
codes listed which have occurred within 25 prints of 3-465. There are other faults listed codes listed which have occurred within 25 prints of 3-466. There are other faults listed
within 25 prints of 3-465. within 25 prints of 3-466.
Y N Y N
If the problem continues, fault code 3-465 may be the result of an unusual condition not If the problem continues, fault code 3-466 may be the result of an unusual condition not
detected as a hardware or software error (3-375 or 3-475). Call the hot line for instruc- detected as a hardware or software error (3-376 or 3-476). Call the hot line for instruc-
tions. A request may be made to perform a dC350, Save Crash Data Files, routine (Gen- tions. A request may be made to perform a dC350, Save Crash Data Files, routine (Gen-
eral Procedures). If Field Engineering cannot be reached, perform the dC 350 routine and eral Procedures). If Field Engineering cannot be reached, perform the dC 350 routine and
contact Field Engineering at the first opportunity. contact Field Engineering at the first opportunity.
Go to the appropriate RAP for the other fault codes listed within 25 print counts. Go to the appropriate RAP for the other fault codes listed within 25 print counts.
If the problem continues, go to the 3-732, Intermittent Internal Error RAP. If the problem continues, go to the 3-732 Intermittent Internal Error RAP.
3-467 RAP • Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
Fault Code, 3-467, indicates that a potential noise problem was detected on the TMN Core occur, the problem is corrected.
PWB that required a software reset. When the fault occurs, a crash file is stored on the rigid • If the fault is clearable but continues to occur, go to the Printer Electrical Noise Procedure
disk. This fault will cause the printer to go into Energy Saver mode during Operator modes or NRD3 (Service Call Procedures).
into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC section
• If power on and power off, does not help, replace the TMN Core PWB (PL 1.19)
of the Low Voltage Power Supply.
Procedure
Initial Actions Ensure that the latest release of software is loaded on the System Controller and the Printer. If
• If Fault Code, 3-389, is present in the Queued Faults on the [SCP] screen, go to the 3-
389 RAP.

NOTE: A related fault code is a fault which is associated with other faults by the number of 3-471 RAP
Fault Code, 3-471, indicates that the EDN Core PWB detected a potential software problem
Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault that required the EDN to perform a software reset. When the fault occurs, a crash file is stored
on the Rigid Disk/SMSD. This fault will cause the printer to go into Energy Saver mode during
within 25 prints of 3-467. Operator modes or into Power Interrupt mode during diagnostic mode operation. Both modes
Y N disable the +24 VDC section of the Low Voltage Power Supply.
Initial Actions
eral Procedures). If Field Engineering cannot be reached, perform the dC 350 routine and Perform the following:
• If fault code 3-381 is in the Queued Faults on the [SCP] screen, go to the 3-381 RAP.
Go to the appropriate RAP for the other fault codes listed within 25 print counts. • Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
If the problem continues, go to the 3-732, Intermittent Internal Error RAP. order to force a Self-Test and a system node download. If Fault Code, 3-471, does not
RAP.
• If power on and power off does not help, replace the EDN Core PWB (PL 1.11)
Procedure
the problem continues, look for related fault codes, and investigate the customer application for
unique job parameters and/or sequences that cause this software failure.
Y N
detected as a hardware or noise error (3-371 or 3-461). Call the hot line for instructions. A
Fault Code, 3-472, indicates that the UIM Core PWB detected a potential software problem
that required a software reset. When the fault occurs, a crash file is stored on the Rigid Disk/
SMSD. This fault will cause the printer to go into Energy Saver mode during Operator modes
or into Power Interrupt mode during diagnostic mode. Both modes disable the+24 VDC sec-
RAP.
• If power on and power off, does not help, replace the UIM Core PWB (PL 2.3)

Procedure 3-473 RAP
Fault Code, 3-473, indicates that the MIN Core PWB detected a potential software problem
the problem continues, look for related fault codes and investigate the customer application for
NOTE: A related fault code is a fault which is associated with other faults by the number of or into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC sec-
prints that have been made (within 25 prints of the fault). tion of the Low Voltage Power Supply.
Initial Actions
within 25 prints of 3-472. Perform the following:
Y N
If the problem continues, fault code 3-472 may be the result of an unusual condition not • If fault code 3-383 is present in the Queued Faults [SCP] screen, go to the 3-383 RAP.
detected as a hardware or noise error (3-372 or 3-462). Call the hot line for instructions. A • Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
request may be made to perform a dC350, Save Crash Data Files, routine (General Pro- order to force a Self-Test and a system node download. If Fault Code, 3-473, does not
cedures). If Field Engineering cannot be reached, perform the dC 350 routine and contact occur, the problem is corrected.
Field Engineering at the first opportunity. • When replacing a Photoreceptor, the movement of the machine clock encoder may cause
this fault. If this is the case, no corrective action is required.
RAP.
• If power on and power off, does not help, replace the MIN Core PWB (PL 1.8)
Procedure
Y N
3-474 RAP • If fault code 3-383 is present in the Queued Faults [SCP] screen, go to the 3-383 RAP.
Fault Code, 3-474, indicates that the PHN Core PWB detected a potential software problem order to force a Self-Test and a system node download. If Fault Code, 3-474, does not
that required a software reset. When the fault occurs, a crash file is stored on the Rigid Disk/ occur, the problem is corrected.
or into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC sec-
RAP.
• If power on and power off, does not help, replace the PHN Core PWB (PL 1.4)
Initial Actions

Procedure 3-475 RAP
Fault Code, 3-475, indicates that the FSN Core PWB detected a potential software problem
NOTE: A related fault code is a fault which is associated with other faults by the number of or into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC sec-
prints that have been made (within 25 prints of the fault). tion of the Low Voltage Power Supply.
Initial Actions
within 25 prints of 3-474. Perform the following:
Y N
If the problem continues, fault code 3-474 may be the result of an unusual condition not • If fault code 3-385 is present in the Queued Faults [SCP] screen, go to the 3-385 RAP.
detected as a hardware or noise error (3-374 or 3-464). Call the hot line for instructions. A • Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
request may be made to perform a dC350, Save Crash Data Files, routine (General Pro- order to force a Self-Test and a system node download. If Fault Code, 3-475, does not
cedures). If Field Engineering cannot be reached, perform the dC 350 routine and contact occur, the problem is corrected.
Field Engineering at the first opportunity. • If the fault is clearable but continues to occur, go to the 3-732 Intermittent Internal Error
RAP.
• If power on and power off, does not help, replace the FSN Core PWB (PL 1.16)
Procedure
Y N

3-476 RAP 3-477 RAP
Fault Code, 3-476, indicates that the FSN Core PWB #2 detected a potential software problem Fault Code, 3-477, indicates that the TMN Core PWB detected a potential software problem
that required a software reset. When the fault occurs, a crash file is stored on the Rigid Disk/ that required a software reset. When the fault occurs, a crash file is stored on the Rigid Disk/
SMSD. This fault will cause the printer to go into Energy Saver mode during Operator modes SMSD. This fault will cause the printer to go into Energy Saver mode during Operator modes
or into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC sec- or into Power Interrupt mode during diagnostic mode. Both modes disable the +24 VDC sec-
tion of the Low Voltage Power Supply. tion of the Low Voltage Power Supply.

• If fault code 3-386 is present in the Queued Faults [SCP] screen, go to the 3-386 RAP. • If Fault Code, 3-389, is present in the Queued Faults on the [SCP] screen, go to the 3-
• Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in 389 RAP.
order to force a Self-Test and a system node download. If Fault Code, 3-476, does not • Switch off the Printer Main Power Switch, S102. Wait 15 seconds, switch on the power in
occur, the problem is corrected. order to force a Self-Test and a system node download. If Fault Code, 3-477, does not
• If the fault is clearable but continues to occur, go to the 3-732 Intermittent Internal Error occur, the problem is corrected.
RAP. • If the fault is clearable but continues to occur, go to the 3-732 Intermittent Internal Error
• If power on and power off, does not help, replace the FSN Core PWB #2 (PL 1.18) RAP.
Procedure • If power on and power off, does not help, replace the TMN Core PWB (PL 1.19)
Ensure that the latest release of software is loaded on the System Controller and the Printer. If Procedure
the problem continues, look for related fault codes and investigate the customer application for Ensure that the latest release of software is loaded on the System Controller and the Printer. If
unique job parameters and/or sequences that cause this software failure. the problem continues, look for related fault codes and investigate the customer application for
prints that have been made (within 25 prints of the fault). NOTE: A related fault code is a fault which is associated with other faults by the number of
codes listed which have occurred within 25 prints of 3-476. There are other faults listed Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault
within 25 prints of 3-476. codes listed which have occurred within 25 prints of 3-477. There are other faults listed
Y N within 25 prints of 3-477.
If the problem continues, fault code 3-476 may be the result of an unusual condition not Y N
detected as a hardware or noise error (3-376 or 3-466). Call the hot line for instructions. A If the problem continues, fault code 3-477 may be the result of an unusual condition not
request may be made to perform a dC350, Save Crash Data Files, routine (General Pro- detected as a hardware or noise error (3-379 or 3-467). Call the hot line for instructions. A
cedures). If Field Engineering cannot be reached, perform the dC 350 routine and contact request may be made to perform a dC350, Save Crash Data Files, routine (General Pro-
Field Engineering at the first opportunity. cedures). If Field Engineering cannot be reached, perform the dC 350 routine and contact
If the problem continues, go to the 3-732, Intermittent Internal Error RAP. Go to the appropriate RAP for the other fault codes listed within 25 print counts.

3-480 RAP 3-482 RAP
Fault Code, 3-480, indicates that the job manager detected too many scheduling segments in Fault Code, 3-482, indicates that the job manager received an unexpected output delivery sig-
the job manager queue and initiated a cycle down of the printer. This fault occurs when one of nal and initiated cycle down of the printer. This fault occurs when either the PHN or FSN sends
the base machine nodes stops requesting job related control messages (segments) before the an unexpected sheet delivery signal to the EDN Core PWB.
job has completed printing.
Initial Actions
Initial Actions Perform the following:
• If these fault codes have occurred when the customer was running a job, he/she should
• If these fault codes have occurred when the customer was running a job, he/she should have already followed the directions on the screen and to have selected the [Control Sys-
have already followed the directions on the screen and to have selected the [Control Sys- tem Reset], and to have continued the job.
tem Reset], and to have continued the job. • If the fault continues to occur, the customer should power off/power on the printer via the
• If the fault continues to occur, the customer should power off/power on the printer via the Printer Main Power Switch. The customer should not power off the System Controller.
Printer Main Power Switch. The customer should not power off the System Controller. Procedure
Procedure Ensure that the latest releases of software are loaded on both the System Controller and the
Ensure that the latest releases of software are loaded on both the System Controller and the Printer. If the problem continues, look for related fault codes or messages at both the System
Printer. If the problem continues, look for related fault codes or messages at both the System Controller and the Printer UI and/or question the customer regarding any unique or stress
Controller and the Printer UI and/or question the customer regarding any unique or stress types of applications that may have been running.
types of applications that may have been running.
NOTE: A related fault code is a fault which is associated with other faults by the number of prints that have been made.
prints that have been made.
Select [SCP] [Last 50]. View the Last 50 shutdowns to determine if there are any other codes
Select [SCP] [Last 50]. View the Last 50 shutdowns to determine if there are any other codes that have occurred within 25 prints of 3-482. There are other faults listed within 25 prints of
that have occurred within 25 prints of 3-480. There are other faults listed within 25 prints of 3-482.
3-480. Y N
Y N Fault Code 3-482 is the result of internal software errors. If this problem has not been
Fault Code 3-480 is the result of internal software errors. If this problem has not been identified on the Software Problem Set, make a Field Service Report, through SPAR, to
identified on the Software Problem Set, make a Field Service Report, through SPAR, to Engineering. Where possible, gather application specific information regarding job param-
Engineering. Where possible, gather application specific information regarding job parameters and conditions that consistently cause these faults and report them to Engineering.
eters and conditions that consistently cause these faults and report them to Engineering. Also where possible, perform an Occurrence Log Dump, GP 6, (General Procedures).
Also where possible, perform an Occurrence Log Dump GP 6 (General Procedures). This This procedure must be performed within minutes after the malfunction. The probability
procedure must be performed within minutes after the malfunction. The probability that that engineering will be able to reproduce and resolve these problems will be greatly
engineering will be able to reproduce and resolve these problems will be greatly enhanced if the Occurrence Log Dump diskettes are received.
enhanced if the Occurrence Log Dump diskettes are received.
Go to the appropriate RAP for the other fault codes listed within 25 prints.

3-483 RAP 3-485 RAP
Fault Code, 3-483, indicates that the job manager detected that either the PHN or FSN initiated Fault Code, 3-485, indicates that the EDN detected that the PSP print response was either late
2 requests for an output delivery scheduling segment and initiated cycle down of the printer. or never received and initiated a cycle down of the printer. This fault occurs when the System
Controller either fails to issue a PSP print response message to the printer within the timing
Initial Actions window or that the PSP print response was never received by the printer.
Initial Actions
• If these fault codes have occurred when the customer was running a job, he/she should Perform the following:
have already followed the directions on the screen and to have selected the [Control Sys-
tem Reset], and to have continued the job. • If these fault codes have occurred when the customer was running a job, he/she should
• If the fault continues to occur, the customer should power off/power on the printer via the have already followed the directions on the screen and to have selected the [Control Sys-
Printer Main Power Switch. The customer should not power off the System Controller. tem Reset], and to have continued the job.
Procedure • If the fault continues to occur, the customer should power off/power on the printer via the
Printer Main Power Switch. The customer should not power off the System Controller.
Ensure that the latest releases of software are loaded on both the System Controller and the
Printer. If the problem continues, look for related fault codes or messages at both the System Procedure
Controller and the Printer UI and/or question the customer regarding any unique or stress Ensure that the latest releases of software are loaded on both the System Controller and the
types of applications that may have been running. Printer. If the problem continues, look for related fault codes or messages at both the System
Controller and the Printer UI and/or question the customer regarding any unique or stress
that have occurred within 25 prints of 3-483. There are other faults listed within 25 prints of
3-483. Select [SCP] [Last 50]. View the Last 50 shutdowns to determine if there are any other codes
Y N that have occurred within 25 prints of 3-485. There are other faults listed within 25 prints of
Fault Code 3-483 is the result of internal software errors. If this problem has not been 3-485.
identified on the Software Problem Set, make a Field Service Report, through SPAR, to Y N
Engineering. Where possible, gather application specific information regarding job param- Fault Code 3-485 is the result of internal software errors. If this problem has not been
eters and conditions that consistently cause these faults and report them to Engineering. identified on the Software Problem Set, make a Field Service Report, through SPAR, to
Also where possible, perform an Occurrence Log Dump, GP 6, (General Procedures). Engineering. Where possible, gather application specific information regarding job param-
This procedure must be performed within minutes after the malfunction. The probability eters and conditions that consistently cause these faults and report them to Engineering.
that engineering will be able to reproduce and resolve these problems will be greatly Also where possible, perform an Occurrence Log Dump, GP 6, (General Procedures).
enhanced if the Occurrence Log Dump diskettes are received. This procedure must be performed within minutes after the malfunction. The probability
that engineering will be able to reproduce and resolve these problems will be greatly
Go to the appropriate RAP for the other fault codes listed within 25 prints. enhanced if the Occurrence Log Dump diskettes are received.
3-492 RAP Procedure
Fault Code, 3-492, indicates that the MIN Core PWB did not receive a main drive enable from
Printer. If the problem continues, look for related fault codes or messages at both the System
the PHN Core PWB within 30 seconds after start was initiated.
Initial Actions
• If these fault codes have occurred when the customer was running a job, he/she should Select [SCP] [Last 50]. View the Last 50 shutdowns to determine if there are any other codes
have already followed the directions on the screen and to have selected the [Control Sys- that have occurred within 25 prints of 3-492. There are other faults listed within 25 prints of
tem Reset], and to have continued the job. 3-492.
• If the fault continues to occur, the customer should power off/power on the printer via the
Printer Main Power Switch. The customer should not power off the System Controller.

Y N 3-494 RAP
Fault Code 3-492 is the result of internal software errors. If this problem has not been
identified on the Software Problem Set, make a Field Service Report, through SPAR, to Initial Actions
Engineering. Where possible, gather application specific information regarding job param-
eters and conditions that consistently cause these faults and report them to Engineering.
Also where possible, perform an Occurrence Log Dump, GP 6, (General Procedures).
• If these Fault Codes have occurred when the customer was running a job, he/she should
This procedure must be performed within minutes after the malfunction. The probability
have already followed the directions on the screen and to have selected the [CONTROL
SYSTEM RESET] and to have continued the job.
• If the fault continues to occur, the customer should power off the printer via the Printer
Main Power Switch. The customer should not power off the System Controller.
Procedure
Printer. If the problem continues, look for related fault codes or messages at both the System
that have occurred within 25 prints of 3-494. There are other faults listed within 25 prints of
3-494.
Y N
Fault Code 3-494 is the result of internal software errors. If this problem has not been
identified on the Software Problem Set, make a Field Service Report, through SPAR, to
Engineering. Where possible, gather application specific information regarding job param-
eters and conditions that consistently cause these faults and report them to Engineering.
Also where possible, perform an Occurrence Log Dump, GP 6, (General Procedures).
This procedure must be performed within minutes after the malfunction. The probability
3-700 Printer Boot RAP Y N
The EDN Core PWB LEDs 2 (CSC Test), 3 (SL Test), 4 (LB Test), and 5
The Printer Boot RAP is used when the Printer has failed to boot properly and /or when the UI (HDLC) come on momentarily every 76 seconds.
displays the message "Please wait System Communication Failure" and no fault code has Y N
been declared. The current Printer boot sequence indicates normal operation. If the prob-
lem continues replace the EDN Core PWB (PL 1.11)
Procedure
To verify that the EDN Core PWB self-test was successful and that the Dynamic Operating Enter the Service Mode. Press the Stop button to display the current meter
reading (will be 00000). Enter dC303. After waiting 60 seconds the UIM
System (DOS) was downloaded and is operating, observe the EDN Core PWB LED 2 (CSC
test). LED 2 (CSC Test) is flashing once per second. PWB is green and all the other PWBs are yellow.
Y N Y N
There is a System Bus communication failure. Go to the 3-201 RAP to find
The EDN Core PWB LED 2 (CSC Test), 3 (SL Test), 4 (LB Test) or 5 (HDLC) are on
constantly. the cause of the failure.
Y N
Check the identification connectors, J5, on the MIN, PHN, and FSN Core
The EDN Core PWB LEDs 2 (CSC Test), 3 (SL Test), 4 (LB Test), and 5 (HDLC)
PWBs to ensure that they are connected properly. The connectors, J5, on the
come on momentarily within a 30 second interval.
core PWBs are connected properly.
Y N Reconnect, repair, or replace the connectors.

This indicates a successful EDN Core PWB self-test. The current Printer Boot
sequence indicates normal operation, but the Printer had failed to boot prop-
erly. Replace the EDN Core PWB (PL 1.11)
Replace the EDN Core PWB (PL 1.11)
This indicates a successful EDN Core PWB self-test. The EDN Core PWB has downloaded the
Dynamic Operating System (DOS), but cannot obtain the Run Code softload from the UIM
Core PWB. The current Printer boot sequence indicates normal operation up to this point. Go
to the 3-390.


3-701 Floppy Disk Drive Failure RAP 3-702 System Bus Bad PWB Isolation RAP
Initial Actions This RAP is intended to be used to assist in the isolation of a difficult System Bus problem. It
contains the procedure outline for isolating a problem to a specific PWB. This RAP should only
be used when directed to this RAP from another RAP.
• Ensure that the Read/Write switch on the floppy diskette is in the "Read/Write" position.
The following procedure outline may induce other fault codes and/or problems. When possible,
This means that the switch should be blocking the open window. If the window is open
the induced fault codes will be described. This is done so as not to confuse the original prob-
and not blocked, the switch is in the "Read Only" position.
lem with the induced problem.
• Clean the heads of the Floppy Disk Drive using the Floppy Disk Head Cleaning Kit and
program dC101.
Procedure
• Ensure that pin 1 of the ribbon cable on the UIM Core PWB is connected to pin 1 of the
Floppy Disk Drive. NOTE: Fault codes may be declared up to 30 seconds after the Printer UI has come up. Do not
Procedure make any decision on the path of the RAP until after 30 seconds have passed.
The Printer is in a state where it can execute a program in dC101. Switch off the printer power. Disconnect the System Bus cables, P700/J3 and P701/J4, from
Y N the UIM Core PWB. Move the Termination Jumper, J5, on the UIM Core PWB to the pin 3
Replace the ribbon cable between the Floppy Disk Drive and the UIM Core PWB (PL 2.3). (TEST) and pin 2 position. Switch on the printer power. (Fault codes, 3-202, 3-203, 3-204, and
If the problem continues, replace the Floppy Disk Drive (PL 2.4) 3-205 should occur. Fault Code 3-331 may occur. Fault codes, 3-201 and 3-371, should not
If the problem continues, replace the UIM Core PWB (PL 2.3) occur).
Check the Queued Faults on the [SCP] screen. Fault code, 3-201 or 3-371, is present, or
Insert a formatted floppy diskette into the Floppy Disk Drive. Select dC101, [Disk Directory]. an Printer UI power up problem occurs.
The Floppy Disk Ready LED, CR1, on the UIM Core PWB is lit for approximately two sec- Y N
onds and then turns off. The problem is related to the System Bus, or to the PWBs that are connected to the Sys-
Y N tem Bus. Switch off the printer power. Reconnect P701/J4 to the UIM Core PWB and
Voltage is +5.0 VDC from pin 4 (+) to pin 3 (-) of the connector, P516. move the Termination Jumper to the pin 1 (NORM) and pin 2 position. Switch on the
Y N printer power. (Fault codes, 3-202, 3-203, and 3-204 should occur. Fault code 3-331 may
Go to the +5 VDC wirenet, Figure 33, (WIRING DATA), and check the wires, 1221 occur. Fault codes, 3-201, 3-205, and 3-371 should not occur).
and 1265, for an open circuit. Check the Queued Faults on the [SCP] screen. Fault code, 3-201 or 3-205 or 3-371 is
present, or an Printer UI power up problem occurs.
Replace the ribbon cable between the Floppy Disk Drive and the UIM Core PWB (PL 2.3) Y N
If the problem continues, replace the Floppy Disk Drive (PL 2.4) The problem is not related to the FSN Core PWB. Switch off the printer power.
If the problem continues, replace the UIM Core PWB (PL 2.3) Reconnect P700/J3 to the UIM Core PWB. Disconnect the System Bus connector,
P361/J4, on the PHN Core PWB. Switch on the power. (Fault codes, 3-202 and 3-
Replace the Floppy Disk Drive (PL 2.4) 203, should occur. Fault code 3-331 may occur. Fault code, 3-204, should not
If the problem continues, replace the UIM Core PWB (PL 2.3) occur).
Check the Queued Faults on the [SCP] screen. Fault code, 3-201 or 3-204 or 3-
371 is present, or an Printer UI power up problem occurs.
Y N
The problem is not related to the PHN Core PWB. Switch off the power. Recon-
nect P361/J4 to the PHN Core PWB. Disconnect the System Bus connector,
J224/J4, on the MIN Core PWB. Switch on the power. (Fault code, 3-202,
should occur. Fault code 3-331 may occur. Fault code, 3-203, should not
occur).
Check the Queued Faults on the [SCP] screen. Fault code, 3-201 or 3-203
or 3-371 is present, or an Printer UI power up problem occurs.
Y N

Check the Identification Connector, P244/J5, on the MIN Core PWB to make Table 1 GENERIC CORE PWB IDENTIFICATION CONNECTOR TABLE
sure that the correct pins are connected and that the pins which are connected
together have continuity. Refer to the GENERIC CORE PWB IDENTIFICATION
CONNECTOR TABLE. The connector is wired properly. Pin 4 & Pin 12 (not connected)
Y N FSN Core 4056/J5 Pin 1 & Pin 9 (connected)
Rewire or repair the connector to the proper termination. Pin 2 & Pin 10 (not connected)
Check the Identification Connector, P372/J5, on the PHN Core PWB in order to
make sure that the correct pins are connected and that the pins which are connected
together have continuity. Refer to the GENERIC CORE PWB IDENTIFICATION
CONNECTOR TABLE. The connector is wired properly.
Y N
Check the Identification Connector, P4056/J5, on the FSN Core PWB in order to make
sure that the correct pins are connected and that the pins which are connected together
have continuity. Refer to the GENERIC CORE PWB IDENTIFICATION CONNECTOR
TABLE. The connector is wired properly.
Y N
The cause of the problem is not related to the System Bus. Switch off the printer power. Recon-
nect the System Bus cables to the UIM Core PWB and move the Termination Jumper to pin 1
(NORM) and pin 2 position. Switch on the printer power.
Go back to the RAP that lead to this RAP or if no other instructions are given in the other RAP,
perform the following:
• Replace the UIM Core PWB (PL 2.3)
• Replace the EDN Core PWB (PL 1.11)
NOTE: Perform the replacement procedure for the EDN Core PWB (REP 1-13) to ensure
• If the problem continues, go to the 3-731 RAP.

Table 1 GENERIC CORE PWB IDENTIFICATION CONNECTOR TABLE

MIN Core P244/J5 Pin 1 & Pin 9 (connected)
PHN Core P372/J5 Pin 1 & Pin 9 (not connected)



A B C D
A B C D

3-703 Software Upgrade Problem RAP 2. DC102 PROGRAM CONTINUES TO PROMPT FOR A DISKETTE AFTER A DISKETTE
HAS BEEN INSERTED INTO THE FLOPPY DISK DRIVE.
Procedure a. This can be caused by the following:
This procedure is intended to be used when a problem occurs during a software or language • The wrong diskette was inserted into the Floppy Disk drive
upgrade. • The diskette is not labeled correctly
• The Floppy Disk drive is not functioning properly
Initial Action
b. Ensure that the correct diskette is inserted into the drive.
• Ensure that the proper diskette is inserted into the Floppy Disk drive.
c. If the problem continues, obtain another diskette, with the same number, from
• If a language upgrade is in progress, ensure that the language upgrade kit is compatible
another software upgrade kit.
with the version of software that is currently running the machine.
d. If the problem continues, go to the 3-701, Floppy Disk Drive Failure RAP.
• The dC102 program may show an error message on the digital display. When an error
message is displayed, always retry the software upgrade procedure. Many times the error 3. THE DIGITAL DISPLAY SHOWS A "1" IN POSITION 8 (A PROBLEM WITH THE
FLOPPY DISK DRIVE).
will not occur the second time. If the error message is displayed a second time, use the
information shown on the digital display in order to determine the corrective action. a. Observe which number disk failed by checking position 1 and 2 of the digital display.
Ex1x033E01 (Example of error message) b. Clean the Floppy Disk drive using the following procedure.
0987654321 (LED position of error message) • Switch off the power, wait 15 seconds, switch on the power.
• When all eights are shown on the digital display, 8888888888, insert the Floppy
Table 1 ERROR MESSAGE DESCRIPTION ON DIGITAL DISPLAY Head Cleaning diskette into the Floppy Disk drive.
LED POSITION # CODE DESCRIPTION • Leave the cleaning diskette there for five seconds and then remove it.
c. Insert software upgrade diskette #1.
1, 2 Number of disk with error
• If the software upgrade diskette #1 does not load properly, go to the 3-701,
3 Disk changing cue
Floppy Disk Drive Failure RAP.
4, 5, 6 Software revision level
d. Within a few seconds, the digital display should prompt for a numbered diskette to
7 Language upgrade be inserted (the number is displayed in position 1 and 2 of the digital display).
7 (blank) Language upgrade e. Insert the requested numbered diskette and continue the software upgrade.
7 L Language upgrade f. If the requested numbered diskette still does not load properly, obtain another copy
8 Error Device Indicator of the requested numbered diskette from a different software upgrade kit.
8 1 Floppy Disk problem g. If the problem continues, go to the 3-701, Floppy Disk Drive Failure RAP.
8 2 Rigid Disk/SMSD problem 4. THE DIGITAL DISPLAY SHOWS A "2" IN POSITION 8 (A PROBLEM WITH THE RIGID
8 3 Language upgrade problem DISK/SMSD).
9 (blank) - a. Go to the 3-390 RAP.
10 E Error Indicator (Flashing E) b. After you have completed the 3-390 RAP, it may be necessary to continue the soft-
ware upgrade. If this is the case, go to the dC 102 Software Upgrade procedure in
Problems List Section 6, Diagnostics.
Check the problem or symptom in the following list and perform the indicated action. 5. THE DIGITAL DISPLAY SHOWS A "3" IN POSITION 8 (A PROBLEM DURING A LAN-
GUAGE UPGRADE).
1. THE MACHINE RESTARTS ITSELF (AS IN POWER OFF/ON), AFTER STARTING THE a. This means that the language upgrade kit is not compatible with the software that is
SOFTWARE UPGRADE FROM DC102. currently loaded on the machine.
a. This means that the upgrade software cannot be loaded from diskette #1. b. Obtain a compatible language upgrade kit and try again.
• Clean the Floppy Disk drive heads using dC101, [Clean Disk Drive]. Insert the
Floppy Head Cleaning diskette into the Floppy Disk drive.
• Start the software upgrade procedure again using dC102.
b. If the problem continues, obtain another copy of diskette #1 and start the software
upgrade procedure again.
c. If the problem continues, go to the 3-701, floppy Disk Drive Failure RAP.

3-730 Intermittent Entry RAP 3-731 Intermittent Communication RAP
Procedure Procedure
1. Select [SCP] [Last 50] icons. View the Last 50 Shutdowns to determine which 3-xxx The most common causes of communications faults (3-2xx) are electrical connections, electri-
series faults are occurring. cal noise, and PWB failures.
2. Select [SCP] [Faults] Control. View the [Top 15 Control Faults] to determine which 3-
xxx series faults are occurring at a higher rate. Initial Action
3. Go to the Intermittent Entry Table and find the Epirote fault or faults and then go to the If the fault code is 3-201, 3-202, 3-203, 3-204, or 3-205, enter dC303 [Communication Test]
Intermittent RAP. [System View]. Lower the [System Bus Comm Rate Delay] to one-half of its current value.
Table 1 INTERMITTENT ENTRY TABLE 1. Go to the Printer Electrical Noise Procedure that is located in the Service Call Procedures
and perform the checks.
FAULTS ACTION REQUIRED
2. CHECK FOR A POOR / INTERMITTENT ELECTRICAL CONNECTION.
(3-2xx) Communications Go to the 3-731 Intermittent Communications An intermittent fault can also be caused by poor electrical connections. It can be isolated
RAP by using the RAP and circuit diagram that contain the functions which control the area of
(3-401 to 3-405, 3-408, 3-412 to 3-415) Com- Go to the 3-731 Intermittent Communications the printer that is producing the problem.
munications RAP
• Check all of the dropouts of the RAP for the communication fault code that is caus-
(3-371 to 3-375, 3-461 to 3-465, 3-471 to 3- Go to the 3-732 Intermittent Internal Error ing the problem.
475) Internal Error RAP • Pull on the wires and shake the connectors in order to induce the fault.
(3-381 to 3-385) Download Go to the 3-733 Intermittent Download RAP • Check the wiring and the plug and jack connectors for loose, bent, or corroded pins.
(3-390 to 3-393) Rigid Disk Go to the 3-734 Intermittent Rigid Disk RAP Removing the pins without using the extracting tool is a common cause of loose or
(3-340 to 3-346) Turnaround Go to the 3-735 Intermittent Turnaround RAP failed pins.
(3-361 & 3-362) NVM Go to the 3-736 Intermittent NVM RAP • Check for areas where the wiring may be rubbing on other parts and shorting.
(3-378, 3-480, 3-482, 3-483, 3-485, 3-492, 3- Go to the 3-737 Intermittent Hardware • Check for connectors that do not mate properly.
494) Hardware Related to Software Related to Software RAP • Check the voltage and ground sources for the proper levels.
Crash / No code Go to the 3-738, Intermittent Crash / No Code • Check the wiring, connectors, and components close to the problem area for any
RAP signs of arcing.
3. CHECK FOR ELECTRICAL INTERMITTENT NOISE.
An intermittent fault that is caused by electrical noise usually is one of two types. to deter-
mine the type, try to determine the exact mode of operation the printer is in when the fault
occurs and run the printer in that mode.
Completely random.
• If the fault can not be isolated to a specific function within the printer, refer to the
Shutdown History information and look for multiple occurrences of fault codes that
may locate the fault within a certain function
• Use the RAPs within the STATUS INDICATOR RAPS section of the Service Manual
to troubleshoot the fault.
• Specific events related.
• If the fault has a consistent pattern, try to relate the pattern to events in the printer,
then eliminate as many functions as possible to isolate a specific event.
• When the cause of the intermittent is isolated to a specific function, go to that func-
tional area and check the ground straps within that area.
CAUTION
Do not exchange a EDN Core PWB from one machine with a EDN Core PWB from another
machine.
4. If it is possible, exchange the suspected PWB with another PWB of the same type.

• If the problem follows the PWB to the new location, replace the PWB. If the problem 3-732 Intermittent Internal Error RAP
does not follow, replace the communication bus cables.
5. If all the above procedures were followed and the problem continues, and if the suspected The most common cause of intermittent internal error faults (3-371 to 3-376) is electrical noise.
PWB was not yet replaced, replace the suspected PWB now.
Procedure
1. Check for electrical intermittent noise.
An intermittent fault that is caused by electrical noise usually is one of two types. The type
is determined by the exact mode of operation the printer is in when the fault occurs. Run
the printer in the mode of operation that the fault occurred.
a. Completely random electrical intermittent noise:
• If the fault can not be isolated to a specific function within the printer, refer to
the Shutdown History information and look for multiple occurrences of fault
codes that may locate the fault within a certain functional area.
• Use the RAPs within the STATUS INDICATOR RAPS section of the Service
Manual to troubleshoot the fault.
b. Specific events related to the electrical intermittent noise:
• If the fault has a consistent pattern, try to relate the pattern to events in the
printer, then eliminate as many functions as possible to isolate a specific event.
• When the cause of the intermittent is isolated to a specific function, go to that
function area and check the ground straps within that function.
2. Perform the Electrical Noise RAP that is located in the SERVICE CALL PROCEDURES.
3. If all the above procedures were followed and the problem continues, and if the suspected
PWB was not yet replaced, replace the suspected PWB now.
25 prints of the fault under investigation).
4. Ensure that the latest release of software is loaded on the system controller and the
printer. If the problem continues, look for related fault codes.
Select [SCP] [Last 50]. View the [Last 50] to determine if there are any other fault codes listed
which have occurred within 25 print counts of 3-371 to 3-376. There are other faults listed
within 15 copy counts of 3-371 to 3-376.
Y N
If this software problem has not been identified on the SYSTEM SOFTWARE PROBLEM
SET, make a field service report, through SPAR, to engineering.

3-733 Intermittent Download RAP 3-734 Intermittent Rigid Disk RAP
Procedure Procedure
The most common causes of download problems (3-380 to 3-387) are electrical noise, PWB The most common causes of Rigid Disk/SMSD faults (3-390 to 3-393) is the ribbon cable(s)
failures, and Rigid Disk failures at power up. that connect the UIM Core PWB to the Rigid Disk/SMSD.
CAUTION 1. With the machine in stand-by, gently move or twist the connectors and ribbon cable(s) to
Do not exchange a EDN Core PWB from one machine with a EDN Core PWB from another attempt to induce the fault. Replace the ribbon cable(s) if the fault can be created the (PL
machine. 2.2)
1. Exchange the suspected generic Core PWB with another generic Core PWB. 2. Switch off power. Inspect the ribbon cable connectors on the UIM Core PWB and Rigid
Exchange as follows: Disk/SMSD for loose, bent, or corroded pins.
• PHN Core PWB & MIN Core PWB (Termination Jumper, J2, on NORM pin 1) 3. Inspect the input power connector, P515, on the Rigid Disk/SMSD for loose, bent, or cor-
roded pins.
If the problem follows the Core PWB to the new location, replace the Core PWB. If the
problem does not follow, continue with this procedure. 4. (With Rigid Disk Only). Switch on power. Enter dC303, select [Seek Test], [Read/Write
Test], [Continuous]. Press the Continue button to attempt to induce the fault.
Exchange the FSN Core PWB & the PHN Core PWB (Termination Jumper J2, on NORM
5. (With Rigid Disk Only). Perform dC 324 RIGID DISK/SMSD VALIDATE (FLOPPY DISK
pin 1 at the PHN position, and on TEST pin 2 in the FSN position).
ROUTINE).
6. If the above steps were followed and the problem continues, replace the following in
3. CHECK FOR ELECTRICAL INTERMITTENT NOISE.
sequence:
An intermittent fault that is caused by electrical noise usually is one of two types. to deter-
• Ribbon cable(s) from the Rigid Disk Drive (PL 2.4)
mine the type, try to determine the exact mode of operation the machine is in when the
fault occurs and run the machine in that mode. NOTE: The Rigid Disk Drive/SMSD Assembly replacement procedure (REP 2-12) must be fol-
a. Completely random. lowed to ensure saving critical disk files.
• If the fault can not be isolated to a specific function within the printer, refer to • Rigid Disk/SMSD (PL 2.4)
• UIM Core PWB (PL 2.3)
codes that may locate the fault within a certain function
b. Specific events related.
functional area and check the ground straps within that area.
4. If all the above procedures were followed and the problem continues, go to the 3-734,
Intermittent Rigid Disk RAP.
3-735 Intermittent Turnaround RAP • associated wire in the +24 VDC harness (WIRING DATA)
• The LVPS (PL 1.9)
Procedure
Turnaround Tests (3-340 to 3-342) are only executed at machine power-up. By their very
nature, Turnaround Tests may only fail some of the time.
1. Go to the appropriate RAP for the fault code that is being declared. Check all the wires
and connectors that are listed in the Output Signals Table for the PWB that is failing. If no
problem is found, go to the 1-717 RAP and check all the dropouts.
2. If the above step was followed and the problem continues, replace the following in this
order:
• PWB that is failing the Turnaround Test (Refer to CD in table)
• associated wire in the input/output harness (Refer to CD in table)

3-737 Intermittent Hardware Related Software Fault RAP 3-738 Intermittent Crash/No Fault Code RAP
Procedure Procedure
These faults are caused by software errors that may be related to machine hardware prob- This problem is defined as when the Printer UI screen and digital display goes blank and then
lems. the machine control logic goes through a normal power-up sequence. It is as if the main AC
Ensure that the latest release of software is loaded on the System Controller and on the power were switched off and then switched on.
Check the following for the cause of this problem:
25 prints).
1. Unstable AC power coming into the printer.
Select [SCP] [Last 50]. View the Last 50 Shutdowns to determine if there are any other fault 2. AC power distribution within the machine or the AC Power Cord.
codes listed which have occurred within 25 prints counts of the 3-xxx. There are other faults 3. LVPS that is affecting the +5 VDC to the UIM Core PWB
listed within 25 copy counts of 3-xxx.
4. +5 VDC wires that go to the UIM Core PWB (Check for intermittent opens and shorts in
Y N
the +5 VDC wiring).
Fault Code, 3-xxx, is the result of an internal software error. If this software problem has
not been identified on the System Software Problem Set, located in the software release 5. Electrical Intermittent Noise
documentation, make a field service report, through SPAR, to engineering. Where possi- An intermittent fault that is caused by electrical noise usually is one of two types. to deter-
ble perform a dC 350 (Save Crash Data Files) (General Procedures). Call the hotline for mine the type, try to determine the exact mode of operation the machine is in when the
further information and instructions. fault occurs and run the machine in that mode.
a. Completely random.
Go to the appropriate RAP for the other fault codes listed within 25 print counts. • If the fault can not be isolated to a specific function within the printer, refer to
codes that may locate the fault within a certain function
b. Specific events related.
function area and check the ground straps within that function.
7. If the above steps were followed and the problem continues, replace the UIM Core PWB
(PL 2.3)

3-750 PWB Drawings Section
Procedure
This section contains drawings to support the 3-000 series RAPs.
The drawings are as follows:
• Communication Bus Block Diagram - Figure 1

• PWB Location Drawing - Figure 2
• EDN Core and MIN Core PWB Circuit Diagram - Figure 3
• UIM Core and PHN Core PWB Circuit Diagram - Figure 4
• FSN Core PWB Circuit Diagram - Figure 5
• Video Engine PWB Circuit Diagram - Figure 6
• Rigid Disk Floppy Disk Circuit Diagram - Figure 7
• CP IOP PWB Circuit Diagram - Figure 8
• MIN ADA#1, ADA#2 PWB Circuit Diagram - Figure 9
• MIN DIO and MIN SLB/RDR PWB Circuit Diagram - Figure 10
• PHN DIO PWB #1, #2 Circuit Diagram - Figure 11
• PHN DIO PWB #6, #5, Reg Servo Circuit Diagram - Figure 12
• FSN DIO PWB #1A, #2A, #3A Circuit Diagram - Figure 13
• FSN Stepper PWB A Circuit Diagram - Figure 14
• FSN DIO PWB #1B, #2B, #3B Circuit Diagram - Figure 15
• FSN Stepper PWB B Circuit Diagram - Figure 16

Figure 1 Communication Bus Block Diagram


Figure 3 EDN Core PWB and MIN Core PWB Circuit Diagram (7310)


Figure 5 FSN Core PWB Circuit Diagram (7312)

Figure 6 Video Engine PWB Circuit Diagram (7301)

Figure 7 Floppy Disk Drive and Rigid Disk Drive Circuit Diagram (7302)

Figure 8 CPIOP PWB Circuit Diagram (7303)

Figure 9 MIN ADA #1 and #2 Circuit Diagram (7304)

Figure 10 MIN DIO PWB and MIN SLB/RDR PWB Circuit Diagram (7305)

Figure 11 PHN DIO PWB #1 and #2 Circuit Diagram (7306)

Figure 12 PHN DIO PWB #6 and #5, PHN Registration Servo PWB Circuit Diagram (7307)

Figure 13 FSN DIO PWB #1A, #2A, and #3A Circuit Diagram (7308)

Figure 14 FSN Stepper PWB A Circuit Diagram (7309)

Figure 15 FSN DIO PWB #1B, #2B, #3B Circuit Diagram (7315)

Figure 16 FSN Stepper PWB B Circuit Diagram

4-201 RAP • Photoreceptor Module Roll-up Cable for an intermittent connection (PL 9.1)
• Machine Clock Sensor Drive Coupling (PL 9.3)
Fault Code, 4-201, (60 Hz) occurs when the control logic senses a Main Drive acceleration
The Machine Clock Sensor drives are OK.
fault. There should be 20 machine clock counts in 160 milliseconds after Start is initiated.
Y N
Repair or replace the defective components.
Fault Code, 4-201, (50 Hz) occurs when the control logic senses a Main Drive acceleration
fault. There should be 20 machine clock counts in 450 milliseconds after Start is initiated.
Check that the Photoreceptor Drive Shaft is rotating. Press the Continue button. The Photo-
receptor Drive Shaft is rotating.
Fault Code, 4-201, also occurs if there is a problem with the (50 Hz) Soft Start Hardware. If the
Y N
Soft Start Relay PWB with the time delay disks is not functioning, the software will measure too
Press the Stop button. Check the Photoreceptor Drive Coupling for misalignment or slip-
many machine counts during the motor start-up in print mode.
ping.
Initial Actions Press the Stop button. +15 VDC is measured between TS 15 (+) and TS 14 (-) on the PHN
Perform the following: Registration Servo PWB.
Y N
• Ensure that all Main Power Circuit Breakers are on. +15 VDC is measured between TH6 (+) and TH8 (-) on the LVPS.
• Ensure that dC131 EDN NVM location 392 is at the value listed in the appropriate level Y N
Software dC 131 EDN Table in General Procedures. Go to the 1-715, +15 VDC.
• Enter dC912, [Main Drive]. Press the Continue button. Observe the measurements of
machine clock counts that appear in the interval windows. Make a note of the range of Go to the +15 VDC Distribution Wirenet, Figure 45, (WIRING DATA) and check wire 529
machine clock counts.
• For 50 Hz machines, go to the 4-708 RAP and ensure that the soft start circuit is operat-
Connect a multimeter between TS 7 (+) and J4-14 (-) on the PHN Registration Servo PWB.
ing properly.
Press the Continue button. The voltage is 2.3 to 2.8 VDC.
Procedure Y N
Enter dC330, [Main Drive Start/Run]. Press the Continue button. Press the Stop button. Disconnect P308 from J4 on the PHN Registration Servo PWB. +
5 VDC is measured between TS 13 (+) and TS 12 (-) on the PHN Registration Servo
NOTE: If Main Power Circuit Breaker, CB103 (60Hz) or CB104 or CB105 (50Hz) switches off PWB.
while running this test, go to the 4-203 RAP. Y N
Replace the PHN Registration Servo PWB (PL 1.4).
The Main Drive Motor comes on and appears to be running at a normal speed.
Y N
Press the Stop button. The dC912 machine clock count interval windows checked in +5 VDC is measured between TS 7 (+) and TS 12 (-) on the PHN Registration Servo
PWB.
the INITIAL ACTION were mostly zeros.
Y N Y N
The machine clock count windows showed numbers greater than zero. Go to the 4- Replace the PHN Registration Servo PWB (PL 1.4).
203 RAP, or the 4-701 Main Drive RAP (50HZ WYE), or the 4-701 Main Drive RAP
(50HZ DELTA). Reconnect P308 to J4 on the PHN Registration Servo PWB. Disconnect CLK1 from the
machine clock. +5 VDC is measured between CLK1-1(+) and CLK1-3(-).
Y N
Go to the 4-700 Main Drive RAP, or the 4-701 Main Drive RAP (50HZ WYE), or the 4-701
Main Drive RAP (50HZ DELTA). Go to Flag 1. Check the wires for an open or short circuit.
+5 VDC is measured at CLK1-2.

Press the Stop button. The dC912 machine clock count interval windows checked in the
INITIAL ACTION were mostly zeros. Y N
Y N Go to Flag 2. Check the wires for an open or short circuit.
The machine clock count windows showed numbers greater than zero. Go to the 4-203
RAP, or the 4-701 Main Drive RAP (50HZ WYE), or the 4-701 Main Drive RAP (50HZ Replace the Machine Clock Sensor, Q401 (PL 9.3).
DELTA).
Press the Stop button. Enter [Power Interrupt]. Check for mechanical binding in drives.
Check the following for slippage or binding: Handcrank the Main Drive clockwise. The Main Drives are free of binding.
• Photoreceptor Drive Belt (PL 4.17)
• Photoreceptor Drive Pulley (PL 4.17)

A B
Y N Press the Stop button. Replace the following components one at a time until the problem
Check the adjustment of the drive belts (ADJ 4-18). Isolate the source of mechanical is resolved:
binding. • Machine Clock Sensor, Q401 (PL 9.3)
• Main Drive Motor, MOT401 (PL 4.18).
Disconnect P243 from the MIN Core PWB. Exit the Power Interrupt mode. Enter dC330, [Main
Drive Start/Run]. Connect a multimeter to TS 10 (+) and TS 12 (-) on the PHN Registration Replace the following components one at a time until the problem is resolved:
Servo PWB. Press the Continue button. The voltage is 2.1 to 2.6 VDC. • Main Drive Run Capacitor, C401 (PL 4.19)
Y N
• Photoreceptor Module Roll-up Cable (PL 9.1)
Press the Stop button. Reconnect P243 to the MIN Core PWB. Disconnect P342 from the
PHN Core PWB. Press the Continue button. The voltage is 2.1 to 2.6 VDC. • Machine Clock Sensor, Q401 (PL 9.3)
Y N • Main Drive Motor MOT401, (PL 4.18).
Press the Stop button. Go to Flag 3 and Flag 4. Check the wires for an short circuit.
If OK, replace the PHN Registration Servo PWB (PL 1.5).
Press the Stop button. Replace the PHN Core PWB (PL 1.5).
Press the Stop button. Reconnect P243 to the MIN Core PWB. Connect the multimeter to
TS11(+) and TS18 (-) on the MIN Core PWB. Press the Continue button. The voltage is 2.1
to 2.6 VDC.
Y N
Press the Stop button. Disconnect P243 from J6 on the MIN Core PWB. + 5 VDC is
measured between TS 11 (+) and TS 18 (-) on the MIN Core PWB.
Y N
Replace the MIN Core PWB (PL 1.8).
Press the Stop button. The printer is a 60Hz version.

Y N
Switch off the printer circuit breakers. Disconnect wire #35 from terminal 1 of the Main
Drive Run Relay, K402. Avoid shorting the wire to any conductive surface. Switch on the
printer circuit breakers. Enter dC330, [Main Drive Start/Run]. Press the Continue but-
ton. The Main Drive runs.
Y N
Press the Stop button. Go to the 4-700 RAP, or the 4-701 Main Drive RAP (50HZ
WYE), or the 4-701 Main Drive RAP (50HZ DELTA).
Press the Stop button. Switch off the printer circuit breakers. Reconnect wire 35 to termi-
nal 1 of K402. Disconnect wire 37 from terminal 2 of K402. Switch on the printer circuit
breakers. Enter dC330, [Main Drive Start/Run]. Press the Continue button. The Main
Drive runs.
Y N
Press the Stop button. Go to the 4-203 RAP, or the 4-701 Main Drive RAP (50HZ
Press the Stop button. Switch off the printer circuit breakers. Reconnect wire 37 to termi-
nal 2 of K402. Disconnect wire 36 from terminal 3 of K402. Switch on the printer circuit
breakers. Enter dC330, [Main Drive Start/Run]. Press the Continue button. The Main
Drive runs.
Y N
Press the Stop button. Go to the 4-700 Main Drive RAP, or the 4-701 Main Drive
RAP (50HZ WYE), or the 4-701 Main Drive RAP (50HZ DELTA).
A B

4-202 RAP

Fault Code, 4-202, occurs when the Control Logic senses a Main Drive speed fault (too many
machine clock counts). The Control Logic performs a check for no more than 1920 machine
clock counts within 980 ms.
Initial Actions
• Ensure that dC131 EDN NVM location 392 is at the value listed in the appropriate level
Software dC 131 EDN Table in General Procedures.
Procedure
Enter dC330, [Main Drive Start/Run]. Press the Continue button. The Main Drive Motor
runs.
Y N
Go to the 4-700 Main Drive RAP (60Hz), or the 4-701 Main Drive RAP (50HZ WYE), or
the 4-701 Main Drive RAP (50HZ DELTA).
Press the Stop button. Check the following:

• Photoreceptor Drive Belt (PL 4.17)
• Photoreceptor Drive Pulley (PL 4.17)
• Machine Clock Sensor coupling alignment.
If OK, replace the PHN Registration Servo PWB (PL 1.4).


A
4-203 RAP Go to Flag 8. Check wires 27, 400, 400A, and 23D for an open circuit. If OK, check the follow-
ing:
Fault code, 4-203, occurs when the control logic senses a main drive acceleration fault (too • Photoreceptor Drive belt and pulley for slipping.
few machine clock counts). The Control Logic performs a check at 200 and 420 machine clock • Alignment of the Machine Clock Sensor coupling.
counts for a minimum of 80 machine clock counts within 50 ms. During print, the machine clock
If they are OK, replace the following components, one at a time, until the problem is resolved:
is checked for 1590-1920 counts in 1 second +/- 20ms.
• Machine Clock Sensor, Q401 (PL 9.3)
• Main Drive Start Relay, K401 (PL 1.6)
Initial Actions
• Main Drive Start Capacitor, C402 (PL 4.19)
• Ensure that dC131 EDN NVM location 392 is at the value listed in the appropriate level
• Main Drive Motor, MOT401 (PL 4.18)
Software dC 131 EDN Table in General Procedures.
Procedure
Enter dC330, [Main Drive Start/Run]. Press Continue.
NOTE: If Main Power Circuit Breaker CB103 switches off any time during this RAP, reset it and
Continue.
The Main Drives come on or try to come on (show any movement).

Y N
Press Stop. Go to the 4-203 (60Hz), or the 4-701 Main Drive RAP (50HZ WYE), or the 4-
701 Main Drive RAP (50HZ DELTA).
Press Stop. Enter [Power Interrupt]. Handcrank the Main Drives. The drives rotate and are
free of binding.
Y N
Isolate the source of mechanical binding by disconnecting drive belts from the Main
Drives. Repair or replace the defective components. Refer to the Drives adjustments,
(ADJ 4-10) thru (ADJ 4-20).
The printer is a 60Hz version.

Y N
Check the Photoreceptor Drive Belt, pulley, and the Machine Clock Sensor coupling for
slipping. If OK, go to the 4-700 Main Drive (60Hz), or the 4-701 Main Drive RAP (50HZ
Exit the Power Interrupt mode. Observe the Fuser/Developer Drives. Press Continue. The
Fuser/Developer Drives appear to rotate at normal speed.
Y N
Press Stop. Go to the 4-705, 60Hz Fuser/Developer Drive RAP.
Press Stop. Observe the Main Drive Start Relay, K401. Press Continue. The relay contacts
pull in momentarily.
Y N
Press Stop. Go to Flag 6. Use the Generic Solenoid/Clutch/Relay RAP GP 6-3 (General
Procedures) to check the DC control circuit for the Main Drive Start Relay, K401. If OK,
replace the Main Drive Start Relay, K401 (PL 1.6).
Press Stop. 115 VAC is measured between K402-4 and terminal 7 of K401.
Y N
A


4-210 RAP
Fault code, 4-210, occurs when the machine clock signal is missing at the PHN CORE PWB.
Procedure
Enter dC330, [Main Drive Start/Run]. Press the Continue button. 2.1 to 2.6 VDC is mea-
sured between TS 10 (+) and TS 12 (-) on the PHN Registration Servo PWB.
Y N
Press the Stop button. Go to the 4-201 RAP.
2 to 3 VDC is measured between TS11 (+) and TS18 (-) on the PHN Core PWB.
Y N
Go to Flag 1. Check the wire for an open or short circuit. If it is OK, replace the PHN Core
PWB (PL 1.4).
Replace the PHN Core PWB (PL 1.4).


4-211, 4-213 RAP Y N
Fault codes, 4-211 and 4-213 occur when the Registration Sync signal is missing at the PHN
Core PWB. Press the Continue button. The voltage between TS13 (+) and TS22 (-) on the PHN Core
PWB goes LO (less than 0.7 VDC) for 1 second.
Procedure Y N
Go to Flag 1. Check the wires for an open circuit. If OK, replace the PHN Core PWB (PL
+5 VDC is measured between TS13 (+) and TS22 (-) on the PHN Core PWB.
Y N 1.4).
Disconnect P342 from PHN Core PWB. +5 VDC is measured between TS13 (+) and TS
Check the wires and connectors for an intermittent condition.
22 (-) on the PHN Core PWB.
Y N
Replace the PHN Core PWB (PL 1.4).
Reconnect P342 to PHN Core PWB. Disconnect P233 from the MIN DIO PWB. +5 VDC
is measured between TS13 (+) and TS22 (-) on the PHN Core PWB.
Y N
Reconnect P233 to the MIN DIO PWB. Disconnect P308 from the PHN Registration
Servo PWB. +5 VDC is measured between TS13 (+) and TS22 (-) on the PHN
Core PWB.
Y N
Go to Flag 1. Check the wires for a short circuit to ground.
Go to Flag 2. Check the wires for a short circuit to ground. If OK, replace the PHN
Registration Servo PWB (PL 1.4).
Replace the MIN DIO PWB (PL 1.8).
+5 VDC is measured between TS6 (+) and TS12 (-) on the Registration Servo PWB.
Y N
+5 VDC is measured between TS45 (+) and TS37 (-) on the MIN DIO PWB.
Y N
Enter dC330, [Reg Sync]. Press the Continue button.
NOTE: The [Reg Sync] output test is a limited duty cycle (1 second) test.
The voltage between TS45 (+) and TS37 (-) on the MIN DIO PWB goes LO (less than 0.7
VDC) for one second.
Y N
Press the Continue button. The voltage between TS4 (+) and TS12 (-) on the Registration
Servo PWB goes LO (less than 0.7 VDC) for 1 second.
Y N
Go to Flag 2. Check the wires for an open circuit. If OK, replace the PHN Registration
Servo PWB (PL 1.4).
Press the Continue button. The voltage between TS6 (+) and TS12 (-) on the PHN Regis-
tration Servo PWB goes LO (less than 0.7VDC) for 1 second.


4-212 RAP
Fault code, 4-212, occurs when a Reg. Sync signal arrives at the PHN Core unexpectedly. This
fault is often caused by electrical noise problems.
Procedure
The fault is occurring just as the Main Drive Run Relay, K402 is energizing.
Y N
Go to Flag 1 and 2. Check the wires for an intermittent short circuit. If OK, go to the Non-
Repeatable Problem Entry Procedure.
Ensure that Resistor Capacitor Networks, RC401, RC402, and RC403, are across terminals 1
and 4, 2 and 5, and 3 and 6 of K402. If each of these is present and the connections are OK,
replace all three Resistor Capacitor Networks, RC401, RC402, and RC403 (PL 1.5).


4-220 RAP
Fault code, 4-220, on 50Hz systems, indicates that the three phases of the AC power entering
the printer are not connected in the correct configuration. This can cause the Main Drives to
run backwards and result in serious printer damage.
Fault Code P04-220 also indicates a problem with 50 Hz Soft Start hardware. This hardware is
used to slow down the rapid acceleration profile of the 50 Hz Main Drive Motor and the Fuser/
Developer Motor, and to prevent long term damage to the drive components such as belts or
pulleys. This problem can cause a hard shutdown during start print, or can be recorded as a
log-only fault.
This fault causes a hard shutdown during power up. This fault is intended only to apply on
50Hz systems. If this fault occurs on 60Hz systems, it indicates that there is an incorrect NVM
value at MIN 178.
Initial Actions
WARNING
AC Power is present in the Line Interface Module and at the Input Terminal Block when-
ever the service power circuit breaker or disconnect switch is on or the Power Cord is
plugged in to the power outlet (if so equipped). Use care when working in these areas.
• Switch the Printer power off/on and verify that the problem is repeatable.
• For 50 Hz machines, go to 4-708 and ensure that the soft start circuit is operating prop-
erly.
Procedure
The fault is occurring on a 50Hz machine.
Y N
Enter dC131, [Special Access] [MIN]. Select address 178. Ensure that the data con-
tained at this address is at the value shown in the appropriate level Software dC 131
Table in General Procedures.
Switch off the Printer circuit breakers. Disconnect all Printer power. Access the Input terminal
block, TB101. Record the positions of the power cord wires that are connected to TB101.
Switch the positions of any two of the wires from the power cord connected to terminals 1, 2, or
3. Switch on the Printer circuit breakers. A 4-220 is declared after initialization.
Y N
The problem has been corrected.
Switch off the Printer circuit breakers. Disconnect all Printer power. Return the wires at TB101
to the positions they were connected to. Connect a jumper wire between TS 6 and TS 37 on
the MIN DIO PWB. Switch on the Printer circuit breakers. A 4-220 is declared.
Y N
Remove the jumper wire. Go to Flag 1 and 2. Check the wires for an open circuit. If OK,
replace the 3 Phase Detection PWB (PL 1.1).
Switch off the Printer circuit breakers. Remove the jumper wire. Replace the MIN DIO PWB
(PL 1.8).


4-221 RAP
Fault code, 4-221, indicates that +24 VDC is missing in the Marking and Imaging Module. The
Printer will enter the Power Interrupt mode and will disable the +24 VDC section of the LVPS
when this fault occurs.
Initial Actions
Check the queued faults for 1-220 faults. If there are 1-220 faults present, go to the 1-220.
Procedure
Y N
Y N
Go to the 1-717 +24, +34, and -34 VDC.
+24 VDC is measured between P260-3 (+) on the +24 VDC Sensor Q462 and TS37 (-) on
the MIN DIO PWB.
Y N
+24 VDC is measured between P260-3 (+) and P260-1 (-) on the +24 VDC Sensor Q462.
Y N
Enter dC330, [1-4]. Disconnect P248 from J7 on the MIN DIO PWB. Connect a jumper wire
from TS4 to TS37 on the MIN DIO PWB. The MIN LVPS Monitor display is L.
Y N
Go to Flag 3. Check the wires for an open circuit. If OK, replace the +24 VDC LVPS Sensor,
Q462 (PL 1.8).


A B
4-700 Main Drive RAP (60HZ) Switch off the Printer. Slide out the Xerographic Drawer and the Fuser Drawer. Handcrank
the Main Drives. The drives rotate at least 1/8 revolution.
Procedure Y N
Isolate the source of the mechanical binding. Refer to adjusting the tension of the
If the Main Drive Motor runs continuously when the Printer power is on, go to the end of this
RAP, to the paragraph labeled "Main Drive Runs Continuously". drive belts, adjustment (4-X), if necessary. Repair or replace the defective compo-
nents. If binding has occurred, Main Drive Motor, MOT401, may be in an overheat
WARNING condition. If the motor does not recover within one hour, replace the Main Drive
Use caution when working near the motor. The Main Drive Motor, MOT401, may run Motor, MOT 401 (PL 4.18).
automatically. If the motor becomes too hot, it is switched off by an internal thermal sen-
sor. This sensor will reset when the motor cools (up to 1 hour). Also, the outside sur- NOTE: For a reference diagram of the Drives, see the 4-702 Circuit Diagram.
faces of the motor could also be very hot.
Go to Flag 8. Check wires 27,400, and 400A for an open circuit. Also check wire 23D. If
Enter dC330, [Main Drive Start/Run]. Observe the Main Drive Run Relay, K402. Press the OK, replace these components one at a time until the problem is resolved:
Continue button. K402 actuates. • Main Drive Start Relay, K401 (PL 1.6)
Y N
• Main Drive Start Capacitor, C402 (PL 4.19)
Press the Stop button. +24 VDC is measured between TS 58 and TS 56 on the MIN
ADA PWB 1. • Main Drive Run Capacitor, C401 (PL 4.19)
Y N • Main Drive Motor, MOT401 (PL 4.19)
Go to wirenet 1006 (WIRING DATA). Check for an open circuit. If OK, go to 1-220.
115 VAC is measured between K402-4 and 2A7TB1-7.
Go to Flag 2. Check the DC control circuit of the Main Drive Run Relay, K402 (Generic Y N
Relay RAP GP 6-3, General Procedures). Go to the ACN Wirenets, (Wiring Data) and check the wire 4 for an open circuit.
Press the Stop button. Observe the Main Drive Start Relay, K401. Press the Continue button. Press Continue. Less than 30 VAC is measured between terminals 1 and 4 of K402.
The relay pulls in momentarily. Y N
Y N Press Stop. Replace the Main Drive Run Relay, K402 (PL 1.6).
Press the Stop button. Go to Flag 6. Check the DC control circuit of the Main Drive Start
Relay, K401 (Generic Relay RAP GP 6-3, General Procedures), (PL 1.6). Press Stop. A problem exists with power to the Waste Compactor Auger Motor, Ozone
Blower, or the Toner Filter Blower Motor.
Press the Stop button. 115 VAC is measured at P355-3. Y N
Press the Continue button. 115 VAC is measured at P355-3.
Press the Stop button. 115 VAC is measured at terminal 4 of the Main Drive Run Main Drive Motor Runs Continuously.
Relay, K402. Go to Flag 2. Check the control circuit of the Main Drive Run Relay, K402 (Generic Relay RAP
Y N GP 6-3, General Procedures). If OK, replace the Main Drive Run Relay, K402 (PL 1.6).
115 VAC is measured at terminal 7 of the Power On Relay, K101.
Y N
115 VAC is measured at terminal 1 of the Main Drive Run Relay, K402.
Y N
Replace the Main Drive Run Relay, K402 (PL 1.6).
Press the Stop button. 115 VAC is measured between K402-4 and K401-7.
Y N
A B

A B C
4-701 Main Drive RAP (50HZ WYE) Y N
+24 VDC is measured at P212-2.
Initial Actions Y N
Table 1 AC VOLTAGE SPECIFICATIONS
The thermal overheat device in the Fuser/Developer Drive Motor has
NOMINAL PHASE-TO-NEUTRAL VOLTAGE PHASE-TO-PHASE VOLTAGE RANGE opened. Switch off the Printer power and switch off all Printer Circuit
220 VAC 342 to 418 VAC Breakers. Check for binding in the Fuser/Developer Drives. The motor
230 VAC 358 to 438 VAC should recover within one hour, if it does not, replace the Fuser/Developer
Drive Motor, MOT402 (PL 4.20).
240 VAC 373 to 457 VAC

Procedure
If the Main Drive Motor runs continuously when the printer power is on, go to the end of this Go to Flag 9. Check the wires for an open circuit. If OK, check the control circuit of
RAP, to the paragraph labeled "Main Drive Motor Runs Continuously". the Main Drive Run Relay, K402 (GP 6-3 Generic Relay RAP, General Procedures).
WARNING
Press Stop. Replace the Main Drive Run Relay, K402 (PL 1.5).
Use caution when working near the motor. The Main Drive Motor, MOT401, may run
automatically. If the motor overheats, it is switched off by an internal thermal sensor.
The Fuser/Developer Drive Motor is running.
This sensor will reset when the motor cools (up to 1 hour). The outside surfaces of the
Y N
motor may also be very hot.
Press the Stop button. Disconnect P355 from the Main Drive Motor. Refer to Table 1 for
Enter dC330, [Main Drive Start/Run]. Observe the Main Drive Run Relay, K402. Press Con- the proper phase-to-phase voltage ranges. The phase-to-phase voltage is measured
tinue. K402 energizes. between terminals 4 and 5 of K402.
Y N Y N
+24 VDC is measured between terminals A and B of K402. The phase-to-phase voltage is measured between terminals B and D of the
Y N Main Power Circuit Breaker, CB104.
Press Stop. +24 VDC is measured between TS 58 and TS 56 on the MIN ADA Y N
PWB 1. Go to the 1-707, AC Input Power (50 Hz WYE).
Y N
Go to wire 1021B wirenet and check for an open circuit. If OK, go to the 1-220. The phase-to-phase voltage is measured between P9-1 and P9-3 on the Soft
Start PWB.
Press Continue. +24 VDC is measured at terminal A (orange wire) of K402. Y N
Enter the Power Interrupt mode. Disconnect P356 from the Main Drive Motor.
Continuity is measured between J2-1 and J2-2 at the Main Drive Motor, The phase-to-phase voltage is measured between P9-2 and P9-4 on the Soft
MOT401. Start PWB.
Y N Y N
The thermal overheat sensor has opened. Switch off printer Main Power Go to 4-708, (50 Hz) Soft Start RAP.
and disconnect the Power Cord. Check the following:
• Shorted Main Drive Run Relay, K402 (PL 1.5) Go to Flag 15. Check the wires for an Open circuit.
• Binding in drive system.
The phase-to-phase voltage is measured between terminals 5 and 6 of K402.
NOTE: For a reference diagram of the Drives, see the 4-702 Circuit
Y N
Diagram.
The phase-to-phase voltage is measured between terminals D and F of CB104.
If the thermal sensor has not recovered within 1 hour from the thermal Y N
overheat condition, replace the Main Drive Motor, MOT401 (50Hz) (PL Go to the 1-707, AC Input Power RAP (50 Hz WYE).
4.18). If the motor runs when power is turned on, replace the MIN ADA
PWB 1 (PL 1.8). The phase-to-phase voltage is measured between P9-3 and P9-5 on the Soft
Start PWB.
Reconnect P356 to the Main Drive Motor. Exit the Power Interrupt mode. +24 Y N
VDC is measured at P212-1. Go to Flag 3. Check the wires for an open circuit.
A B C D E F
D E F G
The phase-to-phase voltage is measured between P9-4 and P9-6 on the Soft The phase-to-neutral voltage is measured between P355-1 and P355-5.
Start PWB. Y N
Y N Press Stop. Go to Flag 7. Check the wires for an open circuit.
Go to 4-708, (50 Hz) Soft Start RAP.
Go to Flag 16. Check the wires for an Open circuit. Y N
Press Stop. Go to Flag 8. Check the wires for an open circuit.
Put the multimeter leads across terminals 1 and 4 of the K402. Press Continue. Less
than 30 VAC is measured. Press Stop. Replace the following, one at a time until the problem is resolved:
Y N • Machine Clock Sensor, Q401 (PL 9.3)
Press Stop. Replace the Main Drive Run Relay, K402 (PL 1.5). • Main Drive Motor, MOT401 (PL 4.18).
Main Drive Motor Runs Continuously.
Less than 30 VAC is measured between terminals 2 and 5 of K402.
Switch off the printer circuit breakers. Disconnect all printer power. Check the Main Drive Run
Y N
Relay, K402 (PL 1.5) for shorted contacts. If OK, go to Flag 1. Check the control circuit of K402
(GP 6-3 Generic Relay RAP, General Procedures).

Y N
Press Stop. The phase-to-neutral voltage is measured between terminal 4 of K402

and 2A7TB3-3.
Y N
Go to Flag 11. Check the wires for an open circuit. If OK, go to the 1-707, Input
Power.
The phase-to-neutral voltage is measured between terminal 4 of K402 and 2A7TB3-

6.
Y N
Power.
The phase-to-neutral voltage is measured between terminal 4 of K402 and 2A7TB3-

10.
Y N
Power.
The phase-to-phase voltage is measured between P355-1 and P355-3.

Y N
Press Stop. Reconnect P355 to the Main Drive Motor. Go to Flag 4. Check the wires for
an open circuit.

Y N
Press Stop. Reconnect P355 to the Main Drive Motor. Go to Flag 5. Check the wires for
an open circuit.

Y N
G
Figure 1 4-701 Circuit Diagram (7414) Continue on the next page...


A B C D
4-701 Main Drive RAP (50HZ DELTA) Reconnect P356 to the Main Drive Motor. Exit the Power Interrupt mode. +24
VDC is measured at P212-1.
Initial Actions Y N
Table 1 AC VOLTAGE SPECIFICATIONS Y N
NOMINAL PHASE-TO-PHASE VOLTAGE PHASE-TO-PHASE VOLTAGE RANGE
220 VAC 198 to 242 VAC The thermal overheat device in the Fuser/Developer Drive Motor has
230 VAC 207 to 253 VAC opened. Switch off the Printer power and switch off all Printer Circuit
Breakers. Check for binding in the Fuser/Developer Drives. The motor
240 VAC 216 to 264 VAC
should recover within one hour, if it does not, replace the Fuser/Developer
Procedure
If the Main Drive Motor runs continuously when printer power is on, go to the end of the RAP, to Go to Flag 10. Check the wires for an open circuit.
the paragraph labeled "Main Drive Motor Runs Continuously".
WARNING Go to Flag 9. Check the wires for an open circuit. If OK, check the control circuit of
the Main Drive Run Relay, K402 (Generic Relay RAP GP 6-3, General Procedures).
Use caution when working near the motor. The Main Drive Motor, MOT401, may run
automatically. If the motor overheats, it is switched off by an internal thermal sensor.
This sensor will reset when the motor cools (up to 1 hour). The outside surfaces of the
motor may also be very hot.
The Fuser/Developer Drive Motor is running.
NOTE: After completing corrective actions, reconnect connectors P355 and P264 if they were Y N
disconnected during the procedure. Press Stop. Disconnect P355 from the Main Drive Motor. Refer to Table 1 for the proper
phase-to-phase voltage ranges. The phase-to-phase voltage is measured between
Enter dC330, [Main Drive Start/Run]. Observe the Main Drive Run Relay, K402. Press the terminals 4 and 5 of K402.
Continue button. K402 energizes. Y N
Y N The phase-to-phase voltage is measured between P9-1 and P9-3 on the Soft
+24 VDC is measured between terminals A and B of K402. Start PWB.
Y N Y N
Press Stop. +24 VDC is measured between TS 58 and TS 56 on the MIN ADA Go to Flag 2. Check the wires for an open circuit.
PWB 1.
Y N The phase-to-phase voltage is measured between P9-2 and P9-4 on the Soft
Go to wire 1021B wirenet and check for an open circuit. If OK, go to 1-220. Start PWB.
Y N
Press Continue. +24 VDC is measured at terminal A (orange wire) of K402. Go to 4-708, (50 Hz) Soft Start RAP.
Y N
Enter the Power Interrupt mode. Disconnect P356 from the Main Drive Motor. Go to Flag 15. Check the wires for an Open circuit.
Continuity is measured between J2-1 and J2-2 at the Main Drive Motor,
MOT401. The phase-to-phase voltage is measured between terminals 5 and 6 of K402.
Y N Y N
The thermal overheat sensor has opened. Switch off printer Main Power The phase-to-phase voltage is measured between P9-3 and P9-5 on the Soft
and disconnect the Power Cord. Check the following: Start PWB.
• Shorted Main Drive Run Relay, K402 (PL 1.5) Y N
• Binding in drive system. Go to Flag 3. Check the wires for an open circuit.
NOTE: For a reference diagram of the Drives, see the 4-702 Circuit
The phase-to-phase voltage is measured between P9-4 and P9-6 on the Soft
Diagram.
Start PWB.
If the thermal sensor has not recovered within 1 hour from the thermal Y N
overheat condition, replace the Main Drive Motor, MOT401 (50Hz) (PL Go to 4-708, (50 Hz) Soft Start RAP.
4.18). If the motor runs when power is turned on, replace the MIN ADA
PWB 1 (PL 1.8). Put the multimeter leads across terminals 1 and 4 of the K402. Press Continue. Less
than 30 VAC is measured.
A B C D E
E F
Y N If OK, replace the Main Drive Motor, MOT401 (PL 4.18).
Press Stop. Replace the Main Drive Run Relay, K402 (PL 1.5). Main Drive Motor Runs Continuously
Switch off the Printer circuit breakers. Disconnect all Printer power. Check the Main Drive Run
Less than 30 VAC is measured between terminals 2 and 5 of K402. Relay, K402 (PL 1.5) for shorted contacts. If OK, go to Flag 1. Check the control circuit of K402
Y N (Generic Relay GP 6-3, General Procedures).

Y N
Press Stop. Disconnect P264 from the Fuser/Developer Drive Motor, MOT402. The
phase-to-phase voltage is measured between terminal 4 of K402 and 2A7TB3-10.
Y N
The phase-to-phase voltage is measured between terminal 4 of K402 and 2A7TB3-

6.
Y N
The phase-to-phase voltage is measured between terminal 5 of K402 and 2A7TB3-

2.
Y N
Check the wires and connections for an intermittent condition.
Press Stop. The phase-to-phase voltage is measured between terminal 4 of K402 and
P355-1.
Y N
The phase-to-phase voltage is measured between terminal 5 of K402 and P355-3.

Y N
The phase-to-phase voltage is measured between terminal 6 of K402 and P355-2.

Y N
The phase-to-phase voltage is measured between K402-4 and P355-4.

Y N

Y N

Y N
F
Figure 1 4-701 Circuit Diagram (50Hz DELTA) (7414)

Figure 2 4-701 Circuit Diagram (50Hz DELTA) (704002)

A
4-702 Printer Drives Noise RAP Press Stop. Remove the cheater key. Reinstall the Xerographic Drawer. Slide out Tray 1.
Press Continue. The noise is still present.
Audible noise in the printer drives can be caused by defective bearings, drive rolls rubbing on Y N
baffles, improperly tensioned or frayed belts, or defective idlers. Use this procedure to isolate Press Stop. Go to the 8-704, PHM Noise.
components that are causing noise in the printer drives.
Press Stop. Reinstall Tray 1. Slide out Tray 2. Press Continue. The noise is still present.
Initial Actions Y N
Press Stop. Go to the 8-704, PHM Noise.
WARNING
Use caution when performing service actions on the main drives. Put the printer into the Press Stop. Remove the MIM Drive Belt (REP 4-29). EnterdC330, [Main Drive Start/Run].
Power Interrupt mode or switch off the printer circuit breakers. Press Continue. The noise is still present.
Press Stop. Reinstall the MIM Drive Belt. Remove the Decurler Drive Belt (REP 4-23).
• Remove the printer rear covers and check the drives for loose or frayed drive belts, pulley Press Continue. The noise is still present.
condition, and broken or missing idler springs. Y N
• On 50Hz machines without phase reversal detection implemented, reversed phases will Press Stop. Check the Decurler Drive Belt adjustment (ADJ 4-11). Isolate the noise
cause the main drives to run in reverse. Ensure that the drives are running in the proper to the Decurler drive components (PL 10.12).
direction.
Press Stop. Remove the Decurler Intermediate Drive Belt (REP 4-24). Press Continue.
Procedure The noise is still present.
Enter dC330, [Main Drive Start/Run]. Press Continue. The noise still is present. Y N
Y N Press Stop. Check the Decurler Intermediate Drive Belt and Decurler Intermediate
Select [8B] [Vertical Xport]. Press Continue. The noise returns. Drive Pulley adjustments (ADJ 4-11, 4-12). If OK, replace the Decurler Drive Assem-
Y N bly (PL 10.11), Decurler Drive Belt (PL 10.12), and the Decurler Intermediate Drive
Run the various printer options using dC 106 and try to reproduce the problem and Belt (PL 10.12).
further isolate to a particular area of the machine.
Press Stop. Reinstall the Decurler Drive Belt and the Decurler Intermediate Drive Belt.
Go to the 8-704, PHM Noise. Remove the Cleaner Drive Belt (REP 4-20). Press Continue. The noise is still present.
Y N
Press Stop. Disconnect P264 from the Fuser/Developer Drive Motor. Press Continue. The Check the Cleaner Drive Belt adjustment (ADJ 4-10). Isolate the noise to the cleaner
noise is still present. drives or cleaner assembly (PL 9.22).
Y N
Press Stop. Reconnect P264 to the Fuser/Developer Drive Motor. Bypass the Printer Press Stop. Reinstall the Cleaner Drive Belt. Remove the Prefuser Drive Belt (REP 4-34).
Interlocks. Slide out the Fuser Drawer. Press Continue. The noise is still present. Press Continue. The noise is still present.
Y N Y N
Press Stop. Isolate the cause of the noise to the Fuser area. Press Stop. Remove the Prefuser Transport (REP 10-12). Press Continue. The
noise is still present.
Press Stop. Isolate the cause of the noise to the Developer area. Y N
CAUTION Press Stop. Check the Prefuser Belt adjustment (ADJ 4-19). Isolate the cause
Do not crank the Developer Housing in the counterclockwise direction, damage to the of the noise in the Prefuser Transport area (PL 8.12).
Mag Seal Bearing may occur. Do not pour the material between Roll 1 and Roll 2, the
Developer Material can compact and stay on the rolls permanently. Press Stop. Check the following:
• Photoreceptor Drive Assembly Bearing (PL 4.17)
NOTE: If this a MICR Developer Housing, DO NOT hand crank the Developer Housing
• Prefuser Belt Idler (PL 4.16)
slowly. If hand cranked slowly, there may be lumping of the developer material. If lumping
occurs, the lumps should be loosened by hand. • Prefuser Drive Assembly (PL 4.16)
Press Stop. Bypass the Printer Interlocks. Slide out the Xerographic drawer. Press Continue. Press Stop. Reinstall the Prefuser Drive Belt. Remove the Fuser Drive Belt (REP 4-40).
The noise is still present. Press Continue. The noise is still present.
Y N Y N
Press Stop. Isolate the cause of noise in the Xerographic Drawer. Press Stop. Check the following:
• Developer Drive Assembly (PL 4.20)
A B C
B C
• Fuser Drive Belt adjustment (ADJ 4-21)
• Fuser Belt Idler Assembly (PL 4.17)
• Fuser Drive Assembly (PL 4.17)
• Tri-pulley (PL 4.17)
Press Stop. Check the following:

• Photoreceptor Drive Assembly (PL 4.17)
• Machine Clock Sensor (PL 9.3)
• MIM Drive Belt and MIM Drive Pulley adjustments (ADJ 4-16, ADJ 4-18)
Press Stop. Remove the Intermediate Drive Belt (REP 4-26). Press Continue. The noise is
still present.
Y N
Press Stop. Remove the Top Transport Drive Belt (REP 4-35). Press Continue. The
noise is still present.
Y N
Press Stop. Check the Top Transport and isolate the cause of the noise (PL 4.19).
Press Stop. Replace the Top Transport Drive Assembly (PL 4.19).
Press Stop. Reinstall the Intermediate Drive Belt. Remove the PHM Drive Belt (REP 4-30).
Press Continue. The noise is still present.
Y N
• PHM Drive Belt and Pulley adjustment (ADJ 4-17, ADJ 4-18)
• PHM Drive Belt Idler (PL 4.18)
• Intermediate Drive Assembly adjustment (ADJ 4-14)
• Tray 1 Feeder Drive adjustment (ADJ 4-20)
• Tray 2 Feeder Drive adjustment (ADJ 4-20)
• PHM Belt Idlers (PL 4.18)
• Intermediate Drive Belt adjustment (ADJ 4-15)
Press Stop. Replace the Main Drive Motor, MOT 401, (PL 4.18).

Figure 1 4-702 RAP

A
4-703 Print Power Rap (60HZ) Press Stop. Check the wires and the connectors for an intermittent condition.
Procedure
Enter dC330, [Main Drive Start/Run]. Press Continue. The Main Drive Motor runs.
Y N
Press Stop. Go to 4-700, Main Drive RAP.
Press Stop. Observe the Print Power Relay, K403. Press Continue. K403 energizes.
Y N
+24 VDC is measured between terminal A and B of K403.
Y N
Y N
Press Stop. Go to Flag 3. Check the wire for an open circuit.
Press Stop. Go to Flag 4. Check the wire for an open circuit.
Press Stop. Replace the Print Power Relay, K403 (PL 1.6).
Press Stop. 115 VAC is measured at terminal 7 of K403.

Y N
Y N
Go to the 1-703, AC Switched On Power.

Y N
Y N
115 VAC is measured at terminal 1 of the Print Power Relay, K403.

Y N
Replace the Print Power Relay, K403 (PL 1.6).
Press Continue. 115 VAC is measured at terminal 4 of K403.

Y N
Press Stop. Replace the Print Power, K403 (PL 1.6).
Press Stop. 115 VAC is measured at terminal 2 of the Print Power Relay, K403.
Y N
Press Continue. 115 VAC is measured at terminal 5 of K403.

Y N
A

4-704 Print Power Rap (50HZ)
Procedure
Enter dC330. [Main Drive Start/Run]. Press Continue. The Main Drive Motor runs.
Y N
Press Stop. Go to the 4-700 Main Drive RAP, or the 4-701 Main Drive RAP (50HZ WYE),
or the 4-701 Main Drive RAP (50HZ DELTA).
Press Stop. Observe the Print Power Relay, K403. Press Continue. K403 energizes.
Y N
Press Stop. Go to Flag 4 and Flag 5. Check the wires for an open circuit.
range.
Press Stop. 115 VAC is measured between terminals 8 and 9 of K403.

Y N
Y N

Y N
115 VAC is measured between 2A7TB4-15 and terminal 3 of K403.

Y N
Press Continue. 115 VAC is measured between 2A7TB4-15 and terminal 6 of K403.
Y N
Press Stop. 115 VAC is measured between 2A7TB4-5 and terminal 2 of K403.
Y N
Press Continue. 115 VAC is measured between 2A7TB4-4 and terminal 5 of K403.
Y N
115 VAC is measured between 2A7TB4-5 and terminal 4 of K403.

Y N


4-705 60HZ Fuser/Developer Drive Motor RAP Y N
Press Stop. Go to Flag 13. Check the wires for an open circuit. Reconnect the Resistor/
Procedure Capacitor device.
WARNING Press Stop. Use peak hold on the multimeter. Press Continue. 115 VAC is measured
Use caution when working near the motor. The Fuser/Developer Drive Motor, MOT402, between terminal 2 of K402 and terminal 5 of the Main Drive Start Relay, K401.
may run automatically. If the motor becomes overheated, it is switched off by an internal Y N
thermal sensor. This sensor will reset when the motor cools (up to 1 hour). The outside Press Stop. Replace the Main Drive Start Relay, K401 (PL 1.6).
surfaces of the motor could also be very hot.
Enter dC330 [Main Drive Start/Run]. Press Continue. Press Stop. Use peak hold on the multimeter. Press Continue. 115 VAC is measured
between P264-3 and P264-7.
NOTE: If the Main Power Circuit Breaker switches off during this RAP, reset it and Continue.
Y N
Try to keep the Main Drives on for the shortest time possible.
Press Stop. Go to Flag 12. Check all the wiring from K401-5 to the motor for an open cir-
The Main Drive motor runs. cuit. If OK, replace the following one at a time until the problem is resolved:
Y N • Fuser/Developer Drive Start Capacitor C404 (PL 4.20).
Press Stop. Go to the 4-700, Main Drive RAP. • Fuser/Developer Drive Run Capacitor C403 (PL 4.20).
• Fuser/Developer Drive Motor MOT402 (PL 4.20).
Press Stop. Enter [Power interrupt] mode. Handcrank the Fuser/Developer drives. The
Reconnect the Resistor/Capacitor device.
drives rotate normally with no binding or unusual noise.
Y N
Press Stop. Go to Flag 14. Check the wires for an open circuit. If OK, replace the following
Check the (ADJ 4-21) Fuser/Developer Drive Belt adjustment. Isolate the source of bind-
components one at a time until the problem is resolved:
ing.
• Fuser/Developer Drive Start Capacitor C404 (PL 4.20).
• Fuser/Developer Drive Run Capacitor C403 (PL 4.20).
Exit the power interrupt mode. 115 VAC is measured at terminal 5 of the Main Drive Run
Relay, K402. • Fuser/Developer Drive Motor MOT402 (PL 4.20).
Y N Reconnect the Resistor/Capacitor device.
115 VAC is measured at terminal 8 of the Power On Relay, K101.
Y N
Go to the 1-701, Standby AC Power.
Enter the power interrupt mode. Disconnect the Resistor/Capacitor device which is connected
between terminals 5 and 2 of the Main Drive Run Relay. Exit the power interrupt mode. Enter
dC330 [Main Drive Start/Run]. Press Continue. 115 VAC is measured at terminal 2 of the
Main Drive Run Relay, K402.
Y N
115 VAC is measured between terminal 2 of K402 and 2A7TB1-11.

Y N
Press Stop. Check the terminal block 2A7TB1 for an open circuit. Reconnect the Resis-
tor/Capacitor device.
Press Stop. Disconnect P264 from the Fuser/Developer Drive Motor. Press Continue. 115
VAC is measured at P264-3.
Y N
Press Stop. Go to Flag 11. Check the wires for an open circuit. Reconnect the Resistor/
Capacitor device.
115 VAC is measured between P264-3 and P264-8.



4-706 50HZ Fuser/Developer Drive Motor RAP
The Fuser/Developer Drive Motor RAP is designed to aid in troubleshooting problems with the
Fuser/Developer Drive Motor. The AC Power for this motor is supplied from the Main Drive
Run Relay, K402, through the same contacts that supply the Main Drive Motor, MOT401. Any
problems with the Main Drive Motor should be corrected before using this RAP.
Procedure
Table 1 AC VOLTAGE SPECIFICATIONS

NOMINAL PHASE-TO-NEUTRAL VOLTAGE PHASE-TO-PHASE VOLTAGE RANGE
220 VAC 342 to 418 VAC
230 VAC 358 to 438 VAC
240 VAC 373 to 457 VAC
WARNING
The Fuser/Developer Drive Motor, MOT402, may run automatically. If the motor over-
heats, it is switched off by an internal thermal sensor. This sensor will reset when the
motor cools (up to 1 hour). The outside surfaces of the motor may also be very hot. Use
caution when working near the motor.
Enter dC330, [1-4], [Main Drive Start/Run]. Press Continue. The Main Drive Motor,
MOT401, runs.
Y N
Press Stop. Go to the 4-700 Main Drive RAP, or the 4-701 Main Drive RAP (50HZ WYE),
or the 4-701 Main Drive RAP (50HZ DELTA).

• Connector P1/J285 for damaged pins, and/or pins backed out of housing
• Connector P273 at the Fuser/Developer Drive motor for damaged pins, and/or pins
backed out of housing
• Terminal block 2A7TB3 for proper contact between the terminals
If OK, verify that voltage is present at the motor before replacing it. The phase-to-phase volt-
age is measured between P273-1 and P273-3.
Y N

Y N
Press Stop. Go to Flag 3, 4, and 5. Check the wires for an open circuit. If OK, replace the
Fuser/Developer Drive Motor, MOT402 (PL 4.20).


4-707 ODOR RAP 4-708 (50 Hz) Soft Start RAP
Fault code, 4-707, is used when the customer has complained of an odor from the Printer. Fault Code 4-708 is used to troubleshoot problems with the Soft Start circuit for 50 Hz
machines. This hardware is used to slow down the rapid acceleration profile of the 50 Hz Main
Procedure Drive Motor and the Fuser/Developer Drive Motor, and to prevent long term damage to the
1. Ensure that the odor is not caused by over-heated components such as motors, solenoids drive components such as belts or pulleys.
or PWBs. If you suspect a component of overheating, enter SCP, Fault History and
check the subsystem history for faults related to the suspected component. If faults are If the Soft Start Relay PWB with the time delay disks is not functioning, the software will mea-
present, go to the appropriate NRD. If fault codes are not present, but the component still sure too few machine counts during the motor start-up in print mode.
is suspect of being too hot, replace the component.
2. Ensure that the odor is not caused by the Fuser. New Fuser components can create an
Initial Actions
odor. Ensure that the Fuser is operating at the correct temperature (ADJ 10-6). If the odor • Inspect the Soft Start Relay PWB to ensure that the thermistors on the PWB are not
is coming from the Fuser and the Fuser is operating properly, inform the customer about burned.
the normal odor of the Machine. • Switch off the power to the Printer.
3. If not other defect can be located, and the odor is similar to the smell of a “new carpet”, Procedure
the odor may be caused by the heating of the toner in the Fuser. The odor should be con- With the power to the Printer off, go to Flag 1. Check for continuity on the Soft Start Relay PWB
centrated at the rear of the Printer at the Cavity Cooling Filter. This odor is not harmful. If
from J1-1 to J1-2, from J1-3 to J1-4, and from J1-5 to J1-6. The circuits are OK.
the customer is concerned about the odor, have the customer contact the Sales Repre- Y N
sentative regarding the purchase of a Heat Vent Kit. The Heat Vent Kit is a customer pur- Replace the Soft Start Relay PWB.
chased item.
CAUTION
The Soft Start Relay PWB will be damaged if the relay is left energized. The thermistors may
overheat if the relay is actuated for longer than a few minutes.
Switch on the power to the Printer. Connect a jumper from TS23 to TS56 on the MIN ADA
PWB #1 and monitor the relay contacts. The contacts open.
Y N
Disconnect the jumper. +24 VDC is measured from P401-1 (+) on the Soft Start Relay
PWB to TH14 (-) on the LVPS.
Y N
+24 VDC is measured from TS58 (+) to TS56 (-) on MIN ADA PWB #1.
Y N
Replace MIN ADA PWB #1 (PL 1.8).
Go to Flag 2. Check the wiring for an open circuit.
Set the voltmeter to Peak Hold. Connect the meter from TS58 (+) to TS23 (-) on MIN ADA
#1. Run a sample job. The meter reads +24 VDC.
Y N
Replace the MIN ADA PWB #1 (PL 1.8).
Set the voltmeter to Peak Hold. Connect the meter from J2-1 (+) to J2-2 (-) on the Soft
Start Relay PWB. Run a sample job. The meter reads+24 VDC.
Y N
Replace the Soft Start Relay PWB.
Disconnect the jumper. The contacts close.

Y N
Replace the Soft Start PWB.
A
A
Set the voltmeter to Peak Hold. Connect the meter from TS58 (+) to TS23 (-) on MIN ADA #1.
Run a sample job. The meter reads +24 VDC.
Y N
Set the voltmeter to Peak Hold. Connect the meter from J2-1 (+) to J2-2 (-) on the Soft Start
Relay PWB. Run a sample job. The meter reads +24 VDC.
Y N
Set the voltmeter to Peak Hold. Connect the meter from TS16 (+) to TS37 (-) on the MIN DIO
PWB #1. Run a sample job. The meter reads +5 VDC.
Y N
Connect the meter from TS16 (+) to TS37 (-) on the MIN DIO PWB #1. Connect a jumper
from TS23 to TS56 on MIN ADA #1. The meter reads +5 VDC.
Y N
Disconnect the jumper. Disconnect P248/J7 on MIN DIO PWB #1. +5 VDC is mea-
sured from TS16 (+) to TS37 (-) on MIN DIO PWB #1.
Y N
Replace the MIN DIO PWB #1 (PL 1.8).
Go to Flag 4. Check the wiring to the Soft Start Sensor. If the wiring is correct,
replace the MIN ADA PWB #1 (PL 1.8).
Check the connectors for intermittent connections. If the wiring is correct, replace the MIN
ADA PWB #1 (PL 1.8).
The Soft Start circuit is operating properly. Return to the RAP that directed you to the 4-708
RAP and Continue troubleshooting.


6-202 RAP
Polygon Motor Self Test Fault: During diagnostic self test the Polygon Motor interface is
tested for accuracy of interface between the Card Cage and the ROS. If an error is detected,
fault 6-202 is declared.
Procedure
WARNING
Danger. Laser Radiation when the Photoreceptor drawer is open. Avoid direct eye expo-
sure to the Beam. (Laser Light Warning)
WARNING
Switch off power before any component is disconnected or removed, and before any
component is connected or installed.
Perform the following actions:
• Reseat connector at J111 on the Card Cage.
• Reseat connector, P2101, at J201 on the RCM PWB.
• ROS Reset Procedure: Go to [Xero/Imaging] [6] and press the ROS Reset button.
Alternatively PO/PO (Power Off/Power On) the Machine.
• Enter dC606, ROS Self Test. Press Continue. If Polygon Motor Test fails again, enter
Fault History [SCP].
Fault code 6-202 is declared again.
Y N
It is possible that the fault has been falsely declared by electrical noise. Go to the Printer
Electrical Noise Procedure located in the Service Call Procedures and perform the steps

• If 6-354 is also declared, go to RAP 6-354.
• Observe and record the values on the screen that are associated with Fault Code, 6-202.
• Go to Flag 1. Perform the checks indicated in Table 1.
Table 1 dC606 Values For 6-202 With Probable Cause

dC606 VALUE AT FLAG 1 CHECK FOR
0 Short circuits to GND in the MPA SD wires (1 through 5)
31 Opens in the MPA SD wires (1 through 5)
10, 21 MPA SD wires short circuited together

Figure 1 Test Points on the RCM PWB

Figure 2 ROS Components

PL PL
1.11 1.11
PL PL PL
1.11 6.1 1.11
Figure 3 Circuit Diagram for 6-202 RAP, Polygon Motor Self-test Fault
6-203 RAP

The Thermal Electric Cooler (TEC) stabilizes the Visible Laser Diode to a specific operating
temperature. If temperature is not within 1 degree Centigrade from its proper operating temper-
ature, fault, 6-203 will be declared.
Initial Actions
WARNING
Check Fault History. If fault codes 6-203 and 6-240 are all declared at the same time and hung
in that condition, go to Flag 2, and check for a short circuit (the wire between P2201-25 and
P2113-25) to +5 VDC or to adjacent wires. A short circuit to +5 VDC can be checked between
TH40 (+) and TH50 (-) on the RCM PWB.
Procedure
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine.
WARNING
Fault code 6-203 is declared again.
Y N
Non-repetitive random occurrences of the fault code suggests electrical noise to be the
source of false Fault Code declarations. Go to the Printer Electrical Noise Procedure
located in the Service Call Procedures and perform the steps.
Measure from TS4 (BO ROS) / TH35 (B1 ROS) to TS50 on the RCM PWB. The voltage mea-
sured is approximately equal to +3 VDC.
Y N
Replace the RCM PWB (PL 6.1).
Measure from TS3 to TS50 on the RCM PWB. The voltage measured is +4 to +5 VDC.
Y N
Go to Flag 3. Check for a short circuit in the TEC Control wire. If the wire is OK, replace
the RCM PWB (PL 6.1).
Measure from TS8 to TS50 on the RCM PWB. The voltage measured is approximately
equal to +1.6 VDC.
Y N
Go to Flag 1 and Flag 3 and check for short or open circuits. If the wires are OK, replace
the RCM PWB (PL 6.1) and/or the VLD/Collimator Assembly (PL 6.1).
This may be a false fault. Replace the RCM PWB (PL 6.1) and the SLB/RDR PWB (PL 1.11).
Go to Flag 1, and go to Flag 3. Check for an open / short circuit.


Figure 2 Circuit Diagram for 6-203 RAP, Thermoelectric Cooler (TEC) Fault
6-213 RAP

The Visible Laser Diode (VLD) when operating at low power and high current indicates a near
failure condition. Fault, 6-213, indicates a warning that the VLD is close to failing and should be
replaced at the earliest convenience.
Initial Actions
If fault code 6-214, 6-215, 6-353, 6-360 or 6-366, is also declared, go to 6-214, go to 6-215, go
to 6-353, or go to 6-360 first, resolve the problem cause, and return to this RAP.
WARNING
Procedure
Perform the ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. Fault cannot
be generated after PO/PO. Occurs during cycle down. Fault code 6-213 is declared again.
Y N
If repetitive random occurrences of 6-213 are logged into Fault history, it is possible that
electrical noise is causing a false declaration of 6-213. Go to the Printer Electrical Noise
Procedure located in the Service Call Procedures and perform the steps.
WARNING
There is +1.6 VDC to +1.7 VDC between TS7 (+) and TS58 (-) on the RCM PWB.
Y N
Replace the following components:
• VLD/Collimator Assembly (PL 6.1)
• RCM PWB (PL 6.1)
Replace the following components:

• SLB/RDR PWB (PL 1.11)


PL PL
PL
6.1 6.1
1.11
PL
1.11
PL
1.11
PL
1.11
Figure 2 Circuit Diagram for 6-213 RAP, VLD near failure

A
6-214 RAP Perform the following:
• Replace the RCM PWB (PL 6.1)
The +15 VDC is monitored on the RCM PWB. If there is a RCM +15 Volt Fault, 6-214, is • Replace the SLB/RDR PWB (PL 1.11)
declared.
Initial Actions
If fault code, 6-353 or 6-358, is also declared, go to 6-353 or go to 6-358, resolve the problem
cause, and return to this RAP.
WARNING
Check Fault History. If fault codes 6-214, 6-237, and 6-355 are all declared at the same time
and hung in that condition, go to Flag 3, and check for a short circuit (the wire between P2201-
8 and P2113-8) to +5 VDC or to adjacent wires. A short circuit to +5 VDC can be checked
between TH42 (+) and TH50 (-) on the RCM PWB. Check for +14.25 to +15.75 VDC between
J114-23 (+) and J114-23 (-) at the Card Cage. If the voltage is present but out of range, go to 1-
715.
Procedure
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. Fault code, 6-214, is
declared again. Figure 1 RCM PWB Test Points
Y N
Go to the Printer Electrical Noise Procedure located in the Service Call Procedures and
perform the steps.
WARNING
There is +14.25 to +15.75 VDC between TH22 (+) and TH50 (-) on the RCM PWB.
Y N
Disconnect the cable connector from J114 at the Card Cage. There is +14.25 to 15.75
VDC measured between the harness connector to J114-7 (+) and J114-8 (-) at the
Card Cage.
Y N
There is +14.25 to +15.75 VDC measured between TH6 (+) and TH8 (-) on the
LVPS "A" PWB.
Y N
go to 1-715.
There is +14.25 to +15.75 VDC between J113-1 and J113-2.

Y N
Check out the Backplane. Replace as necessary (PL 1.11).
Reconnect P2116 to J114. Go to Flag 2, and check that J2202 and J114 are OK. Discon-
nect J2202 from the RCM PWB. Check for +14.25 to +15.75 VDC between P2202-7 (+)
and P2202-8 (-). If the voltage is OK, replace the RCM PWB (PL 6.1). If the voltage is not
OK, replace/repair the harness.
A

PL
1.11
Figure 3 Circuit Diagram for +5 VDC fault at the RCM PWB

6-215 RAP • Replace the SLB/RDR PWB (PL 1.11)
RCM +5V Monitor Fault: The + 5 V fault is monitored on the RCM PWB. If there is a RCM +5
Volt fault, 6-215 is declared.
Initial Actions
WARNING
Check Fault History. If fault code 6-353 is declared, go to 6-353. If fault codes 6-215 and 6-330
are all declared at the same time and hung in that condition, go to Flag 3, and check for a short
circuit (the wire between P2201/J201-8 and P2113/J111-8) to +5 VDC or to adjacent wires. A
short circuit to +5 VDC can be checked between TH43 (+) and TH50 (-) on the RCM PWB.
Procedure
declared again.
Y N
perform the steps. Figure 1 RCM PWB Test Points
WARNING
There is +4.75 to +5.25 VDC between TH24 (+) and TH50 (-) on the RCM PWB.
Y N
Disconnect P2116 from J114 at the Card Cage. There is +4.75 to +5.25 VDC between
J114-5 (+) and J114-6 (-).
Y N
There is +4.75 to +5.25 VDC between TS2 (+) and TS8 (-) on the LVPS PWB.
Y N
go to 1-713.
Reconnect P2116 to J114. Disconnect J115, J116, J119 and J120. +4.75 VDC to
+5.25 VDC is measured from P115-1 (+) to P115-2 (-), and from P120-1 (+) to
P120-2 (-).
Y N
Replace the Backplane (PL 1.11.)

• Reconnect P2116 to J114.
• Go to Flag 1 and check for an open/short circuit. Disconnect J2202 from the RCM
PWB. Check for +5 VDC between P2202-9 (+) and P2202-10 (-). If the voltage is
OK, replace the RCM PWB (PL 6.1). If the voltage is not OK, replace/repair the har-
ness.
• Replace the RCM PWB (PL 6.1)


PL PL PL
PL
1.11 6.1 1.11
1.10
PL
1.11
PL
1.11
PL
1.11
Figure 3 Circuit Diagram for +5 VDC fault at the RCM PWB

6-232 RAP
ROS not ready fault, 6-232, indicates the RCM controller failed self test. If there is a ROS Sys-
tem Ready fault, 6-232, is declared.
Initial Actions
WARNING
Procedure
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. Fault code 6-232 is
declared again.
Y N
Enter Fault History. Repeated random occurrences of fault code 6-232 at the same time
as Xerographics faults could indicate false declarations induced by electrical arcs. Go to
the Printer Electrical Noise Procedure located in the Service Call Procedures and perform
the steps.
WARNING
Perform ROS Reset procedure: PO/PO (Power Off/Power On) the Machine. Check for +5
VDC between TH37 (+) and TH50 (-) on the RCM PWB. The +5 VDC between TH37 (+) and
TH50 (-) switches from logic high (+5 VDC) to logic low (0 to +1 VDC) when ROS Reset is
toggled.
Y N
Go to Flag 1, and check for a short circuit to ground. If the circuit is OK, replace the follow-
ing components in the order given:

• Go to Flag 2, and check for a short circuit between P2201-7 and P2113-7 to +5 VDC or to
adjacent wires. A short circuit to +5 VDC can be checked between TH44 (+) and TH50 (-)
on the RCM PWB.
• Replace the RCM PWB (PL 6.1).
• Replace the SLB/RDR PWB (PL 1.11.)


PL
PL PL
1.11
6.1 1.11
PL
PL 1.11
1.11
Figure 2 Circuit Diagram for 6-232 RAP, ROS not ready

6-233 RAP SOS, EOS, and VLD MON readings track the Exp Ref settings.
Y N
The VLD power is monitored on the RCM PWB and corrected for any change in power. If the Refer to Figure 3. B1 Exp [TS75 (+) to TS58 (-)] and B2 Exp [TS74 (+) to TS58 (-)]
power drifts out of range, 6-233 is declared. manifest a pattern of uniform response at all Exp Ref settings and are within 0.2
VDC of each other at all Exp Ref settings.
Initial Actions Y N
Resolve any causes of power faults declared for power failure at the RCM PWB, such as 6-214
(+15 VDC), 6-215 (+5 VDC), 6-366 (-5 VDC), 6-240 (+25 VDC), 6-360 (-15 VDC) and then pro-
ceed with this RAP. Replace the VLD/Collimator Assembly (PL 6.1).
Check the voltages at the Scan Detector PWBs at the locations in Table 2. If the voltage(s) are
WARNING out of range, go to the appropriate RAP, and check the circuit for the source of a voltage loss.
sure to the Beam. (Laser Light Warning) Table 2 Scan Detector LVPS Inputs and Acceptable Voltage Ranges
Procedure Voltage Voltage Range J301/302 Test Points RAP
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. +36 VDC +28 to +38 VDC Pin 8 (+), Pin 12 (-) 6-330
NOTE: Fault will occur only during Print or when Laser Write is active. +15 VDC +14.25 VDC to +15.75 Pin 2 (+), Pin 12 (-) 6-214
VDC
Enter dC606 and print any Internal Test Pattern. Fault code 6-233 is declared again.
+5 VDC +4.75 VDC to +5.25 Pin 10 (+), Pin 12 (-) 6-215
Y N
VDC
perform the steps. -5.2 VDC -4.94 VDC to -5.46 Pin 1(+), Pin 12 (-) 6-366
VDC
WARNING
Switch off power before any component is disconnected or removed, and before any Go to Flag 1, go to Flag 2, go to Flag 3, go to Flag 4 and go to Flag 5. Check for an open/short
component is connected or installed. circuit. If the circuits are OK, replace the following components in the order given:
Perform the following: • VLD/Collimator Assembly (PL 6.1)
• Enter dC606, [ROS Outputs]. • RCM PWB (PL 6.1)
• Activate Laser Write. • SLB/RDR PWB (PL 1.11)
• Select dC606 [ROS Intensity Test].
• Set Print Normal Exposure Value (Exp Ref) to the values in Table 1.
• Measure Scan Detector (SOS and EOS) Intensity voltages and VLD Monitor at each of
the Exposure Ref values set in Table 1.
NOTE: The Table 1 voltages for the SOS Detector and the EOS Detector and VLD Monitor are
typical. Measured voltages should manifest similar patterns of uniform response.
EXAMPLE OF POSSIBLE MEASUREMENTS:
Table 1 Exp Ref Values Vs. Typical Scan Detector and Monitor Voltages
EXP REF SOS PK EOS PK VLD MON
B1 ROS TS9 (+) to TH50 (-) TS10 (+) to TH50 (-) TS7 (+) to TH58 (-)
B0 R0S TS54 (+) to TS50 (-) TS55 (+) to TS50 (-) TS57 (+) to TS50 (-)
0 2.9 VDC 1.73 VDC 0.7 VDC
50 +3.1 VDC +2.59 VDC +1.03 VDC
100 +4.28 VDC +3.57 VDC +1.4 VDC
200 6.66 VDC +5.6 VDC +2.2 VDC
255 +7.88 VDC +6.62 VDC +2.6 VDC

Figure 1 RCM PWB Test Points


PL PL
1.11 PL
6.1
PL 6.1
1.11
PL
6.1
PL
PL 1.11 PL
6.1 1.11
Figure 3 Circuit Diagram for 6-233 RAP, VLD near failure

6-234 RAP
The Polygon Motor slow to speed fault, 6-234, indicates a near failure condition. Fault code, 6-
234, indicates that the Polygon Motor is close to failing and should be replaced at the earliest
convenience.
Initial Actions
WARNING
Check Fault History. If fault code 6-240 is declared, go to 6-240, fix the problem cause, and
return to this RAP.
Procedure
NOTE: 6-234 fault code is logged (not declared) at initial power up. PO-PO is required to
declare this fault. Fault History needs to be updated.
6-234 is logged again.

Y N
perform the steps.
WARNING
Perform the following in the order given until the problem is resolved:
• Polygon Motor Assembly (PL 6.1)


PL
6.1
PL
6.1
PL
PL 1.11
6.1 PL
1.11
Figure 2 Circuit Diagram for 6-234 RAP, MPA Slow to Speed

6-236 RAP
ROS profile chip error occurs when no chip is installed or the chip is blank. If failure is detected,
6-236, is declared.
Initial Actions
WARNING
Check the Fault History. If the fault codes 6-236 and 6-356 are declared simultaneously and
hung in that condition, go to Flag 1, and check for a shot circuit (the wire between P2201-24
and P2113-24) to +5 VDC or to adjacent wires. A short circuit to +5 VDC can be checked
between TH41 (+) and TH50 (-) on the RCM PWB.
Procedure
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. Fault code 6-236 is
declared again.
Y N
perform the steps.
WARNING
A new RCM PWB has just been installed.
Y N
Reseat the ROS Profile Chip. If the problem is not fixed, go to Flag 1 and check for an
open/short circuit. If the Circuit is OK, replace the RCM PWB (PL 6.1).
NOTE: The ROS profile chip is "married" to the VLD Collimator Assembly. When the RCM
PWB is replaced, the ROS Profile Chip must be transferred from the old PWB to the new
PWB.
If replacing the RCM PWB does not fix the 6-236 fault, replace the ROS Assembly.
The ROS profile chip was not moved from the old RCM PWB to the new RCM PWB (part of the
repair procedure). Move the ROS Profile Chip to the new RCM PWB. If the ROS Profile Chip
has been damaged or otherwise cannot be transferred to the new RCM PWB, replace the ROS
Assembly.


PL
PL
1.11
6.1
PL
1.11
Figure 2 Circuit Diagram for RAP 6-236, ROS Profile Chip error

A
6-237 RAP • B1 overide = less than +3 VDC between TS32 (+) and TS50 (-) on the RCM PWB.
• B2 overide = less than +3 VDC between TS31 (+) and TS50 (-) on the RCM PWB.
The Visible Laser Diode (VLD) should be off in standby. If VLD is on in standby (when LASER-
• B1 threshold = 0 VDC between TS1 (+) and TS50 (-) on the RCM PWB.
WRITE is off), 6-237, is declared.
• B2 threshold = 0 VDC between TS2 (+) and TS50 (-) on the RCM PWB.
NOTE: When LASERWRITE is active in dC330 and dC606, 6-237 may be displayed. All the voltages measured above are correct.
Y N
Initial Actions • Go to Flag 4, and check for an open / short circuit.
WARNING • Replace the RCM PWB (PL 6.1)
sure to the Beam. (Laser Light Warning) Replace the VLD/Collimator Assembly (PL 6.1).
Check the Fault History. If the fault codes 6-214, 6-237 and 6-355 are declared simultaneously
Go to Flag 3, and check for a short circuit. If the circuit is OK, replace the following compo-
and hung in that condition, go to Flag 2, and check for a short circuit (the wire between P2201-
nents:
23 and P2113-23} to +5 VDC or to adjacent wires. A short circuit to +5 VDC can be checked
FALSE 6-237 FAULTS - When in dC606, a 6-237 fault is generated when [ROS Outputs] and • Backplane (PL 1.11)
[Laser Write] are activated. This fault cannot be cleared while in diagnostics. No other function
is disabled and all routines can be performed other than those that require printing. When
Laser Write is needed while in the diagnostics mode, use dC330, Chain 6, instead of dC606. If
a RAP directs you to perform Laser Write in dC606, perform the requisite tasks in dC606 per
the RAP. When 6-237 is declared, ignore the fault unless you need to print in diagnostics. In
that case, to clear the fault, exit then re-enter diagnostics and then access the print routine
needed. Exiting diagnostics clears the 6-237 fault.
Procedure
ROS Rest Procedure: PO/PO (Power Off/Power On) the Machine. Fault code 6-237 is
declared again.
Y N
perform the steps.
Observe the LEDs on the RCM PWB. All seven LEDs on the RCM PWB are lit.
Y N
Check for voltage on the VLD Monitor circuit. 1.6 VDC minimum is present between
TS7 (+) and TH58 (-) on the RCM PWB.
Y N
Go to Flag 1, and check for an open/short circuit. If the circuit is OK, replace the
VLD/Collimator Assembly (PL 6.1).
WARNING
Check if the Laser Write signal is stuck ON (Logic L). There is Logic L between TH38 (+)
and TH58 (-) on the RCM PWB.
Y N
Check B1 and B2 Exposure and Threshold signal levels on the RCM PWB as follows:
• B1 set = less than +3 VDC between TS34 (+) and TS50 (-) on the RCM PWB.
A

PL PL
PL 6.1 6.1
1.11
PL
1.11
PL
PL
1.11
1.11
Figure 2 Circuit Diagram for 6-237 RAP, VLD on in Standby

6-240 RAP • RCM PWB (PL 6.1)
RCM +25V Monitor Fault: The 25 Volts supplies power to the Polygon Motor. The + 25 V fault
is monitored on the RCM PWB. If there is a RCM +25 Volt fault, 6-240, is declared.
Initial Actions
If fault code, 6-353, is also declared, go to 6-353 first, resolve the problem cause, and return to
this RAP.
WARNING
Check Fault History. If fault codes 6-203 and 6-240 are declared simultaneously and hung in
that condition, go to Flag 2, and check for a short circuit (the wire between P2201-25 and
P2113-25) to +5 VDC or to adjacent wires. A short circuit to +5 VDC can be checked between
TH40 (+) and TH50 (-) on the RCM PWB.
Procedure
declared again.
Y N
perform the steps.
WARNING
There is +25 VDC (+24.0 to +26.0 VDC) between TH48 (+) and TH52 (-) on the RCM PWB.
Y N
Disconnect the connector from J202 on the RCM PWB. There is +24.0 to +26.0 VDC
between J2202-1 (the harness end) and J2202-2 (-).
Y N
Remove the cover from the left end of the IOT, and disconnect the plug from J114 on
the Backplane. There is +24.0 to +26.0 VDC between J114-1 (+) and J114-2 (-) on
the Backplane.
Y N
• Replace the ROS LVPS (PL 1.11)
• Replace the Backplane (PL 1.11)
Go to Flag 1. Check the harness between J202 and J114 for a loose connection,
bent pins, or a short circuit

• Go to Flag 1. Check the harness between J202 and J114 for a loose connection,
bent pins, or an open circuit.
Replace the following components in the order given until the problem cause is resolved:


PL
6.1
PL
1.11
PL
1.11 PL
1.11
PL
1.11
Figure 2 Circuit Diagram for 6-240 RAP, +25 VDC fault at the RCM PWB

A
6-250/251 RAP Enter dC330 [6], Output Imaging ROS and deselect Laser Write while monitoring for Logic
(L) and H) between TH38 (+) and TH50 (-) on the RCM PWB. The Logic L voltage toggles
Fault Code 6-250 indicates that at least one Start of Scan signal was not detected by the SOS from L to H as monitored between TH38 (+) and TH52 (-).
PWB. Y N
Fault Code 6-251 indicates that at least one End of Scan signal was not detected by the EOS • Go to Flag 6, and check for an open/short circuit.
PWB. • Replace the RCM PWB (PL 6.1)
• Replace the SLB/RDR PWB (PL 1.11)
Initial Actions • Replace the Backplane (PL 1.11)
WARNING
Danger. Laser Radiation when the Photoreceptor drawer is open. Avoid direct eye expo- Make sure LASERWRITE is disabled. The Polygon Motor is turning.
sure to the Beam. (Laser Light Warning) Y N
Go to 6-354.
• If this RAP does not correct the problem, electrical noise may be causing the ROS faults.
Go to SCP Printer Fault History. If 9 and/or 3 faults occur simultaneously as the 6 ROS
faults, go to the Printer Electrical Noise Procedure located in the Service Call Procedures Check the Scan Detector voltages. See Table 1. The voltages are OK.
Y N
and perform the steps.
Refer to the appropriate wirenet for missing voltages.
• If fault codes 6-250, 6-251, 6-364, and 6-233 are declared at the same time, an inopera-
tive (low power) VLD is the probable cause. Go to the 6-233 RAP.
Replace the ROS Assembly (PL 6.1) as required.
Procedure
WARNING Table 1 Scan Detector LVPS Inputs and Acceptable Voltage Ranges
Switch off power before any component is disconnected or removed, and before any RCM PWB Test
component is connected or installed. Voltage Voltage Range J301/302 Test Points Points
Fault Code 6-250 and 6-251 are declared together. +36 VDC +28 to +38 VDC Pin 8 (+), Pin 12 (-) TH47 (+), TH50 (-)
Y N +15 VDC +14.25 to +15.75 VDC Pin 2 (+), Pin 12 (-) TH22 (+), TH50 (-)
Swap PWBs. The other fault is declared.
+5 VDC +4.75 to +5.25 VDC Pin 10 (+), Pin 12 (-) TH24 (+), TH50 (-)
Y N
6-250 only is declared (but not 6-251). -5.2 VDC -4.94 to -5.46 VDC Pin 1 (+), Pin 12 (-) TH23 (+), TH50 (-)
Y N
• Go to Flag 3, and check the voltage inputs to the EOS PWB.
• Go to Flag 4, and check for open/short circuits.
• Go to Flag 3, and check the EOS for proper installation and alignment.
• Replace the RCM PWB (PL 6.1). If the problem persists, replace the ROS
Assembly (PL 6.1).

• Go to Flag 2, and check the voltage inputs to the SOS PWB.
• Go to Flag 4, and check for open/short circuits.
• Go to Flag 2, and check the SOS PWB for proper installation and alignment.
• Replace the RCM PWB (PL 6.1). If the problem persists, replace the ROS
Assembly (PL 6.1).

• Replace the failed Scan Detector PWB (PL 6.1).
• Perform the ROS Power Calibration (ADJ 6-4).
A
6-250/251 ?-500 No Product Name Assigned

No Product Name Assigned ?-501 6-250/251
Figure 2 ROS Assembly

PL PL PL
1.11 6.1 6.1
PL
1.11
PL
6.1
PL
1.11 PL
1.11
PL
6.1
Figure 3 Circuit Diagram for 6-250/251 RAP

6-252/253 RAP
An extra SOS or EOS signal generated within the nominal timing for SOS or EOS will declare a
6-252/253 fault.
Electrical noise and intermittent connections are the most probable cause for the declaration of
6-252 or 6-253 fault codes.
Initial Actions
WARNING
NOTE: A 6-252/253 fault typically indicates random electrical noise. Seek Engineering sup-
port.
Procedure
WARNING
6-252/253 is declared again.
Y N
perform the steps.
Go to Flag 1, go to Flag 2, go to Flag 3, go to Flag 4, and go to Flag 5. Check for open / short
circuit. If the circuits are OK, replace the following components in the order given until the prob-
lem cause is fixed:



PL PL
1.11 PL 1.11
6.1
PL PL
1.11 1.11
PL
6.1
PL
6.1
Figure 3 Circuit Diagram for 6-252/253 RAP, Extra SOS/EOS signal

6-330 RAP
RCM +28V Monitor Fault: The + 28V fault is monitored on the RCM PWB. If there is a RCM
+28 Volt fault at the RCM PWB, 6-330, is declared.
Initial Actions
If fault code, 6-353, is also declared, go to 6-353 first, resolve the problem cause, and return to
this RAP.
WARNING
Check the Fault History. If the fault codes 6-215, and 6-330 are declared simultaneously and
hung in that condition, go to Flag 2, and check for a short circuit (the wire between P2201-8
and P2113-8) to +5 VDC or to adjacent wires. A short circuit to +5 VDC can be checked
Procedure
declared again.
Y N
perform the steps.
There is +28 VDC to +38 VDC between TH47 VDC (+) and TH50 (-) on the RCM PWB.
Y N
Disconnect the connector from J202 on the RCM PWB. There is +28 VDC to +38 VDC
on J2202-11 (the harness end) and J2202-12.
Y N
Remove the cover from the left end of the IOT, and disconnect the plug from J114-1
on the Backplane. There is +28 VDC to + 38 VDC between J114-11 (+) and J114-
12 (-) on the Backplane.
Y N
Replace the following:
• ROS LVPS PWB (PL 1.11). If the problem persists, replace the Backplane
(PL 1.11).
• Backplane (PL 1.11)
Go to Flag 1. Check the harness for a short or open circuit.
Replace the following components in the order given until the problem cause is resolved:


PL PL
6.1 1.11
PL
PL 1.11
1.11
PL
1.11
Figure 2 Circuit Diagram for 6-330 RAP, +28 VDC fault at the RCM PWB

6-331 RAP Table 1 Acceptable Measured Voltages For Exposure Reference Decimal Values
Backplane RCM PWB
The exposure self test fault indicates an interface error, in which an incorrect value was sent to
Decimal Voltage PWB Test Test
or received from the ROS and Card Cage. If error is detected, 6-331 is declared. The only way
Value Range Points Points NO YES
to receive this fault is while running dC606 Self Test.
255 +9.5 VDC J111-12 (+) TS4 (+) to (1) go to Flag 2 and Replace the RCM
Initial Actions to +10.5 to J111-31 TS9 (-) check for a short/ PWB (PL 6.1)
VDC (-) open circuit to
WARNING ground.
Danger. Laser Radiation when the Photoreceptor drawer is open. Avoid direct eye expo- (2) Replace the SLB/
sure to the Beam. (Laser Light Warning) RDR PWB (PL 1.11)
Procedure
• Enter dC606, ROS Self Test., and press Continue.
• Read and record the Value associated with the Exposure Test Fault, 6-331.
• Enter dC606, ROS Intensity Test. Set the previously recorded value in Print Exposure
Normal Value on the screen.
• Enter dC606, ROS Outputs. Select Laser Write.
• For the decimal value entered on the screen, check the voltage range at the Test Points
on the RCM PWB per Table 1.
WARNING
The voltage is within range at that value.
Y N
Perform the corrective actions in the "NO" Column of Table 1.
A false fault was declared. Check for the cause. If no cause is found perform the corrective
action in the "YES" column of Table 1.
Table 1 Acceptable Measured Voltages For Exposure Reference Decimal Values

Backplane RCM PWB
Decimal Voltage PWB Test Test
Value Range Points Points NO YES
0 +0 VDC to J111-12 (+) TS4 to (1) go to Flag 2 and Replace the RCM
+0.5 VDC to J111-31 TS9 check for a short cir- PWB (PL 6.1)
(-) cuit to a voltage such
as +5 VDC.
(2) Replace the SLB/
RDR PWB (PL 1.11)
85 +3.0 VDC J111-12 (+) TS4 (+) to Replace the SLB/ Replace the RCM
to +3.6 to J111-31 TS9 (-) RDR PWB (PL 1.11) PWB (PL 6.1)
VDC (-)
170 +6.3 VDC J111-12 (+) TS4 (+) to Replace the SLB/ Replace the RCM
to +6.9 to J111-31 TS9 (-) RDR PWB (PL 1.11) PWB (PL 6.1)
VDC (-)

PL PL
1.11 6.1
PL
PL
1.11
1.11
PL
1.11
Figure 1 Circuit Diagram for 6-331 RAP, Exposure self-test fault

6-351 RAP
Fault Code 6-351 indicates that the Voltage Controlled Oscillator, which generates a byte clock
signal at 22 MHz, is out of range, or missing.
Initial Actions
faults, go to the Printer Electrical Noise Procedure located in the Service Call Procedures
• Enter [SCP], [Call Overview], to view Queued Faults. If 6-250 or 6-251 is displayed, go to
6-250/251, resolve the problem and return to this RAP.
• If 9-201 is included in Queued Faults, go to 9-201, resolve the problem and return to this
RAP.
WARNING
Procedure
WARNING
Cover the Photoreceptor, under the ROS Assembly, outboard to inboard with white paper.
Cheat the Processor Interlock Bypass Switch. Enter dC330 [6]. Select [Laser Write]. Press
Continue. The fault is still present.
Y N
perform the steps.
Enter dC330 [6]. Select Laser Write. Select Patch. Press Continue. The scanline is com-
pletely off in the patch area (approximately in the middle of the PR Belt.)
Y N
Go to Flag 1 and check for open and short circuits. Go to Flag 2 and check the card cage
for bent/broken pins to SLB/RDR and pixel PWBs. If the pins are OK, replace the Pixel
PWB board (PL 1.11), SLB/RDR PWB (PL 1.11), Backplane (PL 1.11), 37 pin harness (PL
1.11), and the RCM PWB (PL 6.1).
Replace the following components in the order given:

• Pixel PWB (PL 1.11)
• Backplane (PL 1.11)


PL
1.11
PL
1.11
PL
1.11
Figure 2 Circuit Diagram for 6-351 RAP, VCO out of range or missing

6-352 RAP
Fault Code 6-352 indicates that the Pixel Clock Output signals were missing for at least 30
microseconds.
Initial Actions
• If any other fault codes such as 6-358, 6-351, 6-250, 6-251, or 9-201 are declared also,
go to 6-351, go to 6-358, go to 6-250/251 or go to 9-201.
• If this RAP does not correct the problem, electrical noise may be causing the ROS fault.
WARNING
Procedure
WARNING
NOTE: Before replacing any PWB, check its connector for bent/broken pins.
Replace the following one at a time and in the order given:
• The SLB/RDR PWB (PL 1.11)

• The Pixel PWB (PL 1.11)


PL
1.11
PL
1.11 PL
1.11
Figure 2 Circuit Diagram for 6-352 RAP, SLB/RDR Clock Missing

A
6-353 RAP Replace the following:
• The SLB/RDR PWB (PL 6.1). The SLB/RDR PWB has made a false declaration.
Display of this fault indicates that one or more of the voltages supplied by the ROS Low Volt- • The Pixel PWB (PL 1.11)
age Power Supply (PIXEL / Card Cage Low Voltage Power Supply) is missing.
• The Backplane (PL 1.11)
The absence of the voltages provided by the ROS LVPS is monitored at the Pixel PWB. If ROS • Go to 6-353 in the 6 NRD Fault Code Tables
LVPS voltages are missing at the Pixel PWB, a 6-353 fault is declared.
Initial Actions
WARNING
Procedure
ROS Reset Procedure: PO/PO (Power Off and Power On) the machine. The 6-353 fault code
is declared again.
Y N
perform the steps.
WARNING
Observe the top LED on the Pixel PWB. The Pixel PWB LED is lit.
Y N
NOTE: In the following actions, reinstall any previously removed component before going
to the next step.
Measure -5 VDC between TP1 (+) and TP4 (-) on the ROS LVPS PWB.
Measure +25 VDC between TP7 (+) and TP4 (-) on the ROS LVPS PWB.
Measure +28 VDC between TP3 (+) and TP4 (-) on the ROS LVPS PWB. The voltages
are OK.
Y N
• Remove the SLB/RDR, and observe the Pixel PWB LED. If the LED lights,
check J191 for bent/broken pins. If J191 is OK, replace the SLB/RDR PWB (PL
1.11).
• Remove the EDN PWB, and observe the top Pixel PWB LED. If the LED lights,
check J161 for bent/broken pins. If J161 is OK, replace the EDN PWB (PL
1.11).
• Disconnect P2116 from J114 on the Backplane. If the LED lights, check the
cable between J114 (on the Backplane) and J202 (on the RCM PWB) for open/
short circuits or intermittent circuits. If the circuit is OK, replace the RCM (PWB
PL 6.1).
• Replace the ROS LVPS (PL 1.11).

• The ROS LVPS (PL 1.11)
• The Pixel PWB (PL 1.11)
A

PL
1.11
PL
1.11
PL PL
1.11 1.11
PL
6.1
Figure 2 Circuit Diagram for 6-353 RAP, LVPS voltage(s) missing at the Pixel PWB

A
6-354 RAP Go to Flag 1 and Flag 2, and check for an open/short circuit. If the circuit is OK, replace the
Polygon Motor Assembly (PL 6.1). If the problem persists, replace the RCM PWB (PL 6.1).
Fault Code 6-354 indicates that the voltages from the RCM PWB to the Polygon Motor are
missing or are not at the correct frequency. Table 1 Approximate Acceptable Values For Polygon Motor Phase Signals
Signal Nominal Voltage (+) Test Point (-) Test Point
Initial Actions
PA 7.87 VDC, 5.96 VAC TH79 TH89
WARNING PB 7.88 VDC, 5.90 VAC TH80 TH89
PC 7.89 VDC, 5.95 VAC TH81 TH89
H1 2.494 VDC, 2.644 VAC TH88 TH89
WARNING H2 2.504 VDC, 2.601 VAC TH87 TH89
H3 2.476 VDC, 2.644 VAC TH86 TH89
• Ensure that the connector P2113/J111 on the Backplane is seated properly.
• Ensure that the connectors P2201/J201, and J207 on the RCM PWB are seated properly.
• If any of power supply faults 6-214, 6-215, 6-240, 6-330, 6-353, 6-360, or 6-366, are
declared, go to the appropriate RAP, resolve the problem cause, and return to this RAP.
• If fault occurs after power up from slumber mode, this is normal and should be ignored.
• If fault occurs after a system crash or reboot, go to the cause of the system crash or the
cause of the reboot.
• Check Fault History. If fault code 6-354 is declared and hung up in that condition, go to
Flag 4, and check for a short circuit (the wire between P2201-26 and P2113-26) to +5
VDC or to adjacent wires. A short circuit to +5 VDC can be checked between TH39 (+)
and TH50 (-) on the RCM PWB.
Procedure
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. If 6-202 is declared, go to
6-202. Check for Logic Low (L) between TH15 (+) and TH50 (-) on the RCM PWB. Press Con-
tinue. There is Logic L between TH15 (+) and TH50 (-) on the RCM PWB.
Y N
Go to Flag 5 and check for an open/short circuit. If the circuit is OK, replace the 37 pin
harness, Backplane (PL 1.11), SLB/RDR PWB (PL 1.11), and the RCM PWB (PL 6.1).
Check the Polygon Motor phase voltages according to Table 1:
NOTE: Both AC and DC voltages must be measured and must be stable.
Any of the AC/DC voltages measured as in Table 1 are unstable.

Y N
There is approximately +1.1 VDC measured between TH84 (+) and TH89 (-) on the
RCM PWB.
Y N
Polygon Motor Assembly (PL 6.1), the RCM PWB (PL 6.1).
A

PL
6.1
PL
6.1
PL
PL 1.11
6.1 PL
1.11
Figure 2 Circuit Diagram for 6-354 RAP, Polygon Motor phase fault

6-355 RAP • Check the +5 VDC wirenet to P202 on the RCM PWB.
Fault Code 6-355 indicates that +5 VDC is missing on the SOS PWB. The failure of the con-
nection between the SOS PWB and the ROS Control Module PWB is monitored at the RCM
PWB. If there is a SOS PWB connector fault, 6-355, is declared.
Initial Actions
WARNING
• Check Fault History. If fault codes 6-355, 6-214, and 6-237 are declared simultaneously
and hung in that condition, go to Flag 5, and check for a short circuit (the wire between
P2201-23 and P113-23) to +5 VDC or to adjacent wires. A short circuit to +5 VDC can be
checked between TH42 (+) and TH50 (-) on the RCM PWB.
• If +5 VDC fault code 6-215 is declared, go to 6-215, resolve the problem cause, and
return to this RAP.
• Ensure that the connector J301/J1 on the SOS PWB is connected properly.
Procedure
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. 6-355 is declared again.
Y N
perform the steps.
WARNING
6-355 and 6-356 are both declared.
Y N
There is +5 VDC between TH26 (+) and TH50 (-) on the RCM PWB.
Y N
• Reseat P301and P205.
• Go to Flag 2 and go to Flag 4, and check for open/short circuits.
• Swap the SOS PWB with the EOS PWB. If 6-355 is declared, replace the RCM
PWB (PL 6.1).
• If 6-356 is declared, replace the SOS PWB (PL 6.1), which is now in the EOS
PWB location.


• Check/reseat P205.


PL PL
6.1 1.11
PL
PL 1.11
6.1
PL
6.1
Figure 2 Circuit Diagram for 6-355 RAP, SOS/EOS connection fault

6-356 RAP • Reseat/check P205.
• Check the +5 VDC wirenet to P202 on the RCM PWB.
Fault Code 6-356 indicates that +5 VDC is missing on the EOS PWB. The failure of the con-
nection between the EOS PWB and the ROS Control Module PWB is monitored at the RCM
PWB. If there is an EOS PWB connector fault, 6-356, is declared.
Initial Actions
WARNING
• Check Fault History. If fault codes 6-356 and 6-236 are all declared simultaneously and
hung in that condition, go to Flag 5 and check for a short circuit (the wire between P2201-
24 and P2113-24) to +5 VDC or to adjacent wires. A short circuit to +5 VDC can be
checked between TH41 (+) and TH50 (-) on the RCM PWB.
• If +5 VDC fault code 6-215 is declared, go to 6-215, resolve the problem cause and return
to this RAP.
• Ensure that the connector J302/J1 on the EOS PWB is connected properly.
Procedure
WARNING
Fault Code 6-356 is declared again.
Y N
perform the steps.
6-355 and 6-356 are both declared.

Y N
There is +5 VDC between TH27 (+) and TH50 (-) on the RCM PWB.
Y N
• Reseat P301 and P205.
• Go to Flag 1 and go to Flag 3 and check for open/short circuits.
• Swap the EOS PWB with the SOS PWB. If 6-356 is declared, replace the RCM
PWB (PL 6.1).
• If 6-355 is declared, replace the EOS PWB (PL 6.1), which is now in the SOS
PWB location.



PL PL
6.1 1.11
PL
PL 1.11
6.1
PL
6.1
Figure 2 Circuit Diagram for 6-356 RAP, SOS/EOS connection fault

A B
6-358 RAP Y N
Replace the Backplane (PL 1.11).
The failure of a drive voltage reaching the pixel Clock PWB is monitored by the Pixel PWB. If
there is a +15 VDC fault or a -15 VDC at the Pixel PWB, a 6-358 fault is declared. Replace the Pixel PWB (PL 1.11).
Initial Actions Perform the following in the order listed:

• Go to Flag 2, and check the harness to the RCM PWB for short/open circuits
WARNING between P/J114 and P/J202.
Procedure Replace the following:
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. Fault code 6-358 is • Pixel PWB (PL 1.11)
declared again. • SLB/RDR PWB (PL 1.11)
Y N • EDN PWB (PL 1.11)
perform the steps.
WARNING
Measure +15 VDC and -15 VDC without disconnecting the harness. Where do you measure?
The voltage is OK.
Y N
Disconnect P/J113 from the Card Cage. Perform the voltage measurements listed in
Table 1 at the harness connector that was disconnected from P/J113.
Table 1 LVPS Voltages and Test Points On J113 Harness Connector

VOLTAGE CONNECTOR TEST POINTS
+14.25 to +15.75 VDC J113-1 (+) and J113-2 (-)
-14.25 to -15.75 VDC J113-3 (+) and J113-4 (-)
All voltages listed at P/J113 could be measured at the harness connector.

Y N
go to 1-715, +15 VDC RAP or 1-716, -15 VDC RAP.
Reinstall P213 to J113 on the Card Cage. Disconnect P/J114 from the Card Cage. Per-
form the voltage measurements listed in Table 2 at J114 on the Card Cage.
Table 2 LVPS Voltages and Test Points On J114

VOLTAGE CONNECTOR TEST POINTS
+14.25 to +15.75 VDC J114-7 (+) and J114-8 (-)
-14.25 to -15.75 VDC J114-9 (+) and J114-10 (-)
All voltages listed in Table 2 could be measured at J114.

Y N
Leave J114 disconnected. Remove the Pixel PWB, and repeat the measurements of
Table 1. All voltages listed in Table 1 could be measured at J114.
A B

PL
1.11 PL
1.11
PL
1.10
PL PL
1.11 1.11
PL
6.1
Figure 2 Circuit Diagram for 6-358 RAP, +/-15 VDC fault at the Pixel PWB

6-360 RAP
RCM -15 V Monitor Fault: The -15 V fault is monitored on the RCM PWB. If there is a RCM -
15 VDC fault, 6-360 is declared.
Initial Actions
If fault code, 6-353, or 6-358 is also declared, go to 6-353 or go to 6-358, resolve the problem
cause, and return to this RAP.
WARNING
Procedure
declared again.
Y N
perform the steps.
WARNING
There is -14.25 to -15.75 VDC between TH52 (+) and TH21 (-) on the RCM PWB.
Y N
Disconnect P2202 from J202 at the RCM PWB. There is -14.25 to -15.75 VDC mea-
sured between P2202-9 (+) and P2202-10 (-) on the harness side.
Y N
Disconnect the plug from J114. There is -14.25 to -15.75 VDC between J114-9 and
J114-1.
Y N
Go to 6-358.

• Go to Flag 2.
• Check for an open circuit.
Go to Flag 3, and check for a short circuit (the wire between P2201-6 and P2113-6) to +5 VDC
or to adjacent wires. A short circuit to +5 VDC can be checked between TH45 (+) and TH50 (-)
on the RCM PWB.
Replace the following components until the problem cause is resolved:


PL PL PL PL
1.10 1.11 6.1 1.11
PL
1.11
Figure 2 Circuit Diagram for 6-360 RAP, -15 VDC missing at the RCM PWB

A
6-364 RAP Y N
The 6-364 fault is monitored on the RCM PWB. If there is any drift of the Scan Detector PWB RCM PWB (PL 6.1).
linearity, 6-364 is declared.
Replace the SOS PWB (PL 6.1) which is now in the EOS location.
Initial Actions
There is +7.0 to +9.0 VDC measured between TS10 (B1 ROS) / TS55 (B0 ROS) (+) and
WARNING TS50 (-) on the RCM PWB.
Danger. Laser Radiation when the Photoreceptor drawer is open. Avoid direct eye expo- Y N
sure to the Beam. (Laser Light Warning) Switch off power. Swap the EOS PWB with the SOS PWB. Repeat the voltage measure-
• Select [SCP] [Initial]. Check for Queued Faults. If Fault Code 6-250, and/or 6-251 are also ment. Activate the laser and set the Exposure Value to 255. There is +7.0 to +9.0
present, go to the 6-250/251. If Fault Code, 9-201, is queued with this fault, go to the 9- VDC measured between TS9 (B1 ROS) / TS54 (B0 ROS) (+) and TS50 (-) on the RCM
201 RAP. PWB.
Procedure Y N
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. Fault Code 6-364 is
RCM PWB (PL 6.1).
declared again.
Y N
Replace the EOS PWB (PL 6.1) which is now in the SOS location.
If another fault occurs, follow that RAP, otherwise go to the Printer Electrical Noise Proce-
dure located in the Service Call Procedures and perform the steps.
• Enter dC606. Perform the ROS Self Test. If a fault occurs, follow the RAP for that fault
WARNING code.
Switch off power before any component is disconnected or removed, and before any • Go to Flag 2 and check for open/short circuits.
• Reseat P206.
Enter dC606, [ROS Outputs[. Activate [Laser Write], [ROS Intensity]. Set Print Normal
• If the circuit is OK, replace the VLD/Collimator Assembly (PL 6.1), and/or the RCM PWB
Exposure Value at 255. There is +9.5 VDC to +10.5 VDC between TS4 (B1 ROS) / TS35 (B0
(PL 6.1).
ROS) (+) and TS58 (-) on the RCM PWB.
Y N
• Enter dC606. Perform Self Test.
• Follow the RAP from the dC 606, Imaging Tests routine.
There is +0 VDC to + 5 VDC (B1 Exp) between TH75 (+) and TH50 (-) on the RCM PWB.
Y N
Disconnect P206 from the RCM PWB. Activate the laser and set the Exposure Value to
255. There is +0 VDC to +5 VDC between TH75 (+) and TH50 (-) on the RCM PWB.
Y N
Go to Flag 2, and check for an open/short circuit. If the circuit is OK, replace the VLD/Col-
limator (PL 6.1).
There is +7.0 to +9.0 VDC measured between TS9 (B1 ROS) / TS54 (B0 ROS) (+) and
TS50 (-) on the RCM PWB.
Y N
Switch off Power. Swap the SOS PWB with the EOS PWB. Repeat the voltage measure-
ment. Activate the laser and set the Exposure Value to 255. There is +7.0 to +9.0 VDC
measured between TS9 (B1 ROS) / TS54 (B0 ROS) (+) and TS50 (-) on the RCM
PWB.
A


PL PL PL
1.11 6.1 6.1
PL
1.11
PL
6.1
PL
1.11
PL
1.11
PL
6.1
Figure 3 Circuit Diagram for 6-364 RAP, Scan Detector linearity drift

6-366 RAP
If a -5 VDC fault is monitored on the RCM PWB, 6-366 is declared.
Initial Actions
WARNING
Procedure
ROS Reset Procedure: PO/PO (Power Off/Power On) the Machine. 6-366 is declared again.
Y N
perform the steps.
WARNING
There is -5.15 to -5.25 VDC between TH23 (+) and TH50 (-) on the RCM PWB.
Y N
Disconnect the connector from J202 on the RCM PWB. There is -5.15 to -5.25 VDC
between J2202-3 (+) (the harness end) and J2202-4 (-)
Y N
Remove the cover from the left end of the IOT, and disconnect the plug from J114-1
on the Backplane. There is -5.15 to -5.25 VDC between J114-3 (+) and J114 (-) on
the Backplane.
Y N
Remove the Pixel PWB (PL 1.11) and the SLB/RDR PWB (PL 1.11) from the
Card Cage. There is -5.15 to -5.25 VDC between J114-3 (+) and J114-4 (-)
on the Backplane.
Y N
Replace the ROS LVPS (PL 1.11).

• Visually inspect J171 and J191 in the Card Cage for bent/broken pins.
• Reinstall the Pixel PWB and the SLB/RDR PWB one at a time in the Card
Cage while monitoring for -5 VDC between J114-3 (-) and J114-4 (+) on
the Backplane.
Go to Flag 1. Check the harness for a short/open circuit.
Go to Flag 2, and check the harness for an open/short circuit. If the harness is OK, replace the
following components in the order given until the problem is resolved:


PL
6.1
PL PL
1.11 1.11
PL PL
1.11 1.11
Figure 2 Circuit Diagram for 6-366 RAP, -5 VDC fault at RCM PWB

6-367 RAP
Any failure causing the temperature in the Electronics Module Card Cage to exceed accept-
able operating levels is detected, a Card Cage Over Temperature fault, 6-367 is declared, a
soft shutdown is initiated and the IOT is put into IOT slumber mode (to prevent additional dam-
age to the card cage PWBs due to operating at overtemperature conditions).
Procedure
WARNING
PO-PO the machine to verify the fault code. 6-367 is declared again.
Y N
perform the steps.
Check the state of the ROS fans to determine if the heat is being evacuated.
WARNING
The Printer Card Cage Cooling fans are running.
Y N
115 VAC is measured between P282-1 and P292-2 on the Card Cage Cooling Fan
Assembly.
Y N
115 VAC is measured between 1T1-3 and 1TB1-5.
Y N
Go to RAP 1-702.
Go to Flag 1. Check the circuit of the Card Cage Cooling Fans for an open circuit.
Replace the Card Cage Cooling Fans (PL 1.11).

• Check the Fans and Card Cage for obstructions that may reduce air flow.
• Replace the Pixel PWB (PL 1.11). (The Pixel PWB could either be creating heat or could
have a fault which causes it to falsely declare an over-temperature condition.)
• ROS LVPS PWB (PL 1.11).
• Replace ROS Signal Harness, which is the 37-Pin Cable between J201 on the RCM PWB
and J111 on the Backplane (PL 1.11).

PL
1.11
PL PL
1.11 1.11
Figure 1 Circuit Diagram for 6-367 RAP, Overtemperature fault at the Card Cage

A B C
6-701 RAP Go to Flag 2. Check for an open in the Patch Enable circuit.
If the circuit is OK, replace the following components one at a time and in the order
6-701 RAP is used to troubleshoot the problems that are related to the ROS and cause one or given, until the problem is resolved:
more of the following Xerographic faults: 9-203, 9-213, 9-215 or 9-353. • The SLB/RDR PWB (PL 1.11)
• The RCM PWB (PL 6.1)
Procedure • The ROS Assembly (PL 6.1)
WARNING
Danger. Laser Radiation when the Photoreceptor drawer is open. Avoid direct eye expo- Press the Stop button to turn off the [Patch]. With [Laser Write] on, select [ROS Patch
Exposure]. Press Continue. You can see 50% reduction in ROS Intensity in at least
the Patch Area.
WARNING Y N
Switch off power before any component is disconnected or removed, and before any There is +5 VDC (ROS Patch Exposure) between TH36 (+) and TS50 (-) on the
component is connected or installed. RCM PWB.
Y N
NOTE: Some of the steps in this RAP have been performed previously. Redo the steps in this
RAP as directed.
Insert a piece of paper on the PR Belt under the ROS. Enter dC330, [6]. Select [Laser Go to Flag 4. Check the Analysis Control (ROS Patch Exposure) circuit. If the circuit
Write]. Press Continue. Observe the scanline on the paper. There is a full scanline is OK, replace the Pixel PWB (PL 1.11).
(Answer YES if there is a full scanline and missing scan in the Patch Area).
Y N Perform ROS Self Test. If OK, ROS is not the problem.
6-250/251 is declared.
Y N Remove the paper from the Photoreceptor. With [Laser Write] on, +5 VDC is measured
Remove Video Cables from RCM PWBA. There is a full scan line. from TS17 (+) to TS20 (-) on the MIB PWB #1.
Y N Y N
NOTE: Patch Enable is off, but something is hanging it on.
Troubleshoot the video circuit by performing the following: Go to Flag 1. Check for a short circuit in the Patch Enable circuit. If the circuit is OK,
• Go to Flag 3, and check for an open circuit. replace the following components, one at a time and in the order given, until the problem
• Replace the SLB/RDR PWB (PL 1.11). is resolved:
• Replace the Backplane (PL 1.11). • The MIN ADA PWB # 2 (PL 1.8)
• The MIB PWB #1 (PL 1.8)
Go to 6-250/251.
The is Logic L (+0.0 to +0.8 VDC) between TS18 (+) and TS20 (-) on the MIB PWB #1
The scanline is completely off in the Patch Area. Y N
Y N Go to Flag 2. Check for a short in the Patch Enable circuit. Pull the SLB/RDR PWB and
With [Laser Write] on, select [Patch]. Press Continue. The scanline is completely off the Pixel PWB from the Card Cage and inspect the connectors for bent and broken pins.
in the patch area (approximately the middle of the PR Belt). If the circuit is OK, replace the following components one at a time and in the order given,
Y N until the problem is resolved:
Remove the paper from the Photoreceptor. 0 +/- 0.8 VDC is measured from TS18 • MIB PWB #1 (PL 1.8)
(+) to TS20 (-) on the MIB PWB #1. • SLB/RDR PWB (PL 1.11)
Y N • Pixel PWB (PL 1.11)
+5 VDC is measured from TS17 (+) to TS20 (-) on the MIB PWB #1.
Y N Replace the MIB PWB #1 (PL 1.8).
Go to Flag 1. Check for an open in the Patch Enable circuit.
If the circuit is OK, replace the following components, one at a time and in
the order given, until the problem is resolved:
• The MIN ADA PWB #2 (PL 1.8)
• The MIB PWB #1 (PL 1.8)
Replace the MIB PWB #1 (PL 1.8).
A B C
PL
1.11
PL
1.11
PL PL
1.8 1.8
PL
1.11
Figure 1 Circuit Diagram for 6-701 RAP, Xerographic Faults, Sheet 1

PL
6.1
Figure 2 Circuit Diagram for 6-701 RAP, Xerographic Faults, Sheet 2

7-211, 7-212 RAP Y N
This ia a 60 HZ printer
Fault code, 7-211, indicates that the Tray 1 Elevator failed to actuate the Stack Height Sensor, Y N
Q711, within nine seconds after the Elevator Up signal switched on, or that the Elevator (50 HZ printer). 115 VAC is measured between 2A7TB2-13 and 2A7TB2-5.
indexed on more than two consecutive feeds. Y N
Go to the 1-711-1, Inverter/Stacker A Standby AC Power.
Fault code, 7-212, indicates that the Tray 1 Elevator failed to actuate the Tray 1 Down/Low
Paper Sensor, Q714, within nine seconds after the Elevator Down signal switched on, or that Enter [dC] [Power Interrupt]. Go to Flag 4. Check for continuity from 2A7TB2-13 to
the Elevator indexed on more than two consecutive feeds. J1-11 of AC Remote PWB #1 and from 2A7TB2-5 to J1-3 of AC Remote PWB #1. If
the wires are OK, replace the Tray 1 Interlock Switch (PL 9.9).
Initial Actions
• Ensure that the Latch holds Tray 1 in position until the elevator drives up and the Lock (60 HZ). 115 VAC is measured between 2A7TB2-20 and 2A7TB2-13.
Y N
Assembly engages. Ensure that the Tray remains in position during print. Replace the
Latch (PL 7.3) Go to the 1-701, AC Standby Power.
• Ensure that the Feed Head rotates freely at the pivot. Check for seized bearings or wire
Enter [dC] [Power Interrupt]. Go to Flag 3. Check for continuity from 2A7TB2-20 to J1-
harness interference.
11 of AC Remote PWB #1 and from 2A7TB2-13 to J1-3 of AC Remote PWB #1. If the
• Check the Paper Plate Parallelism part of the Paper Feed Setup (ADJ 7-9). If the Tray is wires are OK, replace the Tray 1 Interlock Switch (PL 7.9)
not parallel, perform the Paper Feed Setup (ADJ 7-9).
Procedure 115 VAC is measured between J1-3 of PHN AC Remote PWB #1 and P330-3 of the Eleva-
Enter dC. Open Tray 1. Manually unlock the tray as required. Enter dC330, [7-8]. Rotate the tor Motor, MOT711.
Y N
Feed Head to actuate the Tray 1 Stack Height Sensor. The display changes from H to L.
Y N Go to Flag 5. Check wires 409 and 414 for an open or a short circuit. If the wire is OK,
Go to Flag 1. Check the circuit of the Tray 1 Stack Height Sensor. (GP 6-2, General Pro- replace the AC Remote PWB #1 (PL 1.4)
cedures).
Enter [dC] [Power Interrupt]. Go to Flag 6. Disconnect P330 at the Elevator Motor. A resis-
Ensure that the elevator is in the down position. The Tray 1 Down/Low Paper Sensor display tance of approximately 150 Ohms is measured between pin 1 and pin 2 of the Elevator
motor connector.
should be (L). Use a screwdriver to rotate the Elevator Front Lead Screw clockwise five to ten
turns to raise the elevator from the bottom. The Tray 1 Down/Low Paper Sensor display Y N
changes from H to L. Replace the Elevator Motor, MOT711, (PL 7.7)
Y N
Go to Flag 2. Check the circuit of the Tray 1 Down/Low Paper Sensor. (GP 6-2, General WARNING
Procedures). If the Elevator Motor is in an overheat condition, the motor will automatically reset when
cooled. Make the following measurement when the motor is cool to the touch.
+5 VDC is measured between TS33 (+) and TS37 (-) of the PHN DIO PWB #1. A resistance of approximately 75 Ohms is measured between pin 1 and pin 3 of the Ele-
Y N vator Motor connector.
Go to wire, 503, wirenet. Check the +5 VDC distribution. Y N
Replace the Elevator Motor, MOT711, (PL 7.7)
+5 VDC is measured between TS52 (+) and TS37 (-) of the PHN DIO PWB #1.
Y N Go to Flag 7. Check the wires from the motor to the PWB for an open or a short circuit. The
Go to Flag 8. Check the wires from TS52 to P338-4 for an open or a short circuit. If the wires from P330-1 to P339-1 are OK.
wires are OK, replace the PHN AC Remote PWB #1 (PL 1.4) Y N
Go to Flag 7. Ensure that the Up Limit Switch, (S714), is not actuated. Check the switch
+5 VDC is measured between TS43 (+) and TS37 (-) of the PHN DIO PWB #1. for failure. Check the Elevator Up Limit Switch adjustment (ADJ 7-3). Replace the Eleva-
Y N tor Motor Capacitor, (C711), (PL 7.7)
Go to Flag 10. Check the wires from TS43 to P338-2 for an open or a short circuit. If the
wires are OK, replace the PHN AC Remote PWB #1 (PL 1.4) The wires from P330-2 to P339-5 are OK.
Y N
Cheat the Tray 1 Interlock. 115 VAC is measured between J1-11 and J1-3 of PHN AC Go to Flag 7. Ensure that the Down Limit Switch, (S715), is not actuated. Check the
Remote PWB #1. switch for failure. Replace the Elevator Motor Capacitor, (C711), (PL 7.7)
A
A
Disconnect P339 at the PHN AC Remote PWB #1. Cheat the Front Door Interlock. Enter 7-214 RAP
dC330, [7-8], [Tray 1 Elevator Up]. Press Continue. 0 VDC is measured between TS43 (+)
and TS37 (-) of the PHN DIO. Fault code, 7-214, indicates that the Tray 1 Interlock Switch, S710, was opened during the print
Y N mode. Tray 1 must be selected for this fault to occur.
Initial Actions
Press Stop. Select [Tray 1 Elevator DN]. Press Continue. 0 VDC is measured between
Ensure that paper is properly loaded in the tray.
TS52 (+) and TS37 (-) of the PHN DIO PWB #1.
Y N
Procedure
Enter dC. Unlock Tray 1. Open the Right Front Door. Open Tray 1. Enter dC330, [7-8]. Manu-
Press Stop. Enter [dC] [Power Interrupt]. Reconnect P330 and P339. Press Continue. Enter ally actuate the Tray 1 Interlock Switch. The Tray 1 INTLK SW display changes from L to H.
dC330, [7-8], [Tray 1 Elevator Up]. Press Continue. 0 VAC is measured between P330-2 Y N
of the Elevator Motor and J1-3 of the PHN AC Remote PWB #1. Leave the Tray 1 Interlock Switch open. +5 VDC is measured between TS8 (+) and
Y N TS37 (-) of the PHN DIO PWB #1.
Press Stop. If 115 VAC is measured, replace the Capacitor, C711, (PL 7.7) Y N
If greater than 115 VAC is measured, the Capacitor is OK. Measure the resistance of the Go to Flag 9. Check the wires and the Interlock Switch, (S710), for a short circuit. If
motor between pin 2 and pin 3. If approximately 75 Ohms is not measured, replace the the circuit is OK, replace the PHN DIO PWB #1 (PL 1.4)
Elevator Motor (PL 7.7)
Cheat the Tray 1 Interlock Switch. 0 VDC is measured.
Press Stop. Select [Tray 1 Elevator DN]. Press Continue. 0 VAC is measured at P330-1 of Y N
the Elevator Motor. Go to Flag 9. Disconnect the P334 connector. Check the wires for an open circuit.
Y N Check the Interlock Switch for a failure.
Press Stop. If 115 VAC was measured, replace the Capacitor, C711, (PL 7.7)
If greater than 115 VAC was measured, the Capacitor is OK. Measure the resistance of Check the Tray 1 Interlock.
the motor between pin 2 and pin 3. If approximately 75 Ohms is not measured, replace • Actuator is damaged or bound.
the Elevator Motor (PL 7.7) • Actuator Spring is bent or broken.
• Interlock Switch Bracket is bent or loose.
Press Stop. Inspect the Elevator drives for the following:
• Ensure that the Lock Arm is secure. Check the Lock Assembly adjustment (ADJ 7-
• Elevator is not binding.
10).
• Drive Belts or pulleys for wear or damage and that the belts are set to the correct tension.
• Elevator Drive Belt adjustment (ADJ 7-11). Cheat the Right Front Door Interlock Switch. Enter dC. Close Tray 1. Check the Tray Latch.
• Check the Paper Plate Parallelism part of the Paper Feed Setup (ADJ 7-9). If the Tray is When closed, the tray should maintain position as the Elevator drives until the Lock arm
not parallel, perform the Paper Feed Setup adjustment (ADJ 7-9). engages. The Latch holds the tray in position.
Y N
Replace the Latch (PL 7.3)
Select [Tray 1 Elevator Up]. Press Continue. When the Elevator stops moving, check the
Tray Lock. The tray is locked into position.
Y N
Ensure that the Lock Arm does not bind on the frame pin. Inspect the Tray Lock Arm and
Lock Actuator for damage (PL 7.3)
Check the Tray 1 Interlock:

• Actuator is not damaged or bound.
• Actuator spring is not bent or broken.
• Interlock Switch Bracket is not bent or loose.
• Ensure that the Lock Arm is secure. Check the Lock Assembly adjustment (ADJ 7-10).

Figure 1 7-211/212, 7-214 Circuit Diagram (7700B).

Figure 2 7-211/212, 7-214 Circuit Diagram (7701C).

7-221, 7-222 RAP Y N
This is a 60 HZ Printer.
Fault code, 7-221, indicates that the Tray 2 Elevator failed to actuate the Stack Height Sensor, Y N
Q721, within nine seconds after the Elevator Up signal was switched on, or that the Elevator (50 HZ) 115 VAC is measured between 2A7TB2-13 and 2A7TB2-5.
indexed on more than two consecutive feeds. Y N
Go to the 1-711-1, Inverter/Stacker A Standby AC Power.
Fault code, 7-222, indicates that the Tray 2 Elevator failed to actuate the Tray 2 Down/Low
Paper Sensor, Q724, within nine seconds after the Elevator Down signal was switched on, or Enter [dC] [Power Interrupt]. Go to Flag 4. Check for continuity from 2A7TB1-13 to
that the Elevator indexed on more than two consecutive feeds. J1-17 of AC Remote PWB #1 and from 2A7TB2-5 to J1-8 of AC Remote PWB #1. If
the wires are OK, replace the Tray 2 Interlock Switch (PL 7.9)
Initial Actions
• Ensure that the Latch holds Tray 2 in position until the elevator drives up and the Lock 115 VAC is measured between 2A7TB2-20 and 2A7TB2-13.
Y N
Assembly engages. Ensure that the tray remains in position during print. Replace the
Latch (PL 7.3) Go to the 1-701, AC Standby Power.
• Ensure that the Feed Head rotates freely at the pivot. Check for seized bearings or wire
Enter [dC] [Power Interrupt]. Go to Flag 3. Check for continuity from 2A7TB2-20 to J1-
harness interference.
17 of AC Remote PWB #1 and from 2A7TB2-13 to J1-8 of AC Remote PWB #1. If the
• Check the Paper Plate Parallelism part of the Paper Feed Setup (ADJ 7-9). If the Tray is wires are OK, replace the Tray 2 Interlock Switch (PL 7.9)
not parallel, perform the Paper Feed Setup (ADJ 7-9).
Procedure 115 VAC is measured between J1-8 of PHN AC Remote PWB #1 and P330-3 at the Eleva-
Enter dC. Open Tray 2. Manually unlock the tray as required. Enter dC330, [7-8]. Rotate the tor Motor.
Y N
Feed Head to actuate the Tray 2 Stack Height Sensor. The display changes from H to L.
Y N Go to Flag 5. Check wire 409 for an open or a short circuit. If the wire is OK, replace the
Go to Flag 1. Check the circuit of the Tray 2 Stack Height Sensor (GP 6-2, General Proce- AC Remote PWB #1 (PL 1.4)
dures).
Enter [dC] [Power Interrupt]. Go to Flag 6. Disconnect P330 at the Elevator Motor. A resis-
Ensure that the Elevator is in the down position. The Tray 2 Down/Low Paper Sensor display tance of approximately 150 Ohms is measured between pin 1 and pin 2 of the Elevator
Motor connector.
should be (L). Use a screwdriver to rotate the Elevator Front Lead Screw clockwise five to ten
turns to raise the Elevator. The Tray 2 Down/Low Paper Sensor display changes from H to Y N
L. Replace the Elevator Motor, MOT721, (PL 7.7)
Y N
Go to Flag 2. Check the circuit of the Tray 2 Down/Low Paper Sensor (GP 6-2, General WARNING
Procedures). If the Elevator Motor is in a overheat condition, the motor will automatically reset when
cooled. Make the following measurements when the motor is cool to the touch.
+5 VDC is measured between TS33 (+) and TS37 (-) of the PHN DIO PWB #1. A resistance of approximately 75 Ohms is measured between pin 1 and pin 3 of the Ele-
Y N vator Motor connector.
Go to wire, 503, wirenet. Check the +5 VDC distribution. Y N
Replace the Elevator Motor, MOT721, (PL 7.7)
Y N Go to Flag 7. Check the wires from the motor to the PWB for an open or a short circuit. The
Go to Flag 8. Check the wires from TS53 to P338-8 for an open or a short circuit. If the wires from P330-1 to P339-6 are OK.
wires are OK, replace the PHN AC Remote PWB #1 (PL 1.4) Y N
Ensure that the Up Limit Switch, (S724), is not actuated. Check the switch for failure.
+5 VDC is measured between TS44 (+) and TS37 (-) of the PHN DIO PWB #1. Check the Elevator Up Limit Switch adjustment (ADJ 7-3). Replace the Elevator Motor
Y N Capacitor, (C721), (PL 7.7)
wires are OK, replace the PHN AC Remote PWB #1 (PL 1.4) The wires from P330-2 to P339-10 are OK.
Y N
Cheat the Tray 2 Interlock. 115 VAC is measured between J1-17 and J1-8 of PHN AC Ensure that the Down Limit Switch, (S725), is not actuated. Check the switch for failure.
Remote PWB #1. Replace the Elevator Motor Capacitor, (C721), (PL 7.7)
A
A
Disconnect P339 at the PHN AC Remote PWB #1. Cheat the Front Door Interlock. Enter 7-224 RAP
dC330, [7-8], [Tray 2 Elevator Up]. Press Continue. 0 VDC is measured between TS44 (+)
and TS37 (-) of the PHN DIO PWB #1. Fault code, 7-224, indicates that the Tray 2 Interlock Switch, S720, was opened during the print
Y N mode. Tray 2 must be selected for this fault to occur.
Initial Actions
Press Stop. Select [Tray 2 Elevator Dwn]. Press Continue. 0 VDC is measured between
Ensure that paper is properly loaded in the tray.
TS53 (+) and TS37 (-) of the PHN DIO PWB #1.
Y N
Procedure
Enter dC. Unlock Tray 2. Open the Right Front Door. Open Tray 2. Enter dC330, [7-8]. Manu-
Press Stop. Enter [Power Interrupt]. Reconnect P330 and P339. Press Continue. Enter ally actuate the Tray 2 Interlock Switch. The Tray 2 INTLK SW display changes from L to H.
dC330, [7-8], [Tray 2 Elevator Up]. Press Continue. 0 VAC is measured between P330-2 Y N
of the Elevator Motor and J1-8 of the PHN AC Remote PWB #1. Leave the Tray 2 Interlock Switch open. +5 VDC is measured between TS21 (+) and
Y N TS37 (-) of the PHN DIO PWB #1.
Press Stop. If 115 VAC was measured, replace the Capacitor, C721, (PL 7.7) Y N
If greater than 115 VAC was measured, the Capacitor is OK. Measure the resistance of Go to Flag 9. Check the wires and the Interlock Switch, S720, for a short circuit. If
the motor between pin 2 and pin 3. If approximately 75 Ohms is not measured, replace the circuit is OK, replace the PHN DIO PWB #1 (PL 1.4)
the Elevator Motor (PL 7.7)
Cheat the Tray 2 Interlock Switch. 0 VDC is measured.
Press Stop. Select [Tray 2 Elevator Dwn]. Press Continue. 0 VAC is measured at P330-1 Y N
(+) of the Elevator Motor and J1-8 of the AC Remote PWB #1. Go to Flag 9. Disconnect the P336 connector. Check the wires for an open circuit.
Y N Check the Interlock Switch for a failure.
Press Stop. If 115 VAC was measured, replace the Capacitor, C721, (PL 7.7)
If greater than 115 VAC was measured. The Capacitor is OK. Measure the resistance of Check the Tray 2 Interlock.
the motor between pin 2 and pin 3. If approximately 75 Ohms is not measured, replace • Actuator is damaged or bound.
the Elevator Motor (PL 7.7) • Actuator Spring is bent or broken.
• Interlock Switch bracket is bent or loose.
Press Stop. Inspect the Elevator drives for the following:
• Ensure that the Lock Arm is secure. Check the Lock Assembly adjustment (ADJ 7-
• Elevator is not binding.
10).
• Drive Belts or pulleys for wear or damage and that the belts are set to the correct tension.
• Elevator Drive Belt adjustment (ADJ 7-11). Cheat the Front Door Interlock. Enter dC. Close Tray 2. Check the Tray Latch. When closed,
• Check the Paper Plate Parallelism part of the Paper Feed Setup (ADJ 7-9). If the Tray is the tray should maintain position as the Elevator drives until the Lock Arm engages. The
not parallel, perform the Paper Feed Setup (ADJ 7-9). Latch hold the tray in position.
Y N
Replace the Passive Latches (PL 7.3)
Select [Tray 2 Elevator up]. Press Continue. When the Elevator stops moving, check the
Tray Lock. The tray is locked into position.
Y N
Ensure that the Lock Arm does not bind on the frame pin. Inspect the Lock Arm and Lock
Actuator for damage (PL 7.3)
Check the Tray 2 Interlock:

• Actuator is not damaged or bound.
• Actuator Spring is not bent or broken.
• Interlock Switch Bracket is not bent or loose.
• Ensure that the Lock Arm is secure. Check the Lock Assembly adjustment (ADJ 7-10).

Figure 1 7-221/222, 7-224 Circuit Diagram (7702B).

Figure 2 7-221/222, 7-224 Circuit Diagram (7703C).

A B
7-241, 7-244 RAP • Stack Height/Stack Height Sensor adjustment (ADJ 7-31).
• Low Paper Sensor adjustment (ADJ 7-33).
Fault code, 7-241, indicates that the HCT Elevator failed to move up to actuate either the Stack
Height Sensor, Q735, or the Low Paper Sensor, Q738, within 16 seconds (22 seconds 50HZ) Reconnect P422. Observe the Tray as Continue is pressed. The Elevator drives up.
after the Elevator Up signal was switched on, or three consecutive indexes occurred with three Y N
consecutive feeds. (The elevator drove down). Go the Flag 5. Check the wires for a short circuit.
Fault Code, 7-244, indicates that the HCT Elevator failed to move down to actuate the Tray (The elevator drove up). Go to the Flag 4. Check the wires for a short circuit.
Down Sensor, Q737, within 16 seconds (22 seconds 50HZ) after the Elevator Down signal was
switched on. Actuate the Tray Down Sensor. The Tray Down/Low Paper Sensor display changes from H
to L.
Y N
Go to Flag 2. Check the circuit of the Tray Down Sensor. (GP 6-2, General Procedures).
NOTE: This procedure can be used for 7-241/244 faults that occur in any of the Feeder/
Stacker modules. Actuate the Low Paper Sensor. The Tray Down/Low Paper Sensor display changes from H
to L.
Initial Actions Y N
• Check the condition of the paper in the Tray. Go to Flag 3. Check the circuit of the Low Paper Sensor. (GP 6-2, General Procedures).
• Ensure that the Width Guide is positioned against the paper stack.
• Ensure that the Stack Height Sensor is mounted properly. Check for bent or broken actu- +5 VDC is measured between TS40 (+) and TS37 (-) of the FSN DIO PWB #2.
ator. If the Stack Height Sensor can not be actuated by the paper stack, replace the Width Y N
Guide. +5 VDC is measured between TS35 (+) and TS37 (-) of the FSN DIO PWB #2.
Y N
• If the Tray Elevator drives in dC330 but not in the customer mode, go to the 7-248.
+5 VDC is measured between PS2P2 (+) and PS2P1 (-) of the IFS LVPS.
Procedure Y N
Enter dC330, [Feeder 3/4, or 4/5], [7-8X]. Open the Tray. Cheat the appropriate IFS, MM, or Line to Neutral (60 Hz), Phase to Neutral (50 Hz) is measured between ter-
F/S Interlock Bypass Switch. Manually unlatch the Tray as required. Actuate the Stack Height minal L (+) and terminal N of the IFS LVPS.
Sensor (Q735). The display changes from L to H. Y N
Y N Replace the IFS LVPS Relay (PL 1.15).
Go to Flag 1. Check the circuit of the Stack Height Sensor. (GP 6-2, General Procedures).
Replace the IFS LVPS (PL 1.15).
WARNING
If the Elevator Motor is in an overheat condition, the motor will automatically reset when Go to wire, 61S, wirenet Figure 34. Check the +5 VDC distribution.
cooled. Make the following checks when the motor is cool to the touch.
Go to Flag 4. Check the wires for an open circuit. If the wires are OK, replace the FSN
Handcrank the Elevator about 20 turns to a mid position (turn CW to raise the elevator). Ensure
DIO PWB #2 (PL 1.16)
that the Tray Down, Low Paper, and the Stack Height Sensors are not actuated.
NOTE: If the Elevator motor energizes while handcranking, a short circuit is indicated. Follow Select [Tray Elevator UP]. Press the Continue button. 0 VDC is measured.
the N leg of this statement. Y N
Replace the FSN DIO PWB #2 (PL 1.16)
The Elevator can be handcranked to a mid position.
Y N Press the Stop button. +5 VDC is measured between TS49 (+) and TS37 (-) of the FSN DIO
(Short circuit or binding problem). Enter dC [Power Interrupt]. Disconnect P422 at the PWB #2.
Elevator Drive Motor. Handcrank the Elevator to a mid position (turn CW to raise the ele- Y N
vator). The Elevator can be handcranked without binding. Go to Flag 5. Check the wire for an open circuit. If the wire is OK, replace the FSN DIO
Y N PWB #2 (PL 1.16)
Check the following Elevator drive components:
• Elevator assembly for binding. Select [Tray Elevator DN]. Press the Continue button. 0 VDC is measured.
• Lead Screw Bearings seized. Y N
• Belts and pulleys for wear or damage. Ensure proper belt tensions. Replace the FSN DIO PWB #2 (PL 1.16)
• Elevator Drive Belt adjustment (ADJ 7-30).
A B C
C
NOTE: To ensure good connections, measure 115 VAC at the wires of the P412 connector, not • Lead Screw Bearings seized.
at J1 of the AC Remote PWBs. If this is a 50 HZ printer disconnect wire 1H from pin 1 of • Belts and pulleys for wear or damage. Ensure proper belt tensions.
Feeder Main Drive Run Relay K803 (K3), to avoid incorrect voltage readings due to a feedback
• Elevator Drive Belt adjustment (ADJ 7-30).
path. Reconnect the wire after taking the voltage reading.
• Stack Height/Stack Height Sensor adjustment (ADJ 7-31).
115 VAC is measured between P412-3 and P412-11 of the FSN AC Remote PWB #3 • Low Paper Sensor adjustment (ADJ 7-33).
Y N
• If the above checks are OK, replace the Elevator Motor and Capacitor as required (PL
115 VAC is measured between TB3-14 and TB3-7.
7.7).
Y N
(60 HZ) Go to the 1-705-1 or 1-705-2 Feeder Standby AC Power.
(50 HZ) Go to the 1-712-1 or 1-705-2 Feeder Standby AC Power.
Go to Flag 6. Check wires 2D and 1C for an open circuit.
115 VAC is measured between P412-3 and P412-1 of the FSN AC Remote PWB #3
Y N
115 VAC is measured between P412-3 of the FSN AC Remote PWB #3 and P422-3 at
the Elevator Motor.
Y N
Go to Flag 7. Check wire 11, wirenet for an open circuit. If the wires are OK, replace
the FSN AC Remote PWB #3 (PL 1.16)
Enter dC [Power Interrupt]. Disconnect P422 at the Elevator Motor. Measure the resis-
tance between J1-1 and J1-2. 65 +/- 15 Ohms is measured.
Y N
Replace the HCT Elevator Motor (PL 7.18)
Measure the resistance between J1-1 and J1-3. 40 +/- 15 Ohms is measured.
Y N
Replace the HCT Elevator Motor (PL 7.18)
Go to Flag 8. Check the wires from the AC Remote to the Elevator Motor. Ensure that
there is not an open circuit. Ensure that the Up Limit Switch and the Overtravel Switch are
not actuated. Check the Overtravel Switch and the Up Limit Switch for failure. If the circuit
is OK, replace the Elevator Motor and Capacitor as required (PL 7.18).
Press the Continue button. 0 VAC is measured.

Y N
Replace the FSN AC Remote PWB #3 (PL 1.16)
115 VAC is measured between P412-3 and P412-5 of the FSN AC Remote PWB #3
Y N
Go to Flag 9. Check the wires from the AC Remote PWB to the Elevator Motor. Ensure
that there is not an open circuit. Ensure that the Down Limit Switch is not actuated. Check
the Down Limit Switch for failure (PL 7.17)
Press the Continue button. 0 VAC is measured.

Y N
Replace the FSN AC Remote PWB #3 (PL 1.16)
Check the following Elevator drive components:

• Elevator assembly for binding.

Figure 1 7-241/244 Circuit Diagram (T7704D).

Figure 2 7-241/244 Circuit Diagram (T7705B).

7-248 RAP
Fault Code, 7-248, indicates that the Tray Closed Switch, S730, detected the Tray unlatched
during print.
NOTE: This procedure can be used for 7-248 faults that occur in any of the Feeder/Stacker
modules.
Procedure
Open the Tray. Enter dC330, [Feeder 3/4, 5/6], [7-8x]. Manually actuate the Tray Closed
Switch. The display changes from H to L.
Y N
Go to Flag 1. Check the circuit of the Tray Closed Switch circuit. (GP 6-2, General Proce-
dures).
Select [Tray Release] Solenoid. Press Continue. The Release Solenoid energizes.
Y N
Check the Tray Release Solenoid Assembly for binding.
Press Stop. +24 VDC measured between TS42 (+) and TS37 (-) of the FSN DIO PWB
#2.
Y N
Disconnect the P4067 connector at FSN DIO PWB #2. +24 VDC measured
between TS36 (+) and TS37 (-) of the FSN DIO PWB #2.
Y N
Check the +24 VDC distribution. This is a Tray 3 problem.
Y N
(Tray 4 problem). Go to wire, 81A, wirenet. Repair the open circuit.
(Tray 3 problem). Go to wire, 63F, wirenet. Repair the open circuit.
Go to Flag 2. Check the wires from TS42 to J1-2, and from TS36 to J1-1 for an open
or a short circuit. If the wires are OK, replace the Tray Release Solenoid (PL 7.17)
Press Continue. 0 VDC is measured.

Y N
Replace the Tray Release Solenoid (PL 7.17)
Press Stop. Close the tray. Check the Tray Latch Assembly. The Tray latches properly.
Y N
• Latch Arm moves freely without binding.
• Release Solenoid for burrs or binding. Replace as required (PL 7.17)
• Latch Assembly adjustment (ADJ 7-32).

• Latch Arm moves freely without binding.
• Release Solenoid for burrs or binding. Replace as required (PL 7.17)
• If a "Tray not in the Feed Position" Operator message exists, go to the 7-241, 7-244.

Figure 1 7-248 Circuit Diagram. (7706C)
7-250 RAP Fault Code, 7-250, indicates that the F/S Vertical Transport Door Interlock Switch, S1118,
opened during print.

Note: This procedure can be used for faults that occur in any of the Feeder/Stacker modules. 7-251 RAP
Initial Actions Fault Code, 7-251, indicates that the F/S Horizontal Transport Interlock Sensor, S1120, opened
during print.
• Check the Vertical Transport Door for damage. Ensure that the door hinges are secure.
• Check the door to Interlock Switch alignment. Ensure that the Interlock mounting bracket Note: This procedure can be used for faults that occur in any of the Feeder/Stacker modules.
is secure.
• Ensure that the Vertical Transport baffles are seated. Initial Actions
Procedure • Check the Horizontal Transport Door for damage. Ensure that the door hinges are secure.
NOTE: The following procedure can be used for fault codes that may appear in any of the • Check the door to Interlock Switch alignment. Ensure that the Interlock mounting bracket
Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter is secure.
(A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in • Ensure that the Horizontal Transport baffles are seated.
order to properly diagnose the fault codes. Procedure
Enter dC330, [Feeder X], [7-8X]. Observe the Tray Vert Xport INTLK Sw display. The dis- Enter dC330, [7-8x]. Observe the Tray Horiz Xport INTLK Sw display. The display is L.
play is L. Y N
Y N Manually actuate the Horizontal Transport Door Interlock Switch. The display changes
Manually actuate the Vertical Transport Door Interlock Switch. The display changes from H to L.
from H to L. Y N
Y N Check the circuit of the F/S Horizontal Transport Door Interlock Switch, S1120, (GP
Check the circuit of the F/S Vertical Transport Door Interlock Switch, S1118, (GP 6-2, 6-2, General Procedures). Go to Flag 3. Check for an open circuit. Go to Flag 4.
General Procedures). Go to Flag 1. Check for an open circuit. Go to Flag 2. Check Check for an open or a short circuit.
for a short or an open circuit.
Check the following: • Interlock mounting bracket is secure.
• Interlock mounting bracket is secure. • Door to switch alignment.
• Door to switch alignment. • P4069/J6 wiring harness for possible intermittent connections.
• P4069/J6 wiring harness for possible intermittent connections.
Manually actuate the Horizontal Transport Interlock Switch. The display changes from L to
Manually actuate the Vertical Transport Interlock Switch. The display changes from L to H. H.
Y N Y N
Go to Flag 1. Check for a short circuit (GP 6-2, General Procedures). Go to Flag 3. Check for a short circuit (GP 6-2, General Procedures).
Check the P4069/J6 wiring harness for possible intermittent connections. Check the P4069/J6 wiring harness for possible intermittent connections.

Figure 1 7-250/251 Circuit Diagram (T7707B).
7-701 Tray 1 Capacity PWB Failure RAP The LEDs on the Tray Capacity PWB are not operating correctly, or the Tray Unlock Switch has
failed.

Procedure Go to Flag 4. Check the wire from TS34 to TH3 for an open or a short circuit. If the wires
Open the HCT. There is an open circuit measured from TH2 to TH1 of the Tray Capacity are OK, replace the Tray Capacity PWB (PL 7.3)
PWB when the Unlock Switch is not actuated.
Go to Flag 5. Measure the voltage between TS37 (-) and each of the following: (+) TS46,
Y N
Ensure that the Tray Unlock Switch is not binding in the bezel. Replace the Tray Capacity TS47, TS39, and TS48. +5 VDC is measured at each test stake of the PHN DIO PWB #1.
PWB (PL 7.3) Y N
Go to Flag 5. Check the wires from TS46 to TH8, TS47 to TH7, TS39 to TH6, and TS48 to
Press the Tray Unlock button. A short circuit is measured. TH5 for an open or a short circuit. If the wires are OK, replace the Tray Capacity PWB (PL
Y N 7.3)
Ensure that the Tray Unlock Button is not damaged. Replace the Tray Capacity PWB (PL
7.3) Fill the Tray with paper to maximum capacity. Close the tray. Go to Flag 5. Measure the voltage
between TS37 (-) and each of the following: (+) TS46, TS47, TS39. and TS48. O VDC is
measured at each test stake.
+5 VDC is measured between TH4 (+) and TH2 (-) of the Tray Capacity PWB.
Y N Y N
+5 VDC is measured between TS35 (+) and TS37 (-) of the PHN DIO PWB #1. Go to Flag 5. Check the following wires for an open or a short circuit. From TS46 to TH8,
TS47 to TH7, TS39 to TH6, and TS48 to TH5. If the wires are OK, replace the PHN DIO
Y N
Go to wire, 502, wirenet Figure 31. Check the +5 VDC distribution. PWB #1 (PL 1.4)
The PHN DIO and the Tray Capacity PWB are operating correctly. Check the wire harness for
Go to Flag 1. Check the wire from TS35 to TH4 for an open circuit. Go to Flag 2. Check
the wire from TS37 to TH2 for an open circuit. If the wires are OK, replace the Tray 1 possible pinched wires. Check the PWB connectors for damage.
Capacity PWB (PL 7.3)
+5 VDC is measured between TS2 (+) and TS37 (-) at the PHN DIO PWB #1.
Y N
Go to Flag 3. Check the wire for an open or a short circuit. If the wire is OK, replace the
Tray 1 Capacity PWB (PL 7.3)
Tray Capacity PWB Auto Checkout.

Enter dC330, [7-8], [Tray 1 Capacity]. The Tray Capacity LEDs are divided into four groups as
shown in the component diagram. When the Continue button is pressed, the test sequence
begins with Group 1. Initially, all LEDs in that group are switched on. Then one LED at a time is
switched off until all the LEDs in that group are off. Then group 2 LEDs are switched on and
switched off in the same way. The test sequence will cycle continuously through all four LED
groups until the Stop button is pressed.
Ensure that the Tray Interlock is actuated. Press Continue. The Tray Capacity PWB failed
the LED test.
Y N
The Tray Capacity PWB is OK.
Press [Clear Outputs]. +24 VDC is measured between TH3 (+) and TH2 (-) of the Tray
Capacity PWB.
Y N
Y N
+24 VDC is measured between TH10 (+) and TH8 (-) at the LVPS.
Y N
Go to the 1-717, +24, +34, -34VDC.
Go to wire, 508, wirenet Figure 36. Check the +24 VDC distribution.

A B
Figure 1 7-701 Component Diagram (7708A).
A B
Figure 2 7-701 Circuit Diagram (7709B).

7-702 Tray 2 Capacity PWB Failure Y N
Go to the 1-717, +24, +34, -34VDC.
The LEDs on the Tray Capacity PWB are not operating correctly, or the Tray Unlock Switch has
failed. Go to wire, 508, wirenet Figure 36. Check the +24 VDC distribution.
Procedure Go to Flag 4. Check the wire from TS34 to TH3 for an open or a short circuit. If the wires
are OK, replace the Tray 2 Capacity PWB (PL 7.3)
Open the HCT. There is an open circuit measured from TH2 to TH1 of the Tray Capacity
PWB when the Unlock Switch is not actuated.
Y N Go to Flag 5. Measure the voltage between TS37 (-) and each of the following: (+) TS40,
TS49, TS51, and TS41. +5 VDC is measured at each test stake of the PHN DIO PWB #1.
Ensure that the Tray Unlock Switch is not binding in the bezel. Replace the Tray 2 Capac-
ity PWB (PL 7.3) Y N
Go to Flag 5. Check the wires from TS40 to TH8, TS49 to TH7, TS51 to TH6, and TS41 to
TH5 for an open or a short circuit. If the wires are OK, replace the Tray 2 Capacity PWB
Press the Tray Unlock button. Continuity measured.
Y N (PL 7.3)
Ensure that the Tray Unlock Button is not damaged. Replace the Tray 2 Capacity PWB
Fill the Tray with paper to maximum capacity. Close the tray. Go to Flag 5. Measure the voltage
(PL 7.3)
between TS37 (-) and each of the following: (+) TS40, TS49, TS51, and TS41. O VDC is
+5 VDC is measured between TH4 (+) and TH2 (-) of the Tray Capacity PWB. measured at each test stake.
Y N
Y N
+5 VDC is measured between TS35 (+) and TS37 (-) of the PHN DIO PWB #1. Go to Flag 5. Check the following wires for an open or a short circuit. From TS40 to TH8,
Y N TS49 to TH7, TS51 to TH6, and TS41 to TH5. If the wires are OK, replace the PHN DIO
PWB #1 (PL 1.4)
Go to wire, 502, wirenet Figure 31. Check the +5 VDC distribution.
Go to Flag 1. Check the wire from TS35 to TH4 for an open circuit. Go to Flag 2. Check The PHN DIO PWB and the Tray Capacity PWB are operating correctly. Check the wire har-
ness for possible pinched wires. Check the PWB connectors for damage.
the wire from TS37 to TH2 for an open circuit. If the wires are OK, replace the Tray 2
Capacity PWB (PL 7.3)
+5.0 VDC is measured between TS32 (+) and TS37 (-) at the PHN DIO PWB #1.
Y N
Go to Flag 3. Check the wire from TS32 to TH1 for an open or a short circuit. If the wire is
OK, replace the Tray 2 Capacity PWB (PL 7.3)
Tray Capacity PWB Auto Checkout.

Enter dC330, [7-8], [Tray 2 Capacity]. The Tray Capacity LEDs are divided into four groups as
begins with Group 1. Initially, all LEDs in that group are switched on. Then one LED at a time is
switched off until all the LEDs in that group are off. Then group 2 LEDs are switched on and
switched off in the same way. The test sequence will cycle continuously through all four LED
groups until the Stop button is pressed.
Ensure that the Tray Interlock is actuated. Press Continue. The Tray 2 Capacity PWB failed
the LED test.
Y N
Press [Clear Outputs]. +24 VDC is measured between TH3 (+) and TH2 (-) of the Tray
Capacity PWB.
Y N
Y N

A B
Figure 1 7-702 Components Diagram (7710A).
A B
Figure 2 7-702 Circuit Diagram (7711B).

7-703 HCT Capacity PWB Failure +5 VDC is measured between TS28 (+) and TS37 (-) at the FSN DIO PWB #2.
Y N
The LEDs on the Tray Capacity PWB are not operating correctly, or the Tray Unlock Switch has Go to Flag 3. Check the wire from TS28 to TH1 for an open or a short circuit. If the wire is
failed. OK, replace the Tray Capacity PWB (PL 7.15)
NOTE: This procedure can be used for problems that occur in any of the Feeder/Stacker mod- Tray Capacity PWB Auto Checkout.
ules. Enter dC330, [7-8x], [Tray Capacity]. The Tray Capacity LEDs are divided into four groups as
Procedure begins with Group 1. Initially, all LEDs in that group are switched on. Then one LED at a time is
Place about one ream of paper in the Tray. Close the Tray. Enter dC330, [7-8x]. Select [Tray switched off until all the LEDs in that group are off. Then group 2 LEDs are then switched on
Elevator Dwn]. Press Continue. Observe the Tray Position Sensor display. The display and switched off in the same way. The test sequence will cycle continuously through all four
changes from H to L. LED groups until the Stop button is pressed.
Y N Ensure that the Tray Interlock is actuated. Press the Start button. The Tray Capacity PWB
Go to Flag 6. Check the circuit of the Tray Position Sensor, Q739. Check the actuator for failed the LED test.
damage (PL 7.17) Y N
An open circuit is measured between TH2 (-) and TH1 (+) of the Tray Capacity PWB
when the Tray Unlock Switch is not actuated. Press [Clear Outputs]. +24 VDC is measured between TH3 (+) and TH2 (-) of the Tray
Y N Capacity PWB.
Ensure that the Tray Unlock Switch is not binding in the bezel. Replace the Tray Capacity Y N
PWB (PL 7.15) This is a Tray 4 Problem.
Y N
Press the Tray Unlock button. Continuity is measured. (Tray 3 problem). +24 VDC is measured between TH10 (+) and TH14 (-) at the
Y N LVPS.
Ensure that the Tray Unlock Button is not damaged. Replace the Tray Capacity PWB (PL Y N
7.15) Go to the 1-717 +24, +34, -34VDC.
+5 VDC is measured between TH4 (+) and TH2 (-) of the Tray Capacity PWB. Go to Flag 4. Check wire, 65D, wirenet for an open circuit. Check wire, 63D, wirenet
Y N for an open or a short circuit. If the wires are OK, replace the Tray Capacity PWB (PL
This is a Tray 4 Problem. 7.15)
Y N
(Tray 3 problem). +5 VDC is measured between PS2P2 (+) and PS2P1 (-) of the +24 VDC is measured between TB8-2A (+) and TB8-11B.
IFS LVPS. Y N
Y N Go to the 1-717 +24, +34, -34VDC.
Line to Neutral (60 Hz), Phase to Neutral (50 Hz) is measured between ter-
minal L (+) and terminal N of the IFS LVPS. Go to Flag 4. Check wire, 65D, wirenet for an open or a short circuit. Check wire, 63D,
Y N wirenet for an open or a short circuit. If the wires are OK, replace the Tray Capacity PWB
Replace the IFS LVPS Relay (PL 1.15). (PL 7.15)
Replace the IFS LVPS (PL 1.15). Go to Flag 5. Measure the voltage between TS37 (-) and each of the following: (+) TS46,
TS47, TS39, and TS48. +5 VDC is measured at each test stake of the FSN DIO PWB #2.
Go to Flag 1. Check wire, 61H, wirenet for an open or a short circuit. Check wire, Y N
62H, wirenet for an open circuit. If the wires are OK, replace the Tray Capacity PWB Go to Flag 5. Check the wires from TS46 to TH8, TS47 to TH7, TS39 to TH6, and TS48 to
(PL 7.15) TH5 for an open or a short circuit. If the wires are OK, replace the Tray Capacity PWB (PL
7.15)
(Tray 4 problem). +5 VDC is measured between TB8-2A (+) and TB8-11B (-).
Y N Enter [dC] [Current Program]. Fill the Tray with paper to maximum capacity. Close the tray.
Go to Flag 2. Check wire, 61H, wirenet for an open or a short circuit. Check wire, Go to Flag 5. Measure the voltage between TS37 (-) and each of the following: (+) TS46,
62H, wirenet for an open circuit. TS47, TS39. and TS48. O VDC measured at each test stake.
Go to Flag 8. Check wire, 61A, wirenet for an open or a short circuit. Check wire, 62A,
wirenet for an open circuit.

A
Y N The FSN DIO and the HCT Capacity PWB are operating correctly. Check the wire harness for
Go to Flag 5. Check the following wires for an open or a short circuit. From TS46 to TH8, possible pinched wires. Check the PWB connectors for damage.
TS47 to TH7, TS39 to TH6, and TS48 to TH5. If the wires are OK, replace the FSN DIO
PWB #2 (PL 1.16)
Figure 1 7-703 Component Diagram (7712C).

A
B

7-704 HCT Unlatch RAP Ensure that nothing interferes with the Latch during normal operation. Ensure that the Latch
foot falls down and rests on the top of the pin. Adjust the Latch Assembly (ADJ 7-32).
This RAP is used to repair Tray Locking problems.
Note: The following procedure can be used to repair Tray latching problems that occur in any
Feeder/Stacker module.
Initial Actions
• Check for interference with the Relay Chassis harness at the back of the tray.
• Check the Latch Assembly adjustment (ADJ 7-32).
Procedure
Remove the Rear Cover from the Feeder/Stacker. Manually actuate the Tray Latch and open
the tray. Inspect the Latch Assembly. Ensure that the Solenoid Plunger is not damaged, check
the linkage for damage or interference. The Latch Arm moves freely without binding.
Y N
Replace the Tray Latch Assembly (PL 7.17)
Close the Tray. Enter dC330, [7-8x], [Tray Release] Solenoid. Press Continue. The Release
Solenoid energizes.
Y N
Press Stop. +24 VDC is measured between TS42 (+) and TS37 (-) of the FSN DIO
PWB #2.
Y N
+24 VDC is measured between TS36 (+) and TS37 (-) of the FSN DIO PWB #2.
Y N
This is a Tray 3 problem.
Y N
(Tray 4 problem). Check wire, 81A, wirenet. Check the +24 VDC distribu-
tion.
(Tray 3 problem). +24 VDC is measured between TH10 (+) and TH14 (-) of
the LVPS.
Y N
Go to the 1-717, +24, +34, -34VDC.
Check wire, 85C, wirenet. Check the +24 VDC distribution.
Go to Flag 1. Check the circuit of the Tray Release Solenoid. (GP 6-3, General Pro-
cedures.)
Press Continue. There is 0 VDC measured.

Y N
Check the Solenoid Assembly for mechanical binding. Replace the Tray Release Sole-
noid (PL 7.17)

A
Figure 1 7-704 Circuit Diagram (T7714B).
A
A
8-100, 8-101 RAP Y N
Go to wire 63M. Check for an open circuit.
Fault Code, 8-100, indicates that the lead edge of the sheet of paper failed to arrive at the Pre-
registration Sensor, Q850, within the specified number of clock counts after the lead edge was Go to Flag 3. Check the Tray 3 Oversize Nip Release Solenoid circuit (Generic Solenoid
detected at the Horizontal Transport Sensor, Q854A. After shutdown, the Preregistration Sen- RAP GP 6-3, General Procedures)
sor was unblocked.
Fault Code, 8-101, indicates that the lead edge of the sheet of paper failed to arrive at the Pre- • Tray 3 Oversize Nip Release Solenoid adjustment (ADJ 8-13).
registration Sensor, Q850, within the specified number of clock counts after the lead edge was • Solenoid linkage for binding or damaged, loose, or missing hardware.
detected at the Horizontal Transport Sensor, Q854A. After shutdown, the Preregistration Sen-
sor was blocked.
• Drive Belts for wear, damage, contamination, and that they are set to the correct tension
(PL 8.14).
Initial Actions • Horizontal Transport and Preregistration Transport Drive Rolls for wear, damage, or con-
Check the following: tamination (PL 8.21) (PL 8.25).
• Horizontal Transport and Preregistration Transport Idlers rotate freely (PL 8.22) and (PL
• Preregistration Sensor and Horizontal Transport Sensor are clean and are not obstructed.
8.26).
• Paper is properly loaded and within specification for use in the Printer (Section 4, General
• Idler Tension Springs are present and are not damaged or stretched (PL 8.22) (PL 8.26).
Service Data).
• Horizontal Transport and Preregistration Transport jam clearance baffles for damage and
• If the sheet is damaged go to the 8-705, and 8-706.
that they seat correctly (ADJ 8-10), (ADJ 8-12), and (ADJ 8-14).
• Paper path for obstructions.
• Flexible Drive Shaft for damage, loose coupling, or loose setscrew (PL 8.25).
Procedure • Preregistration Idler Roll Clearance (ADJ 8-11).
Enter dC330, [8]. Block the Preregistration Sensor. The display changes from H to L. • Preregistration Transport Baffle adjustment (ADJ 8-9).
Y N
• IFS to Printer and FS to IFS alignment.
Go to Flag 1. Check the Preregistration Sensor Circuit (GP 6-2, General Procedures).
• Preregistration Edge for wear or damage (PL 8.26).
Select [7-8A]. Block the Horizontal Transport Sensor. The display changes from H to L. • Oversize Nip Release Solenoid for proper operation.
Y N
Go to Flag 2. Check the Horizontal Transport Sensor circuit (GP 6-2, General Proce-
dures).
Select [Tray 3 Xport Drive] Motor. Press Continue. The Horizontal Transport Drive Rolls
rotate.
Y N
The Feeder Main Drive Motor comes on.
Y N
Go to the 8-708, Feeder Main Drive Motor RAP.

• Drive Belts for wear, damage, contamination, and that they are set to the correct ten-
sion (PL 8.14)
• Drive pulleys for damage or slippage on shaft
• Bearings for wear or damage.
Perform dC 703, Feed Timing Set-up, after replacing any of the above.
The problem occurs in the 3 pitch mode. Select [Tray 3 Oversize Nip Release] Solenoid.
Press Continue. The Tray 3 Oversize Nip Release Solenoid energizes.
Y N
Press Stop. +24 VDC is measured at TS54.
A
Figure 1 8-100/101 Circuit Diagram (7800C)
8-102, 8-103 RAP

• Solenoid linkage for binding or damage, loose, or missing hardware.
Fault Code, 8-102, indicates that the trail edge of the sheet of paper failed to arrive at the Pre-
registration Sensor, Q850, within the specified number of clock counts after the lead edge was If the problem continues, go to the 8-104, 8-105.
detected at the sensor. After shutdown, the sensor was unblocked. Check the following:
• Drive belts for correct tension and for wear, damage, or contamination (PL 8.14)
Fault Code, 8-103, indicates that the trail edge of the sheet of paper failed to arrive at the Pre- • Preregistration Transport and Registration Transport Drive Rolls for wear, damage, or
registration Sensor, Q850, within the specified number of clock counts after the lead edge was contamination (PL 8.25) (PL 8.4)
detected at the sensor. After shutdown, the sensor was blocked. • Preregistration Transport and Registration Transport Idlers rotate freely (PL 8.3) and (PL
8.26)
Initial Actions • Idler Tension Springs are present and are not damaged (PL 8.26), (PL 8.4)
Check the following: • Preregistration Transport Pivot Baffle, ADJ 8-10 and Preregistration Transport Baffle,
(ADJ 8-9).
• Preregistration Sensor is clean and is not obstructed.
• Paper is properly loaded and is within specification for use in the Printer (Section 4, Gen-
• Registration Edge for wear or damage (ADJ 8-4).
eral Service Data).
• Registration Transport Assembly adjustment (ADJ 8-4).
• Registration Baffle adjustment (ADJ 8-0).
• IFS to Printer and FS to IFS alignment.
• The Upper Right Transition Baffle is seated in the down position.
Procedure
Enter [dC330], [8]. Block the Preregistration Sensor. The display changes from H to L.
Y N
Go to Flag 1. Check the Preregistration Sensor Circuit (GP 6-2, General Procedures).
Select [7-8A] [Tray 3 Xport Drive] Motor. Press Continue. The Preregistration Transport
Drive Rolls rotate.
Y N
Y N

• Drive belts for correct tension and for wear, damage, or contamination (PL 8.14)
• Drive pulleys loose or damaged
• Bearings for wear or damage
Perform dC 703, Feed Timing Set-up, after replacing any of the above.
The problem occurs in oversize mode. Select [Tray 3 Oversize Nip Release] Solenoid. Press
Continue. The Tray 3 Oversize Nip Release Solenoid energizes.
Y N
Press Stop. +24VDC is measured at TS54..
Y N
Go to wire 63M. Check for an open circuit.
Go to Flag 3. Check the Tray 3 Oversize Nip Release Solenoid circuit (Generic Solenoid
RAP GP 6-3, General Procedures)

• Tray 3 Oversize Nip Release Solenoid adjustment (ADJ 8-13).

8-104, 8-105 RAP

A B C
Replace the Registration Servo PWB (PL 1.4).
Fault Code, 8-104, indicates that the lead edge of the sheet of paper failed to arrive at the Reg-
istration Transport Sensor, Q861, within the specified number of clock counts after the lead
edge was detected at the Preregistration Sensor Q850. In oversize mode after shutdown, the Go to Flag 1. Check the Return wire from P390-2 to P308-21 for an open circuit. If the
wire is OK, replace the Registration Servo PWB (PL 1.4).
Preregistration Transport Sensor, Q850 was unblocked.
Fault Code, 8-105, oversize mode only, indicates that the lead edge of the sheet of paper failed Ensure that the Cross Roll Sensor Bracket is not bent. Block the Cross Roll Sensor. The dis-
play changes from L to H.
to arrive at the Registration Transport Sensor, Q861, within the specified number of clock
counts after the lead edge was detected at the Preregistration Sensor Q850. After shutdown, Y N
the Preregistration Transport Sensor, Q850, was blocked. Go to Flag 3. Check the Cross Roll Sensor for an open or a short circuit, (GP 6-2, General
Procedures).
Initial Actions Select [Cycle Mode] [Oversize Nip Release]. Press Continue. The Vertical Transport Lower
Check the following: Magnetic Strips move without binding.
Y N
• SCP HFSI 08-816, Table 2 table, and 08-817 Table 4. Go to the 8-156.
• Paper is properly loaded and is within specification for use in the Printer. (Section 4, Gen-
eral Service Data). Check the Registration Transport Turn baffle. Ensure that the baffle is mounted on the locating
• Bias the Lower Right Baffle (PL 8.3) to the right to ensure that the sheets enter the PHM pin at the back of the transport. Check the baffle for damage. Ensure that the Upper Baffle
without LE problems. positioning tabs are not bent. Check the Registration Transport jam clearance spring for dam-
• IFS to Printer and FS to IFS alignment. age. Verify that all Registration Transport jam clearance baffles are seated. Ensure that the
idler rolls seat with the Servo Drive rolls and the Vertical Transport Drive rolls when the baffles
are closed. The Registration Transport is OK.
Procedure Y N
Check the Registration Transport Sensor lens for damage (PL 8.4). Be cautious not to crack Repair the Registration Transport as required (PL 8.5).
the sensor lens while cleaning. Clean the Registration Transport Sensor, Cross Roll Sensor,
and Reflective tape. Check the Registration Edge for damage or obstructions (paper plugs or Enter dC703, [Tests], [Velocity]. Press Continue. If a 3-245 or a 8-310 fault occurs during the
debris). Velocity Test, the test has failed. Follow the N path after the next statement. A message indi-
If the fault occurs using transparencies, verify that the Registration Transport Sensor can be cates that the Velocity test passed.
actuated by transparencies. Enter dC330, [8]. Block the Registration Transport Sensor. The Y N
display changes from H to L. Go to Flag 10. Carefully check the P391 and J1 connectors of the Reg Servo Motor,
Y N (MOT862). Ensure that the pins and wires are not damaged and the connection secure.
Check for +5 VDC at the Registration Transport Sensor. Disconnect P390. +5 VDC is Check the wire from P391-1 of the Reg Servo Motor, MOT862, to TS18 of the PHN Reg-
measured between machine frame (-) and each of the following pins at the P390 istration Servo PWB for an open circuit. If the wire and connectors are OK and the Veloc-
connector (+) P390-1, P390-3, P390-4. ity Test still fails, go to the 8-302.
Y N
Go to Flag 1. Check the wire that did not measure +5 VDC for an open circuit. If the Check the Cross Roll drive rolls for damage or flat spots. The Cross Rolls are free of dam-
wires are OK, replace the Registration Servo PWB (PL 1.4). age.
Y N
Go to Flag 9. +5 VDC is measured between TS16 (+) and TS37 (-) on the PHN DIO Replace the Cross Rolls (PL 8.7).
PWB #2. Perform dC 703, Feed Timing Set-up.
Y N
Replace the PHN DIO PWB #2 (PL 1.4). Check the Cross Roll drive belt tension. Manually rotate the Cross Roll Drives. The Cross
Roll Drives turn freely without binding.
Go to Flag 2. +5 VDC is measured between TS37 (-) on the PHN DIO PWB #2 and Y N
TS9 (+) on the Reg Servo PWB. Repair the Cross Roll Assembly Drives (PL 8.5).
Y N Perform dC 703, Feed Timing Set-up.
Disconnect P308 at the Registration Servo PWB. Continuity is measured
between P308-16 and TS16 on the PHN DIO PWB #2. Enter dC330, [8], [Cross Roll] Motor. Press Continue. The Cross Rolls rotate.
Y N Y N
Repair the open circuit. Press Stop. +5 VDC is measured between TS52 (+) and TS37 (-) on the PHN DIO
PWB #2.
A B C D
D D E
Y N Ensure that the Cross Roll Drives turn freely without binding. If the drives are OK, replace
+5 VDC is measured between J2-5 (+) on PHN AC Remote #2 and TS37 (-) on the Cross Roll Motor (PL 8.7). Perform dC 703, Feed Timing Set-up
PHN DIO PWB #2.
Y N Select [Cross Roll Left] Solenoid. Press Continue. The Left Cross Roll Solenoid ener-
Go to wire 538. Check the +5 VDC distribution. gizes.
Y N
Go to Flag 8. Check the wires from TS52 to P385-6 for an open or a short circuit. If Press Stop. +24 VDC is measured between TS50 (+) and TS37 (-) on PHN DIO PWB
the wire is OK, replace the PHN AC Remote PWB #2 (PL 1.4). #2.
Y N
Press Continue. 0 VDC is measured. +24 VDC is measured between TS36(+) and TS37(-) on the PHN DIO PWB #2.
Y N Y N
Replace the PHN DIO PWB #2 (PL 1.4). +24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS.
Y N
Press Stop. 115 VAC measured between J1-6 (+) and J1-8 (-) on the PHN AC Remote Go to the 1-717.
PWB #2.
Y N Check wire, 544. Check the +24 VDC distribution.
115 VAC is measured between J1-18 (+) and J1-8 (-) on the PHN AC Remote
PWB #2. Go to Flag 6. Check the Left Cross Roll Solenoid circuit. (Generic Solenoid GP 6-3,
Y N General Procedures.)
(60HZ) Go to the 1-702, AC Interlocked Power RAP.
(50HZ) Go to the 1-709, AC Interlocked Power RAP. Press Continue. 0 VDC is measured.
Y N
Go to Flag 5. Check for continuity from P389-1 to P396-6, and from P389-2 to P396- Replace the PHN DIO PWB #2 (PL 1.4).
18. If the wires are OK, ensure that the Cross Roll Drives are not binding. Replace
the Cross Roll Motor (PL 8.7). Perform dC 703, Feed Timing Set-up Replace the Left Cross Roll Solenoid (PL 8.5).
Press Continue. There is 0 VAC measured. The Cross Roll Idler lifts and lowers freely without binding.
Y N Y N
Replace the PHN AC Remote PWB #2 (PL 1.4). Replace the Solenoid Assembly (PL 8.5).
Press Stop. Go to Flag 11. Check the wires at the Cross Roll Motor Capacitor, C861. Select [Cross Roll Right] Solenoid. Press Continue. The Right Cross Roll Solenoid ener-
Ensure that the white wire is connected to the left terminal and the black wire is con- gizes.
nected to the right terminal of the capacitor. Leave one meter lead at J1-8 (-) of PHN AC Y N
Remote PWB #2. Place the other meter lead (+) at the white wire (left capacitor terminal). Press Stop. +24 VDC is measured between TS42 (+) and TS37 (-) on PHN DIO PWB
Press Continue. 0 VAC is measured. #2.
Y N Y N
Go to Flag 11. Check the white wire from the Capacitor to P389-1 for an open circuit. Go to Flag 7. Check the Right Cross Roll Solenoid circuit. (Generic Solenoid GP 6-3,
If the wire is OK, replace the Cross Roll Motor Capacitor, C861, (PL 8.7). Manually General Procedures.)
rotate the Cross Roll drives, ensure that the Cross Roll Assembly is not binding.
Measure the voltage to the black wire (+) (right capacitor terminal). Press Continue. Y N
+240 VAC is measured. Replace the PHN DIO PWB #2 (PL 1.4).
Y N
Press Stop. Enter [Power Interrupt]. Go to Flag 11. Check the black wire from the Replace the Right Cross Roll Solenoid (PL 8.5).
Capacitor to P389-1 for an open circuit. A resistance of about 400 ohms should be
measured. The wire is OK. The Cross Roll Idler lifts and lowers freely without binding.
Y N Y N
Repair the wire. If the wire cannot be repaired, replace the Cross Roll Motor Replace the Solenoid Assembly (PL 8.5).
(PL 8.7) Perform dC 703, Feed Timing Set-up.
Check the Cross Roll Idler Lift Fingers. When the idlers are in the down position, ensure that
Replace the Cross Roll Motor Capacitor, C681, (PL 8.7). Manually rotate the Cross the fingers do not contact the idler shafts. The fingers are below the idler shafts.
Roll drives, check the Cross Roll Assembly for binding.
D E
Y N • If the problem occurs with lightweight papers, ensure that the Cross Roll Lever is in the
Repair/Replace the Cross Roll Idler Lift Assembly (PL 8.5). down position. If the problem occurs with heavy weight papers, ensure that the Cross Roll
Lever is in the up position. If the problem continues, replace the Cross Roll Idler assembly
Enter dC726. Select [Printer Options], [Tray 3/4], [Sample Tray], 50 prints. Press Con- (PL 8.5).
tinue. Observe the Registration Xport. The Servo Drive Rolls rotate in a counterclockwise • Look for paper related problems or multifeeds. Check [SCP] [Faults] for 8-182/183 or 8-
direction. 903 indicating possible Tray 3/4 multifeeds. If 8-302 faults are indicated, go to the 8-302.
Y N
If the Servo Rolls are not rotating, check the drive belt for damage or improper tension.
Check for shaft failure (PL 8.4).
If the Servo Rolls are rotating in the clockwise direction, go to Flag 10. Reverse the posi-
tions of pin 1 and pin 2 at the J1 motor connector.
The Left Cross Roll Idler, (both Idlers in 3-pitch), lifts only one time per sheet of paper.
Y N
Replace the Reflective tape if it is damaged or missing. Ensure that the Sensor Bracket is
not bent. If the problem is with special stock ensure that the stock, will actuate the sensor.
Replace the Cross Roll Sensor, Q871, as required (PL 8.6).
Observe the sheets entering the Registration Transport. Look for excessive skew. Ensure that
the corners of the sheets do not snag on the Registration Edge entrance chute. The sheets
enter the transport without skew or snags.
Y N
Go to the 8-706.
The sheets pass through the transport without catching on the Registration Edge.
Y N
Remove the Registration Edge. Check the edge for grooves or surface flaws. Ensure that
the Reg Edge is seated properly. Replace the Reg Edge as required (PL 8.4).
Check the output copies carefully. If paper damage or skew has not been observed and no
damage or misregistration has been reported by the operator, there could be an intermittent
problem with the Registration Transport Sensor. Replace the sensor (PL 8.4).
If the problem continues, check the following:
• Lower Preregistration Transport Baffle (ADJ 8-9).
• Lower Preregistration Transport Corrugator Rolls (ADJ 8-11).
• Lower Preregistration Transport Pivot Baffle (ADJ 8-10).
• Oversize Nip Release Solenoid for proper operation.
• Transport drive rolls for wear, damage, or contamination.
• Transport idler rolls and springs for proper operation and position.
• Preregistration Drive Belt for wear, damage, and proper tension (PL 8.2).
• Check the Tray 3/4 Feed Belt tracking.
• Ensure that the Tray 3/4 Width Guide is not bent. Fill the paper tray to max level. If there
is greater than 3mm gap between the guide and the paper stack, replace the Width Guide
(PL 7.16). Instruct the Operator as to proper closing of the Tray.
• Check the Tray 3/4 Latch Assembly adjustment (ADJ 7-32).
• Ensure that vibration in Tray 1 and Tray 2 does not cause random feeds. If this problem is
observed, check the Tray coupling alignment.

Figure 1 8-104/105 Registration Xport Components (7817B)


A B
8-111 RAP Replace the Stack Relief Solenoid (PL 7.1).
Fault Code, 8-111, indicates that the lead edge of the sheet of paper failed to move from the Block the Tray 1 Stack Relief Sensor. The display changes from L to H.
top of the stack in Tray 1 to the Tray 1 Stack Relief Sensor, Q812, within the specified number Y N
of clock count after the Tray 1 Feed Clutch, CL811, was energized. Go to Flag 4. Check the Stack Relief Sensor circuit. (GP 6-2, General Procedures.)
Initial Actions Select [7-8] [Tray 1 Elevator Up]. Press Continue. The elevator moves up without bind-
• Check SCP HFSI for 08-802, Table 4. ing.
Y N
• Check the condition of the paper in the tray. Transparencies must be loaded with the
A Tray Elevator problem exists. Go to the 7-211, 7-212.
white strip at the lead edge. Clear the Feed Head of obstructions.
• If the tray is in the overtravel position, hand crank the tray until the Overtravel Switch is no Select [7-8] [Tray 1 Feed] [Cycle Mode]. Press Continue. The feed clutch energizes.
longer actuated. Y N
• If the Length Guide moves away from the paper stack when the tray is closed, adjust the Press Stop. +24 VDC is measured between TS42 (+) and TS37 (-) of the PHN DIO
Length Guide Tension ADJ 7-5. PWB #1.
• If edge reinforced drilled stock is being used, ensure that the Tray Plate Assembly is prop- Y N
erly positioned. Go to Flag 5. Check the Tray 1 Feed Clutch circuit. (Generic Clutch GP 6-3, General
• If Tray 1 is empty when the fault is declared, check the Down/Low Paper Sensor adjust- Procedures.)
ment ADJ 7-2.
• If Tray 1 opens during print, check the Lock Assembly adjustment (ADJ 7-10).
Y N
Procedure Replace the PHN DIO PWB #1 (PL 1.4).
Open Tray 1. Cheat the Tray 1 Interlock Switch. Enter dC330, [7-8]. Block the Tray 1 Stack
Height Sensor. The display changes from H to L. Replace the Tray 1 Feed Clutch (PL 7.12). Perform dC 703, Feed Timing Set-up,
Y N
Go to Flag 1. Check the Tray 1 Stack Height Sensor for a short circuit, (GP 6-2, General Press Stop. Close Tray 1. Enter dC726. Select [Printer Options], [Tray 1], [Sample Tray], 50
Procedures.) prints. Select [Paper Path] [1]. Press Continue. The graph indicates feed variations or
operation out of the specified range.
Block the Tray 1 Down/Low Paper Sensor. The display changes from H to L. Y N
Y N Check SCP [Faults] [Actual] [Almost] [PHM]. If the faults occurred in clusters and are
Go to Flag 2. Check the Tray 1 Down/Low Paper Sensor circuit. (GP 6-2, General Proce- not reproducible at the present time, there may be a paper related problem. If there are
dures.) no, 8-113, Fault Codes indicated, replace the Feed Clutch (PL 7.12). Go to the 8-701,
Friction Retard Checkout.
Select [7-8] [Tray 1 Stack Relief] Solenoid. Press Continue. The solenoid energizes.
Y N Verify that the Feed Head rotates freely. Remove the Feed Head Safety Covers. Ensure that
+24 VDC is measured between TS34 (+) and TS37 (-) of the PHN DIO PWB #1. the Feed Head Bearings are located against the stops on the tray frame. Check the following:
Y N • Feed Belt Pulley or Feed Belt Idler one way clutch for binding or slipping (PL 7.10)
+24 VDC is measured between TH12 (+) and TH14 (-) of the LVPS. • Loose, worn, or damaged drive belts or idlers (PL 7.12)
Y N • Tube Shaft for binding
Go to the 1-717, +24, +34, -34 VDC RAP.
• Takeaway Shaft Endplay Adjustment (ADJ 7-1)
• Feeder Drive coupling for binding
Go to wire 508. Check the +24 VDC distribution.
• Tray 1 Feeder Drive Adjustment (ADJ 4-20)
+24 VDC is measured between TS54 (+) and TS37 (-) of the PHN DIO PWB #1. • Feed Clutch Belt Adjustment (ADJ 7-0)
Y N • Go to the 8-701, Friction Retard Checkout. If the problem continues, replace the Feed
Go to Flag 3. Check the Stack Relief Solenoid circuit, (Generic Solenoid GP 6-3, Clutch (PL 7.12).
General Procedures.)
Press Continue. 0 VDC is measured. Perform dC 703, Feed Timing Set-up if any of the above are replaced.
Y N
Replace the PHN DIO PWB #1 (PL 1.4).
A B
Figure 1 8-111 Circuit Diagram (7859A).

Figure 2 8-111 Components (7803B).

8-112 RAP Y N
Go to Flag 3. Check the Tray 1 Takeaway Roll Sensor circuit, (GP 6-2, General Proce-
Fault Code, 8-112, indicates that the lead edge of the sheet of paper fed from Tray 1 did not dures).
arrive at the Tray 1 Takeaway Roll Sensor, Q811, within the specified number of clock counts
after the Tray 1 Feed Clutch, CL811, was energized. When this fault is declared, the Tray 1 Close Tray 1. Enter dC726. Select [Printer Options], [Tray 1], [Sample Tray], [50] prints.
Takeaway Roll Sensor, Q811, is blocked. Select [Paper Path] [1]. Press Continue. The graph indicates feed variations or operation
outside of the specified range.
Initial Actions Y N
• Check SCP HFSI and 08-802, Table 4. Check SCP [Faults] [Actual] [Almost] [PHM]. If the faults occurred in clusters and are
not reproducible at the present time, there may be a paper related problem. If there are,
• Check the condition of the paper in the tray. Transparencies must be loaded with the
8-111, Fault Codes and no, 8-113, Fault Codes, there is a possible intermittent clutch
white strip at the lead edge.
problem. Replace the Tray 1 Feed Clutch (PL 7.12)
• If the Tray is in the overtravel position, handcrank the tray until the Overtravel Switch is no
longer actuated. Verify that the Feed Head rotates freely at the pivot. Remove the Feed Head Safety Covers.
• If the Length Guide moves away from the paper stack when the tray is closed, adjust the Ensure that the Feed Head Bearings are located against the stops on the Tray frame. Check
Length Guide Tension (ADJ 7-5). the following:
• If Tray 1 is empty when the fault is declared, check the Down/Low Paper Adjustment (ADJ • Takeaway Roll Idler one way clutch for binding or slipping (PL 7.10)
7-2). • Tube Shaft for binding
• If Tray 1 opens during print, check the Lock Assembly Adjustment (ADJ 7-10). • Feeder Drive Coupling for binding
• Check the Feed Clutch Belt Adjustment (ADJ 7-0). • Loose, worn, or damaged drive belts or idlers (PL 7.12)
Procedure • Takeaway Shaft Endplay Adjustment (ADJ 7-1)
Open Tray 1. Cheat the Tray 1 Interlock Switch. Enter dC330, [7-8], [Tray 1 Stack Relief] • Tray 1 Feeder Drive Adjustment (ADJ 4-20)
solenoid. Press Continue. The solenoid energizes. • Go to the 8-701, Friction Retard Checkout. If the problem continues, replace the Feed
Y N Clutch (PL 7.12).
+24 VDC is measured between TS34 (+) and TS37 (-) of the PHN DIO PWB #1. Perform dC 703, Feed Timing Set-up, if any of the above are replaced.
Y N
Y N
Go to the 1-717, +24, +34, -34 VDC RAP.
Y N
Go to Flag 1. Check the Tray 1 Stack Relief Solenoid circuit, (Generic Solenoid RAP
GP 6-3, General Procedures).

Y N
Replace the Tray 1 Stack Relief Solenoid (PL 7.1).
Block the Tray 1 Stack Relief Sensor. The display changes from L to H.
Y N
Go to Flag 2. Check the Tray 1 Stack Relief Sensor circuit, (GP 6-2, General Procedures).
Block the Tray 1 Takeaway Roll Sensor. The display changes from L to H.

Figure 1 8-112 Components (7860A)

Figure 2 8-112 Circuit Diagram (7804B)

A
8-113 RAP Leave the clutch energized. Open the machine Right Front Door. Cheat the interlocks. Select
[1-4] [Main Drive Start/Run] motor. Press Continue. The Vertical Transport Belts are
Fault Code, 8-113, indicates that the trail edge of the sheet of paper fed from Tray 1 failed to rotating.
leave the Tray 1 Takeaway Roll Sensor, Q811, within the specified number of clock counts from Y N
the time the lead edge of the sheet arrived at that sensor, or the lead edge of a transparency Manually rotate the Vertical Transport Lower Shaft assembly. Binding occurs within the
was late to the Vertical Transport Sensor, Q851. transport.
Y N
Initial Actions Check the following:
• Check SCP HFSI 08-802, and 08-808, Table 4. • PHM Drive Belt Tension (ADJ 4-17)
• Check for possible multifeeds due to excessive tray vibration resulting from drive coupling • Idlers and springs for damage (PL 8.1)
misalignment. Adjust the Tray 1 Feeder Drives (ADJ 4-20). • Universal Coupling (PL 8.1)
• Check the Feed Clutch Belt Adjustment (ADJ 7-0). • Drive Coupling Insert (PL 8.1)
• Ensure that the rubber sleeve is still bonded to the Takeaway Roll (PL 7.10). • Drive Pulley/Clutch Assembly (PL 8.1). If replaced, perform dC 703, Feed Tim-
ing Set-up
Procedure
Observe the Feed Head during operation. Ensure that the Feed Clutch is not on constantly. Disengage the Vertical Transport from the Drive Coupling. Manually rotate the Vertical
There is a gap between each sheet during feeding. Transport Lower Shaft assembly. Binding occurs within the transport.
Y N Y N
Go to the circuit diagram for 8-111 RAP, Flag 5. Check the Tray 1 Feed Clutch for a short Replace the Drive Coupling Assembly (PL 8.1). Check the idlers and springs for
circuit (Generic Clutch RAP GP 6-3, General Procedures). If the Feed Clutch circuit is damage.
OK, or, 8-113, Fault Codes continue, go to the next statement in this RAP.
Repair or replace the Vertical Transport Assembly (PL 8.1). Perform dC 703, Feed Timing
Enter dC330, [7-8]. Block the Tray 1 Takeaway Roll Sensor. The display changes from L to Set-up
H.
Y N Press Stop. Select [7-8] [Tray 1 Elevator Dn]. Press Continue. Open Tray 1. Manually rotate
Go to Flag 1. If the Tray 1 Takeaway Roll and Tray 1 Stack Relief Sensors indicate L the Tube Shaft in the counterclockwise direction. The Tray 1 Takeaway Roll rotates.
when not blocked, check the DC Com wires for an open circuit. If the Stack Relief Sensor Y N
is OK, check the Takeaway Roll Sensor for an open circuit, (GP 6-2, General Proce- Replace the Tray 1 Takeaway Roll (PL 7.10). Perform dC 703, Feed Timing Set-up
dures).
Inspect the Tray 1 Takeaway Roll Drive area. A nip is present at the Takeaway Roll.
Select [8] [Vertical Xport] clutch. Press Continue. The clutch energizes. Y N
Y N Check the Tray 1 Takeaway Roll Drive area for the following:
Press Stop. +24 VDC is measured between TS35 (+) and TS37 (-) of the PHN DIO • Idler worn or contaminated
PWB #2.
• Idler springs damaged or out of position (PL 7.10)
Y N
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. • Obstructions in the paper path
Y N
Clean the Tray 1 Takeaway Roll and Idler. Enter dC726. Select [Printer Options], [Tray 1],
Go to the 1-717, +24, +34, -34 VDC RAP.
[Sample Tray], and [50] prints. Select [Paper Path] [2]. Press Continue. The graph indi-
Go to wire 516. Check the +24 VDC distribution. cates that the sheets are slow off the Tray 1 Takeaway Roll Sensor.
Y N
+24 VDC is measured between TS40 (+) and TS37 (-) of the PHN DIO PWB #2. Check SCP [Faults] [Actual] [Almost] [PHM]. If the faults occurred in clusters and are
Y N not reproducible at the present time, there may have been a paper related problem.
Go to Flag 2. Check the Vertical Transport Clutch circuit, (Generic Clutch GP 6-3,
General Procedures). Check the Takeaway Roll Idler for binding due to shaft contamination. Ensure that the Idler
Springs are not worn or out of position. Replace the Tray 1 Takeaway Roll (PL 7.10). Check the
Vertical Transport for slippage. Ensure that the proper Magnetic Strips are installed and that
Y N they are properly positioned (PL 8.2). Check the Feed Clutch Belt and Takeaway Drive Belt
tension (ADJ 7-0). Check SCP [Faults] [Actual] [ALMOST] [PHM]. If Fault Code, 8-112, is
indicated, go to the 8-701, Friction Retard Checkout.
Replace the Vertical Transport Clutch (PL 4.18). Perform dC 703, Feed Timing Set-up,
A

A
8-115 RAP Y N
Fault Code, 8-115, indicates that the lead edge of the sheet of paper fed from Tray 1, failed to • Universal Coupling (PL 8.1)
arrive at the Vertical Transport Sensor, Q851, within the specified number of clock counts from • Drive Coupling Insert (PL 8.1)
the time the lead edge of that sheet of paper arrived at the Tray 1 Takeaway Roll Sensor, Q811.
• Drive Belt tension
When this fault occurs, the Takeaway Roll Sensor, Q811, is not blocked.
• Idlers and springs (PL 8.1)
Initial Actions • Magnetic Strips for interference
• Check SCP HFSI for 08-802 and 08-808, Table 4. • If no drive problem is found, replace the Vertical Transport Belts (PL 8.1). If the
problem continues, replace the Vertical Transport Clutch (PL 4.18). Perform dC
• Check the condition of the paper in the Tray 1.
703, Feed Timing Set-up,
• Check the PHM Drive Belt tension (ADJ 4-17).
• Ensure that the Vertical Transport Magnetic Strips (PL 8.2) are undamaged and properly Disengage the Vertical Transport from the drive coupling. Manually rotate the Vertical
positioned. Clear all paper from the transport. Transport Lower Shaft assembly. Binding occurs within the transport.
• Ensure that the rubber sleeve is still bonded to the Tray 1 Takeaway Roll (PL 7.10). Y N
Clean the Vertical Transport Belts and Magnetic Strips. Check the Vertical Transport
Procedure timing. Enter dC726. Select [Printer Options], [Tray 1], [Sample Tray], [50] prints.
Enter dC330, [8], [Vertical Xport], [Cycle Mode]. Press Continue. The Vertical Transport Select [Paper Path] [57]. Press Continue. If the timing is not within the specified
Clutch energizes and deenergizes. range, replace the Vertical Transport Belts (PL 8.1).
Y N
Select [Clear Outputs]. +24 VDC is measured between TS40 (+) and TS37 (-) of the Repair or replace the Vertical Transport Assembly (PL 8.1).
PHN DIO #2.
Y N Enter dC330. Select [7-8], [Tray 1 Elevator Dn]. Press Continue. Open Tray 1. Manually
+24 VDC is measured between TS35 (+) and TS37 (-). rotate the Tube Shaft in a counterclockwise direction. The Takeaway Roll rotates.
Y N Y N
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. Check the belts for damage. Replace the Takeaway Roll (PL 7.10).
Y N
Go to the 1-717. Inspect the Tray 1 Takeaway Roll Drive area. A nip is present at the Takeaway Roll.
Y N
Go to wire 516. Check the +24 VDC distribution. Check the Tray 1 Takeaway Roll Drive area for the following:
• Idler worn or contaminated (PL 7.11)
Go to Flag 2. Check the Vertical Transport Clutch circuit (Generic Clutch GP 6-3,
• Obstructions in the paper path
Y N Clean the Takeaway Roll and idler. Enter dC726. Select [Printer Options], [Tray 1], [Sample
Tray], [50] prints. Select [Paper Path] [2]. Press Continue. The graph indicates that the
sheets are slow off the Tray 1 Takeaway Roll Sensor.
Replace the Vertical Transport Clutch (PL 4.18). Perform dC 703, Feed Timing Set-up, Y N
Check SCP [Faults] [Actual] [Almost] [PHM]. If, 8-115, Fault Codes have occurred in
Select [Clear Outputs]. Block the Vertical Transport Sensor. The display changes from H to clusters and are not reproducible at the present time, there may have been a paper
L. related problem.
Y N
Go to Flag 1. Check the Vertical Transport Sensor circuit, (GP 6-2, General Procedures). Check the Tray 1 Takeaway Roll Idler for binding due to shaft contamination. Ensure that the
idler springs are in position. Verify that there is nip present at the takeaway roll. Replace the
Tray 1 Takeaway Roll (PL 7.10). If the problem continues, go to the 8-701, Friction Retard
Enter dC726. Select [Printer Options], [Tray 1], [Sample Tray], [50] prints. Select [Paper
Path] [3]. Press Continue. The graph indicates that the machine operation is within the Checkout.
specified range.
Y N
Manually rotate the Vertical Transport Lower Shaft assembly. Binding occurs within the
transport.
A

A B
8-121 RAP Replace the Stack Relief Solenoid (PL 7.1).
Fault Code, 8-121, indicates that the lead edge of the sheet of paper failed to move from the Block the Tray 2 Stack Relief Sensor. The display changes from L to H.
top of the stack in Tray 2 to the Stack Relief Sensor, Q822, within the specified number of clock Y N
counts after the Feed Clutch, CL821, was energized. Go to Flag 5. Check the Stack Relief Sensor circuit. (GP 6-2, General Procedures.)
Initial Actions Select [7-8] [Tray 2 Elevator Up]. Press Continue. The Elevator moves up without bind-
• Check SCP HFSI for 08-804, Table 4. ing.
Y N
• Check the condition of the paper in the trays. Clear the Feed Head of obstructions. Trans-
A Tray Elevator problem exists. Go to the 7-221, 7-222.
parencies must be loaded with the white strip at the lead edge.
• If the Tray is in the overtravel position, handcrank the tray until the Overtravel Switch is no Select [8] [Tray 2 Feed] [Cycle Mode]. Press Continue. The Feed Clutch energized.
longer actuated. Y N
• If the Length Guide moves away from the paper stack when the Tray is closed, adjust the Press Stop. +24 VDC is measured between TS50 (+) and TS37 (-) of the PHN DIO
Length Guide Tension (ADJ 7-5). PWB #1.
• If edge reinforced drilled stock is being used, ensure that the Tray Plate Assembly is prop- Y N
erly positioned. Go to Flag 3. Check the Feed Clutch circuit. (Generic Clutch RAP GP 6-3, General
• If Tray 2 is empty when the fault is declared, check the Down/Low Paper Sensor Adjust- Procedures.)
ment ADJ 7-2.
• If Tray 2 opens during print, check the Lock Assembly Adjustment (ADJ 7-10).
Y N
Procedure Replace the PHN DIO PWB #1 (PL 1.4).
Open Tray 2. Cheat the Tray 2 Interlock Switch. Enter dC330, [7-8]. Block the Tray 2 Stack
Height Sensor. The display changes from H to L. Replace the Feed Clutch (PL 7.12). Perform dC 703, Feed Timing Set-up,
Y N
Go to Flag 1. Check the Tray 2 Stack Height Sensor circuit. (GP 6-2, General Proce- Press Stop. Close Tray 2. Enter dC726. Select [Tray 2], [Sample Tray], 50 prints. Select
dures.) [Paper Path] [4]. Press Continue. The graph indicates timing variations or operation out-
side of the specified range.
Block the Tray 2 Down/Low Paper Sensor. The display changes from H to L. Y N
Y N Check SCP [Faults] [Actual] [Almost] [PHM]. If the faults occurred in clusters and do
Go to Flag 2. Check the Tray 2 Down/Low Paper Sensor circuit. (GP 6-2, General Proce- not reproduce at the present time, there may have been a paper related problem. If there
dures.) are no, 8-123, faults indicated, replace the Feed Clutch (PL 7.12). Go to the 8-701 Friction
Retard Checkout.
Select [8A] [Tray 2 Stack Relief] Solenoid. Press Continue. The solenoid energizes.
Y N Verify that the Feed Head rotates freely at the pivot. Remove the Feed Head Safety Covers.
+24 VDC is measured between TS34 (+) and TS37 (-) of the PHN DIO PWB #1. Ensure that the Feed Head Bearings are located against the stops on the Tray frame. Check
Y N the following:
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. • Feed Belt Pulley or Feed Belt Idler one way clutch for binding or slipping (PL 7.10)
Y N • Loose, worn, or damaged drive belts or idlers (PL 7.10)
Go to the 1-717, +24, +34, -34 VDC RAP. • Check the Feed Clutch Belt Adjustment (ADJ 7-0)
• Tube Shaft for binding
+24 VDC is measured between TS45 (+) and TS37 (-) of the PHN DIO PWB #1. • Feeder Drive Coupling bound on shaft (PL 7.11)
Y N • Tray 2 Feeder Drive Adjustment (ADJ 4-20)
Go to Flag 4. Check the Stack Relief Solenoid circuit. (Generic Solenoid GP 6-3, • Go to the 8-701, Friction Retard Checkout. If the problem continues, replace the Feed
General Procedures.) Clutch (PL 7.12). Perform dC 703, Feed Timing Set-up,

Y N
A B


A
8-122 RAP Close Tray 2. Enter dC726. Select [Tray 2], [Sample Tray],50 prints. Select [Paper Path] [4].
Press Continue. The graph indicates timing variations or operation outside of the speci-
Fault code, 8-122, indicates that the lead edge of the sheet of paper fed from Tray 2 did not fied range.
arrive at the Tray 2 Takeaway Roll Sensor, Q821, within the specified number of clock counts Y N
after the Tray 2 Feed Clutch, CL821, energized. When this fault is declared, the Takeaway Roll Check SCP [Faults] [Actual] [Almost] [PHM]. If the faults occurred in clusters and do
Sensor is blocked. not reproduce at the present time, there may have been a paper related problem. If there
are, 8-121, faults and no, 8-123, faults, there is a possible intermittent clutch problem.
Initial Actions Replace the Feed Clutch (PL 7.12). Go to the 8-701, Friction Retard Checkout.
• Check SCP HFSI 08-804, Table 4.
Verify that the Feed Head can rotate freely at the pivot. Remove the Feed Head Safety Covers.
• Check the condition of the paper in the trays. Transparencies must be loaded with the
Ensure that the Feed Head Bearings are located against the stops on the Tray frame. Check
white strip at the lead edge.
the following:
• If the tray is in the overtravel position, handcrank the tray until the Overtravel Switch is no • Takeaway Roll Idler one way clutch for binding or slipping (PL 7.10)
longer actuated.
• Tube Shaft for binding
• If the Length Guide moves away from the paper stack when the tray is closed, adjust the
• Feeder Drive Coupling bound on shaft (PL 7.11)
Length Guide Tension (ADJ 7-5).
• Loose, worn, or damaged drive belts or idlers
• If Tray 2 is empty when the fault is declared, check the Tray Down/Low Paper Sensor
Adjustment (ADJ 7-2).
• Tray 2 Feeder Drive Adjustment (ADJ 4-20)
• If Tray 2 opens during print, check the Lock Assembly Adjustment (ADJ 7-10).
• Go to the 8-701, Friction Retard Checkout. If the problem continues, replace the Feed
• Check Feed Clutch Belt Adjustment (ADJ 7-0).
Clutch (PL 7.12). Perform dC 703, Feed Timing Set-up,
Procedure
Open Tray 2. Cheat the Tray 2 Interlock Switch. Enter dC330, [8], [Tray 2 Stack Relief] Sole-
noid. Press Continue. The solenoid energizes.
Y N
Y N
Y N
Go to the 1-717, +24, +34, -34 VDC RAP.
Y N
Go to Flag 2. Check the Stack Relief Solenoid circuit. (Generic Solenoid RAP GP 6-
3, General Procedures.)

Y N
Replace the Stack Relief Solenoid (PL 7.1).
Block the Tray 2 Stack Relief Sensor. The display changes from L to H.
Y N
Go to Flag 3. Check the Stack Relief Sensor circuit. (GP 6-2, General Procedures.)
Block the Tray 2 Takeaway Roll Sensor. The display changes from L to H.
Y N
Go to Flag 4. Check the Takeaway Roll Sensor circuit. (GP 6-2, General Procedures).
A


A
8-123 RAP Leave the clutch energized. Open the Right Front Door. Cheat the interlocks. Select [1-4]
[Main Drive Start/Run] motor. Press Continue. The Vertical Transport Belts are rotating.
Fault code, 8-123, indicates that the trail edge of the sheet of paper fed from Tray 2 failed to Y N
leave the Tray 2 Takeaway Roll Sensor, Q821, within the specified number of clock counts Manually rotate the Vertical Transport Lower Shaft assembly. Binding occurs within the
from the time the lead edge of that sheet arrived at the sensor, or the lead edge of a transpar- transport.
ency was late to the Vertical Transport Sensor, Q851. When this fault is declared, the Take- Y N
away Roll Sensor is blocked. Check the following:
• PHM Drive Belt Tension (ADJ 4-17)
Initial Actions • Idlers and spring for damage (PL 8.1)
• Check SCP HFSI for 08-808, Table 4, or HFSI TABLES to see all of HFSI. • Universal Coupling (PL 8.1)
• Check for possible multifeeds due to excessive tray vibration from drive coupling mis- • Drive Coupling Insert (PL 8.1)
alignment. Adjust the Tray 2 Feeder Drives (ADJ 4-20). • Drive Pulley/Clutch Assembly (PL 8.1). If replaced, Perform dC 703, Feed Tim-
• Check the Feed Clutch Belt tension (ADJ 7-0). ing Set-up.
• Ensure that the urethane sleeve is still bound to the Takeaway Roll (PL 7.10).
Disengage the Vertical Transport from the Drive Coupling. Manually rotate the Vertical
Procedure Transport Lower Shaft assembly. Binding occurs within the transport.
Clear the Feed Head of obstructions. Observe the feeder during operation. Ensure that the Y N
Feed Clutch is not energized constantly. There is a gap between sheets being fed. Replace the Drive Coupling Assembly (PL 8.1).
Y N
Go to the circuit diagram for the 8-121 RAP, Flag 3. Check the Feed Clutch for a short cir- Repair or replace the Vertical Transport Assembly (PL 8.1).
cuit. (Generic Clutch RAP GP 6-3, General Procedures.) If the circuit is OK, and the 8-
123, faults continue, go to the next step of this RAP. Press Stop. Select [7-8] [Tray 2 Elevator Dn]. Press Continue. Open Tray 2. Manually rotate
the Tube Shaft in a counterclockwise direction. The Takeaway Roll rotates.
Enter dC330, [7-8]. Block the Tray 2 Takeaway Roll Sensor. The display changes from L to Y N
H. Replace the Takeaway Roll (PL 7.10). Perform dC 703, Feed Timing Set-up
Y N
Go to Flag 1. If both the Takeaway Roll and Stack Relief Sensors indicate L when not Inspect the Takeaway Roll Drive area. A nip is present at the Takeaway Roll.
blocked, check the DC Com wires for an open circuit. If the Stack Relief Sensor is OK, Y N
check the Takeaway Roll Sensor for an open circuit. (GP 6-2, General Procedures.) Check the Takeaway Roll Drive area for the following:
• Idler worn or contaminated
Select [8] [Vertical Xport] Clutch. Press Continue. The clutch energizes.
Y N
Press Stop. +24 VDC is measured between TS35 (+) and TS37 (-) of the PHN DIO • Obstructions in the paper path
PWB #2.
Clean the Takeaway Roll and Idler. Enter dC726. Select [Tray 2], [Sample Tray], 50 prints.
Y N
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. Select [Paper Path] [5]. The graph indicates that the sheets are slow off the Takeaway
Y N Roll Sensor.
Y N
Go to the 1-717, +24, +34, -34 VDC RAP.
Check SCP [Faults] [Actual] [Almost] [PHM]. If the faults occurred in clusters and are
Go to wire 516. Check the +24 VDC distribution. not reproducible at the present time, there may be a paper related problem.
+24 VDC is measured between TS40 (+) and TS37 (-) of the PHN DIO PWB #2. Check the Takeaway Roll Idler for binding due to shaft contamination. Ensure that the Idler
Y N Springs are not worn or out of position. Replace the Takeaway Roll (PL 7.10). Check the Verti-
cal Transport for slippage. Verify the Magnetic Strip position. Check SCP [Faults] [Actual]
Go to Flag 2. Check the Vertical Transport Clutch circuit. (Generic Clutch GP 6-3,
General Procedures.) [Almost] [PHN]. If 8-122 faults are indicated, go to the 8-701, Friction Retard Checkout.

Y N
Replace the Vertical Transport Clutch (PL 4.18). Perform dC 703, Feed Timing Set-up,
A

A
8-144 RAP Select [Clear Outputs]. Block the Vertical Transport Sensor. The display changes from H to
L.
Fault code, 8-144, indicates that the lead edge of the print fed from the Duplex Inverter failed to Y N
arrive at the Vertical Transport Sensor, Q851, within the specified number of clock counts from Go to Flag 1. Check the Vertical Transport Sensor circuit. (GP 6-2, General Procedures.)
when the lead edge of the print arrived at the Duplex Takeaway Roll Sensor, Q842.
Select [Oversize Nip Relief] solenoid. Press Continue. The Nip Relief Solenoid energizes.
Initial Actions Y N
Check SCP HFSI for 08-808, Table 4, or HFSI TABLES to see all of HFSI. +24 VDC is measured between TS54 (+) and TS37 (-) of the PHN DIO PWB #6.
Y N
Y N
• Magnetic Strips (PL 8.2) are undamaged and properly positioned. Go to wire 540. Check the +24 VDC distribution.
• If output prints are damaged, go to the 8-705. For excessive curl problems, consult the
Go to Flag 3. Check the Nip Relief Solenoid circuit. (Generic Solenoid GP 6-3, Gen-
Operator Manual.
eral Procedures.)
Procedure
Enter dC330, [8]. Block the Duplex Takeaway Roll Sensor. The display changes from H to Press Continue. 0 VDC is measured.
L. Y N
Y N Replace the PHN DIO PWB #6 (PL 1.4).
Go to Flag 2. Check the Duplex Takeaway Roll Sensor circuit. (GP 6-2, General Proce-
dures.) Check the Nip assembly for binding. If OK, replace the Nip Relief Solenoid (PL 10.23).
Select [1-4] [Main Drive Start/Run] motor. Press Continue. Select [8] [Vertical Xport] Ensure that the Vertical Transport rotates without binding. Binding occurs within the trans-
Clutch. Cheat the Printer Interlock Bypass Switch. Press Continue. The Vertical Transport port.
Lower Shaft is turning. Y N
Y N Clean or replace the Vertical Transport belts (PL 8.1). Check the Upper Drive Shaft
Select [Clear Outputs]. +24 VDC is measured between TS40 (+) and TS37 (-) of the assembly for binding. Check the idlers and springs (PL 8.1)
PHN DIO PWB #2.
Y N Disengage the Vertical Transport from the Drive Coupling. Manually rotate the Vertical Trans-
+24 VDC is measured between TS35 (+) and TS37 (-) of PHN DIO PWB #2. port Shaft assemblies. Binding occurs within the transport.
Y N Y N
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. Replace the Drive Coupling (PL 8.1).
Y N
Go to the 1-717, +24,+34,-34 VDC RAP. Repair the Vertical Transport Assembly. Check the Drive Belt tension. Ensure that the Drive
and Idler Rolls are not seized. Check the idler springs. Check the Upper and Lower Shaft
Go to wire 516. Check the +24 VDC distribution. assemblies for binding. Replace as required (PL 8.1).
If the problem continues, go to the 8-145.
Go to Flag 4. Check the Vertical Transport Clutch circuit. (Generic Clutch RAP GP 6-

Y N
Check the drive belt and idler to the Vertical Xport Clutch. Remove the Vertical Transport
and check the following:
• Flexible Coupling and shaft for damage (PL 8.1)
• Drive Coupling, Coupling Insert, and Drive Pulley for damage (PL 8.1)
• Upper and Lower Shafts for binding
A


A B
8-145 RAP Clean or replace the Forward Reverse Drive Rolls (PL 10.21). Go to Flag 2 and Flag 3.
Check the Forward and Reverse Clutch circuits (Generic Clutch RAP GP 6-3, General
Fault Code, 8-145, indicates that the lead edge of the sheet of paper failed to arrive at the Procedures).
Duplex Takeaway Roll Sensor, Q842, within the specified number of clock counts after the
Duplex Forward Clutch, CL841, energized. Check the following:
• Dual Drive Rolls for wear or contamination (PL 10.20)
Initial Actions • Baffle fingers are not bent or bowing into the paper path
Check the following: • Torsion springs are not loose or missing (PL 10.20).
• Paper for excessive curl
• Paper path for obstructions
• Decurler Adjustment (ADJ 10-8)
• Jam clearance baffles are seated and latched correctly
• Load fresh or replace the paper
Procedure
Enter dC106. Select [Duplex], [Tray 1], and 50 prints. Press Continue. The sheet stopped
at or in the Dual Drive Rolls.
Y N
The sheet stopped at or in the Forward Reverse Drive Rolls nip.
Y N
The sheet stopped at or in the Exit Drive Rolls nip.
Y N
Enter dC330, [8]. Block the Duplex Takeaway Roll Sensor. The display
Y N
Go to Flag 1. Check the Takeaway Roll Sensor circuit (Generic Sensor
RAP GP 6-2, General Procedures).
Clean or replace the Dual Drive Rolls (PL 10.20) and Exit Drive Rolls (PL
10.21) as required. If the problem continues, replace the Duplex Takeaway Roll
Sensor (PL 10.20).
Clear the sheets from the paper path. Enter dC702. Press Continue. The edge of
the sheet is between the two outside hash marks.
Y N
• Clean or replace the Forward Reverse Drive Rolls (PL 10.21)
• (ADJ 10-14), Duplex Timing
• If the problem still exists, replace the Inverter Gear Box Assembly (PL
10.23).
The Drag Brake turns freely with no drag felt.

Y N
Remove the sheet from the Duplex Inverter area. Press Continue. Run dC702
again. The sheet consistently stops in the same location.
Y N
Replace the Inverter Gear Box Assembly (PL 10.23)
Perform ADJ 10-14, Duplex Timing. If the problem still exists, replace the
Inverter Gear Box assembly (PL 10.23).
Replace the Drag Brake (PL 10.23).
A B

A
8-146 RAP • Vertical Transport Belts for wear or contamination (PL 8.1).
• Dual Drive Rolls and Exit Drive Rolls for wear or contamination (PL 10.19).
Fault Code, 8-146, indicates that the trail edge of a sheet of paper failed to leave the Duplex
• Magnetic Strips on the Vertical Transport for burrs.
Takeaway Roll Sensor, Q842, within the specified number of clock counts after the lead edge
• If the problem still exists, replace the Duplex Takeaway Roll Sensor (PL 10.20).
of the sheet arrived at the sensor, or that the sensor is blocked during print.
Go to Flag 1. Check the Duplex Takeaway Roll Sensor circuit (GP 6-2, General Procedures).
Initial Actions
1. Paper path for obstructions

2. Jam clearance baffles are positioned and latched correctly
3. Check for Vertical Transport Belt slippage as follows:
a. Apply white out to the end of the Vertical Transport Assembly Upper Shaft PL 8.1
such that half of the area is covered.
b. Shine a flashlight on the area and monitor the shaft speed while paper enters the
Vertical Transport from the Paper Trays.
c. If the shaft speeds up as the paper enters the Vertical Transport, the Belts are slip-
ping.
d. Replace the Vertical Transport Belts PL 8.1 and ensure the correct Skis are installed.
Procedure
Enter dC106. Select [Printer Options], [Duplex], and [Tray 1]. Press Continue. Run the
machine until a fault is declared. Fault Code, 8-146, is declared.
Y N
The sheet stopped with the trail edge past the Duplex Takeaway Roll Sensor.
Y N
• Compression Spring on the Lower Baffle Latches is not broken (PL 10.22).
• Inverter Jam Clearance Baffle latches correctly.
• Vertical Transport Belts for wear or contamination.
• Dual Drive Rolls and Exit Drive Rolls for wear or contamination.
• Magnetic Strips on the Vertical Transport for burrs.
Enter dC330. Select [1-4], [Main Drive/Start Run] motor. Press Continue. Select [8]
and [Vertical Transport] clutch. Press Continue. The Vertical Transport Belts are
turning.
Y N
The Vertical Transport Clutch energized.
Y N
Go to Flag 2. Check the Vertical Transport Clutch Circuit (Generic Clutch RAP

• Vertical Transport Drives for binding.
• Drive Belts for wear, damage or contamination.

• Compression Spring on the Lower Baffle Latches is not broken (PL 10.22).
• Inverter Jam Clearance Baffle latches correctly.
A

A
8-147 RAP • Baffle fingers bent or bowed
• Torsion springs loose or missing (PL 10.21).
Fault Code, 8-147, indicates that the lead edge of the sheet of paper did not arrive at the
• Paper for excessive curl
Duplex Takeaway Roll Sensor, Q842, within the specified number of clock counts after the
Duplex Forward Clutch, CL841, was energized.
Enter dC330. Select [1-4], [Main Drive Run] motor. Press Continue. Select [8] [Duplex
Reverse] clutch. Press Continue. The Forward Reverse Drive Roll is turning counter-
Initial Actions clockwise.
Check the following: Y N
Go to Flag 2 and 3. Check the Forward and Reverse Clutch circuits (Generic Clutch RAP
• Paper path for obstructions GP 6-3, General Procedures).
Select [Clear Outputs]. Check the following:
Procedure • Forward Reverse Drive Rolls for wear, damage, or contamination
Enter dC106. Select [Printer Options], [Duplex], [Tray 3], 50 prints. Ensure that Tray 3 is
• Drag Brake is not binding
loaded with oversized (A3) paper. Press Continue. Run the machine until a fault is declared.
The edge of the sheet stopped within the two outside hash marks on the Jam Clearance • If the problem still exists, replace the Inverter Gear Box Assembly (PL 10.23)
Baffle.
Y N
The sheet is jammed at or in the Dual Drive Roll nip.
Y N
The sheet is jammed at or in the Exit Drive Roll nip.
Y N
The sheet is blocking the Takeaway Roll Sensor.
Y N
Clear the paper path. Enter dC702. Press Continue. The edge of the
sheet is between the two outside hash marks.
Y N
Adjust the Duplex Timing (ADJ 10-14). If the problem continues,
replace the Inverter Gear Box Assembly (PL 10.23).

Y N
If the sheet consistently jams at the same location, adjust the
Duplex Timing. If the problem continues, replace the Inverter
Gear Box Assembly (PL 10.23).
Enter dC330, [8]. Block the Duplex Takeaway Roll Sensor. The display
Y N
Go to Flag 1. Check the Duplex Takeaway Roll Sensor circuit (GP 6-
2, General Procedures).
Clean or replace the Dual Drive Roll (PL 10.20)
Check the Dual Drive Rolls and the Forward Reverse Drive Rolls for wear,
damage, or contamination.
Check the Forward Reverse Drive Rolls for wear, damage or contamination.

• Dual Drive Roll for wear, damage, or contamination (PL 10.20)
A

8-149 RAP
Fault Code, 8-149, indicates that the sheet failed to arrive at the Vertical Transport Sensor,
Q851, within the specified number of clock counts after arriving at the Duplex Takeaway Roll
Sensor, Q842.
Initial Actions

Procedure
Enter dC106. Select [Printer Options], [Duplex], [Tray 3], 50 prints. Ensure that Tray 3 is
loaded with oversize (A3) paper. Press Continue. A sheet jammed at the Vertical Transport
Sensor.
Y N
Enter dC330. Select [1-4], [Main Drive/Start Run] motor. Press Continue. Select [8],
[Vertical Transport]. Press Continue. The Vertical Transport Belts are turning.
Y N
Go to the 8-144.

• Vertical Transport Belts for wear, damage, or contamination (PL 8.1)
• Dual Drive Roll and Exit Drive Roll for wear, damage, or contamination (PL 10.20)
• Magnetic Strips for burrs
• Nip Release Solenoid Cable for binding
• If the problem continues, replace the Vertical Transport Sensor (PL 8.1)
Enter dC330, [8]. Block the Vertical Transport Sensor. The display changes from H to L.
Y N
Go to Flag 1. Check the Vertical Transport Sensor circuit (GP 6-2, General Procedures).

• Vertical Transport Belts for wear, damage, or contamination (PL 8.1)
• Dual Drive Roll and Exit Drive Roll for wear, damage, or contamination (PL 10.20)
• Magnetic Strips for burrs
• Nip Release Solenoid Cable for binding
• If the problem still exists, replace the Vertical Transport Sensor (PL 8.1).


A B C D
8-151 RAP Go to wire 516. Check the +24 VDC distribution.
Fault code, 8-151, indicates that the trail edge of the sheet of paper did not leave the Vertical Go to Flag 2. Check the Vertical Transport Clutch circuit. (Generic Clutch RAP GP 6-
Transport Sensor, Q851, within the specified number of clock counts after the lead edge of that 3, General Procedures.)
sheet arrived at the sensor.
Initial Actions Y N
• Check the SCP HSFI for 08-808 Table 4, and 08-816 Table 3, or HFSI TABLES to see all Replace the PHN DIO PWB #2 (PL 1.4).
of HFSI.
If the Vertical Transport Clutch, CL851, does not energize, replace the clutch (PL 4.18).
Check the Vertical Transport Clutch Drive Belt. Remove the Vertical Transport. Check for
Service Data).
binding in the upper and lower shafts.
• Check the paper path for obstructions. • Check the drive belt and idler to the lower Shaft Assembly for damage (PL 8.1).
• Check that the Registration Transport Turn baffle is mounted on the locating pin at the • Check the Flexible Coupling and Shaft for damage (PL 8.1).
rear of the transport.
• Check the Drive Coupling, Coupling Insert, and Drive Pulley for damage (PL 8.1).
• Check that the Registration Transport jam clearance baffles are seated correctly.
• Check that the Pinch Roll Shaft rolls (PL 8.3) seat with the drive rolls when the baffles are Press Stop. Enter dC726. Select [Tray 1], [Sample Tray], 100 prints. Select [Paper Path],
closed. [3]. Press Continue. Observe the sheets entering the Registration Transport. There may be
• Check the SCP [Faults] for PHM. If 8-302 faults are indicated, go to the 8-302. If 8-151 intermittent problems at the transition from the Vertical Transport. The sheets pass the Verti-
faults continue, return to this procedure. cal Transport Idler Nips without excessive drag or interference.
Y N
Procedure Replace the Vertical Transport Nip Idler Bracket (PL 8.1).
Clean the Vertical Transport Belts and Magnetic Strips. Ensure that the Magnetic Strips are
undamaged and are seated against the Transport Belts. Ensure that the Vertical Transport Check for excessive skew. Ensure that the corners of the sheets do not snag on the Registra-
Double Nip Idler is seated with the springs properly positioned. The Vertical Transport Belts, tion Edge entrance chute. The sheets enter the Transport without skew or snags.
Magnetic Strips, and Idlers are OK. Y N
Y N Go to the 8-706. Diagnose Vertical Transport and Tray 1 and 2 areas.
Repair the Vertical Transport as required (PL 8.1). Replace the Magnetic Strips as
required (PL 8.2). The graph indicates that the timing is within the normal operating window.
Y N
Enter dC330. Select [8]. Block the Vertical Transport Sensor. The display changes from H to Move the Vertical Transport Belts out of position. Manually rotate the Vertical Transport
L. Lower Shaft Assembly. Binding occurs within the transport.
Y N Y N
Go to Flag 1. Check the Vertical Transport Sensor circuit. (GP 6-2, General Procedures.) Check the Upper Drive Shaft Assembly for binding. Check the idlers and springs (PL
8.1). Replace the Vertical Transport Belts (PL 8.1).
Select [Cross Roll]. Press Continue. The Cross Rolls rotate.
Y N Disengage the Vertical Transport from the drive coupling. Manually rotate the Vertical
Press Stop. Go to the 8-152. Transport Shaft Assembly. Binding occurs within the transport.
Y N
Press Stop. Select [1-4] [Main Start/Run] motor. Press Continue. Select [8] [Vertical Xport] Replace the Vertical Transport Drive Coupling (PL 8.1).
clutch. Press Continue. The Vertical Transport Lower Shaft is turning.
Y N Repair the Vertical Transport Assembly. Check the Drive Belt Tension. Ensure that the
Select [Clear Outputs]. +24 VDC is measured between TS40 (+) and TS37 (-) of the Drive and Idler Rolls are not binding. Check the idler springs. Check the Upper and Lower
PHN DIO PWB #2. Shaft assemblies for binding. Replace as required (PL 8.1).
Y N
+24 VDC is measured between TS35 (+) and TS37 (-) of PHN DIO PWB #2. Check the Registration Transport for the following; Turn Baffle is installed in the rear pin. Verify
Y N that the flat portion of the Turn Baffle is not bowed. All jam clearance baffles are properly
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. seated. The Registration Transport is OK.
Y N Y N
Go to the 1-717, +24, +34, -34 VDC RAP. Repair the Registration Transport as required (PL 8.3).
A B C D E
E
Run the Customer job that produced the fault. Check for the following: • Observe the feeder of the associated paper tray. Check the tray latches and Length
• Ensure that during operation the Cross Roll Solenoids are not energized continually. Guides operation. Look for paper related problems or multifeeds.
• Check for a skew problem. for skew problems go to the 8-706. • Check SCP [Faults] [Almost] [Actual] and [PHM] for 8-901, or 8-902 indicating possible
• Check SCP [Faults] [Almost] [Actual] and [PHM] for 8-152. If indicated, go to the 8- multifeeds. Go to the 8-701, Friction Retard Checkout RAP for Tray 1 and Tray 2.
152. • If the problem continues, replace the Vertical Transport Sensor (PL 8.1).


A B
8-152 RAP Go to Flag 2. Check the return wire from P390-2 to P308-21 for an open circuit. If the wire
is OK, replace the Registration Servo PWB (PL 1.4).
Fault code, 8-152, indicates that the lead edge of the sheet of paper delivered from the Vertical
Transport did not arrive at the Registration Transport Sensor, Q861, within the specified num- Ensure that the Cross Roll Sensor Bracket is not bent. Block the Cross Roll Sensor. The dis-
ber of clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, play changes from L to H.
Q851. Y N
Go to Flag 9. Check the Cross Roll Sensor circuit. (GP 6-2, General Procedures.)
Initial Actions
Check the following: Block the Vertical Transport Sensor. The display changes from H to L.
Y N
• SCP HSFI for 08-808 and 08-817 in Table 3, and 08-816 in Table 2, or HFSI TABLES to Go to Flag 1. Check the Vertical Transport Sensor circuit. (GP 6-2, General Procedures.)
see all of HFSI.
Check the Registration Transport Turn baffle. Ensure that the baffle is mounted on the locating
pin at the back of the transport. Check the baffle for damage. Ensure that the Upper Baffle
Service Data).
positioning tabs are not bent. Check the Registration Transport jam clearance spring for dam-
• Paper path for obstructions. age. Verify that all Registration Transport jam clearance baffles are seated. Ensure that the
• Cross Roll Idlers and Servo Roll Idlers rotate freely. idler rolls seat with the Servo Drive rolls and the Vertical Transport Drive rolls when the baffles
• Vertical Transport Belts and Magnetic Strips for damage or contamination (PL 8.2). are closed. The Registration Transport is OK.
Y N
• Vertical Transport Pinch Rolls are seated with the springs properly positioned.
Repair the Registration Transport as required (PL 8.3).
• Verify that the Registration Transport Cross Roll levers are properly installed. If the 7 x 10
Registration Transport Kit (TAG P-267) is installed, there are three (3) levers. for heavy Enter dC703. Select [Tests], [Velocity]. Press Continue. If 3-245 or 8-310 fault occurs during
weight paper, turn the left lever counterclockwise and turn the other two (2) levers clock-
the Velocity Test, the test has failed, answer N. A message indicates that the Velocity test
wise. passed.
• Inspect the Registration Transport for a bowed or bent Baffle. Y N
Procedure Go to Flag 12. Carefully check P391 and J1 connectors of the Reg Servo Motor, MOT862.
Enter dC330. Select [8]. Block the Registration Transport Sensor. The display changes from Ensure that the pins and wires are not damaged and the connection is secure. Check the
wire from P391-1 of the Reg Servo Motor, MOT862, to TS18 of the PHN Registration
H to L.
Y N Servo PWB for an open circuit. If the wire and connectors are Ok and the Velocity Test still
Check for +5 VDC at the Registration Transport Sensor. Disconnect P390. +5 VDC is fails, go to the 8-302.
measured between machine frame (-) and each of the following pins at the P390
connector (+) P390-1, P390-3, P390-4. Check the Cross Roll drive rolls for damage or flat spots. The Cross Rolls are free of dam-
Y N age.
Y N
Go to Flag 2. Check each wire that did not measure +5 VDC for an open circuit. If
the wires are OK, replace the Registration Servo PWB (PL 1.4). Replace the Cross Roll Idlers as required (PL 8.5). Perform dC 703, Feed Timing Set-up
Check the Cross Roll Drive Belt Tension. Manually rotate the Cross Roll drives. The Cross
Go to Flag 10. +5 VDC is measured between TS16 (+) and TS37 (-) of the PHN DIO
PWB #2. Roll Drives turn freely without binding.
Y N Y N
Repair the Cross Roll Assembly Drives (PL 8.5). Perform dC 703, Feed Timing Set-up
Go to Flag 3. +5 VDC is measured between TS37 (-) of the PHN DIO PWB #2 and TS9 Enter dC330, [8], [Cross Roll] motor. Press Continue. The Cross Rolls rotate.
Y N
(+) of the Reg Servo PWB.
Y N Press Stop. +5 VDC is measured between TS52 (+) and TS37 (-) of the PHN DIO
Disconnect P308 at the Registration Servo PWB. Continuity is measured PWB #2.
Y N
between P308-16 and TS16 of the PHN DIO PWB #2.
Y N +5 VDC is measured between J2-5 (+) of AC Remote #2 and TS37 (-) of DIO #2.
Repair the open circuit. Y N
Replace the Registration Servo PWB (PL 1.4).
Go to Flag 4. Check the wires from TS52 to P385-6 for an open or a short circuit. If
the wire is OK, replace the PHN AC Remote PWB #2 (PL 1.4).
A B C D
C D E
Press Continue. 0 VDC is measured. Y N
Y N +24 VDC is measured between TS36(+) and TS37(-) of the PHN DIO PWB #2.
Replace the PHN DIO PWB #2 (PL 1.4). Y N
Press Stop. 115 VAC is measured between J1-6 (+) and J1-8 (-) of the PHN AC Y N
Remote PWB #2. Go to the 1-717, +24, +34, -34 VDC RAP.
Y N
115 VAC is measured between J1-18 (+) and J1-8 (-) of the PHN AC Remote Check wire 544. Check the +24 VDC distribution.
PWB #2.
Y N Go to Flag 7. Check the Left Cross Roll Solenoid circuit. (Generic Solenoid RAP GP
(60HZ) Go to the 1-702, AC Interlocked Power RAP. 6-3, General Procedures.)
Go to Flag 5. Check for continuity from P389-1 to P396-6, and from P389-2 to P396- Y N
18. If the wires are OK, ensure that the Cross Roll Drives are not binding. Replace Replace the PHN DIO PWB #2 (PL 1.4).
the Cross Roll Motor (PL 8.10). Perform dC 703, Feed Timing Set-up
Replace the Left Cross Roll Solenoid (PL 8.5).
Press Continue. 0 VAC is measured.
Y N The Cross Roll Idlers lift and lower freely without binding.
Replace the PHN AC Remote PWB #2 (PL 1.4). Y N
Replace the Solenoid Assembly (PL 8.5).
Press Stop. Go to Flag 11. Check the wires at the Cross Roll Motor Capacitor, C681.
Ensure that the white wire is connected to the left terminal and the black wire is con- Select [Right Cross Roll] Solenoid. Press Continue. The Right Cross Roll Solenoid ener-
nected to the right terminal of the capacitor. Leave one meter lead at J1-8 (-) of PHN AC gizes.
Remote PWB #2. Place the other meter lead (+) at the white wire (left capacitor terminal). Y N
Press Continue. 0 VAC is measured. Press Stop. +24 VDC is measured between TS42 (+) and TS37 (-) of PHN DIO PWB
Y N #2.
Go to Flag 11. Check the white wire from the Capacitor to P389-1 for an open circuit. Y N
If the wire is OK, replace the Cross Roll Motor Capacitor, C681, (PL 8.7). Manually Go to Flag 8. Check the Right Cross Roll Solenoid circuit. (Generic Solenoid RAP
rotate the Cross Roll drives, ensure that the Cross Roll Assembly in not binding. GP 6-3, General Procedures.)
Measure to the black wire (+) (right capacitor terminal). Press Continue. +240 VAC is Press Continue. 0 VDC is measured.
measured. Y N
Y N Replace the PHN DIO PWB #2 (PL 1.4).
Press Stop. Enter [Power Interrupt]. Go to Flag 11. Check the black wire from the
Capacitor to P389-1 for an open circuit. A resistance of about 400 ohms should be Replace the Right Cross Roll Solenoid (PL 8.5).
measured. The wire is OK.
Y N The Cross Roll Idlers lift and lower freely without binding.
Repair the wire. If the wire cannot be repaired, replace the Cross Roll Motor Y N
(PL 8.7). Perform dC 703, Feed Timing Set-up Replace the Solenoid Assembly (PL 8.5).
Replace the Cross Roll Motor Capacitor, C681, (PL 8.7). Manually rotate the Cross Check the Cross Roll Idler Lift Fingers. When the idlers are in the down position, ensure that
Roll drives, check the Cross Roll Assembly for binding. the fingers do not contact the idler shafts. The fingers are below the idler shafts.
Y N
Ensure that the Cross Roll Drives turn freely without binding. If the drives are OK, replace Repair/Replace the Cross Roll Idler Lift Assembly
the Cross Roll Motor (PL 8.7). Perform dC 703, Feed Timing Set-up
Press Stop. Enter dC106. Select [Tray 1], [Sample Tray], and 100 prints. Press CONTINUE.
Select [Left Cross Roll] Solenoid. Press Continue. The Left Cross Roll Solenoid ener- Observe the sheets entering the Registration Xport. There may be intermittent problems at the
gizes. transition from the Vertical Transport. The sheets pass the Vertical Transport Nip Idlers
Y N without excessive drag or interference.
Press Stop. +24 VDC is measured between TS50 (+) and TS37 (-) of PHN DIO PWB Y N
#2. Replace the Vertical Transport Nip Idler Bracket (PL 8.1).
E F
F
Look for excessive skew. Ensure that the corner of the sheets do not snag on the Registration
Edge entrance chute. The sheets enter the Transport without snags or excessive skew.
Y N
Go to the 8-706. Diagnose the Vertical Transport and Tray 1 and 2 areas.
The sheets pass through the transport without catching on the Registration Edge.
Y N
Ensure that the Registration Edge is seated properly. Check the Edge for damage or
grooves. Replace the Registration Edge (PL 8.4) as required. PerformdC604 Registration
Setups.
Clean the Servo Drive Rolls and the Cross Rolls. Observe the Cross Roll area during machine
operation. The Cross Rolls lift only one time per sheet of paper.
Y N
Ensure that the Reflective Tape is not damaged or missing. Check the Cross Roll Sensor
bracket for damage. Question the operator, the problem may be with special papers,
replace the Cross Roll Sensor (PL 8.6)
If the problem occurs with heavy weight papers, lift the Cross Roll Idler Lever. If the problem
occurs with lightweight paper, replace the Cross Roll Idler (PL 8.5). If the problem occurs with
transparencies, ensure that the Registration Transport Sensor can be actuated with transpar-
encies.
• Observe the feeder of the associated paper tray. Look for paper related problems or mul-
tifeeds. Check Tray 1 and Tray 2 for a bent drive shaft or coupling misalignment which
may cause random feeds or paper damage.
• Check the top edge of the paper for damage. Remove the Registration Edge. Check for
grooves or surface imperfections (PL 8.4).
• Check the Vertical Transport Belts for slippage (PL 8.2).
• Check SCP [Faults] [Actual] [Almost] and [PHM]. If there are 8-302 faults indicated, go
to the 8-302.

Figure 1 8-152 Components (7854B)


A
8-155 RAP Check the Cross Roll Assembly for binding. Check the Cross Roll Idler Lift Fingers. When the
idlers are in the down position, ensure that the fingers do not contact the idler shafts. The fin-
Fault code, 8-155, indicates that the trail edge of the sheet of paper did not leave the Registra- gers are below the idler shafts.
tion Transport Sensor, Q861, within the specified number of clock counts after the lead edge of Y N
that sheet arrived at the sensor. Repair or replace the Cross Roll Idler Lift Assembly (PL 8.3).
Initial Actions The Pretransfer baffle is properly seated and is not obstructed, burred, or damaged.
• Check SCP HSFI for 08-817 Table 4, or HFSI TABLES to see all of HFSI. Y N
Replace the Pretransfer Baffle (PL 8.8).
• Check that the Servo Roll Idlers are seated and rotate freely and that the spring are in
place.
The Pretransfer Lift Block (PL 8.8) is properly positioned under the Pretransfer Baffle.
• Check that the Registration Transport Sensor connector is secure. Check the sensor lens Y N
for damage. Remove the Lift Block and reinstall. Replace as required (PL 8.8)
• Check the Pretransfer baffle area for obstructions.
• Ensure the PR Drive coupling is properly lubricated with Moly Grease (PL 25.1). See The Mylar Transport Strip between the Registration Transport and the Pretransfer Baffle
ROLLOVERS PC 3676--RO-177643 in the Service Information Section for additional is properly seated and not damaged.
information on the lubricant and a tool for its application. Y N
Reposition or replace the Transport Strip (PL 8.4).
• Check the Processor registration and skew. Go to the 8-706 as required.
Procedure Check the following:
Follow jam clearance procedures. The 8-155 fault can be cleared. • Servo Rolls and Idlers for damage, contamination, or binding and that the rolls are seated
Y N (PL 8.3)
Enter [Power Interrupt]. Disconnect P390 at the Registration Transport Sensor. +5 VDC • Idler Tension Springs for damage and are in position
is measured between pin P390-1 (+) and machine frame (-).
• Cross Rolls for binding (PL 8.4)
Y N
• Registration Transport is seated properly
Go to Flag 1. Check the wire between P390-1 and P308-19 for an open or a short
circuit to ground. If the wire is OK, replace the Registration Servo PWB (PL 1.4). • If paper damage or skew has not been observed and no paper damage or misregistration
has been reported by the operator, there could be an intermittent problem with the Regis-
+5 VDC is measured between pin P390-4 (+) and machine frame (-). tration Transport Sensor, replace the sensor (PL 8.4).
Y N • Registration Transport Upper Baffle Adjustment ADJ 8-0.
Go to Flag 1. Check the wire between P390-4 and P308-18 for a short circuit to • If there is a potential Transfer or Detack Dicorotron problem, go to PQ 9-626 Dicorotron
ground. If the wire is OK, replace the Registration Servo PWB (PL 1.4). Checkout. If the problem continues, go to the 8-302.
Go to Flag 2. There is a short circuit to ground at TS9 of the Registration PWB.

Y N
Replace the Registration Transport Sensor (PL 8.4).
Disconnect P308 at the Registration Servo PWB. Check the wire from P308-16 to TS16
for a short circuit. If the wire is OK, replace the Registration Servo PWB (PL 1.4).
Check the Registration Transport Upper Baffle for damage or bowing, jam clearance spring is
not stretched or broken, and the baffle seats correctly. The Transport baffles are OK.
Y N
Repair the Transport (PL 8.3).
Clean the Servo Drive Rolls and Cross Rolls. Observe the Registration Transport area during
machine operation. The sheets pass without catching on the Registration Edge.
Y N
Ensure that the Registration Edge is seated properly and is not damaged or grooved.
Replace the Registration Edge (PL 8.4).
A
8-156 RAP

A
Check the Nip Release Solenoid Assembly Adjustment (ADJ 8-6). If the problem continues,
Fault code, 8-156, indicates that the sheet failed to arrive at the Registration Transport Sensor,
Q861, within the specified number of clock counts after the trail edge left the Vertical Transport replace the Nip Release Solenoid (PL 8.5).
Sensor, Q851. This fault occurs in the Oversized mode only.
Initial Actions
• Ensure all jam clearance baffles are latched properly.
• Check the Nip Release Solenoid Cable operation.
• Ensure that the paper path is not obstructed.
• Ensure that the operator has correctly adjusted the Dual Force Cross Roll Idlers for the
type of paper used.
• Enter dC131 and ensure the PHN NVM Locations: 252, 253, 254, 255 are at the values
given in the appropriate level Software dC 131 NVM Table in General Procedures.
Procedure
Enter dC606. Select [Printer Options], [Job Setup], [Simplex], [Tray 3], [25 Prints]. Ensure
that Tray 3 is loaded with Oversize paper. Press [Continue]. When job is complete, select
[Duplex], [25 Prints] [Continue]. Jams occurred only in the duplex mode on side 2.
Y N
Go to the 8-151.
Enter dC330, [8]. Block the Registration Transport Sensor. The display changes from H to
L.
Y N
Go to Flag 2. Check the Registration Transport Sensor Circuit (GP 6-2, General Proce-
dures).
Select [Oversize Nip Release] Solenoid. Press Continue. The solenoid energizes.
Y N
Press Stop. There is + 24 VDC measured between TS54(+) and TS37 (-) of the PHN
DIO PWB 6.
Y N
Go to Flag 3. Check the circuit of the Nip Release Solenoid (Generic Solenoid RAP
The Vertical Transport Lower Drive Roll and the Tray 2 Magnetic Strip are pulled back
when the Nip Release Solenoid energizes.
Y N
Ensure that the Yoke Linkage is properly seated over the Idler Shaft. Check for a broken
Nip Release Solenoid Cable or broken linkage (PL 8.5).
Press Stop. The Vertical Transport Lower Drive Roll and the Tray 2 Magnetic Strip return
to their normal positions.
Y N
Check for binding in the Nip Release Solenoid Cable and Linkage. Check the Nip
Release Solenoid Assembly Adjustment (ADJ 8-6). If the problem still exists, replace the
Nip Release Solenoid (PL 8.5).
A
8-164, 8-165 RAP

A
Y N
Fault code, 8-164-1, indicates that the lead edge of the sheet of paper delivered from the Tray
4 Horizontal Transport failed to arrive at the Tray 3 Turn Baffle Sensor, Q853A, within the spec- Go to Flag 2. Check the Horizontal Transport Sensor circuit (GP 6-2, General Proce-
ified number of clock counts after the lead edge arrived at the Tray 4 Horizontal Transport Sen- dures).
sor, Q854B. When the fault is declared Q854B is actuated.
Select [Tray X Xport Drive] motor. Press Continue. The Horizontal Transport Drive Rolls
Fault code, 8-164-2, indicates that the lead edge of the sheet of paper delivered from the Tray rotate.
Y N
5 Horizontal Transport failed to arrive at the Tray 4 Turn Baffle Sensor, Q853B, within the spec-
ified number of clock counts after the lead edge arrived at the Tray 4 Horizontal Transport Sen- The Feeder Main Drive Motor comes on.
sor, Q854C When the fault is declared Q854C is actuated. Y N
6 Horizontal Transport failed to arrive at the Tray 5 Turn Baffle Sensor, Q853C, within the spec- Check the following:
• Drive Belts for wear, damage, contamination, and correct tension (PL 8.14)
ified number of clock counts after the lead edge arrived at the Tray 5 Horizontal Transport Sen-
sor, Q854D. When the fault is declared Q854D is actuated. • Drive pulleys for damage or slippage on shaft
4 Horizontal Transport failed to arrive at the Tray 3 Turn Baffle Sensor, Q853A, within the spec- Check the following:
ified number of clock counts after the lead edge arrived at the Tray 4 Horizontal Transport Sen- • Drive Belts for wear, damage, contamination, and correct tension (PL 8.20).
sor, Q854B. When the fault is declared, Q853A and Q854B, are blocked. • Horizontal Transport and Turn Baffle Transport Drive Rolls for wear, damage, or contami-
nation (PL 8.21) (PL 8.19).
• Horizontal Transport and Turn Baffle Transport Idlers rotate freely (PL 8.22) (PL 8.19).
5 Horizontal Transport failed to arrive at the Tray 4 Turn Baffle Sensor, Q853B, within the spec-
ified number of clock counts after the lead edge arrived at the Tray 5 Horizontal Transport Sen- • Idler Tension Springs are present and are not damaged or stretched (PL 8.22).
sor, Q854C. When the fault is declared, Q853B and Q854C, are blocked. • Horizontal Transport (ADJ 8-15) and Turn Baffle Transport jam clearance baffles for dam-
age and that they seat correctly.
Fault code, 8-165-3, indicates that the lead edge of the sheet of paper delivered from the Tray • IFS to MM to FS alignment
6 Horizontal Transport failed to arrive at the Tray 5 Turn Baffle Sensor, Q853C, within the spec-
sor, Q854D. When the fault is declared, Q853C and Q854D, are blocked.
Initial Actions
• Turn Baffle Sensor and Horizontal Transport Sensor are clean and are not obstructed.
Service Data).
Procedure
NOTE: The following procedure can be used for fault codes that may appear in any of the
Inverter Feeder Stacker / Middle Module / Feeder/Stacker modules. The correct module letter
(A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in
order to properly diagnose the fault codes.
Enter dC330, [Feeder 3/4, 5/6], [7-8X]. Actuate the Turn Baffle Sensor. The display changes
from H to L.
Y N
Go to Flag 1. Check the Turn Baffle Sensor Circuit (GP 6-2, General Procedures).
Select [7-8X]. Actuate the Horizontal Transport Sensor. The display changes from L to H.
A
Figure 1 8-164/165 Circuit Diagram (7820B)
8-166, 8-167 RAP

Fault code,8-166-1, indicates that the trail edge of the sheet of paper delivered from the Tray 3 Procedure
Vertical Transport failed to arrive at the Turn Baffle Sensor, Q853A, within the specified number
of clock counts after the lead edge of that sheet arrived at the Turn Baffle Sensor, Q853A.
Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter
When the fault is declared, Q853A, is actuated.
Fault code,8-166-2, indicates that the trail edge of the sheet of paper delivered from the Tray 4
Vertical Transport failed to arrive at the Turn Baffle Sensor, Q853B, within the specified number Enter dC330, [Feeder X], [7-8X]. Actuate the Turn Baffle Sensor. The display changes from
of clock counts after the lead edge of that sheet arrived at the Turn Baffle Sensor, Q853B. H to L.
When the fault is declared, Q853B, is actuated. Y N
Vertical Transport failed to arrive at the Turn Baffle Sensor, Q853C, within the specified num- Select [Tray X Xport Drive] motor. Press Continue. The Horizontal Transport Drive Rolls
ber of clock counts after the lead edge of that sheet arrived at the Turn Baffle Sensor, Q853C. rotate.
When the fault is declared, Q853C, is actuated. Y N
Fault code,8-166-4, indicates that the trail edge of the sheet of paper delivered from the Tray 6 Y N
Vertical Transport failed to arrive at the Turn Baffle Sensor, Q853D, within the specified num- Go to the 8-708, Feeder Main Drive Motor RAP.
ber of clock counts after the lead edge of that sheet arrived at the Turn Baffle Sensor, Q853D.
When the fault is declared, Q853D, is actuated. Check the following:
Fault code,8-167-1, indicates that the trail edge of the sheet of paper delivered from the Tray 3 • Drive pulleys for damage or slippage on shaft (PL 8.17) (PL 8.19)
Vertical Transport failed to arrive at the Turn Baffle Sensor, Q853A, within the specified number
of clock counts after the lead edge of that sheet arrived at the Turn Baffle Sensor, Q853A.
When the fault is declared, Q853A, is deactuated.
• Drive Belts for wear, damage, contamination, and correct tension (PL 8.14).
Vertical Transport failed to arrive at the Turn Baffle Sensor, Q853B, within the specified number • Vertical Transport and Turn Baffle Transport Drive Rolls for wear, damage, or contamina-
tion (PL 8.17).
of clock counts after the lead edge of that sheet arrived at the Turn Baffle Sensor, Q853B.
When the fault is declared, Q853B, is deactuated. • Vertical Transport and Turn Baffle Transport Idlers rotate freely (PL 8.17) (PL 8.19).
• Idler Tension Springs are present and are not damaged or stretched (PL 8.22).
Fault code,8-167-3, indicates that the trail edge of the sheet of paper delivered from the Tray 5 • Vertical Transport and Turn Baffle Transport jam clearance baffles for damage and that
Vertical Transport failed to arrive at the Turn Baffle Sensor, Q853C, within the specified num- they seat correctly.
ber of clock counts after the lead edge of that sheet arrived at the Turn Baffle Sensor, Q853C.
When the fault is declared, Q853C, is deactuated.
Vertical Transport failed to arrive at the Turn Baffle Sensor, Q853D, within the specified num-
ber of clock counts after the lead edge of that sheet arrived at the Turn Baffle Sensor, Q853D.
When the fault is declared, Q853D, is deactuated.
Initial Actions
• Turn Baffle Sensor and Vertical Transport Sensor are clean and are not obstructed.
• Paper is loaded properly and within specification for use in the Printer (Section 4, General
Service Data).

8-168, 8-169 RAP

Fault code, 8-168-1, indicates that the lead edge of the sheet of paper delivered from the Procedure
Lower Turn Transport did not arrive at the Horizontal Transport Sensor, Q854A, within the
specified number of clock counts after the lead edge of the sheet arrived at the Turn Baffle
Sensor, Q853A. When the fault is declared, Q854A, is deactuated.
Fault code, 8-168-2, indicates that the lead edge of the sheet of paper delivered from the
Lower Turn Transport did not arrive at the Horizontal Transport Sensor, Q854B, within the Enter dC330, [Feeder X], [7-8X]. Block the Horizontal Transport Sensor. The display
specified number of clock counts after the lead edge of the sheet arrived at the Turn Baffle changes from H to L.
Sensor, Q853B. When the fault is declared, Q854B, is deactuated. Y N
Fault code, 8-168-3, indicates that the lead edge of the sheet of paper delivered from the dures).
Lower Turn Transport did not arrive at the Horizontal Transport Sensor, Q854C, within the
specified number of clock counts after the lead edge of the sheet arrived at the Turn Baffle Block the Turn Baffle Sensor. The display changes from H to L.
Sensor, Q853C. When the fault is declared, Q854C, is deactuated. Y N
Go to Flag 1. Check the Turn Baffle Sensor circuit (GP 6-2, General Procedures).
Lower Turn Transport did not arrive at the Horizontal Transport Sensor, Q854D, within the Select [Tray X Xport Drive] motor. Press Continue. The Horizontal Transport Drive Rolls
specified number of clock counts after the lead edge of the sheet arrived at the Turn Baffle rotate.
Sensor, Q853D. When the fault is declared, Q854D, is deactuated. Y N
Fault code, 8-169-1, indicates that the lead edge of the sheet of paper delivered from the Y N
Lower Turn Transport did not arrive at the Horizontal Transport Sensor, Q854A, within the Go to the 8-708, Feeder Main Drive Motor RAP.
Sensor, Q853A. When the fault is declared, Q854A, is actuated. Check the following:
Fault code, 8-169-2, indicates that the lead edge of the sheet of paper delivered from the • Drive pulleys for damage or slippage on shaft (PL 8.21)
Lower Turn Transport did not arrive at the Horizontal Transport Sensor, Q854B, within the
Sensor, Q853B. When the fault is declared, Q854B, is actuated.
Lower Turn Transport did not arrive at the Horizontal Transport Sensor, Q854C, within the • Horizontal Transport Drive Rolls for wear, damage, or contamination (PL 8.21).
specified number of clock counts after the lead edge of the sheet arrived at the Turn Baffle • Horizontal Transport Idlers rotate freely (PL 8.22).
Sensor, Q853C. When the fault is declared, Q854C, is actuated. • Inverter Horizontal Transport Drive Rolls for wear, damage, or contamination (PL 8.25).
• Inverter Horizontal Transport Idlers rotate freely.
Lower Turn Transport did not arrive at the Horizontal Transport Sensor, Q854D, within the
specified number of clock counts after the lead edge of the sheet arrived at the Turn Baffle • Horizontal Transport jam clearance baffles for damage and seated correctly (PL 8.21).
Sensor, Q853D. When the fault is declared, Q854D, is actuated. (ADJ 8-14), (ADJ 8-15).
Initial Actions
• Horizontal Transport Sensor is clean and is not obstructed.

• Paper is loaded properly and within specification for use in the Printer (Section 4, General
Service Data).

8-170 RAP

Y N
Fault Code, 8-170, indicates that the sheet failed to arrive at the Duplex Sheet Sensor, Q841,
within the specified number of clock counts after arriving at the Top Transport Jam Sensor, The REV Clutch energized.
Q1012. Y N
Go to Flag 2. Check the Duplex REV Clutch circuit (Generic Clutch RAP GP 6-3,
Initial Actions
Check the following: Check the following:
• Forward Reverse Drive Rolls Drive Belt for wear, damage, contamination, and cor-
• Duplex Sheet Sensor is biased to the right. rect tension (PL 10.23).
• Jam Clearance baffles are seated and latched correctly. • Forward Reverse Drive Rolls Drive Pulley for damage and that the drive pin is not
• Paper path for obstructions. broken (PL 10.22).
Procedure • Drag Brake for binding (PL 10.24).
Enter dC330, [8]. Block the Duplex Sheet Sensor. The display changes from L to H. • Inverter Gear Box Assembly for wear (PL 10.23).
Y N • Forward Reverse Drive Rolls for wear, damage, or contamination (PL 10.21).
Go to Flag 1. Check the Duplex Sheet Sensor circuit (GP 6-2, General Procedures). • Forward Reverse Drive Rolls bearings for binding (PL 10.21).
Select [1-4] [Main Drive Start/ Run] motor. Press Continue. The Exit Drive Roll is turning. Select [Clear Outputs]. Select [10] [Duplex Gate] Solenoid. Press Continue. The gate
Y N moves freely without binding.
• Inverter Drive Coupling for damage and that the pin is not sheared. The Duplex Gate Solenoid energized.
• Inverter Drive Bracket for damage and is not loose. Y N
• Drive belt for wear, damage, or contamination. Go to Flag 5. Check the Duplex Gate Solenoid circuit (Generic Solenoid RAP GP 6-
• Drive Pulley for damage. 3, General Procedures).
The Dual Drive Roll is turning. Check the following:

Y N • Duplex Gate for binding.
Check the following: • Duplex Gate linkage for damage (PL 10.15).
• Gear Box Drive Belt for wear, damage or contamination and proper tension. • If the problem still exists, replace the Duplex Gate Solenoid (PL 10.15)
• One-way clutch is operating correctly.
• Exit Drive Roll Pulley for damage and that the pin is not sheared. Check the following:
• Exit Drive Roll for wear, damage or contamination.
Select [8] [Duplex FWD] clutch. Press Continue. The Forward Reverse Drive Rolls are • Dual Drive Roll for wear, damage or contamination (PL 10.20).
turning clockwise. • Duplex Gate for damage (PL 10.15).
Y N • Excessive paper curl.
The FWD Clutch energized.
• Inverter Gear Box for wear (PL 10.23).
Y N
Go to Flag 3. Check the Duplex FWD Clutch circuit (Generic Clutch RAP GP 6-3,

• Dual Drive Roll and Forward Reverse Drive Rolls for wear, damage or contamination
(PL 10.21).
• Inverter Gate fingers for damage and that they do not obstruct the paper path (PL
10.22).
• Inverter Drive Belt for wear, damage, contamination, and correct tension (PL 10.23).
Press the Stop button. Select [Duplex REV] Clutch. Press Continue. The Forward Reverse
Drive Rolls are turning counterclockwise.

8-171 RAP

A B
Y N
Fault Code, 8-171, indicates that the trail edge of the sheet failed to depart the Duplex Sheet
Sensor, Q841, within the FIT +50 Clock Counts after the Duplex Reverse Clutch, CL842, ener- The sheet jammed at the Exit Drive Roll.
gized. (FIT is the Forward Invert Time which equals the sheet width (mm) - forward clearance Y N
time, divided by 1128 mm/sec).
Y N
Go to Flag 1. Check the Duplex Sheet Sensor Circuit (GP 6-2, General
Initial Actions Procedures).
Replace the Clutch Brake Assembly (PL 10.23). Perform dC 703, Feed Timing
• Jam clearance baffles are seated and latched correctly. Set-up.
Procedure Perform Duplex Timing (ADJ 10-14).
If the problem still exists, replace the Forward Reverse Drive Roll (PL 10.23), the
Enter dC330, [8]. Block the Duplex Sheet Sensor. The display changes from L to H.
Dual Drive Roll (PL 10.23) and the Inverter Gear Box Assembly as required.
Y N
Go to Flag 1. Check the Duplex Sheet Sensor Circuit (GP 6-2, General Procedures).
• Duplex Upper Baffle fingers for damage or binding.
Enter dC106. Select [Duplex]. Press Continue. The fault code 8-171 is declared at cycle
up. • Duplex Upper Baffle is not obstructing the paper path.
Y N • Torsion springs for damage or missing.
A sheet of paper started to feed out of the Duplex Inverter (the edge of the sheet is • Paper for excessive curl. If present, perform the Decurler Adjustment (ADJ 10-8).
to the right of the two hash marks on the outboard edge of the jam clearance baffle.
Y N Go to Flag 1. Check the Duplex Sheet Sensor Circuit (GP 6-2, General Procedures).
The trail edge of the paper is to the left of the Forward Reverse Drive Roll.
Y N
Enter dC330, [8], [Duplex REV] Clutch. Press Continue. The Reverse
Clutch energized.
Y N
Go to Flag 2. Check the Reverse Clutch circuit (Generic Clutch RAP GP
6-3, General Procedures).

• Forward Reverse Drive Belt for wear, damage or contamination.
• Upper Idler Rolls and springs for wear or damage.
• Duplex Lower Baffle Latching Springs for damage.
If the problem still exists, replace the Inverter Gear Box Assembly (PL 10.23).
Enter dC330, [8], [Duplex FWD] Clutch. Press Continue. The Forward Clutch
energized.
Y N
Go to Flag 3. Check the Forward Clutch circuit (Generic Clutch RAP GP 6-3,

• Forward Reverse Drive Belt for wear, damage or contamination.
• Upper Idler Rolls and springs for wear or damage.
• Duplex Lower Baffle Latching Springs for damage.
If the problem still exists, replace the Inverter Gear Box Assembly (PL 10.23).
The sheet jammed under the Duplex Upper Baffle.
A B
8-172, 8-173 RAP

A
Press Stop. Select [Duplex REV] Clutch. Press Continue. The Forward Reverse Drive
Fault Code, 8-172, indicates that the oversized sheet failed to arrive at the Duplex Sheet Sen-
sor, Q841, within the specified number of clock counts after arriving at the Top Transport Jam Rolls are turning counterclockwise.
Sensor, Q1012. When the fault is declared, the Top Transport Sensor is unblocked. Y N
The REV Clutch energized.
Fault Code, 8-173, indicates that the oversized sheet failed to arrive at the Duplex Sheet Sen- Y N
sor, Q841, within the specified number of clock counts after arriving at the Top Transport Jam Go to Flag 2. Check the Duplex REV Clutch circuit (Generic Clutch RAP GP 6-3,
Sensor, Q1012. When the fault is declared, the Top Transport Sensor is blocked.

Initial Actions • Forward Reverse Drive Rolls Drive Belt for wear, damage, contamination, and cor-
Check the following: rect tension (PL 10.23).
• Forward Reverse Drive Rolls Drive Pulley for damage or sheared pin (PL 10.22).
• Duplex Sheet Sensor is biased to the right.
• Drag Brake for binding.
• Jam Clearance baffles are seated and latched correctly.
• Inverter Gear Box Assembly for wear (PL 10.23).
• Forward Reverse Drive Rolls for wear, damage, or contamination (PL 10.21).
Procedure • Forward Reverse Drive Rolls bearings for binding (PL 10.21).
Enter dC330, [8]. Block the Duplex Sheet Sensor. The display changes from L to H.
Perform dC 703, Feed Timing Set-up, if any of the above are replaced.
Y N
Go to Flag 1. Check the Duplex Sheet Sensor circuit (GP 6-2, General Procedures).
Select [Clear Outputs]. Select [10] [Duplex Gate] Solenoid. Press Continue. The gate
moves freely without binding.
Select [1-4] [Main Drive Start/ Run] motor. Press Continue. The Exit Drive Roll is turning.
Y N
Y N
The Duplex Gate Solenoid energized.
Y N
• Inverter Drive Coupling for damage or sheared pin.
Go to Flag 5. Check the Duplex Gate Solenoid circuit (Generic Solenoid RAP GP 6-
• Drive belt for wear, damage, or contamination. 3, General Procedures).
• Drive Pulley for damage.
The Dual Drive Roll is turning. • Duplex Gate for binding.
Y N • Duplex Gate linkage for damage (PL 10.15).
• If the problem still exists, replace the Duplex Gate Solenoid (PL 10.15)
• Gear Box Drive Belt for wear, damage, contamination, and proper tension.
• One-way clutch is operating correctly. Check the following:
• Exit Drive Roll Pulley for damage or sheared pin. • Exit Drive Roll for wear, damage or contamination.
• Dual Drive Roll for wear, damage or contamination (PL 10.20).
Select [8] [Inverter FWD] Clutch. Press Continue. The Forward Reverse Drive Rolls are
• Duplex Gate for damage (PL 10.15).
turning clockwise.
• Excessive paper curl.
Y N
The FWD Clutch energized. • Inverter Gear Box for wear (PL 10.23).
Y N
Go to Flag 3. Check the Duplex FWD Clutch circuit (Generic Clutch RAP GP 6-3,

• Dual Drive Roll and Forward Reverse Drive Rolls for wear, damage or contamination
(PL 10.23).
• Inverter Gate fingers for damage and that they do not obstruct the paper path (PL
10.22).
• Inverter Drive Belt for wear, damage, contamination, and correct tension (PL 10.23).
A
8-179 RAP

Go to the 8-188, 8-189.
Optional Feeder Fault code, 8-179, indicates that the Printer initiated a command to feed a
sheet of paper, from the Optional Feeder, and that the sheet did not arrive at the Turn Baffle
Sensor, Q853, within the specified number of clock counts.
The specified time equals the personality profile time entered for P1 (the specific third party
feeder being used) plus 151.5ms.
Initial Actions
• Turn Baffle Sensor and Horizontal Transport Sensor are clean and not obstructed.
Service Data).
• Ensure that the third party device is correctly docked.
• Ensure that the personality profile entered for P1 is correct.
Procedure
Enter dC330, [Feeder3/4], [7-8X]. Block the Turn Baffle Sensor, Q853, in the Feeder Stacker
before tray 7 (Optional Feeder). The display changes from H to L.
Y N
Select [TRAY 4 Xport Drive]. Press Continue. The Horizontal Transport Drive Rolls
rotate.
Y N
Y N

• Drive belts for wear, damage, contamination, and correct tension (PL 8.20).
• Drive pulleys for damage or slippage on shaft (PL 8.21) (PL 8.23).
• Bearings for wear or damage.

• Horizontal Transport Pivot Baffle Adjustment (ADJ 8-15).
• Horizontal Transport and Turn Baffle Transport Drive Rolls for wear, damage, or contami-
nation (PL 8.21) (PL 8.19).
• Horizontal Transport and Turn Baffle Transport Idlers rotate freely. (PL 8.20) (PL 8.19).
• Idler Tension Springs are present and are not damaged or stretched.
• Horizontal Transport and Turn Baffle Transport jam clearance baffles for damage and cor-
rectly seated (PL 8.21) (PL 8.19).
If the problem continues enter dC726, [Printer Options]. Select [TRAY 4], [Paper Path]. Run
50 Prints from Tray 4. The Histogram indicates a problem.
Y N
Go to the 8-999.

8-180, 8-181 RAP

• Tray 3/4/5/6 Latches and the Elevator moves into the proper feed position with the tray
Fault code, 8-180-1, indicates that the lead edge of the sheet of paper fed from Tray 3 did not
closed
arrive at the Tray 3 Feed Sensor, Q857A, within the specified number of clock counts after the
Tray 3 Feed Clutch was energized. When this fault is declared the Feed Sensor, Q857A, is not • Enter dC131 and ensure FSN#1 NVM locations 197, 198, 199, 200 are at the values
blocked. given in the appropriate level Software dC 131 Table in General Procedures.
NOTE: With Level 10.XX software these values are not adjustable (they are hard coded) and
have been removed from dC131.
arrive at the Tray 4 Feed Sensor, Q857B, within the specified number of clock counts after the
Tray 4 Feed Clutch was energized. When this fault is declared the Feed Sensor, Q857B, is not • If Tray 3/4/5/6 is empty when the fault is declared, check (ADJ 7-33), Down/ Low Paper
blocked. Sensor Adjustment.
• Stack Height Adjustment (ADJ 7-31).
arrive at the Tray 5 Feed Sensor, Q857C, within the specified number of clock counts after the
Procedure
Tray 5 Feed Clutch was energized. When this fault is declared the Feed Sensor, Q857C, is not NOTE: The following procedure can be used for fault codes that may appear in any of the
blocked. Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter
Fault code, 8-180-4, indicates that the lead edge of the sheet of paper fed from Tray 6 did not order to properly diagnose the fault codes.
arrive at the Tray 6 Feed Sensor, Q857D, within the specified number of clock counts after the
Tray 6 Feed Clutch was energized. When this fault is declared the Feed Sensor, Q857D, is not Enter dC330. Select [Feeder X], [7-8X], [Tray X Feed] clutch. Select [Cycle Mode]. Press
blocked. Continue. The [Tray X] Feed Clutch energizes.
Y N
Fault code, 8-181-1, indicates that the lead edge of the sheet of paper fed from Tray 3 did not Press Stop. +24 VDC is measured between TS50 (+) and TS37 (-) of the FSN DIO
arrive at the Tray 3 Feed Sensor, Q857A, within the specified number of clock counts after the PWB #2.
Tray 3 Feed Clutch was energized. When this fault is declared the Feed Sensor, Q857A, is Y N
blocked. +24 VDC is measured between TS36 (+) and TS37 (-) of the FSN DIO PWB #2.
Y N
Fault code, 8-181-2, indicates that the lead edge of the sheet of paper fed from Tray 4 did not Go to the 1-717, +24, -34, +34 VDC RAP for Tray 3, Go to the 1-719, P/S 24V
arrive at the Tray 4 Feed Sensor, Q857B, within the specified number of clock counts after the LVPS RAP for Tray 4.
Tray 4 Feed Clutch was energized. When this fault is declared the Feed Sensor, Q857B, is
blocked. Go to wire 63F (Tray 3/5), 81A (Tray 4/6). Check the +24 VDC distribution.
Go to Flag 1. Check the Tray X Feed Clutch circuit. (Generic Solenoid Checkout
Fault code, 8-181-3, indicates that the lead edge of the sheet of paper fed from Tray 5 did not RAP GP 6-3, General Procedures.)
arrive at the Tray 5 Feed Sensor, Q857C, within the specified number of clock counts after the
Tray 5 Feed Clutch was energized. When this fault is declared the Feed Sensor, Q857C, is Press Continue. 0 VDC is measured.
blocked. Y N
Replace the FSN DIO PWB #2 (PL 1.17).
arrive at the Tray 6 Feed Sensor, Q857D, within the specified number of clock counts after the Replace the Tray X Feed Clutch (PL 8.15).
Tray 6 Feed Clutch was energized. When this fault is declared the Feed Sensor, Q857D, is
blocked. Press Stop. Select [7-8X] [Tray X] Release. Press Continue. Open Tray X, actuate the Stack
Height Sensor. The display changes from L to H.
Initial Actions Y N
Go to Flag 3. Check the Stack Height Sensor circuit. (GP 6-2, General Procedures.)
Position the Paper Guides against the paper stack. Select [7-8X]. Check the Tray X Feed Sen-
• SCP HFSI for 08-806 Table 4, or HFSI TABLES to see all of HFSI.
sor Actuator for damage (It is easier to access the Tray X Transport at the back of the
• Paper is properly loaded and within specification for use in the Printer (Section 4, General machine). Actuate the Tray X Feed Sensor. The display changes from H to L.
Service Data). Y N
• Length and Width Guides stay in position against the paper stack Go to Flag 2. Check the Tray X Feed Sensor circuit. (GP 6-2, General Procedures.)
• Tray 3/4/5/6 Blower Motor drive belt
• Tray 3/4/5/6 Air duct and hose connections are secured
A
A
Ensure that the Stacker Door Interlocks are cheated. Select [Tray X Xport Drive] motor. Press
Continue. Observe the Tray X Drive motor shaft in the back of the machine. The Tray X
Drive Motor shaft is turning.
Y N
Select [Tray X] Blower motor. Press Continue. Place a sheet of paper against the Feed Belts
in the feed position to check the Air System. The Vacuum holds the sheet in the feed posi-
tion against the Feed Belts.
Y N
Go to the 8-707, Tray X Air System Checkout.
Remove the sheet of paper. Select [Tray X Feed]. Press Continue. The Feed Belts Rotate.
Y N
Press Stop. Check the Feeder Drive Belt for damage (PL 8.14).
Remove the Drag Brake. Select [Tray X Xport Drive] [Tray X Feed]. Press Continue.
The Feeder Drive Shaft rotates.
Y N
Remove the Feeder Assembly. Check for a broken shaft or coupling. If the problem
continues, replace the Feed Clutch (PL 8.15).
Replace the Drag Brake (PL 8.13).

• Feed Belts for wear and proper tracking (PL 8.13)
• Timing Belt tension
• Idlers for damage (PL 8.13)
• Tray X Feed Sensor actuator for damage (PL 8.12)
• Feeder and Upper Tray X Transport area for obstructions
• Drag Brake and Feed Clutch for intermittent operation (PL 8.13), (PL 8.15)
Press [Clear Outputs]. Enter dC726. Select [Printer Options], [Tray X], [Sample Tray], 50
Prints. Select [Paper Path] [7]. Press Continue. If the graph indicates that the machine oper-
ation is outside of the specified range, go to the 8-707, Tray X Air System Checkout. If the
problem continues, replace the Feed Sensor, Drag Brake(PL 8.13), or Feed Clutch (PL 8.15)
as required.


8-182, 8-183 RAP Refer to the appropriate level Software Table (Section 6, General Procedures, in the Service
Manual). Ensure that the following dC 131 and dC 131 NVM Locations are at the values shown
Fault code, 8-182-1, indicates that the trail edge of the sheet of paper fed from Tray 3 failed to in the Table.
leave the Feed Sensor, Q857A, within the specified number of clock counts from when the lead
edge of that sheet actuated that sensor. When this fault is declared, the sensor is blocked. Table 1 FSN#1 and FSN#2 Check
Address Current Value Address Current Value
Fault code, 8-182-2, indicates that the trail edge of the sheet of paper fed from Tray 4 failed to
leave the Feed Sensor, Q857B, within the specified number of clock counts from when the lead 280 336
edge of that sheet actuated that sensor. When this fault is declared, the sensor is blocked. 281 337
282 338
283 339
leave the Feed Sensor, Q857C, within the specified number of clock counts from when the
lead edge of that sheet actuated that sensor. When this fault is declared, the sensor is blocked. 284 340
285 341
leave the Feed Sensor, Q857D, within the specified number of clock counts from when the • Check paper for damage. Go to the 8-705.
lead edge of that sheet actuated that sensor. When this fault is declared, the sensor is blocked.
• Q857 actuator is not bent or misaligned.
Fault code, 8-183-1, indicates that the trail edge of the sheet of paper fed from Tray 3 failed to Procedure
leave the Feed Sensor, Q857A, within the specified number of clock counts from when the lead NOTE: The following procedure can be used for fault codes that may appear in any of the
edge of that sheet actuated that sensor. When this fault is declared, the sensor is not blocked. Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter
Fault code, 8-183-2, indicates that the trail edge of the sheet of paper fed from Tray 4 failed to order to properly diagnose the fault codes.
leave the Feed Sensor, Q857B, within the specified number of clock counts from when the lead
edge of that sheet actuated that sensor. When this fault is declared, the sensor is not blocked. Open Tray X. Enter dC330, [Feeder X], [7-8X]. Block the Tray X Feed Sensor. The display
changes.
Fault code, 8-183-3, indicates that the trail edge of the sheet of paper fed from Tray 5 failed to Y N
leave the Feed Sensor, Q857C, within the specified number of clock counts from when the Go to Flag 1. Check the circuit of the Tray X Feed Sensor. (GP 6-2, General Procedures.)
lead edge of that sheet actuated that sensor. When this fault is declared, the sensor is not
blocked. Block the Tray X Width Sensor. The display changes.
Y N
Fault code, 8-183-4, indicates that the trail edge of the sheet of paper fed from Tray 6 failed to Go to Flag 2. Check the circuit of the Tray X Width Sensor. (GP 6-2, General Procedures.)
leave the Feed Sensor, Q857D, within the specified number of clock counts from when the
lead edge of that sheet actuated that sensor. When this fault is declared, the sensor is not Check the following:
blocked. • Tray X Transport Upper Turn Baffle for damaged or burrs.
• Jam clearance baffles are seated.
Initial Actions • Jam clearance baffle linkage for damage.
Check Tray 3/4/5/6 for the following: • Takeaway Roll Idler and springs are in position.
• Transport drive idler bracket for damage.
• SCP HFSI for 08-806 and 08-808 Table 4, or HFSI TABLES to see all of HFSI.
The Tray X Transport hardware is OK.
• Length and Width Guides maintain position against the paper stack when the tray is
Y N
closed.
Repair the Tray X Transport (PL 8.17).
• Retard Bracket does not contact the Feed Belts.
• Idler Roll tabs broken at the Feeder. Select [7-8X] [Tray X Xport Drive] Motor. Press Continue. Select [Tray XFeed]. Press Con-
• Paper is properly loaded and within specification for use in the Printer (Section 4, General tinue. The Transport Idler Rolls and Feed Belts turn freely.
Service Data). Y N
Check the drives:
• Timing belt tensioned and routed properly. Check the pin on the timing belt idler for a
broken weld. Replace the Idler Bracket (PL 8.11). Check the belt tension. Takeaway
Roll pin broken.
A
A
• Bearings seized
Enter dC726. Select [Printer Options], [Tray 3/4], [Tray 5/6] 50 copy job. Select [Paper
Path], [8, (Tray 3)/13, (Tray 4)/18, (Tray 5)/23, (Tray 6). Press Continue. Store the graph.
Clean the Magnetic Strips, Transport Belts, and rolls. Inspect for damage or wear. Rerun
dC726, [8/13/18/23]. The graph indicates that the machine operation is within the speci-
fied range and the graph is less than 4 columns wide.
Y N
• Feed Head for damage.
• Retard Bracket does not contact the Feed Belts. If the bracket cannot be biased to
create a 1mm gap, replace the Feeder assembly (PL 8.12).
• Feed Clutch and Drag Brake for intermittent operation if there are wide variations in
consecutive arrivals.
• Go to the 8-707, Tray 3/4/5/6 Air System Checkout.
If the problem continues, replace the Tray 3/4/5/6 Feed Sensor or Drag Brake (PL 8.12),
(PL 8.13)
Check the Feed Clutch and Drag Brake for intermittent operation, if there are wide variations in
consecutive arrivals. Replace as required (PL 8.13).
Check the Feed Head for damage. Replace as required (PL 8.13).


8-184, 8-185 RAP • Tray 3/4/5/6 Latch Assembly Adjustment ADJ 7-32.
• Stack Height Adjustment ADJ 8-0.
Fault code, 8-184-1, indicates that the lead edge of the sheet of paper fed from Tray 3 failed to • If the sheet is damaged go to the 8-705, and 8-706.
arrive at the Vertical Transport Sensor, Q852A, within the specified number of clock counts
from when the lead edge arrived at the Feed Sensor, Q857A. When this fault is declared, Procedure
Q852A, is not blocked. NOTE: The following procedure can be used for fault codes that may appear in any of the
Fault code, 8-184-2, indicates that the lead edge of the sheet of paper fed from Tray 4 failed to (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in
arrive at the Vertical Transport Sensor, Q852B, within the specified number of clock counts order to properly diagnose the fault codes.
from when the lead edge arrived at the Feed Sensor, Q857B. When this fault is declared,
Q852B, is not blocked. Ensure that the Feed Clutch is not energized constantly. There is a gap between each sheet
fed.
Fault code, 8-184-3, indicates that the lead edge of the sheet of paper fed from Tray 5 failed to Y N
arrive at the Vertical Transport Sensor, Q852C, within the specified number of clock counts ms Go to Flag 2. Check the Feed Clutch wiring for a short circuit. (Generic Clutch RAP GP 6-
from when the lead edge arrived at the Feed Sensor, Q857C. When this fault is declared, 3, General Procedures.)
Q852C, is not blocked.
Inspect the Tray X Transport Idlers. Verify that the rolls are not binding. Ensure that the Idler
Fault code, 8-184-4, indicates that the lead edge of the sheet of paper fed from Tray 6 failed to Roll Shaft Guides are seated and that the Idler Roll Springs are in place. Ensure that the jam
arrive at the Vertical Transport Sensor, Q852D, within the specified number of clock counts clearance linkage is connected. Check the Drive Rolls for wear, damage, or contamination.
from when the lead edge arrived at the Feed Sensor, Q857D. When this fault is declared, Ensure that the Drive Belts are set to the proper tension The Transport hardware is OK.
Q852D, is not blocked. Y N
Repair Tray X Transport as required (PL 8.17).
Fault code, 8-185-1, indicates that the lead edge of the sheet of paper fed from Tray 3 failed to
arrive at the Vertical Transport Sensor, Q852A, within the specified number of clock counts Check the Vertical Transport Sensor actuator for damage. Enter dC330, [Feeder X], [7-8X].
from when the lead edge arrived at the Feed Sensor, Q857A. When this fault is declared, Block the Vertical Transport Sensor. The display changes from H to L.
Q852A, is blocked. Y N
Go to Flag 1. Check the Vertical Transport Sensor circuit. (GP 6-2, General Procedures.)
arrive at the Vertical Transport Sensor, Q852B, within the specified number of clock counts Observe the operation of the Tray X Transport. The sheets are without damage or skew in
from when the lead edge arrived at the Feed Sensor, Q857B. When this fault is declared, the transport.
Q852B, is blocked. Y N
Go to the 8-705, and 8-706.
arrive at the Vertical Transport Sensor, Q852C, within the specified number of clock counts Enter dC726. Select [Printer Options], [Tray 3/4/]/[Tray 5/6], [Sample Tray]. Select [Paper
from when the lead edge arrived at the Feed Sensor, Q857C. When this fault is declared, Path], [9 (Tray 3)/14, (Tray 4)/19, (Tray 5)/24, (Tray 6)]. Press Continue. Store the graph.
Q852C, is blocked. Clean the Lower Drive Shaft Rolls. Check for binding. Rerun dC726, [9/14/19/24]. If there is no
improvement in the arrival times, or if the problem continues, replace the Lower Drive Assem-
Fault code, 8-185-4, indicates that the lead edge of the sheet of paper fed from Tray 6 failed to bly (PL 8.19).
arrive at the Vertical Transport Sensor, Q852D, within the specified number of clock counts Check the following:
from when the lead edge arrived at the Feed Sensor, Q857D. When this fault is declared, • Paper in the tray is properly loaded. Check the paper supply for excessive curl. Go to
Q852D, is blocked. Print Paper Diagnostics (Service Call Procedures) for diagnostics.
Initial Actions
• Tray 3/4/5/6 is secure in the closed position.
• Tray 3/4/5/6 Closed Switch does not bias the Tray outward.
• Interference between the AC Relay Chassis wire harness and the Elevator Safety Cover.

8-186, 8-187 RAP

Y N
Go to Flag 2. Check the Feed Clutch wiring for a short circuit. (Generic Clutch RAP GP 6-
leave the Vertical Transport Sensor, Q852A, within the specified number of clock counts from
when the lead edge arrived at that sensor. When this fault is declared, Q852A is blocked.
Inspect the Tray X Transport Idlers. Verify that the rolls are not binding. Ensure that the Idler
Roll Shaft Guides are seated and that the Idler Roll Springs are in place. Check the Drive Rolls
leave the Vertical Transport Sensor, Q852B, within the specified number of clock counts from
for wear, damage, or contamination. Ensure that the jam clearance linkage is connected. The
when the lead edge arrived at that sensor. When this fault is declared, Q852B is blocked.
Transport hardware is OK.
Y N
Repair Tray X Transport as required (PL 8.17).
leave the Vertical Transport Sensor, Q852C, within the specified number of clock counts from
when the lead edge arrived at that sensor. When this fault is declared, Q852C is blocked.
Check the Vertical Transport Sensor actuator for damage. Enter dC330, [Feeder], [7-8X].
Block the Vertical Transport Sensor. The display changes from H to L.
Y N
leave the Vertical Transport Sensor, Q852D, within the specified number of clock counts from
Go to Flag 1. Check the Vertical Transport Sensor circuit. (GP 6-2, General Procedures.)
when the lead edge arrived at that sensor. When this fault is declared, Q852D is blocked.
Observe the operation of the Tray X Transport. The sheets are without skew or damage in
the transport.
leave the Vertical Transport Sensor, Q852A, within the specified number of clock counts from
Y N
when the lead edge arrived at that sensor. When this fault is declared, Q852A is unblocked.
Go to the 8-705, and 8-706.
Enter dC726. Select [Printer Options], [Tray 3/4]/[Tray 5/6], [Sample Tray]. Select [Paper
leave the Vertical Transport Sensor, Q852B, within the specified number of clock counts from
Path], [10 (Tray 3)/15, (Tray 4)/20, (Tray 5)/25, (Tray 6)]. Press Continue. Store the graph.
when the lead edge arrived at that sensor. When this fault is declared, Q852B is unblocked.
Clean the Lower Drive Shaft Rolls. Check for binding. Rerun dC726, [10/15/20/25]. If there is
no improvement in the arrival times, or if problem continues, replace the Lower Drive Assembly
(PL 8.19).
leave the Vertical Transport Sensor, Q852C, within the specified number of clock counts from
when the lead edge arrived at that sensor. When this fault is declared, Q852C is unblocked.
• Paper in the tray is properly loaded. Check the paper supply for excessive curl. Go to
Print Paper Diagnostics (Service Call Procedures) for diagnostics.
leave the Vertical Transport Sensor, Q852D, within the specified number of clock counts from
when the lead edge arrived at that sensor. When this fault is declared, Q852D is unblocked.
Initial Actions
• Vertical Transport Baffles are seated properly.
• Stack Height Adjustment ADJ 7-31.
Procedure
Ensure that the Feed Clutch is not energized constantly. There is a gap between each sheet
fed.

8-188, 8-189 RAP

Fault code, 8-188-1, indicates that the lead edge of the sheet of paper delivered from the Verti- Procedure
cal Transport failed to arrive at the Turn Baffle Sensor, Q853A, within the specified number of
clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, Q852A.
When the fault is declared, Q852A, is not blocked.
Fault code, 8-188-2, indicates that the lead edge of the sheet of paper delivered from the Verti-
cal Transport failed to arrive at the Turn Baffle Sensor, Q853B, within the specified number of Inspect the Tray X Transport Idlers. Verify that the rolls are not binding. Ensure that the Idler
clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, Q852B. Roll Shaft Guides are seated and that the Idler Roll Springs are in place. Ensure that the jam
When the fault is declared, Q852B, is not blocked. clearance linkage is connected. The Transport hardware is OK.
Y N
Fault code, 8-188-3, indicates that the lead edge of the sheet of paper delivered from the Verti- Repair Tray X Transport as required (PL 8.17).
cal Transport failed to arrive at the Turn Baffle Sensor, Q853C, within the specified number of
clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, Q852C. Check the Vertical Transport Sensor actuator for damage. Enter dC330, [Feeder X], [7-8X].
When the fault is declared, Q852C, is not blocked. Block the Vertical Transport Sensor. The display changes from H to L.
Y N
Fault code, 8-188-4, indicates that the lead edge of the sheet of paper delivered from the Verti- Go to Flag 1. Check the Vertical Transport Sensor circuit. (GP 6-2, General Procedures.)
cal Transport failed to arrive at the Turn Baffle Sensor, Q853D, within the specified number of
clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, Q852D. Observe the operation of the Tray X Transport. The sheets are without skew in the trans-
When the fault is declared, Q852D, is not blocked. port.
Y N
Fault code, 8-189-1, indicates that the lead edge of the sheet of paper delivered from the Verti- Go to the 8-706.
cal Transport failed to arrive at the Turn Baffle Sensor, Q853A, within the specified number of
clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, Q852A. Observe the paper entering the Vertical Transport. The sheets catch at the transition baffle
When the fault is declared, Q852A, is blocked. or have folded corners.
Y N
Fault code, 8-189-2, indicates that the lead edge of the sheet of paper delivered from the Verti- Enter dC726. Select [Printer Options], [Tray 3/4]/[Tray 5/6], [Sample Tray]. Select
cal Transport failed to arrive at the Turn Baffle Sensor, Q853B, within the specified number of [Paper Path], [11 (Tray 3) / 16 (Tray 4) / 21 (Tray 5) / 26 (Tray 6)]. Press Continue.
clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, Q852B. Store the graph. Clean the Lower Drive Shaft Rolls. Check for binding. Rerun dC726, [11/
When the fault is declared, Q852B, is blocked. 16/21/26]. If there is no improvement in the arrival times, or if problem continues, replace
the Lower Drive Assembly (PL 8.19). Continued problems go to the 8-203.
cal Transport failed to arrive at the Turn Baffle Sensor, Q853C, within the specified number of Go to the 8-705, Damage.
clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, Q852C. Check the following:
When the fault is declared, Q852C, is blocked. • Check the paper supply for excessive curl. Go to Print Paper Diagnostics (Service Call
Procedures) for diagnostics.
cal Transport failed to arrive at the Turn Baffle Sensor, Q853D, within the specified number of
clock counts after the lead edge of that sheet arrived at the Vertical Transport Sensor, Q852D.
When the fault is declared, Q852D, is blocked.
Initial Actions
• Check the Lower and Vertical Transports for damage.
• Check the paper path for obstructions and/or damage.
• Check the condition of the drive belts.
• Check that the paper tray is loaded correctly.
• Ensure that the jam clearance baffles are seated properly.
• Check the Tray 3/4/5/6 Feed Belt for proper tracking.
• Check the transport idler rolls and springs, for proper operation and position.
• Check the Shaft Assembly Drive Rolls for contamination, damage, or wear.

Figure 1 8-188-1/189-1 Circuit Diagram (7835B)
8-190 RAP

A
• Drive pulleys for damage or slippage on shaft (PL 8.21), (PL 8.23)
4 Horizontal Transport failed to arrive at the Tray 3 Turn Baffle Sensor, Q853A, within the spec- • Bearings for wear or damage
ified number of clock counts after the lead edge arrived at the Tray 4 Horizontal Transport Sen- Perform dC 703, Feed Timing Set-up, if any of the above are replaced.
sor, Q854B. When the fault is declared, Q854B, is blocked.
Fault code, 8-190-2, indicates that the lead edge of the sheet of paper delivered from the Tray • Drive Belts for wear, damage, contamination, and correct tension (PL 8.20).
5 Horizontal Transport failed to arrive at the Tray 4 Turn Baffle Sensor, Q853B, within the spec- • Horizontal Transport Pivot Baffle adjustment (ADJ 8-15).
• Horizontal Transport and Turn Baffle Transport Drive Rolls for wear, damage, or contami-
sor, Q854C. When the fault is declared, Q854C, is blocked.
nation (PL 8.21), (PL 8.19).
Fault code, 8-190-3, indicates that the lead edge of the sheet of paper delivered from the Tray • Horizontal Transport and Turn Baffle Transport Idlers rotate freely (PL 8.20), (PL 8.19).
6 Horizontal Transport failed to arrive at the Tray 5 Turn Baffle Sensor, Q853C, within the spec- • Idler Tension Springs are present and are not damaged or stretched.
ified number of clock counts after the lead edge arrived at the Tray 6 Horizontal Transport Sen- • Horizontal Transport and Turn Baffle Transport jam clearance baffles for damage and
sor, Q854D. When the fault is declared, Q854D, is blocked. seated correctly (PL 8.21), (PL 8.19).
• IFS to Middle Module to FS alignment
Initial Actions Perform dC 703, Feed Timing Set-up, if any of the above are replaced.
• Turn Baffle Sensor and Horizontal Transport Sensor are clean and are not obstructed.
Service Data).
Procedure
Enter dC330, [Feeder X], [7-8X]. Block the Tray X Turn Baffle Sensor. The display changes
from H to L.
Y N
Select [7-8X]. Block the Tray X Horizontal Transport Sensor. The display changes from H to
L.
Y N
dures).
Select [Tray X Xport Drive] motor. Press CONTINUE. The Horizontal Transport Drive Rolls
rotate.
Y N
Y N

A
Figure 1 8-190 Circuit Diagram (T7836C)
8-191, 8-194 RAP

A B
The Cross Roll Idler lifts and lowers freely without binding.
Fault code, 8-191, indicates the Registration Transport Sensor, Q861, dynamic width measure-
ment of a sheet of paper fed from Tray 1 is less than 55 servo clock counts from the expected Y N
paper width. Replace the Solenoid Assembly (PL 8.5).
Fault code, 8-194, indicates the Registration Transport Sensor, Q861, dynamic width measure- Ensure that the Length Guide is positioned against the paper stack. Firmly push the tray
ment of a sheet of paper fed from Tray 1 is greater than 55 servo clock counts from the closed. Open the tray. The paper guide maintained position against the paper stack.
Y N
expected paper width.
Check the Length Guide Position and Tension adjustments (ADJ 7-4) and (ADJ 7-5).
Replace the Length Guide as required (PL 7.2).
Initial Actions
• Check dC131 NVM PHN location 220 and 222 is at the value shown in the appropriate Close Tray 1. Enter dC703. Select [Printer Options], [Tray 1], [Sample Tray], 50 prints.
level Software dC 131 Table in General Procedures. Select [Setups], [Paper Width]. Press Continue. Check, do not adjust, the sheet timing
• Check the Vertical Transport Magnetic Strips position. Inspect for damage. across the Registration Transport Sensor. The difference between the Minimum Error and
• Clean the Servo Drive Rolls and Idlers. Clean the Registration Transport Sensor and the Maximum Error is less than 30 counts.
check for lens damage. Ensure that all jam clearance baffles are seated. Y N
Adjust to the recommended value. Run the Paper Width Setup again. Press Continue.
Procedure The difference between the Minimum Error and the Maximum Error is less than 30
Check the paper in Tray 1 for damage, curl, or other defects. Remove the paper stack. Select counts.
dC330, [7-8]. Move the Length Guide to the extreme positions. Tray 1 Length Sensor A dis- Y N
play changes from L to H. Check the Sample Tray output copies for defects. Timing variations can be caused
Y N by one of the following.
Check the Length Guide cam for damage, and ensure that the sensor is being actuated. • Misregistered or skewed sheets. Go to the 8-706.
Go to Flag 1. Check the Length Sensor A circuit. (GP 6-2, General Procedures.)
• Damage. Go to the 8-705.
• Multifeeds. Go to the 8-113.
Move the Length Guide to the extreme positions. Tray 1 Length Sensor B display changes
from H to L to H. • Servo operation problem. Go to the 8-302.
Y N
Check the Length Guide cam for damage, and ensure that the sensor is being actuated. Adjust to the recommended value. If the problems continue, go to the 8-302 to check out
Go to Flag 2. Check the Length Sensor B circuit. (GP 6-2, General Procedures.) the Servo operation.
Select [8] [Cross Roll Left] Solenoid. Press [Continue]. The Left Cross Roll Solenoid Examine the Error values. A problem is indicated if the Minimum Error, Average Error, and
energizes. Maximum Error values are biased greater than 25 counts from zero in the same direction,
Y N either positive or negative. (Example: Min Error +26 Average Error +30 Max Error +35.) The
Press Stop. +24 VDC is measured between TS50 (+) and TS37 (-) of PHN DIO PWB Error values are centered around zero +/- 20 counts without extreme bias either positive
#2. or negative.
Y N Y N
+24 VDC is measured between TS36(+) and TS37(-) of the PHN DIO PWB #2. Exit Service Mode. Ensure that the paper is loaded properly and within specification for
Y N use in the Printer (Section 4, General Service Data). If the problem continues, there may
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. be an intermittent Registration Servo problem. Go to the 8-302.
Y N
Go to the 1-717, +24, +34, -34 VDC RAP. Adjust to the recommended value. Check SCP Faults Top 15 Actual PHM Jams. There are
more 8-191 Jams indications than there are 8-194 Jams.
Check wire 544. Check the +24 VDC distribution. Y N
There are Tray 1 related faults, 8-113 and 8-155, indicating possible multifeed prob-
Go to Flag 3. Check the Left Cross Roll Solenoid circuit. (Generic Solenoid RAP GP lems.
6-3, General Procedures.) Y N
Question the operator about any problem with special papers. If the problem contin-
Press Continue. 0 VDC is measured. ues, there may be an intermittent Registration Servo problem. Go to the 8-302.
Y N
Replace the PHN DIO PWB #2 (PL 1.4). Question the operator about any problem with special papers. Go to the 8-113 to diag-
nose the multifeed problem. If the problem continues, there may be an intermittent Regis-
Replace the Left Cross Roll Solenoid (PL 8.5). tration Servo problem. Go to the 8-302.
A B C D
C D
There are numerous Registration Transport related 8-151, 8-152, or 8-154 faults indicat-
ing possible skew or paper damage problems.
Y N
There are 8-302 faults indicating possible Servo Motor or Servo PWB problems.
Y N
If the problem is difficult to reproduce question the operator about problems with
special papers. Observe the paper passing through the Registration Transport. Look
for damage, skew, or multifeeds. Go to the 8-706, and 8-705 (diagnose the Reg
Xport and Cross Roll areas), or the 8-113 to diagnose the multifeed problems as
required.
Go to the 8-302.
Observe the paper passing through the Registration Transport. Look for damage, skew, or mul-
tifeeds. Go to the 8-706, and 8-705 (diagnose the Reg Xport and Cross Roll areas), or 8-113 to
diagnose multifeed problems. There may be an intermittent Reg Servo problem. Go to the 8-
302.

Figure 1 8-191/194 Circuit Diagram (T7837B)

A B
8-192, 8-195 RAP Replace the Left Cross Roll Solenoid (PL 8.5).
Fault code, 8-192, indicates the Registration Transport Sensor, Q861, dynamic width measure- The Cross Roll Idler lifts and lowers freely without binding.
ment of a sheet of paper fed from Tray 2 is less than 55 servo clockcounts from the expected Y N
paper width. Replace the Solenoid Assembly (PL 8.5).
Fault code, 8-195, indicates the Registration Transport Sensor, Q861, dynamic width measure- Ensure that the Length Guide is positioned against the paper stack. Firmly push the tray
ment of a sheet of paper fed from Tray 2 is greater than 55 servo clockcounts from the closed. Open the tray. The paper guide maintained position against the paper stack.
expected paper width. Y N
Check the Length Guide Position and Tension adjustments (ADJ 7-4) and (ADJ 7-5).
Initial Actions Replace the Length Guide as required (PL 7.2).
• Check dC131 NVM PHN locations 220 and 222 are at the values shown in the appropri-
Close Tray 2. Enter dC703. Select [Printer Options], [Tray 2], [Sample Tray], 50 prints.
ate level Software dC 131 Table in General Procedures.
Select [Setups], [Paper Width]. Press Continue. Check, do not adjust, the sheet timing
• Check the Vertical Transport Magnetic Strips position. Inspect for damage.
across the Registration Transport Sensor. The difference between the Minimum Error and
• Clean the Servo Drive Rolls and Idlers. Clean the Registration Transport Sensor and the Maximum Error is less than 30 counts.
check for lens damage. Ensure that all jam clearance baffles are seated. Y N
Procedure Adjust to the recommended value. Run the Paper Width Setup again. Press Continue.
The difference between the Minimum Error and the Maximum Error is less than 30
Check the paper in Tray 2 for damage, curl, or other defects. Remove the paper stack. Select
dC330, [7-8]. Move the Length Guide to the extreme positions. Tray 2 Length Sensor A dis- counts.
play changes from L to H. Y N
Check the Sample Tray output copies for defects. Timing variations can be caused
Y N
Check the Length Guide cam for damage, ensure that the sensor is being actuated. Go to by one of the following.
Flag 1. Check the Length Sensor A circuit. (GP 6-2, General Procedures.) • Misregistered or skewed sheets. Go to the 8-706.
• Damage. Go to the 8-705.
Move the Length Guide to the extreme positions. Tray 2 Length Sensor B display changes • Multifeeds. Go to the 8-123.
from H to L to H. • Servo operation problem. Go to the 8-302.
Y N
Check the Length Guide cam for damage, ensure that the sensor is being actuated. Go to Adjust to the recommended value. If the problems continue, go to the 8-302 to check out
Flag 2. Check the Length Sensor B circuit. (GP 6-2, General Procedures.) the Servo operation.
Select [8] [Cross Roll Left] Solenoid. Press [Continue]. The Left Cross Roll Solenoid Examine the Error values. A problem is indicated if the Minimum Error, Average Error, and
energizes. Maximum Error values are biased greater than 25 counts from zero in the same direction,
Y N either positive or negative. (Example: Min Error +26 Average Error +30 Max Error +35.) The
Press Stop. +24 VDC is measured between TS50 (+) and TS37 (-) of PHN DIO PWB Error values are centered around zero +/- 20 counts without extreme bias either positive
#2. or negative.
Y N Y N
+24 VDC is measured between TS36(+) and TS37(-) of the PHN DIO PWB #2. Exit Service Mode. Ensure that the paper is properly loaded and within specification for
Y N use in the Printer (Section 4, General Service Data). If the problem continues, there may
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. be an intermittent Registration Servo problem. Go to the 8-302.
Y N
Go to the 1-717, +24, +34, -34 VDC RAP. Adjust to the recommended value. Check SCP Faults Top 15 Actual PHM Jams. There are
more 8-191 Jams indications than there are 8-194 Jams.
Check wire 544. Check the +24 VDC distribution. Y N
There are Tray 2 related faults, 8-123 and 8-155, indicating possible multifeed prob-
Go to Flag 3. Check the Left Cross Roll Solenoid circuit. (Generic Solenoid RAP GP lems.
6-3, General Procedures.) Y N
Question the operator about any problem with special papers. If the problem contin-
Press Continue. 0 VDC is measured. ues, there may be an intermittent Registration Servo problem. Go to the 8-302.
Y N
A B C D
C D
Question the operator about any problem with special papers. Go to the 8-123 to diag-
nose the multifeed problem. If the problem continues, there may be an intermittent Regis-
tration Servo problem. Go to the 8-302.
There are numerous Registration Transport related 8-151, 8-152, or 8-154 faults indicat-
Y N
Y N
If the problem is difficult to reproduce, question the operator about problems with
special papers. Observe the paper passing through the Registration Transport. Look
for damage, skew, or multifeeds. Go to the 8-706, and 8-705, (diagnose the Reg
Xport and Cross Roll areas), or the 8-123 to diagnose the multifeed problems as
required.
Go to the 8-302.
Observe the paper passing through the Registration Transport. Look for damage, skew, or mul-
tifeeds. Go to the 8-706, 8-705, (diagnose the Reg Xport and Cross Roll areas), or the 8-123 to
diagnose multifeed problems. There may be an intermittent Reg Servo problem, go to 8-302.


8-193, 8-196 RAP Initial Actions
• Ensure dC131 PHN NVM locations 220, 221, 222 and 223 are at the values given in the
Fault code, 8-193-1, indicates the Registration Transport Sensor, Q861, dynamic width mea-
appropriate level Software dC 131 Table in General Procedures.
surement of a sheet of paper fed from Tray 3 is narrower than the nominal width by more than
• Ensure that all transport baffles are seated. Verify that Registration Transport Lower Right
55 servo clockcounts from the expected paper width. The expected paper widths are deter-
mined by the combined states of the tray sensors, HCT Length Sensor A, Q742, HCT Length Baffle, at the FBN transition area, is properly positioned with the tabs engaged in the
Sensor B, Q733, and HCT Width Sensor, Q734. Lower Left Baffle.
• Clean the Registration Transport Sensor and check for lens damage (PL 8.4). Clean the
Fault code, 8-193-2, indicates the Registration Transport Sensor, Q861, dynamic width mea- Servo Drive Roll and Idlers. Ensure that all baffles are seated.
surement of a sheet of paper fed from Tray 4 is narrower than the nominal width by more than • Ensure the PR Drive coupling is properly lubricated with Moly Grease (PL 25.1). See
55 servo clockcounts from the expected paper width. The expected paper widths are deter- ROLLOVERS PC 3676--RO-177643 in the Service Information Section for additional
mined by the combined states of the tray sensors, HCT Length Sensor A, Q742, HCT Length information on the lubricant and a tool for its application.
Sensor B, Q733, and HCT Width Sensor, Q734. Procedure
Fault code, 8-193-3, indicates the Registration Transport Sensor, Q861, dynamic width mea- NOTE: The following procedure can be used for fault codes that may appear in any of the
surement of a sheet of paper fed from Tray 5 is narrower than the nominal width by more than Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter
55 servo clockcounts from the expected paper width. The expected paper widths are deter- (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in
mined by the combined states of the tray sensors, HCT Length Sensor A, Q742, HCT Length order to properly diagnose the fault codes.
Sensor B, Q733, and HCT Width Sensor, Q734.
Open Tray X. Check the paper in Tray X for damage, curl, or other defects. Remove the paper
stack. Select dC330, [Feeder X], [7-8X]. Move the Width Guide between the extreme posi-
tions. The Tray X Width Sensor display changes.
surement of a sheet of paper fed from Tray 6 is narrower than the nominal width by more than
Y N
55 servo clockcounts from the expected paper width. The expected paper widths are deter-
Check the Width Guide cam for damage, ensure that the sensor can be actuated. Go to
mined by the combined states of the tray sensors, HCT Length Sensor A, Q742, HCT Length
Flag 1. Check the Width Sensor circuit. (GP 6-2, General Procedures.)
Sensor B, Q733, and HCT Width Sensor, Q734.
Move the Length Guide to the extreme positions. The Tray X Length Sensor A display
changes.
surement of a sheet of paper fed from Tray 3 is greater than 55 servo clockcounts from the
Y N
expected paper width. The expected paper widths are determined by the combined states of
Check the Length Guide cam for damage, ensure that the sensor is be actuated. Go to
the tray sensors, HCT Length Sensor A, Q742, HCT Length Sensor B, Q733, and HCT Width
Flag 2. Check the Length Sensor A circuit. (GP 6-2, General Procedures.)
Sensor, Q734.
Move the Length Guide to the extreme positions. The Tray X Length Sensor B display
changes.
Y N
Check the Length Guide cam for damage, ensure that the sensor can be actuated. Go to
Flag 3. Check the Length Sensor B circuit being actuated. (GP 6-2, General Procedures.)
Sensor, Q734.
Ensure that the Length Guide and Width guides are positioned against the paper stack. Select
[7-8X]. Select Tray X. Firmly push the tray closed. Press [Continue]. Open the tray. The
paper guides maintain position against the paper stack.
Y N
Replace the Length or Width Guide as required (PL 7.2).
Sensor, Q734.
Select [8] [IOT Paper Path] [Cross Roll Left] Solenoid. Press [Continue]. The Left Cross
Roll Solenoid energizes.
Y N
Press Stop. +24 VDC is measured between TS50 (+) and TS37 (-) of PHN DIO PWB
#2.
Sensor, Q734.
Y N
+24 VDC is measured between TS36(+) and TS37(-) of the PHN DIO PWB #2.
A B
A B C
Y N Adjust to the recommended value. Check SCP [Faults] [PHM] [Top 15] [Actual]. There are
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. more 8-193 Jams indications than there are 8-196 Jams.
Y N Y N
Go to the 1-717, +24, +34, -34 VDC RAP (Tray 3). GO to 1-719, P/S 24V There are Tray 3/4/5/6 related faults, 8-180, 8-181, 8-182, 8-183, 8-155 indicating pos-
LVPS RAP (Tray 4). sible multifeed problems.
Y N
Check wire 544. Check the +24 VDC distribution. Question the operator about any problem with special papers. If the problem contin-
ues, there may be an intermittent Registration Servo problem. Go to the 8-302.
Go to Flag 4. Check the Left Cross Roll Solenoid circuit. (Generic Solenoid RAP GP
6-3, General Procedures.) Question the operator about any problem with special papers. Go to the 8-182, 8-183 to
diagnose the multifeed problem. If the problem continues, there may be an intermittent
Press Continue. 0 VDC is measured. Registration Servo problem. Go to the 8-302.
Y N
Replace the PHN DIO PWB #2 (PL 1.4). There are numerous Registration Transport related 8-151, 8-152, or 8-203 faults indicat-
Replace the Left Cross Roll Solenoid (PL 8.5). Y N
The Cross Roll Idler lifts and lowers freely without binding. Y N
Y N If the problem is difficult to reproduce question the operator about problems with
Replace the Solenoid Assembly (PL 8.5). special papers. Observe the paper passing through the Registration Transport. Look
for damage, skew, or multifeeds. Go to the 8-706, and 8-705, (diagnose the Reg
Close Tray 3/4/5/6. Enter dC703 select [Printer Options], [Tray 3/4]/[Tray5/6], [Sample Xport and Cross Roll areas), or the 8-182, 8-183 to diagnose the multifeed problems
Tray], 50 prints. Select [Setups], [Paper Width]. Press Continue. Check the sheet timing as required.
variations across the Registration Xport Sensor. The difference between the Minimum Error
and the Maximum Error is less than 30. Go to the 8-302.
Y N
Adjust to the recommended value. Run the Paper Width Setup again. Press Continue. Observe the paper passing through the Registration Transport. Look for damage, skew, or mul-
The difference between the Minimum Error and the Maximum Error is less than 30 tifeeds. Go to the 8-706, 8-705, (diagnose the Reg Xport and Cross Roll areas), or the 8-182,
counts. 8-183 to diagnose the multifeed problem. There may be an intermittent Reg Servo problem. Go
Y N to the 8-302.
Check the output copies in the Sample Tray for defects. Timing variations can be
caused by any of the following:
• Misregistered or skewed sheets. Go to the 8-706.
• Paper damage. Go to the 8-705.
• Multifeeds. Go to the 8-182, 8-183.
• Servo operation problem. Go to the 8-302.
Adjust to the recommended value. If the problems continue, go to 8-302 to check out the
Servo operation.
Examine the Error values. A problem is indicated if the Minimum Error, Average Error, and
Maximum Error values are biased greater than 25 counts from zero in the same direction,
either positive or negative. (Example: Min Error +26 Average Error +30 Max Error +35.) The
Error values are centered around zero +/- 20 counts without extreme bias either positive
or negative.
Y N
Ensure that the paper options programmed are consistent with the actual paper size in
the tray. If the problem continues, there may be an intermittent Registration Servo prob-
lem. Go to the 8-302.
C

8-197, 8-198 RAP Procedure
Fault code, 8-197-1, indicates that the trail edge of the sheet of paper delivered from the Hori- NOTE: The following procedure can be used for fault codes that may appear in any of the
zontal Transport failed to arrive at the Horizontal Transport Sensor, Q854A, within the specified Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter
number of clock counts after the lead edge of that sheet arrived at the Horizontal Transport (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in
Sensor, Q854A. When the fault is declared, Q854A, is blocked. order to properly diagnose the fault codes.
Enter dC330, [Feeder X], [7-8X]. Block the Horizontal Transport Sensor. The display
Fault code, 8-197-2, indicates that the trail edge of the sheet of paper delivered from the Hori-
zontal Transport failed to arrive at the Horizontal Transport Sensor, Q854B, within the specified
Y N
number of clock counts after the lead edge of that sheet arrived at the Horizontal Transport
Sensor, Q854B. When the fault is declared, Q854B, is blocked.
dures).
Select [Tray X Xport Drive motor. Press Continue. The Horizontal Transport Drive Rolls
zontal Transport failed to arrive at the Horizontal Transport Sensor, Q854C, within the specified
rotate.
Y N
Sensor, Q854C. When the fault is declared, Q854C, is blocked.
Y N
zontal Transport failed to arrive at the Horizontal Transport Sensor, Q854D, within 245ms after
the lead edge of that sheet arrived at the Horizontal Transport Sensor, Q854D. When the fault
is declared, Q854D, is blocked.
• Drive pulleys for damage or slippage on shaft (PL 8.21)
zontal Transport failed to arrive at the Horizontal Transport Sensor, Q854A, within the specified • Bearings for wear or damage
number of clock counts after the lead edge of that sheet arrived at the Horizontal Transport Perform dC 703, Feed Timing Set-up, if any of the above are replaced.
Sensor, Q854A. When the fault is declared, Q854A, is unblocked.
Fault code, 8-198-2, indicates that the trail edge of the sheet of paper delivered from the Hori- • Drive Belts for wear, damage, contamination, and correct tension (PL 8.20).
zontal Transport failed to arrive at the Horizontal Transport Sensor, Q854B, within the specified • Horizontal Transport Drive Rolls for wear, damage, or contamination (PL 8.21).
• Horizontal Transport Idlers rotate freely (PL 8.22).
Sensor, Q854B. When the fault is declared, Q854B, is unblocked.
Fault code, 8-198-3, indicates that the trail edge of the sheet of paper delivered from the Hori- • Horizontal Transport jam clearance baffles for damage and that they seat correctly ADJ 8-
zontal Transport failed to arrive at the Horizontal Transport Sensor, Q854C, within the specified 14, ADJ 8-15.
number of clock counts after the lead edge of that sheet arrived at the Horizontal Transport • Lower Preregistration Transport Pivot Baffle (ADJ 8-10) and (ADJ 8-12).
Sensor, Q854C. When the fault is declared, Q854C, is unblocked. • Lower Preregistration Transport Baffle adjustment (ADJ 8-9).
• IFS to Middle Module to FS alignment.
zontal Transport failed to arrive at the Horizontal Transport Sensor, Q854D, within the specified
number of clock counts after the lead edge of that sheet arrived at the Horizontal Transport • Oversize Nip Release Solenoid for proper operation.
Sensor, Q854D. When the fault is declared, Q854D, is unblocked. Perform dC 703, Feed Timing Set-up, if any of the above are replaced.
Initial Actions
• Horizontal Transport Sensor are clean and are not obstructed.

Service Data).
• Horizontal Transport paper path for obstructions.

8-203 RAP

Fault code, 8-203, indicates that the lead edge of the sheet of paper arrived at the Registration 8-204 RAP
Transport Sensor, Q861, greater than the specified number of clock counts from when the
Fault code, 8-204, indicates that the lead edge of the transparency arrived at the Registration
Control Logic received the Registration Sync signal. The sheet is too late to be registered cor-
Transport Sensor, Q861, less than the specified number of clock counts of the previous trans-
rectly. This fault is recorded in NVM only.
parency.
Initial Actions
Procedure
• Check HFSI 08-808 R, 08-817 C, and 08-818 C, in the HFSI TABLES
Check SCP [Faults] [Actual] [Almost] and [PHM]. Look for fault clusters indicating possible
• Clear any jammed paper or other obstructions from the paper path. Verify that the Cross Registration Transport problems. There are fault counts indicated for 8-152.
Roll idlers and Servo Roll idlers rotate freely. Ensure that the idler rolls seat with the drive
Y N
rolls when the baffles are closed. Clean the Registration Transport Sensor, Q861. Look for fault clusters indicating possible feed problems from Tray 1 or Tray 2. There are
• Ensure that all Registration Xport jam clearance baffles are seated properly, specifically fault counts indicated for 8-111, 8-112, 8-113, 8-115, 8-121, 8-122, or 8-123.
the lower right baffle at the PHM entrance. Y N
• Ensure that the Operator is adjusting the Registration Cross Rolls (using the positioning There are fault counts indicated for 8-144.
levers) to the proper position for heavy weight and oversize papers. Ensure that the cus- Y N
tomer is aware that there is an additional lever on the 7X10 Registration Transport. Observe the output prints. Go to the 8-705, or 8-706 as required.
Procedure
Go to the 8-144.
Check SCP [Faults] [Actual] [Almost] and [PHM] for related jams. There are faults.
Y N
There are 8-152 faults.
Y N
Go to the 8-152.
If the fault occurs using transparencies. Verify that the Cross Roll Sensor can be
actuated by transparencies. Ensure that the paper in the trays is properly loaded and
within the Processor Specification for Paper Tray Capabilities.
Go to the 8-152.
Go to the 8-225.

8-210 RAP 8-211 RAP
Fault code, 8-210, indicates that, during the print mode, the Tray 1 feed timing increased to Fault code, 8-211, indicates that during print mode, the value for the Tray 1 feed timing
more than the specified number of clock counts. This fault is recorded in SCP only. decreased to less than the specified number of clock counts. This fault is recorded in NVM
only.
Procedure
Check SCP [Faults] [Actual] [Almost] and [PHM]. There are counts indicated for 8-113 Procedure
faults. Check SCP [Faults] [Actual] [Almost] and [PHM]. There are counts indicated for any of
Y N the following: 8-112, 8-113, or 8-152.
There are 8-115 faults indicated. Y N
Y N Enter dC726. Check the timing of the fault codes listed above. The graph indicates a
There are 8-152 faults indicated. timing problem.
Y N Y N
Check the following: The problem does not reproduce at this time. The Customer may have encountered
• Vertical Transport Belts are clean. problems in previous jobs with a particular substrate. Check the following:
• Magnetic Skis are positioned correctly. • Vertical Transport Belts are clean.
• Output prints for damage or skew. Go to the 8-705, or 8-706, Misregistra- • Magnetic Skis are clean and are positioned correctly.
tion and Skew as required. • Feed Head is free of debris or contamination.
• Takeaway Roll is clean and is not damaged.
Go to the 8-152.
There is a timing problem identified. Go to the RAP associated with the timing interval.
Go to the 8-115.
Go to the 8-113.
8-212 RAP 8-213 RAP
Fault code, 8-212, indicates that during the print mode, the Tray 2 feed timing increased to Fault code, 8-213 indicates that during print mode the Tray 2 feed timing decreased to less
more than the specified number of clock counts. This fault is recorded in NVM only. than the specified number of clock counts. This fault is recorded in NVM only.
Procedure Procedure
Check SCP [Faults] [Actual] [Almost] and [PHM]. There are counts indicated for any of Check SCP [Faults] [Actual] [Almost] and [PHM]. There are counts indicated for any of
the following: 8-122, or 8-123. the following fault codes: 8-122, 8-123, or 8-151.
Y N Y N
There are 8-152 faults indicated. There are 8-152 or 8-155 Registration Transport related faults indicated.
Y N Y N
Check the following: If the problem does not reproduce at this time, it is possible that the Customer may
• Cross Rolls Motor (60 hz in a 50 hz machine) have encountered problems in a previous job with a particular substrate.
• Registration Transport and Vertical Transport drives for wear or damage. Check the following:
• Vertical Transport Belts are clean.
• Vertical Transport Belts are clean.
• Takeaway Roll is clean.
• Magnetic Skis are positioned correctly.
• Magnetic Skis are clean.
• For continued diagnostics, go to the Non Repeatable Fault RAP (Service Call
Procedures). • Feed Head is free of contamination and is not damaged.
Go to the 8-152. Go to appropriate RAP.
Go to the appropriate RAP. Go to appropriate RAP.

8-216, 8-218 RAP There are 8-184 counts indicated.
Y N
Fault code, 8-216-1, indicates that during print mode, the Tray 3 feed timing increased by more Replace the Tray X Feed Clutch (PL 8.15). Perform dC 703, Feed Timing Set-up.
than the specified number of clock counts in Standard mode (7 and 8 pitch). This fault is
recorded in the SCP only. Check the Tray X Drive Motor for 60Hz in a 50Hz machine. Ensure proper Tray X Transport
operation. Check for pulleys or roller damage.
Fault code, 8-216-2, indicates that during print mode, the Tray 4 feed timing increased by more
recorded in the SCP only.
than the specified number of clock counts in Oversized mode (3,4,5,6 pitch). This fault is
recorded in SCP only.
than the specified number of clock counts in Oversized mode(3,4,5,6 pitch). This fault is
Procedure
Check SCP [Faults] [Actual] and [Almost]. There are counts indicated for 8-180, 8-184, or
8-203.
Y N
There are 8-203 counts indicated.
Y N
Check the Cross Roll Motor for 60 hz in a 50 hz machine.
Check the Tray X Drive Motor for 60Hz in a 50Hz machine. Ensure proper Tray X Trans-
port operation. Check for pulleys or roller damage. If the problem continues, go to the 8-
203.

A
8-217 RAP Go to the RAP for the associated timing interval.
Fault code, 8-217-1, indicates that during print mode, the Tray 3 feed timing decreased by
more than the specified number of clock counts below the nominal feed time in Standard mode
(7 and 8 pitch). This fault is recorded in SCP only.
Fault code, 8-217-2, indicates that during print mode, the Tray 4 feed timing decreased by less
than the specified number of clock counts below the nominal feed time in Standard mode (7
and 8 pitch). This fault is recorded in SCP only.
Fault code, 8-219-1, indicates that during print mode, the Tray 3 feed timing decreased by
more than the specified number of clock counts below the nominal feed time in Oversized
mode (3,4,5,6 pitch). This fault is recorded in SCP only.
than 88ms below the nominal feed time in Oversized mode (3,4,5,6 pitch). This fault is
than the specified number of clock counts below the nominal feed time in Oversized mode
(3,4,5,6 pitch). This fault is recorded in SCP only.
than the specified number of clock counts below the nominal feed time in Oversized mode
(3,4,5,6 pitch). This fault is recorded in SCP only.
Procedure
Check SCP [Faults] [Actual] and [ALMOST]. There are counts indicated for 8-180, 8-182,
8-185, or 8-203.
Y N
Enter dC726. Check the timing for the faults indicated. The graph indicates a timing
problem.
Y N
The problem does not reproduce at this time. The Customer may have encountered
problems in previous jobs with a particular substrate. Ensure that the Feed Head is
free of debris or contamination. Clean the Takeaway Roll.
Go to the RAP for the associated timing interval.

A
A
8-225 RAP Procedure
Check the Cross Roll Sensor for lens damage. Ensure that the sensor bracket is not damaged
Fault code, 8-225, indicates that no sheet was detected at the Cross Roll Sensor, Q871. This
or bent out of position. Clean the Cross Roll Sensor and reflective tape. If the tape appears
fault is recorded in NVM only.
worn or cannot be cleaned, replace the Cross Roll Sensor (PL 8.9). Enter dC330, [8]. Block
the Cross Roll Sensor. The display changes from H to L.
Initial Actions Y N
Check the following: Check the Cross Roll Sensor circuit. (GP 6-2, General Procedures).
• Paper is properly loaded and within specifications for use in the Printer (Section 4, Gen- Ensure that the customers paper will actuate the sensor. Check for obstructions in the paper
eral Service Data). path. Check SCP [Faults] [Actual] [Almost] and [PHM] for related jams 8-152. If indicated,
go to the 8-152. If the fault continues, replace the Cross Roll Sensor (PL 8.6).
A
8-226, 8-227 RAP NOTE: For the following measurements:
If a Fluke DMM is used, set the meter to the 40 VDC range. Select min/max, then
Fault Code 8-226 indicates that the Control Logic did not detect a change of state of the Trans- (peak min/max). There will be a 1 ms record time which will display approximately 22
fer Blade Sensor Q907, 80ms after the Transfer 1 Solenoid SOL903 was energized or de-ener- volts peak (+) voltage.
gized.
If a Simpson DMM is used, set the meter to the 20 VDC range. The voltage dis-
played will be approximately +4 VDC.
Fault code 8-227 indicates that the Control Logic did not detect a change of state of the Trans-
fer Blade Sensor Q907, 80ms after the Transfer 4 Solenoid SOL904 was energized or de-ener- The proper voltage is displayed on the DMM.
gized. Y N
Go to Flag 2, and troubleshoot for an Open circuit.
These faults are recorded as Range Faults in the SCP and will not be recorded when running
in the Service Mode. Check the following components:
• Transfer Blade Assembly and Transfer 1 Solenoid for binding (PL 9.12)
Procedure • Plastic Bearing Clips (10 clips total) that allow the Transfer Blade Actuator Seg-
Open the Processor Right Front Door. While observing the Transfer 1 Solenoid SOL903, ments to pivot for the correct engagement (PL 9.12)
Transfer 2 Solenoid SOL905, Transfer 3 Solenoid SOL906, and the Transfer 4 Solenoid • Plastic Solenoid Blocks for the correct engagement to the blade actuator (PL
SOL904, actuate and de-actuate the Right Front Door Interlock Switch several times. 9.12)
NOTE: Leave the interlock switch actuated for the remainder of this RAP. • If no binding is found, replace the Transfer 1 Solenoid, SOL903 (PL 9.12)
One or more of the solenoids energize when actuating the interlock switch and deener- Press Stop. Select [Transfer 4 Solenoid]. Observe the Transfer 4 Solenoid, SOL904.
gize when deactuating the interlock switch. Press Continue. The solenoid energizes.
Y N Y N
Enter dC330 [Xerographics], [9]. Select [Cycle], [Transfer 1 Solenoid]. Observe the Press Stop. +24 VDC is measured from TS53 (+) to TS37 (-) on the PHN DIO
Transfer 1 Solenoid, SOL903. Press Continue. The solenoid energizes. PWB #6.
Y N Y N
Press Stop. +5 VDC is measured from TS45 (+) to TS37 (-) on the PHN DIO PWB +24 VDC is measured between TS44 (+) and TS37 (-) on the PHN DIO PWB
#2. #6.
Y N Y N
+5 VDC is measured from TH1 (+) to TH3 (-) on the TAD PWB. Go to Flag 4. Check the +24 VDC Interlock Power circuit to the Transfer 3
Y N and 4 Solenoids.
Go to Flag 8, and troubleshoot for a +5 VDC problem.
Go to Flag 5. Check the Transfer 4 Solenoid circuit (Go to GP 6-3, Generic
Power down the Printer. Separate J2/P397 on the PHN DIO PWB #2. Power up Solenoid RAP, General Procedures).
the Printer. +5 VDC is measured between P397/3 (+) and TS37 (-) on the If the circuit is OK, replace the Transfer 4 Solenoid, SOL904 (PL 9.12).
PHN DIO PWB #2.
Y N Press Continue. The voltage goes low for 1 second.
Go to Flag 6, and check continuity. If OK, replace the TAD PWB (PL 9.11). Y N
Select [Printer Power Interrupt].
Replace the PHN DIO PWB #2 (PL 1.4). Disconnect P/J3000. Measure the resistance between J3000-3 and J3000-4.
The resistance is less than 15 ohms.
Disable [Cycle]. Press Continue. The voltage goes (L) between TS45 (+) and Y N
TS37 (-) on the PHN DIO PWB #2. Replace the PHN DIO PWB #6 (PL 1.4).
Y N
Replace the PHN DIO PWB #2 (PL 1.4). Replace the PHN DIO PWB #6 (PL 1.4) and the Transfer 4 Solenoid SOL904
(PL 9.12).
+24 VDC is measured between TH2 (+) and TH3 (-) on the TAD PWB.
Y N Check the following components:
Go to Flag 7, and troubleshoot a +24 VDC problem. • Transfer Blade Assembly and Transfer 4 Solenoid for binding (PL 9.12)
• Plastic Bearing Clips (10 clips total) that allow the Transfer Blade Actuator Seg-
ments to pivot for the correct engagement (PL 9.12)

A B C
• Plastic Solenoid Blocks for the correct engagement to the blade actuator (PL Replace the PHN DIO PWB #6 (PL 1.4) and the Transfer 3 Solenoid SOL906
9.12) (PL 9.12).
If no binding is found, replace the Transfer 4 Solenoid SOL904 (PL 9.12).
Check the following components:
Press Stop. Select [Transfer 2 Solenoid]. Observe the Transfer 2 Solenoid SOL905. • Transfer Blade Assembly and Transfer 3 Solenoid for binding (PL 9.12)
Press Continue. The solenoid energizes. • Plastic Bearing Clips (10 clips total) that allow the Transfer Blade Actuator Seg-
Y N ments to pivot for the correct engagement (PL 9.12)
Press Stop. +24 VDC is measured from TS52 (+) to TS37 (-) on the PHN DIO • Plastic Solenoid Blocks for the correct engagement to the blade actuator (PL
PWB #6. 9.12)
Y N
If no binding is found, replace the Transfer 3 Solenoid SOL906 (PL 9.12).
Solenoid RAP, General Procedures). If the circuit is OK, replace the Transfer 2
Check the following components in the Transfer Blade Assembly for binding and other
Solenoid SOL905 (PL 9.12).
symptoms:
• Plastic Bearing Clips (10 clips total) that allow the Transfer Blade Actuator Segments
Press Continue. The voltage goes low for 1 second.
to pivot for the correct engagement
Y N
Select [Printer Power Interrupt]. • Plastic Solenoid Blocks for the correct engagement to the blade actuator
Disconnect P/J3000. Measure the resistance between J3000-2 and J3000-5. • Solenoid Return Springs for damage
The resistance is less than 15 ohms. If the above checks are OK:
Y N • Go to Flag 1. Check the circuit of the Transfer Blade Sensor Q907 (Go to GP 6-2,
Replace the PHN DIO PWB #6 (PL 1.4). Generic Sensor RAP, General Procedures).
• Energize and de-energize all the Transfer Solenoids. Enter dC330 [9], [Xerograph-
Replace the PHN DIO PWB #6 (PL 1.4) and the Transfer 2 Solenoid SOL905 ics]. Select [Cycle Outputs]. Do this for at least 5 continuous minutes. If any of the
(PL 9.12). solenoids become sluggish or intermittent, repair/replace as required (PL 9.12).
Check the following components: The Transfer 4 Solenoid energizes when actuating the interlock switch and de-energizes
• Transfer Blade Assembly and Transfer 2 Solenoid for binding (PL 9.12) when de-actuating the interlock switch.
• Plastic Bearing Clips (10 clips total) that allow the Transfer Blade Actuator Seg- Y N
ments to pivot may be disengage (PL 9.12) The Transfer 3 Solenoid energizes when actuating the interlock switch and de-ener-
• Plastic Solenoid Blocks may be disengaged from the blade actuator (PL 9.12) gizes when de-actuating the interlock switch.
If no binding is found, replace the Transfer 2 Solenoid SOL905 (PL 9.12). Y N
The Transfer 2 Solenoid energizes when actuating the interlock switch and de-
energizes when de-actuating the interlock switch.
Press Stop. Select [Transfer 3 Solenoid]. Observe the Transfer 3 Solenoid SOL906.
Press Continue. The solenoid energizes. Y N
Y N Go back to the beginning of this RAP and answer No to the first statement.
Press Continue. +24 VDC is measured from TS44 (+) to TS37 (-) on the PHN
DIO PWB #6. Go to Flag 3. Check for a short in the Transfer 2 Solenoid circuit (Go to GP 6-3,
Y N Generic Solenoid RAP, General Procedures).
If the circuit is OK, replace the PHN DIO PWB #6 (PL 1.4).
Solenoid RAP, General Procedures). If the circuit is OK, replace the Transfer 3
Solenoid SOL906 (PL 9.12). Go to Flag 4. Check for a short in the Transfer 3 Solenoid circuit (Go to GP 6-3, Generic
Solenoid RAP, General Procedures).
Press Continue. The voltage goes low for 1 second. If the circuit is OK, replace the PHN DIO PWB #6 (PL 1.4).
Y N
Go to Flag 5. Check for a short in the Transfer 4 Solenoid circuit (Go to GP 6-3, Generic Sole-
Select [Printer Power Interrupt].
Disconnect P/J3000. Measure the resistance between J3000-4 and J3000-6. noid RAP, General Procedures).
The resistance is less than 15 ohms. If the circuit is OK, replace the PHN DIO PWB #6 (PL 1.4).
Y N
A D A D
A B C A D
A D A D
A D A E F
Figure 1 8-226, 8-227 Circuit Diagram (708102)
A E F
8-302 RAP CAUTION
The +5 VDC LED wire at P301-1 in the next check is not current limited. Shorting this wire to
The Registration Servo Controller failed to execute an initialize command. ground will cause a machine crash.
Go to Flag 1. Disconnect the P301 connector. +5.0 VDC is measured between P301-1 and
Initial Actions TS12 of the PHN Registration Servo PWB.
Ensure that the Registration Servo Motor connectors P301 and P391 are connected. Y N
Go to Flag 1. Check the wire between P301-1 and TS13 of the PHN Registration Servo
Procedure PWB for an open circuit. If the wire is OK, replace the PHN Registration Servo PWB, (PL
1.4).
Enter dC703, [Test], [Velocity]. Press Continue. If a 3-245 or 8-310 fault occurs during the
Velocity test, the test has failed.
Go to Flag 3. Check the wires between P301-2 and P308-28 and between P301-3 and P308-
NOTE: When making any measurement or running any dC Tests in the following procedure, 29 for an open or a short circuit. The wires are OK.
clear machine faults. Y N
Repair the wires, if the problem continues replace the PHN Registration Servo PWB, (PL
A fault occurred during the test or a message indicates that the Velocity Test failed.
1.4).
Y N
Check the Reg Servo Motor for an internal failure. Place the multimeter between TS8 (+)
Reconnect the P301 and P308 connectors. Select Power Interrupt. Go to Flag 2. Disconnect
and TS12 (-) of the PHN Reg Servo PWB. Very slowly rotate the Servo Drive Rolls
the P391 connector. Check the wires between P391-2 and TS16 and between P391-1 and
(located in the Lower Reg Transport under the Pinch Roll Shaft). The Encoder voltage
TS18 for an open or a short circuit. The wires are OK.
oscillates between 5.0 VDC to 0 VDC
Y N
Y N
Go to Flag 2. If the wires are OK, replace the PHN Registration Servo PWB (PL 1.4).
Replace the Reg Servo Motor, MOT862 (PL 8.7). Perform dC 703, Feed Timing Set-
up.
Reconnect the P391 connector. Press Continue. Check the Servo Drives. The Servo Drive
Rolls rotate freely.
Select [Phase Lock]. Press Continue. A message indicates that the Phase Lock Test
Y N
failed.
Remove the Registration Transport. Check the drive belt tension to the Registration
Y N
Transport. Remove the Servo Drive belts. The Servo Nip Shaft rotates freely.
If the problem continues, go to the last Y dropout of this procedure. Perform the
Y N
intermittent problem checks.
Replace the Shaft Assembly (PL 8.4)
-15 VDC is measured between TS11 (+) and TS14 (-) of the PHN Reg Servo PWB.
The motor shaft rotates freely.
Y N
Y N
-15 VDC is measured between TH7 (+) and TH8 (-) at the LVPS.
Replace the Servo Motor, MOT862 (PL 8.4). Perform dC 703, Feed Timing Set-up.
Y N
Go to the 1-716, -15 VDC RAP.
Check the transport drive belts and bearings for wear or failure. Ensure that there is no
idler damage.
Go to wire 530. Check the -15 VDC distribution.
The Servo Pinch Rolls rotate freely.
Go to the last Y dropout of this procedure. Perform the intermittent problem checks.
Y N
Replace the Pinch Rolls (PL 8.3).
+24 VDC is measured between TS19 (+) and TS17 (-) of the PHN Registration Servo
PWB.
Measure the resistance of the Servo Motor. Go to Flag 2. Disconnect P391. Place the multime-
Y N
ter between J1-1 and J1-2. Manually rotate the Servo Drive Roll shaft to any position. Measure
+24 VDC is measured between TH12 (+) and TH14 (-) of the LVPS.
and record the motor resistance with the shaft stationary. Rotate the shaft to another position
Y N
and measure the resistance. Perform this check six times. Ignore the highest and lowest resis-
Go to the 1-717, +24, -24, -34 VDC RAP.
tance measurements. Calculate the average of the other four measurements. The average of
the 4 remaining readings is between 1-40 ohms.
Y N
Replace the Registration Servo Motor (PL 8.4). Perform dC 703, Feed Timing Set-up.

A
Reconnect P391. Check the Reg Servo Motor for an internal failure. Place the multimeter
between TS8 (+) and TS12 (-) of the PHN Registration Servo PWB. Very slowly rotate the
Servo Drive Rolls (located in the Lower Reg Transport under the Pinch Roll Shaft). The
Encoder voltage oscillates between 5.0 VDC to 0 VDC
Y N
Replace the Registration Servo Motor, MOT862 (PL 8.4). Perform dC 703, Feed Timing
Set-up.
Enter dC703, [Tests], [Velocity]. Observe the voltage while cycling the Velocity test on and
off. Press Continue. Check the voltage. Press Stop, wait one second, then press Continue
and check the voltage again. Repeat this procedure a few times. The Encoder voltage when
the Continue button is pressed is consistent at each check (+/- 0.1 VDC).
Y N
There may be an internal Servo Motor shaft failure, replace the Registration Servo Motor,
MOT862 (PL 8.4). When installing the Drive Belt do not apply excess tension, this is a self
tensioning idler. Perform dC 703, Feed Timing Set-up.
Intermittent problem checks.

• Servo Motor and Encoder harness for damage or poor connections.
• Pinch Rolls or the Servo Drive Shaft for binding.
• Check the Machine Clock Sensor, Q401, wiring for damage or poor connections.
• Check SCP [Faults] [Actual] and [Other] for 3-245 or other communication faults. Go to
the appropriate RAP.
• Replace the PHN Reg Servo PWB (PL 1.4).
• Replace the Servo Motor, MOT 862 (PL 8.4). When installing the Drive Belt do not apply
excess tension, this is a self tensioning idler.
A B
B

8-310, 8-312 RAP
Fault Code, 8-310, indicates that the Control Logic is unable to communicate with the PHN
Registration Servo PWB.
Fault code, 8-312, indicates that the PHN Registration Servo PWB has failed the Turnaround
Diagnostics Test (TAD). The test is performed each time dC703 is entered.
Procedure
Check SCP Faults [Other]. This procedure was entered to diagnose 8-312 faults.
Y N
An 8-310 fault will be declared by itself, but often 8-310's are a secondary fault during an
8-302 shutdown. If there is a high frequency of both 8-302 and 8-310 faults, there is a
"fault pair" association. If there are numerous 8-310 faults but few or no 8-302 faults,
there is not a fault pair association. SCP indicates an 8-310 and 8-302 fault pair asso-
ciation.
Y N
For 8-310 fault diagnostics alone, go to the 3-245.
For 8-310 faults with associated 8-302 faults, go to the 8-302.
Perform the TAD test as follows: Enter dC703. If no message indicates a TAD failure, the TAD
test has passed and the PWB is operating properly. Exit this procedure.
If the TAD failed, go to Flag 1. Disconnect the J4 connector. To check the TAD test, exit, then
enter dC703 a few times. The PHN Registration Servo PWB passed the TAD test.
Y N
Check the J4 connector for damaged pins or poor wire connections. Reconnect J4. Go to Flag
1. Check the wire from P301-2 to TS8 for a short circuit to frame. A short circuit is indicated.
Y N
If problems continue, go to the 3-245.
Disconnect J4. Check the wire from P301-2 to P308-28 for a short circuit. If the wire is OK and
TS8 is short circuited to ground, replace the PHN Registration Servo PWB (PL 1.4).


8-700 Registration Servo Tests RAP Observe the sheets in the Registration Transport for skew. The sheets are registered by the
Registration Transport.
This RAP is used to diagnose failure of dC703 setups. Y N
Go to the 8-706, PHM Misregistration and Skew RAP.
Initial Actions
• Ensure that the paper size indicated on the screen is consistent with the actual size of the Select [Test] [Velocity]. Press Continue. If a 3-245 or a 8-310 fault occurs the Velocity test
fails. A message indicates that the machine passed the Velocity test.
paper in the tray.
Y N
• If the machine fails Turnaround Diagnostics, go to the 8-310, 8-312.
Go to the 8-302.
• Ensure that the dC131 PHN NVM locations 222 and 223 are at the values shown in the
appropriate level Software dC 131 NVM Table in General Procedures. Verify that the Servo Pinch Roll Idlers are seated properly and not seized. Ensure that the
Procedure springs are in position. Clean the Servo Rolls and rerun the test. If the variation continues,
inspect the Servo Drives and replace the Servo Drive Roller (PL 8.4), go to the 8-706, PHM
Enter [dC703], [Setups]. Press Continue. The difference between the minimum and maxi-
mum value is greater than 32 servo counts for 7 pitch, or 64 servo counts for 3 pitch. Misregistration and Skew diagnostics table.
Y N
Adjust to the recommended value. If a problem continues, go to 8-302.
Figure 1 8-700 Components (708065)

A
8-701 Friction Retard Checkout RAP The Friction Retard is operating properly. If there is a lead edge shear or tear problem, replace
the Retard Roll (PL 7.13). Perform the Paper Feed Setup Series (ADJ 7-9); then return to the
RAP that directed you to this checkout.
The purpose of this checkout is to ensure the correct operation of the Friction Retard Feeder.
Initial Actions
Check the Feed Head for the following:
• Entry Guide for wear, damage, or contamination.

• Retard Roll for flat spots or wear.
• Pulleys and belts for wear, damage, or contamination.
• Feed Belt for wear, damage, contamination, and correct tension (ADJ 7-9).
Perform the Paper Feed Setup Series (ADJ 7-9) if any of these components were replaced.
Procedure
A
Pull out the paper tray. Raise the Feed Belt. Check the Retard Brake. The Retard Roll
rotates in a clockwise direction.
Y N
Replace the Retard Brake (PL 7.13).
If they have not just been replaced, clean the Feed Belt and Retard Roll with Formula A then
wipe the surfaces with a water dampened cloth. Use the following procedure each time you are
directed to handcrank the Feed Belt.
1. Remove the rear safety cover.
2. Latch the Feed Belt.
3. Enter dC330, [7-8]. Select [Tray Feed] Clutch for the appropriate tray.
Press Continue.
4) Rotate the Tube Shaft in a counterclockwise direction.
Observe the Retard Roll as you handcrank the Feed Belt. Press down on the frame that sup-
ports the Feed Belt Idler in order to remove the play in the Feed Belt Latch. Handcrank the
Feed belt. The Retard Roll rotates.
Y N
Replace the Feed Belt Kit (PL 7.13), then return to the second step of this procedure.
(Replace the Retard Brake if you have already replaced the Feed Belt Kit).
Place a three inch strip of paper between the Feed Belt and the Retard Roll. Press down on the
frame that supports the Feed Belt. Handcrank the Feed Belt. The Retard Roll rotates.
Y N
Replace the Feed Belt Kit (PL 7.13), then return to the second step of this procedure.
(Replace the Retard Brake if you have already replaced the Feed Belt Kit).
This is a dynamic check of the Retard Brake. Place two sheets of paper between the Feed Belt
and the Retard Roll so that the lead edge is just past the Stack Relief Sensor. Enter dC606.
Select [Printer Options], appropriate tray and one print. Press Continue. One of the two
sheets remains between the Feed Belt and the Retard Roll.
Y N
Replace the Retard Brake (PL 7.13).
8-704 Noise Diagnostics RAP This procedure is intended to diagnose noise in the Paper Handling Module and the HCF.

Initial Actions 8-705 Paper Damage RAP
This procedure is intended to isolate paper damage defects.
• Transports for paper that may be jammed in the drive areas.
• Jam clearance baffles are in the correct operating position.
Initial Actions
Procedure
Observe the machine in normal operation. Exercise each of the paper trays. Use dC330 to iso- • Paper is properly loaded and within specification for use in the Printer (Section 4, General
late noise to a specific component. Service Data).
Table 1 Paper Handling Noise
• Check paper for excessive curl.
Component Action
• Change paper from tray to tray to isolate the problem.
Trays 3 and 4 Check the Blower for binding. Check the O-Ring Belt for Procedure
damage and excessive slip.
Check the transport drive pulleys and belts for wear, dam- Table 1 Table 8.2 Paper Damage Diagnostic
age, and proper belt tension.
Area/Damage Action
Check the Elevator for binding. Drive the Tray up and down.
Check the Paper Plate Parallelism ADJ 7-9. Check the drive Tray 1 and 2
components for wear or damage. Ensure that the clamp for Lead Edge Shear Replace the Retard Roll (PL 7.13). If the prob-
the Air Hose to the Air Knife is positioned with the locking lem persists replace the Retard Brake (PL
feature at the bottom. 7.13).
Trays 1 and 2 Ensure that the Feed Head rotates freely at the pivot. Tears/Notches Replace the Retard Roll (PL 7.13). If the prob-
Check Tray Feed Belt Drives Adjustment (ADJ 4-20). lem persists replace the Retard Brake (PL
7.13).
Check for worn or damaged teeth on the Tube Shaft cou-
plings or Wear Element. Tray 3 and 4
Open the tray. Manually rotate the Tube Shaft. Replace the Bent Corners Check SCP HSFI for 08-806 Table 4, or HFSI
Tube Shaft if binding is present. TABLES to see all of HFSI. Observe the out-
board edge of paper passing through the Tray
Drive the Tray Elevator up and down. Check for binding or
3/4 Transport. Ensure that the Feed Belts are
poor tracking. Replace any worn or damaged parts. Ensure
tracking properly. Ensure that the Retard Fin-
proper elevator drive belt tension. Check the Paper Plate
gers do not contact the Feed Belts. Verify that
Parallelism (ADJ 7-9).
the Width and Length Guides maintain posi-
Vertical Transport Check Upper and Lower Shaft Assemblies for binding.
tion against the paper stack. Check the Paper
Ensure that the Flexible Coupling is properly aligned and not Plate and Stack Height Sensor Adjustments
damaged. Inspect the wear element. (ADJ 7-31). Check the Latch Assembly
To further isolate, disengage the transport. Run the drives Adjustment (ADJ 7-32), and the Tray Closed
and observe the Drive Coupling, pulleys, belts, and tension- Switch (ADJ 7-33) adjustments. Check the
ing idler. Drag Brake for slippage (PL 8.13). Check the
Registration Transport Ensure that transport baffles are properly seated. IFS to Printer alignment and the FS to IFS
alignment. Ensure that the transport baffles
Check the drive belt, idler, and pulleys for damage.
are adjusted; Lower Prereg Xport Baffle (ADJ
Check the Cross Rolls and Cross Roll Shaft Bearing Assem-
8-9), Lower Prereg Xport Pivot Baffle (ADJ 8-
bly 10), Lower Prereg Xport Pivot Baffle Bumper
Check the Servo Motor in dC 703. Lift the baffle to check the (ADJ 8-12), IFS/FS Horizontal Xport Pivot
Nip Idler for binding. Inspect the belt, pulleys, and idlers. Baffle (ADJ 8-14), Intermediate Horizontal
Ensure proper belt tension. Xport Pivot Baffle (ADJ 8-15). Check the
Top Transport Check the drive pulleys and belt for wear or damage. Ensure Lower Prereg Xport Corrugator Rolls (ADJ 8-
that the transport baffles are properly seated. Check the idler 11). Go to the 8-707 Tray 3/4 Air System
rolls for binding. Check the turn roll area for jammed paper. Checkout RAP.

Table 1 Table 8.2 Paper Damage Diagnostic 8-706 Misregistration And Skew RAP
Area/Damage Action
This procedure is used to isolate and repair problems that are causing misregistration and
Printer Use the panic stop procedure and the Diag- skew.
nostic Footprint to isolate the problem.
Registration Transport Ensure that the Registration Sensor does not Initial Actions
interfere with the paper path. Ensure that the
Cross Rolls lift only one time for every sheet.
Clean/replace the Cross Roll Sensor and • Paper is properly loaded and within specification for use in the Printer (Section 4, General
reflective tape.
Service Data).
Pre-Fuser Use the panic stop procedure and the Diag-
nostic Footprint to isolate the problem. Go to
• Jam clearance baffles are properly seated.
the 8-706 Misregistration and Skew RAP.
• If the output prints have curl adjust the Decurler lever. Examine prints for machine
Post-Fuser Ensure that the Top Transport baffles are
induced damage. Use the Diagnostic Footprint to isolate the problem area.
seated properly and that the cover latches
securely. Ensure that the wire forms or cables • Check SCP HSFI for 08-816 and 08-817 Table 2 Table, or HFSI TABLES to see all of
are not binding. Ensure that the springs are HFSI.
not damaged or missing and are securely in • Ensure that the dC131 PHN NVM locations 209 and 210 are at the values shown in the
place. appropriate level Software dC 131 Table in General Procedures.
Printer Edge Damage (Top Edge) Check the Registration edge for wear, • Check SCP [Faults] [Other] for 8-302 faults. If present, go to the 8-302.
grooves, or damage. Manually move paper • Ensure that the paper is square
against edge to check smoothness. Check the
Tray 3/4 Paper Guides for proper position
Procedure
against the paper stack. Ensure that the Refer to Section 3, Image Quality RAPS. Enter dC106, select [Test Patterns and PQ] and
guides are not bent. [Dimensional]. Press Continue. Inspect the output prints for Wavy Lines, Borders, Edge Loss
of Image, or other image defects that may be perceived as Misregistration or Skew problems.
Edge Damage (Lead/Trail) Check for excessive skew or binding in the
The prints are free of Image Defects.
Cross Roll Assembly. Check the Cross Roll
Y N
Solenoids in dC330, [8]. Use the PHM Diag-
Go to PQ 9-601, Printer Image Quality Entry RAP.
nostic Footprint to isolate the problem.
Curl Check the curl of the paper in the trays. Go to
Run 10 prints from each paper tray. The same amount of Misregistration or Skew is
the operators manual for specification and observed on all prints.
diagnostics. Adjust the Decurler lever for Y N
excessive print curl.
Isolate the Misregistration or Skew to a specific tray or transport. Use the Misregistration
And Skew Diagnostics Table to correct the problem.
Inspect each print in a 10 print job for skew. The Skew on each of the prints is within speci-
fication (less than 0.7mm).
Y N
From the 10 print job, select the two prints that represent the skew extremes. The differ-
ence between the two prints is the sheet to sheet skew variation. The skew variation in
the 10 print set is greater than 1.4mm.
Y N
There is a Skew mean shift problem. Perform the Pretransfer Baffle Adjustment ADJ
8-1. Inspect each print in a 10 print job for skew. The Skew on each of the prints
is within specification (less than 0.7mm).
Y N
Perform the Pretransfer Baffle adjustment (ADJ 8-1). The Skew on each of
the prints is within specification (less than 0.7mm).

Y N Y N
The paper with respect to the image is skewed in the clockwise Replace the Cross Roll Solenoid assembly (PL 8.5).
direction.
Y N Check the Servo Rolls for damage. Clean the drive rolls and idlers. Ensure that the idler
Reset the Pretransfer Baffle Cams to zero. If the problem continues, rolls freely rotate. Ensure that the Servo nip spring and bracket are properly seated.
return to the Y leg of the previous statement. Ensure the shaft is not bent. The Servo Rolls and Idlers are OK.
Y N
Reset the Pretransfer Baffle Cams to Zero. If the problem continues check Repair/replace the Servo Rolls or Idlers (PL 8.4).
the P/R Module alignment.
Check for excessive skew at the Registration Transport entrance. The sheets enter
Adjust the Top to Bottom registration. Select [Side to Side]. Press the Con- Registration Transport with excessive skew.
tinue button. The Side to Side registration variation is less than 1.4 mm. Y N
Y N Go to the Misregistration And Skew Diagnostic Table. Perform all the Registration
Go to the Misregistration And Skew Diagnostic Table. Perform the Regis- Transport actions A-F.
tration Transport actions A and D. Check SCP Faults, if 8-302 faults are
indicated go to the 8-302. Isolated the problem to a specific Tray or Transport. Use the Misregistration And Skew
Diagnostic Table to correct the skew problem then return to this procedure.
Adjust the Side to Side registration.
Adjust the Top to Bottom registration. Select [Side to Side]. Press the Continue button. The
Adjust the Top to Bottom registration. Select [Side to Side]. Press the Continue Side to Side registration variation is less than 1.4 mm.
button. The Side to Side registration variation is less than 1.4 mm. Y N
Y N Go to the Misregistration And Skew Diagnostic Table. Perform the Registration Transport
Go to the Misregistration And Skew Diagnostic Table. Perform the Registration actions A and D. Check SCP Faults, if 8-302 faults are indicated go to the 8-302.
Transport actions A and D. Check SCP Faults, if 8-302 faults are indicated go
to the 8-302. Adjust the Side to Side registration.
Adjust the Side to Side registration. Table 1 Misregistration and Skew Diagnostics
Area Action
Check the Registration Transport Left Upper Baffle. Ensure that the jam clearance spring
is not stretched or broken. Ensure that the upper baffle seating tabs are not bent. Check Tray 3 and 4 Check SCP HSFI for 08-806 Table 4, or HFSI TABLES to see all of HFSI.
the baffle for bowing. The transport is OK. Feeder Ensure that the Feed Belts are tracking properly and that the Retard Bracket
Y N does not contact the Feed Belts. Go to the 8-707 Tray 3/4 Air System Check-
Repair the Registration Transport. Adjust the Upper Baffles ADJ 8-0. out RAP.
Elevator Ensure that the AC Relay wire harness does not interfere with the Elevator
Check the Right and Left Solenoid operation in dC330. If the wrong solenoid lifts when Safety Cover. Load the Tray to max capacity. Position the Width and Length
the output is energized reverse the solenoid connectors and continue. Program a 25 print Guides against the paper stack. If greater than 3mm gap exists between the
job using the paper causing the problem. Observe the sheets in the Registration Trans- top of the paper stack and the guides, replace the guides (PL 7.2). Check the
port Cross Roll area. The Cross Roll Idlers lift only one time per sheet of paper. Paper Plate and Stack Height Sensor Adjustments (ADJ 7-31). Check the
Y N Latch Assembly (ADJ 7-32) and Tray Closed Switch (ADJ 7-33) adjustments.
Check the Cross Roll Sensor Bracket for damage. Ensure that the Reflective tape on
Transport Check the IFS to Printer alignment and the FS to IFS alignment. Ensure that
the lower baffle is not damaged or missing. Clean the Sensor and tape. Enter
the transport baffles are adjusted; Lower Prereg Xport Baffle (ADJ 8-9), Lower
dC330, [8]. Actuate the Cross Roll Sensor. The display changes from L to H.
Prereg Xport Pivot Baffle (ADJ 8-10), Lower Prereg Xport Pivot Baffle Bumper
Y N
ADJ 8-12, IFS/FS Horizontal Xport Pivot Baffle (ADJ 8-14), Intermediate Hori-
Go to the circuit diagram for the 8-225. Check the Cross Roll Sensor circuit.
zontal Xport Pivot Baffle (ADJ 8-15). Check the Oversize Nip Release Sole-
noid for proper operation. Ensure that the transition baffles are latched and
If the solenoids do not energize, go to 8-152 to diagnose the Cross Roll Solenoid
adjusted properly. Check the transport drive rolls for contamination. Check the
operation. The problem may be related to a specific stock type. If the problem contin-
transport idler rolls and springs for proper operation and position.
ues replace the Cross Roll Sensor, Q871 (PL 8.6).
Check the Cross Rolls for damage or flat spots. Ensure that the idlers are free to rotate.
When in the down position ensure that the idlers rest properly on the drive rolls and that
the lift fingers do not contact the idler shaft. The Cross Rolls and Idlers are OK.
A B C
A B C A
Table 1 Misregistration and Skew Diagnostics 8-707 Tray 3/4 Air System RAP
Area Action
The following procedure is used to set the manometer and measure the air system pressure
Tray 1 and 2 Check SCP HSFI for 08-802 and 08-804 Table 4, or HFSI TABLES to see all and vacuum for any of the feeders.
of HFSI. Ensure that the Feed Head latches properly. Check the Feed Head
for obstructions. Check the Length Guide for damage. Replace the guide if it Initial Actions
does not maintain position against the stack when the tray is closed (PL 7.2).
• Ensure that dC105 is properly programmed for site altitude and that the High Altitude Kit
Ensure that there is no interference with the paper stack or the Feed Head
is installed as required.
when the Trays are in the operating position. Ensure that the Tray latches
properly. Check the feedhead for excessive vibration during operation indicat- • Check the Stack Height Adjustment (ADJ 7-31).
ing coupling misalignment. Check for a bent feed shaft. Go to the 8-701 Fric- • Load 20 lb. 8.5 x 11 inch or 80gsm A4 paper into Tray 3/4.
tion Retard Checkout RAP. • Ensure proper Tray 3/4 Feed Belt tracking.
Registration Check SCP HSFI for 08-816 Table 2, and 08-817 Table 4, or HFSI TABLES to • Ensure that the Elevator raises up to the feed position when the Tray is closed.
Transport see all of HFSI. • Calibrate the Manometer, see GP 2, Manometer Usage (General Procedures).
A Verify that the Registration Transport is seated under the clips in the back of
the machine. Verify that the front pins are in the frame locating holes. Ensure
Procedure
that the Reg Xport Turn Baffle is properly seated in the rear pin. Ensure that TRAY 3/4 PRESSURE CHECK
the baffles are not bowed. Ensure that the jam clearance Spring is not Enter dC330, [7-8A/B], [Tray 3/4 Release]. Press Continue. Open Tray 3/4. Firmly insert the
stretched or broken. Check the Registration Transport Upper Baffles Adjust- manometer tube into the hole in the Airknife. Close the Tray carefully to prevent damage to the
ment ADJ 8-0. Ensure that the top section of the Right Lower Baffle is biased tube or Airknife. Set the right hand (positive) side of the scale to 0 mm. Select [Tray 3/4
to the right. Check the IF/S to PHM alignment. Blower]. Press Continue. Ensure that the vacuum holds the sheet against the feed head. The
measured value should be between +54 to +66 mm. Note the value. Press Stop.
B Check for obstruction or burrs in the Pretransfer Baffle. Ensure that the Trans-
port Strip in the pretransfer area is not out of position. Ensure that the Pivot
TRAY 3/4 VACUUM CHECK
guide is seated. Ensure that the lift block is seated under the baffle. Ensure
Select dC330, [7-8A/B], [Tray 3/4 Release]. Press Continue. Open Tray 3/4. Firmly insert the
that the mounting brackets are seated on the cams.
manometer tube into the small hole on the side of the Vacuum Duct. Set the left hand (nega-
C Remove the Reg Edge. Replace if damaged or a groove is worn. Ensure that tive) side of the scale to 0 mm. Select [Tray 3/4 Blower]. Press Continue. Ensure that the
the Registration Edge is seated and the hardware is secure. Verify that the vacuum holds the sheet against the feed head. The measured value should be between -42
Registration Sensor does not obstruct the paper path.
and -52 mm of water. Note the value. Press
D Check the Servo Nip. Inspect the Rolls for contamination or wear. Ensure that Stop.
the Idlers are not binding. Check for a bent Servo Drive Roll or Pinch Roll
Shaft. Check the Idler Spring Bracket seating. Ensure that the spring is not NOTE: If both the Vacuum and Pressure measurements are in specification, exit this proce-
broken and is resting on the idler shaft. dure.
E Check the Cross Rolls for flats. Inspect the Rolls for damage or contamination. Press Continue. The Blower Motor turns on.
Ensure that the Idlers and springs are positioned properly and are not binding. Y N
Ensure that the roll does not contact the Reg Edge. Ensure that the Finger Press Stop. The following is a check for a thermal overheat. Go to Flag 4. Disconnect
Guides are not interfering with the Idler Shaft. Ensure that the Cross Roll Sen- connector P417. Measure the motor resistance between pin 3 and pin 1 and between pin
sor and Reflective tape are clean. Verify the Cross Roll Solenoids operate 3 and pin 2. Determine the motor condition and continue with this RAP.
freely without binding. dC330, [8]. • If both measurements indicate an open circuit the motor is in an overheat condition.
F If the problem is with light papers, ensure that the Cross Roll Lever is in the The motor will internally reset.
down position. If the problem is with heavy weight papers, increase the Cross • If both measurements are between 20 and 60 Ohms the motor is OK.
Roll drive force by lifting the lever on the solenoid assembly. • If one measurement is OK and the other indicates an open replace the Blower Motor
Vertical Check SCP HSFI for 08-808 Table 4, or HFSI TABLES to see all of HFSI. (PL 8.15).
Transport Check the Xport belts for slippage during operation. Ensure that the Magnetic Remove the O-Ring Drive to the Blower. Press Continue. The motor comes on.
Strips are in position. Check the Double Nip Idler. Ensure that the Springs are
Y N
not broken or out of position. Ensure that the rolls are seated and not seized. Press Stop. +5 is VDC measured between TS41 (+) and TS37 (-) of the FSN DIO
PWB #2
Y N
+5 VDC is measured between TS35 (+) and TS37 (-) of the FSN DIO PWB
#2.
A
Y N Y N
Go to wire 61S. Check the +5 VDC distribution. The Vacuum Check was out of specification. Check the Air Hoses. Ensure that they are
not broken or obstructed and are properly connected and clamped. Check the O-Ring belt
Go to Flag 1. Check for continuity from TS41 to 4075-8, and from TS35 to position on the pulleys (50 HZ on the large pulley.) Clean the pulleys and check for dam-
4075-7. If the wires are OK, replace the FSN AC Remote PWB #3 (PL 1.16). age. Replace the O-Ring Belt. If the problem continues, replace the Feed Head Housing
(PL 8.13).
Y N Inspect the Air Ducts. Ensure that they are not broken or obstructed and are properly con-
Replace the FSN DIO PWB #2 (PL 1.16). nected and clamped. Check the hose position. Check the O-Ring Belt position on the pulleys
(50HZ on the large pulley.) Clean the pulley and check for damage. Replace the O-Ring Belt. If
Press Stop. 115 VAC is measured between J1-10 (+) and J1-8 (-) of the FSN AC the problem continues, replace the Airknife (PL 8.12).
Remote #3.
Y N
115 VAC is measured between J1-18 (+) and J1-8 (-) of the FSN AC Remote
PWB #3.
Y N
115 VAC is measured between TB3-12 (+) and TB3-5 (-).
Y N
(60Hz): Go to the 1-705-1, or 1-705-2.
(50Hz): Go to 1-712-1, or 1-712-2.
Go to Flag 2. Check wires, 2C and 1D, for an open circuit. If the wires are
OK, replace the FSN AC Remote PWB #3 (PL 1.16).
Go to Flag 3. Check wires, 9A, 10A, 18D, and 19A, for an open circuit. If the
wires are OK, replace the Blower Motor and Capacitor C832 as required (PL
8.15).
Press Continue. 0 VAC is measured.

Y N
Go to Flag 5. Check for continuity from P4082-32 to 4075-7. If the wire is OK,
replace the FSN AC Remote PWB #3 (PL 1.16).
Press Stop. Check the Drive Belt tension. Replace the Blower Motor and Capacitor
C832 as required (PL 8.15).
Check the O-Ring Belt for wear. Rotate the Blower and check for binding. Replace the
Blower and O-Ring Belt as required (PL 8.14).
If the Pressure and Vacuum measurements are out of specification in the same direction,
either too high or too low, a drives failure is indicated. The measurements are not in the
same direction.
Y N
• If both measurements are low, check the Blower O-Ring Belt position, (50 HZ on the
large pulley). Check the Blower for binding. Check the Blower Motor for binding or
for excessive belt tension.
• If both measurements are high, check the Blower O-Ring Belt position, (50 HZ on
the large pulley).
The Pressure Check was out of specification.
A B C
A B C

8-708 Feeder Main Drive Motor RAP Y N
(60Hz): Go to the 1-705-1, or 1-705-2.
The purpose of the Feeder Main Drive Motor RAP is to aid in the troubleshooting of the Feeder (50Hz): Go to the 1-712-1, or 1-712-2.
Main Drive Motor and related circuitry. This RAP is designed to be used for the Feeder Main
Drive Motor of any Feeder module. (60Hz Printers) - Less than 10 VAC is measured between TB3-8 and Printer frame.
(50Hz Printers) - Keep the multimeter leads on the same terminals. Enter [dC330], [7-8A/B],
Initial Actions [3/4Feed], [Start/Run]. Press Continue. The voltage remains the same between TB3-8
and TB3-3.
WARNING Y N
The Feeder Main Drive Motor may run automatically. There is an internal thermal sensor Press the Stop button. (60Hz): Go to the 1-705-1, or 1-704-2.
that opens when the motor overheats. When the motor cools, the thermal sensor will (50Hz): Go to the 1-712-1, or 1-712-2.
close, allowing power to the motor. The outside surfaces of the motor could also be
very hot. Use caution when working near the motor. Press the Stop button. 115 VAC is measured between TB3-3 and terminal 1 of the Feeder
Perform the following: Main Drive Run Relay, K803 (K-3).
Y N
• Ensure that the Interlocks are bypassed. Go to Flag 4. Check the wire for an open circuit.
• Ensure that the Feeder Main Drives rotate freely.
• Check for a loose pulley on the motor. 115 VAC is measured between terminal 1 and 2 of K803 (K-3).
Y N
Procedure Disconnect P420 from the Feeder Main Drive Motor, MOT831. 115 VAC is measured
With the Printer power switched off, or in the Power Interrupt mode, disconnect P420 from the between P420-3 and TB3-8.
Feeder Main Drive Motor, MOT831. Measure the resistance between J1-1 and J1-3. The Y N
resistance is less than 300 Ohms. Go to Flag 11. Check the wire for an open circuit.
Y N
The motor is in an overheat condition. Check the Feeder Main Drives for binding. The Go to Flag 10. Check the wires for an open circuit. If OK, replace the Feeder Main Drive
motor must cool for the thermal sensor to reset. If it does not, replace the Feeder Main Motor, MOT831 (PL 8.14).
Press Continue. The voltage goes Low.
Reconnect P420 to the motor. Enter dC330, [7-8A/B], [3/4 Xport Drive]. Observe the Feeder Y N
Main Drive Start Relay, K804 (K-4). Press Continue. K804 momentarily actuates. Press Stop. +5 VDC is measured between TS36 (+) and TS37 (-) on the FSN DIO
Y N PWB #3.
Press Stop. +24 VDC is measured between TS33 (+) and TS37 (-) on the FSN DIO Y N
PWB #3. Go to the Wirenets (Wiring Data) and check wire #61U for an open circuit.
Y N
Go to the Wirenets (Wiring Data) and check wire #63L (Feeder 3) or #63J (Feeder 4) +5 VDC is measured between TS42 (+) and TS37 (-) on the FSN DIO PWB #3.
for an open circuit. Y N
Go to Flag 3. Check the wires for an open circuit. If OK, replace the Feeder Main
+24 VDC is measured between TS43 (+) and TS37 (-) on the FSN DIO PWB #3. Drive Run Relay, K803 (K-3) (PL 1.17).
Y N
Go to Flag 1 and Flag 2. Check the wires for an open circuit. If OK, replace the Press Continue. 0.2 to 1.0 VDC is measured between TS42 (+) and TS37 (-) on the
Feeder Main Drive Start Relay, K804 (K-4) (PL 1.17). FSN DIO PWB #3.
Y N
Press Continue. The voltage momentarily drops from +24 VDC to less than 1 VDC. Press Stop. Replace the FSN DIO PWB #3 (PL 1.16).
Y N
Press Stop. Replace the FSN DIO PWB #3 (PL 1.16). Press Stop. Replace the Feeder Main Drive Run Relay, K803 (K-3) (PL 1.17).
Press Stop. Replace the Feeder Main Drive Start Relay, K804 (K-4) (PL 1.17). Press Stop. 115 VAC is measured between K803-1(K-3) and terminal 9 of the Feeder Main
Drive Start Relay, K804 (K-4).
Press Stop. 115 VAC is measured between TB3-8 and TB3-3. NOTE: On 50Hz printers, Y N
enter the Power Interrupt mode and disconnect P412 from J1 on the FSN AC Remote 115 VAC is measured between K803-1(K-3) and terminal 1 of the Start Capacitor,
PWB #3 before making this measurement to ensure accurate readings due to feedback C830.
path. Reconnect the connector when the RAP is finished.

Y N
Go to Flag 7. Check the wire and connections for an open circuit.
115 VAC is measured between K803-1(K-3) and K804-4(K-4).

Y N
Press Stop. Go to Flag 5 and check for an open circuit.
Select Peak Hold on the multimeter. Press Continue. Greater than 35 VAC is measured
between K803-1(K-3) and K804-6(K-4).
Y N
Go to Flag 6. Check the wire for an open circuit. If OK, replace the Feeder Main Drive
Relay, K804 (K-4) (PL 1.17).
Replace the following components one at a time until the problem is resolved:
• Run Capacitor, C831 (PL 8.14)
• Start Capacitor, C830 (PL 8.14)
• Feeder Main Drive Motor, MOT831 (PL 8.14)
A
A
Figure 1 8-708 CIRCUIT DIAGRAM (7864C)

8-709 Cross Roll Motor RAP Y N
Go to Flag 11. Check the white wire from the Capacitor to P389-1 for an open circuit. If the
The purpose of the Cross Roll Motor RAP is to aid in the troubleshooting of the Cross Roll wire is OK, replace the Cross Roll Motor Capacitor, C681, (PL 8.7). Manually rotate the
Motor and related circuitry. Cross Roll drives, ensure that the Cross Roll Assembly in not binding.
Initial Actions Measure the voltage at the black wire (+) (right capacitor terminal). Press Continue. +240
VAC is measured.
Y N
• Ensure that the Interlocks are bypassed. Press Stop. Enter [Power Interrupt]. Go to Flag 11. Check the black wire from the
Capacitor to P389-1 for an open circuit. A resistance of about 400 ohms should be mea-
• Ensure that the Cross Roll Idlers and Servo Roll Idlers rotate freely.
sured. The wire is OK.
• Check for a loose pulley on the motor. Y N
Procedure Repair the wire. If the wire cannot be repaired, replace the Cross Roll Motor (PL
Enter dC330, [8], [Cross Roll] motor. Press Continue. +5 VDC is measured between TS52 8.7).
(+) and TS37 (-) of the PHN DIO PWB #2.
Replace the Cross Roll Motor Capacitor, C681, (PL 8.7). Manually rotate the Cross Roll
Y N
+5 VDC is measured between J2-5 (+) of AC Remote #2 and TS37 (-) of DIO #2. drives, check the Cross Roll Assembly for binding.
Y N
Ensure that the Cross Roll Drives turn freely without binding. If the drives are OK, replace the
Cross Roll Motor (PL 8.7).
wire is OK, replace the PHN AC Remote PWB #2 (PL 1.4).
Press Continue. There is 0 VDC measured.

Y N
Press Stop. 115 VAC is measured between J1-6 (+) and J1-8 (-) of the PHN AC Remote
PWB #2.
Y N
115 VAC is measured between J1-18 (+) and J1-8 (-) of the PHN AC Remote PWB #2.
Y N
Go to Flag 6. Check wires 4AA and 23 for an open. If the wires are OK, replace the PHN
AC Remote PWB #2 (PL 1.4).
Go to Flag 5. Check for continuity from P389-1 to P396-6, and from P389-2 to P396-18. If
the wires are OK, ensure that the Cross Roll Drives are not binding. Replace the Cross
Roll Motor (PL 8.7).
Press Continue. There is 0 VAC measured.

Y N
Replace the PHN AC Remote PWB #2 (PL 1.4).
Press Stop. Go to Flag 11. Check the wires at the Cross Roll Motor Capacitor, C681. Ensure
that the white wire is connected to the left terminal and the black wire is connected to the right
terminal of the capacitor. Leave one meter lead at J1-8 (-) of PHN AC Remote PWB #2. Place
the other meter lead (+) at the white wire (left capacitor terminal). Press Continue. There is 0
VAC measured.


8-901 RAP Y N
Fault code, 8-901, indicates that the Registration Transport Sensor, Q861, dynamic width mea-
surement of the first sheet fed from Tray 1 was greater than +/- 55 servo clockcounts from the Replace the Left Cross Roll Solenoid (PL 8.5).
expected paper width or a transparency was detected during a job originating with any other
paper type. Expected paper widths are determined by the paper type selected and the com- The Cross Roll Idlers lift and lower freely without binding.
bined states of the tray length sensors, Length Sensor A, Q712, and Length Sensor B, Q713. Y N
Initial Actions
The fault occurs on the first sheet fed from Tray 1.
• Ensure that the dC 131 locations 280 and 340 are at the values shown in the appropriate
level Software Table in General Procedures. Y N
If transparencies are not mixed with other paper types in Tray 1 the problem may be hard
• Ensure that the paper size programmed matches the paper in the tray.
to reproduce. Question the operator about special paper usage. Question if gross misreg-
Procedure istration has been observed in the prints purged to the Purge Tray when the fault is
Open Tray 1. Ensure that the Length Guide is positioned against the paper stack. Firmly push declared.
the tray closed. Open the tray. The paper guide maintained position against the paper If the problem continues, check SCP Faults Top 15 Actual PHM Jams, if 8-191 or 8-194
stack. faults are indicated with few or no indication of 8-193, 8-194, 8-195, or 8-196 faults the
Y N problem is Tray 1 specific. Go to the 8-191, 8-194. If the other 8-190's or 8-150's faults are
Check the Length Guide Position and Tension Adjustments, (ADJ 7-4) and (ADJ 7-5), indicated there is a probable Registration System problem, go to the appropriate RAP.
replace the Length Guide as required (PL 7.2).
Ensure that the paper loaded in Tray 1 is the correct size. The Tray 1 paper size pro-
Remove the paper from Tray 1. Enter dC330, [7-8]. Move the Length Guide to the extreme grammed matches the paper size loaded.
positions. The Tray 1 Length Sensor A display changes from L to H. Y N
Y N Exit the Service Mode. Select Tools [Tray Size]. Ensure that the length and width dimen-
Check the Length Guide cam for damage, ensure that the sensor is being actuated. sions are properly programmed for the paper being used. Advise the operator that the
Go to Flag 1. Check the Length Sensor A circuit. (GP 6-2, General Procedures.) paper being used must be properly programmed, direct the operator to reprogram as
required.
Move the Length Guide to the extreme positions. The Tray 1 Length Sensor B display
changes from H to L to H. The problem may be related to special papers. Question the operator about special paper
Y N usage. Check for gross misregistration in the prints purged to the Purge Tray when the fault is
Check the Length Guide Cam for damage, ensure that the sensor is being actuated. declared if observed. Go to the 8-706. If there is copy damage, go to the 8-705.
Go to Flag 2. Check the Length Sensor B circuit. (GP 6-2, General Procedures.)
Select [8] [Left Cross Roll] Solenoid. Press Continue. The Left Cross Roll Solenoid ener-
gizes.
Y N
#2.
Y N
Y N
Y N
Go to the 1-717, +24, +34, -34 VDC RAP.
Check wire 544. Check the +24 VDC distribution.
6-3, General Procedures.)

A
A
8-902 RAP Y N
Fault code, 8-902, indicates that the Registration Transport Sensor, Q861, dynamic width mea-
surement of the first sheet fed from Tray 2 was greater than +/- 55 servo clockcounts from the Replace the Left Cross Roll Solenoid (PL 8.5).
expected paper width or a transparency was detected during a job originating with any other
paper type. Expected paper widths are determined by the paper type selected and the com- The fault occurs on the first sheet fed from Tray 2.
bined states of the tray length sensors, Length Sensor A, Q722, and Length Sensor B, Q723. Y N
If transparencies are not mixed with other paper types in Tray 2 the problem may be diffi-
Initial Actions cult to reproduce. Question the operator about special paper usage. Question if gross
misregistration has been observed in the prints purged to the Purge Tray when the fault is
• Ensure that the dC 131 locations 280 and 340 are at the values shown in the appropriate
level Software Table in General Procedures. declared.
If the problem continues, check SCP Faults Top 15 Actual PHM Jams, if 8-192 or 8-195
faults are indicated with few or no indication of 8-191, 8-193, 8-194, or 8-196 faults the
Procedure problem is Tray 2 specific. Go to the 8-192, 8-195. If the other 8-190's or 8-150's faults are
Open Tray 2. Ensure that the Length Guide is positioned against the paper stack. Firmly push indicated there is a probable Registration System problem, go to the appropriate RAP.
the tray closed. Open the tray. The paper guide maintained position against the paper
stack. Ensure that the paper loaded in Tray 2 is the correct size. The Tray 2 paper size pro-
Y N grammed matches the paper size loaded.
Check the Length Guide Position and Tension Adjustments, (ADJ 7-4) and (ADJ 7-5). Y N
Replace the Length Guide as required (PL 7.2). Exit the Service Mode. Select Tools [Tray Size]. Ensure that the length and width dimen-
sions are properly programmed for the paper being used. Advise the operator that the
Remove the paper from Tray 2. Enter dC330, [7-8]. Move the Length Guide to the extreme paper being used must be properly programmed, direct the operator to reprogram as
positions. The Tray 2 Length Sensor A display changes from L to H. required.
Y N
Check the Length Guide Cam for damage, ensure that the sensor is being actuated. The problem may be related to special papers. Question the operator about special paper
Go to Flag 1. Check the Tray 2 Length Sensor A circuit. (GP 6-2, General Procedures.) usage. Check for gross misregistration in the prints purged to the Purge Tray when the fault is
declared if observed. Go to the 8-706. If there is copy damage, go to the 8-705.
Move the Length Guide to the extreme positions. The Tray 2 Length Sensor B display
changes from H to L to H.
Y N
Check the Length Guide Cam for damage, ensure that the sensor is being actuated.
Go to Flag 2. Check the Tray 2 Length Sensor B circuit. (GP 6-2, General Procedures.)
Select [8] [Left Cross Roll] Solenoid. Press Continue. The Left Cross Roll Solenoid ener-
gizes.
Y N
#2.
Y N
Y N
Y N
Go to the 1-717, +24, +34, -34 VDC RAP.
Check wire 544. Check the +24 VDC distribution.
6-3, General Procedures.)

A
A
8-904 RAP Go to Flag 1. Check the Tray Width Sensor circuit (GP 6-2, General Procedures).
Feeder A Fault Code, 8-904-1, indicates that the Registration Transport Sensor, Q861, Move the Length Guide to the extreme positions. The Tray Length Sensor A display
dynamic width measurement of the first sheet fed from Tray 3 was greater than +/- 55 servo changes from H to L.
clockcounts from the expected paper width or a transparency was detected during a job origi- Y N
nating with any other paper type. Expected paper widths are determined by the paper type Check the Length Guide cam for damage. Ensure that the sensor is being actuated.
selected and the combined states of the HCT Length Sensor A, Q741, HCT Length Sensor B, Go to Flag 2. Check the Tray Length Sensor A circuit (GP 6-2, General Procedures).
Q733, and HCT Width Sensor, Q734.
Move the Length Guide to the extreme positions. The Tray Length Sensor B display
Feeder B Fault Code, 8-904-2, indicates that the Registration Transport Sensor, Q861, changes from H to L to H.
dynamic width measurement of the first sheet fed from Tray 4 was greater than +/- 55 servo Y N
clockcounts from the expected paper width or a transparency was detected during a job origi- Check the Length Guide Cam for damage. Ensure that the sensor is being actuated.
nating with any other paper type. Expected paper widths are determined by the paper type Go to Flag 3. Check the Tray Length Sensor B circuit (GP 6-2, General Procedures).
selected and the combined states of the HCT Length Sensor A, Q741, HCT Length Sensor B,
Q733, and HCT Width Sensor, Q734. Select [8] [IOT Paper Path] [Left Cross Roll] Solenoid. Press Continue. The Left Cross
Roll Solenoid energizes.
Feeder C Fault Code, 8-904-3, indicates that the Registration Transport Sensor, Q861, Y N
dynamic width measurement of the first sheet fed from Tray 5 was greater than +/- 55 servo Press Stop. +24 VDC is measured between TS50 (+) and TS37 (-) of PHN DIO PWB
clockcounts from the expected paper width or a transparency was detected during a job origi- #2.
nating with any other paper type. Expected paper widths are determined by the paper type Y N
selected and the combined states of the HCT Length Sensor A, Q741, HCT Length Sensor B, +24 VDC is measured between TS36(+) and TS37(-) of the PHN DIO PWB #2.
Q733, and HCT Width Sensor, Q734. Y N
Feeder D Fault Code, 8-904-4, indicates that the Registration Transport Sensor, Q861, Y N
dynamic width measurement of the first sheet fed from Tray 6 was greater than +/- 55 servo Go to the 1-717, +24, +34, -34VDC RAP.
clockcounts from the expected paper width or a transparency was detected during a job origi-
nating with any other paper type. Expected paper widths are determined by the paper type Check wire 544. Check the +24 VDC distribution.
selected and the combined states of the HCT Length Sensor A, Q741, HCT Length Sensor B,
Q733, and HCT Width Sensor, Q734. Go to Flag 4. Check the Left Cross Roll Solenoid circuit (Generic Solenoid RAP GP
Initial Actions
• Ensure dC 131 locations 280, 281, 340 and 341 are at the values given in the appropriate Press Continue. 0 VDC is measured.
level Software Table in General Procedures. Y N
Procedure Replace the Left Cross Roll Solenoid (PL 8.5).
The Cross Roll Idlers lift and lower freely without binding.
Y N
Open Tray X. Ensure that the Length and Width Guides are positioned against the paper stack. The fault occurs on the first sheet fed from the tray.
Look for loose or bent guides. Firmly push the tray closed. Open the tray. The paper guides Y N
maintained position against the paper stack. Question the operator about special paper usage. Transparencies are not generally feed
Y N from the tray. If the problem is not transparencies mixed with other paper types in the tray
Replace the Length Guide or Width Guide as required (PL 7.2). the problem may be hard to reproduce. Question if gross misregistration has been
observed in the prints purged to the Purge Tray when the fault is declared.
Remove the paper from the tray. Enter dC330, [Feeder X], [7-8X]. Move the Width Guide to If the problem continues, check SCP Faults Top 15 Actual PHM Jams, if 8-193 or 8-196
the extreme positions. The Tray Width Sensor display changes. faults are indicated with few or no indication of 8-191, 8-192, 8-194, or 8-195 faults the
Y N problem is tray specific. Go to the 8-193, 8-196. If the other 8-190's or 8-150's faults are
Check the base of the Width Guide for damage (PL 7.2). indicated there is a probable Registration System problem, go to the appropriate RAP.

A
The problem may be related to special papers. Question the operator about special paper
usage. Check for gross misregistration in the prints purged to the Purge Tray when the fault is
declared if observed. Go to the 8-706. If there is copy damage, go to the 8-705.

A B
B
8-904-5 RAP Y N
Adjust to the recommended value. Run the Paper Width Setup again. Press Continue.
Optional Feeder Fault code, 8-904-5, indicates that the Registration Transport Sensor, Q861, The difference between the Minimum Error and the Maximum Error is less than 30
dynamic width measurement of the first sheet fed from the Optional Feeder was greater than +/ counts.
- 55 servo clockcounts from the expected paper width or a transparency was detected during a Y N
job originating with any other paper type, or that the dynamic width measurement of a sheet of Check the Sample Tray output prints for defects. Timing variations can be caused by
paper fed from the Optional Feeder is less than 55 servo clockcounts from the expected paper one of the following:
width, or that the dynamic width measurement of a sheet of paper feed from the Optional • Misregistered or skewed sheets, go to the 8-706.
Feeder is greater than 55 servo clockcounts from the expected paper width. Expected paper • Damage, go to 8-705, Copy Damage RAP.
widths for the Optional Feeder are determined by the paper type selected and programmed
• Multifeeds, notify the customer that the third party feeder is in need of service.
into the printer.
• Servo operation problem, go to the 8-302.
Initial Actions Adjust to the recommended value. If the problems continue, go to the 8-302 to check out
• Ensure that the paper size programmed matches the paper in the Optional Feeder. the Servo operation.
• Clean the Servo Drive Rolls and Idlers.
• Clean the Registration Transport sensor and check for lens damage. Examine the Error values. A problem is indicated if the Minimum Error, Average Error, and
• Ensure that all jam clearance baffles are properly seated. Maximum Error values are biased greater than 25 counts from zero in the same direction,
either positive or negative. (Example: Min Error +26 Average Error +30 Max Error +35.) The
Procedure Error values are centered around zero +/- 20 counts without extreme bias either positive
Enter dC330 [IOT Paper Path]. Select [8], [Cross Roll Left] Solenoid. Press [Continue]. or negative.
The Left Cross Roll Solenoid energizes. Y N
Y N Exit Service Mode. Ensure that the Paper is loaded properly and within specification for
Press Stop button. +24 VDC is measured between TS50 (+) and TS37 (-) on PHN DIO use in the printer (Section 4, General Service Data). If the problem continues, there may
PWB #2. be an intermittent Registration Servo problem, go to the 8-302.
Y N
+24 VDC is measured between TS36(+) and TS37(-) on the PHN DIO PWB #2. Observe the paper passing through the Registration Transport. Look for damage, skew, or mul-
Y N tifeeds. Go to the 8-706, 8-705, (diagnose the Reg Xport and Cross Roll areas), or the third
+24 VDC is measured between TH12 (+) and TH14 (-) at the LVPS. party feeder to diagnose multifeed problems. There may be an intermittent Reg Servo prob-
Y N lem, go to 8-302.
Go to the 1-717, +24, +34, -34VDC RAP. Question the operator about special paper usage. Transparencies are not generally feed from
Tray 7. If the problem is not transparencies mixed with other paper types in Tray 7 the problem
Check wire 544. Check the +24 VDC distribution. may be hard to reproduce. Question if extreme misregistration has been observed in the first
two prints purged to the Top Tray when the fault is declared.
NOTE: When this fault occurs only the first two prints are attempted to be registered.
If the other 8-19X's or 8-104, 105, 152, 155, or 156 faults are indicated there is a probable
Press Continue. 0 VDC is measured. Registration System problem, go to the appropriate RAP.
Y N The problem may be related to special papers. Question the operator about special paper
Replace the PHN DIO PWB #2 (PL 1.4). usage. Check for misregistration in the prints purged to the Purge Tray when the fault is
declared. If observed, go to the 8-706. If there is copy damage, go to the 8-705.
Replace the Left Cross Roll Solenoid (PL 8.5).
Press Stop. The Cross Roll Idler lifts and lowers freely without binding.
Y N
Enter dC703. Select [Printer Options], [Optional Feeder], [Sample Tray] 50 prints. Select
[Setups] [Paper Width]. Press Continue. Check, do not adjust, the sheet timing across the
Registration Transport Sensor. The difference between the Minimum Error and the Maxi-
mum Error is less than 30 counts.


8-999 RAP +24VDC is available at TS53 on the Opto Isolator PWB.
Y N
Status message, 8-999, indicates that the Third Party Feeder faulted during print. Go to Flag 1. Check the red, and yellow wires for an open.
Initial Actions +24VDC is available at TS50 on the Opto Isolator PWB.

• Ensure that the Third Party Interface Cable is properly connected at both ends and is not Y N
Replace the Opto Isolator PWB (PL 4.28).
visibly damaged.
• Ensure that the Third Party Feeder has power and is switched on.
+24VDC is available at TS50 on the FSN DIO PWB 1.
Procedure Y N
Disconnect the Third Party Interface Cable from the Opto Isolator PWB in the F/S. Use the Go to Flag 2. Check the orange wire for an open.
+5VDC scale and connect the meter to TS22 (+) and TS 37 (-) on the FSN DIO PWB 1. Place
an E-Z hook from TS 22 on the FSN DIO PWB 3B to TS20 on the Opto Isolator PWB in the F/ Replace the FSN DIO PWB 1 (PL 1.16).
S. Place an E-Z hook from TS37 on the FSN DIO PWB 1 to TS4 on the Opto Isolator PWB.
Enter dC330, [Third Party], [Fin 2]. Select [C4]. Press Continue. Less than 1.2VDC is indi- Press Stop. Ensure that all counters are cleared before beginning this procedure. Place an E-
cated on the meter. Z hook from TS23 on the FSN DIO PWB 3 to TS27 on the Opto Isolator PWB in the FSN.
Y N Place an E-Z hook from TS37 on the FSN DIO PWB 3 to TS11 on the Opto Isolator PWB.
+24VDC is available at TS36 on the FSN DIO PWB 1. Enter [Third Party], [Fin 2]. [S5] changes state and the counter has incremented for the
Y N S5 counter.
+24VDC is available at J1-6 on the FSN DIO PWB 1. Y N
Y N +5VDC is available at TS04 on the FSN DIO PWB 3.
Go to the 79A wire net and check for an open. Y N
Replace the FSN DIO PWB 1B (PL 1.16). Y N
Go the 61T wirenet and check for an open.
+24VDC is available at TS53 on the Opto Isolator PWB.
Y N Replace the FSN DIO PWB 3 (PL 1.16).
Go to Flag 1. Check the red, and yellow wires for an open.
+24VDC is available at TS49 on the Opto Isolator PWB. Y N
Y N Go to Flag 1. Check the blue wire for an open.
+24VDC is available at TS42 on the FSN DIO PWB 1. Y N
Y N Replace the Opto Isolator PWB (PL 4.28).
Go to Flag 2. Check the brn wire for an open.
Go to Flag 2. Check the green wire for an open. If no open is found, replace the FSN DIO
Replace the FSN DIO PWB 1 (PL 1.16). PWB 3 (PL 1.16).
Press Stop. Move the E-Z hook from TS20 to TS19 on the Opto Isolator PWB. Move the E-Z Press Stop. Move the E-Z hook from TS27 to TS26 on the Opto Isolator PWB in the FSN.
hook from TS4 to TS3 on the Opto Isolator PWB. Enter [Third Party], [Fin 2]. Select [C5]. Move the E-Z hook from TS11 to TS10 on the Opto Isolator PWB. Enter [Third Party], [Fin 2].
Press Continue. Less than 1.2VDC is indicated on the meter. [S6] changes state and the counter has incremented for the S6 counter.
Y N Y N
+24VDC is available at TS36 on the FSN DIO PWB 1. +5VDC is available at TS16 on the FSN DIO PWB 3.
Y N Y N
+24VDC is available at J1-6 on the FSN DIO PWB 1. +5VDC is available at TS33 on the FSN DIO PWB 3.
Y N Y N
Go to the 79A wire net and check for an open. Go the 61T wirenet and check for an open.
Replace the FSN DIO PWB 1 (PL 1.16). Replace the FSN DIO PWB 3 (PL 1.16).

A B
Y N
Go to Flag 1. Check the yellow wire for an open.

Y N
Go to Flag 2. Check the red wire for an open. If no open is found, replace the FSN DIO
PWB 3 (PL 1.16).
Press Stop. Move the E-Z hook from TS26 to TS25 on the Opto Isolator PWB in the FSN.
Move the E-Z hook from TS10 to TS09 on the Opto Isolator PWB. Enter [Third Party], [Fin 2].
[S7] changes state and the counter has incremented for the S7 counter.
Y N
Y N
Y N
Go the 61T wirenet and check for an open.
Replace the FSN DIO PWB 3 (PL 1.16).

Y N
Go to Flag 1. Check the brown wire for an open.

Y N
Go to Flag 2. Check the white wire for an open. If no open is found, replace the FSN DIO
PWB 3 (PL 1.16).
Replace the Third Party Interface cable (PL 1.17).

If the problem continues advise the customer that the problem is believed to be in the third
party feeder and that the third party service company should be notified.
A B C
C

A
9-101, 9-102 RAP Ensure that the print paper (light, curl, duplex) and environment (humidity) are not at
unacceptable levels. Advise the customer of any problems (General Procedures, Printer
Fault Code, 9-101, indicates that the Paper On Photoreceptor (POP) Sensor, Q904, is blocked Specifications).
in the standard mode (A4).
Check the following components for damage or burrs. Repair or replace the components as
Fault Code, 9-102, indicates that the Paper On Photoreceptor (POP) Sensor, Q904, is blocked required.
in the oversize mode (A3). • Pretransfer Baffle (PL 8.8).
• Stripper Fingers (PL 9.3).
Initial Actions Ensure that the print paper (light, curl, duplex) and environment (humidity) are not at unaccept-
• If the Photoreceptor Drawer has just been installed, ensure that the guides on the Pre- able levels. Advise the customer of any problems (Printer Specifications, Section 4).
transfer Baffle, the Prefuser Transport, and the Photoreceptor Stripper Fingers are all in Check for loss of the PR Ground Brush circuit. If the wires to the Ground Brush are open, and
the operating position. the Ground Brush fibers "flare" and contact the PR Module frame, an arc can cause a noise
• Ensure that the paper is within the Printer Specifications. Excessive curl or high humidity, spike greater than 2 volts at TS17 on the MIN DIO PWB. Voltage can be measured during
specifically with light-weight papers, will increase problem occurrences. dC606 operation using the negative peak hold.
• Check the condition and routing of the Belt Hole Sensor LED (CR901) wires. Ensure that
the insulation of the gray wire to connector M13 is not worn through and intermittently
touching the P/R Belt Cleaner Roll.
NOTE: Check [SCP] Queued Faults and [Faults] [Last 50]. If 9-201, 9-327, 9-328, or 9-329
faults are indicated, and this RAP does not fix the problem, go to the RAP for those fault codes.
Procedure
Enter dC330, [9]. Open the Printer front doors. Slide the Photoreceptor Drawer partially out of
the Printer. Manually actuate the POP Sensor with a sheet of paper. The display changes
from H to L.
Y N
Go to Flag 1. Check the circuit of the POP Sensor, Q904. (GP 6-2, General Procedures).
Clear any paper from the POP Sensor. Slide the Photoreceptor Drawer into the Printer. Enter
dC140, Tests [Dicorotron Values]. Observe the Dtac Shld Current displays. Press Con-
tinue. The Dtac SI Monitor is within +/- 0.5 of the Control Point V.
Y N
Press Stop. Clean the Detack Dicorotron Shield. Replace the Detack Dicorotron if the
coronode wire is contaminated (PL 9.11). Reinstall the Detack Dicorotron. Clean the
Dicorotron Connectors. Press Continue. The Dtac SI Monitor is within +/- 0.5 of the
Control Point V.
Y N
Replace the Detack Dicorotron and/or the HVDC PWB (PL 9.11).
Run prints in the customer failure mode. If the 9-101/102 problem continues, restart this
RAP procedure.
Press Stop. Locate the HVDC Calibration Tag. Enter dC314, [DC PWB (10-18)]. The Trans-
fer Current Control (TRANS$$SI) Current value and the Detack Current Control
(DTAC$$SI) Current value are equal to the values on the HVDC PWB Calibration Tag.
Y N
Enter the correct calibration values. Run prints in the customer failure mode. If the 9-101/
102 problem continues, check the following components. Repair or replace the compo-
nents as required.
• Pretransfer Baffle (PL 8.8).
• Stripper Fingers (PL 9.3).
A

9-201 RAP Y N
(Arc Simulation or Arc Detection Circuitry problem). Enable Arc Simulation. Enter
Fault Code, 9-201, indicates that a High Voltage Power Supply arc was detected. Either the dC131 [MIN]. Enter Address 179. Enter the current Data value recorded for Address 179.
Arc Detection Simulation did not function properly, the Arc Detection Circuitry did not function Enable ROS Faults. Enter Address 125. Enter the current Data value recorded for
properly, or the Arc Detection Circuitry detected a High Voltage Arc. Address 125. +5 VDC is measured between TP4 (+) and TP1 (-) of the HVAC PWB.
Y N
The 9-201 fault descriptions below correlate with the data value in NVM dC131 [MIN]. Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the HVAC PWB
Addresses 441 and 442. Address 441 indicates the cause of the current fault, and address 442 (PL 1.7).
indicates the cause of the previous fault.
Enter dC131 [MIN]. Enter Address 146. Add 15 to the current Data value recorded for
Initial Actions Address 146. Enter this temporary Data value at Address 146. (Dicor ACV Ref) Increased
This RAP requires that temporary changes be made to the NVM values at certain Address to produce Arc Simulation failures. Enter dC140, [Dicorotron Values]. Observe the
Coronode ACV displays. The ACV Monitor is within +/- 0.3 of the Control Point V and
locations. Enter dC131 and record the current MIN NVM values at the following locations.
the ACI Monitor is greater than 2.0 VDC.
Y N
Table 1 MIN Check
Enter dC314. Obtain the AC and DC PWB calibration cards. The AC PWB AND DC
MIN Address Current Value PWB values entered in dC314 are correct.
125 Y N
Enter the correct calibration values. Enter dC951, [Initialize]. Press Continue.
146
When initialization is completed, enter dC606. Program a 200 print job. Press
179 Continue. If a 9-201 fault is declared, return to the beginning of this procedure.
• Wipe the DSS clean using anti-static solution (8R90275) with a clean, soft, lint free cloth. Replace the HVAC Output Module (PL 1.7).
• Check the Photoreceptor Ground Brush for loose and/or frayed fibers. Pinch the fibers
with thumb and finger pulling on the fibers. If any fibers dislodge, vacuum the area, Greater than 10 VDC is measured between TP9 (+) and TP1 (-) of the HVAC PWB.
replace the Ground Brush (PL 9.7). Y N
• Inspect the Dicorotrons during operation. Replace the dicorotron if arcing is observed. Disconnect J4/P214 at MIN ADA PWB #1. Greater than 10 VDC is measured
between TP9 (+) and TP1 (-) on the HVAC PWB #1.
NOTE: If after using this RAP the problem continues, go to the Additional Diagnostic Checks Y N
located at the end of this RAP procedure. Go to Flag 6. Check the wires for a short circuit. If the wire is ok, replace the
HVAC PWB (PL 1.7).
Procedure
NOTE: Ensure that a record is made of all NVM values that are being changed prior to the Replace the MIN ADA PWB #1 (PL 1.8).
change. Ensure that all values changed during troubleshooting are reset back to their original
values prior to completion of the service call. Enter dC606. Press Continue. Measure AC voltage. There is 2.5 +/- 0.5 VAC mea-
sured between TP8 and TP1 of the HVAC PWB.
Enter dC131 [MIN]. Enter Address 125. Subtract 16 from the current Data value recorded for Y N
Address 125. Enter this temporary Data value at Address 125. This temporary value at MIN Go to Flag 5. Check for a short circuit.
address 125 disables 6-xxx ROS Faults for diagnostics.
Enter [MIN] Address 179. Subtract 128 (w/ 19.XX Level Software) from or Add 128 (w/ Measure DC voltage. +15 VDC measured between TP20 (+) and TP1 (-) of the HVAC
10.XX Level Software) to the current Data value recorded for Address 179. Enter this tempo- PWB.
rary Data value at Address 179. This temporary Data value at address 179, disables Arc Simu- Y N
lation at power up. This is a Fault Masking address for diagnostics. Replace the HVAC PWB (PL 1.7).
NOTE: In this procedure different portions of the circuit will be isolated. During dC606 opera-
+15 VDC measured between TP20 (+) and TS56 (-) of the MIN ADA PWB #1.
tion, faults will be produced. A 9-201 fault will indicate arcing, a 9-326 fault will indicate no arc-
Y N
ing in that portion of the circuit being checked. It will be necessary to clear the faults by
Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA
pressing the R (Reset) button after each occurrence between checks.
PWB #1 (PL 1.8).
Enter dC606. Press Continue. A 9-201 fault occurs. (Answer, Yes to the following state-
ment if the problem is intermittent). Go to Flag 3. Check for an open or a short circuit to ground. If the circuits are OK, replace
the MIN ADA PWB #1 (PL 1.8).
A
A B
(Actual HV Arc detected. Potential cause of MIN address 441=10). Enable Arc Simulation. Y N
Enter dC131 [MIN]. Enter Address 179. Enter the current Data value recorded for Address Go to Flag 1. Check for a short circuit. If the circuit is Ok, replace the HVAC PWB
179. Disconnect the HVAC Output Module Twist Lock Connector. Pull the HVDC PWB out to (PL 1.7).
disconnect the HV Cable Connector. Ensure that the Ribbon Cable between the HVDC and the
HVAC PWB remains connected. Replace the MIN ADA PWB #1 (PL 1.8).
CAUTION
Ensure that the HVAC connector is secured away from the drives to prevent damage. -15 VDC is measured between (J1) P294-6 (+) and TP1 (-) of the HVAC PWB.
Enter dC606. Press Continue. A 9-201 fault code is displayed immediately. Y N
Y N Enable ROS Faults. Enter dC131 [MIN]. Enter Address 125. Enter the current Data value
recorded for Address 125. Go to wire, 1010H, wirenet. Check for an open circuit.
(High Voltage Arc problem). Reconnect the HVDC PWB and the HVAC Output Module
Twist Lock Connector. Check the HVDC Cables and connections for arcing. Ensure that
they are not against any metal that could cause arcing. Replace the HV Harness if dam- +5 VDC is measured between TP4 (+) and TP1 (-) of the HVAC PWB.
Y N
aged (PL 1.7).
Enter [dC] [Power Interrupt]. Disconnect the wire at (J2) P238-13 of the HVAC PWB.
NOTE: One at a time, remove each dicorotron and observe the pin/socket for contamina- Press Continue. +5 VDC is measured between TS19 (+) and TS37 (-) of the MIN DIO
tion and/or discoloration that indicates arcing. Yellow, brown, and/or gray residue on the PWB.
wires and/or metal near wires is an indication of arcing spots. Cracks or nicks in the wires Y N
will also cause arcing. After inspection return the dicorotron to it's rail but do not push in Reconnect the wire at (J2) P238-13 of the HVAC PWB. Enable ROS Faults. Enter
completely. dC131 [MIN]. Enter Address 125. Enter the current Data value recorded for Address
125. Replace the MIN DIO PWB (PL 1.8).
NOTE: It may be necessary to press Continue several times to produce an arc.
Cheat the Printer Interlock Bypass Switch. Slide all Dicorotrons and Shields out about 2 Reconnect the wire at (J2) P238-13 of the HVAC PWB. Enter dC606. Press Continue. A
inches to disconnect HVAC and HVDC. Enter dC606. Press Continue. A 9-326 fault 9-201 fault code is displayed.
code is displayed. Y N
Y N Enable ROS Faults. Enter dC131 [MIN]. Enter Address 125. Enter the current Data
(A 9-201 fault code is displayed). Enable ROS Faults. Enter dC131 [MIN]. Enter value recorded for Address 125. Go to Flag 2. Check for a short circuit. If the circuit
Address 125. Enter the current Data value recorded for Address 125. Remove the is OK, replace the HVAC PWB (PL 1.7).
HVAC Output Module and inspect for arcing, (white film on wires). If arcing is
observed, replace the HVAC Output Module (PL 1.7). Enable ROS Faults. Enter dC131 [MIN]. Enter Address 125. Enter the current Data value
• All Dicorotrons (PL 9.10). recorded for Address 125. Go to Flag 5. Check for an open circuit. If the circuit is OK,
replace the HVAC Output Module and/or the HVAC PWB (PL 1.7).
• HVAC Output Module (PL 1.7).
• HVAC PWB (PL 1.7).
Enable ROS Faults. Enter dC131 [MIN]. Enter address 125. Enter the current Data value
• MIN ADA PWB #1 (PL 1.8). recorded for Address 125. -34 VDC is measured between P294-2 (+) and P294-10 (-) of the
• MIN DIO PWB (PL 1.8). HVAC PWB.
• Ozac System and connectors (PL 9.8). Y N
Go to wires, 1019 and 1020 wirenets. Check for an open circuit.
Enable ROS Faults. Enter dC131 [MIN]. Enter Address 125. Enter the current Data value
recorded for Address 125. Test the individual dicorotrons. Install each dicorotron into the Go to Flag 3. Check for a short circuit. Go to Flag 4. Check for an open circuit. Remove the
Transfer position. Run dC606 for each dicorotron. If a 9-327 fault occurs the dicorotron is HVAC Output Module and inspect for arcing, (white film on wires). If arcing is found, replace
OK. Return that dicorotron to its original position, do not completely install yet. If a 9-201 the HVAC Output Module and/or the HVAC PWB (PL 1.7).
fault occurs the dicorotron has failed. Replace that Dicorotron (PL 9.10). • All Dicorotrons (PL 9.10).
• HVAC Output Module (PL 1.7).
(Arc Detection Circuitry problem. Potential cause of MIN address 441=4, 5, or 6). Enter • HVAC PWB (PL 1.7).
[dC] [Power Interrupt]. Reconnect the HVDC PWB and the HVAC Output Module Twist
• MIN ADA PWB #1 (PL 1.8).
Lock Connector. Press Continue. +15 VDC is measured between TP20 (+) and TP1 (-) of
the HVAC PWB. • MIN DIO PWB (PL 1.8).
Y N Additional Diagnostic Checks:
Enable ROS Faults. Enter dC131 [MIN]. Enter Address 125. Enter the current Data value To be used after using the RAP Procedure. The list that follows contains problems, which are
recorded for Address 125. Disconnect P214 (J4) of the MIN ADA PWB #1. +15 VDC is not covered in the RAP Procedure, which have been infrequent, and which have caused long
measured between TP20 (+) and TP1 (-) of the HVAC PWB. service calls.
B
• Run the Printer while the Transfer Assist Device is unplugged. Check for pinched wires.
• Incorrect ID on the PHN DIO #2. Causes a +24 VDC line problem.
• +/- 15 VDC and +34 VDC to the HVAC PWB. Intermittents or bad board.
• Replace the Drawer Roll Up Ribbon Cable (PL 9.1).
• Check for an intermittent -15 VDC at MIN ADA PWB #2. See Flag 1 of the circuit diagram
for the 9-203, 9-213 RAP.
• Check the +24 VDC input to the HVAC PWB at (J1-1). This voltage should not drop below
23.5 VDC.

9-202 RAP

A B
Measure between TS37 (+) and TS38 (-) of the MIN ADA PWB #2. Enter dC606. Press Con-
Fault Code, 9-202, indicates that the Coronode AC Voltage Setpoint is at or outside the preset
limits during the print cycle. This fault is logged for future service. The Printer does not shut tinue. Greater than 0.5 VDC is measured.
down. Y N
Press Stop. Measure between TP103 (+) and TP2 (-) of the HVDC PWB. Press Con-
tinue. Greater than 0.5 VDC is measured.
Initial Actions Y N
• Enter SCP [Faults] [Last 50]. If 9-329 faults are indicated, go to the 9-329 RAP first. Press Stop. Disconnect the wire from (J5) P200-16.Measure between TP103 (+)
• Enter dC131 [MIN]. Ensure Addresses 353 and 354 are at the values given in appropriate and TP2 (-) of the HVDC PWB. Press Continue. Greater than 0.5 VDC is mea-
level Software dC 131 Table in General Procedures. sured.
Y N
NOTE: Address 353 is the ACV Factor, address 354 is the ACV deadband.
Reconnect the wire to (J5) P200-16. Replace the HVDC PWB (PL 1.8).
• Ensure that the Cleaner Zone Roll is in the operating position.
Reconnect the wire to (J5) P200-16. Go to Flag 2. Check for a short circuit.
Inspect for open circuits, loose connections, contamination, arcing and discoloration of the fol-
lowing:
Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2
(PL 1.7).
• Dicorotrons and connectors (PL 9.10).
• Ozac Duct and connectors (PL 9.8).
Press Stop. Measure between TS35 (+) and TS36 (-) of the MIN ADA PWB #2. Press Con-
• HVDC Cables (PL 1.7). tinue. Greater than 0.5 VDC is measured.
If either of the Charge Dicorotrons have been replaced, check the Charge Dicorotron Balance Y N
(ADJ 9-6) and Charge Dicorotron Height (ADJ 9-7). Press Stop. Measure between TP102 (+) and TP2 (-) of the HVDC PWB. Press Con-
tinue. Greater than 0.5 VDC is measured.
Procedure Y N
Enter dC140, [Dicorotron Values]. Observe the Coronode ACV display. Press Continue. Disconnect the wire from (J5) P200-2. Press Continue. Greater than 0.5 VDC is
measured between TP102 (+) and TP2 (-) of the HVDC PWB.
The ACV Monitor is within +/- 0.5 of the Control Point V.
Y N Y N
The voltage measured between TS27 (+) and TS28 (-) on the MIN ADA PWB #1 is Reconnect the wire to (J5) P200-2. Replace the HVDC PWB (PL 1.8).
within +/- 0.5 VDC of the ACV Monitor display.
Y N Reconnect the wire to (J5) P200-2. Go to Flag 3. Check for a short circuit.
Go to Flag 1. Check for an open or a short circuit. If the circuit is OK, replace the
Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2
HVAC PWB (PL 1.7).
(PL 1.7).
Press Stop. Clean the Charge Dicorotrons Shields. Replace any dicorotron if the coronode
wire is contaminated. Enter dC951, [Initialize]. Press Continue. Observe the ACV setpoint.
The ACV Setpoint Current Reading is between the Target Readings range.
Y N
Replace both Charge Dicorotrons and Shields (PL 9.10).
Enter dC951, [Initialize]. Observe the ACV setpoint. Press Continue. The ACV Set-
point Current Reading is between the Target Readings range.
Y N
Press Stop. Measure between TS35 (+) and TS36 (-) of the MIN ADA PWB #2.
Press Continue. Greater than 0 VDC is measured.
Y N
Go to Flag 3. Check the wires for an open or a short circuit. If the circuit is OK,
replace the HVDC PWB (PL 1.7).
Fault has been repaired, exit this procedure.

A B
Figure 1 9-202 Circuit Diagram (7903E)
9-203, 9-213 RAP

• Step 14f: ROS Low Correction Factor (ADJ 6-3)
NOTE: Fault code, 9-203, is often caused by failed or out of adjustment xerographic compo-
nents (ESV, DSS, Erase Lamps, etc.). NOTE: The electrical life of a P/R in the 4180 is normally around 2 million prints. However, its
useful life is reduced due to mechanical wear, spots, chemical contamination (OZAC) etc.
Fault Code, 9-203, indicates a Photoreceptor Belt failure (End of life). Either the initial Charge,
(Vo), is at it's maximum value of 1500 volts, or the Dark Decay value exceeds the NVM Dark If the problem continues, try a Photoreceptor from a different batch.
Decay Breakpoint Value of 700 volts, or the Dark Decay Index Limit, DDI End, is reached. The
5 fault descriptions below correlate with the data value in NVM dC131 [MIN]. Addresses 385 Enter SCP [HFSI] [Dicorotrons]. If any Dicorotron or Shield, 09-815 through 09-824 is at or
and 386. Address 385 indicates the cause of the current fault, and address 386 indicates the near service intervals as listed in the HFSI TABLES, replace.
cause of the previous fault.
Ensure that the correct Dicorotron is being used in the proper location.
1. Either the initial charge, (Vo), is at its maximum value of 1,500 volts, or the Dark Decay
value exceeds the NVM Dark Decay Breakpoint value of 700 volts. Ensure that the Charge Dicorotron Height (ADJ 9-7) and Charge Dicorotron Balance (ADJ 9-6)
2. The current value for Vddp Setpoint has reached a maximum value of 255 Bits. are correct.
3. The current value for Exposure Setpoint has reached a maximum value 255 Bits.
NOTE: Excessive removal of the Dicorotron housings, (not shields), can cause premature fail-
4. The current value for Rolls 1 & 2 Developer Bias Setpoint has reached a maximum value ure of the dicorotron and/or connectors. Do not remove the dicorotrons for cleaning or inspec-
of 255 Bits. tion unless directed to do so by HFSI requirements or RAP diagnostics.
5. The current value for Roll 3 Developer Bias Setpoint has reached a current maximum
value of 255 Bits. Dicorotrons: Inspect the circuits for open or loose connections. Check for contamination, arc-
ing, and discoloration of the Dicorotrons, Shields, and connectors (PL 9.10).
Fault Code, 9-213, indicates an ESV failure. The 6 fault descriptions below correlate with the
data value in NVM dC131 [MIN]. Addresses 443 and 444. Address 443 indicates the cause of
NOTE: Inspect the Dicorotrons and Shields, and their circuits thoroughly. High voltage arcing
the current fault, and address 444 indicates the cause of the previous fault.
through these components is a major contributor to this fault.
1. The Dark Decay Intercept is less than 0 or greater than 35 bits. Ensure that the Patch Generator is positioned correctly on the mounting pins, and that the ESV
2. The Dark Decay Low is greater than the Dark Decay High, and their difference is greater is not skewed. Clean the ESV and Patch Generator with a clean, soft, dry cloth. Perform the
than 10 bits. ESV Height Adjustment (ADJ 9-12).
3. During the Power Up Sequence or the Initialization Procedure the ESV Monitor is less
Go to dC 909 and perform the [ESV-DSS Test].
than 0.8 Volts (21 bits) or greater than 1.4 Volts (35 bits) or the Dark Decay Intercept is
greater than 35 bits.
Ensure that the ROS Assembly is correctly positioned, not skewed on the rails. Check the ROS
4. The ESV Offset is greater than +/-5 bits.
Low Correction Factor (ADJ 6-3).
5. The ESV reading is less than 61 volts, and the ESV error is greater than 118 volts >20
BITS on two consecutive VDDP patches. Locate the HVAC and HVDC calibration tags. Enter dC314. Ensure that all AC PWB and DC
6. The ESV reading is more than 300 Volts above the CHG 2 Shld bias on two consecutive PWB Power Supply Calibration Values programmed, match the calibration tag values for those
VDDP patches. PWBs.
Initial Actions
Ensure that the covers and inner panels are on.
Enter dC105, ensure [F10] is Deselected,
NOTE: If this RAP does not fix the problem or electrical noise is suspected go to the Non-
Verify Erase Lamp operation and PR Brush integrity.
Repeatable Problem Entry Procedure (Service Call Procedures).
NOTE: In some software versions the dC107 counter had the units incorrectly labeled as Procedure
pitches, the counter actually counts P/R Belt revolutions.
WARNING
Enter dC107, [Xero]. Replace the P/R Belt if greater than 100K revolutions (700K pitches) (PL Laser Radiation. Avoid direct exposure to the beam. The ROS can and will reflect off the
9.1). If less than 700 pitches, do not replace the PR Belt. Perform a complete Xerographic photoreceptor belt. DO NOT look down into the machine from the top with the machine
Setup (ADJ 9-3). Pay special attention to the following: top cover and the ROS safety cover removed.
Cover the Photoreceptor, under the ROS Assembly, inboard to outboard with white paper.
• Step 1: All HFSI Actions as listed in the HFSI TABLES
Cheat the Printer Interlock Bypass Switch. Enter dC330, [6]. Select [Laser Write]. Press Con-
• Step 12: Charge Dicor Balance (ADJ 9-6) tinue. Observe the scan line on the paper. There is a continuous scan line across the
• Step 14e: dC314 Power Supply Cal paper.

Y N Table 1 MIN NVM
Address Current Value Description
NOTE: Scan line observations are easily made using the Remote Hand Held Device (RHHD). 353 ACV Factor
For detailed Operating Instructions of the RHHD, go to (GP 1). 354 ACV Slope Convergence
The scan line is of equal brilliance across the entire length of paper.
Y N (HVDC PWB leakage check.) Enter dC140, [Dicorotron Values]. Press Start. After 10 sec-
onds all the dicorotron values should be stable. Open the Printer Right Front Door to interrupt
operation. Observe the Dicorotron Monitor Voltages for 30 seconds. The Monitor values
Keep [Laser Write] energized. Select [Patch Exposure]. The inboard half of the beam should cycle down to less than 0.3 after 30 seconds.
Y N
become dimmer than the outboard. Press Continue.
HVDC PWB leakage problem, replace the HVDC PWB (PL 1.7).
NOTE: Toggle the output on/off several times while observing the scan line if you are unsure of
the above check. Clear the faults and press Continue. Observe the Chg 2 Shld Voltage display. The Control
Point V and the Chg 2 SV Monitor are less than 9.5.
The scan line is dimmer on the inboard side.
Y N
Y N
Replace the appropriate Dicorotron and Shield (PL 9.10).
Observe the Pcln Shld Current display. The Control Point V and the Pcln SI Monitor are
Press Stop. Select [Laser Write] [Patch Enable]. Press Continue. The scan line is com-
less than 9.5.
pletely off in the patch area.
Y N
Y N
Replace the Preclean Dicorotron and Shield (PL 9.10).
Enter dC951, [Initialize]. Press Continue. Observe the dC951 Screen. The ESV Monitor
CAUTION
Current Reading is less than 36.
Ensure that all paper is removed from under the ROS Assembly to avoid Printer damage dur- Y N
ing operation. (Potential cause for MIN NVM 443=3.) Switch off Printer power. Clean the ESV with a
Exit dC330. Remove the paper from the Photoreceptor. Close the Printer Front Doors. -15 soft, dry, clean cloth. Check the air lines to the ESV. Perform the ESV Height Adjustment
VDC is measured between P293-6 (+) and TP-2 (-) of the HVDC PWB. (ADJ 9-12).
Y N If the problem continues, go to PQ 9-619, ESV RAP, and PQ 9-618, PR Ground RAP. If
-15 VDC is measured between TH7 (+) and TH8 (-) on the LVPS. the problem continues, replace the HVDC PWB (PL 1.7).
Y N
Go to the 1-716 RAP. Observe the dC951 Screen. If a random number less than 22 is displayed answer no. The
ESV Monitor Current Reading is always greater than 21 bits.
Go to wire 1010F, wirenet. Y N
(Potential cause for MIN NVM 443=3.) Enter dC909, [ESV-DSS]. The ESV Monitor
-15 VDC is measured between TS55 (+) and TS56 (-) of the MIN ADA PWB #2 reading is 1 +/- 0.2 volts.
Y N Y N
Go to Flag 1. Check wire 1010D for an open circuit. If the wire is Ok, replace the MIN ADA Clean the ESV and Patch Generator again. Enter dC909, [ESV-DSS]. If the ESV
PWB #2 (PL 1.8). Monitor reading is not 1 +/- 0.2 volts, replace the ESV Assembly (PL 1.7).
Enter dC131 [MIN]. Ensure that the following MIN NVM Addresses are at the values as listed Enter dC106. +5 VDC is measured between TS7 (+) and TS20 (-) of the MIB PWB #1.
in the appropriate level Software dC 131 Table in General Procedures. Y N
Disconnect the J2 connector at the MIB PWB #1. +5 VDC is measured between
Table 1 MIN NVM TS7 (+) and TS20 (-) of the MIB PWB #1.
Address Current Value Description Y N
Replace the MIB PWB #1 (PL 1.8).
179 Arc Simulation/Fault Mask
223 Dicorotron AC Target Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB
260 ESV Adjust (PL 1.8).
285 Patch Location
A
A B C
+15 VDC is measured between TS12 (+) and TS20 (-) of the MIB PWB #1. Go to Flag 4. Check for an open or a short circuit. If the circuit is OK, replace the HVDC
Y N PWB and/or the HVAC PWB (PL 1.7).
Disconnect the J2 connector of the MIB PWB #1. +15 VDC is measured between
the disconnected wire P211-13 (+) and TS20 (-) of the MIB PWB #1. Enter dC909. Select [Charge Control], [Open], [Print Patch], [Yes]. Program a 50 print job.
Y N Press Continue. Record the value of the dC909 Dark Decay V for future reference, after prints
+24 VDC is measured between P205-7 (+) and P205-6 (-) of the ESV Power are completed.
Supply.
NOTE: If faults occur and no reading is displayed in dC909 or dC912, go to PQ 9-621, Patch
Y N
Go to wires 1038B and 1039B wirenets. Check for an open circuit. Gen/Patch Integrity RAP.
A Patch is printed.
Go to Flag 5. Check for a short circuit. If the circuit is OK, replace the ESV Y N
Power Supply (PL 1.7). Go to PQ 9-621, Patch Gen/Patch Integrity RAP.
Replace the MIB PWB (PL 1.8). Enter dC912. Press Continue. The All Panels (Range) is less than 70 VDC.
Y N
Replace the Charge Dicorotrons and Shields (PL 9.10). Go to the PQ 9-633, PR Belt Uniformity RAP.
Observe the dC951 Screen. The Hi Charge Dark Decay is less than 30. Look at the dC909 Dark Decay V previously recorded. The recorded dC909 Dark Decay V is
Y N within 50 VDC of the dC912 Dark Decay Volts.
Open the Printer Front Doors. Cheat the Door Interlocks. Enter dC330, [9]. Select [Pre- Y N
Charge/Prexfr Lamps]. Press Continue. All segments on the Precharge Lamp and +15 VDC is measured between TS12 (+) and TS20 (-) of the MIB PWB.
the Pretransfer Lamp are lit. Y N
Y N Go to Flag 5. Check for an open circuit. If the circuit is Ok, replace the ESV Power
Go to PQ 9-624, Precharge/Pretransfer Lamp RAP. Supply (PL 1.7).
Enter dC909. Select [Charge Control], [Open Loop]. Press Continue. An Image is +5 VDC is measured between TS43 (+) and TS37 (-) of the MIN DIO PWB.
present on the prints. Y N
Y N Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the MIB PWB (PL
Go to Flag 3. Check for an open circuit. Ensure that the Endblock Tab is making a 1.8).
good connection with the Shield. If the circuit is OK, replace the Charge Dicorotrons
and Shields (PL 9.10). Go to the PQ 9-621, Patch Gen/Patch Integrity RAP.
If the problem still exists, replace the following as required
• HVDC PWB (PL 1.7). The dC912 Dark Decay Volts is less than 225 VDC.
• HVAC PWB (PL 1.7). Y N
• High Voltage Output Module (PL 1.7). Compare the printed patch to the DK:UM density on the XTP 564.001 (82E4161) test pat-
tern. The exact density is not critical. The prints have a patch nearly as dark as the
Ensure that the DC Leads of the Charge Dicorotrons are connected to the proper DK:UM.
dicorotron. If the problem continues, go to PQ 9-619, ESV RAP. Y N
Go to PQ 9-621, Patch Gen/Patch Integrity RAP.
Observe the dC951 Screen. The Lo Charge Dark Decay reading is less than 28 or greater
than 0, and the Dark Decay Intercept is less than 35 or greater than 0. Go to PQ 9-618, PR Ground RAP.
Y N
Replace the Charge Dicorotrons and Shields (PL 9.10). If 9-213 fault codes still recur, perform the following:
• Replace the Photoreceptor Belt (PL 9.1).
Observe the dC951 Screen. The ACV Setpoint reading is less than 245. • Run Initialization.
Y N • Clean the POP Sensor.
Enter dC909. Select [Charge Control], [Open]. Press Continue. The prints are blank.
• Clean the DSS. Use anti-static solution (8R90275) with a clean, soft, lint-free cloth.
Y N
Replace the Charge Dicorotrons and Shields (PL 9.10). • Replace the Developer Material.
B C D
D
• Reaching this point indicates proper printer operation. If there are continued problems,
and electrical noise is suspected go to the Printer Electrical Noise Procedure NRD 3, or
the Non-Repeatable Problem Entry Procedure NRD 1 (Service Call Procedures).


9-211 RAP
Fault Code, 9-211, indicates a Patch Generator failure. The Patch Generator cannot generate
the current required to produce the correct light output.
Procedure
CAUTION
DO NOT install an analog Patch Generator into a 4180 machine, damage to the MIN DIO PWB
will result. 4180 machines use a digital Patch Generator.
CAUTION
The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to
under two (2) minutes. DO NOT leave the Patch Generator energized in dC330 for longer than
two (2) minutes or severe xerographic problems may result. If the belt module will be exposed
to light for longer than two minutes, remove the photoreceptor from the belt module and place
it immediately into the protective photoreceptor bag. or place the bag over the Photoreceptor
with it on the belt module.
Clear the fault. Enter dC330, [9]. The Patch Generator Failure Detector display is H.
Y N
Disconnect P240/J1 at the Patch Generator. The display is H.
Y N
Connect P240. Disconnect P249/J6 at the MIN DIO PWB. The display is H.
Y N
Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the Patch Genera-
tor (PL 9.10).
Replace the Patch Generator (PL 9.10).
Select [Patch Gen High (pulsed)]. Press Continue. The Patch Generator Failure Detect
display goes L.
Y N
Go to Flag 1. Check for an intermittent short circuit. If no broken insulation or no intermit-
tent short circuit is found, replace the Patch Generator (PL 9.10).


A
9-212 RAP Y N
Fault Code, 9-212, indicates a DSS failure. The reflectance of a clean patch is less than 75%,
or more than 10%, of the reflectance of a normal clean patch. This fault will occur if the DSS Press Stop. Select [Laser Write] [Patch Enable]. Press Continue. The scan line is com-
Monitor signal is less than 25 for three or more consecutive reads, or during Power Up Conver- pletely off in the patch area.
gence the clean belt reading is not 232 +/-14 after five attempts. Y N
Initial Actions
Pull out the Xerographic Drawer. Check the Photoreceptor Ground Brush for contamination CAUTION
and/or deformation (PL 9.7). Ensure that all paper is removed from under the ROS Assembly to avoid Printer damage dur-
ing operation.
CAUTION Exit dC330. Remove the paper from the Photoreceptor. Close the Printer Front Doors. -15
Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox VDC is measured between P293-6 (+) and TP-2 (-) of the HVDC PWB.
anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV Y N
should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before clean- -15 VDC is measured between TH7 (+) and TH8 (-) on the LVPS.
ing the ESV and DSS. The Printer will perform a Power Up Sequence when the power is Y N
switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are Go to the 1-716 RAP.
performed with the components clean.
Check the ROS Low Correction Factor (ADJ 6-3). Go to wire 1010F, wirenet.
Enter dC909, [ESV-DSS Test]. Observe variations during five DSS Recalibrations. Press
Clean the DSS. Ensure that the Photoreceptor Belt over the DSS is clean. Enter dC909, [ESV-
DSS Tests]. Select [DSS Recalibrate]. Select [Patch Test] and press Continue. This will [DSS Recalibrate] record the value each time. The DSS Reading is 232 +/- 12 after each
force a power up sequence to establish the new DSS calibration value. If experiencing multiple recalibration, and the variation between any of the readings does not exceed 6.
Y N
occurrences of DSS failures (replacements), go to Multiple DSS Failures at the end of this
RAP. +15 VDC is measured between IRD-5 (+) and IRD-2 (-) at the DSS.
Y N
+15 VDC is measured between IRD-5 (+) at the DSS and machine frame (-).
Procedure Y N
WARNING +15 VDC is measured between TH6 (+) and TH8 (-) at the LVPS.
Laser Radiation. Avoid direct exposure to the beam. Y N
Cover the Photoreceptor, under the ROS Assembly, inboard to outboard with white paper. Go to the 1-715 RAP.
Go to Flag 4. Check the wire 1009N and 1009P, wirenets for an open circuit.
tinue. Observe the scan line on the paper. There is a continuous scan line across the
paper.
Y N Go to Flag 5. Check the wire, 1008P, wirenet for an open circuit.
+15 VDC is measured between IRD-6 (+) and IRD-2 (-) of the DSS.
NOTE: Scan line observations are easily made using the Remote Hand Held Device (RHHD). Y N
Go to Flag 4. Check the wire, 1009N, wirenet for an open circuit.
For detailed Operating Instructions of the RHHD, go to (GP 1).
The scan line is of equal brilliance across the entire length of paper. Greater than +3.0 VDC is measured between TS24 (+) and TS37 (-) of the MIN DIO
Y N PWB.
Go to the 6-701 RAP. Y N
Disconnect the wire from P249-27. 5 VDC is measured between TS24 (+) and
Keep [Laser Write] is energized. Select [Patch Exposure]. The inboard half of the beam TS37 (-) of the MIN DIO PWB.
should become dimmer than the outboard. Press Continue. Y N
the above check.
Go to Flag 6. Check for a short circuit. If the circuit is OK, replace the DSS (PL 9.7).
+15 +/-.75 VDC is measured between TS10 (+) and TS56 (-) of the MIN ADA PWB #1.
A B C
B C
Y N CAUTION
Disconnect the wire at P214-17, (J4) of the MIN ADA PWB #1. 4.0 to 5.5 VDC is The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to
measured between TS10 (+) and TS56 (-) the MIN ADA PWB #1. under two (2) minutes. If the belt module will be exposed to light for longer than two minutes,
Y N remove the photoreceptor from the belt module and place it immediately into the protective
Go to Flag 3. Check for a short circuit and replace the DSS (PL 9.7). photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module.
Open the Front Doors. Pull out the Photoreceptor Drawer. Raise the Photoreceptor Module at
Go to Flag 3. Check for an open or a short circuit. If the circuit is OK, replace the
least 30 degrees from the horizontal and leave it there. The DSS Reading is less than 50.
DSS (PL 9.7).
Y N
Replace the DSS (PL 9.7).
Greater than +1.0 VDC is measured between TS51 (+) and TS56 (-) of the MIN ADA
PWB #1.
Select [DSS Recalibrate]. A 9-212 fault code is declared.
Y N
Y N
Disconnect the wire at P206-1 (J7) of the MIN ADA PWB #1. Greater than +1 VDC
+15 VDC is measured between TS8 (+) and TS56 (-) of the MIN ADA PWB #1.
is measured between the disconnected wire and TS56 (-) of the MIN ADA PWB
Y N
#1.
Go to Flag 2. Check for an open or short circuit. If the circuit is OK, replace the DSS
Y N
(PL 9.7).
Go to Flag 1. Check for an open or a short circuit. If the circuit is OK, replace
the DSS (PL 9.7).
Select [DSS Recalibrate]. Use Pulse Detection (Procedure at the end of this RAP). A
negative going pulse is measured between TS8 (+) and TS56 (-) of the MIN ADA
PWB #1 every time the DSS Recalibrate button is pressed.
Y N
Use Pulse Detection. (The procedure is at the end of this RAP). A negative going pulse
is measured approximately every 2 seconds between TS10 (+) and TS56 (-) of the
MIN ADA PWB #1.
Y N
Go to Flag 6. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB (PL 1.8).
If the above checks are OK, go to PQ 9-619, ESV RAP.
+15 is measured between TS8 (+) and TS56 (-) the MIN ADA PWB #1.
If the problem continues, go to the Multiple DSS Failures checklist at the end of this proce-
Y N
dure.
Disconnect the wire at P214-19, (J4) of the MIN ADA PWB #1. 4.0 to 5.5 VDC is
DMM Pulse Detection Procedure:
measured between TS8 (+) and TS56 (-) the MIN ADA PWB #1.
• Meter Probes in the Volt-Ohm (+) and the COM (-) Jacks
Y N
Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the DSS (PL • Press in the Ohm Button.
9.7). • Press in the 200K Button.
• Press in the AC Button if Audible Pulse Detection is desired.
Go to Flag 2. Check for an open or a short circuit. If the circuit is OK, replace the For the negative going pulses measured in this RAP:
DSS (PL 9.7). • The UP Arrow will be displayed.
• The DOWN Arrow will Flash with the negative going pulses.
Select [DSS Recalibrate]. Use Pulse Detection. A negative going pulse is measured
between TS8 (+) and TS56 (-) of the MIN ADA PWB #1 every time the DSS Recali- • If the Audible Pulse Detection is used, a BEEP will be heard when the Down Arrow
Flashes.
brate button is pressed.
Y N CAUTION
Replace the MIN ADA PWB #1 (PL 1.8). Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox
anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV
Replace the DSS (PL 9.7). should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before clean-
ing the ESV and DSS. The Printer will perform a Power Up Sequence when the power is
switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are
Multiple DSS Failures
• Ensure that the Photoreceptor Ground Strip is not damaged.

• Ensure that there is a CP Connector by the DSS. If the CP Connector is not by the DSS,
go to the ADA PWB #1 and find the CP Connector by J7. Remove the CP Connector and
disconnect the wire at P206-3 (J7) of the ADA PWB #1. Connect the CP Connector by the
DSS across pins 2 & 3 per the CD.
• Ensure that the DSS Wires are tucked under the L-shaped Frame of the Photoreceptor
Drawer.
• Check the Ground Brush ground path back to the HV PWBs (PQ 9-618, PR Ground
RAP).
• Switch Off Printer power. Unplug the Printer. Check the ground between the Machine
Frame and the Power Cord.
• Ensure that all green ground wires in the Fuser area are connected and secure.
• Ensure that the DSS wires are not against any AC high voltage wires.
• Perform the Charge Dicorotron Balance (ADJ 9-6) and Height (ADJ 9-7) adjustments.
• Replace the Transfer and Preclean Dicorotrons (PL 9.10).
• Replace the Drawer Roll Up Ribbon Cable (PL 9.1).
• If the failure is at first power up, replace the Position 3 (A) PWB of the LVPS (PL 1.10).
• Clean the DSS. Ensure that the Photoreceptor Belt over the DSS is clean. Enter dC909,
[ESV-DSS Tests]. Select [DSS Recalibrate]. Select [Patch Test] and press Continue.
This will force a power up sequence to establish the new DSS calibration value.


A
9-215 RAP WARNING
Laser Radiation when the PR Drawer is open. Avoid eye exposure to the beam.
Fault Code, 9-215, indicates a toner dispense failure. Two consecutive DSS patch readings
are above the Dead Cycle Set point of the Toner Dispense Motor. The machine will dead cycle Cover the Photoreceptor Belt, under the ROS Assembly, inboard to outboard with white paper.
with the Toner Dispense Motor switched on at 100% duty cycle. If, after 75 pitches, the DSS
reading still exceeds the Full Dispense Set Point (and there is toner present), the fault is tinue. Observe the scan line on the paper. There is a continuous scan line across the
declared. paper.
Y N
Initial Actions
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx NOTE: Scan line observations are easily made using the Remote Hand Held Device (RHHD).
faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP For detailed Operating Instructions of the RHHD, go to (GP 1).
does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem
Entry Procedure (Service Call Procedures).
Y N
CAUTION Go to the 6-701 RAP.
Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox
Keep [Laser Write] energized. Select [Patch Exposure]. Observe the scan line when the
should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before clean- Continue button is pressed. The inboard half of the beam should be dimmer than the outboard
ing the ESV and DSS. The Printer will perform a Power Up Sequence when the power is half. Press Continue.
switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are NOTE: The difference in beam intensity is not that great, press (Stop/Continue) several times
performed with the components clean. while observing the scan line to verify check.
Check/repair the following:
Y N
• Check for toner in the dry ink bottle. If there is no toner in the bottle, skip the rest of the Ini-
tial Action steps and go directly to the Procedure. Go to the 6-701 RAP.
• Ensure that [Precision Patch] is selected in dC105.

Press Stop. Select [Patch Enable]. Press Continue. The scan line is completely off in the
• Ensure that the ROS Assembly is correctly positioned not skewed in the rails. patch area.
• Check the ROS Low Correction Factor (ADJ 6-3). Y N
• Check the DSS Timing (ADJ 9-14). Go to the 6-701 RAP.
• Check the Patch Generator Timing (ADJ 9-5).
Select Clear Outputs. The Patch Generator LED's are off.
• Clean the ESV, DSS, and the Patch Generator. Check the ESV Height (ADJ 9-12). Y N
• Developer Door Seal and Dump Door for excessive developer leakage (PL 9.17). (Patch Gen problem). +5 VDC is measured between TS8 (+) and TS20 (-) of the MIB
• Metal chips in the developer from the Paddle Wheel Bearing. PWB.
• Developer Drive Coupling for wear. Y N
Go to Flag 6. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB
• Ensure that the Photoreceptor is seated properly.
(PL 1.8).
• Ensure that all covers are installed and that there are no light leaks.
• Ensure dC131, MIN NVM locations 243, 244, and 245 are at the proper values as listed in CAUTION
the appropriate level Software dC 131 Table in General Procedures. DO NOT install an analog Patch Generator into a 4180 machine, damage to the MIN DIO
Procedure PWB will result. 4180 machines use a digital Patch Generator.
Go to Flag 7. Check for a short circuit. If the circuit is ok, replace the MIB PWB (PL 1.8).
NOTE: MICR (DP180MX) Machines use a red Toner Bottle that is not compatible with DP180.
Pull out the Xerographic Drawer. Remove the paper from the Photoreceptor. Raise the Photo-
Inspect the Developer Housing. Determine if there is abnormal developer flow (reverse devel-
oper flow) or excessive developer on the Input Chute of the BRD Roll. The developer flow is receptor Module. Select [Precharge/Prexfr Lamps]. Press Continue. All segments of the
normal. Precharge and Pretransfer Lamps are lit.
Y N
Y N
Go to PQ 9-616, Development RAP. If some, but not all of the segments, of a lamp are lit, replace that lamp (PL 9.4).
If a lamp does not light, go to the PQ 9-624, Precharge/Pretransfer Lamps RAP.
A B
B C D
Close and latch the Xerographic Drawer. Select [Main Drive Start/Run]. Press Continue. Press Stop. 115 VAC is measured between P272-11 and P272-3 of the MIN AC
The Developer Rolls rotate. Remote PWB #1.
Y N Y N
Check the Developer Gear teeth for wear and/or breakage. The gears are OK. This is a 60HZ Printer.
Y N Y N
Remove the Developer Housing from the Printer. Remove the gears. Rotate the (50HZ). 115 VAC is measured between K102-9 (+) and K102-8 (-).
rolls, the auger, and the paddle wheel. Check for bearing failures. Repair the compo- Y N
nents as required (PL 9.14). Go to the 1-709, AC Interlock Power RAP.
Remove the Paddle Wheel Gear. Rotate each roll. Check for packed developer or debris. Go to Flag 2. Check wires 4FF and 31 wirenets. Check for a open circuit.
Ensure proper operation of the bearings. The rolls rotate.
Y N (60HZ). 115 VAC is measured between K102-5 (+) and 2A7TB1-15 (-).
Clean/replace the components as necessary (PL 9.18). Y N
Go to the 1-702, AC Power Interlock RAP.
Rotate the auger. Check for binding. The auger rotates.
Y N Go to Flag 2. Check wires 4FF and 31 wirenets. Check for a open circuit.
Replace the Auger Bearing (PL 9.16).
115 VAC is measured between P272-5 (+) and P272-3 (-) of the MIN AC Remote PWB
The Paddle Wheel rotates. #1.
Y N Y N
Check for binding and replace the Paddle Wheel (PL 9.18). Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the Toner Dis-
pense Motor, MOT902, (PL 9.19).
Replace Developer Roll #2 (PL 9.15).
Press Continue. Less than 10 VDC is measured between P272-5 (+) and P272-3 (-) of
Select [Clear Outputs]. Open the Xerographic Drawer. Remove the dry ink bottle. the MIN AC Remote PWB #1.
Y N
NOTE: To avoid a toner spill, clean the area before reinstalling the dry ink bottle.
Replace the MIN AC Remote PWB #1 (PL 1.7).
There is dry ink in the hopper.
Y N Replace the Toner Dispense Motor, MOT902, (PL 9.19).
CAUTION
Use care when handling the Low Toner Sensor Q903. Do not touch the sensor portion of NOTE: The Toner Bottle may have to be removed to observe the Paddle.
Q903.
The Anti-Bridging Paddle appears to operate correctly.
Go to Flag 4. Check the circuit of the Low Toner Sensor, Q903 (GP 6-2, General Proce-
Y N
dures, may be used as a guideline; however, notice the difference in the input voltage
Check for any clogged dry ink. If the dry ink is OK, replace the MIN AC Remote PWB (PL
level). If the circuit checks OK, replace the Low Toner Sensor (PL 9.19).
1.7).
Enter dC330, [9], [Toner Dispenser]. Press Continue. Observe the Anti-Bridging Paddle
Press Stop. Select [Toner Thumper]. Press Continue.
action. The Toner Dispenser Motor rotates.
Y N NOTE: Listening for the Thumper may not be adequate. Cheat the Front Door Interlocks.
Press Stop. Ensure that the frame mounted connector, P256, is seated properly. +5 VDC Observe the Solenoid actuation.
is measured between TS47 (+) and TS37 (-) of the MIN DIO PWB.
The Toner Thumper Solenoid actuates.
Y N
Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN AC Y N
Remote PWB #1 (PL 1.7). Go to Flag 5. Check the Toner Thumper Solenoid, SOL901, circuit. (GP 6-2, General Pro-
cedures).
Press Continue. Less than +1.0 VDC is measured between TS47 (+) and TS37 (-) of
the MIN DIO PWB. The Toner Thumper hits the toner bottle.
Y N
Y N
Replace the MIN DIO PWB (PL 1.8). Adjust the Toner Thumper (ADJ 9-0). Check for any clogged dry ink.
The LOW toner Sensor display is H.
C D
Y N
CAUTION
Use care when handling the Low Toner Sensor Q903. Do not touch the sensor portion of
Q903.
Go to Flag 6. Check the circuit of the Low Toner Sensor circuit. (GP 6-2, General Proce-
dures, may be used as a guideline; however notice the difference in the input voltage
level).
Press Stop.Enter dC106. Select [Test Patterns and PQ], [Xerographic]. Program a 25 print
job. Press Continue. Compare the prints to the Xerographic Test Pattern. The density of
block #3 on the prints is less than or equal to the STD: Restore block on the 82E4161
test pattern.
Y N
Go to Flag 5. Check for an intermittent short circuit in the Toner Thumper Solenoid circuit.
Adjust the Toner Thumper (ADJ 9-0). If the problem continues, go to the PQ 9-610, High
Image Darkness RAP, the PQ 9-616, Development RAP, and PQ 9-620, DSS RAP as
required.
Enter dC131 [MIN]. Enter Address 250. Lower the Data value by 6 bits. Run 200 copies to
detone the system. Perform the Xerographic Setup (ADJ 9-3). If the problem continues, go to
PQ 9-610, High Image Darkness RAP. If the problem continues, go to PQ 9-616, Development
RAP, and 9-620, DSS RAP.


9-220, 9-222 RAP

Y N
Fault Code, 9-220, indicates that the Belt Hole Sensor, Q901, did not detect the belt hole within
3152 milliseconds of the previous belt hole detection, or twice within one hundred average cal- Go to the 4-201 RAP.
culations of the time between belt holes, the average calculation was greater than 50 millisec-
The Photoreceptor Belt is rotating.
onds above the last ten average calculations (Intermittent Slow Belt Hole Detection).
Y N
Fault Code, 9-222, indicates that the Belt Hole Sensor, Q901, detected the belt hole less than Press Stop. Troubleshoot the Photoreceptor Module Input Drives. Closely examine
the Drive Coupling for wear.
2840 milliseconds since the previous belt hole detection, or twice within one hundred average
calculations of the time between belt holes, the average calculation was less than 50 millisec-
onds below the last ten average calculations (Intermittent Fast Belt Hole Detection). CAUTION
The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to
Initial Actions light to under two (2) minutes. If the belt module will be exposed to light for longer than
two minutes, remove the Photoreceptor from the belt module and place it immediately into
• If the Photoreceptor Belt and/or the Machine Clock Sensor has just been replaced, clear
the protective photoreceptor bag. or place the bag over the Photoreceptor with it on the
the fault and run the printer to verify operation.
belt module.
• Ensure that the Belt Hole Sensor, Q901, and the Belt Hole LED are connected.
Press Stop. Remove the Photoreceptor Belt.
• Ensure that the Photoreceptor Module is securely seated in the Drawer Assembly. Check Check the following:
the Drawer Roll-up Cable, (PL 9.1). • Blocked Belt Hole
• Enter dC131 EDN NVM ensure that location 392 is 180. • Photoreceptor Belt for edge damage or seam show-through
Procedure • Loose Machine Clock Sensor
Cheat the Printer Interlock Bypass Switch. Run a few prints to observe the system operation. • Tension Roll for damaged or binding bearings
Determine if the fault is intermittent. The fault code is consistently displayed during the • Idler Roll for damaged or binding bearings
print cycle.
• Stripper Roll for damaged or binding bearings
Y N
(The fault is intermittent). • Broken Tension Roll Springs
• Cleaner Module, Developer Housing, or Machine Drives for binding
NOTE: The nominal value of Machine Clocks between Belt Holes is 5533. The nominal
The above checks are Ok.
value of Milliseconds between Belt Holes is 3052. This may not be seen until after the dis-
Y N
played fault code is cleared, and the test restarted.
Repair the components as required.
Enter dC912, [Belt Hole]. Press Continue. The Milliseconds between Belt Holes val-
ues indicate that random Belt Holes are detected far outside the general range of Pull out the Xerographic Drawer. Lift the Photoreceptor Module. Reinstall the Photorecep-
readings. tor Belt. +5 VDC is measured between TS15 (+) and TS18 (-) of the MIN Core PWB.
Y N Y N
Replace the Machine Clock Sensor (PL 9.3). +5 VDC is measured between TB3-8A (+) and TS18 (-) of the MIN Core PWB.
Y N
Check the following: Go to the wire, 1000L wirenet. Check for an open circuit.
• Blocked Belt Hole
• Photoreceptor Belt for edge damage or seam show-through Clean the Belt Hole LED and the Sensor. Go to Flag 2. Check the circuit of the Belt
Hole Sensor (GP 6-2, General Procedures).
• Loose Machine Clock Sensor
• Tension Roll for damaged or binding bearings Rotate the Photoreceptor to uncover the Belt Hole LED. Lower the Photoreceptor Mod-
• Idler Roll for damaged or binding bearings ule. Less than +1 VDC is measured between TS15 (+) and TS18 (-) of the MIN Core
• Stripper Roll for damaged or binding bearings PWB.
• Broken Tension Roll Springs Y N
Clean the Belt Hole LED and the Sensor. Go to Flag 1 and Flag 2. Check the circuit
of the Belt Hole LED and the Sensor (GP 6-2, General Procedures).
If the problem continues, replace the Belt Hole Sensor, Q901, (PL 9.7).
A 9-222 fault code is displayed.

Y N
Enter dC330, [Main Drive Start/Run] Motor. Press Continue. The Main Drives (paper
transports) are rotating.
A B
A B C
NOTE: The nominal value of Machine Clocks between Belt Holes is 5533. The nom- • Blocked Belt Hole
inal value of Milliseconds between Belt Holes is 3052. This may not be seen until • Photoreceptor Belt for edge damage
after the displayed fault code displayed is cleared and the test restarted.
Enter dC912, [Belt Hole]. Press Continue. The Milliseconds between Belt Holes • Tension Roll for damaged or binding bearings
values, indicate random Belt Holes detected far outside the general range of • Idler Roll for damaged or binding bearings
readings.
• Stripper Roll for damaged or binding bearings
Y N
• Broken Tension Roll Springs
Replace the Machine Clock Sensor (PL 9.3).
Replace the Belt Hole Sensor, Q901 (PL 9.7). • If the above checks are OK, replace the Belt Hole Sensor, Q901, (PL 9.7).
Replace the MIN Core PWB (PL 1.8). Check the following:
• Tension Roll Springs for damage
CAUTION • Tension Roll bearings and shafts for loosening or binding that could cause mistracking
The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to • Stripper Roll bearings and shafts for loosening or binding that could cause mistracking
under two (2) minutes. If the belt module will be exposed to light for longer than two minutes,
• Developer Housing for correct position
remove the photoreceptor from the belt module and place it immediately into the protective
• Photoreceptor Edge Guide
photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module.
• Check P/J 300 for rubbing on drives. P/J 300 is located by the Reg Servo PWB (PL 1.4).
Open the front doors and slide the Xerographic Drawer out of the machine. Partially cover the
Belt Hole Sensor, Q901, with black electrical tape. Inspect the PR Belt. The front edge of the The mistracking problem was corrected.
Photoreceptor Belt is damaged. Y N
Y N Replace the Photoreceptor Module and Photoreceptor Belt (PL 9.1).
Press the Red Test Button on the Photoreceptor Module. Rotate the Photoreceptor over
the Precharge Lamp. Inspect the ground strip area of the belt. Look for any scratches that Replace the Photoreceptor Belt (PL 9.1).
transmit light, or if the seam transmits light wider than 2mm. The Photoreceptor Belt
Ground Strip is OK.
Y N
Replace the Photoreceptor Belt (PL 9.1). Check the following for possible causes of
the damage:
• Foreign material in the Developer Housing or in the Cleaner Housing
• Damaged or contaminated Ground Brush
• Charge Dicorotron Height Adjustment (ADJ 9-7).
• Loose Drive Belt Idler
Go to Flag 1 and Flag 2. Check the circuit of the Belt Hole LED, CR901, and the Belt Hole
Sensor, Q901 (GP 6-2, General Procedures). The circuit is OK.
Y N
Repair the circuit as required (PL 9.2).
NOTE: The nominal value of Machine Clocks between Belt Holes is 5533. The nominal
value of Milliseconds between Belt Holes is 3052. This may not be seen until after the
fault code displayed is cleared and the test restarted.
Enter dC912, [Belt Hole]. Press Continue. The Milliseconds between Belt Holes val-
ues, indicate random Belt Holes detected far outside the general range of readings.
Y N
Replace the Machine Clock Sensor (PL 9.3).
Press Stop. Remove the Photoreceptor Belt. Check the following:

C

9-221 RAP
Fault Code, 9-221, indicates that the Ozone Vacuum Switch, S902, detected inadequate air
flow.
Procedure
WARNING
When the Main Drive is running, use extreme caution when working in the vicinity of the
Toner Filter Blower/Motor and the MIN Compressor.
Remove the Rear Cover. Access the Ozone Blower. Enter dC330, [Main Drive Start/Run].
Press Continue. The Ozone Blower operates.
Y N
115 VAC is measured between P276-1 and P276-2 of the Ozone Blower connector.
Y N
115 VAC is measured between 1TB1-16 and 1TB1-10.
Y N
(60 HZ) Go to the 4-700, Main Drive RAP.
(50 HZ) Go to 4-704, Print Power RAP.
Go to Flag 1. Check wires 32A and 4N for an open circuit.
150 VAC +/-20 VAC is measured between P276-5 and P276-6 of the Ozone Blower
Motor connector.
Y N
Select [Clear Outputs]. Switch Off Printer power. Disconnect P276 from the Ozone
Blower. A resistance of 200 to 230 Ohms is measured between P1-5 and P1-6 of
the Ozone Blower, MOT904.
Y N
Replace the Ozone Blower Motor, MOT904 (PL 9.9).
Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the Ozone Blower
Capacitor, C901, (PL 9.8).
Select [Clear Outputs]. Switch Off Printer power. Disconnect P276 from the Ozone
Blower Motor. A resistance of 90 to 110 Ohms is measured between P1-1 and P1-2 of
the Ozone Blower Motor, MOT904.
Y N
Replace the Ozone Blower Motor, MOT904 (PL 9.9).
Check for binding in the Ozone Blower Motor, MOT904. Repair or replace the Motor as
required (PL 9.9).
With the Ozone Blower still operating, there is air flow out of the Ozone Duct.
Y N
Repair/replace the Ozone Duct (PL 9.9).
Select [9]. The Ozone Vacuum SW display should be L. Press Stop. The display should go L
as the printer cycles down. This does not stop main drive motor. Go back to 1-4 on screen and
turn off the motor. Check the Ozone Vacuum Switch for binding. There may be an intermittent
electrical problem. Go to Flag 3. Check the circuit of the Ozone Vacuum Switch. (GP 6-2, Gen-
eral Procedures).

Figure 1 9-221 Circuit Diagram (7911D)

A
9-320 RAP • Check the Rear two Contact Points. If either Contact Point is damaged or broken,
replace the Developer Assembly (PL 9.13).
Fault Code, 9-320, indicates that the Dev Rolls 1&2 Bias Monitor voltage is less the Dev Rolls • If the Contact Points are OK, perform the Developer Zone Roll Adjustment (ADJ 9-
1&2 Bias Control voltage (dC140). The Monitor voltage is either 50% less for two consecutive 1).
samples, or 75% less for five consecutive samples.
• If the above checks are OK, replace the Developer Drive Coupling (PL 4.17).
Initial Actions With dC140 still on. Observe the Dev Rolls 1&2 Bias displays. Compare the Required display
Ensure that the Ribbon Cable between the HVAC and HVDC PWBs is securely connected. If and the measured voltage. The difference is greater than +/- 20 VDC.
loose or damaged, replace the Ribbon Cable (PL 9.1). Y N
(The measured voltage equals the Required display +/- 20 VDC). Measure the voltage
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx between TS18 (+) and TS19 (-) of the MIN ADA PWB #2. Observe the Dev Rolls 1&2
faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP Bias displays. Press Continue. The measured voltage is within +/- 0.5 VDC of the
does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Control display.
Entry Procedure (Service Call Procedures). Y N
Measure the voltage between TP502 (+) and TP2 (-) of the HVDC PWB. Observe
NOTE: If this RAP does not fix the problem, check the HV output module.
the Dev Rolls 1&2 Bias displays. Press the Continue button. The measured volt-
NOTE: Except for missing or broken contact points on the Developer Housing, replacing the age is within +/- 0.5 VDC of the Control display.
assembly will not repair the 9-320 faults. Y N
Press Stop. Disconnect the wire from P201-1 (J6) of the MIN ADA PWB #2.
Procedure Measure the voltage between TP502 (+) and TP2 (-) of the HVDC PWB.
Enter dC131 [MIN]. Enter address 125. Ensure that the Data value equals the value as listed Observe the Dev Rolls 1&2 Bias displays. Press the Continue button. The
in the appropriate level Software dC 131 Table in General Procedures. If address 125 does not measured voltage is within +/- 0.5 VDC of the Control display.
equal the value listed in the appropriate table, ROS 6-3xx series faults may be masked and the Y N
9-320 fault will result. MIN address 125 equals the table value. Reconnect the wire to P201-1 (J6) of the MIN ADA PWB #2. Go to Flag 1.
Y N Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL
Enter address 125. Enter the Data value listed in the appropriate level Software dC 131 1.7).
Table (Section 6, General Procedures, of the Service Manual). Enter dC606. Run any job
to determine what fault code displays. If any 6-3xx series fault occurs, go to the RAP for Reconnect the wire to P201-1 (J6) of the MIN ADA PWB #2. Replace the MIN
that fault. If the 9-320 fault occurs, continue with this RAP. ADA PWB #2 (PL 1.8).
WARNING Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA
PWB #2 (PL 1.8).
The Printer will not shutdown due to 9-3xx series faults in dC140. Select Stop between
measurements, when checking for an open or a short circuit, and when removing or
Check the Developer Drive Assembly for the following problems:
replacing parts.
• Check the Contact Points for the Developer Zone Roll on the Developer Housing. If
Enter dC140, [DC Bias Values]. Open the Printer Front Doors. Cheat the Printer Interlock the Contact Points are broken or missing, replace the Developer Housing (PL 9.13).
Bypass Switch. Measure the Dev Rolls 1&2 Bias voltage. (See the circuit diagram for the test
• Separation of the Developer Drive Pulley Flange.
point.) Measure between the Developer Housing left side extrusion, located under the Devel-
• Wobble in the Drive Pulley during operation
oper Catch Tray, and the Printer Frame (-).
• Scrapping on the inside of the Developer Drive Clam Shell due to interference with
NOTE: dC140 will not operate with a fault queued. Press R (reset) button on the Printer UI the Developer Drive Pulley.
Control Panel to clear faults.
One of the above Developer Drive problems exist.
Press Continue. Y N
NOTE: An intermittent short will not drop the voltage to 0 VDC.
The measured voltage reading is stable +/- 2 VDC. Replace the Developer Drive Assembly (PL 9.14).
Y N
Press Stop. Check the following: (The measured voltage does not equal the Required display +/- 20 VDC). Press Stop. -15
VDC is measured between TS55 (+) and TS56 (-) of the MIN ADA PWB #2
• Flag 6 and Flag 7. Check Developer Roll 1&2 Bias wire for a short circuit.
• Check the Developer Housing, Front two Contact Points. If either Contact Point is
damaged or broken, replace the Front Bearing Clamp Assembly (PL 9.15).
A
B C D
Y N Y N
Go to Flag 10. Check wire 1010D for an open circuit. If the wire is Ok, replace the MIN Go to wire, 1009D, wirenet. Check for an open circuit.
+15 VDC is measured between P293-4 (J4) (+) and TP2 (-) on the HVDC PWB.
Y N Reconnect the wire to J5-14 of the MIN ADA PWB #2. Go to Flag 2. Check for a
+15 VDC is measured between TH6 (+) and TH8 (-) on the LVPS. short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).
Y N
Go to the 1-715 RAP. Press Stop. Measure the voltage between TP501 (+) and TP2 (-) of the HVDC PWB.
Observe the Dev Rolls 1&2 Bias displays. Press Continue. The measured voltage is
Check wire, 1009K, wirenet. within +/- 0.5 VDC of the Control display.
Y N
+15 VDC is measured between (P294) J1-4 (+) and TP1 (-) on the HVAC PWB. Go to Flag 2. Check for an open circuit.
Y N
Check wire, 1009J, wirenet. Press Stop. +34 VDC is measured between P293-7 (+) and P293-10 (-) of the HVDC
PWB.
Greater than +8 VDC is measured between TP9 (+) and TP1 (-) on the HVAC PWB. Y N
Y N +34 VDC is measured between TH16 (+) and TH18 (-) on the LVPS.
Go to Flag 8. Check for a short or an open circuit. If the wires are Ok, replace the MIN Y N
ADA PWB #1 (PL 1.8). Disconnect J298 of the LVPS. +34 VDC is measured between TH16 (+) and
TH18 (-) of the LVPS.
Greater that +8 VDC is measured between TS16 (+) and TS56 (-) on the MIN ADA PWB Y N
#1. Go to the 1-717, +24, +34, -34 VDC RAP.
Y N
Go to Flag 8. Check for an open circuit. Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the HVDC
PWB (PL 1.7).
Press Continue. Less than 1 VDC is measured between TS16 (+) and TS56 (-) on the MIN
ADA PWB #1. Go to Flag 3. Check for an open circuit.
Y N
Replace the MIN ADA PWB #1 (PL 1.8). -34 VDC is measured between P294-2 (+) and P294-10 (-) of the HVAC PWB.
Y N
Press Stop. Enter [dC] [Power Interrupt]. Disconnect P291 (J6) at the HVDC PWB. Press -34 VDC is measured between TH17 (+) and TH18 (-) on the LVPS.
Continue. Enter dC140, [DC BiasValues]. Measure the voltage between J6-1 (+) and TP2 (-) Y N
at the HVDC PWB. Observe the Dev Rolls 1&2 Bias displays. Press Continue. The mea- Disconnect J298 of the LVPS. -34 VDC is measured between TH17 (+) and
sured voltage is within +/- 20 VDC of the Required display. TH18 (-) of the LVPS.
Y N Y N
Press Stop. Enter [dC] [Power Interrupt]. Reconnect P291 at the HVDC PWB. Press Go to the 1-717, +24, +34, -34 VDC RAP.
Continue. Enter dC140, [DC Bias Values]. Measure the voltage between TS11 (+) and
TS56 (-) of the MIN ADA PWB #2. Observe the Dev Rolls 1&2 Bias displays. Press Con- Go to Flag 4. Check for a short circuit. If the circuit is OK, replace the HVAC
tinue. The voltage measured is within +/- 0.5 VDC of the Control display. PWB (PL 1.7).
Y N
Press Stop. Enter [dC] [Power Interrupt]. Disconnect the wire from J5-14 of the Go to Flag 4. Check for an open circuit.
MIN ADA PWB #2. Press Continue. Enter dC140, [DC Bias Values]. Measure the
voltage between TS11 (+) to TS56 (-) of the MIN ADA PWB #2. Observe the Dev +24 VDC is measured between P294-5 (+) and TP1 (-) at the HVAC PWB.
Rolls 1&2 Bias displays. Press Continue. The voltage measured is within +/- 0.5 Y N
VDC of the Control display. Go to Flag 9. Check for an open circuit. If the circuit is OK, replace the HVAC PWB
Y N (PL 1.7).
Press Stop. Enter [dC] [Power Interrupt]. Reconnect the wire to J5-14 of the
MIN ADA PWB #2. Press Continue. Enter dC140, [DC Bias Values]. Press Press Continue. Greater than +8 VDC is measured between TP5 (+) and TP1 (-) of
Continue. +15 VDC is measured between TS57 (+) and TS56 (-) of the MIN the HVAC PWB.
ADA PWB #2.
B C D B
B
Y N
Press Stop. Unplug the ribbon cable between the HVDC and the HVAC PWBs.
Press Continue. Ignore the displayed fault code. Greater than +8 VDC is mea-
sured between TP5 (+) and TP1 (-) of the HVAC PWB.
Y N
Between +14.15 and +15.85 VDC is measured between TH6 (+) and TH8 (-)
of the LVPS.
Y N
Replace the POS.3 Output A PWB in the LVPS (PL 1.9).
Replace the HVAC PWB (PL 1.7).
Go to Flag 5. Check for a short circuit. If the circuit is OK, replace the HVDC PWB
(PL 1.7).
Press Continue. Greater than +8 VDC is measured between TP4 (+) and TP2 (-) of
the HVDC PWB.
Y N
Replace the Ribbon Cable (PL 9.1).
Replace the HVDC PWB (PL 1.7).
Press Stop. Enter [dC] [Power Interrupt]. Reconnect the P291 (J6) connector to the HVDC
PWB. Disconnect the P/J204 connector by the Dry Ink Bottle. Press Continue. Observe the
Dev Rolls 1&2 Bias displays. Press Continue. The Monitor display is within +/- 0.5 of the
Control display.
Y N
Go to Flag 6. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL
1.7).
Press Stop. Check the following potential causes of a short circuit:

• Go to Flag 7. Check Developer Bias #1 and #2 wires for a short circuit.
• Excessive leakage of developer
• Chips or cracks in the Developer Housing or the seals
• Repair or replace the Paddle Wheel, bearings, seals, or Developer Housing as required
(PL 9.14).
• Check the Contact Points for the Developer Zone Roll on the Developer Housing. If the
Contact Points are broken or missing, replace the Developer Housing (PL 9.15).
• Developer Drive Pulley or Drive Coupling failures (PL 9.14).


Figure 2 9-320 Circuit Diagram (7934A)

A B C D
9-321 RAP Reposition the wire in P202-18. Enter dC131 [MIN]. Enter address 125. Enter
the current Data value recorded for Address 125. Go to Flag 2. Check for a
Fault Code, 9-321, indicates that the Dev Roll 3 Bias Monitor voltage is less the Dev Roll 3 short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).
Bias Control voltage (dC140). The Monitor voltage is either 50% less for two consecutive sam-
ples, or 75% less for five consecutive samples. Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for
Address 125. Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the
Initial Actions HVDC PWB (PL 1.7).
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx Press Stop. Reconnect P291 at the HVDC PWB. Disconnect P/J204 by the Dry Ink Bot-
faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP tle. Press Continue. Observe the Dev Roll 3 Bias displays. The Dev Roll 3 Bias Moni-
does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem tor is within +/- 0.5 VDC of the Control display.
Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for
Procedure Address 125. Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the
NOTE: This RAP requires that temporary changes be made to the NVM values at certain HVDC PWB (PL 1.7).
Address locations. Ensure that a record is made of all NVM values that are being changed
prior to the change. Ensure that all values changed during troubleshooting are reset back to Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for
their original values prior to completion of the service call. Address 125. Press Stop. Check the following possible causes:
• Go to Flag 4. Check the Developer Roll #3 Bias wire for a short or an open circuit.
Enter dC131 [MIN]. Enter Address 125. Record the current Data value. Subtract 16 from the
• Chips or cracks in the Developer Housing or the Seals, causing excessive leakage
current Data value. Enter this temporary Data value at Address 125. This temporary value at
of Developer.
MIN address 125 disables ROS Faults for diagnostics.
Enter dC140, [DC Bias Values]. Open the front doors. Cheat the Printer Interlock Bypass • Repair or replace the Paddle Wheel, Bearings, Seals, or Developer Housing as
Switch. Measure the Developer Roll 3 voltage between the hex head screw in metal extrusion required (PL 9.14).
on the right hand of the Developer Housing and the machine frame. (See the circuit diagram • Check the Developer Housing front two contact points. If either point is damaged or
for test point.) Compare the measured voltage to the Dev Roll 3 Bias Required display. Press broken, replace the Front Bearing Clamp Assembly (PL 9.15).
Continue. • Check the Developer Housing rear two contact points. If either point is damaged or
broken, replace the Developer Housing Assembly (PL 9.14).
NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the Printer UI
Control Panel to clear the faults. • If all contact points are Ok, go to the Developer Zone Roll Adjustment (ADJ 9-1).
The measured voltage is within +/- 20 VDC of the Required display. Press Stop. Measure the voltage between TS39 (+) and TS40 (-) of the MIN ADA PWB #2.
Y N Press Continue. Observe the Dev Roll 3 Bias displays. The measured voltage is within +/-
Press Stop. Enter [dC] [Power Interrupt]. Disconnect connector P291 (J6) at the HVDC 0.5 VDC of the Control display.
PWB. Press Continue. Enter dC140, [DC Bias Values]. Measure the voltage between Y N
J6-6 (+) and TP2 (-) of the HVDC PWB. Press Continue. The measured voltage is Press Stop. Measure the voltage between TP801 (+) and TP2 (-) of the HVDC PWB.
within +/- 20 VDC of the Required display. Press Continue. Observe the Dev Roll 3 Bias displays. The measured voltage is
Y N within +/- 0.5 VDC of the Control display.
Press Stop. Enter [dC] [Power Interrupt]. Reconnect the P291 connector. Press Y N
Continue. Enter dC140, [DC Bias Values]. Measure the voltage between TS5 (+) Press Stop. Enter [dC] [Power Interrupt]. Disconnect the wire from P201-21 (J6) of
and TS56 (-) of the MIN ADA PWB #2. Press Continue. Observe the Dev Roll 3 the MIN ADA PWB #2. Press Continue. Enter dC140, [DC Bias Values]. Press
Bias displays. The measured voltage is within +/- 0.5 VDC of the Control dis- Continue. Observe dev roll 3 display. Measure the voltage between TP801 (+) and
play. TP2 (-) of the HVDC PWB. The measured voltage is within +/- 0.5 VDC of the
Y N Control display.
Press Stop. Enter [dC] [Power Interrupt]. Disconnect the wire from P202-18 Y N
(J5) of the MIN ADA PWB #2. Press Continue. Enter dC140, [DC Bias Val- Reposition the wire in P201-21. Enter dC131 [MIN]. Enter address 125. Enter
ues]. Measure between TS5 (+) and TS56 (-) of the MIN ADA PWB #2. Press the current Data value recorded for Address 125. Go to Flag 1. Check for a
Continue. Observe the Dev Roll 3 Bias displays. The measured voltage is short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).
within +/- 0.5 VDC of the Control display.
Y N Reposition the wire in P201-21. Enter dC131 [MIN]. Enter address 125. Enter the
Reposition the wire in P202-18. Enter dC131 [MIN]. Enter address 125. current Data value recorded for Address 125. Replace the MIN ADA PWB #2 (PL
Enter the current Data value recorded for Address 125. Replace the MIN 1.8).
A B C D E F
E F E
Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address
Address 125. Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN 125. Replace the MIN ADA PWB #2 (PL 1.8).
E

A
9-322 RAP Y N
Go to Flag 3. Check for a short circuit. There is a short circuit in the Cleaner
Fault Code, 9-322, indicates that the Cleaner Brush Bias Monitor voltage is less than the Brush Bias wire.
Cleaner Brush Bias Control voltage (dC140). The Monitor voltage is either 50% less for two Y N
consecutive samples, or 75% less for five consecutive samples. Go to the 9-706 RAP.
Initial Actions Determine the cause of the short circuit. Repair the circuit.
Check [SCP] Queued Faults and [Last 50] shutdowns. If the fault codes alternate between
any of the following; 9-325, 9-326, 9-327, 9-328, and/or 9-329, go to the 9-328 RAP first. Press Stop. Check the following in order as needed:
• Go to Flag 4. Check for a short circuit.
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx • Check for a short in the Cleaner Assembly.
faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP • Check the Tension Roll/Springs for proper actuation.
does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem • Adjust the Photoreceptor Tension (ADJ 9-11).
Measure the voltage between TP18 (+) to TP1 (-) of the HVAC PWB. Press Continue. The
Procedure voltage is within +/- 0.5 of the Cleaner Brush Bias Control display.
Enter dC140, [DC Bias Values]. Open the Printer Front Doors. Cheat the Printer Interlock Y N
Bypass Switch. Measure the voltage between the Cleaner Brush Shaft and the machine frame. Press Stop. Disconnect the wire from P242-13 (J6) of the MIN ADA PWB 1. Measure the
Press Continue. voltage between TP18 (+) and TP1 (-) of the HVAC PWB. Press Continue. The voltage
NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the Printer UI is within +/- 0.5 of the Cleaner Brush Bias Control display.
Control Panel to clear the faults. Y N
Reconnect the wire to P242-13 (J6) of the MIN ADA PWB 1. Go to Flag 1. Check for
The measured voltage is within +/- 20.0 VDC of the Cleaner Brush Bias Required dis- a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).
play.
Y N Reconnect the wire to P242-13 (J6) of the MIN ADA PWB 1. Replace the MIN ADA PWB
Measure the voltage between TP17 (+) and TP1 (-) of the HVAC PWB. Press Continue. #1 (PL 1.8).
The measured voltage is within +/- 0.5 VDC of the Cleaner Brush Bias Control dis-
play. Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #1 (PL
Y N 1.8).
Measure the voltage between TS1 (+) and TS56 (-) of the MIN ADA PWB #1. Press
Continue. The measured voltage is within +/- 0.5 of the Cleaner Brush Bias
Control display.
Y N
Press Stop. Disconnect the wire from P246-6 (J5-6) of the MIN ADA PWB #1.
Measure the voltage between TS1 (+) and TS56 (-) of the MIN ADA PWB 1.
Press Continue. The measured voltage is within +/- 0.5 VDC of the Cleaner
Brush Bias control display.
Y N
Reconnect the wire to P246-6 (J5-6) of the MIN ADA PWB #1. Replace
the MIN ADA PWB 1 (PL 1.8).
Enter [dC] [Power Interrupt]. Reconnect the wire to P246-6 (J5-6) of the MIN
ADA PWB #1. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace
the HVAC PWB (PL 1.7).
Enter [dC] [Power Interrupt]. Go to Flag 2. Check for an open circuit. If the circuit is
OK, replace the HVAC PWB (PL 1.7).
Press Stop. Disconnect the Cleaner Brush Bias Wire P290-1 at the Cleaner Assembly.
Press Continue. The Cleaner Brush Bias Monitor display is within +/- 0.5 of Cleaner
Brush Bias Control display.
A

A
9-323 RAP Y N
Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the HVAC PWB
Fault Code, 9-323, indicates that the (Upper Detoning Roll) UDTR Bias Monitor voltage is less (PL 1.7).
than the UDTR Bias Control voltage. The Monitor voltage is either 50% less for two consecu-
tive samples, or 75% less for five consecutive samples. Go to Flag 4. Check for a short circuit. If the circuit is OK, check for a short in the Cleaner
Assembly.
Initial Actions
Check [SCP] Queued Faults following the shutdown. If a combination of 9-325, 9-326, 9-327, Measure the voltage between TS30 (+) and TS31 (-) of the MIN ADA PWB #1. Press Con-
9-328,and/or 9-329 fault codes is indicated and this RAP does not repair the problem, go to the tinue. The voltage is within +/- 0.5 VDC of the UDTR Bias Control display.
Y N
9-328 RAP.
Press Stop. Disconnect the wire from P242-9 (J6) of the MIN ADA PWB #1. Measure the
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx voltage between TS30 (+) and TS31 (-) of the MIN ADA PWB #1. Press Continue. The
voltage is within +/- 0.5 VDC of the UDTR Bias Control display.
faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP
does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Y N
Entry Procedure (Service Call Procedures). Reconnect the wire to P242-9 (J6) of the MIN ADA PWB #1. Replace the MIN ADA
PWB #1 (PL 1.8).
Procedure
Enter dC140, [DC Bias Values]. Measure between the Upper Detoning Roll and the Cleaner Reconnect the wire to P242-9 (J6) of the MIN ADA PWB #1. Go to Flag 1. Check for a
short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).
Brush. Press the Continue button.
NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the IOT Con- Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #1 (PL
trol Panel to clear the faults. 1.8).
The measured voltage is within +/- 20 VDC of the UDTR Bias Required display.
Y N
Press Stop. Measure the voltage between TP19 (+) and TP-1 (-) of the HVAC PWB.
Press Continue. The measured voltage is within +/- 0.5 VDC of the UDTR Bias Con-
trol display.
Y N
Press Stop. Measure the voltage between TS4 (+) and TS56 (-) of the MIN ADA
PWB #1. Press the Continue button. The measured voltage is within +/- 0.5 VDC
of the UDTR Bias Control display.
Y N
Measure the voltage from TS4 (+) to TS56 (-) of the MIN ADA PWB #1. Press
Continue. The measured voltage is within +/- 0.5 VDC of the UDTR Bias
Control display.
Y N
Reconnect the wire to P246-8 (J5) of the MIN ADA PWB #1. Replace the
MIN ADA PWB #1 (PL 1.8).
Reconnect the wire to P246-8 (J5) of the MIN ADA PWB #1. Enter [dC] [Power
Interrupt]. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace
Press Stop. Enter [dC] [Power Interrupt]. Disconnect the wire at P290-3. Press Con-
tinue. Enter [dC140], [DC Bias Values]. Press Continue. Observe the UDTR Bias dis-
plays. The Monitor is within +/- 0.5 of the Control display.
A

A
9-324 RAP Measure the voltage between TP16 (+) and TP1 (-) of the HVAC PWB. Press Continue. The
measured voltage is within +/- 0.5 VDC of the LDTR Bias Control display value.
Fault Code, 9-324, indicates that the (Lower Detoning Roll) LDTR Bias Monitor voltage is less Y N
than the LDTR Bias Control voltage. The Monitor is either 50% less for two consecutive sam- Press Stop. Disconnect the wire from the P242-11 (J6) of the MIN ADA PWB #1. Mea-
ples, or 75% less for five consecutive samples. sure between TP16 (+) and TP1 (-) of the HVAC PWB. Press Continue. The voltage is
within +/- 0.5 VDC of the LDTR Bias Control display value.
Initial Actions Y N
Reconnect the wire to P242-11 (J6) of the MIN ADA PWB #1. Go to Flag 1. Check
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).
does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Reconnect the wire to P242-11 (J6) of the MIN ADA PWB #1. Replace the MIN ADA PWB
Entry Procedure (Service Call Procedures). #1 (PL 1.8).
Procedure Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #1 (PL
Enter dC140, [DC Bias Values]. Cheat the Printer Interlock Bypass Switch. Measure between 1.8).
P290-2 (+) and P290-3 (-) of the Cleaner Assembly. Press Continue.
NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the IOT Con-
trol Panel to clear the faults.
The measured voltage is within +/- 20 VDC of the LDTR Bias Required display.
Y N
Measure the voltage between TP15 (+) and TP1 (-) of the HVAC PWB. Press Continue.
The measured voltage is within +/- 0.5 VDC of the LDTR Bias Control display value.
Y N
Continue. The measured voltage is within +/- 0.5 of the LDTR Bias Control dis-
play value.
Y N
Press Stop. Disconnect the wire P246-4 (J5) of the MIN ADA PWB #1. Mea-
sure between TS3 (+) and TS56 (-) of the MIN ADA PWB #1. Press Continue.
The measured voltage is within +/- 0.5 VDC of the LDTR Bias Control dis-
play value.
Y N
Press Stop. Disconnect the LDTR Bias wire from P290-2. Press Continue. The LDTR
Bias Monitor display is within +/- 0.5 of the LDTR Bias Control display value.
Y N
Reconnect the LDTR Bias wire to P290-2. Go to Flag 3. Check for a short circuit. If
the circuit is OK, replace the HVAC PWB (PL 1.7).
Reconnect the LDTR Bias wire to P290-2. Go to Flag 4. Check for a short circuit in the
wire and the Cleaner Assembly.
A

9-325 RAP Y N
Press Stop. Disconnect the wire at P201-9 (J6) of the MIN ADA PWB #2. Press Con-
Fault Code, 9-325, indicates that the Chg2 SV Monitor voltage is less than the Chg2 Shld Volt- tinue. Greater than 0 VDC is measured between TS30 (+) and TS31 (-) of the MIN
age Control Point V (dC140). The Monitor is either 50% less for two consecutive samples, or ADA PWB #2.
75% less for five consecutive samples. Y N
Reconnect the wire to P201-9 of the MIN ADA PWB #2. Replace the MIN ADA PWB
Initial Actions #2 (PL 1.8).
Check [SCP] Queued Faults following the shutdown. If the Fault Codes include any combina-
tion of the following; 9-325, 9-326, 9-327, 9-328, and/or 9-329, go to the 9-328 RAP first. Reconnect the wire to P201-9 of the MIN ADA PWB #2. Go to Flag 1 and Flag 3. Check
for a short circuit. If the circuits are OK, replace the HVDC PWB (PL 1.7).
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx
faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP Observe the Chg2 Shld Voltage displays. The Charge 1 SV Monitor is greater than 0.
Y N
Entry Procedure (Service Call Procedures). Go to Flag 4. Check for a short in the Charge 1 Shield Bias.
Inspect for opens, loose connections, contamination, arcing, and discoloration of the following: Observe the Chg2 Shld Current displays. The Charge 2 SI Monitor is less than 10.
Y N
• Dicorotrons and connectors (PL 9.10). Clean or replace all of the Charge Dicorotrons and Shields (PL 9.10).
• Ozac System and connectors (PL 9.8).
• HVDC Cables (PL 1.7). Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2 (PL
1.8).
Procedure
Enter dC140, [Dicorotron Values]. Cheat the Printer Interlock Bypass Switch. Press Con-
tinue. Observe the Coronode ACV displays.
NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the IOT Con-
The ACV Monitor display is within +/- 0.5 of the Control Point V.
Y N
Press Continue. Greater than 0 VDC is measured between TS12 (+) and TS56 (-) of the
MIN ADA PWB #2.
Y N
Press Stop. Disconnect the wire at P202-22 (J5) of the MIN ADA PWB #2. Press Con-
tinue. Greater than 0 VDC is measured between TS12 (+) and TS56 (-) of the MIN
ADA PWB #2.
Y N
Reconnect the wire to P202-22 (J5) of the MIN ADA PWB #2. Replace the MIN ADA
PWB #2 (PL 1.8).
Reconnect the wire to P202-22 (J5) of the MIN ADA PWB #2. Go to Flag 2. Check for a
short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).
Press Continue. Greater than 0 VDC is measured between TP201 (+) and TP2 (-) of the
HVDC PWB.
Y N
Go to Flag 2. Check for an open circuit.
Press Continue. Greater than 0 VDC is measured between TS30 (+) and TS31 (-) of MIN
ADA #2.


A B
9-326 RAP Y N
Reconnect the wire at P202-20 (J5) of the MIN ADA PWB #2. Replace the MIN
Fault Code, 9-326; indicates that the Tran SI Monitor voltage is less than the Tran Shld Current ADA PWB #2 (PL 1.8).
Control Point V (dC140). The Monitor is either 50% less for two consecutive samples, or 75%
less for five consecutive samples. Reconnect the wire at P202-20 (J5) of the MIN ADA PWB #2. Go to Flag 2. Check
for an open or short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).
Initial Actions
Check [SCP] Queued Faults following the shutdown. If combinations of 9-325, 9-326, 9-327, Measure between TP303 (+) and TP2 (-) of the HVDC PWB. Observe the Tran Shld Cur-
9-328, and/or 9-329 codes are indicated, go to the 9-328 RAP first. rent displays. Press Continue. The measured voltage is within +/- 0.5 of the Control
Point V.
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx Y N
faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP Press Stop. Disconnect the wire at P201-25 (J6) of the MIN ADA PWB #2. Measure
between TP303 (+) and TP2 (-) of the HVDC PWB. Observe the Tran Shld Current
Entry Procedure (Service Call Procedures). displays. Press Continue. The measured voltage is within +/- 0.5 of the Control
Point V.
Procedure Y N
Enter dC140, [Dicorotron Values]. Press Continue. Observe the Coronode ACV displays. Reconnect the wire at P201-25 (J6) of the MIN ADA PWB #2. Go to Flag 1 and
3. Check for a short or an open circuit. If the circuits are OK, replace the HVDC
NOTE: dC140 will not operate with a queued fault. Press the R (reset) button on the Printer UI PWB (PL 1.7).
Control Panel to clear faults.
Reconnect the wire at P201-25 (J6) of the MIN ADA PWB #2. Replace the MIN ADA
PWB #2 (PL 1.8).
Y N
Go the 9-329 RAP.
Go to Flag 1. Check for an open circuit. Go to Flag 3. Check for an open or a short circuit.
If the circuit is OK, replace the MIN ADA PWB #2 (PL 1.8).
Press Stop. Open the Printer Front Doors. Bypass the Processor Interlocks. Press Continue.
The Transfer Dicorotron glows.
Replace the Transfer Dicorotron (PL 9.11).
Y N
Press Stop. Remove the Transfer Dicorotron. Install the Preclean Dicorotron in the Trans-
fer position. Press Continue. The new Transfer Dicorotron glows.
Y N
(HVAC problem). Install the Preclean Dicorotron into it's original position. Inspect for
open or loose connection of the Transfer Dicorotron coronode wire. Inspect the fol-
lowing for contamination, arcing, and discoloration:
• All Dicorotrons and connectors (PL 9.10).
• HVDC Cables (PL 1.7).
Install the Preclean Dicorotron into its original position. Replace the Transfer Dicorotron
(PL 9.10).
A hot spot or arc is observed.

Y N
Measure between TP301 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe
the Tran Shld Current displays. The measured voltage is within +/- 0.5 of the Control
Point V.
Y N
Press Stop. Disconnect the wire at P202-20 (J5) of the MIN ADA PWB #2. Measure
between TS7 (+) and TS56 (-) of the MIN ADA PWB #2. Observe the Tran Shld
Current displays. Press Continue. The measured voltage is within +/- 0.5 of the
Control Point V.
A B

A B
9-327 RAP Y N
Fault Code, 9-327; indicates that the Dtac SI Monitor voltage is less than the Dtac Shld Current
Control Point V (dC140). The Monitor voltage is either 50% less for two consecutive samples Go to Flag 2. Check for an open or a short circuit. If the circuit is OK, replace the
or 75% less for five consecutive samples. HVDC PWB (PL 1.7).
Initial Actions Measure between TP602 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe
Check [SCP] Queued Faults following the shutdown. If combinations of 9-325, 9-326, 9-327, the Dtac Shld Current displays. The measured voltage is within +/- 0.5 of the Control
9-328, and/or 9-329 codes are indicated, go to the 9-328 RAP first. Point V.
Y N
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx Press Stop. Disconnect the wire at P201-23 (J6) of the MIN ADA PWB #2. Measure
faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP between TP602 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe the
Dtac Shld Current displays. The measured voltage is within +/- 0.5 of the Con-
Entry Procedure (Service Call Procedures). trol Point V.
Y N
Procedure Go to Flag 1. Check for a short circuit. Go to Flag 3. Check for an open or a
Enter dC140, [Dicorotron Values]. Press Continue. Observe the Coronode ACV displays. short circuit. If the circuits are OK, replace the HVDC PWB (PL 1.7).
NOTE: dC140 will not operate with a queued fault. Press the R (reset) button on the Printer UI Replace the MIN ADA PWB #2 (PL 1.8).
Control Panel to clear the faults.
Go to Flag 1. Check for an open circuit. Go to Flag 3. Check for an open or a short circuit.
If the circuits are OK, replace the MIN ADA PWB #2 (PL 1.8).
Y N
Replace the Detack Dicorotron (PL 9.11).
Press Stop. Open the Printer Front Doors. Cheat the Printer Interlock Bypass Switch. Press
Continue. The Detack Dicorotron glows.
Y N
Press Stop. Remove the Detack Dicorotron. Install the Preclean Dicorotron into the
Detack position. Press Continue. The new Detack Dicorotron glows.
Y N
(HVAC problem). Install the Preclean Dicorotron into its original position. Inspect for
an open or a loose connection of the Detack Dicorotron Coronode wire.
Inspect the following for contamination, arcing, and discoloration:
• All Dicorotrons and connectors (PL 9.10).
Install the Preclean Dicorotron into its original position. Replace the Detack Dicorotron
(PL 9.11).
A hot spot or arc is observed.

Y N
Measure between TP601 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe
the Dtac Shld Current displays. The measured voltage is within +/- 0.5 of the Control
Point V.
Y N
between TS9 (+) and TS56 (-) of the MIN ADA PWB #2. Press Continue. Observe
the Dtac Shld Current displays. The measured voltage is within +/- 0.5 of the
Control Point V.
A B

A B
9-328 RAP Y N
Fault Code, 9-328, indicates that the Pcln SI Monitor voltage is less than the Pcln Shld Current
Control Point V (dC140). The Monitor voltage is either 50% less for two consecutive samples, Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the HVAC PWB
or 75% less for five consecutive samples. (PL 1.7).
Initial Actions Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the HVDC PWB (PL
Enter [dC] [Power Interrupt]. Reseat the HVDC PWB and HVAC PWB. Thoroughly inspect 1.7).
the following for open or loose connections, contamination, arcing, and discoloration:
Enter dC140, [Dicorotron Values]. Press Continue. Observe the Coronode ACV displays.
• Dicorotrons and connectors (PL 9.10). The ACV Monitor is within +/- 0.7 of the Control Point V.
Y N
• Ozac System/connectors (PL 9.8).
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx The Preclean Dicorotron glows.
Y N
does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Other Dicorotrons glow.
Check the Ozac Twist-Lock Connector P2. If the connector is OK, replace the HVAC
Procedure Output Module (PL 1.7).
+24 VDC is measured between P294-1 (+) and TP1 (-) of the HVAC PWB.
Press Stop. Install the Transfer Dicorotron into the Preclean position. Press Continue.
Y N
+24 VDC is measured between TH13 (+) and TH8 (-) on the LVPS. The new Preclean Dicorotron glows.
Y N Y N
Replace the Ozac System (PL 9.8).
Go to the 1-717, +24, +34, -34 VDC RAP.
Go to the wire, 1021, wirenet. Check for an open circuit. Return the Transfer Dicorotron to its original position. Replace the Preclean Dicorotron
(PL 9.11).
Enter dC140, [Dicorotron Values]. Measure between TP3 (+) and TP2 (-) of the HVDC PWB
(15 VDC in standby). Press Continue. There is a normal even glow without arcing or hot spots.
Y N
NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the Printer UI Arcing observed, replace the Preclean Dicorotron (PL 9.10).
Observe the Pcln Shld Current display. The Pcln SI Monitor display is within +/- 0.5 of the
3.0 +/- 0.5 VDC is measured between TP3 (+) and TP2 (-) of the HVDC PWB.
Control Point V.
Y N
Y N
Press Continue. Less than 1.0 VDC is measured between TP12 (+) and TP1 (-) of the
The Pcln SV Monitor is greater than 2.0.
HVAC PWB.
Y N
Y N
Measure between TS15 (+) and TS56 (-) of the MIN ADA PWB #2. Press Continue.
Press Continue. 14 to 26 VAC is measured between TP10 (+) and TP1 (-) of the
The measured voltage is within +/- 0.5 of the Control Point V.
HVAC PWB.
Y N
Y N
Press Stop. Disconnect the wire at P202-24 (J5) of the MIN ADA PWB #2.
Go to Flag 4. Check for an open circuit. If the circuit is OK, replace the HVAC
Measure between TS15 (+) and TS56 (-) of the MIN ADA PWB #2. Press Con-
Output Module (PL 1.7).
tinue. The measured voltage is within +/- 0.5 of the Control Point V.
Y N
Reconnect the wire at P202-24 (J5) of the MIN ADA PWB #2. Replace the
Press Continue. +15 VDC is measured between TP3 (+) and TP2 (-) of the HVDC
PWB.
Reconnect the wire at P202-24 (J5) of the MIN ADA PWB #2. Go to Flag 2.
Y N
Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).
Unplug the Ribbon Cable Between the HVDC and the HVAC PWBs. +15 VDC is
measured between TP3 (+) and TP2 (-) of the HVDC PWB.
A B C D E
C D E
Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the HVDC PWB
(PL 1.7).
Measure between TP403 (+) and TP2 (-) of the HVDC PWB. Press Continue. The mea-
sured voltage is within +/- 0.5 of the Pcln Control Point V.
Y N
between TP403 (+) and TP2 (-) of the HVDC PWB. Press Continue. The mea-
sured voltage is within +/- 0.5 of the Pcln Control Point V.
Y N
The Pcln SI Monitor is greater than 0 VDC.
Y N
Reconnect the wire at P201-5 (J6) of the MIN ADA PWB #2. Go to Flag 1
and Flag 5. Check for a short circuit. If the circuits are OK, replace the
HVDC PWB (PL 1.7).
Reconnect the wire at P201-5 (J6) of the MIN ADA PWB #2. Replace the Pre-
clean Dicorotron and Shield (PL 9.10).
Reconnect the wire at P201-5 (J6) of the MIN ADA PWB #2. Replace the MIN ADA
PWB #2 (PL 1.8).
Go to Flag 1 and Flag 5. Check for an open circuit. If the circuits are OK, replace the MIN
Go to Flag 1 and Flag 5. Check for a short circuit. If the circuits are OK, replace the HVDC
PWB (PL 1.7).


A B C
9-329 RAP Enter [dC] [Power Interrupt]. Go to Flag 1. Check for an open circuit. If the circuit is
Fault Code, 9-329, indicates that the Coronode ACV Monitor voltage is less than the Coronode
ACV Control Point V (dC140). The Monitor voltage is either 50% less for two consecutive sam- Replace the HVAC PWB (PL 1.7).
ples, or 75% less for five consecutive samples.
Measure the voltage between TS27 (+) and TS28 (-) of the MIN ADA PWB #1. Press Con-
Initial Actions tinue. The voltage is within +/- 0.5 VDC of the Coronode ACV Control Point V.
Check [SCP] Queued Faults following the shutdowns. If combinations of 9-325, 9-326, 9-327, Y N
9-328, and/or 9-329 fault codes are indicated, go to the 9-328 RAP first. Go to Flag 4. Check for an open circuit.
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx Replace the MIN ADA PWB #1 (PL 1.8).
Ensure that all connectors on the HVAC PWB and MIN ADA PWB #1 are secure.
Inspect for opens, loose connections, contamination, arcing, and discoloration of the following:

Procedure
Enter dC140, [Dicorotron Values]. Measure the voltage between TP13 (+) and TP1 (-) of the
HVAC PWB. Press Continue. Observe the Coronode ACV displays.
NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the Printer UI
Control Panel to clear the fault.
The measured voltage is within +/- 0.5 VDC of the Control Point V.
Y N
Measure the voltage between TP11 (+) and TP1 (-) of the HVAC PWB. Press Continue.
The measured voltage is within +/- 0.5 VDC of the Coronode ACV Control Point V.
Y N
Continue. The measured voltage is within +/- 0.5 VDC of the Coronode ACV
Control Point V.
Y N
Measure the voltage between TS2 (+) and TS56 (-) of the MIN ADA PWB #1.
Press Continue. The measured voltage is within +/ - 0.5 VDC of the Coron-
ode ACV Control Point V.
Y N
A B C

A B C
9-330 RAP Measure the voltage between TP204 (+) and TP2 (-) of the HVDC PWB. Press Con-
tinue. The measured voltage is within +/- 0.5 of the Control Point V.
Fault Code, 9-330, indicates that the Chg2 SI Monitor voltage is less than the Chg2 Shld Cur- Y N
rent Control Point V (dC140). The Monitor voltage is either 50% less for two consecutive sam- Press Stop. Disconnect the wire at P201-7 (J6) of the MIN ADA PWB #2. Mea-
ples or 75% less for five consecutive samples. The fault is not declared unless the Chg2 sure the voltage between TP204 (+) and TP2 (-) of the HVDC PWB. Press
Current Control Point V is greater than 0.4 VDC. Continue. The measured voltage is within +/- 0.5 of the Control Point V.
Y N
Initial Actions Go to Flag 1. Check for a short circuit. Go to Flag 3. Check for an open cir-
Check [SCP] Queued Faults following the shutdown. If combinations of 9-325, 9-326, 9-327, cuit. If the circuits are OK, replace the HVDC PWB (PL 1.7).
9-328, and/or 9-329 faults are indicated, go to the 9-328 RAP first.
Reconnect the wire at P201-7 (J6) of the MIN ADA PWB #2. Replace the MIN
NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx ADA PWB #2 (PL 1.8).
does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA
Entry Procedure (Service Call Procedures). PWB #2 (PL 1.8).
Inspect for open circuits, loose connections, contamination, arcing, and discoloration of the fol- Press Stop. Check the following:
lowing: • Go to Flag 2. Check for an open or short circuit.
• Go to Flag 1. Check for a short circuit.
• If both checks are OK, replace the MIN ADA PWB #2 (PL 1.8).
• HVDC Cables (PL 1.7). Press Stop. Enter dC140. Do not press Continue.
Perform the Charge Dicorotron Balance (ADJ 9-6) and Height (ADJ 9-7) adjustments.
NOTE: dC140 will not operate with a queued fault. Press the R (reset) button on the IOT Con-
Procedure
Enter dC909, [Printer Options], [Test Patterns and PQ], [Lighter 1], [Patch Test]. Program The Chg2 Shld Current Control Point V is 0.
a 500 print job. Press Continue. Observe the Control Values displays. Run a few prints until Y N
The Chg2 Shld Current Control Point V is not=0, go to the 9-203, 9-213 RAP.
the Charge 2 ua and the Dark Decay V stabilizes. The Charge 2 ua display is greater than
50.
Y N The Chg2 Shld Current Control Point V is=0, go to the Printer Electrical Noise Procedure NRD
3 (Service Call Procedures).
Press Stop. Enter dC140. Press Continue. Observe the Chg2 Shld Current displays.
NOTE: dC140 will not operate with a queued fault. Press the R (reset) button on the IOT
The Chg2 SI Monitor is 0.0 +/- 0.1.

Y N
Press Stop. Measure the voltage between TP202 (+) and TP2 (-) of the HVDC
PWB. Press Continue. The measured voltage is within +/- 0.5 of the Control
Point V.
Y N
Press Stop. Disconnect the wire at P202-16 (J5) of the MIN ADA PWB #2.
Measure the voltage between TS14 (+) and TS56 (-) of the MIN ADA PWB #2.
Press Continue. The measured voltage is within +/- 0.5 of the Control
Point V.
Y N
Go to Flag 2. Check for an open or a short circuit. If the circuit is OK, replace
the HVDC PWB (PL 1.7).
A B C

9-332 RAP 9-353 RAP
Fault code, 9-332, indicates a failure to complete Cycle Up Convergence after power up. Fault Code, 9-353, indicates that the control logic sensed a failure to converge contrast poten-
tials during dC951 Setup.
Procedure
Initial Actions
CAUTION
• Ensure that the Cleaner Zone Roll is engaged. The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to
• Check the PR Ground Strip for damage. under two (2) minutes. If the belt module will be exposed to light for longer than two minutes,
• Check the Ground brush for contamination, deformation, or loss of fibers. Replace as remove the photoreceptor from the belt module and place it immediately into the protective
required (PL 9.7). photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module.
• Check the ESV Height Adjustment (ADJ 9-12). • Ensure that the Cleaner Zone Roll is engaged.
• Check the Charge Dicorotron Height (ADJ 9-6) and Charge Dicorotron Balance (ADJ 9- • Check ROS Low Correction Factor (ADJ 6-3).
7). • Enter dC107, [Xero]. Check the P/R Belt life. If greater than threshold, replace the Photo-
• Check the ESV Monitor voltage in dC909 ESV/DSS Test for 1.0 +/- 0.2 Volts. receptor Belt.
• Perform the Xerographic Set-up (ADJ 9-3). If the fault continues, go to the PQ 9-633, PR Procedure
Uniformity RAP. WARNING
Laser Radiation. Avoid direct exposure to the beam.
Cover the Photoreceptor Belt, under the ROS Assembly, inboard to outboard with white paper.
tinue. Observe the scan line on the paper. There is a continuous scan line across the
paper.
Y N
NOTE: Scan line observations are easily made using the Remote Hand Held Device (RHHD).
For detailed Operating Instructions of the RHHD, go to (GP 1).
Y N
Keep [Laser Write] energized. Select [Patch Exposure]. The inboard half of the beam should
become dimmer than the outboard. Press Continue.
the above check.

Y N
Press Stop. Remove the paper from the Photoreceptor Belt. Close the Printer Front Doors.
Select [Laser Write]. Press Continue. +5 VDC is measured between TH4 (+) and TH15 (-)
on the ROS Distribution PWB.
Y N
CAUTION ing operation.

Ensure that all paper is removed from under the ROS Assembly to avoid Printer damage dur- +5 VDC is measured between TS30 (+) and TSPWR GND (-) on the RCM PWB.
A
A
Y N
Go to PQ 9-633, PR Uniformity RAP. Return to this RAP after completing the PQ 9-633 proce-
dure.
Adjust the ROS Low Correction Factor (ADJ 6-3). Perform the Xerographic Setup (ADJ 9-3). If
the problem continues, the ROS assembly may have been miscalibrated for the ROS Patch
Exposure setup. There is no field adjustment for the ROS Patch Exposure, replace the ROS
Assembly (PL 6.1), adjust the ROS Low Correction Factor (ADJ 6-3) and perform the Xero-
graphic Setup (ADJ 9-3).

9-354 RAP Fault Code, 9-354, indicates that the control logic sensed a failure to set toner concentration
during the dC951 Automatic Xerographic Setup.

A
Initial Actions NOTE: The correlation between DSS readings and output density is as follows: The DSS
CAUTION reading range is 234 +/- 14. The higher the reading the lighter the density should be.
Example: If the DSS reading is 248 the patch density should be about STD/LT:UM. If the
The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to
DSS reading is 220 the patch density should be about STD:Restore.
under two (2) minutes. If the belt module will be exposed to light for longer than two minutes,
remove the photoreceptor from the belt module and place it immediately into the protective The correlation between output density and DSS reading is correct.
photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module. Y N
• Ensure that the Photoreceptor area is clean and that all the covers and inner panels are in Perform the DSS Timing (ADJ 9-14), then repeat the output density correlation
place. check. If no correlation is seen, replace the DSS (PL 9.7).
• Check the DSS Timing (ADJ 9-14).
The Patch is 17.5 mm wide in the process direction, and is 20 to 25 mm high, cen-
• Check the DSS Timing (ADJ 9-14).
tered top-to-bottom, on a 14 inch sheet of paper.
• Enter dC1311, MIN NVM. Ensure that locations 220=51, 251=101 and 125=252. Y N
• Enter dC105. Ensure the Precision Patch is Enabled. Go to PQ 9-621, Patch Gen/Patch Integrity RAP.
Procedure
Enter dC131 [MIN]. Select Address 348 (TC detone). Enter the Data value listed in the appro-
priate level Software dC 131 Table in General Procedures. Enter dC951. Select [TC/PGen].
The DSS has been calibrated with a dirty belt. Go to PQ 9-617, Cleaner RAP.
Press Continue. A 9-354 fault is declared.
Y N
If another fault presents continued problems go to the RAP for that fault code. If the Xero-
graphic Setup was successfully completed, exit this procedure.
Pull out the Xerographic Drawer. Raise the Photoreceptor Module. Select [Precharge/Prexfr
Lamps]. Press Continue. Examine the lamps closely. All segments of both lamps are lit.
Y N
If some, but not all of the segments, of a lamp are lit, replace that lamp (PL 9.4).
If an entire lamp does not light, go to PQ 9-624, Precharge/Pretransfer Lamps RAP.
Select [TC/Patch Gen]. Press Continue. When the Setting Toner Concentration screen
appears, observe the Average DSS display. The Average DSS Current Reading is greater
than the DSS Target Reading. (The Printer thinks the patch is too light).
Y N
Press Stop. Enter dC909. Select [Print Patch] (Yes). Press Continue. Compare the
patch density to the STD:Restore on the XTP 564.001 (82E4161). The patches are
darker than STD:Restore.
Y N
Enter dC951, [Initialize]. Press Continue. Hardstop the printer as soon as a DSS reading is
displayed, about 10 seconds after the Continue button is pressed. Slide out the PR Module
and inspect the PR Belt. Toner is present on the PR Belt before and after the Cleaner.
Y N
Enter dC909. Select [Patch Test], [Patch Print (Yes). Press Continue. Observe the
DSS readings during operation.
A

A
9-355 RAP Y N
Fault Code, 9-355, indicates that the control logic sensed a failure to set the Patch Generator
during the dC951 Automatic Xerographic setup. Measure between TS53 (+) and TS37 (-) of the MIN DIO PWB. Select [Patch Gen High].
Press Continue.
Initial Actions NOTE: When [Patch Gen High] is energized in dC330, [9]. The signal is pulsed as a
• Ensure that the Cleaner Zone Roll is engaged. square wave. Use Peak Hold (-) to measure the low pulse as required. The DMM Peak
• Ensure that all covers and inner panels are in place. Hold Procedure is located at the end of this RAP.
• Check the Patch Generator Timing (ADJ 9-5).
The voltage pulses between 5 VDC and 0 VDC.
• Enter dC105. Ensure that the Digital Patch Generator is Enabled. Y N
Procedure Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB
CAUTION (PL 1.8).
DO NOT install an analog Patch Generator into a 4180 machine, damage to the MIN DIO PWB
Measure between TS8 (+) and TS20 (-) of the MIB PWB. The voltage pulses between
will result. 4180 machines use a digital Patch Generator.
5 VDC and 0 VDC.
CAUTION Y N
The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to Go to Flag 1. Check for an open circuit.
under two (2) minutes. Also, DO NOT leave the Patch Generator energized for longer than two
minutes. Severe xerographic problems may result. If the belt module will be exposed to light for Measure between TS13 (+) and TS20 (-) of the MIB PWB. The voltage pulses between
longer than two minutes, remove the photoreceptor from the belt module and place it immedi- 2.5 VDC and 0 VDC.
ately into the protective photoreceptor bag or place the bag over the Photoreceptor with it on Y N
the belt module. Replace the MIB PWB (PL 1.8).
Cheat the Printer Interlock Bypass Switch. Pull out the Xerographic Drawer. Raise the Photore-
ceptor Module. Enter dC330, [9]. Select [Precharge/Prexfr Lamps]. Press Continue. Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the Patch Generator
Observe the Precharge and the Pretransfer Lamps. All segments of each lamp are lit. (PL 9.10).
Y N
If some, but not all of the segments, of a lamp are lit, replace that lamp (PL 9.3). All 4 LEDs are lit.
If an entire lamp does not light, go to PQ 9-624, Precharge/Pretransfer Lamps RAP. Y N
Press Stop.
Enter dC131 [MIN]. Ensure that the following MIN NVM Addresses are at the values as listed Close the Xerographic Drawer. Cheat the Printer Interlock Bypass Switch. Observe the Patch
in the appropriate level Software dC 131 Table in General Procedures. Change the data as Generator during operation. Enter dC606, [Printer Options]. Program a 25 print job. Press
required. Continue. The Patch Generator LED's flash on and off during printer operation.
Y N
Table 1 Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2
(PL 1.8).
Address Current Value Description
135 PGen Increment Enter dC330, [9], [Patch Gen High]. Measure the voltage between TS32 (+) and TS37 (-) of
250 PGen Intercept the MIN DIO PWB. Press Continue.
254 PGen Normal NOTE: When [Patch Gen High] is energized in dC330, [9]. The signal is pulsed as a square
wave. Use Peak Hold (-) to measure the low pulse as required. The DMM Peak Hold Proce-
Enter dC951. Select [TC/Patch Gen]. Press Continue. A 9-355 fault is declared. dure is located at the end of this RAP.
Y N
The voltage pulses between 5 VDC and 0 VDC.
The Xerographic Setup was successfully completed. Exit this procedure.
Y N
Go to Flag 5. Check for an open or a short circuit. If the circuit is OK, replace the Patch
Select [Patch Gen High]. Use a mirror to observe the Patch Generator light. Press Continue.
Generator (PL 9.10).
At least one LED is lit.
Y N
Press Stop. +5 VDC is measured between P240-2 (+) and P240-4 (-) of the Patch
Generator connector.
A B
B
Enter dC606, [Printer Options], [Test Patterns and PQ]. Using Peak Hold (+), measure
between TS2 (+) and TS56 (-) of the MIN ADA PWB #2 for each Print Darkness measurement.
Press Continue.
NOTE: The measured voltage may vary from the voltage listed below, but the relative voltage
from mode to mode should change as shown:
• +1.8 VDC is measured in [Normal]

The voltages are OK.
Y N
After the Initialization Screen is completed and the Toner Concentration Setup is operating,
observe the Average DSS displays. After 10 updates, press Stop.
NOTE: There should not be greater than +/- 5 bits variation in readings from one update to
another.
The Readings are consistent.

Y N
Go to PQ 9-630, Toner/Charge Control RAP and PQ 9-633, PR Uniformity RAP as
required.

DMM Peak Hold Procedure:
• Select V or mA as required.
• Select AC or DC and range as required.
• Place Meter Probes in the Volt-Ohm (+) and the COM (-) Jacks
• Press (+) or (-) polarity.
NOTE: To measure for negative peaks on a positive voltage, first select (+) peak polarity, press
the Peak Hold button then switch polarity to (-) peak polarity. For further information, go to the
DMM operators Manual.
• To make a new measurement, release the Peak Hold button to clear previous reading and
repeat procedure.


9-356 RAP 9-360 RAP
The Fault Code 9-356 indicates a failure to converge charge in toner concentration setup dur- The Fault Code 9-360 indicates that the ROS Low Correction Factor adjustment failed to con-
ing dC951. verge in dC951.

Check the following components: WARNING
Avoid direct exposure to the beam. Laser Radiation is present.
• Cleaner Zone Roll for proper engagement
Cover the Photoreceptor, under the ROS Assembly, outboard to inboard with white paper.
• PR Belt Ground Strip for damage
Cheat the Processor Interlock Bypass Switch. Enter dC330, [6]. Select [Laser Write]. Press
• Ground Brush for contamination and/or damage the Continue button. Observe the scanline on the paper. (The scanline should not be missing
• ESM Timing, dC951 MIN location 260=40 in the middle of the PR Belt area). There is a full scanline across the paper.
• ROS Patch Exposure, dC330. If not OK, go to the 9-360 RAP Y N
Procedure
Enter dC909. Select [Charge Control], [Open]. Press the Continue button. Check the ESV NOTE: If you are not sure, continue with the [Yes] path.
readings for stability after 40 prints. The readings for ID Zones 2, 4, and 6 are within +/-25
VDC of themselves. With [Laser Write] on, the scanline appears to be of equal brilliance across the paper
Y N (the inboard half of the beam should not be dimmer than the outboard half).
Select [Stop]. Check the Charge Dicorotrons for arcing. Clean the shields and reseat the Y N
Dicorotrons. If the problem is still present, go to PQ 9-619, ESV RAP. Go to the 6-701 RAP.
Go to PQ 9-624, Precharge/Pretransfer Erase Lamps RAP. If the PQ 9-624 RAP is OK, go to With [Laser Write] on, select [Patch Enable]. Press the Continue button. The scanline is
PQ 9-617, Cleaner RAP. completely off in the patch area (approximately the middle of the PR Belt).
Y N
Press the Stop button to turn off the [Patch Enable] output. With [Laser Write] on, select
[Patch Exposure]. While observing the scanline, press the Continue button. The scanline is
visible dimmer on the inboard side of the paper, compared to the outboard side (approx-
imately from the middle of the belt to the inboard end of the beam should be about half
the brightness of the outboard end). HINT: Toggle the output several times on/off while
observing the scanline, if you are unsure of the above check.
Y N
Replace the following, one at a time and in the order given, until the problem is resolved:
• Pixel Clock PWB (PL 1.11).
• SLB/RDR PWB (PL 1.11).
• ROS Assembly (PL 6.1).

9-361 RAP
Fault Code 9-361 indicates that the ROS adjustment was out of range in dC951.
Procedure
Cover the Photoreceptor, under the ROS assembly, outboard to inboard with white paper.
Cheat the Processor Interlock Bypass Switch. Enter dC330, [6]. Select [Write Laser]. Press
the Continue button. Observe the scanline on the paper. There is a full scanline across the
paper (the scanline should not be missing in the middle of the page).
Y N
With the (Write Laser) on. The scanline appears to be equal in brilliance across the paper
(the inboard half of the beam should be not dimmer than the middle of the PR Belt).
Y N
With the (Laser Write) on, select (Patch). Press the CONTINUE button. The scanline is com-
pletely off in the middle of the Patch area (approximately the middle of the PR Belt).
Y N
Press the STOP button to turn off the (Patch) output. With (Laser Write) on, select (Patch
Exposure). While observing the scanline, press the CONTINUE button.
NOTE: If your not sure, continue with the (YES) path.
The scanline is visibly dimmer on the inboard side of the paper, compared to the out-
board side (approximately from the middle of the belt to the inboard end of the beam
should be about half the brightness of the outboard end)
Y N
NOTE: Toggle the output several times ON and OFF while observing the scanline if your not
sure of the above check.
Check for excessive dirt in the Xerographic area of the printer. If there is a excessive build up
of dirt, find the cause of the build up and repair it. If dirt was found clean in the Xerographic
subsystem, The likely cause of the dirt are the Cleaner and developer area of the machine. If
the problem continues, replace the ROS Assembly.

9-702 Dry Ink Level Low Message RAP
Message indicates that the Low Toner Sensor, Q903, sensed no toner.
Procedure
NOTE: MICR (DP180MX) Machines use a red Toner Bottle that is not compatible with DP180.
Enter dC330, [9]. Select [Toner Thumper]. Press Continue.
NOTE: Listening for the Thumper may be inadequate. Cheat the Front Door Interlocks.
Observe the solenoid actuation.
The Toner Solenoid Thumper is working.

Y N
Go to Flag 2. Check the circuit of the Toner Thumper Solenoid. (Generic Solenoid RAP
The Thumper hits the bottle.

Y N
Adjust the Toner Thumper (ADJ 9-10). Replace the Thumper Assembly as required (PL
9.19).
The Low Toner Sensor is H.

Y N
+24 VDC is measured between MT10-1 (+) of the Low Toner Sensor and TS37 (-) of
the MIN DIO PWB.
Y N
Go to wire, 1005M/1005H wirenet. Check for a short or an open circuit.
Go to Flag 1. Check the circuit of the Low Toner Sensor. (GP 6-2, General Procedures).
Remove Toner Bottle. Check the operation of the cross mix baffle.


9-703 Replace the Waste Bottle Message RAP
Initial Actions
Ensure that a Waste Container is in the printer.
Ensure that the Waste Bottle Full Sensor is clean and mounted properly.
Procedure
Inspect the PR Drawer Ribbon Cable connections. Ensure that the plugs are secure at the
back of the Xerographic Drawer and at the frame near the HVAC/HVDC PWBs Enter dC330,
[9]. Move the Waste Bottle to actuate the sensor. The Waste Bottle Full Sensor display
goes L.
Y N
Go to Flag 1. Check the circuit of the Waste Bottle Full Sensor, Q906. (GP 6-2, General
Procedures).

• Sensor Band for damage or burrs (PL 9.7).
• Bottle Guide Bracket for proper orientation
• Waste Bottle for damage in area of the Sensor Band
• If the above checks are OK, replace the Waste Container (PL 9.22).


9-704 Toner Filter Blower Motor RAP
Initial Actions
Check the Toner Filter Blower O-Rings for damage (PL 9.20).
Ensure that the wires are connected to the Toner Filter Blower Motor Capacitor.
Procedure
WARNING
When the Main Drive is running, be careful when working near the Toner Filter Blower
Motor and the MIN Compressor.
Remove the Blower Pulley Guard and the Toner Filter Blower O-Rings. Enter dC606. Press
Continue. The Toner Filter Blower Motor operates.
Y N
Press Stop. Reinstall the Blower Pulley Guard and the Toner Filter Blower O-Rings.
Press Continue. 115 VAC is measured between PVC-1 and PVC-2 of the Toner Filter
Blower Motor Connector.
Y N
115 VAC is measured between 1TB1-18 and 1TB1-12.
Y N
(60HZ) Go to the 4-700, Main Drive RAP.
(50HZ) Go to the 4-704, Print Power RAP.
Go to Flag 1. Check for an open circuit. If the circuit is OK, Check for loose or miss-
ing pins in the 1TB1 Terminal Block.
Replace the Toner Filter Blower Motor MOT905, (PL 9.20).
Spin the Toner Filter Blower Shaft by hand. A binding or resistance is felt in the shaft.
Y N
Replace the Capacitor C902, (PL 9.20).
Replace Toner Filter Blower (PL 9.20).


9-705 MIN Cooling Fan RAP
This procedure is used to diagnose MIN Cooling Fan failures.
Initial Actions
Ensure that the fan connector is not damaged and is securely fastened.
Clear any obstructions from the fan area that may restrict air flow.
Procedure
WARNING
When the Main Drive is running, use Caution when working in the vicinity of the Toner
Filter Blower Motor and the MIN Compressor.
115 VAC is measured between JBT-1 and JBT-2 of the MIN Cooling Fan Connector.
Y N
115 VAC is measured between 1TB1-3 and 1TB-5.
Y N
(60HZ) Go to the 1-703, AC Switched On Power RAP.
(50HZ) Go to the 1-710, AC Switched On Power RAP.
Go to Flag 1. Repair the open circuit.
Enter [dC] [Power Interrupt] Disconnect the two pin connector on the MIN Cooling Fan. Press
Continue. 115 VAC is measured between PBT1-1 and PB1-2 at the Cooling Fan.
Y N
Replace the MIN Cooling Fan (PL 4.9).


A B C
9-706 Power Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVDC PWB
(PL 1.7).
This RAP is used to diagnose standby power to the HVAC and HVDC PWBs.
Procedure
+15 VDC is measured between P294-4 (+) and P294-9 (-), (J1) of the HVAC PWB. 7.3 +/- 0.2 VAC is measured between TP1 (+) and TP2 (-) of the HVDC PWB.
Y N
Y N
+15 VDC is measured between TH6 (+) and TH8 (-) on the LVPS. Greater than 7.6 VAC is measured between TP1 (+) and TP2 (-) of the HVDC PWB.
Y N Y N
Disconnect the Ribbon Cable between the HVDC and HVAC PWB. Greater than
6.6 VAC is measured between TP1 (+) and TP2 (-) of the HVDC PWB.
Go to the wire, 1009J, wirenet. Y N
-15 VDC is measured between P294-6 (+) and P294-9 (-), (J1) of the HVAC PWB.
Y N Go to Flag 3. Check for an short circuit. If the circuit is OK, replace the HVAC PWB
(PL 1.7).
-15 VDC is measured between TH7 (+) and TH8 (-) on the LVPS.
Y N
Go to the 1-716 RAP. Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the HVAC PWB (PL
1.7).
Go to the wire, 1010H, wirenet.
+24 VDC is measured between P294-5 (+) and P294-9 (-), (J1) of the HVAC PWB.
Y N
+34 VDC is measured between P294-7 (+) and P294-10 (-) of the HVAC PWB.
Y N
Y N
Go to the 1-717, +24, +34, -34 VDC RAP.
Check the +34 VDC wirenet 1018A/1018C for an open.
+15 VDC is measured between P293-4 (+) and P293-9 (-), (J1) of the HVDC PWB.
Y N
Y N
Go to the wire, 1009H, wirenet.
3.5 +/- 0.5 VAC is measured between P293-3 (+) and P293-8 (-) of the HVDC PWB.
Y N
3.5 +/- 0.5 VAC is measured between TH19 (+) and TH20 (-) on the LVPS.
Y N
Switch Off Printer power. Wait for the LVPS LEDs to go off. Disconnect P354 from
the LVPS. Switch on Printer power. 3.5 +/- 0.5 VAC is measured between TH19 (+)
and TH20 (-) of the LVPS.
Y N
Replace the LVPS (PL 1.9).
A B C
Figure 1 9-706 Circuit Diagram (7932D)

A B C
10-101 RAP Place a sheet of paper (8 1/2 x 11 or A3 if available) on the Prefuser Transport. The
vacuum holds the sheet on the Prefuser Transport.
Fault Code, 10-101, indicates that a print did not actuate the Prefuser Sensor, Q1009, within Y N
the specified number of clock counts after it arrived at the Registration Sensor. Check the Prefuser Transport Assembly for vacuum leaks and restricted or
damaged air ducts (PL 8.12).
Initial Actions
Select [Clear Outputs] [1-4] [Main Drive/Start Run] motor. Press the Continue
• Ensure that the Prefuser Sensor and Reflector are not obstructed and that the Prefuser
Sensor and Reflector are clean and in proper position. button. The Prefuser Transport Belts rotate.
Y N
• Ensure that the Prefuser Transport is in the normal operating position.
Check the Prefuser Transport Drive system for damaged or worn components
• Check the Prefuser Transport adjustment (ADJ 10-18). (PL 4.16).
• The Fault Code, 10-101, occurring at machine start may be due to a dirty or defective
Registration Transport Sensor, Q861. Check the following:
• Ensure that the paper path is free from obstructions. • Damaged or contaminated Prefuser Transport Drive Belts (PL 4.16).
• Load fresh paper and run the machine. If the fault is no longer present advise the Key • Binding Prefuser Transport Bearings (part of the drive roll) (PL 8.12).
Operator about the storage and use of paper. • Worn Prefuser Transport Drive Coupling (part of the drive coupling) (PL 8.12).
• Ensure that the paper is loaded correctly and that curl is not excessive. • Obstructed Prefuser Transport Manifold holes
Procedure • Check the Prefuser Transport adjustment (ADJ 10-18).
Enter dC106. Run the machine until Fault Code, 10-101, is declared. Inspect the image on the • If all other checks are good refer to the Generic Sensor GP 6-2, (General Pro-
jammed print. The image is skewed or misregistered. cedures) and ensure that the sensor voltages for the Registration Transport
Y N Sensor and Prefuser Sensor are correct.
Enter dC330, [8]. Block and then clear the Registration Sensor, Q861. The display
changes from H to L. Check the following:
Y N • Obstructions in the paper path
Go to the 8-155. • Condition of the paper
• Operation and condition of the Transfer and Detack Dicorotrons (REP 9-39 and REP
Select [10]. Open, then close the Fuser Drawer. The Prefuser Sensor display changes 9-49).
from L to H.
• Condition of the Pretransfer Baffle (PL 8.11).
Y N
Measure the voltage at TS24 (+) and TS37 (-) on the PHN DIO PWB #2. If the • Condition of the Stripper Finger Assembly (PL 9.3).
voltage is greater than +0.5 VDC, clean the Prefuser Sensor. Check the Pre- • Condition and operation of the Transfer Assist Blade (PL 9.11).
fuser Sensor Reflector for damage or contamination (ensure that the sensor • Condition of the Detack Guide (PL 9.11).
and reflector are aligned). If +0.5 VDC or less cannot be obtained, replace the
Prefuser Sensor (PL 8.12). Go to the 8-706 PHM Misregistration and Skew RAP.
Y N
Go to Flag 1. Check the circuit of the Prefuser Sensor.
Rerun the machine to ensure that the problem is resolved. If the problem reoccurs
go to the beginning of this RAP.
Clear the Fault Code. If Fault Code, 10-101, can not be cleared, switch off and then reset
all printer circuit breakers. Enter dC106. Run the machine until Fault Code, 10-101, is
declared (if Fault Code, 10-101, is not declared, go to the declared fault). The print is
jammed or stopped before the Prefuser Transport.
Y N
Install a cheater in the Printer Interlock Bypass Switch. Select [Prefuser Vacuum]
motor. Press the Continue button. The Prefuser Vacuum Motor comes on.
Y N
Go to the 10-706 Prefuser Vacuum Motor RAP.
A B C
10-102 RAP Fault Code, 10-102, can also be declared if the specified number of clock counts is exceeded
(during seven pitch mode) after actuating the Fuser Sensor, Q1010, the Prefuser Sensor,
Fault Code, 10-102, indicates that a print did not reach the Fuser Jam Sensor, Q1010, within Q1009, is still blocked.
the specified number of clock counts after it arrived at the Prefuser Jam Sensor, Q1009, and
that the Prefuser Jam Sensor, Q1009, is still blocked after machine cycle-down.

Initial Actions Measure the voltage between TS21 (+) and TS37 (-) on the PHN DIO PWB #2. If volt-
age is greater than +0.5 VDC, clean the Fuser Sensor. Check the Fuser Sensor
WARNING Reflector for damage or contamination. If +0.5 VDC or less cannot be obtained,
Whenever the IOT Compressor is running keep hands and clothing away from the com- replace the Fuser Sensor (PL 10.5
pressor area. Use extreme caution when performing service in this area. Y N
If the Compressor Motor is in an overheat condition it will run automatically when cool Go to Flag 1. Check the circuit of the Fuser Sensor (GP 6-2 General Procedures).
and the internal thermal switch resets.
CAUTION Clear the Fault Code. If the Fault Code, 10-102, can not be cleared, switch off and then
reset all printer circuit breakers. Check the Fuser Roll Temperature (ADJ 10-6). The
Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to
Fuser Temperature is in specification.
the cover may occur.
Y N
Perform the following: Ensure that the Fuser and Metering Roll Thermistors are clean and making proper
contact. Enter dC701. Adjust the Fuser Roll Temperature (ADJ 10-6).
• Check SCP HFSI due for the Fuser Module (10-800 series) and perform as necessary.
• Ensure that the Prefuser Sensor and Reflector are clean and are not obstructed. Ensure Install a cheater in the Printer Interlock By-pass Switch. Enter dC330, [10]. Select [Pre-
that the sensor and reflector are correctly aligned. Fault Code, 10-102, occurring at print fuser Vacuum] motor. Press the Continue button. The Prefuser Vacuum Motor comes
cycle up may be due to a dirty or defective Prefuser Sensor. on.
• Ensure that the Prefuser Transport is in the normal operating position. Y N
• Check the Prefuser Transport adjustment (ADJ 10-18). Go to the 10-706 Prefuser Vacuum Motor RAP.
NOTE: Use only Fuser Agent for the DP180. Place a sheet of paper (8 1/2 x 11 or A3 if available) on the Prefuser Vacuum Transport.
The vacuum holds the sheet on the Prefuser Transport.
• Check the Fuser Agent level. If the reservoir is empty and the machine has not detected
Y N
this condition, go to the 10-705 Low Fuser Agent Level RAP.
Check the Prefuser Transport for vacuum leaks and restricted or damaged air ducts.
• Enter dC131. Ensure that the PHN NVM locations 180, 181, 182, and 183 are at the val-
ues given in the appropriate level Software dC 131 Table in General Procedures.
The image on the jammed print is completely and correctly fused.
• Ensure that the print paper is loaded correctly and that paper curl is not excessive (refer Y N
to the Decurler section in the Operators Manual). Run the machine. The Fuser Heat Roll rotates.
• Load fresh paper and run the machine. If the fault is no longer present advise the Opera- Y N
tor about the storage and use of paper. Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The
• Image that extends to the edge of the prints can cause an increased frequency of jams. Fuser Drive Coupling (at rear of machine) rotates.
Avoid dense images at the lead and trail edges of the print for superior performance. Y N
Notify operator of the lead edge lightening operation as described in the Operators Man- The Fuser / Developer Drive Motor Comes on.
ual. Y N
Go to the 4-705 Fuser Developer Drive Motor RAP.
• Ensure the PR Drive coupling is properly lubricated with Moly Grease (PL 25.1). See Roll-
overs (PC 3676, RO 177643) in the Service Information section for additional information
Check the Fuser Drive assembly for damaged or worn components (PL
on the lubricant and a tool for its application.
4.17).
Procedure
Enter dC606. Run the machine until Fault Code, 10-102, is declared (if Fault Code, 10-102, is Inspect Fuser Drive Gears and Fuser Drive Coupling for wear. The gears or
not declared go to the declared fault). Inspect the image on the jammed print. The image is coupling are worn.
skewed or misregistered. Y N
Y N Move the Fuser Drive Coupling in and out. The Fuser Drive Coupling
Enter dC330, [10]. Open, then close the Fuser Drawer. The Prefuser Sensor display moves in and out freely.
changes from L to H. Y N
Y N Clean, repair, or replace the Fuser Drive Coupling (PL 4.17).
Go to Flag 2. Check the circuit of the Prefuser Sensor (GP 6-2, General Proce-
dures). Enter dC606. Run the machine. Inspect the Fuser Idler Gear while the
machine is running. Intermittent Fuser drive is observed.
Y N
Clean, repair, or replace the Fuser Roll (REP 10-1).
A B C D
A B C D A B
Clean, repair, or replace the Fuser Drive Coupling (PL 4.17). Y N
Check for a blocked or damaged Air Line between the Air Gauge and Air
Replace the Fuser Drive Gear or Fuser Drive Coupling (PL 4.17). Knife Solenoid. If OK, replace the Air Knife Solenoid (PL 10.5).
Enter dC106. Run the machine. The Pressure Roll cams in. Check for a blocked or damaged Air Knife Manifold or Air Line to the Air Knife
Y N Manifold.
Check for binding or worn components in the Pressure Roll Camming system
(PL 10.2). Check the Air Knife Manifold condition and adjustment (ADJ 10-4). The Air Knife
Manifold is OK.
Enter dC330, [10], [Compressor] motor. Press the Continue button. The Com- Y N
pressor Motor comes on. Repair or replace the Air Knife Manifold (PL 10.5).
Y N
Go to the 10-703, Printer Compressor Motor RAP. Check the Stripper Finger Baffle Assembly (ADJ 10-15). The Stripper Finger Baf-
fle Assembly is adjusted correctly.
The Air Knife Pressure is at 20 +/- 1 PSI (ADJ 10-5). Y N
Y N Adjust the Stripper Finger Baffle Assembly (ADJ 10-15).
The Air Knife Pressure can be adjusted to 20 +/- 1 PSI (ADJ 10-5).
Y N Check the following:
Go to the 10-702 Fuser Air System Checkout and check for an air leak. • Condition of the Fuser Entrance Baffle (PL 10.4).
• The Pressure Roll Contact Arc (ADJ 10-2).
Select [Air-Knife], [Cycle]. Press the Continue Button. The Air Knife Sole-
• Ensure that the Fuser Drive Coupling moves in and out freely
noid cycles on and off.
• The Fuser Drive Coupling (ensure to check both the drive side and the mating
Y N
Go to Flag 3. Check the circuit of the Air Knife Solenoid. side on the fuser) for wear, damage, and proper engagement (PL 4.17).
Inspect the Fuser Roll and Pressure Roll surfaces for damage. Either roll is damaged.
There is less than a 2 PSI momentary decrease in air pressure as the air
knife solenoid energizes. Y N
Y N The jammed print has completely exited the Fuser Exit Baffle.
Y N
Check for a leak in the air line between the Pressure Regulator and the Air
Knife Manifold. Enter dC330, [10], [Compressor] motor. Press the Continue button. The
Compressor Motor comes on.
Y N
• Condition and operation of the Air Knife Solenoid (PL 10.5). Go to the 10-703, Printer Compressor Motor RAP.
• Adjustment of the Air Knife Manifold (ADJ 10-4).

The Air Knife Pressure is at 20 +/- 1 PSI (ADJ 10-5).
• Damaged or kinked air line between the Pressure Regulator and the Air Y N
Knife Manifold The Air Knife Pressure can be adjusted to 20 +/- 1 PSI (ADJ 10-5).
• Go to the 10-702 RAP and perform the check for the Moisture Trap / Air Y N
Filter Go to the 10-702 Fuser Air System Checkout and check for an air
leak.
Pull out the Fuser Drawer. Bypass the Processor Interlocks. Select [Air Knife],
[Cycle]. Press the Continue button. A pulsating Air jet can be felt at all the Air The Air Knife Solenoid energizes.
Knife Manifold openings. Y N
Y N Go to Flag 3. Check the circuit of the Air Knife Solenoid.
The Air Knife Solenoid is energized.
Y N There is less than a 2 PSI momentary decrease in air pressure as the
Go to Flag 3. Check the circuit of the Air Knife Solenoid. air knife solenoid energizes.
Y N
Disconnect the Air Line from the Air Knife side of the Air Knife Solenoid. Air is Check for a leak in the air line between the Pressure Regulator and
discharged from the Air Knife Solenoid. the Air Knife Manifold.

A B A E F G H
A E F G H A E F I J
• Condition and operation of the Air Knife Solenoid (PL 10.5). Ensure that the PHN NVM location 188 =18. Place the output hose from
• Adjustment of the Air Knife Manifold (ADJ 10-4). the Fuser Agent Pump into the cap from a Fuser Agent bottle (bottle part
• Damaged or kinked air line between the Pressure Regulator and the number is 8R2955). Enter dC330, [10] [Fuser Agent] Pump [Cycle].
Press the Continue button. Count the number of strokes, of the Fuser
Air Knife Manifold
Agent Pump Solenoid, necessary to fill the cap. Press the Stop button.
Pull out the Fuser Drawer. Bypass the Processor Interlocks. Select [Air Knife] The cap filled in 15 or less strokes. NOTE: The Fuser Agent Solenoid
should be run for a few minutes to ensure that all air is removed from
solenoid. Press the Continue button. Air jet can be felt at all the Air Knife
Manifold openings. the fuser agent lines prior to the test.
Y N Y N
Replace the Fuser Agent Pump Assembly (PL 10.8).
The Air Knife Solenoid is energized.
Y N
Go to Flag 3. Check the circuit of the Air Knife Solenoid. Exit dC330. Manually rotate the Donor Roll. The Donor Roll rotates
freely and is not damaged.
Disconnect the Air Line from the Air Knife side of the Air Knife Solenoid. Y N
Air is discharged from the Air Knife Solenoid. Clean or replace the Donor Roll or Donor Roll Bearings (PL 10.8).
Y N
Check for a blocked or damaged Air Line between the Air Gauge and Remove the Metering Roll and check the following:
Air Knife Solenoid. If OK, replace the Air Knife Solenoid (PL 10.5). • Metering Roll and Metering Roll Bearings (PL 10.7).
• Metering Blade for damage or wear (PL 10.7).
Check for a blocked or damaged Air Knife Manifold or Air Line to the Air • Condition of the Fuser Wick (PL 10.7).
Knife Manifold. • Condition of the Fuser Drives for noise or wear (PL 4.17).
• Fuser Static Brush for damage (PL 10.4).
Check the Air Knife Manifold condition and adjustment (ADJ 10-4). The Air
Knife Manifold is OK.
Repair or replace the Fuser Entrance Baffle (PL 10.3).
Y N
Repair or replace the Air Knife Manifold (PL 10.5).
• Condition of the Fuser Exit Baffle (PL 10.4).
Check the Stripper Finger Baffle Assembly (ADJ 10-15). The Stripper Finger
Baffle Assembly is adjusted correctly. • Condition of the Fuser Static Brush (PL 10.4).
Y N • Air Knife Pressure (especially with lightweight paper) (ADJ 10-5), if the Air Knife
Adjust the Stripper Finger Baffle Assembly (ADJ 10-15). pressure cannot be adjusted properly go to the 10-702, Fuser Air System
Checkout and check for an air leak
Select [Camming] motor. Press the Continue button. The Fuser Roll, Donor • Condition of the Fuser Drives for noise or wear (PL 4.17).
Roll, and Metering Roll cam in properly. • Condition of the Donor Roll loading hardware (PL 10.8).
Y N
• Ensure that the Vacuum Manifold and the Air Knife Manifold (ADJ 10-4) are
Check the Camming System for damaged or worn components (PL 10.2).
adjusted correctly
Enter dC106. Run the machine. Observe the prints entering the Fuser nip. The
Determine, and repair the cause of the damage, then replace the damaged Fuser Roll
prints are catching on the Fuser Entrance Baffle.
(REP 10-1).
Y N
Enter dC330, [10], [Fuser Agent Pump] solenoid [Cycle]. Press the
Go to the 8-706 PHM Misregistration and Skew RAP.
Continue button. The Fuser Agent Pump Solenoid cycles on and off.
Y N
Go to the 10-708, Fuser Agent Dispense RAP.
Fuser Agent is being dispensed.

Y N
Check the input and output Fuser Agent Lines for obstruction or dam-
age. Repair or replace as required (PL 10.8).
A E F I J


10-104 RAP Y N
Enter dC330, [10], [Compressor] motor. Press the Continue button. The Air Gauge
Fault Code, 10-104, indicates that a print did not actuate the Decurler Sensor, Q1011, within can be adjusted to 20 +/-1 PSI (ADJ 10-5).
the specified number of clock counts after it arrived at the Fuser Sensor, Q1010. Y N
Check for damaged or restricted air lines. If OK, go to the 10-703 MIN Compressor
Initial Actions Motor RAP.
• Check SCP HFSI due for Fuser Module (10-800 series) actions and perform as neces-
sary. Select [Air-Knife] [Cycle]. Press the Continue Button. The air pressure momentarily
decreases about 2 to 3 PSI as the Air Knife Solenoid energizes.
• Ensure that the Decurler Sensor is not obstructed and that the Decurler Sensor Actuator
Y N
is not damaged.
The Air Knife Solenoid energizes.
• Ensure that the Decurler paper path is free from obstructions. Y N
• Ensure that the Decurler Jam Clearance baffle is positioned correctly. Go to Flag 3. Check the circuit of the Air Knife Solenoid, go to (GP 6-3)
• If the problem occurs only with high humidity or just after machine power-up, check for (Generic Solenoid RAP, General Procedures).
condensed water vapor on Decurler or Top Transport.
• Check the Fuser Vacuum Manifold for proper installation.
• If there is less than a 2 to 3 PSI decrease:
• Fault Code, 10-104, during print cycle-up may be due to a dirty or failed Fuser Sensor,
• Condition and operation of the Air Knife Solenoid (PL 10.5).
Q1011.
• Adjustment of the Air Knife Manifold (ADJ 10-4).
• Ensure that the paper is loaded correctly and that the curl is not excessive (refer to the
Operator Manual, Decurler section). • Damaged or kinked air lines between the Pressure Regulator and the Air Knife
Manifold.
• Image that extends to the edge of prints may cause an increased frequency of jams.
Avoid dense images at the lead and trail edges of the print for superior performance. • If there is a greater than 2 to 3 PSI decrease:
Notify operator of lead edge density suppression (Jam Bypass Operation) (refer to the • Check for a leak in the air line between the Pressure Regulator and the Air
Operator Manual, Options section). Knife Manifold.
NOTE: Use only Fuser Agent for the DP180. Check the condition (PL 10.5).
• If Fuser Agent is not being dispensed go to the 10-708 Fuser Agent Dispense RAP.
Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The Decurler Belts
• Enter dC131. Ensure that the PHN NVM locations 180, 181, 182, and 183 are at the val-
rotate.
ues given in the appropriate level Software dC 131 Table in General Procedures.
Y N
Cheat the Printer Door Interlocks. Enter dC330, [10]. Actuate the Decurler Sensor. The dis- • Damaged or contaminated Decurler Belts (PL 10.12).
play changes from H to L. • Binding or worn Decurler Drive Belts or Pulleys (PL 10.12).
Y N
• Perform Panic Stop Procedure.
Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures).
Select [Clear Outputs]. Enter [SCP] [HFSI] [Print Transport] [10-813]. The number of
Measure the voltage between TS21 (+) and TS37 (-) on the PHN DIO PWB #2. If voltage
prints on Decurler Belts is over threshold.
is greater than +0.5 VDC, clean the Fuser Sensor. Check the Fuser Sensor Reflector for
Y N
damage or contamination. If + 0.5 VDC or less cannot be obtained, replace the Fuser
Sensor (PL 10.5
• Worn or damaged parts
Y N
Go to Flag 2. Check the circuit of the Fuser Sensor (GP 6-2,General Procedures). • Air Knife is adjusted correctly (ADJ 10-4).
• Vacuum Manifold is adjusted correctly.
Select [Camming] motor. Press the Continue button. The Pressure Roll cams in. • If the above checks are OK, replace the Decurler Clutch (PL 10.12).
Y N
Go to the 10-707 Camming Motor RAP. Replace the Decurler Belts (PL 10.12).
Clear the Fault Code. If Fault Code, 10-104, can not be cleared, switch off and then reset all
printer circuit breakers). Run the machine until Fault Code, 10-104, is declared (if Fault Code,
10-104, is not declared, go to the declared fault). The jammed print is started into the
Decurler.


A
10-105 RAP Go to the 8-705 PHM Copy Damage RAP.
Fault Code, 10-105, indicates that the trail edge of the print did not leave the Decurler Sensor, Table 1 HISTOGRAM RESULTS
Q1011, within the specified number of clock counts after actuating the sensor, and that the sen-
Distribution Probable Cause
sor is still actuated after the machine cycle-down.
Random Distribution Check: sensors, drives, loose or worn belts and pulleys in
Initial Actions the Top Transport and Decurler, obstructions in the paper
path, damaged paper path components, excessive paper
• Ensure that the Decurler Jam Clearance Baffle is properly seated and that the Jam Clear-
curl.
ance Baffle Handle is not bent.
Normal Distribution Check: sensors, drives, loose or worn belts and pulleys in
• Check that the paper path and the Decurler Sensor are not obstructed, and that the
the Top Transport or Decurler, obstructions in the paper path,
Decurler Sensor Actuator is not damaged or binding.
damaged paper path components, excessive paper curl.
Procedure Also check the Hardware Induced Crash checklist (Service
Enter dC330, [10]. Actuate the Decurler Sensor. The display changes from H to L. Call Procedures). If the problem continues replace the Top
Y N Transport Slip Clutch (PL 10.14).
Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Late Distribution Replace the Top Transport Clutch and check the following:
drives, loose or worn belts or pulleys in the Decurler and Top
Enter dC726, [53]. Select [100 prints], [Top Tray]. Use the same paper that the customer was Transport drives, proper Decurler Sensor, Q1011, actuation.
using. Run the machine. A 10-105 fault is declared.
Y N
Enter dC330, [10]. The Decurler Sensor actuates before going below the upper baf-
fle, and the actuator goes below the cutout in the post Decurler assembly (proper
overtravel).
Y N
Replace the Decurler Sensor (PL 10.16).
Enter dC726, [53]. Select [100 prints], [Top Tray]. Use the heaviest paper the customer
has available. Refer to the chart below and perform the appropriate action based on the
results of the histogram.
Observe the jammed print without opening the Decurler Jam Clearance Baffle. The Decurler
Sensor is covered.
Y N
Examine the prints in the Top Tray and all the prints in the paper path. The prints are dam-
aged.
Y N
• The Decurler Sensor actuates before going below the upper baffle, and the actuator
goes below the cutout in the Post Decurler assembly (proper overtravel) (PL 10.16).
• Obstructions in the paper path
• All Top Transport idlers and rollers are clean and correctly positioned (all springs are
present and correctly located) (PL 10.15).
• Loose or worn Top Transport drive belts and pulleys (PL 10.14).
• Paper for excessive curl, refer to the Print Paper Diagnostics (Service Call Proce-
dures).
• Loose or worn belts and pulleys in the Decurler Transport Drives (PL 4.16).
• Decurler belts for wear or damage (PL 10.12).
• Replace the Top Transport Slip Clutch (PL 10.14).
A

A
10-106 RAP Go to the 8-705 Print Damage RAP.
Fault Code, 10-106, indicates that the trail edge of the print did not leave the Decurler Sensor, Table 1 HISTOGRAM RESULTS
Q1011, within the specified number of clock counts after actuating the sensor, and that the sen-
Distribution Probable Cause
sor is not actuated after the machine cycle-down.
Random Distribution Check: sensors, drives, loose or worn belts and pulleys in
Initial Actions the Top Transport and Decurler, obstructions in the paper
path, damaged paper path components, excessive paper
• Ensure that the Decurler Jam Clearance Baffle is properly seated and that the Jam Clear-
curl.
ance Baffle Handle is not bent.
Normal Distribution Check: sensors, drives, loose or worn belts and pulleys in
• Check that the paper path and the Decurler Sensor are not obstructed and that the
the Top Transport or Decurler, obstructions in the paper path,
Decurler Sensor Actuator is not damaged.
damaged paper path components, excessive paper curl.
Procedure Also check the Hardware Induced Crash Checklist (Service
Enter dC330, [10]. Actuate the Decurler Sensor. The display changes from H to L. Call Procedures). If the problem continues replace the Top
Y N Transport Slip Clutch (PL 10.14).
Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Late Distribution Replace the Top Transport Clutch (PL 10.14).
Enter dC726, [53]. Select [100] prints, [Top Tray]. Use the same paper that the customer was
using. Fault Code, 10-106, is declared.
Y N
Enter dC330, [10]. The Decurler Sensor actuates before going below the upper baf-
fle, and the actuator goes below the cutout in the Post Decurler assembly (proper
overtravel).
Y N
Enter dC726, [53]. Select [100] prints, [Top Tray]. Use the heaviest weight paper the
customer has available. Refer to the chart below and perform the appropriate action
based on the results of the histogram.
Examine the prints in the Top Tray and all the prints in the paper path. The prints are dam-
aged.
Y N
Enter dC726, [53]. Select [100] prints, [Top Tray]. Use the heaviest paper the customer
has available. The Histogram indicates times approaching the yellow arrow or
beyond (late).
Y N
• Paper path components for damage
• Loose or worn belts or pulleys in the Decurler Transport drives (P L 4.16)
• Decurler Exit Baffle Adjustment (ADJ 10-8).
• Loose or worn belts or pulleys in the Top Transport Drives (PL 10.14).
• Top Transport rollers and idlers are clean and properly seated, and that all
springs are properly installed
Replace the Top Transport Slip Clutch (PL 10.14).
A

A B
10-107 RAP • If the problem continues replace the Top Transport Slip Clutch (PL 10.16).
Fault Code, 10-107, indicates that a print lead edge did not actuate the Top Transport Sensor, Replace the Top Transport Slip Clutch (PL 10.14).
Q1012, within the specified number of clock counts after the print lead edge arrived at the
Decurler Sensor, Q1011. Enter dC330, [1-4] [Main Drives/Start/Run]. Press the Continue button. All the Top Trans-
port Idlers and Rollers rotate.
Initial Actions Y N
• Ensure that the Decurler Sensor, Top Transport Sensor, and Top Transport paper path are Check the following:
free from obstructions. • Drive belts and pulleys
• Ensure that the Decurler Sensor Actuator is not damaged. • Rollers and Idlers for binding or wear
• Ensure that the Top Transport Sensor is not damaged or binding. • Drive clutches
• Ensure that the Top Transport Baffles are seated properly.

The jammed print is damaged.
• Ensure that the Top Transport Idler Rolls and springs are seated properly and that the Y N
rolls turn freely. Check the following:
• Ensure that the paper is loaded correctly, and that curl is not excessive (refer to the • Drive belts and pulleys
Decurler Section of the Operators Manual). • Rollers and Idlers for binding or wear
Procedure • Drive clutches
Enter dC330, [10]. Actuate the Top Transport Sensor. The display changes from H to L. • Circuit of the Top Transport Sensor
Y N
Go to Flag 1. Check the circuit of the Top Transport Sensor (GP 6-2, General Proce- Go to the 8-705 Print Damage RAP to determine the cause of the paper damage.
dures).
The Top Transport Sensor actuates before going below the upper baffle, and the actua-
tor goes below the cutout in the Top Transport (proper overtravel).
Y N
Replace the Top Transport Sensor (PL 10.16).
The Decurler Sensor actuates before going below the upper baffle, and the actuator
goes below the cutout in the Post Decurler Transport (proper overtravel).
Y N
Actuate the Decurler Sensor. The display changes from H to L.

Y N
Go to Flag 2. Using the Generic Sensor RAP GP 6-2,General Procedures, check the cir-
cuit of the Decurler Sensor.
Use the paper that the customer was using. Enter dC726, [55]. Press the Continue button.
The Fault Code, 10-107, occurs.
Y N
Load the heaviest weight paper the customer has available. Enter dC106. Select [100]
prints, [Top Tray]. Press the Continue button. Observe the histogram. The histogram
indicates times approaching the yellow arrow or beyond (late).
Y N
• Top Transport Drive Rolls and Idlers are clean, rotate freely, and that all springs
are installed correctly (PL 10.14).
• Top Transport Drive Belts (PL 10.14).
• All drive belts are installed correctly, are properly tensioned and are not worn
A B

Figure 2 PWB Location (7313)

A B
10-108, 10-109 RAP Y N
Repair or replace the Duplex Gate (PL 10.14).
Fault Code, 10-108, indicates that the trail edge of a print going to the Duplex Tray, did not
leave the Top Transport Sensor, Q1012, within the specified number of clock counts after the The Duplex Gate is adjusted correctly (ADJ 10-9).
print lead edge actuated the sensor, and that the Top Transport Sensor, Q1012, is still actuated Y N
after the machine cycle-down. Perform the Duplex Gate Adjustment (ADJ 10-9).
Fault Code, 10-109, indicates that the trail edge of a print going to the Duplex Tray, did not Select [Clear Outputs] [1-4] [Main Drive/Start Run] motor. Press the Continue
leave the Top Transport Sensor, Q1012, within the specified number of clock counts after the button. The Top Transport Rolls rotate.
print lead edge actuated the sensor, and that the Top Transport Sensor, Q1012, is not actuated Y N
after the machine cycle-down. Check for binding or worn components in the Top Transport drive system (PL
4.19).
Initial Actions
• Ensure that the Top Transport Sensor and Turn Roll area of the paper path are not Check the following:
obstructed. • Worn or dirty Top Transport Rolls (PL 10.15).
• Ensure that the Top Transport Sensor Actuator is not damaged, or binding. • Worn or dirty Top Transport Clutch (PL 10.14).
• Ensure that the Top Transport Baffles are attached to the cover and are properly seated. • Decurler Setting
• Worn or damaged Top Transport drive system components (PL 4.19).
Procedure
• Worn or damaged Top Transport pulleys and belts (PL 10.14).
Enter dC330, [10]. The Decurler Sensor actuates before going below the upper baffle,
and, the actuator goes below the cutout in the Post Decurler Transport (proper Over- • Damaged Top Transport Springs (PL 10.15).
travel). • Worn or damaged Duplex drive system components (PL 10.14).
Y N • Duplex Gate Solenoid Adjustment (ADJ 10-9).
Enter dC330, [10], [Duplex Gate] solenoid. Press the Continue button. Press the Stop
Actuate the Decurler Sensor. The display changes from H to L. button. The Duplex Gate Solenoid comes on and then goes off.
Y N Y N
Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Go to Flag 2. Check the circuit of the Duplex Gate Solenoid.
Actuate the Top Transport Sensor. The display changes from H to L. Manually actuate and deactuate the Duplex Gate. The Duplex Gate moves freely.
Y N Y N
Go to Flag 1. Check the circuit of the Top Transport Sensor (GP 6-2, General Proce- Repair or replace the Duplex Gate (PL 10.14).
dures).
The Duplex Gate is adjusted correctly (ADJ 10-9).
Select SCP [Last 50] Fault Code listing. 10-110 Faults are also present. Y N
Y N Perform the Duplex Gate Adjustment (ADJ 10-9).
Using the same paper that the customer used, run the same duplex job that the customer
ran when the fault occurred. There is paper damage. Select [Clear Outputs] [1-4] [Main Drive/Start Run] motor. Press the Continue button.
Y N The Top Transport Rolls rotate.
The Top Transport Sensor actuates before going below the upper baffle, and Y N
the actuator goes below the cutout in the Top Transport (proper overtravel). Check for binding or worn components in the Top Transport Drive system (PL 4.19).
Y N
Replace the Top Transport Sensor (PL 10.16). Go to the 8-705, Copy Damage RAP, to determine the cause of the paper damage.
Enter dC330, [10], [Duplex Gate] solenoid. Press the Continue button. Press the Go to the 10-110.
Stop button. The Duplex Gate Solenoid comes on and then goes off.
Y N
Go to Flag 2. Check the circuit of the Duplex Gate Solenoid.
Manually actuate and deactuate the Duplex Gate. The Duplex Gate moves freely.
A B
Figure 1 10-108/10-109 Circuit Diagram (8008A)

Figure 2 PWB Location (7313)

A
10-110 RAP • Worn or damaged Top Transport Pulleys and Belts (PL 10.14).
• Worn or damaged Duplex Drive system components (PL 10.14).
Fault Code, 10-110, indicates that the trail edge of a print going to the Inverter Feeder/Stacker,
did not leave the Top Transport Sensor, Q1012, within the specified number of the specified Go to the 8-705, Print Damage RAP, to determine the cause of the paper damage.
number of clock counts after the print lead edge actuated the sensor.
Initial Actions
• Ensure that the Top Transport Sensor and Turn Roll area of the paper path are not
obstructed.
• Ensure that the Top Transport Sensor Actuator is not damaged, or binding.
• Ensure that the Top Transport Baffles are attached to the cover and are properly seated.
Procedure
Enter dC330, [10]. Actuate the Top Transport Sensor. The display changes from H to L.
Y N
Go to Flag 1. Check the circuit of the Top Transport Sensor (GP 6-2, General Proce-
dures).
The Top Transport Sensor actuates before going below the upper baffle, and the actua-
tor goes below the cutout in the Top Transport (proper overtravel).
Y N
Replace the Top Transport Sensor (PL 10.16).
Enter dC330, [10], [Duplex Gate] solenoid. Press the Continue button and then the Stop but-
ton. The Duplex Gate Solenoid energizes and then deenergizes.
Y N
Go to Flag 2. Check the circuit of the Duplex Gate Solenoid.
Manually actuate and deactuate the Duplex Gate. The Duplex Gate moves freely.
Y N
Repair or replace the Duplex Gate (PL 10.14).
The Duplex Gate is adjusted correctly (ADJ 10-9).

Y N
Perform the Duplex Gate Adjustment (ADJ 10-9).
Enter dC330, [1-4], [main Drive/Start/Run] motor. Press the Continue button. The Top
Transport Idlers and Rollers rotate.
Y N
Check for binding or worn components in the Top Transport drive system (PL 4.19).
Enter dC726, [54]. Select [100] prints, [Top Tray]. Use the same paper that the customer was
using. Press Continue. Examine the prints in the Top Tray. The prints are damaged.
Y N
• Duplex Gate Solenoid adjustment (ADJ 10-9).
• Worn or dirty Top Transport Rolls (PL 10.15).
• Worn or dirty Top Transport Slip Clutch (PL 10.14).
• Decurler Setting
• Worn or damaged Top Transport Drive system components (PL 4.19).
A

Figure 2 Run Control PWB Location

A B
10-111 RAP Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The Top
Transport Rolls rotate.
Fault Code, 10-111, indicates that the trail edge of the print (A3 Mode) did not leave the Y N
Decurler Sensor, Q1011, within the specified number of clock counts after actuating the sensor. Check the following for wear or damage:
• Top Transport Drive system (PL 10.14).
Initial Actions • Top Transport Clutch (PL 10.14).
• Ensure that the Top Transport Baffles are attached to the cover and are seated properly. • Top Transport Pulleys and Belts (PL 10.14).
• Ensure that the Decurler Sensor Actuator is not damaged and moves freely. • Top Transport Springs (PL 10.14).
• Ensure that the paper path is not obstructed. • Decurler Drive system (PL 4.16).
Procedure
Enter dC330, [10]. Actuate the Decurler Sensor. The display changes from H to L.
• Decurler Jam Sensor is adjusted all the way into the paper path and the switch actu-
Y N
ator moves freely
• Obstructed paper path
Clear the Fault Code. If Fault Code, 10-111, can not be cleared, switch off and then reset all the • Worn or dirty Top Transport Rolls (PL 10.14).
printer circuit breakers. Select A3 Mode. Enter dC106 and run the machine until Fault Code, • Worn or dirty Top Transport Slip Clutch (PL 10.14).
10-111, is declared (if Fault Code, 10-111, is not declared, go to the declared fault). A jammed
print is observed. Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The Decurler Belts
Y N rotate.
• Obstructed paper path Check the Decurler Drive system for wear or damage (PL 4.16).
• Damaged paper path components
• Loose or worn belts and pulleys in the Decurler Transport Drives (PL 4.16).
• Worn or damaged Top Transport Drive Belts (PL 10.14).
• Decurler Exit Baffle Adjustment (ADJ 10-8).
• Worn or dirty Top Transport Slip Clutch (PL 10.14).
The lead edge of the print arrived at the first Top Transport Drive Roll. • Worn or damaged Top Transport Pulleys and Belts (PL 10.14).
Y N • Damaged or missing Top Transport Springs (PL 10.14).
The jammed print is damaged. • Worn or damaged Decurler Drives (PL 4.16).
Y N
Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The
Decurler Belts rotate.
Y N
Check the Decurler Drive system and Decurler One-way Clutch for wear or dirt
(PL 10.14).
Check the Decurler Setting.

• Obstructed paper path
• Damaged or worn paper path components
The trail edge of the print is in the Decurler.

Y N
The jammed print is covering the Decurler Jam Sensor.
Y N
Check the Decurler Jam Sensor. Ensure that the sensor is adjusted all the way into
the paper path and that the actuator moves freely.
A B

A B
10-112 RAP • Damaged or contaminated Prefuser Transport Belts (PL 8.12).
• Binding Prefuser Transport Bearings (part of the drive roll and idler shaft) (PL
Fault Code, 10-112, indicates that a print did not actuate the Prefuser Sensor, Q1009, within 8.12).
the specified number of clock counts after it arrived at the Registration Sensor, in 3 pitch mode.
• Worn Prefuser Transport Drive Coupling (PL 8.12).
• Obstructed Prefuser Transport Manifold holes
Initial Actions
• If the above checks are good, go to GP 6-2 (Generic Sensor RAP, General Pro-
• Ensure that the Prefuser Sensor and Reflector are not obstructed and that the Prefuser
cedures) and ensure that all the sensor voltages are correct.
Sensor and Reflector are clean and in proper position.
• Ensure that the Prefuser Transport is in the normal operating position. Check the following:
• The Fault Code, 10-112, occurring at print cycle-up may be due to a dirty or defective • Obstructions in the paper path
Registration Transport Sensor, Q861. • Condition of the paper
• Ensure that the paper path is free from obstructions. • Operation and condition of the Transfer and Detack Dicorotrons (REP 9-39 and REP
Procedure 9-49).
Enter dC106. Run the machine until Fault Code, 10-112 is declared. Inspect the image on the • Condition of the Pretransfer Baffle (PL 8.11).
jammed print. The image is skewed or misregistered. • Condition of the Stripper Finger Assembly (PL 9.3).
Y N • Condition and operation of the Transfer Assist Blade (PL 9.11).
Enter dC330, [8]. Block and then clear the Registration Transport Sensor. The display
• Condition of the Detack Guide (PL 9.11).
Y N
Go to the 8-706 Printer Misregistration and Skew RAP.
Go to the 8-155.
Select [10]. Open, then close the Fuser Drawer. The Prefuser Sensor display changes
from H to L.
Y N
Go to Flag 1. Check the circuit of the Prefuser Sensor (GP 6-2, General Proce-
dures).
Clear the Fault Code. If Fault Code, 10-112, can not be cleared, switch off and then reset
all the printer circuit breakers. Enter dC106. Run the machine until Fault Code, 10-112, is
declared (if Fault Code, 10-112, is not declared, go to the declared fault). The print is
jammed or stopped before the Prefuser Transport.
Y N
Install a cheater in the Processor Interlock Bypass Switch. Select [Prefuser Vac-
uum] motor. Press the Continue button. The Prefuser Vacuum Motor comes on.
Y N
Select [Clear Outputs]. Go to the 10-706 Prefuser Vacuum Motor RAP.
Place a sheet of paper (8 1/2 x 11 or A3 if available) on the Prefuser Transport. The

vacuum holds the sheet on the Prefuser Transport.
Y N
Check the Prefuser Transport Assembly for vacuum leaks and restricted or
damaged air ducts (PL 8.12).
Select [Clear Outputs] [1-4] [Main Drive/Start Run] motor. Press the Continue
button. The Prefuser Transport Belts rotate.
Y N
Select [Clear Outputs]. Check the Prefuser Transport Drive system for dam-
aged or worn components (PL 4.16).

A B

10-201 RAP
Fault Code, 10-201, indicates that one of the following conditions exists: the Fuser did not
reach the operating temperature within eight and one half minutes of start-up; that no change
(decrease) in the Fuser Thermistor resistance has been detected for five and one half minutes;
or no change (decrease) in Fuser Thermistor resistance was detected within 10 seconds after
clearing Fault Code, 10-204.
Initial Actions
• Inspect the Fuser Roll Thermistors for debris or damage, and ensure that they are making
proper contact with the Fuser Roll.
• Ensure that the Fuser Roll Thermostat is adjusted correctly (ADJ 10-0).
• Ensure that the Metering Roll Thermostat is adjusted correctly (ADJ 10-1).
Procedure
The Cavity Cooling Fan is turning.
Y N
Go to Flag 22. Check the circuit of the Cavity Cooling Fan. If there is a problem with the
Cavity Fan return line go to wirenet 3DD. If the inputs to the Print Power Relay, K403, are
missing go to the 4-703 (60 Hz), or go to the 4-704 (50 Hz), Print Power RAPs.
The Cavity Cooling Fan is clean and has good airflow.

Y N
Clean or replace the Cavity Cooling Fan and Screen (PL 9.8).
Enter then exit diagnostics (Press button R). If fault code 10-201 can not be cleared, switch off
and then reset the machine circuit breakers. Open the Fuser drawer. Enter dC140, [Fuser Val-
ues]. Wait until the Thermistor value for the Inboard and Outboard Thermistors are both 10.
DO NOT place any cheaters in any interlock switches. Close the fuser drawer ensuring that the
fuser interlock switch is properly actuated. The fuser rod turns on.
Y N
Go to the 10-714.
The Inboard or Outboard Thermistor value drops below 10 before a 10-201 fault is
declared.
Y N
Open the fuser drawer. Go to the 10-714.
The value for the Outboard Thermistor is less then 10.

Y N

Figure 1 10-201/202/204/711/714 Circuit Diagram (T710001) Continued on next page

Figure 2 10-201/202/204/711/714 Circuit Diagram (4920) Continued on next page

Figure 3 10-201/202/204/711/714 Circuit Diagram (T710002)

10-202 RAP Y N
Go to Flag 34 and Flag 35. Check the wires for a short, if no short is found replace the
Fault Code, 10-202, indicates that the Fuser has reached a temperature of 455° F (overtem- MIN ADA PWB #1 (PL 1.8).
perature).
DO NOT place a cheater in the Printer Interlock Bypass switch. Disconnect the Inboard
Procedure Fuser Roll Thermistor, RT1003. Measure resistance of the Inboard Fuser Roll Ther-
mistor, RT1003. Resistance is 2 Megohms at room temperature or 8.5K to 11.5K Ohms at
Ensure that the fuser is below operating temperature before beginning this RAP. +15 VDC is
available at P287-2 of MIB PWB#1. operating temperature (410° to 425°F).
Y N Y N
Replace the Inboard Fuser Roll Thermistor, RT1003, (PL 10.4).
Go to Flag 3. Check the wire 1009A. If ok, go to the 1-715 +15 VDC RAP.
+15 VDC is available from P287-2 to P287-5 of MIB PWB#1. Reconnect the Inboard Fuser Roll Thermistor, RT1003. Disconnect P259 from J-3 at the MIB
PWB#2. DO NOT place a cheater in the Printer Interlock Bypass switch. Resistance is 2
Y N
Go to Flag 4. Check the wire 1008A. Megohms at room temperature or 8.5K to 11.5K Ohms at operating temperature 410° to
425°F).
Y N
-15 VDC is available at P 287-3 of the MIB PWB#1.
Y N Go to Flag 30 and Flag 31. Check the wires for a short.
Go to Flag 5. Check the wire 1010A. If ok, go to the 1-716 -15 VDC RAP.
Reconnect P259 and clear any faults. 2 VDC to +9.5 VDC is available at J3-7 (+) to J3-8 (-)
Inspect the Outboard Fuser Roll Thermistor, RT1001, for debris and proper contact to the of the MIB PWB#2.
Fuser Roll. The Outboard Fuser Roll Thermistor, RT1001, is making proper contact. Y N
Replace the MIB PWB#2 (PL 1.8).
Y N
Clean, repair, or replace the Fuser Roll Thermistor, RT1001 (PL 10.4).
2 to +9.5 VDC is available at TS45 (+) to TS46 (-) of the MIN ADA PWB #2.
Y N
Check the Fuser Roll Thermostat adjustment (ADJ 10-0). The Fuser Roll Thermostat adjust-
ment is within specification. Go to Flag 32 and Flag 33. Check the wires for a short, if no short is found replace the
Y N MIN ADA PWB #2 (PL 1.8).
Adjust the Fuser Roll Thermostat (ADJ 10-0).
Open the fuser Drawer and allow the fuser to cool below operating temperature. Disconnect
DO NOT place a cheater in the Printer Interlock Bypass switch. Disconnect the Out- HR12/P1. Refer to GP 7, Section 6 General Procedures, for the correct procedure to pulse the
lamp in the next step. Enter dC701, [Fuser Roll Temp]. Close the fuser drawer. The Fuser
board Fuser Roll Thermistor, RT1001. Measure resistance of the Outboard Fuser Roll
Thermistor, RT1001. Resistance is 2 Megohms at room temperature or 8.5K to 11.5K Heat Rod is on.
Ohms at operating temperature (410° to 425°F). Y N
Open the fuser drawer. Reconnect HR12/P1. Disconnect HR14/P1. Refer to GP 8, Sec-
Y N
Replace the Outboard Fuser Roll Thermistor, RT1001, (PL 10.4). tion 6 General Procedures, for the correct procedure to pulse the lamp in the next step.
Enter dC701, [Thermistor Cal]. Close the fuser drawer. The fuser heat rod comes on.
Y N
Reconnect the Outboard Fuser Roll Thermistor, RT1001. Disconnect P208 from J-3 at the MIB
PWB#1. DO NOT place a cheater in the Printer Interlock Bypass switch. Resistance is 2 Open the fuser drawer. Reconnect HR14/P1. Check the following for intermittent
Megohms at room temperature or 8.5K to 11.5K Ohms at operating temperature (410° to operation:
• Thermistor CAL ADJ 10-17
425°F).
Y N • Fuser Roll Thermostat Adjustment (ADJ 10-0) and operation
Go to Flag 36 and Flag 37. Check the wires for a short. • Metering Roll Thermostat Adjustment (ADJ 10-1) and operation
• Fuser Roll Thermistors (RT1001 and RT1001)
Reconnect P208 and clear any faults. 2 VDC to +9.5 VDC is available at J3-7 (+) to J3-8 (-)
• Metering Roll Thermistor
of the MIB PWB#1.
• Fuser Relay, K1007
Y N
Replace the MIB PWB#1 (PL 1.8). • The MIN ADA PWB #1
• The MIN ADA PWB #2
2 to +9.5 VDC is available at TS39 (+) to TS40 (-) of the MIN ADA PWB #1. • The MIB#1 PWB
• Wiring and connectors
• Fuser Heat Rod
A B
A B C
Open the fuser drawer. Reconnect HR14/P1. Close the Fuser and all doors and covers. Y N
Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of Fuser Replace the Fuser Relay, K1007 (PL 1.3).
Relay, K1002.
Y N Go to Flag 123. Check the orange wires.
+5 VDC is available at TS 60 of the MIN ADA PWB #2.
Y N Go to Flag 123. Check the orange wires for a short. There is a short in the orange wires.
Go to wirenet 1005N. Check the wires for an open circuit. Y N
Disconnect P233 from J2 on the MIN DIO PWB. Greater then 100 ohms is measured
+5 VDC is available at pin 3 of the Fuser Relay, K1002. from J2-7 on the MIN DIO PWB to machine frame.
Y N Y N
Go to Flag 6. Check the yellow wires. Replace the Fuser Relay, K1007 PL 1.3.
+5 VDC is available at pin 4 of the Fuser Relay, K1002. Replace the MIN DIO PWB PL 1.8.
Y N
Replace the Fuser Relay, K1002 (PL 1.3). Replace or repair the orange wires.
+ 5 VDC is available at TS 16 of the MIN ADA PWB #2.

Y N
Go to Flag 2, Flag 7, and Flag 10. Check the wires for a short circuit to ground. A short
circuit to ground exists.
Y N
Go to Flag 1. Check the wiring of the Fuser Roll Thermistor for a short circuit to
ground. A short circuit to ground exists.
Y N
Replace the Fuser Relay, K1002 (PL 1.3).
Go to Flag 1. Repair or replace the Fuser Thermistor wiring.
Repair or replace the wire.
Close the Fuser and all doors and covers. Use Peak + Voltage. Greater than +4 VDC is
available from pin 3 to pin 4 of Fuser Relay, K1007.
Y N
+5 VDC is available from TS 60 of the MIN ADA PWB #2 to TS44 of the MIN DIO
PWB.
Y N
+5 VDC is available at TS60 of the ADA PWB #2.
Y N
If +5 VDC is available at J1-10, replace the MIN ADA PWB #1. If +5 VDC is not
available, go to Flag 25 and check the wire 1000N.
Go to the 10-709, MIB PWB RAP.
+5 VDC is available at pin 4 of the Fuser Relay, K1007.

Y N
Go to Flag 1. Check the yellow wires.
+5 VDC is available at pin 3 of the Fuser Relay, K1007.

C



A
10-203 (60HZ) RAP +15 VDC is available at P287-2 of MIB PWB.
Y N
Fault Code, 10-203, indicates that the voltage to the Fuser is less than 170 VAC. Go to Flag 9. Check the wire 1009A.
Procedure -15 VDC is available at P287-3 of MIB PWB.

Y N
WARNING Go to Flag 10. Check the wire 1010A.
Performing service actions in the vicinity of the Printer Compressor represents a safety
hazard. Use caution when performing service in this area. +15 VDC is available from P287-2 to P287-5 of MIB PWB.
When performing service in the vicinity of the cleaner, the moving pulleys and belts rep- Y N
resent a safety hazard. Use caution when performing service in this area. Go to Flag 11. Check the wire 1008A.
+15 VDC is available at TS57 of the MIN ADA PWB #1.
Y N +1.0 to 7.0 VDC is available from P242-17 to P242-16 of MIN ADA PWB.
Go to Flag 12. Check the wire 1009C. If ok, go to the 1-715 +15 VDC RAP. Y N
+1.0 to 7.0 VDC is available at TS6 of MIB PWB.
+15 VDC is available from TS57 to TS56 of MIN ADA PWB#1. Y N
Y N Replace the MIB PWB (PL 1.8).
Go to Flag 13. Check the wire 1008C.
+1.0 to 7.0 VDC is available from P208-11 to P208-12 of MIB PWB.
-15 VDC is available at TS55 of the MIN ADA PWB#1. Y N
Y N Go to Flag 5. Check the red wire.
Go to Flag 14. Check the wire 1010C. If ok, go to the 1-716 -15 VDC RAP.
Go to Flag 6. Check the brown wire.
Greater than 170 VAC is available from pin B to pin D of Circuit Breaker, CB102.
Y N Enter dC140. Select [Fuser Values]. The Fuser Analog Voltage is within specification.
Go to the 1-700 AC Input Power RAP. Y N
Greater than 170 VAC is available from pin 1 to pin 2 of Fuser Power Relay, K1001.
Y N Assume a momentary low line voltage condition occurred.
Disconnect wire 6 (pin 2) at Fuser Power Relay, K1001. Greater than 85 VAC is avail-
able on wire 6.
Y N
Go to Flag 4. Check the wire 6.
Greater than 85 VAC is available at pin 2 of Fuser Transformer, T1001.

Y N
Go to Flag 1. Check the wire 5A.
Greater than 85 VAC is available at pin 1 of Fuser Transformer, T1001.

Y N
10 to 15 VAC is available from pin 3 to pin 4 of Fuser Transformer, T1001.

Y N
Replace the Fuser Transformer (PL 1.1).
10 to 15 VAC is available from J3-6 to J3-5 on MIB PWB.

Y N
Go to Flag 7 and Flag 8. Check the violet and gray wires.
A

A
10-203 (50HZ) RAP 10 to 15 VAC is available from J3-6 to J3-5 on MIB PWB.
Y N
Fault Code, 10-203, indicates that the voltage to the Fuser is less than 170 VAC. 10 to 15 VAC is available at J3-6 of the MIB PWB.
Y N
Procedure Go to Flag 7. Check the violet wire.
WARNING Go to Flag 8. Check the gray wire.
Performing service actions in the vicinity of the Printer Compressor, represents a safety
hazard. Use caution when performing service in this area. +15 VDC is available at P287-2 of MIB PWB.
When performing service in the vicinity of the cleaner, the moving pulleys and belts rep- Y N
resent a safety hazard. Use caution when performing service in this area. Go to Flag 9. Check the wire 1009A.
+15 VDC is available at TS57 of the MIN ADA PWB #1.
Y N -15 VDC is available at P287-3 of MIB PWB.
Go to Flag 12. Check the wire 1009C. If ok, go to the 1-715 +15 VDC RAP. Y N
+15 VDC is available from TS57 to TS56 of MIN ADA PWB#1.
Y N +15 VDC is available from P287-2 to P287-5 of MIB PWB.
Go to Flag 13. Check the wire 1008C. Y N
-15 VDC is available at TS55 of the MIN ADA PWB#1.
Y N +1.0 to 7.0 VDC is available from P242-17 to P242-16 of MIN ADA PWB.
Go to Flag 14. Check the wire 1010C. If ok, go to the 1-716 -15 VDC RAP. Y N
+1.0 to 7.0 VDC is available at TS6 of MIB PWB.
Greater than Phase to Phase minimum voltage is available from pin H to pin B of Circuit Y N
Breaker, CB104. Replace the MIB PWB (PL 1.8).
Y N
Go to the 1-707 AC Input Power RAP (50HZ). +1.0 to 7.0 VDC is available from P208-11 to P208-12 of MIB PWB.
Y N
Greater than Phase to Phase minimum voltage is available from pin 1 to pin 2 of Fuser Go to Flag 6. Check the brown wire.
Power Relay, K1001.
Disconnect wire 4A (pin 2) at Fuser Power Relay, K1001. Greater than Phase to Earth
minimum voltage is available at wire 4A. Enter dC140. Select [Fuser Values]. The Fuser Analog Voltage is within specification.
Y N Y N
Go to Flag 4. Check the wire 4A. Replace the MIN ADA PWB #1 (PL 1.8).
Go to Flag 2. Check the wire 5C. Assume a momentary low line voltage condition occurred.
Greater than Phase to Earth minimum voltage is available at pin 2 of Fuser Transformer,
T1001.
Y N
Greater than Phase to Earth minimum voltage is available at pin 1 of Fuser Transformer,
T1001.
Y N
Go to Flag 3. Check the wire 4E.
10 to 15 VAC is available from pin 3 to pin 4 of Fuser Transformer, T1001.

Y N
A
Figure 1 10-203 (50 HZ) Circuit Diagram (8015A)

A
10-204, 10-206 RAP Disconnect the Metering Roll Thermistor. Measure the resistance of the Metering Roll Ther-
mistor. Resistance is 2 Megohms at room temperature or 17K to 75K Ohms at operating
Fault Code, 10-204, indicates that the Fuser temperature is 35 degrees below operating tem- temperature.
perature after the Fuser had reached operating temperature. Y N
Replace the Metering Roll Thermistor (PL 10.7).
Fault Code, 10-206, indicates that the Fuser temperature momentarily dropped 35 degrees
below operating temperature after the Fuser reached operating temperature. This is not a Inspect the Outboard Fuser Roll Thermistor, RT1001, for debris and proper contact to the
declared fault but is logged in NVM. Fuser Roll. The Outboard Fuser Roll Thermistor, RT1001, makes proper contact.
Y N
Procedure Clean, repair, or replace the Outboard Fuser Roll Thermistor, RT1001, (PL 10.4).
WARNING Disconnect the Outboard Fuser Roll Thermistor, RT1001. Measure the resistance of the Fuser
When performing service in the vicinity of the cleaner, the moving pulleys and belts rep- Roll Thermistor. Resistance is 2 Megohms at room temperature or 17K to 75K Ohms at
resent a safety hazard. Use caution when performing service in this area. operating temperature.
CAUTION Y N
Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to Replace the Fuser Roll Thermistor (PL 10.7).
The system can fault with an undertemp problem while it is in standby mode, or while the sys- Check the last 50 Fault Code Listing. Fault Code, 10-210, is listed at the same copy count
as this Fault Code.
tem is printing. The system faults in standby mode.
Y N Y N
Enter dC606. Select [10] prints. Press the Continue button, wait 10 seconds and press
WARNING the Stop button. The Cavity Cooling Fan comes on at low speed.
AC Power is present in the Line Interface Assembly whenever the printer power Y N
cord is plugged into the wall outlet. Use caution when working in this area. Go to Flag 22. Check the circuit of the Cavity Cooling Fan. If there is a problem with
Disconnect the printer power cord(s). Open the Line Interface Assembly. Pull out the the Cavity Fan return line go to the 3DD wirenet. If the inputs to the Print Power
Fuser Drawer. Disconnect HR11 (at the outboard end of the Fuser Roll). Check for conti- Relay, K403, are missing go to the 4-703 (60 Hz), or go to the 4-704 (50 Hz), Print
nuity between K1001-5 (in the Line Interface Assembly) and HR11. The wiring is cor- Power RAPs.
rect.
Y N Enter then exit diagnostics (Press button R). If fault code 10-201/10-204 can not be
Go to Flag 6. Check the wiring from HR11 to K1001-5. Ensure that the connectors cleared, switch off and then reset the machine circuit breakers. Open the Fuser drawer.
P252-1, and P/J4-1 are properly connected. Enter dC140, [Fuser Values]. Wait until the Thermistor value for the Inboard and Out-
board Thermistors are both 10. DO NOT place any cheaters in any interlock switches.
Reconnect HR11. Disconnect HR12 (at the inboard end of the Fuser Roll). Check for con- Close the Fuser Drawer ensuring that the Fuser Interlock Switch is properly actuated.
tinuity between K1002-2 (in the Line Interface Assembly) and HR12. The wiring is cor- The fuser rod turns on.
rect. Y N
Y N Go to the 10-714 RAP.
Go to Flag 5. Check the wiring from HR12 to K1002-2. Ensure that connectors P253-
1, and P/J3-1 are properly connected. The Inboard or Outboard Thermistor value drops below 10 before a 10-201 fault is
declared.
Reconnect HR12. Disconnect HR14 (at the inboard end of the Fuser Roll). Check for con- Y N
tinuity between K1007-2 (in the Line Interface Assembly) and HR14. The wiring is cor- Open the fuser drawer. Go to the 10-714 RAP.
rect.
Y N The value for the Outboard Thermistor is less then 10.
Go to Flag 111. Check the wiring from HR14 to K1007-2 to HR14. Ensure that the Y N
connectors P/J255-1, and P/J11-1 are properly connected. Open the fuser drawer. Go to the 10-714 RAP.
Reconnect HR14. Restart this RAP and follow the Yes path in the first statement. Open the fuser drawer. Go to the 10-711 RAP
Inspect the Metering Roll Thermistor for debris and proper contact to the Metering Roll. The Go to the 10-210 or go to the 10-210.
Metering Roll Thermistor makes proper contact.
Y N
Clean, repair, or replace the Metering Roll Thermistor (PL 10.7).
A



A B C
10-205 RAP Less than +7.0 VDC is available from P242-17 to P242-16 of MIN ADA PWB.
Y N
Fault Code, 10-205, indicates that the voltage to the Fuser is greater than 265 VAC. Less than +7.0 VDC is available at TS6 of MIB PWB.
Y N
Initial Actions Replace the MIB PWB (PL 1.8).
• Inspect the Fuser System for overheat damage.
Less than +7.0 VDC is available from P208-11 to P208-12 of MIB PWB.
• Troubleshoot this fault by using peak hold on the meter, and switching off and then reset-
Y N
ting all the printer circuit breakers for each step of this RAP.
Go to Flag 5. Check the red wire.
Procedure
WARNING Go to Flag 6. Check the brown wire.
Performing service actions in the vicinity of the Printer Compressor represents a safety
hazard. Use caution when performing service in this area.
When performing service in the vicinity of the cleaner, the moving pulleys and belts rep- 60Hz - Go to the 1-700 AC Input Power RAP.
resent a safety hazard. Use caution when performing service in this area. 50Hz - Go to the 1-707 AC Input Power RAP.
Greater than 130 VAC is available at pin 4 of Fuser Power Relay, K1001.
Y N 60Hz - Go to the 1-700 AC Input Power RAP.
Greater than 130 VAC is available at pin 5 of Fuser Power Relay, K1001. 50Hz - Go to the 1-707 AC Input Power RAP.
Y N
Less than 130 VAC is available at pin 2 of Fuser Transformer, T1001.
Y N
Less than 130 VAC is available at pin 1 of Fuser Transformer, T1001.

Y N
Less than 15 VAC is available from pin 3 to pin 4 of Fuser Transformer, T1001.
Y N
Less than 15 VAC is available from pin 6 to pin 5 of J3 on MIB PWB.

Y N
Less than 15 VAC is available at TS3 of MIB PWB.
Y N
Go to Flag 4. Check the violet wire.
Go to Flag 3. Check the gray wire.
+15 VDC is available at P287-2 of MIB PWB.

Y N
-15 VDC is available at P287-3 of MIB PWB.

Y N
+15 VDC is available from P287-2 to P287-5 of MIB PWB.

Y N
A B C

A B C D E
10-210 (60HZ) RAP +5 VDC is available at pin 4 of the Metering Roll Relay, K1004.
Y N
Fault Code, 10-210, indicates that the Metering Roll did not reach a temperature of 250°F Replace the Metering Roll Relay K1004 (PL 1.3).
within 7 minutes of start-up or that the Metering Roll temperature is below 250°F in Print
(Under-Temperature). Go to Flag 8. Check the green wire.
Initial Actions Replace the Metering Roll Relay K1004 (PL 1.3).
• Inspect the Fuser Roll Thermistor for debris or damage, and ensure that it is making
proper contact with the Fuser Roll. Go to Flag 4. Check the wire 17.
115 VAC is available at P1-1 (Metering Roll Heater side of HT2).
• Ensure that the Metering Roll Thermostat is adjusted correctly (ADJ 10-1). Y N
Procedure 115 VAC is available at HT2-2.
Place a cheater in the Printer Interlock Bypass Switch. Check the Metering Roll Heater (use Y N
Temperature Tape). The Metering Roll Heater is heating up. 115 VAC is available at pin 2 of Fuser Power Relay, K1001.
Y N
Y N
Remove pin 1 from HT2 of the Metering Roll Heater. Measure the voltage to the Metering 115 VAC is available at pin D of CB102.
Roll Heater. 115 VAC is available at HT2-1. Y N
Go to the 1-700 AC Input Power RAP.
Y N
Open the Line Interface Box. 115 VAC is available at pin 1 of Metering Roll Relay,
K1004. Go to Flag 2. Check the wire 6.
Y N
115 VAC is available at pin 1 of Fuser Power Relay, K1001. 115 VAC is available at pin 5 of Fuser Power Relay, K1001.
Y N Y N
Replace the Fuser Power Relay K1001 (PL 1.3).
115 VAC is available at pin B of CB102.
Y N
Go to the 1-700 AC Input Power RAP. Go to Flag 5. Check the wire 14.
Go to Flag 7. Check the wire 5. Replace the Metering Roll Heater (PL 10.7).
Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of the
115 VAC is available at pin 4 of Fuser Power Relay, K1001.
Y N Metering Roll Relay, K1004.
Replace the Fuser Power Relay K1001 (PL 1.3). Y N
+5 VDC is at TS13 to TS60 of the MIN ADA PWB #2.
Go to Flag 3. Check the wire 13. Y N
+5 VDC is at TS 60 of the MIN ADA PWB #2.
Y N
115 VAC is available at pin 2 of Metering Roll Relay, K1004.
Y N Replace the MIN ADA PWB #2 (PL 1.3).
Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of
Go to the 10-709 MIB PWB RAP.
the Metering Roll Relay, K1004.
Y N
+5 VDC is at TS13 to TS60 of the MIN ADA PWB #2. +5 VDC is available at pin 3 of the Metering Roll Relay, K1004.
Y N
Y N
Check for +5 VDC at TS 60 of the MIN ADA PWB #2, if +5 VDC is Go to Flag 1. Check the blue wire.
present, go to the 10-709, MIB PWB RAP. If +5 VDC is not present,
+5 VDC is available at pin 4 of the Metering Roll Relay, K1004.
Y N
+5 VDC is available at pin 3 of the Metering Roll Relay, K1004. Replace the Metering Roll Relay K1004 (PL 1.3).
Y N
Go to Flag 1. Check the blue wire. Go to Flag 8. Check the green wire.
Replace the Metering Roll Relay K1004 (PL 1.3).

A B C D E A
A
Remove the cheater from the Printer Interlock Bypass Switch. Inspect the Metering Roll Ther-
mistor for debris and proper contact to the Metering Roll. The Metering Roll Thermistor
makes proper contact.
Y N
Disconnect the Metering Roll Thermistor. Measure the resistance of the Metering Roll Ther-
temperature.
Y N
Enter dC701. Select [Fuser Adjustments]. Adjust the Metering Roll Temperature (ADJ 10-7).



A B C D E
10-210 (50HZ) RAP +5 VDC is available at pin 4 of the Metering Roll Relay, K1004.
Y N
Fault Code, 10-210, indicates that the Metering Roll did not reach a temperature of 250°F Replace the Metering Roll Relay, K1004 (PL 1.2).
within 7 minutes of start-up or that the Metering Roll temperature is below 250°F in Print
(Under-Temperature). Go to Flag 8. Check the green wire.
Initial Actions Replace the Metering Roll Relay, K1004 (PL 1.2).
proper contact to the Fuser Roll. Go to Flag 4. Check the wire, 17.
Phase to Earth voltage is available at P1-1 (Metering Roll Heater side of HT2).
• Ensure that the Metering Roll Thermostat is adjusted correctly (ADJ 10-1). Y N
Procedure Phase to Earth voltage is available at HT2-2.
Place a cheater in the Printer Interlock Bypass Switch. Check the Metering Roll Heater (use Y N
Temperature Tape (ADJ 10-7). The Metering Roll Heater is heating up. Phase to Earth voltage is available at pin 2 of Fuser Power Relay, K1001.
Y N
Y N
Remove pin 1 from HT2 of the Metering Roll Heater. Measure the voltage to the Metering Phase to Earth voltage is available at pin H of CB104.
Roll Heater. Phase to Earth voltage is available at HT2-1. Y N
Go to the 1-707 AC Input Power RAP.
Y N
Open the Line Interface Box. Phase to Earth voltage is available at pin 1 of
Metering Roll Relay, K1004. Go to Flag 2. Check the wire 4A.
Y N
Phase to Earth voltage is available at pin 1 of Fuser Power Relay, K1001. Phase to Earth voltage is available at pin 5 of Fuser Power Relay, K1001.
Y N Y N
Replace the Fuser Power Relay, K1001 (PL 1.2).
Phase to Earth voltage is available at pin B of CB104.
Y N
Go to the 1-707 AC Input Power RAP. Go to Flag 5. Check the wire 14.
Go to Flag 7. Check the wire 5. Replace the Metering Roll Heater (PL 10.7).
Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of Metering
Phase to Earth voltage is available at pin 4 of Fuser Power Relay, K1001.
Y N Roll Relay, K1004.
Replace the Fuser Power Relay, K1001 (PL 1.2). Y N
+5 VDC is available at TS 13 to TS60 of the MIN ADA PWB #2.
Go to Flag 3. Check the wire 13. Y N
+5 VDC is at TS60 of the MIN ADA PWB #2.
Y N
Phase to Earth voltage is available at pin 2 of Metering Roll Relay, K1004.
Y N Replace the MIN ADA PWB #2 (PL 1.8).
Use Peak + Voltage. Greater than + 4 VDC is available from pin 3 to pin 4 of
the Metering Roll Relay, K1004.
Y N
+5 VDC is available at TS13 to TS60 of the MIN ADA PWB #2. +5 VDC is available at pin 3 of Metering Roll Relay, K1004.
Y N
Y N
Check for +5 VDC at TS60 of the MIN ADA PWB#2. If +5 VDC is Go to Flag 1. Check the blue wire.
present, go to the 10-709 MIB PWB RAP. If +5 VDC is not present,
+5 VDC is at pin 4 of the Metering Roll Relay,K1004.
Y N
+5 VDC is available at pin 3 of the Metering Roll Relay, K1004. Replace the Metering Roll Relay, K1004 (PL 1.2).
Y N
Go to Flag 1. Check the blue wire. Go to Flag 8. Check the green wire.
Replace the Metering Roll Relay, K1004 (PL 1.2).

A B C D E A
A
Remove the cheater from the Printer Interlock Bypass Switch. Inspect the Metering Roll Ther-
mistor for debris and proper contact to the Metering Roll. The Metering Roll Thermistor
makes proper contact.
Y N
Disconnect the Metering Roll Thermistor. Measure the resistance of the Metering Roll Ther-
temperature.
Y N
Enter [dC701] Adjust the Metering Roll Temperature (ADJ 10-7).


Figure 2 10-210 (50 HZ) Circuit Diagram (8028)

10-211 RAP
Fault Code, 10-211, indicates that the Metering Roll has exceeded a temperature of 380°F
(Over-Temperature).
Procedure
Inspect the Metering Roll Thermistor for debris and proper contact to the Metering Roll. The
Metering Roll Thermistor makes proper contact.
Y N
DO NOT bypass any Printer Interlock. Disconnect the Metering Roll Thermistor. Mea-
sure the resistance of the Metering Roll Thermistor. Resistance is 2 Megohms at room
temperature or 17K to 75K Ohms at operating temperature.
Y N
Greater than +4 VDC is available from pin 3 to pin 4 of Metering Roll Relay, K1004.
Y N
Go to Flag 2. Check the green wire for a short circuit to ground. A short circuit to ground
exists.
Y N
Go to Flag 1. Check the wiring of the Metering Roll Thermistor for a short circuit to
ground. A short circuit to ground exists.
Y N
Go to Flag 1. Check the wiring in the Metering Roll Thermistor circuit. The wiring
checks ok.
Y N
Repair the wiring.
Go to Flag 2. Repair or replace the green wire.

10-212, 10-217 RAP Fault Code, 10-217, indicates that the Cam-In Sensor, Q1002, was unblocked during machine
initialization.
Fault Code, 10-212, indicates that the Cam-In Sensor, Q1002, was unblocked during Print.

Initial Actions 10-213, 10-218 RAP
Fault Code, 10-213, indicates that the Cam-Out Sensor, Q1003, was unblocked during cycle
down.
• Ensure that the Cam-In Sensor is clean and not obstructed.
• Ensure that the Fuser Camming Brake is not being actuated when the fuser drawer is Fault Code, 10-218, indicates that the Cam-Out Sensor, Q1003, was unblocked during
closed. Be sure to check the Ozac tubes and or Cleaner vacuum duct as these items machine initialization.
have been known to contact the brake.
• If the Camming Motor runs continuously, Go to the 10-710 Camming Motor Runs Contin- Initial Actions
uously RAP.
Procedure
Enter dC330, [10], [Camming] Motor. Press the Continue button. The Cam-In Sensor dis- • Ensure that the Cam-Out Sensor is clean and not obstructed.
play changes from L to H. • Ensure that the Fuser Camming Brake is not being actuated when the fuser drawer is
Y N closed. Be sure to check the Ozac tubes and or Cleaner vacuum duct as these items
Check the Camming Flag. The Camming Flag is OK. have been known to contact the brake.
Y N
• If the Camming Motor runs continuously, go to the 10-710 Camming Motor Runs Continu-
Repair or replace the Camming Flag (PL 10.5).
ously RAP.
Go to Flag 1. Check the circuit of the Cam-In Sensor, Q1002, GP 6-2 (Generic Sensor Procedure
Rap, General Procedures). Enter dC330, [10], [Camming] Motor. Press the Continue button. The Cam-Out Sensor dis-
Check the Cam-In Sensor and Camming Flag for debris and or damage. Clean, repair, or Y N
replace the Cam-In Sensor or Camming Flag (PL 10.5). Check the Camming Flag. The Camming Flag is OK.
Y N
Go to Flag 2. Check the circuit of the Cam-Out Sensor, Q1003, (GP 6-2, General Proce-
dures).
Check the Cam-Out Sensor and Camming Flag for debris and or damage. Clean, repair, or
replace the Cam-Out Sensor or Camming Flag (PL 10.5).

10-212, 10-217, 10-213, 10-218 ?-836 No Product Name Assigned
A
10-214, 10-215, 10-219 RAP Check the Cam-Out and Cam-In Sensors for debris or damage. Clean, repair, or replace the
Sensors (PL 10.5).
Fault Code, 10-214, indicates that the Camming Motor, MOT1004, failed to stop during cam-in
while in Print.
Fault Code, 10-215, indicates that the Camming Motor, MOT1004, failed to stop during cam-
out while in Print.
Fault Code, 10-219, indicates that the Camming Motor, MOT1004, failed to stop during cam-
out at machine initialization.
Initial Actions
• Inspect the Camming Flag, Camming Motor Brake, Cam-In Sensor, and Cam-Out Sensor
for debris or damage.
• Ensure that the Fuser Camming Brake is not being actuated when the fuser drawer is
closed. Be sure to check the Ozac tubes and or Cleaner vacuum duct as these items
have been known to contact the brake.
• If the Camming Motor runs continuously, go to the 10-710 Camming Motor Runs Continu-
ously RAP.
Procedure
Enter dC330, [10], [Camming] motor. Press the Continue button. The Cam-In Sensor dis-
Y N
Go to Flag 1. Check the circuit of the Cam-In Sensor, Q1002, GP 6-2 Generic Sensor
RAP, General Procedures).
Press the Stop button. Inspect the Camming Flag for damage or wear. The Camming Flag is
OK.
Y N
Inspect the Camming Motor Brake. Camming Motor Brake is OK.

Y N
Clean, repair, or replace the Camming Motor Brake (part of the Camming Motor assem-
bly) (PL 10.3).
Press the Continue button, then the Stop button. The Camming Motor Brake operates cor-
rectly. (The Camming Motor stops in the correct location, the flag is covering the Cam
Out Sensor and the Pressure Roll is cammed out.)
Y N
Replace the Camming Motor Brake (part of the Camming Motor Assembly) (PL 10.3).
Press the Continue button, then the Stop button. The Cam-Out Sensor display changes
from H to L.
Y N
Go to Flag 2. Check the circuit of the Cam-Out Sensor, Q1003, (GP 6-2, General Proce-
dures).
A
No Product Name Assigned ?-837 10-214, 10-215, 10-219
Figure 1 10-212/10-213/10-214/10-215/10-217/10-218/10-219 Circuit Diagram (8030A)
10-216 RAP

A
Check the Camming Motor Brake (part of the Camming Motor Assembly), if the brake is
Fault Code, 10-216, indicates that the Camming Motor, MOT1004, failed to operate when com-
manded to do so. This fault code will cause the machine to disable the +24 VDC section of the OK or cannot be repaired, replace the Camming Motor Assembly (PL 10.3).
Low Voltage Power Supply. A loss of +24 VDC from the LVPS will declare a false, 10-216, dur-
Select [Clear Outputs]. Inspect the Camming Flag for damage or wear. The Camming
ing Power-Up.
Flag is OK.
Y N
Initial Actions Repair or replace the Camming Flag (PL 10.5).
WARNING
If the Camming Motor is in a thermal overheat condition it will run when it resets itself. Select [Camming] motor. Press the Continue button. The Cam-In Sensor display changes
from H to L.
Y N
• Ensure that the Pressure Roll is not partially cammed in. Go to Flag 1. Check the circuit of the Cam-In Sensor, Q1002, (GP 6-2, General Proce-
dures).
• Ensure that the Camming Motor Brake (part of the Camming Motor assembly) is not on,
or that the Camming Assembly is not binding.
The Cam-Out Sensor display changes from H to L.
• If the Camming Motor runs continuously go to the 10-710 Camming Motor Runs Continu- Y N
ously RAP. Go to Flag 2. Check the circuit of the Cam-Out Sensor, Q1003, (GP 6-2, General Proce-
• Ensure that all power cords are correctly installed and that all circuit breakers are on. dures).
• Ensure that the Air Knife Solenoid is not shorted (has a resistance of 3 to 5 ohms). A good
Solenoid should measure 30 to 40 ohms. Check the Cam-In Sensor for debris or damage. Clean, repair, or replace the Cam-In Sensor
or Camming Flag (PL 10.5).
Procedure
Connect a jumper wire between TS 53 and TS37 on the PHN DIO PWB #2 to re-enable +24
VDC from the LVPS. Leave this jumper in place until the problem is resolved, even if refer-
enced to other RAPs.
Remove the Fuser Front Cover. Ensure that the Fuser Drawer is closed correctly. Do not place
a cheater in the Printer Interlock Bypass Switch. Open the Processor left and right front doors
and place a cheater in the left and right door interlock switches. Enter dC330, [10], [Camming]
motor. Press the Continue button. The Cams rotate, the Fuser and Pressure Rolls engage
and disengage.
Y N
The Camming Motor comes on, or tries to come on.
Y N
+24VDC is measured between TH12(+) and TH14(-)on the LVPS.
Y N
Go to the 1-717 +24, +34, -34 VDC RAP.
Open the Fuser drawer and place a cheater in the Fuser Interlock Switch. Do not
place a cheater in the Printer Interlock By-pass Switch. 115VAC is available from
P1-1 to P1-2 of the Camming Motor (ensure Camming Motor is selected and
has not timed out).
Y N
Go to the 10-707 Camming Motor RAP.
Check the Camming Motor Brake (part of the Camming Motor Assembly), if the
brake is OK or cannot be repaired, replace the Camming Motor Assembly (PL 10.3).
Inspect the Camming Motor Coupling for damage or wear. The Camming Motor Cou-
pling is OK.
Y N
Repair or replace the Camming Motor Coupling (PL 10.3).
A


Figure 3 Component Location (8054A)

10-601 Fuser Lead Edge Smear RAP 10-602 Fuser Print Gloss RAP
Procedure Procedure
Check the following: CAUTION
• Load fresh paper and run the machine. If the defect is no longer present advise the Key the cover may occur.
Operator about the storage and use of paper.
Overall Print Gloss
• Ensure that the paper is loaded correctly and that curl is not excessive (refer to the
Decurler section of the Operators Manual). • Repetitive prints of the same document may cause a differential gloss defect.
• Remove the Prefuser Transport. Clean the Prefuser Transport Vent Holes and the Pre- • Ensure that the Fuser Roll Thermistor is clean and is making proper contact.
fuser Transport.
• Enter dC701, check the Fuser Roll Temperature (ADJ 10-6).
• Check the condition of the Fuser Entrance Baffle.
• Replace the Fuser Roll (REP 10-1).

10-603 Wrinkle RAP
Initial Actions
CAUTION
• Ensure that the Fuser Entrance Baffle is installed correctly (all four screws are installed
and are tight) and in good condition.
• Wrinkle caused by the Fuser is seen most often on the first 10 to 15 sheets of A3 (11x17)
paper when the machine has been started from a cold condition (the pressure roll is cold).
• Check the HSFIs for the Fuser.
Procedure
Enter dC701. Select [Contact Arc Setup]. The Fuser Contact Arc is correct (ADJ 10-2).
Y N
Perform the Contact Arc Adjustment (ADJ 10-2).
Select [Temperature Setups]. The Fuser Roll Temperature is in specification (ADJ 10-6).
Y N
Perform the Fuser Roll Temperature Adjustment (ADJ 10-6).
Using a fresh (unopened) ream of paper, load the largest size paper that the customer uses
into the appropriate tray. Enter dC106. Run the machine. Wrinkles still occur.
Y N
Advise the customer about the correct storage and use of paper.
The wrinkles are only at the trail edge of the print.

Y N
Run the machine. Observe the prints entering the fuser. The sheets are skewed or
damaged.
Y N
Check the Fuser Entrance Baffle for debris or damage, and ensure that all four of the
mounting screws are present and are tight.
Go to the 8-706 PHM Skew and Misregistration RAP.
Replace the Pressure Roll (PL 10.4).


10-604 Fuser Agent On Print RAP 10-605 Lead Edge To Trail Edge Streaks (Unfused Print)
Initial Actions RAP
• If there is a large build up of clay in the Fuser Agent Module in the vicinity of the Fuser Procedure
Wick, or the Metering Blade, clean the area, replace the Fuser Wick (PL 10.7). CAUTION
• Go to the HFSI TABLES, and perform all 10-800 HFSI actions due. Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to
• Excess Fuser Agent may be noticed on the first few prints when using colored stock (the the cover may occur.
Fuser Agent on the prints should evaporate after a few days).
Inspect the Fuser Roll for damage. Inspect the Fuser Roll for wear, especially wear in the 11"
NOTE: Use only Fuser Agent for the DP180. (A4) area. The Fuser Roll is damaged, or worn.
Y N
Procedure Inspect the Pressure Roll for damage, or wear in the 11" (A4) area, and replace if neces-
Inspect the Stripper Finger Baffle. There is a build up of Fuser Agent and paper dust on sary (PL 10.4).
the Stripper Finger Baffle caused by the baffle scraping the Pressure Roll.
Y N Replace the Fuser Roll (REP 10-1).
Inspect the Metering Blade for damage or debris. The Metering Blade is OK and prop-
erly located.
Y N
The Metering Roll is damaged.
Y N
Clean the Metering Roll of any toner build-up and clean, rotate, or replace the
Metering Blade (PL 10.7).
Replace the Metering Roll (PL 10.7).
Inspect the Donor Roll for damage or debris. Discoloration and banding of the donor roll is
considered normal. The Donor Roll is OK.
Y N
Clean or replace the Donor Roll (PL 10.8).
Clean or replace the Metering Roll (PL 10.7).
Clean the Stripper Finger Baffle and perform the Stripper Finger Baffle Clearance ADJ 10-15.

10-606 Dry Ink Spots On Prints/Spot Deletions RAP 10-607 Unable to Type on Prints RAP
CAUTION Determine whether this is a machine, paper, or typewriter problem. Proceed with this RAP only
Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to if the problem is caused by the machine.
Perform a panic stop (General Procedures) and check to see if the defect is present before the Procedure
fuser. If the defect is not being caused by the fuser go to the appropriate area to troubleshoot The problem occurs ONLY on cold start-up of machine (first 30 prints out after Power
the cause. On).
Y N
Procedure Enter dC701, [Fuser Roll Temp]. Check the Fuser Roll Temperature. The Fuser Roll
Temperature is in specification.
Inspect the Fuser Roll for damage. The Fuser Roll is OK.
Y N
Y N
Adjust Fuser Roll Temperature (ADJ 10-6).
Replace the Fuser Roll (REP 10-1).
Replace the Metering Blade and the Fuser Wick (PL 10.7).
Inspect the Pressure Roll for damage and replace if necessary (PL 10.4).
Check the Last 50 Faults in SCP for Metering Roll Undertemperature Faults (10-210). Meter-
ing Roll Undertemperature Faults have occurred.
Y N
Enter dC701, [Metering Roll Temp]. The Metering Roll Temperature is in specifica-
tion.
Y N
Adjust Metering Roll Temperature (ADJ 10-7).
Go to the 10-210 RAP or the 10-210.

10-608 Dry Ink Not Fixed RAP
Procedure
The problem occurs only on cold start-up of machine (first 30 prints out after Power On).
Y N
Enter dC701, [Fuser Roll Temp]. The Fuser Roll Temperature is in specification.
Y N
Adjust Fuser Roll Temperature (ADJ 10-6).
Enter dC701, [Contact Arc]. The Contact Arc is in specification.

Y N
Adjust Contact Arc (ADJ 10-2)
If the problem has not been resolved, go to the 10-201.
Check the Last 50 Faults in SCP for Metering Roll Undertemperature Faults, 10-210. Meter-
ing Roll Undertemperature Faults have occurred.
Y N
Enter dC701, [Metering Roll Temp]. The Metering Roll Temperature is in specifica-
tion.
Y N
Adjust Metering Roll Temperature (ADJ 10-7). Ensure that the Metering Roll Heater
comes on.
If the problem has not been resolved, go to the 10-201.
Check the following and then go to the 10-210 or go to the 10-210.

• The Metering Roll Blade (PL 10.7).
• The Metering Blade Bracket Support Assembly is properly mounted to the Metering
Assembly Housing (it is necessary to remove the Metering Roll and the Blade Support to
ensure that it is located properly)
• The correct Dry Ink is being used, especially if this is a MIRC Machine.
• The correct Fuser Agent is being used.

10-701 Bent Corners RAP
Initial Actions
• Check for damaged or obstructed paper path components.
• Check the area from the Registration Transport to the Prefuser Transport for damaged
components.
• Go to the HFSI TABLES, and perform all 10-800 HFSI actions due.
• Ensure that the paper is loaded in the appropriate tray correctly and that curl is within
specification (Decurler section of the Operator Manual).
Procedure
Enter dC701, [Stripper]. The Fuser Air Knife Manifold Air Pressure is in specification.
Y N
Adjust Air Manifold and the Air Knife Pressure (ADJ 10-5).
Enter dC106. Select [Job Setup], [Sample Tray], [Simplex], [Test Patterns and PQ], [Half-
tone], and [100] prints. Run prints to the Sample Tray until a bent corner is observed. The
bent corner is (away from the image).
Y N
The image is distorted.
Y N
• Adjust the Air Knife Manifold (ADJ 10-4).
• Check the Fuser Roll condition
• Condition and operation of the Decurler
Check the condition and operation of the Pre Fuser Baffle.
Adjust the Stripper Finger Baffle Clearance (ADJ 10-15).

Figure 1 10-607/608/701 Circuit Diagram (8036A)

10-702 Fuser Air System Checkout NOTE: The internal air filter element (part of the Moisture Trap / Air Filter) should not be
removed from the Moisture Trap / Air Filter. If a problem is found, the filter should be replaced
Procedure not removed. If the filter is removed, it can result in excess moisture in the ESV, Prefuser Sen-
sor, and Fuser Sensor. This moisture can cause failure of these components. Dirt and dust can
Use the Fuser Air System Checkout schematics on the following pages as an aid to locate and
determine the operation of the various Fuser air components. also be sent to these components that could cause problems, or clogging of the Air Knife Man-
ifold holes.
Most air leaks in the Manhattan air system should be audible and not require a directive proce- To check the Air Filter for internal contamination perform the following:
dure to repair. The following procedure is intended to be used when there is an air system
problem that is not obvious. 1. Remove the air line at the quick disconnect at the 90 degree fitting where the air hose
exits the umbilical cord by the fuser left rail.
Check the Air Gauge (PL 10.9).
2. Enter dC330, [10], [Compressor]. Press [Continue] and observe the Air Gauge. If the
gauge reads above 8 PSI the Moisture Trap / Air Filter (PL 10.10) should be replaced.
The MIM Compressor should turn on in dC330. Enter dC330, [10]. Select [Compressor].
Press [Continue]. If the MIM Compressor does not turn on, go to 10-703, Compressor Motor
RAP.
The Manhattan Printer requires 20 PSI of air for proper operation. Since the MIM Compressor
is capable or supplying greater amounts of air, the pressure in excess of 29 PSI is vented
through a Relief Valve.
The Relief Valve should be adjusted to 29 PSI (ADJ 10-16). If the Relief Valve cannot be
adjusted to 29 PSI, check for the following:
• A leak in the air system

• A failed Bleed Off Solenoid (PL 10.10) (or the wiring, the Timer Relay and the software
that controls it)
• A failed Air Gauge (PL 10.9)
• A failed compressor (PL 10.9)
• A failed Relief Valve (PL 10.10)
• A failed Moisture Trap / Air Filter. See the Moisture Trap / Air Filter procedure later in this
RAP to check the Moisture Trap / Air Filter operation
• A failed Compressor Intake Air Filter (PL 10.9)
• A restriction in the air system between the Compressor and the Air Gauge
The Air Knife Pressure / Pressure Regulator should be adjusted to 20 PSI (ADJ 10-5). The Air
Knife Pressure should not be adjusted until the Relief Valve has been properly adjusted (ADJ
10-16).
The Moisture Trap / Air Filter (PL 10.10) should be checked for proper operation. Ensure that
the vent on the bottom moves freely. Cut the tie wrap and remove the foam from the bottom of
the vent. Under pressure (with the compressor turned on in dC330) the vent should be in the
down position. The vent should move up when pushed up. The vent should move back down
and close when released. If the vent does not close, an air loss will result. If the vent does not
open, moisture will not be removed. The internal air filter element (part of the Moisture Trap /
Air Filter) should also be checked for proper operation. Reinstall the foam when the check has
been finished.

Figure 1 10-702 Fuser Air System Checkout (8037B)

Figure 2 10-702 Fuser Air System Checkout (8039B)

A B
10-703 (60HZ) Compressor Motor RAP Y N
Procedure
Go to Flag 5. Check the wire 4F.
WARNING
Performing service actions in the vicinity of the Compressor represents a safety hazard. 115 VAC is available at P270-3.
Use caution when servicing in this area. Y N
When performing service in the vicinity of the cleaner, the moving pulleys and belts rep- Go to Flag 4. Check the wire 59A.
resent a safety hazard. Use caution when servicing in this area.
If the Compressor Motor is in a thermal overheat condition it will run when it resets Go to Flag 3. Check the wire 3S.
itself.
Enter dC330, [10], [Compressor] motor. Press the Continue button. 115 VAC is available There is greater than 170 VAC across the terminals of the Compressor Motor Run
Capacitor.
from P270-3 to P270-1.
Y N Y N
115 VAC is available from J268-16 to J268-7. Check the wires to the Compressor Motor Run Capacitor, if ok replace the Compressor
Motor Run Capacitor (PL 10.9).
Y N
115 VAC is available at pin 7 of Power On Relay, K101.
Y N Select [Clear Outputs]. Air can be heard from the Bleed Off Solenoid.
Y N
Go to the 1-701 AC Standby Power RAP.
Press the Continue button. The Compressor Motor attempts to start (hum or rotate).
115 VAC is available at pin 1 of Compressor Relay, K1005. Y N
Replace the Compressor Motor (PL 10.9).
Y N
Go to the 10-704 Bleed Off Solenoid RAP.
115 VAC is available at pin 2 of Compressor Relay, K1005.
Y N Replace the Compressor Motor (PL 10.9).
Less than +4 VDC is available from pin 3 to pin 4 of Compressor Relay,
K1005.
Y N
Replace the Compressor Relay, K1005 (PL 1.3).
+5 VDC is available at pin 3 of Compressor Relay, K1005.

Y N
+5 VDC is available at TS35 of the MIN DIO PWB.
Y N

Y N
+5 VDC is available at TS46 of MIN DIO PWB.

Y N
115 VAC is available at J268-16.
A B

A B
10-703 (50HZ) Compressor Motor RAP Y N
Procedure
WARNING
Performing service actions in the vicinity of the Compressor represents a safety hazard. The Phase to Earth voltage is available at P270-3.
Use caution when working in this area. Y N
When performing service in the vicinity of the cleaner, the moving pulleys and belts rep- Go to Flag 4. Check the wire 59A.
If the Compressor Motor is in a thermal overheat condition it will run when it resets Go to Flag 3. Check the wire 3S.
itself.
Enter dC330, [10], [Compressor] motor. Press the Continue button. The Phase to Neutral Select [Clear Outputs]. Air can be heard from the Bleed Off Solenoid.
Y N
voltage is available from P270-1 to P270-3.
Y N Go to the 10-704 Bleed Off Solenoid RAP.
The Phase to Neutral voltage is available from J268-16 to J268-7.
Replace the Compressor Motor (PL 10.9).
Y N
The Phase to Earth voltage is available at pin 8 of Power On Relay, K101.
Y N
The Phase to Earth voltage is available at pin 1 of Printer Compressor Relay,

K1005.
Y N
The Phase to Earth voltage is available at pin 2 of Compressor Relay, K1005.

Y N
Less than +4 VDC is available from pin 3 to pin 4 of Compressor Relay,
K1005.
Y N

Y N
+5 VDC is available at J3-20 of the MIN DIO PWB.
Y N

Y N
+5 VDC is available at TS46 of MIN DIO PWB.

Y N
The Phase to Earth voltage is available at J268-16.

A B

10-704 Bleed-Off Solenoid RAP
Procedure
WARNING
Performing service in the vicinity of the Compressor Motor represents a safety hazard.
Use caution when servicing in this area.
Enter dC330, [10], [Compressor] Motor. Press the Continue button. The Compressor
Motor starts, or attempts to start (hum or rotate).
Y N
Go to the 10-703 Compressor Motor RAP.
115 VAC is measured between P2002-1 and P2002-3.

Y N
Y N
+5 VDC is measured between TS35 (+) and TS37 (-) on the MIN DIO PWB
Y N
Go to 1-713 and troubleshoot a +5 VDC problem.
Press Stop. +5 VDC is measured between TS13 (+) and TS56 (-) on the MIN ADA
PWB #1.
Y N
Go to Flag 1 and Flag 2. Check for Open circuits. If OK, replace the MIN AC Remote
PWB #1 (PL 1.7).
Press Continue. Measure between TS13 (+) and TS56 (-) on the MIN ADA PWB #1.
The voltage drops from +5 VDC to less than 1 VDC.
Y N
Go to Flag 3. Check or an Open circuit. If OK, replace the MIN AC Remote PWB #1 (PL
1.7).
Replace the Bleed Off Solenoid, SOL1003 (PL 10.11).


10-705 Low Fuser Agent Level RAP
Initial Actions
• Check the Fuser Agent level. Fill Fuser Agent Reservoir, if required.
• After the Fuser Agent Reservoir has been filled, the machine must cycle for at least 30
seconds before the Operator Message, Fuser Agent Is Low, or Add Fuser Agent, mes-
sage will be removed.
NOTE: Use only Fuser Agent for the DP180.
Procedure
Enter dC330, [10]. Actuate and deactuate the Fuser Agent Level Switch. The display
Y N
+5 VDC is available from L1-1 to L1-2.
Y N
+5 VDC is available at L1-2.
Y N
+5 VDC is available at P248-2 of MIN DIO PWB.
Y N
Go to Flag 1. Check the wire.
+5 VDC is available at P248-1 of MIN DIO PWB.

Y N
Replace the Fuser Agent Level Switch (PL 10.1).
Check for binding of the Fuser Agent Level Switch actuator.


A B
10-706 (60HZ) Prefuser Vacuum Motor RAP Go to Flag 5. Check the wire 117.
Procedure Replace the Prefuser Vacuum Motor (PL 8.12).

WARNING
Performing service actions in the vicinity of the Compressor represents a safety hazard.
When performing service in the vicinity of the cleaner, the moving pulleys and belts rep-
Enter dC330, [10], [Prefuser Vacuum] motor. Press the Continue button. 115 VAC is avail-
able from P271-1 to P271-2.
Y N
115 VAC is available from J1-18 to J1-6 on MIN AC Remote PWB #1.
Y N
115 VAC is available at 2A7TB2-18.
Y N
115 VAC is available at J1-17 on MIN AC Remote PWB #1.

Y N
Go to Flag 2. Check the wires, 16AA and 16AB.
115 VAC is available from J1-8 to J1-17 on MIN AC Remote PWB #1.
Y N
Go to Flag 1. Check the wires 3LL and 3LM.
+5 VDC is available from J2-5 to J2-6 on MIN AC Remote PWB #1.

Y N
+5 VDC is available at J2-5 on MIN AC Remote PWB #1.
Y N
+5 VDC is available at TS 35 on MIN DIO PWB.
Y N
Go to Flag 3. Check the green wire.

Y N
+5 VDC is available at TS39 on MIN DIO PWB.

Y N
Go to Flag 4. Check the blue wire.
115 VAC is available at P271-1.

Y N
Go to Flag 6. Check the wire 110H.
A B

A
10-706 (50HZ) Prefuser Vacuum Motor RAP Y N
Go to Flag 6. Check the wire 110H.
Procedure
WARNING
Performing service actions in the vicinity of the Compressor represents a safety hazard. Replace the Prefuser Vacuum Motor (PL 8.12).
When performing service in the vicinity of the cleaner, the moving pulleys and belts rep-
Enter dC330, [10], [Prefuser Vacuum] motor. Press the Continue button. The Phase to
Neutral voltage is available from P271-1 to P271-2.
Y N
The Phase to Neutral voltage is available from J1-18 to J1-6 on MIN AC Remote
PWB #1.
Y N
The Phase to Earth voltage is available at 2A7TB2-12.
Y N
Go to the 1-708 AC Standby Power (50HZ) RAP.
The Phase to Earth voltage is available at J1-17 on MIN AC Remote PWB #1.
Y N
Go to Flag 2. Check the wires 16AA and 16AB.
The Phase to Neutral voltage is available from J1-17 to J1-8 on MIN AC Remote
PWB #1.
Y N
Go to Flag 1. Check the wires 3LL and 3LM.
+5 VDC is available from J2-5 to J2-6 on MIN AC Remote PWB #1.

Y N
Y N
+5 VDC is available at TS35 of the MIN DIO PWB.
Y N
Go to Flag 3. Check the green wire.

Y N
+5 VDC is available at TS39 on MIN DIO PWB.

Y N
Go to Flag 4. Check the blue wire.
The Phase to Earth voltage is available at P271-1.
A

A B
10-707 (60HZ) Camming Motor RAP Allow the Camming Motor to cool down and then go to the start of this RAP.
Initial Actions 115 VAC is available from pin 1 to pin 2 of the Fuser Camming Relay, K1006.
Y N
NOTE: When performing checks during this procedure ensure that the camming motor has 115 VAC is available from J1-5 to J1-13 on PHN AC Remote PWB #2.
been selected and has not timed out. Y N
115 VAC is available from J1-11 to J1-3 on PHN AC Remote PWB #2.
Procedure Y N
Enter dC330, [10], [Camming] motor. Open the Fuser Drawer. Place a cheater in the Printer 115 VAC is available at pin 19 of 2A7TB1.
Interlock Bypass switch. Press the Continue button. The Camming Motor fails to come on. Y N
(If the Camming Motor does not come on follow the yes path.) Go to the 1-701 AC Standby Power RAP.
Y N
Press the Stop button. Remove the cheater from the Printer Interlock Bypass Switch. 115 VAC is available at J1-11 on the PHN AC Remote PWB #2.
Place a cheater in the left door, right door and Fuser Interlock switches. Press the Con- Y N
tinue button. The Camming Motor comes on. Go to Flag 3. Check the wires.
Y N
+24 VDC is available at pin 1 of the Fuser Interlock Switch. Go to Flag 11. Check the wire 3MM for an open circuit. The wire 3MM shows
Y N an open circuit.
+24 VDC is available at 1TB4-1A. Y N
Y N Go to the 1-701 AC Standby Power RAP.
There is +24 VDC available between TH12 (+) and TH14 (-) of the Low
Voltage Power Supply. Repair or replace the wire.
Y N
Go to the 1-717 +24, +34, -34 RAP. +5 VDC is available from J2-3 to J2-4 on PHN AC Remote PWB #2.
Y N
Go to the +24VDC Distribution wirenet. Check the wire 1028 for an open +5 VDC is available at 2TB4-12A.
circuit. Y N
Go to Wirenets (Wiring Data) Check the wire #538 for an open circuit.
Go to Flag 8. Check the wiring between 1TB4 and the Fuser Interlock Switch.
+5 VDC is available from 2TB4-12A to PHN DIO PWB #2 J2-11.
Go to Flag 9. Check the wiring between the Fuser Interlock Switch and the and the Y N
Fuser Camming Relay. If the wiring checks good replace the Fuser Interlock Switch Replace the PHN DIO PWB #2 (PL 1.4).
(PL 10.1).
+5 VDC is available from 2TB4-12A to PHN AC Remote PWB #2 J2-4.
Check or adjust the actuator of the Fuser Interlock Switch. Y N
If the camming Motor came on in the previous step this is not the correct path, start the proce-
dure over. Less than 90 VAC is available from B2-1 to B2-2. +5 VDC is available from 2TB4-12 to PHN AC Remote PWB #2 J2-3.
Y N Y N
The Camming Motor is hot to the touch. Replace the PHN AC Remote PWB #2 (PL 1.4).
Y N
Manually operate the Camming Motor. Check for binding in the Camming mecha- Go to Flag 4. Check the red wire.
nism. Binding of the Camming mechanism is present.
Y N Replace the PHN AC Remote PWB #2 (PL 1.4).
There is pitting on the contacts of the Camming Motor Relay, K1006.
Y N 115 VAC is available at pin 2 of Fuser Camming Relay, K1006.
Replace the Camming Motor (PL 10.3). Y N
Replace the Camming Motor Relay, K1006 (PL 1.3).
Repair or replace the cause of the binding.
Less than 90 VAC is available from pin 4 to pin 5 of the Fuser Camming Relay, K1006.
A B
Y N
115 VAC is available at B2-2.
Y N
Go to Flag 1. Check the wires.
+24 VDC is available from pin A to pin B on Fuser Camming Relay, K1006.
Y N
+24 VDC is available at pin A on Fuser Camming Relay, K1006.
Y N
+24 VDC is available at pin 1B of Fuser Interlock Switch.
Y N
+24VDC is available at 1TB4-1A.
Y N
There is +24VDC available between TH12 (+) and TH14 (-) of the Low
Voltage Power Supply.
Y N
Go to the 1-717 +24, +34, -34 VDC RAP.
Go to the +24VDC Distribution wirenet. Check the wire 1028 for an open
circuit.
Go to Flag 8. Check the wiring between 1TB4-1A and the Fuser Interlock
Switch.
Go to Flag 9. Check the wiring between the Fuser Interlock Switch and the Fuser
Camming Relay. If the wiring checks good replace the Fuser Interlock Switch (PL
10.1).
Go to Flag 10. Check the wire for an open circuit. The wire shows an open circuit.
Y N
Go to the +24VDC Return Distribution wirenet. Check the wire 1029 for an open cir-
cuit.
Go to Flag 10. Repair or replace the wire.
Replace the Fuser Camming Relay, K1006 (PL 1.3).


A
10-707 (50HZ) Camming Motor RAP 115VAC is available from pin 1 to pin 2 of the Fuser Camming Relay, K1006.
Y N
Initial Actions 115VAC is available from J1-5 to J1-13 on PHN AC Remote PWB #2.
Y N
NOTE: When performing checks in this procedure ensure that the Camming Motor has been 115VAC is available from J1-11 to J1-3 on PHN AC Remote PWB #2.
selected and has not timed out. Y N
115VAC is available from pin 14 of 2A7TB2 to pin 6 of MIM Power Relay
Procedure K107.
Enter dC330, [10], [Camming] motor. Open the Fuser Drawer. Place a cheater in the Printer Y N
Interlock Bypass Switch. Press the Continue button. The Camming Motor fails to come on. Go to the 1-711-1 Inverter/Stacker A Standby AC Power (50HZ) RAP (The
(If the Camming Motor does not come on follow the yes path.) AC Power for the Camming Relay is controlled through the IFS Power
Y N Relay, K107, which is checked in the 1-711-1 RAP).
Press the Stop button. Remove the cheater from the Printer Interlock bypass Switch.
Place a cheater in the left door, right door and the Fuser Interlock switches. Press the 115VAC is available at J1-11 on the PHN AC Remote PWB #2.
Continue button. The Camming Motor comes on. Y N
Y N Go to Flag 3. Check the wires 16CC and 16FF.
+24 VDC is available at pin 1 of the Fuser Interlock Switch.
Y N Go to Flag 11. Check the wires, 3FF and 3MM for an open circuit. The wire
+24 VDC is available at pin 1A of 1TB4. 3FF or 3MM shows an open circuit.
Y N Y N
There is +24 VDC available between TH12 (+) and TH14 (-) of the Go to the 1-711-1 Inverter/Stacker Standby AC Power (50HZ) RAP (The
LVPS. AC Power for the Camming Relay is controlled through the IFS Power
Y N Relay, K107, which is checked in the 1-711-1 RAP).
Go to the 1-717 +24, +34, -34 VDC RAP.
Repair or replace the wire.
Go to the +24 VDC Distribution wirenet. Check the wire 1028 for an open
circuit. +5 VDC is available from J2-3 to J2-4 on PHN AC Remote PWB #2.
Y N
Go to Flag 8. Check for an open circuit between 1TB4 and the Fuser Interlock +5 VDC is available at 2TB4-12A.
Switch. Y N
Go to the Wirenets (Wiring Data) and check the wire #538 for an open cir-
Go to Flag 9. Check the wiring between the Fuser Interlock Switch and the Fuser cuit.
Camming Relay. If the wires check good replace the Fuser Interlock Switch (PL
10.1). +5 VDC is available from 2TB4-12A to PHN DIO PWB #2 J2-11.
Y N
Check or adjust the actuator of the Fuser Interlock Switch. Replace the PHN DIO PWB #2 (PL 1.4).
(If the Camming Motor came on in the previous step, this is not the correct path. Start the pro- +5 VDC is available from 2TB4-12A to PHN AC Remote PWB #2 J2-4.
cedure over.) Less than 90 VAC is available from B2-1 to B2-2. Y N
Y N Go to Flag 5. Check the brown wire.
The Camming Motor is hot to the touch.
Y N +5 VDC is available from 2TB4-12 to PHN AC Remote PWB #2 J2-3.
Manually release the Camming motor brake and operate the Camming Motor. Check Y N
for binding in the Camming mechanism. Binding of the Camming mechanism is Replace the PHN AC Remote PWB #2 (PL 1.4).
present.
Replace the Camming Motor (PL 10.3).
Replace the PHN AC Remote PWB #1 (PL 1.4).
Repair or replace the cause of the binding.
115VAC is available at pin 2 of Fuser Camming Relay, K1006.
Allow the Camming Motor to cool, then go to the start of this RAP. Y N
A B C
B C
Less than 90 VAC is available from pin 4 to pin 5 of the Fuser Camming Relay, K1006.
Y N
115VAC is available at B2-2.
Y N
+24 VDC is available from pin A to pin B on Fuser Camming Relay, K1006.
Y N
+24 VDC is available at pin A on Fuser Camming Relay, K1006.
Y N
+24 VDC is available at pin 1 of Fuser Interlock Switch.
Y N
+24 VDC is available at pin 1A of 1TB4.
Y N
+24 VDC is available between TH12 (+) and TH14 (-) with of the LVPS.
Y N
Go to the 1-717 +24, +34, -34 VDC RAP.
Go to the +24 VDC Distribution wirenet. Check the wire 1028 for an open
circuit.
Go to Flag 8. Check the wiring between 1TB4-1A and the Fuser Interlock
Switch.
Go to Flag 9. Check the wiring between the Fuser Interlock Switch and the Fuser
Camming Relay. If the wiring checks good replace the Fuser Interlock Switch.
Go to Flag 10. Check the wire for an open circuit. The wire shows an open circuit.
Y N
Go to the 24 VDC Return Distribution wirenet. Check the wire 1029.
Go to Flag 10. Repair or replace the wire.
Replace the Fuser Camming Relay, K1006 (PL 1.2).


10-708 Fuser Agent Dispense RAP NOTE: If a new Fuser Agent Pump is not available, change PHN NVM location 188 to 36. (This
is only a temporary attempt to increase the flow rate). Be sure to change the PHN NVM loca-
Procedure tion 188 back to 18 when a new pump has been installed. It may be helpful to leave a note in
the machine log as a reminder to reset the NVM back to default when the pump is replaced.
Enter dC330, [10], [Fuser Agent Pump] solenoid. Place a cheater in the Printer Interlock
Bypass switch. Press the Continue button. The Fuser Agent Pump Solenoid cycles on and
off.
Y N
The Fuser Agent solenoid energizes and remains energized.
Y N
+24 VDC is available at J1-7 of the PHN DIO PWB #2.
Y N
Go to Flag 1. Check wire 516.
+24VDC is available at J3-8 of the PHN DIO PWB #2.

Y N
+24VDC is available B1-2 of the Fuser Agent Pump Solenoid.

Y N
Go to Flag 2. Check the wires for an open.
+24 VDC is available at B1-1 of the Fuser Agent Pump Solenoid.

Y N
Replace the Fuser Agent Pump Solenoid (PL 10.8).
+24VDC is available at J3-7 of the PHN DIO PWB#2.

Y N
Go to Flag 3. Check the wires for an open.
+24VDC is available at TS51 of the PHN DIO PWB #2.

Y N
Go to the 24VDC Return Distribution wirenet. Check for an open.
Go to Flag 3. Check for a short to ground. If no short is found replace the PHN DIO PWB
#2 (PL 1.4).
Fuser Agent is being dispensed.

Y N
Check for damaged, loose, or obstructed lines. If no problems are found replace the
Fuser Agent Pump Solenoid (PL 10.8).
Check the PHN NVM location 188 =18. Place the output hose from the Fuser Agent Pump into
the cap from a Fuser Agent bottle (bottle part number is 8R2955). Enter dC330, [10] [Fuser
Agent] Pump [Cycle]. Press the Continue button. Count the number of strokes, of the Fuser
Agent Pump Solenoid, necessary to fill the cap. Press the Stop Button. If less than 15 strokes,
the pump is operating correctly. If 16 to 20 strokes the pump is marginal and should be
replaced (PL 10.8).


A
10-709 MIB PWB RAP Replace the MIN ADA PWB #1 (PL 1.8).
Procedure
+15 VDC is available at P287-2 of MIB PWB.
Y N
Go to Flag 10. Check the wire, 1009A. If ok, go to the 1-715 +15 VDC RAP.
-15 VDC is available at P287-3 of MIB PWB.

Y N
Go to Flag 9. Check the wire, 1010A. If ok, go to the 1-716 -15 VDC RAP.
+15 VDC is available from P287-2 to P287-5 of MIB PWB.

Y N
Go to Flag 8. Check the wire, 1008A.
This RAP was entered from the 10-210 RAP.

Y N
Enter dC330, [LVPS 24VDC]. Press the Start button (ensure that the LVPS has been
reset and that 24VDC is enabled). 0 to 10 VDC is available between TS 39 and TS 40
of the MIN ADA PWB #1. (It may be necessary to wait up to 4 minutes for the volt-
age to register the temperature change.)
Y N
0 to 10 VDC is at J3-7 to J3-8 of the MIB PWB.
Y N
0 to 10 VDC available at J3-1 to J3-2 of the MIB PWB.
Y N
Go to Flag 7, and check the wires of the Fuser Roll Thermistor circuit. If
the wires check OK, replace the Fuser Roll Thermistor (PL 10.4).
Replace the MIB PWB (PL 1.8).
Go to Flag 3 and Flag 4, and check the blue and green wires.
Enter dC330, [LVPS 24VDC]. Press the Start button (ensure that the LVPS has been reset
and that 24VDC has been enabled). 0 to 10 VDC is available between TS 37 and TS 38 of
the MIN ADA PWB #1. (It may be necessary to wait up to 4 minutes for the voltage to reg-
ister the temperature change.)
Y N
0 to 10 VDC is available at J3-9 to J3-10 of the MIB PWB.
Y N
0 to 10 VDC is at J3-4 to J3-3 of the MIB PWB.
Y N
Go to Flag 6, and check the wires of the Metering Roll Thermistor circuit. If OK,
replace the Metering Roll Thermistor (PL 10.7).
Replace the MIB PWB (PL 1.8).
Go to Flag 1 and Flag 2, and check the Yellow and Orange wires.
A

10-710 Camming Motor Runs Continuously RAP
Initial Actions
• If in the service mode, ensure that the Camming Motor is not selected.
• Ensure that the problem is present (motor runs continuously) while performing this RAP.
Procedure
+ 5 VDC is available at TS 43 (+) and TS 37 (-) on PHN DIO PWB #2.
Y N
Go to Flag 5, and check for a short. If no short is found replace the PHN DIO PWB #2 (PL
1.4).
Go to Flag 7, and 2, and check for a short. If no short is found replace the PHN AC Remote
PWB #2 (PL 1.4).


10-711 RAP Y N
Place a cheater in the Printer Interlock Bypass Switch. +24 VDC is available at pin A of
Fault Code, 10-711, indicates that a 10-201 or 10-204 fault code has been declared. The 10- Fuser Power Relay, K1001.
711 RAP troubleshoots a problem with the either the 115VAC supply or the lamp switching por- Y N
tion of the circuit. +24 VDC is available at pin 1 (N.O.) of Printer Interlock Bypass Switch.
Y N
Initial Actions Go to Flag 14. Check the orange wires.
proper contact with the Fuser Roll. +24 VDC is available at pin 1 (Com) of Printer Interlock Bypass Switch.
Y N
Replace the Printer Interlock Bypass Switch (PL 1.15).
Procedure +24 VDC is available at ST2-2 of Fuser Roll Thermostat.
+15 VDC is available at P257-2 of the MIB#2 PWB. Y N
Y N Go to Flag 11 and Flag 18. Check the wires.
Go to Flag 29. Check the wire 1009T. If ok, go to the 1-715 +15 VDC RAP.
+24 VDC is available at pin 1 of Fuser Roll Thermostat.
-15 VDC is available at P257-3 of the MIB#2 PWB. Y N
Replace the Fuser Roll Thermostat (PL 10.4).
Y N
Go to Flag 28. Check the wire 1010K. If ok, go to the 1-716 -15 VDC RAP.
+24 VDC is available at pin 1 of Metering Roll Thermostat.
Y N
+15 VDC is available from P257-2 to P257-5 of the MIB#2 PWB.
Y N Go to Flag 12. Check the white wires.
Go to Flag 27. Check the wire 1008U.
Enter then exit diagnostics (Press button R). If Fault Code, 10-201/10-204, can not be cleared, Y N
switch off and then reset the machine circuit breakers. Open the Fuser Drawer. Disconnect Replace the Metering Roll Thermostat (PL 10.7).
HR12/P1 at the rear of the Fuser. Refer to GP 8, Section 6 General Procedures, for the correct
procedure to pulse the lamp in the next step. Enter dC701, [Thermistor Cal]. Place a cheater +24 VDC is available at pin 1 (diode input side) of CR1.
in the Printer Interlock Bypass Switch. The Fuser Heat Rod is off. Y N
Y N
Check the Fuser Roll Temperature (ADJ 10-6). The Fuser Temperature is below speci-
fication. +24 VDC is available at pin 1 (diode output side) of CR1.
Y N
Y N
Check the Fuser Roll Thermistor, RT1003, for debris or damage. The Fuser Ther- Replace the Diode CR1 (PL 24.5).
mistor is clean and making proper contact.
Go to Flag 16. Check the orange wire.
Y N
Clean or replace the Fuser Roll Thermistors, RT1001 and RT1003, (PL 10.4).
Remove the Cheater from the Printer Interlock Bypass Switch. Make sure the Fuser
Drawer is closed. +24 VDC is available at pin 1 of the Fuser Interlock Switch.
Go to Flag 124. Check the circuit of the Fuser Roll Thermistor, RT1003.
Y N
Remove the cheater from the Printer Interlock Bypass Switch. Reconnect HR14/P1. Go to Go to Flag 13. Check the wires, 1005F, 1005R and 1005T. If OK, go to the 1-717
+24, +34, and -34 VDC RAP.
Flag 7. Check the circuit of the Fuser Roll Thermistor, RT1003. Check the Metering Roll
(ADJ 10-1) and Fuser Roll (ADJ 10-0) Thermostats for adjustment and condition. Inspect
the Metering Roll Thermistor (PL 10.7). +24 VDC is available at pin 2 of the Fuser Interlock Switch.
Y N
Perform the Thermistor Cal adjustment (ADJ 10-13).
If the problem continues replace the Fuser Relays, K1002, K1007 (PL 1.3). Check the alignment of the Fuser Interlock Switch Actuator. If ok, replace the Fuser
Interlock Switch (PL 10.1).
Remove the cheater from the Printer Interlock Bypass Switch. Reconnect HR12/P1. Ensure
that the Fuser drawer is closed and that the Fuser Interlock switch is properly actuated. +24 +24 VDC is available at ST2-2 of the Fuser roll thermostat.
Y N
VDC is available at pin A of Fuser Power Relay, K1001.
Go to Flag 11 and Flag 17. Check the wires.
A B
A B C D
Go to Flag 17. Check the orange wire. Y N
+5VDC is available from TS60 of the ADA PWB #2 to TS44 of the MIN DIO
+24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin B (-) of the PWB.
Power On Relay, K101. Y N
Y N +5VDC is available at TS60 of the MIN ADA PWB #2.
+24 VDC is available from pin A (+) to Pin B (-) of the Fuser Power Relay, K1001. Y N
Y N If +5VDC is available at J1-10 replace the MIN ADA PWB #2 (PL
+24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin 2 1.8).
(diode output side) of CR1.
Y N Go to the 10-709 MIB PWB RAP
+24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to
pin 2 (-) (diode input side) of CR1. +5VDC is available at pin 4 of the Fuser Relay, K1007.
Y N Y N
Go to Flag 15. Check the violet wire and connections. If OK, replace the Go to Flag 1. Check the yellow wires.
Power On Relay, K101 (PL 1.3).
+5VDC is available at pin 3 of the Fuser Relay, K1007.
Replace the Diode, CR1 (PL 24.5). Y N
Replace the Fuser Relay, K1007, (PL 1.3).
Go to Flag 9. Check the violet wire and connections for an Open.
Go to Flag 123. Check the orange wires.
Replace the Fuser Power Relay, K1001 (PL 1.3).
Replace the Fuser Relay, K1007, (PL 1.3).
NOTE: During the next procedure the voltage will only be available when the lamp pulses. The
description of the operation of the lamp is contained in GP 8. Go to Flag 111. Check the wires 82A, 82C, and 82E.
Open the Fuser Drawer. Disconnect HR14/P1 at rear of Fuser Heat Rod. Refer to GP 8, Sec-
115 VAC is available at P1-1 (at the rear of Fuser Heat Rod).
tion 6 General Procedures, for the correct procedure to pulse the lamp in the next step. Enter
Y N
dC701, [Thermistor Cal]. Place a cheater in the Printer Interlock Bypass switch. 115 VAC is
115 VAC is available at HR11-1 (at front of Fuser Heat Rod).
available at HR14-1 (at rear of Fuser Heat Rod). NOTE: After the cause of the problem
Y N
has been identified in the following steps, reconnect HR14/P1.
Go to Flag 6. Check the wires 14A, and 19A.
Y N
Open the Line Interface Box. 115 VAC is available at pin 1 of Fuser Relay, K1007.
Replace the Fuser Heat Rod (REP 10-1).
Y N
115 VAC is available at pin 1 of the Fuser Relay, K1002.
An intermittent 10-201 is suspected. Check the following for intermittent operation:
Y N
• Fuser Roll Thermostat Adjustment (ADJ 10-0) and operation
115 VAC is available at pin 1 of Fuser Inductor, L1001.
Y N • Metering Roll Thermostat Adjustment (ADJ 10-1) and operation
Go to Flag 3. Check the wire 13C. • Fuser Roll Thermistors (RT1001 and RT1003)
• Metering Roll Thermistor
115 VAC is available at pin 2 of Fuser Inductor, L1001. • Thermistor CAL ADJ 10-17
Y N
• Fuser Relay, K1007 and K1002
Replace the Fuser Inductor, L1001 (PL 1.3).
Go to Flag 4. Check the wire 18. • The MIN ADA PWB #2
• The MIB#2 PWB
Go to Flag 123. Check the wire 18A. • Fuser Heat Rod
115 VAC is available at pin 2 of Fuser Relay, K1007.
Y N
Fuser Relay, K1007.
C D



10-714 RAP Y N
Place a cheater in the Printer Interlock Bypass Switch. +24 VDC is available at pin A of
Fault Code, 10-714, indicates that a 10-201 or 10-204 fault code has been declared. The 10- Fuser Power Relay, K1001.
714 RAP troubleshoots a problem with either the 115VAC supply or the temperature control Y N
portion of the circuit. +24 VDC is available at pin 1 (N.O.) of Printer Interlock Bypass Switch.
Y N
Initial Actions Go to Flag 14. Check the orange wires.
proper contact with the Fuser Roll. +24 VDC is available at pin 1 (Com) of Printer Interlock Bypass Switch.
Y N
Replace the Printer Interlock Bypass Switch (PL 1.15).
Procedure +24 VDC is available at ST2-2 of Fuser Roll Thermostat.
+15 VDC is available at P287-2 of the MIB#1 PWB. Y N
Y N Go to Flag 11 and Flag 18. Check the wires.
Go to Flag 19. Check the wire 1009A. If ok, go to the 1-715 +15 VDC RAP.
+24 VDC is available at pin 1 of Fuser Roll Thermostat.
-15 VDC is available at P287-3 of the MIB#1 PWB. Y N
Replace the Fuser Roll Thermostat (PL 10.4).
Y N
Go to Flag 20. Check the wire 1010A. If ok, go to the 1-716 -15 VDC RAP.
Y N
+15 VDC is available from P287-2 to P287-5 of the MIB#1 PWB.
Y N Go to Flag 12. Check the white wires.
Check the Fuser Roll Temperature (ADJ 10-6). The Fuser Temperature is below specifica- Y N
tion. Replace the Metering Roll Thermostat (PL 10.7).
Y N
Check the Fuser Roll Thermistor, RT1001, for debris or damage. The Fuser Thermistor +24 VDC is available at pin 1 (diode input side) of CR1.
is clean and making proper contact. Y N
Y N
Clean or replace the Fuser Roll Thermistor, RT1001, (PL 10.4).
+24 VDC is available at pin 1 (diode output side) of CR1.
Y N
Go to Flag 7. Check the circuit of the Fuser Roll Thermistor, RT1001.
Replace the Diode CR1 (PL 24.5).
Enter then exit diagnostics (Press button R). If Fault Code, 10-201, can not be cleared, switch
Go to Flag 16. Check the orange wire.
off and then reset the machine circuit breakers. Open the Fuser Drawer. Ensure that the Fuser
temperature is below operating temperature. Disconnect HR14/P1 at the rear of the Fuser.
Refer to GP 7, Section 6 General Procedures, for the correct procedure to pulse the lamp in Remove the Cheater from the Printer Interlock Bypass Switch. Make sure the Fuser
Drawer is closed. +24 VDC is available at pin 1 of the Fuser Interlock Switch.
the next step. Enter dC701, [Fuser Roll Temp]. Place a cheater in the Printer Interlock Bypass
Switch. Observe the Fuser Heat Rod. The Fuser Heat Rod is off. Y N
Y N Go to Flag 13. Check the wires, 1005F, 1005R and 1005T. If OK, go to the 1-717
+24, +34, and -34 VDC RAP.
Open the fuser drawer. Reconnect HR14/P1. Check the Metering Roll (ADJ 10-1) and
Fuser Roll (ADJ 10-0) Thermostats for adjustment and condition. Inspect the Metering
Roll Thermistor (PL 10.7). +24VDC is available at pin 2 of the Fuser Interlock Switch.
Y N
Perform the Thermistor Cal adjustment (ADJ 10-17).
If the problem continues, replace the Fuser Relays K1001, K1003 (PL 1.3). Check the alignment of the Fuser Interlock Switch Actuator. If ok, replace the Fuser
Interlock Switch (PL 10.1).
Remove the cheater from the Printer Interlock Bypass Switch. Reconnect HR14/P1. Ensure
that the Fuser drawer is closed and that the Fuser Interlock switch is properly actuated. +24 +24 VDC is available at ST2-2 of the Fuser roll thermostat.
Y N
VDC is available at pin A of Fuser Power Relay, K1001.
Go to Flag 11 and Flag 17. Check the wires.
A B
A B C D
Go to Flag 17. Check the orange wire. Y N
+5VDC is available from TS16 to TS60 of the ADA PWB #2.
+24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin B (-) of the Y N
Power On Relay, K101. +5VDC is available at TS60 of the MIN ADA PWB #2.
Y N Y N
+24 VDC is available from pin A (+) to Pin B (-) of the Fuser Power Relay, K1001. If +5VDC is available at J1-10 replace the MIN ADA PWB #2 (PL
Y N 1.8).
+24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin 2
(diode output side) of CR1. Go to the 10-709 MIB PWB RAP.
Y N
+24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to +5VDC is available at pin 3 of the Fuser Relay, K1002.
pin 2 (-) (diode input side) of CR1. Y N
Y N Go to Flag 1. Check the yellow wires.
Go to Flag 15. Check the violet wire and connections. If OK, replace the
Power On Relay, K101 (PL 1.3). +5VDC is available at pin 4 of the Fuser Relay, K1002.
Y N
Replace the Diode, CR1 (PL 24.5). Replace the Fuser Relay, K1002, (PL 1.3).
Go to Flag 9. Check the violet wire and connections for an Open. Go to Flag 2. Check the orange wires.
Replace the Fuser Power Relay, K1001 (PL 1.3). Replace the Fuser Relay, K1002, (PL 1.3).
NOTE: During the next procedure the voltage will only be available when the lamp pulses. The Go to Flag 5. Check the wires 19 and 14C.
description of the operation of the lamp is contained in GP 8.
115 VAC is available at P1-1 (at the rear of Fuser Heat Rod).
Open the Fuser Drawer. Ensure that the Fuser temperature is below operating temperature.
Y N
Disconnect HR12/P1 at the rear of the Fuser. Refer to GP 7, Section 6 General Procedures, for
115 VAC is available at HR11-1 (at front of Fuser Heat Rod).
the correct procedure to pulse the lamp in the next step. Enter dC701, [Fuser Roll Temp].
Y N
Place a cheater in the Printer Interlock Bypass Switch. Measure voltage to the Fuser Heat
Go to Flag 6. Check the wires 14A, and 19A.
Rod.
NOTE: Ensure that after the cause of the fault has been repaired, in the following steps, the Replace the Fuser Heat Rod (REP 10-1).
heat rod is reconnected.
An intermittent 10-201 is suspected. Check the following for intermittent operation:
115 VAC is available at HR12-1 (at rear of Fuser Heat Rod). • Thermistor CAL ADJ 10-17
Y N
• Fuser Roll Thermostat Adjustment (ADJ 10-0) and operation
Open the Line Interface Box. 115 VAC is available at pin 1 of Fuser Relay, K1002.
• Metering Roll Thermostat Adjustment (ADJ 10-1) and operation
Y N
115 VAC is available at pin 1 of Fuser Inductor, L1001. • Fuser Roll Thermistors (RT1001 and RT1001)
Y N • Metering Roll Thermistor
Go to Flag 3. Check the wire 13C. • Fuser Relay, K1007
115 VAC is available at pin 2 of Fuser Inductor, L1001.
Y N
Replace the Fuser Inductor, L1001 (PL 1.3). • The MIB#1 PWB
Go to Flag 4. Check the wire 18. • Fuser Heat Rod
115 VAC is available at pin 2 of Fuser Relay, K1002.

Y N
Fuser Relay, K1002.
C D



11-100 RAP
Fault Code, 11-100, indicates that a print arrived at the Inverter Entrance Sensor, Q1155, early.
The print missed the Printer Duplex Gate, or a stray print arrived at the Inverter Entrance Sen-
sor.
Initial Actions
• Inverter Entrance Sensor is clean and not obstructed.

• Paper path is not obstructed.
• The Printer Duplex Gate pivots freely and is not damaged.
Procedure
Enter dC330, [10], [Duplex Gate] solenoid. Insert a cheater into the Printer Top Cover Inter-
lock Switch. Press Continue. The Duplex Gate Solenoid energizes and the gate actuates.
Y N
• Gate to solenoid linkage (PL 10.14).
• Duplex Gate and Solenoid RAP Adjustment (ADJ 10-9).
If OK, go to Flag 2. Check the Printer Duplex Gate Solenoid circuit GP 6-3 (Generic Sole-
noid RAP, General Procedures).
Press Stop. Check the (ADJ 10-9), Duplex Gate Solenoid adjustment. The adjustment is
correct.
Y N
Perform (ADJ 10-9), Duplex Gate and Solenoid RAP adjustment.
Enter dC330, [10]. Block the Inverter Entrance Sensor. The Inverter Entrance Sensor dis-
Y N
Go to Flag 1. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures).
(PL 11.24)
Go to the 10-108, 10-109.


11-102 RAP

Fault Code, 11-102 indicates that the lead edge of the print delivered from the Printer Top
Transport Sensor, Q1012, did not arrive at the Inverter Entrance Sensor, Q1155, within the
specified amount of time.
Initial Actions
• Inverter Entrance Sensor is clean and is not obstructed

• Paper path is not obstructed
• Transport jam clearance baffles for damage and that they are seated correctly
• Printer Top Transport drive rolls, idlers, belts, and bearings for wear, damage, or contami-
nation
Diagnostic Tools:
• dC226, Inverter/Stacker Paper Path Timing Diagnostics, interval #1, LE from Top Trans-
port Sensor Q1012, to LE at Inverter Entrance Sensor Q1155
• dC227, Inverter/Stacker Jam Bypass
Procedure
Observe the Prints entering the Inverter. The prints are free from damage, skew, and
excessive curl.
Y N
• IF/S to Printer Alignment/Leveling
• Drive Rolls and Idlers for wear, damage, or contamination (PL 10.14)
If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diag-
nostics (Service Call Procedures) for additional information.
Enter dC330, [10]. Block the Inverter Entrance Sensor. The Inverter Entrance Sensor dis-
Y N
Go to Flag 1. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures).
(PL 11.24)
Insert a cheater into the Top Cover Interlock Switch. Select [1-4] [Main Drive Start/Run].
Press Continue. The Top Transport Drive Rolls are rotating.
Y N
Press the Stop button. Check the PHM Top Transport Drives for loose, defective or dam-
aged components (PL 10.14).

• Drive belts for wear, damage, or contamination and that they are set to the correct ten-
sion.
• Drive Pulley for damage and that it is not slipping on the shaft (PL 10.14).
• Drive Rolls and Idlers for wear, damage, or contamination (PL 10.14).


11-104, 11-105 RAP

A
The Inverter Transport Motor Fan is running.
Fault Code, 11-104, indicates that the trail edge of a print arrived later than the specified
amount of time at the Inverter Entrance Sensor, Q1155. When this fault is declared, the sensor Y N
is unblocked. CAUTION
Before removing the Inverter Motor Cooling Fan from the mounting bracket, note the
Fault Code, 11-105, indicates that the trail edge of a print arrived later than the specified orientation of the Fan and the direction of the air flow.
amount of time at the Inverter Entrance Sensor, Q1155. When this fault is declared, the sensor Loosen the screws (2) securing the Fan bracket to the Inverter Assembly Motor and
is blocked. replace the Inverter Transport Motor Fan (PL 11.22).
Initial Actions Press Stop. Check the following;

Check the following: • Drive belts for wear, damage, or contamination. (PL 11.22).
• Drive Rolls for wear, damage, or contamination. (PL 11.22).
• Inverter Pivot Assembly is latched properly. • All jam clearance baffles are latched.
• Inverter Entrance Sensor is clean and is not obstructed • Drive belts broken, loose, or damaged.
• Paper path is not obstructed. • Idler Rolls rotate without binding. (PL 11.22).
• IF/S is aligned properly with printer • Idler Springs are mounted properly.
• Inverter Gate pivots freely and is not damaged.
Observe the Inverter Gate Solenoid, SOL1108 (with Printer power on in a standby condition).
Diagnostic Tools:
The Inverter Gate Solenoid is actuated.
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #2, LE at Inverter Y N
The problem only occurs in duplex mode.
Entrance Sensor to TE at Inverter Entrance Sensor
Y N
• dC227 - Inverter/Stacker Jam Bypass
Procedure • Drive belts for wear, damage, or contamination. (PL 10.14) and (PL 11.22).
Observe the prints entering the Inverter. The prints are free from damage, skew, and exces- • Drive Rolls and Idlers for binding or wear (PL 11.23)
sive curl. • Inverter Gate for damage or (PL 11.23)
Y N
• Inverter Gate for missing or damaged Gate Return Spring (PL 11.24)
• Paper path for obstruction.
Select [Inverter FWD] motor. The Inverter Motor comes on in the forward direction
• Drive Rolls and Idlers for wear, damage, or contamination (PL 10.14). (Counterclockwise viewed from rear).
If OK, go to the 8-705 Print Damage RAP, or to the Physical Checks, Print Paper Diagnos- Y N
tics (Service Call Procedures) for additional information. Press Stop. Go to the 11-707, Inverter Drive Motor RAP.
Enter dC330, [10]. Block the Inverter Entrance Sensor. The Inverter Entrance Sensor dis- Press Stop. Select [Inverter REV] motor. Press Continue. The Inverter Motor comes
play changes from L to H. on in the reverse direction (clockwise viewed from rear).
Y N Y N
Go to Flag 1. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures). Press Stop. Go to the 11-707, Inverter Drive Motor RAP.
(PL 11.24)
WARNING • Drive belts for wear, damage, or contamination (PL 11.24). After replacing, perform
The Inverter Main Drive Motor may run automatically. There is an internal thermal sen- the Inverter Transport Motor Belt Tension adjustment (ADJ 11-14).
sor in the motor that opens when the motor overheats. When the motor cools, the ther- • Drive Rolls and Idlers for binding or wear (PL 11.23) and PL 11.25).
mal sensor will close, allowing power to the motor. The outside surfaces of the motor • Inverter Gate for damage (PL 11.23)
could also be very hot. Use caution when working near the motor. • Inverter Gate for missing or damaged Gate Return Spring (PL 11.24)
Press Stop. Select [Inverter Start/Run] motor. Press Continue. The Inverter Drive Rolls and • IF/S to Printer Alignment/Leveling
Idlers rotate.
• Proper pulley on reversing Shaft (60Hz-24 teeth, 50Hz-20 teeth)
Y N
The Inverter Main Drive Motor comes on.
Go to Flag 3. Check the wire for a short circuit. If OK, replace the PHN DIO PWB #5 (PL 1.17).
Y N
Press Stop. Go to the 11-708 Inverter Main Drive Motor RAP.
A B
B
Figure 1 11-104/105 Circuit Diagram (8102) l

11-106 RAP

A
• Proper Inverter Main Drive Motor is present (60Hz, 21 teeth on pulley), (50Hz, 25 teeth on
Fault Code, 11-106, indicates that the lead edge of an inverted print arrived earlier than the
specified amount of time at the Post Inverter Sensor, Q1156, from the Inverter Entrance Sen- pulley).
sor, Q1155. The duplex print missed the Inverter Gate.
Initial Actions
• Post Inverter Sensor actuator is not obstructed or damaged.

• Inverter Gate is not obstructed.
• Inverter Gate Solenoid Return Spring is not damaged, missing, or stretched.
• Inverter Gate Solenoid plunger moves freely.
Diagnostic Tools:
dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #3, LE from Inverter
Entrance Sensor to LE at Post Inverter Sensor
Procedure
Enter dC330, [10]. Actuate the Post Inverter Sensor. The Post Inverter Sensor display
changes from L to H.
Y N
Go to Flag 1. Check the Post Inverter Sensor circuit (GP 6-2, General Procedures). (PL
11.2)
Select [Inverter Gate] solenoid. Press Continue. The Inverter Gate actuates.
Y N
The Inverter Gate Solenoid energizes.
Y N
Press Stop. +24 VDC is measured between TS35 (+) and TS37 (-) on the PHN
DIO PWB #5.
Y N
Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit.
Go to Flag 2. Check the Inverter Gate Solenoid circuit (Generic Solenoid RAP GP
6-3, General Procedures), (PL 11.24).

• Inverter Gate for damage or binding (PL 11.23)
• Gate pivot for damage or binding (PL 11.23)
• Bearing for binding (PL 11.23)
• (ADJ 11-1), Inverter Gate Solenoid adjustment
• Solenoid RAP plunger for binding
Press Stop. Select [Cycle Mode]. Press Continue. Let the solenoid cycle for several min-
utes. The Inverter Solenoid RAP energizes and deenergizes without binding.
Y N
Press Stop. Replace the Inverter Gate Solenoid (PL 11.24).

• (ADJ 11-1), Inverter Gate Solenoid adjustment.
A
11-107 RAP

A
Fault Code, 11-107, indicates that the lead edge of an inverted print from the Inverter Entrance
Sensor, Q1155, arrived earlier than the specified amount of time at the Sample Tray Sensor, • Proper Inverter Main Drive Motor is present (60Hz, 25 teeth on pulley), (50Hz, 21 teeth on
Q1157. The print missed the Inverter Gate. pulley).
Initial Actions
• Sample Tray Sensor is clean and not obstructed.

• Paper path is clear.
• Inverter Gate pivots freely and is not damaged.
• Inverter Gate Solenoid Return Spring is not damaged, missing, or stretched.
• Inverter Gate Solenoid plunger moves freely.
Diagnostic Tools:
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #7, LE from Inverter
Entrance Sensor to LE at Sample Tray Sensor.
Procedure
Enter dC330, [10]. Actuate the Sample Tray Sensor. The Sample Tray Sensor display
Y N
Go to Flag 1. Check the Sample Tray Sensor circuit (GP 6-2, General Procedures). (PL
11.26)
Select [Inverter Gate] solenoid. Press Continue. The Inverter Gate actuates.
Y N
The Inverter Gate Solenoid energizes.
Y N
Press Stop. +24 VDC is measured between TS35 (+) and TS37 (-) on the PHN
DIO PWB #5.
Y N
Go to Flag 2. Check the Inverter Gate Solenoid circuit (Generic Solenoid RAP, GP 6-
3 General Procedures) (PL 11.24).

• Inverter Gate for damage or binding (PL 11.23)
• Gate pivot for damage or binding (PL 11.23)
• Bearing for binding (PL 11.23)
• (ADJ 11-1), Inverter Gate Solenoid adjustment
• Check the solenoid plunger for binding
Press Stop. Select [Cycle Mode]. Press Continue. Let the solenoid cycle for several min-
utes. The Inverter Solenoid RAP energizes and deenergizes without binding.
Y N
Press Stop. Replace the Inverter Gate Solenoid (PL 11.24).
A
11-108 RAP Fault Code, 11-108, indicates that the lead edge of a print delivered from the Inverter Entrance
Sensor, Q1155, did not arrive at the Post Inverter Sensor, Q1156, within the specified amount
of time.

A
Initial Actions Observe the Sample Tray Gate Solenoid, SOL1110. The solenoid is NOT actuated.
The solenoid IS actuated. Check the following:
• Sample Tray Gate and linkage for binding (PL 11.27).
• Inverter Entrance Sensor is clean and not obstructed.
• Sample Gate Return Spring
• Post Inverter Sensor actuator is not obstructed or damaged.
• Flag 4. Check the wire for a short circuit.
• Paper path for obstructions or burrs.
If OK, replace the PHN DIO PWB #5 (PL 1.17).
• Jam clearance baffles are not damaged and that they are latched correctly.
• Inverter Gate and Sample Tray Gate are not damaged and that they are free to move.
WARNING
• Gate return springs for damage or missing.
The Inverter Main Drive Motor, Inverter Drive Motor, or the Stacker Main Drive Motor may
• IF/S is aligned and leveled properly with the Printer run automatically. There is an internal thermal sensor in each of these motors that
• Ensure the PR Drive coupling is properly lubricated with Moly Grease (PL 25.1). See Roll- opens when the motor overheats. When the motor cools, the thermal sensor will close,
overs (PC 3676, RO 177643) in the Service Information for additional information on the allowing power to the motor. The outside surfaces of the motor could also be very hot.
lubricant and a tool for its application. Use caution when working near the motor.
• SCP HFSI 11-803 Table 4, or HFSI TABLES to see all of HFSI. Select [Inverter Start/Run] motor. Press Continue. The Inverter Transport Drive Rolls
• Check FSN AC Remote #2 for damaged components. rotate.
Diagnostic Tools: Y N
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #3, LE from Inverter Y N
Entrance Sensor to LE at Post Inverter Sensor Press Stop. Go to the 11-708, Inverter Main Drive Motor RAP.
The Inverter Transport Motor Fan is running.
Procedure Y N
Observe the prints entering the Inverter. The prints are free from damage and are not CAUTION
skewed or have excessive curl. Before removing the Inverter Motor Cooling Fan from the mounting bracket, note the
Y N orientation of the Fan and the direction of the air flow.
Loosen the screws (2) securing the Fan bracket to the Inverter Assembly Motor and
replace the Inverter Transport Motor Fan (PL 11.22).
• Drive Rolls and Idlers for wear, damage, or contamination (PL 10.14).
If OK, go to the 8-705, PHM Print Damage RAP or to the Physical Checks, Print Paper Press Stop. Check the following:
Diagnostics (Service Call Procedures) for additional information. • Drive Belts for wear, damage, or contamination and that they are set to the correct
tension (PL 11.22).
Enter dC330, [10]. Actuate the Post Inverter Sensor. The Post Inverter Sensor display • Drive shaft bearings for binding (PL 11.24) and (PL 11.25) After replacing, perform
changes from H to L. the Inverter Transport Motor Belt Tension adjustment (ADJ 11-14).
Y N
• Drive belt idlers for binding (PL 11.27).
Go to Flag 1. Check the Post Inverter Sensor circuit (GP 6-2, General Procedures) (PL
• Drive pulleys for damage and they are not slipping on the shaft (PL 11.21), (PL
11.2).
11.26).
Block the Inverter Entrance Sensor. The Inverter Entrance Sensor display changes from L
Press Stop. Select [Inverter FWD] motor. Press Continue. The Inverter Motor operates in
to H.
Y N the forward direction (Counterclockwise viewed from rear).
Go to Flag 2. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures) Y N
Press Stop. Go to the 11-707, Inverter Motor RAP.
(PL 11.24).
Check that the Passive Gate is straight and that the fingers are lined up with the baffle cutouts. Press Stop. Select [Inverter REV] motor. Press Continue. The Inverter Motor operates in
the reverse direction (Clockwise viewed from rear).
The Passive Gate is OK.
Y N Y N
Check the Top and Bottom Hinge Adjustment (ADJ 11-4). If OK, replace the Passive Gate
(PL 11.25).
A B
B
Press Stop. Select [11A1] [Stacker Start/Run]. Press Continue. The Preregistration Drive • Proper Inverter Bottom Drive Shaft is present (60Hz, 24 teeth on pulley), (50Hz, 20 teeth
Rolls rotate. on pulley).
Y N
The Stacker Main Drive Motor comes on.
Y N
Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.
The Preregistration Transport Drive Rolls operate correctly.

Y N
• Drive belts for wear, damage, or contamination and that they are set to the cor-
rect tension (PL 11.2).
• Flexible Drive Cable for damage, loose, coupling, or missing or loose setscrew
(PL 11.2).

• Preregistration Drive and Idler rolls for wear, damage, or contamination (PL 11.2).
• Idler springs for wear or damage (PL 11.2).
• (ADJ 11-6), Stacker Preregistration Corrugator Rolls Adjustment.
Press Stop. Select [10] [Inverter Gate]. Press Continue. The Inverter Gate actuated.
Y N
The Inverter Gate Solenoid energized.
Y N
Go to Flag 3. Check the Inverter Gate Solenoid circuit (Generic Solenoid RAP GP 6-
3, General Procedures), (PL 11.24).

• Gate bushings for damage (PL 11.23).
• Gate linkage for damage (PL 11.24).
• Check the solenoid plunger for binding (PL 11.23)

• Ensure that the A3 Nip Release Solenoid RAP is not actuated.
• Passive Gate is straight (PL 11.25).
• Drive Shaft bearings for binding (PL 11.26).
• Drive Belt idlers for binding (PL 11.27).
• Drive Rolls and Idlers for wear, damage, or contamination (PL 11.25), (PL 11.26).
• (ADJ 11-2), Gate Flat Spring adjustment.
• (ADJ 11-3), Inverter Output Baffle adjustment.
• (ADJ 11-4), Top and Bottom Hinge adjustment.
• (ADJ 11-7), Inverter Pivoting Assembly adjustment.
• (ADJ 11-12), Post Inverter Latch Adjustment.
• Baffles for damage (PL 11.24), (PL 11.25).
• Processor Top Transport Exit Drive Rolls for wear, damage, or contamination (PL 10.14).
• Drive belts for wear, damage, or contamination and that they are set to the correct tension
(PL 10.14).

11-110 RAP

A B
Y N
Fault Code, 11-110, indicates that the trail edge of a print did not arrive at the Post Inverter
Sensor, Q1156, within the specified amount of time after the lead edge of the print arrived at Press Stop. Check the following:
the sensor. • Drive belts for wear, damage, or contamination and correct tension (PL 11.2).
• Flexible Drive Shaft for damage, loose, coupling, or missing or loose setscrew
Initial Actions (PL 11.2).

• Post Inverter Sensor actuator is not bent, damaged, or interfering with baffle. The Sensor
can be installed incorrectly and possibly interfere with the baffle. Refer to (REP 11-25)
Post Inverter Sensor for correct positioning. • (ADJ 11-6), Stacker Preregistration Corrugator Roll Adjustment.
• Jam clearance baffle is latched correctly and is not damaged.
• IF/S is aligned and leveled properly with the Printer.
Diagnostic Tools:
• Drive Rolls for wear, damage, or contamination (PL 11.2).
• Baffles for damage (PL 11.2).
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #5, LE at Post Inverter
Sensor to TE at Post Inverter Sensor • Preregistration Drive Rolls for wear, damage, or contamination (PL 11.2).
• dC227 - Inverter/Stacker Jam Bypass • Drive belts for wear, damage, or contamination and correct tension (PL 11.1, PL 11.2).
Procedure • Preregistration Transport Pivot baffle is latched properly
Observe the prints entering the Preregistration Transport. The prints are free from damage,
skew, and excessive curl.
Y N
• Drive Rolls and Idlers for wear, damage, or contamination (PL 11.2)
• Idler roll retaining springs for damage or missing (PL 11.2)
Go to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for addi-
tional information on paper problems.
Enter dC330, [10]. Actuate the Post Inverter Sensor. The Post Inverter Sensor display
Y N
11.2).
WARNING
Use caution when working near the motor. The Stacker Main Drive Motor may run auto-
matically. There is an internal thermal sensor that opens when the motor overheats.
When the motor cools, the thermal sensor will close, allowing power to the motor. The
outside surfaces of the motor could also be very hot.
Select [11A1] [Stacker Start/Run]. Press Continue. The Preregistration Drive Rolls rotate.
Y N
Y N
A B
11-112 RAP

A
Y N
Fault Code, 11-112, indicates that the lead edge of the print delivered from the Post Inverter
Sensor, Q1156, did not arrive at the Prestacker Sensor, Q1158, within the specified amount of The Stacker Main Drive Motor comes on.
time. When this fault is declared the Prestacker Sensor is unblocked. Y N
Initial Actions The Preregistration Transport Drive Rolls operate correctly.
• Post Inverter Sensor and the Prestacker Sensor are clean and are not obstructed. • Drive belts for wear, damage, or contamination and correct tension (PL 11.2).
• Registration Edge on the Preregistration Transport for build up of adhesive from non-spec • Flexible Drive Shaft for damage, loose, coupling, or missing or loose setscrew
label stock. (PL 11.2).
• Jam clearance baffles for damage and that they are correctly seated. Press Stop. Check the following:
• SCP, HFSI 11-805 Table 4, or HFSI TABLES to see all of HFSI.
Diagnostic Tools:
• (ADJ 11-6), Stacker Preregistration Corrugator Roll adjustment.
• dC227 - Inverter/Stacker Paper Path Timing Diagnostics, interval 6, LE at Post Inverter
Sensor to LE at Prestacker Sensor. The Preregistration Drive Rolls and Idlers rotate correctly.
Y N
Procedure • Drive Rolls and Idlers for correct installation (PL 11.2), (PL 11.28).
Observe the prints entering the Preregistration Transport. The prints are free from damage, • Drive belts for wear, damage, or contamination and correct tension (PL 11.2), (PL
skew, and excessive curl. 11.23).
Y N
• Drive Roll for slipping on shaft (PL 11.2).
• Idler Roll bearings for binding (PL 11.28).
• Idler Rolls for binding or retaining springs loose or missing (11.2).
• Idler Roll for springs missing or damaged (PL 11.28).
• Inverter Gate or Sample Gate for damage or incorrect position (PL 11.23), (PL
11.25). • (ADJ 11-6), Stacker Preregistration Corrugator Roll adjustment.
• Drive Rolls, idlers, and idler springs for wear, damage or contamination (PL 11.2),
(PL 11.26). Select [10]. Block the Prestacker Sensor. The Prestacker Sensor display changes from L
to H.
If OK, go to the 8-705, PHM Print Damage RAP or to the Physical Checks, Print Paper
Y N
Diagnostics (Service Call Procedures) for additional information.
Go to Flag 1. Check the Prestacker Sensor circuit (GP 6-2, General Procedures) (PL
11.2).
Enter dC330, [10]. Block the Post Inverter Sensor. The Post Inverter Sensor display
changes from L to H
The original problem only occurs in the 3 pitch mode.
Y N
Y N
11.2).
• Registration Edge on the Preregistration Transport for wear (PL 11.2)
The Preregistration Transport baffle is seated and latched correctly. • Drive Rolls for slipping on shaft (PL 11.2).
Y N • Drive Belt idlers for binding (PL 11.28).
Check the baffle for nicks, burrs, or other damage (PL 11.28). Reseat the baffle. • (ADJ 11-6), Stacker Preregistration Corrugator Roll adjustment.
• Drive or Preregistration Rolls for wear, damage, or contamination (PL 11.2)
WARNING • Baffles for damage (PL 1.2).
Use caution when working near the motor. The Stacker Main Drive Motor may run auto- • Bypass Transport Drive Rolls and Idlers for wear, damage, or contamination (PL
matically. There is an internal thermal sensor that opens when the motor overheats. 11.11), (PL 11.15).
When the motor cools, the thermal sensor will close, and the motor may restart. The
• Drive belts for wear, damage, or contamination and correct tension (PL 11.2), (PL
11.11).
• Bypass Transport grounded correctly.
A B
B
Press Stop. Select [Cycle Mode] [Nip Release A3]. Press Continue. The A3 Inverter Nip
Release Rolls operate.
Y N
The A3 Inverter Nip Release Solenoid RAP energizes.
Y N
Press Stop. +24 VDC is measured at TS34.
Y N
Go to the Wirenets (Wiring Data) and check wire #64F for an open circuit.
Press Stop. Go to Flag 4. Check the A3 Inverter Nip Release Solenoid RAP circuit
(Generic Solenoid RAP GP 6-3, General Procedures), (PL 11.28).

• (ADJ 11-9), A3 Nip Release Solenoid RAP adjustment.
• Lift linkage for binding or damaged, loose, or missing hardware (PL 11.28).
• A3 Nip Release solenoid on all the time

• Registration edge on the Preregistration Transport for wear.
• Drive Rolls for slipping on shaft (PL 11.2).
• Drive or Preregistration Rolls for wear, damage, or contamination (PL 11.2)
• Bypass Transport Drive Rolls and Idlers for wear, damage, or contamination (PL 11.11),
(PL 11.28).
• Drive belts for wear, damage, or contamination and correct tension (PL 11.2), (PL 11.11).

11-114 RAP

A B
Fault Code, 11-114, indicates that the trail edge of a print did not arrive at the Prestacker Sen-
sor, Q1158, within the specified amount of time after the lead edge of the print arrived at the Y N
sensor. The valid destination for the sheet is beyond Stacker A. Press Stop. Check the following:
• Drive belts for wear, damage, or contamination and correct tension (PL 11.2).
Initial Actions • Flexible Drive Cable for damage, loose, coupling, or missing or loose setscrew
(PL 11.2).
• Prestacker Sensor is clean and is not obstructed.
• Registration edge on the Preregistration Transport for a build up of adhesive from non-
• Idler retaining springs damaged or missing (PL 11.28).
spec label stock.
• Jam clearance baffles are seated correctly and not damaged. The Bypass Transport Drive Rolls and Idlers rotate correctly.
Diagnostic Tools: Y N
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #8, LE at Prestacker • Drive Rolls and Idlers installed correctly (PL 11.11), (PL 11.15).
Sensor to TE at Prestacker Sensor. • Drive belts for wear, damage, contamination, and correct tension (PL 11.11).
• dC227 - Inverter/Stacker Jam Bypass • Drive Roll for slipping on shaft (PL 11.11).
Procedure • Idler Roll bearings for binding (PL 11.15).
Observe the prints entering the Bypass Transport. The prints are free from damage, skew, • Idler retaining springs damaged or missing (PL 11.15).
and excessive curl.
Y N Press Stop. Check the following:
Check the following: • Drive Rolls for slipping on shaft (PL 11.2), (PL 11.11).
• Jam clearance baffles for wear or damage and they are seated correctly (PL 11.4), • Drive Belt idlers for binding (PL 11.2), (PL 11.15).
(PL 11.22), (PL 11.25), (PL 11.26), (PL 11.28).
• Bypass Transport Drive Rolls and Idlers for wear, damage, or contamination (PL 11.11),
• Drive Rolls and Idlers for wear, damage, or contamination (PL 11.2). (PL 11.15).
• Idler retaining springs damaged or missing (PL 11.2). • Drive belts for wear, damage, contamination, and correct tension (PL 11.11).
If OK, go to the 8-705, PHM Print Damage RAP or to the Physical Checks, Print Paper • Bypass Gate is positioned properly. Ensure that the Gate Return Spring is functioning
Diagnostics (Service Call Procedures) for additional information. properly and that the Gate is closing fully. Check the Bypass Transport Gate Solenoid
adjustment, (ADJ 11-11).
Enter dC330, [10]. Block the Prestacker Sensor. The Prestacker Sensor display changes
from L to H.
Y N
11.2).
The Preregistration Transport pivot baffle is seated and latched correctly.

Y N
• Pivot baffle for damage (PL 11.28)
• Latch assembly (PL 11.28)
Y N
Y N
A B
11-116, 11-117 RAP

A
Y N
Fault Code, 11-116, indicates that the lead edge of a print delivered from the Inverter Entrance
Sensor, Q1155, did not arrive at the Sample Tray Sensor, Q1157, within the specified amount Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit.
of time. When this fault is declared, the sensor is unblocked.
Check the solenoid plunger for binding, (ADJ 11-8) Sample Tray Gate Solenoid.
Fault Code, 11-117, indicates that the lead edge of a print delivered from the Inverter Entrance Go to Flag 4. Check the Sample Tray Gate Solenoid circuit (Generic Solenoid RAP
Sensor, Q1155, did not arrive at the Sample Tray Sensor, Q1157, within the specified amount GP 6-3, General Procedures) (PL 11.26).
of time. When this fault is declared, the sensor is blocked.
• (ADJ 11-8), Sample Tray Gate Solenoid adjustment.
Initial Actions
• Gate bushings damaged (PL 11.27).
• Gate linkage for damage (PL 11.27).
• Inverter Entrance Sensor and the Sample Tray sensors are clean and are not obstructed. • Gate Actuator positioned properly (PL 11.27).
• Paper path is not obstructed
Press Stop. Select [Inverter Gate]. Press Continue. The Inverter Gate actuates.
• Jam clearance baffles are latched correctly and are not damaged.
Y N
• Inverter Gate and Sample Tray Gate for damage and that they are free to move. Check The Inverter Gate Solenoid energized.
the gate return springs for damage. Y N
• Drive Belts for wear, damage, contamination, and correct tension. Press Stop. Go to Flag 3. Check the circuit of the Inverter Gate Solenoid.
• SCP, HFSI 11-803 Table 4, or HFSI TABLES to see all of HFSI
Diagnostic Tools: Press Stop. Check the following:
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #7, LE from Inverter • Solenoid RAP plunger for binding (PL 11.24).
Entrance Sensor to LE at Sample Tray Sensor. • Gate bushings damaged or contaminated (PL 11.23).
• dC227 - Inverter/Stacker Jam Bypass • Gate linkage for damage or binding (PL 11.24).
Procedure
Press Stop. Select [Inverter Start/Run]. Press Continue. The Inverter Transport Drive
Observe the prints entering the Inverter. The prints are free from damage, skew, or exces-
Upper Rolls rotate.
sive curl.
Y N
Y N
Y N
Press Stop. Go to the 11-708, Inverter Main Drive Motor RAP.
• IF/S to Printer alignment/leveling
• Idler Rolls and retaining springs binding or loose (PL 10.14). Press Stop. Check the following:
• Processor Top Transport Exit Drive Rolls for wear, damage, or contamination (PL • Drive Belts for wear, damage, contamination, and correct tension (PL 11.26).
10.14). • Drive shaft bearings and Drive Belt Idlers for binding (PL 11.26).
If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diag- • Drive pulley for damage and that it is not slipping on the shaft (PL 11.26).
Block the Inverter Entrance Sensor. The Inverter Entrance Sensor display changes from L
Enter dC330, [10]. Block the Sample Tray Sensor. The Sample Tray Sensor display to H.
changes from L to H. Y N
Y N Go to Flag 1. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures)
Go to Flag 2. Check the Sample Tray Sensor circuit (GP 6-2, General Procedures) (PL (PL 11.24).
11.26).
The fault only occurs when running in the duplex mode.
Select [Sample Tray Gate] solenoid. Press Continue. The Sample Tray Gate actuated. Y N
Y N Check the following:
The Sample Tray Gate Solenoid energized. • Drive Shaft bearings and Drive Belt Idlers for binding (PL 11.26).
Y N • Sample Tray Gate to Solenoid RAP linkage (PL 11.27).
Press Stop. +24 VDC is measured at TS35 (+) on the PHN DIO PWB #5.
• Drive Rolls, idlers, and belts for wear, damage, or contamination (PL 11.26).
A B
B
• (ADJ 11-4), Inverter Top and Bottom Hinge Adjustment
• (ADJ 11-3), Inverter Output Baffle Adjustment
• (ADJ 11-7), Inverter Pivot Assembly Adjustment
Press Stop. Select [Inverter FWD] motor. Press Continue. The Inverter Motor operates in
the forward direction (Counterclockwise from rear).
Y N
Press Stop. Select [Inverter REV] motor. Press Continue. The Inverter Motor operates in
the reverse direction (Clockwise from rear).
Y N
Press Stop. Observe the Inverter Gate Solenoid, SOL1108. The solenoid is actuated in the
standby condition.
Y N
• Inverter Passive Gate is straight (PL 11.25).
• (ADJ 11-2), Gate Flat Spring Adjustment
• Drive Shaft bearings and Drive Belt Idlers for binding (PL 11.24), (PL 11.26). After
replacing, perform the Inverter Transport Motor Belt Tension adjustment (ADJ 11-
14).
• Drive Rolls and belts for wear, damage, or contamination (PL 11.24), (PL 11.26).
After replacing, perform the Inverter Transport Motor Belt Tension adjustment (ADJ
11-14).
Go to Flag 3. Check the wire for a short circuit. If OK, replace the PHN DIO PWB #5 (PL 1.17).

11-118, 11-119 RAP

A
Y N
Fault Code, 11-118, indicates that the trail edge of a print did not arrive at the Sample Tray
Sensor, Q1157, within the specified amount of time after the lead edge of the sheet arrived at Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit.
the sensor. When the fault is declared, the sensor is unblocked.
Go to Flag 2. Check the Sample Tray Gate Solenoid circuit (Generic Solenoid RAP
Fault Code, 11-119, indicates that the trail edge of a print did not arrive at the Sample Tray GP 6-3, General Procedures).
Sensor, Q1157, within the specified amount of time after the lead edge of the sheet arrived at
the sensor. When the fault is declared, the sensor is blocked.
• (ADJ 11-8), Sample Tray Solenoid RAP adjustment.
Initial Actions • Gate bushings for damage (PL 11.27)
• Gate linkage for damage (PL 11.27)
NOTE: The Sample Tray utilizes corrugated rolls to decelerate the sheets to allow adequate
• Check the solenoid plunger for binding (PL 11.27)
stacking at high speeds. Corrugation Rolls should be set to a nominal penetration of 1.6 mm.
Check the following: Press Stop. Select [Inverter Start/Run]. Press Continue. The Inverter Transport Upper
Drive Rolls rotate.
• Maximum of 100 prints are in the Sample Tray. Y N
• Sample Tray sensor is clean and is not obstructed.
Y N
• Idler rolls positioned properly and retaining springs not loose.
Press Stop. Go to the 11-708, Inverter Main Drive Motor RAP.
• Jam clearance baffles are seated correctly and are not damaged. Press Stop. Check the following:
• Drive Belts for wear, damage, contamination, and correct tension. • Drive Belts for wear, damage, contamination, and correct tension (PL 11.26)
• Sample Tray is installed correctly. • Drive shaft bearings for binding (PL 11.26)
• Check the Sample Tray Corrugation Roll adjustment (ADJ 11-13). • Drive belt idlers for binding (PL 11.28)
Diagnostic Tools: • Drive pulley for damage and that it is not slipping on the shaft (PL 11.26)
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #41, LE at Sample Tray Press Stop. Check the following:
Sensor to TE at Sample Tray Sensor. • Drive Shaft bearings for binding (PL 11.26)
• dC227 - Inverter/Stacker Jam Bypass • Drive Belt idlers for binding (PL 11.28)
Procedure • Drive Rolls for wear, damage, or contamination (PL 11.26)
Observe the prints entering the Inverter. The prints are free from damage, skew, or exces- • Drive belts for wear, damage, contamination, and correct tension (PL 11.26)
sive curl. • Sample Tray corrugating idler is seated correctly and that the springs are in place (PL
Y N 11.27)
• Idler Rolls and retaining springs for binding.
• Processor Top Transport Exit Drive Rolls for wear, damage, or contamination.
Enter dC330, [10]. Block the Sample Tray Sensor. The display changes from L to H.
Y N
Go to Flag 1. Check the Sample Tray Sensor circuit (GP 6-2, General Procedures).
Select [Sample Tray] solenoid. Press Continue. The Sample Tray Gate actuated.
Y N
The Sample Tray Gate Solenoid energized.
Y N
Press Stop. +24 VDC is measured at TS35 (+) on the PHN DIO PWB #5.
A
11-130 RAP Stacker A Fault Code, 11-130-1, indicates that the lead edge of a print was detected at the Disk
Sheet Sensor, Q1106A, when it was not expected.

Stacker B Fault Code, 11-130-2, indicates that the lead edge of a print was detected at the Disk
Sheet Sensor, Q1106B, when it was not expected.
Stacker C Fault Code, 11-130-3, indicates that the lead edge of a print was detected at the
Disk Sheet Sensor, Q1106C, when it was not expected.
Stacker D Fault Code, 11-130-4, indicates that the lead edge of a print was detected at the
Disk Sheet Sensor, Q1106D, when it was not expected.
Initial Actions
• Disk Sheet Sensor is clean and is not obstructed.

• Bypass Transport Gate is not obstructed and is operating correctly.
• Bypass Transport baffle is seated correctly.
Procedure
Enter dC330, [Stacker X], [11X1]. Block the Disk Sheet Sensor.
The Disk Sheet Sensor display changes from L to H.

Y N
Go to Flag 1. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL
11.29).
Observe the Bypass Gate Solenoid. The Bypass Solenoid RAP is actuated in a standby
condition.
Y N
• (ADJ 11-10), Bypass Transport adjustment
• (ADJ 11-11), Bypass Gate Solenoid RAP adjustment
Go to Flag 2. Check the wire for a short circuit. If OK, replace the FSN DIO PWB #3 (PL 1.17).



11-131-1, 11-132-1, 11-133-1 RAP Y N
Stacker A Fault Code, 11-131-1, indicates that the lead edge of print did not arrive at the Disk 11.14).
Sheet Sensor, Q1106A, within the specified amount of time after the Prestacker Sensor, Q1158
sensed the lead edge. When this fault is declared, the Prestacker Sensor is unblocked and the Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated.
Disk Sheet Sensor is unblocked. Y N
The Bypass Gate Solenoid energized.
Stacker A Fault Code, 11-132-1, indicates that the lead edge of print did not arrive at the Disk Y N
Sheet Sensor, Q1106A, within the specified amount of time after the Prestacker Sensor, Q1158 Press Stop. +24 VDC is measured at TS34 (+) on the FSN DIO PWB #3A.
sensed the lead edge. When this fault is declared, the Prestacker Sensor is blocked and the Y N
Disk Sheet Sensor is unblocked. Go to the Wirenets (Wiring Data) and check wire #63M for an open circuit.
Stacker A Fault Code, 11-133-1, indicates that the lead edge of print did not arrive at the Disk Check the solenoid plunger for binding (PL 11.11).
Sheet Sensor, Q1106A, within the specified amount of time after the Prestacker Sensor, Q1158 Go to Flag 4. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 6-
sensed the lead edge. When this fault is declared, the Prestacker Sensor is unblocked and the 3, General Procedures).
Disk Sheet Sensor is blocked.
Initial Actions • Bypass Gate for wear, damage, or binding (PL 11.14).
Check the following: • (ADJ 11-11), Bypass Gate Solenoid RAP adjustment.
• Prestacker Sensor and the Disk Sheet Sensor are clean and are not obstructed. Press Stop. Select [Stacker Start/Run]. Press Continue. The Bypass Transport Drive
• Paper path for obstructions. Rolls rotate.
Y N
• Jam clearance baffles for damage and that they are seated correctly.
• Drive rolls and Idlers for wear, damage or contamination. Y N
• Disks are positioned correctly. Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.
• Disk Gate moves freely.
• Ensure that the Stacker Tray is stopping at the correct height, indexing down in the proper The Bypass Transport Drive Rolls operate correctly.
Y N
sequence of intervals, and is not interfering with disk rotation.
Diagnostic Tools:
• Telescopic Drive Shaft for damage, loose coupling, or missing or loose set-
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #9, LE at Prestacker
screw (PL 11.11).
Sensor to LE at Stacker A Disk Sheet Sensor.
Procedure • Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL 11.11),
Observe the prints entering the Disk Module. The prints are free from damage, skew, or (PL 11.15).
excessive curl. • Idler springs for wear or damage (PL 11.15).
Y N
Check the following: Press Stop. Select [10]. Block the Prestacker Sensor. The Prestacker Sensor display
• Drive Rolls and Idlers for damage or binding (PL 11.2, PL 11.32). changes from L to H.
• Obstructions in the paper path Y N
• (ADJ 11-6) Stacker Preregistration Corrugator Rolls Adjustment
11.2).
• Drive Shaft bearings for binding (PL 11.2, PL 11.11, PL 11.32).
Enter dC330, [11A1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display
changes from L to H. • Drive Belt idlers for binding (PL 11.2, PL 11.11).
• Drive Rolls for wear, damage, or contamination (PL 11.2, PL 11.11)

11-131-1, 11-132-1, 11-133-1 ?-920 No Product Name Assigned
• Baffles for damage (PL 11.2, PL 11.11, PL 11.15, PL 11.32).
• Processor Top Transport Exit Drive Rolls for wear, damage, or contamination.
• Drive belts for wear, damage, contamination, and correct tension (PL 11.2 PL 11.11).
• A3 Nip Release Solenoid RAP for proper operation
• Bypass Gate for binding

No Product Name Assigned ?-921 11-131-1, 11-132-1, 11-133-1
Figure 1 11-131-1/132-1/133-1 Circuit Diagram (8112)

A
11-131-2, 11-132-2, 11-133-2 RAP Enter dC330, [11B1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display
Stacker B Fault Code, 11-131-2, indicates that the lead edge of print did not arrive at the Disk Y N
Sheet Sensor, Q1106B, within the specified amount of time after the Bypass Transport Sensor, Go to Flag 3. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL
Q1158A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is 11.29).
unblocked and the Disk Sheet Sensor is unblocked.
Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated.
Stacker B Fault Code, 11-132-2, indicates that the lead edge of print did not arrive at the Disk Y N
Sheet Sensor, Q1106B, within the specified amount of time after the Bypass Transport Sensor, The Bypass Gate Solenoid energized.
Q1158A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is Y N
blocked and the Disk Sheet Sensor is unblocked. Press Stop. +24 VDC is measured at TS34 (+) on the FSN DIO PWB #3B.
Y N
Stacker B Fault Code, 11-133-2, indicates that the lead edge of print did not arrive at the Disk Go to the Wirenets (Wiring Data) and check wire #86A for an open circuit.
Sheet Sensor, Q1106B, within the specified amount of time after the Bypass Transport Sensor,
Q1158A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is Check the solenoid plunger for binding (PL 11.13).
unblocked and the Disk Sheet Sensor is blocked. Go to Flag 4. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 6-
3, General Procedures) (PL 11.13).
Initial Actions
• Bypass Gate for wear, damage, or binding (PL 11.13).
• Bypass Transport Sensor and the Disk Sheet Sensor are clean and are not obstructed. • (ADJ 11-11), Bypass Gate Solenoid RAP adjustment.
Press Stop. Select [Stacker Start/Run]. Press Continue. The Stacker B Bypass Transport
• Jam clearance baffles are seated correctly and are not damaged.
Drive Rolls rotate.
• Drive rolls and Idlers for wear, damage or contamination. Y N
• Bypass Transport Gate is operating correctly The Stacker Main Drive Motor comes on.
• Disks are positioned correctly. Y N
• Ensure that the Stacker Tray is stopping at the correct height, indexing down in the proper
The Bypass Transport Drive Rolls operate correctly.
sequence of intervals, and is not interfering with disk rotation. Y N
• F/S is aligned/leveled properly with the IF/S Press Stop. Check the following:
• SCP, HFSI 11-806-1 Table 4, or HFSI TABLES to see all of HFSI • Drive belts for wear, damage, contamination, and correct tension (PL 11.13).
• Ensure that F/S Tag-36 is installed (improved Bypass Gate). • Telescopic Drive Shaft for damage, loose coupling, or missing or loose set-
Diagnostic Tools: screw (PL 11.13).
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #13, LE at Stacker A Press Stop. Check the following:
Bypass Transport Sensor to LE at Stacker B Disk Sheet Sensor. • Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL
11.13), (PL 11.32).
• Idler springs for wear or damage (PL 11.11), (PL 11.32).
Procedure
Observe the prints entering the Disk Module. The prints are free from damage, skew, or Press Stop. Select [11A1]. Block the Stacker A Bypass Transport Sensor. The Bypass
excessive curl. Transport Sensor display changes from L to H
Y N Y N
Check the following: Go to Flag 2. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures)
• (ADJ 11-10), Stacker A Bypass Transport Adjustment (PL 11.29).
• Drive Rolls and Idlers for damage or binding (PL 11.2), (PL 11.11), (PL 11.15), (PL
11.32). Press Stop. Check the following:
If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diag- • Drive Shaft bearings for binding (PL 11.13).
nostics (Service Call Procedures) for additional information. • Drive Belt idlers for binding (PL 11.13).
A
• Bypass Transport Gate for binding.
Observe the prints entering the Disk Module. The prints are free from damage, skew, or
excessive curl.
Y N
• (ADJ 11-10), Stacker A Bypass Transport Adjustment
• Drive Rolls and Idlers for damage or binding (PL 11.2), (PL 11.11), (PL 11.15), (PL
11.32).
Enter dC330, [11B1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display
Y N
11.29).


Figure 2 11-131-2/132-2/133-2 Component Location (711005)

A
11-131-3, 11-132-3, 11-133-3 RAP If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diag-
Stacker C Fault Code, 11-131-3, indicates that the lead edge of print did not arrive at the Disk
Sheet Sensor, Q1106C, within the specified amount of time after the Bypass Transport Sensor, Enter dC330, [Stacker C], [11C1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor dis-
Q1158B sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is play changes from L to H.
unblocked and the Disk Sheet Sensor is unblocked. Y N
Stacker C Fault Code, 11-132-3, indicates that the lead edge of print did not arrive at the Disk 11.29).
Sheet Sensor, Q1106C, within the specified amount of time after the Bypass Transport Sensor,
Q1158B sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated.
blocked and the Disk Sheet Sensor is unblocked. Y N
Stacker C Fault Code, 11-133-3, indicates that the lead edge of print did not arrive at the Disk Y N
Sheet Sensor, Q1106C, within the specified amount of time after the Bypass Transport Sensor, Press Stop. +24 VDC is measured at TS34 (+) on the FSN DIO PWB #3C.
Q1158B sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is Y N
unblocked and the Disk Sheet Sensor is blocked. Go to the Wirenets (Wiring Data) and check wire #86A for an open circuit.
Initial Actions Check the solenoid plunger for binding (PL 11.13).
Go to Flag 4. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 6-
• In a 3 or 4 Module System, ensure that P/J4230 are connected between Module 2 and
Module 3 and the wires show continuity.
• Bypass Transport Sensor and the Disk Sheet Sensor are clean and are not obstructed.
• (ADJ 11-11), Bypass Gate Solenoid RAP adjustment.
• Jam clearance baffles are seated correctly and are not damaged. Press Stop. Select [Stacker Start/Run]. Press Continue. The Stacker C Bypass Transport
• Drive rolls and Idlers for wear, damage or contamination. Drive Rolls rotate.
• Bypass Transport Gate is operating correctly Y N
• Disks are positioned correctly.
Y N
sequence of intervals, and is not interfering with disk rotation. The Bypass Transport Drive Rolls operate correctly.
• IF/S to MM to F/S is aligned and leveled properly. Y N
• SCP, HFSI 11-806-3 Table 4, or HFSI TABLES to see all of HFSI Press Stop. Check the following:
• Ensure that F/S Tag-36 is installed (improved Bypass Gate). • Drive belts for wear, damage, contamination, and correct tension (PL 11.13).
Diagnostic Tools: • Telescopic Drive Shaft for damage, loose coupling, or missing or loose set-
screw (PL 11.13).
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #13, LE at Stacker A
Bypass Transport Sensor to LE at Stacker B Disk Sheet Sensor. Press Stop. Check the following:
• Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL
11.13), (PL 11.32).
Procedure • Idler springs for wear or damage (PL 11.11), (PL 11.32).
excessive curl. Press Stop. Select [11C1]. Block the Stacker C Bypass Transport Sensor. The Bypass
Y N Transport Sensor display changes from L to H
• (ADJ 11-10), Stacker C Bypass Transport Adjustment Go to Flag 2. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures)
• Drive Rolls and Idlers for damage or binding (PL 11.2), (PL 11.11), (PL 11.15), (PL (PL 11.29).
11.32).
A


A
11-131-4, 11-132-4, 11-133-4 RAP If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diag-
Stacker D Fault Code, 11-131-4, indicates that the lead edge of print did not arrive at the Disk
Sheet Sensor, Q1106D, within the specified amount of time after the Bypass Transport Sensor, Enter dC330, [Stacker D], [11D1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor dis-
Q1158C sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is play changes from L to H.
unblocked and the Disk Sheet Sensor is unblocked. Y N
Stacker D Fault Code, 11-132-4, indicates that the lead edge of print did not arrive at the Disk 11.29).
Sheet Sensor, Q1106D, within the specified amount of time after the Bypass Transport Sensor,
Q1158C sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated.
blocked and the Disk Sheet Sensor is unblocked. Y N
Stacker D Fault Code, 11-133-4, indicates that the lead edge of print did not arrive at the Disk Y N
Sheet Sensor, Q1106D, within the specified amount of time after the Bypass Transport Sensor, Press Stop. +24 VDC is measured at TS34 (+) on the FSN DIO PWB #3D.
Q1158C sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is Y N
unblocked and the Disk Sheet Sensor is blocked. Go to the Wirenets (Wiring Data) and check wire #86A for an open circuit.
Initial Actions Check the solenoid plunger for binding (PL 11.13).
• In a 3 or 4 Module System, ensure that P/J4230 are connected between Module 2 and
Module 3 and the wires show continuity.
• Bypass Transport Sensor and the Disk Sheet Sensor are clean and are not obstructed.
• Jam clearance baffles are seated correctly and are not damaged. Press Stop. Select [Stacker Start/Run]. Press Continue. The Stacker D Bypass Transport
• Drive rolls and Idlers for wear, damage or contamination. Drive Rolls rotate.
• Bypass Transport Gate is operating correctly Y N
• Disks are positioned correctly.
Y N
sequence of intervals, and is not interfering with disk rotation. The Bypass Transport Drive Rolls operate correctly.
• IF/S to MM to F/S is aligned and leveled properly. Y N
• SCP, HFSI 11-806-3 Table 4, or HFSI TABLES to see all of HFSI Press Stop. Check the following:
• Ensure that F/S Tag-36 is installed (improved Bypass Gate). • Drive belts for wear, damage, contamination, and correct tension (PL 11.13).
Diagnostic Tools: • Telescopic Drive Shaft for damage, loose coupling, or missing or loose set-
screw (PL 11.13).
Bypass Transport Sensor to LE at Stacker B Disk Sheet Sensor. Press Stop. Check the following:
• Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL
11.13), (PL 11.32).
Procedure • Idler springs for wear or damage (PL 11.11, (PL 11.32).
excessive curl. Press Stop. Select [11D1]. Block the Stacker D Bypass Transport Sensor. The Bypass
Y N Transport Sensor display changes from L to H
• (ADJ 11-10), Stacker D Bypass Transport Adjustment Go to Flag 2. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures)
• Drive Rolls and Idlers for damage or binding (PL 11.2), (PL 11.11), (PL 11.15), (PL (PL 11.29).
11.32).
A
• Drive belts for wear, damage, contamination, and correct tension (ADJ 11-13).


11-138, 11-139 RAP • Ensure that the Stacker Bypass Transport Gate is not bowed down (more than 1 mm) in
the center (PL 11.14).
Stacker A Fault Code, 11-138-1, indicates that the lead edge of the print delivered from the • SCP, HFSI 11-806-1 Table 4, or HFSI TABLES to see all of HFSI
Prestacker Sensor, Q1158, did not arrive at the Bypass Transport Sensor, Q1107A, within the
Diagnostic Tools:
specified amount of time and the Bypass Transport Sensor, Q1107A, is unblocked.
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #11, LE at Prestacker
Stacker B Fault Code, 11-138-2, indicates that the lead edge of the print delivered from the
Sensor to LE at Stacker A Bypass Transport Sensor.
Bypass Transport Sensor, Q1107A, did not arrive at the Bypass Transport Sensor, Q1107B,
within the specified amount of time and the Bypass Transport Sensor, Q1107B, is unblocked. • dC227 - Inverter/Stacker Jam Bypass.
This Fault is valid for modules 3, 4, 5, 6 or for a Transition Module configuration. Procedure
Stacker C Fault Code, 11-138-3, indicates that the lead edge of the print delivered from the
Bypass Transport Sensor, Q1107B, did not arrive at the Bypass Transport Sensor, Q1107C,
within the specified amount of time and the Bypass Transport Sensor, Q1107C, is unblocked.
This Fault is valid for modules 3, 4, 5, 6 or for a Transition Module configuration.
Observe the prints entering the Bypass Transport. The prints are free from damage, skew,
Stacker D Fault Code, 11-138-4, indicates that the lead edge of the print delivered from the or excessive curl.
Bypass Transport Sensor, Q1107C, did not arrive at the Bypass Transport Sensor, Q1107D, Y N
within the specified amount of time and the Bypass Transport Sensor, Q1107D is unblocked. Check the following:
This Fault is valid for modules 3, 4, 5, 6 or for a Transition Module configuration. • Drive Rolls and Idlers for wear, damage or contamination (PL 11.11.
• Idler retaining springs for damage or missing (PL 11.11.
Stacker A Fault Code, 11-139-1, indicates that the lead edge of the print delivered from the
Prestacker Sensor, Q1158, did not arrive at the Bypass Transport Sensor, Q1107A, within the
specified amount of time and the Bypass Transport Sensor, Q1107B, is blocked. nostics (Service Call Procedures) for additional information.
Enter dC330, [Stacker X], [11X1]. Block the Bypass Transport Sensor, Q1107X. The display
Stacker B Fault Code, 11-139-2, indicates that the lead edge of the print delivered from the
Prestacker Sensor, Q1107A, did not arrive at the Bypass Transport Sensor, Q1107B,within the changes from L to H.
specified amount of time and the Bypass Transport Sensor, Q1107B, is blocked. This Fault is Y N
Go to Flag 2. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures)
valid for modules 3, 4, or for a Transition Module configuration.
(PL 11.29).
Stacker C Fault Code, 11-139-3, indicates that the lead edge of the print delivered from the
Prestacker Sensor, Q1107B, did not arrive at the Bypass Transport Sensor, Q1107C,within the WARNING
specified amount of time and the Bypass Transport Sensor, Q1107C, is blocked. This Fault is Use caution when working near the motor. The Stacker Main Drive Motor may run auto-
valid for modules 3, 4, 5, 6 or for a Transition Module configuration. matically. There is an internal thermal sensor that opens when the motor overheats.
Stacker D Fault Code, 11-139-4, indicates that the lead edge of the print delivered from the outside surfaces of the motor could also be very hot.
Prestacker Sensor, Q1107C, did not arrive at the Bypass Transport Sensor, Q1107D,within the Press Stop. Select [Stacker Start/Run]. Press Continue. The Stacker X Bypass Transport
specified amount of time and the Bypass Transport Sensor, Q1107D, is blocked. This Fault is Drive Rolls rotate.
valid for modules 3, 4, 5, 6 or for a Transition Module configuration. Y N
The Stacker X Main Drive Motor comes on.
Initial Actions Y N
Check the following: Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.
• Prestacker Sensor is clean and not obstructed. The Bypass Transport Drive Rolls operate correctly.
• Paper path is not obstructed. Y N
• Idler springs missing or idlers that are bound.
• Flexible Drive Cable for damage, loose coupling, or missing or loose setscrew
• Stacker A Bypass Transport Gate is operating correctly and is not obstructing the paper (PL 11.11).
path.
A
A B
• Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL 11.11). Y N
• Idler springs for wear or damage (PL 11.11). Press Stop. Check the solenoid plunger for binding. If no binding is found, go to Flag
4. Check the circuit of the Stacker Output Gate Solenoid (Generic Solenoid RAP GP
Press Stop. Select [11X1] [Stacker Start/Run]. Press Continue. The Stacker X Entrance 6-3, in General Procedures.
Drive Rolls rotate.
Y N Press Stop. Check the following:
The Stacker X Main Drive Motor comes on. • Purge Gate for wear or damage
Y N • (ADJ 13-1), Stacker Output Gate adjustment
The Stacker X Entrance Drive Rolls operate correctly. • Drive rolls for wear, damage, or contamination (PL 11.12).
Y N • Drive belt idler for binding (PL 11.13).
(ADJ 13-1), Stacker Output Gate adjustment.
• Flexible Drive cable for damage, loose coupling, or missing or loose setscrew
(PL 11.12).

• Entrance drive rolls and idlers for wear, damage, or contamination (PL 11.12).
Press Stop. Select [IOT Paper Path], [10]. Block the Prestacker Sensor, Q1158. The dis-
play change from L to H.
Y N
11.2).
Select [11X1] [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated.
Y N
Y N
Press Stop. Go to Flag 3. Check the Bypass Gate Solenoid circuit (Generic Sole-
noid RAP GP 6-3, General Procedures) (PL 11.11).

• Bypass Gate for wear or damage (PL 11.13).
Press Stop. The machine has a Transition Module/Enablement Kit installed.

Y N
• Drive shaft bearings for binding (PL 11.13)
• Drive idlers for binding (PL 11.13)
• (ADJ 11-10), Stacker A Bypass Transport Adjustment
Select [Third Party] [Fin 1] [Stacker Output Gate] Solenoid RAP. Press Continue. The
Stacker Output Gate actuates.
Y N
The Stacker Output Gate Solenoid Energizes.
B


Stacker A Fault Code, 11-140-1, indicates that the trail edge of the print did not arrive at the NOTE: The following procedure can be used for fault codes that may appear in any of the
Bypass Transport Sensor, Q1107A, within the specified amount of time after the lead edge of Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter
the print arrived at the Bypass Transport Sensor, Q1107A,. When the fault is declared the (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in
Bypass Transport Sensor is blocked. The valid destination for this print is beyond Stacker A. order to properly diagnose the fault codes.
Enter dC330, [Stacker X], [11X1]. Block the Stacker X Bypass Transport Sensor. The
Stacker A Fault Code, 11-141-1, indicates that the trail edge of the print did not arrive at the
Bypass Xport Sensor display changes from L to H.
Bypass Transport Sensor, Q1107A, within the specified amount of time after the lead edge of
Y N
the print arrived at the Bypass Transport Sensor, Q1107A. When the fault is declared the
Go to Flag 1. Check the Stacker X Bypass Transport Sensor circuit (GP 6-2, General Pro-
Bypass Transport Sensor is unblocked. The valid destination for this sheet is beyond Stacker
cedures) (PL 11.30).
A.
Stacker B Fault Code, 11-140-2, indicates that the trail edge of the print did not arrive at the
WARNING
Bypass Transport Sensor, Q1107B, within the specified amount of time after the lead edge of Use caution when working near the motor. The Stacker Main Drive Motor may run auto-
the print arrived at the Bypass Transport Sensor, Q1107B,. When the fault is declared the matically. There is an internal thermal sensor that opens when the motor overheats.
Bypass Transport Sensor, Q1107B, is blocked. The valid destination for this print is beyond When the motor cools, the thermal sensor will close, allowing power to the motor. The
Stacker B. outside surfaces of the motor could also be very hot.
Select [Stacker Start/Run]. Press Continue. Observe the Bypass Transport Exit Roll. The
Stacker B Fault Code, 11-141-2, indicates that the trail edge of the print did not arrive at the Exit Roll rotates.
Bypass Transport Sensor, Q1107B, within the specified amount of time after the lead edge of Y N
the print arrived at the Bypass Transport Sensor, Q1107B. When the fault is declared the The Stacker X Main Drive Motor comes on.
Bypass Transport Sensor, Q1107B, is unblocked. The valid destination for this sheet is beyond Y N
Stacker B. Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.
Stacker C Fault Code, 11-140-3, indicates that the trail edge of the print did not arrive at the Press Stop. Check the following:
Bypass Transport Sensor, Q1107C, within the specified amount of time after the lead edge of • Drive belts wear, damage, contamination, and correct tension (PL 11.11), (PL 11.30).
the print arrived at the Bypass Transport Sensor, Q1107C,. When the fault is declared the • Bearings for binding (PL 11.11, (PL 11.30).
Bypass Transport Sensor is blocked. The valid destination for this print is beyond Stacker C.
• Drive Rolls for wear, damage, or contamination and that they are not slipping on
shaft (PL 11.11, (PL 11.30).
Stacker C Fault Code, 11-141-3, indicates that the trail edge of the print did not arrive at the
• Idler Rolls for binding and for missing idler roll springs (PL 11.15).
Bypass Transport Sensor, Q1107C, within the specified amount of time after the lead edge of
the print arrived at the Bypass Transport Sensor, Q1107C. When the fault is declared the
Bypass Transport Sensor is unblocked. The valid destination for this sheet is beyond Stacker Press Stop. Select [11X1] [Stacker Start/Run]. Observe the Stacker X Bypass Transport
Entrance Drive Roll. Press Continue. The Drive Roll rotates.
C.
Y N
The Stacker X Main Drive motor comes on.
Initial Actions Y N
Check the following: Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.
• Bypass Transport Sensor is clean and is not obstructed Press Stop. Check the following:
• Bypass Transport for obstructions. • Drive belts and idlers for wear, damage, contamination, and correct tension (PL
• Jam clearance baffles for damage and that they are seated correctly. 11.13).
• Transport Drive Rolls and Nip Springs for binding or contamination. • Bearings for binding (PL 11.13).
• SCP, HFSI 11-806-1 Table 4, or HFSI TABLES to see all of HFSI. • Drive Rolls for wear, damage, or contamination and that they are not slipping on
shaft (PL 11.13).
Diagnostic Tools:
• Idler Rolls for binding and for missing idler roll springs (PL 11.13).
Bypass Transport Sensor to TE at Bypass Transport Sensor. Press Stop. Select [Bypass Gate] solenoid. Press Continue. The Stacker X Bypass Gate
• dC227 - Inverter/Stacker Jam Bypass actuates.

Y N
Y N
Press Stop. Check the solenoid plunger for binding.


• Drive Rolls and Idlers for wear, damage, or contamination (PL 11.12) and (PL 11.15).
• (ADJ 11-10), Bypass Transport adjustment.
• Bypass Transport for binding (PL 11.12).
• Static in any of the transports.
• If the problem is occurring at the last Bypass Transport and a Transition Module is
enabled, go to the 13-131 RAP and the 13-132 RAP.

Figure 1 11-140-1/141-1 Circuit Diagram (8518)

11-142-2, 11-143-2, 11-144-2 RAP Y N
Go to Flag 2. Check the Purge Transport Sensor circuit (GP 6-2, General Procedures)
Stacker B fault Code, 11-142-2, indicates that the lead edge of the print delivered from the (PL 11.12).
Stacker A Bypass Transport Sensor, Q1107A, did not arrive at the Stacker B Purge Transport
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker B WARNING
Purge Transport Sensor is unblocked and the Stacker A Bypass Transport Sensor is Use caution when working near the motor. The Stacker Main Drive Motor may run auto-
unblocked. The valid destination for the print is the Purge Tray.
Stacker B fault code, 11-143-2, indicates that the lead edge of the print delivered from the outside surfaces of the motor could also be very hot.
Select [11B1] [Stacker Start/Run]. Press Continue. The Purge Transport Drive Rolls
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker B
rotate.
Purge Transport Sensor is unblocked and the Stacker A Bypass Transport Sensor is blocked.
Y N
The valid destination for the print is the Purge Tray.
Y N
Stacker B fault code, 11-144-2, indicates that the lead edge of the print delivered from the
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker B
The Purge Transport Drive Rolls operate correctly.
Purge Transport Sensor is blocked and the Stacker A Bypass Transport Sensor is unblocked.
Y N
Initial Actions
screw (PL 11.13).
• Purge Tray is too full or obstructed.

• Stacker A Bypass Transport Sensor is clean and not obstructed. • Purge Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13).
• Purge Transport Sensor is clean and is not obstructed. • Idler springs for wear or damage (PL 11.16).
• Jam clearance baffles are seated correctly and are not damaged. Press Stop. Select [11A1]. Block the Stacker A Bypass Transport Sensor. The display
• Idler springs missing or idlers that are bound or contaminated.
Y N
• Bypass Transport Gate is operating correctly and is not obstructing the paper path.
• SCP, HFSI 11-806-2 Table 4, or HFSI TABLES to see all of HFSI. (PL 11.30).
Diagnostic Tools:
Observe the Bypass Transport Gate. The Gate is actuated in standby.
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #15, LE Y N
• dC227 - Inverter/Stacker Jam Bypass. The machine has a Transition Module installed.
Y N
Observe the prints entering the Bypass Transport. The prints are free from damage, skew, • Drive Shaft bearings for binding (PL 11.13).
or excessive curl.
Y N
• (ADJ 11-10), Bypass/Purge Transport Adjustment
• Drive Rolls for wear, damage or contamination (PL 11.11).
Press Stop. Select [Third Party] [Fin 1] [Stacker Output Gate] Solenoid RAP. Press
• Idler Rolls and retaining springs for damage or binding (PL 11.15).
Continue. The Stacker Output Gate Solenoid actuates.
If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diag- Y N
nostics (Service Call Procedures) for additional information. The Stacker Output Gate Solenoid energizes.
Y N
Enter dC330, [Stacker A/B], [11B2]. Block the Purge Transport Sensor. The display Press Stop. Check the solenoid plunger for binding. If no binding is present, go
changes from L to H. to Flag 4. Check the circuit of the Purge Gate Solenoid, (Generic Solenoid RAP
A B C
A B C
• Purge gate for wear or damage.
• (ADJ 13-1), Stacker Output Gate adjustment.

• Drive rolls and idlers for wear, damage, or contamination (PL 11.12).
• Drive belt idler for binding (PL 11.13).
Go to Flag 3. Check the wire for a short circuit. If OK, replace the FSN DIO PWB 3B (PL 1.17).

Figure 1 11-142/143/144-2 Circuit Diagram (8514)


11-142-3, 11-143-3, 11-144-3 RAP Y N
Stacker C fault Code, 11-142-3, indicates that the lead edge of the print delivered from the (PL 11.12).
Stacker B Bypass Transport Sensor, Q1107B, did not arrive at the Stacker C Purge Transport
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker C WARNING
Purge Transport Sensor is unblocked and the Stacker B Bypass Transport Sensor is Use caution when working near the motor. The Stacker Main Drive Motor may run auto-
Stacker C fault code, 11-143-3, indicates that the lead edge of the print delivered from the outside surfaces of the motor could also be very hot.
Select [11C1] [Stacker Start/Run]. Press Continue. The Purge Transport Drive Rolls
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker C
rotate.
Purge Transport Sensor is unblocked and the Stacker B Bypass Transport Sensor is blocked.
Y N
Y N
Stacker C fault code, 11-144-3, indicates that the lead edge of the print delivered from the
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker C
Purge Transport Sensor is blocked and the Stacker B Bypass Transport Sensor is unblocked.
Y N
Initial Actions
screw (PL 11.13).

• Stacker B Bypass Transport Sensor is clean and not obstructed. • Purge Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13).
• Jam clearance baffles are seated correctly and are not damaged. Press Stop. Select [11B1]. Block the Stacker B Bypass Transport Sensor. The display
Y N
Diagnostic Tools:
Y N
or excessive curl.
Y N
Y N
Enter dC330, [Stacker C], [11C2]. Block the Purge Transport Sensor. The display changes Press Stop. Check the solenoid plunger for binding. If no binding is present, go
from L to H. to Flag 4. Check the circuit of the Purge Gate Solenoid, (Generic Solenoid RAP
A B C
A B C

Go to Flag 3. Check the wire for a short circuit. If OK, replace the FSN DIO PWB 3C (PL 1.17).



11-142-4, 11-143-4, 11-144-4 RAP Y N
Stacker D fault Code, 11-142-4, indicates that the lead edge of the print delivered from the (PL 11.12).
Stacker C Bypass Transport Sensor, Q1107C, did not arrive at the Stacker D Purge Transport
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker D WARNING
Purge Transport Sensor is unblocked and the Stacker C Bypass Transport Sensor is Use caution when working near the motor. The Stacker Main Drive Motor may run auto-
Stacker D fault code, 11-143-4, indicates that the lead edge of the print delivered from the outside surfaces of the motor could also be very hot.
Select [11D1] [Stacker Start/Run]. Press Continue. The Purge Transport Drive Rolls
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker D
rotate.
Purge Transport Sensor is unblocked and the Stacker C Bypass Transport Sensor is blocked.
Y N
Y N
Stacker D fault code, 11-144-4, indicates that the lead edge of the print delivered from the
Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker D
Purge Transport Sensor is blocked and the Stacker C Bypass Transport Sensor is unblocked.
Y N
Initial Actions
screw (PL 11.13).

• Stacker C Bypass Transport Sensor is clean and not obstructed. • Purge Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13).
• Jam clearance baffles are seated correctly and are not damaged. Press Stop. Select [11C1]. Block the Stacker C Bypass Transport Sensor. The display
Y N
Diagnostic Tools:
Y N
or excessive curl.
Y N
Y N
Enter dC330, [Stacker D], [11D2]. Block the Purge Transport Sensor. The display changes Press Stop. Check the solenoid plunger for binding. If no binding is present, go
from L to H. to Flag 4. Check the circuit of the Purge Gate Solenoid, (Generic Solenoid RAP
A B C
A B C

Go to Flag 3. Check the wire for a short circuit. If OK, replace the FSN DIO PWB 3D (PL 1.17).



A
11-145-2 RAP • Idler Rolls for binding and for missing idler roll springs (PL 11.16).
Stacker B Fault Code, 11-145-2, indicates that the trail edge of the print did not arrive at the The machine has a Transition Module installed.
Purge Transport Sensor, Q1164, within the specified amount of time after the lead edge of the Y N
print arrived at the Purge Transport Sensor. The valid destination for this print is the Purge Check the following:
Tray. • Drive shaft bearings for binding (PL 11.13).
• Drive idlers for binding (PL 11.13).
Initial Actions • Bypass Purge Transport adjustment (ADJ 11-10).
NOTE: The Purge Tray utilizes corrugated rolls to decelerate the sheets to allow adequate
stacking at high speeds. Corrugation Rolls should be set to a nominal penetration of 1.6 mm. Press Stop. Select [Third Party] [Fin 1] [Stacker Output Gate] Solenoid RAP. Press Con-
tinue. The Stacker Output Gate Solenoid actuates.
Press Stop. Check the solenoid plunger for binding. If no binding is found, go to Flag 4.
• Purge Transport Sensor is clean and is not obstructed. Check the circuit of the Stacker Output Gate Solenoid, (Generic Solenoid RAP GP 6-3,
• Purge Tray is not obstructed. General Procedures).
• Paper path is not obstructed. Press Stop. Check the following:
• Stacker Output Gate for wear or damage.
• Bypass Transport is not obstructed.
• Jam Clearance baffles are seated correctly and are not damaged.
• Check the Purge Tray Corrugation Roll adjustment (ADJ 11-13). Press Stop. Check the following:
Diagnostic Tools: • Drive Rolls and Idlers for wear, damage, or contamination (PL 11.13) and (PL 11.16).
• (ADJ 11-10), Bypass/Purge Transport adjustment.
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #16, LE at Purge Trans-
port Sensor to TE at Purge Transport Sensor.
• Static in the I F/S
• dC227 - Inverter/Stacker Jam Bypass.
• (ADJ 13-1), Stacker Output Gate Adjustment.
Procedure • Jam clearance baffles are seated correctly and are not damaged.
Enter dC330, [11B2]. Block the Purge Transport Sensor. The display changes from L to H.
Y N
Go to Flag 1. Check the circuit of the Purge Transport Sensor (GP 6-2, General Proce-
dures) (PL 11.12).
WARNING
Select [11B1] [Stacker Start/Run]. Press Continue. Observe the Purge Transport Exit Roll.
The Exit Roll rotates.
Y N
Y N

• Drive belts and idlers for wear, damage, contamination, and correct tension (PL
11.13).
• Bearings for binding (PL 11.13).
• Drive Rolls for wear, damage, or contamination and that they are not slipping on
shaft (PL 11.13).
A


A
11-145-3 RAP • Drive Rolls for wear, damage, or contamination and that they are not slipping on
shaft (PL 11.13).
Stacker C Fault Code, 11-145-3, indicates that the trail edge of the print did not arrive at the • Idler Rolls for binding and for missing idler roll springs (PL 11.16).
Purge Transport Sensor, Q1164, within the specified amount of time after the lead edge of the
print arrived at the Purge Transport Sensor. The valid destination for this print is the Purge The machine has a Transition Module installed.
Tray. Y N
Initial Actions • Drive shaft bearings for binding (PL 11.13).
• Drive idlers for binding (PL 11.13).
NOTE: The Purge Tray utilizes corrugated rolls to decelerate the sheets to allow adequate
stacking at high speeds. Corrugation Rolls should be set to a nominal penetration of 1.6 mm. • Bypass Purge Transport adjustment (ADJ 11-10).
Check the following: Press Stop. Select [Third Party], [Fin 1], [Stacker Output Gate] Solenoid RAP. Press Con-
tinue. The Stacker Output Gate Solenoid actuates.
• Purge Transport Sensor is clean and is not obstructed. Y N
• Purge Tray is not obstructed. Press Stop. Check the solenoid plunger for binding. If no binding is found, go to Flag 4.
• Paper path is not obstructed. Check the circuit of the Stacker Output Gate Solenoid, (Generic Solenoid RAP GP 6-3,
• Bypass Transport is not obstructed. General Procedures).
• Stacker Output Gate for wear or damage.
• Check the Purge Tray Corrugation Roll adjustment (ADJ 11-13).
Diagnostic Tools:
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #16, LE at Purge Trans- • Drive Rolls and Idlers for wear, damage, or contamination (PL 11.13) and (PL 11.16).
Procedure • Static in the I F/S
Enter dC330, [Stacker C], [11C2]. Block the Purge Transport Sensor. The display changes • (ADJ 13-1), Stacker Output Gate Adjustment.
from L to H.
Y N
dures) (PL 11.12).
WARNING
Select [11C1], [Stacker Start/Run]. Press Continue. Observe the Purge Transport Exit Roll.
Y N
Y N

11.13).
A


A
11-145-4 RAP • Drive Rolls for wear, damage, or contamination and that they are not slipping on
shaft (PL 11.13).
Stacker D Fault Code, 11-145-4, indicates that the trail edge of the print did not arrive at the • Idler Rolls for binding and for missing idler roll springs (PL 11.16).
Purge Transport Sensor, Q1164, within the specified amount of time after the lead edge of the
print arrived at the Purge Transport Sensor. The valid destination for this print is the Purge Press Stop. Check the following:
Tray. • Drive Rolls and Idlers for wear, damage, or contamination (PL 11.13) and PL 11.16).
Initial Actions • Bypass Transport for binding (PL 11.12).
NOTE: The Sample Tray utilizes corrugated rolls to decelerate the sheets to allow adequate • Static in the I F/S
stacking at high speeds. Corrugation Rolls should be set to a nominal penetration of 1.6 mm. • Jam clearance baffles are seated correctly and are not damaged.
• Purge Transport Sensor is clean and is not obstructed.

• Purge Tray is not obstructed.
• Bypass Transport is not obstructed.
• Check the Purge Tray Corrugation Roll adjustment (ADJ 11-13).
Diagnostic Tools:
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #16, LE at Purge Trans-
Procedure
Enter dC330, [Stacker D], [11D2]. Block the Purge Transport Sensor. The display changes
from L to H.
Y N
dures) (PL 11.12).
WARNING
Select [11D1] [Stacker Start/Run]. Press Continue. Observe the Purge Transport Exit Roll.
Y N
Y N

11.13).
A


Stacker A fault code, 11-146-1, indicates that the lead edge of a print did not arrive at the Disk NOTE: The following procedure can be used for fault codes that may appear in any of the
Lead Edge Sensor, Q1166A, within the specified amount of time after the lead edge of the print Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter
actuated the Disk Sheet Sensor, Q1106A. This fault only occurs in the 7 pitch mode. (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in
Stacker B fault code, 11-146-2, indicates that the lead edge of a print did not arrive at the Disk
Enter dC330, [Stacker X], [11X1]. Rotate the Disks. The Disk Home Sensor display
Lead Edge Sensor, Q1166B, within the specified amount of time after the lead edge of the print
actuated the Disk Sheet Sensor, Q1106B. This fault only occurs in the 7 pitch mode.
Y N
Ensure that the Disk flag is aligned with the sensor and not loose. If OK, go to Flag 3.
Stacker C fault code, 11-146-3, indicates that the lead edge of a print did not arrive at the Disk
Check the Disk Home Sensor circuit (GP 6-2, General Procedures) (PL 11.30).
Lead Edge Sensor, Q1166C, within the specified amount of time after the lead edge of the print
actuated the Disk Sheet Sensor, Q1106C. This fault only occurs in the 7 pitch mode.
Block the Disk Lead Edge Sensor. The Disk Lead Edge Sensor display changes from H to
L.
Stacker D fault code, 11-146-4, indicates that the lead edge of a print did not arrive at the Disk
Y N
Lead Edge Sensor, Q1166D, within the specified amount of time after the lead edge of the print
Go to Flag 2. Check the Disk Lead Edge Sensor circuit (GP 6-2, General Procedures) (PL
actuated the Disk Sheet Sensor, Q1106D. This fault only occurs in the 7 pitch mode.
11.30).
Stacker A fault code, 11-147-1, indicates that the lead edge of a print did not arrive at the Disk
Enter dC203, [Stacker Disk], [Stacker X], [7 Pitch or 3 Pitch], [Continuous Run]. Press
Lead Edge Sensor, Q1166A, within the specified amount of time after the lead edge of the print
Continue. Compare the measured times with the expected range. The Disk module cycles
actuated the Disk Sheet Sensor, Q1106A. This fault only occurs in the 3 pitch mode.
smoothly and the measured times are within the expected range.
Y N
Stacker B fault code, 11-147-2, indicates that the lead edge of a print did not arrive at the Disk
The Disk Motor comes on.
Lead Edge Sensor, Q1166B, within the specified amount of time after the lead edge of the print
Y N
actuated the Disk Sheet Sensor, Q1106B. This fault only occurs in the 3 pitch mode.
Press Stop. Go to the 11-700, Disk Motor RAP.
Stacker C fault code, 11-147-3, indicates that the lead edge of a print did not arrive at the Disk
Press Stop. Perform the Disk Home Position Adjustment (ADJ 11-25). Check the Disk
Lead Edge Sensor, Q1166C, within the specified amount of time after the lead edge of the print
Module components for wear, damage, and proper location (PL 11.30).
actuated the Disk Sheet Sensor, Q1106C. This fault only occurs in the 3 pitch mode.
Press Stop. Check the Disk Entrance Gate hardware for wear, damage, and proper operation.
Stacker D fault code, 11-147-4, indicates that the lead edge of a print did not arrive at the Disk
The Disk Gate hardware is OK.
Lead Edge Sensor, Q1166D, within the specified amount of time after the lead edge of the print
Y N
actuated the Disk Sheet Sensor, Q1106D. This fault only occurs in the 3 pitch mode.
Repair, replace the Disk Entrance Gate hardware as necessary (PL 11.14, (PL 11.30).
Initial Actions Enter dC330, [Stacker X], [11X1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor dis-
Check the following: play changes from L to H.
Y N
• Disk Sheet Sensor and Disk Lead Edge Sensor are clean and not obstructed. Go to Flag 1. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL
• Disk entrance and stacker areas are not obstructed. 11.30).
Select [Stacker Start/Run]. Observe the Disk Entrance Drive Roll. Press Continue. The
• Disk Entrance Gate for binding or damage.
Disk Entrance Drive Roll rotates.
• Disk Entrance Gate Cam Follower for binding or damage. Y N
• Disks are positioned correctly. Press Stop. Check the Disk Entrance Drive Roll for a loose or broken belt or pulley (PL
• Stack is not interfering with Disk. 11.30).
Diagnostic Tools:
The Trail Edge Assist belts are turning.
Y N
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #29 or 30, LE at Disk
Press Stop. Check the Stacker Main Drives for broken belts, gears, or loose pulleys (PL
Sheet Sensor to LE at Disk Lead Edge Sensor
11.11).
A
A
Observe the prints entering the stacker. The prints are free of curl.
Y N
Curled prints, especially in heavy or lightweight papers may cause this fault. Upward curl
as prints enter the disk area can cause the prints to miss the disk fingers or jam in the
Disk Entrance Gate area. Upward curl on prints in a stack may interfere with the disks,
stalling them. Go to the Physical Checks, Print Paper Diagnostics (Service Call Proce-
dures) for more information on curl.
The prints are free of skew and paper damage.

Y N
• (Stacker X) - Preregistration Transport and Inverter area for obstructions
• (Stacker X) - Bypass Transport area for obstructions
• Drive Rolls for contamination (PL 11.11) and (PL 11.13).
• Idler Rolls for proper tension
• Baffles seated or latched properly
• Bypass Gate for binding (PL 11.14)

• (ADJ 11-25), Disk Home Position adjustment.
• (ADJ 11-26), Disk Entrance Gate Height adjustment.
• (ADJ 11-27), Stack Height Adjustment.
• Disk Entrance Drive Roll idler (PL 11.14)
• Bypass Gate for binding (PL 11.14)


Stacker A fault code, 11-148-1, indicates that the trail edge of a print did not actuate the Disk NOTE: The following procedure can be used for fault codes that may appear in any of the
Lead Edge Sensor, Q1166A, after the lead edge of the print actuated the sensor. When the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter
fault is declared, the sensor is blocked. (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in
Stacker B fault code, 11-148-2, indicates that the trail edge of a print did not actuate the Disk
Enter dC330, [Stacker X], [11X1]. Block the Disk Lead Edge Sensor. The Disk Lead Edge
Lead Edge Sensor, Q1166B, after the lead edge of the print actuated the sensor. When the
Sensor display changes from H to L.
fault is declared, the sensor is blocked.
Y N
Go to Flag 1. Check the circuit of the Disk Lead Edge Sensor (GP 6-2, General Proce-
Stacker C fault code, 11-148-3, indicates that the trail edge of a print did not actuate the Disk
dures) (PL 11.30).
Lead Edge Sensor, Q1166C, after the lead edge of the print actuated the sensor. When the
fault is declared, the sensor is blocked.
WARNING
Stacker D fault code, 11-148-4, indicates that the trail edge of a print did not actuate the Disk Use caution when working near the motor. The Stacker Main Drive Motor may run auto-
Lead Edge Sensor, Q1166D, after the lead edge of the print actuated the sensor. When the matically. There is an internal thermal sensor that opens when the motor overheats.
fault is declared, the sensor is blocked. When the motor cools, the thermal sensor will close, allowing power to the motor. The
Stacker A fault code, 11-149-1, indicates that the trail edge of a print did not actuate the Disk Select [Stacker Start/Run]. Press Continue. The Stacker Main Drives come on.
Lead Edge Sensor, Q1166A, after the lead edge of the print actuated the sensor. When the Y N
fault is declared, the sensor is unblocked. Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.
Stacker B fault code, 11-149-2, indicates that the trail edge of a print did not actuate the Disk The Trail Edge Assist Belts are all turning.
Lead Edge Sensor, Q1166B, after the lead edge of the print actuated the sensor. When the Y N
fault is declared, the sensor is unblocked. Press Stop. Check the Telescopic Drive Shaft for proper operation and the belts, pulleys,
and gears that drive the Trail Edge Assist Belts (PL 11.11).
Stacker C fault code, 11-149-3, indicates that the trail edge of a print did not actuate the Disk
Lead Edge Sensor, Q1166C, after the lead edge of the print actuated the sensor. When the Press Stop. Check the Front and rear Tampers for proper operation. Enter dC203, [Tamper
fault is declared, the sensor is unblocked. Fingers], [Stacker X], [Back Tamper], [Continuous Run]. Press Continue. Check the mea-
sured times against the expected range. Repeat the test for the Front Tamper. The mea-
Stacker D fault code, 11-149-4, indicates that the trail edge of a print did not actuate the Disk sured times are within the expected range.
Lead Edge Sensor, Q1166D, after the lead edge of the print actuated the sensor. When the Y N
fault is declared, the sensor is unblocked. Press Stop. Check the following:
• Tamper components for damage or wear (PL 11.5).
These faults are only declared in the 7 pitch mode. • Right Guide Adjustments (ADJ 11-28).
• Back Guide Adjustment (ADJ 11-29).
Initial Actions
Check the following: Press Stop. Check the following:
• Trail Edge assist belts are tracking properly (PL 11.14).
• Disk Entrance Gate or Stacker areas are not obstructed. • Trail edge assist belts not loose or slipping (PL 11.14).
• Disk Lead Edge Sensor is clean and not obstructed. • Disk Entrance Gate hardware for proper operation (PL 11.14).
• The upper transport is seated properly. • Disk Entrance Gate Height adjustment, (ADJ 11-26).
• Stack is not interfering with Disk. • Disk Home Position Adjustment (ADJ 11-25).
• SCP, HFSI 11-802 Table 4, or HFSI TABLES to see all of HFSI.
Diagnostic Tools:
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #31 or 32, LE at Disk
Lead Edge Sensor to TE at Disk Lead Edge Sensor


A
11-150 RAP WARNING
Stacker A fault code, 11-150-1, indicates that the trail edge of a print did not arrive at the A3
Trail Edge Sensor, Q1167A, within the specified amount of time after the trail edge was
detected at the Disk Lead Edge Sensor, Q1166A.
Stacker B fault code, 11-150-2, indicates that the trail edge of a print did not arrive at the A3 Select [Stacker Start/Run]. Press Continue. The Stacker Main Drives come on.
Y N
Trail Edge Sensor, Q1167B, within the specified amount of time after the trail edge was
detected at the Disk Lead Edge Sensor, Q1166B. Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.
The Trail Edge Assist Belts are all turning.

Stacker C fault code, 11-150-3, indicates that the trail edge of a print did not arrive at the A3
Trail Edge Sensor, Q1167C, within the specified amount of time after the trail edge was Y N
detected at the Disk Lead Edge Sensor, Q1166C. Press Stop. Check the following:
• Telescopic Drive Shaft for proper operation (PL 11.11, PL 11.13).
Stacker D fault code, 11-150-4, indicates that the trail edge of a print did not arrive at the A3 • Bypass Drive Belts for damage, wear, and contamination (PL 11.11, PL 11.13).
Trail Edge Sensor, Q1167D, within the specified amount of time after the trail edge was • Gears and pulleys for damage, wear, and contamination (PL 11.11, PL 11.13).
detected at the Disk Lead Edge Sensor, Q1166D.
Press Stop. Check the Front and rear Tampers for proper operation. Enter dC203, [Tamper
This fault only occurs in the 3 pitch mode. Fingers], [Stacker X], [Back Tamper], [Continuous Run]. Press Continue. Check the mea-
sured times against the expected range. Repeat the test for the Front Tamper. The mea-
Initial Actions sured times are within the expected range.
Y N
• A3 Trail Edge Sensor is clean and not obstructed. • Tamper components for damage or wear (PL 11.5).
• Stacker and Disk Entrance Gate areas are not obstructed. • Back Guide Adjustment, (ADJ 11-29).
• Guides are positioned properly. • Right Guide Adjustment, (ADJ 11-28).
• Ensure that the paper stock is within the specifications for the printing system.
• Upper Transport is seated properly. • Trail Edge assist belts are tracking properly (PL 11.14).
• SCP, HFSI 11-802 Table 4, or HFSI TABLES to see all of HFSI. • Trail Edge assist belts not loose or slipping (PL 11.14).
Diagnostic Tools: • Disk Entrance Gate hardware for proper operation (PL 11.14).
• Disk Entrance Gate Height adjustment, (ADJ 11-26).
• dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #33 or 34, TE at Disk
Lead Edge Sensor to TE at A3 Trail Edge Sensor • Stack Height Adjustment, (ADJ 11-27).
• dC227 - Inverter/Stacker Jam Bypass • A3 Nip Release Mechanism for proper operation (PL 11.28)
Procedure
Enter dC330, [Stacker X], [11X1]. Block the A3 Trail Edge Sensor. The A3 Trail Edge sen-
sor display changes from H to L.
Y N
Go to Flag 1. Check the A3 Trail Edge Sensor circuit (GP 6-2, General Procedures) (PL
11.14).
A

11-200 RAP
Fault Code, 11-200, indicates that the Inverter Front Door Interlock Switch, S1153, opened with
the High Capacity Feeder 3 or Stacker A Main Drive Motor on.
Procedure
Open the Inverter Front Door. Enter dC330. Manually actuate the Inverter Front Door Interlock
Switch. The Inverter Door INTLK SW display changes from H to L.
Y N
Go to Flag 1. Check the Inverter Front Door Interlock circuit (Generic Switch RAP GP 6-1,
General Procedures) (PL 4.11).
Close and open the door several times. The Inverter Door INTLK SW display changes from
H to L as the door is closed and opened.
Y N
• Inverter Front Door Interlock adjustment, (ADJ 4-5).
• Inverter Front Door is not damaged or obstructed (PL 4.11).
• Door hinges and pins are in place and intact (PL 4.11).
• Pre-registration transport is seated correctly
• Interlock mounting bracket is not damaged (PL 4.11).
Check the Inverter Front Door Interlock Switch and its associated wires for intermittent opera-
tion.


A
11-220 RAP WARNING
Use caution when working near the motor. The Stacker Elevator Motor may run auto-
Stacker A Fault Code, 11-220-1, indicates that the Elevator failed to leave the home position
(max down). The Stacker Elevator Down Sensor, Q1135A, failed to deactuate within the speci-
fied amount of time after the UP winding of the Elevator Motor, MOT1106A, was energized to
raise the Elevator.
Select [Stacker Elevator Up] motor. Press Continue. The Stacker Elevator moves up.
Y N
Stacker B Fault Code, 11-220-2, indicates that the Elevator failed to leave the home position
(max down). The Stacker Elevator Down Sensor, Q1135B, failed to deactuate within the speci- The Stacker Elevator Motor comes on.
fied amount of time after the UP winding of the Elevator Motor, MOT1106B, was energized to Y N
Press Stop. Go to the 11-703, Stacker Elevator Motor RAP.
raise the Elevator.
Stacker C Fault Code, 11-220-3, indicates that the Elevator failed to leave the home position Press Stop. Check the following:
• Lead screw or bearing for binding (PL 11.18).
(max down). The Stacker Elevator Down Sensor, Q1135C, failed to deactuate within the speci-
fied amount of time after the UP winding of the Elevator Motor, MOT1106C, was energized to • Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).
raise the Elevator. • Elevator Drive belt for wear, damage, contamination, and correct tension (PL 11.18).
Stacker D Fault Code, 11-220-4, indicates that the Elevator failed to leave the home position Press Stop. Check the following:
(max down). The Stacker Elevator Down Sensor, Q1135D, failed to deactuate within the speci- • Lead screw or bearings for binding (PL 11.18).
fied amount of time after the UP winding of the Elevator Motor, MOT1106D, was energized to • Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).
raise the Elevator.
• Elevator Drive Belt for wear, damage, contamination, and that it is under tension (PL
11.18).
Initial Actions
WARNING
Keep fingers/hands away from moving elevator parts.
• Stacker Drawer is closed and latched.

• Main Pallet is positioned correctly and the "spider" latch is latched.
• Ensure that the containers or pallet is empty.
Procedure
Enter dC330, [Stacker X], [11X2]. Block the Stacker Elevator Down Sensor. The Elevator
Down / Home Sensor display changes from L to H.
Y N
Go to Flag 1. Check the Stacker Elevator Down / Home Sensor circuit (Generic Switch
RAP GP 6-1, General Procedures) (PL 11.18).
Block the Stacker Empty Sensor. The Stacker Empty Sensor display changes from L to H.
Y N
Go to Flag 2. Check the Stacker Empty Sensor circuit (GP 6-2, General Procedures) (PL
11.18).
A

A B
11-221 RAP Press Stop. Check the following:
Stacker A Fault Code, 11-221-1, indicates that the Stacker Elevator Down Sensor, Q1135A, • Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).
failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker
• Elevator Drive belt for wear, damage, or contamination and that it is under tension
Elevator Motor, MOT1106A, was energized to lower the Elevator.
(PL 11.18).
Stacker B Fault Code, 11-221-2, indicates that the Stacker Elevator Down Sensor, Q1135B, • Lift Frame is not damaged (PL 11.17).
failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker • Pallet Lift Frame Parallelism Adjustment (ADJ 11-31).
Elevator Motor, MOT1106B, was energized to lower the Elevator.
Stacker C Fault Code, 11-221-3, indicates that the Stacker Elevator Down Sensor, Q1135C, • Lead screw or bearings for binding (PL 11.18).
failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker • Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).
Elevator Motor, MOT1106C, was energized to lower the Elevator. • Elevator Drive Belt for wear, damage, or contamination and that it is under tension (PL
11.18).
Stacker D Fault Code, 11-221-4, indicates that the Stacker Elevator Down Sensor, Q1135D,
failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker
Elevator Motor, MOT1106D, was energized to lower the Elevator.
Initial Actions
WARNING
• Stacker Drawer is closed and latched fully.

• Stacker Doors are closed.
• Elevator path is not obstructed.
Procedure
Enter dC330, [STACKER X], [11X2]. Block the Stacker Elevator Down Sensor.
The Elevator Down / Home Sensor display changes from L to H.

Y N
Go to Flag 1. Check the Stacker Elevator Down / Home Sensor circuit (Generic Switch
RAP GP 6-1, General Procedures) (PL 11.18).
WARNING
Select [Elevator Dn]. Press Continue. The Stacker Elevator moves down.
Y N
The Stacker Elevator Motor comes on.
Y N
A B

A
11-222 RAP If OK, go to Flag 1. Check the Elevator Motor Encoder circuit (GP 6-2, General Proce-
dures) (PL 11.19).
Stacker A Fault Code, 11-222-1, indicates that there were no encoder pulses received from the
Stacker Elevator Encoder Sensor, Q1124A, with the Stacker Elevator Motor, MOT1106A, acti- Select [11X1]. The Stacker Drawer In Switch display indicates an L.
vated. The fault code can result when the motor is activated in either the up or down mode. Y N
Go to Flag 4. Check the circuit of the Stacker Drawer In Switch, S1129 (Generic Switch
Stacker B Fault Code, 11-222-2, indicates that there were no encoder pulses received from the RAP GP 6-1, General Procedures) (PL 11.18).
Stacker Elevator Encoder Sensor, Q1124B, with the Stacker Elevator Motor, MOT1106B, acti-
vated. The fault code can result when the motor is activated in either the up or down mode. Select [11X2]. Block the Stack Height Sensor. The Stack Height Sensor display changes
from L to H.
Stacker C Fault Code, 11-222-3, indicates that there were no encoder pulses received from the Y N
Stacker Elevator Encoder Sensor, Q1124C, with the Stacker Elevator Motor, MOT1106C, acti- Go to Flag 5. Check the circuit of the Stack Height Sensor, Q1122 (GP 6-2, General Pro-
vated. The fault code can result when the motor is activated in either the up or down mode. cedures) (PL 11.30).
Stacker D Fault Code, 11-222-4, indicates that there were no encoder pulses received from the Observe the position of the Elevator Lift Frame. The Lift Frame is in the home (down) posi-
Stacker Elevator Encoder Sensor, Q1124D, with the Stacker Elevator Motor, MOT1106D, acti- tion.
vated. The fault code can result when the motor is activated in either the up or down mode. Y N
Block the Stacker Elevator Down Sensor. The Elevator Down/Home Sensor display
Initial Actions changes from L to H.
Y N
WARNING Go to Flag 2. Check the circuit of the Stacker Elevator Down Sensor, Q1125 (GP 6-
Keep fingers/hands away from moving elevator parts. 2, General Procedures) (PL 11.18).
WARNING
• Stacker Drawer is closed and latched fully.
Use caution when working near the motor. The Stacker Elevator Motor may run
• Stacker Doors are closed. automatically. There is an internal thermal sensor that opens when the motor over-
• Loose pins or connectors on the Stacker Door Interlock Switches. heats. When the motor cools, the thermal sensor will close, allowing power to the
• Main Pallet is positioned correctly and the Pallet Latch is latched. motor. The outside surfaces of the motor could also be very hot.
• Elevator path is not obstructed. Select [Elevator Down]. Press Continue. The Stacker Elevator moves down.
Y N
• Lift Frame is not damaged.
Y N
• Remove all paper from the stacker pallets
Procedure Press Stop. Check the following:
Enter dC330, [Stacker X], [11X2]. Manually rotate the Stacker Drive Belt. • Lead screw or bearing for binding (PL 11.18).
• Pallet Lift Frame Parallelism Adjustment (ADJ 11-31)
Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter • Elevator Drive Assembly for damage, binding, or obstructions (PL 11.18).
(A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in • Elevator Drive belt for wear, damage, or contamination and that it is under ten-
order to properly diagnose the fault codes. sion (PL 11.18).
• Lift Frame is not damaged (PL 11.17).
NOTE: If the Stacker Elevator is in the home (full down) position, access to the belt will have to
be made from underneath with the High Capacity Tray open.
Press Stop. Select [Elevator up]. Press Continue. The Stacker Elevator moves up.
The display for the Stacker Elevator Motor Encoder toggles between L and H as the belt Y N
is rotated. The Stacker Elevator Motor comes on.
Y N Y N
Check the following: Press Stop. Go to the 11-703, Stacker Elevator Motor RAP.
• Encoder Sensor is clean and is not obstructed (PL 11.19).
• Encoder Flag is not loose or broken (PL 11.19).
• Lead screw or bearings for binding (PL 11.18).
• Encoder Sensor and Flag alignment.
A B C
B C
• Pallet Lift Frame Parallelism Adjustment (ADJ 11-31) • Elevator Drive belt for wear, damage, or contamination and that it is under tension (PL
• Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19). 11.18).
• Elevator Drive Belt for wear, damage, contamination, and under proper tension
(PL 11.18).

• Elevator Drive Assembly for damage, binding, or obstructions (PL 11.18).
• Elevator Drive belt for wear, damage, contamination, and under proper tension (PL
11.18).
Ensure that the Stacker Elevator Down Sensor is blocked by the flag on the lift frame. The
Stacker Elevator Down Sensor display is H.
Y N
Go to Flag 4. Check the circuit of the Stacker Empty Sensor, Q1130 (GP 6-2, General
Procedures) (PL 11.18).
Block the Stacker Empty Sensor. The Stacker Empty Sensor display changes from L to H.
Y N
Go to Flag 2. Check the circuit of the Stacker Empty Sensor, Q1130 (GP 6-2, General
Procedures) (PL 11.18).
WARNING
Select [Elevator up]. Press Continue. The Stacker Elevator moves up.
Y N
Y N

• Lead screw or bearings for binding (PL 11.18).
• Elevator Drive Belt for wear, damage, or contamination and that it is under tension
(PL 11.18).

• Lift Frame for damage (PL 11.17).



A B C
11-223 RAP Press Stop. Check the following:
Stacker A Fault Code, 11-223-1, Stacker B Fault Code, 11-223-2, Stacker C Fault Code, 11- • Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).
223-3, or Stacker D Fault Code, 11-223-4, indicates either one of the following problems:
• Elevator Drive belt for wear, damage, or contamination and that it under tension
(PL 11.19).
The Stacker Elevator failed to interrupt the Stack Height Sensor, Q1122, within 28 seconds
after the Stacker Elevator Motor, MOT1106, was energized to drive the elevator up. • Lift Frame is not damaged (PL 11.17).
The Stacker Elevator failed to reach the Stacker Elevator Down Sensor, Q1135, within 18 sec- Press Stop. Select [Elevator up]. Press Continue. The Stacker Elevator moves up.
onds after the Stacker Elevator Motor, MOT1106, was energized to drive the elevator down. Y N
Y N
Initial Actions Press Stop. Go to the 11-703, Stacker Elevator Motor RAP.
WARNING
Keep fingers/hands away from moving elevator parts. Press Stop. Check the following:
Check the following: • Lead screw or bearings for binding (PL 11.18).
• Stacker Elevator is not obstructed • Elevator Drive Belt for wear, damage, or contamination and that it is under ten-
• Stacker Doors close and latch correctly. sion (PL 11.18).
• Lift Frame is not damaged. • Lift Frame is not damaged (PL 11.17).
Procedure Press Stop. Check the following:
Enter dC330, [Stacker X], [11X2]. Block the Stack Height Sensor. • Lead screw or bearing for binding (PL 11.18).
NOTE: The following procedure can be used for fault codes that may appear in any of the • Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).
Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter • Elevator Drive belt for wear, damage, or contamination and that it is under tension
(A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in (PL 11.18).
order to properly diagnose the fault codes. • Lift Frame is not damaged (PL 11.17).
The Stack Height Sensor display changes from L to H.
Select [Elevator up]. Press Continue. The Stacker Elevator moves up.
Y N
Go to Flag 1. Check the Stack Height Sensor circuit (GP 6-2, General Procedures) (PL Y N
11.30). The Stacker Elevator Motor comes on.
Y N
Block the Stacker Elevator Down Sensor. The display changes from L to H. Press Stop. Go to the 11-703, Stacker Elevator Motor RAP.
Y N
Go to Flag 2. Check the Stacker Elevator Down Sensor circuit (Generic Switch RAP GP
6-1, General Procedures) (PL 11.18). • Lead screw or bearings for binding (PL 11.18).
Observe the position of the Elevator Lift Frame. The Lift Frame is in the home (down) posi- • Elevator Drive Belt for wear, damage, or contamination and that it is under tension
tion. (PL 11.18).
Y N
WARNING Press Stop. Check the following:
Use caution when working near the motor. The Stacker Elevator Motor may run • Lead screw or bearing for binding (PL 11.18).
automatically. There is an internal thermal sensor that opens when the motor over- • Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).
heats. When the motor cools, the thermal sensor will close, allowing power to the • Elevator Drive belt for wear, damage, or contamination and that it is under tension (PL
motor. The outside surfaces of the motor could also be very hot. 11.18).
Select [Elevator Down]. Press Continue. The Stacker Elevator moves down. • (ADJ 11-31), Pallet Lift Frame Parallelism Adjustment
Y N
Y N
A B C

11-224 RAP
Stacker A Fault Code, 11-224-1, indicates that the Stacker Module Top Cover was sensed
open while Stacker A was in use.
Stacker B Fault Code, 11-224-2, indicates that the Stacker Module Top Cover was sensed
open.
Stacker C Fault Code, 11-224-3, indicates that the Stacker Module Top Cover was sensed
open.
Stacker D Fault Code, 11-224-4, indicates that the Stacker Module Top Cover was sensed
open.
Initial Actions
• Top Cover closes correctly and is not obstructed.

• Top Cover hinges for damage and that the pins are secure.
• Interlock actuator aligns with switch and is not damaged,
• Bypass Transport baffles are seated correctly.
• Interlock mounting bracket is not damaged.
Procedure
Enter dC330, [Stacker X], [11X1]. Close the Top Cover.
The Top Cover Interlock SW display indicates a L.

Y N
Open the Top Cover. Manually actuate the Top Cover Interlock. The display changes
from H to L.
Y N
Go to Flag 1. Check the Top Cover Interlock circuit (GP 6-2, General Procedures)
(PL 4.14).

• Top Cover Interlock adjustment, (ADJ 4-3).
• Top Cover and hinges for damage (PL 4.14).
Check the Top Cover/actuator to switch alignment.


A B C
11-228, 11-229 RAP Go to Flag 1. Check the Stacker Left Door Interlock circuit (Generic Switch RAP GP
6-1, General Procedures, (PL 4.12).
Stacker A Fault Code, 11-228-1, indicates that the Stacker Left Door Interlock Switch, S1163A,
deactuated with print in process to the Stacker bin. Check the following:
• (ADJ 4-5), Left Door Interlock adjustment
Stacker B Fault Code, 11-228-2, indicates that the Stacker Left Door Interlock Switch, S1163B, • Front Door and hinges for damage (PL 4.12).
deactuated with print in process to the Stacker bin.
The Stacker RH Door INTLK SW display indicates a L.
Stacker C Fault Code, 11-228-3, indicates that the Stacker Left Door Interlock Switch, S1163C, Y N
deactuated with print in process to the Stacker bin. Open and close the Right Door several times. The display changes from H to L.
Y N
Stacker D Fault Code, 11-228-4, indicates that the Stacker Left Door Interlock Switch, S1163D, Remove the Stacker Front Cover assembly. Check the interlock actuator hardware
deactuated with print in process to the Stacker bin. for proper actuation of the interlock switch. The switch is being actuated properly.
Y N
Stacker A Fault Code, 11-229-1, indicates that the Stacker Right Door Interlock Switch, Repair or replace the defective components (PL 4.12).
S1138A, deactuated with a print in process to the Stacker bin.
Go to Flag 2. Check the Stacker Right Door Interlock circuit (Generic Switch RAP
Stacker B Fault Code, 11-229-2, indicates that the Stacker Right Door Interlock Switch, GP 6-1, General Procedures), (PL 4.12).
S1138B, deactuated with a print in process to the Stacker bin.
Stacker C Fault Code, 11-229-3, indicates that the Stacker Right Door Interlock Switch, • (ADJ 4-5), Right Door Interlock adjustment
S1138C, deactuated with a print in process to the Stacker bin.
• Front Door and hinges for damage (PL 4.12).
Stacker D Fault Code, 11-229-4, indicates that the Stacker Right Door Interlock Switch,
S1138D, deactuated with a print in process to the Stacker bin.
• Magnets and strike plates are not missing or damaged (PL 4.12).
• Obstructions keeping doors from closing fully.
Initial Actions
• Front Doors close correctly and are not obstructed.

• Front Door hinges for damage and that the pins are secure.
• Interlock mounting bracket is not damaged.
• Interlock Switch connectors are not loose or pulled off.
• The Stacker Door Interlocks are adjusted properly, (ADJ 4-5).
Procedure
Enter dC330, [Stacker X], [11X1]. Close the Stacker Front Doors.
The Stacker LH Door INTLK SW display indicates a L.

Y N
Open and close the Left Door several times. The display changes from H to L.
Y N
Remove the Stacker Front Cover assembly. Check the interlock actuator hardware
for proper actuation of the interlock switch. The switch is being actuated properly.
Y N
Repair or replace the defective components (PL 4.12).
A B C

A
11-231 RAP • dC131 FSN1, address location 176 value in the appropriate level Software dC 131
Table in General Procedures.
Stacker A Fault Code, 11-231-1, indicates that there were no transitions in 117 steps seen on • Disk shaft for binding (PL 11.30)
the Disk Home Sensor, Q1121A. There were too many steps required to find the disk home
• Disk Gate Cam Follower binding on the Disk Shaft (PL 11.30)
position.
• Disk Drive Coupling (PL 11.30)
Stacker B Fault Code, 11-231-2, indicates that there were no transitions in 117 steps seen on • Stack Height Adjustment, (ADJ 11-27)
the Disk Home Sensor, Q1121B. There were too many steps required to find the disk home • Stack is not binding against Disk. Check the Stacker Disk Gate Height Adjustment
position. (ADJ 11-25)
If OK, go to the 11-700, Disk Motor RAP.
Stacker C Fault Code, 11-231-3, indicates that there were no transitions in 117 steps seen on
the Disk Home Sensor, Q1121C. There were too many steps required to find the disk home Press Stop. Enter dC330, [Stacker X], [11X1]. Block the Disk Sheet Sensor. The Disk Sheet
position. Sensor display changes from L to H.
Y N
Stacker D Fault Code, 11-231-4, indicates that there were no transitions in 117 steps seen on Go to Flag 1. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL
the Disk Home Sensor, Q1121D. There were too many steps required to find the disk home 11.30).
position.
Initial Actions • Disk shaft for binding (PL 11.30)
Check the following: • Disk Gate Cam Follower binding on the Disk Shaft (PL 11.30)
• Disk Home Adjustment (ADJ 11-25)
• Binding of the Disk shaft
• Disk Drive Coupling (PL 11.30)
• Excessive upcurl of the stack causing the Disk to bind
• Stack Height Adjustment, (ADJ 11-27)
• Disk Home Sensor is clean and not obstructed
• Stack is not binding against Disk.
• Disk Home Sensor actuator for damage
• Disk Entrance Gate Height Adjustment, (ADJ 11-26)
• Disk Drive Coupling assembly loose or damaged
• Disk Home Sensor actuator for damage or obstructions (PL 11.30)
Procedure • Disk Assembly for damage (PL 11.30)
A Stacker Elevator which is not indexing down can cause a 11-231 fault. If Stacker Elevator
fault codes 11-221,222,or 223 are occurring, go to the respective RAP. If messages indicating
problems with the stacker elevators are occurring, go to the 11-222 RAP.
Enter dC330, [Stacker X], [11X1]. Rotate the disk to block the Disk Home Sensor.
The display changes from L to H.

Y N
Go to Flag 2. Check the Disk Home Sensor circuit (GP 6-2, General Procedures) (PL
11.30).
Enter dC203. Select [Stacker Disk], [Stacker X], [7 Pitch or 3 Pitch], [Continuous Run].
Press Continue. Observe the Disk Module for several cycles. The Disk Module cycles
smoothly and the measured times are consistent and fall within the expected range.
Y N
The Disk Motor comes on.
Y N
Press Stop. Go to the 11-700, Disk Motor RAP.

A

11-232, 11-233 RAP Y N
The Right Guide Motor comes on.
Stacker A Fault Code, 11-232-1, indicates that the Right Guide Home Sensor, Q1132A, Y N
remained blocked after 100 steps of the Right Guide Motor, MOT1105A. Press Stop. Go to the 11-702, Right Guide Motor RAP.
Stacker B Fault Code, 11-232-2, indicates that the Right Guide Home Sensor, Q1132B, Press Stop. Check the following:
remained blocked after 100 steps of the Right Guide Motor, MOT1105B.
NOTE: Use Parts List (PL 11.9).
Stacker C Fault Code, 11-232-3, indicates that the Right Guide Home Sensor, Q1132C, • Right Guide positioning mechanism for binding.
remained blocked after 100 steps of the Right Guide Motor, MOT1105C.
• Drive Belt for wear, damage, or contamination and that it is set to the correct tension.
Stacker D Fault Code, 11-232-4, indicates that the Right Guide Home Sensor, Q1132D, • Lead screw for binding.
remained blocked after 100 steps of the Right Guide Motor, MOT1105D. • Drive pulley for slippage on shaft.
• Rails for binding.
Stacker A Fault Code, 11-233-1, indicates that the Right Guide Home Sensor, Q1132A, • Coil cord not catching.
remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Right Guide Motor,
MOT1105A. Press Stop. Check the Right Guide mechanism for parallel to the Rear Frame. The mecha-
nism is parallel.
Stacker B Fault Code, 11-233-2, indicates that the Right Guide Home Sensor, Q1132B, Y N
remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Right Guide Motor, Perform (ADJ 11-28), Right Guide adjustment.
MOT1105B.
Stacker C Fault Code, 11-233-3, indicates that the Right Guide Home Sensor, Q1132C,
remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Right Guide Motor, NOTE: Use Parts List (PL 11.9).
MOT1105C.
• Drive belt for wear, damage, contamination, and correct tension.
Stacker D Fault Code, 11-233-4, indicates that the Right Guide Home Sensor, Q1132D, • Drive pulley for slippage on shaft.
remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Right Guide Motor, • Rails for binding.
MOT1105D. • Lead Screws for binding.
Initial Actions
• Right Guide for obstructions

• Right Guide Home Sensor is clean and is not obstructed.
• Flag is not damaged and is aligned to the sensor.
Procedure
Enter dC330, [Stacker X], [11X2]. Block the Right Guide Home Sensor.
The Right Guide Home Sensor display changes from L to H.

Y N
Go to Flag 1. Check the Right Guide Home Sensor circuit (GP 6-2, General Procedures)
(PL 11.9).
Enter dC203. Select [Edge Guides], [Stacker X], [Right Guide], [Continuous Run]. Press
Continue. The Right Guide moves forward and backward.


11-237, 11-238 RAP Y N
The Back Guide Motor comes on.
Stacker A Fault Code, 11-237-1, indicates that the Back Guide Home Sensor, Q1133A, Y N
remained blocked after 100 steps of the Back Guide Motor, MOT1105A. Press Stop. Go to the 11-701, Back Guide Motor RAP.
Stacker B Fault Code, 11-237-2, indicates that the Back Guide Home Sensor, Q1133B, Press Stop. Check the following:
remained blocked after 100 steps of the Back Guide Motor, MOT1105B. • Back Guide positioning mechanism for binding (PL 11.7).
• Drive Belt for wear, damage, or contamination and that it is set to the correct tension
Stacker C Fault Code, 11-237-3, indicates that the Back Guide Home Sensor, Q1133C, (PL 11.7).
remained blocked after 100 steps of the Back Guide Motor, MOT1105C.
• Lead screw for binding (PL 11.7).
Stacker D Fault Code, 11-237-4, indicates that the Back Guide Home Sensor, Q1133D, • Drive pulley for slippage on shaft (PL 11.7).
remained blocked after 100 steps of the Back Guide Motor, MOT1105D. If OK, go to the 11-701, Back Guide Motor RAP.
Stacker A Fault Code, 11-238-1, indicates that the Back Guide Home Sensor, Q1133A, Press Stop. Check the Back Guide mechanism for parallel to the Rear Frame. The mecha-
remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor, nism is parallel.
MOT1105A. Y N
Perform (ADJ 11-29), Back Guide adjustment.
Stacker B Fault Code, 11-238-2, indicates that the Back Guide Home Sensor, Q1133B,
remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor, Check the following:
MOT1105B. • Drive belt for wear, damage, contamination, and correct tension (PL 11.7).
• Drive pulley for slippage on shaft (PL 11.7).
Stacker C Fault Code, 11-238-3, indicates that the Back Guide Home Sensor, Q1133C, • Lead screw for binding (PL 11.7).
remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor,
MOT1105C.
Stacker D Fault Code, 11-238-4, indicates that the Back Guide Home Sensor, Q1133D,
remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor,
MOT1105D.
Initial Actions
• Back Guide for obstructions

• Back Guide Home Sensor is clean and is not obstructed.
• Flag is not damaged and is aligned to the sensor.
Procedure
Enter dC330, [Stacker X], [11X2]. Block the Back Guide Home Sensor.
The Back Guide Home Sensor display changes from L to H.

Y N
Go to Flag 1. Check the Back Guide Home Sensor circuit (GP 6-2, General Procedures)
(PL 11.7).
Enter dC203. Select [Edge Guides], [Stacker X], [Back Guide], [Continuous Run]. Press
Continue. The Back Guide moves forward and backward.


A B C
11-242 RAP The Front Tamper motor comes on.
Y N
Stacker A Fault Code, 11-242-1, indicates that there was a Front Tamper positioning failure Select [Clear Outputs]. Go to the 11-704, Front Tamper Motor RAP.
after the second attempt to extend or retract the Front Tamper Fingers. The Front Tamper
Clutch actuated without the Front Tamper Position Sensor, Q1135A, transitioning within Select [Clear Outputs]. Check the following:
200ms. • Bearing for binding (PL 11.8).
• Front Tamper positioning mechanism for binding (PL 11.8).
Stacker B Fault Code, 11-242-2, indicates that there was a Front Tamper positioning failure
• Drive coupling for damage (PL 11.8).
Clutch actuated without the Front Tamper Position Sensor, Q1135B, transitioning within • Drive coupling for slippage on shaft (PL 11.8).
200ms. • Clutch Drive Gear for damage (PL 11.8).
• Proper Right Guide positioning. Check the Right Guide Adjustment (ADJ 11-
Stacker C Fault Code, 11-242-3, indicates that there was a Front Tamper positioning failure 28).
Clutch actuated without the Front Tamper Position Sensor, Q1135C, transitioning within The Front Tamper Position Sensor display toggles as the Tampers extend and
200ms. retract.
Y N
Stacker D Fault Code, 11-242-4, indicates that there was a Front Tamper positioning failure Select [Clear Outputs]. Go to Flag 1. Check the Front Tamper Position Sensor cir-
after the second attempt to extend or retract the Front Tamper Fingers. The Front Tamper cuit (GP 6-2, General Procedures) (PL 11.8).
Clutch actuated without the Front Tamper Position Sensor, Q1135D, transitioning within
200ms. Select [Clear Outputs]. Check the following:
• Bearing for binding (PL 11.8).
Initial Actions • Front Tamper positioning mechanism for binding (PL 11.8).
Check the following: • Drive coupling for slippage on shaft or damage (PL 11.8).
• Clutch Drive Gear for damage (PL 11.8).
• Tamper Linkage Arm Short Shafts. Ensure that the shafts have not come out of position.
• Tamper Position Sensor is clean and is not obstructed. Press Stop. Check the following:
• Tamper finger area for obstructions. • Front Tamper positioning mechanism for intermittent binding (PL 11.8).
• Guides are not too tight against stack. • Drive coupling for slippage on shaft or damage (PL 11.8).
• Gears for wear or damage. • Clutch Drive Gear for damage (PL 11.8).
• Linkages for binding. • Proper Right Guide positioning. Check the Right Guide Adjustment (ADJ 11-28).
• Drive Coupling is not loose.
Procedure
Enter dC203, [Tamper Fingers], [Stacker X], [Tamper Front], [Continuous Cycle]. Press
Continue.
The Front Tampers extend and retract correctly within the expected times.
Y N
Enter dC330, [Stacker X], [11X2], [Front Tamper] motor. Press Continue. Select [Off-
set FWD] clutch. Press Continue. The Tamper fingers extend and retract correctly.
Y N
The Front Tamper Clutch energized.
Y N
Select [Clear Outputs]. Go to Flag 2. Check the Front Tamper Clutch circuit
(Generic Clutch RAP GP 6-3, General Procedures) (PL 11.8).
A B C

A B
11-244 RAP • Proper positioning of Tampers against stack. Check the Back Guide Adjust-
ment, (ADJ 11-29).
Stacker A Fault Code, 11-244-1 indicates that there was a Back Tamper positioning failure • Bearing for binding (PL 11.7).
after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper
• Back Tamper positioning mechanism for binding (PL 11.7).
Clutch actuated without the Back Tamper Position Sensor, Q1134A, transitioning within 100ms.
• Drive Belt for wear, damage, contamination, and correct tension (PL 11.7).
Stacker B Fault Code, 11-244-2, indicates that there was a Back Tamper positioning failure • Drive pulley for slippage on shaft (PL 11.7)
after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper • Clutch Drive Gear for damage (PL 11.7).
Clutch actuated without the Back Tamper Position Sensor, Q1134B, transitioning within 100ms.
The Back Tamper Position Sensor display toggles.
Stacker C Fault Code, 11-244-3 indicates that there was a Back Tamper positioning failure Y N
after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper Select [Clear Outputs]. Go to Flag 1. Check the Back Tamper Position Sensor cir-
Clutch actuated without the Back Tamper Position Sensor, Q1134C, transitioning within 100ms. cuit (GP 6-2, General Procedures) (PL 11.7).
Stacker D Fault Code, 11-244-4, indicates that there was a Back Tamper positioning failure Select [Clear Outputs]. Check the following:
after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper • Bearing for binding (PL 11.7).
Clutch actuated without the Back Tamper Position Sensor, Q1134D, transitioning within 100ms. • Back Tamper positioning mechanism for binding (PL 11.7).
• Drive Belt for wear, damage, contamination, and correct tension (PL 11.7).
Initial Actions • Drive pulley for slippage on shaft (PL 11.7).
• Clutch Drive Gear for damage (PL 11.7).
• Tamper Linkage Arm Short Shafts. Ensure that they are positioned properly.
• Tamper Position Sensor is clean and is not obstructed. • Back Guide Adjustment (ADJ 11-29).
• Tamper finger area for obstructions. • Back Tamper positioning mechanism for intermittent binding (PL 11.7).
• Gears for wear or damage. • Drive Belt for wear, damage, contamination, and correct tension (PL 11.7).
• Tamper drive belt has tension. • Drive pulley for slippage on shaft (PL 11.7).
Procedure • Clutch Drive Gear for damage (PL 1.7).
Enter dC203, [Tamper Fingers], [Stacker X], [Back Tamper], [Continuous Run]. Press the
Continue button.
The Back Tampers extend and retract correctly within the expected times.
Y N
Press Stop. Enter dC330, [Stacker X], [11X2], [Offset Back] clutch. Press Continue.
Select [Back Tamper] motor. Press Continue. The Tamper fingers extend and retract
correctly.
Y N
The Back Tamper Clutch energized.
Y N
Select [Clear Outputs]. Go to Flag 2. Check the Back Tamper Clutch circuit
(Generic Clutch RAP GP 6-3, General Procedures), (PL 11.7).
The Back Tamper motor comes on.

Y N
Select [Clear Outputs]. Go to the 11-705, Back Tamper Motor RAP.

A B

11-250-1 RAP
Fault code, 11-250-1, indicates that +24 VDC is missing in the Inverter Feeder/Stacker (mod-
ule A).
Initial Actions
• Check the queued faults for 1-220 or 10-216. If they are present, go to the appropriate
RAP.
Procedure
+24 VDC is measured between the orange and violet sides of A-TB7.
Y N
Y N
Go to the 1-717 +24, +34, and -34 VDC RAP.

Y N
Enter dC330, [11A2]. Disconnect P4069 from J6 on the FSN DIO PWB #3A. Connect a jumper
wire from TS32 to TS37 on the PWB. The F/S LVPS Monitor display is L.
Y N
Replace the FSN DIO PWB #3A (PL 1.17).
Go to Flag 5. Check the wires for an open circuit. If OK, replace the 24 LVPS Sensor, Q1162
(PL 1.16).


11-250-2 RAP
Stacker B fault code, 11-250-2, indicates that a loss of +24 VDC has been detected in the
Feeder/Stacker module. The Printer will enter the Power Interrupt mode when this fault occurs.
Initial Actions
• Connect a jumper wire between TS53 and TS37 on the PHN DIO PWB #2 before starting
the procedure. If directed to the 1-719 RAP, leave the jumper in place. Remove the
jumper when the fault is corrected.
Procedure
The 24V LVPS Cooling Fan, MOT108, is operating.
Y N
Go to the 1-719, F/S 24VDC RAP.

Y N

Y N
Enter dC330, [11B2]. Observe the F/S LVPS Monitor display. Connect a jumper wire between
TS 32 and TS 37 on the FSN DIO PWB #3B. The F/S LVPS Monitor display toggles from H
to L.
Y N
Go to Flag 3. Check the wires for a short circuit. If OK, replace the FSN DIO PWB #3B
(PL 1.16).
Go to Flag 3. Check the wires for an open circuit. If OK, replace the 24 VDC Sensor, Q1162
(PL 1.16).


11-250-3 RAP
Stacker C fault code, 11-250-3, indicates that a loss of +24 VDC has been detected in the
Initial Actions
Procedure
Y N

Y N

Y N
Enter dC330, [Stacker C], [11C2]. Observe the F/S LVPS Monitor display. Connect a jumper
wire between TS 32 and TS 37 on the FSN DIO PWB #3C. The F/S LVPS Monitor display
toggles from H to L.
Y N
Go to Flag 3. Check the wires for a short circuit. If OK, replace the FSN DIO PWB #3C
(PL 1.16).
(PL 1.16).


11-250-4 RAP
Stacker D fault code, 11-250-4, indicates that a loss of +24 VDC has been detected in the
Initial Actions
Procedure
Y N

Y N

Y N
Enter dC330, [Stacker X], [11D2]. Observe the F/S LVPS Monitor display. Connect a jumper
wire between TS 32 and TS 37 on the FSN DIO PWB #3D. The F/S LVPS Monitor display
toggles from H to L.
Y N
Go to Flag 3. Check the wires for a short circuit. If OK, replace the FSN DIO PWB #3D
(PL 1.16).
(PL 1.16).


11-270-2 RAP
Fault Code, 11-270-2, indicates that a stray print arrived at the Purge Transport Sensor,
Q1164B, unexpectedly. This fault is logged in NVM only.
Initial Actions
• The Purge Transport Sensor is clean and is not obstructed.

• Jam clearance baffles for damage and that they are seated correctly.
Procedure
Observe the prints entering the Bypass Transport. The prints are free from damage and are
not skewed.
Y N
Enter dC330, [11A1]. Block the Stacker A Bypass Transport Sensor. The display changes
from L to H.
Y N
(PL 11.29).
Select [11B2]. Block the Purge Transport Sensor. The display changes from L to H.
Y N
(PL 11.12).
Y N
Y N
Press Stop. Go to Flag 3. Check the Bypass Gate Solenoid circuit (Generic Sole-
noid RAP GP 6-3, General Procedures), (PL 11.12).

Press Stop. Check the Bypass Gate Solenoid RAP circuit for an intermittent condition.


11-600 Poor Stacking Quality RAP CAUTION
If the Customer is senstive to offset stacking quality, perform the following step. However, note
Procedure that as short report/jobs run, perform degradation may be experienced when the following step
1. Check the following: is performed.
• Quality of the paper supply. Ensure that the paper falls within the capabilities of the 6. Enter dC131 [EDN]. Change EDN location 494 from 000 to 001. The (Skip Pitch Mode) is
Printer. Refer to the System Specifications. now enabled.
• Printer to IF/S Alignment.
• Ensure that the Right Guide Tamper Motor is working. Use dC330, [Tamper Front].
If not OK, go to the 11-704.
• Lift Frame for damage. Ensure that it is not broken or bent and that it is keeping the
pallet level.
• Main Pallet or Container Pallet is seated properly. Ensure that the locating studs on
the lift frame line up properly with the locating holes.
• Pallet Lift Frame Parallelism adjustment, (ADJ 11-31).
NOTE: It may be beneficial to remove the Stacker Front Cover and view the Stacker while
stacking. Bypass the Feeder/Stacker Interlocks.
2. Match the sketch and problem descriptions shown in Figure 1 with what best describes
the defects that are occurring. The table below will reference the appropriate RAP.
Table 1
Problem Description RAP
1. Sloppy set, side-to-side Go to the 11-601 RAP
2. Sloppy set, skewed sheets Go to the 11-602 RAP
3. Sloppy set, front-to-back Go to the 11-603 RAP
4. Bottom sheet misregistration Go to the 11-604 RAP
5. Clumped misregistration, top of set Go to the 11-605 RAP
6. Shingled set/stack Go to the 11-606 RAP
7. Sloppy set, curled prints Go to the 11-607 RAP
8. Random misregistration Go to the 11-608 RAP
9. Rolled or folded prints 8.5X11 or A4 Go to the 11-609 RAP
10. Rolled or folded prints 11X17 or A3 Go to the 11-610 RAP
11. Sloppy Set, all sides. Elevator too low Go to the 11-611 RAP
Sloppy Offset Stacking (7 X 11 Paper) Go to the 11-612 RAP
3. To set the Printer to use 7 X 10 paper, enter dc105. Under the Features icon, select 7x10
F2.
4. When using 7 X 10 paper, the stacking quality may be poor when:
a. Printing short report/jobs which require short offsetting time between jobs.
b. Light weight paper is usedd, less than 20 lb. (75 g/m).
• If stacking quality is poor, continue with Step 5.
5. The DP180LPS IOT software is enabled with a feature that allows the Stacker to “Skip” a
pitch (Skip Pitch Mode) before the Stacker offsets to the next stack. This allows for the
last sheet to settle on the stack before the next offset occurs.

Figure 1 11-600 Stacking Quality Diagram

11-601 Sloppy Set, Side-To-Side RAP 11-602 Sloppy Set, Skewed Sheets RAP
Perform the following: Check the following:
• Check the quality of the paper supply. • Preregistration baffle is closed.

Procedure • Right Guide is square to the stack. Perform the Right Guide Adjustment (ADJ 11-28).
Check the following: • The scatter guards are positioned properly and that they are not binding.
• The pallet is level front to back. Check the Pallet Lift Frame Parallelism Adjustment (ADJ
• Excessive paper curl of the prints entering the stacker. Refer to the Physical Checks, Print 11-31).
Paper Diagnostics (Service Call Procedures). • Stack Height Adjustment, (ADJ 11-27).
• The Front and Back Tampers are positioned properly and are not damaged.
• The Right Guide Tamper Motor is working. Use dC203 to check for proper operation. (The
Right Guide Tamper Motor is energized with the Front Tamper Motor).
• Right Guide Adjustment, (ADJ 11-28).
• The Stack Height Sensor toggles in dC330.
• Stack Height Adjustment, (ADJ 11-27).

11-603 Sloppy Set, Front-To-BacK RAP 11-604 Bottom Sheet Misregistration RAP
Perform the following: Check the following:
• Check the quality of the paper supply. • Possible high static condition on the pallet. Clean the Pallet.
Procedure • Check the static eliminators in the paper path. Go to the (TBD) Procedure.
• Excessive paper curl. Refer to the Physical Checks, Print Paper Diagnostics (Service Call
Procedures).
• Perform the Back Guide Adjustment (ADJ 11-29).
• The Front and Back Tampers are working properly in dC203.
• The scatter guards are positioned properly and not binding.
• The prints are being registered against the registration edge on the Preregistration Trans-
port. Check the Corrugator Rolls for wear or contamination. Check the Corrugator Rolls
Adjustment, (ADJ 11-6)

11-605 Clumped Registration, Top Of Set RAP 11-606 Shingled Set/Stack RAP
Ensure that the Edges Guides are not too tight. Check the following: Perform the following:
• Back Guide Adjustment (ADJ 11-29). • Ensure that the pallet is positioned properly.
• Right Guide Adjustment (ADJ 11-28). Procedure
• Tamper Finger Short Shaft is in proper position. Ensure that it has not come out of its Check the following:
mounting tabs.
• Right Guide Adjustment (ADJ 11-28).
• Back Guide Adjustment (ADJ 11-29)
• Feeder/Stacker Leveling Adjustment (ADJ 11-27).

11-607 Sloppy Set, Curled Prints RAP 11-608 Random Misregistration RAP
Check the following: Perform the following:
• Refer to the Physical Checks, Print Paper Diagnostics (Service Call Procedures). • Check the quality of the paper supply.
Procedure
NOTE: The Stacker offsets one sheet after every jam. Do not confuse this with random misreg-
istration.
• Back Guide Adjustment (ADJ 11-29).

• Right Guide Adjustment (ADJ 11-28).
• Stack Height Adjustment (ADJ 11-27).
• Excessive curl. Go to the Physical Checks, Print Paper Diagnostics (Service Call Proce-
dures)

11-609 Rolled Or Folded Prints RAP 8.5X11 OR A4 11-610 Rolled Or Folded Prints RAP 11X17 OR A3
• Ensure that there are no obstruction in the paper path. • Ensure that there are no obstructions in the paper path.
Procedure Procedure
Check the following: Check the following:
• Bypass Transport Gate for proper operation. Ensure that it is not binding. • Trail Edge Assist assembly for proper operation. Ensure that the belts are tracking prop-
• Disk Gate for proper operation. Ensure that the Cam Follower is working properly. erly and are not slipping.
NOTE: The smooth side of the belts should ride on the drive rollers.
• Bypass Transport Gate and Disk Gate for proper operation. Ensure that they are not bind-
ing.
• Perform the Stack Height Sensor Adjustment (ADJ 11-27).

11-611 Sloppy Set, Elevator Too Low RAP 11-612 Poor Stacking Quality (7X10 Paper) RAP
Procedure The purpose of the 11-612 RAP is to improve on what the customer views as poor Offset Qual-
ity when 7 X 10 paper stock is used.
Enter dC330, [11X2]. Block the Stack Height Sensor. The Stack Height Sensor display
Y N Initial Actions
Go to the 11-222. Go to Flag 5 on the Circuit Diagram and check the circuit of the Stack Check the following:
Height Sensor.
• Quality of the paper supply. Ensure that the paper falls within the capabilities of the
Check the following: Printer. Refer to the System Specifications.
• Excessive Curl or bent corners. Go to the Physical Checks, Print Paper Diagnostics (Ser- • Printer to IF/S Alignment.
vice Call Procedures).
• Ensure that the Right Guide Tamper Motor is working. Use dC330, [Tamper Front]. If not
• Image build-up. If one area of the prints has most of the image, in a large stack this area OK, go to the 11-704.
will protrude upward and possibly cause the Stack Height Sensor to overcompensate.
• Lift Frame for damage. Ensure that it is not broken or bent and that it is keeping the pallet
• Stack Height Adjustment (ADJ 11-27). level.
If the problem continues only when the stack is near maximum capacity, the stack height can • Main Pallet or Container Pallet is seated properly. Ensure that the locating studs on the lift
be limited to avoid poor stacking. See the Operators Manual for the procedure. frame line up properly with the locating holes.
• Go to (ADJ 11-31) and perform the Pallet Lift Frame Parallelism adjustment.
Procedure
NOTE: It may be beneficial to remove the Stacker Front Cover and view the Stacker while
stacking. Bypass the Feeder/Stacker Interlocks.
1. Stacking quality may be poor and especially noticeable using 7 X 10 paper when:
a. Printing short report/jobs which require short offsetting time between jobs.
b. Light weight paper is used, less than 20 lb. (75 g/m).
2. The DP180LPS IOT software is enabled with a feature that allows the Stackers to “Skip” a
pitch (Skip Pitch Mode) before the Stacker offsets to the next stack. This allows time for
the last sheet to settle on the stack before the next offset occurs.
3. Before initiating the Skip Pitch Mode, ensure that the steps in the Initial Actions have been
completed to eliminate causes for poor stacking quality.
CAUTION
If the Customer is sensitive to the offset stacking quality, perform the following step. Advise the
customer that performance degradation may be experienced (jobs will run and stack slower)
with the Skip Pitch Mode enabled.
4. To enable the Skip Pitch Mode, enter dC131 [EDN]. Change EDN location 494 from
default 000 to 001, (7 X 10, 8Pitch Enablement).

11-700 Disk Motor, MOT1103 RAP Y N
Switch off the Printer Power. Disconnect wire # 64H from P444-8 at the FSN Stepper
The purpose of the Disk Motor RAP is to aid in the troubleshooting of Disk Motor and related PWB. Switch on the Printer power. Wait for printer to complete initialization. +24 VDC is
control circuitry. This RAP is designed to be used for the Disk Motor of any Stacker module. measured between wire #64H (+) (Stacker A) or wire #88A (+) (Stacker B,C,D) and
The correct module letter (A/B) must be inserted into the procedure instructions (in place of X) TS9 (-) on the FSN Stepper PWB.
and circuit diagram component designators order to properly diagnose the fault. Y N
(Stacker A) +24 VDC is measured between TH11 (+) and TH14 (-) on the LVPS.
Initial Actions (Stacker B,C,D) +24 VDC is measured between J136-23 (+) and J136-5 (-).
(Stacker A) Go to the 1-717, +24, -34, +34VDC RAP.
• Disk Motor for physical damage. (Stacker B,C,D) Go to the 1-719, Feeder/Stacker #2 +24 VDC RAP.
• Defective bearing causing the motor shaft to sound rough or to be bound when rotated by
(Stacker A) Go to the Wirenets (Wiring Data). Check the wire #64H for an open cir-
hand.
cuit.
• Disk mechanism rotates smoothly and there are no obstructions that interfere with the (Stacker B, C, D) Go to the Wirenets (Wiring Data). Check the wire #88A for an open
rotation of the disk Module. circuit.
• Motor to disk drive coupling hardware is OK.
Procedure Go to Flag 2 and Flag 3. Check the wires for a short circuit. If a short circuit is found,
repair the wires and then replace the FSN Stepper PWB (PL 1.17). If no short circuit is
Visually inspect the component marked U13 on the FSN Stepper PWB. (It is one of the three
found in the wires, replace the Disk Motor, MOT1103 (PL 11.29) and the FSN Stepper
devices mounted to a heat sink). Look for the following:
PWB (PL 1.17).
• A bubble and/or cracks in the component.
• Burn marks and/or discoloration on the component legs. Enter the Power Interrupt mode. Disconnect P4073 from J2 on the FSN Stepper PWB. Mea-
The U13 component is OK. sure the resistance between the following points:
Y N • P4073-1 and P4073-2
There is a short circuit in the output of the FSN Stepper PWB. Do not replace the FSN • P4073-5 and P4073-6
Stepper PWB until the following checks are made and the short circuit is located.
The resistance of both measurements is between 80 and 127 ohms.
Enter the [Power Interrupt] mode. Disconnect P497 from J1 at the Disk Motor,
Y N
MOT1103. Measure the resistance between the following points:
Reconnect P4073 to the FSN Stepper PWB. Disconnect P497 from the Disk Motor. Mea-
• J1-6 and J1-5
sure the resistance between the following points:
• J1-2 and J1-1 • J1-1 and J1-2
The resistance of the above checks is between 80 and 200 ohms. • J1-5 and J1-6
Y N
Replace the Disk Motor, MOT1103 (PL 11.29) and the FSN Stepper PWB (PL 1.17).
Y N
Replace the Disk Motor, MOT1103 (PL 11.29), and if the resistance was less than 80
Go to Flag 2 and Flag 3. Locate and repair the short circuit, then replace the FSN Stepper
ohms, also replace the FSN Stepper PWB (PL 1.17).
PWB (PL 1.17).
Go to Flag 2 and Flag 3. Check the wires for an open or short circuit. If a short circuit is
Press Stop. Enter dC330, [11X1]. Disconnect P497 from the Disk Motor, MOT1103. Rotate the
found, replace the FSN Stepper PWB (PL 1.17).
Disk shaft so that the encoder disk is positioned to interrupt the Disk Home Sensor, Q1121.
The Disk Home Sensor display toggles when the sensor is interrupted.
Reconnect P4073 to the FSN Stepper PWB. Exit the Power Interrupt mode. Enter dC203,
Y N
[Stepper Motor], [Stacker X], [Stacking Disk]. Press Continue. Measure the voltage
Go to Flag 1. Check the circuit of the Disk Home Sensor, Q1121, (GP 6-2, General Proce-
between the following test stakes on the FSN Stepper PWB:
dures) (PL 11.29).
• TS27 (+) and TS9 (-)
• TS26 (+) and TS9 (-)
Reconnect P497 to the Disk Motor. +24 VDC is measured between TS24 (+) and TS9 on the
FSN Stepper PWB (#1 or #2). • TS23 (+) and TS9 (-)
• TS22 (+) and TS9 (-)

NOTE: Voltage will be applied to the motor windings sequentially for a period of 2 sec-
onds. Leave the meter probes on the test points for at least 10 seconds to ensure enough
time for the routine to energize all windings.
+24 VDC is measured between all four pairs of test stakes.

Y N
Press Stop. Replace the FSN Stepper PWB (PL 1.17).

• Binding bearings (PL 11.29).
• Wires and connectors for intermittent connections.
• Ensure that the Encoder flag is secure and has two lobes (PL 11.29).
• Ensure that the Disk Home Sensor is secure (PL 11.29).
• Disk Motor mounting hardware (PL 11.29).
• Disk Drive coupling hardware (PL 11.29).
• Disk shaft bearing failure (PL 11.29).
• Mechanical Interference.
If no problems can be found, replace the Disk Motor, MOT1103 (PL 11.29).


A B C
11-701 Back Guide Motor, MOT1104 RAP (Stacker A) Go to the Wirenets (Wiring Data). Check the wire #64J for an open cir-
cuit.
The purpose of the Back Guide Motor RAP is to aid in the troubleshooting of the Back Guide (Stacker B, C, D) Go to the Wirenets (Wiring Data). Check the wire #90A for an open
Motor and related circuitry. This RAP is designed to be used for the Back Guide Motor of any circuit.
Stacker module. The correct module letter (A/B) must be inserted into the procedure instruc-
tions (in place of X) and circuit diagram component designators order to properly diagnose the Go to Flag 2 and Flag 3. Check the wires for a short circuit. If a short circuit is found,
fault. repair the wires and then replace the FSN Stepper PWB (PL 1.16). If no short circuit is
found in the wires, replace the Back Guide Motor, MOT1104 (PL 11.6) and the FSN Step-
Initial Actions per PWB (PL 1.16).
Switch off the Printer power. Disconnect P4073 from J2 on the FSN Stepper PWB. Measure
• Back Guide Motor for physical damage. the resistance between the following points:
• P4073-13 and P4073-14
• Loose pulley on the motor.
• P4073-17 and P4073-18
hand.
Y N
• Ensure that the Offset mechanism moves freely.
Reconnect P4073 to the FSN Stepper PWB. Go to Flag 2 and Flag 3. Check the wires for
• Lead screw bearing failure causing the motor to bind due to fatigue or contamination. an open or short circuit. If a short circuit is found, replace the FSN Stepper PWB (PL
Procedure 1.16).
Visually inspect the component marked U12 on the FSN Stepper PWB. (It is one of the three If the wires are OK, replace the Back Guide Motor, MOT1104 (PL 11.6), and if the resis-
tance was less than 50 ohms, also replace the FSN Stepper PWB (PL 1.16).
Reconnect P4073 to the FSN Stepper PWB. Switch on the Printer power. Enter dC203, [Step-
• Burn marks and/or discoloration on the component legs.
per Test], [Back Guide], [Stacker X]. Press Continue. Measure the voltage between the fol-
The U12 component is OK. lowing test stakes on the FSN Stepper PWB:
Y N • TS32 (+) and TS9 (-)
There is a short circuit in the output of the FSN Stepper PWB. Do not replace the FSN
• TS31 (+) and TS9 (-)
Enter the [Power Interrupt] mode. Disconnect P499 from J1 at the Back Guide Motor, • TS29 (+) and TS9 (-)
MOT1104. Measure the resistance between the following points: • TS28 (+) and TS9 (-)
• J1-6 and J1-5
• J1-2 and J1-1 onds. Leave the meter probes on the test points for at least 10 seconds to ensure enough
The resistance of the above checks is between 80 and 200 ohms. time for the routine to energize all windings.
Y N
Replace the Back Guide Motor, MOT1104 (PL 11.6) and the FSN Stepper PWB (PL
1.16). Y N
PWB (PL 1.16). Press Stop. Check the following:
• Binding lead screws, bearings, and linkage mechanisms (PL 11.6).
+24 VDC is measured between TS30 (+) and TS9 on the FSN Stepper PWB (#1 or #2). • Check the wires for intermittent connections.
Y N If no problems can be found, replace the Back Guide Motor, MOT1104 (PL 11.6).
Switch off the Printer Power. Disconnect wire # 64K (Stacker A) or wire #90A (Stacker
B,C,D) from P444-10 at the FSN Stepper PWB. Switch on the Printer power. +24 VDC is
measured between wire #64H (or 90A) (+) and TS9 (-) on the FSN Stepper PWB.
Y N
(Stacker B,C,D) +24 VDC is measured between J136-23 (+) and J136-5 (-).
Y N
(Stacker B, C, D) Go to the 1-719, Feeder/Stacker #2 +24 VDC RAP.
A B C

A B C
11-702 Right Guide Motor, MOT1105 RAP (Stacker A) Go to the Wirenets (Wiring Data). Check the wire #64J for an open cir-
cuit.
The purpose of the Right Guide Motor RAP is to aid in the troubleshooting of the Right Guide (Stacker B, C, D) Go to the Wirenets (Wiring Data). Check the wire #89A for an open
Motor and related circuitry. This RAP is designed to be used for the Right Guide Motor of any circuit.
Stacker module. The correct module letter (A/B) must be inserted into the procedure instruc-
tions (in place of X) and circuit diagram component designators order to properly diagnose the Go to Flag 2 and Flag 3. Check the wires for a short circuit. If a short circuit is found,
fault. repair the wires and then replace the FSN Stepper PWB (PL 1.16). If no short circuit is
found in the wires, replace the Right Guide Motor, MOT1105, (PL 11.9) and the FSN Step-
Initial Actions per PWB (PL 1.16).
Switch off the Printer power. Disconnect P4053 from J2 on the FSN Stepper PWB. Measure
• Right Guide Motor for physical damage. the resistance between the following points:
• P4053-7 and P4053-8
• Loose pulley on the motor.
• P4053-11 and P4053-12
hand.
Y N
• Ensure that the Right Guide moves freely.
Reconnect P4053 to the FSN Stepper PWB. Go to Flag 2 and Flag 3. Check the wires for
• Lead screw bearing failure causing the motor to bind due to fatigue or contamination. an open or short circuit. If a short circuit is found, replace the FSN Stepper PWB (PL
Procedure 1.16).
Visually inspect the component marked U10 on the FSN Stepper PWB. (It is one of the three If the wires are OK, replace the Right Guide Motor, MOT1105, (PL 11.9), and if the resis-
tance was less than 50 ohms, also replace the FSN Stepper PWB (PL 1.16).
Reconnect P4053 to the FSN Stepper PWB. Switch on the Printer power. Enter dC203, [Step-
• Burn marks and/or discoloration on the component legs.
per Test], [Right Guide], [Stacker X]. Press Continue. Measure the voltage between the fol-
The U10 component is OK. lowing test stakes on the FSN Stepper PWB:
Y N • TS25 (+) and TS9 (-)
There is a short circuit in the output of the FSN Stepper PWB. Do not replace the FSN
• TS19 (+) and TS9 (-)
Enter the [Power Interrupt] mode. Disconnect P498 from J1 at the Right Guide Motor, • TS21 (+) and TS9 (-)
MOT1105. Measure the resistance between the following points: • TS20 (+) and TS9 (-)
• J1-6 and J1-5
• J1-2 and J1-1 onds. Leave the meter probes on the test points for at least 10 seconds to ensure enough
The resistance of the above checks is between 80 and 200 ohms. time for the routine to energize all windings.
Y N
Replace the Right Guide Motor, MOT1105, (PL 11.9) and the FSN Stepper PWB (PL
1.16). Y N
PWB (PL 1.16). Press Stop. Check the following:
• Binding lead screws, bearings, and linkage mechanisms, (PL 11.9).
+24 VDC is measured between TS18 (+) and TS9 on the FSN Stepper PWB. • Check the wires for intermittent connections.
Y N If no problems can be found, replace the Right Guide Motor, MOT1105, (PL 11.9).
Switch off the Printer Power. Disconnect wire # 64J (Stacker A) or wire #89A (Stacker
B,C,D) from P444-8 at the FSN Stepper PWB. Switch on the Printer power. +24 VDC is
measured between wire #64H (or 89A) (+) and TS9 (-) on the FSN Stepper PWB.
Y N
(Stacker B, C, D) +24 VDC is measured between J136-22 (+) and J136-5 (-).
Y N
(Stacker B,C,D) Go to the 1-719, Feeder/Stacker #2 +24 VDC RAP.
A B C

A B C
11-703 Stacker Elevator Motor, MOT1106 RAP Y N
Go to the Wirenets (Wiring Data) and check the wire #63A (Stacker A) and
The purpose of the Stacker Elevator Motor RAP is to aid in the troubleshooting of the Stacker wire #78A (Stacker B) for an open circuit.
Elevator Motor and related circuitry. This RAP is designed to be used for the Stacker Elevator
Motor of any Stacker module. The correct module letter (A/B) must be inserted into the proce- Go to Flag 1 and Flag 2. Check the wires and the switches for an open circuit.
dure instructions (in place of X) and circuit diagram component designators order to properly
diagnose the fault. Go to Flag 3. Check the wires for an open circuit. If OK, replace the Stacker Elevator
Relay, K1109 (PL 1.16).
Initial Actions
115 VAC is measured between J1-3 and J1-11.
WARNING Y N
Use caution when working near the motor. The Stacker Elevator Motor may run auto- Go to Flag 9. Check the wires for an open circuit.
When the motor cools, the thermal sensor will close, allowing power to the motor. The Replace the FSN AC Remote PWB #1 (PL 1.16).
The Stacker Elevator Lift Frame is not grounded. Whenever working in the vicinity of the Connect the meter leads to TS35 (+) and TS37 (-) on the FSN DIO PWB #1. Press and hold
elevator lift frame, be sure to maintain proper positioning of all AC wiring and avoid the Bin Unload button on the Stacker Control Panel.
contact to the lift frame.
NOTE: Actuation of the Bin Unload button is necessary to prevent erroneous readings due to a
feedback path through the Stacker Control Panel.
+5 VDC is measured between TS35 (+) and TS37 (-) on the FSN DIO PWB #1.
• Ensure that the Stacker Left Door and Right Door are closed. Y N
+5 VDC is measured between PS2P2 (+) and PS2P1 (-) of the IFS LVPS.
• Stacker Tray is level. Check the Pallet Lift Frame Parallelism Adjustment, (ADJ 11-31)
Y N
• Stacker Elevator moves freely.
Line to Neutral (60 Hz), Phase to Neutral (50 Hz) is measured between terminal
Procedure L (+) and terminal N of the IFS LVPS.
115 VAC is measured between J1-12 and J1-3 on the FSN AC Remote PWB #1. Y N
Y N Replace the IFS LVPS Relay (PL 1.15).
115 VAC is measured between TB5-9 and TB4-6.
Y N Replace the IFS LVPS (PL 1.15).
(60Hz-Stacker A) Go to the 1-704-1, Inverter/Stacker Standby AC Power RAP.
(60Hz-Stacker B) Go to the 1-704-2, Stacker Standby AC Power RAP. Go to the Wirenets (Wiring Data) and check wire # 61M for an open circuit.
(50Hz-Stacker B) Go to the 1-711-2, Stacker Standby AC Power RAP. +4.1 to 5.3 VDC is measured between TS40 (+) and TS37 (-).
Y N
(60Hz Printers) - Less than 10 VAC is measured between TB5-9 and Printer frame. Go to Flag 10 and Flag 6. Check the wires for an open circuit. If OK, replace the FSN AC
(50Hz Printers) - Keep the multimeter leads on the same terminals as the previous check. Remote PWB #1 (PL 1.16).
Enter dC330, [11X1], [Stacker Start/Run]. Press Continue. The voltage remains the
same between TB5-9 and TB4-6. +4.1 to 5.3 VDC is measured between TS49 (+) and TS37 (-).
Y N Y N
(60Hz-Stacker A) Go to the 1-704-1, Inverter/Stacker Standby AC Power RAP. Go to Flag 5. Check the wires for an open circuit. If OK, replace the FSN AC Remote
(60Hz-Stacker B) Go to the 1-704-2, Stacker Standby AC Power RAP. PWB #1 (PL 1.16).
(50Hz-Stacker B) Go to the 1-711-2, Stacker Standby AC Power RAP. Enter dC330, [11X2], [Elevator DN]. Press Continue. The message "Output deenergized:
Limit encountered" appears on the dC330 screen.
115 VAC is measured between terminal 4 and terminal 6 of the Stacker Elevator Y N
Relay, K1109.
NOTE: The component will only stay energized for approximately 20 seconds without ele-
Y N
vator movement. If it times out before the measurement is taken, press Continue again.
Y N 0.6 VDC (+/- 0.4 VDC) is measured between TS49 (+) and TS37 (-) on the FSN DIO
+24 VDC is measured between TB7-B (+) and TB7-A (-). PWB #1.
A B C D
D
Y N Y N
Press Stop. Replace the FSN DIO PWB #1 (PL 1.16). Press Stop. Go to Flag 7. Check the wires and the Stacker Overtravel Up Switch, S1140,
for an open circuit (PL 11.18).
115 VAC is measured between J1-5 and J1-12 on the FSN AC Remote PWB #1.
Y N Press Stop. Go to Flag 12. Check the wire for an open circuit. If OK, check the following:
Press Stop. Replace the FSN AC Remote PWB #1 (PL 1.16). • Loose Pulley on the Stacker Elevator Drive Motor (PL 11.19)
• Drive belt for damage and that it is under tension
Press Stop. Enter the Power Interrupt mode. Disconnect P413 from the FSN AC
• Idler Pulley
Remote PWB #1. Measure the resistance between P413-5 and P413-12. The resis-
tance is less than 40 ohms. • Intermittent binding in the elevator assembly
Y N • The lead screws are operating freely in their bearings (PL 11.18)
Check for continuity between P413-5 and P424-1 at the Stacker Elevator Motor. If OK, replace the following one at a time:
Continuity is measured. • Stacker Elevator Capacitor, C1106 (PL 11.18).
Y N • Stacker Elevator Drive Motor, MOT1106 (PL 11.19).
Go to Flag 8. Check the wires and the Stacker Overtravel Down Switch, S1141,
for an open circuit (PL 11.18).
Go to Flag 4 and check the wires for an open circuit.

If the wires are OK, the motor may still be in an overheat condition if it still feels
warm. Allow the motor to cool and look for mechanical causes for the motor over-
heat.
If the motor is not warm, replace the following components one at a time until the
problem is resolved:
• Stacker Elevator Run Capacitor C1105 (PL 11.18).
• Stacker Elevator Motor MOT1106 (PL 11.19).
Press Stop. Go to Flag 11. Check the wires for an open circuit. If OK, check the following:
• Loose Pulley on the Stacker Elevator Drive Motor (PL 11.19)
• Drive belt for damage, ensure that it is under tension
• Idler Pulley
• Intermittent binding in the elevator assembly
• The lead screws are operating freely in their bearings (PL 11.19)
If OK, replace the following one at a time:
• Stacker Elevator Capacitor, C1106 (PL 11.18).
• Stacker Elevator Drive Motor, MOT1106 (PL 11.19).
Select [Elevator UP]. Press Continue. 0.6 VDC (+/- 0.4 VDC) is measured between TS40
(+) and TS37 (-) on the FSN DIO PWB #1.
Y N
Press Stop. Replace the FSN DIO PWB #1 (PL 1.16).
115 VAC is measured between J1-1 and J1-12 on the FSN AC Remote PWB #1.
Y N
Press Stop. Replace the FSN AC Remote PWB #1 (PL 1.16).
Press Stop. Enter the Power Interrupt mode. Disconnect P413 from the FSN AC Remote
PWB #1. Measure the resistance between P413-1 and P413-12. The resistance is less than
40 ohms.

Figure 1 11-703 Circuit Diagram (8152) Continued on the next page...


A B
11-704 Front Tamper Motor, MOT1107, And Right Guide The Front Tamper Motor does not comes on. Press Stop. Enter the Power Interrupt
mode, disconnect P418 from the Front Tamper Motor, MOT1107. Measure the resistance
Tamper Motor, MOT1113 RAP between J1-1 and J1-3. The resistance is less than 200 Ohms.
Y N
The purpose of the Front Tamper Motor and Right Guide Tamper Motor RAP is to aid in the
troubleshooting of the Front Tamper Motor, Right Guide Tamper Motor and related circuitry. The motor is in an overheat condition. Check the Tamper Drives for binding. The
This RAP is designed to be used for the Front Tamper Motor and Right Guide Tamper Motor of motor must cool for the thermal sensor to reset. If it does not reset after allowing the
motor to cool, replace the Front Tamper Motor, MOT1107 (PL 11.5).
any Stacker module. The correct module letter (A/B) must be inserted into the procedure
instructions (in place of X) and circuit diagram component designators order to properly diag-
nose the fault. Enter dC330, [11X2], [Tamper Front]. Press Start. 115 VAC is measured between
P418-1 and P418-3.
Y N
Initial Actions Press Stop. Go to Flag 3 and Flag 4. Check the wires and connections for an open
WARNING circuit.
Use caution when working near the motor. The Front Tamper Motor and Right Guide
Tamper Motor may run automatically. There is an internal thermal sensor that opens Press Stop. Go to Flag 5. Check the wires for an open circuit. If OK, replace the following
when the motor overheats. When the motor cools, the thermal sensor will close, allow- components one at a time, until the problem is resolved:
ing power to the motor. The outside surfaces of the motor could also be very hot. • Capacitor C1106 (PL 11.5)
Perform the following: • Front Tamper Motor MOT1107 (PL 11.5)
• Ensure that the Stacker Doors are closed or that the Interlocks are bypassed. Press Stop. 115 VAC is measured between TB4-9 and TB5-10.
• Ensure that the Tamper Drive system moves freely. A motor bearing failure will cause the Y N
motor shaft to sound rough or be bound when rotated by hand. (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP
for Stacker B.
• Ensure that the coupling hardware is tight.
(50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP
Procedure for Stacker B.
Enter dC330, [11X2], [Tamper Front]. Press Continue. Both the Front Tamper Motor and
the Right Guide Tamper Motor DO NOT come on. (60Hz Printers) - Less than 10 VAC is measured between TB5-10 and Printer frame.
Y N (50Hz Printers) - Keep the multimeter leads on the same terminals as the previous check.
The Right Guide Tamper Motor comes on. Enter dC330, [11X2], [Tamper Front]. Press Continue. The voltage remains the same
Y N between TB4-9 and TB5-10.
Y N
NOTE: It may be necessary to extend the Right Guide out using dC203 to access (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP
the connector. for Stacker B.
115 VAC is measured between P1-1 and P1-2. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP
for Stacker B.
Y N
115 VAC is measured between J1-8 and J1-17 on the FSN AC Remote PWB #1
Y N
Press Stop. With the Printer power switched off, or in the Power Interrupt mode, dis-
connect P1 from the Right Guide Tamper Motor, MOT1113. Measure the resistance Go to Flag 1. Check the wires for an open circuit.
between J1-1 and J1-2. The resistance is less than 300 Ohms.
Press Continue. 115 VAC is measured between J1-10 and J1-19 on the FSN AC Remote
Y N
The motor is in an overheat condition. Check the Tamper Drives for binding. PWB #1
The motor must cool for the thermal sensor to reset. If it does not reset after Y N
Press Stop. +5 VDC is measured between TS41 (+) and TS37 (-) on the FSN DIO
allowing the motor to cool, replace the Right Guide Tamper Motor, MOT1113,
(PL 11.9). PWB #1.
Y N
Go to Flag 7. Check the wires for an open circuit. If OK, replace the Right Guide
Tamper Motor, MOT1113, (PL 11.9). Y N
Go to the Wirenets (Wiring Data) and check the wire #61M for an open circuit.
A B C D
C D C E
Press Continue. Less than 1 VDC is measured between TS35 (+) and TS41 (-). Press Stop. Replace the FSN AC Remote PWB #1 (PL 1.16).
Y N
Press Stop. Replace the FSN DIO PWB #1 (PL 1.16). Press Stop. Go to Flag 6. Check the wires for an open circuit.
C E

A
11-705 Back Tamper Motor, MOT1108 RAP Deactuate the Bin Unload button. +5 VDC is measured between TS51 (+) and TS37 (-) on
the FSN DIO PWB #1.
The purpose of the Back Tamper Motor RAP is to aid in the troubleshooting of the Back Y N
Tamper Motor and related circuitry. This RAP is designed to be used for the Back Tamper Go to Flag 2. Check the wires for an open circuit.
Motor of any Stacker module. The correct module letter (A/B) must be inserted into the proce-
dure instructions (in place of X) and circuit diagram component designators order to properly Enter dC330, [11X2], [Tamper Back]. Press Continue. .2 to 1 VDC is measured between
diagnose the fault. TS51 (+) and TS37 (-).
Y N
Initial Actions Press Stop. Replace the FSN DIO PWB #1 (PL 1.16).
WARNING Press Stop. 115 VAC is measured between TB5-10 and P413-6.
Use caution when working near the motor. The Back Tamper Motor may run automati- Y N
cally. There is an internal thermal sensor that opens when the motor overheats. When Go to Flag 3, Flag 4, and Flag 5, and check the wires and connections for an open circuit.
the motor cools, the thermal sensor will close, allowing power to the motor. The outside
surfaces of the motor could also be very hot. Press Continue. The voltage goes LOW.
• Ensure that the Stacker Doors are closed or that the Interlocks are bypassed.
• Ensure that the Tamper Drive system moves freely. A motor bearing failure will cause the Press Stop. If the wires are OK, the motor may be in an overheat condition. If the motor feels
motor shaft to sound rough or be bound when rotated by hand. warm, check the Tamper Drives for binding. The motor must cool for the thermal sensor to
• Check for a loose pulley on the motor. reset. If it does not reset after allowing the motor to cool, replace the Back Tamper Motor,
MOT1108 (PL 11.6).
Procedure If the motor was not still warm, replace the following components one at a time, until the prob-
103 to 127 VAC is measured between TB4-9 and TB5-10. lem is resolved:
Y N • Capacitor C1107 (PL 11.6)
(60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP • Back Tamper Motor MOT1108 (PL 11.6)
for Stacker B.
for Stacker B.
(60Hz Printers) - Less than 10 VAC is measured from TB5-10 to Printer frame.
(50Hz Printers) - Enter dC330, [11X1], [Stacker Main Drive Start/Run]. Press Continue.
The voltage between TB4-9 and TB5-10 remains between 103 to 127 VAC.
Y N
for Stacker B.
for Stacker B.
115 VAC is measured between J1-8 and J1-17 on the FSN AC Remote PWB #1
Y N
Press Stop. Connect the meter leads to TS35 (+) and TS37 (-) on the FSN DIO PWB #1.
Press and hold the Bin Unload button on the Stacker Control Panel.
NOTE: Actuation of the Bin Unload button is necessary to prevent erroneous readings due to a
feedback path through the Stacker Control Panel.
Y N
Go to the Wirenets (Wiring Data) and check the wire #61M for an open circuit.
A

A B
11-706 Stacker Main Drive Motor, MOT1110 RAP Press Continue. The voltage momentarily drops from +24 VDC to less than 1 VDC.
Y N
The purpose of the Stacker Main Drive Motor RAP is to aid in the troubleshooting of the Press Stop. Replace the FSN DIO PWB #1 (PL 1.16).
Stacker Main Drive Motor and related circuitry. This RAP is designed to be used for the Stacker
Main Drive Motor of any Stacker module. The correct module letter (A/B) must be inserted into Press Stop. Replace the Stacker Main Drive Start Relay, K1106 (PL 1.16).
the procedure instructions (in place of X) and circuit diagram component designators to prop-
erly diagnose the fault. Press Stop. 115 VAC is measured between TB5-8 and TB4-7.
Y N
Initial Actions (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for
Stacker B.
WARNING (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, for
Use caution when working near the motor. The Stacker Main Drive Motor may run auto- Stacker B.
When the motor cools, the thermal sensor will close, allowing power to the motor. The (60Hz Printers) - Less than 10 VAC is measured between TB5-8 and Printer frame.
outside surfaces of the motor could also be very hot. (50Hz Printers) - Keep the multimeter leads on the same terminals. Enter dC330, [11X1],
Perform the following: [Stacker Start/Run]. Press Continue. The voltage remains the same between TB5-8 and
TB4-7.
• Ensure that the Stacker Doors are closed or that the Interlocks are bypassed. Y N
• Ensure that the Stacker Main Drives rotate freely. (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for
• Check for a loose pulley on the motor. Stacker B.
Press Stop. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-
Procedure 711-2, for Stacker B.
With the Printer power switched off, or in the Power Interrupt mode, disconnect P421 from the
Stacker Main Drive Motor, MOT1110. Measure the resistance between J1-1 and J1-3. The Press Stop. 115 VAC is measured between TB4-7 and terminal 1 of the Stacker Main
resistance is less than 300 Ohms. Drive Run Relay, K1105.
Y N Y N
The motor is in an overheat condition. The motor must cool for the thermal sensor to Go to Flag 4. Check the wire for an open circuit.
reset. If it does not, replace the Stacker Main Drive Motor, MOT1110 (PL 11.1). When it
does reset, measure the voltage between TS44 (-) and TS33 (+) on the FSN DIO PWB 115 VAC is measured between terminal 1 and 2 of K1105.
#1. +24 VDC is measured. Y N
Y N Disconnect P421 from the Stacker Main Drive Motor, MOT1110. 115 VAC is measured
Check for the following causes of overheating: between P421-3 and TB5-8.
• Stacker Main Drives for binding Y N
• Stacker Main Drive Start Relay, K1106, for shorted contacts (PL 1.17) Go to Flag 11. Check the wire for an open circuit.
• Flag 2 for a short circuit
Go to Flag 10. Check the wires for an open circuit. If OK, replace the Stacker Main Drive
Motor, MOT1110 (PL 11.1).
Enter dC330, [11X1], [Stacker Start/Run]. Observe the Stacker Main Drive Start Relay, Press Continue. The voltage goes Low.
Y N
K1106. Press Continue. K1106 momentarily actuates.
Y N Press Stop. +5 VDC is measured between TS34 (+) and TS37 (-) on the FSN DIO
Press Stop. +24 VDC is measured between TS33 (+) and TS37 (-) on the FSN DIO PWB #1.
Y N
PWB #1.
Y N Go to the Wirenets (Wiring Data) and check wire #61N for an open circuit.
Go to the Wirenets (Wiring Data) and check wire #63J (Stacker A) or #78C (Stacker
B) for an open circuit.
Y N
+24 VDC is measured between TS44 (+) and TS37 (-) on the FSN DIO PWB #1. Go to Flag 3. Check the wires for an open circuit. If OK, replace the Stacker Main
Y N Drive Run Relay, K1105 (PL 1.17).
Go to Flag 1 and Flag 2. Check the wires for an open circuit. If OK, replace the
Press Continue. 0.2 to 1.0 VDC is measured between TS45 (+) and TS37 (-) on the
Stacker Main Drive Start Relay, K1106 (PL 1.17).
FSN DIO PWB #1.
A B C
C
Y N
Press Stop. Replace the FSN DIO PWB #1 (PL 1.17).
Press Stop. Replace the Stacker Main Drive Run Relay, K1105 (PL 1.17).
Press Stop. 115 VAC is measured between K1105-1 and terminal 9 of the Stacker Main
Drive Start Relay, K1106.
Y N
115 VAC is measured between K1105-1 and terminal A1 of the Start Capacitor,
C1111.
Y N
115 VAC is measured between K1105-1 and K1106-4.

Y N
between K1105-1 and K1106-6.
Y N
Press Stop. Go to Flag 6. Check the wire for an open circuit. If OK, replace the Stacker
Main Drive Relay, K1106 (PL 1.16).
Press Stop. Replace the following components one at a time until the problem is resolved:
• Run Capacitor C1110 (PL 11.22)
• Start Capacitor C1111 (PL 11.22)
• Stacker Main Drive Motor MOT1110 (PL 11.1)


A
11-707 Inverter Drive Motor, MOT1111 RAP 115 VAC is measured between J1-8 and J1-17 on the FSN AC Remote PWB #2.
Y N
The purpose of the Inverter Drive Motor RAP is to aid in the troubleshooting of the Inverter Go to Flag 1. Check the wires for an open circuit.
Drive Motor and related circuitry.
115 VAC is measured between P403-3 and A-TB5-5.
Initial Actions Y N
WARNING
Use caution when working near the motor. The Inverter Motor may run automatically. NOTE: Ensure that the RHHD is disconnected from the F/S when performing this voltage mea-
There is an internal thermal sensor that opens when the motor overheats. When the surement. This is necessary due to a feedback path through the RHHD which will give incor-
motor cools, the thermal sensor will close, allowing power to the motor. The outside rect readings.
surfaces of the motor could also be very hot.
Perform the following: +5 VDC is measured between TS33 (+) and TS37 (-) on the PHN DIO PWB #5.
Y N
• Check the Inverter Motor for signs of physical damage. Go to the Wirenets (Wiring Data) and check the wire #61D for an open circuit.
• Ensure that the Stacker Doors are closed or that the Interlocks are bypassed.
+4.2 to 5.2 VDC is measured between TS43 (+) and TS37 (-) on the PHN DIO PWB #5.
• Ensure that the Inverter Drive system moves freely. A motor bearing failure will cause the Y N
motor shaft to sound rough or be bound when rotated by hand. Go to Flag 2. Check the wires for an open circuit.
• Check for a loose pulley on the motor.
Procedure Enter dC330, [10], [Inverter FWD]. Press Continue. 0.2 to 1.0 VDC is measured between
TS43 (+) and TS37 (-).
Y N
Inverter Motor, MOT1111. Measure the resistance between J1-1 and J1-3. The resistance is
Press Stop. Replace the PHN DIO PWB #5 (PL 1.16).
less than 300 Ohms.
Y N
Press Stop. +4.2 to 5.2 VDC is measured between TS52 (+) and TS37 (-) on the PHN DIO
The motor is in an overheat condition. Check the Inverter Drives for binding. The motor
PWB #5.
must cool for the thermal sensor to reset. If it does not reset after allowing the motor to
Y N
cool, replace the Inverter Motor, MOT1111 (PL 11.24).
Perform the Inverter Transport Motor Belt Tension adjustment (ADJ 11-14).
Select [Inverter REV]. Press Continue. 0.2 to 1.0 VDC is measured between TS52 (+) and
NOTE: The Remote Hand Held Device (RHHD) may be used to remotely operate the Printer
TS37 (-) on the PHN DIO PWB #5.
components when taking measurements or observing component operation. For detailed
Y N
Operating Instructions of the RHHD, go to (GP 1) Remote Hand Held Device (RHHD).
Reconnect P403 to the Inverter Drive Motor. Switch on the Printer power. Allow time for Sys-
tem Download to be completed. 115 VAC is measured between A-TB4-4 and A-TB5-5. Press Stop. 115 VAC is measured between P402-6 and A-TB5-5.
Y N Y N
(60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP Go to Flag 7. Check the wires and connections for an open circuit.
for Stacker B.
(50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP Keep the meter leads on the same terminals. Press Continue. The voltage goes LOW.
for Stacker B. Y N
(60Hz Printers) - Less than 10 VAC is measured from A-TB5-5 and Printer frame.
(50Hz Printers) - Keep the multimeter leads on the same terminals as the previous check. Press Stop. 115 VAC is measured between P402-10 and A-TB5-5.
Enter dC330, [10], [Inverter FWD]. Press Continue. The voltage remains the same Y N
between A-TB4-4 and A-TB5-5. Go to Flag 8. Check the wires and connections for an open circuit.
Y N
(60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP Select [Inverter FWD]. Keep the meter leads on the same terminals. Press Continue. The
for Stacker B. voltage goes LOW.
(50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP Y N
for Stacker B. Press Stop. Replace the FSN AC Remote PWB #2 (PL 1.16).
A B
B
Press Stop. Go to Flag 5 and Flag 6. Check the wires and connections for an open circuit. If • Inverter Motor MOT1111 (PL 11.24). After replacing, perform the Inverter Transport Motor
OK, replace the following components one at a time until the problem is resolved: Belt Tension adjustment (ADJ 11-14).
• Capacitor C1101 (PL 11.22).

A B
11-708 Inverter Main Drive Motor, MOT1112 RAP Press Stop. Replace the Inverter Main Drive Start Relay, K1108 (PL 1.16).
The purpose of the Inverter Main Drive Motor RAP is to aid in the troubleshooting of the Press Stop. 115 VAC is measured between A-TB5-6 and A-TB4-11.
Inverter Main Drive Motor and related circuitry. Y N
(60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for
Initial Actions Stacker B.
WARNING Stacker B.
Use caution when working near the motor. The Inverter Main Drive Motor may run auto-
matically. There is an internal thermal sensor that opens when the motor overheats. (60Hz Printers) - Less than 10 VAC is measured between A-TB5-6 and Printer frame.
When the motor cools, the thermal sensor will close, allowing power to the motor. The (50Hz Printers) - Keep the multimeter leads on the same terminals as the previous check.
outside surfaces of the motor could also be very hot. Enter dC330, [10], [Inverter Start/Run]. Press Continue. The voltage between A-TB5-6
Perform the following: and A-TB4-11 remains the same.
Y N
• Ensure that the Inverter Front Door is closed or that the Interlocks are bypassed. (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for
• Ensure that the Inverter Main Drives rotate freely. Stacker B.
• Check for a loose pulley on the motor. Press Stop. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or the
1-711-2 for Stacker B.
Procedure
With the Printer power switched off, or in the Power Interrupt mode, disconnect P404 from the Press Stop. 115 VAC is measured between A-TB4-11 and terminal 1 of the Inverter Main
Inverter Main Drive Motor, MOT1112. Measure the resistance between J1-1 and J1-3. The Drive Run Relay, K1107.
resistance is less than 300 Ohms. Y N
Y N Go to Flag 4. Check the wire for an open circuit.
The motor is in an overheat condition. The motor must cool for the thermal sensor to
reset. If it does not, replace the Inverter Main Drive Motor, MOT1112 (PL 11.22). When it 115 VAC is measured between terminal 1 and 2 of K1107.
does reset, measure the voltage between TS40 (-) and TS35 (+) on the PHN DIO PWB Y N
#5. +24 VDC is measured. Disconnect P404 from the Inverter Main Drive Motor, MOT1112. 115 VAC is measured
Y N between P404-3 and A-TB5-6.
Check for the following causes of overheating: Y N
• Inverter Main Drives for binding Go to Flag 11. Check the wire for an open circuit.
• Inverter Main Drive Start Relay, K1108, for shorted contacts (PL 1.17)
• Flag 2 for a short circuit Go to Flag 10. Check the wires for an open circuit. If OK, replace the Inverter Main Drive
Motor, MOT1112 (PL 11.22).
Switch printer power on. Enter dC330, [10], [Inverter Start/Run]. Observe the Inverter Main Y N
Press Stop. +5 VDC is measured between TS33 (+) and TS37 (-) on the PHN DIO
Drive Start Relay, K1108. Press Continue. K1108 momentarily actuates.
Y N PWB #5.
Press Stop. +24 VDC is measured between TS35 (+) and TS37 (-) on the PHN DIO Y N
PWB #5.
Y N
Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit. +5 VDC is measured between TS53 (+) and TS37 (-) on the PHN DIO PWB #5.
Y N
+24 VDC is measured between TS40 (+) and TS37 (-) on the PHN DIO PWB #5. Go to Flag 3. Check the wires for an open circuit. If OK, replace the Inverter Main
Y N Drive Run Relay, K1107 (PL 1.16).
Go to Flag 1 and Flag 2. Check the wires for an open circuit. If OK, replace the
Inverter Main Drive Start Relay, K1108 (PL 1.16). Press Continue. 0.2 to 1.0 VDC is measured between TS53 (+) and TS37 (-) on the
PHN DIO PWB #5.
Press Continue. The voltage momentarily drops from +24 VDC to less than 1 VDC. Y N
Y N Press Stop. Replace the PHN DIO PWB #5 (PL 1.16).
Press Stop. Replace the Inverter Main Drive Run Relay, K1107 (PL 11.22).
A B C
C
Press Stop. 115 VAC is measured between K1107-1 and terminal 7 of the Inverter Main
Drive Start Relay, K1108.
Y N
115 VAC is measured between K1107-1 and terminal 1 of the Start Capacitor, C1112.
Y N

Y N
Y N
Press Stop. Go to Flag 6. Check the wire for an open circuit. If OK, replace the Inverter
Main Drive Relay, K1108 (PL 1.16).
• Inverter Main Drive Motor MOT1112 (PL 11.22)


11-709 Interlock Bypass Switch RAP
This RAP is for troubleshooting problems with the logic side of the Interlock Bypass Switch.
Procedure
Enter dC330, [11X1]. Actuate the Interlock Bypass Switch. The Interlock Bypass SW dis-
play changes from H to L.
Y N
Go to Flag 1. Check the circuit of the Interlock Bypass Switch, S1152 (Generic Switch
General Procedures, GP 6-1).

• Loose wires or connectors
• Switch for damage


11-710 Container Sensing RAP • Container magnetic actuators missing, misaligned, or damaged.
• Container hardware for damage or misadjustment in the area where the magnets are
The Container Sensing RAP will aid in troubleshooting problems with the container decoding. located.
• Ensure that the positions of the magnets are the same as the locations shown in the
Initial Actions chart.
Check the following: • (ADJ 11-31), Pallet Lift Frame Parallelism adjustment.
• (ADJ 11-32), Container Size Sensor adjustment (Ensure that the top edge of the sensor is
• Paper size matches the container size.
flush with the alignment block)
• Container size on the System Controller Printer Status screen matches the Container that
If OK, replace the container (PL 11.17).
is being used
• Container is properly seated on the pallet.
• Stacker Drawer is fully latched
• Run with the container pallet only or try another container if available (any size).
Procedure
CAUTION
The following procedure can be used for fault codes that may appear in any of the Feeder/
Stacker modules. The correct module letter (A/B) must be inserted into the procedure direc-
tions (in place of X) and circuit diagrams in order to properly diagnose the fault codes.
Enter dC330, [11X1]. Actuate the Container Size A Sensor (use a small magnet, such as the
magnetic pick up tool). The location of the A, B, or C sensor is marked on the top surface of the
sensor. The display changes from H to L.
Y N
Go to Flag 1. Check the Container Size A Sensor circuit (GP 6-2, General Procedures)
(PL 11.18).
Actuate the Container Size B Sensor. The display changes from H to L.

Y N
Go to Flag 2. Check the Container Size B Sensor circuit (GP 6-2, General Procedures)
(PL 11.18).
Actuate the Container Size C Sensor. The display changes from H to L.

Y N
Go to Flag 2. Check the Container Size C Sensor circuit (GP 6-2, General Procedures)
(PL 11.18).
Ensure that the Main Pallet is in the home (down) position. The Pallet Latch display indi-
cates an L.
Y N
Ensure that the Pallet Latch Sensor is not blocked. The Pallet Latch should be pivoted so
that the flag is not blocking the sensor in the Container mode. If OK, go to Flag 4. Check
the circuit of the Pallet Latch Sensor, Q1149 (GP 6-2 Generic Sensor RAP, General Pro-
cedures).
The Drawer In SW display indicates an L.

Y N
Go to Flag 5. Check the circuit of the Drawer In Switch (Generic Switch RAP GP 6-1,

Figure 1 11-710 Circuit Diagram (8154) Continued on the next page


11-711 Stacker Attention Light RAP
This RAP is designed to aid in troubleshooting a non-functioning Attention Light.
Procedure
Enter dC330, [Attention Light]. Press Continue. The Attention Light comes on.
Y N
Press Stop. Connect a jumper wire between TS49 and TS37 on the PHN DIO PWB #5.
The Attention Light comes on.
Y N
Remove the jumper wire. +24 VDC is measure at TS35 on the PHN DIO PWB #5.
Y N
Go to the Wirenets (WIRING DATA) and check wire #64D for an open circuit.
Disconnect P4053 from J3 on the PHN DIO PWB #5. Enter dC330, [Attention
Light]. Press the Continue button. +24 VDC is measured between TS35 (+) and
TS49 (-).
Y N
Press Stop. Reconnect P4053 to J3. Go to Flag 1 and Flag 2. Check the wires for an
open circuit. If OK, replace the Attention Light (PL 4.14).
Press Stop. Check the wires and connectors for an intermittent circuit.


A B
11-712 Inverter/Stacker Noise RAP Press Stop. Check the following on the Stacker Preregistration Transport:
• Drive Belts for wear or damage
Audible noise in the Inverter/Stacker can be caused by defective bearings on shafts or idlers, • Drive Pulleys for damage or slippage on the shaft
drive rolls rubbing on baffles, or defective idlers. Use this procedure to isolate components that
• Bearings
are causing noise in the Inverter/Stacker.
• Idlers are free and positioned properly
Procedure • Baffles for interference with shafts
Enter dC330, [10], [Inverter Start/Run]. Press Continue. The sound levels are normal. • Drive Belt Idler for wear or damage
Y N
Press Stop. Select [11B1] [Stacker Start/Run]. Press Continue. The sound levels are nor-
• Drive Gears for wear, damage, or contamination mal.
Y N
Press Stop. Check the following on the Purge Transport:
• Drive Pulleys for damage or slippage on the shaft • Drive Belts for wear or damage
• Drive Belt idlers for wear or damage • Drive Pulleys for damage or slippage on the shaft
• Idlers free and are positioned properly • Bearings
• Bearings • Idlers are free and positioned properly
• Inverter Main Drive Motor • Baffles for interference with shafts
• Stacker Main Drive Motor
Press Stop. Select [Inverter FWD]. Press Continue. The sound levels are normal.
Y N • Telescopic Drive Shaft
Press Stop. Select [11X2] [Elevator Dn]. Press Continue.
• Inverter Drive Belt for wear or damage
• Drive Pulleys for damage or slippage on the shaft NOTE: This part of the procedure will work for both Stacker A and Stacker B. Use A or B in
• Bearings place of X in the procedure instructions. If unsure of the location of the noise, do this procedure
first on Stacker A and the Stacker B.
• Inverter Motor
The sound levels are normal.
Press Stop. Select [Inverter REV]. Press Continue. The sound levels are normal. Y N
Y N Press Stop. Check the following on the Stacker Elevator:
Press Stop. Check the following: • Lead Screws for binding
• Inverter Drive Belt for wear or damage
• Drive Pulleys for damage or slippage on the shaft
• Drive Pulleys for wear or damage
• Bearings
• Bearings
• Inverter Motor
• Lift Frame for interference
Press Stop. Select [11A1] [Stacker Start/Run]. Press Continue. The sound levels are nor- • Stacker Elevator Motor
mal.
Press Stop. Select [11X2] [Elevator Up]. Press Continue. The sound levels are normal.
Y N
Press Stop. Disconnect the Drive Belt from the Preregistration Transport Drive Pulley and Y N
the Stacker Main Drive Motor RAP. Press Continue. The sound levels are normal. Press Stop. Check the following:
• Lead Screws for binding
Y N
Press Stop. Check the following on the Bypass Transport: • Drive Belts for wear or damage
• Drive Belts for wear or damage • Drive Pulleys for wear or damage
• Drive Pulleys for damage or slippage on the shaft • Bearings
• Bearings • Lift Frame for interference
• Idlers are free and positioned properly • Stacker Elevator Motor
• Baffles for interference with shafts
Press Stop. Select [11X1] [Tamper Front]. Press Continue. The sound levels are normal.
• Stacker Main Drive Motor
• Telescopic Drive Shaft
A B
Y N • Select and energize clutches and solenoids that may be causing noise
Press Stop. Check the following on the Front Guide and Right Guide Tampers: • Ensure all transports are latched properly
• Drive Coupling for damage or slipping
• Gears for wear or contamination
• Linkages for damage or binding
• Bearings
• Front Tamper Motor
• Right Guide Tamper Motor
Press Stop. Select [Tamper Back]. Press Continue. The sound levels are normal.
Y N
Press Stop. Check the following on the Back Guide Tampers:
• Gears for wear or contamination
• Linkages for damage or binding
• Bearings
• Back Tamper Motor
Press Stop. Enter dC203, [Stacker Disk], [Stacker X], [7 pitch], [Continuous Run]. Press
Continue. The sound levels are normal.
Y N
• Disk Shaft for binding or interference
• Bearings
• Disk Motor
Press Stop. Select [Edge Guides] [Stacker X] [Right Guide] [Continuous Run]. Press
Continue. The sound levels are normal.
Y N
• Drive belt for wear or contamination
• Drive belt tensioned properly
• Interference with Right Guide
• Bearings
• Right Guide Motor
Press Stop. Select [Back Guide] [Stacker X] [Continuous Run]. Press Continue. The
sound levels are normal.
Y N
• Drive Belt for wear or damage
• Drive Belt for proper tension
• Interference with Back Guide
• Bearings
• Back Guide Motor
Press Stop. If the noise is still present when the Stackers are running, perform the following:


11-713 Stacker Control Panel RAP
The Stacker Control Panel RAP will assist in diagnosing faults with the Stacker Control Panel
PWB and related circuitry.
Procedure
Enter dC330, [11A2]. Press the Bin Unload button. The Bin Unload SW display toggles
from H to L.
Y N
Connect a jumper wire between TS21 and TS37 on the FSN DIO PWB #1. The Bin
Unload SW display toggles from H to L when the jumper is connected.
Y N
Go to Flag 1. Check the wires for an open or short circuit. If OK, replace the Stacker Con-
trol Panel PWB (PL 4.12).
Select [11A1] [Ready to Unload]. Press Continue. The Ready to Unload light illuminates.
Y N
Press Stop. Connect a jumper wire between TS46 and TS37 on the FSN DIO PWB #1.
The Ready to Unload lamp illuminates.
Y N
Remove the jumper wire. Go to Flag 2. Check the wires for an open or short circuit.
If OK, replace the Stacker Control Panel PWB (PL 4.12).
Remove the jumper wire. Replace the FSN DIO PWB #1 (PL 1.17).
Press Stop. Select [Stacker In Use]. Press Continue. The Stacker In Use lamp illumi-
nates.
Y N
The Stacker In Use lamp illuminates.
Y N
Press Stop. Select [Stacker Please Wait]. Press Continue. The Stacker Please Wait lamp
illuminates.
Y N
The Stacker Please Wait lamp illuminates.
Y N
Press Stop. The Stacker Control Panel is OK. Check the wires and connectors for an intermit-
tent circuit.


11-901-X Purge Tray Is Not Available RAP
Fault Code, 11-901-X, indicates the presence of paper in the purge path. The Primary Fault
becomes masked at this time.
Initial Actions
• Remove all Paper from the Purge Path to enable the start of a new job to any Upstream
destination.
Procedure
Check the Queued Faults [SCP] [Last 50]. Identify the Primary Fault prior to the 11-901-X
Fault. Refer to the Primary Fault RAP to diagnose any hardware problem associated with the
primary fault code.

No Product Name Assigned ?-1047 11-901-X
11-901-X ?-1048 No Product Name Assigned
A
13-131 RAP Press Stop. Select dC330, [Third Party], [Fin 2], [Output Drive Motor]. Press Continue.
The Output Exit Transport Drive Rolls rotate.
Fault Code, 13-131, indicates that the lead edge of the print, delivered from the Bypass Sen- Y N
sor, Q-1307, did not arrive at the Output Exit Sensor, Q1375, within 1114 milli seconds after The Output Drive Motor, MOT 1301, comes on.
actuating the sensor. (LE Q1307 late to LE Q1375) Y N
Press Stop. Go to the 13-700, Output Drive Motor RAP, Mot 1301.
Initial Actions
• Ensure that all Transition Module Baffles are closed properly and are not damaged. The Output Exit Drive Rolls operate correctly.
Y N
• Ensure that all drive roll idlers are properly seated, and that the idler springs are correctly
installed.
• Drive belts for wear, damage, contamination, and correct tension.
• Ensure that the paper path is free of obstructions.
• One way clutch, pulley or shaft for wear, binding, or slipping.
• Ensure that the Bypass Transport Sensor and Output Exit Sensor are clean and not
obstructed. Press Stop. Check the following:
Procedure • Drive and Idler Rolls for wear, damage, or contamination.
Observe the Prints entering the Transition Module. The Prints are free from damage, skew, • Idler Springs for wear or damage.
or excessive curl.
Y N Press Stop. Select [Stacker A/B] [11X1]. Block and then unblock the Bypass Transport Sen-
Check the following: sor. The display changes from L to H.
• Paper path for obstructions. Y N
Go to Flag 2. Check the circuit of the Bypass Transport Sensor, (GP 6-2, General Proce-
• Transition Module Height Adjustment (ADJ 13-5).
dures).
• Transition Module Inboard/Outboard Adjustment (ADJ 13-6).
• Drive Rolls and Idlers for wear damage or contamination. Check the following:
• Idler Retaining Springs for damage missing. • ADJ 13-5, Transition Module Height.
• If a problem is not found, or if the prints are damaged, skewed, or curled before • Drive Shaft Bearings for binding.
entering the Transition Module, Go to the 8-705, or to the Physical Checks, Print • Drive belts for wear, damage, contamination and tension.
Paper Diagnostics (Service Call Procedures).
• Drive belt idlers for binding.
Enter dC330, [Third Party], [Fin 2]. Block and then clear the Output Exit Sensor, Q1375. The • Static in the Descending Transport.
display changes from L to H.
Y N
Go to Flag 1. Check the circuit of the Output Exit Sensor (GP 6-2, General Procedures).
Enter [Stacker A/B] [11X1]. Select [Stacker Start/Run]. Press Continue. The Stacker
Bypass Transport Drive Rolls rotate.
Y N
Y N
Press Stop. Go to the 11-706, Stacker Main Drive Motor, Mot 1110, RAP.
The Bypass Drive Rolls operate correctly.

Y N
Press Stop. Check The following:
• Drive belts for wear, damage, contamination, and correct tension.
• Flexible Drive Cable for damage, loose coupling, or loose setscrew.

• Bypass Transport Drive and Idler Rolls for wear, damage or contamination.
• Idler Springs for wear damage or missing.
A
13-132 RAP Fault Code, 13-132, indicates that the trail edge of the print did not arrive at the Output Exit
Sensor, Q1375, within the specified amount of time, after the lead edge arrived at the sensor.

Initial Actions
• Ensure that all Transition Module Baffles are closed properly and are not damaged.
• Ensure that all Drive Roll Idlers are properly seated, and that the idler springs are cor-
rectly installed.
• Ensure that the paper path is free of obstructions.
• Ensure that the Bypass Transport Sensor and Output Exit Sensor are clean and not
obstructed.
• Ensure that the Transition Module static brushes do not obstruct the paper path.
Procedure
Enter dC330, [Third Party], [Fin 2]. Block and then clear the Output Exit Sensor, Q1375. The
display changes from L to H.
Y N
Go to Flag 1. Check the circuit of the Output Exit Sensor (GP 6-2, General Procedures).
Select [Output Drive Motor]. Press Continue. The Output Exit Drive Rolls rotate.
Y N
The Output Drive Motor comes on.
Y N
Press Stop. Go to the 13-700, Output Drive Motor, Mot 1301, RAP.
Press Stop. Check The following:

• Drive belts for wear, damage, contamination, and correct tension (PL 11.40), (PL
11.41).
• Bearings for binding (PL 11.40, (PL 11.41).
• Drive Rolls for wear, damage, or contamination, and that they are not slipping on the
shaft (PL 11.40)
• Idler Rolls for binding, and for missing Idler Roll springs (PL 11.40)

• Drive belts for wear, damage, contamination, and correct tension (PL 11.40)
• Bearings for binding (PL 11.40)
• Drive Rolls for wear, damage or contamination, and that they are not slipping on the shaft
(PL 11.40)
• Idler Rolls for binding and for missing idler roll springs (PL 11.40)
• Ensure that there is continuity in the harness to the third party device (PL 1.19)
• Ensure that the third party devices are operational.
• Ensure that the third party device is properly aligned to the Transition Module.

13-201 RAP Fault Code, 13-201, indicates that the Transition Module Front Door Interlock Switch, S1381,
opened with the Transition Module Main Drive Motor on.

Procedure
Open the Transition Module Front Door. Enter dC330, [Third Party], [Fin 2]. Manually actuate
the Transition Module Front Door Interlock Switch. The Transition Module Door INTLK SW
display changes from H to L.
Y N
Go to Flag 1. Check the Transition Module Front Door Interlock circuit (Generic Switch
RAP GP 6-1, General Procedures).
Close and open the door several times. The Transition Module Door INTLK SW display
changes from H to L as the door is closed and opened.
Y N
• Transition Module Front Door Interlock is adjusted properly.
• Transition Module Front Door is not damaged or obstructed (PL 4.25).
• Door hinges and pins are in place and intact (PL 4.25).
• Interlock mounting bracket is not damaged (PL 4.25).
The Interlock appears to be OK. The problem may be intermittent. Check the Transition Mod-
ule Front Door Interlock Switch, its associated wires, and the interlock actuator for intermittent
operation.


13-203 RAP
Fault Code, 13-203, indicates that a loss of +24 VDC has been detected in the TMN Module.
This fault will cause the machine to go into the Power Interrupt mode and will disable the +24
Initial Actions
Checked the queued faults. If any of the following faults are present, 1-220, 10-216, or 11-250-
2, go to the appropriate RAP.
Procedure
+24 VDC is measured between TB12-2 (+) and TB12-11 (-) in the TMN.
Y N
+24 VDC is measured between J803 pin 1 (+) and pin 2 (-).
Y N
+24 VDC is measured between TB7-12B (+) and TB7-12A (-) in the last Feeder
Stacker Module.
Y N
Go to the 11-250-2 RAP.
+24 VDC is available at J803-1.

Y N
Go to Flag 1. Check the wire 133J for an open.
Go to Flag 2. Check the wires 134H for an open.
+24 VDC is available at TB12-2.

Y N
Go to Flag 3. Check the wire 133A for an open.
Go to Flag 4. Check wire 134A for an open.

Y N
+24 VDC is available at P804-3.
Y N
Go to Flag 5 and check wire 133F for an open.
Go to Flag 6 and check wire 134D for an open.
Enter dC330, [Third Party] [Fin 1]. Disconnect P810 from J7 on the TMN DIO PWB. Connect
a jumper from TS2 to TS37 on the TMN DIO PWB. The TMN +24 VDC monitor is L.
Y N
Replace the TMN DIO PWB (PL 1.19).
Go to Flag 7. Check the wires for an open. If an open is not found, replace the 24 VDC Sensor,
Q1384 (PL 1.19).


A B
13-205 RAP +24 VDC is available at TS53 on the Opto-Isolator PWB.
Y N
Fault Code, 13-205, indicates that the Third Party Finisher faulted during print. Go to Flag 1. Check the black, and Grey wires for an open.
Initial Actions +24 VDC is available at TS55 on the Opto-Isolator PWB.

• Ensure that the Third Party Interface Cable is properly connected at both ends and is not Y N
Replace the Opto-Isolator PWB (PL 1.19).
visibly damaged.
• Ensure that the Third Party Finisher has power and is switched on.
+24 VDC is available at TS 47 on the TMN DIO PWB.
Procedure Y N
Disconnect the Third Party Interface Cable from the Opto-Isolator PWB in the Transition Mod- Go to Flag 2. Check the violet wire for an open.
ule. Use the +5 VDC scale and connect the meter to TS22 (+) and TS 37 (-) on the TMN DIO
PWB. Place an E-Z hook from TS 22 on the TMN DIO PWB to TS24 on the Opto-Isolator PWB Replace the TMN DIO PWB (PL 1.19).
in the TMN. Place an E-Z hook from TS37 on the TMN DIO PWB to TS8 on the Opto-Isolator
PWB. Enter dC330, [Third Party], [Fin 2]. Select [C0]. Press Continue. Less than 1.2 VDC Move the E-Z hook from TS23 to TS22 on the Opto-Isolator PWB. Move the E-Z hook from
is indicated on the meter. TS7 to TS6 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C2]. Press
Y N Continue. Less than 1.2 VDC is indicated on the meter.
+24 VDC is available at TS35 on the TMN DIO PWB. Y N
Y N +24 VDC is available at TS35 on the TMN DIO PWB.
+24 VDC is available at J1-7 on the TMN DIO PWB. Y N
Y N +24 VDC is available at J1-7 on the TMN DIO PWB.
Go to the 133D wire net and check for an open. Y N
Go to the 133D wire net and check for an open.
+24 VDC is available at TS53 on the Opto-Isolator PWB.
Y N +24 VDC is available at TS53 on the Opto-Isolator PWB.
Go to Flag 1. Check the black, and Grey wires for an open. Y N
Go to Flag 1. Check the black, and grey wires for an open.
Replace the Opto-Isolator PWB (PL 1.19). Y N
+24 VDC is available at TS 46 on the TMN DIO PWB.
Go to Flag 2. Check the white wire for an open. Y N
Go to Flag 2. Check the green wire for an open.
Move the E-Z hook from TS24 to TS23 on the Opto-Isolator PWB. Move the E-Z hook from
TS8 to TS7 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C1]. Press Move the E-Z hook from TS22 to TS21 on the Opto-Isolator PWB. Move the E-Z hook from
Continue. Less than 1.2 VDC is indicated on the meter. TS6 to TS5 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C3]. Press
Y N Continue. Less than 1.2 VDC is indicated on the meter.
+24 VDC is available at J1-7 on the TMN DIO PWB. Y N
Y N +24 VDC is available at J1-7 on the TMN DIO PWB.
Go to the 133D wire net and check for an open. Y N
A B C D
C D E F
+24 VDC is available at TS53 on the Opto-Isolator PWB. +5 VDC is available at TS43 on the Opto-Isolator PWB.
Y N Y N
Go to Flag 1. Check the black, and grey wires for an open. Go to Flag 1. Check the red wire for an open.
Y N Y N
Replace the Opto-Isolator PWB (PL 1.19). Replace the Opto-Isolator PWB (PL 1.19).
+24 VDC is available at TS48 on the TMN DIO PWB. Go to Flag 2. Check the black wire for an open. If no open is found, replace the TMN DIO
Y N PWB (PL 1.19).
Go to Flag 2. Check the orange wire for an open.
Move the E-Z hook from TS32 to TS31 on the Opto-Isolator PWB in the TMN. Move the E-Z
Replace the TMN DIO PWB (PL 1.19). hook from TS16 to TS15 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S1]
changes state and the counter has incremented for the S0 counter.
Move the E-Z hook from TS21 to TS18 on the Opto-Isolator PWB. Move the E-Z hook from Y N
TS5 to TS2 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C3]. Press +5 VDC is available at TS28 on the TMN DIO PWB.
Continue. Less than 1.2 VDC is indicated on the meter. Y N
Y N Go the 59F wirenet and check for an open.
+24 VDC is available at J1-7 on the TMN DIO PWB.
Y N Replace the TMN DIO PWB (PL 1.19).
Replace the TMN DIO PWB (PL 1.19). Y N
Go to Flag 1. Check the orange wire for an open.
Go to Flag 1. Check the black, and grey wires for an open. Y N
Replace the Opto-Isolator PWB (PL 1.19). Y N
Go to Flag 2. Check the brown wire for an open.
+24 VDC is available at TS51 on the TMN DIO PWB.
Y N Replace the TMN DIO PWB (PL 1.19).
Go to Flag 2. Check the violet wire for an open.
Replace the TMN DIO PWB (PL 1.19). hook from TS15 to TS14 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S2]
Ensure that all counters are cleared before beginning this procedure. Place an E-Z hook from Y N
TS23 on the TMN DIO PWB to TS32 on the Opto-Isolator PWB in the TMN. Place an E-Z hook +5 VDC is available at TS21 on the TMN DIO PWB.
from TS37 on the TMN DIO PWB to TS16 on the Opto-Isolator PWB. Enter dC330, [Third Y N
Party], [Fin 2]. [S0] changes state and the counter has incremented for the S0 counter. +5 VDC is available at TS38 on the TMN DIO PWB.
Y N Y N
+5 VDC is available at TS17 on the TMN DIO PWB. Go the 59F wirenet and check for an open.
Y N
+5 VDC is available at TS38 on the TMN DIO PWB. Replace the TMN DIO PWB (PL 1.19).
Y N
Go the 59F wirenet and check for an open. +5 VDC is available at TS44 on the Opto-Isolator PWB.
Y N
Replace the TMN DIO PWB (PL 1.19). Go to Flag 1. Check the blue wire for an open.
E F G H
G H I J
Y N Y N
Replace the Opto-Isolator PWB (PL 1.19). Replace the Opto-Isolator PWB (PL 1.19).
+5 VDC is available at TS20 on the TMN DIO PWB. +5 VDC is available at TS31 on the TMN DIO PWB.
Y N Y N
Go to Flag 2. Check the yellow wire for an open. Go to Flag 2. Check the black wire for an open.
Replace the TMN DIO PWB (PL 1.19). Replace the TMN DIO PWB (PL 1.19).
Move the E-Z hook from TS30 to TS29 on the Opto-Isolator PWB in the TMN. Move the E-Z Check the cable.
hook from TS14 to TS13 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S3]
Y N
Y N
Y N
Go the 59F wirenet and check for an open.

Y N
Go to Flag 1. Check the white wire for an open.

Y N

Y N
Go to Flag 2. Check the violet wire for an open.
hook from TS13 to TS12 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S3]
Y N
Y N
Y N
Go the 59F wirenet and check for an open.

Y N
Go to Flag 1. Check the red wire for an open.
I J
13-206 RAP Fault Code, 13-206, indicates that no Set delivery signal was received from the Third Party
Module within the allowed time interval.

Initial Actions 13-207 RAP
• Ensure that the Third Party Interface Cable is properly connected at both ends and is not
Fault Code, 13-207, indicates that no Sheet delivery signal was received from the Third Party
visibly damaged.
Module within the allowed time interval.
• Ensure that the Third Party Finisher has power and is switched on.
• Ensure that the personality profile is configured correctly for the Third Party equipment. Initial Actions
• Ensure that there are no Jams in the Third Party Module.
• Ensure that the Third Party Interface Cable is properly connected at both ends and is not
Procedure visibly damaged.
Press R (Reset) on the IOT Monitor or type CLE on the ESS System Console to reset the sys- • Ensure that the Third Party Finisher has power and is switched on.
tem. If the Fault does not clear, go to 13-205 RAP. • Ensure that the personality profile is configured correctly for the Third Party equipment.
• Ensure that there are no Jams in the Third Party Module.
Procedure
Press R (Reset) on the IOT Monitor or type CLE on the ESS System Console to reset the sys-
tem. If the Fault does not clear, go to 13-205 RAP.

13-208 RAP 13-700 Transition Module Main Drive Motor, MOT1301 RAP
Fault Code, 13-208, indicates that the Set delivery signal was received before the Sheet deliv- The purpose of the Output Transport Main Drive Motor RAP is to aid in the troubleshooting of
ery signal from the Third Party Module within the allowed time interval. the Output Transport Main Drive Motor and related circuitry.

• Ensure that the Third Party Interface Cable is properly connected at both ends and is not WARNING
visibly damaged. Use caution when working near the motor. The Output Transport Main Drive Motor may
• Ensure that the Third Party Finisher has power and is switched on. run automatically. There is an internal thermal sensor that opens when the motor over-
• Ensure that the personality profile is configured correctly for the Third Party equipment. heats. When the motor cools, the thermal sensor will close, allowing power to the motor.
• Ensure that there are no Jams in the Third Party Module. The outside surfaces of the motor could also be very hot.
Procedure Perform the following:
Press R (Reset) on the IOT Monitor or type CLE on the ESS System Console to reset the sys-
• Ensure that the Transition Module Door is closed or that the Interlock is bypassed.
tem. If the Fault does not clear, go to 13-205 RAP.
• Ensure that the Transition Module Main Drive rotates freely.
• Check for a loose pulley on the motor.
Procedure
Output Transport Main Drive Motor, MOT1301. Measure the resistance between J1-1 and J1-
3. The resistance is less than 300 Ohms.
Y N
The motor is in an overheat condition. The motor must cool for the thermal sensor to
reset. If it does not, replace the Output Transport Main Drive Motor, MOT1301 (PL 11.39).
When it does reset, power on the printer and measure the voltage between TS43 (-) and
TS33 (+) on the TMN DIO PWB. +24 VDC is measured.
Y N
Check for the following causes of overheating:
• Transition Module Main Drives for binding.
• Transition Module Main Drive Start Relay, K1372, for shorted contacts (PL
1.19).
• Flag 2, for a short circuit.
DO NOT reconnect P801 at this time. Power on the Printer. Enter dC330, [Third Party],
[Fin 2], [Output Transport Start/Run]. Observe the Transition Module Main Drive Start
Relay, K1372. Press Continue. K1372 momentarily actuates.
Y N
Press Stop. +24 VDC is measured between TS33 (+) and TS37 (-) on the TMN DIO
PWB.
Y N
Go to the Wirenets (Wiring Data) and check wire #133C for an open circuit.
+24 VDC is measured between TS43 (+) and TS37 (-) on the TMN DIO PWB.
Y N
Go to Flag 1 and 2. Check the wires for an open circuit. If OK, replace the Transition
Module Main Drive Start Relay, K1372 (PL 1.19).
Press Continue. The voltage momentarily drops from +24 VDC to less than 1 VDC.
A
A
Y N Y N
Press Stop. Replace the TMN DIO PWB (PL 1.19). 115 VAC is measured between the Transition Module Interlock Relay, K1376-4 and
K1376-9.
Press Stop. Replace the Transition Module Main Drive Start Relay, K1372 (PL 1.19). Y N
Go to Flag 15, and check wire 21H for an open.
Press Stop. 115 VAC is measured between J800-3, and J800-15.
Y N Replace the Transition Module Interlock Relay, K1376, (PL 1.19)
Stacker B. 115 VAC is measured between the Transition Module Main Drive Run Relay, K1373-1,
(50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, for and the Transition Module Interlock Relay, K1376-9.
Stacker B. Y N
Ensure that the TMN front door is closed properly. 115 VAC is measured between J800-3,
and Transition Module Interlock Relay, K1376-9. Reconnect P801. 115 VAC is measured between terminal 1 and 2 of K1373.
Y N Y N
115 VAC is measured between J800-3, and the Transition Module Interlock Relay, Disconnect P801 from the Output Transport Main Drive Motor, MOT1301. 115 VAC is
K1376-6. measured between P801-3 and K1373-1.
Y N Y N
115 VAC is measured between J800-3, and TB10-8. Go to Flag 11. Check the wire for an open circuit.
Y N
Go to Flag 13, and check wire 40H for an open. Go to Flag 10 and 12. Check the wires for an open circuit. If OK, replace the Output
Transport Main Drive Motor, MOT1301 (PL 11.39).
Go to Flag 14, and check wire 40J, for an open.
The TMN Interlock Relay, K1376, is actuated. Y N
Y N Press Stop. +5 VDC is measured between TS34 (+) and TS37 (-) on the TMN DIO
+24 VDC is measured between TB12-2 (+) and TB12-11 (-). PWB.
Y N Y N
Go to Flag 16 and 17, and check for an open. If an open is not found go to the Go to the Wirenets (Wiring Data) and check wire #59H for an open circuit.
wirenets (Wiring Data) and check wires 82A and 78A.
+24 VDC is measured between pin 2 of the TMN front door interlock switch (+) Y N
and TB12-11 (-). Go to Flag 3. Check the wires for an open circuit. If OK, replace the Transition Mod-
Y N ule Main Drive Run Relay, K1373 (PL 1.19).
Check the TMN Front Door Interlock Actuator for proper operation. If the actua-
tor is operating correctly, Go to Flag 18, and check wire 133H for an open. If the Press Continue. 0.2 to 1.0 VDC is measured between TS54 (+) and TS37 (-) on the
wire is OK replace the TMN Front Door Interlock Switch (PL 4.25). TMN DIO PWB.
Y N
+24 VDC is measured between pin B (+) of the TMN Interlock Relay, K1376, and Press Stop. Replace the TMN DIO PWB (PL 1.19).
TB12-11 (-).
Y N Press Stop. Replace the Transition Module Main Drive Run Relay, K1373 (PL 1.19).
Go to Flag 19, and check wire 136A for an open. If the wire is OK replace the
TMN Interlock Relay, K1376 (PL 1.19). Press Stop. 115 VAC is measured between K1373-1 and terminal 9 of the Transition Mod-
ule Main Drive Start Relay, K1372.
Go to Flag 20, check wire 134F for an open. Y N
115 VAC is measured between K1373-1 and terminal A1 of the Start Capacitor,
Replace the Transition Module Interlock Relay (PL 1.19). C1371.
Y N
115 VAC is measured between the Transition Module Interlock Relay, K1376- 7 and Go to Flag 8 and 9. Check the wires for an open circuit.
K1376-9.
B
B
Y N
Y N
Press Stop. Go to Flag 6. Check the wire for an open circuit. If OK, replace the Transition
Module Main Drive Relay, K1373 (PL 1.19).
• Transition Module Main Drive Motor MOT1301 (PL 11.39)


Transmittal Page
Product Title Part Number
DocuPrint 180F Service Manual 720P16290B

Section 3 : Print Quality
Status Date
Revision November 2000

THIS PAGE INTENTIONALLY LEFT BLANK
3. Image Quality RAPS
Image Quality Analysis RAPs Printing Of Single Pixel Fine Lines: Printer Specification ................................................ 3-101
PQ 9-601 Printer Image Quality Entry RAP .................................................................... 3-3 Registration Top-to-bottom (Fast Scan): Printer Specification ........................................ 3-102
PQ 9-601.1 Printer Motion Quality Procedure................................................................. 3-5 ROS Image Squareness: Printer Specification ............................................................... 3-104
PQ 9-602 Black Print RAP .............................................................................................. 3-11 Skew: Printer Specification.............................................................................................. 3-105
PQ 9-603 Blank Print RAP .............................................................................................. 3-11 Motion Quality Controller Resident Test Pattern (MMQT02)........................................... 3-107
PQ 9-604 Prints With Agglomerates/Debris RAP ........................................................... 3-13
PQ 9-606 Print Distortion RAP ........................................................................................ 3-13
Image Quality Defects
Background, Blotchy ....................................................................................................... 3-113
PQ 9-607/608 Uniform And Non-Uniform High Background RAP .................................. 3-15
Background, Halftone (Gray Page) ................................................................................. 3-115
PQ 9-609 Low Image Darkness (Low Signal Strength, w/MICR) RAP ........................... 3-18
Background, Xerographic................................................................................................ 3-117
PQ 9-610 High Image Darkness RAP ............................................................................. 3-19
Background, Structured................................................................................................... 3-119
PQ 9-611 Dark Streaks/Scratches/Bands RAP .............................................................. 3-20
Dark band, Top-To-Bottom (Fast Scan) Direction, Every Belt Revolution ...................... 3-120
PQ 9-612 Light Streaks/Bands RAP ............................................................................... 3-23
Dark Band, Side-To-Side (Slow Scan) Direction............................................................. 3-122
PQ 9-613 Black Spots RAP ............................................................................................ 3-24
Band Deletion, Side-To-Side (Slow Scan) Direction ....................................................... 3-125
PQ 9-614 Non-Uniform Image Darkness RAP ................................................................ 3-25
Blotch Toner .................................................................................................................... 3-129
PQ 9-615 Deletions RAP ................................................................................................ 3-26
Fine, Dark Lines, Side-To-Side (Slow Scan) Direction Across Print, Greater Frequency At Top
PQ 9-616 Development RAP .......................................................................................... 3-27
And Bottom (Fast Scan Direction) On Print..................................................................... 3-131
PQ 9-617 Cleaner RAP................................................................................................... 3-32
SLB/RDR Failure Defect ................................................................................................. 3-135
PQ 9-618 PR Ground RAP ............................................................................................. 3-35
PQ 9-619 ESV RAP ........................................................................................................ 3-37
PQ 9-620 DSS RAP ........................................................................................................ 3-40
PQ 9-621 Patch Gen/Patch Integrity RAP ...................................................................... 3-43
PQ 9-622 Transfer Assist Device RAP ........................................................................... 3-47
PQ 9-623 Border Bands RAP ......................................................................................... 3-49
PQ 9-624 Precharge/Pretransfer Lamps RAP ................................................................ 3-50
PQ 9-625 White Spots RAP ............................................................................................ 3-52
PQ 9-626 Dicorotron RAP............................................................................................... 3-53
PQ 9-627 Patch Integrity RAP ........................................................................................ 3-54
PQ 9-628 HVAC RAP ..................................................................................................... 3-55
PQ 9-629 HVDC RAP ..................................................................................................... 3-56
PQ 9-630 Toner/Charge Control RAP............................................................................. 3-57
PQ 9-631 Bead Carryout RAP ........................................................................................ 3-58
PQ 9-632 Dirt RAP .......................................................................................................... 3-62
PQ 9-633 PR Belt Uniformity RAP .................................................................................. 3-63
PQ 9-634 Residual Image RAP ...................................................................................... 3-64
PQ 9-635 Smear RAP..................................................................................................... 3-65
PQ 9-636 Blur RAP ......................................................................................................... 3-66
PQ 9-637 Slow Scan Magnification Checkout Procedure ............................................... 3-67
PQ 9-638 Scratches/Crayoning Fault Analysis ............................................................... 3-70
PQ 9-639 MICR Image Quality Analysis Procedure ....................................................... 3-72
PQ 9-640 MICR Checkout Procedure............................................................................. 3-81
PQ 9-641 MICR Signal Strength Tester Correlation Procedure...................................... 3-81
Image Quality Specifications

Test Patterns................................................................................................................... 3-83
Registration, Side-To-Side (Slow Scan): Printer Specification........................................ 3-96
System Magnification Procedure .................................................................................... 3-98
Printing Of High Density Solid Areas: Printer Specification ............................................ 3-100
Revision 11/00 Image Quality Raps

Image Quality Raps 11/00 Revision
PQ 9-601 Printer Image Quality Entry RAP a. Obtain the customers defect samples or the samples generated in the Initial Actions
of the Service Call Procedure. If the defect is identified in the list below, go to RAP
The purpose of this RAP is to isolate Print Quality defects that are caused by the IOT. Once the indicated for repair. For additional diagnostics, go Print Quality Specifications, com-
defect is isolated, the service action or RAP will be identified. pare the defect to the Image Quality Defect Samples in the RAPs. If the defect can-
not be identified or repaired, return to the next of this RAP.
Procedure b. MlM IMAGE DEFECTS.
1. THE IMAGE DEFECT OCCURS ONLY WITH ETHERNET JOBS. • Bead Carryout on prints, go to the PQ 9-631, Bead Carryout RAP.
• Go to the DP NPS System Fault Analysis Procedure or the DP IPS System Fault • Blur, go to the PQ 9-636, Blur RAP.
Analysis Procedure. • Dark Border Bands, go to the PQ 9-623, Border Bands RAP.
2. THE DEFECT IS BLACK or BLANK, OR A PROBLEM IN THE MICR LINE. • Edge Defects, go to the PQ 9-623, Border Bands RAP.
• Go to; PQ 9-602, Black Print RAP, PQ 9-603, Blank Print RAP or PQ 9-639, PQ 9- • Light Streaks or Bands, go to the PQ 9-612, Light Streaks/Bands RAP.
640 MICR RAPs.
• Residual image, go to the PQ 9-634, Residual Image RAP.
3. DETERMINE IF CONTROLLER OR PRINTER DEFECT.
• Scratches, Dark Streaks, Crayon effect or Bands, go to the PQ 9-611, Black
NOTE: MIN Address 420 is the mode selection for: (48)=300 SPI or (96)=600 SPI and Lead Streaks/Scratches/Bands RAP.
Edge Lightening (00)=no LEL, (02)=normal, and (03)=stress. • Dark horizontal marks (in the process direction only) that resemble fine lines,
go to the PQ 9-638, Scratches/Crayoning Fault Analysis RAP.
a. Enter dC131 [MIN]. Enter address 420. Enter the Data value shown in the appropri-
• Smear, go to the PQ 9-635, Smear RAP.
ate level Software dC 131 Table in Section 6, General Procedures, of the Service
Manual (300 SPI with normal lead edge lightening). • Solid Area Deletions or Line deletions, go to the PQ 9-615, Deletions RAP.
b. Enter dC606. Select one of the resident Printer test patterns that is best suited to • Spots or Dark marks, go to the PQ 9-613, Dark Spots RAP.
produce the defect. Run at least 20 prints. Ensure that the defect is not in duplex • Background, go to the PQ 9-607/608, Uniform and Non-Uniform High Back-
mode only. If the defect appears on at least one of the prints generated, go to 4. If ground RAP.
the defect does not appear, continue with step 3c. • Uneven Density or Uneven Darkness, go to the PQ 9-614, Nonuniform Image
c. Enter dC106. Select one of the resident Controller Test patterns that is best suited to Darkness RAP.
produce the defect. Run at least 20 prints. If the defect does NOT appear on at least • White Spots, go to the PQ 9-625, White Spots RAP.
one of the prints generated, go to 4. If the defect does appear, go to 11.
c. FUSER RELATED DEFECTS.
4. THE DEFECT IS ON EVERY SEVENTH PRINT IN STANDARD MODE OR EVERY
• Fuser Shield/Agent on Prints, go to the 10-604, Fuser Shield/Agent on Prints
THIRD PRINT IN OVERSIZED MODE.
RAP.
a. Inspect the Photoreceptor Belt for damage. Repair the source of the damage.
• Glossy Print, go to the 10-602, Fuser Print Gloss RAP.
Replace the Photoreceptor Belt (PL 9.1).
• Lead Edge Smear, go to the 10-601, Fuser Lead Edge Smears RAP.
5. THE DEFECT OCCURS ON SIDE 2 PRINT ONLY.
• Lead Edge to Trail Edge Streaks, go to the 10-605, Fuser Lead Edge to Trail
a. Deletions on side 2 only, go to the PQ 9-615, Deletions RAP.
Edge Streaks (Unfused Print) RAP.
b. Wrong sign toner on side 2, go to the PQ 9-616, Development RAP.
• Type on prints unacceptable, go to the 10-607, Unable to Type on Prints RAP.
6. THE DEFECT IS MISREGISTRATION OR SKEW.
• Perform the Printer Fuse Fix Crease/Fold Test, referenced in Step 9e of the
a. Check/adjust the ROS Magnification (ADJ 6-1). Test Patterns procedure. If the prints fail the Crease/Fold Test, go to 10-608,
b. Check/adjust the ROS Image Squareness (ADJ 6-2). Dry Ink Not Fixed RAP.
c. Check/adjust the Pretransfer Baffles (skew) (ADJ 8-1). • Unfused Prints, go to the 10-608, Dry Ink Not Fixed RAP.
• Wrinkles, go to the 10-603, Wrinkle RAP.
NOTE: If there is gross misregistration, 4 to 5 inches, there may be a Reg Sync Signal prob-
lem, go to the 4-211, 4-213. 8. THERE IS A SYSTEM MOTION QUALITY (STROBING) PROBLEM.
a. Go to STEP 12.
d. Check/adjust the Top-to-Bottom Registration (ADJ 8-2).
9. STACKER RELATED DEFECTS.
e. Check/adjust the Side-to-Side Registration (ADJ 8-3).
a. Go to the 11-600, Poor Stacking Quality RAP.
7. CATEGORIZE THE PRINTER DEFECT.
10. UNABLE TO IDENTIFY DEFECT.
a. Perform the Xerographic Setup (ADJ 9-3). If the defect continues, return to STEP 1.
11. CONTROLLER DEFECTS.

No Product Name Assigned ?-3 PQ 9-601
a. Enter dC106. Run prints of the Quadrille test pattern. Examine the prints. If one of
the slow scan (side to side) pixel lines has multiple lines printing out and the pattern
is repeating every 8 lines, go to the Test Patterns, Section 3. Troubleshoot open
image data lines.
b. Examine the Quadrille prints. If no defect is seen, check the printer Interface cable.
Visually inspect the connectors at both ends. Ensure that there is no damage. Check
continuity of all wires from one end to the other. If the cable is OK, reseat the SLB/
RDR PWB.
c. Inspect the front and rear of the Controller Backplane for bent and touching pins.
Reform the pins. If the problem continues, replace the SLB/RDR PWB (PL 1.11)
12. PRINTER MOTION QUALITY DIAGNOSTICS.
If the problem is a Motion Quality problem, go to PQ 9-601.1, Printer Motion Quality Pro-
cedure.

PQ 9-601 ?-4 No Product Name Assigned
PQ 9-601.1 Printer Motion Quality Procedure
This RAP is a continuation of the PQ 9-601 for Printer Motor Quality Problems. The purpose of
this RAP is to isolate Printer motion quality defects.
Procedure
Perform the following for a Printer Motion Quality Problem:
1. Enter Job Exerciser, dC106. Select [Test Pattern (Halftone)], press Continue. Examine
the prints. Using the 150 mm scale, measure the interval between the strobing patterns.
Refer to (Figure 1).

No Product Name Assigned ?-5 PQ 9-601.1
Figure 1 PQ 9-601.1 Strobing Measurement

PQ 9-601.1 ?-6 No Product Name Assigned
2. After the intervals have been determined, proceed to Table 1 for the appropriate service • Replace the Motor Polygon Assembly (PL 6.1).
action to perform. • Replace the RCM PWB (PL 6.1).
3. For intervals that are greater than 150 mm, place the prints in sequential order, side by • If the problem is not corrected, go to Table 1 Strobing Frequency Service Action
side, to determine the frequency. Be sure the prints are separated by approximately 30 Chart for an IOT Motion Quality problem at the same frequency.
mm (8.5x11 in. paper) or 36 mm (A4 paper) from each other, in order to yield an accurate
5. If Fault Code, 6-233, VLD Range (5% Power Fault) is declared, go to 6-233.
measurement of the interval (interdocument zone allowance).
6. If the strobing is within the image structure, replace the following components in the order
NOTE: There may be more than one strobing frequency on the prints. The strobing fre- given:
quency that is most easily recognizable is the primary strobing frequency There may be • Motor Polygon Assembly (PL 6.1).
secondary frequencies that are not as apparent. This secondary strobing frequency infor-
• VLD Collimator Assembly PL 6.1).
mation is useful in further isolating the cause of the strobing.
• ROS Assembly (PL 6.1).
4. If strobing is present at a wobble frequency or strobing jitter is present, perform the follow- • Photoreceptor (PL 9.1).
ing:
7. If the problem is still not solved, go to Table 1 Strobing Frequency Service Action Chart.
Table 1 Strobing Frequency Service Action Chart

PRIMARY SECONDARY
FREQUENCY FREQUENCY SERVICE ACTION
A. 161 mm C. 78.5 mm Check the P/R Drive Roll for excessive runout. Replace the P/R Drive Roll Assembly (PL 9.3) if runout exceeds 0.2 mm total runout (peak-
peak).
Inspect the P/R Drive and P/R Drive Roll couplings for excessive wear/keyway backlash. Replace, as necessary (PL 9.3).
Re-align the P/R Drive Assembly (ADJ 9-10), (PL 4.17).
Inspect / re-align the Prefuser Transport Drive assembly, (PL 4.16).
B. 106.5 mm E. 53.7 mm Inspect the P/R Drive Tri-pulley or Bi-pulley for dirt buildup in the pulley grooves. Clean, if buildup is present (PL 4.17).
Replace the Tri-pulley or Bi-pulley (REP 4-48 ).
C. 78.5 mm F. 39.3 mm Check P/R Stripper roll assembly (top roll) for excessive runout. Replace, if greater than 0.2 mm total runout (peak to peak) (PL 9.3).
Inspect the P/R Drive and P/R Drive Roll couplings for excessive wear/keyway backlash. Replace, as necessary (PL 9.3).
Re-align the P/R drive assembly (ADJ 9-10), (PL 4.17).
Inspect and re-align the PreFuser Transport drive assembly (PL 4.16).
C. 106.7 mm K. 4.0 mm Adjust Cleaner Drive Belt Tension (ADJ 4-10), (PL 4.16).
D. 60.8 mm None Check the Main Drive Motor pulleys (PL 4.18) for dirt buildup in the grooves or a key/pulley mechanical defect. Clean/repair as necessary. If the
Main Drive Motor is okay, check the Fuser-Developer Drive Motor pulley, and repair, as required (REP 4-41), (PL 4.20).
Ensure the Main Drive motor pulleys (PL 4.18) and the Fuser-Developer Drive motor pulleys (PL 4.20) are fastened securely and are positioned
properly on the motor shafts.
Replace the Drive Motor (REP 4-27), (PL 4.18) if the output shaft appears to be bent (shaft runout), or if there is excessive radial free-play when
the shaft is biased at the free end of the shaft.
Replace 32T pulley on Main Drive Motor (REP 4-28), (PL 4.18).
Replace 40T pulley on Main Drive Motor (REP 4-28), (PL 4.18).
Replace the pulley on the Fuser-Developer Drive Motor (REP 4-41), (PL 4.20).
D. 50.3 mm N. 2.4 mm Realign the Prefuser Transport Drive Assembly (PL 4.16).
F. 37.3 mm C. 81.1 mm, A. 167.7 Check the Decurler drive and subsystem for binding, excessive load, or part failure. Repair/replace as required (REP 4-22), (PL 4.16).
mm
F. 106.7 mm C. 96.6 mm, N. 5.1 Verify that the Cleaner subsystem has had Preventive Maintenance per the specified interval.
mm

PRIMARY SECONDARY
Check the Cleaner Assembly for excessive binding at the drive shaft.
183 mm Check for clogged/foreign material in Cleaner Assembly.
F. 40.0 mm I. 20.0 mm Check the P/R drive roll for excessive runout. Replace the P/R drive roll assembly (PL 9.3), if runout exceeds 0.2 mm total runout (peak-to-
peak).
Inspect the P/R drive and P/R drive roll couplings for excessive wear or keyway backlash. Replace as necessary (PL 9.3).
Realign the P/R drive assembly (ADJ 9-10).
Inspect/re-align the Pre-fuser Transport Drive assembly (PL 4.16).
F. 167 mm J. 8.0 mm Adjust the tension of the Prefuser Transport drive belt (ADJ 4-19).
G. 28.2 mm None Check CHM - Duplex Idler Roll.
H. 24.5 mm, I. 20 C. 78.5 mm IF SECONDARY FREQUENCY "C" IS PRESENT:
mm
Check the P/R Drive Roll for excessive runout. Replace the P/R drive roll (PL 9.3) assembly if runout exceeds 0.2 mm total runout (peak-to-
peak).
Ensure that the idler lock down screw of the Prefuser Transport Drive Assembly is seated fully and is torqued (PL 4.16).
Inspect the P/R drive and P/R drive roll couplings (PL 9.3) for excessive wear or keyway backlash. Replace, as necessary.
Re-align the P/R drive assembly (ADJ 9-10).
Inspect and re-align the Prefuser Transport Drive Assembly (PL 4.16).
IF SECONDARY FREQUENCY "C" IS NOT PRESENT:

Ensure that the MIM Air Compressor Motor or its air fittings are not contacting the Printer frames.
Ensure that the MIM Air Compressor Motor rubber isolator mounts are in satisfactory condition.
Ensure that the MIM Air Compressor Motor mounting plate bolts are secure.
J. 13.1 mm D. 60.6 mm Ensure that the ROS Upper Mounting clamps are secure.
Check the Fuser-Developer Drive Motor bracket mounting screws (6) for tightness.
Replace the P/R Stripper Roll (PL 9.3).
K. 10.2 mm None None
L. 8 mm None Retension Pre-Fuser drive belt (ADJ 4-19). Clean pulley teeth.
M. 5.6 mm, N. 4.7 R. 2.3 mm None
mm
Adjust the tension of the P/R Intermediate Drive Belt (Main Drive Motor to tri-pulley / bi-pulley) (ADJ 4-15), (PL 4.17).
Inspect P/R Drive Tri-pulley or Bi-pulley and the 36T pulley on the P/R Drive Assembly for dirt buildup in the pulley grooves. Clean the pulleys,
if buildup is present (PL 4.17).
Check the drive belt that runs from the P/R drive Tri-pulley or Bi-pulley to the P/R drive assembly (i.e., the belt that does not have a tensioning
idler) for abnormal or excessive wear. Replace as necessary (PL 4.17).
Verify that the Cleaner Assembly has had Preventive Maintenance per the specified interval.
Verify that the Fuser Metering Roll Blade is not tucked and that the Fuser Rolls are in good condition.
Verify that the Fuser Roll (Contact Arc) is set to specification. Reset as necessary, (ADJ 10-2).
Inspect the Developer (also check for foreign material) drive assembly and their subsystems for excessive binding of bearing or other failures.
Inspect the P/R dive assembly, P/R module rolls, and their subsystems for excessive binding of bearing or other failures.

PRIMARY SECONDARY
Inspect all other driven elements in the MIM and their subsystems for excessive binding of bearing or other failures.
Inspect all other driven elements in the PHM and their subsystems for excessive binding or bearing or other failures.
NOTE: Evidence of excessive fretting (rust colored) or drive belt (black) deposits may be a sign of the problem cause. Adjust the tension of the
Fuser-Developer Drive Belt (ADJ 4-21).
N. 4.7 mm C. 78.5 mm Ensure that the P/R drawer is latched securely and that the Pretransfer Lead-in Baffle is cammed into the operating position.
If this action does not resolve the problem, proceed to other service actions associated with strobing interval "N."
O. 4.4 mm None Check the Bi-pulley, Tri-pulley, and 36T P/R Drive pulley for contamination in the grooves. Verify that the Bi-pulley and Tri-pulley to P/R Drive
belt are in good condition.
Reset the tension in the belt that connects the Main Drive Motor to the Bi-/Tri-pulley (ADJ 4-16).
Ensure that there is no binding within the P/R Module rolls or P/R Drive assembly.
P. 3.9 mm and for 4.0 None Verify that the Cleaner Assembly has had Preventive Maintenance per the specified interval.
mm
Check the Cleaner De-toning Roll Drive Gears for abnormal or excessive wear. Replace as required (PL 4.16).
Q. 3 mm None Check the Developer subsystem gear teeth for abnormal wear (all gears). Repair/replace as necessary (PL 4.17).
Check the Developer subsystem sump and rolls for foreign objects Repair/replace as required (PL 4.17).
R. 2.5 mm None Motor gear mesh frequency.
S. 1.7 mm None Ensure that the upper ROS mounts are secure.
Ensure that the lower inboard ROS Mounting Spring is restraining the ROS Guide Pin against the ROS Guide Rail. Reset (bias it counter-clock-
wise) and replace the spring PL 6.1, as necessary.
Verify that the Fuser Metering Roll Blade is not tucked, and that the Fuser Rolls are in good condition.
Check/adjust the tension of the Fuser-Developer Drive Belt (ADJ 4-21). Adjust Fuser-Developer Intermediate Drive Belt (ADJ 4-23).
Check/adjust Pressure Roll contact arc (ADJ 10-2).
Replace the Fuser-Developer Drive Motor (REP 4-41), (PL 4.20).
T. 1.5 mm U 1.4 mm (may be Ensure that the ROS is seated securely in the upper mounting blocks and its inboard guide pin is seated within the guide rail, held by the bias
present) spring.
Ensure that the P/R Module and drawer assemblies are latched securely.
Replace the ROS Polygon Motor Assembly. Go to (PL 6.1).
If the problem persists, and secondary frequency U. is present, go to REP 4-27 and replace the Fuser-Developer Drive Motor.
U. 1.4 mm None 50 Hz. Machine
Ensure that the upper ROS Mounts are secure.
wise) and replace the spring, as necessary.
Replace ROS Polygon Motor Assembly (PL 6.1).
60 Hz Machine
Ensure that the upper ROS Mounts are secure.
wise) are replace the spring, as necessary.
Check/adjust the tension of the Fuser-Developer Drive Belt (ADJ 4-21). Adjust Fuser-Developer Intermediate Drive Belt (ADJ 4-23).

PRIMARY SECONDARY
Check/adjust Pressure Roll contact arc (ADJ 10-2).
Replace the Fuser-Developer Drive Motor (REP 4-41), (PL 4.20).
Replace the ROS Polygon Motor Assembly (PL 6.1).
V. 1.3 mm None None
W. 247.0 mm None Realign the Paper Tray 1 and/or 2 Drive assemblies (ADJ 4-20), or replace the Paper Tray 1 and/or 2 Drive assemblies (REP 4-36).
X. 6.3 mm None Replace Main Drive Motor (REP 4-27), (PL 4.18) or replace Aux Drive Motor

PQ 9-602 Black Print RAP PQ 9-603 Blank Print RAP
A Black print has a black image covering the entire print. Because no area of the Photorecep- A Blank print has no image on the print. This can be caused by the PR being totally discharged
tor was discharged. or transfer not occurring.

Enter dC131 [MIN]. Check MIN NVM Address 125 in the appropriate level Software dC 131 Enter dC131 [MIN]. Enter Address 210. Enter Data 112 (Transfer current normal).
Table (Section 6, General Procedures of the Service Manual).
NOTE: If MIN Address 125 is at the Initial default value, RDR Fault (ROS Diagnostic Recov-
Procedure
ery) is enabled. The machine will not produce black prints as a result of a ROS related defect. WARNING
There will be a fault declared and no prints will run. If address 125 is at (the Initial default value Laser Radiation. Avoid direct exposure to beam.
+1), the Printer Internal Test Pattern is enabled. The machine will only print what appears to be
CAUTION
Black Prints or possibly Quadrille prints.
The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2)
The Data value is at the Initial default value. minutes or severe xerographic problems may result. If the belt module will be exposed to light
Y N for more than two minutes, remove the photoreceptor from the belt module and place it in the
Enter the Initial default value. Enter dC606. Program any job to check Print Quality. The protective bag, or place the bag over the photoreceptor with it on the belt module.
Print is Ok. Cheat the Printer Interlock Bypass Switch. Remove the ROS Lower Inner Panel. Enter dC330
Y N [6]. Select [Laser Write]. Press Continue.
A fault code is displayed.
Y N NOTE: [Polygon Drive] and [Laser Enable] are energized when dC330 [6] is entered.
Go to the PQ 9-618, PR Ground RAP.
The reflection of the laser light can be seen on the Photoreceptor belt.
Y N
Go to the RAP for the fault displayed.
Go to the 6-250/251 RAP.
Problem is resolved.
With [Laser Write] energized, select [Patch Enable]. Observe the reflection of the laser light
on the Photoreceptor, specifically noting the patch area. There is a break in the reflected
Go to the PQ 9-618, PR Ground RAP. If the problem is not solved, go to the PQ 9-601, Printer
laser light where the patch area is located, approximately the center of the Photorecep-
Image Quality Entry RAP.
tor belt.
Y N
Go to the 6-701, Patch Enable RAP.
Leave all outputs energized. Select [1-4] [Page Sync]. Press Continue.
NOTE: The ROS is on for only a brief period. Use the Remote Hand Held Device (RHHD) to
make ROS observations. For detailed Operating Instructions of the RHHD, go to (GP 1)
Remote Hand Held Device (RHHD).
The ROS illuminates the Patch area.

Y N
• The video cables are both connected to the ROS module at J203 and J204 of the
Image RCM PWB (Figure 1).
• The video cables are both connected to the Printer Backplane at J103 and J104.
• Check P101/J101 connector on the Printer backplane. If the Return Byte Clock (+
and -) signals at pins 40 and 41 of this connector are missing, blank prints can be
made without a fault code being declared during normal run.
Enter dC131 [MIN]. Enter Address 125. The Data value is at the Initial default value listed
in the appropriate level Software dC 131 Table in Section 6, General Procedures, of the
Service Manual.

No Product Name Assigned ?-11 PQ 9-602, PQ 9-603
A B
Y N Go to the RAP for the fault code displayed.
Change value to the Initial default value. Enter dC606. Run any job. A fault is declared.
Y N Enter dC909. Observe the Control Value display for Charge 1 ua. Press Continue. The
Enter dC909. Observe the Control Value display for Charge 1 ua. Press Continue. Charge 1 ua value is greater than 150.
The Charge 1 ua value is greater than 150. Y N
Y N Go to the PQ 9-630, Toner/Charge Control RAP.
Go to the PQ 9-630, Toner/Charge Control RAP.
Go to the PQ 9-616, Development RAP.
A B
Figure 1 PQ 9-603 Component Diagram (8310B)

PQ 9-604 Prints With Agglomerates/Debris RAP PQ 9-606 Print Distortion RAP
Agglomerates: Agglomerates are toner particles that are partially fused together forming A printed image appears to be stretched in either (or both) the slow scan or the fast scan direc-
larger masses. Partial fusing is caused by the pressure and heated surfaces areas found in the tion. Distortion can be categorized as follows:
Cleaner, Developer Housing, Toner Dispenser, Waste and Transport systems, and the Photo-
receptor module. • Slow scan distortion problems (motion quality problems relating to the PR speed or paper
transportation speed) appear on the print as a defect in the fast scan direction.
DCDs: Agglomerates can cause deletions in solid areas. These are called Debris Centered • Fast scan distortion problems (Polygon Motor speed fluctuations) appear on the print as
Deletions (DCDs). The major causes of DCDs are agglomerates and paper debris. The gener- defects in the slow scan direction.
ation of these is caused by incorrect Xerographic Setups.
Initial Actions
Procedure Observe the output prints. If wrinkles or folds are observed, go to the 10-604 Fuser Wrinkle
RAP.
1. Developer Housing Contaminants and their source.

Procedure
Enter dC131 [MIN]. Ensure that Address 420 is at the Data value shown in the appropriate
• Check the cleaner for agglomerates. Refer to PQ 9-617, Cleaner RAP.
level Software dC 131 Table in Section 6, General Procedures, of the Service Manual.
• Ensure that the Dicorotrons or other hardware is not contacting the Photoreceptor
belt. NOTE: MIN Address 420 is the mode selection for: (48)=300 PSI or (96)=600 PSI and Lead
• Check for obstructions and agglomerates in the Developer Housing. Refer to PQ 9- Edge Lightning (00)=no LEL, (02)=normal, and (03)=stress.
616, Development RAP. Check the sequential prints for a repeatable pattern of print distortion. Enter dC106.
2. Toner Dispense System. Select [Test Patterns and PQ] [Halftone]. Program a 50 print job. Press Continue. Num-
Remove the Toner Bottle. Dump a small amount of toner onto a sheet of paper. If agglom- ber the prints as they exit the machine. Examine the prints for distortion. Determine if
erates are present in the toner, replace the toner. Perform the Developer Dump and distortion is observed in a pattern.
Thump (REP 9-6). Y N
3. Check/Verify the following: The distortion occurs on every seventh print (A4 mode) or every third print (A3
mode).
• The Cleaner Zone Roll is fully engaged (PL 9.2)
Y N
• The Developer Housing, Xerographic Drawer, and Photoreceptor module are prop- CAUTION
erly locked into their operating positions.
The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to
• Enter dC131 [MIN]. Ensure that Address 202=125 (Dtac Current ref) and Address under two (2) minutes or severe xerographic problems may result. If the belt module
210=112 (Tran Shld current).
will be exposed to light for more than two minutes, remove the photoreceptor from
• Enter dC314. Select [DC PWB (10-18)]. Ensure that the calibration values entered the belt module and place it in the protective bag, or place the bag over the photore-
for DTAC$$SI (Detack Current Control) and TRAN$$SI (Transfer Current Control) ceptor with it on the belt module.
equal the values on the HVDC PWB calibration card. The distortion occurs on every print.
• DCDs are dependent on process control setup. Low TC, for example increases Y N
DCDs. Perform the Xerographic Setup (ADJ 9-3). The distortion occurs randomly. Check the following:
• Certain papers generate more debris than others. If paper debris is suspected try dif- • Broken Light Shield (PL 9.2)
ferent paper stock. • Any damaged Photoreceptor Module components that support the PR
• If agglomerates or debris remain a problem, replace the Toner Dispenser Assembly Belt from the back.Foreign objects under the PR Belt. Fold, curl, or dam-
(PL 9.19) age to the PR Belt. Repair/replace as required.
• Photoreceptor Belt Tension Roll and the Cleaner Zone Roll are properly
engaged. Check the Photoreceptor Tension (ADJ 9-11).
• Ensure that the wires going to the Photoreceptor Module, P212 connector,
are not rubbing against the PR Belt. Redress as required. If damaged,
replace the Photoreceptor Belt (PL 9.1)
• Xerographic Drawer properly mounted. Ensure that the drawer is aligned
and securely engages into the closed position. Check the PR Module
Alignment (ADJ 9-10).
• Check the Photoreceptor Drives
A B C
A B C A
• Continued problems, go to the Printer Electrical Noise Procedure RAP.
The defect appears on the print as a line in the slow scan direction.
Y N
If the defect appears as a deletion, go to the PQ 9-615 Deletions RAP.
If the defect appears as a smear, go to the PQ 9-635 Smear RAP.
CAUTION
under two (2) minutes or severe xerographic problems may result. If the belt module
the belt module and place it in the protective bag, or place the bag over the photore-
ceptor with it on the belt module.
• Dirt/Contamination on the ROS exiting window. Clean as required.
• Scratches on the Photoreceptor Belt. Replace the Photoreceptor (PL 9.1). Per-
form a Xerographic Setup (ADJ 9-3).
• Scratches/Build-up on the Fuser (PL 10.6)
• Build-up on the paper transport rolls. Go to the 8-705 Print Damage RAP.
Determine the problem area. Repair as required.
• Continued problems, go to the Printer Electrical Noise Procedure RAP.
CAUTION Figure 1 PQ 9-606 Component Diagram (8311A).

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under
two (2) minutes or severe xerographic problems may result. If the belt module will be
exposed to light for more than two minutes, remove the photoreceptor from the belt mod-
ule and place it in the protective bag, or place the bag over the photoreceptor with it on
the belt module.
• Any damaged Photoreceptor Module components that support the Photoreceptor
Belt from the back.Foreign objects under the Photoreceptor Belt. Fold, curl, or dam-
age to the Photoreceptor Belt. Repair/replace as required.
• Photoreceptor Belt Tension Roll and the Cleaner Zone Roll are properly engaged.
Check the Photoreceptor Tension (ADJ 9-11).
• Ensure that the wires going to the Photoreceptor Module, P212 connector, are not
rubbing against the Photoreceptor Belt. Redress as required. If damaged, replace
the Photoreceptor Belt (PL 9.1)
• Xerographic Drawer properly mounted. Ensure that the drawer is aligned and
securely engages into the closed position. Check the PR Module Alignment (ADJ 9-
10).
• Check the Photoreceptor Drives
• Continued problems, go to Printer Electrical Noise Procedure RAP.
A A
A
PQ 9-607/608 Uniform And Non-Uniform High Background Procedure
RAP Enter dC131 [MIN]. Check the following NVM addresses and enter the data values as listed in
the appropriate level Software dC 131 Table, Section 6, General Procedures, in the Service
Uniform background - a noticeable darkness or dirtiness in all areas of a print where no Manual.
image appears.
Table 1 MIN NVM
Nonuniform background - a noticeable darkness or dirtiness discernible in localized areas of
Address Address Address Address
a print where no image appears.
187 205 243 347
Structured background - a background defect that appears as fast or slow scan black lines 189 206 244 348
on the non-image areas of a print, which may have a woodgrain or plywood appearance, and 192 207 245 349
can appear on the entire print or in localized areas.
194 208 247 350
199 210 251 351
Initial Actions
200 217 300 352
• Check for Reverse Developer Flow (Figure 1). Inspect the Developer Material flow across
Developer Roll #1. Reverse Developer Flow exists when Developer Material accumulates 203 218 302
between rolls 1 and 2 and appears to flow in the reverse from normal direction. It can 204 220 305
occur at one or at both ends of Developer Roll #1. If Reverse Developer Flow is in evi-
dence, go to the PQ 9-631, Bead Carryout RAP, Check for Reverse Developer Flow CAUTION
section at the end of the RAP.
• Enter dC107 [Xero]. Replace the Developer Material (REP 9-4) as required. minutes or severe xerographic problems may result. If the belt module will be exposed to light
• Replace the Photoreceptor (PL 9.2). for more than two minutes, remove the photoreceptor from the belt module and place it in the
• Check/clean the exterior of the Developer Housing and all Dicorotron Shields. Inspect all protective bag, or place the bag over the photoreceptor with it on the belt module.
dicorotron shields and wires for contamination. Replace them as required. Reset the All printer MIN NVM Data values were equal to the values listed in the appropriate level
HFSI counters. Software Table.
• Examine the shoulder washer located on the back of the PR Module Drive Roll for wear or Y N
damage (PL 9.3). Inspect the Photoreceptor Belt for surface wear. Replace if it has a buffed or streaked
appearance (PL 9.1) Change data values as required. Perform Xeroxgraphic Setup, (ADJ
• Examine the rear edge of the Photoreceptor for damage. If damage is apparent, examine
9-3).
the rear of the Edge Guide (PL 9.5) for fused toner. If fused toner is found, replace the
Edge Guide (REP 9-45).
Open the Printer Front Doors. Pull out the Xerographic Drawer. Raise the Photoreceptor Mod-
• Enter dC909. Run 200 prints. The difference between Roll 1 and Roll 2 Bias and ESV ule. Verify the operation of the discharge lamps. Press the Red test button on the Photorecep-
Zone 2 is approximately 120 volts. If it is not, run dC951, Xerographic Setup. During the
tor Module. All segments of the Precharge and the Pretransfer Lamps are lit.
dC909 Print Run, the DSS readings in ID Zone 2, 4, 6 are between 90 and 100. If they are Y N
not, perform DSS Saturation (ADJ 9-13), DSS Timing (ADJ 9-14) and PGen Timing (ADJ Go to the PQ 9-624, Precharge/Pretransfer Lamps RAP.
9-5). Immediately run dC951, Complete Setup.
• Enter dC951 [Automatic Xerographic Setup]. Ensure that the ROS Calibration display Examine the background on the sample prints. The background is uniform on the prints.
value is equal to the value on the ROS Calibration tag on the front of the ROS assembly. Y N
Perform the ROS Low Correction Factor adjustment (ADJ 6-3). Perform the Xerographic (Nonuniform Background). Perform the following checks:
Setup (ADJ 9-3). • Enter dC314. Select [DC PWB #2]. Ensure that the calibration values entered for
• Ensure that the Transfer Assist Device is in place. DETAC$$SI (Detac current control) and TRAN$$SI (Transfer current control) equal
• Go to the PQ 9-616, Development RAP. Return to this RAP upon completion. the values on the HVDC calibration card.
• Go to the PQ 9-617, Cleaner RAP. Return to this RAP upon completion. • Inspect the Photoreceptor Belt for surface wear. Replace the belt if it has a buffed or
• Go to the PQ 9-620, DSS RAP. Return to this RAP upon completion. streaked appearance (PL 9.1).
• Check for any kinked or damaged Ozone Ducts (PL 9.8).
• Go to the PQ 9-616, Development RAP.
(Uniform Background). Enter dC909. Press Continue. Observe the Control Values, Charge
2V and ESV #2 (Patch reading #2 under Image Frame). Charge 2V is LESS THAN 750
VDC, or ESV #2 is less than 200 VDC.

No Product Name Assigned ?-15 PQ 9-607/608
Y N
Verify the DSS Saturation (ADJ 9-13). Perform the Xerographic Setup (ADJ 9-3). If back-
ground problem continues, return to this RAP; go to the Y response to the previous state-
ment.
Select [ESV-DSS Test]. Record the DSS reading. Carefully wipe off the Photoreceptor Belt
directly over the DSS with a clean piece of cotton. Recheck the DSS reading for the clean Pho-
toreceptor Belt. The difference between the two DSS readings is less than 5 units.
Y N
(The difference between the two DSS readings is greater than 5 units). This indicates that
a DSS calibration was done with toner on the Photoreceptor Belt. Enter dC951 [TC/
PGen]. Press the Continue button. When the program is completed, check the DSS Sat-
uration (ADJ 9-13), and perform a Xerographic Setup (ADJ 9-3). Look for background on
the last prints. If background is still present, go to Flag 1. Check the Developer Bias 1 and
2 wires. If the problem continues, perform the following actions until the problem is fixed:
• Perform PQ 9-621, Patch Gen/Patch Integrity RAP.
• Perform PQ 9-619, ESV RAP.
If the problem continues, perform the following actions.

• Go to Flag 2. Check for a short circuit or an open circuit.
• Check the DSS Saturation (ADJ 9-13)
• Perform PQ 9-621, Patch Gen/Patch Integrity RAP.
• Perform PQ 9-619, ESV RAP.
• Perform the Automatic Low ROS Correction Factor procedure in dC951 Xerographic
Setup (ADJ 9-3).
• Verify that the DSS Read Timing is correct.

PQ 9-607/608 ?-16 No Product Name Assigned
Figure 1 PQ 9-607/608 Circuit Diagram (703007).

No Product Name Assigned ?-17 PQ 9-607/608
A
PQ 9-609 Low Image Darkness (Low Signal Strength, w/ (The deletion areas are seen on the 1 Pixel Black Line prints.) Enter dC106. Select [Test Pat-
terns and PQ] [Xerographic]. Program a 20 print job. Press Continue. Look for density varia-
MICR) RAP tion in the solid area density blocks of the output prints. The density is uniform without vari-
ation.
The overall image density on the prints is light (undertoned).
Y N
Go to the PQ 9-614, Nonuniform Image Darkness RAP.
Initial Actions
• Ensure that the Patch Generator and the DSS are operating. Go to the PQ 9-621, Patch Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to
Gen/Patch Integrity RAP and the PQ 9-620, DSS RAP. When complete, return to this pro- the values listed in the appropriate level Software dC 131 Table, Section 6, General Proce-
cedure. dures.
• Ensure that a Digital Patch Generator was installed and that the Digital Patch Generator
is enabled in dC105. Table 1 MIN NVM
• Perform the following: MIN Address Current Value MIN Address Current Value
1. Power off the Printer.
210 220
2. Saturate a clean, lint free cloth with Xerox Anti-static Fluid (8R90275).
215 221
3. Wipe the DSS with the saturated cloth so that the fluid beads on the DSS.
4. After a few seconds, wipe with a clean, dry, lint free cloth. The data values at the addresses were equal to the values listed in the appropriate level
5. Perform the DSS Saturation adjustment (ADJ 9-13). Software Table.
WARNING Y N
Enter the correct data values. Perform the Xerographic Setup (ADJ 9-3).
Put on Safety glasses before inspecting the Dicorotron coronodes. Eye injury could
result if the glass coronode breaks.
Enter dC909 [ESV-DSS Test] [DSS Recalibrate]. Record the DSS value. The DSS value is
• Clean all dicorotron shields. Inspect all dicorotrons. If the shields or wires are contami-
greater than 232 +/- 14.
nated, replace as necessary, and recheck the image darkness.
Y N
• Check the OZAC system for air leaks and/or cracks in the OZAC Ducts. Repair/replace CAUTION
the ducts as required (PL 9.8)
Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use
• Remove the toner bottle. Ensure that there is toner in the hopper and in the bottle. Ensure Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth.
that toner is not caked in the hopper. If toner is caked, perform the Developer Dump and The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power
Thump Procedure (REP 9-6), replace the developer material (REP 9-4) and add new before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when
toner. the power is switched on, and will ensure that the ESV Monitor measurements and the
• Ensure that the proper PQ Basic and Special Controls are being used for the job. Advise DSS calibrations are performed with the components clean.
the operator if required. Clean the DSS, ESV and Patch Generator. Enter dC106. Select [Printer Options] [Test
• Enter dC107 [Xerographic Counters]. Replace developer material (REP 9-4) as Patterns and PQ] [Halftone]. Program a 150 print job. Press Continue. Examine the
required. Perform the Xerographic Setup (ADJ 9-3). image darkness of the last few prints. Select [Xerographic]. Press Continue. A 9-215
Procedure fault code may occur if the machine attempts a tone up cycle. Clear the fault and con-
tinue. When the job has completed, go to the Yes response to the previous statement,
Enter dC606. Select Black Lines [1-Pixel Lines] Image Size [8.5 by 14 inch]. Select [Printer
and continue with this RAP.
Options]. Select a tray with 14 inch paper. Select [Test Patterns and PQ] [Darker 2]. Press
Continue. Examine the prints.
Enter dC140 [DC Bias Values]. Press Continue. Measure the Dev Roll 1 & 2 Bias voltage.
NOTE: ROS Flare Light slow scan deletion bands may appear as Low Image Darkness. These Measure at the Developer Housing left side extrusion (located under the Developer Catch
deletion bands are 1/8 to 1/2 of an inch in width, and usually more than one band appears on Tray), and the machine frame. Observe the Dev Rolls 1&2 Bias displays. The measured
the print. voltage is 180 to 320 VDC.
Y N
The deletion areas are seen on the 1 Pixel Black Line prints. Press Stop. Switch Off the printer power. Check for continuity from P256-5 (the connector
Y N at the rear of the Toner Dispenser) to the drive shaft of Rolls 1 and 2. There is continu-
Ensure that the Developer Bias P204 connector at the back of the Developer Housing is ity.
connected securely. (Possible ROS flare light induced defect). Replace the ROS. Perform Y N
the Xerographic Setup (ADJ 9-3). Go to 6-233 and go to 6-233, and perform the proce- Repair as required.
dures.
A B C
B C
Go to the 9-320 RAP. To diagnose the problem (assuming there is no fault code present), PQ 9-610 High Image Darkness RAP
follow the first No response of the 9-320 RAP.
The overall image density on the prints is dark (overtoned).
Press Stop. Measure the Dev Roll 3 Bias. Measure the voltage between the Developer Hous-
ing extrusion under the Developer Air Manifold and machine frame. Observe the Dev Roll 3 Initial Actions
Bias displays. Press Continue. The measured voltage is within 20 VDC of the required • Observe the solid area blocks on the prints.
display value.
• The density of block 3 is equal to the STD:Restore density block. If not, check the Print
Y N
Darkness level set by the Operator in the Print Management Screen. For Normal Print
Press Stop. Switch Off the printer power. Check for continuity from P256-8 (the connector
Darkness, set Darkness Level to 4.
at the rear of the toner dispenser) to the right-hand surface of the Developer Housing
extrusion. There is continuity. Procedure
Y N If the Xerographic Setup has not been completed this call, go to Xerographic Setup (ADJ 9-3).
Repair as required. Enter dC131 [MIN]. Record the Data values at the following Addresses.
Go to the 9-321 RAP. To diagnose the problem (assuming there is no fault code present), Table 1 MIN NVM
follow the first No response of the 9-321 RAP.
MIN Address Current Value
If not already completed, perform the following actions until the problem is repaired. 220
• ESV checkout: go to the PQ 9-619, ESV RAP. 222
• Patch Generator checkout: go to the PQ 9-621, Patch Generator/Patch Integrity RAP. 251
• DSS checkout: go to the PQ 9-620, DSS RAP. 300
• Replace the developer material (REP 9-4). Perform the Xerographic Setup (ADJ 9-3). 302
• Advise the customer to use modified PQ settings. Store the modified settings in the Pro-
grammed Job icon. Enter dC909. Run a 200 print job. Observe the DSS Readings in the ID Zone 2, 4, 6. Values
• Ensure the dC131 NVM values at the following locations compare them to the values over deadcycle setpoint (100). The Machine is deadcycling (Adjusting Print Quality.
listed in the appropriate level Software dC 131 Table in Section 6, General Procedures Y N
Perform the DSS Saturation (ADJ 9-13). Go below to STEP A.
Table 2 MIN NVM
MIN Address Current Value MIN Address Current Value Perform the following:
• DSS Timing (ADJ 9-14).
243 251
• DSS Saturation (ADJ 9-13).
244 300
(STEP A)
245 302 Compare the values listed in the Table 1 to the appropriate level Software dC 131 Table in Sec-
tion 6, General Procedures. The data values at the MIN NVM addresses in Table 1 were
• Continued problems, go to the 9-215 RAP. equal to the values listed in the appropriate level Software Table.
Y N
Enter the correct data values, perform the Xerographic Setup (ADJ 9-3).
Enter dC106. Select [Test Patterns and PQ] [Xerographic]. Program a 75 print job. Press
Continue. Compare the prints to the Standard Image Reference test pattern (82E4161). The
background on the prints is less than the All:BKGD block.
Y N
(Background is high). Go to PQ 9-607/608, Uniform and Non-uniform High Background
RAP.
Look for density variations across the prints. Check the top and bottom density blocks on the
prints. The density is uniform without variation.
Y N
Density variations observed, go to PQ 9-614, the Non-uniform Image Darkness RAP.
A
A
Observe the solid area blocks on the prints. The density of block 3 is less than or equal to PQ 9-611 Dark Streaks/Scratches/Bands RAP
the STD:Restore density block.
Y N Dark streaks and bands are toner deposits (marks on copy) in any direction. Streaks and
(The density is too dark). Enter dC131 [MIN]. Enter Address 250 (Patch Generator Inter- scratches are narrow widths, such as the width of a line, that is up to one millimeter across.
cept Value) and record the value. Decrease the current Data value by 3. Select [Enter]. Bands are wider widths greater than one millimeter across.
Enter dC606. Program a 500 print job. Press Continue. After the 200 prints are complete,
check the block 3 density. Repeat the decreasing of Address 250, 3 bits at a time, up to 5 Initial Actions
times (maximum 15 bits). If the density of block 3 is not less than or equal to the Observe the MIN cooling fan. If the fan is not functioning properly, go to the 9-705, MIN Cooling
STD:Restore, enter the original Data value in Address 250. Go to PQ 9-621, the Patch Fan RAP.
Gen/Patch Integrity RAP, and PQ 9-620, the DSS RAP.
If the PQ defect is a fast scan band running the entire length of the print, go to the PQ 9-618,
Normal Mode density is OK. Instruct the customer to use the Print Quality darkness controls to PR Ground RAP. Return to this RAP if the problem continues.
optimize Print Quality.
WARNING
Put on Safety glasses before inspecting dicorotron coronodes. Eye injury could result if
the glass coronode breaks.
Clean the dicorotron shields and ensure that the dicorotrons are seated properly. Check the
wires for hot spots, cracked glass. Replace components as required (PL 9.10)
If the defect occurs only in the 11 to 14 inch area of the prints, replace the Metering Blade and
Wick (PL 10.7)
Procedure
Classify the symptom. Enter dC606. Select [Light Dusting]. Run 14 prints using the longest
print paper stock available. Determine which of the following categories the prints fall into:
Scratches/Streaks/Bands.
• Slow Scan Direction (parallel to the Process Direction), go to STEP 1.

• Fast Scan Direction (perpendicular to Process Direction), go to STEP 2.
1. SLOW SCAN DEFECTS (parallel to process direction)
a. Slow Scan Bands. Go to the Print Quality Defect section if the bands are as follows:
• Dark Bands, (1 scan line) 0.042mm wide every 0.25mm or 0.35mm in the fast
scan direction.
NOTE: Do not assume that new Developer or new Toner is defect free. Always compare the
batch numbers to past bulletins and purge notices to determine if the consumable has
been previously identified as being defective.
b. Consumable Check. Determine if the Toner and/or the Developer Material are
defective. Check the batch numbers against any past bulletins or purge notices.
c. Toner batch number identified as defective. Remove the Toner Bottle. Empty the
Toner out of the hopper. Tap the sides of the Hopper with the handle of a screwdriver
as you vacuum it out. Perform the Developer Dump and Thump (REP 9-6). Install
new Developer Material (REP 9-4). Go to STEP 3 in this RAP.
d. Developer material batch number identified as defective. Perform the Developer
Dump and Thump (REP 9-6). Install new Developer Material (REP 9-4). Go to STEP
3 in this RAP.

PQ 9-610, PQ 9-611 ?-20 No Product Name Assigned
CAUTION NOTE: The spots blade must be adjusted after a cleaner replacement.
• Check/clean toner debris/deposits from the Cleaner Housing right side
(Entrance Baffle). Check that the Spots Blade (brown) contact area is 0.5mm to
3mm and adjust if required (ADJ 9-16).
• If the Photoreceptor has numerous scratches with a brushed appearance, vac-
the belt module.
uum the Cleaner Module. Replace the Cleaner Brush (PL 9.24) and the Flicker
e. Photoreceptor. If the marks or lines on the prints repeat every seventh print (A4
Bar (PL 9.24). Go to STEP 3 in this RAP.
mode), inspect the Photoreceptor Belt for scratches or Crayoning.
CAUTION
• Scratches; There may be a PR Tension (ADJ 9-11) or a PR Module Alignment
(ADJ 9-10) problem. If the adjustments are OK, complete this procedure to The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under
identify the cause.
• Crayoning is piled up toner areas on the PR Belt. If crayoning (Toner buildup) is
observed on the Photoreceptor, perform the Developer Dump and Thump Pro-
the belt module.
cedure (REP 9-6). Replace the Developer Material (REP 9-4). Replace the
g. Short Slow Scan Scratches - less than 18mm long. Inspect the Photoreceptor Belt.
Toner Bottle (REP 9-0). Clean the Mixing Auger (REP 9-13). Go to STEP 3 in
this RAP. • If the Photoreceptor is damaged at the inboard edge, replace the Photoreceptor
Belt (PL 9.1)
NOTE: Always replace the Spots Blade (PL 9.26) whenever the PR Belt is replaced for Long
• Inspect the Developer Catch Tray and the developer material for contaminants.
scratch problems. The blade has probably suffered edge damage. Do not immediately
If contaminants are found, check for binding, interference and /or bearing fail-
install a new Spots Blade with a new PR Belt. Run dC951 first with no blade. Wipe the
ure of the Developer Rolls (REP 9-9), BRD Roll (REP 9-8), Trimmer Bar (REP
new blade with toner before installing to eliminate tuckunder that stresses the blade.
9-11), Mixing Auger (REP 9-13), and Paddle Wheel (REP 9-12). Go to the PQ
f. Long Slow Scan Scratches - scratches on the Photoreceptor greater than 18mm 9-616, Development RAP. Return to this RAP and perform STEP 3 in this RAP.
long. Before replacing the Photoreceptor Belt (PL 9.1), note the position of the • Unlatch and raise the Photoreceptor Module. Ensure that the Developer Hous-
scratches. Determine if they line up with any of the components of each subsystem ing is securely installed in the machine. Check the front and rear contact points.
around the PR Belt. Some causes of scratches and their corrective actions are: If either of the front two contact points are damaged or worn, replace the Front
• Broken/loose components around the Photoreceptor Module, repair/replace Bearing Clamp (PL 9.15)
components as required. 2. FAST SCAN DEFECTS (Perpendicular to process direction).
• Inspect the Developer Housing and the Cleaner Housing for contaminants or The defect only appears on the last print of any print run.
binding. Go to the appropriate RAP, PQ 9-616, Development RAP or the PQ 9- a. There may be an intermittent connection in the Preclean Dicorotron shield circuit.
617, Cleaner RAP if a problem is suspected. Clean and reseat the Preclean Dicorotron shield. If the problem continues, inspect
• Transfer Assist Blade touching the Photoreceptor. Ensure that the Mylar blade the dicorotron shield connector, dicorotron shield lead, and the HVDC PWB shield
is not touching the Photoreceptor in standby. If it is, check for blade damage connector.
and also that the blade is indexed to the proper position for the short paper b. There is an intermittent connection in the circuit of the Charge 1 or the Charge 2
being used by the customer. For additional information, see Transfer Blade dicorotron shield. Clean and reset the Charge 1 and the Charge 2 dicorotron shield.
Repair (REP 9-48).
c. The defect may be caused because of a failed Precharge or Pretransfer Discharge
• Ensure that the Developer housing, Xerographic Drawer, and Photoreceptor Lamp. Open the front covers and the Xerographic Drawer. Pull out the Photorecep-
Belt Module are positioned properly and locked into the operating position. tor Module to its maximum position. Press the R (Red) lamps test switch on the Pho-
• Ensure that the Charge Dicorotrons are not contacting the Photoreceptor Belt. toreceptor Module. If a lamp does not light, go to the PQ 9-624, Precharge/
Perform the Charge Dicorotron Balance (ADJ 9-6) and Height (ADJ 9-7) adjust- Pretransfer Lamps RAP.
ments. d. The defect may be caused by the Cleaning system. Go to the PQ 9-617, Cleaner
• Ensure that the ESV is not contacting the Photoreceptor Belt. Perform the ESV RAP. If the problem continues, go to the PQ 9-616, Development RAP. Return to this
Height Adjustment (ADJ 9-12). RAP and perform 3 in this RAP.
• Place white paper under the Cleaner. Remove the Cleaner Brush. Tap the e. Black, fast scan line on the lead edge of the prints. If the defect is a black line or
Cleaner Module with the handle of a screwdriver. Check the debris on the white a smear on the lead edge of the prints in the direction of the fast scan, enter dC131
paper for contaminants. If large contaminants are found, a binding auger prob- [PHN]. Ensure that Address 251=0. Check the Transfer Assist Blade Timing (ADJ 9-
lems exists, or if toner buildup on the detoning rolls is present, go to the PQ 9- 9). If the problem continues, replace the Transfer Blade (PL 9.11)
617, Cleaner RAP. 3. FINAL ACTION.

• Ensure that all sources of contamination have been purged from the System to pre- CAUTION
vent a callback for the spots problem. If the above or no other cause of Photorecep- Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox
tor scratches are found, replace the Cleaner Brush (PL 9.24). anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV
Possible Sources of Contamination should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before clean-
Ensure all sources of contamination have been purged from the System to prevent callback for
the spots problem. Perform the following actions unless already done while troubleshooting. switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are
Paper Dust • Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Pre-
charge Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Vacuum
• Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper the Photoreceptor Ground Brush.
Trays and the paper path areas. Wipe areas as required. • Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays
Paper Stock and the paper path area. Ensure that no developer material has accumulated on the BRD
roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt, Perform
• Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If the Xerographic Setup (ADJ 9-3).
expected as a contaminant, direct the Operator to discard the top and bottom sheets of Fuser
any new reams of paper added to the Trays. Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not con-
• Pre-drilled paper: suggest that paper be drilled after printing if possible. taminating the developer assembly. If any oil is identified in the Developer Assembly, replace
• Label stock: adhesives from the labels can cause spots. the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the
• Carbonless paper is not recommended for use on this system. Xerographic Setup (ADJ 9-3).
• Paper stock: certain brands are known spot generators.
• Spray adhesives: any sprays used near the system can enter the machine air system and
can cause spots and damage the Photoreceptor.
Tray 1 / Tray 2 Feed Components
Oil leaking from the sides of bearings or debris from the following:
• Takeaway Roll (PL 7.13)

• Feed Belt Idler (PL 7.12)
• Feed Belt Pulley (PL 7.12)
• Feed Belt Spool (PL 7.12)
• Idler and Retard Brake (PL 7.13)
Belts wearing:
• Takeaway Drive Belt (PL 7.10)

• Feed Clutch Belt (PL 7.10)
• Top Transport Belts (4) (PL 7.10)
Dirt Shield, clean or replace as required (PL 7.10)
Xerographic
CAUTION
minutes or severe xerographic problems may result. If the belt module will be exposed to light
for more than two minutes, remove the photoreceptor from the belt module and place it in the
protective bag, or place the bag over the photoreceptor with it on the belt module.
• Photoreceptor Hydraulic Lift assembly. Check for leaks. Replace Lift as required (PL 9.4).

A B
PQ 9-612 Light Streaks/Bands RAP Y N
Look for dirt or obstructions in the transfer area and in the stripper finger area.
The appearance of light streaks and/or light bands is an indication that there is not enough or
an absence of toner in the required areas. Streaks are narrow widths, such as the width of a Rotate the Developer Rolls two revolutions counterclockwise with the Belt Module
line, that are a maximum of 1mm across. Bands are widths greater than 1mm across. opened to its maximum position. Observe the developer material on the rolls. The
developer material is smooth and even.
Initial Actions Y N
Check the Developer. Remove the obstruction from the Trimmer Bar area. Per-
WARNING form the Developer Dump and Thump (REP 9-6). Perform the Xerographic
Put on safety glasses before inspecting dicorotron coronodes. Eye injury could result if Setup (ADJ 9-3).
the glass coronode breaks.
• Clean the dicorotron shields, and inspect the dicorotrons. If the shields or wires are con- Look for a large amount of developer material on the top of the Developer Housing
taminated, replace them as necessary, and recheck the image darkness. or on the Bead Removal Device (BRD Roll). Material is present and is high
• Check the OZAC system for air leaks and/or cracks in the OZAC ducts. Repair/replace enough to touch the Photoreceptor Belt.
the ducts as required (PL 9.8). Y N
If this fault is random, it may be caused by undetected, intermittent dicorotron
• If the defect repeats on every seventh print, replace the Photoreceptor Belt (PL 9.1).
faults. Remove all dicorotrons, and inspect the HVAC contacts for signs of arc-
Procedure ing or corrosion. Replace the dicorotron as required (PL 9.10)
Enter dC606. Select Black Lines [1-Pixel Lines]. Select [Printer Options] [Tests Patterns
and PQ] [Darker 2]. Press Continue. Examine the prints. Use the vacuum cleaner to clean the top of the Developer Housing and the BRD.
Change the Developer Material (REP 9-4). Perform Xerographic Setup (ADJ 9-3).
NOTE: ROS Flare Light slow scan deletion bands may appear as Low Image Darkness. These
deletion bands are 1/8 to 1/2 of an inch in width, and usually more than one band appears on
Go to the PQ 9-621, Patch Gen/Patch Integrity RAP.
the print.
The deletion areas are seen on the 1 Pixel Black Line prints. CAUTION
Y N The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2)
(ROS flare light induced defect). Replace the ROS (PL 6.1). minutes or severe xerographic problems may result. If the belt module will be exposed to light
The defect is in the fast scan direction. protective bag, or place the bag over the photoreceptor with it on the belt module.
Y N Open the Photoreceptor Module. Press the (Red) lamps test switch on the front of the module.
The defect is a deletion band that is approximately 20 millimeters wide in a vertical The Pretransfer and Precharge Lamps are lit.
direction and is 180 millimeters from the top edge of the copy. Y N
Y N Go to the PQ 9-624, Precharge/Pretransfer Lamps RAP.
Enter dC106. Select [Test Patterns and PQ] [Xerographic]. Program a 20 print
job. Press Continue. After approximately 10 prints have been made, open the The Developer Rolls rotate with a smooth motion.
Printer Right Front Door. Carefully remove the print from the prefuser area. The Y N
defect is on the unfused print. Repair the cause of the defective developer drive.
Y N
Look for obstructions in the fuser area. Ensure that the Fuser Wick is positioned Look for light l leaks in the imaging areas.
correctly.
CAUTION
Open the Xerographic Drawer, and lift the Belt Module to its maximum position.
Inspect the developed image area on the photoreceptor. Determine if the defect is
present. The defect is on the developed image.
A B
PQ 9-613 Black Spots RAP NOTE: If the spots are clustered together but are in an ordered pattern they may be the result
of a damaged PR belt. If the PR Module is lowered incorrectly, the result can be spots that
Black spots are areas of unwanted marks or deposits of toner within a print. Excessive image appear in a fast scan direction.
darkness on copies will tend to aggravate the dark spots problem.
NOTE: In early software versions the dC107 counter had the units incorrectly labeled as
pitches, the counter actually indicates P/R Belt revolutions.
Initial Actions
• Ensure that the Photoreceptor Module and the Xerographic Drawer are locked into their a. Ensure that the Spots Blade is properly installed. Check the Spots Blade Contact
operating positions. (ADJ 9-16).
• If toner is falling out of the Cleaner causing toner blotches, go to the PQ 9-617, Cleaner b. Examine the Photoreceptor Belt for fuser agent or other contaminants. Use the Pho-
RAP. toreceptor Spots Cleaning procedure (REP 9-55), or replace the Photoreceptor (PL
• If the spots are only on the backside of the print and occur randomly, inspect/clean the 9.1).
Transfer Assist Blade. Check/adjust the Transfer Blade Timing (ADJ 9-9). c. Enter dC107, [Xero]. Replace the Photoreceptor if greater than 100K revolutions
(PL 9.1).
• Check the customers PQ settings. Black spots will increase if print darkness is set too
high. d. Inform the customer that certain items can increase the potential for spots. Refer to
• Check for fuser agent leaking into the xerographic area. last check of this RAP, Possible sources of contamination.
6. Black spots appear randomly on the prints.
Procedure
a. Ensure that the Toner Filter Assembly Cover is closed and latched correctly.
1. Check sequential prints for a repeatable pattern of black spots.
b. Enter SCP [HFSI] [Dicorotrons]. Check 09-822 Preclean Dicorotron, replace if near
Enter dC606. Select [Light Dusting]. Program 250 prints. Press Continue. Examine the
or over threshold (PL 9.10)
prints for dark spots.
c. Check for excessive toner/developer build up around the Developer Housing. If the
a. Dark Spots pattern repeats on every print. Go to the PQ 9-601, Printer Image
developer material is contaminated and it has been in the machine for less than
Quality Entry RAP.
500K copies, check the machine for sources of contamination. Correct the contami-
b. Dark Spots no repeat pattern. Go to STEP 6. nation problem. Replace the Developer Material (REP 9-4). Go to the PQ 9-616,
2. Dark Spots on prints whose image darkness is excessive. Development RAP.
Select dC106 [Test Patterns and PQ] [Xerographic]. Press Continue. Check the print 7. Determine if the dark spots are present past the Cleaner.
specifications: a. Run 20 prints of the light dusting. Enter dC106. Select [Test Patterns and PQ]
a. The background on the print is greater than the ALL:BKGD block, go to the PQ 9- [Halftone]. Press Continue.
607/608, Uniform and Non-uniform High Background RAP. b. After 10 prints have been made, open the Printer Front Doors. Observe the Cleaner
b. Block 3 on the print is greater than the STD:Restore block, go to the PQ 9-610, High Assembly. If excessive toner is in the cleaner or black spots are present on the Pho-
Image Darkness RAP. toreceptor Belt past the Cleaner, go to the PQ 9-617, Cleaner RAP.
3. Black spots repeat on almost every copy, but tend to move across the page at the 8. If considerable levels of dirt are found in the belt module area, correct the dirt prob-
rate of six to 10mm print to print. lem. Go to the PQ 9-632, Dirt RAP.
Check for offset toner images on the fuser roll. Go to the 10-606, Dry Ink Spots on Prints/ 9. Clean sources of contamination from the System to prevent callback. Perform the
Spots Deletions RAP. following actions unless already done while troubleshooting:
4. Black spots repeat on almost every copy, but occur in a Slow Scan direction that Possible Sources of Contamination
aligns with the front or rear edge of Tray 1 or Tray 2 Feed Heads.
a. Remove the following parts from the feed heads and wipe off any excess grease the spots problem. Perform the following actions unless already done while troubleshooting.
with a dry towel:
• Take Away Drive Roll Paper Dust
• Feed Belt Idler
• Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper
• Feed Belt Pulley
Trays and the paper path areas. Wipe areas as required.
b. Replace the Photoreceptor Belt (PL 9.1). Perform the Xerographic Setup (ADJ 9-3).
Paper Stock
5. Black spots repeat every seventh print and are judged unacceptable.
• Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If
expected as a contaminant, direct the Operator to discard the top and bottom sheets of
any new reams of paper added to the Trays.
• Pre-drilled paper: suggest that paper be drilled after printing if possible.

• Label stock: adhesives from the labels can cause spots. PQ 9-614 Non-Uniform Image Darkness RAP
• Carbonless paper is not recommended for use on this system.
There is a noticeable difference in image density on the same print. Variations in the fast scan
• Paper stock: certain brands are known spot generators.
or slow scan direction.
Initial Actions
• Check for and repair light leaks around the machine, ensure there is no ambient light get-
ting into the Printer around the covers.
• Check the OZAC system for air leaks, cracks in the OZAC Ducts. Repair/replace compo-
• Takeaway Roll (PL 7.13) nents as required (PL 9.8).
• Feed Belt Idler (PL 7.12) WARNING
• Feed Belt Pulley (PL 7.12) Put on safety glasses before inspecting dicorotron coronodes. Eye injury could result if
• Feed Belt Spool (PL 7.12) the glass coronode breaks.
• Idler and Retard Brake (PL 7.13) Clean all dicorotron shields. Inspect the dicorotrons for contamination. Replace dicorotrons as
necessary (PL 9.10).
Belts wearing:
Check the Charge Dicorotron Balance (ADJ 9-6).

Procedure
Enter dC606. Select Black Lines [1-Pixel Lines] Select [Printer Options] [Tests Patterns
Dirt Shield, clean or replace as required (PL 7.10) and PQ] [Darker 2]. Press Continue. Examine the prints.
Xerographic NOTE: ROS Flare Light slow scan deletion bands may appear as Low Image Darkness. These
CAUTION type of deletion bands are 1/8th to 1/2 of an inch in width and usually more than one band
appears on the print.
minutes or severe xerographic problems may result. If the belt module will be exposed to light The deletion areas are seen on the 1 Pixel Black Line prints.
for more than two minutes, remove the photoreceptor from the belt module and place it in the Y N
protective bag, or place the bag over the photoreceptor with it on the belt module. (ROS flare light induced defect). Replace the ROS, and Perform the Xerographic Setup
• Photoreceptor Hydraulic Lift assembly. Check for leaks. Replace Lift as required (PL 9.4). (ADJ 9-3). If the deletion areas are seen on the 1 Pixel Black Line prints, return to the Yes
CAUTION response to the previous statement.
Perform the following items in the order given until the problem is resolved.
• PQ 9-626, Dicorotron RAP.
should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before clean-
ing the ESV and DSS. The Printer will perform a Power Up Sequence when the power is • PQ 9-616, Development RAP.
switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are • PQ 9-624, Precharge/Pretransfer Lamps RAP.
performed with the components clean. If the problem continues, the Photoreceptor Belt may be suffering from light shock. Check all
• Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Pre- the panels for light leaks. If the problem continues, replace the Photoreceptor Belt (PL 9.1).
charge Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Vacuum If the problem continues after the Xerographic Setup. Enter dC106 [Test Pattern and PQ]
the Photoreceptor Ground Brush. [Xerographic]. Program a 15 print job. Press Continue. Determine if the nonuniformity of the
• Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays image darkness is a problem in the solid areas or in the fine line areas of the prints run. If the
solid areas appear to be uniform but the fine lines are not uniform in darkness, replace the
and the paper path area. Ensure that no developer material has accumulated on the BRD
roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt, Perform ROS Assembly (PL 6.1).
the Xerographic Setup (ADJ 9-3).
Fuser
Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not con-
taminating the developer assembly. If any oil is identified in the Developer Assembly, replace
the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the
Xerographic Setup (ADJ 9-3).

PQ 9-615 Deletions RAP NOTE: It may be necessary to run 50 prints of a line/text image that extends to all edges of the
print to evaluate deletions (HALFTONE).
Deletions are the localized loss of image or light images which can be taken as a deletion on
the print. The most effective stress test for line print deletions is to make prints of the E Form 1. Bead Carryout. (Deletions occur at random locations). These deletions are mainly circu-
lar, occurring predominantly and more severely in the initial prints generated. In severe
on lightweight (16 pound) paper.
cases some of the circular deletions are joined together. Look for developer beads on the
NOTE: Deletions within the outer 6mm of all four edges of the prints are within specification. print in the deletion areas. Inspect the printer following areas for developer beads: Devel-
oper Housing manifold, Xerographic Drawer area, DSS area, Pretransfer Baffle, and the
Adjustment of the Transfer Assist Device will not eliminate deletions along the edges.
Transfer and Detack Dicorotrons. If beads are found carryout problem is indicated, go to
Initial Actions the PQ 9-631 Bead Carryout RAP.
• Check SCP Range Faults for 08-225 Faults. If the deletion is occurring along the Top 2. Observe the Transfer Assist Device during operation. Ensure that all four solenoids
Edge (50 mm) of the prints, ensure that the Registration Transport Cross Roll solenoids energize with 14 inch paper. Ensure that the entire Actuator Lever moves without binding.
are operating properly. If the fault is logged, go to the 8-225, return to this RAP if the dele- If binding or other Transfer Assist Device problems are suspected, go to the PQ 9-622
tion problem continues. Transfer Assist Device RAP.
• Check SCP Range Faults for 08-226 or 8-227 Faults. If either fault is logged, go to the 8- 3. The deletion occurs at a specific location and repeats every seventh print (7 pitch
226, 8-227 RAP, return to this RAP if the deletion problem continues. mode) or every third print (3 pitch mode). Replace the Photoreceptor Belt (PL 9.1).
Check [SCP] [HFSI] [Dicorotrons] for the Transfer and Detack Dicorotrons. Ensure that 4. The deletion appears on most prints and moves approximately six to 10 millimeters
the dicorotrons electrical connectors are secure. Ensure that the connectors are not from print to print and there are unfused areas near the deletions. Go to the 10-606
reversed. Check the Transfer and Detack Dicorotron wires for contaminants. Dry Ink Spots on Prints/Spot Deletions RAP.
• Check [SCP] [HFSI] [Belt Module]. Clean/replace the Transfer Assist Blade (PL 9.11). 5. The deletion repeats at a specific location. Go to the 8-705, Print Damage RAP.
• Ensure that the Xerographic Drawer and Belt Module are latched into the operating posi- 6. The deletion occurs on side 2 of the prints and/or the deletions are accompanied
tions. Ensure that the Cleaner Backup Roll is fully engaged. Ensure that the Pretransfer with dirt on the back of the print or dirt on the lead edge of the print.
Baffle is latched left, in the operating position. Check for light leaks in the belt module a. Determine if the sheets entering the Duplex Inverter are hitting the LE of the sheets
image area that corresponds to the area where the deletions are occurring. Ensure that exiting the inverter. If this is occurring, check/adjust Duplex Registration Timing,
Fuser Agent is not contaminating the PR Belt. dC702.
• Ensure dC131 [PHN]. Ensure Address 251=0, (4 Transfer Solenoids). If the Data value b. If the deletions are occurring only in 3 pitch mode, check the Registration assembly
required change, power the printer off and power on to set NVM. Enter dC606 and run for proper operation. Go to the 8-706 PHM Misregistration and Skew RAP.
prints to see if the problem is resolved. c. Go to the PQ 9-622 Transfer Assist Device RAP
• Enter dC131 [MIN]. Address 210=112, (Transfer Shield Current Normal) and Address 7. Predominantly in the solid areas. If the defect resembles debris centered deletions, sol-
220=(77 w/o MICR), or (51 w/MICR), (Developer rolls 1 & 2, Reference for toner setup). ids that contain debris in the center (longer than developer beads), go to the PQ 9-604
If the Data values require change, perform the Xerographic Setup (ADJ 9-3). Prints with Agglomerates/Debris RAP.
Procedure 8. Predominantly in the fast scan direction. Deletions can be caused by undetected,
Determine which paper trays were being used when the deletions occurred. If a specific tray or intermittent dicorotron faults. Remove all dicorotrons and inspect the HVAC contacts for
trays are identified, use those trays to generate prints for diagnostic analysis. If the deletion signs of arcing or corrosion. Replace as required. If the problem persists, check the HVAC
problem occurs from all three paper trays, first use the tray having the highest frequency of contacts in the OZAC components for signs of arcing or corrosion. Replace as required. If
deletions, then repeat the process with the other trays as required. the problem persists, go to the PQ 9-628 HVAC RAP.
9. Deletion band(s) in the Slow scan (process direction).
Load the paper tray with a fresh ream of 14 inch/16 lb. paper. If 16 lb. paper is not available, a. Check the positioning of the Pretransfer Assembly (REP 8-5).
use the lightest weight paper available.
b. Check the OZAC System for air leaks, cracks in the OZAC Duct. Use the manometer
to measure -51mm vacuum at the air nipple of the Ozone Duct. Repair/replace Ozac
Cheat the Printer Interlock Bypass Switch. Enter dC106. Select [Duplex]. Select the longest
System as required (PL 9.8).
paper available. Select [Test Patterns and PQ] [E Form]. Program a 50 print job. Press the
Continue button. NOTE: ROS Flare Light slow scan deletion bands may appear as Low Image Darkness. These
type of deletion bands are 1/8th to 1/2 of an inch in width and usually more than one band
appears on the print.
c. Enter dC606. Select Black Lines [1-Pixel Lines] Image Size [8.5 by 14 inch].
Select [Printer Options] [Tests Patterns and PQ] [Darker 2]. Press Continue.
Examine the prints. If the deletion areas are seen on the 1 Pixel Black Line prints.
(ROS flare light induced defect). Replace the ROS (PL 6.1).

10. The deletion occurs on tab stock. PQ 9-616 Development RAP
a. Ensure the customer stock is not curled or damaged.
The purpose of this RAP is to diagnose development related problems.
b. Perform the Transfer Blade Timing (ADJ 9-9).
c. Perform the PR Module Alignment (ADJ 9-10).
Initial Actions
Check/Repair the Developer Housing (REP 9-5).
Enter [SCP] [HFSI]. Ensure that all Xerographic (09) HFSI due items that are listed in the
HFSI TABLES have been performed. Reset the counters as required.
Enter dC131 [MIN]. Check the Data values at the following Addresses and compare them to
the values listed in the appropriate level Software dC 131 Table, Section 6, General Proce-
dures.
Table 1 MIN NVM

203 220
215 221
217
218
If any of the MIN NVM values required change, perform the Xerographic Setup (ADJ 9-3).
Procedure
Inspect the Zone Roll Support Pads on the Developer Housing. If the front pads are broken or
missing, replace the Front Bearing Clamp (PL 9.15)
Check the Developer Zone Roll position (ADJ 9-1). Ensure that the Zone Roll aligns with the
Support Pads on the housing. Ensure that the Photoreceptor Module latches properly. Ensure
that the Developer Housing is securely installed in the machine. The Photoreceptor Module
to Developer Housing interface is OK.
Y N
CAUTION
the belt module.
• Damage to the Xerographic Drawer to Photoreceptor Module hinge Bracket and
Shaft (PL 9.6).
• Photoreceptor Module Frame for warping (PL 9.1).
• Check the PR Module Alignment (ADJ 9-10).
Inspect the Developer Housing area. Check for contaminated developer or developer leakage
around and under the housing. Check for bead carryout. There is a normal level of devel-
oper material under the housing (no leakage).
Y N
(There is a leakage problem). Check/repair the following:
A
A B
• The Developer Seals (PL 9.15). Y N
• The Dump Door, the Latch Mechanism, Seal, and the Developer Plates for cracks or Low vacuum or a loss of vacuum will result in dirt across the entire width of the man-
breaks (PL 9.17). ifold. Enter dC330 [1-4] [Main Drive/Start]. Press Continue. The vacuum measure-
ment at the outboard end of the manifold should be a minimum of 8mm of vacuum.
• Continued bead carryout problems, go to the PQ 9-631, Bead Carryout RAP.
There is greater than 8mm of vacuum measured.
NOTE: If this is a MICR Developer Housing, DO NOT handcrank the Developer Housing Y N
Check for a clogged filter or a kinked or a plugged hose in the rear of the
slowly, there may be lumping of the developer material. If lumping occurs, the lumps should be
loosened by hand. machine. Replace components as required (PL 9.14)
Handcrank the developer assembly in a Clockwise direction ONLY. (Developer Roll 1 should Attach the vacuum cleaner to the manifold. Tap the bottom of the manifold with the
rotate counterclockwise). All three rolls rotate. blunt end of a screwdriver while vacuuming the manifold. After cleaning the mani-
Y N fold, go to the Y response two statements earlier, "Inspect the PR Belt for scratches",
Check all developer drive gears. Ensure that the gear teeth are not broken or worn. and continue this RAP.
Ensure that the gears properly mesh. The developer roll drive gears are OK.
Y N CAUTION
Remove the drive gears. Individually rotate the Developer Rolls, the Mixing Auger, The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under
and the Paddle Wheel. Check for bearing failures. Repair as necessary (PL 9.15). two (2) minutes or severe xerographic problems may result. If the belt module will be
Remove the Paddle Wheel Gear (REP 9-12). Rotate each roll. Check for packed devel- ule and place it in the protective bag, or place the bag over the photoreceptor with it on
oper, defective bearings, and debris. The rolls rotate. the belt module.
Y N
Inspect the PR Belt for scratches that appear on the prints. Check the Developer material
Clean or replace as necessary (PL 9.15).
for contaminants. The rolls are free of contaminants (metal chips, toner agglomer-
ates, foreign materials, etc.).
Rotate the Mixing Auger. Check for binding. The Mixing Auger rotates.
Y N
Y N
(There are contaminants in/on the developer rolls.) Check/replace the following:
Replace the Auger Bearings (PL 9.16).
• Paddlewheel bearing (PL 9.17).
Rotate the Paddle Wheel. Check for binding. The Paddle Wheel rotates freely. • Find and repair the cause of the contamination. Refer to Possible Sources of
Contamination at the end of this procedure. Replace the Developer Material
Y N
Replace the Paddle Wheel and/or the Paddle Wheel Shaft (PL 9.18). (REP 9-4).
Prepare the printer for operation. Cheat the Printer Interlock Bypass Switch. Enter dC330
Check the Paddle Wheel Shaft Roll Pin. Replace the Paddle Wheel Shaft as required (PL
9.18). [1-4]. Select [Main Drive Start/Run]. Press Continue. Observe the drive gears and the
developer rolls. The Developer Rolls rotate.
Y N
Check the BRD for dirt, developer beads, and toner. Developer build up on the BRD Roll may
cause deleted or poorly developed patches. Check the developer for binding. Clean as Inspect the Developer Drive Coupling at the rear of the Xerographic Drawer. The
required. Handcrank the developer assembly in a Clockwise direction ONLY, to ensure that the Drive Couplings are worn or broken.
Y N
BRD rotates. The BRD rotates.
Y N Remove the Dry Ink bottle. There is dry ink in the hopper.
Repair/replace the Clutch Assembly and/or BRD roll (PL 9.15) Y N
Go to the 9-702, Low/Out of Dry Ink Message RAP.
Check for continuity between Roll 3 and the BRD roll. There is continuity.
Y N Close the Xerographic Drawer. Select dC330 [9] [Toner Dispenser]. Observe
the Bell Crank Mechanism through the front window hole (to the right of the
Repair/replace the spring wire from the BRD drive shaft to the Developer Housing Extru-
sion Bushing (PL 9.14). Toner Bottle Latch Handle). Press Continue. The Toner Dispenser Motor
rotates.
NOTE: When the manifold is operating normally, there will be an accumulation of toner to Y N
the left of the manifold air holes (front view of housing) and there will be a clean curved Go to the 9-215 RAP.
area between the air holes. A small amount of toner to the right of the manifold holes is
also normal. The Stirrer is rotating.
Y N
The Manifold is free of excess toner.
Replace the Toner Dispenser (PL 9.19)
B B C D E
B C D E B F
Go to the 9-215 RAP. CAUTION
Replace the Developer Drive Couplings (PL 9.14) two (2) minutes or severe xerographic problems may result. If the belt module will be
Remove the developer roll 2 drive gear and reinstall the screw. Enter dC140. Select [dC ule and place it in the protective bag, or place the bag over the photoreceptor with it on
Bias Values]. Press Continue. Using Peak Hold (-) measure the voltage between the the belt module.
Developer Housing Left Side Extrusion (a test point is located under the Developer Catch
Press Stop. Reinstall the developer Roll 2 drive gear. If the machine does not have Pro-
tray) and machine frame. Record the measured value for use later. The roll 1 & 2 bias is
cessor Tag 80, go to the next Yes statement. Pull the xerographic drawer out, raise the
within +/- 20 VDC of the displayed value on the dC140 screen AND the bar graph on
Photoreceptor module and check for continuity between surface of Roll 3 and the BRD
the DMM is steady.
roll. There is continuity between the Roll 3 and the BRD Roll.
Y N
Y N
Press Stop. Check for continuity from P256-5 (the connector at the rear of the toner
Repair or replace the spring wire from the BRD drive shaft to the Developer housing
housing) to the bias strap at the rear of the developer housing. The continuity
extrusion brush (PL 9.14).
check is good.
If there is still no continuity between roll 3 and the BDR roll, replace the developer
Y N
roll 3 (PL 9.14).
Repair as required.
If continuity is OK, and the Developer Bias checks out OK, return the subsystem and the
Go to the 9-320 RAP. Assuming there is no other fault present, the first No leg of the
Xerographic Drawer to the operate position.
9-320 RAP should be followed.
Otherwise, open the Xerographic Drawer. Raise the Photoreceptor module. Observe the
developer material.
While still measuring the Developer housing Left Side Extrusion and machine frame
Open the Xerographic Drawer. Raise the Photoreceptor module. Observe the developer
switch from Peak Hold (-) to Peak Hold (+) and monitor the DMM for 30 seconds. The
material.
voltage is within +/- 20 VDC of the recorded value of the left side extrusion.
Y N NOTE: Hand cranking the Developer Assembly can produce bare spots. Do not hand
Replace the developer drive coupling (PL 9.14) and continue with the next Yes crank the developer at this time.
statement.
There is an even coating of developer on all three rolls.
Ensure that the wire is connected at the inboard end of the Developer Housing. Using Y N
Reverse developer flow, an uneven coating, and/or bare spots may indicate that
Peak Hold (+) measure the voltage between the screw head on the outboard end of rolls
1 and 2 and machine frame. Repeat the procedure using Peak Hold (-). The voltage there is too much or not enough developer material in the housing. Determine and
reading are within +/- 10 VDC of the recorded values of the left side extrusion. repair the cause of the leak, replace the Developer Material (REP 9-4). If Bead Car-
ryout is observed, go to the PQ 9-631, Bead Carryout RAP.
Y N
Replace the developer roll that did not meet specification (PL 9.15) and continue
with the next Yes statement. Press Stop. The Development subsystem is OK.
Measure the voltage between the Developer Housing Right Side Extrusion (under the POSSIBLE SOURCES OF CONTAMINATION
Developer Manifold) and machine frame. The reading is within +/- 20 VDC of the Roll 3 Ensure all sources of contamination have been purged from the System to prevent callback for
Bias on the dC140 display. the problem. Perform the following actions unless already done while troubleshooting.
Y N
Press Stop. Check the continuity between P256-8 (at the connector at the rear of Paper Dust
the toner dispenser) and the Developer Housing Right Side. The continuity is OK.
Y N Check the paper trays and paper path areas for excessive paper dust. Vacuum these areas.
Repair as required. Clean all areas as required.
Go to the wirenets and check wire 176/176A for an open. Paper Stock
Adhesives from the paper wrapper can be transferred to the Photoreceptor Belt. If expected as
a contaminant, direct the Operator to discard the top and bottom sheets of any new reams of
paper added to the Trays.
Predrilled paper: suggest that paper be drilled after printing if possible.
B F
Label stock: label adhesive can cause spots. Ensure that fuser Shield or oil leaking from the Fuser/Developer Drive Motor is not contaminat-
ing the developer assembly. If oil is identified in the Developer Assembly, replace the Devel-
Carbonless paper is not recommended for use on this system. oper Assembly (PL 9.13).
Paper stock: certain brands are known to cause spots.
Spray adhesives: any sprays used near the system can enter the machine air system and can
cause spots and damage the Photoreceptor Belt.

• Idler and Retard Brake (PL 7.13)
Belts wearing:

CAUTION
Xerographic
CAUTION
Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Precharge
Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Vacuum the Photore-
ceptor Ground Brush.
Vacuum the top of the Developer Housing including the seals. Ensure that no developer mate-
rial has accumulated on the BRD roll. Vacuum the Photoreceptor Module area. Reinstall the
Photoreceptor Belt. Perform the Xerographic Setup (ADJ 9-3).
Fuser

Figure 1 PQ 9-616 Circuit Diagram (713006)

A B
PQ 9-617 Cleaner RAP Check/replace any broken gears. After the repair is complete, return to (Step 1) of this
RAP.
The purpose of this RAP is to ensure that the cleaning system is working properly. Poor clean-
ing can contribute to many image quality defects. Press Stop. Enter dC140 [DC Bias Values]. Press Continue. Measure the Cleaner Brush
Bias voltage at the shaft. The Cleaner Brush Bias voltage is -250 +/- 10 VDC to ground.
Initial Actions Y N
Press Stop. Measure between P290-1 (+) and P290-4 (-). Press Continue. The voltage
• Ensure that the Cleaner Zone Rolls are engaged when the Xerographic Drawer is
latched. is -250 +/- 10 VDC.
Y N
• Ensure that the P290 connector is secured at the Cleaner chassis.
• Vacuum any toner from the Waste Toner Duct assembly, the Auger Drive Pulley, the Com-
pactor Drive Motor Pulley, and the Drive Belt. Go to Flag 3. Check the Cleaner Assembly for an open circuit.
Procedure
Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to The Upper Detoning Roll Bias (UDTR) voltage is -200 +/- 20 VDC to the Cleaner Brush.
the values listed in the appropriate level Software dC 131 Table, Section 6, General Proce- Y N
Press Stop. Measure between P290-3 (+) and P290-1 (-). Press Continue. The voltage
dures.
is -200+/- 20 VDC.
Table 1 MIN NVM Y N
Replace the HVAC PWB (PL 1.7)
MIN Address Current Value MIN Address Current Value
199 206 Go to Flag 3. Check the Cleaner Assembly for an open circuit.
200 207
The Lower Detoning Roll Bias (LDTR) voltage is +170 +/- 10 VDC to the Upper Detoning
205 208
Roll.
Y N
All the MIN NVM addresses have the data values listed in the appropriate level Software Press Stop. Measure between P290-2 (+) and P290-3 (-). Press Continue. The voltage
Table. is +170 +/- 20 VDC.
Y N Y N
Change the data values as required. Perform the Xerographic Setup (ADJ 9-3). Replace the HVAC PWB (PL 1.7)
Check the Waste Bottle Full Sensor, Q906, for proper mounting. Enter dC330 [9] [Waste Bot- Go to Flag 3. Check the Cleaner Assembly for an open circuit.
tle Full]. Place a piece of paper between the sensor and the Waste Bottle. The display
changes from H to L. WARNING
Y N
Use the convenience outlet on the machine for vacuum cleaner power. If a wall outlet is
Go to Flag 2. Check the circuit of the Waste Toner Full Sensor, Q906. Go to GP 6-2, used, verify that the wall outlet is grounded before using it.
Generic Sensor RAP and GP 6-3 Generic Solenoid RAP in General Procedures section.
Switch off Printer power. Vacuum the Cleaner Housing, the Brush, and the Flicker Bar. Remove
any impacted toner from the Flicker Bar. Replace the Filter Bag (REP 9-22) if it is more than
Remove the Waste Bottle. Place a sheet of paper under the Compactor Auger. Cheat the
half full. Use a flashlight to observe both cleaner augers through the waste toner duct at the
Printer Interlock Bypass Switch. Enter dC330, [1-4], [Main Drive Run] Motor. Press Continue.
rear of the machine. Handcrank the machine (rotate the drive shaft clockwise, ONLY) from the
Verify that the Compactor Auger is rotating. The Compactor Auger rotates.
rear while observing that both augers rotate. The Augers rotate.
Y N
Y N
Check the Waste Compactor Drive Belt (REP 9-18), the Auger Drive Pulley and the Auger
Replace the Auger or drives as necessary (PL 9.25).
(PL 9.23).
Use a screwdriver in the slot of the Main Drive Motor Shaft. Rotate the shaft one complete rev-
(Step 1)
olution (turn the shaft clockwise, front of machine view) while observing the cleaner detoning
Press Stop. Install the Toner Waste bottle. With the drives still on, ensure that the upper and
rolls with a flashlight. Examine both rolls for toner banding. The Cleaner is free of toner
lower Cleaner Detoning Roll shafts are rotating. The Cleaner Detoning Roll shafts rotate.
banding.
Y N
Remove the Auger Gear Box. The shafts can be turned within the gear backlash.
Y N
(Indicates a bound Cleaner). Replace the Cleaner Module (PL 9.24).
A B
Y N
Replace the appropriate Cleaner Blade (PL 9.22). Enter dC330. Select [Main Drive
Run]. Press Continue. Operate the drives for 10 seconds. Switch off the Printer power.
Check the Detoning Rolls for banding. Switch on the Printer power. Run test prints to
ensure that the banding disappears. The toner banding continues.
Y N
Continue this procedure below at (Step 2). The Yes response to the previous state-
ment.
WARNING
Start the following step with the blade pulled out about 2 inches. Keep body parts
and clothing away from the moving machine parts.
Pull the appropriate blade out about 2 inches. Enter dC330. Select [Main Drive Run].
Press Continue. While the drives are running, reinsert the blade and pull it back out
about 2 inches, repeat this sawing action 3 or 4 times. Press the Stop button. Check for
toner banding. Repeat the procedure as necessary to remove any toner banding. If band-
ing remains, use Formula A to clean the band. Continue this procedure below at (Step 2).
(Step 2)
Ensure that the Cleaner Backup Roll, when cammed up, is against the bottom of the cleaner,
both in front and rear. Enter dC330, [9]. Select [Precharge/Prexfer]. The Lamps operate
properly.
Y N
Go to the PQ 9-624, PreCharge/Pretransfer Lamps RAP. After the repair are complete,
continue this RAP, return to the Yes leg of the previous statement.
Check for toner past the Cleaner. Enter dC606. Select [Printer Options] [Pages Per Set
(30)]. Select [Printer Options], [Black Lines], [12-Pixel Lines]. Program a 30 print job and
select a Tray with 14inch paper. Press Continue. After 15 print have been run, open the front
door. Inspect the Photoreceptor Belt for toner past the cleaner. There is toner past the
cleaner.
Y N
Vacuum the manifold, the blower hose. Ensure that the hoses are OK. Repair/replace as
required. Replace the filter bag if it is more than half full. Replace the Cleaner Brush (PL
9.24).
Use the manometer to check for more than 51 mm of water at the pressure tap on the elbow of
the Cleaner Blower Hose. The pressure is greater than 51mm.
Y N
Go to the 9-704, Toner Filter Blower RAP.
Vacuum any spilled toner in the entire Photoreceptor Module area. If the machine is extremely
dirty, go to the PQ 9-632, Dirt RAP. Perform the Xerographic Setup (ADJ 9-3).


A
PQ 9-618 PR Ground RAP • Lower and latch the Photoreceptor Module. Ensure that the Ground Brush contacts
the Photoreceptor ground strip with enough force to depress the Ground Brush.
The purpose of this RAP is to ensure that the Photoreceptor is grounded properly. Without a Replace the Ground Brush if necessary (PL 9.7).
good pathway to ground, the Photoreceptor will not discharge properly and xerographics can-
not be setup or maintained correctly. The Photoreceptor ground is OK.
Initial Actions
CAUTION
• Inspect the Photoreceptor Belt surface for a ground plane break. If present, the break will
appear as a sharply defined line all the way around the Photoreceptor Belt.
• Pull out the Xerographic Drawer. Raise the Photoreceptor Module. Pinch the Ground
Brush, pulling on the fibers. If any fibers dislodge, replace the Ground Brush (PL 9.7)
NOTE: Do not use the Printer frame as a PR ground during diagnostics, electrical noise and
the related faults will be generated. Only ground the PR through the PR Ground Brush circuit.
Procedure
Ensure that the two green ground wires are securely attached to the Ground Brush. The wires
must be attached to an internal star washer type of connector that penetrates the special con-
ductive plastic of the Ground Brush. The Ground Brush and electrical connections are OK.
Y N
Repair any poor connections.
• Replace the Ground Brush if is worn or damaged (PL 9.7).
• Inspect the Photoreceptor ground strip for damage. Replace the Photoreceptor belt
if necessary (PL 9.1).
Lower the Photoreceptor Module. Measure the resistance from the Photoreceptor ground strip
to machine ground (the unpainted metal bracket that holds the detack dicor is a good one).
The resistance is less than 50K ohms.
Y N
Raise the Photoreceptor Module. Measure the resistance from the Ground Brush to
machine ground. The resistance is less than 1K ohms.
Y N
Measure the resistance from the Ground Brush to the ground wires attached to the
Ground Brush. The resistance is less than 1K ohms.
Y N
Replace the Ground Brush (PL 9.7)
Go to Flag 1. Check for an open circuit between the ground wires on the Ground
Brush and J298-17 of the Low Voltage Power Supply.
Inspect the Photoreceptor ground strip for breaks or wear, replace the Photoreceptor Belt
if necessary (PL 9.1)
• Measure the resistance between the Ground Brush and the ground wires attached to
the Ground Brush. If the resistance is not less than 1K ohms, replace the Ground
Brush (PL 9.7)
A
Figure 1 PQ 9-618 P/R Ground Circuit Diagram (713002A).

A B
PQ 9-619 ESV RAP CAUTION
The purpose of this RAP is to ensure that the ESV is working properly. If the ESV is not work- two (2) minutes or severe xerographic problems may result. If the belt module will be
ing properly, it can give erroneous readings, and the Xerographic setup will be incorrect. exposed to light for more than two minutes, remove the photoreceptor from the belt mod-
Initial Actions the belt module.
CAUTION If the Photoreceptor Ground Brush fibers are contacting the AMAT portion of the PR Belt,
The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) the ESV Monitor reading may be as low as 20 and as high as 38. Each time the Initialize
minutes or severe xerographic problems may result. If the belt module will be exposed to light is run, the values may be different. Enter dC909. Select [ESV-DSS Test]. Observe the
for more than two minutes, remove the photoreceptor from the belt module and place it in the ESV Monitor voltage. Normal voltage should be between 1.0 VDC +0.4VDC/-0.2 VDC. If
protective bag, or place the bag over the photoreceptor with it on the belt module. the ground brush fibers are contacting the AMAT portion of the PR Belt, the voltage will
fluctuate from +0.7 VDC to +3.5 VDC. Replace the Ground Brush (PL 9.7)
Locate the Photoreceptor black plastic bag. Ensure that the bag is clean it will be used to make
ESV checks.
(Step 2)
Enter dC909. Select [ESV-DSS Test]. The value of the ESV reading is equal to or less
WARNING than 24 VDC.
Do not touch the ESV probe. The probe can have a high voltage on it, about 1KV, when- Y N
ever the power is on. Although the 1KV is a low energy source, personal injury can Go to Flag 1. Measure the ESV Peak Monitor Output signal at TS21 (+) and TS22 (-) of
occur responding to the shock. the MIN ADA PWB #1. The ESV Peak Monitor Output signal is +1 VDC+/- 0.2 VDC.
CAUTION Y N
The ESV should be cleaned with a clean, dry lint free cloth. Switch off the Printer power before Connect the DMM to TS12 (+) of the MIB and frame ground (-). Set the DMM to (+)
cleaning the ESV. The Printer will perform a Power Up Sequence when the power is switched Peak Hold. The DMM reads +15 +/- 1.5 VDC.
on, and will ensure that the ESV Monitor measurements are performed with the component Y N
clean. Switch Off Printer power. Go to Flag 2. Check the wire between the MIB PWB
Pull out the Xerographic Drawer. Clean the ESV probe. Check for toner on the PR Belt. If toner and the ESV Power Supply for an open or a short circuit to ground. Repair/
is observed, go to the PQ 9-617, Cleaner RAP. replace as required. If the wire is OK, switch On the Printer power. Ensure that
the J2 connector securely attached to the ESV Power Supply. 24 +/- 1.2 VDC
Ensure that the ESV is not skewed in relationship to the Photoreceptor. Check the ESV Height measured between J2-7 (+) and J2-6 of the ESV Power Supply.
(ADJ 9-12). Y N
Go to Flag 4. Check the +24 VDC wiring. After repair, go back to the
Close the drawer. Switch off the Printer power. Wait 10 seconds. Switch On the Printer power. beginning of (Step 2) in this RAP.
Enter dC106. Run 10 prints to force the machine through its power-up checks.
If the 24 VDC is OK, replace the ESV Assembly (PL 1.7).
Enter dC131 [MIN]. Ensure that Address 225 is at the value shown in the appropriate level
Software dC 131 Table in Section 6, General Procedures, of the Service Manual (ESV calibra- Measure the ESV Reset (L) + 15 VDC signal at TS12 (+) of the MIB PWB and the
frame ground (-). Approximately once each second, the DMM reads a low volt-
tion factor relating the ESV reading and the dark decay to the ddp setpoint). If the data value
requires a change, perform the Xerographic Setup (ADJ 9-3). age of about +0.6 VDC.
Y N
Go to Flag 3. Measure the ESV Reset (L) +5 VDC signal at TS7 (+) of the MIB
Procedure PWB and the chassis ground (-).
(Step 1) Perform the following:
Enter dC951. Select [Initialize]. Press Continue. Observe the ESV Monitor value. The nor- • If approximately once each second, the DMM reads a voltage change
mal value should be between 22-35. The ESV monitor values are between 22 and 35 from +5 VDC down to about +0.6 VDC, switch off the Printer power. Go to
Y N Flag 2. Check the J2-13 wire for a short to ground. If the wire is OK,
(HVDC PWB leakage check.) Enter dC140 [Dicorotron Values]. Press Start. After 10 replace the MIB PWB (PL 1.7).
seconds all the dicorotron values should be stable. Open the Printer Right Front Door to
• If the ESV signal in not present at TS7, go to Flag 3. Check for the signal
interrupt operation. Observe the Dicorotron Monitor Voltages for 30 seconds. The Moni-
at TS43 (+) and TS37 (-) of the MIN DIO PWB. If the signal is present,
tor values cycle down to less than 0.3 after 30 seconds.
switch off Printer power. Check the wire between the MIN DIO PWB and
Y N
the MIB PWB. Go back up to (Step 2) of this RAP after the repair.
HVDC PWB leakage problem, replace the HVDC PWB (PL 1.7)
• If the signal is not present at TS43 (+) and TS37 (-), replace the MIN DIO
PWB (PL 1.8).
A B C D E
C D E F G
Perform the following: • Switch Off the Printer power. Go to Flag 2. Check the wire between the MIB
• Switch Off the Printer power. Go to Flag 2. Check the wire between the MIB PWB and the ESV Power Supply. If the wire is OK, ensure that the ESV probe
PWB and the ESV Power Supply. If the wire is OK, ensure that the ESV probe connector is attached securely to J1 of the ESV Power Supply. Ensure that +24
connector is attached securely to J1 of the ESV Power Supply. Ensure that +24 VDC ± 1.2 VDC is present between J2-7 (+) and J2-6 (-) of the ESV Power
VDC +/- 1.2 VDC is present between J2-7 (+) and J2-6 (-) of the ESV Power Supply.
Supply. • If the above checks are OK, replace the ESV Assembly (PL 1.7)
• If the above checks are OK, replace the ESV Assembly (PL 1.7).
The ESV is OK.
Observe the dC909, [ESV-DSS Test], ESV Monitor reading. The ESV Monitor Reading is 1.0
VDC ±0.2.
Y N
Go to Flag 1. Measure the ESV Peak Monitor Output signal at TS21 (+) and TS22 (-) of
the MIN ADA PWB #1. The ESV Peak Monitor Output signal is +1 VDC ± 0.2 VDC.
Y N
Connect the DMM to the MIB PWB TS12 (+) and frame ground. Set the DMM to (+)
Peak Hold. The DMM reads 15 ± 1.5 VDC.
Y N
Switch Off Printer power. Go to Flag 2. Check the wire between the MIB PWB
and the ESV Power Supply for an open or a short circuit to ground. Repair/
replace as required. If the wire is OK, switch On the Printer power. Ensure that
the J2 connector securely attached to the ESV Power Supply. 24 ± 1.2 VDC
measured between J2-7 (+) and J2-6 of the ESV Power Supply.
Y N
Go to Flag 4. Check the +24 VDC wiring. After repair, go back to the
beginning of (Step 2) in this RAP.
If the 24 VDC is OK, replace the ESV Assembly (PL 1.7).
Measure the ESV Reset (L) + 15 VDC signal at TS12 (+) of the MIB PWB and the
frame ground (-). Approximately once each second, the DMM reads a low volt-
age of about +0.6 VDC.
Y N
Go to Flag 3. Measure the ESV Reset (L) +5 VDC signal at TS7 (+) of the MIB
PWB and the chassis ground (-). Perform the following:
• If approximately once each second, the DMM reads a voltage change
from +5 VDC down to about 0.6 VDC, switch off the Printer power. Go to
Flag 2. Check the J2-13 wire for a short to ground. If the wire is OK,
replace the MIB PWB (PL 1.8).
• If the ESV signal in not present at TS7, go to Flag 3. Check for the signal
at TS43 (+) and TS37 (-) of the MIN DIO PWB. If the signal is present,
switch off Printer power. Check the wire between the MIN DIO PWB and
the MIB PWB. Go to back to (Step 2) of this RAP after the repair.
• If the signal is not present at TS43 (+) and TS37 (-), replace the MIN DIO
PWB (PL 1.8).
F G

PQ 9-620 DSS RAP Y N
Measure the input voltage to the DSS between IRD-5 and IRD-2. +15 VDC +/- .75 VDC
The purpose of this RAP is to ensure that the Density Sample Sensor (DSS) is operating cor- is measured.
rectly and determine / correct the cause if it is not. If the DSS is not working properly it can give Y N
erroneous readings and the xerographic setups will be incorrect. Move the meter lead from IRD-2 to frame. +15 VDC +/- .75 VDC is measured.
Y N
Initial Actions Go to Flag 4. Check for an open circuit in the +15 VDC line.
CAUTION
Go to Flag 5. Check the violet wire for an open circuit.
Measure the voltage between TS24 (+) and TS37 (-) of the MIN DIO PWB. Greater than
+3 VDC is measured.
Y N
CAUTION Go to Flag 6. Check for an open or short circuit. If the circuit is OK, replace the MIN
Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox DIO PWB (PL 1.8).
anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. Switch off the
Printer power before cleaning the DSS. The Printer will perform a Power Up Sequence when Exit the ESV-DSS Test. Measure the voltage between TS10 (+) and TS56 (-) at the MIN
the power is switched on, and will ensure that the DSS calibrations are performed with the DIO PWB. +15 VDC +/- .75 VDC is measured.
component clean. Y N
• Pull out the Xerographic drawer and clean the DSS with a clean, soft, lint free cloth. Go to Flag 3. Check for an open or short circuit. If the line is OK, replace the DSS
(PL 9.7).
• Ensure that the Photoreceptor Belt over the DSS is clean. Return the Photoreceptor Mod-
ule to the lowered position.
Select [ESV-DSS Test]. Check for a negative going pulse at the between TS10 (+) and
Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to TS56 (-) MIN ADA PWB #1. The meter indicates a negative going pulse approxi-
the values listed in the appropriate level Software dC 131 Table, Section 6, General Proce- mately every 2 seconds.
dures. If any of the NVM values require change, perform the Xerographic Setup (ADJ 9-3).
Y N
Table 1 MIN NVM
MIN Address Current Value MIN Address Current Value Exit ESV-DSS. Measure the voltage between TS8 (+) and TS56 (-) at the MIN ADA PWB
#1. +15 VDC +/- .75 VDC is measured.
199 245
Y N
200 246
205 247 (PL 9.7).
206 248
207 249 Press the [DSS Recalibrate] button. Check for a negative going pulse between TS8 and
TS56. The meter indicates a negative pulse every time the DSS Recalibrate button
208 251
is pressed.
243 253
Y N
244 254 Replace the MIN ADA PWB #1 (PL 1.8).
Procedure Replace the DSS (PL 9.7).
CAUTION
Raise the Photoreceptor module at least 30 degrees from the horizontal and leave it there.
The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) The DSS Monitor reading is less than 50.
minutes or severe xerographic problems may result. If the belt module will be exposed to light Y N
for more than two minutes, remove the photoreceptor from the belt module and place it in the Replace the DSS (PL 9.7).
Enter dC909. Select [ESV-DSS Test]. Observe the DSS monitor. Select [DSS Recalibrate] Select [DSS Recalibrate]. A 9-212 fault is declared.
five times. The DSS Monitor reading is 232 +/- 12 after each recalibration and the varia- Y N
tion between any of the readings does not exceed 6. Exit ESV-DSS Test. Measure the voltage between TS8 (+) and TS56 (-) at the MIN ADA
PWB #1. The voltage measures +15 VDC +/- 0.75VDC.
A
A
Y N
(PL 9.7).
Leave the meter connected. Press the [DSS Recalibrate] button. Check for a negative
going pulse between TS8 and TS56. The meter indicates a negative pulse every time
the DSS Recalibrate button is pressed.
Y N
Replace the DSS (PL 9.7)
Lower the Photoreceptor Module. Close the Xerographic drawer. Clear the 9-212 fault. Press
[DSS Recalibrate]. Run any job to force a Cycle up convergence. Enter dC606. Press Con-
tinue. The DSS operation is OK. Perform the DSS Timing (ADJ 9-14).

Figure 1 PQ 9-620 DSS RAP Circuit Diagram (8304)

A B C
PQ 9-621 Patch Gen/Patch Integrity RAP Go to Flag 1. Check for an open circuit. If the wires are OK, replace the MIN DIO
PWB (PL 1.8)
The purpose of this RAP is to ensure that the patch has been correctly created and developed
to ensure proper toner concentration control setups. Enter dC330 [9]. Select [Patch Gen High]. Press Continue.
NOTE: When [Patch Gen High] is energized in dC330 [9]. The signal is pulsed as a
Initial Actions square wave. Use negative Peak Hold (-) to measure the low pulse as required.
CAUTION
NOTE: The DMM Peak Hold Procedure is located at the end of this RAP.
minutes. Also, do not leave the Patch Generator energized in dC330 for longer than two (2) The voltage pulses between 5 VDC and 0 VDC.
minutes. Severe xerographic problems may result. If the belt module will be exposed to light for Y N
more than two minutes, remove the photoreceptor from the belt module and place it in the pro- Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB
tective bag, or place the bag over the photoreceptor with it on the belt module. (PL 1.8)
• Open the Xerographic Drawer and clean the Patch Generator by wiping the window with
a clean, dry cloth. Leave the drawer open. +2.5 VDC is measured between TS13 (+) and TS20 (-) of the MIB PWB.
• Enter dC131 [MIN]. Record the Data values at the following Addresses and ensure they Y N
compare to the values listed in the appropriate level Software dC 131 Table, Section 6, Disconnect P211 (J2) at the MIB PWB. +2.5 VDC is measured between P211-15
General Procedures. If any of the NVM values require change, perform the Xerographic (+) and TS20 (-) of the MIB PWB.
Setup (ADJ 9-3). Y N
Go to Flag 2. Check for a short or an open circuit. If the wires are OK, replace
Table 1 MIN NVM the Patch Generator (PL 9.10)
MIN Address Current Value MIN Address Current Value Replace the MIB PWB (PL 1.8)
249 254
251 285 Press Continue.
253 NOTE: When [Patch Gen High] is energized in dC330 [9]. The signal is pulsed as a
square wave. Use negative Peak Hold (-) to measure the low pulse as required.
• Enter dC105 [Features]. Digital Patch Generator enabled. Check the Patch Generator
NOTE: The DMM Peak Hold Procedure is located at the end of this RAP.
Timing (ADJ 9-5).
Procedure The voltage pulses between 2.5 VDC and 0 VDC.
Y N
CAUTION
Replace the MIB PWB (PL 1.8)
minutes. Also, do not leave the Patch Generator energized in dC330 for longer than two (2) Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the Patch Generator
minutes. Severe xerographic problems may result. If the belt module will be exposed to light for (PL 9.10)
more than two minutes, remove the photoreceptor from the belt module and place it in the pro-
tective bag, or place the bag over the photoreceptor with it on the belt module. Open the Xerographic Drawer. Clean the Patch Generator by wiping the window with a clean
Observe the Patch Generator while the printer is idle. The Patch Generator LED's are off dry cloth. Leave the drawer open.
when the printer is in standby. Enter dC330 [9]. Select [Patch Gen High]. Press Continue. The Patch Generator should
Y N cycle on and off.
+5 VDC is measured between TS43 (+) and TS37 (-) at the MIN DIO PWB.
Y N NOTE: Use the inspection mirror to observe the four LEDs inside the Patch Generator window.
+5 VDC is measured between TS8 (+) and TS20 (-) at the MIB PWB. Because of the viewing angle there may appear to be more than four LEDs, look for a dark
spot between any two lit LEDs, if you see a dark spot, one or more of the LEDs are out.
Y N
Disconnect the P211 (J2) connector at the MIB PWB. +5 VDC is measured All four LEDs are lit.
between TS8 (+) and TS20 (-) at the MIB PWB. Y N
Y N At least one LED is lit.
Replace the MIB PWB (PL 1.8) Y N
No LEDs are lit, go to the 9-355 RAP.
Go to Flag 1. Check for a short circuit. If the wires are OK, replace the MIN DIO
PWB (PL 1.8) Replace the Patch Generator (PL 9.10).
A B C D
D E
+5 VDC is measured between TS52 (+) and TS37 (-) at the MIN DIO PWB. The measured Patch height is from 20 to 25 mm.
Y N Y N
Disconnect the P233/J2 connector at the MIN DIO PWB. +5 VDC is measured between Ensure that the Cleaner Zone Roll is correctly positioned against the Photoreceptor belt
P233-9 (+) and TS37 (-) of the MIN DIO PWB. and held securely in the Photoreceptor Module frame. Go to the PQ 9-616, Development
Y N RAP.
Go to Flag 3. Check for and Open circuit. If OK, replace the Patch Generator (PL
9.10). The Patch width, including lead/trail edge dark bands, is from 16 to 19 mm.
Y N
Select [Enable]. The voltage between TS52 (+) and TS37 (-) at the MIN DIO PWB Check/adjust the following items in the order given:
changes from 0.5 VDC to 0 VDC. • Enter dC604 Registration Setup. Press Continue. Check and adjust registration if
Y N required.
Replace the MIN DIO PWB (PL 1.8) • Enter dC909 [PGen Timing]. Adjust the Patch Generator Timing.
• Ensure that the Cleaner Zone Roll is correctly positioned against the Photoreceptor
belt and held securely in the Photoreceptor Module.
Select [Enable]. The voltage between TS52 (+) and TS37 (-) at the MIN DIO PWB changes • Replace the PPMD PWB (PL 1.11).
from +5 VDC to 0 VDC. • Go to the PQ 9-616, Development RAP.
Y N
Replace the MIN DIO PWB (PL 1.8) All ID zones are free of toner (except those with the patches printed).
Y N
NOTE: For information on the physical characteristics of the patch, refer the Patch Generator Go to the PQ 9-617, Cleaner RAP. Check the ID zone for uncleaned patches.
Timing/Patch properties check at the end of this RAP.
Enter dC909 [PGen Timing]. Adjust the Patch Generator Timing (ADJ 9-5).
Exit dC330. Enter [dC909]. Select [Patch Print] (Yes), [Charge Control] (Open). Program DMM Peak Hold Procedure
a 50 print job. Press Continue. The developed patches have uniform density.
• Select V or mA as required.
Y N
Check Developer Roll 1, 2, and Roll 3 Bias at the Developer Housing. Refer to the circuit • Select AC or DC and range as required.
diagram for test points. The bias's are OK. • Place Meter Probes in the Volt-Ohm (+) and the COM (-) Jacks
Y N • Press (+) or (-) polarity.
Go to the PQ 9-616, Development RAP. • To make a new measurement, release the Peak Hold button to clear previous reading and
repeat procedure.
Observe the generated patches. The patch is free of dark, LE or TE fast scan direc-
tion bands. NOTE: To measure for negative peaks on a positive voltage, first select (+) peak polarity,
Y N press the Peak Hold button then switch polarity to (-) peak polarity. For further informa-
Dark bands of 2mm or less at the LE or TE are OK. If the dark bands are greater tion, go to the DMM operators Manual.
than 2mm, check/adjust the following items in the order given:
• Enter dC604 Registration Setup. Press Continue. Check and adjust Top To Patch Generator Timing/Patch Properties
Bottom Registration (ADJ 8-2) and Side To Side Registration (ADJ 8-3). The diagram below gives the correct patch dimensions as well as an example of the banding
• Enter dC909 [PGen Timing]. Adjust the Patch Generator Timing (ADJ 9-5). due to a Patch Generator timing error. Dark Bands at the lead and trail edge of the patch will
result, if there is an error in the dC909 [PGEN Timing] setup. These bands effect DSS reading
If the patches have light streaks or bands, go to the PQ 9-612, Light Streaks/Light Bands of patch density and the calculation of Process Controls. The bands are sometimes hard to
RAP. identify. Use Print Darker 2, if required, to observe the bands in the patch area during the PGen
• If the patches have dark streaks or bands, go to the PQ 9-611, Dark Streaks/ timing setup. Ensure that the Patch Generator exposure of the latent patch is uniform through-
Scratches/Bands RAP. out the patch area.
• If the patches have white spots, go to the PQ 9-625, White Spots RAP.
• If the patches have deletions, go to the PQ 9-615, Deletions RAP.
• If the patches have streaks/scratches or bands, go to the PQ 9-611, Dark Streaks/
Scratches/Bands RAP.
• If the patches have dark spots or marks, go to the PQ 9-613, Dark Spots RAP.
• If the patches have uneven density or darkness, go to the PQ 9-614, Nonuniform
Image Darkness RAP.
E
NOTE: With the Digital Patch Generator installed and enabled in dC105, no timing variations
are expected.
Figure 1 Patch Properties (8314A)


PQ 9-622 Transfer Assist Device RAP 4. Select [Xfr Sol 2]. Observe Transfer Solenoid 2. Press Continue. If Transfer Solenoid 2
does not energize, press the Stop button. Go to Flag 3. Check the circuit of the Transfer
This RAP is used to diagnose failure of the Transfer Assist Device. Generally Transfer Assist Solenoid 2, SOL905 (Generic Solenoid RAP, GP 6-3, General Procedures).
problems are seen as deletions 25 mm from the lead edge and/or the trail edge of the prints. 5. Select [Xfr Sol 3]. Observe Transfer Solenoid 3. Press Continue. If Transfer Solenoid 3
Complete the following procedure prior to adjusting the Transfer Blade Timing (ADJ 9-9). does not energize, press the Stop button. Go to Flag 4. Check the circuit of the Transfer
Solenoid 3, SOL906 (Generic Solenoid RAP, GP 6-3, General Procedures).
INITIAL ACTION
6. Select [Xfr Sol 4]. Observe Transfer Solenoid 4. Press Continue. If Transfer Solenoid 4
does not energize, press the Stop button. Go to Flag 5. Check the circuit of the Transfer
• Ensure that the Transfer Blade and the Transfer Dicorotron are completely installed. The Solenoid 4, SOL904 (Generic Solenoid RAP, GP 6-3, General Procedures).
transfer Blade can vibrate out of position. Inboard deletions can occur.
7. Perform Transfer Blade Timing (ADJ 9-9). During the Transfer Assist Blade Timing Proce-
• Check SCP Range Faults for 8-226 or 8-227 Faults. If either of these faults are logged,
dure, adjust the lead edge to 4.00 mm and the trail edge to 8.00 mm. This will increase
go to the 8-226, 8-227 RAP RAP, return to this RAP if the problem continues. the range of the pull-in time of the Transfer Solenoid. If the problem continues, replace the
NOTE: When using transparencies, the Transfer Assist Device does not function. This is nor- Transfer Assist Device (PL 9.11)
mal operation. 8. Program a sustained job (1000 prints) with the longest paper available. Observe the
Transfer Assist Device during operation to determine if there is a thermal breakdown
Enter dC131 [PHN]. Ensure that Address 251=0 (4 Transfer Solenoids). If the Data value (overheat) of one or more of the Transfer Assist Solenoids. If sluggish operation or exces-
required change, power the printer off then on to set NVM. Enter dC606 and run prints to see if sive heat is indicated, replace solenoids as required (PL 9.12).
the problem is resolved.
9. Explanation of the Pulsed DC Voltage between TH4 (+) and TH3 (-) on the TAD PWB
output to Solenoid 1.
Procedure
a. TS45 on the PHN DIO PWB #2 (J2/P397-3) is the normal +5 VDC signal. It toggles
WARNING low to actuate the TAD PWB (J1/P399-1).
Use caution when observing/checking the Transfer Assist Device as the Transfer Assist b. When PHN DIO PWB #2, the TAD PWB supplies +24 VDC to Solenoid 1 for approx-
Blade has high voltage on it (in print). Ensure that clothing and body parts do not come imately 16 ms (between TH4 (+) and TH3 (-) on the TAD PWB).
in contact with moving machine parts. The Main Drive motor can get very warm, be
c. After that time, the +24 VDC is removed, and the +5 VDC is applied for the remain-
careful when performing the standby checks.
der of the Duty Cycle (approximately 220 ms) in dC330.
Check [SCP] [HFSI] [Belt Module]. Clean/replace the Transfer Assist Blade (PL 9.11)
NOTE: Due to the short duration of the 16 ms that the +24 VDC is on, it will not be possible to
1. Open the Processor Right Front Door. Observe the Transfer Assist Solenoids while actu- read the +24 VDC output voltage between TH4 and TH3 on the TAD PWB.
ating/deactuating the Printer Right Front Door Interlock. If one or more of the solenoids Digital Multimeter Tips:
energized when the interlock switch is actuated, there is a short in the solenoid circuit. If using a Fluke DMM, continue with Step d below. If using a Simpson DMM, go to Step e.
Refer to the Circuit Diagram to troubleshoot the solenoid or solenoids. Diagnose the high-
est # solenoid first. (If three solenoids actuate with the interlock switch, go to sol #3 circuit d. FLUKE Meter:
first). i. Set the DMM to the 40 VDC Range.
2. In standby, manually actuate each solenoid. Check for binding. Observe each segment of ii. Select Min/Max, then select Peak Min/Max.
the Transfer Assist Actuator Lever and Blade. Ensure that the blade does not touch the iii. The DMM will have a record time of 1 ms, and will display approx. 22 volts
PR belt when the solenoid is actuated. Ensure that the plastic clips that allow the blade (peak + voltage).
segments to pivot and the plastic solenoid blocks are engaged properly. Ensure that the
e. SIMPSON Meter:
actuator assembly does not interfere with the blade when the solenoids are actuated. If
the actuator interferes, replace the Actuator Lever (PL 9.12). i. Set the DMM to the 20 VDC Range.
3. Cheat the Processor Right Front Door Interlock. Enter dC330 [9]. Select [Xfr Sol 1]. ii. The voltage displayed should be about +4 VDC between TH4 (+) and TH3 (-).
Observe Transfer Solenoid 1. Press Continue. If Transfer Solenoid 1 does not energize,
press the Stop button.
Verify that the following test holes on the TAD PWB have the correct voltages:
• TH1 is +5 VDC at the input of the TAD PWB
• TH2 is +24 VDC at the input of the TAD PWB
• TH3 is DC COM output to Solenoid 1
• TH4 is a Pulsed DC Voltage output to Solenoid 1 (+24 VDC is on for 16 milliseconds,
the +5 VDC remains on). See the explanation of this voltage in 9 at the end of this
RAP.


A
PQ 9-623 Border Bands RAP • Check the Photoreceptor Belt for inboard and outboard scratches. Replace the Pho-
toreceptor Belt (PL 9.1).
Border bands are dark areas along the perimeter of the print.
Initial Actions • Photoreceptor Belt ground, go to the PQ 9-618, PR Ground RAP.
Observe the Transfer Assist Device during operation. If a problem is observed or suspected
with the transfer assist, go to the PQ 9-622, Transfer Assist Device RAP.
Procedure
CAUTION
Access the Xerographic Drawer. Press the (Red) Lamps test button on the Photoreceptor Mod-
ule. Observe the discharge lamps. The Precharge and Pretransfer lamps light.
Y N
Go to the PQ 9-624, Precharge/Pretransfer Lamps RAP.
NOTE: If there are border bands in more than one area on the print (example: top edge
and bottom edge), correct the problem in one area and then go to the next area.
Border bands are located at the top edge (outboard edge) of the prints.
Y N
Border bands are located at the bottom edge (inboard edge) of the prints.
Y N
Border bands are located at the lead edge and/or trail edge of prints.
Y N
There is no border band problem.

• Enter dC604 [Registration Setup]. Check and adjust registration if required.
• Check for dirt on the edges of the prints. This may be caused by the Transfer
Assist Blade timing problems. Check/Adjust the Transfer Assist Blade Timing
(ADJ 9-9).
CAUTION
• Check the Photoreceptor Belt for inboard and outboard scratches. Determine
and repair the cause of the scratches. Replace the Photoreceptor Belt (PL 9.1).
• The bands may be dark bands that are coincident with the borders (and are
really not border bands), go to the PQ 9-611, Dark Streaks/Bands RAP, PQ 9-
612, Light Streaks/Bands, or PQ 9-615, Deletions RAP.

• Enter dC604 Registration Setup. Check and adjust registration if required.
A
PQ 9-624 Precharge/Pretransfer Lamps RAP Y N
Replace the Precharge Lamp (PL 9.4).
This RAP is used for diagnosing the Precharge and the Pretransfer Lamps (Discharge Lamps).
Closely examine the Pretransfer Lamp when it is on. All lamp segments light.
Procedure Y N
CAUTION Replace the Pretransfer Lamp (PL 9.3).
Press Stop. Press the Red Lamps Test Switch, S901, on the Photoreceptor Module. Both
Lamps energize (light).
Y N
There is a problem with the Test Switch, S901. Go to Flag 1. Check for continuity across
Cheat the Printer Interlock Bypass Switch. Pull the Xerographic Drawer out to the latched posi- the Test Switch S901, when it is pressed. Check the wires from the Test Switch, S901, to
tion. Raise the Photoreceptor Module to observe the Lamps. Both lamps should be off. Both the PWB. Replace the Test Switch (PL 9.3).
lamps are off.
Y N The Precharge/Pretransfer Lamps are OK.
(A lamp is on all the time). Go to Flag 4. Check for a short circuit. If the wires are OK,
replace the MIN ADA PWB #2 (PL 1.8)
Enter dC330 [9] [Precharge/Prexfr Lamps]. Press Continue. If at least one segment of both
lamps light, answer Yes to the following statement.
NOTE: The Red Test button on the Photoreceptor Module does not check the entire circuit.
Use dC330 [9] to energize the lamps during diagnostics.
Both Lamps energize.

Y N
One or both of the lamps energizes (lights).
Y N
Press Stop. Press the Red Lamps Test Switch, S901, on the Photoreceptor Module.
One or both Lamps energize (light).
Y N
There is +24 VDC between J1-10 (+) and J1-8 (-) at the Discharge Lamps
Power Supply.
Y N
There is +24 VDC between TB4-12A (+) and TB4-8B (-).
Y N
Go to the 1-717, +24, +34, -34 VDC RAP.
Go to Flag 2. Check the +24 VDC wiring from TB4-12A and TB4-4A to the
PWB for an open circuit. If the +24 wiring is ok, go to Flag 3 and check the
DC Com wiring from TB4-8B and TB4-12B to the PWB for an open circuit.
Go to Flag 3. Check the DC Com wiring from TB4-8B and TB4-12B to the PWB
Go to Flag 4. Ensure that there is not an open circuit between TS17 of MIN ADA #2
and J1-5 of the Discharge Lamps Power Supply. Repair the circuit as required. If the
wires are OK, replace the Discharge Lamps Power Supply PWB (PL 9.4) Figure 1 PQ9-624 Discharge Lamp Components (8315A).
Go to Flag 5. Check the wiring for the particular Lamp that does not light. If the wiring is
OK, replace the lamp (PL 9.3)
Closely examine the Precharge Lamp when it is on. All lamp segments light.

Figure 2 PQ 9-624 Precharge/PreTransfer Lamps Circuit Diagram (8305).

PQ 9-625 White Spots RAP • Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper
Trays and the paper path areas. Wipe areas as required.
White spots are deletions (absence or lack of toner) in a solid area. Halftone or continuous Paper Stock
tone images that are circular in appearance with sharply defined edges. Deletions caused by
agglomerates do not have sharply defined edges. • Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If
expected as a contaminant, direct the Operator to discard the top and bottom sheets of
Initial Actions any new reams of paper added to the Trays.
Examine the white spots with an eye loupe. If the white spots do not have sharply defined • Pre-drilled paper: suggest that paper be drilled after printing if possible.
edges, go to the PQ 9-604, Prints with Agglomerates/Debris RAP. If there are sharply defined • Label stock: adhesives from the labels can cause spots.
edges, continue with this RAP.
Enter SCP [HSFI]. Ensure that all Xerographic (09) HFSI listed in the HFSI TABLES are com- • Paper stock: certain brands are known spot generators.
pleted. • Spray adhesives: any sprays used near the system can enter the machine air system and
Procedure Tray 1 / Tray 2 Feed Components
1. Check sequential prints for a repeatable pattern of white spots.
a. Enter dC606. Select [Dark Dusting]. Select a Tray with 14 inch paper and program
a 14 print job. Press Continue. Number the prints as they come out of the machine
from 1 to 14.
b. Check the prints for white spots.
If the defect repeats on every seventh print, go to 4.
If the defect repeats on every print in the same exact location, go to the PQ 9-601,
System Image Quality Entry RAP. • Idler and Retard Brake (PL 7.13)
Belts wearing:
NOTE: Light image darkness on prints will tend to aggravate the white spots problem.
2. White spots occur on prints whose image darkness is light.
Enter dC106. Select [Test Pattern and PQ] [Xerographic]. Program a 14 print job.
Press Continue. Compare the prints to the 82E4161 test pattern. Observe blocks "A" and • Top Transport Belts (4) (PL 7.10)
"3" on the prints. The blocks are equal to or darker than the "STD:LT/UM" block on the Dirt Shield, clean or replace as required (PL 7.10)
test pattern.
If the prints are equal to or darker than the test pattern, go to STEP 5. Xerographic
If the prints are less than the test pattern, go to the PQ 9-609, Low Image Darkness RAP. CAUTION
3. White spots repeat on almost every print, but tend to move across the page at the The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2)
rate of six to ten millimeters print to print. minutes or severe xerographic problems may result. If the belt module will be exposed to light
Go to the 10-606, Dry Ink Spots on Prints/Spot Deletions RAP. for more than two minutes, remove the photoreceptor from the belt module and place it in the
4. White spots repeat every seventh print and are judged unacceptable.
Replace the Photoreceptor Belt (REP 9-35), (PL 9.1). Perform the Xerographic Setup
(ADJ 9-3). CAUTION
5. Replace the Developer Material (PL 9.4). Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox
6. Considerable levels of dirt are found in the belt module area.
Go to the PQ 9-632, Dirt RAP.
Possible Sources of Contamination switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are
Ensure all sources of contamination have been purged from the System to prevent callback for performed with the components clean.
the spots problem. Perform the following actions unless already done while troubleshooting. • Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Pre-
Paper Dust the Photoreceptor Ground Brush.

• Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays PQ 9-626 Dicorotron RAP
roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt, Perform Initial Actions
Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to
Fuser the values listed in the appropriate level Software dC 131 Table, Section 6, General Proce-
Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not con- dures, in the Service Manual. If any NVM values require change, perform the Xerographic
taminating the developer assembly. If any oil is identified in the Developer Assembly, replace Setup (ADJ 9-3).
the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the
Xerographic Setup (ADJ 9-3). Table 1 MIN NVM
202 216
204 223
210
Procedure
Enter dC131 [MIN]. Select Address 223 (Dicorotron AC Target). Ensure that the Data value is
95. Enter dC951. Press Continue. The Charge Ratio is between 92 and 98.
Y N
The Charge Ratio is greater than 98.
Y N
(The ratio is less than 92). Check/adjust the Charge Dicorotron Height Adjustment
(ADJ 9-7), it could be too far. If adjustment is OK, check the Charge 1 Dicorotron
shield for dirt, oxidation or a poor electrical connection. Repair/replace the shield as
required (PL 9.10).
(The ratio is greater than 98). Check/adjust the Charge Dicorotron Height adjustment
(ADJ 9-7). It could be too close. If the adjustment is OK, replace the Charge 1 Dicorotron
with a known good one and recheck the ratio. Leakage is suspected between the shield
and ground. If the problem still exists, check the Charge 1 circuit. If the problem still exists
and the machine is in a high altitude location (6000 feet or more), enter dC105 and
ensure that the machine is set for high altitude operation.
WARNING
Put on safety glasses before inspecting the coronodes. Eye injury could result if the
glass coronode breaks.
Cheat the Printer Interlock Bypass Switch. Remove the inner covers. Pull all 5 dicorotrons so
that each is disconnected from the high voltage connection. Enter dC140. Press Continue.
Allow the printer approximately 60 seconds to warm up. The Coronode ACV Monitor display
is within +/- 0.7 of the Coronode ACV Control display.
Y N
Press Stop. Disconnect the HVAC Output Remote signal line connector. Press Con-
tinue. The Coronode ACV Monitor display is within +/- 0.7 of the Coronode ACV
Control display.
Y N
Go to the PQ 9-628, HVAC RAP.

A
A
• HVAC cable routing. HVAC cables should not touch other HVAC wires or cables. No PQ 9-627 Patch Integrity RAP
HVAC cable should touch low voltage DC wires or DC ground wires.
• The HVAC connectors for evidence of arcing or corrosion. The purpose of this RAP is to ensure that the patch has been created and developed correctly
to ensure proper toner concentration control setups.
• The HVAC cables for signs of arcing or deterioration.
• Repair or replace cables and/or connectors (PL 9.8)
Initial Actions
• If problem continues, replace the HVAC Output Module (PL 1.7)
• Clean the Patch Generator with a dry, soft cloth.
Press Stop. Push in all the dicorotrons and shields. Press Continue. Observe the dicorotrons. • Clean the ROS exiting window with a lint-free cloth.
All 5 dicorotrons are glowing. • Enter dC105 [Features]. Ensure that the Precision Patch is enabled.
Y N Procedure
Exchange the dicorotrons between the 5 dicorotron positions. Determine if the problem is
Enter dC909. Select [Printer Options], [Pages Per Set (50)], [Test Pattern (Xerographics)].
dicorotron or position related. Ensure that all 5 dicorotron positions are filled with
Reselect [Printer Options]. Select [Patch Print (Yes)], [Charge Control (Open)], [Start].
dicorotrons.
The developed patches have uniform density.
• If the problem is related to a certain dicorotron, replace that dicorotron (PL 9.10),
Y N
• If the problem is position related, check the coronode sockets for damage, pitting,
Check Developer Roll 1 and 2 Bias by measuring between the Developer Housing Left
arcing, corrosion or foreign substances. Side Extrusion (located under the Developer Catch Tray), and the Machine Frame. Check
• If the socket is good, replace the HVAC Output Module (PL 1.7), the Developer Roll 3 Bias by measuring between the Developer Housing Right Side
• If the above checks do not solve the problem, go to the PQ 9-628 HVAC RAP. Extrusion and the Machine Frame. If OK, continue on here, if not, go to PQ 9-616. The
patch is free of dark, Le or TE bands in the fast scan direction.
Each dicorotron glows evenly, without "hot" spots. Y N
Y N Dark bands of 2 mm or less at the lead or trail edge is OK. If the dark bands are
Replace the defective Dicorotron (PL 9.10), greater than 2 mm, check/adjust the registration if required. Enter Printer dC604 and
select [Registration Adjustment], [Start].
Press Stop. Enter dC910 [High Stress]. Rotate each of the dicorotrons in sequence into the Enter dC911, and perform Patch Generator Timing (ADJ 9-5).
Transfer Dicorotron position. Ensure that all 5 dicorotron positions are always occupied during Enter dC131 [MIN]. Check the following NVM addresses and enter the data values
this procedure. Press Continue. "Hot spots" and/or arcing is present on the dicorotron. as listed in the appropriate level Software dC 131 Table, Section 6, General Proce-
Y N dures, in the Service Manual.
The dicorotrons are OK. • Location 249
• Location 253
Replace the dicorotron with the "hot spots" or the arcing dicorotron (PL 9.10), • Location 254
• Location 285
• Location 420
If any of the above NVM values are changed, perform Xerographic Setup (ADJ 9-3).
Check/perform the following:

• If the patches have light streaks or bands, go to PQ 9-612.
• If the patches have white spots, go to PQ 9-625 White Spots RAP.
• If the patches have deletions, go to PQ 9-615 Deletions RAP.
• If the patches have dark streaks or bands which are horizontal, check that the Patch
Generator LEDs come on. Enter dC330, and select [9], [Patch Generator High Out-
put], [Start]. If the Patch Generator is OK, go to PQ 9-611 Dark Streaks/Bands RAP.
• If the patches have dark spots or marks, go to PQ 9-613 Dark Spots RAP.
• If the patches have uneven density or darkness, go to PQ 9-614 Non-uniform Image
Darkness RAP.
The measured patch height is from 20 to 25 mm.

Y N PQ 9-628 HVAC RAP
Ensure that the cleaner and charge zone rolls are positioned correctly against the PR Belt
and held securely in the PR module frame (PL 9.2). The purpose of this RAP is to ensure that the HVAC PWB is working correctly.
Go to PQ 9-616.
Procedure
NOTE: With the Precision Patch, the patch width should be exactly the same size for every The following steps list some general areas to be checked and references the fault code raps
patch.
that can be used to troubleshoot suspected problems with the HVAC PWB.
Patch width, including load/trail edge dark bands, is from 17.5 mm.
Y N 1. AC Coronode Voltage
Enter Printer dC604. Select [Registration Adjustment], [Start]. Go to ADJ 8-2 and check a. Check for secure connections between the HVAC PWB, the Twist Lock Connector to
and adjust registration as required. the HVAC Output Module, and the MIN ADA PWB #1, repair/replace as required (PL
Enter Printer dC911, and perform the Patch Generator Timing (ADJ 9-5). 9.8).
Check that both Cleaner and Charge Zone Rolls are correctly positioned against the Pho- b. Check the condition and connection of the ribbon cable between the HVAC and
toreceptor and held securely in the Photoreceptor Module frame (PL 9.2). HVDC PWBs, repair/replace as required.
Go to PQ 9-616.
c. Check the operation of the MIN ADA PWB #1 and HVAC PWB. Go to the 9-329.
2. Cleaner Biases
All ID zones are free of background (except those with the printed patches).
Y N a. Check for secure connections between the HVAC PWB, the Cleaner and the MIN
Go to PQ 9-607/608 RAP. If the PQ 9-607-608 RAP does not solve the problem, go to PQ ADA PWB #1, repair/replace as required.
9-617 Cleaner RAP. b. Check for proper operation of the control circuits and the correct voltages between
the MIN ADA PWB #1, the HVAC PWB and the Cleaner. To perform these checks,
The Patch integrity is OK. refer to the 9-322 (cleaner voltage out of range), 9-323 (upper detoning roll bias out
of range), or 9-324 (lower detoning roll out of range) as required.
3. Control Circuit Operation for Transfer, Detack and Preclean Shield Currents
a. To evaluate these circuits, refer to RAPs 9-326, 9-327 and 9-328.
4. ARC Detection
a. Go to RAP 9-201.

PQ 9-629 HVDC RAP
The purpose of this RAP is to ensure that the HVDC PWB is working correctly.
Procedure
The following steps list some general areas to be checked and references to the RAP's to be
used to troubleshoot suspected problems with the HVDC PWB.
1. Developer Bias #1 and #2 Voltage

a. Check for secure connections between the HVDC PWB, the Developer Bias Rolls
and the MIN ADA PWB #2. Repair/replace as required (PL 9.8).
b. Ensure that the developer biases are isolated from machine ground and Photore-
ceptor Belt ground, that is, the biases are not shorted to ground. Ensure that there is
a 50 +/- 4 VDC difference between Developer Bias 1 and 2. If not, go to 9-320.
c. Check for the correct operation of the MIN ADA PWB #2 and HVDC PWB. Go to 9-
320 to diagnose MIN and 9-321 to diagnose HVDC as appropriate.
2. Charge 1 and 2 Dicorotron Voltage
NOTE: Because Charge 1 is controlled by Charge 2 feedback, only Charge 2 Dicorotron is

checked.
a. Check for secure connections between the HVDC PWB, the Charge 2 Dicorotron
and the MIN ADA PWB #2. Repair/replace as required, go to step b.
b. Check for proper operation of the control circuits and the correct voltages between
the MIN ADA PWB #2, the HVDC PWB and the Charge #2 Dicorotron. Go to the 9-
325 RAP, to perform these checks.
3. Control Circuit Operation for Transfer, Detack, and Preclean Dicorotrons 0 and
interaction between HVDC and HVAC circuits
a. To evaluate these circuits, go to RAPs 9-326, 9-327, and 9-328.
4. ARC Detection
a. Go to RAP 9-201.
Figure 1 PQ 9-628 Component Diagram (713007)

A B
PQ 9-630 Toner/Charge Control RAP Recheck the ESV ID zone values by entering dC909. Program a 250 print job. Press
Continue. Observe the ESV and DSS ID zones 2, 4, 6 readings during the first ten
The purpose of this RAP is to ensure that the toner and charge control system components are updates. The range for the ESV ID 2, 4, 6 updates is now less than 50 volts.
working correctly. Y N
Check the ESV Height Adjustment (ADJ 9-12). Go to the PQ 9-619, ESV RAP.
Initial Actions If the problem continues, go to Printer Electrical Noise Procedure RAP.
Check SCP [Faults]. If 9-215 faults are indicated, go to the 9-215. If the problem continues
return to this RAP. The range for the DSS ID 2, 4, 6 is between 75-100 units.
Y N
Select [ESV-DSS Test], [DSS Recalibrate]. This will cause a power up con-
the values listed in the appropriate level Software dC 131 Table, Section 6, General Proce- vergence at the next print cycle. Program a 200 print job. Press Continue.
dures. Observe the DSS ID 2, 4, 6 readings during the first ten updates. If the range
for the DSS updates is still not between 75-100 units, go to the PQ 9-620, DSS
RAP. If the problem continues, go to the PQ 9-621, Patch Gen/Patch Integrity
Table 1 MIN NVM
RAP.
179 251 ESV is OK.
220 260
DSS is OK.
243 275
244 289 The range for the DSS ID 2, 4, 6 updates is between 75-100 units.
245 295 Y N
246 296 Select [ESV-DSS Test] [DSS Recalibrate]. This will cause a power up convergence at
the next print cycle. Program a 200 print job. Press Continue. Observe the DSS ID 2, 4, 6
247 420
readings during the first ten updates. If the range for the DSS ID 2, 4, 6 is still not between
75-100 units, go to the PQ 9-620, DSS RAP. If the problem continues, go to the PQ 9-621,
• If any of the MIN NVM values required change, perform Xerographic Setup (ADJ 9-3). Patch Gen/Patch Integrity RAP.
Procedure
Enter dC912. Press Continue. Check the All Panels Range display. The All Panels Range Toner/Charge Control is OK.
display reading is less than 50 volts
Y N
Go to the PQ 9-633, PR Belt Uniformity RAP.
Enter dC909. Program a 250 print job. Press Continue. Observe the ESV and DSS ID 2, 4, 6
readings during the first ten updates. The range for the ESV ID 2, 4, 6 updates is less than
50 volts.
Y N
Select [ESV-DSS Test] [DSS Recalibrate]. This will cause a power up convergence at
the next print cycle. Program a 200 print job. Press Continue. Observe the ESV and DSS
ID 2,4,6 readings during the first ten updates. The range for the ESV ID 2,4,6 is less
than 50 volts.
Y N
Enter dC131 [MIN]. Enter Address 126 (Vddp Setpoint Minimum). Record the data
value. Enter Data value 32.
Enter dC912. Press Continue. Record the Dark Decay Volts. Calculate the Dark
Decay Offset by dividing the Dark Decay Volts by 5.88. Enter dC131 [MIN]. Enter
Address 158 (Minimum Dark Decay for a Photoreceptor). Enter the calculated dark
decay offset value rounded off, into address 158.
Enter Address 126. Enter the initial Data value recorded above.
A B
A
PQ 9-631 Bead Carryout RAP Select [Start] to measure between the left side extrusion of the Developer Housing (located
under the Developer Catch Tray) (+) and the Machine Frame (-). The measured voltage is
Bead Carryout is excessive amounts of Developer beads located on the Developer Manifold within +/- 10 VDC of [Dev Rolls 1 & 2] Bias Required Display.
and outside of the Developer Housing Area. The primary causes of Bead carryout are: Incor- Y N
rect toner concentration, incorrect or missing developer bias, or a mechanical problem with the Select [Stop] and check the following:
Developer Housing. It is impossible to completely eliminate all BC from a correctly operating • Refer to the Figure 1. Go to Flag 1 and Flag 2 and check the Developer Rolls 1 and
system. A small residual amount of BC which does not cause deletions or excessive machine 2 Bias circuitry for an open. If the circuits check out OK, replace the HVDC PWB (PL
contamination is acceptable. 1.7).
NOTE: DO NOT perform the DSS Saturation or dC951 Xerographic Setup until instructed to In dC140 [DC Bias Values], measure between the right side extrusion of the Developer Hous-
do so in this procedure. This prevents the setup procedure from being unnecessarily repeated ing (+) and the Machine Frame (-). The measured voltage is within +/- 10 VDC of [Dev Roll
several times. 3] Bias Required Display,
Y N
Initial Actions select [Stop] and check the following:
Make a copy of Figure 2 (refer to hardcopy graphic), for later use in this procedure to record • Refer to the CD. Go to Flag 3 and Flag 4. Check for an open circuit. If the circuit is
the dC909 values. OK, replace the HVDC PWB (PL 1.7).
Check/adjust the following. If the Bead Carryout Problem continues after completing this Initial Check the Developer Zone Roll Support Pads. If either of the two Outboard Support Pads are
Action, continue with the RAP Procedure. damaged or missing, replace the Front Bearing Clamp Assembly (PL 9.15).
Ensure that the Hydraulic Dump Actuator is properly adjusted to relieve pressure from the cyl-
• Developer Zone Roll (ADJ 9-1) inder when the PR Module is closed. Adjust the actuator or replace the Hydraulic Lift with the
• Photoreceptor Tension (ADJ 9-11) Mechanical Lift Assembly P-192 (600K25820).
• PR Module Alignment (ADJ 9-10) Ensure that the Developer Zone Roll is properly aligned on the Support Pads (ADJ 9-1).
• DSS Saturation (ADJ 9-13) NOTE: The PR Tension Springs and Developer Seals Kit should NOT be installed except as a
• Xerographic Setup (ADJ 9-3) part of a complete Bead Carry Out procedure. The 12 lb. PR Tension Springs alone may not
Cheat the Processor Interlock Bypass Switch. reduce Bead Carry Out.
Check for Tags P-228 and P-216. For machines with out TAG P-228, order and install the PR
Procedure Tension Springs (P-228) and Developer Seals (P-216) Kit (600K32850). Developer Seal sets
(Developer Bias Checks) Enter dC140. Select [DC Bias Values], [Start]. Measure the DC can be ordered individually (outboard set - 35K4130, inboard set 35K4120).
Bias from the Developer Roll 1 drive gear (+) to the frame ground (-). Compare the values Clean the entire PR Module (inside & outside), Dicorotrons & Shields, Developer Housing and
measured with the DMM to the values displayed on the dC140 screen for the corresponding Seals, Cleaner Housing (inside, outside, brush, augers & channels), Registration Transport,
Dev Roll Biases. The measured voltage is within +/- 10 VDC Actual display. Top Transport, transfer zone, Transfer Assist Blade, and entire paper path (including duplex
Y N path and inverter) with the vacuum cleaner.
Enter dC902. Check and adjust the AC PWB and DC PWB Calibration Values per the Inspect the PR Belt for seam damage or edge damage. If the PR Belt has any edge damage or
Calibration Tags (found in the Machine Log Book). upward curl, ensure that the PR Edge Guides are not damaged and are free of fused toner
buildup. Replace the Edge Guides if they are damaged or contaminated with fused toner.
Enter Printer dC140. Enter [DC Bias Values]. Measure between the left side extrusion of the Clean the Edge Guides at every PR change. Replace a damaged PR Belt.
Developer Housing (located under the Developer Catch Tray) (+) and the Machine Frame (-). If the Developer Material has been in the machine for more than 500K prints, perform the
Select [Start]. Developer Dump and Thump (REP 9-6).
Ensure that the power supply calibrations are correct. Perform the DSS Saturation (ADJ 9-13).
NOTE: An intermittent short will not drop the voltage of 0 VDC. If there is a short, the SCP
Printer Fault History should have Fault Codes 9-320 and 9-321 logged. NOTE: A small amount of reverse developer flow may remain, and not significantly contribute
to BCO.
The measured voltage is steady within +/- 2 VDC.
Y N Check for Reverse Developer Flow:
Select [Stop]. Perform the following checks for possible causes for a short: Refer to (Figure 1) for an illustration of Reverse Developer Flow. Inspect the Developer Mate-
• Refer to the CD. Go to Flag 1 and Flag 2, and check the Developer Rolls 1 and 2 rial flow across Developer Roll #1. Reverse Developer Flow exists when Developer Material
Bias circuitry for a short. accumulates and appears to flow in the reverse from normal direction. It can occur at one or at
• Check the Developer Zone Roll Support Pads. If either of the Outboard Support both ends of Developer Roll #1. There is normal developer flow.
Y N
Pads are damaged or broken, replace the Front Bearing Clamp Assembly (PL 9.15).
Reverse Developer Flow is present, perform the following:
• If the above checks are OK, replace the Developer Drive (PL 4.17).
A B
B
• Check the Developer Housing Support Pads for the Developer Zone Roll. If either of
the two Outboard Support Pads are damaged or broken, replace the Front Bearing
Clamp Assembly (PL 9.15).
• Inspect the Developer Rolls. Replace the rolls if they are damaged or show wear-out
(roll surfaces worn smooth), (REP 9-9) or (REP 9-10).
• Inspect / clean the Trimmer Bar. Replace the Trimmer Bar if damaged (REP 9-11),
(PL 9.16).
• Inspect and adjust the Trimmer Bar toward the Developer Roll 2. If reverse devel-
oper flow still exists, install Tag P-488, the Developer Rollback Solution Kit.
Perform the following tasks:

• Inspect the Developer Rolls. Replace the rolls if they are damaged or wear-out (roll sur-
faces worn smooth), (REP 9-9) or (REP 9-10).
• Print ten halftone images from Tray 1 and Tray 2 and examine the prints for deletions.
• If there is still unacceptable BCO and the Developer was free of reverse developer flow,
replace the Photoreceptor Module (PL 9.1).


Figure 2 dC909 Values

A B
PQ 9-632 Dirt RAP • Go to the PQ 9-624, Pretransfer/Precharge Lamps RAP.
• Examine the Cleaner. Go to the PQ 9-617, Cleaner RAP.
The purpose of this RAP is to determine the cause of the dirt/contamination.
Determine the source. Repair as required. Clean up all filings.
Initial Actions
If the dirt is toner on the back of the prints or on the lead edge of the prints, go to the PQ 9-622, Perform the following:
Transfer Assist Device RAP. Return to this RAP if the problem continues. • Ensure that the Photoreceptor Module is latched properly. Ensure that the Developer
Housing is properly installed in the machine and is secured.
Clean any dirt and contamination that are the result of adding consumables to the machine. CAUTION
Follow the cleaning procedures in the Service Data (Section 4) for the following items: minutes or severe xerographic problems may result. If the belt module will be exposed to light
• The light shields on the Screening Device, Precharge/Pretransfer Lamps, Belt Hole Sen- protective bag, or place the bag over the photoreceptor with it on the belt module.
sor.
• Pull out the Photoreceptor Drawer. Lift the Photoreceptor Module to the full open position.
• The Patch Generator (REP 9-36), the ESV (REP 9-37) and the DSS (REP 9-38) Inspect the Developer Housing seals for dirt and damage. Repair/replace components as
• The Dicorotron Shields (REP 9-39) required (PL 9.15).
• The Photoreceptor Ground Strip • Check the Bead Rollout Device for dirt. Ensure that the DRD rotates freely. Clean/repair
• Replace the Dicorotron electrical connectors if they are dirty, contaminated or broken components as required (PL 9.15).
(REP 9-40). • Check for developer leaks from the Dump Door, repair/replace components as required
• The Developer Housing and Photoreceptor Module. Check/replace the Developer Seals if (PL 9.17).
damaged or missing, (PL 9.15) Possible Sources of Contamination
Hints about the Developer Manifold. Ensure all sources of contamination have been purged from the System to prevent callback for
the spots problem. Perform the following actions unless already done while troubleshooting.
• When the manifold is operating normally, there will be an accumulation of toner between
the Developer Housing and the air holes, and there will be a clean curved area between Paper Dust
the air holes. A small amount of toner to the right (front view of housing) of the manifold
holes is normal. • Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper
• A loss of vacuum or low vacuum will result in dirt across the entire width of the manifold. Trays and the paper path areas. Wipe areas as required.
Clean the Developer Manifold. Remove the air hose. Tap the bottom of the manifold with Paper Stock
the handle of a screwdriver while cleaning the manifold with the vacuum cleaner. With the
Main Drive running, the vacuum measurement at the test hole at the outboard end of the • Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If
manifold should be a minimum of 8mm of vacuum (-). If 8mm of vacuum is not mea- expected as a contaminant, direct the Operator to discard the top and bottom sheets of
sured, check for a clogged filter, or kinked/plugged hoses in the rear of the machine. any new reams of paper added to the Trays.
Procedure • Pre-drilled paper: suggest that paper be drilled after printing if possible.
CAUTION • Label stock: adhesives from the labels can cause spots.
The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) • Carbonless paper is not recommended for use on this system.
minutes or severe xerographic problems may result. If the belt module will be exposed to light • Paper stock: certain brands are known spot generators.
Inspect the Xerographic area for dirt. Examine the dirt. Most of the dirt is developer beads.
Y N
Most of the dirt is metal or plastic filings.
Y N
Check for a broken machine part or a part that is out of position. Look for a sheet of
paper or a foreign object in the Cleaner or Developer Housing. If any of the above
items are found, repair as required.
If the previous checks are negative, the dirt problem is most likely the result of the • Feed Belt Pulley (PL 7.12)
interaction between the cleaning, the transfer, and the process controls. Perform the • Feed Belt Spool (PL 7.12)
following: • Idler and Retard Brake (PL 7.13)
A B
Belts wearing: PQ 9-633 PR Belt Uniformity RAP
• Takeaway Drive Belt (PL 7.10) The purpose of this RAP is to determine if the Photoreceptor Belt is being charged uniformly.
• Top Transport Belts (4) (PL 7.10) Procedure
Dirt Shield, clean or replace as required (PL 7.10) CAUTION
Xerographic minutes or severe xerographic problems may result. If the belt module will be exposed to light
CAUTION for more than two minutes, remove the photoreceptor from the belt module and place it in the
Clean the Photoreceptor Belt ground block, brush, and the ground strip. Enter dC912. Press
for more than two minutes, remove the photoreceptor from the belt module and place it in the Continue. The All Panels Range is less than 70 volts.
protective bag, or place the bag over the photoreceptor with it on the belt module. Y N
Note the image zone(s) with the maximum and minimum voltage readings. Repeat
dC912. Press Continue. Again, note the image zone(s) with the maximum and minimum
CAUTION voltage readings. Determine if the voltage extremes are related to a specific image zones
Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox or panels on the Photoreceptor Belt. The maximum and minimum readings are on the
anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV same image zones each time.
should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before clean- Y N
ing the ESV and DSS. The Printer will perform a Power Up Sequence when the power is Go to the PQ 9-618, PR Ground RAP. After completing that procedure, return to this
switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are RAP. Enter dC912. Press Continue. The All Panels Range is less than 70 volts.
performed with the components clean. Y N
• Remove the Photoreceptor. Clean the Pretransfer and Precharge Lamps. Clean the Belt Enter dC106. Select [Test Patterns and PQ] [Halftone]. Program 20 prints.
Hole Sensor with a clean, water dampened cloth. Clean the DSS, ESV and the Patch Choose a Tray with 14 inch paper. Press Continue. The prints have random
Generator with a soft, lint free cloth. Clean the ESV Vacuum the Photoreceptor Ground fast scan direction deletions (or light fast scan direction strobes) about
Brush. one half inch in width.
Y N
• Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays
Go to the Printer Electrical Noise Procedure RAP. Repeat dC912 after
repair.
The prints have fast scan direction white bands.
Fuser Y N
Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not con- Remove the rear covers. Check the Photoreceptor Drives:
taminating the developer assembly. If any oil is identified in the Developer Assembly, replace • Examine the drives for loose, jumping belts and /or pulleys (PL 4.17).
the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the • Check for Broken/missing idler springs (PL 4.17).
• Check for Shaft and bearing wear signs (noise/wobble). Repair or
replace as required (PL 4.17).
Go to the PQ 9-612, Light Streaks/Bands RAP.
The Photoreceptor Uniformity is OK. If the Xerographic Drawer area is extremely

dirty, go to the PQ 9-632, Dirt RAP.
Go to the PQ 9-618, PR Ground RAP. After completing the procedure return to this RAP.
Enter dC912. Press Continue. The All Panels Range is less than 70 volts.
Y N
Go to the PQ 9-619, ESV RAP. After completing the procedure return to this RAP.
Enter dC912. Press Continue. Check the All Panels Range value. If the range is still
70 volts, replace the Photoreceptor Belt (PL 9.1).
A B
A B
The Photoreceptor Uniformity is OK. If the Xerographic Drawer area is extremely dirty, go PQ 9-634 Residual Image RAP
to the PQ 9-632, Dirt RAP.
Residual image is a secondary or partial image that appears with the primary or desired image.
The Photoreceptor Uniformity is OK. If the xerographic drawer area is extremely dirty, go to the Residual image is caused by Photoreceptor Belt cleaning problems or fusing problems.
PQ 9-632, Dirt RAP.
Initial Actions
If the residual image appears only after fuser mis-trips and disappears after several prints, go
to the 10-102 RAP.
If the residual image appears only in the first 30 prints from a cold start, go to the 10-608 RAP.
NOTE: When duplex prints are being run, a double image can occur due to improperly loaded
first side prints in the paper trays. Examine the defective prints and inform the operator. Paper
Tray 1 and 2 should be loaded with the first side image down, top of the print to the outboard
side. In Tray 3 the first side image should be loaded face up, with the top of the print to the out-
board side.
Procedure
Enter dC106. Select [Test Patterns and PQ] [Dimensional]. Program a 30 print job. Choose
a Tray with 14 inch paper. Press Continue. After approximately 10 prints, open the Printer
Front Doors to hard stop the printer. Inspect the PR Belt surface for toner past the Cleaner.
There is toner past the Cleaner.
Y N
Carefully remove the prints from the Fuser and the Decurler area. Examine the prints for
residual image. If present, check the Fuser Roll Temperature (ADJ 10-6) and then go to
the 10-708, Fuser Agent Dispense RAP.
Clear the fault. Check/perform the following in the order specified:

• Go to the PQ 9-617, Cleaner RAP. Clean/vacuum any spilled Dry Ink. Vacuum the Photo-
receptor module and area. Closely inspect and clean any dry ink accumulation from the
PR Edge guides (the guides are located on the inboard and outboard ends of the rubber
rolls). Dry ink accumulation and build up on the guides can damage the edge of the PR
Belt. If excessive dirt is observed, go to the PQ 9-632, Dirt RAP. Return to this procedure
after completing the PQ 9-632, Dirt RAP.
• Check the operation of the Precharge and Pretransfer Lamps. Go to the PQ 9-624, Pre-
charge/Pretransfer Lamps RAP to repair.
• Clean all dicorotron shields. Ensure that the Transfer and Preclean dicorotrons glow in
operation. Repair/replace components as required (PL 9.10)
the values listed in the appropriate level Software dC 131 Table, Section 6, General Proce-
dures. If any of the NVM values require change, perform the Xerographic Setup (ADJ 9-3).
Table 1 MIN NVM

199 206
200 207
204 208
205 239

PQ 9-635 Smear RAP
Smear is the spread of toner on a print from an image area to adjacent non-imaged areas and
possibly overlapping other images.
Initial Actions
If the smeared image appears only in the first 30 prints after a cold start, go to the 10-608, Dry
Ink Not Fixed RAP.
Check the Spots Blade Installation (REP 9-57).
Procedure
Enter dC106. Select [Test Patterns and PQ] [Halftone]. Program a 50 print job. Choose a
Tray with 14 inch paper. Press Continue. After approximately 10 copies have been made,
open the printer front door to hardstop the printer. Observe the post Transfer prints. The
Smearing originates before the fuser roll.
Y N
Smearing occurs in the Fuser or post Fuser areas.
• Check the Fuser Subsystem: Go to the 10-608 Dry Ink Not Fixed RAP and then the
10-708, Fuser Agent Dispense RAP.
• If the smeared images only appear on prints delivered to the Top Tray are not
smeared, go to the 8-705, Print Damage RAP.
Smearing occurs before the Fuser Roll. Perform the following checks:
• Load fresh paper and run the machine. If the smear is no longer present advise the Key
Operator about the storage and use of paper.
• Ensure that the paper is loaded correctly and that curl is not excessive.
• Remove the Prefuser Transport (REP 10-12). Clean the Prefuser Transport vent holes
and the transport.
• Check the condition of the Fuser Entrance Baffle.
CAUTION
Pull out the Xerographic Drawer. Lift the Photoreceptor Belt module and examine the devel-
oped images on the Photoreceptor Belt. The images on the Belt are smeared. Figure 1 PQ 9-635 Component Diagram (713008)
Y N
Check the Transfer Dicorotron, Detack Dicorotron, POP Sensor, Precharge/Prexfer Lamp
Reflectors, and Prefuser Transport areas for potential causes.
Determine where the smear first occurs and look for the cause at that point. Also check/correct
as required the following:
• Check the Transfer Assist Blade for toner contamination. Adjust the Transfer Blade Tim-
ing as required. (ADJ 9-9).
• Check the exit lip of the Developer Housing for contamination, defective seals, or a phys-
ical interference.
• Ensure that the Bead Rollout Device is free of contaminants and rotates freely.
• Ensure that the Developer Zone rolls contact the Developer Housing tabs.

PQ 9-636 Blur RAP Possible Sources of Contamination
Blur is the scattering of Dry Ink (Toner) particles around individual characters on the Print when
the spots problem. Perform the following actions unless already done while troubleshooting.
background and fusing are acceptable.
Paper Dust
Procedure
The Blur is a fast scan direction band 15-40 mm wide about 70-100 mm from the trail • Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper
edge of 81/2 inch prints. Trays and the paper path areas. Wipe areas as required.
Y N Paper Stock
The blur is an irregular band centered in the fast scan direction and running in the
process direction. • Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If
Y N expected as a contaminant, direct the Operator to discard the top and bottom sheets of
The blur is in the central area of the print and is in a band about 25 X 75 mm. any new reams of paper added to the Trays.
Y N
• Pre-drilled paper: suggest that paper be drilled after printing if possible.
Go to the Possible Sources of Contamination checklist at the end of this
• Label stock: adhesives from the labels can cause spots.
RAP.
The Photoreceptor Belt may be contaminated from the Preclean Dicorotron. Con- • Paper stock: certain brands are known spot generators.
tamination occurs in standby and is due to outgassing (the emission of vapors) from • Spray adhesives: any sprays used near the system can enter the machine air system and
the plastic materials of the Dicorotron which coats the Photoreceptor surface imme- can cause spots and damage the Photoreceptor.
diately under the dicorotron. Contamination can occur if immediately after a long run
the fuser is pulled out and left out for more than five minutes. With the fuser out, the
airfoil through the preclean dicorotron is interrupted and the harmful vapors are not
carried away. Normally (with the fuser in and all components in place) the fuser pro-
vides a convective airflow through the preclean dicorotron which carries the vapors
away from the Photoreceptor surface.
The blur caused by this type of contamination will eventually (in about a day) go • Feed Belt Idler (PL 7.12)
away as the contaminant dissipates. If the defect is unacceptable, replace the Pho- • Feed Belt Pulley (PL 7.12)
toreceptor Belt (PL 9.1). • Feed Belt Spool (PL 7.12)
NOTE: A preventive measure (when the Fuser must be pulled out after a long print • Idler and Retard Brake (PL 7.13)
run) is to remove the preclean dicorotron and keep it out until the Fuser is reseated. Belts wearing:
Check/perform the following: • Takeaway Drive Belt (PL 7.10)

• Check the OZAC Ducts for leaks and blockage.
• Check for blocked air passages in the dicorotron endblocks.
• Check for fuser agent (oil) leaks on the Photoreceptor belt. Find and repair the cause
of the leak and replace the Photoreceptor Belt (PL 9.1).
• Check for foreign objects in the dicorotrons. If the problem still exists after repair/ Xerographic
cleaning, replace the Photoreceptor Belt (PL 9.1).
CAUTION
Check/perform the following: The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2)
• Check the OZAC Ducts for leaks and blockage. minutes or severe xerographic problems may result. If the belt module will be exposed to light
• Check for blocked air passages in the dicorotron endblocks.
• Check for fuser agent (oil) leaks on the Photoreceptor belt. Find and repair the cause of
the leak and replace the Photoreceptor Belt (PL 9.1).
• Replace the Preclean Dicorotron and Shield (PL 9.10).
• Enter dC106. Select [Test Patterns and PQ] [Halftone]. Select [Printer Options]. Pro-
gram a Duplex, 300 print job. Choose a Tray with 14 inch paper. Press Continue.
Recheck the blur problem. If the problem still exists, replace the Photoreceptor Belt (PL
9.1).

CAUTION PQ 9-637 Slow Scan Magnification Checkout Procedure
anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV The purpose of this RAP is to determine and repair the cause of slow scan magnification prob-
should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before clean- lems.
switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are Initial Actions
performed with the components clean. Observe the Fuser/Developer drive belts in the rear of the IOT. Check for wear or improper
• Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Pre- operation while running prints.
the Photoreceptor Ground Brush. Procedure
• Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays Use the Slow Scan Magnification procedure as an aid to locate and repair causes of Slow scan
and the paper path area. Ensure that no developer material has accumulated on the BRD magnification problems.
the Xerographic Setup (ADJ 9-3). NOTE: If transparencies are not available, two quadrille prints oriented as in Figure 1, can be
Fuser used to perform the procedure.
Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not con- 1. Enter dC606 and make one print of the two pixel quadrille test pattern on a transparency,
taminating the developer assembly. If any oil is identified in the Developer Assembly, replace and ten prints on 8.5 X11 inch paper. Enter dC106 and make 5 prints of the Halftone test
the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the pattern on 8.5 X 11 inch paper.
2. Lay the fast scan direction of the transparency on the slow scan direction of the quadrille
prints to determine the magnitude and frequency of the variation (Figure 1). Observe the
halftone prints for evidence of banding. If a banding problem is observed, go to the PQ 9-
601, and perform the Motion Quality Diagnostics, after completing this procedure.
3. Check the IOT to ensure that it is level, Section 3 of the System Printer Installation Man-
ual. Ensure that when the IOT is level that all casters are in contact with the floor.
4. Ensure that the Fast Scan and Slow Scan magnification are at 100% using the ROS Mag-
nification Setup procedure (ADJ 6-1).
5. Repeat Steps 1 and 2 after adjusting the magnification to 100% to determine if magnifica-
tion was a cause of the initial problem. If the problem continues, go to Step 6 below. If the
Slow scan magnification is now in specification, the IOT is not the cause of any problem,
however, the customer application may be a cause if the problem continues.
NOTE: Even slight key or keyway wear has been identified as a known cause of Slow Scan
Magnification problems.
6. Remove the P/R Drive Assembly (REP 4-31) and check the drive coupling for wear or
binding on the "D" shaft, and the shafts and bearings for binding. Check for any key and
keyway wear (PL 4.17). The drive will be reinstalled in step 11.
7. Open and close the Photoreceptor drawer. Observe the cleaner locating pin to ensure
that the cleaner and P/R drawer are properly aligned. Handcrank the Cleaner Assembly
drive in a Clockwise direction ONLY and check for abnormal resistance. Repair/replace
as required (PL 9.22).
8. Remove the Developer Drive Housing (REP 4-39) and check the coupling, key and key-
way for wear and binding (PL 4.17). The drive will be replaced in step 9.
9. Align the Developer Drive housing. Ensure that the Photoreceptor drawer is closed and
latched properly. Align the assembly with the developer coupling, rotating several times
while tightening the drive assembly to ensure alignment (REP 4-39).
10. Remove the Fuser Drive Assembly and check for wear or binding (PL 4.17). Install the
Fuser Drive Assembly ensuring that the drive and coupling are aligned (REP 4-39).

11. Ensure that the Photoreceptor drawer is closed and latched properly. Insert the Photore-
ceptor alignment tool, (600T2008) from the rear of the machine, onto the coupling. Install
the P/R Drive Assembly, rotating the coupling clockwise while tightening the assembly to
ensure proper alignment.
12. Unlatch the P/R drawer and remove the alignment tool. Slide the P/R drawer closed sev-
eral times, checking proper alignment of the drive and coupling.
13. Adjust the tension of the Fuser/Developer Drive Belt (REP 4-40).
14. Check and adjust the following:
• Top to bottom registration (ADJ 8-2)
• Side to side registration (ADJ 8-3)
• ROS Magnification setup (ADJ 6-1)
• Pretransfer Baffle (ADJ 8-1)
• ROS Image Squareness (ADJ 6-2).
If the problem continues perform the following:
a. Replace the photoreceptor drive housing (PL 4.17). Inspect the photoreceptor drive
shaft, coupling, and drive coupling key. Perform Steps 1 and 2 at the beginning of
this RAP to determine if the problem has been resolved, if not continue with step b.
b. Replace the photoreceptor drive roll (PL 9.3) and check the key for wear. Perform
Steps 1 and 2 at the beginning of this RAP to determine if the problem has been
resolved, if not continue with step c.
c. Replace the photoreceptor drive casting assembly (PL 4.17). Perform Steps 1 and 2
at the beginning of this RAP to determine if the problem has been resolved, if not
continue with step d.
d. Replace the bi-pully (PL 4.17). Perform Steps 1 and 2 at the beginning of this RAP to
determine if the problem has been resolved, if not continue with step e.
e. Replace the photoreceptor module drawer assembly. Repeat Steps 6 through 14,
and then perform Steps 1 and 2 at the beginning of this RAP.

Print Transparency (Print
if Transparency is
not available)
Figure 1 9-637 Slow Scan Magnification Checkout Procedure (4907)

PQ 9-638 Scratches/Crayoning Fault Analysis CAUTION
This photoreceptor is extremely sensitive to light exposure. Limit the exposure of the pho-
Dark horizontal marks (in the process direction) that resemble fine lines from 0.5 to 10 mm in toreceptor to light for two (2) minutes maximum or severe xerographic problems may
length and 100 microns wide. The lines print out more in Light Original mode. result. If the belt module will be exposed to light longer than two minutes, remove the pho-
toreceptor from the belt module and place it immediately in the protective photoreceptor
Initial Actions bag, or place the bag over the photoreceptor with it on the belt module.
• Enter dC606.
NOTE: If the Photoreceptor is damaged at the edge toward the inside of the machine,
• Select [Quadrille Patterns]: Press Continue. replace the Photoreceptor (REP 9-35), (PL 9.1), and check for wear on the Shoulder
• Make 14 copies with the longest paper available. Press Stop. Washer. If there is wear on the Shoulder Washer, replace it (PL 9.3).
• Make certain that the DP180 Developer Housing is installed.
a. Ensure that the Cooling Fans are clean and running.
• Determine which of the following categories the copies fit into.
b. Unlatch and raise the Photoreceptor module.
Procedure c. Dump the Developer Material.
Categories d. Perform the Developer Housing Inspection Procedure PQ 9-616.
e. Install the Developer Housing in the machine.
• Consumable check. Installing new Toner or Developer Material does not mean that the
new material is not defective. If diagnostics is not conclusive and if no problems can be f. Perform the Developer Zone Roll Adjustment (ADJ 9-1).
found, it could be a consumable problem. Go to STEP 1 in the Diagnostics section. g. Lower and latch the Photoreceptor Module ensuring that the Photoreceptor Module
latches properly.
• Scratches that are 6 mm to 10 mm long. Usually slightly curved or wavy. Go to STEP 2 in
the Diagnostics section. h. Cleaner Checks:
• Scratches around the circumference of the Photoreceptor. Go to STEP 3 in the Diagnos- i. Place white paper under the Cleaner Module.
tics section. ii. Remove the Cleaner Brush (REP 9-23).
Diagnostics: iii. Tap the Cleaner Module with the handle of a screw driver.
iv. Check the debris on the paper for large contaminants. If large contaminants are
1. Consumable Checks: found, or if binding, auger problems, and/or toner buildup (banding) on the
a. Check the Toner Batch number. Refer to past Bulletins and Purge notices to deter- detoning rolls exist, go to PQ 9-617.
mine if the Toner has been identified as a possible defective batch. If the batch num- i. Perform the STEP 4 at the end of this RAP.
ber was listed, perform the following:
3. Long Scratches:
i. Remove the Toner Bottle.
CAUTION
ii. Dump out the Toner in the Hopper, tap the sides of the Hopper with the handle
of a screw driver and vacuum.
toreceptor to light for two (2) minutes maximum or severe xerographic problems may
iii. Perform the Developer Dump and Thump Procedure (REP 9-6). result. If the belt module will be exposed to light longer than two minutes, remove the pho-
iv. Install new Toner and Developer Material with a different batch number than the toreceptor from the belt module and place it immediately in the protective photoreceptor
removed material. bag, or place the bag over the photoreceptor with it on the belt module.
b. Check the Developer Material batch Number. Refer to past Bulletins and Purge
NOTE: Always replace the Spots Blade (REP 9-57) whenever the PR Belt is replaced for
notices to determine if the Developer has been identified as a possible defective
Long Scratch Problems. The blade has probably suffered edge damage. Do not install a
batch. If the batch number was listed, perform the following:
new Spots Blade with a new PR Belt. Run dC951 first without the blade. Wipe the new
i. Perform the Developer Dump and Thump Procedure (REP 9-6). blade with toner before installing to eliminate tuck-under that stresses the blade.
ii. Install new Developer Material with a different batch number than the removed
material. a. Inspect the Photoreceptor for scratches. Before replacing the Photoreceptor (PL 9.1)
note the position of the scratches and check to see if they line up with any of the
c. Perform STEP 4 at the end of this RAP.
components or subsystems around the Photoreceptor area. Some causes of
2. Short Scratches/Crayoning: scratches and their corrective actions are:
• Broken/loose components around the Photoreceptor Module, repair/replace as
required.
• The Transfer Assist Blade may be touching the Photoreceptor. Visually check
that the blade is not touching the Photoreceptor in Standby. If it is, check for
blade damage. Perform the Transfer Blade Timing, (ADJ 9-9).

• Ensure that the Developer Housing, Xerographic Drawer, and Photoreceptor i. Replace the Cleaner Brush (REP 9-23).
Module are positioned properly and locked into the operating position. Ensure ii. Dump out the Toner in the Hopper.
that the Cleaner Backup Roll is fully engaged.
iii. Tap the sides of the hopper with the handle of a screw driver and vacuum.
• Check for binding in the Developer Housing. If bound, go to (PQ 9-616).
iv. Install new Toner with a different batch number than the removed material.
• Check for ESV scraping. Perform the ESV Height Adjustment, (ADJ 9-12).
m. Perform the Developer Dump and Thump Procedure, (REP 9-6).
• Check the Field Stop Brackets for scraping.
n. Install new Developer Material with a different batch number than the removed mate-
• Check for large particles in the Development Housing area. rial (REP 9-4).
• Check the BRD. Handcrank the developer in a Clockwise direction ONLY and o. Install new Toner, (if needed) with a different batch number than the removed mate-
check that the BRD rotates. rial (REP 9-0).
• Scraping may be due to Photoreceptor Alignment, perform the PR Module p. Install a new Photoreceptor (PL 9.1) and perform the Xerographic Setup (ADJ 9-3).
Alignment, (ADJ 9-10), and/or the Photoreceptor Tension Adjustment, (ADJ 9-
q. Enter dC606, select [White Dusting]. Press Continue
11).
r. Make 14 copies with the longest paper available. Press Stop.
• Vacuum the Developer Rolls.
s. If spots are present, go to PQ 9-613.
NOTE: The spots blade must be adjusted after a Cleaner replacement.
• Check/clean toner debris/deposits from the Cleaner housing right side

(Entrance Baffle). Check that the Spots Blade (brown) contact area is 0.5 mm
to 2 mm and adjust as required, (ADJ 9-16).
b. Perform STEP 4 at the end of this RAP.
4. End of Call Checks:
CAUTION
toreceptor to light for two (2) minutes maximum or severe xerographic problems may
result. If the belt module will be exposed to light longer than two minutes, remove the pho-
toreceptor from the belt module and place it immediately in the protective photoreceptor
bag, or place the bag over the photoreceptor with it on the belt module.
a. Power OFF the Machine and perform the following:
b. Open the machine and remove the Photoreceptor (REP 9-35).
c. Clean the Pretransfer Lamp and the Preclean Lamp.
d. Clean the Belt Hole Sensor with a soft towel.
CAUTION
Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth.
The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power
before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when
the power is switched on, and will ensure that the ESV Monitor measurements and the
DSS calibrations are performed with the components clean.
e. Clean the DSS, ESV and Patch Generator with a clean, soft, lint free cloth.
f. Vacuum the Photoreceptor Ground Brush.
g. Vacuum the Paper Trays and the paper path areas.
h. Vacuum the Photoreceptor Module area.
i. Vacuum the general area of the Machine which surrounds the Photoreceptor Mod-
ule.
j. Vacuum the top of the Developer Housing including the Seals.
k. Check that there is no accumulated developer material on the BRD roll.
l. If no exact cause of the Photoreceptor scratches are found, perform the following:

PQ 9-639 MICR Image Quality Analysis Procedure a. Place the document at the bottom of the Clearwave Gauge. Line up the right edge of
the document with the right edge of the Clearwave Gauge. Observe the left most
The purpose of this procedure is to ensure that all MICR print quality specifications are met.
transit symbol. The right edge of this transit symbol should fall between the dotted
lines in boxes 42 and 43 of the Clearwave Gauge (Figure 4).
Procedure b. If the right edge of the Transit Symbol does not fall between the dotted lines in boxes
Ensure that MICR MODE (Print darkness 4) is being used for MICR prints. 42 and 43, the entire MICR line is out of horizontal adjustment, (too far to the left or
right). If the MICR line is out of adjustment, and the rest of the form is in the correct
If available, load 24 lb. (90gsm) paper stock in the feeder. position, there is a problem in the software program. If all the printing on the docu-
ment is out of horizontal adjustment (not just the MICR line), there is probably a reg-
Examine the Clearwave Position and Dimension gauge (600T80025) (Figure 1), and the 8X istration problem. Several documents should be checked before taking action on
Comparator (600T80026) (Figure 2) for contamination, and clean the tools if necessary. registration problems.
6. Character size.
NOTE: If the customer is not available to print a sample job of a document with a MICR line, all
a. Use the 8X Comparator to check for character size specification (the position and
assessments cannot be made. If the customer is not available to print a job, use the MICR Test
Form for this procedure. width of the stroke). If the character is in specification, the comparator will be able to
be moved around so that the vertical and horizontal lines of the character fall outside
1. Ask the customer to send a sample job of a document (MICR line), which will be used to the small boxes in the grid. The illustration (Figure 5) shows the number "8" within
make the following print quality assessments. specification, while the small and large font characters are marginally acceptable. Be
2. When performing the following steps, make a note of all steps in which the assessment aware that the difference between the Small, Nominal, and the Large font sizes is
did not meet the specification. At the end of the procedure, perform the repair actions for subjective. That means that both the nominal and the large fonts would meet specifi-
the specification(s) that were not met. cation.
3. *** ***Physical Dimensions.*** *** b. Xerographic MICR characters will usually fall at the upper limits of the specification.
a. Refer to Figure 1 and assess the document for physical dimensions (length and This is because Xerographic MICR ink has a lower content of magnetite than litho-
graphic MICR ink and will put more ink on the print in order to maintain proper signal
width).
strength. For this reason, most MICR characters may appear to be large.
b. Place the document lengthwise in the Clearwave gauge. Align the right edge of the
document with the right edge of the gauge. Ensure that the length is at or between c. Use only the 8X comparator to check the character size.
the indicated areas of the gauge. d. Problems with character size, such as line width or spacing, may have several
c. Place the document (vertically) in the Clearwave gauge. Align the bottom of the doc- causes, including:
ument with the right edge of the gauge. Ensure that the width (or the perforation of • Xerographic Setup
the document is on or between the indicated areas on the gauge. • Motion Quality
Refer to Figure 1. • Using a non Xerox MICR font
4. Vertical alignment • Incorrect ROS power
a. Use the 8X Comparator or the Clearwave Gauge, to assess the vertical alignment of • Dry Ink
the MICR character. • CD/IG operating incorrectly
Place the document in the Clearwave Gauge. Ensure that the bottom of the MICR • Verify that the font and IOT performance is in specification (dC909).
characters are positioned within the dash lines of the Vertical Character Alignment
7. Using the 8X Comparator, assess the entire document, especially the Clearband
reference.
area for white spots (deletions) and black spots.
If using the 8X Comparator, place the 8X Comparator over the MICR line.
a. Scan the Clearband area of the document with a magnifying glass.
The vertical variation from one character to the next must be less than.015 inches up
b. If there are any spots, place the void (deletion) or ink spot under the Measured spec-
or down, (Figure 2).
ification squares. Ensure that the spots stay within the borders of the measured
On the DP180MX MICR printer, this type of variation can be caused by software, specification squares.
image motion, paper effects, fonts and paper feeding. However, it will seldom occur.
c. Ensure that the spots meet the specification in PQ 9-613, less than 0.10" in the
b. The vertical variation for the entire MICR line is evaluated with the Clearwave Gauge Clearband area.
Figure 1.
d. Ensure that the deletions meet the specification in PQ 9-615, in the Clearband area.
Line up the right edge of the document with the gauge. Ensure that the bottom of the
e. If the dry ink is not fixed, go to the 10-608, Dry Ink not fixed RAP.
document is at the bottom of the Clearwave Gauge.
8. Assess the Clear Band Area of the document.
Ensure that the bottom of the characters fall between the top and bottom lines of the
character boxes (Figure 3). a. Place the document in the Clearwave Gauge, aligning the bottom of the check with
the bottom of the gauge.
5. Transit Symbol.

b. Ensure that there is no magnetic printing of any kind other than the actual MICR 12. Refer to the Repair Actions at the end of this section, and perform the corrective action for
information in the Clear Band Area (this includes the second side of the print). the assessment that did not meet the specification.
9. Character to Character spacing 13. If all of the assessments met the specification indicated, go to the 0-4 Final Action RAP.
a. Using the Clearwave Gauge ensure that the distance from the right edge of one Repair Actions
MICR character to the right edge of the next is 0.125 inches +/ 0.010 inches. Each
character box on the bottom of the gauge is 0.125 inches wide, (Figure 6) 1. Physical Dimension
If it is possible to move the document so all characters fall within a character box, Inform the customer that the length and width of the paper supply must meet specifica-
then place the right edges of as many characters as possible on the right edges of tions.
their character boxes. 2. Vertical Alignment
Look at the entire MICR line and check for any characters that do not have their right Ensure that the prints meet all the print quality specifications in PQ 9-601.
edges touching the right edges of their character boxes. A character whose right
Ensure that the correct MICR font is being used.
edge does not touch the right edge of the character box is more or less than 0.125
inches from its next closest character. To find out how much more or less than 0.125 Ensure that the Top to Bottom Registration (ADJ 8-2) is in specification.
inches it is from the neighboring character, bring the suspected character into char- 3. Transit Symbol
acter box 15. (Figure 7) If the MICR line is out of Horizontal adjustment and the rest of the form is in alignment,
b. Line up the right edge of the character to its right (in box 14) with the right edge of there is an error in the software. If the whole document is out of horizontal alignment, per-
box 14. Look at the suspect character in box 15 and see if its right edge falls form the Side to Side Registration (ADJ 8-3).
between the two dotted lines on either edge of the character in box 15. 4. Character Size
If the right edge of the suspect character falls outside of the dotted lines, it is outside Go to the PQ 9-639 RAP.
of the +/ 0.010" leeway from 0.125” and is out of specification. It is also too close to, 5. Spots
or too far away from, the character on its right.
If the problem is white spots (deletions), go to the PQ 9-615 RAP. If the problem is black
c. The 8X Comparator may also be used to check the spacing between any two char- spots, go to the PQ 9-613 RAP. If the problem is image rubbing off, go to the10-608, Dry
acters. Look through the comparator and place the right edge of the character Ink not fixed RAP.
against the right edge of the vertical line marking 0.125 inches.
6. Clear Band Area
Determine if the right edge of the right character falls within the 0.010" (two of the
Advise the customer to change the format of the document so that this area will meet the
smallest divisions) from the vertical line marking 0.125”.
specification. Recommend the use of a 5/8 inch clearband area in the document design.
If the right edge falls less than two small division away from the 0.125” line, it is
Ensure that there is no printing on the second side of the print in the clearband area.
within specification.
7. Character to Character Spacing
d. Problems of character to character spacing, like vertical position, may have many
Verify the spacing on the MICR11 test pattern, run in @PQ1MX. If the problem is present
causes. If a spacing problem is observed, talk to the appropriate individual at the
account to verify that the job was programmed correctly, and that they have the cor- only on the customer application, change the application program. If not, go to the PQ 9-
rect MX E13B font. If the problem continues, gather as much information as possible 637 Slow Scan Magnification Checkout procedure.
and call for assistance. 8. Skew
10. Skew. Individual skewed characters are not possible on the Printer. If skew is present in the
amount field only, it is possible that it is being caused by an impact printer (the amount
a. To check for line skew, place the document in the Clearwave Gauge. Move the doc-
ument so that the tops of all the MICR characters touch the line form at the top of the field is added after the check has been printed). Line skew is possible but the entire line
MICR line boxes, (Figure 7). will be skewed not just the MICR line. What may appear to be skew can also be caused
by the way the documents are cut.
b. Once in place, hold the document firmly so it will not slip. The bottom of the docu-
ment should now bisect the vertical skew scales below boxes 6 and 46. The scales
are graduated in 0.5 degree divisions from 0 to 2.5 degrees (not marked). Write
down, to the nearest degree, where the check bisects the skew scales. Subtract the
smaller number from the larger. The remainder is the degree of line skew. Line skew
cannot exceed 1.5 degrees. In Figure 7, the bottom of the check bisects box 46 at
0.5 degrees and box 7 at 2 degrees. Subtracting 0.5 from 2 gives a total skew of 1.5
degrees of line skew.
11. If the call was for Signal Strength failed documents, but no defect was found in the previ-
ous steps, the fault may be signal strength. Use the Xerox MICR LPS Signal Strength
Tester Correlation Document to verify signal strength is within specification. Go to the PQ
9-640, Signal Strength Tester Correlation Procedure.

Vertical Character Alignment
Length Width
Figure 1 Clearwave Gauge

0.030 inch MAXIMUM 0.030 inch MAXIMUM 0.030 inch MAXIMUM
0.030 inch MAXIMUM 0.030 inch MAXIMUM
Figure 2 Individual Character Alignment

MICR Line too high
MICR Line centered
MICR Line too low
Figure 3 Vertical Alignment

Right edge of transit
symbols
Maximum Allowable Ideal Horizontal Minimum Allowable

Tolerance Alignment Tolerance
Acceptable MICR Exceeds minimum allowable Exceeds maximum

Alignment tolerance, too far to the right allowable tolerance,
too far to the left
Unacceptable MICR
Alignment
Figure 4 Transit Symbol

Nominal Font Size: average edge of all Small Font Size: average edge of all Large Font Size: average edge of al
lines falls between the boxes and does lines falls within the boxes lines falls on the edge of the boxes
not run through the boxes
Figure 5 Character Size

Character to Character Distance
Distance between Characters
Character Spacing
Tolerance Zone
Acceptable Spacing
Unacceptable spacing too tight
Unacceptable spacing too spread out
Figure 6 Character to Character Spacing

Figure 7 Line Skew

PQ 9-640 MICR Checkout Procedure PQ 9-641 MICR Signal Strength Tester Correlation
The purpose of this procedure is to determine if there are any Image Quality defects that might Procedure
affect MICR prints. The purpose of this procedure is to provide a method to compare signal strength from a print of
a MICR line made on the DP180MX and a Correlation document of known Signal Strength on
Procedure the customers Signal Strength Tester.
• Check the HFSI counters and replace the developer and photoreceptor if required. Procedure
• Run a dC951 Xerographic Setup. 1. Ensure that the calibration process has been completed successfully, using the vendors
Check the ROS Magnification. The magnification is within specification. signal strength calibration document.
Y N 2. Enter dC106. Select [Test Patterns and Print Quality]. Select [MICR]. Run 14 prints of
Perform the Magnification Setup Procedure (ADJ 6-1). the MICR Test pattern on 24 pound short grain stock. Select 2 prints at random.
3. Select the MICR line on the test pattern that is closest to the area that the customer is
Check the ROS Image squareness. The ROS Image Squareness is within specification.
experiencing the problem in. Run the MICR line through the customers Signal Strength
Y N
Tester and record the values for:
Perform the ROS Image Squareness Setup (ADJ 6-2).
a. Average Signal Strength Value for On Us Symbols in the MICR line.
Perform the following: b. Average Signal Strength Value for all characters and Symbols in the MICR line.
• Transfer Blade Timing Adjustment (ADJ 9-9). 4. Run the Xerox 4635MX LPS Signal Strength Tester Correlation Document through the
• The Fuser Roll Temperature Adjustment (ADJ 10-6). customers Signal Strength Tester and record the values for:
• The Pressure Roll (Contact Roll) Adjustment (ADJ 10-2). a. Average Signal Strength Value for On Us Symbols in the MICR line.
• If the problem continues, go to the PQ 9-637 Slow Scan Magnification RAP. b. Average Signal Strength Value for all characters and Symbols in the MICR line.
5. Compare the values recorded for the MICR line and the values recorded for the Correla-
tion Document. The Signal Strength values recorded for the MICR line should be within +/
- 20 of the values recorded for the MICR line of the Correlation document.
a. If the recorded values are within +/ 20, there is not a problem with the DP180MX
system. The customers signal strength tester is suspect. No MICR service action is
expected.
b. If the recorded values are greater than +/ 20, there is a signal strength problem in
the DP180MX system. Ensure that all HFSI listed in the HFSI TABLES and service
actions are performed. If the problem continues, call for assistance.

Figure 1 9-640 Signal Strength Correlation Document (4912)

Test Patterns Xerographics - An electronic test pattern with Images used for setup and evaluation of ROS
Exposure and Xerographics.
Introduction
This section of the Service Manual provides the information required for the correct evaluation Halftone - A uniformly composed electronic test pattern of a dot matrix variety used to evalu-
of the print PQ against the specifications. The PQ Specifications are categorized into 2 groups: ate defects, such as charge imbalance and Printer motion quality problems, as well as PQ
Quantitative Analysis defects.
• System Specifications
• Printer Specifications E Form - Provides edge to edge image quality evaluation.
All evaluations are based on 8.5 x 11 inch prints, unless otherwise stated.
Quadrille - A uniformly composed electronic test pattern consisting of one pixel wide black grid
lines that are one pixel wide and repeat every 127 pixels in the fast and slow scan directions.
The information is presented in the following manner:
Prints of this pattern have a 1 inch trail edge deletion.
• The PQ parameters are listed alphabetically.
MICR - Magnetic Ink Character Recognition. A uniformly composed test pattern containing the
• Interdependent procedures are identified as prerequisite procedures. specifications for MICR printing. The test pattern checks for MICR unique copy quality specifi-
• A procedure is provided that describes how to set up the machine to check the PQ cations.
parameter.
• An illustration of the test pattern that identifies the specific feature used for the check is Printer Resident Test Patterns
provided (if necessary).
The following test patterns are generated electronically by the Printer SLB/RDR PWB. The test
• The specification for the parameter is defined. Specifications for more than one module patterns are programmable in Printer dC606.
may be given, such as Registration which has a different system specification from the
Printer specification. Light Dusting - All white test pattern.
Where applicable two levels of a specification are listed. When only one specification is given,
it is for the UM and the Setup level. Dark Dusting - All black test pattern.
UM level - Corrective action should be taken to restore the module or system to the setup level Quadrilles - Solid pixel thickness that repeat every 128 pixels in the fast scan direction. The
if the UM level is not being achieved. Prints that are run on Every Service Call should be eval- pixel width and background are selectable in dC 606. For 240SPI, pixels repeat every 160 pix-
uated against the UM level specification, unless the primary cause of the call is an PQ prob- els in the fast scan direction and every 128 pixels in the slow scan direction.
lems.
300SPI and 240SPI Special Test Patterns, seven separate patterns used to test the 300SPI-to-
Setup level - This is the minimum level of acceptance for a given specification, if the primary 600SPI and 240SPI-to-600SPI Resolution Conversion feature on the C-SLB/RDR PWB. Pat-
reason for the service call was for this particular problem. Also, if during a service call, the PQ tern #7 prints a section of all 7 patterns on the same page.
evaluation detects a specification below UM level the Setup level for that specification must be
achieved before Call Closeout. 600SPI 2ON - 2OFF Test Pattern, Three slow scan bands on the inboard, center, and outboard
of the print. Each band consists of 2ON - 2OFF black bars, each 8 bytes long in the fast scan
NOTE: If an PQ parameter is not in specification, go to the PQ 9-601 System PQ Entry Level direction with 4 bits separation between adjacent bars. The pattern repeats every 34 bytes in
RAP. the fast scan direction and every 4 lines in the slow scan direction.
Test/Patterns Test Pattern Usage

Only use the approved test patterns listed in this specification for assessing the PQ of the
The purpose of this section is to provide an overview of the hardprint test patterns and the con-
machine.
troller resident test patterns, used to evaluate PQ performance and to perform PQ setups.
Refer to the PQ Specifications for detailed information on the procedures and specifications of
Controller Resident Test Patterns each PQ parameter.
The following test patterns are stored on the Controller disks. These test patterns are loaded
during software installation and can be printed in several of the dC programs. Using the System PQ Test Pattern 82E4161
See Figure 1.
Dimensional - An electronic test pattern with Images needed for setup and evaluation of the
fast and slow scan image placement of the Printer and Controller. Bar Codes are used to check
1. Magnification Lines
BCR operation.

No Product Name Assigned ?-83 Test Patterns
NOTE: Due to test pattern error, actual dimension is 199.8 mm. The 300mm scale The following table lists the number of allowable black spots for given spot sizes per any
(600T41501) should be used for the measurement. given print. Failure at any size category represents a machine failure. Refer to the Dark
Spot Size Reference Scale on 82E4161.
• Used for evaluating the system 100% magnification. The target 1b is composed of
parallel elements that are 200.0 mm apart.
Table 2 Allowable Black Spot Specification
2. Density Solid Areas
Spot size in Microns Setup Level UM Level
Used for evaluating the High Density Solid Area Development and Fusing.
125-200 15 Customer Complaint
3. Density and Background References, 8a -8d.
Used for evaluating the high density solid area development and background.
4. References 9a to 9d are used for evaluating the Xerographic controller resident test pat-
tern. (600 SPI Mode) Larger than 400 None Customer Complaint
9a. Printer halftone visual reference - to evaluate Halftone Uniformity. All sizes More Than 2 Per Sq. Inch Customer Complaint
9b. Printer 1 Black: 2 White reference - to evaluate Exposure, Charge, and Development.
9c. Printer 2 Black: 1 White reference - to evaluate Exposure, Charge, and Development. 9h. System Fine Line Visual reference - to evaluate System reproduction of 600 SPI Den-
sity Single Pixel Lines.
9d. Printer 1 Pixel Line Visual reference - to evaluate Printer reproduction of single pixel
fine lines.
References 9e to 9h are used to evaluate the following:
9e. Printer Fuse Fix Crease/Fold Test - to evaluate Fusing.
Fold one of the prints in half (long edges together) with the image towards the inside.
Apply medium pressure along the fold to create a crease. Unfold the print, and lightly rub
the crease area of the fold two times with cotton or a soft clean cloth. Rub the crease in
the direction of the fold. Ensure that the print meets the following Fuse Fix Specification.
Fuse Fix Specification:

Referring to the loss of toner at Crease/Fold Reference Scale (9e) on the 82E4161 Test
Pattern.
• If there is a loss of Toner along the crease area of the three solid area blocks that is
similar to or less than the visual reference on 82E4161 titled "Acceptable Loss of
Toner at Crease/Fold," then specification has been met.
• If there is a loss of Toner along the crease area that is equal to or greater than the
visual reference on 82E4161 titled "Acceptable Loss of Toner at Crease/Fold," then
specification has not been met. Go to 10-608, Dry Ink Not Fixed RAP.
9f. White Spot Category reference - to evaluate White spots.
The following table lists the number of allowable white spots for given spot sizes per any
given print. Failure at any size category represents a machine failure. Refer to the White
Spot Size Reference Scale on 82E4161.
Table 1 Allowable White Spot Specification

Spot size in Microns Setup Level UM Level
500 or greater None Customer Complaint
All sizes More Than 2 Per Sq. Inch Customer Complaint
9g. Black Spot Category reference - to evaluate Black spots.

Test Patterns ?-84 No Product Name Assigned
Figure 1 Test pattern 82E4161
Using the "Xerographic" Controller Resident Test Pattern 1. Halftones of Six Different Shades

Three sets of six, each 15 mm square, halftone targets of the following fractional area
coverage: See Figure 2.
a. 6/64 (or 6 pixels out of an 8 x 8 sized screen)
b. 10/64
c. 16/64
d. 32/64
e. 48/64
f. 58/64
These are used for evaluating the High frequency ROS imaging noise, charge uniformity
and exposure uniformity.
2. ESV & DSS Read Patches
a. 16/64 Halftone is used for 82E4161 comparison.
b. No image here, ESV and DSS read background in dC909.
c. All black image, ESV and DSS reads are related to Vddp and the black developed
patch.
d. 1 pixel black lines spaced every other scanline for the fast scan direction and 1 pixel
lines are spaced every other pixel in the slow scan direction.
e. 48/64 Halftone
3. High Solid Area Density Blocks
Used for charge balance high density area uniformity, and high density solid area devel-
opment specification check. The reference for Restore and UM is on the 82E4161 test
pattern.
4. Background Check Swatches
Exposure Set Up Array is used in manufacturing and the field to evaluate Exposure in
dC951 setups.
• Block 1: Slightly Visible
• Block 2: Visible
• Block 4: Clearly Visible
5. Sample Text Paragraphs
Avant Garde 10 point Roman and Tiffany 6 point Roman. Used for evaluating a text repro-
duction.

Figure 2 XERO11 (Controller resident Test Pattern)
6. AB/BA Pattern: See Figure 3.

Staggered two on/two off Motion Quality AB/BA Array. Used to identify beam A and beam
B spacing failures. See Figure 3 for an enlarged illustration and explanation.
7. 8 pixel, 2 pixel and 1 pixel Top-to-Bottom (Fast Scan) and Side-to-Side (Slow Scan) Lines
Used for evaluation of print line density and ROS power exposure, relative to photorecep-
tor charge voltage. The reference for "Restore" level is on the 82E4161 test pattern.

Figure 3 AB/BA Target
Using the "Dimensional" Controller Resident Test Pattern

1. Magnification: See Figure 4.
Slow scan distance from line A to line B should be 200.0 mm (+/- 0.5mm) using the aver-
age of five consecutive prints.
Fast scan distance from line C to line D should be 200.0 mm (+/- 0.4mm).
2. Lead Edge Arrow:
Used to indicate the lead edge of the page.
3. Registration and Skew Targets:
X1 is used for measuring top-to-bottom (fast scan) Printer registration.
X1 and X2 are used for measuring the Printer skew.
X1, X2, X3 and X5 are used for measuring the ROS skew.
X4 is not currently used for PQ specification checks.
4. Bar Codes:
00039 and 00128 are used to check the operation of the BCR Assembly.

Figure 4 DIME11 (Dimensional Controller Test Pattern)

Using the "Quadrille" dC106 Controller Resident Test Pattern
The Quadrille pattern is a repetitive test pattern with single pixel wide lines spaced every 127
pixels in the fast and slow scan directions. This pattern is useful for detecting any open image
data lines in the Controller to Printer Image Data cable. Refer to the next page for an expanded
use of the Quadrille pattern for any open image data line problems. See Figure 5.
Figure 5 Quadrille (Controller Test Pattern)

NOTE: The prints of the Quadrille pattern have a one inch trail edge deletion. Using the "Qua-
drille" Controller Resident Test Pattern for Image Data Line Problems.
Using the "Quadrille" Controller Resident Test Pattern for Image Data
Line Problems
The Image Data Signals from the Controller can be associated with specific lines on the dC106
Quadrille Test Pattern. On the diagram below, Image Data Bit 2 is shown as defective. Note the
effect on the corresponding lines on the prints. Refer to the Controller-Printer Image Data
Cable Chart to troubleshoot the corresponding line that is exhibiting the defect. Visually inspect
any bent or touching pins at the ends of the cable, the mating connectors on the ROS, and the
Backplanes. See Figure 6.

NOTE: An open Image Data Bit defect has three or four lines printing out when only one line
should print, or the line that should be printed is deleted. The pattern will repeat on the entire
print for the corresponding image data bit that is defective.
Figure 6 Magnified Quadrille Pattern
Using the "Halftone" Controller Resident Test Pattern A 25% area coverage halftone, with a spur shaped dot growth as shown in 16 pixel x 16
pixel section.
1. Lead Edge Arrow
This pattern is used for examining the Printer motion quality problems, halftone exposure,
Indicates the lead edge of the page
and development uniformity.
2. Halftone Bitmap Composition

Figure 7 HalfTone (Controller Test Pattern)
Using the "MICR" Controller Resident Test Pattern Refer to MICR Controller Test Pattern (Figure 8).

1. Lead Edge Image Disturbance • Used to check visual lead edge registration. Not to be used to check for skew. Use the
Used to determine if there is unacceptable lead edge image disturbance after the first existing skew check (ADJ 8-1). If Horizontal Registration is not correct, go to the PQ 9-
4.75mm from the lead edge of the document. 601 Printer Image Quality Entry RAP.
2. Trail Edge Image Disturbance • With the right edge of the MICR document positioned against the right edge of the clear-
wave gauge, the right edge of the left most transit symbol shall fall between the dotted
Used to determine if there is unacceptable trail edge image disturbance prior to 4.75mm
from the trail edge of the document. lines of boxes 42 and 43.
3. Motion Quality 14. Magnification
106 Dots Per Inch (DPI). Used to determine if there is any visual banding present. If
• Used as a quick visual assessment of magnification. Use the existing magnification pro-
banding is observed, go to the Motion Quality section of the PQ 9-601 Image Quality
cedure, ROS Magnification Setup (ADJ 6-1) to ensure magnification is in specifications.
Entry RAP. motion quality defects.
15. Slow Scan Magnification
5, 6 and 27, 28. Signal Strength balance of the MICR line, Character to Character spacing
and Vertical Alignment.
• Used as a visual assessment to determine if there are slow scan magnification problems.
Visually inspect the characters for size and spacing (may be cut on line 19 and inserted
Signal Strength
into the clearwave gauge). If Slow Scan Magnification problems are present, go to the
PQ 9-637 Slow Scan Magnification RAP.
• Used to check the signal strength of the ON-US characters in the MICR line using the
16. Font Name
customers signal strength tester.
Vertical Alignment
• Used to verify that the correct MX E13B/CMC7 font and rev is being used.
• Used to determine the proper vertical position in the MICR line. With the right edge of the 17, 18, 19, and 20. Cut lines
MICR document positioned against the right edge of the Clearwave gauge, and with the
bottom of the MICR document pushed against the bottom of the clearwave gauge, the • Used as a guide for cutting. All cuts should be made as close to the line as possible but
MICR characters shall fall between the top and bottom lines of the character boxes. always a little above the line.
Character to Character Alignment 22. Landscape cut line
• Used to verify proper character to character alignment of the MICR line. The distance • Used as a guide for cutting. This cut should be made on the line.
between the right edge of adjacent MICR characters shall be 0.125 +/- 0.010 inches. 23, 24, and 25. Solid area density
Check character to character spacing using the Clearwave gauge by positioning the right
edge of a given character against the right edge of box 14 and check that the right edge of • Used as a quick check to visually assess the solid area density.
the adjacent character in box 15 is within the dotted lines. • The reference for restore and UM is located on the 82E4161 test pattern.
7 & 8. Dicorotron Balance 26. Landscape MICR Line
• Used as a quick visual check of the Dicor balance. If the Dicorotron balance is incorrect, • Used to check a landscape MICR line to ensure the signal strength of the ON-US charac-
go to the Charge Dicorotron Balance Procedure (ADJ 9-6). ters in the MICR line using the customers signal strength tester.
9 & 10. Line pair balance
NOTE: This line is not correctly formatted.
• Used to determine if the line pair balance is correct. Both 3.5 line pairs should be 33. MICR Quality sign off
resolved. If both 3.5 line pairs are not resolved, go to the PQ 9-601 Printer Image Quality
Entry RAP. • Used to record the customers acceptance of MICR quality, the date and the meter read-
Stroke Width ings.
• The diameter of each individual dot should be Six thousandths. When using the 8X Com-
• The 3.5 X 3.5 Line pairs shall be equal in width and spacing. Using the 8X Comparator, parator the "dot" should touch each side of the 0.006" box.
the 3.5 line and the white space between the lines should fall within the Nominal Stroke
width Tolerance (0.013"). The maximum Stroke Width Tolerance is 0.015", and the Mini-
mum is 0.011".
11 & 12. Horizontal Registration

Figure 8 MICR (Controller Test Pattern)

Registration, Side-To-Side (Slow Scan): Printer
Specification
Prerequisite Procedure
• Printer Magnification
• ROS Image Squareness
• Printer Skew
Procedure
Enter Printer dC604. Select [Registration Adjustment], [Start] to make 10 prints of the
Dimensional test pattern. With the 150 mm scale, measure the distance (estimate within the
nearest 0.25 mm) from the tip of the arrowhead to the edge of the print. Use the eyeloupe if
needed. If the X3 arrowhead is off the page, choose a common reference line on the X3 target
arrow, and measure it to the print edge. Check the results against the following specifications.
PRINTER SIDE-TO-SIDE (slow scan) REGISTRATION SPECIFICATION
UM Level: Evaluate one print.
The arrowhead tip of the selected print must be within 0.65 mm of the print edge.
Setup level: Evaluate five non-consecutive prints. Calculate the average distance for all five
prints.
The average distance of the arrowhead tip must be within 0.3 mm of the print edge. No individ-
ual print arrowhead tip can be more than 0.65 mm from the print edge.

Registration, Side-To-Side (Slow Scan): Printer Spec- ?-96 No Product Name Assigned
Figure 1 Printer (slow scan) Registration

No Product Name Assigned ?-97 Registration, Side-To-Side (Slow Scan): Printer
System Magnification Procedure
Procedure
Check
1. TOP TO BOTTOM (Fast Scan) MAGNIFICATION:

a. Enter dC603, [Printer Options], [Test Patterns and PQ], [Dimensional], [Magnifi-
cation], and press the Continue button.
NOTE: Use the 300mm scale (600T41501) to measure the prints.
NOTE: Use A4 (8 1/2 x 11) or larger paper size in tray 1.
b. Measure the C - D (200mm +/- 0.4mm) distance on the prints. Use the 300mm scale
(600T41501) for this check.
2. SIDE-TO-SIDE (Slow Scan) MAGNIFICATION:
b. Measure the A - B (200 mm +/- 0.5 mm) distance on 5 consecutive prints. Using the
average of the 5 prints the distance A - B should be 200 mm +/- 0.5 mm using the
300mm scale (600T41501).
Setup Level
1. TOP-TO-BOTTOM (Fast Scan) MAGNIFICATION:
NOTE: Increasing the range value increases the C-D distance.
a. Adjust the C-D distance to 200mm using the up and down arrows.
2. SIDE-TO-SIDE (Slow Scan) MAGNIFICATION:
NOTE: Increasing the Range value increases the A-B distance.
a. Adjust the A-B distance to 200mm using the left and right arrows.

System Magnification Procedure ?-98 No Product Name Assigned

No Product Name Assigned ?-99 System Magnification Procedure
Printing Of High Density Solid Areas: Printer Specification Choose a print of average darkness, and compare the solid areas on the prints to the reference
blocks on 82E4161.
Procedure
Enter dC106 [Test Patterns and PQ][Xerographic]. Select quantity 10. Press the Continue but- UM High Density Spec: For a service call, in which a xerographic setup has not been per-
ton. Evaluate the prints. formed, the darkness level of the blocks on the print must be uniform, and be equal to or darker
than the block labeled STD/LT:UM on the right edge of 82E4161.
Specification
Setup High Density Spec: After xerographic setup, the three blocks must have a darkness level
that is equal to or darker than the block labeled STD:RESTORE on the right edge of 82E4161.
Figure 1 System Specification Check

Printing Of High Density Solid Areas: Printer Specifi- ?-100 No Product Name Assigned
Printing Of Single Pixel Fine Lines: Printer Specification Specification
Procedure The darkness level of the fast scan or slow scan orientation lines on the print should be uni-
Enter dC106 [Test Patterns and PQ][Xerographic]. Select quantity 10. Press the Continue but- form, and should be at least as dark as the 1 Pixel Line Visual Reference Scale on 82E4161.
ton. Evaluate the prints.
Figure 1 Pixel Lines Specification
Registration Top-to-bottom (Fast Scan): Printer

Specification

No Product Name Assigned ?-101 Printing Of Single Pixel Fine Lines: Printer Specifi-
• Printer Skew
Procedure
Enter Printer dC604. Select [Registration Adjustment], and [Start] to make 10 prints of the
Dimensional test pattern. With the 150 mm scale, measure the distance (estimate within the
nearest 0.25 mm) from the tip of the arrowhead to the edge of the print. Use the eyeloupe if
needed. If the X1 arrowhead is off the page, choose a common reference line on a X1 target
arrow, and measure it to the print edge. Check the results against the following specification.
Printer Top-To-Bottom (fast scan) Registration Specification
UM Level: Evaluate one print. The arrowhead tip of the print selected must be within 0.65 mm
of the print edge.
Setup level: Evaluate five non-consecutive prints. Calculate the average distance for all five
prints from ideal registration. The average distance of the X1 arrowhead tip must be within 0.3
mm of the print edge and no individual print arrowhead tip can be more than 0.65 mm from the
print edge.

Registration Top-to-bottom (Fast Scan): Printer ?-102 No Product Name Assigned
Figure 1 Printer (Fast Scan) Registration

No Product Name Assigned ?-103 Registration Top-to-bottom (Fast Scan): Printer
ROS Image Squareness: Printer Specification Align the corner with the number 4 line on targets X1 and X3.
Procedure Specification
Enter dC 106 (Test pattern and PQ Dimensional). Select quantity 10. Press, Continue.
Evaluate the prints. The edge of the test pattern must be aligned with the #4 line on X5 within +/- 0.5mm.
Align the corner with the number 4 line on targets X2.
Figure 1 ROS Squareness Evaluation

ROS Image Squareness: Printer Specification ?-104 No Product Name Assigned
Skew: Printer Specification
Procedure
Enter printer dC604. Select [Skew Check], [Start] to make 10 prints of the Dimensional test
pattern. The edge skew targets (X1) & (X2) are 200 mm apart, and are located along the end of
fast scan (top edge) of print (Figure 1). The targets have marks identified by the numbered
graduations. With the 150 mm scale, measure the distance (estimate within the nearest 0.25
mm) from the left target, X1, and the right target, X2, to the edge of the print. Calculate the dif-
ference between them. Use the eyeloupe if needed. Check the results against the following
specification.
Specification
UM Level: Evaluate 1 Print.
16 lb. (RX 60 GSM) to 32 lb. (RX 120 GSM) paper: Difference between left target, X1, and right
target, X2, is within 0.8 mm.
13 lb. (RX 49 GSM) or 110 lb. (RX 200 GSM) paper: Difference between left target, X1, and
right target, X2, is within 1.2 mm.
Setup Level: Evaluate five prints. Calculate the average difference for all five prints.
16 lb. (RX 60 GSM) to 32 lb. (RX 120 GSM) paper: The average difference between the left
target, X1 and right target, X2 is within 0.5 mm and no individual print target difference is more
than 0.8 mm.
13 lb. (RX 49 GSM) or 110 lb. (RX 200 GSM) paper: The average difference between the left
target, X1, and right target, X2, is within 0.8 mm. No individual print target difference is more
than 1.2 mm.
Calculations:
Distance (mm) of X1 arrow (mm) from the print edge minus the distance (mm) of X2 arrow from
the print edge equals the Printer skew.
NOTE: If the arrowhead is not visible on the print, use a reference line from the target to evalu-
ate the skew. Ensure that the same reference line is used for X1 and X2 dimensions.
UM Level: Evaluate one print.
X1 - X2 - mm skew
Setup Level: Calculate the skew for the five prints, add the total, and divide by five for the aver-
age skew.
[(X1 - X2) + (X1 - X2) + (X1 - X2) + (X1 - X2) + (X1 - X2)] / 5=Average skew

No Product Name Assigned ?-105 Skew: Printer Specification
NOTE: If X1 - X2 < 0.Clockwise Skew Problem. If X1 - X2 () 0.Counterclockwise Skew Prob-
lem
Figure 1 Printer Skew Evaluation

Skew: Printer Specification ?-106 No Product Name Assigned
Motion Quality Controller Resident Test Pattern (MMQT02)
Procedure
1. Registration Targets for Automated CQM Evaluation of Motion Quality
• Used for registering the prints with an automated image quality measurement fixture
by Xerox. Not used by the field service personnel.
2. High Solid Area Density Blocks
• Used for charge balance high density area uniformity, and high density solid area
development specification check. The reference for Restore and UM is on the
82E4161 test pattern.
3. 8 Pixel, 2 Pixel and 1 Pixel Top-to-Bottom (Fast Scan) and Side-to-Side (Slow Scan)
Lines
• Used for evaluation of print line density and ROS power exposure, relative to photo-
receptor charge voltage. The reference for "Restore" level is on the 82E4161 test
pattern.
4. Halftone 106 cycles per inch at 45 degrees - 25% fractional area coverage.
7. Diagonal lines at 45 degrees.
• This is similar to the 82E4161 test pattern diagonal lines.
10. Ziptone 300 line pairs per inch - 50% fractional area coverage.
• Lines run in the fast scan direction.
11. Ziptone 300 line pairs per inch - 50% fractional area coverage.
• Lines run in the slow scan direction.
12. AB/BA Pattern
• Staggered two on/two off Motion Quality AB/BA array. Used to identify beam A and
beam B spacing failures. See Figure 3 for an enlarged illustration and explanation.
13. Quadrille Target
• Single pixel lines spaced every 127 pixels in the fast scan direction. Used as a deter-
mination of open or shorted Controller to Printer video line wire pairs. See Figure 4
for an enlarged illustration and explanation.
14. Registration Targets for Automated CQM Evaluation of ROS Beam Distortion
• Used for registering the prints with an automated measurement fixture by Xerox. The
ROS targets are item #13. Not used by the field service personnel.
Figure 1
Figure 1 "Motion Quality" Controller Resident Test Pattern
Figure 2

No Product Name Assigned ?-107 Motion Quality Controller Resident Test Pattern
Figure 2 Targets 4, 5, 6, 8, 9, 10 and 11
Figure 3

Motion Quality Controller Resident Test Pattern ?-108 No Product Name Assigned
Figure 3 AB/BA Target 12

In Figure 4, the Image Data Signals from the Controller can be associated with specific lines on
the dC106 "Motion Quality" Test Pattern. Ignoring the xerographic thinning or other effects on
single pixel slow scan lines, the illustrations below show a good target and three failed targets.
Note the effect on the corresponding lines on the prints. Refer to the Controller-Printer Image
Data Cable Chart to troubleshoot the corresponding line that is exhibiting the defect. Visually
inspect any bent or touching pins at the ends of the cable, the mating connectors on the ROS,
and the Backplanes.

Figure 4 Image Data Line Problems - Target 13
NOTE: An open Image Data Bit defect has three or four lines printing out when only one line
should print, or the line that should be printed is deleted. The pattern will repeat for the corre-
sponding image data bit that is defective.

Background, Blotchy
Symptom
This defect has a "beehive like" appearance, with small blotches that resemble highly localized
areas of high background.
Probable Cause
Toner concentration is too high.
Development problems
Corrective Action
Ensure that the bias lines are connected to the Developer Housing.
Decrease the toner concentration by decreasing the MIN NVM location 135 (Patch Generator
exposure) by 3 units, and then run 250 prints.
NOTE: It may not be possible to make the blotches completely disappear by reducing toner
concentration. Do not over reduce toner concentration because it may cause solid area dele-
tions.

No Product Name Assigned ?-113 Background, Blotchy
Figure 1 Blotchy Background Defect

Background, Blotchy ?-114 No Product Name Assigned
Background, Halftone (Gray Page)
Symptom
The size of background "toner" deposits is considered to be smaller than the smallest spots
shown on 82E4161. Background is deposited uniformly on the print.
Probable Cause
Xerographic Problem. Possible problem with Charge, Photoreceptor or other Xerographic
components. However, Fault Codes should be displayed. Resolve all Fault Codes before using
this RAP.
Corrective Action
Perform ROS Reset procedure: Power Off / Power On the printer. If the defect is still present
continue to troubleshoot.
Examine the background areas with an eyeloupe.
• If the background is random, go to the Background, Xerographic subsection.

• If the background is in ordered arrays, the probable cause is that one beam is stuck on
the ROS.
• Try ROS Reset and troubleshoot the problem if it does not work.

No Product Name Assigned ?-115 Background, Halftone
Figure 1 Halftone Background

Background, Halftone ?-116 No Product Name Assigned
Background, Xerographic
Symptom
The size of background "toner" deposits is considered to be smaller than the smallest spots
shown on 82E4161. Background may be on the entire print or in localized areas, e.g., the lead
or trail edges only. Also, background can be uniformly or nonuniformly deposited on the print,
and some areas may have more toner and will be darker than other areas.
Probable Cause
Incorrect use of the IQ controls.
Xerographic problems such as high toner concentration.
Corrective Action
Examine the background areas with an eyeloupe.
If the background is random, go to the PQ 9-607/608 Uniform / Nonuniform High Background

RAP.
If the background is in ordered arrays, go to the Figure 1 subsection.

No Product Name Assigned ?-117 Background, Xerographic
Figure 1 Xerographic Background

Background, Xerographic ?-118 No Product Name Assigned
Background, Structured Probable Cause
Symptom ROS exposure problem
The background resembles plywood or woodgrain if viewed without using an eyeloupe. Back-
ground can be accompanied by fast scan fine lines, and can be on the entire print or in local-
Corrective Action
ized areas. Go to the PQ 9-607/608 Uniform High Background RAP.
Figure 1 Structured Background

No Product Name Assigned ?-119 Background, Structured
Dark band, Top-To-Bottom (Fast Scan) Direction, Every
Belt Revolution
Symptom
On every seventh print (or every third print for 11x17 inch or A3 paper) a dark band appears on
the print in the top-to-bottom (fast scan) direction. The band has the appearance of an area
with very high background.
Probable Cause
Toner buildup on the photoreceptor ground brush
Toner concentration is too high
Poor cleaning on the outboard end of the PR belt module
Corrective Action
Clean the photoreceptor ground brush.
Ensure that the cleaner is operating properly and that toner is not accumulating on the ground
brush.
Perform the following procedures:
Xerographic Setup Adjustment
Xerographic Fine Adjustment
Photoreceptor Seam Adjustment

Dark band, Top-To-Bottom (Fast Scan) Direction, Ev- ?-120 No Product Name Assigned
Figure 1 Dark Band (top to bottom) Fast Scan

No Product Name Assigned ?-121 Dark band, Top-To-Bottom (Fast Scan) Direction,
Dark Band, Side-To-Side (Slow Scan) Direction
Symptom
A dark line or band appears across the entire print in the side-to-side (slow scan) direction on
every print. The thickness can be one pixel wide (1/600 inch) or wider.
Probable Cause
Dirt on the ROS exiting window
Corrective Action
Enter Printer dC606. Select [Light Dusting], [Start]. Examine the prints.
If the defect is present, check the ROS exiting window for contamination.
If the problem is not resolved, go to the PQ 9-601 System IQ Entry Level RAP for further defect
analysis.
Dark Band, 22-30 mm. Wide, Side-To-Side (Slow Scan) Direction
Side-to-side (slow scan) dark band that is 22 mm to 30 mm wide is appearing 166 mm to 192
mm from the top edge of the prints. For an extended job, the first seven prints exhibit the prob-
lem. This problem usually is accompanied with Fault Code PQ 9-212 or PQ 9-215.
Probable Cause
The Patch enable signal is staying on and the PR is not being discharged in the patch area.
Suspect a bad Pixel Clock PWB.
Corrective Action
Go to the 6-701 in the Service Dialog.

Dark Band, Side-To-Side (Slow Scan) Direction ?-122 No Product Name Assigned
Figure 1 Dark Band (side to side) Slow Scan

No Product Name Assigned ?-123 Dark Band, Side-To-Side (Slow Scan) Direction
Figure 2 Dark Band 22-30mm wide Side to Side

Dark Band, Side-To-Side (Slow Scan) Direction ?-124 No Product Name Assigned
Band Deletion, Side-To-Side (Slow Scan) Direction
Symptom
On long sustained printing runs, the deletion shows in halftones and in fine lines (usually can
be seen on lines that are two pixels or less). This deletion may spread in the top-to-bottom (fast
scan) direction as the printing continues.
Probable Cause
By-products of the Dicorotron coronas are setting onto the PR. There is an inadequate air flow
for removing the by-products.
Corrective Action
Go to the PQ 9-615, Deletions RAP.
Deletion Band, 22-30 mm Wide, Side-To-Side (Slow Scan) Direction
Side-to-side (slow scan) deletion band that is 22 mm to 30 mm wide is appearing 166 mm to

192 mm from the top edge of the prints.
Probable Cause
1. The Patch Generator is staying on.
2. There is a bad Detack/Preclean Dicorotron.
Corrective Action
Go to the PQ 9-621 Patch Generator RAP. If the problem still exists, replace the Detack/Pre-
clean Dicorotron.
Partial Deletion Band, 22-30 mm Wide, Side-To-Side (Slow Scan) Direction
Side-to-side (slow scan) deletion band that is 22 mm to 30 mm wide is appearing 160 mm to

170 mm from the top edge of the prints.
Probable Cause
1. The Digital Patch Generator Enable Signal is missing.
Corrective Action
Go to the PQ 9-621 Patch Generator RAP.

No Product Name Assigned ?-125 Band Deletion, Side-To-Side (Slow Scan) Direction
Figure 1 Process Band Deletion on Halftone Print

Band Deletion, Side-To-Side (Slow Scan) Direction ?-126 No Product Name Assigned
Figure 2 Deletion Band (slow scan) Side to Side

No Product Name Assigned ?-127 Band Deletion, Side-To-Side (Slow Scan) Direction
Figure 3 Partial Deletion Band (slow scan) Side to Side

Band Deletion, Side-To-Side (Slow Scan) Direction ?-128 No Product Name Assigned
Blotch Toner
Symptom
Toner blotch appears on the print. Toner blotches are deposits of toner placed on the print "out-
side of development," e.g., toner that has accumulated in the Cleaner Assembly (cleaner drop-
pings).
A typical size of a toner blotch is 5 mm to 10 mm. The central area of the blotch will have a con-
centration of toner surrounded by toner spots. A typical toner spot is less than 0.5 mm and is
circular in shape.
Probable Cause
• Excess toner is being dropped from the Cleaner Assembly.
• Defect on the Photoreceptor.
Corrective Action
• Go to the PQ 9-617, Cleaner RAP.

No Product Name Assigned ?-129 Blotch Toner
Figure 1 Toner Blotch Defect

Blotch Toner ?-130 No Product Name Assigned
Fine, Dark Lines, Side-To-Side (Slow Scan) Direction
Across Print, Greater Frequency At Top And Bottom (Fast
Scan Direction) On Print
Sysptom
Fine lines are running in the side-to-side (slow scan) direction with a higher frequency toward
the top and bottom on the prints. Increasing the print darkness will increase the amount of
lines on the prints.
NOTE: Problem might initially appear as lines at the top or the bottom of the print, or along an
edge. Problem may become more severe, with lines on the whole page or fast scan direction
bands.
Probable Cause
SLB/RDR PWB malfunction, ESS malfunction.
Corrective Action
To be Developed.

No Product Name Assigned ?-131 Fine, Dark Lines, Side-To-Side (Slow Scan) Direc-
Figure 1 Fine Lines (greater frequency at the top)

Fine, Dark Lines, Side-To-Side (Slow Scan) Direction ?-132 No Product Name Assigned
Figure 2 Dark fine Lines (every seventh print)

No Product Name Assigned ?-133 Fine, Dark Lines, Side-To-Side (Slow Scan) Direc-
Figure 3 Digital Image Offset Defect

Fine, Dark Lines, Side-To-Side (Slow Scan) Direction ?-134 No Product Name Assigned
SLB/RDR Failure Defect
Symptom
There is fast scan image displacement of approximately 185 mm (area on the print usually dis-
placed from the bottom to the top of the print). There are lightened areas on the prints occur-
ring in bands of varying widths. The lightened areas begin where the image is repeated and
shifted. As the failure progresses, part of the print may be completely blackened.
Probable Cause
Failed SLB/RDR PWB
Corrective Action
Reseat the SLB/RDR PWB. Run the prints and see if the defect still is present. If it is still
present, replace the SLB/RDR PWB.

No Product Name Assigned ?-135 SLB/RDR Failure Defect
Figure 1 SLB/RDR DEFECT

SLB/RDR Failure Defect ?-136 No Product Name Assigned
4. Repairs and Adjustments
1. Printer Electrical REP 4-21 Cleaner Drive Support .................................................................................... 4-66
REP 1-0 Autotransformer (T101) (50 HZ) ....................................................................... 4-7 REP 4-22 Decurler Drive Assembly ................................................................................ 4-67
REP 1-1 Line Interface Module Front Components ........................................................ 4-8 REP 4-23 Decurler Drive Belt.......................................................................................... 4-68
REP 1-2 Line Interface Module (50 HZ).......................................................................... 4-9 REP 4-24 Decurler Intermediate Drive Belt..................................................................... 4-69
REP 1-3 Line Interface Module (60 HZ).......................................................................... 4-11 REP 4-25 Handcranking the Main Drive Motor ............................................................... 4-70
REP 1-4 HVAC Output Module ....................................................................................... 4-13 REP 4-26 Intermediate Drive Belt ................................................................................... 4-71
REP 1-5 AC Remote PWBs (TYPICAL).......................................................................... 4-14 REP 4-27 Main Drive Motor (MOT401) ........................................................................... 4-72
REP 1-6 ADA PWBs (Typical) ........................................................................................ 4-14 REP 4-28 MIM and PHM Drive Pulleys........................................................................... 4-74
REP 1-7 CORE PWBs (MIN, PHN, FSN) ....................................................................... 4-15 REP 4-29 MIM Drive Belt ................................................................................................ 4-75
REP 1-8 DIO PWBs (Typical) ......................................................................................... 4-15 REP 4-30 PHM Drive Belt, Intermediate Drive Assembly ............................................... 4-76
REP 1-9 HVAC PWB ...................................................................................................... 4-16 REP 4-31 Photoreceptor Drive Assembly ....................................................................... 4-80
REP 1-10 HVDC PWB .................................................................................................... 4-17 REP 4-32 Photoreceptor Drive Belt................................................................................. 4-81
REP 1-11 MIB PWB ........................................................................................................ 4-19 REP 4-33 Prefuser Drive Assembly ................................................................................ 4-82
REP 1-12 SLB/RDR PWB AND ROS LVPS PWB .......................................................... 4-19 REP 4-34 Prefuser Drive Belt.......................................................................................... 4-83
REP 1-13 EDN PWB....................................................................................................... 4-21 REP 4-35 Top Transport Drive Assembly ....................................................................... 4-86
REP 1-14 Printer Card Cage Assembly .......................................................................... 4-24 REP 4-36 Tray 1 and 2 Feeder Drives ............................................................................ 4-88
REP 1-16 Low Voltage Power Supply............................................................................. 4-29 REP 4-38 Vertical Transport Clutch Assembly (CL851).................................................. 4-89
REP 1-17 Low Voltage Power Supply PWBs.................................................................. 4-31 REP 4-39 Developer Drive Assembly ............................................................................. 4-91
REP 1-18 Low Voltage Power Supply Cooling Fans ...................................................... 4-33 REP 4-40 Fuser-Developer Drive Belt ............................................................................ 4-93
REP 1-19 Low Voltage Power Supply Relays (K103/K104) ........................................... 4-36 REP 4-41 Fuser-Developer Drive Motor (MOT402) ........................................................ 4-94
REP 1-21 C-Pixel PWB................................................................................................... 4-38 REP 4-42 Fuser-Developer Intermediate Drive Belt ....................................................... 4-97
REP 4-43 Fuser Drive Assembly..................................................................................... 4-100
2. Printer UI REP 4-44 Jackshaft Assembly ........................................................................................ 4-101
REP 2-1 CP IOP PWB .................................................................................................... 4-41 REP 4-45 Fuser-Developer Drive Motor Run and Start Capacitors (C403/C404)(60 HZ) 4-103
REP 2-2 Control Panel PWB........................................................................................... 4-41 REP 4-46 Main Drive Motor Run and Start Capacitors (C401/402) (60HZ).................... 4-106
REP 2-3 Floppy Disk Drive Assembly ............................................................................. 4-42 REP 4-47 Fuser-Developer Drive Dirt Shields ................................................................ 4-109
REP 2-4 UIM Core PWB ................................................................................................. 4-43 REP 4-48 Bi-Pulley.......................................................................................................... 4-111
REP 2-5 Video Engine PWB ........................................................................................... 4-44 REP 4-49 Stacker Front Cover........................................................................................ 4-112
REP 2-6 Local/Remote Power Switch (S102)................................................................. 4-44 REP 4-50 Stacker Top Cover.......................................................................................... 4-113
REP 2-7 UI Front Cover Assembly ................................................................................. 4-45 REP 4-51 Stacker Rear Top Cover ................................................................................. 4-116
REP 2-8 UI Touch Screen Assembly .............................................................................. 4-46 REP 4-52 Inverter Top Cover.......................................................................................... 4-118
REP 2-9 UI Video Display Assembly .............................................................................. 4-47 REP 4-53 Stacker Rear Top Cover ................................................................................. 4-118
REP 2-10 UI AC EMI Filter (FL105) ................................................................................ 4-48 REP 4-54 Inverter Left Side Cover.................................................................................. 4-119
REP 2-11 UI DC EMI Filter (FL106)................................................................................ 4-49
REP 2-12 Rigid Disk Drive/SMSD Assembly .................................................................. 4-49 6. ROS
REP 2-13 UI Keyboard Buttons ...................................................................................... 4-54 REP 6-1 ROS Assembly ................................................................................................. 4-121
REP 2-14 UI Brightness/Contrast Controls ..................................................................... 4-55 REP 6-2 VLD/Collimator Assembly ................................................................................. 4-123
REP 2-15 UI Swivel Wear Ring....................................................................................... 4-56 REP 6-3 Polygon Motor (MOT601) ................................................................................. 4-124
REP 2-16 UI Tilt Bar........................................................................................................ 4-57 REP 6-4 EOS and SOS PWBs........................................................................................ 4-125
REP 2-17 UI Tilt Cap....................................................................................................... 4-57 REP 6-5 ROS Control Module (RCM) PWB.................................................................... 4-127
REP 2-18 UI Tilt Shoe..................................................................................................... 4-58 REP 6-6 ROS Profile EPROM......................................................................................... 4-131
4. Covers and Drives 7. Paper Trays 1 and 2

REP 4-0 Printer Right Top Cover.................................................................................... 4-59 REP 7-0 Feed Head Assembly ....................................................................................... 4-135
REP 4-1 Printer Side Covers and Rear Covers .............................................................. 4-60 REP 7-1 Tube Shaft ........................................................................................................ 4-137
REP 4-2 Printer Left Top Cover ...................................................................................... 4-61 REP 7-2 Retard Brake, Retard Roll, and Entry Guide..................................................... 4-138
REP 4-3 Electrical Module Top Cover ............................................................................ 4-62 REP 7-3 Feed Belt .......................................................................................................... 4-139
REP 4-20 Cleaner Drive Belt .......................................................................................... 4-63 REP 7-4 Feed Belt Latch Arm ......................................................................................... 4-140
Revision 11/00 Repairs and Adjustments

REP 7-5 Feed Belt Pulley ............................................................................................... 4-140 REP 8-21 Feeder Motor Drive Belt.................................................................................. 4-191
REP 7-6 Feed Belt Idler .................................................................................................. 4-141 REP 8-22 Feeder Main Drive Belt ................................................................................... 4-192
REP 7-7 Feed Belt Spool ................................................................................................ 4-142 REP 8-24 Feeder Assembly............................................................................................ 4-193
REP 7-8 Feed Clutch Pulley ........................................................................................... 4-142 REP 8-40 Lower Preregistration Transport ..................................................................... 4-195
REP 7-9 Feed Clutch Belt ............................................................................................... 4-143 REP 8-41 Registration Baffle Assembly.......................................................................... 4-198
REP 7-10 Feed Clutch (CL811/821) ............................................................................... 4-145 REP 8-43 Lower Preregistration Transport Corrugator Rolls .......................................... 4-199
REP 7-11 Takeaway Idler Roll ........................................................................................ 4-146 REP 8-45 Lower Preregistration Transport Flexible Drive Shaft ..................................... 4-199
REP 7-12 Takeaway Drive Belt....................................................................................... 4-147 REP 8-46 Registration Assembly .................................................................................... 4-200
REP 7-13 Takeaway Roll ................................................................................................ 4-148 REP 8-47 Corrugator Roll Drive Shafts And Belt ............................................................ 4-201
REP 7-14 Length Guide .................................................................................................. 4-150 REP 8-50 Intermediate Horizontal Transport .................................................................. 4-202
REP 7-15 Elevator Up Limit Switch (S714/724) .............................................................. 4-151 REP 8-55 Horizontal Transport (IFS) .............................................................................. 4-205
REP 7-16 Elevator Belt ................................................................................................... 4-151 REP 8-56 Horizontal Transport (FS) ............................................................................... 4-208
REP 7-17 Elevator Drive Motor (MOT711/721) .............................................................. 4-153 REP 8-59 Horizontal Transport Pivot Baffle (IFS) ........................................................... 4-210
REP 7-18 Elevator MOTOR Capacitor (C711/721)......................................................... 4-154 REP 8-60 Horizontal Transport Pivot Baffle (FS) ............................................................ 4-211
REP 7-19 Lock Arm and Lock Actuator .......................................................................... 4-155 REP 8-65 Lower Turn Transport (IFS/FS)....................................................................... 4-213
REP 7-20 Stack Relief Solenoid (SOL811/821) .............................................................. 4-155 REP 8-66 Lower Turn Transport Baffle/pivot Shaft/springs (IFS/FS).............................. 4-215
REP 7-21 Stack Height Sensor (Q711/721).................................................................... 4-156 REP 8-67 Lower Turn Transport Upper Drive Shaft........................................................ 4-216
REP 7-22 Tray 1 and 2 Front Covers.............................................................................. 4-156 REP 8-68 Lower Turn Transport Lower Drive Shaft........................................................ 4-217
REP 7-23 Lead Screws (Front), Bearings, and the Lift Nuts........................................... 4-157 REP 8-69 Lower Turn Transport Sensor Assembly ........................................................ 4-217
REP 7-24 Lead Screws (Rear), Bearings, and the Lift Nuts ........................................... 4-160 REP 8-75 Vertical Transport (IFS/FS)............................................................................. 4-218
REP 7-25 Elevator Assembly.......................................................................................... 4-162 REP 8-76 Vertical Transport Upper Baffle/Pivot Shaft/Spring (IFS/FS) .......................... 4-221
REP 7-26 Paper Plate..................................................................................................... 4-165 REP 8-77 Vertical Transport Lower Baffle/Pivot Shaft (IFS/FS) ..................................... 4-223
REP 7-27 Tray Capacity PWB ........................................................................................ 4-166 REP 8-78 Vertical Transport Lower Baffle Release Assembly Components .................. 4-225
REP 7-28 Elevator Drive Belt .......................................................................................... 4-166 REP 8-79 Vertical Transport Sensor Assembly .............................................................. 4-227
REP 8-80 Vertical Transport Drive Belt/drive Shafts....................................................... 4-227
7. High Capacity Trays
REP 7-34 HCT Elevator Assembly ................................................................................. 4-169 9. Xerographics
REP 7-35 HCT Elevator Drive Belt ................................................................................. 4-170 REP 9-0 Toner Bottle ...................................................................................................... 4-229
REP 7-36 HCT Elevator Drive Motor (MOT731) ............................................................. 4-171 REP 9-1 Toner Thumper Solenoid (SOL901) ................................................................. 4-230
REP 7-37 HCT Lead Screws .......................................................................................... 4-172 REP 9-2 Toner Dispenser Assembly............................................................................... 4-230
REP 7-38 HCT Switch Assembly .................................................................................... 4-173 REP 9-3 Toner Dispenser Motor (MOT902).................................................................... 4-231
REP 7-39 HCT Paper Plate ............................................................................................ 4-174 REP 9-4 Developer Material............................................................................................ 4-232
REP 7-40 HCT Slides ..................................................................................................... 4-174 REP 9-5 Developer Assembly......................................................................................... 4-234
REP 7-41 HCT Front Cover ............................................................................................ 4-175 REP 9-6 Developer Dump And Thump ........................................................................... 4-236
REP 7-42 Tray Capacity PWB ........................................................................................ 4-175 REP 9-7 Front Bearing Clamp......................................................................................... 4-236
REP 9-8 BRD Roll (w/Tag P-118 and Tag P-300) .......................................................... 4-237
8. Paper Feeding REP 9-9 Developer Roll 1 or 2 ........................................................................................ 4-239
REP 8-0 Vertical Transport Assembly............................................................................. 4-177 REP 9-10 Developer Roll 3 ............................................................................................. 4-240
REP 8-1 Vertical Transport Drive Belt............................................................................. 4-178 REP 9-11 Trimmer Bar.................................................................................................... 4-242
REP 8-2 Turn Baffle ........................................................................................................ 4-179 REP 9-12 Paddle Wheel ................................................................................................. 4-242
REP 8-3 Registration Transport Assembly ..................................................................... 4-180 REP 9-13 Mixing Auger................................................................................................... 4-244
REP 8-4 Cross Rolls Assembly....................................................................................... 4-182 REP 9-14 Low Toner Sensor (Q903) .............................................................................. 4-245
REP 8-5 Pretransfer Baffle.............................................................................................. 4-183 REP 9-15 Waste Bottle Full Sensor (Q906) .................................................................... 4-245
REP 8-6 NIP Release Solenoid (SOL851) ...................................................................... 4-184 REP 9-16 Waste Compactor Shield ................................................................................ 4-246
REP 8-7 NIP Release Solenoid Assembly and Idler Bracket.......................................... 4-185 REP 9-17 Upper Waste Toner Duct ................................................................................ 4-247
8. IFS, FS Lower Transports REP 9-18 Waste Compactor Drive Belt .......................................................................... 4-249
REP 8-15 Blower Motor (MOT832)/O-Ring Pulley .......................................................... 4-187 REP 9-19 Waste Compactor Motor Bracket.................................................................... 4-250
REP 8-16 Blower Assembly ............................................................................................ 4-188 REP 9-20 Waste Compactor Auger ................................................................................ 4-251
REP 9-21 Waste Compactor Motor (MOT903) ............................................................... 4-252
REP 8-17 O-Ring Drive Belt............................................................................................ 4-189
REP 8-18 Feeder Clutch ................................................................................................. 4-189 REP 9-22 Lower Waste Toner Duct ................................................................................ 4-253
REP 9-23 Cleaner Brush................................................................................................. 4-253
REP 8-20 Feeder Main Drive Motor (MOT831) .............................................................. 4-190
REP 9-24 Cleaner Manifold............................................................................................. 4-254
Repairs and Adjustments 11/00 Revision

REP 9-25 Cleaner Augers or Blade ................................................................................ 4-257 REP 10-12 Prefuser Transport Assembly ....................................................................... 4-347
REP 9-26 Cleaner Module .............................................................................................. 4-259 REP 10-13 Exit Transport Assembly............................................................................... 4-348
REP 9-27 Cleaner Drive Gears ....................................................................................... 4-265 REP 10-14 Decurler Assembly........................................................................................ 4-349
REP 9-28 Toner Filter Bag.............................................................................................. 4-267 REP 10-15 Decurler Belts ............................................................................................... 4-351
REP 9-29 Toner Filter Assembly..................................................................................... 4-268 REP 10-16 Flexible Coupling .......................................................................................... 4-352
REP 9-30 Toner Filter Blower Motor (MOT905).............................................................. 4-269 REP 10-17 Duplex Inverter Assembly............................................................................. 4-353
REP 9-31 Toner Filter Blower ......................................................................................... 4-271 REP 10-18 Inverter Gear Box Drive Belt and Inverter Reversing Roll Drive Belt............ 4-355
REP 9-32 Waste Bottle ................................................................................................... 4-273 REP 10-19 Inverter Gear Box Assembly......................................................................... 4-357
REP 9-33 Flicker Bar ...................................................................................................... 4-273
REP 9-34 Xerographic Drawer........................................................................................ 4-274 11A. IFS, FS Upper Transports
REP 9-35 Photoreceptor Belt .......................................................................................... 4-275 REP 11-1 Inverter Transport ........................................................................................... 4-359
REP 9-36 Patch Generator ............................................................................................. 4-278 REP 11-2 Inverter Gate Solenoid (SOL1108) ................................................................. 4-362
REP 9-37 ESV ................................................................................................................ 4-279 REP 11-3 Inverter Drive Motor (MOT1111)..................................................................... 4-363
REP 9-38 DSS ................................................................................................................ 4-281 REP 11-4 Inverter Latch Assembly ................................................................................. 4-364
REP 9-39 Dicorotron and Shield ..................................................................................... 4-282 REP 11-5 Inverter Top and Bottom Hinges..................................................................... 4-365
REP 9-40 Dicorotron Connectors W- P287..................................................................... 4-284 REP 11-6 Inverter Pivoting Assembly ............................................................................. 4-366
REP 9-41 OZAC Duct ..................................................................................................... 4-285 REP 11-7 Inverter Passive Gate ..................................................................................... 4-367
REP 9-42 Ozone Filter Assembly ................................................................................... 4-289 REP 11-8 Inverter Bottom Drive Shaft ............................................................................ 4-369
REP 9-43 Ozone Blower (MOT904)................................................................................ 4-290 REP 11-9 Inverter Top and Middle Shafts....................................................................... 4-370
REP 9-44 Cavity Cooling Fan (MOT105)........................................................................ 4-291 REP 11-10 Stacker Main Drive Motor (MOT1110).......................................................... 4-373
REP 9-45 PR Edge Guides or Tension Roll.................................................................... 4-291 REP 11-11 Post Inverter Transport ................................................................................. 4-374
REP 9-46 PR Module...................................................................................................... 4-292 REP 11-12 Post Inverter Transport Gear Bracket/Main Drive Belt/Lower Shaft ............. 4-378
REP 9-47 Xerographic Drawer Slides ............................................................................. 4-294 REP 11-13 Post Inverter Upper Drive Shaft/Sample Tray Drive Shaft............................ 4-382
REP 9-48 Transfer Blade ................................................................................................ 4-295 REP 11-14 Inverter Drive Belt/Short Shaft ...................................................................... 4-382
REP 9-49 Transfer Dicorotron......................................................................................... 4-296 REP 11-15 Sample Tray Gate Solenoid (SOL1110)/Actuator Arm Assembly ................ 4-383
REP 9-50 Transfer Assist Device.................................................................................... 4-299 REP 11-16 Sample Tray Gate/Sample Tray Gate Actuator ............................................ 4-384
REP 9-51 Transfer Solenoids 1-4 (SOL903/904/905/906).............................................. 4-302 REP 11-20 Stacker Preregistration Transport................................................................. 4-385
REP 9-52 Xerographic Drawer Latch Cable ................................................................... 4-305 REP 11-21 Stacker Preregistration Transport Drive Pulley Assembly ............................ 4-388
REP 9-53 Discharge Lamps PWB (PS902) .................................................................... 4-307 REP 11-22 Prestacker Drive Roll Shaft........................................................................... 4-389
REP 9-54 Hydraulic Lift Assembly .................................................................................. 4-308 REP 11-23 Stacker Preregistration Transport Flexible Drive Shaft................................. 4-389
REP 9-55 Photoreceptor Spot Cleaning ......................................................................... 4-310 REP 11-25 Post Inverter Sensor (Q1156)....................................................................... 4-390
REP 9-56 Transfer Blade Sensor (Q907) ....................................................................... 4-313 REP 11-26 Registration Assembly .................................................................................. 4-391
REP 9-57 Spots Blade .................................................................................................... 4-315 REP 11-27 Stacker Preregistration Transport Corrugator Rolls...................................... 4-392
REP 9-58 Spots Blade Guide.......................................................................................... 4-318 REP 11-28 Corrugator Roll Drive Shafts and Belts......................................................... 4-393
REP 9-59 PR Mini-rug..................................................................................................... 4-319 REP 11-29 Stacker Lead in Baffle/Trail Edge Assist Idler Roll/Disk Sheet Sensor (Q1106)
REP 9-60 POP Sensor (Q904) Cleaning ........................................................................ 4-320 (Purge and Bypass Transport) ........................................................................................ 4-394
REP 9-61 Cleaner Detoning Rolls or Bearing Plates ...................................................... 4-321 REP 11-30 Chute Baffle (IFS/FS) ................................................................................... 4-395
REP 9-62 Transfer Solenoids (SOL903/SOL904/SOL905/SOL906) .............................. 4-323 REP 11-31 Bypass Transport Top Baffle ........................................................................ 4-396
REP 11-32 Purge Transport Top Baffle .......................................................................... 4-399
10. Print Transports and Fuser REP 11-33 Bypass Transport/Purge Transport............................................................... 4-400
REP 10-0 Camshaft ........................................................................................................ 4-329 REP 11-34 BYPASS LEAD IN BAFFLE.......................................................................... 4-402
REP 10-1 Fuser Roll and Heat Rod (HTR1001) ............................................................. 4-330 REP 11-35 Bypass/Purge Transport Gate ...................................................................... 4-403
REP 10-2 Metering Assembly ......................................................................................... 4-333 REP 11-36 Disk Gate ...................................................................................................... 4-404
REP 10-3 Metering Assembly Cleaning.......................................................................... 4-334 REP 11-37 Bypass/Purge Transport Gate Solenoid (SOL1104)..................................... 4-405
REP 10-4 Metering Roll .................................................................................................. 4-335 REP 11-38 Trail Edge Assist Drive Shaft (Bypass or Purge Transport).......................... 4-406
REP 10-5 Metering Blade ............................................................................................... 4-336 REP 11-39 Trail Edge Assist Belts (Bypass or Purge Transport) ................................... 4-407
REP 10-6 Air Knife Manifold Cleaning ............................................................................ 4-338 REP 11-40 Telescopic Drive Shaft.................................................................................. 4-408
REP 10-7 Fuser Wick and Fuser Agent Filter ................................................................. 4-339 REP 11-41 Middle Drive Shaft (Bypass or Purge Transport) .......................................... 4-409
REP 10-8 Fuser Sensor (Q1010) CLEANING ................................................................ 4-340 REP 11-42 Right Drive Shaft (Bypass or Purge Transport) ............................................ 4-410
REP 10-9 Left and Right Drawer Slide............................................................................ 4-341 REP 11-43 Left Drive Shaft (Bypass or Purge Transport)............................................... 4-411
REP 10-10 MIM Compressor (MOT1002)....................................................................... 4-343 REP 11-44 Purge Output Drive Shaft.............................................................................. 4-412
REP 10-11 Top Transport Assembly .............................................................................. 4-345 REP 11-45 Purge Lead in Baffle ..................................................................................... 4-414

REP 11-46 Inverter Transport Motor Fan........................................................................ 4-415 7A. Paper Trays 1 2
REP 11-47 Blower Assembly .......................................................................................... 4-415 ADJ 7-0 Feed Clutch Belt and Takeaway Drive Belt....................................................... 4-475
ADJ 7-1 Takeaway Shaft Endplay................................................................................... 4-476
11B. Print Stacking ADJ 7-2 Down/Low Paper Sensor (Q714/724) ............................................................... 4-478
REP 11-58 Pallet Lift Frame ........................................................................................... 4-417
ADJ 7-3 Elevator Up Limit Switch (S714/724)................................................................. 4-479
REP 11-59 Stacker Elevator Motor (MOT1106).............................................................. 4-418
ADJ 7-4 Length Guide Position ....................................................................................... 4-481
REP 11-60 Stacker Elevator Drive Belt........................................................................... 4-419
ADJ 7-5 Length Guide Tension ....................................................................................... 4-482
REP 11-61 Lead Screw................................................................................................... 4-420
ADJ 7-6 Auto Latch ......................................................................................................... 4-483
REP 11-62 Stacker Overtravel Down Switch (S1141)/Stacker Elevator Down Sensor (Q1125)
ADJ 7-7 Front Cover Frame ............................................................................................ 4-484
4-421
ADJ 7-8 Front Cover Support.......................................................................................... 4-485
REP 11-63 Stacker Overtravel up Switch (S1140) ......................................................... 4-421
ADJ 7-9 Paper Feed Setup ............................................................................................. 4-487
REP 11-64 Container Size Sensors (Q1126, Q1127, Q1128) ........................................ 4-422
ADJ 7-10 Lock Assembly ................................................................................................ 4-502
REP 11-68 Stack Height Sensor (Q1122)....................................................................... 4-423
ADJ 7-11 Elevator Drive Belt........................................................................................... 4-503
REP 11-70 Back Guide ................................................................................................... 4-424
REP 11-71 Front Guide................................................................................................... 4-426 7B. High Capacity Trays
REP 11-72 Right Guide................................................................................................... 4-427 ADJ 7-30 Elevator Drive Belt........................................................................................... 4-505
REP 11-73 Disk Stepper Motor ....................................................................................... 4-430 ADJ 7-31 Stack Height/stack Height Sensor (Q735)....................................................... 4-505
REP 11-74 Right Guide Tamper Motor (MOT1113)........................................................ 4-431 ADJ 7-32 Latch Assembly ............................................................................................... 4-509
REP 11-75 Right Guide Drive Belt .................................................................................. 4-433 ADJ 7-33 Low Paper Sensor (Q738)............................................................................... 4-511
REP 11-85 Disk Module Weldment (IFS)........................................................................ 4-434 ADJ 7-34 Front Cover ..................................................................................................... 4-512
REP 11-86 Disk Module Weldment (FS)......................................................................... 4-436 ADJ 7-35 HIGH CAPACITY TRAY SWITCH ASSEMBLY .............................................. 4-514
2. Printer UI 8. Paper Feeding
ADJ 2-0 Printer UI Tilt ..................................................................................................... 4-439 ADJ 8-0 Registration Transport Upper Baffles ................................................................ 4-523
ADJ 8-1 Pretransfer Baffle .............................................................................................. 4-524
4. Covers and Drives ADJ 8-2 Top-to-Bottom Registration ............................................................................... 4-526
ADJ 4-0 Printer Right Top Cover .................................................................................... 4-441
ADJ 8-3 Side-to-Side Registration .................................................................................. 4-527
ADJ 4-1 Printer Right Door Latch.................................................................................... 4-442
ADJ 8-4 Registration Transport....................................................................................... 4-528
ADJ 4-2 Printer Rear Covers .......................................................................................... 4-445
ADJ 8-5 Paper Width Timing........................................................................................... 4-532
ADJ 4-3 Interlock Actuator .............................................................................................. 4-446
ADJ 8-6 NIP Release Solenoid (SOL851)....................................................................... 4-532
ADJ 4-4 Stacker Top Cover Counterbalances ................................................................ 4-447
ADJ 4-5 Stacker Doors Interlock Switches (S1138) & (S1163) ...................................... 4-447 8. IFS, FS Lower Transports
ADJ 4-10 Cleaner Drive Belt ........................................................................................... 4-449 ADJ 8-9 Lower Preregistration Transport Registration Baffle Assembly......................... 4-535
ADJ 4-11 Decurler Drive Belt .......................................................................................... 4-450 ADJ 8-10 Lower Preregistration Transport Pivot Baffle................................................... 4-537
ADJ 4-12 Decurler Intermediate Drive Belt ..................................................................... 4-452 ADJ 8-11 Lower Preregistration Transport Corrugator Rolls........................................... 4-541
ADJ 4-13 Decurler Intermediate Drive Pulley ................................................................. 4-453 ADJ 8-12 Lower Preregistration Transport Pivot Baffle Bumper ..................................... 4-542
ADJ 4-14 Intermediate Drive Assembly .......................................................................... 4-454 ADJ 8-13 Tray 3 Oversize NIP Release Solenoid (SOL852) .......................................... 4-543
ADJ 4-15 Intermediate Drive Belt.................................................................................... 4-456 ADJ 8-14 IFS/FS Horizontal Transport Pivot Baffle ........................................................ 4-545
ADJ 4-16 MIM Drive Belt................................................................................................. 4-457 ADJ 8-15 Intermediate Horizontal Transport Pivot Baffle................................................ 4-548
ADJ 4-17 PHM Drive Belt................................................................................................ 4-458
ADJ 4-18 PHM/MIM Drive Pulleys .................................................................................. 4-459 9. Xerographics
ADJ 4-19 Prefuser Drive Belt .......................................................................................... 4-460 ADJ 9-0 Toner Thumper.................................................................................................. 4-549
ADJ 4-20 Tray 1 and 2 Feeder Drives ............................................................................ 4-461 ADJ 9-1 Developer Zone Roll.......................................................................................... 4-550
ADJ 4-21 Fuser-Developer Drive Belt ............................................................................. 4-464 ADJ 9-2 NVM Read/Write ............................................................................................... 4-552
ADJ 4-22 Fuser-Developer Drive Pulley ......................................................................... 4-465 ADJ 9-3 Xerographic Setup............................................................................................. 4-553
ADJ 4-23 Fuser-developer Intermediate Drive................................................................ 4-468 ADJ 9-5 Patch Generator Timing .................................................................................... 4-556
ADJ 9-6 Charge Dicorotron Balance ............................................................................... 4-557
6. ROS ADJ 9-7 Charge Dicorotron Height.................................................................................. 4-559
ADJ 6-1 ROS Magnification Setup.................................................................................. 4-469 ADJ 9-8 Photoreceptor Seam Timing.............................................................................. 4-561
ADJ 6-2 ROS Image Squareness ................................................................................... 4-471 ADJ 9-9 Transfer Blade Timing ....................................................................................... 4-561
ADJ 6-3 ROS Low Correction Factor .............................................................................. 4-474 ADJ 9-10 PR Module Positioning Tool Instructions, TAG P-318..................................... 4-565
ADJ 6-4 ROS Power Calibration ..................................................................................... 4-474 ADJ 9-11 Photoreceptor Tension .................................................................................... 4-568
ADJ 9-12 ESV Height...................................................................................................... 4-569

ADJ 9-13 DSS Saturation ............................................................................................... 4-571 ADJ 11-33 Back Guide Squareness................................................................................ 4-654
ADJ 9-14 DSS Timing ..................................................................................................... 4-572 ADJ 11-34 Right Guide Moving Wall Squareness........................................................... 4-656
ADJ 9-15 NVM Node Initialization Recovery (60HZ, 50HZ)............................................ 4-573 ADJ 11-35 Stacker Module Paper Path Adjustment ...................................................... 4-657
ADJ 9-16 Spots Blade Contact ....................................................................................... 4-574
ADJ 9-17 PR Mini-rug Height .......................................................................................... 4-576 13. Transition Module
ADJ 9-18 Preclean Dicorotron Height ............................................................................. 4-577 ADJ 13-1 Bypass Transport Stacker Output Gate: ......................................................... 4-661
ADJ 9-19 Developer Drive Assembly Alignment ............................................................. 4-580 ADJ 13-2 Bypass Transport Purge Baffle: ...................................................................... 4-663
ADJ 13-3 Bypass Transport Exit Baffle: .......................................................................... 4-664
10. Print Transports and Fuser ADJ 13-4 Transition Module Main Drive Motor: .............................................................. 4-665
ADJ 10-0 Fuser Roll Thermostat (THS1002) .................................................................. 4-581 ADJ 13-5 Transition Module Height: ............................................................................... 4-666
ADJ 10-1 Metering Roll Overheat Thermostat (THS1001) ............................................. 4-582 ADJ 13-6 Transition Module Inboard/Outboard Position:................................................ 4-668
ADJ 10-2 Pressure Roll (Contact ARC) .......................................................................... 4-583
ADJ 10-4 Air Knife Manifold and Fuser Roll.................................................................... 4-585
ADJ 10-5 Air Knife Pressure, Pressure Regulator, Compressor (MOT1002) ................. 4-587
ADJ 10-6 Fuser Roll Temperature .................................................................................. 4-588
ADJ 10-7 Metering Roll Temperature ............................................................................. 4-589
ADJ 10-8 Decurler Exit Baffle ......................................................................................... 4-591
ADJ 10-9 Duplex Gate and Solenoid (SOL1002)............................................................ 4-592
ADJ 10-10 Decurler Sensor (Q1011) .............................................................................. 4-593
ADJ 10-11 Left and Right Drawer Slide .......................................................................... 4-593
ADJ 10-12 Fuser Latch Assembly................................................................................... 4-597
ADJ 10-13 Donor Roll Contact ARC ............................................................................... 4-599
ADJ 10-14 Duplex Timing ............................................................................................... 4-600
ADJ 10-15 Stripper Finger Baffle Clearance................................................................... 4-600
ADJ 10-16 Relief Valve ................................................................................................... 4-603
ADJ 10-17 Thermistor Cal............................................................................................... 4-605
ADJ 10-18 Prefuser Transport ........................................................................................ 4-606
11. IFS, FS Upper Transports

ADJ 11-1 Inverter Gate Solenoid (SOL1108).................................................................. 4-611
ADJ 11-2 Gate Flat Spring .............................................................................................. 4-613
ADJ 11-3 Inverter Output Baffle ...................................................................................... 4-614
ADJ 11-4 Inverter Top And Bottom Hinges ..................................................................... 4-616
ADJ 11-6 Stacker Preregistration Transport Corrugator Rolls ........................................ 4-618
ADJ 11-7 Inverter Pivoting Assembly Alignment............................................................. 4-620
ADJ 11-8 Sample Tray Gate Solenoid (SOL1110) ......................................................... 4-621
ADJ 11-9 A3 NIP Release Solenoid (SOL1111) ............................................................. 4-622
ADJ 11-10 Bypass Transport/Purge Transport ............................................................... 4-624
ADJ 11-11 Bypass/Purge Transport Gate Solenoid (SOL1104) ..................................... 4-628
ADJ 11-12 Post Inverter Latch ........................................................................................ 4-629
ADJ 11-13 Sample Tray and Purge Tray Corrugator Rolls ............................................. 4-632
ADJ 11-14 Inverter Transport Motor Belt Tension .......................................................... 4-636
11. Print Stacking

ADJ 11-25 Disk Home Position ....................................................................................... 4-639
ADJ 11-26 Disk Gate Height ........................................................................................... 4-641
ADJ 11-27 Stack Height .................................................................................................. 4-643
ADJ 11-28 Right Guide ................................................................................................... 4-644
ADJ 11-29 Back Guide.................................................................................................... 4-645
ADJ 11-30 Stacker Overtravel Up Switch (S1140) ......................................................... 4-646
ADJ 11-31 Pallet Lift Frame Parallelism ......................................................................... 4-648
ADJ 11-32 Container Size Sensors (Q1126, Q1127, Q1128)......................................... 4-649

REP 1-0 Autotransformer (T101) (50 HZ)
Parts List on PL 1.1
Removal
1. REMOVE ALL SYSTEM POWER.
2. REMOVE THE LINE INTERFACE MODULE (REP 1-2).
3. REMOVE THE AUTOTRANSFORMER (Figure 1).
1
2 DISCONNECT
REMOVE THE
SCREWS (2)
3
REMOVE THE
AUTOTRANSFORMER
ASSEMBLY
Figure 1 Removing the Autotransformer Assembly

No Product Name Assigned ?-7 REP 1-0
REP 1-1 Line Interface Module Front Components Parts List on PL 1.1
Removal
2. ACCESS THE LINE INTERFACE MODULE COMPONENTS (Figure 1).
2
REMOVE THE EM
TOP COVER 3
REMOVE THE EM
INNER PANEL
4
REMOVE THE EM
FRONT TRIM
STRIP
5
TURN THE QUARTER-
TURN FASTENER
6
SLIDE THE
DRAWER OUT OF
THE MACHINE
1
OPEN THE EM
FRONT DOOR
Figure 1 Accessing the Line Interface Module Components

REP 1-1 ?-8 No Product Name Assigned
REP 1-2 Line Interface Module (50 HZ)
Removal 1
DISCONNECT
2. REMOVE THE EM REAR COVER.
3. REMOVE THE TONER FILTER ASSEMBLY (REP 9-29).
4. REMOVE THE POWER CORD ISOLATION BOX (Figure 1).
2
3 DISCONNECT THE
REMOVE THE WIRES (5)
ISOLATION BOX
3
DISCONNECT
1 Figure 2 Preparing to Remove the Line Interface Module

LOOSEN THE
STRAING RELIEF 6. REMOVE THE EM INNER PANEL.
SCREWS 7. REMOVE THE EM TRIM STRIP.
2
REMOVE THE 8. REMOVE THE LINE INTERFACE MODULE (Figure 3).
SCREWS (2)
Figure 1 Removing the Isolation Box
5. PREPARE TO REMOVE THE LINE INTERFACE MODULE (Figure 2).

3
MOVE THE PWB PANEL AWAY
FROM THE PRINTER
4
DISCONNECT THE AIR LINES (2)
5
SLIDE THE MODULE OUTWARDS
2
REMOVE THE PWB
PANEL SCREWS (4)
1
REMOVE THE
MOUNTING SCREW
Figure 3 Removing the Line Interface Module (50 HZ)
Replacement REP 1-3 Line Interface Module (60 HZ)

1. ENSURE THAT THE LEADS FROM THE LINE INTERFACE MODULE ARE CON- Parts List on PL 1.1
NECTED TO THE FOLLOWING TERMINALS OF TB101:
a. the brown lead (marked L1) to terminal 1
Removal
b. the black lead (marked L2) to terminal 2
2. LIFT AND SLIDE THE ELCI ASSEMBLY OFF OF THE SUPPORT BRACKETS OF THE
c. the black lead (marked L3) to terminal 3
PRINTER REAR COVER.
d. the blue lead to terminal 4
3. REMOVE THE EM REAR COVER.
e. the green lead to the ground terminal
4. REMOVE THE TONER FILTER ASSEMBLY (REP 9-29).

5. REMOVE THE POWER CORD ISOLATION BOX (Figure 1).
1
3 DISCONNECT
SLIDE OUT THE
ISOLATION BOX
2
DISCONNECT
THE WIRES (6)
3
DISCONNECT
THE GROUND
WIRE(S)
1
LOOSEN THE
SCREWS (4)
2
REMOVE THE
SCREWS (2)
Figure 2 Preparing to Remove the Line Interface Module

Figure 1 Removing the Isolation Box
7. REMOVE THE EM INNER PANEL.
6. PREPARE TO REMOVE THE LINE INTERFACE MODULE (Figure 2). 8. REMOVE THE EM TRIM STRIP.
9. REMOVE THE LINE INTERFACE MODULE (Figure 3).

2
DISONNECT THE AIR LINES (2)
3
SLIDE THE MODULE OUTWARDS
1
REMOVE THE MOUNTINT SCREW
Figure 3 Removing the Line Interface Module (60 HZ)
Replacement REP 1-4 HVAC Output Module

1. ENSURE THAT THE LEADS FROM THE LINE INTERFACE MODULE ARE ATTACHED Parts List on PL 1.7
TO THE FOLLOWING TERMINALS OF TB101:
a. the black lead to terminal 1
Removal
1. SWITCH OFF THE PRINTER POWER.
b. the red lead to terminal 2
2. REMOVE THE PRINTER RIGHT REAR COVER.
c. the white lead to terminal 3
3. REMOVE THE PRINTER LEFT REAR COVER.
d. the black lead to terminal 4
4. OPEN THE XEROGRAPHIC CARD CAGE.
e. the red lead to terminal 5
a. Disconnect P203, P200, and P238 to allow the card cage to swing out fully.
f. the white lead to terminal 6
5. OPEN THE TONER FILTER HOUSING.
g. the green lead to the ground terminal
6. REMOVE THE HVAC OUTPUT MODULE (Figure 1).

3
REMOVE THE HVAC
OUTPUT MODULE
2
DISCONNECT
1
REMOVE THE
MOUNTING
SCREWS (5)
Figure 1 Removing the HVAC Output Module

REP 1-5 AC Remote PWBs (TYPICAL) REP 1-6 ADA PWBs (Typical)
Parts List on PL 1.4 and PL 1.7 Parts List on PL 1.8
Removal Removal
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
2. DISCONNECT THE PWB CONNECTORS. 2. DISCONNECT THE PWB CONNECTORS.
NOTE: AC Remote PWBs are interchangeable. NOTE: ADA #1 and ADA #2 are interchangeable PWBs.
3. REMOVE THE AC REMOTE PWB. 3. REMOVE THE ADA PWB.

REP 1-5, REP 1-6 ?-14 No Product Name Assigned
REP 1-7 CORE PWBs (MIN, PHN, FSN) REP 1-8 DIO PWBs (Typical)
Parts List on PL 1.4 and PL 1.8 Parts List on PL 1.4
Removal Removal
1. SWITCH OFF THE PRINTER POWER. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
2. DISCONNECT THE CORE PWB CONNECTORS. 2. DISCONNECT THE DIO PWB CONNECTORS.
3. REMOVE THE CORE PWB. 3. REMOVE THE DIO PWB.
Replacement Replacement
CAUTION CAUTION
Ensure that the Printer Power Cords are disconnected. Reconnecting the PWB connectors Ensure that the Printer Power Cords are disconnected. Reconnecting the PWB connectors
with power applied can damage the CORE PWB. with power applied can damage the DIO PWB.
1. REINSTALL THE CORE PWB. RECONNECT THE PWB CONNECTORS. 1. REINSTALL THE DIO PWB. RECONNECT THE PWB CONNECTORS.
2. POSITION THE J2 TERMINATION JUMPER AS FOLLOWS.
NOTE: The IFS, MIN, and PHN DIO PWBs are interchangeable.
WITH A 2 MODULE SYSTEM:
2. RECONNECT ALL PRINTER POWER CORDS. SWITCH ON THE PRINTER POWER.
a. MIN CORE PWB - Connect the J2 Termination Jumper across pin 1 and pin 2
(NORM).
b. PHN CORE PWB - Connect the J2 Termination Jumper across pin 1 and pin 2
(NORM)
c. FSN CORE PWB - Connect the J2 Termination Jumper across pin 2 and pin 3
(TEST)
WITH A 3 OR 4 MODULE SYSTEM:
a. STEPS a AND b FROM THE FIRST BULLET LIST
b. FSN CORE PWB #1 - Connect the J2 Termination Jumper across pin 1 and pin 2
(NORMAL)
c. FSN CORE PWB #2 - Connect the J2 Termination Jumper across pin 2 and pin 3
(TEST)
WITH A BTM CORE PWB:
a. STEPS a AND b FROM THE SECOND BULLET LIST
b. FSN CORE PWB #2 - Connect the J2 Termination Jumper across pin 1 and pin 2
(NORMAL)
c. BTM CORE PWB - Connect the J2 Termination Jumper across pin 2 and pin 3
(TEST)
3. RESTORE THE PRINTER POWER.

No Product Name Assigned ?-15 REP 1-7, REP 1-8
REP 1-9 HVAC PWB
Parts List on PL 1.7 P231
Removal
2. REMOVE PRINTER RIGHT REAR COVER.
3. MOVE THE TONER FILTER HOUSING AWAY TO ACCESS THE XEROGRAPHIC
CARD CAGE.
4. OPEN THE XEROGRAPHIC CARD CAGE (Figure 1).
RIBBON CABLE
P294
2 1
MOVE LOOSEN
Figure 2 Disconnecting the HVAC PWB Connectors
6. REMOVE THE HVAC PWB (Figure 3).
Figure 1 Opening the Xerographic Card Cage
5. DISCONNECT THE HVAC PWB CONNECTORS (Figure 2).

REP 1-10 HVDC PWB
Removal
3. MOVE THE TONER FILTER HOUSING AWAY TO ACCESS THE XEROGRAPHIC
CARD CAGE.
4. OPEN THE XEROGRAPHIC CARD CAGE (Figure 1).
5. DISCONNECT THE HVDC PWB CONNECTORS (Figure 1).
HVDC
HVAC
P291
Figure 3 Removing the HVAC PWB from the Xerographic Card Cage
Replacement
1. WHEN INSTALLING A NEW PWB, REPLACE THE OLD CALIBRATION CARD IN THE P293
MACHINE LOG BOOK WITH A CARD FROM THE NEW PWB.
NOTE: When installing the HVAC PWB, ensure that the PWB is in the upper and lower guides RIBBON CABLE
in the Card Cage. P200
NOTE: Ensure that at least one calibration card is attached to the HVAC PWB. P203
2. INSTALL THE HVAC PWB.

3. RECONNECT THE HVAC PWB CONNECTORS. Figure 1 Disconnecting the HVAC and the HVDC PWB Connectors
4. CLOSE THE XEROGRAPHIC CARD CAGE.
5. RECONNECT THE POWER. WARNING
6. SWITCH ON THE PRINTER. Do not touch any components or soldered connections on the high voltage area of the
HVDC PWB. It is possible to receive an electrical shock if the area shown is touched
7. WHEN INSTALLING A NEW HVAC PWB, PERFORM THE FOLLOWING:
(Figure 2).
a. Enter dC314.
6. REMOVE THE HVDC PWB (Figure 3).
b. Using the values from the new calibration card, reset the NVM values in dC314.

WARNING
DO NOT TOUCH THE
PWB IN THIS AREA
HVDC
HVAC
Figure 2 Shock Area on the HVDC PWB Figure 3 Removing the HVAC or HVDC PWB
Replacement
1. WHEN INSTALLING A NEW PWB, REPLACE THE OLD CALIBRATION CARD IN THE
MACHINE LOG BOOK WITH A CARD FROM THE NEW HVDC PWB.
NOTE: When installing the HVDC PWB, ensure that the PWB is in the upper and lower guides
in the Card Cage.
NOTE: Ensure that at least one calibration card remains attached to the HVDC PWB.
2. INSTALL THE HVDC PWB.
NOTE: Ensure that the HVDC PWB is fully seated in the HVDC Cable connector.
3. RECONNECT THE HVDC PWB CONNECTORS.

5. RECONNECT THE PRINTER POWER.
6. SWITCH ON THE PRINTER.
7. WHEN INSTALLING A NEW HVDC PWB, PERFORM THE FOLLOWING:
a. Enter dC314.
b. Using the values from the new calibration card, reset the NVM values in dC314.

REP 1-11 MIB PWB REP 1-12 SLB/RDR PWB AND ROS LVPS PWB
Parts List on PL 1.8 Parts List on PL 1.11
Removal Removal
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Compo-
2. REMOVE THE PRINTER LEFT SIDE COVER. nents and Functions section.
3. OPEN THE ELECTRICAL MODULE PWB PANEL.
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
4. DISCONNECT ALL MIB PWB CONNECTORS.
2. ACCESS THE PRINTER CARD CAGE (
5. REMOVE THE MIB PWB.
a. Open the EM Front Door.
Replacement b. Remove the EM Top Cover.
CAUTION
3. OPEN THE CARD CAGE (Figure 1).
Ensure that the Printer Power Cords are disconnected. Reconnecting the PWB connectors
with power applied can damage the MIB PWB.
3
1. INSTALL THE MIB PWB. RECONNECT THE PWB CONNECTORS.
REMOVE THE PWB 1
2. RESTORE ALL PRINTER POWER. ACCESS PANEL DISCONNECT THE
CARD CAGE CON-
NECTOR (P284)
2
REMOVE THE
SCREWS (3)
Figure 1 Opening the Card Cage
4. REMOVE THE APPROPRIATE PWB (Figure 2).

ROS LVPS PWB
PIXEL PWB
SLB/RDR PWB
EDN PWB
Figure 2 Removing the Appropriate PWB

REP 1-13 EDN PWB
Parts List on PL 1.11 3
REMOVE THE PWB
Removal ACCESS PANEL
1
DISCONNECT THE
To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Compo- CARD CAGE CON-
nents and Functions section. NECTOR (P284)
1. Perform the following steps to backup the machine setup parameters. Do not use the
floppy disk that was stored in the system and previously used to store the save setup
parameters.
a. Enter service mode.
b. Enter dC101.
2
c. Perform clean disk drive. REMOVE THE
d. Format a new floppy disk via the floppy disk format routine. SCREWS (3)
e. Save the machine setup parameters via the save setup parameters routine to the
floppy disk that was formatted in step d.
NOTE: Record the meter A value:
f. Select the dC file cabinet icon.

g. Enter dC103.
h. Record the Meter A value for future reference in this procedure.
i. Select the SCP file cabinet icon.
NOTE: During the time the message (Please Wait NVM Upload is in progress. Do not power
off system until completed) is being displayed an image of the current NVM values resi-
dent on the EDN PWB is being stored on the IOT Disk Drive. These values are needed so
they can be downloaded from the IOT Printer Disk Drive to the replacement EDN PWB
later in the procedure.
j. Select the service mode exit icon and wait until the message (Please Wait NVM
Upload is in Progress. Do not Power off System until Completed) clears.
5. REMOVE THE EDN PWB (Figure 2).
CAUTION
Electrostatic Discharge precautions must be followed for these procedures.
3. ACCESS THE PRINTER CARD CAGE.
b. Remove the EM Top Cover.

ROS LVPS PWB
PIXEL PWB
SLB/RDR PWB
EDN PWB
Figure 2 Removing the EDN PWB
Replacement
1. CLEAR NVM VALUES ON REPLACEMENT EDN PWB.
a. Using a set of Easy Hook jumpers and a Meter Probe, short the Negative (-) battery
terminal to the solder pad on the right side of the surface-mount resistor R46 for at
least 25 seconds. Refer to Figure 3.
Figure 3 Clearing NVM on EDN PWB
2. INSTALL THE EDN PWB.

NOTE: Watch UIM display while Printer boots. Ensure a 03-361 fault is briefly (2 sec) dis- c. Select [03-362 NVM Reset]. This NVM Reset Button only appears in dC131 when
played on UIM before being automatically reset. This verifies NVM was properly cleared on an 03-362 fault is declared. The system will go into slumber mode and return to the
replacement EDN PWB. If fault display was missed, select SCP [Initial] screen and press diagnostic main menu screen. Wait until all shadows reappear on the diagnostic
[Update Data]. Review [Last 50] shutdowns screen to ensure the 03-361 fault is logged. main menu folders before going to next step.
8. UPDATE THE PROCESSOR SERIAL NUMBER.
a. Enter dC105.
CAUTION
b. Select [Processor Serial Number].
If service mode is entered to isolate and correct the Systems Communications Failure do not
exit diagnostics until steps 5b and 5c are performed. Exiting diagnostics without initializing the c. Enter the correct Processor Serial Number.
EDN PWB via dC323 will result in permanent loss of Billing Meter Values, Machine Setup 9. RESTORE THE [SAVE SETUP PARAMETERS].
Data, HFSI, dC107 counter values and other backup data stored on the IOT Disk Drive. a. Select the dC File Cabinet icon.
4. PERFORM THE EDN INSTALLATION PROCEDURE AS SHOWN IN THE MESSAGE b. Enter dC101.
ON THE UI.
c. If the Save Setup Parameters were successfully stored on a floppy disk at beginning
Message: Not ready- Systems Communications Failure. of procedure continue with step 9d if not go to step 9i.
Next step: Repair the Systems Communications Failure and continue with step 5. d. Insert the floppy disk, made at beginning of procedure with the saved setup parame-
Message: Not ready - 03-362 EDN NVM NOT Initialized. ters into the Floppy Disk Drive.
Next step: Continue with step 7. e. Select [Restore Setups-Source Floppy].
Message: Not ready - No message or any other messages posted. f. Select [Confirm].
Next Step: Continue with step 5. g. Press Continue. The system will automatically go into slumber mode and exit
Message: Ready - No message or any other messages posted. dC101 displaying a Not Ready Please Wait System communications Failure as part
5. INITIALIZE THE REPLACEMENT EDN PWB. of the Restore Setups process. If an 03-471 is displayed, press R (reset) button on
the IOT Printer control panel. After approximately two minutes all shadows reappear
CAUTION
on the diagnostic main menu file folders and stackers are initialized. Remove the
Do not exit service mode until steps 5b and 5c are performed. Exiting diagnostics without floppy disk. If Restore Setups-Source Floppy is successful continue with step 10. If
initializing the EDN PWB via dC323 will result in permanent loss of Billing Meter Values, unsuccessful go to Step 9h.
Machine Setup Data, HFSI, dC107 Counter Values and other backup data stored on the
h. Get the backup floppy disk stored in the machine containing the Save Setup Param-
IOT Disk Drive.
eters from a previous call and continue with step 9i.
a. Enter the service mode at the IOT Printer UI.
i. Insert the backup floppy disk stored in the machine with the saved Setup Parame-
b. Enter dC323. ters into the Floppy Disk Drive.
c. Select Initialize. The system will automatically go into slumber mode and exit dC323 j. Select [Restore Setups-Source Floppy].
displaying a Not Ready Please Wait System Communications Failure as part of the
k. Select [Confirm].
EDN PWB initialization process. Wait about two minutes until all shadows reappear
on the diagnostic main menu file folders and the stackers are initialized. l. Press Continue. The system will automatically go into slumber mode and exit
dC101 displaying a Not Ready Please Wait system communications failure as part of
6. CHECK TO VERIFY THAT THE NVM IMAGE WAS TRANSFERRED FROM THE IOT
the restore setups process. If an 03-471 is displayed press the (R) reset button on
PRINTER DISK DRIVE TO THE REPLACEMENT NVM PWB.
the IOT Printer Control Panel. After approximately two minutes all shadows reap-
a. Enter dC103. pear on the diagnostic main menu file folders and stackers are initialized. Remove
b. Verify the Meter A value recorded at beginning of procedure is equal to present the floppy disk.
Meter A value. If the values are not equal any meter change information will need to 10. THE EDN PWB REPLACEMENT PROCESS IS COMPLETE. VERIFY MACHINE OPER-
be reported to the customer and appropriate organizations. ATION AND REPORT ANY METER CHANGE INFORMATION TO THE APPROPRIATE
c. Select the SCP File Cabinet icon. PERSONNEL.
d. Select the Update Data to update all SCP data. After the shadows on the SCP
screen reappear continue with the next step.
e. If any problems occurred during the EDN Initialization process (step 5) go to step 8.
Otherwise continue to step 10.
7. AT THE IOT PRINTER UI ONLY IF AN 03-362 FAULT IS SHOWN.
a. Enter service mode.
b. Enter dC131.

REP 1-14 Printer Card Cage Assembly 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
2. ACCESS THE PRINTER CARD CAGE ASSEMBLY (Figure 1).
Removal
To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Compo-
nents and Functions section.
1
5 OPEN THE EM
REMOVE THE EM FRONT DOOR
TOP COVER
4
REMOVE THE
PRINTER LEFT
REAR COVER
2
REMOVE THE EM
3 INNER PANEL
REMOVE THE EM
LEFT COVER
Figure 1 Accessing the Printer Card Cage
3. DISCONNECT THE CARD CAGE ELECTRICAL CONNECTORS (Figure 2).

P284
P2113/J111
J103/J104 VIDEO
CABLES (2)
P2112/J112
P/J101
PRINTE INTERFACE P213J113
CABLE
P2116/J114
P2102/J102
J105 SHARED LINE J108 SHARED LINE

(MIN CORE) (MIN DIO)
Figure 2 Printer Card Cage Electrical Connectors
4. PREPARE THE REAR OF THE CARD CAGE FOR REMOVAL (Figure 3).

2
DISCONNET THE
WIRES (4)
1 1
DISCONNET THE FAN
REMOVE THE
CONNECTOR (P282)
3 SCREWS (3)
LOOSEN (2)
Figure 3 Preparing the rear of the Card Cage for Removal Figure 4 Removing the Card Cage Front Mounting Screws
5. REMOVE THE CARD CAGE FRONT MOUNTING SCREWS (Figure 4). 6. REMOVE THE CARD CAGE ASSEMBLY (Figure 5).

1
LIFT
3
REMOVE
2
ROTATE
Figure 5 Removing the Printer Card Cage Assembly
Replacement
1. REINSTALL THE CARD CAGE ASSEMBLY.
2. RECONNECT THE CARD CAGE DC POWER WIRES (Figure 6).

P120
P115
Figure 6 Reconnecting the Card Cage DC Power Connectors (Shown with the Fan Assembly removed)

REP 1-16 Low Voltage Power Supply 1. SWITCH OFF THE PRINTER POWER.
3. OPEN THE PRINTER PWB PANEL.
Removal 4. LOWER THE AC DISTRIBUTION PANEL.
5. DISCONNECT THE CONNECTORS AT THE LOW VOLTAGE POWER SUPPLY (Figure
1).
P/J395
P/J503/503A/ IN
LINE PIGTAIL
J681/P430
P/J251
P/J505A
GROUND WIRE(S)
SCREW
P/J298
P4222/J58/J481
P315
P354
Figure 1 Disconnecting the Low Voltage Power Supply
CAUTION
When removing the Low Voltage Power Supply, ensure that the Mechanical Copy Meter is not
damaged.
6. REMOVE THE LOW VOLTAGE POWER SUPPLY (Figure 2).

2
SLIDE THE POWER SUPPLY
OUT OF THE PRINTER
1
REMOVE THE POWER SUPPLY
MOUNTING SCREWS (2)
Figure 2 Removing the Low Voltage Power Supply
Replacement REP 1-17 Low Voltage Power Supply PWBs

1. SLIDE THE LOW VOLTAGE POWER SUPPLY INTO THE MACHINE. Parts List on PL 1.10
2. ENSURE THAT THE ALIGNMENT PIN, LOCATED ON THE FRONT OF THE BOTTOM
BRACKET, SEATS PROPERLY INTO THE FRONT OF THE SUPPLY.
Removal
3. RECONNECT THE POWER SUPPLY CONNECTORS.

2. REMOVE THE LOW VOLTAGE POWER SUPPLY (REP 1-16).
3. REMOVE THE LOW VOLTAGE POWER SUPPLY RIGHT SIDE COVER (Figure 1).

1
REMOVE THE MOUNTING SCREWS (7)
FOR THE RIGHT SIDE ACCESS PANEL
2
REMOVE THE
ACCESS PANEL
Figure 1 Removing the Right Side Access Panel for the Low Voltage Power Supply
4. REMOVE THE REQUIRED PWB (Figure 2).

PULL THE PWB RETRACTING LEVERS (2)
SIMULTANEOUSLY AND REMOVE THE PWB
(TYPICAL)
Figure 2 Removing a Low Voltage Power Supply PWB (typical)

REP 1-18 Low Voltage Power Supply Cooling Fans Parts List on PL 1.10
Removal
2. ACCESS THE LOW VOLTAGE POWER SUPPLY FANS (Figure 1).
1
OPEN THE
PRINTER RIGHT
FRONT DOOR
2
REMOVE THE PRINTER
TRANSPORT INNER
PANEL
Figure 1 Accessing the Front of the Low Voltage Power Supply
NOTE: Only one Cooling Fan is shown in the procedure illustrations. This procedure is used
for removing each Cooling Fan.
3. REMOVE THE AIR FILTER (Figure 2).

PULL THE FILTER
AWAY FROM THE FAN
Figure 2 Removing a Low Voltage Power Supply Air Filter (typical)
4. REMOVE THE LOW VOLTAGE POWER SUPPLY COOLING FAN (Figure 3).

4 1
REMOVE THE FAN REMOVE THE
FAN MOUNTING
SCREWS (4)
3
DISCONNECT THE FAN
POWER CONNECTOR
2
REMOVE THE FILTER
HOUSING
Figure 3 Removing a Low Voltage Power Supply Cooling Fan (typical)

REP 1-19 Low Voltage Power Supply Relays (K103/K104) 2. REMOVE THE PRINTER RIGHT REAR COVER.
3. DISCONNECT P/J395, P/J503, P4221/P430, P4222/J431, AND P354 FROM THE LOW
Parts List on PL 1.10 VOLTAGE POWER SUPPLY (Figure 1).
Removal
P/J395
P/J503/503A/ IN
LINE PIGTAIL
J681/P430
P/J251
P/J505A
GROUND WIRE(S)
SCREW
P/J298
P4222/J58/J481
P315
P354
Figure 1 Disconnecting the Low Voltage Power Supply
4. REMOVE THE REAR ACCESS COVER FOR THE LVPS (Figure 2).

1
REMOVE THE MOUNTING SCREWS (3)
FOR THE REAR ACCESS PANEL
2
ROTATE TO REMOVE
THE ACCESS PANEL
Figure 2 Removing the Rear Access Panel for the Low Voltage Power Supply
5. REMOVE THE REQUIRED RELAY. REP 1-21 C-Pixel PWB

Removal

2. ACCESS THE PRINTER CARD CAGE.

b. Remove the EM Top Cover.
3
REMOVE THE PWB 1
ACCESS PANEL DISCONNECT THE
CARD CAGE CON-
NECTOR (P284)
2
REMOVE THE
SCREWS (3)
4. REMOVE THE APPROPRIATE PWB (Figure 2).

ROS LVPS PWB
C-PIXEL PWB
SLB/RDR PWB
EDN PWB
Figure 2 Removing the C-Pixel PWB
Replacement
1. INSTALL THE C-PIXEL PWB.
3. CHECK/ADJUST THE TOP-TO-BOTTOM REGISTRATION (ADJ 8-2)
4. CHECK/ADJUST ROS MAGNIFICATION SETUP (ADJ 6-1).

REP 2-1 CP IOP PWB REP 2-2 Control Panel PWB
Removal Removal
2. REMOVE THE UI REAR HOUSING COVER. 2. REMOVE THE UI REAR HOUSING COVER.
3. DISCONNECT ALL CP IOP PWB CONNECTORS. CAUTION
4. REMOVE THE CP IOP PWB. Place the UI Front Cover Assembly on a flat surface before removing the Control Panel PWB
to ensure that the Keyboard Buttons are not disturbed.
3. REMOVE THE UI FRONT COVER ASSEMBLY (REP 2-7).
4. REMOVE THE CONTROL PANEL PWB (Figure 1).
1
PLACE THE FRONT COVER
ON FLAT SURFACE
2
REMOVE HEX
SCREWS (5)
3
REMOVE THE CONTROL
PANEL PWB
Figure 1 Removing the Control Panel PWB

REP 2-3 Floppy Disk Drive Assembly 2. REMOVE THE UI BASE REAR COVER.
3. REMOVE THE UI CARD CAGE COVER.
CAUTION
Removal Do not scrape the UIM Core PWB when removing the Disc Drive.
4. REMOVE THE UI FLOPPY DISC DRIVE ASSEMBLY (Figure 1).
1
REMOVE (1)
2
SLIDE ASSEMBLY
OUT
4 3
CAUTION DISCONNECT
REMOVE
Figure 1 Removing the Floppy Disc Drive Assembly
5. REMOVE THE BASE PLATE FROM THE FLOPPY DISC DRIVE ASSEMBLY. REP 2-4 UIM Core PWB
Replacement Parts List on PL 2.2
1. INSTALL THE BASE PLATE ON THE FLOPPY DISC DRIVE ASSEMBLY.
Removal
2. CONNECT THE RIBBON AND HARNESS CABLES TO THE FLOPPY DISC DRIVE.
1. ENTER dC101.
3. REPLACE THE FLOPPY DISC ASSEMBLY.
2. INSERT A NEW FLOPPY DISK INTO THE FLOPPY DISK DRIVE.
NOTE: Do not use a disk that has been previously used for the SAVE SET-UP PARAMETERS.
NOTE: If you are unable to perform this step, the previously SAVED SET-UP PARAMETERS
should be used when installing the new board.
3. SELECT [Floppy Disk Format], [Confirm], AND PRESS the Continue BUTTON.

4. AFTER FORMATTING IS COMPLETE SELECT [Save Setup Parameters], [Confirm], REP 2-5 Video Engine PWB
AND PRESS the Continue BUTTON.
5. AFTER ALL FILES HAVE BEEN COPIED, REMOVE THE FLOPPY DISK FROM THE
FLOPPY DISK DRIVE. LABEL IT AS THE MOST RECENT SAVED SET-UP PARAME- Removal
TERS. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
6. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. 2. REMOVE THE UI BASE REAR COVER.
7. REMOVE THE UI BASE REAR COVER. 3. REMOVE THE UI CARD CAGE COVER.
8. REMOVE THE UI CARD CAGE COVER. 4. DISCONNECT ALL VIDEO ENGINE PWB CONNECTORS.
9. DISCONNECT ALL UIM CORE PWB CONNECTORS. 5. DISCONNECT THE UIM CORE PWB CONNECTORS AS REQUIRED.
10. REMOVE THE UIM CORE PWB. 6. REMOVE THE VIDEO ENGINE PWB.
Replacement
1. INSTALL THE UIM CORE PWB.
NOTE: Check the Termination Jumper, J5, on the UIM Core PWB to determine if it is properly
connected. The jumper should be on pin 1 (NORM) and pin 2.
2. CONNECT ALL UIM CORE PWB CONNECTORS.

3. SWITCH ON THE PRINTER.
4. ENTER dC323, [Initialize].
5. PRESS the Continue BUTTON.
6. WHEN dC323---00 IS DISPLAYED ON THE DIGITAL DISPLAY, REMOVE THE DIAG-
NOSTIC UTILITY DISK FROM THE FLOPPY DISK DRIVE.
7. PRESS the Stop BUTTON TWICE TO REBOOT THE MACHINE.
8. IF A 03-362 FAULT CODE IS DISPLAYED, PERFORM THE FOLLOWING:
a. Enter dC131.
b. Select [03-362 RESET].
c. Enter dC105 [Serial number and Service Phone].
d. Select [Printer Serial Number].
e. Enter the eleven digit machine serial number, and press [Enter].
f. Enter dC101.
g. Insert the floppy diskette into the Floppy Disk Drive that was used to store the latest
save setup parameters.
h. Select [Restore Setups-Source] [Floppy], [Confirm], and press the Continue but-
ton.
i. When the message "All files have been copied. Remove the floppy disk from
the floppy drive." appears on the Video Display, remove the floppy diskette from
the Floppy Disk Drive.
j. Switch off the Printer Circuit Breakers.
k. Switch on the Printer.
NOTE: All current Top 15 fault screens, all the current HFSI counters, all the current counters
in dC107, all counters on the SCP Entry screen, the Billing counters, and the current session
information for the Auditron account are reset to zero. The Auditron mode is also reset to the
off mode. This information resides in NVM and is therefore invalid when 03-0362 faults are
declared.
9. INSTALL THE UI CARD CAGE COVER.

10. INSTALL THE UI BASE REAR COVER.

REP 2-6 Local/Remote Power Switch (S102) 2. REMOVE THE UI BASE REAR COVER.
4. OPEN THE UI BASE FRONT COVER.
Removal 5. REMOVE THE LOCAL/REMOTE POWER SWITCH (Figure 1).
3
PUSH TOWARDS THE
FRONT OF THE COVER
1
REMOVE SCREWS (2)
2
DISCONNECT THE
GROUND STRAP
Figure 1 Removing the Local/Remote Power Switch
Replacement REP 2-7 UI Front Cover Assembly

NOTE: Ensure that the switch is installed with pins 1 and 4 up. Parts List on PL 2.2
1. REPLACE THE LOCAL/REMOTE POWER SWITCH. Removal
2. REMOVE THE UI REAR HOUSING COVER.
3. REMOVE THE UI FRONT COVER ASSEMBLY (Figure 1).

2
REMOVE
3
DISCONNECT AND
SLIDE THE RIBBON
CABLE OUT
1
LOOSEN SCREWS
(2 EACH SIDE)
Figure 1 Removing the UI Front Cover Assembly
REP 2-8 UI Touch Screen Assembly

Removal
3. REMOVE THE UI TOUCH SCREEN ASSEMBLY (Figure 1).

REP 2-9 UI Video Display Assembly
Removal
1 2 CAUTION
LOOSEN SCREWS (2) REMOVE SPRINGS
(2) TOP AND (2) Ensure that the power has been disconnected for a minimum of 120 seconds before removing
BOTTOM the Printer UI housing cover. Residual voltage is a shock hazard and could damage the electri-
cal components.
WARNING
Do not touch the CRT high voltage anode. Residual voltage will remain on the CRT high
voltage anode after power is disconnected. Residual voltage is a shock hazard.
2. REMOVE THE UI HOUSING COVER.
4. REMOVE THE UI TOUCH SCREEN ASSEMBLY (REP 2-8).
5. PREPARE TO REMOVE THE VIDEO DISPLAY ASSEMBLY (Figure 1).
3
MOVE AWAY
5 4
REMOVE DISCONNECT
Figure 1 Removing the Touch Screen Assembly

1
DISCONNECT THE
VIDEO CABLES (4)
2
DISCONNECT 5
DISCONNECT THE
POTENTIOMETER
HARNESS
3
DISCONNECT (4) 4
REMOVE CP IOP PWB
Figure 1 Preparing to remove the Video Display Assembly
6. REMOVE THE VIDEO DISPLAY ASSEMBLY (Figure 2).

REP 2-10 UI AC EMI Filter (FL105)
Removal
2. REMOVE THE UI BASE REAR COVER.
4. REMOVE THE UIM CORE PWB (REP 2-4).
5. REMOVE THE VIDEO ENGINE PWB (REP 2-5).
6. REMOVE THE AC EMI FILTER.
2 1
REMOVE THE REMOVE CHASSIS
VIDEO DISPLAY SCREWS (4)
Figure 2 Removing the Video Display Assembly
Replacement
NOTE: When reinstalling the Potentiometer Harness, ensure that Pin 1 on the Harness aligns
with Pin 1 on the Potentiometer.

REP 2-11 UI DC EMI Filter (FL106) REP 2-12 Rigid Disk Drive/SMSD Assembly
Removal Removal
1. REMOVE ALL SYSTEM POWER. 1. SWITCH OFF THE PRINTER POWER SWITCH AND WAIT 15 SECONDS.
2. REMOVE THE UI BASE REAR COVER. NOTE: Be prepared to insert the Diagnostic Diskette into the Floppy Disk Drive during the time
3. REMOVE THE UI CARD CAGE COVER. the 8s are displayed on the Digital Display.
NOTE: The Magenta Diagnostic Diskette (701P16850) MUST be used with the SMSD. Previ-
5. REMOVE THE VIDEO ENGINE PWB (REP 2-5). ous versions of the Diagnostic Diskette cannot be used.
6. REMOVE THE DC EMI FILTER.
NOTE: The current Burgundy Diagnostic Disk supersedes the Orange Diagnostic Disk and
supports all Rigid Disk drives 540 MB and above.
2. SWITCH ON THE PRINTER POWER SWITCH. INSERT THE DIAGNOSTIC DISKETTE

INTO THE FLOPPY DISK DRIVE DURING THE TIME THE 8s ARE DISPLAYED ON
THE DIGITAL DISPLAY.
3. PERFORM dC 325 SAVE CRITICAL DISK FILES.
a. Press the [F5] button to scroll to dC325.
b. When dC325 is displayed on the Digital Display, press the Continue button.
If the new Diagnostic Disk is being used:
i. When the digital Display reads San1 Edn2, Press 2 on the keyboard.
ii. When the digital Display reads Edn, Press the Continue button.
c. When InS FLOPPy is displayed on the Digital Display, remove the Diagnostic Dis-
kette, and insert a formatted floppy diskette.
d. Press the Continue button.
NOTE: When the program is complete, dC325---00, will be displayed on the Digital Display. If
an error occurs refer to dC 325, Save Critical Disk Files in the Service Manual.
4. REMOVE THE FLOPPY DISKETTE.

5. SWITCH OFF THE PRINTER AND THE PRINTER CIRCUIT BREAKERS.
6. REMOVE THE UI BASE REAR COVER.
CAUTION
The Rigid Disk Drive/SMSD Assembly is extremely delicate. If the assembly is dropped from a
distance of 1 inch (25.4 mm) or more, possible damage could occur.
10. REMOVE THE RIGID DISK DRIVE/SMSD ASSEMBLY (Figure 1).

3
SLIDE THE DRIVE
TOWARDS REAR
OF CARD CAGE
TO REMOVE
2 1
LOOSEN THE DISCONNECT THE
NUTS (2) CABLES (2)
Figure 1 Removing the Rigid Disk Drive/SMSD Assembly
CAUTION
Do not handle the PWB on the Rigid Disk Drive/SMSD in the removal procedure.
11. REMOVE THE BOTTOM PLATE FROM THE RIGID DISK DRIVE/SMSD ASSEMBLY BY
UNDOING THE 4 SCREWS.
Replacement
NOTE: No jumper is used on the SMSD drive.
1. CHECK THE POSITION OF THE JUMPER ON THE RIGID DISK DRIVE ASSEMBLY
(Figure 2).

THE JUMPER IS
POSITIONED AS
SHOWN
Figure 2 The Correct Position of the Rigid Disk Drive Jumper (2.1 GB)
2. IF PROVIDED RECORD THE INFORMATION ON THE BAD BLOCK TABLE LABEL

THAT APPEARS ON THE TOP OF THE RIGID DISK DRIVE ASSEMBLY.
3. MOUNT THE BOTTOM PLATE WITH 4 SCREWS TO THE RIGID DISK DRIVE/SMSD
ASSEMBLY.
4. INSTALL THE RIGID DISK DRIVE/SMSD ASSEMBLY.
5. CONNECT THE RIBBON CABLE AND POWER CONNECTOR (Figure 3).

POWER
RIBBON CABLE CONNECTOR
PIN 1
1
ENSURE THAT THE SIDE OF
THE CABLE WITH THE RED
STRIPE GOES TO PIN 1 OF
THE CONNECTOR
Figure 3 Connecting the Ribbon Cable
6. REINSTALL THE VIDEO ENGINE PWB, AND UIM CORE PWB. NOTE: If dEFAULt bb is not displayed, refer to dC 322, Rigid Disk Formatter (Floppy Disk
7. PERFORM dC 322 RIGID DISK FORMATTER. Routine).
a. Switch on the printer. d. When dEFAULt bb is displayed, press the Continue button.
b. Insert the Diagnostic Diskette into the Floppy Disk Drive during the time the 8s are
NOTE: The Digital Display will cycle down to 000 and then cycle back up again before the pro-
displayed on the Digital Display.
gram is complete.
c. When dC322 is displayed on the Digital Display, press the Continue button.
e. When dC322---00 is displayed, press the Stop button.
8. REMOVE THE DIAGNOSTIC DISKETTE FROM THE FLOPPY DISK DRIVE.

9. PERFORM AN ENTIRE SOFTWARE UPGRADE. c. When InS FLOPPy is displayed, remove the Diagnostic Diskette and insert the
a. Press the Stop button. floppy diskettes used in Step 3 of the removal procedure into the Floppy Disk Drive.
b. Insert Software Upgrade Diskette number one into the Floppy Disk Drive during the d. Press the Continue button.
time the 8s are being displayed on the Digital Display. When Full upgrade appears
NOTE: When the program is complete, dC326---00 will be displayed on the Digital display. If
press continue.
an error occurs, refer to dC 326, Restore Critical Disk Files.
c. When a flashing d followed by 02 is displayed on the Digital Display, remove the
Software Upgrade Diskette number one from the Floppy Disk Drive. 12. PRESS the Stop BUTTON. REMOVE THE FLOPPY DISKETTE FROM THE FLOPPY
d. Insert the remaining Software Upgrade Diskettes into the Floppy Disk Drive in the DISK DRIVE.
order they are displayed on the Digital Display. The number that follows the flashing 13. SWITCH OFF THE PRINTER POWER SWITCH AND WAIT 15 SECONDS.
d will indicate the next Software Upgrade Diskette to be inserted. 14. SWITCH ON THE PRINTER POWER SWITCH.
e. When the Digital Display indicates that the software upgrade is complete, Remove REP 2-13 UI Keyboard Buttons
the last Software Upgrade Diskette. (The revision level is displayed on the digital dis-
play i.e. 70.xx). Parts List on PL 2.2
10. PRESS the Continue BUTTON. INSERT THE DIAGNOSTIC DISKETTE INTO THE Removal
FLOPPY DISK DRIVE DURING THE TIME THE 8s ARE BEING DISPLAYED ON THE 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
DIGITAL DISPLAY.
11. PERFORM dC 326, RESTORE CRITICAL DISK FILES:
a. Press the F5 button to scroll to dC326.
CAUTION
b. When dC326 is displayed on the Digital Display, press the Continue button.
Place the Front Cover Assembly on a flat surface to ensure that the Keyboard Buttons are not
If the new Diagnostic Disk is being used: disturbed. The Keyboard Buttons are held in place by the Control Panel PWB.
When the digital Display reads San1 Edn2, Press 2 on the keyboard. 4. REMOVE THE CONTROL PANEL PWB (Figure 1).
When the digital Display reads Edn, Press the Continue button. 5. REMOVE THE UI KEYBOARD BUTTONS.
Figure 1 The Positions of the Keyboard Buttons

REP 2-14 UI Brightness/Contrast Controls
Removal 2
ADJUST
4. DISCONNECT THE WIRES THAT ARE CONNECTED TO THE CONTROL TERMINALS.
5. REMOVE THE BRIGHTNESS/CONTRAST CONTROL ASSEMBLY (Figure 1).
1
ENSURE
2 ADEQUATE
REMOVE SPRING CLEARANCE
3
TIGHTEN
1
REMOVE NUTS (2)
Figure 2 Adjusting the Brightness/Contrast Control Assembly

3
REMOVE 2. CONNECT THE WIRES TO THE BRIGHTNESS/CONTRAST CONTROLS (Figure 3).
Figure 1 Removing the Brightness/Contrast Control Assembly
Replacement
1. ADJUST THE POSITION OF THE BRIGHTNESS/CONTRAST CONTROL ASSEMBLY
BRACKET TO ENSURE THAT THE UI FRONT COVER DOES NOT INTERFERE WITH
THE CONTROL KNOBS (Figure 2).

REP 2-15 UI Swivel Wear Ring
Removal
4. REMOVE THE VIDEO DISPLAY ASSEMBLY (REP 2-9).
5. REMOVE THE UI TILT SHOE (REP 2-18).
6. REMOVE THE UI TILT CAP (REP 2-17).
7. REMOVE THE SWIVEL WEAR RING.
WIRE 1253
WIRE 1254
BLANK
WIRE 1250
WIRE 1251
WIRE 1252
Figure 3 Wiring of the Brightness/Contrast Control

REP 2-16 UI Tilt Bar REP 2-17 UI Tilt Cap
Removal Removal
2. REMOVE THE UIM CORE PWB (REP 2-4). 2. REMOVE THE UIM CORE PWB (REP 2-4).
3. REMOVE THE VIDEO ENGINE PWB (REP 2-5). 3. REMOVE THE VIDEO ENGINE PWB (REP 2-5).
4. REMOVE THE VIDEO DISPLAY ASSEMBLY (REP 2-9). 4. REMOVE THE UI VIDEO DISPLAY ASSEMBLY (REP 2-9).
5. REMOVE THE SHOULDER BOLT. 5. REMOVE THE UI TILT SHOE (REP 2-18).
6. REMOVE THE UI TILT BAR. 6. REMOVE THE UI TILT CAP.

REP 2-18 UI Tilt Shoe
Removal
4. REMOVE THE UI VIDEO DISPLAY ASSEMBLY (REP 2-9).
5. REMOVE THE UI TILT BAR (REP 2-16).
6. REMOVE THE UI TILT SHOE.

REP 4-0 Printer Right Top Cover Parts List on PL 4.5
Removal
2. REMOVE THE RIGHT TOP COVER (Figure 1).
3
LOOSEN THE
SCREWS (4), AND
REMOVE THE
COVER
2
REMOVE THE
1 SCREWS (4), AND
DISCONNECT THE SAMPLE
PINS (2), AND TRAY
LOWER THE
BAFFLES (2)
Figure 1 Removing the Right Top Cover
Replacement REP 4-1 Printer Side Covers and Rear Covers

1. INSTALL THE TOP COVER. Parts List on PL 4.7 PL 4.8
2. ADJUST THE PRINTER RIGHT TOP COVER (ADJ 4-0).
Removal
1. REMOVE THE SIDE AND REAR COVERS (Figure 1).

COVER BRACKET
COVER
1
USING A SCREW-
DRIVER, RELEASE
THE QUARTER-
PIN
TURN LATCH
FRAME CHANNEL
2
REMOVE THE
COVER
Figure 1 Removing the Side Covers and the Rear Covers
Replacement REP 4-2 Printer Left Top Cover

1. ADJUST THE PRINTER REAR COVERS (ADJ 4-2). Parts List on PL 4.6
Removal
NOTE: Protect the Photoreceptor Belt from exposure to the light.

2. REMOVE THE LEFT TOP COVER (Figure 1).

4
OPEN THE
5 PRINTER RIGHT
REMOVE THE TOP COVER
COVER
3
LOOSEN THE
NUTS (2)
LATCH BRACKET
1 2
OPEN THE
REMOVE THE
FRONT DOORS
INNER PANEL
Figure 1 Removing the Printer Left Top Cover
REP 4-3 Electrical Module Top Cover

Removal
2. REMOVE THE ELECTRICAL MODULE TOP COVER (Figure 1).

2
REMOVE THE
ELECTRICAL
MODULE TOP
COVER
1
LOOSEN THE
SCREW (1)
Figure 1 Removing the Electrical Module Top Cover
REP 4-20 Cleaner Drive Belt NOTE: Do not completely remove the Prefuser Drive Belt.
Parts List on PL 4.16 7. LOOSEN THE PREFUSER DRIVE BELT (Figure 1).
Removal
CAUTION
To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer then protect the
PR Belt.
2. PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER.
3. REMOVE THE PRINTER REAR COVERS (REP 4-1).
CAUTION
To prevent damage to the Photoreceptor and Cleaner, do not handcrank the Main Drive Motor
in a counterclockwise direction.
4. REMOVE THE PHOTORECEPTOR DRIVE BELT (REP 4-32).
5. REMOVE THE DECURLER INTERMEDIATE DRIVE BELT (REP 4-24).
6. OPEN THE PHN PWB PANEL.

2
MOVE UP THE IDLER
WHILE TIGHTENING
THE BOLT
1
LOOSEN BOLT
Figure 1 Loosening the Prefuser Drive Belt
NOTE: Remove the Cleaner Drive Belt by sliding the belt under the loosened Prefuser Drive
Belt, and then sliding the belt off the Prefuser Drive Assembly.
8. REMOVE THE CLEANER DRIVE BELT (Figure 2).

1
2 LOOSEN BOLT
MOVE DOWN THE IDLER
WHILE TIGHTENING THE
BOLT
3
REMOVE
THE BELT
Figure 2 Removing the Cleaner Drive Belt
Replacement REP 4-21 Cleaner Drive Support

1. ADJUST THE CLEANER DRIVE BELT (ADJ 4-10). Parts List on PL 4.16
2. ADJUST THE PREFUSER DRIVE BELT (ADJ 4-19).
Removal
3. ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12).
4. INSTALL THE PHOTORECEPTOR DRIVE BELT (REP 4-32).
2. REMOVE THE PRINTER LEFT REAR COVER.
5. CLOSE THE XEROGRAPHIC DRAWER.
3. REMOVE THE UPPER WASTE TONER DUCT (REP 9-17).
CAUTION
Ensure that the Locking Key is not lost when removing the Cleaner Support.
4. REMOVE THE CLEANER DRIVE SUPPORT (Figure 1).

1 10
LOOSEN BOLT CAUTION
2 REMOVE THE LOCKING KEY
MOVE BRACKET
9
LOOSEN THE
3 SETSCREW
REMOVE BELT AND REMOVE
FROM IDLER THE SUPPORT
PULLLEY
8
REMOVE NUTS (3)
7
NOTE: REMOVE
THE PULLEY
4
ALLOW IDLER
BRACKET TO MOVE
6
5 LOOSEN THE
SETSCREW
WARNING
REMOVE THE CAP
Figure 1 Removing the Cleaner Drive Support
Replacement WARNING
The Cleaner Drive Support Cap must be reinstalled to protect against electrical shock
NOTE: Position the Locking Key on the flat of the shaft with the closed end inward and the
during machine operation.
open end flush with the bearing surface. Ensure that the setscrew in the support bearing is
centered between the legs of the key before tightening. NOTE: Push the pulley and the ground clip onto the shaft until the pulley just contacts the
1. REINSTALL THE CLEANER SUPPORT. bearing support and then tighten the setscrew.
2. REINSTALL THE PULLEY AND CAP.

3. REINSTALL AND ADJUST THE CLEANER DRIVE BELT (ADJ 4-10).

REP 4-22 Decurler Drive Assembly
Removal
2. PULL OUT THE FUSER.
4. REMOVE THE DECURLER DRIVE BELT (REP 4-23).
5. REMOVE THE DECURLER DRIVE ASSEMBLY (Figure 1).
4 3
REMOVE THE REMOVE THE
ASSEMBLY BOLTS (2)
2
REMOVE THE
TENSION SPRING
1
LOOSEN BOLTS (2)
Figure 1 Removing the Decurler Drive Assembly
Replacement
1. ADJUST THE DECURLER DRIVE BELT (ADJ 4-11).

REP 4-23 Decurler Drive Belt 2. PULL OUT THE FUSER.
3. REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).
Removal NOTE: Open the Printer Right and Left Top Covers in order to remove the Belt.
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. 4. REMOVE THE DECURLER DRIVE BELT (Figure 1).
10
NOTE: REMOVE
THE BELT
9
TIGHTEN THE
1 BOLTS
REMOVE THE
SCREWS (2)
8
MOVE THE DRIVE
ASSEMBLY
2
REMOVE THE FAN
7
LOOSEN THE
BOLTS (2)
3 6
REMOVE THE TIGHTEN BOLT
FAN SUPPORT
5
MOVE THE
4 IDLER BRACKET
LOOSEN BOLT
Figure 1 Removing the Decurler Drive Belt
Replacement REP 4-24 Decurler Intermediate Drive Belt

1. ADJUST THE DECURLER DRIVE BELT (ADJ 4-11). Parts List on PL 4.16
Removal

2. REMOVE THE PRINTER REAR COVERS (REP 4-1). NOTE: Handcrank the Main Drive Motor in the clockwise direction only when removing the
3. ACCESS THE MIM DRIVE PULLEY BY OPENING THE AC DISTRIBUTION PANEL. Decurler Intermediate Drive Belt.
4. REMOVE THE DECURLER INTERMEDIATE DRIVE BELT (Figure 1).
2
MOVE AND HOLD
THE IDLER
1
LOOSEN BOLT
3 4
TIGHTEN BOLT REMOVE THE
BELT
Figure 1 Removing the Decurler Intermediate Drive Belt
Replacement REP 4-25 Handcranking the Main Drive Motor

1. ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12). Parts List on PL 4.18
Removal
2. PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.
CAUTION
Pull out the Xerographic Drawer, then protect the Photoreceptor Belt.
3. HANDCRANK THE MAIN DRIVE MOTOR FROM THE FRONT (Figure 1).

CAUTION
HANDCRANK THE
MAIN DRIVE
MOTOR
MAIN DRIVE
MOTOR
CAUTION
HANDCRANK THE
MAIN DRIVE MOTOR
Figure 1 Handcranking the Main Drive Motor from the Front Figure 2 Handcranking the Main Drive Motor from the Rear
4. HANDCRANK THE MAIN DRIVE MOTOR FROM THE REAR (Figure 2).

REP 4-26 Intermediate Drive Belt 2. REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).
Parts List on PL 4.19 NOTE: Loosen the bolts just enough to allow the drive assembly to pivot.
Removal 3. REMOVE INTERMEDIATE DRIVE BELT (Figure 1).
1 4
REMOVE THE
NOTE: LOOSEN
BELT
THE BOLTS (2)
3
TIGHTEN THE
BOLT (1)
2
MOVE AND HOLD
THE DRIVE REAR VIEW
Figure 1 Removing the Intermediate Drive Belt
Replacement REP 4-27 Main Drive Motor (MOT401)

1. ADJUST THE INTERMEDIATE DRIVE BELT (ADJ 4-15). Parts List on PL 4.18
Removal
To see additional information go to Xerographics in the DocuPrint 180 Unique Components
and Functions section.
1. PARTIALLY PULL OUT TRAY 1, AND TRAY 2.


NOTE: The Left Cross Roll Solenoid and the Nip Release Solenoid must be moved temporarily
in order to remove the Main Drive Motor. Ensure that the wire harness for the Nip Release
Solenoid is not positioned under the Main Drive Motor.
3. MOVE THE LEFT CROSS ROLL SOLENOID, AND THE NIP RELEASE SOLENOID (Fig-
ure 1).
4
MAKE SCRIBE
THE MAIN DRIVE LINES (2)
MOTOR
3
MOVE SOLENOID
ASSEMBLY
5
REMOVE NUTS (2),
AND MOVE THE
NIP RELEASE
SOLENOID ASSEM-
2 BLY
NOTE: DO NOT
DISCONNECT THE
ELECTRICAL CON-
NECTORS 1
REMOVE NUTS (2)
Figure 1 Moving the Cross Roll/Solenoid Assemblies

5. REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).
6. OPEN THE AC DISTRIBUTION PANEL, AND THE PHN PANEL DOOR.
7. REMOVE THE MIM, AND PHM DRIVE PULLEYS (REP 4-28).
NOTE: Ensure that the motor harness is not damaged during removal. Position the motor with
the gear box vent hole up to prevent lubricant from leaking. Replace cable ties as required.
8. PREPARE TO REMOVE THE MOTOR (Figure 2).

4
3 NOTE: REMOVE
2 THE MOTOR
LOOSEN BOLT (1)
NOTE: DISCONNECT
MOTOR CONNECTOR
3
ROTATE AND LIFT
THE MOTOR, AND
REMOVE BOLT
FROM THE FRAME
2
CAUTION
POSITION THE
HARNESS
4 1
REMOVE BOLTS (2) 1 PULL CONNECTOR
THROUGH FRAME
REMOVE COVER
Figure 2 Preparing To Remove the Motor Figure 3 Removing the Motor from the Frame
NOTE: Access the motor from the rear of the Printer, with Tray 1 and Tray 2 fully opened. Lift Replacement
and pull the motor away from the frame, and gently lower it onto the Registration Transport.
1. REMOVE THE VENT HOLE PLUG FROM THE MOTOR GEAR BOX, AND INSTALL
9. REMOVE THE MOTOR FROM THE FRAME (Figure 3). THE NEW MOTOR.
2. ADJUST THE PHM/MIM DRIVE PULLEYS (ADJ 4-18).
3. ADJUST THE PHM DRIVE BELT (ADJ 4-17).
4. ADJUST THE MIM DRIVE BELT (ADJ 4-16)
5. ALIGN THE NIP RELEASE SOLENOID ASSEMBLY WITH THE SCRIBE LINES, ON
THE TOP OF THE REGISTRATION TRANSPORT, AND TIGHTEN THE MOUNTING
HARDWARE.
7. CHECK/ADJUST THE NIP RELEASE SOLENOID ASSEMBLY (ADJ 8-6).
8. INSTALL THE LEFT CROSS ROLL SOLENOID ASSEMBLY.

REP 4-28 MIM and PHM Drive Pulleys
Removal 1 4
To see additional information go to Xerographics in the DocuPrint 180 Unique Components LOOSEN BOLT CAUTION
and Functions section. DISCONNECT
THE BELT
4. OPEN THE AC DISTRIBUTION PANEL AND THE PHN PWB PANEL.
5. REMOVE THE MIM DRIVE BELT FROM MIM PULLEY (Figure 1).
4
CAUTION
DISCONNECT 3
THE BELT 2 TIGHTEN BOLT
MOVE THE
IDLER BRACKET
Figure 2 Removing the PHM Drive Belt from PHM Pulley

3
TIGHTEN IDLER BOLT 1 7. REMOVE THE PULLEYS (Figure 3).
LOOSEN THE
IDLER BOLT
2
MOVE THE
IDLER BRACKET
Figure 1 Removing the MIM Drive Belt from MIM Pulley
6. REMOVE THE PHM DRIVE BELT FROM PHM PULLEY (Figure 2).

REP 4-29 MIM Drive Belt
2 Removal
REMOVE THE 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
PULLEYS CAUTION
To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer then protect the
PR Belt.
2. PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER
4. OPEN THE AC DISTRIBUTION PANEL.
CAUTION
Do not handcrank the Main Drive Motor in a counterclockwise direction.
1 5. REMOVE THE PHOTORECEPTOR DRIVE BELT (REP 4-32).
LOOSEN THE SET-
SCREWS 6. REMOVE THE MIM DRIVE BELT (Figure 1).
3
CAUTION
REMOVE THE BELT
Figure 3 Removing the Pulleys
Replacement
1. ADJUST THE PHM AND MIM DRIVE PULLEYS (ADJ 4-18).
3. ADJUST THE MIM DRIVE BELT (ADJ 4-16).
2
MOVE IDLER AND
TIGHTEN BOLT
1
LOOSEN BOLT
Figure 1 Removing the MIM Drive Belt
Replacement

NOTE: Handcrank the Main Drive Motor in a clockwise direction only while reinstalling the REP 4-30 PHM Drive Belt, Intermediate Drive Assembly
Photoreceptor Drive Belt.
Parts List on PL 4.18 PL 4.19
Removal
4. OPEN THE AC DISTRIBUTION PANEL AND THE PHM PWB PANEL.
5. REMOVE THE INTERMEDIATE DRIVE BELT (REP 4-26).
CAUTION
6. REMOVE THE MIM DRIVE BELT FROM THE MIM PULLEY (REP 4-29).
NOTE: Cut, and replace cable ties as required.
7. REMOVE THE PHM DRIVE BELT (Figure 1).

5
REMOVE THE
BELT
1
DISCONNECT CLUTCH
CONNECTOR
3
MOVE, AND HOLD
2 THE IDLER 4
LOOSEN BOLT TIGHTEN BOLT
Figure 1 Removing the PHM Drive Belt
8. REMOVE THE INTERMEDIATE DRIVE ASSEMBLY (Figure 2).

1
LOOSEN SCREW,
AND MOVE IDLER
4
DISCONNECT THE
SPRING, AND REMOVE
THE ASSEMBLY
2
REMOVE INVERTER
DRIVE BELT
3
REMOVE BOLTS (2)
Figure 2 Removing the Intermediate Drive Assembly
CAUTION
Do not loose the key, when removing the small gear.
9. REMOVE THE PHM DRIVE BELT (Figure 3).

6 5 3
REMOVE BELT MOVE REMOVE
4 2
LOOSEN SET- LOOSEN SET-
SCREW SCREW
1
REMOVE
CAUTION
DO NOT LOSE KEY
Figure 3 Removing the PHM Drive Belt
Replacement
1. REPLACE THE PHM DRIVE BELT.
2. ADJUST THE INTERMEDIATE DRIVE ASSEMBLY (ADJ 4-14).
CAUTION
When reinstalling the spring, ensure that the outward hook is installed into the frame hole, oth-
erwise damage may occur to the spring.
NOTE: When installing the Intermediate Drive Assembly, ensure that the rear edge of the bear-
ing is positioned in the hole of the frame, so that the assembly sits evenly against the frame.
3. INSTALL THE INTERMEDIATE DRIVE ASSEMBLY.

4. ADJUST THE INTERMEDIATE DRIVE BELT (ADJ 4-15).
6. INSTALL, AND TIGHTEN THE INVERTER DRIVE BELT.

REP 4-31 Photoreceptor Drive Assembly 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
2. REMOVE THE BI-PULLEY (REP 4-48 ).
3. REMOVE THE PHOTORECEPTOR DRIVE ASSEMBLY (Figure 1).
Removal
NOTE: DIRT SHIELD
2
REMOVE THE
BOLTS
3
PULL THE LOWER END OF THE
ASSEMBLY OUT, AND REMOVE FROM
THE PREFUSER DRIVE BELT
1
LOOSEN THE BOLT, AND
DISENGAGE THE SPRING
Figure 1 Removing the Drive Assembly
NOTE: Apply lubricant, as required, onto the drive coupling teeth, and the sliding coupler con- NOTE: Replace the Photoreceptor Drive Assembly with the Xerographic Drawer closed.
tact surface on the shaft. This will ensure that the Photoreceptor Drive Couplings align properly before tightening
the bolts for the Photoreceptor Drive Assembly.
4. LUBRICATE THE PHOTORECEPTOR DRIVE ASSEMBLY WITH 70P31 LUBRICANT IF
REQUIRED. NOTE: Reinstall the Dirt Shield behind the washer of the top bolt.
Replacement a. Ensure that the Photoreceptor drawer is closed and properly latched. Insert the Pho-
1. REPLACE THE PHOTORECEPTOR DRIVE ASSEMBLY. toreceptor alignment tool (600T2008) from the rear of the machine, onto the cou-
pling. Install the P/R Drive Assembly, rotating the coupling clockwise while tightening
the assembly to ensure proper alignment.
b. Unlatch the P/R drawer and remove the alignment tool. Slide the P/R drawer closed
several times, checking for proper alignment of the drive and coupling.
2. INSTALL THE BI-PULLEY (REP 4-48 ).

3. ADJUST THE PREFUSER DRIVE BELT (ADJ 4-19). REP 4-32 Photoreceptor Drive Belt
5. INSTALL THE PHOTORECEPTOR DRIVE BELT.
Removal

2. PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER
CAUTION
5. REMOVE THE PHOTORECEPTOR DRIVE BELT (Figure 1).
2
PULL THE BELT FROM THE PULLEY,
WHILE SLOWLY HANDCRANKING
THE MAIN DRIVE MOTOR
1
CAUTION
HANDCRANK SLOWLY
IN A CLOCKWISE
DIRECTION ONLY
Figure 1 Removing the Photoreceptor Drive Belt

REP 4-33 Prefuser Drive Assembly Replacement
Parts List on PL 4.16 NOTE: Position the Prefuser Drive coupler onto the transport coupler in order to ensure proper
Removal coupler engagement. Install the bottom bolts (2) first, in order to position the assembly. Ensure
that the assembly is flat against the frame.
2. PULL OUT THE FUSER. 1. ADJUST THE CLEANER DRIVE BELT (ADJ 4-10).
3. REMOVE THE DECURLER INTERMEDIATE DRIVE BELT FROM THE PREFUSER 2. ADJUST THE PREFUSER DRIVE BELT (ADJ 4-19).
DRIVE ASSEMBLY (REP 4-24). 3. ADJUST THE DECURLER INTERMEDIATE DRIVE PULLEY (ADJ 4-13).
4. REMOVE THE PREFUSER DRIVE BELT FROM THE PREFUSER DRIVE ASSEMBLY 4. ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12).
(REP 4-34). 5. CONNECT THE PRECLEAN DICOROTRON CONNECTOR.
5. REMOVE THE CLEANER DRIVE BELT (REP 4-20).
NOTE: Replace cable ties as required.
6. REMOVE THE PREFUSER DRIVE ASSEMBLY (Figure 1).
6. CONNECT THE OZAC AND THE CLEANER EXHAUST DUCTS.
CAUTION
1 in a counterclockwise direction.
REMOVE THE
BOLTS (4) 7. INSTALL THE PHOTORECEPTOR DRIVE BELT WHILE SLOWLY HANDCRANKING
THE MAIN DRIVE MOTOR.
8. PUSH IN, AND LATCH THE FUSER.
9. INSTALL THE PRECLEAN DICOROTRON.
2
REMOVE THE
ASSEMBLY
Figure 1 Removing the Prefuser Drive Assembly
NOTE: Apply lubricant, as required, onto the gear teeth, drive coupling teeth and the sliding
coupler contact surface on the shaft.
7. LUBRICATE THE PREFUSER DRIVE ASSEMBLY WITH 70P31 LUBRICANT.

REP 4-34 Prefuser Drive Belt 4. REMOVE THE PRINTER REAR COVERS (REP 4-1).
CAUTION
Removal Do not handcrank the Main Drive Motor in a counterclockwise direction.
6. REMOVE THE PHOTORECEPTOR DRIVE BELT (REP 4-32).
2. REMOVE THE PRECLEAN DICOROTRON (REP 9-39).
7. DISCONNECT THE OZAC, AND CLEANER EXHAUST DUCTS (Figure 1).
1
CUT CABLE TIE
2
LOOSEN HOSE CLAMP,
AND DISCONNECT THE
DUCT
5
DISCONNECT THE
PRECLEAN
DICOROTRON
3
CUT CABLE TIE
4
DISCONNECT THE
DUCT
Figure 1 Disconnecting the Ozac and Cleaner Exhaust Ducts
8. OPEN THE PHN PWB PANEL.

9. LOOSEN THE PREFUSER DRIVE BELT (Figure 2).

2
MOVE UP THE IDLER
WHILE TIGHTENING
THE BOLT
1
LOOSEN BOLT
Figure 2 Loosening the Prefuser Drive Belt
CAUTION
Do not lose the Shaft key when removing the Decurler Intermediate Drive Pulley.
10. REMOVE THE PREFUSER DRIVE BELT (Figure 3).

1
LOOSEN SET-
SCREW
3
CAUTION
2 REMOVE THE PULLEY 4
REMOVE THE REMOVE THE BELT
RETAINING RING
Figure 3 Removing the Prefuser Drive Belt
Replacement
1. ADJUST THE PREFUSER DRIVE BELT (ADJ 4-19).
NOTE: Ensure that the key is positioned between the pulley, and the shaft.
2. ADJUST THE DECURLER INTERMEDIATE DRIVE PULLEY (ADJ 4-13).

4. CONNECT THE PRECLEAN DICOROTRON CONNECTOR.
NOTE: Replace cable ties as required.
5. CONNECT THE OZAC, AND THE CLEANER EXHAUST DUCTS.

CAUTION
6. INSTALL THE PHOTORECEPTOR DRIVE BELT WHILE SLOWLY HANDCRANKING
THE MAIN DRIVE MOTOR.
8. INSTALL THE PRECLEAN DICOROTRON.

REP 4-35 Top Transport Drive Assembly 2. REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).
3. REMOVE THE PRINTER RIGHT TOP COVER (REP 4-0).
4. PARTIALLY INSTALL THE PRINTER LEFT TOP COVER IN ORDER TO PROTECT THE
Removal PHOTORECEPTOR BELT FROM THE LIGHT.
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. 5. REMOVE THE TOP TRANSPORT DRIVE BELT (Figure 1).
1
LOOSEN THE IDLER,
AND REMOVE THE
BELT FROM THE
DRIVE ASSEMBLY
TOP TRANSPORT
DRIVE ASSEMBLY
Figure 1 Removing the Top Transport Drive Belt
NOTE: Loosen the bolts (2) just enough to allow the Intermediate Drive Assembly to move.
7. REMOVE THE TOP TRANSPORT DRIVE ASSEMBLY (Figure 2).

3 4
TIGHTEN THE REMOVE THE BELT
BOLT (1)
TRANSPORT
DRIVE ASSEMBLY
5
REMOVE THE
BOLTS (2), AND
THE DRIVE
2 ASSEMBLY
MOVE, AND HOLD
THE INTERMEDI-
ATE DRIVE
ASSEMBLY
1
NOTE: LOOSEN
THE BOLTS (2)
Figure 2 Removing the Top Transport Drive Assembly
Replacement REP 4-36 Tray 1 and 2 Feeder Drives

1. ADJUST THE INTERMEDIATE DRIVE BELT (ADJ 4-15). Parts List on PL 4.18
2. INSTALL AND TIGHTEN THE TOP TRANSPORT DRIVE BELT.
Removal
3. INSTALL ALL COVERS.
2. PULL OUT THE XEROGRAPHIC DRAWER.

NOTE: Cut and replace cable ties on Tray 2 Feeder Drive, as required.
5. REMOVE THE FEEDER DRIVE (Figure 1).
4
REMOVE THE
BELT 5
REMOVE THE
BOLTS (2)
6
REMOVE THE
3 DRIVE
TIGHTEN THE
BOLT
1
LOOSEN THE
2 BOLT
MOVE THE
BRACKET
Figure 1 Removing the Feeder Drive
Replacement REP 4-38 Vertical Transport Clutch Assembly (CL851)

NOTE: Apply lubricant, as required, onto the shaft where the sliding coupler contacts the shaft. Parts List on PL 4.18
1. LUBRICATE THE FUSER DRIVE ASSEMBLY WITH 70P31 LUBRICANT. Removal
2. ADJUST THE TRAY 1 OR 2 FEEDER DRIVE (ADJ 4-20). 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
3. ADJUST THE PHM DRIVE BELT (ADJ 4-17). 2. PULL OUT THE XEROGRAPHIC DRAWER.
4. INSTALL THE PRINTER REAR COVER (REP 4-1). 3. REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).
NOTE: Access the Vertical Transport Drive Belt from the front of the Printer.
5. PREPARE TO REMOVE THE CLUTCH ASSEMBLY (Figure 1).

OPPOSITE SIDE
OF FRAME
10
REMOVE THE
PULLEY
8 9
REMOVE THE VER- LOOSEN THE
TICAL TRANSPORT SETSCREW
DRIVE BELT
7 6
TIGHTEN THE MOVE THE IDLER
BOLT BRACKET 5
LOOSEN THE
BOLT
4
DISCONNECT THE
PHM DRIVE BELT
3
TIGHTEN THE
2 BOLT
1 MOVE THE IDLER
LOOSEN THE BRACKET
BOLT
Figure 1 Preparing To Remove the Clutch Assembly
NOTE: Cut and replace cable ties as required.
6. REMOVE THE CLUTCH ASSEMBLY (Figure 2).

NOTE: POSITION
OF THE CLUTCH
1
NOTE: DISCON-
NECT CONNECTOR
2
REMOVE THE
NUTS (4)
3
REMOVE CLUTCH
ASSEMBLY (CL 851)
Figure 2 Removing the Clutch Assembly
Replacement
NOTE: Position the clutch with the tab in the slot as shown in Figure 2.
1. REPLACE THE CLUTCH ASSEMBLY.

2. INSTALL AND TIGHTEN THE VERTICAL TRANSPORT DRIVE BELT.
CAUTION

REP 4-39 Developer Drive Assembly NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assem-
bly. Toner will fall from assembly connection.
3. OPEN THE TONER FILER ASSEMBLY, AND THE XEROGRAPHIC CARD CAGE.
Removal
4. REMOVE THE HVAC OUTPUT MODULE (REP 1-4).
5. LOOSEN THE FUSER-DEVELOPER DRIVE BELT (Figure 1).
NOTE: Squeeze the Belt

together near the center
with the hand to aid in
2
MOVE THE IDLER, AND
loosening
TIGHTEN THE BOLT
3
DISCONNECT THE
BELT FROM THE
DRIVE PULLEY
1
LOOSEN THE
BOLT
THE DEVELOPER
DRIVE ASSEMBLY
Figure 1 Loosening the Fuser-Developer Drive Belt
6. REMOVE THE DEVELOPER DRIVE ASSEMBLY (Figure 2).

WARNING
THE INSULATING
CAP
1
REMOVE THE
BOLTS (4), AND
WASHERS (4)
2
REMOVE THE
ASSEMBLY
Figure 2 Removing the Developer Drive Assembly
Replacement
NOTE: Push the coupler in, and apply lubricant, as required, onto the shaft where the sliding
coupler contacts the shaft.
1. LUBRICATE THE DEVELOPER DRIVE ASSEMBLY WITH 70P31 LUBRICANT.

WARNING
Ensure that the Insulating Cap is installed. An electrical shock hazard exists, if the drive
pulley is contacted during machine run operation.
2. ENSURE THAT THE XEROGRAPHIC DRAWER IS IN THE CLOSED POSITION, AND
INSTALL THE DEVELOPER DRIVE ASSEMBLY.
3. PERFORM THE DEVELOPER DRIVE ASSEMBLY ALIGNMENT (ADJ 9-19).
4. INSTALL THE HVAC OUTPUT MODULE (REP 1-4).
5. CONNECT THE OZAC DUCT TO THE OZONE FILTER.
6. REPLACE THE CABLE TIES AS REQUIRED, AND ENSURE THAT THE CLEANER
HOSES AND OZAC HOSES ARE AWAY FROM MOVING PARTS.

REP 4-40 Fuser-Developer Drive Belt NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assem-
4. OPEN THE TONER FILTER ASSEMBLY.
Removal
7. REMOVE THE FUSER-DEVELOPER DRIVE BELT (Figure 1).
NOTE: Squeeze the Belt

together near the center
with the hand to aid in 2
loosening MOVE THE IDLER, AND
TIGHTEN THE BOLT
1
LOOSEN THE
BOLT
3
DISCONNECT THE
BELT FROM THE
IDLER
6
REMOVE THE
BELT
5
REMOVE THE
SPRINGS (2) 4
LOOSEN THE
BOLT
Figure 1 Removing the Fuser-Developer Belt
Replacement
1. ADJUST THE FUSER-DEVELOPER DRIVE BELT (ADJ 4-21).

NOTE: Handcrank the Drive Pulley in a clockwise direction in order to ensure that the belt is REP 4-41 Fuser-Developer Drive Motor (MOT402)
seated.
Removal
NOTE: Replace cable ties as required, and ensure that the Cleaner and Ozac hoses are away 2. REMOVE THE PHOTORECEPTOR BELT (REP 9-35).
from moving parts. 3. REMOVE THE ROS ASSEMBLY (REP 6-1).
4. CLOSE THE XEROGRAPHIC DRAWER. 4. REMOVE THE FUSER-DEVELOPER DRIVE DIRT SHIELD (REP 4-47).
CAUTION
To prevent lubricant from leaking, store the motor with the gear box vent hole up.
6. REMOVE THE FUSER-DEVELOPER DRIVE MOTOR (Figure 1).

5
LOOSEN THE
BOLTS (3)
4
REMOVE THE BELT 6
FROM THE PULLEY REMOVE THE
MOTOR
2
LOOSEN THE
SCREW 1
DISCONNECT
CONNECTORS (2)
3
MOVE THE IDLER
THEN TIGHTEN
THE SCREW
Figure 1 Removing the Fuser-Developer Drive Motor
7. REMOVE THE MOTOR PULLEY, AND THE MOUNTING SCREWS. CAUTION

Replacement Remove the vent hole plug from the motor gear box when replacing the motor.
WARNING 2. INSTALL, AND CONNECT THE NEW DRIVE MOTOR.
To prevent possible personal injury, do not move your fingers along the sharp edges of 3. INSTALL, AND TIGHTEN THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT.
the keyway. 4. CENTER THE INTERMEDIATE DRIVE BELT ON THE MOTOR PULLEY (Figure 2).
NOTE: Ensure that the key is positioned between the pulley and shaft. Do not tighten the set-
screw of the pulley at this time.
1. INSTALL THE MOTOR PULLEY ON THE MOTOR SHAFT.

3 TOP FRONT VIEW
REAR VIEW TIGHTEN THE
SETSCREW
1
2 ROTATE THE PULLEY FIVE
CENTER THE BELT FULL REVOLUTIONS IN A
ON THE PULLEY COUNTERCLOCKWISE
DIRECTION
Figure 2 Positioning the Belt on the Pulley
5. INSTALL THE ROS ASSEMBLY (REP 6-1). REP 4-42 Fuser-Developer Intermediate Drive Belt
6. INSTALL THE PHOTORECEPTOR BELT (REP 9-35).
Removal
NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assem-
bly.
3. OPEN THE TONER FILTER ASSEMBLY.

4. OPEN THE XEROGRAPHIC CARD CAGE. 6. LOOSEN THE FUSER-DEVELOPER DRIVE BELT (Figure 1).
2
MOVE THE IDLER,
AND TIGHTEN THE
BOLT
3
DISCONNECT THE
BELT FROM THE
DRIVE PULLEY
1
LOOSEN THE BOLT
Figure 1 Loosening the Fuser-Developer Belt
7. REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

8. REMOVE THE ROS ASSEMBLY (REP 6-1).
9. REMOVE THE FUSER-DEVELOPER DRIVE DIRT SHIELD (REP 4-47).
10. LOOSEN THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (Figure 2).

LEFT REAR VIEW
TOP FRONT VIEW
1
LOOSEN THE
3 SCREW
REMOVE THE BELT 2
FROM THE PULLEY MOVE THE IDLER,
AND TIGHTEN THE
SCREW
Figure 2 Loosening the Fuser-Developer Intermediate Belt
NOTE: If a new Jackshaft Assembly is being installed, it will not be necessary to remove the
Intermediate Drive Belt from the Printer.
11. REMOVE THE BELT (Figure 3).

1
PUSH THE BELT
THROUGH THE
CUTOUT AND OVER
THE DRIVE PULLEY
2
REMOVE THE BELT
TOP FRONT VIEW
Figure 3 Removing the Belt
Replacement
1. ADJUST THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (ADJ 4-23).
NOTE: Replace cable ties as required, and ensure that the Cleaner hoses and Ozac hoses are
away from moving parts.
5. INSTALL THE ROS ASSEMBLY (REP 6-1).

6. INSTALL THE FUSER-DEVELOPER DRIVE DIRT SHIELD (REP 4-47).

REP 4-43 Fuser Drive Assembly NOTE: Place a drop cloth under the rear of the Printer before opening the Toner Filter Assem-
bly.
3. OPEN THE TONER FILTER ASSEMBLY AND THE XEROGRAPHIC CARD CAGE.
Removal
5. REMOVE THE FUSER-DEVELOPER DRIVE ASSEMBLY (Figure 1).
5 4
FUSER DRIVE BOLTS (4)
ASSEMBLY
3
REMOVE THE
BELT FROM THE
DRIVE PULLEY
1
LOOSEN BOLT
2
MOVE THE IDLER, AND
TIGHTEN THE BOLT
Figure 1 Removing the Fuser Drive Assembly
Replacement 1. LUBRICATE THE FUSER DRIVE ASSEMBLY WITH 70P31 LUBRICANT.

2. CLOSE THE FUSER, AND INSTALL THE FUSER DRIVE ASSEMBLY.
NOTE: Apply lubricant, as required, onto the shaft where the sliding coupler contacts the shaft.

4. INSTALL THE HVAC OUTPUT MODULE (REP 1-4). REP 4-44 Jackshaft Assembly
Removal
NOTE: Place a drop cloth under the rear of the Printer before opening the Toner Filter Assem-
bly.
3. OPEN THE TONER FILTER ASSEMBLY, AND THE XEROGRAPHIC CARD CAGE.
NOTE: Do not remove the belt completely.

8. REMOVE THE FUSER-DEVELOPER DRIVES DIRT SHIELD (REP 4-47).
9. REMOVE THE FUSER-DEVELOPER DRIVE MOTOR (REP 4-41).
NOTE: Do not remove the Drive Motor Pulley from the motor shaft.
10. REMOVE THE JACKSHAFT ASSEMBLY (Figure 1).

1 FRONT TOP VIEW
REMOVE BOLTS (3)
2
REMOVE THE JACKSHAFT
AND THE BELT
REAR VIEW
Figure 1 Removing the Jackshaft Assembly
11. REMOVE THE DRIVE PULLEY FROM THE OLD JACKSHAFT ASSEMBLY. 6. ADJUST THE FUSER-DEVELOPER DRIVE PULLEY (ADJ 4-22).
Replacement 7. ADJUST THE FUSER-DEVELOPER DRIVE BELT (ADJ 4-21).
1. INSTALL THE FUSER-DEVELOPER DRIVE PULLEY LOOSELY ON THE NEW JACK- 8. INSTALL THE HVAC OUTPUT MODULE (REP 1-4).
SHAFT ASSEMBLY.
NOTE: Replace cable ties as required, and ensure that the Cleaner hoses and Ozac hoses are
2. INSTALL THE NEW JACKSHAFT ASSEMBLY. away from moving parts.
3. INSTALL THE FUSER-DEVELOPER DRIVE MOTOR (REP 4-41).
NOTE: Ensure that the motor connectors are reconnected. 10. INSTALL THE ROS ASSEMBLY (REP 6-1).
4. ADJUST THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (ADJ 4-23). 11. INSTALL THE PHOTORECEPTOR BELT (REP 9-35).
5. INSTALL THE FUSER-DEVELOPER DRIVES DIRT SHIELD (REP 4-47).

REP 4-45 Fuser-Developer Drive Motor Run and Start 2. REMOVE THE ROS UPPER INNER PANEL.
3. REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).
Capacitors (C403/C404)(60 HZ)
CAUTION
Parts List on PL 4.20 Do not interchange the wires.
Removal 4. REMOVE THE RUN CAPACITOR (C403) (Figure 1).
FRONT TOP VIEW 4

REMOVE THE RUN
CAPACITOR
THE START
CAPACITOR
3
LOOSEN SCREW
1
PULL BACK THE
INSULATOR 2
DISCONNECT THE
FASTONS (4)
C1-1
C1-2
Figure 1 Removing the Run Capacitor
5. REMOVE THE START CAPACITOR (C404) (Figure 2).

3
DISCONNECT THE
FASTONS (2)
1
REMOVE THE
CAPACITOR FROM
THE BRACKET
2
REMOVE THE CAP
Figure 2 Removing the Start Capacitor
Replacement
NOTE: Do not interchange the wires. Ensure that the lip of the Run Capacitor does not touch
the frame.
1. INSTALL THE NEW RUN CAPACITOR (Figure 3).

3 2
TIGHTEN THE
NOTE: CONNECT SCREW
THE FASTONS (4)
C1-2
NOTE: POSITION THE

CAPACITOR 5.0 mm
MAXIMUM FROM THE
FRONT OF THE
4 FRAME
INSTALL THE
INSULATOR
C1-1
Figure 3 Installing the Run Capacitor
2. CONNECT THE WIRES FOR THE START CAPACITOR. REP 4-46 Main Drive Motor Run and Start Capacitors
3. INSTALL THE END CAP.
(C401/402) (60HZ)
4. PUSH THE CAPACITOR INTO THE MOUNTING BRACKET. ENSURE THAT THE END
CAPS ARE SEATED IN THE DETENTS. Parts List on PL 4.19
Removal
3. OPEN THE AC DISTRIBUTION PANEL AND THE PHN PANEL DOOR.
4. REMOVE THE RUN CAPACITOR (Figure 1).

3
DISCONNECT
FASTONS (4) 4
LOOSEN SCREW
5
REMOVE THE
CAPACITOR
2
OBSERVE THE
WIRING
1
PULL BACK THE
INSULATOR
Figure 1 Removing the Run Capacitor
5. REMOVE THE START CAPACITOR (Figure 2).

1
REMOVE THE
CAPACITOR FROM
THE BRACKET
3
DISCONNECT THE
FASTONS (2) 2
REMOVE THE CAP
Figure 2 Removing the Start Capacitor
Replacement
NOTE: Ensure that the lip of the Run Capacitor does not touch the frame. Do not interchange
the wires.
1. INSTALL THE RUN CAPACITOR (Figure 3).

2
POSITION CAPACITOR
5.0 MM MAXIMUM
FROM THE FRONT OF
THE PLATE
3
TIGHTEN SCREW
1
NOTE: CONNECT
THE FASTONS (4) 4
INSTALL THE
INSULATOR
Figure 3 Installing the Run Capacitor
2. CONNECT THE START CAPACITOR. REP 4-47 Fuser-Developer Drive Dirt Shields
3. INSTALL THE END CAP.
4. PUSH THE CAPACITOR INTO THE MOUNTING BRACKET. ENSURE THAT THE END
CAPS ARE SEATED IN THE DETENTS. Removal
5. CLOSE THE AC DISTRIBUTION PANEL, AND THE PHN PANEL DOOR. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
6. INSTALL THE PRINTER RIGHT REAR COVER (REP 4-1). 2. REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

NOTE: Carefully remove the dirt shield in order to prevent any buildup of debris within the
Shield from falling into the Printer. Move the Right Dirt Shield forward, rotate it in a clockwise
direction, and remove it from the Printer.
5. REMOVE THE DIRT SHIELDS (Figure 1).
1
2 NOTE: LOOSEN THE
FASTENERS (2), AND
NOTE: LOOSEN REMOVE THE SHIELD
THE FASTENER,
AND REMOVE
THE SHIELD
FRONT TOP VIEW
Figure 1 Removing the Dirt Shields
Replacement
1. WIPE THE INSIDE SURFACES OF THE DIRT SHIELDS WITH FILM REMOVER
(43P45).
2. INSTALL THE DIRT SHIELDS (Figure 2).

2
1 POSITION THE
INSTALL THE LEFT RIGHT DIRT
DIRT SHIELD, AND SHIELD HERE
SEAT THE FASTENER
3
INSTALL THE
RIGHT DIRT
4 SHIELD
ENSURE THAT
THE SHIELDS
ARE CORRECTLY
MATED
Figure 2 Installing the Dirt Shields
3. PUSH IN THEN LATCH THE FUSER. REP 4-48 Bi-Pulley

4. INSTALL THE PRINTER LEFT TOP COVER (REP 4-2).
5. INSTALL THE ROS UPPER INNER PANEL.
Removal
2. REMOVE THE FOLLOWING:
a. Printer Rear Covers (REP 4-1).
NOTE: Place a dropcloth under the waste compactor motor bracket. Partially remove the
waste compactor motor bracket to access the Bi-pulley.
b. Waste Compactor Motor Bracket (REP 9-19).

c. Upper Waste Toner Duct (REP 9-17).
d. The Flywheel (Figure 1).

2
NOTE: LOOSEN
AND MOVE THE
LOWER DUCT
1 2
HOLD THE SLOTTED REMOVE THE
STUD, AND REMOVE FLYWHEEL 1 3
THE NUT REMOVE THE REMOVE THE
RETAINING RING BI-PULLEY
Figure 1 Removing the Flywheel Figure 2 Removing the Bi-pulley
e. Photoreceptor Drive Belt (REP 4-32). Replacement

f. MIM Drive Belt (REP 4-29). 1. REPLACE THE BI-PULLEY.
3. REMOVE THE BI-PULLEY (Figure 2). 2. ADJUST THE MIM DRIVE BELT (ADJ 4-16).
NOTE: Ensure that the Waste Toner Duct is properly clamped and that the Lower Waste Toner
Duct mounting bolts are tight.
4. INSTALL WASTE TONER DUCT AND THE WASTE COMPACTOR MOTOR BRACKET.
5. INSTALL THE REAR COVERS (REP 4-1).

REP 4-49 Stacker Front Cover
Removal 1
DISCONNECT
CAUTION
Do not remove the Stacker Front Cover when the Pallet Lift Frame is positioned all the way
down. The Front Doors Interlock Switch Brackets could be damaged. 2
1. PARTIALLY RAISE THE PALLET LIFT FRAME. DISCONNECT
3. RAISE THE APPROPRIATE STACKER TOP COVER. 3
CAUTION DISCONNECT (2)
Do not allow the Stacker Front Cover to drop after the 10mm screws are removed.
4. REMOVE THE TWO 10 mm SCREWS SECURING THE TOP OF THE STACKER
FRONT COVER.
5. WITH THE BOTTOM BRACKETS ON THE FRONT COVER INSTALLED, LOWER THE
TOP OF THE FRONT COVER AWAY FROM THE FRAME, AND DISCONNECT THE
CONNECTORS LOCATED BEHIND THE COVER (Figure 1).
4
DISCONNECT
Figure 1 Disconnecting the Front Cover Connectors

REP 4-50 Stacker Top Cover Parts List on PL 4.14
Removal
1. REMOVE THE FS UPPER REAR COVER.
2. REMOVE THE STACKER REAR TOP COVER (Figure 1).
1 2
LOOSEN NUTS (4) REMOVE THE
COVER
Figure 1 Removing the Rear Top Cover
3. OPEN THE STACKER TOP COVER.

CAUTION
Do not allow the Bypass Transport Top Baffle to drop after unlatching it from the Stacker Top
Cover.
4. UNLATCH AND LOWER THE BYPASS TRANSPORT TOP BAFFLE (Figure 2).

1
UNLATCH THE
BYPASS
TRANSPORT
TOP BAFFLE
2
CAUTION
LOWER THE
BAFFLE
Figure 2 Unlatching the Baffle
5. REMOVE THE STACKER TOP COVER (Figure 3).

1
LOOSEN NUTS (4)
2
REMOVE THE COVER
Figure 3 Removing the Top Cover
Replacement REP 4-51 Stacker Rear Top Cover

NOTE: Ensure that the Stacker Top Cover studs are fully seated in the slots of the Counterbal- Parts List on PL 4.14
ance Brackets before tightening the nuts. Removal
1. REINSTALL THE STACKER TOP COVER AND TIGHTEN THE NUTS. 1. OPEN THE PURGE TRAY TOP COVER.
2. REMOVE THE NUT AND DISCONNECT THE CABLE SECURING THE PURGE
TRANSPORT TOP BAFFLE TO THE PURGE TRAY TOP COVER. LOWER THE BAF-
FLE.
3. REMOVE THE FS UPPER REAR COVER.

1
REMOVE NUTS (4)
2
REMOVE THE COVER
Figure 1 Removing the Rear Top Cover
5. REMOVE THE PURGE TRAY TOP COVER (Figure 2).

2
REMOVE THE COVER
1
REMOVE NUTS (4)
Figure 2 Removing the Purge Tray Top Cover
Replacement REP 4-52 Inverter Top Cover

NOTE: Ensure that the Stacker Top Cover studs are fully seated in the slots of the Counterbal- Parts List on PL 4.14
ance Brackets before tightening the nuts. Removal
1. REINSTALL THE PURGE TRAY TOP COVER AND TIGHTEN THE NUTS. 1. SWITCH OFF THE PRINTER POWER.
2. OPEN THE INVERTER DOOR.
3. REMOVE THE INVERTER TOP COVER (Figure 1).

REP 4-53 Stacker Rear Top Cover
3 Removal
LIFT THE FRONT
UP SLIGHTLY 1. REMOVE THE STACKER UPPER REAR COVER.
4 2
PULL THE COVER LOOSEN NUT
OUT, AND REMOVE
1
DISCONNECT
Figure 1 Removing the Top Cover

REP 4-54 Inverter Left Side Cover Parts List on PL 4.10
Removal
1. REMOVE THE INVERTER TOP COVER (REP 4-52).
2. REMOVE THE INVERTER LEFT SIDE COVER (Figure 1).
2
REMOVE THE COVER
1
LOOSEN SCREWS (2)
Figure 1 Removing the Cover

REP 6-1 ROS Assembly CAUTION
The Photoreceptor is extremely sensitive to light exposure. Limit the exposure of the PR Belt to
Parts List on PL 6.1 under two (2) minutes. If the PR Belt will be exposed to light a longer period, remove the Pho-
Removal toreceptor from the belt module and place it immediately in the protective bag, or place the bag
To see additional information go to Imaging in the DocuPrint 180 Unique Components and over the Photoreceptor with it on the belt module.
Functions section. 1. SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL
POWER CORDS.
2. REMOVE AND PROTECT THE PHOTORECEPTOR BELT (REP 9-35).
4. PREPARE TO REMOVE THE ROS ASSEMBLY (Figure 1).
1
DISCONNECT THE
CONNECTORS (2)
2
DISCONNECT THE
VIDEO
Figure 1 Preparing to Remove the ROS Assembly
5. REMOVE THE ROS ASSEMBLY (Figure 2).

3
LIFT THE ROS ASSEMBLY
OUT OF THE MACHINE
2
MOVE (2)
1
LOOSEN (2)
Figure 2 Removing the ROS Assembly
Replacement
1. REINSTALL THE ROS ASSEMBLY.
2. REINSTALL THE PHOTORECEPTOR BELT (REP 9-35).
3. REINSTALL ALL MACHINE COVERS.
4. PERFORM THE FOLLOWING ADJUSTMENTS:
a. ROS Image Squareness Setup (ADJ 6-2).
b. Side-to-Side (Slow Scan) Registration Setup (ADJ 8-3).
c. Top-to-Bottom (Fast Scan) Registration Setup (ADJ 8-2).
d. Belt Seam Timing (ADJ 9-8).
e. ROS Magnification Setup (ADJ 6-1).
f. ROS Power Calibration (ADJ 6-4).
g. Xerographic Setup (ADJ 9-3).

REP 6-2 VLD/Collimator Assembly 1. SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL
POWER CORDS.
Parts List on PL 6.1 2. REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).
Removal 3. REMOVE THE ROS INNER PANEL.
To see additional information go to Imaging in the DocuPrint 180 Unique Components and 4. REMOVE THE VLD ASSEMBLY (Figure 1).
Functions section.
4
3 REMOVE THE
DISCONNECT THE SCREWS (3) 5
CONNECTOR TILT THE ASSEMBLY
AWAY FROM THE
HOUSING AND REMOVE
2
REMOVE THE COVER
1
REMOVE THE
SCREWS (4)
Figure 1 Removing the VLD/Collimator Assembly
Replacement 3. PERFORM THE ROS POWER CALIBRATION (ADJ 6-4).

1. INSTALL THE VLD/COLLIMATOR ASSEMBLY. 4. PERFORM THE XEROGRAPHIC SETUP PROCEDURE (ADJ 9-3).
2. INSTALL A NEW ROS PROFILE EPROM (REP 6-6).

REP 6-3 Polygon Motor (MOT601) 2. REMOVE AND PROTECT THE PHOTORECEPTOR BELT (REP 9-35).
CAUTION
Removal Use extreme care when accessing the internal optical components of the ROS Assembly. Dirt
To see additional information go to Imaging in the DocuPrint 180 Unique Components and and smudges on the laser optical components can cause print quality problems and disturb the
Functions section. operation of the ROS system. Avoid all contact with any laser optical path component.
4. REMOVE THE POLYGON MOTOR (Figure 1).
1. SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL
POWER CORDS.
1
REMOVE THE 2
LIGHT SHIELD REMOVE THE
COVER SCREWS (7)
3
6 REMOVE THE
REMOVE THE COVER
POLYGON MOTOR
5
REMOVE THE
POLYGON MOTOR
SCREWS (3)
4
DISCONNECT THE
POLYGON MOTOR
CONNECTOR
Figure 1 Removing the Polygon Motor
Replacement REP 6-4 EOS and SOS PWBs

CAUTION Parts List on PL 6.1
Use care when handling the Polygon Motor. If the motor is dropped, it will be damaged and
cause image quality problems.
Removal
To see additional information go to Imaging in the DocuPrint 180 Unique Components and
1. INSTALL THE POLYGON MOTOR.
Functions section.
2. PERFORM THE ROS MAGNIFICATION SETUP (ADJ 6-1).
1. SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL
POWER CORDS.

3. PREPARE TO REMOVE THE SCAN DETECTOR PWBs (Figure 1).
1
DISCONNECT THE
SCAN DETECTOR
PWB CONNECTOR
2
REMOVE THE
SCREWS (4) AND
WASHERS (4)
Figure 1 Preparing to Remove the Scan Detector PWBs
4. REMOVE THE SCAN DETECTOR PWB (Figure 2).

SOS PWB EOS PWB
1
REMOVE
Figure 2 Removing the Scan Detector PWBs
Replacement REP 6-5 ROS Control Module (RCM) PWB

1. INSTALL THE SCAN DETECTOR PWB. Parts List on PL 6.1
2. REINSTALL ALL MACHINE COVERS.
Removal
3. CHECK/PERFORM THE FOLLOWING ADJUSTMENTS:
a. ROS Magnification Setup (ADJ 6-1). Functions section.
b. Top-to-Bottom (Fast Scan) Registration (ADJ 8-2).
c. If the SOS PWB has been replaced, perform ROS Power Calibration (ADJ 6-4). 1. SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL
d. Xerographic Setup (ADJ 9-3). POWER CORDS.
2. REMOVE AND PROTECT THE PHOTORECEPTOR BELT (REP 9-35).

3. REMOVE THE ROS ASSEMBLY (REP 6-1). 4. IF INSTALLING A NEW RCM PWB, REMOVE THE ROS PROFILE EPROM FROM OLD
PWB TO BE INSTALLED IN THE NEW PWB (Figure 1).
1
INSERT INDEX FINGER INTO
RING AT THE TOP OF THE
EXTRATION TOOL
RCM PWB
3
2 GENTLY SQUEEZE TOOL
INSERT THE EXTRACTION WITH THUMB AND MIDDLE
TOOL TIPS INTO SLOTS AT FINGER AND PULL UPWARD
CORNERS OF SOCKET TO REMOVE THE EPROM
Figure 1 Removing the ROS Profile EPROM

5. REMOVE THE ROS CONTROL MODULE PWB (Figure 2).
3
DISCONNECT
1
REMOVE BRACKET
2
DISCONNECT 4
DISCONNECT
5
REMOVE THE
SCREWS (7) AND
REMOVE PWB
Figure 2 Removing the ROS Control Module PWB
Replacement
1. INSTALL THE NEW ROS CONTROL MODULE PWB.
CAUTION
Ensure that the EPROM is installed in the correct position, to avoid damage to the EPROM or
the PWB. Use both indicators: the Flattened Corners on both the EPROM and the Socket; and
the Pin 1 Indicator Spot on both the EPROM and the Socket.
2. INSTALL THE ROS PROFILE EPROM (Figure 3).

EPROM
PIN 1 INDICATOR
SPOTS
EXTRACTION SLOT
FLATTENED
CORNERS
OCATOR ARROW
SOCKET
Figure 3 Installing the ROS Profile EPROM
3. ADJUST THE ROS POWER CALIBRATION (ADJ 6-4). REP 6-6 ROS Profile EPROM
Removal
Functions section.

2. REMOVE THE ROS PROFILE EPROM (Figure 1).

1
INSERT INDEX FINGER INTO
RING AT THE TOP OF THE
EXTRATION TOOL
RCM PWB
3
2 GENTLY SQUEEZE TOOL
WITH THUMB AND MIDDLE
INSERT THE EXTRACTION
FINGER AND PULL UPWARD
TOOL TIPS INTO SLOTS AT
TO REMOVE THE EPROM
CORNERS OF SOCKET
Figure 1 Removing the ROS Profile EPROM

Replacement
CAUTION
Ensure that the EPROM is installed in the correct position, to avoid damage to the EPROM or
the PWB. Use both indicators: the Flattened Corners on both the EPROM and the Socket; and
the Pin 1 Indicator Spot on both the EPROM and the Socket.
1. INSTALL THE ROS PROFILE EPROM (Figure 2).
EPROM
PIN 1 INDICATOR
SPOTS
EXTRACTION SLOT
FLATTENED
CORNERS
OCATOR ARROW
SOCKET
Figure 2 Installing the ROS Profile EPROM

REP 7-0 Feed Head Assembly
Removal
1. PULL OUT THE TRAY.
3. REMOVE THE FEED HEAD (Figure 1).
1 2
RETAINER COVER
3
DISCONNECT THE
CONNECTOR
4
5 REMOVE THE
REMOVE THE RETAINER
FEED HEAD
Figure 1 Removing the Feed Head
Replacement
1. POSITION THE STACK RELIEF SOLENOID PIN (Figure 2).

NOTE: POSITION THE
SOLENOID PIN IN
FRONT OF THE TABS
ON THE TRAY FRAME
Figure 2 Positioning the Stack Relief Solenoid Pin
2. POSITION THE FRONT BEARING IN THE SLOT OF THE BEARING MOUNT. REP 7-1 Tube Shaft
3. ENSURE THAT THE FEED HEAD MOVES FREELY, AND THAT THE WIRES DO NOT
INTERFERE WITH THE FEED HEAD CASTING.
4. IF INSTALLING A NEW FEED HEAD CHECK/ADJUST THE FOLLOWING: Removal
a. Tray 1 and 2 Feeder Drives (ADJ 4-20). 1. PULL OUT THE TRAY.
b. Auto Latch (ADJ 7-6). 2. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
c. Paper Feed Setup (ADJ 7-9). 3. REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).
4. REMOVE THE SAFETY COVERS FROM THE TUBE SHAFT.
5. REMOVE THE TUBE SHAFT (Figure 1).

4
REMOVE THE
SHAFT
3
REMOVE THE
RETAINING RING,
AND HOLD THE
PULLEY AND BELT
1 2
REMOVE THE MOVE THE IDLER
RETAINING RING, AWAY
AND LOOSEN THE
SETSCREW
Figure 1 Removing the Tube Shaft
Replacement
CAUTION
Before the idler is tightened, rotate the Takeaway Drive Belt five revolutions. In order to prevent
damage to the idler, do not manually apply extra tension to the idler.
1. INSTALL THE TUBE SHAFT.
2. CHECK/ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0).

REP 7-2 Retard Brake, Retard Roll, and Entry Guide 2. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
3. REMOVE THE RETARD BRAKE AND THE ENTRY GUIDE (Figure 1).
Removal
1
UNLATCH
SLOTS (2) ON THE

FEED HEAD
FRAME
ENTRY GUIDE
2
LIFT AND ROTATE ENTRY GUIDE
TO THE LEFT NOTCHES (2)
Figure 1 Removing the Retard Brake and Entry Guide
4. REMOVE THE RETARD ROLL (Figure 2).

REP 7-3 Feed Belt
1 Parts List on PL 7.10
REMOVE THE Removal
RETAINING RING
3. REMOVE THE SAFETY COVER FROM THE TUBE SHAFT.
CAUTION
2 Body oil from the hands can contaminate the belt. Do not place a sharp bend in the feed belt.
REMOVE THE 4. REMOVE THE FEED BELT (Figure 1).
RETARD ROLL
2 1
REMOVE REMOVE
RETARD BRAKE
5
TURN, AND PULL
Figure 2 Removing the Retard Roll
Replacement
NOTE: Ensure that the two notches on either side of the Entry Guide are installed into the slots
4
PRESS DOWN
of the Feed Head frame. 3
1. INSTALL THE RETARD ROLL AND ENTRY GUIDE. RELEASE, AND
RAISE
Figure 1 Removing the Feed Belt
Replacement
1. IF A NEW FEED BELT WAS INSTALLED PERFORM THE PAPER FEED SETUP (ADJ 7-
9).

REP 7-4 Feed Belt Latch Arm REP 7-5 Feed Belt Pulley
Removal Removal
1. PULL OUT THE TRAY. 1. PULL OUT THE TRAY.
3. REMOVE THE SAFETY COVER FROM THE FEED HEAD. 3. REMOVE THE TWO SAFETY COVERS FROM THE FEED HEAD.
4. REMOVE THE FEED BELT LATCH ARM AND THE SPRING (Figure 1). CAUTION
Body oil from the hands can contaminate the belt, and induce misfeeds. Do not bend or twist
the belt.
4 4. REMOVE THE FEED BELT (REP 7-3).
REMOVE THE
ARM AND SPRING 5. PREPARE TO REMOVE THE FEED BELT PULLEY (Figure 1).
TORSION SPRING
4
REMOVE THE
E-RING AND
THE SPACER
3
REMOVE THE 1
SHAFT UNLATCH THE
FEED BELT
2 1
REMOVE THE E- 2 LOOSEN THE
RING 3 MOVE THE SCREW
DISENGAGE
IDLER AWAY
THE BELT
FROM THE
Figure 1 Removing the Feed Belt Latch Arm and Spring BELT
Replacement
1. PERFORM THE PAPER FEED SETUP (ADJ 7-9).
2. CHECK/ADJUST THE AUTO LATCH (ADJ 7-6). Figure 1 Preparing to Remove the Feed Belt Pulley
6. REMOVE THE FEED BELT PULLEY (Figure 2).

REP 7-6 Feed Belt Idler
Removal
3
REMOVE THE FEED 1. PULL OUT THE TRAY.
BELT PULLEY 2. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
CAUTION
Body oil from the hands can contaminate the belt, and induce misfeeds.
4. REMOVE THE FEED BELT (REP 7-0).
5. REMOVE THE FEED BELT IDLER (Figure 1).
4
REMOVE THE FEED 1
BELT SPOOL REMOVE
2 BRACKET, FEED
PUSH THE BELT IDLER, AND
1 SHAFT TOWARD TWO WASHERS
CUT THE CABLE TIE THE FRONT
2
PUSH THE FEED
BELT SPOOL
BRACKET DOWN
UNTIL THE SLOT
CLEARS THE PIN
Figure 2 Removing the Feed Belt Pulley
Replacement
3
NOTE: Ensure that the collar of the Feed Clutch is installed on the flat part of the shaft on the LIFT SLOWLY,
Feed Head frame, and that the locating pin of the clutch is engaged in the casting. AND REMOVE
THE SPRING
1. INSTALL THE FEED BELT PULLEY WITH THE PART NUMBER TOWARDS THE REAR
SO THAT THE PULLEY ROTATES ONLY IN A COUNTERCLOCKWISE DIRECTION.
2. ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0).
PIN
Figure 1 Removing the Feed Belt Idler
Replacement
1. REINSTALL THE FEED BELT IDLER WITH THE PART NUMBER TOWARDS THE
REAR SO THAT THE IDLER ROTATES ONLY IN A COUNTERCLOCKWISE DIREC-
TION.

REP 7-7 Feed Belt Spool REP 7-8 Feed Clutch Pulley
Removal Removal
3. REMOVE THE FEED BELT (REP 7-3). 3. REMOVE THE SAFETY COVERS FROM THE TUBE SHAFT, AND REMOVE THE FEED
4. REMOVE THE FEED BELT SPOOL (Figure 1). HEAD.
CAUTION
Do not bend or twist the Feed Clutch Belt.
4. REMOVE THE FEED CLUTCH PULLEY (Figure 1).
2 5
REMOVE THE 1
SHAFT AND THE NOTE: REMOVE RAISE
SPOOL THE FEED CLUTCH
PULLEY
4
REMOVE THE
BELT FROM THE 2
FEED CLUTCH
LOOSEN THE
PULLEY
SCREW
1
REMOVE THE
RETAINING RING 3
MOVE THE IDLER
AWAY FROM THE
Figure 1 Removing the Feed Belt Spool
Replacement
Figure 1 Preparing to Remove the Feed Clutch
NOTE: Install the spool with the wider flange towards the front of the printer.
1. INSTALL THE SPOOL. Replacement

NOTE: Rotate the Feed Clutch Belt five revolutions. Do not apply additional tension to the
idler.
1. INSTALL THE FEED CLUTCH PULLEY.

REP 7-9 Feed Clutch Belt 2. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
3. REMOVE THE TWO FEED HEAD SAFETY COVERS, AND REMOVE THE SUPPORT
Parts List on PL 7.10 BRACKET (Figure 1).
Removal
1
REMOVE THE
TWO SAFETY
COVERS
2
REMOVE THE
SUPPORT
BRACKET
Figure 1 Removing the Two Safety Covers and the Support Bracket
CAUTION
4. REMOVE THE FEED CLUTCH BELT (Figure 2).

4 5
SECURE THE IDLER REMOVE THE FEED
AWAY FROM THE CLUTCH BELT FROM
FEED CLUTCH BELT THE FEED CLUTCH
PULLEY
3
LOOSEN THE
SCREW
2
REMOVE THE TAKEAWAY 1
ROLL SENSOR DISCONNECT THE
CONNECTOR
Figure 2 Removing the Feed Clutch Belt
Replacement REP 7-10 Feed Clutch (CL811/821)

1. ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0). Parts List on PL 7.12
Removal
3. REMOVE THE TWO FEED HEAD SAFETY COVERS AND THE SUPPORT BRACKET.
CAUTION
NOTE: Push the shaft of the Feed Clutch to the rear when removing the Feed Clutch.
4. PREPARE TO REMOVE THE FEED CLUTCH (Figure 1).

5. REMOVE THE FEED CLUTCH (Figure 1).

REP 7-11 Takeaway Idler Roll
4 Removal
REMOVE THE
FEED CLUTCH 1. PULL OUT THE TRAY.
3. REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).
CAUTION
The springs are under high tension. Holding the idler bracket while removing the screws will
prevent damage to the springs.
4. REMOVE THE TAKEAWAY IDLER ROLL (Figure 1).
1
CUT THE CABLE TIE
2
REMOVE THE
SCREWS
3
DISCONNECT THE
CONNECTOR
Figure 1 Removing the Feed Clutch
Replacement
NOTE: Ensure that the Thrust Washer is installed on the flat part of the shaft, and that the
locating pin of the clutch is engaged in the casting.
1. INSTALL THE FEED CLUTCH.

2. ADJUST THE FEED CLUTCH BELT AND THE TAKEAWAY DRIVE BELT (ADJ 7-0).

REP 7-12 Takeaway Drive Belt
REMOVE THE TAKE- 4 Removal
AWAY IDLER ROLL REMOVE THE 1. PULL OUT THE TRAY.
TENSIONING TAKEAWAY IDLER
SPRINGS (2) ROLL 2. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
3. REMOVE THE TWO FEED HEAD SAFETY COVERS AND THE SUPPORT BRACKET.
CAUTION
4. REMOVE THE TAKEAWAY DRIVE BELT (Figure 1).
2
CAUTION
REMOVE THE
1 RETAINER, BELT,
SECURE THE IDLER AND PULLEY
AWAY FROM THE
TAKEAWAY DRIVE
BELT
1
CAUTION
REMOVE THE SCREWS
2
REMOVE THE
IDLER BRACKET
3
NOTE: REMOVE
Figure 1 Removing the Takeaway Idler Roll THE WASHERS
(A)
5
REMOVE THE 4
TAKEAWAY REMOVE THE BELT
PULLEY
Figure 1 Removing the Takeaway Drive Belt

Replacement REP 7-13 Takeaway Roll
NOTE: Ensure that the tab of the large washer is positioned below the idler pulley (A). Parts List on PL 7.10
1. ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0). Removal
a. Safety Covers and Support Bracket.
b. Feed Head Assembly (REP 7-0).
c. Takeaway Idler Roll (REP 7-11).
CAUTION
Do not bend the Feed Clutch Belt or the Takeaway Drive Belt.
4. PREPARE TO REMOVE THE TAKEAWAY ROLL (Figure 1).
1
RAISE
2
LOOSEN THE
SCREW
3
SECURE THE IDLER 4
AWAY FROM THE LOOSEN THE
FEED CLUTCH BELT SETSCREW
Figure 1 Preparing to Remove the Takeaway Roll
5. REMOVE THE TAKEAWAY DRIVE BELT (REP 7-12).

6. REMOVE THE TAKEAWAY ROLL (Figure 2).

2
REMOVE THE
TAKEAWAY ROLL
1
MOVE THE SHAFT
TO THE REAR
Figure 2 Removing the Takeaway Roll
Replacement REP 7-14 Length Guide

1. ADJUST THE TAKEAWAY SHAFT ENDPLAY (ADJ 7-1). Parts List on PL 7.2
2. ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0).
Removal
1. OPEN THE PRINTER RIGHT DOOR.
NOTE: Pull out Tray 1 to access the Tray 1 and/or Tray 2 Interlock Switches.

WARNING
Ensure that the Right Door Interlock Switch is not actuated. This will prevent personal
injury, and ensure that the elevator does not move when the Elevator Interlock Switch is
cheated.
3. CHEAT THE ELEVATOR INTERLOCK SWITCH.
4. TRAY 2 ONLY: PUSH TRAY 1 INTO PRINTER.
5. RAISE THE PAPER PLATE. ENTER dC330, [7-8]. SELECT [Tray 1 Elevator UP] OR
[Tray 2 Elevator UP]. PRESS THE Continue BUTTON.

7. MOVE THE LENGTH GUIDE TO THE REAR OF THE TRAY. REP 7-15 Elevator Up Limit Switch (S714/724)
8. REMOVE THE LENGTH GUIDE (Figure 1).
Removal
5 4 1. PULL OUT THE TRAY.
REMOVE THE REMOVE THE 2. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
LENGTH GUIDE SO SCREWS (4)
THAT IT CLEARS 3. REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).
THE PAPER TRAY 4. REMOVE THE ELEVATOR UP LIMIT SWITCH (Figure 1).
3 1
DISCONNECT THE
DISCONNECT THE
CONNECTORS (2)
CONNECTOR
2
REMOVE THE SCREWS
AND THE SWITCH
1
LOOSEN THE
SCREWS (2) 2
REMOVE THE
COVER
Figure 1 Removing the Elevator Up Limit Switch
Figure 1 Removing the Length Guide Replacement

1. ADJUST THE ELEVATOR UP LIMIT SWITCH (ADJ 7-3).
Replacement
NOTE: Do not tighten the mounting screws (4) before adjusting the Length Guide.
1. INSTALL THE LENGTH GUIDE SO THAT THE GUIDE IS CENTERED (SIDE-TO-SIDE)

IN THE PAPER PLATE OPENING.
2. ADJUST THE LENGTH GUIDE POSITION (ADJ 7-4).

REP 7-16 Elevator Belt
Removal
4. REMOVE THE ELEVATOR (REP 7-25).
CAUTION
Do not press down with excessive force or move the elevator across the work surface when
the elevator is upside down. The release lever on the Length Guide may break.
NOTE: There are five screws for Tray 2.
5. REMOVE THE BOTTOM PLATE (Figure 1).
2
REMOVE THE
SCREWS (2)
3
REMOVE THE
BOTTOM PLATE
1
NOTE: REMOVE
THE SCREWS (6)
Figure 1 Removing the Bottom Plate
NOTE: The lead screw may move down when the pulley is pressed. If this occurs, hold the top
of the lead screw.
6. REMOVE THE ELEVATOR BELT (Figure 2).

4
REMOVE THE BELT
1
NOTE: REMOVE
THE RETAINERS
3
MOVE THE IDLER
AWAY FROM THE
BELT
2
REMOVE THE PULLEYS
AND BELT
Figure 2 Removing the Elevator Belt
Replacement REP 7-17 Elevator Drive Motor (MOT711/721)

1. PERFORM THE PAPER FEED SETUP (ADJ 7-9). Parts List on PL 7.7
Removal
NOTE: The Elevator Drive Motor of Tray 2 can be removed without removing the elevator. For
better access, remove the elevator.
4. TRAY 1 ONLY: REMOVE THE ELEVATOR (REP 7-25).
5. TRAY 1 ONLY: REMOVE THE BOTTOM PLATE FROM THE ELEVATOR (Figure 1).
of the lead screw.
6. REMOVE THE ELEVATOR MOTOR (Figure 1).

1
2
REMOVE THE NOTE: PUSH DOWN
RETAINING RINGS THE PULLEY
5
DISCONNECT,
AND REMOVE
4
REMOVE THE
3 SCREWS (4)
REMOVE THE
PULLEYS (2) AND
THE BELT
Figure 1 Removing the Elevator Motor
Replacement
1. ADJUST THE ELEVATOR DRIVE BELT (ADJ 7-11).

REP 7-18 Elevator MOTOR Capacitor (C711/721) NOTE: There are five screws for Tray 2.
Parts List on PL 7.7 5. REMOVE THE BOTTOM PLATE (Figure 1).

Removal WARNING
1. OPEN THE PRINTER RIGHT DOOR. Discharge the Elevator Motor Capacitor with a screwdriver before touching the termi-
nals. This will prevent an electrical shock.
6. REMOVE THE ELEVATOR MOTOR CAPACITOR (Figure 1).
1 3
WARNING REMOVE THE
DISCONNECT THE CAPACITOR
LEADS
410A
GROUND WIRE 410
411A
411
2
2 REMOVE THE
SCREWS (4)
Figure 1 Removing the Elevator Motor Capacitor

REP 7-19 Lock Arm and Lock Actuator REP 7-20 Stack Relief Solenoid (SOL811/821)
Removal Removal
3. REMOVE THE TRAY 1 AND 2 FRONT COVERS (REP 7-22). 3. REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).
4. REMOVE THE TRAY LOCK ARM AND LOCK ACTUATOR (Figure 1). 4. REMOVE THE STACK RELIEF SOLENOID (Figure 1).
3
REMOVE THE
SOLENOID
ASSEMBLY
CAUTION
LOCK ACTUATOR
1
LOOSEN THE
SETSCREW 1
REMOVE THE
2 SCREWS (2)
DISCONNECT THE
2 CONNECTOR
REMOVE THE
SHAFT
Figure 1 Removing the Tray Lock Arm and Lock Actuator Figure 1 Removing the Stack Relief Solenoid
Replacement Replacement
CAUTION 1. PERFORM THE PAPER FEED SETUP (ADJ 7-9).
Do not allow the actuator to bind. Ensure that the Lock Actuator Return Spring and the Lock
Actuator are under the tab on the Paper Plate Support.
1. REINSTALL THE LOCK ARM AND ACTUATOR.

REP 7-21 Stack Height Sensor (Q711/721) REP 7-22 Tray 1 and 2 Front Covers
Removal Removal
3. REMOVE THE FEED HEAD ASSEMBLY (REP 7-0). 3. REMOVE THE FRONT COVER (Figure 1).
4. REMOVE THE TRAY 1 AND 2 FRONT COVERS (REP 7-22).
NOTE: Make a scribe mark around the washers (2) before removing the screws (2).
THE LABEL PANEL
5. REMOVE THE STACK HEIGHT SENSOR (Figure 1).
2
DISCONNECT THE
CONNECTOR
1
NOTE: REMOVE
THE SCREWS (2)
1
LOOSEN THE
2 3 SCREWS (2)
DISCONNECT, REMOVE THE
AND REMOVE THE COVER
SENSOR
Figure 1 Removing the Front Cover
Figure 1 Removing the Stack Height Sensor
Replacement
NOTE: Install the sensor so that the washers of the mounting screws are aligned with the
scribe marks on the frame.
1. INSTALL THE SENSOR IN THE ORIGINAL POSITION.


REP 7-23 Lead Screws (Front), Bearings, and the Lift Nuts
Removal
CAUTION
6. RAISE THE PAPER PLATE HALF WAY UP THE LEAD SCREWS.
7. REMOVE THE TRAY FRONT COVER AND THE LABEL PANEL.
8. REMOVE THE LEAD SCREW PULLEY (Figure 1).
3 1
REMOVE THE SECURE THE
PULLEYS (2), THE IDLER AWAY
SPRINGS (2), AND FROM THE BELT
THE SPACERS (2)
2
REMOVE THE
RETAINING RINGS (2)
Figure 1 Removing the Lead Screw Pulley
9. REMOVE THE PAPER PLATE (Figure 2).

2
REMOVE THE
SCREWS (5)
PAPER PLATE PAPER PLATE

SUPPORT
1
REMOVE THE NUT
AND GROUND WIRE
4
REMOVE THE
3 PAPER PLATE
REMOVE THE NUT
Figure 2 Removing the Paper Plate
10. REMOVE THE LEAD SCREW (Figure 3).

3 2
1 3 HOLD THE NUT
REMOVE THE REMOVE THE INSTALL THE
RETAINER LEAD SCREW RETAINER
1
INSTALL THE
LEAD SCREW AND
THE LIFT NUT
2
REMOVE THE
SUPPORT 4
ROTATE THE
BEARING LEAD SCREW TO
CENTER THE NUT
LATCH ASSEMBLY
Figure 3 Removing the Lead Screw Figure 4 Installing the Lead Screw
11. REMOVE THE LIFT NUT FROM THE LEAD SCREW. 3. INSTALL THE PAPER PLATE SUPPORT (Figure 5).
12. REMOVE THE CLAMPS AND REMOVE THE BEARINGS, IF REQUIRED.
Replacement
1. INSTALL THE LIFT NUT AND THE RETAINER ONTO THE LEAD SCREW.
2. INSTALL THE LEAD SCREW, AND POSITION THE LIFT NUT (Figure 4).

REP 7-24 Lead Screws (Rear), Bearings, and the Lift Nuts
2 Removal
INSTALL THE SUP- 1
PORT CENTER THE 1. OPEN THE PRINTER RIGHT DOOR.
OTHER NUT ON 2. PULL OUT THE TRAY.
THE LEAD SCREW 3. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
CAUTION
5. REMOVE THE BOTTOM PLATE FROM THE ELEVATOR (Figure 1).

6. RAISE THE PAPER PLATE HALF WAY UP BY MOVING THE ELEVATOR DRIVE BELT.
7. REMOVE THE PULLEY FROM EITHER THE LEFT OR THE RIGHT LEAD SCREW (Fig-
ure 1).
3
ROTATE THE LEAD
GROUND STRAP 1 2
SCREWS UNTIL THE SECURE THE REMOVE THE
SUPPORT IS LEVEL IDLER AWAY PULLEYS AND
FROM THE BELT THE BELT
Figure 5 Installing the Paper Plate Support
NOTE: The retainer of the left rear lead screw must be removed in order to rotate the lift nut.
4. ROTATE THE REAR LIFT NUTS TO THE CENTER OF THE LEAD SCREWS.
5. INSTALL THE SPACER, SPRING, AND PULLEY.
NOTE: Ensure that the lead screw pulleys do not rotate in the clockwise direction.
6. INSTALL THE ELEVATOR DRIVE BELT, AND POSITION THE IDLER.

4
REMOVE THE
7. INSTALL THE BOTTOM PLATE. RETAINER, PULLEY,
8. INSTALL THE ELEVATOR. AND BELT
3
NOTE: The Paper Plate will be reinstalled when performing the Paper Plate Parallelism in the REMOVE THE
Paper Feed Setup Series. Check/adjust the Feed Belt Tension first, then proceed to the Paper PULLEY, SPRING,
Plate Parallelism Adjustment. AND SPACER
Figure 1 Removing the Lead Screw Pulleys
8. REMOVE THE PAPER PLATE (Figure 2).

9. REMOVE THE LEFT OR THE RIGHT LEAD SCREW (Figure 2).
2 BEARING (2)
REMOVE THE
RETAINERS
CLAMP (2)
1
3 REMOVE THE
REMOVE THE SUPPORTS
LEAD SCREWS
Figure 2 Removing the Lead Screw
10. REMOVE THE LIFT NUT FROM THE LEAD SCREW.

11. REMOVE THE CLAMPS, AND REMOVE THE BEARINGS IF REQUIRED (Figure 2).
Replacement
NOTE: Perform Steps 1 and 2 to reinstall the left and the right rear lead screws.
1. INSTALL THE LIFT NUT AND THE RETAINER ONTO THE LEAD SCREW.
NOTE: Do not install the left rear lead screw retainer until you position the lift nut.
2. INSTALL THE LEAD SCREW, AND POSITION THE LIFT NUT (Figure 3).

REP 7-25 Elevator Assembly
INSTALL THE Removal
RETAINER
NOTE: The two screws secure the ribbon cable to the cover only.
4. PREPARE TO ACCESS THE RIBBON CABLE CONNECTOR (Figure 1).
3 2
LIFT AND PUSH TO
NOTE: LOOSEN THE REAR
THE SCREWS (2)
3 1
ROTATE THE LIFT INSTALL THE
NUT UNTIL IT LEAD SCREW
TOUCHES THE TOP
OF THE ELEVATOR
Figure 3 Installing the Lead Screw
3. INSTALL THE SPACER, SPRING, AND PULLEY.
NOTE: Ensure that the lead screw pulleys do not rotate in the clockwise direction.
4. INSTALL THE ELEVATOR BELT, AND POSITION THE IDLER.

5. INSTALL THE ELEVATOR DRIVE BELT AND PULLEYS.
6. INSTALL THE BOTTOM PLATE.
7. INSTALL THE ELEVATOR.
8. PERFORM THE PAPER FEED SETUP (ADJ 7-9). 4 1
PUSH THE SCREWS
REMOVE THE
THROUGH THE HOLES
SCREW
IN THE COVER
Figure 1 Preparing to Access the Ribbon Cable Connector

5. DISCONNECT THE RIBBON CABLE CONNECTORS (Figure 2).
1 2
TURN THE COVER
DISCONNECT
ON ITS SIDE
THE CABLE
1
PULL THE RIBBON
OUT OF THE ELEVA-
2 TOR
PUSH (2), AND
REMOVE THE
ELEVATOR
3 Figure 3 Removing the Elevator

PUSH THE GUIDE
AND CABLE DOWN
INTO THE PRINTER Replacement
1. HOLD THE RAILS, AND SLIDE THE ELEVATOR IN UNTIL IT IS SECURED BY THE
CLIPS.
NOTE: To prevent the guide from being misaligned with the ribbon cable support, do not pull
the plastic guide into the elevator farther than necessary.
2. INSTALL THE RIBBON CABLE AND GUIDE (Figure 4).
Figure 2 Disconnecting the Ribbon Cable Connectors
6. REMOVE THE ELEVATOR (Figure 3).

2 3 2 3
CONNECT THE PUSH THE RIBBON INSTALL THE
CONNECTORS (2) NOTE: PULL THE
AND TABS UNDER SCREW
GUIDE UNTIL THE
THE FRAME
TAB PASSES THE
COVER STOP
THE COVER STOP 1

SECURE THE SCREWS
1 IN THE SLOTS
PULL THE RIBBON
THROUGH THE REAR
OF THE ELEVATOR
Figure 4 Installing the Ribbon Cable and Guide Figure 5 Installing the Ribbon Cable Clamp on the Cover
NOTE: Ensure that the clamp is properly positioned so that tab is in the slot in the cable, then 4. INSTALL THE FEED HEAD ASSEMBLY (REP 7-0).
secure the clamp to the cover. 5. IF A NEW ELEVATOR WAS INSTALLED CHECK/ADJUST THE FOLLOWING:
3. INSTALL THE RIBBON CABLE CLAMP AND THE COVER (Figure 5). a. Auto Latch (ADJ 7-6).
b. Paper Feed Setup (ADJ 7-9).

REP 7-26 Paper Plate 4. TRAY 2 ONLY: PUSH TRAY 1 INTO THE PRINTER.
5. RAISE THE PAPER PLATE. ENTER dC330, AND SELECT [Tray 1 Elevator UP] OR
Parts List on PL 7.2 [Tray 2 Elevator UP]. PRESS THE Continue BUTTON.
Removal 6. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
NOTE: Do not remove the supports from the Lift Nuts. Removing the supports may misadjust
NOTE: To improve access to the Tray 2 Interlock Switch, pull out Tray 1. the paper plate parallelism.
2. PULL OUT THE TRAY, AND REMOVE THE PAPER. 7. REMOVE THE PAPER PLATE (Figure 1).
WARNING
injury, and ensure that the elevator does not move when the Tray Interlock Switch is
cheated.
3. CHEAT THE TRAY 1 OR TRAY 2 INTERLOCK SWITCH.
2
REMOVE THE
SCREWS (5)
PAPER PLATE PAPER PLATE

SUPPORT
1
REMOVE THE NUT
AND GROUND WIRE
4
REMOVE THE
PAPER PLATE
3
REMOVE THE NUT
Figure 1 Removing the Paper Plate
Replacement REP 7-27 Tray Capacity PWB

1. INSTALL THE PAPER PLATE WITH THE LENGTH GUIDE IN THE CENTER (SIDE-TO- Parts List on PL 7.3
SIDE) OF THE PAPER PLATE OPENING.
2. PERFORM THE PAPER FEED SETUP SERIES (ADJ 7-9).
Removal

2. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. REP 7-28 Elevator Drive Belt
3. REMOVE THE TRAY 1 AND 2 FRONT COVERS (REP 7-22).
4. REMOVE THE PWB (Figure 1).
Removal
1 3. REMOVE THE ELEVATOR ASSEMBLY OF TRAY 1 (REP 7-25).
REMOVE THE
SCREWS (4) CAUTION
NOTE: There are only five screws on Tray 2.
4. REMOVE THE BOTTOM PLATE OF THE ELEVATOR FROM TRAY 1 (Figure 1).
of the lead screw.
5. REMOVE THE ELEVATOR DRIVE BELT (Figure 1).
1
2 NOTE:
REMOVE THE PWB PUSH DOWN
THE PULLEY
Figure 1 Removing the PWB
3
REMOVE THE
PULLEYS (2)
AND BELTS
2
REMOVE THE
RETAINING RINGS (2)
Figure 1 Removing the Elevator Drive Belt

Replacement
1. ADJUST THE ELEVATOR DRIVE BELT (ADJ 7-10).

REP 7-34 HCT Elevator Assembly 3. REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.
4. LOWER THE FS RELAY PANEL.
Removal NOTE: Position the Harness Bridge so that it will not be damaged as the Elevator Assembly is
removed.
1. PULL OUT THE HCT.
2. REMOVE ALL PAPER FROM THE TRAY. 5. PREPARE TO REMOVE THE ELEVATOR ASSEMBLY (Figure 1).
1 HARNESS BRIDGE
6
REMOVE SAFETY REMOVE THE
SHIELD GROUND SCREW
5
NOTE: REMOVE
THE BOLTS (2)
4
DISCONNECT J445
2 3
DISCONNECT J414 DISCONNECT J476
Figure 1 Preparing To Remove the Elevator Assembly
NOTE: A Slide Latch is located on each slide.
6. PULL UP ON THE SLIDE LATCHES AND PULL OUT AND REMOVE THE HCT.

Replacement REP 7-35 HCT Elevator Drive Belt
CAUTION Parts List on PL 7.18
Do not damage the Harnesses when reinstalling the HCT.
Removal
NOTE: The Elevator Assembly will push in hard when it is reinstalled. When reinstalling the 1. PULL OUT THE APPROPRIATE HCT.
Elevator Assembly, ensure that the Rails on the Elevator Assembly are aligned with the slides. 2. REMOVE THE HCT BOTTOM COVER.
1. PUSH THE ELEVATOR ASSEMBLY INTO THE SLIDES UNTIL THE SLIDES ARE 3. LOWER THE HORIZONTAL TRANSPORT DOOR.
LATCHED. 4. LOOSEN THE ELEVATOR DRIVE BELT IDLER.
NOTE: It may be necessary to disconnect one end of the Idler Spring before removing the
Drive Belt.
5. REMOVE THE ELEVATOR DRIVE BELT.

Replacement
1. REINSTALL THE ELEVATOR DRIVE BELT.
2. CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).

REP 7-36 HCT Elevator Drive Motor (MOT731) 8. DISCONNECT AND REMOVE THE ELEVATOR DRIVE MOTOR.
Parts List on PL 7.18 Replacement

1. REINSTALL THE ELEVATOR DRIVE MOTOR.
Removal
2. REINSTALL THE ELEVATOR DIVE BELT.
1. PULL OUT THE APPROPRIATE HCT.
3. REMOVE THE ELEVATOR DRIVE BELT (REP 7-35). REP 7-37 HCT Lead Screws
4. REMOVE THE APPROPRIATE STACKER LOWER REAR COVER. Parts List on PL 7.17
5. LOWER THE FS RELAY PANEL. Removal
6. REMOVE THE AC SAFETY SHIELD. 1. PULL OUT THE APPROPRIATE HCT.
NOTE: Position the HCT towards the rear of the FS to allow access to the four motor mounting 2. REMOVE THE PAPER PLATE (REP 7-39).
screws. 3. REMOVE THE ELEVATOR DRIVE BELT (REP 7-35).
7. REMOVE THE FOUR SCREWS SECURING THE ELEVATOR DRIVE MOTOR. NOTE:
4
REMOVE THE
1 LEAD SCREW
REMOVE THE
SCREW AND
THE BUSHING
2 3
REMOVE THE LIFT THE LEAD SCREW UNTIL THE
SCREW AND THE LOWER BEARING CLEARS THE
BEARING RETAINER ELEVATOR ASSEMBLY BASE
Replacement 3. CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).
1. REINSTALL THE ELEVATOR DRIVE BELT.
2. REINSTALL THE PAPER PLATE.

REP 7-38 HCT Switch Assembly 6. REMOVE THE HCT PAPER PLATE (REP 7-39).
7. REMOVE THE SWITCH ASSEMBLY (Figure 2).
Removal
2. REMOVE THE APPROPRIATE FS LOWER REAR COVER.
3. PREPARE TO REMOVE THE SWITCH ASSEMBLY (Figure 1).
1
REMOVE THE
2 SCREWS (2)
REMOVE SWITCH
ASSEMBLY
1 2
DISCONNECT DISCONNECT
Figure 2 Removing the Switch Assembly
Replacement
1. REINSTALL THE SWITCH ASSEMBLY.
Figure 1 Preparing to Remove the Switch Assembly 3. CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).
4. CHECK/ADJUST THE LOW PAPER SENSOR (Q738) (ADJ 7-33).
4. MANUALLY UNLATCH AND PUSH OUT THE HCT.
5. REMOVE ALL OF THE PAPER FROM THE TRAY.

REP 7-39 HCT Paper Plate REP 7-40 HCT Slides
Removal Removal
1. PULL OUT THE APPROPRIATE HCT. 1. REMOVE THE ELEVATOR ASSEMBLY (REP 7-34).
2. REMOVE THE PAPER FROM THE TRAY. 2. REMOVE THE TRAY CLOSED SWITCH (S730) AND MOUNTING BRACKET FROM
3. SWITCH OFF THE PRINTER POWER. THE REAR OF THE LEFT SLIDE.
4. HANDCRANK THE PAPER PLATE DOWN TO APPROXIMATELY THE HALFWAY POSI- 3. REMOVE THE TWO BOLTS SECURING EACH SLIDE, AND REMOVE THE SLIDES.
TION. Replacement
NOTE: Secure the Retaining Clips, located under the Paper Plate, when removing the four 1. REPLACE THE RIGHT SLIDE, AND TIGHTEN THE TWO BOLTS.
screws. 2. REPLACE THE LEFT SLIDE. DO NOT COMPLETELY TIGHTEN THE TWO BOLTS AT
THIS TIME.
5. REMOVE THE FOUR SCREWS AND RETAINING CLIPS SECURING THE PAPER
3. REPLACE THE ELEVATOR ASSEMBLY.
PLATE.
4. POSITION THE LEFT SLIDE FOR THE BEST ELEVATOR ASSEMBLY MOVEMENT.
6. REMOVE THE PAPER PLATE.
5. TIGHTEN THE TWO BOLTS SECURING THE LEFT SLIDE.
Replacement

REP 7-41 HCT Front Cover REP 7-42 Tray Capacity PWB
Removal Removal
1. PULL OUT THE HCT. 1. PULL OUT THE APPROPRIATE HCT.
2. SWITCH OFF THE PRINTER POWER. 2. SWITCH OFF THE PRINTER POWER.
3. REMOVE THE MANOMETER. 3. REMOVE THE HCT FRONT COVER (REP 7-41).
4. SCRIBE A LINE ON EACH MOUNTING BRACKET ALONG THE EDGE OF EACH 4. REMOVE THE FOUR SCREWS SECURING THE TRAY CAPACITY PWB.
COVER SUPPORT BRACKET. 5. REMOVE THE TRAY CAPACITY PWB.
5. LOOSEN THE FOUR NUTS SECURING THE FRONT COVER. Replacement
NOTE: The Tray Capacity PWB Safety Shield may have to be removed to disconnect the con- NOTE: The Tray Unlock Button may fall out when the PWB is removed. Ensure that the button
nector. is reinstalled properly, before replacing the capacity PWB.
6. REMOVE THE FRONT COVER FROM THE SUPPORT BRACKETS AND DISCON-
1. REINSTALL THE TRAY CAPACITY PWB.
NECT THE TRAY CAPACITY PWB CONNECTOR.
2. REINSTALL THE HCT FRONT COVER.
Replacement
1. REINSTALL THE FRONT COVER.
2. ADJUST THE FRONT COVER IF REQUIRED.

REP 8-0 Vertical Transport Assembly
MAGNETIC SKIS 1
Removal INSTALL GUIDE
To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Compo- BETWEEN VERTICAL
nents and Functions section. XPORT BELTS AND
MAGNETIC SKIS AND
TURN THE BAFFLE
NOTE: See PL 8.1 through PL 8.32.

2. OPEN THE PRINTER FRONT DOORS.
3. REMOVE THE PRINT TRANSPORT INNER PANEL.
4. REMOVE THE SPRING FROM THE TURN BAFFLE.
NOTE: Ensure plastic wear element does not fall out of coupling. Also ensure that the Switch
Actuator does not get damaged.
5. REMOVE THE VERTICAL TRANSPORT ASSEMBLY (Figure 1).
2
DISCONNECT
4
REMOVE THE
TRANSPORT
SWITCH
ACTUATOR
3
REMOVE SCREWS (2)
Figure 1 Removing the Transport
Replacement
1. CHECK THAT THE SWITCH ACTUATOR IS TIGHT. IF NOT, PUSH ON SPRING
RETAINER TO TIGHTEN.
NOTE: The Guide for the Replacement is stored in the parts cabinet.
NOTE: Ensure that plastic wear element is positioned fully clockwise in coupling when replac-
ing transport.
2. INSTALL THE GUIDE AGAINST THE MAGNETIC SKIS, AND CAREFULLY PUSH THE
VERTICAL TRANSPORT INTO THE PRINTER.

3. FOR NEW BELT INSTALLATION ONLY: REP 8-1 Vertical Transport Drive Belt
a. Enter [SCP], [HFSI Status].
b. Select [P08-808 Vertical Transport Belts], and press [Reset].
4. CHECK/ADJUST THE NIP RELEASE SOLENOID (ADJ 8-6).
Removal
To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Compo-

2. PULL THE VERTICAL TRANSPORT ASSEMBLY OUT APPROXIMATELY 1 INCH (REP
8-0).
3. REMOVE THE BELT (Figure 1).
2
REMOVE THE
BELT
1
LOOSEN THE
SCREW

REP 8-2 Turn Baffle 2. OPEN THE PRINTER FRONT DOORS.
3. REMOVE THE PRINT TRANSPORT INNER PANEL.
4. REMOVE THE REGISTRATION TRANSPORT INNER PANEL.
Removal 5. REMOVE THE VERTICAL TRANSPORT (REP 8-0).
NOTE: See PL 8.1 through PL 8.32. 6. REMOVE THE NIP RELEASE SOLENOID ASSEMBLY AND THE IDLER BRACKET
(REP 8-7).
7. REMOVE THE TURN BAFFLE (Figure 1).
CAUTION
4
REMOVE THE
BAFFLE
3
REMOVE THE
2 SCREW
1 DISENGAGE THE
RAISE THE HANDLE SPRING
Figure 1 Removing the Turn Baffle
Replacement 2. INSTALL THE NIP RELEASE ASSEMBLY.

1. REPLACE THE TURN BAFFLE. 3. ADJUST THE NIP RELEASE SOLENOID (ADJ 8-6).

REP 8-3 Registration Transport Assembly
Removal

a. Cross Rolls Assembly (REP 8-4).
b. Vertical Transport Assembly (REP 8-0).
c. Disconnect the cable on the Nip Release Sol851 (REP 8-6).
4. DISCONNECT THE ELECTRICAL CONNECTORS FOR THE REGISTRATION TRANS-
PORT (REAR) (Figure 1).
2 3
DISCONNECT (2) RETRACT CABLES
THROUGH THE
HOLE IN FRAME
1
OPEN THE AC DISTRIBUTION
PANEL
Figure 1 Disconnecting the Transport (Rear)
5. REMOVE THE REGISTRATION TRANSPORT (Figure 2).

3
REMOVE THE 2
4 BAFFLES (2) RELEASE THE
REMOVE NUTS (2), AND HINGE CLIPS (2)
RAISE BRACKET
1
DISCONNECT
GROUND WIRE
PRETRANSFER
BAFFLE
CAUTION
8
REMOVE THE
BRACKET EASILY TRANSPORT
5 BROKEN
DISCONNECT THE
6 CAUTION
ELECTRICAL CON-
NECTIONS (5) REMOVE THE SHOULDER ENSURE THE CABLES
SCREW AT THE NIP SOLENOID
7 DO NOT CATCH ON
BRACKET TO DISCONNECT REMOVE THE THE MACHINE FRAME
THE CABLE BETWEEN THE SCREWS (2)
BRACKET AND THE MAGNETIC
SKIS
Figure 2 Removing the Registration Transport
Replacement 4. CLOSE THE AC DISTRIBUTION PANEL, AND REINSTALL THE PRINTER RIGHT
REAR COVER.
CAUTION
5. INSTALL THE VERTICAL TRANSPORT ASSEMBLY (REP 8-0).
Ensure that the white plastic Transition Strips (6) are all positioned into the opening of the Pre-
transfer Baffle, and that the black plastic Lift Block is positioned under the Pretransfer Baffle 6. INSTALL THE TURN BAFFLE (REP 8-2).
Upper Baffle. 7. INSTALL THE CROSS ROLLS ASSEMBLY (REP 8-4).
1. REPLACE THE REGISTRATION TRANSPORT. 8. SWITCH ON THE PRINTER.
2. INSTALL THE BRACKET, AND TIGHTEN HARDWARE. 9. ADJUST THE NIP RELEASE SOLENOID (ADJ 8-6).
3. CONNECT THE ELECTRICAL CONNECTORS FOR THE REGISTRATION TRANS- 10. IF INSTALLING A NEW REGISTRATION TRANSPORT ASSEMBLY CHECK/ADJUST
PORT. THE FOLLOWING:

a. Pretransfer Baffle (ADJ 8-1). REP 8-4 Cross Rolls Assembly
b. Top to Bottom Registration (ADJ 8-2).
c. Side to Side Registration (ADJ 8-3).
Removal

3. REMOVE THE REGISTRATION TRANSPORT INNER PANEL.
4. REMOVE THE CROSS ROLLS ASSEMBLY (Figure 1).
1
REMOVE (4)
2
DISCONNECT THE
CONNECTOR WHILE
REMOVING THE
ASSEMBLY
Figure 1 Removing the Cross Rolls Assembly
5. FOR NEW CROSS ROLL INSTALLATION ONLY: REP 8-5 Pretransfer Baffle
a. Enter Printer Diagnostics, [SCP], [HFSI Status].
b. Select [P08-816 Registration Cross Rolls], and press [Reset].

Parts List on PL 8.8 2. REMOVE BAFFLE (Figure 1).
Removal
1. REMOVE PHOTORECEPTOR BELT (REP 9-35).
3
REMOVE PRETRANSFER
BAFFLE
2 TRANSITION
LOWER THE BELT STRIPS (6)
MODULE
UPPER BAFFLE
1 THE LIFT BLOCK

REMOVE SCREW
Figure 1 Removing the Pretransfer Baffle
Replacement
CAUTION
Ensure that the Pretransfer Baffle is positioned under the white plastic Transition Strips (6),
and that the Upper Baffle is positioned over the black plastic Lift Block (Figure 1).
Also ensure that the Baffle is latched into the spring clip before pushing the Photoreceptor
Drawer back into the Printer.
1. REPLACE THE BAFFLE.
2. INSTALL THE PHOTORECEPTOR BELT.
3. CHECK/ADJUST THE PRETRANSFER BAFFLE (ADJ 8-1).

REP 8-6 NIP Release Solenoid (SOL851) Parts List on PL 8.5
Removal

2. REMOVE THE NIP RELEASE SOLENOID (Figure 1).
FRONT VIEW
3
REMOVE THE
SOLENOID
NOTE: LINKAGE
1
DISCONNECT THE
CONNECTOR 2
REMOVE THE
SCREWS (2)
Figure 1 Removing the Nip Release Solenoid (SOL851)
Replacement 1. INSTALL THE NEW NIP RELEASE SOLENOID.

2. CHECK/ADJUST THE NIP RELEASE SOLENOID (SOL851) (ADJ 8-6).
NOTE: Ensure that the pin in the solenoid plunger is seated in the linkage.

REP 8-7 NIP Release Solenoid Assembly and Idler Bracket 2. REMOVE THE NIP RELEASE SOLENOID ASSEMBLY AND THE IDLER BRACKET
(Figure 1).
Removal
2
REMOVE THE SCREW,
3 AND DISCONNECT
REMOVE THE THE CABLE
NUTS (2)
1
REMOVE THE
SPRING
FRONT VIEW
4 6
DISCONNECT THE REMOVE THE NUTS AND
CONNECTOR THE IDLER BRACKET
5
REMOVE THE
SOLENOID
ASSEMBLY
Figure 1 Removing the Nip Release Solenoid Assembly and the Idler Bracket
Replacement NOTE: Do not tighten the mounting nuts for the solenoid assembly at this time.
1. INSTALL THE NEW IDLER BRACKET. 2. INSTALL THE NEW NIP RELEASE SOLENOID ASSEMBLY AND IDLER BRACKET.
3. CHECK/ADJUST THE NIP RELEASE SOLENOID (ADJ 8-6).

REP 8-15 Blower Motor (MOT832)/O-Ring Pulley 5. REMOVE THE BLOWER MOTOR (Figure 2).

Removal
1
REMOVE THE
2. REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75). SCREWS (4)
3. REMOVE THE O-RING DRIVE BELT.
NOTE: If removing just the O-Ring Pulley, perform only steps 2 and 3 of Figure 1.
4. PREPARE TO REMOVE THE BLOWER MOTOR (Figure 1).
2
ROTATE CENTER SCREW WITH
SCREWDRIVER WHILE HOLDING
O-RING PULLEY TO LOOSEN
2
REMOVE THE MOTOR
Figure 2 Removing the Blower Motor
Replacement
3 1
UNSCREW AND DISCONNECT 1. REINSTALL THE BLOWER MOTOR.
REMOVE PULLEY
NOTE: Ensure that the O-Ring Pulley is reinstalled with the Smaller diameter groove facing
towards the rear of the FS.
2. REINSTALL THE O-RING PULLEY.

3. REINSTALL THE O-RING DRIVE BELT (REP 8-17).
Figure 1 Preparing to Remove the Blower Motor

REP 8-16 Blower Assembly Replacement
Parts List on PL 8.15 1. REINSTALL THE BLOWER ASSEMBLY.
2. REINSTALL THE O-RING DRIVE BELT (REP 8-17).
Removal
3. REMOVE THE TWO AIR DUCTS FROM THE BLOWER ASSEMBLY.
4. REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).
5. REMOVE THE O-RING DRIVE BELT.
6. REMOVE THE BLOWER ASSEMBLY (Figure 1).
1
REMOVE THE
SCREWS (3)
2
REMOVE BLOWER
ASSEMBLY
Figure 1 Removing the Blower Assembly

REP 8-17 O-Ring Drive Belt REP 8-18 Feeder Clutch
Removal Removal
2. REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75). 2. REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).
3. REMOVE THE O-RING DRIVE BELT. 3. REMOVE THE FEEDER MOTOR DRIVE BELT (REP 8-21).
Replacement 4. REMOVE THE APPROPRIATE FEEDER ASSEMBLY (REP 8-24).
1. IF THE O-RING DRIVE BELT IS BEING INSTALLED ON A 60 HZ MACHINE, ROUTE 5. REMOVE THE FEEDER MAIN DRIVE BELT.
THE BELT AROUND THE REAR GROOVE OF THE BLOWER PULLEY AND AROUND 6. REMOVE THE FEEDER CLUTCH ASSEMBLY (Figure 1).
THE SMALLER DIAMETER GROOVE OF THE BLOWER MOTOR PULLEY.
2. IF THE O-RING DRIVE BELT IS BEING INSTALLED ON A 50 HZ MACHINE, ROUTE
THE BELT AROUND THE FRONT GROOVE OF THE BLOWER PULLEY AND AROUND
THE LARGER DIAMETER GROOVE OF THE BLOWER MOTOR PULLEY. 2 1
REMOVE THE DISCONNECT
BOLTS (2)
3
REMOVE CLUTCH
ASSEMBLY
Figure 1 Removing the Feeder Clutch
7. REMOVE THE TWO SCREWS SECURING THE FEEDER CLUTCH TO THE MOUNT-
ING BRACKET AND REMOVE THE CLUTCH.
Replacement
1. REINSTALL THE FEEDER MAIN DRIVE BELT (REP 8-22).
2. REINSTALL THE FEEDER ASEMBLY.
3. REINSTALL THE FEEDER MOTOR DRIVE BELT.
4. REINSTALL THE VERTICAL TRANSPORT.

REP 8-20 Feeder Main Drive Motor (MOT831)
Removal 2
LOOSEN IDLER
1. SWITCH OFF THE PRINTER POWER. MOUNTING
2. REMOVE THE APPROPRIATE STACKER REAR DRIVES INNER COVER (PL 11.21 SCREW
3. REMOVE THE APPROPRIATE STACKER UPPER REAR COVER AND LOWER REAR
COVER.
4. SWING OUT THE STEPPER PWB PANEL.
5. REMOVE THE STACKER REAR INNER COVER (PL 11.21
NOTE: In Figure 1, one Capacitor has been removed for clarity.
6. PREPARE TO REMOVE THE FEEDER MAIN DRIVE MOTOR (Figure 1).
1
DISCONNECT
Figure 1 Preparing to Remove the Motor
7. REMOVE THE FEEDER MAIN DRIVE MOTOR (Figure 2).

REP 8-21 Feeder Motor Drive Belt
REMOVE THE Removal
SCREWS (4)
3. REMOVE THE APPROPRIATE STACKER REAR DRIVES INNER COVER (PL 11.21
NOTE: In Figure 1, one Capacitor has been removed for clarity.
4. LOOSEN THE FEEDER MOTOR DRIVE BELT IDLER (Figure 1).
3
REMOVE THE
MOTOR 1
REMOVE THE
DRIVE BELT
LOOSEN THE
IDLER MOUNTING
SCREW
Figure 2 Removing the Motor
Figure 1 Loosening the Idler
5. REMOVE THE FEEDER MOTOR DRIVE BELT.

REP 8-22 Feeder Main Drive Belt
Removal
3. REMOVE THE FEEDER MOTOR DRIVE BELT (REP 8-21).
4. REMOVE THE APPROPRIATE FEEDER ASSEMBLY (REP 8-24).
5. REMOVE THE FEEDER MAIN DRIVE BELT.
Replacement
NOTE: Ensure that the Drive Belt is routed around all of the components shown in Figure 1 in
preparation for the Vertical Transport reinstallation.
1. REINSTALL THE FEEDER MAIN DRIVE BELT (Figure 1).
1
ROUTE THE BELT
AROUND ALL THE
COMPONENTS
2
REPOSITION THE
TABS IN REAR AS
SHOWN
Figure 1 Routing the Drive Belt

REP 8-24 Feeder Assembly 2. REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.
3. MANUALLY UNLATCH THE HIGH CAPACITY TRAY, AND PUSH IT OPEN.
4. BEGIN TO REMOVE THE FEEDER ASSEMBLY (Figure 1).
Removal
2
DISCONNECT
1
REMOVE THE
AIR DUCTS
Figure 1 Preparing to Remove the Feeder
5. REMOVE THE FEEDER ASSEMBLY (Figure 2).

1
DISCONNECT (J415)
2
REMOVE THE
NUTS (2)
3
REMOVE FEEDER
ASSEMBLY
Figure 2 Removing the Feeder
Replacement REP 8-40 Lower Preregistration Transport

NOTE: Ensure that the Feeder Drive Coupling aligns with the coupling on the shaft of the Parts List on PL 8.24
Feeder Drive Motor. Removal
1. REINSTALL THE FEEDER ASSEMBLY. 1. SWITCH OFF THE PRINTER POWER.
2. REMOVE THE INVERTER REAR COVER.
3. OPEN THE INVERTER PWB PANEL.
4. ACCESS THE REAR OF THE LOWER PREREGISTRATION TRANSPORT (Figure 1).

3
LOOSEN THE
SCREWS (2)
5
REMOVE THE
SHIELD
VIEWED FROM THE

FRONT OF THE
STACKER WITH THE
2 INVERTER DOOR OPEN
REMOVE THE
SHIELD
4
LOOSEN THE
BOLTS (2)
1
LOOSEN THE
SCREWS (2)
Figure 1 Accessing the Transport
5. PREPARE THE REAR OF THE LOWER PREREGISTRATION TRANSPORT FOR

REMOVAL (Figure 2).

2
LOOSEN IDLER
MOUNTING
SCREW
3
REMOVE THE
BELT
1
LOOSEN
Figure 2 Preparing the Rear of the Transport
NOTE: After removing the two nuts (step 4, Figure 3), position the Baffle Spring Support on the
transport and secure it with your hand during removal.
7. REMOVE THE LOWER PREREGISTRATION TRANSPORT (Figure 3).

4
NOTE: REMOVE
THE NUTS (2)
3 2 1
REMOVE DISCONNECT LOOSEN
Replacement REP 8-41 Registration Baffle Assembly

NOTE: After the transport is positioned in the machine, it may be necessary to position the rear Parts List on PL 8.26
tab under the bolt from the rear of the IFS. Removal
1. REINSTALL THE LOWER PREREGISTRATION TRANSPORT. 1. SWITCH OFF THE PRINTER POWER.
2. REMOVE THE PREREGISTRATION TRANSPORT (REP 8-40).
3. REMOVE THE REGISTRATION ASSEMBLY (REP 8-46).
4. REMOVE THE REGISTRATION BAFFLE ASSEMBLY (Figure 1).

1
REMOVE THE
NUTS (4)
2
REMOVE THE REGISTRATION
BAFFLE ASSEMBLY
Figure 1 Removing the Registration Baffle
Replacement REP 8-43 Lower Preregistration Transport Corrugator

NOTE: Ensure that the Registration Baffle Assembly is positioned fully against the tabs on the Rolls
front of the Lower Preregistration Transport before tightening the four nuts. Parts List on PL 8.25
1. REINSTALL THE REGISTRATION BAFFLE ASSEMBLY. Removal
2. REMOVE THE LOWER PREREGISTRATION TRANSPORT (REP 8-40).
4. LOSEN THE SETSCREW AND REMOVE THE CORRUGATOR ROLL.
Replacement
NOTE: Replace the Corrugator Roll by pushing it on the drive shaft as far as it will go, then
tighten the setscrew.
1. REINSTALL THE CORRUGATOR ROLL.

2. REINSTALL THE LOWER PREREGISTRATION TRANSPORT.

REP 8-45 Lower Preregistration Transport Flexible Drive 4. LOOSEN THE SETSCREW LOCATED AT EACH END OF THE FLEXIBLE DRIVE
SHAFT.
Shaft 5. REMOVE THE FLEXIBLE DRIVE SHAFT.
REP 8-46 Registration Assembly
Removal
Removal
3. POSITION THE LOWER PREREGISTRATION TRANSPORT ON A FLAT SURFACE
WITH THE REGISTRATION ASSEMBLY FACING UPWARDS. 2. REMOVE THE LOWER PREREGISTRATION TRANSPORT (REP 8-40).
1
LOOSEN THE
SETSCREW
3 2
REMOVE REGISTRATION REMOVE THE
ASSEMBLY NUTS (2)
Figure 1 Removing the Registration Assembly
REP 8-47 Corrugator Roll Drive Shafts And Belt

Removal
4. REMOVE THE CORRUGATOR ROLL DRIVE SHAFTS AND BELTS (Figure 1).

3
LOOSEN RETAINER
MOUNTING SCREW
(2 PLACES)
4
REMOVE THE
DRIVE SHAFTS
AND BELT
2 1
REMOVE SCREW REMOVE THE
AND SPRING CORRUGATOR
RETAINER ROLLS (2)
Figure 1 Removing the Shafts and Belts
Replacement REP 8-50 Intermediate Horizontal Transport

NOTE: Replace the Corrugator Rolls by pushing it on the drive shaft as far as it will go, then Parts List on PL 8.26
tighten the setscrew. Removal
1. REINSTALL THE CORRUGATOR ROLLS. 1. SWITCH OFF THE PRINTER POWER.
2. REMOVE THE STACKER LOWER REAR COVER FROM THE FS.
3. MANUALLY UNLATCH TRAY 4, AND PUSH IT OPEN.
4. LOWER THE AC RELAY PANEL.
5. REMOVE THE AC SAFETY SHIELD (Figure 1).

2
REMOVE THE
SHIELD
1
REMOVE NUTS (2)
Figure 1 Removing the Shield
6. PREPARE TO REMOVE THE INTERMEDIATE HORIZONTAL TRANSPORT (Figure 2).

5
REMOVE NUT AND
THE LINK SPRING
4
DISCONNECT
3
LOOSEN
1
LOOSEN THE
IDLER MOUNTING 2
SCREW REMOVE THE
BELT
Figure 2 Preparing to Remove the Transport
7. PUSH IN TRAY 4, AND LOWER THE FS HORIZONTAL TRANSPORT DOOR.

CAUTION
Do not damage the Intermediate Horizontal Transport or the Jam Sensor (Q854B) when
removing or installing the transport.
8. REMOVE THE INTERMEDIATE HORIZONTAL TRANSPORT (Figure 3).

1
REMOVE
2
CAUTION
REMOVE THE
TRANSPORT
Replacement
NOTE: After the Intermediate Horizontal Transport has been placed inside the FS from the
front, it will have to be guided into mounting position from the rear.
1. REINSTALL THE INTERMEDIATE HORIZONTAL TRANSPORT.

REP 8-55 Horizontal Transport (IFS) 3. MANUALLY UNLATCH AND PUSH OPEN TRAY 3.
4. LOWER THE IFS RELAY PANEL.
5. REMOVE THE IFS AC SAFETY SHIELD (Figure 1).
Removal 6. SWING OUT THE INVERTER PWB PANEL.
2. REMOVE THE INVERTER REAR COVER AND THE IFS LOWER REAR COVER.
3
LOOSEN THE 5
SCREWS (2) REMOVE THE
SHIELD
2
REMOVE THE
SHIELD
4
LOOSEN THE
BOLTS (2)
1
LOOSEN THE
SCREWS (2)
8. LOOSEN THE IDLER ON THE REAR OF THE LOWER PREREGISTRATION TRANS-

PORT AND REMOVE THE LOWER PREREGISTRATION TRANSPORT DRIVE BELT
FROM THE IFS HORIZONTAL TRANSPORT.
9. LOOSEN THE IDLER ON THE REAR OF THE IFS VERTICAL TRANSPORT AND
REMOVE THE VERTICAL TRANSPORT DRIVE BELT FROM THE IFS HORIZONTAL
TRANSPORT.
10. PREPARE THE REAR OF THE HORIZONTAL TRANSPORT FOR REMOVAL (Figure 2).

1
DISCONNECT
(J482)
2
REMOVE THE
BOLTS (2)
Figure 2 Preparing the Transport
11. PUSH IN TRAY 3 AND LOWER THE IFS HORIZONTAL TRANSPORT DOOR.
NOTE: Scribe a line along the top of the Interlock Bracket (step 2, Figure 3) to ensure that it is
positioned correctly when it is reinstalled.
12. REMOVE THE IFS HORIZONTAL TRANSPORT (Figure 3).

2
1
DISCONNECT INTERLOCK NOTE:
CONNECTORS (2)
REMOVE THE INTERLOCK SWITCH
AND THE MOUNTING BRACKET
ASSEMBLY
4 REMOVE
TRANSPORT
3
REMOVE BOLTS (2)
Replacement REP 8-56 Horizontal Transport (FS)

NOTE: It will be necessary to guide the IFS Horizontal Transport into the correct mounting Parts List on PL 8.20
position from the rear of the IFS. Removal
1. REINSTALL THE IFS HORIZONTAL TRANSPORT. 1. SWITCH OFF THE PRINTER POWER.
2. REMOVE THE FS LOWER REAR COVER.
3. MANUALLY UNLATCH AND PUSH OPEN TRAY 4.
5. REMOVE THE FS AC SAFETY SHIELD (Figure 1).

6. LOOSEN THE IDLER ON THE REAR OF THE FS VERTICAL TRANSPORT AND 7. PREPARE THE REAR OF THE HORIZONTAL TRANSPORT FOR REMOVAL (Figure 1).
REMOVE THE VERTICAL TRANSPORT DRIVE BELT FROM THE FS HORIZONTAL
TRANSPORT.
1
REMOVE THE NUT AND
THE LINK SPRING
2
LOOSEN IDLER
MOUNTING SCREW
3
REMOVE THE
BELT
4
REMOVE BOLTS (2)
Figure 1 Preparing the Transport
8. PUSH IN TRAY 4 AND LOWER THE FS HORIZONTAL TRANSPORT DOOR.
NOTE: Scribe a line along the top of the Interlock Bracket (step 2, Figure 2) to ensure that it is
9. REMOVE THE FS HORIZONTAL TRANSPORT (Figure 2).

1
DISCONNECT
2
INTERLOCK THE NOTE: REMOVE THE INTERLOCK
CONNECTORS (2) SWITCH AND MOUNTING BRACKET
ASSEMBLY
4 REMOVE
TRANSPORT
3
REMOVE THE BOLTS (2)
Replacement REP 8-59 Horizontal Transport Pivot Baffle (IFS)

NOTE: It will be necessary to guide the FS Horizontal Transport into the correct mounting posi- Parts List on PL 8.29
tion from the rear of the FS. Removal
1. REINSTALL THE FS HORIZONTAL TRANSPORT. 1. PULL OUT THE HCT.
3. REMOVE THE IFS LOWER REAR COVER.
4. LOWER THE IFS RELAY PANEL.
5. REMOVE THE AC SAFETY SHIELD.

CAUTION
Do not damage the Sensor Actuator Spring. Ensure that the Sensor is removed from the
bracket and positioned on the baffle before removal. Do not damage any harnesses when
removing the Pivot Baffle.
NOTE: There is spring tension on the Lift Assembly Mounting Bracket.
6. REMOVE THE IFS HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 1).
1
REMOVE LIFT ASSEMBLY
BRACKET NUTS (3)
2
NOTE: REMOVE LIFT
ASSEMBLY BRACKET
3
CAUTION
REMOVE THE SENSOR
FROM THE MOUNT-
ING BRACKET AND
POSITION ON THE
PIVOT BAFFLE
CAUTION
5
6 REMOVE PIVOT REMOVE NUTS (6)
BAFFLE AND GROUND STRAP 4
DISCONNECT (2)
Figure 1 Removing the Pivot Baffle
Replacement formed.
NOTE: Do not tighten the six rear nuts on the Pivot Baffle until the adjustment has been per- 1. REINSTALL THE PIVOT BAFFLE.

2. Adjust the Horizontal Transport Pivot Baffle (ADJ 8-14). REP 8-60 Horizontal Transport Pivot Baffle (FS)
Removal
1. PULL OUT THE HCT.
3. REMOVE THE FS LOWER REAR COVER.
5. REMOVE THE AC SAFETY SHIELD.
CAUTION
Do not damage any harnesses when removing the Pivot Baffle.
NOTE: There is spring tension on the Lift Assembly Mounting Bracket.
6. REMOVE THE FS HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 1).

1
REMOVE LIFT ASSEMBLY 2
BRACKET NUTS (3) NOTE: REMOVE LIFT
ASSEMBLY BRACKET
3
REMOVE NUT AND
LINK SPRING
CAUTION
4
5 REMOVE PIVOT REMOVE NUTS (6)
BAFFLE AND GROUND STRAP
Figure 1 Removing the Pivot Baffle
Replacement REP 8-65 Lower Turn Transport (IFS/FS)

NOTE: Do not tighten the six rear nuts on the Pivot Baffle until the adjustment has been per- Parts List on PL 8.16
formed. Removal
1. REINSTALL THE PIVOT BAFFLE. 1. SWITCH OFF THE PRINTER POWER.
2. Adjust the Horizontal Transport Pivot Baffle (ADJ 8-14). 2. REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).
3. PREPARE THE REAR OF THE LOWER TURN TRANSPORT FOR REMOVAL (Figure
1).

3
REMOVE THE
SHIELD
2
LOOSEN
1
LOOSEN
4
DISCONNECT (J483)
Figure 1 Preparing the Rear of the Transport
NOTE: Scribe a line along the edge of the Interlock Mounting Bracket to ensure that it is posi-
tioned correctly when it is reinstalled.
4. REMOVE THE VERTICAL TRANSPORT DOOR INTERLOCK SWITCH AND THE

MOUNTING BRACKET FROM THE FRAME.
5. IF THE FS LOWER TURN TRANSPORT IS BEING REMOVED, REMOVE THE FS
LOWER SIDE COVER.
6. REMOVE THE LOWER TURN TRANSPORT (Figure 2).

3
REMOVE THE
TRANSPORT
1
REMOVE
2
REMOVE
Replacement REP 8-66 Lower Turn Transport Baffle/pivot Shaft/springs

NOTE: It will be necessary to guide the Lower Turn Transport into the correct mounting posi- (IFS/FS)
tion from the rear of the FS. Parts List on PL 8.19
1. REINSTALL THE LOWER TURN TRANSPORT. Removal
2. REMOVE THE VERTICAL TRANSPORT (REP 8-75).
3. REMOVE THE LOWER TURN TRANSPORT (REP 8-65).
4. POSITION THE LOWER TURN TRANSPORT ON A FLAT SURFACE WITH THE BAF-
FLE FACING UPWARDS.
NOTE: Ensure to notice the position of the Torsion Springs before removing the Baffle Pivot
Shaft. The Torsion Springs must be reinstalled in the same position to operate correctly.
5. REMOVE THE BAFFLE, PIVOT SHAFT AND SPRINGS (Figure 1).

1 6
REMOVE NUT AND GROUND STRAP REMOVE THE
FROM REAR OF TRANSPORT BAFFLE
5
REMOVE SHAFT
WHEN REAR END
OF SHAFT IS FREE
OF FRAME AND
BAFFLE
2
REMOVE CLIP
4
PULL SHAFT TOWARDS FRONT OF
TRANSPORT WHILE ROTATING THE
SHAFT CLOCKWISE AND COUNTER-
CLOCKWISE
3
PLACE A 5.5mm
WRENCH ON FLATS
OF THE SHAFT
Figure 1 Removing the Baffle, Pivot Shaft and Springs
Replacement REP 8-67 Lower Turn Transport Upper Drive Shaft

NOTE: Ensure to install tension on the Torsion Springs when reinstalling the Pivot Shaft. Parts List on PL 8.19
1. REINSTALL THE BAFFLE, PIVOT SHAFT AND SPRINGS. Removal
3. REMOVE THE LOWER TURN TRANSPORT (REP 8-65).
4. POSITION THE LOWER TURN TRANSPORT ON A FLAT SURFACE WITH THE BAF-
FLE FACING UPWARDS.

5. REMOVE THE UPPER DRIVE SHAFT (Figure 1).
4
REMOVE THE
DRIVE SHAFT
3
REMOVE BEARING
RETAINER 1
REMOVE SCREWS (2) AND
2 THE BRUSH BRACKET
REMOVE THE
SCREW
Figure 1 Removing the Upper Drive Shaft

REP 8-68 Lower Turn Transport Lower Drive Shaft REP 8-69 Lower Turn Transport Sensor Assembly
Removal Removal
2. REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75). 2. REMOVE THE LOWER TURN TRANSPORT (REP 8-65).
3. REMOVE THE LOWER TURN TRANSPORT (REP 8-65). 3. POSITION THE LOWER TURN TRANSPORT ON A FLAT SURFACE WITH THE BAF-
4. POSITION THE LOWER TURN TRANSPORT ON A FLAT SURFACE WITH THE BAF- FLE FACING DOWNWARD.
FLE FACING UPWARDS. 4. REMOVE THE TWO SCREWS SECURING THE SENSOR ASSEMBLY.
5. LOOSEN THE MOUNTING SCREW AND REMOVE THE RETAINER SECURING THE
NOTE: Ensure to note the position of the Sensor Assembly before removal. Cut and replace
LOWER DRIVE SHAFT. cable ties as required.
6. REMOVE THE LOWER DRIVE SHAFT.
5. DISCONNECT AND REMOVE THE SENSOR ASSEMBLY.
Replacement
NOTE: Ensure that the Sensor Assembly is reinstalled in the same position as it was before
removal.
1. REINSTALL THE SENSOR ASSEMBLY.

REP 8-75 Vertical Transport (IFS/FS) 5. PREPARE THE UPPER REAR PORTION OF THE VERTICAL TRANSPORT FOR
REMOVAL (Figure 2).
Removal
3. MANUALLY UNLATCH THE APPROPRIATE HCT.
4. PREPARE THE LOWER REAR PORTION OF THE VERTICAL TRANSPORT FOR
REMOVAL (Figure 1).
1
LOOSEN IDLER
MOUNTING
SCREW
2
REMOVE THE
BELT
3
DISCONNECT
(J484)
Figure 1 Preparing the Lower Portion

1
LOOSEN
4
MOVE TAB
COMPLETELY
2
UNLATCH IDLER
TENSIONER
3
MOVE TAB
COMPLETELY
Figure 2 Preparing the Upper Portion
6. REMOVE THE APPROPRIATE STACKER FRONT COVER (REP 4-49).

7. OPEN THE VERTICAL TRANSPORT DOOR.
NOTE: Scribe a line along the top of the Latch Bracket (step 2, Figure 3) to ensure that it is
8. REMOVE THE VERTICAL TRANSPORT (Figure 3).

1 2
REMOVE SCREW
AND BRACKET NOTE: REMOVE
SCREWS (2) AND
BRACKET
3
REMOVE BOLT
6
SLIDE OUT AND
REMOVE TRANSPORT
4
5 REMOVE SCREW
OPEN THE HCT
Replacement REP 8-76 Vertical Transport Upper Baffle/Pivot Shaft/

NOTE: It will be necessary to guide the Vertical transport into the correct mounting position Spring (IFS/FS)
from the rear of the FS. Parts List on PL 8.18
1. REINSTALL THE VERTICAL TRANSPORT. Removal
2. REINSTALL THE TOP MOUNTING BOLT BUT DO NOT TIGHTEN. 1. SWITCH OFF THE PRINTER POWER.
3. REINSTALL THE BOTTOM MOUNTING SCREW AND TIGHTEN. 2. REMOVE THE VERTICAL TRANSPORT (REP 8-75).
4. TIGHTEN THE TOP MOUNTING BOLT. 3. POSITION THE VERTICAL TRANSPORT ON A FLAT SURFACE WITH THE BAFFLES
FACING UPWARDS.

NOTE: Ensure to notice the position of the Torsion Spring before removing the Upper Baffle
Pivot Shaft. The Torsion Spring must be reinstalled in the same position to operate correctly.
4. REMOVE THE UPPER BAFFLE, PIVOT SHAFT AND SPRING (Figure 1).
2 3
REMOVE CLIP
NOTE: REMOVE THE
PIVOT SHAFT
1
REMOVE THE NUT AND
THE GROUND STRAP
FROM THE REAR OF THE
TRANSPORT
5
REMOVE THE 4
UPPER BAFFLE LIFT THE LOWER
BAFFLE
Figure 1 Removing the Upper Baffle
Replacement
NOTE: Rotating the pivot shaft counterclockwise will install tension on the Torsion Spring and
align the "D" end of the shaft with the D-Hole in the frame.
1. REINSTALL THE UPPER BAFFLE, PIVOT SHAFT AND SPRING (Figure 2).

6 3
REINSTALL CLIP POSITION REAR END OF THE
SHAFT THROUGH THE BAFFLE
2
INSERT FRONT
END OF PIVOT
SHAFT THROUGH
THE BAFFLE AND
THE FRAME
7
REINSTALL THE
GROUND STRAP
ANDTHE NUT
1
POSITION THE UPPER BAFFLE
5 UNDER THE LOWER BAFFLE
NOTE: ROTATE SHAFT COUNTER- 4
CLOCKWISE TO TENSION SPRING PLACE A 5.5mm
AND INSERT "D" END OF SHAFT WRENCH ON FLATS
THROUGH D-HOLE IN FRAME OF THE SHAFT
Figure 2 Reinstalling the Upper Baffle

REP 8-77 Vertical Transport Lower Baffle/Pivot Shaft (IFS/
FS)
Removal
2. REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.
3. PREPARE TO REMOVE THE LOWER BAFFLE AND PIVOT SHAFT (Figure 1).
REMOVE E-RING
Figure 1 Preparing to Remove the Lower Baffle
4. MANUALLY UNLATCH THE HCT.

5. OPEN THE VERTICAL TRANSPORT DOOR.
6. REMOVE THE LOWER BAFFLE AND PIVOT SHAFT (Figure 2).

3
1 REMOVE E-RING
REMOVE NUT AND GROUND
STRAP FROM REAR OF THE
TRANSPORT 4
REMOVE SHAFT
5
2 SLIDE OUT THE HCT
UNLATCH LOWER
BAFFLE
6
REMOVE THE
BAFFLE
Figure 2 Removing the Lower Baffle

REP 8-78 Vertical Transport Lower Baffle Release 2. REMOVE THE VERTICAL TRANSPORT (REP 8-75).
3. POSITION THE VERTICAL TRANSPORT ON A FLAT SURFACE WITH THE BAFFLES
Assembly Components FACING DOWNWARDS.
Parts List on PL 8.17 PL 8.18 4. BEGIN TO REMOVE THE RELEASE ASSEMBLY COMPONENTS (Figure 1).
Removal
4
REMOVE THE
5 SPRING PLATE
REMOVE THE SUPPORT
SPRING PLATE
3
REMOVE NUTS (3)
2
REMOVE THE
REAR LATCH ARM
1
REMOVE NUT
Figure 1 Beginning to Remove the Release Assembly Components
5. REMOVE THE RELEASE ASSEMBLY SHAFTS (Figure 2).

2
REMOVE THE NUT
3 AND FRONT LATCH
REMOVE CLIP
4 1
REMOVE SHAFTS REMOVE CLIP
Figure 2 Removing the Release Assembly Shafts
6. REMOVE THE CLIPS SECURING THE SHAFT LINKS ON THE SHAFTS AND REMOVE REP 8-79 Vertical Transport Sensor Assembly
THE LINKS.
Replacement
Removal
NOTE: Ensure that the Front Latch and the Rear Latch Arm engage the shaft on the Lower
Baffle.
2. REMOVE THE VERTICAL TRANSPORT (REP 8-75).
1. REINSTALL THE RELEASE ASSEMBLY COMPONENTS. 3. POSITION THE VERTICAL TRANSPORT ON A FLAT SURFACE WITH THE BAFFLES
FACING DOWNWARD.
4. REMOVE THE TWO SCREWS SECURING THE SENSOR ASSEMBLY.

NOTE: Ensure to note the position of the Sensor Assembly before removal. Cut and replace REP 8-80 Vertical Transport Drive Belt/drive Shafts
cable ties as required.
5. DISCONNECT AND REMOVE THE SENSOR ASSEMBLY.
Removal
Replacement 1. SWITCH OFF THE PRINTER POWER.
NOTE: Ensure that the Sensor Assembly is reinstalled in the same position as it was before 2. REMOVE THE APPRORIATE VERTICAL TRANSPORT (REP 8-75).
removal. 3. POSITION THE VERTICAL TRANSPORT ON A FLAT SURFACE WITH THE BAFFLES
FACING UPWARDS.
1. REINSTALL THE SENSOR ASSEMBLY.
4. LOOSEN THE IDLER MOUNTING SCREW ON THE REAR OF THE TRANSPORT AND
REMOVE THE DRIVE BELT.
5. LOOSEN THE APPROPRIATE RETAINER MOUNTING SCREW AND REMOVE THE
APPROPRIATE SHAFT RETAINER.
6. REMOVE THE APPROPRIATE DRIVE SHAFT.

REP 9-0 Toner Bottle 4. REDUCE THE TONER LEVEL IN THE DISPENSER RESERVOIR BY APPROXIMATELY
10 MM.
Parts List on PL 25.1 5. CLEAN THE SEAL, AND CLEAN THE AREA SURROUNDING THE RESERVOIR WITH
Removal THE VACUUM CLEANER.
NOTE: MICR (DP180MX) Machines use a Red Toner Bottle that is not compatible with DP180.

2. OPEN THE XEROGRAPHIC DRAWER (REP 9-34).
3. REMOVE TONER BOTTLE (Figure 1).
3
REMOVE THE
BOTTLE
2
TURN HANDLE
1
PULL THE BOTTLE
AGAINST THE STOP
Figure 1 Removing the Toner Bottle

REP 9-1 Toner Thumper Solenoid (SOL901) REP 9-2 Toner Dispenser Assembly
Removal Removal
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. NOTE: MICR (DP180MX) Machines use a Red Toner Bottle that is not compatible with DP180.
2. REMOVE PHOTORECEPTOR BELT (REP 9-35).
3. REMOVE TONER BOTTLE (REP 9-0).
4. REMOVE THE TONER THUMPER SOLENOID ASSEMBLY (Figure 1).
3. REMOVE, AND CLEAN THE DEVELOPER CATCH TRAY.
5. USE THE VACUUM CLEANER IN ORDER TO CLEAN THE TONER FROM THE TONER
1 DISPENSER ASSEMBLY.
REMOVE THE
SOLENOID LEADS 6. REMOVE THE ASSEMBLY (Figure 1).
1
DISCONNECT THE 2
CONNECTOR LOOSEN THE TWO
RIGHT NUTS COM-
PLETELY
2
REMOVE THE
SCREW
4 3
ASSEMBLY TWO LEFT NUTS
Figure 1 Removing the Solenoid Assembly
5. REMOVE THE TWO SCREWS THAT HOLD THE SOLENOID TO BRACKET.

6. REMOVE SOLENOID AND THE PLUNGER.
7. REPLACE TONER THUMPER ASSEMBLY, IF THE PIVOT HAS EXCESSIVE WEAR.
Replacement Figure 1 Removing the Dispenser
1. INSTALL THE TONER BOTTLE.

Replacement
2. ADJUST THE TONER THUMPER (ADJ 9-0).
1. PUSH THE DISPENSER ASSEMBLY TOWARD THE LEFT WHILE TIGHTENING THE
FOUR NUTS.
2. CHECK THAT ALL TERMINALS OF THE DEVELOPER BIAS HARNESS ARE CON-
NECTED.

3. INSTALL THE TONER BOTTLE. REP 9-3 Toner Dispenser Motor (MOT902)
4. IF A NEW DISPENSER WAS INSTALLED, CHECK/ADJUST THE TONER THUMPER
(ADJ 9-0).
5. INSTALL THE PHOTORECEPTOR BELT (REP 9-35). Removal
3. REMOVE THE PRINTER LEFT DOOR.
5. REMOVE THE TONER DISPENSER MOTOR (Figure 1).
3
REMOVE THE
MOTOR
2
DISCONNECT THE
CONNECTOR
1
REMOVE THE
NUTS (2)

REP 9-4 Developer Material
GEAR GUARD
Removal REMOVED

3. POSITION THE DROPCLOTH UNDER THE XEROGRAPHIC DRAWER.
NOTE: Install a clean Dump Tray when using the same Developer material again.
4. CLEAN THE DEVELOPER CATCH TRAY.
NOTE: Pushing in the nut, and then handcranking it clockwise will open the Dump Door. Do
not use the Dump Door Handle to open the Door.
5. OPEN THE DEVELOPER DUMP DOOR (Figure 1).
1
PUSH THE DUMP
TRAY INTO THE
RAIL AND UNDER
THE DUMP DOOR
DUMP TRAY
SHOWN CUT
AWAY
2
PUSH IN THE CRANK,
ROTATE 30 DEGREES
CLOCKWISE TO OPEN
THE DOOR
Figure 1 Opening the Dump Door
NOTE: Gently thump the sides of the Developer Housing, open and close the Dump Door sev-
eral times in order to shake loose any remaining Developer Material.
6. PURGE ALL DEVELOPER MATERIAL FROM THE HOUSING (Figure 2).

1
RAISE AND PUSH THE
HANDLE LIGHTLY
CLOCKWISE
2
ROTATE CW 2
REVOLUTIONS,
THEN CCW 2 REV-
OLUTIONS.
REPEAT SEV-
ERAL TIMES
1
ROTATE THE DEVELOPER
DRIVE GEAR CW 12 REVO-
LUTIONS, THEN CCW 3 2
REVOLUTIONS PUSH TO THE REAR, AND ROTATE
COUNTERCLOCKWISE UNTIL THE
DOOR IS LATCHED
Figure 2 Purging the Developer Material Figure 3 Closing the Dump Door
7. IF THE DEVELOPER IS REPLACED DUE TO A CLEANER FAILURE, DEBRIS CEN- CAUTION

TERED DELETIONS, OR A PROCESS DIRECTION SCRATCH ON THE PR BELT, PER- If this is a MICR Developer Housing, DO NOT handcrank the Developer Housing slowly, there
FORM THE DUMP AND THUMP (REP 9-6). may be lumping of the developer material. If lumping occurs, the lumps should be loosened by
8. USE THE VACUUM CLEANER, AND CLEAN THE FOLLOWING: hand.
NOTE: If the Manifold is heavily covered with toner, check for obstructions in the Manifold CAUTION
Holes, the operation of the Filter Blower, a clogged Filter Bag or Vacuum Duct. Do not crank the Developer Housing in the counterclockwise direction, or pour the material
between Roll 1 and Roll 2. The Developer Material can compact and can permanently stay on
a. Disconnect the Exhaust Tube, clean the Exhaust Tube and the Vacuum Manifold. the Rolls.
b. Clean the area between the BRD Roll and Roll 3.
NOTE: Two Bottles of Developer Material must be installed.
c. Clean the Top Surface of the Lower Right Housing Plate.
d. Clean the Front Seal, the Rear Seal, and the PR Ground Wiper. 2. POUR THE DEVELOPER (Figure 4).
Replacement
1. CLOSE THE DUMP DOOR (Figure 3).

REP 9-5 Developer Assembly
Removal

2. REMOVE THE PRINTER LEFT DOOR.
4. DUMP THE DEVELOPER MATERIAL (REP 9-4).
5. REMOVE THE TONER DISPENSER ASSEMBLY (REP 9-2).
6. REMOVE THE DEVELOPER MANIFOLD (Figure 1).
2
REMOVE THE
SCREWS (2)
2
CAUTION
POUR DEVELOPER
1 IN THIS LOCATION
HANDCRANK CLOCKWISE ONLY
ONLY WHILE POURING THE
DEVELOPER MATERIAL
Figure 4 Installing the Developer
CAUTION
Ensure that the Developer Rolls are evenly covered with Developer material before closing the
1
PR Module.
LOOSEN THE CLAMP
3. CLEAN THE DUMP TRAY. DISCARD THE USED DEVELOPER MATERIAL AND THE 3 AND REMOVE VACUUM
DROPCLOTH. WARNING HOSE FROM MANIFOLD
4. IF INSTALLING THE NEW DEVELOPER MATERIAL, SELECT [SCP], [HFSI], [Cleaner/ REMOVE MANIFOLD
Developer], [09-825 R Developer], AND [Reset Count].
5. PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).
Figure 1 Removing the Manifold
7. REMOVE THE DEVELOPER ASSEMBLY (Figure 2).

2
3 LOOSEN SCREWS 2
LIFT DEVELOPER AND RAISE HOLD CAUTION
ASSEMBLY OFF DOWN BRACKETS
THE LOCATING PUSH THE MANIFOLD
PINS DOWN, AND TIGHTEN
THE SCREWS (2)
1 3
SLIDE THE MANIFOLD REINSTALL THE VAC-
1 INTO HOUSING UUM HOSE AND
REMOVE THE TIGHTEN THE CLAMP
SCREWS
Figure 2 Removing the Developer Assembly Figure 3 Reinstalling the Manifold
Replacement 4. WHEN INSTALLING A NEW DEVELOPER ASSEMBLY LOOSEN THE DEVELOPER

DRIVE ASSEMBLY (REP 4-39).
CAUTION
5. ALIGN THE DEVELOPER DRIVE ASSEMBLY (ADJ 9-19).
The DP180MX has a unique Developer Housing and it is not compatible with the DP180.
6. INSTALL THE PHOTORECEPTOR.
NOTE: Do not release the Xerographic Drawer Latch while installing the Developer Housing.
7. CHECK THAT THE DEVELOPER ROLLS ARE EVENLY COVERED WITH DEVELOPER
Check that the Developer Housing is seated flat on the clean mounting pads.
BEFORE CLOSING THE PR MODULE.
1. INSTALL THE DEVELOPER HOUSING. 8. INSTALL THE TONER DISPENSER ASSEMBLY.
2. REINSTALL 2 SCREWS AND SECURE HOLD DOWN BRACKETS. 9. IF A NEW DEVELOPER ASSEMBLY, OR NEW DEVELOPER, WAS INSTALLED, PER-
3. REINSTALL THE DEVELOPER MANIFOLD (Figure 3). FORM THE FOLLOWING:
a. Enter dC107, select [Xero], [Developer], and press [Reset counter to zero and
update History.].
b. The Xerographic Set-up (ADJ 9-3).

REP 9-6 Developer Dump And Thump REP 9-7 Front Bearing Clamp
Removal Parts List on PL 9.15
NOTE: MICR (DP180MX) Machines use a Red Toner Bottle that is not compatible with DP180. Removal
2. DUMP THE DEVELOPER MATERIAL (REP 9-4).
3. REMOVE DEVELOPER GEAR GUARD.
CAUTION
4. REMOVE THE PR GROUND STRIP CLEANER.
If this is a MICR Developer Housing, DO NOT handcrank the Developer Housing slowly, there
may be lumping of the developer material. If lumping occurs, the lumps should be loosened by NOTE: Inspect the Front Bearing Clamp for any cracks on the mounting surface and replace if
hand. necessary.
CAUTION 5. REMOVE THE BEARING CLAMP (Figure 1).
Do not crank the Developer Housing in the counterclockwise direction, or pour the material
between Roll 1 and Roll 2. The Developer Material can compact and can permanently stay on
the Rolls.
1
3. HANDCRANK THE DEVELOPER ASSEMBLY CLOCKWISE APPROXIMATELY 20 REV-
2 REMOVE THE PR
OLUTIONS IN ORDER TO CLEAN OUT THE AUGER. GROUND CLEANER
REMOVE THE
4. HANDCRANK THE DEVELOPER ASSEMBLY, AND CLEAN THE ROLLS WITH THE SCREWS (5)
VACUUM CLEANER.
5. REMOVE THE DEVELOPER ASSEMBLY (REP 9-5).
6. PLACE THE DEVELOPER ASSEMBLY ON A DROPCLOTH, AND CAREFULLY OPEN
THE DUMP DOOR.
7. RAISE THE REAR OF THE ASSEMBLY APPROXIMATELY 60 DEGREES, AND SHAKE
THE ASSEMBLY IN ORDER TO DISLODGE ANY MATERIAL CAUGHT AT THE REAR
OF THE ASSEMBLY.
8. RAISE THE FRONT, AND SHAKE THE ASSEMBLY IN ORDER TO DUMP THE TONER
FROM THE AUGER.
9. PLACE THE ASSEMBLY ON ITS REAR SURFACE, AND GENTLY TAP THE LEFT AND
THE RIGHT SIDES OF THE HOUSING WITH THE HANDLE OF A SCREWDRIVER.
10. REPEAT STEPS 7 TO 9 UNTIL ALL MATERIAL HAS BEEN REMOVED FROM THE
ASSEMBLY, AND INSTALL THE DEVELOPER ASSEMBLY (REP 9-5).
11. INSTALL THE DEVELOPER MATERIAL (REP 9-4).
12. INSTALL THE PHOTORECEPTOR BELT (REP 9-35), CLOSE THE XEROGRAPHIC
DRAWER, SWITCH ON THE PRINTER, AND MAKE 1 PRINT. DO NOT SWITCH OFF
THE PRINTER UNTIL THE XEROGRAPHIC SET-UP HAS BEEN PERFORMED.
3
13. PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3). REMOVE THE
BEARING CLAMP
Figure 1 Removing the Bearing Clamp
Replacement
NOTE: Ensure that the bearing cavities are clean before seating a Bearing. Use the Vacuum
Cleaner and a cotton swab to remove all dirt. Dirt in a bearing cavity can change the distance
between the Developer Roll and the Photoreceptor, which will cause a print quality problem.
1. CHECK THAT ALL BEARINGS ARE SEATED IN THEIR CAVITIES.

NOTE: Do not tighten the screws too much, the threaded inserts can pull out. REP 9-8 BRD Roll (w/Tag P-118 and Tag P-300)
2. INSTALL THE SHORT SCREW IN THE FAR RIGHT HOLE OF THE BEARING CLAMP, Parts List on PL 9.15
THEN INSTALL THE REMAINING FOUR SCREWS.
Removal
3. INSTALL THE PR GROUND STRIP CLEANER.
a. Clean the Bearing Clamp between the two screw holes in front of Developer Roll 3 NOTE: It is not necessary to remove the Developer Assembly if only the Gears, Front Bearing
with the film remover. Clamp, the BRD One-Way Clutch or the Front Bearings of the Developer Roll will be removed.
b. Align the two bosses of the Cleaner in the two screw holes in front of Roll 3, and 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
push the Cleaner into position. 2. REMOVE DEVELOPER ASSEMBLY (REP 9-5).
3. REMOVE THE FRONT BEARING CLAMP (REP 9-7).
4. REMOVE THE DRIVE GEAR FROM ROLL 3.
5. REMOVE THE SCREW FROM REAR OF BRD ROLL SHAFT.
6. ROTATE ROLL 3 IN ORDER TO PLACE THE HIGH POINT OF THE CAM UPWARDS.
7. REMOVE BRD ROLL (Figure 1).
3
REMOVE THE
CAM FOLLOWER
2
HIGH POINT OF
CAM UP
ONE-WAY CLUTCH
4
REMOVE THE
1 BRD ROLL
REMOVE THE GEAR
Figure 1 Removing the BRD Roll

Replacement
CAUTION
1
1. Ensure that the bearing cavities are clean before seating a Bearing. Use the Vacuum
CHECK CONTINUITY
Cleaner and a cotton swab to remove all dirt. Dirt in a bearing cavity can change the dis- BETWEEN THE BRD
tance between the Developer Roll and the Photoreceptor, which will cause a print quality ROLL AND BIAS TAB
problem.
2. Inspect the Front Bearing Clamp for any cracks on the mounting surface and replace if
required.
1. CLEAN THE BEARING CAVITIES.
2. ALIGN THE FLAT ON THE REAR SHAFT WITH REAR HOUSING, AND INSERT THE
ROLL.
3. INSTALL THE ONE-WAY CLUTCH WITH THE PLASTIC SEAL TOWARD THE REAR SO
THAT THE CLUTCH ROTATES IN THE CLOCKWISE DIRECTION.
4. SEAT THE ONE-WAY CLUTCH AND FRONT OF BRD SHAFT IN FRONT HOUSING.
PUSH THE CLUTCH TOWARD THE REAR.
5. INSTALL THE BRD BIAS WIRE (Figure 2).
BRD SHAFT
Figure 3 Checking the Continuity
7. INSTALL THE CAM ON ROLL 3 SHAFT. INSTALL CAM FOLLOWER ON BRD SHAFT.
8. INSTALL THE SCREW IN REAR SHAFT.
9. INSTALL THE DRIVE GEAR FOR ROLL 3 WITH THE RECESS TOWARD THE FRONT.
10. INSTALL FRONT BEARING CLAMP.
11. INSTALL THE DEVELOPER ASSEMBLY (REP 9-5).
12. INSTALL THE TONER DISPENSER ASSEMBLY.
WIRE BETWEEN
SHOULDER AND
SCREW
WIRE AGAINST
VERTICAL RIB
Figure 2 Installing the Bias Wire
6. CHECK THE CONTINUITY BETWEEN THE BRD ROLL AND THE BIAS TAB (Figure 3).
REP 9-9 Developer Roll 1 or 2

Removal CAUTION
To see additional information go to Xerographics in the DocuPrint 180 Unique Components 1. Ensure that the bearing cavities are clean before seating a Bearing. Use the Vacuum
and Functions section. Cleaner and a cotton swab to remove all dirt. Dirt in a bearing cavity can change the dis-
tance between the Developer Roll and the Photoreceptor, which will cause a print quality
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. problem.
2. REMOVE THE PHOTORECEPTOR BELT (REP 9-35). 2. Inspect the Front Bearing Clamp for any cracks on the mounting surface and replace if
required.
3. REMOVE DEVELOPER ASSEMBLY (REP 9-5).
4. REMOVE THE FRONT BEARING CLAMP (REP 9-7).
2. INSERT THE REAR SHAFT IN THE REAR PLATE.
5. REMOVE THE DRIVE GEAR. GENTLY LIFT THE FRONT SHAFT IN ORDER TO
REMOVE THE BEARING. NOTE: Check that the slots in shafts are aligned with the keys of the Rear Bearing Clamp.
6. REMOVE THE REAR BEARING CLAMP (Figure 1).
3. INSTALL THE REAR BEARING CLAMP.
a. Place a hex wrench between the vertical faces of the slot in the rear shaft. Rotate the
wrench until it just jams in the slot. Rotate the shaft for the preliminary alignment.
1 b. Position the Clamp so that the two metal keys are aligned in the slots in rear shafts.
REMOVE THE Gently tighten the three screws, in order to move the Clamp into position.
SCREWS (3) AND 4. CONNECT THE BIAS LEAD.
THE CLAMP
5. INSTALL THE FRONT BEARING WITH THE PROTRUDING END OF THE INNER RACE
TOWARD THE REAR. SEAT THE BEARING IN CAVITY IN THE FRONT PLATE.
THE BIAS LEAD
6. INSTALL THE DRIVE GEAR WITH THE FLAT SURFACE TOWARD FRONT.
7. INSTALL FRONT BEARING CLAMP.
8. INSTALL DEVELOPER ASSEMBLY (REP 9-5).
9. INSTALL THE TONER DISPENSER ASSEMBLY.
10. INSTALL PHOTORECEPTOR BELT (REP 9-35).
Figure 1 Removing the Rear Bearing Clamp.
7. PUSH THE REAR SHAFT TOWARD THE FRONT IN ORDER TO REMOVE THE ROLL.
8. REMOVE ROLL 1 OR ROLL 2.

REP 9-10 Developer Roll 3 2. REMOVE THE PHOTORECEPTOR BELT (REP 9-35).
3. HANDCRANK THE DEVELOPER ASSEMBLY IN A CLOCKWISE DIRECTION ONLY
Parts List on PL 9.15 AND CLEAN THE ROLLS WITH THE VACUUM CLEANER.
Removal 4. REMOVE THE FRONT BEARING CLAMP (REP 9-7).
NOTE: The DP180MX has a unique Developer Roll 3 and it is not compatible with the DP180. 5. REMOVE THE DRIVE GEAR, CAM FOLLOWER, AND CAM (Figure 1).
ROLL 3
2
REMOVE THE
CAM FOLLOWER
1
REMOVE
THE GEAR 3
REMOVE
THE CAM
Figure 1 Removing the Drive Gear, Cam Follower, and Cam
6. LIFT THE FRONT SHAFT, AND REMOVE THE BEARING.

7. REMOVE THE REAR BEARING CLAMP (Figure 2).

6. INSTALL THE FRONT BEARING WITH THE PROTRUDING END OF THE INNER RACE
TOWARD THE REAR. SEAT THE BEARING IN THE CAVITY IN FRONT HOUSING
PLATE.
1 7. INSTALL THE CAM AND CAM FOLLOWER.
REMOVE REAR
BEARING CLAMP 8. INSTALL THE DRIVE GEAR WITH THE RECESS TOWARD THE FRONT.
(2 SCREWS) 9. INSTALL THE FRONT BEARING CLAMP.
BIAS LEAD
HOUSING BIAS TAB
Figure 2 Removing the Rear Bearing Clamp
8. PUSH THE REAR SHAFT TOWARD THE FRONT, AND REMOVE DEVELOPER ROLL
3.
Replacement
CAUTION
1. Ensure that the bearing cavities are clean before seating a Bearing. Use the Vacuum
Cleaner and a cotton swab to remove all dirt. Dirt in a bearing cavity can change the dis-
tance between the Developer Roll and the Photoreceptor, which will cause a print quality
problem.
2. Inspect the Front Bearing Clamp for any cracks on the mounting surface and replace if
required.
2. INSERT THE REAR SHAFT IN THE REAR PLATE.
3. ALIGN THE REAR SHAFT SO THAT THE SLOT IS ALIGNED WITH THE KEY OF THE
CLAMP.
4. INSTALL THE REAR BEARING CLAMP.
5. CONNECT THE BIAS LEAD TO THE HOUSING BIAS TAB.
REP 9-11 Trimmer Bar

Parts List on PL 9.16 REP 9-12 Paddle Wheel
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. Removal
2. REMOVE THE PHOTORECEPTOR BELT (REP 9-35). 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS AND DISCONNECT ALL THE
3. REMOVE DEVELOPER MATERIAL (REP 9-5). POWER CORDS.
4. REMOVE DEVELOPER ROLL 1 (REP 9-9).
NOTE: Do not remove the Paddle Wheel when replacing only the front and rear bearings.
5. REMOVE THE TRIMMER BAR (Figure 1).
a. The Developer Material (REP 9-4).
2 b. Developer Assembly (REP 9-5).
PRY THE REAR c. Developer Rolls 1 and 2 (REP 9-9).
CAP BACKWARD
d. Trimmer Bar (REP 9-11).
1
REMOVE REAR 3. REMOVE THE DRIVE GEAR FROM THE FRONT OF PADDLE WHEEL ASSEMBLY.
CAP (2 SCREWS) 4. REMOVE THE BEARING HOUSING, THE BEARING RETAINER AND THE FRONT
BEARING (Figure 1).
3 1
TRIMMER BAR SCREWS (3)
Figure 1 Removing the Trimmer Bar
Replacement 2
1. LOOSELY INSTALL THE TRIMMER BAR WITH THE MARK TOP ON TOP, AND WITH REMOVE THE
THE TAPERED EDGE TOWARD ROLL 1. BEARING
RETAINER
2. PUSH THE TRIMMER BAR TOWARD THE BRD ROLL, AND TIGHTEN THE CAPS.
3. INSTALL DEVELOPER ROLL 1.
Figure 1 Removing the Front Bearing
5. REMOVE THE DEVELOPER DRIVE COUPLING (Figure 2).

1
RAISE THE WIRE,
AND REMOVE THE
SHAFT TOWARD
THE FRONT
2
1 REMOVE THE
LOOSEN THE COUPLING
SCREW
Figure 2 Removing the Developer Drive Coupling Figure 3 Removing the Shaft
6. CHECK THE DRIVE SHAFT, REMOVE ANY BURRS (BY THE DRIVE COUPLING). 9. REMOVE THE PADDLE WHEEL.
NOTE: Gently hit the rear end of the shaft with the handle of a screwdriver while raising the 10. REMOVE THE AUGER FROM THE REAR HOUSING PLATE HUB (SAVE TO INSTALL
NEW PARTS).
wire out of the slot in shaft. When the wire will no longer fall back into the slot, reinstall the drive
gear in order to provide a temporary handle. 11. CHECK THE DEVELOPER SUMP FOR FOREIGN OBJECTS.
7. REMOVE THE REAR BEARING RETAINER AND THE REAR BEARING.

Replacement
8. REMOVE PADDLE WHEEL SHAFT (Figure 3). 1. DROP IN THE NEW PADDLE WHEEL.
2. INSTALL THE NEW PADDLE WHEEL DRIVE SHAFT.
NOTE: Take care not damage the Augers while inserting the Paddle Wheel Shaft. Install the
drive gear on the shaft in order to provide a temporary handle.
3. CHECK THAT THE RETAINING WIRE IS SEATED IN THE SLOT OF THE DRIVE
SHAFT.
CAUTION
Align the Bearing Retainer with the locating pin of the bearing housing.
4. INSTALL THE FRONT BEARING, THE FRONT BEARING RETAINER AND THE BEAR-
ING HOUSING.
5. TIGHTEN THE SCREWS (3).

6. INSTALL THE DRIVE GEAR. REP 9-13 Mixing Auger
NOTE: Use the old Auger as a tool to push the new Auger onto the shaft. Parts List on PL 9.16
7. INSTALL THE NEW (BLACK) REAR AUGER, PRESS TO SHOULDER ON THE SHAFT. Removal
8. INSTALL THE TOLERANCE RING IN THE REAR END GROOVE ON THE SHAFT. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
NOTE: Use the old Auger as a tool to position the new Auger onto the shaft. Gently hit the old
Auger with a soft faced mallet or the handle of a screwdriver until the Bearing is seated in the 3. REMOVE THE MIXING AUGER GEAR.
rear housing. 4. REMOVE THE MIXING AUGER (Figure 1).
9. INSTALL THE REAR BEARING.

10. INSTALL THE REAR BEARING RETAINER. TIGHTEN THE SCREWS (3).
11. INSTALL THE DRIVE COUPLING. TIGHTEN THE SCREW (1).
2
1 REMOVE THE
12. ENSURE THE PADDLE WHEEL TURNS FREELY. REMOVE THE BEARING CAP
13. INSTALL TRIMMER BAR (REP 9-11). SCREWS (3)
14. INSTALL DEVELOPER ROLLS 1 AND 2 (REP 9-9).
3
REMOVE THE
BEARING
4 RETAINER
REMOVE THE
AUGER
Figure 1 Removing the Mixing Auger
Replacement
1. SECURE THE HARNESS WITH A CABLE CLAMP AT THE TOP SCREW OF THE
BEARING CLAMP.

REP 9-14 Low Toner Sensor (Q903) REP 9-15 Waste Bottle Full Sensor (Q906)
Removal Removal
2. REMOVE PHOTORECEPTOR BELT (REP 9-35). 2. OPEN THE XEROGRAPHIC DRAWER (REP 9-34).
3. REMOVE THE TONER BOTTLE (REP 9-0). 3. OPEN THE PR MODULE, AND COVER THE DEVELOPER CAVITY.
4. CLEAN THE TONER INSIDE THE TONER HOPPER WITH THE VACUUM CLEANER. 4. PROTECT THE PHOTORECEPTOR BELT AS SHOWN IN THE REMOVAL PROCE-
CAUTION DURE OF THE PHOTORECEPTOR BELT (REP 9-35).
Use caution when handling the Low Toner Sensor. Do not touch the sensor portion. 5. PULL THE RIGHT END OF THE WASTE BOTTLE FULL SENSOR OUT OF THE CUT-
OUT IN BRACKET. THEN LIFT THE RIGHT END, AND REMOVE THE SENSOR
5. CLEAN THE FOAM SEAL OF THE TONER DISPENSER, AND CLEAN THE SUR-
TOWARD THE LEFT (Figure 1).
ROUNDING AREA AFTER REMOVING THE BOTTLE, AND BEFORE INSTALLING IT.
6. REMOVE THE LOW TONER SENSOR (Figure 1).
2
2 PULL THE RIGHT END OUT OF THE
REMOVE THE CUTOUT THEN REMOVE SENSOR
SCREWS TOWARD THE LEFT
1 1
DISCONNECT THE
3 DISCONNECT THE
CONNECTOR REMOVE THE CONNECTOR
SENSOR
Figure 1 Removing the Sensor


REP 9-16 Waste Compactor Shield 3. PULL THE WASTE COMPACTOR SHIELD FROM WASTE COMPACTOR BRACKET.

1. REMOVE THE OLD ADHESIVE, AND CLEAN THE TOP SURFACE OF THE BRACKET
Removal WITH THE CLEANING SOLVENT.
2. REMOVE THE PROTECTIVE FILM FROM THE NEW SHIELD.
3. INSTALL THE SHIELD (Figure 1).
1 2 3
CLEAN THE TOP REMOVE THE ALIGN THE LEFT AND
OF THE BRACKET PROTECTIVE FILM THE REAR EDGES,
AND ATTACH SHIELD
SHIELD
REAR VIEW 4
POSITION
THE FLAP
Figure 1 Installing the Shield
4. POSITION THE D-SHAPED FLAP SO THAT IT COVERS THE LARGER, RECTANGU- REP 9-17 Upper Waste Toner Duct
LAR LEFT END OF THE SHIELD.
Removal

CAUTION
Do not bend the Agitator Spring.
3. REMOVE UPPER WASTE TONER DUCT (Figure 1).
1
REMOVE THE
SCREW
UPPER WASTE
TONER DUCT
2
CAUTION
PUSH TOP OF WASTE DUCT
TOWARD PRINTER WHILE PULL-
ING DUCT UP, AND THEN OUT
Figure 1 Removing the Waste Toner Duct
4. REMOVE THE AGITATOR SPRING (Figure 2).

2
SLIDE THE AGITATOR
1 COIL SPRING ONTO
REMOVE THE THE WIRE
AGITATOR COIL
SPRING
1
SEAT THE RETAINING
2 END OF AGITATOR
CAREFULLY PULL WIRE IN RECESSES
THE RETAINING
END OF AGITATOR
WIRE OUT OF
RECESSES
Figure 2 Removing the Waste Agitator Spring Figure 3 Installing the Waste Agitator Springs
Replacement CAUTION
1. INSTALL THE AGITATOR SPRING (Figure 3). Do not bend the Agitator Spring.
2. INSTALL THE UPPER WASTE TONER DUCT.
REP 9-18 Waste Compactor Drive Belt NOTE: Push the Motor out of the tensioning hole of the Bracket in order to provide belt slack.
Parts List on PL 9.23 3. REMOVE THE WASTE COMPACTOR DRIVE BELT (Figure 1).
Removal
2. REMOVE PRINTER LEFT REAR COVER (REP 4-1).

1 3
LOOSEN THE REMOVE BELT
SCREWS AT LEAST 3 1
(CLOCKWISE
3 REVOLUTIONS TIGHTEN THE INSTALL THE BELT
ROTATION)
SCREWS (2)
2
PULL THE MOTOR INTO
2 THE TENSIONING HOLE
PUSH THE PULLEY
TOWARD THE FRONT
Figure 1 Removing the Belt Figure 2 Installing the Drive Belt
Replacement 2. CHECK THAT THE D-SHAPED FLAP OF THE SHIELD COVERS THE LARGER, RECT-
ANGULAR LEFT END OF THE SHIELD.
NOTE: Position the hub of Motor into the tensioning hole of the Bracket. Pivot the Motor in a
counterclockwise direction, and seat its positioning hub in the tensioning hole of the bracket.
Hold the Motor, while tightening the screws.
1. INSTALL THE DRIVE BELT (Figure 2).

REP 9-19 Waste Compactor Motor Bracket Replacement
Parts List on PL 9.23 NOTE: Install the Clutch Bearing Retainer with the tapered end up so that the tangs push
Removal against the bearing. Slide the tangs of retainer over the clutch shaft. Lower the Bracket into
position behind the two screws.
2. REMOVE THE PRINTER LEFT REAR COVER (REP 4-1). 1. POSITION THE ASSEMBLY IN PRINTER, AND INSTALL THE BRACKET (Figure 2).
3. REMOVE THE WASTE COMPACTOR DRIVE BELT (REP 9-18).
4. REMOVE WASTE COMPACTOR MOTOR BRACKET (Figure 1).
2
TIGHTEN THE
SCREWS (3) 1
4 POSITION THE
REMOVE THE RETAINER AND
SCREW THE BRACKET
5
REMOVE THE
BRACKET WITH
THE MOTOR 3
LOOSEN THE
SCREWS (2)
1 4
LOOSEN THE 2 CONNECT THE
SCREWS (2) CUT CABLE TIE, CONNECTOR,
AND DISCONNECT INSTALL THE
CONNECTOR 3 CABLE TIE
TIGHTEN THE
SCREWS (2)
Figure 2 Installing the Bracket
NOTE: Set the positioning hub of Motor into the tensioning hole of the Bracket.
Figure 1 Removing the Bracket
2. INSTALL THE DRIVE BELT.
3. CHECK THAT THE D-SHAPED FLAP OF THE SHIELD COVERS THE LARGER, RECT-

REP 9-20 Waste Compactor Auger
Removal
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. 2
2. REMOVE PRINTER LEFT REAR COVER (REP 4-1). REMOVE THE
SCREW 1
LOOSEN THE
4. REMOVE UPPER WASTE TONER DUCT (REP 9-17). SCREWS (2)
NOTE: Do not bend the Agitator Spring during removal or replacement.
5. REMOVE WASTE AGITATOR SPRINGS (Figure 1).
1
REMOVE THE AGITATOR
COIL SPRING
3
PULL OUT
THE AUGER
2
CAREFULLY PULL Figure 2 Removing the Compactor Auger
THE RETAINING END
OF AGITATOR WIRE
OUT OF RECESSES Replacement
1. ALIGN THE KEYED ONE-WAY CLUTCH OF THE COMPACTOR AUGER IN THE
KEYED SEAT IN THE LOWER WASTE TONER DUCT. THEN PUSH THE AUGER INTO
POSITION.
NOTE: Install the bearing clamp for Auger with the tapered corner up so that the tangs push
against the bearing.
2. INSTALL THE AUGER BEARING CLAMP.
NOTE: Position the hub of Motor in the tensioning hole of the bracket.
3. INSTALL THE DRIVE BELT.

4. CHECK THAT THE D-SHAPED FLAP OF THE WASTE COMPACTOR SHIELD COVERS
THE LARGER, RECTANGULAR LEFT END OF THE SHIELD.
Figure 1 Removing the Waste Agitator Springs 5. INSTALL THE WASTE AGITATOR SPRINGS (Figure 3).
6. REMOVE WASTE COMPACTOR AUGER (Figure 2).

REP 9-21 Waste Compactor Motor (MOT903)
Removal 1
POSITION THE MOTOR AS SHOWN,
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. AND LOOSELY INSTALL THE
2. REMOVE PRINTER LEFT REAR COVER (REP 4-1). SCREWS (2)
4. REMOVE WASTE COMPACTOR MOTOR BRACKET (REP 9-19).
NOTE: Push the motor pulley through clearance hole in bracket in order to remove Motor.
5. REMOVE THE MOTOR (Figure 1).
1
REMOVE SCREWS (2)
AND REMOVE MOTOR
FRONT VIEW
Figure 2 Installing a Motor
2. POSITION THE MOTOR IN THE TENSIONING HOLE OF THE BRACKET WHILE

INSTALLING THE DRIVE BELT.
3. CHECK THAT THE D-SHAPED FLAP OF THE SHIELD COVERS THE LARGER, RECT-
Replacement
NOTE: Align the Motor so that the leads entering the housing are at the four o'clock position
(viewed from the front).
1. INSTALL THE MOTOR (Figure 2).

REP 9-22 Lower Waste Toner Duct REP 9-23 Cleaner Brush
Removal Removal
2. REMOVE THE UPPER WASTE TONER DUCT (REP 9-17). 2. OPEN THE XEROGRAPHIC DRAWER (REP 9-34).
3. REMOVE THE WASTE COMPACTOR MOTOR BRACKET (REP 9-19). 3. COVER THE AREA UNDER THE CLEANER BRUSH WITH PAPER.
4. REMOVE WASTE COMPACTOR AUGER (REP 9-20). NOTE: Store the Brush on its rear hub if it will be reinstalled. Do not place the brush on its bris-
5. REMOVE THE LOWER WASTE TONER DUCT (Figure 1). tles. Store the brush on the rear hub.
4. PARTIALLY CLOSE THE DRAWER, AND REMOVE THE CLEANER BRUSH (Figure 1).
1 2
COVER THE PHOTO- LOOSEN THUMB
RECEPTOR SCREWS (2)
1
REMOVE THE
SCREWS (2) AND
REMOVE THE DUCT
3
REMOVE THE
FRONT COVER
4
CAUTION
REMOVE THE BRUSH
Figure 1 Removing the Lower Waste Toner Duct
Figure 1 Removing the Cleaner Brush
Replacement
WARNING
Wash the hands with soap and water after installing a new Brush. Residues of acids
used in the manufacturing of the fibers could cause mild irritation.
1. CLEAN THE NEW OR USED BRUSH WITH THE VACUUM CLEANER.
2. INSTALL THE USED BRUSH IN THE SAME DIRECTION OF ROTATION.

NOTE: Rotate the Brush in order to seat it on the rear arbor. REP 9-24 Cleaner Manifold
3. TAKE OUT THE PAPER PROTECTING THE AREA UNDER THE CLEANER BRUSH. Parts List on PL 9.24
NOTE: Running 500 Prints is not required if performing the Xerographic Set-up. Removal
4. IF INSTALLING A NEW BRUSH RUN AT LEAST 500 PRINTS.
5. IF A NEW BRUSH WAS INSTALLED, ENTER [SCP], SELECT [HFSI], [Cleaner/Devel-
oper], [09-801 R Cleaner Brush and Blades], AND PRESS [Reset Count]. 3. REMOVE THE PHOTORECEPTOR INNER PANEL.
4. COVER THE FLOOR WITH A DROPCLOTH.
5. REMOVE THE FUSER OIL DRIP PAN (Figure 1).
2
OPEN THE FUSER, AND
REMOVE THE DRIP PAN
1
LOOSEN THE
SCREW FACING
TOWARD THE
RIGHT
Figure 1 Removing the Drip Pan
6. REMOVE THE CLEANER MANIFOLD (Figure 2).

2
1 MOVE THE LATCH
PIVOT THE TO THE REAR
THREE LATCHES
3
MOVE THE LATCH
TO THE FRONT
AND SECURE
WITH RETAINER
4
PULL OFF THE
HOSE FROM THE
ADAPTER TUBE
Figure 2 Removing the Manifold
Replacement
1. CLEAN THE MANIFOLD AND THE DUCT WITH THE VACUUM CLEANER.
2. REMOVE IMPACTED TONER FROM FLICKER BAR WITH THE FILM REMOVER.
NOTE: Check that the Manifold is latched securely, and check that the exhaust duct is seated
in order to form a tight seal. Air leaks anywhere in the toner exhaust system will cause a
Cleaner failure. Install the left edge of the Manifold first, then continue with a rocking motion
toward the lower right side.
3. INSTALL AND CHECK THE MANIFOLD (Figure 3).

3
THE EXHAUST
DUCT IS INSTALLED
TIGHTLY ON THE
ADAPTER TUBE
2
ALL 4 LATCHES
HOLD DOWN THE
MANIFOLD
1
NOTE: NO GAP
BETWEEN THE
MANIFOLD AND
HOUSING
Figure 3 Installing and Checking the Manifold Installation
4. INSTALL THE DRIP PAN. REP 9-25 Cleaner Augers or Blade

5. CLOSE AND LATCH THE FUSER.
6. INSTALL THE PHOTORECEPTOR INNER PANEL.
Removal
2. REMOVE THE PHOTORECEPTOR INNER PANEL.
3. PROTECT THE PHOTORECEPTOR BELT (REP 9-35), LEAVE THE XEROGRAPHIC
DRAWER PARTIALLY OPENED.
4. REMOVE AND STORE THE CLEANER BRUSH (REP 9-23).
5. ACCESS THE WASTE TONER AUGERS (Figure 1).

1
REMOVE THE 1
SCREWS (2) CAUTION
REMOVE BLADE
2
GRASP WITH
NEEDLENOSE
PLIERS, AND
REMOVE THE
2 CLEANER AUGER
REMOVE AUGER
GEAR HOUSING
Figure 1 Accessing the Components Figure 2 Removing the Auger or the Blade
CAUTION Clean
Rotate the Auger in a clockwise direction during removal or replacement in order to prevent the CAUTION
stretching of the spring. Prevent dirt by holding the nozzle of the vacuum cleaner near the
Do not touch the bristles of the Brush with the hands. Store the Brush only on the rear hub.
opening while pulling out any of these components.
Reinstall the brush so that it will rotate in the original direction.
6. REMOVE THE CLEANER BLADE OR THE AUGER (Figure 2).
1. CLEAN THE BRUSH AND OTHER COMPONENTS WITH THE VACUUM CLEANER.
USE THE VACUUM ADAPTER TUBE IN ORDER TO CLEAN THE INSIDE OF THE
AUGER CAVITIES.
Replacement
CAUTION
Do not damage the thin sealing strip during installation of the Auger. Clean the Cleaner Brush
Housing before installing the components.
1. INSTALL THE AUGERS WITH THE TWO ALIGNMENT FINS SEATED IN THE TWO
HOUSING SLOTS (Figure 3).

NOTE: THE LONG
TABS TOWARD
THE FRONT
1
ROTATE AUGER
CLOCKWISE
2 DURING STEP 2
SEAT THE FINS IN
SLOTS IN ORDER TO
INSTALL AUGER
Figure 3 Installing the Auger or the Blade
CAUTION
Rotate the Auger in a clockwise direction during installation.
2. ENSURE THAT THE AUGERS TURN FREELY BEFORE INSTALLING THE GEAR
HOUSING.
3. ALIGN THE AUGER DRIVE SHAFTS, AND SEAT THEM IN THEIR DRIVE GEARS
WHEN REINSTALLING THE GEAR HOUSING.
4. REINSTALL THE CLEANER BRUSH (REP 9-23).
5. CLOSE THE PR MODULE.
8. IF NEW BLADES WERE INSTALLED, ENTER [SCP], [HFSI], SELECT [Cleaner/Devel-
oper], [09-802 R Cleaner Brush and Blades], AND PRESS [Reset Count].

REP 9-26 Cleaner Module 3. REMOVE PHOTORECEPTOR BELT (REP 9-35), AND COVER THE PR MODULE
UNDER THE CLEANER MODULE WITH PAPER.
Parts List on PL 9.22 4. REMOVE THE CLEANER MANIFOLD (REP 9-24).
Removal 5. REMOVE THE UPPER WASTE TONER DUCT (REP 9-17).
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. 6. REMOVE THE PRECLEAN DICOROTRON CONNECTOR (REP 9-40).
NOTE: Do not remove the Cleaner Module if only a cleaning procedure will be performed. 7. REMOVE THE WASTE TONER DUCT SLIDE (PL 9.23
8. REMOVE THE CLEANER DRIVE BELT (Figure 1).
2. REMOVE PRECLEAN DICOROTRON (REP 9-39).
2 1
MOVE AND HOLD LOOSEN THE
THE IDLER BOLT
3
TIGHTEN THE
BOLT
NOTE: THE CLEANER

AND OZAC DUCTS ARE
NOT SHOWN
4
REMOVE THE
BELT
Figure 1 Removing the Cleaner Drive Belt
9. PREPARE THE REAR OF THE MODULE FOR REMOVAL (Figure 2).

7 6
REMOVE SCREW REMOVE THE
DRIVE SUPPORT
5
REMOVE NUTS
AND WASHERS (3)
4
REMOVE PULLEY
AND THE CLIP
1
DISCONNECT
CLEANER HARNESS
3
LOOSEN THE
2 SETSCREW
REMOVE THE CAP
Figure 2 Preparing the Rear of the Module for Removal
10. CLOSE THE XEROGRAPHIC DRAWER, AND PREPARE THE FRONT OF THE MOD-
ULE FOR REMOVAL (Figure 3).

20. INSERT A ROLLED SHEET OF 14 INCH PAPER INTO THE CLEANER CAVITY IN
ORDER TO TEMPORARILY BLOCK THE AIR FLOWING THROUGH THE MANIFOLD.
PULL THE PAPER AWAY QUICKLY SEVERAL TIMES IN ORDER TO DISLODGE
1 ACCUMULATED TONER BY DISTURBING THE AIR FLOW.
REMOVE THE
21. USE THE SAME TECHNIQUE IN ORDER TO CLEAN THE DEVELOPER MANIFOLD
SCREWS (2)
AND EXHAUST DUCT.
22. INSPECT THE FLICKER BAR. IF IMPACTED TONER IS VISIBLE REMOVE THE
CLEANER MANIFOLD (REP 9-24), AND REPLACE THE FLICKER BAR (REP 9-33).
23. ENSURE THAT THE PAPER IS REMOVED FROM THE DEVELOPER MANIFOLD
AFTER COMPLETING THE CLEANING PROCEDURE.
24. IF INSTALLING A NEW CLEANER MODULE REMOVE THE FOLLOWING COMPO-
NENTS AND INSTALL THEM ON THE NEW MODULE:
a. Preclean Dicorotron Rail and Spacers.
NOTE: Do not install the Spots Blade at this time.
b. Spots Blade Guides (REP 9-58).

Replacement
1. INSTALL THE AUGERS WITH THE TWO ALIGNMENT TABS SEATED IN THE TWO
HOUSING SLOTS
CAUTION
2 Rotate the Auger in a clockwise direction during installation.
3 REMOVE SCREW
PULL ASSEMBLY OFF AND THE DRIVE 2. ENSURE THAT THE AUGERS TURN FREELY BEFORE INSALLING THE GEAR
THE LOCATING PINS SUPPORT HOUSING.
3. ALIGN THE AUGER DRIVE SHAFTS AND SEAT THEM IN THEIR DRIVE GEARS
WHEN REINSTALLING THE GEAR HOUSING
4. POSITION THE CLEANER MODULE ON THE XEROGRAPHIC DRAWER.
5. GENTLY PUSH IN THE DRAWER UNTIL THERE IS RESISTANCE TO MOTION.
Figure 3 Preparing the Front of Module for Removal 6. PULL THE HARNESS CONNECTOR THROUGH THE GEAR CLEARANCE HOLE IN
REAR FRAME.
11. GENTLY PULL OUT XEROGRAPHIC DRAWER UNTIL RESISTANCE IS DETECTED.
7. SEAT THE REAR OF THE MODULE IN THE TWO LOCATING HOLES.
12. FEED THE HARNESS THROUGH THE OPENING IN THE REAR FRAME.
WARNING
13. PULL OUT XEROGRAPHIC DRAWER, AND REMOVE THE CLEANER MODULE.
The Cleaner Insulating Cap must be reinstalled in order to protect against electrical
NOTE: The following Steps (14-24) are for the Cleaning only. shock during Printer operation.
14. ACCESS THE CLEANER AUGERS AND BLADES NOTE: Push the pulley and the clip onto the shaft until pulley just contacts the Drive Support,
CAUTION and then tighten the setscrew.
Keep the area clean by holding the nozzle of the vacuum cleaner near the opening while pull- 8. INSTALL REAR OF THE CLEANER MODULE (Figure 4).
ing out any of these components.
15. REMOVE CLEANER BLADE AND AUGER.
16. REMOVE THE CLEANER BRUSH (REP 9-23), AND CLEAN THE INSIDE OF THE
CLEANER HOUSING WITH THE VACUUM CLEANER.
17. USE THE VACUUM CLEANER IN ORDER TO CLEAN THE SLOTS ABOVE AND
BELOW EACH DETONING ROLL.
18. COVER THE HOLES IN THE DEVELOPER MANIFOLD WITH PAPER.
19. INSERT THE NOZZLE OF THE VACUUM CLEANER IN THE EXHAUST ADAPTER FOR
THE TONER FILTER. SWITCH ON THE VACUUM CLEANER.

2
INSTALL SUPPORT
1 BRACKET LOOSELY
FINGERTIGHTEN
THE SCREW
3
INSTALL PULLEY
AND CLIP
6
DO NOT TIGHTEN 5
THE IDLER AT CONNECT THE 4
THIS TIME CLEANER HARNESS WARNING
INSTALL THE CAP
Figure 4 Installing the Rear of the Cleaner Module
NOTE: Loosely install the three screws securing the tripod and the screw securing the Cleaner
Module. Do not tighten the four screws until the front support bracket has been reinstalled.
Ensure that the anti-rattle clip is reinstalled between the wide (8 mm) flat on shaft and the bear-
ing.
9. INSTALL THE CLEANER BRUSH AND THE FRONT SUPPORT BRACKET OF THE
CLEANER MODULE (Figure 5).

2
SECURE THE
BRACKET (3 SCREWS)
1
LATCH THE
DRAWER
Figure 5 Installing the Front Support
10. OPEN THE FUSER. TIGHTEN THE 3 SCREWS SECURING THE TRIPOD BRACKET
AND TIGHTEN THE SCREW SECURING THE CLEANER MODULE TO REAR FRAME.
11. INSTALL THE PRECLEAN DICOROTRON CONNECTOR (REP 9-40).
12. INSTALL THE WASTE TONER DUCT SLIDE (PL 9.23).
13. INSTALL AND TIGHTEN THE CLEANER DRIVE BELT (REP 4-20).
14. INSTALL THE UPPER WASTE TONER DUCT (REP 9-17).
15. ROUTE THE CLEANER HARNESS THROUGH OPENING BETWEEN TUBES OF THE
WASTE TONER DUCT.
16. CONNECT THE OZAC DUCT AND THE CLEANER EXHAUST DUCT.
17. CONNECT THE CLEANER EXHAUST DUCT.
18. INSTALL THE CLEANER MANIFOLD AND THE FUSER DRIP PAN (REP 9-24).
19. INSTALL THE PRECLEAN DICOROTRON (REP 9-39).
20. CHECK/ADJUST THE PRECLEAN DICOROTRON HEIGHT (ADJ 9-18).
21. CHECK THAT ALL CONNECTIONS IN THE TONER EXHAUST SYSTEM ARE TIGHT.
22. REPLACE THE CABLE TIES AS REQUIRED (Figure 6).

1
REPLACE THE
CABLE TIES (2)
Figure 6 Replacing the Cable Ties
23. PERFORM THE DEVELOPER DUMP AND THUMP PROCEDURE AS REQUIRED (REP REP 9-27 Cleaner Drive Gears
9-6).
24. REINSTALL THE PHOTORECEPTOR BELT (REP 9-35).
25. ENTER [SCP], [HFSI]. SELECT [Cleaner/Developer], [09-826 C Cleaner Housing, Removal
Manifold and hose]. PRESS [Reset Count]. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
26. CHECK/ADJUST THE SPOTS BLADE CONTACT (ADJ 9-16). 2. REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).
27. PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3). 3. REMOVE THE UPPER WASTE TONER DUCT (REP 9-17).
4. DISCONNECT THE CLEANER DRIVE BELT, AND REMOVE THE DRIVE SUPPORT
(Figure 1).

3
REMOVE THE
DRIVE SUPPORT
2
REMOVE THE
SCREWS (3)
1
REMOVE
Figure 1 Removing the Cleaner Drive Support
5. REMOVE THE CLEANER GEARS (Figure 2).

4. RESTORE ALL PRINTER POWER.
LOOSEN A DETONING
GEAR CLOCKWISE LOOSEN AN IDLER
(LEFT HAND THREAD) GEAR COUNTER-
CLOCKWISE
LOOSEN THE
SETSCREW IN
ORDER TO
REMOVE THE
DRIVE GEAR
1
HOLD SHAFT IN ORDER
TO REMOVE A DETON-
ING OR IDLER GEAR
Figure 2 Removing the Gears
Replacement
1. INSTALL THE DRIVE SUPPORT.
WARNING
The Cleaner Insulating Cap must be reinstalled in order to protect against electrical
shock during Printer operation.
NOTE: Push the pulley and the clip onto the shaft until pulley just contacts the Drive Support,
and then tighten the setscrew.
2. INSTALL PULLEY, CLIP, AND CLEANER DRIVE CAP.

3. ADJUST THE CLEANER DRIVE BELT (ADJ 4-10).

REP 9-28 Toner Filter Bag
Removal
2. REMOVE THE ELECTRICAL MODULE REAR COVER (REP 4-1).
NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Housing.
Toner will fall from the Housing connection.
3. OPEN THE TONER FILTER HOUSING, AND CAREFULLY PULL THE TONER FILTER
BAG OUT.
4. DISCARD THE OLD FILTER IN THE PLASTIC BAG.
5. INSERT THE HOSE OF THE VACUUM CLEANER IN THE FILTER COUPLING, AND
CLEAN THE TONER EXHAUST DUCT.
6. CLEAN THE INSIDE OF THE FILTER HOUSING.
7. ACCESS THE STATIONARY END OF THE DEVELOPER VACUUM COUPLING BY
PULLING OUT THE XEROGRAPHIC DRAWER A SUFFICIENT DISTANCE. CLEAN
THE OPENING WITH THE VACUUM CLEANER.
8. CLEAN THE MATING END OF THE EXHAUST TUBE AND THE TOP SURFACE OF
THE VACUUM MANIFOLD. CHECK THAT THE HOLES IN THE VACUUM MANIFOLD
ARE NOT OBSTRUCTED.
Replacement
NOTE: Do not disturb a Filter after it is installed. Once a filter is installed, the seal will conform
to the coupling adapter, and the seal will leak if the bag is disturbed.
1. DO NOT INSTALL A USED FILTER.

2. INSTALL THE NEW FILTER.

REP 9-29 Toner Filter Assembly 2. REMOVE THE ELECTRICAL MODULE REAR COVER (REP 4-1).
3. PLACE A DROPCLOTH ON THE FLOOR, AND REMOVE THE TONER FILTER ASSEM-
Parts List on PL 9.20 BLY (Figure 1).
Removal
2
DISCONNECT THE
CONNECTOR
3
LIFT AND REMOVE
THE ASSEMBLY
TONER FILTER BAG
TOP REAR VIEW
1
UNLATCH AND
OPEN THE
ASSEMBLY
Figure 1 Removing the Toner Filter Assembly

REP 9-30 Toner Filter Blower Motor (MOT905) 2. REMOVE THE ELECTRICAL MODULE REAR COVER, AND REMOVE THE BLOWER
PULLEY GUARD.
Parts List on PL 9.20 3. PREPARE TO REMOVE THE MOTOR (Figure 1).
Removal
1
DISCONNECT THE
CONNECTOR
3
ROTATE THE PULLEY
TO THE LEFT AND
REMOVE THE PULLEY
2
REMOVE THE
O-RING BELTS
Figure 1 Preparing to Remove the Motor
NOTE: Observe the orientation of the motor capacitor.
4. REMOVE THE MOTOR (Figure 2).

1
NOTE: OBSERVE THE
ORIENTATION OF THE
MOTOR CAPACITOR
3 2
MOTOR SCREWS (4)
Replacement REP 9-31 Toner Filter Blower

NOTE: Ensure that the orientation of the motor is correct. Parts List on PL 9.20
1. INSTALL THE MOTOR ONTO THE BRACKET. Removal
2. INSTALL THE MOTOR PULLEY AND THE BELTS. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
3. CONNECT THE MOTOR, AND INSTALL THE PULLEY GUARD. 2. REMOVE THE ELECTRICAL MODULE REAR COVER (REP 4-1).
4. INSTALL THE ELECTRICAL MODULE REAR COVER. 3. REMOVE THE TONER FILTER ASSEMBLY (REP 9-29).
5. AFTER INSTALLING NEW BELTS, ENTER [SCP], [HFSI], SELECT [Cleaner/Devel- 4. REMOVE THE TONER FILTER BAG.
oper], [09-807 R Cleaner Blower O-ring Drive Belts], AND PRESS [Reset Count]. 5. REMOVE THE FILTER HOUSING FROM THE BLOWER BRACKET AND TONER FIL-
TER BLOWER (Figure 1).

2
SEPARATE AND
REMOVE FILTER
HOUSING
1
REMOVE THE
SCREWS (4)
Figure 1 Removing the Filter Housing from the Blower and Bracket.
6. REMOVE THE PULLEY GUARD AND THE O-RING BELTS.

7. REMOVE THE BLOWER PULLEY.
a. Hold the vanes inside the Blower.
b. Rotate the Pulley in a clockwise direction (left hand thread).
8. REMOVE THE BLOWER (Figure 2).

1
OBSERVE ORIENTATION
OF THE DISCHARGE
DUCT
3
REMOVE THE
BLOWER
2
REMOVE THE
SCREWS (3)
Figure 2 Removing the Blower
Replacement REP 9-32 Waste Bottle

1. REPLACE THE BLOWER. Parts List on PL 9.22
2. INSTALL THE BLOWER PULLEY.
Removal
a. Hold the vanes inside the Blower.
b. Rotate the Pulley in a counterclockwise direction (Left hand thread).
2. OPEN THE PRINTER FRONT DOORS, AND PULL OUT THE WASTE BOTTLE.
3. INSTALL THE O-RING BELTS AND THE PULLEY GUARD.
3. SEAL THE BOTTLE WITH THE CAP FROM THE NEW BOTTLE.
4. INSTALL THE FILTER HOUSING ONTO THE BLOWER AND BLOWER BRACKET.
5. INSTALL THE TONER FILTER ASSEMBLY.
Replacement
1. CHECK THAT THE BOTTLE IS SEATED COMPLETELY.
6. INSTALL THE TONER FILTER, AND CONNECT THE MOTOR.
2. IF A NEW BOTTLE WAS INSTALLED, RESET THE FOLLOWING:
7. INSTALL THE ELECTRICAL MODULE REAR COVER.
a. Enter dC107.
b. Select [Xero], [Waste Bottle], and press [Reset counter to zero and update His-
tory].

REP 9-33 Flicker Bar Replacement
Parts List on PL 9.24 1. CHECK THAT THE FLICKER BAR IS INSTALLED CORRECTLY, AND CHECK THAT IT
IS SEATED ON THE ALIGNMENT PADS (Figure 1).
Removal 2. IF A NEW FLICKER BAR WAS INSTALLED, ENTER [SCP], [HFSI], SELECT [Cleaner/
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. Developer], [09-808 R Cleaner Flicker Bar], AND PRESS [Reset Count].
2. REMOVE THE CLEANER MANIFOLD (REP 9-24).
3. REMOVE THE FLICKER BAR (STEP 1, Figure 1).
FRONT STOP
1
REMOVE SCREWS (2)
AND THE BAR
FRONT VIEW
2
THE CORRECT
LOCATION OF
THE BAR
Figure 1 Removing and Installing the Flicker Bar

REP 9-34 Xerographic Drawer
2
Removal PULL OUT
To see additional information go to Xerographics in the DocuPrint 180 Unique Components DRAWER
and Functions section. COMPLETELY

WARNING
Close the drawer when it is unattended. Someone could fall over the extended drawer.
2. OPEN THE PRINTER FRONT DOORS, AND PREPARE TO OPEN THE XERO-
GRAPHIC DRAWER (Figure 1).
2
LOCK PREFUSER
TRANSPORT IN
THE DISENGAGED
POSITION 1
PULL OUT KNOB,
3 AND ROTATE
DEPRESS THE
LATCH AND CLOSE
THE DRAWER
1 Figure 2 Opening the Xerographic Drawer

LATCH THE PRE-
TRANSFER BAFFLE Replacement
1. DEPRESS THE DRAWER LATCH IN ORDER TO CLOSE THE DRAWER.
CAUTION
Close and latch the Xerographic Drawer as gently as possible to reduce the possibility of dam-
age to lamp filaments.
2. ENSURE THAT THE DRAWER IS SECURED:
a. Gently push in the Drawer until it is seated.
b. Rotate the PR Module Latch handle clockwise, and push in the knob.
c. Pull out the Prefuser Transport knob, and release the transport.
d. Push the Pretransfer Baffle to the left into the operating position.
Figure 1 Preparing to Open the Drawer
CAUTION
Protect the Photoreceptor Belt from light shock, and then cover the developer cavity in order to
prevent contamination of Developer Material.
3. OPEN THE XEROGRAPHIC DRAWER (Figure 2).

REP 9-35 Photoreceptor Belt
Removal 2 1
RELEASE THE PR
To see additional information go to Xerographics in the DocuPrint 180 Unique Components RAISE STRIPPER
BELT TENSION
and Functions section. FINGER ASSEMBLY

2. OBSERVE THE FOLLOWING GUIDELINES WHEN HANDLING A PR BELT.
a. Do not expose a good PR Belt to the light for more than a few minutes in order to
prevent the light shock.
b. Do not touch the photoconductive surface of the PR Belt except at the front and rear
edges.
c. Handle a PR Belt by the inside surface when ever possible.
d. Do not buckle or crease the PR Belt. Protect the PR Belt from surface defects that
can cause image quality problems.
e. Do not wash the PR Belt.
CAUTION
Protect the PR Belt from the light fatigue, and cover the Developer Cavity in order to pre-
vent contamination of the Developer Material.
f. Protect the PR Belt from solvent vapors or ammonia vapors. 3
WARNING CAUTION
REMOVE THE PR BELT
Close the Xerographic Drawer when you are not working in the immediate area; some-
one could fall over the open drawer. Do not work below the PR Module unless the mod-
ule is supported securely. Support the module securely until it is seated in one of the
detents above an angle of 30 degrees. Below this angle the module will fall freely.
Figure 1 Removing the PR Belt
CAUTION
Protect the Photoreceptor from a light shock. Do not pinch the Photoreceptor or touch it in the
5. COVER THE DEVELOPER CAVITY.
photoconductive area. Handle the Photoreceptor only by grasping the edges.
4. PUSH THE PR MODULE LATCH TO THE RIGHT, RAISE THE PR MODULE FULLY,
Replacement
AND REMOVE THE PR BELT (Figure 1). WARNING
Do not touch the ESV if the Printer is switched on. High voltage is present on the ESV
when the Printer is in the operating mode.
1. BEFORE INSTALLING THE PHOTORECEPTOR, PERFORM THE FOLLOWING:
a. Inspect the PR Module and the Xerographic Drawer components for dirt.
b. Use the vacuum cleaner in order to clean any dirty areas of the PR Module, the
Developer Assembly, and the Xerographic Drawer.
c. Wipe the smooth rolls in the PR Module with a cleaning towel.
d. Check the surfaces of the PR Edge Guides for loose or fused toner and clean them
as required.

CAUTION
Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth.
The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power
before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when
the power is switched on, and will ensure that the ESV Monitor measurements and the
DSS calibrations are performed with the components clean.
e. Clean the following components with a clean, soft, lint free cloth:
• The DSS
• The ESV
• The Patch Generator
• Empty any Developer Material from the Developer Catch Tray.
• Clean any stray Developer Material from the Developer Housing.
WARNING
Use caution when working in the area below the PR Module. Ensure that the Xero-
graphic Door Knob is fully rotated to the left. Do not attempt to lower a raised Pho-
toreceptor module by downward pressure or the lever latch bracket will be
damaged. To lower this module depress the lever release behind the handle while
raising the module slightly, then lower the Photoreceptor module slowly until it is
seated on the Xerographic Drawer.
f. If the Photoreceptor must be replaced because of process direction scratches, per-
form the Developer Dump and Thump procedure (REP 9-6).
2. INSTALL THE PHOTORECEPTOR (Figure 2).

2
ENSURE THAT THE PR BELT IS
POSITIONED BETWEEN THE FRONT 4
GUIDE AND THE REAR GUIDE SEAT THE STRIPPER FINGER
ASSEMBLY AND GENTLY
LOWER THE PR MODULE
5
3 LOWER THE
LATCH THE PR PR MODULE
TENSIONER
1
INSTALL THE PR BELT
WITH THE BELT HOLE
TOWARD THE FRONT
Figure 2 Installing the PR Belt
NOTE: Push the tall rear brush off the rear developer seals toward the front before closing the REP 9-36 Patch Generator
PR module.
3. CLOSE THE XEROGRAPHIC DRAWER (REP 9-34).
Removal
4. IF A NEW PR BELT WAS INSTALLED, RESET THE FOLLOWING:
a. Enter dC107. and Functions section.
b. Select [Xero], [P/R Belt], and press [Reset counter to zero and update History.].
5. IF A NEW PR BELT WAS INSTALLED, PERFORM THE FOLLOWING: 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
a. The Photoreceptor Seam Timing (ADJ 9-8). 2. REMOVE THE ROS ASSEMBLY (REP 6-1).
b. The Xerographic Set-up (ADJ 9-3).

3. COVER THE PR WITH PAPER COVER IN ORDER TO PROTECT THE PR BELT FROM WARNING
THE LIGHT DAMAGE.
High voltage is present on the ESV when the Printer is in the operating mode.
4. REMOVE THE PATCH GENERATOR (Figure 1).
3
PUSH AGAINST THE
FITTING WHILE
PULLING THE INLET
PURGE TUBE
2
PUSH AGAINST THE
FITTING WHILE
PULLING THE
PURGE TUBE
5 4
DISCONNECT THE
REMOVE THE SCREWS (2)
1 CONNECTOR
RIGHT SIDE VIEW AND THE PATCH GENERATOR
DISCONNECT THE
CONNECTOR
Figure 1 Removing the Patch Generator
CAUTION Replacement
Handle the ESV carefully; it is easily damaged. Do not break off the alignment pin on the Patch 1. CLEAN THE PATCH GENERATOR WITH A SOFT, DRY, LINT-FREE CLEANING
Generator. TOWEL.
5. CAREFULLY REMOVE ESV FROM THE PATCH GENERATOR. 2. CAREFULLY INSTALL THE OLD ESV ON THE NEW PATCH GENERATOR.
3. INSTALL THE PATCH GENERATOR.

4. CHECK THAT THE ALIGNMENT BOSSES ON THE PATCH GENERATOR ARE REP 9-37 ESV
SEATED IN THE MATING HOLES IN BRACKET.
5. REMOVE THE PAPER FROM THE PR.
CAUTION Removal
Ensure that the Purge Tube is connected in order to prevent a process control failure. To see additional information go to Xerographics in the DocuPrint 180 Unique Components
6. CONNECT THE INLET PURGE TUBE.
7. CHECK/ADJUST THE ESV HEIGHT (ADJ 9-12). 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
8. INSTALL THE ROS ASSEMBLY. 2. PROTECT PHOTORECEPTOR BELT FROM THE LIGHT SHOCK.
WARNING
Voltage is present on the ESV when the Printer is in the operating mode.
3. REMOVE THE PATCH GENERATOR (REP 9-36).
CAUTION
Do not break off the alignment pin on the Patch Generator during the removal or replacement
of the ESV.
4. REMOVE ESV (Figure 1).

c. Perform the Xerographic Set-up (ADJ 9-3).
1
REMOVE THE ESV
PURGE TUBE FROM
THE Y-CONNECTOR
2
REMOVE THE
SCREW
3
REMOVE THE ESV
BOTTOM VIEW OF THE

PATCH GENERATOR
Figure 1 Removing the ESV
WARNING
5. CLEAN THE ESV WITH A CLEAN, DRY, LINT FREE CLOTH.
Replacement
1. REPLACE THE ESV, AND REPLACE THE ESV ASSEMBLY AS A MATCHED SET.
2. IF A NEW ESV WAS INSTALLED, PERFORM THE FOLLOWING:
a. Check/Adjust ESV Height (ADJ 9-12).
b. Install the ROS Assembly (REP 6-1).

REP 9-38 DSS
2
Removal REMOVE THE REMOVE THE DSS
To see additional information go to Xerographics in the DocuPrint 180 Unique Components SCREW

2. OPEN THE XEROGRAPHIC DRAWER AND RAISE THE PR MODULE FULLY.
3. PROTECT THE PHOTORECEPTOR BELT AS SHOWN IN THE REMOVAL PROCE-
DURE OF THE PHOTORECEPTOR BELT (REP 9-35).
CAUTION
Follow all ESD procedures. Handle the DSS carefully.
4. REMOVE THE DSS (Figure 1).
1
DISCONNECT THE
CONNECTOR
Figure 1 Removing the DSS
Replacement
CAUTION
anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. Switch off the
Printer power before cleaning the DSS. The Printer will perform a Power Up Sequence when
the power is switched on, and will ensure that the DSS calibrations are performed with the
components clean.
1. CLEAN THE DSS USING ANTI-STATIC SOLUTION AND A CLEAN, SOFT, LINT FREE
CLOTH.
2. CHECK THAT THE DSS IS SEATED CORRECTLY BEFORE TIGHTENING THE
SCREW.

3. IF THE DSS IS NEW, PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3). REP 9-39 Dicorotron and Shield
Removal

2. OPEN THE PRINTER RIGHT AND LEFT DOORS.
3. REMOVE PHOTORECEPTOR INNER PANEL.
4. REMOVE THE TRANSFER DICOROTRON (REP 9-49).
WARNING
Always wear safety glasses when handling the dicorotrons. Do not touch the wire. Eye
injury could result if glass breaks. Wash your hands after handling the dicorotrons.
NOTE: Do not use this procedure for the Transfer Dicorotron. Use the following procedure for
all other dicorotrons.
5. REMOVE DICOROTRON AND SHIELD (Figure 1).
WARNING
DO NOT TOUCH
THE WIRE
BOTTOM VIEW
1
PUSH AND HOLD
2
BIAS TAB TO UNLATCH
THEN PULL OUT THE
DICOROTRON ASSEMBLY
(CORONODE AND
SHIELD)
Figure 1 Removing a Dicorotron

6. CHECK THE DICOROTRON CONNECTORS FOR CORROSION. REPLACE THE
DICOROTRONS, DICOROTRON CONNECTORS (REP 9-40), AND THE HVAC OUT-
PUT MODULE (REP 1-4), AS REQUIRED.
CAUTION
Do not put grease from the insulator onto housing.
7. CLEAN THE SHIELD (Figure 2).
1
REMOVE THE
BIAS SHIELD
CLEAN THE OUTSIDE

WITH A DRY TOWEL
3
CLEAN THE
INSIDE WITH A
DRY TOWEL
Figure 3 Cleaning the Housing

2
CLEAN THE OUTSIDE 9. ENTER [SCP], [HFSI], SELECT [P09-815 Dicorotron Shields], AND PRESS [Reset
WITH A DRY CLEANING Count].
TOWEL
Replacement
1. INSTALL THE DICOROTRON WITHOUT THE SHIELD, THEN INSTALL THE SHIELD IN
THE DICOROTRON.
2. IF A NEW DICOROTRON WAS INSTALLED, ENTER [SCP], [HFSI], [Dicorotrons],
AND SELECT THE APPROPRIATE:
Figure 2 Cleaning a Shield a. [09-820 R Charge 1], [Reset Count].
b. [09-822 R Preclean], [Reset Count].
CAUTION c. [09-823 R Transfer], [Reset Count].
Use only a dry cleaning towel. Water or solvents damage the coating and cause the print qual- d. [09-824 R Detack], [Reset Count].
ity defects. 3. IF A NEW CHARGE DICOROTRON IS INSTALLED, PERFORM THE XEROGRAPHIC
8. CLEAN THE HOUSING (Figure 3). SET-UP (ADJ 9-3).

REP 9-40 Dicorotron Connectors W- P287
3
Removal DEPRESS THE
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. LATCH, AND PULL
OUT CONNECTOR
NOTE: Use the following procedure in order to remove connectors of the OZAC Dicorotrons.
2. REMOVE DICOROTRON AND SHIELD (REP 9-39).

3. IF REMOVING THE CHARGE DICOROTRON CONNECTOR, REMOVE THE HVAC
OUTPUT MODULE (REP 1-4). THE HVAC OUTPUT MODULE DOES NOT NEED TO BE
REMOVED TO REMOVE ANY OF THE OTHER DICOROTRON CONNECTORS.
4. DISCONNECT THE OZAC DUCT FROM THE DICOROTRON CONNECTORS (Figure
1).
2
DISCONNECT THE
DC LEAD
1
SEPARATE THE
DUCT FROM THE
CONNECTOR
DISCONNECT THE
DUCT Figure 2 Removing the Connector (Charge Dicorotron shown)
Replacement
1. REPLACE THE DICOROTRON CONNECTOR.
2. CONNECT THE OZAC DUCT.
3. INSTALL THE HVAC OUTPUT MODULE, IF IT WAS REMOVED.
4. INSTALL THE DICOROTRON AND SHIELD.
Figure 1 Disconnecting the OZAC Duct
NOTE: Pull the duct up in order to separate it from the Charge Dicorotron Connectors, all other
ducts are pulled toward rear.
5. REMOVE CONNECTOR (Figure 2).

REP 9-41 OZAC Duct NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assem-
Removal
4. OPEN THE XEROGRAPHIC CARD CAGE, AND PREPARE TO REMOVE OZAC DUCT
(Figure 1).
2. REMOVE THE PRINTER LEFT REAR COVER AND THE ELECTRICAL MODULE REAR
COVER (REP 4-1).
2
DISCONNECT THE
AC CONNECTOR
1
CUT THE CABLE
TIES (4)
Figure 1 Preparing to Remove the Ozac Duct
5. LOCATE THE VERTICALLY ROUTED WIRE HARNESS BELOW THE CHARGE

DICOROTRONS. TEMPORARILY DISCONNECT THE WIRE HARNESS FROM THE
CABLE CLAMP.
6. DISCONNECT THE CHARGE DICOROTRON CONNECTORS FROM THE CHARGE
DICOROTRONS.
NOTE: Do not discard the clamps.
7. REMOVE OZAC DUCT (Figure 2).

4
LOOSEN THE
CLAMPS (2), AND
REMOVE THE
OZAC DUCT
3 1
SEPARATE THE DUCT SEPARATE THE DUCT FROM
FROM THE DETACK AND 2 THE CHARGE DICOROTRON
TRANSFER DICOROTRONS SEPARATE THE DUCT CONNECTORS (2)
FROM THE PRECLEAN
DICOROTRON
Figure 2 Removing the Ozac Duct
Replacement
CAUTION
Ensure that the red wires for the Charge Dicorotron Connectors are connected to the appropri-
ate Dicorotron Connector, and ensure that the Dicorotron Connectors are reinstalled in the cor-
rect location. Failure to do this will result in improper charging of the Photoreceptor Belt.
NOTE: Connect the Charge 1 Dicorotron Connector and the Charge 2 Dicorotron Connector to
the Ozac Duct at the same time.
1. REPLACE THE OZAC DUCT (Figure 3).

5
CONNECT THE
DUCTS, AND
TIGHTEN THE
CLAMPS (2)
1
CONNECT THE DUCT
CONNECTORS TO THE
CHARGE DICOROTRON
CONNECTORS (2)
4
3
CONNECT DUCT TO THE PRE-
CONNECT THE
2
CLEAN, DETACK, AND TRANSFER PUSH IN THE
DICOROTRON CONNECTORS AC CONNECTOR
DICOROTRON
CONNECTORS (2)
Figure 3 Replacing the Ozac Duct
2. REPLACE THE CABLE TIES (Figure 4).

INSTALL THE
CABLE TIES (4)
Figure 4 Installing the Cable Ties
3. CONNECT THE VERTICAL WIRE HARNESS TO THE CABLE CLAMP. REP 9-42 Ozone Filter Assembly
5. CLOSE THE TONER FILTER ASSEMBLY.
Removal
COVER (REP 4-1).

NOTE: Cut cable ties as required. 5. REMOVE THE OZONE FILTER ASSEMBLY (Figure 1).
2
DISCONNECT THE
1 VACUUM SWITCH
CUT CABLE TIE CONNECTOR
3
REMOVE NUTS
(2), WASHERS (4),
AND BRACKET
4
DISCONNECT THE
BLOWER CONNECTOR
5
DISCONNECT THE
DUCT AND REMOVE
FILTER ASSEMBLY
Figure 1 Removing the Filter Assembly
6. REMOVE THE OZONE BLOWER (MOT904) (REP 9-43).

Replacement
1. CONNECT THE OZONE BLOWER (MOT904) TO THE NEW FILTER.
2. INSTALL THE FILTER ASSEMBLY.
NOTE: Check that the wiring is not pinched between Blower Motor and Accumulator Bottle.
3. PUSH THE ASSEMBLY COMPLETELY TO THE RIGHT BEFORE TIGHTENING THE

MOUNTING NUTS.
4. INSTALL THE HVAC OUTPUT MODULE.
5. REPLACE CABLE TIES.

REP 9-43 Ozone Blower (MOT904) 2. REMOVE THE OZONE FILTER ASSEMBLY (REP 9-42).
3. REMOVE THE OZONE BLOWER (Figure 1).
Removal
3 4
REMOVE NUTS (2) REMOVE THE
OZONE BLOWER
1
REMOVE THE
SCREWS (2) AND
THE VACUUM
SWITCH
2
REMOVE NUT AND
WASHERS (2)
Figure 1 Removing the Ozone Blower
Replacement REP 9-44 Cavity Cooling Fan (MOT105)

1. INSTALL THE OZONE VACUUM SWITCH (S902). Parts List on PL 9.8
2. CONNECT THE OZONE FILTER TO THE NEW OZONE BLOWER.
Removal
NOTE: Check that the gasket is positioned between the blower and the filter. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
3. INSTALL THE FILTER ASSEMBLY. NOTE: Positioning of the foam gasket that surrounds the fan will be easier if the printer left top
4. INSTALL THE OZONE FILTER ASSEMBLY (REP 9-42). cover is removed.
5. INSTALL THE HVAC OUTPUT MODULE. 2. REMOVE THE PRINTER LEFT TOP COVER.
6. REPLACE CABLE TIES. 3. REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).
4. REMOVE THE CAVITY COOLING FAN (Figure 1).

REP 9-45 PR Edge Guides or Tension Roll
Removal
3 3. COVER THE DEVELOPER CAVITY IN ORDER TO PREVENT CONTAMINATION OF
PULL THE FAN OFF THE DEVELOPER MATERIAL.
THE LOCATING PINS 4. REMOVE THE LEFT DEVELOPER ZONE ROLL.
5. IF ONLY THE TENSION ROLL MUST BE REMOVED, PERFORM THE FOLLOWING:
a. Remove the nut securing the rear cable to the tensioning arm.
b. Pull the rear PR Edge Guide to the left in order to remove the Tension Roll.
6. REMOVE PR EDGE GUIDES (Figure 1).
1
RELEASE THE
2 CABLE TENSION
REMOVE THE
SCREWS (2)
1
CUT THE CABLE TIES AND
DISCONNECT CONNECTOR
2
REMOVE THE
NUTS (4)
Figure 1 Removing the Fan (MOT105)
Replacement
1. ENSURE THAT THE WIRING IS SECURED AWAY FROM THE MOVING COMPO-
NENTS AND THE FOAM GASKET IS REPISITIONED AROUND THE FAN. 3
REMOVE THE TEN-
2. REINSTALL THE PRINTER LEFT REAR AND LEFT TOP COVER. SION ROLL AND THE
EDGE GUIDES
Figure 1 Removing the Edge Guides
7. CLEAN ANY FUSED TONER FROM THE PHOTORECEPTOR SUPPORTING SUR-

FACES OF THE EDGE GUIDES.
Replacement
1. INSTALL THE EDGE GUIDE (Figure 2).

REP 9-46 PR Module
BEARING
Removal
NUTS PULLEY
NOTE: Ensure that PR Module Alignment Tool is available before removing the Module.

3. COVER THE DEVELOPER CAVITY, AND REMOVE PHOTORECEPTOR BELT (REP 9-
35).
BUSHING 4. RAISE THE PR MODULE, AND DISCONNECT THE HARNESS FROM REAR OF MOD-
ULE.
WARNING
For Machines with Hydraulic Lift Assemblies. Support the raised PR Module whenever
the Hydraulic Lift Assembly is disconnected from Xerographic Drawer. The Module can
SPRING fall freely, and can cause an injury.
5. PREPARE PR MODULE FOR REMOVAL (Figure 1).
1 2
POSITION THE INSTALL THE
CABLE EDGE GUIDE
Figure 2 Installing the Edge Guide
2. ADJUST THE PHOTORECEPTOR TENSION (ADJ 9-11).

3. INSTALL THE LEFT DEVELOPER ZONE ROLL AND PHOTORECEPTOR BELT.

2 1
RELEASE THE
REMOVE THE
VALVE DURING
BOLT AND THE
STEP 3
HINGE PIN
3
PUSH BRACKET
1 FLUSH WITH 2
PR MODULE REMOVE THE
WARNING THE FRAME REAR FRAME MODULE
SUPPORT THE MODULE
AND REMOVE SCREWS (2)
Figure 1 Preparing the Module for Removal Figure 2 Removing the Module
NOTE: Grasp the PR Module only near the center of the front and rear frame. Replacement
6. REMOVE PR MODULE (Figure 2). NOTE: Grasp the PR Module only near the center of the front and rear frame.
1. SEAT THE PR MODULE ON THE RIGHT HINGE PIN.

2. INSTALL THE OTHER HINGE PIN.
3. RAISE PR MODULE, AND PULL BRACKET OF THE HYDRAULIC LIFT ASSEMBLY
INTO ALIGNMENT WITH THE MOUNTING HOLES. SUPPORT THE PR MODULE, AND
INSTALL SCREWS.
4. CONNECT HARNESS.
5. PERFORM PR MODULE ALIGNMENT (ADJ 9-10).

REP 9-47 Xerographic Drawer Slides
Removal
2. REMOVE PR MODULE (REP 9-46). CAUTION
REMOVE THE BOLTS
(4 ON THE LEFT OR 3
4. DISCONNECT CONNECTORS OF RIBBON CABLE FROM XEROGRAPHIC DRAWER, ON THE RIGHT)
AND HOLD THEM TOGETHER WHILE ALLOWING THEM TO RETRACT SLOWLY
TOWARD THE REAR.
5. ENSURE THAT THE DRAWER IS EXTENDED AND LATCHED.
CAUTION
Do not loosen the bolts. Loosening the bolts could require replacement of the Printer.
6. REMOVE XEROGRAPHIC DRAWER FRAME (Figure 1).
1
CAUTION
REMOVE THE
NUTS (4)
2
REMOVE THE
SLIDE
Figure 2 Removing a Slide
Replacement
1. INSTALL THE NEW SLIDES ON BASE PLATE OF PRINTER. ENSURE THAT THE
SEMIPERFS ARE SEATED IN THE ALIGNMENT HOLES IN THE BASE PLATE OF
PRINTER.
2. EXTEND THE SLIDES AND THE DRAWER LATCH LINKAGE COMPLETELY.
2 3. POSITION THE DRAWER ON THE SLIDE BRACKETS, AND SEAT THE LATCH LINK-
REMOVE THE FRAME AGE IN THE DETENT OF THE STOP BRACKET ON BASE PLATE.
CAUTION
Do not loosen any of the other hardware. The Slides are aligned at the factory.
4. TIGHTEN THE FOUR NUTS.
5. CONNECT THE RIBBON CABLE TO THE XEROGRAPHIC DRAWER.
Figure 1 Removing the Drawer Frame 6. INSTALL DEVELOPER ASSEMBLY.
7. INSTALL PR MODULE.
7. REMOVE THE LEFT SLIDE AND/OR THE RIGHT SLIDE (Figure 2).

REP 9-48 Transfer Blade Replacement
Parts List on PL 9.11 WARNING
Removal Always wear safety glasses when handling a Dicorotron. Do not touch a Dicorotron
wire.
and Functions section. 1. INSTALL THE TRANSFER DICOROTRON (REP 9-49).
2. INSTALL THE TOOL (Figure 2).
2. OPEN THE FRONT DOORS.
3. REMOVE THE TRANSFER BLADE (Figure 1).
NOTE: TOOL IS
SEATED WHEN THE
NOTCH IS AT FRONT
END OF PREFUSER
RELEASE BRACKET
THE TRANSFER
DICOROTRON
1
PUSH THE TOOL BETWEEN TOP OF
THE BLADE ACTUATOR LEVER AND
1 BOTTOM OF THE DICOROTRON
DEPRESS THE BLADE HANDLE
IN ORDER TO REMOVE BLADE
Figure 2 Installing the Tool
CAUTION
Do not install the Transfer Blade and the Transfer Dicorotron as a pair. Damage to the Photore-
Figure 1 Removing the Transfer Blade
ceptor Belt may occur.
CAUTION 3. INSTALL THE TRANSFER BLADE (Figure 3).
Ensure that the edge of the Transfer Blade is not damaged. A damaged edge will scratch the
Photoreceptor Belt, and/or cause a copy quality defect.
4. CLEAN THE EDGE OF THE TRANSFER BLADE WITH A DRY, SOFT CLOTH.

REP 9-49 Transfer Dicorotron
Removal

1 WARNING
SEAT THE BLADE Always wear safety glasses when handling a Dicorotron. Do not touch a Dicorotron
ON THE EDGE OF wire.
THE DICOROTRON
CAREFULLY CAUTION
Do not actuate the Transfer Blade Solenoid while removing the Transfer Dicorotron Assembly.
The Transfer Blade will be damaged if the Solenoid is actuated during removal.
3. REMOVE THE TRANSFER DICOROTRON (Figure 1).
2
PUSH THE TRANSFER
BLADE IN COMPLETELY
3
HOLD THE BLADE IN
POSITION WHILE
REMOVING THE TOOL
Figure 3 Installing the Transfer Blade
4. IF A NEW TRANSFER BLADE WAS INSTALLED, ENTER [SCP], [HFSI], [Belt Module],
SELECT [P09-803 R, Transfer Assist Blade] AND PRESS [Reset Count].
1
2 CAUTION
WARNING PUSH UP, AND HOLD
PULL OUT THE
DICOROTRON
ASSEMBLY
Figure 1 Removing the Transfer Dicorotron
4. PULL THE TRANSFER BLADE OUT OF ITS CHANNEL IN THE TRANSFER

DICOROTRON (Figure 2).

1
REMOVE THE
BIAS SHIELD
3
CLEAN THE INSIDE
OF END WITH A DRY,
CLEAN, LINT FREE
TOWEL
2
2 CLEAN THE OUTSIDE
CAREFULLY PULL 1 WITH A DRY, CLEAN,
THE BLADE OUT PUSH AND HOLD LINT FREE TOWEL
OF THE CHANNEL
Figure 2 Removing the Transfer Blade Figure 3 Cleaning the Shield
5. CHECK THE DICOROTRON CONNECTORS FOR CORROSION. REPLACE THE CAUTION

DICOROTRONS, DICOROTRON CONNECTORS, AND THE HVAC OUTPUT MODULE Do not put grease from insulator onto the housing.
(REP 1-4).
7. CLEAN THE HOUSING (Figure 4).
6. CLEAN THE SHIELD (Figure 3).

CLEAN THE OUTSIDE
WITH A DRY TOWEL
Figure 4 Cleaning the Housing
Replacement
CAUTION
Handle the Transfer Blade with care in order to prevent the damage. Do not bend the clear
plastic strip.
1. INSTALL THE TRANSFER DICOROTRON.
2. INSTALL THE TRANSFER BLADE (REP 9-48).
3. IF A NEW TRANSFER DICOROTRON WAS INSTALLED, ENTER [SCP], [HFSI],
SELECT [Dicorotrons], [09-823 R Transfer] AND PRESS [Reset Count].

REP 9-50 Transfer Assist Device d. Prefuser Transport Assembly (REP 10-12).
Parts List on PL 9.11 NOTE: Before removing the Pretransfer Baffle record the positions of the upper and lower cam
in order to avoid the adjustment.
Removal
To see additional information go to Xerographics in the DocuPrint 180 Unique Components e. Pretransfer Baffle (REP 8-5).
and Functions section. f. Registration Transport Assembly (REP 8-3).
4. SECURE THE DICOROTRON SPRINGS OF THE TRANSFER DICOROTRON. USE
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. THE ADHESIVE TAPE ON THE DICOROTRON SIDE OF THE RAIL IN ORDER TO
2. OPEN THE PRINTER FRONT DOORS, AND REMOVE THE PHOTORECEPTOR KEEP THE SPRINGS IN THE POSITION.
INNER PANEL. CAUTION
3. REMOVE THE FOLLOWING: Handle the Transfer Assist Device carefully. Do not touch the Actuator Segments of the Trans-
a. Detack Dicorotron (REP 9-39). fer Assist Device because the Actuator Segments may be deformed. Loosen the Locking
b. Transfer Dicorotron (REP 9-49). Knobs just enough so that the Assist Device can be carefully pushed down, and then removed
c. Photoreceptor Belt (REP 9-35). to the right.
5. REMOVE THE TRANSFER ASSIST DEVICE (Figure 1).
3 4 5
DISCONNECT L2 DISCONNECT L3 DISCONNECT L4
2
DISCONNECT L1
1
DISCONNECT THE
SENSOR CONNECTOR
6
CAUTION
LOOSEN THE KNOBS
(1/2 REVOLUTION)
Figure 1 Removing the Transfer Assist Device

Replacement
NOTE: If the plastic clips for the Actuator Segments and the plastic Actuator Blocks for the
Transfer Solenoids are not correctly assembled the device may bind, cause erratic Transfer
Blade Timing, and cause deletions on the lead and trail edge of the prints.
1. CHECK THE TRANSFER ASSIST DEVICE (Figure 2).
SOLENOID BLOCK
3 2
CHECK:
CHECK THAT THE 1 GAP OF 5.0 MM MINIMUM
RETAINING CLIPS (2) CHECK THAT THE WHEN THE SOLENOID
ARE SEATED BEARING CLIPS (10) BLOCKS (4) ARE FULLY
ARE SEATED SEATED
Figure 2 Checking the Transfer Assist Device
NOTE: Ensure that the mounting brackets of the device are seated flat against the dicorotron 2. INSTALL THE TRANSFER ASSIST DEVICE (Figure 3).
rail, between the upper and the lower rib on the rail. Check that the dicorotron springs are posi-
tioned correctly, and check the wires for the solenoids are not pinched between the device and
the frame.

4 3 2
CONNECT L2 CONNECT L3 CONNECT L4
5
CONNECT L1
6
CONNECT SENSOR
CONNECTOR
1
CAUTION
SEAT THE MOUNTING BRACKETS
BETWEEN THE RIBS ON RAIL, AND
TIGHTEN THE LOCKING KNOBS
Figure 3 Installing the Transfer Assist Device
3. CHECK THAT THE TRANSFER ASSIST DEVICE IS FULLY SEATED AGAINST THE
FRAME.
4. MANUALLY ACTUATE THE FOUR TRANSFER SOLENOIDS TO CHECK THE PROPER
OPERATION.
5. INSTALL THE FOLLOWING:
a. Registration Transport Assembly (REP 8-5).
NOTE: Move the upper and lower cam to the positions recorded during the removal.
b. Pretransfer Baffle (REP 10-7).

c. Prefuser Transport Assembly (REP 10-0).
d. Transfer Dicorotron (REP 9-49).
e. Detack Dicorotron (REP 9-39).
f. Photoreceptor Belt (REP 9-35).
6. CHECK/ADJUST THE TRANSFER BLADE TIMING (ADJ 9-9).

REP 9-51 Transfer Solenoids 1-4 (SOL903/904/905/906) 2. REMOVE THE TRANSFER ASSIST DEVICE (REP 9-50).
Parts List on PL 9.12 NOTE: The following method of removal applies to all four Solenoids. All Solenoid Bodies must
be removed in order to access any of the Solenoid Plungers. Electrically disconnect only the
Removal Solenoid that has to be replaced.
3. REMOVE THE SOLENOID BODY (Figure 1).
2
REMOVE THE
CLIPS
3
REMOVE SOLENOID
BODY (4)
1
CUT THE CABLE TIE
AND DISCONNECT THE RIGHT SIDE VIEW
SOLENOID
Figure 1 Removing the Solenoid Body
4. REMOVE THE SUPPORT BRACKET (Figure 2).

1
TOP RIGHT VIEW REMOVE THE SCREWS (2)
AND THE GROUND WIRES (4)
2
HOLD THE BOTTOM OF THE
ASSEMBLY TOGETHER
3
REMOVE THE
SUPPORT
BRACKET
Figure 2 Removing the Support Bracket
NOTE: The spring of Solenoid 1 (SOL903) is larger than the other three Solenoid springs.
Save the Springs and Washers so that they can be installed on new Solenoids.
5. REMOVE THE SOLENOID PLUNGER (Figure 3).
RIGHT SIDE VIEW
LARGER SPRING
1
NOTE: REMOVE THE
SPRING, WASHER,
AND PLUNGER
Figure 3 Removing the Solenoid Plunger
Replacement
1. CHECK THE ROUTING OF THE WIRES (Figure 4).

3
CHECK THE
CABLE TIES
2
CHECK THE
SOLENOID
WIRES (4)
1
CHECK THE
GROUND WIRES (4)
Figure 4 Checking the Routing of the Wires
2. INSTALL THE TRANSFER ASSIST DEVICE (REP 9-50). REP 9-52 Xerographic Drawer Latch Cable
Removal
4. REMOVE NUT SECURING THE LATCH CABLE, AND REMOVE CABLE.
Replacement
1. INSTALL THE CABLE (Figure 1).

4
ATTACH THE
CABLE
3
ONE COMPLETE
WRAP
1
ROUTE THE
CABLE
2
ONE COMPLETE
WRAP AROUND
THE PULLEY
Figure 1 Installing the Cable
2. ADJUST THE CABLE TENSION (Figure 2).

REAR VIEW
2
SPECIFICATION: THE
LEFT EDGE OF LATCH
TOUCHES RIGHT
EDGE OF BRACKET
0.0 TO 0.5 mm
1
PREVENT CABLE
FROM TURNING,
AND TIGHTEN THE
ADJUSTING NUT TO
SPECIFICATION OF
3 STEP 2
TIGHTEN THE
LOCK NUT
Figure 2 Adjusting the Cable Tension

REP 9-53 Discharge Lamps PWB (PS902) 2. REMOVE THE PHOTORECEPTOR BELT (REP 9-35).
3. REMOVE THE DISCHARGE LAMPS POWER SUPPLY PWB (Figure 1).
Removal
1
HOLD OPEN THE
PR MODULE
2
REMOVE THE PWB
Figure 1 Removing the PWB

REP 9-54 Hydraulic Lift Assembly NOTE: Prepare a stack of paper in order to hold the PR Module open while removing the Cyl-
inder.
6. RAISE THE PR MODULE, AND REMOVE THE HYDRAULIC CYLINDER (Figure 2).
Removal
2. REMOVE THE PHOTORECEPTOR INNER PANEL.
3. REMOVE THE PHOTORECEPTOR BELT (REP 9-35). 3
4. REMOVE THE LOWER SAFETY SHIELD OF THE PR MODULE. REMOVE THE NUT
5. LOWER THE PR MODULE, AND REMOVE THE RIGHT LIGHT SHIELD (Figure 1).
4 3
LIGHT SHIELD SCREWS (FRONT
1 AND REAR 1) 4
PUSH IN PISTON,
REMOVE THE
RETAINING RING
AND CYLINDER
1
SUPPORT THE PR
MODULE WITH A
STACK OF PAPER
2 2
1 REMOVE THE REMOVE THE RETAINING RING
LOOSEN THE SCREWS DUMP BUTTON AND THE CLEVIS PIN
(FRONT 1 AND REAR 1) COVER
Figure 2 Removing the Hydraulic Cylinder
7. REMOVE THE CLEVIS PIN RECEIVER FROM THE OLD PISTON ROD, AND THREAD
IT ONTO THE NEW PISTON ROD.
Replacement
1. INSTALL THE CYLINDER (Figure 3).
Figure 1 Removing the Light Shield

3 1
INSTALL THE DUMP BUTTON, 0.25 mm to 0.75 mm GAP
AND TIGHTEN THE NUT
HYDRAULIC
DUMP BUTTON
1
INSTALL THE CYL-
INDER AND 2
SECURE WITH MOVE ACTUATOR
THE RETAINING UNTIL BUTTON
RING JUST HOLDS THE
SHIM, THEN
TIGHTEN THE
SCREWS (2)
XEROGRAPHIC
DRAWER FRAME
PR MODULE
FRAME
2
INSTALL THE CLEVIS PIN VIEW FROM THE LEFT
AND RETAINING RING
Figure 3 Installing the Cylinder Figure 4 Adjusting the Dump Actuator
2. HOLD THE PR MODULE, AND REMOVE THE STACK OF PAPER. 4. INSTALL THE RIGHT LIGHT SHIELD, AND TIGHTEN THE FOUR SCREWS ON THE
3. LOWER THE PR MODULE, AND ADJUST THE HYDRAULIC DUMP ACTUATOR (Fig- TWO LIGHT SHIELDS.
ure 4). 5. INSTALL THE DUMP BUTTON COVER.
6. CHECK THAT THE NEW CYLINDER SUPPORTS THE PR MODULE BY CAREFULLY
OPENING AND CLOSING THE MODULE A FEW TIMES.
7. OPEN THE PR MODULE, AND INSTALL THE LOWER SAFETY SHIELD.

REP 9-55 Photoreceptor Spot Cleaning CAUTION
Work as quickly as possible to keep the light shock to a minimum. Replace the Photoreceptor
Parts List on PL 9.26 Belt if it is exposed to the room light for more than 10 minutes.
Clean 2. SWITCH OFF THE PRINTER CIRCUIT BREAKERS, AND OPEN THE XEROGRAPHIC
NOTE: Before performing this procedure, ensure that all other causes of spots, streaks, or hor- DRAWER.
izontal lines have been eliminated. (Refer to the Print Quality RAPs.) The following materials CAUTION
are required to clean the spots: Film Remover (43P45), Cotton Swabs (35P2162), and Foam Ensure that the PR Module is securely blocked in the upward position, and ensure the Photo-
Pads (600S4653). receptor Belt does not touch the Developer Housing. This will prevent the damage to the Pho-
toreceptor Belt.
1. CUT THE FOAM PAD INTO FOUR EQUAL SIZE SQUARES.
3. PREPARE THE PR MODULE (Figure 1).
3
CAREFULLY LOWER
THE PR MODULE
ONTO THE PLIERS
1
UNLATCH AND
RAISE THE PR
MODULE
2
POSITION THE PLIERS
Figure 1 Preparing the PR Module
CAUTION NOTE: The interdocument gap in the 7 pitch mode is 30 mm. The distance between the PR
Clean any Transfer Blade Timing Ink marks only with a Cotton Swab moistened with water. The Belt seam and the lead edge of print #1 is 8 mm. The distance between the trail edge of print
ink must be removed with water. Film remover will make the marks permanent. #7 and the PR Belt seam is 22 mm.
4. ROTATE THE PR BELT IN A COUNTERCLOCKWISE DIRECTION ONE COMPLETE 6. ALIGN THE PRINTS THAT WERE GENERATED IN THE BLACK SPOTS RAP ON THE
REVOLUTION, AND CHECK FOR CONTAMINATION BY THE TRANSFER BLADE TIM- PR BELT, WITH THE PRINT ORIENTED FACE DOWN AND THE LEAD EDGE ARROW
ING INK. USE ONLY WATER TO CLEAN THE TIMING INK. POINTING TOWARDS THE LEFT, TO LOCATE THE IMAGE FRAME WITH A SPOT(S)
5. ROTATE THE PR BELT UNTIL THE PR BELT SEAM IS CENTERED ON TOP OF THE (Figure 2).
PHOTORECEPTOR MODULE.

FRONT EDGE OF PR BELT SEAM
THE PR BELT 1
NOTE: POSITION THE
PRINTS WITH THE LEAD
EDGE ARROW FACING
THE PR BELT
Figure 2 Aligning the Prints on the PR Belt
NOTE: The visibility of the spot(s) will be enhanced if the surface of the PR Belt is viewed at an CAUTION
angle. Wipe away all background Toner from the surrounding area of a spot before applying the Film
7. CAREFULLY LIFT THE EDGE OF THE PRINT, AND LOCATE THE SPOT(S) ON THE Remover, otherwise blotches of the image will result. Do not use excessive pressure when
PR BELT THAT CORRESPOND(S) TO THE SPOT(S) ON THE PRINT. cleaning spots from the PR Belt. The belt may be scratched or permanently deformed.
8. ROTATE THE PHOTORECEPTOR BELT UNTIL THE SPOT(S) IS POSITIONED 9. POUR A SMALL AMOUNT OF THE FILM REMOVER INTO THE BOTTLE CAP, AND
CLEAN THE SPOT(S):
DIRECTLY ON TOP OF THE CARPET IN ORDER TO PROVIDE MORE SUPPORT
WHILE CLEANING THE PR BELT. a. Wipe any loose Toner off the Photoreceptor Belt with the edge of one of the
sponges. Use a clean edge for each spot area.

b. Touch the spot(s) with the Cotton Swab that has been lightly soaked with Film 12. ENTER dC106, SELECT [Printer Options], [Test Patterns and PQ], Dimensional],
Remover. After the spot(s) is wetted, gently rub it with the wet swab in a circular AND [Lighter 2].
motion until the spot(s) disappear. When the spot disappears, wipe the area dry with 13. MAKE 100 PRINTS, AND VERIFY THAT THE SPOTS HAVE BEEN REMOVED.
a clean edge of a sponge.
14. IF SPOTS REMAIN, PERFORM THE FOLLOWING:
NOTE: Wetting the spot prior to the cleaning will allow some Film Remover to penetrate a. Replace the Photoreceptor Belt (REP 9-35).
between the dirt and the Photoreceptor Belt, and assist in loosening the dirt. b. Perform the Xerographic Set-up (ADJ 9-3).
c. Repeat Steps 6-9 until all circled spots, on each print, of the Set are cleaned. Work REP 9-56 Transfer Blade Sensor (Q907)
as quickly as possible to reduce the amount of light shock.
10. REMOVE THE PLIERS, LATCH THE PR MODULE, AND CLOSE THE XEROGRAPHIC
DRAWER. Removal
11. RESTORE THE PRINTER TO THE OPERATING CONDITION. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
1
AND THE GROUND WIRES (4)
TRANSFER BLADE
SENSOR (Q907)
2
3 HOLD THE
MOVE THE SUPPORT ASSEMBLY
BRACKET TOGETHER
Figure 1 Moving the Support Bracket
4. REMOVE THE TRANSFER BLADE SENSOR (Figure 2).

1 THE LOCATING PIN
REMOVE THE
SCREW AND
THE SENSOR
THE SUPPORT
BRACKET
Figure 2 Removing the Transfer Blade Sensor
Replacement
1. REPLACE THE TRANSFER BLADE SENSOR.
2. CHECK THE ROUTING OF THE WIRES (Figure 3).

3
CHECK THE
CABLE TIES
2
CHECK SOLENOID
WIRES (4)
1
CHECK THE
GROUND WIRES (4)
Figure 3 Checking the Routing of the Wires
3. INSTALL THE TRANSFER ASSIST DEVICE (REP 9-50). REP 9-57 Spots Blade
5. CHECK THE TRANSFER BLADE SENSOR (Q907):
a. Enter dC330, [9], and [Xfer Blade Sol 1].
Removal
b. Press the Continue button, and check that the Transfer Blade Position Sensor NOTE: The DP180MX has a unique Spots Blade and it is not compatible with the DP180.
display changes from [L] to [H].
2. REMOVE THE FUSER DRIP PAN (Figure 1).

2
OPEN THE FUSER
1
LOOSEN THE
SCREW 3
REMOVE THE
DRIP PAN
Figure 1 Removing the Drip Pan
3. REMOVE THE BLADE BRACKET (Figure 2).

BLADE GUIDES
LEFT SIDE VIEW
1
REMOVE THE
BLADE BRACKET CLEANER MODULE
Figure 2 Removing the Blade Bracket
4. REMOVE THE SPOTS BLADE (Figure 3).

LEFT SIDE VIEW BLADE BRACKET
2
REMOVE THE
BLADE
1
REMOVE THE
NUTS (2)
Figure 3 Removing the Spots Blade
Replacement
CAUTION
Do not install a new spots blade and a new PR belt simultaneously. Perform the Xerographic
Setup (ADJ 9-3) with the new PR belt, then install the new spots blade.
1. INSTALL THE NEW BLADE ONTO THE BLADE BRACKET.
CAUTION
Toner must be applied to the edge of the Spots Blade along its entire length. The toner will pro-
tect the Photoreceptor Belt by acting as a lubricant between the new Spots Blade and the Belt.
2. USE THE TONER PAD SUPPLIED, AND APPLY THE TONER TO THE ENTIRE
LENGTH OF THE SPOTS BLADE.
3. INSTALL THE BLADE BRACKET INTO THE FRONT AND THE REAR BLADE GUIDES.
4. ENSURE THAT THE BLADE BRACKET MOVES FREELY.
5. IF INSTALLING A NEW SPOTS BLADE, SELECT [SCP], [HFSI], [Cleaner/Developer],
[09-805 R Post-Cleaner Blade], AND PRESS [Reset Count].
6. Inspect old spots blade to insure contact area (brown) is 0.5mm to 0.3mm adjust spots
blade contact (ADJ 9-16) if required.

REP 9-58 Spots Blade Guide 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
3. REMOVE THE FUSER DRIP PAN (Figure 1).
Removal 4. REMOVE THE BLADE BRACKET (Figure 2).
5. REMOVE THE BLADE GUIDES (Figure 1).
1
REMOVE THE
E-RINGS (2)
3
REMOVE THE SHAFT
2 AND THE FRONT GUIDE
MOVE THE SHAFT AND
REMOVE THE REAR GUIDE
Figure 1 Removing the Guides
6. REMOVE THE SPOTS BLADE (Figure 2).
LEFT SIDE VIEW BLADE BRACKET
2
REMOVE THE
BLADE
1
REMOVE THE
NUTS (2)
Figure 2 Removing the Spots Blade
Replacement 1. CHECK/ADJUST THE SPOTS BLADE CONTACT (ADJ 9-16).

REP 9-59 PR Mini-rug 3. CLOSE THE PR MODULE.
Removal NOTE: Save the Screws (4) and the Spring Washers (4).
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. 4. DISCARD THE PR MINI-RUG (Figure 1).
1
REMOVE THE SCREWS (4) AND
THE SPRING WASHERS (4) 2
REMOVE THE
MINI-RUG
Figure 1 Removing the PR Mini-Rug
Replacement
CAUTION
Do not tighten the screws. The spring washers can be flattened, and will not support the Mini-
Rug correctly.
1. POSITION THE MINI-RUG (Figure 2).

REP 9-60 POP Sensor (Q904) Cleaning
3
CAUTION Clean
VERY LOOSELY INSTALL 1. SWITCH OFF THE PRINTER POWER.
THE SCREWS (4) 2. OPEN THE XEROGRAPHIC DRAWER.
3. CLEAN THE POP SENSOR.
4. ENTER [SCP], [HFSI], [Belt Module], SELECT [09-809 C POP Sensor], AND PRESS
[Reset Count].
2
ALIGN HOLES OF
MINI-RUG WITH THE
WASHERS (4)
1
CENTER THE SPRING
WASHERS TO THE
MOUNTING HOLES (4)
Figure 2 Positioning the PR Mini-Rug
2. ADJUST THE PR MINI-RUG HEIGHT (ADJ 9-17).

REP 9-61 Cleaner Detoning Rolls or Bearing Plates
Removal
1. Switch off the Printer Circuit Breakers.
NOTE: Replace a bound up cleaner module. Do not attempt to clean it.
2. Remove Photoreceptor (REP 9-35) and cover the PR Module under the cleaner module
with paper.
3. Remove the Cleaner Brush (REP 9-23).
4. Remove the ROS lower inner panel.
5. Remove the Cleaner Manifold (REP 9-24).
6. Place a stack of paper (approx. 13mm thick) between the PR Module and the Cleaner
Housing to support the Cleaner Module.
7. Remove the Preclean Dicorotron (REP 9-39).
8. Remove the Front Spots Blade Guide (REP 9-58).
9. Remove the Cleaner Augers and Blades (REP 9-25). Discard the Cleaner Blades.
10. Clean the Augers.
11. Remove the nuts securing the Front Detoning Roll Gears and remove the gears.
12. Remove Dicorotron Connectors (OZAC) of the Preclean Dicorotron (REP 9-40).
13. Remove the upper waste toner duct (REP 9-17). Remove the Auger Tube Support
located behind the upper Waste Toner Duct.
14. Remove the Cleaner Drive Gears (REP 9-27).
15. Visually check the gears for excessive wear.
16. Check the bearings of the Detoning Rolls. If the ball bearings have fallen out or the bear-
ing races rotate in the plastic housing, the plates or the cleaner module must be replaced.
To replace the rear plate, the cleaner module must be removed (REP 9-26).
17. Remove the cleaner front support.
CAUTION
Avoid damaging the plate while separating it from the housing by gently prying all along the
interface. Do not lose the Spring for the manifold latch.
18. Remove the front plate (Figure 1).

NOTE: MANIFOLD LATCH
SPRING IS BEHIND THIS
SCREW
1
DETACH THE FRONT
DICOROTRON RAIL,
SAVE THE SHIM(S)
2
REMOVE SCREWS (6),
THEN REMOVE THE
FRONT PLATE
Figure 1 Removing the Front Plate
19. Remove the detoning rolls. Clean the inside housing with the vacuum adapter tube. Clean 6. Reinstall the cleaner drive gears with the part numbers toward the front (REP 9-27).
the bearing areas of the plates. Ensure that new gears are installed if required.
Replacement 7. Reinstall the upper waste toner duct.
CAUTION 8. Reinstall Dicorotron Connectors (OZAC) of the Preclean Dicorotron (REP 9-40).
Wrap the roll in paper during the handling or installation to prevent scratches which will lead to 9. Install the Front Detoning Roll Gears so that the gear teeth are toward the front.
premature roll failure. 10. Install new Cleaner Blades.
1. Install the new detoning rolls with the slotted end of the shaft in the rear plate. Protect the 11. Reinstall the Augers (REP 9-25).
coated surface of the roll during installation. 12. Install a new Cleaner Brush.
2. Ensure that the manifold latch spring is seated in the housing and install the front plates. 13. Guide the alignment pin on the brush door into the locating hole in the xerographic drawer
3. Reinstall the Preclean Dicorotron Rail and shim(s) on the front plate. and latch the drawer.
4. Check/Adjust the Preclean Dicorotron Height (ADJ 9-18). 14. Tighten the screws of the cleaner front support.
5. Loosely reinstall the front support bracket of the cleaner. Remove the paper support for 15. Reinstall and check adjust the Spots Blade Guide (REP 9-58).
the Cleaner Module. 16. Reinstall the Photoreceptor (REP 9-35).

17. Reinstall the Fuser Drip Tray and inner panels. REP 9-62 Transfer Solenoids (SOL903/SOL904/SOL905/
18. Switch on the printer power. Run a print job while visually verifying from the back side of
the printer that the Cleaner Augers and the waste compactor motor are operating.
SOL906)
19. Reinstall all panels, doors, and covers. Restore the printer to an operational condition. Parts List on PL 9.12
Removal
1. SWITCH OFF THE PRINTER AND DISCONNECT ALL PRINTER POWER CORDS.
CAUTION
Handle the Transfer Assist Device carefully. Do not touch the actuator segments of the Trans-
fer Assist Device because the actuator segments may be deformed.
2. REMOVE THE TRANSFER ASSIST DEVICE (REP 9-50).
NOTE: The body of each of the four Solenoids must be removed to access the solenoid
plungers.
3. REMOVE THE BODY OF EACH SOLENOID (Figure 1).

3 2
REMOVE AND DISCARD REMOVE THE
THE BODY OF THE CLIPS (4)
DEFECTIVE SOLENOID
RIGHT SIDE VIEW
4
NOTE: TEMPORARILY
REMOVE THE BODIES OF
THE THREE REMAINING
SOLENOIDS
TRANSFER 4
1 SOLENOID
CUT CABLE (SOL904)
TRANSFER 1 TIE OF THE TRANSFER 2 TRANSFER 3
SOLENOID DEFECTIVE SOLENOID SOLENOID
(SOL903) SOLENOID (SOL905) (SOL906)
Figure 1 Removing the Body of Each Transfer Solenoid
4. DISCONNECT THE GROUND WIRES AND REMOVE THE SUPPORT BRACKET

(Figure 2).

TOP RIGHT VIEW
1
AND DISCONNECT THE
GROUND WIRES (4)
2
SQUEEZE THE
ASSEMBLY
3. TOGETHER
REMOVE THE
SUPPORT
BRACKET
Figure 2 Disconnecting the Ground Wires and Removing the Support Bracket
5. REMOVE AND DISCARD THE DEFECTIVE SOLENOID PLUNGER (Figure 3).

RIGHT SIDE VIEW NOTE: LARGEST SPRING
NYLON WASHER
1
SOLENOID #1:
REMOVE PLUNGER METAL WASHER
AND TRANSFER THE
SPRING, WASHERS
AND GRIP RING TO
THE NEW PLUNGER
2
SOLENOIDS #2, 3 AND 4:
REMOVE PLUNGER AND
TRANSFER THE SPRING,
WASHER, E-RING AND
NYLON SPRING HOLDER
TO THE NEW PLUNGER
Figure 3 Removing the Defective Solenoid Plunger
NOTE: The spring on the plunger of the Transfer 1 Solenoid is the largest and strongest b. Install the new plunger.
spring.
NOTE: Ensure that the four ground wires and the solenoid wires are routed cor-
6. REMOVE AND RETAIN THE SPRING AND MOUNTING HARDWARE FROM THE OLD rectly. This will prevent the wires from catching on internal Printer components.
PLUNGER.
c. Reinstall the Support Bracket and ensure that the ground wires are reconnected
Replacement (Figure 4).
1. INSTALL THE SOLENOID.
a. Install the retaining ring(s), washer(s) and spring onto the new plunger.

RIGHT SIDE VIEW
2
CHECK: ENSURE
THAT THE SOLE-
NOID WIRES ARE
ROUTED COR-
RECTLY
1
CHECK: ENSURE
THAT THE
GROUND WIRES
(4) ARE ROUTED
CORRECTLY
Figure 4 Ensuring that the Ground Wires and Solenoid Wires are Routed Correctly
d. Install the body of the new solenoid and reinstall the bodies of the remaining sole-
noids.
e. Reinstall the clips (4). Ensure that the clip is seated in the notches on Solenoid #1.
f. Replace the cable tie for the new solenoid connector (Figure 1).
2. REINSTALL THE TRANSFER ASSIST DEVICE (REP 9-50).

REP 10-0 Camshaft Parts List on PL 10.2
Removal
CAUTION
If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean
Dicorotron before performing this procedure in order to avoid contamination of the PR, and to
avoid possible blurred image problems.
2. REMOVE CAMSHAFT (Figure 1).
1 2
REMOVE COVER
MOVE 3
PUSH DOWN, AND
DISENGAGE (FRONT
AND REAR)
6
REMOVE THE
CAMSHAFT
5
REMOVE SENSOR
ASSEMBLY
4
MOVE
THE COVER
SCREWS
Figure 1 Removing the Camshaft
Replacement REP 10-1 Fuser Roll and Heat Rod (HTR1001)

NOTE: The coupling slider may drop into motor mount. Position the slider on motor coupling Parts List on PL 10.6
hub before installing the camshaft. Removal
1. IF INSTALLING A NEW CAMSHAFT, USE THE COUPLING HUB FROM OLD CAM- To see additional information go to Fuser in the DocuPrint 180 Unique Components and Func-
SHAFT. tions section.
2. INSTALL CAM WITH THE LOW POINT AT THE BOTTOM POSITION.
3. CHECK/ADJUST THE PRESSURE ROLL CONTACT ARC (ADJ 10-2).

WARNING 2. OPEN THE PRINTER FRONT DOORS.
Fuser is hot. Keep Fuser Agent away from eyes. 3. PULL OUT THE FUSER.
CAUTION 4. REMOVE THE FUSER INNER PANEL.
If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean 5. REMOVE FUSER ROLL (Figure 1).
Dicorotron before performing this procedure in order to avoid contamination of the PR and pos-
sible blurred image problems.
6 1
REMOVE THE RAISE STRIPPER
FUSER ROLL ASSEMBLY 2
PUSH DOWN, AND
DISENGAGE
(FRONT AND REAR)
5
DISCONNECT 3
(FRONT (1) AND RAISE PRESSURE
REAR (2)) ROLL
4
LOOSEN AND
REMOVE CLAMPS (2)
(FRONT AND REAR)
Figure 1 Removing the Fuser Roll
6. REMOVE HEAT ROD (Figure 2).

1
REMOVE
2
REMOVE THE
HEAT ROD
Figure 2 Removing the Heat Rod
Replacement REP 10-2 Metering Assembly

1. INSTALL HEAT ROD WITH TWO CONNECTORS TOWARDS THE REAR. Parts List on PL 10.4
2. CLEAN THE THERMISTORS BEFORE INSTALLING FUSER ROLL.
Removal
NOTE: Push down on the Clamps while tightening. WARNING
3. INSTALL THE CLAMPS WITH THE SCREW FACING OUT. Fuser is hot. Keep Fuser Agent away from eyes.
4. RESTORE THE PRINTER POWER. CAUTION
5. LUBRICATE THE NEW FUSER ROLL, AND RESET THE COUNTERS: If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean
a. Enter dC701, [Fuser Setups]. Dicorotron before performing this procedure in order to avoid contamination of the PR, and to
b. Select [Fuser Roll Prep], and press the Continue button.
c. Enter dC107, select [Fuser], [Fuser Roll], and press [Reset counter to zero and
update History.]. 2. OPEN THE PRINTER FRONT DOORS.
6. CHECK/ADJUST THE FUSER ROLL TEMPERATURE (ADJ 10-6). 3. PULL OUT THE FUSER.
7. CHECK/ADJUST THE PRESSURE ROLL CONTACT ARC (ADJ 10-2). 4. REMOVE METERING ASSEMBLY (Figure 1).

4
DISCONNECT (2)
3 5
MOVE UP RELEASE (2)
2
UNLATCH 1 6
REMOVE CAP, REMOVE METERING
AND PLACE IN ASSEMBLY
NOTCH ABOVE
Figure 1 Removing Metering Assembly
Replacement REP 10-3 Metering Assembly Cleaning

NOTE: Ensure latch pins are fully engaged with side frame holes. Rotate pin handles up into Parts List on PL 10.7 PL 10.8
frame notches. Clean
1. REPLACE METERING ASSEMBLY. WARNING
2. FILL THE METERING ASSEMBLY WITH FUSER AGENT TO THE OVERFLOW LEVEL Fuser is hot. Keep Fuser Agent away from eyes.
INDICATOR. 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
3. IF A NEW DONOR ROLL WAS INSTALLED, ENTER [SCP], [HFSI], SELECT [Fuser CAUTION
Module], [10-803 R Donor Roll], AND PRESS [Reset Count].
If a long print run was just completed (15 minutes or longer), remove the Preclean Dicorotron in
order to avoid contamination of the Photoreceptor Belt, and to avoid possible blurred image
problems.
2. PULL OUT THE FUSER, AND REMOVE THE FOLLOWING:
a. Metering Assembly (REP 10-2).
b. Metering Roll (REP 10-4).
c. Metering Blade (REP 10-5).
d. Fuser Wick and Fuser Agent Filter (REP 10-7).

3. WIPE AWAY ALL FUSER AGENT AND CONTAMINANTS FROM THE FOLLOWING c. [10-814 C Metering Assembly] AND PRESS [Reset Count]
COMPONENTS:
REP 10-4 Metering Roll
a. Housing of the Metering Assembly
b. Metering Blade
c. Metering Roll Thermistor (RT1002) Removal
4. INSTALL THE FOLLOWING: CAUTION
a. Fuser Wick and Fuser Agent Filter (REP 10-7). If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean
Dicorotron before performing this procedure in order to avoid contamination of the PR, and to
b. Metering Blade (REP 10-5).
c. Metering Roll (REP 10-4).
d. Metering Assembly (REP 10-2).
5. FILL THE HOUSING WITH FUSER AGENT TO THE OVERFLOW LEVEL.
6. RESTORE THE PRINTER POWER, AND ENTER [SCP], [HFSI], AND [Fuser Module]
4. REMOVE METERING ASSEMBLY (REP 10-2).
TO RESET THE FOLLOWING SELECT:
a. [10-801 Ro/R Metering Blade] AND PRESS [Reset Count] NOTE: Cut and replace cable ties as required.
b. [10-802 R Wick and Fuser Agent Filter] AND PRESS [Reset Count]
3
REMOVE THE
METERING ROLL
1
MOVE
2
PUSH DOWN (2)
Figure 1 Removing Metering Roll
Replacement AGENT TO ROLL TO AVOID DAMAGE TO METERING BLADE.

1. IF INSTALLING A NEW METERING ROLL, APPLY A LIGHT COATING OF FUSER

CAUTION REP 10-5 Metering Blade
Ensure Metering Blade is in the down position and the Metering Roll is installed on top of
blade. Damage to the Donor Roll will occur if blade is not under the Metering Roll.
2. PUSH METERING ROLL BEARINGS DOWN UNTIL THE LATCHES ARE SECURE. Removal
3. CHECK/ADJUST THE METERING ROLL OVERHEAT THERMOSTAT (THS1001) (ADJ CAUTION
10-1). If the Printer just completed a long print run (15 minutes or longer), remove the Preclean
4. IF A NEW METERING ROLL WAS INSTALLED, ENTER [SCP], [HFSI], [Fuser Module], Dicorotron before performing this procedure in order to avoid contamination of the PR, and to
SELECT [10-812 R Metering Roll], AND PRESS [Reset Count]. avoid possible blurred image problems.
2. REMOVE METERING ROLL (REP 10-4).
3. REMOVE METERING BLADE (Figure 1).
WICK
1
REMOVE THE
METERING BLADE
Figure 1 Removing the Metering Blade
Replacement 1. IF INSTALLING A NEW BLADE, APPLY A LIGHT COATING OF FUSER AGENT TO

BLADE, AND INSTALL EDGE NUMBER "1".
CAUTION
Ensure Metering Blade is in the down position, and the Metering Roll is installed on top of NOTE: If 4 corners are cut, install a new blade.
blade. Damage to the Donor Roll will occur if blade is not under the Metering Roll.
2. IF EXISTING METERING BLADE IS BEING ROTATED TO A NEW EDGE, CUT THE
NOTE: To avoid stretching the blade, insert blade into holder and work from the ends toward CORNER OF THE USED EDGE (Figure 2), AND INSTALL NEXT HIGHER NUMBER
the center. EDGE.

METERING BLADE
USED EDGE
CUT CORNER
Figure 2 Cutting the Corner
3. INSTALL THE FOLLOWING:

a. Metering Roll (REP 10-4).
NOTE: After the metering roll is installed, check for a gap of at least 2.0 mm between each end
of the metering blade and metering roll bearings. If required, trim the metering blade to
achieve the required gap.
b. Metering Assembly (REP 10-2).

6. IF A NEW METERING BLADE WAS INSTALLED OR THE EXISTING BLADE WAS
ROTATED, ENTER [SCP], [HFSI], [Fuser Module], SELECT [10-801 Ro/R Metering
Blade], AND SELECT [Reset Count].

REP 10-6 Air Knife Manifold Cleaning 2. REMOVE THE PRINT TRANSPORT INNER PANEL.
3. INSTALL A CHEATER IN THE PRINTER INTERLOCK BYPASS SWITCH (S103).
4. ENTER dC330, SELECT [10], [Compressor], AND PRESS THE Continue BUTTON.
Clean 5. SELECT [Cycle Mode], [Air Knife], AND PRESS THE Continue BUTTON.
NOTE: The purpose of this procedure is to prevent dirt from being pushed into the holes, and 6. PULL OUT THE FUSER.
clog the holes.
NOTE: Ensure that the Air Knife Manifold holes are free of any obstructions
7. CLEAN THE AIR KNIFE MANIFOLD WITH FORMULA "A" (Figure 1).
1
RAISE THE
STRIPPER
ASSEMBLY
2
CLEAN THE
MANIFOLD
RIGHT FRONT VIEW
Figure 1 Cleaning the Air Knife Manifold
8. CLOSE THE FUSER. REP 10-7 Fuser Wick and Fuser Agent Filter
Removal

CAUTION 3. REMOVE THE FUSER WICK (Figure 1).
If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean
Dicorotron before performing this procedure in order to avoid contamination of the PR, and, to
2. REMOVE THE METERING ROLL (REP 10-4).
1
REMOVE THE
FUSER WICK
METERING BLADE
Figure 1 Removing the Fuser Wick
4. REMOVE THE FUSER AGENT FILTER (Figure 2).
1
LEFT SIDE VIEW LOOSEN AND DISCONNECT
THE HOSE (2)
3
LOOSEN AND DISCONNECT
THE HOSE
2
REMOVE THE FILTER
AND THE SPRING
Figure 2 Removing the Fuser Agent Filter
5. WIPE AWAY ALL FUSER AGENT AND CONTAMINANTS FROM THE FOLLOWING a. Housing of the Metering Assembly
COMPONENTS: b. Metering Blade

c. Metering Roll Thermistor (RT1002) REP 10-8 Fuser Sensor (Q1010) CLEANING
Replacement Parts List on PL 10.6
CAUTION
Clean
Ensure that the new filter is installed with the end marked OUT towards the Fuser Agent Pump.
1. CLEAN THE SENSOR AND REFLECTIVE TAPE ON AIR KNIFE USING 43P81 LENS
1. INSTALL A NEW FUSER AGENT FILTER. AND MIRROR CLEANER: USE COTTON SWAB 35P2162, AND INSERT THE SWAB
2. INSTALL A NEW FUSER WICK, AND APPLY ENOUGH FUSER AGENT TO SATURATE FROM THE TOP OF THE STRIPPER MANIFOLD.
IT.
CAUTION
Ensure that the Metering Blade is centered and seated in the Blade Support. Also ensure that
the Metering Roll is installed on top of the blade. Damage to the Donor Roll will occur if blade is
not under the Metering Roll.
3. INSTALL THE METERING ROLL (REP 10-4).
4. FILL THE METERING ASSEMBLY WITH FUSER AGENT TO THE OVERFLOW LEVEL
INDICATOR.
5. INSTALL THE METERING ASSEMBLY (REP 10-2).
8. ENTER [SCP], [HFSI], [Fuser Module], SELECT [10-802 R Wick and Agent Filter],
AND SELECT [Reset Count].

REP 10-9 Left and Right Drawer Slide 2. PLACE THE SUPPORT UNDER THE FUSER ASSEMBLY, AND REMOVE THE RIGHT
SLIDE (Figure 1).
Removal
1
SCRIBE THE POSITIONS OF 5
THE SLIDE BRACKETS (2) REMOVE THE
RIGHT SLIDE
4
REMOVE THE
SCREWS (2)
2 3
PLACE THE BOX OF PAPER UNDER THE REMOVE THE
FUSER ASSEMBLY, AND ADD PAPER TO SCREWS (2 EACH
FIRMLY SUPPORT THE FUSER ASSEMBLY NOTE: ACCESS THE SIDE)
REAR SCREWS
THROUGH HOLE IN
THE SLIDE
Figure 1 Removing the Right Slide
3. DISENGAGE THE HARNESS, AND REMOVE THE LEFT SLIDE (Figure 2).

2
PULL THE
BRACKET OUT
1
REMOVE THE
SCREWS (2)
5
REMOVE THE
LEFT SLIDE
3
REMOVE THE
CLAMP
4
MOVE HARNESS
THE OUT OF THE
CLAMP BRACKET
Figure 2 Disengaging the Harness and Removing the Left Slide
Replacement
1. REMOVE THE HARNESS CLAMP BRACKET FROM THE OLD SLIDE, AND INSTALL IT
ON NEW THE SLIDE.
2. INSTALL THE SLIDES FROM THE FRONT. ENSURE THAT THE PINS AT THE REAR
END OF THE SLIDE ENGAGE WITH THE SLOTS IN THE REAR BRACKETS.
NOTE: The scribe marks are used only for the rough positioning of the slides. The brackets will
not necessarily align to the scribe marks after the final adjustment.
3. ALIGN THE FRONT BRACKETS TO THE SCRIBE MARKS, AND INSTALL THE
SCREWS (4).
4. INSTALL THE SCREWS (4) TO FUSER ASSEMBLY.
5. ADJUST THE LEFT AND THE RIGHT DRAWER SLIDES (ADJ 10-11).

REP 10-10 MIM Compressor (MOT1002) 2. REMOVE THE ELECTRICAL MODULE REAR COVER.
3. REMOVE THE TONER FILTER ASSEMBLY (Figure 1).
Removal
1
DISCONNECT THE REAR VIEW
CONNECTOR
2
OPEN AND REMOVE
THE TONER FILTER
ASSEMBLY
3
DISCONNECT P209
Figure 1 Removing the Filter Assembly
4. REMOVE THE COMPRESSOR (Figure 2).

3
DISCONNECT THE FAS-
TON CONNECTORS (2)
2
DISCONNECT P270
1 4
DISCONNECT THE LOOSEN THE
AIR LINE 10MM SCREW
7
REMOVE THE MIM
COMPRESSOR 5
REMOVE THE
10MM SCREW
6
LOOSEN THE
10MM SCREW
Figure 2 Removing the MIM Compressor
Replacement REP 10-11 Top Transport Assembly

1. CHECK/ADJUST THE AIR KNIFE PRESSURE, PRESSURE REGULATOR, COMPRES- Parts List on PL 10.13
SOR (MOT 1002) (ADJ 10-5).
2. IF A NEW COMPRESSOR WAS INSTALLED, ENTER dC107, SELECT [Fuser], [Com-
Removal
pressor Motor], AND PRESS [Reset counter to zero and update History]. To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Compo-


4. REMOVE THE LATCH SUPPORT PLATE FOR THE PRINTER RIGHT TOP COVER.
6. OPEN THE PHN PANEL DOOR, AND PREPARE TO REMOVE THE TOP TRANSPORT
ASSEMBLY (Figure 1).
REAR VIEW
1
DISCONNECT P/J393
Figure 1 Preparing to Remove the Top Transport Assembly
7. REMOVE THE TOP TRANSPORT ASSEMBLY (Figure 2).

4 1
REMOVE THE LOOSEN IDLER AND
TRANSPORT REMOVE THE BELT
2
LOOSEN IDLER AND
3 REMOVE THE BELT
REMOVE THE
SCREWS (4)

REP 10-12 Prefuser Transport Assembly
Removal
NOTE: Cut the cable tie for the blower wire harness.
2. REMOVE THE TRANSPORT ASSEMBLY (Figure 1).
3
PULL THE
FUSER OUT
2
REMOVE SCREW
AND BRACKET
1
DISCONNECT
4 CONNECTORS (2)
PULL TRANSPORT AND AIR HOSE
OUT AND REMOVE
Figure 1 Removing the Transport Assembly
Replacement
1. WHEN INSTALLING NEW TRANSPORT BELTS OR A NEW PREFUSER VACUUM
TRANSPORT, RESET THE FOLLOWING:
a. Enter [SCP], [HSFI], [Print Transport], [10-811 R Prefuser Transport Belts], and
[Reset Count].
b. Enter [SCP], [HSFI], [Print Transport], [10-815 C Prefuser Transport vacuum
holes], and press [Reset Count].

REP 10-13 Exit Transport Assembly 2. OPEN THE PRINTER RIGHT FRONT DOOR, AND REMOVE THE PRINTER RIGHT
TOP COVER (REP 4-0). REMOVR THE PRINTER TRANSPORT INNER PANEL.
Parts List on PL 10.13 REMOVE THE PRINTER LATCH SUPPORT PLATE.
Removal 3. REMOVE THE EXIT TRANSPORT ASSEMBLY (Figure 1).
3
REMOVE THE
TRANSPORT
2
REMOVE THE
1 SCREWS (4)
LOOSEN IDLER AND
REMOVE THE BELT
Figure 1 Removing the Exit Transport

REP 10-14 Decurler Assembly 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
CAUTION
Removal Remove and protect the Photoreceptor from the light.
3. REMOVE THE ROS UPPER INNER PANEL AND THE PRINT TRANSPORT INNER
PANEL.
4. PREPARE TO REMOVE THE DECURLER ASSEMBLY (Figure 1).
TOP FRONT VIEW
4
LIFT AND MOVE
THE BRACKET
3
LOOSEN CLAMP
AND REMOVE HOSE
2
REMOVE NUT (1)
1
REMOVE SCREWS (2)
Figure 1 Preparing to Remove the Decurler Assembly
5. REMOVE THE DECURLER ASSEMBLY (Figure 2).

3
REMOVE THE
DRIVE BELT
4
REMOVE THE
DECURLER ASSEMBLY
2
MOVE OFF THE
MOUNTING PINS
1
REMOVE SCREW
Figure 2 Removing the Decurler Assembly
Replacement REP 10-15 Decurler Belts

1. ADJUST THE DECURLER DRIVE BELT (ADJ 4-11). Parts List on PL 10.12
2. CHECK/ADJUST THE DECURLER JAM SENSOR (ADJ 10-10).
Removal

2. REMOVE THE DECURLER ASSEMBLY (REP 10-14).
3. REMOVE DECURLER BELTS (Figure 1).

2
REMOVE
THE BELTS
1
PULL THE LOWER ROLL
OUT OF THE FRAME
Figure 1 Removing the Decurler Belts
Replacement REP 10-16 Flexible Coupling

1. ENTER [SCP], [HSFI], [Print Transport], [10-813 R Decurler Belts], and press [Reset Parts List on PL 10.1 PL 10.2 PL 10.3 PL 10.4 PL 10.5 PL 10.6 PL 10.7
Count].
PL 10.8 PL 10.9 PL 10.10 PL 10.11 PL 10.12 PL 10.13 PL 10.14 PL 10.15
PL 10.16 PL 10.17 PL 10.18 PL 10.19 PL 10.20 PL 10.21 PL 10.22
Replacement
1. REMOVE THE VERTICAL TRANSPORT ASSEMBLY (REP 8-0).
CAUTION
The flexible pivot of the coupling must be located as far towards the front of the transport as
possible, to avoid premature wear.
2. INSTALL COUPLING COMPLETELY TOWARDS FRONT OF TRANSPORT (Figure 1).

PUSH THE COUPLING
COMPLETELY TOWARDS
THE FRONT
Figure 1 Replacing the Flexible Coupling

REP 10-17 Duplex Inverter Assembly 2. REMOVE THE TOP TRANSPORT ASSEMBLY (REP 10-11).
3. REMOVE OR COVER THE PHOTORECEPTOR BELT TO PREVENT LIGHT SHOCK
Parts List on PL 10.13 (REP 9-35).
Removal 4. DISCONNECT THE ELECTRICAL CONNECTOR OF THE INVERTER ASSEMBLY (Fig-
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. ure 1).
REAR VIEW
1
DISCONNECT THE
CONNECTOR P/J363
THE INVERTER
ASSEMBLY
Figure 1 Disconnecting the Electrical Connector for the Inverter
CAUTION
Hold the Inverter handle while releasing the latches. The left side of the Inverter will fall down-
wards.
5. REMOVE THE INVERTER ASSEMBLY (Figure 2).

FRONT TOP VIEW 4
LIFT THE
INVERTER OUT
3 OF THE PRINTER
CAUTION
RELEASE THE
LATCHES (2)
1
REMOVE BOLTS (2)
2
GRASP AND HOLD
THE HANDLE
Figure 2 Removing the Inverter Assembly
Replacement REP 10-18 Inverter Gear Box Drive Belt and Inverter
1. CHECK/ADJUST THE DUPLEX TIMING (ADJ 10-14). Reversing Roll Drive Belt
Removal
3. OPEN THE PHN PANEL DOOR.
4. REMOVE THE INVERTER COUPLER ASSEMBLY (Figure 1).

1
REAR VIEW LOOSEN THE SCREW
AND MOVE THE IDLER
4
REMOVE THE
INVERTER COUPLER
ASSEMBLY
2
REMOVE THE INVERTER
DRIVE BELT
3
REMOVE BOLTS (3)
Figure 1 Removing the Inverter Coupler Assembly
5. REMOVE THE INVERTER GEAR BOX DRIVE BELT AND THE INVERTER REVERSING
ROLL DRIVE BELT (Figure 2).

REAR VIEW
1
LOOSEN NUT AND
MOVE THE IDLER
6
REMOVE THE
REVERSING
ROLL DRIVE
3 5 BELT
REMOVE THE TIGHTEN THE NUT
2 GEAR BOX 4
TIGHTEN NUT DRIVE BELT LOOSEN NUT AND
THE MOVE THE IDLER
Figure 2 Removing the Inverter Gear Box Drive Belt and the Reversing Roll Drive Belt
Replacement REP 10-19 Inverter Gear Box Assembly

1. TIGHTEN THE GEAR BOX DRIVE BELT, THE REVERSING ROLL DRIVE BELT, AND Parts List on PL 10.22
THE INVERTER DRIVE BELT.
Removal
2. REMOVE THE INVERTER GEAR BOX DRIVE BELT AND THE INVERTER REVERSING
ROLL DRIVE BELT (REP 10-18).

CAUTION
Gently remove the Inverter Gear Box from the Inverter Frame. The electrical connector for the
Gear Box must be disconnected before the Gear Box is completely removed from the Printer.
3. REMOVE THE INVERTER GEAR BOX ASSEMBLY (Figure 1).
REAR VIEW
3
DISCONNECT THE
ELECTRICAL CON-
NECTOR
2
CAUTION
GENTLY PULL THE
GEAR BOX AWAY
FROM THE INVERTER
1
REMOVE NUTS (3)
Figure 1 Removing the Inverter Gear Box Assembly
Replacement
1. CHECK/ADJUST THE DUPLEX TIMING (ADJ 10-14).

REP 11-1 Inverter Transport
Removal 2
DISCONNECT
2. REMOVE THE INVERTER LEFT SIDE COVER (REP 4-54).
5. REMOVE THE TRIM STRIP LOCATED BETWEEN THE PRINTER RIGHT TOP COVER
AND THE INVERTER LEFT SIDE COVER.
6. DISCONNECT THE INVERTER CONNECTORS (Figure 1).
1
DISCONNECT
Figure 1 Disconnecting the Connectors
7. REMOVE THE INVERTER DOOR INTERLOCK SWITCH AND BRACKET FROM THE
FRAME.
NOTE: After the mounting bolts have been removed, lower the front of the Inverter Transport
until it is positioned on the inner panel located below the Inverter.
8. REMOVE THE INVERTER MOUNTING BOLTS (Figure 2).

1
REMOVE
2
REMOVE
Figure 2 Removing the Mounting Bolts
9. REMOVE THE DRIVE BELT FROM THE REAR OF THE INVERTER TRANSPORT (Fig-
ure 3).

1
MOVE THE INVERTER
FORWARD UNTIL THE
TAB IS REMOVED
FROM THE SLOT
2
MOVE THE
INVERTER TOWARD
THE LEFT SLIGHTLY
3
REMOVE THE BELT
FROM THE INVERTER
PULLEY
CAUTION
Do not damage any existing harnesses when removing or installing the Inverter Transport.
NOTE: It may be necessary to remove the hinge pins and the Inverter Door.
10. REMOVE THE INVERTER TRANSPORT.

Replacement
NOTE: If a new Inverter Transport is being installed, ensure that the Inverter Guard Bracket is
removed and discarded. Disconnect the Inverter Entrance Sensor (Q1155) and the Inverter
Gate Solenoid from the auxiliary harness and discard the harness.
1. PARTIALLY INSTALL THE INVERTER TRANSPORT AND REINSTALL THE DRIVE

BELT.
2. INSTALL THE INVERTER (Figure 4).

REP 11-2 Inverter Gate Solenoid (SOL1108)
Removal
2 1. SWITCH OFF THE PRINTER POWER.
REINSTALL THE
NOTE: The solenoid removal is possible without removing the Inverter. However, replacement
INVERTER
MOUNTING BOLTS is easier with the Inverter removed.
2. REMOVE THE INVERTER TRANSPORT (REP 11-1).

3. REMOVE THE INVERTER GATE SOLENOID (Figure 1).
5
REMOVE THE 4
SOLENOID REMOVE THE
SCREWS (2)
3
DISCONNECT
THE PLUNGER
LINKAGE
1
ENSURE TAB ON
INVERTER IS
LOCATED IN SLOT
ON POST INVERTER 3
RECONNECT
CONNECTORS (3)
2
REMOVE SPRING
1
DISCONNECT THE
CONNECTOR
Figure 4 Installing the Inverter
Figure 1 Removing the Inverter Gate Solenoid
Replacement
1. REPLACE THE INVERTER GATE SOLENOID.
2. CHECK/ADJUST THE INVERTER GATE SOLENOID (ADJ 11-1).
3. REINSTALL THE INVERTER TRANSPORT.

REP 11-3 Inverter Drive Motor (MOT1111)
Removal
NOTE: Ensure that the motor is supported from underneath when removing the mounting
hardware.
3. REMOVE THE INVERTER DRIVE MOTOR (Figure 1).
2
REMOVE THE MOTOR
1
REMOVE THE
SCREWS (4)
REAR VIEW
Figure 1 Removing the Inverter Motor
Replacement
1. REPLACE THE INVERTER DRIVE MOTOR.
2. PERFORM THE INVERTER MOTOR BELT TENSION ADJUSTMENT (ADJ 11-14).

REP 11-4 Inverter Latch Assembly 2. OPEN THE INVERTER FRONT DOOR.
4. REMOVE THE INVERTER LATCH ASSEMBLY (Figure 1).
Removal
INVERTER OUTPUT
2 BAFFLE
REMOVE THE
LATCH ASSEMBLY
1
REMOVE THE
SCREWS (2) RIGHT SIDE VIEW
FRONT VIEW
Figure 1 Removing the Latch Assembly
Replacement REP 11-5 Inverter Top and Bottom Hinges

1. REPLACE THE INVERTER LATCH ASSEMBLY. Parts List on PL 11.24
2. CHECK/ADJUST THE INVERTER OUTPUT BAFFLE (ADJ 11-3).
Removal
CAUTION
Do not allow the Pivoting Assembly to fall when the hinges are removed.
3. REMOVE THE HINGES (Figure 1).

REP 11-6 Inverter Pivoting Assembly
Removal
3. PREPARE TO REMOVE THE PIVOTING ASSEMBLY (Figure 1).
1
REMOVE THE
SCREWS (2) AND
THE TOP HINGE
2
REMOVE THE 2
SCREWS (2) AND REMOVE THE
BOTTOM HINGE SCREWS (2) AND
THE TOP HINGE
1
REMOVE THE
SCREW AND
GROUND STRAP
FROM PIVOTING
ASSEMBLY
Figure 1 Removing the Hinges
Replacement
NOTE: The Top and Bottom Hinges are not interchangeable.
1. REPLACE THE HINGES.

2. CHECK/ADJUST THE TOP AND BOTTOM HINGES (ADJ 11-4).
3. CHECK/ADJUST THE INVERTER PIVOTING ASSEMBLY ALIGNMENT (ADJ 11-8). Figure 1 Preparing to Remove the Pivoting Assembly
4. UNLATCH THE PIVOTING ASSEMBLY AND LIFT IT OFF OF THE BOTTOM HINGE.

Replacement REP 11-7 Inverter Passive Gate
1. REPLACE THE PIVOTING ASSEMBLY. Parts List on PL 11.25
2. CHECK/ADJUST THE TOP AND BOTTOM HINGES (ADJ 11-4).
Removal
3. CHECK/ADJUST THE PIVOTING ASSEMBLY ALIGNMENT (ADJ 11-8).
3. DISCONNECT THE PASSIVE GATE SPRING (Figure 1).
2
DISCONNECT
GATE SPRING
3
1 CLOSE THE ASSEMBLY
OPEN THE PIVOTING
ASSEMBLY
Figure 1 Disconnecting the Passive Gate Spring
NOTE: The illustration depicts only the rear hardware, because the front and rear hardware
are identical.
4. REMOVE THE INVERTER OUTPUT BAFFLE (Figure 2).

1 2
REMOVE E-RING REMOVE BEARING
2
MOVE THE
SPRING AWAY
1
LOOSEN THE
NUTS (4)
3
REMOVE THE
SCREWS (4)
4
REMOVE THE 3
BAFFLE REMOVE GATE
Figure 2 Removing the Inverter Output Baffle Figure 3 Removing the Passive Gate
5. REMOVE THE PASSIVE GATE (Figure 3). Replacement

1. REPLACE THE PASSIVE GATE.
2. RECONNECT THE PASSIVE GATE SPRING.
3. REINSTALL THE INVERTER OUTPUT BAFFLE.
4. CHECK/ADJUST THE GATE FLAT SPRINGS (ADJ 11-2).
NOTE: Ensure that the passive gate spring is reinstalled.

REP 11-8 Inverter Bottom Drive Shaft 2. REMOVE THE INVERTER TRANSPORT (REP 11-1).
3. REMOVE THE BOTTOM DRIVE SHAFT (Figure 1).
Removal
5
PUSH THE SHAFT
6 TOWARD THE REAR
REMOVE BELT
7
REMOVE SHAFT
4
REMOVE BEARING
RETAINER
2
REMOVE THE
REAR BEARING 3
RETAINER REMOVE SCREW
1
REMOVE SCREW
Figure 1 Removing the Bottom Drive Shaft
Replacement REP 11-9 Inverter Top and Middle Shafts

NOTE: Ensure that the front and rear retainers are seated firmly against the bearings. Parts List on PL 11.25
1. REPLACE THE BOTTOM DRIVE SHAFT. Removal
2. PERFORM THE INVERTER MOTOR BELT TENSION ADJUSTMENT (ADJ 11-14). 1. SWITCH OFF THE PRINTER POWER.
3. REINSTALL THE INVERTER TRANSPORT. 2. REMOVE THE INVERTER TRANSPORT (REP 11-1).
3. REMOVE THE INVERTER LATCH ASSEMBLY (Figure 1).

3 2
REMOVE SCREW REMOVE LATCH
1
REMOVE THE
SCREWS (2)
4
REMOVE BEARING
RETAINER AND FRONT VIEW
GROUND TAB
Figure 1 Removing the Inverter Latch Assembly
4. REMOVE THE INVERTER OUTPUT BAFFLE (Figure 2).

2
REMOVE SCREWS (4)
1
LOOSEN NUTS (4)
AND MOVE THE
SPRINGS AWAY
3
REMOVE THE BAFFLE
Figure 2 Removing the Inverter Output Baffle
5. REMOVE THE TOP AND MIDDLE SHAFTS (Figure 3).

2
REMOVE BEARING
3 RETAINER
REMOVE TOP
SHAFT
4
REMOVE MIDDLE
SHAFT 1
REMOVE SCREW
REAR VIEW
Figure 3 Removing the Top And Middle Shafts
Replacement
NOTE: Ensure that the bearing retainers are seated firmly against the bearings.
1. REPLACE THE TOP AND MIDDLE SHAFTS.

2. REINSTALL THE INVERTER OUTPUT BAFFLE.
3. REINSTALL THE INVERTER LATCH ASSEMBLY.
4. ADJUST THE GATE FLAT SPRINGS (ADJ 11-2).

REP 11-10 Stacker Main Drive Motor (MOT1110) 2. REMOVE THE INVERTER TOP COVER (REP 4-52).
Removal 5. REMOVE THE STACKER MAIN DRIVE MOTOR (Figure 1).
5
REMOVE THE
MOTOR
4
REMOVE NUTS (4)
AND BOLTS (4)
1
LOOSEN THE
IDLER MOUNTING
SCREW
2
3 REMOVE BELT
DISCONNECT
Figure 1 Removing the Drive Motor

REP 11-11 Post Inverter Transport 2. REMOVE THE STACKER PRE-REGISTRATION TRANSPORT (REP 11-20).
4. REMOVE THE TRIM STRIP LOCATED BETWEEN THE PRINTER RIGHT TOP COVER
Removal AND THE INVERTER LEFT SIDE COVER.
1. SWITCH OFF THE PRINTER POWER. 5. PREPARE TO REMOVE THE POST INVERTER TRANSPORT (Figure 1).
1
3 DISCONNECT
LOOSEN THE IDLER
MOUNTING SCREW
AND REMOVE THE
DRIVE BELT
2
DISCONNECT
6. REMOVE THE POST INVERTER TRANSPORT MOUNTING HARDWARE (Figure 2).

1
REMOVE THE
UPPER BOLTS (2)
3
REMOVE THE
SAMPLE TRAY
STATIC BRUSH
2
REMOVE BOLT
Figure 2 Removing the Hardware
CAUTION
Do not damage any existing harnesses when removing or installing the transport.
NOTE: Remove the sample tray static brush, set aside to be reinstalled.
7. REMOVE THE POST INVERTER TRANSPORT (Figure 3).

1
REMOVE THE TRANSPORT
FROM THE ALIGNMENT PINS
2
MOVE THE TRANSPORT
TOWARDS THE REAR
3
4 REMOVE THE BELT
CAUTION FROM LOWER PULLEY
REMOVE THE
TRANSPORT
Replacement
NOTE: Reinstall the sample tray static brush.
1. INSTALL THE POST INVERTER TRANSPORT (Figure 4).

2
INSTALL BOLTS (3)
1
ENSURE THAT THE TAB IS
POSITIONED IN THE SLOT
Figure 4 Installing the Transport
2. REINSTALL THE STACKER PREREGISTRATION TRANSPORT. REP 11-12 Post Inverter Transport Gear Bracket/Main Drive
Belt/Lower Shaft
Removal
2. REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).
3. REMOVE THE POST INVERTER TRANSPORT (REP 11-11).
4. REMOVE THE SAMPLE TRAY GATE SOLENOID (REP 11-15).
5. PREPARE TO REMOVE THE GEAR BRACKET (Figure 1).

3
REMOVE SPRING
4
LOOSEN IDLER
MOUNTING
SCREW AND
REMOVE THE
BELT FROM
UPPER GEARS
1
LOOSEN SCREW AND
REMOVE THE BEARING 2
RETAINER
REMOVE SHAFT
AND BELT
Figure 1 Preparing to Remove the Gear Bracket 1
NOTE: Scribe a line along the top of the Gear Bracket before removing the mounting hardware
to ensure that it is reinstalled in the same position.
6. REMOVE THE GEAR BRACKET (Figure 2).

1
NOTE: REMOVE THE
NUTS (2)
2
LOOSEN SCREW
AND REMOVE
THE BEARING
RETAINER
3
MOVE SHAFT SLIGHTLY
4
REMOVE THE
GEAR BRACKET
Figure 2 Removing the Gear Bracket
7. REMOVE THE MAIN DRIVE BELT.

8. IF NECESSARY, REMOVE THE LOWER SHAFT.
Replacement
1. BEGIN TO REINSTALL THE GEAR BRACKET AND MAIN DRIVE BELT (Figure 3).

4
REINSTALL NUTS (2)
BUT DO NOT TIGHTEN
5
REINSTALL THE
BEARING RETAINER
AND TIGHTEN THE
SCREW
3
MOVE THE SHAFT AND
THE BRACKET INTO
MOUNTING POSITION
2 1
POSITION BRACKET ENSURE BELT IS
ON THE SHAFT ON THE PULLEY
Figure 3 Beginning to reinstall the Gear Bracket
2. REINSTALL THE GEAR BRACKET (Figure 4).

5
TIGHTEN NUTS (2)
4
REINSTALL SPRING
1
REINSTALL BELT ON
UPPER GEARS AND
TIGHTEN THE IDLER
MOUNTING SCREW
3
REINSTALL RETAINER 2
AND TIGHTEN SCREW REINSTALL THE
SHAFT AND BELT
Figure 4 Reinstalling the Gear Bracket
3. REINSTALL THE SAMPLE TRAY GATE SOLENOID. REP 11-13 Post Inverter Upper Drive Shaft/Sample Tray
4. REINSTALL THE POST INVERTER TRANSPORT.
Drive Shaft
5. REINSTALL THE STACKER PREREGISTRATION TRANSPORT.
6. CHECK/ADJUST THE SAMPLE TRAY GATE SOLENOID (ADJ 11-8).
Removal
4. REMOVE THE MAIN DRIVE BELT (REP 11-12).

5. REMOVE THE RETAINER AND THE UPPER DRIVE SHAFT. REP 11-14 Inverter Drive Belt/Short Shaft
6. REMOVE THE RETAINER AND THE SAMPLE TRAY DRIVE SHAFT.
Replacement
Removal
1. REINSTALL THE MAIN DRIVE BELT.
2. REINSTALL THE POST INVERTER.
4. REMOVE THE INVERTER DRIVE BELT/SHORT SHAFT (Figure 1).
1
LOOSEN
2
REMOVE BEARING
RETAINER
4
REMOVE BELT
3
REMOVE SHAFT
Figure 1 Removing the Drive Belt

REP 11-15 Sample Tray Gate Solenoid (SOL1110)/Actuator 2. REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).
Arm Assembly
Parts List on PL 11.27 NOTE: It is necessary to remove just the mounting screws (2) when removing the solenoid
only.
Removal
4. REMOVE THE SAMPLE TRAY GATE SOLENOID/ACTUATOR ARM ASSEMBLY (Figure
1).
1
REMOVE SPRING
FROM THE POST
2
REMOVE SCREWS (2)
3
REMOVE THE SOLENOID AND
ACTUATOR ARM ASSEMBLY
Figure 1 Removing the Solenoid
Replacement REP 11-16 Sample Tray Gate/Sample Tray Gate Actuator

1. REINSTALL THE SAMPLE TRAY GATE SOLENOID. Parts List on PL 11.27
Removal
4. POSITION THE POST INVERTER ON A FLAT SURFACE SO THAT THE PIVOTING
ASSEMBLY IS FACING UPWARDS.
5. REMOVE THE PIVOTING ASSEMBLY HINGE PIN AND PIVOTING ASSEMBLY.

6. REMOVE THE SAMPLE TRAY GATE SOLENOID AND ACTUATOR ARM ASSEMBLY 7. REMOVE THE SAMPLE TRAY GATE/SAMPLE TRAY GATE ACTUATOR (Figure 1).
(REP 11-15).
2 3
REMOVE E-RING REMOVE THE GATE
ACTUATOR FROM
THE GATE SHAFT
1
REMOVE CLIP
4
REMOVE GATE
Figure 1 Removing the Sample Tray Gate
Replacement REP 11-20 Stacker Preregistration Transport

1. REINSTALL THE SAMPLE TRAY GATE/SAMPLE TRAY GATE ACTUATOR. Parts List on PL 11.2
Removal

5. DISCONNECT THE STACKER PRE-REGISTRATION TRANSPORT CONNECTORS
(Figure 1).
1
DISCONNECT
2
DISCONNECT
6. REMOVE THE STACKER PRE-REGISTRATION TRANSPORT DRIVE BELT (Figure 2).

2
REMOVE THE BELT
1
LOOSEN THE IDLER
MOUNTING SCREW
CAUTION
Do not damage any existing harnesses when removing or installing the transport.
7. REMOVE THE STACKER PRE-REGISTRATION TRANSPORT (Figure 3).

1
REMOVE THE
UPPER BOLTS (2)
2
LOOSEN THE
LOWER BOLTS (2)
3
CAUTION
REMOVE THE
TRANSPORT

REP 11-21 Stacker Preregistration Transport Drive Pulley 2. REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).
3. REMOVE THE STACKER PREREGISTRATION TRANSPORT DRIVE BELT.
Assembly
4. POSITION THE STACKER PREREGISTRATION TRANSPORT ON A FLAT SURFACE
Parts List on PL 11.2 WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.
Removal 5. REMOVE THE DRIVE PULLEY ASSEMBLY (Figure 1).
2
REMOVE SCREWS
(2)
1
LOOSEN SETSCREW
2
REMOVE SCREWS (2)
3
REMOVE PULLEY
ASSEMBLY
Figure 1 Removing the Drive Pulley Assembly

REP 11-22 Prestacker Drive Roll Shaft REP 11-23 Stacker Preregistration Transport Flexible Drive
Parts List on PL 11.2 Shaft
1. SWITCH OFF THE PRINTER POWER. Removal
2. REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20). 1. SWITCH OFF THE PRINTER POWER.
3. REMOVE THE STACKER PREREGISTRATION TRANSPORT DRIVE BELT. 2. REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).
4. LOOSEN THE SCREW AND REMOVE THE DRIVE ROLL SHAFT RETAINER. 3. POSITION THE STACKER PREREGISTRATION TRANSPORT ON A FLAT SURFACE
5. REMOVE THE PRESTACKER DRIVE ROLL SHAFT. WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.
4. LOOSEN THE SETSCREW LOCATED AT EACH END OF THE FLEXIBLE DRIVE
SHAFT.
5. REMOVE THE FLEXIBLE DRIVE SHAFT.

REP 11-25 Post Inverter Sensor (Q1156)
Removal 3
1. SWITCH OFF THE PRINTER POWER. INSTALL SENSOR
ON BRACKET
WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.
4. REMOVE THE POST INVERTER SENSOR (Figure 1).
1
REMOVE NUTS (2)
1
CAUTION
INSTALL ACTUATOR
IN SLOT OF SHAFT
2
2 INSTALL CLIP
REMOVE SENSOR ON SHAFT
AND MOUNTING
BRACKET
Figure 2 Installing the Actuator

2. REINSTALL THE POST INVERTER SENSOR.
Replacement
CAUTION
Ensure that the Actuator is positioned on the Sensor exactly as shown in Figure 2.
1. IF A NEW SENSOR IS BEING INSTALLED, INSTALL THE ACTUATOR ON THE SEN-
SOR (Figure 2).

REP 11-26 Registration Assembly 2. REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).
Parts List on PL 11.2 WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.
Removal 4. REMOVE THE REGISTRATION ASSEMBLY (Figure 1).
1
LOOSEN THE
SETSCREW
3
REMOVE THE 2
REGISTRATION REMOVE NUTS (2)
ASSEMBLY
Figure 1 Removing the Registration Assembly

REP 11-27 Stacker Preregistration Transport Corrugator Replacement
Rolls NOTE: Replace the Corrugator Roll by pushing it on the drive shaft as far as it will go, then
Parts List on PL 11.3 tighten the setscrew.
Removal 1. REINSTALL THE CORRUGATOR ROLL.

1. SWITCH OFF THE PRINTER POWER. REP 11-28 Corrugator Roll Drive Shafts and Belts
2. REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20). Parts List on PL 11.3
Removal
4. LOSEN THE SETSCREW AND REMOVE THE CORRUGATOR ROLL.
3
LOOSEN THE RETAINER
MOUNTING SCREW (3 PLACES)
4
REMOVE THE DRIVE
SHAFTS AND BELTS
2 1
REMOVE THE SCREW AND NOTE: REMOVE THE
SPRING RETAINER (2 PLACES) CORRUGATOR ROLLS (3)
Figure 1 Removing the Shafts and Belts

Replacement REP 11-29 Stacker Lead in Baffle/Trail Edge Assist Idler
NOTE: Replace the Corrugator Rolls by pushing it on the drive shaft as far as it will go, then Roll/Disk Sheet Sensor (Q1106) (Purge and Bypass
tighten the setscrew. Transport)
1. REINSTALL THE CORRUGATOR ROLLS. Parts List on PL 11.14
Removal
2. OPEN THE APPROPRIATE STACKER TOP COVER.
3. REMOVE THE BYPASS GATE (REP 11-35).
4. REMOVE THE BYPASS LEAD IN BAFFLE (REP 11-34) OR THE PURGE LEAD IN BAF-
FLE (REP 11-45).
5. REMOVE THE STACKER LEAD IN BAFFLE AND THE TRAIL EDGE ASSIST IDLER
ROLL (Figure 1).
4
REMOVE THE
2 IDLER ROLL
REMOVE NUTS (3)
3
REMOVE BAFFLE
1
DISCONNECT
SPRINGS (2)
Figure 1 Removing the Baffle and Idler Roll
6. DISCONNECT AND REMOVE THE DISK SHEET SENSOR. REP 11-30 Chute Baffle (IFS/FS)

Parts List on PL 11.16 e. Remove the Top Trim Strip.
Removal f. Continue with Step 4.
3. IF REMOVING THE FS CHUTE BAFFLE, PERFORM THE FOLLOWING:
a. Open both Stacker Top Covers.
2. IF REMOVING THE IFS CHUTE BAFFLE, PERFORM THE FOLLOWING:
b. Remove the FS Front Cover (REP 4-49).
a. Open the Stacker Top Cover.
c. Remove both Stacker Upper Rear Covers.
b. Remove the IFS Front Cover (REP 4-49).
d. Remove the Top Trim Strip.
c. Remove the Inverter Top Cover (REP 4-52).
e. Continue with Step 4.
d. Remove the Inverter Rear Cover and the Stacker Upper Rear Cover.
4. REMOVE THE CHUTE BAFFLE (Figure 1).
4 2
REMOVE THE REMOVE SCREW
CHUTE BAFFLE
1
REMOVE SCREWS (2)
3
REMOVE THE
GROUND WIRE
Figure 1 Removing the Chute Baffle

REP 11-31 Bypass Transport Top Baffle
Removal
CAUTION
Do not allow the Bypass Transport Top Baffle to drop after unlatching it from the Stacker Top
Cover.
2. UNLATCH AND LOWER THE BYPASS TRANSPORT TOP BAFFLE (Figure 1).
1
UNLATCH BYPASS
TRANSPORT TOP
BAFFLE
2
CAUTION
LOWER THE
BAFFLE
Figure 1 Unlatching the Baffle
3. REMOVE THE BYPASS TRANSPORT TOP BAFFLE (Figure 2).

1
2 REMOVE THE
REMOVE SCREWS (4) GROUND WIRE
3
REMOVE THE BYPASS
TRANSPORT TOP BAFFLE
Figure 2 Removing the Baffle
Replacement
CAUTION
Do not damage the Bypass Transport Sensor when reinstalling the Bypass Transport Top Baf-
fle.
1. REINSTALL THE BYPASS TRANSPORT TOP BAFFLE (Figure 3).

1
CAUTION 2 3
7 INSTALL THE BAFFLE INSTALL SCREWS INSTALL THE
TIGHTEN THE (4) AND SNUG GROUND WIRE
SCREWS (4) AND NUT
5 4
ENSURE THAT THE RAISE AND LOWER THE
6 BAFFLE TABS (2) ARE BAFFLE TO ENSURE THAT
RAISE AND LOWER THE BAFFLE POSITIONED IN THE IT CLEARS THE SENSOR
TO ENSURE THAT THERE IS NO SLOTS ON THE
INTERFERENCE TRANSPORT FRAME
Figure 3 Reinstalling the Baffle

REP 11-32 Purge Transport Top Baffle Replacement
Parts List on PL 11.15 1. REINSTALL THE PURGE TRANSPORT TOP BAFFLE.
Removal NOTE: Ensure that the Cable that secures the Baffle to the Top Cover is reinstalled exactly as
1. OPEN THE PURGE TRAY TOP COVER. shown in Figure 2.
2. REMOVE THE NUT AND DISCONNECT THE CABLE THAT SECURES THE PURGE 2. RECONNECT THE BAFFLE TO THE TOP COVER (Figure 2).
TRANSPORT TOP BAFFLE TO THE PURGE TRAY TOP COVER.
3. LOWER THE BAFFLE.
4. REMOVE THE PURGE TRANSPORT TOP BAFFLE (Figure 1).
1 2
DISCONNECT THE REMOVE THE
GROUND WIRE SCREWS (2)
1
NOTE: REINSTALL
CABLE ON STUD
2
REINSTALL THE
NUT AND TIGHTEN
Figure 2 Reinstalling the Cable
3
REMOVE THE PURGE
TRANSPORT TOP BAFFLE

REP 11-33 Bypass Transport/Purge Transport
Removal
2
REMOVE THE HARNESS
2. REMOVE THE APPROPRIATE STACKER TOP COVER (REP 4-50) OR (REP 4-51). FROM THE CLIP
3. REMOVE THE APPROPRIATE TRANSPORT TOP BAFFLE (REP 11-31) OR (REP 11-
32).
NOTE: The Bypass Transport and Purge Transport are removed in the same manner. The
transport shown in the following figures is the Bypass Transport.
4. PREPARE TO REMOVE THE TRANSPORT (Figure 1).
1
DISCONNECT
(P473) AND PULL
3 THE HARNESS
ROTATE THE NUT UNTIL THROUGH FRAME
IT TOUCHES THE COUN-
TERBALANCE (2 PLACES)

CAUTION
Do not damage the loose harness when removing the Transport.
5. REMOVE THE TRANSPORT (Figure 2).
4
REMOVE NUTS (4)
5
DISCONNECT THE
GROUND WIRE
6
CAUTION
REMOVE THE
TRANSPORT
3
CLOSE THE TRANSPORT
2 1
OPEN THE BYPASS LOOSEN SETSCREW
TRANSPORT AND ON THE COUPLING
DISENGAGE THE
DRIVE SHAFT
Replacement REP 11-34 BYPASS LEAD IN BAFFLE

NOTE: Ensure that the tab located on the left rear corner of the Bypass Transport, is posi- Parts List on PL 11.11
tioned in the slot on the weldment frame before tightening the four nuts. Removal
1. REINSTALL THE TRANSPORT. 1. SWITCH OFF THE PRINTER POWER.
2. CHECK/ADJUST THE TRANSPORT (ADJ 11-10). 2. OPEN THE APPROPRIATE STACKER TOP COVER.

3. REMOVE THE BYPASS GATE (REP 11-35). 6. REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLER ROLLS AND PARTIALLY
4. RAISE THE BYPASS TRANSPORT. REMOVE THE FOUR TRAIL EDGE ASSIST BELTS.
5. LOOSEN THE NUT SECURING THE A3 ROLLOVER SHAFT AND REMOVE THE 7. REMOVE THE BYPASS LEAD IN BAFFLE (Figure 1).
SHAFT.
2
REMOVE THE
NUTS (4)
3
LOWER THE
TRANSPORT
1
REMOVE THE
NUTS (2) AND
THE BRACKET
4
REMOVE THE
BAFFLE

REP 11-35 Bypass/Purge Transport Gate 2. RAISE THE APPROPRIATE STACKER TOP COVER.
3. PARTIALLY RAISE THE BYPASS OR PURGE TRANSPORT.
4. REMOVE THE TRANSPORT GATE (Figure 1).
Removal
3
SQUEEZE TABS AND
PULL OUT THE GATE
2
UNWIND THE CABLE
FROM THE GATE 1
SHAFT (1 1/4 TURNS) REMOVE SPRING
END FROM POST
Figure 1 Removing the Bypass Gate
Replacement REP 11-36 Disk Gate

NOTE: Ensure that the routing of the cable is started over the top of the Bypass Transport Parts List on PL 11.14
Gate Shaft and that the ball on the cable is positioned in the indent. Removal
1. REINSTALL THE TRANSPORT GATE. 1. SWITCH OFF THE PRINTER POWER.
3. REMOVE THE BYPASS GATE (REP 11-35).
4. REMOVE THE BYPASS LEAD IN BAFFLE (REP 11-34) OR THE PURGE LEAD IN BAF-
FLE (REP 11-45).
5. REMOVE THE DISK GATE (Figure 1).

3
REMOVE THE
DISK GATE
2
RAISE THE TRANSPORT
1
REMOVE SCREWS (2)
Figure 1 Removing the Disk Gate

REP 11-37 Bypass/Purge Transport Gate Solenoid 2. RAISE THE APPROPRIATE STACKER TOP COVER.
3. PARTIALLY RAISE THE BYPASS OR PURGE TRANSPORT.
(SOL1104)
4. REMOVE THE LEFT DRIVES COVER AND MOUNTING BRACKET.
Parts List on PL 11.13 PL 11.11 5. REMOVE THE TRANSPORT GATE SOLENOID (Figure 1).
Removal
3
REMOVE SCREW
4
DISCONECT AND
REMOVE THE
SOLENOID
2
UNWIND THE CABLE
FROM GATE SHAFT 1
(1 1/4 TURNS) REMOVE SPRING
END FROM POST
Figure 1 Removing the Solenoid
Replacement REP 11-38 Trail Edge Assist Drive Shaft (Bypass or Purge
NOTE: Ensure that the routing of the cable is started over the top of the Bypass Transport Transport)
Gate Shaft and that the ball on the cable is positioned in the indent. Parts List on PL 11.11 PL 11.13
1. REINSTALL THE TRANSPORT GATE SOLENOID. Removal
2. REMOVE THE APPROPRIATE STACKER UPPER REAR COVER.
NOTE: Scribe a line along the Rear Cover Mounting Bracket to ensure that it is positioned cor-
rectly when reinstalled.
3. PREPARE TO REMOVE THE TRAIL EDGE ASSIST DRIVE SHAFT (Figure 1).

1
REMOVE NUTS (4)
2
REMOVE THE
COVER
3
NOTE: REMOVE THE
SCREWS (2) AND THE
REAR COVER MOUNTING
BRACKET
Figure 1 Preparing to Remove the Shaft
4. OPEN THE APPROPRIATE STACKER TOP COVER. 10. PUSH THE TRAIL EDGE ASSIST SHAFT TOWARDS THE REAR OF THE FS UNTIL IT
5. REMOVE THE TRANSPORT'S LEFT DRIVES COVER AND MOUNTING BRACKET. IS REMOVED FROM THE FRONT FRAME OF THE TRANSPORT.
6. RAISE THE TRANSPORT. 11. REMOVE THE FOUR TRAIL EDGE ASSIST BELTS.
7. REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLERS. CAUTION
8. REMOVE THE SCREW THAT SECURES THE TRAIL EDGE ASSIST SHAFT Do not damage the Transport Drive Belt when removing the Trail Edge Assist Shaft.
RETAINER. 12. REMOVE THE TRAIL EDGE ASSIST SHAFT THROUGH THE REAR OF THE FS.
9. PULL THE TRAIL EDGE ASSIST SHAFT FORWARD SLIGHTLY AND REMOVE THE
RETAINER.

REP 11-39 Trail Edge Assist Belts (Bypass or Purge REP 11-40 Telescopic Drive Shaft
Transport) Parts List on PL 11.11 PL 11.12
Parts List on PL 11.14 Removal
Removal 1. OPEN THE APPROPRIATE STACKER TOP COVER.
1. SWITCH OFF THE PRINTER POWER. 2. RAISE THE BYPASS TRANSPORT OR THE PURGE TRANSPORT.
2. OPEN THE APPROPRIATE STACKER TOP COVER. CAUTION
3. REMOVE THE TRANSPORT'S LEFT DRIVES COVER AND MOUNTING BRACKET. Do not bend the Telescopic Drive Shaft during removal or installation.
4. RAISE THE TRANSPORT. 3. REMOVE THE TELESCOPIC DRIVE SHAFT (Figure 1).
5. REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLERS.
6. REMOVE THE SCREW THAT SECURES THE TRAIL EDGE ASSIST SHAFT
RETAINER.
3
CAUTION
7. PULL THE TRAIL EDGE ASSIST SHAFT FORWARD SLIGHTLY AND REMOVE THE
REMOVE DRIVE SHAFT
RETAINER.
8. PUSH THE TRAIL EDGE ASSIST SHAFT TOWARDS THE REAR OF THE FS UNTIL IT
IS REMOVED FROM THE FRONT FRAME OF THE TRANSPORT.
2
9. REMOVE THE FOUR TRAIL EDGE ASSIST BELTS. LOOSEN THE
SETSCREWS
1
ROTATE BELT TO ACCESS
THE SETSCREWS
Figure 1 Removing the Drive Shaft

REP 11-41 Middle Drive Shaft (Bypass or Purge Transport) 4. REMOVE THE APPROPRIATE TRANSPORT'S LEFT DRIVES COVER AND MOUNT-
ING BRACKET.
Parts List on PL 11.11 PL 11.13 5. REMOVE THE APPROPRIATE TRANSPORT (REP 11-33).
Removal
NOTE: Place the Transport on a flat surface with the Trail Edge Assist Belts facing upwards.
2. REMOVE THE APPROPRIATE STACKER TOP COVER (REP 4-50) OR (REP 4-51). 6. REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLERS.
3. REMOVE THE APPROPRIATE TRANSPORT TOP BAFFLE (REP 11-31) OR (REP 11- 7. REMOVE THE MIDDLE DRIVE SHAFT (Figure 1).
32).
6
REMOVE THE
RETAINER
5
LOOSEN IDLER AND
REMOVE BELT FROM
REAR OF SHAFT
7
REMOVE SHAFT
4
REMOVE NUTS (2)
AND BRACKET
3
REMOVE NUTS (2)
1 AND BRACKET
LOOSEN IDLER
2
REMOVE BELT

REP 11-42 Right Drive Shaft (Bypass or Purge Transport) 3. REMOVE THE APPROPRIATE TRANSPORT TOP BAFFLE (REP 11-31) OR (REP 11-
32).
Parts List on PL 11.11 PL 11.13 4. REMOVE THE APPROPRIATE TRANSPORT'S RIGHT DRIVES COVER.
Removal 5. REMOVE THE APPROPRIATE TRANSPORT (REP 11-33).
2. REMOVE THE APPROPRIATE STACKER TOP COVER (REP 4-50) OR (REP 4-51).
6. REMOVE THE RIGHT DRIVE SHAFT (Figure 1).
3
LOOSEN IDLER
AND REMOVE
BELT FROM REAR
OF SHAFT
4
REMOVE THE
RETAINER
5
REMOVE SHAFT
1
LOOSEN IDLER
2
REMOVE BELT
VIEW SHOWN
WITH TRAIL EDGE
ASSIST BELTS
REMOVED

REP 11-43 Left Drive Shaft (Bypass or Purge Transport) 4. REMOVE THE APPROPRIATE TRANSPORT'S LEFT DRIVES COVER AND MOUNT-
ING BRACKET.
Parts List on PL 11.11 PL 11.13 5. REMOVE THE APPROPRIATE TRANSPORT (REP 11-33).
Removal
2. REMOVE THE APPROPRIATE STACKER TOP COVER (REP 4-50) OR (REP 4-51). 6. REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLERS.
3. REMOVE THE APPROPRIATE TRANSPORT TOP BAFFLE (REP 11-31) OR (REP 11- 7. REMOVE THE LEFT DRIVE SHAFT (Figure 1).
32).
2 3
REMOVE BELT
REMOVE CLIP
AND GEAR
4
REMOVE NUTS (2)
AND BRACKET
5
REMOVE THE
RETAINER
1
LOOSEN IDLER
6
REMOVE SHAFT

REP 11-44 Purge Output Drive Shaft 3. REMOVE THE PURGE TRANSPORT TOP BAFFLE (REP 11-31).
4. REMOVE THE PURGE TRANSPORT'S LEFT DRIVES COVER AND MOUNTING
Parts List on PL 11.12 BRACKET.
Removal 5. REMOVE THE PURGE LEAD IN BAFFLE (REP 11-45).
1. SWITCH OFF THE PRINTER POWER. 6. REMOVE THE PURGE OUTPUT DRIVE SHAFT (Figure 1).
2. REMOVE THE STACKER REAR TOP COVER (REP 4-51).
3
LOOSEN SCREW
AND REMOVE THE
RETAINER
4
REMOVE SHAFT
1
LOOSEN IDLER
2
REMOVE BELT
Figure 1 Removing the Shaft
7. (Figure 2).

3
LOOSEN SCREW
AND REMOVE THE
RETAINER
4
REMOVE SHAFT
1
LOOSEN IDLER
2
REMOVE BELT
Figure 2 Removing the Shaft

REP 11-45 Purge Lead in Baffle 4. LOOSEN THE MOUNTING SCREW THAT SECURES THE PURGE TRANSPORT SEN-
SOR (Q1164).
Parts List on PL 11.12 5. RAISE THE PURGE TRANSPORT.
Removal 6. LOOSEN THE NUT SECURING THE A3 ROLLOVER SHAFT AND REMOVE THE
1. SWITCH OFF THE PRINTER POWER. SHAFT.
2. OPEN THE STACKER PURGE TRAY TOP COVER. 7. REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLER ROLLS AND PARTIALLY
3. REMOVE THE PURGE TRANSPORT'S LEFT DRIVES COVER. REMOVE THE FOUR TRAIL EDGE ASSIST BELTS.
8. REMOVE THE PURGE LEAD IN BAFFLE (Figure 1).
1
REMOVE NUTS
3
LOWER THE TRANSPORT
2
REMOVE THE
BAFFLE
Figure 1 Removing the Purge Lead In Baffle
Replacement REP 11-46 Inverter Transport Motor Fan

1. REINSTALL THE PURGE LEAD IN BAFFLE. Parts List on PL 11.22
2. BIAS THE PURGE TRANSPORT SENSOR UPWARD AGAINST THE BOTTOM OF THE
PURGE TRANSPORT LEAD IN BAFFLE AND TIGHTEN THE MOUNTING SCREW.
Removal
1. SWITCH OFF THE PRINTER POWER, THE CIRCUIT BREAKERS AND DISCONNECT
ALL POWER CORDS.

4. DISCONNECT THE INVERTER MOTOR FAN POWER CONNECTOR. REP 11-47 Blower Assembly
5. LOOSEN THE SCREWS (2) WHICH SECURE THE FAN BRACKET ASSEMBLY AND
SLIDE THE BRACKET ASSEMBLY OFF THE MOTOR (PL 11.22).
Removal
1. SWITCH OFF THE PRINTER POWER, THE CIRCUIT BREAKERS AND DISCONNECT
CAUTION
ALL POWER CORDS.
Before removing the Fan from the mounting Bracket, note the orientation of the Fan and the
direction of the air flow.
3. REMOVE THE AIR HOSE CLAMP AND AIR HOSE AT THE BLOWER ASSEMBLY.
6. REMOVE THE FAN MOUNTING SCREWS (4) AND THE FAN FROM THE BRACKET.
4. DISCONNECT BLOWER ASSEMBLY FROM WIRING HARNESS.
Replacement
5. REMOVE THE BLOWER ASSEMBLY, FIGURE 1.
1. ENSURE THE NEW FAN IS INSTALLED ONTO THE MOUNTING BRACKET WITH THE
AIR FLOW IN THE PROPER DIRECTION.
2. REINSTALL THE MOUNTING BRACKET ASSEMBLY ONTO THE INVERTER TRANS- 2. LIFT BLOWER ASSEMBLY UP AND 1. REMOVE NUTS (2)
PORT MOTOR AND RECONNECT THE FAN POWER CONNECTOR. OUT OF MACHINE
3. REAPPLY POWER AND CHECK THE PRINTER FOR PROPER OPERATION.
INBOARD PULLEY
(50 HZ)
OUTBOARD PULLEY
(60 HZ)
Figure 1 REMOVING BLOWER ASSEMBLY.
6. REMOVE O-RING BELT FROM BLOWER ASSEMBLY

7. SEPERATE BLOWER FROM BRACKET.

Replacement
1. INSTALL BLOWER ASSEMBLY USING REVERSE ORDER OF THE REMOVAL PRO-
CEDURE.
NOTE: See Figure 1 for correct O-Ring position.

REP 11-58 Pallet Lift Frame 2. PRESS THE Stop BUTTON WHEN THE ELEVATOR IS JUST BELOW THE HALFWAY
DOWN POSITION.
Parts List on PL 11.17 3. SWITCH OFF THE PRINTER POWER.
Removal 4. REMOVE THE STACKER FRONT COVER (REP 4-49).
NOTE: Be prepared to press the Stop button when the Elevator is just below the halfway down 5. REMOVE THE MAIN PALLET.
position. 6. REMOVE THE PALLET LIFT FRAME (Figure 1).
1. ENTER dC330. SELECT [11X2], [Elevator DN] AND PRESS THE Continue BUTTON.
3 2 1
REMOVE THE REMOVE SCREW AND REMOVE SCREWS (2)
LIFT FRAME BRACKET (4 PLACES) AND THE RETAINER
Figure 1 Removing the Lift Frame
Replacement REP 11-59 Stacker Elevator Motor (MOT1106)

1. REINSTALL THE PALLET LIFT FRAME. Parts List on PL 11.19
2. CHECK/ADJUST THE PALLET LIFT FRAME PARALLELISM (ADJ 11-31).
Removal
1. ENSURE THAT THE STACKER ELEVATOR IS IN THE RAISED POSITION.
3. REMOVE THE STACKER FRONT COVER (REP 4-49).
4. PULL OUT THE PALLET BASE.
5. REMOVE THE ELEVATOR BASE COVER.
6. REMOVE THE STACKER ELEVATOR MOTOR (Figure 1).

6
DISCONNECT AND
REMOVE MOTOR
1
LOOSEN IDLER
5
REMOVE SCREWS (4)
2
DISCONNECT ONE
END OF IDLER SPRING
4 3
DISCONNECT
REMOVE THE DRIVE
BELT FROM MOTOR
AND IDLER
Replacement REP 11-60 Stacker Elevator Drive Belt

NOTE: Ensure that the Drive Belt is positioned around all of the pulleys and idlers. Parts List on PL 11.18
1. REINSTALL THE STACKER ELEVATOR DRIVE BELT. Removal
2. CHECK/ADJUST THE PALLET LIFT FRAME PARALLELISM (ADJ 11-31). NOTE: The HCT is pulled out to aid in accessing the Stacker Elevator Drive Belt.
1. UNLATCH THE APPROPRIATE HCT.

2. ENSURE THAT THE STACKER ELEVATOR IS IN THE RAISED POSITION.
6. REMOVE THE ELEVATOR BASE COVER.
7. REMOVE THE STACKER ELEVATOR DRIVE BELT (Figure 1).

5 1
REMOVE THE BELT LOOSEN IDLER
4 3 2
REMOVE RETAINER REMOVE RETAINER DISCONNECT ONE
END OF IDLER SPRING
Replacement REP 11-61 Lead Screw

NOTE: Ensure that the Drive Belt is positioned around all of the pulleys and idlers. Parts List on PL 11.18
1. REINSTALL THE STACKER ELEVATOR DRIVE BELT. Removal
2. CHECK/ADJUST THE PALLET LIFT FRAME PARALLELISM (ADJ 11-31). 1. REMOVE THE MAIN PALLET.
2. REMOVE THE PALLET LIFT FRAME (REP 11-58).
4. IF REMOVING EITHER OF THE RIGHT LEAD SCREWS, REMOVE THE ELEVATOR
BASE COVER.

5. IF REMOVING THE LEFT REAR LEAD SCREW, REMOVE THE CONTAINER SIZE NOTE: Although some of the lower retainers are different, all of the Lead Screws are removed
SENSORS BRACKET FROM THE FRAME. in the same manner.
6. REMOVE THE LEAD SCREW (Figure 1).
3
REMOVE THE UPPER
MOUNTING SCREW
4
LIFT UP THE LEAD
SCREW UNTIL THE
LOWER BEARING
CLEARS THE FRAME
5
REMOVE THE
LEAD SCREW
2
NOTE: REMOVE THE LOWER
MOUNTING SCREW AND
RETAINER
1
LOOSEN IDLER
Replacement REP 11-62 Stacker Overtravel Down Switch (S1141)/

1. REINSTALL THE LEAD SCREW. Stacker Elevator Down Sensor (Q1125)
2. REINSTALL THE LIFT FRAME.
3. CHECK/ADJUST THE PALLET LIFT FRAME PARALLELISM (ADJ 11-31).
Removal

2. OPEN THE APPROPRIATE STACKER DOORS. REP 11-63 Stacker Overtravel up Switch (S1140)
3. REMOVE THE STACKER REAR DRIVES INNER COVER (PL 11.21
4. LOOSEN THE TWO SCREW SECURING THE LEFT SIDE OF THE STACKER REAR
INNER COVER (PL 11.21 Removal
5. REMOVE THE APPROPRIATE STACKER UPPER REAR COVER. 1. SWITCH OFF THE PRINTER POWER.
6. SWING OUT THE APPROPRIATE STACKER PWB PANEL. 2. OPEN THE APPROPRIATE STACKER DOORS.
CAUTION 3. REMOVE THE STACKER REAR DRIVES INNER COVER (PL 11.21
Do not damage any harnesses when removing the Stacker Rear Inner Cover. 4. LOOSEN THE TWO SCREW SECURING THE LEFT SIDE OF THE STACKER REAR
INNER COVER (PL 11.21
7. LOOSEN THE TWO SCREWS SECURING THE RIGHT SIDE OF THE STACKER REAR
INNER COVER AND REMOVE THE COVER. 5. REMOVE THE APPROPRIATE STACKER UPPER REAR COVER.
6. SWING OUT THE APPROPRIATE STACKER PWB PANEL.
NOTE: The following step is performed to ensure that the sensor is not damaged when remov-
CAUTION
ing the Stacker Overtravel Down Switch. If the sensor is being replaced, disconnect and
remove it at this time. Do not damage any harnesses when removing the Stacker Rear Inner Cover.
7. LOOSEN THE TWO SCREWS SECURING THE RIGHT SIDE OF THE STACKER REAR
8. REMOVE THE STACKER ELEVATOR DOWN SENSOR (Q1125) FROM THE MOUNT-
INNER COVER AND REMOVE THE COVER.
ING BRACKET.
8. DISCONNECT AND REMOVE THE STACKER OVERTRAVEL UP SWITCH.
CAUTION
Do not allow the left mounting screw to drop into the lower transports.
NOTE: Reference to the mounting screws and mounting bracket are made from the rear of the
FS.
9. REMOVE THE LEFT MOUNTING SCREW SECURING THE SWITCH MOUNTING

BRACKET.
10. LOOSEN THE RIGHT MOUNTING SCREW AND ROTATE THE MOUNTING BRACKET
CLOCKWISE UNTIL BOTH SWITCH MOUNTING SCREWS CAN BE ACCESSED.
11. DISCONNECT AND REMOVE THE STACKER OVERTRAVEL DOWN SWITCH.
Replacement
NOTE: Align the mounting brackets left mounting hole and tighten the right mounting screw
before reinstalling the left mounting screw.
1. REINSTALL THE STACKER OVERTRAVEL DOWN SWITCH.

2. REINSTALL THE ELEVATOR DOWN SENSOR ON THE MOUNTING BRACKET.

REP 11-64 Container Size Sensors (Q1126, Q1127, Q1128)
3
Removal INSTALL THE INSTALL SENSOR
SHORT SCREW AND ALIGNMENT
1. ENTER dC330. SELECT [11x2], [Elevator DN] AND PRESS Continue. BLOCK
2. WHEN THE ELEVATOR IS IN THE DOWN POSITION, OPEN THE STACKER DOORS
AND REMOVE THE MAIN PALLET.
3. CLOSE THE STACKER DOORS.
4. SELECT [Elevator UP], AND PRESS Start.
5. WHEN THE PALLET LIFT FRAME IS IN THE UP POSITION, SWITCH OFF THE
PRINTER POWER.
6. OPEN THE STACKER DOORS.
7. DISCONNECT THE CONTAINER SIZE SENSOR AND REMOVE THE SENSOR AND
MOUNTING BRACKET ASSEMBLY.
NOTE: Retain one Sensor mounting screw for future use.
8. REMOVE THE CONTAINER SIZE SENSOR FROM THE OLD MOUNTING BRACKET
AND DISCARD THE BRACKET (Figure 1).
SENSOR
ALIGNMENT
2 BLOCK
INSTALL THE
LONG SCREW
Figure 1 Removing the Container Size Sensor
Replacement
NOTE: Ensure that the top surface of the Sensor is flush with the top surface of the Sensor
Alignment Block. Ensure that the top surface of the Sensor is parallel with the top edge of the
new Mounting Bracket.
1. INSTALL THE CONTAINER SIZE SENSOR, ALIGNMENT BLOCK AND HARNESS CLIP
ONTO THE NEW MOUNTING BRACKET.
2. REINSTALL THE SENSOR AND THE NEW MOUNTING ASSEMBLY INTO THE
FEEDER STACKER. DO NOT TIGHTEN THE BRACKET MOUNTING SCREWS AT
THIS TIME.

3. INSTALL THE MAIN PALLET ONTO THE PALLET BASE. REP 11-68 Stack Height Sensor (Q1122)
4. CHECK/ADJUST THE CONTAINER SIZE SENSORS (ADJ 11-32).
Removal
1. ENTER dC330. SELECT [11X2], [Elevator DN], AND PRESS THE Continue BUTTON.
4. REMOVE THE STACK HEIGHT SENSOR (Figure 1).
2
DISCONNECT 1
REMOVE SCREW
3
REMOVE NUTS (2)
5
REMOVE THE STACK
HEIGHT SENSOR
4
DISCONNECT
Figure 1 Removing the Stack Height Sensor
Replacement 1. INSTALL THE STACK HEIGHT SENSOR.

2. CHECK/ADJUST THE STACK HEIGHT (ADJ 11-27). REP 11-70 Back Guide
Removal
2. RAISE THE BYPASS TRANSPORT OR THE PURGE TRANSPORT.
3. PLACE A CHEATER IN THE STACKER TOP COVER INTERLOCK SWITCH.
CAUTION
Do not manually extend the Back Guide.
4. ENTER dC203. SELECT [Edge Guides], [Stacker X], AND [Back Guide].
5. PRESS THE Continue BUTTON. WHEN THE BACK GUIDE IS FULLY EXTENDED,
PRESS THE Stop BUTTON.
7. REMOVE THE STACKER TOP COVER (REP 4-50) OR (REP 4-51).
8. IF REMOVING THE BACK GUIDE FROM THE IFS, REMOVE THE BYPASS TRANS-
PORT TOP BAFFLE (REP 11-31).
9. RAISE THE BYPASS/PURGE TRANSPORT.
10. PREPARE THE REAR OF THE BACK GUIDE FOR REMOVAL (Figure 1).
2 1
DISCONNECT DISCONNECT
Figure 1 Preparing the Back Guide

CAUTION
Do not damage the Back Guide or any stacking components when removing the Back Guide.
The Back Guide is very delicate when it is fully extended.
NOTE: The Back Guide will have to be removed through the Stacker Doors.
11. REMOVE THE BACK GUIDE (Figure 2).
1
REMOVE SCREWS (2)
NOTE: ON THE NEW

STYLE REAR GUIDES,
THE SCREWS ARE
REMOVED FROM
UNDER THE GUIDE.
BYPASS TRANSPORT
SHOWN REMOVED
FOR CLARITY
2
CAUTION
REMOVE THE
GUIDE
Figure 2 Removing the Back Guide
REP 11-71 Front Guide

Removal
1. SWITCH OFF PRINTER POWER.
5. REMOVE THE FRONT GUIDE (Figure 1).

4 1
REMOVE THE LOOSEN SETSCREWS
FRONT GUIDE (2) AND DISENGAGE
COUPLING FROM THE
MOTOR DRIVE SHAFT
3 2
REMOVE SCREWS (2) DISCONNECT
Figure 1 Removing the Front Guide
Replacement REP 11-72 Right Guide

NOTE: Ensure that the coupling is equally engaged on both shafts. Parts List on PL 11.9
1. REINSTALL THE FRONT GUIDE. Removal
4. REMOVE THE APPROPRIATE STACKER FRONT COVER (REP 4-49).
5. REMOVE THE APPROPRIATE STACKER UPPER REAR COVER.
6. IF REMOVING THE RIGHT GUIDE FROM STACKER B, REMOVE THE STACKER
UPPER RIGHT SIDE COVER.
7. PREPARE TO REMOVE THE RIGHT GUIDE (Figure 1).

1
LOOSEN SCREW
FRONT AND REAR
2
REMOVE SCREWS (2)
Figure 1 Preparing the Right Guide
NOTE: If removing the Right Guide from Stacker A, the Stacker Right Inner Cover must be
removed to access the connectors.
8. DISCONNECT THE CONNECTORS AND REMOVE THE GUIDE (Figure 2).

2
REMOVE THE
GUIDE
1
NOTE: DISCONNECT (3)
Replacement
CAUTION
Do not damage the Right Guide Connectors during the reinstallation.
NOTE: Ensure that the Right Guide is properly positioned under the Spring Loaded Bracket.
1. REINSTALL THE RIGHT GUIDE (Figure 3).

1
RECONNECT THE
CONNECTORS 2
NOTE: POSITION
THE RIGHT GUIDE
UNDER SPRING
LOADED BRACKET
4
PUSH DOWN AND
TIGHTEN SCREW
FRONT AND REAR
3
INSTALL SCREWS (2)
Figure 3 Reinstalling the Right Guide
2. CHECK/ADJUST THE RIGHT GUIDE (ADJ 11-28). REP 11-73 Disk Stepper Motor
Removal
2. REMOVE THE STACKER REAR TOP COVER (REP 4-53).
CAUTION
Do not allow the screws to drop into the machine during removal.
3. REMOVE THE DISK STEPPER MOTOR (Figure 1).

2
CAUTION
REMOVE SCREWS (4)
3
REMOVE THE
STEPPER MOTOR
1
DISCONNECT (P497)
Figure 1 Removing the Stepper Motor
Replacement
NOTE: Ensure that the coupling on the Stepper Motor Shaft aligns with the spacer and the
coupling on the Disk Shaft.
1. REPLACE THE DISK STEPPER MOTOR.

REP 11-74 Right Guide Tamper Motor (MOT1113) 2. REMOVE THE APPROPRIATE RIGHT GUIDE (REP 11-72).
3. ROTATE THE BELT PULLEYS AND FULLY EXTEND THE RIGHT GUIDE.
Removal NOTE: Ensure that the Link is not lost when removing the Moving Wall Assembly.
1. SWITCH OFF THE PRINTER POWER. 4. REMOVE THE MOVING WALL ASSEMBLY (Figure 1).
2
NOTE: REMOVE THE
MOVING WALL ASSEMBLY
1
LOOSEN NUTS (4)
Figure 1 Removing the Moving Wall Assembly
5. REMOVE THE THREE SCREWS SECURING THE TAMPER MOTOR.

6. CUT THE CABLE TIE SECURING THE TAMPER MOTOR HARNESS AND DISCON-
NECT THE CONNECTOR.
7. REMOVE THE RIGHT GUIDE TAMPER MOTOR.
Replacement
CAUTION
Route the harnesses exactly as shown in the following Figures. Damage to the harnesses will
occur if the harnesses are not routed exactly as shown.
NOTE: It will be necessary to route the Coil Cord Harness under the tab and behind the
Tamper Motor before the motor can be positioned in the housing.
1. INSTALL THE RIGHT GUIDE TAMPER MOTOR (Figure 2).

1
NOTE: ROUTE THE
COIL CORD HARNESS
BEHIND THE MOTOR
AND UNDER THE TAB
2
POSITION THE MOTOR
IN THE HOUSING AND
REINSTALL SCREWS (3)
Figure 2 Installing the Motor
CAUTION
Do not allow the harness to interfere with any portion of the Right Guide during movement.
Extend and retract the Right Guide after securing the harnesses to ensure that there is not any
interference.
NOTE: Ensure that the Tamper Motor Harness is routed through the push in cable tie.
2. SECURE THE HARNESS (Figure 3).

REP 11-75 Right Guide Drive Belt
NOTE: ROUTE Removal
TAMPER MOTOR 1. SWITCH OFF THE PRINTER POWER.
2 HARNESS THROUGH
PUSH IN CABLE TIE NOTE: It is necessary to remove the Right Guide to ensure that the Housings are square after
CONNECT
the Drive Belt is reinstalled.
2. REMOVE THE RIGHT GUIDE (REP 11-72).
NOTE: It is necessary to scribe a line along the Drive Belt Idler to ensure that it is repositioned
in the same location.
3. SCRIBE A LINE ALONG THE DRIVE BELT IDLER.

4. LOOSEN THE IDLER.
5. REMOVE THE DRIVE BELT.
Replacement
NOTE: Do not allow one Drive Belt Pulley to rotate more than the other when installing the
Drive Belt.
1. REINSTALL THE DRIVE BELT.

2. TENSION THE DRIVE BELT AND TIGHTEN THE IDLER.
3. CHECK THAT THE RIGHT GUIDE HOUSINGS ARE SQUARE (Figure 1).
3
CAUTION
INSTALL CABLE TIE
TO SECURE HARNESS
Figure 3 Securing the Harness
NOTE: Ensure that the Link is engaged with the motor.
3. REINSTALL THE RIGHT GUIDE MOVING WALL ASSEMBLY.

4. REINSTALL THE RIGHT GUIDE.

REP 11-85 Disk Module Weldment (IFS)
CHECK: Parts List on PL 11.30
THAT THE SMALL Removal
HOUSING IS
SQUARE WITH NOTE: Two CSE's will be required to perform this removal.
THE MAIN HOUS-
ING +/-1mm 1. EXTEND THE BACK GUIDE BY PERFORMING THE FOLLOWING:
NOTE: The following step is performed to ensure that the Back Guide is not manually
extended. The Back Guide can be damaged if it is manually extended.

MAIN b. Raise the Bypass Transport.
HOUSING c. Place a Cheater in the Stacker Top Cover Interlock Switch.
d. Enter dC203. Select [Edge Guides], [Stacker X], and [Back Guide].
e. Press the Continue button. When the Back Guide is fully extended, press the Stop
button.
3. REMOVE THE STACKER TOP COVER (REP 4-50).
4. REMOVE BOTH OF THE STACKER FRONT COVERS (REP 4-49).
6. OPEN THE STACKER PURGE TRAY TOP COVER.
7. REMOVE THE BYPASS TRANSPORT TOP BAFFLE (REP 11-31).
8. REMOVE THE TELESCOPIC DRIVE SHAFT (REP 11-40).
9. REMOVE THE BYPASS TRANSPORT (REP 11-33).
SMALL HOUSING
10. REMOVE THE IFS AND FS CHUTE BAFFLE (REP 11-30).
11. REMOVE THE IFS UPPER TRANSPORTS DRIVE BELTS (PL 11.29
Figure 1 Checking the Right Guide Squareness 12. DISCONNECT THE IFS DISK STEPPER MOTOR (REP 11-73).
CAUTION
4. IF NECESSARY, SQUARE THE HOUSINGS BY ROTATING THE APPROPRIATE Do not remove the Bypass Transport Left Counterbalance. Ensure that it is the Stacker Top
DRIVE BELT PULLEY. Cover Left Counterbalance that is removed.
13. REMOVE THE STACKER TOP COVER LEFT COUNTERBALANCE (PL 4.14
14. REMOVE THE BACK GUIDE (REP 11-70).
15. REMOVE THE FRONT GUIDE (REP 11-71).
17. REMOVE THE STACK HEIGHT SENSOR (Q1122) (REP 11-68).
18. REMOVE THE DISK MODULE WELDMENT (Figure 1).

6 7 1
DISCONNECT SENSOR REMOVE PUSH IN DISCONNECT (2)
HARNESS (P460) CABLE TIE
8
REMOVE SCREWS (4)
2
DISCONNECT
9
REMOVE WELDMENT
4
DISCONNECT THE 3
5 INTERLOCK AND
REMOVE SHAFT REMOVE LATCH BRACKET
REMOVE BRACKET
Figure 1 Removing the Disk Module Weldment
Replacement e. Stack Height (ADJ 11-27).

1. REMOVE THE FRONT TAMPER MOTOR AND CAPACITOR (C1106) FROM THE OLD f. Back Guide (ADJ 11-29).
DISK MODULE WELDMENT AND INSTALL THEM ON THE NEW WELDMENT. g. Right Guide (ADJ 11-28).
2. REINSTALL THE DISK MODULE WELDMENT AND COMPONENTS.
3. CHECK/ADJUST THE FOLLOWING:
a. Bypass Transport (ADJ 11-10).
b. Upper Transports Drive Belts.
c. Disk Home Position (ADJ 11-25).
d. Disk Gate Height (ADJ 11-26).

REP 11-86 Disk Module Weldment (FS)
Removal
NOTE: Two CSE's will be required to perform this removal.
1. EXTEND THE BACK GUIDE BY PERFORMING THE FOLLOWING:
NOTE: The following step is performed to ensure that the Back Guide is not manually
extended. The Back Guide can be damaged if it is manually extended.

b. Raise the Bypass Transport.
c. Place a Cheater in the Stacker Top Cover Interlock Switch.
d. Enter dC203. Select [Edge Guides], [Stacker X], and [Back Guide].
e. Press the Continue button. When the Back Guide is fully extended, press the Stop
button.
3. REMOVE THE STACKER PURGE TRAY TOP COVER (REP 4-51).
4. REMOVE BOTH OF THE STACKER FRONT COVERS (REP 4-49).
5. REMOVE THE PURGE TRANSPORT TOP BAFFLE (REP 11-32).
6. REMOVE THE TELESCOPIC DRIVE SHAFT (REP 11-40).
7. REMOVE THE PURGE TRANSPORT (REP 11-33).
8. REMOVE THE FS CHUTE BAFFLE (REP 11-30).
9. REMOVE THE FS UPPER TRANSPORTS DRIVE BELTS (PL 11.29
10. DISCONNECT THE FS DISK STEPPER MOTOR (REP 11-73).
CAUTION
Do not remove the Purge Transport Left Counterbalance. Ensure that it is the Stacker Purge
Tray Top Cover Left Counterbalance that is removed.
11. REMOVE THE STACKER PURGE TRAY TOP COVER LEFT COUNTERBALANCE (PL
4.14
12. REMOVE THE BACK GUIDE (REP 11-70).
13. REMOVE THE FRONT GUIDE (REP 11-71).
15. REMOVE THE STACK HEIGHT SENSOR (REP 11-68).
16. REMOVE THE DISK MODULE WELDMENT (Figure 1).

6 7
DISCONNECT SENSOR REMOVE PUSH IN 1
HARNESS (P460) CABLE TIE DISCONNECT (2)
8
REMOVE SCREWS (4)
2
DISCONNECT
9
REMOVE WELDMENT
4
5 DISCONNECT THE 3
REMOVE SHAFT INTERLOCK AND REMOVE LATCH BRACKET
REMOVE BRACKET
Figure 1 Removing the Disk Module Weldment
Replacement e. Stack Height (ADJ 11-27).

1. REMOVE THE FRONT TAMPER MOTOR AND CAPACITOR (C1106) FROM THE OLD f. Back Guide (ADJ 11-29).
DISK MODULE WELDMENT AND INSTALL THEM ON THE NEW WELDMENT. g. Right Guide (ADJ 11-28).
2. REINSTALL THE DISK MODULE WELDMENT AND COMPONENTS.
a. Purge Transport (ADJ 11-10).
b. Upper Transports Drive Belts.
c. Disk Home Position (ADJ 11-25).
d. Disk Gate Height (ADJ 11-26).

ADJ 2-0 Printer UI Tilt
Purpose
The purpose is to tighten the Printer UI Shoulder Bolt so that the UI can be tilted up or down
freely and still hold any tilted position after adjustment.
Check
1. CHECK THAT THE UI WILL STAY IN THE LOWER TILTED POSITION.
Adjustment
2. REMOVE THE UI HOUSING COVER.
NOTE: An additional wrench will be needed to hold the bolt when tightening the nut.
3. TIGHTEN THE UI SHOULDER BOLT (Figure 1).
TIGHTEN THE
SHOULDER BOLT
Figure 1 Tightening the Shoulder Bolt

No Product Name Assigned ?-425 ADJ 2-0
ADJ 2-0 ?-426 No Product Name Assigned
ADJ 4-0 Printer Right Top Cover Adjustment
Purpose 1. OPEN THE PRINTER RIGHT DOOR.
The purpose is to ensure that the Right Top Cover is flush with the Printer Left Top Cover and 2. ADJUST THE RIGHT TOP COVER (Figure 1).
the top edge of the Printer Right Door.
3 4
MOVE THE BUMPERS (2) UNTIL THE PUSH DOWN THE COVER AND
COVER IS FLUSH WITHIN +/-1.0 mm TIGHTEN THE SCREWS (2)
OF THE LEFT TOP COVER AND THE
TOP EDGE OF THE RIGHT DOOR
5
TIGHTEN THE
LOCK NUTS (2)
2
LOOSEN THE
LOCK NUTS (2) 1
LOOSEN THE
SCREWS (2)
Figure 1 Adjusting the Right Top Cover
ADJ 4-1 Printer Right Door Latch Check

Purpose 1. CHECK THE RIGHT DOOR (Figure 1).
The purpose is to ensure that the right door does not bind and that the left door is flush against
the Printer Left Top Cover.

2
MEASURE THE GAP:
4.0 +/-1.0 mm
1
CHECK THAT THE DOOR
CLOSES CORRECTLY
Figure 1 Checking the Door
Adjustment
1. REMOVE THE ROS UPPER INNER PANEL.
2. ADJUST THE LATCH (Figure 2).

3
MOVE THE BRACKET
4
TIGHTEN THE SCREWS (2) 2
LOOSEN THE SCREWS (2)
1
CLOSE THE
RIGHT DOOR
Figure 2 Adjusting the Latch
3. ADJUST THE DOOR (Figure 3).

TOP COVER GAP: 4.0 +/- 1.0
4
TIGHTEN THE
SCREW DOOR
2
LOOSEN THE SCREW
3
MOVE THE LATCH
FOR THE GAP OF
4.0 +/- 1.0 mm
1
CLOSE THE
RIGHT DOOR
Figure 3 Adjusting the Door

ADJ 4-2 Printer Rear Covers Adjustment
Purpose NOTE: If the top corner dimension of +/-1.0 mm cannot be set, the side cover must be
The purpose is to ensure that the rear covers are installed with the proper clearances. removed and the bumper studs (2) turned in or out so that the cover is within specification.
1. ADJUST THE PRINTER REAR COVERS (Figure 1).
7
TIGHTEN THE PIN
6
ADJUST:
MOVE FOR A GAP OF 1
3 +/-1.0 mm LOOSEN THE PIN
5
LOOSEN THE PIN
2
MOVE THE COVER
3 UNTIL THE BOTTOM
TIGHTEN THE PIN IS FLUSH WITH THE
SIDE COVER
4
MEASURE THE GAP:
3 +/-1.0 mm
Figure 1 Adjusting the Rear Covers

ADJ 4-3 Interlock Actuator • Printer Right Door
• Printer Right Top Cover
Purpose
The purpose of this adjustment is to ensure that the Interlock Actuator is centered within the
Adjustment
Interlock Switch. This adjustment procedure includes the following covers and doors: NOTE: There are two different types of Interlock Actuators. When adjusting the Interlock Actu-
ator, refer to the correct configuration shown on Figure 1.
• Printer Left Door
1. ADJUST THE INTERLOCK ACTUATOR (Figure 1).
VERTICAL
ACTUATOR
2 1
MOVE THE LOOSEN THE
ACTUATOR SCREWS
3 HORIZONTAL
TIGHTEN THE ACTUATOR
SCREWS
Figure 1 Adjusting the Interlock Actuator

ADJ 4-4 Stacker Top Cover Counterbalances ADJ 4-5 Stacker Doors Interlock Switches (S1138) &
Purpose (S1163)
The purpose is to adjust the Counterbalances so that the Stacker Top Cover remains station- Purpose
ary in any open position.
The purpose is to ensure that the Stacker Doors Interlock Switches are deactuated before the
doors are opened to far.
Check
1. OPEN THE APPROPRIATE STACKER TOP COVER APPROXIMATELY 120mm. Check
2. ENSURE THAT THE COVER REMAINS STATIONARY. 1. SWITCH OFF THE PRINTER POWER.
3. ADJUST THE COUNTERBALANCES IF THE STACKER TOP COVER CLOSES OR
NOTE: It will be necessary to listen for the deactuation of the interlock switch.
OPENS FURTHER.
Adjustment 2. OPEN EACH STACKER DOOR SEPARATELY AND CHECK EACH INTERLOCK
1. REMOVE THE APPROPRIATE STACKER UPPER REAR COVER. SWITCH (Figure 1).
CAUTION
Ensure that the Stacker Top Cover Counterbalances are adjusted.
NOTE: The two Counterbalances must be adjusted at the same time and rotated the same
amount. Rotating the hex head shaft clockwise will increase the spring force.
2. ROTATE THE 8mm HEX HEAD SHAFT ON EACH COUNTERBALANCE AS

REQUIRED.
3. RECHECK THE COUNTERBALANCES.

No Product Name Assigned ?-433 ADJ 4-4, ADJ 4-5
1 2
POSITION THE 4
SCALE AGAINST NOTE: OPEN THE 3
DOOR BEING OPEN THE DOOR AND TIGHTEN NUT
CLOSED DOOR
CHECKED SLOWLY RECHECK DEACTUATION
3
CHECK:
THAT THE INTERLOCK SWITCH 2
DEACTUATES WHEN THE INSIDE LIP MOVE INTERLOCK
OF THE DOOR BEING OPENED IS SWITCH AS
EVEN WITH THE OUTSIDE SURFACE REQUIRED
OF THE CLOSED DOOR 1
LOOSEN NUT
Figure 1 Checking the Interlock Switch

Figure 2 Adjusting the Interlock Switch
Adjustment
1. REMOVE THE STACKER FRONT COVER (REP 4-49). 3. REINSTALL THE STACKER FRONT COVER.
2. ADJUST THE INTERLOCK SWITCH (Figure 2).

ADJ 4-10 Cleaner Drive Belt CAUTION
To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer and protect the
Purpose PR Belt.
The purpose is to adjust the belt tension, using a spring loaded idler, so that there is no belt
slippage.
4. REMOVE THE PRINTER LEFT AND RIGHT REAR COVERS (REP 4-1).
Adjustment 5. OPEN THE AC DISTRIBUTION PANEL.
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION
2. OPEN THE PRINTER FRONT DOORS. To prevent damage to the Photoreceptor and Cleaner, do not handcrank the Main Drive Motor
6. ADJUST THE CLEANER DRIVE BELT (Figure 1).
1
LOOSEN BOLT
3
TIGHTEN BOLT
2
CAUTION
HANDCRANK THE MAIN DRIVE
MOTOR TWO REVOLUTIONS IN A
CLOCKWISE DIRECTION ONLY
Figure 1 Adjusting the Cleaner Drive Belt Tension
7. CLOSE THE XEROGRAPHIC DRAWER. ADJ 4-11 Decurler Drive Belt

Purpose
The purpose is to adjust the belt tension, in order to prevent belt slippage, noise, and wear of
the bearings.
Adjustment

2. OPEN THE PRINTER FRONT DOORS. 4. REMOVE THE PRINTER LEFT REAR COVER.
CAUTION 5. REMOVE TENSION FROM THE DECURLER INTERMEDIATE DRIVE BELT (Figure 1).
PR Belt.
2
MOVE THE
IDLER BRACKET
1
LOOSEN BOLT
3
TIGHTEN BOLT
Figure 1 Removing the Tension from Decurler Intermediate Drive Belt
CAUTION
Handcrank the Main Drive Motor in a clockwise direction in order to ensure that the belts run
smoothly.
NOTE: Always adjust the tension of the Decurler Drive Belt with the Decurler Intermediate
Drive Belt loose.
6. ADJUST THE DECURLER DRIVE BELT (Figure 2).

3
TIGHTEN BOLTS (2)
2
NOTE: ALLOW THE
SPRING TO PULL
THE ASSEMBLY
4
LOOSEN BOLT
1
LOOSEN BOLTS (2)
5
ALLOW THE IDLER
BRACKET TO MOVE
6
TIGHTEN BOLT
Figure 2 Adjusting the Decurler Drive Belt
7. ADJUST THE TENSION OF THE DECURLER INTERMEDIATE DRIVE BELT (Figure 2, ADJ 4-12 Decurler Intermediate Drive Belt
STEPS 4-6).
Purpose
The purpose is to adjust the belt tension, using a spring loaded idler, so that there is no belt
slippage.
Adjustment
CAUTION
PR Belt.
5. ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (Figure 1).

2
ALLOW THE IDLER
BRACKET TO MOVE
1
LOOSEN BOLT
3
TIGHTEN BOLT
Figure 1 Adjusting the Decurler Intermediate Drive Belt
CAUTION ADJ 4-13 Decurler Intermediate Drive Pulley

Purpose
The purpose of the adjustment is to position the Decurler Intermediate Drive Pulley in order to
6. HANDCRANK THE MAIN DRIVE MOTOR IN A CLOCKWISE DIRECTION IN ORDER
ensure that the drive belt stays in the center of the pulley.
TO ENSURE THAT THE BELTS RUN SMOOTHLY.
Check
2. CHECK THE PULLEY (Figure 1, STEP 1).

1
CHECK:
80 +/-0.2 mm
2
LOOSEN THE
SETSCREW
3 4
ADJUST: CAUTION
MOVE THE PULLEY
TIGHTEN THE
80 +/-0.2 mm FROM
SETSCREW PREFUSER DRIVE
THE FRAME
ASSEMBLY
Figure 1 Checking/Adjusting the Pulley
Adjustment ADJ 4-14 Intermediate Drive Assembly

CAUTION Purpose
To prevent damage to the pulley, ensure that the key is positioned under the setscrew. The purpose is to adjust gear alignment and gap to ensure proper gear engagement to reduce
1. ADJUST THE PULLEY (Figure 1, STEPS 2-4). wear.
Check
NOTE: The 0.13 mm MAX. GAP is between the small gear and the retaining ring.
3. CHECK THE INTERMEDIATE DRIVE ASSEMBLY (Figure 1).

2
CHECK:
THE LARGE GEAR
SURFACE FLUSH
+/-0.50 mm TO THE
SMALL GEAR
1
CHECK:
0.13 mm MAX
Figure 1 Checking the Intermediate Drive Assembly
Adjustment
1. ADJUST THE INTERMEDIATE DRIVE ASSEMBLY (Figure 2).

6
TIGHTEN
5
ADJUST:
4 FLUSH TO SMALL
LOOSEN SET GEAR +/-0.50 mm
SCREW
1
3 LOOSEN SET
TIGHTEN 2 SCREW
ADJUST:
THE GEAR AGAINST THE
RETAINER 0.13 mm MAX. GAP
Figure 2 Adjusting the Intermediate Drive Assembly

ADJ 4-15 Intermediate Drive Belt Adjustment
Purpose 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
The purpose is to adjust belt tension, so that there is no belt slippage. 2. REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).
NOTE: Loosen bolts (2) just enough to allow the Intermediate Drive Assembly to move.
3. ADJUST THE INTERMEDIATE DRIVE BELT (Figure 1).
2
ALLOW THE
DRIVE ASSEMBLY
TO MOVE
3
TIGHTEN BOLTS (2)
1
NOTE: LOOSEN
THE BOLTS (2)
REAR VIEW
Figure 1 Adjusting the Belt Tension

ADJ 4-16 MIM Drive Belt 6. CLOSE THE XEROGRAPHIC DRAWER.
Purpose
The purpose is to adjust belt tension, using a spring-loaded idler, so that there is no belt slip-
page.
Adjustment
CAUTION
PR Belt.
CAUTION
in a Counterclockwise direction.
5. ADJUST THE TENSION OF THE MIM DRIVE BELT (Figure 1).
2
CAUTION
HANDCRANK THE
MAIN DRIVE MOTOR
SEVEN REVOLUTIONS
3 1
TIGHTEN IDLER LOOSEN IDLER
BOLT BOLT
Figure 1 Adjusting the MIM Drive Belt Tension

ADJ 4-17 PHM Drive Belt 6. CLOSE THE XEROGRAPHIC DRAWER.
Purpose
The purpose is to adjust belt tension, using a spring loaded idler, so that there is no belt slip-
page.
Adjustment
CAUTION
PR Belt.
CAUTION
5. ADJUST THE TENSION OF THE PHM DRIVE BELT (Figure 1).
3
TIGHTEN BOLT
2
CAUTION
1 HANDCRANK THE MAIN
LOOSEN BOLT DRIVE MOTOR SEVEN
REVOLUTIONS
Figure 1 Adjusting the PHM Drive Belt Tension

ADJ 4-18 PHM/MIM Drive Pulleys CAUTION
Purpose
2. ADJUST THE PULLEYS (Figure 2).
The purpose is to position the pulleys so that the drive belts stay seated in the center of the
pulleys.
Check
CAUTION
PR Belt.
3. REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1). 0.13 mm MAX
8.0 +/-0.5 mm
5. CHECK THE PULLEY DIMENSIONS (Figure 1).
2
ADJUST THE PULLEYS
3
TIGHTEN THE
SETSCREWS (2)
1
LOOSEN THE
SETSCREWS (2)
0.13 mm MAX
8.0 +/-0.5 mm
Figure 2 Adjusting the Pulleys
Figure 1 Checking the Pulley Dimensions
Adjustment
1. DISENGAGE THE MIM DRIVE BELT (REP 4-29).

ADJ 4-19 Prefuser Drive Belt CAUTION
Purpose PR Belt.
The purpose is to adjust the belt tension, using a spring-loaded idler, so that there is no belt
slippage.
3. REMOVE THE PRINTER LEFT AND RIGHT REAR COVERS (REP 4-1).
Adjustment 4. OPEN THE AC DISTRIBUTION PANEL.
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION

5. ADJUST THE PREFUSER DRIVE BELT (Figure 1).
1
LOOSEN BOLT
3
TIGHTEN BOLT
2
CAUTION
HANDCRANK THE MOTOR
2 REVOLUTIONS IN A
CLOCKWISE DIRECTION
Figure 1 Adjusting the Prefuser Drive Belt
6. CLOSE THE XEROGRAPHIC DRAWER. ADJ 4-20 Tray 1 and 2 Feeder Drives
Purpose
The purpose is to align the feeder drive coupling to the feed head coupling in the tube shaft.
This will ensure the proper operation, without excessive wear, noise or vibration.
Check
1. OPEN THE PRINTER LEFT AND RIGHT FRONT DOORS.

2. PULL OUT TRAY.
4. INSERT THE PIN (271W1852) INTO THE HOLE AT THE REAR OF THE TUBE SHAFT
COUPLING (Figure 1).
NOTE: THE HOLE

IS IN THE MIDDLE
OF THE TUBE
SHAFT COUPLING
Figure 1 Inserting the Pin
5. SLOWLY BUT FIRMLY PUSH THE TRAY INTO THE PRINTER.

6. IF THE TRAY MOVES INTO THE LATCH POSITION, THE ALIGNMENT IS GOOD. IF
THE TRAY DOES NOT MOVE INTO THE LATCH POSITION, PERFORM THE ADJUST-
MENT.
Adjustment
NOTE: Loosen bolts (2) only enough to allow movement of the drives.
1. PREPARE TO ADJUST THE FEEDER DRIVE (Figure 2).

5
NOTE: LOOSEN
THE BOLTS (2)
1
LOOSEN BOLT
4
REMOVE BELT
FROM DRIVE
2
MOVE THE
BRACKET
3
TIGHTEN BOLT
Figure 2 Preparing to Adjust the Feeder Drive
NOTE: Turn the Feeder Drive Pulley by hand to ensure that the drive coupling is properly
engaged (Figure 3).
2. MOVE THE FEEDER DRIVE UNTIL THE TRAY MOVES INTO THE LATCH POSITION.

NOTE: COUPLING
ENGAGEMENT
Figure 3 Ensuring Proper Coupler Engagement
3. TIGHTEN THE TWO FEEDER DRIVE BOLTS.

4. PULL OUT TRAY AND REPEAT STEPS 5 AND 6 OF THE CHECK.
5. REMOVE THE PIN.
6. ENGAGE AND ADJUST THE PHM DRIVE BELT (ADJ 4-17).

ADJ 4-21 Fuser-Developer Drive Belt 3. REMOVE THE PRINTER REAR COVERS (REP 4-1).
Purpose NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assem-
The purpose is to adjust belt tension, using a spring-loaded idler, so that there is no belt slip- bly. Toner will fall from assembly connection.
page. 4. OPEN THE TONER FILTER ASSEMBLY.
Adjustment 6. REMOVE THE HVAC OUTPUT MODULE (REP 1-4).
7. ADJUST THE TENSION OF THE FUSER DEVELOPER DRIVE BELT (Figure 1).
2
ALLOW IDLER
BRACKET TO
MOVE AND THEN
TIGHTEN THE
BOLT
1
LOOSEN BOLT
3
ADJUST:
HANDCRANK THE DRIVE
PULLEY 7 REVOLUTIONS IN
A CLOCKWISE DIRECTION
Figure 1 Adjusting the Fuser Developer Drive Belt

NOTE: Handcrank the Drive Pulley in a clockwise direction in order to ensure that the belt is ADJ 4-22 Fuser-Developer Drive Pulley
seated.
Purpose
8. INSTALL THE HVAC OUTPUT MODULE (REP 1-4). The purpose is to position the Drive Pulley on the Jackshaft so that the Fuser-Developer Drive
9. CONNECT THE OZAC DUCT TO THE OZONE FILTER. Belt stays seated in the center of the Drive Pulley.
NOTE: Replace cable ties as required and ensure that the Cleaner and Ozac hoses are away
from moving parts. Check
10. CLOSE THE XEROGRAPHIC DRAWER. NOTE: Use a 6 inch and a 150 mm scale from the Basic Tool Kit (600T1835) and the Metric
Tool Kit (600T1880).

COVER (REP 4-1).
NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assem-
3. OPEN THE TONER FILTER ASSEMBLY AND THE XEROGRAPHIC CARD CAGE.

2
MOVE THE IDLER
AND TIGHTEN THE
BOLT
3
DISCONNECT THE
BELT FROM THE
JACKSHAFT
1
LOOSEN BOLT
Figure 1 Loosening the Fuser-Developer Drive Belt
6. CHECK/ADJUST THE DRIVE PULLEY (Figure 2).

RIGHT REAR VIEW 1
PLACE THE
SCALE ACROSS
THE CUTOUT
5
TIGHTEN THE
SETSCREW 2
CHECK:GAP MUST
BE 28.0 +/-0.0 mm
SCALE
FRAME
4 3
ADJUST: LOOSEN THE
POSITION THE PUL- SETSCREW
LEY AT 12.0 +/-0.0 mm
Figure 2 Checking /Adjusting the Drive Pulley
7. CONNECT AND TIGHTEN THE DRIVE BELT. ADJ 4-23 Fuser-developer Intermediate Drive
8. HANDCRANK THE DRIVE PULLEY IN A CLOCKWISE DIRECTION IN ORDER TO
ENSURE THAT THE BELT IS SEATED.
Purpose
The purpose is to adjust belt tension, using a spring-loaded idler, so that there is no belt slip-
page.
11. REPLACE CABLE TIES AS REQUIRED AND ENSURE THAT THE CLEANER AND Adjustment
OZAC HOSES ARE AWAY FROM MOVING PARTS.

4. REMOVE THE FUSER-DEVELOPER DRIVE DIRT SHIELD (REP 4-47). 5. ADJUST THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (Figure 1).
FRONT TOP VIEW

REAR VIEW
1
LOOSEN THE
3 SCREW
2 TIGHTEN THE
ALLOW THE SCREW
IDLER TO MOVE
Figure 1 Adjusting the Fuser-Developer Intermediate Drive Belt

ADJ 6-1 ROS Magnification Setup
Purpose
The purpose is to ensure that the Magnification parameters remain within specification after
the replacement of critical ROS components.
Check
NOTE: Use the 300 mm scale (600T41501) to measure the prints.
1. TOP-TO-BOTTOM (FAST SCAN) MAGNIFICATION:
NOTE: Use A4 (8 1/2 x 11) or a larger paper size in Tray 1.
b. Measure the C - D (200 mm +/- 0.4 mm) distance on the prints using the 300mm
scale (600T41501).
2. SIDE-TO-SIDE (SLOW SCAN) MAGNIFICATION:
b. Measure the A - B (200 mm +/- 0.5 mm) distance on 5 consecutive prints. Using the
average of the 5 prints the distance A - B should be 200 mm +/- 0.5 mm using the
300mm scale (600T41501).
Adjustment
1. TOP-TO-BOTTOM (FAST SCAN) MAGNIFICATION:
NOTE: Increasing the Range value increases the C - D distance.
a. Correct the C - D distance by using the Up and Down Arrows.

2. SIDE-TO-SIDE (SLOW SCAN) MAGNIFICATION:
NOTE: Increasing the Range value increases the A - B distance.
a. Correct the A - B distance by using the Left and Right Arrows.

a. Pre Transfer Baffle (ADJ 8-1)
b. ROS Image Squareness (ADJ 6-2)
c. (Figure 1).

ADJ 6-2 ROS Image Squareness

Purpose Check
The purpose of the ROS Image Squareness Adjustment is to ensure that the scanned image 1. PLACE 500 SHEETS OF 20 LB (80 GSM), 14 INCH OR B4 PAPER INTO TRAY 3.
on the Photoreceptor Belt is square regardless of other factors, such as out-off-square paper 2. ENTER dC106, [Printer Options], [Test Patterns and PQ], [Dimensional], SELECT 50
or paper path skew. PRINTS, AND PRESS THE Continue BUTTON.
3. USING THE XTP #564.001 (82E4161), CHECK THE PRINTS FOR THE ROS IMAGE
SQUARENESS (Figure 1).
2 1
ALIGN THE CORNER OF THE ALIGN THE EDGE OF
TEST PATTERN WITH THE #4 THE TEST PATTERN
LINES ON X1 AND X3 WITH THE #4 LINE
ON X2
PRINT
TEST PATTERN
3
THE EDGE OF THE TEST PATTERN
SHOULD BE ALIGNED WITH THE #4
LINE ON X5 WITHIN +/- 0.5 mm
Figure 1 Checking the ROS Image Squareness
Adjustment 3. LOOSEN THE ROS ASSEMBLY REAR HOLD DOWN CLAMP.

1. REMOVE THE ROS UPPER INNER PANEL.

CAUTION
Do not drop the Clamp.
4. REMOVE THE ROS ASSEMBLY FRONT HOLD DOWN CLAMP (Figure 2).
2
CAUTION
REMOVE THE CLAMP
1
CAUTION
LOOSEN THE SCREW
Figure 2 Removing the Hold Down Clamp
5. ADJUST THE ROS IMAGE SQUARENESS (Figure 3).

1
LOOSEN THE FRONT SCREWS (2)
4
TIGHTEN THE
SCREWS (2)
3
TURN THE SCREW CLOCKWISE IF EDGE OF
PATTERN IS BETWEEN THE #4 LINE AND
THE EDGE OF THE PRINT
2
TURN THE SCREW COUNTER-CLOCKWISE
IF EDGE OF PATTERN IS BETWEEN #4 AND
#10 LINES
Figure 3 Adjusting the ROS Image Squareness
6. INSTALL AND TIGHTEN THE FRONT HOLD DOWN CLAMP. ADJ 6-3 ROS Low Correction Factor
7. TIGHTEN THE ROS ASSEMBLY REAR HOLD DOWN CLAMP.
Purpose
8. REPEAT THE CHECK IF REQUIRED.
The purpose is to establish a basic ROS calibration parameter to ensure the proper charge
9. INSTALL THE PRINTER LEFT TOP COVER (REP 4-2). and exposure of the Photoreceptor Belt.
Adjustment
1. ENTER PRINTER DIAGNOSTICS, [dC951, ROS Correction].
NOTE: Do Not press [Continue] to run the Autocal.
2. Set value to 50%, or set to the Cal Tag value if there is one.
3. Press [Enter].

ADJ 6-4 ROS Power Calibration
Purpose
The purpose is to calibrate the ROS power.
Adjustment
1. ENTER dC131 [MIN] LOCATION [32]. SET DATA VALUE TO [1].
2. ENTER dC606. SELECT [TESTS], [ROS Self Test]. PRESS [CONTINUE].
3. IF A FAULT IS DECLARED, FIX THE PROBLEM AND REPEAT STEP 2 UNTIL IT
PASSES THE SELF TEST.
NOTE: It is important to run prints after the Self Test is performed to ensure all the proper
values are downloaded to NVM.
4. SELECT [SETUPS], [6] PRINTS.

ADJ 6-3, ADJ 6-4 ?-460 No Product Name Assigned
ADJ 7-0 Feed Clutch Belt and Takeaway Drive Belt Adjustment
Purpose CAUTION
The purpose is to adjust the tension of the Feed Clutch Belt and the Takeaway Drive Belt. Rotate the Takeaway Pulley and the Feed Clutch Pulley five times. Do not manually apply
extra tension to the belt or the tension idler.
NOTE: While holding the Feed Clutch Pulley the Takeaway Roll should rotate only in the coun-
terclockwise direction.
1. ADJUST FEED CLUTCH BELT (Figure 1, STEPS 1-4).
1 9
RAISE TIGHTEN THE
2 SCREW
LOOSEN THE
SCREW 8
TIGHTEN THE
SETSCREW
TAKEAWAY DRIVE
BELT
FEED CLUTCH
BELT
7
CAUTION
ROTATE THE
PULLEY FIVE
3 TIMES
CAUTION 4
ROTATE THE PULLEY TIGHTEN THE 5
FIVE TIMES SCREW LOOSEN THE 6
SCREW LOOSEN THE
SETSCREW
Figure 1 Adjusting the Feed Clutch Belt/Takeaway Drive Belt
2. ADJUST TAKEAWAY DRIVE BELT (Figure 1, STEPS 1, 5-9). ADJ 7-1 Takeaway Shaft Endplay
Purpose
The purpose is to minimize skew by properly aligning the Feed Belt with the Takeaway Roll and
to properly compress the grease seal in order to prevent leakage of grease from the Takeaway
Roll.
Check

NOTE: Turn the roll in a counterclockwise direction while pushing in order to remove endplay
(Figure 1, Step 2).
NOTE: Do not interfere with the grease seal when measuring the gap between the roll and
casting (Figure 1, Step 3).
3. CHECK THE ENDPLAY (Figure 1).
FEED BELT CASTING
GREASE SEAL
FEED HEAD
CASTING
3
NOTE: CHECK
1.9 +/-0.15 mm
1 2
PUSH TO
NOTE: PUSH TO
REMOVE
REMOVE THE PLAY
THE PLAY
Figure 1 Checking the Endplay
Adjustment
NOTE: Do not interfere with the grease seal when inserting the shim (Figure 2, Step 3).
NOTE: In the following step, it is easier to move the roll along the shaft if you simultaneously
turn the roll in a counterclockwise direction, as viewed from the front (Figure 2, Step 4).
2. ADJUST THE ENDPLAY (Figure 2).

FEED BELT CASTING GREASE SEAL
7 1
TIGHTEN LOOSEN
2
PUSH AND HOLD
3
NOTE: INSERT THE
1.9 mm SHIM
5 4
6
PUSH THE PULLEY PUSH THE CASTING NOTE: PUSH THE ROLL
AGAINST THE CASTING AGAINST THE ROLL AGAINST THE SHIM
Figure 2 Adjusting the Endplay

ADJ 7-2 Down/Low Paper Sensor (Q714/724) Adjustment
Purpose 1. REMOVE ALL PAPER FROM THE TRAY.
The purpose is to ensure that a low paper condition will be detected within the normal range of 2. REMOVE THE LABEL PANEL TO ACCESS THE SETSCREW.
expected paper weights. WARNING
Ensure that the Right Door Interlock Switch is not cheated; this will prevent the elevator
Check from moving up when the Tray Interlock Switch is cheated.
1. REMOVE ALL PAPER FROM THE TRAY.
NOTE: To access the Tray 1 and/or the Tray 2 Interlock Switches, pull out Tray 1.
2. PLACE APPROXIMATELY 60 SHEETS OF 20 LB (80 GSM) PAPER INTO THE TRAY.
3. CHEAT THE TRAY INTERLOCK SWITCH.
3. ENTER dC106, [Tray 1] OR [Tray 2] AND MAKE 50 PRINTS.
4. TRAY 2 ONLY: PUT PAPER IN TRAY 1 AND PUSH IN THE TRAY.
4. IF A LOW PAPER CONDITION IS NOT DETECTED, GO TO THE ADJUSTMENT.
5. ENTER dC330 [7-8]. SELECT [Tray 1 Elevator UP] OR [Tray 2 Elevator UP] AND
5. OPEN THE PRINTER RIGHT DOOR. PULL OUT THE TRAY AND COUNT THE NUM-
PRESS THE Continue BUTTON.
BER OF SHEETS THAT REMAIN IN THE TRAY AFTER THE LOW PAPER CONDITION
IS DETECTED. 6. STAY IN dC330, [7-8]. OBSERVE Tray 1 Down/Low Paper Sensor OR Tray 2 Down/
Low Paper Sensor.
6. PERFORM THE ADJUSTMENT IF LESS THAN 30 SHEETS OR MORE THAN 50
SHEETS REMAIN IN THE TRAY. NOTE: It may be necessary to break the Glyptol seal in order to perform the adjustment.
7. PREPARE TO ADJUST THE DOWN/LOW PAPER SWITCH (Figure 1).
SETUP TOOL
2
ROTATE UNTIL
PAPER PLATE THE TOP OF THE
TOOL IS FLUSH
WITH THE GATE
GATE
1
POSITION THE
SETUP TOOL
Figure 1 Preparing to Adjust the Down/Low Paper Sensor

8. ADJUST THE DOWN/LOW PAPER SENSOR (Figure 2). ADJ 7-3 Elevator Up Limit Switch (S714/724)
Purpose
The purpose is to position the Elevator Up Limit switch in order to eliminate elevator overtravel.
2 1
ROTATE UNTIL THE Check
ROTATE UNTIL
DISPLAY CHANGES
THE DISPLAY IS H 1. OPEN THE PRINTER RIGHT DOOR.
FROM H TO L
NOTE: If this check is being done on Tray 2, lower the Tray 1 Elevator to access the Tray Inter-
lock Switches.

5. REMOVE THE SAFETY COVER (Figure 1).
2
REMOVE THE
SAFETY COVER
Figure 2 Adjusting the Down/Low Paper Sensor
9. DEACTUATE THE TRAY INTERLOCK SWITCH.

10. REPEAT THE CHECK.
11. APPLY A SMALL AMOUNT OF ADHESIVE 63P561 (USMG) OR 600T90352 (RXL) TO
THE SETSCREW ON THE LOW PAPER SENSOR.
1
REMOVE THE
SCREWS (3)
Figure 1 Removing the Safety Covers
6. INSTALL THE FEED HEAD ASSEMBLY.
NOTE: Pull out Tray 1 in order to access the Tray 1 and/or Tray 2 Interlock Switches.

8. TRAY 2 ONLY: PUSH TRAY 1 INTO PRINTER. 3. REPEAT STEP 11 OF THE CHECK.
9. SWITCH ON THE PRINTER CIRCUIT BREAKERS.
10. RAISE THE PAPER TRAY PLATE. ENTER dC330, [7-8]. SELECT [Tray 1 Elevator UP]
OR [Tray 2 Elevator UP] AND PRESS THE Continue BUTTON.
11. HANDCRANK THE LEAD SCREW AND CHECK THAT THE SWITCH ACTUATES
WHEN THE PAPER TRAY PLATE IS 5.0 +/- 0.5 mm ABOVE GATE.
Adjustment
1. HANDCRANK THE LEAD SCREWS UNTIL THE PAPER PLATE IS 5.0 +/- 0.5 mm
ABOVE GATE.
2. ADJUST THE ELEVATOR UP LIMIT SWITCH (Figure 2).
1
LOOSEN THE
SCREWS (2)
2
PUSH AGAINST THE
FEED HEAD UNTIL
THE SWITCH ACTU-
ATES
3
HOLD THE SWITCH
AND TIGHTEN THE
SCREWS
GATE
PAPER PLATE
Figure 2 Adjusting the Switch

ADJ 7-4 Length Guide Position
Purpose 3
ADJUST: 4
The purpose is to adjust the Length Guide so that it reports the correct paper length. TIGHTEN (4)
120 +/-0.5 mm
Check
NOTE: Tray 2 only: Pull out Trays 1 and 2 out of the printer.
1. PULL OUT THE TRAY AND REMOVE THE PAPER.

2. REMOVE THE SAFETY COVER AT THE REAR OF TRAY 1 IN ORDER TO ACCESS
THE TRAY INTERLOCK SWITCHES.
WARNING
injury and ensure that the elevator does not move when the Tray Interlock Switch is
cheated.
NOTE: Access the Tray 1 or Tray 2 Elevator Interlock Switch through Tray 1.

4. TRAY 2 ONLY: PUT PAPER IN TRAY 1 AND PUSH THE TRAY INTO PRINTER.
5. RAISE THE PAPER PLATE: 1
a. Tray 1: Enter dC330, [7-8], [Tray 1 Elevator UP]. Press the Continue Button. CHECK:
<120> +/-0.5 mm
b. Tray 2: Enter dC330, [7-8], [Tray 2 Elevator UP]. Press the Continue Button.
LOOSEN
NOTE: Ensure that the Length Guide is in the center (side-to-side) of the Paper Plate opening.
7. CHECK THE LENGTH GUIDE (Figure 1).
Figure 1 Adjusting the Length Guide
Adjustment
NOTE: Ensure that the Length Guide is in the center of the Paper Plate opening before tight-
ening the screws.
1. ADJUST THE LENGTH GUIDE (Figure 1).

ADJ 7-5 Length Guide Tension
Purpose
The purpose is to ensure that the Length Guide moves when the release lever is pressed, and
that the Length Guide remains positioned against the paper stack when the tray is pushed into RELEASE THE
the printer. LEVER
Check
1. PULL OUT THE TRAY AND REMOVE THE PAPER.
2. PRESS THE RELEASE LEVER AND CHECK THAT THE LENGTH GUIDE MOVES
FRONT TO REAR WITHIN THE CUTOUT OF THE PAPER PLATE.
3. FILL THE TRAY WITH PAPER AND POSITION THE LENGTH GUIDE AGAINST THE
REAR OF THE PAPER STACK.
4. QUICKLY AND FIRMLY PUSH THE TRAY INTO THE PRINTER.
5. PULL THE TRAY OUT OF THE PRINTER AND CHECK THAT THE LENGTH GUIDE
REMAINED STATIONARY AGAINST THE PAPER STACK.
Adjustment
1. IF THE LENGTH GUIDE MOVED AWAY FROM THE PAPER STACK, TURN THE NUT
IN A COUNTERCLOCKWISE DIRECTION UNTIL THE LENGTH GUIDE REMAINS STA-
TIONARY (Figure 1).
ADJUS THE NUT
Figure 1 Adjusting the Release Lever
2. REPEAT THE CHECK.

3. IF THE LENGTH GUIDE DOES NOT MOVE WHEN THE RELEASE LEVER IS
PRESSED, TURN THE NUT IN A CLOCKWISE DIRECTION UNTIL THE LENGTH
GUIDE CAN BE RELEASED (Figure 1).
4. REPLACE THE LENGTH GUIDE IF THE TWO CONDITIONS CANNOT BE ACHIEVED.

ADJ 7-6 Auto Latch 3. REMOVE THE SAFETY COVER AT THE FRONT OF THE FEED HEAD.
CAUTION
Purpose
Manually latch the mechanism before pulling out the Paper Tray. When beginning the adjust-
The purpose is to ensure that the Auto Latch mechanism will latch the Feed Belt casting with-
ment, the casting may not automatically latch and this will prevent damage to the Feed Belt.
out damaging the Feed Belt.
NOTE: Unlatch the Feed Belt Casting and perform the test several times. Push the paper tray
Adjustment slowly and do not apply any vertical force to the paper tray. Observe the Feed Belt Casting in
1. OPEN THE PRINTER RIGHT DOOR AND CHEAT THE RIGHT DOOR INTERLOCK order to ensure that it is latched when the tray is pushed into the printer.
SWITCH. 4. ADJUST THE LOWER LIMIT SETSCREW SO THAT THE FEED BELT CASTING
2. PULL OUT THE TRAY AND REMOVE THE PAPER. LATCHES WHEN SLOWLY PUSHING IN THE PAPER TRAY (Figure 1, STEPS 1-3).
1
4 CAUTION
INSERT A 5.0 mm ROTATE COUNTER-
HEX KEY CLOCKWISE UNTIL
THE AUTO LATCH IS
FLUSH WITH THE
BOTTOM OF THE
CASTING
2
3
ROTATE CLOCKWISE NOTE: ROTATE CLOCKWISE IN
ANOTHER 1/2 REVO- 1/2 TURN INCREMENTS UNTIL
LUTION THE FEED BELT LATCHES
Figure 1 Adjusting the Auto Latch
5. APPLY A SMALL AMOUNT OF ADHESIVE 63P561 (USO), OR 600T90352 (RXL), TO 8. PLACE APPROXIMATELY 75 SHEETS OF PAPER (8 mm HIGH) INTO THE TRAY.
THE LOWER LIMIT SETSCREW. 9. CHEAT THE RIGHT DOOR INTERLOCK SWITCH.
WARNING 10. WHEN THE ELEVATOR STOPS MOVING, REMOVE THE PAPER FROM THE TRAY.
NOTE: Position the hex key as shown in Figure 1. This will ensure that the flats of the hex key
injury and ensure that the elevator does not move when the Tray Interlock Switch is
contact the Feed Belt and the Cork Pad.
cheated.
6. CHEAT THE TRAY INTERLOCK SWITCH. 11. INSERT A 5 mm HEX KEY BETWEEN THE FEED BELT AND THE CENTER OF THE
CORK PAD (Figure 1).
7. TRAY 2 ONLY: PUSH TRAY 1 INTO THE PRINTER.

12. ENTER dC330, [7-8]. THE Tray 1 Stack Height Sensor OR Tray 2 Stack Height Sen- ADJ 7-7 Front Cover Frame
sor DISPLAY MUST INDICATE H.
13. HANDCRANK THE ELEVATOR UPWARD UNTIL THE DISPLAY GOES TO L.
Purpose
The purpose is to position the frame so that the Tray 1 and 2 covers are flush with the Printer
14. REMOVE THE HEX KEY FROM THE TRAY.
Right Door.
NOTE: Lightly tap the Feed Head before measuring the gap to ensure an accurate measure-
ment. Check
15. MEASURE THE GAP BETWEEN THE FEED BELT AND THE CENTER OF THE CORK 1. PULL OUT THE TRAY.
PAD (Figure 2). IF THE GAP IS WITHIN SPECIFICATION CONTINUE WITH STEP 17. IF 2. LOOSEN THE TWO SCREWS THAT SECURE THE TRAY COVER. ENSURE THAT
THE GAP IS NOT WITHIN SPECIFICATION, GO TO STEP 16. THE COVER IS SEATED, THEN TIGHTEN THE SCREWS.
3. PUSH IN THE TRAY.
CAUTION NOTE: Check the alignment on the right and the left sides of the cover.
DO NOT DEFLECT THE
1 TRAY WHEN TAKING A 4. CHECK THE ALIGNMENT (Figure 1).
INSERT A 1.0 mm MEASUREMENT
GAUGE ON TOP OF
THE CORK PAD AND
UNDER THE FEED
BELT
FEED BELT
2 CHECK:
CHECK: THAT THE FRONT
2.15 +0.05/-0.0 mm SURFACE OF THE
TRAY COVER IS
FLUSH WITHIN +/-1.0
mm OF THE
PRINTER RIGHT
CORK PAD DOOR
1.0 mm GAUGE
Figure 2 Measuring the Gap
16. PERFORM THE PAPER FEED SETUP (ADJ 7-9). DO NOT COMPLETE THIS PROCE-
DURE.
17. REMOVE THE CHEATER FROM THE RIGHT DOOR INTERLOCK SWITCH. Figure 1 Checking the Alignment
18. INSTALL THE FRONT SAFETY COVER ON THE FEED HEAD.
19. REMOVE THE CHEATER FROM THE TRAY INTERLOCK SWITCH. Adjustment
3. REMOVE THE TRAY FRONT COVER AND THE LABEL PANEL (REP 7-28).

4. PUSH IN THE TRAY. ADJ 7-8 Front Cover Support
NOTE: Do not connect the Tray Capacity PWB connector or tighten the screws (2). Ensure Purpose
that the cover is fully seated. The purpose is to ensure that the Tray 1 and 2 covers are centered in the opening of the
5. ADJUST THE ALIGNMENT (Figure 2). Printer Right Door. This will prevent interference between the trays and the door and also pro-
vide an even appearance.
Check
2 1. CHECK THE GAPS BETWEEN THE TRAY COVERS AND THE RIGHT DOOR (Figure
NOTE: INSTALL THE 1).
FRONT COVER AND
MOVE THE FRAME TO 1
SET THE ALIGNMENT LOOSEN THE
SCREWS (2)
3
OPEN THE RIGHT
DOOR
CHECK:
FRAME FOR UNIFORM GAPS
3.0 + 0.0/-1.0 mm
4
TIGHTEN THE
SCREWS (2)
Figure 2 Adjusting the Alignment
6. CLOSE THE RIGHT DOOR.

7. CHECK THE POSITION OF THE COVER.
8. REPEAT STEPS 5, 6, AND 7 UNTIL THE ALIGNMENT IS SET.
Figure 1 Checking the Front Cover Gap
9. OPEN THE RIGHT DOOR AND REMOVE THE TRAY COVER.
10. PULL OUT THE TRAY AND CONNECT THE TRAY CAPACITY PWB.
Adjustment
11. INSTALL THE LABEL PANEL AND THE TRAY COVER.
3. REMOVE THE TRAY FRONT COVER AND THE LABEL PANEL (REP 7-28).
4. PUSH IN THE TRAY.

NOTE: Do not connect the Tray Capacity PWB connector or tighten the screws (2). Ensure
that the cover is fully seated.
5. ADJUST THE FRONT COVER FRAME (Figure 2).
2
1
NOTE: INSTALL THE
LOOSEN THE
FRONT COVER AND
SCREWS (4) TO
MOVE THE FRAME
FINGERTIGHTEN
TO SET THE GAPS
4
TIGHTEN THE
SCREWS (4)
FRAME
3
OPEN THE RIGHT
DOOR
Figure 2 Adjusting the Front Cover Frame
6. CLOSE THE RIGHT DOOR.

7. CHECK THE FRONT COVER GAPS.
8. REPEAT STEPS 5, 6, AND 7 UNTIL THE GAPS ARE SET.
9. OPEN THE RIGHT DOOR AND REMOVE THE TRAY COVER.
NOTE: Connect the Tray Capacity PWB connector.
11. INSTALL THE LABEL PANEL AND TRAY COVER; CLOSE THE RIGHT DOOR.

ADJ 7-9 Paper Feed Setup
Purpose
The purpose is to check and adjust the components of either Tray 1 or 2 in one continuous pro-
cedure to ensure proper paper feeding.
The following checks and adjustments are included in this procedure:
• Feed Belt Tension

• Paper Plate Parallelism
• Paper Plate Endplay
• Paper Stack Height (Stack Height Sensor)
• Stack Force (Stack Height Sensor)
• Stack Relief Solenoid
Adjustment
NOTE: The steps of this procedure must be done in sequence. Performing one of these
adjustments out of sequence may cause all of the following adjustments to be out of specifica-
tion.

3. REMOVE THE PAPER FROM THE TRAY.
4. CHECK THAT THE FEED HEAD HAS BEEN INSTALLED CORRECTLY.
a. Check that the bearing at the front of the Feed Head is correctly seated in the chan-
nel.
b. Look at the Feed Head and ensure it is engaged with the Stack Relief Solenoid.
c. Check that the front and rear bearing retainers are tight.
6. REMOVE THE PAPER TRAY SETUP TOOL, LOCATED UNDER THE TRAY 1 LABEL
PANEL.
7. REMOVE THE AUTO LATCH BRACKET FROM THE FEED HEAD.
CAUTION
Do not damage the Entry Guide with the setup tool or feeler stock. If the Paper Tray Setup Tool
does not touch the Entry Guide, unlatch the Feed Belt and insert the feeler stock between the
tool and the Entry Guide. Latch the Feed Belt and measure the gap. Unlatch the Feed Belt in
order to remove the feeler stock.
NOTE: Ensure that the Paper Tray Setup Tool can be inserted and removed from the left shaft
without moving the shaft upward.
8. CHECK THE FEED BELT TENSION (Figure 1).

3
VIEWED FROM CHECK:
THE RIGHT SIDE THE POSITION OF
OF THE FEED THE ECCENTRIC PIN
HEAD ASSEMBLY
LEFT OF CENTER RIGHT OF CEN-

2
ENSURE THAT
THE FEED BELT
IS LATCHED
4
CHECK:
1 THE PAPER TRAY SETUP TOOL
MUST TOUCH THE ENTRY GUIDE,
NOTE: POSITION OR THERE MUST BE NO MORE
THE PAPER TRAY THAN A 0.1 mm GAP
SETUP TOOL CAUTION
ENTRY GUIDE
Figure 1 Checking the Feed Belt Tension
9. IF THE CHECK IS GOOD, GO TO STEP 11. IF THE CHECK IS NOT GOOD, GO TO

STEP 10.
10. ADJUST THE FEED BELT TENSION (Figure 2).

VIEWED FROM THE
REAR OF THE FEED
HEAD ASSEMBLY
1
LOOSEN THE
SMALL NUT
2
POSITION THE
ECCENTRIC PIN
RIGHT OF CENTER
LEFT OF CENTER
3
ENTRY GUIDE 4 ROTATE THE ECCENTRIC PIN SO
HOLD THE THAT THE PAPER TRAY SETUP TOOL
ECCENTRIC PIN CONTACTS THE ENTRY GUIDE, OR
AND TIGHTEN THE THERE IS NO MORE THAN A 0.1 mm
SMALL NUT GAP BETWEEN THE TOOL AND THE
ENTRY GUIDE
Figure 2 Adjusting the Feed Belt Tension
11. REMOVE THE PAPER TRAY SETUP TOOL AND REINSTALL THE SAFETY COVER 14. WHEN ADJUSTING ONLY TRAY 2: ADD PAPER TO TRAY 1 AND PUSH THE TRAY
OVER THE TUBE SHAFT. INTO THE PRINTER.
12. REINSTALL THE AUTO LATCH BRACKET. 15. RAISE THE PAPER PLATE TO THE MIDDLE POSITION:
WARNING a. Manually rotate the right front lead screw, or insert a cheater into the Printer Right
Ensure that the Right Door Interlock Switch is not actuated. This will prevent personal Door Interlock.
injury and ensure that the elevator does not move when the Tray Interlock Switch is b. Enter dC330, [7-8]. Select Tray 1 Elevator Up] or [Tray 2 Elevator Up]. Press the
cheated. Continue Button.
c. Press the Stop button when the paper plate is in the middle position.
NOTE: Access the Tray 1 or Tray 2 Interlock Switch through Tray 1.
d. Remove the cheater from the Printer Right Door Interlock.

NOTE: This check is to ensure that the paper plate is parallel with the gate (front to rear). If this
is correct, then side-to-side parallelism will be within specification.
16. CHECK THE FRONT-TO-REAR PAPER PLATE PARALLELISM (Figure 3).
MEASURE FROM THE

PAPER PLATE TO THE GATE
3
MEASUREMENT AT THE
1
POSITION THE
REAR OF THE TRAY
SCALE AT THE
MUST BE EQUAL TO THE
FRONT OF THE
FRONT WITHIN 1.0 mm
TRAY
2
RAISE THE PAPER PLATE TO THE
HALF-WAY POSITION
Figure 3 Checking the Paper Plate Parallelism
STEP 18.
CAUTION
Hold the left front lift nut so that it cannot rotate. The nut may break if it is allowed to rotate.
NOTE: One revolution of the lift nut is equal to approximately 3.0 mm of paper plate travel.
18. ADJUST THE FRONT-TO-REAR AND SIDE-TO-SIDE PAPER PLATE PARALLELISM

AS FOLLOWS:
a. Remove the paper plate and the plate supports (Figure 4).

3
REMOVE THE NUT
2
REMOVE THE
SCREWS (4)
4
REMOVE THE
PLATE
1
REMOVE THE
SCREW, NUT AND
GROUND WIRE
FROM THE UNDER
5 SIDE OF THE PAPER
REMOVE THE PLATE
SUPPORTS
Figure 4 Removing the Paper Plate and the Supports
b. Rotate the right front lead screw in order to position the left front lift nut so that the
tool can be properly inserted (Figure 5).

CAUTION
ROTATE THE LEAD
SCREW TO POSITION
THE NUT
Figure 5 Positioning the Left Front Lift Nut
c. Rotate the right front lift nut so that tool can be properly inserted (Figure 6). Do not
turn the lead screw.

1
2 ROTATE THE NUT TO
REMOVE THE CONTACT THE TOOL
RETAINER
3
PUSH
4
ROTATE THE NUT TO
CONTACT THE TOOL
5
REINSTALL THE
RETAINER
Figure 6 Positioning the Rear Lift Nuts
d. Position the rear lift nuts (Figure 6). Do not turn the lead screw.
e. Reinstall the front and rear supports; ensure that they are not installed upside down.
f. Reinstall the paper plate. Ensure that the Length Guide is in the center (side-to-side)
of the paper plate opening.
g. Check the paper plate parallelism again (Figure 7).

MEASURE FROM THE PAPER
PLATE TO THE GATE
3
MEASUREMENT AT THE 1
REAR OF THE TRAY MUST POSITION THE
BE EQUAL TO THE FRONT SCALE AT THE
WITHIN 1.0 mm FRONT OF THE
TRAY
2
RAISE THE PAPER PLATE TO THE
HALF-WAY POSITION
19. IF THE CHECK IS GOOD, GO TO STEP 20. IF THE CHECK IS NOT GOOD, REPEAT
STEP 18 UNTIL THE PARALLELISM IS CORRECT.
20. ENSURE THAT THE GROUND WIRE AND NUT HAVE BEEN REINSTALLED.
21. CHECK THE PAPER PLATE ENDPLAY (Figure 8).

SUPPORT LIFT NUT
SUPPORT LIFT NUT
3
CHECK:
GAP 1.0 TO 1.5 mm 2
CHECK:
GAP 0.5 TO 1.0 mm
1
PUSH THE PLATE
TOWARD THE FRONT
Figure 8 Checking the Paper Plate Endplay
STEP 23.
23. LOOSEN THE PAPER PLATE SCREWS (5) AND THE LEFT REAR SUPPORT NUT (1)
(Figure 9).

LEFT SUPPORT LIFT NUT SUPPORT LIFT NUT 7
MOVE THE RIGHT
REAR SUPPORT
1.0 TO 1.5 mm AGAINST THE FEELER
ADJUST:
0.5 TO 1.0 mm
8 TIGHTEN THE
SCREWS (2)
6
TIGHTEN THE
SUPPORT NUT (1)
1
PUT THE FEELER
BETWEEN THE LIFT
NUT AND THE LEFT
5 REAR SUPPORT
2
PUSH AND HOLD 3 HOLD THE PAPER
THE PLATE TO PUSH FRONT
THE FRONT 4 SUPPORT
PLATE AGAINST
TIGHTEN THE THE FEELER
AGAINST THE
SCREWS (3)
LIFT NUTS
Figure 9 Adjusting the Paper Plate Endplay
NOTE: Hold the feeler gauge in place with tape or place the hex keys through the holes in the
feeler gauge.
24. ADJUST THE PAPER PLATE ENDPLAY (Figure 9).

25. RAISE THE PAPER PLATE:
a. Manually rotate the right front lead screw, or insert a cheater into the Printer Right
Door Interlock.
b. Enter dC330, [7-8]. Select Tray 1 Elevator Up] or [Tray 2 Elevator Up]. Press the
Continue button.
26. CHECK THE STACK HEIGHT ADJUSTMENT (Figure 10).

3
CHECK:
THE TOOL MUST BE
FLUSH TO THE PAPER
PLATE AND GATE WITH
NO MORE THAN 0.5 mm
PAPER PLATE GATE
1
HANDCRANK
CLOCKWISE UNTIL
THE STACK HEIGHT
DISPLAY GOES TO L
2
POSITION THE
TOOL
Figure 10 Checking the Stack Height
a. Observe the Stack Height Sensor:

Enter dC330, [7-8]. Observe the Tray 1 Stack Height Sensor or Tray 2 Stack
Height Sensor display.
b. Check the stack height (Figure 10).
27. IF THE CHECK IS GOOD, GO TO OF STEP 29. IF THE CHECK IS NOT GOOD, GO TO
STEP 28.
NOTE: It may be necessary to break the Glyptol seal in order to perform this adjustment.
28. ADJUST THE STACK HEIGHT (Figure 11).

3
ROTATE COUNTER-
CLOCKWISE UNTIL
THE STACK HEIGHT
DISPLAY GOES TO L
2
ROTATE CLOCK-
WISE UNTIL THE
STACK HEIGHT
DISPLAY IS H
1
ROTATE THE LEAD SCREW UNTIL
THE TOOL IS FLUSH WITH THE
PAPER PLATE AND THE GATE
PAPER PLATE
Figure 11 Adjusting the Stack Height
NOTE: If the Stack Height Sensor display does not change to H (Figure 12, Step 5), adjust the
Auto Latch (ADJ 7-6). Continue from this point in the procedure when the Auto Latch adjust-
ment has been completed.
29. PREPARE TO CHECK THE STACK FORCE (Figure 12).

2
ENSURE THAT THE
STACK RELIEF
SOLENOID MOVES
FREELY
TURNED 90
DEGREES
1
ENSURE THAT
THE FEED HEAD
3 ASSEMBLY
INSTALL A 5.0 mm MOVES FREELY
HEX KEY BETWEEN
THE FEED BELT
AND THE CORK PAD
6
HANDCRANK CLOCKWISE UNTIL THE
STACK HEIGHT DISPLAY GOES TO L
5
4 NOTE: HANDCRANK
ENSURE THAT THE HEX KEY IS IN COUNTERCLOCKWISE
THE CENTER OF THE FEED BELT, UNTIL THE STACK
AND THAT THE END DOES NOT HEIGHT DISPLAY
CONTACT THE ENTRY GUIDE GOES TO H
Figure 12 Preparing to Check the Stack Force
NOTE: When the Feed Head is moved, or when the force is adjusted, the Feed Head may not
return to nominal position. Before the stack force is checked or adjusted, lightly tap the Feed
Head to ensure the correct position.
30. REMOVE HEX KEY AND CHECK THE STACK FORCE (Figure 13).

1
INSERT A 1.0 mm
GAUGE ON THE TOP
OF THE CORK PAD
AND UNDER THE
FEED BELT
TURNED 180°
CAUTION
DO NOT DEFLECT
FEED BELT THE TRAY WHEN
TAKING A MEA- 3
ADJUST:
ROTATE THE NUT CLOCKWISE
1.0 mm GAUGE FROM THE TOP TO DECREASE
2
THE GAP
CHECK:
0.15 +0.05/-0.0 mm
CORK PAD
Figure 13 Checking/Adjusting the Stack Force
31. IF THE CHECK IS GOOD, GO TO STEP 33. IF THE CHECK IS NOT GOOD, GO TO 35. IF THE CHECK IS GOOD, GO TO STEP 38. IF THE CHECK IS NOT GOOD, GO TO
STEP 32. STEP 36.
NOTE: If the gap is too large and cannot be set to specification, adjust the Auto Latch (ADJ 7- NOTE: If the adjustment cannot be achieved before the screw is at the end of travel, ensure
6). Continue from this point in the procedure when the Auto Latch adjustment has been com- that the solenoid is energized. If the adjustment still cannot be performed with the solenoid
pleted. energized, de-energize it and go to step 26 (stack height adjustment).
32. ADJUST THE STACK FORCE (Figure 13). 36. ADJUST THE STACK RELIEF SOLENOID (Figure 14).
33. REMOVE THE FEELER STOCK FROM THE PAPER PLATE.
34. CHECK THE STACK RELIEF SOLENOID.
a. Energize the solenoid by entering dC330, [7-8]. Select [Tray 1 Stack Relief] or
[Tray 2 Stack Relief]. Press the Continue button.
b. Ensure that the plunger on the solenoid is pressed in completely.
c. Do not press the Stop button.
d. With the solenoid still energized, observe the Tray 1 Stack Height Sensor or Tray 2
Stack Height Sensor display.
e. Verify that the Tray 1 or 2 Stack Height Sensor display is H and changes to L when a
very small amount of upward pressure is applied to the feed head.

1
ENERGIZE THE
STACK RELIEF
3
2 ROTATE COUNTERCLOCKWISE UNTIL
SLOWLY ROTATE THE STACK HEIGHT DISPLAY IS L,
CLOCKWISE UNTIL THEN CLOCKWISE UNTIL DISPLAY
THE STACK HEIGHT GOES TO H
DISPLAY IS H
Figure 14 Adjusting the Stack Relief Solenoid
37. REPEAT STEPS 34e and 35. ADJ 7-10 Lock Assembly
38. DE-ENERGIZE THE STACK RELIEF SOLENOID BY ENTERING dC330, [7-8]. SELECT
[Tray 1 Stack Relief] OR [Tray 2 Stack Relief].
Purpose
The purpose is to ensure that Trays 1 and 2 are securely locked when the trays are in the
39. LOWER THE PAPER PLATE BY ENTERING dC330, [7-8]. SELECT [Tray 1 Elevator
closed position.
Dn] OR [Tray 2 Elevator Dn]. PRESS THE Continue BUTTON.
40. REMOVE THE CHEATER FROM THE PRINTER RIGHT DOOR INTERLOCK SWITCH.
Check
41. REMOVE THE CHEATER FROM THE TRAY INTERLOCK SWITCH.
42. IF THE STACK HEIGHT WAS ADJUSTED, ADJUST THE DOWN/LOW PAPER SENSOR NOTE: Ensure that the trays are fully closed when checking for the 0.75 mm gap.
(ADJ 7-2). 1. OPEN THE PRINTER RIGHT DOOR AND CHECK THE LOCK ASSEMBLY (Figure 1).

3
TIGHTEN THE NUT
1
CHECK:
2 GAP: 0.75 +/- 0.25 mm
ADJUST:
LOOSEN THE NUT AND
MOVE THE PIN FOR A
GAP OF 0.75 +/- 0.25 mm
Figure 1 Checking/Adjusting the Lock Assembly
Adjustment ADJ 7-11 Elevator Drive Belt

1. ADJUST THE LOCK ASSEMBLY (Figure 1). Purpose
The purpose is to adjust the tension of the Elevator Drive Belt to prevent the binding or an
erratic movement of the elevator.
Adjustment
CAUTION
To prevent damage to the length guide, do not press down on the bottom plate with excessive
force, or move upper side of elevator across the work surface.
1. REMOVE THE ELEVATOR ASSEMBLY.

2
REMOVE THE
3
TIGHTEN (4) 2
SCREWS (2)
NOTE: MOVE THE
ELEVATOR MOTOR
TO TENSION THE
BELT
3
REMOVE THE
BOTTOM PLATE
1
REMOVE THE 1
SCREWS (6) LOOSEN (4)
Figure 1 Removing the Bottom Plate

Figure 2 Adjusting the Belt Tension
NOTE: The binding of the elevator will occur if the belt is too tight. Apply minimum tension to
the belt.
3. ADJUST THE BELT TENSION (Figure 2).

ADJ 7-30 Elevator Drive Belt ADJ 7-31 Stack Height/stack Height Sensor (Q735)
Purpose Purpose
The purpose is to adjust the tension of the Elevator Drive Belt in order to prevent the elevator The purpose of the Stack Height Adjustment is to ensure that the Paper Plate is parallel with
from erratic movement or binding. the Feeder Assembly, and that the Stack Height Sensor (Q735) is adjusted to ensure that the
paper stack is positioned properly.
Adjustment
1. PULL OUT THE HIGH CAPACITY TRAY. Adjustment
2. REMOVE THE BOTTOM PLATE. NOTE: These adjustment steps must be performed in sequence.
NOTE: Allow the spring-loaded idler to set the tension of the belt. Do not add more force to the 1. PULL OUT THE PAPER TRAY.
belt.
2. REMOVE THE PAPER FROM THE PAPER TRAY.
3. LOOSEN THE SCREW SECURING THE IDLER TO ADJUST THE ELEVATOR DRIVE
NOTE: In dC330, it will be necessary to use the UI to raise and lower the elevator. Raise the
BELT.
elevator to approximately 100mm from the surface around the bearing retainers.
4. CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (ADJ 7-31).
3. RAISE THE ELEVATOR. ENTER dC330, SELECT [7-8X], [Tray X Elevator UP] AND
4. CHECK THE PAPER PLATE PARALLELISM (Figure 1).
2
CHECK:
THE MEASURED
AREAS (4) MUST
BE PARALLEL
WITHIN 1.0 mm
NOTE: ENSURE THAT THE FRONT

MEASUREMENTS ARE MADE
1 BETWEEN THE PAPER PLATE AND THE
ENSURE THAT
SURFACE AROUND THE BEARING
THE PAPER PLATE
RETAINERS
IS SEATED ON
THE LIFT NUTS (4)

5. IF THE CHECK IS GOOD, GO TO STEP 10. IF IT IS NOT GOOD, CONTINUE WITH 6. SWITCH OFF THE PRINTER POWER.
STEP 6. 7. ADJUST THE PAPER PLATE PARALLELISM (Figure 2).
2
ADJUST:
LIFT THE PAPER PLATE AND TURN
THE LIFT NUTS TO RAISE OR LOWER
THE PLATE
1
REMOVE THE SCREWS (4), AND THE
CLIPS (4) FROM THE UNDERSIDE OF
THE PAPER PLATE
3
MEASURE AND ADJUST
THE AREAS (4) UNTIL
PLATE IS PARALLEL
WITHIN 1.0 mm
Figure 2 Adjusting the Paper Plate Parallelism
8. RECHECK THE PAPER PLATE PARALLELISM. READJUST IF NECESSARY.

9. SWITCH ON THE PRINTER POWER.
10. ENTER dC330, SELECT [7-8X]. OBSERVE Tray X Stack Height Sensor.
CAUTION
Do not damage the Switch Actuator when positioning the Switch Actuator on the paper plate.
Before exiting dC330, lower the elevator approximately 100mm, this will avoid possible tray
damage.
NOTE: Trim the paper so it will lie flat on the Tray Ramp between the Length Guide and the
side wall.
11. CHECK THE STACK HEIGHT SENSOR (Q735) (Figure 3).

FEED BELT 5
CHECK:
A SMALL AMOUNT OF RESISTANCE 1
SHOULD BE FELT AS THE PAPER IS PUSH THE TRAY IN UNTIL THE
PULLED BETWEEN THE RAMP AND TRAY RAMP IS POSITIONED
THE BELT UNDER THE FIRST FEED BELT
TRAY RAMP
2
NOTE: POSITION A
PIECE OF 20LB (80
GSM) PAPER ON
TOP OF THE TRAY
RAMP
3
CAUTION
PUSH THE WIDTH
GUIDE IN UNTIL IT IS
AGAINST THE
PAPER PLATE
4
HANDCRANK THE ELEVATOR
UP UNTIL THE [Tray X Stack
Height Sensor] CHANGES TO H
Figure 3 Checking the Stack Height Sensor
12. IF THE CHECK IS GOOD, THE PROCEDURE IS COMPLETE. IF THE CHECK IS NOT
GOOD, CONTINUE WITH STEP 13.
NOTE: If the Stack Height Sensor Case has slotted mounting holes, ensure that the actuator
arm is horizontal to the Paper Plate. If needed, loosen the mounting hardware and adjust the
switch.
13. ADJUST THE STACK HEIGHT SENSOR (Figure 4).

3
IF THE [Tray X Stack Height Sensor] IS H,
ROTATE THE SETSCREW CLOCKWISE
UNTIL THE SENSOR CHANGES TO L
4
ROTATE THE SETSCREW COUNTER-
CLOCKWISE UNTIL [Tray X Stack
Height Sensor] CHANGES TO H
1
POSITION A SHEET OF 20 LB
(80 GSM) PAPER BETWEEN
THE RAMP AND THE FEED
BELT
2
HANDCRANK THE ELEVATOR UP
UNTIL RESISTANCE IS FELT ON THE
PAPER AS IT IS PULLED BETWEEN
THE RAMP AND BELT
Figure 4 Adjusting the Stack Height Sensor
14. RECHECK THE STACK HEIGHT SENSOR. READJUST IF NECESSARY. ADJ 7-32 Latch Assembly
15. CHECK/ADJUST THE LOW PAPER SENSOR (Q738) (ADJ 7-33).
Purpose
The purpose is to ensure that HCT is securely locked into the processor when the tray is
closed, and to ensure the smooth release of the Latch Assembly.
Check
NOTE: Ensure that the tray is fully closed and biased to the rear of the machine.
1. CHECK THE LATCH ASSEMBLY (Figure 1).

1
ENSURE THAT THE
TRAY IS FULLY CLOSED
2
CHECK:
MEASURE
FOR A GAP OF
1.0 +/-0.5 mm
Figure 1 Checking the Latch Assembly
Adjustment
NOTE: Ensure that the two screws securing the Latch Assembly and the two screws securing
the Release Solenoid are tight.
1. ADJUST THE LATCH ASSEMBLY (Figure 2).

2
ENSURE THAT THE
TRAY IS CLOSED
3
ADJUST:
MOVE THE BRACKET
TO ACHIEVE THE GAP
OF 1.0 +/- 0.5 mm
1
LOOSEN THE
NUTS (2) 4
TIGHTEN THE
NUTS (2)
Figure 2 Adjusting the Latch Assembly

ADJ 7-33 Low Paper Sensor (Q738)
Purpose LOW PAPER SENSOR
(Q738)
The purpose of this procedure is to ensure that the Low Paper Sensor (Q738) actuates when
the paper quantity is low.
Check
1. OPEN THE TRAY.
2. REMOVE ALL THE PAPER FROM THE TRAY.
3. PLACE APPROXIMATELY 50 SHEETS OF 20 LB (80 GSM) PAPER INTO THE TRAY.
4. CLOSE THE TRAY.
NOTE: In dC330, it will be necessary to use the UI to raise and lower the elevator.
5. RAISE THE ELEVATOR. ENTER dC330, SELECT [7-8X], [Tray X Elevator UP] AND
6. CHECK THAT THE Tray X Down/Low Paper Sensor AND THE Tray X Stack Height
Sensor ARE BOTH DISPLAYING H.
Adjustment
4. ACCESS THE SENSORS (PL 7.17).
5. CHECK THAT THE SENSOR ACTUATOR ARMS ARE NOT BENT OR BROKEN.
6. IF THE CHECK IS GOOD, CONTINUE. IF THE CHECK IS NOT GOOD, REPLACE THE
SWITCH ASSEMBLY.
7. SWITCH ON THE PRINTER POWER.
8. OPEN THE TRAY.
NOTE: In dC330, it will be necessary to use the UI to raise and lower the elevator.
1
9. ENSURE THAT THERE ARE 50 SHEETS OF20 LB (80 GSM) PAPER IN THE TRAY.
NOTE: ADJUST THE
10. CLOSE THE TRAY. SCREW UNTIL THE
11. RAISE THE ELEVATOR TO THE STACK HEIGHT USING dC330. SENSOR CHANGES
TO H
NOTE: It may be necessary to break the Glyptol seal from the screw before performing the
adjustment.
12. OBSERVE THE Tray X Down/Low Paper Sensor ON THE SCREEN WHILE ADJUST- Figure 1 Adjusting the Low Paper Sensor
ING THE LOW PAPER SENSOR (Figure 1).
13. APPLY A SMALL AMOUNT OF ADHESIVE 63P561 (USMG) OR 600T90352 (RXL) TO
THE SCREW ON THE LOW PAPER SENSOR.

ADJ 7-34 Front Cover Adjustment
Purpose NOTE: The Manometer must be removed to access the nuts.
The purpose is to position the Front Cover flush with the Stacker Front Cover, Vertical Trans-
1. PULL OUT THE HIGH CAPACITY TRAY.
port Door and Horizontal Transport Door. The Front Cover is also positioned so that there is a
visually uniform gap around the cover. 2. ADJUST THE ALIGNMENT OF THE FRONT COVER (Figure 2).
Check
1. CHECK THE ALIGNMENT OF THE FRONT COVER (Figure 1).
1
CHECK:
ENSURE THAT THE COVER IS FLUSH
+/-1 mm TO THE STACKER FRONT
COVER AND THE DOORS
2
CHECK:
ENSURE THAT THERE IS A VISUALLY
UNIFORM GAP AROUND THE COVER
Figure 1 Checking the Alignment of the Cover

1
ADJUST:
LOOSEN THE NUTS (4)
TO SET THE COVER
FLUSH +/- 1 mm
2
ADJUST:
LOOSEN SCREWS (6)
TO SET A UNIFORM
GAP
Figure 2 Adjusting the Cover

ADJ 7-35 HIGH CAPACITY TRAY SWITCH ASSEMBLY
Purpose
The purpose of this adjustment is to ensure the proper relationship between the Low Paper
Sensor, the Tray Up Limit Switch, the Tray Down Sensor, and the Tray Down Limit Switch.
Proper adjustment of these switches will minimize the number of elevator faults and/or the
almost fault condition 07-241 where no fault is declared on the Printer Monitor but a fault is
recorded in the Printer Performance Log (PPR).
Adjustment
NOTE: These adjustment steps must be performed in sequence.
1. LOWER THE TRAY AND REMOVE ALL THE PAPER FROM THE TRAY TO BE
ADJUSTED.
2. REMOVE THE LOWER REAR IFS OR FS COVER TO ACCESS THE SWITCH ASSEM-
BLIES.
3. REMOVE THE SWITCH ASSEMBLY SAFETY COVER.
4. ENTER DC330 (FEEDER 3/4) (7-8 A/B) LOW PAPER SENSOR (Q738) ADJUSTMENT.
5. IN DC330 RAISE THE PAPER TRAY WHILE VISUALLY ENSURING THAT THE LOW
PAPER/TRAY DOWN SENSOR CHANGES LOGIC STATE.
6. MANUALLY LOWER THE TRAY A FEW TURNS PAST THE POINT WHERE THE
SWITCHES ACTIVATE. NOW SLOWLY RAISE THE TRAY WHILE WATCHING THE
PRINTER MONITOR SWITCH SENSOR ICON. ADJUST AND STOP THE TRAY
UPWARD MOVEMENT AT THE EXACT POINT THE SENSOR SWITCH ACTUATION
POINT IS REACHED.
7. MEASURE THE DISTANCE FROM THE TOP SURFACE OF THE UPPER ACTUATOR
TAB TO THE TOP OF THE SWITCH ASSEMBLY. THE DISTANCE SHOULD BE 37MM
+/- 0.5. IF THE DISTANCE IS NOT CORRECT PERFORM THE FOLLOWING STEPS
Figure 1.

MEASUREMENT
DISTANCE UPPER ACTUATOR
TAB
MEASURE AND
ADJUST GAP TO
37MM +/- 0.5
PAPER TRAY
UP LIMIT (UPPER
SWITCH POSITION)
(S741)
LOW PAPER/TRAY
UPPER ACTUATOR DOWN SENSOR S738
TAB
ADJUST:
ENT SET
SCREWS
(UPPER)
Figure 1 ADJUST SENSOR
a. MANUALLY RAISE OR LOWER THE TRAY TO OBTAIN THE 37MM +/- 0.5 DIS-
TANCE.

b. ADJUST THE SET SCREW SLOWLY UNTIL THE LOW PAPER/TRAY DOWN SEN-
SOR ICON JUST CHANGES STATE ON THE PRINTER MONITOR. THIS SWITCH
IS NOW PROPERLY ADJUSTED.
8. MANUALLY RAISE THE TRAY UNTIL THE TRAY UP LIMIT SWITCH (S741) IS ACTU-
ATED. A CLICKING SOUND WILL BE HEARD FROM THE SWITCH, OR THE USE OF A
120 VAC VOLTMETER CAN BE USED.
TAB TO THE TOP OF THE TRAY UP LIMIT SWITCH. THE DISTANCE SHOULD BE
34MM +/- 0.5. IF THE DISTANCE IS NOT CORRECT PERFORM THE FOLLOWING
STEPS Figure 2.

MEASUREMENT UPPER
DISTANCE ACTUATOR
TAB
MEASURE AND
ADJUST GAP TO
34MM +/- 0.5
PAPER TRAY
(UPPER
UP LIMIT POSITION)
SWITCH S741
LOW PAPER/TRAY DOWN

SENSOR S738
UPPER ACTUATOR
TAB
ADJUST:
ENT SET
SCREWS
(UPPER)
a. RAISE OR LOWER THE TRAY TO OBTAIN THE 34MM +/- 0.5 DISTANCE.

NOTE: Ensure that the distance of 3mm exists between actuation points of the low paper sen-
sor (Q738) and the tray up limit switch (S741). Readjust the sensor to switch gap as nec-
essary. One turn of the lead screw is equal to approximately 3mm.
b. ADJUST THE SET SCREW UNTIL THE TRAY UP LIMIT SWITCH (S741) HAS
JUST ACTUATED.
10. ENTER DC330, LOWER THE TRAY. ENSURE THE LOW PAPER/TRAY DOWN SEN-
SOR ICON CHANGES STATE.
11. MANUALLY RAISE THE TRAY A FEW TURNS PAST THE POINT WHERE THE
SWITCHES ACTIVATE. NOW SLOWLY LOWER THE TRAY WHILE WATCHING THE
PRINTER MONITOR SWITCH SENSOR ICON. ADJUST AND STOP THE TRAY DOWN-
WARD MOVEMENT AT THE EXACT POINT THE SENSOR SWITCH ACTUATION
POINT IS REACHED.
Figure 3.

MEASUREMENT
DISTANCE
UPPER
ACTUATOR
MEASURE TAB
AND ADJUST
THE GAP TO
51MM +/- 0.5
UPPER ACTUATOR
TAB
ADJUST:
ENT SET SCREWS
(LOWER POSITION)
LOW PAPER/TRAY
DOWN LIMIT
DOWN SENSOR
SWITCH S740
S737
a. RAISE OR LOWER THE TRAY TO OBTAIN THE 51MM +/- DISTANCE. b. ADJUST THE SET SCREW UNTIL THE LOW PAPER/TRAY DOWN SENSOR
ICON JUST CHANGES STATE.

13. MANUALLY LOWER THE TRAY UNTIL THE TRAY DOWN LIMIT SWITCH (S740) IS
ACTUATED. A CLICKING SOUND WILL BE HEARD FROM THE SWITCH, OR THE
USE OF A 120 VAC VOLTMETER CAN BE USED.
14. MEASURE THE DISTANCE FROM THE TOP SURFACE OF THE SWITCH ACTUATOR
Figure 4.

MEASUREMENT
DISTANCE UPPER
MEASURE ACTUATOR
AND TAB
ADJUST
GAP TO
54MM +/- 0.5
UPPER ACTUATOR
TAB
ADJUST:
ENT SET SCREWS
(LOWER POSITION)
LOW PAPER/TRAY DOWN LIMIT

DOWN SENSOR SWITCH S740
S737
a. MANUALLY RAISE OR LOWER THE TRAY TO OBTAIN THE 54MM +/- 0.5 DIS- TANCE.

NOTE: Ensure that the distance of 3mm exists between actuation points of the tray down sen-
sor (Q730) and the tray down limit switch (S740). Readjust the sensor to switch gap as
necessary. One turn of the lead screw is equal to approximately 3mm.
b. ADJUST THE SET SCREW SLOWLY UNTIL THE TRAY DOWN LIMIT SWITCH
(S740) IS JUST ACTUATED.

ADJ 8-0 Registration Transport Upper Baffles Check
Purpose 1. CHECK THAT HOLES IN UPPER BAFFLES ARE ALIGNED WITH HOLES IN THE
LOWER BAFFLES (Figure 1).
The purpose is to ensure proper alignment of the Upper Baffles, so that the idlers are located
over the cross rolls.
FRONT VIEW
3 2
LOOSEN NUTS (3) LOOSEN NUTS (2)
4 mm HEX KEY TO ADJUST TO ADJUST
1
CHECK:
THE HEX KEYS FIT
THROUGH HOLES
6 mm HEX KEY
Figure 1 Checking/Adjusting the Baffles
Adjustment ADJ 8-1 Pretransfer Baffle

1. ADJUST BAFFLES (Figure 1). Purpose
The purpose of this adjustment is to position the Pretransfer Baffles so that the skew between
the lead and trail edge of a print does not occur.

Check NOTE: When using 13 or 110 lb papers, the distance between X1 and X2 must be 0 +/- 1.2
mm on all 10 prints.
1. LOAD THE PAPER TRAY 1 WITH 11 INCH (A4) 20 LB (80 GSM) PAPER.
3. CHECK THE PRINTS FOR SKEW (Figure 1).
NOTE: The printer will generate 10 prints of the Test Pattern. Save these prints so that it can
be determined in which direction the Pretransfer Baffle Cams have to move.
2. ENTER dC604, SELECT [Tests], [Skew], AND PRESS THE Continue BUTTON.
CHECK:
THE DIFFERENCE BETWEEN
DISTANCE X1 AND DISTANCE X2
MUST BE 0.00 +/- 0.8 mm ON ALL
10 PRINTS
Figure 1 Checking the Prints for Skew
Adjustment
1. OPEN THE PRINTER FRONT DOORS AND REMOVE THE PHOTORECEPTOR INNER
PANEL.
NOTE: Use the Test Pattern prints to determine in which direction the Cams have to move.
2. ADJUST THE PRETRANSFER BAFFLE (Figure 2).

2
1 LOOSEN 1/2 REVOLUTION
LOOSEN SCREWS (2)
3
IF DISTANCE X2 IS
FARTHER FROM THE
EDGE OF THE PRINT
THAN DISTANCE X1,
SET THE LOWER
CAM TO "0" AND
ADJUST THE UPPER
CAM
NOTE: “0” POSITION IS THE

HIGHEST POSITON OF THE CAM
UPPER CAM
4
IF DISTANCE X1 IS
FARTHER FROM THE
EDGE OF THE PRINT
THAN DISTANCE X2,
SET THE UPPER
CAM TO "0" AND
ADJUST THE LOWER
CAM
5
TIGHTEN THE
SCREWS (3)
LOWER CAM
Figure 2 Adjusting the Pretransfer Baffle
3. CLOSE THE PRINTER FRONT DOORS, PRESS THE Continue BUTTON AND CHECK ADJ 8-2 Top-to-Bottom Registration
THE PRINTS FOR SKEW.
4. REPEAT STEPS 2 AND 3 UNTIL THE SKEW IS WITHIN SPECIFICATION.
Purpose
The purpose is to ensure that the image is transferred to the paper in the correct location with
5. IF THE SKEW CANNOT BE SET TO SPECIFICATION, ADJUST THE REGISTRATION
respect to the top and bottom edges of the paper.
TRANSPORT (ADJ 8-4).
6. CHECK/ ADJUST THE ROS IMAGE SQUARENESS (ADJ 6-2).
Check
7. CHECK/ADJUST THE SIDE-TO-SIDE REGISTRATION (ADJ 8-3).
1. ENTER dC604, SELECT [setups], [Printer Options], [Test Patterns and PQ], and
8. CHECK/ADJUST THE TOP-TO-BOTTOM REGISTRATION (ADJ 8-2).
[Dimensional].
2. SELECT [Registration] AND PRESS THE Continue BUTTON.

3. CHECK THE PRINTS FOR THE TOP-TO-BOTTOM REGISTRATION (Figure 1).
2
CHECK: THE REGISTER
DISTANCE X1 MUST EDGE
BE 10.0 +/- 0.65 mm
1
CHECK:
ARROW MUST
BE VISIBLE
THE LEAD EDGE
Figure 1 Checking the Top-To-Bottom Registration
Adjustment ADJ 8-3 Side-to-Side Registration

1. CHECK/ADJUST THE PRETRANSFER BAFFLE (ADJ 8-1). Purpose
2. ADJUST THE TOP-TO-BOTTOM REGISTRATION: The purpose is to ensure that the image is transferred to the paper in the correct location with
a. Use the arrows (Up to increase, Down to decrease) to position the arrow correctly, respect to the lead and trail edges of the paper.
then press the Continue button.
b. Repeat the adjustment until specification is achieved. Check
1. ENTER dC604, SELECT [Setups], [Printer Options], [Test Patterns and PQ], and
[Dimensional].
2. SELECT [Registration] AND PRESS THE Continue BUTTON.
3. CHECK THE PRINTS FOR THE SIDE-TO-SIDE REGISTRATION (Figure 1).

LEAD EDGE
REGISTRATION
EDGE
1 2
CHECK: CHECK:
ARROW MUST X3 DISTANCE MUST
BE VISIBLE BE 10.0 +/- 0.65 mm
Figure 1 Checking the Side-To-Side Registration
Adjustment ADJ 8-4 Registration Transport

1. CHECK/ADJUST THE PRETRANSFER BAFFLE (ADJ 8-1). Purpose
2. ADJUST THE SIDE-TO-SIDE REGISTRATION: The purpose of this adjustment is to move the Registration Transport into a nominal position so
NOTE: Decreasing the Range value increases the visibility of the X3 grid. that skew can be eliminated by the fine adjustment of the Pretransfer Baffle.
a. Use the left and right arrows to position the X3 distance correctly, then press the Adjustment
Continue button.
1. LOAD THE PAPER TRAY 1 WITH 11 INCH (A4) 20LB (80 GSM) PAPER.
b. Repeat the adjustment until specification is achieved.
2. REMOVE THE PHOTORECEPTOR INNER PANEL AND INSTALL THE CHEATER IN
3. CHECK/ADJUST TRANSFER BLADE TIMING (ADJ 9-9). THE RIGHT DOOR INTERLOCK SWITCH.
3. MOVE THE UPPER AND THE LOWER PRETRANSFER BAFFLE CAMS INTO THE
ZERO POSITION (Figure 1).

2
1 LOOSEN 1/2 REVOLUTION
LOOSEN SCREWS (2)
3
SET THE UPPER
CAM TO "0"
THE UPPER CAM
4
SET THE LOWER
CAM TO "0"
5
TIGHTEN THE SCREWS (3)
THE LOWER CAM
Figure 1 Moving the Cams into the Zero Position
4. CLOSE THE PRINTER FRONT DOORS AND ENTER dC604, [Tests].

5. SELECT [Skew] AND PRESS THE Continue BUTTON.
NOTE: The printer will generate 10 prints of the Test Pattern. Save these prints so that it can
be determined in which direction the Registration Transport has to move.
6. EVALUATE THE PRINTS FOR SKEW (Figure 2).

CHECK:
THE DIFFERENCE BETWEEN X1
DISTANCE AND X2 DISTANCE
MUST BE 0.00 +/-1.0 mm ON ALL
10 PRINTS
Figure 2 Evaluating the Prints for Skew
7. PREPARE TO MOVE THE TRANSPORT (Figure 3).

FRONT VIEW
2
LIFT AND LATCH
THE UPPER
RIGHT BAFFLE
3
LOOSEN THE
SCREW AND
REMOVE THE
REGISTRATION
TRANSPORT
4
1 UNLATCH AND LOWER
LIFT AND LATCH THE THE BAFFLES (2)
UPPER LEFT BAFFLE
Figure 3 Preparing to Move the Transport
NOTE: Moving the Registration Transport will provide only a coarse adjustment to eliminate
some of the print skew, use the prints of the Test Pattern to determine in which direction the
transport has to move.
8. MOVE THE TRANSPORT (Figure 4).

5
TIGHTEN THE MOUNTING HARDWARE
4
ADJUST:
IF X2 DISTANCE IS FARTHER
FROM THE EDGE OF THE PRINT
THAN X1 DISTANCE, PUSH IN
AND ROTATE THE TRANSPORT
IN A COUNTERCLOCKWISE
DIRECTION
3
ADJUST:
IF X1 DISTANCE IS FARTHER
FROM THE EDGE OF THE PRINT
THAN X2 DISTANCE, PULL AND
ROTATE THE TRANSPORT IN A
1 CLOCKWISE DIRECTION
LIGHTLY LOOSEN
THE 7 mm SCREW
2
LIGHTLY LOOSEN THE
3 mm ALLEN SCREW
Figure 4 Moving the Transport
9. PRESS THE Continue BUTTON AND EVALUATE THE PRINTS FOR THE SKEW. ADJ 8-5 Paper Width Timing
10. REPEAT STEPS 7-9.
Purpose
NOTE: If the skew cannot be set to the specifications, perform the fine adjustment (Pretransfer The purpose is to measure and adjust the Paper Width Timing. The Printer will measure the
Baffle) as required. elapse time between the lead edge and the trail edge of 50 prints at the Registration Transport
Sensor (Q861). The Printer will then specify the correct value to be entered into memory.
11. CHECK/ADJUST THE PRETRANSFER BAFFLE (ADJ 8-1).
12. CHECK/ADJUST THE NIP RELEASE SOLENOID ASSEMBLY (ADJ 8-6).
Adjustment
1. ENTER dC703, [Setups].
2. SELECT [Paper Width] AND PRESS THE Continue BUTTON.

3. FOLLOW THE INSTRUCTIONS ON THE PRINTER UI AND PERFORM THE PAPER ADJ 8-6 NIP Release Solenoid (SOL851)
WIDTH TIMING.
Purpose
The purpose is to position the Nip Release Solenoid so that there is adequate clearance
between the Pinch Rollers when running oversized paper.
Check
1. PREPARE 2 ORANGE SHIMS AND 1 BROWN SHIM FOR THE REQUIRED GAP OF
1.78 MM.
2. OPEN THE PRINTER RIGHT FRONT DOOR AND REMOVE THE INNER PANEL.
3. CHEAT THE PROCESSOR INTERLOCK BYPASS SWITCH (S103).
4. ENTER dC330 AND SELECT [8], [Nip Release], THEN PRESS THE Continue BUT-
TON.
5. CHECK THE NIP:
a. Insert the shim at the rear and check the Nip between the Rollers, Check 1 (Figure
1).
3
CHECK:
1.78 mm +/- 0.25
mm AT THE REAR
4
CHECK:
ZERO GAP AT THE
2 1 FRONT AND REAR
ROTATE THE SCREW SLIGHTLY LOOSEN
TO SET THE GAP AND THE NUTS (3)
TIGHTEN THE NUTS (3)
Figure 1 Checking/Adjusting the Nip
b. Remove the shim, press the Stop button and check for a zero gap at the front and Adjustment
the rear, Check 2 (Figure 1).
1. PRESS THE Continue BUTTON AND ADJUST THE NIP:

a. Insert the shim 1.78 mm at the rear and adjust the Nip. To obtain Check 1, do step 1
and 2 (Figure 1).
b. Remove the shim, press the Stop button and check for a zero gap at the front and
the rear0 Check 2 (Figure 1).
2. REPEAT THE CHECK/ADJUSTMENT IF REQUIRED.

ADJ 8-9 Lower Preregistration Transport Registration
Baffle Assembly
Purpose
The purpose is to ensure that the Registration Baffle Assembly is positioned properly to allow
paper to be registered without skew.
Check
2. CHECK THE LOWER PREREGISTRATION TRANSPORT REGISTRATION BAFFLE
ASSEMBLY (Figure 1).
CHECK:
THAT THE REGISTRATION BAFFLE
IS POSITIONED FULLY AGAINST
THE TABS
TABS (2)
Figure 1 Checking the Registration Baffle
Adjustment
3. POSITION THE LOWER PREREGISTRATION TRANSPORT ON A FLAT SURFACE
WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.
4. ADJUST THE REGISTRATION BAFFLE ASSEMBLY (Figure 2).

1
LOOSEN NUTS (4)
3
TIGHTEN NUTS (4)
2
ADJUST:
POSITION BAFFLE ASSEMBLY FULLY
AGAINST THE TABS ON THE FRONT
OF THE TRANSPORT
Figure 2 Adjusting the Registration Baffle
5. REINSTALL THE LOWER PREREGISTRATION TRANSPORT. ADJ 8-10 Lower Preregistration Transport Pivot Baffle
Purpose
The purpose is to ensure that the Lower Preregistration Transport Pivot Baffle is positioned
properly to allow paper to pass through without jamming.
Check
3. BEGIN TO CHECK THE PIVOT BAFFLE (Figure 1).

1
LOOSEN NUTS (4)
3
2
CHECK:
THAT THE BAFFLE
IS POSITIONED
FULLY TO THE
REAR
Figure 1 Beginning to Check the Pivot Baffle
4. REMOVE THE INVERTER REAR COVER AND SWING OUT THE INVERTER PWB
PANEL.

3
LOOSEN SCREWS (2)
5
REMOVE THE
SHIELD
2
REMOVE THE
SHIELD
4
LOOSEN THE
BOLTS (2)
1
LOOSEN SCREWS (2)
6. CHECK THE LOWER PREREGISTRATION TRANSPORT PIVOT BAFFLE (Figure 3).

CHECK:
THAT THE TABS (2) ARE POSITIONED
AGAINST THE FRAME AT THE TOP
OF CUTOUTS
Figure 3 Checking the Pivot Baffle
Adjustment
1. ADJUST THE PIVOT BAFFLE (Figure 4).

VIEW FROM
1 THE FRONT
LOOSEN NUTS (4)
2
ADJUST:
POSITION THE TABS (2)
AGAINST THE FRAME
3 AT THE TOP OF THE
CUTOUTS
Figure 4 Adjusting the Pivot Baffle

ADJ 8-11 Lower Preregistration Transport Corrugator Adjustment
Rolls 1. RAISE THE PIVOT BAFFLE.
Purpose NOTE: Check the condition of the Leaf Springs before performing the adjustment. If the Leaf
The purpose of this adjustment is to ensure proper pressure on the Corrugator Rolls. Springs were overtightened, it may be necessary to remove the springs and reform them.
2. ADJUST THE CORRUGATOR ROLLS (Figure 2).

Check
2. RAISE THE PIVOT BAFLE ON THE LOWER PRE-REGISTRATION TRANSPORT.
1
3. CHECK THE CORRUGATOR ROLL PRESSURE (Figure 1). INSERT A 2.5mm ALLEN WRENCH
BETWEEN THE PRE-REGISTRATION
TRANSPORT TRAY AND ROLL
1
INSERT A 2.5mm ALLEN WRENCH
TRANSPORT TRAY AND THE ROLL
(2 PLACES)
2
ADJUST:
ROTATE NUT FOR A HEIGHT OF
2.5mm +/- 0.25mm BETWEEN
TRAY AND ROLL (2 PLACES)
2
CHECK:
FOR A HEIGHT OF
2.5mm +/- 0.25mm Figure 2 Adjusting the Corrugator Roll Pressure
Figure 1 Checking the Corrugator Roll Pressure

ADJ 8-12 Lower Preregistration Transport Pivot Baffle
Bumper PIVOT BAFFLE
Purpose
The purpose of this adjustment is to maintain the correct height between the Pivot Baffle and
the Lower Preregistration Transport Tray.
1
Check INSERT A 6mm ALLEN WRENCH
1. LOWER THE HORIZONTAL TRANSPORT DOOR ON THE IFS. TRANSPORT TRAY AND THE PIVOT
2. RAISE THE PIVOT BAFFLE ON THE IFS HORIZONTAL TRANSPORT. BAFFLE
4. CHECK THE HEIGHT OF THE PIVOT BAFFLE ON THE LOWER PRE-REGISTRATION
TRANSPORT (Figure 1).
2
CHECK:
FOR A GAP OF 6.0mm +/- 0.5mm AND
THAT THE BUMPER JUST TOUCHES
THE TRANSPORT
Figure 1 Checking the Pivot Baffle Height
Adjustment
1. ADJUST THE PIVOT BAFFLE BUMPER (Figure 2).

ADJ 8-13 Tray 3 Oversize NIP Release Solenoid (SOL852)
Purpose
3 1 The purpose of this adjustment is to ensure that there is not any pressure on the Horizontal
TIGHTEN THE NUT INSERT A 6mm Transport Roller Assemblies when operating in the oversize paper mode.
ALLEN WRENCH
Check
NOTE: The check must be made while the solenoid is energized. It may be necessary to use
the Remote Hand Held Device (RHHD) to perform the check. For detailed Operating Instruc-
tions of the RHHD, go to (GP 1).
2. ENTER dC330. SELECT [7-8A], [Tray 3 Oversize Nip Release] AND PRESS THE Con-
tinue BUTTON.
3. CHECK THE TRAY 3 OVERSIZE NIP RELEASE SOLENOID WHILE IT IS ENERGIZED
(Figure 1).
CHECK:
2 INSERT A 0.508mm
ADJUST: SHIM AND CHECK
LOOSEN NUT AND ROTATE BUMPER THE GAP
UNTIL IT TOUCHES THE TRANSPORT
Figure 2 Adjusting the Bumper
Figure 1 Checking the Solenoid
Adjustment
1. UNLATCH AND PULL OUT TRAY 3.

NOTE: The solenoid will have to be adjusted from the rear of the machine. 3. ADJUST THE TRAY 3 OVERSIZE NIP RELEASE SOLENOID (Figure 2).
2. REMOVE THE IFS LOWER REAR COVER.
2
ADJUST:
MOVE THE SOLENOID TOWARDS
THE FRONT TO INCREASE THE
GAP OR TOWARDS THE REAR TO
DECREASE THE GAP
3
TIGHTEN THE SCREWS (2)
1
LOOSEN THE SCREWS (2)
Figure 2 Adjusting the Solenoid
4. PERFORM THE CHECK AGAIN. READJUST IF NECESSARY. ADJ 8-14 IFS/FS Horizontal Transport Pivot Baffle
Purpose
The purpose is to ensure that the Horizontal Transport Pivot Baffle is positioned properly to
allow paper to pass through without jamming.

Check
2. REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.
3. LOWER THE STACKER AC RELAY PANEL.
4. MANUALLY UNLATCH AND OPEN THE HIGH CAPACITY TRAY.
2
REMOVE THE
SHIELD
1
REMOVE THE NUTS (2)
Figure 1 Removing the Shield
6. CHECK THE HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 2).

2
CHECK:
THAT THE ROUND
TABS (2) ARE
POSITIONED
AGAINST FRAME
1
CHECK:
THAT THE TABS (3) ARE POSITIONED
AGAINST FRAME AT TOP OF CUTOUTS
Figure 2 Checking the Baffle
Adjustment
1. ADJUST THE HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 3).

4 1
ADJUST: LOOSEN THE
MOVE THE BAFFLE TOWARDS THE NUTS (6)
REAR UNTIL THE ROUND TABS (2)
ARE POSITIONED AGAINST THE
FRAME AND TIGHTEN THE NUTS (6)
3
LOOSEN THE
NUTS (6)
2
ADJUST:
POSITION THE TABS (3) AGAINST
THE FRAME IN TOP OF CUTOUTS
AND TIGHTEN THE NUTS (6)
Figure 3 Adjusting the Baffle

ADJ 8-15 Intermediate Horizontal Transport Pivot Baffle 2. REMOVE THE STACKER LOWER REAR COVER FROM THE FS.
3. MANUALLY UNLATCH TRAY 4 AND PUSH IT OPEN.
Purpose
4. LOWER THE AC RELAY PANEL.
The purpose is to ensure that the Horizontal Transport Pivot Baffle is positioned properly to
allow paper to pass through without jamming.
6. ADJUST THE INTERMEDIATE HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 1).
Adjustment
1 4
LOOSEN NUTS (2) ADJUST:
POSITION THE HINGE ALL
THE WAY DOWN AND
TIGHTEN NUTS (2)
VIEW ROTATED 90°
2
ADJUST:
POSITION THE BAFFLE ALL THE 3
WAY TO THE REAR AND TIGHTEN LOOSEN NUTS (2)
THE NUTS (2)
Figure 1 Adjusting the Pivot Baffle

ADJ 9-0 Toner Thumper Adjustment
Purpose 1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.
The purpose is to position the thumper screw, so that the thumper contacts the bottle. 2. OPEN THE XEROGRAPHIC DRAWER (REP 9-34).
3. ADJUST THE THUMPER (Figure 1).
RIGHT FRONT VIEW
TONER BOTTLE
3
TIGHTEN THE
JAM NUT
2
TONER DISPENSER
ADJUST SCREW
ASSEMBLY
FOR 9.5+/-1.0 mm
GAP
1
LOOSEN THE
JAM NUT
Figure 1 Adjusting the Thumper
ADJ 9-1 Developer Zone Roll Purpose

The purpose is to improve the copy quality by ensuring that the Developer Zone Roll is aligned
in the area of optimal development within the Developer Assembly. The Zone Roll is moved
from the nominal position (white Bearing Housings) to either the left, or to the right, by using
the appropriate color-coded Bearing Housing.

Check 5. CLEAN THE SUPPORT PADS, AND APPLY A THIN COATING OF WHITE OPAQUE
CORRECTION FLUID. LOWER AND SEAT THE PR MODULE BEFORE THE FLUID IS
NOTE: White opaque correction fluid (or an equivalent marking medium) is needed in order to DRY.
perform this check.
WARNING
1. SWITCH OFF THE PRINTER CIRCUIT BREAKERS. Support the PR Module when working in the area below it. Failure to take precautions
2. REMOVE THE PHOTORECEPTOR BELT (REP 9-35). could result in injury in the event of an accidental failure of the PR Module hydraulic
3. RAISE THE PR MODULE COMPLETELY. support system.
4. LOCATE THE OUTBOARD AND THE INBOARD SUPPORT PADS FOR THE LEFT CAUTION
DEVELOPER ZONE ROLL (THE METAL PADS BETWEEN ROLL 1 AND ROLL 2, Cover the cavity of the Developer Assembly in order to prevent contamination of the Developer
SHOWN ON Figure 1). Material.
6. PERFORM THE CHECK (Figure 1):
a. Measure the distance from the left edge of the support pad to the center of the
impression in the correction fluid.
b. Record the measurement for the Outboard support pad.
c. Record the measurement for the Inboard support pad.
d. If the distance from the left edge of the support pad to the center of the impression is
1 between 5.5 +/- 0.5 mm, Outboard and Inboard, the alignment is in specification.
MEASURE FROM THE LEFT
EDGE TO THE CENTER OF Adjustment
IMPRESSION IN THE FLUID 1. OBSERVE THE EXAMPLE IN Figure 2, AND USE THE FOLLOWING PROCESS TO
DETERMINE THE COLOR OF THE BEARING HOUSING WHICH MUST BE
INSTALLED (PART OF TABLE 3 FOR THE EXISTING OUTBOARD BEARING HOUS-
ING IS SHOWN IN THE FOLLOWING EXAMPLE).
ROLL 2
LEFT OUTBOARD
SUPPORT PAD
ROLL 1
Figure 1 Checking the Roll Position

b. Locate the column in that table which includes the value of the measurement
recorded in Step 6b of the Check. The correct color of the Bearing Housing to be
installed, is listed below the value in the applicable table.
1
SELECT THE TABLE FOR Table 1 : VIOLET Existing OUTBOARD Bearing Housing
THE EXISTING BEARING
HOUSING COLOR 3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
WHITE YELLOW VIOLET (Adjustment not (Adjustment not
(In Specification) available) available)
Table 2 : YELLOW Existing OUTBOARD Bearing Housing

3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
BROWN WHITE YELLOW VIOLET (Adjustment not
(In Specification) available)
Table 3 : WHITE Existing OUTBOARD Bearing Housing

3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
2 GRAY BROWN WHITE YELLOW VIOLET
LOCATE THE COLUMN THAT INCLUDES THE
(In Specification)
RECORDED VALUE TO DETERMINE THE
COLOR OF THE REPLACEMENT HOUSING
Table 4 : BROWN Existing OUTBOARD Bearing Housing
3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
(Adjustment not GRAY BROWN WHITE YELLOW
available) (In Specification)
Table 5 : GRAY Existing OUTBOARD Bearing Housing

Figure 2 Determining the Bearing Housing Color 3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
(Adjustment not (Adjustment not GRAY BROWN WHITE
NOTE: Along with the color, the positioning bosses on all but the white Bearing Housings are available) available) (In Specification)
marked in order to indicate the direction and distance the Zone Roll is displaced from
nominal. Determine the Zone Roll displacement while viewing from the front of the 3. USE THE FOLLOWING TABLES (6 - 10) IN ORDER TO DETERMINE THE COLOR OF
Machine. THE INBOARD BEARING HOUSING TO BE INSTALLED (PL 9.4)
• Violet (-2): Moves the Outboard end of roll 2 mm to the left a. Select the table which corresponds to the color of the existing Inboard Bearing
Violet (-2): Moves the Inboard end of roll 2 mm to the right Housing.
• Yellow (-1): Moves the Outboard end of roll 1 mm to the left b. Locate the column in that table which includes the value of the measurement
recorded in Step 6b of the Check. The correct color of the Bearing Housing to be
Yellow (-1): Moves the Inboard end of roll 1 mm to the right
installed, is listed below the value in the applicable table.
• White (Nominal): Originally installed in all PR Modules.
• Brown (+1): Moves the Outboard end of roll 1 mm to the right Table 6 : GRAY Existing INBOARD Bearing Housing
Brown (+1): Moves the Inboard end of roll 1 mm to the left 3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
• Gray (+2): Moves the Outboard end of roll 2 mm to the right WHITE BROWN GRAY (Adjustment not (Adjustment not
Gray (+2): Moves the Inboard end of roll 2 mm to the left (In Specification) available) available)
2. USE THE FOLLOWING TABLES (1 - 5) IN ORDER TO DETERMINE THE COLOR OF
THE OUTBOARD BEARING HOUSING TO BE INSTALLED (PL 9.4). Table 7 : BROWN Existing INBOARD Bearing Housing
a. Select the table which corresponds to the color of the existing Outboard Bearing 3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
Housing. YELLOW WHITE BROWN GRAY (Adjustment not
(In Specification) available)

Table 8 : WHITE Existing INBOARD Bearing Housing ADJ 9-2 NVM Read/Write
3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
Purpose
VIOLET YELLOW WHITE BROWN GRAY
The purpose is to read or write values in MIN NVM Addresses as needed in order to perform a
(In Specification)
Xerographic Setup procedure.
Table 9 : YELLOW Existing INBOARD Bearing Housing

Adjustment
3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
1. ENTER dC131, [NVM Read/Write].
(Adjustment not VIOLET YELLOW WHITE BROWN
available) (In Specification) NOTE: Ensure that the correct values are entered in NVM or there will be an erroneous setup.
2. SELECT [MIN] OR [PHN] AS REQUIRED.

Table 10 : VIOLET Existing INBOARD Bearing Housing
3. ENTER THE ADDRESS NUMBER ON THE CONTROL PANEL.
3.0 - 4.0 mm 4.0 - 5.0 mm 5.0 - 6.0 mm 6.0 - 7.0 mm 7.0 - 8.0 mm
4. SELECT [Enter] ON THE Address DISPLAY.
(Adjustment not (Adjustment not VIOLET YELLOW WHITE
5. ENTER THE DESIRED DATA VALUE ON THE CONTROL PANEL.
available) available) (In Specification)
6. SELECT [Enter] ON THE Data DISPLAY.
4. REMOVE THE LEFT DEVELOPER ZONE ROLL, AND THE BEARING HOUSING(S) 7. PERFORM THIS PROCEDURE FOR EACH MIN AND PHN ADDRESS REQUIRING
WHICH MUST BE REPLACED. DATA CHANGE.
5. INSTALL THE PROPER BEARING HOUSING(S) (OUTBOARD AND/OR INBOARD),
ENSURING THAT THE TWO POSITIONING BOSSES ARE SECURELY SEATED IN
THE FRAME OF THE PR MODULE.
6. SEAT THE INBOARD BEARING OF THE ZONE ROLL IN THE INBOARD HOUSING,
THEN PUSH THE OUTBOARD BEARING INTO THE OUTBOARD HOUSING.
7. REPEAT THE CHECK (STEPS 5 AND 6).
8. REINSTALL THE PHOTORECEPTOR AND THE PHOTORECEPTOR INNER PANEL.

ADJ 9-3 Xerographic Setup b. Press the Lamp Test Switch (S901). Ensure that all segments of the Pretransfer
Lamp (DS901) and the Precharge Lamp (DS902) are lit.
Purpose c. If either lamp does not function correctly proceed to the PQ 9-624, Precharge/Pre-
The purpose of this procedure is to adjust the Xerographic process control parameters. transfer Lamps RAP.
Adjustment
WARNING
NOTE: If NVM was lost or a NODE INIT was performed, check/adjust the NVM Node Initializa- CAUTION
tion Recovery (ADJ 9-15). Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox
NOTE: Excessive removal of the Dicorotron housing, (not shields), can cause premature fail-
ure of the dicorotron and/or connectors. Do not remove the dicorotrons for cleaning or inspec-
tion until directed to do so by HFSI requirements or RAP diagnostics.
1. ENTER THE DIAGNOSTICS MODE. SELECT [SCP], [HFSI], [Dicorotrons]. PERFORM performed with the components clean.
THE MAINTAINENCE ACTIONS FOR ALL ITEMS EXCEEDING THEIR SERVICE Do not clean the Dicorotron Housing or Wires. Do not put grease from the insulator onto hous-
INTERVAL. SELECT [Reset Count] AS REQUIRED. ing.
NOTE: If the toner is low in the bottle, the Xerographic Set-up procedure will not be completed. 6. CLEAN THE DSS AND THE ESV WITH A CLEAN, SOFT, LINT FREE CLOTH.
7. CLEAN THE FOLLOWING COMPONENTS WITH A SOFT, DRY, LINT-FREE CLOTH
2. ENSURE THAT THERE IS AN ADEQUATE SUPPLY OF TONER IN THE TONER BOT- ONLY:
TLE.
a. Patch Generator (REP 9-36)
NOTE: Developer must be prepared in order to refresh its triboelectric properties. This is b. Belt Hole Sensor
accomplished by running enough prints to purge the toner from the new developer and dis- c. POP Sensor (Q904) Cleaning (REP 9-60).
pense fresh toner.
d. Dicorotron Shields only (REP 9-39)
3. IF NEW DEVELOPER WAS INSTALLED, PERFORM THE DEVELOPER PREPARA- e. Clean the bottom of the Cleaner Housing (REP 9-26)
TION, OTHERWISE GO TO STEP 4 BELOW. 8. INSPECT THE XEROGRAPHIC MODULES FOR DIRT AND ANY DAMAGE. CLEAN OR
a. Place at least two reams (1000 sheets) of A4 (8 1/2 x 11) or a larger paper size in REPAIR AS REQUIRED. USE THE VACUUM CLEANER IN ORDER TO CLEAN THE
Tray 1. FOLLOWING COMPONENTS:
NOTE: Refer to NVM READ/WRITE (ADJ 9-2), if additional information is needed. a. PR Module
b. PR Ground Brush
b. Enter dC131, NVM Read/Write.
c. Developer Assembly (REP 9-5)
c. Select [MIN].
d. MIM Cavity Cooling Fan
NOTE: MIN Address 250 is the PGen Reference Increment value. Decreasing this value cre- 9. EMPTY THE DEVELOPER CATCH TRAY.
ates a darker patch, extending the tone down cycle. An extended tone down cycle forces 10. RESTORE THE PRINTER POWER.
the purging of toner from the developer material. MIN NVM address 250 data value will be
11. ENSURE THAT ALL COVERS ARE CORRECTLY INSTALLED TO PREVENT AMBIENT
automatically updated during the TC/PGen Setup.
LIGHT FROM ENTERING THE XEROGRAPHIC MODULE.
d. Enter Address 250. Reduce the existing Data value by 5. 12. IF A NEW INSTALL AND/OR A MIN NODE INIT WAS PERFORMED, OR THE DSS WAS
e. Enter dC909. Select [Printer Options], [Tray 1], [Stacker A], [Test Patterns and REPLACED DURING THIS SERVICE CALL, PERFORM THE DSS SATURATION (ADJ
PQ], [XERO]. 9-13). WHEN COMPLETED, CONTINUE WITH STEP 12.
f. Select [Patch Test]. 13. CHECK THE CHARGE DICOROTRON BALANCE (ADJ 9-6).
g. Program 1000 Prints. Press Continue. NOTE: If the Xerographic Set-Up IS NOT initiated due to an HSFI replacement of Developer
4. ENSURE THAT ALL ELEMENTS OF THE PRETRANSFER LAMP (DS901) AND THE material, perform 15.
PRECHARGE LAMP (DS902) ARE OPERATING CORRECTLY AS FOLLOWS:
14. IF THE XEROGRAPHIC SETUP IS INITIATED DUE TO THE HFSI REPLACEMENT OF
a. Pull out the Xerographic Drawer, and open the Photoreceptor module in order to
DEVELOPER MATERIAL, ONLY THE [TC/PGEN] PORTION OF DC951 IS REQUIRED,
observe the lamps.
PERFORM THE FOLLOWING:

a. Enter dC951. Select [TC/PGen], [Printer Options], [Tray 1], [Stacker A]. Press c. If the solid area density block 3 is greater than STD: RESTORE or, the background
Continue. is greater than ALL: BKGD, go below to 20.
b. Go to Step 15. d. If this is a MICR Machine, enter [Printer Options], [PQ]. Select [MICR14], [Fine
15. PERFORM THE XEROGRAPHIC SET-UP: Adjust]. Program 15 prints and press Continue.
a. Enter dC951. Select [Load Defaults], [Confirm]. i. If the average Signal Strength of all the characters is less than 100, go below to
19.
NOTE: Refer to NVM READ/WRITE (ADJ 9-2), if additional information is needed.
ii. If the average Signal Strength of all the characters is greater than 160, go
b. Enter dC131, [NVM Read/Write]. below to 20.
c. Select [MIN]. 19. INCREASE THE TONER CONCENTRATION BY PERFORMING THE FOLLOWING:
d. Check the following NVM addresses and verify the Data values are as listed in the a. Program 500 prints.
appropriate level Software dC 131 Table (Section 6, General Procedures, in the Ser-
NOTE: Do not increase the [Patch Gen Ref] by more than two bits at one time, or more than 6
vice Manual).
bits total. Refer to the PQ 9-609, Low Image Darkness RAP if a problem occurs.
Table 1 b. Increase the value of the [Patch Gen Ref] by one or two bits.
Min Address Value Min Address Value c. Press Continue. Allow at least 250 prints before evaluating the print quality.
d. Repeat 19 until the Toner Concentration is in specification.
124 243
20. DECREASE THE TONER CONCENTRATION:
125 244
a. Program 500 prints.
202 245
210 251 NOTE: Do not decrease the [Patch Gen Ref] by more than two bits at one time, or more than
220 260 6 bits total. (Do not change the Toner Concentration below the value of 26.) If there is
a problem with the adjustment that requires more than 6 bits, go to the PQ 9-610, High
225 466
Image Darkness RAP.
228 466
b. Decrease the value of the [Patch Gen Ref] by one or two bits.
e. Enter dC314. Check the Power Supply Calibration values using the HVAC/HVDC c. Press Continue. Allow at least 250 prints before evaluating the print quality.
Calibration Cards located in the Printer Log Book.
NOTE: Adjusting "Exposure" in Fine adjust has no effect on actual exposure. If PQ problems
f. Enter dC951. Select [ROS Correction]. Perform the ROS Low Correction Factor are encountered, use the appropriate PQ RAP.
(ADJ 6-3).
d. Repeat 20 until the Toner Concentration is in specification.
g. Select [Xero], [Printer Options], [Tray 1], [Stacker A].
21. CHECK THE 1-PIXEL @ 600 SPI LINES.
h. Load two reams of A4 (8 1/2 x 11) or a larger paper size in Tray 1. Select [Xero],
Press Continue. NOTE: This routine runs prints 1 pixel at 600 SPI quadrilles.
NOTE: A message will indicate Xero Setup Successfully Completed, and the Fine Adjust a. Enter dC951. Select [600 SPI Pattern].
Button will appear on the Setups scorecard.
b. Select [Printer Options]. Select the tray with the longest size paper available.
NOTE: The [Fine Adjust] icon is only enabled after portions of the Xerographic Setup are suc- c. Program 15 prints. Press Continue.
cessfully completed. Exiting dC951 before completing the Fine Adjustment will disable the d. Compare the print to the XTP #564.001 (82E4161). Use the Printer 1 Pixel Line
[Fine Adjust] icon. The icon will not appear again unless certain parts of the Xerographic Visual Reference to evaluate the 1-pixel lines. The 1-Pixel lines must be visible in
Setup are performed. both the fast scan and slow scan directions. In addition no visible structured (pat-
16. SELECT [Fine Adjust]. PROGRAM 15 PRINTS. PRESS Continue. terned) background should be observed (Figure 1).
17. SELECT THE PRINT WITH THE HIGHEST BACKGROUND.

18. COMPARE THE PRINT SELECTED WITH THE XTP #564.001 (82E4161), AND CHECK
THE FOLLOWING:
a. If the solid area density block 3 is equal to the STD: RESTORE block, and the back-
ground is less than or equal to ALL: BKGD, go to 21.
b. If the solid area density block 3 is less than the STD: RESTORE block, go below to
19.

CHECK: 1-PIXEL
LINE MUST BE
VISIBLE IN BOTH
DIRECTIONS
Figure 1 Checking the 1-Pixel Lines
NOTE: If the ROS Calibration % was changed, it is necessary to rerun the Xerographic setup
but do not change the ROS Calibration % back to the value on the ROS assembly in 15 of
the setup.
NOTE: Adjusting "Exposure in Fine Adjust" has no effect on actual Exposures. If PQ

problems continue, Go to the appropriate PQ RAP.
e. If the 1-Pixel Lines are not visible in both directions, or if the 1-Pixel Lines are visible
in both directions, but there is background, Enter dC951. Select [ROS Correction].
Ensure that the ROS Calibration % on the screen is equal to the value on the ROS
assembly. Press Continue.

ADJ 9-5 Patch Generator Timing c. Enter dC131 MIN, enter address 129 and record the initial value.
d. Enter dC131 MIN, enter address 128. Add 15 to the value recorded from address
Purpose 129 and enter this new combined number into address 128.
The purpose is to ensure that the patch generator is properly exposing the patch.
e. Enter dC909. Select [Charge Control] open, [Patch Print] Yes. select 25 prints
and press Continue.
NOTE: Prior to performing this procedure ensure that the ROS Magnification setup is correct
(ADJ 6-1). f. Examine a print with a patch. The white area should be centered around the patch. It
is this white area that is moved when adjusting dC 909 setups pgen timing.
Check g. If the check is good, restore dc131 MIN address 128 to its initial data value. If not
1. Perform the following procedure: proceed to the adjustment.
a. Save the setup parameters at the printer. Adjustment
b. Enter dC131 MIN, enter address 128 and record the initial value. 1. Enter dC909. Select [Setups], [P Gen Timing]. Use the arrows to move the exposure
window right or left to vary the position of the Pgen exposure. Select [Enter] (Figure 1).
EXPOSURE WINDOW
WHITE AREA CENTERED

AROUND THE PATCH
UNEXPOSED PATCH
LESS THAN 2.0 mm
LEAD EDGE AND TRAIL
EDGE OF PATCH
Figure 1 Checking the Patch Generator Timing
2. Select [Tests], [Charge Control] open, [Patch Print] Yes. Select 25 Prints. Press Con- 5. Perform Xerographic Setup (ADJ 9-3).
tinue.
3. Examine a print with a patch. The white area around the patch should be centered.
Repeat steps 1 and 2 until the patch is centered.
4. Enter dC131 MIN, address 128 and restore it to the initial data value.

ADJ 9-6 Charge Dicorotron Balance
Purpose
The purpose is to ensure a uniform charging of the Photoreceptor. The adjustment is per-
formed by raising or lowering the front end of the Dicorotrons.
Check
NOTE: Use the longest size paper available.
NOTE: When performing Dicorotron balance, it is critical that the balance be set as uniformly
as possible to ensure even Signal Strength Inboard to Outboard.
1. ENTER dC131, [MIN] LOC 128. RECORD THE CURRENT VALUE.

2. SELECT [MIN] LOC 129. ADD 10 TO LOC 129 VALUE AND ENTER THIS NEW NUM-
BER IN LOC 128.
3. ENTER dC909. SELECT [Print Options], [Test Patterns and PQ], [Xerographic], [Nor-
mal], [Tests], [Patch Test]. CHANGE [Charge Control] TO Open. SELECT 7 PRINTS,
AND PRESS THE Continue BUTTON.
4. INSPECT THE PRINTS FOR A VERY LIGHT BACKGROUND.
NOTE: If the Background is too dark, re-enter [MIN] Loc 128, increase the value by 10 or less,
and repeat Steps 3 and 4.
5. COMPARE THE TEST PATTERN DENSITIES FROM TOP TO BOTTOM (Figure 1).

1
CHECK:
HALFTONE
DENSITIES ARE
EQUAL
2 3
CHECK: CHECK:
LINE PAIR SOLID DENSITIES
DENSITIES ARE EQUAL
ARE EQUAL
Figure 1 Comparing the Densities
6. IF THE DENSITIES ARE UNIFORM, CHANGE THE [MIN] LOC 128 BACK TO THE Adjustment
VALUE RECORDED AT THE BEGINNING OF THIS PROCEDURE.
CAUTION
7. IF THE DENSITIES ARE NOT UNIFORM, PERFORM THE ADJUSTMENT.
Do not adjust the Charge Dicorotron Balance with the Printer in the run mode or with the cov-
ers removed in order to avoid the damage to the Photoreceptor Belt.
NOTE: The adjustment screw can be accessed through the hole in the ROS Lower Inner
Panel. The illustration shows the panel removed.
NOTE: The Charge '2' Dicorotron is not used in the DP180.
1. ADJUST THE DICOROTRONS (Figure 2).

ADJ 9-7 Charge Dicorotron Height
Purpose
The purpose is to ensure the correct Photoreceptor charging by positioning the Charge
1 Dicorotron rails at the correct distance from the PR Belt.
LOOSEN SCREW
Check
1. POWER OFF THE PRINTER, THE CIRCUIT BREAKERS AND DISCONNECT ALL OF
THE POWER CORDS.
NOTE: This adjustment will require some persistent effort and an understanding of the interac-

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Transmittal Page

Product Title Part Number

DocuPrint 180F Service Manual 720P16290

Revision November 2000

This is a complete revision of the DocuPrint 180F Service Manual.

DocuPrint 180F Service Manual

Adobe® is a registered trademark of Adobe Systems, Inc.

Revision 11/00 Introduction

Service Manual Revision Section 3: Print Quality RAPs

Publication Comment Sheet Section 5: Parts List

Section 1: SERVICE CALL PROCEDURES

Preliminary Working Document 0/0/00 Section Name

Section 7: WIRING DATA

Section Name 0/0/00 Preliminary Working Document

Table 2 AC Voltage Specifications - USMG and XCI

Table 3 AC Voltage Specifications - XL

Table 4 Autotransformer AC Voltage Specification - XL

Preliminary Working Document 0/0/00 Section Name

Section Name 0/0/00 Preliminary Working Document

Preliminary Working Document 0/0/00 Section Name

Section Name 0/0/00 Preliminary Working Document

Preliminary Working Document 0/0/00 Section Name

Glossary of Terms Term Definition

BCR Bar Code Reader ESV Electrostatic Voltmeter

Section Name 0/0/00 Preliminary Working Document

Preliminary Working Document 0/0/00 Section Name

Section Name 0/0/00 Preliminary Working Document

Initial Action Paper Handling PHM Group Fault Tables

Revision 11/00 Service Call Procedures

Preliminary Working Document 0/0/00 Section Name

Section Name 0/0/00 Preliminary Working Document

Preliminary Working Document 0/0/00 Section Name

Preliminary Working Document 0/0/00 Section Name

Section Name 0/0/00 Preliminary Working Document

Preliminary Working Document 0/0/00 Section Name

Table 1 1M SM HFSI Activities

Section Name 0/0/00 Preliminary Working Document

Table 2 2M SM HFSI Activities

Preliminary Working Document 0/0/00 Section Name

Table 3 HFSI Activities Less Than 2M

Table 4 HFSI Activities Greater Than 2M

Section Name 0/0/00 Preliminary Working Document

Preliminary Working Document 0/0/00 Section Name

Section Name 0/0/00 Preliminary Working Document

The problem reported is an Odor problem.

The defect is related to the image location (Skew, Registration, or magnifica-

The problem is associated with a fault code.

Go to 11-600, Poor Stacking

Go to 10-607, Unable to Type on

Go to the Print Defect Entry Procedure.

Go to the Print Damage Entry Procedure.

Go to the 4-702, Processor Drive Noise RAP or 11-

The unfused prints exhibit lead edge-to-trail edge

Go to the 8-705, PHM Print Damage RAP.

Go to the 10-603, Wrinkle RAP.

Reset the ELCI/RCD. The ELCI/RCD trips again.

Go to the 1-731 RAP.

Section Name 0/0/00 Preliminary Working Document

Go to the 3-224, RAP.

Go to the 3-380, RAP.

Go to the 3-224, RAP.

Go to the 2-700, Printer UI Entry Procedure.

Preliminary Working Document 0/0/00 Section Name