DocumentCentre 240 - 255 - 265 - 460 - 470 - DT65 - DP65 (SM, PC)

TransmittalPage
Product
Title
PartNumber
DC240/255/265/
460/470
DT65/DP65
AgentServiceManual
701P22840
Status
Date
Re-Issue
May2003
(Supercedes701P22160November2002)
CHANGEHIGHLIGHTS:
StatusIndicatorRAPs
Chain5
Revised05-100RAP,05-CRAP,05-MRAPtoincludeDocumentInputTraySideGuides
Kit,PL2.1A.
05-102RAPAddedcheckoutofRegistrationGate
05-ARAPAddedreferencetotheDADFCounterbalanceHingeKitPL2.1B.
Chain707-BRAP-the4InputIIOCPWBisnowspared.
Chain808-115RAPmodifiedduetoachangeinsparingstrategyofHCFFeedSprings
Chain10
AllreferencestoGP42CSEFuserRebuild/ReturnProcessarenolongerNASGonly.
NumerousRAPsmodifiedtoreflectPartsListchanges
Chain12CMFF12-761RAPand12-762RAPupdatedperengineeringfeedback.
Chain1414-335RAPmodifiedperengineeringfeedback
Chain12CMFF12-761RAPand12-762RAPupdatedperengineeringfeedback.
OtherFaultsRAPsOF-6RAPrevisedwithupdatedMFFfaultmessages.
RepairsandAdjustments
AddedREP12.13.204-BarExitDriveShaftandREP12.13.21CompilerEntranceSensor,
S46.
PartsList
Revisedtoincludenewsparesthroughout.
GeneralProceduresandinformation
InformationforthefollowingIOTTagshasbeenadded123,139,140,141,and278.
Informatio0nforthefollowingMFFTagshasbeenadded:M022,M023,M024,M027,M028,
andM029.
GP42,CSEFuserRebuild/ReturnProcessisnowforNASGandXEandXEshippinginformationhasbeenadded
DocumentCentre
240/255/265/460/470
DT65/DP65
DocumentCentre240/255/265
460/470
DT65/DP65
XeroxDocumentCentre240/255/265/460/470
DT65/DP65ServiceDocumentation
701P22840
May2003
ForSelf-ServiceofXeroxDC240/255/265/460/470DT65/DP65Products
DC240/255/265/460/470
WhileXeroxhastriedtomakethedocumentationaccurate,Xeroxwillhavenoliabilityarising
outofanyinaccuraciesoromissions.
AgentServiceManual
DocumentCentre240/255/265/460/470ServiceDocumentation
701P22840
May2003
Preparedby:
WARNING
This equipment generates, uses and can radiate radio frequency energy, and if not
installedandusedinaccordancewiththeinstructionsdocumentation,maycauseinterferencetoradiocommunications.Ithasbeentestedandfoundtocomplywiththelimits
foraClassAcomputingdevicepursuanttosubpartJofpart15ofFCCrules,whichare
designedtoprovidereasonableprotectionagainstsuchinterferencewhenoperatedina
commercial environment. Operation of this equipment in a residential area is likely to
causeinterferenceinwhichcasetheuser,athisownexpense,willberequiredtocorrecttheinterference.
XeroxCorporation
GlobalKnowledgeandLanguageServices
800PhillipsRoad-Bldg.845-17S
Webster,NewYork14580
2003byXeroxCorporation.Allrightsreserved.Xeroxandallidentifyingnumbersusedin
connectionwiththeXeroxproductsmentionedinthispublicationaretrademarksoftheXerox
Corporation.
***XeroxPrivateData***
AllservicedocumentationissuppliedtoXeroxexternalcustomersforinformationalpurposes
only.Xeroxservicedocumentationisintendedforusebycertified,product-trainedservicepersonnelonly.Xeroxdoesnotwarrantorrepresentthatitwillnotifyorprovidetosuchcustomer
anyfuturechangetothisdocumentation.Customerperformedserviceofequipment,ormodules,components,orpartsofsuchequipmentmayaffectwhetherXeroxisresponsibletofix
machine defects under the warranty offered by Xerox with respect to such equipment. You
shouldconsulttheapplicablewarrantyforitstermsregardingcustomerorthird-partyprovided
service.
Xerox
DiagnosticNavigator isatrademarkoftheXeroxCorporation.
AdobeisaregisteredtrademarkofAdobeSystems,Inc.
AppleTalkisaregisteredtrademarkofAppleComputer,Inc.
Microsoft,MS-DOSareregisterdtrademarks,andWindows isatrademarkofMicrosoft
Corporation.
Novell,NetWare,PConsole,andNPrintareregisteredtrademarkofNovell,Inc.
PostScriptisaregisteredtrademarkofAdobeSystems,Inc.
SectionName
Introduction
About This Documentation..............................................................................................
Organization....................................................................................................................
How To Use This Documentation ...................................................................................
Additional Product Safety Information.............................................................................
Tag Usage.......................................................................................................................
Translated Warnings .......................................................................................................
iii
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vi
vii
viii
V0.042
May 2003
1
Document Centre 240/255/265/460/470 DT65/DP65
Introduction
Introduction
May 2003
2
V0.042
About This Documentation
Organization
Introduction
Service Documentation Sections
The Document Centre 240/255/265/460/470 DT65/DP65 Service Documentation is part of the

multinational documentation system for the Document Centre 240/255/265/460/470 family of
copiers, printers, and Multi-Function devices and the DocuTech 65 and DocuPrint products. It
is structured in standard Xerox service documentation format. This documentation will help in
the isolation and repair of faults that may occur in the Document Centre 240/255/265/460/470
family of products and the DocuTech 65 and DocuPrint 65 products.
The Document Centre 240/255/265/460/470 DT65DP65 Service Documentation is the primary

document used for repairing and maintaining Document Centre products and the secondary
document for servicing the DocuTech 65 and DocuPrint 65 products. Information is contained
in this documentation within the following sections.
The Document Centre 240/255/265/460/470 DT65/DP65 documentation contains information

that applies to NASG-US (USCO), XE, and NASG-Canada (XCL) duplicators. NASG-US
(USCO) references normally apply to NASG-Canada (XCL) and 60 HZ duplicators. If there is
a difference, "NASG-US Only (USCO Only") or NASG-Canada Only ("XCL only") will be
specified. All "XE" references apply to Xerox Europe and 50 HZ copiers/printers.
This section should always be used to start and complete the service call. This section is
used to identify a suspected problem. The procedures will either direct you to a RAP or
identify a faulty component or subassembly.
Section 1 Service Call Procedures
Section 2 Status Indicator Repair Analysis Procedures

This section contains Repair Analysis Procedures (RAPs). You will be directed to this
section to isolate a faulty component or subassembly.
Service Documentation Revisions

The Self-Service Documentation for the Xerox Document Centre 240/255/265/460/470 products will be updated as the product changes or as problem areas are identified. Changes will
be highlighted by a vertical change bar located in the left margin adjacent to any modified text
or graphics.
Section 3 Image Quality Repair Analysis Procedures

This section contains Image Quality Repair Analysis Procedures (IQ RAPs) and Image
Quality samples. You will refer to this section to identify test pattern samples or isolation
procedures for common image quality defects.
Section 4 Repair / Adjustment
This section contains the instructions for removal, replacement, and adjustment of the
spared parts within the terminal.
Section 5 Parts List
This section consists of a series of illustrations and an associated parts listing. Any part
that is spared or any part that must be removed to access a spared part is illustrated.
Common hardware is shown as a letter callout.
Section 6 General Procedures /Information
This section contains the general repair and diagnostic procedures, product specifications, supplemental tools and supplies, Tag information, and install instructions.
Section 7 Wiring Data
This section contains illustrations which show the location of all PWBs and connectors.
This section contains system block diagrams for power, control signal, and ground distribution. This section also contains pin assignment lists for all connectors.
Section 10 Principles of Operation
This section contains the principles of operation for the product.
Section 11 Supplemental Training
This section contains L0.18.xx Software Highlights, Document Centre 460/470 Differences, Smart Tray Finisher Differences, and 19.02 Software Highlights.
V0.042
May 2003
iii
Introduction
How To Use This Documentation

Introduction
Section 1: SERVICE CALL PROCEDURES
This section contains procedures that determine what actions are to be taken during a service
call on the Document Centre 240/255/265/460/470, and in what sequence they are to be completed. This is the entry level for all service calls.
This section contains the RAPs and CDs and other diagnostic aids for troubleshooting image
defect problems. RAPs associated with image defect symptoms all contain the prefix "IQ" to
differentiate them from the rest of the failure symptoms. If a Xerographic fault code is present,
diagnostics of that failure should be done using the appropriate RAP in the Status Indicator
RAPs section. This section also contains image quality specifications and image defect samples.
Section 4: REPAIR/ADJUSTMENTS PROCEDURES
The SCP-02, Introduction to Call Flow, is intended to provide a systematic approach to the
entire call. SCP-03, Initial Actions, identifies the recommended steps to be done to get a "snapshot" of the machine condition. SCP-04, Corrective Actions, describes the recommended process for diagnosing and repairing the failure, and SCP-07, Final Actions, describes what
precautions are recommended to ensure that the machine is in the best possible condition
when the call is completed.
This section contains the Component Locational drawings and all repair and adjustment procedures for the Document Centre 240/255/265/460/470.
The System Fault Analysis Procedure creates a systematic for diagnosing the cause of the failure when it may not be apparent, or when there are conflicting or ambiguous symptoms. It is
important that this procedure be used in order to ensure that the correct symptom is being
diagnosed.
This section contains special checkout procedures used when troubleshooting or repairing the
machine. Also included in this section are text versions of the PWS Diagnostic routines and
various reference documentation.
Section 5: PARTS LIST

Section 6: GENERAL PROCEDURES
Section 7: WIRING DATA

Section 2: STATUS INDICATOR RAPs
This section contains:
This section contains the Repair Analysis Procedures (RAPs) and Circuit Diagrams (CDs) that
are used for troubleshooting the Fault Code and non- Fault Code related problems.
The following information pertains to the RAP and CD numbering:
The RAP/CD number is identical to the fault code generated by the machine and displayed on the UI Fault screens or on the PWS, with the exception that the fault code
extension may (00-000.XX) may not appear in the RAP title.
The first pair of digits in a RAP/CD number identify the functional area (chain) to which the
fault code refers.
The 100 series faults (XX-100) refer to document or paper jam faults. 200 series faults
(XX-200) refer to timing faults. 300 series faults refer to control faults.
The 500 series (XX-500), are reserved for status messages, that is, messages that are
displayed on the UI Display Panel. RAPs are not written for status codes.
The 700 series faults are reserved for non-shutdown faults. These faults are logged in the
error log, but do not appear in the Last 40 Faults. These faults will not normally impact
the customer, but may be useful in diagnosing machine problems.
RAPs/CDs number with a chain followed by an alpha character (05-A), are assigned by
GKLS (Service Education). The machine software cannot identify these failures, therefore cannot assign a fault code.
RAPs/CDs with OF followed by an alpha character are assigned by GKLS (Service Education). These faults do not fall into one particular chain. Examples are OF-1, Noise RAP
and OF-6 Status Messages.
Section 3: IMAGE QUALITY RAPs
Introduction
Plug/Jack locational drawings, PWB drawings, and the IIOC PWB locational drawings.
They are accessible through the table of contents, but would normally be accessed by a
hotlink within the RAP or procedure.
Wirenet drawings of power distribution networks in the machine.
Section 10: PRINCIPLES OF OPERATION

This section contains the Principles of Operation for the product.
Section 11: SUPPLEMENTAL TRAINING
This section contains L0.18.xx Software Highlights, Document Centre 460/470 Differences, Smart Tray Finisher Differences, and 19.02 Software Highlights.
Voltage Measurement and Specifications
Measurements of DC voltage must be made with reference to the specified DC Common,
unless some other point is referenced in a diagnostic procedure. All measurements of AC voltage should be made with respect to the adjacent return or ACN wire ( Table 1).
Table 1 Voltage Measurement and Specifications
VOLTAGE
SPECIFICATION
115 VAC 60Hz
103.5 to 126.5 VAC
200 VAC 50Hz
180 to 220 VAC
220 VAC 50Hz
198 to 242 VAC
230 VAC 50Hz
207 to 253 VAC
240 VAC 50Hz
216 to 264 VAC
+5 VDC
+5.05 VDC TO +5.25 VDC
+12 VDC
+11.4 VDC TO +12.6 VDC
May 2003
iv
V0.042
This symbol is used to refer to notes which are found on the same page of a circuit
diagram. A note is used whenever it is necessary to highlight an operating or maintenance procedure, a practice, condition, or statement.
Table 1 Voltage Measurement and Specifications

VOLTAGE
SPECIFICATION
-12 VDC
-11.4 VDC TO -12.6 VDC
+24 VDC
+22.8VDC TO +25.2 VDC
+36 VDC
+34.2 VDC TO +37.8 VDC

3.
Logic Voltage Levels

Measurements of logic levels must be made with reference to the specified DC Common,
unless some other point is referenced in a diagnostic procedure (Table 2).
This symbol, example (PL2.1), refers to the Parts List exploded view page where the
part can be found.
4.
Adjustment
This symbol refers to an adjustment procedure in the Repair/Adjustments section.
Table 2 Logic Levels

VOLTAGE
Parts List
H/L SPECIFICATIONS
+5 VDC
H= +3.00 TO +5.25 VDC, L=

0.0 TO 0.8 VDC
+24 VDC
H= +23.37 TO +27.06 VDC,

L= 0.0 TO 0.8 VDC
5.
Test Point, Test Hole, Test Stake

This symbol is used to indicate that a test point, test hole, or test stake is available
for accessing the signal line. The prefix indicates whether the access is a test point
(TP), test hole (TH), or test stake (TS).
DC Voltage Measurements in RAPs

The RAPs have been designed so that when it is required to use the DMM to measure a DC
voltage, the first test point listed is the location for the red (+) meter lead and the second test
point is the location for the black meter lead. For example, the following statement may be
found in a RAP:
6.
Commoning Point
This symbol is used to refer to a location in the machine wiring where more than two
wires a connected together at a single point.
There is +5 VDC from TP7 to TP68.

In this example, the red meter lead would be placed on TP7 and the black meter lead on TP68.
Model Distinction
Another example of a statement found in a RAP might be:
If different parts or actions exist because of different models, the model distinction (40ppm,
55ppm, or 65ppm, NASG (USCO), XE, FX) will identify the appropriate part or action.
There is -15 VDC from TP21 to TP33.

In this example, the red meter lead would be placed on TP21 and the black meter lead would
be placed on TP33.
If a second test point is not given, it is assumed that the black meter lead may be attached to
the copier frame.
Reference Symbology
The following reference symbols are used throughout the Document Centre 240/255/265/460/
470 Service Documentation.
1.
Example 1). 3.1 VDC is measured (40ppm) or 5.2 VDC is measured (55ppm and 65ppm)
Example 2). Check the Bottle Sensor (FX Only)
Some procedures utilize the ability of the browser to display or hide parts of a procedure that
are pertinent. This is possible due to the ability of the PWS to read the machine configuration.
If the machine is not connected to a machine, some configuration values can be set manually
using the Book Configuration.
Terminology and Symbols

The following are examples of the terminology and symbols that are used in this documentation for an Electrostatic Device Caution, Laser Warning, and general Warnings, Cautions, or
Notes.
Flag
This symbol indicates a reference point into a circuit diagram from a RAP.
2.
Note
V0.042
May 2003
v
Introduction
CAUTION
Certain components in this product are susceptible to damage from electrostatic discharge.
Observe all ESD procedures to avoid component damage.
Additional Product Safety Information

Introduction
The following is additional product safety information for the Document Centre 240/255/265/
460/470 and DT65/DP65.
Warning, Cautions, and Notes

WARNING
WARNING
Improper operation may result in injury to a person.
The plug is the disconnect device. It is necessary to unplug the copier to remove all
power. Do not depend on the On/Off switch.
WARNING
CAUTION
Improper operation may result in machine damage.
NOTE: Hints or other information that may assist the user.
Use of controls, adjustments and/or performance or procedures other than those specified herein may result in hazardous light exposure.
CAUTION
During normal operation, this machine produces ozone gas. The amount of ozone produced
does not present a hazard to the operator. However, it is advisable that the machine be operated in a well ventilated area.
NOTE: This is a Class 1 Laser Product (XE Only)
Electrostatic Discharge (ESD) Field Service Kit

The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of
electronic components that are handled by the Field Service Personnel. This program is being
implemented now as a direct result of advances in microcircuitry technology, as well as a new
acknowledgment of the magnitude of the ESD problem in the electronics industry today.
This program will reduce Field Service costs that are charged to PWB failures. Ninety percent
of all PWB failures that are ESD related do not occur immediately. Using the ESD Field Service Kit will eliminate these delayed failures and intermittent problems caused by ESD. This
will improve product reliability and reduce callbacks.
The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive
components are being handled. This includes activities like replacing or reseating of circuit
boards or connectors. The kit should also be used in order to prevent additional damage when
circuit boards are returned for repair.
The instructions for using the ESD Field Service Kit can be found in GP5 in the General Procedures section of the Service Documentation.
Introduction
May 2003
vi
V0.042
Tag Usage
This symbol
Tags
If different parts or actions exist because of a modification, the Tag number will identify the
appropriate part or action.
Example 1). Tag xx: PWB . . .
Example 2) PWB (Tag xx) . . .
indicates that a surface can be hot. Use caution when reaching in the machine to avoid touching the hot surfaces.
Tag Symbols
This symbol
is used to show a particular part or area of a figure which has been modified by the Tag number
within the circle.
Danger label indicates where electrical currents travel when the machine is closed and operating. Use caution when reaching in the machine.
This symbol
is used to show a particular part or area of a figure which has not been modified by the Tag
number within the circle.
This symbol
is used to show a Tag change has modified an area of the terminal.

This symbol
is used to show a Tag change has not modified an area of the terminal.
The following safety icons are displayed on the machine:
This symbol
points to the location to install, to gain access to, or to release an object.

V0.042
May 2003
vii
Introduction
Translated Warnings
Introduction
May 2003
viii
V0.042
Publication Information
WARNING
This equipment generates, uses and can radiate radio frequency energy, and if not
installed and used in accordance with the instructions documentation, may cause interference to radio communications. It has been tested and found to comply with the limits
for a Class A computing device pursuant to subpart J of part 15 of FCC rules, which are
designed to provide reasonable protection against such interference 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 expense, will be required to correct the interference.
DANGER: Cet quipement gnre, utilise et peut mettre des frquences radio, et, s'il
n'est pas install et utilis selon les recommandations du manuel d'instructions, peut
causer des interfrences aux communications radio. Il a t test et jug conforme aux
limites des systmes de catgorie A, conformment la partie 15 de l'alina J des rglements FCC, tablis pour protger contre de telles interfrences pendant le fonctionnement en milieu commercial. Dans une zone rsidentielle, il peut causer des
interfrences; dans ce cas, l'utilisateur devra corriger le problme ses propres frais.
Introduction
DANGER: Dans l'tape suivante, la carte de distribution sera dconnecte de l'alimentation LVPS ce qui mettra hors d'tat le contact d'arrt instantan. Il faut dbrancher le
cble d'alimentation pour dconnecter la carte de distribution de l'alimentation LVPS.
01-C No 36 VDC Output From LVPS
WARNING
In the following step, P13 will be disconnected from the Distribution PWB which will disable the Instant OFF Switch. If it is necessary to switch the power OFF while P13 is disconnected from the Distribution PWB, the Power Cord must be unplugged from the wall
plug.
DANGER: Dans l'tape suivante, la prise P13 sera dconnecte de la carte de distribution ce qui mettra hors d'tat le contact d'arrt instantan. Il faut dbrancher le cble
d'alimentation pour dconnecter la prise P13 de carte de distribution.
9. Marking
09-318 Light 87.5% Patch Fault
WARNING
Switch off the machine power and unplug from the wall outlet.
How to use this documentation
DANGER: Mettre la machine sur Arrt et dbrancher le cble d'alimentation de la prise

murale.
WARNING
09-338 Electrostatic Setup Convergence Failure
Improper operation may result in injury to a person.

DANGER: Un fonctionnement incorrect peut provoquer des blessures.
WARNING
Additional Product Safety Information
WARNING
The plug is the disconnect device. It is necessary to unplug the copier to remove all
power. Do not depend on the On/Off switch.
DANGER: La mise hors tension se fait avec la prise de courant. Il faut dbrancher le
copieur pour l'isoler compltement. Ne pas se contenter du contact Marche/Arrt.
WARNING
Use of controls, adjustments and/or performance or procedures other than those specified herein may result in hazardous light exposure.
DANGER: Des vrifications, utilisations ou rglages non spcifis dans ce manuel peuvent vous exposer de dangereux rayons laser.
AVVERTENZA:

murale.
WARNING
murale.
12C. Multi-Function Finisher
12-114 LE Late to the Compiler Entrance Sensor RAP
WARNING
The machine power must be switched off and the MFF power cord disconnected, to
avoid the electrical hazard of personal injury or machine damage. Switching off the
machine power alone will not remove power from the MFF.
VORSICHT:
AVISO:
Status Indicator RAPs
DANGER: La machine doit tre mise hors tension et le cordon d'alimentation du MFF
dbranch, pour viter toute blessure ou toute dtrioration au matriel. La mise sur
Arrt de la machine ne coupe pas l'alimentation du MFF.
1. Standby Power
01-A DC Voltage Checkout Procedure
12-115 LE Late to the Top Tray Exit Sensor RAP
WARNING
In the following step, the Distribution PWB will be disconnected from the LVPS which
will disable the Instant OFF Switch. If it is necessary to switch the power OFF while the
Distribution PWB is disconnected from the LVPS, the Power Cord must be unplugged
from the wall plug.
V0.042
WARNING
May 2003
ix
Introduction
12-232 Eject Housing Home Fault RAP
12-117 TE Late to the Finisher Entrance Sensor RAP
Use caution when running these tests. Subsystems in the Multi-Function Finisher operate forcefully and rapidly and can cause injury. Some tests may pause and restart. Be
sure the test is completed before handling the hardware.
WARNING
12-124 Unexpected Sheet at the Top Tray Exit Sensor RAP
WARNING
WARNING
DANGER: Faire attention en excutant ces tests. Les sous-ensembles du module de

finition multifonction (MFF) sont actionns brusquement avec force, et peuvent causer
des blessures. Certains tests peuvent faire une pause avant de redmarrer. S'assurer
que le test est termin avant de manipuler le matriel.
WARNING
12-233 Stapler Transport Home Fault RAP
12-126 Lead Edge Late to the Buffer Module Entrance Sensor RAP
WARNING
WARNING

12-234 Main Tray Offset Home Fault RAP
WARNING
12-127 Compiler Jam Sensor RAP
WARNING
12-230/231 Main Tray Elevator Fault RAP
WARNING
WARNING
12-238 Flapper Home Fault
Introduction
May 2003
x
V0.042
WARNING
WARNING

12-761 MFF DC Power RAP
WARNING
12-239 4 Bar Home Fault RAP
WARNING
12-765 Finisher Noise RAP
WARNING
12-241/242 Compiler Tamper Fault RAP
WARNING
12-800 LE Late to Booklet Entrance Sensor RAP
WARNING
WARNING
12-801 TE Late to Booklet Entrance Sensor RAP
12-755 Main Tray Not Offsetting RAP
WARNING
WARNING

12-804 LE Late to the Crease Exit Sensor RAP
12-756 Pause to Unload Switch RAP
WARNING
V0.042
May 2003
xi
Introduction
Stay clear of the Crease Blade and the associated mechanical hardware. The Crease
Blade comes on quickly and with great force. When working within the Crease Blade
Assembly area, switch off the power in order to avoid personal injury.
DANGER: Rester l'cart du couteau de pliage et de la visserie associe. Le couteau de
pliage est actionn brusquement avec une grande force. En travaillant dans cette zone,
dbrancher la machine pour viter toute blessure.
ate forcefully and rapidly and can cause injury. Some tests may pause and restart. Be
WARNING
12-806 LE Late to Booklet Exit Sensor RAP
WARNING
12-807 TE Late to Booklet Exit Sensor RAP
WARNING
WARNING
12-818/819 Crease Blade Home Fault RAP
12-808/809 Booklet Tamper Fault RAP
WARNING
12-810/812 Booklet Backstop Fault RAP
WARNING

12-820 Crease Blade Motor Encoder Fault RAP
WARNING
WARNING

12-822 Crease Roll Gate RAP
12-817 Crease Roll Gate RAP
WARNING
Use caution when running these tests. Subsystems in the Multi-Function Finisher operIntroduction
WARNING
May 2003
xii
V0.042
WARNING
12-823 Lead Edge Late to the Tri-Fold Jam Sensor RAP
The machine power must be switched off and disconnected, to avoid the electrical hazard of personal injury or machine damage.
DANGER: La machine doit tre dbranche pour viter toute blessure ou toute dtrioration au matriel.
2. User Interface
REP 02-1 User Interface Assembly
WARNING
WARNING
REP 02-2 UI Processor PWB (With Tag #082 Only)
Image Quality
WARNING
REP 02-3 UI LCD Module (With Tag #082 Only)
Image Quality RAPs
WARNING
IQ-7 Copies/ Prints Too Light RAP
WARNING
murale.
Repairs-Adjustments
3. Machine Run Control
REP 03-1 SCAM PWB
1. Standby Power
WARNING
REP 01-1 Distribution PWB
WARNING
REP 01-2 AC Distribution Panel
WARNING
V0.042
REP 03-2 IPS1 Daughter PWB (240/255/265 Only)
WARNING
WARNING
REP 01-3 Low Voltage Power Supply (LVPS)
REP 03-3 Accessory PWB
WARNING
May 2003
xiii
Introduction
REP 03-4 Main Control PWB (Atlanta '96-to-'96 or Gold-to-Gold) (without Tag 077)
REP 03-5 Rotation SRAM SIMM (without Tag 077)
REP 03-11 Main Control PWB (Atlanta Platinum-to-Platinum) (With Tag 077 Only)
WARNING
WARNING
REP 03-6 EPC DRAM SIMM (without Tag 077)
REP 03-12 Electronic Hole Removal (EHR) PWB, 460/470
WARNING
WARNING
REP 03-7 NVM RAM Chip (without Tag 077)
REP 03-13 Card Cage Riser PWB (460/470 Only)
WARNING
WARNING
REP 03-8 Main Control PWB: Upgrade from Atlanta '96 (without Tag 015) to Atlanta Gold
(Installing Tag 015)
4. Start Print Power

REP 04-1 Developer Drive Motor
WARNING
WARNING
REP 03-9 EPC SDRAM DIMM (With Tag 077 Only)
WARNING
Introduction
WARNING
REP 03-10 Software/NVM Module (With Tag 077 Only)
WARNING
REP 04-2 Fuser Drive Motor
WARNING
REP 04-3 Developer Gear Bracket
WARNING
May 2003
xiv
V0.042
REP 04-4 Decurler/OCT Drive Bracket
WARNING
REP 05-4 DADF Feeder Assembly
WARNING
REP 04-5 Decurler Drive Belt
WARNING
WARNING
Perform the following steps with the DADF raised. Otherwise, the DADF can spring up
unexpectedly when its weight is reduced by the removal of parts, possibly causing
machine damage or personal injury.
REP 04-6 Developer Drive Belt
WARNING
5. Document Transportation
DANGER: Suivre les tapes avec le chargeur automatique DADF en position souleve.
Sinon le DADF risque de se soulever brutalement quand son poids baissera du fait du
dmontage de certains de ses lments, risquant ainsi de provoquer des blessures ou
des dtriorations.
REP 05-5 DADF Registration Deskew Assembly
WARNING
REP 05-1 DADF Cleaning Procedure
WARNING
WARNING
REP 05-2 DADF Assembly
WARNING
WARNING
The DADF is heavy and awkward to lift. Ensure that you have a firm, balanced grip on
the DADF before lifting it.
DANGER: Le chargeur automatique DADF est lourd et difficile soulever. S'assurer de
saisir le DADF fermement et de manire quilibre avant de le soulever.
REP 05-3 DADF Top Cover Assembly
WARNING
V0.042
des dtriorations.
REP 05-6 Document Input Tray Assembly
WARNING
REP 05-7 DADF Exit Shaft
WARNING
DANGER: La machine doit tre dbranche pour viter toute blessure ou toute dtrio-
May 2003
xv
Introduction
ration au matriel.
WARNING
des dtriorations.
des dtriorations.
6. ROS Imaging
REP 06-1 ROS
REP 05-8 DADF Feed Motor
WARNING
WARNING
REP 06-2 ROS Polygon Motor (With Tag #057 Only)
WARNING
WARNING
des dtriorations.
7. Paper Supply
REP 07-1 Paper Feed Drives Plate
REP 05-9 CVT Drive On Glass Kit
WARNING
WARNING
REP 07-3 HCF/Bypass Tray Assembly
REP 05-10 DADF Feed Roll Cartridge Release Lever Kit
WARNING
WARNING
REP 07-4 Bypass Tray Assembly
REP 05-11 DADF Exit Clutch
WARNING
WARNING
REP 07-5 HCF Elevator Motor
WARNING
Introduction
WARNING
May 2003
xvi
V0.042
ration au matriel.
REP 08-5 HCF Feeder
REP 07-6 Bypass Input Tray
WARNING
WARNING
REP 08-6 HCF Paper Handling Baffle
REP 07-9 HCF PWB
WARNING
WARNING
REP 08-7 Registration Sensor (S2)
8. Paper Transportation
WARNING
REP 08-1 Vertical Transport
WARNING
REP 08-2 Registration Transport Assembly
REP 08-8 Registration Clutch
WARNING
WARNING
9. Marking
REP 09-1 Xerographic Module
REP 08-3 HCF/Bypass Tray Feed Motor
WARNING
WARNING
REP 09-2 Developer Housing
REP 08-4 Bypass Tray Feeder
WARNING
WARNING
REP 09-3 BTAC Sensor
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May 2003
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Introduction
WARNING
ration au matriel.
REP 09-4 Toner Dispenser
REP 09-10 Developer Housing Support Rail
WARNING
WARNING
REP 09-5 Photoreceptor Drive Module
REP 09-11 Photoreceptor Drive Module Cleaning Procedure
WARNING
WARNING
REP 09-6 Charge HVPS
REP 09-12 Developer HVPS Contacts Cleaning Procedure
WARNING
WARNING
REP 09-7 Developer HVPS
WARNING
Any Film Remover on the contacts must be completeley dry before the machine power
is switched on. Otherwise, a fire may result.
DANGER: S'assurer que tout rsidu de "Film Remover" sur les contacts est compltement sec avant de mettre la machine sous tension, afin d'viter tout risque d'incendie.
REP 09-13 Donor Roll Cleaning Procedure
WARNING
REP 09-8 Transfer/Detack HVPS
WARNING
10. Print Transport and Fusing
WARNING
REP 10-1 Prefuser Transport (PFT)
WARNING
REP 09-9 BTAC Sensor Cleaning Procedure
WARNING
DANGER: La machine doit tre dbranche pour viter toute blessure ou toute dtrioIntroduction
WARNING
Be sure to reinstall the PFT Clip. The PFT Clip is required for safety, to prevent the PFT
from being removed accidentally.
DANGER: S'assurer de rinstaller le clip du transport pr-four. Ce clip est requis pour
May 2003
xviii
V0.042
des raisons de scurit, afin d'empcher la dpose accidentelle du transport pr-four.
ard of personal injury or machine damage.
REP 10-2 Duplex Transport
WARNING
WARNING
Support the Stacker Tray when removing the Stacker Drive Motor, and then lower the
tray gently. Otherwise, the Stacker Tray will drop quickly, possibly causing damage or
personal injury.
WARNING
Take care not to cut yourself on the top edge of the left frame opening in the next step.
This edge has not been deburred on frames built before June 8, 1998, and may be sharp.
DANGER: Lors de l'tape suivante, faire attention de ne pas se couper sur le bord
suprieur de l'ouverture de gauche du bti. Sur les btis fabriqus avant le 8 juin 1998,
ce bord n'est pas barb et peut tre tranchant.
WARNING
Take care not to cut yourself on the top edge of the left frame opening in the next step.
This edge has not been deburred on frames built before June 8, 1998, and may be sharp.
DANGER: Soutenir le magasin de rception lors du dmontage de son moteur puis le

descendre lentement. Sinon le magasin risque de tomber brutalement et de causer des
blessures ou dtriorations.
REP 12-3 Finisher Service Tray Assembly
WARNING
DANGER: Lors de l'tape suivante, faire attention de ne pas se couper sur le bord
suprieur de l'ouverture de gauche du bti. Sur les btis fabriqus avant le 8 juin 1998,
ce bord n'est pas barb et peut tre tranchant.
REP 12-4 Moving Stapler
REP 10-3 Dual Decurler or Exit Baffle
WARNING
WARNING
REP 12-5 Fixed Stapler
WARNING
REP 10-4 Inverter Drive Assembly, Drive Roll, or Feed/Reverse Roll
WARNING
REP 12-6 Nip 1 Drive Shaft
WARNING
12. Finishing - Disk Finisher

REP 12-1 Top Module Assembly
WARNING
REP 12-2 Stacker Drive Motor
The machine power must be switched off and disconnected, to avoid the electrical haz-
WARNING
WARNING
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REP 12-8 Finisher Transport Baffle
May 2003
xix
Introduction
WARNING
REP 12-9 Disk Baffle Assembly
Do not attempt the following step (unhooking the bottom two docking hooks) without
first having performed the previous step (deactivating the spring-loading of the right
castors). (Refer to the WARNING above.)
DANGER: Ne pas commencer l'tape suivante (dverrouillage des deux crochets du
bas) sans avoir effectu l'tape prcdente (blocage des roulettes de droite). Se rfrer
la note de scurit ci-dessus.
REP 12-13 Nip 1/2 Drive Belt
WARNING
REP 12-10 Disk Drive Motor
WARNING
WARNING
REP 12-11 Disk Shaft
WARNING
REP 12-15 Finisher Lubrication
WARNING
REP 12-12 Finisher Assembly (Undocking the Finisher)
WARNING
REP 12-16 Finisher Top Tray Back Wall
WARNING
WARNING
Use extreme care in performing the following three steps. If all four Finisher docking
hooks are unhooked from the IOT while the right castors' spring-loading is still active,
the Finisher will become extremely unstable. The top of the Finisher will then tend to tilt
to the left while the bottom rolls to the right, possibly resulting in the Finisher falling
and causing equipment damage or personal injury.
DANGER: Faire trs attention lors des trois tapes suivantes. Si les quatre crochets de
verrouillage du module de finition sont dcrochs de l'imprimante alors que les roulettes de droite sont encore libres, le module de finition deviendra trs instable. Le haut
du module aura tendance basculer vers la gauche alors que le bas roulera vers la
droite, risquant ainsi d'entraner sa chute, donc aussi des risques de blessure et de
dtrioration.
WARNING
WARNING
REP 12-18 Stapler Lead-In Baffle
WARNING
REP 12-20 Stacker Tray Drive Belts
WARNING
Introduction
May 2003
xx
V0.042
WARNING
ration au matriel.
WARNING
personal injury.
DANGER: Soutenir le magasin de rception lors du dmontage de son moteur puis le
descendre lentement. Sinon le magasin risque de tomber brutalement et de causer des
blessures ou dtriorations.
ADJ 12.02.02 Booklet Stapler Anvils
REP 12-21 Stacker Tray Drive Belt Clamps
WARNING
WARNING
WARNING
If the Stacker Drive Motor was not already removed, support the Stacker Tray when
removing the Stacker Drive Belt Clamps, and then lower the tray gently. Otherwise, the
Stacker Tray will drop quickly, possibly causing damage or personal injury.
DANGER: Si le moteur du magasin de rception n'est pas encore dpos, soutenir ce
magasin lors du dmontage des brides de maintien de la courroie d'entranement puis
le descendre lentement. Sinon le magasin risque de tomber brutalement et de causer
des blessures ou dtriorations.
REP 12-22 Fixed-Stapler Safety Gate
ADJ 12.02.06 Crease Roll Gate
WARNING
ADJ 12.02.07 Booklet Maker Drawer Alignment
WARNING
REP 12-23 Moving-Stapler Safety Gate
WARNING
REP 12-24 Tamper Cable
WARNING
WARNING
ADJ 12.04.02 Tri-Fold Second Crease Position
WARNING
ADJ 12.12.01 Compiler Tamping
WARNING
12. Finishing - Multi-Function Finisher

ADJ 12.02.01 Crease Blade
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Introduction
REP 12.02.02 Crease Blade
WARNING
REP 12.01.01 Main Tray Elevator Belt
WARNING
REP 12.02.03 Crease Rolls
WARNING
REP 12.01.02 Main Tray Offset Motor (M50)
WARNING
REP 12.02.04 Crease Roll Motor (M68)
WARNING
REP 12.01.03 Main Tray Offset Panel/Rails
WARNING
REP 12.02.05 Crease Roll Gears
WARNING
REP 12.01.04 Main Tray Elevator Motor (M51)
WARNING
REP 12.02.06 Crease Blade Motor (M67)
WARNING
REP 12.02.01 Booklet Maker Assembly
WARNING
Introduction
May 2003
xxii
V0.042
WARNING
REP 12.02.07 Crease Blade Motor Encoder and Sensor (S70)
WARNING
REP 12.02.13 Booklet Backstop Belt and Drive Belt
WARNING
REP 12.02.08 Booklet Compiler Flapper
WARNING
REP 12.02.15 Booklet Stapler (Rear)
WARNING
REP 12.02.09 Booklet Tamper Assembly
WARNING
REP 12.02.16 Booklet Stapler (Front)
WARNING
REP 12.02.10 Booklet Tamper Motor (M62)
WARNING
REP 12.03.01 Booklet Exit Sensor (S73)
WARNING
REP 12.02.11 Booklet Backstop Assembly
WARNING
REP 12.04.01 Tri-Folder Assembly
WARNING
REP 12.02.12 Booklet Backstop Motor (M63)
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May 2003
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Introduction
REP 12.06.01 Top Cover
WARNING
REP 12.04.02 Tri-Folder Drive Belt
WARNING
REP 12.07.01 Eject Housing Assembly
WARNING
REP 12.05.01 Compiler Tamper Assembly
WARNING
REP 12.07.02 Compiler Flapper Home Sensor (S40)
WARNING
REP 12.05.02 Compiler Backstop Assembly
WARNING
REP 12.07.03 Compiler Flappers
WARNING
REP 12.05.03 Compiler Finger Assembly
WARNING
REP 12.07.04 Eject Shaft Drive Belt
WARNING
REP 12.05.04 Compiler Tamper Motor (M44)
WARNING
Introduction
May 2003
xxiv
V0.042
WARNING
REP 12.08.01 MFF Control PWB
WARNING
REP 12.12.02 Main Stapler Position Motor (M43)
WARNING
REP 12.10.01 MFF Docking
WARNING
REP 12.12.03 Main Stapler
WARNING
REP 12.11.01 Master Lock Assembly (Upper Section)
WARNING
REP 12.13.01 Buffer/Compiler Module Assembly
WARNING
REP 12.11.02 Master Lock Assembly (Lower Section)
WARNING
REP 12.13.02 Nip 3 or 4 Drive Shaft
WARNING
REP 12.11.03 Guide Assembly (Master Lock)
WARNING
REP 12.13.03 Nip 5 Drive Shaft
WARNING
REP 12.12.01 Main Stapler Carriage Assembly
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May 2003
xxv
Introduction
REP 12.13.09 Buffer Nip Motor (M30)
WARNING
REP 12.13.04 Buffer Transport, Nip 6/7
WARNING
REP 12.13.10 Buffer Entrance Nip Motor (M31)
WARNING
WARNING
REP 12.13.11 Compiler Eject Motor (M40)
WARNING
REP 12.13.06 Nip 8 Release Solenoid (L31)
WARNING
REP 12.13.12 4 Bar Position Motor (M45)
WARNING
REP 12.13.07 Nip 9 Clutch
WARNING
REP 12.13.13 4 Bar Exit Motor (M41)
WARNING
REP 12.13.08 Paper Path Nip Motor (M110)
WARNING
Introduction
May 2003
xxvi
V0.042
WARNING
REP 12.13.14 4 Bar Assembly
WARNING
REP 12.13.21 Compiler Entrance Sensor S46
WARNING
WARNING
REP 12.13.16 Buffer Gate Solenoid (L33) or Trail Edge Clamp Solenoid (L30)
14. Scanning
REP 14-1 Image Module, Scanner Video Cable Kit
WARNING
WARNING
REP 12.13.17 Top Tray Diverter Solenoid L40
REP 14-2 Illumination Lamp Module
WARNING
WARNING
REP 12.13.18 Compile Belts
REP 14-3 Scanner Cleaning Procedure
WARNING
WARNING
REP 12.13.20 4-Bar Exit Drive Shaft
REP 14-4 Document Glass Frame
WARNING
REP 14-5 Scanner Top Frame
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May 2003
xxvii
Introduction
WARNING
ard of personal injury or machine damage.
REP 16-3 ESS DRAM SIMM's (240/255/265 Only)
WARNING
Take care not to cut yourself on the edges of the Scanner Top Frame. These edges can
be sharp -- especially the inside edges.
DANGER: Faire attention de ne pas se couper sur les bords du haut du bti du scanner,
ces bords pouvant tre tranchants, en particulier les bords intrieurs.
REP 14-6 Scanner Main Cover
WARNING
REP 16-4 Token Ring PWB or Image Processing Accelerator (IPA) PWB or 100 Mb Ethernet
PWB (240/255/265 Only)
WARNING
REP 14-8 Illumination Lamp Power Supply
WARNING
REP 16-5 PCI Bus Adapter PWB (240/255/265 Only)
WARNING
WARNING
It is extremely important to ensure that all power is removed from the machine before
servicing the Illumination Lamp Power Supply. Otherwise, severe machine damage and
possible personal injury could occur due to electrical arcing.
DANGER: Il est trs important de s'assurer que la machine est totalement hors tension
avant d'intervenir sur l'alimentation de la lampe d'exposition. Sinon, de srieux dgts
peuvent survenir la machine ainsi que des risques d'accident provoqus par des
arcages lectriques.
REP 16-6 Bykal Remote PWB (DT 65 / DP 65 Only)
WARNING
REP 14-9 Scan Carriage Motor
WARNING
REP 16-7 ESS SDRAM DIMM(s) (460/470 Only)
WARNING
16 - ESS.
REP 16-1 ESS Disk Drive
WARNING
REP 16-8 Image Processing Accelerator (IPA) PWB, 460/470
REP 16-2 ESS PWB
WARNING
The machine power must be switched off and disconnected, to avoid the electrical hazIntroduction
WARNING
May 2003
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V0.042
REP 16-9 Token Ring PWB, 460/470
WARNING
DANGER: Chaque fois que la machine devra tre dplace de la gauche vers la droite
ou inversement sur de la moquette, il est recommand de vous faire aider d'une deuxime personne. La force requise pour cette tche risque d'tre trop importante pour une
personne seule.
GP42 CSE Fuser Rebuild/Return Process for NASG
WARNING
The machine power must be switched off and the power cord disconnected, to avoid the
electrical hazard of personal injury or machine damage.
19. Video and System Control

REP 19-1 Image Disk Drive
WARNING
WARNING
Allow the Fuser to cool sufficiently to avoid burning yourself while working on the
Fuser.
14. Scanning
DANGER: Lors de toute intervention sur le four, laisser celui-ci se refroidir suffisamment pour viter des brlures.
ADJ 14-1 Image Module Set-Up
GP46 460/470 Software Upgrade Tool Usage
WARNING
WARNING
General Procedures and Information
Finishing - Multi-Function Finisher
Copier/Printer Procedures
WARNING
GP12 Moving the Machine for Service
WARNING
Whenever possible, push forward, away from the front of your body (not sideways) to
move the machine. This method uses your body's strongest muscles, minimizing the
risk of personal injury.
DANGER: Autant que possible, poussez la machine droit devant vous (et non de ct)
pour la dplacer. Cette mthode permet d'utiliser au mieux votre force musculaire et
minimisera les risques d'accident.
WARNING
Any time that the machine must be moved in the end-to-end direction (left-to-right or
right-to-left) on carpet, it is recommended that you get help from a second person. The
force required for this task can exceed the recommended maximum for a single person.
DANGER: Chaque fois que la machine devra tre dplace de la gauche vers la droite
ou inversement sur de la moquette, il est recommand de vous faire aider d'une deuxime personne. La force requise pour cette tche risque d'tre trop importante pour une
personne seule.
WARNING
Any time that the machine must be moved in the end-to-end direction (left-to-right or
right-to-left) on carpet, it is recommended that you get help from a second person. The
force required for this task can exceed the recommended maximum for a single person.
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Introduction
Introduction
May 2003
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1. Service Call Procedures

SCP-01 Introduction to Service Call Procedures ............................................................
SCP-02 Introduction to Call Flow ....................................................................................
SCP-03 Initial Actions .....................................................................................................
SCP-04 Corrective Actions .............................................................................................
SCP-05 Subsystem Checks............................................................................................
SCP-06 Every Call Activities ...........................................................................................
SCP-07 Final Actions ......................................................................................................
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1-3
1-3
1-4
1-4
1-7
1-9
1-10
May 2003
1-1
Service Call Procedures
May 2003
1-2
V0.042
SCP-01 Introduction to Service Call Procedures
SCP-02 Introduction to Call Flow
Service Call Procedures are a guide for performing any service on the Document Centre 240/
255/265/460/470 machine. The procedures are designed to be used with the Document Centre
240/255/265/460/470 Service Documentation.
Introduction to Call Flow shows the relationship of actions performed during a service call. The
functions in Call Flow correspond to service documentation sections as follows:
Initial Actions
Service Call Procedures contain the following sections:
Introduction to Call Flow

Call Flow shows the relationship of actions performed during a service call.
Gather information about the call and the machine condition from the customer and from
machine observation.
Decide which repair activities are needed.
Go to Corrective Actions to diagnose and repair the problems.
Corrective Actions
Initial Actions
Initial Actions are performed to gather information about the condition of the machine, the problem that caused the service call, and login procedures.
Diagnose and repair all problems. Use PWS Diagnostics and/or SCP-04 Corrective
Actions.
Go to Subsystem Checks.
Corrective Actions
Subsystem Checks
Corrective Actions are activities that are required to correct the problem that caused the service call and any secondary problems identified in the Initial Actions.
Perform Subsystem Checks if applicable.
Go to Every Call Activities
Every Call Activities
Subsystem Checks
Subsystem Checks are performed to classify faults that are not identified.
Perform this procedure on every service call.
Go to Final Actions
Every Call Activities
Final Actions
This section is to check the total operation of the system, reset service related files, and find
additional troubleshooting information.
Perform Final Actions to clear the service call with the customer as closed or incomplete.
Final Actions
Final Actions verify machine operation and return it to the customer. Administrative activities
are also performed in the Final Actions.
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May 2003
1-3
SCP-01, SCP-02
SCP-03 Initial Actions
SCP-04 Corrective Actions
The purpose of the Initial Actions section of Service Call Procedures is to help organize the
service call. Customer input, machine observation, and the PWS are used to gather the information about the service call and the condition of the printer/copier. Make note of symptoms,
error codes, or other information concerning the problem that the operator may provide. This
information may help identify an intermittent or unusual problem.
Perform the System Fault Analysis RAP to correct the primary problem. If secondary problems
have been identified, perform this RAP again to help identify additional corrective actions.
Primary Maintenance Activities - Are all activities related to the customers description of the
reason for the call (UM). Primary activities include performing the Corrective Action for the reason for the call and any active faults related to the reason for the call.
Ensure that the machine is connected to a proper power source
Ensure that the main power switch is on
Ensure that the machine is not in power saver mode.
If experiencing problems reloading machine software, and the software upgrade instructions dont help, go to GP28.
Secondary Maintenance Activities - Are all activities identified during the service call which are
not related to the primary activity but may lead to a future UM or negatively affect customer satisfaction. This could be a high incidence of a particular fault code in the fault history, IQ defects
noticed while running samples, or other malfunctions discovered during the service call.
Initial Actions
Check the following:
Procedure
Y
Procedure
1.
Check that the customer(s) have performed the appropriate call avoidance actions.
2.
If available, ask the operator(s) to describe or demonstrate the problem, if possible to verify the problem.
3.
a.
Try to determine the specific information regarding the job that was being run at the
time the problem occurred. Also, question the customer as to any other machine
problems that may be occurring at this time.
b.
Inspect any rejected copies/prints if available. Look for indications of excessive

paper jams, such as wrinkles in the paper, unfused images, skewed images, excessive misregistration. Try to identify the specific defects which caused the customer to
reject the copies/prints.
c.
Determine if any machine features have been disabled due to malfunctions and if
the machine is running in degraded mode.
d.
If the problem is the result of improper operator action, refer the operator to the reference manual or to other customer support documentation.
e.
Refer to the machine service log. Evaluate the recent service actions and possible
relevance to the current problem.
Connect the PWS (Portable Workstation) to the machine with the PWS Serial Cable
(GP1 ) Switch on the PWS power.
This is an On-Site service call.

N
Go to the System Fault Analysis Remote Diagnostic Procedure.
Go to the System Fault Analysis On-Site Diagnostic Procedure.
System Fault Analysis Remote Diagnostic Procedure

Perform this procedure for the primary problem. When the primary problem is resolved, enter
this procedure to identify corrective actions for secondary problems. When completed, go to
SCP-07, Final Actions.
There is an known broken part reported.
Y
N
The PWS can connect to the machine and the machine info was downloaded successfully to the PWS.
Y
N
If possible, determine if the machine is functional enough to connect remotely. The
customer complaint indicates that the machine is not booting, such as; there
is a message asking the operator to power the machine off/on, the Document
Centre banner is continuously displayed, or it repeatedly resets.
Y
N
Go to the 21-A, Remote Connection Problem RAP.
If no problem can be found, send service and restart the Call Flow.
There is a major machine malfunction, therefore Remote Diagnostics will not work.
Send service, use the System Fault Analysis On-Site Diagnostic Procedure.
If there is a problem with the PWS, check the following:

a.
Ensure the power cord is connected to the PWS.
b.
The plug ends are OK on the PWS Serial Cable.
c.
Serial port connector on the Laptop and the machine PWS port connector are OK.
d.
If the above checks are OK, refer to the 19-A, PWS Lost Communications RAP.
4.
Access the machine service log and check for any previous actions that may be relevant
to the call. Check the meters for customer printer credits. Record the printer/copier credits
in the Service Log.
5.
Enable GSNLock by entering user name and password.
There is a configuration error message window that appears when communication is established to the machine.
Y
N
Select [Faults/Counters tab , Faults]. View the Last 40 faults. Note any patterns,
especially the most recent events that might be associated with the customer complaint.
Determine whether there are unclearable messages (such as Call for Service), frequent shutdowns, or jams. The primary customer complaint is paper jams, document jams, a call for service message, and/or machine shutdowns/statuses.
Y
N
There is a UI problem.
6.
7.
8.
Go to SCP-04, Corrective Actions.

A
SCP-03, SCP-04
May 2003
1-4
C
V0.042
A
Y
N
Check the machine model and determine if the machine is connected to a
network. The machine is a LP or ST model, or a DocuTech 65, and is
connected to a network.
Y
N
Go to the Table 1 Other Problems Table.
NOTE: If 03-348 faults are appearing in the Last 40 fault list, go to that RAP first.
Go to the OF-9 Configuration Problem RAP.
Send service. If a part is broken, go to OF-10 Broken Part RAP. If the part is not covered in this
RAP, repair as necessary.
System Fault Analysis On-Site Diagnostic Procedure

Perform this procedure for the primary problem. When the primary problem is resolved, enter
this procedure to identify corrective actions for secondary problems. When completed, go to
SCP-07, Final Actions.
There is an obvious or known broken part.
Y
N
The machine Control Panel Display is alive (LEDs on, screen images visible).
Y
N
Go to the 02-C Machine Appears Off, Nothing Visible on UI RAP.
The PWS can be connected to the machine and the machine info was downloaded
successfully to the PWS.
Y
N
Go to the 19-A PWS Connection Problems RAP.
There is a configuration error message window that appears when communication is established to the machine.
Y
N
Select [Faults/Counters tab , Faults]. View the Last 40 faults. Note any patterns,
especially the most recent events that might be associated with the customer complaint.
Determine whether there are unclearable messages (such as Call for Service), frequent shutdowns, or jams. The primary customer complaint is paper jams, document jams, a call for service message, and/or machine shutdowns/statuses.
Y
N
There is a UI problem.
Y
N
Check the machine model and determine if the machine is connected to a
network. The machine is a LP or ST model, or a DocuTech 65, and is
connected to a network.
Y
N
Go to 16-A, ESS Fault Code RAP.

Go to 18-A, Network Printing Problem RAP.
Enter [ESS/Network tab , ESS Error Log]. Select [All] [Retrieve].
Check for 16-XXX Faults. 16-0XX or 16-1XX faults are occurring.
Y
N
An 03-331 or 03-332 is an indication that the ESS is not operating properly. Go to the 16-B, ESS Boot RAP.
The checks performed until now indicate no IOT problems. If the machine
is not jamming, has good image quality, and no faults are occurring but
there are problems trying to print jobs, return to the DocuTech 65 Service
Documentation and continue troubleshooting there.
The main customer complaint is related to problems when trying to

print jobs from clients.
Y
N
Choose the following which best describes the problem:
A
B
V0.042
Unable to Select Machine Feature - Go to the 02-A Unable to Select

Machine Feature at the UI Control Panel RAP.
Dark or Dim LCD on UI - Go to the 02-D Dark/Dim LCD on UI RAP.
UI is Exhibiting Strange Behavior - Go to the 02-E UI is Exhibiting Strange

Behavior RAP.
Enter PWS Diagnostics. Select [Faults/Counters tab , Faults]. Observe the Last 40
faults and associate the most likely fault with the customer complaint. Give higher
priority to faults that begin with the lowest chain number. After the most likely fault is
selected, go to Status Indicator RAPs to access the RAP for that fault.
The main customer complaint is problems when trying to print jobs

from clients.
Y
N
The machine is a DocuTech 65.
Y
N
Enter [Faults/Counters tab , Faults]. View the Last 40 faults.
Check for a 03-331 or 03-332 faults, either the most recent event or a
high number of 03-331/03-332 faults in the log. 03-331 or 03-332
faults are occurring.
Y
N
Enter [ESS/Network tab , ESS Test Jobs]. Select [Power On/
Demo] (default) [Start Job].
The Power On/Demo job completes successfully.
Y
N
Enter [ESS/Network tab , ESS Error Log]. Select [All]
[Retrieve].
Check for 16-XXX Faults. 16-0XX or 16-1XX faults are
occurring.
Y
N
Go to 16-B, ESS Boot RAP.
D
May 2003
1-5
H
SCP-04
H
The machine is a DocuTech 65.
Y
N
Enter [Faults/Counters tab , Faults]. View the Last 40 faults.
Check for 03-331 or 03-332 faults, either the most recent event or a
high number of 03-331 or 03-332 faults in the log. 03-331 or 03332 faults are occurring.
Y
N
Enter [ESS/Network tab , ESS Test Jobs]. Select [Power On/
The Power On/Demo job completes successfully.
Y
N
Enter [ESS/Network tab , ESS Error Log]. Select [All]
[Retrieve]. View the ESS Faults.
Check for 16-XXX Faults. 16-0XX or 16-1XX faults are
occurring.
Y
N
E
NOTE: If 03-348 faults are appearing in the Last 40 fault list, go to that RAP first.
Go to the OF-9 Configuration Problem RAP.
If a part is broken, go to OF-10 Broken Part RAP. If the part is not covered in this RAP, repair as
necessary.

Go to 18-A, Network Printing Problems RAP.
View the ESS Faults.
Y
N
An 03-331 or 03-332 is an indication that the ESS is not operating properly. Go to the 16-B, ESS Boot RAP.
The checks performed until now indicate no IOT problems. If the machine
is not jamming, has good image quality, and no faults are occurring but
there are problems trying to print jobs, return to the DocuTech 65 Service
Documentation and continue troubleshooting there.
Choose the following which best describes the problem:
Unable to Select Machine Feature - Go to the 02-A Unable to Select

Machine Feature at the UI Control Panel RAP.
Dark or Dim LCD on UI - Go to the 02-D Dark/Dim LCD on UI RAP.
UI is Exhibiting Strange Behavior - Go to the 02-E UI is Exhibiting Strange

Behavior RAP.
If the problem is a "Check Tray" message, go to the 08-D RAP.
Enter PWS Diagnostics. Select [Faults/Counters tab , Faults]. Observe the

Last 40 faults and associate the most likely fault with the customer complaint.
Give higher priority to faults that begin with the lowest chain number. After the
most likely fault is selected, go to Status Indicator RAPs to access the RAP for
that fault.
If no faults are occurring that seem related to the customer complaint, go to the
OF-6 Status Message RAP.
D
E
SCP-04
May 2003
1-6
V0.042
Table 2 Other Problems Table

Table 1 Other Problems Table
PROBLEM DESCRIPTION
GO TO
Image Quality Defects
IQ-1 Image Quality Entry

RAP
PROBLEM DESCRIPTION
GO TO
Image Quality Defects
IQ-1 Image Quality Entry

RAP
Print/Copy Damage
OF-2 Print Damage RAP
Document Feeder Problems
05-A Document Feeder Entry

RAP
Print/Copy Damage
OF-2 Print Damage RAP
Document Feeder Problems
05-A Document Feeder Entry

RAP
Document Damage
05-B DADF Document Damage RAP
Document Damage
Stacking Problems (OCT)
12-A Offsetting Catch Tray

Entry RAP
Stacking Problems (OCT)
12-A Offsetting Catch Tray

Entry RAP
Stacking Problems (Finisher) 12-AA Finisher Entry RAP
Stacking Problems (Finisher) 12-AA Finisher Entry RAP
Stapling Problems (Finisher) 12-AA Finisher Entry RAP

Stacking Problems (MultiFunction Finisher)
12-750 MFF Entry RAP
Stapling Problems (Finisher) 12-AA Finisher Entry RAP

Stacking Problems (MultiFunction Finisher)
Stapling Problems (MultiFunction Finisher)
Stapling Problems (MultiFunction Finisher)
Unusual Noise
OF-1 Audible Noise RAP
Unusual Noise
OF-1 Audible Noise RAP
Unclearable Status Message OF-6 Status Message RAP

with No Fault Code
Unclearable Status Message OF-6 Status Message RAP

with No Fault Code
Convenience Stapler Problem
OF-3 Convenience Stapler

RAP
Convenience Stapler Problem
OF-3 Convenience Stapler

RAP
Odor, Heat, or Dirt Problem

(40ppm)
OF-4 Odor, Heat or Dirt RAP

(40ppm)

(65 and 55ppm)

(65 and 55ppm)
Install Wizard Problems
OF-7 Install Wizard RAP
Configuration Problems
Install Wizard Problems
OF-7 Install Wizard RAP
OF-9 Configuration Problem

RAP
Configuration Problems
OF-9 Configuration Problem

RAP
Request For Off Switch Won't 01-E Request For Off Switch
Work
Does Not Switch Off Machine
RAP
Dead Copier/Printer
19-A PWS Local Communications RAP
UI Display Continuously
Changes from a Close the
Front Door back to normal
status screen
03-809 IIOC Module W8A1

Failed the IIOC Controller
Test RAP
Request For Off Switch Won't 01-E Request For Off Switch
Work
Does Not Switch Off Machine
RAP
Dead Copier/Printer
19-A PWS Local Communications RAP
UI Display Continuously
Changes from a Close the
Front Door back to normal
status screen
03-809 IIOC Module W8A1

Failed the IIOC Controller
Test RAP
Network Scan Filing or Scan 18-L Network Scanning/Fax

to File IQ Problems
RAP
Network Scanning, Filing, or 18-L Network Scanning/Fax

Scan to File Scrogged Image RAP
Problems
LAN Fax Problems
LAN Fax Problems
SCP-05 Subsystem Checks
18-L Network Scanning/Fax

RAP
V0.042
May 2003
1-7
18-L Network Scanning/Fax

RAP
SCP-04, SCP-05
v.
IIT Subsystem Checkout

Use this checkout when experiencing a high number of various DADF and Scanner shutdowns.
1.
Inspect the Document Glass (CVT and manual), clean if needed. If the underside of the
glass is contaminated, perform the RIS Cleaning Procedure REP 14-3.
2.
Observe the Lamp Power Supply. The 3 right hand LEDs on the Lamp Power supply
should be on. If any of the 3 LEDs are not on, go to 14-A Illumination Checkout RAP.
3.
Check the Document Glass Pad PL 2.1A Item 8, for contamination or damage. Clean or
replace as required.
4.
Check DADF Document Timing.

a.
Load 10 fresh sheets of 8.5 X 11 inch (A4), paper in the Document Input Tray in portrait orientation (LEF).
b.
Ensure that the Document Input Tray Side Guides are touching the paper and that
the paper is inserted fully to the stops (to the right) of the Document Input Tray.
c.
In DADF Document Timing, select [IIT tab , DADF Document Timing Test].
d.
Check the test results for Lead Edge At Q1. If the test results indicate all the feed
times are between High and Jam Time, do the following:
e.
i.
Check the DADF Feeder Cartridge PL 2.2 Item 4, for wear or contamination.
ii.
In DADF Clutch / Solenoid Tests, select [Feed Clutch and Nudger Solenoid],
then [Start Test]. Enter [IIT tab , DADF Clutch / Solenoid Tests]. If the Feed
Clutch and Nudger Solenoid test fails, replace the DADF Feeder Assembly PL
2.2 Item 2
g.
5.
Check the test results for Time Over Q4. If the test results indicate all the times are
between High and Jam Time, do the following
i.
Ensure the 3-Arm Sheet Separators are in place and move freely without binding. Replace the Left CVT Baffle PL 2.4 Item 5 if necessary.
ii.
Check the Document Output Tray for damage, obstructions, or contamination.

Replace the Document Glass Cover/Document Output Tray PL 2.1A Item 7 if
necessary.
In NVM Read/Write, check the following locations listed in Table 1. Ensure the NVM values are within the ranges listed. Enter [NVM tab , NVM Read/Write].
If the values are not within range, perform ADJ 14-2, IIT Registration and Magnification.
times are between High and Jam Time, do the following
i.
f.
h.
In DADF Clutch / Solenoid Tests, select [Exit Clutch and Inverter Clutch], then
[Start Test].Enter [IIT tab , DADF Clutch / Solenoid Tests]. If the Exit Clutch and
Inverter Clutch test fails, replace the DADF Exit Shaft PL 2.2 Item 9.
Ensure the Document Feeder Top Cover is closing correctly.
ii.
Check the Take-away Roll and the Idler for contamination.
iii.
In DADF Clutch / Solenoid Tests, select [DADF Registration Gate Solenoid],

then [Start Test]. Enter [IIT tab , DADF Clutch / Solenoid Tests]. If the DADF
Registration Gate Solenoid test fails, replace the DADF Registration Deskew
Assembly PL 2.1B Item 6.
i.
Ensure the Right CVT Baffle is closing correctly and the foam pads are present
and are not damaged.
ii.
Ensure the Idler Roll moves freely and the tension spring is in place. Replace
the Right CVT Baffle PL 2.4 Item 6 if required.
i.
Ensure the CVT Ski, are in place and move freely without binding.
ii.
Ensure the CVT Drive ON Glass Roll moves freely up and down without binding.
iii.
Replace the Part of DADF Assembly PL 2.4, if necessary.
iv.
Ensure the Left CVT Baffle is closing correctly and the foam pads are present
and are not damaged. Ensure the Idler Rolls move freely and the tension
springs are in place. Replace the Left CVT Baffle PL 2.4 Item 5 if necessary.
SCP-05
May 2003
1-8
V0.042
Table 1 IIT NVM Locations and Values

Service
Name (ID)
Value
Scan Service
CVT Velocity Corr (40)
-100 and 100
Scan Service
Carriage Velocity Corr (41)
-100 and 100
Image Processing
CVT Center (4)
2280 and 2680
Image Processing
CVT Slow Scan Reg (5)
559 and 985
Image Processing
Platen Fast Scan Reg (6)
75 and 200
Image Processing
Platen Slow Scan Reg (7)
50 and 200
SCP-06 Every Call Activities

This procedure should be performed on every service call.
Procedure
Clean the Photoreceptor Drive Module backer bars. REP 09-11.
On the UI, select [Machine Status], [Supplies]. Check the projected End of Life for the
Paper Feed Roll Cartridges. If any are less than 30 days, replace them (this can vary
depending on customer machine usage). If any are replaced, reset the counter using
GP6, Life Counter Reset.
Also check the projected End of Life for the Xerographic and Fuser CRUs. Replace or
rebuild either CRU if within 20K of End of Life. For the Fuser CRU go to (GP42 CSE
Fuser Rebuild/Return Process for NASG). If any are replaced, reset the counter using
GP6, Life Counter Reset.
Check if the filters need to be replaced. In Diagnostic Navigator, enter [Faults/Counters

tab , Counters Display], select [Diagnostic Data]. If the value is over 2 million, replace the
filters. Use the NOHAD Filter Kit PL 9.1 Item 1.
If the filters are replaced, remember to reset the NOHAD Filter Life Counter. Enter [Faults/
Counters tab , Counters Display], select [Diagnostic Data]. Click on the line that contains
the NOHAD Filter Life Counter. Select [Reset] [Yes].
Perform REP 05-1, DADF Cleaning Procedure.
Clean the Platen Glass with Lens and Mirror Cleaner, 43P81.
Check and advise Customer on supplies and CRU inventory levels.
Determine if the customer is having difficulty opening any of the IOT Paper Trays.
Go to OF-10 Broken Part RAP to resolve this problem.
V0.042
May 2003
1-9
SCP-05, SCP-06
SCP-07 Final Actions

The purpose of Final Actions is to provide a checklist of actions that must be performed at the
end of every service call and to identify any actions necessary to clear the call with the customer.
Procedure
1.
Verify that the repairs have been successful. Be sure to exercise the machine in the correct mode(s) for a thorough verification of the repairs.
2.
Perform the SCP-06, Every Call Activities if you have not already done so.
3.
Record the appropriate Billing Meters for your OPCO.
4.
Notify the customer that the machine has been repaired. Leave an image quality sample
of the Customer Letter, if applicable.
5.
If applicable, make a note of the printer credits and enter the credit information on the
Credit Labels or Meter Cards.
6.
Complete the service log.
7.
8.
Ensure that the MRD is in the floppy drive on the PWS, so that the NVM data will be
saved. Answer Yes to the prompt "Do you want to save NVM data?".
9.
When the Close Machine Communications window appears, select [Exit and Clear
Counters].
NOTE: If the Call is incomplete, select [Exit Diagnostics].
10. If the Start Print button was activated during diagnostics, when the message appears "Do
you wish to reset the machine?", select [Yes].
11. Close Case Server (releases machine from Diagnostic mode).
12. Final Check. Ensure that the printer and the service area are clean before leaving.
13. Close out the service call.
SCP-07
May 2003
1-10
V0.042
2. Status Indicator RAPs

1. Standby Power
01-301 Front Door Interlock Fault ...................................................................................
01-305 HCF or Bypass Top Cover Opened In Print........................................................
01-310 36 VDC Interlock Opened In Print.......................................................................
01-705/710 IOT Overheat Fault ......................................................................................
01-A DC Voltage Checkout Procedure ...........................................................................
01-B The Machine Cannot Be Switched On ...................................................................
01-C No 36 VDC Output From LVPS..............................................................................
01-D LVPS Outputs Incorrect With Distribution PWB Connected ...................................
01-E The Machine Cannot Be Switched Off With The (White) Power On/Off Switch .....
01-F Unable to Clear the Message: "Either a tray 6 cover or an output tray door is open"
01-G The Machine Cannot Be Switched Off With The (Red) Instant Off Switch ............
2-7
2-9
2-9
2-11
2-12
2-15
2-17
2-21
2-23
2-25
2-25
2. User Interface
02-300/302/304/306/308 UI Failures..............................................................................
02-309/364 UI Power On Self Test Failure ....................................................................
02-312/704 UI Application Software Checksum Incorrect...............................................
02-320/380 UI Communication Failures..........................................................................
02-390/391 UI Communication Failures..........................................................................
02-705/706 UI Diagnostic Test Failure............................................................................
02-711 RAM Space Fault ................................................................................................
02-A Unable to Select A Machine Feature At The User Interface...................................
02-B All LEDs On The User Interface Are Blinking .........................................................
02-C Nothing Is Visible On The User Interface (Dark Display) .......................................
02-D The User Interface Is Too Bright Or Too Dim.........................................................
02-E The User Interface is Exhibiting Strange Behavior .................................................
02-F The UI Continuously Displays the Boot-Up Screen ................................................
02-G The UI Continuously Displays A PO/PO Message.................................................
2-27
2-27
2-28
2-28
2-29
2-29
2-30
2-30
2-31
2-32
2-32
2-33
2-37
2-40
2-41
2-41

03-301/305 SCAM PWB Communication Fault ..............................................................
03-311 ROS Communication Fault .................................................................................
03-312/313/314 Finisher Communication Fault ..............................................................
03-321 SCVM Communication Fault...............................................................................
03-322 SCVM Download Failure.....................................................................................
03-323 SCVM Communication Failure............................................................................
03-325 The Wall Clock Does Not Increment ...................................................................
03-331 ESS Communication Fault..................................................................................
03-332 ESS Communication Fault..................................................................................
03-335 Unexpected Finisher PWB Reset .......................................................................
03-336 SCAM PWB Reset Detected...............................................................................
03-337 ROS Control Module Reset Detected .................................................................
03-338 Main Control PWB Reset Detected.....................................................................
03-340 IIOC Bus 0 Communication Fault .......................................................................
V0.042
2-43
2-45
2-48
2-50
2-50
2-51
2-51
2-52
2-52
2-53
2-53
2-54
2-54
2-57
2-60
2-62
03-343 IIOC Bus 4 Communication Fault........................................................................

03-345 All IIOC Buses Communication Fault..................................................................
03-346 Control Panel Communication Fault ...................................................................
03-347 User Interface (UI) Communication Fault............................................................
03-348 Main Control PWB Fault......................................................................................
03-349 SCSI PWB Communication Fault........................................................................
03-352 Autosegmentation PWB Fault .............................................................................
03-354 Scanner Communication Fault............................................................................
03-355 MCB POST Failure .............................................................................................
03-360 EP-SV Communication Fault ..............................................................................
03-370/371/372/374/375 Control Data Error ..................................................................
03-377 MFF Interface Data Error ....................................................................................
03-380 Distribution PWB Fault ........................................................................................
03-381 MFF Not Responding ..........................................................................................
03-382 MFF RS-422 Connection Fault ...........................................................................
03-383 MFF RS-422 Communication Fault.....................................................................
03-390 Software Upgrade Automation Failed .................................................................
03-777 Power Lost Detected...........................................................................................
03-800 IIOC Bus 0 Failed The IIOC Controller Test........................................................
03-801 IIOC Module W8A2 Failed The IIOC Controller Test ..........................................
03-803 IIOC Module A7A1 Failed The IIOC Controller Test ...........................................
03-808 IIOC Module W25A1 Failed The IIOC Controller Test ........................................
03-831 An HCF Circuit Failed The IIOC Controller Test .................................................
03-832 A Bypass Tray Or HCF Circuit Failed The IIOC Controller Test .........................
03-837 An HCF Circuit Failed The IIOC Controller Test .................................................
May 2003
2-1
2-64
2-65
2-66
2-66
2-70
2-71
2-71
2-72
2-72
2-73
2-73
2-74
2-77
2-77
2-79
2-82
2-85
2-87
2-87
2-88
2-90
2-90
2-91
2-91
2-92
2-94
2-96
2-98
2-100
2-102
2-104
2-106
2-106
2-107
2-107
2-108
2-108
2-110
2-111
2-112
2-114
2-116
2-118
2-120
2-122
2-124
2-124
03-A Common SCB Circuit RAP .....................................................................................
03-B Common CRUM Communication Failure RAP .......................................................
03-C IIOC Bus 0 Module Pin Configuration ....................................................................
03-D IIOC Bus 1 Module Pin Configuration ....................................................................
03-E IIOC Bus 2 Module Pin Configuration.....................................................................
03-F Continuous Resets RAP .........................................................................................
03-G Main Control PWB RAP .........................................................................................
03-H Foreign Accessory RAP .........................................................................................
03-J Checksum Error RAP ..............................................................................................
03-K Atlanta Gold And Atlanta Platinum Main Control PWBs .........................................
03-L IOT Wont Boot RAP ...............................................................................................
2-125
2-127
2-129
2-131
2-132
2-132
2-133
2-134
2-138
2-140
2-140
2-141
2-143
2-150
2-154
2-161
2-164
2-171
05-100 Document LE Late to Input Tray Exit Sensor RAP .............................................
05-102 Document LE Late to the DADF Registration Gate Sensor RAP........................
05-103 Document TE Late to DADF Registration Gate Sensor RAP .............................
05-104 Document LE Late to CVT Start of Scan Sensor RAP .......................................
05-106 Document LE Late to DADF Exit/Invert Sensor RAP..........................................
05-107 Document TE Late to DADF Exit/Invert Sensor RAP .........................................
05-108 Document LE Late to Input Tray Exit Sensor (Pass 2 or 3) RAP........................
05-109 Document LE Late to Input Tray Exit Sensor (Pass 2 or 3) RAP........................
05-110 Document LE Late to DADF Registration Gate Sensor (Pass 2 or 3) RAP ........
05-310 DADF Raised During Document Feed RAP .......................................................
05-325 DADF Cover Opened During Document Feed RAP ...........................................
05-330 DADF IIOC Internal Turnaround Failure RAP.....................................................
05-331 DADF IIOC Chain RAP .......................................................................................
05-340 DADF Nudger Solenoid IIOC Failure RAP..........................................................
05-345 DADF Feed Clutch IIOC Failure RAP .................................................................
05-350 DADF Registration Gate Solenoid IIOC Failure RAP .........................................
05-355 DADF Exit Clutch IIOC Failure RAP ...................................................................
05-360 DADF Inverter Clutch IIOC Failure RAP .............................................................
05-365/375 DADF Feed Motor Fault RAP ......................................................................
05-370/380 CVT Motor Fault RAP ..................................................................................
05-A DADF Fault Entry RAP ...........................................................................................
05-B DADF Document Damage RAP .............................................................................
05-C DADF Misfeed RAP................................................................................................
05-D DADF Image Distortion RAP ..................................................................................
05-E DADF Document Size Sensing RAP ......................................................................
05-F DADF Registration and Skew RAP.........................................................................
05-G Document Output Stacking RAP............................................................................
05-H DADF Unclearable Status RAP..............................................................................
05-J DADF Interlock Switch RAP ....................................................................................
05-K Document Feeder Top Cover Sensor RAP ............................................................
2-226
2-227
2-230
6. ROS Imaging
06-310/311/312/313/314/315 Polygon Motor Faults .......................................................
06-320/330 Laser Not On Fault.......................................................................................
06-340 No Start of Scan Fault.........................................................................................
06-341 Start of Scan Not Within Window Fault ...............................................................
06-350/360/370 Laser Control Fault................................................................................
06-380 ROS Interlock Fault.............................................................................................
06-385 ROS Configuration Mis-match Fault ...................................................................
2-233
2-237
2-242
2-242
2-243
2-246
2-249
7. Paper Supply

04-201 Developer Drive Motor Fault RAP.......................................................................
04-202 Developer Drive Motor Load Fault RAP..............................................................
04-205 Photoreceptor Drive Motor Fault RAP ................................................................
04-206 P/R Drive Motor Load Fault RAP ........................................................................
04-210 Fuser Drive Motor Fault RAP..............................................................................
04-211 Fuser Drive Motor Load Fault RAP .....................................................................
05-L DADF Noise RAP....................................................................................................

05-M Intermittent Document Jam RAP............................................................................
05-N DADF CVT Motor Ground Check ...........................................................................
2-177
2-179
2-180
2-181
2-185
2-187
2-188
2-189
2-189
2-190
2-191
2-192
2-192
2-195
2-197
2-199
2-200
2-203
2-205
2-207
2-211
2-212
2-212
2-214
2-216
2-219
2-220
2-220
2-224
2-225
07-202.01/202.02/202.03/202.04 Tray 1 through 4 Elevator Fault RAP .........................

07-202.06 HCF (Tray 6) Elevator Fault ...........................................................................
07-700 Paper Tray Fault Entry RAP................................................................................
07-A Tray 6 (HCF) Will Not Go Down .............................................................................
07-B Paper Size Sensing RAP........................................................................................
07-C An IOT Paper Tray Will Not Fully Close .................................................................
07-D Tray 6 (HCF) Will Not Raise ...................................................................................
07-E IOT Paper Heater RAP ...........................................................................................
07-F HCF Paper Heater RAP..........................................................................................
2-251
2-254
2-254
2-255
2-256
2-257
2-257
2-259
2-261
08-101.01/.02/.03/.04 IOT Paper Tray Misfeed...............................................................
08-101.05 Tray 5 (Bypass Tray) Misfeed ........................................................................
08-101.06 Tray 6 (HCF) Misfeed.....................................................................................
08-105.01/.02/.03/.04 IOT Paper Tray Jam.....................................................................
08-105.05 Tray 5 (Bypass Tray) Jam..............................................................................
08-105.06 Tray 6 (HCF) Jam ..........................................................................................
08-110 Registration Transport Jam.................................................................................
08-701 Misfeed From Any Paper Tray ............................................................................
08-705 Modified Feed Timing Boundary .........................................................................
08-706 False TE transition of the Wait Station Sensor ...................................................
08-710 Vertical Transport Entrance Jam From Any Paper Tray .....................................
08-A Lead Edge Misregistration RAP..............................................................................
08-B Top Edge Misregistration RAP ...............................................................................
08-C Skewed Image RAP ...............................................................................................
08-D "Check Tray X" Message RAP ...............................................................................
08-E Paper Feed Drives Plate Jumper RAP ...................................................................
2-263
2-266
2-268
2-269
2-271
2-273
2-274
2-277
2-281
2-284
2-284
2-285
2-285
2-286
2-286
2-290
2-292
2-293
9. Marking
09-210 No Photoreceptor Seam Detected RAP..............................................................
09-215 Multiple Photoreceptor Seams Detected RAP ....................................................
09-220 No Machine Clock on Main Control PWB ...........................................................
09-300 BTAC Offset Voltage Low Fault ..........................................................................
09-302 BTAC Offset Voltage High Fault .........................................................................
09-304 BTAC Loop Counter Fault...................................................................................
09-306 BTAC Max Read Fault ........................................................................................
09-310 No Patch RAP .....................................................................................................
May 2003
2-2
2-295
2-297
2-298
2-303
2-306
2-309
2-312
2-313
V0.042
09-312 All Process Control Patches are Dark.................................................................

09-314 0% Patch Low Fault ............................................................................................
09-316 0% Patch High Fault ...........................................................................................
09-318 Light 87.5% Patch Fault......................................................................................
09-320 Dark 87.5% Patch Fault ......................................................................................
09-324 Background Threshold Exceeded During Run....................................................
09-330 Toner Concentration is Low ................................................................................
09-332 Toner Concentration is High ...............................................................................
09-334 Toner Control Patch is Low.................................................................................
09-336 Toner Control Patch is High................................................................................
09-338 Electrostatic Setup Convergence Failure............................................................
09-344 Failure to Converge in Material Conditioning RAP .............................................
09-350 Xerographic Module Open RAP..........................................................................
09-351 Invalid Xerographic Module Count ......................................................................
09-352 Wrong Xerographic Module Fault .......................................................................
09-353 Incorrect Xerographic Module Configuration ......................................................
09-354 No Xerographic Module CRUM Fault .................................................................
09-355 Cant Communicate with CRUM Fault ................................................................
09-358 Developer Collector Full RAP .............................................................................
09-360/362 Out of Toner RAP ........................................................................................
09-370 Transfer Power Fault RAP ..................................................................................
09-372 Detack Power Fault RAP ....................................................................................
09-374 Charge Power Fault RAP....................................................................................
09-376 Developer Power Fault RAP ...............................................................................
09-380 Transfer Arc Fault RAP .......................................................................................
09-382 Detack Arc Fault RAP .........................................................................................
09-384 Charge Pin Arc Fault RAP ..................................................................................
09-386 Development HVPS Arc Fault RAP ....................................................................
09-870/880 Toner Bottle Empty RAP..............................................................................
09-A Charge HVPS Checkout RAP ................................................................................
09-B Transfer HVPS Checkout RAP ...............................................................................
09-C Toner Dispenser Checkout RAP ............................................................................
09-D +36 VDC Checkout RAP ........................................................................................
09-E Detack HVPS Checkout RAP .................................................................................
09-F Xerographic Electrical Noise Checkout ..................................................................
09-G Developer HVPS Checkout RAP ...........................................................................
09-H Developer Collector Checkout RAP .......................................................................
09-J Xerographic Module Checkout RAP .......................................................................
09-K Developer Housing Checkout RAP ........................................................................
09-L ROS Checkout RAP................................................................................................
2-316
2-319
2-320
2-320
2-325
2-329
2-330
2-331
2-332
2-333
2-334
2-337
2-338
2-340
2-340
2-341
2-341
2-343
2-345
2-347
2-349
2-353
2-357
2-361
2-365
2-369
2-373
2-376
2-381
2-381
2-386
2-390
2-392
2-395
2-399
2-400
2-405
2-406
2-410
2-411

10-100 PreFuser Transport Jam .....................................................................................
10-101 Fuser Exit Jam ....................................................................................................
10-105 Inverter Entrance Jam.........................................................................................
10-115 Inverter Exit Jam .................................................................................................
10-130 Inverter Jam ........................................................................................................
10-300 Fuser Thermistor Circuit Open............................................................................
V0.042
2-413
2-415
2-417
2-418
2-423
2-425
2-426
2-428
2-429
2-429
10-301 Fuser Failed To Warm Up...................................................................................

10-302 Fuser Undertemperature Fault............................................................................
10-303 Fuser Overtemperature Fault..............................................................................
10-350 Fuser Module Connector Open...........................................................................
10-351 Invalid Fuser Module Count ................................................................................
10-352 Wrong Fuser Module Fault..................................................................................
10-353 Incorrect Fuser Module Configuration.................................................................
10-354 No Fuser Module CRUM Fault............................................................................
10-355 No Fuser Module CRUM Fault............................................................................
10-357/358 Decurler Configuration Mismatch.................................................................
10-705 Enabled Decurler Home Fault.............................................................................
10-706 Exit Decurler Fault...............................................................................................
10-720 Duplex TEER Communication Fault ...................................................................
10-722 / 724 / 726 / 730 / 732 Duplex TEER Calibration Failure ....................................
10-728 / 734 Duplex TEER Faults During Read .............................................................
10-A Decurler Checkout Procedure ................................................................................
2-431
2-438
2-439
2-445
2-447
2-448
2-448
2-449
2-451
2-452
2-453
2-453
2-458
2-461
2-462
2-462
12A. Offsetting Catch Tray

12-101.60 (12-101.00) LE Late to the OCT Tray Full Sensor RAP.................................
12-213.60 (12-213.00) OCT Offset Motor Fault RAP......................................................
12-A OCT Fault Entry RAP .............................................................................................
12-B OCT Print Damage RAP.........................................................................................
12-C OCT No Offset RAP ...............................................................................................
12-D OCT Stacking RAP.................................................................................................
12-E OCT Jam RAP ........................................................................................................
12-F OCT Noise RAP......................................................................................................
12-G OCT Tray Status RAP ............................................................................................
12-H OCT Static Checkout RAP .....................................................................................
12-J Output Device Configuration for Third Party Service ..............................................
2-467
2-469
2-471
2-471
2-472
2-472
2-474
2-475
2-476
2-477
2-477
12B. Disk Finisher

12-100 Unexpected Sheet at the Finisher Entrance Sensor RAP...................................
12-101 LE Late to the Finisher Entrance Sensor RAP....................................................
12-102 TE Late to the Finisher Entrance Sensor RAP....................................................
12-105 Unexpected Sheet at the Top Tray Paper Path Sensor RAP .............................
12-106 LE Late to the Top Tray Paper Path Sensor RAP...............................................
12-107 TE Late to the Top Tray Paper Path Sensor RAP ..............................................
12-108 Disk Home Fault RAP .........................................................................................
12-200 Stacker Tray Raise Fault RAP ............................................................................
12-201 Stacker Tray Upper Limit Fault RAP ...................................................................
12-202 Stacker Tray Lower Fault RAP............................................................................
12-203 Stacker Tray Offset Fault RAP............................................................................
12-204 Tamper Home Fault RAP....................................................................................
12-205.01 Moving Stapler Interlock Switch Deactuation Fault RAP ...............................
12-205.02 Fixed Stapler Interlock Switch Deactuation Fault RAP ..................................
12-206 Stapler Position Home Fault RAP .......................................................................
12-207.01 Moving Stapler Home Fault RAP ...................................................................
12-207.02 Fixed Stapler Home Fault RAP ......................................................................
12-208.01 Moving Stapler Interlock Switch Fault RAP....................................................
12-208.02 Fixed Stapler Interlock Switch fault RAP........................................................
12-209.01 Moving Stapler Clinch Motor Fault RAP.........................................................
12-209.02 Fixed Stapler Clinch Motor Fault RAP ...........................................................
May 2003
2-3
2-479
2-480
2-483
2-486
2-489
2-493
2-496
2-499
2-502
2-504
2-507
2-508
2-510
2-512
2-514
2-516
2-519
2-522
2-526
2-530
2-535
12-210 Stacker Tray Lower Limit Fault RAP ...................................................................

12-213 Top Tray Offset Home Fault RAP .......................................................................
12-214 Stacker Tray Offset Fault RAP Smart Tray .......................................................
12-220 Set Eject Cycle Fault RAP ..................................................................................
12-222 Stack Height Fault RAP ......................................................................................
12-307 Stapler Access Door Interlock Switch RAP.........................................................
12-309 Finisher Interlock Switch RAP.............................................................................
12-310 Stacker Tray Offset Motor Fault RAP .................................................................
12-315 Stacker Tray Offset Motor Fault RAP Smart Tray .............................................
12-323 Finisher Configuration Error RAP .......................................................................
12-700 Finisher Configuration Error RAP .......................................................................
12-AA Finisher Fault Entry RAP......................................................................................
12-AB Finisher Print Damage RAP .................................................................................
12-AC Finisher Misregistration RAP ...............................................................................
12-AD Finisher Moving Stapler RAP ...............................................................................
12-AE Finisher Fixed Stapler RAP..................................................................................
12-AF Finisher Noise RAP ..............................................................................................
12-AG Finisher Unclearable Status RAP ........................................................................
12-AH Stacker Tray Status RAP .....................................................................................
12-AJ Finisher Top Tray Status RAP ..............................................................................
12-AK Finisher Moving Stapler Status RAP ....................................................................
12-AL Fixed Stapler Status RAP .....................................................................................
12-AM Pause Resume Switch RAP ................................................................................
12-AN Finisher Top Tray Not Offsetting RAP .................................................................
12-AP Finisher Static Checkout RAP..............................................................................
12-AR Transport Drive Motor Checkout..........................................................................
12-AS Stacker Tray Not Offsetting RAP .........................................................................
12-AT Stacker Tray Upper Limit Switch RAP..................................................................
12-AU Paper Cooling Fan Checkout ...............................................................................
2-540
2-542
2-544
2-544
2-547
2-549
2-551
2-553
2-556
2-559
2-559
2-560
2-562
2-563
2-571
2-574
2-576
2-579
2-580
2-583
2-584
2-587
2-589
2-591
2-591
2-594
2-597
2-597
2-599
14. Scanning
14-300 Scanner Calibration Failed..................................................................................
14-312 Scanner Configuration Mismatch........................................................................
14-313 Scanner AGC Loop Not Settled ..........................................................................
14-314 / 315 / 316 / 317 / 318 / 319 / 320 Scanner Calibration Failed............................
14-325 Start of Scan Not Sensed ...................................................................................
14-335 Scan Carriage Encoder Not Sensed...................................................................
14-340 No Motor Done Signal.........................................................................................
14-345/347 12 VDC Not Sensed.....................................................................................
14-350 Scanner Video Cable Failure ..............................................................................
14-700 Illumination Lamp Output Is Too Low .................................................................
14-703/704 Scanner Calibration Failed...........................................................................
14-705 / 706 / 714 / 715 Scanner Calibration Failed.......................................................
14-710 NVM Value Out Of Range (High or Low) ............................................................
14-716 Scanner Lamp Stability Fault ..............................................................................
14-A Illumination Checkout RAP .....................................................................................
14-B Scanner Noise RAP................................................................................................
14-C Scanner Loop Faults RAP......................................................................................
14-D Illumination Lamp Filaments Not Lit RAP ...............................................................
2-603
2-605
2-605
2-606
2-606
2-608
2-611
2-611
2-612
2-612
2-613
2-613
2-615
2-616
2-616
2-617
2-619
2-622
2-626
2-627
2-629
16. ESS
16-A ESS Fault Codes RAP............................................................................................
16-B ESS Boot RAP........................................................................................................
16-C ESS Software Verification and Repair RAP ...........................................................
16-781.19 Memory Error for Network Scanning RAP ....................................................
16-785.19 IPA PWB Missing or Defective RAP .............................................................
16-786.19 IPA PWB Missing or Defective RAP .............................................................
16-787.19 Memory Error for LAN FAX RAP...................................................................
2-631
2-645
2-655
2-655
2-656
2-656
2-657
18. Network Printing

18-A Network Printing Problems Entry RAP ...................................................................
18-B Novell NetWare Checkout RAP ..............................................................................
18-C TCP/IP Checkout RAP ...........................................................................................
18-D Appletalk Checkout RAP ........................................................................................
18-E NETBIOS Checkout RAP .......................................................................................
18-F Banyan Vines Network Troubleshooting RAP ........................................................
18-G Problem Printing Job RAP......................................................................................
18-H Network Hardware Problems RAP .........................................................................
18-K Job Prints Incorrectly RAP......................................................................................
18-L Network Scanning/Fax Problems RAP ...................................................................
2-659
2-664
2-666
2-668
2-669
2-670
2-671
2-672
2-674
2-675

19-300 Image Disk Read Failure RAP ...........................................................................
19-301 Image Disk Write Failure RAP ...........................................................................
19-302 Image Disk Data Error RAP ...............................................................................
19-303 Image Disk Format Failure RAP ........................................................................
19-310 Can't Determine Image Disk Capacity RAP ........................................................
19-401/402/403 Out of Memory Resources ....................................................................
19-404 Video Compressor DVMA Timeout ....................................................................
19-405 Video Decompresser DVMA Timeout .................................................................
19-406 Video Loopback DVMA Timeout .........................................................................
19-407 Video Middle Function Input DVMA Timeout ......................................................
19-408 Video Middle Function Output DVMA Timeout ...................................................
19-409 Video Job Integrity Fault RAP .............................................................................
19-410 IPS Not Responding To Set Up Request ............................................................
19-750 EPC Memory Configuration Mismatch RAP........................................................
19-751 IPS1 Option Card Configuration Mismatch RAP.................................................
19-752 Image Rotation SIMMs Configuration Mismatch RAP ........................................
19-753 Platen Cover Configuration Mismatch RAP ........................................................
19-754 Image Disk Configuration Mismatch RAP ...........................................................
19-A PWS Lost Communication RAP (Direct Connection) .............................................
2-679
2-684
2-689
2-694
2-697
2-701
2-703
2-706
2-707
2-707
2-708
2-708
2-709
2-709
2-710
2-710
2-711
2-711
2-712
21. RDT
21-300 Main Controller PWB Cannot Communicate with Modem RAP ..........................
21-304 No RDT Dial Tone at Modem RAP ....................................................................
21-308 Modem Blacklist Fault RAP.................................................................................
21-708 Host Modem Doesn't Answer RAP ....................................................................
21-712 No Carrier After Answer RAP..............................................................................
21-716/720 Problems After Connect RAP.......................................................................
21-724 Lost Session After Login RAP.............................................................................
21-728 Modem Failed to Disconnect RAP .....................................................................
21-732 Host Cancellation RAP.......................................................................................
May 2003
2-4
2-713
2-713
2-714
2-714
2-715
2-715
2-716
2-716
2-717
V0.042
21-736 Protocol Transmission Failure RAP ....................................................................

21-740 Protocol Reception Failure RAP .........................................................................
2-717
2-718
22 . System Faults
22-300.04 Scheduling Table Missing RAP......................................................................
22-300.05 Image Complete Not Received RAP..............................................................
22-300.10 Decompresser End of Record RAP ...............................................................
22-300.16 Real Time Clock Overflow RAP .....................................................................
22-301.04 Initial State Scheduling Error RAP .................................................................
22-301.05 Scan Resources Not Available RAP ..............................................................
22-302.04 Current State Scheduling Error RAP .............................................................
22-303.04 Shifted Proposal Invalid RAP .........................................................................
22-303.05 Document Too Large RAP .............................................................................
22-304.04 Schedule Missing RAP ..................................................................................
22-305.04 Dead Cycle Error RAP ...................................................................................
22-306.04 Rejection Error RAP.......................................................................................
22-307.04 Reschedule Error RAP...................................................................................
22-308.04 Execution State Error RAP ............................................................................
22-309.04 No Except Timeout Error RAP ......................................................................
22-310.04 Compound Service Image Sequence Error RAP ..........................................
22-311.04 Proposal Response Timeout Error RAP ........................................................
22-312.04 Sync Information Error RAP...........................................................................
22-313.04 Missing Sync Error RAP ................................................................................
22-314.04 Module Registration Error RAP......................................................................
22-315.04 Module Completion Fault RAP.......................................................................
22-316.04 Job Requires Paper Tray That Does Not Exist RAP......................................
22-317.04 Job Requires IOT Capability That Does Not Exist RAP.................................
22-318.04 Job Requires Finisher Capability That Does Not Exist RAP ..........................
22-319.04 IOT Cycle Down/Cycle Up Loop Detected RAP ............................................
22-330.xx List Jobs Request Timed Out .........................................................................
22-700.04 Module Timeout Error RAP............................................................................
22-701.04 Module Completion Error RAP.......................................................................
22-750.04 Output Device Configuration Error RAP ........................................................
22-750.17 Accessory Card Configuration Error RAP ......................................................
22-751.04 Bypass Tray (SMH) or HCF Configuration Error RAP ...................................
22-751.17 ESS Configuration Error RAP ........................................................................
22-752.17 EP-SV / EP-Lyzer Configuration Error RAP...................................................
22-754.17 UI Configuration Error RAP............................................................................
22-755.17 RDT Configuration Error RAP........................................................................
22-756.17 Scanner Configuration Error RAP ..................................................................
22-757.04 Mark Service Configuration Problem RAP.....................................................
2-719
2-719
2-722
2-723
2-723
2-724
2-724
2-725
2-725
2-727
2-727
2-727
2-727
2-728
2-728
2-729
2-729
2-730
2-730
2-731
2-731
2-732
2-732
2-733
2-733
2-734
2-734
2-735
2-735
2-736
2-736
2-737
2-737
2-738
2-738
2-739
2-739
OF-6D 06-5XX and 07-5XX Status Message RAP .........................................................

OF-6E 08-5XX Status Message RAP..............................................................................
OF-6F 09-5XX (Xerographic) Status Message RAP .......................................................
OF-6G 10-5XX Status Message RAP .............................................................................
OF-6H 12-5XX Status Message RAP .............................................................................
OF-6J 14-5XX (Scanner) Status Message RAP .............................................................
OF-6K 16-5XX (ESS) Status Message RAP ...................................................................
OF-6L 19-5XX, 21-5XX, and 22-5XX Status Message RAP ...........................................
OF-7 Install Wizard Failure..............................................................................................
OF-8 Staple Cartridge Checkout Procedure ...................................................................
OF-9 Configuration Problem RAP ...................................................................................
OF-10 Broken Part RAP..................................................................................................
2-776
2-779
2-781
2-787
2-801
2-807
2-809
2-817
2-827
2-827
2-829
2-832
Other Faults RAPs

OF-1 Noise RAP .............................................................................................................
OF-2 Paper Damage RAP ..............................................................................................
OF-3 Convenience Stapler RAP .....................................................................................
OF-4 40 ppm IOT Odor, Heat and Dirt RAP. ..................................................................
OF-5 55 ppm and 65 ppm IOT Odor, Heat And Dirt RAP. ..............................................
OF-6 Status Messages ...................................................................................................
OF-6A 01-5XX and 02-5XX Status Message RAP .........................................................
OF-6B 03-5XX Status Message RAP .............................................................................
OF-6C 05-5XX (DADF) Status Message RAP ................................................................
V0.042
2-741
2-748
2-752
2-757
2-759
2-760
2-761
2-764
2-773
May 2003
2-5
May 2003
2-6
V0.042
01-301 Front Door Interlock Fault

The Front Door Interlock Switch is opened during cycle up, print, or cycle down. The fault code
is not declared when the switch is opened in the standby mode.
01-301 On-Site Diagnostic Procedure

In IIOC Controller Tests, select [IIOC Self Tests] and [IOT], then run the [Type 1] and [Type 2]
tests. Look for fault code 03-809. Enter [Self Tests tab , IIOC Controller Tests].
The test fails with an 03-809 code.
Y
N
In [Component Control], enter [IOT General] and [Front Door Interlock Switch], then [Start
Monitor]. Observe the PWS display as you manually actuate the switch. Enter [Copier
Sys tab , Component Control].
The display changes when the switch is actuated and deactuated.
Y
N
Replace the Front Door Interlock Switch PL 1.1A Item 3.
The problem continues.
Y
N
Return to Service Call Procedures.
Replace the IIOC PWB W8A1 PL 1.5 Item 2.
Y
N
Check the wiring of the Front Door Interlock Switch for an open or short circuit. Go to
Flag 1. Repair or replace as necessary.
Check for the following problems:
Check for a broken, bent, or missing actuator on the Front Door, and check for a
bent or damaged Front Door PL 7.2 Item 1. Repair or replace as required.
Check for a damaged Front Door Interlock Switch PL 1.1A Item 3.
Go to the 03-809 RAP.
V0.042
May 2003
2-7
01-301
Figure 1 01-301 RAP Circuit Diagram
01-301
May 2003
2-8
V0.042
01-305 HCF or Bypass Top Cover Opened In Print
01-310 36 VDC Interlock Opened In Print
The HCF/Bypass Top Cover or Bypass Tray Top Cover was opened in print mode. This fault
code is not declared when the cover is opened in the standby mode.
The Front Door Interlock Switch or a Side Interlock Switch opened in print mode. This fault
code is not declared when those switches are opened in the standby mode.
Initial Actions
In Component Control, select [IOT Paper Trays] [Bypass Tray Top Cover Interlock] and [Start
Monitor]. Observe the PWS as you open and close the HCF/Bypass Top Cover. Enter [Copier
Ensure the Front Door, and the left side input device, and the right side output device are fully
closed and latched.
NOTE: The HCF/Bypass has two electrical devices (a switch and a sensor) which actuate
almost simultaneously when the HCF Top Cover is opened and closed. The switch is used to
interlock the +24 VDC to the HCF components. The sensor is used for the cover open/closed
detection, and is checked in Component Control. If you listen for the switch actuation during
the Component Control check of the sensor, it may not happen at the exact time the PWS display changes because the PWS responds to the state of the sensor, and not the switch. If a difference in actuation points exists between the switch and sensor, that alone does not mean the
switch or sensor is defective. Be sure to follow this RAP completely.
The PWS display indicates the sensor actuates and deactuates as the cover is opened
and closed.
Y
N
The machine has an HCF.
Y
N
Replace the Bypass Tray Assembly PL 4.3 Item 1.
If the machine does not have a Tray 5 (Bypass Tray), ensure the Knockout Panel (PL 7.2 Item
7) is installed securely and the latches are fully engaged in the Left Side Cover.
If the problem continues, use this RAP to isolate the problem.

Go to Flag 1 and check for a loose connection or intermittent open or short circuit. While
checking the wiring, ensure the physical actuation of each interlock switch is good when the
interlocked component is fully closed and latched.
If the wiring is good, and the switch actuation is good, suspect a defective interlock switch.
Front Door Interlock Switch PL 1.1A Item 3.
Machines w/o TAG 120, Input Device Safety Interlock PL 1.5 Item 4.
Machines w/o TAG 114, Output Device Safety Interlock PL 1.5 Item 4.
Replace the HCF Elevator Motor PL 4.2B Item 9.

If the problem continues, replace the HCF PWB PL 4.2B Item 10.
The switch is operating correctly. Ensure the switch actuates before the cover is fully closed,
and the cover is securely latched when closed.
If the switch actuation is marginal, or if an intermittent problem exists, replace the appropriate
part(s):
If the machine has only a Bypass Tray, replace the Bypass Tray Assembly PL 4.3 Item 1.
If the machine has an HCF, replace the HCF Elevator Motor PL 4.2B Item 9. If the problem continues, replace the HCF PWB PL 4.2B Item 10.
V0.042
May 2003
2-9
01-305, 01-310
01-310
May 2003
2-10
V0.042
01-705/710 IOT Overheat Fault
Fault code 01-705 is declared when the temperature inside the IOT exceeds the normal
operating temperature during cycle up, run, or cycle down modes.
Fault code 01-710 is declared when the temperature inside the IOT exceeds the normal
operating temperature while the IOT is in standby.
Initial Actions
NOTE: The machine specification for maximum ambient temperature is 90 degrees fahrenheit.
An over temperature fault may occur if the ambient temperature at the customers site is
greater than 90 degrees fahrenheit.

Check the Filter Life Counter in NVM. Enter NVM Tool. Select Mark Service and go to location
15.
The value is 2 million or more.
Y
N
In Component Control, select [IOT General] and [NOHAD Thermostat], then [Start Monitor]. Enter [Copier Sys tab , Component Control].
The signal from the NOHAD Thermostat is low.
Y
N
Go to Flag 3 and check the circuit of the NOHAD Thermostat for an open or short circuit.
If the wiring checks good, replace the NOHAD Thermostat PL 1.5 Item 5.
If the problem continues, replace the IIOC PWB W8A4 PL 1.5 Item 2.
In IIOC Controller Tests, select [IIOC Self Tests] and [IOT], then run the [Type 1] and
[Type 2] tests. Look for an 03-801 code on 40 ppm machines and 03-801 or 03-836 code
on 65 ppm machines. Enter [Self Tests tab , IIOC Controller Tests].
The test declares an 03-801 code.
Y
N
The test declares an 03-836 code.
Y
N
Check the following fans for correct operation and for obstructed airflow:
The Fuser Fan/Duct PL 9.1 Item 5 (all machines).
The ROS/Developer Cooling Fan PL 9.1 Item 6 (65 ppm machines only).
If necessary, replace the filters in the NOHAD Filter Kit PL 9.1 Item 1.
Figure 1 01-705/710 RAP Circuit Diagram
Go to the 03-836 RAP to diagnose the problem.

Go to the 03-801 RAP to diagnose the problem.
Replace the filters in the NOHAD Filter Kit PL 9.1 Item 1.
V0.042
May 2003
2-11
01-705/710
01-A DC Voltage Checkout Procedure
NOTE: 36 VDC will NOT be available with the Distribution PWB disconnected
because the IOT interlock circuit is open.
This procedure should be performed if any DC Voltage from the Low Voltage Power Supply is
missing. The purpose of the procedure is to determine the state of the Low Voltage Power Supply (LVPS) and identify the most appropriate RAP to diagnose the problem.
All voltages listed in the table are correct (except 36 VDC).

Y
N
At least one output is correct.
Y
N
Measure the AC line voltage to the LVPS.
Procedure
Prepare to measure the outputs of the LVPS.
Switch the power OFF, wait 10 seconds, then switch the power ON. (This ensures the
machine is not in the Power Saver mode, all outputs of the LVPS are enabled, and all
faults are reset.)
Remove the back cover of the IOT and open the card cage to gain access to the test
points on the LVPS.
Set the meter to measure DC voltage.
Attach the (-) meter lead to the metal case of the LVPS.
Identify the type of LVPS installed in the machine. If the machine has Tag 011, a Venray
LVPS is installed. If the machine does not have Tag 011, a Zytec LVPS is installed.
Refer to Figure 1 (Venray LVPS, with Tag 011) or Figure 2 (Zytek LVPS, w/o Tag 011) to
identify the LVPS test point locations.
Measure the voltage at each test point listed in Table 1 and make a record of each voltage
measurement.
Switch the power OFF and disconnect the Power Cord from the wall outlet.
Connect A10P42 to the LVPS at J2, and A10P43 to the LVPS at J3.
Connect the Power Cord to the wall outlet, and switch the power ON.
Measure the voltage at each test point listed in Table 1 and make another
record of each voltage measurement.

Y
N
Perform the following tasks:
Disconnect the Distribution PWB from the J4 on the LVPS. REP 01-1
Disconnect 2P45 from J5 on the LVPS ( P45/J5).
Disconnect P46 from J6 on the LVPS ( P46/J6).
Disconnect A10P2 from J7 on the LVPS (FX only).
Disconnect A10P43 from the LVPS at J3.
01-A
The wires in A10P43 are associated with three LVPS outputs and all wires go to
the Card Cage (Main Control PWB). Refer to Table 3 and go to the indicated
wirenet drawings to check the wires for a short circuit to DC Com.
Switch the power ON, then measure the voltage at each test point listed in Table 1
and make another record of each voltage measurement.
A
B

Y
N
The wires in A10P42 are associated with three LVPS outputs and all wires
go to the Card Cage (Main Control PWB and ESS PWB). Refer to Table 2
and go to the indicated wirenet drawings to check the wires for a short circuit to DC Com.
Disconnect all LVPS output connectors.
Measure the voltage between pins 1 and 3 of connector P41.
Removal and/or installation of electrical components with power switched ON could

damage those components. To ensure the power is switched OFF while the Distribution PWB is disconnected from the LVPS, the Power Cord must be unplugged from
the wall plug.
Disconnect A10P43 from J3 on the LVPS ( P43/J3).
Replace the LVPS PL 1.2A Item 3.
CAUTION
Locate the AC input connector P41 at the left side of the LVPS
In the following step, the Distribution PWB will be disconnected from the LVPS
which will disable the Instant OFF Switch. If it is necessary to switch the power
OFF while the Distribution PWB is disconnected from the LVPS, the Power
Cord must be unplugged from the wall plug.
Disconnect A10P42 from J2 on the LVPS ( P42/J2).
Set the meter to measure AC voltage.
The AC line voltage is between 85 VAC and 264 VAC.

Y
N
Go to the 01-B RAP.
WARNING
Disconnect the (-) meter lead from the LVPS.
( P41).
All voltages listed in the table are correct.

Y
N
All LVPS outputs are correct except 36 VDC.
Y
N
Switch the power OFF.
A
May 2003
2-12
B
V0.042
Connect the Distribution PWB to the LVPS at J4.

Y
N
The connector, P2, is used on FX machines only. The wires in P2 are associated with one LVPS output and the wires go to the Card Cage. Refer to Table 5
and go to the indicated wirenet drawing to check the wires for a short circuit to
DC Com.
NOTE: Ensure ALL connectors are connected to the Distribution PWB at this
time. If any connectors are not connected, the results of the following check
could be erroneous.
The LVPS outputs are correct and the problem cannot be duplicated. Operate the
machine in order to identify any other problems.
NOTE: With the Distribution PWB connected to the LVPS, the red Instant OFF
Switch, behind the Front Door, will again be functional.
Y
N
Go to the 01-D RAP.
Connect 2P45 to the LVPS at J5.
Go to the 01-C RAP.

The LVPS and associated power distribution circuits are OK. If the PO/PO solved the problem,
suspect the machine may have been in the Power Saver mode. The minimum Power Saver
interval is 15 minutes and the maximum interval is 225 minutes. If the customer wants to
change the interval on this machine, direct him or her to the DCS 265/255/240 Reference
Guide.
Switch the power ON.

Y
N
The wires in 2P45 are associated with two LVPS outputs and all wires go to the
IIT. Refer to Table 4 and go to the indicated wirenet to check the wires for a
short circuit to DC Com.
Connect P46 to the LVPS at J6.

Y
N
Go to the 01-C RAP.
This is an FX machine.
Y
N
The LVPS outputs are correct and the problem cannot be duplicated. Operate
the machine in order to identify any other problems.
Connect P2 to the LVPS at J7.
A
B
V0.042
May 2003
2-13
01-A
Figure 1 Venray LVPS (with Tag 011) Test Points
01-A
Figure 2 Zytec LVPS (w/o Tag 011) Test Points
May 2003
2-14
V0.042
Table 4 Wirenets for P45

Table 1 LVPS Output Voltages
Test Points
Test Points
(Venray LVPS) (Zytec LVPS)
Tag 011
w/o Tag 011
Voltage Specification
+36V
36V
34.2 to 37.8 VDC
+24V
24V
22.8 to 25.2 VDC
-12V
-12V
-11.4 to -12.6 VDC
+24V ES
24 PSV
22.8 to 25.2 VDC
+5 VES
5.15 PSV
5.05 to 5.25 VDC
+5V
5.15V
5.05 to 5.25 VDC
+12V
+12V
+11.4 to +12.6 VDC
+12V ES
N/A
+11.4 to +12.6 VDC
Voltage
Pin(s)
Wirenet
+24 VDC (ES)
Figure 29
+24 VDC
Figure 29
Table 5 Wirenets for A10P2

Voltage
Pin(s)
Wirenet
+24 VDC (ES)
Figure 29
01-B The Machine Cannot Be Switched On

The machine appears off with nothing displayed on the UI Control Panel and the machine does
not respond to the Power ON switch.
Procedure
Determine if the AC line voltage is correct for the market region.

Wirenet
Switch the power OFF, then unplug the Power Cord from the wall outlet.
Set the meter to measure AC voltage, then measure the voltage at the wall outlet.
Compare the voltage measurement to the voltage specification for the machine model
and the market region as listed in the Product Specifications .
Voltage
Pin(s)
+5 VDC (ES)
240/255/265
8, 9, 10, 11, 12
Figure 9 (w/o ESS)

Figure 10 (with ESS)
+5 VDC (ES)
460/470
8, 9, 10, 11, 12
Figure 22
Figure 23
+12 VDC (ES)

240/255/265
Figure 25 (w/o ESS)

+12 VDC (ES)

460/470
Figure 27 (w/o ESS)

Measure the AC line voltage at the AC Distribution Panel.
-12 VDC
240/255/265
Figure 25 (w/o ESS)

Unplug the Power Cord from the AC Distribution Panel.
-12 VDC
460/470
Measure the voltage at the end of the Power Cord that plugs into the AC Distribution
Panel.
(w/o ESS)
(with ESS)
Figure 27 (w/o ESS)


Voltage
Pin(s)
Wirenet
+5 VDC
240/255/265
1, 2, 3
Figure 9
+5 VDC
460/470
1, 2, 3
+12 VDC
240/255/265
+12 VDC
460/470
Figure 22
The line voltage is correct for the market region.

Y
N
Inform the customer the AC input power is not in specification.
Connect the Power Cord to the wall outlet.
The voltage is correct.

Y
N
Replace the Power Cord PL 1.2A Item 2.
Check continuity through the Power ON/OFF Switch.
DO NOT connect the Power Cord to the AC Distribution Panel.
Disconnect P48 from the AC Distribution Panel. ( P48)
Set the meter to measure resistance.
Figure 25 (w/o ESS)

Connect the meter leads to P48-1 and P48-2.
Observe the meter while actuating the Power ON/OFF Switch to the ON position.
Figure 27 (w/o ESS)

-12 VDC
240/255/265
Figure 25 (w/o ESS)

The resistance changes from infinity to 0 ohms when the switch is actuated.
Y
N
Go to Flag 4 and check for an open or short circuit.
If the wires are good, replace the Power ON/OFF Switch PL 1.1A Item 4.
-12 VDC
460/470
Figure 27 (w/o ESS)

Go to Figure 1 and check several circuits as follows:
V0.042
May 2003
2-15
Go to Flag 5 and check for an open circuit.

01-A, 01-B
Go to Flag 2 and check the wire "Request for Off (L)" for a short circuit to DC COM.
Go to Flag 1 and check the wire "Instant OFF Switch Actuated (L)" for a short circuit to DC
COM.
If all of the wires are good, replace the LVPS PL 1.2A Item 3.
Figure 1 Power ON/OFF Circuit
01-B
May 2003
2-16
V0.042
01-C No 36 VDC Output From LVPS
All LVPS outputs are present except 36 VDC.

Entry to this RAP is only from the 01-A Voltage Checkout Procedure, and 36 VDC is the
ONLY voltage not available from the LVPS.
Procedure
Ensure the Front Door Interlock Switch and Side Interlock Switches (w/o TAG 114 and TAG
120) are closed and actuated.
If the machine does not have a Tray 5 (Bypass Tray), ensure the Knockout Panel (PL 7.2 Item
7) is installed securely and the latches are fully engaged in the Left Side Cover.
Ensure the (-) meter lead is still attached to the metal case of the LVPS.
Measure the voltage at the LVPS test point marked INT-IN.
The voltage is 24 VDC.
Y
N
Measure the voltage at the LVPS test point marked INT-OUT.
Y
N
WARNING
In the following step, P13 will be disconnected from the Distribution PWB
which will disable the Instant OFF Switch. If it is necessary to switch the power
OFF while P13 is disconnected from the Distribution PWB, the Power Cord
must be unplugged from the wall plug.
CAUTION
Removal and/or installation of electrical components with power switched ON could
damage those components. To ensure the power is switched OFF while P13 is disconnected from the Distribution PWB, the Power Cord must be unplugged from the
wall plug.
Disconnect P13 from J13 on the Distribution PWB ( P/J13).
Switch the power ON, then measure the voltage at J13, pin 8.
Y
N
If the problem continues, replace the Distribution PWB PL 1.5 Item 7.
Go to Flag 1 (Figure 1) and check for a short circuit to DC Com.
Go to Flag 1 (Figure 1) and check for an open circuit.
Check for +24 VDC. Measure the voltage at the +24V test point on the LVPS.
The voltage is +22.8 to 25.2 VDC.
Y
N
Go to the 01-D RAP.
Measure the voltage at the LVPS test point marked +36V.
The voltage is in the range of 34.2 to 37.8 VDC.

Y
N
The LVPS is OK. The problem is in a +36 VDC distribution circuit. Disconnect the 36 VDC harness from the SCAM PWB.
Disconnect P21 from J1 on the SCAM PWB ( P21/J1).
Reconnect P46 to J6 on the LVPS ( P46/J6).
Switch the power ON, then measure the voltage at the LVPS test point marked +36V.

Y
N
Switch the power OFF. Go to Flag 1 (Figure 2) and check for a short circuit to ground.
The harness from the LVPS to the SCAM PWB is OK. The problem is with the SCAM PWB, or
one of the 36 VDC output circuits from the SCAM PWB.
Disconnect B2P1 from J2 on the SCAM PWB ( B2P1/J2) (Fuser Drive Motor).
Disconnect A1B1P1 from J3 on the SCAM PWB ( A1B1P1/J3) (Photoreceptor Drive

Motor).
Disconnect B1P1 from J4 on the SCAM PWB ( B1P1/J4) (Developer Drive Motor).
Disconnect P29 from J9 on the SCAM PWB ( P29/J9) (Developer HVPS).
Disconnect P20 from J10 on the SCAM PWB ( P20/J10) (Charge HVPS and Transfer/
Detack HVPS).
Reconnect P21 to J1 on the SCAM PWB ( P21/J1).

Y
N
Replace the SCAM PWB PL 1.5 Item 6.
The SCAM PWB is OK. Connect the drive motor connectors to determine if one of those circuits is shorted.
Reconnect B2P1 to J2 on the SCAM PWB.( B2P1/J2) (to Fuser Drive Motor)
Reconnect A1B1P1 to J3 on the SCAM PWB ( A1B1P1/J3) (to Photoreceptor Drive

Motor)
Reconnect B1P1 to J4 on the SCAM PWB.( B1P1/J4) (to Developer Drive Motor)

Y
N
A drive motor is defective. Prepare to isolate the defective motor.
Disconnect all 36 VDC loads, then measure the 36 VDC output from the LVPS.
Disconnect B2P1 from J2 on the SCAM PWB. ( B2P1/J2) (to Fuser Drive Motor)
Disconnect P46 from J6 on the LVPS ( P46/J6).
A
V0.042
May 2003
2-17
01-C
A
Y
N
The Fuser Drive Motor is OK. Continue to isolate the defective motor.
Disconnect A1B1P1 from J3 on the SCAM PWB. ( A1B1P1/J3) (to the Photoreceptor Drive Motor)
Switch the power ON, then measure the voltage at the LVPS test point marked
+36V.

Y
N
Replace the Developer Drive Motor PL 7.1 Item 1.
Replace the Photoreceptor Drive Motor (part of the Photoreceptor Drive Module PL
5.1A Item 2).
Replace the Fuser Drive Motor PL 7.1 Item 3.
The three drive motors are OK. The problem is with a HVPS.
Reconnect P29 to J9 on the SCAM PWB ( P29/J9) (Developer HVPS).

Y
N
Switch the power OFF. Go to Flag 2 (Figure 2) and check for a short circuit. Repair if necessary. If the wiring is OK, replace the Developer HVPS PL 1.2A Item 7.
The problem is in the Charge HVPS or the Transfer/Detack HVPS.
Reconnect P20 to J10 on the SCAM PWB ( P20/J10).
Disconnect P65 from J1 on the Detack HVPS ( P65/J1).
Disconnect P66 from J1 on the Transfer HVPS ( P66/J1).

Y
N
Switch the power OFF. Go to Flag 3 and check for a short circuit. Repair if necessary. If
the wiring is OK, replace the Charge HVPS PL 1.2A Item 5.
Switch the power OFF. Go to Flag 4 and Flag 5 and check for a short circuit. Repair if necessary. If the wiring is OK, replace the Transfer/Detack HVPS PL 1.2A Item 6.
01-C
May 2003
2-18
V0.042
Figure 1 01-C RAP Circuit Diagram
V0.042
May 2003
2-19
01-C
Figure 2 +36 VDC Distribution Circuits
01-C
May 2003
2-20
V0.042
A
01-D LVPS Outputs Incorrect With Distribution PWB

Connected
Connect connector P1 to J1 on the Distribution PWB.
All LVPS outputs are OK with all outputs disconnected, but some or all LVPS outputs are missing with the Distribution PWB connected to the LVPS at J4. This problem can be caused by a
faulty Distribution PWB, or a shorted output connected to the Distribution PWB.
measurement.
Entry to this RAP is only from the 01-A DC Voltage Checkout Procedure.

Y
N
The wires in P1 are associated with the +24 VDC (ES) LVPS output. Refer to Table 3 and
go to the indicated wirenet drawing to check the wires for a short circuit to DC Com.
Procedure
Disconnect all connectors from the Distribution PWB, then connect the Distribution PWB
to the LVPS at J4.
Connect the following connectors to the Distribution PWB: P3 to J3; P7 to J7; P11 to J11.
Connect the Power Cord to the Wall outlet, then switch the power ON.
measurement.
measurement.

Y
N
Replace the Distribution PWB PL 1.5 Item 7.

Y
N
The wires in P3, P7, and P11 are associated with the +24 VDC LVPS output. Refer to
Table 4 and go to the indicated wirenet drawings to check the wires for a short circuit to
DC Com.
Connect the following connectors to the Distribution PWB: P2 to J2, and P8 to J8.
Connect the Power Cord to the wall outlet, then switch the power ON.
measurement.
Connect the following connectors to the Distribution PWB: P12 to J12; P15 to J15.

Y
N
The wires in P2 and P8 are associated with the +5 VDC (ES) LVPS output. Refer to Table
1 and go to the indicated wirenet drawings to check the wires for a short circuit to DC
Com.
measurement.

Y
N
The wires in P12 and P15 are associated with the +5 VDC and +24 VDC LVPS outputs.
Refer to Table 5 and go to the indicated wirenet drawings to check the wires for a short
circuit to DC Com.
Connect the following connectors to the Distribution PWB: P4 to J4, P13 to J13, and P14
to J14.
Connect the Power Cord to the wall outlet, then switch the power ON.
Connect connector P10 to J10 on the Distribution PWB.
measurement.
measurement.
NOTE: With P13 connected to the Distribution PWB, the red Instant OFF Switch, behind the
Front Door, will again be functional.
Y
N
The wires in P4, P13, and P14 are associated with the +5 VDC LVPS output. Refer to
Table 2 and go to the indicated wirenet drawings to check the wires for a short circuit to
DC Com.
A
V0.042

Y
N
The wires in P10 are associated with several LVPS outputs and all wires go to the ROS.
Refer to Table 6 and go to the indicated wirenet drawings to check the wires for a short
circuit to DC Com.
B
May 2003
2-21
01-D
B
The LVPS outputs are OK and the problem cannot be duplicated. Operate the machine in order
to identify any other problems.
Table 1 Wirenets for P2 and P8
Pin(s)
Destination
Wirenet
SCAM PWB (240/255/265)
Figure 12
P2
SCAM PWB (460/470)
Figure 20
P8
1, 2
User Interface (240/255/265) Figure 11
P8
1, 2
User Interface (460/470)
P2
Figure 19
Table 2 Wirenets for P4, P13, and P14

Pin(s)
P4
Destination
Wirenet
Finisher & TEER Sensor (240/255/265)
Figure 12
P4
Finisher & TEER Sensor (460/470)
Figure 20
P13
AC Distribution Panel (240/255/265)
Figure 11
P13
AC Distribution Panel (460/470)
Figure 19
P14
1, 11
Fuser & Xerographic Modules (240/255/265)
Figure 11
P14
1, 11
Fuser & Xerographic Modules (460/470)
Figure 19

Destination
Wirenet
P10
Pin(s)
9
+12 VDC to ROS (240/255/265)
Figure 25 w/o ESS

Figure 26 with ESS
P10
+12 VDC to ROS (460/470)
Figure 27 w/o ESS

Figure 28 with ESS
P10
10
-12 VDC to ROS (240/255/265)
Figure 25 w/o ESS

Figure 26 with ESS
P10
10
-12 VDC to ROS (460/470)
Figure 27 w/o ESS

Figure 28 with ESS
P10
12
+24 VDC to ROS
Figure 29

Pin(s)
P1
Destination
Wirenet
IIOC Bus 0
Figure 29
Table 4 Wirenets for P3, P7, and P11

Pin(s)
P3
Destination
Wirenet
IIOC Bus 0
Figure 29
P7
IIOC Bus 1
Figure 29
P11
IIOC Bus 2
Figure 29
Table 5 Wirenets for P12 and P15

Pin(s)
Destination
Wirenet
P12
15
+5 VDC to DADF (240/255/265)
Figure 11
P12
15
+5 VDC to DADF (460/470)
Figure 19
P12
17
+24 VDC to DADF
Figure 29
P15
3, 11
+5 VDC to Scanner (240/255/265) Figure 11
P15
3, 11
+5 VDC to Scanner (460/470)
Figure 19
P15
+24 VDC to Scanner
Figure 29

Destination
Wirenet
P10
Pin(s)
7
+5 VDC to ROS (240/255/265)
Figure 11
P10
+5 VDC to ROS (460/470)
Figure 19
01-D
May 2003
2-22
V0.042
01-E The Machine Cannot Be Switched Off With The

(White) Power On/Off Switch
The machine does not respond to the "OFF" command from the (white) Power ON/OFF
Switch. Pressing that switch does not result in the machine power being switched off.
Procedure
Check the operation of the (red) Instant OFF Switch.
The machine can be switched off with the (red) Instant OFF Switch.
Y
N
If the problem continues, replace the LVPS PL 1.2A Item 3.
Switch the power ON. In IIOC Controller Tests, select [IIOC Self Tests] and [IOT], then run the
[Type 1] and [Type 2] tests. Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
Go to the RAP for the indicated fault code.
Access the connector on the back of the Power ON/OFF Switch. Check the voltage on pin 1.
The voltage is in the range of +5.05 to +5.25 VDC with the switch not actuated.
Y
N
Go to Flag 2 and check the wire for an open circuit.
If the wire is good, replace the Power ON/OFF Switch PL 1.1A Item 4 (the contacts are
always closed).
The voltage goes to 0 VDC when the switch is actuated to the OFF position.
Y
N
If the wire is good, replace the Power ON/OFF Switch PL 1.1A Item 4
If the wire is good, replace the IIOC PWB W8A2 PL 1.5 Item 2.
V0.042
May 2003
2-23
01-E
Figure 1 01-E RAP Circuit Diagram
01-E
May 2003
2-24
V0.042
01-F Unable to Clear the Message: "Either a tray 6 cover or

an output tray door is open"
01-G The Machine Cannot Be Switched Off With The (Red)

Instant Off Switch
The IOT has two side interlock switches.
The machine does not respond to the (red) Instant OFF Switch. Pressing that switch does not
result in the machine power being switched off.
The Left Side Interlock Switch senses when either the Bypass Tray Assembly, or the
HCF/Bypass Tray Assembly, or the Left Side Cover is correctly mounted on the IOT.
The Right Side Interlock Switch senses when either the OCT, or the High Capacity Disk
Finisher, or the Mailbox is correctly mounted on the IOT.
If either switch is opened in Standby mode, the following message is displayed on the UI:
"Either a tray 6 cover or an output tray door is open."
Procedure
Examine the input device (left side) and the output device (right side) to ensure the devices are
mounted securely and the Interlock Switches are actuated correctly.
If the problem continues, go to the 01-310 RAP and diagnose the Interlock Switch circuit.
Procedure
Check the operation of the (white) Power ON/OFF Switch.
The machine can be switched off with the (white) Power ON/OFF Switch.
Y
N
If the problem continues, replace the LVPS PL 1.2A Item 3.
Access the connector on the back of the (red) Instant OFF Switch. Check the voltage on pin 2.
The voltage is in the range of +5.05 to +5.25 VDC with the switch not actuated.
Y
N
Go to Flag 1 and check the GRN wire for an open circuit.
The voltage goes to 0 VDC when the switch is actuated to the OFF position.
Y
N
Go to Flag 1 and check the BLU wire for an open circuit.
If the wire is good, replace the Instant OFF Switch PL 1.1A Item 2.
V0.042
May 2003
2-25
01-F, 01-G
Figure 1 01-G RAP Circuit Diagram
01-G
May 2003
2-26
V0.042
02-300/302/304/306/308 UI Failures
02-309/364 UI Power On Self Test Failure
02-300: The User Interface RAM failed during the User Interface Power On Self Test.
02-302: The User Interface Self Test detected a Flash Rewrite failure.
02-309: The User Interface Button Test and/or the Touch Area Test failed during the User
Interface Power On Self Test. The User Interface is operating in a degraded mode.
02-304: The User Interface VRAM failed during the User Interface Power On Self Test.
02-306: The User Interface Self Test detected a Flash Erase failure.
02-308: The User Interface Self Test detected a Flash Download failure.
02-364: The User Interface Self Test Boot Checksum was incorrect during the User Interface Power On Self Test. This fault causes all User Interface LED indicators to blink on
and off, and the User Interface is inoperative.
Procedure
Procedure
Replace the UI Control Panel Assembly PL 1.1A Item 1. Be sure to follow REP 02-1 and
ensure the UI software is compatible with the Main Control PWB software.
V0.042
May 2003
2-27
02-300/302/304/306/308, 02-309/364
02-312/704 UI Application Software Checksum Incorrect
02-320/380 UI Communication Failures
02-312: The User Interface Application Software Checksum was incorrect during the
Power On Self Test. This fault causes all User Interface LED indicators to blink on and off.
02-320: User Interface Data Time Out Error. The UI does not receive the requested data
from the Main Control PWB within the specified time.
02-704: The User Interface Application Software Checksum was incorrect during the User
Interface Diagnostic Test.
02-380: Communication Turnaround Failure. The User Interface is inoperative because of

a communication failure between the User Interface and the Main Control PWB. The User
Interface can still be used in the Diagnostics Mode.
Procedure
Reload or upgrade the UI software to the correct level, using the appropriate software release
kit.
Initial Actions
02-320 - Check to see if the LVPS Fan Filter is dirty and is restricting air flow to cool the
LVPS. The LVPS can shut down due to a thermal cutout and generate a 02-320 fault. (PL
9.1, item 13, Machine Cooling and Filters).
Procedure
Go to the 03-347 User Interface Communication RAP.
02-312/704, 02-320/380
May 2003
2-28
V0.042
02-390/391 UI Communication Failures
02-705/706 UI Diagnostic Test Failure
02-390: During powerup all configurable services have not achieved a stable state after 5
minutes from powerup.
02-705: The Audio Tone test failed during the User Interface Diagnostic Test. The fault
counter increments once for each occurrence of this fault.
02-391: All services that UI is waiting for in the registry do not appear even though the
Atlanta / UI sync occurred.
02-706: A VRAM failure was detected during the User Interface Diagnostic Test. The fault
counter increments once for every third occurrence of this fault.
Initial Actions
Procedure
DC470: If a 03-382 fault is also present suspect a communication failure between the MFF and
the IOT.
Procedure
Switch the power Off, then On to clear the fault.
The problem continues
Y
N
Return to Call Flow.
V0.042
May 2003
2-29
02-390/391, 02-705/706
02-707: The Button Test failed during the User Interface Diagnostic Test. The fault counter
increments once for each occurrence of this fault.
02-709: The Touch Area Test failed during the User Interface Diagnostic Test. The fault
02-715: An LED failure was detected during the User Interface Diagnostics Test. The fault
02-712: A pixel failure was detected during the User Interface Diagnostics Test. The fault
Procedure
Procedure
IOT TAG 082 is installed.

Y
N
Replace the UI Control Panel Assembly (with TAG 082) PL 1.1A Item 1. Be sure to follow REP
02-1 and ensure the UI software is compatible with the Main Control PWB software.
02-707/715, 02-709/712
May 2003
2-30
V0.042
02-711 RAM Space Fault

This fault indicates that the application is at 10 percent of remaining memory. The fault will be
counted and User Interface operation will continue until the User Interface reboots. This fault is
corrected by performing a soft boot of the User Interface.

Using Customer Tools, perform a soft boot of the User Interface by performing the following
steps.
1.
Press the [Access] or [Key] button on the User Interface.
2.
Enter the password, then press [Enter]. (The default password is 1111, but it can be
changed by the customer.)
3.
Select [Machine Tests].
4.
Select [More Features].
5.
Select [Reset User Interface].
V0.042
May 2003
2-31
02-711
02-A Unable to Select A Machine Feature At The User

Interface
02-B All LEDs On The User Interface Are Blinking

When all LEDs on the User Interface are blinking, the User Interface has failed its internal self
test.
02-A On-Site Diagnostic Procedure

In Faults, check the [Last 40 Faults] for 02-380 and/or 03-347 faults. Enter [Faults/Counters tab
, Faults].
An 02-380 and/or 03-347 fault is logged.
Y
N
Using Customer Tools, perform the [User Interface Button Test] and the [Touch Area Test].
Perform the following steps:
1.
2.
3.
4.
Select [User Interface Tests].
5.
Select the [User Interface Button Test] and follow the directions on the User Interface.
6.
Select the [Touch Area Test] and follow the directions on the User Interface.
NOTE: Before using this RAP, it is important to verify ALL LEDs are blinking, and not just
TWO LEDs. The blinking of only two LEDs represents a different problem and will be accompanied by a fault code. If only two LEDs are blinking, use the RAP for the associated fault code.
Procedure
Both tests pass.

Y
N
Ensure the connectors on the User Interface PWB are all securely connected. If the
connectors are OK and the problem continues, replace the UI Control Panel Assembly PL 1.1A Item 1. Be sure to follow REP 02-1 and ensure the UI software is compatible with the Main Control PWB software.
Reload the UI Software using the REP 02-1 Procedure.
The software loaded correctly.
Y
N
Replace the UI Control Panel Assembly PL 1.1A Item 1. Be sure to follow REP 02-1
and ensure the UI software is compatible with the Main Control PWB software.
The repair is complete. Return to Service Call Procedures.
02-A, 02-B
May 2003
2-32
V0.042
02-C Nothing Is Visible On The User Interface (Dark

Display)
Later version, access the bottom side of the User Interface (Figure 3) (REP 02-1). Check the
LEDs, CR3 and CR4, on the User Interface PWB.
Early version, CR2 is blinking and CR1 is on steady. Later version, CR4 is blinking and
CR3 is on steady.
Y
N
Go to the 02-C 5VDC Checkout Procedure.
(04April2002)
There are five reasons why the machine may exhibit this problem.
The machine is switched on and the fans are running correctly, but the UI display is dark.
The machine has entered Power Saver Mode 1, where power is removed from most subsystems, but the LVPS remains switched on. Touching any button on the UI should
restore the machine power and cause the Fuser to warm up.
The machine has entered Power Saver Mode 2, where the power is automatically
switched off after being in Power Saver Mode 1 for a period of time. In this condition,
power is switched on using the Power On/Off switch on the right side of the machine.
The machine has developed a malfunction which prevents the power from being switched
on.
The machine (ST) has shut-off while coming out of Power Save Mode because there is an
overload on the (12VDC ES) output of the LVPS, caused by both hard drives starting up
at the same time. The machine can be powered on again and this problem may occur
again when coming out of Power Save Mode. This problem can occur with LVPS,
105K16168 and earlier.
02-C On-Site Diagnostic Procedure

The machine may be in the Power Saver Mode, but the Power Saver LED may not be lit. Press
any button on the User Interface.
Y
N
The Power Saver LED is defective. Replace the UI Control Panel Assembly PL 1.1A Item
1. Be sure to follow REP 02-1 and ensure the UI software is compatible with the Main
Control PWB software.
The machine may be unplugged or switched off, or the machine may have entered Power
Saver Mode 2 which automatically switches the machine Off. Ensure the Power Cord is
plugged into an active electrical outlet, then actuate the Power On Switch to switch the power
On.
Y
N
If the customer is dissatisfied with the Power Saver Mode 2 interval, advise the customer
the interval can be changed using the information in the Machine Reference Guide.
Connect the PWS and launch a session. The PWS can communicate with the Main Control PWB.
Y
N
Go to the 01-A Voltage Checkout RAP.
Set the meter to measure 600 VAC.

Measure the Backlight Power Supply output voltage between pins:
1 and 5 at connector CN7 for the early version .
1 and 4 at connector CN2 for the later version .
The voltage is 300 +/- 30 VAC.

Y
N
Go to the 02-C 5VDC Checkout Procedure.
Replace the Backlight PL 1.1A Item 6.
02-C 5VDC Checkout Procedure

Go to Flag 1 and check for +5 VDC between J2-1 (+) and J2-3 (-), and between J2-2 (+) and
J2-4 (-).on the User Interface PWB.
The voltage is +5.15 +/- 0.25 VDC.
Y
N
Check for +5 VDC at the LVPS.
Use the test point marked +5V on the Venray LVPS.
Use the test point marked 5.15V on the Zytec LVPS.

Y
N
Check for +5 VDC at the Distribution PWB between P8-1 (+) and P8-3 (-), and between
P8-2 (+) and P8-4 (-).
Y
N
Go to Flag 1 and check the wiring for an open circuit.
Go to Flag 2 and check the wiring between the Liquid Crystal Display (LCD) Module and the
User Interface PWB for an open circuit. If the wiring is OK, replace the UI Control Panel
Assembly PL 1.1A Item 1. Be sure to follow REP 02-1 and ensure the UI software is compatible with the Main Control PWB software.
NOTE: There are two versions of the User Interface PWB. The early version has the Backlight
Power Supply mounted next to the UI PWB while the later version has the Power Supply
mounted on the UI PWB.
Early version, access the bottom side of the User Interface (Figure 2) (REP 02-1). Check the
LEDs, CR1 and CR2, on the User Interface PWB.
V0.042
May 2003
2-33
02-C
02-C
May 2003
2-34
V0.042
R65
Figure 2 240/255/265 User Interface
V0.042
May 2003
2-35
02-C
Backlight Power Supply
Figure 3 460/470 User Interface
02-C
May 2003
2-36
V0.042
A
02-D The User Interface Is Too Bright Or Too Dim

(04April2002)
The UI display is lit, but the images are too bright or too dim or not clearly visible.
NOTE: If the UI display is dark (the display is blank and no image is visible), and/or the
machine appears to be switched off, go to the 02-C RAP to diagnose the problem.
02-D On-Site Diagnostic Procedure

Adjust the brightness of the User Interface using the following procedure.
1.
2.
3.
4.
Select [Display Brightness].
5.
Use the adjustment keys to change the brightness of the display.
The brightness can be adjusted to an acceptable appearance.

Y
N
Using Customer Tools, perform a soft boot of the User Interface by performing the following steps:
1.
2.
3.
Select [Go To Tools].
4.
Select [System Settings].
5.
Select [Display Brightness].
6.
Ensure the brightness is set to 10.
7.
Save the adjustment, then exit Customer Tools.
Do the following to adjust the User Interface brightness potentiometer:

1.
Access the underside of the User Interface Assembly (REP 02-1).

NOTE: There are two versions of the User Interface PWB. The early version has the
Backlight Power Supply mounted next to the UI PWB while the later version has the
Power Supply mounted on the UI PWB.
2.
3.
Locate the potentiometer to adjust the UI brightness.
Early version, the potentiometer is R65.
Later version, the potentiometer is R141.
Adjust the potentiometer until the brightness of the User Interface is acceptable. If
necessary, scrape off the glyptol coating on the potentiometer.
The brightness can be adjusted to an acceptable appearance.

Y
N
and ensure the software on the UI matches the software on the Main Control PWB.
A
V0.042
May 2003
2-37
02-D
R65
Figure 1 Early Version of User Interface
02-D
May 2003
2-38
V0.042
Figure 2 Later Version of User Interface
V0.042
May 2003
2-39
02-D
02-E The User Interface is Exhibiting Strange Behavior

One or more of the following symptoms are associated with the User Interface.
Scrambled messages.
Extraneous sounds.
Erratic display.
LEDs blinking on at the wrong time.
E
3.
Select [Machine Maintenance].
4.
Select [User Interface Tests].
All four tests pass.

Y
N
Ensure the connectors at J3, J7, and J8 are securely connected
to the User Interface PWB.
If the connectors are OK and the problem continues, replace the
following parts.
Initial Actions
If any of the following specific conditions exist, go to the indicated RAP.
If the only problem is the User Interface is dim, go to the 02-D RAP.
If the only problem is the User Interface is dark (the display is blank, and no image is visible), and/or the machine appears to be switched off, go to the 02-C RAP.
If the only problem is the User Interface indicates the Front Door is being repetitively
opened and closed, go to the 03-809 RAP.
Replace the UI Control Panel Assembly PL 1.1A Item 1.

Be sure to follow REP 02-1 and ensure the UI software is
compatible with the Main Control PWB software.
Using Customer Tools, perform a soft boot of the User Interface by

performing the following steps:
1.
02-E On-Site Diagnostic Procedure
2.
The operator has selected a function or language that is not available.

Y
N
Enter the password, then press [Enter]. (The default password

is 1111, but it can be changed by the customer.)
3.
An error code is displayed on the User Interface or some LEDs are blinking.
Y
N
Using Customer Tools, perform a soft boot of the User Interface by performing the
following steps:
1.
2.
Enter the password, then press [Enter]. (The default password is 1111, but it
can be changed by the customer.)
3.
4.
5.
Button Test
Touch Test
LED Test
Sound Test
5.
The display is OK after the soft boot is performed.

Y
N
Replace the UI Control Panel Assembly PL 1.1A Item 1. Be
sure to follow REP 02-1 and ensure the UI software is compatible with the Main Control PWB software.
The display is OK after the soft boot is performed.

Y
N
Perform a hard boot: switch the machine power Off, wait 10 seconds, then
switch the power On. The display is OK after the hard boot is performed.
Y
N
In Faults, check the [Last 40 Faults] for 02-380 and 03-347 faults.
Enter [Faults/Counters tab , Faults]. An 02-380 or 03-347 fault is
logged.
Y
N
Using Customer Tools, perform the following tests:
4.

Check the LEDs on the UI.
If all LEDs are blinking, perform the appropriate replacement:
and ensure the UI software is compatible with the Main Control PWB software.
If only TWO LEDs on the User Interface are blinking, check for a fault code and go to the
appropriate RAP. Enter [Faults/Counters tab , Faults].
Inform the operator that the function/language selected is not available.
Use the following steps to enter Customer Tools:
A
B
C
D
E
02-E
1.
2.
Enter the password, then press [Enter]. (The default password

is 1111, but it can be changed by the customer.)
May 2003
2-40
V0.042
02-F The UI Continuously Displays the Boot-Up Screen
02-G The UI Continuously Displays A PO/PO Message
The boot-up screen (The Document Center logo) is displayed continuously, and a series of
dots is slowly displayed in a horizontal line. After five minutes, a UI Communication fault will be
displayed.
A PO/PO (Power Off/Power On) message is displayed continuously.
02-F On-Site Diagnostic Procedure
Procedure
Go to the 03-347 Control Panel Communication Fault RAP.
The PWS can connect and communicate to the machine.

Y
N
Go to the 19-A PWS Lost Communication RAP.
Go to the 03-347 Control Panel Communication Fault RAP.
V0.042
May 2003
2-41
02-F, 02-G
02-F, 02-G
May 2003
2-42
V0.042
03-301/305 SCAM PWB Communication Fault
N
Go to Flag 3 and check the wires for an open circuit. Repair or replace as necessary.
The Main Control PWB is unable to communicate with the SCAM PWB.
Fault Code 03-301 indicates the Main Control PWB cannot communicate with the Developer Motor and Fuser Motor processor on the SCAM PWB.
Fault Code 03-305 indicates the Main Control PWB cannot communicate with the Photoreceptor Motor and Analog processor on the SCAM PWB.
With the [Communication Test 2] still running, measure the voltage between TH13 (-) and
TH39 (+) on the SCAM PWB.
The voltage is approximately +2.5 VDC.
Y
N

Check the Distribution Cable between the Main Control PWB and the Distribution PWB.
The cable is securely connected.
Y
N
Connect the cable. Run copies/prints to ensure the problem is corrected.
With the [Communication Test 2] still running, measure the voltage between GND (-) and
P2-5 (+) on the Distribution PWB.
Y
N
Check the harness from the Distribution PWB J2 to the SCAM PWB J6.
The harness is securely connected.
Y
N
Connect the harness. Run copies/prints to ensure the problem is corrected.
Connect the meter to measure DC voltage between TH13 (-) and TH41 (+) on the SCAM PWB.
In [Copier Sys tab , Communications Test], select [SCB], and [Reset Test].
The voltage is within the range of 4.9 to 5.4 VDC.
Y
N
Measure the voltage at TH13 (-) and TH20 (+) on the SCAM PWB.
Y
N
Measure the voltage at P2-3 (-) and P2-4 (+) on the Distribution PWB.
Y
N
Connect the meter to measure DC voltage between GND (-) and TH4 (+) on the Distribution PWB. In [Copier Sys tab , Communications Test], select [SCB], and [Communication
Test 2].
Y
N
Go to Flag 2 and check the Distribution Cable for an open circuit.
If the circuit is open, replace the Distribution Cable PL 1.2A Item 9.
If the circuit is OK, the Main Control PWB may have failed. Go to the 03-G RAP.
TH46 (+) on the Distribution PWB.
Y
N
In [Copier Sys tab , Communications Test], select [SCB], and [Communication Test 2]. With the
[Communication Test 2] running, measure the voltage between GND (-) and P2-7 (+) on the
Distribution PWB.
Y
N
Go to Flag 6 and check the wire for an open circuit. Repair or replace as necessary.
With the [Communication Test 2] still running, measure the voltage between GND (-) and TH37
(+) on the Distribution PWB.
Y
N
Y
N
With the [Communication Test 2] still running, measure the voltage between TH13 (-) and
TH40 (+) on the SCAM PWB.
A
V0.042
May 2003
2-43
03-301/305
03-301/305
May 2003
2-44
V0.042
03-311 ROS Communication Fault
The Main Control PWB cannot communicate with the ROS Control Module.

The machine is also having Finisher configuration problems.
Y
N
Check the wire harness from P/J10 on the Distribution PWB to P72 on the ROS.
The wire harness is securely connected.
Y
N
Connect the meter to measure DC voltage between P10-8 (-) and P10-2 (+) on the Distribution PWB.
In [Copier Sys tab , Communications Test], select [SCB], and [Communication Test 1].
Y
N
If the problem continues, replace the ROS PL 5.2 Item 3.
If the problem continues, the Main Control PWB may have failed. Go to the 03-G
RAP.
Check the Fault Log for 03-312, 03-313, and 03-314 faults. Enter [Faults/Counters tab ,
Faults].
03-312, 03-313, and 03-314 faults are logged in addition to the 03-311 fault.
Y
N
Go to the 03-311 ROS Communication Fault Isolation Procedure.
With the [Communication Test 1] still running, measure the voltage between P10-8 (-) and
Y
N
Go to Flag 3 and Flag 4 and check the wiring for an open circuit.
The wiring associated with Flag 3 and Flag 4 checks OK.
Y
N
Repair the wiring.
Switch the Power Off. Disconnect connector P72 from the ROS. Switch the Power On.
The 03-312, 03-313, and/or 03-314 faults occur again.
Y
N
Go to the 03-311 ROS Communication Fault Isolation Procedure.
Go to the 03-A, Common SCB Circuit RAP.
Replace the ROS PL 5.2 Item 3.
Go to Flag 4 (Figure 2). Check for an open or intermittent circuit, especially P/J4-1 at the Distribution PWB. The ROS, Finisher, and TEER Sensor share an SCB receive line on the Distribution PWB. When 5VDC is missing to the Finisher and TEER Sensor, the receive line is held
low, preventing ROS communication.

If the problem continues, the Main Control PWB may have failed. Go to the 03-G RAP.
03-311 ROS Communication Fault Isolation Procedure

If not already done, switch the power Off. Disconnect connector P72 from the ROS. Switch
the power On. Measure the voltage between P10-8 (-) and P10-7 (+) on the Distribution PWB.
Y
N
Go to Flag 1 and check for a short circuit.
The wiring associated with Flag 1 checks OK.
Y
N
Repair the wiring.
N
Go to Flag 2 and check the wiring for a short or open circuit.
The wiring associated with Flag 2 checks OK.
Y
N
Repair the wiring.
Switch the Power Off.

Disconnect all connectors from the ROS.
Switch the Power On.
The 03-312, 03-313, and/or 03-314 faults occur again.
Y
N
Replace the ROS PL 5.2 Item 3
Reconnect all connectors to the ROS. Go to the 03-A, Common SCB Circuit RAP.
If the wiring is good, replace the Distribution PWB PL 1.5 Item 7.

If the problem continues the Main Control PWB may have failed. Go to the 03-G RAP.
Switch the power off and connect P72 to the ROS. Switch the power On. Measure the voltage
again between P10-8 (-) and P10-7 (+) on the Distribution PWB.
Y
N
Connect the meter to measure DC voltage between P10-8 (-) and P10-4 (+) on the Distribution
PWB. In [Copier Sys tab , Communications Test], select [SCB], and [Reset Test].
V0.042
May 2003
2-45
03-311
03-311
May 2003
2-46
V0.042
V0.042
May 2003
2-47
03-311
03-312/313/314 Finisher Communication Fault
B
Y
Fault Code 03-312 indicates the Main Control PWB cannot communicate with the Finisher (Nodes 16 and 17).
N
Replace the Finisher Controller PWB PL 8.3 Item 16.
With the [Communication Test 1] still running, measure the voltage between J4-2 (-)
and J4-3 (+) on the Distribution PWB.
Y
N

Check the wire harness from P4 on the Distribution PWB to P69 on the Finisher.
The harness is securely connected.
Y
N
Check the Fault Log for 03-311 faults. Enter [Faults/Counters tab , Faults].
03-311 faults are logged in addition to the 03-312 through 03-314 faults.
Y
N
Connect the meter to measure DC voltage between J1-2 (-) and J1-5 (+) on the Finisher
Controller PWB. In [Copier Sys tab , Communications Test], select [SCB], and [Reset
Test].
Y
N
Measure the voltage between J1-2 (-) and J1-1 (+) on the Finisher Controller PWB.
Y
N
Measure the voltage between P4-2 (-) and P4-1 (+) on the Distribution PWB.
Y
N
In Communications Test, select [SCB], and [Communication Test 1]. Enter [Copier Sys tab
, Communications Test]. With the [Communication Test 1] running, measure the voltage
between J4-2 (-) and J4-3 (+) on the Distribution PWB.
Y
N
Switch the power Off. Disconnect P72 from the ROS. Switch the power On.
The 03-312, 03-313, and/or 03-314 fault(s) still occur.
Y
N
Go to the 03-A, Common SCB Circuit RAP.
Connect the meter to measure DC voltage between J1-2 (-) and J1-4 (+) on the Finisher Controller PWB.
In Communications Test, select [SCB], and [Communication Test 1]. Enter [Copier
Sys tab , Communications Test].
Y
N
With the [Communication Test 1] still running, measure the voltage between J42 (-) and J4-4 (+) on the Distribution PWB.
Y
N
With the [Communication Test 1] still running, measure the voltage between J1-2 (-)
and J1-3 (+) on the Finisher Controller PWB.
A
B
03-312/313/314
May 2003
2-48
V0.042
Figure 1 03-312/313/314 RAP Circuit Diagram
V0.042
May 2003
2-49
03-312/313/314
03-321 SCVM Communication Fault
03-322 SCVM Download Failure
The Main Control PWB cannot communicate with the SCVM.
The download of applications software from the Main Control PWB to the SCVM failed.
Procedure
Procedure
The Main Control PWB may have failed. Go to the 03-G RAP.
03-321, 03-322
May 2003
2-50
V0.042
03-323 SCVM Communication Failure
03-325 The Wall Clock Does Not Increment
Failure of SCVM applications to return a calibration complete to the Main Control PWB.
The wall clock, a function of the Main Control PWB, does not increment.
Procedure
Procedure
V0.042
May 2003
2-51
03-323, 03-325
03-331 ESS Communication Fault
03-332 ESS Communication Fault
The Main Control PWB cannot communicate with the ESS PWB. Status 03-563 is declared.
The Main Control PWB will attempt to reestablish communication with the ESS PWB for five
minutes. If communication is not reestablished within five minutes, fault code 03-332 will be
declared.
Fault Code 03-331 was active for five minutes and the Main Control PWB was unable to reestablish communication with the ESS PWB during that time.
Procedure
CAUTION
Procedure
Enter this RAP only from Service Call procedures.
CAUTION
Enter this RAP only from Service Call Procedures.
This fault is usually caused by the ESS, not the Main Control PWB. Service Call Procedures
contains the troubleshooting steps required to differentiate between those two components. If
you did not enter this RAP from Service Call Procedures, go there now (SCP-04).
Switch the power OFF, wait 10 seconds, then switch the power ON.
The fault continues after the PO/PO.
Y
N
Enter [ESS/Network tab , ESS Error Log]. Select [All] [Retrieve]. View the ESS Faults.
16-XXX faults are occurring.
Y
N
Return to Service Call Procedures (SCP-04).
This fault is usually caused by the ESS, not the Main Control PWB. Service call Procedures
contains the troubleshooting steps required to differentiate between those two components. If
you did not enter this RAP from Service call Procedures, go there now (SCP-04).
Switch the power OFF, wait 10 seconds, then switch the power ON.
The fault continues after the PO/PO.
Y
N
Enter [ESS/Network tab , ESS Error Log]. Select [All] [Retrieve]. View the ESS Faults.
16-XXX faults are occurring.
Y
N
Return to Service Call Procedures (SCP-04).
An 03-331 or 03-332 is an indication that the ESS is not operating correctly. Go to the 16-B,
ESS Boot RAP.
An 03-331 or 03-332 is an indication that the ESS is not operating correctly. Go to the 16-B,
ESS Boot RAP.
03-331, 03-332
May 2003
2-52
V0.042
03-335 Unexpected Finisher PWB Reset
03-336 SCAM PWB Reset Detected
The system detects an unplanned reset of the Finisher Controller PWB.
The system detects an unplanned reset of the SCAM PWB.
Procedure
Check the Last 40 Faults for instances of 03-312, 03-313, or 03-314 faults. Enter [Faults/
Counters tab , Faults].
An 03-312, 03-313, or 03-314 fault is logged.
Y
N
This fault is usually caused by electrical noise. Use the following list to identify and eliminate potential sources of electrical noise.
Check the last 40 Faults for instances of 03-301 or 03-305 faults. Enter [Faults/Counters tab ,
Faults].
An 03-301 or 03-305 fault is logged.
Y
N
With power off, ensure all connectors are firmly seated on the Distribution PWB,
SCAM PWB, and the Main Control PWB.
Ensure all subsystem ground wires are correctly installed.
Check for arcing xerographic components by ensuring no image quality defects

exist.
NOTE: When making voltage measurements in this RAP, connect the (-) meter lead to
the metal case of the LVPS, unless instructed otherwise.
Check the voltage at TH20 on the SCAM PWB.
The voltage is within the range of +5.05 to +5.25 VDC.
Y
N
Go to the 01-A RAP.
If the problem continues, replace the Finisher Controller PWB PL 8.3 Item 16.
Check the voltage at TH41 on the SCAM PWB.

Y
N
Check the last 40 Faults for instances of 09-370, 09-372, 09-374, 09-376, 09-380,
09-382, 09-384, or 09-386 faults. Enter [Faults/Counters tab , Faults].
Any of the listed faults are logged.
Y
N
Go to the 03-312/313/314 RAP.
Go to the RAP(s) for the logged faults.

Check the voltage at TH37 on the Distribution PWB.
Y
N
Go to the 03-301/305 RAP.
V0.042
May 2003
2-53
03-335, 03-336
03-337 ROS Control Module Reset Detected
03-338 Main Control PWB Reset Detected
The system detects an unplanned reset of the ROS Control Module.
The system detects a reset of the Main Control PWB because the watch-dog timer timed out or
the application software wrote to an illegal address.
Procedure
Check the last 40 Faults for instances of 03-311 faults. Enter [Faults/Counters tab , Faults].
An 03-311 fault is logged.
Y
N
This fault is usually caused by electrical noise. Use the following list to identify and eliminate potential sources of electrical noise.
With power off, ensure all connectors are firmly seated on the Distribution PWB,
SCAM PWB, and the Main Control PWB.
Ensure all subsystem ground wires are correctly installed.
Check for arcing xerographic components by ensuring no image quality defects

exist.

Initial Actions
If a Multi-Function Finisher is installed:
Ensure the MFF Power Cord is connected to the AC wall outlet or adapter box and there
is AC power at the wall outlet.
Check the LEDs on the IOT/MFF interface PWB and on the MFF control PWB. If the
LEDs CR2 and CR3 on the IOT/MFF interface PWB Figure 1 are flashing and the LEDs
D405, D402, and D401 on the MFF Control PWB Figure 2 are not lit or flashing, go to 12761 MFF DC Power RAP.
If the MFF LVPS is not operating, communication faults may occur. If you suspect the
MFF LVPS is not operating, go to 12-761 MFF DC Power RAP.
Procedure
Perform a PO/PO in order to reset the fault.
The fault resets (clears) after the PO/PO.
Y
N
Ensure all connectors to the Main Control PWB are fully seated. If any connector is not
fully seated, re-seat the connector, clear the fault(s), then run copies to determine if the
problem is solved.
The problem still occurs.
Y
N
There are other fault codes in the Active Faults list.
Y
N
Go to the RAP for the other fault code. If there is more than one other fault code, go to the
RAP for the lowest number fault code.
03-337, 03-338
May 2003
2-54
V0.042
Figure 1 IOT/MFF Interface PWB
V0.042
May 2003
2-55
03-338
Figure 2 MFF Control PWB Test Points
03-338
May 2003
2-56
V0.042
A
Repair or replace as necessary.
03-340 IIOC Bus 0 Communication Fault

The system cannot communicate with IIOC Bus 0. All other IIOC Buses are functional.

Ensure the IIOC Bus 0 harness connector P1 is securely connected to J1 on the Distribution
PWB, and P3 is securely connected to J3 on the Distribution PWB. If necessary, connect the
connectors, then switch the power [OFF], then [On] in order to force a Power-On Self Test
(POST).
The problem continues after checking the connector.
Y
N
NOTE: When making voltage measurements in this RAP, connect the (-) meter lead to the
metal case of the LVPS, unless instructed otherwise.
Check for 24 1.2 VDC at IIOC Bus 0 harness connector P1-1.
Y
N
Switch the power [OFF]. Set the meter to measure resistance. Disconnect P1 from J1 at
the Distribution PWB. Measure the resistance from P1-1 to the metal case of the LVPS.
The resistance is greater than 100K ohms.
Y
N
Check for a short circuit on the 24 VDC wire of the IIOC Bus 0 harness. Go to the
+24 VDC Wirenet Figure 29.
Y
N
Y
N
Go to Flag 2, Flag 3, and Flag 4. Check for an open or short circuit in the Clock, SID, and SOD
lines.
A problem with the wiring is found.
Y
N
In [Self Tests tab , IIOC Controller Tests], select [IIOC Chain Controller Tests] and [Main
Controller] and [Start].
The test passes.
Y
N
If the problem continues, replace the Distribution Cable PL 1.2A Item 9.
A
V0.042
May 2003
2-57
03-340
t703032a
03-340
May 2003
2-58
V0.042
t703033a
V0.042
May 2003
2-59
03-340


PWB. If necessary, connect the connector, then switch the power [OFF], then [On] in order to
force a Power-On Self Test (POST).
Y
N
Y
N
Y
N
Go to Flag 3. Check the SID, SOD, and Clock lines for an open or short circuit.
A problem is found with the wiring.
Y
N
The test passes.
Y
N
03-341
May 2003
2-60
V0.042
V0.042
May 2003
2-61
03-341


PWB. If necessary, connect the connector, then switch the power [OFF], then [ON] in order to
force a Power-On Self Test (POST).
Y
N
Y
N
Switch the power [OFF]. Set the meter to measure resistance. Disconnect P11 from J11
at the Distribution PWB. Measure the resistance from P11-1 to the metal case of the
LVPS.
Y
N
Go to Flag 2. Check the SID, SOD, and Clock lines for an open or short circuit.
A problem is found with the wiring.
Y
N
The test passes.
Y
N
03-342
May 2003
2-62
V0.042
V0.042
May 2003
2-63
03-342

The system cannot communicate with IIOC Bus 4 (DADF). All other IIOC Buses are functional.
Procedure
Go to 05-331 DADF IIOC RAP.
03-343
May 2003
2-64
V0.042
03-345 All IIOC Buses Communication Fault
D
There is an apparent problem in the Bus 2 IIOC harness to the Finisher or OCT.
Repair the harness, or replace the Finisher or OCT, as appropriate.
The system cannot communicate with any IIOC Bus.

Replace the IIOC Bus 1 Harness PL 1.5 Item 9.
If the problem continues, disconnect the components which are connected to the
IIOC Bus 1 Harness one at a time until the problem is identified.

Check the connections of the Distribution Cable at the Main Control PWB (J13) and the Distribution PWB (J5).
The cable connections are secure.
Y
N
Securely connect the connectors and test the system to ensure the problem is resolved.
Disconnect all IIOC Harnesses from the Distribution PWB EXCEPT IIOC Bus 0 (ES).
IIOC Bus 0 at P3/J3.
IIOC Bus 4 (to DADF) at P12/J12.
IIOC Module IIOC PWB W3A1 PL 4.1A Item 4.
Tray 3/4 Paper Feed Drives Plate PL 4.1A Item 4.
Inverter PL 6.2A Item 2.
Enabled Decurler PL 6.1A Item 4 and the Decurler IIOC Harness PL 1.6 Item 3.
HCF/Bypass Tray Assembly PL 4.2A Item 1 or the Bypass Tray Assembly PL

4.3 Item 1.
Replace the IIOC Bus 0 Harness PL 1.5 Item 3.

If the problem continues, replace the Tray 1/2 Paper Feed Drives Plate PL 4.1A Item 4.

The 03-345 fault occurs again.
Y
N
Connect the IIOC Bus 0 harness to the Distribution PWB at P3/J3.
Y
N
Y
N
Y
N
Connect the IIOC Bus 4 (DADF) harness to the Distribution PWB at P12/
J12.
Y
N
Apparently the disconnecting/connecting of the P/J connectors has
solved the problem.

Disconnect IIOC Bus 0 (ES) Harnesses from the Distribution PWB at P1/J1.
Connect IIOC Bus 1 harness to the Distribution PWB at P7/J7.
Y
N
Replace the IIOC Bus 0 (ES) Harness PL 1.5 Item 10.
If the problem continues, there is a defective IIOC PWB (PL 1.5 Item 2) on the IIOC Bus 0
(ES) Harness. Use a new PWB to swap with the PWBs on the harness, one at a time,
until the defective PWB is identified.
IIOC PWB W8A1
IIOC PWB W8A2
IIOC PWB W8A3
IIOC PWB W8A4
IIOC PWB W8A5
Replace the defective IIOC PWB.

Replace the following parts, one at a time, until the problem is solved.
Distribution Cable PL 1.2A Item 9.
Distribution PWB PL 1.5 Item 7.
Replace the DADF Harness PL 2.3 Item 2 .

If the problem continues, disconnect P1 from the DADF PWB and check
for a short circuit the CLK line (Fig 1, Flag 1).
If the wiring is good, replace the DADF PWB PL 2.3 Item 4.
A
B
V0.042
May 2003
2-65
03-345
03-346 Control Panel Communication Fault
03-347 User Interface (UI) Communication Fault
Fault code 03-347 was active for over 30 seconds. Status 03-520 is declared.
The Main Control PWB cannot communicate with the UI PWB. Status 03-521 is declared.
The Main Control PWB will attempt to reestablish communication with the UI PWB for 30 seconds. If communication is not reestablished within 30 seconds, fault code 03-346 will be
declared.
Procedure
NOTE: The UI will not display this fault because of the communication problem with the main
Control PWB. This fault can be viewed only with the PWS.

NOTE: This fault can occur if the UI software version is not compatible with the Main Control
PWB software version. Refer to General Procedures / Product Specifications / Software Version Compatibility to determine the correct software versions for the machine being serviced. If
necessary, reload the UI software to correct this fault. If the UI software version is not the
cause of this fault, continue in this RAP.
NOTE: This fault can occur while installing the machine using the Install Wizard if the HCF is
not mated correctly to the IOT. Ensure the (Left Side Interlock Switch, w/o TAG 120) is actuated with the HCF installed.
There is an LED on the Main Control PWB which can be Blinking, or OFF, or On steadily. Blinking is the normal state for the LED. On steadily or OFF are abnormal states for the LED.
Observe the LED on the Main Control PWB.
The LED is blinking.
Y
N
There could be a DC voltage problem, or the Main Control PWB may have failed. Go to
the 03-G RAP.
Check the connections of the Distribution Cable at the Main Control PWB (J13) and the Distribution PWB (J5).
The connections are secure.
Y
N
Check the connections of the wire harness between the Distribution PWB (J13) and the Control Panel (J4).
The connections are secure.
Y
N
Determine if the Control Panel Backlight is switched on or off.
The Backlight is on.
Y
N
Go to the 02-D Dark/Dim Control Panel Display RAP.
In Communications Test, select [UI] and [Start]. After starting the test, allow the test to keep
running and use the Browser 'Back' button to come back to this RAP to make the voltage measurements in the next several steps.
03-346, 03-347
May 2003
2-66
V0.042
Enter [Copier Sys tab , Communications Test].

Set the meter to measure DC voltage. Connect the (-) meter lead to the metal case of the
LVPS. Connect the (+) meter lead to TH 45 on the Distribution PWB. (Refer to Figure 1.)
With the Communications Test running, the voltage is between 2.5 and 5.4 VDC.
Y
N
Check the Distribution Cable for an open or short circuit (Flag 4).
If the Distribution Cable is good, the Main Control PWB may have failed. Go to the 03-G
RAP.
Connect the (+) meter lead to J13-10 of the Distribution PWB. (Refer to Figure 1).
Y
N
Access the underside of the Control Panel Assembly (REP 02-1). Measure the voltage
between J2-4 (-) and J4-2 (+) on the Control Panel PWB.
J2 without TAG 082.
J2 with TAG 082.
Y
N
Check the harness between the Distribution PWB and the Control Panel Assembly for an
open or short circuit. (Flag 3)
A
Measure the voltage between J2-4 (-) and J4-1 (+) on the Control Panel PWB.
J2 without TAG 082.
J2 with TAG 082.
Y
N
Connect the (-) meter lead to the metal case of the LVPS. Connect the (+) meter lead to J13-9
on the Distribution PWB. (Refer to Figure 1.)
Y
N
Check the harness between the Distribution PWB and the Control Panel Assembly for an
open or short circuit. (Flag 2)
Connect the (+) meter lead to TH 50 on the Distribution PWB. (Refer to Figure 1.) Check the UI
RX signal at the Distribution PWB.
Y
N
Check the Distribution Cable for an open or short circuit (Flag 1).
If the Distribution Cable is good, the Main Control PWB may have failed. Go to the 03-G RAP.
V0.042
May 2003
2-67
03-347
Figure 2 User Interface (Without Tag 082)
03-347
May 2003
2-68
V0.042
Figure 3 UI Processor PWB (With Tag 082)
V0.042
May 2003
2-69
03-347
A
NOTE: If the machine has TAG 077, ensure the EPC SDRAM DIMM in location #1 is populated
before running the Rotation Memory Test (REP 03-9). If the SDRAM DIMM is not installed in
location #1, the test will fail.
03-348 Main Control PWB Fault

The Main Control PWB malfunctioned during the Power-On Self-Test (POST).
This RAP frequently mentions TAG 077. This tag refers to the Main Control PWB.
Machines without TAG 077 have an Atlanta Gold (or earlier) Main Control PWB.
Machines with TAG 077 have an Atlanta Platinum Main Control PWB.
460/470 machines have an Atlanta Platinum 360NLX Main COntrol PWB.

Ensure all P/J connectors and all PWBs attached to the Main Control PWB are fully seated.
For machines without TAG 077, check the Auto Segmentation PWB, the Accessory PWB,
the Rotation SRAM SIMM, the EPC DRAM SIMM, and the NVM RAM Chip.
For machines with TAG 077, check the Accessory PWB, the EPC SDRAM DIMM, and the
Software/NVM Module.
Run the Rotation Memory Test in the Diagnostic Navigator. (Select Self Tests, Video and
Controls POST, Main Controller Tests (1), then Rotation Memory Test.) Enter [Self Tests
tab , Video and Controls POST].
The Rotation Memory Test passes.
Y
N
The machine has TAG 077.
Y
N
Replace the Rotation SRAM SIMM PL 1.4A Item 5.
Run the Rotation Memory Test again.
Y
N
If any connector or PWB is not fully seated, correct the problem, then switch the power ON and
check for the 03-348 fault.
Y
N
Check the low voltage inputs to the Main Control PWB listed in Table 1. (Connect the (-) meter
lead to the metal case of the Low Voltage Power Supply.)
The voltages are in specification.
Y
N
Go to the 01-A DC Voltage Checkout Procedure.
Replace the EPC SDRAM DIMM PL 1.4B Item 5 (or PL 1.4C Item 6 if a 460/470
machine).
Run the Rotation Memory Test again.
Y
N
Run the EPC Memory Test in Diagnostic Navigator. (Select Self Tests, Video and Controls
POST, Main Controller Tests (1), then EPC Memory Test.) Enter [Self Tests tab , Video and
Controls POST].
NOTE: Ignore any message displayed when the screen is initially displayed. The test must be
run before the messages will be reliable.
Table 1 MCB Input Voltages

Voltage
P/J
Pin
+5 VDC (ES)
P1/
J13
12
+5.05 to +5.25 VDC
The EPC Memory Test passes.

Y
N
For machines without TAG 077, replace the EPC DRAM SIMM PL 1.4A Item 6.
For machines with TAG 077, replace the EPC SDRAM DIMM PL 1.4B Item 5.
For 460/470 machines, replace the EPC SDRAM DIMM PL 1.4C Item 6.
+5 VDC
P2/J7
+5.05 to +5.25 VDC
+12 VDC
P2/J7
7
5, (DC460/470)
+11.4 to +12.6 VDC
-12 VDC
P2/J7
8
6, DC460/470)
-11.4 to -12.6 VDC
Run the EPC Memory Test again.

The EPC Memory Test passes.
Y
N
A
03-348
May 2003
2-70
V0.042
03-349 SCSI PWB Communication Fault
03-352 Autosegmentation PWB Fault
The Main Control PWB cannot communicate with the SCSI Expansion PWB.
The VCM and IPM Loop Back Test fails when the Autosegmentation PWB is connected, but
passes when the Autosegmentation PWB is bypassed.

Switch the power [OFF]. Check the connection of the SCSI Expansion PWB to the Main Control PWB. If the connection is not good, correct the problem, if possible.
Switch the power [On] and check for an 03-349 fault.
The 03-349 fault continues.
Y
N
Replace the SCSI Expansion PWB.
V0.042

Switch the power [OFF]. Check the connection of the Auto Segmentation PWB to the Main
Control PWB. If the connection is not good, correct the problem, if possible.
Switch the power [On] and check for an 03-352 fault.
Y
N
Replace the Auto Segmentation PWB PL 1.4A Item 3.
May 2003
2-71
03-349, 03-352
03-354 Scanner Communication Fault
03-355 MCB POST Failure
The Main Control PWB cannot communicate with the Scanner in the IIT.
A Main Control PWB Power-On Self-Test (POST) failure was detected during the NVM Integrity Test.

This fault can usually be corrected by a PO/PO. Switch the power OFF, wait 10 seconds, then
switch the power ON. Check for an 03-354 fault.
Y
N
Ensure all connectors to the Main Control PWB are fully seated. If any connector is not fully
seated, re-seat the connector, clear the fault(s), then run copies to determine if the problem
occurs again.
Y
N

Ensure all connectors to the Main Control PWB are fully seated. Also ensure the NVM RAM
Chip is fully seated on the Main Control PWB. If any connector or the module is not fully
seated, correct the problem, then clear the faults.
Run the NVM Test in the Diagnostic Navigator. (Select Self Tests, Video and Controls POST,
Main Controller Tests (1), then NVM Test.) Enter [Self Tests tab , Video and Controls POST].
The NVM Test passed.
Y
N
Without TAG 077, replace the NVM RAM Chip PL 1.4A Item 8.
With TAG 077, replace the Software/NVM Module PL 1.4B Item 6.
On 460/470 machines, replace the Software/NVM Module PL 1.4C Item 5.
Run the NVM Test again.

The NVM Test passed.
Y
N
Replace the Image Module PL 3.2 Item 1.


03-354, 03-355
May 2003
2-72
V0.042
03-360 EP-SV Communication Fault
03-370/371/372/374/375 Control Data Error
The Main Control PWB cannot communicate with the EP-SV.
03-370: The IOT control software cannot obtain the data required to continue operation.
03-371: The HCF/Bypass Tray control software cannot obtain the data required to continue operation.
03-372: The Bypass Tray control software cannot obtain the data required to continue
operation.
03-374: The Finisher control software cannot obtain the data required to continue operation.
03-375: The OCT control software cannot obtain the data required to continue operation.

Switch the power [OFF]. Check the connection of the EP-SV harness to the Main Control
PWB. If the connection is not good, correct the problem, if possible. If necessary, replace the
EP-SV Harness. Switch the power [On]. and check for an 03-360 fault.
Y
N
Replace the EP-SV. If the problem continues, the Main Control PWB may have failed. Go to
the 03-G RAP.
Procedure
These faults are job-related and do not represent a hardware failure. If any of these faults happen, it is usually a transitory event and the software should recover without customer or CSE
intervention. If any of these faults occur frequently, collect data about the job type and function
programming, and forward that information to the DC265 Software Change Control Board.
V0.042
May 2003
2-73
03-360, 03-370/371/372/374/375
03-377 MFF Interface Data Error

This fault is declared whenever invalid data or an invalid command is received from the IOT.
Initial Actions

Switch the power [OFF]. Check the connections of the MFF Interface Cable and the RS422
Cable Figure 3. If a connection is not good, correct the problem, if possible. If necessary,
replace the MFF Interface PWB. Switch the power [On]. and check for an 03-377 fault.
Y
N
Replace the MFF Interface Cable.
If the problem continues, replace the RS422 Cable.
If the problem continues, replace MFF Control PWB PL 8.22A.
03-377
May 2003
2-74
V0.042
V0.042
May 2003
2-75
03-377
03-377
May 2003
2-76
V0.042
03-380 Distribution PWB Fault
03-381 MFF Not Responding
The Main Control PWB cannot communicate with the Distribution PWB at Power-Up.
This fault is declared due to a Serial Control Bus (SCB) Harness break, a bad SCB transmit or
SCB transmit not acknowledged.

Switch the power [OFF]. Check the connection of the Distribution Cable to the Main Control
PWB. If the connection is not good, correct the problem, if possible. If necessary, replace the
Distribution Cable PL 1.2A Item 9. Switch the power [On]. and check for an 03-380 fault.
Y
N
Return to Service Call Procedures
Replace the Distribution PWB PL 1.5 Item 7. If the problem continues, the Main Control PWB
may have failed. Go to the 03-G RAP.
V0.042

Switch the power [OFF]. Check the connections of the SCB Harness. If a connection is not
good, correct the problem, if possible. If necessary, replace the SCB Harness. Switch the
power [On]. and check for an 03-381 fault.
Y
N
Replace the MFF Interface PWB PL 8.22A.
If the problem continues, the IOT Main Control PWB may have failed. Go to the 03-G
RAP.
May 2003
2-77
03-380 , 03-381
03-381
May 2003
2-78
V0.042
03-382 MFF RS-422 Connection Fault

This fault indicates that the RS-422 Harness is not connected.
Initial Actions

Y
N
Replace the RS422 Cable
V0.042
May 2003
2-79
03-382
03-382
May 2003
2-80
V0.042
V0.042
May 2003
2-81
03-382
03-383 MFF RS-422 Communication Fault

This fault indicates that an RS-422 Transmit was not acknowledged.
Initial Actions

Y
N
If the problem continues, replace the RS422 Cable
03-383
May 2003
2-82
V0.042
V0.042
May 2003
2-83
03-383
03-383
May 2003
2-84
V0.042
03-390 Software Upgrade Automation Failed
13. Power off and power on the machine.
The system detects that Automatic Software Upgrade was not completed. Only machines with
19.02.xx software and later can have this fault cone.
1.
Select [Marking tab , Xerographic Diagnostics]
2.
Select [Set-up], and select [Start].
3.
Move the Run-Time Data window out of the way of the Xerographic Diagnostics window.
4.
When the Results box in Xerographic Diagnostics window displays, Xerographic Set-Up
Passed, [Close] the Run-Time Data window and [Exit] the Xerographic Diagnostics routine.
May 2003
2-85
Initialize the Xerographic NVM

1.
Select the [NVM tab , IOT Variable NVM Initialization], answer [No] to the confirmation to
download NVM.
2.
Select the Category: [Xerographics], and select [Start]. Answer [Yes] to the confirmation
to continue.
3.
Select [OK] to dismiss the notification to power off and power on the machine, but do not
power off and on the machine at this time.
Perform a Xerographic Setup
NOTE: You will be instructed to power off and power on the machine later, after you have
made the required NVM changes.
4.
[Exit] the IOT Variable NVM Initialization routine.
Enter NVM Values and ensure Xerographic control is in closed-loop

mode
1.
Open the Front Door of the machine, observe the Bar Code Label (Figure 1) on the front
of the ROS, and record the following numbers from the label
a.
From under the third bar code, record the three digits that appear after the letter L
this is the (imageFastScanReg).
b.
From under the second bar code, record the four or five digits that appear after the
letter H, this is the (hallPeriodRef).
c.
From under the second bar code, record the number (a zero, decimal point, and four
digits) that appear between the letter H, this is the (exposureCallibration).
2.
Close the Front Door.
3.
Select [NVM tab , NVM Tool].
4.
Select the [Machine] menu and select [Download] or select the Download Icon from the
menu bar.
5.
A dialog box appears asking if you want to initiate download. Select [Yes] and wait for the
download to complete.
6.
After the download completes, select Service: [Mark Service].
7.
Scroll or [Search] to location 723 (imageFastScanReg), double click and change the
value to the number recorded earlier.
8.
Scroll or [Search] to location 729 (hallPeriodRef), double click and change the value to
the number recorded earlier.
9.
Scroll or [Search] to location 793 (exposureCalibration), double click and change the
value to the number recorded earlier.
10. If this is a High Altitude machine (with Tag# 297 and above 4000 ft. (1200 m)): Scroll (or
[Search] to location 841 (machineAltitude), double click and change the value to the altitude, in feet, at which the machine is installed.
NOTE: To convert meters to feet, multiply the number of meters by 3.
11. Scroll or [Search] to location 870 (openLoopEnabled), double click and change the value
to (0) zero.
12. Exit the NVM Tool (select the [File] menu and select [Exit]).
V0.042
03-390
ROS Serial#
Part#
Hall Period Reference (Preceded by letter H)

HallPeriodRefFa - NVM Loc = 1397
HallPeriodRefGb - NVM Loc = 729
Image Fast Scan Reg
(NVM 723)
Exposure Calibration
(preceded by the letter E)
(NVM 793)
Figure 1 ROS Bar Code Label
03-390
May 2003
2-86
V0.042
03-777 Power Lost Detected
03-800 IIOC Bus 0 Failed The IIOC Controller Test
The System detects that power was lost due to the user selecting the Red Power Off button,
Input Power lost during power-up, or power lost while coming out of Power Saver mode.
Procedure
Ensure that the user does not unplug the machine or select the Red Power Off Button during
machine power-up.
V0.042
IIOC Bus 0 failed the IIOC Controller Test. This fault code indicates a failure of the Bus Controller Chip on the Main Control PWB.
Procedure
May 2003
2-87
03-777, 03-800
03-801 IIOC Module W8A2 Failed The IIOC Controller Test

IIOC Module W8A2 failed the IIOC Controller Test.
A
The presence of all of the listed faults indicates a failure of the portion of IIOC Bus 0 which is
powered by +24VDC (ES).
Perform the following corrective actions:
The following components are suspect for this failure.
Check the connection of IIOC Bus 0 (P1) to the Distribution PWB (J1) ( P/J1). Reconnect
or repair as necessary.
Toner Dispenser Motor (Part of the Dry Ink Dispenser) PL 5.1B Item 4.
Fuser Fan/Duct PL 9.1 Item 5.
If the problem continues, replace the Bus 0 (ES) IIOC Harness PL 1.5 Item 10.
IIOC PWB W8A2 PL 1.5 Item 2.
Bus 0 (ES) IIOC Harness PL 1.5 Item 10.

Check the Last 40 Faults for the presence of each of the following faults: 03-801, 03-809, 03811, 03-812, and 03-813. Enter [Faults/Counters tab , Faults].
ALL of the listed faults are logged.
Y
N
The use of this RAP assumes the IIOC Controller Test has failed, and you know whether
the failure is a Type 1 or Type 2. If you do not know the failure type, enter [Self Tests tab ,
IIOC Controller Tests], select [IIOC Self Tests] and [IOT], then run the [Type 1] and [Type
2] tests.
The 03-801 fault code occurred after the Type 1 test.
Y
N
A Type 2 test failure indicates the energizing voltage through the output component
was not gated to zero by the IIOC PWB.
Check the output components and the associated wiring for a short circuit across the
load.
Refer to Flag 2 for the Toner Dispenser Motor.
Refer to Flag 4 for the Fuser Fan/Duct.
There is a short circuit across the load.

Y
N
Replace the IIOC PWB W8A2 PL 1.5 Item 2. Go to the 03-C IIOC Bus 0 Module
Pin Configuration to check the pin connections from the IIOC Housing to the
IIOC PWB.
If a component has a short circuit, replace the component. (Go to the top of this RAP
for the PL links.) If the wiring has a short circuit, repair the wiring.
A Type 1 test failure indicates the energizing voltage through an output component was
not sensed by the IIOC PWB.
Check the output components and the associated wiring for an open circuit or a short circuit to DC COM.
Refer to Flag 2 for the Toner Dispenser Motor.
Refer to Flag 4 for the Fuser Fan/Duct.
There is an open circuit or a short circuit to DC COM.

Y
N
Replace the IIOC PWB W8A2 PL 1.5 Item 2. Go to the 03-C IIOC Bus 0 Module Pin
Configuration to check the pin connections from the IIOC Housing to the IIOC PWB.
If a component has an open or short circuit, replace the component. (Go to the top of this
RAP for the PL links.) If the wiring has an open or short circuit, repair the wiring.
A
03-801
May 2003
2-88
V0.042
V0.042
May 2003
2-89
03-801
03-803 IIOC Module A7A1 Failed The IIOC Controller Test
IIOC Module A7A1 failed the IIOC Controller Test. This IIOC Module controls the Elevator
Motors for Tray 1 and Tray 2.
IIOC Module A7A2 failed the IIOC Controller Test. This IIOC Module controls the Paper Size
Sensing Switches in Tray 1.
Y
N
Replace the Tray 1/2 Paper Feed Drives Plate PL 4.1A Item 4.
Y
N
powered by +24VDC (not ES).
If the problem continues, replace the Bus 0 IIOC Harness PL 1.5 Item 3.
03-803, 03-804
May 2003
2-90
V0.042
IIOC Module A7A4 failed the IIOC Controller Test. This IIOC Module controls the Stack Height
Sensors and the Nudger Solenoids for Tray 1 and Tray 2.
Y
N
Y
N
V0.042
May 2003
2-91
03-805, 03-806

IIOC Module A7A5 failed the IIOC Controller Test. This IIOC Module controls the Wait Station
Sensors and the Feed Motor for Tray 1 and Tray 2.

Y
N
03-807
May 2003
2-92
V0.042
V0.042
May 2003
2-93
03-807
N
You can be directed to this RAP from the 22-757.04 RAP (Mark Service Configuration Error),
or as a result of IIOC Module W25A1 failing the IIOC Controller Test. This IIOC module is
present only on 55 ppm machines, and is required for electronic validation that the machine is
a 55 ppm machine.
NOTE: The W25A1 IIOC module is on 55 ppm machines only. It is located just to the
right of W8A3, shown on Component Locator Drawing 14 (IIOC PWB W8A3). It is
also the same part number as W8A3, shown on Parts List 1.5, Item 2.
Go to the 03-C IIOC Bus 0 Module Pin Configuration to check the pin connections
from the IIOC Housing to the IIOC PWB.
Resistor Module (not spared).

Check the Last 40 Faults for the presence of each of the following faults: 03-801, 03-809, 03811, 03-812, 03-813, and 03-815. Enter [Faults/Counters tab , Faults].
Y
N
2] tests.
Y
N
load.
Refer to Flag 1 for the Resistor Module.

Y
N
NOTE: The W25A1 IIOC module is on 55 ppm machines only. It is located just
to the right of W8A3, shown on Component Locator Drawing 14 (IIOC PWB
W8A3). It is also the same part number as W8A3, shown on Parts List 1.5, Item
2.
Go to the 03-C IIOC Bus 0 Module Pin Configuration to check the pin connections from the IIOC Housing to the IIOC PWB.
Refer to Flag 1 for the Resistor Module.

A
03-808
May 2003
2-94
V0.042
V0.042
May 2003
2-95
03-808

C
A Type 1 test failure indicates the energizing voltage through an output component
was not sensed by the IIOC PWB.
Check the output components and the associated wiring for an open circuit or a
short circuit to DC COM.
Refer to Flag 2 for the Toner Bottle Motor.
Toner Bottle Motor (Part of the Dry Ink Dispenser) PL 5.1B Item 4.
Refer to Flag 4, Flag 5, Flag 6, and Flag 7 for the Power On Relay.
Overheat thermostat (Part of the Fuser Module) PL 6.2A Item 1 .
Power On Relay K1 (Part of the AC Distribution Panel) PL 1.2A Item 1.

Y
N
IIOC PWB.
If a component has an open or short circuit, replace the component. (Go to the top of
this RAP for the PL links.) If the wiring has an open or short circuit, repair the wiring.
Y
N
Switch the power [OFF].

Disconnect both output components from W8A1 (J2 and J4).
Switch the power [ON].
Open the Front Door and DO NOT use the Interlock Cheater.
The Front Door indicator or message has a steady indication that the Front Door
is open.
Y
N
NOTE: Shorted output components can cause an IIOC PWB to go into thermal overload
which usually results in a cycling OFF/On condition of the PWB as it goes through the
states of ''overload', 'reset', 'overload', 'reset', etc. The cycling frequency increases as the
temperature of the IIOC PWB increases.
For IIOC Module W8A1, thermal overload could manifest itself with a cycling of the Control Panel to indicate the Front Door is being repetitively opened and closed. Also, Relay
K1 can be heard to energize and de-energize at the same rate as the cycling of the Front
Door indicator or message.
The Front Door indicator or message shows the door being repetitively opened
and closed.
Y
N
The use of this RAP assumes the IIOC Controller Test has failed, and you know
whether the failure is a Type 1 or Type 2. If you do not know the failure type, enter
[Self Tests tab , IIOC Controller Tests], select [IIOC Self Tests] and [IOT], then run
the [Type 1] and [Type 2] tests.
Y
N
A Type 2 test failure indicates the energizing voltage through the output component was not gated to zero by the IIOC PWB.
Check the output components and the associated wiring for a short circuit
across the load.
Refer to Flag 2 for the Toner Bottle Motor.
Refer to Flag 4, Flag 5, Flag 6, and Flag 7 for the Power On Relay.

Y
N
If a component has a short circuit, replace the component. (Go to the top of this
RAP for the PL links.) If the wiring has a short circuit, repair the wiring.
A
B
C
03-809

Connect the Toner Bottle Motor to J2 on W8A1.
Open the Front Door and DO NOT use the Interlock Cheater.
The Front Door indicator or message has a steady indication that the Front Door
is open.
Y
N
Replace the Dry Ink Dispenser PL 5.1B Item 4
If the problem continues, replace the IIOC PWB W8A1 PL 1.5 Item 2. Go to the 03-C
IIOC Bus 0 Module Pin Configuration to check the pin connections from the IIOC
Housing to the IIOC PWB.
Replace the AC Distribution Panel PL 1.2A Item 1.
If the problem continues, replace the IIOC PWB W8A1 PL 1.5 Item 2. Go to the 03-C IIOC
Bus 0 Module Pin Configuration to check the pin connections from the IIOC Housing to
the IIOC PWB.
May 2003
2-96
V0.042
V0.042
May 2003
2-97
03-809
B
LVPS Cooling Fan/Duct PL 9.1 Item 2 and PWB Cooling Fan/Duct PL 9.1 Item 3.
Pre-Reg Solenoid (Part of the Duplex Transport) PL 6.1A.
All service actions must be performed on-site.

Y
N
2] tests.
Y
N
load.
Refer to Flag 2 for the LVPS Cooling Fan/Duct and the PWB Cooling Fan/Duct.
Refer to Flag 3 for the Duplex Transport Pre-Reg Solenoid.

Y
N
IIOC PWB.
Refer to Flag 2 for the LVPS Cooling Fan/Duct and the PWB Cooling Fan/Duct.
Refer to Flag 3 for the Duplex Transport Pre-Reg Solenoid.

Y
N
A
B
03-811
May 2003
2-98
V0.042
V0.042
May 2003
2-99
03-811

A
Duplex Wait Clutch PL 6.1B Item 2.
PFT Fan (Part of the Prefuser Transport) PL 6.1A Item 1.

Y
N
2] tests.
Y
N
load.
Refer to Flag 2 for the Duplex Wait Clutch.
refer to Flag 4 for the PFT Fan.

Y
N
IIOC PWB.
Refer to Flag 2 for the Duplex Wait Clutch.
Refer to Flag 4 for the PFT Fan.

Y
N
A
03-812
May 2003
2-100
V0.042
V0.042
May 2003
2-101
03-812
B
PreCharge Erase Lamp (Part of the Xerographic Module) PL 5.1A Item 1.
Xerographic Blower PL 9.1 Item 11.

Y
N
2] tests.
Y
N
load.
Refer to Flag 1 for the Xerographic Blower.
Refer to Flag 2 for the PreCharge Erase Lamp.

Y
N
IIOC PWB.
Refer to Flag 1 for the Xerographic Blower.
Refer to Flag 2 for the PreCharge Erase Lamp.

Y
N
A
B
03-813
May 2003
2-102
V0.042
V0.042
May 2003
2-103
03-813
IIOC Module W20A1 failed the IIOC Controller Test. This IIOC module is present only on FX
machines, and is used to increment two mechanical billing meters.
NOTE: The W20A1 IIOC module is on FX machines only. It is located just to the right
of W8A3, shown on Component Locator Drawing 14 (IIOC PWB W8A3). It is also the
same part number as W8A3, shown on Parts List 1.5, Item 2.
Main Copy Counter (M1).
Resettable Copy Counter (M2).
Go to the 03-C IIOC Bus 0 Module Pin Configuration to check the pin connections
from the IIOC Housing to the IIOC PWB.

Check the Last 40 Faults for the presence of each of the following faults: 03-801, 03-809, 03811, 03-812, 03-813, and 03-815. Enter [Faults/Counters tab , Faults].
Y
N
2] tests.
Y
N
load.
Refer to Flag 1 for the Main Copy Counter (M1).
Refer to Flag 2 for the Resettable Copy Counter (M2).
N

Y
N
NOTE: The W20A1 IIOC module is on FX machines only. It is located just to
the right of W8A3, shown on Component Locator Drawing 14 (IIOC PWB
W8A3). It is also the same part number as W8A3, shown on Parts List 1.5, Item
2.
Refer to Flag 1 for the Main Copy Counter (M1).

Refer to Flag 2 for the Resettable Copy Counter (M2).
A
03-815
May 2003
2-104
V0.042
V0.042
May 2003
2-105
03-815
IIOC Module A8A3 failed the IIOC Controller Test. This IIOC Module controls the Elevator
Motors for Tray 3 and Tray 4.
Procedure
Procedure
03-820, 03-823
May 2003
2-106
V0.042
Procedure
Procedure
V0.042
May 2003
2-107
03-824, 03-825
IIOC Module A8A4 failed the IIOC Controller Test. This IIOC Module controls the Stack Height
Sensors and the Nudger Solenoids for Tray 3 and Tray 4.
IIOC Module A8A5 failed the IIOC Controller Test. This IIOC Module controls the Wait Station
Sensors and the Feed Motor for Tray 3 and Tray 4.
Procedure
Procedure
03-826, 03-827
May 2003
2-108
V0.042
V0.042
May 2003
2-109
03-827
Inverter Close Nip Solenoid (Part of the Inverter) PL 6.2A Item 2.
IIOC Module A4W1A1 failed the IIOC Controller Test. This IIOC module is a part of the
Inverter.
IIOC PWB A4A1 (Part of the Inverter) PL 6.2A Item 2.
Procedure
Replace the Inverter PL 6.2A Item 2.
Inverter Reverse Drive Solenoid (Part of the Inverter) PL 6.2A Item 2.
03-828
May 2003
2-110
V0.042
Inverter Duplex Gate Solenoid (Part of the Inverter) PL 6.2A Item 2.
IIOC Module A4W1A2 failed the IIOC Controller Test. This IIOC module is a part of the Inverter.
IIOC PWB A4A2 (Part of the Inverter) PL 6.2A Item 2
Procedure
Inverter Entrance Gate Solenoid (Part of the Inverter) PL 6.2A Item 2.
V0.042
May 2003
2-111
03-829
03-831 An HCF Circuit Failed The IIOC Controller Test

An IIOC controller on the HCF PWB failed the IIOC Controller Test.
HCF Elevator Motor Assembly PL 4.2B Item 9.
HCF PWB PL 4.2B Item 10.
HCF/Bypass Tray Assembly PL 4.2A Item 1.

Check the Last 40 Faults for the presence of each of the following faults: 03-831, 03-832, 03833, and 03-834. Enter [Faults/Counters tab , Faults].
Y
N
Perform the following actions.
Go to Flag 3 and check for an open or short circuit. Repair as required.
If the wiring is good, replace the HCF Elevator Motor Assembly PL 4.2B Item 9.
The presence of all of the listed faults indicates a failure of IIOC Bus 1 within the HCF/Bypass
Tray Assembly. Replace the HCF PWB PL 4.2B Item 10.
If the problem continues, replace the HCF/Bypass Tray Assembly PL 4.2A Item 1.
03-831
May 2003
2-112
V0.042
V0.042
May 2003
2-113
03-831
03-832 A Bypass Tray Or HCF Circuit Failed The IIOC

Controller Test
An IIOC controller for the Bypass Tray and/or HCF failed the IIOC Controller Test.
If the problem is on a machine which has only a Bypass Tray, the following component is suspect for this failure.
Bypass Tray Assembly PL 4.3 Item 1.
If the problem is on a machine which has a Bypass Tray/HCF combination, the following components are suspect for this failure.
Procedure
The machine has an HCF/Bypass Tray Assembly.
Y
N
Replace the HCF PWB PL 4.2B Item 10.
03-832
May 2003
2-114
V0.042
V0.042
May 2003
2-115
03-832

Controller Test

Y
N
Bypass Tray Solenoid, part of the Bypass Tray Feeder PL 4.2B Item 4.
HCF Solenoid, part of the HCF Feeder PL 4.2B Item 3.
HCF/Bypass tray Assembly PL 4.2A Item 1.
Tray Assembly. Perform the following actions.
Replace the Replace the HCF PWB PL 4.2B Item 10.
If the problem continues, replace the HCF/Bypass tray Assembly PL 4.2A Item 1.

Y
N
Y
N
2] tests.
Y
N
load.
Refer to Flag 3 for the Bypass Tray Solenoid.
Refer to Flag 4 for the HCF Solenoid.

Y
N
Refer to Flag 3 for the Bypass Tray Solenoid.
Refer to Flag 4 for the HCF Solenoid.
A
03-833
May 2003
2-116
V0.042
V0.042
May 2003
2-117
03-833

Controller Test
HCF/Bypass Tray Feed Motor PL 4.2B Item 8.

Y
N
Y
N
Perform the following actions.
Replace the HCF/Bypass Tray Feed Motor PL 4.2B Item 8.
Tray Assembly. Perform the following actions.
03-834
May 2003
2-118
V0.042
V0.042
May 2003
2-119
03-834

On machines without TAG 022 or with TAG 040, module W21A1 is connected to the
Enabled Decurler.
On machines with TAG 022 and without TAG 040, module W21A1 is connected to a
Resistor Plug at connector P2.
Procedure
With TAG 022 and without TAG 040, replace the Resistor Plug PL 6.1A Item 7.
Without TAG 022 or with TAG 040, replace the Enabled Decurler PL 6.1A Item 4.
03-835
May 2003
2-120
V0.042
V0.042
May 2003
2-121
03-835

ROS/Developer Cooling Fan PL 9.1 Item 8.
Registration Clutch PL 4.1B Item 13.
IIOC PWB W3A1 PL 1.5 Item 2
This RAP must be performed on-site.
Initial Actions
Ensure IOT TAG 112 Convenience Stapler Harness Kit is installed. This kit was designed to
help decrease failures of W3A1 by isolating the static created by the Convenience Stapler
Cord.
Procedure
The use of this RAP assumes the IIOC Controller Test has failed, and you know whether the
failure is a Type 1 or Type 2. If you do not know the failure type, enter [Self Tests tab , IIOC
Controller Tests], select [IIOC Self Tests] and [IOT], then run the [Type 1] and [Type 2] tests.
Y
N
Type 2 test failures indicate the energizing voltage through the output component was not
gated to zero by the IIOC PWB.
load.
Refer to Flag 2 for the ROS/Developer Cooling Fan.
Refer to Flag 4 for the Registration Clutch.

Y
N
Replace the IIOC PWB W3A1 PL 1.5 Item 2. Go to the 03-D IIOC Bus 0 Module Pin
If a component has a short circuit, replace the component. (Go to the top of this RAP for
the PL links.) If the wiring has a short circuit, repair the wiring.
Type 1 test failures indicate the energizing voltage through an output component was not
sensed by the IIOC PWB.
Check the output components and the associated wiring for an open circuit or a short circuit to
DC COM.
Refer to Flag 2 for the ROS/Developer Cooling Fan.
Refer to Flag 4 for the Registration Clutch.

Y
N
Replace the IIOC PWB W3A1 PL 1.5 Item 2. Go to the 03-D IIOC Bus 0 Module Pin Configuration to check the pin connections from the IIOC Housing to the IIOC PWB.
If a component has an open circuit or a short circuit, replace the component. (Go to the top of
this RAP for the PL links.) If the wiring has an open circuit or a short circuit, repair the wiring.
03-836
May 2003
2-122
V0.042
V0.042
May 2003
2-123
03-836
03-837 An HCF Circuit Failed The IIOC Controller Test
An IIOC controller on the HCF PWB failed the IIOC Controller Test.

Procedure
03-837, 03-840
May 2003
2-124
V0.042

IIOC Module W1A1 (on the OCT) failed the IIOC Controller Test.
OCT Offset Motor (Part of the Offsetting Catch Tray Assembly PL 8.1 Item 1.
OCT IIOC PWB W1A1 (Part of the Offsetting Catch Tray Assembly PL 8.1 Item 1.
Procedure
The use of this RAP assumes the IIOC Controller Test has failed, and you know whether the
failure is a Type 1 or Type 2. If you do not know the failure type, enter [Self Tests tab , IIOC
Controller Tests], select [IIOC Self Tests] and [IOT], then run the [Type 1] and [Type 2] tests.
Y
N
A Type 2 test failure indicates the energizing voltage through the output component was
not gated to zero by the IIOC PWB.
load.
Refer to Flag 3 for the OCT Offset Motor.

Y
N
Replace the OCT IIOC PWB W1A1 PL 1.5 Item 2. Go to the 03-E IIOC Bus 2 Module Pin Configuration to check the pin connections from the IIOC Housing to the IIOC
PWB.
If a component has a short circuit, replace the component. (Go to the top of this RAP for
the PL links.) If the wiring has a short circuit, repair the wiring.
A Type 1 test failure indicates the energizing voltage through an output component was not
sensed by the IIOC PWB.
Check the output components and the associated wiring for an open circuit or a short circuit to
DC COM.
Refer to Flag 3 for the OCT Offset Motor.

Y
N
Replace the OCT IIOC PWB W1A1 PL 1.5 Item 2. Go to the 03-E IIOC Bus 2 Module Pin
If a component has an open or short circuit, replace the component. (Go to the top of this RAP
for the PL links.) If the wiring has an open or short circuit, repair the wiring.
V0.042
May 2003
2-125
03-841
03-841
May 2003
2-126
V0.042
03-A Common SCB Circuit RAP
B
RAP.
The purpose of this procedure is to check the SCB circuitry that is common to the ROS and the
Finisher in the event the Main Control PWB cannot communicate with both the ROS and the
Finisher.
With the [Communication Test 1] running, measure the voltage at TH44 on the Distribution PWB.
Y
N
Main Control PWB PL 1.4A Item 1 (without TAG 077) or PL 1.4B Item 1 (with TAG 077) or
PL 1.4C Item 1 (on 460/470s).
ROS PL 5.2 Item 3.
Go to Flag 3 and check the Distribution Cable for an open circuit. If the circuit is open,
replace the Distribution Cable PL 1.2A Item 9.
If the Distribution Cable checks OK, the Main Control PWB may have failed. Go to the 03G RAP.
This RAP must be performed on-site.

Go to Flag 1 and check the Distribution Cable for an open circuit. If the circuit is open, replace
the Distribution Cable PL 1.2A Item 9.
If the Distribution Cable checks OK, the Main Control PWB may have failed. Go to the 03-G
RAP.
Procedure
Switch the power Off. Disconnect connector P72 from the ROS. Switch the power On.
The machine problem continues.
Y
N
Switch the power Off. Reconnect the ROS connector P72. Check the Distribution Cable connections at the Main Control PWB and the Distribution PWB.
Y
N
Switch the power On. Set the meter to measure DC volts. Connect the meter leads to P4-2 (-)
and P4-1 (+) at the Distribution PWB.
Y
N
Connect the meter leads to P10-8 (-) and P10-7 (+) at the Distribution PWB.
Y
N
Connect the meter leads to P10-8 (-) and P10-2 (+) at the Distribution PWB. In Communications Test, select [SCB], and [Reset Test]. Enter [Copier Sys tab , Communications Test].
Y
N
Connect the (-) meter lead to the metal case of the LVPS. Connect the (+) meter lead to
TH38 (+) on the Distribution PWB. In Communications Test, select [SCB] and [Communication Test 1], and observe the voltage measurement. Enter [Copier Sys tab , Communications Test].
Y
N
Go to Flag 2 and check the Distribution Cable for an open circuit. If the circuit is
open, replace the Distribution Cable PL 1.2A Item 9.
A
B
V0.042
May 2003
2-127
03-A
Figure 1 03-A RAP Circuit Diagram
03-A
May 2003
2-128
V0.042
03-B Common CRUM Communication Failure RAP

This procedure is performed when the 9-350 Fault and the 10-350 Fault are both present. Both
faults present at the same time indicate the Main Control PWB cannot communicate with either
the Xerographic Module CRUM (9-350 Fault) or the Fuser Module CRUM (10-350 Fault).
03-B On-Site Diagnostic Procedure

Check the Distribution Cable between the Main Control PWB and the Distribution PWB.
Y
N
In Communication Test, select [CRUM] and [Start Test]. Enter [Copier Sys tab , Communications Test].
The CRUM Communication Test passes.
Y
N
Go to Flag 1 and check the three lines for an open circuit.
One of the lines is open.
Y
N
In Communication Test, select [CRUM] and [Start Test]. Enter [Copier Sys tab , Communications Test].
The CRUM Communication Test passes.
Y
N
Replace the Distribution Cable PL 1.2A Item 9.
Perform the following actions in the order listed until the problem is solved.
If the problem continues, go to Flag 2 and check for an open on both the Fuser Module
CRUM clock and Xerographic Module CRUM clock lines. Repair or replace as necessary.
If no open is found, go to Flag 3 and check for an open on both the Fuser Module CRUM
data and Xerographic Module CRUM data lines. Repair or replace as necessary.
V0.042
May 2003
2-129
03-B
Figure 1 03-B RAP Circuit Diagram
03-B
May 2003
2-130
V0.042
03-C IIOC Bus 0 Module Pin Configuration
Table 1 IIOC Housing Pin Connections
Procedure
Within Bus 0, each IIOC PWB is uniquely controlled by the matrix of pins which touch the PWB
from the IIOC Housing. (Refer to Figure 1.)
The five large pins in the IIOC Housing make the connection of the IIOC harness to the
IIOC PWB. All five large pins must touch the IIOC PWB.
The seven small pins in the IIOC Housing are the programming pins. Each IIOC module
has a unique address, determined by which programming pins are bent down into the
IIOC Housing and DO NOT touch the IIOC PWB.
Module
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
W20A1 (FX Only)
W25A1 (55 ppm Only)
Refer to Table 1 for specific Module # and Pin # combinations.
Figure 1 IIOC Pins

Module
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
A7A1 (Paper Tray Plate)
W8A1 (IOT rear)
W8A2 (IOT rear)
W8A3 (IOT rear)
W8A4 (IOT rear)
W8A5 (IOT rear)
V0.042
May 2003
2-131
03-C
03-D IIOC Bus 1 Module Pin Configuration
03-E IIOC Bus 2 Module Pin Configuration
Procedure
Procedure
from the IIOC Housing. (Refer to Figure 1)
from the IIOC Housing. (Refer to Figure 1)
Figure 1 03-D RAP Circuit Diagram

Module
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
A4A1 (Inverter Module)
A4A2 (Inverter Module)
A8A 5 (Paper Tray Plate)
A14A1
W3A1 (IOT rear)
W21A1
03-D, 03-E
Figure 1 IIOC Pins
Module
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
A7A1 (Finisher)
W1A1 (OCT)
May 2003
2-132
V0.042
03-F Continuous Resets RAP

The machine stays in a continuous cycle of power up, reset, power up, reset, etc.
Procedure
Check the voltage at the +5V test point on the LVPS.
Y
N
Go to the 01-A DC Voltage Checkout Procedure to diagnose the problem.
V0.042
May 2003
2-133
03-F
03-G Main Control PWB RAP
CAUTION
The NVM Chip can be installed incorrectly which will result in an apparent failure of
the Main Control PWB. When moving the NVM Chip from the old MCB to the new
MCB, be sure to install it in the manner described in repair procedure REP 03-7.
NOTE: You should use this RAP only when directed here from another RAP.
The purpose of this RAP is two-fold.
First, this RAP will ensure the low voltages to the Main Control PWB are correct BEFORE
replacing the PWB.
Second, replacement of the Main Control PWB may not always be successful because
the NVM chip which will be transferred from the old Main Control PWB to the new Main
Control PWB may be corrupted. This RAP provides additional troubleshooting steps to
follow when that situation occurs.
The problem is resolved and the machine operates correctly with the new Main
Control PWB.
Y
N
Install a new NVM RAM Chip PL 1.4A Item 8.
CAUTION
The NVM Chip can be installed incorrectly which will result in an apparent failure of the Main Control PWB. Be sure to install the new NVM Chip in the manner described in repair procedure REP 03-7.
Procedure
The machine appears to operate normally after the NVM RAM chip is
replaced and the NVM values are reloaded.
Y
N
The new Main Control PWB is apparently defective. Replace the Main
Control PWB again PL 1.4A Item 1.
CAUTION
The machine has TAG 077 installed.

Y
N
Go to the procedure for Main Control PWB Without Tag 077
The machine is a 460 or 470.
Y
N
Go to the procedure for Main Control PWB With Tag 077
The NVM Chip can be installed incorrectly which will result in an apparent
failure of the Main Control PWB. When moving the NVM Chip from the old
MCB to the new MCB, be sure to install the NVM Chip in the manner
described in repair procedure REP 03-7.
Go to the procedure for Main Control PWB (460/470 - Atlanta Platinum 360 NLX).
Main Control PWB Without Tag 077
The problem is the machine time of day clock is not maintaining the correct time.
Y
N
Check to see if the machine has the Electronic Hole Removal (EHR) PWB TAG 296
installed.
If the Electronic Hole Removal (EHR) PWB is installed, switch the power Off, remove
the PWB, then switch the power On.
If the machine does NOT have TAG 296, answer Yes to the following statement.

Switch off the machine power and disconnect all connectors from the ESS PWB. Switch
on the machine power and check for normal IOT boot-up.
The IOT now boots up normally.
Y
N
Replace the Main Control PWB PL 1.4A Item 1, following the procedure in REP 034.
CAUTION
The problem continues with the EHR PWB removed.

Y
N
Replace the Electronic Hole Removal PWB. Ensure the correct EHR PWB is used.
Refer to Table 2.
The NVM Chip can be installed incorrectly which will result in an apparent failure of
the Main Control PWB. When moving the NVM Chip from the old MCB to the new
MCB, be sure to install it in the manner described in repair procedure REP 03-7.
Before replacing the Main Control PWB, ensure the machine is NOT in power saver
mode, then check the low voltage inputs to the Main Control PWB listed in Table 1. (Connect the (-) meter lead to the metal case of the Low Voltage Power Supply.)
Y
N
Control PWB.
Y
N
CAUTION
The NVM Chip can be installed incorrectly which will result in an apparent failure of the Main Control PWB. Be sure to install the new NVM Chip in the manner described in repair procedure REP 03-7.
The machine has an ESS.

Y
N
Replace the Main Control PWB PL 1.4A Item 1, following the procedure in REP 034.
A
B
03-G
The machine appears to operate normally after the NVM RAM chip is
replaced and the NVM values are reloaded.
Y
N
Control PWB again PL 1.4A Item 1.
A
May 2003
2-134
E
V0.042
E
CAUTION
The NVM Chip can be installed incorrectly which will result in an apparent
failure of the Main Control PWB. When moving the NVM Chip from the old
MCB to the new MCB, be sure to install the NVM Chip in the manner
described in repair procedure REP 03-7.

Go to the 16-B RAP.
CAUTION
The NVM Chip can be installed incorrectly which will result in an apparent failure of the Main
Control PWB. Be sure to install the new NVM Chip in the manner described in repair procedure
REP 03-7.
V0.042
May 2003
2-135
03-G
H
Y
Main Control PWB With Tag 077

Y
N
Check to see if the machine has the Electronic Hole Removal (EHR) PWB TAG 080
installed.
If the Electronic Hole Removal (EHR) PWB is installed, switch the power Off, remove
the PWB, then switch the power On.
N
Control PWB again PL 1.4B Item 1.

Go to the 16-B RAP.

Y
N
Replace the Electronic Hole Removal PWB. Ensure the correct EHR PWB is used.
Refer to Table 2.
Main Control PWB (460/470 - Atlanta Platinum 360 NLX)
Y
N
Y
N
Switch the power Off. Remove the Electronic Hole Removal (EHR) PWB, then switch the
power On.
Y
N
Replace the Electronic Hole Removal PWB PL 1.4C Item 3.
Install a new Software/NVM Module PL 1.4B Item 6.

Y
N
Replace the Main Control PWB PL 1.4B Item 1, following the procedure in REP 034.
Control PWB.
Y
N
The machine appears to operate normally after the Software/NVM Module
is replaced and the NVM values are reloaded.
Y
N
Control PWB again PL 1.4B Item 1.
Y
N
Y
N
Replace the Main Control PWB PL 1.4C Item 1, following the procedure in REP 034.
Control PWB.
Y
N
Install a new Software/NVM Module PL 1.4C Item 5.
Y
N
Control PWB again PL 1.4C Item 1.

Y
N
Replace the Main Control PWB PL 1.4B Item 1, following the procedure in REP 034.
Control PWB.
Y
N
F
G H
03-G

I
May 2003
2-136
V0.042
I
Y
N
Replace the Main Control PWB PL 1.4C Item 1, following the procedure in REP 034.
Control PWB.
Y
N
Y
N
Control PWB again PL 1.4C Item 1.
Go to the 16-B RAP.

Table 1 MCB Input Voltages
Voltage
P/J
Pin
+5 VDC (ES)
P1/J13
12
+5.05 to +5.25 VDC
+5 VDC
P2/J7
+5.05 to +5.25 VDC
+12 VDC
P2/J7
7
5, (DC460/470)
+11.4 to +12.6 VDC
-12 VDC
P2/J7
8
6, (DC460/470)
-11.4 to -12.6 VDC
Table 2 EHR PWB Compatibility

Main Control
PWB Name
Main Control EHR PWB Part

PWB Tag
Number
EHR PWB
Tag
Atlanta Gold
015
160K59430
or
160K64130
296
Atlanta Platinum
077
160K64610
080
V0.042
May 2003
2-137
03-G
03-H Foreign Accessory RAP
When the problem is solved, remove the tool and reconnect the Foreign Interface Cable.
The Xerox machine does not function correctly when a foreign accessory is connected.
The following terms are associated with the connection of a foreign accessory to a Xerox
machine.
Foreign Accessory - An electronic or electromechanical device marketed by a company

other than Xerox which allows a customer to restrict the use of a Xerox machine and/or
track the use of a Xerox machine.
Foreign Interface Cable - The wire harness which connects the Foreign Accessory to
the Xerox machine Foreign Interface Port. The Foreign Interface Cable is part of the Foreign Accessory, and is NOT maintained by Xerox.
Foreign Interface Port - The electrical connector on the Xerox machine to which the Foreign Interface Cable is connected.
Foreign Interface Tool (600T2127) - An electronic tester which plugs into the Foreign
Interface Port in place of the Foreign Interface Cable. The tool indicates, via the blink of
an LED, the occurrence of a Copy Count signal.
Program 5 copies of 1 original, then press Start. Observe the LED on the tool while the
machine is making the copies.
The LED blinks 5 times (once for each copy).
Y
N
Check which level of software is installed in the IOT. (On the UI, select [Machine Status],
then select [Machine Details].)
Version 1.12 Software (Tag 029) (or higher) is installed.
Y
N
Install Version 1.12 Software (TAG 029), or higher version, if available.
After installing the software, allow the machine to come to Ready. Program 5 copies
of 1 original, then press Start. Observe the LED on the tool while the machine is
making the copies.
The LED blinks 5 times (once for each copy).
Y
N
Replace the Accessory PWB.
w/o TAG 077 PL 1.4A Item 4
Initial Actions
w/ TAG 077 PL 1.4B Item 4
In order to service a machine with a foreign accessory, use one of the following options.
460/470 PL 1.4C Item 2
The CSE must use the Foreign Interface Tool 600T2127 in order to enable the operation
of the Xerox machine without the foreign accessory.
Alternatively, the CSE can request the customer to set up an account on the foreign
accessory in order to enable the making of copies during the service call.
If the problem continues, the Main Control PWB may have failed. Go to the 03G RAP.
Procedure
The problem is solved. Remove the tool and reconnect the Foreign Interface Cable.
Ensure the Foreign Accessory is enabled.
From the main tool selection screen, select [More].
From the next two screens, select [Auditron Administration], then [Authentication Mode].
460/470 PL 1.4C Item 2
The External Auditron should be the active selection. If necessary, select [External
Auditron], then select [Save].
Select [Exit Tools], then operate the machine to determine if the problem still exists.
The Xerox machine still does not function correctly when the foreign accessory is connected.
Y
N
The foreign interface circuits of the copier are functioning correctly. Remove the tool and
reconnect the Foreign Interface Cable. Advise the customer the machine is functioning correctly and the problem is associated with the Foreign Accessory device or its cable.
Disconnect the Foreign Interface Cable at P7 on the Card Cage. Connect the Foreign Interface
Tool 600T2127 to P7.
With the tool in place, the machine is in the "Ready" or enabled mode.
Y
N
460/470 PL 1.4C Item 2
A
03-H
May 2003
2-138
V0.042
Figure 1 03-H RAP Circuit Diagram
V0.042
May 2003
2-139
03-H
03-J Checksum Error RAP

There are six software modules on the Main Control PWB. Each module has a specific checksum associated with it, determined by which version of software is installed in the machine.
The checksum values are listed in Product Specifications .
There are two concepts which are important to understand when troubleshooting a checksum
error.
1.
2.
If the software is corrupted, you will NOT get a checksum error. When the machine boots
up, the Run Time software reads all of the checksums from memory and validates them
against stored checksum values. If the values are different, the machine boots up into a
software installation mode. Therefore, incorrect checksums caused by corrupted software
will never be seen by the CSE.
If there is a valid checksum error, it is because different levels of software are installed in
the machine. (For example, the Boot Loader could be at Version 1.12, but the Boot Sector
could be at Version 1.0.) In all cases, checking the displayed checksum value against the
checksum table in PRODUCT SPECIFICATIONS will reveal which version of software is
installed for any software module.
Software checksum errors are normally seen only after a software upgrade. When a checksum
error occurs, follow the procedure in this RAP.
Procedure
Make a record of the software checksums displayed in the Diagnostic Navigator. Enter [System, Imaging, and IOT Configuration].
Compare those checksums to the data in the IOT Checksums table in Product Specifications
The checksum for each module is correct for the software version being installed on
the machine.
Y
N
Reload the software. Be sure to correctly answer all prompts and select the correct version of software.
The checksums are correct after reloading software.
Y
N
03-K Atlanta Gold And Atlanta Platinum Main Control

PWBs
NOTE: This information was originally issued in Lakes Bulletin 368.
A new Main Control PWB was cut in by manufacturing during the third quarter of 1999 for DC
265 Family copiers and printers. This new PWB is assigned Tag 077, and is referred to as
"Atlanta Platinum" because it is the successor to the "Atlanta Gold" Main Control PWB (Tag
015).
The 460/470 has a new Main Control PWB, also known as Atlanta Platinum 360 NLX. This
PWB cannot be installed in a 240/255/265, unless it is part of a machine upgrade kit. Most of
the changes in the PWB are due to the new ESS and card cage architecture. It also is only
compatible with L19 or later software.
The cut-in by manufacturing is for new-build machines only. Machines going through re-manufacturing will not be upgraded from "Gold" to "Platinum" unless there is a failure of the Main
Control PWB.
NOTE: This new PWB is NOT yet being installed in DT65/DP65 products. DT65/DP65 software releases (5.03 (17.05.05) and 5.09 (17.09.01)) do NOT support the Atlanta Platinum
PWB. Therefore, the Atlanta Gold PWB will continue to be the only Main Control PWB for
these products until the Atlanta Platinum PWB is supported by a future software release.
Field Service Strategy

Replacing an Atlanta Gold Main Control PWB (Tag 015) with an Atlanta Platinum Main Control
PWB (Tag 077) also requires replacement of the RAM and NVM components, because the
RAM and NVM components which attach to either of the PWBs are NOT interchangeable. The
only component which is common to both PWBs is the Accessory PWB. Therefore, the following strategy is in effect:
If an Atlanta Gold Main Control PWB (Tag 015) fails, or if a component on that PWB fails,
replace the failed component with a like component per the information on PL 1.4A in the
EDOC.
If an Atlanta Platinum Main Control PWB (Tag 077) fails, or if a component on that PWB
fails, replace the failed component with a like component per the information on PL 1.4B
in the EDOC.
If an Atlanta Platinum 360 NLX Main Control PWB on a 460/470 machine fails, or if a
component on that PWB fails, replace the failed component with a like component per the
information on PL 1.4C in the EDOC.

03-J, 03-K
May 2003
2-140
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CAUTION
ATLANTA PLATINUM REQUIRES RELEASE 5.08 (17.08.65) SOFTWARE. If you must
replace an Atlanta Gold PWB with an Atlanta Platinum PWB, do NOT use any other software
version until a newer software version that supports the Atlanta Platinum PWB is announced
and released to the field.
Table 1 summarizes the unique spares and service information needed to be understood by
CSE's in order to service this new configuration.
03-L IOT Wont Boot RAP

This RAP is used when the IOT wont boot up correctly. UI has power and may display a
screen that indicates that there is a communication problem.
Initial Actions
DC460/470 If you have just installed a Smart Tray Finisher and you receive the following
message during boot-up: Not Ready - Configuration Mismatch exists, Automatic Configuration detected an unrecoverable hardware problem, go to 12-700, Finisher Configuration
Error RAP.
DC460/470 - An intermittent boot problem seen as dots across the UI Screen may occur
on machines with Controller PWB 160K73823). To resolve this problem install (TAG 118 Controller PWB 160K73824) and ensure that you also have (L19.01.503) or later software
installed.
Table 1 Unique Spares

Atlanta Gold
Atlanta Platinum
Tag Number
015
077
EDOC v0.038 Parts List
PL 1.4A, Item 1
PL 1.4B, Item 1
Accessory PWB (Common to both PWB's) PL 1.4A, Item 4
PL 1.4B, Item 4
EPC DRAM SIMM
PL 1.4A, Item 6
N/A
Procedure
EPC SDRAM DIMM
N/A
PL 1.4B, Item 5
Perform the following:
NVM RAM Chip
PL 1.4A, Item 8
N/A
1.
Access the Card Cage at the back of the machine.
Software/NVM Module
N/A
PL 1.4B, Item 6
2.
Ensure that the EPC DRAM SIMMS (or EPC SDRAM DIMM w/TAG 077) are present.
"Heartbeat" LED Color
Green
Red
3.
Observe the LED on the lower left corner of the Main Control PWB (it may be obstructed
by the Accessory PWB, but if the LED is on, the light will be visible).
NOTE: On machine without Tag 077 (Atlanta Platinum) the LED is green, with Tag 077,
the LED is red.
The EPC DRAM SIMMS (or EPC SDRAM DIMM w/TAG 077) are present on the Main Control PWB.
Y
N
The EPC DRAM SIMMS (or EPC SDRAM DIMM w/TAG 077) must have been removed
from the machine. Inform the customer. Install new EPC DRAM SIMMS PL 1.4A Item 2
(or PL 1.4B Item 5 w/TAG 077) or PL 1.4C Item 6 (on 460/470).
Observe the LED. The LED is blinking about once per second (answer NO if blinking
slower).
Y
N
Observe the LED. The LED is On.
Y
N
The LED is off. There may be a power problem. Check all of the connectors on
the Main Control PWB, especially at J13 and J7. Inspect the harness from these
connectors back to the LVPS. Ensure that they are connected correctly and not damaged. If OK, go to the 01-A, Voltage Checkout RAP.
Go to the 03-G, Main Control PWB Replacement RAP.
This is the normal state for the LED. Re-assess the first question of this RAP. If there is no
doubt that the machine will not boot, no error codes are present on the UI Display, and the
PWS won't connect, go to the 03-G, Main Control PWB Replacement RAP.
V0.042
May 2003
2-141
03-K, 03-L
03-K, 03-L
May 2003
2-142
V0.042
04-201 Developer Drive Motor Fault RAP
NOTE: In some versions of machine software, the Last 40 fault list refers to the 04-201 as
Main Drive Motor 1 Fault.
A Developer Drive Motor motion system hardware failure was detected.
Encoder feedback from the Developer Drive Motor was not detected, or the encoder feedback
detected was incorrect.
In Component Control, select [IOT Paper Path], [Developer Drive Motor], then [Output On].
Enter [Copier Sys tab , Component Control].
Observe the Developer Drive Motor. The motor energizes briefly in Component Control.
Y
N
CAUTION
Failure to wait 10 seconds after the machine power has been turned off before disconnecting the motor connector from the SCAM PWB will result in damage to the motor.
Waiting at least 10 seconds before disconnecting the motor from the SCAM PWB will
allow the LVPS output voltages to fully dissipate.
For more information, go to: Motor Control and Fault Declaration in the Principles of Operation
section of this manual.
Do the following:

In Faults, select [Last 40 Faults]. Note all Drive Motor (04-2XX) faults, and Xerographic (097XX) faults, that are listed in the Last 40 Faults. Enter [Faults/Counters tab , Faults].
Table 1 Faults and Actions - On-Site

Faults in Last 40
Action
04-201 Only
Go to the 04-201 Developer Drive Motor Checkout Procedure.

Go to 04-202 Developer Motor Load Fault RAP
04-201 and 04-205
04-201 and 04-210
04-201, 04-205, and 04-210
Go to the 04-201 +36 VDC Checkout Procedure.
04-201, 04-205, 09-370, 09-372, 09-374,

and 09-376
04-201, 04-210, 09-370, 09-372, 09-374,

and 09-376
04-201, 04-205, 04-210, 09-370, 09-372,

09-374, and 09-376
Do the following:
Disconnect B1P1/J4 on the SCAM PWB.
Reconnect B1P1/J4 and switch the power [ON].
Make prints to ensure the problem is resolved.
Check the Last 40 Faults for an 04-201 fault. Enter [Faults/Counters tab , Faults].
An 04-201 fault occurred after reconnecting B1P1.
V0.042
Measure the voltage between J4 - 2 (-) and J4 -1 (+) on the SCAM PWB.
In Component Control, select [IOT Paper Path], [Developer Drive Motor], then [Output
On].
Measure the voltage between TH13 (-) and TH38 (+) on the SCAM PWB ( TH13 (-) and
TH38 (+) on TAG 108 MSCAM PWB).
The voltage drops to less than +3 VDC when the Developer Drive Motor energizes.
Y
N
CAUTION
Disconnect B1P1/J4 on the SCAM PWB and switch the power [ON].
TH36 (+) on TAG 108 SCAM PWB).
On]. Enter [Copier Sys tab , Component Control].
The voltage drops to less than +3 VDC when the Developer Drive Motor energizes.
Y
N
Replace the SCAM PWB PL 1.5 Item 6 .
Failure to wait 10 seconds after the machine power has been turned off before disconnecting
the motor connector from the SCAM PWB will result in damage to the motor. Waiting at least
10 seconds before disconnecting the motor from the SCAM PWB will allow the LVPS output
voltages to fully dissipate.
Switch off power.
Measure the voltage between J4 -4 (-) and J4 -3 (+) on the SCAM PWB.
The voltage is +5 VDC.
Y
N
04-201 Developer Drive Motor Checkout Procedure

Y
N
Refer to Table 2 for actions required.
04-201 and 04-202
N
Measure the voltage between TH13 (-) and TH37 (+) on the SCAM PWB ( TH13 (-) and TH37
(+) on TAG 108 SCAM PWB).
The voltage is approximately +2.5 VDC when the Developer Drive Motor energizes.
May 2003
2-143
04-201
N
04-201 +36 VDC Checkout Procedure

Do the following:
Disconnect P21/J1 on the SCAM PWB and switch the power [On].
Measure the voltage between P21 -1 (-) and P21 -2 (+) on the connector.

Y
N
If the machine has Tag 011, a Venray LVPS is installed. If the machine does not have Tag
011, a Zytec LVPS is installed.
Refer to Figure 3 (Zytek LVPS, w/o Tag 011) or Figure 4 (Venray LVPS, with Tag 011) to
identify the +36 VDC test point locations.
Measure the voltage between the metal case of the LVPS (-) and +36 VDC (+) on the
LVPS.
Y
N
Go to Flag 1. Check the wires for an open circuit.
04-201
May 2003
2-144
V0.042
V0.042
May 2003
2-145
04-201
TH28
TH30
TH32
TH33
TH13
TH34
TH35
TH36
TH37
TH38
Figure 2 SCAM PWB
04-201
May 2003
2-146
V0.042
Figure 3 Zytec LVPS (w/o tag 011) Test Points
V0.042
May 2003
2-147
04-201
04-201
May 2003
2-148
V0.042
TH28
TH30
TH13
TH32
TH33
TH34
TH35
TH36
TH37
TH38
Figure 5 Tag 108 SCAM PWB
V0.042
May 2003
2-149
04-201
04-202 Developer Drive Motor Load Fault RAP
Connect the meter leads to TH13 (-) and TH38 (+) on the SCAM PWB ( TH13
(-) and TH38 on TAG 108 SCAM PWB).
Main Drive Motor 1 Load Fault.
In Component Control, select [IOT Paper Path], [Developer Drive Motor], then
[Output On]. Enter [Copier Sys tab , Component Control].
The PWM duty cycle is less than 85% when the Vertical Transport is removed.
Y
N
Do the following to measure the PWM duty cycle:
The PWM duty cycle for the Developer Drive Motor was greater than 95% for a duration of
more than 100 ms. when the Developer Drive Motor was energized.
Reinstall the Vertical Transport.
Remove the Registration Transport Assembly (REP 08-2) and switch the
power [ON].
A Fluke meter is available for use in troubleshooting.

Y
N
Go to the Developer Drive Motor Load Checkout.
On the Fluke meter select AC voltage. Press the Hz button twice to

select % duty cycle. Press the PEAK MIN MAX button.
Connect the meter leads to TH13 (-) and TH38 (+) on the SCAM PWB (
TH13 (-) and TH38 on TAG 108 SCAM PWB).
Do the following to measure PWM duty cycle:
In Component Control, select [IOT Paper Path], [Developer Drive Motor],

then [Output On]. Enter [Copier Sys tab , Component Control].
Remove drive from the Developer Housing by removing the Developer Drive Belt.
On the Fluke meter select AC voltage. Press the Hz button twice to select % duty cycle.
Press the PEAK MIN MAX button.
Connect the meter leads to TH13 (-) and TH38 (+) on the SCAM PWB ( TH13 (-) and
TH38 on TAG 108 SCAM PWB).
The PWM duty cycle is less than 85% when the Registration Transport is
removed.
Y
N
If the problem continues, replace the SCAM PWB PL 1.5 Item 6.
Replace the Registration Transport Assembly PL 4.1A Item 8 .
Replace the Vertical Transport PL 4.1A Item 7.
PWM duty cycle is less than 85% when the Developer Drive Belt is removed.
Y
N
Do the following to measure PWM duty cycle:
Replace the Duplex Transport PL 6.1A Item 2.

Check the Developer Collector Tube. The Developer Collector Tube is clogged.
Y
N
Replace the Developer Housing PL 5.1B Item 1.
Reinstall the Developer Drive Belt.
Remove the Duplex Transport (REP 10-2) and switch the power [ON].
On the Fluke meter select AC voltage. Press the Hz button twice to select % duty
cycle. Press the PEAK MIN MAX button.
Go to the 09-H Developer Collector Checkout RAP.
Connect the meter leads to the SCAM PWB at TH13 (-) and TH38 (+) ( TH13 (-)
and TH38 on TAG 108 SCAM PWB).
NOTE: Use this procedure when no Fluke meter is available.
In Component Control, select [IOT Paper Path], [Developer Drive Motor], then [Output On]. Enter [Copier Sys tab , Component Control].
The PWM duty cycle is less than 85% when the Duplex Transport is removed.
Y
N
Developer Drive Motor Load Checkout

Do the following:
Remove drive from the Developer Housing by removing the Developer Drive Belt and
switch the power [ON].
In Diagnostic Navigator, select the [Copier System] tab. In Component Control, select
[IOT Paper Path], [Developer Drive Motor], then [Output On]. Enter [Copier Sys tab ,
Component Control].
Reinstall the Duplex Transport.
Remove the Vertical Transport (REP 08-1) and switch the power [ON].
After approximately 10 seconds, select [Developer Drive Motor], [Output Off], then [Exit].
On the Fluke meter select AC voltage. Press the Hz button twice to select %
duty cycle. Press the PEAK MIN MAX button.
In Faults, select [Last 40 Faults]. Enter [Faults/Counters tab , Faults].
A
B
04-202
An 04-202 fault occurred with drive to the Developer Housing removed.
May 2003
2-150
V0.042
N
Check the Developer Collector Tube. The Developer Collector Tube is clogged.
Y
N
Go to the 09-H Developer Collector Checkout RAP.

Do the following:
Remove the Duplex Transport (REP 10-2) and switch the power [ON].
Component Control].
An 04-202 fault occurred with the Duplex Transport removed.

Y
N
Do the following:
Reinstall the Duplex Transport.
Remove the Vertical Transport (REP 08-1) and switch the power [ON].
Component Control].
An 04-202 fault occurred with the Vertical Transport removed.

Y
N
Do the following:
Reinstall the Vertical Transport.
Remove the Registration Transport Assembly (REP 08-2) and switch the power [ON].
Component Control].
An 04-202 fault occurred with the Registration Transport removed.

Y
N
Replace the Registration Transport Assembly PL 4.1A Item 8.
V0.042
May 2003
2-151
04-202
TH28
TH30
TH32
TH33
TH34
TH13
TH35
TH36
TH37
TH38
Figure 1 SCAM PWB
04-202
May 2003
2-152
V0.042
TH28
TH30
TH13
TH32
TH33
TH34
TH35
TH36
TH37
TH38
V0.042
May 2003
2-153
04-202
04-205 Photoreceptor Drive Motor Fault RAP
N
A Photoreceptor Drive Motor motion system hardware failure was detected.

Encoder feedback from the Photoreceptor Drive Motor was not detected, or the encoder feedback detected was incorrect.
In Component Control, select [IOT General], [Photoreceptor Drive Motor], then [Output On].
Observe the Photoreceptor Drive Motor. The motor energizes briefly in Component Control.
Y
N
CAUTION

Do the following:
In Faults, select [Last 40 Faults]. Make a note of all Drive Motor (04-2XX) faults, and
Xerographic (09-7XX) faults, that are listed in the Last 40 Faults. Enter [Faults/Counters
tab , Faults].
Do the following:

Action
04-205 Only
Go to the 04-205 Photoreceptor Drive Motor

Checkout Procedure.
04-205 and 04-206
Go to 04-206 Photoreceptor Motor Load Fault

RAP
04-205 and 04-201
04-205 and 04-210
04-205, 04-201, and 04-210
04-205, 04-201, 09-370, 09-372, 09-374,

and 09-376
04-205, 04-210, 09-370, 09-372, 09-374,

and 09-376
04-201, 04-205, 04-210, 09-370, 09-372,

09-374, and 09-376
TH33 (+) on the TAG 108 SCAM PWB).
In Component Control, select [IOT General], [Photoreceptor Drive Motor], then [Output
The voltage drops to less than +3 VDC when the Photoreceptor Drive Motor energizes.
Y
N
CAUTION
Do the following:
Disconnect A1B1P1/J3 on the SCAM PWB.
Reconnect A1B1P1/J3 and switch the power [ON].
An 04-205 fault occurred after reconnecting A1B1P1.
04-205
In Component Control, select [IOT General], [Photoreceptor Drive Motor], then [Output
The voltage drops to less than +3 VDC when the Photoreceptor Drive Motor energizes.
Y
N
Disconnect A1B1P1/J3 on the SCAM PWB and switch the power [ON].
Measure the voltage between J3 -4 (-) and J3 -3 (+) SCAM PWB.

Y
N
04-205 Photoreceptor Drive Motor Checkout Procedure

Y
N
Faults in Last 40
Replace the Photoreceptor Drive Module PL 5.1A Item 2.

(+) on the TAG 108 SCAM PWB).
In Component Control, select [IOT General], [Photoreceptor Drive Motor], then [Output On].
May 2003
2-154
V0.042
The voltage is approximately +2.5 VDC when the P/R Drive Motor energizes.
Y
N

Do the following:

Y
N
LVPS.
Y
N
V0.042
May 2003
2-155
04-205
04-205
May 2003
2-156
V0.042
TH28
TH30
TH32
TH33
TH34
TH13
TH35
TH36
TH37
TH38
Figure 2 SCAM PWB
V0.042
May 2003
2-157
04-205
04-205
May 2003
2-158
V0.042
V0.042
May 2003
2-159
04-205
TH28
TH30
TH13
TH32
TH33
TH34
TH35
TH36
TH37
TH38
04-205
May 2003
2-160
V0.042
04-206 P/R Drive Motor Load Fault RAP
The PWM duty cycle for the Photoreceptor Drive Motor was greater than 80% for a duration of
more than 100 ms. when the Photoreceptor Drive Motor was energized.

Y
N
Go to the Photoreceptor Drive Motor Load Checkout.
Open the IOT Front Door.
Remove the Xerographic Module.
Close the IOT Front Door.
[IOT General], [Photoreceptor Drive Motor], then [Output On]. Enter [Copier Sys tab ,
Component Control].
The PWM duty cycle is 40% to 80% with the Xerographic Module removed.
Y
N
Replace the Xerographic Module PL 5.1A Item 1.
Photoreceptor Drive Motor Load Checkout

Do the following:
Close the IOT Front Door.
[IOT General], [Photoreceptor Drive Motor], then [Output On]. Enter [Copier Sys tab ,
Component Control].
After approximately 10 seconds, select [Photoreceptor Drive Motor], [Output Off], then
[Exit].
An 04-206 fault occurs with Xerographic Module removed.

Y
N
V0.042
May 2003
2-161
04-206
TH28
TH30
TH32
TH33
TH13
TH34
TH35
TH36
TH37
TH38
Figure 1 SCAM PWB
04-206
May 2003
2-162
V0.042
TH28
TH30
TH13
TH32
TH33
TH34
TH35
TH36
TH37
TH38
V0.042
May 2003
2-163
04-206
04-210 Fuser Drive Motor Fault RAP
CAUTION
Main Drive Motor 2 Fault.
A Fuser Drive Motor motion system hardware failure was detected.
Do the following:
Encoder feedback from the Fuser Drive Motor was not detected, or the encoder feedback
detected was incorrect.

Do the following:
In Faults, select [Last 40 Faults]. Make a note of all Drive Motor (04-2XX) faults, and
Xerographic (09-7XX) faults, that are listed in the Last 40 Faults. Enter [Faults/Counters
tab , Faults].
Reinstall the original Fuser Module if it was replaced with a different one for troubleshooting.
Disconnect B2P1/J2 on the SCAM PWB.
Reconnect B2P1/J2 and switch the power [ON].
An 04-210 fault occurred after reconnecting B2P1.
Y
N
Do the following:
Open the Front Door.
Cheat the Front Door Interlock Switch.
Faults in Last 40
Action
04-210 Only
Go to the 04-210 Fuser Drive Motor Checkout

Procedure.
In Component Control, select [IOT Paper Path], [Fuser Drive Motor], then [Output On].
Observe the Fuser Jam Clearance Knob. The Fuser Jam Clearance Drive Knob rotates
briefly. (This indicates the Fuser Motor energizes briefly in Component Control.)
Y
N
CAUTION
04-210 and 04-211
Go to 04-211 Fuser Motor Load Fault RAP
04-210 and 04-201
04-210 and 04-205
04-210, 04-201, and 04-205
04-210, 04-201, 09-370, 09-372, 09-374,

and 09-376
04-210, 04-205, 09-370, 09-372, 09-374,

and 09-376
04-210, 04-201, 04-205, 09-370, 09-372,

09-374, and 09-376
Do the following:
Disconnect B2P1/J2 on the SCAM PWB and switch the power [ON].

Y
N
04-210 Fuser Drive Motor Checkout Procedure

If the customer has not already done so, replace the Fuser Module, PL 6.2A Item 1. Make
prints to ensure the problem is resolved.
An 04-210 fault is declared.
Y
N
Measure the voltage between J2-4 (-) and J2-3 (+) on the SCAM PWB.
Y
N
Enter [Copier Sys tab , Component Control]
The voltage drops to less than +3 VDC when the Fuser Drive Motor energizes.
A
04-210
B
May 2003
2-164
V0.042
B
Y
N
[IOT Paper Path], [Fuser Drive Motor], then [Output On]. Enter [Copier Sys tab , Component Control].
The voltage drops to less than +3 VDC when the Fuser Drive Motor energizes.
Y
N
Replace the Fuser Drive Motor PL 7.1 Item 3
(+) on the TAG 108 SCAM PWB).
In Component Control, select [IOT Paper Path], [Fuser Drive Motor], then [Output On]. Enter
[Copier Sys tab , Component Control].
The voltage is approximately +2.5 VDC when the Fuser Drive Motor energizes.
Y
N

Do the following:

Y
N
LVPS.
Y
N
V0.042
May 2003
2-165
04-210
04-210
May 2003
2-166
V0.042
TH28
TH30
TH32
TH33
TH13
TH34
TH35
TH36
TH37
TH38
Figure 2 SCAM PWB
V0.042
May 2003
2-167
04-210
04-210
May 2003
2-168
V0.042
V0.042
May 2003
2-169
04-210
TH28
TH30
TH13
TH32
TH33
TH34
TH35
TH36
TH37
TH38
04-210
May 2003
2-170
V0.042
04-211 Fuser Drive Motor Load Fault RAP
Main Drive Motor 2 Load Fault.
The PWM duty cycle for the Fuser Drive Motor was greater than 95% for a duration of more
than 100 ms. when the Fuser Drive Motor was energized.
In Component Control, select [IOT Paper Path], [Fuser Drive Motor], then [Output
The PWM duty cycle is less than 85% when the Decurler Drive Belt is removed.
Y
N

Y
N
Go to the Fuser Drive Motor Load Checkout.
Remove the Fuser Module and close the IOT Front Door.
Remove the Decurler Drive Belt.
Reinstall the Decurler Drive Belt.
Remove the Prefuser Transport (REP 10-1) and switch the power [ON].
(-) and TH30 (+) on the TAG 108 SCAM PWB)
In Component Control, select [IOT Paper Path], [Fuser Drive Motor], then [Output On]. Enter [Copier Sys tab , Component Control].
The PWM duty cycle is less than 85% when the Prefuser Transport Assembly
is removed.
Y
N
Replace the Fuser Drive Motor PL 7.1 Item 3 .
The PWM duty cycle is less than 85% when the Fuser Module is removed.
Y
N
Check for the installation of a Decurler (a Decurler is required on machines with an
OCT). A Decurler is installed.
Y
N
Replace the Prefuser Transport PL 6.1A Item 1.

Check the following for binding:
The Offsetting Catch Tray Assembly PL 8.1 Item 1 (if installed).
The Decurler/OCT Drive Bracket PL 7.1 Item 4.
(-) and TH30 (+) on the TAG 108 SCAM PWB)
Replace the Fuser Module PL 6.2A Item 1.

The PWM duty cycle is less than 85% when the Prefuser Transport Assembly
is removed.
Y
N
TH30 (+) on the TAG 108 SCAM PWB)

Reinstall the Fuser Module.
A
V0.042
The Decurler PL 6.1A Item 4.
The PWM duty cycle is less than 85% after replacing the Fuser Module.
Y
N
Reinstall the original Fuser Module.
May 2003
2-171
04-211
04-211 On-Site Diagnostic Procedure (470, Mohican 65 Copier)
Fuser Drive Motor Load Checkout

Y
N
Go to the 470, Mohican 65 Copier Fuser Drive Motor Load Checkout.

Do the following:
The PWM duty cycle is less than 85% when the Fuser Module is removed.
Y
N
Connect the meter leads to TH13 (-) and TH30 (+) on the SCAM PWB ( TH13 (-)
and TH30 (+) on the TAG 108 SCAM PWB)
The PWM duty cycle is less than 85% when the Prefuser Transport Assembly is
removed.
Y
N
After approximately 10 seconds, select [Fuser Drive Motor], [Output Off], then [Exit].
An 04-211 fault occurs with the Fuser Module removed.

Y
N
Do the following:

Check for the installation of a Decurler (a Decurler is required on machines with an OCT). A
Decurler is installed.
Y
N
Do the following:

Replace the Fuser Module and close the IOT Front Door.
An 04-211 fault occurs after the Fuser Module is replaced.

Y
N
In Component Control, select [IOT Paper Path], [Fuser D rive Motor], then [Output
An 04-211 fault occurs with the Prefuser Transport removed.

Y
N
The PWM duty cycle is less than 85% after replacing the Fuser Module.
Y
N
Do the following:
04-211
Remove the Decurler Drive Belt and switch the power [ON].
May 2003
2-172
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In Component Control, select [IOT Paper Path], [Fuser D rive Motor], then [Output On].
Do the following:
An 04-211 fault occurs with the Decurler Drive Belt removed.

Y
N
The Decurler PL 6.1A Item 4.
The Offsetting Catch Tray Assembly PL 8.1 Item 1 (if installed).
C
Do the following:

Y
N


Y
N
470, Mohican 65 Copier Fuser Drive Motor Load Checkout

Do the following:
An 04-211 fault occurs with the Fuser Module removed.

Y
N
Do the following:
Replace the Fuser Module and close the IOT Front Door.
An 04-211 fault occurs after the Fuser Module is replaced.

Y
N
B
C
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May 2003
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04-211
TH28
TH30
TH32
TH33
TH13
TH34
TH35
TH36
TH37
TH38
Figure 1 SCAM PWB
04-211
May 2003
2-174
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TH28
TH30
TH13
TH32
TH33
TH34
TH35
TH36
TH37
TH38
V0.042
May 2003
2-175
04-211
04-211
May 2003
2-176
V0.042
05-100 Document LE Late to Input Tray Exit Sensor RAP
Read the value displayed for Pass 1 Feeds (Scan). The value for Pass 1 Feeds is
greater than or equal to 100,000.
Y
N
Do the following:
The lead edge of the document was late to the Input Tray Exit Sensor.
Initial Actions
If the Document Feeder does not feed all documents due to one or more documents
being kicked back into the Document Input Tray, go to 05-C DADF Misfeed RAP.
Load a fresh sheet of 8.5 X 11 in (A4), paper in the Document Input Tray in
portrait orientation (LEF).
Open the DADF Top Cover. Ensure the DADF Paper Feed Roll Drive Coupling is fully
engaged. If the drive coupling is being disengaged by the operator during jam clearance,
install the Feed Roll Cartridge Release Lever Kit PL 2.2 Item 12.
Ensure the Document Input Tray Side Guides are touching the paper and
the paper is inserted fully to the stops (to the right) of the Document Input
Tray.
Check the document path entrance (right side of Document Input Tray) for obstructions
including foreign objects.
In DADF Sensor Tests, select [DADF Document Path Sensors Test] from
the Test Selection dropdown menu. Enter [IIT tab , DADF Sensor Tests].
If the customer has a Document Centre 240/255/265, and they are having problems when
feeding curled originals, install the Document Input Tray Side Guides Kit, PL 2.1A .
The results of the DADF Document Path Sensors Test indicate the Document Loaded Sensor passed (a check mark next to the sensor name).
Y
N
Check the flag actuator for the Document Loaded Sensor. The actuator
is free from damage, and is free to block and unblock the Document
Loaded Sensor.
Y
N
Replace the DADF Feeder Assembly PL 2.2 and reset the Life
Counter for the DADF Paper Feed Roll Cartridge. Refer to GP6.

Do the following:
Switch the power [Off] then switch the power [On].
In Faults, select [Last 40 Faults]. Note any 05-340, 05-345, 05-365, or 05-370 faults listed
in the Last 40 Faults that occurred when the power was switched on.
Enter [Faults/Counters tab , Faults].
Go to Flag 1. Check wires for an open circuit or a short circuit.

Repair the harness or replace the defective component.
An 05-340, 05-345, 05-365, or an 05-370 fault occurred when the power was switched on.
Y
N
The Last 40 Faults list indicates the 05-100 faults are intermittent.
Y
N
In DADF Clutch / Solenoid Tests, select [Feed Clutch Nudger Solenoid], then [Start
Test]. Enter [IIT tab , DADF Clutch / Solenoid Tests].
The results indicate the Feed Clutch Nudger Solenoid test passed.
Y
N
Replace the DADF Feeder Assembly PL 2.2 Item 2and reset the Life Counter
for the DADF Paper Feed Roll Cartridge. Refer to GP6.
Ensure the DADF Top Cover is closed and the DADF is closed (lowered).
In IIT Motor Tests, select [Start Test]. Enter [IIT tab , IIT Motor Tests].
DADF PWB PL 2.3.
Load a fresh sheet of 8.5 X 11 in (A4), paper in the Document Input Tray in
portrait orientation (LEF).
Ensure the Document Input Tray Side Guides are touching the paper and
the paper is inserted fully to the stops (to the right) of the Document Input
Tray.
In DADF Sensor Test, select [DADF Document Path Sensors Test] from
the Test Selection dropdown menu, then select [Start]. Enter [IIT tab ,
DADF Sensor Tests].
The results of the DADF Document Path Sensors Test indicate the DADF
Registration Gate Sensor passed (a check mark next to the sensor name).
Y
N
Replace the DADF Feeder Assembly PL 2.2 and reset the Life Counter for
the DADF Paper Feed Roll Cartridge. Refer to GP6.
Repair the harness or replace the defective component
Replace the DADF Feed Motor PL 2.2 Item 7.
Input Tray Exit Sensor PL 2.1B Item 3.
DADF PWB PL 2.3.
Replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4 and reset the Life
Run the job that caused the failure.
In Diagnostic Navigator, select the [Faults/Counters] tab. Select the [Counters Display] button. In [Counters Display], select the [Diagnostic Data] tab.
Document Loaded Sensor PL 2.2 Item 6.
Do the following:
Check the test results for the Feed Motor. The results of the IIT Motor Tests indicate the Feed Motor passed.
Y
N
In IIT Motor Test, select [Feed Motor], then [Start Test]. Enter [IIT tab , IIT Motor
Tests].
Check the test results for the CVT Drive Belts. The results of the IIT Motor
Tests indicate the CVT Drive Belts passed.
Y
N
Replace the Exit Clutch Drive Belt PL 2.3 Item 5 and the CVT/Reg Roll
Drive Belt PL 2.3 Item 6.
A
B
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A
May 2003
2-177
B
05-100
A
The problem continues after replacing the DADF Paper Feed Roll Cartridge.
Y
N
DADF Paper Feed Roll Cartridge replaced, return to Service Call Procedures.
Do the following:
Ensure the Document Input Tray Side Guides are touching the paper and the
paper is inserted fully to the stops (to the right) of the Document Input Tray.
In DADF Sensor Tests, select [DADF Document Path Sensors Test] from the
Test Selection dropdown menu. Enter [IIT tab , DADF Sensor Tests].
The results of the DADF Document Path Sensors Test indicate the Document
Loaded Sensor passed (a check mark next to the sensor name).
Y
N
Check the Document Loaded Sensor Actuator PL 2.2 Item 8 for the Document
Loaded Sensor. The actuator free from damage, and is free to block and
unblock the Document Loaded Sensor.
Y
N
Replace the DADF Feeder Assembly PL 2.2 and reset the Life Counter for
C
Go to the 05-M Intermittent Document Jam RAP
An 05-340 or an 05-345 fault occurred when the power was switched on.
Y
N
An 05-370 fault occurred when the power was switched on.
Y
N
Go to the 05-365/375 DADF Feed Motor Fault RAP.
Go to the 05-370/380 CVT Motor Fault RAP.
Y
N
Go to the 05-345 DADF Feed Clutch IIOC Failure RAP.
Go to the 05-340 DADF Nudger Solenoid IIOC Failure RAP.

DADF PWB PL 2.3.
Do the following:
Load a fresh sheet of 8.5 X 11 in (A4), paper in the Document Input Tray in portrait orientation (LEF).
Ensure the Document Input Tray Side Guides are touching the paper and the
paper is inserted fully to the stops (to the right) of the Document Input Tray.
In DADF Sensor Tests, select [DADF Document Path Sensors Test] from the
Test Selection dropdown menu, then select [Start]. Enter [IIT tab , DADF Sensor Tests].
The results of the DADF Document Path Sensors Test indicate the DADF Registration Gate Sensor passed (a check mark next to the sensor name).
Y
N
Replace the DADF Feeder Assembly PL 2.2 and reset the Life Counter for the
DADF Paper Feed Roll Cartridge. Refer to GP6.
Repair the harness or replace the defective component:
DADF PWB PL 2.3.
Remove the DADF Feeder Assembly PL 2.2 Item 2 (REP 05-4). Check the Retard
Bracket Spring.
The Retard Bracket Spring is seated correctly in the retaining cup.
Y
N
Reinstall the DADF Feeder Assembly (REP 05-4). Ensure the Retard Bracket Spring
is seated correctly in the retaining cup.
A
C
05-100
May 2003
2-178

V0.042
05-102 Document LE Late to the DADF Registration Gate

Sensor RAP
The lead edge of the document was late to the DADF Registration Gate Sensor on pass 1.
Initial Actions
If the 05-102 jams are intermittent, go to the 05-M Intermittent Document Jam RAP.

Do the following:
Ensure the Document Input Tray Side Guides are touching the paper, and the paper is
inserted fully to the stops (to the right) of the Document Input Tray.
In DADF Sensor Tests, select [DADF Document Path Sensors Test] from the Test Selection dropdown menu, then select [Start]. Enter [IIT tab , DADF Sensor Tests].
The results of the DADF Document Path Sensors Test indicate the CVT Start of Scan
Sensor passed (a check mark next to the sensor name).
Y
N
Check the document path between the Input Tray Exit Sensor and the DADF Registration
Gate Sensor for obstructions. The document path between the Input Tray Exit Sensor and the DADF Registration Gate Sensor is free from obstructions.
Y
N
Remove the obstruction that is blocking the document path.
Ensure the Registration Gate is connected to the DADF Registration Gate Solenoid
and the Registration Gate moves freely without binding.
The DADF Take Away Roll for binding, contamination, or damage.
The DADF Take Away Roll Idler for binding, contamination, or damage.
Replace the DADF Registration Deskew Assembly PL 2.1B Item 6, if required.

Replace the DADF Top Cover Assembly PL 2.1B Item 2, if required.
DADF Registration Gate Sensor PL 2.1B Item 3.
DADF PWB PL 2.3.
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May 2003
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05-102
05-103 Document TE Late to DADF Registration Gate

Sensor RAP
The trail edge of the document is late to the DADF Registration Gate Sensor
Check the following for binding, contamination, damage, or wear:
Initial Actions
Open the DADF Top Cover. Ensure the DADF Paper Feed Roll Cartridge PL 2.2 Item 4 is
seated correctly.
Remove the DADF Main Cover.

Check the CVT/Reg Roll Drive Belt PL 2.3 Item 6. The CVT/Reg Roll Drive Belt is
worn, damaged, or broken.
Y
N
Replace the CVT Motor PL 2.3 Item 3.
Replace the Exit Clutch Drive Belt PL 2.3 Item 5 and the CVT/Reg Roll Drive Belt PL 2.3
Item 6.
Do the following:
Load 10 sheets of paper in the Document Input Tray.
Program a 1 to 1 job and press the Start button.
Observe the sheets as they feed from the Document Input Tray. The paper is multi-sheet
feeding from the Document Input Tray.
Y
N
The jam is occurring when feeding 11 x 17 inch (A3) documents, or when feeding
8.5 x 14 inch paper, SEF.
05-103
The Left CVT Baffle PL 2.4 Item 5.
The Right CVT Baffle PL 2.4 Item 6.
Replace the DADF Exit Shaft PL 2.2 Item 9.
Check the test results for the CVT Motor. The results of the IIT Motor Test indicate the CVT
Motor passed.
Y
N
Check the test results for the CVT Drive Belts. The results of the IIT Motor Tests indicate the CVT Belts passed.
Y
N
Replace the Exit Clutch Drive Belt PL 2.3 Item 5 and the CVT/Reg Roll Drive Belt PL
2.3 Item 6.
A
The CVT Drive On Glass Kit PL 2.4 Item 7.
Check the Document Restack Guide. The Document Restack Guide is in the correct
position and is free from damage.
Y
N
Ensure the Document Restack Guide is in the correct position and that it moves
freely to rest on the documents in the Document Output Tray.
Replace the Document Restack Guide PL 2.1A Item 9, if necessary.
Do the following:
If the above checks are good, replace the DADF Assembly PL 2.1A Item 1 and reset
the Life Counter for the DADF Paper Feed Roll Cartridge. Refer to GP6.
In DADF Clutch Solenoid Tests, select [Exit Clutch and Inverter Clutch], then [Start Test]. Enter
[IIT tab , DADF Clutch / Solenoid Tests].
The test results indicate the Exit Clutch AND the Inverter Clutch passed.
Y
N
N
Check for IOT Tag 048. The machine has Tag 048 installed.
Y
N
Install TAG 048.
Check the documents the customer is using.

The documents the customer is using are free from static, damage, and staples.
Y
N
Advise the customer to use the Document Glass when copying documents that are damaged or show evidence of static.
Y
N
Install TAG 048.
Do the following:
Replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4 and reset the Life Counter for
Check for 05-103 jams. A 05-103 jam occurs after replacing the DADF Paper Feed Roll
Cartridge.
Y
N
Remove the DADF Feeder Assembly PL 2.2 Item 2 (REP 05-4). Check the Retard Bracket
Spring.
The Retard Bracket Spring is missing or damaged.
Y
N
Do the following:
Reinstall the DADF Feeder Assembly (REP 05-4). Ensure the Retard Bracket Spring
is seated correctly in the retaining cup.
B
May 2003
2-180
V0.042
Ensure the Document Input Tray Side Guides are touching the paper, and the paper
is inserted fully to the stops (to the right) of the Document Input Tray.
The lead edge of the document is late to the CVT Start of Scan Sensor.
Check for 05-103 jams. A 05-103 jam occurs after reinstalling the DADF Feeder
Assembly.
Y
N
Replace the DADF Feeder Assembly PL 2.2 Item 2.
05-104 Document LE Late to CVT Start of Scan Sensor

RAP
Initial Actions

Do the following:
Check the test results for the CVT Motor. The results of the IIT Motor Tests indicate the
CVT Motor passed.
Y
N
Check the test results for the CVT Drive Belts. The results of the IIT Motor Tests indicate the CVT Drive Belts passed.
Y
N
Replace the Exit Clutch Drive Belt PL 2.3 Item 5 and the CVT/Reg Roll Drive Belt PL
2.3 Item 6.
Check the CVT/Reg Roll Drive Belt PL 2.3 Item 6. The CVT/Reg Roll Drive Belt is
worn, damaged, or broken.
Y
N
Replace the Exit Clutch Drive Belt PL 2.3 Item 5 and the CVT/Reg Roll Drive Belt PL 2.3
Item 6.
In DADF Clutch Solenoid Tests, select [DADF Registration Gate Solenoid], then [Start Test].
Enter [IIT tab , DADF Clutch / Solenoid Tests].
The results of the DADF Registration Gate Solenoid Test indicate the DADF Registration
Gate passed.
Y
N
In Component Control, select [Document Handler/Scanner], [CVT SOS Sensor], [Start
Monitor], [Copier Sys tab , Component Control]. Block and unblock the CVT Start of Scan
Sensor (Q3) with a sheet of paper.
The display indicates the state of the CVT Start of Scan Sensor changed.
Y
N
Go to the CVT Start of Scan Sensor Check.
Replace the DADF Registration Deskew Assembly PL 2.1B Item 6.
Do the following:
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May 2003
2-181
05-103, 05-104
The results of the Document Path Sensors Test indicate the DADF Exit/Invert Sensor
passed (indicating the document made it past the CVT Start of Scan Sensor).
Y
N
Go to the 05-104 Document path checkout
Check the foam pads on the Right CVT Baffle. The foam pads are present, free from
damage, and are in the correct position on the Right CVT Baffle.
Y
N
Replace the Right CVT Baffle PL 2.4 Item 6.
Go to the CVT Start of Scan Sensor Check.
CVT Start of Scan Sensor Check

Check the surface of the CVT Start of Scan Sensor The surface of the CVT Start of Scan
Sensor is discolored (amber or orange in color).
Y
N
Measure the voltage between P/J2 -1 (-) and P/J2 -2 (+) on the DADF PWB.
Observe the meter while blocking and unblocking the CVT Start of Scan Sensor. The
voltage goes from +5 VDC to 0 VDC to +5 VDC.
Y
N
Go to Flag 1. Check the wires for a short circuit or an open circuit.
CVT Start of Scan Sensor PL 2.1B Item 3
DADF PWB PL 2.3.
N
Check the document path between the DADF Registration Gate Sensor and the CVT
Start of Scan Sensor for obstructions. The document path between the DADF Registration Gate Sensor and the CVT Start of Scan Sensor is free from obstructions.
Y
N
Remove the obstruction that is blocking the document path.
Check the Right CVT Baffle. The Right CVT Baffle is damaged or warped.
Y
N
The Registration Roll for binding, contamination, or damage.
The Right CVT Roll for binding, contamination, or damage.
Replace the DADF Registration Deskew Assembly PL 2.1B Item 6 if required.

Replace the DADF Assembly PL 2.1A Item 1 if required.
If the DADF Assembly is replaced, reset the Life Counter for the DADF Paper
Feed Roll Cartridge. Refer to GP6.
Measure the voltage between P/J12 -13 (-) and P/J12 -14 (+) on the Distribution PWB.
Y
N
Go to Flag 2. Check the wire for an open circuit.
If the wire is good, replace the DADF PWB PL 2.3 Item 4.
Replace the DADF Top Cover Assembly PL 2.1B Item 13.
Measure the voltage between the machine frame (-) and TH15 (+) on the Distribution
PWB.
Y
N
If the problem continues, the Main Control PWB may have failed. Go to the 03-G Main
Control PWB Replacement RAP.
Replace the CVT Start of Scan Sensor PL 2.1B Item 3.
05-104 Document path checkout

Y
N
Replace the DADF Top Cover Assembly PL 2.1B Item 13 (TAG 037).
Check the DADF Top Cover Assembly. The surface of the DADF Top Cover Assembly is
scratched/cut (causing interference with paper travel).
05-104
May 2003
2-182
V0.042
V0.042
May 2003
2-183
05-104
TH15
Figure 2 Distribution PWB Test Points
05-104
May 2003
2-184
V0.042
05-106 Document LE Late to DADF Exit/Invert Sensor RAP
NOTE: The DADF may have two CVT Skis, three CVT Skis, or a single CVT
Ski.
The lead edge of the document was late to the DADF Exit/Invert Sensor.
Manually rotate the CVT Drive on Glass Roll and the CVT Skis. The
Drive on Glass Roll and the CVT Skis move freely without binding.
Y
N
Replace the CVT Drive On Glass Kit PL 2.4 Item 7.
Initial Actions
In Component Control, select [Document Handler/Scanner], [CVT Motor] then

[On Open Loop]. Enter [Copier Sys tab , Component Control].
Observe the CVT Drive on Glass Roll. The CVT Drive-on-Glass Roll is turning when the CVT Motor energizes.
Y
N
Observe the Left CVT Roll. The Left CVT Roll is turning when the CVT
Motor energizes.
Y
N
Replace the DADF Assembly PL 2.1A Item 1 and reset the Life
Do the following:
In Faults, select [Last 40 Faults]. Note any 05-355 faults listed in the Last 40 Faults that
occurred when the power was switched on.

Y
N
Do the following:
Check the belt that drives the CVT Drive-on-Glass Roll The belt that
drives the CVT Drive-on-Glass Roll is damaged or missing.
Y
N
Replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4 and
reset the Life Counter for the DADF Paper Feed Roll Cartridge. Refer
to GP6.
Check the test results for the CVT Motor. The results of the IIT Motor Tests indicate
the CVT Motor passed.
Y
N
In IIT Motor Tests, select [Start Test]. Enter [IIT tab , IIT Motor Tests]
Check the test results for the CVT Drive Belts The results of the IIT Motor Tests
indicate the CVT Belts passed.
Y
N
Replace the Exit Clutch Drive Belt PL 2.3 Item 5 and the CVT/Reg Roll Drive
Belt PL 2.3 Item 6.
Replace the CVT Drive On Glass Kit PL 2.4 Item 7 .

Check the Left CVT Roll Idler. The Left CVT Roll Idler is damaged or is
binding.
Y
N

Do the following:
Load a fresh sheet of 8.5 X 11 in (A4), paper in the Document Input Tray in portrait
orientation (LEF).
Ensure the Document Input Tray Side Guides are touching the paper, and the paper
is inserted fully to the stops (to the right) of the Document Input Tray.
Replace the Left CVT Baffle PL 2.4 Item 5.

Do the following to access the DADF Exit/Invert Sensor:
In DADF Sensor Tests, select [DADF Document Path Sensors Test] from the Test
Selection dropdown menu, then select [Start]. Enter [IIT tab , DADF Sensor Tests].
Remove the DADF Feeder Assembly (REP 05-4).

The results of the DADF Document Path Sensors Test indicate the DADF Exit/Invert
Y
N
Observe the position of the paper. The paper exits the Document Feeder document path into the Document Output Tray.
Y
N
Raise the Document Feeder.
A
B
V0.042
CVT
DADF Exit/Invert Sensor PL 2.2 Item 11.
DADF PWB PL 2.3.
Raise the Document Feeder to access the CVT Drive on Glass Roll and the CVT Skis.
NOTE: The DADF may have two CVT Skis, three CVT Skis, or a single CVT Ski.
Manually rotate the CVT Drive on Glass Roll and the CVT Skis. The
Glass Roll and the CVT Skis move freely without binding.
Y
N
A
May 2003
2-185
CVT
Drive
on
D
05-106
D
In Component Control, select [Document Handler/Scanner], [CVT Motor] then [On Open
Loop]. Enter [Copier Sys tab , Component Control].
Observe The CVT Drive on Glass Roll. The CVT Drive on Glass Roll is turning when
the CVT Motor energizes.
Y
N
Observe the Left CVT Roll. The Left CVT Roll is turning when the CVT Motor
energizes.
Y
N
Replace the DADF Assembly PL 2.1A Item 1 and reset the Life Counter for the
Check the belt that drives the CVT Drive-on-Glass Roll. The belt that drives the
CVT Drive-on-Glass Roll is damaged or missing.
Y
N
Check the idler on the Left CVT Baffle. The idler on the Left CVT Baffle is damaged or
is binding.
Y
N
Check the idler on the Right CVT Baffle. The idler on the Right CVT Baffle is
damaged or is binding.
Y
N

Do the following:
Ensure the DADF Exit Roll Idler is in the correct position and moves freely.
Ensure the Left CVT Roll Idler is in the correct position and moves freely.
Check the Left CVT Baffle for burrs and obstructions.
The check of the Left CVT Baffle and the idlers is good.
Y
N
Replace the Left CVT Baffle PL 2.4 Item 5 if necessary.
Replace the DADF Exit Clutch PL 2.2 Item 13
If the problem continues, replace the DADF Exit Shaft PL 2.2 Item 9.
Go to the 05-355 DADF Exit Clutch IIOC Failure RAP.
05-106
May 2003
2-186
V0.042
05-107 Document TE Late to DADF Exit/Invert Sensor RAP
Ensure the Document Restack Guide is attached correctly to the bottom of the Document Input Tray, is not damaged, and rests on the top of the documents as they are
stacked in the Document Output Tray. Replace the Document Restack Guide PL
2.1A Item 9 , if it is damaged.
Replace suspect DADF Exit Clutch PL 2.2 Item 13.
The trail edge of the document was late to the DADF Exit/Invert Sensor.
Initial Actions
Replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4 and reset the Life Counter for the

In DADF Clutch Solenoid Tests, select [Exit Clutch and Inverter Clutch], then [Start Test]. Enter
[IIT tab , DADF Clutch / Solenoid Tests].
The test results of the Exit Clutch and Inverter Clutch Test indicate the Exit Clutch and
the Inverter Clutch passed.
Y
N
Replace the DADF Exit Clutch PL 2.2 Item 13.
Do the following:
Load a sheet of 8.5 X 11 in (A4), paper in the Document Input Tray in portrait orientation
(LEF).
The results of the DADF Document Path Sensors Test indicate the DADF Exit/Invert
Y
N
Remove the following to access the DADF Exit/Invert Sensor:
The DADF Main Cover.
The DADF Feeder Assembly (REP 05-4).

DADF Exit Clutch PL 2.2 Item 13.
DADF PWB PL 2.3.
Do the following:
Load 10 sheets of 8.5 X 11 in (A4), paper in the Document Input Tray in portrait orientation
(LEF).
Observe the paper as it is fed from the Document Input Tray. The paper is multi-sheet feeding from the Document Input Tray.
Y
N
Do the following:
Check the surface of the Document Output Tray for obstructions, damage, or contamination. If the Document Output Tray is damaged, replace the Document Glass
Cover/Document Output Tray PL 2.1A Item 7.
A
V0.042
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2-187
05-107
05-108 Document LE Late to Input Tray Exit Sensor (Pass 2

or 3) RAP
The lead edge of the document was late to the Input Tray Exit Sensor on the second or third
pass, and the sheet was detected at the DADF Exit/Invert Sensor after the DADF Inverter
Clutch was energized.

Do the following:
Ensure the Document Input Tray Side Guides are touching the paper and the paper is
In the DADF Sensor Tests, select [DADF Document Path Sensors Test] from the Test
Selection dropdown menu, then select [Start]. Enter [IIT tab , DADF Sensor Tests].
The results of the DADF Document Path Sensors Test indicate the Input Tray Exit Sensor passed (a check mark next to the sensor name).
Y
N
Remove the DADF Top Cover Assembly.
DADF PWB PL 2.3.
Check the document invert path between the DADF Exit Invert Sensor and the Input Tray Exit
Sensor for obstructions. The document invert path between the DADF Exit Invert Sensor
and the Input Tray Exit Sensor is free from obstructions.
Y
N
Remove the obstruction that is blocking the document invert path.
The DADF Inverter Gate for binding damage.
The DADF Exit Roll for binding, contamination, or damage.
The DADF Exit Roll Idler for binding, contamination, or damage.
Replace the DADF Registration Deskew Assembly PL 2.1B Item 6 if required.

Replace the DADF Exit Shaft PL 2.2 Item 9 if required.
Replace the Left CVT Baffle PL 2.4 Item 5 if required.
05-108
May 2003
2-188
V0.042
05-109 Document LE Late to Input Tray Exit Sensor (Pass 2

or 3) RAP
05-110 Document LE Late to DADF Registration Gate

Sensor (Pass 2 or 3) RAP
The lead edge of the document was late to the Input Tray Exit Sensor on the second or third
pass, and the sheet was not detected at the DADF Exit/Invert Sensor after the DADF Inverter
Clutch was energized.
The lead edge of the document was late to the DADF Registration Gate Sensor, on the second
or third pass.
Initial Actions
In DADF Clutch Solenoid Tests, select [Exit Clutch and Inverter Clutch], then [Start Test] [Start
The results of the Exit Clutch and Inverter Clutch Test indicate the Exit Clutch and the
Inverter Clutch passed.
Y
N
Replace the DADF Exit Shaft PL 2.2 Item 9
If the 05-109 jams are intermittent, Go to the 05-M Intermittent Document Jam RAP.

Do the following:
In Faults, select [Last 40 Faults]. Note any 05-360 faults listed in the Last 40 Faults that
occurred when the power was switched on.
Go to 05-102 Document LE Late to DADF Registration Gate Sensor RAP.

Y
N
In DADF Clutch Solenoid Tests, select [Exit Clutch and Inverter Clutch], then [Start Test].
The results of the Exit Clutch and Inverter Clutch Test indicate the Exit Clutch and
the Inverter Clutch passed.
Y
N
Go to the 05-360 DADF Inverter Clutch IIOC Failure RAP.
V0.042
May 2003
2-189
05-109, 05-110
05-310 DADF Raised During Document Feed RAP

The DADF Interlock Switch was opened (Document Feeder raised) while the Document
Feeder was in operation.
For more information, go to: DADF Interlock Switch in the Principles of Operation section of
this manual.

Check the position of the DADF Interlock Switch. The DADF Interlock Switch is seated
correctly in the DADF frame.
Y
N
Reseat the DADF Interlock Switch.
Go to ADJ 05-1 DADF Skew Adjustment.
The problem can be resolved by performing the adjustment.
Y
N
NOTE: When checking for an open circuit of the DADF Interlock Switch circuit, ensure the
DADF is closed.
There is an open circuit in the DADF Interlock Switch circuit.
Y
N
DADF Interlock Switch PL 2.1B Item 13.
DADF PWB PL 2.3 Item 4.
Replace the Scanner Main Cover PL 3.1 Item 2.

If the problem occurs again, go to Flag 1. Check the circuit of the DADF Interlock Switch
for an intermittent condition, including P/J2 and P22.
05-310
May 2003
2-190
V0.042
05-325 DADF Cover Opened During Document Feed RAP

The Document Feeder Top Cover Sensor was opened while the Document Feeder was in
operation.
For more information, go to: DADF Top Cover Sensor in the Principles of Operation section of
this manual.

Open the DADF Top Cover and check the DADF Top Cover Hinge Pin PL 2.1B Item 10.
The DADF Top Cover Hinge Pin is damaged or missing.
Y
N
Do the following:
Ensure the DADF Top Cover is closed (The message 'The Document Feeder is
cover open' is not displayed on the User Interface).
In DADF Sensor Tests, select [DADF Top Cover Test] from the Test Selection dropdown menu. Enter [IIT tab , DADF Sensor Tests].
Observe the PWS while the opening and then closing the Document Feeder Top Cover.
The results of the DADF Top Cover Test indicate the Document Feeder Top Cover
Sensor passed.
Y
N
Check the Document Feeder Top Cover Sensor Actuator. The actuator for the
Document Feeder Top Cover Sensor is damaged or missing
Y
N
Open then close the Document Feeder Top Cover. The Document Feeder
Top Cover is closing correctly.
Y
N
Go to Flag 1. Check wires for an open circuit.

Document Feeder Top Cover Sensor PL 2.2 Item 6.
DADF PWB PL 2.3.

If the problem occurs again, Go to Flag 1.
Check the circuit of the Document Feeder Top Cover Sensor for an intermittent condition,
including P18 and P/J5.
Replace the DADF Top Cover Hinge Pin PL 2.1B Item 10.
V0.042
May 2003
2-191
05-325
05-330 DADF IIOC Internal Turnaround Failure RAP
05-331 DADF IIOC Chain RAP
The Control Logic has detected the IIOC Internal (SCVM local) Turnaround Test has failed.
The Control Logic has detected the IIOC Turnaround Test has failed for the entire IIOC Bus 4
(DADF)

The Main Control PWB may have failed. Go to the 03-G Main Control PWB Replacement RAP.

In Faults, select [Last 40 Faults]. Note all Scanner (14-XXX) faults, that are listed in the Last 40
Faults. Enter [Faults/Counters tab , Faults].
One or more of the following fault codes are in the Last 40 Faults, 14-325, 14-335, or 14340.
Y
N
Measure the voltage between:
The machine frame (-) and P/J1 -7 (+) on the DADF PWB.
The following voltages are measured: +0.25 VDC to +4.75 VDC at P1-7 (SID), +0.25
VDC to +4.75 VDC at P1-8 (SOD), and approximately 2.7 VDC at P1-9 (CLK).
Y
N
Switch off the power.
Disconnect P/J1 from the DADF PWB, and switch the power [ON].
The machine frame (-) and P/J1 -7 (+) on the connector.
The following voltages are measured: +0.25 VDC to +4.75 VDC at P1-7 (SID),
+0.25 VDC to +4.75 VDC at P1-8 (SOD), and approximately 2.7 VDC at P1-9
(CLK).
Y
N
The machine frame (-) and P/J12 -12 (+) on Distribution PWB.
The following voltages are measured: +0.25 VDC to +4.75 VDC at J12-12
(SID), +0.25 VDC to +4.75 VDC at J12-11 (SOD), and approximately 2.7
VDC at J12-10 (CLK).
Y
N
Disconnect P/J12 on the Distribution PWB, and switch the power [ON].
The following voltages are measured: +0.25 VDC to +4.75 VDC at

P12-12 (SID), +0.25 VDC to +4.75 VDC at P12-11 (SOD), and approximately 2.7 VDC at P12-10 (CLK).
Y
N
A
05-330, 05-331
May 2003
2-192
E
V0.042
E
If the problem continues, the Main Control PWB may have failed. Go
to the 03-G Main Control PWB Replacement RAP.
Go to Flag 1. Check the DADF Harness for a short circuit.
Replace the DADF Harness PL 2.3 Item 2 if required.
Go to Flag 1. Check the DADF Harness for an open circuit.

Replace the DADF Harness PL 2.3 Item 2 if required.
Replace the DADF PWB PL 2.3 Item 4.
Go to GP44 and perform the DADF ground checks.
The DADF is grounded correctly.
Y
N
Ensure the DADF is grounded correctly (refer to Step 7 of GP44 ).
Do the following:
CVT Motor passed.
Y
N
The Main Control PWB may have failed. Go to the 03-G Main Control PWB Replacement
RAP.
V0.042
May 2003
2-193
05-331
05-331
May 2003
2-194
V0.042
05-340 DADF Nudger Solenoid IIOC Failure RAP

The Control Logic has detected the IIOC external Turn Around Test for the DADF Nudger Solenoid has failed.

In Faults, select [Last 40 Faults]. Note 05-340 and 05-345 faults that are listed in the Last 40
Both 05-340 and 05-345 faults are in the Last 40 Faults.
Y
N
Go to Flag 2. Check the circuit of the Nudger Solenoid for an open circuit or a short circuit.
The check of the Nudger Solenoid circuit is good.
Y
N
Replace the DADF Feeder Assembly PL 2.2 Item 2 if necessary.
If the DADF Feeder Assembly is replaced, reset the Life Counter for the DADF
Paper Feed Roll Cartridge. Refer to GP6.
Do the following:
Replace the DADF Feeder Assembly PL 2.2 Item 2 and switch the power [ON].
Reset the Life Counter for the DADF Paper Feed Roll Cartridge. Refer to GP6.
An 05-340 fault occurs after replacing the DADF Feeder Assembly.

Y
N
Do the following:
Ensure connector P/J5 at the DADF PWB is connected securely.
Switch the power [On].
05-340 and 05-345 faults occur after connector P/J 5 is connected securely.
Y
N
V0.042
May 2003
2-195
05-340
05-340
May 2003
2-196
V0.042
05-345 DADF Feed Clutch IIOC Failure RAP

The Control Logic has detected the IIOC external Turn Around Test for the Feed Clutch has
failed.
05-345 On-Site Diagnostic procedure

Y
N
Go to Flag 2. Check the circuit of the DADF Feed Clutch for an open circuit or a short circuit.
The check of the DADF Feed Clutch circuit is good.
Y
N
Replace the DADF Feeder Assembly PL 2.2 Item 2 if necessary.
Do the following:
Replace the DADF Feeder Assembly PL 2.2 Item 2 and switch the power [ON].
Reset the Life Counter for the DADF Paper Feed Roll Cartridge. Refer to GP6.
An 05-345 fault occurs after replacing the DADF Feeder Assembly.

Y
N
Do the following:
Y
N
V0.042
May 2003
2-197
05-345
05-345
May 2003
2-198
V0.042
05-350 DADF Registration Gate Solenoid IIOC Failure RAP

The Control Logic has detected the IIOC external Turn Around Test for the DADF Registration
Gate Solenoid has failed.

Go to Flag 2. Check the circuit of the DADF Registration Gate Solenoid for an open circuit or a
short circuit.
The check of the DADF Registration Gate Solenoid circuit is good.
Y
N
Replace the DADF Registration Deskew Assembly PL 2.1B Item 6 if necessary.
A
A
Do the following:
Replace the DADF Registration Deskew Assembly PL 2.1B Item 6 and switch the power
[ON].
A 05-350 fault occurs when the power is switched on.

Y
N
DADF Registration Deskew Assembly replaced, return to Service Call Procedures.
V0.042
May 2003
2-199
05-350
05-355 DADF Exit Clutch IIOC Failure RAP

The Control Logic has detected the IIOC external Turn Around Test for the Exit Clutch has
failed.

Y
N
Go to Flag 2 (Flag 2 on Figure 2 for FX). Check the circuit of the DADF Exit Clutch for an
open circuit or a short circuit.
The check of the DADF Exit Clutch circuit is good.
Y
N
Replace the DADF Exit Shaft PL 2.2 Item 9 if necessary.
Do the following:
Replace the DADF Exit Shaft PL 2.2 Item 9 and switch the power [ON].
A 05-355 fault occurs after replacing the DADF Exit Shaft.

Y
N
DADF Exit Shaft replaced, return to Service Call Procedures.
Perform the DADF Ground Checkout GP44 , and correct any problems found.
If the problem continues, replace the DADF PWB PL 2.3 Item 4.
Do the following:
05-355 and 05-360 faults occur after connector P/J is connected securely.
Y
N
05-355
May 2003
2-200
V0.042
V0.042
May 2003
2-201
05-355
05-355
May 2003
2-202
V0.042
05-360 DADF Inverter Clutch IIOC Failure RAP

The Control Logic has detected the IIOC external Turn Around Test for the Inverter Clutch has
failed.

Y
N
Go to Flag 2. Check the circuit of the DADF Inverter Clutch for an open circuit or a short
circuit.
The check of the DADF Inverter Clutch circuit is good.
Y
N
Replace the DADF Exit Shaft PL 2.2 Item 9 if necessary.
Do the following:
Replace the DADF Exit Shaft PL 2.2 Item 9 and switch the power [ON].
An 05-360 fault occurs after the DADF Exit Shaft is replaced.

Y
N
DADF Exit Shaft replaced, return to Service Call Procedures.
Do the following:
Y
N
V0.042
May 2003
2-203
05-360
05-360
May 2003
2-204
V0.042
05-365/375 DADF Feed Motor Fault RAP

05-365 The Feed Motor did not provide encoder feedback.
05-375 The Feed Motor did not provide a Motor Done signal.
Go to Figure 1. Check the circuit of the DADF Feed Motor.
Do the following:
B
In Component Control, select [All Outputs Off]. Select [Exit Clutch], [Output On], [Feed
Motor], and [On Open Loop]. Enter [Copier Sys tab , Component Control].
Observe the Feed Motor when the Exit Clutch energizes. The Feed Motor runs freely
without binding.
Y
N
Go to Figure 1. Check the circuit of the DADF Feed Motor for an intermittent condition.
Check the test results for the Feed Motor. The results of the IIT Motor Tests indicate the
Feed Motor passed.
Y
N
Check the test results for the CVT Motor. The results of the IIT Motor Tests indicate
Y
N
Go to Flag 1. Check the wire for a short circuit or an open circuit.
Main Control PWB PL 1.4A Item 1 PL 1.4B Item 1 (Machines with TAG 077).
Before replacing the Main Control PWB. Go to the 03-G Main Control PWB Replacement RAP.
Do the following:
Manually rotate the Feed Motor (CCW as viewed from the rear), by turning the Registration Roll Drive Gear. The Feed Motor turns freely without binding.
Y
N
Check the Registration Roll Shaft for binding. The check of the Registration Roll
shaft is good.
Y
N
Replace the DADF Feed Motor PL 2.2 Item 7.
Do the following:
In Component Control, select [Document Handler/Scanner], [Feed Clutch], [Output

On], [Feed Motor], and [On Open Loop]. Enter [Copier Sys tab , Component Control].
Observe the Feed Motor when the Feed Clutch energizes. The Feed Motor runs freely
without binding.
Y
N
Replace the DADF Feeder Assembly PL 2.2 Item 2 and reset the Life Counter for
A
B
V0.042
May 2003
2-205
05-365/375
05-365/375
May 2003
2-206
V0.042
05-370/380 CVT Motor Fault RAP
Manually rotate the CVT Motor (CCW as viewed from the rear). The
Motor turns freely without binding.
Y
N
05-370 The CVT Motor did not provide encoder feedback.
CVT
05-380 The CVT Motor did not provide a Motor Done signal.
Each Registration Roll and each Registration Roll Idler. Replace the
DADF Registration Deskew Assembly PL 2.1B Item 6, if necessary.
The Right CVT Roll. Replace the DADF Assembly PL 2.1A Item 1, if
necessary.
Check the IOT Change Tag Matrix. IOT TAG 084 has been marked off.
Y
N
Go to 05-N DADF CVT Motor Ground Checkout.
If the DADF Assembly is replaced, reset the Life Counter for the
The Right CVT Idler. Replace the Right CVT Baffle PL 2.4 Item 6, if
necessary.
The Drive on Glass Roll. Replace the CVT Drive On Glass Kit PL 2.4
Item 7, if necessary
Continuity is measured between the CVT Motor frame and the machine frame.
Y
N
Remove the CVT Motor and reform the small ground tab on the Ground Bracket to ensure
contact with the CVT Motor frame.
The Left CVT Roll. Replace the DADF Assembly PL 2.1A Item 1, if
necessary.
Do the following:
Do the following:
Switch the power [OFF] and remove the DADF Main Cover.
Check for continuity between the CVT Motor frame and the machine frame.
Ensure the DADF Top Cover is closed and the DADF is closed (lowered)
If the DADF Assembly is replaced, reset the Life Counter for the

In Component Control, select [Document Handler/Scanner], [CVT Motor], then [On
Open Loop]. Enter [Copier Sys tab , Component Control].
Observe the CVT Motor. The CVT Motor energizes in Component Control.
Y
N
In Component Control, select [Document Handler/Scanner], [CVT Motor], then
[Output Off]. Enter [Copier Sys tab , Component Control] if necessary.
Measure the voltage between P1/J8 - 2 (-) and P1/J8 -1 (+) on the DADF
PWB. The voltage is +24 VDC.
Y
N
Measure the voltage between P/J12 - 8 (-) and P/J12 -17 (+) on the Distribution PWB. The voltage is +24 VDC.
Y
N
CVT Motor passed.
Y
N
Check the test results for the RIS Motor. The results of the IIT Motor Tests indicate
the RIS Motor failed (an indication the CVT and RIS Motor Common Feedback Leg
failed).
Y
N
Check the test results for the Feed Motor. The results of the IIT Motor Tests indicate the Feed Motor passed.
Y
N
Go to Flag 1. Check the wire for an open circuit or a short circuit.
Main Control PWB PL 1.4A Item 1 PL 1.4B Item 1 (Machines with TAG
077).

If the wires are good, replace the DADF PWB PL 2.3.
Measure the voltage between P1/J8 -4 (-) and P1/J8 -3 (+) on the DADF
PWB. The voltage is +5 VDC.
Y
N
Replace the DADF PWB PL 2.3.
Before replacing the Main Control PWB. Go to the 03-G Main Control PWB
Replacement RAP.
Manually rotate the CVT Motor (CCW as viewed from the rear). The CVT Motor
turns freely without binding.
Y
N
Remove the Exit Clutch Drive Belt and the CVT/Reg Roll Drive Belt from the
CVT Motor pulley.
A
B
V0.042
The Left CVT Idler. Replace the Left CVT Baffle PL 2.4 Item 5, if necessary.
Measure the voltage between P1/J8 -4 (-) and P1/J8 -5 (+) on the DADF PWB.
The voltage drops to less than +1.0 VDC when the CVT Motor energizes.
A
May 2003
2-207
D
05-370/380
A
Y
N
Measure the voltage between P/J12 -8 (-) and P/J12 -7 (+) on the Distribution PWB. The voltage drops to less than +1.0 VDC when the CVT
Motor energizes.
Y
N
Go to Flag 4. Check the CVT Motor Encoder feedback circuit for an
open condition.
DADF PWB PL 2.3.
CVT Motor PL 2.3 Item 3.
Main Control PWB PL 1.4A Item 1 PL 1.4B Item 1 (Machines with

TAG 077).
E
If the wires are good, replace the CVT Motor PL 2.3 Item 3.
Measure the voltage between P/J12 - 13 (-) on the Distribution PWB and P87/J14 17 (+) on the Main Control PWB. The voltage is approximately +2.5 VDC when
the CVT Motor energizes.
Y
N
Make one of the following checks:
Before replacing the Main Control PWB. Go to the 03-G Main Control
PWB Replacement RAP.
[On Open Loop]. Enter [Copier Sys tab , Component Control].
The voltage is approximately +5 VDC when the CVT Motor energizes.
Y
N
Measure the voltage between P/J12 - 13 (-) and P/J12 -6 (+) on the Distribution PWB. The voltage is approximately +5 VDC when the CVT
Motor energizes.
Y
N
Go to Flag 5. Check the wires for an open circuit. If the wires are
good, replace the Distribution PWB PL 1.5 Item 7.
The Main Control PWB may have failed. Go to the 03-G Main Control
Observe the CVT Motor. The CVT Motor runs in the forward direction (counter
clockwise as viewed from the rear).
Y
N
Go to Flag 6 and Flag 7. Check the circuit for the CVT DIR signal for a short.
Go to Flag 5. Check the CVT Motor Encoder feedback circuit for an open
condition.
If the voltage measured is approximately +5 VDC. Go to Flag 9 and Flag

10. Check the circuit for CVT Motor Encoder feedback, including the Distribution PWB and the DADF PWB, for an open circuit. If the circuit is
good, replace the CVT Motor PL 2.3 Item 3.
If the voltage measured is approximately +0 VDC. Go to Flag 9 and Flag

10. Check the circuit for CVT Motor Encoder feedback, including the Distribution PWB and the DADF PWB, for a short circuit. If the circuit is good,
replace the CVT Motor PL 2.3 Item 3.
The Main Control PWB may have failed. Go to the 03-G Main Control PWB Replacement RAP.
Go to Flag 1. Check the SCVM Share PWM signal, including the Distribution PWB, for a
short circuit or an open circuit.
If the check of the SCVM Share PWM circuit is good, the Main Control PWB may have
failed. Go to the 03-G Main Control PWB Replacement RAP.
Go to Figure 2. Check the circuit of the CVT Motor for an intermittent condition.
Go to Flag 6. Check the wires for an open circuit. If the wires are good,
replace the DADF PWB PL 2.3.
[On Open Loop].
The voltage drops to less than +3 VDC when the CVT Motor energizes.
Y
N
Measure the voltage between P/J12 - 13 (-) and P/J12 -5 (+) on the Distribution PWB. The voltage drops to less than +3 VDC when the CVT
Motor energizes.
Y
N
If the wires are good, replace the DADF PWB PL 2.3.
A
B
D
E
05-370/380
May 2003
2-208
V0.042
Ground Bracket
Retainer
DADF PWB
Figure 1 Ground Bracket and Retainer
V0.042
May 2003
2-209
05-370/380
05-370/380
May 2003
2-210
V0.042
05-A DADF Fault Entry RAP
Table 1 DADF Problems
If a 22-300.05 fault is displayed in the Last 40 Faults, go to the 22-300.05 Image Complete Not
Received RAP.
Initial Actions
Open the DADF Top Cover. Ensure the DADF Paper Feed Roll Drive Coupling is fully
engaged. If the drive coupling is being disengaged during jam clearance, install the Feed
Roll Cartridge Release Lever Kit PL 2.2 Item 12.
feeding curled originals, install the Document Input Tray Sides Guide Kit PL 2.1A.
05-A On-Site Procedure

The following is a table of Document Feeder problems, an explanation of each problem, and
the action to take if the problem occurs. If a Document Feeder (05-XXX) fault code is displayed, Go to the appropriate RAP for the fault code.
Table 1 DADF Problems
Problem
Action
There is an abnormal sound or vibration when the Document Feeder is

operating.
Go to the 05-L DADF Noise RAP.
A status code cannot be cleared in the

Document Feeder.
Go to the 05-H, DADF Unclearable Status RAP.
The message, The Document Feeder

Cover is open, is displayed on the UI
when the DADF Top Cover is closed.
Go to the 05-K Document Feeder Top Cover Sensor

RAP.
The reduction or enlargement is incorrect when Auto Reduce/Enlarge is

selected.
Go to the 05-E DADF Document Size Sensing RAP.
The paper supply tray is incorrect when Go to the 05-E DADF Document Size Sensing RAP.
Auto Paper Tray is selected.
The original documents are smeared, Go to the 05-B DADF Document Damage RAP.
nicked, dog-eared creased, torn, or the
image is damaged, by components in
the DADF document path.
A document is partially ejected into the Check the DADF Exit/Invert Sensor for contaminaDocument Output Tray and no jam is
tion.
declared.
The Document Feeder will not run
when documents are in the Document
Input Tray.
Go to the 05-C DADF Misfeed RAP.
The Scanner scans the Document

Go to the 05-C DADF Misfeed RAP.
Glass, and the Document Feeder does
not feed documents.
The original documents are multi-sheet Replace the DADF Paper Feed Roll Cartridge PL
feeding from the Document Input Tray. 2.2 Item 4 and reset the Life Counter for the DADF
The message, The job was deleted

because a document was larger than
expected...., is displayed on the User
Interface.
Go to the 22-303.05 RAP.
The DADF will not stay in the raised

position or will not stay in the partially
raised position.
Install the DADF Counterbalance Hinge Kit PL 2.1B.
05-A Registration/Skew Check Procedure

Place a document on the Document Glass and make a copy.
Check the image on the output copies. The image on the copies is misregistered or
skewed.
Y
N
Go to the 05-F DADF Registration and Skew RAP
Go to the IQ-1 Image Quality Entry RAP.
The image on the output copies is mis- Go to the 05-A Registration/Skew Check Procedure.
registered or skewed.
V0.042
Action
The image on the output copies is

cropped (the trail edge of the image is
deleted).
The Document Feeder does not feed all Go to the 05-C DADF Misfeed RAP.
documents from the Document Input
Tray due to one or more documents
being kicked back into the Document
Input Tray.
The message, The Document Feeder is Go to the 05-J DADF Interlock Switch RAP.
raised, is displayed on the UI when the
Document Feeder is lowered.
The image on the output copies exhibits Go to the 05-A Image Check Procedure.
one of the following defects: incorrect
magnification, blur, poor resolution,
ragged lines, deformed image, or a thin
black line on the trail edge that runs IB
to OB.
Problem
05-A Image Check Procedure

Place a document on the Document Glass and make a copy.
Check the image on the copies. The magnification is incorrect, or the image shows one
of the following defects: blur, poor resolution, ragged lines, deformed image, a thin
black line on the trail edge that runs IB to OB.
Y
N
Go to the 05-D DADF Image Distortion RAP.
Go to the IQ-1 Image Quality Entry RAP.
May 2003
2-211
05-A
The documents are smeared, nicked, dinged, dog-eared creased, torn, or the image is damaged by components in the DADF document path.
Initial Actions
Ensure the documents the customer is using are not damaged, stapled, and they meet the size
and paper weight requirements for the Document Feeder.
Check all idlers in the Document Feeder document path. Ensure the idlers are not binding, and they are positioned correctly.

The document damage is dog-ears or creases in the feed direction.
Y
N
Check the documents in the Document Output Tray. The document damage is an
'accordion fold' of the documents as they enter the Document Output Tray.
Y
N
Check the documents in the Document Output Tray. The document damage is
lead edge nicks or dings.
Y
N
Mark a sheet of paper 'Top', Bottom', and 'Lead Edge'. Make 6 copies of the
marked up sheet of paper using the Document Glass. Place the 6 copies in the
Document Input Tray. Program a 1 to 2 job. Determine the cause of the damage by comparing the damage on the copies to the location of Document
Feeder components.
Replace the assembly containing the component that is causing the damage.
In DADF Clutch / Solenoid Tests, select [DADF Registration Gate Solenoid], then
[Start Test]. Enter [IIT tab , DADF Clutch / Solenoid Tests].
The results of the DADF Registration Gate Solenoid Test indicate the DADF
Registration Gate passed.
Y
N
Check the 2 sided (Sides Imaged) selection used when the damage occurred. The damage
occurs on 1 to 2 sided, 2 to 2 sided, or 2 to 1 sided copy selections.
Y
N
Place the a stack of 5 sheets of paper in the Document Input Tray. Program a 1 to 1 job.
Press the Start button. Observe the sheets as they are feeding from the Document Input
Tray The documents are skewing as they are feeding from the Document Input
Tray.
Y
N
Check the DADF Inverter Gate for correct operation. Replace the DADF Registration
Deskew Assembly PL 2.1B Item 6 if required.
If the problem continues, replace the DADF Feeder Assembly PL 2.2 Item 2 and reset the
Life Counter for the DADF Paper Feed Roll Cartridge. Refer to GP6.
The DADF Inverter Gate for correct operation. Replace the DADF Registration Deskew
Assembly PL 2.1B Item 6 if required.
The plastic baffle on the Feeder Assembly that guides the inverted documents to the
Takeaway Roll is not damaged or deformed. Replace the DADF Feeder Assembly PL 2.2
Item 2 if required.
Document lead edge nicks or dings may be caused by one of the following:
The DADF Take Away Roll Idler is not contacting the DADF Take Away Roll.
Ensure the DADF Top Cover PL 2.1B Item 2, is closing correctly.
The Right CVT Baffle, is not seated correctly when the Document Feeder is
lowered. If the foam pads are missing, damaged, or not in the correct position,
replace the Right CVT Baffle PL 2.4 Item 6.
The Right CVT Baffle PL 2.4 Item 6 is damaged or warped.
The Left CVT Baffle, is not seated correctly when the Document Feeder is lowered. Replace the Left CVT Baffle PL 2.4 Item 5, if necessary.
N
In DADF Clutch / Solenoid Tests, select [DADF Registration Gate Solenoid], then [Start
The results of the DADF Registration Gate Solenoid Test indicate the DADF Registration Gate passed.
Y
N
If the DADF Feeder Assembly is replaced, reset the Life Counter for the DADF Paper
Feed Roll Cartridge. Refer to GP6.
Ensure the Document Restack Guide is attached correctly to the bottom of the Document
Input Tray, is not damaged, and rests on top of the documents as they are stacked in the
Document Output Tray.
Replace the Document Restack Guide PL 2.1A Item 9 if it is damaged.
The document damage is dog-ears.
05-C DADF Misfeed RAP

05-B, 05-C
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When a document or documents are placed in the Document Input Tray and the Start button is pressed, the documents will not feed, and a blank sheet will be delivered to the output device.
The Document Feeder does not feed all documents due to one or more documents being
kicked back into the Document Input Tray.
The problem of document kickback continues after replacing the DADF Paper
Feed Roll Cartridge.
Y
N
Initial Actions
If the Document Feeder does not feed all documents due to one or more documents
being kicked back into the Document Input Tray, replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4 and reset the Life Counter for the DADF Paper Feed Roll Cartridge.
Refer to GP6.
feeding curled originals, install the Document Input Tray Side Guides Kit PL 2.1A.
If the problem continues, follow the procedure in this RAP.

In Faults, select [Last 40 Faults]. Note any 05-330, 05-340, 05-345, 05-350, 05-355, 05-360,
05-365, or 05-375 faults listed in the Last 40 Faults. Enter [Faults/Counters tab , Faults].
An 05-330, 05-331, 05-340, 05-345, 05-350, 05-355, or an 05-360 fault is listed in the Last
40 Faults.
Y
N
An 05-365 or an 05-375 fault is listed in the Last 40 Faults.
Y
N
The problem is identified as one or more documents being kicked back into
the Document Input Tray.
Y
N
Open the DADF Top Cover.
Check the flag actuator for the Document Loaded Sensor PL 2.4 Item 6. The
flag actuator is free from damage, and moves freely to block and unblock
the Document Loaded Sensor.
Y
N
Replace the DADF Feeder Assembly PL 2.2 Item 2 and reset the Life
Go to 05-365/375 DADF Feed Motor Fault RAP.

Go to the appropriate RAP:
05-330 IIOC Internal Failure RAP.
05-340 DADF Nudger Solenoid IIOC Failure RAP.
05-345 DADF Feed Clutch IIOC Failure RAP.
05-350 DADF Registration Gate Solenoid IIOC Failure RAP.
05-355 DADF Exit Clutch IIOC Failure RAP.
05-360 DADF Inverter Clutch IIOC Failure RAP.
The Document Loaded Sensor is seated correctly.

Y
N
Reseat the Document Loaded Sensor in the correct position.
Go to Flag 1. Check the wires for an open circuit or a short circuit.
Y
N
Install TAG 048.
If not already done, replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4 and
reset the Life Counter for the DADF Paper Feed Roll Cartridge. Refer to GP6.
A
B
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05-C
05-D DADF Image Distortion RAP

The image on the output copies exhibits one of the following defects: incorrect magnification, a
thin black line on the trail edge that runs IB to OB, blur, poor resolution, ragged lines, or
deformed image.
A
Perform IIT Registration and Magnification. Go to ADJ 14-2.
Check the copies for correct magnification. The horizontal (lead edge to trail edge) magnification is incorrect.
Y
N
The vertical (top edge to bottom edge) magnification is incorrect.
Y
N
The image quality defect is incorrect magnification which may cause a thin black line
on the trail edge that runs IB to OB on all the copies.
Y
N
The image quality defect is poor resolution or blurred image.
Y
N
Do the following:
In Diagnostic Navigator, select the [NVM] tab. Using [NVM Tool], search for the location indicated in Table 1.
Compare that value to the value for Hall Period Reference located on the ROS bar
code label. The Hall Period Ref number is the 4 or 5 digit number that is preceded by
the letter H under the second bar code (Figure 1).
Use [NVM Tool] to reset the value to the value indicated on the ROS bar code label.
NOTE: The DADF may have two CVT Skis, three CVT Skis, or a single CVT Ski.
Check the CVT Drive On Glass Kit and the CVT Skis. The CVT Drive on Glass Roll
and the CVT Skis are free from damage and move freely without binding.
Y
N
Replace the DADF Assembly PL 2.1A Item 1 and reset the Life Counter for the DADF
The horizontal (lead edge to trail edge) magnification is incorrect.
Y
N
The vertical (top edge to bottom edge) magnification is incorrect.
Y
N
Do the following:
In Diagnostic Navigator, select the [NVM] tab. Using [NVM Tool], search for the
location indicated in Table 1.
Compare that value to the value for Hall Period Reference located on the ROS
bar code label. The Hall Period Ref number is the 4 or 5 digit number that is
preceded by the letter H under the second bar code (Figure 1).
Use [NVM Tool] to reset the value to the value indicated on the ROS bar code
label.
Do the following:
Check the test results for the CVT Motor. The results of the IIT Motor Test indicate
Y
N
Replace the DADF Assembly PL 2.1A Item 1 and reset the Life Counter for the DADF
A
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B
Part #
ROS Serial #
Image Fast Scan

Reg
Hall Period Reference (preceded by letter

H).
HallPeriodRef - NVM Loc = 729

Table 1 Hall Period Reference
Product
Gb ROS (19.01 S/W and lower)
470 DC/ST
Mark Service, location 729, hallPeriodRef Mark Service, location 729, hallPeriodRefGb
Mark Service, location 1397, hallPeriodRefFa
460 DC/ST
255/265 DC/ST
Mark Service, location 729, hallPeriodRef N/A
N/A
240 DC/ST
N/A
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Fa ROS (19.02 S/W and higher)
05-D
05-E DADF Document Size Sensing RAP

The following problems may be caused by incorrect Document Feeder Size Sensing:
A
The results of the DADF Input Tray Guides Test indicate the Side Guide Sensor 2
passed.
Y
N
The magnification is incorrect when Auto Reduce/Enlarge is selected on the User Interface.
The incorrect paper supply tray is selected when Auto is selected for the paper tray.
Side Guide Sensor 2 PL 2.1A Item 5.
One or more black edges on the output copies.
The image on the output copies is cropped (the trail edge of the image is deleted).
19-404 DVMA time-out faults.
22-303.05 Document too large faults.
Do the following:
For additional information, go to: Document Size Sensing in the Principles of Operation section
of this manual.
Initial Actions
Ensure the Document Input Tray Side Guides in the Document Input Tray move freely
and contact the edge of the documents.
Ensure the documents in the Document Input Tray are the same size front to rear.
The customer may be using a document that is a different size than the document sizes
that are set in Tools. Go to GP30 , to ensure the document sizes are set correctly for the
size document(s) the customer is using.

In the Diagnostic Navigator, select [Configuration], [System, Imaging, and IOT Configuration],
[System].
The Market Region is correct for the location of this machine.
Y
N
Select the correct Market Region from the menu. Select [Apply], then select [OK].
Check the paper size displayed on the UI for each of the paper trays.
The paper size displayed on the User Interface for each paper tray matches the paper
size loaded in the paper tray.
Y
N
Go to the 07-B Paper Size Sensing RAP.
Clear all documents from the Document Input Tray.
In DADF Sensor Tests, select [DADF Input Tray Sensors Test] from the Test Selection
dropdown menu. Enter [IIT tab , DADF Sensor Tests]
Depress the switch actuators, in the surface of the Document Input Tray, one at a time.
The results of the DADF Input Tray Sensors Test indicate the Input Tray Sensor 1
passed.
Y
N
Input Tray Sensor 1 PL 2.1A Item 5.
The results of the DADF Input Tray Sensors Test indicate the Input Tray Sensor 2
passed.
Y
N
Input Tray Sensor 2 PL 2.1A Item 5.

CVT Start of Scan Sensor PL 1.2B Item 3.
Do the following:
Clear all documents from the Document Input Tray.
In DADF Sensor Tests, select [DADF Input Tray Guides Test] from the Test Selection
dropdown menu, then select [Start]. Enter [IIT tab , DADF Sensor Tests]
Slide the Document Input Tray side guides in to the end of their travel, then slide them out
to the end of their travel.
The results of the DADF Input Tray Guides Test indicate the Side Guide Sensor 1
passed.
Y
N
Side Guide Sensor 1 PL 2.1A Item 5.
A
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05-E
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05-F DADF Registration and Skew RAP

The lead edge or the top edge of image is misregistered, or the image is skewed.
Initial Actions
Ensure the Document Input Tray Side Guides in the Document Input Tray move freely
and contact the edge of the documents.
Ensure the documents in the Document Input Tray are the same size front to rear.
Remove, then reinstall the DADF Paper Feed Roll Cartridge, to verify the DADF Paper
Feed Roll Cartridge is seated correctly. Ensure the DADF Paper Feed Roll Drive Coupling
is fully engaged.

The image on the output copies is skewed.
Y
N
The following may cause image registration problems:
Originals with dog-eared or torn corners.
Originals with a dark image on the lead edge or trail edge.
Check the original documents. If the originals have a dog-eared corner, a torn corner, or
dark image on the lead edge or trail edge, instruct the customer to use the document
glass.
A
In DADF Clutch / Solenoid Tests, select [DADF Registration Gate Solenoid], then [Start Test].
The results of the DADF Registration Gate Solenoid Test indicate the DADF Registration
Gate passed.
Y
N
Do the following:
Place a stack of 5 sheets in the Document Input Tray.
Observe the sheets as they are feeding from the Document Input Tray.
The documents are skewing as they are feeding from the Document Input Tray.
Y
N
Open and close the DADF Top Cover and observe each Registration Roll Idler. Each
Registration Roll Idler moves freely and contacts the Registration Roll when the
DADF Top Cover is closed.
Y
N
Check the spring that rests against the shaft of the Registration Roll Idler. Ensure
that it is not damaged or missing.
Replace the DADF Registration Deskew Assembly PL 2.1B Item 6 if necessary.
The DADF Skew can be resolved by performing the adjustment.
Y
N
Side 1 of the image is skewed.

Y
N
Right CVT Roll Idler is positioned correctly and moves freely without binding.
Y
N
The DADF Exit Roll Idler is positioned correctly and moves freely without binding.
Y
N
The DADF Inverter Gate for correct operation. Replace the DADF Registration
Deskew Assembly PL 2.1B Item 6 if required.
The plastic baffle on the Feeder Assembly that guides the inverted documents to the
Takeaway Roll is not damaged or deformed. Replace the DADF Feeder Assembly
PL 2.2 Item 2 if required.

Replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4 and reset the Life Counter for the
If the problem continues, replace the DADF Feeder Assembly PL 2.2 Item 2 and reset the Life
Perform the following checks if not previously done:
Close the DADF Top Cover. Raise the Document Feeder.
Inspect the drive rolls and all black-colored surfaces for contamination.
Inspect the drive rolls and all black-colored surfaces for contamination.
The Document Feeder drive components are free from contamination.
Y
N
Go to REP 05-1, DADF Cleaning Procedure.
A
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05-F
05-G Document Output Stacking RAP
05-H DADF Unclearable Status RAP
The documents are rolling over as they enter the Document Output Tray or the documents are
stacking poorly in the Document Output Tray.
The message on the User Interface indicates there is a document jam in the Document Feeder
when no document is present.
05-G On-Site Diagnostic Procedure
Initial Actions
The problem is the documents are rolling over as they enter the Document Output Tray
Y
N
Check the Document Restack Guide, attached to the bottom of the Document Input
Tray. The Document Restack Guide is attached correctly to the Document Input
Tray.
Y
N
Ensure the Document Restack Guide is attached correctly.
Clean the Document Glass that is located on the right side of the IOT (the portion of the
document glass under the Document Feeder).
Ensure the Input Tray Exit Sensor, the DADF Registration Gate Sensor, and the CVT
Start of Scan Sensor, are free of paper dust.
Ensure the DADF Exit/Invert Sensor, and the reflectance area of the sensor, are free of
paper dust.
Check the Document Restack Guide for damage. The Document Restack Guide is
attached to the Document Input Tray, is free from damage, and rests on top of the
documents as they are stacked in the Document Output Tray.
Y
N
Replace the Document Restack Guide PL 2.1A Item 9.
Measure the resistance between machine frame and the metal bar on the DADF Static
Eliminator.
There is continuity between the DADF Static Eliminator and the machine frame.
Y
N
Ensure the braid connector for the DADF Static Eliminator is connected.
The DADF Static Eliminator is worn or damaged.
Y
N
Check the surface of the Document Output Tray for damage or contamination.
If the Document Output Tray is damaged, replace the Document Glass Cover/Document Output Tray PL 2.1A Item 7.
05-H On-Site Diagnostic Procedure

Ensure the document path, the Document Glass, and the Document Output Tray, are free from
any obstructions. Lower the Document Feeder, and close the DADF Top Cover.
The message, Clear the misfeed in area 6a of the Document Feeder, is displayed on the
User Interface.
Y
N
In Component Control, select [Document Handler/Scanner], [DADF Reg Gate Sensor],
[Start Monitor], [CVT SOS Sensor], [Start Monitor], [DADF Exit/Invert Sensor], [Start Monitor], [DADF Top Cover Sensor], and [Start Monitor]. Enter [Copier Sys tab , Component
Control].
The state of the DADF Reg Gate Sensor is low.
Y
N
Go to Flag 2. Check the wires for a short circuit.
DADF Registration Gate Sensor PL 2.3 Item 4.
The state of the CVT SOS Sensor is low.

Y
N
Replace the Document Input Tray PL 2.1A Item 3.

Check each 3-Arm Sheet Separator. Each 3-Arm Sheet Separator is in place and is free
from damage.
Y
N
CVT Start of Scan Sensor PL 2.1B Item 3.
The state of the DADF Exit/Invert Sensor is low.

Y
N
Check the condition of the customers documents. Ensure the customer is not using documents
with excessive curl.
Open then close the DADF Top Cover. The state of the DADF Top Cover Sensor
changes.
Y
N
A
05-G, 05-H
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Go to 05-J DADF Interlock Switch RAP.

In Component Control, select [Document Handler/Scanner], [Input Tray Exit Sensor], [Start
Monitor], [DADF Reg Gate Sensor], [Start Monitor], [DADF Top Cover Sensor], and [Start Monitor]. Enter [Copier Sys tab , Component Control].
The state of the Input Tray Exit Sensor is low.
Y
N
The state of the DADF Reg Gate Sensor is low.

Y
N
DADF Registration Gate Sensor PL 2.3 Item 4.
Open then close the DADF Top Cover. The state of the DADF Top Cover Sensor
changes.
Y
N
Go to 05-J DADF Interlock Switch RAP.
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05-H
05-H
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05-H
05-J DADF Interlock Switch RAP

The message on the User Interface indicates the Document Feeder is open when the Document Feeder is closed.
The message on the User Interface indicates the Document Feeder is closed when the Document Feeder is open.
05-J On-Site Diagnostic Procedure

Check the magnet on the Scanner Main Cover PL 3.1 Item 2. The magnet on the Scanner
Main Cover is missing.
Y
N
The problem can be resolved by performing the adjustment.
Y
N
Check the position of the DADF Interlock Switch. The DADF Interlock Switch is
seated correctly in the DADF frame.
Y
N
Reseat the DADF Interlock Switch.
NOTE: When checking for an open circuit in the DADF Interlock Switch circuit,
ensure the DADF is closed.
NOTE: When checking for a short circuit in the DADF Interlock Switch circuit, ensure
the DADF is open.
Go to Flag 1. Check the wires for an open circuit and a short circuit.
There is an open circuit or a short circuit in the DADF Interlock Switch circuit.
Y
N
DADF Interlock Switch PL 2.1B Item 13.
Replace the PL 3.1 Item 2.

If the problem occurs again, Go to Flag 1. Check the circuit of the DADF Interlock
Switch for an intermittent condition, including P/J2 and P22
Replace the Scanner Main Cover PL 3.1 Item 2.
05-H, 05-J
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05-K Document Feeder Top Cover Sensor RAP

The message 'The Document Feeder cover is open.' is displayed on the User Interface when
the DADF Top Cover is closed
05-K On-Site Diagnostic Procedure

Open the DADF Top Cover. Check the Document Feeder Top Cover Sensor Actuator.
The
actuator for the Document Feeder Top Cover Sensor is damaged or missing
Y
N
Open then close the DADF Top Cover. The DADF Top Cover is closing correctly.
Y
N
Open the DADF Top Cover and check the DADF Top Cover Hinge Pin PL 2.1B Item
10.
The DADF Top Cover Hinge Pin is damaged or missing.
Y
N
Replace the DADF Top Cover Hinge Pin PL 2.1B Item 10.
Open the DADF Top Cover. Check the Document Feeder Top Cover Sensor PL 2.2.
The Document Feeder Top Cover Sensor is seated correctly.
Y
N
Reseat the Document Feeder Top Cover Sensor.
Figure 1 05-J RAP Circuit Diagram

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05-J, 05-K
05-L DADF Noise RAP

There is an abnormal sound or vibration when the Document Feeder is operating.
05-L On-Site Diagnostic Procedure

Do the following:
Remove the DADF Paper Feed Roll Cartridge. Reinstall the DADF Paper Feed Roll Cartridge. Ensure the DADF Paper Feed Roll Drive Coupling is fully engaged.
Load a stack of 5 sheets of paper in the Document Input Tray.
Listen for noise as the sheets are feeding from the Document Input Tray.
after reinstalling the DADF Paper Feed Roll Cartridge
Y
N
The noise occurs
Do the following:
Figure 1 05-K RAP Circuit Diagram
Load a stack of 5 sheets of paper in the Document Input Tray.
Listen for noise as the sheets are feeding from the Document Input Tray. The noise occurs
after replacing the DADF Paper Feed Roll Cartridge
Y
N
In Component Control, select [Document Handler/Scanner], [DADF Exit Clutch], [Output On],
[CVT Motor], then select [Output On]. Enter [Copier Sys tab , Component Control].
Listen for noise when the CVT Motor energizes. The noise occurs when the DADF Exit
Clutch and the CVT Motor are energized.
Y
N
In Component Control, select [Document Handler/Scanner], [All Outputs Off], [DADF
Feed Motor], then select [Output On]. Enter [Copier Sys tab , Component Control].
Listen for noise when the DADF Feed Motor energizes. The noise occurs when the
DADF Feed Motor energizes.
Y
N
In Component Control, select [Document Handler/Scanner], [Feed Clutch], then
Listen for noise when the Feed Clutch energizes. The noise occurs when the
Feed Clutch energizes.
Y
N
In Component Control, select [Document Handler/Scanner], [Feed Clutch],
[Output Off], [Inverter Clutch], then [Output On]. Enter [Copier Sys tab , Component Control].
Listen for noise when the Inverter Clutch energizes. The noise occurs when
the Inverter Clutch energizes.
Y
N
In Component Control, select [Document Handler/Scanner], [All Outputs
Off], [DADF Registration Gate Solenoid], then [Output On]. Enter [Copier
A
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D
Listen for noise when the DADF Registration Gate Solenoid energizes.
The noise occurs when the DADF Registration Gate Solenoid energizes.
Y
N
In Component Control, select [Document Handler/Scanner], [All Outputs Off], [Nudger Solenoid], then [Output On]. Enter [Copier Sys tab
, Component Control].
Listen for noise when the Nudger Solenoid energizes. The noise
occurs when the Nudger Solenoid energizes.
Y
N
The Document Feeder noise is intermittent. Return to Service
Call Procedures.
Replace the DADF Feeder Assembly PL 2.2 Item 2 and reset the Life
Check the DADF Exit Shaft PL 2.2 Item 9.
Use this procedure to diagnose the intermittent document jams listed below:
05-102, Document LE Late to the DADF Registration Gate Sensor.
05-104, Document LE Late to CVT Start of Scan Sensor.
05-106, Document LE Late to DADF Exit/Invert Sensor.
05-107, Document TE late to DADF Exit/Invert Sensor
05-109, Document TE late to Input Tray Exit Sensor (Pass 2 or 3).
Initial Actions
feeding curled originals, install the Document Input Tray Side Guides Kit PL 2.1A.
For intermittent 05-104, 05-106, and 05-107 jams, check the DADF Exit Clutch. If the part number on the clutch body is 121E10382 or lower, replace DADF Exit Clutch, PL 2.2 Item 13. If the
part number is 121E10383 or higher, continue with the RAP.
05-M On-Site Diagnostic Procedure
The DADF Top Cover Assembly PL 2.1B Item 2 including the DADF Take Away Roll
Idler
DADF Feed Motor PL 2.2 Item 7
Check part number on the DADF Exit Clutch.

The part number on the clutch body is 121E10382 or lower
Y
N
The Left CVT Baffle PL 2.4 Item 5 including the DADF Exit Roll Idler.
The Right CVT Baffle PL 2.4 Item 6 including the Right CVT Roll Idler.
The DADF Exit Shaft PL 2.2 Item 9 including the DADF Exit Clutch PL 2.2 Item 13.
The CVT Motor PL 2.3 Item 3.
Do the following:
Load 10 fresh sheets of 8.5 X 11 in (A4), paper in the Document Input Tray in portrait orientation (LEF).
Ensure the Document Input Tray Side Guides are touching the paper and the paper is
In DADF Document Timing Test, select [Start]. Enter [IIT tab , DADF Document Timing
Test].
Check the test results for Lead Edge At Q1 (Input Tray Exit Sensor), Lead Edge At Q2 (DADF
Registration Gate Sensor), Lead Edge At Q3 (CVT Start of Scan Sensor), and Lead Edge At
Q4 (DADF Exit/Invert Sensor). One or more of the DADF document path sensors have
feed times that are all between High and Jam Time.
Y
N
Check the test results for Time Over Q4 (DADF Exit/Invert Sensor). The test results for
Time Over Q4 (DADF Exit/Invert Sensor) indicate all the feed times are between
High and Jam Time.
Y
N
Check one of the following:
A
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05-100, Document LE Late to the Input Tray Exit Sensor.
NOTE: If the customer also complains of chattering noise in this area, replace the DADF Exit
Clutch PL 2.2 Item 13.
Check the DADF Feeder Assembly PL 2.2 Item 2.
Replace the DADF Exit Clutch PL 2.2 Item 13.
05-M Intermittent Document Jam RAP
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For intermittent 05-100 jams, go to Flag 2 in Figure 1. Check the circuit of the
Input Tray Exit Sensor, for an intermittent condition.
DADF Registration Gate Sensor, for an intermittent condition.
For intermittent 05-104 jams, go to Flag 1, Flag 2, and Flag 3 in Figure 3.

Check the circuit of the CVT Start of Scan Sensor, for an intermittent condition.
DADF Exit/Invert Sensor, for an intermittent condition.
B
05-L, 05-M
B
Do the following:
Ensure each 3-Arm Sheet Separator is in place and moves freely without binding.
Replace the Left CVT Baffle PL 2.4 Item 5 if necessary.
Check the Document Output Tray for damage, obstructions, or contamination.

Replace the Document Glass Cover/Document Output Tray PL 2.1A Item 7 if necessary.
In DADF Clutch / Solenoid Tests, select [Feed Clutch and Nudger Solenoid], then [Start
Test]. Enter [IIT tab , DADF Clutch / Solenoid Tests]. If the Feed Clutch Nudger Solenoid
test fails, replace the DADF Feeder Assembly PL 2.2 Item 2
Check the test results for Lead Edge At Q1 (Input Tray Exit Sensor). The test results for
Lead Edge At Q1 (Input Tray Exit Sensor) indicate all the feed times are between High
and Jam Time
Y
N
Check the test results for Lead Edge At Q2 (DADF Registration Gate Sensor). The test
results for Lead Edge At Q2 (DADF Registration Gate Sensor) indicate all the feed
times are between High and Jam Time
Y
N
Check the test results for Lead Edge At Q3 (CVT Start of Scan Sensor). The test
results for Lead Edge At Q3 (CVT Start of Scan Sensor) indicate all the feed
times are between High and Jam Time
Y
N
Do the following
Ensure the CVT Skis, are in place and move freely without binding.
Ensure the CVT Drive on Glass Roll moves freely up and down without
binding.
Replace the CVT Drive On Glass Kit PL 2.4 Item 7, if necessary.
Ensure the Left CVT Baffle is closing correctly. Ensure the Idler Rolls
move freely and the tension springs are in place. Replace the Left CVT
Baffle PL 2.4 Item 5 if necessary.
Do the following
Ensure the Right CVT Baffle is closing correctly and the foam pads are present
and are not damaged.
Ensure the Right CVT Roll Idler moves freely and the tension spring is in place.
Replace the Right CVT Baffle PL 2.4 Item 6 if required.
Do the following
Ensure the DADF Top Cover Assembly PL 2.1B Item 2 is closing correctly.
Check the DADF Take Away Roll and the DADF Take Away Roll Idler for contamination.
In DADF Clutch / Solenoid Tests, select [DADF Registration Gate Solenoid], then
[Start Test]. Enter [IIT tab , DADF Clutch / Solenoid Tests]. If the DADF Registration
Gate Solenoid test fails, replace the DADF Registration Deskew Assembly PL 2.1B
Item 6
Figure 1 05-M RAP Circuit Diagram
Do the following:
Check the DADF Paper Feed Roll Cartridge PL 2.2 Item 4, for wear or contamination.
If the DADF Paper Feed Roll Cartridge is replaced, reset the Life Counter for the DADF
05-M
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05-M
05-N DADF CVT Motor Ground Check

The purpose of this procedure is to ensure all components of TAG 084, DADF CVT Motor
Grounding Kit, are installed correctly. Without the installation of these components, electrostatic buildup between the CVT Motor and the motor mount can cause an electrostatic field
around the CVT Motor especially on large paper sizes (11x17 in (A3) and/or large scan runs
(large number of documents). This disrupts the normal operation of the motor and may result in
05-370 faults and/or incorrect magnification.
Procedure
Check for the presence of the following CVT Motor Grounding Kit components:
Shield (Figure 2).
Ground Bracket (Figure 1).
Retainer (Figure 1).
All the CVT Motor Ground Kit components are present and installed correctly.
Y
N
Do the following:
Ensure all components of the CVT Motor Grounding Kit (TAG 084) are installed correctly.
Mark off IOT Tag 084 on the IOT Change Tag Matrix.
Make 50 copies of the hard copy test pattern 82E12191 (11") or 82E12320 (A4).
Place the 50 copies in the DADF Input Tray.
Program a 2-2 sided copy job.
Do the following:
Ensure all components of the CVT Motor Grounding Kit (TAG 084) are installed correctly.
Mark off IOT Tag 084 on the IOT Change Tag Matrix.
Make 75 copies of the hard copy test pattern 82E12191 (11") or 82E12320 (A4).
Place the 75 copies in the DADF Input Tray.
Program a 2-2 sided copy job.
In Faults, select [Last 40 Faults]. Enter [Faults/Counters tab , Faults]. A 05-370 fault
occurred.
Y
N
Check the DADF magnification (refer to Magnification [DADF Mode]) The magnification is correct.
Y
N
Go to IQ-15.
Go to the 05-370/380 CVT Motor Fault RAP
Continuity is measured between the CVT Motor frame and the machine frame.
Y
N
Remove the CVT Motor and reform the small ground tab on the Ground Bracket to ensure
contact with the CVT Motor frame.
A
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A
Mark off IOT Tag 084 on the IOT Change Tag Matrix. Go to the appropriate RAP (05-370/380
or IQ-15).
Ground Bracket
CVT Motor
Retainer
Shield
(black side)
Figure 2 CVT Motor Shield
DADF PWB
Figure 1 CVT Motor Ground Bracket and Retainer
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05-N
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06-310/311/312/313/314/315 Polygon Motor Faults
Fault Code, 06-310, indicates that the ROS Polygon Motor did not start after 3 attempts.
Fault Code, 06-311, indicates that the ROS Polygon Motor did not reach minimum operating speed after 3 attempts.
Fault Code, 06-312, indicates that the ROS Polygon Motor did not reach the control
speed after 3 attempts.
Fault Code, 06-313, indicates that the ROS Polygon Motor fell below the operating speed.
Fault Code, 06-314, indicates that the ROS Polygon Motor does not reach minimum operating speed in the allotted times after 3 attempts.
Fault Code, 06-315, indicates that the Polygon Motor cannot reach or maintain simmer
speed.
N
Replace the ROS Assembly PL 5.2 Item 3.
Check for TAG 057. The machine has TAG 057.

Y
N
Replace the ROS Polygon Motor PL 5.2 Item 2.
Check for the reoccurrence of the fault. The fault still occurs.
Y
N
The problem is corrected. Return to Service Call Procedures.
06-310/311/312/313/314/315 On-Site Diagnostic Procedure

In Diagnostic Navigator, select [NVM tab , NVM Tool]. Search for the location indicated in Table
1.
Compare that value to the value for the Hall Period Reference located on the ROS bar code
label (on the side of the ROS that is viewable from the front of the machine). The Hall Period
Ref number is the 4 or 5 digit number that is preceded by the letter H under the second bar
code. Figure 2 The value matches the value for Hall Period Reference on the ROS
Assembly bar code label.
Y
N
Enter [NVM tab , NVM Tool] and reset the value to the value indicated on the ROS
Assembly bar code label. (Mark Service, location 729, hallPeriodRef) The Hall Period
Reference number is the 4 or 5 digit number that is preceded by the letter H under the
second bar code.
Measure the voltage between P/J10-12 (+) and P/J10-11 (-) at the Distribution PWB.
+24 1.2 VDC is measured.
Y
N
Measure the voltage between the 24V (+) (without IOT TAG 011) or +24V (+) (with IOT
TAG 011) and LVPS frame (-). +24 1.2 VDC is measured.
Y
N
Go to the 01-A, DC Voltage Checkout RAP.
Measure the voltage between P72-12 (+) and P72-11 (-) at the ROS Assembly. To gain
access to this connector, remove the Developer Housing REP 09-2 and the Developer Support
Rail REP 09-10. Remove any input devices from the left side of the machine and/or the left
side cover. P72 can now be disconnected from the ROS Assembly. Switch on the machine
power.
+24 1.2 VDC is measured.
Y
N
The ROS is OK. Go to Flag 1. Check the wires for an open circuit. If necessary, replace
the ROS Power Harness PL 1.5 Item 8.
Observe the ROS part number on the ROS Assembly bar code label.
Verify that the correct part number ROS was installed for machine speed (40ppm vs. 65ppm).
The correct ROS Assembly is installed.
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Figure 1 06-310/311/312/313/314/315 RAP Circuit Diagram
06-310/311/312/313/314/315
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Part #
ROS Serial #

Image Fast Scan Reg

(NVM 723)
(NVM 793)
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06-310/311/312/313/314/315
36V
+36V
24V
+24V
-12V
24 PSV
+24 VES
INT-OUT
Interlock Outp
Interlock Inpu
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
5.15V
+12V
+12V
-12V
+12 VES
5.15 PSV
Figure 3 LVPS Test Points

Product
470 DC/ST
460 DC/ST
255/265 DC/ST
N/A
240 DC/ST
N/A
06-310/311/312/313/314/315
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06-320/330 Laser Not On Fault
Fault Code, 06-320, indicates that Laser A does not come on.
Fault Code, 06-330, indicates that Laser B does not come on.
N
Go to Flag 1. Check for an open circuit. If necessary, replace the ROS Power Harness PL
1.5 Item 8.
Replace the ROS Assembly PL 5.2 Item 3
Initial Actions
Ensure that the ROS External Cooling Fan connector is seated securely.
06-320/330 On-Site Diagnostic Procedure

Check the value in NVM for the Exposure Calibration. Select [NVM] [NVM Tool] [Mark Service].
Go to location 793.
The value is between .03 and .3.
Y
N
Enter [NVM tab , NVM Tool] and reset this value to its correct value as noted on the ROS
Assembly bar code label. The Exposure Calibration number is the number that is preceded by the letter E under the second bar code. Figure 2
Enter [NVM tab , NVM Tool] select [Set-Up], then [Start Test]. A fault occurred during
Set-up or the fault is still present.
Y
N
Return to Service Call Procedures and close the call.
Replace the ROS Assembly (PL 5.2 Item 3).
Check the value for the Exposure Control in NVM
(Loc 720 - SW earlier than 19.01.503) or (Loc 1366 - 19.01.503 S/W and higher)
The value is greater than 15.
Y
N
In [Marking tab , Xerographic Diagnostics], select [Set-Up], then [Start Test]. This will
reset the Exposure Calibration to the correct value.
The fault is still present.
Y
N
Return to Service Call Procedures and close the call.
Replace the ROS Assembly (PL 5.2 Item 3).
Measure the voltage between the +12V (+) (without IOT TAG 011) or +12V (+) (with IOT TAG
011) and LVPS frame (-). The voltage is +12 .6 VDC.
Y
N
Measure the voltage between the -12V (+) (without IOT TAG 011) or -12V (+) (with IOT TAG
011) and LVPS frame (-). The voltage is -12 .6 VDC.
Y
N
Check +12 VDC and -12 VDC Power to the ROS Assembly. To gain access to this connector,
remove the Developer Housing REP 09-2 and the Developer Support Rail REP 09-10.
Remove any input devices from the left side of the machine and/or the left side cover. P72 can
now be disconnected from the ROS Assembly. Switch on the machine power.
Check for +12 VDC and -12 VDC. +/- 12 VDC to the ROS is OK.
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Part #
ROS Serial #

Image Fast Scan Reg

(NVM 723)
(NVM 793)
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36V
+36V
24V
+24V
-12V
24 PSV
+24 VES
INT-OUT
Interlock Outp
Interlock Inpu
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
5.15V
+12V
+12V
-12V
+12 VES
5.15 PSV
06-320/330
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06-320/330
06-340 No Start of Scan Fault
06-341 Start of Scan Not Within Window Fault
Fault Code, 06-340, indicates that no SOS pulses were seen at Start Print.
Fault Code, 06-341, indicates that the SOS pulses were not seen within the detection window
at Start Print.

Replace the ROS Assembly PL 5.2 Item 3. This problem may be caused by a dirty SOS Sensor in the ROS Assembly. Inspect the defective ROS Assembly for high dirt level. Check area
near the ROS Assembly for contamination. If contamination is a problem, take measures to
diagnose and repair the cause of the high dirt level.

Switch the machine power off/on.
Check for reoccurrence of the fault. The problem is gone.
Y
N
In [Faults/Counters tab , Faults], check the [Last 40] faults.
Check for 09-380, 09-382, 09-384, or 09-386 occurring near the times when 06-341 is
occurring. There are 09-380, 09-382, 09-384, or 09-386 faults present occurring.
Y
N
If the problem continues, replace the Xerographic Module PL 5.1A Item 1.
Go to the RAP for the occurring fault.
09-380
09-382
09-384
09-386
06-340, 06-341
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06-350/360/370 Laser Control Fault
Fault Code, 06-350, indicates that the Laser Bias did not converge at Start Print.
Fault Code, 06-360, indicates that the Laser Level did not converge.
Fault Code, 06-370, indicates that the Laser A or B Level fell out of range during run.
06-350/360/370 On-Site Diagnostic Procedure

Check the value in NVM for the Exposure Calibration. Select [NVM tab , NVM Tool] [Mark Service]. Go to location 793.
The value is between .03 and .3.
Y
N
Use [NVM tab , NVM Tool] to reset this value to its correct value as noted on the ROS
Assembly bar code label. Select [Mark Service]. Go to location 793. Change the Current
Value to match the Exposure Calibration number on the ROS label. The Exposure Calibration number is the number that is preceded by the letter E under the second bar code.
Figure 1
Check the value for the Exposure Control in NVM
(Loc 720 - SW earlier than 19.01.503) or (Loc 1366 - 19.01.503 S/W and higher)
The value is greater than 15.
Y
N
In [Marking tab , Xerographic Diagnostics], select [Set-Up], then [Start Test].
reset the Exposure Calibration to the correct value.
This will
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06-350/360/370
Part #
ROS Serial #

Image Fast Scan Reg

(NVM 723)
(NVM 793)
06-350/360/370
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ROS
Figure 2 Location of ROS
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06-380 ROS Interlock Fault

Fault Code, 06-380, indicates that the ROS Interlock is open.
Initial Actions
Ensure that the Xerographic Module is correctly and fully inserted in the machine.

Switch off the machine power. Disconnect P/J14 from the Distribution PWB.
Measure continuity between P/J14-15 and P/J14-16. Continuity is measured.
Y
N
Go to Flag 1, check for an open circuit. Ensure that the Xerographic Module is fully
inserted and latched correctly.
Go to Flag 2. Check for an open circuit.
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06-380
ROS
Figure 2 Location of ROS
06-380
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B
Incorrect IOT Software installed. Go to Table 1, ROS Compatibility Chart, and check that
the Software installed is compatible with the ROS, and that the IOT NVM Values are correct.
06-385 ROS Configuration Mis-match Fault

Fault Code, 06-385, indicates that the ROS Type and Speed versus IOT hardware is not compatible.
Incorrect ROS (hardware) installed. Speed and Type does not match IOT configuration. Go to
Table 1, ROS Compatibility Chart and determine which ROS is compatible with the IOT configuration. Check ROS part number, PL 5.2, and replace with correct Type and Speed. Refer to
Figure 1 ROS Bar Code Label to determine which ROS you have in the machine.
This procedure must be performed on-site.

The problem is caused by one of the following:
Machine NVMs corrupted
Wrong IOT configuration (speed)
Incorrect IOT software loaded
Incorrect ROS hardware installed (PL 5.2)
Table 1 ROS Compatibility Chart
Product
Procedure
The ROS was replaced.
Y
N
The IOT software was upgraded.
Y
N
The IOT configuration was changed.
Y
N
Machine NVMs corrupted. Initialize IOT NVMs. Go to Table 1, and ensure that
the NVM values for the ROS are set correctly.
DC470
ROS
Type
NVM Name
FA /
new
GB /
old
Incorrect IOT (speed) configuration. Go to Table 1, ROS Compatibility Chart and

check for correct machine configuration.
A
NVM
Loc
NVM Values
Min
Nom
Max
HallPeriodRef
FA
1397
9194
9243
9284
SimmerSpeed
FA
1291
9244
12000
12014
HallPeriodRef
GB
729
8924
8964
8999
SimmerSpeed
GB
1398
8970
11650
11670
Software
Release
L00.19.02
and later
any
Part #
ROS Serial #

Image Fast Scan Reg

(NVM 723)
(NVM 793)
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07-202.01/202.02/202.03/202.04 Tray 1 through 4 Elevator

Fault RAP
Paper Feed Drives Plate PL 4.1A Item 4.
Replace the Paper Feed Drives Plate PL 4.1A Item 4.
The Stack Height Sensor senses the Paper Tray is not in the feed position after the Tray Elevator Motor has been on for 7 seconds.
Replace the malfunctioning Paper Tray PL 4.1A Item 1.

Replace the Paper Feed Drives Plate PL 4.1A Item 4 and/or the Paper Tray PL 4.1A Item
1, depending on which coupling is damaged.
Initial Actions
Check that the Stack Height Sensor actuator flag on the rear of the paper tray is seated correctly and move freely without binding. If the actuator is damaged or missing, replace the
Paper Tray PL 4.1A Item 1.
If the problem continues, use this RAP.
07-202.01 On-Site Diagnostic Procedure

Ensure the Paper Feed Roll Cartridge is functional and installed correctly. Ensure the Paper
Tray is fully seated and held in place by the latch at the rear.
The 'Tray Is Open' message is displayed when the Paper Tray is seated.
Y
N
Pull out the suspect Paper Tray. In Component Control, select [IOT Paper Trays], then
select the [Tray Elevator Motor]. Enter [Copier Sys tab , Component Control].
The Tray Elevator Motor runs.
Y
N
Remove as many Paper Trays as necessary to gain access to the paper size switches on the
Paper Feed Drives Plate. In Component Control, select [IOT Paper Trays], then select each
paper size sensing switch for each tray and observe the PWS while actuating and deactuating
each switch. Enter [Copier Sys tab , Component Control].
The signal level changes state as each switch is actuated and deactuated.
Y
N
Check the condition and position of the switch actuators at the rear of the Paper Tray to ensure
they actuate the appropriate paper size switches. If the actuators are damaged, bent, or missing, replace the Paper Tray PL 4.1A Item 1.
Remove the Paper Tray which experiences the fault. Check the drive couplings between
the Paper Feed Drive Plate and the Paper Tray.
A coupling is damaged.
Y
N
Manually rotate the coupling on the Paper Tray.
The tray raises when the coupling is turned.
Y
N
Replace the Paper Tray PL 4.1A Item 1.
Remove another Paper Tray which is functioning correctly and install that tray in the
place of the malfunctioning tray.
The substitute tray works correctly in place of the malfunctioning tray.
Y
N
Do the following:
In Component Control, select [IOT Paper Trays], [Tray x Stack Height

Sensor], and [Start Monitor]. Enter [Copier Sys tab , Component Control].
Block and unblock the Tray x Stack Height Sensor.
The display indicates the state of the Stack Height Sensor changed
Y
N
Go to Flag 1 for Tray 1, Flag 3. for Tray 2, Flag 5 for Tray 4, or Flag 7 for
Tray 4. Check the circuit of the Tray x Stack Height Sensor.
A
B
V0.042
Tray Stack Height Sensor PL 1.6 Item 14.
IIOC PWB A7A4 (Tray 1/2 Drives Plate) PL 1.6 Item 1.
IIOC PWB A8A4. (Tray 3/4 Drives Plate) PL 1.6 Item 1.
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07-202.06 HCF (Tray 6) Elevator Fault
07-700 Paper Tray Fault Entry RAP
The Stack Height Sensor senses Tray 6 is not in the feed position after the HCF Tray Elevator
Motor has been on for 15 seconds.
Use this RAP to identify paper tray problems and the action to take if the problem occurs.
Procedure
Initial Actions
Check the installation and coupling of the Paper Feed Roll Cartridge.
Verify the paper guides (2), located on each side panel inside in the HCF paper loading
area, are set to the correct size (8 1/2" x 11" or A4)
The following are Paper Tray. problems an explanation of each problem, and the action to take
if the problem occurs. If a Paper Tray (07-XXX) fault code is displayed, go to the appropriate
RAP for the fault code.
Table 1 Paper Tray Problems

tests. Look for codes 03-831 through 03-837. Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
. Go to the RAP for the fault code. (03-831 RAP) (03-832 RAP) (03-833 RAP) (03-834
RAP) (03-835 RAP) (03-836 RAP) (03-837 RAP)
Observe the UI while opening and closing the paper stack cover on the HCF.
The message, Close Tray 6 cover to raise the tray to feed position, is displayed when
the cover is open, and is not displayed when the cover is closed.
Y
N
Replace the HCF Door Interlock Switch PL 4.2A Item 4.
If the problem continues, replace the HCF PWB PL 4.2A Item 10.
In Component Control, select [IOT Paper Trays], [HCF Stack Height Sensor], and [Start Monitor]. Enter [Copier Sys tab , Component Control].
The input is high.
Y
N
Replace the HCF Feeder PL 4.2A Item 3.
Problem
Action
There is abnormal sound or vibration when a tray is

being raised or when paper is being fed from a tray.
Go to the OF-1 RAP.
Tray 5 (Bypass Tray) and Tray 6 (HCF) are not available for selection. No fault code is displayed.
Tray 6 will not go down after the HCF Door Interlock

Switch is actuated.
Go to the 07-A RAP.
The paper size displayed on the User Interface for Go to the 07-B RAP.
one or more paper trays does not match the paper
size loaded in the paper tray.
An IOT Paper Tray Will Not Fully Close.
Go to the 07-C RAP.
Tray 6 will not raise to the feed position.
Go to the 07-D RAP.
The IOT Paper Heater is not functioning correctly.
Go to the 07-E. RAP.
NOTE: The heater functions only when the machine

power is switched off.
The HCF Paper Heater is not functioning correctly.
Go to the 07-F RAP.
NOTE: The heater functions only when the machine

power is switched off.
In Component Control, select [HCF Elevator Motor] and [HCF Elevator Direction] to run the
HCF Elevator down for approximately 10 seconds, then stop the motor. Enter [Copier Sys tab ,
Component Control].
The Stack Height Switch input is now high.
Y
N
Replace the HCF Feeder PL 4.2A Item 3.
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A
Drive the tray up and down several times to ensure the problem is corrected.
07-A Tray 6 (HCF) Will Not Go Down

Tray 6 will not go down after the HCF Door HCF Door Interlock Switch is actuated.
This problem must be diagnosed on-site.
Initial Actions
Ensure the HCF has Tags TAG H002 and TAG H005 installed (kit number 605K09161).
Procedure
Check that the IOT Front Door is fully closed
The IOT Front Door is fully closed and Tray 6 will still not go down.
Y
N
Check the Tray 6 Door Interlock Switch for binding.
The Tray 6 Door Interlock Switch actuator moves freely.
Y
N
Check Tray 6 for obstructions or binding which would prevent the tray from going down. Be
sure to remove the rear HCF Cover. (REP 07-7) and check if the elevator harness is caught on
the Top Cover Interlock mechanism.
An obstruction or binding was found.
Y
N
Ensure the jumper on the HCF PWB is installed correctly. Refer to REP 07-9.
The jumper is installed correctly.
Y
N
Install the jumper correctly.
[Type 2] tests. Look for codes 03-831 through 03-837. Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
Go to the RAP for the fault code. (03-831 RAP) (03-832 RAP) (03-833 RAP) (03-834
RAP) (03-835 RAP) (03-836 RAP) (03-837 RAP)
Observe the UI while opening and closing the paper stack cover on the HCF.
The message, Close Tray 6 cover to raise the tray to feed position, is displayed
when the cover is open, and is not displayed when the cover is closed.
Y
N
The obstruction or binding can be removed.
Y
N
Replace the HCF/Bypass Tray Assembly PL 4.2A Item 1.
A
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07-A
A
The paper size sensing problem is resolved. Return to Service Call Procedures.
07-B Paper Size Sensing RAP

The paper size sensing problem occurs only in the Bypass Tray.
Y
N
Do the following:
Pull out the paper tray which is sensing the incorrect paper size.
Ensure the side guides are touching the edge of the paper.
Close the paper tray.
Check the paper size displayed on the UI .
. The displayed paper size matches the actual paper size loaded in the paper tray.
Y
N
Remove another Paper Tray which is sensing paper size correctly and install that
tray in the place of the malfunctioning tray.
The substitute tray senses the paper size correctly in place of the malfunctioning tray.
Y
N
Replace the 4 Input IIOC PWB PL 1.6 for the tray position which does not
sense the paper size correctly.
If the problem continues, replace the Paper Feed Drives Plate PL 4.1A Item 4
for the tray position which does not sense the paper size correctly.
If the problem occurs only on small size papers in Trays 1-4, the machine may need
TAG 063. If necessary, install TAG 063 PL 4.1C Item 2.
If the retrofit is installed, and the problem continues, replace the malfunctioning
Paper Tray PL 4.1A Item 1.
The paper size sensing problem resolved. Return to Service Call Procedures.
Select [More] in the Paper Supply column on the UI.
The "Tray Type" for Tray 5 is "Fully Adjustable"
Y
N
Change the Tray Type for Tray 5 in Tools:
In Tools select [System Settings] then select [Tray Settings].
In Tray Settings select [Tray Settings].
In the second Tray Settings screen, select [Tray 5] and [Change Description].
Change Tray 5 to Fully Adjustable.
Select [Save] [Close] and [Exit Tools].
Do the following:
Remove the paper from Tray 5.
Place the paper back in Tray 5 and ensure the side guides are touching the edge of the
paper.
Check the paper size displayed on the UI .
The displayed paper size matches the actual paper size loaded in Tray 5.
Y
N
Replace the Bypass Input Tray PL 4.2B Item 7.
A
07-B
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07-C An IOT Paper Tray Will Not Fully Close
07-D Tray 6 (HCF) Will Not Raise
Tray 6 will not raise to the feed position.
Procedure
This fault happens when the drive couplings on the Paper Feed Drives Plate and the Paper
Tray do not engage when the tray is pushed in. The problem can be corrected with the following action.
Initial Actions
Pull out the Paper Tray enough to observe the drive coupling at the left rear of the tray.
Place a finger under the Nudger Roll of the Paper Feed Roll Cartridge, and rotate the
Nudger Roll in order to turn the drive coupling. (Any movement of more than a few
degrees of rotation Paper Feed Drives Plate PL 4.1A Item 4 is enough to solve the problem.)
Push in the Paper Tray.
Ensure the Paper Feed Roll cartridge is installed correctly. Customers can unlatch the cartridge during jam clearance actions.
Procedure
Check the User Interface .
The message Tray 6 contains too much paper is displayed when Tray 6 is in the down
position and the tray is not over-filled.
Y
N
The HCF Elevator Motor may not be running at the correct speed or torque. Replace the
HCF Elevator Motor PL 4.2B Item 9.
Enter [Self Tests tab , IIOC Controller Tests], select [IIOC Self Tests] and [IOT], then run the
[Type 1] and [Type 2] tests.
The test fails with an 03-833 fault.
Y
N
Go to Flag 4. Check the circuit of the HCF Solenoid for an intermittent condition.
Repair the wiring or replace the defective component:
HCF Feeder PL 4.2B Item 3.
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07-C, 07-D
07-D
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07-E IOT Paper Heater RAP

The function of the IOT Paper Heater is to maintain an acceptable humidity level within the
paper tray area of the IOT. The heater functions only when the machine power is switched off.
The heater can be diagnosed only On-Site.
Procedure
Test the IOT Paper Heater in the following manner.
Switch the machine power off.
Remove all paper trays from the IOT and locate the heater openings at the right side of
the paper tray area.
Breathe (exhale) closely into the bottom of the heater in order to activate the humidity
sensor. The heater fan should switch on.
Continue to breathe (exhale) into the bottom of the heater as necessary to keep the fan
running for at least one minute.
After approximately one minute of continuous operation, heated air comes out of the
heater vent nearest the Tray 4 location.
Y
N
Replace the IOT Paper Heater Kit PL 1.2B Item 9.
The heater is functioning normally. Reinstall the paper trays.
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07-E
07-E
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07-F HCF Paper Heater RAP

The function of the HCF Paper Heater is to maintain an acceptable humidity level within the
HCF. The heater functions only when the machine power is switched off.
The heater can be diagnosed only On-Site.
Procedure
Check the operation of the HCF Paper Heater. Switch the machine power off, then wait five
minutes for the HCF Paper Heater to warm up.
After five minutes, the HCF Paper Heater is warm.
Y
N
Check the voltage to the HCF Paper Heater.
Switch the machine power off.
Disconnect the HCF Paper Heater harness from the connector at the side of the IOT
(under the HCF Assembly).
Measure the AC voltage at the IOT connector with the machine power still switched
off.
The voltage is correct for the operating company (115VAC in USCO and XCL;.
220VAC in XE;. or 100VAC in FX)
Y
N
Check the voltage at the AC Distribution Panel.
Disconnect J5 from P5 at the bottom of the AC Distribution panel.
Measure the AC voltage at P5 with the machine power still switched off.
The voltage is correct for the operating company (115VAC in NASG and XCL;.
220VAC in XE;. or 100VAC in FX)
Y
N
Replace the HCF Heater Relay in the AC Distribution Panel PL 1.2B Item 1.
Check the wiring and the fuse from connector J110 to connector P5.
If necessary, replace the fuse PL 1.2B Item 8.
Replace the HCF Paper Heater PL 4.2A Item 9.
The heater is functioning normally.
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07-F
Figure 1 07-F RAP Circuit Diagram
07-F
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08-101.01/.02/.03/.04 IOT Paper Tray Misfeed

The lead edge of a sheet fed from an IOT Paper Tray arrived late at its Wait Station Sensor.
The fault code suffix identifies the tray from which the sheet was fed:
.01 = Tray 1 (Tray 1 Wait Station Sensor)
Check the position of the sheet when the misfeed occurred.

The sheet fed from the tray and was under the Wait Station Sensor when the jam
was declared.
Y
N
Remove and set aside the misfeeding tray. Remove another tray which feeds correctly and install that tray in the place of the misfeeding tray. Make copies/prints from
that tray.
08-101 faults occur from the substitute tray.
Y
N
Return the substitute tray to its original position. If not previously done, replace
the Paper Feed Roll Cartridge PL 4.1A Item 3 in the misfeeding tray. Reset the
Life Counter for the new cartridge (GP6).
If the problem continues, replace the Paper Tray Assembly PL 4.1A Item 1.
Initial Actions
Check for and remove any obstructions in the paper path for the tray not feeding correctly.
Check the installation of the Paper Feed Roll Cartridge in the tray not feeding correctly.
Turn over and reload the stack of paper in the tray not feeding correctly, making sure the
paper is loaded correctly and the side guides are set correctly. Ensure there are no
obstructions in the paper path between the paper tray and the Vertical Transport.
If the problem continues, load fresh paper from a new ream in the tray not feeding correctly, making sure the paper is loaded correctly and the Tray Paper Guides are set correctly.
If the customer is experiencing 08-101 jams while feeding heavyweight (greater than 32
lb. (120 gsm)) paper from Trays 1-4, have them open the tray then close the tray. When
the Tray x Information dialog box is displayed on the UI, select [Change Description].
Ensure the 'Stock Type' is set to [Heavyweight]. Select [Save], then select [Confirm].
Return the substitute tray to its original position. Replace the Paper Feed Drives
Plate PL 4.1A Item 4 for the tray position with the misfeeding problem.
[Type 2] tests. Look for codes 03-806 or 03-807 (Tray 1 and Tray 2) or codes 03-826 or
03-827 (Tray 3 and Tray 4). Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
Replace the Paper Feed Drives Plate PL 4.1A Item 4 for the misfeeding tray.

Ensure the paper in the misfeeding tray(s) is turned over and/or replaced with fresh paper as
described in Initial Actions.
Attempt to make copies/prints from each IOT paper tray in order to identify which trays exhibit
the misfeeding problem.
The 08-101.0X fault occurs only from a pair of trays (both Trays 1 and 2, or both Trays 3
and 4).
Y
N
NOTE: If more than one tray is misfeeding, diagnose only one tray at a time.
Perform the following actions:
Check for, and remove obstructions in the paper path between the Vertical Transport
and the misfeeding tray.
Clean and reseat the Wait Station Sensor for the jamming tray. Ensure the sensor
wires do not obstruct the paper path.
If the customer has not already done this, install a new Paper Feed Roll Cartridge PL
4.1A Item 3 in the misfeeding tray. Ensure the Paper Feed Roll Cartridge is installed
correctly. Reset the Life Counter for the new cartridge (GP6).
Load a fresh supply of the same kind of paper that was misfeeding and make
copies/prints from that tray.
The problem continues from that tray.

Y
N
Run enough copies/prints to ensure the problem is corrected.
A
B
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B
Check the Paper Specifications table in General Procedures to determine if the customer's paper meets the specifications for use in this machine.
The customer's paper meets the specifications in the table.
Y
N
Advise the customer the paper does not conform to the machine specifications.
Replace the Upper Guide Assembly PL 4.1A Item 6 for the misfeeding tray.
If the problem continues, replace the Paper Feed Drives Plate PL 4.1A Item 4 for the misfeeding tray.
This problem will occur if the wire harness connections to the Wait Station Sensors are
swapped.
The wire colors going to the Tray 1 Wait Station Sensor are Yellow, Green, and Blue.
The wire colors going to the Tray 2 Wait Station Sensor are Brown, Red, and Orange.
The wire colors going to the Tray 3 Wait Station Sensor are Yellow, Green, and Blue.
The wire colors going to the Tray 4 Wait Station Sensor are Brown, Red, and Orange.
Check the wire harness connections for the Wait Station Sensors for the misfeeding trays.
The Wait Station Sensors are connected correctly.
Y
N
Connect the sensors correctly. If the problem continues, replace the Paper Feed Drives
Plate PL 4.1A Item 4 for the misfeeding tray.
In Component Control, select [IOT Paper Trays], [Tray x Wait Station Sensor] and [Monitor
Input]. Enter [Copier Sys tab , Component Control].
Block and unblock the Tray x Wait Station Sensor with a sheet of paper. The display indicates the state of the Tray x Wait Station Sensor changed.
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08-101.01/.02/.03/.04
N
Go to the appropriate flag.
Go to Flag 1. Check the circuit of the Tray 1 Wait Station Sensor, PL 4.1A Item 13.
This problem will also occur if the Paper Feed Drives Plate jumper configuration is incorrect.
For a 40 ppm IOT, there should be a jumper on IIOC PWB A7A5 on Paper Drives Plate
(Trays 1 and 2), IIOC PWB A8A5 on Paper Tray Drives Plate (Tray 3 and 4).
For a 55 ppm or 65 ppm IOT, the jumper should be removed.
Check the jumper configuration for the Paper Feed Drives Plate for the misfeeding trays (Figure 2). The jumper configuration is correct.
Y
N
Go to the 08-E RAP.
In Component Control, select [IOT Paper Trays], [Tray x Feed Motor] and [Output On].
The Tray 1/2 Feed Motor (Tray 3/4 Feed Motor) energizes in component control
Y
N
If the problem is occurring with Tray 1 or Tray 2, go to Flag 5. Check the circuit of the Tray
1/2 Feed Motor.
If the problem is occurring with Tray 3 or Tray 4, go to Flag 6. Check circuit of the Tray 3/
4 Feed Motor.
Tray Feed Motor PL 1.6 Item 13
Paper Feeder PWB PL 1.6 Item 12.
Check the Paper Feed Drive Belt on the back of the Paper Feed Drives Plate. Ensure the
Paper Feed Drive Belt is installed correctly. Replace the Paper Feed Drives Plate PL 4.1A Item
4 for the misfeeding tray if necessary.
08-101.01/.02/.03/.04
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08-101.01/.02/.03/.04
08-101.05 Tray 5 (Bypass Tray) Misfeed

The lead edge of a sheet fed from Tray 5 arrived late at the Bypass Tray Wait Sensor.
Initial Actions
Ensure this
jumper is in
place for a 40
ppm machine,
but not in place
for a 55ppm or
65 ppm
machine.)
Check for and remove any obstructions in the Tray 5 paper path.
Check the installation of the Tray 5 Paper Feed Roll Cartridge and ensure the coupling is
engaged and that the pin is engaged in the fork.
Ensure the paper size loaded in the tray matches the paper size displayed on the User
Interface.
Turn over and reload the stack of paper in Tray 5, making sure the paper is loaded correctly (arrow down/seam side down), the Paper Guides are set correctly, and the stack is
below the 'Max Fill' line.
If the problem continues, load fresh paper from a new ream in Tray 5, making sure the
paper is loaded correctly, the Paper Guides are set correctly, and the stack is below the
'Max Fill' line.

Check the Last 40 Faults for 08-110.05 faults. Enter [Faults/Counters tab , Faults].
08-110.05 faults are logged.
Y
N
Check for, and remove obstructions in the Bypass Tray paper path.
Clean and reseat the Bypass Tray Wait Sensor in the Bypass Tray Feeder PL 4.2B
Item 4.
If the customer has not already done this, install a new Paper Feed Roll Cartridge
(PL 4.2B Item 6) in the misfeeding tray. Ensure the Paper Feed Roll Cartridge is
installed correctly and the coupling is engaged and that the pin is engaged in the
fork. Reset the Life Counter for the new cartridge (GP6).
Load a fresh supply of the same kind of paper that was misfeeding. Ensure the
paper size displayed on the Control Panel matches the size paper loaded in the
Bypass Tray.
Attempt to make copies/prints from the Bypass Tray.
An 08-101.05 fault occurs again.

Y
N
Run additional copies/prints to ensure the problem is corrected.
Figure 2 Jumper on Paper Feed Drives Plate
Y
N
The machine also has an HCF.
Y
N
A
08-101.01/.02/.03/.04, 08-101.05
May 2003
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B
V0.042
B
The machine also misfeeds from the HCF (08-101.06 faults).
Y
N
In Component Control, select [IOT Paper Trays]. Select [Bypass Tray Wait Sensor]
and [Start Monitor]. Enter [Copier Sys tab , Component Control].
Block and unblock the Bypass Tray Wait Sensor several times. The display indicates the state of the Bypass Tray Wait Sensor changes when the sensor is
blocked and unblocked.
Y
N
Paper Feed Roll Cartridge (Bypass Tray)
Bypass Tray Wait Sensor
Bypass Tray Feeder PL 4.2B Item 4.
[Type 2] tests. Look for codes 03-832 or 03-833 or 03-834. Enter [Self Tests tab , IIOC
Controller Tests].
The tests pass.
Y
N
Go to the RAP for the fault code (03-832 RAP) (03-833 RAP) (03-834 RAP).
HCF Wait Sensor
Paper Feed Roll

Cartridge (HCF)
HCF
Figure 1 08-101.05 RAP Component Locations
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08-101.05
08-101.06 Tray 6 (HCF) Misfeed
B
Y
The lead edge of a sheet fed from Tray 6 arrived late at the HCF Wait Sensor.
Initial Actions
Check for and remove any obstructions in the Tray 5/6 paper path.
Check the installation of the Tray 6 Paper Feed Roll Cartridge and ensure the coupling is
engaged, and the pin is engaged in the fork.
Turn over and reload the stack of paper in Tray 6, making sure the paper is loaded correctly, the Paper Guides are set correctly, and the stack is below the 'Max Fill' line.
paper is loaded correctly (arrow down/seam side down), the Paper Guides are set correctly, and the stack is below the 'Max Fill' line.
(240/255/265) Ensure the HCF has been retrofitted with TAG H007.
Check for, and remove obstructions in the HCF paper path.
Clean and reseat the HCF Wait Sensor in the Bypass Tray Feeder PL 4.2B Item 4.
If the customer has not already done this, install a new Paper Feed Roll Cartridge
(PL 4.2B Item 6) in Tray 6. Ensure the Paper Feed Roll Cartridge is installed correctly, the coupling is engaged, and the cartridge pin is engaged in the fork. Reset
the Life Counter for the new cartridge (GP6).
Load a fresh supply of the same kind of paper that was misfeeding.
Make copies/prints from the Tray 6.
HCF Feeder PL 4.2B Item 3
HCF/Bypass Tray Feed Motor PL 4.2B Item 8
In Component Control, select [IOT Paper Trays]. Select the [HCF Wait Sensor] and [Start
Monitor]. Enter [Copier Sys tab , Component Control].
Block and unblock the HCF Wait Sensor several times. The display indicates the state
of the HCF Wait Sensor changes when the sensor is blocked and unblocked.
Y
N
Replace the Bypass Tray Feeder PL 4.2B Item 4. (This feeder contains the HCF
Wait Station Sensor).
If the problem continues, replace the HCF PWB PL 4.2B Item 10. If the problem continues, replace the HCF/Bypass Tray Feed Motor PL 4.2B Item 8.

Check the Last 40 Faults for 08-110.06 faults and/or 07-202.06 faults. Enter [Faults/Counters
tab , Faults].
08-110.06 faults and/or 07-202.06 faults are logged.
Y
N
N

08-110.06 faults are logged.
Y
N
Go to the 08-110 RAP and diagnose that problem.

Y
N
Y
N
The sheet fed from the HCF and was under the HCF Wait Sensor when the jam was
declared.
Y
N
The machine also misfeeds from the Bypass Tray (08-101.05 faults).
A
B
08-101.06
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08-105.01/.02/.03/.04 IOT Paper Tray Jam

The trail edge of a sheet fed from an IOT Paper Tray (Tray 1, Tray 2, Tray 3, or Tray 4) was not
detected by its Wait Station Sensor.
.01 = Tray 1
.02 = Tray 2
.03 = Tray 3
.04 = Tray 4
Initial Actions
HCF Wait Sensor
Paper Feed Roll

Cartridge (HCF)
Check for and remove any obstructions in the paper path for the tray not feeding correctly.
Ensure there are no obstructions in the paper path between the paper tray and the Vertical Transport.
Check the physical installation of the Paper Feed Roll Cartridge in the tray not feeding
correctly and ensure the coupling is engaged.
If this is a new machine install, or the Paper Feed Roll Cartridge was recently replaced,
ensure the Life Counter is reset to 0 in the tray not feeding correctly (GP6).
If this problem occurs only when feeding pre-drilled papers, a hole in the paper may be
aligned with a paper path sensor. Try rotating the paper in the tray, or feeding the paper
from a different tray.
Turn over and reload the stack of paper in the tray not feeding correctly, making sure the
paper is loaded correctly and the Paper Guides are set correctly.
If the problem continues, load fresh paper from a new ream in the tray not feeding correctly, making sure the paper is loaded correctly and the Paper Guides are set correctly.

NOTE: The paper feed timing for a pair of trays (Trays 1 and 2, or Trays 3 and 4) will be incorrect if their Paper Feed Motor runs at the wrong speed. The motor speed is slower for 40 ppm
IOT's than for 65 ppm IOT's. If a 40 ppm machine is configured for 65 ppm, the sheets can be
fed fast enough so the lead edge of a second or subsequent sheet can overtake the trail edge
of a previous sheet before arriving at the Wait Station Sensor. If that occurs, the trail edge of
the previous sheet will not be detected and an 08-105.0X fault will be declared.
Check the paper feeding from all IOT paper trays.
The 08-105.0X fault occurs only from a pair of trays (both Trays 1 and 2, or both Trays 3
and 4).
Y
N
HCF
NOTE: If more than one tray is misfeeding, diagnose only one tray at a time.
Check for, and remove obstructions in the paper path between the Vertical Transport
and the misfeeding tray.
Clean and reseat the Wait Station Sensor for the jamming tray. Ensure the sensor
wires do not obstruct the paper path.
A
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08-101.06, 08-105.01/.02/.03/.04
If the customer has not already done this, install a new Paper Feed Roll Cartridge PL
4.1A Item 3 in the misfeeding tray. Ensure the Paper Feed Roll Cartridge is installed
correctly. Reset the Life Counter for the new cartridge (GP6).
Load a fresh supply of the same kind of paper that was misfeeding and make
copies/prints from that tray.
Replace the Upper Guide Assembly PL 4.1A Item 6 for the misfeeding tray.
If the problem continues, replace the Paper Feed Drives Plate PL 4.1A Item 4 for the misfeeding tray.
An 08-105 fault occurs again from that tray.

Y
N
N
Y
N

The sheet fed from the tray and was under the Wait Station Sensor when the jam
was declared.
Y
N
Remove and set aside the misfeeding tray. Remove another tray which feeds correctly and install that tray in the place of the misfeeding tray. Make copies/prints from
that tray.
08-105 faults occur from the substitute tray.
Y
N
Return the substitute tray to its original position. If the customer has not
already done this, install a new Paper Feed Roll Cartridge PL 4.1A Item 3 in the
misfeeding tray. Ensure the Paper Feed Roll Cartridge is installed correctly.
Reset the Life Counter for the new cartridge (GP6).
Check the [Last 40 Faults] for occurrences of 08-101.0X faults. Enter [Faults/Counters tab ,
Faults].
08-101.0X faults are logged.
Y
N
Check the jammed sheets for damage such as nicks, dings, dog-ears, etc. The sheets
show some form of damage.
Y
N
Observe the sheets as they feed out of the Paper Tray. The sheets are skewed.
Y
N
In IIOC Controller Tests, select [IIOC Self Tests] and [IOT], then run the [Type 1]
and [Type 2] tests. Look for codes 03-806 or 03-807 (Tray 1 and Tray 2) or
codes 03-826 or 03-827 (Tray 3 and Tray 4). Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
Go to the RAP for the fault code. (03-806 RAP) (03-807 RAP) (03-826
RAP) (03-827 RAP).
The problem occurs only with transparencies.

Y
N
Return the substitute tray to its original position. Replace the Paper Feed
Drives Plate PL 4.1A Item 4 for the tray position with the misfeeding problem.
Y
N
Go to the 08-E RAP.
At least one IOT paper tray feeds without jamming.

Y
N
Return the substitute tray to its original position. Replace the Upper Guide Assembly
PL 4.1A Item 6 for the misfeeding tray.
Y
N
Remove the tray with the jamming problem and set aside. Remove another tray
which feeds correctly and install that tray in the place of the misfeeding tray.
Make copies/prints from that tray.
08-105.0X faults occur from the substitute tray.
Y
N
Return the substitute tray to its original position.
Replace the Paper Tray Assembly PL 4.1A Item 1 which exhibits the jamming problem.
Replace the Paper Feed Drives Plate PL 4.1A Item 4 for the tray position with the
misfeeding problem.
[Type 2] tests. Look for codes 03-806 or 03-807 (Tray 1 and Tray 2) or codes 03-826 or
03-827 (Tray 3 and Tray 4). Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
A
08-105.01/.02/.03/.04
Return the substitute tray to its original position.

Replace the Upper Guide Assembly PL 4.1A Item 6.
If the problem continues, replace the Paper Feed Drives Plate PL 4.1A Item 4.
B
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D
V0.042
D
Go to the 08-C Skewed Image RAP.
Go to OF-2 Print Damage RAP.

Go to the 08-101.01/.02/.03/.04 IOT Paper Tray Misfeed RAP.
Ensure this
jumper is in
place for a 40
ppm machine,
but not in place
for a 55 ppm or
65 ppm
machine.)
08-105.05 Tray 5 (Bypass Tray) Jam

The trail edge of a sheet fed from Tray 5 was not detected by the Bypass Tray Wait Sensor.
Initial Actions
Check for and remove any obstructions in the Tray 5 paper path.
Check the physical installation of the Paper Feed Roll Cartridge (Bypass Tray) and
ensure the coupling is engaged and the pin is engaged in the fork.
Interface. This fault will always occur if the physical paper size is longer than what
is displayed on the User Interface.
If running plain paper, turn over and reload the stack of paper in Tray 5, making sure the
'Max Fill' line.
If running hole-punched paper, check for TAG H004. If not installed, order and install TAG
H004. If the problem continues, try running from a different tray.
'Max Fill' line.

Check for, and remove obstructions in the Bypass Tray paper path.
Ensure that the Duplex Transport is mated and latched correctly with the Registration
Transport Assembly (front and rear).
Sheets fed from the HCF/Bypass Tray are pulled into the IOT by a drive roll on the Registration Transport Assembly and an idler roll on the Duplex Transport. Ensure the Duplex
Transport idler roll is seated correctly on the Registration Transport Assembly drive roll
and the spring is attached correctly. (Refer to REP 10-2.)
Clean and reseat the Bypass Tray Wait Sensor in the Bypass Tray Feeder PL 4.2B Item
4.
If the customer has not already done this, install a new Paper Feed Roll Cartridge PL 4.2B
Item 6 in the misfeeding tray. Ensure the Paper Feed Roll Cartridge (Bypass Tray) is
installed correctly. Reset the Life Counter for the new cartridge (GP6).
Load a fresh supply of the same kind of stock that was misfeeding. Ensure the paper
size displayed on the Control Panel matches the size paper loaded in the Bypass Tray.
Attempt to make copies/prints from the Bypass Tray.

Y
N
Check the Paper Specifications table in General Procedures to determine if the customer's
paper meets the specifications for use in this machine.
Y
N
Advise the customer that the paper does not conform to the machine specifications.
A
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08-105.01/.02/.03/.04, 08-105.05
A
Y
N
Clean the Bypass Tray Wait Sensor. If the problem continues, replace the Bypass Tray
Assembly PL 4.3 Item 1.
The HCF jams with 08-105.06 faults.

Y
N
Registration Transport Assembly PL 4.1A Item 8
tests. Look for codes 03-832 or 03-833 or 03-834. Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
Go to the RAP for the fault code. (03-832 RAP) (03-833 RAP) (03-834 RAP).
If the problem continues, replace the Bypass Tray Feeder PL 4.2B Item 4.
If the problem continues, replace the Registration Transport Assembly PL 4.1A Item 8.
HCF Wait Sensor
Paper Feed Roll

Cartridge (HCF)
HCF
08-105.05
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08-105.06 Tray 6 (HCF) Jam

The trail edge of a sheet fed from Tray 6 was not detected by the HCF Wait Sensor.
Initial Actions
Check for and remove any obstructions in the Tray 5/6 paper path.
Check the physical installation of the Tray 6 Paper Feed Roll Cartridge and ensure the
coupling is engaged, and the pin is engaged in the fork.
If this is a new machine install, or the Paper Feed Roll Cartridge (HCF) was recently
replaced, ensure the Tray 6 Life Counter is reset to 0 (GP6).
Interface.
aligned with a paper path sensor. Try running plain paper, or feeding the paper from a different tray. If the problem still occurs, the machine may need TAG H004.
Turn over and reload the stack of paper in Tray 6, making sure the paper is loaded correctly, the Paper Guides are set correctly, and the stack is below the 'Max Fill' line.
'Max Fill' line.
The sheet fed from the HCF and was under the HCF Wait Station Sensor when the jam
was declared.
Y
N
Enter [Copier Sys tab , Component Control]. Select [IOT Paper Trays]. Select the [HCF
Wait Sensor] and [Start Monitor].
Block and unblock theHCF Wait Sensor several times. The display indicates the state
of the HCF Wait Sensor changes when the sensor is blocked and unblocked.
Y
N
Replace the following, one-at-a-time, until the problem is corrected:
location 34, hcfPreloadControl
location 38, ElevRaiseSlope
location 39, ElevRaiseIntercept
The NVMs are all set to their nominal values.

Y
N
Use [NVM tab , NVM Tool] to reset the values to nominal. Ensure that the problem is
corrected.
NOTE: A High Capacity Feeder with product code CTH is not designed to operate with Document Centre 240/255/265/460/470. Ensure an HCF with product code H4D or NF4 is installed.
The Bypass Tray misfeeds with 08-105.05 faults.

Y
N
Check for, and remove obstructions in the HCF paper path.
Transport idler roll is seated correctly on the Registration Transport Assembly drive roll
front and rear. (Refer to REP 10-2.)
Ensure the Duplex Transport is latched to the Registration Transport Assembly.
Clean and reseat the HCF Wait Station Sensor in the Bypass Tray Feeder PL 4.2B Item 4.
If the customer has not already done this, install a new Paper Feed Roll Cartridge PL 4.2B
Item 6 in the misfeeding tray. Ensure the Paper Feed Roll Cartridge (HCF) is installed correctly. Reset the Life Counter for the new cartridge (GP6).
Load a fresh supply of the same kind of paper that was misfeeding.
In Diagnostic Navigator, select [NVM tab , NVM Tool] and initiate an NVM download. In
NVM Tool, select service [Mark Service], module [HCFwithCovers]. Check the following
NVM locations:
location 33, hcfModFeedEnable
Replace the HCF Feeder PL 4.2B Item 3.

Replace the following, one-at-a-time, until the problem is corrected:
HCF/Bypass Feed Motor PL 4.2B Item 8
HCF PWB PL 4.2B Item 10
Make copies/prints from the HCF (Tray 6).

Y
N
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08-105.06
08-110 Registration Transport Jam

The lead edge of a sheet arrived early at the Registration Sensor (S2) in the Registration
Transport Assembly.
.01 to.04 = IOT Paper Tray 1 to Tray 4
.05 = Bypass Tray (Tray 5)
.06 = HCF (Tray 6)
.99 = Duplex Transport
Initial Actions
Obtain a supply of fresh paper from a new ream (8.5 x 11 in, 20 lb or A4, 80 gsm). Load
the paper in any tray that exhibited the jamming problem.
Check the Paper Specifications table to determine if the paper the customer is using is
listed. Enter Product Specifications . If the paper the customer is using is not listed in the
table, advise the customer the paper does not conform to the machine specifications
If the problem continues after performing the above actions, follow the procedure in the RAP.

HCF Wait Sensor
Paper Feed Roll

Cartridge (HCF)
Check the following list for specific symptoms. If any symptom exists, perform the indicated
action.
Check the jammed sheets for damage such as nicks, dings, or dog ears. If the sheets are
damaged, go to the OF-2 Print Damage RAP.
Observe the sheets for skew as they feed into the Registration Transport Assembly. If the
sheets are skewed, go to the 08-C Skewed Image RAP.
If either of the listed symptoms do not exist, continue in this RAP.

08-110 faults occur when feeding from any tray.
Y
N
The jams occur only with sheets feeding from the Duplex Transport (fault code 08110.99)
Y
N
The jams occur only when feeding from Tray 5 (the Bypass Tray) or Tray 6 (the
HCF).
Y
N
The jams occur from all IOT Paper Trays.
Y
N
The jams occur from both trays that share the same Paper Feed
Drives Plate: [Tray 1 and Tray 2] or [Tray 3 and Tray 4].
Y
N
Replace the Upper Guide Assembly (PL 4.1A Item 6) for the tray with
the jamming problem.
HCF
A
08-105.06, 08-110
May 2003
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For a 40 ppm IOT, there should be a jumper on IIOC PWB A7A5 on

Paper Drives Plate (Trays 1 and 2), IIOC PWB A8A5 on Paper Tray
Drives Plate (Tray 3 and 4).
D
V0.042
A
Check the Drives Plate jumper for the trays that exhibit the jamming problem. Refer to REP 07-1 for specific information. The jumper configuration is correct (installed on a 40 ppm IOT; removed on a 55 ppm or 65
ppm IOT).
Y
N
Make the jumper configuration correct. Run copies to ensure the
problem is solved.
E
Clean the Registration Sensor and ensure it is seated correctly in the Registration Transport Assembly.
Y
N
Replace the Paper Feed Drives Plate PL 4.1A Item 4 for the misfeeding
trays.
Clean the Registration Sensor and ensure it is seated correctly in the Registration Transport Assembly.
Y
N
[Type 2] tests. Look for fault codes 03-811 or 03-812. Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
Go to the RAP for the fault code.
Do the following:
RAP 03-811, IIOC PWB W8A4 Failed The IIOC Controller Test.
In the [Paper] tab, select [IOT Paper Path Setup]. Select [SMH Feed
Time], [8.5 x 11] or [A4], then select [Start Job].
Enter [Paper tab , IOT Paper Path Timing].
Do the following:
The problem continues after performing the setup.

Y
N
In the [Paper] tab, select [IOT Paper Path Setup]. Select [Duplex Feed Time], [8.5 x
11] or [A4], then select [Start Job].
Enter [Paper tab , IOT Paper Path Timing].

Y
N

[Type 2] tests. Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
Check the following on the Duplex Transport:
The Preregistration Nip Solenoid Spring PL 6.1A Item 10.
The Preregistration Gate Link PL 6.1A Item 11.
Replace the Duplex Transport PL 6.1A Item 2, if necessary.

The machine has an HCF/Bypass Assembly.
Y
N
In Diagnostic Navigator, select [NVM tab , NVM Tool] and initiate an NVM download.
In NVM Tool, select service [Mark Service], module [HCFwithCovers]. Check the following NVM locations:
location 33, hcfModFeedEnable
location 34, hcfPreloadControl
The NVMs are all set to their nominal values.

Y
N
Use [NVM tab , NVM Tool] to reset the NVMs to the correct values.
A
B
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In Component Control, select [IOT Paper Path], [Registration Sensor] and [Monitor Input].
Block and unblock the Registration Sensor with a sheet of paper.
The display indicates the state of the Registration Sensor changed.
Y
N
Go to Flag 2. Check the circuit of the Registration Sensor for a short circuit.
Registration Sensor PL 4.1B Item 2.
Registration Transport Assembly PL 4.1A Item 8.
In [Faults/Counters tab , Faults], select [Fault Counters]. Filter by Chain [08]. Check
the value for 08-105.06.
There is a count of over 100 for 08-105.06.
Y
N
E
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08-110
08-110
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The lead edge of a sheet arrived late at the Registration Sensor (S2) in the Registration Transport Assembly.
.06 = HCF (Tray 6)
N
If the problem is feeding 2- or 4-hole drilled paper from any IOT paper tray,
install TAG 066 (PL 4.1A Item 18).
Y
N
The jams occur from all IOT Paper Trays.
Y
N
The jams occur from more than one IOT Paper Tray.
Y
N
Replace the Paper Feed Roll Cartridge for the tray with the jamming
problem. Reset the Life Counter for the new cartridge (GP6).
Initial Actions
Ensure the tray side guides are set correctly.
Ensure the Area 2 Handle is securely snapped in place. If the handle is damaged, replace
the Registration Transport Handle Kit PL 4.1B Item 3.
aligned with a paper path sensor. Try rotating the paper in the tray, or feeding the paper
from a different tray.
Ensure that the paper that is jamming meets the machine spec. Check the Paper Specifications table to determine if the paper is listed. Enter Product Specifications
If the paper is a special stock, try running from a different tray.
If not already done, ensure that a new Paper Feed Roll Cartridge is installed.
If the customer is experiencing 08-115 jams while feeding heavyweight (greater than 32
lb. (120 gsm)) paper from Trays 1-4, have them open the tray then close the tray. When
the Tray x Information dialog box is displayed on the UI, select [Change Description].
Ensure the 'Stock Type' is set to [Heavyweight]. Select [Save], then select [Confirm].
The jams occur from both trays which share the same Paper Feed
Drives Plate: [Tray 1 and Tray 2] OR [Tray 3 and Tray 4].
Y
N
Check the jammed sheets for damage such as nicks, dings, or dog ears. If the sheets are
damaged, go to the OF-2 Print Damage RAP.
Ensure that the Duplex Transport is mated correctly with the Registration Transport
Assembly.
Transport idler roll is seated correctly on the Registration Transport Assembly drive roll.
(Refer to REP 10-2.)
Observe the sheets for skew as they feed into the Registration Transport Assembly. If the
sheets are skewed, go to the 08-C Skewed Image RAP.
Ensure the idler balls press against the Vertical Transport belt
so that paper does not slip between the balls and the belt.
Check for obstructions in the paper path, such as wiring or

pieces of paper.
NOTE: The paper feed timing for a pair of trays (Trays 1 and 2, or Trays 3
and 4) will be incorrect if their Paper Feed Motor runs at the wrong speed.
The motor speed is slower for 40 ppm IOT's than for 55 ppm or 65 ppm
IOT's. If a 40 ppm machine is configured for 55 ppm or 65 ppm, the sheets
can be fed fast enough so the lead edge of a second or subsequent sheet
can overtake the trail edge of a previous sheet before arriving at the Wait
Station Sensor. If that occurs, the trail edge of the previous sheet will not
be detected and an 08-105.0X fault will be declared.
If either of the listed symptoms do not exist, continue in this RAP.

08-115 faults occur when feeding from any tray.
Y
N
The jams occur only with sheets feeding from the Duplex Transport (08-115.99).
Y
N
The jams occur only when feeding from Tray 5 (Bypass Tray) or Tray 6 (HCF).
A
B
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Ensure the Vertical Transport receives drive from the Developer

Drive Motor, and there is no binding or slipping of the Vertical
Transport belt. Remove the Developer Drive Motor REP 04-1
and check the gears on the motor. If the gears are damaged,
replace them using the Developer Drive Motor Gear Kit PL 7.1
Item 9.
If the problem continues, replace the Paper Feed Drives Plate PL

4.1A Item 4 for the problem trays.
Clean the Registration Sensor (S2).

Check the following list for specific symptoms. If any symptom exists, perform the indicated
action.
For a 40 ppm IOT, there should be a jumper on IIOC PWB A7A5 on

Paper Drives Plate (Trays 1 and 2), IIOC PWB A8A5 on Paper Tray
Drives Plate (Tray 3 and 4).
Check the Drives Plate jumper for the trays that exhibit the jamming problem. The jumper configuration is correct (Figure 2).
Y
N
Go to the 08-E RAP.
A
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E
08-115
E
Replace the Paper Feed Drives Plate PL 4.1A Item 4 for the misfeeding
trays.
The HCF/Duplex Baffle is seated correctly on the Duplex Transport and is free
from damage.
Y
N
Replace the HCF/Duplex Baffle PL 6.2B Item 8 if necessary.
Ensure the Vertical Transport receives drive from the Developer Drive
Motor, and there is no binding or slipping of the Vertical Transport belt.
Ensure the idler balls press against the Vertical Transport belt so that
paper does not slip between the balls and the belt.
Check for obstructions in the paper path, such as wiring or pieces of

paper.

If the problem continues, replace the HCF Feeder PL 4.2B Item 3.
If the problem is still not resolved, enter [Faults/Counters tab , Faults], select [Fault
Counters]. Filter by Chain [08]. Check the value for 08-105. If any high values exist
for 08-105 faults, go to that RAP.
If the machine has an HCF, ensure the following HCF Tags are installed:
TAG H002 (Mylar harness shield added to HCF/Bypass Tray Feed Motor)
TAG H005 (New HCF Paper Feeder)
TAG H007 (HCF Feed Improvement Kit) PL 4.2B Item 20.
Ensure the Duplex Transport is seated correctly on the Registration Transport. Run several duplex copies.
Y
N
If the problem is feeding lightweight papers with the HCF, it may also be necessary
to install TAG H112 (HCF Feed Improvement Kit for Lightweight Paper) PL 4.2B Item
20).
TAG H002 and TAG H005 are installed, and TAG H007 or TAG H112 is installed,
and the problem continues.
Y
N
Check the HCF/Duplex Baffle.

The HCF/Duplex Baffle is seated correctly on the Duplex Transport and is free from
damage.
Y
N
Replace the HCF/Duplex Baffle PL 6.2B Item 8 if necessary.
Run several duplex copies and observe the paper feeding from the Duplex Transport to
the Registration Transport Assembly.
The sheets are noticeably skewed.
Y
N
[Type 2] tests. Look for fault codes 03-811 and 03-812. Enter [Self Tests tab , IIOC
Controller Tests].
The tests pass.
Y
N
If the machine has an HCF, ensure the correct feeder spring is installed. Refer to
Optimizing the Tray 6 Nip Force.
The correct spring is installed for the customers applications and the problem
continues.
Y
N
Install the correct spring.
Install a new Paper Feed Roll Cartridge PL 4.1A Item 3 in the problem tray. Reset
the Life Counter for the new cartridge (GP6). Run copies to determine if the problem
is resolved.
08-115 jams still occur when feeding with the new Paper Feed Roll Cartridge.
Y
N
Check the following on the Duplex Transport:

In System Registration Setup, select [IOT System Registration], [Tray 5] or [Tray 6]
as appropriate, and [Start Setup]. Enter [Paper tab , System Registration Setup].
Y
N
The Helical Drive Gear PL 6.1B Item 3.
The Duplex Transport Belt PL 6.1B Item 15.
The Preregistration Nip Solenoid Spring PL 6.1A Item 10.
The Preregistration Gate Link PL 6.1A Item 11.
Replace the Duplex Transport PL 6.1A Item 2, if necessary.

Program the machine to run 40 copies/prints. Observe the HCF Tray and ensure that
the tray raises slightly every 5-15 copies/prints.
The tray raises slightly every 5-15 copies/prints.
Y
N

In Faults, select [Last 40 Faults]. Make a note of any 08-105.xx faults. Enter [Faults/Counters
tab , Faults].
An 08-105.xx fault occurred when the 08-115 fault occurred.
Check the HCF/Duplex Baffle.

A
B
08-115
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N
The test fails with a 03-836 fault.
Y
N
In Component Control, select [IOT Paper Path], [Registration Sensor] and [Monitor
Input]. Block and unblock the Registration Sensor with a sheet of paper.
The display indicates the state of the Registration Sensor changed.
Y
N
Go to Flag 2. Check the circuit of the Registration Sensor, for an open circuit or
a short circuit.
Registration Sensor PL 4.1B Item 2.
Registration Transport Assembly PL 4.1A Item 8.

Go to RAP 03-836, IIOC Module W3A1 Failed the IIOC Controller Test.
Go to the 08-105.01/.02/.03/.04 RAP, the 08-105.05 RAP, or the 08-105.06 RAP.
Optimizing the Tray 6 Nip Force

If the Tray 6 Paper Feed Roll Cartridge needs frequent replacement, it could be because the
nip force needs to be changed for the customers specific applications. The nip force is
changed by using one of two springs in listed below. Each spring produces a different force of
the Tray 6 feed nip for specific papers.
CAUTION
There is no single spring which is ideal for all applications. For example, using the nominal
force spring may actually INCREASE the number of 8-105.06's when feeding lightweight
papers. Be sure to choose the spring which will produce the best results for the customer.
NOTE: The two springs are unmarked and can be differentiated only by their length and form.
The retrofit kit instructions contain a diagram to aid in the identification of the springs.
The spring in the HCF Feed Improvement Kit (low force) PL 4.2B Item 20 will improve the
performance of lightweight papers, i.e. 16lb-18lb (60gsm). This spring should be used if
the customer runs a high percentage of lightweight papers.
The spring in the HCF Feed Improvement Kit (nominal force) PL 4.2B Item 11 is the
spring to use for all other papers, especially 20lb (80gsm). This spring is recommended
for customers who feed a wide range of papers from the HCF.
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08-115
08-115
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The trail edge of a sheet was not detected by the Registration Sensor in the Registration
Transport Assembly.
Ensure this
jumper is in
place for a 40
ppm machine,
but not in place
for a 55 or 65
ppm machine.)
.06 = HCF (Tray 6)
Initial Actions
Check for and remove any obstructions in the paper path.
Ensure the paper the customer is using meets specifications. Refer to the Paper Specifications table in General Procedures.
If the problem is 08-120.05 (paper was fed from the Bypass Tray) ensure the paper size
loaded in the tray matches the paper size displayed on the User Interface. This fault is
likely to occur if the physical paper size is longer than what is displayed on the User Interface.
Turn over and reload the stack of paper in the tray the customer was using when the jam
occurred.
If the problem continues, load fresh paper from a new ream in the tray the customer was
using when the jam occurred.
If the problem continues after performing the above actions, use the RAP.

Check the [Last 40 Faults] for instances of Xerographic (09-xxx faults) and/or 10-100 faults.
09-xxx faults and/or 10-100 faults are listed in the Last 40.
Y
N
Check the following list for specific symptoms. If any symptom exists, perform the indicated action.
Check the jammed sheets for damage such as nicks, dings, or dog ears. If the
sheets are damaged, go to the OF-2 Print Damage RAP.
Observe the sheets for skew as they feed into the Registration Transport Assembly.
If the sheets are skewed, go to the 08-C Skewed Image RAP.
If the jams are intermittent, check the finished copy/print image for skew. If the
printed image is skewed more than +/- 5 mm, replace the Registration Transport
Assembly PL 4.1A Item 8.
If none of the listed symptoms exist, continue in this RAP.

Check the fault history for 08-115 and 08-110 faults.
Enter [Faults/Counters tab , Faults]. 08-115 faults are logged.
Y
N
08-110 faults are logged.
Y
N
Check the source of the jammed sheet.
The jams occur only on sheets fed from the Duplex Transport.
A
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C
08-115, 08-120
A
Y
N
Check the location of the jammed sheet.
The jammed sheet is stopped between the Prefuser Transport (PFT)
and the registration rolls (over the S2 sensor).
Y
N
Ensure the Mylar, PL 4.1B Item 6, on the Registration Transport

Assembly is adhered correctly and is not damaged
Ensure the PFT is seated correctly and paper is not stubbing on the
lead edge of the PFT.
Remove the Fuser Drive Motor and inspect the Drive Gear for wear
or damage. Replace the Fuser Drive Gear PL 7.1 Item 5 or the Fuser
Drive Motor PL 7.1 Item 3, as appropriate

In IOT Paper Path Setup, perform the Duplex Feed Time setup. Enter
[Paper tab , IOT Paper Path Setup].
If the problem continues after the setup, go to the 08-C Skewed Image
RAP.
[Type 2] tests. Look for fault code 03-836. Enter [Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
If the problem is still not resolved, enter [Faults/Counters tab , Faults],

select [Fault Counters]. Filter by Chain [08]. Check the value for 08-105. If
any high values exist for 08-105 faults, go to that RAP
Check the duplex sheets for skew.
The sheets are skewed.
Y
N
Check the duplex sheets in the Registration Transport Assembly.
The sheets are skewed in the Registration Transport Assembly.
Y
N
In IIOC Controller Tests, select [IIOC Self Tests] and [IOT], then run
the [Type 1] and [Type 2] tests. Look for fault codes 03-836. Enter
[Self Tests tab , IIOC Controller Tests].
The tests pass.
Y
N
Go to RAP 03-836, IIOC Module W3A1 Failed the IIOC Controller Test.
Check the Registration Clutch using the Component Control.
In Component Control, select [IOT Paper Path], [Developer

Drive Motor] and [Output On]. Select the [Registration Clutch]
and [Cycle Output].
Observe the Registration Idler Rolls to ensure they start and

stop with the cycling of the clutch.
After you have observed the Registration Idler Rolls, select [All
Outputs Off].
Enter [Copier Sys tab , Component Control]. The Registration Idler

Rolls start and stop with the cycling of the clutch.
Y
N
Go to Flag 1. Check the circuit of the Registration Clutch.
A
B
C
D
E
F
08-120
In Component Control, select [IOT Paper Path], [Developer Drive Motor] and [Output
On].
Select the [Registration Clutch], then make alternate selections of [Output On] and
[Output Off].
Observe the Registration Transport Assembly to ensure the Registration Rolls start
and stop with the cycling of the clutch.
After you have observed the Registration Rolls, select [All Outputs Off].

The registration rolls start and stop with the cycling of the clutch.
Y
N
Go to Flag 1. Check the circuit of the Registration Clutch.
Do the following:
F
If the problem continues, replace the Registration Transport
Assembly PL 4.1A Item 8.
Do the following:
If the problem continues, replace the Registration Transport Assembly PL 4.1A Item
8.
Do the following.
If there are 09-xxx faults in the fault history, go to the appropriate RAP.
If there are 10-100 faults in the fault history, go to the 10-100 RAP.
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08-120
08-701 Misfeed From Any Paper Tray
08-705 Modified Feed Timing Boundary
The lead edge of the sheet was not detected by the Tray Wait Station Sensor.
Software automatically modifies feed timing as components age in order to maintain optimum
feeder performance. This fault indicates the automatic adjustment has reached its limit and the
paper feed components in the appropriate tray should be serviced.
Procedure
Go to the 08-101.01/.02/.03/.04 RAP.
Initial Actions
Check for 08-115 Faults. Go to the 08-115 RAP.
Procedure
The problem is in one of the IOT Paper Trays.
Y
N
The problem is in the Bypass Tray.
Y
N
HCF Paper Feed Roll Cartridge PL 4.2B Item 6. Reset the Life Counter for the
new cartridge (GP6).
Replace the Paper Feed Roll Cartridge PL 4.2B Item 6 in the Bypass Tray.
Y
N
Y
N
Bypass Tray Paper Feed Roll Cartridge PL 4.2B Item 6. Reset the Life Counter
for the new cartridge (GP6).
Bypass Tray Paper Feed Roll Cartridge PL 4.2B Item 6. Reset the Life Counter for
the new cartridge (GP6).
08-701, 08-705
Replace the Paper Feed Roll Cartridge PL 4.1A Item 3 in the tray experiencing the problem. Reset the Life Counter for the new cartridge (GP6).
Replace the Paper Tray Assembly PL 4.1A Item 1 experiencing the problem.
Replace the Paper Feed Drives Plate PL 4.1A Item 4 for the tray experiencing the problem.
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08-706 False TE transition of the Wait Station Sensor

Counts the number of potential 08-105.06 faults averted via declaring a false trail edge transition at the Wait Station Sensor when feeding from the HCF (Tray 6) rather than an actual trail
edge transition at the Wait Station Sensor.
This fault is intended to eliminate the occurrence of 08-105.06 faults. This fault will not cause a
shutdown and no operator action is required.
08-710 Vertical Transport Entrance Jam From Any Paper

Tray
The trail edge of the sheet was not detected by the Tray Wait Station Sensor.
Procedure
Go to the 08-105.01/.02/.03/.04 RAP.
Procedure
Check the last 40 Faults for 08-115.06 faults and 08-120.98 faults. Enter [Faults/Counters tab ,
Faults].
Check the fault counters for a high occurrence of 08-706 faults. Enter [Faults/Counters tab ,
Counters Display].
Take one of the following actions
If there are 08-115.06 faults in the Last 40 Faults, go to the 08-115 RAP.
If there are 08-120.98 faults in the Last 40 Faults, go to the 08-120 RAP.
If there are 08-115.06 and/or 08-120.98 faults in the Last 40 Faults and a high occurrence
of 08-706 faults in counters, go to the 08-105.06 RAP.
If there are no 08-115.06 or 08-120.98 faults in the Last 40 Faults, return to Service Call
Procedures.
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08-706, 08-710
08-A Lead Edge Misregistration RAP
08-B Top Edge Misregistration RAP
The image is misregistered at the lead edge of the paper.
Side 1 or Side 2 Top Edge Registration is not within specification.
Initial Actions
NOTE: Top edge registration on the 2nd side of duplex copies relies on the Top Edge Electronic Registration (TEER) Sensor in the Duplex Transport to measure the exact position of the
outboard edge of the paper in the Duplex Transport paper path. Software uses the TEER Sensor data to delay or advance the timing of the ROS so the 2nd side will be placed correctly with
respect to the edge of the paper.
Have the customer select [Image Adjustment] and [No Shift.] on the UI, and then run
some copies. If those selections correct the misregistration problem, return to Service
Call Procedures

Check the prints for image skew. The prints exhibit skew in addition to the misregistration.
Y
N
Use the 08-A Registration Setup Procedure to correct the misregistration.
Initial Actions
Have the customer select [Image Adjustment] and [No Shift] on the UI, and then run some
copies. If those selections correct the misregistration problem, return to Service Call Procedures
Verify the Side 1 and Side 2 skew is in specification. Go to the 08-C RAP to diagnose IOT
skew problems.
Check Side 1 and Side 2 of the prints for folded-over corners (dog-ears) on the lead
edge of the prints. If the prints are dog-eared, remove the obstruction in the paper path.
Check for undersized paper (5.5 x 8.5 in [A5]) oriented SEF. When run SEF, this paper is
too narrow to be detected by the TEER Sensor. Continue in this RAP only if the Top Edge
Registration problem occurs with 8.5 x 11 in (A4) letter-size paper (or larger).
08-A Registration Setup Procedure

Perform ADJ 8-1A.
The registration is OK after the registration setup procedure was performed.
Y
N

In Faults, select [Fault Counters] or [Last 40 Faults]. Make a note of all Duplex TEER (10-7XX)
faults, that are listed in the Last 40 Faults.
NOTE: For duplex TEER systems using early versions of firmware, faults will not be logged in
[Last 40 Faults], This will be true for most 240/255/265/460/470 machines (upgrades made
starting March 2001 time frame). In these cases the [Fault Counters] must be checked and
used to determine if TEER faults have been and/or are occurring.
10-7xx faults are displayed in the [Fault Counters] or in the [Last 40 Faults].
Y
N
Make 5 prints from the suspect tray, or all trays if the suspect tray is not known.
In TEER Diagnostics, select [Group 2 Tests], [Print Test], Print count [5]. Select the
suspect tray, then select [Start].
Ensure the tray to be tested has 8.5 x 11 in (A4) paper loaded.
Enter [Paper tab, TEER Diagnostic].
Repeat for all other trays including the Bypass Tray (Tray 5) and the HCF (Tray 6).
Check the 4th and 5th print (refer to Figure 1). Top edge misregistration occurs.
Y
N
Go to the 08-B Intermittent Misregistration Checkout Procedure.
The problem occurs from all paper trays.
Y
N
Check the paper size displayed on the User Interface for each of the paper trays.
A
08-A, 08-B
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B
V0.042
A
The paper size displayed on the User Interface for each paper tray matches the
paper size loaded in the paper tray.
Y
N
The problem is with Tray 1 - 4.
Y
N
Check the IOT Entrance Baffle at the left end of the Duplex Transport. Ensure
that the baffle is installed and seated correctly. Check for any obstructions or
damage such as a broken finger.
The Entrance Baffle is OK.
Y
N
Repair replace the IOT Entrance Baffle as necessary PL 6.1B Item 8.
The problem is with the Bypass Tray.
Y
N
Replace the following items until the problem is resolved.
HCF Paper Handling Baffle PL 4.2B Item 2.
Paper Tray Feed Head PL 4.1A Item 17.
Paper Tray Assembly PL 4.1A Item 1.
Upper Guide Assembly PL 4.1A Item 6.
Top Edge Misregistration is also occurring when feeding from Tray 4.

Y
N
Vertical Transport PL 4.1A Item 7.

Side 1 registration is correct.
Y
N
Check the Mylar on the Registration Transport Assembly.
The Mylar is adhered correctly and is free from damage.
Y
N
Replace the Mylar PL 4.1B Item 6.
A
C
V0.042
D
The direction and amount of image shift is approximately the same on all the
prints.
Y
N
Go to the 08-B Variable Misregistration Checkout Procedure.
Perform ADJ 8-1B and run internal test pattern 17. Check Side 1 of the prints.
The problem continues after performing the adjustment.
Y
N
Replace the Registration Transport Assembly. PL 4.1A Item 8.
Go to the 08-B Side 2 Checkout Procedure.

Go to the RAP for the fault(s) displayed.
08-B Side 2 Checkout Procedure

In Faults, select [Last 40 Faults]. Make a note of any 08-115.99, 10-105, 10-115, 10-120, 10125 faults that are listed in the Last 40 Faults. Enter [Faults/Counters tab , Faults].
08-115.99, 10-105, 10-115, 10-120, 10-125 faults are displayed in the Last 40 Faults.
Y
N
Perform ADJ 8-1C, IOT Top Edge Registration (IB-OB), Side 2, Small Paper or ADJ 8-1D
IOT Top Edge Registration (IB-OB), Side 2, Large Paper
The problem continues after performing the adjustment.
Y
N
Top Edge Misregistration is occurring when feeding from Tray 1 or Tray 2.

Y
N

If the problem continues, replace the Duplex Transport PL 6.1A Item 2.
Go to the appropriate RAP (08-115, 10-105, 10-115, 10-120, 10-125).
NOTE: Go to the RAP for the fault with the lowest number first if more than one of these faults
occurred at the approximately the same time.
08-B Variable Misregistration Checkout Procedure

In Faults, select [Last 40 Faults]. Make a note of any 08-101, 08-110, 08-115, 08-120 faults that
are listed in the Last 40 Faults. Enter [Faults/Counters tab , Faults].
08-101, 08-110, 08-115, 08-120 faults are displayed in the Last 40 Faults.
Y
N
Go to the appropriate RAP (08-101.01/.02/.03/.04, 08-115, 08-110, 08-120).
occurred at the approximately the same time.
08-B Intermittent Misregistration Checkout Procedure
In TEER Diagnostics, select [Group 1 Tests], [Communications Test], then [Start]. Enter
[Paper tab, TEER Diagnostic].
Repeat the test for Registration TEER 9 more times.
In TEER Diagnostics, select [Group 1 Tests], [Communications Test], then [Start]. Enter
[Paper tab, TEER Diagnostic].
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08-B
Repeat the test for Registration TEER 9 more times.
Check the results of all 10 tests. 10-7xx TEER faults are displayed in the test results window.
Y
N
In TEER Diagnostics, select [Group 2 Tests], [Print Test], Print count [5]. Select the
suspect tray, then select [Start]. Enter [Paper tab, TEER Diagnostic].
F

Go to the RAP for the TEER fault displayed
Repeat the Group 2 test for the tray selected 4 more times.
Check the data in column 2 for each of the 5 tests (Refer to Table 1). The
between the highest value and the lowest value is greater than 3 mm.
Y
N
difference
The problem occurred in Tray 1, Tray 2, Tray 3, or Tray 4.

Y
N
In TEER Diagnostics, select [Group 2 Tests], [Print Test], Print count [5], [Tray
4], then select [Start]. Enter [Paper tab, TEER Diagnostic].
Repeat the Group 2 test for Tray 4 4 more times.
difference between the highest value and the lowest value is greater than 3 mm.
Y
N
HCF Paper Handling Baffle PL 4.2B Item 2.
In TEER Diagnostics, select [Group 2 Tests], [Print Test], Print count [5], [HCF], then
select [Start]. Enter [Paper tab, TEER Diagnostic].
Repeat the Group 2 test for the HCF 4 more times.
difference
between the highest value and the lowest value is greater than 3 mm.
Y
N
In TEER Diagnostics, select [Group 2 Tests], [Print Test], Print count [5], [HCF]
or [Tray 2], then select [Start]. Enter [Paper tab, TEER Diagnostic].
NOTE: If the problem is occurring in Tray 1 or Tray 2 run the Group 2 test using
Tray 4. If the problem is occurring in Tray 3 or Tray 4 run the Group 2 test using
Tray 2.
Repeat the Group 2 test for Tray 4 or Tray 2 4 more times.
difference between the highest value and the lowest value is greater than 3 mm (24
pixels).
Y
N
E
F
08-B
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occurred.
top edge of paper
Table 1 Data in TEER test results window

Column 1
(Print
Number)
Column 2
(Side 2 at Duplex TEER Sensor)
(1)
(2)
(3)
(4)
(5)
Teer Position is xxx

top horizontal line

near lead edge
top edge
registration measurement
NOTE: The measurements in column 2 is the number of mm or pixels the center of the paper is
from the center of the paper path (8 pixels is equal to 1 mm). A negative measurement (-x.xxx)
indicates the paper is inboard from the center of the paper path. A positive measurement
(x.xxx) indicates the paper is outboard from the center of the paper path.
lead edge
of paper
Figure 1 Top Edge Registration
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08-B
08-C Skewed Image RAP

The image is skewed on the lead edge of the paper.
Have the customer perform the following actions:

Flip the paper in the Paper Tray.
Make sure that the Paper Tray side guides are in the correct position (Trays 1-5).

amount
Replace the Paper Feed Roll Cartridge PL 4.2B Item 6.
Check the HCF Feeder PL 4.2B Item 3, for damage
The paper path between the Registration Transport Assembly and the
HCF/Duplex Baffle for obstructions.
The surface of the HCF Paper Handling Baffle PL 4.2B Item 2 for nicks or
contamination.
If necessary, run several 2-sided prints to determine if the skew occurs on Side 1 and Side 2.
The skew occurs on Side 1 and Side 2 of the prints
Y
N
The skew occurs on the second side of two-sided prints.
Y
N
Make prints from all 4 IOT Paper Trays, the Bypass Tray (Tray 5) and the HCF (Tray
6).
The skew occurs from all IOT Paper Trays, Tray 5 and Tray 6.
Y
N
The skew occurs from Tray 5 and/or Tray 6 only.
Y
N
Ensure the Registration Transport Assembly is correctly mounted to the Duplex

Transport.
Ensure the HCF/Duplex Baffle (part of the Duplex Transport PL 6.1A Item 2) is
seated correctly and is free from damage.
Ensure the Registration Transport Assembly has free play (Refer to REP 08-2,
Replacement)

Transport.
Ensure the HCF/Duplex Baffle (part of the Duplex Transport PL 6.1A Item 2) is
seated correctly and is free from damage.

Y
N
Check the following on the Inverter:
NOTE: A No response means the skew does not occur on paper fed
from Tray 5 and/or Tray 6 but occurs from one or more IOT paper trays.
The Inverter Exit Roll PL 6.3 Item 7 for glazing and wear.
The Feed/Reverse Roll PL 6.3 Item 7 for glazing and wear
The check of the Inverter rolls is good.

Y
N
Go to the 08-C IOT Paper Tray Skew Checkout.

The skew occurs from Tray 5 and Tray 6
Y
N
If the skew is occurring from Tray 5 only do the following. Check for skew
after performing each action listed.
Remove then reinstall the Paper Feed Roll Cartridge PL 4.2B Item 6
in Tray 5.
The prints show some form of damage, such as nicks, corner folds, etc.
Y
N
Do the following:
IOT Skew Diagnostic Procedure
08-C
Remove then reinstall the Paper Feed Roll Cartridge PL 4.2B Item 6
in Tray 6.
If the problem continues, replace the Registration Transport Assembly PL 4.1A Item
8.
Go to the IOT Skew Diagnostic Procedure.
A
B
C
D
Do the following:
Perform adjustment procedure ADJ 8-2. Check if the skew is still present after performing the
adjustment.
Y
N
Check the Bypass Tray Feeder PL 4.2B Item 4, for damage
Check the following
Check that the amount of skew is equal from all trays and is less than 1.5mm. The
of skew is equal from all trays and less than 1.5mm.
Y
N
Go to the IOT Skew Diagnostic Procedure.
If the skew is occurring from Tray 6 only do the following. Check for skew
after performing each action listed.
Initial Actions

Go to 08-C Side 1 and Side 2 Skew Checkout.
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08-C Side 1 and Side 2 Skew Checkout
Skew occurs on paper fed from the tray in its new position.
Y
N
Return the Paper Tray to its original position.
Make the following checks on the components adjacent to the Paper Tray:
The prints show some form of damage, such as nicks, corner folds, etc.
Y
N
Run several copies from Tray 6 and observe the paper buckle at the Registration Transport Assembly.
Measure the height of the paper buckle. Refer to GP41 Measuring the Height of the Paper
Buckle. The buckle height is between 20 mm and 30 mm.
Y
N
Check for obstructions between the Upper Guide PL 4.1A Item 14 and the
Lower Guide PL 4.1A Item 5.
Check the idlers on the Upper Guide PL 4.1A Item 14, for wear
A component in the Paper Tray is causing skew. Do the following, checking for skew after
performing each action listed.
NOTE: A No response means the buckle height is NOT correct.

In [IOT Paper Path Setup], select [Duplex Feed Time], then select and [Start Job].
When the setup is complete, run copies to determine it the problem is solved. Enter
[Paper tab , IOT Paper Path Setup].
Y
N
[Type 2] tests. Look for fault codes 03-811 and 03-812. Enter [Self Tests tab , IIOC
Controller Tests].
The tests pass.
Y
N
Go to the RAP for the fault code. (03-811 RAP) (03-812 RAP)
Do the following:
Ensure the Preregistration Nip Solenoid Gate Spring PL 6.1A Item 10 on the
Duplex Transport is not damaged or missing.
Ensure the Preregistraion Gate Link PL 6.1A Item 11 on the Duplex Transport is
not damaged and is attached to the Preregistration Gate.
Remove then reinstall the Paper Feed Roll Cartridge PL 4.1A Item 3.
Replace the Paper Feed Roll Cartridge PL 4.1A Item 3.
Check the Paper Tray Feed Head PL 4.1A Item 17, for damage and obstructions.
Do the following:
Check the paper path at the top of the Vertical Transport for obstructions.
Ensure the Vertical Transport is mounted correctly to the Registration Transport Assembly. Refer to REP 08-1.
Check the Vertical Transport PL 4.1A Item 7, for wear.

NOTE: If the Vertical Transport is worn, also check the Upper Guide Assembly PL 4.1A
Item 14, for wear
Check the idlers on the Upper Guide - Tray 1 PL 4.1A Item 14 (Tray 1), for wear.
Replace the Duplex Transport PL 6.1A Item 2 if necessary.

Y
N
Do the following:

Transport.
Ensure the Registration Transport Assembly has free play (Refer to REP 08-2,
Replacement)
08-C IOT Paper Tray Skew Checkout

The skew occurs on paper fed from all 4 IOT paper trays.
Y
N
Move the Paper Tray the skew is occurring from to another position. Program a job to
feed paper from the tray in its new position.
E
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08-C
08-D "Check Tray X" Message RAP

The message, "Check Tray X" (where X is a number, 1 through 6), is declared when the control logic detects an out of paper or misfeed condition.
Initial Actions
Check that the Stack Height Sensor actuator flag on the rear of the paper tray is seated
and not stuck.
Procedure
Clear all jobs in the queue.
Y
N
Ensure this
jumper is in
place for a 40
ppm machine,
but not in place
for a 55ppm or
65 ppm
machine.)
The Check Tray X message occurs from a pair of trays (both Trays 1 and 2, or both
Trays 3 and 4).
Y
N
Perform a soft PO/PO using the switch on the right side of the IOT.
Y
N
The "X" in the description represents the tray number in which the misfeed occurred.
For numbers 1 through 4 (IOT paper trays), go to the 08-101.01/.02/.03/.04 RAP.
For number 5 (the Bypass Tray), go to the 08-101.05 RAP.
For number 6 (the HCF), go to the 08-101.06 RAP.
Y
N
Go to the 08-E RAP.
Perform a soft PO/PO using the switch on the right side of the IOT.
Y
N
Go to the 08-101.01/.02/.03/.04 RAP.
08-D
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08-E Paper Feed Drives Plate Jumper RAP

Feed problems will occur if the Paper Feed Drives Plate jumper configuration is incorrect.
For a 55 ppm or a 65 ppm IOT, the jumper should be removed.
Procedure
Do the following
Correct the jumper configuration. Refer to REP 07-1 for specific information.
NOTE: If the jumper is missing from a 40 ppm IOT, it will be necessary to replace the
Paper Feeder PWB PL 4.1A Item 12.
In [NVM tab , NVM Read/Write], select [Mark Service], ensure that the following NVM
variables are set to 0.
For Tray 1/2 Drives Plate, ensure the value in location 110 and location 111 is set to
[0].
For Tray 3/4 Drives Plate, ensure the value in location 112 and location 113 is set to
[0]
When the values have been modified, exit NVM Read/Write and exit Diagnostic Navigator.
Enter [NVM tab , NVM Read/Write]
The problem continues after correcting the jumper configuration.

Y
N
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08-E
08-E
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09-210 No Photoreceptor Seam Detected RAP

Fault Code, 09-210, indicates the PR Belt seam was not seen in the timing window or not
detected within 2 belt pitches at initialization.
Initial Actions
If any of the following faults occur, go to the RAP for those faults:
BTAC Faults (09-310, 09-320)
PR Motor Encoder Faults (04-205)
ROS Faults (06-xxx)
Ensure the Raster Output Scanner Video Cable is correctly connected at the ROS and
the Main Control PWB.
DC460/470 - 09-210 faults along with 14-325 and 14-335 faults can be caused by electrical noise. Electrical noise can be caused by a defective Illumination Lamp, PL 3.2 Item 7
or a poor Lamp Cable connection at the Illumination Lamp Power Supply PL 3.2 Item 5.
Check connection at the Illumination Lamp Power Supply and check the Illumination
Lamp for black ends or a burned out filament and replace as required.
Remove the Developer Housing REP 09-2
Inspect the Developer HVPS Contact Springs on the Developer

Housing for damage/dirt. Figure 1
Ensure the Developer HVPS is mounted/located correctly
Reinstall the Developer Housing REP 09-2.

If the problem continues, replace the Photoreceptor Drive Module PL
5.1A Item 2
A black copy/print occurred at the same time the fault occurred.

Y
N
Remove the Xerographic Module from the machine.
Inspect the photoreceptor seam for de-lamination and check
the Xerographic Module for a piece of paper that may have entered the Xerographic
Module and may be between the BTAC Sensor and the P/R Belt. There is de-lamination of the Photoreceptor or there is a piece of paper seen in the Xerographic Module.
Y
N
Try to make copies.
Observe when the fault occurs. The fault occurs immediately after the machine
begins to cycle-up.
Y
N
Clean the BTAC Sensor REP 09-9. Re-install the Xerographic Module.
Make copies/prints and recheck for the 09-210 fault. The fault still occurs.
Y
N
The 09-210 fault has been corrected by cleaning the BTAC Sensor. Check
for a high level of machine contamination, which may be responsible for
contaminating the BTAC Sensor. Return to Call Flow and troubleshoot the
dirt problem if present.
The Xerographic Module has already been replaced while trying to solve
this problem.
Y
N
The problem is corrected.
Y
N
Go to Flag 1. Inspect the ground wire connected to the BTAC Sensor
Assembly. Ensure there is a good connection to ground.
There is a good ground connection to the BTAC shield.
Y
N
Repair or replace as necessary BTAC Sensor PL 5.1B Item 3.
D
E
F
Ensure the BTAC Sensor brackets are not bent and the BTAC Sensor is correctly positioned on the Developer Housing. Repair as necessary.
Make copies/prints to check for the fault. The problem continues.
Y
N
F
Check/perform the following:
Check for reoccurrence of the fault. The fault is still occurring.

Y
N
A
B
V0.042

Go to Flag 1. Inspect the ground wire connected to the BTAC Sensor Assembly. Ensure there is a good connection to ground.
There is a good ground connection to the BTAC shield.
Y
N
Repair or replace as necessary BTAC Sensor PL 5.1B Item 3.
Remove the Developer Housing REP 09-2
Inspect the Developer HVPS Contact Springs on the Developer for damage/dirt
Ensure the Developer HVPS is mounted/located correctly
Reinstall the Developer Housing.
Check for reoccurrence of the fault. The fault is still occurring.

Y
N
Ensure the BTAC Sensor is correctly positioned on the Developer Housing.
Ensure that it is not out of position. Repair as necessary.
Y
N
If the problem continues, replace the Photoreceptor Drive Module PL 5.1A Item
2
A
May 2003
2-295
B
09-210
B
Repair or replace the Xerographic Module PL 5.1A Item 1.
Go to 09-A Charge Power Supply Checkout.
Clean
Clean Shaft
(especially discolored area)
Figure 1 Donor Roll Shaft
09-210
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09-215 Multiple Photoreceptor Seams Detected RAP

Fault Code, 09-215, indicates the seam was indistinguishable from scratches on the photoreceptor.
Initial Actions
Ensure the machine has been powered off/on at least once before continuing.

Ensure the BTAC Sensor brackets are not bent and the BTAC Sensor is correctly positioned on
the Developer Housing. Ensure that it is not out of position. Repair as necessary.
Y
N
Y
N
Check the continuity from the BTAC shield to the machine frame. There is a
ground connection to the BTAC shield.
Y
N
Go to Flag 1. Repair or replace as necessary BTAC Sensor PL 5.1B Item 3.
good
Replace the Developer Housing PL 5.1B Item 5. If the problem continues, replace the
SCAM PWB PL 1.5 Item 6.
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09-215
09-220 No Machine Clock on Main Control PWB

Fault Code, 09-220, indicates the machine clock was not detected on the Main Control PWB
within 250ms of start-up.

Enter [Faults/Counters tab , Faults], select [Last 40].
Inspect the Last 40 Faults for the following faults: 04-210, 09-370, 09-372, 09-374, 09-376.
04-210, 09-370, 09-372, 09-374, 09-376 are in the Last 40 log.
Y
N
In [Copier Sys tab , Component Control], select [IOT General] [Photoreceptor Drive
Motor], then [Output On].
Allow the test to run several seconds. Select [Output Off]. Check for 04-205 faults. At
the bottom of the component control window, right mouse click, select [Show System Status]. At the bottom of the System Status window, right mouse click and select [Show
Faults]. A 04-205 fault occurs.
Y
N
Measure the voltage between TH42 (+) and TH14 (-) on the SCAM PWB.
Select [Output On]. Measure the voltage. Select [Output Off]. The voltage is 2.0
.2 VDC
Y
N
If OK, replace the SCAM PWB PL 1.5 Item 6.
Measure the voltage between TH41 (+) and GND (-) on the Distribution PWB.
Select [Output On]. Measure the voltage. Select [Output Off]. The voltage is 2.5
.3 VDC.
Y
N
If OK, replace the Distribution PWB PL 1.5 Item 7.
Check/perform the following, one-at-a-time, until the problem is resolved:
Go to Flag 2. Check the wires for an open or short circuit.
If OK, go to the 03-G, Main Control PWB Replacement RAP.
Go to the 04-205.
Go to the 01-A, Voltage Checkout RAP.
09-220
May 2003
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09-220
SCAM PWB
Distribution PWB
Figure 2 Component Location
09-220
May 2003
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TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
Figure 3 SCAM PWB Test Holes
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09-220
TH41
Figure 4 Distribution PWB Test Holes
09-220
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09-300 BTAC Offset Voltage Low Fault

Fault Code, 09-300, indicates the BTAC Offset Voltage is out of range (less than 0.39 V).
Initial Actions
Ensure that all covers are installed and no stray light is hitting the BTAC Sensor.

In [Copier Sys tab , Component Control], select [IOT General] [BTAC Reset].
Select [Output On]. The voltage measured between TH44 (+) and TH14 (-) on the SCAM
PWB is 0.5 0.1 VDC.
Y
N
Select [Output Off]. Go to Flag 1 and Flag 2. Check the wire for an open or short circuit.
Remove the Developer Housing and check the pins in P/J50 especially pin 1 which supplies BTAC Ground.
If OK, replace the BTAC Sensor PL 5.1B Item 3.
Select [Output Off]. Replace the SCAM PWB PL 1.5 Item 6.
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09-300
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
09-300
May 2003
2-304
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May 2003
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09-300
09-302 BTAC Offset Voltage High Fault

Fault Code, 09-302, indicates the BTAC Offset Voltage is out of range (greater than 0.67 V).
Initial Actions

If the Developer Housing was recently removed and re-installed, remove the Developer
Housing and check the pins in P/J50 especially pin 1 which supplies BTAC Ground.
In [Copier Sys tab , Component Control], select [IOT General] [BTAC Reset].
Select [Output On]. (Keep the component on until instructed to switch the output off) The
voltage measured between TH44 (+) and TH14 (-) on the SCAM PWB is 0.5 0.1 VDC.
Y
N
The voltage measured between TH45 (+) and TH14 (-) on the SCAM PWB is 5.0
0.5 VDC.
Y
N
Select [Output Off]. Switch off the machine Power. Disconnect P25/J5 from the
SCAM PWB. Switch on the machine power. In [Copier Sys tab , Component Control], select [IOT General] [BTACS Reset].
Select [Output On]. The voltage measured between TH45 (+) and TH14 (-) on
the SCAM PWB is 5.0 0.5 VDC.
Y
N
Select [Output Off]. Go to Flag 1 and Flag 2. Check the wires for a short circuit.
Select [Output Off]. Go to Flag 1 and Flag 2. Check the wires for an open or short circuit.
09-302
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09-302
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
09-302
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09-304 BTAC Loop Counter Fault

Fault code, 09-304, indicates the BTAC loop counter exceeded 32 steps in trying to increase
Vcal to 3.5 v.
Initial Actions
Check the fault history for any ROS faults (06-XXX). If any are indicated, go to the appropriate RAP.
If black prints are occurring, go to the IQ-17, IOT Black Prints RAP.
Check with customer and ensure that all covers are in place and no stray light is entering
the machine.

Check for an obstruction between the BTAC Sensor and the P/R Belt (such as paper
stuck in the Xerographic Module). Remove or repair as necessary.
Clean the BTAC Sensor REP 09-9.
Make copies/prints. The problem is now corrected.

Y
N
In [Copier Sys tab , Component Control], select [IOT General] [BTAC Cal], then [Output
On].
Measure the voltage between TH46 (+) and TH14 (-) on the SCAM PWB. The voltage
is less than 0.7 VDC.
Y
N
Select [Output Off]. Switch off the IOT Power. Disconnect P25/J5 from the SCAM
PWB. Switch on the IOT power. In [Copier Sys tab , Component Control], select [IOT
General] [BTAC Cal], then [Output On].
Measure the voltage between TH46 (+) and TH14 (-) on the SCAM PWB. The
voltage is less than 0.7 VDC.
Y
N
Select [Output Off]. Go to Flag 3. Check the wires for a short circuit.
Select [Output Off]. Replace the Xerographic Module PL 5.1A Item 1.
If there is paper stuck in the Xerographic Module and this has occurred more than once, the
Detack HVPS may have failed. Go to the 09-E, Detack HVPS Checkout RAP. Return to Service Call Procedures.
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09-304
09-304
May 2003
2-310
V0.042
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
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09-304
09-306 BTAC Max Read Fault

Fault Code, 09-306, indicates the BTAC Max read has been exceeded. Vcal was greater than
4.5v in 2 successive calibration runs.
Initial Actions
Ensure that all machine covers are in place and that no stray light is hitting the BTAC Sensor.

Go to Flag 1. Inspect the ground wire connected to the BTAC Sensor Assembly. With a meter
check for 0 ohms between the BTAC Shield and the frame. There is a good ground connection to the BTAC shield.
Y
N
Repair or replace as necessary. BTAC Sensor PL 5.1B Item 3
Replace the BTAC Sensor PL 5.1B Item 3.
If the problem continues, replace the Xerographic Module PL 5.1A Item 1.
09-306
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09-310 No Patch RAP
Fault Code, 09-310, indicates that no process control patches were detected. The 12% and
50% patch raw reads are both within 8 bits of the clean belt read.
Jumping Gap out of spec. Go to 09-M Jumping Gap Checkout RAP.
Charge HVPS
NOTE: Ignore any other parts that are in the Parts to Replace message
that are not in the list above.
Initial Actions
If a 03-337 fault is occurring, ([Faults/Counters tab , Faults]) go to the 03-337 RAP.
If a 04-201 or 04-202 fault is occurring, ([Faults/Counters tab , Faults]) go to the 04-201 or

04-202 RAP.
If any arcing faults are occurring, go to that RAP. (09-384 , 09-380 , 09-382)
The parts to replace message includes one or more from the above
list.
Y
N
Go to the 09-310 Without Exerciser Procedure.
The Xerographic Exerciser is displaying a Parts to Replace message.

There may be a single item, or several on the list. The first item is the main
suspect, but make a note of the other items for possible future reference.
Go to the RAP listed below for the part that was the first one listed in the
Xerographic Exerciser parts to replace message.
Developer HVPS, go to the 09-G, Developer HVPS Checkout RAP

Inspect the Xerographic Module for a piece of paper that may have entered the Xerographic
Module and may be blocking the ROS or Developer window. There a piece of paper seen in
the Xerographic Module.
Y
N
Check for Developer Housing Drive. Remove the Back Cover and observe the Developer
Drives. In [Copier Sys tab , Component Control], select [IOT Paper Path] [Developer
Drive Motor] [Output On].
Observe the Developer Drives. The Developer Drives are functioning correctly.
Y
N
Repair or replace the appropriate components.
Developer Housing PL 5.1B Item 5
Xerographic Module (Ground), go to the 09-J, Xerographic Module

Checkout RAP
Developer Housing, go to the 09-K, Developer Housing Checkout

RAP
ROS, go to the 09-L, ROS Checkout RAP
Charge HVPS - Go to the 09-A, Charge HVPS Checkout RAP

Jumping Gap out of spec. Go to 09-M Jumping Gap Checkout RAP.
Developer Drive Motor PL 7.1 Item 1
Developer Gear Bracket PL 7.1 Item 2
ROS A/B Test Failed, go to the 09-L, ROS Checkout RAP
BTAC Noise - Go to the 09-F, Xerographic Electrical Noise Checkout.
Non-Uniform Image Detected - There may be an IQ problem which

could lead to incorrect results in the Xerographic Exerciser. Run
some 106 DPI Halftones and check for banding. If banding exists, go
to IQ-1, Image Quality Entry RAP.

Rotate the Xerographic Module Cam Handle a few times and observe the Donor Roll
backer bar (Figure 1.) Does it feel as if it might be binding? When cammed does it should
touch the Donor Roll on the IB and OB ends. There are two large screws on the right side
of the backer bar, one IB and one OB. If you pull on these screws and overcome the
spring force, the backer bar should move freely without binding. The P/R Belt/Donor
Roll backer bar is free of binding.
Y
N
Replace the Photoreceptor Drive Module PL 5.1A Item 2
In [Marking tab , Xerographic Diagnostics], select [Exerciser], then [Start Test].
Observe the test results. The test passed.
Y
N
The test failed with a fault code.
Y
N
There is a message that indicates the ROS A/B Test failed.
Y
N
Check the parts to replace message against the following list:
Developer HVPS, Developer Drives
A
B
V0.042
Non-Uniform Image Detected
Xerographic Module (Ground)
Developer Housing
ROS
BTAC Noise
Go to the 09-L, ROS Checkout RAP.

If an 09-310 occurred, go to the 09-310 Without Exerciser Procedure. If another fault
occurred, go to the RAP for that fault code.
Go to the 09-310 Without Exerciser Procedure.
Check the Registration Transport. Ensure that it is latched correctly.
Remove paper from or replace the Xerographic Module PL 5.1A Item 1.
If this has occurred more than once, the Detack HVPS may have failed. Go to the 09-E,
Detack HVPS Checkout RAP.
May 2003
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09-310
09-310 Without Exerciser

If still occurring, check the following:
P/R Grounding (Xerographic Module) - Remove the Xerographic Module and inspect the
P/R Ground strip located on the IB side. Ensure it is not damaged or contaminated.
Replace the Xerographic Module PL 5.1A Item 1 if necessary. If the Xerographic Module
is heavily contaminated, check the Developer Housing for leakage. Replace as necessary
Developer Housing PL 5.1B Item 5.
Video from Image Processing getting to ROS. Ensure the Raster Output Scanner Video
Cable PL 1.2A Item 4 is seated correctly at the ROS and at the Main Control PWB. Run
[Self Tests tab , Video Path Diagnostics] [VCM_Loop Test] and if the machine is an ST or
DC model, run the [SCVM Digital Test]. If either test fails, go to the 03-G, Main Control
2 Large
Screws (this
Side
NOTE: Do not run the SCVM Digital Test on a LP machine, the test will fail. This is normal, since the SCVM function is not enabled on a LP machine.
Developer Housing getting correct drive. Ensure the drive belt is not slipping, and the
developer mag and donor rolls are turning. Replace the Developer Housing PL 5.1B Item
5 if necessary.
Developer AC Enable from SCAM to Developer HVPS. Go to the 09-G, Developer HVPS
Checkout RAP.
Perform the 09-M, Jumping GAP Checkout RAP.
If the problem continues, replace the Developer Housing PL 5.1B Item 5 if necessary.
If the problem continues, the Photoreceptor Drive Module may have a backer bar problem. Replace the Photoreceptor Drive Module PL 5.1A Item 2
Donor Roll Backer

Bar
Figure 1 Photoreceptor Drive Module (shown with Developer Housing removed)
09-310
May 2003
2-314
V0.042
V0.042
May 2003
2-315
09-310
09-312 All Process Control Patches are Dark

Fault Code, 09-312, indicates that all patches are less than 60 bits.

Enter [Marking tab , Print Test Pattern]. Select [Blank Page]. Make 10 prints of the blank page
pattern.
Check for a reoccurrence of the fault. The fault occurs.
Y
N
The problem may be intermittent. Repeat the previous step until the fault reoccurs. If it is
not reproducible, return to Service Call Procedures.
Observe the PR Belt through an opening. The PR Belt is covered with toner from edge to
edge.
Y
N
Check the Raster Output Scanner Video Cable.
Ensure that it not damaged and connected correctly between the ROS and Main Control
PWB. The Raster Output Scanner Video Cable is OK.
Y
N
Repair or replace the Raster Output Scanner Video Cable PL 1.2A Item 4 as necessary.
Go to the 09-L, ROS Checkout RAP
Run the machine to see if problem reoccurs. The 09-312 fault is still occurring.
Y
N
Replace the Charge HVPS PL 1.2A Item 5.
Run the machine to see if problem reoccurs. The 09-312 fault is still occurring.
Y
N
Check for 36 VDC at the SCAM PWB. +36 2.0 VDC is measured between TH1 (+) and
TH2 (-) on the SCAM PWB.
Y
N
Go to Flag 1. Check the wiring for an open or short circuit.
09-312
May 2003
2-316
V0.042
V0.042
May 2003
2-317
09-312
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
09-312
May 2003
2-318
V0.042
09-314 0% Patch Low Fault

Fault Code, 09-314, indicates the 0% patch is out of range low. 0% patch raw read is less than
3.0v.
Observe the results. Xero Set-Up completed successfully.

Y
N
If a 09-314 occurred, go to the 09-F, Xerographic Electrical Noise Checkout. If another
fault occurred, go to the RAP for that fault code.
Initial Actions
Done. Return to Service Call Procedures.
If any 09-210, Charge Faults, or 09-306 faults are occurring, fix them first.

Y
N
Y
N
Y
N
Xerographic Module (Cleaner)
Developer Housing
Charge HVPS
BTAC Noise
Non-Uniform image detected
NOTE: Ignore any other parts that are in the Parts to Replace message that are
not in the list above.
The parts to replace message includes one or more from the above list.
Y
N
Go to the 09-F, Xerographic Electrical Noise Checkout.
The Xerographic Exerciser is displaying a Parts to Replace message. There
may be a single item, or several on the list. The first item is the main suspect,
but make a note of the other items for possible future reference.
Xerographic Module (Cleaner), go to the 09-J, Xerographic Module

Checkout RAP
Developer Housing, go to the 09-K, Developer Housing Checkout RAP
Non-Uniform Image Detected - There may be an IQ problem which could

lead to incorrect results in the Xerographic Exerciser. Run some 106 DPI
Halftones and check for banding. If banding exists, go to IQ-1, Image
Quality Entry RAP.

If a 09-314 occurred, go to the 09-F, Xerographic Electrical Noise Checkout. If another
fault occurred, go to the RAP for that fault code.

V0.042
May 2003
2-319
09-314
09-316 0% Patch High Fault
09-318 Light 87.5% Patch Fault
Fault Code, 09-316, indicates the 0% patch is out of range. 0% patch raw read is greater than
4.5v.
Fault Code, 09-318, indicates the 87.5% patch is light. Three consecutive 87.5% relative
reflectance readings greater than the 87.5% target plus 5 units.
Initial Actions
Initial Actions
If any 09-210, Charge Faults, or 09-306 faults are occurring, fix them first.
Ensure that Tag 086 is installed (L17.8.64 or later software). This level of software has
improved process control software that decreases the likelihood of having 09-318 faults.

The Xerographic Module has already been replaced while trying to solve this problem.
Y
N
Check for a reoccurrence of the fault. The problem continues.
Y
N
09-318 Diagnostic Procedure

The ROS was recently replaced.
Y
N
Go to the 09-F, Xerographic Electrical Noise Checkout.
Go to Flag 1. Inspect the ground wire connected to the BTAC Sensor Assembly.
Ensure there is a good connection to ground. If OK, go to step 2.
Check pin 1 of P/J50. Ensure that it has not been bent due to strain on the connector.
There is a problem with the BTAC Shield or pin 1 of P/J50.

Y
N
Go to REP 09-12 . Perform the Developer HVPS Contacts Cleaning Procedure.
When complete, run the machine and see if the faults still occur. The
problem
continues.
Y
N
Suspect electrical noise problem. Go to the 09-F, Xerographic Electrical Noise Checkout.
Refer to Figure 2. Clean the Donor Roll shaft where the bias makes contact. Use
Film Remover to clean the shaft.
Check for a reoccurrence of the problem. The problem continues.
Y
N
Y
N
Y
N
Y
N
Toner Dispenser
A
09-316, 09-318
May 2003
2-320
Developer PS (Developer HVPS) or loss of Developer Drive
XRM (Ground) (Xerographic Module)
Developer Housing
ROS
BTAC Noise
General Image Noise
E
V0.042
E
NOTE: Ignore any other parts that are in the Parts to Replace message that are not in the list above.
The parts to replace message includes one or more from the
above list.
Y
N
Go to the 09-318 Without Exerciser Procedure Procedure.
The Xerographic Exerciser is displaying a Parts to Replace message. There may be a single item, or several on the list. The first item
is the main suspect, but make a note of the other items for possible
future reference.
Go to the RAP listed below for the part that was the first one listed in
the Xerographic Exerciser parts to replace message.
Toner Dispenser, go to the 09-C, Toner Dispenser Checkout

RAP
Developer HVPS, Developer Drives, check for correct operation

of the Developer Drives. If OK, go to the 09-G, Developer HVPS
Checkout RAP
Xerographic Module (Ground), go to the 09-J, Xerographic

Module Checkout RAP
BTAC Noise - Go to the 09-F, Xerographic Electrical Noise

Checkout.
Jumping Gap out of spec. Replace Photoreceptor Drive Module

PL 5.1A Item 2.
Non-Uniform Image Detected - There may be an IQ problem

which could lead to incorrect results in the Xerographic Exerciser. Run some 106 DPI Halftones and check for banding. If
banding exists, go to IQ-1, Image Quality Entry RAP.
A
NOTE: When checking the NVM values below and comparing them to the ROS bar code, be
sure the numbers are entered exactly as they are on the label. For instance, the Exposure Calibration value always begins with a decimal point. If the decimal point is incorrect, the Exposure will be incorrect and 09-318 faults may occur.
In Diagnostic Navigator, select [NVM tab , NVM Tool]. Search for the location 793 Exposure
Calibration (Figure 3). The value matches the value indicated on the ROS bar code label.
Y
N
Reset this value to its correct value as noted on the ROS bar code label. The Exposure
Calibration number is the number that is preceded by the letter E under the second bar
code. Run Xerographic Setup. Figure 3
In Diagnostic Navigator, select [NVM tab , NVM Tool]. Search for the location indicated in Table
1.
The value is between 8784 and 9147 (65 and 55ppm) or 14281 and 14864 (40ppm).
Y
N
Use [NVM tab , NVM Tool] to reset the value to the default values, 8964 (65 and 55ppm)
or 14567 (40ppm). Send service to reset this value to its correct value as noted on the
ROS bar code label. The Hall Period Ref number is the 4 or 5 digit number that preceded
by the letter H under the second bar code. Run Xerographic Setup. Figure 3
If the values above are correct and the problem is still occurring, return to the beginning of the
RAP and answer NO to the statement about a new ROS.
09-318 Without Exerciser Procedure

Check for a clogged Developer Housing. Older housings (date code before 10/98), can clog at
the Developer Waste tube and cause an excess amount of developer in the housing. Check for
toner smeared/rubbed from the Donor Roll, which may indicate an over-filled housing. Check
for heavy contamination around the housing. Also, check for damaged drive gears on the
housing. One or more of these symptoms are occurring.
Y
N
WARNING
Possible poor contact between the Developer Housing and the Developer HVPS. This
contact is made by a pair of compression springs (Developer HVPS Contact Springs) on
the inboard end of the Developer Housing which push directly against the pads of the
Developer HVPS. On most machines, the two springs are covered by a small plastic
shield to prevent them from being damaged.
Go to the RAP for that fault code.

The ROS may be incorrectly positioned. Check for a correct installation of the ROS
REP 06-1.
Observe the ROS. The ROS is installed correctly.
Y
N
Re-install the ROS correctly REP 06-1.
Replace the following one-at-a-time, until the problem is corrected:
Replace the BTAC Sensor PL 5.1B Item 2
Remove the Developer Housing from the machine. See Figure 2 and clean the
Donor Roll Shaft contact area with Scotch Brite, (43P74) or Pumice Paper (43P46).
Examine the two high voltage springs to determine if they are bent or snagged.
Check the plastic shield that covers them for damage. The shield is spring loaded,
and it should move in and out smoothly without catching on the two high voltage
springs.
If OK, access the Developer HVPS. With the machine power off, wiggle the Developer HVPS slightly to improve the contact of the springs to the HVPS.
Perform REP 09-12, Developer HVPS Contacts Cleaning Procedure.
Check for occurrence of the fault. The problem continues.

A
V0.042
F
May 2003
2-321
09-318
F
Y
N
The problem was corrected by improving the HVPS contact. Return to Service Call
Procedures.
Refer to Figure 2. Clean the Donor Roll shaft where the bias makes contact. Use Film
Remover to clean the shaft.
Y
N
Enter [Marking tab , Print Test Pattern]. Select [Step Wedge]. Make 5 prints.
Observe the prints for overall density. The prints are dark.
Y
N
Go to the 09-M Jumping Gap Checkout RAP. Perform that procedure. Return here
when complete.
Check for a reoccurrence of the fault. The fault continues.
Y
N
When the set-up completes, run some test pattern prints to try to reproduce the
fault. The fault occurs.
Y
N
Done. Set-Up has corrected the problem. Return to Service Call Procedures.
Go to Flag 1. Check for continuity between the BTAC Shield and machine frame.
Continuity is measured.
Y
N
Repair/replace as necessary.
Go to the 09-C Toner Dispenser Checkout RAP.
The ROS may be incorrectly positioned. Check for a correct installation of the ROS REP
06-1.
Y
N

Replace the Developer Housing PL 5.1B Item 5. Check the Toner Dispenser PL 5.1B Item 4 for
damage. Check for any areas of contamination and clean as necessary
09-318
May 2003
2-322
V0.042
Clean
Clean Shaft
V0.042
May 2003
2-323
09-318
Part #
ROS Serial #

(NVM 793)
Image Fast Scan Reg

(NVM 723)

Product
470 DC/ST
460 DC/ST
255/265 DC/ST
N/A
240 DC/ST
N/A
09-318
May 2003
2-324
V0.042
09-320 Dark 87.5% Patch Fault
Fault Code, 09-320, indicates the 87.5% patch is dark. Three consecutive 87.5% relative
reflectance readings greater than the 87.5% target minus 5 units.
Jumping Gap out of spec. Replace Photoreceptor Drive Module

PL 5.1A Item 2.
BTAC Noise - Go to the 09-F, Xerographic Electrical Noise

Checkout.
Non-Uniform Image Detected - There may be an IQ problem

which could lead to incorrect results in the Xerographic Exerciser. Run some 106 DPI Halftones and check for banding. If
banding exists, go to IQ-1, Image Quality Entry RAP.
Initial Actions
Ensure that TAG 086 is installed (L17.8.64 or later software). This level of software has
09-320 On-Site Procedure

The ROS was recently replaced.
Y
N
In PWS Diagnostics, select [Faults/Counters tab , Faults] [Last 40 Faults].
Inspect the Last 40 Faults for other 09 faults, such as 09-210, 09-215, 09-220, 09-306,
09-314, 09-318. Any of those faults are in the Last 40 log.
Y
N
Y
N
Y
N
Y
N
Developer Housing
BTAC Noise
Jumping Gap out of spec. Replace the Photoreceptor Drive

Module.
Charge HVPS
NOTE: Ignore any other parts that are in the Parts to Replace message that are not in the list above.
The parts to replace message includes one or more from the
above list.
Y
N
The Xerographic Exerciser is displaying a Parts to Replace message. There may be a single item, or several on the list. The first item
is the main suspect, but make a note of the other items for possible
future reference.
Go to the RAP listed below for the part that was the first one listed in
the Xerographic Exerciser parts to replace message.
Xerographic Module (Cleaner), go to the 09-J, Xerographic

Module Checkout RAP
A
B
V0.042
Go to the 09-L, ROS Checkout RAP

Most likely an Electrical noise problem. Go to the 09-F, Xerographic Electrical Noise
Checkout.
NOTE: When checking the NVM values below and comparing them to the ROS bar code, be
sure the numbers are entered exactly as they are on the label. For instance, the Exposure Calibration value always begins with a decimal point. If the decimal point is incorrect, the Exposure will be incorrect and 09-320 faults may occur.
In Diagnostic Navigator, select [NVM tab , NVM Tool]. Search for location 793 (expCalibration).
Check the value in NVM for the Exposure Calibration (Figure 3). The value matches the
value indicated on the ROS bar code label.
Y
N
Reset this value to its correct value as noted on the ROS bar code label. The Exposure
Calibration number is the number that is preceded by the letter E under the second bar
code. In [Marking tab , Xerographic Diagnostics], run Xerographic Setup after resetting
the NVM value. Figure 3
In Diagnostic Navigator, select [NVM tab , NVM Tool]. Search for the location indicated in
Table 1.
The value is between 8784 and 9147 (65 and 55ppm) or 14281 and 14864 (40ppm).
Y
N
Use [NVM tab , NVM Tool] to reset the value to the default values, 8964 (65 and 55ppm)
or 14567 (40ppm). Send service to reset this value to its correct value as noted on the
ROS bar code label. The Hall Period Ref number is the 4 or 5 digit number that preceded
by the letter H under the second bar code. Figure 3
If the values above are correct and the problem is still occurring, return to the beginning of the
RAP and answer NO to the statement about a new ROS.

May 2003
2-325
09-320
When the set-up completes, run some test pattern prints to try to reproduce the fault. The
fault occurs.
Y
N
Done. Set-Up has corrected the problem. Return to Service Call Procedures.
Possible poor contact between the Developer Housing and the Developer HVPS. This contact
is made by a pair of compression springs (Developer HVPS Contact Springs) on the inboard
end of the Developer Housing which push directly against the pads of the Developer HVPS. On
most machines, the two springs are covered by a small plastic shield to prevent them from
being damaged.
Remove the Developer Housing from the machine. See Figure 2 and clean the Donor
Roll Shaft contact area with Scotch Brite, (43P74) or Pumice Paper (43P46). Examine
the two high voltage springs to determine if they are bent or snagged. Check the plastic
shield that covers them for damage. The shield is spring loaded, and it should move in
and out smoothly without catching on the two high voltage springs.
If OK, access the Developer HVPS. With the machine power off, wiggle the Developer
HVPS slightly to improve the contact of the springs to the HVPS.

Y
N
The problem was corrected by improving the HVPS contact. Return to Service Call Procedures.
Go to Flag 1. Check for continuity between the BTAC Shield and machine frame. Continuity
is measured.
Y
N
Repair/replace as necessary.
Go to the 09-CToner Dispenser Checkout RAP.
09-320
May 2003
2-326
V0.042
Clean
Clean Shaft
V0.042
May 2003
2-327
09-320
Part #
ROS Serial #

(NVM 793)
Image Fast Scan Reg

(NVM 723)

Product
470 DC/ST
460 DC/ST
255/265 DC/ST
N/A
240 DC/ST
N/A
09-320
May 2003
2-328
V0.042
09-324 Background Threshold Exceeded During Run
Fault Code, 09-324, indicates the background value is greater than 10.
Initial Actions
Ensure the correct toner is being used.
Refer to Figure 1. Clean the Donor Roll shaft where the bias makes contact. Use Scotch Brite ,
(43P74) or Pumice Paper (43P46) to clean the shaft.
Y
N

Y
N
Y
N
Y
N
Developer Housing
Charge HVPS
BTAC Noise
Perform a cleaner stress test. Select [Marking tab , Print Test Pattern]. Select [IQ Test #4] [Start
Job]. The blank prints at the end of the job are clean with no smears, background, or
residual image.
Y
N
Go to the 09-A Charge Checkout RAP. If the problem continues, replace the Developer Housing PL 5.1B Item 5.
Clean
Y
N
Go to the RAP listed below for the part that was the first one listed in the Xerographic Exerciser parts to replace message.

Checkout RAP

Quality Entry RAP.
Clean Shaft

V0.042
May 2003
2-329
09-324
09-330 Toner Concentration is Low

Fault Code, 09-330, indicates the toner patch delta relative reflectance is less than 10.
C
Initial Actions
If a 04-201 or 04-202 fault is occurring, [Faults/Counters tab , Faults], go to the 04-201 or

04-202 RAP.
Developer Housing
Developer HVPS or Developer Drive
Jumping Gap out of spec. Replace the Photoreceptor Drive Module.
Charge HVPS
BTAC Noise
Go to the 09-C, Toner Dispenser Checkout RAP.

Perform GP40, Initializing Xerographic NVMs.
If the problem continues, replace the Developer Housing PL 5.1B Item 5.

Y
N
Y
N
Y
N
Toner Dispenser
Y
N
Toner Dispenser, go to the 09-C, Toner Dispenser Checkout RAP
Jumping Gap out of spec. Replace Photoreceptor Drive Module PL 5.1A

Item 2.
General Image Noise - There may be an IQ problem which could lead to

incorrect results in the Xerographic Exerciser. Run some 106 DPI Halftones and check for banding. If banding exists, go to IQ-1, Image Quality
Entry RAP.
A
B
C
09-330
May 2003
2-330
V0.042
09-332 Toner Concentration is High

Fault Code, 09-332, indicates the toner patch delta relative reflectance is greater than 55.
B
Initial Actions

Y
N
Y
N
Y
N
Toner Dispenser
Developer Housing
Charge HVPS
BTAC Noise
Y
N

Item 2.

Quality Entry RAP.

A
B
V0.042
May 2003
2-331
09-332
09-334 Toner Control Patch is Low
Fault Code, 09-334, indicates the tone up loop was exceeded in Xero Set-Up.
Remove the Developer Housing from the machine. See Figure 1 and clean the Donor Roll
Shaft contact area with Scotch Brite, (43P74) or Pumice Paper (43P46). Examine the two
high voltage springs to determine if they are bent or snagged. Check the plastic shield
that covers them for damage. The shield is spring loaded, and it should move in and out
smoothly without catching on the two high voltage springs.

Y
N
Y
N
Y
N

Quality Entry RAP.
Developer HVPS, go to the 09-G , Developer HVPS Checkout RAP
Xerographic Module (Ground) (Cleaner) (P/R Belt), go to the 09-J, Xerographic Module Checkout RAP

Item 2.
If the problem continues:
Check the connectors on the Rear of the ROS for correct mating.
Go to the 09-C, Toner Dispenser Checkout RAP.
Clean
Clean Shaft


being damaged.
09-334
May 2003
2-332
V0.042
09-336 Toner Control Patch is High
Fault Code, 09-336, indicates the tone down loop was exceeded in Xero Set-Up.

Y
N
Y
N
Y
N

Quality Entry RAP.

Item 2.
Clean
Clean Shaft



being damaged.
V0.042
May 2003
2-333
09-336
09-338 Electrostatic Setup Convergence Failure
WARNING
Fault Code, 09-338, indicates the electrostatic setup failed to achieve image quality limits.
Initial Actions
If the problem is occurring with a new Xerographic Module, pull the unit out slightly and push
back in completely and re-latch.
springs.

Xero Set-Up was run as part of a service action.
Y
N
The Xerographic Module was just replaced (by the customer or as part of a service
action).
Y
N
Go to REP 09-12. Perform the Developer HVPS Contacts Cleaning Procedure.
When complete, run the machine and see if the faults still occur. The
problem
continues.
Y
N
Enter [Marking tab , Print Test Pattern]. Select 50% Halftone. Make 200 prints of the
106dpi 50% halftone pattern. In [Marking tab , Xerographic Diagnostics], select [SetUp], then [Start Test
Observe the results. A fault occurred during the Xero Set-Up.
Y
N
Set-Up has corrected the problem. Return to Service Call Procedures.
The ROS may be incorrectly positioned. Check for a correct installation of the ROS
REP 06-1.
Y
N
Enter [Marking tab , Xerographic Diagnostics], select [Set-Up], then [Start Test].
Check for occurrence of the 09-338. The problem continues.
Y
N
Procedures.
If the problem continues, go to the RAP for the 09-xxx fault code that was in the fault log
before the 09-338.
The problem began after a Xerographic Module was replaced.
Y
N
The problem began after a Developer Housing was replaced.
Y
N
The problem began after a Photoreceptor Drive Module was replaced.
Y
N
The problem occurred after a ROS was replaced. In Diagnostic Navigator,
select [NVM tab , NVM Tool]. Check the value for location 793 (expCalibration).
Figure 2.
NOTE: When checking the NVM values below and comparing them to the ROS
bar code, be sure the numbers are entered exactly as they are on the label. For
instance, the Exposure Calibration value always begins with a decimal point. If
the decimal point is incorrect, the Exposure will be incorrect and 09-338 faults
may occur.
Replace the following one-at-a-time, until the problem is corrected:
Replace the BTAC Sensor PL 5.1B Item 3
The value matches the value indicated on the ROS bar code label.
Y
N
Reset this value to its correct value as noted on the ROS bar code label.
The Exposure Calibration number is the number that is preceded by the
letter E under the second bar code. In [Marking tab , Xerographic Diagnostics], run Xerographic Setup after resetting the NVM value. Figure 3
Go to 09-J Xerographic Module Checkout RAP.

The problem began after a part was replaced (Xerographic Module, Developer Housing,
ROS, or Photoreceptor Drive Module).
In Diagnostic Navigator, select [NVM tab , NVM Tool]. Search for the location
indicated in Table 1.
The value is between 8784 and 9147 (65 and 55ppm) or 14281 and 14864
(40ppm).
A
09-338
May 2003
2-334
C
V0.042
A
Y
N
Use [NVM tab , NVM Tool] to reset the value to the default values, 8964
(65 and 55ppm) or 14567 (40ppm). Send service to reset this value to its
correct value as noted on the ROS bar code label. The Hall Period Ref
number is the 4 or 5 digit number that preceded by the letter H under the
second bar code. Figure 3
If the values above are correct and the problem is still occurring, ensure the
Raster Output Scanner Video Cable is connected correctly at both ends. If the
problem continues, return to the beginning of the RAP and answer NO to the
statement about a new ROS.
C
Donor Roll Shaft contact area with Scotch Brite, (43P74) or Pumice Paper
(43P46). Examine the two high voltage springs to determine if they are bent or
snagged. Check the plastic shield that covers them for damage. The shield is
spring loaded, and it should move in and out smoothly without catching on the
two high voltage springs.
If OK, access the Developer HVPS. With the machine power off, wiggle the
Developer HVPS slightly to improve the contact of the springs to the HVPS.
If the problem continues, return to the RAP from which directed here.
There may be a problem with the installation of the Photoreceptor Drive Module. Check
for correct installation. If OK, replace the Photoreceptor Drive Module PL 5.1A Item 2.
Clean
Clean Shaft
V0.042
May 2003
2-335
09-338
Part #
ROS Serial #

(NVM 793)
Image Fast Scan Reg

(NVM 723)

Product
470 DC/ST
460 DC/ST
255/265 DC/ST
N/A
240 DC/ST
N/A
09-338
May 2003
2-336
V0.042
09-344 Failure to Converge in Material Conditioning RAP

At the end of material conditioning, the 87% relative reflectance is out of range.
Clean

Y
N
Y
N
Y
N

Quality Entry RAP.
Jumping Gap out of spec - Go to 09-M Jumping Gap Checkout RAP.
Clean Shaft

being damaged.
V0.042
May 2003
2-337
09-344
09-350 Xerographic Module Open RAP

Fault Code, 09-350, indicates the Main Control PWB detected the ROS Interlock open, and
also could not communicate with the Xerographic Module CRUM.
NOTE: This fault will occur if the Xerographic Module is pulled out with the Front Door Interlock
cheated. Ensure these faults were not the result of that condition before troubleshooting.

In Faults, check the [Last 40 Faults] for any 10-350 faults (in addition to 09-350 faults). Enter
[Faults/Counters tab , Faults]. 10-350 faults are present.
Y
N
The Xerographic Module has just been replaced.
Y
N
Replace the Xerographic Module PL 5.1A Item 1. If problem continues, check the
following:
Ensure Xerographic Module is located and latching correctly.
Xerographic Module drawer connector is not damaged and is mating correctly.
The previous Xerographic Module was functional when replaced and is still available.
Y
N
Replace the Xerographic Module PL 5.1A Item 1. If problem continues, check the
following:
Xerographic Module DC Drawer Connector is not damaged and is mating correctly. PL 1.6 Item 6
Reinstall the previous Xerographic Module.

09-350 is still present.
Y
N
Replace the Xerographic Module PL 5.1A Item 1. The new Xerographic Module was
defective.
Replace the Xerographic Module PL 5.1A Item 1. If problem continues, check the following:
Xerographic Module DC Drawer Connector is not damaged and is mating correctly.

PL 1.6 Item 6
Go to the 03-A RAP.
09-350
May 2003
2-338
V0.042
V0.042
May 2003
2-339
09-350
09-351 Invalid Xerographic Module Count
09-352 Wrong Xerographic Module Fault
Fault Code, 09-351, indicates the machine run control detects the Maximum Print Volume
Value is less than Print Count and/or the Maximum Pixel Usage Value less than Pixel Usage.
Fault Code, 09-352, indicates that an inappropriate Xerographic Module has been detected in
the machine.
A new Xerographic Module has just been installed.

Y
N
Unlatch the Xerographic Module, slide it out slightly on its rails, and then slide it back in
place and latch it.
The fault is now resolved.
Y
N
Machine configuration may be set-up incorrectly or the wrong Xerographic Module was
installed.
09-351, 09-352
In [System, Imaging, and IOT Configuration], select the [System] tab. Ensure the Market
Region is correct for this machine.
Ensure the correct Fuser Module part number was installed for the machine market
region and service plan (sold, non-sold). Refer to PL 6.2A Item 1 for the correct Fuser
Module part numbers. To change the Service Plan, use GP16.
May 2003
2-340
V0.042
09-353 Incorrect Xerographic Module Configuration
09-354 No Xerographic Module CRUM Fault
Fault Code, 09-353, indicates the machine run control detects the Xerographic Module was
previously initialized on a machine of a different configuration. Either a Xerographic Module
was initialized on a DC/ST and then installed in a LP/Docutech 65 or it was initialized on a LP/
Docutech 65 and then installed on a DC/ST.
Fault Code, 09-354, indicates that a Xerographic Module has been detected in the machine
without a CRUM.
Initial Actions
Switch the machine power off, wait 10 seconds. Switch the machine power back on. See if the
problem continues.
There is no action that needs to be taken for this fault code.

In [Faults/Counters tab , Faults], check for occurrences of 10-354. A 10-354 is also occurring.
Y
N
A new Xerographic Module has recently been installed.
Y
N
Go to Flag 1. Check the wires for an open circuit. If OK, replace the following, oneat-a-time, until the problem is resolved:
Distribution PWB PL 1.5 Item 7
Xerographic Module PL 5.1A Item 1
Replace the Xerographic Module PL 5.1A Item 1. If the problem continues,
Xerographic Module DC Drawer Connector is not damaged and is mating correctly.

PL 1.6
Go to Flag 1. Check the wires for an open circuit. If OK, replace the Distribution PWB
PL 1.5 Item 7.
V0.042
May 2003
2-341
09-353, 09-354
09-354
May 2003
2-342
V0.042
09-355 Cant Communicate with CRUM Fault

Fault Code, 09-355, indicates the Service Plan is set to Other, and the machine cannot communicate with a 3rd party Xerographic Module.
NOTE: If the service plan is set to Other and a competitive CRU is used in the machine, an
Enabling Kit must be installed in the machine. This kit adds an In-Line CRUM harness to the
machine wiring harness to enable the use of competitive CRUs.
Initial Actions
Switch the machine power off, wait 10 seconds. Switch the machine power back on. See if the
problem continues.

This fault is declared when the service plan is set to Other and the software cannot communicate with the Xerographic CRUM.
If the Xerographic Module is manufactured by Xerox, the CRUM is internal to the Fuser
Module.
If the Xerographic Module is of competitive manufacture, it does not have an internal

CRUM. When a competitive CRU is used, the machine must have TAG XXX installed,
which is an in-line wiring harness with two CRUM chips: one for the Xerographic Module
and the other for the Fuser Module.
Check for the installation of TAG XXX (the In-Line CRUM Harness).
Tag xxx is installed.
Y
N
Install the In-Line CRUM Harness Kit 98S04279.
Replace the In-Line CRUM Harness 162K57260.
V0.042
May 2003
2-343
09-355
09-355
May 2003
2-344
V0.042
09-358 Developer Collector Full RAP

Fault Code, 09-358, indicates the Developer Collector is full or is missing.

Ensure the Developer Collector Bottle is present and located correctly. The Developer Collector Bottle is present and correctly located.
Y
N
Repair or replace the Developer Collector Bottle PL 5.1B Item 8 as necessary.
Remove the Developer Collector Bottle. The Developer Collector Bottle is full.
Y
N
In [Self Tests tab , IIOC Controller Tests], select [IOT] [Type 1], then [Start].
Observe the test results. The Type 1 test passed.
Y
N
Observe the fault display in the IIOC Self-Test screen. An 03-836 fault is detected.
Y
N
If some other fault is detected, make a note and evaluate the faults effect on
other machine problems that might be occurring.
If the problem continues,
replace the Developer Collector Sensor PL 5.1B Item 9. If the problem continues, replace the IIOC PWB W3A1 PL 1.5 Item 2.
In IIOC Tests, select [IOT] [Type 2].
Select [Start]. The Type 2 test passed.
Y
N
Y
N
other machine problems that might be occurring.
If the problem continues,
replace the Developer Collector Sensor PL 5.1B Item 9. If the problem continues, replace the IIOC PWB W3A1 PL 1.5 Item 2.
Go to Flag 1, check for an open circuit.
If OK, replace the Developer Collector Sensor PL 5.1B Item 9. If the problem continues,
replace the IIOC PWB W3A1 PL 1.5 Item 2.
Replace the Developer Collector Bottle PL 5.1B Item 8. Determine if the Developer Collector
Bottle is being replaced at the correct time (with Xerographic Module). If it was not, remind the
customer of the need to replace this at the scheduled interval. If the Developer Collector was
replaced at the correct time and has filled up ahead of schedule, replace the Developer Housing PL 5.1B Item 5.
V0.042
May 2003
2-345
09-358
09-358
May 2003
2-346
V0.042
09-360/362 Out of Toner RAP

Fault Code, 09-360, indicates the total dispense time = 60 seconds after the Low Toner Sensor
detected low toner and displayed an "Add Dry Ink" message.
Fault Code, 09-362, indicates the 09-360 was reset (by po/po or open closing the front cover)
and there was 30 seconds of dispense time without toner being sensed by the Low Toner Sensor, or the Dry Ink Cartridge motor has been on for 4 minutes without the Low Toner Sensor
detecting toner in the sump.
These codes will be declared if the Dry Ink Cartridge is not replaced after "Add Dry Ink" is displayed.
Initial Actions
Ensure the customer has installed a new Dry Ink Cartridge.
If using an interlock cheater while troubleshooting a fault, ensure that you remove the
cheater to clear the fault from the UI screen.

Y
N
Y
N
If some other fault is detected, make a note and evaluate the faults effect on other
machine problems that might be occurring. Remove the Developer Housing REP 092 and check the Dry Ink Cartridge drive gears for a mispositioned gear. Repair or
replace as necessary. If unable to determine problem, replace the Toner Dispenser
PL 5.1B Item 4. If the problem continues, replace the IIOC PWB W8A1 PL 1.5 Item
2.
Y
N
Y
N
machine problems that might be occurring. Remove the Developer Housing REP 092 and check the Dry Ink Cartridge drive gears for a mispositioned gear. Repair or
replace as necessary. If unable to determine problem, replace the Toner Dispenser
PL 5.1B Item 4. If the problem continues, replace the IIOC PWB W8A1 PL 1.5 Item
2.
Remove the Developer Housing REP 09-2 and check the Dry Ink Cartridge drive gears for a
broken, damaged, or mispositioned gear. Repair or replace as necessary. If unable to determine problem, replace the Toner Dispenser PL 5.1B Item 4. If the problem continues, replace
the IIOC PWB W8A1 PL 1.5.
V0.042
May 2003
2-347
09-360/362
09-360/362
May 2003
2-348
V0.042
09-370 Transfer Power Fault RAP

Fault Code, 09-370, indicates the Transfer HVPS fuse is open or the power supply is on in
standby. The Transfer Fault Monitor signal is High when the Transfer Enable should be Low.
Initial Actions
Ensure the Left and Right Side Interlock Switches are closed.
Ensure the machine has TAG 012.

In [Faults/Counters tab , Faults], observe the [Last 40] faults.
Check for the following faults:
09-372
09-374
09-376
04-210
One or more of those faults occurred at the same time as the 09-370.
Y
N
+34 to +38 VDC is measured between TS2 (+) and TS1 (-) on the Transfer HVPS.
Y
N
Switch off the machine power. Disconnect P66 ( P66/J1) from the Transfer HVPS.
Switch on the machine power.
Measure the voltage between P66-1 (+) and P66-2 (-). +34 to +38 VDC is measured between P66-1 and P66-2.
Y
N
Go to Flag 1. Check the wiring for an open circuit.
Replace the Transfer/Detack HVPS PL 1.2A Item 6.
Less than 1 VDC is measured.
Y
N
+12 1 VDC is measured.
Y
N
Go to Flag 2. Check the wires for an open circuit. If OK, replace the Transfer/Detack
HVPS PL 1.2A Item 6 .
Suspect 36 VDC open, shorted, or bad LVPS. Go to the 09-D +36 VDC Checkout RAP.
V0.042
May 2003
2-349
09-370
09-370
May 2003
2-350
V0.042
TS1
TS2
TS3
TS4
Figure 2 Transfer HVPS Test Stakes
V0.042
May 2003
2-351
09-370
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
09-370
May 2003
2-352
V0.042
09-372 Detack Power Fault RAP

Fault Code, 09-372, indicates the Detack HVPS fuse is open or the power supply is on in
standby.
Initial Actions

09-370
09-374
09-376
04-210
Y
N
+34 to +38 VDC is measured between TS2 (+) and TS1 (-) on the Detack HVPS.
Y
N
Switch off the machine power. Disconnect P65 from the Detack HVPS. Switch on the
machine power.
Y
N
Y
N
Y
N
Go to Flag 2. Check the wires for an open circuit. If OK, replace the Transfer/Detack
HVPS PL 1.2A Item 6.
V0.042
May 2003
2-353
09-372
09-372
May 2003
2-354
V0.042
TS4
TS3
TS2
TS1
Figure 2 Detack HVPS Test Stakes
V0.042
May 2003
2-355
09-372
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
09-372
May 2003
2-356
V0.042
09-374 Charge Power Fault RAP

Fault Code, 09-374, indicates the Charge HVPS fuse is open or the power supply is on in
standby.
Initial Actions

09-370
09-372
09-376
04-210
Y
N
+34 to +38 VDC is measured between TS2 (+) and TS1 (-) on the Charge HVPS.
Y
N
Switch off the machine power. Disconnect P67 from the Charge HVPS. Switch on
the machine power.
Y
N
Y
N
Y
N
Go to Flag 2. Check the wires for an open circuit. If OK, replace the Charge HVPS
PL 1.2A Item 5.
V0.042
May 2003
2-357
09-374
09-374
May 2003
2-358
V0.042
TS4
TS3
TS2
TS1
Figure 2 Charge HVPS Test Stakes
V0.042
May 2003
2-359
09-374
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH11
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
09-374
May 2003
2-360
V0.042
09-376 Developer Power Fault RAP

Fault Code, 09-376, indicates the Developer HVPS fuse is open or the power supply is on in
standby.
Initial Actions

09-370
09-372
09-374
04-210
Y
N
+34 to +38 VDC is measured between TS2 (+) on the Developer HVPS and
machine frame (-).
Y
N
Switch off the machine power. Disconnect P64 from the Developer HVPS. Switch on
the machine power.
Y
N
Replace the Developer HVPS PL 1.2A Item 7.
Y
N
Y
N
Go to Flag 2. Check the wires for an open circuit. If OK, replace the Developer HVPS
PL 1.2A Item 7.
V0.042
May 2003
2-361
09-376
09-376
May 2003
2-362
V0.042
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
V0.042
May 2003
2-363
09-376
TS10
TS9
TS8
TS7
TS6
TS5
TS4
TS3
TS2
TS1
Figure 3 Developer HVPS Test Stakes
09-376
May 2003
2-364
V0.042
09-380 Transfer Arc Fault RAP

Fault Code, 09-380, indicates that a Transfer Corotron pin current or voltage is too high.

Xerographic Module has already been replaced while trying to correct this problem.
Y
N
Verify the repair. The problem is now corrected.
Y
N
Return to the top of this procedure.
B
Select [Start].
is less than 1.0 VDC.
Y
N
Select [Stop]. Go to Flag 1. Check the wire for an open circuit.
voltage
Select [Stop]. Replace the Transfer/Detack HVPS PL 1.2A Item 6.

Measure the voltage between TH7 (+) and TH47 (-) on the SCAM PWB. The voltage is 5.0
0.3 VDC.
Y
N
Select [Stop]. Go to Flag 2.
Check the wire for a short circuit. The wire is OK.
Y
N
Repair the wiring.
CAUTION
This test will not stop automatically. Do not leave machine unattended with this routine running.
Select the Stop button on the PWS when measurements are completed.
NOTE: Wait 20 seconds before making any measurements, to allow all of the drives and outputs to activate.

Select [Stop]. All checks are correct and the Transfer/Detack HVPS is OK. Return to the procedure from which directed.
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Transfer HVPS Test].
Select [Start]. Measure the voltage between TS3 (+) and TS1 (-) on the Transfer HVPS. Refer
to the PWS for the correct value for Transfer Output Current. The value measured is equal
to the value on the PWS ( 0.6 VDC).
Y
N
The voltage is less than the specified range.
Y
N
The voltage is higher. Select [Stop]. Replace the Transfer/Detack HVPS PL 1.2A
Item 6.
Select [Stop].
Measure the voltage between TS2 (+) and TS1 (-) on the Transfer HVPS. The voltage
is 36.0 2.0 VDC.
Y
N
Measure the voltage between TH1 (+) and TH2 (-) on the SCAM PWB. The voltage is 36.0 2.0 VDC.
Y
N
Measure the voltage between P21/J1-4 (+) and P21/J1-3 (-) at the SCAM
PWB. The voltage is 36.0 2.0 VDC.
Y
N
Replace the SCAM PWB PL 1.5 Item 6
Go to Flag 5.
Check for an open circuit. The circuit is OK.
Y
N
Repair the wiring.
A
B
V0.042
May 2003
2-365
09-380
09-380
May 2003
2-366
V0.042
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
V0.042
May 2003
2-367
09-380
TS1
TS2
TS3
TS4
Figure 3 Transfer/Detack HVPS Test Stakes
09-380
May 2003
2-368
V0.042
09-382 Detack Arc Fault RAP
B
Select [Stop Test]. Replace the Transfer/Detack HVPS PL 1.2A Item 6. If the problem continues, replace the SCAM PWB PL 1.5 Item 6.
Fault Code, 09-382, indicates that a Detack Corotron current or voltage is high.

The Xerographic Module has already been replaced while trying to correct this problem.
Y
N
Replace the Xerographic Module PL 5.1A Item 1
Verify the repair. The problem is now corrected.
Y
N
Return to the beginning of this procedure.
CAUTION
Measure the voltage between TS4 (+) and TS1 (-) on the Detack HVPS. Set the DMM to read
AC voltage. Refer to the PWS for the correct value for Detack AC Output Current. The value
measured is equal to the value on the PWS ( 0.5 VAC) for Detack AC Output.
Y
N
Select [Stop Test]. Replace the Transfer/Detack HVPS PL 1.2A Item 6.
Set the DMM to read DC voltage. Measure the voltage between TH5 (+) and TH47 (-) on the
SCAM PWB. The voltage is 5.0 0.3 VDC.
Y
N
Select [Stop Test]. Go to Flag 2.
Y
N
Repair the wiring.
Select [Stop Test]. The Transfer/Detack HVPS is OK.
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Detack HVPS Test].
Select [Start]. Measure the voltage between TS3 (+) and TS1 (-) on the Detack HVPS. Refer
to the PWS for the correct value for Detack DC Output Current. The value measured is
equal to the value on the PWS ( 1.1 VDC) for Detack DC Output.
Y
N
Y
N
The voltage was higher than the specified range. Select [Stop Test]. Replace the
Transfer/Detack HVPS PL 1.2A Item 6.
Select [Stop Test].
Measure the voltage between TS2 (+) and TS1 (-) on the Detack HVPS. The voltage
is 36.0 2.0 VDC.
Y
N
Y
N
Y
N
Go to Flag 5.
Y
N
Repair the wiring.
A
B
V0.042
May 2003
2-369
09-382
09-382
May 2003
2-370
V0.042
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
V0.042
May 2003
2-371
09-382
TS4
TS3
TS2
TS1
09-382
May 2003
2-372
V0.042
09-384 Charge Pin Arc Fault RAP

Fault Code, 09-384, indicates the Charge Scorotron pin current or pin voltage was high.
Initial Actions
If a 09-310 fault is also occurring, troubleshoot the 09-384 first.
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Charge HVPS
Test] [Start].
is +5.0 0.5 VDC.
Y
N
Select [Stop]. Go to Flag 1. Check the wire for a short circuit to ground.

Xerographic Module has already been replaced while trying to correct this problem.
Y
N
Verify the Repair A new Xerographic Module corrected the problem.
Y
N
Verify the Repair The problem is corrected.
Y
N
Ensure the machine is in standby mode.
+12 VDC 2 VDC is measured.
Y
N
Go to Flag 3. Check the wire for an open circuit. If OK, replace the SCAM
PWB PL 1.5 Item 6.
B
Ensure the machine is on and in a standby condition.
Measure the voltage between TH12 (+) and TH9 (-) on the SCAM PWB. +0.7 VDC or
less is measured.
Y
N
Select [Stop]. Replace the SCAM PWB PL 1.5 Item 6.

Ensure the machine is on and in a standby condition.

Measure the voltage between TH12 (+) and TH9 (-) on the SCAM PWB. +0.7
VDC or less is measured.
Y
N
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Charge
HVPS Test] [Start].
The voltage is +5.0 0.5 VDC.
Y
N
Select [Stop]. Go to Flag 1. Check the wire for a short circuit to ground.
Verify the Repair. The problem is corrected.
Y
N
Ensure the machine is in standby mode.
Measure the voltage between TH10 (+) and TH47 (-) on the SCAM PWB. +12 VDC 2
VDC is measured.
Y
N
Go to Flag 3. Check the wire for an open circuit. If OK, replace the SCAM PWB PL
1.5 Item 6.
A
B
V0.042
May 2003
2-373
09-384
09-384
May 2003
2-374
V0.042
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH9
TH10
TH11
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
V0.042
May 2003
2-375
09-384
09-386 Development HVPS Arc Fault RAP

Fault Code, 09-386, indicates that a short circuit was sensed between the Donor to Mag Roll or
the Donor Roll to the P/R Belt.

Replace the Developer Material PL 5.1B Item 18 .
Run the machine to verify the fix. 09-386 is still occurring.
Y
N
CAUTION
A
Measure the voltage between TS10 (+) and TS1 (-) on the Developer HVPS. Refer to the
PWS screen for the value for Mag DC Output. The voltage measured is equal to the value
on the PWS ( .15 VDC) for Mag DC Output.
Y
N
Measure the voltage between TS4(+) and TS9 (-) on the Developer HVPS. Refer to the
PWS screen for the value for Mag DC Reference. The voltage measured is equal to
the value on the PWS ( 0.1 VDC) for Mag DC Reference.
Y
N
voltage measured is equal to the value on the PWS ( 0.1 VDC) for Mag DC Reference.
Y
N
Select [Stop]. Go to Flag 8. Check the wire for a short circuit to machine frame.
Select [Stop]. Go to Flag 8. Check the wire for a open circuit.
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Developer HVPS].
Select [Start]. Measure the voltage between TH15 (+) and TH47 (-) on the SCAM PWB.
Less than 1.0 VDC is measured.
Y
N
Measure the voltage between TH16 (+) and TH47 (-) on the SCAM PWB. The voltage is
5.0 0.3 VDC.
Y
N
Select [Stop]. Go to Flag 2. Check the wire for a short circuit to machine frame. If OK,
replace the Developer Housing PL 5.1B Item 5. If the problem continues, replace the
Developer HVPS PL 1.2A Item 7.
Measure the voltage between TS6 (+) and TS1 (-) on the Developer HVPS. Refer to the PWS
screen for the value for Donor DC Output. The voltage measured is equal to the value on
the PWS ( .23 VDC) for Donor DC Output.
Y
N
PWS screen for the value for Donor DC Reference. The voltage measured is equal to
the value on the PWS ( 0.1 VDC) for Donor DC Reference.
Y
N
Measure the voltage between TH21 (+) and TH47 (-) on the SCAM PWB. Refer to
the PWS screen for the value for Donor DC Reference. The voltage measured is
equal to the value on the PWS ( 0.1 VDC) for Donor DC Reference.
Y
N
Select [Stop]. Go to Flag 5. Check the wire for a short circuit. If OK, replace the
SCAM PWB PL 1.5 Item 6.
Select [Stop]. Replace the Developer HVPS PL 1.2A Item 7.

Use the Peak Hold function on the DMM.
screen for the value for Donor AC Output. The voltage measured is equal to the value on
the PWS ( .23 VDC) for Donor AC Output.
Y
N
Deselect the Peak Hold function on the DMM.
PWS screen for the value for Mag AC Output. The voltage measured is equal to the
value on the PWS ( .50 VDC) for Mag AC Output.
Y
N
Deselect and reselect Peak Hold on the DMM. Measure the voltage between TH17
(+) and TH47 (-) on the SCAM PWB. The voltage is less than 1 VDC.
Y
N
Select [Stop]. Go to Flag 3. Check the wire for an open circuit. If OK, replace
the SCAM PWB PL 1.5 Item 6. If the problem continues, replace the Developer
Select [Stop]. Measure the voltage between TH17 (+) and TH47 (-) on the SCAM
PWB. +14 1.0 VDC is measured.
Y
N
Go to Flag 3. Check the wire for an open circuit. If OK, replace the Developer

A
09-386
B
May 2003
2-376
Deselect Peak Hold on the DMM. Measure the voltage between TS5 (+) and TS9 (-) on
the Developer HVPS. Refer to the PWS screen for the value for Donor AC Reference.
The voltage measured is equal to the value on the PWS ( .1 VDC) for Donor AC
Reference.
Y
N
voltage measured is equal to the value on the PWS ( .1 VDC) for Donor AC
Reference.
C
V0.042
C
Y
N
Select [Stop]. Go to Flag 7. Check the wire for a short circuit to machine frame.

screen for the value for Mag AC Output. The voltage measured is equal to the value on the
PWS ( .50 VDC) for Mag AC Output.
Y
N
Select [Stop]. If this RAP was not entered because of a Xerographic Exerciser failure message,
the Developer HVPS checks out OK. Return to the RAP that indicated this checkout should be
performed. If this RAP was performed because of an Exerciser failure, continue.
Another Part was identified in the Xerographic Exerciser as failed.
Y
N
The Xerographic Exerciser was unsuccessful in determining the cause. Return the RAP
which directed you here (original fault) and perform the RAP as if the Exerciser had
passed.
Choose the next part the Xerographic Exerciser identified from the list below and go to the indicated RAP:
Xerographic Module 09-J
Toner Dispenser 09-C
V0.042
May 2003
2-377
09-386
09-386
May 2003
2-378
V0.042
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
V0.042
May 2003
2-379
09-386
TS10
TS9
TS8
TS7
TS6
TS5
TS4
TS3
TS2
TS1
09-386
May 2003
2-380
V0.042
09-870/880 Toner Bottle Empty RAP
09-A Charge HVPS Checkout RAP
NOTE: Only 265DC machines built for the FX market have a Toner Bottle Sensor.
This procedure checks out the Charge HVPS. It is an On-Site procedure.
Fault Code, 09-880, occurs when the Toner Bottle Sensor does not detect toner in the bottle.
The fault will clear if the Front Door is open/closed, the machine power is switched off/on, or a
09-870 is detected.
Fault Code, 09-870, occurs when the Toner Bottle Sensor does not detect toner in the bottle
after an 09-880 was cleared and the Toner Bottle motor has run for 40 seconds. The fault will
clear when toner is detected.
Initial Actions
Ensure the Toner Bottle has been replaced (that it does have toner in it).
If using an interlock cheater while troubleshooting a fault, ensure that you remove the
cheater to clear the fault from the UI screen.

The Type 1 test passed.
Y
N
Y
N
machine problems that might be occurring. Replace the Toner Dispenser (with Sensor) PL 5.1B Item 4. If the problem continues, replace the IIOC PWB W8A2 PL 1.5.
Go to the 03-801RAP.
In standby mode,
measure the voltage between TS3 (+) and TS1 (-) (Pin Current Monitor) on the Charge
HVPS. The voltage is 0.0 VDC
Y
N
is 12.0 1.0 VDC
Y
N
Go to Flag 1. Check for a short circuit. If OK, replace the SCAM PWB PL 1.5 Item 6.
Replace Charge HVPS PL 1.2A Item 5.
less than 1.0 VDC.
Y
N
Go to Flag 2. Check the wire for an open circuit. If OK, replace the Charge HVPS PL 1.2A
Item 5.
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Charge HVPS Test].
CAUTION

Y
N
Y
N
machine problems that might be occurring. Replace the Toner Dispenser (with Sensor) PL 5.1B Item 4. If the problem continues, replace the IIOC PWB W8A2 PL 1.5.
Replace the Toner Dispenser PL 5.1B Item 4. If the problem continues, replace the IIOC PWB
W8A2 PL 1.5 Item 2.
Select [Start]. Measure the voltage between TS4 (+) and TS1 (-) on the Charge HVPS. On the
PWS, refer to the Grid Output voltage value. The voltage measured is equal to the value (
0.3 VDC) on the PWS for the Grid Output.
Y
N
Continue with the [Charge Test].
Measure the voltage between TS3 (+) and TS1 (-) on the Charge HVPS. On the PWS,
refer to the Pin Current Output value. The voltage measured is equal to the value (
0.2 VDC) on the PWS for the Pin Current Output.
Y
N
The voltage is less than 1.8 VDC.
Y
N
Select [Stop]. Replace Charge HVPS PL 1.2A Item 5
Select [Stop].
Measure the voltage between TS2 (+) and TS1 (-) on the Charge HVPS. The
voltage is 36 2 VDC.
Y
N
voltage is 36 2 VDC.
Y
N
Measure the voltage between J1-4 (+) and J1-3 (-) on the SCAM PWB.
The voltage is 36 2 VDC.
A
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May 2003
2-381
D
09-870/880, 09-A
A
Y
E
Measure the resistance between P67/JI-6 and machine frame. Less
ohms is measured.
Y
N
N
than
100
Measure the voltage between P67/JI-1 (+) and P67/JI-2 (-) on the Charge
HVPS. The voltage is 36 2 VDC.
Y
N
Select [Stop]. Switch off machine power.

Check continuity from P20/J10-1 to P67/JI-6 and from P20/J10-2 to P67/JI-5. Continuity is measured on BOTH wires.
Y
N

voltage is 12.0 2.0 VDC.
Y
N
The voltage is less than 10 VDC.
Y
N
The Xerographic Module has already been replaced in an effort to solve this problem.
Y
N
Run machine to see if problem is corrected. The problem is now resolved.
Y
N
Replace the Charge HVPS PL 1.2A Item 5
Go to Flag 1. Check the wires for an open or short circuit. If OK, replace the
Charge HVPS PL 1.2A Item 5.

Select [Start]. Measure the voltage between TH10 (+) and TH47 (-) on the SCAM
PWB. The voltage is less than or equal to 1.0 VDC.
Y
N
Select [Stop]. Replace the SCAM PWB PL 1.5 Item 6
Continue with the [Charge Test].
voltage is 5.0 0.2 VDC.
Y
N
Select [Stop]. Replace the Xerographic Module PL 5.1A Item 1.
NOTE: If the Xerographic Module has already been replaced for this problem,
answer No to the following statement.

Measure the voltage between TH11 (+) and TH47 (-) on the SCAM PWB. The voltage 5.0
0.3 VDC.
Y
N
Select [Stop]. Go to Flag 2. Check the wire for a short circuit. The wire is shorted.
Y
N
Run machine to see if problem is corrected. The problem is now resolved.
Y
N
Run machine to see if problem is corrected. The problem is gone.

Y
N
Repair the short circuit.

Select [Stop]. The Charge function checks out OK. Return to the procedure which directed you
here.

Continue with the [Charge HVPS Test].
Measure the voltage between TH11 (+) and TH47 (-) on the SCAM PWB. Refer to the
PWS for the correct value for Grid Reference. The voltage measured is equal to the
PWS value ( 0.15 VDC) for Grid Reference.
Y
N
Select [Stop]. Switch off machine power. Disconnect P20/J10 from the SCAM PWB
and P67/JI from the Charge HVPS.
A
E
09-A
May 2003
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May 2003
2-383
09-A
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH9
TH10
TH11
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
09-A
May 2003
2-384
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TS4
TS3
TS2
TS1
Figure 3 Charge HVPS Test Stakes
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May 2003
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09-A
09-B Transfer HVPS Checkout RAP
This procedure checks out the Transfer HVPS. It is an On-Site procedure.

In standby mode,
measure the voltage between TS3 (+) and TS1 (-) on the Transfer HVPS. 0.0 VDC is measured.
Y
N
Measure the voltage between TH6 (+) and TH47 (-) at the SCAM PWB. The voltage is
12.0 1.0 VDC.
Y
N
Go to Flag 3.
Check for an short circuit. The circuit is OK.
Y
N
Repair the wiring.

Go to Flag 5.
Y
N
Repair the wiring.
Select [Stop Test]. Replace the SCAM PWB PL 1.5 Item 6.
The machine is a 65ppm or 55ppm machine.

Y
N
Select [Start].
Measure the voltage between TH8 (+) and TH47 (-) on the SCAM PWB. The voltage is less than 1.0 VDC.
Y
N

Measure the voltage between TH7 (+) and TH47 (-) at the SCAM PWB. The voltage is less
than 1.0 VDC.
Y
N
Go to Flag 2.
Y
N
Repair the wiring.

Select [Start].
is greater than 1.0 VDC.
Y
N
CAUTION
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Transfer HVPS Test].
Select [Start]. Measure the voltage between TS3 (+) and TS1 (-) on the Transfer HVPS. Refer
to the PWS for the correct value for Transfer Output Current. The value measured is equal
to the value on the PWS ( 0.35 VDC for 40ppm) or ( 0.5 VDC for 65ppm or 55ppm).
Y
N
Y
N
Select [Stop].
Measure the voltage between TS2 (+) and TS1 (-) on the Transfer HVPS. The voltage
is 36.0 2.0 VDC.
A
09-B
N
Y
N
Y
N
voltage

Measure the voltage between TH7 (+) and TH47 (-) on the SCAM PWB. The voltage is 5.0
0.3 VDC.
Y
N
Select [Stop]. Go to Flag 2.
Y
N
Repair the wiring.
Select [Stop]. The Transfer/Detack HVPS is OK.
May 2003
2-386
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May 2003
2-387
09-B
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
09-B
May 2003
2-388
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TS1
TS2
TS3
TS4
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May 2003
2-389
09-B
09-C Toner Dispenser Checkout RAP
This procedure is used in conjunction with the Xerographic Exerciser whenever the Toner Dispenser is identified as a part to replace. The Exerciser may see a failure in the Toner Dispenser
that is caused by a wiring or IIOC problem.
N
passed.

Y
N
Observe the fault display in the IIOC Self-Test screen. An 03-801-1 fault is detected.
Y
N
machine problems that might be occurring. Replace the Toner Dispenser PL 5.1B
Item 4. If the problem continues, replace the IIOC PWB W8A1 PL 1.5 Item 2.
Developer Housing 09-K
Developer HVPS 09-G

NOTE: Intermittent failure of the Fuser Fan can cause the IIOC and Toner Dispenser Motor to
not function. In some cases the IIOC tests may pass though this fan is shorting intermittently.
To ensure a Fuser Fan problem is not the cause of this, perform the following:
Enter [Copier Sys tab , Component Control]. Select [Copier Sys | IOT Paper Path | Fuser
Fan]. Select [Output On]. Let run for several minutes.
Select [Output Off], enter [Self Tests tab , IIOC Controller Tests]. Select [IOT] [Type 1],
then [Start].

Y
N
As a final check of the Fuser Fan, check the resistance of the fan. Switch off the machine
power. Disconnect the connector and measure the resistance across the fan.
With the black lead to the black motor lead and the red meter lead to the red motor wire, the
resistance should be approximately 5 Megohms. With the leads reversed, the resistance
should be infinite. The resistance is OK.
Y
N
Replace the Fuser Fan/Duct PL 9.1 Item 5.
Replace the Toner Dispenser PL 5.1B Item 4.
When the Toner Dispenser installation is complete. Re-check for the original fault or defect.
The fault or defect continues.
Y
N
Go to Flag 2 and Flag 3.
Check the wires for an open circuit. The wiring is OK.
Y
N
09-C
May 2003
2-390
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May 2003
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09-C
09-D +36 VDC Checkout RAP

Use this RAP if 09-370, 09-372, 09-374, and 09-376 faults are occurring. It is an On-Site procedure.
Initial Actions
Ensure the Side Interlock Switches are closed.

On machines without a Bypass Tray or HCF/Bypass Tray, check the following:
Check the Left Side Cover Upper Knockout. This is a filler cover that fits over the opening
in the Left Side Cover.
Check the Left Side Cover Upper Knockout for damaged latches. If the latches are damaged, the Left Side Safety Interlock Switch will not be reliably actuated.
If the latches are damaged, replace the Left Side Cover Upper Knockout PL 7.2 Item 7
(48E3664).
When installing a new Knockout panel, press the latches down to guide them into their
mating holes in the Left Side Cover.
If OK or the machine has a Bypass Tray, continue here.

Check the machine tag matrix. The machine has IOT TAG 011 installed.
Y
N
Check the machine tag matrix. The machine has IOT TAG 012 installed.
Y
N
Install repair kit 606K6580.
Measure the voltage between 36V (+) and LVPS frame (-) on the LVPS. +36 2 VDC is
measured.
Y
N
Go to the 01-A DC Voltage Checkout RAP.
Go to Flag 1. Check the wires for an open circuit. If OK, replace the 01-A PL 1.5 Item 6.
Measure the voltage between +36V (+) and LVPS frame (-) on the LVPS. +36 2 VDC is
measured.
Y
N
Go to the 01-A DC Voltage Checkout RAP.
Go to Flag 1. Check the wires for an open circuit. If OK, replace the SCAM PWB PL 1.5 Item 6.
09-D
May 2003
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May 2003
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09-D
36V
+36V
24V
+24V
-12V
24 PSV
+24 VES
INT-OUT
Interlock Outp
Interlock Inpu
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
5.15V
+12V
+12V
-12V
+12 VES
5.15 PSV
09-D
May 2003
2-394
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09-E Detack HVPS Checkout RAP
This procedure checks out the Detack HVPS. It is an On-Site procedure.

In standby mode,
measure the voltage between TS3 (+) and TS1 (-) on the Detack HVPS. 0.0 VDC is measured.
Y
N
Measure the voltage between TH3 (+) and TH47 (-) at the SCAM PWB. The voltage is
12.0 1.0 VDC.
Y
N
Go to Flag 3.
Check for an short circuit. The circuit is OK.
Y
N
Repair the wiring.
N
Y
N
Y
N
Go to Flag 5.
Y
N
Repair the wiring.

Measure the voltage between TH5 (+) and TH47 (-) at the SCAM PWB. The voltage is less
than 1.0 VDC.
Y
N
Go to Flag 2.
Y
N
Repair the wiring.
CAUTION
Measure the voltage between TS4 (+) and TS1 (-) on the Transfer HVPS. Set the DMM to
read AC voltage. Refer to the PWS for the correct value for Detack AC Output Current. The
value measured is equal to the value on the PWS ( .35 VAC) for Detack AC Output.
Y
N
Set the DMM to read DC voltage. Measure the voltage between TH5 (+) and TH47 (-) on the
SCAM PWB. The voltage is 5.0 0.3 VDC.
Y
N
Select [Stop Test]. Go to Flag 2.
Y
N
Repair the wiring.
Select [Stop Test]. The Transfer/Detack HVPS is OK.
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Detack HVPS Test].
Select [Start]. Measure the voltage between TS3 (+) and TS1 (-) on the Detack HVPS. Refer
to the PWS for the correct value for Detack DC Output Current. The value measured is
equal to the value on the PWS ( 1.1 VDC) for Detack DC Output.
Y
N
Y
N
Select [Stop Test].
Measure the voltage between TS2 (+) and TS1 (-) on the Detack HVPS. The
is 36.0 2.0 VDC.
A
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voltage
May 2003
2-395
09-E
09-E
May 2003
2-396
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TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
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May 2003
2-397
09-E
TS4
TS3
TS2
TS1
09-E
May 2003
2-398
V0.042
09-F Xerographic Electrical Noise Checkout

This procedure is used when electrical noise is a suspect for any xerographic faults.

1.
Go to Flag 1. Inspect the ground wire connected to the BTAC Sensor Assembly. Ensure
there is a good connection to ground. If OK, go to step 2.
2.
With your meter check pin 1 of P/J50. Ensure that it has not been bent due to strain on
the connector.
3.
Replace the Developer Housing PL 5.1B Item 5. If the problem continues, go to step 4.
4.
5.
Figure 1 09-F RAP Circuit Diagram
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May 2003
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09-F
09-G Developer HVPS Checkout RAP
Select [Start]. Measure the voltage between TH15 (+) and TH47 (-) on the SCAM PWB.
Y
N
This procedure will check out the Developer HVPS. It is an On-Site procedure.
Initial Actions
If 09-370, 09-372, 09-374, and 09-376 faults are occurring, go to the 09-D +36 VDC
Checkout RAP.

STANDBY MODE CHECKS
With the machine on and in standby mode,
measure the voltage between TS2 (+) and TS1 (-) on the Developer HVPS. The voltage is
+36 2 VDC.
Y
N
Use the DMM test probes to measure the voltage between P64-1(+) and P64-2 (-). Carefully measure the voltage by probing the back of connector P64.
The voltage is +36 2 VDC.
Y
N
Go to Flag . Check the wires for an open circuit.
In standby,
measure the voltage between TH15 (+) and TH47 (-) on the SCAM PWB. +15.5 1 VDC is
measured.
Y
N
Y
N
Go to Flag 4. Check the wire for an open circuit. If OK, replace the Developer HVPS
PL 1.2A Item 7.
Go to Flag 4. Check the wire for an short circuit to ground. If OK, replace the SCAM PWB
PL 1.5 Item 6.
less than 1.0 VDC.
Y
N
Go to Flag 2. Check the wire for an open circuit. If OK, replace the Developer HVPS PL
1.2A Item 7. If the problem continues, replace the SCAM PWB PL 1.5 Item 6.
RUN MODE CHECKS
CAUTION
5.0 0.3 VDC.
Y
N
Select [Stop]. Go to Flag 2. Check the wire for a short circuit. If OK, replace the Developer
Housing PL 5.1B Item 5. If the problem continues, replace the Developer HVPS PL 1.2A
Item 7.
screen for the value for Donor DC Output. The voltage measured is equal to the value on
the PWS ( .23 VDC) for Donor DC Output.
Y
N
PWS screen for the value for Donor DC Reference. The voltage measured is equal to
the value on the PWS ( 0.1 VDC) for Donor DC Reference.
Y
N
Measure the voltage between TH21 (+) and TH47 (-) on the SCAM PWB. Refer to
the PWS screen for the value for Donor DC Reference. The voltage measured is
equal to the value on the PWS ( 0.1 VDC) for Donor DC Reference.
Y
N
Select [Stop]. Go to Flag 5. Check the wire for a short circuit to machine
ground. If OK, replace the SCAM PWB PL 1.5 Item 6.
PWS screen for the value for Mag DC Output. The voltage measured is equal to the value
on the PWS ( .15 VDC) for Mag DC Output.
Y
N
Measure the voltage between TS4(+) and TS9 (-) on the Developer HVPS. Refer to the
PWS screen for the value for Mag DC Reference. The voltage measured is equal to
the value on the PWS ( 0.1 VDC) for Mag DC Reference.
Y
N
voltage measured is equal to the value on the PWS ( 0.1 VDC) for Mag DC Reference.
Y
N
In [Marking tab , Xerographic Diagnostics], select [Power Supply Tests] [Developer HVPS].
09-G

May 2003
2-400
V0.042
screen for the value for Donor AC Output. The voltage measured is equal to the value on
the PWS ( .23 VDC) for Donor AC Output.
Y
N
Deselect and reselect the Peak Hold function on the DMM.
PWS screen for the value for Mag AC Output. The voltage measured is equal to the
value on the PWS ( .50 VDC) for Mag AC Output.
Y
N
Deselect Peak Hold on the DMM. Measure the voltage between TH17 (+) and
TH47 (-) on the SCAM PWB. The voltage is less than 1 VDC.
Y
N
Select [Stop]. Go to Flag 3. Check the wire for an open circuit. If OK, replace
the SCAM PWB PL 1.5 Item 6. If the problem continues, replace the Developer
N
passed.

Figure 1
Figure 2
Figure 3
Select [Stop]. Measure the voltage between TH17 (+) and TH47 (-) on the SCAM
PWB. +18 1.5 VDC is measured.
Y
N
Go to Flag 3. Check the wire for an open circuit. If OK, replace the Developer
Deselect Peak Hold. Measure the voltage between TS5 (+) and TS9 (-) on the Developer HVPS. Refer to the PWS screen for the value for Donor AC Reference. The voltage measured is equal to the value on the PWS ( .1 VDC) for Donor AC Reference.
Y
N
voltage measured is equal to the value on the PWS ( .1 VDC) for Donor AC
Reference.
Y
N
screen for the value for Mag AC Output. The voltage measured is equal to the value on the
PWS ( .50 VDC) for Mag AC Output.
Y
N
Select [Stop]. If this RAP was not entered because of a Xerographic Exerciser failure message,
the Developer HVPS checks out OK. Return to the RAP that indicated this checkout should be
performed. If this RAP was performed because of an Exerciser failure, continue.
V0.042
May 2003
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09-G
Figure 1 RAP 09-G Circuit Diagram
09-G
May 2003
2-402
V0.042
TH1
TH2
TH3
TH4
TH5
TH6
TH7
TH8
TH10
TH12
TH14
TH15
TH16
TH17
TH18
TH19
TH41
TH42
TH21
TH44
TH45
TH46
TH47
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May 2003
2-403
09-G
TS10
TS9
TS8
TS7
TS6
TS5
TS4
TS3
TS2
TS1
09-G
May 2003
2-404
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09-H Developer Collector Checkout RAP

This procedure checks out the correct operation of the Developer Collector system.
Initial Actions
Check for any 09-358 faults. If occurring, go to that RAP (09-358).

Check the Developer Collector bottle. The Developer Collector bottle is full.
Y
N
Check the Developer Collector Tube. Ensure that it is not clogged.
Check the Developer Collector Tube. Ensure that it is correctly connected to the
Developer Housing and the Developer Collector.
Repair or replace the Developer Collector PL 5.1B Item 8 or the Developer Collector Tube
PL 5.1B Item 7 as necessary.
If the Developer Housing became bound due to a clogged tube or bottle and caused
motor faults, replace the Developer Housing PL 5.1B Item 5.
If no problems were found, return to the procedure that sent you here.
Go to Flag 1, check for an open circuit.
If OK, replace the Developer Collector Sensor
PL 5.1B Item 9. If the problem continues, replace the IIOC PWB W3A1 PL 1.5.
If the Developer Housing became bound and caused motor faults, replace the Developer
Housing PL 5.1B Item 5.
V0.042
May 2003
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09-H
09-J Xerographic Module Checkout RAP

This checkout procedure is used in conjunction with the Xerographic Exerciser in some situations to diagnose problems beyond the capabilities of the Xerographic Exerciser.
R09-J On-Site Diagnostic Procedure

Refer to the original Exerciser message. The Xerographic Exerciser failed with a parts to
replace message that indicated: Xerographic Module (Ground) or XRM (Ground).
Y
N
Refer to the original Exerciser message. The Xerographic Exerciser failed with a
parts to replace message that indicated: Xerographic Module (Cleaner) or XRM
(Cleaner).
Y
N
The Xerographic Exerciser failed with a parts to replace message that indicated:
Xerographic Module (Belt) or XRM (Belt). In Component Control, select [IOT Paper
Path] [CRU Blower] [Output On].
Check the Xerographic Blower. Ensure that it is working. The blower is working.
Y
N
40PPM: Go to the OF-4, Noise, Odor, Heat, and Dirt RAP to diagnose the CRU
Blower circuit.
65PPM or 55PPM: Go to the OF-5, Noise, Odor, Heat, and Dirt RAP to diagnose the CRU Blower circuit.
Check for reoccurrence of the fault/defect. The fault and/or defect is still occurring.
Y
N
Go to the 09-A Charge HVPS Checkout RAP. Perform this procedure until a corrective action is identified or until the Charge HVPS checks out OK. If it checks out OK,
return here (use the back button on the browser).
A solution was found in the Charge Checkout RAP.
Y
N
Y
N
The Xerographic Exerciser was unsuccessful in determining the cause.
Return the RAP which directed you here (original fault) and perform the
RAP as if the Exerciser had passed.
B
Remove the Xerographic Module from the machine. In [Copier Sys tab , Component Control], select [IOT General] [Photoreceptor Drive Motor], then [Output On].
Observe the Cleaner Brush Drive Shaft (Figure 2). The Cleaner Brush Drive Shaft
rotates when the motor is energized.
Y
N
Select [Output Off]. Replace the Photoreceptor Drive Module PL 5.1A Item 2.
Select [Output Off]. Replace the Xerographic Module PL 5.1A Item 1.
Check for reoccurrence of the fault/defect. The fault and/or defect is still occurring.
Y
N
Y
N
The Xerographic Exerciser was unsuccessful in determining the cause. Return the
RAP which directed you here (original fault) and perform the RAP as if the Exerciser
had passed.
Choose the next part the Xerographic Exerciser identified from the list below and go to the
indicated RAP:
Developer HVPS 09-G

Inspect the IB end of the Xerographic Module. Check the P/R Belt for damage along the IB
side (Figure 1) of the belt. The P/R Belt has damage along the IB side.
Y
N
Inspect the IB end of the Xerographic Module. Check the P/R Belt for excess toner and
dirt on the IB side of the belt, around the ground strip area (Figure 1) on the belt. There
is toner contamination on the ground strip.
Y
N
Check for reoccurrence of the fault or defect. The fault or defect is still occurring.
Y
N
Y
N
The Xerographic Exerciser was unsuccessful in determining the cause. Return
the RAP which directed you here (original fault) and perform the RAP as if the
Exerciser had passed.
Choose the next part the Xerographic Exerciser identified from the list below
and go to the indicated RAP:
Developer HVPS 09-G
Choose the next part the Xerographic Exerciser identified from the list below and go
to the indicated RAP:

A
B
09-J
C
May 2003
2-406
Developer HVPS 09-G
D
V0.042
Observe the Xerographic Module.

Inspect the air manifold just below the development area (Figure 1). Determine if there is
a toner build-up either on top of the manifold or in the manifold itself. There is heavy
toner build-up on top of the manifold.
Y
N
There is heavy toner build-up inside of the manifold.
Y
N
Check for reoccurrence of the fault or defect. The fault or defect is still
occurring.
Y
N
Y
N
The Xerographic Exerciser was unsuccessful in determining the cause.
Return the RAP which directed you here (original fault) and perform the
RAP as if the Exerciser had passed.
Choose the next part the Xerographic Exerciser identified from the list below
and go to the indicated RAP:
Developer HVPS 09-G
In Component Control, select [IOT Paper Path] [CRU Blower] [Output On].
Check the Xerographic Blower. Ensure that it is working. The blower is working.
Y
N
40PPM: Go to the OF-4, Noise, Odor, Heat, and Dirt RAP to diagnose the CRU
Blower circuit.
65PPM or 55PPM: Go to the OF-5, Noise, Odor, Heat, and Dirt RAP to diagnose the CRU Blower circuit.
Replace the Xerographic Module PL 5.1A Item 1 and replace the Developer Housing PL
5.1B Item 5.
Inspect the Photoreceptor Drive Module for any signs of obvious malfunction. Ensure the Drive
Rolls are not damaged. Repair/replace as necessary Photoreceptor Drive Module PL 5.1A
Item 2.Whether the Photoreceptor Drive Module is replaced or not, replace the Xerographic
Module PL 5.1A Item 1.
If belt damage continues to be a problem, replace the Photoreceptor Drive Module PL 5.1A
Item 2.
V0.042
May 2003
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09-J
Ground Contact
Ground Strip
area
Air Manifold
Figure 1 Xerographic Module
09-J
May 2003
2-408
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Cleaner Brush
Drive Shaft
Xerographic
Blower
(CRU Blower)
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May 2003
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09-J
09-K Developer Housing Checkout RAP

This procedure is used in conjunction with the Xerographic Exerciser whenever the Developer
Housing is identified as a part to replace.
Clean

Check for Developer Housing Drive. Remove the Back Cover and observe the Developer
Drives. In [Copier Sys tab , Component Control], select [IOT Paper Path] [Developer Drive
Motor] [Output On].
Observe the Developer Drives. Check for any broken or damaged gears. Check that all gears
are rotating and mating correctly. Check for any unusual noise. The Developer Drives are
functioning correctly.
Y
N
Select [Output Off]. Repair or replace the appropriate components.
Developer Drive Motor PL 7.1 Item 1
Developer Gear Bracket PL 7.1 Item 2
Select [Output Off]. Perform REP 09-13 Donor Roll Cleaning Procedure or replace the Donor
Roll PL 5.1B item 19.
Recheck for the original fault or defect. The fault or defect is still occurring.
Y
N
Replace the Developer Housing, PL 5.1B Item 4. After the Developer Housing has been
replaced, recheck for the original fault or defect. The fault or defect is still occurring.
Y
N
Clean Shaft

Y
N
The Xerographic Exerciser was unsuccessful in determining the cause. Return to the
RAP which directed you here (original fault) and perform the RAP as if the Exerciser had
passed.
Developer HVPS 09-G
09-K
May 2003
2-410
V0.042
09-L ROS Checkout RAP
This procedure is used in conjunction with the Xerographic Exerciser whenever the ROS is
identified as a part to replace.
Developer HVPS 09-G

The Exerciser indicated the ROS A/B test failed.
Y
N
Check for reoccurrence of the fault or defect. The fault or defect is still occurring.
Y
N
Y
N
The Xerographic Exerciser was unsuccessful in determining the cause. Return the
RAP which directed you here (original fault) and perform the RAP as if the Exerciser
had passed.
Choose the next part the Xerographic Exerciser identified from the list below and go to the
indicated RAP:
Developer HVPS 09-G
XRU 09-J
Replace the Raster Output Scanner Video Cable PL 1.2A Item 4.

Try to reproduce the original fault or defect. The original fault or defect is still occurring.
Y
N
Go to the 03-G RAP and replace the Main Control PWB.
Y
N
Y
N
Y
N
passed.
V0.042
May 2003
2-411
09-L
09-L
May 2003
2-412
V0.042
10-100 PreFuser Transport Jam

The lead edge of a sheet from Registration / Transfer arrived late at the Prefuser Transport
(PFT) Sensor.
The fault code suffix identifies whether the job is simplex or duplex:
10-100.98 = Simplex job
10-100.99 = Side 2 of a duplex job
Initial Actions
occurred
If 10-100.99 jams are occurring when using lightweight paper (less than 20 lb [80 gsm]),
install the Light Weight Paper Duplex Kit PL 6.1A Item 2, TAG 298.

10-100 faults can be caused by a dirty PFT Sensor. Do the following
Clear the jam. Ensure the Fuser/Inverter Drawer and the Prefuser Transport (refer to the
replacement procedure REP 10-1) are fully seated. Install the interlock cheater. Make one copy
and observe the Prefuser Transport belts and the Fuser Jam Clearance Knob.
The Fuser Jam Clearance Knob is turning before the jam occurs.
Y
N
Ensure the Fuser Module is correctly installed on the Inverter and the Fuser Drive Gear,
PL 7.1 Item 5, is fully meshed with the drive gear on the Fuser Drive Motor when the
drawer is fully seated. Inspect the Fuser Drive Gear for excessive wear.
If necessary, replace the Fuser Drive Gear (part of the Fuser Drive Gear Kit PL 7.1 Item
15) and/or the Fuser Module PL 6.2A Item 1.
If the problem continues, replace the Fuser Drive Motor PL 7.1 Item 3.
The PreFuser Transport belts are moving before the jam occurs.
Y
N
Pull out the Fuser/Inverter Drawer (Handle 3) in order to check the Prefuser Transport
(PFT) drive gears.
The PFT gears are functional and they engage correctly.
Y
N
Replace the component(s) with the defective gear.
Remove the Fuser Module and the Xerographic Module to gain access to the underside
of the Prefuser Transport.
Clean the face of the PFT Sensor (located on the Prefuser Transport between the second
and third Prefuser Transport belts)
Attempt to make copies/prints

Y
N
Prefuser Transport PL 6.1A Item 1.
Fuser Drive Motor PL 7.1 Item 3.
Attempt to run copies/prints to determine if reseating the Fuser Module corrected the
problem.
The problem continues after reseating the Fuser Module.
Y
N
Run enough copies/prints to verify problem is corrected. Return to Service Call Procedures.
Make copies/prints in order to create the jam condition. Pull out the Fuser/Inverter Drawer
(Handle 3) and check the location of the jammed sheet.
The lead edge of the sheet is located under Area 3A (the PreFuser Transport).
Y
N
Clear the jam, paying attention to the location of the sheet.
The lead edge of the sheet is in the Xerographic Module.
Y
N
The sheet is jammed in the Registration Transport. Go to the 08-120 RAP.
A
B
V0.042
It is possible to install the Fuser Module incorrectly which causes the Prefuser Transport
(PFT) to be pushed up as the Fuser Module is pushed into the machine, resulting in disengagement of the PFT drive gears. Pull out the Fuser/Inverter Drawer (Handle 3). Check
the four corners of the Fuser Module cover and ensure the cover is fully seated on the
module. Reseat the module on the drawer. Observe the PFT as you firmly push in the
Fuser/Inverter Drawer.
The PFT gears remain engaged as the Fuser/Inverter Drawer is pushed in and
seated.
Y
N
If the problem continues, replace the Prefuser Transport PL 6.1A Item 1.
The problem continues after the PFT Sensor is cleaned.

Y
N
Check the [Last 40 Faults] for instances of 09-370, 09-372, 09-380, or 09-382 faults.
Any of the listed faults are logged.
Y
N
B
Go to the RAP for the fault code. (09-370) (09-372) (09-380) (09-382)

Do the following:
Ensure the interlock cheater is installed.
In Component Control, select [IOT Paper Path], [PFT Vacuum Fan], and [Output On].
May 2003
2-413
10-100
Hold a sheet of paper against the PFT Transport Belts.
The sheet of paper is held against the PFT Transport Belts when the PFT Vacuum Fan
energizes.
Y
N
tests. Enter [Self Tests tab , IIOC Controller Tests].
The tests fail with an 03-812 code.
Y
N
10-100
May 2003
2-414
V0.042
10-101 Fuser Exit Jam

The display indicates the state of the Inverter Entrance Sensor changed.
Y
N
Go to Flag 1. Check the circuit of the Inverter Entrance Sensor PL 6.3 Item 6.
The lead edge of a sheet from the Fuser arrived late at the Inverter Entrance Sensor PL 6.3
Item 6.
The tests fail with an 03-828 or 03-829 code.
Y
N
Initial Actions
Ensure the Area 2 Handle is securely snapped in place.
Ensure the Shim (Baffle Jack) is installed on the Fuser Module.
Turn over and reload the stack of paper in the tray the customer was using when the Finisher jam occurred
using when the Finisher jam occurred.
Go to the RAP for the fault code. (03-828) (03-829)

(Handle 3) and check the location of the jammed sheet.
The sheet is located under area 3A and pulls out easily. (If the sheet is held firmly by
the rolls in the Fuser, answer 'No'.)
Y
N
Check for a Fuser mis-strip by observing the position of the lead edge of the jammed
sheet.
The lead edge of the sheet extends beyond the Inverter Entrance Sensor.
Y
N
Examine both the position of the sheet in the machine and the position of the image
on the sheet. (Use the trail edge of the sheet for the check, because the lead edge
could be twisted or damaged as a result of a partial mis-strip.)
Either the sheet or the image is significantly skewed.
Y
N
The sheet is mis-stripped by the Fuser Stripper Fingers. Clear the jam and
ensure the Stripper Finger Baffle is firmly closed and latched. Attempt to run
copies/prints.
A 10-101 fault occurs again.
Y
N
Run enough copies/prints to verify problem is corrected. Return to Service
Call Procedures.
Clear the jam. Ensure the Fuser/Inverter Drawer is fully seated. Install the interlock cheater.
Make one copy and observe the Prefuser Transport belts and the Fuser Jam Clearance Knob.
The Fuser Jam Clearance Knob was turning before the jam occurred.
Y
N
Ensure the Fuser Module is correctly installed on the Fuser/Inverter Drawer and the Fuser
Drive Gear, PL 7.1 Item 5, is fully meshed with the drive gear on the Fuser Drive Motor
when the drawer is fully seated.
Do the following:
Inspect the Drive Gear on the back of the Fuser Module PL 6.2A Item 1 for damage.

The PreFuser Transport belts were moving before the jam occurred.
Y
N
Ensure the Prefuser Transport (refer to the replacement procedure REP 10-1) is fully
seated. Attempt to make copies/prints.
The problem continues after reseating the Prefuser Transport.
Y
N
Pull out the Fuser/Inverter Drawer in order to check the PreFuser Transport (PFT) drive
gears.
The PFT gears are functional and they engage correctly.
Y
N
Replace the component(s) with the defective gear.

NOTE: After correcting the cause of the skew it may still be necessary to troubleshoot the 10-101 fault, but the skew problem must be solved first.
Prefuser Transport PL 6.1A Item 1.
Fuser Drive Motor PL 7.1 Item 3.
It is possible to install the Fuser Module incorrectly which causes the (PFT) to be pushed
up as the Fuser Module is pushed into the machine, resulting in disengagement of the
PFT drive gears. Pull out the Fuser/Inverter Drawer (Handle 3). Check the four corners of
the Fuser Module cover and ensure the cover is fully seated on the module. Reseat the
module on the drawer. Observe the PFT as you firmly push in the Fuser/Inverter Drawer.
In Component Control, select [IOT Paper Path], [Inverter Entrance Sensor], and [Monitor
Input]. Remove the jammed sheet of paper.
Inspect the Fuser Drive Gear PL 7.1 Item 5on the Fuser Drive Motor for damage.
The check of the drive gears is good.

Y
N
Replace the Fuser Drive Gear (part of the Fuser Drive Gear Kit PL 7.1 Item 15) and/
or the Fuser Module PL 6.2A Item 1.
Check the Pressure Roll Stripper Fingers for damage.

Replace the Fuser Module PL 6.2A Item 1if necessary.
A
V0.042
B
May 2003
2-415
10-101
B
The PFT gears remain engaged as the Fuser/Inverter Drawer is pushed in and
seated.
Y
N
If the problem continues, replace the Prefuser Transport PL 6.1A Item 1.
Attempt to run copies/prints to determine if reseating the Fuser Module corrected the
problem.
Y
N
C
C
The tests fail with an 03-812 code.
Y
N
10-101
May 2003
2-416
V0.042
10-105 Inverter Entrance Jam
NOTE: After correcting the cause of the skew it may still be necessary to troubleshoot
the 10-105 fault, but the skew problem must be solved first.
The trail edge of a sheet to be inverted arrived late at the Inverter Entrance Sensor (S4).
B
Clear the jammed sheet. Ensure the Stripper Finger Baffle is seated correctly. Make another
copy/print to determine if the problem is solved.
Y
N
Run enough copies to ensure the problem is corrected. If 10-105 faults occur again,
replace the Fuser Module PL 6.2A Item 1.
Initial Actions
Clean the Inverter Entrance Sensor and the Inverter Exit Sensor.
Ensure the Inverter Entrance Sensor PL 6.3 Item 6 and the Inverter Exit Sensor PL 6.3
Item 6 are mounted correctly. If the sensor cannot be seated correctly due to a broken
mount, replace the sensor.
If the problem continues after cleaning the sensors and ensuring the sensors are seated correctly, use this RAP.

(Handle 3), but do not clear the jam.
The sheet is misstripped by the Fuser Stripper Fingers.
Y
N
Check both the position of the jammed sheet in the Inverter and the position of the image
on the sheet. (Use the trail edge of the sheet for the checks, because the lead edge could
be twisted or damaged as a result of the jam.)
Y
N
Clear the jammed sheet. Check for obstructions in the Inverter which would prevent
normal paper movement.
An obstruction was found and removed.
Y
N
Check the Feed/Reverse Roll. The Feed/Reverse Roll shows evidence of
glazing.
Y
N
Do the following:
Check the link on the Reverse Drive Solenoid for damage.
Check the Inverter Entrance Gate PL 6.3 Item 12 for dislodged fingers.
Ensure the Feed/Reverse Roll Idler PL 6.3 Item 14 is not damaged or

missing, and is seated correctly.
Ensure the Idler Spring PL 6.3 Item 15 is not damaged or missing.
Check the Inverter Drive Gear PL 6.2C for damage.
Replace the Inverter PL 6.2A Item 2 if necessary.

Replace the Feed/Reverse Roll PL 6.3 Item 7 and the Inverter Exit Roll PL 6.3
Item 6.
If the problem continues, replace the Inverter PL 6.2A Item 2.
check the Inverter Entrance Gate for damage including dislodged fingers.
A
B
V0.042
May 2003
2-417
10-105
10-115 Inverter Exit Jam
The lead edge of an inverted sheet going to the Exit Baffle or Decurler arrived late at the
Inverter Exit Sensor (S5).
Do the following:
Initial Actions
If the 10-115 jams are intermittent, go to the 10-115 Intermittent Diagnostic Procedure.
occurred
NOTE: This fault can be caused by NVM corruption. If this RAP does not identify the cause of
this fault, then it may be necessary to reload the NVM from the MRD.
(Handle 3) and check both the position of the jammed sheet in the Inverter and the position of
the image on the sheet. (Use the trail edge of the sheet for the checks, because the lead edge
could be twisted or damaged as a result of the jam.)
Y
N
A 12-102 fault occurred when the 10-115 fault occurred.
Y
N
The tests fail with an 03-828 or 03-829 code.
Y
N
Check for obstructions in the Inverter which would prevent normal paper movement.
Y
N
Open Paper Trays 1 and 2. Check Area 3E for sheets of paper.
One or more sheets were found in area 3E.
Y
N
Do the following:
10-115
Check the Close Nip Link PL 6.3 Item 2 and the Reversing Baffle PL 6.3 Item 4 for damage.
Check the Inverter Entrance Gate PL 6.3 Item 13 for damage

and dislodged fingers.
Ensure the Feed/Reverse Roll Idler PL 6.3 Item 14 is not damaged or missing, and is seated correctly.
Ensure the Idler Spring PL 6.3 Item 15 is not damaged or missing.
Check the Inverter Drive Gear PL 6.2C for damage.
Ensure the Close Nip Solenoid Spring and the Reverse Drive
Solenoid Spring are not broken.
Clear the sheets from Area 3E. Run enough copies to ensure the problem
is corrected.
If the problem continues, do the following:
A
B
C
D
E
Replace the Inverter PL 6.2A Item 2 if necessary.
If the problem continues after performing the above actions, use this RAP.
The display indicates the state of the Inverter Exit Sensor

changed.
Y
N
Go to Flag 3. Check the circuit of the Inverter Exit Sensor PL 6.3
Item 6.
In Component Control, select [IOT Paper Path], [Inverter Exit

Sensor], and [Monitor Input]. Block and unblock the sensor with
a sheet of paper.
Ensure the Reverse Drive Solenoid Spring is not damaged or missing.
Check the Inverter Drive Assembly PL 6.3 Item 17. It should pivot
freely without binding.
Run enough copies to ensure the problem is corrected. If 10-115 faults occur
again, check the Duplex Gate PL 6.3 Item 12 for damage.
Go to the RAP for the fault code. (03-828) (03-829)
NOTE: After correcting the cause of the skew it may still be necessary to troubleshoot the 10115 fault, but the skew problem must be solved first.
10-115 Intermittent Diagnostic Procedure

NOTE: This procedure must be performed on site.
Do the following:
Check the Feed/Reverse Roll for glazing.
Check the number of copies since the Inverter or Feed/Reverse Roll has been replaced.
The Feed/Reverse Roll is glazed or the number of copies since the Inverter or Feed/
Reverse Roll has been replaced is greater than 2.5 million.
May 2003
2-418
V0.042
N
Load 65 lb. (175 gsm) or 110 lb. (200 gsm) paper (use the largest paper size available) in
Tray 1. When the Tray 1 information dialog box is displayed on the UI, select [Change
Description]. Ensure the Stock Type is set to [Heavyweight]. Select [Save], then select
[Confirm].
Program a job with the following attributes:
2 - 2 Sided
Finisher top Tray
50 copies
A 10-115 fault occurs.

Y
N
Do the following:
Slide the Fuser/Inverter Drawer to the jam clearance position.
Check the position of both Duplex Guides (Figure 2). The Top edge of the
Duplex Guides should not be visible.
The both Duplex Guides are in the correct position

Y
N
Ensure both Duplex Guides are installed correctly. Refer to Figure 3.
Go to Flag 3. Check the circuit of the Inverter Exit Sensor PL 6.3 Item 6 for an intermittent condition.
Perform ADJ 10-1, Inverter Reverse Roll Nip.
Replace the Feed/Reverse Roll PL 6.3 Item 7.
V0.042
May 2003
2-419
10-115
10-115
May 2003
2-420
V0.042
Top edge of Rear

Duplex Guide
Top edge of Front

Duplex Guide
Figure 2 Checking the position of the Duplex Guides
V0.042
May 2003
2-421
10-115
1
Remove Paper Trays 1 through 4.
2
Remove the Paper Tray 2 Rail.
3
Reinstall the Paper Tray 2 Rail. Ensure
the top edge of the Duplex Guides are
under the metal inverter pan.
NOTE: If the top of the Duplex Guides
are not under the metal inverter pan,
paper extending downward from the
inverter will catch on the top of the
Duplex Guides,
Figure 3 Installing the Duplex Guides in the correct position
10-115
May 2003
2-422
V0.042
NOTE: After correcting the cause of the skew it may still be necessary to troubleshoot the
10-120 fault, but the skew problem must be corrected first.
The lead edge of a not inverted sheet arrived late at the Inverter Exit Sensor (S5).
B
Initial Actions
occurred

Y
N
Check both the position of the jammed sheet in the Inverter and the position of the image
on the sheet. (Use the trail edge of the sheet for the checks, because the lead edge could
be twisted or damaged as a result of the jam.)
Y
N
Clear the jammed sheet. Check for obstructions in the Inverter and in Area 3E (the
area below the Inverter) which would prevent normal paper movement.
Y
N
In Component Control, select [IOT Paper Path], [Inverter Exit Sensor], and
[Monitor Input]. Block and unblock the sensor with a sheet of paper.
The display indicates the state of the Inverter Exit Sensor changed.
Y
N
Go to Flag 1. Check the circuit of the Inverter Exit Sensor PL 6.3 Item 6.
Do the following:
Check the Inverter Exit Roll Idler and the spring for damage and correct
position.
Check the Inverter Entrance Gate PL 6.3 Item 13 for dislodged or damaged fingers, and damage to the main portion of the gate.
Replace the Inverter PL 6.2A Item 2, if necessary.

check the Inverter Entrance Gate PL 6.3 Item 13 for dislodged or broken fingers, or
damage to the main portion of the gate.
A
B
V0.042
May 2003
2-423
10-120
10-120
May 2003
2-424
V0.042

The trail edge of a non inverted sheet was not detected by the Inverter Exit Sensor (S5).
Initial Actions
Ensure the paper the customer is using meets specifications. Refer to the Product Specifications , Paper Specifications Table in General Procedures.
occurred.
Replace the Inverter Drive Gear PL 6.2C.

Do the following:
NOTE: Intermittent operation of the Transport Drive Motor and/or incorrect Nip 1/2 Drive Belt
tension in the Finisher may cause intermittent 10-125 and 10-126 faults.
Obstructions
Damaged lead-in baffle (black plastic)
Missing lead-in baffle
Remove the Upper Rear Cover and the Lower Rear Cover of the Finisher.
In Component Control, select [Finisher], [Transport Drive Motor], then [Output

On].
Observe the Transport Drive Motor . The Transport Drive Motor rotates.
Y
N
Go to the 12-AR Transport Drive Motor Checkout.

Check the jammed sheets for damage such as nicks, dings, or dog-ears. The
sheets are damaged.
Y
N
Check the jammed sheets for a skewed image.
The image is skewed.
Y
N
Check the exact location of the jammed sheet.
The lead edge of the sheet is in Area 5 or Area 5B of the Finisher.
Y
N
The lead edge of the sheet stopped in the Inverter.
Y
N
The sheet was entering the Duplex Transport.
Y
N
A Decurler is installed
Y
N
Check the Exit Baffle for the following:
D
Check the Inverter/Fuser Drive by rotating the Fuser Jam Clearance Knob and
observing the Inverter Drive gears.
The Inverter drive gears rotate.
Y
N
Pull out the Inverter/Fuser Drawer and check the Inverter Drive Gear.
The Inverter Drive Gear is damaged or worn
Y
N
jammed
Check the following items in the Finisher:
The Nip 1/2 Drive Belt PL 8.3 Item 10 for correct tension and damage.
The pulley on the Nip 1 Drive Shaft PL 8.4 Item 2 for damage.
The actuator for the Finisher Entrance Sensor PL 8.3 Item 15 for wear (See
Figure 1). Replace the sensor if the check indicated excessive wear.
Go to 08-C, Skewed Image RAP.

Go to OF-2 Print Damage RAP
Go to 10-A Decurler Checkout Procedure.

The Duplex Gate PL 6.3 Item 12 for binding or failure.
The gate solenoid for correct operation
The Outboard Gate Bushing PL 6.3 Item 19 and the Inboard Gate
Bushing PL 6.3 Item 20 on the Duplex Gate for damage or wear.

A
B
V0.042
May 2003
2-425
10-125

Measure the length of the sensor
actuator as shown. A length of less
than 13.5 mm is an indication of
excessive wear
The trail edge of an inverted sheet going to the output device was not detected by the Inverter
Exit Sensor (S5).
Initial Actions
NOTE: Intermittent operation of the Transport Drive Motor and/or incorrect Nip 1/2 Drive Belt
tension in the Finisher may cause intermittent 10-125 and 10-126 faults.
Figure 1 Checking the Finisher Entrance Sensor actuator.
Check the jammed sheets for damage such as nicks, dings, or dog-ears.
The jammed sheets are damaged.
Y
N
Check the jammed sheet for a skewed image.
Check the image on the jammed sheets. The image is skewed.
Y
N
Program a 1-2 sided job, 10 copies.
Y
N
Check the exact location of the jammed sheet.
The lead edge of the sheet is in Area 5 or Area 5B of the Finisher.
Y
N
Check the Inverter/Fuser Drive by rotating the Fuser Jam Clearance Knob
and observing the Inverter Drive gears.
The Inverter drive gears rotate.
Y
N
Pull out the Fuser/Inverter Drawer and check the Inverter Drive Gear.
The Inverter Drive Gear is damaged or worn.
Y
N
Replace the Inverter Drive Gear PL 6.2C.
A Decurler is installed
Y
N
Obstructions
The check of the Exit Baffle is good

Y
N
Replace the Exit Baffle PL 6.1A Item 6.
A
10-125, 10-126
May 2003
2-426
E
V0.042
E
Go to 10-A Decurler Checkout Procedure.
Do the following:
Remove the Upper Rear Cover and the Lower Rear Cover of the Finisher.
In Component Control, select [Finisher], [Transport Drive Motor], then

[Output On].

excessive wear

Y
N
Check the following in the Finisher:
The Nip 1/2 Drive Belt PL 8.3 Item 10 for correct tension and damage.
The pulley on the Nip 1 Drive Shaft PL 8.4 Item 2 for damage.
The actuator for the Finisher Entrance Sensor for wear (See Figure 1).
Replace the sensor if the check indicated excessive wear
The Inverter Exit Roll PL 6.3 Item 7 for glazing and cracking.
An obstruction between the Duplex Gate and Duplex Transport.
Replace the Inverter PL 6.2A Item 2, if required.

Go to OF-2, Print Damage RAP.
V0.042
May 2003
2-427
10-126

The trail edge of an inverted sheet going to the Duplex Transport was not detected by the
Inverter Exit Sensor.
10-127.98 = Simplex job.
10-127.99 = Side 2 of a duplex job.
C
Obstructions
The check of the Exit Baffle is good

Y
N
Initial Actions
An obstruction between the Duplex Gate PL 6.3 Item 12 and the Finisher.
The Outboard Gate Bushing PL 6.3 Item 19 and the Inboard Gate Bushing PL
6.3 Item 20 on the Duplex Gate for damage or wear.
Check the jammed sheets for damage such as nicks, dings, or dog-ears.
The jammed sheets are damaged.
Y
N
Check the image on the jammed sheets.
The image is skewed.
Y
N
Program a job with the following attributes:

Go to OF-2, Print Damage RAP
2-sided
Output to Finisher Main Tray
Quantity of 10
A 10-126 fault occurred.

Y
N
The lead edge of the sheet got past the Duplex Acceleration Roll (Duplex
Acceleration Nip). The Duplex Acceleration Roll is the first set of rolls in
the Duplex Transport.
Y
N
The sheet is jammed in the Decurler or Exit Baffle (an indication the
sheet was misdirected).
Y
N
Check the following in the Inverter:
The Inverter Exit Roll Idler for binding.
The Inverter Exit Roll for binding
Obstructions
The Duplex Gate PL 6.3 Item 12 for binding. Repair if necessary.
The Outboard Gate Bushing PL 6.3 Item 19 and the Inboard Gate
Bushing PL 6.3 Item 20 on the Duplex Gate for binding.

Check the Duplex Transport for obstructions and drive to the Duplex Acceleration Rolls.
Replace the Duplex Transport PL 6.1A Item 2, if required.
A
B
C
10-127
May 2003
2-428
V0.042
10-130 Inverter Jam
10-300 Fuser Thermistor Circuit Open
The lead edge of a sheet to be inverted arrived early at the Inverter Exit Sensor (S5).
Software received a value of less than 5 from the Thermistor, which indicates the circuit is
open.
10-130.98 = Simplex job.
10-130.99 = Side 2 of a duplex job.
Procedure
If the customer has not already done so, PO/PO and reseat the electrical connections of the
Fuser Module.
The occurrence of this fault normally means the Inverter Entrance Gate failed to divert the
paper into the Inverter.
Switch the power Off.
Pull out the Fuser/Inverter Drawer (Handle 3).
Check for obstructions in the Inverter which would prevent movement of the Inverter
Entrance Gate.
Firmly push in the Fuser/Inverter Drawer.
Switch the power On.
Ensure the Inverter Exit Sensor is seated correctly in its mounting holes.
If there are no obstructions, and the sensor is seated correctly, replace the Inverter PL
6.2A Item 2.

Y
N
Carefully inspect the physical condition of the DC Drawer Connector, PL 1.6 Item 6, and
the Fuser Module DC Connector PL 6.2B Item 3.
The DC Drawer Connector and/or the Fuser Module DC Connector is damaged.
Y
N
Replace the DC Drawer Connector PL 1.6 Item 6 and/or the Fuser Module DC Connector,
PL 6.2B Item 3.
If the customer has not already done so, replace the Fuser Module PL 6.2A Item 1.
Go to GP42 CSE Fuser Rebuild/Return Process, before replacing the Fuser Module.
Y
N
Do the following:
Reinstall the original Fuser Module if it was replaced with a different one for troubleshooting.
Switch the power Off
Disconnect P26 PWB from the SCAM J2.
Measure the resistance of the thermistor circuit between P26-1 and P26-2 (Flag 1).
The resistance is between 1K Ohms (thermistor hot) and 20K Ohms (thermistor cold).
Y
N
Go to Flag 1 and check the wiring of the FUSER TEMP signal and the FUSER REF signal
for an open circuit (greater than 20K ohms) or a short circuit (less than 1K ohms). Carefully inspect the physical condition of both halves of the Fuser Module DC Drawer Connector, PL 1.6 Item 6, and replace if necessary.
V0.042
May 2003
2-429
10-130, 10-300
10-300
May 2003
2-430
V0.042
10-301 Fuser Failed To Warm Up

The Fuser temperature is not increasing, or is not increasing fast enough, at start up of the
control system.
B
Y
N

Switch the power Off. Pull out the Fuser/Inverter Drawer (Handle 3). Check the contacts of the
AC Drawer Connector on the machine frame and on the Fuser Module for dirt and/or evidence
of arcing.
The contacts are OK.
Y
N
Replace the AC Drawer Connector PL 1.6 Item 5 and/or the Fuser Module PL 6.2A Item
1, as appropriate.
Measure the resistance of the Fuser Heat Lamp by measuring across the outside terminals of
the AC Connector.
The resistance is less than 10 ohms.
Y
N
Reinstall the Fuser Module, and firmly seat the Fuser/Inverter Drawer. Switch the power On
and install the Interlock Cheater. Visually check for Fuser Heat Lamp operation.
The lamp is on (steady, not pulsating).
Y
N
Check the [Last 40 Faults] for instances of 03-340, 03-809 and/or 10-303 faults. Enter
[Faults/Counters tab , Faults].
03-340 and/or 03-809 faults are logged.
Y
N
Y
N
Measure the continuity between P1-7and P1-8 on the Fuser Module connector.
Continuity is measured between P1-7 and P1-8.
Y
N
Go to GP42 CSE Fuser Rebuild/Return Process, before replacing the
Fuser Module.
Connect the meter leads from TH24 to TH27 on the SCAM PWB.
Monitor the voltage for 4 minutes.
The voltage goes to +5 VDC after 4 minutes (indicating the correct SCAM
PWB control signal for the Fuser SSR)
Y
N
If the wires are good, replace the SCAM PWB PL 1.5 Item 6.
Go to the 10-303 On-Site Diagnostic Procedure.
A
B
V0.042
Wait for the machine to warm up and come to Ready, or declare the fault again.
10-301 is declared again.
Y
N
The problem was solved by the PO/PO and/or reseating the Fuser Module. Return to Service Call Procedures.
Check the AC line voltage with the machine switched on.
The voltage is greater than the minimum allowable voltage for the market region.
(Refer to the Product Specifications for specific voltages.)
Y
N
Inform the customer the line voltage is too low.
Select [NVM] [NVM Tool] [Mark Service] [F2IOT] or [F1IOT]. Check the Fuser NVM values in
locations 502 through 521, and locations 546 through 548. Enter [NVM tab , NVM Tool].
NOTE: Select [F2IOT] for 55 PPM and 65 PPM machines, or [F1IOT] for 40 PPM machines.
The Current Value is the same as the Nominal Value for each location.
Y
N
Reset the value(s) to the correct number using [NVM tab , NVM Tool].
Exit Diagnostics for the NVM changes to take effect.
Y
N
Switch the power Off, wait 10 seconds, then switch the power On in order to reset the
control logic.
Y
N
10-301 On-Site Diagnostic Procedure (XE)

Switch the power Off. Pull out the Fuser/Inverter Drawer (Handle 3). Check the contacts of the
AC Drawer Connector on the machine frame and on the Fuser Module for dirt and/or evidence
of arcing.
The contacts are OK.
Y
N
Replace the AC Drawer Connector PL 1.6 Item 5 and/or the Fuser Module PL 6.2A Item
1, as appropriate.
C
May 2003
2-431
10-301
C
Measure the resistance of the Fuser Heat Lamp by measuring across the outside terminals of
the AC Connector.
The resistance is less than 10 ohms.
Y
N
Reinstall the Fuser Module, and firmly seat the Fuser/Inverter Drawer. Switch the power On
and install the Interlock Cheater. Visually check for Fuser Heat Lamp operation.
The lamp is on (steady, not pulsating).
Y
N
Check the [Last 40 Faults] for instances of 03-340, 03-809 and/or 10-303 faults. Enter
[Faults/Counters tab , Faults].
03-340 and/or 03-809 faults are logged.
Y
N
Y
N
Check the IOT Change Tag Matrix.
TAG 105, Flicker Control, is installed.
Y
N
Measure the continuity between P1-7and P1-8 on the Fuser Module connector.
Y
N
The voltage goes to +5 VDC after 4 minutes (indicating the correct
SCAM PWB control signal for the Fuser SSR)
Y
N
Go to Flag 2 on Figure 3. Check the wires for an open circuit.
Do the following:
Disconnect P27 from J7 on the SCAM PWB.
Switch the power [OFF]. Reconnect P27 to the SCAM PWB and switch the
power [ON]. Measure the voltage between TH53 and TH13 on the SCAM
PWB
10-301
F
The voltage measured is +5 VDC.
Y
N
Switch the power [OFF] and disconnect the Power Cord. Go to Flag 2 on
Figure 2. Check the Flicker Control DC Harness PL 1.2A Item 12 for an
If the harness is good, replace the Flicker Control PWB PL 1.2A Item 11.
Replace the Flicker Control PWB PL 1.2A Item 11.
Go to the 10-303 On-Site Diagnostic Procedure (XE).

Y
N
Wait for the machine to warm up and come to Ready, or declare the fault again.
Y
N
The problem was solved by the PO/PO and/or reseating the Fuser Module. Return to Service Call Procedures.
Check the AC line voltage with the machine switched on.
The voltage is greater than the minimum allowable voltage for the market region.
(Refer to the Product Specifications for specific voltages.)
Y
N
Inform the customer the line voltage is too low.
Select [NVM] [NVM Tool] [Mark Service] [F2IOT] or [F1IOT]. Check the Fuser NVM values in
locations 502 through 521, and locations 546 through 548. Enter [NVM tab , NVM Tool].
NOTE: Select [F2IOT] for 55 PPM and 65 PPM machines, or [F1IOT] for 40 PPM machines.
Switch the power Off, wait 10 seconds, then switch the power On in order to reset the
control logic.
Y
N
Measure the voltage between TH53 and TH13. The voltage measured is +5
VDC.
Y
N
D
E
F
Y
N
Y
N
The LVPS Cooling Fan is operating.

Y
N

May 2003
2-432
V0.042
Figure 1 10-301 RAP Circuit Diagram (60Hz)
V0.042
May 2003
2-433
10-301
Figure 2 10-301 RAP Circuit Diagram (50 Hz W/Tag 105)
10-301
May 2003
2-434
V0.042
Figure 3 10-301 RAP Circuit Diagram (50 Hz W/O Tag 105)
V0.042
May 2003
2-435
10-301
TH13
TH53
TH24
Figure 4 SCAM PWB Tag 108
10-301
May 2003
2-436
V0.042
AC Connector
Figure 6 Fuser Module AC Connector
P1-8
P1-7
P1-1
P1-3
Figure 5 Fuser Module DC Connector
V0.042
May 2003
2-437
10-301
10-302 Fuser Undertemperature Fault

This fault code occurs if the Fuser temperature drops to an under temperature condition after
having been at ready temperature. If the fault occurs during a run, the IOT will cycle out. If the
fault occurs while the machine is in standby, the machine will be inhibited from starting. Normally, the Fuser temperature control circuitry will bring the Fuser back to correct temperature
and operation can be resumed. If the Fuser control circuit does not bring the Fuser temperature up to operating temperature, a 10-301, Failure to Warm-up Fault will be declared.
Procedure
Check the following items as possible causes of the fault.
Damaged or dirty Fuser AC Connector (which causes a reduction of the actual AC voltage
applied to the fuser heat rod).
Low AC line voltage with the machine running.
High moisture paper (which takes more heat out of the fuser than dry paper).
The machine may be operating in a cold environment. The minimum ambient temperature
for reliable machine operation is 50 F / 10 C.
Select [NVM] [NVM Tool] [Mark Service] [F2IOT] or [F1IOT]. Check the Fuser NVM values
in locations 502 through 521, and locations 546 through 548. Enter [NVM tab , NVM Tool].
NOTE: Select [F2IOT] for 55 PPM and 65 PPM machines, or [F1IOT] for 40 PPM
machines.
The Current Value should be the same as the Nominal Value for each location. If necessary, reset the value(s) to the correct number.
The Fuser Module may be defective. If necessary, replace the Fuser Module PL 6.2A Item
1.
10-302
May 2003
2-438
V0.042
10-303 Fuser Overtemperature Fault
N
The Control Logic has detected the Fuser has reached the overtemperature limit.
The voltage goes to +5 VDC after 4 minutes (indicating the correct SCAM PWB control signal for the Fuser SSR)
Y
N

Switch the power Off, then unplug the Power Cord from the wall outlet.

Y
N
Go to the appropriate 03-xxx RAP.
10-303 On-Site Diagnostic Procedure (XE)
Inform the customer the AC input power is not in specification. DO NOT connect the
power cord to the wall outlet until the problem is corrected.
Replace the AC Distribution Panel PL 1.2A Item 1. The over-voltage condition damaged components within the AC Distribution Panel.
Replace the Fuser Module PL 6.2A Item 1. The over-voltage condition significantly
shortened the life of the Fuser.

Switch the power Off, then unplug the Power Cord from the wall outlet.

Y
N
Do the following:
Ensure the machine power still switched [Off].
Check the DC Drawer Connector, PL 1.6 Item 6, and the Fuser Module DC Connector PL
6.2B Item 3, for damage.
Inform the customer the AC input power is not in specification. DO NOT connect the
power cord to the wall outlet until the problem is corrected.
Replace the AC Distribution Panel PL 1.2A Item 1. The over-voltage condition damaged components within the AC Distribution Panel.
Replace the Fuser Module PL 6.2A Item 1. The over-voltage condition significantly
shortened the life of the Fuser.
The DC Drawer Connector and the Fuser Module DC Connector are free from damage.
Y
N
Replace the DC Drawer Connector, PL 1.6 Item 6, and/or the Fuser Module DC Connector PL 6.2B Item 3.
Firmly push in the Fuser/Inverter Drawer. Switch the power On.
The tests fail with an 03-xxx code.
Y
N
Y
N
Y
N
Measure the continuity between P1-7 and P1-8 on the Fuser Module.
A
V0.042
Do the following:
Ensure the machine power still switched [Off].
Check the DC Drawer Connector, PL 1.6 Item 6, and the Fuser Module DC Connector PL
6.2B Item 3, for damage.
The DC Drawer Connector and the Fuser Module DC Connector are free from damage.
Y
N
Replace the DC Drawer Connector, PL 1.6 Item 6, and/or the Fuser Module DC Connector PL 6.2B Item 3.
Firmly push in the Fuser/Inverter Drawer. Switch the power On.
The tests fail with an 03-xxx code.
Y
N
B
May 2003
2-439
10-303
B
Y
N
Y
N
Check the IOT Change Tag Matrix.

TAG 105, Flicker Control, is installed.
Y
N
Measure the continuity between P1-7 and P1-8 on the Fuser Module.
Y
N
The voltage goes to +5 VDC after 4 minutes (indicating the correct SCAM PWB
control signal for the Fuser SSR)
Y
N
Go to Flag 2 on Figure 3. Check the wires for a short circuit.
The LVPS Cooling Fan is operating.
Y
N
Monitor the voltage for 5 minutes. The voltage drops to less than +2.5 VDC (indicating the correct SCAM PWB control signal for the Flicker Control PWB)
Y
N
Replace the Flicker Control PWB PL 1.2A Item 11.
Go to the appropriate 03-xxx RAP.
10-303
May 2003
2-440
V0.042
Figure 1 10-303 RAP Circuit Diagram (60Hz)
V0.042
May 2003
2-441
10-303
Figure 2 10-303 Circuit Diagram (50 Hz W/Tag 105)
10-303
May 2003
2-442
V0.042
Figure 3 10-303 Circuit Diagram (50 Hz W/O Tag 105)
V0.042
May 2003
2-443
10-303
TH13
TH53
TH24
TH27
Figure 4 SCAM PWB Tag 108
10-303
May 2003
2-444
V0.042
10-350 Fuser Module Connector Open

The Main Control PWB detected an invalid reading from the Fuser Thermistor, and also could
not communicate with the Fuser CRUM with all other IOT interlocks closed.

Pull out the Fuser/Inverter Drawer (Handle 3), then firmly slide it back in place.
The message Pull out the Fuser Module, then firmly push it back in is displayed on the
User Interface.
Y
N
Check the [Last 40 Faults] for any 09-350 faults. Enter [Faults/Counters tab , Faults].
Y
N
If the problem continues, check for the following causes:
The DC Drawer Connector, PL 1.6 Item 6, may be damaged and not mating correctly.
The Fuser Module DC Connector PL 6.2B Item 3, may be damaged and not mating
correctly.
The Fuser Module may not be seated correctly on the Inverter.
The Inverter may not be fully seated when pushed in.
An open circuit at Flag 1.
Go to the 03-B RAP.
P1-8
P1-7
P1-1
P1-3
Figure 5 Fuser Module Connector
V0.042
May 2003
2-445
10-303, 10-350
Figure 1 10-350 Circuit Diagram
10-350
May 2003
2-446
V0.042
10-351 Invalid Fuser Module Count

Software detects the Print Count exceeds the Maximum Print Volume and/or the Fuser Web
Usage exceeds the Maximum Fuser Web Usage.
Procedure
V0.042
May 2003
2-447
10-351
10-352 Wrong Fuser Module Fault
10-353 Incorrect Fuser Module Configuration
An inappropriate Fuser Module is detected in the machine.
Fault Code, 10-353, indicates the Fuser Module was previously initialized on a machine of a
different configuration. Either the Fuser Module was initialized on a DC/ST and then installed in
a LP/Docutech 65 or it was initialized on a LP/Docutech 65 and then installed on a DC/ST.

A new Fuser Module has just been installed.
Y
N
Pull out the Fuser/Inverter Drawer (Handle 3), then firmly slide it back in place.
The fault is now resolved.
Y
N
Procedure
No action needs to be taken for this fault code.

Machine configuration may be set-up incorrectly or the wrong Fuser Module was installed.
Do the following:
In Diagnostic Navigator, select the [Configuration] tab. Select [System, Imaging, and IOT
Configuration], then select the [System] tab. Ensure the Market Region is correct for this
machine.
Ensure the correct Fuser Module part number was installed for the machine market
region and service plan (sold, non-sold). Refer to PL 6.2A Item 1 for the correct Fuser
Module part numbers.
10-352, 10-353
May 2003
2-448
V0.042
10-354 No Fuser Module CRUM Fault

A Fuser Module has been detected in the machine but there is no communication with the
Fuser CRUM.

In [Faults/Counters tab , Faults], check for 09-354 faults.
An 09-354 fault occurred when the 10-354 fault occurred.
Y
N
Reseat the Fuser Module by pulling out the Fuser/Inverter Drawer and pushing it back in
firmly.
Y
N
A new Fuser Module was just installed.
Y
N
Go to Flag 1. Check the wires for an open circuit. If OK, replace the Fuser Module
PL 6.2A Item 1.
The old Fuser Module was replaced for 10-354 faults.
Y
N
Replace the Fuser Module PL 6.2A Item 1 (the one just installed was defective).
Do the following:
Ensure the DC Drawer Connector PL 1.6 Item 6, is not damaged and is mating correctly.
Ensure the Fuser Module DC Connector PL 6.2B Item 3, is not damaged and is mating correctly.
Ensure the Fuser Module is seated correctly on the Fuser/Inverter Drawer, and the
drawer is fully seated in the machine.
Check for an open circuit at Flag 1. If the wiring is OK, replace the Distribution PWB
PL 1.5 Item 7.
The DADF may not be grounded correctly. Go to GP44 DADF Ground Checkout.
If the DADF is grounded correctly, check all the connectors on the Distribution PWB. Ensure
they are seated correctly and there are no loose pins or damage. If the connectors are good,
replace the Distribution PWB PL 1.5 Item 7.
V0.042
May 2003
2-449
10-354
10-354
May 2003
2-450
V0.042
10-355 No Fuser Module CRUM Fault

The Service Plan is set to Other and software cannot communicate with the Fuser CRUM.
NOTE: If the service plan is set to Other and a competitive CRU is used in the machine, an
Enabling Kit must be installed in the machine. This kit adds an In-Line CRUM harness to the
machine wiring harness to enable the use of competitive CRUs.

This fault is declared when the service plan is set to Other and the software cannot communicate with the Fuser CRUM.
If the Fuser Module is manufactured by Xerox, the CRUM is internal to the Fuser Module.
If the Fuser Module is of competitive manufacture, it does not have an internal CRUM.
When a competitive CRU is used, the machine must have an In-Line CRUM Bypass Harness installed, which is an in-line wiring harness with two CRUM chips: one for the Xerographic Module and the other for the Fuser Module.
Check for the installation of the In-Line CRUM Harness (See Figure 1 for the location of the
harness).
The In-Line CRUM Bypass Harness is installed.
Y
N
Install the CRUM Enablement Kit PL 1.2A Item 10.
Replace the CRUM Enablement Kit PL 1.2A Item 10.
Fuser Drive Motor
P60/
CRUM Bypass Harness
Figure 1 In-Line CRUM Bypass Harness.
V0.042
May 2003
2-451
10-355
10-357/358 Decurler Configuration Mismatch

For information on the operation of the TAG 279 Exit Decurler, select More Information.
Automatic configuration has detected the wrong Decurler configuration in a Document Centre
460/470 equipped with a Disk Finisher or with a Multi-Function Finisher (MFF).
NOTE: This fault will be declared on machines with software version 07.19.04.03x or above.
The following message is displayed on the User Interface:
Not Ready - Configuration Mismatch exists.
Automatic Configuration detected an unrecoverable hardware problem.
Procedure
Ensure that the correct Decurler (TAG 279) is installed in the machine. Refer to PL 6.1D for the
correct Decurler part number.
The correct Decurler is installed
Y
N
Install the TAG 279 Decurler PL 6.1D.
Do the following:
Select [NVM] [NVM Tool] [Mark Service] [<All>]. Check the value in location 529 Exit
Decurler Config Type. Enter [NVM tab , NVM Tool].
Using [NVM tab , NVM Tool], Ensure the NVM value in location 529 is set to one of the following:
2 if a New Decurler is installed.
0 if no Decurler is installed
10-357/358
May 2003
2-452
V0.042
10-705 Enabled Decurler Home Fault
10-706 Exit Decurler Fault
The Enabled Decurler rolls did not separate within 650 ms after the control logic generated the
'Decurler Home' signal.
For information on the operation of the Exit Decurler (TAG 279), select More Information.
The Decurler does not match the expected configuration or is malfunctioning.
NOTE: With Tag 022, the Decurler is disconnected, and it is expected the fault logs will be full
of 10-705 faults. If the machine being serviced has Tag 022 (the Decurler is disconnected),
ignore 10-705 faults because they will constantly occur with the Decurler disconnected.
Automatic configuration has detected an incorrect Decurler configuration.

One of the following messages are displayed on the User Interface:
Check the Decurler electrical and mechanical connections. The Decurler is plugged in.
Y
N
Connect the Decurler. Make copies/prints to ensure the problem is corrected. Return to
Service Call Procedures.
The tests fail with an 03-835 fault code.
Y
N
Remove the Rear Cover in order to observe the Decurler/OCT Drive Bracket and related
mechanical parts. In Component Control, select [IOT Paper Path], [Fuser Drive Motor],
and [Output On]. Enter [Copier Sys tab , Component Control].
The Decurler Drive Belt and the clutch and gears on the Decurler/OCT Drive
Bracket are turning.
Y
N
Exit Component Control. Switch the machine power Off. Isolate the problem to one
of the following parts:
Check the Decurler Drive Belt for damage, wear, correct tension and routing.
Check the Decurler/OCT Drive Bracket for damage and one-way clutch operation.
Check the Fuser Drive Motor for damaged gears or the pulley that drives the
Decurler Drive Belt, and for correct operation of the Decurler Drive Belt Idler.
A one-way clutch transmits the drive through the Decurler/OCT Bracket. Observe the
gear at the back of the bracket which transmits the drive to the Decurler Clutch.
The Decurler Clutch is receiving drive from the Decurler/OCT Drive Gear.
Y
N
Exit Component Control. Replace the Decurler/OCT Drive Bracket PL 7.1 Item 4.
Replace the Decurler PL 6.1A Item 4.

or
Printer Fault - Please call for assistance

An Exit Decurler is installed.
Y
N
Select [NVM] [NVM Tool] [Mark Service] [<All>]. Ensure the value in location 529, Exit
Decurler Config Type, is set to 0. Enter [NVM tab , NVM Tool].
Check the Decurler Configuration.
The Decurler configuration is valid for the output device installed. Refer to Table 1.
Y
N
Ensure a valid Decurler is installed.
Select [NVM] [NVM Tool] [Mark Service] [<All>]. Check the value in location 529 Exit Decurler
Config Type. Refer to Table 1. Enter [NVM tab , NVM Tool].
The NVM value is correct for the Decurler configuration installed.
Y
N
In NVM Tool enter the correct NVM value in location 529.
In Component Control, select [IOT Paper Path], [Decurler cam Motor/ Clutch], then [CycleOutput].
Observe the Decurler Cam Drive Motor. The Decurler Cam Drive Motor energizes in Component Control.
Y
N
Switch the power [Off] and undock the Finisher.
Go to Flag 4. Check the circuit of the Decurler Cam Drive Motor for an open circuit.
Decurler PL 6.1D.
Switch the power [Off] and undock the Finisher.

Check the following on the Decurler:
The drive gear on the Decurler Cam Drive Motor for damage.
The Decurler Cam Drive Belt for damage.
The Decurler cam drive components are free from damage:

Y
N
Replace the Decurler Cam Drive Motor, or the Decurler, PL 6.1D, as required.
A
V0.042
May 2003
2-453
10-705, 10-706
A
Check the position of the Decurler Position Sensor.
The sensor is in the correct position.
Y
N
Reseat the Decurler Position Sensor in the correct position.
If the sensor cannot be reseated due to a broken mount, replace the Decurler Position
Sensor PL 6.1D.
In Component Control, select [IOT Paper Path], [Decurler Position Sensor], then [Monitor
Input].
The display indicates the state of the sensor changed.
Y
N
Go to Flag 3. Check the circuit of the Decurler Position Sensor for a short circuit or an
open circuit.
Decurler Position Sensor PL 6.1D.
Decurler PL 6.1D.
Check the position of the Decurler Home Sensor.

The sensor is in the correct position.
Y
N
Reseat the Decurler Home Sensor in the correct position.
If the sensor cannot be reseated due to a broken mount, replace the Decurler Home Sensor.
Go to Flag 1. Check the circuit of the Decurler Home Sensor for a short circuit or an open circuit.
Decurler Home Sensor PL 6.1D.
Decurler PL 6.1D.
10-706
May 2003
2-454
V0.042
V0.042
May 2003
2-455
10-706
Decurler Cam Drive Motor
P5
P4
Decurler Home Sensor
P3
Decurler Cam Drive Belt
Decurler Position
Sensor
Decurler Gate
Solenoid
10-706
May 2003
2-456
P137
V0.042
Figure 2 Decurler Component Locations

Table 1 Decurler Configurations and NVM Values
Decurler/Exit Baffle
Configuration
Value in Mark
Service Location 529 Valid with the following Output Devices
Exit Baffle with shunt

0
New Decurler (TAG 279) 2
Multi-Function Finisher
Exit Baffle with shunt

0
New Decurler (TAG 279) 2
Disk Finisher
Disk Finisher
Old Decurler
Offsetting Catch Tray
V0.042
May 2003
2-457
10-706
10-720 Duplex TEER Communication Fault

The Main Control PWB cannot communicate with the Duplex TEER Sensor.
Software will use the default value for duplex top edge registration until communication is
restored with the TEER Sensor.
NOTE: Ignore these faults unless you have a problem with top edge registration.
This procedure must be performed On-Site.

In Faults, select [Last 40 Faults]. Note all 03-312, 03-313, and 03-314 faults that are listed in
the Last 40 Faults and occurred approximately the same time. Enter [Faults/Counters tab ,
Faults].
03-312, 03-313, or 03-314 faults occurred when the 10-720 fault occurred
Y
N
Switch the power [Off] and remove the Xerographic Module to gain access to P/
J116.
Ensure the connector P/J116 is connected securely.
Reinstall the Xerographic Module.
Ensure all machine covers are in place and the Front Door is closed.
Switch the power [On]
10-720 faults still occur with the harness connected securely.

Y
N
Go to Flag 2 and Flag 6 (For Document Centre 460/470, go to Flag 2 and Flag 6 on Figure 2). Check the wires for an open circuit going to the Duplex TEER PWB.
If the wires are good, replace the Duplex Transport PL 6.1A Item 2.
Do the following:
Switch the power [Off]
Ensure P/J 4 on the Distribution PWB is connected securely.
10-720, 03-312, 03-313, and 03-314 faults occur after reseating the connector.
Y
N
Go to the 03-A Common SCB Circuit RAP.
10-720
May 2003
2-458
V0.042
V0.042
May 2003
2-459
10-720
Figure 2 RAP Circuit Diagram 460/470
10-720
May 2003
2-460
V0.042
10-722 / 724 / 726 / 730 / 732 Duplex TEER Calibration

Failure
10-722: The TEER Sensor LEDs did not illuminate, or the TEER Sensor photosensors did
not sense light during the TEER calibration.
10-724: Indicates the TEER Sensor sensed light when the LEDs were off.
10-726: During calibration, the center LED in the TEER Sensor is switched on and the
photosensors are 'read' to determine the electrical 'center' of the photosensor array. This
failure indicates the 'center' of the photosensor array is too far out of range for TEER Sensor to be reliable.
10-730: Excess transitions have been seen or the LED(s) have reached maximum intensity during calibration, indicating the TEER sensor is dirty.
N
Replace the Duplex TEER PWB Kit PL 6.1B Item 20. In TEER Diagnostics, select [Group 1
Tests], [Communications Test], TEER unit [Duplex], then [Start]. Enter [Paper tab, TEER Diagnostic]
Check the test results window 10-722, 10-724, 10-726, 10-730, or 10-732 faults were
declared.
Y
N
NOTE: This fault will not cause the software to use default readings. The readings taken
by the TEER Sensor will be used.
10-732: Reset fault. Indicates the TEER Sensor has failed or there was a static charge
build-up.
Software will use the default value for duplex top edge registration until there is a successful
calibration of the Duplex TEER Sensor.
This procedure must be performed On-Site.
10-722/724/726/730/732 On-Site Diagnostic Procedure

Do the following
Ensure the Duplex TEER Sensor is not blocked by a piece of paper or other object.
Ensure all machine covers are in place and the Front Door is closed.
Switch the power [Off] then switch the power [On] (upon power up the Duplex TEER Sensor will attempt to calibrate).
In TEER Diagnostics, select [Group 1 Tests], [Communications Test], TEER unit [Duplex], then
[Start]. Enter [Paper tab, TEER Diagnostic].
Check the test results window. 10-722, 10-724, 10-726, 10-730, or 10-732 faults were
declared.
Y
N
Clean the TEER Sensors and LEDs. In TEER Diagnostics, select [Group 1 Tests], [Communications Test], TEER unit [Duplex], then [Start]. Enter [Paper tab, TEER Diagnostic].
NOTE: The Duplex TEER Sensor can be easily cleaned with a cotton swab inserted into the
access hole at front left side of Duplex Transport.
Check the test results window. 10-722, 10-724, 10-726, 10-730, or 10-732 faults were
declared.
V0.042
May 2003
2-461
10-722 / 724 / 726 / 730 / 732
10-728 / 734 Duplex TEER Faults During Read
10-A Decurler Checkout Procedure
Initial Actions
Software reads the TEER Sensor output for each duplex sheet. A 10-728 or 10-734 fault is
declared when the output of the TEER Sensor is not in the range of expected results (>9mm)
or paper is not present when reading is taken (Lead edge late to TEER sensor).
Software will use the default value for duplex top edge registration for each sheet associated
with this fault.
Excessive curl may cause 10-125, 10-126, and 12-113 jams. For machines equipped with a
TAG 279 Decurler, go to GP49 Exit Decurler to increase the amount of decurling.
Procedure
A TAG 279 Decurler is installed (460/470 only).
Y
N
Do the following:
Initial Actions
Remove the IOT Rear Cover.
Do the following:
Ensure there are no obstructions in the Deculer paper path and Finisher entrance.
Ensure the Paper Tray side guides are in the correct position.
Ensure the registration nip (handle #2) is correctly latched.
Turn over and reload the stack of paper in the tray the customer was using when the fault
occurred. If the problem continues, load fresh paper from a new ream in the tray the customer was using.
The Decurler Drive Belt moves while the Fuser Drives Test is running.
Y
N
Check the following components to determine why the belt is not moving.
Check the Decurler Drive Belt PL 7.1 Item 7 for damage, wear, correct tension
and routing.
Check the Decurler/OCT Drive Bracket PL 7.1 Item 4 for damage and one-way
clutch operation.
Check the Fuser Drive Motor PL 7.1 Item 3 for damaged gears or the pulley
that drives the Decurler Drive Belt, and for correct operation of the Decurler
Drive Belt Idler.
In Faults, select [Fault Counters] and/or [Last 40 Faults]. Note all 10-728, 10-734, and 08115.99 faults that are listed in the Fault Counters / Last 40 Faults and occurred approximately the same time.
NOTE: For duplex TEER systems using early versions of firmware, faults will not be
logged in [Last 40 Faults], This will be true for most 240/255/265/460/470 machines
(upgrades made starting March 2001 time frame). In these cases the [Fault Counters]
must be checked and used to determine if TEER faults have been and/or are occurring.
Remove, turn over, and reload the paper in the paper tray. Run copies/prints to determine
if the jams still occur.
The paper jams in the Decurler nip after flipping the paper or running different
paper
Y
N
The problem is paper related. Check the paper curl. If excessive, replace the paper
with a new ream that meets the specification and has not been opened.
Refer to Table 2 for action required.

Faults in Last 40
Replace the Decurler PL 6.1A.
Action
10-728 Only
10-734 Only
Go to the 08-115 Registration Transport Jam RAP.
10-734 and 08-115.99
Go to the 08-115 Registration Transport Jam RAP.
Do the following:
Remove the IOT Rear Cover.
Ensure there are no obstructions in the Deculer paper path and Finisher entrance.
The Decurler Drive Bracket rotates while the Fuser Drive Motor is running.
Y
N
Check the following components to determine why the belt is not moving.
Check the Decurler Drive Belt PL 7.1 for damage, wear, correct tension and routing.
Check the pulley on the Decurler Drive Bracket PL 7.1 for damage.
Check Fuser Drive Motor PL 7.1 Item 3 for damaged gears or the pulley that drives
the Decurler Drive Belt, and for correct operation of the Decurler Drive Belt Idler.
A
10-728 / 734, 10-A
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A
Check the drive gear on the Decurler Drive Bracket for damage.
The drive gear is free from damage.
Y
N
Replace the Decurler Drive Bracket PL 7.1.
In Component Control, select [IOT Paper Path], [Decurler Sol/ Clutch Reset], then [CycleOutput].
Observe the Decurler Gate Solenoid. The Decurler Gate Solenoid energizes in Component Control.
Y
N
Go to Flag 2. Check the circuit of the Decurler Gate Solenoid for an open circuit.
Switch the power [Off] and undock the Finisher. Manually actuate the Decurler Gate, moving it
between the upper position and the lower position.
The Decurler Gate moves between the upper position and the lower position freely without binding.
Y
N
If the Solenoid is the source of binding, replace the Decurler Gate Solenoid PL 6.1D.
If the solenoid is not binding, replace the Decurler PL 6.1D.
The Decurler is mounted correctly to the IOT Frame and the drive gear on the Decurler is
meshing correctly with the gear on the Decurler Drive Bracket.
Y
N
Ensure the Decurler is mounted correctly to the IOT Frame.
Replace the Decurler PL 6.1D.
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10-A
P5
P4
P3
Decurler Position
Sensor
Decurler Gate
Solenoid
P137
10-A
May 2003
2-464
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V0.042
May 2003
2-465
10-A

excessive wear
10-A
May 2003
2-466
V0.042
12-101.60 (12-101.00) LE Late to the OCT Tray Full Sensor

RAP
The lead edge of a sheet is late to the OCT Tray Full Sensor.
N
An 10-115 fault occurred when the 12-101.60 fault occurred.
Y
N
Go to the 10-120 Inverter Exit Jam RAP.
(11Jan2001)
Go to the 10-101 Fuser Exit Jam RAP.

If a 10-101, 10-115, or 10-120 fault is in the Last 40 Faults, note when it occurred. A 10-101,
10-115, or a 10-120 fault was declared when the 12-101.60 fault occurred.
Y
N
Run the [Paper tab , Fuser Drives Test].
The Fuser Drives Test passes.
Y
N
The Dual Decurler may not be installed correctly, or the Decurler setting may incorrect, causing the paper to be late to the OCT.
Do the following:
Switch the power [Off] and remove the Offsetting Catch Tray.
Ensure the connector for the Dual Decurler is plugged into the Decurler. Refer
to Figure 2.
Reinstall the Offsetting Catch Tray and Switch the power [On].
Enter Tools.
In Tools Screen 1, select System Settings, then select More.
In the System Settings 2 screen, select Relative Humidity Adjustment.
Ensure High Decurling is selected, then select Save.
Exit Tools.
Make copies and check for 12-101.60 faults. A 12-101.60 fault occurs.
Y
N
12-101 OCT Checkout Procedure

The lead edge of the sheet is jammed before the flag of the OCT Tray Full Sensor.
Y
N
The flag of the OCT Tray Full Sensor, is free from damage, and is free to block and
unblock the sensor.
Y
N
Replace the Offsetting Catch Tray Assembly PL 8.1 Item 1.
Go to Flag 1. Check the circuit of the OCT Tray Full Sensor.
Do the following:
Clear all paper from the Catch Tray, the Offsetting Catch Tray paper path, and the IOT
paper path.
The Offsetting Catch Tray Drive Rolls rotate when the Fuser Motor energizes.
Y
N
Observe the gears on the Decurler/OCT Drive Bracket.
The Decurler/OCT
Bracket is turning when the Fuser Drive Motor energizes.
Y
N
The Decurler Drive Belt PL 7.1 Item 7.
The Decurler/OCT Drive Bracket PL 7.1 Item 4
Drive
Inspect the OCT drives. Replace the Offsetting Catch Tray Assembly PL 8.1 Item 1, if
necessary.
Go to the 12-101 OCT Checkout Procedure

The Decurler setting may be incorrect, causing the paper to be late to the OCT.
Do the following:
Enter Tools.
The Offsetting Catch Tray Assembly Drive Rolls for contamination, wear, and damage.
The Offsetting Catch Tray Assembly Idlers for contamination, wear, damage, and correct
tension.
Exit Tools.
If any of the drive rolls are damaged or worn, or if the idlers are damaged, worn, or have the
incorrect tension, Replace the Offsetting Catch Tray Assembly PL 8.1 Item 1.
Make copies and check for 12-101.60 faults. A 12-101.60 fault occurs.
Y
N
Go to the 12-101 OCT Checkout Procedure.
An 10-101 fault occurred when the 12-101.60 fault occurred.
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12-101.60
Ensure the connector for

the Dual Decurler is
plugged in.
Figure 1 12-101.60 RAP Circuit Diagram
Figure 2 Checking the Decurler Connector
12-101.60
May 2003
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12-213.60 (12-213.00) OCT Offset Motor Fault RAP

The Control Logic senses the OCT Offset Sensor, failed to actuate within 500 ms after the OCT
Offset Motor, energized.

Check the area around the Offsetting Catch Tray for obstructions. There are obstructions at
the customer site that are blocking the Offsetting Catch Tray from moving freely.
Y
N
In IIOC Controller, select [IIOC Self Tests], [IOT], [Type 1], then [Start]. Enter [Self Tests
tab , IIOC Controller Tests].
Y
N
In IIOC Controller, select [IIOC Self Tests], [IOT], [Type 2], then [Start]. Enter [Self
Tests tab , IIOC Controller Tests].
Y
N
In Component Control, select [Finisher], [OCT Offset Motor], then [Output On].
B
Go to 03-841 IIOC Module W1A1 Failed The IIOC Controller Test
Do the following:
Remove the obstruction that is blocking the Offsetting Catch Tray.
Switch the power [Off], then switch the power [On] to reset the Control Logic.
NOTE: Leave the OCT Offset Motor energized in Component Control in order
to make the next check.
Observe the Offsetting Catch Tray when the OCT Offset Motor energizes.
The Catch Tray moves when the OCT Offset Motor energizes.
Y
N
The check of the wiring at Flag 2 is good.
Y
N
Replace the OCT IIOC Harness PL 8.1 Item 2.
Replace the OCT IIOC PWB PL 8.1 Item 3.
If the problem continues, Replace the Offsetting Catch Tray Assembly PL
8.1 Item 1.
Observe the movement of the Offsetting Catch Tray when the OCT Offset
Motor energizes. The Catch Tray offsets to the front position and to the
rear position at a constant rate of speed.
Y
N
The check of the wiring at Flag 1 is good.
Y
N
Replace the OCT IIOC Harness PL 8.1 Item 2.
Replace the OCT IIOC PWB PL 8.1 Item 3.
If the problem continues, replace the Offsetting Catch Tray Assembly PL 8.1
Item 1.
Go to 03-841 IIOC Module W1A1 Failed The IIOC Controller Test.
A
B
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May 2003
2-469
12-213.60
12-213.60
May 2003
2-470
V0.042
12-A OCT Fault Entry RAP
OCT Stacking Checkout
Use this RAP to identify Offsetting Catch Tray problems and the action to take if the problem
occurs.

The following is a table of Offsetting Catch Tray problems, an explanation of each problem, and
the action to take if the problem occurs. If an Offsetting Catch Tray fault code is displayed, Go
to the appropriate RAP for the fault code.
Ensure the mounting hook for the Offsetting Catch Tray is attached correctly to the IOT frame,
the Catch Tray is seated correctly on the Offsetting Catch Tray, and the Offsetting Catch Tray is
closed securely.
The problem of incorrect stacking in the Offsetting Catch Tray continues.
Y
N
Go to the 12-D OCT Stacking RAP.
OCT Jam Checkout
Table 1 OCT Problems
The sets of prints are not offset.
Go to the 12-C OCT No Offset RAP.
The prints or sets of prints are not stacking correctly in the Catch Tray.
Go to the OCT Stacking Checkout .
Ensure the mounting hook for the Offsetting Catch Tray is attached correctly to the IOT frame,
the Catch Tray is seated correctly on the Offsetting Catch Tray, and the Offsetting Catch Tray is
closed securely.
The problem of jams continues after ensuring the Offsetting Catch Tray Assembly and
the Catch Tray are installed correctly and closed securely.
Y
N
Prints are jamming in the Offsetting Catch Tray.

A 12-101.60 fault code may be declared.
Go to the OCT Jam Checkout.
Go to the 12-E OCT Jam RAP.
There is abnormal sound or vibration when the

Offsetting Catch Tray is operating.
Go to the 12-F OCT Noise RAP.
Problem
Action
There are streaks or smudges on the image. The Go to the 12-B OCT Print Damage RAP.
paper is nicked, dogeared, torn, or dinged.
The Catch Tray is full with no message on the UI Go to the 12-G OCT Tray Status RAP.
indicating the Catch Tray is full. The message on
the UI indicates the Catch Tray is full when the
Catch Tray is not full.
A static problem in the Offsetting Catch Tray may If you suspect static is causing a problem
cause one or more of the problems listed below: in the Offsetting Catch Tray, Go to 12-H
OCT Static Checkout.
False OCT Tray Full status messages.
Poor set registration.
Paper handling problems in the Offsetting

Catch Tray (prevalent in environments
where the relative humidity is equal to or
less than 25%).
A
Remove the source of the contamination.
12-B OCT Print Damage RAP

There are streaks or smudges on the image. The paper is nicked, dog eared, torn, or dinged.

Check each OCT Stacking Finger for damage The OCT Stacking Fingers are free from
damage.
Y
N
Replace the damaged OCT Stacking Finger PL 8.1 Item 9.
Check the Offsetting Catch Tray Drive Rolls, Idlers, and Corrugator Baffle for contamination.
There is contamination on the Drive Rolls, the Idlers, or the Corrugator Baffle.
Y
N
A
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2-471
12-A, 12-B
12-C OCT No Offset RAP
12-D OCT Stacking RAP
The sets of copies are not being offset in the Offsetting Catch Tray.
The copies or sets of copies are not stacking correctly in the Offsetting Catch Tray.
Initial Actions
(11Jan2001)
If the problem occurred immediately after installing the Offsetting Catch Tray, have the customer perform the following:
Initial Actions
Switch the power [Off].
Ensure that all packing material is removed from the Offsetting Catch Tray.
Check the air flow at the customer's site. Excessive air flow may cause poor stacking in the Offsetting Catch Tray.
Ensure the Offsetting Catch Tray connector is connected securely to P69 on the IOT.
If the problem occurred immediately after installing the Offsetting Catch Tray, have the customer perform the following:

Check for 12-213 OCT Offset Motor Faults. There is a 12-213 OCT Offset Motor Fault in
the Last 40 Faults.
Y
N
Finisher Module Type. The Finisher Module Type displayed for this machine is OCT.
Y
N
In the Diagnostic Navigator, select [Configuration] [System, Imaging, and IOT Configuration]. Ensure Finishing Devices , Output Device #1 is set to OCT then select
[OK].
Go to the 12-213.60 (12-213.00) OCT Offset Motor Fault RAP.
Procedure
Check for 12-213 OCT Offset Motor Faults. There is a 12-213 OCT Offset Motor Fault in
the Last 40 Faults.
Y
N
Go to the 12-J Output Device Configuration for Third Party Service. If the problem continues after configuring the output device, replace the Offsetting Catch Tray Assembly PL
8.1 Item 1.
Ensure that all packing material is removed from the Offsetting Catch Tray.
Ensure the Offsetting Catch Tray connector is connected securely to P69 on the IOT.
Ensure the mounting hook for the Offsetting Catch Tray is attached correctly to the IOT
frame, and the Catch Tray is seated correctly on the Offsetting Catch Tray.
Close the Offsetting Catch Tray securely and switch the power [On].

Check the surface of the Catch Tray. The surface of the Catch Tray is free from damage.
Y
N
Replace the OCT Tray PL 8.1 Item 8.
Check each OCT Stacking Finger. The OCT Stacking Fingers are installed and free from
damage.
Y
N
Replace the damaged or missing OCT Stacking Finger PL 8.1 Item 9.
Y
N
The Dual Decurler may not be installed correctly, or the Decurler setting may incorrect,
causing the paper to be late to the OCT.
Do the following:
Go to the 12-213.60 (12-213.00) OCT Offset Motor Fault RAP.
Ensure the connector for the Dual Decurler is plugged into the Decurler. Refer to Figure 2.
Enter Tools.
Exit Tools.
Make copies and observe the sheets as they are stacked in the Offsetting Catch Tray
The problem of poor stacking continues.
A
12-C, 12-D
May 2003
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V0.042
A
Y
N
Go to the 12-D OCT Checkout Procedure

Do the following:
Enter Tools.
Exit Tools.
Make copies and observe the sheets as they are stacked in the Offsetting Catch Tray The
problem of poor stacking continues.
Y
N
Go to the 12-D OCT Checkout Procedure
12-D OCT Checkout Procedure

Place 5 sheets of paper in the Document Feeder. Program a job for 5 sets, collated.
Observe the sheets as they are stacked in the Offsetting Catch Tray The trail edge of the
sheet entering the Offsetting Catch Tray is slow to settle on the stack of paper in the
tray.
Y
N
The Offsetting Catch Tray Assembly Drive Rolls for contamination.
The Offsetting Catch Tray Assembly Idlers for contamination.
There is contamination on the Drive Rolls or on the Idlers.

Y
N
The Offsetting Catch Tray Assembly Drive Rolls for damage.
The Offsetting Catch Tray Assembly Idlers for damage.

plugged in.
Replace the Offsetting Catch Tray Assembly PL 8.1 Item 1 if necessary.

Check the vertical surface (back wall) of the Offsetting Catch Tray Assembly. The
surface of the Offsetting Catch Tray is free from damage.
Y
N
vertical
Go to the 12-H OCT Static Checkout RAP.
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12-D
12-E OCT Jam RAP
Make copies and observe the sheets as they are stacked in the Offsetting Catch Tray
Y
N
(11Jan2001)
Initial Actions
Check the Offsetting Catch Tray Assembly paper path and the Catch Tray for obstructions.
Ensure the mounting hook for the Offsetting Catch Tray is attached correctly to the IOT
frame, the Catch Tray is seated correctly on the Offsetting Catch Tray, and the Offsetting
Catch Tray is closed securely.
Go to 12-E OCT Checkout Procedure.

If the prints are stacked incorrectly in the Catch Tray, Go to the 12-D OCT Stacking RAP.
If the prints are stacked correctly, but are stacked higher than the output drives of the Offsetting
Catch Tray, Go to the 12-G OCT Tray Status RAP.
12-E OCT Checkout Procedure

Do the following:
Check each OCT Stacking Finger. The OCT Stacking Fingers are free from damage.
Y
N
Replace the damaged OCT Stacking Finger PL 8.1 Item 9.
Check the prints in the Offsetting Catch Tray. The prints are stacked incorrectly in the
Catch Tray or are stacked higher than the output drives of the Offsetting Catch Tray
Assembly.
Y
N
Y
N
The Dual Decurler may not be installed correctly, or the Decurler setting may incorrect, causing the paper to be late to the OCT.
Do the following:
Ensure the connector for the Dual Decurler is plugged into the Decurler. Refer
to Figure 2.
Enter Tools.
Exit Tools.
Clear all paper from the Offsetting Catch Tray, the Offsetting Catch Tray paper path, and
the IOT paper path.
The Offsetting Catch Tray Assembly Drive Rolls rotate when the Fuser Motor energizes.
Y
N
Observe the gears on the Decurler/OCT Drive Bracket.
The Decurler/OCT Drive
Bracket is turning when the Fuser Drive Motor energizes.
Y
N
The Decurler Drive Belt PL 7.1 Item 7.
Inspect the OCT drives. Replace the Offsetting Catch Tray Assembly PL 8.1 Item 1,if necessary.
The Offsetting Catch Tray Assembly Drive Rolls for contamination, wear, and damage.
The Offsetting Catch Tray Assembly Idlers for contamination, wear, damage, and correct
tension.
If any of the drive rolls are damaged or worn, or if the idlers are damaged, worn, or have the
incorrect tension, Replace the Offsetting Catch Tray Assembly PL 8.1 Item 1.
Make copies and observe the sheets as they are stacked in the Offsetting Catch
Tray The problem continues.
Y
N
Go to 12-E OCT Checkout Procedure.
Do the following:
Enter Tools.
Exit Tools.
A
12-E
May 2003
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12-F OCT Noise RAP

Initial Actions
Ensure the Offsetting Catch Tray is closed securely.

In Component Control, select [IOT Paper Path], [Fuser Drive Motor], then [Output On]. Enter
Listen for noise in the Offsetting Catch Tray when the Fuser Drive Motor energizes.
The
noise occurs when the Fuser Drive Motor energizes.
Y
N
Check the Offsetting Catch Tray Assembly offset components for obstructions.
The
Offsetting Catch Tray Assembly offset components are free from obstructions.
Y
N
Remove the obstruction.
Remove the Offsetting Catch Tray Assembly and switch the power [On].
Listen for noise in the Offsetting Catch Tray when the Fuser Drive Motor energizes. The
noise occurs when the Fuser Drive Motor energizes with the Offsetting Catch Tray
Removed.
Y
N
plugged in.
Reinstall the Offsetting Catch Tray Assembly and switch the power [On].
Listen for noise in the Offsetting Catch Tray when the Fuser Drive Motor energizes.
The noise occurs when the Fuser Drive Motor energizes.
Y
N

The noise is not being caused by the Offsetting Catch Tray. Go to the OF-1 Noise RAP.
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2-475
12-E, 12-F
12-G OCT Tray Status RAP

The Catch Tray is full with no message on the UI indicating the Offsetting Catch Tray is full.
The message on the UI indicates the Offsetting Catch Tray is full when the Catch Tray is not
full.
Initial Actions
Check the air flow at the customer's site. Excessive air flow may cause poor stacking in the Offsetting Catch Tray and a false Offsetting Catch Tray full status message.

Place 5 sheets of paper in the Document Feeder. Program a job for 5 sets, collated.
Observe the sheets as they are stacked in the Offsetting Catch Tray The trail edge of the
sheet entering the Offsetting Catch Tray is slow to settle on the stack of paper in the
tray.
Y
N
The flag of the OCT Tray Full Sensor, is not damaged, and is free to block and
unblock the sensor.
Y
N
Go to Flag 1. Check the circuit of the OCT Tray Full Sensor.
Check the vertical surface (back wall) of the Offsetting Catch Tray Assembly. The
surface of the Offsetting Catch Tray free from damage.
Y
N
vertical
Go to the 12-J Output Device Configuration for Third Party Service. If the problem continues
after configuring the output device, go to the 12-H OCT Static Checkout RAP.
Figure 1 12-G RAP Circuit Diagram
12-G
May 2003
2-476
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12-H OCT Static Checkout RAP
12-J Output Device Configuration for Third Party Service
If the Static Eliminator in the Offsetting Catch Tray or the Static Eliminator on the Dual Decurler
is damaged, worn, or not connected securely to the machine frame, the Offsetting Catch Tray
may exhibit one or more of the problems listed below:
This procedure is used to ensure the output device is configured correctly.
False OCT Tray Full status messages.
Do the following:
Poor set registration.
Paper handling problems in the Offsetting Catch Tray (prevalent in environments where
the relative humidity is equal to or less than 25%).
Disconnect the Offsetting Catch Tray connector, P69 from the IOT.
When the Configuration Details screen is displayed on the UI, select [Yes] to accept
Output Device: None
After the machine completes the seft-test and is in the ready condition, switch the power
[Off].

Check the Static Eliminator on the Offsetting Catch Tray for correct contact with the OCT
frame. The Static Eliminator is connected securely to the Offsetting Catch Tray frame.
Y
N
Ensure the Static Eliminator is connected securely to the Offsetting Catch Tray Assembly
frame.
If the Static Eliminator cannot be connected securely to the Offsetting Catch Tray frame,
Check the Static Eliminator on the Offsetting Catch Tray for damage and wear. The
Eliminator is free from damage and wear.
Y
N
Static
Output Device Configuration Procedure
Reconnect the Offsetting Catch Tray connector, P69 to the IOT.
When the Configuration Details screen is displayed on the UI, select [Yes] to accept
Output Device: Offsetting Catch Tray.
If the machine cannot be configured correctly, contact Xerox Corporation.
Check the Static Eliminator on the Decurler for damage and wear. The Static Eliminator is
free from damage and wear.
Y
N
Ensure there is continuity between the Static Eliminator on the Offsetting Catch Tray and the
frame of the IOT. Check the following:
The grounding clip on the Offsetting Catch Tray Assembly for damage. Replace the Offsetting Catch Tray Assembly PL 8.1 Item 1 if necessary.
The grounding clip on the Offsetting Catch Tray Assembly for corrosion.
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12-H, 12-J
12-H, 12-J
May 2003
2-478
V0.042
12-100 Unexpected Sheet at the Finisher Entrance Sensor

RAP
Unexpected arrival of a sheet at the Finisher Entrance Sensor during run.

If a 10-127.98 fault is in the Last 40 Faults, note when it occurred. A 10-127.98 fault was
declared when the 12-100 fault occurred.
Y
N
If a 12-101 fault is in the Last 40 Faults, note when it occurred. A 12-101 fault was
declared when the 12-100 fault occurred.
Y
N
Check the flag actuator for the Finisher Entrance Sensor. The actuator is free
from damage, and moves freely to block and unblock the Finisher Entrance
Sensor.
Y
N
Replace the Finisher Entrance Sensor PL 8.3 Item 15.
The Finisher Entrance Sensor is seated correctly.
Y
N
Reseat the Finisher Entrance Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Finisher
Entrance Sensor PL 8.3 Item 15.
Do the following:
Disconnect the P3 from the Finisher Controller PWB, and switch the power
[On].
In Component Control, select [Finisher], [Finisher Entrance Sensor], then [Start

The state of the Finisher Entrance Sensor is high.

Y
N
Go to Flag 1. Check the wire for a short circuit.
If the wire is good, replace the Finisher Entrance Sensor PL 8.3 Item 15.
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12-100
12-101 LE Late to the Finisher Entrance Sensor RAP

The lead edge of a sheet is late to the Finisher Entrance Sensor.
Do the following:
A 12-101 fault may be declared as the primary fault when the problem is actually in the IOT. If
the machine has a history of 10-101 or 10-115 faults, troubleshoot the cause of the IOT faults.
Initial Actions
If the 12-101 Fault occurred when the Top Tray of the Finisher was full, the Top Tray Full
Sensor may have failed. Go to 12-AJ. Finisher Top Tray Status RAP.
Ensure the Finisher Transport Baffle PL 8.3 Item 11 is seated correctly
Turn over and reload the stack of paper in the tray the customer was using when the Finisher jam occurred.
The Exit Baffle.

Note when the 12-101 fault occurred. The fault occurred immediately after
installation of the Finisher.
Y
N
Carefully undock the Finisher from the IOT (REP 12-12).
Check the input paper path of the Finisher including the Finisher Transport
Baffle. The input area of the Finisher including the Finisher Transport Baffle, is free from damage.
Y
N
Replace the Finisher Transport Baffle PL 8.3 Item 11 if necessary.
the Nip 1/2 Drive Belt PL 8.3 Item 10 for damage, wear, and correct
tension.
The pulley on the Nip 1 Drive Shaft PL 8.4 Item 2 for damage and
wear.
The pulley on the Nip 2 Drive Shaft PL 8.4 Item 2 for damage and
wear.
The pulley on the Transport Drive Motor PL 8.5 Item 14 for damage
and wear.
the Nip 1/2 Idler and the Dual Idler for damage and wear
Check the Finisher Diverter Gate. Ensure it is not obstructing the Finisher
Paper path.
If the Finisher Diverter Gate cannot be reseated correctly on the Finisher Transport Baffle, replace the Finisher Transport Baffle PL 8.3 Item 11.
Go to 12-AF Finisher Noise RAP.
Do the following to gain access to the Finisher components.
Open the Finisher Top Cover Door.
Raise the Finisher Transport Baffle (Handle 5) to the jam clearance position.
Check the actuator of the Finisher Entrance Sensor The flag actuator for the Finisher
Entrance Sensor, is free from damage, and moves freely to block and unblock the
Finisher Entrance Sensor.
Check the Nip 1 Idlers for excessive wear and/or contamination. Ensure
the idlers are in the correct position. Install the Transport Baffle Idler Kit PL
8.3 Item 30, if necessary.
12-101

Check the Nip 1 Drive Rolls. The Nip 1 Drive Rolls are free from contamination and excessive wear.
Y
N
If the Nip 1 Drive Rolls are contaminated, remove the source of the contamination from the Nip 1 Drive Rolls.
If the Nip 1 Drive Rolls are worn, replace the Nip 1 Drive Shaft PL 8.4 Item
2
Check the following in the IOT:

On].
A noise occurs when the Transport Drive Motor energizes.

Y
N
Observe the Nip 1 Drive Shaft. The Nip 1 Drive Shaft is turning.
Y
N

If a 10-101, 10-115, or 10-120 fault is in the Last 40 Faults, note when it occurred. A 10-101,
10-115, or a 10-120 fault was declared when the 12-101 fault occurred.
Y
N
The lead edge of the jammed sheet has actuated the flag of the Finisher Entrance
Sensor.
Y
N
Check the position of the jammed sheet. The lead edge of the sheet has reached
the Nip 1 Drive Rolls.
Y
N
The lead edge of the jammed sheet has exited the IOT.
Y
N
The Inverter Exit Roll, the Duplex Gate and the Inverter Exit Roll
Idler, on the Inverter.
Move the Finisher Transport Baffle to the jam clearance position.
Open the Finisher Top Cover Door and cheat the Finisher Interlock Switch.
Y
N
If the problem continues, use the RAP to diagnose the problem.
A
B
C
D
D
Ensure the mounting hooks for the Finisher are engaged in the IOT frame.
A
May 2003
2-480
V0.042
A
Y
N
Check the actuator of the Finisher Entrance Sensor for excessive wear. See Figure 3.
The actuator is free from excessive wear.
Y
N
Check the position of the Finisher Entrance Sensor. The Finisher Entrance Sensor is
seated correctly.
Y
N
If the sensor cannot be reseated due to a broken mount, replace the Finisher
Entrance Sensor PL 8.3 Item 15.
In Component Control, select [Finisher], [Finisher Entrance Sensor], then [Start Monitor].
NOTE: In Component Control, the state of the Finisher Entrance Sensor may transition
several times due to sensor actuator bounce. The machine run time software is designed
to filter these multiple sensor transitions.
Actuate the Finisher Entrance Sensor by manually moving the flag actuator. The state
of the Finisher Entrance Sensor changed.
Y
N
Measure the voltage between SIGNALGND (-) and TH72 (+) on the Finisher Controller PWB.
Place a piece of paper on the actuator of the Finisher Entrance Sensor and lower the
Finisher Transport Baffle. Observe the meter while the Finisher Entrance Sensor is
actuated. The voltage is 0 VDC.
Y
N
If the wires are good, replace the Finisher Entrance Sensor PL 8.3 Item 15.

Go to Flag 1. Check the circuit of the Finisher Entrance Sensor for an intermittent condition.
NOTE: A faulty Inverter may slow the paper enough to cause 12-101 or 12-102 faults in
the Finisher.
Y
N
Y
N
Go to the 10-101 Fuser Exit Jam RAP.
V0.042
May 2003
2-481
12-101
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
TH72
Figure 2 Finisher Controller PWB Test Holes
12-101
May 2003
2-482
V0.042
12-102 TE Late to the Finisher Entrance Sensor RAP

excessive wear
The trail edge of the sheet is late leaving the Finisher Entrance Sensor.
Initial Actions

Have the customer check the paper size displayed on the User Interface for each of the paper
trays.
The paper size displayed for each paper tray matches the paper size loaded in the paper
tray.
Y
N
Raise the Finisher Transport Baffle (Handle 5) to the jam clearance position.
Check the actuator of the Finisher Entrance Sensor The flag actuator for the Finisher
Entrance Sensor, is free from damage, and moves freely to block and unblock the Finisher Entrance Sensor.
Y
N
Check the actuator of the Finisher Entrance Sensor for excessive wear. See Figure 3.
Y
N
The Finisher Entrance Sensor is seated correctly
Y
N
If the sensor cannot be reseated, replace the Finisher Entrance Sensor PL 8.3 Item 15.
In Component Control, select [Finisher], [Finisher Entrance Sensor], then [Start Monitor]. Block
and unblock the Finisher Entrance Sensor by manually moving the flag actuator.
NOTE: In Component Control, the state of the Finisher Entrance Sensor may transition several
times due to sensor actuator bounce. The machine run time software is designed to filter these
multiple sensor transitions.
The state of the Finisher Entrance Sensor changed.
Y
N
Measure the voltage between SIGNALGND (-) and TH72 (+) on the Finisher Controller
PWB.
A
V0.042
May 2003
2-483
12-101, 12-102
A
Place a piece of paper on the actuator of the Finisher Entrance Sensor and lower the Finisher Transport Baffle. Observe the meter while the Finisher Entrance Sensor is actuated. The voltage is 0 VDC.
Y
N
If the wires are good, replace the Finisher Entrance Sensor PL 8.3 Item 15.
Check the Finisher Diverter Gate. The Finisher Diverter Gate is in the correct position
(not blocking the lower paper path when the Finisher Diverter Gate Solenoid is deenergized).
Y
N
If the Finisher Diverter Gate cannot be reseated correctly on the Finisher Transport Baffle,
replace the Finisher Transport Baffle PL 8.3 Item 11.
The Nip 3/4 Drive Belt PL 8.3 Item 2.
The Nip 2 Idlers on the Disk Baffle Assembly PL 8.3 Item 12 for damage, wear, and contamination.
The Nip 3 Idlers and Nip 4 Idlers on the Finisher Transport Baffle for damage, wear, and
contamination. Install the Transport Baffle Idler Kit PL 8.3 Item 30, if necessary.
The Nip 2 Drive Rolls on the Nip 2 Drive Shaft PL 8.4 Item 2 for damage, wear, and contamination.
The Nip 3 Drive Rolls (Nip 3 Drive Shaft) and the Nip 4 Drive Rolls (Nip 4 Drive Shaft) on
the Top Module Assembly PL 8.3 Item 1 for wear, contamination, damage.
NOTE: A component in the IOT paper path may slow the paper enough to cause 12-101 or 12102 faults in the Finisher.
If no problems are found in the Finisher, check the following in the IOT:
The Inverter Exit Roll, the Duplex Gate and the Inverter Exit Roll Idler, on the Inverter.
The Exit Baffle.
12-102
May 2003
2-484
V0.042
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
TH72
V0.042
May 2003
2-485
12-102

excessive wear
12-105 Unexpected Sheet at the Top Tray Paper Path

Sensor RAP
Unexpected arrival of the lead edge of a sheet at the Top Tray Paper Path Sensor.
Failure of the Finisher Diverter Gate during a job running the paper described above is one
cause of 12-105 paper jams. For more information, go to: Paper Transport in the Principles of
Operation section of this manual.
Initial Actions
If the 12-105 Fault occurred when the Top Tray of the Finisher was full, the Top Tray Full Sensor may have failed. Go to 12-AJ Finisher Top Tray Status RAP.

Ensure all paper is cleared from the Finisher and open the Finisher Top Cover Door.
Check the position of the Top Tray Paper Path Sensor. The sensor is seated correctly
Y
N
Reseat the Top Tray Paper Path Sensor.
If the sensor cannot be reseated, replace the Top Tray Paper Path Sensor PL 8.4 Item 3.
Check the flag actuator for the Top Tray Paper Path Sensor. The flag actuator for the Top
Tray Paper Path Sensor is free from damage and moves freely to block and unblock the
sensor.
Y
N
Replace the Top Tray Paper Path Sensor PL 8.4 Item 3.
In Component Control, select [Finisher], [Top Tray Paper Path Sensor], then [Start Monitor].
Block and unblock the Top Tray Paper Path Sensor by manually moving the actuator. The
state of the Top Tray Paper Path Sensor changes.
Y
N
Observe the state of the Top Tray Paper Path Sensor when the sensor is not actuated
The state of the Top Tray Paper Path Sensor is high.
Y
N
Go to Flag 2. Check the wire for a short circuit.
Top Module Assembly PL 8.3 Item 1, if the harness cannot be repaired.
Top Tray Paper Path Sensor PL 8.4 Item 3.
Finisher Controller PWB PL 8.3 Item 16.

In Component Control, select [Finisher], [Finisher Diverter Gate Solenoid]. Select [Output On],
and then [Output Off], several times to cycle the Finisher Diverter Gate Solenoid.
12-102, 12-105
May 2003
2-486
V0.042
Observe the operation of the Finisher Diverter Gate. The Finisher Diverter Gate opens
then closes when the solenoid is cycled.
Y
N
Switch the power [Off]. Manually move the Finisher Diverter Gate up and down.
The Finisher Diverter Gate moves freely without binding.
Y
N
Check the Finisher Diverter Gate for the source of binding. Replace the Finisher
Transport Baffle PL 8.3 Item 11 if necessary.
If the return spring on the Finisher Diverter Gate Solenoid is damaged, replace the Finisher
Transport Baffle PL 8.3 Item 11.
The mounting tabs for the Finisher Diverter Gate are securely snapped in the correct
position.
the Finisher Diverter Gate Solenoid Heat Cover is securely snapped in the correct
position.
The Finisher Diverter Gate mounting tabs and the solenoid heat cover are in the
correct position.
Y
N
If the Finisher Diverter Gate mounting tabs or the Finisher Diverter Gate Solenoid
heat cover are broken or damaged, replace the Finisher Transport Baffle PL 8.3 Item
11.
Do the following;
Measure the voltage between P/J4 -13 (-) and P/J4 -12 (+) on the Finisher Controller PWB.
In Component Control, select [Finisher], [Finisher Diverter Gate Solenoid], then [Output On]. Enter [Copier Sys tab , Component Control].
The voltage is +24 VDC when the Finisher Diverter Gate Solenoid energizes.
Y
N
Go to Flag 1. Check the circuit of the Finisher Diverter Gate Solenoid for a short circuit.
Finisher Transport Baffle PL 8.3 Item 11.
Go to Flag 1. Check the harness for an open circuit.

If the wires are good, replace the Finisher Transport Baffle PL 8.3 Item 11.
The Finisher Diverter Gate may not be operating correctly. Check the following:
The mounting tabs for the Finisher Diverter Gate are securely snapped in the correct position.
The Finisher Diverter Gate Solenoid Heat Cover is securely snapped in the correct position
The return spring on the Finisher Diverter Gate Solenoid.
The circuit at Flag 1 for a intermittent short to the Finisher frame.
If the Finisher Diverter Gate mounting tabs or the Finisher Diverter Gate Solenoid heat cover
are broken or damaged, replace the Finisher Transport Baffle PL 8.3 Item 11.
V0.042
May 2003
2-487
12-105
12-105
May 2003
2-488
V0.042
12-106 LE Late to the Top Tray Paper Path Sensor RAP
If the wires are good, replace the Top Tray Paper Path Sensor PL 8.4 Item
3.
The lead edge of a sheet is late to the Top Tray Paper Path Sensor.
Failure of the Finisher Diverter Gate is one cause of 12-106 paper jams. For more information,
go to: Paper Transport in the Principles of Operation section of this manual.
Do the following:
Initial Actions

On].
If the 12-106 Fault occurred when the Top Tray of the Finisher was full, the Top Tray Full Sensor may have failed. Go to 12-AJ. Finisher Top Tray Status RAP.
Observe the Nip 3 Drive Shaft. The Nip 3 Drive Shaft rotates when the Transport
Drive Motor energizes.
Y
N

Check the position of the jammed sheet. The sheet of paper is jammed in the lower paper
path of the Finisher (in the Disk).
Y
N
Check the position of the Top Tray Paper Path Sensor. The sensor is seated correctly.
Y
N
Reseat the Top Tray Paper Path Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Top Tray Paper
Path Sensor PL 8.4 Item 3.
Open the Finisher Top Cover Door. Observe the position of the actuator for the Top Tray
Paper Path Sensor.
The tip of the Top Tray Paper Path Sensor actuator is below the top surface of the
Finisher Transport Baffle.
Y
N
In Component Control, select [Finisher], [Top Tray Paper Path Sensor], then [Start
Block and unblock the sensor by manually moving the actuator. The state of the
Top Tray Paper Path Sensor changes.
Y
N
Measure the voltage between P/J4-13 (-) and P/J4-12 (+) on the Finisher
Controller PWB.
The pulley on the on the Nip 3 Drive Shaft (part of the Top Module Assembly PL 8.3 Item 1) for damage and wear.
the Nip 3/4 Idler (part of the Top Module Assembly PL 8.3 Item 1) for damage and wear.
Ensure the Nip 3 Idlers are from damage and rotate freely. Install the Transport
Baffle Idler Kit PL 8.3 Item 30, if necessary.
Check the Nip 3 Drive Rolls on the Nip 3 Drive Shaft (Part of Top Module
Assembly PL 8.3 Item 1) for excessive wear.
In Component Control, select [Finisher], [Finisher Diverter Gate Solenoid]. Select [Output On],
and then [Output Off], several times to cycle the Finisher Diverter Gate Solenoid.
Observe the operation of the Finisher Diverter Gate. The Finisher Diverter Gate opens
then closes when the solenoid is cycled.
Y
N
Switch the power [Off]. Manually move the Finisher Diverter Gate up and down.
The Finisher Diverter Gate moves freely without binding.
Y
N
Check the Finisher Diverter Gate for the source of binding. Replace the Finisher
Transport Baffle PL 8.3 Item 11 if necessary.
Block the Top Tray Paper Path Sensor with a piece of paper.
Replace the Finisher Transport Baffle PL 8.3 Item 11.
Check the voltage when the Top Tray Paper Path Sensor is blocked. The voltage is 0 VDC when the Top Tray Paper Path Sensor is blocked.
Y
N
Go to Flag 2. Check the harness for an for an open circuit.
A
B
V0.042
The Nip 3/4 Drive Belt PL 8.3 Item 2 for damage, wear, and correct tension.
Do the following:
Check the actuator of the Top Tray Paper Path Sensor for excessive wear. See Figure 3.
Y
N
The flag actuator for the Top Tray Paper Path Sensor is not damaged and moves
freely to block and unblock the sensor.
Y
N
The mounting tabs for the Finisher Diverter Gate are securely snapped in the correct
position.
the Finisher Diverter Gate Solenoid Heat Cover is securely snapped in the correct
position.
The Finisher Diverter Gate mounting tabs and the solenoid heat cover are in the
correct position.
E
May 2003
2-489
12-106
E
Y
N
If the Finisher Diverter Gate mounting tabs or the Finisher Diverter Gate Solenoid
heat cover are broken or damaged, replace the Finisher Transport Baffle PL 8.3 Item
11.
Do the following;
Measure the voltage between P/J4 -13 (-) and P/J4 -12 (+) on the Finisher Controller
PWB.
In Component Control, select [Finisher], [Finisher Diverter Gate Solenoid], then [Output On]. Enter [Copier Sys tab , Component Control].
The voltage is +24 VDC when the Finisher Diverter Gate Solenoid energizes.
Y
N
Go to Flag 1. Check the circuit of the Finisher Diverter Gate Solenoid for a short circuit.
Finisher Transport Baffle PL 8.3 Item 11.

If the wires are good, replace the Finisher Transport Baffle PL 8.3 Item 11.
The Finisher Diverter Gate may not be operating correctly. Check the following:
The mounting tabs for the Finisher Diverter Gate are securely snapped in the correct position.
The Finisher Diverter Gate Solenoid Heat Cover is securely snapped in the correct position
The return spring on the Finisher Diverter Gate Solenoid.
The circuit at Flag 4 for a intermittent short to the Finisher frame.
If the Finisher Diverter Gate mounting tabs or the Finisher Diverter Gate Solenoid heat cover
are broken or damaged, replace the Finisher Transport Baffle PL 8.3 Item 11.
If the return spring on the Finisher Diverter Gate Solenoid is damaged, replace the Finisher
Transport Baffle PL 8.3 Item 11.
12-106
May 2003
2-490
V0.042
V0.042
May 2003
2-491
12-106
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
12-106
May 2003
2-492
V0.042
12-107 TE Late to the Top Tray Paper Path Sensor RAP

excessive wear
The trail edge of a sheet is late leaving Top Tray Paper Path Sensor.
Initial Actions
Check the Top Tray for obstructions.
Ensure the Finisher Transport Baffle PL 8.3 Item 11 is seated correctly and is not
obstructing the paper path.
12-107 On-Site Top Tray Paper Sensor Checkout

Check the Finisher Change Tag Matrix.
Finisher TAG F032 is marked off.
Y
N
Check the serial number of the Finisher (manufacturing did not mark off Tag F032 on
some Finishers).
The Finisher serial number is within the range 6UP-756189 and 6UP-757750.
Y
N
Do the following:
Perform the Top Tray Paper Path Sensor Mounting Tab Procedure.
Mark of Tag 32 on the Finisher Change Tag Matrix.
If the problem continues, go to 12-107 On-Site Diagnostic Procedure to diagnose the

problem
Figure 3 Checking the Top Tray Paper Path Sensor actuator.
TAG F032 has been installed in manufacturing. Mark of Tag 32 on the Finisher Change
Tag Matrix then go to 12-107 On-Site Diagnostic Procedure.
NOTE: Finisher TAG F032 is a new Finisher bracket the Top Tray Paper Path Sensor Mounting
Tab is attached to and is at the correct angle, so the sensor does not bounce as the paper goes
across it.

tray.
Y
N
Look for evidence that static is effecting the stacking of sheets in the Finisher Top Tray. Static
is effecting the stacking of sheets in the Finisher Top Tray.
Y
N
The Top Tray Full Sensor is seated in the correct position.
Y
N
Reseat the Top Tray Full Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Top Tray Full
Sensor PL 8.4 Item 1.
A
V0.042
May 2003
2-493
B
12-106, 12-107
B
Check the Top Tray Full Sensor Actuator. The actuator is free from damage, and
moves freely to block and unblock the sensor.
Y
N
Replace the Top Tray Full Sensor Actuator PL 8.4 Item 6.
In Component Control, select [Top Tray Full Sensor], then [Start Monitor].
Block and unblock the Top Tray Full Sensor by manually moving the actuator. The state
of the Top Tray Full Sensor changes.
Y
N
Go to Flag 1. Check the circuit of the Top Tray Full Sensor.
Top Tray Full Sensor PL 8.4 Item 1.
8.
Check the position of the Top Tray Paper Path Sensor actuator. The actuator should be
flush or slightly above the surface of the Finisher Transport Baffle (Figure 3). If the actuator is not in the correct position, repeat steps 5-7.
NOTE: Ensure the Top Tray Paper Path Sensor is not dislodged from the tab.
9.
When the Top Tray Paper Path Sensor actuator is in the correct position, reinstall the two
screws in the 5a Baffle.
Do the following:
In Component Control, select [Finisher], [Transport Drive Motor], then [Output On].
Observe the Nip 4 Drive Shaft. The Nip 4 Drive Shaft is turning.
Y
N
Check the pulley on the Nip 4 Drive Shaft (Part of Top Module Assembly PL 8.3 Item
1) for damage and wear.
Do the following:
Ensure the Nip 4 Idlers are free from damage and rotate freely. Install the Transport
Baffle Idler Kit PL 8.3 Item 30, if necessary.
Check the Nip 4 Drive Rolls on the Nip 4 Drive Shaft (Part of Top Module Assembly
PL 8.3 Item 1) for excessive wear.
Go to the 12-AP Finisher Static Checkout RAP.
Top Tray Paper Path Sensor Mounting Tab Procedure

1.
Switch off the machine power.
2.
Open the Finisher Top Cover and open area 5.
3.
Remove the two 5.5mm (T20 torx) screws that secure the metal 5a Baffle (Exit Baffle) to
the Finisher frame. A 5.5mm wrench or socket may be required to remove the screws.
4.
Remove the 5a Baffle.
5.
Locate the tab where the Top Tray Paper Path Sensor is mounted. Move the tab clockwise approximately 10 degrees (Figure 2).
NOTE: Moving the bracket too much will cause the sensor actuator to bind on the Exit
Baffle.
6.
Reinstall the 5a Baffle but do not install the 2 screws.
7.
Ensure the Finisher Transport Baffle (labeled 5) is in the correct position against the Exit
Baffle.
12-107
May 2003
2-494
V0.042
The actuator should be flush or

slightly above the surface of the
Finisher Transport Baffle
Figure 2 Moving the tab for the Top Tray Paper Path Sensor
V0.042
Figure 3 Checking the position of the sensor actuator
May 2003
2-495
12-107
12-108 Disk Home Fault RAP
Observe the Front Bale Arm and the Rear Bale Arm. The Front Bale Arm and the Rear
Bale Arm raise and lower freely without binding when the Disk Shaft is rotated.
Y
N
Do the following:
The Disk Home Sensor was not activated within the allotted time after the Disk Motor energized during initialization.
The Disk Home Sensor was not activated within the allotted time after the Disk Motor energized for sheets less than 9 inches.
The Disk Home Sensor was not deactivated within the allotted after the command to send the
Disk home, for sheets greater than 9 inches.
For more information, go to: Disk Loading and Disk Drives in the Principles of Operation section of this manual.
Initial Actions
Ensure the customer has not sent a job to the Finisher that exceeds capacity of the Stapler. Refer to Finishing in Table 6.
The 12-108 fault may be cleared by cycling the Finisher Interlock Switch. Open then close
the Finisher Top Cover Door.
Turn over and reload the stack of paper in the tray the customer was using when the Finisher jam occurred. If the problem continues, load fresh paper from a new ream in the tray
the customer was using when the Finisher jam occurred.
Ensure the Bale Arms are not hitting the Disk Baffle Assembly PL 8.3 Item 12
as they raise and lower.
Check each Bale Arm Spring PL 8.5 for damage. Be sure each spring is
installed correctly.
Check the Front Bale Arm and the Rear Bale Arm for damage and wear.
Replace the Service Tray Assembly PL 8.5 Item 1 if necessary.
Check all four Disk Fingers. If any of the Disk Fingers are damaged or broken, install the
Disk Fingers Kit PL 8.3 Item 31.
The Disk Home Sensor is seated correctly.
Y
N
Reseat the Disk Home Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Disk Home Sensor
PL 8.3 Item 4.
Go to Flag 2. Check the circuit of the Disk Home Sensor.
Disk Motor Checkout Procedure

Observe the Disk Motor. The Disk Motor energizes in Component Control.
Y
N
Do the following:

Do the following:
Remove all copies from the Stacker Tray.
Remove the Finisher Rear Cover.
Remove any obstructions including foreign objects, from the Stacker Tray.
Open and close the Finisher Top Cover.
Manually rotate the Top Module Assembly by turning the Disk Drive Gear counter
clockwise as viewed from the rear of the Finisher.
The Disk Motor rotates freely without binding.

Y
N
Do the following:
The Disk Shaft rotates.

Y
N
In Component Control, select [Finisher], and [Disk Motor On].
Observe the Disk Motor. The Disk Motor energizes in Component Control.
Y
N
Go to the Disk Motor Checkout Procedure.
Check the Disk Drive Motor PL 8.3 Item 6 for binding.
Check the Disk Shaft for binding.
Ensure the Disk Fingers are not hitting The Disk Baffle Assembly PL 8.3 Item
12.
Do the following:
the Disk Drive Gear PL 8.3 Item 5.
Set the meter to measure +24 VDC.
the Disk Shaft.
Connect the (-) meter lead to the Finisher frame.
Measure the voltage at the Finisher Controller PWB at P2 -8 (+) and P2 -11 (+).
The Disk Shaft rotates, pauses, then rotates again.

Y
N
Do the following:
Both voltages measured are +24 VDC.

Y
N
Switch the power [Off]. Disconnect P/J2 from the Finisher Controller PWB. Set the
meter to measure Ohms.
Check for a short circuit from:
Manually rotate the Disk Shaft by turning the Disk Drive Gear counter clockwise as
viewed from the rear of the Finisher.
A
12-108
B
May 2003
2-496
The Finisher frame (-) to P2 -8 (+) on the connector.
The Finisher frame (-) to P2 -11 (+) on the connector.
C
V0.042
C
One or both of the +24 VDC outputs to the Disk Motor are shorted to the Finisher frame.
Y
N
Go to Flag 1. Check the wires in the harness for a short circuit to the Finisher
Frame. One or both of the wires are shorted to the Finisher frame.
Y
N
Replace the following:
the Disk Drive Motor PL 8.3 Item 6.
the Finisher Controller PWB PL 8.3 Item 16.
Do the following:
Repair the harness.
Switch the power [Off] and Disconnect P/J2 from the Finisher Controller PWB.
Measure the resistance at the following pins on P2:
From P2 -7 to P2 -8
From P2 -8 to P2 -9
From P2 -10 to P2-11
From P2 -11 to P2-12
The resistance measured is greater than 0 ohms but less than 10 ohms.
Y
N
Go to Flag 1. Check the wires for a short circuit or an open circuit.
If the wires are good, replace the Disk Drive Motor PL 8.3 Item 6.
the Disk Drive Gear PL 8.3 Item 5.
the Disk Shaft.
V0.042
May 2003
2-497
12-108
12-108
May 2003
2-498
V0.042
12-200 Stacker Tray Raise Fault RAP

The Stack Too High Sensor fails to block 6000 ms after the Stacker Tray Drive Motor energizes.
For more information, go to: Stacker Tray Drives and Stack Height Sensing in the Principles of

Do the following:
Empty the Stacker Tray.
Remove the Finisher Lower Rear Cover.
In Stack Height/Elevator Tests, select [Single Cycle].

Enter [Finishing tab, Finisher Tests].
Observe the Stacker Tray Drive Motor. The Stacker Tray Drive Motor turns when the Stack
Height/Elevator Function Test runs.
Y
N
Do the following:
Connect the meter leads to the Finisher Controller PWB at P/J10 -9 (-) and P/J10 10 (+).
In Component Control, select [Finisher], [Stacker Tray Up] then [Output On].

Y
N
If the wires are good, replace the Stacker Tray Drive Motor PL 8.3 Item 3.

The Stacker Tray moves when the Stack Height/Elevator Function Test runs.
Y
N
Check the Stacker Tray Drive Belts. The Stacker Tray Drive Belts are free from damage.
Y
N
Replace the Stacker Tray Drive Belt PL 8.5 Item 8 (front) and PL 8.3 Item 8 (rear).
Do the following:
Check each Stacker Tray Drive Belt Clamp PL 8.5 Item 7 (front) and PL 8.3 Item 7
(rear) for damage.
Check the Stacker Tray Drive Pulley PL 8.3 Item 9 for damage.
Ensure each Stacker Tray Drive Belt is mounted correctly on the Stacker Tray Drive
Pulley.
To gain access to Finisher components, undock the Finisher from the IOT (REP 12-12).
Manually raise and lower the Rear Bale Arm by rotating the Disk in the process direction.
Observe the actuator on the Rear Bale Arm. The Rear Bale Arm move freely and the actuator for the Stack Too High Sensor is free from damage.
V0.042
May 2003
2-499
12-108, 12-200
N
Replace the Service Tray Assembly PL 8.5 Item 1.
The Stack Height Sensor/Stack Too High Sensor is seated correctly.

Y
N
Reseat the sensor.
If the sensor cannot be reseated in the correct position, replace the Stack Height Sensor /
Stack Too High Sensor PL 8.5 Item 10.
Go to Flag 2. Check the circuitry of the Stack Height Sensor /Stack Too High Sensor for an
Replace the defective component.
Stack Height Sensor /Stack Too High Sensor PL 8.5 Item 10.
Service Tray Assembly PL 8.5 Item 1 (if the harness cannot be repaired).
12-200
May 2003
2-500
V0.042
V0.042
May 2003
2-501
12-200
12-201 Stacker Tray Upper Limit Fault RAP

The Stacker Tray Upper Limit Switch was actuated when the Stacker Tray was being raised.
B
The Stack Height Sensor/Stack Too High Sensor is free from damage (the body of
the sensor should be at a 90 degree angle in relation to the base of the sensor).
Y
N
Replace the Stack Height Sensor/Stack Too High Sensor PL 8.5 Item 10.
Go to Flag 1. Check the circuit of the Stack Too High Sensor for an open circuit or a short
circuit.
Do the following:
Remove any obstructions including foreign objects, from the Stacker Tray.
Do the following:

Y
N
Observe whether the Stacker Tray is approximately level (parallel with the Stapler Access
Door). The Stacker Tray is level.
Y
N
Perform the Stacker Tray Leveling Procedure (part of REP 12-21).
Switch off the power and disconnect the Power Cord.
Remove the Finisher Front Cover (disconnect the Pause/Resume Switch).
Check the position of the Disk Shaft Actuator (refer to Figure 3).
The Disk Shaft Actuator is in the correct position

Y
N
Do the following to ensure the Disk Shaft Actuator is in the correct position (refer to Figure
3).
Do the following:
Open the Finisher Top Cover Door to deactuate the Finisher Interlock Switch.
Manually rotate the Disk Shaft in the process direction
Observe the Rear Bale Arm as the Disk Shaft is rotating. The Rear Bale Arm is not damaged and raises and lowers freely.
Y
N
Check the Rear Bale Arm components on the Service Tray Assembly PL 8.5 Item 1 for
binding.
In Component Control, select [Finisher], [Stack Too High Sensor], then [Start Monitor].
Block and unblock Stack Too High Sensor by manually raising and lowering the Rear Bale
Arm.
The state of the Stack Too High Sensor changed.

Y
N
The actuator for the Stack Too High Sensor, located on the Rear Bale Arm, is free
from damage.
Y
N
Raise the end of the Disk Shaft slightly.
Move the actuator until the Disk Shaft rests in the rounded notch of the actuator.
Check the Finisher Change Tag Matrix

The Finisher Tag Matrix indicates Tag F030 is installed.
Y
N
Go to Flag 2. Check the circuit of Stacker Tray Upper Limit Switch for an open circuit.
Do the following:
Stacker Tray Upper Limit Switch PL 8.5 Item 5.
Go to Flag 2 (Figure 2). Check the circuit of Stacker Tray Rear Upper Limit Switch and the
Stacker Tray Upper Limit Switch for an open circuit.
Stacker Tray Rear Upper Limit Switch PL 8.2 Item 19.
Check the position of the Stack Height Sensor /Stack Too High Sensor. The sensor is
seated correctly.
Y
N
Reseat the Stack Height Sensor /Stack Too High Sensor.
If the sensor cannot be reseated in the correct position, replace the Stack Height
Sensor /Stack Too High Sensor PL 8.5 Item 10.
A
B
12-201
May 2003
2-502
V0.042
Figure 1 12-201 RAP Circuit Diagram (without Tag F030)
Figure 2 12-201 RAP Circuit Diagram (with Tag F030)
V0.042
May 2003
2-503
12-201
12-202 Stacker Tray Lower Fault RAP

View of Disk Shaft with actuator in the correct position
The Stack Too High Sensor failed to unblock 1000 ms after the Stacker Tray Drive Motor energizes to drive the Stacker Tray down.
End of Disk
Shaft
Initial Actions
Check the Stacker Tray of the Finisher for obstructions that may be preventing the Stacker Tray
from moving down. If an obstruction was found, remove the obstruction and run the job again.
If the problem was not caused by an obstruction that was blocking the Stacker Tray, follow the
procedure.

Do the following:
Remove any obstructions that may be preventing the Stacker Tray from lowering.

Y
N
Disk Shaft Actuator
Figure 3 12-201 RAP Component Location
Program and print a job with the following attributes:
2 sheets
2 staples
5 copies
Observe the sheets as they enter the Stacker Tray. Greater than one sheet of paper is on
top of the Finisher Set Separator when the fault occurs.
Y
N
In Disk Finisher Stack Height / Elevator Function Tests, select [Single Cycle].
Observe the Stacker Tray Drive Motor. The Stacker Tray Drive Motor turns when
Stack Height / Elevator Function Test is run.
Y
N
The Stacker Tray is level from front to rear.
Y
N
Check the Stacker Tray Drive Belts. The Stacker Tray Drive Belts are free
from damage.
Y
N
Replace the front and rear Stacker Tray Drive Belt PL 8.3 Item 8.
Do the following:
A
12-201, 12-202
May 2003
2-504
Check the front and rear Stacker Tray Drive Belt Clamp PL 8.3 Item 7 for
damage.
Check the Stacker Tray Drive Pulley PL 8.3 Item 9 for damage.
Ensure each Stacker Tray Drive Belt PL 8.3 Item 8 is mounted correctly
on the Stacker Tray Drive Pulley.
C
V0.042
C
Do the following:
Connect the meter leads to the Finisher Controller PWB at P/J10 -10 (-) and
P/J10 -9 (+).
In Component Control, select [Finisher], [Stacker Tray Up] then [Output On].
Observe the operation of the Finisher Set Separator and the Set Separator Solenoid. The Set
Separator Solenoid energizes.
Y
N
Go to Flag 1 in Figure 2. Check wires for a short circuit or an open circuit.

Y
N
Attempt to manually move the Kicker to the eject position (out) and back to the home
position (in) several times.
CAUTION
Finisher Set Separator PL 8.5 Item 19 (PL 8.5 Item 13 For Document Centre 460/
470 with a Smart Tray Finisher installed).
NOTE: A Smart Tray Finisher is identified by the serial number NF3xxxxxx.
If the Finisher Set Separator does not rest on the top of the set in the Stacker Tray, the operation of the Set Separator is intermittent, replace the Finisher Set Separator PL 8.5 Item 19 (PL
8.5 Item 13 For Document Centre 460/470 with a Smart Tray Finisher installed).
Resistance should be detected if the Kicker mechanism is not damaged. Forcing the
Kicker to move if resistance is detected will cause damage to the mechanical components
of the Kicker.
The Kicker moves freely to the eject position (out) and to the home position (in).
Y
N
To gain access to Finisher components, undock the Finisher from the IOT (REP 1212).
Manually raise and lower the Rear Bale Arm by rotating the Disk. Observe the actuator for the Stack Too High Sensor on the Rear Bale Arm. The Rear Bale Arm
move freely and the actuator for the Stack Too High Sensor is free from damage.
Y
N
Check the position of the Stack Height Sensor /Stack Too High Sensor. The sensor
is seated correctly.
Y
N
Reseat the Stack Height Sensor/Stack Too High Sensor.
If the sensor cannot be reseated in the correct position, replace the Stack
Height Sensor /Stack Too High Sensor PL 8.5 Item 10.
Go to Flag 2. Check the circuitry of the Stack Too High Sensor for a short circuit.
Offset Drive Link PL 8.5 Item 10.

Place a single stack of paper in the Stacker Tray.
In Component Control, select [Finisher], [Set Separator Solenoid], then [Output On]. Enter
V0.042
May 2003
2-505
12-202
12-202
May 2003
2-506
V0.042
12-203 Stacker Tray Offset Fault RAP

The Stacker Tray Offset Sensor does not transition to blocked 500 ms after the Stacker Offset
Motor energizes.
Initial Actions
from offsetting. If an obstruction was found, remove the obstruction and run the job again. If the
problem was not caused by an obstruction that was blocking the Stacker Tray, follow the procedure.

Check the [Last 40 Faults] for 12-310 faults. A 12-310 fault occurred when the 12-203 fault
occurred.
Y
N
In Component Control, select [Finisher], [Stacker Tray Offset], then [Output On]. Enter
For Document Centre 460/470 with a Smart Tray Finisher installed, do the following:
In the Diagnostic Navigator, select [Finishing] tab, [Finisher Tests], then select the
[Main Tray Offset / Position] tab.
Select [Continuous Cycle], [Mode 2], then select [Start].
Select the [Continue] button when displayed to continue the test.
Observe the Stacker Tray. The Stacker Tray moves when the Stacker Tray Offset
Motor energizes.
Y
N
Remove the bottom portion of the Stacker Tray.
Check the Stacker Tray offset drive components for binding, damage, and wear.
Replace the Stacker Tray PL 8.2 Item 16 if required.
Remove the bottom portion of the Stacker Tray to gain access to the Stacker Tray Offset
Sensor.
The Stacker Tray Offset Sensor is seated in the correct position.
Y
N
Reseat the Stacker Tray Offset Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Stacker Tray PL
8.2 Item 16.
Stacker Tray PL 8.2 Item 16.
Go to the 12-310 Stacker Tray Offset Motor Fault RAP.
V0.042
May 2003
2-507
12-202, 12-203
12-204 Tamper Home Fault RAP

The Tamper Home Sensor fails to transition within 1000 ms after the Tamper Motor energizes
to send the Tamper to the home position.
For more information, go to: Tamping in the Principles of Operation section of this manual.
Initial Actions
Open then close the Finisher Top Cover Door.
If the fault cannot be cleared by opening and then closing the Finisher Top Cover Door, follow
the procedure.

Do the following:
Clear all paper from the Stacker Tray.
Open the Finisher Top Cover Door to open the Finisher Interlock Switch.
Manually move the Tamper Arm to the home (rear) position.
In Component Control, select [Finisher], [Tamper In/Out], then [Output On].

Observe the Tamper Arm. The Tamper moves when the Tamper Motor energizes.
Y
N
Do the following:
Open the Finisher Top Cover Door to open the Finisher Interlock Switch.
Manually move the Tamper Arm back and forth.
The Tamper Arm moves freely without binding.

Y
N
Do the following:
Check the Tamper Arm Gear Rack for wear and damage (Finishers without
TAG F029).
Check the Tamper Arm Drive Cable for wear and damage (Finishers with TAG
F029)
Check the Tamper Ball Slide for wear, damage, or obstructions including loose
staples.
Ensure the Tamper Ball Slide is secured to the frame of the Service Tray
Assembly.
Check the Tamper Arm for wear and damage. Ensure it is secured to the
Tamper Ball Slide.
The Tamper components are free from damage and wear, and are secured correctly as described above.
Y
N
If any of the Tamper components are damaged or worn, replace the Service
Tray Assembly PL 8.5 Item 1.
Replace the Disk Baffle Assembly PL 8.3 Item 12.
Check the Finisher Change Tag Matrix for TAG F029.
The Finisher Tag Matrix indicates Tag 029 is installed.
A
12-203, 12-204
May 2003
2-508
V0.042
B
Y
N
Switch the power [Off]. Disconnect P5 from the Finisher Controller PWB.
From P5 -4 to P5 -5
From P5 -6 to P5 -7
If the Tamper does not move freely after removing the obstruction from the
Tamper Ball Slide, replace the Service Tray Assembly PL 8.5 Item 1.
The resistance measured is 4-6 ohms.

Y
N
If the wires are good, replace the Service Tray Assembly PL 8.5 Item 1.

Undock the Finisher from the IOT (REP 12-12). Do not disconnect J15 from P69.
On machines without TAG 114, cheat the Right Side Interlock Switch.
Reconnect the Power Cord.
The Tamper Arm Drive Cable is loose.

Y
N
From P5 -4 to P5 -5
From P5 -6 to P5 -7
From P5 -6 to P5 -7
From P5 -4 to P5 -5

Y
N
Go to Flag 2 Check the wires for an open circuit or a short circuit.
Tighten the Tamper Ball Slide mounting screws.

If the screws can not be tightened, replace the Service Tray Assembly PL 8.5 Item 1.
The Tamper Home Sensor is seated correctly.
Y
N
Reseat the Tamper Home Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Tamper Home Sensor PL 8.5 Item 4.
The actuator for the Tamper Home Sensor, located on the Tamper Arm, is broken or
missing.
Y
N
Go to Flag 1. Check the circuit of the Tamper Home Sensor for an open circuit or a short
circuit.

Y
N
Perform REP 12-24 Tamper Cable.
If the cable is damaged and cannot be re-installed correctly, replace the Service Tray
Assembly PL 8.5 Item 1, if required.
The Tamper moves quietly and smoothly when the Tamper Motor energizes in Component Control.
Y
N
Tamper Home Sensor PL 8.5 Item 4.
NOTE: An abnormal sound or vibration is an indication the Tamper Motor is not operating
correctly, the Ball Slide mounting screws for the Tamper are loose, or there are obstructions such as staples in the ball slide.
Check the Tamper Ball Slide mounting screws. The Tamper Ball Slide mounting
screws are loose.
Y
N
Check the Ball Slide for obstructions including staples. The Tamper Ball Slide is
free from obstructions.
Y
N
Remove the obstruction from the Tamper Ball Slide.
B
C
V0.042
May 2003
2-509
12-204
12-205.01 Moving Stapler Interlock Switch Deactuation

Fault RAP
The Moving Stapler Interlock Switch failed to open 200 ms after the Moving Stapler Safety
Gate Solenoid de-energizes. The Stacker Tray is unavailable.
For more information, go to: Stapling in the Principles of Operation section of this manual.
NOTE: The Moving Stapler in the Finisher is also referred to as Stapler 1 in User Interface
messages.
Initial Actions
The 12-205.01 fault may be cleared by cycling the Finisher Interlock Switch. Open then close
Verify the fault has been cleared by programming and printing a job with the following
attributes:
2 sheets
1-sided
1 staple

Check the position and movement of the Canard Wing. The Canard Wing moves freely
without binding and is in the correct position on the Moving Stapler.
Y
N
Reseat the Canard Wing in the correct position. If the Canard Wing is damaged or cannot
be reseated correctly, replace the Moving Stapler PL 8.5 Item 3.
In Component Control, select [Finisher], [Moving Stapler Interlock Switch], then [Start Monitor].
The state of the Moving Stapler Interlock Switch is low (not actuated).
Y
N
Exit diagnostics to clear the fault.
Check for obstructions in the Moving Stapler mechanism that may be causing the Moving
Stapler Safety Gate to stay in the down position. There is an obstruction in the Moving Stapler Safety Gate mechanism.
Y
N
Clear the obstruction.
Program a job for 10 stapled sets of 2 sheets.
Check the operation of the Moving Stapler after clearing the obstruction. A
fault occurs after the clearing the obstruction
Y
N
12-205.01

Do the following:
12-204, 12-205.01
May 2003
2-510
In Component Control, select [Finisher], [Moving Stapler Intlk Switch], then [Start Monitor].
V0.042
Select [Moving Stapler Safety Gate Solenoid], [Output On], then [Output Off] to lower and
raise the Moving Stapler Safety Gate.
The state of the Moving Stapler Interlock Switch is high.

Y
N
Go to Flag 1. Check the circuit of the Moving Stapler Interlock Switch for a short circuit.
Observe the state of the Moving Stapler Interlock Switch when the Moving Stapler Safety Gate
is lowered and then raised. The display indicates the state of the Moving Stapler Interlock
Switch goes from low to high to low.
Y
N
Do the following:
Switch the power [Off]. Disconnect P9 from the Finisher Controller PWB. Switch the
power [On].
In Component Control, select [Finisher], [Moving Stapler Interlock Switch], then

[Start Monitor].
Disk Baffle Assembly PL 8.3 Item 12.

The Moving Stapler Interlock Switch is functional, but the Moving Stapler Safety Gate Solenoid
deactuates too slowly. replace the Disk Baffle Assembly PL 8.3 Item 12.

V0.042
May 2003
2-511
12-205.01
12-205.02 Fixed Stapler Interlock Switch Deactuation Fault

RAP
The Fixed Stapler Interlock Switch failed to open 200 ms after the Fixed Stapler Safety Gate
Solenoid de-energizes. The Stacker Tray is unavailable.
attributes:
1-sided
2 staples
Switch the power [Off]. Disconnect P9 from the Finisher Controller PWB. Switch the
power [On].
In Component Control, select [Finisher], [Fixed Stapler Interlock Switch], then [Start
Monitor].
Initial Actions
2 sheets
The state of the Fixed Stapler Interlock Switch is high.

Y
N
Go to Flag 1. Check the circuit of the Fixed Stapler Interlock Switch for a short circuit.
NOTE: The Fixed Stapler in the Finisher is also referred to as Stapler 2 in User Interface messages.
N
Do the following:

The Fixed Stapler Interlock Switch is functional, but the Fixed Stapler Safety Gate Solenoid
deactuates too slowly. replace the Disk Baffle Assembly PL 8.3 Item 12.

In Component Control, select [Finisher], [Fixed Stapler Interlock Switch], then [Start Monitor].
The state of the Fixed Stapler Interlock Switch is low (not actuated).
Y
N
Exit diagnostics to clear the fault.
Check for obstructions in the Fixed - Stapler Safety Gate mechanism that may be causing
the Fixed Stapler Safety Gate to stay in the down position. There is an obstruction in
the Fixed Stapler Safety Gate mechanism.
Y
N
Clear the obstruction.
Program a job for 10 stapled sets of 2 sheets.
Check the operation of the Fixed Stapler after clearing the obstruction. A
fault occurs after the clearing the obstruction.
Y
N
12-205.02

Do the following:
In Component Control, select [Finisher], [Fixed Stapler Intlk Switch], then [Start Monitor].
Select [Fixed Stapler Safety Gate Solenoid], [Output On], then [Output Off] to lower and
raise the Fixed Stapler Safety Gate.
Observe the state of the Fixed Stapler Interlock Switch when the Fixed Stapler Safety Gate is
lowered and then raised. The display indicates the state of the Fixed Stapler Interlock
Switch goes from low to high to low.
12-205.02
May 2003
2-512
V0.042
V0.042
May 2003
2-513
12-205.02
12-206 Stapler Position Home Fault RAP

The Stapler Position Home Sensor fails to transition within 2000 ms after the Stapler Position
Motor energizes to send the Moving Stapler to the home position.
C
Check the Moving Stapler Gear Rack for damage or obstructions. If the gear rack is
damaged, replace the Service Tray Assembly PL 8.5 Item 1.
Do the following:
Check connector P2 on the Stapler Position Motor.
Connector P2 is connected securely to the Stapler Position Motor.

Y
N
Unsure connector P2 is connected securely to the Stapler Position Motor.
Initial Actions
Open then close the Finisher Top Cover Door.
If the fault cannot be cleared by opening and then closing the Finisher Top Cover Door, follow
the procedure.
Disconnect P6 from the Finisher Controller PWB.

From P6 -10 to P6 -11
Do the following:
From P6 -12 to P6 -13
To gain access to the Finisher components, undock the Finisher from the IOT (REP 1212). Do not disconnect J15 from P69.
Y
N
If the wires are good, replace the Moving Stapler PL 8.5 Item 3.
Reconnect the Power Cord and switch the power [On].
Manually move the Moving Stapler to the rear position.
In Component Control, select [Finisher], [Stapler Position Front], [Output On]. Select [Stapler Position Rear], then [Output On].

Observe the Moving Stapler. The Moving Stapler moves smoothly and quietly to the
front position, and to the rear position.
Y
N
The harness for the Moving Stapler is attached securely to the Service Tray Assembly and the harness does not interfere with the movement of the stapler.
Y
N
Ensure the harness for the Moving Stapler is attached securely to the Service Tray
Assembly.
Switch the power [Off]. Manually move the Moving Stapler through its entire length of
travel.
The Stapler moves smoothly without binding.
Y
N
Check the following Moving Stapler components:
the Moving Stapler Ball Slide for damage or obstructions including loose staples.
the Moving Stapler drive gears for damage or obstructions including loose staples.
the Stapler Position Motor for binding.
The Stapler Position Home Sensor is seated correctly.

Y
N
Reseat the Stapler Position Home Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Stapler Position
Home Sensor PL 8.3 Item 4.
Go to Flag 1. Check the circuit of the Stapler Position Home Sensor for an open circuit or a
short circuit.
Stapler Position Home Sensor PL 8.5 Item 4.
Service Tray Assembly PL 8.5 Item 1 (if the harness cannot be repaired.
The Moving Stapler drive components are free from damage or obstructions.
Y
N
Clear the obstruction. If any of the components are damaged, replace the Moving Stapler PL 8.5 Item 3.
A
B
C
12-206
May 2003
2-514
V0.042
V0.042
May 2003
2-515
12-206
12-207.01 Moving Stapler Home Fault RAP
The head of the Moving Stapler was not detected in the home position by the Moving Stapler
Home Sensor before the staple cycle began. The Stacker Tray will be unavailable.
N

messages.
Initial Actions
attributes:
2 sheets
1-sided
2 staples
81/2 x 11 in or A4 paper
2 copies
If a 12-207.01 fault occurs, follow the procedure in this RAP.

Enter, then exit Component Control. Enter [Copier Sys tab , Component Control].
Observe the Moving Stapler head. The Moving Stapler head moves when exiting the
diagnostic mode.
Y
N
Do the following:
Measure the resistance between P7 -5 and P7 -6, on the connector
Y
N
Do the following:
Place a stack of paper in the Moving Stapler.
PWB.
In Component Control, select [Finisher], [Moving Stapler Safety Gate Solenoid], [Output
On], [Cycle Moving Stapler Once], then [Output On]. Enter [Copier Sys tab , Component
Control].
The voltage changes when the Moving Stapler Clinch Motor energizes.
12-207.01
May 2003
2-516
V0.042
V0.042
May 2003
2-517
12-207.01
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
12-207.01
May 2003
2-518
V0.042
12-207.02 Fixed Stapler Home Fault RAP
The head of the Fixed Stapler was not detected in the home position by the Fixed Stapler
Home Sensor before the staple cycle began. The Stacker Tray will be unavailable.
N
If the wires are good, replace the Fixed Stapler PL 8.5 Item 2

NOTE: The Fixed Stapler in the Finisher is also referred to as Stapler 2 in User Interface messages.
Initial Actions
attributes:
2 sheets
1-sided
2 staples
2 copies

Enter, then exit Component Control. Enter [Copier Sys tab , Component Control].
The Fixed Stapler head moves when exiting the Component Control.
Y
N
Do the following:
Measure the resistance between P7 -11 and P7 -12, on the connector
Y
N
If the wires are good, replace the Fixed Stapler PL 8.5 Item 3.
Do the following:
Place a stack of paper in the Fixed Stapler.
PWB.
In Component Control, select [Finisher], [Fixed Stapler Safety Gate Solenoid], [Output
On], [Cycle Fixed Stapler Once], then [Output On].
Measure the voltage between SIGNALGND and TH51 on the Finisher Controller. The voltage changes when the Fixed Stapler Clinch Motor energizes.
V0.042
May 2003
2-519
12-207.02
12-207.02
May 2003
2-520
V0.042
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
V0.042
May 2003
2-521
12-207.02
12-208.01 Moving Stapler Interlock Switch Fault RAP
The Moving Stapler Interlock Switch fails to actuate 60 ms after the Moving Stapler Safety Gate
Solenoid energizes.
Observe the Moving Stapler Safety Gate. The Moving Stapler Safety Gate is lowered
and then raised when the Moving Stapler Safety Gate Solenoid energizes and then
deenergizes.
Y
N
The Moving Stapler Safety Gate is damaged.
Y
N
Do the following:
messages.
Initial Actions
the customer was using when the Finisher jam occurred
Ensure the customer has not sent a job to the Finisher that exceeds capacity of the Stapler. Refer to General Information/Specifications, Product Specifications, Capabilities.
The 12-208.01 fault may be cleared by cycling the Finisher Interlock Switch. Open then
close the Finisher Top Cover Door.
A 12-208.01 fault may occur if the Stacker Tray is not level. Go to the Stacker Tray Levelling Procedure. Ensure the Stacker Tray is level
In Component Control, select [Finisher], [Moving Stapler Safety Gate Solenoid],

[Output On], [Moving Stapler Safety Gate Solenoid], then [Output Off]. Enter [Copier
2 sheets
Long Edge Feed (LEF)
1-sided
1 staple
In Component Control, select [Finisher], [Moving Stapler Interlock Switch], [Start Monitor],
[Moving Stapler Safety Gate Solenoid], [Output On], then [Output Off]. Enter [Copier Sys
tab , Component Control].
The state of the Moving Stapler Interlock Switch changed.
Y
N
Switch the power [Off]. Manually raise and lower the Moving Stapler Safety Gate.
The Moving Stapler Safety Gate raises and lowers freely without binding.
Y
N
Remove the Disk Baffle Assembly (REP 12-9).
Check the position of the bracket for the Stapler Lead-In Baffle (Figure 3).
The mounting bracket for the Stapler Lead-In baffle is positioned against the frame
of the Moving Stapler.
Y
N
Replace the Moving Stapler PL 8.5 Item 3.
Do the following:
To gain access to the Finisher components, undock the Finisher from the IOT (REP
12-12). Do not disconnect J15 from P69.

Y
N
Do the following:
C
A
B
12-208.01
In Component Control, select [Finisher], [Moving Stapler Safety Gate

Solenoid], then [Output On]. Enter [Copier Sys tab , Component Control].
Replace the Moving - Stapler Safety Gate PL 8.3 Item 26.
Check the output in the Stacker Tray.

Multiple small sets are stapled together.
Y
N
Y
N
Reseat the Canard Wing in the correct position. If the Canard Wing is damaged or
cannot be reseated correctly, replace the Moving Stapler PL 8.5 Item 3.

If the wires are good, replace the Disk Baffle Assembly PL 8.3 Item 12.
Measure the voltage between P3 -7 (-) and P3 -6 (+) on the Finisher Controller PWB.
The voltage is +24 VDC when the Moving Stapler Safety Gate Solenoid
energizes.
Y
N
If the problem continues, replace the Finisher Controller PWB PL 8.3 Item
16.
attributes:
The gears on the Moving - Stapler Safety Gate (part of the Disk Baffle
Assembly PL 8.3 Item 12).
The Moving Stapler Safety Gate Solenoid (part of the Disk Baffle Assembly PL 8.3 Item 12).
The Moving - Stapler Safety Gate PL 8.3 Item 26.

Measure the voltage between SIGNALGND (-) and P9 -2 (+) on the Finisher Controller PWB.
In Component Control, select [Finisher], [Moving Stapler Safety Gate Solenoid], then
[Output On].
C
May 2003
2-522
V0.042
Check the actuator for the Moving Stapler Interlock Switch (located on the
Moving - Stapler Safety Gate).
The actuator is damaged or missing.

Y
N
Go to Flag 1. Check the circuit of the Moving Stapler Interlock Switch for
an open circuit or a short circuit.
Replace the Moving - Stapler Safety Gate PL 8.3 Item 26.

Go to Flag 1. Check the circuit of the Moving Stapler Interlock Switch for an intermittetcondition.
Replace the Staple Cartridge in the Moving Stapler
2 sheets
1-sided
1 staple
10 sets
The problem continues after replacing the Staple Cartridge.

Y
N
In Component Control, select [Finisher], [Kicker On], then [Output On]. Enter [Copier Sys tab ,
Component Control].
Observe the Kicker. The Kicker moves to the eject position and back when the Kicker
Motor energizes.
Y
N
Check the mechanical components of the Kicker for damage. Replace the Service Tray
Assembly PL 8.5 Item 1 if necessary.
V0.042
May 2003
2-523
12-208.01
12-208.01
May 2003
2-524
V0.042
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
V0.042
May 2003
2-525
12-208.01
12-208.02 Fixed Stapler Interlock Switch fault RAP

The Fixed Stapler Interlock Switch, fails to actuate 60 ms after the Fixed Stapler Safety Gate
Solenoid, energizes.
NOTE: The Fixed Stapler in the Finisher is also referred to as Stapler 2 in User Interface
messages.
Initial Actions
the customer was using when the Finisher jam occurred
Ensure the customer has not sent a job to the Finisher that exceeds capacity of the Stapler. Refer to General Information/Specifications, Product Specifications, Capabilities.
The 12-208.02 fault may be cleared by cycling the Finisher Interlock Switch. Open then
close the Finisher Top Cover Door.
attributes:
2 sheets
1-sided
2- staples

Multiple small sets are stapled together.
Y
N
Do the following:
Bracket for the Stapler

Lead-In Baffle
To gain access to the Finisher components, undock the Finisher from the IOT (REP
12-12). Do not disconnect J15 from P69.
In Component Control, select [Finisher], [Fixed Stapler Safety Gate Solenoid], [Output On], [Fixed Stapler Safety Gate Solenoid], then [Output Off]. Enter [Copier Sys
Figure 3 Correct position of the mounting bracket for the Stapler Lead-In Baffle
Observe the Fixed Stapler Safety Gate. The Fixed Stapler Safety Gate is lowered and
then raised when the solenoid energizes and then deenergizes.
Y
N
The Fixed Stapler Safety Gate is damaged.
Y
N
Do the following:
A
12-208.01, 12-208.02
May 2003
2-526
In Component Control, select [Finisher], [Fixed Stapler Safety Gate Solenoid], then [Output On]. Enter [Copier Sys tab , Component Control].
C
V0.042
A
The voltage is +24 VDC when the Fixed Stapler Safety Gate Solenoid
energizes.
Y
N
If the problem continues, replace the Finisher Controller PWB PL 8.3 Item
16.
If the wires are good, replace the Disk Baffle Assembly PL 8.3 Item 12.
E
Go to Flag 1. Check the circuit of the Fixed Stapler Interlock Switch for an intermittent
condition.
Replace the Staple Cartridge in the Fixed Stapler

Replace the Fixed - Stapler Safety Gate PL 8.3 Item 27.

In Component Control, select [Finisher], [Fixed Stapler Interlock Switch], [Start Monitor],
[Fixed Stapler Safety Gate Solenoid], [Output On], then [Output Off]. Enter [Copier Sys
The state of the Fixed Stapler Interlock Switch changed.
Y
N
Switch the power [Off]. Manually raise and lower the Fixed Stapler Safety Gate.
The Fixed Stapler Safety Gate raises and lowers freely without binding.
Y
N
The gears on the Fixed - Stapler Safety Gate (part of the Disk Baffle
Assembly PL 8.3 Item 12).
The Moving Stapler Safety Gate Solenoid (part of the Disk Baffle Assembly PL 8.3 Item 12).
The Fixed - Stapler Safety Gate PL 8.3 Item 27.
2 sheets
1-sided
2 staples
10 sets
The problem continues after replacing the Staple Cartridge.

Y
N
In Component Control, select [Finisher], [Kicker On], then [Output On]. Enter [Copier Sys tab ,
Component Control].
Observe the Kicker. The Kicker moves to the eject position and back when the Kicker
Motor energizes.
Y
N
Check the mechanical components of the Kicker for damage. Replace the Service Tray

In Component Control, select [Finisher], [Moving Stapler Safety Gate Solenoid], then
[Output On].
Y
N
Do the following:
Check the actuator for the Fixed Stapler Interlock Switch (located on the
Fixed - Stapler Safety Gate).
The actuator is damaged or missing.

Y
N
Go to Flag 1. Check the circuit of the Fixed Stapler Interlock Switch for an
Replace the Fixed - Stapler Safety Gate PL 8.3 Item 27.

A
D
V0.042
May 2003
2-527
12-208.02
12-208.02
May 2003
2-528
V0.042
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
V0.042
May 2003
2-529
12-208.02
12-209.01 Moving Stapler Clinch Motor Fault RAP
The Moving Stapler Home Sensor fails to block within 500 ms after the Moving Stapler Clinch
Motor energizes.
2 sheets
1-sided
2 staples
5 copies (the first few sets may not contain any staples).
The Moving Stapler Interlock Switch is deactuated after the staple cycle begins due to bounce
of the Moving Stapler Safety Gate.
messages.
In Faults, select [Last 40 Faults]. Enter [Faults/Counters tab , Faults]. A 12-209.01 fault
occurs after reinstalling the Staple Cartridge in the Moving Stapler.
Y
N
Initial Actions
The 12-209.01 fault may be cleared by cycling the Finisher Interlock Switch. Empty the
Stacker Tray, open then close the Finisher Top Cover Door.
Do the following:
attributes:
2 sheets
1-sided
2 staples
In Component Control, select [Stacker Tray Down] then [Output On], to lower the
Stacker Tray.
Replace the Staple Cartridge.
Exit [Copier Sys tab , Component Control].
2 sheets
1-sided
2 staples
occurs after replacing the Staple Cartridge in the Moving Stapler.
Y
N

The problem occurs on 40 to 50 sheet stapled sets only.
Y
N
Y
N
Do the following:
Check the position of the bracket for the Stapler Lead-In Baffle (Figure 5).
The mounting bracket for the Stapler Lead-In Baffle is positioned against the frame
of the Moving Stapler.
Y
N
Place a stack of 5 sheets of paper in the throat of the Moving Stapler.

[Output On], [Cycle Moving Stapler Once], then [Output On]. Enter [Copier Sys tab ,
Component Control].
Observe the Moving Stapler. The Moving Stapler Clinch Motor energizes to cycle
the Moving Stapler.
Y
N
Do the following:
Do the following:
Stacker Tray.
Remove the Staple Cartridge from the Moving Stapler. Clear any jammed staples
Ensure the Driver Bar on the Staple Cartridge is in the correct position (refer to Figure 3) and the first staple is in the correct position and the staple is not damaged
(refer to Figure 4).
A
12-209.01
Reinstall the Staple Cartridge and Exit [Copier Sys tab , Component Control].
On the Fluke meter select DC voltage. Press the MIN MAX button to select
the RECORD mode. Press PEAK MIN MAX button once to select the RECORD
MAX mode.
Measure the voltage between P7 -6 (-) and P7 -5 (+) on the Finisher Controller
PWB.

[Output On], [Cycle Moving Stapler Once], then [Output On]. Enter [Copier Sys

A
May 2003
2-530
B
V0.042
B
Y
N
If the problem continues, replace the Moving Stapler PL 8.5 Item 3.

Do the following:
Place a stack of 5 sheets of paper in the throat of the Moving Stapler.
Measure the voltage from the SIGNALGND (-) and TH42 (+) on the Finisher Controller PWB.

Component Control].
The voltage changes when the Moving Stapler Clinch Motor energizes.
Y
N
The Moving Stapler Safety Gate is not keeping the Moving Stapler Interlock Switch actuated
when the Moving Staple Clinch Motor is operating. Replace the Moving - Stapler Safety Gate
PL 8.3 Item 26.
V0.042
May 2003
2-531
12-209.01
12-209.01
May 2003
2-532
V0.042
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
V0.042
May 2003
2-533
12-209.01
Incorrect edge Correct edge

tab position
tab position
If the Driver Bar is not even

with the edge of the cartridge,
use a pen or other pointed tool
to move the edge tab the correct position.
Ensure the Driver Bar is even

with the edge of the cartridge.
Figure 3 Checking the Driver Bar position
Remove the staple if it is

malformed, or it is in this
position.
Figure 4 Staple Checking the staple position
12-209.01
May 2003
2-534
V0.042
12-209.02 Fixed Stapler Clinch Motor Fault RAP

The Fixed Staple Home Sensor fails to block within 500 ms after the Fixed Stapler Clinch Motor
energizes.
The Fixed Stapler Interlock Switch is deactuated after the staple cycle begins due to bounce
of the Fixed Stapler Safety Gate.
NOTE: The Fixed Stapler in the Finisher is also referred to as Stapler 2 User Interface messages.
Initial Actions
1.
Ensure the customer has not sent a job to the Finisher that exceeds capacity of the
Stacker Tray. Refer to Finishing. in Table 6
2.
Ask the customer if anything was inserted into the Stapler when a set was being compiled.
3.
The 12-209.02 fault may be cleared by cycling the Finisher Interlock Switch. Empty the
Stacker Tray, open then close the Finisher Top Cover Door.
4.
attributes:
2 sheets
1-sided
2 staples

Lead-In Baffle

The problem occurs on 40 to 50 sheet stapled sets only.
Y
N
Empty the Stacker Tray, switch the power [Off], then switch the power [On].
2 sheets
1-sided
2 staples
occurs after power off and power on.
Y
N
Do the following:
Stacker Tray.
A
V0.042
May 2003
2-535
12-209.01, 12-209.02
Ensure the Driver Bar on the Staple Cartridge is in the correct position (refer to Figure 3) and the first staple is in the correct position and the staple is not damaged
(refer to Figure 4).
In Component Control, select [Finisher], [Fixed Stapler Safety Gate Solenoid],

[Output On], [Cycle Fixed Stapler Once], then [Output On]. Enter [Copier Sys
Reinstall the Staple Cartridge and Exit [Copier Sys tab , Component Control].

Y
N
If the problem continues, replace the Fixed Stapler PL 8.5 Item 2.
Remove the Staple Cartridge from the Fixed Stapler. Clear any jammed staples.
2 sheets
1-sided
2 staples

Do the following:
occurs after the Staple Cartridge is reinstalled in the Fixed Stapler.
Y
N
Do the following:
Stacker Tray.
Replace the Staple Cartridge in the Fixed Stapler.
Exit [Copier Sys tab , Component Control].
2 sheets
1-sided
2 staples
Place a stack of 5 sheets of paper in the throat of the Fixed Stapler.
In Component Control, select [Finisher], [Fixed Stapler Safety Gate Solenoid], [Output On], [Cycle Fixed Stapler Once], then [Output On]. Enter [Copier Sys tab , Component Control].
The voltage changes when the Fixed Stapler Clinch Motor energizes.
Y
N

The Fixed Stapler Safety Gate is not keeping the Fixed Stapler Interlock Switch actuated when
the Fixed Staple Clinch Motor is operating. Replace the Fixed - Stapler Safety Gate PL 8.3 Item
27.
occurs after replacing the Staple Cartridge in the Fixed Stapler.
Y
N
Do the following:
Place a stack of 5 sheets of paper in the throat of the Fixed Stapler.
Observe the Fixed Stapler. The Fixed Stapler Clinch Motor energizes to cycle the
Fixed Stapler.
Y
N
Do the following:
MAX mode.
A
B
12-209.02
May 2003
2-536
V0.042
V0.042
May 2003
2-537
12-209.02
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
12-209.02
May 2003
2-538
V0.042

to move the edge tab the correct position.

tab position
tab position

Figure 3 Checking the Driver Bar position

position.
Figure 4 Checking the staple position
V0.042
May 2003
2-539
12-209.02
12-210 Stacker Tray Lower Limit Fault RAP

The Stacker Tray Lower Limit Switch was actuated when the Stacker Tray was being lowered.
Procedure
This is an On-Site service call.
Y
N
Go to the 12-210 Remote Diagnostic Procedure.

A 12-210 fault is declared.
Y
N
Go to Flag 2. Check the circuitry of the Stacker Tray Lower Limit Switch for an intermittent
condition.
Stacker Tray Lower Limit Switch PL 8.5 Item 6.
Check the Stacker Tray Lower Limit Switch. The Stacker Tray Lower Limit Switch is actuated by the Stacker Tray Front Bracket.
Y
N
Go to Flag 2. Check the circuitry of the Stacker Tray Lower Limit Switch for an open circuit.
Stacker Tray Lower Limit Switch PL 8.5 Item 6.
Check the position of the Stacker Tray Full Sensor. The Stacker Tray Full Sensor is seated
correctly.
Y
N
Reseat the Stacker Tray Full Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Stacker Tray Full
Go to Flag 1. Check the circuit of the Stacker Tray Full Sensor for a short circuit.
Stacker Tray Full Sensor PL 8.5 Item 4.
12-210
May 2003
2-540
V0.042
V0.042
May 2003
2-541
12-210
12-213 Top Tray Offset Home Fault RAP
The voltage is +24 VDC when the Top Tray Offset Motor energizes.
Y
N
Measure the resistance between P4 -11(-) and P4 -10 (+) on the connector.
The Top Tray Offset Sensor does not transition to unblocked 1000 ms after the Top Tray Offset
Motor energizes.
Initial Actions
Check the Top Tray of the Finisher for obstructions that may be preventing the Top Tray
from offsetting.
If an obstruction was found, remove the obstruction and run the job again.
If the problem was not caused by an obstruction that was blocking the Top Tray, follow the
procedure in this RAP.
NOTE: The resistance measured varies with the position of the motor
armature in the Top Tray Offset Motor at the time the measurement is
taken. A value of less than 35 Ohms is an indication of a short circuit.
The resistance is 35 to 200 Ohms.
Y
N
If the wires are good, replace the Top Module Assembly PL 8.3 Item
1.

Do the following:
Place 2 sheets of the same size paper the customer was using when the fault occurred
into the Document Input Tray.
Program a job of 5 collated sets.

If the wires are good, replace the Top Module Assembly PL 8.3 Item 1
The Finisher Top Tray is offsetting the sets.

Y
N
In Component Control, select [Finisher], [Top Tray Offset Motor], then [Output On]. Enter
Observe the Finisher Top Tray. The Finisher Top Tray offsets when the Top Tray Offset Motor energizes in Component Control.
Y
N
In Component Control, select [Finisher], [Top Tray Offset Motor], then [Output On].
Observe the Top Tray Offset Motor. The Top Tray Offset Motor energizes in
Component Control.
Y
N
Check the position of the Finisher Top Tray guide rollers. The Finisher Top
Tray guide rollers are in the correct position.
Y
N
The Back Wall of the Finisher Top Tray may have become dislodged from
the Top Module Assembly frame during operation of the Finisher or during
installation of the Finisher Top Tray.
Go to REP 12-16.
Check the Top Tray Offset Drive Gear for wear or damage. Replace the Top Module
Check the position of the Top Tray Offset Sensor PL 8.4 Item 1. The Top Tray Offset
Sensor is seated in the correct position.
Y
N
Reseat the Top Tray Offset Sensor.
If the sensor cannot be reseated due to a broken mount, replace the Stapler Position
In Component Control, select [Finisher], [Top Tray Offset Sensor], [Start Monitor], [Top
Tray Offset], then [Output On]. Enter [Copier Sys tab , Component Control].
The state of the Top Tray Offset Sensor changes.
Y
N
Check for contamination of the Top Tray Offset Sensor The Top Tray Offset Sensor is free from contamination.
Y
N
Check the following offset components for binding:
The gears driven by the Top Tray Offset Motor.

The Finisher Top Tray upper guide rollers.
The Finisher Top Tray lower guide rollers.
Top Tray Offset Sensor PL 8.4 Item 1.
The Finisher Top Tray offset components are free from binding.
Y
N
Replace the Top Module Assembly PL 8.3 Item 1, if necessary.
Measure the voltage between P4 -11 (-) and P4 -10 (+)on the Finisher Controller PWB.
In Component Control, select [Finisher], [Top Tray Offset Motor], then [Output
A
B
C
12-213
The Back Wall of the Finisher Top Tray may have become dislodged from the Top Module
Assembly frame during operation of the Finisher or during installation of the Finisher Top
Tray.
Go to REP 12-16.
May 2003
2-542
V0.042
V0.042
May 2003
2-543
12-213
12-214 Stacker Tray Offset Fault RAP Smart Tray
12-220 Set Eject Cycle Fault RAP
NOTE: This RAP is for Document Centre 460/470 DC/ST only.
The Kicker Home Sensor was not actuated in the allowed time after the Kicker Motor energized.
The Stacker Tray has been moved greater than 2 mm off position. The occurs if the tray is
bumped out of position
Initial Actions
Check the Stacker Tray for obstructions that may be preventing the tray from offsetting.
Procedure

Check the prints/copies in the Stacker Tray. The prints/copies show signs of excessive
static.
Y
N
In Component Control, select [Finisher], [Kicker On], then [Output On]. Enter [Copier Sys
Observe the Kicker. The Kicker moves to the eject position and back when the
Kicker Motor energizes.
Y
N
MAX mode.
Measure the voltage between P6 -5 (-) and P6 -4 (+) on the Finisher Controller
PWB.
In Component Control, select [Finisher], [Kicker On], then [Output On]. Enter
The voltage is approximately +23 VDC.

Y
N
If the problem continues, replace the Service Tray Assembly PL 8.5 Item 1.
In Component Control, select [Finisher], [Kicker Home Sensor], then [Start Monitor]. Enter
The state of the Kicker Home Sensor Changes.
Y
N
Check the position of the Kicker Home Sensor. The sensor is seated correctly.
Y
N
Reseat the Kicker Home Sensor in the correct position.
If the sensor cannot be reseated due to a broken mount, replace the Kicker
Go to Flag 1. Check the circuit of the Kicker Home Sensor for an open circuit or a
short circuit. The check of the Kicker Home Sensor circuit is good.
Y
N
Kicker Home Sensor PL 8.5 Item 4.
Replace the Service Tray Assembly PL 8.5 Item 1

Check the Kicker mechanism for binding or damage.
A
12-214, 12-220
May 2003
2-544
V0.042
A
Replace the Service Tray Assembly PL 8.5 Item 1 if necessary.
V0.042
May 2003
2-545
12-220
12-220
May 2003
2-546
V0.042
12-222 Stack Height Fault RAP
Stack Too High

Sensor
The Stack Too High Sensor is blocked when the Stack Height Sensor is unblocked.
Stack Height
Sensor actuator
Initial Actions
Switch the power [Off] then switch the power [On] to attempt to clear the fault.
Stack Height
Sensor
Check the Stack Height Sensor actuator (located on the Rear Bale Arm).
The actuator for the Stack Height Sensor is broken.
Y
N
Check the Stack Too High Sensor for contamination.
The Stack Too High Sensor is free from contamination.
Y
N
Rear Bale
Arm
Do the following:
In Component Control, select [Finisher], [Stack Too High Sensor], then [Start Monitor].
Block and unblock Stack Too High Sensor by manually raising and lowering the Rear
Bale Arm.

Figure 1 12-222 RAP Component Location
The state of the Stack Too High Sensor changed.

Y
N
Go to Flag 2. Check the circuit of Stack Too High Sensor for a short circuit.
Go to Flag 3. Check the circuit of Stack Height Sensor for an open circuit.
V0.042
May 2003
2-547
12-222
12-222
May 2003
2-548
V0.042
A
If the problem occurs again, check the following:
12-307 Stapler Access Door Interlock Switch RAP

The Stapler Access Door Interlock Switch opened when the Finisher was in operation.
The message 'Close the door to the stapler cartridges' is displayed on the User Interface, when
the Stapler Access Door is closed.
Intermittent actuation of the Stapler Access Door Interlock Switch by the Stapler Access
Door.
Go to Flag 2. Check the circuit of the Stapler Access Door Interlock Switch for an intermittent open condition.
For more information, go to: Finisher Power and Interlocks in the Principles of Operation section of this manual.

The Stapler Access Door Interlock Switch PL 8.5 Item 12.

Press the Pause Resume Switch and observe the Stapler Access Door when the Stacker Tray
is lowered.
The Stapler Access Door remains closed when the Stacker Tray is lowered.
Y
N
Ensure the Stapler Access Door spring is attached correctly. If the spring is damaged or
missing, Replace the Finisher.
Do the following:
Ensure the Stapler Access Door is closed securely.
In Component Control, select [Finisher], [Stapler Access Door Interlock Switch], then
[Start Monitor]. Enter [Copier Sys tab , Component Control].
The state of the Stapler Access Door Interlock Switch is high.

Y
N
Ensure the Stapler Access Door is closed.
PWB.
Y
N
The actuator on the Stapler Access Door Interlock Switch PL 8.5 Item 12
The actuator for the Stapler Access Door Interlock Switch, located on the Finisher frame.
The actuator located on the Stapler Access Door PL 8.5 Item 12 that actuates
the Interlock Switch.
The Stapler Access Door Interlock components are free from damage.
Y
N
Replace the component or components that are damaged.
The Stapler Access Door Interlock Switch PL 8.5 Item 12.
the Stapler Access Door PL 8.5 Item 12.

If the wires are good, replace the Stapler Access Door Interlock Switch PL 8.5 Item
12.
A
V0.042
May 2003
2-549
12-307
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH49
TH51
TH53
TH69
TH66
TH50
12-307
May 2003
2-550
V0.042
12-309 Finisher Interlock Switch RAP

The Finisher Interlock Switch opened when the Finisher was in operation.
A message to close the Finisher Top Cover is displayed on the User Interface, when the Finisher Top Cover is closed.

Do the following:
Use the interlock cheater to actuate the Finisher Interlock Switch.
In Component Control, select [Finisher], [Finisher Interlock Switch], then [Start Monitor].
The state of the Finisher Interlock Switch is high.

Y
N
Measure the voltage between SIGNALGND (-) and TH44 (+) on the Finisher Controller.
Y
N
If the wires are good, replace the Finisher Interlock Switch PL 8.2 Item 22.
Check the actuator for the Finisher Interlock Switch Actuator. The Finisher Interlock Switch
Actuator is damaged or missing.
Y
N
Check the following for damage:
The pin on the Finisher Top Cover Door PL 8.2 Item 8.
The snap fit for the door pin on the Finisher Top Cover PL 8.2 Item 7.
Replace the Finisher Top Cover Door PL 8.2 Item 8.

V0.042
May 2003
2-551
12-309
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
12-309
May 2003
2-552
V0.042
12-310 Stacker Tray Offset Motor Fault RAP
The Stacker Tray Offset Motor does not provide encoder feedback to the Finisher Controller
PWB.
Initial Actions
from offsetting. If an obstruction was found, remove the obstruction and run the job again. If the
problem was not caused by an obstruction that was blocking the Stacker Tray, follow the procedure.

Do the following:
Clear all copies from the Stacker Tray.
Remove any obstructions that may be preventing the Stacker Tray from offsetting, including foreign objects in the Stacker Tray and paper jammed between the Stacker Tray and
the Stacker Tray Front Bracket.
Send a job to the Stacker Tray.

Y
N
In the Diagnostic Navigator, select [Finishing] tab, [Finisher Tests], then select the [Main
Tray Offset / Position] tab.
Go to Flag 1 and to Flag 2. Check the wires an open circuit.

If the wires are good, replace the Stacker Tray PL 8.2 Item 16.
Replace the Stapler Access Door PL 8.5 Item 11.
Measure the voltage between J6 -1 (-) and J6 -3 (+) on the Finisher Controller PWB.
Y
N
If the problem continues, replace the Stacker Tray PL 8.2 Item 16.
Do the following:
PWB.
In Component Control, select [Finisher], [Stacker Tray Offset (Open loop)], then [Output
N
Go to Flag 2. Check the wires an a short circuit.
In Component Control, select [Finisher], [Stacker Tray Offset (Open loop)], then [Output On].
The Stacker Tray offsets continuously and smoothly.

Y
N
Check the Stapler Access Door.
The Stapler Access Door is interfering with the movement of the Stacker Tray.
Y
N
Y
N
PWB.
The voltage is approximately +2.5 VDC when the Stacker Tray Offset Motor energizes.
Y
N
Go to Flag 3 and Flag 5. Check the wires for an open circuit.
If the wire is good, replace the Stacker Tray PL 8.2 Item 16.
A
B
V0.042
May 2003
2-553
12-310
12-310
May 2003
2-554
V0.042
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
V0.042
May 2003
2-555
12-310
12-315 Stacker Tray Offset Motor Fault RAP Smart Tray
C
Go to Flag 1 and to Flag 2. Check the wires an open circuit.

The Stacker Tray Offset Motor (Smart Tray configuration) does not provide encoder feedback
to the Finisher Controller PWB.
Initial Actions
Replace the Stapler Access Door PL 8.5 Item 11.
from offsetting including foreign objects in the Stacker Tray and paper jammed between the
Stacker Tray and the Stacker Tray Front Bracket.
Measure the voltage between J6 -1 (-) and J6 -3 (+) on the Finisher Controller PWB.
Y
N
If the problem continues, replace the Stacker Tray PL 8.2 Item 16.
If an obstruction was found, remove the obstruction and run the job again. If the problem was
not caused by an obstruction that was blocking the Stacker Tray, follow the procedure.
Do the following:

Do the following:
Clear all copies from the Stacker Tray.
Send a job to the Stacker Tray.
PWB.
Tray Offset / Position] tab. Select [Continuous Cycle], [Mode 2], then select [Start]. Select
the [Continue] button when displayed to continue the test. Enter [Finishing tab, Finisher
Tests].
The voltage is approximately +2.5 VDC when the Stacker Tray Offset Motor energizes.
Y
N
If the wire is good, replace the Stacker Tray PL 8.2 Item 16.

Y
N
Do the following:
The Stacker Tray offsets continuously and smoothly.

Y
N
Check the Stapler Access Door.
The Stapler Access Door is interfering with the movement of the Stacker Tray.
Y
N
Y
N
Y
N
A
B
C
12-315
May 2003
2-556
V0.042
V0.042
May 2003
2-557
12-315
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
Figure 2 Finisher Controller PWB Test Points
12-315
May 2003
2-558
V0.042
12-323 Finisher Configuration Error RAP
12-700 Finisher Configuration Error RAP
Automatic configuration has detected an incorrect Finisher configuration.
Automatic configuration has detected a Smart Tray configuration Finisher installed on an IOT
with software version 07.19.0.056 or lower.
The following message is displayed on the User Interface:
Check the Finisher serial number.

The Finisher serial number is NF3xxxxxx, 6UPxxxxxx, or DCExxxxxx.
Y
N
Install one of the following:
A Finisher with serial number 6UPxxxxxx.
A Finisher with serial number NF3xxxxxx


Check the Finisher serial number. The serial number for a Smart Tray Finisher is NF3xxxxxx.
A Smart Tray Finisher is installed.
Y
N
NOTE: A NF3xxxxxx Finisher requires version 07.19.01.503 or higher software.
A Finisher with serial number DCExxxxxx

NOTE: A DCExxxxxx Finisher requires version 07.19.02.xxx or higher software and
will be available late 2001.

The Smart Tray configuration Finisher, serial number NF3xxxxxx, is not designed to operate
with IOT software versions 7.00 (07.19.0.027), 7.01 (07.19.0.028), or 7.02 (07.19.0.056).
Perform one of the following two actions:
If software version 07.19.01.503 or higher is not available, do the following:
Remove the Smart Tray configuration Finisher,
Install a non Smart Tray configuration Finisher (serial number 6UPxxxxxx)
If software version 07.19.01.503 or higher is available, do the following to enable the

Smart Tray Finisher on a 460/470 IOT.
Remove the Smart Tray configuration Finisher.
Reinstall a non Smart Tray Finisher if available and switch the power [On].
NOTE: If a 6UPxxxxxx Finisher is not available, cheat the Right Side Interlock
Switch (machines without TAG 114) and accept the configuration of no output
device.
Install software version 07.19.01.503 or higher.
Remove the non Smart Tray configuration Finisher (if installed).
Install the Smart Tray configuration Finisher and switch the power [On].
If installing a new Finisher, enter the Tamper setting for the new Finisher, in Tools on the UI:
V0.042
Enter the Tools pathway on the UI.
Select [More].
Select [Configuration and Setup], and select [Close] to dismiss the warning message
Select [Disk Finisher Setup].
Open the Finisher Top Cover Door and read the tamper value from the label on the inside
of the door.
Enter the tamper value on the UI and select [Save].
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12-323, 12-700
Select [Close] and select [Reboot]. After the machine resets, it will come up no longer in
Tools.
12-AA Finisher Fault Entry RAP

Use this RAP to identify Finisher problems and the action to take if the problem occurs.
Initial Actions
If the problem is identified as poor stacking, mis-stapled sets, or poor set registration of thin
stapled sets, go to GP30 to program the Finisher settings for thin stapled sets. If the problem
continues, go to the table below to identify the correct procedure for correcting the problem.
Procedure
The following are Finisher problems an explanation of each problem, and the action to take if
the problem occurs. If a Finisher fault code is displayed, go to the appropriate RAP for the fault
code.
Table 1 Finisher Problems
Problem
Action
The stapled or unstapled sets of prints are stacked

Go to the 12-AC Finisher Misregisincorrectly in the Stacker Tray, or in the Finisher Top
tration RAP.
Tray.
There are misregistered sheets in the stapled or unstapled sets of prints delivered to the Stacker Tray or to
the Finisher Top Tray.
Sheets skipping over the top of the Disk Fingers caus-
ing set registration problems
Install the Finisher Paper Cooling and Stacking Kit PL 8.7 TAG
F109.
If TAG F109 is already installed,

or the problem continues after
installing the kit, go to the 12AC Finisher Misregistration
RAP.
The sets of prints are not being offset in the Finisher

Top Tray.
Go to the 12-AN Finisher Top Tray

Not Offsetting RAP.
TAG F109 is installed and one or more of the Cooling

Fans are not operating.
Go to the 12-AU Cooling Fan Checkout.
The sets of prints are not being offset in the Stacker

Tray
Go to the 12-AS Stacker Tray Not

Offsetting RAP.
11 x 17 in (A3) paper is being folded in half as it is com- Go to the 12-AC Finisher Misregispiled in the Stacker Tray.
tration RAP.
The print damage is dog-ears, nicks, tears, dings, wrin- Go to the OF-2 Paper Damage RAP.
kles, or roller marks.
The Pause Resume Switch (Elevator Switch Button) is Go to the 12-AM Pause Resume
not operating correctly.
Switch RAP.
There is abnormal sound or vibration when the Finisher Go to the 12-AF Finisher Noise RAP.
is operating.
The Stacker Tray is oscillating up and down.
12-700, 12-AA
May 2003
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Replace the Stack Height Sensor /

Stack Too High Sensor PL 8.5 Item
10.
V0.042
Problem
Action
Problem
Action
The status message, Clear the jam in the Finisher, is

displayed on the User Interface, when no paper is
jammed in the Finisher.
Go to the 12-AG Finisher Unclearable Jam RAP.
A static problem in the Finisher may cause:
If you suspect static is causing a

problem in the Finisher, Go to the 12AP Finisher Static Checkout RAP.
The status message, The Finisher main tray is not

available. Please remove any obstructions, is displayed on the User Interface, when the there are no
obstructions in the Stacker Tray and no 12-201 faults
are declared.
Go to the 12-AT Stacker Tray Upper

Limit Switch RAP.
The Stacker Tray is full with no message on the User Go to the 12-AH Finisher Stacker
Interface indicating the Stacker Tray is full, or the mes- Tray Status RAP.
sage on the User Interface indicates the Stacker Tray
is full when the Stacker Tray is not full.
The Finisher Top Tray is full with no message on the
User Interface indicating the Top Tray is full, or the
message on the User Interface indicates the Finisher
Top Tray is full when the Top Tray is not full.
Go to the 12-AJ Finisher Top Tray

Status RAP.
False Top Tray Full status message
Flower Stacking (sheets folded in half)
In-set misregistration
Poor set registration in the Stacker Tray or in the

Top Tray
Sheets falling out of the Stacker Tray
Set ejection problems in the Stacker Tray
Paper handling problems in the Stacker Tray or in

the Top Tray
Dog-ears
Intermittent electrical problems caused by static

eliminator brush fibers contacting electrical components
A message to close the Stapler Access Door is disGo to the 12-307 Stapler Access
played on the User Interface, when the Stapler Access Door Interlock Switch RAP.
Door is closed.
A message to close the Finisher Top Cover Door is dis- Go to the 12-309 Finisher Interlock
played on the User Interface, when the Finisher Top
Switch RAP.
Cover Door is closed.
The message displayed on the User Interface indicates
the Staple Cartridge needs to be replaced when the
Staple Cartridge is installed correctly and the Staple
cartridge contains greater than 19 staples. There is no
message displayed on the User Interface when the
Staple Cartridge contains less than 19 staples.
Go to the 12-AK Finisher Moving

Stapler Status RAP.
or
Go to the 12-AL Finisher Fixed Stapler Status RAP.
The sets of prints are not stapled, the staple quality is

poor, two or more sets of copies are stapled together,
the first sheet of the set is not stapled to the set, or the
staples are in the incorrect position.
Go to the 12-AD Finisher Moving

Stapler RAP.
or
Go to the 12-AE Finisher Fixed Stapler RAP.
Landscape stapling options are not available for selec- Go to the 12-AH Finisher Stacker
tion (Smart Tray Finisher Only).
Tray Status RAP.
NOTE: A Smart Tray Finisher is identified by the serial
number NF3xxxxxx.
When the Stacker Tray becomes full and the operator
is directed to remove copies from the tray, the tray
does not raise after the copies are removed.
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12-AA
12-AB Finisher Print Damage RAP
The print damage is dog-ears, nicks, tears, dings, wrinkles, or roller marks.
Entry to this RAP is only from the OF-2 Paper Damage RAP.
12-AB On-Site Diagnostic Procedure

Check the Finisher for paper or other foreign objects that may be obstructing the paper path.
The Finisher paper path is free from obstructions.
Y
N
Clear the obstruction from the Finisher paper path.
If the Nip 4 Idlers are damaged, install the Transport Baffle Idler Kit PL 8.3 Item 30.
Check the prints in the Finisher Top Tray. The print damage is roller marks or creases on
the prints.
Y
N
Check the damaged prints. The print damage is dog-ears.
Y
N
The print damage is nick, dings, or tears on the lead edge.
Y
N
tray.
Y
N
the Finisher Transport Baffle PL 8.3 Item 11 for burrs

The Finisher Diverter Gate for correct operation. Ensure the fingers are
not obstructing the upper paper path. Replace the Finisher Transport Baffle PL 8.3 Item 11 if necessary.
The Finisher Input Baffle for burrs.
2 staples
5 copies
Go to ADJ 12-1, Tamping. If the problem continues after performing the Tamper
Setup, Replace the Service Tray Assembly PL 8.5 Item 1.
Check the following components that may be causing the Finisher Diverter Gate to
obstruct the Finisher paper path:
Check the prints in the Finisher Top Tray. The print damage is creases in the process direction.
Y
N
2 sheets
Observe the sheets as they are being compiled in the Stacker Tray. The
Tamper Arm is 'over tamping' the sets.
Y
N
Check the Retractable Registration Edge for damage. Replace the Moving
Stapler PL 8.5 Item 3, if necessary.
The damage is occurring on prints sent to the Stacker Tray.

Y
N
Check the prints in the Finisher Top Tray. The print damage is roller marks on the
prints.
Y
N
The heat cover for the Finisher Diverter Gate Solenoid is snapped firmly in
place.
The return spring for the Finisher Diverter Gate Solenoid is not damaged or
broken.
the snap fit for the Finisher Diverter Gate is snapped firmly in place on the Finisher Transport Baffle.
The check of the Finisher Diverter Gate components is good

Y
N
Replace the Finisher Transport Baffle PL 8.3 Item 11 if necessary.
Check the Disk Fingers, including the springs, for damage. The Disk Fingers and
the springs are free from damage.
Y
N
Install the Disk Fingers Kit PL 8.3 Item 31.
Check the Nip 1 Idlers, Nip 3 Idlers, and the Nip 4 Idlers for binding and correct position.
If the Nip 1 Idlers, the Nip 3 Idlers, or the Nip 4 Idlers are damaged, install the Transport Baffle Idler Kit PL 8.3 Item 30.
Check the following for contamination or damage. Remove the source of the contamination or replace the part indicated.
The Front Registration Edge on the Moving Stapler PL 8.5 Item 3 for damage.
If the Nip 1 Drive Rolls are damaged, Replace the Nip 1 Drive Shaft PL 8.4 Item 2.
The Middle Registration Edge on the Fixed Stapler PL 8.5 Item 2 for damage.
If the Nip 3 Drive Rolls (on the Nip 3 Drive Shaft), are damaged, replace the Top
Module Assembly PL 8.3 Item 1.
The Rear Registration Edge on the Disk Baffle Assembly PL 8.3 Item 12 for
damage.
The Finisher Transport Baffle PL 8.3 Item 11 for burrs.
The Disk Baffle Assembly PL 8.3 Item 12 for burrs.
If the Nip 4 Drive Rolls (on the Nip 4 Drive Shaft), are damaged, replace the Top
Module Assembly PL 8.3 Item 1.
A
12-AB
The Canard Wing for binding or damage.
B
May 2003
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V0.042
The Canard Wing and the Stapler Lead-In Baffle PL 8.5 Item 15 on the Moving Stapler for damage.
12-AC Finisher Misregistration RAP
The Nip 1 Idlers, Nip 3 Idlers, and Nip 4 Idlers on the Finisher Transport Baffle for
binding. Install the Transport Baffle Idler Kit PL 8.3 Item 30, if necessary.
The stapled or unstapled sets of prints are stacked incorrectly in the Stacker Tray, or in the Finisher Top Tray.
The Nip 2 Idlers on the Disk Baffle Assembly PL 8.3 Item 12 for binding.
The Nip 4 Idlers for correct position. Install the Transport Baffle Idler Kit PL 8.3 Item
30, if necessary.
Check the prints in the Finisher Top Tray. The print damage is creases in the process
direction.
Y
N
Check the following for contamination or damage. Remove the source of the contamination or replace the part indicated.
There are misregistered sheets in the stapled or unstapled sets of prints delivered to the
Stacker Tray or to the Finisher Top Tray.
11 x 17 in (A3) paper is being folded in half as it is compiled in the Stacker Tray.
Initial Actions
Check the air flow at the customer's site. Excessive air flow may cause poor stacking,
resulting in misregistration.
If the Nip 1 Drive Rolls are damaged, Replace the Nip 1 Drive Shaft PL 8.4 Item 2.
Check the Stacker Tray and the Finisher Top Tray for obstructions.
If the Nip 2 Drive Rolls (on the Nip 2 Drive Shaft), are damaged, Replace the Nip 2
Drive Shaft PL 8.4 Item 2.
Turn over and reload the stack of paper in the tray the customer was using when the Finisher jam occurred.
If the Nip 2 Idlers are damaged, install the Disk Baffle Assembly PL 8.3 Item 12.
Check the following for binding and correct position:
The Nip 1 Idlers on the Finisher Transport Baffle. Install the Transport Baffle Idler Kit PL
8.3 Item 30, if necessary.
The Nip 2 Idlers on the Disk Baffle Assembly PL 8.3 Item 12.
Misregistration may occur if the Stacker Tray is not level. Go to the Stacker Tray Levelling
Procedure. Ensure the Stacker Tray is level
If the problem continues follow the procedure in this RAP.
12A-C On-Site Diagnostic Procedure

Determine where the problem is occurring. The problem is occurring in the Finisher Top
Tray.
Y
N
Observe the Paper Cooling Fans. All three fans are operating when the Transport
Drive Motor is running.
Y
N
Go to 12-AU Cooling Fan Checkout.
The customer is sending greater than 80 2-15 sheet stapled sets to the Stacker Tray.
Y
N
2 sheets
2 staples
5 copies
Observe the operation of the Finisher Set Separator as the sets are being compiled
and ejected into the Stacker Tray. The Finisher Set Separator rests on top of the
ejected sets.
Y
N
Check for strip of black adhesive film on the surface of the foam strip (located
where the Set Separator rests on the surface of the Stacker Tray).
A strip of black adhesive film is installed.
Y
N
Install the Finisher Set Separator Kit PL 8.5 Item 19.
Do the following:
A
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May 2003
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C
12-AB, 12-AC
In Component Control, select [Finisher], [Set Separator Solenoid], then

Observe the operation of the Finisher Set Separator and the Set Separator
Solenoid. The Set Separator Solenoid energizes.
Y
N
Go to Flag 1. Check wires for a short circuit or an open circuit.
Finisher Set Separator PL 8.5 Item 19 (PL 8.5 Item 13 For Document
Centre 460/470 with a Smart Tray Finisher installed).
NOTE: A Smart Tray Finisher is identified by the serial number
NF3xxxxxx.
Service Tray Assembly PL 8.5 Item 1 (if the harness cannot be

repaired).
B
Inform the customer the Stacker Tray can reliably stack a maximum of 80 2-15 sheet stapled sets. Go to GP30 . Ensure the maximum number of sets that will be sent to the
Stacker Tray before the unload message is displayed is set to 80 or less.
Check the copies/prints in the Finisher Top Tray. The sheets are dog-eared.
Y
N
Check the Finisher Top Tray The Finisher Top Tray is installed correctly on the Top
Module Assembly.
Y
N
Remove then reinstall the Finisher Top Tray.
Replace the Finisher Top Tray PL 8.2 Item 3 if it cannot be reinstalled correctly due
to damage.
Check the job the customer is sending to the Top Tray. The job is greater than 200
copies/prints on 5.5 x 8.5 in (A5) paper.
Y
N
Check the Top Tray Static Eliminator for wear and damage. The Top Tray Static
Eliminator is damaged or worn.
Y
N
Check the Top Tray Full Sensor Actuator. The actuator is free from damage,
and moves freely to block and unblock the Top Tray Full Sensor.
Y
N
If the Finisher Set Separator does not rest on the top of the set in the Stacker
Tray, check the mechanical components of the Finisher Set Separator for binding or damage.
Replace the Finisher Set Separator PL 8.5 Item 19 (PL 8.5 Item 13 For Document Centre 460/470 with a Smart Tray Finisher installed), if required.
Do the following:
Lower the Stacker Tray by pressing the Pause/Resume Switch
Open the Stapler Access Door
Manually raise and lower both the Front Bale Arm and the Rear Bale Arm
(resistance should be felt when raising either of Bale Arms).
The Top Tray Full Sensor is seated correctly.

Y
N
If the sensor cannot be reseated due to a broken mount, replace the Top
Tray Full Sensor PL 8.4 Item 1.
In Component Control, select [Finisher], [Top Tray Full Sensor], then [Start
Actuate the Top Tray Full Sensor by manually moving the actuator. The state
of the Top Tray Full Sensor changed.
Y
N
Flag 1. Check the wires for a short circuit or an open circuit.
NOTE: No resistance is an indication the Bale Arm springs are broken or missing
The Bale Arm check is good.
Y
N
The problem is set to set misregistration.
Y
N
Go to the 12A-C In-Set Registration Checkout Procedure.
In Component Control, select [Finisher], [Stacker Tray Offset (Open Loop)], then
Observe the operation of the Stacker Tray. The tray moves smoothly.
Y
N
Check the Stacker Tray drives for binding.
12-AC
Top Module Assembly PL 8.3 Item 1, if the harness cannot be

repaired.
Check the following.
Check the Collapsable Kicker Arm. Ensure it is not missing and moves to the collapsed position and back freely.
A
B
D
May 2003
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the Nip 1 Drive Rolls for damage and wear. Replace the Nip 1 Drive Shaft
PL 8.4 Item 2, if necessary.
The Nip 3 Drive Rolls (on the Nip 3 Drive Shaft) and the Nip 4 Drive Rolls
(on the Nip 4 Drive Shaft) for damage and wear. Replace the Top Module
Assembly PL 8.3 Item 1, if necessary.
F
V0.042
the Nip 1 Idlers, the Nip 2 Idlers, and the Nip 3 Idlers for binding and correct position. Replace the Transport Baffle Idler Kit PL 8.3 Item 30, if necessary.
K
Finisher Set Separator PL 8.5 Item 19 (PL 8.5 Item 13 For Document Centre 460/470 with a Smart Tray Finisher installed).
NF3xxxxxx.
Replace the Top Tray Static Eliminator PL 8.4 Item 7.

Inform the customer the Top Tray can reliably stack a maximum of 200 sheets of 5.5 x 8.5
in (A5) paper.
A component in the IOT is causing dog-ears. Go to OF-2, Paper Damage RAP.
12A-C On-Site Diagnostic Procedure (with Smart Tray)
Service Tray Assembly PL 8.5 Item 1 (if the harness cannot be

repaired).
If the Finisher Set Separator does not rest on the top of the set in the
Stacker Tray, check the mechanical components of the Finisher Set Separator for binding or damage. Replace the Finisher Set Separator PL 8.5
Item 19 (PL 8.5 Item 13 For Document Centre 460/470 with a Smart Tray
Finisher installed), if required.
Determine where the problem is occurring. The problem is occurring in the Finisher Top
Tray.
Y
N
Do the following:
In the Diagnostic Navigator, select [Finishing] tab, [Finisher Tests], then select the
[Main Tray Offset / Position] tab.
Do the following:
Lower the Stacker Tray by pressing the Pause/Resume Switch
Open the Stapler Access Door
Manually raise and lower both the Front Bale Arm and the Rear Bale Arm
(resistance should be felt when raising either of Bale Arms).
Observe the [Faults] window. There are 12-214 or 12-315 faults displayed in the faults
window.
Y
N
The customer is sending greater than 80 2-15 sheet stapled sets to the Stacker
Tray.
Y
N
2 sheets
2 staples
5 copies
NOTE: No resistance is an indication the Bale Arm springs are broken or missing
The Bale Arm check is good.
Y
N
The problem is set to set misregistration.
Y
N
Go to the 12A-C In-Set Registration Checkout Procedure.
Observe the operation of the Finisher Set Separator as the sets are being compiled and ejected into the Stacker Tray. The Finisher Set Separator rests on
top of the ejected sets.
Y
N
Check for strip of black adhesive film on the surface of the foam strip
(located where the Set Separator rests on the surface of the Stacker Tray).
The strip of plastic adhesive film is installed.
Y
N
Do the following:
In Component Control, select [Finisher], [Set Separator Solenoid],

then [Output On]. Enter [Copier Sys tab , Component Control].

tray
moves
smoothly
Check the Collapsable Kicker Arm. Ensure it is not missing and moves to the
collapsed position and back freely.
Observe the operation of the Finisher Set Separator and the Set Separator Solenoid. The Set Separator Solenoid energizes.
Y
N
G H
V0.042
In the Diagnostic Navigator, select [Finishing] tab, [Finisher Tests], then

select the [Main Tray Offset / Position] tab.
Observe the operation of the Stacker Tray. The

between all 4 positions.
Y
N
Check the Stacker Tray drives for binding.
Do the following:
G
May 2003
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I
12-AC
I
Inform the customer the Stacker Tray can reliably stack a maximum of 80 2-15 sheet
stapled sets. Go to GP30 . Ensure the maximum number of sets that will be sent to
the Stacker Tray before the unload message is displayed is set to 80 or less.
Check the job the customer is sending to the Top Tray. The job is greater than 200
copies/prints on 5.5 x 8.5 in. (A5) paper.
Y
N
Check the Top Tray Static Eliminator for wear and damage. The Top Tray Static
Eliminator is damaged or worn.
Y
N
Check the Top Tray Full Sensor Actuator. The actuator is free from damage,
and moves freely to block and unblock the Top Tray Full Sensor.
Y
N
Inform the customer the Top Tray can reliably stack a maximum of 200 sheets of 5.5 x 8.5
(A5) paper.
A component in the IOT is causing dog-ears. Go to OF-2, Paper Damage RAP.
12A-C In-Set Registration Checkout Procedure

The problem is in-set misregistration of stapled sets.
Y
N
The paper size displayed for each paper tray matches the paper size loaded in the
paper tray.
Y
N
Check the Stapler Lead-In Baffle (Figure 5). The Stapler Lead-In Baffle is free from
damage (bent or deformed).
Y
N
Check the Canard Wing. The Canard Wing is free from damage, moves freely, and is
in the correct position on the Retractable Registration Edge.
Y
N
If the Canard Wing is damaged, replace the Moving Stapler PL 8.5 Item 3.
The Top Tray Full Sensor is seated correctly.

Y
N
If the sensor cannot be reseated due to a broken mount, replace the Top
Tray Full Sensor PL 8.4 Item 1.
Make the following checks for all four Disk Fingers:
In Component Control, select [Finisher], [Top Tray Full Sensor], then [Start
Actuate the Top Tray Full Sensor by manually moving the actuator. The state
of the Top Tray Full Sensor changed.
Y
N
Flag 1. Check the wires for a short circuit or an open circuit.
the Nip 1 Drive Rolls for damage and wear. Replace the Nip 1 Drive Shaft
PL 8.4 Item 2, if necessary.
They are not retracted (an indication of a missing spring).
The Nip 3 Drive Rolls (on the Nip 3 Drive Shaft) and the Nip 4 Drive Rolls
(on the Nip 4 Drive Shaft) for damage and wear. Replace the Top Module
Assembly PL 8.3 Item 1, if necessary.
L
M N
12-AC
They should not move freely from side to side.
Check the center portion of the Disk Baffle Assembly between the Disk Fingers. The
center portion of the Disk Baffle Assembly is bent into the paper path.
Y
N
Program a job to send 11 x 17 in (A3) paper to the Stacker Tray. Check the copies as
they are being compiled in the Stacker Tray.
The sheets are being folded in half as they are compiled in the Stacker Tray.
Y
N
Open, then close the Finisher Top Cover Door.
Check the following.
The check of all four Disk Fingers is good.

Y
N
Install the Disk Fingers Kit PL 8.3 Item 31.
Top Module Assembly PL 8.3 Item 1, if the harness cannot be

repaired.
the Nip 1 Idlers, the Nip 2 Idlers, and the Nip 3 Idlers, for binding and correct position. Replace the Transport Baffle Idler Kit PL 8.3 Item 30, if necessary.
Check the copies/prints in the Finisher Top Tray. The sheets are dog-eared.
Y
N
Check the Finisher Top Tray The Finisher Top Tray is installed correctly on the Top
Module Assembly.
Y
N
Remove then reinstall the Finisher Top Tray.
Replace the Finisher Top Tray PL 8.2 Item 3 if it cannot be reinstalled correctly due
to damage.
O
May 2003
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2 sheets
1-sided
1 staple
5 copies
Q
V0.042
O
Observe the sets as they are entering the Stacker Tray. The Tamper Arm
contacts the edge of the prints as they are being compiled in the Stacker
Tray.
Y
N
Perform ADJ 12-1, Tamping.
The problem continues after performing the Tamper Setup.
Y
N
Q
Go to the 12-AP Finisher Static Checkout RAP
Replace the Disk Baffle Assembly PL 8.3 Item 12 if necessary.

Perform ADJ 12-2 Tamper Position.
If the problem continues after performing the adjustment, replace the Service Tray Assembly
PL 8.5 Item 1.
Do the following:
To gain access to the Finisher components, undock the Finisher from

the IOT (REP 12-12). Do not disconnect J15 from P69.
In Component Control, select [Finisher], [Retractable Reg. Edge

Solenoid]. Select [Output On] and [Output Off] several times to cycle
the Retractable Registration Edge Solenoid.
The Retractable Registration Edge Solenoid energizes.

Y
N
Go to Flag 1 on Figure 2. Check the circuit of the Retractable Registration Edge Solenoid for an open circuit or a short circuit.
Moving Stapler PL 8.5 Item 3.
The Retractable Registration Edge is raised and lowered when the

solenoid actuates and de-actuates.
Y
N
Check the Retractable Registration Edge for binding. replace the
Moving Stapler PL 8.5 Item 3, if required.
Figure 1 12-AC RAP Circuit Diagram
Check the Retractable Registration Edge for damage. replace the Moving
Stapler PL 8.5 Item 3, if required.
Observe the prints as they are entering the Stacker Tray. The
sticking to the Disk Baffle Assembly.
Y
N
prints
are
The Nip 1 Drive Rolls on the Nip 1 Drive Shaft PL 8.4 Item 2, for wear
or contamination.
The Nip 2 Drive Rolls on the Nip 2 Drive Shaft PL 8.4 Item 2, for wear
or contamination.
the Nip 1 Idlers on the Finisher Transport Baffle PL 8.3 Item 11 for
binding, correct position, and contamination.
The Nip 2 Idlers on the Disk Baffle Assembly PL 8.3 Item 12 for binding, correct position, and contamination.

O P
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12-AC
12-AC
May 2003
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V0.042
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12-AC
adhesive film

Lead-In Baffle
Figure 5 Adhesive film installed on Stacker Tray.
12-AC
May 2003
2-570
V0.042
12-AD Finisher Moving Stapler RAP

The problem is one of the following
The sets are not stapled.
The staple quality is poor (clinched incorrectly).
The sheets within the stapled set are not registered correctly.
The staples are not in the correct vertical (cross process) position in the set.
The staples are not in the correct horizontal (process) position in the set.
Two or more sets of copies are stapled together.
The first sheet of the set is not stapled to the set.
12-AD On-Site Diagnostic Procedure

Ask the customer about the job they were doing when the problem occurred. A job that meets
the following conditions may cause stapling problems:
Sets that exceeds 50 sheets of 20 lb (80 gsm) paper, or equivalent thickness.
Greater than 50 stapled sets that contain 2 to 10 copies per set.
20 lb (80 gsm) paper
Remove the Staple Cartridge.
Perform the OF-8 Staple Cartridge Checkout Procedure.
Reinstall the Staple Cartridge.
Send a stapled job to the Finisher.
The problem continues after performing the Staple Cartridge Checkout Procedure.
Y
N
Replace the Staple Cartridge and resend a stapled job to the Finisher.
Check the stapled sets of prints. The problem continues after replacing the Staple
Cartridge.
Y
N
The customer is attempting to staple a set that exceeds 50 sheets of 20 lb (80 gsm)
paper, or equivalent thickness, or the programmed job is greater than 50 stapled sets
that contain 2 to 10 copies per set.
Y
N
The staples are missing or clinched incorrectly.
Y
N
Check the Stapler Lead-In Baffle on the Moving Stapler. The Stapler Lead-In Baffle is
in the correct position (slightly above the edge of the Stapler Access Door).
Y
N
Ensure the Stapler Lead-In Baffle is in the correct position.
If the Stapler Lead-In Baffle cannot be positioned correctly, replace the Stapler LeadIn Baffle PL 8.5 Item 15.
NOTE: If the paper size in the paper tray is different from what is displayed on the
User Interface, the staples may be placed in the incorrect position.
The paper size displayed for each paper tray matches the paper size loaded in
the paper tray.
Y
N
The Stapler Lead-In Baffle is free from damage.

Y
N
Replace the Stapler Lead-In Baffle PL 8.5 Item 15.
The harness for the Moving Stapler is attached securely to the Service Tray
Assembly, and the harness does not interfere with the movement of the stapler.
Y
N
Ensure the harness for the Moving Stapler is attached securely to the Service
Tray Assembly.
Y
N
Check the Moving Stapler Gear Rack for any contamination or obstructions, including stray staples.
If the source of the binding cannot be removed, replace the Service Tray Assembly
PL 8.5 Item 1.
5 copies
The unformed staple roll may be wound too tightly or the Driver Bar may be out of position.
Do the following:
If the sheets within the stapled set are not registered correctly, or both staples in a 2 stapled set
are not in the correct position, Go to the 12-AC Finisher Misregistration RAP.
2 staples
The problem of missing or incorrectly clinched staples continues.

Y
N
The customer may be attempting to staple a set that exceeds the capacity of the Finisher. Inform the customer the stapling capacity of the Finisher is 50 sheets of 20 lb
(80 gsm) paper, or equivalent thickness. refer to Finishing. in Table 6
Initial Actions
5 sheets
Collated
5 copies
Observe the sets as they are compiled and ejected into the Stacker Tray.
10 sheets
A
V0.042
A
May 2003
2-571
12-AD
Observe the sets as they are being compiled. The Retractable Registration Edge contacts the edge of the prints as they are being compiled in the Stacker Tray.
Y
N
Do the following:
To gain access to the Finisher components, undock the Finisher from the IOT
(REP 12-12). Do not disconnect J15 from P69.
C
NF3xxxxxx.
If the Finisher Set Separator does not rest on the top of the set in the Stacker Tray,
check the mechanical components of the Finisher Set Separator for binding or damage. Replace the Finisher Set Separator PL 8.5 Item 19 (PL 8.5 Item 13 For Document Centre 460/470 with a Smart Tray Finisher installed), if required.
In Component Control, select [Finisher], [Retractable Reg. Edge Solenoid].

Select [Output On] and [Output Off] several times to cycle the Retractable Registration Edge Solenoid.
Do the following:
Remove the Staple Cartridge from the Moving Stapler.
In Component Control, select [Finisher], [Moving Stapler Empty Sensor], then [Start
The Retractable Registration Edge Solenoid energizes.

Y
N
Go to Flag 1 on Figure 2. Check the circuit of the Retractable Registration Edge
Solenoid for an open circuit or a short circuit.
Moving Stapler PL 8.5 Item 3.
The state of the Moving Stapler Empty Sensor is high (an indication of an empty
Staple Cartridge).
Y
N
Go to the 12-AK Moving Stapler Status RAP.
The Retractable Registration Edge is raised and lowered when the solenoid
actuates and de-actuates.
Y
N
Check the Retractable Registration Edge for binding. replace the Moving Stapler PL 8.5 Item 3, if required.
Check the Retractable Registration Edge for damage. Replace the Moving Stapler
PL 8.5 Item 3, if required.
The customer's programmed job is greater than 50 stapled sets that contain 2 to 10 copies per set.
Y
N
Inform the customer the stapling capacity of the Finisher is 50 sheets of 20 lb (80 gsm)
paper, or equivalent thickness. refer to Finishing. in Table 6
Inform the customer they can program the Finisher settings for thin stapled sets (refer to GP30
).
Observe the operation of the Finisher Set Separator. The Finisher Set Separator rests
on top of the ejected sets.
Y
N
Check for a strip of black adhesive film on the surface of the foam strip (located
Y
N
Do the following:
In Component Control, select [Finisher], [Set Separator Solenoid], then [Output

Observe the operation of the Finisher Set Separator and the Set Separator Solenoid. The Set Separator Solenoid energizes.
Y
N
A
B
C
12-AD
May 2003
2-572
V0.042
Figure 1 12-AD RAP Circuit Diagram
adhesive film
Figure 3 Black Adhesive film installed on Stacker Tray.
Figure 2 12-AD RAP Circuit Diagram
V0.042
May 2003
2-573
12-AD
12-AE Finisher Fixed Stapler RAP
The problem is one of the following
The second (rear) staple in a 2 stapled job is missing.
The staple quality is poor (clinched incorrectly).
The staples are not in the correct vertical (cross process) position in the set.
Two or more sets of copies are stapled together.
The first sheet of the set is not stapled to the set.
B
5 sheets
Collated
5 copies
Observe the operation of the Finisher Set Separator. The Finisher Set Separator rests
on top of the ejected sets.
Y
N
Check for a strip of black adhesive film on the surface of the foam strip (located
Y
N
Initial Actions
If the sheets within the stapled set are not registered correctly, or both staples in the set are not
in the correct position, Go to the 12-AC Finisher Misregistration RAP.
12-AE On-Site Diagnostic Procedure
Do the following:
Ask the customer about the job they were doing when the problem occurred. A job that meets
the following conditions may cause stapling problems:
In Component Control, select [Finisher], [Set Separator Solenoid], then [Output

Sets that exceeds 50 sheets of 20 lb (80 gsm) paper, or equivalent thickness. refer to Finishing. in Table 6
Greater than 50 stapled sets that contain 2 to 10 copies per set. refer to Finishing. in
Table 6
Observe the operation of The Finisher Set Separator and the Set Separator Solenoid. The Set Separator Solenoid energizes.
Y
N
The customer is attempting to staple a set that exceeds 50 sheets of 20 lb (80 gsm)
paper, or equivalent thickness, or the programmed job is greater than 50 stapled sets
that contain 2 to 10 copies per set.
Y
N
NF3xxxxxx.
NOTE: If the paper size in the paper tray is different from what is displayed on the User
Interface, the staples may be placed in the incorrect position.
The paper size displayed for each paper tray matches the paper size loaded in the
paper tray.
Y
N
If the Finisher Set Separator does not rest on the top of the set in the Stacker Tray,
check the mechanical components of the Finisher Set Separator for binding or damage. Replace the Finisher Set Separator PL 8.5 Item 19 (PL 8.5 Item 13 For Document Centre 460/470 with a Smart Tray Finisher installed), if required.
The unformed staple roll may be wound too tightly or the Driver Bar may be out of position.
Do the following:
Do the following:
Remove the Staple Cartridge from the Fixed Stapler.
In Component Control, select [Finisher], [Fixed Stapler Empty Sensor], then [Start
Send a stapled job (2-Staples) to the Finisher.
The state of the Fixed Stapler Empty Sensor is high (an indication of an empty Staple Cartridge).
Y
N
Go to the 12-AL Fixed Stapler Status RAP.
The problem continues after performing the Staple Cartridge Checkout Procedure.
Y
N
Replace the Staple Cartridge and send a stapled job (2-Staples) to the Finisher.
Check the stapled sets of prints. The problem continues after replacing the Staple
Cartridge.
Y
N
A
B
12-AE
Replace the Fixed Stapler PL 8.5 Item 2.

The customer's programmed job is greater than 50 stapled sets that contain 2 to 10 copies per set.
May 2003
2-574
V0.042
N
Inform the customer the stapling capacity of the Finisher is 50 sheets of 20 lb (80 gsm)
paper, or equivalent thickness. refer to Finishing. in Table 6
Inform the customer they can program the Finisher settings for thin stapled sets (refer to GP30
)
Figure 1 12-AE RAP Circuit Diagram
adhesive film
Figure 2 Adhesive film installed on Stacker Tray.
V0.042
May 2003
2-575
12-AE
12-AF Finisher Noise RAP
B
Y
There is abnormal sound or vibration when the Finisher is operating.
Initial Actions
Ensure the Finisher Noise Reduction Pad Kit PL 8.6 Item 1, is installed.
12-AF On-Site Diagnostic Procedure

In Faults, select [Last 40 Faults]. Check for 12-204 or 12-206 faults.
There is a 12-204 or a 12-206 fault in the Last 40 Faults.
Y
N
The noise occurs when the print job is sent to the Finisher Top Tray
Y
N
Go to the 12-AF Stacker Tray Paper Path Checkout.
N
Do the following:
Reinstall the Nip 3/4 Drive Belt.
Perform the Finisher Lubrication procedure (REP 12-15).

The noise occurs after performing the Finisher Lubrication procedure.

Y
N
Replace the Nip 3 Drive Shaft Bearing and the Nip 4 Drive Shaft Bearing PL 8.3
Item 18
If the noise continues, replace the Top Module Assembly PL 8.3 Item 1.
Go to the 12-AF Top Tray Paper Path Checkout.
Do the following:
There is a 12-204 fault in the Last 40 Faults.

Y
N
Go to the 12-206 Stapler Position Home Fault RAP.
Go to the 12-204 Tamper Home Fault RAP.
The noise occurs with the Nip 1/2 Drive Belt removed.
Y
N
Do the following:
12-AF Top Tray Paper Path Checkout

In Component Control, select [Finisher], [Top Tray Offset Motor], then [Output On]. Enter
The noise occurs when the Top Tray Offset Motor energizes.
Y
N
In Component Control, select [Finisher], [Finisher Diverter Gate Solenoid], then [Output
The noise occurs when the Finisher Diverter Gate energizes.
Y
N
Do the following:
Raise the Finisher Transport Baffle to the jam clearance position.


Remove the Nip 3/4 Drive Belt, and switch the power [On].

A
B
12-AF


One of the following components is causing the noise.
Do the following:

Y
N
The noise occurs when the Finisher Transport Baffle is in the jam clearance
position.
Y
N
The Nip 1 Drive Shaft Bearing PL 8.4 Item 12.
The Nip 1 Idlers on the Finisher Transport Baffle PL 8.3 Item 11.
The Nip 1/2 Idler or the Dual Idler.
Replace the Transport Drive Motor PL 8.5 Item 14.

Replace the Top Module Assembly PL 8.3 Item 1.
May 2003
2-576
V0.042
12-AF Stacker Tray Paper Path Checkout
For Document Centre 460/470 with a Smart Tray Finisher installed, do

the following:
Program a job for 10 unstapled sets of 2 sheets.

The noise occurs when an unstapled job is run.
Y
N
The noise is in one of the following. Check each component listed using component control.

NF3xxxxxx.
In Component Control, select [Finisher], [Fixed Stapler Safety Gate Solenoid], [Output On], then [Output On]. Enter [Copier Sys tab , Component Control].
Replace the Disk Baffle Assembly PL 8.3 Item 12, if the noise occurs.

[Output On], then [Output On]. Enter [Copier Sys tab , Component Control].
If the noise occurs, check the Stacker Tray PL 8.2 Item 16.
Replace the Disk Baffle Assembly PL 8.3 Item 12, if the noise occurs.
In Component Control, select [Finisher], [Disk Motor On], then [Output

In Component Control, select [Finisher], [Set Separator Solenoid], then

Place a stack of paper in the Moving Stapler.
If the noise occurs, check the Disk Drive Motor PL 8.3 Item 6.

Component Control].
If the noise occurs, replace the Staple Cartridge. If the problem continues, replace
the Moving Stapler PL 8.5 Item 3.
If the noise occurs, replace the Finisher Set Separator PL 8.5 Item 19 (PL
8.5 Item 13 For Document Centre 460/470 with a Smart Tray Finisher
installed).
Place a stack of paper in the Fixed Stapler.


NF3xxxxxx.
If the noise occurs, replace the Staple Cartridge. If the problem continues, replace
the Fixed Stapler PL 8.5 Item 2.
In Component Control, select [Finisher], [Transport Drive Motor], then [Output On]. Enter
The noise occurs when the Transport Drive Motor energizes.
Y
N
In Component Control, select [Finisher], [Tamper In/Out], then [Output On]. Enter [Copier
The noise occurs when the Tamper Motor energizes.
Y
N
In Component Control, select [Finisher], [Stapler Position Front], [Output On], [All
Outputs Off], [Stapler Position Rear], then [Output On]. Enter [Copier Sys tab , Component Control].
The noise occurs when the Stapler Position Motor energizes.
Y
N
The noise is in one of the following. Check each component listed using Component Control.
In Component Control, select [Finisher], [Stacker Tray Up], [Output On],

[All Outputs Off], [Stacker Tray Down], then [Output On]. Enter [Copier Sys
If the noise occurs, check the Stacker Tray Drive Motor PL 8.3 Item 3 and
the front and rear Stacker Tray Drive Belt PL 8.3 Item 8.
C
D
V0.042
In the Diagnostic Navigator, select [Finishing] tab, [Finisher Tests],

then select the [Main Tray Offset / Position] tab.
In Component Control, select [Finisher], [Stacker Tray Offset], then [Output On]. Enter [Copier Sys tab , Component Control].
In Component Control, select [Finisher], [Retractable Reg. Edge Solenoid], then [Output On]. Enter [Copier Sys tab , Component Control].
if the noise occurs, replace the Service Tray Assembly PL 8.5 Item 1.
Replace the Moving Stapler PL 8.5 Item 3

The Finisher Tag Matrix indicates Tag 12 is installed.
Y
N
Install TAG F012.
Do the following:
Ensure connector P/J2 at the Finisher Controller PWB is connected securely.
The noise occurs when the Transport Drive Motor energizes.

Y
N
Do the following:
Raise the Finisher Transport Baffle to the jam clearance position.
May 2003
2-577
12-AF
The noise occurs when the Finisher Transport Baffle is in the jam clearance position.
Y
N
The Nip 1 Idlers on the Finisher Transport Baffle PL 8.3 Item 11.
The Nip 1/2 Idler or the Dual Idler.
Do the following:
Y
N
Do the following:

Y
N
Replace the Nip 3 Drive Shaft Bearing and the Nip 4 Drive Shaft Bearing PL 8.3 Item 18
If the noise continues, replace the Top Module Assembly PL 8.3 Item 1.
Do the following:
Y
N
Do the following:

Y
N
One of the following components is causing the noise.
F
12-AF
May 2003
2-578
V0.042
12-AG Finisher Unclearable Status RAP
A message to clear the jam in the Finisher is displayed on the User Interface, when no
paper is jammed in the Finisher.
A message to close the Finisher Top Cover is displayed on the User Interface, when the
Finisher Top Cover is closed.
A message to close the Stapler Access Door is displayed on the User Interface, when the
Stapler Access Door is closed.
The message, Finisher Main Tray not available, remove any obstructions, is displayed on
the User Interface.
E
Go to Flag 1. Check the circuit of the Finisher Entrance Sensor for a short
circuit.
Finisher Entrance Sensor PL 8.3 Item 15.

Check the flag actuator of the Top Tray Paper Path Sensor. The flag actuator of the Top Tray Paper Path Sensor is not damaged, and is free to block
and unblock the sensor.
Y
N
Initial Actions
Ensure the Finisher paper path is clear of all paper, including small pieces that may have been
left in the Finisher after clearing a jam.
12-AG On-Site Diagnostic Procedure
Go to Flag 2. Check the circuit of the Top Tray Paper Path Sensor for a short
circuit.
Do the following:
Remove any obstructions from the Stacker Tray.
Switch the power [Off], then Switch the power [On].
Go to the 12-307 Stapler Access Door Interlock Switch RAP.
The message, Finisher Main Tray not available, remove any obstructions, is displayed
on the User Interface.
Y
N
Do the following:
Open the Finisher Top Cover Door. The message on the User Interface indicates the
Finisher Top Cover Door is open.
Y
N
Go to Flag 3. Check the circuit of the Finisher Interlock Switch for a short circuit.
Top Module Assembly PL 8.3 Item 1.
Close the Finisher Top Cover Door.

The message on the User Interface indicates the Finisher Top Cover Door is open.
Y
N
Ensure the Stapler Access Door is closed.
The message on the User Interface indicates the Stapler Access Door is open.
Y
N
In Component Control, select [Finisher], [Finisher Entrance Sensor], then [Start
The state of the Finisher Entrance Sensor is high.
Y
N
Check the flag actuator of the Finisher Entrance Sensor. The flag actuator of the Finisher Entrance Sensor is not damaged, and is free to
block and unblock the sensor.
Y
N
A
B
V0.042
Undock the Finisher from the IOT (REP 12-12).
Ensure the Finisher connector J15 is securely connected to P69 on the IOT.
Dock the Finisher to the IOT and switch the power [On].
Ensure the Finisher Top Cover Door is closed.
The message on the User Interface indicates the Finisher Top Cover Door is open.
Y
N
Go to the 12-309 Finisher Interlock Switch RAP.
Go to the 12-AT Stacker Tray Upper Limit Switch RAP.
May 2003
2-579
12-AG
12-AH Stacker Tray Status RAP
The Stacker Tray is full with no message on the User Interface indicating the Stacker Tray
is full, or the message on the User Interface indicates the Stacker Tray is full when the
Stacker Tray is not full.
Landscape stapling options are not available for selection (Smart Tray Finisher only).
When the Stacker Tray becomes full and the operator is directed to remove copies from
the tray, the tray does not raise after the copies are removed.
12-AH On-Site Diagnostic Procedure

In Stack Height/Elevator Tests, select [Single Cycle]. Enter [Finishing tab, Finisher Tests].
When the Stack Height/Elevator Tests is run, the Stacker Tray moves to the full position
and stops.
Y
N
Go to Flag 1. Check the circuit of the Stacker Tray Full Sensor for an open circuit or a
short circuit.
The Stacker Tray Full Sensor is seated correctly.

Y
N
Reseat the Stacker Tray Full Sensor in the correct position.
If the sensor cannot be reseated due to a broken mount, replace the Stacker Tray Full
The actuator for the Stack Too High Sensor, located on the Rear Bale Arm, is free from
damage.
Y
N
Figure 1 12-AG RAP Circuit Diagram
Check the Stack Height Sensor /Stack Too High Sensor. The Stack Height Sensor/Stack
Too High Sensor is free from damage (the body of the sensor should be at a 90 degree
angle in relation to the base of the sensor).
Y
N
Replace the Stack Height Sensor/Stack Too High Sensor PL 8.5 Item 10.
The Finisher Tag Matrix indicates TAG F027 is installed.
Y
N
Go to Flag 1. Check the circuit of the Stacker Tray Full Sensor for an open circuit.
Go to Flag 1. Check the circuit of the Stacker Tray Full Sensor for an open circuit. The check
of the Stacker Tray Full Sensor is good.
12-AG, 12-AH
May 2003
2-580
V0.042
N
Go to Flag 3. Check the circuit of the Finisher Empty Sensor (located in the Stacker Tray) for
an open circuit or a short circuit.
Stacker Tray PL 8.2 Item 16.
IIOC PWB A7A1 PL 8.6 Item 7.
V0.042
May 2003
2-581
12-AH
Figure 1 12-AH RAP Circuit Diagram
12-AH
May 2003
2-582
V0.042
12-AJ Finisher Top Tray Status RAP

The message The top tray is full is not displayed on the User Interface when the Finisher Top
Tray is full.
The message The top tray is full is displayed on the User Interface when the Finisher Top Tray
is not full.
Initial Actions
Check the air flow at the customer's site. Excessive air flow may cause poor stacking, resulting
in a false Finisher Top Tray status message.
12-AJ On-Site Diagnostic Procedure

5 sheets
Collated
5 copies
Observe the sheets as they are stacked in the Finisher Top Tray. The trail edge of the sheet
entering the Finisher Top Tray is slow to settle on the stack of paper in the tray.
Y
N
Check the Top Tray Full Sensor Actuator. The actuator is not damaged, and moves
freely to block and unblock the Top Tray Full Sensor.
Y
N
Figure 1 12-AJ RAP Circuit Diagram
In Component Control, select [Finisher], [Top Tray Full Sensor], then [Start Monitor]. Enter
Block and unblock the Top Tray Full Sensor by manually moving the flag actuator. The
state of the Top Tray Full Sensor changes.
Y
N
If the problem occurs again, Go to Flag 1. Check the circuit of the Top Tray Full Sensor PL
8.4 Item 1 for an intermittent condition.
Check the vertical surface (back wall) of the Finisher Top Tray. The vertical surface of the
Finisher Top Tray is free from damage.
Y
N
Replace the Top Module Assembly PL 8.3 Item 1.
V0.042
May 2003
2-583
12-AJ
12-AK Finisher Moving Stapler Status RAP

The User Interface indicates Staple Cartridge 1 needs to be replaced when the Staple Cartridge is installed correctly and the Staple Cartridge is not empty.
The User Interface does not indicate Staple Cartridge 1 needs to be replaced when the Staple
Cartridge is empty.
Block the Moving Stapler Empty Sensor by pushing up on the white actuator in the Moving Stapler. The voltage is 0 VDC when the Moving Stapler Empty Sensor is blocked.
Y
N
12-AK On-Site Diagnostic Procedure

Do the following
Press the Pause Resume Switch to lower the Stacker Tray and open the Stapler Access
Door.
NOTE: The Stacker Tray will raise 30 seconds after the Pause Resume Switch is actuated unless the Stapler Access Door is open.
Remove the Staple Cartridge from the Moving (front) Stapler and set aside. Remove the
functioning Staple Cartridge from the Fixed (rear) Stapler and install it in the Moving Stapler.
Close the Stapler Access Door.
Check the message on the User Interface. A message to Replace Staple Cartridge 1 is displayed on the User Interface.
Y
N
Do the following
Press the Pause Resume Switch to lower the Stacker Tray and open the Stapler
Access Door.
NOTE: The Stacker Tray will raise 30 seconds after the Pause Resume Switch is
actuated unless the Stapler Access Door is open.
Remove Staple Cartridge from the Moving (front) Stapler.
A message to Replace Staple Cartridge 1 is displayed on the User Interface.

Y
N
Do the following:
Switch the power [Off]. Disconnect P7 from the Finisher Controller PWB and
switch the power [On].
In Component Control, select [Finisher], [Moving Stapler Empty Sensor], then

The state of the Moving Stapler Empty Sensor is high.

Y
N
If the wires are good, replace the Moving Stapler PL 8.5/3.
Reinstall the functioning Staple Cartridge in the Fixed Stapler. Replace the Staple Cartridge.
Remove the Staple Cartridge from the Moving Stapler.
12-AK
May 2003
2-584
V0.042
Figure 1 12-AK RAP Circuit Diagram
V0.042
May 2003
2-585
12-AK
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
12-AK
May 2003
2-586
V0.042
12-AL Fixed Stapler Status RAP

The User Interface indicates Staple Cartridge 2 needs to be replaced when the Staple Cartridge is installed correctly and the Staple Cartridge is not empty.
The User Interface does not indicate Staple Cartridge 2 needs to be replaced when the Staple
Cartridge is empty.
Block the Fixed Stapler Empty Sensor by pushing up on the white actuator in the Fixed Stapler. The voltage is 0 VDC when the Fixed Stapler Empty Sensor is blocked.
Y
N
12-AL On-Site Diagnostic Procedure

Do the following
Press the Pause Resume Switch to lower the Stacker Tray and open the Stapler Access
Door.
NOTE: The Stacker Tray will raise 30 seconds after the Pause Resume Switch is actuated unless the Stapler Access Door is open.
Remove the Staple Cartridge from the Fixed (rear) Stapler and set aside. Remove the
functioning Staple Cartridge from the Moving (front) Stapler and install it in the Fixed Stapler.
Check the message on the User Interface . A message to Replace Staple Cartridge 2 is
displayed on the User Interface .
Y
N
Do the following
Press the Pause Resume Switch to lower the Stacker Tray and open the Stapler
Access Door.
NOTE: The Stacker Tray will raise 30 seconds after the Pause Resume Switch is
actuated unless the Stapler Access Door is open.
Remove Staple Cartridge from the Fixed (rear) Stapler.
Figure 1 12-AL RAP Circuit Diagram
A message to Replace Staple Cartridge 2 is displayed on the User Interface.

Y
N
Do the following:
Switch the power [Off]. Disconnect P7 from the Finisher Controller PWB and
switch the power [On].
In Component Control, select [Finisher], [Fixed Stapler Empty Sensor], then

The state of the Fixed Stapler Empty Sensor is high.

Y
N
Reinstall the functioning Staple Cartridge in the Moving Stapler.
Replace the Staple Cartridge in the Fixed Stapler.
Remove the Staple Cartridge from the Fixed Stapler.
V0.042
May 2003
2-587
12-AL
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
12-AL
May 2003
2-588
V0.042
12-AM Pause Resume Switch RAP

The Stacker Tray will not lower when the Pause Resume Switch is actuated. The customer
cannot pause a job in progress to unload the Stacker Tray, or lower the Stacker Tray to replace
a Staple Cartridge.
12-AM On-Site Diagnostic Procedure

Y
N
Do the following:
Disconnect P/J11 on the Finisher Controller PWB and switch the power [On].
The voltage is +5 VDC when the Pause Resume Switch is disconnected.

Y
N
Go to Flag 1. Check the wires for a short circuit. If the wires are good, replace the Pause
Resume Switch PL 8.2 Item 18.
Press the Pause Resume Switch. The voltage drops to approximately 0 VDC when the
Pause Resume Switch is actuated.
Y
N
Go to Flag 1. Check the wires for an open circuit. If the wires are good, replace the Pause
Resume Switch PL 8.2 Item 18.
Figure 1 12-AM RAP Circuit Diagram
V0.042
May 2003
2-589
12-AM
TH6
TH42
TH40
TH44
TH45
SIGNALGND
TH51
TH53
TH69
TH66
TH50
12-AM
May 2003
2-590
V0.042
12-AN Finisher Top Tray Not Offsetting RAP
12-AP Finisher Static Checkout RAP
The Finisher Top Tray is not offsetting.
If any of the 2 Static Eliminators in the Finisher or the Static Eliminator on the Dual Decurler/
Exit Baffle are damaged, worn, or not connected securely to the machine frame, the Finisher
may exhibit one or more of the problems listed below:
12-AN On-Site Diagnostic Procedure

Check the Last 40 Faults for a 12-213 fault. A 12-213 fault is in the Last 40 Faults.
Y
N
Open the Finisher Top Cover Door. Check the Offset Drive Link.
The Offset Drive Link is attached to the pin on the offset drive gear.
Y
N
Ensure the Offset Drive Link is attached to the pin on the drive gear.
The Offset Drive Link is damaged.
Y
N
The Back Wall of the Finisher Top Tray may have become dislodged from the Top
Module Assembly frame during operation of the Finisher or during installation of the
Finisher Top Tray.
Go to REP 12-16.
Replace the Offset Drive Link PL 8.4 Item 10.
Go to the 12-213 Top Tray Offset Home Fault RAP.
False Top Tray Full status message.
Flower Stacking (sheets folded in half)
In-set misregistration
Poor set registration in the Stacker Tray or in the Top Tray.
Sheets falling out of the Stacker Tray.
Set ejection problems in the Stacker Tray.
Paper handling problems in the Stacker Tray or in the Top Tray.
Dog-ears.
Intermittent electrical problems caused by static eliminator brush fibers contacting electrical components.
12-AP On-Site Diagnostic Procedure

Static is affecting sheets sent to the Stacker Tray.
Y
N
Check the Top Tray Static Eliminator for correct contact with the Finisher frame. The Top
Tray Static Eliminator is connected securely to the Finisher frame.
Y
N
Ensure the Top Tray Static Eliminator is connected securely to the Finisher frame.
replace the Top Tray Static Eliminator PL 8.4 Item 7, if it cannot be reseated on the
Finisher frame.
Check the Top Tray Static Eliminator for damage and wear. The Top Tray Static Eliminator is damaged or worn.
Y
N
Check the Static Eliminator on the Decurler, PL 6.1A Item 4, for damage and wear.
The Static Eliminator is free from damage and wear.
Y
N
Ensure there is continuity between the Finisher frame and the IOT frame. Check the
mounting hooks on the Finisher for corrosion if there is not continuity between the
Finisher frame and the IOT frame.
Check the Static Eliminator for correct contact with the Finisher frame. The Static Eliminator
is connected securely to the Finisher frame.
Y
N
Ensure the Static Eliminator is connected securely to the Finisher frame. replace the
Static Eliminator PL 8.4 Item 8, if it cannot be reseated on the Finisher frame.
Check the Static Eliminator for damage and wear. The Static Eliminator is damaged or
worn (brush fibers are bent in the direction of paper movement).
Y
N
TAG 040, Exit Baffle Kit PL 6.1A Item 6, is installed on the IOT.
A
V0.042
May 2003
2-591
12-AN, 12-AP
A
Y
N
Remove the Decurler and install the Exit Baffle Kit PL 6.1A Item 6 (TAG 040).
If the problem continues, ensure there is continuity between the Finisher frame and
the IOT frame. Check the mounting hooks on the Finisher for corrosion if there is not
continuity between the Finisher frame and the IOT frame
Y
N
TAG F112, Finisher Active Static Eliminator is installed.
Y
N
Install TAG F112, Static Eliminator Kit (PL 8.3 Item 22).
B
TAG F112, Finisher Active Static Eliminator is installed.
Y
N
Go to Flag 1 and Flag 2. Check the circuit of the Finisher Active Static Eliminator for an open
circuit.
Static Eliminator Kit PL 8.3 Item 22.
Go to Flag 1 and Flag 2. Check the circuit of the Finisher Active Static Eliminator for
an open circuit.
Check the Static Eliminator on the Exit Baffle for damage and wear. The Static Eliminator is free from damage and wear.
Y
N
Ensure there is continuity between the Finisher frame and the IOT frame. Check the
mounting hooks on the Finisher for corrosion if there is not continuity between the Finisher frame and the IOT frame.
Y
N
TAG F112, Finisher Active Static Eliminator is installed
Y
N
Go to Flag 1 and Flag 2. Check the circuit of the Finisher Active Static Eliminator for an
open circuit.
Replace the Static Eliminator PL 8.1 Item 8.

The problem continues after replacing the Static Eliminator.
Y
N
B
12-AP
May 2003
2-592
V0.042
Figure 1 RAP 12-AP RAP Circuit Diagram
V0.042
May 2003
2-593
12-AP
12-AR Transport Drive Motor Checkout
Observe the following restrictions for the use of this RAP.
N
Check for a short circuit between:
Entry to this checkout is only from the 12-101, 12-102, 12-106, or 12-107 RAP
The Finisher frame (-) and P2 -2 (+) on the connector.
The Finisher frame (-) and P2 -5 (+) on the connector.
Procedure
One or both of the +24 VDC outputs to the Transport Drive Motor are shorted
to the Finisher frame.
Y
N
The +24 VDC outputs for the Transport Drive Motor may be shorting to the
mounting hook for the Finisher Controller PWB. Check the back of connector
J2.
The back of connector J2 is contacting the mounting hook for the Finisher Controller PWB.
Y
N
Incorrect tension on the Nip 1/2 Drive Belt and on the Nip 3/4 Drive Belt may cause binding of
the Transport Drive Motor. Do the following:
Remove the Finisher Rear Cover and the Upper Rear Cover.
Loosen the T20 idler screw on the Nip 1/2 Idler and on the Nip 3/4 Idler 1/4 turn.
Ensure the idlers move freely (this will allow the idlers to apply the correct tension to the
drive belts).
Tighten the T20 idler screw on the Nip 1/2 Idler and on the Nip 3/4 Idler.
Replace the Finisher Controller PWB PL 8.3 Item 16. Ensure the back of connector J2 does not make contact with the mounting hook for the Finisher Controller PWB.

Y
N
Do the following:
Go to Flag 2. Check the wires in the harness for a short circuit to the Finisher
Frame. One or both of the wires are shorted to the Finisher frame.
Y
N
Replace the following:
Remove the Nip 1/2 Drive Belt and the Nip 3/4 Drive Belt.
the Transport Drive Motor PL 8.5 Item 14.
Manually rotate the Transport Drive Motor Counter Clockwise (as viewed from the rear of
the Finisher). The Transport Drive Motor rotates freely without binding.
Y
N
Do the following:
Repair the harness
Check the following transport drive components for binding:
the Nip 1 Drive Shaft.
the Nip 2 Drive Shaft.
the Nip 3 Drive Shaft, The Nip 4 Drive Shaft and the Nip 3/4 Idler, on the Top Module
Assembly.
Measure the resistance between the following pins on connector P2:
the Nip 1/2 Idler and the Dual Idler.
The transport drive components rotate freely without binding.

Y
N
Replace the component or components that are binding:
the Nip 2 Drive Shaft PL 8.4 Item 2.
The Top Module Assembly PL 8.3 Item 1, if the Nip 3 Drive Shaft, the Nip 4
Drive Shaft, or the Nip 3/4 Idler is binding.
The Finisher, if the Nip 1/2 Idler or the Dual Idler, is binding.
The Finisher frame (-) and P2 -2 (+) on the Finisher Controller PWB.
The Finisher frame (-) and P2 -5 (+) on the Finisher Controller PWB.
P2 -1 and P2-2
P2 -2 and P2 -3
P2 -4 and P2 -5
P2 -5 and P2 -6
The resistance is 4-6 Ohms.

Y
N
Go to Flag 2. Check the harness for a short circuit or an open circuit.
If the wires are good, replace the Transport Drive Motor PL 8.5 Item 14.
the Nip 1 Drive Shaft PL 8.4 Item 2.

Both voltages measured are +24 VDC.

A
12-AR
May 2003
2-594
V0.042
Figure 1 12-AR RAP Circuit Diagram
V0.042
May 2003
2-595
12-AR
T20 idler screw
Figure 2 12-AM RAP Component Location
12-AR
May 2003
2-596
V0.042
12-AS Stacker Tray Not Offsetting RAP
12-AT Stacker Tray Upper Limit Switch RAP
The Stacker Tray is not offsetting.
The message, Finisher Main Tray not available, remove any obstructions, is displayed on the
User Interface. The message cannot be cleared.
12-AS On-Site Diagnostic Procedure

Check the Last 40 Faults for a 12-310 fault. A 12-310 fault is in the Last 40 Faults.
Y
N
Replace the Stacker Tray PL 8.2 Item 16.
Go to the 12-310 Stacker Offset Motor Fault RAP.
12-AT On-Site Diagnostic Procedure

Do the following:
Switch off the power and disconnect the Power Cord.
Remove the Finisher Front Cover (disconnect the Pause/Resume Switch).
Check the position of the Disk Shaft Actuator (refer to Figure 1).
The Disk Shaft Actuator is in the correct position

Y
N
Do the following to ensure the Disk Shaft Actuator is in the correct position (refer to Figure
1).
Raise the end of the Disk Shaft slightly.
Move the actuator until the Disk Shaft rests in the rounded notch of the actuator.

The Finisher Tag Matrix indicates Tag F030 is installed.
Y
N
Go to Flag 2. Check the circuit of the Stacker Tray Upper Limit Switch for an open circuit.
Go to Flag 2 (Figure 3). Check the circuit of Stacker Tray Rear Upper Limit Switch and the
Stacker Tray Upper Limit Switch for an open circuit.
V0.042
Stacker Tray Rear Upper Limit Switch PL 8.2 Item 19.
May 2003
2-597
12-AS, 12-AT
View of Disk Shaft with actuator in the correct position

End of Disk
Shaft
Disk Shaft Actuator
Figure 2 12-AT RAP Circuit Diagram (without Tag F030)
Figure 1 12-AT Component Location
12-AT
May 2003
2-598
V0.042
12-AU Paper Cooling Fan Checkout

One or two of the Paper Cooling Fans are not operating, indicating a defective fan or an open
circuit.
All three Paper Cooling Fans are not operating, indicaing an open circuit or a defective Finisher
Controller PWB.
Observe the following restrictions for the use of this RAP.
Entry to this checkout is only from the 12-AA or the 12-AC RAP
This procedure is for Finishers with TAG F109 installed.
Procedure
Do the following:
Observe the Cooling Fans. One or Two of the Cooling Fans are operating.
Y
N
Do the following:
Switch the Power [Off].
Disconnect P2 from J13 on the Finisher Controller PWB and switch the power [On].
Measure the voltage between the Finisher frame (-) and J13-2 (+) on the Finisher
Controller PWB.

Y
N
If the wires are good, replace the defective Cooling Fan PL 8.7.
Figure 3 12-AT RAP Circuit Diagram (with Tag F030)
V0.042
May 2003
2-599
12-AT, 12-AU
Figure 1 12-717 RAP Circuit Diagram (Tag F109)
12-AU
May 2003
2-600
V0.042
J13
Paper Cooling Fans

Finisher Controller PWB
Figure 2 Paper Cooling Fans
V0.042
P2
Figure 3 Paper Cooling Fans Connector
May 2003
2-601
12-AU
12-AU
May 2003
2-602
V0.042
14-300 Scanner Calibration Failed
D
14-300 faults still occur after replacing the Image Module.
Y
N
The control system did not detect a signal at the AGC patch, which indicates the Illumination
Lamp is not lit or there is a failure in the video path. Scanning is disabled with this fault.
The AGC Patch is the white patch on the underside of the clip on the outboard (front) end of
the Image Module.
In Video Path Diagnostics, select [SCVM Digital Test] and [Start Test], then
observe the results of the test. Enter [Self Tests tab , Video Path Diagnostics].
The test passes.
Y
N

Check the IOT Change Tag Matrix for TAG 077.
The machine has Tag 077 installed.
Y
N
Intermittent 14-300 faults can be caused by the Illumination Lamp or the Illumination
Lamp Power Supply. Raise the Document Glass Cover and observe LED2 (24VLMP) on
the Illumination Lamp Power Supply (Figure 1).
LED2 (24VLMP) is on.
Y
N
Go to the 14-A Illumination Checkout RAP.
Replace the Scanner Video Cable PL 3.2 Item 4.

14-300 faults still occur after replacing the Scanner Video Cable.
Y
N
Y
N
Visually check the Illumination Lamp for signs of aging, such as dark ends or a yellowed
surface.
The Illumination Lamp appears to be good.
Y
N
Replace the Illumination Lamp Module PL 3.2 Item 7.
Reset the counter for the Illumination Lamp using the [IIT tab , Lamp Life Reset]
routine.
Ensure the lamp filaments are lit after the Lamp Module is replaced and the
machine is switched on. If the filaments are not lit, go to the 14-D RAP.
If background is present after replacing the Module, burn-in the Lamp for 15
minutes using [Copier Sys tab , Component Control].
Check the fault counters for 14-712, 14-713, 14-714, and 14-715 faults. Enter [Faults/
Counters tab , Counters Display]
At least one of the listed faults is logged.
Y
N
In Scanner Tests, select [Lamp Operation] and [Start], then observe the results of the
test. Enter [IIT tab , Scanner Tests].
The [Results] window has the message: Lamp turn on passed.
Y
N
This is a call back for 14-300 faults and/or black copies.
Y
N
The machine has a TAG 015 Main Control PWB installed.
Y
N
Y
N
A
B
V0.042
Go to the 14-300 Intermittent Checkout Procedure.
Go to the RAP for the counted fault. If more than one fault is counted, go to the RAP for
the fault with the highest count.
For 14-712 faults, go to the 14-712 RAP.
For 14-714 or 14-715 faults, go to the 14-C RAP.
Check the NVM value in Scan Service, location 20 (lampoffset). Enter [NVM tab , NVM Tool].
If the [Current Value] is 0, change the [Current Value] to be the same as the [Previous
Value].
If the [Current Value] is a value other than 0, do NOT change the [Current Value].
Y
N
Intermittent 14-300 faults can be caused by the Illumination Lamp or the Illumination Lamp
Power Supply. Raise the Document Glass Cover and observe LED2 (24VLMP) on the Illumination Lamp Power Supply ( Figure 1).
Y
N
Visually check the Illumination Lamp for signs of aging, such as dark ends or a yellowed surface.
May 2003
2-603
14-300
The Illumination Lamp appears to be good.

Y
N
Reset the counter for the Illumination Lamp using the [IIT tab , Lamp Life Reset] routine.
Ensure the lamp filaments are lit after the Lamp Module is replaced and the machine
is switched on. If the filaments are not lit, go to the 14-D RAP.
If background is present after replacing the Module, burn-in the Lamp for 15 minutes
using [Copier Sys tab , Component Control].
Check the fault counters for 14-712, 14-713, 14-714, and 14-715 faults. Enter [Faults/Counters
tab , Counters Display]
At least one of the listed faults is logged.
Y
N
In Scanner Tests, select [Lamp Operation] and [Start], then observe the results of the test.
Enter [IIT tab , Scanner Tests].
The [Results] window has the message: Lamp turn on passed.
Y
N
P/J15 the Distribution PWB.
P/J5 on the Distribution PWB.
Switch the power [On]. Make several scans to ensure the problem is corrected.
The problem continues after seating the connectors.
Y
N
Replace the Illumination Lamp Power Supply PL 3.2 Item 5. Make several scans to ensure the
problem is corrected.
The problem continues after replacing the Illumination Lamp Power Supply.
Y
N
One of the following components may have an intermittent problem. Replace the items listed
one at a time in the order they are listed until the problem is resolved:
Scanner Video Cable PL 3.2 Item 4.
Illumination Lamp Module PL 3.2 Item 7.
This is a call back for 14-300 faults and/or black copies.

Y
N
In Video Path Diagnostics, select [SCVM Digital Test] and [Start Test], then observe
the results of the test. Enter [Self Tests tab , Video Path Diagnostics].
The test passes.
Y
N
Y
N
Y
N
Figure 1 Illumination Lamp Power Supply LEDs
Go to the 14-300 Intermittent Checkout Procedure.
Go to the RAP for the counted fault. If more than one fault is counted, go to the RAP for the
fault with the highest count.
14-300 Intermittent Checkout Procedure

Switch the power [Off]. Ensure the following connectors are securely connected:
P4, A1DS1P1 (ribbon cable), and P1 on the Lamp Power Supply.
14-300
May 2003
2-604
V0.042
14-312 Scanner Configuration Mismatch
14-313 Scanner AGC Loop Not Settled
The control system has detected the Scanner and the Main Control PWB have an incompatible
configuration. Scanning is disabled.
The Scanner AGC Loop has not settled within 10 seconds after initialization. Scanning is disabled.
Procedure
This fault is encountered only after a part is changed or the software is upgraded. Perform the
following actions.
In Scanner Lamp Profile, select [Lamp On], then [Start], then observe the results of the test.
Enter [IIT tab , Scanner Lamp Profile].
The Lamp Profile checks OK. (The green line stays within the indicated range.)
Y
N
If the Main Control PWB is the Atlanta Gold configuration, ensure the jumper on the PWB
is set to the correct machine type: F1 or F2. Refer to REP 03-4.
If the Scanner or the Main Control PWB was just replaced, ensure the part number of the
new part is correct for the machine configuration.
If the software has just been upgraded, ensure the software version is correct for the
machine configuration.
In Scanner Tests, select [AGC Tab Test] and [Start], then observe the results of the test. Enter
[IIT tab , Scanner Tests].
The AGC Tab Test passes.
Y
N
Do the following:
Remove the Scanner Assembly REP 14-4. Clean or repair the AGC Tab.
In Scanner Tests, select [AGC Tab Test] and [Start], then observe the results of the
test. Enter [IIT tab , Scanner Tests].
The AGC Tab Test passes.

Y
N
If the problem continues, replace the Image Module PL 3.2 Item 1.
NOTE: After replacing the Scanner Video Cable or the Image Module, ensure the filaments in the Illumination Lamp are lit when the power is switched on.
Perform the Scanner Cleaning Procedure REP 14-3. Reassemble the Scanner.
In Scanner Tests, select [AGC Tab Test] and [Start], then observe the results of the test. Enter
[IIT tab , Scanner Tests].
Y
N
Y
N
V0.042
May 2003
2-605
14-312, 14-313
14-314 / 315 / 316 / 317 / 318 / 319 / 320 Scanner Calibration

Failed
14-314: The Dark Loop is not settled within 10 seconds after initialization. Scanning is disabled.
14-315: The Offset Loop, First In First Out (FIFO) Number 1, is not settled within 10 seconds after initialization. Scanning is disabled.
14-316: The Offset Loop, First In First Out (FIFO) Number 2, is not settled within 10 seconds after initialization. Scanning is disabled.
14-317: The Full Scale D/A Loop, First In First Out (FIFO) Number 1, is not settled within
10 seconds after initialization. Scanning is disabled.
14-318: The Full Scale D/A Loop, First In First Out (FIFO) Number 2, is not settled within
14-319: The Full Scale A/D Loop, First In First Out (FIFO) Number 1, is not settled within
14-320: The Full Scale A/D Loop, First In First Out (FIFO) Number 2, is not settled within

Go to the 14-C Scanner Loop Faults RAP.
14-325 Start of Scan Not Sensed

The Start of Scan (SOS) Sensor did not change state which indicates the scan carriage did not
move. Scanning is disabled.

Ensure all connectors to the Distribution PWB and the Main Control PWB are fully seated. If
any connector is not fully seated, reseat the connector.
14-325 faults occur again.
Y
N
Check the [Last 40 Faults] for 14-335 faults. Enter [Faults/Counters tab , Faults].
Y
N
In Scanner Tests, select [Scan Carriage] and [Start] and observe the test results for the
Platen Start of Scan (PSOS) Sensor and the Scanner Drives. Enter [IIT tab , Scanner
Tests].
The PSOS Sensor failed.
Y
N
The Scanner Drives failed.
Y
N
Switch the power [Off]. Remove the Scanner Assembly. Manually move the
Scan Carriage to check for binding.
The scan carriage binds.
Y
N
Replace the Scan Carriage Motor PL 3.2 Item 6.
Replace the Scanner Assembly PL 3.1 Item 1.
Replace the SOS Sensor PL 3.2 Item 9.
In Scanner Tests, select [Scan Carriage] and [Start] and observe the test results for the
PSOS Sensor. Enter [IIT tab , Scanner Tests].
The new sensor passes the test.
Y
N
Check the wiring between the SOS Sensor and the Distribution PWB for an open circuit. Go to Flag 1.
The wiring checks OK.
Y
N
Repair the wiring or replace the Scanner IOT Harness PL 3.2 Item 10.
Check the Distribution Cable between the Distribution PWB and the Main Control
PWB for an open circuit.
Go to Flag 2. The Distribution Cable checks OK.
Y
N
A
14-314 / 315 / 316 / 317 / 318 / 319 / 320, 14-325
May 2003
2-606
C
V0.042
C
RAP.
B
V0.042
May 2003
2-607
14-325
14-335 Scan Carriage Encoder Not Sensed
N
The Scan Carriage Motor does not provide encoder feedback.

Check the SCVM CARR DIR circuit for continuity between the Main Control PWB and the
Distribution PWB. Go to Flag 1.
If the circuit is OK, replace the Distribution PWB PL 1.5 Item 7.

Disconnect the Scan Carriage Motor. Measure the resistance of the fuse on the PWB of the
Scan Carriage Motor.
The fuse checks good.
Y
N
Replace the Scan Carriage Motor PL 3.2 Item 6
Reconnect the Scan Carriage Motor. Ensure all connectors to the Distribution PWB and the
Main Control PWB are fully seated. If any connector is not fully seated, reseat the connector.
14-335 faults occur again.
Y
N
The Lamp Operation test passes.
Y
N
Go to the 01-A Voltage Checkout RAP and verify your voltages.
If the voltage checks are OK, replace the Illumination Lamp Module PL 3.2.
If the problem continues, replace the Illumination Lamp Power Supply PL 3.2.
Check the operation of the Platen Start-of-Scan (PSOS) Sensor using Component Control
Select [PSOS Sensor] and [Start].
Move the Scan Carriage by turning the Scan Carriage Motor by hand.
Observe the PWS to determine if there is a change of state as the flag on the Image Module passes through the PSOS Sensor.

The PWS indicates a change of state as the flag passes through the Sensor.
Y
N
Examine the PSOS flag to determine if it is bent to an incorrect shape or position. If necessary, reform the flag to function correctly.
The flag appears to function correctly.
Y
N
Replace the SOS Sensor PL 3.2 Item 9.
In IIT Motor Tests, select [Start], and observe the results of the test. Enter [IIT tab , IIT Motor
Tests].
The results indicate the RIS Motor passed.
Y
N
Measure the voltage between P15-4 (-) and P15-3 (+) on the Distribution PWB.
The voltage is 5.0 0.5 VDC.
A
14-335
Measure the voltage between P15-4 (-) and P15-5 (+) on the Distribution PWB. In Component
Control, select the [Scan Carriage Motor] and [Cycle Output]. Observe the meter while the
motor is switched on. Enter [Copier Sys tab , Component Control].
The voltage is less than 0.5 VDC with the motor running.
Y
N
With the motor still running, measure the voltage between TP GND (-) and P5-1 (+) on the
Distribution PWB.
Y
N
RAP.
With the motor still running, measure the voltage between P15-4 (-) and P15-7 (+) on the Distribution PWB.
Y
N
With the motor running, measure the voltage between TP GND (-) and P5-10 (+) on the
Distribution PWB.
Y
N
RAP.
With the motor still running, measure the voltage between P15-4 (-) and P15-6 (+) on the Distribution PWB.
The voltage toggles between 5.0 VDC and less than 0.5 VDC with the motor running.
Y
N
With the motor still running, measure the voltage between TP GND (-) and P5-2 (+) on the
Distribution PWB.
The voltage toggles between 5.0 VDC and less than 0.5 VDC with the motor running.
Y
N
RAP.
B
May 2003
2-608
V0.042
B
Switch the power [Off]. Remove the Document Glass. Manually move the Scan Carriage to
check for binding.
The scan carriage binds.
Y
N
V0.042
May 2003
2-609
14-335
14-335
May 2003
2-610
V0.042
14-340 No Motor Done Signal
14-345/347 12 VDC Not Sensed
The Scan Carriage Motor does not provide a 'Motor Done' signal.
Fault Code 14-345 indicates +12 VDC is not detected by the Main Control PWB.
Fault Code 14-347 indicates -12 VDC is not detected by the Main Control PWB.
Scanning is disabled with these faults.
any connector is not fully seated, reseat the connector, clear the fault(s), then run copies to
determine if the problem occurs again.
The problem occurs again.
Y
N
Y
N
Go to the 14-335 RAP and diagnose that problem.

The DADF may not be grounded correctly. Go to GP44 DADF Ground Checkout. After ensuring the DADF is grounded correctly, clear the fault(s), then run copies to determine if the problem occurs again.
Y
N
any connector is not fully seated, reseat the connector, clear the fault(s), then run copies to
determine if the problem occurs again.
Y
N
The fault code is 14-345.
Y
N
Measure the -12 VDC power at the LVPS.
Connect the (-) meter lead to the metal case of the LVPS.
Connect the (+) meter lead to the test point labeled -12V.
The voltage is within the range of -11.4 to -12.6 VDC.

Y
N
Check the -12 VDC wiring between the LVPS and the Main Control PWB for an open circuit (Figure 27).
Measure the +12 VDC power at the LVPS.
Connect the (+) meter lead to the test point labeled +12V.

Y
N
Check the +12 VDC wiring between the LVPS and the Main Control PWB for an open circuit
(Figure 27).
V0.042
May 2003
2-611
14-340, 14-345/347
14-350 Scanner Video Cable Failure
14-700 Illumination Lamp Output Is Too Low
Fault Code 14-350 indicates the scanner video cable is disconnected or has failed. Scanning is
disabled.
The Illumination Lamp output is less than 35% of the original output.
Switch the power [Off]. Disconnect, then reconnect the Scanner Video Cable at the Main Control PWB and the Image Module. Switch the power [On].
Y
N
Ensure the lamp filaments are lit after the Lamp Module is replaced and the machine is
switched on. If the filaments are not lit, go to the 14-D RAP.
Switch the power [Off]. Replace the Scanner Video Cable PL 3.2 Item 4. Switch the power
[On].
Y
N
14-350, 14-700
May 2003
2-612
V0.042
14-703/704 Scanner Calibration Failed
The Dark Offset step made too many iterations during the Scanner Calibration.
14-703: The Scanner failed to calibrate because the pixel gain was too high.
14-704: The Scanner failed to calibrate because the pixel gain was too low.
With these faults, the Scanner is operating in the degraded mode and some print quality problems may be observed.

The machine has Tag 077 installed
Y
N
Y
N
Y
N
In Video Path Diagnostics, select [SCVM Digital Test] and [Start Test], then observe the
results of the test. Enter [Self Tests tab , Video Path Diagnostics].
The test passes.
Y
N
Y
N
Check the [Last 40 Faults] for 14-712, 14-713, 14-714, or 14-715 faults. Enter [Faults/Counters
tab , Faults].
14-712, 14-713, 14-714, or 14-715 faults are logged.
Y
N
Check the IOT Tag Matrix for TAG 077.
Y
N
In Scanner Lamp Profile, select [Lamp Off], then [Start], then observe the results of
the test. Enter [IIT tab , Scanner Lamp Profile].
The Lamp Profile checks OK. (The green line is flat at the 'MIN' level on the
graph.)
Y
N
Y
N
14-703 or 14-704 faults still occur after replacing the Image Module.
Y
N
The test passes.
Y
N

Y
N

Y
N
In Scanner Lamp Profile, select [Lamp On], then [Start], then observe the results of
Y
N
One or more points of the Lamp Profile (the green line) exceed a high or
low limit (the black lines) on the graph.
Y
N
Send service to perform the Scanner Cleaning Procedure REP 14-3. After
the cleaning, perform the [IIT tab , Scanner Calibration].
A
V0.042
May 2003
2-613
D
14-702, 14-703/704
A
Y
N
E
Y
N
Go to 14-A Illumination Checkout RAP.

Y
N
Y
N
In Scanner Lamp Profile, select [Lamp Off], then [Start], then observe the results of the
test. Enter [IIT tab , Scanner Lamp Profile].
The Lamp Profile checks OK. (The green line is flat at the 'MIN' level on the graph.)
Y
N
Y
N
The test passes.
Y
N
In Scanner Lamp Profile, select [Lamp On], then [Start], then observe the results of the
Y
N
One or more points of the Lamp Profile (the green line) exceed a high or low
limit (the black lines) on the graph.
Y
N
Send service to perform the Scanner Cleaning Procedure REP 14-3. After the
cleaning, perform the [IIT tab , Scanner Calibration].
Y
N

Y
N
Perform the [IIT tab , Scanner Calibration].
The problem continues after the calibration.
Y
N
The problem cannot be reproduced at this time, but there may be an intermittent problem in the system. The two suspect components are the Image Module PL 3.2 Item 1 and the Main Control PWB PL 1.4A Item 1. Replacement of
these components without a consistent, repeatable failure is at the discretion of
the district.
Go to 14-A Illumination Checkout RAP.

Y
N

Y
N
Y
N
Y
N
The problem cannot be reproduced at this time, but there may be an intermittent
problem in the system. The two suspect components are the Image Module PL 3.2
Item 1 and the Main Control PWB PL 1.4B Item 1. Replacement of these components without a consistent, repeatable failure is at the discretion of the district.
The test passes.
Y
N
A
B
E
14-703/704
A
May 2003
2-614

Y
N
F
V0.042
F
14-705 / 706 / 714 / 715 Scanner Calibration Failed
Go to the RAP for the counted fault. If more than one fault is counted, go to the RAP for the
fault with the highest count.
14-705: The Scanner failed to calibrate because the pixel offset was too high. One or
more of the pixels is higher than the desired level and cannot be adjusted lower. Scanning
is disabled.
14-706: The Scanner failed to calibrate because the pixel offset was too low. One or more
of the pixels is lower than the desired level and cannot be adjusted higher. Scanning is
disabled.
14-714: The Scanner failed to calibrate because the dark gain is at the minimum and the
darkest pixel is too low after adjusting dark pixel offset. Scanning is disabled.
14-715: The Scanner failed to calibrate because the dark gain is at the maximum and the
highest pixel is too high when the darkest pixel is at minimum (dark pixel offset). Scanning
is disabled.
Procedure
Go to the 14-C Scanner Loop Faults RAP.
V0.042
May 2003
2-615
14-703/704, 14-705 / 706 / 714 / 715
14-710 NVM Value Out Of Range (High or Low)
A scanner NVM value was detected out of range, high or low.
The Control Logic senses a failure to calibrate the Scanner with the overall gain at maximum.
The brightest pixel cannot be raised to an acceptable level. With this fault, the Scanner is operating in the degraded mode and some print quality problems may be observed.
Procedure
Perform a PO/PO to clear this fault.

Y
N
Check the Fault Counters for 14-700, 14-714 or 14-715 faults. Enter [Faults/Counters tab
, Counters Display].
At least one of the listed faults is counted.
Y
N
graph.)
Y
N
Y
N
The problem cannot be reproduced at this time, but there may be an intermittent
problem in the system. The two suspect components are the Image Module PL 3.2
Item 1 and the Main Control PWB PL 1.4A Item 1. Replacement of these components without a consistent, repeatable failure is at the discretion of the district.
Y
N
Y
N
The test passes.
Y
N
A
14-710, 14-712
May 2003
2-616
B
V0.042
B
Go to the 14-A Scanner Loop Faults RAP.
Check the Fault Counters for 14-700, 14-714 or 14-715 faults. Enter [Faults/Counters tab ,
Counters Display].
Y
N
Y
N
RAP.
The Control Logic senses a failure to calibrate the Scanner with the overall gain at minimum.
The brightest pixel is at too high a level and cannot be adjusted lower. With this fault, the Scanner is operating in the degraded mode and some print quality problems may be observed.
Y
N
RAP.

Y
N
Check the Fault Counters for 14-714 or 14-715 faults. Enter [Faults/Counters tab ,
Counters Display].
Y
N
graph.)
Y
N
Y
N
The problem cannot be reproduced at this time, but there may be an intermittent problem
in the system. The two suspect components are the Image Module PL 3.2 Item 1 and the
Main Control PWB PL 1.4B Item 1. Replacement of these components without a consistent, repeatable failure is at the discretion of the district.
Go to the 14-A Scanner Loop Faults RAP.
Initial Actions
Have the customer check the prints made when this fault code is displayed. If the prints have
bands from lead edge to trail edge and one of the bands is a band of no image approximately
5/8 inch wide from lead edge to trail edge, a sensor in the Image Module is defective. Send
service to replace the Image Module PL 3.2 Item 1.
Y
N
Y
N
Y
N
Y
N
A
V0.042
May 2003
2-617
C
14-712, 14-713
C
The test passes.
Y
N
Go to the 14-C Scanner AGC Loop Faults RAP.
Check the Fault Counters for 14-714 or 14-715 faults. Enter [Faults/Counters tab , Counters
Display].
Y
N
Y
N
Y
N
Y
N
Y
N
Go to the 14-C Scanner AGC Loop Faults RAP.
14-713
May 2003
2-618
V0.042
14-716 Scanner Lamp Stability Fault

Lamp stability cannot be achieved after Lamp Test Max time in NVM has elapsed. With this
fault, the Scanner is operating in the degraded mode and some print quality problems may be
observed.
C
Raise the Document Glass Cover and check the LEDs on the Illumination Lamp Power
Supply (Figure 1).
LED3 (24VHTR) is on.
Y
N
Remove the Document Glass Frame.
Disconnect the Illumination Lamp ribbon cable A1DS1P1 from J4 on the Illumination
Lamp Power Supply.
Measure the resistance between Pin 4 and Pin 5 of A1DS1P1. Go to Flag 2.
The resistance is 10 to 14 ohms.
Y
N

Check the IOT Change Tag Matrix for TAG 077
Y
N
Y
N
Y
N
Reset the counter for the Illumination Lamp using the [IIT tab , Lamp Life
Reset] routine.
Ensure the lamp filaments are lit after the Lamp Module is replaced and
the machine is switched on. If the filaments are not lit, go to the 14-D RAP.
If background is present after replacing the Module, burn-in the Lamp for
15 minutes using [Copier Sys tab , Component Control].
The test passes.
Y
N
Replace the Illumination Lamp Power Supply PL 3.2 Item 5.

Check the Scanner Dust Filter.
The filter is dirty.
Y
N
If the covers were not in place before the fault occurred, replace the covers then switch
the IOT power [Off]. Wait at least one minute, then switch the IOT power [On]. (These
steps are necessary to force the Illumination Lamp through a warm-up and calibration
cycle.)
Y
N
Check the operation of the Scanner Cooling Fan.
The Scanner Cooling Fan is running.
Y
N
Raise the Document Glass Cover and check the LEDs on the Illumination Lamp
Power Supply (Figure 1).
Y
N
Switch the power [Off]. Check the +24VDC (PS) and +24 VDC RET lines
between the LVPS and the Illumination Lamp Power Supply for an open circuit.
Go to Flag 1. Repair or replace as necessary.
Check the electrical connections to the Scanner Cooling Fan. If the fan is correctly
connected, replace the Scanner Cooling Fan PL 9.1 Item 10. Now perform the [IIT
tab , Scanner Calibration].
The fault continues.
Y
N
A
B
V0.042
Replace the Scanner Dust Filter (part of the NOHAD Filter Kit) PL 9.1 Item 1.
In [IIT tab , Scanner Calibration], perform the [Full] Calibration.
The 14-716 fault occurs after the calibration.
Y
N
If the covers were not in place before the fault occurred, replace the covers then switch the IOT
power [Off]. Wait at least one minute, then switch the IOT power [On]. (These steps are necessary to force the Illumination Lamp through a warm-up and calibration cycle.)
Y
N
Check the operation of the Scanner Cooling Fan.
The Scanner Cooling Fan is running.
Y
N
Raise the Document Glass Cover and check the LEDs on the Illumination Lamp Power
Supply (Figure 1).
D
May 2003
2-619
14-716
D
Y
N
Switch the power [Off]. Check the +24VDC (PS) and +24 VDC RET lines between
the LVPS and the Illumination Lamp Power Supply for an open circuit. Go to Flag 1.
Check the electrical connections to the Scanner Cooling Fan. If the fan is correctly connected, replace the Scanner Cooling Fan PL 9.1 Item 10. Now perform the [IIT tab , Scanner Calibration].
Y
N
Raise the Document Glass Cover and check the LEDs on the Illumination Lamp Power Supply
(Figure 1).
Y
N
Lamp Power Supply.
Measure the resistance between Pin 4 and Pin 5 of A1DS1P1. Go to Flag 2.
The resistance is 10 to 14 ohms.
Y
N
routine.

Check the Scanner Dust Filter.
The filter is dirty.
Y
N
Replace the Scanner Dust Filter (part of the NOHAD Filter Kit) PL 9.1 Item 1.
In [IIT tab , Scanner Calibration], perform the [Full] Calibration.
The 14-716 fault occurs after the calibration.
Y
N
14-716
May 2003
2-620
V0.042
V0.042
May 2003
2-621
14-716
14-A Illumination Checkout RAP

Use this RAP only when directed by another RAP. This RAP is used to troubleshoot why the
Illumination Lamp is not providing the correct output or the output is not stable.
NOTE: Ensure the machine is not in Energy Saver mode when using this RAP.
Procedure
A1DS1P1
At least one 14-700 fault is logged.
Y
N
Go to the 14-A Illumination System Diagnostics.
Pin 4
Pin 5
Ensure the lamp filaments are lit after the Lamp Module is replaced and the machine is
switched on. If the filaments are not lit, go to the 14-D RAP.
Run copies to determine if the problem is resolved. The problem continues.

Y
N
Figure 3 Illumination Lamp ribbon cable pin locations.
Go to the 14-A Illumination System Diagnostics.
14-A Illumination System Diagnostics

Raise the Document Glass Cover and observe LED2 (24VLMP) on the Illumination Lamp
Power Supply (Figure 1).
Y
N
Remove the Document Glass Frame (REP 14-4) in order to gain access to the input connector J1 on the Illumination Lamp Power Supply.
Measure the voltage between J1-2 (-) and J1-3 (+) (Figure 2).
Y
N
Switch the power [Off]. Check the +24VDC and +24 VDC RET lines between the
LVPS and the Illumination Lamp Power Supply for an open circuit. Go to Flag 1.
Observe the LEDs again (Figure 1).
Y
N
Check the Scanner Cooling Fan. The Scanner Cooling Fan is running.
A
14-716, 14-A
May 2003
2-622
V0.042
A
Y
N
Switch the power [Off]. Check the +24VDC (PS) and +24 VDC RET. lines between
the LVPS and the Illumination Lamp Power Supply for an open circuit. Go to Flag 2.
B
The Illumination Module Cable (A1DS1P1) was reseated on a previous service call.
Y
N

In Component Control, select [Document Handler/Scanner], [Illumination Lamp], then [Output
On]. Observe the LEDs again (Figure 1). Enter [Copier Sys tab , Component Control].
LED1 (ENBL) is on when the Illumination Lamp energizes in Component Control.
Y
N
With the Illumination Lamp still switched on, measure the voltage between J15-13 (-) and
J15-14 (+) on the Distribution PWB.
The voltage is less than 0.5 VDC.
Y
N
If the problem still occurs, the Main Control PWB may have failed. Go to the 03-G
RAP.
Unplug, then reseat the Illumination Module Cable (A1DS1P1) at the Illumination
Lamp Power Supply.
Install the Document Glass Frame.
Switch the power [On] and allow the system to warm up.
Check the Illumination Lamp.
routine.
If the problem continues, replace the Illumination Lamp Power Supply PL 3.2 Item 5.
Run copies to determine if the problem is corrected.
Y
N
Replace the Scanner Video Cable PL 3.2 Item 4. Run copies to determine if the
problem is corrected
Y
N
In Component Control, select [Document Handler/Scanner], [Illumination Lamp], then [Output

Off].
Observe the LEDs again (Figure 1). LED4 (HTR) is on.
Y
N
Lamp Power Supply.
Measure the resistance between Pin 4 and Pin 5 of A1DS1P1. The resistance is 10
to 14 ohms.
Y
N
routine.
The Illumination Lamp comes on.

Y
N
Check the Lamp Enable and Lamp Enable Return lines for continuity. Go to Flag 3.
If the wiring is defective, repair the wiring or replace the Scanner IOT Harness PL 3.2 Item
10.
If the wiring is OK, replace the Illumination Lamp Power Supply PL 3.2 Item 5.

Replace the Scanner Video Cable PL 3.2 Item 4. Run copies to determine if the problem is corrected.
Y
N
Move the scan carriage in order to view the filaments at both ends of the Illumination Lamp.
Observe the filaments. Both filaments are glowing.
Y
N
Go to the 14-D RAP.
B
V0.042
May 2003
2-623
14-A
14-A
May 2003
2-624
V0.042
V0.042
May 2003
2-625
14-A
14-B Scanner Noise RAP

An unusual noise is coming from the Scanner. Enter this RAP only from the OF-1 RAP.
Procedure
There are two known causes of scanner noise.
A1DS1P1
One cause of scanner noise is the Glass Glide at the rear of the Image Module. Noise can
be caused as the Glass Guide rubs against the underside of the Document Glass and the
metal edge of the scanner frame.
To eliminate this noise, replace the Glass Glide (PL 3.2 Item 2). If a replacement part is
not available, swap the rear Glass Glide with a front Glass Glide.
The other cause of scanner noise is one or both Illumination Lamp sockets on the Illumination Lamp Module rub against the underside of the scanner frame.
To eliminate this noise, remove the Illumination Lamp Module (REP 14-2) and reform the
ends downward so the sockets do not rub against the underside of the scanner frame.
Reinstall the Illumination Lamp Module.
Pin 4
Pin 5
14-A, 14-B
May 2003
2-626
V0.042
14-C Scanner Loop Faults RAP

Y
N
Go to one of the following wirenet drawings and check the -12 VDC wiring
between the LVPS and the Main Control PWB for a bad or intermittent connection:
This RAP is used to troubleshoot the following fault codes: 14-314, 14-315, 14-316, 14-317,
14-318, 14-319, 14-320, 14-705, 14-706, 14-714, 14-715. Scanning is disabled when any of
those faults occur.

Check the [Last 40 Faults] for 14-345, 14-347, or 14-350 faults. Enter [Faults/Counters tab ,
Faults].
14-345, 14-347, or 14-350 faults are logged.
Y
N
The machine has tag 077 installed.
Y
N
The problem is 14-705, 14-706, 14-714, or 14-715 faults.
Y
N
Y
N
Connect the (+) meter lead to J7 pin 8 on the Main Control PWB.
Figure 25 +12 VDC and -12 VDC Distribution (240/255/265 DC)
Figure 26 +12 VDC and -12 VDC Distribution (255/265 ST)
Figure 27 +12 VDC and -12 VDC Distribution (460/470 DC)

Y
N
Keep the meter connected to the test points. Disconnect the Image Module
Cable at the Main Control PWB.
The voltage is +5.25 0.3 VDC after the cable is disconnected.
Y
N
Y
N
Measure the +12 VDC power at the Main Control PWB.
Measure the +5.25 VDC power at the Main Control PWB.
NOTE: In the following step, you are required to access P2/J7 on the Main Control
PWB. On machines with TAG 015 Main Control PWB (Atlanta Gold), the Accessory
PWB must be removed in order to access J7. Refer to REP 03-3 in order to remove
the Accessory PWB. After the PWB is removed, and the machine power is switched
[On], ignore any faults caused by the removal of the Accessory PWB.
A
B
V0.042
Reinstall the Accessory PWB REP 03-3.
The test passes.
Y
N

Y
N
Go to one of the following wirenet drawings and check the -12 VDC wiring
between the LVPS and the Main Control PWB for a bad or intermittent connection:

Measure the -12 VDC power at the Main Control PWB.

Y
N
The problem still occurs after replacing the Scanner Video Cable.
Y
N


A
May 2003
2-627
B
14-C
A
Y
N

RAP.

Y
N
Measure the +12 VDC power at the Main Control PWB.


Y
N
Go to one of the following wirenet drawings and check the -12 VDC wiring between
the LVPS and the Main Control PWB for a bad or intermittent connection:

RAP.
NOTE: In the following step, you are required to access P2/J7 on the Main Control PWB.
The Accessory PWB must be removed in order to access J7. Refer to REP 03-3 in order
to remove the Accessory PWB. After the PWB is removed, and the machine power is
switched [On], ignore any faults caused by the removal of the Accessory PWB.

Y
N

RAP.

Y
N
Keep the meter connected to the test points. Disconnect the Image Module Cable at
The voltage is +5.25 0.3 VDC after the cable is disconnected.
Y
N
The problem is 14-705, 14-706, 14-714, or 14-715 faults.

Y
N
Y
N
C
Measure the +5.25 VDC power at the Main Control PWB.

Go to the RAP for the logged fault. If more than one of the listed faults are logged, go to the
RAP for the fault with the most occurrences.

Measure the -12 VDC power at the Main Control PWB.

Y
N
Go to one of the following wirenet drawings and check the -12 VDC wiring between
the LVPS and the Main Control PWB for a bad or intermittent connection:

A
C
14-C
May 2003
2-628
V0.042
14-D Illumination Lamp Filaments Not Lit RAP

The filament at either or both ends of the Illumination Lamp are not lit with machine power
switched on.
NOTE: Ensure the machine is not in Energy Saver mode when using this RAP.

Disconnect the Illumination Lamp ribbon cable A1DS1P1 from J4 on the Illumination Lamp
Power Supply.
Measure the resistance between Pin 1 and Pin 2, then between Pin 8 and Pin 9 of
A1DS1P1.
The resistance is approximately 3 ohms between pins 1 and 2, and also between pins 8
and 9.
Y
N
Ensure the lamp filaments are lit after the Lamp Module is replaced and the machine
is switched on. If the filaments are not lit, continue in this RAP.
A
Perform the Scanner Cleaning Procedure REP 14-3. Reassemble the scanner and run prints
to determine if problem is corrected.
Y
N
Check the scanner video harness, which is part of the Image Module, for a secure connection and continuity.
The harness is OK.
Y
N
Reseat the Illumination Module Cable on the Illumination Power Supply. Switch the power [On]
and allow the system to begin to warm up. Observe the filaments in the Illumination Lamp.
The filaments are glowing.
Y
N
A1DS1P1
Pin 1
Pin 2
Pin 8

Y
N
Pin
The fault which directed you to this RAP was 14-712.

Y
N
Replace the Scanner Video Cable PL 3.2 Item 4. Run copies to determine if the problem
is corrected
Y
N
RAP.
A
V0.042
May 2003
2-629
14-D
14-D
May 2003
2-630
V0.042
16-A ESS Fault Codes RAP
C
Done. The ESS Software Verification Tool has repaired/replaced the corrupt file(s).
Verify the problem is corrected and return to Service Call Procedures.
This RAP is used troubleshoot ESS fault codes.
SHUTDOWN- Format 16-0XX.XX or 16-1XX.XX - These faults indicate that a serious

error occurred that caused the ESS to cold reset. If frequent reboots are a problem, or
directed here from another procedure, continue below.
NON-SHUTDOWN- The ESS has many non-shutdown faults that can occur during operation. In most cases, these faults have no impact to the observable operation of the ESS or
printer. Often, conditions that trigger a fault are temporary, and the ESS will recover and
continue. These faults may be helpful to Field Engineering if difficult to diagnose problems
need to be escalated. If these problems persist, they often lead to a shutdown fault.
Shutdown faults (faults that are of the format 16-0XX.XX or 16-1XX.XX) are better indications of more serious problems and should be looked at first if printer operation becomes
abnormal.

If any of the following faults are occurring, go to the appropriate RAP. Otherwise, continue
below.
16-781.19
16-785.19
16-786.19
16-787.19
For all shutdown faults (16-0XX.XX or 16-1XX.XX), go to the 16-A Shutdown Fault Procedure .
For non-shutdown faults, go to the 16-A Non-Shutdown Fault Procedure. For a description of
the faults, refer to Table 1 for shutdown faults and Table 2 for non-shutdown faults.
16-A Shutdown Fault Procedure

To ensure there are no ESS hardware faults, go to the 16-B, ESS Boot RAP. Perform that procedure and return here.
Try to reproduce the problem. The problem persists.
Y
N
Enter [ESS/Network tab , ESS Software Verification Tool]. Select [Start Test].
A message is displayed that the routine can't be run or the routine stops before it is
complete.
Y
N
A message is displayed on the PWS indicating that ESS Software must be
reloaded.
Y
N
A message was displayed indicating that a repair was made.
Y
N
Switch the machine power off/on to reboot the ESS.
Try to reproduce the problem. The problem continues.
Y
N
Reload the ESS Software.

16-A Shutdown Fault Procedure Part 2

Refer to the [ESS/Network tab , ESS Error Log] and try to determine under what situations the
problem is occurring.
Determine which of the following characterizes the problem most appropriately:
The problem occurs randomly
The problem occurs on one particular job from one particular client
The problem occurs on all jobs sent from one client
The problem occurs with one job from any client
The problem occurs when printing with one PDL (Postscript or HP-PCL) and the other
PDL is OK
The problem occurs randomly.

Y
N
The problem occurs on one particular job from one particular client.
Y
N
The problem occurs on all jobs sent from one client.
Y
N
The problem occurs with only one job from any client.
Y
N
The problem is related to one client. The problem only occurs with one
PDL. Enter [ESS/Network tab , ESS Test Jobs]. Select [Test Pattern],
then the appropriate Composition selection (PS or HP-PCL). Select
[Start].
The problem occurs with the Test Pattern job.
Y
N
Determine if another 240/255/265/460/470 printer is available.
There is another Document Centre 240/255/265/460/470 available to print to.
Y
N
Have the customer contact the Customer Service Center.
Try to re-create the problem. The problem can be re-created on
the other printer.
Y
N
Check the ESS software version for both printers
The printer with the problem has an older version of software.
Y
N
Reload the ESS Software. If the problem continues, escalate the service call.
Obtain and load the latest ESS Software.
Go to the 16-A Shutdown Fault Procedure Part 2
Run the job from another client.

A
B
V0.042
D
May 2003
2-631
H
16-A
D
Y
N
There is a problem with the client. Check the client configuration. If the problem continues, reload the client driver software.
(460/470) Replace the following, one-at-a-time, until the problem is corrected
Have the customer contact the Customer Service Center.

Check the machine software level.
The machine has L18.x software or the machine is a 460/470.
Y
N
Use GP24 to test the ESS DRAM. At the Ok prompt, type showstack [Enter]. After the ok prompt, type the following depending on
your memory configuration:
For 32MB, type 10000 1DE6666 mem-bits-test [Enter]
For 64MB, type 10000 3EE6666 mem-bits-test [Enter]
For 96MB, type 10000 5DE6666 mem-bits-test [Enter]
ESS Disk Drive / Image Disk Drive PL 1.3A Item 4 and

ESS Hard Disk Drive Ribbon Cable PL 1.3A Item 8
ESS DRAM SIMMS PL 1.3B Item 2
ESS PWB PL 1.3A Item 1
ESS Disk Drive / Image Disk Drive PL 1.3C Item 4 and

ESS Hard Disk Drive Ribbon Cable PL 1.3C Item 11
ESS DRAM DIMM PL 1.3C Item 2
ESS PWB PL 1.3C Item 1
D
E
F
G
16-A
ESS Disk Drive / Image Disk Drive PL 1.3A Item 4 and ESS Hard
Disk Drive Ribbon Cable PL 1.3A Item 8

is
Inform Field Engineering that a Software Problem Action Report needs to be

generated.
Ensure the following:
Have the system administrator check the network configuration on the client
(compare to working client).
Have the system administrator ensure the client has the required resources.
Have the system administrator reload the print driver on the client.
If the problem continues, have the customer call the Customer Support Center.
Reload the print driver on the affected workstation.
Run ESS Memory Test. Use GP25 , Running the ESS Memory Test.
Observe the test results. The test passes.
Y
N
(255/265) Replace the ESS DRAM SIMMS PL 1.3B Item 2.
(460/470) Replace the ESS DRAM DIMM PL 1.3C Item 2.
Obtain and load the latest ESS Software.
(255/265) Replace the ESS DRAM SIMMS PL 1.3B Item 2.

(460/470) Replace the ESS DRAM DIMM PL 1.3C Item 2.
ESS Disk Drive / Image Disk Drive PL 1.3C Item 4 and ESS Hard
Disk Drive Ribbon Cable PL 1.3C Item 11
Try to re-create the problem. The problem can be re-created on the other
printer.
Y
N
Check the ESS software version for both printers
The printer with the problem has an older version of software.
Y
N
Reload the ESS Software. If the problem continues, escalate the service call.
Determine if another 240/255/265/460/470 printer is available. There

another Document Centre 240/255/265/460/470 available to print to.
Y
N
Escalate the service call.
Observe the results of the test. If no results are returned, the test
passed. If a memory address is listed, the test failed. The
test
failed.
Y
N
ESS Disk Drive / Image Disk Drive PL 1.3A Item 4 and ESS Hard Disk Drive Ribbon
Cable PL 1.3A Item 8
ESS Disk Drive / Image Disk Drive PL 1.3C Item 4 and ESS Hard Disk Drive Ribbon
Cable PL 1.3C Item 11
If the problem continues, escalate the service call.
May 2003
2-632
V0.042
16-A Non-Shutdown Fault Procedure
Table 1 Shutdown Faults Table
No action should normally be taken on non-shutdown faults that are referred to this procedure.
If these faults seem related to a customer complaint, perform the 16-A Shutdown Fault Procedure .
Fault Code
Description
Action
16-000
Cannot create RPC connection with ENS
Go to the 16-A Shutdown Fault Procedure
16-001
Unable to do start-up synchronization
16-002
Unable to register as RPC

server
16-003
Too many IPC handlers
16-004
RPC failure to connect to

ESS Registration Service
16-005
RPC call failure to ESS

Registration Service
16-006
Cannot register for events
16-007
Invalid RPC data received
16-008
Unable to free IPC

resources
16-009
16-010
Unable to send IPC message
16-011
Cannot remove RPC connection
Fault Code
Description
Action
16-022

service
16-023
RPC call failure to ENS
16-024
Unable to create RPC con- Go to the 16-A Shutdown Fault Procedure

nection
16-025
Invalid IPC message type
16-026
Memory allocation error
16-027
Unable to obtain well known Go to the 16-A Shutdown Fault Procedure

queue ID
16-028
Invalid range string
16-029
No acknowledgment to
RPC message
16-030
Unable to get RPC client

handle
16-031
Unexpected event notification
16-032
NVM connection failure
16-033
NVM detach error
16-034
Unable to specify shutdown Go to the 16-A Shutdown Fault Procedure

routine during initialization
16-035
Unable to free XDR data
16-036
Unable to unmarshall XDR

IPOC data
16-037
Unable to open file for write Go to the 16-A Shutdown Fault Procedure
16-038
Unable to initialize with

queue service library
16-039
P thread create error
16-040
Unable to create semaphore

16-012
Unable to do shutdown syn- Go to the 16-A Shutdown Fault Procedure

chronization
16-013
DC Peer Service synchroni- Go to the 16-A Shutdown Fault Procedure

zation error
16-014
DC Peer Service communi- Go to the 16-A Shutdown Fault Procedure

cation error
16-041
16-015
SESS data store environmental variable not set
Cannot log fault to ESS

fault service
16-042
Invalid internal parameters
16-016
Data store initialization

failed
16-043
Unable to close file
16-044
Unable to read from file
16-017
Sending of event failure
16-045
Unable to write to file

16-018
Event rejection by ENS
16-046
Unable to delete file
16-019
Unable to unregister ESS

Reg. Service due to RPC
failure
16-048
Cannot set ESS client bind- Go to the 16-A Shutdown Fault Procedure
ing
16-115.28
Unable to unregister ESS

Reg. Service due to Reg.
Service failure
Scan to file EJS template

fault
16-020
16-150.09
Cannot send registration

event
Unable to get host name
16-021
V0.042
May 2003
2-633
16-A

Action
Table 2 Logged Faults Table
Fault Code
Description
Fault Code
Description
16-150.14
Unable to obtain IPC trans- Go to the 16-A Shutdown Fault Procedure

port
16-601.35
System control initialization Go to the 16-A Non-Shutdown Fault Profailed

cedure
16-150.19
Unable to sync peer
16-601.46
16-150.26
Fault Service failed to write Go to the 16-A Shutdown Fault Procedure

to log
Fault service failed IPC

queue setup
Go to the 16-A Non-Shutdown Fault Procedure
16-601.47
16-150.90
Invalid RPC request destination
Diag service failed IPC

queue setup
16-601.66
16-150.92
Consumer interface fault
Unable to do start-up synchronization
16-151.09
Invalid IPC command
16-602.07
16-151.14
SNMP event registration

failed
RPC Service registration

failure
16-602.09
16-151.26
Fault service failed to get

log handle

service during shutdown
16-602.35
RPC Server registration
16-151.90
Put environment variable

failure
16-602.38
16-152.14
Empty internal event

received by ENS
RPC Server registration

failed
16-602.66
16-152.19
Unable to send request to

SESS
Unable to register as an
RPC server
16-603.46
Too many IPC handles
16-152.26
Fault service could not open Go to the 16-A Shutdown Fault Procedure
fault log
16-603.66
Too many IPC handles
16-153.09
Unable to obtain IPC queue Go to the 16-A Shutdown Fault Procedure
16-153.14
Cannot initialize internal

event list
16-604.14

16-153.19
NVM save failure
16-604.38
16-154.19
NVM read failure
Could not register with Reg- Go to the 16-A Non-Shutdown Fault Proistration Service
cedure
16-155.19
ESS failure to boot from

alternate partition
16-605.07
Unable to register with Reg- Go to the 16-A Non-Shutdown Fault Proistration Service
cedure
16-156.19
Service run loop failed
16-605.66

16.605.XX

16-606.XX
Cannot register for events
Action
Fault Code
Description
Action
16-600.07
16-607.XX
16-600.35
16-608.XX
Unable to free IPC

resources
16-600.46
16-608.26
Fault service failed to

unbind with SC
16-600.66
16-608.38
Unable to register as IPC

server
16-601.26
Fault service failed IPC

queue setup
16-608.66
Unable to free IPC

resources
16-A
May 2003
2-634
V0.042

Fault Code
Description
Action
Fault Code
Description
16-609.XX
Invalid IPC data received
16-612.46
Unable to do shutdown syn- Go to the 16-A Non-Shutdown Fault Prochronization

cedure
16-609.07
Received message from

unexpected source
16-613.09
DC synchronization error
16-610.07
Failure to initialize with

PrintSpi
16-613.19
DC System Manager synchronization error
16-610.19
16-614.09
DC Registration communications error
16-610.26
16-614.19
DC System Manager communications error
16-610.35
16-615.35
Data store environment

variable not set
16-610.90
IPC send response error
16-615.46
SESS Data store environment variable not set
16-610.92
Failure to send queue status
16-615.66
16-610.99
16-615.90
16-611.07
Client removal failed
16-616.35

failed
16-611.09
16-616.38
Shared memory failure
16-611.14
16-616.46

failed
16-611.19
16-619.14
Unable to unregister Regis- Go to the 16-A Non-Shutdown Fault Protration service

cedure
16-611.26
16-619.19

cedure
16-611.38
Client removal failed
16-619.26

cedure
16-611.46
16-619.46
16-611.47
Unable to unregister Regis- Go to the 16-A Non-Shutdown Fault Protration service due to RPC cedure
failure
16-620.07
16-611.66
Unable to unregister with

ESS Registration Service
16-620.14
16-611.99

cedure
16-620.19
16-612.09

cedure

cedure
16-620.35
16-612.14

cedure

cedure
16-620.38
16-612.35

cedure

cedure
V0.042
May 2003
2-635
Action
16-A

Fault Code
Description
Fault Code
Description
Action
16-620.46
Go to the 16-A Non-Shutdown Fault ProUnable to unregister with

cedure
ESS Registration service
due to Registration Service
failure
16-623.35
16-623.47

cedure
failure
16-624.46
Unable to create RPC con- Go to the 16-A Non-Shutdown Fault Pronection

cedure
16-625.35
Invalid IPC type
16-625.46
16-625.66
16-620.92
16-620.99
Action

cedure
failure
16-621.07
16-625.90
16-621.35
Get host name failed
Invalid queue service IPC

message type
16-626.47
Memory allocation error
16-621.47
16-628.07
16-621.66
Range string could not be

computed
16-628.35
16-621.99
Range string calculation

failed
16-628.46
16-622.07
RPC unregister server

failed
Object write value out of

range
16-629.26
16-622.09
Unable to unregister as
RPC service during shutdown
No acknowledgement to
RPC message OR Fault
Service call to PWC callback failed
16-622.14
16-629.46
RPC message
16-629.92
16-622.19
RPC message
16-630.26

handle
16-622.26
Fault Service to unregister Go to the 16-A Non-Shutdown Fault Proas RPC service during shut- cedure
down
16-630.35

handle
16-630.38
Client create failed
16-622.35
RPC service
16-630.46
16-622.38
RPC service

handle
16-630.47
16-622.46
RPC service

handle
16-630.99
16-622.66

handle
16-631.19
Invalid event notification

received
16-A
May 2003
2-636
V0.042

Fault Code
Description
Action
Fault Code
Description
Action
16-631.46
Unexpected event notification
16-643.47
16-633.19
NVM detach error
16-644.26
Unable to read from file
16-634.46
Unable to specify shutdown Go to the 16-A Non-Shutdown Fault Proroutine during initialization cedure
16-644.47
Unable to read from file OR Go to the 16-A Non-Shutdown Fault ProSW Verify get data failed
cedure
16-635.07
Cannot free XDR data
16-645.26
16-635.35
16-645.46
16-635.46
16-645.47
16-635.99
16-646.26
Failed to delete a systems

job file
16-636.99
16-649.35
Invalid service attributes

fault
16-637.26
Unable to open file
16-650.35
Invalid service attribute

requested
16-637.38
Unable to open file for write Go to the 16-A Non-Shutdown Fault Procedure
16-651.35
Cannot register for SESS

events
16-637.47
Unable to open file
16-652.38
Unable to enroll Spi callbacks
16-639.38
Create thread fault
16-653.38
Invalid job handle fault
16-639.46
Pthread create error
16-654.38
Return from Spi register

fault
16-640.35
RPC send
16-655.38
Return from Spi register

fault
16-640.46
Unable to create semaphore
16-656.38
RPC processing fault
16-641.00
Cannot log fault to ESS fault Go to the 16-A Non-Shutdown Fault Prolog
cedure
16-658.07
16-641.26
Cannot log fault to ESS fault Go to the 16-A Non-Shutdown Fault Prolog
cedure
16-672.09
Unable to remove file from

system
16-641.46
Cannot log fault to ESS fault Go to the 16-A Non-Shutdown Fault Proservice
cedure
16-700
Unknown attribute
requested
16-642.46
16-700.66
Unknown attribute
requested
16-642.47
16-707.00
Unknown queue request

received
16-643.19
16-709.00
Unknown modify request

received
16-643.26
16-710.00
IPC send message failure
V0.042
May 2003
2-637
16-A
Fault Code
Description
Action
Fault Code
Description
Action
16-710.35
IPC send message failure
16-751.35
Failure to initialize with DM

agent
16-716.00
Data store init failed failure
16-751.38
Unknown attribute
16-728.00
Unable to compute range

string failure
16-751.46
Unknown object (on write)
16-730.00
Unable to create client han- Go to the 16-A Non-Shutdown Fault Prodle failure
cedure
16-751.47
Software Verify repair dir

failed
16-730.35
Unable to create client han- Go to the 16-A Non-Shutdown Fault Prodle failure
cedure
16-751.92
Job state fault
16-750.07
Message received from DM Go to the 16-A Non-Shutdown Fault Pronot processed correctly fail- cedure
ure
16-752.07
Queue service library initial- Go to the 16-A Non-Shutdown Fault Proization failed
cedure
16-752.09
16-750.09
Cannot add existing service Go to the 16-A Non-Shutdown Fault Procedure
Attempt to register too

many services
16-752.14
16-750.14
Retry SNMP event registra- Go to the 16-A Non-Shutdown Fault Protion

cedure
Retry SESS sys control

event registration
16-752.19
16-750.19
Invalid Online/Offline
request
Cannot acknowledge system mode change
16-752.26
16-750.26
Invalid number of faults

requested
Unrecognized SESS error

code
16-752.35
16-750.35
Queue service library initial- Go to the 16-A Non-Shutdown Fault Proization failed
cedure
Failure to initialize with

PrintSpi
16-752.46
Invalid table row (on read)
16-750.38
Error - SPI Init fault
16-752.47
Invalid test pattern source
16-750.46
Unknown object (on read)
16-752.92
16-750.47
SC Diag startup failed
PrintSpi cannot read frame

type from data store
16-753.09
16-750.90
Invalid queue service IPC

queue ID
Number of services
attempts to go below zero
16-753.14
16-750.92
Bad file descriptor
Invalid event number error

received by ENS
16-753.19
16-751.07
Message received from

ESS AAA not processed
correctly
Unable to send event to

ESS ENS
16-753.26
Unable to become client of

PWS
16-751.09
Registration service
receives unrequested ENS
notification
16-753.35
Unable to change EJS state Go to the 16-A Non-Shutdown Fault Proto offline
cedure
16-751.14
SESS SC event registration Go to the 16-A Non-Shutdown Fault Profailed

cedure
16-753.46
Invalid table row (on write)
16-751.19
Unable to set time/date
16-753.47
Failed to close directory
16-751.26
Unrecognized fault code
16-753.90
Null return address
16-A
May 2003
2-638
V0.042

Fault Code
Description
Action
Fault Code
Description
Action
16-753.92
Printspi cant read frame

type from data store
16-756.35
Unable to read NVM value
16-754.09
Exiting with ESS services

still registered
16-756.46
Service run loop failed
16-754.14
Event notification via IPC

error - no queue
16-756.47
SC run diagnostic failed
16-754.19
Shutdown request reason

unknown
16-757.09
Unable RPC parameters

service
16-754.26
Fault service encountered

error reading fault log
16-757.14
RPC control error
16-754.35
Cannot generate SESS

event
16-757.19
MCB system manager

operation completion error
16-754.46
Attempted write of readonly object write)
16-757.26
Fault service could not

close fault log
16-754.47
SW Verify repair file failed
16-757.35
Unable to write NVM value
16-754.90
Attempt to free null node
16-757.46
Failed to get specific IPC

queue
16-754.92
Consumer interface fault
16-757.47
SW Verify repair checksum Go to the 16-A Non-Shutdown Fault Profailed

cedure
16-755.09
Unable to register
requested service
16-758.09
Invalid service failure
16-755.14
Event notification via IPC

error - full queue
16-758.14
RPC communication error

to client
16-755.19
Unable to provide new sw

config to SESS
16-758.19
Invalid job control error error Go to the 16-A Non-Shutdown Fault Procedure
16-755.26
Fault service failed to clear

fault log
16-758.26
16-755.35
Unable to update data store Go to the 16-A Non-Shutdown Fault Proattribute

cedure
Fault service encountered

error trying to access its
own queue ID
16-758.46
16-755.46
Object type mismatch
Registration monitor failure Go to the 16-A Non-Shutdown Fault Procedure
16-758.47
Error finding job ID
16-755.47
SW Verify repair permission Go to the 16-A Non-Shutdown Fault Profailed

cedure
16-759.09
16-755.90
Exceeding queue array size Go to the 16-A Non-Shutdown Fault Procedure
Unable to process death

map
16-759.19
16-756.09
Unable to register
requested service
ESS failed cold reset 3

times in a row
16-759.26
16-756.14
RPC creation error: unable Go to the 16-A Non-Shutdown Fault Proto create RPC communica- cedure
tion to client services
Unrecognized service id
Go to the 16-A Non-Shutdown Fault Prorequesting fault information cedure
16-759.46
Failed to disable or enable a Go to the 16-A Non-Shutdown Fault Proprocess

cedure
Memory allocation failure
16-759.47
Failed to abort process
16-756.26
V0.042
May 2003
2-639
16-A

Fault Code
Description
Action
Fault Code
Description
16-760.09
Scan to file process death

map
16-765.19
System Manager call failed Go to the 16-A Non-Shutdown Fault Procedure
Action
16-760.14
Invalid unregister request
16-765.46
Failed to clear sm status
16-760.19
ESS initializing
16-765.47
Novell daemon not running Go to the 16-A Non-Shutdown Fault Procedure
16-760.26
Unable to become a client

of RDT
16-766.09
PostScript Process Failed
16-766.19
DM admin error
16-760.46
Processes are in an
unknown state
16-766.46
Failed to set sm status
16-760.47
Incorrect checksum partition 1
16-766.47
No servers responded
16-760.99
Request for system policy

failed
16-767.09
HP-PCL Process Failed
16-761.09
LPD Process Failed
16-767.19
16-761.19
ESS shutting down
Request to cancel spooling Go to the 16-A Non-Shutdown Fault Projob error

cedure
16-767.46
16-761.26
Unable to become a client

of UI
Failed to send SESS alert/

event
16-768.09
Parallel Process Failed
16-761.46
Ethernet status file error
16-768.19
Hold / Release of jobs error Go to the 16-A Non-Shutdown Fault Procedure
16-761.47
SW Verify init file failed
16-768.46
Request had invalid param- Go to the 16-A Non-Shutdown Fault Proeters

cedure
16-762.09
Netware Process Failed
16-768.47
16-762.19
DC Platform Manager
comm error
ESS not connected to

server
16-769.09
HTTP Process Failed
16-762.46
Token Ring status file error
16-769.19
Novell Network communica- Go to the 16-A Non-Shutdown Fault Protions error

cedure
16-763.09
NetBios Process Failed
16-769.46
16-763.19
System Manager comm

error
Config methods library error Go to the 16-A Non-Shutdown Fault Procedure
16-769.47
16-763.46
DHCP status file error
ESS not attached to print

queue
16-770.09
Unexpected Process Failed
16-763.47
Invalid permission
16-770.19
Online/Offline request time- Go to the 16-A Non-Shutdown Fault Proout

cedure
16-764.09
AppleTalk Process Failed
16-770.46
16-764.17
Incorrect checksum partition 2
Cannot register for SESS

events
16-770.47
16-764.19
Set-up of the SIGALRM sig- Go to the 16-A Non-Shutdown Fault Pronal failed
cedure
Attached to queue and

server
16-771.09
16-764.46
RARP status file error
Print service EJS process

death
16-771.19
16-765.09
Banyon Vines Process

Failed
Online/Offline callback failure
16-A
May 2003
2-640
V0.042

Fault Code
Description
Action
Fault Code
Description
16-771.46
Internal error with synchronizer queue
16-782.09
ESS configuration synchro- Go to the 16-A Non-Shutdown Fault Pronization process death
cedure
16-771.47
Novell config info failure
16-782.47
SESS IPX test failed on

bind for receive
16-772.09
ESS Print SPI process

death
16-783.09
Unable to send
sc_proc_disable
16-772.19
Failure to set ESS Platform Go to the 16-A Non-Shutdown Fault Promanager service state
cedure
16-783.47
SESS IPX test send failure
16-772.47
RPC failure for communica- Go to the 16-A Non-Shutdown Fault Protion

cedure
16-784.09
Missing service type
16-773.09
ESS Print service surrogate Go to the 16-A Non-Shutdown Fault Proprocess death
cedure
16-784.47
SESS IPX test receive fail- Go to the 16-A Non-Shutdown Fault Proure
cedure
16-773.19
Unknown client requested

online/offline
16-785.09
ESS SNMP Agent process Go to the 16-A Non-Shutdown Fault Prodeath

cedure
16-774.09
ESS Lakes protocol module process death
16-785.47
SESS IPX test bad data in Go to the 16-A Non-Shutdown Fault Proreceive
cedure
16-774.19
Cannot obtain RPC connec- Go to the 16-A Non-Shutdown Fault Protion

cedure
16-786.47
SESS IPX test unknown

error
16-775.19
Cannot obtain datastore

handle for server object
16-787.47
SESS Apple test zip failure Go to the 16-A Non-Shutdown Fault Pro- network unreachable
cedure
16-776.09
ESS Fault service process

death
16-788.47
SESS Apple test no zones Go to the 16-A Non-Shutdown Fault Profound

cedure
16-776.19
Cannot delete jobs using

the map library
16-789.47
SESS Apple test unknown Go to the 16-A Non-Shutdown Fault Proerror

cedure
16-777.09
ESS completed job log ser- Go to the 16-A Non-Shutdown Fault Provice/SPI process death
cedure
16-790.47
SESS Banyan test

unknown error
16-777.19
Cannot access datastore

element
16-791.47
SESS Banyan test no network
16-778.09
ESS configuration utility

process death
16-792.47
SESS Banyan test open

failure
16-778.19
Invalid enable Demo Job

setting
16-793.47
SESS Banyan test echo

failure
16-779.09
ESS Diagnostic Service

process death
16-794.47
SESS Banyan test no serv- Go to the 16-A Non-Shutdown Fault Proers

cedure
16-779.47

open for send
16-795.47
SESS NetBIOS test no

lanas found
16-780.09
ESS authentication SPI pro- Go to the 16-A Non-Shutdown Fault Process death
cedure
16-796.47
SESS NetBIOS test invalid Go to the 16-A Non-Shutdown Fault Procommand

cedure
16-780.47

open for receive
16-797.47
SESS NetBIOS test interface busy
16-781.09
ESS counters utility process Go to the 16-A Non-Shutdown Fault Prodeath

cedure
16-798.47
SESS NetBIOS test too

many commands
16-781.47

bind for send
16-799.47
SESS NetBIOS test invalid Go to the 16-A Non-Shutdown Fault Proadapter

cedure
V0.042
May 2003
2-641
Action
16-A

Fault Code
Description
Fault Code
Description
Action
16-800.47
SESS NetBIOS test cannot Go to the 16-A Non-Shutdown Fault Procancel

cedure
16-821.47
SESS NetBIOS test MAC

driver went offline
16-801.47
SESS NetBIOS test oem x Go to the 16-A Non-Shutdown Fault Pro(unusual network problem) cedure
16-822.47
SESS NetBIOS test error

during reset
16-802.47
SESS NetBIOS test

adapter malfunction
16-823.47
SESS NetBIOS test

unknown error
16-803.47
SESS NetBIOS test cannot Go to the 16-A Non-Shutdown Fault Proinit token ring
cedure
16-824.47
SESS UNIX test unknown

error
16-804.47

cable connected to board
16-825.47
Echo Test Failure; SESS

diag name not found
16-805.47
SESS NetBIOS test could

not join ring
16-826.47
SESS Apple test zip failure Go to the 16-A Non-Shutdown Fault Pro- system error
cedure
16-806.47
SESS NetBIOS test cable

not connected to MAU
16-827.47
SESS Apple test zip failure Go to the 16-A Non-Shutdown Fault Pro- invalid parameters
cedure
16-807.47
SESS NetBIOS test memory allocation error
16-828.47
SESS Apple test zip failure Go to the 16-A Non-Shutdown Fault Pro- no router found
cedure
16-808.47

more minor devices available
16-829.47
SESS Apple test zip failure Go to the 16-A Non-Shutdown Fault Pro- unknown zip error
cedure
16-830.47
16-809.47
SESS NetBIOS test token

ring board was stopped
GetNetData IP Diagnostic - Go to the 16-A Non-Shutdown Fault Profailed to get default router. cedure
16-831.47
16-810.47
SESS NetBIOS test network is bad
GetNetData IP Diagnostic - Go to the 16-A Non-Shutdown Fault Profailed to get subnet mask.
cedure
16-832.47
16-811.47
SESS NetBIOS test command timed out
GetNetData IP Diagnostic - Go to the 16-A Non-Shutdown Fault Profailed to get local devices. cedure
16-833.47
16-812.47
SESS NetBIOS test message incomplete
GetNetData IP Diagnostic - Go to the 16-A Non-Shutdown Fault Profailed on ARP.

cedure
16-834.47
16-813.47

resources on local adapter
Novell GetNetData - failed

getting default file server
16-835.47
16-814.47
SESS NetBIOS test duplicate name in local name

table

getting frame type
16-836.47

to init Netware
16-815.47
SESS NetBIOS test name

table is full
16-837.47
GetNetData - Diagnostic
Name not found
16-816.47
SESS NetBIOS test unexpected protocol received
16-838.47
SWVerify Setup Alarm

Failed
16-817.47
SESS NetBIOS test NetBIOS/ix being reset
16-839.47
SWVerify Repair File length Go to the 16-A Non-Shutdown Fault ProFailed

cedure
16-818.47
SESS NetBIOS test NetBIOS/ix being stopped
16-840.47
System call failed
16-819.47
SESS NetBIOS test NetBIOS/ix not loaded
16-841.47
SWVerify Missing Directory Go to the 16-A Non-Shutdown Fault Procedure
16-820.47
SESS NetBIOS test NetBIOS/ix not running
16-842.47
SWVerify Process Not

Running
16-A
Action
May 2003
2-642
V0.042

Fault Code
Description
Action
Fault Code
Description
Action
16-843.47
SWVerify Repair Time-out
16-865.47
SESS NETBIOS test session closed.
16-844.47
Failed to save data to NVM Go to the 16-A Non-Shutdown Fault Procedure
16-866.47
SESS NETBIOS test com- Go to the 16-A Non-Shutdown Fault Promand canceled.
cedure
16-845.47
Failed to initialize NVM
16-867.47
SESS NETBIOS test name Go to the 16-A Non-Shutdown Fault Proderegistered.

cedure
16-846.47
Failed to restore contents

of NVM
16-868.47
SESS NETBIOS test local

session table full.
16-847.47
Failed to write value to

NVM
16-869.47
SESS NETBIOS test no lis- Go to the 16-A Non-Shutdown Fault Proten in remote computer
cedure
16-848.47
Failed to read faults
16-870.47
SESS NETBIOS test illegal Go to the 16-A Non-Shutdown Fault Proname number.
cedure
16-849.47
Failed to create command

array
16-871.47
SESS NETBIOS test can- Go to the 16-A Non-Shutdown Fault Pronot find name or no answer. cedure
16-850.47
Failed to add substitution

string
16-872.47
SESS NETBIOS test name Go to the 16-A Non-Shutdown Fault Proin use.
cedure
16-851.47
Failed calling stream editor Go to the 16-A Non-Shutdown Fault Procedure
16-873.47
SESS NETBIOS test name Go to the 16-A Non-Shutdown Fault Prodeleted.

cedure
16-852.47
Failed to process fault for

error report
16-874.47
SESS NETBIOS test session appended.
16-853.47
Failed to get last reset time Go to the 16-A Non-Shutdown Fault Procedure
16-875.47
SESS NETBIOS test name Go to the 16-A Non-Shutdown Fault Proconflict.

cedure
16-854.47
Failed on call to fault service
16-977.35
Queue List Jobs failure
16-855.47
Failed on call send event
16-978.35
Unable to get Copy jobs
16-856.47
Failed on system command Go to the 16-A Non-Shutdown Fault Procedure
16-979.35
Unknown Attribute returned Go to the 16-A Non-Shutdown Fault Procedure
16-857.47
Failed to find process
16-980.35
DM request Handle NULL
16-858.47
Failed to dump log
16-981.35
Unable to obtain Job handle
16-859.47
Failed on software verify
16-982.35
Unknown Finishing Value

returned
16-860.47
No response for IP Ping

Test
16-983.35
Unknown Offset value

returned
16-861.47
Registration Monitor Failure.
16-984.35
Unknown Job State Reason value returned
16-862.47
SESS NETBIOS test

invalid cancel command.
16-985.35
Unknown Medium Type

value returned
16-863.47
SESS NETBIOS test illegal Go to the 16-A Non-Shutdown Fault Probuffer length.
cedure
16-986.35
Unknown Collation value

returned
16-864.47
SESS NETBIOS test illegal Go to the 16-A Non-Shutdown Fault Prolocal session number.
cedure
16-987.35
Unknown Tray value

returned
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16-A

Fault Code
Description
Action
16-988.35
Unknown signature value

returned.
16-989.35
Unknown Plex Value

returned
16-990.35
Promote Response from

DM received with errors
16-991.35
Request to DM to promote Go to the 16-A Non-Shutdown Fault ProJob Failed

cedure
16-992.35
Unable to build SESS Job

Identifier for promote
16-993.35
Unable to get admin. name Go to the 16-A Non-Shutdown Fault Profrom data store for promote cedure
16-994.35
Cancel response with

errors
16-995.35
Request to DM to Cancel
Job Failed
16-996.35
Warning- Unable to build

SESS Job Identifier
16-997.35
Unable to get admin. name Go to the 16-A Non-Shutdown Fault Profrom data store
cedure
16-998.35
Job not set to Released

State
16-999.35
Could Not Obtain Job PIN

for Authorization
16-A
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16-B ESS Boot RAP

Used to diagnose causes of ESS boot failures or ESS hardware or software initialization faults.
Initial Actions
Ensure the IOT and the Main Control PWB are functioning before entering this RAP. Ensure
that Call Flow and the SCP-04, System Fault Analysis has been performed.
NOTE: Some machines may have the ESS Hard DIsk located in a Removable Disk Drive.
These are machines that have special security requirements. The ESS Disk Drive and Image
DIsk Dive is located in a DIsk Carrier which is external to the machine. The Drive(s) can be
removed and secured when the machine is not in use. The Disk Carrier is connected by cable
to the Machine. Some steps in the RAP are different if the machine has this option.

If OK, replace the ESS PWB PL 1.3A Item 1.
Check the POST results for a memory failure. Look at the line: Testing /memory@0
Check for a Selftest failed message on the next line. A memory failure is indicated by the
POST test results.
Y
N
Look at the lines:
Ensure the Removable Disk Drive is plugged in to the wall outlet, and the wall outlet has
the correct voltage (the green LED on the front of the Drive Enclosure indicates power is
available).
Ensure the Removable Drive was powered up correctly. The power for the Removable
Disk Drive should be switched on first, with a constant 0 on the seven segment display
before the machine power is switched on.
Ensure the cables in the rear of the Drive Enclosure are correctly connected.
Ensure the disk carrier is inserted correctly in to the drive enclosure.
Ensure the number on the Disk Carrier matches the number in the Drive Enclosure.
Testing /pci/isa@b/nvram@i74
Testing /pci/isa@b/rtc@i74
NOTE: Failures in these tests WILL prevent the ESS from booting
If the machine has the Removable Disk Drive option, ensure the following:
C
Go to the 16-B Removable Disk Drive Troubleshooting.
Check for a Selftest failed message on the next line after any of the above. A failure is
indicated.
Y
N
Look for the line Trying. . . , hdisk Booting
Check the POST results for a cannot open boot device message. A cannot open
boot device is indicated (answer No if an fsck or boot file problem is indicated).
Y
N
POST indicated a fsck or boot file problem.
Y
N
Look at the following lines:
16-B On-Site Diagnostic Procedure (255/265 - PowerPC ESS)

With the machine on and in standby, at the rear of the machine, check the ESS LEDs.
Check if the green LED is ON. The green LED is ON.
Y
N
Go to Flag 1 and Flag 2. Check the wires for an open circuit. If there is no open circuit,
replace the ESS PWB PL 1.3A Item 1.
Connect the PWS to the ESS serial port. (See GP22 ). Switch the machine power off/on to
reboot the ESS and view the results of the Power On Self-Test (POST).
Observe the PWS screen. ESS POST results are displayed on the PWS.
Y
N
Disconnect P1/J5 on the ESS PWB.
Measure the voltage between the +12V (+) (without IOT TAG 011) or +12V (+) (with
IOT TAG 011) and LVPS frame (-). +12 VDC is measured.
Y
N
Go to the 01-A, DC Voltage Checkout Procedure.
Executing install_ELTNR 2.0 and check for a line ELTNR

Driver installed. . .following it.
Executing install_ELT 2.0 and check for a line ELT Driver

installed. . . following it.
Executing install_SMC 2.0 and check for line SMC Driver

installed. . . following it.
Executing install Daemon 2.0 and Installing the ELT

Daemon. . .and check for line ELT Daemon installed successfully. . . following it.
NOTE: If you see the message BAD DEST PORT 111. . . dropping
msg can be ignored, it is not a problem.
All of the above installed successfully.
Y
N
Check the interface between the ESS PWB / Main Control PWB.
Carefully inspect the interconnections of these PWBs. Ensure the
PWB's are positioned correctly and the mating connectors are correctly mated. Refer to REP 16-2 for more information.
The PWB's are connected correctly.
Y
N
Repair as necessary. Return to Service Call Procedures.
Reconnect P1/J5 on the ESS PWB.

Measure the voltage between the +12V (+) (without IOT TAG 011) or +12V (+) (with
IOT TAG 011) and LVPS frame (-). +12 VDC is measured.
Y
N
The machine has a Removable Disk Drive option.
Y
N
Replace the ESS Hard Disk Drive Power Cable PL 1.3A Item 7. If the problem
continues, replace the ESS Disk Drive / Image Disk Drive PL 1.3A Item 4 .
A
B
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Refer to GP23 to access the alternate boot menu. Select option 2),
Reset ESS Configuration Files. When complete, select option b),
Boot SCSI Disk.
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16-B
Done. Notify the Systems Administrator the printer will have to be

reinstalled on the network. Return to Service Call Procedures.
Look at the lines:
Testing /pci/ethernet
Testing /pci/isa@b/c11283@i900
Testing /pci/isa@b/parallel@i3bc
Main Control PWB (Use 03-G Main Control PWB Replacement RAP)
The ESS reboots after the above messages are displayed.

Y
N
Any failures for the following can be ignored. They are declared
on hardware that is not present or supported.
Testing /pci/isa@b/z8536@i844
J
If the above does not correct the problem, replace the following,
one-at-a-time, until the problem is resolved.
Observe the POST results. The above drivers now install OK.
Y
N
Ensure the Main Control PWB is functioning correctly. If the IOT
is OK, go to the 16-C, ESS Software Verification RAP.
If the ESS Software verify does not correct the problem, replace
the following, one-at-a-time, until the problem is resolved.
Testing /pci/isa@b/z85230@i840
Testing /pci/isa@b/floppy@i3f0
Testing /pci/isa@b/serial@i2f8
Testing /pci/isa@b/serial@i3f8
The POST did not detect any ESS hardware problems. Return
to the RAP from which directed.
NOTE: These will NOT prevent the ESS from booting

Check the current software level on the machine.
The machine has L18.x software installed.
Y
N
Check for a Selftest failed message on the next line after any of the
above. A failure is indicated.
Y
N
NOTE: The message(s) Lowlevel SCSI: device 2: selection timed out can be ignored, it is not a problem.
Y
N
Replace the indicated ESS DRAM SIMMS PL 1.3B Item 2.
Check for the following messages:
***********
**********
*********** ESS System is 'SYNCHRONIZED' with

SYSTEM MANAGER **********
*********** UI PLATFORM 'AVAILABLE' **********
*********** DIGITAL COPIER PLATFORM 'AVAILABLE'

**********
ESS
System
is
'OPERATIONAL'
From the Alternate Boot Tool (see GP23 ), run the ESS Software Verify test.
A message is displayed the routine can't be run or the routine
stops before it is complete.
Y
N
A message is displayed on the PWS indicating that ESS
Software must be reloaded.
Y
N
A message was displayed indicating that a repair was
made.
Y
N
No problem was detected with the ESS Software.
Reload ESS Software.
All of the above messages are present.

Y
N
The only message that is present is ESS System is OPERATIONAL.
Y
N
If the other messages do not appear, it is likely an IOT
problem. Return to Service Call Procedures and re-evaluate the system symptoms. Check for IOT fault codes that
might indicate a UI or Main Control PWB problem.
Done. The ESS Software Verification Tool has repaired/

replaced the corrupt file(s). Verify the problem is corrected
and return to Service Call Procedures.
D
E
F
G I
J
16-B
Verify the IOT is operational. Ensure the IOT comes up

normally and that prints can be printed from the PWS.
Ensure the machine is configured correctly.

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Any of these failures will not prevent the ESS from booting. There may be
a failure of some feature or function to work. Ensure the failure is pertinent
to the main reason for service. The following defines what features those
self-tests control:
Testing /pci/ethernet The Ethernet controller on the ESS
PWB. If the printer won't connect to the ethernet network and Echo
Test fails, the PWB should be replaced.
Testing /pci/isa@b/c11283@i900IEEE 1284 parallel port. An

inability to upload software could be caused by a failure of this port.
Testing /pci/isa@b/parallel@i3bc Parallel printing host

port, PC87323
ESS Hard Disk Drive Ribbon Cable PL 1.3A Item 8
ESS Disk Drive / Image Disk Drive PL 1.3A Item 4.
ESS PWB PL 1.3A Item 1.
Replace the ESS Disk Drive / Image Disk Drive PL 1.3A Item 4 and ESS Hard
Disk Drive Ribbon Cable PL 1.3A Item 8.
Switch the machine power off/on to reboot the ESS. Observe the POST results
again. A hard disk drive failure is indicated.
Y
N

Y
N
Replace the ESS Disk Drive / Image Disk Drive PL 1.3A Item 4.
Replace the ESS PWB PL 1.3A Item 1.

From the alternate boot menu, select 3) Format ESS SCSI Disk.
When format is complete, reload ESS software and check if the problem is
resolved. The problem persists.
Y
N

Switch the machine power off. Reseat the ESS Hard Disk Drive Ribbon Cable (ribbon cable) and the ESS Hard Disk Drive Power Cable at both ends.
Switch the machine power on to reboot the ESS. Observe the POST results again.
A cannot open boot device message is still indicated.
Y
N
Use GP24 to test the communication to the hard disk. At the Ok prompt, type
probe-scsi
Observe the results of the test. (An ok with no other information is a failure) A
description of the hard drive was displayed before the ok prompt.
Y
N
Y
N
Go to Flag 3 and Flag 4. Check the wires for an open circuit. The
wiring is OK.
Y
N
Repair or replace the cables as necessary ESS Hard Disk Drive
Power Cable PL 1.3A Item 7 or ESS Hard Disk Drive Ribbon Cable
PL 1.3A Item 8.
If the problem continues, replace the following one-at-a-time, until the
problem is corrected.
Refer to GP23 to access the alternate boot menu. Select option 1) Check and
Repair SCSI Disk.
A message indicates the disk is defective or the disk can't be repaired.
Y
N
The repair completed. Select option b) Boot SCSI Disk.
Observe the POST results again. The POST fails again.
Y
N
Refer to GP23 to access the alternate boot menu. Select option 1), Check
and Repair SCSI Disk. When complete, select option b), Boot SCSI
Disk.
Observe the POST results again. The POST fails again.
Y
N
If any of the failures may be related to a required function, replace the

D
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Y
N
Y
N
Check the ESS DRAM SIMMS, ensure they are in correct position. Remove and reinstall
the SIMMS. If the problem continues, replace both of the ESS DRAM SIMMS PL 1.3B
Item 2.
Observe the test results. The test has a problem starting or completing.
Y
N
The test should have completed with a memory failure detected. Replace the indicated
ESS DRAM SIMMS PL 1.3B Item 2.
ESS Hard Disk Drive Power Cable PL 1.3A Item 7.
M
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16-B
M
Replace both of the ESS DRAM SIMMS PL 1.3B Item 2.
16-B On-Site Diagnostic Procedure (460/470 - Intel ESS)

After a few seconds, listen for two short beeps from the card cage area. Two short beeps
can be heard (answer NO if more than two beeps are heard).
Y
N
Check the ESS DRAM DIMM(s). Ensure they are present and installed correctly. If the
problem continues, restart the RAP and answer YES to the first statement.
Check Power LEDs on the Card Cage Riser PWB (Figure 4). Check CR10, the +5VDC red
LED. CR10 is lit.
Y
N
Go to Flag 7. Ensure the power harness is connected to the Card Cage Riser PWB (connector is on the bottom side of PWB).
Check CR9, the +3.3VDC red LED. CR9 is lit.
Y
N
Replace the Card Cage Riser PWB PL 1.4C Item 4.
Check the ESS Hard Disk Power Cable and Data Cable. Check for good connections at the Card Cage Riser PWB and at the ESS Hard Disk. If OK, replace the following, one-at-a-time until the problem is resolved:
Reload ESS Software
Check CR7, the +12VDC red LED. CR7 is lit.

Y
N
Switch off the machine power. Disconnect the ESS Hard Disk Power Cable from the Card
Cage Riser PWB. Switch on the machine power.
CR7 is lit.
Y
N
Go to Flag 6. Ensure the power harness is connected to the Card Cage Riser PWB
(connector is on the bottom side of PWB). If the problem continues, replace the Card
Cage Riser PWB PL 1.4C Item 4.
Switch off the machine power. Use GP38 , Getting POST Results, to prepare the PWS to connect to the ESS and read the POST results. Switch on the machine power.
Activity is seen in the AltBoot terminal window (info from ESS is displayed on screen).
Y
N
Close the terminal window. Switch off the machine power. Start the AltBoot tool again,
switch on the machine power. Repeat the previous check one more time to ensure it is
repeatable. If it continues, replace the following in order one-at-a-time until the problem is
resolved:.
ESS Hard Disk Drive PL 1.3C Item 3

Card Cage Riser PWB PL 1.4C Item 4
ESS Hard Disk Drive PL 1.3C Item 3
ESS Hard Disk Power Cable PL 1.3C Item 10 and ESS Hard Disk Data Cable
PL 1.3C Item 11
Card Cage Riser PWB PL 1.4C Item 4
Refer to GP23 to access the alternate boot menu. Select option 4), Reset ESS
Configuration Files. When complete, select option b), Boot SCSI Disk.
Observe the ESS boot again. The Atlanta to ESS Connection PASSED.
Y
N
Ensure the Main Control PWB is functioning correctly. If the IOT is OK, go to
the 16-C, ESS Software Verification RAP.
If the ESS Software verify does not correct the problem, replace the following,
one-at-a-time, until the problem is resolved.
Reload ESS Software
Check the POST results for errors.

NOTE: You can ignore the following errors:
After a couple of minutes a banner message appears on the screen which indicates
the Atlanta to ESS connection Test PASSED.
Y
N
Switch off the machine power. Check the interface between the ESS PWB / Main
Control PWB and the Riser PWB. Carefully inspect the interconnections of these
PWBs. Ensure the PWB's are positioned correctly and the mating connectors are
correctly mated. Refer to REP 16-2 for more information.
The PWB's are connected correctly.
Y
N
Repair as necessary. Return to Service Call Procedures.
Check the ESS Hard Disk Power Cable for a short circuit. If it looks OK, replace the ESS
Hard Disk Drive PL 1.3C Item 3. If the problem continues, replace the ESS Hard Disk
Power Cable PL 1.3C Item 10.
ERROR: Keyboard Not Functional
There are errors in addition to the two listed above.

Y
N
Press any key to reboot system. Observe the PWS AltBoot window as the ESS boots.
After the Press Any Key For AltBoot Menu message appears, more information is
displayed on the screen as the ESS boots.
Y
N
No information is displayed after the Press Any Key For AltBoot Menu message.
Switch off the machine power. Switch on the machine power. Observe the AltBoot
window again. When the Press Any Key For AltBoot Menu message appears,
press any key. Use GP23 and download the Lynx Mini-Kernel. Select item 1) Repair
(Recreate) ESS SCSI Disk Partitions.
Observe the AltBoot terminal window. There is a message Fatal Error: failed to
partition SCSI disk.
Y
N
There may have been a corrupt file on the disk boot partition that prevented the
disk from booting. Check if the problem is resolved and re-enter this RAP if
necessary.
ERROR: CMOS Configuration Error

N
16-B
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P
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P
Done. Notify the Systems Administrator the printer will have to be reinstalled on the
network. Return to Service Call Procedures.
Q
Check for the following messages:
Check for any of the following errors:
CMOS Battery Failure
*********** ESS System is 'OPERATIONAL' **********
CMOS System Options Not Set
*********** ESS System is 'SYNCHRONIZED' with SYSTEM MANAGER

**********
CMOS Checksum Error
CMOS Memory Size Different
*********** UI PLATFORM 'AVAILABLE' **********
NVRAM Checksum Error, NVRAM Cleared
*********** DIGITAL COPIER PLATFORM 'AVAILABLE' **********
NVRAM Cleared by Jumper
All of the above messages are present.

Y
N
The only message that is present is ESS System is OPERATIONAL.
Y
N
If the other messages do not appear, it is likely an IOT problem. Return to Service Call Procedures and re-evaluate the system symptoms. Check for IOT
fault codes that might indicate a UI or Main Control PWB problem.
NVRAM Data Invalid, NVRAM Cleared
Serial Port 1 Resource Conflict
Verify the IOT is operational. Ensure the IOT comes up normally and that prints
can be printed from the PWS.
Ensure the machine is configured correctly.
One or more of those errors are present.

Y
N
Check for the error Primary Boot Device Not Found.
The error is present.
Y
N
Any other error will not prevent the ESS from booting and can be ignored. Return to
the spot in the RAP that asked if there were errors in addition to the two listed and
answer NO and continue the RAP.
If the above does not correct the problem, replace the following, one-at-a-time, until
the problem is resolved.
Replace the Card Cage Riser PWB PL 1.4C Item 4.

If the problem continues, replace the following, one-at-a-time, until the problem is
resolved.
Reload machine IOT Software
ESS Hard Disk Power Cable PL 1.3C Item 10 and ESS Hard Disk Data Cable PL
1.3C Item 11
The ESS reboots after the above messages are displayed.

Y
N
The ESS is booting normally. Return to the RAP from which directed.
Replace the ESS PWB PL 1.3C Item 1.
Y
N
Replace the indicated ESS DRAM DIMM PL 1.3C Item 2.
Observe the LEDs on the front of the Drive Enclosure. The green LED on the front of the
Drive Enclosure is ON.
Y
N
Ensure the Removable Drive Module is switched on and plugged into the wall outlet, with
correct voltage available. If the wall outlet is OK, replace the Drive Enclosure.
16-B Removable Disk Drive Troubleshooting
From the Alternate Boot Tool (see GP23 ), run the ESS Software Verify test.
A message is displayed that the routine can't be run or the routine stops before it
is complete.
Y
N
reloaded.
Y
N
Y
N
No problem was detected with the ESS Software. Reload ESS Software.
Done. The ESS Software Verification Tool has repaired/replaced the corrupt
file(s). Verify the problem is corrected and return to Service Call Procedures.
N
Q
V0.042
Check the Removable Drive SCSI Cable at the back of the Removable Drive and at the Main
Control PWB for good connections. The connections look OK.
Y
N
Repair or replace the Removable Drive SCSI Cable as necessary PL 1.1B Item 7.
Swap the two SCSI cables. Use the ESS cable for the Image Disk and the Image DIsk cable
for the ESS. The ends will have to be reversed to enable the connectors to mate.
Check for a reoccurrence of the fault. The problem still occurs with a different cable.
Y
N
Replace the Removable Drive SCSI Cable PL 1.1B Item 7 (if swapped to the Image Disk
Removable Drive, replace that one).
If the problem continues, replace the Removable Disk Drive Assembly PL 1.1B Item 1.
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16-B
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36V
24V
24 PSV
Interlock Output
Interlock Input
5.15V
+12V
-12V
5.15 PSV
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16-B
+36V
+24V
-12V
+24 VES
INT-OUT
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
+12V
+12 VES
16-B
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CR7
CR10
CR9
Figure 4 Intel ESS
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16-B
Figure 5 16-B Circuit Diagram

16-B
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16-C ESS Software Verification and Repair RAP
16-781.19 Memory Error for Network Scanning RAP
This RAP provides a procedure to verify and repair problems that may be caused by corrupted
ESS software.
Fault code, 16-781.19, indicates there is not enough ESS DRAM available to support Network
Scanning.
A message is displayed that the routine can't be run or the routine stops before it is
complete.
Y
N
reloaded.
Y
N
Y
N
Enter [ESS/Network tab , ESS Test Jobs]. Select [Power On/Demo] [Generate New Configuration Report], then the appropriate Composition selection (PS or HP-PCL). Select [Start]
Check the configuration report. Under the Device Profile section, check the ESS RAM size.
The ESS RAM is reported as 96MB or greater.
Y
N
Access the ESS PWB. Check for the presence of at least 96 MB of ESS DRAM. There
should be 4 SIMMs installed. A pair of 16MB SIMMS, and a pair of 32MB SIMMs, or two
pair of 32MB SIMMs.
There is at least 96MB of ESS RAM installed.
Y
N
Determine if memory had been previously present and is now missing. Install additional ESS DRAM to equal 96MB of total ESS DRAM (PL 1.3B Item 2).
Done. The ESS Software Verification Tool has repaired/replaced the corrupt file(s).
Verify the problem is corrected and return to Service Call Procedures.
Switch off the machine power. Reseat each SIMM in its socket.
Select [Power On/Demo] [Generate New Configuration Report], then the appropriate
Composition selection (PS or HP-PCL). Select [Start]. Under the Device Profile section,
check the ESS RAM size. The ESS RAM is reported as 96MB or greater.
Y
N
Run the ESS Memory Test. Start the Alternate Boot Tool. Select [ESS Memory Test].
Y
N
Replace the indicated ESS DRAM DIMM PL 1.3C Item 2.


Switch off the machine power. Reseat each SIMM in its socket. Switch on the machine power.
Y
N
Y
N
Replace the indicated ESS DRAM SIMMS PL 1.3B Item 2 (255/265).
Replace the indicated ESS DRAM DIMM PL 1.3C Item 2 (460/470).
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16-785.19 IPA PWB Missing or Defective RAP
16-786.19 IPA PWB Missing or Defective RAP
Fault code, 16-785.19, indicates the IPA PWB was detected missing or defective. This fault
only occurs when Network Scanning is enabled.
Fault code, 16-786.19, indicates the IPA PWB was detected missing or defective. This fault
only occurs when LAN FAX is enabled.
Access the ESS PWB. Check for an IPA PWB.

There is an IPA PWB installed.
Y
N
Install an IPA PWB PL 1.3B Item 4 PL 1.3C Item 6.
Access the ESS PWB. Check for an IPA PWB.

There is an IPA PWB installed.
Y
N
Install an IPA PWB PL 1.3B Item 4 PL 1.3C Item 6.
Switch off the machine power. Reseat the IPA PWB and the PCI Bus Adaptor PWB.
Switch on the machine power. Check for a reoccurrence of 16-785.19 fault. The fault continues.
Y
N
Switch off the machine power. Reseat the IPA PWB and the PCI Bus Adaptor PWB.
Switch on the machine power. Check for a reoccurrence of 16-785.19 fault. The fault continues.
Y
N
Enter [Self Tests tab , Video Path Diagnostics]. Select [IPA Daughter Card Test] [Start].
Y
N
Replace the IPA PWB PL 1.3B Item 4. If the problem continues, replace the PCI Bus
Adaptor PWB PL 1.3B Item 3 (255/265).
Replace the IPA PWB PL 1.3C Item 6. If the problem continues, replace the Card Cage
Riser PWB PL 1.4C Item 4 (460/470).
Enter [Self Tests tab , Video Path Diagnostics]. Select [IPA Daughter Card Test] [Start].
Y
N
Replace the IPA PWB PL 1.3B Item 4. If the problem continues, replace the PCI Bus
Adaptor PWB PL 1.3B Item 3 (255/265).
Replace the IPA PWB PL 1.3C Item 6. If the problem continues, replace the Card Cage
Riser PWB PL 1.4C Item 4 (460/470).
Go to the 16-C, ESS Software Verification RAP.
16-785.19, 16-786.19
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16-787.19 Memory Error for LAN FAX RAP
Fault code, 16-781.19, indicates there is not enough ESS DRAM available to support LAN
FAX.
16-787.19 On-Site Diagnostic Procedure (255/265)

Y
N
should be 4 SIMMs installed. A pair of 16MB SIMMS, and a pair of 32MB SIMMs, or two
pair of 32MB SIMMs.
Y
N
Determine if memory had been previously present and is now missing. Install additional ESS DRAM to equal 96MB of total ESS DRAM (PL 1.3B Item 4).
Switch off the machine power. Reseat each SIMM in its socket.
Y
N
Run the ESS Memory Test. Use GP35 , Running the ESS Memory Test.
Y
N
Switch off the machine power. Reseat each SIMM in its socket. Switch on the machine power.
Y
N
N
should be 2 DIMMs installed. A 64MB DIMM, and a 32MB DIMM, or two pair of 64MB
DIMMs.
Y
N
Determine if memory had been previously present and is now missing. Install additional ESS DRAM to equal 96MB of total ESS DRAM (PL 1.3C Item 13).
Switch off the machine power. Reseat each DIMM in its socket.
Y
N
Y
N
Replace the indicated ESS DRAM DIMMs PL 1.3C Item 2.
Switch off the machine power. Reseat each DIMM in its socket. Switch on the machine power.
Y
N
Y
N
Replace the indicated ESS DRAM DIMMs PL 1.3C Item 2.
Y
N
16-787.19 On-Site Diagnostic Procedure (460/470)

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16-787.19
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18-A Network Printing Problems Entry RAP
This procedure is provided to help identify and diagnose network printing problems.
Initial Actions
Ensure that the ESS is Online (UI Tools or PWS [ESS/Network tab , ESS Online/Offline])
It is assumed that before this procedure was entered, that the System Fault Analysis RAP
in Service Call Procedures was performed and that the IOT is OK.
Ensure that there are no IOT faults exist that prevent the IOT from functioning. That is,
copies can be made on ST machines, or prints can be printed with Print Test Pattern on
the PWS or made from the UI in the Tools area.
Verify that the problem is corrected. If the problem continues, return to the start of
this procedure.
Verify that the problem is corrected. If the problem continues, return to the start of this procedure.
Determine the following:
Are any jobs printing on the printer?
Is the problem related to one workstation?
Is the problem related to one job?
Have any changes been made to the network just prior to a printing problem?
If there are multiple protocols enabled on the printer, and the problems are ONLY occurring
with one network protocol, go to the procedure appropriate for the protocol that has a printing
problem:
NOVELL: 18-B, Novell Netware Checkout RAP
TCP/IP: 18-C, TCP/IP Checkout RAP
APPLETALK: 18-D, AppleTalk Checkout RAP
BANYAN VINES: 18-F, Banyan Vines Checkout RAP
NETBIOS: 18-E, NetBios Checkout RAP
18-A On-Site Diagnostic Procedure (240/255/265)

Access the network connection to the printer.
Check that the printer is physically connected to the network cable and that the cable/connections are OK. Disconnect and reseat the cable at both ends. Check to see if the problem is corrected. The problem continues.
Y
N
Print out a Configuration Report. Enter [ESS/Network tab , ESS Test Jobs]. Select [Power On/
Review the TCP/IP, AppleTalk, Netware, Banyan Vines, and NetBIOS settings. At least one
networking protocol is enabled.
Y
N
The printer is not installed properly. Inform the customer/system administrator that the
printer needs to be installed and setup for the appropriate networking protocol.
Enter [ESS/Network tab , Echo Test].
Check for a selectable protocol. (Not grayed out) There is at least one selectable protocol.
Y
N
Switch off the machine power to reboot the ESS. When machine is ready, enter [ESS/
Network tab , Echo Test] again.
A
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N
Have the system administrator reinstall the printer on the network. When complete,
enter [ESS/Network tab , Echo Test].
Check for a selectable protocol. (Not grayed out) There is at least one selectable
protocol.
Y
N
In [ESS/Network tab , Echo Test], select the desired protocol and run the test.
Y
N
Switch the machine power off/on to reboot the ESS. In [ESS/Network tab , Echo Test],
select the desired protocol and run the test.
Y
N
See if another protocol is enabled.
In [ESS/Network tab , Echo Test], there are other protocols that are selectable.
There is another network protocol selectable.
Y
N
Check if 100Mb Ethernet is enabled. The machine has a 100Mb Ethernet
PWB and has 100 Mb Ethernet Enabled.
Y
N
Check if Token Ring is enabled. The machine has a Token Ring PWB
and has Token Ring Enabled.
Y
N
Use watch-net (GP24 ) to monitor network traffic. At the ok prompt,
type watch-net.
Observe the display for a series of. . . . . . . . . . . . . to be displayed. (A
series of x x x x x x indicates bad packets, nothing at all indicates
watchnet failed to detect network traffic. Watch-net detected network packets.
Y
N
Use test net (GP24 ) to check the ESS. At the ok prompt, type
test net.
Check for an ok prompt to return with no errors. The test net
passed (ok prompt returned with no errors).
Y
N
This problem is occurring on a TCP/IP Network.
Y
N
Check the network drop cable. Repair/replace as necessary. If OK, there may a a network problem. Notify the system administrator.
B
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H
18-A
H
Check the network drop cable. Repair/replace as necessary. If
the problem continues, go to the 18-C, TCP/IP Checkout RAP.
Go to the appropriate RAP for the Network protocol which is not functioning properly:
NOVELL: 18-B, Novell Netware Checkout RAP.
TCP/IP: 18-C, TCP/IP Checkout RAP.
APPLETALK: 18-D, AppleTalk Checkout RAP.
L
BANYAN VINES: 18-F, Banyan Vines Checkout RAP.
NETBIOS: 18-E, NetBios Checkout RAP.
(L17.X Software) Perform the following:
Check the network drop cable. Repair/replace as necessary.
Go to the 16-C, ESS Software Verification and Repair RAP.
If the problem continues, replace the Token Ring PWB PL 1.3B Item
5.
(L17.X Software) Perform the following:
Check the network drop cable. Repair/replace as necessary.
If the problem continues, replace the Token Ring PWB PL 1.3B Item
5.
(L18 or later software) Go to the Token Ring Checkout Procedure.

Go to the 100Mb Ethernet Checkout Procedure (255/265).
(L18.X or later) Go to the Token Ring Checkout Procedure.

Go to the appropriate RAP for the Network protocol type that failed the Echo Test.
Go to the 100Mb Ethernet Checkout Procedure (255/265).
In [ESS/Network tab , Echo Test], select the second protocol, then [Start].
Y
N
Check if 100Mb Ethernet is enabled. The machine has a 100Mb Ethernet
PWB and has 100 Mb Ethernet Enabled.
Y
N
Check if Token Ring is enabled. The machine has a Token Ring PWB
and has Token Ring Enabled.
Y
N
Use watch-net (GP24 ) to monitor network traffic. At the ok prompt,
type watch-net.
Observe the display for a series of. . . . . . . . . . . . . to be displayed. (A
series of x x x x x x indicates bad packets, nothing at all indicates
watchnet failed to detect network traffic. Watch-net detected network packets.
Y
N
Use test net (GP24 ) to check the ESS. At the ok prompt, type
test net.
Check for an ok prompt to return with no errors. The test net
passed (ok prompt returned with no errors).
Y
N
This problem is occurring on a TCP/IP Network.
Y
N
Check the network drop cable. If OK, there may a a network problem. Notify the system administrator.
the problem continues, go to the 18-C, TCP/IP Checkout RAP.
B
C
I
J
K
L
18-A
18-B, Novell Netware Checkout
18-C, TCP/IP Checkout RAP
18-D, AppleTalk Checkout RAP
18-E, NetBios Checkout RAP
18-F, Banyan Vines Checkout RAP
Verify that the problem is corrected. If the problem continues, go to the 16-C, ESS Software Verification and Repair RAP.
Select the most appropriate from the following:
Jobs Won't Print, Can't See Printer, Can't Connect to Printer

For Novell, go to 18-B, Novell NetWare Checkout RAP
For TCP/IP, go to 18-C, TCP/IP Network Checkout RAP
For Appletalk, go to 18-D, AppleTalk Network Checkout RAP
For NETBIOS, go to 18-E, NetBios Network Checkout RAP
For Banyan Vines, go to 18-F, Banyan Vines Network Checkout RAP
A particular Job Won't Print - go to 18-G, Problem Printing Job RAP
Instead of job printing normally, there is a literal printing of the PDL (many pages of cryptic
code) - go to the 18-K, Job Prints Incorrectly RAP
Job prints, but looks wrong. Wrong fonts, missing fonts, other image quality problems - go
to the 18-K Job Prints Incorrectly RAP
18-A On-Site Diagnostic Procedure (460/470)

Access the network connection to the printer.
Check that the printer is physically connected to the network cable and that the cable/connections are OK. Disconnect and reseat the cable at both ends. Check to see if the problem is corrected. The problem continues.
Y
N
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Review the TCP/IP, AppleTalk, Netware, Banyan Vines, and NetBIOS settings. At least one
networking protocol is enabled.
Y
N
The printer is not installed properly. Inform the customer/system administrator that the
printer needs to be installed and setup for the appropriate networking protocol.
R
Y
The ethernet speed may be set incorrectly. Check the setting in

Network Tools for Ethernet Physical Media. Should be set to
Auto, or the correct speed for the network. If set to auto, try
manually selecting the proper speed (10Mbs or 100Mbs).

Y
N
Y
N
Check for a selectable protocol. (Not grayed out) There is at least one selectable
protocol.
Y
N
The network is Novell.

Y
N
In [ESS/Network tab , Echo Test], select [Internal TCP/IP]
[Start].
Y
N
Enter [ESS/Network tab , ESS Software Verification Tool].
Select [Start Test].
A message is displayed that the routine can't be run or
the routine stops before it is complete.
Y
N
A message is displayed on the PWS indicating
that ESS Software must be reloaded.
Y
N
A message was displayed indicating that a
repair was made.
Y
N
No problem was detected with the ESS
Software. Reload ESS Software.
this procedure.
In [ESS/Network tab , Echo Test], select the desired protocol and run the test.
Y
N
Switch the machine power off/on to reboot the ESS. In [ESS/Network tab , Echo Test],
select the desired protocol and run the test.
Y
N
See if another protocol is enabled.
In [ESS/Network tab , Echo Test], there are other protocols that are selectable.
There is another network protocol selectable.
Y
N
Check if Token Ring is enabled. The machine has a Token Ring PWB and
has Token Ring Enabled.
Y
N
Observe the Link Lights on the ethernet connector on the card cage.
Done. The ESS Software Verification Tool has

repaired/replaced the corrupt file(s). Verify that
the problem is corrected and return to Service
Call Procedures.
the problem continues, inform the customer of possible port or
hub problem.
NOTE: The color of the link light indicates what the speed of the network
is. Amber indicates 10Mbs and green indicates 100Mbs.
The link light is flashing indicating network activity.
Y
N
This problem is occurring on a TCP/IP or Novell Network.
N
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N
The link light is on steady.
Y
N
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In [ESS/Network tab , Echo Test], select [PCI Ethernet] [Start].

The test passes.
Y
N
A message is displayed that the routine can't be run or the
routine stops before it is complete.
S
18-A
N
Y
N
A message is displayed on the PWS indicating that
ESS Software must be reloaded.
Y
N
A message was displayed indicating that a repair
was made.
Y
N
The ethernet speed may be set incorrectly. Check the setting in

Network Tools for Ethernet Physical Media. Should be set to
Auto, or the correct speed for the network. If set to auto, try
manually selecting the proper speed (10Mbs or 100Mbs).

repaired/replaced the corrupt file(s). Verify that the
problem is corrected and return to Service Call Procedures.
The network is Novell.

Y
N
In [ESS/Network tab , Echo Test], select [Internal TCP/IP]
[Start].
Y
N
A message is displayed that the routine can't be run or
the routine stops before it is complete.
Y
N
A message is displayed on the PWS indicating
that ESS Software must be reloaded.
Y
N
A message was displayed indicating that a
repair was made.
Y
N
No problem was detected with the ESS
Software. Reload ESS Software.

Check the network drop cable. Repair/replace as necessary. If the
problem continues, inform the customer of possible port or hub problem.

repaired/replaced the corrupt file(s). Verify that
the problem is corrected and return to Service
Call Procedures.
Go to the Token Ring Checkout Procedure.

In [ESS/Network tab , Echo Test], select the second protocol, then [Start].
Y
N
Check if Token Ring is enabled. The machine has a Token Ring PWB and
has Token Ring Enabled.
Y
N
Observe the Link Lights on the ethernet connector on the card cage.

the problem continues, inform the customer of possible network
problem.
NOTE: The color of the link light indicates what the speed of the network
is. Amber indicates 10Mbs and green indicates 100Mbs.

The test passes.
Y
N
A message is displayed that the routine can't be run or the
routine stops before it is complete.
The link light is flashing indicating network activity.

Y
N
This problem is occurring on a TCP/IP or Novell Network.
Y
N
The link light is on steady.
N
O T
U
V
W
18-A
N
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X
V0.042
X
Y
N
A message is displayed on the PWS indicating that
ESS Software must be reloaded.
Y
N
A message was displayed indicating that a repair
was made.
Y
N
repaired/replaced the corrupt file(s). Verify that the
problem is corrected and return to Service Call Procedures.

Check the network drop cable. Repair/replace as necessary. If the
problem continues, inform the customer of possible port or hub problem.
For Banyan Vines, go to 18-F, Banyan Vines Network Checkout RAP
A particular Job Won't Print - go to 18-G, Problem Printing Job RAP
Instead of job printing normally, there is a literal printing of the PDL (many pages of cryptic
code) - go to the 18-K, Job Prints Incorrectly RAP
Job prints, but looks wrong. Wrong fonts, missing fonts, other image quality problems - go
to the 18-K Job Prints Incorrectly RAP
Token Ring Checkout Procedure

(This procedure only for L18 or later software)
Inspect the pigtail cable that connects the network drop cable to the ESS.
Ensure that it is not damaged. Reseat the cable at both ends. Repair/replace as necessary
(plx.x). The problem continues.
Y
N
Observe the PWS screen. Check for a message cannot open TR driver.
Y
N
In [ESS/Network tab , Echo Test], select [Token Ring] [Start].
The test passes.
Y
N
Have the customer replace the network drop cable. Switch off the machine power to
reboot the ESS.
In [ESS/Network tab , Echo Test], select [Token Ring] [Start]. The test passes.
Y
N
Go to the 16-C, ESS Software Verification RAP. If no problems are found and
the problem continues replace the Token Ring PWB PL 1.3B Item 5.
Have the customer move the printer to a different MSAU port. Switch off the machine
power to reboot the ESS.
Y
N
Done. Return to Service Call Procedures. Ensure the customer / system administrator is aware of a possible problem with the original MSAU port.
(L18.X or later) Go to the Token Ring Checkout Procedure.

Go to the appropriate RAP for the Network protocol type that failed the Echo Test.
18-B, Novell Netware Checkout
18-C, TCP/IP Checkout RAP
18-D, AppleTalk Checkout RAP
18-E, NetBios Checkout RAP
18-F, Banyan Vines Checkout RAP
Replace the Token Ring PWB PL 1.3B Item 5.
Verify that the problem is corrected. If the problem continues, go to the 16-C, ESS Software Verification and Repair RAP.
Select the most appropriate from the following:
Jobs Won't Print, Can't See Printer, Can't Connect to Printer

For Novell, go to 18-B, Novell NetWare Checkout RAP
For TCP/IP, go to 18-C, TCP/IP Network Checkout RAP
Go to the 16-C, ESS Software Verification RAP. If no problems are found and the problem continues replace the Token Ring PWB PL 1.3B Item 5.
100Mb Ethernet Checkout Procedure (255/265)

(This procedure only for L18 or later software)
Inspect the 100Mb Ethernet Adaptor Cable that connects the network drop cable to the ESS.
Ensure that it is not damaged. Reseat the cable at both ends. Repair/replace the 100Mb Ethernet Adaptor Cable as necessary PL 1.3B Item 9. The problem continues.
Y
N
For Appletalk, go to 18-D, AppleTalk Network Checkout RAP

For NETBIOS, go to 18-E, NetBios Network Checkout RAP
Y
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18-A
Y
Observe the PWS screen. Check for a message cannot open Fast Ethernet driver.
Y
N
The test passes.
Y
N
Have the customer replace the network drop cable. Switch off the machine power to
reboot the ESS.
In [ESS/Network tab , Echo Test], select [[PCI Ethernet] [Start]. The test passes.
Y
N
Go to the 16-C, ESS Software Verification RAP. If no problems are found and
the problem continues replace the 100Mb Ethernet PWB PL 1.3B Item 6.
Have the customer move the printer to a different MSAU port. Switch off the machine
power to reboot the ESS.
Y
N
Done. Return to Service Call Procedures. Ensure the customer / system administrator is aware of a possible problem with the original MSAU port.
Replace the 100Mb Ethernet PWB PL 1.3B Item 6.
Go to the 16-C, ESS Software Verification RAP. If no problems are found and the problem continues replace the 100Mb Ethernet PWB PL 1.3B Item 6.
18-B Novell NetWare Checkout RAP

Use this RAP if the printer is enabled for Novell Netware protocol, but there are problems printing to it.
It is assumed that before entering here that the IOT is known to be OK.
If not already done, perform 18-A, Network Entry RAP before using this RAP.
Initial Actions
Question the Systems Administrator and determine if any changes have been made to
the machine Network Setup or the network.

Determine if problem is occurring on multiple workstations. Only one workstation is unable
to print.
Y
N
Have the customer or system administrator run pconsole.
Check [Print Queue] [Attached Print Servers]. The print server is attached to the
queue.
Y
N
Check [Print Queue] [Status].
Ensure the flag that indicates that new print servers can attach to queue is set to
Yes. The flag is set to Yes.
Y
N
Have the customer or system administrator set the flag to Yes.
There may be a problem with the Network and Connectivity Setup on the printer. If a
configuration report has not already been run, enter [ESS/Network tab , ESS Test
Jobs]. Select [Power On/Demo] (default) [Start Job]. Consult with the system administrator and ensure that the following Netware settings are correct on the printer:
Physical Media is correct (Ethernet or Token Ring)
IPX Frame Type is correct (Ethernet Only)
Primary Server name is correct (Bindery Only)
NDS Tree and Context is correct (NetWare 4.X NDS Only)
Print Server name is correct
A Print Server password is set and the same as the password set for the print
server object on the NDS tree
All settings are OK.

Y
N
On the machine UI, in the Tools area, select [ESS Offline]. Select Connectivity
and Network Setup. Make changes as appropriate.
Switch the machine power off/on to reboot the ESS. Check for a reoccurrence
of the problem. The problem continues.
Y
N
A
18-A, 18-B
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In pconsole, check [Print Queue] [Print Queue Information] [Status]. Ensure that
the following two flags are set to YES.
Print servers can service jobs in the queue
ESS Serial Port
Users can add jobs to the queue.

NOTE: Must have administrator or Print Queue Operator rights to change these.
Notify customer/system administrator. Check for problems with the client workstation
ESS Parallel
Port
The problem occurs only on one job.

Y
N
Check the workstation configuration.
Reload the print driver on the affected workstation. Ensure that the problem is corrected.
Network Port
Token Ring
ESS LEDs
Figure 1 Port Locations
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18-B
18-C TCP/IP Checkout RAP
E
Y
Use this RAP if the printer is enabled for TCP/IP protocol, but there are problems printing to it.
Initial Actions
Ensure that the printer is properly configured for the TCP/IP Network. Verify with the system administrator that the following printer settings are correct:
N
made.
Y
N
Reload ESS Software. Reinstall the printer to the network
and see if the problem is resolved.
replaced the corrupt file(s). Verify that the problem is corrected
Printer IP address
Subnet mask
Broadcast Address
Default Gateway
For Solaris 2.5, the key operator or system administrator must have root privilege to install
the printer
For SunOS, have the system administrator ensure that the /etc/printcap file is properly
configured
Verify that the problem is corrected. If the problem continues, return to the start
of this procedure.
this procedure.

to print (answer No if unsure).
Y
N
Print out a Configuration Report. Enter [ESS/Network tab , ESS Test Jobs]. Select
[Power On/Demo] (default) [Start Job].
Review the TCP/IP settings. TCP/IP is enabled.
Y
N
The printer is not installed for TCP/IP. Inform the customer/system administrator that
the printer needs to be installed and setup for TCP/IP.
Check if TCP/IP (Unix) is selectable. TCP/IP (Unix) is selectable (not grayed out).
Y
N
Switch off the machine power to reboot the ESS. When machine is ready, enter
[ESS/Network tab , Echo Test] again.
Check if TCP/IP (Unix) is selectable. TCP/IP (Unix) is selectable (not grayed
out).
Y
N
Have the system administrator reinstall the printer on the network. When complete, enter [ESS/Network tab , Echo Test].
Check if TCP/IP (Unix) is selectable. TCP/IP (Unix) is selectable (not grayed
out).
Y
N
Enter [ESS/Network tab , ESS Software Verification Tool]. Select [Start
Test].
A message is displayed that the routine can't be run or the routine
Y
N
A message is displayed on the PWS indicating that ESS Software must be reloaded.
A
B
C
D
E
18-C
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In [ESS/Network tab , Echo Test], select [TCP/IP (Unix)] [Start].

Y
N
This next procedure has two different methods depending on what level software is
in the machine. Choose the correct one based on the current machine software
level:
(L17.X Software) - To complete this next test you must call Field Engineering or
National Technical Specialist to obtain a password. Connect the PWS to the ESS
serial port. (See GP22 ). Switch the machine power off/on to reboot the ESS. When
COPIER
PLATFORM
'AVAILABLE'
the message **********DIGITAL
********** is displayed, press the Enter key on the PWS. At the prompt User
name:, type root and press the enter key. At the Password:, type the password
obtained from Field Engineering and press the enter key. At the prompt, type ping
localhost
(L18.x Software) - In Echo Test, select [Internal TCP/IP] [Start].
Y
N
A message is displayed that the routine can't be run or the routine stops
before it is complete.
Y
N
A message is displayed on the PWS indicating that ESS Software
must be reloaded.
Y
N
Y
N
Reload ESS Software. Reinstall the printer to the network and
see if the problem is resolved. If the problem has not been corrected, continue here.
Check the type of network physical media. The printer uses
Token Ring as the physical media.
F
G H
I
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A
Y
N
Replace the Token Ring PWB PL 1.3B Item 5.

Done. The ESS Software Verification Tool has repaired/replaced the
corrupt file(s). Verify that the problem is corrected and return to Service Call Procedures.
The machine is a 460/470.
Y
N
Use watch-net (GP24 ) to monitor network traffic. At the ok prompt, type
watch-net.
Observe the display for a series of. . . . . . . . . . . . . to be displayed. (A series of
x x x x x x indicates bad packets, nothing at all indicates watchnet failed to
detect network traffic. Watch-net detected network packets.
Y
N
Use test net (GP24 ) to check the ESS. At the ok prompt, type test
net.
Check for an ok prompt to return with no errors. The test net passed (ok
prompt returned with no errors).
Y
N
Check the network drop cable. If OK, there may a a network problem.
Notify the system administrator.
There may be a problem with the network port. Ask the system administrator to test the port.
If the problem continues, have the customer/SA replace the network drop
cable
If the problem continues and the machine has a Token Ring PWB which is
enable, replace the Token Ring PWB PL 1.3B Item 5.
If the problem continues and the machine has Ethernet enabled, replace
the ESS PWB PL 1.3A Item 1.
F
The printer needs to be reinstalled on the network. Have the system administrator reinstall the printer.
For Solaris 2.5, follow Unix procedures in the Systems Administrator Guide
For SunOS, ensure that the /etc/printcap file is properly configured (see Systems
Administrator Guide)
Ensure that all configurations and IP addresses are valid.

Y
N
Ping from the workstation to the IP address of the printer.
Observe results. The workstation can ping the printer successfully.
Y
N
Ping from the workstation to another IP address on the network.
Observe results. The workstation can ping other IP addresses on the network
successfully.
Y
N
There is a problem with the workstation.
Ensure that the Subnet Mask, IP address, broadcast address and Default Gateway
are set properly at the printer.
Have the system administrator check the workstation configuration. Ensure that the workstation is set-up properly to print to the printer according to the following:
For Solaris 2.5, follow Unix procedures in the Systems Administrator Guide
For SunOS, ensure that the /etc/printcap file is properly configured (see Systems
Administrator Guide)
The same job prints OK on another workstation.

Y
N
Have the customer/system administrator reload the print driver on the affected workstation. If the problem continues, escalate the call to the Customer Service Center (CSC).
There is an application problem. Have the customer contact the Customer Service Center.
There may be a problem with the network port. Ask the system administrator
to test the port.
If the problem continues, have the customer/SA replace the network drop cable
enable, replace the Token Ring PWB PL 1.3C .
If the problem continues and the machine has Ethernet enabled, replace the
ESS PWB PL 1.3C.
A
F
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18-C
18-D Appletalk Checkout RAP

Initial Actions

AppleTalk is enabled.
Y
N
The printer is not installed for AppleTalk. Inform the customer/system administrator that
the printer needs to be installed and setup for AppleTalk.
Check if AppleTalk is selectable. AppleTalk is selectable (not grayed out).
Y
N
Y
N
Y
N
A message is displayed that the routine can't be run or the routine stops
before it is complete.
Y
N
A message is displayed on the PWS indicating that ESS Software
must be reloaded.
Y
N
Y
N
Reload ESS Software. Reinstall the printer to the network and
see if the problem is resolved.
A
In [ESS/Network tab , Echo Test], select [AppleTalk] [Start].
Y
N
Use watch-net (GP24 ) to monitor network traffic. At the ok prompt, type watch-net.
Observe the display for a series of. . . . . . . . . . . . . to be displayed. (A series of x x x x x x
indicates bad packets, nothing at all indicates watchnet failed to detect network traffic.
Watch-net detected network packets.
Y
N
Use test net (GP24 ) to check the ESS. At the ok prompt, type test net.
Check for an ok prompt to return with no errors. The test net passed (ok prompt
returned with no errors).
Y
N
Check the network drop cable. If OK, there may a a network problem. Notify the system administrator.
There may be a problem with the network port. Ask the system administrator to test
the port.
If the problem continues and the machine has a Token Ring PWB which is enabled,
replace the Token Ring PWB PL 1.3B Item 5.
If the problem continues and the machine has Ethernet enabled, replace the ESS
PWB PL 1.3A Item 1.
If the problem continues and the machine has a 100MB Ethernet PWB which is
enabled, replace the 100MB Ethernet PWB PL 1.3B Item 6.
Recheck the AppleTalk configuration settings.

Check the AppleTalk configuration settings:
The Printer name is correct
Zone name is correct
The proper printer drivers are installed on the clients and that the printer is visible and
selected in the Chooser.
Done. The ESS Software Verification Tool has repaired/replaced the

corrupt file(s). Verify that the problem is corrected and return to Service Call Procedures.
this procedure.
A
18-D
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18-E NETBIOS Checkout RAP

Use this RAP if the printer is enabled for NETBIOS protocol, but there are problems printing to
it.
G
replaced the corrupt file(s). Verify that the problem is corrected
Initial Actions
If running NETBIOS over an IP network, ensure that the printer is properly configured for
the TCP/IP Network. Verify with the system administrator that the following printer settings are correct:
Verify that the problem is corrected. If the problem continues, return to the start
of this procedure.
this procedure.
Host Name
In [ESS/Network tab , Echo Test], select [NetBIOS] [Start].

Y
N
Use watch-net (GP24 ) to monitor network traffic. At the ok prompt, type watchnet.
Observe the display for a series of. . . . . . . . . . . . . to be displayed. (A series of x x x
x x x indicates bad packets, nothing at all indicates watchnet failed to detect network
traffic. Watch-net detected network packets.
Y
N
Use test net (GP24 ) to check the ESS. At the ok prompt, type test net.
Check for an ok prompt to return with no errors. The test net passed (ok
prompt returned with no errors).
Y
N
Printer Name
Workgroup (domain)

NetBIOS is enabled.
Y
N
The printer is not installed for NetBIOS. Inform the customer/system administrator that the
printer needs to be installed and setup for NetBIOS.
Review the NetBIOS settings for Interface. The interface is IP/Ethernet or IP/Token Ring.
Y
N
Check if NetBIOS is selectable. NetBIOS is selectable (not grayed out).
Y
N
Switch off the machine power to reboot the ESS. When machine is ready, enter
[ESS/Network tab , Echo Test]again.
Y
N
Have the system administrator reinstall the printer on the network. When complete, enter [ESS/Network tab , Echo Test].
Y
N
Enter [ESS/Network tab , ESS Software Verification Tool]. Select [Start
Test].
A message is displayed that the routine can't be run or the routine
Y
N
A message is displayed on the PWS indicating that ESS Software must be reloaded.
Y
N
made.
Y
N
Reload ESS Software. Reinstall the printer to the network
and see if the problem is resolved.
A
B
V0.042
Check the network drop cable. If OK, there may a a network problem. Notify the
system administrator.
There may be a problem with the network port. Ask the system administrator
to test the port.
enable, replace the Token Ring PWB PL 1.3B Item 5.
If the problem continues and the machine has Ethernet enabled, replace the
Recheck the NetBIOS configuration settings.

Enter [ESS/Network tab , ESS Error Log]. Select [Errors and Warnings].
Check for any 16-800.46, 16-801.46, 16.802.46, or 16-803.46. Any of those faults are
occurring.
Y
N
Return to the top of this RAP and answer NO to statement that the interface is IP/Ethernet
or IP/Token Ring.
Go to the 18-C, TCP/IP RAP.
May 2003
2-669
18-E
18-F Banyan Vines Network Troubleshooting RAP

Use this RAP if the printer is enabled for Vines IP protocol, but there are problems printing to it.
Initial Actions
Ensure that the PCPRINT option is enabled on the Vines server.
If the problem is only occurring with one workstation (others are OK), ensure proper configuration and network connections at the workstation.
Talk to the Systems Administrator and determine if any changes have been made to the
machine Network and Connectivity Setups or the network itself.
A
Y
N
Check the workstation configuration and ensure that the Vines Print Service is associated
with the correct port on the workstation. Change to a different printer port.
In [ESS/Network tab , ESS Test Jobs], select [Test Pattern Job]. Choose the same PDL type
as the problem job is using, then [Start].
Check the output. The Test Pattern job prints OK.
Y
N
Perform the 16-C, ESS Software Verification RAP.
Have the customer/system administrator reload the print driver on the affected workstation.

to print.
Y
N
NOTE: This procedure may require a customer or system administrator to be at the
machine to inspect the network cable and/or switch the machine power off/on.
Have the customer or system administrator run muser.
Check that the printer is attached to the server. The printer is attached to the server.
Y
N
Refer to GP23 to access the alternate boot menu. Select option 2), Reset ESS
Configuration Files. When complete, select option b), Boot SCSI Disk. The machine
will have to be reinstalled on the network.
It is very critical in a Banyan environment set-up that the steps below are followed
properly for the printer to log on to the server:
The Print Service entered at the UI matches the Print Service created at the
workstation.
The Streetalk name entered on the UI matches the Streetalk name created at
the server (user account), and also matches the PCPrint Streetalk name.
The Streetalk password is case sensitive. It must be entered identically at the

UI and at the server.
Have the customer or systems administrator run setprint to check the jobs status and
jobs format.
Use the information below and perform the appropriate corrective actions based on the
state of job observed in setprint:
Rejected: The job is corrupted or an internal error occurred at the server. Cancel the
job and re-send.
On Hold: Release the job and ask the system administrator for assistance.
Paper format N.A.: Job format does not match the printer format. Change the job format.
Printer Busy: Ensure that the PC Print Street Talk name entered at the server
matches the user name on the UI. Also, ensure that the PC Print is the destination
configured for the Print Service at the server.
A
18-F
May 2003
2-670
V0.042
18-G Problem Printing Job RAP

Use when a particular job won't print. Other jobs print OK.

Check the output to see if a PDL error sheet was printed. An error sheet was printed.
Y
N
On the machine UI, select [Job Status] [Other Queues] [All Completed Jobs] [Save].
Check the completed job log. The job is in the log.
Y
N
Select [Other Queues] [All Incomplete Jobs] [Save].
Check the queue for the job in question. The job is stuck in the queue.
Y
N
Check for a fault listed against the job in question. There is a fault(s) listed
with the job.
Y
N
Go to the 16-A, ESS Fault Codes RAP.
Switch the machine power off/on to reboot the ESS.
The job printed OK.
Y
N
Delete the job from the queue.
Recreate and re-send the job. The job printed OK.
Y
N
If the problem continues, there may be a problem with the job. See if other
jobs print OK. If not, reload the printer driver on the workstation.
The job must have been printed. Check for the possibility that the job was removed from
the printer by another user.
There may be a problem with the job. See if other jobs print OK. If not, reload the printer driver
on the workstation. If the problem continues, have the customer call the Customer Support
Center.
V0.042
May 2003
2-671
18-G
18-H Network Hardware Problems RAP
open cable
Use this RAP to check for network hardware related problems. Procedure Use the following list
as a guide to possible causes of network related problems:
mis wired, pin-out problems

Short circuit to shielding
4.

1.
pinched kinked, cuts, abrasions
Connector Problems
Poorly installed on cable
If the network is completely new, ensure that the hardware installation conforms to the
network
bent broken pins or center conductors

unclean or corroded conductors
Maximum allowable length of cable
Loose connectors or loose conductors inside
transceiver tap problems

5.
improper grounding
maximum number of nodes
minimum cable length between nodes
2.
Cabling rule and specifications for that topology
If the network was working before, ask the question, "What has changed?" Even the most
subtle disturbance of the network hardware, like bumping cables, or moving transceivers,
can cause problems. Look also, for changes in configuration of hardware or software
such as:
Configuration changes on an existing server
Are the cable lengths correct and are they terminated properly?
3.
Added printers or queues
AUI/DIX/Drop Cable problems
Added servers
Cable Length
Added or removed routers, bridges, communications servers
+12 VDC across pins 6 and 13

Table 1 Cabling Specifications
Ethernet Version
2.0
10base 5
10base 2
10base-T
Token Ring
Cable type
Thick coaxial cable Thick coaxial cable Thin coaxial cable
Unshielded twisted Shielded twisted

pair
pair (STP)
Unshielded twisted
pair (UTP)
Cable Impedance
50 ohms (cable
ends are terminated)
50 ohms (cable
50 ohms (cable
75 - 100 ohms
Maximum cable
segment length
500 m (1640 ft.)
500 m (1640 ft.)
185 m (600 ft.)
100 m to hub
Maximum number
of coax segments
without link segments
N/A
N/A
Maximum number
of segments
including 2 link
segments
N/A
N/A
Maximum network 1500 m (4920 ft.)

span (not including drop cables)
2500 m (8200 ft.)
925 m (3000 ft.)
2500 m (8200 ft.)
Maximum number
of MAUs per segment
100
30
2.5 m (8 ft.)
0.6 m (1.5ft.)
100
Minimum distance 2.5 m (8 ft.)

between nodes
18-H
May 2003
2-672
150 ohms (STP)

100 ohms (UTP)
V0.042
Table 1 Cabling Specifications

Transceiver
external
external
internal or external
Connector type
BNC and T connectors
50 m (164 ft.)
50 m (164 ft.) if
external transceiver is used
Maximum trans50 m (164 ft.)

ceiver to node distance
V0.042
RJ-45 (8 pin connector) 1,4,5,6

straight through
May 2003
2-673
18-H
18-K Job Prints Incorrectly RAP
The job prints, but incorrectly.
N
Go to the 16-B ESS Boot RAP. If no problem is found, go to the 16-C ESS Software
Verification RAP.
Y
N
Discuss the problem with the customer and/or inspect the incorrect output.
There is a font problem.
Y
N
The problem is occurring on all jobs from all clients.
Y
N
Go to the 16-B ESS Boot RAP. If no problem is found, go to the 16-C ESS Software Verification RAP.
The problem is occurring on jobs from one particular client.

Y
N
The problem is related to a particular job. Have the Customer call the Customer
Support Center.
There may be a problem with the client workstation. Check/perform the following:
See if problem is related to a particular job. If so, go to 18-G, Problem Printing

Job RAP.
Ensure that the client meets minimum specifications for the CentreWare drivers.
Ensure the latest printer drivers are loaded on the client
Have the customer / system administrator reload the printer driver
Have the customer view the job in Print Preview of the application. The problem appears in
Print Preview.
Y
N
There may be a font substitution that is not acceptable to the customer. In the Printer
Setup for the print driver, if Always Send to Printer is selected, the actual fonts will be sent
to the printer from the workstation. This will slow down printer performance, but will usually solve the font problem.
There may be a problem with the client workstation. Check/perform the following:
See if problem is related to a particular job. If so, go to 18-G, Problem Printing Job RAP.
Ensure that the client meets minimum specifications for the CentreWare drivers.
Ensure the latest printer drivers are loaded on the client
Have the customer / system administrator reload the printer driver
The print drivers have already been replaced in an attempt to resolve this problem.
Y
N
Have the system administrator/customer replace the print drivers. Ensure that the
latest drivers available are loaded. The problem still continues.
Y
N
Done. Return to Call Flow.
Y
N
Go to the 16-B ESS Boot RAP. If no problem is found, go to the 16-C ESS Software Verification RAP.
Y
N
Go to the 16-B ESS Boot RAP. If no problem is found, go to the 16-C ESS Software
Verification RAP.
A
18-K
May 2003
2-674
V0.042
18-L Network Scanning/Fax Problems RAP
This RAP is intended to help troubleshoot Network Scanning and Fax problems where the
scanned image is either defective or corrupted (0 bytes) or cannot be found on the server.
Initial Actions
Ensure that the machine copies and prints normally. If problems exist, troubleshoot those
first.

Enter [Faults/Counters tab , Faults]. Select [Faults]. Check the Last 40 faults for any 16-781.19,
16-785.19, 16-786.19, 16-787.16, or 22-310.04.
There are 16-781.19, 16-785.19, 16-786.19, 16-787.19, or 22-310.04 faults in the log.
Y
N
Make a copy of the image that is not appearing properly when scanned to a file.
Check the copy for the defect. The copy is OK.
Y
N
The problem is not unique to network scanning. Return to Service Call Procedures
and troubleshoot the problem as a copying IQ problem.
Select [ESS / Atlanta Test] [Start].

The test indicated a problem with the ESS.
Y
N
The test indicated a problem with Atlanta. In [Self Tests tab , Video Path Diagnostics], select [EPC Memory Test] [Start]. This test will take approximately 20
minutes per 32 MB. In L18 software, the routine will estimate time to completion
and give status on the progress of the test. Replace the indicated EPC DRAM
SIMM PL 1.4A Item 6 (without TAG 077) or EPC DRAM DIMM PL 1.4B Item 5
(w/TAG 077).
Enter [ESS/Network tab , ESS Test Jobs]. Select [Test Pattern] [Start Job].
Check the test pattern job and see if it prints normally. The test pattern job is OK.
Y
N
The problem is not unique to Network Scanning. Enter [ESS/Network tab , ESS
Error Log]. Select [All] [Retrieve].
Y
N
Y
N
Replace the ESS DRAM SIMM indicated by the test results PL 1.3B Item 2.
In [Self Tests tab , Video Path Diagnostics], select [EPC Memory Test] [Start]. This
test will take approximately 20 minutes per 32 MB. In L18 software, the routine will
estimate time to completion and give status on the progress of the test.
Y
N
Replace the indicated EPC DRAM SIMM PL 1.4A Item 6 (without TAG 077) or
EPC DRAM DIMM PL 1.4B Item 5 (w/TAG 077).

On the machine UI, select the Network Scanning tab. Select the DEFAULT template (at
the top of the list). Scan a document.
When the scan is complete, check if a Confirmation Report prints. There is a Confirmation Report.
Y
N

Check the Job Status at the top of the page.
The Job Status is FAILED.
Y
N
The image file is corrupted or defective
Y
N
NOTE: Because the messages available on the UI are limited, troubleshooting may
be more difficult if the option to run a Confirmation Report is not enabled.
Select the Job Status button on the machine UI. Select [Other Queues] [Completed
Non-Printing Jobs]. Select the job at the top of the list and check the status.
The status of the job is completed.
Y
N
Go to the UI Status Table Table 1.
If the Scan job output using the default template is OK, there may be a
problem with a user template.
Enter [Self Tests tab , Video Path Diagnostics]. Select [IPA Daughter Card Test]
[Start].
The file image is corrupted or defective.
A
B
V0.042
If the Scan job output using the default template is OK, there may be a
problem with a user template.
Enter [Self Tests tab , Video Path Diagnostics]. Select [IPA Daughter Card Test]
[Start].
Y
N
Replace the indicated IPA PWB PL 1.3B Item 4. If the problem continues,
replace the PCI Bus Extender PWB PL 1.3B Item 3 or the Riser PWB PL 1.4C
Item 4
N
A
May 2003
2-675
C
18-L
C
Y
N
Replace the indicated IPA PWB PL 1.3B Item 4. If the problem continues,
replace the PCI Bus Extender PWB PL 1.3B Item 3 or the Riser PWB PL 1.4C
Item 4
Select [ESS / Atlanta Test] [Start].

The test indicated a problem with the ESS.
Y
N
The test indicated a problem with Atlanta. In [Self Tests tab , Video Path Diagnostics], select [EPC Memory Test] [Start]. This test will take approximately 20
minutes per 32 MB. In L18 software, the routine will estimate time to completion
and give status on the progress of the test. Replace the indicated EPC DRAM
SIMM PL 1.4A Item 6 (without TAG 077) or EPC DRAM DIMM PL 1.4B Item 5
(w/TAG 077).
Y
N
Replace the ESS DRAM SIMM indicated by the test results PL 1.3B Item 2.
In [Self Tests tab , Video Path Diagnostics], select [EPC Memory Test] [Start]. This
test will take approximately 20 minutes per 32 MB. In L18 software, the routine will
estimate time to completion and give status on the progress of the test.
Y
N
Replace the indicated EPC DRAM SIMM PL 1.4A Item 6 (without TAG 077) or
EPC DRAM DIMM PL 1.4B Item 5 (w/TAG 077).
Table 1 UI Job Status

Message
Action
Image formatting
error
Check and reseat

the IPA PWB. Go
to the 16-785.19
RAP
Table 2 Confirmation Report Status

Job Status
Details
Possible Cause
Action
Login failure
User rights, password incorrect
Check login name, passwords,

protocol enabled
Image Formatting
error
Hardware problem
Go to the 16-785.19 RAP
Job canceled by
user
User cancelled or deleted job

before it was completely transferred to the file server.
Possible user training problem.
Job canceled due

to system reset
Machine was reset before images Possible user training. Check for
being transferred to the network
machine problem.
was complete
Remote directory
lock failed
1.

2.
Check the Job Status Details, and go to the Confirmation Report Status Table 2.
16-781.19
16-785.19
16-786.19
16-787.19
If there is a 22-310.04, go to the 16-785.19 RAP

Filing directory
already exists
Table 1 UI Job Status
Message
Action
Login Error
Check login name,

passwords, protocol enabled
Resources unavail- Check the path to

able
the repository
18-L
Directory was locked by

another machine while this
machine was attempting to
lock the same directory
1.
Try again
2.
If there is a .lck directory,

have customer call the Customer Support Center
Existence of same directory

<foldername>.lck on the
remote server in same path
3.
Check repository path
4.
Check repository path
5.
Check if disk full.
3.
Specified filing Volume name

is invalid or incorrect (NetWare only)
4.
Specified filing destination

path is invalid or incorrect
5.
The destination disk is full
Have customer call the Customer

This occurs when the
NEW_EXACT filing policy is used Support Center
and the <foldername>.xsm directory already exists. Occurs when
using CentreWare templates and
choosing Do not save option
when the directory exists.
File delete, replace Overwrite filing policy is selected Check if filing attributes are read
failed
and attempt to remove the existing only or insufficient access rights
files failed.
May 2003
2-676
V0.042

Job Status
Details
Cannot append to
non-XSM format
Possible Cause
Action
User attempted to use multipage

tiff with filing policy of append,
which is not valid.
Change Filing policy
Login name not

specified
Job Status
Details
Possible Cause
Protocol invalid or
not specified
Job template was edited manually Change template

by user
Action
Need to specify login name
Protocol not running
Destination was NetWare server,

but NetWare not enabled
Enable NetWare
File transfer failed
Network problem or destination

disk full
Check network, destination disk
Maximum of 1000
document objects
with same root
name exceeded
The NEW_AUTO_GENERATE fil- Delete some files from the repository

ing policy can only hold 1000
names
Job canceled by
system
Problem with DADF document

size sensing. Possibly operator
induced
Check for machine faults. Ensure

operator doesnt disturb documents while they are being fed.
Miscellaneous filing error
Job template or other file is corrupted
Check if default template is OK
Job canceled due

to lack of
resources
Hard drive errors or out of memory

on the ESS
Scan attribute
missing from job
template
Using something other than CentreWare or CentreWare Internet

Services template
Change template
Scan attribute error Using something other than Cenin job template
treWare or CentreWare Internet
Services template
Change template
Scan image trans- Too many ESS features enabled

fer failure
If Network Scanning, LAN FAX,

and Job Based Accounting are
enabled, remove unused network
protocols
Document attribute Using something other than Cenmissing from job

treWare or CentreWare Internet
template
Services template
Change template
Document attribute Using something other than Cenerror in job temtreWare or CentreWare Internet
plate
Services template
Change template
Image formatting
error
Hardware problem
Go to the 16-785.19 RAP
Filing attribute
missing from job
template

Services template
Change template
Filing attribute
error in job template

Services template
Change template
V0.042
May 2003
2-677
18-L
18-L
May 2003
2-678
V0.042
19-300 Image Disk Read Failure RAP

Fault Code, 19-300, occurs when the system is unable to read data from the Image Disk.
Initial Actions
Replace the Image Disk Cable PL 1.3A Item 6 and Card Cage Harness PL 1.3A Item
5.
See if the problem has been corrected. The problem continues.
Y
N
NOTE: Some machines may have the Image Disk located in a Removable Disk Drive. These
are machines that have special security requirements. The Image Disk Drive (and ESS Disk
Drive if an ST machine) is located in a Disk Carrier which is external to the machine. The
Drive(s) can be removed and secured when the machine is not in use. The Disk Carrier is connected by cable to the Machine. Some steps in the RAP are different if the machine has this
option.
Replace the Image Disk Drive PL 1.3A Item 3.

If the problem continues, go to the 03-G, Main Control PWB Replacement RAP.
available).
Ensure the disk carrier is inserted correctly in to the drive enclosure.
If the machine is a ST model, ensure that an Image Disk is inserted into position #2 in the
Drive Enclosure.
C
Measure the voltage between +12V (+) (Venray LVPS) or +12V (Zydek LVPS) and
the LVPS. GND. +12 VDC is measured.
Y
N
Observe the LEDs on the front of the Drive Enclosure. The green LED on the front of
the Drive Enclosure is ON.
Y
N
Ensure the Removable Drive Module is switched on and plugged into the wall outlet,
with correct voltage available. If the wall outlet is OK, replace the Drive Enclosure.
Check the Removable Drive SCSI Cable at the back of the Removable Drive and at the
Main Control PWB for good connections. The connections look OK.
Y
N
Repair or replace the Removable Drive Cable as necessary PL 1.1B Item 7.
Swap the two SCSI cables. Use the ESS cable for the Image Disk and the Image Disk
cable for the ESS (if an ST machine). The ends will have to be reversed to enable the
connectors to mate. If the machine is a DC machine and only has 1 removable drive,
there should be a spare cable available (the kit comes with two).
Y
N
Replace the Removable Drive Cable PL 1.1B Item 7 (if swapped to the ESS Removable Drive, replace that one).
The problem began immediately after replacing either the Image Disk or the ESS Hard
Disk Drive.
Y
N
Y
N
Ensure that all Image Disk Drive cables are connected correctly Flag 1 Flag 2 Flag 3
Flag 4 (without TAG 044) or Flag 1 Flag 5 Flag 6 Flag 4 (with TAG 044).
Check the Image Disk Drive cable connections. The connections are OK.
Y
N
Repair as necessary. Image Disk Drive PL 1.3A Item 3, Image Disk Cable PL
1.3A Item 6, Card Cage Harness PL 1.3A Item 5.
Ask the customer about the availability of a second removable Image Disk Drive.
There is another Image Disk available.
Y
N
NOTE: The format routine may correct the problem. However, once the test is
started, it cannot be stopped. The machine will not be available for use during the
test. It will take up to 20 minutes to reformat each 1 GB of disk space.
NOTE: If the disk was already reformatted during a remote session, answer Yes to
this and continue without running format.
In Diagnostic Navigator, select [Copier Sys tab , Image Disk Format]. Select Image
Disk Format tab. Select Start.
When the test completes, use [Marking tab , Print Test Pattern] and run some prints
to see if the problem is resolved. The 19-300 faults continue.
Y
N
Y
N

A
B
V0.042
A
May 2003
2-679
D
19-300
D
The problem occurs with a second removable Image Disk.
Y
N
Y
N
Replace the original Image Disk Drive PL 1.3A Item 3.
Replace the Removable Disk Drive Assembly PL 1.1B Item 1.

If the problem began after replacing the Image Disk or ESS Hard Disk, the correct procedures
may not have been performed.
The machine should have L0.17.5.08 (V5.03) or later software
If the Image Disk has a part number 121E16740 or higher, ensure the jumper is installed
as shown in Figure 6.
If the machine has TAG 091, ensure the ESS Hard Disk Drive does NOT have a jumper
Refer to Kit instructions for 600K88170 or the ESS Hard Disk Drive Replacement, REP
16-1, or Image DIsk Replacement, REP 19-1.
19-300
May 2003
2-680
V0.042
V0.042
May 2003
2-681
19-300
36V
+36V
+24V
24V
-12V
24 PSV
+24 VES
INT-OUT
Interlock Outp
Interlock Inpu
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
+12V
5.15V
+12V
-12V
+12 VES
5.15 PSV
Figure 2 . Venray LVPS (With Tag 011)
19-300
Figure 3 . Zytec LVPS (Without Tag 011)
May 2003
2-682
V0.042
Removable Disk Drive

Assembly
LEDs
Figure 4 Removable Disk Drive Assembly

Figure 6 Jumper Positions
Disk Carrier
Figure 5 Disk Carrier

V0.042
May 2003
2-683
19-300
19-301 Image Disk Write Failure RAP

Fault Code, 19-301, occurs when the system is unable to write data to the Image Disk.
Initial Actions
5.
Y
N
option.

available).
Ensure the disk carrier is inserted correctly in to the drive enclosure
Drive Enclosure.
C
Measure the voltage between +12V (+) (without IOT TAG 011) or +12V (with IOT
TAG 011) and LVPS GND (-) on the LVPS. +12 VDC is measured.
Y
N
Y
N
Y
N
Y
N
Disk Drive.
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N

A
B
C
19-301
A
May 2003
2-684
D
V0.042
D
Y
N
Y
N

V0.042
May 2003
2-685
19-301
19-301
May 2003
2-686
V0.042
36V
+36V
+24V
24V
-12V
24 PSV
+24 VES
INT-OUT
Interlock Outp
Interlock Inpu
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
+12V
5.15V
+12V
-12V
+12 VES
5.15 PSV
V0.042
May 2003
2-687
19-301

Assembly
LEDs

Disk Carrier

19-301
May 2003
2-688
V0.042
19-302 Image Disk Data Error RAP

Fault Code, 19-302, occurs when the system detects incorrect data from the Image Disk.
Initial Actions
5.
Y
N
option.

available).
Drive Enclosure.
C
Measure the voltage between +12V (+) (without IOT TAG 011) or +12V (with IOT
TAG 011) and LVPS GND (-) on the LVPS. +12 VDC is measured.
Y
N
Y
N
Y
N
Y
N
Disk Drive.
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N

A
B
V0.042
A
May 2003
2-689
D
19-302
D
Y
N
Y
N

19-302
May 2003
2-690
V0.042
V0.042
May 2003
2-691
19-302
36V
+36V
+24V
24V
-12V
24 PSV
+24 VES
INT-OUT
Interlock Outp
Interlock Inpu
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
+12V
5.15V
+12V
-12V
+12 VES
5.15 PSV
19-302
May 2003
2-692
V0.042

Assembly
LEDs

Disk Carrier

V0.042
May 2003
2-693
19-302
19-303 Image Disk Format Failure RAP
Fault Code, 19-303, occurs when the Image Disk cannot be formatted.
Initial Actions
option.
available).
Drive Enclosure.

Y
N
Ensure that all Image Disk Drive cables are connected correctly Flag 1 Flag 2 Flag 3 Flag
4 (without TAG 044) or Flag 1 Flag 5 Flag 6 Flag 4 (with TAG 044).
Y
N
Repair as necessary. Image Disk Drive PL 1.3A Item 3, Image Disk Cable PL 1.3A
Item 6, Card Cage Harness PL 1.3A Item 5.
N
Y
N
Swap the two SCSI cables. Use the ESS cable for the Image Disk and the Image Disk cable for
the ESS (if an ST machine). The ends will have to be reversed to enable the connectors to
mate. If the machine is a DC machine and only has 1 removable drive, there should be a spare
cable available (the kit comes with two).
Y
N
Replace the Removable Drive Cable PL 1.1B Item 7 (if swapped to the ESS Removable
Drive, replace that one).
Y
N
Y
N
Measure the voltage between +12V (+) (without IOT TAG 011) or +12V (with IOT TAG
011) and LVPS GND (-) on the LVPS. +12 VDC is measured.
Y
N
Replace the Image Disk Cable PL 1.3A Item 6 and Card Cage Harness PL 1.3A Item 5.
Y
N
19-303
May 2003
2-694
V0.042
V0.042
May 2003
2-695
19-303
36V
+36V
+24V
24V
-12V
24 PSV
+24 VES
INT-OUT
Interlock Outp
Interlock Inpu
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
+12V
5.15V
+12V
-12V
+12 VES
5.15 PSV
19-303
May 2003
2-696
V0.042
19-310 Can't Determine Image Disk Capacity RAP

Assembly
Fault Code, 19-310, occurs when the Image Disk capacity cannot be determined at power up.
Initial Actions
option.
LEDs
available).
Drive Enclosure.

Disk Carrier

Y
N
Ensure that all Image Disk Drive cables are connected correctly Flag 1 Flag 2 Flag 3 Flag
4 (without TAG 044) or Flag 1 Flag 5 Flag 6 Flag 4 (with TAG 044).
Y
N
Repair as necessary. Image Disk Drive PL 1.3A Item 3, Image Disk Cable PL 1.3A
Item 6, Card Cage Harness PL 1.3A Item 5.
Measure the voltage between +12V (+) (without IOT TAG 011) or +12V (with IOT TAG
011) and LVPS GND (-) on the LVPS. +12 VDC is measured.
Y
N
Replace the Image Disk Cable PL 1.3A Item 6 and Card Cage Harness PL 1.3A Item 5.
Y
N
V0.042
May 2003
2-697
19-303, 19-310
N
Y
N
Swap the two SCSI cables. Use the ESS cable for the Image Disk and the Image Disk cable for
the ESS (if an ST machine). The ends will have to be reversed to enable the connectors to
mate. If the machine is a DC machine and only has 1 removable drive, there should be a spare
cable available (the kit comes with two).
Y
N
Replace the Removable Drive Cable PL 1.1B Item 7 (if swapped to the ESS Removable
Drive, replace that one).
Y
N
Y
N
19-310
May 2003
2-698
V0.042
V0.042
May 2003
2-699
19-310
36V
+36V
+24V
24V
-12V
24 PSV
+24 VES
INT-OUT
Interlock Outp
Interlock Inpu
RMT-OFF
ES#1
ES#2
INT-IN
+5 VES
+5V
+12V
5.15V
+12V
-12V
+12 VES
5.15 PSV
19-310
May 2003
2-700
V0.042

Assembly
Disk Carrier
LEDs
Table 1 65 PPM Approximate Automatic Electronic Collation Job/Memory Capacities (Build Job Mode**)
32 MB
64 MB
Doc Type
Complexity
8.5x11 (A4)
11x17 (A3)
Text
Low
OK*
OK*
OK*
OK*
Medium
OK*
OK*
OK*
OK*
High
OK*
OK*
OK*
OK*
Text and Graphics Low
OK*
OK*
OK*
OK*
Medium
OK*
OK*
OK*
OK*
High
OK*
OK*
OK*
OK*
Low
OK*
OK*
OK*
OK*
Medium
20
10
50
20
High
10
20
10
Graphics
8.5x11 (A4)
OK* = Limited only by DADF capacity or Image Disk capacity
11x17 (A3)
** = If printing is disabled by using build job mode or scanning with the Front Door open.
Table 2 65 PPM Approximate Automatic Electronic Collation Job/Memory Capacities (Normal Mode)
32 MB
Doc Type
Text
64 MB
Complexity
8.5x11 (A4)
11x17 (A3)
8.5x11 (A4)
11x17 (A3)
Low
OK*
OK*
OK*
OK*
Medium
OK*
OK*
OK*
OK*
High
OK*
OK*
OK*
OK*
V0.042
May 2003
2-701
19-310, 19-401/
Table 2 65 PPM Approximate Automatic Electronic Collation Job/Memory Capacities (Normal Mode)
32 MB
Doc Type
Complexity
8.5x11 (A4)
11x17 (A3)
8.5x11 (A4)
11x17 (A3)
OK*
OK*
OK*
OK*
Medium
OK*
OK*
OK*
OK*
High
20
10
50
20
Low
20
20
40
40
Medium
10
20
10
High
10
Text and Graphics Low
Graphics
19-401/
64 MB
May 2003
2-702
V0.042
19-404 Video Compressor DVMA Timeout

Fault Code, 19-404, indicates the system has detected at video compressor DVMA timeout.

Perform the following if 19-404 faults are occurring at a unreasonable rate:
1.
If the job has mixed size originals, ensure that Mixed Size originals is selected on the UI.
2.
There may be an Image Disk problem. Check for 19-3xx faults are occurring, go to that
RAP. 19-300 19-301 19-302 19-310
3.
If the machine has an Electronic Hole Removal PWB, switch off the machine power,
remove and reseat the PWB and see if the problem continues.
4.
This fault can be caused by DADF problems. Check the Last 40 ([Faults/Counters tab ,
Faults]) for any 05-XXX faults and fix them first.
5.
Ensure that TAG 026 and TAG 039 are installed.
6.
If this fault occurs in manual platen mode with a 22-300.05 or 22-700.05 fault, and a sheet
is printed that is scrogged, it may be related to certain combinations of image shift, edge
erase, and mag. The problem may be alleviated by changing edge erase back to default.
7.
If the fault occurs in DADF mode with a 22-300.05 or 22-700.05 fault, and a sheet is
printed that is scrogged, all black, or partially black, it may be an electrical noise problem.
a.
Ensure the Scanner Top Frame is grounded correctly. Check continuity from the
Scanner Top Frame to the machine frame. If there is a problem, check the Left front
mounting screw of the Scanner Base. Make sure it is present and the metal bracket
carries ground to the Scanner Top Frame. On some machines, other mounting
screws are also used for grounding. Check all four mounting screws. If a metal strip
or wire is connected under the screw, check continuity.
b.
Check ground wire for continuity to machine frame Figure 1
c.
d.
e.
Check the CVT Motor ground wire. One end of the ground wire should be secured
between the screw head and the motor bracket. The other end should be secured
between the screw head and the bearing retainer. (only on machines built before
Sept. 1998. Machines built after have a metal bracket in place of the ground wire.)
NOTE: Be sure the ground wire is connected to the correct screw on the DADF
base, to provide an electrical ground for the CVT Motor. The correct screw is the one
holding the metal bearing retainer, which has a metal ground strap underneath, NOT
the nearby screw which only contacts plastic parts.
f.
If the above do not help, check ground wire for continuity to machine frame (on
machines that had TAG 039 installed at the factory, there will be a braided wire running from the Scanner to the machine frame) Figure 3
Ground Wire
(violet wire)
Figure 1 Ground Wire
V0.042
May 2003
2-703
19-404
Ground Wire
(violet)
19-404
May 2003
2-704
V0.042
Ground Wire
(violet or metal
braid)
Figure 3 IOT Rear
V0.042
May 2003
2-705
19-404
Check Connections
19-405 Video Decompresser DVMA Timeout

Fault Code, 19-405, indicates the system has detected at video decompresser DVMA timeout.
RAP. 19-300 19-301 19-302 19-310
This fault occurs under certain conditions after an IOT paper path jam. It is normal and no
action should be taken for the 19-405 faults. Troubleshoot the cause of the IOT paper
path faults.
If the problem continues, enter [Self Tests tab , Video Path Diagnostics], select [VCM +
IPS1 Loop Test], then [Start]. If the test fails, go to the 03-G Main Control PWB Replacement RAP.
Machines build after Sept. 1998

have metal brackets replacing the
ground wires
Figure 4 Ground Connections
19-404, 19-405
May 2003
2-706
V0.042
19-406 Video Loopback DVMA Timeout
19-407 Video Middle Function Input DVMA Timeout
Fault Code, 19-406, indicates the system has detected at video loopback DVMA time-out.
Fault Code, 19-407, indicates the system has detected at video middle function input DVMA
time-out.
RAP. 19-300 19-301 19-302 19-310
Check the Image Disk Drive connections. Disconnect/reconnect the Image Disk Drive
cables.
V0.042
RAP. 19-300 19-301 19-302 19-310
Check the Image Disk Drive connections. Disconnect/reconnect the Image Disk Drive
cables.
There have been some cases reported where certain instances of image rotation along
with documents fed SEF onto LEF paper caused this fault. It was found only to occur on
machines with 1GB Image Disk Drives. On machines where this problem is occurring,
send service and replace the Image Disk Drive PL 1.3A Item 3.
May 2003
2-707
19-406, 19-407
19-408 Video Middle Function Output DVMA Timeout
19-409 Video Job Integrity Fault RAP
Fault Code, 19-408, indicates the system has detected at video middle function output DVMA
time-out.
Fault Code, 19-409, indicates the video cannot guarantee the integrity of the job being processed.
RAP. 19-300 19-301 19-302 19-310
If the job has mixed size originals, ensure that Mixed Size originals is selected on the UI.
Check the Image Disk Drive connections. Disconnect / reconnect the Image Disk Drive
cables.
If any 19-3xx faults are occurring, go to that RAP. 19-300 19-301 19-302
There have been some cases reported where certain instances of image rotation along
with documents fed SEF onto LEF paper caused this fault. It was found only to occur on
machines with 1GB Image Disk Drives. On machines where this problem is occurring,
send service and replace the Image Disk Drive PL 1.3A Item 3.
Check the connections at the Image Disk Drive.
19-408, 19-409
May 2003
2-708
V0.042
19-410 IPS Not Responding To Set Up Request
19-750 EPC Memory Configuration Mismatch RAP
Fault Code, 19-410, indicates that the IPS does not respond to a set up request from video
when start is selected.
Fault Code, 19-750, indicates the detected EPC Memory does not match the expected configuration. One of the following may have occurred since the last power on:
EPC DRAM was added
Power the machine off, then on, several times.
EPC DRAM was removed
If the problem continues, replace the Main Control PWB.
EPC DRAM is loose or defective
PL 1.4A Item 1, 240/255/265 w/o Tag 077
Initial Actions
PL 1.4B Item 1, 240/255/265 with Tag 077
If there are any 03-348 faults, troubleshoot them first. 03-348
PL 1.4C Item 1 , 460/470

The fault may possibly due to a EPC DRAM SIMM not seated correctly in its socket or
missing. Check the EPC DRAM SIMMs and ensure they are inserted correctly in their
socket and the correct number of SIMMs are present that are expected for the machine (1
SIMM = 32MB, 2 SIMMs = 64MB).
To clear the fault while the problem is diagnosed:
V0.042
May 2003
2-709
Enter [Configuration tab , System, Imaging, and IOT Configuration], select [System]
Change the "Install Phase" for System and Main Controller to [Manufacturing].
Select [Apply] [OK].
Switch off the machine power, then switch it back on.
Troubleshoot the cause of the configuration mismatch. Check for loose or missing
memory.
When the problem is corrected, enter [Configuration tab , System, Imaging, and IOT
Configuration], select [System]
Change the "Install Phase" to [Install Complete]
Select [Main Controller], change the "Install Phase" to [Install Complete].
Select [Apply] [OK]. Switch off the machine power, then switch it back on.
19-410 , 19-750
19-751 IPS1 Option Card Configuration Mismatch RAP

Fault Code, 19-751, indicates the IPS1 Option card configuration does not match the expected
configuration. There are two types of IPS1 Option cards:
Autosegmentation PWB - Only used on pre-Atlanta Gold Main Control PWBs (TAG 015).
Electronic Hole Removal (EHR) PWB - Available on Atlanta Gold and Atlanta Platinum
Main Control PWBs.
One of these PWBs was removed or was added and the correct procedures were not followed
to complete the install.
19-752 Image Rotation SIMMs Configuration Mismatch

RAP
Fault Code, 19-752, indicates the Rotation SIMMs configuration does not match the expected
configuration. Either the SIMM was previously installed and is now gone, or the Rotation
SRAM SIMM was added, and the install was not completed correctly.

This fault may be due to a configuration change (Rotation SRAM SIMM) that was not
completed correctly. If the machine was upgraded and now has 19-752 faults, see if the
customer is available to assist with running the install wizard. If so, enter [Configuration
tab , System, Imaging, and IOT Configuration], select [System] and change the "Install
Phase" for System and Main Controller to [Manufacturing]. Select [OK]. Switch off the
machine power, then switch it back on. When the machine is ready, enter [Configuration
tab , System, Imaging, and IOT Configuration], select [System] and change the "Install
Phase to [Install Complete]. Switch off the machine power, then switch it back on.
When the machine is ready, the fault should be cleared.
The fault may possibly due to a Rotation SRAM SIMM not seated correctly in its socket or
missing. Check the Rotation SRAM SIMM for a good connection to the Main Control
PWB.

This fault may be due to a configuration change (Autosegmentation PWB or EHR PWB
added) that was not completed correctly. If the machine was upgraded and now has 19751 faults, enter [Configuration tab , System, Imaging, and IOT Configuration], select
[System] and change the "Install Phase" for System and Main Controller to [Manufacturing]. Select [OK]. Switch off the machine power, then switch it back on.
When the
machine is ready, enter [Configuration tab , System, Imaging, and IOT Configuration],
select [System] and change the "Install Phase" to [Install Complete]. Switch off the
machine power, then switch it back on. When the machine is ready, the fault should be
cleared.
If the Main Control PWB has an Autosegmentation PWB or EHR PWB, check the connection of the Autosegmentation PWB or EHR PWB to the Main Control PWB.
19-751, 19-752
May 2003
2-710
V0.042
19-753 Platen Cover Configuration Mismatch RAP
19-754 Image Disk Configuration Mismatch RAP
Fault Code, 19-753, indicates the platen cover (gray / white) configuration does not match the
expected configuration.
Fault Code, 19-754, indicates the Image Disk configuration (present / not present) does not
match the expected configuration.
The fault may possibly due to a Document Glass Pad not connected correctly or missing.
Check the Document Glass Pad and ensure it is connected.
This fault may be due to a configuration change (Document Glass Pad) that was not completed correctly. If the machine was upgraded and now has 19-753 faults, enter [Configuration tab , System, Imaging, and IOT Configuration], select [System] and change the
"Install Phase" for System and Main Controller to [Manufacturing]. Select [OK]. Switch
off the machine power, then switch it back on. When the machine is ready, enter [Configuration tab , System, Imaging, and IOT Configuration], select [System] and change the
"Install Phase" to [Install Complete]. Switch off the machine power, then switch it back
on. When the machine is ready, the fault should be cleared.
Enter [Configuration tab , System, Imaging, and IOT Configuration], select [System] and
change the "Install Phase" to [Manufacturing]. Select [OK]. Switch off the machine power,
then switch it back on. When the machine is ready, enter [Configuration tab , System,
Imaging, and IOT Configuration], select [System] and change the "Install Phase" to [Install
Complete]. Switch off the machine power, then switch it back on. When complete, the
machine will recognize the correct Image Disk Drive configuration and the fault will clear.
The fault may possibly due to a Image Disk Drive not connected correctly or missing.
Inspect the Image Disk Drive. Check for any 19-3xx faults.
V0.042
May 2003
2-711
19-753, 19-754
19-A PWS Lost Communication RAP (Direct Connection)
N
Perform the following steps until the problem is resolved:
This RAP will assist in diagnosing problems with PWS to machine communication.
1.
Initial Actions
Check the PWS Serial Cable. Ensure that it is connected correctly at both ends.
Check the pins and connectors for any damage.
2.
If there is a problem when trying to upload software to the machine, go to the GP28 , Software
Upload Failures Procedure.
Disconnect the cable from the machine. Reboot the PWS. When the PWS has up,
reconnect the PWS cable to the machine.
3.
Disconnect the PWS cable from the machine. PO/PO the machine. When the
machine is ready, reconnect the PWS to the machine.
4.
Observe the machine User Interface (UI). The UI Boots up normally to the Basic Copying
screen.
Y
N
Check the COMM port setup. When the connection selection window appears (upon
starting the Diagnostic Navigator or EDOC Browser), ensure the connection type is
set to Local, and click the [Setup] button. The COMM port for the Local Setup should
be Comm1.
5.
Check the Portable Work Station Cable PL 1.2A Item 8 for good connections, damage, etc. Repair/replace as necessary. (If the PWS can connect remotely to this
machine, and the comm port setup is correct for local mode, replace the Portable
Work Station Cable PL 1.2A Item 8.)
1.
Access the Card Cage at the back of the machine.
2.
Ensure the EPC DRAM SIMMS (or EPC SDRAM DIMM w/TAG 077) are present.
3.
Observe the LED on the lower left corner of the Main Control PWB (it may be
obstructed by the Accessory PWB, but if the LED is on, the light will be visible).
NOTE: On machine without Tag 077 (Atlanta Platinum) the LED is green, with Tag
077, the LED is red.
Go to the RAP for the current 03-XXX fault.
The EPC DRAM SIMMS (or EPC SDRAM DIMM w/TAG 077) are present on the Main
Control PWB.
Y
N
The EPC DRAM SIMMS (or EPC SDRAM DIMM w/TAG 077) must have been
removed from the machine. Inform the customer. Install new EPC DRAM SIMMS PL
1.4A Item 2 (or PL 1.4B Item 5 w/TAG 077) or PL 1.4C Item 6 (on 460/470).
Observe the LED. The LED is blinking about once per second (answer NO if blinking slower).
Y
N
Observe the LED. The LED is On.
Y
N
The LED is off. There may be a power problem. Check all of the connectors
on the Main Control PWB, especially at J13 and J7. Inspect the harness from
these connectors back to the LVPS. Ensure they are connected correctly and
not damaged. If OK, go to the 01-A, Voltage Checkout RAP.
This is the normal state for the LED. Re-assess the first question of this RAP. If there is no
doubt the machine will not boot, no error codes are present on the UI Display, and the
PWS won't connect, go to the 03-G, Main Control PWB Replacement RAP.
On the machine UI Control Panel, select [Machine Status]. On the UI DIsplay, select [Faults],
[Error Log].
Observe the Error log for any current fault codes. There are current fault codes that begin
with (Chain) 03.
19-A
May 2003
2-712
V0.042
21-300 Main Controller PWB Cannot Communicate with

Modem RAP
21-304 No RDT Dial Tone at Modem RAP
Fault Code, 21-300, indicates the Main Controller PWB cannot communicate with the modem.

Ensure the Accessory PWB is seated correctly. If OK, replace the Accessory PWB PL 1.4A
Item 4.
V0.042
Fault Code, 21-304, indicates that no dial tone was sensed at the modem. This fault can occur
when an RDT Configuration mismatch exists (22-755.17), such as RDT was configured but the
dial-tone was not sensed at power up. It can also occur on a machine which does not have
RDT enabled. In that case, the fault should be ignored.

1.
This fault can occur if a phone line was at one time connected, and then removed. Determine if the machine is intended to be RDT enabled. If no, this fault can be ignored.
2.
If RDT is supposed to be enabled on this machine, go to the 22-755.17 RAP.
May 2003
2-713
21-300, 21-304
21-308 Modem Blacklist Fault RAP
21-708 Host Modem Doesn't Answer RAP
Fault Code, 21-308, indicates the modem has indicated that one or more phone numbers have
been blacklisted. The modem exceeded the number of allowable attempts to contact the host.
This fault can occur only on XE machines.
Fault Code, 21-708, indicates the host modem won't answer.
Perform the following in order, until the problem is resolved:
1.

1.
Configuration Problems - If Auto-billing has never previously been installed and working
on this machine, or there has recently been a change in the Auto-billing configuration, the
configuration may be incorrect. Enter [RDT tab , RDT Configuration]. Check the following:
a.
Select [Auto-Billing Setup]. Ensure the Direct Dial Phone Number is correct (including Area Code).
a.
b.
b.
Another common problem is in [Dialing Setup]. Ensure the Dial-out Prefix is correct.
If a number is required to reach an outside line (ie. 9,), that should be in the Dial-out
Prefix.
Prefix.
c.
The machine phone number must also be entered for Dial-out to work. Include 1 and
area code.
c.
The machine phone number must also be entered for Dial-out to work.
d.
d.
If the machine is on a phone share device, another device may be using the line.
Determine if another device is blocking access for the machine to dial out.
e.
Ensure the Dial Type is correct (Tone or Pulse).
e.
f.
f.
Use the Auto-Billing Host Test to check the ability to connect to the host. Select
[Start].
[Start].
2.
2.
Host Problem - The Host may be unavailable. If possible, dial the host from a phone
using the same parameters entered in the Auto-Billing Setup (e.g. 9, 18887787012). See
if a modem answers. More than 2 rings indicates a host problem. If a modem does
answer, the Host is probably OK and the problem is on the machine. Go to next item.
3.
3.
Machine Modem Problem - The machine modem may have failed. Ensure the machine
can be contacted using RDT (Sixth Sense). If the machine can be contacted using RDT,
the machine modem and software are OK. If the machine cannot be contacted, use the
21-A RAP to diagnose.
Machine Modem Problem - Finally, the machine modem may have failed. Ensure the
machine can be contacted using RDT (Sixth Sense). If the machine can be contacted
using RDT, the machine modem and software are OK. If fails, use the 21-A RAP to diagnose.
21-308, 21-708
May 2003
2-714
V0.042
21-712 No Carrier After Answer RAP
21-716/720 Problems After Connect RAP
Fault Code, 21-712, indicates there was no carrier after the host answered.
Fault Code, 21-716, indicates there was no login packet after a connection.
Fault Code, 21-720, indicates there was no session after a login.

1.
2.
3.
a.
b.
Prefix.
c.
The machine phone number must also be entered for Dial-out to work. Include 1 and
area code.
d.
e.
f.
[Start].
Check the following in order, until the problem is resolved:

1.
2.
V0.042
May 2003
2-715
21-712, 21-716/720
21-724 Lost Session After Login RAP
21-728 Modem Failed to Disconnect RAP
Fault Code, 21-724, indicates there was a lost session after a login.
Fault Code, 21-728, indicates the modem failed to disconnect from the phone line.
Possible noisy phone line problem. Using a handset, often noise can be heard. If possible try
this and notify the customer if noise is heard. See if another phone line is available to test. If
another phone line is successful, there may be a problem with the original line. Inform the customer.
Ensure the Accessory PWB is seated correctly. If OK, replace the Accessory PWB PL 1.4A
Item 4
21-724, 21-728
May 2003
2-716
V0.042
21-732 Host Cancellation RAP
21-736 Protocol Transmission Failure RAP
Fault Code, 21-732, indicates the host disconnected.
Fault Code, 21-736, indicates there has been a protocol transmission failure.
If this fault has been occurring and there have been problems connecting to the machine,
check for a possible phone line problem. See if another line is available to test.
1.
2.
If no phone line problems are occurring, ensure the Accessory PWB is seated correctly. If OK,
replace the Accessory PWB PL 1.4A Item 4
V0.042
May 2003
2-717
21-732, 21-736
21-740 Protocol Reception Failure RAP

Fault Code, 21-740, indicates there was a protocol reception failure.

If this fault has been occurring and there have been problems connecting to the machine,
check for a possible phone line problem. See if another line is available to test.
If no phone line problems are occurring, ensure the Accessory PWB is seated correctly. If OK,
replace the Accessory PWB PL 1.4A Item 4
21-740
May 2003
2-718
V0.042
22-300.04 Scheduling Table Missing RAP
22-300.05 Image Complete Not Received RAP
Fault Code, 22-300.04, occurs when the system is unable to find the scheduling table. The
machine will attempt to automatically recover from this fault.
Fault Code, 22-300.05, occurs when the system does not receive an image complete status
from the video system. The job must be deleted from the queue to recover from this fault.
This fault, if it happens, is usually a transitory event and the machine will recover without customer or CSE intervention.
This fault, if it happens, is usually a transitory event and the machine will recover without customer or CSE intervention. This fault can be caused by opening the Front Door or the HCF
before the machine has completely cycled out.
If the fault is not causing a problem for the customer, ignore it.
If not already attempted, switch the machine power off/on and see if the problem clears.
If the problem continues, change the job parameters in some way to work around the
problem. Split the job into smaller segments or change the options.
If this fault is causing a problem for the customer, or is occurring at a high rate, clean the
DADF Exit/Invert Sensor.
If this fault occurs in manual platen mode and a sheet is printed that is scrogged, it may
be related to certain combinations of image shift, edge erase, and mag. The problem may
be alleviated by changing edge erase back to default.
Ensure that TAG 026 and TAG 039 are installed.
If the fault occurs in DADF mode and a sheet is printed that is scrogged, all black, or partially black, it may be an electrical noise problem.
1.
Ensure that the Scanner Top Frame is grounded properly. Check continuity from the
Scanner Top Frame to the machine frame. If there is a problem, check the Left front
mounting screw of the Scanner Base. Make sure it is present and the metal bracket
carries ground to the Scanner Top Frame.
2.
3.
4.
5.
Check for a good connection in connectors P95 and P96 on the Prefuser Transport,
PL 6.1A Item 1.
V0.042
May 2003
2-719
22-300.04, 22-300.05
Ground Wire
(violet)
Ground Wire
(violet wire)
22-300.05
May 2003
2-720
V0.042
Machines with TAG 039

installed at the factory
have a braided wire
instead of the violet wire.
It attaches to a different
area of the frame.
Ground Wire
(violet)
Figure 3 IOT Rear
V0.042
May 2003
2-721
22-300.05
Check Connections
22-300.10 Decompresser End of Record RAP

Fault Code, 22-300.10, occurs when the DVMA transfer completes before the decompresser
has finished decompressing the image.

If the problem continues, replace the ROS Video Cable PL 1.2A Item 4
Machines built after

Sept. 98 have metal
brackets providing
ground instead of the
Figure 4 Ground Connections
22-300.05, 22-300.10
May 2003
2-722
V0.042
22-300.16 Real Time Clock Overflow RAP
22-301.04 Initial State Scheduling Error RAP
Fault Code, 22-306.10, occurs when the machine determines it must reset to avoid a real time
clock overflow.
Fault Code, 22-301.04, occurs when the system cannot find the initial state for initial scheduling offset. The machine will attempt to automatically recover from this fault.
If the problem continues, try to change the job parameters in some way to work around
the problem. Split the job into smaller segments or change the options.
V0.042
May 2003
2-723
22-300.16, 22-301.04
22-301.05 Scan Resources Not Available RAP
22-302.04 Current State Scheduling Error RAP
Fault Code, 22-301.05, occurs when the system cannot make scan resources available. The
job must be deleted from the queue to recover from this fault.
Fault Code, 22-302.04, occurs when the system cannot find a transition for the current state.
The machine will attempt to automatically recover from this fault.
22-301.05, 22-302.04
May 2003
2-724
V0.042
22-303.04 Shifted Proposal Invalid RAP
22-303.05 Document Too Large RAP
Fault Code, 22-303.04, occurs when the system detects an invalid shifted proposal. The
Fault Code, 22-303.05, occurs when documents fed into the DADF are longer or shorter (in the
feed direction) by more than 50mm (approximately 2 inches) than the length inferred by the
control system.

The "inferred" length of the document is determined by the DADF Side Guides and sideguide switches.
The "actual" length of the document is determined by the time over the Start of Scan sensor in the DADF paper path as the document is fed.
When this fault occurs, the job is automatically deleted by the system, and the following message is displayed on the UI:
"The job was deleted because a document was larger than expected. Try flattening the
document and scan it through the Document Feeder or scan it from the Document Glass".
This message can be confusing to the operator and to the Service Engineer, because there are
many other causes of this fault in addition to folded originals.

Conditions that cause this fault fall into the following three categories.
1.
The inferred document size is wrong.
2.
The stack of originals contains at least one original that is at least 50mm (2 inches)
smaller than the others, and the user didn't select 'Mixed Size Originals'.
NOTE: This fault does not occur when the user selects "Mixed Size Originals".
3.
The DADF feeds multiple originals in a shingle feed (multiple feed) condition, or feeds the
originals too slowly or quickly in the CVT region, or does not feed at all.
This problem is often caused by operator induced problems or problems with the originals.
V0.042
DADF Side Guides are being set properly
The operator is not holding up the trail edge of an original after Start is pressed
Document Loaded Sensor is not being actuated by the operator's hand or by an object
being placed on the uncovered switch
When using mixed size originals, ensure the "Mixed Size Originals" feature is selected
Originals are stacked properly when placed in the DADF Input Tray
Originals dont have damaged lead edges
Originals are not dog-eared
Originals are not folded (especially folds to let the original be placed in an envelope)
(Note: this is the condition that should be detected by the fault)
Check if originals are 'non-standard sizes' for the particular Market Region DADF zone
Zone of DADF has been setup as a 'non-standard size' and a 'standard size' document is
fed
Check if originals had a staple removed but weren't separated
Check if originals have perforated lead edges
Check if originals are charged with static
May 2003
2-725
22-303.04, 22-303.05
If the problem is not caused by the operability or original problems, check/perform the following:
There may be a problem with the feeding of originals. Multi feeding, misfeeding can contribute to this problem. If not already done, replace the DADF Paper Feed Roll Cartridge
PL 2.2 Item 4.
Problems with the CVT drive could cause this fault. Check for any 05-XXX faults and go to
the pertinent RAP.
Intermittent sensors in the document size sensing function. Go to the 05-E Document
Size Sensing RAP
ADDITIONAL INFORMATION ABOUT THIS FAULT CODE:

Once the operator places an original into the DADF Input Tray, the control system examines
the 4 'size' switches in the DADF Input Tray. The combination of the states of the 4 switches
defines an 'Input Zone'. The control system infers the size of the originals based on the size
defined for that specific zone. Table 1 identifies the inferred sizes based on the Market Region.
In many cases, the same zone for a USCO machine may define a different size than for a XL
machine. Running a foreign size document not expected for the market region can cause the
fault. For example, if a customer with a machine setup for the USCO market region tried to run
B4 paper, which is 257mm x 364mm, the system will infer it is 11 x 17" (279mm x 432mm).
Since the B4 paper is more than 2" shorter than the expected 11 x 17", a 22-303.05 fault will be
declared.
The user can see what size is inferred for a zone by using the 'Document Scanner Size Sensing' Tool and can redefine the default size of the zone using the same tool. Refer to the Reference Guide, under Document Scanner Size Sensing. This is helpful when a multinational
company often copies documents from another market region. Go to Tools, System Settings,
Document Scanner Size Sensing to locate the Document Scanner Size Sensing Tool. Once
the size is redefined, the job can be run with no faults.
The user can receive an output copy in which the image is only partially reproduced. When the
scanner scans an original whose size is greater than expected, it raises a status 22-303.05 and
deletes the job. If this happens on a single sheet job, an output sheet maybe produced with a
truncated (cut-off) image. The above scenario can occur due to a folded/ripped original, or by
the customer holding the trail edge of the input document such that it does not engage the correct Document Feeder sensors.
Table 1 Default Document Sizes for Each Market Region Based on Actuation of the Input Tray Switches
Side Guide
Sensor 2 (Q6)
Side Guide
Sensor 1 (Q7)
Input Tray Sensor Input Tray Sensor

1 (Q11)
2 (Q12)
USCO & XCL
Not Actuated
Not Actuated
Not Actuated
Not Actuated
8.5 x 5.5 SEF
8.5 x 5.5 SEF
A5 SEF
A5 SEF
Not Actuated
Not Actuated
Actuated
Not Actuated
7.25 x 10.5 SEF
7.25 x 10.5 SEF
B5 SEF
B5 SEF
ACO
XL
FX Domestic &
APO
Not Actuated
Not Actuated
Actuated
Actuated
7.25 x 10.5 SEF
7.25 x 10.5 SEF
B5 SEF
B5 SEF
Not Actuated
Not Actuated
Not Actuated
Actuated
7.25 x 10.5 SEF
7.25 x 10.5 SEF
B5 SEF
B5 SEF
Actuated
Not Actuated
Not Actuated
Not Actuated
8.5 x 5.5 LEF
8.5 x 5.5 LEF
A5 LEF
A5 LEF
Actuated
Not Actuated
Actuated
Not Actuated
8.5 x 11 SEF
8.5 x 11 SEF
A4 SEF
A5 LEF
Actuated
Not Actuated
Actuated
Actuated
8.5 x 14
215 x 330mm
215 x 330mm
8.5 x 14
Actuated
Not Actuated
Not Actuated
Actuated
8.5 x 14
215 x 330mm
215 x 330mm
8.5 x 14
Actuated
Actuated
Not Actuated
Not Actuated
8.5 x 11 LEF
8.5 x 11 LEF
8.5 x 11 LEF
B5 LEF
Actuated
Actuated
Actuated
Not Actuated
8.5 x 11 LEF
8.5 x 11 LEF
8.5 x 11 LEF
B5 LEF
Actuated
Actuated
Actuated
Actuated
11 x 17 SEF
11 x 17 SEF
B4 SEF
B4 SEF
Actuated
Actuated
Not Actuated
Actuated
11 x 17 SEF
11 x 17 SEF
B4 SEF
B4 SEF
Not Actuated
Actuated
Not Actuated
Not Actuated
A4 LEF
A4 LEF
A4 LEF
A4 LEF
Not Actuated
Actuated
Actuated
Not Actuated
A4 LEF
A4 LEF
A4 LEF
A4 LEF
Not Actuated
Actuated
Actuated
Actuated
A3 SEF
A3 SEF
A3 SEF
A3 SEF
Not Actuated
Actuated
Not Actuated
Actuated
A3 SEF
A3 SEF
A3 SEF
A3 SEF
22-303.05
May 2003
2-726
V0.042
22-304.04 Schedule Missing RAP
22-305.04 Dead Cycle Error RAP
Fault Code, 22-304.04, occurs when the system detects an missing schedule. The machine
will attempt to automatically recover from this fault.
Fault Code, 22-305.04, occurs when the system detects a scheduling dead cycle. The machine
will attempt to automatically recover from this fault.
22-306.04 Rejection Error RAP
22-307.04 Reschedule Error RAP
Fault Code, 22-306.04, occurs when the system detects no proposal found for rejection. The
Fault Code, 22-307.04, occurs when the system cannot find a reschedule point for rejection.
The machine will attempt to automatically recover from this fault.
V0.042
May 2003
2-727
22-304.04, 22-305.04, 22-306.04, 22-307.04
22-308.04 Execution State Error RAP
22-309.04 No Except Timeout Error RAP
Fault Code, 22-308.04, occurs when the system cannot find a execution state error for rejection. The machine will attempt to automatically recover from this fault.
Fault Code, 22-309.04, occurs when the system received consecutive no accepts from a module. The machine will attempt to automatically recover from this fault.
If any 09-318, 09-330, or 09-334 faults occur about the same time, go the appropriate
RAP
22-308.04, 22-309.04
09-318, 09-330 , 09-334
May 2003
2-728
V0.042
22-310.04 Compound Service Image Sequence Error RAP
22-311.04 Proposal Response Timeout Error RAP
Fault Code, 22-310.04, occurs when the system detected pages received from Extended Job
Service are out of sequence. The status must be cleared at the UI Display Panel.
Fault Code, 22-311.04, occurs when the sequencer did not respond with proposal within the
required time. The machine will attempt to automatically recover from this fault.
If this fault is occurring during a Network Scanning job, go to the 16-785.19 RAP.
V0.042
May 2003
2-729
22-310.04, 22-311.04
22-312.04 Sync Information Error RAP
22-313.04 Missing Sync Error RAP
Fault Code, 22-312.04, occurs when the system cannot find data for the current sync. The
Fault Code, 22-313.04, occurs when no sync was received within the specified time. The status must be cleared at the UI Display Panel.
22-312.04, 22-313.04
May 2003
2-730
V0.042
22-314.04 Module Registration Error RAP
22-315.04 Module Completion Fault RAP
Fault Code, 22-314.04, occurs when a module registration message was received beyond the
required time window. The machine will attempt to automatically recover from this fault.
Fault Code, 22-315.04, occurs when one or more modules did not respond with a completion
message. The machine will attempt to automatically recover from this fault.
V0.042
May 2003
2-731
22-314.04, 22-315.04
22-316.04 Job Requires Paper Tray That Does Not Exist

RAP
22-317.04 Job Requires IOT Capability That Does Not Exist

RAP
Fault Code, 22-316.04, occurs when the job requires a paper tray that does not exist.
Fault Code, 22-317.04, occurs when the job requires a IOT capability that does not exist.
The job is calling for a paper that is not available. The customer should ensure that the proper
paper is available or change the job so it can use available paper in an existing paper tray.
The job is calling for an IOT capability that is not available.
22-316.04, 22-317.04
May 2003
2-732
V0.042
22-318.04 Job Requires Finisher Capability That Does Not

Exist RAP
Fault Code, 22-318.04, occurs when the job requires a Finisher capability that does not exist.

The job is calling for a Finisher capability that is not available.
22-319.04 IOT Cycle Down/Cycle Up Loop Detected RAP

Fault Code, 22-319.04, occurs when the IOT cycles down then back up 10 times within a job.
The job will be deleted and will have to be resubmitted.

V0.042
Go to the fault log, [Faults/Counters tab , Faults]. Check for faults that occur just previous
to the 22-319.04 and troubleshoot those faults.
May 2003
2-733
22-318.04, 22-319.04
22-330.xx List Jobs Request Timed Out
22-700.04 Module Timeout Error RAP
Fault Code, 22-330, indicates that a List Jobs Request Timed Out. The specific codes and
extensions are as follows:
Fault Code, 22-700.04, occurs when one or more modules did not respond with a proposal
within the required time window.
22-330.01 - List Jobs request timed out between the Main Control PWB and the UI
22-330.02 - List Jobs request timed out between the Main Control PWB and the ESS Print
Service
22-330.03 - List Jobs request timed out between the Main Control PWB and the Scan to
File Service
22-330.04 - List Jobs request timed out between the Main Control PWB and the Scan to
Fax Service
22-330.05 - List Jobs request timed out between the Queue Utility and the DC Job Service
22-330.xx On-Site Diagnostic Procedure

Go to the fault log, [Faults/Counters tab , Faults]. Check for faults that occur just previous
to the 22-330.xx and troubleshoot those faults.
22-330.xx, 22-700.04
May 2003
2-734
V0.042
22-701.04 Module Completion Error RAP
22-750.04 Output Device Configuration Error RAP
Fault Code, 22-701.04, occurs when a module completion message was received after the IOT
returned to standby.
Fault Code, 22-750.04, occurs when an output device configuration mismatch was detected.
1.
If there is a 22-757.04 present in the Last 40 faults, go to that RAP (22-757.04 RAP)
2.
This fault may be due to a configuration change that has not been accepted. Ensure that
the customer is correctly identifying the correct configuration when the machine prompts
the customer to accept or not accept the present configuration. When connected to the
machine, if a System Configuration Error window appears that describes platform configuration, compare the detected configuration to the programmed configuration. If the
detected configuration is correct, accept it and the fault should clear.
V0.042
3.
Ensure that the output device is properly connected to the IOT.
4.
Check P/J4 and P/J11 on the Distribution PWB. Ensure that they are connected properly.
Check for any wire or connector damage or pulled out pins.
5.
machine will recognize the proper output device configuration and the fault will clear.
May 2003
2-735
22-701.04, 22-750.04
22-750.17 Accessory Card Configuration Error RAP

Fault Code, 22-750.17, occurs when an Accessory card configuration mismatch was detected.
The machine detected no Accessory PWB when the machine configuration stored in NVM indicates there should be, or an Accessory PWB was detected when the machine configuration
indicates there should not.

detected configuration is correct, accept it and the fault should clear. If the fault returns,
go to step 2.
2.
Check the Accessory PWB. Ensure that it is connected properly.
3.
machine will recognize the proper Accessory PWB configuration and the fault will clear.
22-750.17, 22-751.04
Fault Code, 22-751.04, occurs when a Bypass Tray (SMH) or HCF configuration mismatch
was detected. Either one of these units was detected when it was not expected, or one of
these units was not detected when the machine configuration indicates it should be present.

1.
22-751.04 Bypass Tray (SMH) or HCF Configuration Error

RAP

1.
If there is a 22-757.04 present in the Last 40 faults, go to that RAP (22-757.04 RAP)
2.
detected configuration is correct, accept it and the fault should clear.
3.
Ensure that the device is properly connected to the IOT.
4.
machine will recognize the proper SMH/HCF configuration and the fault will clear.
May 2003
2-736
V0.042
22-751.17 ESS Configuration Error RAP
22-752.17 EP-SV / EP-Lyzer Configuration Error RAP
Fault Code, 22-751.17, occurs when an ESS configuration mismatch was detected.
Fault Code, 22-752.17, occurs when an EP-SV/EP-Lyzer configuration mismatch was

detected.

Enter [ESS/Network tab , ESS Error Log].
and go to the appropriate RAP.
16-760, Go to the 16-A RAP.
Select [All] [Retrieve]. Check for the following faults
V0.042

If this problem occurs on machines other than FX machines, accept the new configuration and
continue.
May 2003
2-737
22-751.17, 22-752.17
22-754.17 UI Configuration Error RAP
22-755.17 RDT Configuration Error RAP
Fault Code, 22-754.17, occurs when an UI configuration mismatch was detected. The type of
UI detected does not match the configuration of the machine stored in NVM.
Fault Code, 22-755.17, occurs when a RDT configuration mismatch was detected. The
machine was configured for RDT but no dial tone is sensed. May occur with a 22-750.17 if
there is an Accessory PWB problem.

1.
This fault should not normally occur. Only one type UI is presently used. Ensure that the
UI is connected properly.
2.
machine will recognize the proper UI configuration and the fault will clear.
22-754.17, 22-755.17
If occurring on a machine which has not had RDT enabled or working, and now a dial tone
is sensed, the configuration needs to be confirmed.
Determine the status of the RDT Phone line. Ensure that it is connected properly to the
machine. If disconnected, the machine will have to be switched off/on, to detect the new
configuration. Confirm the new configuration when prompted.
NOTE: This item is only relevant on XE machines and is not displayed when connected to nonXE machines.
On XE machines, check the DIP Switch settings on the Accessory PWB. Refer to Table 1
for the proper switch settings for the appropriate country.
Verify that the phone line is active. Enter [RDT tab , RDT Dial Tone Test]. Select [Start]. If
the test fails, the phone line has no dial tone. Alternately, connect the PWS to the phone
line and attempt to dial out with another communications application (ie. Call Handling,
Worldgroup, etc.) Inform the customer about the not functioning phone line, if that is the
case. If the phone line is OK, replace the Accessory PWB PL 1.4A Item 4.
Check the fault counters for instances of any 21-XXX faults. Select [Fault Counters]. Filter
by Chain 21. Enter [Faults/Counters tab , Faults]. If any 21-XXX faults are occurring, go
to the appropriate RAP.
May 2003
2-738
V0.042
22-756.17 Scanner Configuration Error RAP
22-757.04 Mark Service Configuration Problem RAP
Fault Code, 22-756.17, occurs when a Scanner configuration mismatch was detected. A Scanner is detected when the configuration of the machine stored in NVM does not include a Scanner, or no Scanner is detected when the machine configuration indicates that there should be a
Scanner.
Fault Code, 22-757.04, occurs when a mismatch occurs with the machine speed configuration.
A 55ppm machine is expected but a 65ppm or 40ppm machine is sensed, a 40ppm machine is
expected, but 55ppm is enabled, or a 65ppm machine is expected and a 55ppm or 40ppm
machine is sensed.
The machine is a 55PPM model.

Y
N
In the Diagnostic Navigator, select [NVM | All IOT NVM Initialization]. Re-initialize the IOT
NVM.
Determine if the machine is being upgraded from an LP to an ST model. The Install Wizard may not have completed properly. If a new configuration is being sensed, it needs to
be accepted to continue. The Install Wizard can also be run to correct the configuration.
All of the connections for the scanner may not have been made properly. Check the connections from the Scanner to the IOT.
Enter [System, Imaging, and IOT Configuration], select [System], change the "Install
Phase" to [Manufacturing], then select [OK]. Select [Main Contol], change the "Install
Phase" to [Manufacturing], then select [OK]. Switch off the machine power, then switch it
back on.
When the machine is ready, enter [System, Imaging, and IOT Configuration], select [System], change the "Install Phase" to [Install Complete], then select [OK]. Select [Main Contol], change the "Install Phase" to [Install Complete], then select [OK].
Y
N
Y
N
machine problems that might be occurring. If the problem continues, replace the
Switch off the machine power, then switch it back on. When complete, the machine will
recognize the proper Scanner configuration and the fault will clear.

Y
N
Y
N
machine problems that might be occurring. If the problem continues, replace the
Go to the Flag 1. Check all the wiring for an open circuit. If the problem continues, replace the
V0.042
May 2003
2-739
22-756.17, 22-757.04
Figure 1 22-757.04 Circuit Diagram
22-757.04
May 2003
2-740
V0.042
A
Go to Standby Noise Checkout Procedure.
OF-1 Noise RAP
Standby Noise Checkout Procedure
(27Jun2001)
There is an audible noise when the machine is in stand-by or when the machine is operating.
Initial Actions
If the noise appears to be in the Document Feeder, the Scanner, or in one of the output
devices, refer to the appropriate RAP listed below.
05-L DADF Noise RAP.
14-B Scanner Noise RAP.
12-F Offsetting Catch Tray Noise RAP.
12-AF Finisher Noise RAP (Disk Finisher).
12-765 Finisher Noise RAP (Multi-Function Finisher - 470 Only).
OF-1 On-Site Diagnostic Procedure

The noise occurs when the machine is in standby.
Y
N
Feed 5 sheets of paper from each of the IOT Paper Trays, and from Tray 5, and Tray 6.
The noise occurs when feeding from every paper tray.
Y
N
Go to the Paper Feeder Checkout Procedure.

Listen for noise when the machine enters Component Control. The noise occurs when
machine enters Component Control.
Y
N
In Component Control, select [IOT Paper Path], [Xerographic Blower], then [Output On].
Listen for noise when the Xerographic Blower is energized. The noise occurs when
the Xerographic Blower is energized.
Y
N
In Component Control, select [IOT Paper Path], [Fuser Fan], then [Output On]. Enter
Listen for noise when the Fuser Fan is energized. The noise occurs when the
Fuser Fan is energized.
Y
N
In Component Control, select [IOT Paper Path], [ROS/Developer Fan], then
Listen for noise when the ROS/Developer Fan is energized.
The
noise
occurs when the ROS Developer Fan is energized.
Y
N
Check the ROS/Developer Filter PL 9.1 Item 7, and the ROS/Developer Cooling Fan PL 9.1 Item 8. The ROS/Developer Filter is mounted correctly, and
the filter is not obstructing the ROS/Developer Cooling Fan.
Y
N
Replace the ROS/Developer Filter PL 9.1 Item 7, if necessary.
In Component Control, select [IOT Paper Path], [Developer Drive Motor], [Output On],
[Registration Clutch], then [Output On]. Enter [Copier Sys tab , Component Control].
Listen for noise when the Developer Drive Motor and the Registration Clutch are energized. The noise occurs when the Developer Drive Motor and Registration Clutch
are energized.
Y
N
In Component Control, select [IOT Paper Path], [All Outputs Off], [Fuser Drive
Motor], then [Output On]. Enter [Copier Sys tab , Component Control].
Listen for noise when the Fuser Drive Motor is energized. The
noise
occurs
when the Fuser Drive Motor is energized.
Y
N
Ensure the Fuser Drive Motor is still energized in Component Control. In Component Control, select [Inverter Reverse Drive Solenoid] then [Output On].
Listen for noise when the Inverter Reverse Drive Solenoid is energized. The
noise occurs when the Inverter Reverse Drive Solenoid is energized.
Y
N
Go to PFT and Xerographic Checkout Procedure.
Check the ROS/Developer Cooling Fan, PL 9.1 Item 8. The ROS/Developer

Cooling Fan is mounted correctly and is free from obstructions.
Y
N
Ensure that the ROS/Developer Cooling Fan is mounted correctly and is
free from obstructions.
Replace the ROS/Developer Cooling Fan PL 9.1 Item 8, if necessary.
Replace the ROS/Developer Cooling Fan Assembly PL 9.1 Item 6.
Check the Fuser Dirt Filter PL 9.1 Item 12 and the Ozone Filter PL 9.1 Item 4.
The Fuser Dirt Filter and the Ozone Filter are mounted correctly, and the Fuser
Dirt Filter is not obstructing the fan in the Fuser Fan/Duct.
Y
N
Replace the Fuser Dirt Filter, PL 9.1 Item 12, if it is damaged.
If the Ozone Filter is damaged, replace the NOHAD Filter Kit PL 9.1 Item 10.

An Offsetting Catch Tray is installed.
Y
N
Go to Fuser Drives Checkout Procedure.
Check the Fuser Fan/Duct PL 9.1 Item 5. The Fuser Fan/Duct is mounted correctly and is free from obstructions.
Y
N
Ensure that the Fuser Fan/Duct is mounted correctly and is free from obstructions.
Replace the Fuser Fan/Duct PL 9.1 Item 5, if necessary.
Go to Fuser Drives/OCT Checkout Procedure.

Go to Developer Drives Checkout Procedure.
A
V0.042
B
May 2003
2-741
D
OF-1
D
F
Y
N
Do the following:
Replace the Bypass Tray Assembly PL 4.3 Item 1 and reset the Life Counter for the
Tray 5 Paper Feed Roll Cartridge. Refer to GP6.
In Component Control, select [Xerographic Blower], select [Output Off].
Select [Xerographic Blower], then [Output On]. Enter [Copier Sys tab , Component
Control].
Run a job to feed paper from Tray 5 and Tray 6.

The noise occurs when feeding from Tray 5 and Tray 6.
Y
N
The noise occurs when feeding from Tray 5.
Y
N
Do the following:
Listen for noise when the Xerographic Blower is energized. The noise occurs with the
Xerographic Module removed.
Y
N
Check for mechanical interference between the Xerographic Module and the Xerographic Blower PL 9.1 Item 11.
Check the mounting of the Xerographic Blower.
If the Xerographic Blower is mounted securely, replace the Xerographic Blower PL 9.1
Item 11.
Replace the Paper Feed Roll Cartridge PL 4.2B Item 6,in Tray 6 and reset
the Life Counter for the Tray 6 Paper Feed Roll Cartridge. Refer to GP6.
Program a job to feed 5 sheets of paper from Tray 6.
The noise occurs after replacing the Paper Feed Roll Cartridge.
Y
N
Switch the power [Off]. Disconnect the Scanner Cooling Fan, PL 9.1 Item 10, and switch the
power [On].
The noise occurs with the Scanner Cooling Fan disconnected.
Y
N
Replace the Scanner Cooling Fan PL 9.1 Item 10.
Press the Up/Down button on Tray 6 to lower Tray 6, then press the Up/Down
button to raise Tray 6.
The noise occurs when Tray 6 is driving up or down.
Y
N
Check the following for wear, damage, or contamination:
Do the following:
The HCF Elevator Motor Assembly PL 4.2B Item 9.
Reconnect the Scanner Cooling Fan.
Disconnect the PWB Cooling Fan/Duct, PL 9.1 Item 3, and switch the power [On].
Tray 6. Replace the HCF Feeder PL 4.2B Item 3 if necessary. If the

HCF Feeder Assembly is replaced, reset the Life Counter for the
The noise occurs with the PWB Cooling Fan disconnected.

Y
N
Replace the PWB Cooling Fan/Duct PL 9.1 Item 3.
The rack for Tray 6 is damaged (broken, bent)

Y
N
Replace the HCF Elevator Motor Assembly PL 4.2B Item 9
Do the following:
Reconnect the PWB Cooling Fan/Duct.
Disconnect the LVPS Cooling Fan/Duct, PL 9.1 Item 2, and switch the power [On].
Replace the HCF/Bypass Tray Assembly PL 4.2A Item 1 and reset the Life
Counter for the Tray 5 and Tray 6 Paper Feed Roll Cartridges. Refer to GP6.
Replace the Paper Feed Roll Cartridge PL 4.3 Item 2, in Tray 5 and reset the Life
Counter for the Tray 5 Paper Feed Roll Cartridge. Refer to GP6.
Run the job to verify the problem is resolved. The noise continues after replacing
the Paper Feed Roll Cartridge.
Y
N
The noise occurs with the LVPS Cooling Fan disconnected.

Y
N
Replace the LVPS Cooling Fan/Duct PL 9.1 Item 2.
The noise may be caused by the ROS or the machine electronics.
Paper Feeder Checkout Procedure

The noise occurs when the paper is feeding from one IOT Paper Tray.
Y
N
The Tray 5 / Tray 6 combination is installed.
Y
N
Replace the Paper Feed Roll Cartridge, in Tray 5 and reset the Life Counter for the
Run the job to verify the problem is resolved. The noise continues after replacing
the Paper Feed Roll Cartridge.
E
F
OF-1
Replace the HCF/Bypass Tray Assembly PL 4.2A Item 1 and reset the Life Counter
for the Tray 5 Paper Feed Roll Cartridge. Refer to GP6.
Replace the HCF Bypass Tray Feed Motor PL 4.2B Item 8.
In Component Control, select [IOT Paper Trays], [Tray X Nudger Solenoid], then [Output On],
for the IOT Paper Tray that is causing the noise. Enter [Copier Sys tab , Component Control].
May 2003
2-742
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G
Listen for noise when the Tray X Nudger Solenoid is energized. The noise occurs when the
Nudger Solenoid is energized.
Y
N
In Component Control, select [IOT Paper Trays], [All Outputs Off], [Tray X Feed Motor],
then [Output On] for the IOT Paper Tray that is causing the noise. Enter [Copier Sys tab ,
Component Control].
Listen for noise when the Tray X Feed Motor is energized. The noise occurs when the
Feed Motor is energized.
Y
N
Do the following:
In Component Control. Select [IOT Paper Trays], select [All Outputs Off].
Pull out the Paper Tray.
In Component Control, select [Tray X Elevator Motor] then [Output On], for the
IOT Paper Tray that is causing the noise. Enter [Copier Sys tab , Component
Control].

Do the following:

Developer Drives Checkout Procedure

In Component Control, ensure the Developer Drive Motor is still energized. Select [Registration
Clutch] then [Output Off]. Enter [Copier Sys tab , Component Control].
Listen for noise when the Developer Drive Motor is energized. The noise still occurs.
Y
N
Do the following:
Remove the Registration Transport Assembly (REP 08-2).
Check the gears on the Registration Transport Assembly.
One or more of the gears are worn or damaged

Y
N
Replace the Registration Clutch PL 4.1B Item 13.
If the noise continues after replacing the Registration Clutch, replace the Registration Transport Assembly PL 4.1A Item 8
Replace the Registration Gear Kit PL 4.1B Item 7.
In Component Control, ensure the Developer Drive Motor is still energized. Select [Duplex Wait
Clutch] then [Cycle Output]. Enter [Copier Sys tab , Component Control].
Listen for noise when the Duplex Wait Clutch is energized. The noise occurs ONLY when
the Duplex Wait Clutch cycles on.
Y
N
Do the following:
In Component Control, select [IOT Paper Trays], select [All Outputs Off].
Pull out the Paper Tray.
In Component Control, select [Tray X Feed Motor], then [Output On], for the IOT
Paper Tray that is causing the noise. Enter [Copier Sys tab , Component Control].
N
Replace the Paper Tray Assembly PL 4.1A Item 1.
Also reset the Life Counter for Tray X Paper Feed Roll Cartridge. Refer to GP6.
Listen for noise when the Tray X Elevator Motor is energized. The noise occurs
when the Tray Elevator Motor is energized.
Y
N
Check the Paper Feed Roll Cartridge. The Paper Feed Roll Cartridge is in
the correct position.
Y
N
Reseat the Paper Feed Roll Cartridge in the correct position.
If the problem continues, replace the Paper Feed Roll Cartridge PL 4.1A
Item 3 and reset the Life Counter for Tray X Paper Feed Roll Cartridge.
Refer to GP6.
Replace the Paper Feed Roll Cartridge PL 4.1A Item 3 and reset the Life
Counter for Tray X Paper Feed Roll Cartridge. Refer to GP6.
If the problem continues, replace the Paper Tray assembly PL 4.1A Item 3.
Listen for noise when the Tray X Feed Motor is energized. The noise occurs when the
Feed Motor is energized with the tray pulled out.
Y
N
Do the following:
Remove the Upper Rear Cover from the IOT.
Check the position of the Developer Drive Alignment Arm. It should be resting
against the SCAM PWB support bracket and not attached to the locating shaft for
the Developer drive.
The Developer Drive Alignment Arm is in the correct position.

Y
N
Move the Developer Drive Alignment Arm to the correct position.
In Component Control, select [IOT Paper Trays], select [All Outputs Off].
Do the following:
Swap a known good tray for the tray which was pulled out. Push the substitute
tray fully in.
To ensure the Developer Gear Bracket meshes correctly with the Developer Housing
drive gear, refer to the Replacement procedure in REP 04-1, then return here.
In Component Control, select [Tray X Feed Motor], then [Output On], for the
IOT Paper Tray position which was causing the noise. Enter [Copier Sys tab ,
Component Control].
Listen for noise when the Tray X Feed Motor is energized. The
noise
when the Feed Motor is energized with the substitute tray installed.
G H
V0.042
occurs
Listen for noise when the Developer Drive Motor is energized. The noise occurs after
aligning the Developer Gear Bracket to the Developer Housing drive gear.
I
May 2003
2-743
OF-1
I
Y
N
Do the following to remove drive from the Developer Housing:
K
N
Determine the Upper Paper Guide that is causing the noise by replacing each
Upper Paper Guide one at a time until the noise occurs. Replace the Upper
Guide assembly PL 4.1A Item 6 causing the noise.
Remove the Developer Drive Belt (REP 04-6).
Do the following:
Remove the Duplex Transport and switch the power [On].
Listen for noise when the Developer Drive Motor is energized. The noise occurs with
the Developer Drive Belt removed.
Y
N
Do the following:
Reinstall the Developer Drive Belt (REP 04-6).
Remove the Developer Housing (REP 09-2).
the Duplex Transport removed
Y
N
Inspect Helical Drive Gear PL 6.1B Item 3 for wear and damage.
The Helical Drive Gear is worn or damaged.
Y
N
Check the components on the Left Drive Plate Assembly PL 6.1B Item 21, for
wear and damage. Replace the Duplex Transport PL 6.1A Item 2, if necessary.
Listen for noise when the Developer Drive Motor is energized. The noise occurs
with the Developer Housing removed.
Y
N
Replace the Helical Drive Gear PL 6.1B Item 3.

Do the following:
Remove the Developer Drive Motor (REP 04-1)
Do the following:
Check the 50 tooth Gear PL 7.1 Item 10 and the 60 tooth Gear PL 7.1 Item 11.
Remove the Vertical Transport (REP 08-1) and switch the power [On].
One or both of the gears are worn or damaged.

Y
N
Replace the Developer Drive Motor PL 7.1.
Replace the Developer Gear Bracket PL 7.1 Item 2.
the Vertical Transport removed.
Y
N
Do the following:
Remove the each Upper Guide Assembly.
Reinstall the Vertical Transport and switch the power [On].
OF-1
Replace the Left Drive Plate Assembly PL 6.1B Item 21.
Fuser Drives/OCT Checkout Procedure

Do the following:
Listen for noise when the Developer Drive Motor is energized. The noise occurs
with the Upper Paper Guides removed.
Y
N
Check the idlers on the Upper Paper Guides for contamination. The idlers on
the Upper Paper Guides are free from contamination.
I
J
K
Replace the Developer Drive Motor Gear Kit PL 7.1 Item 9.
Remove the Offsetting Catch Tray Assembly.
Cheat the Right Side Interlock Switch, and switch the power [On].
Listen for noise when the Fuser Drive Motor is energized. The noise occurs with the OCT
removed.
Y
N
Go to 12-F OCT Noise RAP.
L
May 2003
2-744
V0.042
L
Do the following:
Remove the Prefuser Transport (REP 10-1).
Listen for noise when the Fuser Drive Motor is energized. The noise occurs when the
Fuser Drive Motor is energized and the Prefuser Transport is removed.
Y
N
Listen for noise when the Fuser Drive Motor is energized.

Decurler removed.
Y
N
The noise occurs with the
Do the following:
Ensure the Decurler Drive Belt has the correct tension. Refer to the replacement in REP
04-5.
Do the following:
Remove the Fuser Module.
Listen for noise when the Fuser Module is removed and the Fuser Drive Motor is energized.
The noise occurs with the Fuser Module removed.
Y
N
Check the Fuser Drive Gear for wear, damage, or excessive radial play on the shaft.
The Fuser Drive Gear is damaged, or there is excessive radial play on the shaft.
Y
N
Do the following:
Reinstall the Prefuser Transport.
Remove the Inverter and switch the power [On].
Listen for noise when the Fuser Drive Motor is energized. The noise occurs with
the Inverter removed.
Y
N
Check the mounting post on the rear of the Inverter frame. Refer to Figure 2.
The mounting post on Inverter frame is broken.
Y
N
Install the Inverter Repair Kit PL 6.2B Item 2 .
Install the Fuser Drive Gear Kit PL 7.1 Item 15.
Do the following:
Listen for noise when the Fuser Drive Motor is energized. The noise occurs.
Y
N
Do the following:
Remove the Decurler Drive Belt (REP 04-5).
Listen for noise when the Fuser Drive Motor is energized. The noise occurs with the
Decurler Drive Belt removed.
Y
N
Replace the Decurler/OCT Drive Bracket PL 7.1 Item 4.
Fuser Drives Checkout Procedure

Do the following:
Remove the Prefuser Transport (REP 10-1).
Carefully undock the Finisher from the IOT (Do not disconnect the Finisher connector).
Cheat the Right Side Interlock Switch.
Listen for noise when the Fuser Drive Motor is energized. The noise occurs when the
Fuser Drive Motor is energized and the Prefuser Transport is removed.
Y
N
Do the following:
Remove the Decurler (REP 10-3).
V0.042
May 2003
2-745

OF-1
Remove the Fuser Module.
Listen for noise when the Fuser Module is removed and the Fuser Drive Motor is energized.
The noise occurs with the Fuser Module removed.
Y
N
Check the Fuser Drive Gear for wear, damage, or excessive radial play on the shaft.
The Fuser Drive Gear is worn, damaged, or there is excessive radial play on the
shaft.
Y
N
Do the following:
Reinstall the Prefuser Transport.
Remove the Inverter and switch the power [On].
Listen for noise when the Fuser Drive Motor is energized. The noise occurs with
the Inverter removed.
Y
N
Check the mounting post on the rear of the Inverter frame. Refer to Figure 2.
The mounting post on Inverter frame is broken.
Y
N
Install the Inverter Repair Kit PL 6.2B Item 2.
Install the Fuser Drive Gear Kit PL 7.1 Item 15.

Remove the Decurler (REP 10-3).

Decurler removed.
Y
N
Do the following:
Ensure the Decurler Drive Belt has the correct tension. Refer to the replacement in REP
04-5
Do the following:
OF-1
Do the following:
Do the following:
Check for the installation of a Decurler (a Decurler is required on machines with an OCT). A
Y
N
Check the IOT for a Decurler Drive Belt.
A Decurler Drive Belt is installed
Y
N
M
Listen for noise when the Fuser Drive Motor is energized. The noise occurs.
Y
N

N
Do not reinstall the Decurler Drive Belt. It is not required on machines without a
Decurler.
Listen for noise when the Fuser Drive Motor is energized. The noise occurs with the
Y
N
Replace the Decurler/OCT Drive Bracket PL 7.1 Item 4.
PFT and Xerographic Checkout Procedure
In Component Control, select [IOT Paper Path], [PFT Vacuum Fan], then [Output On]. Enter
Listen for noise when the PFT Vacuum Fan is energized. The noise occurs when the PFT
Fan is energized.
May 2003
2-746
V0.042
N
CAUTION
Energize the Toner Bottle Motor in Component Control only long enough to determine
whether or not the noise is being caused by the Toner Bottle Motor.
Belt Tensioner
Do the following:
In Component Control, select [IOT Paper Path], [All Outputs Off], [IOT General],
[Toner Bottle Motor], [Output On], and [All Outputs Off].
In Component Control, select [IOT General] [Toner Dispense Motor], select [Output
Listen for noise when the Toner Bottle Motor is energized and when the Toner Dispense
Motor is energized. The noise occurs when the Toner Bottle Motor or the Toner Dispense Motor is energized.
Y
N
In Component Control, select [IOT General], [Photoreceptor Drive Motor], then

Developer
Drive Belt
Listen for noise when the Photoreceptor Drive Motor is energized.

The noise
occurs when the Photoreceptor Drive Motor is energized and the Xerographic
Module is removed.
Y
N
Replace the Dry Ink Dispenser PL 5.1B Item 4.
Developer Gear
Bracket
Developer Drive
Alignment Arm
Figure 1 Developer Drive Alignment Arm
V0.042
May 2003
2-747
OF-1
OF-2 Paper Damage RAP

(02Jul2002)
The copies in the Output Device are damaged (dog-ears, nicks, dings, wrinkle, etc.).
Initial Actions
If damage is occurring from a single paper tray, do the following:
Flip the ream of paper in the tray causing the problem and rerun the job.
Load a new ream of paper in the tray causing the problem and rerun the job.
If the damage occurs after performing the above actions, follow the procedure in the RAP.

The damage occurs on sheets fed from all IOT paper trays, Tray 5 (Bypass Tray), and
Tray 6 (HCF).
Y
N
The problem occurs on sheets fed from Tray 5 (Bypass Tray) and/or Tray 6 (HCF)
only.
Y
N
NOTE: A No response means the paper damage does not occur on paper fed from
Tray 5 and/or Tray 6 but occurs from one or more IOT paper trays.
The damage occurs on paper fed from Tray 5 and Tray 6
Y
N
If the damage is occurring on paper fed from Tray 5 only, do the following.
Check for damage after performing each action listed.
Location of broken mounting post.
Remove then reinstall the Paper Feed Roll Cartridge PL 4.2B Item 6 in
Tray 5.
Check the Bypass Tray Feeder PL 4.2B Item 4, for damage
If the damage is occurring on paper fed from Tray 6 only, do the following.
Check for damage after performing each action listed.
Figure 2 Broken mounting post on Inverter
Remove then reinstall the Paper Feed Roll Cartridge PL 4.2B Item 6 in
Tray 6.
Check the HCF Feeder PL 4.2B Item 3, for damage
Check the following
The paper path between the Registration Transport Assembly and the HCF/
Duplex Baffle for obstructions.
The surface of the HCF Paper Handling Baffle PL 4.2B Item 2 for nicks or contamination.
Do the following:
Ensure the HCF/Duplex Baffle PL 6.1B Item 8, is seated correctly and is free from
damage.

Transport.
A
OF-1, OF-2
May 2003
2-748
V0.042
The copy damage is wrinkle only with no other damage.

Y
N
Do the following to isolate the problem to the IOT paper path:
N
The Duplex Gate PL 6.3 Item 12 for burrs or damage.
The Inverter Entrance Gate PL 6.3 Item 13 for burrs or damage.
Remove the output device, cheat the Right Side Interlock Switch, and switch the
power [On].
The Feed/Reverse Roll Idler PL 6.3 Item 14 for burrs and ensure it is seated
correctly.
When the Configuration Details screen is displayed, select [Yes], to confirm there is
no output device installed.
The Inverter Exit Roll Idler PL 6.3 Item 14 for burrs and ensure it is seated correctly.
In [Marking tab , Print Test Pattern], select [Blank Page] and Quantity [5].
The Feed/Reverse Roll PL 6.3 Item 7, for damage and contamination.
Select [8.5" x 11"], [11" x 17"], [A3], or [A4]
Select [Options]. In the Options dialog box, select [Face Up] and [OK].
Select [Start Job].

Depending on the machine configuration, go to one of the following RAPs:
The Print Test Pattern job is free from damage.

Y
N
Y
N
The rollers on the Decurler for damage.
The Exit Baffle for damage and burrs.
The Guide Blade and the rollers on the TAG 279 Decurler for damage.
NOTE: A Guide Blade is installed on machines equipped with a Multi-Function
Finisher.
The Exit Baffle (or Decurler) is free from damage.

Y
N
Replace the defective component:
Replace the Exit Baffle PL 6.1A Item 6
Decurler PL 6.1A Item 4.
TAG 279 Decurler PL 6.1D.
12-B OCT Print Damage RAP
12-AB Finisher Print Damage RAP (Disk Finisher)
12-764 Finisher Print Damage RAP (Multi-Function Finisher - 470 Only).
OF-2 IOT Paper Tray Checkout
Depending upon the machine configuration, check one of the following:
The Inverter Exit Roll PL 6.3 Item 7, for damage and contamination.
The damage occurs on paper fed from all 4 IOT paper trays.
Y
N
Move the Paper Tray the damage is occurring from to another position. Program a job to
feed paper from the tray in its new position.
Damage occurs on paper fed from the tray in its new position.
Y
N
Return the Paper Tray to its original position.
Make the following checks on the components adjacent to the Paper Tray:
Check for obstructions between the Upper Guide PL 4.1A Item 14 and the
Lower Guide PL 4.1A Item 5.
Check the idlers on the Upper Guide PL 4.1A Item 14, for burrs and ensure
they are seated correctly.
A component in the Paper Tray is causing damage. Do the following, checking for damage after performing each action listed.
The problem only occurs on duplex jobs.

Y
N
Go to the OF-2 IOT Paper Tray Checkout.
Make the following selections in the Print Test Pattern diagnostic routine.
Remove then reinstall the Paper Feed Roll Cartridge PL 4.1A Item 3.
Replace the Paper Feed Roll Cartridge PL 4.1A Item 3.
Check the Paper Tray Feed Head PL 4.1A Item 17, for damage and obstructions.
Select [Blank Page], [Simplex], and Quantity [5].
Select [8.5" x 11"], [11" x 17"], [A3], or [A4].
Do the following:
Select [Options]. In the Options dialog box, select [Face Down], [Uncollated],
and [OK].
Check the paper path at the top of the Vertical Transport for obstructions.
Ensure the Vertical Transport is mounted correctly to the Registration Transport Assembly. Refer to REP 08-1.
Check the Vertical Transport PL 4.1A Item 7, for burrs and obstructions.
Enter [Marking tab , Print Test Pattern].
Run the five copies and check them for the copy damage. The
with Simplex, Face Down, and Uncollated selected.
B
C
V0.042
damage
occurs
May 2003
2-749
OF-2
Check the idlers on the Upper Guide - Tray 1 PL 4.1A Item 14 (Tray 1), for burrs and
ensure they are seated correctly.
OF-2
May 2003
2-750
V0.042
P5
P4
P3
Guide Blade
Decurler Position
Sensor
Decurler Gate
Solenoid
P137
Figure 1 Tag 279 Decurler Component Locations
V0.042
May 2003
2-751
OF-2
OF-3 Convenience Stapler RAP
Check the position of the Stapler Head. The Convenience Stapler remains stuck in the
down (clinched or stapled) position.
Y
N
(18Dec2000)
The Convenience Stapler is exhibiting one or more of the following problems:
The Stapler is not operating correctly (poorly clinched staples, no staples).
Do the following:
The Green LED is not illuminated (indicating the stapler not ready).
The Red LED is illuminated (indicating an out of staples condition or a staple jam).
Using the corner of a stack of 10 sheets of paper, push the Stapler Cycle Switch Actuator
to actuate the Stapler Cycle Switch.
The Convenience Stapler is stuck in the down (clinched or stapled) position.
While keeping the Stapler Cycle Switch actuated, switch off the Convenience Stapler
power switch.
Still keeping the Stapler Cycle Switch actuated, switch on the Convenience Stapler power
switch.
Initial Actions
Ensure the power switch on the back of the Convenience Stapler is in the on position.
Ensure the machine is not in the Power Saver mode.
Ensure the Convenience Stapler Harness is connected securely to the Convenience Stapler.

NOTE: After installing the new Convenience Stapler PWB, the customer cannot use the Convenience Stapler off-line. Inform the customer the Convenience Stapler will not operate unless
it is connected to the machine.
Table 1 Convenience Stapler Problems
Problem/Symptom
Action
The Stapler Head of the ConveGo to the Stapler Head Checkout Procedure.
nience Stapler is stuck in the down
(clinched or stapled) position.
The green LED is not illuminated
when the Convenience Stapler
Top Cover is closed and the Staple
Cartridge is present.
Check the Stapler Interlock Switch Actuator, located on

the Convenience Stapler Top Cover.
If the actuator is missing or damaged, replace the Convenience Stapler Top Cover PL 8.1 Item 5.
If the actuator is not damaged or missing, go to the Convenience Stapler Electrical Checkout Procedure.
The Red LED is illuminated when

the Convenience Stapler Top
Cover is closed.

If the problem continues after replacing the Staple Cartridge, go to the Convenience Stapler Electrical Checkout
Procedure to diagnose the problem.
The Convenience Stapler is not

operating correctly (no staples or
poorly clinched staples).
Go to the Convenience Stapler Mechanical Checkout

Procedure.
Check the position of the Stapler Head. The Convenience Stapler remains stuck in the
down (clinched or stapled) position.
Y
N
Replace the Convenience Stapler PWB PL 8.1 Item 15.
If the problem continues, replace the Convenience Stapler Assembly PL 8.1 Item 4.
Convenience Stapler Electrical Checkout Procedure

Ensure the Staple Cartridge is installed correctly. Close the Convenience Stapler Top Cover.
Check the Green LED on the Convenience Stapler. The green LED is illuminated.
Y
N
Check the Stapler Interlock Switch Actuator, located on the Convenience Stapler Top
Cover. Ensure that it is not missing or damaged.
The check of the Stapler Interlock Switch Actuator is good.
Y
N
Replace the Convenience Stapler Top Cover PL 8.1 Item 5.
Check the Green LED on the Convenience Stapler. The green LED is illuminated.
Y
N
Check for +24 VDC at the Convenience Stapler connector P109. Measure from the
inside of the connector (+24 VDC) to the outside of the connector (DC COM).
Y
N
NOTE: When Tag 112 is installed, the Convenience Stapler DC voltage is supplied directly from the LVPS instead of IIOC Bus 1.
Tag 112 is installed.
Y
N
The Convenience Stapler Top

Replace the Convenience Stapler Top Cover PL 8.1 Item
Cover does not remain closed dur- 5.
ing operation of the stapler.
CAUTION
To avoid possible damage to the machine electronics, ensure the Convenience Stapler connector P109 does not come in contact with the machine
frame, the card cage, or electrical components.
Stapler Head Checkout Procedure
Remove the IOT Upper Rear Cover to gain access to P/J87. Measure the
voltage between P87-2 (-) and P87-1 (+).
Do the following:
Switch off the Convenience Stapler power switch located on the back of the Convenience
Stapler.
Switch on the Convenience Stapler power switch.

A
OF-3
May 2003
2-752
D
V0.042
A
Y
N
Go to Flag 2 on Figure 2. Check the wires for an open circuit. Ensure
the wires are seated securely into the IDC connector P/J87. Repair
as required.
The Convenience Stapler operates correctly after reinstalling the Staple Cartridge.
Y
N
Replace the Convenience Stapler Assembly PL 8.1 Item 4.
Do the following:
Ensure the Convenience Stapler Harness is connected to the Convenience Stapler.
Close the Convenience Stapler Top Cover.
Check the Red LED on the Convenience Stapler. The red LED is illuminated.
Y
N
Replace the Convenience Stapler Internal DC Harness PL 8.1 Item
13.
If the problem continues, replace the Convenience Stapler PWB PL
8.1 Item 15.
Replace the Convenience Stapler Harness PL 1.5 Item 1.

If the problem continues after replacing the Staple Cartridge, replace the Convenience
Stapler Assembly PL 8.1 Item 4
Check the Red LED on the Convenience Stapler. The Red LED is illuminated.
Y
N
Attempt to staple a stack of paper.
The Convenience Stapler operates correctly (Stapler Head moves down to clinch a
staple and returns to the raised position).
Y
N
If the problem continues, replace the Convenience Stapler Assembly PL 8.1 Item 4.
CAUTION
To avoid possible damage to the machine electronics, ensure the Convenience
Stapler connector P109 does not come in contact with the machine frame, the
card cage, or electrical components.

If the problem continues after replacing the Staple Cartridge, replace the Convenience Stapler
Assembly PL 8.1 Item 4.
Remove the IOT Upper Rear Cover to gain access to P87/ J87A. Measure the
voltage between P87-2 (-) and P87-1 (+).
Y
N
Go to Flag 2 on Figure 3. Check the wires between P45A and J87A for
an open circuit.
Convenience Stapler Mechanical Checkout Procedure
Do the following:
Ensure the Convenience Stapler Harness is connected to the Convenience Stapler.
Close the Convenience Stapler Top Cover.
NOTE: The customer has described the problem as poorly clinched staples or missing staples.
The customer describes the problem as poorly clinched staples.
Y
N
Remove and then reinstall the Staple Cartridge.
The Convenience Stapler operates correctly after reinstalling the Staple Cartridge.
Y
N
The unformed staple roll may be wound too tightly or the Driver Bar may be out of
position.
Do the following:
Y
N
Replace the Convenience Stapler Internal DC Harness PL 8.1 Item 13.
If the problem continues, replace the Convenience Stapler PWB PL 8.1
Item 15.
The Convenience Stapler operates correctly after performing the Staple Cartridge Checkout Procedure.
Y
N
Replace the Staple Cartridge and attempt to staple a stack of documents.
The Convenience Stapler operates correctly after replacing the Staple
Cartridge.
Y
N
Replace the Convenience Stapler Assembly PL 8.1 Item 4.
Replace the Convenience Stapler Harness PL 1.5 Item 1.
Y
N
Remove and the reinstall the Staple Cartridge.
A
E
V0.042
F
May 2003
2-753
H
OF-3
H

The customer is attempting to staple a set that is greater than 50 sheets of 20 lb. (80
gsm) or equivalent thickness.
Y
N
Replace the Staple Cartridge in the Convenience Stapler
Inform the customer the stapling capacity of the Convenience Stapler is 50 sheets of 20 lb. (80
gsm) or equivalent thickness.
Convenience
Stapler Top
Cover
Stapler
Head
Red LED
Green LED
Stapler Cycle
Switch Actuator
Figure 1 Convenience Stapler Components
OF-3
May 2003
2-754
V0.042
Figure 2 OF-3 RAP Circuit Diagram (without Tag 112)
V0.042
May 2003
2-755
OF-3
Figure 3 OF-3 RAP Circuit Diagram (with Tag 112)
OF-3
May 2003
2-756
V0.042
OF-4 40 ppm IOT Odor, Heat and Dirt RAP.
Check the seal on the Xerographic Module. Replace the Xerographic

Module PL 5.1A Item 1 if required.
(09Jul2001)
Ensure there are no foreign objects or paper preventing the seal on the
Xerographic Module from making contact with the Xerographic Blower.
Indicators of an air flow problem include, increased ozone odor during machine operation,
excessive dirt in the machine, dirt being blown out of the IOT, excessive dirt inside the IOT, no
air flow out of the IOT, repeated premature replacement of the Xerographic Module, buildup of
toner inside the Xerographic Module manifold, or Image Quality problems.
The housing that contains the Xerographic Module dirt filter is cracked.
Y
N
In Component Control, select [IOT Paper Path], [Fuser Fan], then [Output On].
The Fuser Fan energizes in Component Control.
Y
N
Initial Actions
If there is a burning odor coming from the machine, and the odor is traced to the AC Distribution Panel, replace the AC Distribution Panel PL 1.2A Item 1 (TAG 053).
Check the Fuser Fan/Duct for obstructions and ensure it is correctly mounted.

In Diagnostic Navigator, select the [Faults/Counters] tab. Select the [Counters Display] button.
In [Counters Display], select the [Diagnostic Data] tab.
Read the value displayed for NOHAD Filter Life. The value for NOHAD Filter Life is equal
to or greater than 2 million.
Y
N
The problem is repeated premature replacement of the Xerographic Module,
buildup of toner inside the Xerographic Module manifold, or an increased ozone
odor during machine operation.
Y
N
Check the Fuser Dirt Filter PL 9.1 Item 12.
The Fuser Dirt Filter is installed and is free from dirt and contamination.
Y
N
Replace the Fuser Dirt Filter PL 9.1 Item 12.

An 03-801 or an 03-813 fault is declared.
Y
N
Do the following:
In Component Control, select [IOT Paper Path], [Xerographic Blower], then

The Xerographic Blower energizes in Component Control when the Xerographic Module is removed.
Y
N
Replace the Xerographic Blower PL 9.1 Item 11.
Check the Ozone Filter PL 9.1 Item 4. The Ozone Filter is installed and is free
from dirt and contamination.
Y
N
Replace the NOHAD Filter Kit PL 9.1 Item 1, and reset the NOHAD Filter Life
counter. Refer to GP6.
Check the seal on the Xerographic Module. The seal on the Xerographic Module is free from damage and is making contact with the housing of the Xerographic Blower.
Y
N
Do the following:
The Xerographic Blower is mounted correctly to the machine frame.

The seal on the Xerographic Module. Replace the Xerographic Module PL

5.1A Item 1 if required.
Y
N
there are no foreign objects or paper preventing the seal on the Xerographic Module from making contact with the Xerographic Blower.
Y
N
Y
N
Check the seal on the Xerographic Module. The seal on the Xerographic Module
is free from damage and is making contact with the housing of the Xerographic Blower.
Y
N
Do the following:
A
B
V0.042
Ensure the Xerographic Blower is mounted correctly to the machine

frame.
Check the Fuser fan/Duct for obstructions and ensure it is correctly mounted.
A
May 2003
2-757
E
OF-4
E
03-801 RAP.
03-813 RAP.
Replace the PL 9.1 Item 1, and reset the NOHAD Filter Life counter. Refer to GP6.
OF-4
May 2003
2-758
V0.042
OF-5 55 ppm and 65 ppm IOT Odor, Heat And Dirt RAP.
(09Jul2001)
Indicators of an air flow problem include, increased ozone odor during machine operation,
excessive dirt in the machine, dirt being blown out of the IOT, excessive dirt inside the IOT, no
air flow out of the IOT, repeated premature replacement of the Xerographic Module, buildup of
toner inside the Xerographic Module manifold, or Image Quality problems.
C
Y
N
Do the following:
Initial Actions
If there is a burning odor coming from the machine, and the odor is traced to the AC Distribution Panel, replace the AC Distribution Panel PL 1.2A Item 1 (TAG 053).

frame.

Module PL 5.1A Item 1 if required.
Y
N
Y
N

In Diagnostic Navigator, select the [Faults/Counters] tab. Select the [Counters Display] button.
In [Counters Display], select the [Diagnostic Data] tab.
Read the value displayed for NOHAD Filter Life. The value for NOHAD Filter Life is equal
to or greater than 2 million.
Y
N
The problem is repeated premature replacement of the Xerographic Module,
buildup of toner inside the Xerographic Module manifold, or an increased ozone
odor during machine operation.
Y
N
In Component Control, select [IOT Paper Path], [ROS/Developer Fan], then [Output
The ROS/Developer Fan energizes in Component Control.
Y
N
Replace the ROS/Developer Cooling Fan Assembly PL 9.1 Item 6.
An 03-801 or 03-813 fault is declared.
Y
N
Do the following:
Check the Fuser Dirt Filter PL 9.1 Item 12.

The Fuser Dirt Filter is installed and is free from dirt and contamination.
Y
N
Replace the Fuser Dirt Filter PL 9.1 Item 12.

Y
N
Check the Ozone Filter PL 9.1 Item 4. The Ozone Filter is installed and is free
from dirt and contamination.
Y
N
Replace the NOHAD Filter Kit PL 9.1 Item 1, and reset the NOHAD Filter Life
counter. Refer to GP6.
Y
N
Do the following:
Do the following:


frame.
Y
N

Blower PL 5.1A Item 1 if required.
A
B
V0.042
A
May 2003
2-759
D
OF-5
D
Y
N
Y
N
OF-6 Status Messages

(30Apr2001)
The tables referenced in this procedure describe status messages, the conditions that cause
the status to be raised, the function disabled, the conditions required to clear the status, and
the RAP to go to or the action to take if the status cannot be cleared.
To view the active status codes, select the Machine Status Pathway button, then make the following selections on the Touch Screen; Faults and Active Statuses.

Go to one of the following Tables:
03-801 RAP.
Go to one of the following Tables:
03-813 RAP.
Replace the NOHAD Filter Kit PL 9.1 Item 1, and reset the NOHAD Filter Life counter. Refer to
GP6.
OF-5, OF-6
OF-6A 01-5XX and 02-5XX Status Message RAP.
OF-6B 03-5XX Status Message RAP.
OF-6C 05-5XX (Document Feeder) Status Message RAP.
OF-6D 06-5XX and 07-5XX Status Message RAP.
OF-6E 08-5XX Status Message RAP.
OF-6F 09-5XX (Xerographic) Status Message RAP.
OF-6G 10-5XX Status Message RAP.
OF-6H 12-5XX (Finisher and OCT) Status Message RAP.
OF-6J 14-5XX (Scanner) Status Message RAP.
OF-6K 16-5XX (ESS) Status Message RAP.
OF-6L 19-5XX, 21-5XX, and 22-5XX Status Message RAP.
May 2003
2-760
V0.042
OF-6A 01-5XX and 02-5XX Status Message RAP
(28Feb2001)
015XX and 02-5XX Status Messages
Table 1 01-5XX and 02-5XX Status Messages
Function
Disabled
Condition
Required to
Clear
Status
Action
Status
Number
UI Message
Condition to Set Status
01-510
The front door is open.
The Front Door Interlock

Switch is open.
01-512
Ensure the input and out- +36 VDC off line or 01-310 Printing
put devices are installed
fault
correctly, or call for service
01-513.6
Check that the Tray 5

cover is closed.
01-540.1
Check the settings for Tray An operator adjustable tray Feeding

1
is inserted or the size
from Tray 1
changes from power up.
The tray set- N/A

tings are
confirmed or
the tray is
opened.
01-540.2

2
from Tray 2
The tray set- N/A

tings are
confirmed or
the tray is
opened.
01-540.3

3
from Tray 3
The tray set- N/A

tings are
confirmed or
the tray is
opened.
01-540.4

4
from Tray 4
The tray set- N/A

tings are
confirmed or
the tray is
opened.
01-540.5
Check the settings for Tray Tray 5 detects paper for

5
greater than 1 second
after being empty or the
size changed from power
up
Printing
The HCF Interlock is open Printing
V0.042
When the
Go to 01Front Door is 301
closed
+36 VDC on Go to RAP
line
01-F
HCF Interlock Closed
Go to 01305
Feeding
The tray set- N/A
from Tray 5. tings are
confirmed or
the tray is
opened.
May 2003
2-761
OF-6A
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
01-545.1
Tray 1 is a dedicated paper A fixed size tray is inserted Feeding

tray. Reload required stock with the guides not at the from Tray 1
pre-set size position.
and adjust the guides.
N/A
The tray is
opened or
the size is
set to match
the position
of the
guides.
01-545.2

N/A
The tray is
opened or
the size is
set to match
the position
of the
guides.
01-545.3

N/A
The tray is
opened or
the size is
set to match
the position
of the
guides.
01-545.4

The tray is
N/A
opened or
the size is
set to match
the position
of the
guides.
02-515
The Printer is not available.

The User Interface is not
available. Please call for
assistance.
02-520
02-585
There may be a problem

with the Touch Screen or
button selections.
OF-6A
Local UI Failure
Local UI
Exit Diagnostics
Go to 02-A
When fault 02-320 is

declared.
System is
unavailable
Switch the
power [Off]
then switch
the power
[On].
Go to 02320/380
When the following faults

are declared: 02-309, 02704, 02-705, 02-712, 02715.
None
UI Power On Go to 02Self Test

309/364, 02312/704, 02705/706, 02707/715, or
02-709/712.
May 2003
2-762
V0.042
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
02-590
Power Up has failed.

Press the button on the
right side of the machine
to power down. Then turn
the power on using the
same button. If the problem persists call Xerox for
assistance.
All
Configurable services
have not reached a stable
state within 5 minutes of
power up.
Switch the
Go to 02power [Off] 390/391
then switch
the power
[On] then all
services
much reach
a stable
state within
5 minutes.
02-591
Power up has failed.

All services that the UI is All
Press the button on the
waiting for do not appear in
right side of the machine
the registry.
to power down. Then turn
the power on using the
same button. If the problem persists call Xerox for
assistance.
Switch the
Go to 02power [Off] 390/391
then switch
the power
[On] then all
relevant services the UI
is waiting for
should
appear in
the registry.
V0.042
May 2003
2-763
OF-6A
OF-6B 03-5XX Status Message RAP
(28Feb2001)
03-5XX Status Messages
Table 1 03-5XX Status Messages
Status
Number
UI Message
03-501
The machine has received Printing,

a request from the network scanning,
to reset the entire system and filing.
(i.e. all platforms). Any
jobs that are currently
being marked will be canceled & existing jobs within
the input queue will be preserved.
03-505
System Fault - Please call When certain POST failfor assistance.

ures are detected (see
fault 03-348 for details).
03-515

Printing Fault - Please call
for assistance.
OF-6B
Function
Disabled
When fault 03-301, 03305, 03-311, 03-312, 03313, 03-314, or 03-350 is

raised during the Power
Up sequence
Condition
Required to
Clear
Status
Action
None for the N/A
user (i.e.
user cannot
clear the
remote reset
operation at
the local UI),
system
automatically reboots
which eliminates the
request-forreboot state.
Scanner and Initialization In [Faults/

IOT
Complete
Counters tab
, Faults],
check [Last
40] for 033XX and
12-3XX
faults. Go
to the RAP
for the fault
or faults displayed.
Printing and Main Controller reset
copy Job
or Power Off
programming
Go to 03301/305, 03311, or 03312/313/314
May 2003
2-764
V0.042
Status
Number
03-516
UI Message
The Scanner is not available. Please call for assistance.

Scanner Fault. Please call
for assistance.
When fault 03-321, 03-352

or 03-354 is declared during the Power up
sequence or when fault
03-322 is raised on two
successive software
upgrade attempts
Function
Disabled
Condition
Required to
Clear
Status
Action
Go to 03Main ConScanning
and Scan to troller Reset 321, 03-352,
File job pro- or Power Off or 03-322
gramming
03-518 (ST/ Copier services available. When fault 03-332 is

LP only)
raised.
Go to 03Scan to file Main Conjob program- troller reset 332

or Power Off
ming and
network
printing.
03-520

raised.
None
Power Off / Go to 03Power On or 346

communication reestablished
between the
UI and the
Main Control
PWB.
03-521

raised.
None
When com- Go to 03munication 347

is reestablished
between the
UI and the
Main Control
PWB, or
when status
03-520 is
raised.
03-535
Diagnostics are active and When a diagnostics sesthe system is available.

sion is initiated by an
authorized user via a
locally or remotely connected PWS
V0.042
Power Saver When there N/A

are no active
diagnostics
sessions in
progress.
May 2003
2-765
OF-6B
Status
Number
Function
Disabled
UI Message
03-536
Diagnostics are active.

The system is not available. Please wait.
When an intrusive diagnostic routine is initiated by

an authorized user via a
locally or remotely connected PWS
03-541
Press Resume/Cancel
Job is incomplete, print

Printing
service is ready to run and
needs a resume command.
03-555
All machine
operations
that have not
been initiated by
authorized
users via
locally or
remotely
connected
PWS
Note: When
this status is
active, status 03-535
should be
masked so
that it is not
displayed to
the user.
Condition
Required to
Clear
Status
Action
When there N/A
are no active
intrusive
diagnostic
activities in
progress or
when the
PWS initiates a
request to
change to
Non Intrusive Diagnostics
Resume or
Cancel Job
command
from UI
N/A
No more than 50 sheets

The number of sheets to
can be stapled. Output will staple exceeds 50.
not be stapled.
Stapling
Stapling
from run or deselected.
running from
standby
N/A
03-556

Image Disk offline. Jobs
may take longer than normal. Please call for assistance.
Image Disk
(System
runs in Diskless Mode)
03-557
Please wait... The Scanner When fault 03-321 is

is attempting to recover.
declared
OF-6B
When certain Main Controller PWB POST failures

are detected (see fault 03348 for details) or when
fault 03-349 is detected.
Main ConGo to 03troller Reset 348

or Power
Off.
Document
When comFeeding and munication
Scanning
is reestablished with
the SCVM
Go to 03321
May 2003
2-766
V0.042
Status
Number
03-558
UI Message
When the Foreign InterCopying is being prevented by the access con- face is configured and a
connected 3rd Party
trol device.
accessory is reporting that
it is not enabled.
03-559
Function
Disabled
Scanning,
copy job
programming, and
marking of
copy jobs
Condition
Required to
Clear
Status
Action
When the
N/A
Foreign
Interface is
configured
and a connected 3rd
Party accessory is
reporting
that it is
enabled.
System contains non-held System not

available
jobs controlled by 3rd
party access control
device when device Not
Ready.
When status 3-558

clears or
these jobs
are deleted
by the Foreign Interfaces job
termination
timer.
N/A
When the IOT detects a

System not
Tray 3/Tray 4 or FX Billing available
Meter configuration mismatch during the Power
On Sequence
Power Off
N/A
03-560
The machine configuration is invalid.
03-561
Please wait... The System Whenever system initiates IOT

a reset of Serial Command
Bus or when the system
resets SCVM, IPS and
Main Controllers on
Atlanta.
When the
N/A
SCAM,
RCM, and
Finisher
modules are
all successfully up and
running, or
when status
03-515, 03516, 03-556,
or 03-565
03-562
Some jobs have been

deleted.
When the
N/A
operator
acknowledges the
fault via a UI
invocation
Whenever the System ini- None

tiates a reset of the SCVM,
IPS, and Main Controllers
on the Main Controller
PWB
V0.042
May 2003
2-767
OF-6B
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
03-563
Scan to File is not available.

or
The scan to file service is
not available. Please call
for assistance.
When a fault 03-331 is

declared
03-564
Image RotaImage rotation is not avail- When certain Main Conable. Please call for assis- troller PWB POST failures tion
tance.
are detected (see fault 03348 for details)
03-565

System Fault. Please call
for assistance.
When certain Main Controller PWB POST failures

are detected (see fault 03348 for details) or when
fault 03-349 or 03-350 is
detected.
Scanner,
Print
Engine,
copy job
programming, and
Scan to File
job programming
03-566 (FX
Only)
Turn the power to the

machine OFF, then ON
again. Machine may
require service.
Whenever fault 03-360 is

raised or when EP-SV
reports a failure has
occurred between the EPSV and an attached EPSV accessory
Scanning,
Main ConGo to 03printing,
troller Reset 360
copy job
or Power Off
programming, and
Scan to File
job programming
03-567 (FX
Only)
Insert Xerox card or coins

to enable scanning and
printing.
Whenever the EP-SV

reports an accessory not
ready status
Scanning,
printing,
copy job
programming, and
Scan to File
job programming
OF-6B
Scan to File When com- N/A

job program- munication
is reestabming
lished with
the ESS or
when status
03-518 is
raised.
N/A
Main Controller Reset
or Power
Off.
Go to 03Main Controller Reset 345
or Power
Off.
Whenever
N/A
the EP-SV
reports an
accessory
ready status.
May 2003
2-768
V0.042
Status
Number
UI Message
03-568 (FX
Only)
System is unavailable.
Diagnostics are active.
When any of the following

events occur: The EP-SV
requests the display of this
message. Whenever
machine enables the EPSV to update its NVM
03-569 (FX
Only)
Function
Disabled
Condition
Required to
Clear
Status
Action
Scanning,
Printing,
Copy Job
programming, Scan
to File job
programming, and
network job
submissions
When any of N/A

the following events
occur: The
EP-SV
requests a
new message display.
The EP-SV
indicates
that the
NVM update
is complete
for the EPSV.
System status is reporting Whenever the EP-SV

to the Telephone Center.
requests this message to
be displayed
None
N/A
Whenever
the EP-SV
requests a
new message display
03-570 (FX
Only)
System status has been

reported to the Telephone
Center.
Whenever the EP-SV

be displayed
None
Whenever
N/A
the EP-SV
requests a
new message display
03-571 (FX
Only)
Please call the Telephone

Center to report the system failure.
Whenever the EP-SV

be displayed
None
Whenever
N/A
the EP-SV
requests a
new message display.
03-572 (FX
Only)
The EPSV accessory is

ready.
Whenever the EP-SV

be displayed
None
Whenever
N/A
the EP-SV
requests a
new message display
V0.042
May 2003
2-769
OF-6B
Status
Number
UI Message
03-573 (FX
Only)
Diagnostic request has

failed.
If machine does not

None
receive a request to sent
NVM data from the EP-SV
within 7 minutes of sending a preemptive diagnostic request to the EP-SV or
if machine completes
sending the requested
NVM data but does not
receive the results of the
preemptive diagnostics
Any new
selection at
the PWS
N/A
03-574 (FX
Only)
The Check-up request has If machine does not

None
failed. Please contact
receive a request to sent
Telephone center directly. NVM data from the EP-SV
within 7 minutes of sending a preventive maintenance request to the EPSV or if machine completes sending the
requested NVM data but
does not receive the
results of the preventive
maintenance.
Any new
selection at
the UI
N/A
03-575 (FX
Only)
Please wait. Preventative

maintenance is in
progress.
When the
N/A
EP-SV
requests a
new message display
03-576 (FX
Only)
Request for data collection When the EP-SV confirms None

has been sent.
that the request for data
collection was sent
Any PWS
selection
N/A
03-577 (FX
Only)
Request for data collection When the EP-SV confirms None

has failed.).
that the request for data
collection failed
Any PWS
selection
N/A
03-578 (FX
Only)
Service Call is now complete.
When the EP-SV reports

that the Service Call was
closed out
None
Any PWS
selection
N/A
03-579 (FX
Only)
Service Call is not complete.
When the EP-SV reports

that the Service Call was
not closed out
None
Any PWS
selection
N/A
OF-6B
When the user requests

preventive maintenance
from the UI
Function
Disabled
Condition
Required to
Clear
Status
Action
Scanning,
printing,
copy job
programming, and
Scan to File
job programming
May 2003
2-770
V0.042
Status
Number
UI Message
Function
Disabled
03-580 (FX
Only)
When user makes a pre- None

System may be idle in
order to request Check-up/ ventive maintenance
request via the UI and the
Repair.
System is not idle
03-585
Turn the power OFF, then

ON again. Machine may
require service.
IIOC Failure
Printing
03-586
Trays X and Y are not

assistance.
03-587
Condition
Required to
Clear
Status
Action
Any PWS
selection
N/A
Power Off/
Power On
In [Faults/
Counters tab
, Faults],
check [Last
40] for 038XX faults.
Go to the
RAP for the
fault or faults
displayed.
IIOC Failure
Trays X & Y Power Off/

Power On
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
Tray 1 Not Available.
IIOC Failure
Tray 1
Power Off/
Power On
Go to 03804
03-588
IIOC Failure
Tray 2
Power Off/
Power On
Go to 03805
03-589
IIOC Failure
Tray 3
Power Off/
Power On
Go to 03824
03-590
IIOC Failure
Tray 4
Power Off/
Power On
Go to 03825
03-591
Trays X and Y are not

assistance.
IIOC Failure
Trays 3 &
Tray 4.
Power Off/
Power On
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
V0.042
May 2003
2-771
OF-6B
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
03-592
2 Sided output is not avail- IIOC Failure

able.
Duplex and
Face Up
Simplex
Power Off/
Power On
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
03-592 (FX
Only)
2 Sided, and 1 Sided face IIOC Failure

up output are not available.
Duplex and
Face Up
Simplex
Power Off/
Power On
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
03-593
Trays 5 and 6 are not avail- IIOC Failure

able. Please call for assistance.
SMH / HCF
Power Off/
Power On
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
03-596
The finisher is not availIIOC Failure

able. Please call for assistance.
Finishing
Power Off/
Power On
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
03-597
The Document Feeder is IIOC Failure

not available. Use the
Document Glass.
Please call for assistance.
Document
Feeding
Power Off/
Power On
Go to 03800
OF-6B
May 2003
2-772
V0.042
OF-6C 05-5XX (DADF) Status Message RAP
(28Feb2001)
05-5XX (DADF) Status Messages
Table 1 05-5XX (DADF) Status Messages
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
05-507
Check for a stray original

in the Document Tray.
Unscheduled document
None
detected by any Document
Feeder sensor.
Delivery of
unscheduled documents plus
press Start.
N/A
05-511
The Document Feeder

cover is open.
The Document Feeder

cover is open.
Document
Feeder
cover is
closed
Go to 05-K
05-512
The document feeder is

open.
Document Feeder is open Document

(raised)
Feeder
scanning
05-515
The Document Feeder is Document transport fault

not available. Use the
indicates service is
Document Glass.
required.
Please call for assistance.
Document
Feeder
scanning
Service
action or
Power Off/
Power On
In [Faults/
Counters tab
, Faults],
check [Last
Go to 05365/375 or
05-370/380
05-525
The Document Feeder is

empty.
Document Input Tray

empty
Document
Feeder
scanning
Document
placed in
Document
Input Tray
Go to 05-C
05-535
Document in the Document Feeder.
The Document Loaded

Sensor senses a document in the Document
Input Tray.
None
Document
Input Tray
empty
Go to 05100
V0.042
Document
Feeder
scanning
Document
Go to 05-J
Feeder is
closed (lowered)
May 2003
2-773
OF-6C
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
05-550
The Scanner is not ready. Document never made the Document

Clear the misfeed in area Document Tray Input Sen- Feeder
6a of the document feeder. sor, document on the Doc- Scanning
ument Tray Input Sensor,
document never made
Reg. Gate Sensor, document on the Reg. Gate
Sensor, or document never
made the CVT SOS Sensor.
Top Cover
opened and
closed and
no paper on
the Document Tray
Input Sensor
or the Reg.
Gate Sensor.
In [Faults/
Counters tab
, Faults],
check [Last
40] for 05XXX faults.
Go to the
RAP for the
fault or faults
displayed.
05-555
Clear the misfeed in area

6a of the Document
Feeder
Doc. never made the Input Document

Tray Exit Sensor, Doc. on Feeder
the Input Tray Exit Sensor, Scanning
Doc never made the Reg.
Gate Sensor, Doc. on Reg.
Gate Sensor, Doc. never
made CVT SOS Sensor,
and status 05-565 present.
DADF Top
Cover raised
and lowered,
and no
paper on the
Input Tray
Exit Sensor
or on the
Reg. Gate
Sensor.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
05-565
The Scanner is not ready. Doc. on Reg. Gate Sensor, Document

Clear the misfeed in area Doc. never made CVT
Feeder
6b of the document feeder SOS Sensor, Doc. on CVT Scanning
SOS Sensor, Doc. never
made DADF Exit/Invert
Sensor, or Doc. on DADF
Exit/Invert Sensor.
Document
Handler
raised &
lowered and
no paper on
the Reg.
Gate Sensor, the CVT
SOS Sensor, or the
DADF Exit/
Invert Sensor.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
05-570
Re-sort and reload ALL

the originals in the document feeder.
RESUME
JOB command is
given with
documents
in input tray
if required,
or CANCEL
JOB command is
given.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
OF-6C
Document jam is cleared, Document

Document Feeder Cover Feeder
closed, Document Feeder Scanning
closed (lowered), and the
IIT is ready to recover.
May 2003
2-774
V0.042
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
05-570 (FX
Only)
Feed Roll Cartridge needs Document jam is cleared, Document

to be replaced.
Document Feeder Cover Feeder
closed, Document Feeder Scanning
closed (lowered), and the
IIT is ready to recover.
RESUME
JOB command is
given with
documents
in input tray
if required,
or CANCEL
JOB command is
given.
05-571 (FX
Only)
Set by CSE via the PWS.

The Feed Roll has been
replaced.
or
The feed roll cartridge has
been replaced.
N/A
Automatically cleared
0.5 seconds
after being
set
V0.042
None
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
May 2003
2-775
OF-6C
OF-6D 06-5XX and 07-5XX Status Message RAP
(28Feb2001)
06-5XX and 07-5XX Status Messages
Status
Number
Function
Disabled
UI Message
06-511

Pull out the Xerographic
Module, then firmly push it
back in.
The system is capable of

communicating with the
Xerographic Module
CRUM chip and the ROS
interlock is open. Fault
code 06-380 is declared.
06-515

again. Machine may
require service.
Unclearable ROS fault, 06- Printing

310/311/312/313/314/315,
06-320/330, 06-340, 06341 , 06-350/360/370.
07-505.6
Press the button on Tray 6 Initialization Incomplete

to raise the tray to feed
Fuel Gauge NVM equals
position.
255
07-512.6
Printing
Condition
Required to
Clear
Status
Action
Xerographic Go to 06Module
380
CRUM Chip
detected OK
and the
ROS interlock is
closed.
Service
action or
successful
power on.
In [Faults/
Counters tab
, Faults],
check [Last
40] for ROS
faults. Go to
the RAP for
the fault or
faults displayed.
HCF Feeding
When tray
starts to
raise
Go to 07202.06
Close Tray 6 door to raise HCF Door Interlock open.

the tray to feed position.
HCF Feeding
HCF Door
Interlock
closed.
Go to 01305
07-514.1
Tray 1 is open
Tray X is not pushed in
Tray 1 feed- Tray 1 is

ing
pushed in
Go to 07202.01/
202.02/
202.03/
202.04
07-514.2
Tray 2 is open
Tray 2 is not pushed in

ing
pushed in
07-202.01/
202.02/
202.03/
202.04
OF-6D
May 2003
2-776
V0.042
Status
Number
UI Message
07-514.3
Tray 3 is open

ing
pushed in
Go to 07202.01/
202.02/
202.03/
202.04
07-514.4
Tray 4 is open

ing
pushed in
Go to 07202.01/
202.02/
202.03/
202.04
07-515.1
Tray 1 is not available.

Please call for assistance
Paper present sensor still Tray 1 Feed- Tray 1 open Go to 07indicates no paper present ing
202.01/
202.02/
202.03/
202.04
07-515.2

202.01/
202.02/
202.03/
202.04
07-515.3

202.01/
202.02/
202.03/
202.04
07-515.4

202.01/
202.02/
202.03/
202.04
07-515.6
Tray 6 contains too much

paper. Do not load past
the Fill Line.
Tray 6 Stack Height Sen- Tray 6 Feedsor is not LOW after Eleva- ing
tor Down Motor On while
tray down status is in effect
Load/Run
Go to 07-A
Switch
pressed or
Tray 6 Interlock Switch
opened
07-520.6
Tray 6 is low on paper.
Fuel Gauge NVM is

greater than 107 and not
greater than 255
Load paper N/A

and return to
fuel gauge
less than or
equal to 110
and not
greater than
255
V0.042
Function
Disabled
Condition
Required to
Clear
Status
Action
None
May 2003
2-777
OF-6D
Function
Disabled
Condition
Required to
Clear
Status
Action
Misfeed
Feeds from
Tray 1
Tray 1
pushed in
Go to 08101.01/.02/
.03/.04
Check Tray 2
Misfeed
Feeds from
Tray 2
Tray 2
pushed in
Go to 08101.01/.02/
.03/.04
07-525.3
Check Tray 3
Misfeed
Feeds from
Tray 3
Tray 3
pushed in
Go to 08101.01/.02/
.03/.04
07-525.4
Check Tray 4
Misfeed
Feeds from
Tray 4
Tray 4
pushed in
Go to 08101.01/.02/
.03/.04
07-525.5
Add paper to Tray 5.
Tray 5 is empty (Bypass

Tray or HCF/Bypass Tray
combination)
Feeds from
Tray 5
Tray 5
detects
paper
N/A
07-525.6
Add paper to Tray 6
Tray 6 is empty (HCF/

Feeds from
Bypass Tray combination) Tray 6
Tray 6 raised Go to 07to feed

202.06
height
07-530.6
Tray 6 is not ready.
When fault 07-202.06 is

declared.
Go to 07When the
HCF eleva- 202.06
tor is sensed
at its normal
feed position
07-570 (FX
Only)
Feed Roll needs replacement. Please contact Fuji

Xerox for assistance.
Number of feeders with

None
PDRN XX is greater than
the number of Feed Head
Notifications sent and the
EP-SV is connected
Number of
N/A
feeders with
PDRN XX is
equal to the
number of
Feed Head
notifications
sent. System must
wait 0.5 seconds prior to
updating the
Feed Head
notifications
sent value.
07-571 (FX
Only)
Feed head ERU replaced

(no message for FX EPSV).
Set by CSE through PWS. None
AutomatiN/A
cally @ 0.5
seconds
after setting.
Status
Number
UI Message
07-525.1
Check Tray 1
07-525.2
OF-6D
HCF Feeding
May 2003
2-778
V0.042
OF-6E 08-5XX Status Message RAP
(28Feb2001)
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
08-535.5
Remove and restack the

misfed sheet in Tray 5.
Misfeed while tray is not

empty
Tray 5 feed- Empty, then

ing
fill Tray 5 to
toggle the
Tray 5 Paper
Loaded
Sensor
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
08-535.6
Remove misfed sheet from Misfeed while tray is not

Tray 6.
low (HCF/Bypass Tray
combination)
Tray 6 feed- Actuate the

ing
Load/Run
Switch to
raise Tray 6
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
08-540
Clear the jam in area 1.
Trays 1
through 4
Feeding
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
Paper detected in area 1

after cycle down
V0.042
IOT Front
Door closed
and Registration Sensor clear
May 2003
2-779
OF-6E
Status
Number
08-542.5
UI Message
Function
Disabled
Open the Tray 6 cover and Paper on the Tray 5 trans- Tray 5 feedremove any misfed sheets port (Bypass Tray)
ing
from area 7.
or
Open the Tray 5 cover and
remove any misfed sheets
from area 7a.
Condition
Required to
Clear
Status
Action
No paper on
Registration
Sensor after
closing the
Tray 5 Cover
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
No paper on
Registration
Sensor after
closing the
Tray 6 Cover
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
NOTE: The first message

is incorrect. The message
has been corrected in
L0.18.0 S/W
08-542.6
Open the Tray 6 cover and Paper on the Tray 6 trans- Tray 6 feeding
remove any misfed sheets port (HCF/Bypass Tray
combination)
from area 7a.
or
Open the Tray 5 cover and
remove any misfed sheets
from area 7a.
NOTE: The first message
is incorrect. The message
has been corrected in
L0.18.0 S/W
08-555
Clear the jam in area 2

after cycle down
Printing
IOT Front
Door closed
and PFT
Sensor clear
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
08-555 and
08-540
Clear the jam in areas 1

and 2.

and area 2 after cycle
down
Trays 1
through 4
Feeding
IOT Front
Door closed,
Registration
Sensor and
PFT Sensor
clear.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
OF-6E
May 2003
2-780
V0.042
OF-6F 09-5XX (Xerographic) Status Message RAP
(28Feb2001)
09-5XX (Xerographic) Status Messages
Table 1 09-9XX (Xerographic) Status Messages
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
09-510

Check the Xerographic
Module. Ensure that the
proper unit has been
installed.
Machine is capable of
communicating with the
CRUM but no Xerox data
found in the ROM area of
the CRUM
09-511
Pull out the Xerographic

Machine fails to establish
Module, then firmly push it communication with Xeroback in.
graphic Module CRUM
Chip with ROS interlock
open or closed
09-350 fault Go to 09354
09-513

installed.
The software has detected Printing

an invalid Xerographic
Module print count and or
invalid pixel usage value.
Go to 09Max. Print
351
Volume
Value Print
Count and
Max. Pixel
Usage Value
Pixel Usage
when the
Xerographic
Module is
closed.
09-514

installed.
The software has detected Printing

an invalid Xerographic
Module for machine configuration.
The correct Go to 09Xerographic 354

Module is
detected
when the
Xerographic
Module is
closed.
09-515

Printing Fault. Please call
for assistance.
Unclearable 09-312 process control fault
Fault 09-334 Go to 09or 09-330

312
V0.042
Printing
Xerox Data
read from
the ROM
area of the
CRUM when
the Xerographic
Module is
pushed in.
Replace
Xerographic
Module PL
5.1A Item 1.
May 2003
2-781
OF-6F
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
09-516
Xerographic failure.
Please replace the Xerographic Module.
None
Cleaner, Ground Brush,
Charge and or Photoreceptor Failure(s) are
detected when running the
Xerographic Set Up.
Successful
completion
of the Xerographic Setup
09-517
Service needed.
Fault 09-355: Service Plan Printing

is set to Other and S/W
can not communicate with
either the Xerox Xerographic CRUM or the aftermarket Xerographic
CRUM.
Machine is Go to 09capable of
355.
communicating with
the Xerox
Xerographic
CRUM or
the Aftermarket
Xerographic
CRUM when
the ROS
interlock is
closed.
09-519
REMINDER: Order a new

Xerographic Module.
When either of the follow- None

ing criteria are met: Prints
left to end of life/ave. daily
print volume is less than or
equal to 3 to 25 days (10
days being the default), or
Toner waste volume left to
end of life/ave. daily toner
waste volume is less than
or equal to 3 to 25 days
(10 days being the
default).
When the
N/A
Xerographic
Module is
replaced or
status 09573
09-519 and
10-519
Order both Xerographic

and Fuser Modules.
When status 09-519 and

10-519 are raised.
When the
N/A
Xerographic
Module and
the Fuser
Module are
replaced or
status 09573 and 10573 raised.
OF-6F
None
Replace
Xerographic
Module PL
5.1A Item 1.
May 2003
2-782
V0.042
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
09-520
Replace the Xerographic When either of the follow- None

Module now to avoid inter- ing criteria are met: Prints
ruption of service.
equal to 1 day, or Toner
waste volume left to end of
life/ave. daily toner waste
volume is less than or
equal to 1 day.
When the
N/A
Xerographic
Module is
replaced or
status 09525
09-520 and
10-520
Replace both Xerographic When status 09-520 and

and Fuser Modules now to 10-520 are raised.
avoid interruption of service.
N/A
When the
Xerographic
Module and
the Fuser
Module are
replaced or
status 09525 and 10525 raised.
09-521
The Dry Ink is empty.

Replace soon.
None
No Toner detected after
Toner Bottle Motor has
been on for 40 seconds for
the 2nd time. 09-870 fault
declared.
Toner
detected
09-523
Please wait... Printing will

be available soon.
09-362 fault declared and

Front Door open
Printing
Toner
Go to 09detected or 360/362
Toner Bottle
Motor turned
off after 4
minutes.
09-524
The Dry Ink bottle is

almost empty.
09-880 fault declared or

Toner Bottle Sensor
detects a low condition.
None
Power Off/ Go to 09Power On

870/880
and open
and close
The Front
Door Interlock Switch.
Status 09521
V0.042
None
Go to 09360/362
May 2003
2-783
OF-6F
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
09-525
Replace the Xerographic

Module.
When either of the follow- Printing

print volume is equal to 0
days, or Toner waste volume left to end of life/ave.
daily toner waste volume is
equal to 0 days.
When the
Xerographic
Module is
replaced
Replace
Xerographic
Module PL
5.1A Item 1.
09-527
The Dry Ink must be

replaced to resume printing.
09-360 fault declared plus Printing

30 seconds of dispense
time without toner
detected, or 09-362 fault
plus 4 minutes of toner dispense of time without
toner being detected.
Open and
close the
Front Door
Go to 09360/362
09-528

Replace the Developer
Collector.
Fault 09-358: Developer

Collector time bomb
reached zero, or Toner
Bottle detected full or
detected missing.
Printing
The Devel- Go to 09oper Collec- 358

tor is not
sensed full
when the
Front Door is
closed.
09-530
Replace the Developer

Collector now to avoid
interruption of service.
Developer Collector time

bomb started or when the
Xerographic Module is in
the Initialization Process.
None
The Devel- Go to 09oper Collec- 358

tor is not
sensed full
when the
Front Door is
closed, or
the sensor
transitions
from 'Full or
Absent' to
'Not Full'
when the
Xerographic
Module is in
the Initialization Process.
09-570
REMINDER: Please return The Xerographic Module is None

the used replaceable mod- replaced, the Front Door is
ule to Xerox for recycling. closed, and the machine is
ready.
OF-6F
Start
N/A
May 2003
2-784
V0.042
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
09-571
The Dry Ink has been

replaced.
Set by clearing 09-521,

09-526 or 09-527
None
N/A
Automatically at 500
ms after setting.
09-573
The Xerographic Module is When either of the follow- None

near end of life.
days being the default) or
Toner waste volume left to
end of life/ave. daily toner
waste volume is less than
or equal to 2 to 5 days (2
days being the default).
When the
N/A
Xerographic
Module is
replaced or
status 09520 is set.
09-573 and
10-573
Both Xerographic and

Fuser Modules are near
end of life.
When status 09-573 and

10-573 are raised.
N/A
When the
Xerographic
Module and
the Fuser
Module are
replaced, or
status 09520 and 10520 are set.
09-580
Print Quality may be

degraded.
When set-up failed flag set Printing

and 09-3xx fault is
declared.
V0.042
None
Status
cleared after
selecting
Retry Button.
In [Faults/
Counters tab
, Faults],
check [Last
40] for Xerographic
faults. Go to
the RAP for
the fault or
faults displayed.
May 2003
2-785
OF-6F
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
09-582

again. Machine may
require service.
Printing
If one of the following
power faults are declared:
09-370 , 09-372 , 09-374 ,
or 09-376.
The status
09-382 is
not present
after pressing after the
power is
turned on.
In [Faults/
Counters tab
, Faults],
check [Last
40] for Xerographic
faults. Go to
the RAP for
the fault or
faults displayed.
09-584
Please wait... Adjustments are in progress.
Printing
Two consecutive occurrences of fault 09-310 , 09314 , 09-316 , 09-318 ,09320, or 09-324 .
Status cannot be set

until IOT is
in ready
state. Status cleared
after completion of the
Xerographic
Exerciser
In [Faults/
Counters tab
, Faults],
check [Last
40] for Xerographic
faults. Go to
the RAP for
the fault or
faults displayed.
09-585
Check the output. Call the Unclearable process conAdministrator if the quality trol fault declared
is unacceptable.
OF-6F
None
Service
Go to IQ-1
action OK at
START
May 2003
2-786
V0.042
OF-6G 10-5XX Status Message RAP
(28Feb2001)
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
10-505
Please wait...
The Fuser is warming up.
Printing may be delayed.
The Fuser is not to the

operating temperature.
10-510

Check the Fuser Module.
Ensure that the proper unit
has been installed.
The machine software is

Printing
capable of communicating
with the CRUM but no
Xerox data is found in the
ROM area of the CRUM
Xerox Data
is read from
the ROM
area of the
CRUM when
the Fuser
Module is
closed.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-511
Pull out the Fuser Module, The system fails to estab- Printing
then firmly push it back in. lish communication with
the Fuser Module CRUM
Chip with thermistor open
or closed. Faults declared:
10-300, 10-350, 10-354
The Fuser
Module
CRUM Chip
is detected
correctly
when the
Fuser Module is
closed.
If the Fuser/
Inverter
Drawer fails
to stay
latched,
replace the
Fuser/
Inverter
Drawer
Latch PL
6.2A Item 5.
In [Faults/
Counters tab
, Faults],
check [Last
Go to 10300 10-350
10-354
V0.042
Printing
When the
Go to 10Fuser has
301
reached the
operating
temperature.
May 2003
2-787
OF-6G
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
10-513

has been installed.
The machine software has Printing

detected an invalid Fuser
Module Print Count and or
Invalid Fuser Web Usage
Value. Fault 10-351
declared.
Max. Print
Go to 10Volume
351
Value Print
Count and
Max. Fuser
Web Usage
Value Fuser
Web Usage
when the
Fuser Module is
closed.
10-514

has been installed.
The machine software has Printing

detected an invalid Fuser
Module for the machine
configuration. Fault 10-352
declared.
The correct
Fuser Module is
detected
when the
Fuser Module is
closed.
10-515
The Fuser is not available, The machine software has Printing

call for assistance.
detected an overtemp condition.
The Fuser
Go to 10Module is
303.
replaced, or
the fault is
corrected.
10-517
Service needed.
Machine is Go to 10capable of
355.
communicating with
the Xerox
Fuser
CRUM or
the Aftermarket
Fuser
CRUM when
the thermistor circuit is
closed.
OF-6G
Fault 10-355: Service Plan Printing

is set to Other and S/W
can not communicate with
either the Xerox Fuser
CRUM or the Aftermarket
Fuser CRUM.
Go to 10352
May 2003
2-788
V0.042
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
10-519
REMINDER: Order a new

Fuser Module.

amount of Fuser Web left
to end of life/ave. daily
Fuser Web usage is less
than or equal to 3 to 25
days (10 days being the
default).
The Fuser
Module is
replaced or
the status
10-573 is
set.
N/A
10-520
Replace the Fuser Module now to avoid interruption of service.

equal to 1 day, or amount
of Fuser Web left to end of
life/ave. daily Fuser Web
usage is less than or equal
to 1 day.
The Fuser
Module is
replaced or
the status
10-525 is
set.
N/A
10-525
Replace the Fuser Module.
When either of the follow- Printing

equal to 0 days, or amount
to 0 days.
The Fuser
Module is
replaced.
Replace the
Fuser Module PL 6.2A
Item 1.
10-530
Remove any unusable

sheets from the Top Tray.
Stray sheets detected in

IOT after Start
V0.042
Printing per
purge rules
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
May 2003
2-789
OF-6G
Status
Number
UI Message
10-560
Clear the jam in area 3.

after cycle down
Printing
The Front
Door is
closed,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
Module transition to
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-560 and
10-562

and 3E.

and 3E after cycle down.
Printing
The Front
Door is
closed,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-560, 10- Clear the jam in area 3

562, and 08- and 3E, then remove
540
sheets from area 1.

and 3E after cycle down.
Printing
The Front
Door is
closed,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
OF-6G
Function
Disabled
Condition
Required to
Clear
Status
Action
May 2003
2-790
V0.042
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
10-560 and
08-540
Clear the jam in area 3,

then remove sheets from
area 1.
Paper detected in areas 1 Printing

and 3 after cycle down.
The Front
Door is
closed, Registration
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
40] for 08XXX and 10XXX faults.
Go to the
RAP for the
fault or faults
displayed.
10-560 and
08-555

area 2.
Paper detected in areas 2 Printing

and 3 after cycle down.
The Front
Door is
closed, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
V0.042
May 2003
2-791
OF-6G
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
10-560, 10- Clear the jam in areas 3

562 and 08- and 3E, then remove
sheets from area 2.
555
Paper detected in areas 2, Printing

3E, and 3 after cycle
down.
The Front
Door is
closed, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-560, 08- Clear the jam in area 3,

555, and 08- then remove sheets from
540
areas 2 and 1.

2, and 3 after cycle down.
The Front
Door is
Sensor, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
OF-6G
May 2003
2-792
V0.042
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action

2, and 3 after cycle down.
562, 08-555, and 3E, then remove
and 08-540 sheets from areas 2 and 1.
The Front
Door is
Sensor, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-560 and
10-565
The Front
Door is
closed, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.

and 4.

and area 4 after cycle
down
V0.042
Printing
May 2003
2-793
OF-6G
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action

562, and 10- and 3E, then remove
sheets from area 4.
565
Paper detected in area 3, Printing

3E, and area 4 after cycle
down
The Front
Door is
closed, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.

540
areas 4 and 1.
Paper detected in area 1,

3, and area 4 after cycle
down
The Front
Door is
Sensor, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
OF-6G
Printing
May 2003
2-794
V0.042
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action

3, 3E, and area 4 after
and 08-540 sheets from areas 4 and 1. cycle down
Printing
The Front
Door is
Sensor, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.

555
areas 4 & 2.
Printing
The Front
Door is
Sensor, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.

3, and area 4 after cycle
down
V0.042
May 2003
2-795
OF-6G
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action

and 08-555 sheets from areas 4 & 2.

3, 3E, and area 4 after
cycle down
Printing
The Front
Door is
Sensor, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.

565, 08-540, then remove sheets from
and 08-555 areas 4, 2, and 1.

2, 3, and 4 after cycle
down.
The Front
Door is
Sensor, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
OF-6G
May 2003
2-796
V0.042
Status
Number
UI Message
10-560, 10562, 10-565,

08-540, and
08-555

and 3E, then remove
sheets from areas 4, 2,
and 1.

2, 3, 3E, and 4 after cycle
down.
The Front
Door is
Sensor, PFT
Sensor,
Inverter
Entrance
Sensor and
Inverter Exit
Sensor are
clear, and
the Fuser
closed is
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-562
Clear the jam in area 3e.
Paper tracked to between None

TE reached Inverter
Entrance Sensor and LE
reached Inverter Exit Sensor after stopping IOT.
The Front
Door is
closed with
no paper
seen at
Inverter
Entrance
Sensor and
Inverter Exit
Sensor, and
fuser transition to
closed was
detected.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-563
Clear the jam in area 3a.
Duplex Exit Sensor

Printing
detects paper present after
the Front Door is closed.
The Front
Door is
closed with
no paper
seen on
Duplex Exit
Sensor.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
V0.042
Function
Disabled
Condition
Required to
Clear
Status
Action
May 2003
2-797
OF-6G
Status
Number
UI Message
10-564
Clear the jam in area 3d.
Paper detected on Inverter None

Exit Sensor that was
headed for duplex paper
path.
The Front
Door is
closed.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-565
Paper is detected in area 4 Printing

after cycle down
The Front
Door is
closed with
no paper
seen on PFT
Sensor and
Inverter Exit
Sensor.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-565 and
08-540

area 1.
Paper is detected in areas Printing

1 and 4 after cycle down
The Front
Door is
closed with
no paper
seen on
Registration
Sensor, PFT
Sensor, and
Inverter Exit
Sensor.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
10-565 and
08-555

area 2.

1 and 4 after cycle down
The Front
Door is
closed with
no paper
seen on PFT
Sensor and
Inverter Exit
Sensor.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
OF-6G
Function
Disabled
Condition
Required to
Clear
Status
Action
May 2003
2-798
V0.042
Status
Number
UI Message
10-565, 08540, and

08-555

areas 2 and1.

1, 2, and 4 after cycle
down
10-570
REMINDER: Please return The Fuser Module has

the used replaceable mod- been replaced, the Front
ule to Xerox for recycling. Door is closed, and the
machine ready.
10-571 (FX
Only)
The Fuser Web has been

replaced.
Set by pressing the C but- None

ton and the 1 button at
the same time for 2 seconds.
N/A
Automatically cleared
0.5 seconds
after setting.
10-573
The Fuser Module is near

end of life.

default).
The Fuser
Module is
replaced or
the status
10-520 is
set.
10-574 (FX
Only)
The Fuser Web is near the When either of the follow- Printing
end of life.
equal to 0 days, or amount
to 0 days.
V0.042
Function
Disabled
Condition
Required to
Clear
Status
Action
None
The Front
Door is
closed with
no paper
seen on
Registration
Sensor, PFT
Sensor, and
Inverter Exit
Sensor.
In [Faults/
Counters tab
, Faults],
check [Last
Start
N/A
N/A
Set by
N/A
pressing the
C button
and the 1
button at the
same time
for 2 seconds, status
10-576 is
set, or the
Fuser Module is
replaced.
May 2003
2-799
OF-6G
Status
Number
10-576 (FX
Only)
UI Message
Replace the Fuser Web.
When either of the following criteria are met: Prints

default).
OF-6G
Function
Disabled
Set by
pressing the
C button
and the 1
button at the
same time
for 2 seconds, status
10-576 is
set, or the
Fuser Module is
replaced.
Condition
Required to
Clear
Status
Action
N/A
May 2003
2-800
V0.042
OF-6H 12-5XX Status Message RAP
(24Jan2002)
Table 1 12-5XX (Finisher and OCT) Status Messages
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
12-507
Check output for ant extra A stray sheet was sent to

sheets.
the Finisher Stacker Tray
at cycle up.
Printing &
Finishing
Output of all
committed
sheets and
press Start
12-510
The Finisher cover is

open.
Finishing
Finisher Top Go to 12Cover Door 309

is closed.
12-512
The Finisher main tray is The Stacker Tray Upper

not available. Remove any Limit Switch has been
obstructions.
actuated.
Finisher
Stacker
(Main) Tray
The Stacker Go to 12Tray Upper 201

Limit Switch
is not actuated.
12-518
The Finisher is not avail- Failure of any critical func- Stapling and
able. Please call for assis- tions including Disk Motor, stacking
tamping, and Stacker Tray
tance.
elevation.
The Finisher Interlock

Switch is open.
V0.042
Recovery of
the failed
function on
exit from
diagnostics
or the recovery of the
Disk or
Tamper
functions
when the
Finisher
Interlock
Switch is
opened and
then closed.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
Open then
close the
Finisher Top
Cover Door.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
May 2003
2-801
OF-6H
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
12-519
The Finisher main tray and Failure of any critical

Stapling and
stapling are not available. Stacker Tray elevation or stacking
Please call for assistance. stapling functions including staple shifting, stapling and associated
safety switches, or second
occurrence of stapling
failed status.
Recovery of
the failed
function on
exit from
diagnostics
or a successful Finisher reinitialization
12-520.1
Stapler 1 is low on staples. The Moving Stapler Empty None

Sensor detects an empty
stapler condition during
run.
The Moving Go to 12-AK

Stapler
Empty Sensor changes
to not empty
or the status is
upgraded to
Out of Staples.
12-520.2
Stapler 2 is low on staples. Fixed Stapler Empty Sensor detects an empty stapler condition during run.
The Fixed
Go to 12-AL
Stapler
to not empty
or the status is
upgraded to
Out of Staples.
12-525.1
Replace Staple Cartridge

1.
The Moving Stapler Empty Stapling

Sensor indicates an empty
stapler condition at Finisher initialization, or
greater than 19 stapled
sets after a low staple status is declared.
The Moving Go to 12-AK

Stapler
to not empty.
12-525.2
Replace Staple Cartridge

2.
The Fixed Stapler Empty Stapling

Sensor indicates an empty
stapler condition at Finisher initialization, or
greater than 19 stapled
sets after a low staple status is declared.
The Fixed
Go to 12-AL
Stapler
to not empty.
OF-6H
None
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
May 2003
2-802
V0.042
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
12-526
Close the door to the Staple Cartridge.
The Stapler Access Door Stapling and

Interlock Switch indicates stacking
the Stapler Access Door is
open.
The Stapler Go to 12Access Door 307

Interlock
Switch is
closed.
12-532
(OCT)
The Output Tray is full.
The OCT Tray Full Sensor OCT

has been actuated 20
times after the OCT Tray
Full Sensor indicated that
the OCT Tray was full.
The OCT
Tray Full
Sensor
changes to
not full.
Go to 12-G
The Finisher Top

Tray Full
Sensor
changes to
not full.
Go to 12-AJ
12-532 (Fin- The top tray of the Finisher The Finisher Top Tray Full Top Tray
isher)
is full.
Sensor has been actuated
20 times after the Finisher
Top Tray Sensor indicated
that the tray was full.
12-533
The main tray of the Finisher needs to be

unloaded.
The Stacker Tray Full Sen- Stapling and The Stacker Go to 12-AH
sor and the Stack Height
stacking
Tray Full
Sensor are blocked.
Sensor and
the Stack
Height Sensor are
unblocked.
12-533
(MFF)
The main tray of the Finisher needs to be

unloaded. Unload Tray.
Stapling and
stacking
12-535
Finisher has paused.

Press button on the Finisher again to resume.
The IOT reaches standby Stapling and The Pause Go to 12-AM

after being paused via the stacking
Resume
Pause Resume Switch.
Switch is
actuated
again or the
Auto
Resume
Timer
expires,
whichever
occurs first.
V0.042
Go to 12751.
May 2003
2-803
OF-6H
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
12-536
Please wait... Finisher is

cycling down.
When the Pause Resume

Switch is pressed while
the IOT is cycled up.
12-537
(MFF)
Stapling is not available in Failure of any Main Stapler Main Tray

the Main Tray.
stapling function.
Stapling
Recovery of Go to 12failed func- 762

tion on exit
from diagnostics or at
MFF Front
Door Interlock open/
close.
12-540
Clear the jam in the Finisher.
Paper is left between the Finishing

last IOT sensor and Finisher Entrance Sensor, or
between the last IOT sensor and the Top Tray Paper
Path Sensor.
The Finisher
Entrance
Sensor and
the Top Tray
Paper Path
Sensor are
clear after
closing Finisher Top
Cover Door.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
12541(OCT)
Clear the misfed sheet in

the output tray.
Paper is on Exit Sensor

Printing
after the Fuser Motor has
shut off, or set by fault 12101.
Q2 cleared
and (Close
OCT - 36 v
toggled to
on or Open
front door 36 VDC offline with 5
VDC offline)
Go to 12101.60
OF-6H
Stapling and When the

N/A
Stacking
IOT completes its
cycle down
process (i.e.
when status
12-535 is
raised) or
when the
Pause
Resume
Switch is
pressed
again.
May 2003
2-804
V0.042
Function
Disabled
Condition
Required to
Clear
Status
Action
Status
Number
UI Message
12-550
(OCT)
Remove the purged

sheets in the Output Tray.
Any failure that causes an None

unexpected sheet or a
purged sheet to be sent to
the OCT.
When next
job begins
printing.
None

12-550 (Fin- Remove the output from
isher)
the Finisher top tray and
check for any stray pages. purged sheet to be sent to
the Finisher Top Tray
When next
job begins
printing.
Go to 12100
12-555
Remove any unusable

sheets from the Finisher.

purged sheet to be sent to
the Finisher.
Finisher
Go to 12Stacker Tray 100
raised or
when next
job begins
printing.
12-558
Check output for mis-stapled sets.
Failure of Smart Tray offsetting mechanisms.
None
Next job has In [Faults/

begun mark- Counters tab
ing.
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
12-559
(MFF)
Offsetting in the Main Tray Main Tray offset mechais degraded. Printing and nism failure.
finishing may continue.
None
Recovery of In [Faults/
failed func- Counters tab
tion.
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
12-581.1
This set has not been sta- Failure of critical Moving

None
pled. A new set will be
Stapler functions that may
printed and stapled.
recover on the next set.
V0.042
Successful None
operation of
previously
failed function or
upgrade to
Finisher Not
Available
Status.
May 2003
2-805
OF-6H
Status
Number
12-581.2
UI Message
Function
Disabled
None
This set has not been sta- Failure of critical Fixed
Stapler functions that may
pled. A new set will be
recover on the next set.
printed and stapled.
12-587 (Fin- Please call for assistance. The Top Tray Offset Sen- Finisher Top
isher)
Offset in the Output Tray is sor fails to block within 500 Tray Offsetnot functional.
ms of turning Top Tray Off- ting
set Motor on. Set by fault
code 12-213
OF-6H
Condition
Required to
Clear
Status
Action
Successful None
operation of
previously
failed function or
upgrade to
Finisher Not
Available
Status.
Exit diagnostics or
Power Off/
Power On.
Go to 12213
May 2003
2-806
V0.042
OF-6J 14-5XX (Scanner) Status Message RAP
(28Feb2001)
14-5XX (Scanner) Status Messages
Table 1 14-5XX (Scanner) Status Messages
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
14-506
Please wait...
Checks for ready are
Adjustments in progress... incomplete
All scanning Checks

complete
N/A
14-508
Please wait... The scanner is calibrating to

improve image quality.
All scanning. Calibration

complete.
N/A
14-517
The Printer is not availScanner needs service.

able.
The Scanner is not available. Please call for assistance.
All scanning Successful

Power Off/
Power On.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
14-531
14-585
Scanner is Calibrating.
Job is incomplete, scan

All scanning
service is ready to run and
needs a resume command.
Check the output. Call the Calibration related faults
Administrator if the quality detected.
is unacceptable.
V0.042
None
Resume Job N/A

or Cancel
Job command from
the UI.
Successful
Scanner calibration with
no faults
detected.
In [Faults/
Counters tab
, Faults],
check [Fault
Counters]
for 14-7XX
faults. Go
to the RAP
for the fault
or faults displayed
May 2003
2-807
OF-6J
Table 1 14-5XX (Scanner) Status Messages
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
14-590
Check the output. Call the Downloaded NVM values

Administrator if the quality are out of range too low.
is unacceptable.
None
SVCM
receives
NVM data
within correct range.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
14-595
Check the output. Call the Downloaded NVM values

Administrator if the quality are out of range too high.
is unacceptable.
None
SVCM
receives
NVM data
within correct range.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
OF-6J
May 2003
2-808
V0.042
OF-6K 16-5XX (ESS) Status Message RAP
(28Feb2001)
16-5XX (ESS) Status Messages
Table 1 16-5XX (ESS) Status Messages
Status
Number
Condition
Required to
Clear
Status
Action
UI Message
Function
Disabled
16-502
The Network Controller

connection is about to
reset.
When the ESS detects

that a platform reset is
about to occur.
Network
When the
Go to 16-A.
printing and ESS reset is
scan to file. initiated.
16-543
Accounting problem.
Please notify Machine
Administrator.
Authorization file on the

system is corrupted. No
jobs can be authorized.
Print, copy, AuthorizaScan-to-File, tion should

and Fax.
be disabled
until the
Accounting
SA can
purge and
reload the
Authorization database.
16-545
Network scanning commu- Unrecoverable communinication error. Please

cation error.
notify Machine Administrator.
16-546
Network scanning filing

error. Please notify
Machine Administrator.
Go to 16-A.
Scan-To-File ESS Reset Go to 16-A.

Job will be
manually Inicanceled.
tiated by
customer.
Resubmit
job.
Network Repository Filing. Scan-To-File Verify desti- Go to 16-A.

Job will be
nation
canceled.
address;
check
Repository
setup; verify
repository is
online.
Check Network connectivity.
Resubmit
the job.
V0.042
May 2003
2-809
OF-6K
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
16-547
Network scanning templates could not be

retrieved. Please notify
Template retrieval failure.
Scan-To-File
is limited to
the use of
old, default,
or WebUI
templates.
16-548
Network scanning error.

Administrator.
Job Processing error.
Go to 16-A.
Scan-To-File Resubmit
Job will be
job. If probcanceled.
lem persists, ESS
Reset manually Initiated
by customer.
16-549
Network scanning is not

available. Please notify
Failure of any Scan-to-File Scan-to-File. ESS Reset Go to 16-A.

services.
manually Initiated by
customer.
Resubmit
job.
16-550
Machine entering SW
upgrade mode - all jobs
will be canceled.
System going into CusAll

tomer SW Upgrade mode.
16-551
Accounting out of memory. Accounting log is full or a

Disk full state exists.
Administrator.
16-552
Software Options codes

do not match.
OF-6K
Verify
Remote
template
pool settings; verify
that the
Template
Repository
is online.
Check network connectivity.
System
Reset,
Power Off/
Power On.
Go to 16-A.
Go to 16-A.
Print, copy, Fault # is

Go to 16-A.
Scan-to-File, logged.
and Fax.
Accounting
Administrator needs to
retrieve
accounting
data log
from the
system.
Fault 16-782.19. The flag Scan to File When the

Go to 16-A
in system manager is not
ESS reset is
in sync with the ESS Print
initiated.
Manager.
May 2003
2-810
V0.042
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
16-553
Additional memory
required. Please call for
assistance.
Fault 16-781.19. Not

enough physical memory
is configured on the platform to support Scan-tofile.
Scan to File More physi- Go to 16cal memory 781.19

added to the
system.
16-554
Hardware must be added Fault 16-785.19. The IPA

or replaced. Please notify card is either missing or
broken.
Go to 16Scan to File When the

IPA Card is 785.19
added, reinserted, or
replaced.
16-555
Additional memory
required to support Fax.
Administrator.
Fault 16-787.19. Not

enough physical memory
is configured on the platform to support LAN Fax.
LAN Fax
More physi- Go to 16cal memory 787.19

added to the
system.
16-556
Hardware must be added Fault 16-786.19. The IPA

or replaced. Please notify card is either missing or
broken.
LAN Fax
Go to 16When the
IPA Card is 786.19
added, reinserted, or
replaced.
16-557
DC platform recovery
failed.
DC platform DC platform Go to 16-A

becomes
available.
16-558
DC platform call failed.
DC platform DC platform Go to 16-A

becomes
available
16-559
BOOTP Initialization failure. Please notify

Fault 16-802.46. BootP

Connectivconfiguration of IP will use ity fix and
stored IP data.
reboot.
Connectivity fix and

reboot.
16-560
Some Network services

unavailable. Please notify
Fault 16-770
Unknown
ESS reset
Go to 16-A
manually initiated by the
customer
16-561
Incomplete Network Inter- Fault 16-760

face.
The networking option(s)
listed at the right are not
operating correctly.
Please call the Machine
Administrator to reset the
Electronic Subsystem.
Scan to file
ESS reset
Go to 16-A
customer
V0.042
Go to 16-A
May 2003
2-811
OF-6K
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
16-562

face.
LPD connectivity
16-563

face.
Go to 16-A
Novell Con- ESS reset
nectivity
customer
16-564

face.
Go to 16-A
Netbios con- ESS reset
nectivity
customer
16-565

face.
AppleTalk
ESS reset
Go to 16-A
Connectivity manually initiated by the
customer
16-566

face.
Banyan
Vines Connectivity
OF-6K
Go to 16-A
ESS reset
customer
ESS reset
Go to 16-A
customer
May 2003
2-812
V0.042
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
16-567

face.
Postscript
print capability
Go to 16-A
ESS reset
customer
16-568

face.
PCL print
capability.
Go to 16-A
ESS reset
customer
16-569

face.
Go to 16-A
Parallel port ESS reset
connectivity. manually initiated by the
customer
16-570

face.
Web UI con- ESS reset

Go to 16-A
nectivity.
customer
16-571
Network Printing disabled. Please notify

Fault 16-771
Print capability lost.
ESS reset
Go to 16-A
customer
16-572

Fault 16-772
ESS reset
Go to 16-A
customer
16-573

Fault 16-773
ESS reset
Go to 16-A
customer
V0.042
May 2003
2-813
OF-6K
Status
Number
UI Message
Function
Disabled
Go to 16-A
ESS reset
customer
16-574
Job Status information not Fault 16-774

available. Please contact
the Machine Administrator.
16-575

reset.
Fault 16-160
Go to 16-A
All ESS pro- ESS reset
cesses lost manually initiated by the
customer
16-576

reset.
Fault 16-161
Go to 16-A
cesses lost. manually initiated by the
customer
16-577

reset.
Fault 16-162
Go to 16-A
cesses lost. manually initiated by the
customer
16-578
Incomplete system inforFault 16-776

mation. Please contact the
Unable to
log faults.
Go to 16-A
ESS reset
customer
16-579
Job Status information not Fault 16-777

available. Please contact
the Machine Administrator.
Completed
job log data
lost.
ESS reset
Go to 16-A
customer
16-580

No ESS
configuration data.
ESS reset
Go to 16-A
customer
16-581

Fault 16-779
ESS diagnostics lost
ESS reset
Go to 16-A
customer
16-582

Fault 16-780
Print and
scan capability lost.
ESS reset
Go to 16-A
customer
16-583

Unable to
retrieve
counter
data.
ESS reset
Go to 16-A
customer
16-584

reset.

Go to 16-A
cesses lost manually initiated by the
customer
OF-6K
Fault 16-163
Job queue
data lost
Condition
Required to
Clear
Status
Action
May 2003
2-814
V0.042
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
16-585
Fault 16-782
Incomplete system information. Please contact the
No ESS
configuration data to
RDT and
PWS.
Go to 16-A
ESS reset
customer
16-586
Incomplete system information. Please notify

Remote
SNMP operations not
possible.
Go to 16-A
ESS reset
customer
16-587

face.
16-588
Some Network Controller

services unavailable.
Administrator.
16-589

face.
Serial oper- ESS reset

Go to 16-A
ations are
manually ininot possible. tiated by the
customer
16-590
Some Network Controller

services unavailable.
Administrator.
Job Submis- ESS reset

Go to 16-A
sions are not manually inipossible
tiated by the
customer
16-591
Ethernet functions are not Fault 46.16-800

IP over
Ethernet.
Connectivity fix and

reboot.
Go to 16-A
16-592
Token Ring functions are Fault 46.16-801

not available. Please
notify Machine Administrator.
IP over
ConnectivToken Ring. ity fix and
reboot.
Go to 16-A
Fault 16-785
Fault 16-787
Fault 16-789
V0.042
Go to 16-A
Token ring
ESS reset
operations
manually ininot possible. tiated by the
customer
Configuration changes
are not possible.
Go to 16-A
ESS reset
customer
May 2003
2-815
OF-6K
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
16-593
DHCP functions are not

Fault 46.16-802
DHCP con- Connectivfiguration of ity fix and

reboot.
IP, will use
stored IP
data.
Go to 16-A
16-594
RARP functions are not

Fault 46.16-803
RARP con- Connectivfiguration of ity fix and

reboot.
IP, will use
stored
IPdata.
Go to 16-A
16-595
Incomplete Network Inter- LAN_FAX_DEATH_STATU LAN FA.

S. Fault: 16.790.09
face.
ESS Reset Go to 16-A.

Customer.
16-596
Incomplete Network Inter- ACCOUNTING_DEATH_S Accounting

face.
TATUS. Fault: 16.791.09.

Customer.
16-597
Incomplete Network Interface.


Customer.
16-598
IP interface error. Please TCP/IP address is already TCP/IP

notify Machine Administra- in use on the network.
interface is
tor.
not initialized. Fault
772 is
logged.
OF-6K
Tiff printing.
Contact SA. Go to 16-A.

Another IP
address
needs to be
used.
May 2003
2-816
V0.042
OF-6L 19-5XX, 21-5XX, and 22-5XX Status Message RAP
(28Feb2001)
19-5XX, 21-5XX, and 22-5XX Status Messages
Table 1 19-5XX, 21-5XX, and 22-5XX Status Messages
Status
Number
19-502
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
Please wait... Freeing

memory.
Out of memory resources. None
When mem- Go to 19ory

401/
becomes
available.
Memory resources are

low.
None
When mem- N/A

ory
becomes
available.
19-503
19-505
Your job has been deleted. Compressor DVMA timePlease resubmit this job.
out.
or
Your job has been deleted.
please rescan the originals.
Video path
Clears auto- Go to 19matically

404
right after
being raised.
19-510
Please wait...The system


declared.
None
When staGo to 19tus 19-512 is 300

raised.
19-511
Image Disk offline. Job(s)

may take longer than normal. Please call for assistance.
If system detects that it still

cannot read or write to the
Image Disk after the Disk
has been initialized
None Revert to
Diskless
operation
Power Off or In [Faults/

Main Control Counters tab
PWB Reset , Faults],
check [Last
40]. Go to
the RAP for
the fault or
faults displayed.
19-512
Image Disk Offline.

When System InitializaNone
Please call for assistance. tion process completes or
fails after fault 19-300 has
been raised
V0.042
Operator
selection at
the UI.
In [Faults/
Counters tab
, Faults],
check [Last
40]. Go to
the RAP for
the fault or
faults displayed.
May 2003
2-817
OF-6L
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
19-513
Please wait. The image

disk is full.
When the System detects None

that an Image that is being
written to disk cannot fit
into the available free
space.
When the
N/A
System
detects that
the available free
space for
Image data
is greater
than or
equal to
20% of the
total space
on the disk
that has
been allocated for
Image Data.
19-514
One or more printing jobs

has been deleted.
When fault 19-409 fault is

declared.
Video path.
Clears auto- Go to 19404

matically
right after
being raised.
Out of Memory detected

with Multiple Jobs in the
System. When fault 19403 is raised.
Video Path.
When the
N/A
currently
marking job
completes
Marking or
when the
user deletes
a job.
19-515
OF-6L
May 2003
2-818
V0.042
Status
Number
19-516
19-520
UI Message
The Image Disk is nearly

full.
When the System detects

that the available free
space in the working disk
partition is less than 10%
of the total space.
Function
Disabled
None
Scanning aborted due to a Scanning.

System Fault. User needs
to be instructed to start to
try again. If this fails, the
user should be instructed
to try Powering Off and On
and then try again. If that
fails, service is required.
raised.
V0.042
Condition
Required to
Clear
Status
Action
When the
N/A
System
detects that
the available free
space for
Image data
is greater
than or
equal to
20% of the
total space
on the disk
that has
been allocated for
Image Data.
Clears auto- N/A
matically
right after
being raised.
UI continues to display
message
until user
confirms
that the
message
has been
read via a
selection at
the UI or
after Power
On, Power
Off.
May 2003
2-819
OF-6L
Status
Number
UI Message
19-550
Function
Disabled
Whenever the Image Pro- System is

cessing/Video facility
not availdetects one or more of the able.
following configuration
mismatches during the
Power On sequence: EPC
Memory Size, IPS1 Option
Card, Image Rotation
SIMM Document Glass
Cover Pad (Grey vs.
White), or Image Disk
(Present vs. Not Present).
When the
system is
powered off
or when a
Main Control
PWB reset
occurs.
User Clears Go to 21via selec308

tion at the UI
or CSE
clears via a
selection at
a local or
remote
PWS. This
status needs
to be
remembered during Power
Off/Power
On cycles.
21-500
The phone number is not

available.

declared.
22-500.16
Confirming configuration
information...
During the Initial Power On System not

at the Customer's site
available.
when the Main Control
PWB sends the Core Configuration information to
the UI.
OF-6L
Condition
Required to
Clear
Status
Action
Call out to
the Blacklisted Phone
Number(s).
In [Faults/
Counters tab
, Faults],
check [Last
40]. Go to
the RAP for
the fault or
faults displayed.
When the
N/A
Main Control
PWB
receives
confirmation of the
core configuration information from
the UI.
May 2003
2-820
V0.042
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
22-501.04
Please wait...The system

When any of the following IOT

faults are declared: 22300-04 through 22-309-04,
22-311-04, or 22-312-04.
22-501.05
Your job has been deleted. When 22-300-05 is raised IIT

Please resubmit this job.
or
Your job has been deleted.
please rescan the originals.
22-501.16
Please wait... Configuring

the system.
System not
When user or system
available
selects the Quick Controlled Soft Power Down
Option at the UI, or during
the initial power on at the
customer's site when Auto
Configuration setup is initiated.
When the
N/A
System
Manager
receives
confirmation that it is
O.K. to
Power Off,
or when the
Auto Configuration Set
process
completes.
22-502.04
One of the printing jobs

has been deleted.
When either fault 22-310- None

04 or 22-313-04 is raised.
User clears In [Faults/

status via UI Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
V0.042
When the
IOT and the
Finisher
reach
standby.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
Go to 22When the
300.05
job is
deleted from
the queue
May 2003
2-821
OF-6L
Status
Number
22-502.05
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
Remove documents from

the document feeder input
tray or close the document feeder.
Documents Sensed in the DADF ScanDocument Input Tray dur- ning

ing IIT Standby and the
Document Handler is open
(raised).
N/A
Document
Handler lowered or no
documents
sensed in
Document
Input Tray.
When the user selects the None

Quick Controlled Power
Off Option at the UI and
there is either no Image
Disk configured or there
are Images in EPC Memory that have not been
spooled on to a configured
Image Disk, or when the
System initiates the auto
configuration detection
sequence.
When the
None
User either
confirms or
cancels the
Quick Controlled
Power Off
Request, or
when the
System initiates the
auto configuration
detection
sequence.
22-502.16
22-503.04
All incomplete jobs have

been deleted. Please
resubmit the jobs.
When fault 22-315-04 is

raised.
None
User clears None

status via
UI. Note:
This status
must be
remembered
through system resets.
22-503.05
Re-sort and reload ALL

originals in the document
feeder.
The Document Input Tray

empty sensed during
DADF Fault Recovery
before the DADF reaches
the original number
required for recovery.
Document
Feeder
scanning.
Documents
sensed in
the Document Input
Tray or Job
Incomplete
Timer
Expires.
OF-6L
N/A
May 2003
2-822
V0.042
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
22-504.04
Please delete the job. No

tray is configured with the
required stock size.
When job is submitted to

Mark and there is no tray
currently configured to
contain the selected
media.
22-504.05
Invalid original size

detected. It will be treated
as the next largest standard size.
A document length is
None
detected during the document feed cycle that is not
consistent with the document assumed by the
DADF sensors and the
Market Region setting
when the Documents were
initially loaded into the
Document Input Tray.
22-504.16
The system is in Diagnos- When an ESS Platform

Network
When there
tic mode. Do not Power
intrusive diagnostic routine Printing and are no ESS
Off the system.
is being run.
Scan to File. Platform
intrusive
diagnostic
routines
being run
V0.042
IOT
Go to 22Job can315.04
celled by
user or Tray
is configured
by KO for
required
media
When the
None
Document
stack has
been completely
scanned or
when the job
is cancelled
by the user.
N/A
May 2003
2-823
OF-6L
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
22-505.05
Start accepted. job will

begin when the system is
ready.
When Start is selected

while the Scanner Lamp
Calibration is in progress.
22-505.17
Machine is in a non-customer mode.
At Power On when the

None
System detects that Manufacturing Mode is set.
22-506.05
System warming up. It will When the Scanner initiates Scanning

be ready in less than 4
a Warm Up and Cold Caliminutes.
bration.
When the
Warm Up
and Cold
Calibration
completes
or when the
calibration is
halted due
to a calibration fault.
22-506.17
Machine is in a non-customer mode.
Whenever
TBD
Auto Configuration is
enabled via
the PWS
OF-6L
Scanning
Whenever the System

None
detects that Autoconfiguration has been disabled.
When the
Scanner
Lamp Calibration is
complete,
when the
system software has
successfully
interrupted
the Scanner
Lamp Calibration and
has returned
the Scanner
to a Ready
to Scan
state, or
when the
calibration is
halted due
to a calibration fault.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
Whenever
TBD
Manufacturing Mode is
exited via
the PWS.
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
May 2003
2-824
V0.042
Status
Number
UI Message
Function
Disabled
Condition
Required to
Clear
Status
Action
Job cancelled by
user
N/A
22-507.04
Please delete the job. The When a job is submitted to IOT

Printer is not available.
Mark Service specifying
an attribute that system
does not have the capability to provide
22-507.05
The job was deleted.
22-508.04
Scan Service receives a

Start command but cannot acquire resources.
22-510.04
Automatic Configuration
Whenever the Mark Ser- System not
has detected the hardware vice detects one or more available
listed below.
of the following configuration mismatches during the
Power On sequence (OCT,
Finisher, SMH, HCF)
When the
N/A
user confirms or
rejects the
displayed
configuration via a UI
invocation.
22-511.04
Paper required for the current job is not available.

This tray is currently
empty. Load the paper
required for your job.
When the
N/A
System
detects that
there is a
Tray available that
currently
contains the
stock
required to
continue
marking the
job.
22-512.04
All Paper Trays have been Whenever all the configspecified by the SA/KO to ured Paper Trays in the
be Direct Select Trays.
System have been programmed to be [Direct
Select] Paper Trays.
Go to 22303.05.
User needs to be informed Scanning
that Scan Start up will be
delayedWhen Start is
selected but Scan Service
is unable to acquire
resources (No Accept Halt
received from Job Contention).
When the System deterIOT

mines that there is no Tray
available that currently
contains the stock required
to continue marking the
job.
V0.042
None
TBD
When the
Scan Service is able
to acquire
resources or
the Scan
Job is
deleted.
Whenever at TBD
least one
configured
Paper Tray
has been
programmed to
be [Auto
Select].
May 2003
2-825
OF-6L
Status
Number
Function
Disabled
Condition
Required to
Clear
Status
Action
UI Message
One or more queued jobs

needs resources.
None
Whenever one or more
queued jobs in the system
is being held due to the
lack of resources.
Whenever
TBD
there are no
queued jobs
in the system that are
being held
for
resources.
22-550.17
Whenever the DC Platform System not

available.
Manager detects one or
more of the following configuration mismatches during the Power On
sequence (Accessory
Card, ESS, EP-SV/EPLyzer, RDT, or Scanner
Present/Not Present).
For an RDT
configuration mismatch:
When the
Auto Configuration
detection
sequence
complete.
For any
other mismatch:
When the
System is
Powered Off
or when a
Main Control
PWB reset
occurs.
22-551.04
A newly detected configu- Whenever the Mark Ser- System not

ration is invalid.
vice detects the hardware available.
type config. (IIOC Config.
indicator) and the product
identifier (NVM) do not
match.
22-513.04
OF-6L
In [Faults/
Counters tab
, Faults],
check [Last
Go to the
RAP for the
fault or faults
displayed.
When the
Go to OF-9.
Auto Configuration
Detection
sequence
complete
completes
successfully.
May 2003
2-826
V0.042
OF-7 Install Wizard Failure
OF-8 Staple Cartridge Checkout Procedure
(03Mar1999)
The unformed staple roll is wound too tightly in the Staple Cartridge and/or the Driver Bar is out
of position. This may cause the following:
The Installation Wizard failed to complete correctly.
The Moving Stapler or the Fixed Stapler in the Finisher are failing to staple sets of copies.
The Staple Cartridge cannot be installed correctly in the Finisher (Moving Stapler or Fixed
Stapler)
To correct this malfunction, the CSE must force an exit of the Installation Wizard, identify and
correct the cause of the Installation Wizard failure, and then reset the Installation Selection
back to Customer Install and run the Installation Wizard again.
The Convenience Stapler is failing to staple documents.
The Staple Cartridge cannot be installed correctly in the Convenience Stapler.
Use the following procedure to diagnose and correct this failure. (Do not select the hot links
until you are familiar with all of the steps.)
To ensure the unformed staple roll in the Staple Cartridge is not wound too tight, do the following:
1.
In the Diagnostic Navigator, select [Configuration] [System, Imaging, and IOT Configuration]. Enter [System, Imaging, and IOT Configuration].
Using one hand, grasp the Staple Cartridge along the top and bottom.
2.
Locate the [Install Phase] window, and select [Install Complete].
3.
Select [Apply], then select [OK].
4.
After the selection is made, exit the Diagnostic Navigator, then switch the power Off.
Vigorously snap the cartridge in the direction of the arrow (refer to Figure 1) about 10
times being careful not to squeeze the cartridge too tightly. You should be able to hear the
roll clunking back and forth inside the cartridge.
5.
While the power is Off, look at the connectors to the Main Control PWB and the Distribution PWB. Ensure all connectors securely connected.
6.
If the message Ensure the input and output devices are installed correctly, or call for service is displayed on the User Interface, do the following:
Staple Cartridge Checkout
Orient the Staple Cartridge as shown in Figure 1.
To ensure the Driver Bar is in the correct position, do the following:
Check to see if the Driver Bar is flush with the leading edge of the cartridge as shown in
Figure 2.
NOTE: TAG 114 is a 460/470 manufacturing tag that removes the Right Side Interlock
Switch and inserts an in line splice in its place.
If necessary, use a pen or other pointed tool to move the plate edge tab located on the left
side of the cartridge.
Move the tab until the Driver Bar is even with the leading edge of the cartridge.
TAG 120 is a460/470 manufacturing tag that removes the Left Side Interlock Switch and
inserts an in line splice in its place.
If correctly positioned, the staple will be laying down flat on the Driver Bar.
If the staple is oriented on end, as shown in Figure 3, or if the staple appears to be malformed in any way, remove it.
a.
Ensure the Finisher is mounted correctly to the IOT frame (refer to REP 12-12 ).
b.
Ensure the Finisher actuates the Right Side Interlock Switch.
c.
Ensure the HCF is mounted correctly to the IOT frame.
d.
Ensure the HCF actuates the Left Side Interlock Switch.
7.
8.
Go to [Faults/Counters tab , Faults].
9.
Identify all logged faults. Diagnose and repair the cause of the faults.
Ensure the first staple is in the correct position and the staple is not damaged
10. PO/PO the machine in order to clear the active faults and verify the faults do not reoccur.
11. In the Diagnostic Navigator, select [Configuration] [System, Imaging, and IOT Configuration]. Enter [System, Imaging, and IOT Configuration].
12. Locate the [Install Phase] window, and select [Customer Install].
13. Select [Apply], then select [OK].
14. After the selection is made, exit the Diagnostic Navigator, then PO/PO the machine for
the change to take effect.
15. Execute the Install Wizard.
16. Reset the second side registration (ADJ 8-1C and ADJ 8-1D).
V0.042
May 2003
2-827
OF-7, OF-8

tab position
tab position
NOTE: Do not grasp the

exposed staple roll

to move the edge tab to the
correct position.

Figure 2 Checking the Driver Bar
Figure 1 Ensuring the cartridge is not wound too tight
OF-8
May 2003
2-828
V0.042
OF-9 Configuration Problem RAP

(30May2001)
The machine does not recognize the correct machine configuration. At some point in time, a
problem developed in a machine module that created a configuration mismatch. The customer
was prompted to accept the new machine configuration, and a fault would have been logged.
If enough time passes, the fault may move from the Last 40 log.
The machine configuration that is displayed on the PWS or on the User Interface, does not
match what is actually present in the hardware.

Check the message on the User Interface.
The following message is displayed: Not Ready - Configuration Mismatch exists. Automatic Configuration Detected an unrecoverable hardware problem.
Y
N
The machine has a feature or function installed, but it is not recognized by the
machine.
Y
N
Check for any configuration faults. Enter [Faults/Counters tab , Faults]. Select
[Fault Counters]. Check for any configuration faults (12-323, 12-700, 19-7xx or 227xx). Go to the RAP for the fault that exists.
This is a common problem. It can occur for several reasons:
A feature or option was not installed correctly
B
Go to Flag 2, Flag 3, Flag 4, Flag 5, Flag 6, Flag 7, and Flag 8. Check the harness for a
After it has failed, the machine automatic configuration detected the changed configuration, and to continue running the customer accepted the changed configuration.
If the feature or function is still not recognized, there may be a hardware problem.
Figure 3 Checking for deformed staple
A
V0.042
A feature or option which was once working has failed
Perform the following: Enter [System, Imaging, and IOT Configuration], select [System] and change the Install Phase to [Manufacturing]. Select [OK]. Switch off the
machine power, then switch it back on. When the machine is ready, enter [System,
Imaging, and IOT Configuration], select [System] and change the Install Phase to
[Install Complete]. Switch off the machine power, then switch it back on. When
complete, the machine should recognize the correct configuration.

position.
If the feature is an output or input device, ensure they are connected correctly.
Check again for any fault codes, including the fault counters ([Faults/Counters
tab , Faults]. Select [Fault Counters]). If any faults are now present that indicate a configuration problem, go to that RAP.
Go to [Faults/Counters tab , Faults]. Select [Fault Counters]. Check for one of the following
faults 10-357, 10-358, 10-706, 12-323,12-700, 19-750, 19-751, 19-752, 22-750.17.
One of the above faults was listed in the Fault Counters.
Y
N
The output device is a Multi-Function Finisher (470 machines only).
Y
N
Go to the OF-9 Auto Configuration On-Site Procedure.
A
A
B
short circuit or an open circuit.
A
May 2003
2-829
OF-8, OF-9
A
If the harness is good, replace the IOT/MFF Interface PWB PL 8.22A .
If the problem continues, replace the Distribution PWB PL 1.5.
10-357/358 Decurler Configuration Mismatch .
10-706 Decurler Configuration Fault.
12-323 Finisher Configuration Mismatch
12-700 Finisher Configuration Mismatch
19-750 EPC Memory Mismatch
19-751 IPS1 Option Card Mismatch
19-752 Rotation SRAM Mismatch
22-750.17 Accessory PWB Configuration Mismatch
OF-9
May 2003
2-830
V0.042
Figure 1 OF-9 RAP Circuit Diagram
V0.042
May 2003
2-831
OF-9
OF-10 Broken Part RAP
OF-9 Auto Configuration On-Site Procedure

To correct this malfunction, the CSE must identify and correct the cause of the configuration
mismatch, and then reset the Installation Selection back to Manufacturing and force the
machine into Auto Configuration.
Use the following procedure to diagnose and correct this failure. (Do not select the hot links
until you are familiar with all of the steps.)
1.
While the power is Off, look at the connectors to the Main Control PWB and the Distribution PWB. Ensure all connectors securely connected.
2.
Do the following to check the most common causes of configuration errors:

a.
Ensure the Finisher is mounted correctly to the IOT frame (refer to REP 12-12 ).
b.
Ensure the Finisher actuates the Right Side Interlock Switch.
c.
Ensure that the HCF is mounted correctly and that the connector is connected.
3.
4.
Go to [Faults/Counters tab , Faults].
(20Oct2000)
The purpose of the RAP is to inform the CSE of any pertinent service information that may
apply to certain failed parts. This type of information may have been previously issued in a bulletin.
Procedure
When a part is obviously broken or defective, check this list for any service information related
to that part.
If no information is listed here on the broken part, replace the part following the usual procedures.
5.
Identify all logged faults. Diagnose and repair the cause of the faults.
6.
PO/PO the machine in order to clear the active faults and verify the faults do not reoccur.
7.
In the Diagnostic Navigator, select [Configuration] [System, Imaging, and IOT Configuration]. Enter [System, Imaging, and IOT Configuration].
8.
Locate the [Install Phase] window, and select [Customer Install].
9.
Select [Apply], then select [OK].
Paper Feed Drives Plate
Inverter

NOTE: This information is from bulletin # T4180-10-11 (Lakes/Muskegon Bulletin # 406)
Unable to open IOT Paper Trays 1 through 4. The information is valid until 1Oct2002.
Problem:
The customer has difficulty opening IOT Paper Trays 1, 2, 3, or 4, or is unable to open IOT
Paper Trays 1, 2, 3, or 4
11. In the Diagnostic Navigator, select [Configuration] [System, Imaging, and IOT Configuration]. Enter [System, Imaging, and IOT Configuration].
Cause:
12. Locate the [Install Phase] window, and select [Manufacturing].

13. Select [Apply], then select [OK].
15. Reset the second side registration (ADJ 8-1C and ADJ 8-1D).
The locator pin on the Paper Feed Drives Plate may become locked or sticky within the tray
socket, keeping the tray from being opened easily. The Paper Feed Drives Plate pin material
changed from stainless to nickel plating causing a diametrical difference.
Solution:
If the customer is having difficulty opening one of the IOT Paper Trays, coat both locator pins
on each Paper Feed Drives Plate (See Figure 1) with a small amount of molybdenum disulfide
grease (Xerox part # 70E120).
If the tray is locked, and can not be pulled out, do the following:
1.
Remove the surrounding trays.
2.
Pull on inboard side wall of the tray and the tray handle simultaneously.
3.
Once the tray is pulled open, apply the 70E120 grease to the 4 locator pins.
Bookmarks:
OF-9, OF-10
May 2003
2-832
REP 07-1
V0.042
Loacating Pins (4) - 2 on

each Paper Tray Drives
Plate
Figure 1 Locating Pins on the Paper Feed Drives Plate
V0.042
May 2003
2-833
OF-10
Inverter PL 6.2A Item 2

NOTE: This information is from bulletin # T3599-06-03 (Lakes Bulletin # 357) Broken Inverter
Frames.
Problem
Tag 083 introduced an Exit Baffle in place of the Enabled Decurler. The Exit Baffle has a floating entrance guide made from black plastic. This entrance guide can become dislodged during jam clearance, and left that way when the machine is closed up. The next time the Inverter
is pulled out, a part of the Inverter frame can catch on the dislodged entrance guide, and the
inverter frame usually breaks. The breakage is at the rear, near the ground lug.
Newer Exit Baffles have brackets installed (Tag 085) to hold the entrance guide securely. However, hundreds of pre-Tag 085 Exit Baffles are in the field.
Solution
This has proven to be a very expensive problem for Xerox, so two kits have been developed to
reduce the cost of repair, and eliminate the problem.
1.
An Inverter Repair Kit (PL 6.2C Item 2) was developed to repair Inverter frames that are
broken as described above.
2.
An Exit Baffle Bracket Kit (PL 6.1A Item 12) contains brackets to hold the entrance guide
securely in place, preventing it from becoming dislodged and interfering with the movement of the Inverter. As a preventative measure, Exit Baffle brackets should be installed
on all machines with Tag 083 and without Tag 085.
NOTE: The Exit Baffle brackets are also included in the Exit Baffle Kit PL 6.1A Item 6.
Tags
There is no Tag # associated with the repaired Inverter. However, Tag 085 is associated with
the Copy Exit Baffle retrofitted with the new brackets. Tag 085 should be marked off when
these brackets are installed on the Exit Baffle from either the Exit Baffle Kit PL 6.1A Item 6 or
the Exit Baffle Bracket Kit PL 6.1A Item 12.
Tools
Four tools are required to install the DC Thermal Fuse which are NOT part of the standard tool
kit, and also are NOT included in the repair kit.
A small, flat blade screwdriver
Straight-jaw pliers (Channel-Lock or similar)
A sharp utility knife
A fine tooth flat file
OF-10
May 2003
2-834
V0.042
3. Image Quality
Image Quality RAPs
IQ-1 Entry RAP ...............................................................................................................
IQ-2 Image Quality Checkout RAP .................................................................................
IQ-3 Video Path RAP ......................................................................................................
IQ-4 Signature Defects RAP ...........................................................................................
IQ-5 Non-Uniform Copies/Prints RAP .............................................................................
IQ-6 Copies/ Prints Too Dark RAP..................................................................................
IQ-7 Copies/ Prints Too Light RAP ................................................................................
IQ-8 Deletions .................................................................................................................
IQ-9 No Image RAP ........................................................................................................
IQ-10 Distorted Image RAP ............................................................................................
IQ-11 Ghosting/Residual Image/Offsetting RAP .............................................................
IQ-12 Background RAP...................................................................................................
IQ-13 Lines/Bands/Streaks RAP .....................................................................................
IQ-14 Spots/Dirt RAP ......................................................................................................
IQ-15 Geometrics RAP ...................................................................................................
IQ-16 Poor Fusing RAP ..................................................................................................
IQ-17 Black Copies/Prints RAP.......................................................................................
IQ-18 Special Stock RAP ................................................................................................
IQ-19 Motion Quality RAP...............................................................................................
IQ-20 IIT Torn Image RAP ..............................................................................................
IQ-21 IIT Grainy Image RAP ...........................................................................................
IQ-22 IIT Jagged Lines RAP ...........................................................................................
IQ-23 Black Holes Defect RAP .......................................................................................
IQ-24 Toner Blow-Out RAP.............................................................................................
3-3
3-5
3-8
3-10
3-12
3-16
3-17
3-19
3-23
3-23
3-26
3-28
3-30
3-34
3-38
3-43
3-44
3-45
3-46
3-47
3-48
3-48
3-49
3-50
Toner Reload ..................................................................................................................

Skew, LE ........................................................................................................................
Resolution ......................................................................................................................
Magnification ..................................................................................................................
3-91
3-91
3-92
3-92
IQ Defect Samples.
IQ Defect Samples Entry.................................................................................................
IB-OB Bands ...................................................................................................................
LE-TE Streaks/Bands......................................................................................................
Scrogged Images ............................................................................................................
Non-Uniform Copies/Prints .............................................................................................
Smeared Copies/Prints ...................................................................................................
Spots/Dirt ........................................................................................................................
Image Distortion ..............................................................................................................
Toner Disturbance...........................................................................................................
3-53
3-53
3-60
3-63
3-70
3-73
3-78
3-79
3-80
Image Quality Specifications.

Introduction/Test Patterns ..............................................................................................
IQ Definitions ..................................................................................................................
IQ Specifications Entry ...................................................................................................
Background ....................................................................................................................
Spots ..............................................................................................................................
Registration, LE ..............................................................................................................
Registration, Top to Bottom ...........................................................................................
Density ...........................................................................................................................
Deletions ........................................................................................................................
Uniformity .......................................................................................................................
V0.042
3-81
3-85
3-87
3-87
3-88
3-88
3-89
3-89
3-90
3-90
May 2003
3-1
Image Quality
Image Quality
May 2003
3-2
V0.042
IQ-1 Entry RAP
(LP and ST Printers Printer Driver Image Quality Settings)
This RAP is used as an entry point for Image Quality diagnostics.
Lighten/Darken
Reduce/Enlarge
Negative Image
Mirror Image
Bitmap Smoothing
Centered
Initial Actions
100%
If any fault codes are occurring, repair them first.
For problems copying on a DC or ST machine, inspect the originals for quality (question
customer if remote). Ensure that the originals are of sufficient weight to avoid showthrough and do not contain any irregularities at the location of the observed defect.
Not Selected
Not Selected
(DC and ST machines) Ensure that the Document Glass glass is clean. Lines on copies
are often caused by dirty CVT Glass (Refer to REP 05-1, DADF Cleaning Procedure).
If the customer is experiencing intermittent light copies/prints and/or intermittent faults 09318/320, and is running mostly in the SEP mode or alternates frequently between SEF
and LEF mode, suspect a parking deletion problem. This problem affects the patch zone
on the photoreceptor. Replacing the Xerographic Module PL 5.1A Item 1 will fix the problem temporarily. Engineering is working on a permanent fix for this problem. The problem
may re-occur within 50K depending on the customer mode of operation. Disabling Power
Save Mode may help prevent parking deletions by keeping a steady air flow through the
machine. Ensure the air filters are not clogged with dirt.
Emulate DocuTech 135
Margins
Resolution
If the defect repeats only on every other copy/print of 8.5 x 11" (A4), from the Document
Glass, Long Edge Feed (LEF), replace the Xerographic Module PL 5.1A Item 1.
If attempting to reproduce the problem, determine the customers run mode.
Not Selected
Not Selected
Standard
600x600x1
NOTE: If any of the above are not set to the default values, select the button to access the individual settings. A zero on the first screen is equivalent to Normal under the individual screens.
IQ-1 On-Site Diagnostic Procedure
Image Quality should only be evaluated against the specification when the optional IQ settings
are nominal. Question the customer if remote or ensure that the UI Image Quality settings
(under the Image Adjustment tab) are as follows and make a note if any settings are not at the
nominal setting so that they can be restored when complete:
Take appropriate steps to reproduce the problem if possible, or have a customers defective
copies for reference. For information about evaluating IQ using the test patterns, see IQ-2,
Image Quality Checkout RAP and/or the IQ Specifications Entry . Also, samples of IQ defects
are located at IQ Defect Samples Entry.
(DC and ST Machines UI Image Quality Settings)
If any of the following conditions are known to be occurring (main customer complaint), perform
the action indicated:
Image Quality
Type: Normal
Lighten/Darken: 0
Suppression: On
More Image Quality

Contrast: 0
Sharpness: 0
Screen: Auto
Bound Originals
Off
Edge Erase
Border Erase
The defect ONLY occurs when copying/printing on to special stock: Go to IQ-18, Special
Stock RAP.
If the defect repeats only on every other copy/print of 8.5 x 11" (A4), from the Document
Glass, Long Edge Feed (LEF), replace the Xerographic Module PL 5.1A Item 1.
The dry ink is not fused to the paper: Replace the Fuser Module PL 6.2A Item 1.
There are oil marks on the paper: Replace the Fuser Module PL 6.2A Item 1.
There is paper damage such as wrinkles, creases, embossing, dog ears: Go to the OF-2,
Print Damage RAP.
The defect only occurs with jobs that use Image Rotation: Go to the IQ-3 Video Path RAP
(Digital Copier).
Textured paper - The machine cannot run highly textured paper without IQ defects
If the problem began after installing a EHR PWB (Electronic Hole Removal) (see samples
- Figure 7, Figure 8), go to the IQ-3 , Video Path RAP.
3mm
Original Input
If none of the preceding apply, continue here.
Auto
Image Shift
No Shift
V0.042
May 2003
3-3
Image Quality
IQ-1
In [Faults/Counters tab , Faults], check the Last 40 Faults for any 09-338. If any 09-338
appears, check for any of the following faults that precede the 09-338. They would appear two
times, once just before the 09-338: 09-310, 09-314, 09-316, 09-318, 09-320, 09-324, 09330, or 09-332. If that situation occurred, go the RAP for the fault that occurred just prior to
the 09-338. If no 09-338 occurred, on the PWS in the Faults/Counters screen, select [Fault
Counters]. Select the Filter By Chain 09 option. Check for the above fault codes for any unusually high values. If there are high values, troubleshoot the most prevalent fault. If none of these
faults appear in the Last 40 or Fault Counters, continue below.
Halftone Defects Procedure

Read the types of non-image areas defects, and select the defect that best describes the
defect that is presently under investigation:
If the defect is LE-TE streaks that are most prominent in halftones, approximately 3-6mm
wide, not well defined edges (fuzzy), replace the Xerographic Module PL 5.1A Item 1.
Poor halftones, not uniform - go to the IQ-5, Non-Uniform Copies/Prints RAP
Wood-grain or honeycomb type pattern in halftones - go to the IQ-5, Non-Uniform Copies/Prints RAP
Select the condition, which BEST describes the defect that is presently under investigation:
Deletions - go to the IQ-8 Deletions RAP
Spots, Dirt - go to the IQ-14 Spots/Dirt RAP
Non-Image Area Defects - Defects that occur in non-image areas of the print such as
background, dirt, lines and streaks, or dark spots. Go to the Non Image Area Defects
Procedure.
Lines, Streaks - go to the IQ-13, Lines, Streaks, and Bands RAP
Bands - go to the IQ-13, Lines, Streaks, and Bands RAP
Halftone Defects - Defects which are primarily seen in halftone images such as non-uniformity, streaks, or banding. Go to the Halftone Defects Procedure
Deletion Defects Procedure
Deletion Defects - Part or all of the image is missing. Go to the Deletion Defects Procedure
Geometrics - Misregistration, skew, border bands, or magnification problems. Go to the

Geometrics Defects Procedure
Cropped Image, part of image missing and a misregistration problem in DADF mode - go
to the 05-E, Document Size Sensing RAP.
Image Density Problems - The copies/prints are too light or too dark. Go to the Image
Density Defects Procedure
Deletions - go to the IQ-8 Deletions RAP
Line Deletions, Streaks - go to the IQ-13, Lines, Streaks, and Bands RAP
Solid Area Quality - Defects related to the reproduction of solid area. Go to the Solid
Area Defects Procedure
Deletion Bands - go to the IQ-13, Lines, Streaks, and Bands RAP
Blank copies/prints - go to the IQ-9, No Image RAP
Distorted Image - Smeared or blurred copies/prints. The image has been distorted in
some way. Go to the Distorted Image Defects Procedure
Geometrics Defects Procedure
Scrogged Image - The digital image has been altered in some way. Go to the Scrogged
Defects Procedure
Other defects - Go to the Other Defects Procedure
Part of image missing (cropped) and a misregistration problem in DADF mode - go to the
05-E, Document Size Sensing RAP.
Non Image Area Defects Procedure
Misregistration - go to the IQ-15, Geometrics RAP.
Skew - go to the IQ-15, Geometrics RAP.
Incorrect Magnification - go to the IQ-15, Geometrics RAP.
Border Bands - go to the IQ-15, Geometrics RAP
Background - go to the IQ-12 Background RAP
Spots, Dirt - If the spots look like these, Figure 1 or Figure 2, go to the IQ-4, Signature
Defect RAP and troubleshoot Donor Debris Arcing. For other spots or dirt, go to the IQ-14
Spots/Dirt RAP
Jumping Gap Arcing defect (Figure 2, Figure 3, Figure 4, Figure 5, Figure 6) - If defect
looks like these, go to the IQ-4, Signature Defect RAP and troubleshoot Jumping Gap
Arcing Defect.
Image Density Defects Procedure

Read the types of density defects, and select the defect that best describes the defect that is
presently under investigation:
Density not uniform - go to the IQ-5, Non-Uniform Copies/Prints RAP
Copies/prints too light - go to the IQ-7, Copies/Prints too Light RAP
Smears - If smears are occurring in a non-image area, or appear to be unrelated to the

image, go to the IQ-14 Spots/Dirt RAP
Copies/prints too dark - go to the IQ-6, Copies/Prints too Dark RAP
Border Bands - Go to the IQ-15, Geometrics RAP
Colors not reproducing - go to the IQ-5, Non-Uniform Copies/Prints RAP
Lines, Streaks - go to the IQ-13, Lines, Streaks, and Bands RAP
Top Half different Density from Bottom Half of copy - go to the IQ-5
Residual Image - go to the IQ-11, Ghosting/Residual Image/Offsetting RAP
Wide, dark Border Bands - Go to the IQ-15, Geometrics RAP
Solid Area Defects Procedure
Black copies/prints - Go to the IQ-17, Black Copies/Prints RAP
Holes from punched originals visible on copies/prints - Go to the IQ-23, Black Holes RAP.
Copies/prints too light - go to the IQ-7, Copies/Prints too Light RAP
Copies/prints too dark - go to the IQ-6, Copies/Prints too Dark RAP
Image Quality
IQ-1
May 2003
3-4
V0.042
IQ-2 Image Quality Checkout RAP
White Spots - go to the IQ-14 Spots/Dirt RAP
Distorted Image Defects Procedure

Blurred or out of focus - go to the IQ-10, Distorted Image RAP.
Smears - go to the IQ-10, Distorted Image RAP.
Torn Image, image is stretched or compressed in a band from IB-OB - go to the IQ-20, IIT
Torn Image RAP.
NOTE: This defect is a scanning defect.
Image Quality should only be evaluated against the specification when the optional IQ settings
are nominal. Ensure that the UI Image Quality settings (under the Image Adjustment tab) are
as follows and make a note if any settings are not at the nominal setting so that they can be
restored when complete:
(DC and ST Machines UI Image Quality Settings)
Jagged Lines - go to the IQ-22, IIT Jagged Lines Image RAP.
NOTE: This defect is a scanning defect.
The IQ Checkout RAP can be used to help identify IQ defects and ensure that the IQ is meeting spec.
Image Quality
Type: Normal
Check the Image Distortion IQ Samples.
Lighten/Darken: 0
Scrogged Defects Procedure
Suppression: On
Broken Image (Figure 3) - Go to the IQ-3, Video Path RAP.
Out of Sync Image (Figure 2) - Go to the IQ-3, Video Path RAP.
Contrast: 0
Structured Background (Figure 10) (Figure 11) (Figure 12)
Sharpness: 0
Wavy Image (Figure 7) - Go to IQ-3, Video Path RAP
Go to the IQ-3, Video Path RAP.
Screen: Auto
Bound Originals
Edge Erase
Other Defects Procedure
Off
Paper Damage - go to the OF-2, Print Damage RAP
Fusing Problems - go to the IQ-16, Poor Fusing RAP
Doppler Defect - See the Smudges, Smears section of Smeared Copies/Prints.
More Image Quality
Border Erase
3mm
Original Input
Image Shift
Auto
No Shift
(LP and ST Printers Printer Driver Image Quality Settings)
Lighten/Darken
Reduce/Enlarge
Negative Image
Mirror Image
Bitmap Smoothing
Emulate DocuTech 135
Margins
Resolution
Centered
100%
Not Selected
Not Selected
Not Selected
Not Selected
Standard
V0.042
May 2003
3-5
Image Quality
IQ-1, IQ-2
600x600x1
NOTE: More information on IQ Specs can be located at IQ Specifications Entry .
1.
Place test pattern 82E13100 (8.5 x 11") or 82E13110 (A4) on the document glass (select
the appropriate paper size paper supply). Make 3 copies in standard mode.
NOTE: All evaluations should be done with the copies on a flat surface with white paper
underneath.
e.
Skew 1.6mm (8.5 x 11") or 1.7mm (A4)
f.
If out of spec, use the ADJ 8-1 and ADJ 14-2 for adjustment procedures. If the
problem continues, use IQ-1 IQ Entry RAP to identify the correct RAPs for
troubleshooting.
Magnification
a.
2. Examine the copies for the following:

Image Darkness
a.
Compare the solid area patches "A1" and "A2" on the copy to the "V" patch on
the side 2 of the test pattern. The "A1" and "A2" patches on the copy should be
no lighter than the "V" patch on the test pattern.
b.
If the darkness/solid area quality is out of spec, enter [Marking tab , Print Test
Pattern]. Select [Step Wedge]. Make 3 prints.
c.
Examine the 3rd print. Compare the darkest step to the V patch on side 2 of
the test pattern original. If the step wedge is also lighter than the "V" patch, the
problem is in the IOT. Go to the IQ-7, Copies/Prints Too Light RAP. If the IOT
prints are clearly OK, suspect an IIT problem. Go to the IQ-7, Copies/Prints
Too Light RAP.
d.
Compare the "E1" patch on the copy to the "P1" and "P3" patches on the original. The "E1" patch on the copy should be no darker than the "P3" and no
lighter than the "P1" on the test pattern. Also, Compare the "D1" patch on the
copy to the "N1" and "N3" patches on the original. The "D1" patch on the copy
should be no darker than the "N3" and no lighter than the "N1" on the test pattern.
i.
Enter [Marking tab , Print Test Pattern], select [Marking]. Make 1 print of
the Registration test pattern.
ii.
Using the last print of the Registration test pattern, lay the 82E13100 (11")
or 82E13110 (A4) pattern on top.
iii.
Align the K1 mag line on the 82E13100 (11") or 82E13110 (A4) to the closest corresponding line on the registration pattern.
iv.
Compare and note the alignment of the H1 line with the closest corresponding line on the registration pattern. (Each line is 0.5% difference
from nominal mag.)
v.
Perform the same procedure on the bottom edge of the pattern using the
K2 and H2 mag lines. Note the difference in mag from the nominal.
vi.
Average the top and bottom measurements to calculate the Horizontal

Magnification.
vii.
The horizontal mag should be less than or equal to 0.5% (one line) from
the nominal (H1 line). If horizontal mag is out of spec, go to the IQ-15,
Geometrics RAP.
IOT Vertical Magnification Procedure

i.
Enter [Marking tab , Print Test Pattern], select [Marking]. Make 1 print of
the Registration test pattern.
If the darkness is out of spec, enter [Marking tab , Print Test Pattern]. Select
[Step Wedge]. Make 3 prints. Using the 3rd print, compare the 5th darkest step
(find the 100% solid, count down 4 steps or use the graphic on side 2 of the test
pattern) to the "M1" and "M3" patches on side 2 of the test pattern original.
ii.
Using the last print of the Registration test pattern, lay the 82E13100 (11")
or 82E13110 (A4) pattern on top.
iii.
Align the K3 mag line on the 82E13100 (11") or 82E13110 (A4) to a corresponding line on the registration pattern.
f.
If the darkness appears clearly lighter than M1 darker than M3, the problem is
in the IOT. Go to the IQ-7, Copies/Prints Too Light RAP or the IQ-6, Copies/
Prints Too Dark RAP. If the IOT print are OK, suspect an IIT problem. Go to the
IQ-7, Copies/Prints Too Light RAP or the IQ-6, Copies/Prints Too Dark RAP.
iv.
Compare and note the alignment of the H3 line with the closest corresponding line on the registration pattern. (Each line is 0.5% difference
from nominal mag.)
g.
Ensure that both sections of blue text are readable and the blue square are visible on the copies.
v.
Perform the same procedure on the left edge of the pattern using the K4
and H4 mag lines. Note the difference in mag from the nominal.
h.
Check for toner reload. Compare the copies of the "B" and "C" patches to the
"S" and "T" patches on side 2 of the test pattern. Ensure that the lightened area
on the copy is no worse than the "S" and "T" patches. If it is, reload is out of
spec. Go to the IQ-11, Ghosting/Residual Image/Offsetting RAP.
vi.
Average the right and left measurements to calculate the Vertical Magnification.
vii.
The horizontal mag should be less than or equal to 0.5% (one line) from
the nominal (H1 line). If horizontal mag is out of spec, go to the IQ-15,
Geometrics RAP.
e.
i.
Check the copy of patch "A1" with the "V" patch on side 2 of the test pattern.
Solid area quality should be no worse than the "V" patch.
Registration and Skew
c.
Copier Horizontal Magnification Procedure (Platen Mode)

i.
Place the 82E13100 (11") or 82E13110 (A4) on the document glass and
make one copy.
a.
Use the reference scales on the corners of the pattern to check LE Registration, TE Registration, and skew.
ii.
b.
Lead Edge Registration 1.8mm
Align the K1 mag line on the 82E13100 (11") or 82E13110 (A4) to the corresponding line on the copy.
c.
Top Edge Registration (Side 1) 1.5mm
iii.
Compare and note the alignment of the H1 line with the corresponding line
on the copy. (Each line is 0.5% difference from nominal mag.)
d.
Top Edge Registration (Side 2) 2.0mm
Image Quality
IQ-2
b.
IOT Horizontal Magnification Procedure
May 2003
3-6
V0.042
d.
iv.
Perform the same procedure on the bottom edge of the pattern using the
K2 and H2 mag lines. Note the difference in mag from the nominal.
v.
Average the top and bottom measurements to calculate the Horizontal

Magnification.
vi.
The horizontal mag should be less than or equal to 0.7% (one line = 0.5%)
from the nominal (H1 line). If horizontal mag is out of spec, go to the IQ15, Geometrics RAP.
3.
Place test pattern 82E13100 (8.5 x 11") or 82E13110 (A4) in the DADF. Make 3 copies.
Evaluate the copies as in step 1, unless specified below.
Magnification
a.
Copier Vertical Magnification Procedure (Platen Mode)

i.
ii.
Compare and note the alignment of the H3 line with the corresponding line
on the copy. (Each line is 0.5% difference from nominal mag.)
iii.
Perform the same procedure on the left edge of the pattern using the K4
and H4 mag lines. Note the difference in mag from the nominal.
iv.
v.
The horizontal mag should be less than or equal to 0.7% (one line = 0.5%)
from the nominal (H1 line). If horizontal mag is out of spec, go to the IQ15, Geometrics RAP.
Resolution
b.
Copier Horizontal Magnification Procedure (DADF Mode)

i.
Run the 82E13100 (11") or 82E13110 (A4) through the DADF and make one
copy.
ii.
iii.
Compare and note the alignment of the J1 line with the H1 line on the copy.
(Each line is 0.5% difference from nominal mag.) A different mag is applied in
DADF mode to avoid black border lines.
iv.
Perform the same procedure on the bottom edge of the pattern using the K2
and J2 mag lines. Note the difference in mag from the nominal.
v.
Average the top and bottom measurements to calculate the Horizontal Magnification.
vi.
The horizontal mag should be less than or equal to 1.0% (one line = 0.5%) from
the nominal (H1 line). If horizontal mag is out of spec, go to the IQ-15, Geometrics RAP.
Copier Vertical Magnification Procedure (DADF Mode)

i.
ii.
Compare and note the alignment of the H3 line with the corresponding line on
the copy. (Each line is 0.5% difference from nominal mag.)
iii.
Perform the same procedure on the left edge of the pattern using the K4 and
H4 mag lines. Note the difference in mag from the nominal.
Background/Spots
iv.
a.
Check the non-image areas for objectionable background or spots.
v.
b.
Enter [Marking tab , Print Test Pattern]. Select [Blank Page]. Make 5 prints.
c.
Check for objectionable background. If background, there is an IOT problem.

Go to the IQ-12, Background RAP.
The horizontal mag should be less than or equal to 0.7% (one line = 0.5%) from
the nominal (H1 line). If horizontal mag is out of spec, go to the IQ-15, Geometrics RAP.
d.
If no background is present on the internal test pattern, there is an IIT problem.

Go to the IQ-12, Background RAP
a.
Check the R1, R2, R3, R4 patches for blurred lines. The 4.3 lpi pairs should just
be resolved, and 3.5 lpi should be clearly resolved.
b.
Check IOT resolution. Enter [Marking tab , Print Test Pattern]. Make 5 prints of
2on/2off perpendicular lines. Check for banding within this pattern.
c.
Go to the IQ-19, Motion Quality RAP.
Uniformity
a.
Make 3 copies of the test pattern in Photo mode. Inspect the IB-OB (F) and LETE (G) bands to check for objectionable non-uniformity.
b.
Compare the E1 and E2, D1 and D2, A1 and A2 patches for uniformity.
c.
If the uniformity is objectionable, enter [Marking tab , Print Test Pattern]. Make
5 prints of 106 DPI 50% Halftone.
d.
If non-uniformity is objectionable, (clearly worse than X1, X2, Y1-Y3) there is an

IOT problem. Go to the IQ-5 IOT Non-Uniform Prints RAP. If the problem is
Lines, Streaks, or Bands, go to the IQ-13, Lines, Streaks, or Bands RAP. For
high frequency banding (IB-OB), go to the IQ-19, Motion Quality RAP. If the
problem is deletions, go to the IQ-8, Deletions RAP.
e.
If the 106dpi 50% Halftone internal prints are OK, suspect an IIT problem. For a
non-uniformity problem, go to the IQ-5 IOT Non-Uniform Prints RAP. If the
problem is Lines, Streaks, or Bands, go to the IQ-13, Lines, Streaks, or Bands
RAP. If the problem is deletions, go to the IQ-8, Deletions RAP.
V0.042
May 2003
3-7
Image Quality
IQ-2
IQ-3 Video Path RAP
This RAP is intended to used when the IQ-1 Entry RAP indicates that the Imaging Electronics
is the cause of the IQ Defect.
The following definitions pertain to defects that can be generated in the video path:
Scrogged Image: A digital image defect. The digital data sent to the ROS is an incorrect
reproduction of the original document. These defects are usually well defined and have
definite edges. They may be subtle or very dramatic.
Initial Actions
To view samples of this type of defect, go to the Scrogged Images Samples section.
If the machine has an EHR PWB (Electronic Hole Removal PWB), especially if the problem
occurred after replacing or installing an EHR PWB, ensure the following:
If the machine has TAG 077 , ensure that the EHR PWB part number is 160K64610.
If the machine does not have TAG 077 , the EHR PWB can be part number 160K59430 or
160K64130. 160K64610 will not work in machines without TAG 077.
If the machine is a 460/470, the EHR PWB is unique and cannot be one of the older styles
above.
N
Reseat the EPC Memory SIMM or DIMM.
Select the [EPC Memory Test] [Start Test]. The test passes.
Y
N
Without TAG 077 Replace the EPC DRAM SIMMS PL 1.4A Item 6.
If the problem continues, go to the 03-G, Main Control PWB
Replacement RAP.
With TAG 077 Replace the EPC SRAM DIMM PL 1.4B Item 5. If the
problem continues, go to the 03-G, Main Control PWB Replacement
RAP.
On 460/470, replace the EPC SDRAM DIMM PL 1.4C Item 6. If the
problem continues, go to the 03-G, Main Control PWB Replacement
RAP.
Run copies/prints to re-test for defect. The IQ Defect is still present.
Y
N
Select [VCM/IPS1 Loop Test] [Start Test].

Observe the status area. The test passes.
Y
N
Check machine configuration for an IPS1 Daughter Card. (Either AutoSeg
PWB or EHR PWB) This machine has an optional IPS1 Daughter
Card.
Y
N

Check machine configuration. The machine is a LP model or a DocuTech 65 / DocuPrint
65.
Y
N
The defect only occurs with Image Rotation.
Y
N
In [Self Tests tab , Video and Controls POST], select [Main Controller Tests (2)]
[SCVM Loop Test], then [Start Test].
Observe the Faults area. Loop Faults occurred.
Y
N
In [Self Tests tab , Video Path Diagnostics], select [SCVM Digital Test], then
[Start Test].
Y
N
Check the machine for Tag 15. The machine has TAG 015.
Y
N
In [Faults/Counters tab , Faults], check the Last 40 Faults for any 14314, 14-315, 14-316, 14-317, 14-318, 14-319, or 14-320 faults.
There are 14-314, 14-315, 14-316, 14-317, 14-318, 14-319, or 14320 faults in the Last 40.
Y
N
There was a false failure of the SCVM Digital Test. Return to the
step where the SCVM Digital Test was run and answer YES.
Reseat the IPS1 daughter card. Re-run the [VCM/IPS1 Loop Test], then
[Start Test].
Y
N
Switch off the machine power. Remove the IPS1 Daughter Card from
the machine. Switch on the machine power. Re-run the [VCM/IPS1
Loop Test], then [Start Test]
Y
N
Replace the IPS1 Daughter Card (Autoseg PWB or EHR PWB) PL
1.4A Item 3 or PL 1.4B Item 1.
Run copies/prints to re-test for defect.
Observe the copies/prints. The IQ Defect is still present.
Y
N


Select the [EPC Memory Test], then [Start Test].
A
B
C
Image Quality
IQ-3
Replace the Raster Output Scanner Video Cable PL 1.2A Item 4. Run copies/
prints to re-test for defect.
A
May 2003
3-8
C
V0.042
D
Y
N
N

Replace the Image Module, Scanner Video Cable Kit PL 3.2 Item 1. Run copies/
prints to re-test for defect.
Y
N
Select [VCM/IPS1 Loop Test] [Start Test].

Y
N
Check machine configuration for an IPS1 Daughter Card (Either AutoSeg PWB or EHR
PWB). This machine has an optional IPS1 Daughter Card.
Y
N

Reseat the IPS1 daughter card. Re-run the [VCM/IPS1 Loop Test], then [Start Test].
Y
N
Switch off the machine power. Remove the IPS1 Daughter Card from the machine.
Switch on the machine power. Re-run the [VCM/IPS1 Loop Test], then [Start Test]
Y
N
Check machine Tag matrix for TAG 077.

Y
N
Check for correct connection of the Rotation SRAM SIMM.
Ensure that the SIMM is seated correctly in its socket. The SIMM is OK.
Y
N
Repair/Replace as necessary Rotation SRAM SIMM PL 1.4A Item 5.
In [Self Tests tab , Video and Controls POST], select [Main Controller Tests (1)]
[Rotation Memory Test] [Start].
Observe the test results. The test failed.
Y
N
Replace the IPS1 Daughter Card (Autoseg PWB or EHR PWB) PL 1.4A Item 3 or
PL 1.4B Item 1.
Run copies/prints to re-test for defect.
Y
N
Replace the Rotation SRAM SIMM PL 1.4A Item 5.

In [Self Tests tab , Video and Controls POST], select [Main Controller Tests (1)] [Rotation
Memory Test] [Start].
Observe the test results. The test failed.
Y
N
There doesnt appear to be a problem with the Rotation hardware. Return to the
beginning of the RAP and do not answer Yes to the question that indicates an Rotation only problem.
Select the [EPC Memory Test], then [Start Test].

Y
N
Reseat the EPC Memory SIMM or DIMM.
Select the [EPC Memory Test] [Start Test]. The test passes.
Y
N
Replace the EPC DRAM SIMMS PL 1.4A Item 6 (without TAG 077) or EPC SRAM
DIMM PL 1.4B Item 5 (with TAG 077) or EPC SDRAM DIMM PL 1.4C Item 6 (on
460/470). If the problem continues, replace the Main Control PWB PL 1.4A Item 1.
D
V0.042
In printers, this problem can be caused by print drivers, ESS, or the Main Control PWB (even
when Video Path Diagnostics passes). Unless the defect matches one of the defects known to
be caused by the Main Control PWB, there is no way to diagnose it.
Before continuing, if defect is seen in print jobs, but not in any internal IOT test patterns, check
the following:
1.
Run copies/prints to re-test for defect. The IQ Defect is still present.
Ensure that client printer drivers are up to date
2.
Reload print drivers
3.
Ensure that no ESS / Print Controller faults are occurring. If ESS Faults are occurring on a
LP machine, return to Service Call Procedures. If Print Controller faults are occurring on
DocuTech 65 /Docuprint 65, return to the DocuTech 65 service manual.
4.
If the above did not help, continue below.
Replace the Raster Output Scanner Video Cable PL 1.2A Item 4. Run copies/prints to re-test
for the defect.
Y
N
May 2003
3-9
Image Quality
IQ-3
IQ-4 Signature Defects RAP
NOTE: Installing a high altitude kit on machines that are not at high altitudes wont fix
jumping gap arcing. In most cases, it will actually make it worse.
The Signature Defects RAP is designed to be used for unique IQ defects that are easily identifiable.
Using REP 09-11, Photoreceptor Drive Module Cleaning Procedure, thoroughly clean all
surfaces of the Photoreceptor Drive Module. Observe the inside of the Xerographic
Module. Check for contamination, especially on the inside of the P/R Belt. If contaminated, replace the Xerographic Module PL 5.1A Item 1.
Check for a reoccurrence of the problem. The problem continues (Or, if this is the
second service call for this problem on this machine, answer Yes).
Y
N
Initial Actions
Be sure to enter this RAP from another RAP or procedure that refers to this RAP.
Definitions:
Jumping Gap Arcing - When debris in the Photoreceptor Drive Module passes underneath the P/R Belt and momentarily narrows the gap between the Donor Roll and the P/R
belt. There may be a arc, which causes the prominent defect. If is, however, usually limited to a small area on the page. Jumping Gap Arcing IQ Defect Samples (Smudges/
Smears), Figures 2, 3, 4, 5, and 6).
Check the Card Cage for possible shorting to the Developer HVPS. (09-370, 09-372, 09374, 09-376, and 09-386 faults may also occur with this problem) Perform the following:
1. Switch off the machine power. Remove all rear covers.
Jumping Gap Air Breakdown - Similar to Jumping Gap Arcing, but the arcing is not related
to debris narrowing the gap. It is usually related to high altitude conditions where the density of the air increases the likelihood of widespread donor to P/R Belt arcing. Usually is
widespread across the page. If it is occurring at low altitudes it is due to a narrow gap
between the Developer Donor Roll and the PR backer bar. Jumping Gap Air Breakdown
IQ Defect Samples (Smudges/Smears), Figures 7, 8, and 9.
2.
Remove the cover at the HCF end of the machine (the small narrow gray side panel
secured by 2 screws)
3.
Leave the Card Cage in the closed and locked position.
4.
From the rear of the machine, locate the Card Cage hinge blocks that mount to the
IOT side frame member. Determine if the upper portion of the hinge blocks are tilted
inward, creating an uneven gap between the hinge block and the machine frame
member.
5.
The defect is a Jumping Gap Arcing or Jumping Gap Air Breakdown defect.
Y
N
The defect is Donor Debris Arcing.
Y
N
At this time there are no other defects checked in this RAP. Use the IQ Defect Samples Entry or IQ-1, IQ Entry RAP, for specific defect actions.
Loosen the top hinge pin screw and adjust the hinge block by placing a finger behind
the hinge block and pulling the hinge block towards you until it is parallel and tight to
the back frame flange.
6.
Loosen the bottom hinge pin screw and adjust the hinge block by placing a finger
behind the hinge block and pulling the hinge block towards you until it is parallel and
tight to the back frame flange.
7.
Swing open the Card Cage. Ensure the inside cover of the Card Cage is seated and
positioned correctly. Re-position the inside cover if necessary. Close and secure the
Card Cage.
8.
Donor Debris Arcing - Occurs when debris gets between the Donor Roll and P/R Belt.
(Donor Debris Arcing IQ Defect Samples).
Remove the Xerographic Module and Developer Housing.
Inspect all areas near the Developer Housing for any debris or fibers that may interfere with the housing.
Inspect the Xerographic Module for any debris/fibers, especially in the development
area.
Check the ROS window for any fibers/debris.
Go to the 09-K Developer Housing Checkout RAP.
If the problem continues, replace the Photoreceptor Drive Module PL 5.1A Item 2.
See if the problem is resolved. The problem continues.

Y
N
Y
N
Y
N
There is a message that indicates that the ROS A/B Test failed.
Y
N
(Use this list for 15.x software)
Review the definitions and defect samples of Jumping Gap Air Breakdown and Jumping Gap
Arcing if necessary.
Determine if the defect is Jumping Gap Air Breakdown or Jumping Gap Arcing. The
defect
looks like Jumping Gap Air Breakdown.
A
Image Quality
IQ-4
May 2003
3-10
Toner Dispenser
Developer PS (Developer HVPS) or loss of Developer Drive
XRM (Ground) (Xerographic Module)
D
V0.042
Developer Housing
ROS
BTAC Noise
General Image Noise
(Use this list for 17.x or later software)
Toner Dispenser
Developer Housing
Charge HVPS
BTAC Noise
Non-Uniform Image Detected - There may be an IQ problem which

could lead to incorrect results in the Xerographic Exerciser. Run
some 106 DPI Halftones and check for banding. If banding exists, go
to IQ-1, Image Quality Entry RAP.
Xerographic Module (Ground), go to the 09-J, Xerographic Module

Checkout RAP
Jumping Gap out of spec. Replace Photoreceptor Drive Module PL

5.1A Item 2.
NOTE: Ignore any other parts that are in the Parts to Replace message
that are not in the list above.

In [Marking tab , Print Test Pattern], run 200 prints of the 106 DPI 50% Halftone pattern.
When complete, enter [Marking tab , Xerographic Diagnostics]. Select [Set-Up], then
[Start Test].
Check for a reoccurrence of the problem. The problem is corrected.
Y
N
The parts to replace message includes one or more from the above
list.
Y
N
The Xerographic Exerciser is displaying a Parts to Replace message.
There may be a single item, or several on the list. The first item is the main
suspect, but make a note of the other items for possible future reference.
Go to the RAP listed below for the part that was the first one listed in the
Xerographic Exerciser parts to replace message.
Developer HVPS (may say Developer PS) or loss of Developer

Drive, check for correct operation of the Developer Drives. If OK, go
to the 09-G, Developer HVPS Checkout RAP
XRM (Ground), go to the 09-J, Xerographic Module Checkout RAP

RAP
General Image Noise - There may be an IQ problem which could

lead to incorrect results in the Xerographic Exerciser. Run some 106
DPI Halftones and check for banding. If banding exists, go to IQ-1,
Image Quality Entry RAP.

RAP

The machine is at a location where the height above sea level is 4000 feet / 1200 meters
or greater.
Y
N
Go to the 09-E Developer HVPS Checkout. If no problem is found, return here.
The machine has TAG 297 installed.

Y
N
Install TAG 297 and TAG 086 (L17.8.64 SW).
Check the machine for TAG 292 (Dev. Hsg. Gears).
Y
N
Check the machine for TAG 086 (L17.8.64 SW)
Y
N
Obtain and install TAG 086 and TAG 292.
Obtain and install TAG 292 (Dev. Hsg. Gears) PL 5.1B Item 12.
Check the machine for TAG 086 (L17.8.64 SW).
A
B
V0.042
May 2003
3-11
Image Quality
IQ-4
IQ-5 Non-Uniform Copies/Prints RAP
N
Obtain and install TAG 086 (L17.8.64 SW).
Perform the following in order until the problem is resolved:
Ensure that the altitude setting in NVM is correct for the local altitude. Machines that have
this kit installed in VALO are set to 6000 feet. This may not have been adjusted for this
machine.
1.
In [NVM tab , NVM Tool], under the Mark Service, go to location 841.
2.
Ensure that the value is correct for the local altitude in feet.
NOTE: To convert from meters to feet, multiply the altitude in meters by 3.
Non-uniformity: Image density varies from one part of the copy/print to another. This defect is
easiest to see and more likely to appear on copies/prints with halftones that cover a large part
of the page.
Initial Actions
To view samples of this type of defect, go to the Non-Uniform Copies/Prints Samples section.
(DC or ST machines, Copying only) If this defect is only occurring with an original that
contains high frequency lines (4 lines per mm or greater), it is a normal condition.
If the Non-Uniformity appears as streaks or bands, go to the IQ-13 Lines, Bands, and
Streaks RAP.
3.
If the value was not correct, change the value to the correct altitude. Save the
change.
4.
Enter [Marking tab , Xerographic Diagnostics]. Select [Set-Up], then [Start]. When
complete, ensure that the problem is resolved.
Ensure that all Image Quality controls are set to nominal.
If any 09-XXX fault codes are present in the fault logs, troubleshoot them first.
REP 09-11, Photoreceptor Drive Module Cleaning Procedure
Ensure that paper is fresh and in spec. Try a new ream of paper, if necessary.
REP 09-12, Developer HVPS Contacts Cleaning Procedure
(DC or ST machines, Copying only) If the defect is light areas or bands that occur in halftones, generally within 60mm of the lead edge or trail edge, check for TAG 016. If Tag
016 is not installed, order and install Tag 016. Until Tag 016 is installed, perform the following to help overcome the problem:
NOTE: While cleaning the pads on the HVPS, note whether the pads are solid or ribbed.
This information might be needed later.
Perform the 09-E Developer HVPS Checkout. If no problem is found, return here.
a.
On the User Interface display, select [Image Adjustment] [More Image Quality].
Increase the altitude setting by 1000 feet. In [NVM tab , NVM Tool], under the Mark Service, go to location 841, increase the value by 1000. Enter [Marking tab , Xerographic
Diagnostics]. Select [Set-Up], then [Start].
b.
On the Sharpness scale, press [Down] once to move the indicator down one increment into Soft.
If the Developer HVPS had ribbed pads, order a new Developer HVPS PL 1.2A Item 7.
c.
Select [Save]. Under the More Image Quality button, it should now say Sharpness: 1.
Check the Card Cage for possible shorting to the Developer HVPS. (09-370, 09-372, 09374, 09-376, and 09-386 faults may also occur with this problem) Perform the following:
d.
Re-run the job.
e.
If the copies are acceptable, return to Service Call Procedures. If the copies still
have the defect, repeat steps a-d so that the sharpness is: -2. If the problem continues, go to step f.
1.
Switch off the machine power. Remove all rear covers.
2.
Remove the cover at the HCF end of the machine (the small narrow gray side panel
secured by 2 screws)
f.
On the User Interface display, select [Image Adjustment] [Image Quality].
3.
Leave the Card Cage in the closed and locked position.
g.
4.
From the rear of the machine, locate the Card Cage hinge blocks that mount to the
IOT side frame member. Determine if the upper portion of the hinge blocks are tilted
inward, creating an uneven gap between the hinge block and the machine frame
member.
On the Lighten/Darken scale, press [Down] once to move the indicator down one
increment into Darken.
h.
Select [Save]. Under the Image Quality button, it should now say Darken: -1.
i.
If the copies are acceptable, return to Service Call Procedures. If the copies still
have the defect, repeat steps f-i so that the Darken is: -2.
5.
Loosen the top hinge pin screw and adjust the hinge block by placing a finger behind
the hinge block and pulling the hinge block towards you until it is parallel and tight to
the back frame flange.
6.
Loosen the bottom hinge pin screw and adjust the hinge block by placing a finger
behind the hinge block and pulling the hinge block towards you until it is parallel and
tight to the back frame flange.
7.
Swing open the Card Cage. Ensure the inside cover of the Card Cage is seated and
positioned correctly. Re-position the inside cover if necessary. Close and secure the
Card Cage.
8.

The machine is an LP or DocuTech 65 model, OR an ST model AND the defect occurs
when printing jobs from a network or computer.
Y
N
For samples of non-uniformity, see Non-Uniform Copies/Prints. In [Marking tab , Print
Test Pattern], run 5 prints of the 106 DPI 50% Halftone pattern.
Inspect the prints for non-uniformity. The prints are OK.
Y
N
Go to the IQ-5 IOT On-Site Diagnostic Procedure
The original that the defect is occurring with, includes colors or the original itself
is on colored paper.
A
Image Quality
IQ-4, IQ-5
May 2003
3-12
V0.042
A
Y
N
The problem only appears in halftone images.
Y
N
Inspect for high levels of contamination on the Image Module and underside of
document glass. There is a high level of contamination.
Y
N
The defect occurs when making copies from the document glass.
Y
N
Replace the Document Glass Frame PL 3.1 Item 5.
D
Perform the REP 14-3 Scanner Cleaning Procedure. If the problem continues,
return to the beginning of this RAP.
Go to the IQ-3, Video Path RAP.

The defect can be reproduced using a black and white original (test pattern).
Y
N
Make 5 copies of the 82E13100 (8.5x11) or 82E13110 (A4).
Observe the copies. See if the blue text and squares are reproduced completely.
The blue images on the test pattern are fully reproduced.
Y
N
The defect also occurs in the Document Feeder mode.

Y
N
Clean the underside of the document glass cover.
Make copies. The defect is still present.
Y
N
The problem is related to the original. Discuss with the customer the IQ options
which may help improve the IQ of these types of originals.
Return to the beginning of this RAP and answer NO to the statement that this is related to
a colored original.

The problem is non-uniform focus, background, or blur.
Y
N
Observe the Scanner Cooling Fan. The Scanner Cooling Fan is
running.
Y
N
Replace the Scanner Cooling Fan PL 9.1 Item 10
Check the Scanner Dust Filter. The filter is contaminated.
Y
N
Replace the Scanner Dust Filter PL 9.1 Item 9
In [IIT tab , Scanner Lamp Profile], select [Lamp Off], then [Start].
Observe the results of the test.
Observe the test results. The Lamp Profile checks OK. (The green
line is flat at the 0 (zero) level on the graph.)
Y
N
Replace the Image Module PL 3.2 Item 3 .
Replacement RAP.
IQ-5 IOT On-Site Diagnostic Procedure

Inspect the defect prints. There is a wood-grain or honeycomb type pattern in the halftones.
Y
N
The main problem is uneven or light density in solid areas.
Y
N
Inspect the defect prints. The image density varies IB - OB (Lighter or darker at
the Inboard or Outboard side. If the image density varies as you look at the
print density LE-TE, answer No).
Y
N
The image density varies from LE-TE. Determine if the Xerographic Module
may have been out of the machine and uncovered for a period of time. The
Xerographic Module has been exposed to room light.
Y
N
Enter [Marking tab , Xerographic Diagnostics]. Select [Set-up], then [Start
Test].
Observe the test results. The Set-Up completed without any faults.
Y
N
In [Marking tab , Print Test Pattern], select 106 dpi 50% Halftone. Make
prints to check for the defect. The problem is resolved.
Y
N
Replace the following one at a time until the problem is corrected:
In [IIT tab , Scanner Lamp Profile], select [Lamp On], then [Start].
Observe the test results. The Lamp Profile checks OK. (The green
line stays within the indicated range.)
Y
N
Replacement RAP.
Developer HVPS PL 1.2A Item 7
Toner Dispenser PL 5.1B Item 4

If the problem continues, go to the 03-G, Main Control PWB Replacement
RAP.
A
B
V0.042
E
May 2003
3-13
H
Image Quality
IQ-5
H
If the Xerographic Module has been exposed the room light for under 1 hour,
the PR Belt should recover after a short period of time. If it was exposed for an
hour or more, the PR Belt will need several hours of recovery time (overnight).
If the problem continues after sufficient recovery time, replace the Xerographic

Make prints. The problem is resolved.
Y
N
In [Marking tab , Print Test Pattern], select 106 dpi 50% Halftone. Make prints
and check for the defect. The problem is resolved.
Y
N
Replace the CVT Dirt Streaks Label PL 3.1 Item 8.
In [Marking tab , Print Test Pattern], select 106 dpi 50% Halftone. Make
prints and check for the defect. The problem is resolved.
Y
N
XRM (P/R Belt), go to the 09-J, Xerographic Module Checkout RAP
General Image Noise - There may be an IQ problem which could lead to

incorrect results in the Xerographic Exerciser. Run some 106 DPI Halftones and check for banding. If banding exists, go to IQ-1, Image Quality
Entry RAP.
(This list for 17.x or 18.x software)
Developer HVPS, Developer Drives, check for correct operation of the

Developer Drives. If OK, go to the 09-G, Developer HVPS Checkout RAP
Xerographic Module (Ground), go to the 09-J, Xerographic Module Checkout RAP

Checkout RAP
Xerographic Module (P/R Belt), go to the 09-J, Xerographic Module

Checkout RAP

In [Marking tab , Print Test Pattern], run 5 prints of the 1.75" Lead Edge Black Band pattern.

Item 2.
NOTE: Solid area should only be evaluated with the print on a white flat surface (use
paper behind if necessary).

Quality Entry RAP.
Compare the solid area to the V patch on Side 2 of test pattern 82E13100 (8.5 x 11") or
82E13110 (A4). The relative quality of the prints should not be worse than the V patch on
the test pattern. The darkness gradually changes from IB-OB (ramps) and is objectionable.
Y
N
Y
N
(This list for 15.x software)
E
I
J
Image Quality
IQ-5
Developer HVPS (may say Developer PS) or loss of Developer Drive,

check for correct operation of the Developer Drives. If OK, go to the 09-G,
Developer HVPS Checkout RAP
XRM (Ground), go to the 09-J, Xerographic Module Checkout RAP
XRM (Cleaner), go to the 09-J, Xerographic Module Checkout RAP
In [Marking tab , Print Test Pattern], select the Manufacturing pattern. Make 100
prints. Then, enter [Marking tab , Xerographic Diagnostics]. Select [Set-up], then
[Start Test]. In [Marking tab , Print Test Pattern], run 5 prints of the 1.75" Lead Edge
Black Band pattern.
Compare the solid area to the V patch on Side 2 of test pattern 82E13100 (8.5 x 11")
or 82E13110 (A4). The relative quality of the prints should not be worse than the V
patch on the test pattern. The solid area on the prints is now OK.
Y
N
If the problem continues, go to the 09-A, Charge HVPS Checkout RAP.
In [Marking tab , Print Test Pattern], select 106 dpi 50% Halftone. Make prints to help
characterize the problem.
Observe the prints. The darkness is lighter or darker in the center of the print than
it is on the IB and OB areas of the prints.
Y
N
Replace the following in order, one-at-a-time, until the problem is resolved:
May 2003
3-14
K
V0.042
Photoreceptor Drive Module PL 5.1A Item 2
CVT Dirt Streaks Label PL 5.2 Item 3
ROS Assembly PL 5.2 Item 3
Inspect the prints. There is a honeycomb defect and it is seen only on side 2 of duplex
jobs.
Y
N
Inspect the prints. The defect is a woodgrain type pattern in the halftones.
Y
N
Replace the Xerographic Module PL 5.1A Item 1 .
V0.042
May 2003
3-15
Image Quality
IQ-5
IQ-6 Copies/ Prints Too Dark RAP

This procedure is intended to assist with copies/prints that are too dark.
B
Go to the RAP indicated by the fault code.
Initial Actions
Ensure that there are no other defects on the copies/prints. If other defects are occurring,
do not troubleshoot for dark copies/prints.

In [Marking tab , Print Test Pattern], run 5 prints of the Stepwedge pattern.
Inspect the prints for image darkness. Compare the 50% band, which is the 5th band (start with
darkest or look at the arrow that points from the M2 patch to the schematic of the step wedge)
on the IOT print to the patches labeled "M1", "M2", and "M3" on the side 2 of the pattern. The
50% step wedge is equal or lighter than the M3 patch.
Y
N
The defect occurs in both manual platen and DADF mode.
Y
N
If the problem is intermittent or only appears under stress or different conditions, try to
reproduce the conditions, if possible. If the defect is not occurring when making copies
under any conditions, return to the IQ-1 Image Quality Entry RAP. See if the defect can
be classified differently.
Perform the REP 14-3 Scanner Cleaning Procedure,
Make copies and check for the defect. The problem is resolved.
Y
N

NOTE: If a 09-XXX fault occurs when running Xerographic Set-Up at anytime in this RAP, go to
the RAP for that fault to continue troubleshooting.
Enter [Marking tab , Xerographic Diagnostics]. Select [Set-Up], then [Start Test].
Observe the test results. A fault code occurs.
Y
N
Inspect the prints for image darkness. Compare the 50% wedge to the M3 patch on side 2
of the test pattern document. The 50% step wedge is darker than the M3 patch.
Y
N
The ROS Assembly may be incorrectly positioned. Check for a correct installation of the
ROS Assembly REP 06-1.
Observe the ROS Assembly. The ROS Assembly is installed correctly.
Y
N
Re-install the ROS Assembly correctly REP 06-1.
A
B
Image Quality
May 2003
3-16
IQ-6
V0.042
IQ-7 Copies/ Prints Too Light RAP
This procedure is intended to assist in determining causes of light copies/prints.
Initial Actions
In [Marking tab , Print Test Pattern], select Manufacturing test pattern. Make 100 prints.
In [Marking tab , Xerographic Diagnostics]. Select [Set-Up], then [Start Test].
Observe the test results. The Xero Set-Up completed successfully without a fault or failure.
Y
N

Y
N
The main problem is light density in black (on original) solid areas.
Y
N
Inspect the prints for image darkness. Compare the 50% wedge to the M1 patch on
side 2 of the test pattern document. The 50% step wedge is equal to or darker
than the M1 patch.
Y
N
Go to the IQ-7 IOT On-Site Diagnostic Procedure.
The defect occurs in both manual platen and DADF mode.
Y
N
If the problem is intermittent or only appears under stress or different conditions, try to reproduce the conditions, if possible. If the defect is not occurring
when making copies under any conditions, return to the IQ-1 Image Quality
Entry RAP. See if the defect can be classified differently.
The main problem is light density in solid areas.

Y
N
In [Marking tab , Print Test Pattern], select [Step Wedge]. Make prints to check for the
defect.
Inspect the prints. Compare the 50% wedge (see back of 82E1291 or 82E13110) to the
M1 patch on side 2 of the test pattern document. The defect has been corrected.
Y
N
In [Marking tab , Print Test Pattern], select [Step Wedge]. Make prints to check for
the defect. The defect has been corrected.
Y
N
Go to 09-G Developer HVPS Checkout RAP and perform any corrective
actions indicated by the outcome of that RAP. Return here when complete.
In [Marking tab , Print Test Pattern], select [Step Wedge]. Make prints to check
for the defect. The defect has been corrected.
Y
N
Go to 09-B Transfer HVPS Checkout RAP. If the Transfer HVPS Checkout is OK, replace the Developer Housing PL 5.1B Item 5.
Perform the REP 14-3 Scanner Cleaning Procedure,

Make copies and check for the defect. The problem is resolved.
Y
N
Inspect the originals that the defect is occurring with. The original that the
defect is occurring with includes colors.
Y
N

In [Marking tab , Print Test Pattern], run 5 prints of the 1.75" Lead Edge Black Band pattern.
The problem is occurring only with the reproduction of colors other than
black or gray.
Y
N
NOTE: Solid area should only be evaluated with the print on a white flat surface (use paper
behind if necessary).
Compare the solid area on the 5th print to the V patch on Side 2 of test pattern 82E13100 (8.5
x 11") or 82E13110 (A4). The relative quality of the prints should not be worse than the V patch
on the test pattern. Some or all of the solid on the print is worse than the V patch.
Y
N
The solid area appears to be in spec. The problem was corrected by running Xero SetUp.
The darkness gradually changes from IB-OB (ramps) and is objectionable.
Y
N
A
V0.042
May 2003
3-17
Image Quality
IQ-7
A
Y
N
The Xerographic Exerciser is displaying a Parts to Replace message. There may be
a single item, or several on the list. The first item is the main suspect, but make a
note of the other items for possible future reference.
Go to the RAP listed below for the part that was the first one listed in the Xerographic
Exerciser parts to replace message.
Observe the prints. The darkness is lighter or darker in the center of the print than it is
on the IB and OB areas of the prints.
Y
N
Developer HVPS (may say Developer PS), go to the 09-G, Developer HVPS
Checkout RAP
The Xerographic Module (may say XRM) can fail the Exerciser for 3 reasons:
XRM (Belt)
XRM (Cleaner)
XRM (Ground)
Go to the 09-J, Xerographic Module Checkout RAP
General Image Noise - There may be an IQ problem which could lead to incorrect results in the Xerographic Exerciser. Run some 106 DPI Halftones and
check for banding. If banding exists, go to IQ-1, Image Quality Entry RAP.
Clean
WARNING
Possible poor contact between the Developer Housing and the Developer HVPS. This
contact is made by a pair of compression springs (Developer HVPS Contact Springs) on
the inboard end of the Developer Housing which push directly against the pads of the
Developer HVPS. On most machines, the two springs are covered by a small plastic
shield to prevent them from being damaged.
springs.
Clean Shaft

Y
N
Procedures.
Replace the Developer Housing PL 5.1B Item 5
In [Marking tab , Print Test Pattern], select 106 dpi 50% Halftone. Make 5 prints. (These may
help to help characterize the problem.)
Image Quality
IQ-7
May 2003
3-18
V0.042
IQ-8 Deletions
This procedure is intended to assist in troubleshooting causes for deletions.
Deletion Defects: Part or all of an image is missing.
Body Deletions: Deletions within the central area of the copy/print.
Edge Deletions: Deletions along or at any edge of the copy/print.
Spot Deletion: A small deletion in the shape of a spot.
Blank Segments: Segments or strips of the copies/prints are white (color of stock).
Partial Image: Part of the Image area is missing.
Trail Edge Deletion: A deletion that occurs near the trail edge of the copies/prints.
E
Check if the machine has TAG 296 or TAG 080 (Electronic Hole Removal)
AND the defect is occurring within 20mm of the edge of the paper. The
machine has TAG 296 or TAG 080 AND the defect is occurring within
20mm of the edge of the paper.
Y
N
Go to the 05-E, DADF Document Size Sensing RAP. If no problem is
found, return here. (use the back () feature on the browser)
The defect has been corrected.
Y
N
If the deletion is in the shape of a line, streak, or band, go to the IQ-13, Lines, Streaks, and
Bands RAP.
The problem may be caused by the Electronic Black Hole Removal system incorrectly identifying black holes. Check/perform the following:
Check the NVM locations in Table 1 and confirm that they are correct.
NOTE: For small deletions that resemble white spots, go to the IQ-14, IOT Spots RAP.
Initial Actions
If the customers original is a photo, ensure that Photo Mode is used.
Ensure that the Registration Transport is fully latched (Jam Clearance lever 2)
Ensure that all the paper tray side guides are set correctly.
If necessary, the job may have to be run from the Document Glass
instead of the DADF.
If there is any paper damage visible, go to the OF-2, Paper Damage RAP.
If this continues to be a problem, if the value (in Table 1) for Threshold is changed to 0, Electronic Black Hole Removal will be disabled.
Black holes will no longer be removed.
The defect occurs in the DADF mode.

Y
N
Perform ADJ 14-2.
Makes copies and check for the defect. The defect still occurs.
Y
N
NOTE: If problem is solved by using fresh paper, and the customer cannot avoid using
conditioned paper, the problem can be corrected by installing a Paper Tray Heater Kit,
TAG 299 (IOT) or TAG 300 (HCF).

Y
N
The deletions are only occurring on side 2 of two-sided prints/copies.
Y
N
In [Marking tab , Print Test Pattern], run 5 prints of the 106 DPI 50% Halftone pattern
and 20 prints of the Quadrille pattern.
Inspect the prints for deletions. The deletion defect is visible on the prints.
Y
N
If necessary, make a test pattern print for use as an IIT original. In [Marking tab
, Print Test Pattern], select [Quadrille], then [Start Job].
The defect occurs in manual platen mode.
Y
N
Y
N
If the problem is intermittent or only appears under stress or different
conditions, try to reproduce the conditions, if possible. If the defect is
not occurring when making copies under any conditions, return to the
IQ-1 Image Quality Entry RAP. See if the defect can be classified differently.
A
B
V0.042

If the defect is occurring in both of these modes and is not an original problem,
it is not an IIT defect. Return to IQ-1 and repeat that procedure. See if the
defect can be classified differently.
Flip over the paper in the tray from which the deleted copies/prints are being fed.
Run copies/prints again to check for the defect. The problem continues.
Y
N
There may be excessive curl in the paper. Ensure that the paper is being stored and
loaded correctly. Return to Service Call Procedures.
Try running fresh paper
Change the orientation of the original from LEF to SEF (will affect stapling)
Rotate the original 180 degrees in DADF
If a border deletion problem, reduce 4% and use auto-center feature
A
May 2003
3-19
Image Quality
IQ-8
Run job in simplex mode

The deletions are ONLY OCCURRING on SIDE 2 of two-sided prints/copies.
Y
N
Observe samples of the defect and see if they look like the following:
a.
The defect occurs along the IB or OB edges, approximately 80-140mm from the trail
edge of the paper, and is worst with light weight paper, 11x17 or A3 paper, and/or
high humidity conditions
b.
The deletion occurs in the body of the print, has a maximum width of 10mm, a minimum length of 20mm, tend to be long and thin, and is worst with light weight paper,
11x17 or A3 paper, and/or high humidity conditions
In [Copier Sys tab , Component Control], select [IOT Paper Path] [Xerographic Blower] [Output On].
Check the Xerographic Blower. Ensure that it is working. The blower
is working.
Y
N
40PPM: Go to the OF-4, Noise, Odor, Heat, and Dirt RAP to diagnose the Xerographic Blower circuit.
65PPM and 55PPM: Go to the OF-5, Noise, Odor, Heat, and Dirt
RAP to diagnose the Xerographic Blower circuit.
The defect matches one of the descriptions above.

Y
N
Observe samples of the defect. The defect occurs on the trail edge, tends to
angle away from the trail edge at about 45 degrees for about 20-30mm, occurs
on 11 x 17 (A3), is less than 20mm wide, and is worse on lightweight paper.
Y
N
Observe the samples. The defect is a small light line, 1-2mm wide, parallel
to and about 25mm from the trail edge (10mm FX), is visible in halftones
(or solid areas) but not visible in text or the quadrille pattern.
Y
N
Use the Halftone prints printed previously, or in [Marking tab , Print Test
Pattern], make 4 prints of 50% Halftone 106 DPI.
Lay out the prints in the order that they were printed and examine them for
deletions. There is a pattern to the deletions on the page or between
pages.
Y
N
In [Marking tab , Xerographic Diagnostics], select [Set-up], then
[Start Test].
Observe the test results. The deletions are gone.
Y
N

The following actions can be taken by the customer to reduce or eliminate this
defect:
IQ-8
If the deletions are tear-dropped shape and appear in clusters, replace the Developer Housing PL 5.1B Item 5.
If the deletions are horseshoe shaped, replace the Transfer/Detack HVPS PL 1.2A Item 6.
If the above are not occurring, replace the Xerographic

Reduce the image at 95%
Rotate the original 180 degrees in the DADF
Run job on lighter weight paper
Run the job in duplex mode with the image put on side 2
Refer to Figure 1. Move the Skew Adjustment Lever one position at a time, first one
direction and then the other direction until the deletions are gone. When the deletions are eliminated, check for acceptable skew.
The deletions were eliminated and acceptable skew was maintained.
Y
N
Replace the Registration Transport PL 4.1A Item 8.
Inspect the prints. The deletion repeats in the same location only on
every other print when running 8.5 x 11" (A4) simplex prints.
Y
N
Inspect the prints. The deletions repeat every 157mm in the process direction (LE - TE).
Y
N
Open the front door and access the Prefuser Transport PL 6.1A Item 1 .
Check the Prefuser Transport part number. It is located on the bar code label (the
transport will have to be removed to see it). The machine has a Prefuser Transport with a part number 22K63813 or higher.
Y
N
K
The deletion occurs mostly in halftones and is located near the trail
edge.
Y
N
F
G H
I
Image Quality

The defect is like the one described in (a) above.
Y
N
The defect is more like (b) above. Refer to Figure 1. Move the Skew Adjustment
Lever one position at a time, first one direction and then the other direction until the
deletions are gone. When the deletions are eliminated, check for acceptable skew.
Y
N
Replace the Registration Transport PL 4.1A Item 8.
F
May 2003
3-20
M
V0.042
M
O
Y
Observe the prints. The deletions are occurring on the IB edge.

Y
N
The defects are occurring on the OB edge. Refer to Figure 1. Move the Skew
Adjustment Lever one position towards the right and re-check for deletions. Continue to move it to the right if the problem continues.
NOTE: Try to avoid the Full Left position if possible. It may increase the force
required to remove the Xerographic Module.
If the problem cannot be resolved by adjusting the lever, replace the Registration
Transport PL 4.1A Item 8.
If the skew is unacceptable after adjusting the lever, replace the Registration Transport PL 4.1A Item 8.
Refer to Figure 1. Move the Skew Adjustment Lever one position towards the left and recheck for deletions. Continue to move it to the left if the problem continues.
NOTE: Try to avoid the Full Left position if possible. It may increase the force required to
remove the Xerographic Module.
If the problem cannot be resolved by adjusting the lever, replace the Registration Transport PL 4.1A Item 8.
If the skew is unacceptable after adjusting the lever, replace the Registration Transport PL
4.1A Item 8.
Flip over the paper in the tray from which the deleted copies/prints are being fed.
Run copies/prints again to check for the defect. The problem continues.
Y
N
There may be excessive curl in the paper. Ensure that the paper is being stored and
loaded correctly. Return to Service Call Procedures.
N
Ensure that the Fuser Drive Motor is biased clockwise in its mounting. If the
problem continues, perform the following:
Check/replace the following items one-at-a-time, until the problem is resolved:
1.
Duplex Transport PL 6.1A Item 2
2.
Prefuser Transport PL 6.1A Item 1
3.
Inverter Assembly PL 6.2A Item 2
4.
Registration Transport PL 4.1A Item 8
Go to the OF-2, Paper Damage RAP.

Try running fresh paper
Change the orientation of the original from LEF to SEF (will affect stapling)
Change the page layout, rotate 180 degrees
Run job in simplex mode

Table 1 NVM Values
Image
Processing
Service NVM
Name
Location
Value
MinVar
30
MaxVar
31
16
Black
32
28
Threshold
33
360
Observe the copies/prints. The side one image includes halftones or solid areas.
Y
N
Refer to Figure 1. Move the Skew Adjustment Lever one position at a time, first one
direction and then the other direction until the deletions are gone. When the deletions are
eliminated, check for acceptable skew.
Y
N
Run several copies/prints in simplex mode. Take the output and place in the Bypass
Tray (Tray 5) or another tray if there is no bypass. Place the copies/prints in the tray
such that the backside can be imaged. Make copies/prints again in simplex mode so
that side 2 is now imaged.
Check the copies/prints for the deletion on side 2. The deletion still occurs.
Y
N
There may be paper damage occurring during a duplex pass. Check the Duplex
Transport for correct operation/damage. Repair or replace the Duplex Transport as necessary PL 6.1A Item 2.
Inspect the copies for visible paper damage There is damage to the paper.
N
O
V0.042
May 2003
3-21
Image Quality
IQ-8
Full Left
Center
Full Right
Right
Center
Left Center
Figure 1 Skew Adjustment
Image Quality
IQ-8
May 2003
3-22
V0.042
IQ-9 No Image RAP
IQ-10 Distorted Image RAP
This procedure is intended to isolate causes of no image or blank page defects.
This procedure is intended to assist in troubleshooting IOT distorted image problems.
Initial Actions
Troubleshoot all fault codes first.
Blur: Images that are not clear, appear out of focus, not sharp.
NOTE: If blurs occur approximately 80mm from trail edge when using 3 hole punched
paper on a DT65/DP65, disable stock size checking in DocuSP Printer Manager.

In [Faults/Counters tab , Faults], check the Last 40 Faults for any occurrences of 09-310, 09370, or 09-380.
An 09-310, 09-370, or 09-380 fault has occurred.
Y
N
Check the value in NVM for the Image Processing Mode. Select [NVM] [NVM Tool] [Mark
Service]. Go to location 722.
This value should be 24 in most cases. The NVM value is correct.
Y
N
Change the value to the correct value using the following procedure:
1.
Enter NVM Tool. [NVM tab , NVM Tool]
2.
From the menu bar, select [Machine] [Download], then [Yes] after the question Initiate NVM Download?.
Deformed Image: Gross defects where the image has been incorrectly reproduced.
Ghosting: Similar to residual image, but the image appears within an image instead of the
background area.
Poor Resolution: Inability to distinguish fine details, usually fine lines.
Ragged Halftones: Gray areas have small-scale texture, line or herringbone appearance.
Ragged Lines: Lines that should be straight and smooth are ragged, or have bumpy or
ragged edges.
Torn Image: The image appears to be stretched or distorted in a band that runs from IB to
OB on the copy. For this problem, go to the IQ-20, Torn Image RAP.
Smear: The toner in an image is disturbed and appears as a smear on the copies/prints.
Scrogged Image: A digital image defect. The digital data sent to the ROS an incorrect
3.
After NVM loads, select [Mark Service].
4.
Scroll or search to location 722 (imageprocessingmode)
5.
Change the current value to 24 or 8 (as appropriate).
Initial Actions
a.
Position the cursor over the appropriate row and double-click
b.
Type in 24 (or 8 if older 40ppm machine with an Atlanta 95 PWB) into the
[Current Value] field
c.
After the new value is entered, select [Write NVM]
d.
Exit diagnostics, then power off / power on for the NVM changes to take
effect.
Make some copies/prints, and hardstop the machine before the image passes the transfer
zone.
Remove the Xerographic Module and view the PR Belt. There is image seen on the
Photoreceptor Belt.
Y
N
Replace the Raster Output Scanner Video Cable PL 1.2A Item 4.
See if the problem continues. The problem continues.
Y
N

Y
N
In [Marking tab , Print Test Pattern], run 5 prints of the 106 DPI 50% Halftone pattern and
5 prints of the Quadrille pattern.
Inspect the prints for distorted image. The distorted image defect is visible on the
prints.
Y
N
NOTE: Not all IOT defects will always reproduce on the internal IOT test patterns.
The following couple of steps help verify whether the problem is related to the IIT.
Observe the defect copies and determine if the defect is present on all copies of
each original. The defect appears on all copies of an original and in the same
location on every copy.
Y
N
The problem not an IIT problem. Each original is scanned once, and any defect
in scanning would be reproduced on all copies of each original. Return to the
first step of the RAP and answer YES to the first question.

Go to the appropriate (09-310 09-370 09-380) RAP.
Decrease the magnification by 10% (unless the problem is occurring when running a
mag of 101% to 110% or 201% to 210%, then increase the mag by 10%).
A
V0.042
May 2003
3-23
B
Image Quality
IQ-9, IQ-10
A
Make copies to check for the defect. The defect moved with the image.
Y
N
If the defect does not move with the magnification change, the problem is not
related to the IIT. Return to the first step of the RAP and answer YES to the first
question.
Inspect the original defect copies for a torn image. (IB-OB band with well defined
straight edges and an image that appears to be stretched within the band). Refer a
sample of this type of defect in the IQ Defects and Samples section (IB-OB Bands).
The defect is a torn image defect.
Y
N
Inspect the original defect copies. There are smears on the defect copies.
Y
N
There is a blur or out of focus problem.
Check the Scanner for contamination. Observe the Image Module,

Document Glass, and CVT Dirt Reduction Kit. If contaminated, perform the REP 14-3 Scanner Cleaning Procedure, and recheck for
blurred image. If OK, continue with the Procedure.
Ensure that the document is smooth and flat, that it would lie flat
against the document glass.
Check the condition of the Document Glass Cover/Document Output

Tray and Document Glass Pad, replace if necessary PL 2.1A Item
7, PL 2.1A Item 8
E
Y
N
Defect may be related the customers document. Question the customer about the nature of the document used when the problem
occurred. If not related to the document, check the Document Glass
Cover/Document Output Tray and Document Glass Pad for damage,
that is seating correctly against the document glass when closed.
Repair or replace as necessary PL 2.1A Item 7 , PL 2.1A Item 8.
NOTE: If a message appears when trying to make copies from the document
glass about raising the Document Scanner, you may need to change the original input type. In the Image Quality tab on the UI Display, select [Original Input],
[Manual Platen Input], then select the original size of the document being copied.
Inspect the copies. The smear is present on the copies.
Y
N
Make 3 copies using the Document Feeder mode. The
smear
is
present on the copies.
Y
N
The defect is not being reproduced. One of the following may be
occurring:
The problem is related to the customer original. Determine if the

problem is occurring in both the manual and Document Feeder
mode or just the Document Feeder mode. Check the quality of
the original if it is in spec for size and weight.
The problem is not in the IIT. Return to IQ-1.
Replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4.

Make 3 copies using the Document Feeder mode. The
defect
occurs.
Y
N
The defect occurs in the manual document mode.

Y
N
Y
N
Question the customer on the nature of the document used
when the defect occurred. Ensure that the document is smooth
and flat, that it would lie flat against the document glass. If an
unusual document, instruct the customer as to the capabilities
of reproducing such documents. If the problem is intermittent or
only appears under stress or different conditions, try to reproduce the conditions, if possible. If the defect is not occurring
when making copies under any conditions, return to the IQ-1
Image Quality Entry RAP. See if the defect can be classified differently.
IQ-10
Use a print of the Quadrille test pattern made in the beginning of the RAP and
place it on the document glass. Make 3 copies.
Inspect the Document Glass Frame and the Document Glass for damage
or defects. The Document Glass Frame and the Document Glass are
OK.
Y
N
A
B
C
D
Image Quality

RAP.
If any actions were completed, make copies and check for reoccurrence of
the defect. The problem is still occurring.
Y
N
Replace the CVT Drive ON Glass Roll PL 2.4 Item 3 .
still
Replace the DADF Assembly PL 2.1A Item 1.

This defect should not appear in the manual platen mode if caused by the IIT.
Ensure that this defect is not on the original. Return to IQ-1. See if the defect
can be re-classified.
Go to the IQ-20, Torn Image RAP.
E
May 2003
3-24
V0.042
Check IIT and card cage grounding
If the problem continues, go to the IQ-3 Video Path RAP

Table 1 Distorted Image Entry Table
Defect
Ghosting
Go To
IQ-11
Smears/Blurs
Smears Procedure
Scrogged Image
Scrogged Image Procedure
Ragged Halftones
IQ-19 Motion Quality RAP
Smears Procedure
Some IQ samples of Smears/Smudges are in the IQ Samples section. Use this link to view the
samples and descriptions of some known causes - Smeared Copies/Prints.
In [Marking tab , Print Test Pattern], select 2 On 2 Off Perpendicular Lines and 50% 106dpi
Halftones to test for smears. Select the appropriate paper size, tray, and run mode.
1.
Check for paper stuck in the Xerographic Module.
2.
Check for contamination or something in the paper path that may be contacting or rubbing
against the paper.
3.
If narrow, dark smears run IB-OB on the 106 dpi 50% Halftones and occur all across the
page LE-TE, replace the Developer Housing PL 5.1B Item 5.
4.
If the defect only appears on every other print on 8.5 x 11 inch or A4 paper, replace the
Xerographic Module PL 5.1A Item 1. Check the error log for occurrences of 04-701
Faults. If any have occurred, go to the 04-201 RAP. If not, check the operation of the
machine exhaust blowers. If not operating correctly or if this problem has occurred more
than once, go to the OF-4 NOHAD RAP (40ppm) or OF-5 NOHAD RAP (65ppm and
55ppm).
5.
Check the location of the smear. If it is located approximately 55mm from the lead edge of
the paper, check that the Prefuser Transport is located correctly. Check again for smears.
Replace the Prefuser Transport PL 6.1A Item 1 if the problem continues.
6.
Check the location of the smear. If it is located approximately 80mm or less from the trail
edge of the paper, check for high paper curl. Load fresh paper. Check for any type of
obstructions in the transfer area. If the problem continues, replace the Xerographic Module PL 5.1A Item 1.
Scrogged Image Procedure

Some IQ samples of Scrogged Image are in the IQ Samples section Scrogged Images
If not already done, switch the machine power off / on
If the machine has an EHR PWB, ensure that the correct version is on the machine. If the
machine has TAG 077, the EHR PWB should be part number 160K64610. If the machine
does not have TAG 077, the EHR PWB should be either 160K59430 or 160K64130.
If the machine has an EHR PWB, switch off the machine power and remove the EHR
PWB. See if the problem is resolved. Install a new EHR PWB as necessary (PLx.x).
If the machine does not have an TAG 015 (Atlanta Gold Main Control PWB), reseat the
IPS1 Daughter Card (Autoseg PWB) on the Main Control PWB.
Check all the connectors in the video path
V0.042
May 2003
3-25
Image Quality
IQ-10
This procedure is intended to assist in troubleshooting causes for Ghosting or residual image
problems.
C
Y
N
NOTE: Ghosting, residual image, and offsetting are all assumed to be IOT caused problems.
The IIT (Scanner) is not known to be a cause of these types of defects.

If the problem continues, replace the Transfer/Detack HVPS PL 1.2A Item 6.
IQ-11 Ghosting/Residual Image/Offsetting RAP
background area
A reload defect is occurring. Reload occurs when a large amount of toner is removed
from the donor roll of the Developer Housing before it can be fully replenished.
Compare the B and C patches on the copies to the S and T patches on side 2 of the test
pattern. The ghosting on the copies is worse than the ghosting on the S and T
patches on side 2 of the test pattern.
Y
N
This is an expected level of reload under most conditions.
Residual Image: An unwanted reproduction of a previous image.

Offsetting: A form of residual image caused by toner transferring from the fuser on to the paper.
The image will be offset a distance that equals the circumference of the fuser roll.
Reload: A solid area image depletes enough toner from the Donor Roll so that a lightened area
appears in solids or halftones approximately 40-50mm towards the trail edge.
When complete, check the level of reload ghosting again. The ghosting on the copies
is worse than the ghosting on the S and T patches on side 2 of the test pattern.
Y
N
Initial Actions

Prints with the defect are available for observation.
Y
N
Make 5 copies of test pattern 82E13100 (8.5x11) or 82E13110 (A4).
Look at the B and C patches on the copies. A ghost approximately the size of the A1
and A2 patches is visible in the B or C patch.
Y
N
In [Marking tab , Print Test Pattern], select Image Quality Test #4.
Observe the prints. Ghosting is present on the last two 50% halftone prints.
Y
N
There is a residual image that repeats every 159.5mm.
Y
N
Y
N
Observe the fault display in the IIOC Self-Test screen. An 03-813 fault is
detected.
Y
N
If some other fault is detected, make a note and evaluate the faults effect
on other machine problems that might be occurring. If the problem continues, replace the IIOC PWB W8A1 PL 1.5 Item 2.
Observe the defect prints. The defect is a ghosting problem (a negative image of a previous image appears within another image).
Y
N
The defect repeats every 159.5mm.
Y
N
Make 5 copies of test pattern 82E13100 (8.5x11) or 82E13110 (A4).
Look at the B and C patches on the copies. A ghost approximately the size of the A1 and
A2 patches is visible in the B or C patch.
Y
N
Y
N
Observe the fault display in the IIOC Self-Test screen. An
03-813
fault
is
detected.
Y
N
other machine problems that might be occurring. If the problem continues,
replace the IIOC PWB W8A1 PL 1.5 Item 2.

A
B
C
Image Quality
IQ-11
D
May 2003
3-26
V0.042
D
Y
N

If the problem continues, replace the Transfer/Detack HVPS PL 1.2A Item 6.
A reload defect is occurring. Reload occurs when a large amount of toner is removed from the
donor roll of the Developer Housing before it can be fully replenished.
Compare the B and C patches on the copies to the S and T patches on side 2 of the test pattern. The ghosting on the copies is worse than the ghosting on the S and T patches on
side 2 of the test pattern.
N
This is an expected level of reload under most conditions.
When complete, check the level of reload ghosting again. The ghosting on the copies is
worse than the ghosting on the S and T patches on side 2 of the test pattern.
Y
N
Replace the Go to 09-K Developer Housing Checkout RAP.
Figure 1 IQ-11 Circuit Diagram
V0.042
May 2003
3-27
Image Quality
IQ-11
IQ-12 Background RAP
Observe the test results. The Lamp Profile checks OK.

(The green line stays within the indicated range.)
Y
N
This procedure is intended to assist in troubleshooting causes for Background.

Definitions:
Background: Randomly distributed toner particles in a non-image area.
Digital Background: Background that is on the original, but enhanced during copying.
Background Bands: A form of Localized Background.
Localized Background: Background that occurs in a localized area.
Overall Background: Background that is present over the entire copy/print.

When the machine is ready, re-run copies to check for the
original defect. The problem continues.
Y
N
Go to the 14-A, Illumination RAP.
Initial Actions

If the problem continues, go to the 03-G, Main Control
The defect occurs when making copies from the document glass.
Y
N

Y
N
In [Marking tab , Print Test Pattern], make three prints of 0% HT (Blank Page).
Inspect the prints. The background defect appears on the prints.
Y
N
Check if the problem only occurs when running 87, 92, 94, or 98% reduction.
The problem only occurs when reduction is set to 87, 92, 94, or 98%.
Y
N
Inspect copies with the defect. The background varies from the top to bottom edge without any discontinuities, streaks, or bands.
Y
N
The original includes colors or the original itself is on colored
paper.
Y
N
Inspect for high levels of contamination on the Image Module and
underside of document glass. There is a high level of contamination.
Y
N
Switch the machine power off, then on.
Check for the defect. The defect is still present.
Y
N
In [IIT tab , Scanner Lamp Profile], select [Lamp Off], then
[Start].
Observe the test results. All of the green line is below
the MAX level on the graph.
Y
N
The defect also occurs in the Document Feeder mode.

Y
N
Clean the underside of the document glass cover.
Make copies. The defect is still present.
Y
N
Ensure the Border Erase is set to 3mm. Place test pattern
82E13100 (11") or 82E13110 (A4) on the platen glass.
Ensure it is correctly registered on the glass. Make 1 copy.
Check the registration scales on the copy. The lead edge
deletion is 3mm. Check how close the first visible line on
the scale is to the 3mm line. The first visible line on the
registration scale is within 1mm of the 3mm line on the
scale.
Y
N
Go to the ADJ 14-2. Return here when complete.
See if the defect still occurs. The defect is still
occurring.
Y
N
In [IIT tab , Scanner Lamp Profile], select [Lamp On], then

[Start].
A
B
C
D
Image Quality
IQ-12
A
May 2003
3-28
The CVT Dirt Reduction Kit was recently replaced.

Y
N
In [IIT tab , Scanner Lamp Profile], select [Lamp Off], then
[Start].
H
V0.042
Observe the test results. All of the green line is below

the MAX level on the graph.
Y
N
C
This problem occurs due to a defect in the design of the chip in image processing
hardware. Because the problem is in the chip design, replacing the Main Control
PWB will NOT correct the problem. Suggest to the customer that if they increase or
decrease the reduction by 1%, the background will be gone. This problem will be
resolved with the release of L18 software.

In [IIT tab , Scanner Lamp Profile], select [Lamp On], then
[Start].
Observe the test results. The Lamp Profile checks OK.
(The green line stays within the indicated range.)
Y
N
When the machine is ready, re-run copies to check for the
original defect. The problem continues.
Y
N

The background is uniform across the page.
Y
N
In [Marking tab , Print Test Pattern], make three prints of 0% HT (Blank Page). Then run
[IQ Test # 3].
Observe the output prints. Check for localized background and/or toner smearing on the
last two prints of the IQ Test. There was a definite worsening of the localized background problem.
Y
N
Replace the following, one at a time, until the problem is resolved:

If the problem continues, go to the 03-G, Main Control
The CVT Dirt Reduction Kit needs to be burned-in. In [Copier
Sys tab , Component Control], select [Document Handler/Scanner] [Illumination Lamp] [Output On]. Leave the lamp on for 15
minutes. After 15 minutes of on time, select [Output Off]. If the
problem was caused by a new lamp, it should now be resolved.
Perform the REP 14-3 Scanner Cleaning Procedure. If the problem
continues, return to the beginning of this RAP.
The defect can be reproduced using a black and white original (test
pattern).
Y
N
The problem is related to the original. Discuss with the customer the
IQ options which may help improve the IQ of these types of originals.
Return to the beginning of this RAP and answer NO to the statement that
this is related to a colored original.
The problem is intermittent and not currently reproducible.
Y
N
A
B
V0.042

In [Marking tab , Xerographic Diagnostics], select [Set-up], then [Start Test].
Observe the test results. The test completed successfully.
Y
N
Go to the RAP for the fault indicated.
In [Marking tab , Print Test Pattern], make three prints of 0% HT (Blank Page).
Inspect the prints. Background is still present on the prints.
Y
N
In [Marking tab , Print Test Pattern], run Image Quality Test # 3.
Inspect the two blank pages for background. Obvious background resulting from the 1
inch solid area bars is visible.
Y
N
Replace the following, one at a time, until the problem is resolved:
Replace the Illumination Lamp Module PL 3.2 Item 7 and the Illumination
Lamp Power Supply PL 3.2 Item 5.

If the problem continues, replace the Charge HVPS PL 1.2A Item 5.
May 2003
3-29
Image Quality
IQ-12
IQ-13 Lines/Bands/Streaks RAP
This procedure is intended to assist in troubleshooting causes for Lines/Bands/Streaks.
Initial Actions
Ensure all faults are repaired before troubleshooting IQ problems.
Ensure that the Document Glass is cleaned, especially the CVT Glass. This is the MAIN
cause of black lines/streaks that run LE-TE when copies made in DADF mode. Refer to
REP 05-1.
N
Y
N
In [Faults/Counters tab , Faults], check the Last 40 Faults for any 14-314, 14315, 14-316, 14-317, 14-318, 14-319, or 14-320 faults.
There are 14-314, 14-315, 14-316, 14-317, 14-318, 14-319, or 14-320 faults
in the Last 40.
Y
N
There was a false failure of the SCVM Digital Test. Return to the step
where the SCVM Digital Test was run and answer YES.
NOTE: If dirt on the CVT glass has been a problem, a CVT Cleaning Kit can be ordered
for the customer (673K52480).
To help the customer see contamination on the glass, and also reduce the amount of contamination on the glass, ensure that the machine has had a CVT Dirt Reduction Kit PL 3.1
Item 6 installed.
For examples of Lines, Bands, Streaks, refer to the IQ Defect Samples Entry Section.
If deletion bands are occurring in DADF mode on the Trail Edge, the original size may not
be sensed correctly. It may be a non-standard size. Use the Document Scanner Size
Sensing screens on the UI in [Tools] to adjust for any unusual documents.
If the defect is light areas or bands that occur in halftones, generally within 60mm of the
lead edge or trail edge, it may be due to an document which has irregularities. Check the
machine for TAG 016. If tag 16 is not installed, order and install kit # 606K57921 which
includes a new CVT Drive-on-glass Roll that improves the performance of irregular documents.

In [Marking tab , Print Test Pattern], make 20 prints of 50% Halftone 106 DPI and 20
prints of 1" Off and 1" On Black Bands. Lay out the prints in order.
NOTE: The 50% Halftone and black bands patterns will show most streaks. If the streaks
do not appear, increase the quantity.
Inspect the prints. The lines, streaks, or bands are visible on the prints.
Y
N
Enter [Faults/Counters tab , Faults]. Select [Fault Counters]. Select Filter By [Chain
14].
Check for any of the following fault code counters to have a significant value: 14700, 14-702, 14-703, 14-704, 14-705, 14-706, 14-712, 14-713, 14-714, 14-715.
One or more of those faults have a significant value greater than 0.
Y
N
NOTE: Not all IOT defects will always reproduce on the internal IOT test patterns. The following couple of steps help verify whether the problem is related
to the IIT.
The following definitions are used in this procedure and are the types of defects this RAP will
diagnose:
IB-OB: Front-to-rear of the machine or Top to Bottom of the copies/prints.
Lines: A straight and narrow defect that resembles a line. The line may be dark, or a white
or light streak.
Streak: Similar to a line.
Band: Wider than a line or streak, usually run IB-OB. Can be light or dark.
Motion Quality: Banding defects caused by excessive vibration in the system.
Banding: Multiple bands that run IB-OB
High Frequency Banding: Closely spaced lines that run IB-OB, but repeat at such a high
frequency that the bands are less than 2mm apart, and occurs all the way across the
page.
Process Direction: LE-TE
Cross Process Direction: IB-OB
Observe the defect copies and determine if the defect is present on all copies
of each original. The defect appears on all copies of an original and in the
same location on every copy.
Y
N
The problem is not an IIT problem. Each original is scanned once, and any
defect in scanning would be reproduced on all copies of each original.
Return to the first step of the RAP and answer YES to the first question.
Decrease the magnification by 10% (unless the problem is occurring when running a mag of 101% to 110% or 201% to 210%, then increase the mag by
10%).
Make copies to check for the defect. The defect appears and moved with
the image.
Y
N
If the defect does not move with the magnification change, and stays in
the same location, the problem is not related to the IIT. Return to the first
step of the RAP and answer YES to the first question.

Y
N
In [Self Tests tab , Video Path Diagnostics], select [SCVM Digital Test], then [Start Test].
A
Image Quality
IQ-13
A
May 2003
3-30
D
V0.042
If the defect did not appear again, it may be an intermittent Main Control
PWB problem. If the defect appears as a very narrow black line (similar to
dirt on CVT Glass, ensure that the CVT Glass has been cleaned), or a
series of short lines, side-by-side, so that they appear to look like a gray
band that runs IB-OB, go to the 03-G, Main Control PWB Replacement
RAP.

RAP.
Perform the REP 05-1 DADF Cleaning Procedure, and the REP 14-3 Scanner
Cleaning Procedure.
Make copies and check for the defect. The defect is still occurring.
Y
N
NOTE: Ensure that the problem is repeatable on the copies.

To test for the presence of the defect or verify the repair, make a test pattern
print for use as an IIT original as follows; Enter [Marking tab , Print Test Pattern], select [Blank Page] for dark bands/streaks or [106DPI] (50% Halftones)
for light bands/streaks, then [Start Job].
The defect occurs only on halftone images.

Y
N
Inspect the calibration strip on the underside of the Document Glass
Frame. Check for any smears, marks, or defects. There are defects on
the calibration strip.
Y
N
NOTE: If a message appears when trying to make copies from the document
glass about raising the Document Scanner, you may need to change the original input type. In the Image Quality tab on the UI Display, select [Original Input],
[Manual Platen Input], then select the original size of the document being copied.
Observe copies with the defect. The lines, bands, or streaks are running
from LE to TE.
Y
N
The 14-A Illumination Checkout has already been performed for this
problem.
Y
N
Go to the 14-A Illumination Checkout RAP. Return to this RAP if the
problem is not corrected.
Clean the Cal strip.

Make copies and check for the defect. The defect is corrected.
Y
N
Replace the following, one-at-a-time until the problem is resolved:
CVT Drive ON Glass Roll PL 2.4 Item 3
The defect occurs in DADF Mode.

Y
N
Replacement RAP.
A
B
V0.042
Document Glass Frame PL 3.1 Item 5
Image Module PL 3.2 Item 3

RAP.
Go to the RAP with the largest number of occurrences:
Replace the following, one-at-a-time until the problem is resolved:

Image Module, Scanner Video Cable Kit PL 3.2 Item 1
The defect occurs when running in the manual document mode.

Y
N
The defect occurs when running in the DADF mode.
Y
N
If the problem is intermittent or only appears under stress or different conditions, try to reproduce the conditions, if possible. If
the defect is not occurring when making copies under any conditions, return to the IQ-1 Image Quality Entry RAP. See if the
14-700
14-702
14-703/704
14-705 / 706 / 714 / 715
14-712
14-713


If the defect is short horizontal lines or streaks, less than 25mm long, and run LE-TE, (see
Short Horizontal Lines in Section 3, IQ Defect Samples for example) go to the Short Horizontal
Lines Procedure. If not continue below.
May 2003
3-31
Image Quality
IQ-13
NOTE: It is assumed that if the defect is described as a line, streak, or band, that the defect
has a shape that would have a much longer length than width.
Look at the lines, streaks, or bands on the prints and their direction or how they are oriented on
the page (the direction of the length of the line, streak, or band). The line, streak, or band
defect runs LE to TE across the copies/prints.
Y
N
Go to the IB-OB Bands area to view samples of these types of defects.
The defect only occurs on every other copy/print and is in the same location.
Y
N
Observe the 50% Halftone prints for a condition that looks high frequency banding.
Check for closely spaced (less than 3mm) lines or bands that run IB-OB. The
defect appears to be high frequency banding.
Y
N
Observe the test results. Fault codes or failures are indicated.
Y
N
The defect occurs at regularly spaced intervals either within a page
or between pages.
Y
N
The defect repeats every 42.6mm (40ppm) or every 48.5mm (65ppm
and 55ppm).
Y
N
The lines are diagonal to the edges of the paper.
Y
N
Go to IQ-19, IOT Motion Quality RAP.
NOTE: Ignore any message that indicates Xerographic Module Ground Noise,
General Image Noise, or BTAC Noise. Go to the first part that is listed after the
colon (:)
Xerographic Module, go to the 09-J, Xerographic Module Checkout RAP
ROS 09-L, go to the ROS Checkout RAP
ROS A/B Test Failed 09-L, go to the ROS Checkout RAP

Go to the LE-TE Streaks/Bands area to view samples of these types of defects.
The streaks are not well defined, 3 - 6mm wide, and are most prominent in the halftones.
Y
N
Using a print with the defect, fold it in half (if fed SEF, fold the print so the long edges are
together, if fed LE, fold the print so that the short edges are together).
NOTE: Due to the possible variation of top edge registration, the distances from the centerline of the prints can vary. Use the table for measuring distances between streaks if
possible.
Check the location of the streaks. Measure the distance from each streak to the center
fold and distances between streaks if more than one are visible. Refer to Table 1 for distances between the Fuser Stripper Fingers. The defects are a sharp and well defined
narrow line and are at distances of 41mm, 88mm, or 130mm (all 10mm) from the
center fold and/or are separated by one of the distances in the table.
Y
N
Inspect the exposure slit in the Xerographic Module. Check for any fibers that may
be present in the image path. Fibers are seen.
Y
N
Re-run samples. In [Marking tab , Print Test Pattern], make 4 prints of 50%
Halftone 106 DPI. Lay out the prints in order. The defect has been corrected.
Y
N
Remove the Developer Housing from the machine.
Inspect the Donor Roll of the Developer Housing. There should be an
even layer of toner covering the Donor Roll. Check for a change in the
toner layer in the approximate location of the streak or band. There is a
change in the toner layer of the Developer Housing Donor Roll in the
area of the defect.
In [Marking tab , Xerographic Diagnostics], select [Set-up], then

[Start Test].
Run prints to check for the defect. The defect is gone.
Y
N
Replace the Developer Housing PL 5.1B Item 5
Go to IQ-19, IOT Motion Quality RAP.
Observe the test results. A fault code was declared.
Y
N
IQ-13
Go to the RAP for the indicated fault.
NOTE: If a 09-XXX fault occurs when running Xerographic Set-Up at

anytime in this RAP, go to the RAP for that fault to continue troubleshooting.
F
G H
Image Quality
I
May 2003
3-32
L
V0.042
L
Y
N
Check the drive belt on the Photoreceptor Drive Module PL 5.1A Item
2 . The belt is visible through an opening behind the Detack HVPS.
Ensure that the belt is correctly on the idler roll and has not slipped
off on to the shaft.
The belt is OK.
Y
N
Repair/replace as necessary PL 5.1A Item 2.
This table can be used to isolate lines on copies/prints that are caused by fuser stripper fingers
(if more than one line is present). There are six stripper fingers. The farthest OB finger is
labeled #1 on this table. The most IB is labeled #6. For instance, if two lines on the copies/
prints are separated by 76mm, from the table it can be determined that this is the distance
between stripper fingers #3 and #4. Therefore, the lines are most likely caused by the Fuser
Module stripper fingers. Another test of reasonableness, would be to line up the streaks with
fingers #3 and #4 on the Fuser Module.
Short Horizontal Lines Procedure
There are many mechanical and software problems that can cause this defect.
If the machine is overtoned or the toner concentration is above the 7-8% range, the process
controls will maintain it at that value. If detoning of the machine is required, further in-depth
troubleshooting is needed to identify a root cause of the overtoning.

Clean the exposure slit in the Xerographic Module.
Use the IQ-2 Image Quality Checkout RAP to evaluate the copies/prints.

Observe the prints. The streak or band is lighter than the surrounding halftone.
Y
N
Remove the Developer Housing from the machine.
Inspect the Donor Roll of the Developer Housing. There should be an even layer of toner covering the Donor Roll. Check for a change in the toner layer in the approximate location of the
streak or band. There is a change in the toner layer of the Developer Housing Donor
Roll in the area of the defect.
Y
N
Is there background on the copies/prints?
Is there toner contamination inside the machine?
What fault codes are recorded in the error log? Troubleshoot any/all 09-xx fault codes per
the appropriate RAPs.
All of these can contribute to short horizontal streaks. Continue below.

1.
If the machine is in the NASG or FX markets and this is the first time through this procedure, check for defective PR Belt. Perform the Out of Spec PR Belt Checkout and return
here when complete.
2.
If the machine has v5.07 or v5.08 software, ensure that the following two NVM values are
correct:
Table 1. Stripper Finger Spacing
1 (OB)
6 (IB)
1 (OB)
N/A
42mm
89mm
165mm
212mm
254mm
202mm
42mm
N/A
47mm
123mm
170mm
89mm
47mm
N/A
76mm
123mm
165mm
165mm
123mm
76mm
N/A
47mm
89mm
212mm
170mm
123mm
47mm
N/A
42mm
6 (IB)
254mm
202mm
165mm
89mm
42mm
N/A
Mark Service location 1271 should be 2.0
Mark Service location 1281 should be 44
Ensure that the Developer Collector tube is not clogged.
4.
Check the power supplies.
5.
6.
V0.042
3.
Table 1 Stripper Finger Spacing

Finger #
Are the copies/prints overtoned?
May 2003
3-33
Connectors/contacts - check/reseat all connectors and inspect contacts
Charge HVPS - refer to 09-A Charge HVPS Checkout RAP
Developer HVPS - refer to 09-G Developer HVPS Checkout RAP
Check the Developer Top Cover. Check the date/bar code label on the back of the Developer Housing assembly. If the Developer Housing was built:
before 09/24/98 - Replace the Developer Housing PL 5.1B Item 5
Between 09-24/98 and 09/17/99 without Tag 088 - Replace the Developer Housing
Top Cover (Tag 088) PL 5.1B Item 16
After 07/17/99 with Tag 088 - the Developer Housing and Top Cover are OK.
Detone procedure - To be used when the problem root cause has been identified and corrected (not needed if already replaced Developer Housing):
Change Mark Service NVM location 1281 to 41.
Run Xerographic Setup. In [Marking tab , Xerographic Diagnostics], select [Set-up],

then [Start Test].
Change Mark Service NVM location 1281 back to 44.

Image Quality
IQ-13
Run Xerographic Setup. In [Marking tab , Xerographic Diagnostics], select [Set-up],

then [Start Test].
IQ-14 Spots/Dirt RAP
Out of Spec PR Belt Checkout
This procedure is intended to assist in troubleshooting causes for Spots problems.
In June 1999, some PR Belts were manufactured that had a high residual charge problem.
This problem may contribute to:
Spots: Unwanted spots of toner in a non-image area.
High dirt levels in the Developer area
Random dark streaks that run lead edge to trail edge
Prints are very dark, overtoned
Initial Actions
NOTE: Up to 10% of the machines with one of these PR Belts will experience a severe
enough problem to cause a service call.
On machines where one of the above symptoms is occurring, remove the Xerographic Module
from the machine and examine the inside of the photoreceptor belt along the ground strip. The
lot number is on the inside of the belt, repeated at about 300mm spacing. Check if the lot number is one of the following:
210082xxxx
210084xxxx
210086xxxx
210087xxxx
Ensure that the Developer Collector Tube is connected and is not clogged.

Y
N
NOTE: Before answering the first question of this RAP, be sure that the defect is not original related. In other words, if happening only on side two, switch the originals and see if it
follows the original instead of the paper path.
Inspect the original defect copies or determine the run mode in which the defect copies
were occurring. The defect ONLY occurs on side 2 of duplex jobs.
Y
N
IOT/IIT Check In [Marking tab , Print Test Pattern], make 5 prints of Blank Page, 5
prints of 106dpi 50% Halftone, and 5 prints of 1" On and 1" Off Black Bands.
Inspect the prints. Spots similar to the original defect copies appear on any of
the prints.
Y
N
If the Xerographic Module does not have one of the above lot numbers, then an out of spec PR
Belt would not be suspected. Return to the IQ-13 IOT On-Site Diagnostic Procedure.
If the Xerographic Module has a photoreceptor belt with one of the above lot numbers, replace
the Xerographic Module with one from the customers inventory, or order one and ask the customer to replace it on arrival. All Xerographic Modules should be returned through the normal
return process using the shipping box and return label.
NOTE: Not all IOT defects will always reproduce on the internal IOT test patterns. The following couple of steps help verify whether the problem is related
to the IIT.
To help identify which Xerographic Modules might have a high residual photoreceptors, the
pack date can be used. The pack date is listed on the shipping box, usually on one side above
the big red X, and also on the bar code label which is on the Xerographic Module. If the pack
date is from June 15, 1999 to July 15, 1999, the Xerographic Module MIGHT have a high residual photoreceptor. The belt should be checked before it is installed in a machine
Observe the defect copies and determine if the defect is present on all copies
of each original. The defect appears on all copies of an original and in the
same location on every copy.
Y
N
The problem not an IIT problem. Each original is scanned once, and any
defect in scanning would be reproduced on all copies of each original.
Return to the step labeled IOT/IIT Check and answer YES to the question.
NOTE: Not all Xerographic Modules built in this time period have defective photoreceptor
belts.
Decrease the magnification by 10% (unless the problem is occurring when running a mag of 101% to 110% or 201% to 210%, then increase the mag by
10%).
Make copies to check for the defect. The defect moved with the image.
Y
N
If the defect does not move with the magnification change, the problem is
not related to the IIT. Return to the step labeled IOT/IIT Check and
answer YES to the question.
The defect occurs in the manual platen mode.
A
Image Quality
IQ-13, IQ-14
May 2003
3-34
C
V0.042
D
Y

Y
N
If the problem is intermittent or only appears under stress or different
conditions, try to reproduce the conditions, if possible. If the defect is
not occurring when making copies under any conditions, return to the
IQ-1 Image Quality Entry RAP. See if the defect can be classified differently.
Y
N
Inspect the Document Glass for dirt, scratches, or other damage.
Defects are visible on the Document Glass.
Y
N
Perform the REP 05-1 DADF Cleaning Procedure, and the REP 143 Scanner Cleaning Procedure.
Make copies and check for the defect. The defect is still present.
Y
N
N
Inspect the prints. The defect is white spots in halftones or solid areas.
Y
N
Inspect the prints. Determine if the spots, in any way, look like they might
be generated digitally by the imaging system. That is, do they appear regular or have a pattern. See Figure 13 (IQ Defect Samples, Structured
Background) for an example.
The defects appear to have been digitally generated.
Y
N
Inspect the prints. The defect resembles a smear or smudge or
is similar to the defects in the Smudges, Smears section of
Smeared Copies/Prints.
Y
N
Inspect the Developer Collector Tube.
Ensure that it is correctly connected to the Developer Housing
and is not clogged. The Developer Collector Tube is OK.
Y
N
Repair or replace as necessary Developer Collector Tube
PL 5.1B Item 7.
Replace the Xerographic Module PL 5.1A Item 1. When set-up
is complete, enter [Marking tab , Print Test Pattern]. Run 4
prints (11", A4) of the [Blank Page] test pattern. Lay the prints
out in order.
Inspect the prints for spot defects. The spots are gone.
Y
N
Paper path related spots. Try to characterize the spots as
toner or some other material. Inspect the paper path for
toner contamination or any other source of foreign material. Clean or repair as necessary.

Clean or repair as necessary:
Perform the REP 05-1 DADF Cleaning Procedure, and the REP 143 Scanner Cleaning Procedure.
If the defect is occurring in both of these modes and is not an original problem,
it is not an IIT defect. Return to IQ-1 and repeat that procedure. See if the
defect can be classified differently


Inspect the spots closely. Touch the spot with a fingertip. There is a small
dark spot in the center of the white spots and can be felt as a raised area
on the print.
Y
N
Enter [System, Imaging, and IOT Configuration]. Select [Software].
Inspect the software level of the machine. The System Software version is 1.10 or greater.
Y
N
Upgrade the machine software to the latest level available.
Inspect the original defect copies or determine the run mode in which the defect copies were
occurring. The defect ONLY occurs on side 2 of duplex jobs.
Y
N
In [Marking tab , Print Test Pattern], make 6 (8.5 x 11" or A4) prints of [Blank Page] and 6
prints of 106 dpi [50% Halftones]. Discard the first two prints. Lay out the prints 3, 4, 5, 6 in
order.
Inspect the prints for spot defects. Carefully check if the spots repeat ONLY on every
other print. The defect occurs in the same position on every other print.
Y
N
The defect is visible only on the backside of the prints.
Follow REP 09-11, Photoreceptor Drive Module Cleaning Procedure and thoroughly clean the Photoreceptor Drive Module.
Go to IQ-3 Video Path RAP.
D
E
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D
May 2003
3-35
H
Image Quality
IQ-14
H
Switch the machine power off / on. Run the copies/prints again and check
for white spots.
Inspect the copies/prints. White spots are still present on the copies/
prints.
Y
N
Prepare to hardstop the machine. Use an interlock cheater in the Front
Door Interlock Switch and observe the paper as it passes the Prefuser
Transport. Just as the trail edge of the paper passes into the Duplex
Transport, remove the interlock cheater. Enter [Marking tab , Print Test
Pattern]. Run 4 prints (11", A4) of the 106dpi 50% Halftone.
Observe the print for spots. White spots are present on the print.
Y
N
Observe the back side of the copy/print for spots. Spots are present on the back side of
the copy/print.
Y
N
Hardstop the machine again, this time after the copy/print has gone through the Prefuser
Transport, but before the print enters the Duplex Transport.
Observe the back side of the print for spots. Spots are present on the back side of
the copy/print.
Y
N
Check for contamination of the Duplex Transport. Clean / replace the Duplex Transport as
necessary PL 6.1A Item 2 .

The spots are surrounded by a white or lightened circular area when
they appear in an image area.
Y
N
In [Marking tab , Xerographic Diagnostics], select [Set-Up]. Select [Start].
When set-up is complete, enter [Marking tab , Print Test Pattern]. Run 4 prints
(11", A4) of 106 DPI 25% halftone. Lay the prints out in order.
Inspect the prints for spot defects. The spots are gone.
Y
N
Run 100 blank copies/prints.
Observe the copy/print for spots. Spots are still present on the copy/print.
Y
N
Run 50 blank 2-sided copies/prints.
Observe the back side of the copy/print for spots. Spots are still present on the back side
of the copy/print.
Y
N
Prepare to hardstop the machine while making 2 sided copies/prints. Use an interlock cheater
in the Front Door Interlock Switch and observe the paper as it passes the Prefuser Transport.
Just as the trail edge of the paper passes into the Duplex Transport during the 1st pass,
remove the interlock cheater.
Image Quality
IQ-14
May 2003
3-36
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Fuser Module
Toner Dispenser
Figure 1 IOT Front
V0.042
May 2003
3-37
Image Quality
IQ-14
IQ-15 Geometrics RAP
Check the first visible mark on the scales. The last visible mark
on both of the scales is between 2mm and 4.5mm.
Y
N
Go to the 05-A, Document Feeder Fault Entry RAP and troubleshoot a misregistration or border band problem.
This procedure is intended to assist in troubleshooting causes for image location problems on
the machine, such as misregistration, skew, incorrect magnification, border bands, etc.
Initial Actions
Ensure that all side guides are set correctly in the Document Feeder and all paper trays.
If a black border problem in the manual mode, ensure that the originals are placed correctly on the document glass
If a black border problem using the DADF, ensure the original size is correct for the paper
size being run.
If a black border problem using the DADF, ensure that the CVT Glass is clean.
If Registration mag problems occur after doing a software upgrade, perform ADJ 14-2.
Check for a magnification problem. Align the K1 line on the copy to

the K1 line on the original.
Check the alignment of the H1 line on the copy to the J1 line on the
test pattern original. The H1 line is aligned with the J1 line or is
offset less than 2 lines.
Y
N
Go to the 05-A, Document Feeder Fault Entry RAP and troubleshoot a magnification problem.
The problem is black borders when running A5, B5, or Statement paper SEF from the Document Feeder.
Y
N
Go to the RAP or Procedure indicated for the associated defect:

Y
N
The main problem is a magnification problem.
Y
N
If unknown what modes are showing defects, run manual platen and DADF mode,
simplex and duplex modes.
Observe/determine the run mode when the defect occurs. The defect occurs in
the manual platen mode.
Y
N
Y
N
If the problem is intermittent or only appears under stress or different conditions, try to reproduce the conditions, if possible. If the defect is not
occurring when making copies under any conditions, return to the IQ-1
Image Quality Entry RAP. See if the defect can be classified differently.
IQ-15
Image Shear: (ensure that there is no skew, only shear)

Border Bands/ IB-OB Lines near edges: Go to the 05-D,

Document Feeder Image Distortion RAP.
1.
Enter [NVM tab , NVM Tool].
2.
From the NVM Toolbar, select [Machine], then [Download].

Answer [Yes] to the question Initiate NVM Download.
3.
After NVM loads, select [Scan Service].
4.
Scroll (or search) to location 53, (CVT Carr Location). Check the
value in that location
a.
If the value is 5067, go to 10.
b.
If the value is not 5067, continue with the next step.
5.
Change the current value of location 53 to 5067, then select

[Write NVM].
6.
Scroll to location 54, (Lamp Warm-up Location). Change the

current value of location 54 to 5067, then select [Write NVM].
7.
Select [Image Processing Service].
8.
Scroll to location 5, (CVT Slow Scan Registration). Read the

current value in that location.
9.
Subtract 71 from the value read in the previous step. Enter the
new value and select [Write NVM].
10. Exit from NVM Tool and diagnostics. At the end of the session,
answer Yes to the question Do you want to reset the machine.
Check for misregistration. Observe the registration scales (the two

registration scales nearest the R2 resolution scale) on the lead edge
and top edge.
E
Perform the following (Only if TAG 016 is installed and IOT software
level is L15.x or L17.x)
Check the Last 40 faults [Faults/Counters tab , Faults]. The defect is associated with either 22-300.05 or 22-700.05 faults.
Y
N
Check the DADF for contamination. The DADF is dirty.
Y
N
Check for DADF skew. Ensure that the Border Erase is set to 3mm
(0.1"). Using the DADF, make 1 copy of test pattern 82E13100 (11")
or 82E12321 (A4).
Observe the lead edge registration scales on the copy. Notice the
first visible mark on the IB and OB scale. The difference in the
first visible mark on the IB and OB scale is 1mm or less.
Y
N
Go to the 05-F Document Feeder Registration and Skew RAP
and troubleshoot a DADF Skew problem.
A
B
C
D
Image Quality
Perform the REP 05-1 DADF Cleaning Procedure. If the problem continues, go back one step and answer No.
A
May 2003
3-38
D
V0.042
D
Clean the DADF Exit/Invert Sensor.
Run copies/prints again and check for a reoccurrence of the defect. The
defect is still present.
Y
N
Magnification (Top to Bottom): Check the value in NVM for the Hall
Period Reference. Use [NVM | NVM Tool]. The Hall Period Reference
is a calibration factor for the ROS Polygon Motor speed. This value
sets the magnification in the IB-OB (fast-scan) direction. Ensure that
the value matches the value for the Hall Period Reference on the
ROS Bar Code label. Figure 1

1.
Ensure that the Scanner Top Frame is grounded correctly. Check continuity from the Scanner Top Frame to the machine frame. If there is a problem, check the Left front mounting screw of the Scanner Top Frame.
Make sure it is present and the metal bracket carries ground to the Scanner Top Frame.
2.
3.
4.
Check for scanner skew. Ensure that the Border Erase is set to 3mm (0.1").
Make 1 copy of test pattern 82E13100 (11") or 82E12321 (A4) using the platen
mode.
Observe the lead edge registration scales on the copy. Notice the first visible
mark on the IB and OB scale. The difference in the first visible mark on
the IB and OB scale is 1mm or less.
Y
N
Go to the ADJ 14-1.
Check for misregistration. Observe the registration scales (the two registration
scales nearest the R2 resolution scale) on the lead edge and top edge.
Check the first visible mark on the scales. The last visible mark on both of
the scales is between 2mm and 4.5mm.
Y
N
Go to the ADJ 14-2.
The defect is a skew or misregistration problem only on side 2 of duplex copies.

Y
N
In [Marking tab , Print Test Pattern], make 6 prints of the [Registration] pattern]. Discard the first two prints.
NOTE: The Registration pattern is the same pattern used in setting registration
and skew, but without the offset switched off.
Check for a magnification problem. Align the K1 line on the copy to the K1 line
on the original.
Check the alignment of the J1 line on the copy to the J1 line on the test pattern
original. The J1 line is aligned with the J1 line or less than 2 lines off.
Y
N
Go to the ADJ 14-2.
Check the registration and skew of the sixth print. The short lines on the top
edge should be 5mm 2.4mm (95% of all sheets should meet this spec, simplex or duplex. All sheets should be no more than 5mm 3.6mm) from the
edge of the paper. The long line parallel to the lead edge should also be 5mm
1.8mm from the edge of the paper. Lead Edge skew should not be more than
1.6mm (8.5 x 11") or 1.7mm (A4). The Lead Edge and Top Edge Registration, and the Skew are all within spec.
Y
N
To check registration and skew, go to the ADJ 8-1.
Choose the appropriate defect:
All of the geometrics are in spec. Determine if the problem is intermittent or job
run length related. Check the type/quality of original documents. Perform the
above steps again if copies can be reproduced which are out of spec.
Misregistration (Lead Edge), go to 08-A
Misregistration (Lead Edge), go to 08-A.
Misregistration (Top Edge), go to 08-B
Misregistration (Top Edge), go to 08-B Side 2 Checkout Procedure, 08-B Side

2 Checkout Procedure.
Skew, go to 08-C.
NOTE: On some machines with the aluminum ROS TAG 057, burrs
on the alignment pins of the ROS can cause the ROS to shift up to
7mm when the Xerographic Module is inserted. If the ROS has a
serial number 15500 and below, perform the following:
A
B
V0.042
NOTE: Magnification can be checked in the IQ-2, IQ Checkout RAP or in IQ Specifications Entry .
1.
Remove the ROS from the machine.
2.
Cover the window of the ROS with a towel or rag to keep out
contaminates.
If the problem only occurs in the DADF mode, ensure TAG 084 is installed. If already
installed, use the 12-AM RAP to check the DADF CVT Motor Ground kit.
3.
Using emery cloth (43P65), sand the ramps on both alignment

pins until any burrs or roughness are gone.
4.
Reinstall the ROS and verify that the registration is OK.
Magnification (Top to Bottom): Check the value in NVM for the Hall Period Reference. Use [NVM | NVM Tool]. The Hall Period Reference is a calibration factor for
the ROS Polygon Motor speed. This value sets the magnification in the IB-OB (fastscan) direction. Ensure that the value matches the value for the Hall Period Reference on the ROS Bar Code label. Figure 1
Copier Horizontal Mag problem - go to the ADJ 14-2
Skew, go to 08-C
A
May 2003
3-39
Image Quality
IQ-15
A
Misregistration (Top Edge), go to 08-B Side 2 Checkout Procedure, 08-B Side 2 Checkout Procedure.
Skew, go to 08-C
Magnification (Top to Bottom): Check the value in NVM for the Hall Period Reference.
Use [NVM | NVM Tool]. The Hall Period Reference is a calibration factor for the ROS
Polygon Motor speed. This value sets the magnification in the IB-OB (fast-scan) direction.
Ensure that the value matches the value for the Hall Period Reference on the ROS Bar
Code label. Figure 1

To check registration and skew, go to the ADJ 8-1.
Misregistration (Lead Edge), go to 08-A

Product
470 DC/ST
460 DC/ST
255/265 DC/ST
N/A
240 DC/ST
N/A
Part #
ROS Serial #
Hall Period Reference

(NVM 729)
Image Fast Scan Reg
(NVM 723)
(NVM 793)
Figure 1 Bar Code Label
Image Quality
IQ-15
May 2003
3-40
V0.042
Ground Wire
(violet)
Ground Wire
(violet wire)
V0.042
May 2003
3-41
Image Quality
IQ-15
Ground Wire
(violet)
Figure 4 IOT Rear
Image Quality
IQ-15
May 2003
3-42
V0.042
IQ-16 Poor Fusing RAP

This procedure is intended to assist in troubleshooting causes for fusing problems.
Initial Actions
Only perform this procedure if there are no Chain 10 fault codes.

Check whether the problem is occurring with standard 20lb. paper. If not and the problem
is occurring with the customers paper, ensure that the paper stock is not damaged and is
not less than 16 lb or 61 gsm and not greater than110 lb or 203 gsm.
Check for use of non-Xerox toner. Call the Competitive Toner Hotline.
If the above checks are OK, replace the Fuser Module PL 6.2A Item 1.
V0.042
May 2003
3-43
Image Quality
IQ-16
A
The Main Control PWB has apparently failed. Go to the 03-G Main Control PWB Replacement
RAP.
IQ-17 Black Copies/Prints RAP

This procedure is intended to assist in troubleshooting causes for black copies/prints. Prints
that are all halftone or black with no fault codes occurring are most likely caused by a video
path problem.
Initial Actions
Check the Raster Output Scanner Video Cable for good connection at the ROS Assembly and Main Control PWB
All Document Feeder and Scanner grounds (If a DC or ST machine)

Determine the type machine. If an ST machine, check if the problem is only occurring when
copying or printing.
The problem is only occurring when copying or the machine is a DC model.
Y
N
If the machine is a LP machine, or the problem only occurs when printing, go to the IQ-3
RAP.
The [Results] window has the message: "Lamp turn on passed".
Y
N
In Video Path Diagnostics, select [SCVM Digital Test] and [Start Test], then observe the results
of the test. Enter [Self Tests tab , Video Path Diagnostics].
The test passes.
Y
N
Y
N
In [Faults/Counters tab , Faults], check the Last 40 Faults for any 14-314, 14-315,
14-316, 14-317, 14-318, 14-319, or 14-320 faults.
There are 14-314, 14-315, 14-316, 14-317, 14-318, 14-319, or 14-320 faults in
the Last 40.
Y
N
There was a false failure of the SCVM Digital Test. Return to the step where the
SCVM Digital Test was run and answer YES.
Y
N
A
Image Quality
IQ-17
May 2003
3-44
V0.042
IQ-18 Special Stock RAP

Initial Actions
This RAP only deals with Image Quality problems that are present when copying/printing on
special stock such as transparencies, label stock, glossy paper, or paper heavier than 20lb
(80gsm).
For defects that are occurring on 20lb. (80gsm) paper, go to the IQ-1, IQ Entry RAP.

Try to feed standard paper. If a problem exists with standard paper, troubleshoot using the
fault or symptom.
Ensure that the stock is one the Document Centre 240/265 is designed to feed (see
Product Specifications ,
Ensure that the correct tray is being used. In most cases, the Bypass Tray should be used
for special stock. See GP10 .
Ensure that the stock is being loaded per the instructions on the packaging.
Ensure that the stock is not damaged and has been stored correctly.
V0.042
May 2003
3-45
Image Quality
IQ-18
IQ-19 Motion Quality RAP
High Frequency Banding
This RAP is used to help diagnose motion quality problems. Motion quality problems usually
appear as IB-OB banding or smears.

Measure the distance between the bands to determine the frequency. If the defect occurs at a
high frequency (less than 1.3mm), go to the High Frequency Banding. Use [Marking tab , Print
Test Pattern] and select 2 on 2 off Perpendicular Lines or 106 DPI 50% Halftone to show the
defect. Table 1 indicates the frequencies for 40 ppm and 65 ppm and its associated cause and
recommended corrective actions.

1.
If the banding is accompanied by an unusual humming noise when the machine runs,
clean the backer bars in the Photoreceptor Drive Module (REP 09-11). If the problem
continues, replace the Xerographic Module PL 5.1A Item 1.
2.
Check the mounting of the ROS Assembly. Ensure that it is not biased up against any
structural members of the machine (Developer Housing or machine frame).
3.
If #1 does not help, replace the following parts in order or perform the following until the
problem is resolved: ROS Assembly PL 5.2 Item 3
4.
5.
Table 1 Corrective Actions

Freq.
Corrective Actions
Replace
161.3mm
PR Cleaner Tension Idler
Photoreceptor Drive Module PL

5.1A Item 2
92.6mm
PR Tension Roll Shaft

5.1A Item 2
90.9mm
PR Cleaner Brush

5.1A Item 2
79.4mm
PR Strip Roll or PR Idler Shaft

5.1A Item 2, Photoreceptor Drive
Module PL 5.1A Item 2
48.5mm
(65ppm and
55ppm)
Donor Roll
Developer Housing PL 5.1A Item

2
42.5mm
(40ppm)
Donor Roll

2
15.9mm
Photoreceptor Drive Motor

5.1A Item 2
14.7mm
(65ppm and
55ppm)
Mag Roll

2
12.9mm
(40ppm)
Mag Roll

2
2.0mm
PR Idler Pulley and PR Cleaner

Pulley

5.1A Item 2
1.3mm
Developer Idlers
Developer Housing PL 5.1B Item

5
Image Quality
IQ-19
May 2003
3-46
V0.042
IQ-20 IIT Torn Image RAP

This RAP is intended to assist in troubleshooting IIT torn image problems. Refer a sample of
this type of defect in the IQ Defects and Samples section (IQ Defect Samples Entry). This RAP
should not be used for LP machines or ST machines that exhibit this defect when printing.
B
Go to the 03-G, Main Control PWB Replacement Failure RAP.
Torn Image: The image appears to be stretched or distorted in a band that runs from IB to OB
on the copy.
Initial Actions
If this problem occurs in DADF mode, ensure that the DADF Paper Feed Roll Cartridge PL 2.2
Item 4 has been replaced.

The defect occurs in manual platen mode.
Y
N
Y
N
If the problem is intermittent or only appears under stress or different conditions, try
to reproduce the conditions, if possible. If the defect is not occurring when making
copies under any conditions, return to the IQ-1 Image Quality Entry RAP. See if the
Replace the DADF Paper Feed Roll Cartridge PL 2.2 Item 4.
Run copies in the DADF mode to reproduce the problem. The defect still occurs.
Y
N
Run [IIT tab , IIT Motor Tests] (CVT Motor).
The CVT Motor passes.
Y
N
The CVT Belts pass.
Y
N
Replace the Exit Clutch Drive Belt PL 2.3 Item 5 and CVT/Reg Roll Drive Belt PL
2.3 Item 6.
Replace the CVT Drive ON Glass Roll PL 2.4 Item 3.
Y
N
Run [IIT tab , IIT Motor Tests] (Scan Carriage Motor)
The Scan Carriage Motor Test passes.
Y
N
Run copies in manual platen mode to reproduce the problem. The defect still occurs.
Y
N
A
B
V0.042
May 2003
3-47
Image Quality
IQ-20
IQ-21 IIT Grainy Image RAP
IQ-22 IIT Jagged Lines RAP
This RAP is used to diagnose grainy images when scanned from a DC or ST machine.
This RAP is used to diagnose jagged lines when scanned from a DC or ST machine. This RAP
is not for IOT problems.

Y
N
If the problem is intermittent or only appears under stress or different conditions, try to
reproduce the conditions, if possible. If the defect is not occurring when making copies
under any conditions, return to the IQ-1 Image Quality Entry RAP. See if the defect can
be classified differently.
Y
N
Perform the REP 14-3 Scanner Cleaning Procedure.
Perform the REP 14-3 Scanner Cleaning Procedure.
Make copies and check if defect is still present. The defect is still present.
Y
N

In [Marking tab , Print Test Pattern], run 5 prints of the [Quadrille] pattern and 5 prints of 106dpi
50% Halftone.
Inspect the quadrille prints for jagged lines and the 106dpi Halftone for a herringbone or tweed
type pattern. The prints are OK.
Y
N
Y
N
Y
N
If the problem is intermittent or only appears under stress or different conditions, try
to reproduce the conditions, if possible. If the defect is not occurring when making
copies under any conditions, return to the IQ-1 Image Quality Entry RAP. See if the
Go to the 14-A, Illumination Checkout RAP.

Run [IIT tab , IIT Motor Tests] (CVT Motor).
The CVT Motor passes.
Y
N
The CVT Belts pass.
Y
N
Replace the Exit Clutch Drive Belt PL 2.3 Item 5 and CVT/Reg Roll Drive Belt PL
2.3 Item 6.
Replace the CVT Drive ON Glass Roll PL 2.4 Item 3.
Y
N
Run [IIT tab , IIT Motor Tests](Scan Carriage Motor)
The Scan Carriage Motor Test passes.
Y
N
Run copies in manual platen mode to reproduce the problem. The defect still occurs.
Y
N
If the defect is occurring in both DADF and manual platen mode, it is normal line reproduction.
Image Quality
IQ-21, IQ-22
May 2003
3-48
V0.042
IQ-23 Black Holes Defect RAP

This RAP is used to diagnose defects caused by punched holes on documents copied on a DC
or ST machine. This RAP is not for IOT problems.

These types of defects are caused when the document has holes punched (such as 3-hole). To
verify, ensure that the defects match up with the original when copied at 100%. If they do not
match up, return to IQ-1.
The defect is occurring when copying in the DADF mode.
Y
N
The machine has a white platen pad.
Y
N
Instruct the customer to place a white sheet of paper behind the original if the job
cannot be run from the Document Feeder.
The job should be run with the Document Cover closed.
A
Check the CVT Drive on Glass Roll guides to ensure that all three are present, in place and
correctly oriented. The guides are OK.
Y
N
Repair or replace the CVT Drive on Glass Roll PL 2.4 Item 3.
Clean the Document Glass under the CVT area.
The problem is still occurring.
Y
N
TAG 077 is installed.
Y
N
Access the EHR PWB to view the part number.
The EHR PWB has a part number of 160K59430 or 160K64130.
Y
N
Replace the Electronic Hole Removal PWB PL 1.4B Item 3 with the correct one to
make a valid combination.
NOTE: The customer will be unable to use either Auto Paper Select or Auto Reduction/
Enlargement.
Check the NVM values listed in Table 1 for the correct values The NVM values are correct.
Y
N
Enter the correct NVM values from Table 1.
Check the machine for TAG 296 or TAG 080. TAG 296 or TAG 080 is installed.
Y
N
Check the machine for TAG 077.
Y
N
Check the machine for TAG 015.
Y
N
Obtain and install TAG 077 and TAG 080.
Reseat the EHR PWB.

Check for a recurrence of the problem. The problem is still occurring.
Y
N
Replace the Electronic Hole Removal PWB PL 1.4B Item 3.
Check the NVM values listed in Table 1 for the correct values The NVM values are correct.
Y
N
Enter the correct values from Table 1.
Obtain and install TAG 296.

Obtain and install TAG 080.
If the defect is only occurring in Photo Mode, this is normal. If the defect is occurring in the Normal Mode, continue.
Check the distance of the holes from the closest edge of the original. The holes are 20mm
or less from the edge of the paper.
Y
N
If the platen pad is white, run the job from the platen with the document cover closed.
NOTE: The customer will be unable to use either Auto Paper Select or Auto Reduction/Enlargement.
If the platen pad is gray, place a white sheet of paper behind the original and copy
from the platen.
Check the machine for TAG 075. TAG 075 is installed.

Y
N
Install TAG 075.
A
V0.042
Reseat the EHR PWB.

Check for a recurrence of the problem. The problem is still occurring.
Y
N
Replace the Electronic Hole Removal PWB PL 1.4B Item 3.
Table 1 Image Processing Service NVMs
NVM Name
Location
Value
MinVar
30
MaxVar
31
16
Black
32
28
Threshold
33
360
May 2003
3-49
Image Quality
IQ-23
IQ-24 Toner Blow-Out RAP
Toner Blow-Out NVM Values
Toner Blow-Out (TBO) is often an early warning indicator of a larger system problem. Attempts
to minimize TBO by itself without fixing the underlining problem will likely be temporary, and/or
ineffective, and may even induce other problems such as light prints. This RAP is intended to
help resolve the underlying problem not just provide a fix for the TBO symptom.
1.
Load the following NVM values.

NOTE: These NVM Values may cause light prints.
Use (Table 1) values for machines with software (07.19.01.xxx) and later.
Use (Table 2) values for machines with software earlier than (07.19.01.xxx)
Do NOT use Table 1 values for machines above 4000 feet.
NOTE: Toner Blow-Out is most likely to be seen in High Temp/ High RH conditions and will be
more noticeable on low volume and low area coverage machines.
Table 1 (07.19.01.xxx) software and later
Initial Actions
See samples of Toner Blow-Out in the IQ Defect Samples (Toner Disturbance).
If the Developer Housing has more than 400000 prints on it, replace it before continuing
with this RAP. (Skip the Donor Roll Filming Check)
Replace the paper supply with fresh paper.
Enter [Marking tab , Print Test Pattern]. Select [Marking] [Print Test Pattern]. Make 5 prints
of the Perpendicular Lines Test Patterns, 2 On 30 Off and 8 On: 56 Off. Retain the
prints for evaluation or comparison.
NVM Loc
Current NVM
Value
New
NVM Value
776
1500
3000
777
350
1000000
788
265
498
1230
45
45 (no change)
1231
10.5
10
Xerographic Baseline Procedures
1256
1.
Prior to running an initial Xerographic set-up initialize the Xerographic NVMs and re-enter
the ROS NVM values. Run Xerographic set-up.
1257
0.5
1302
39
34
Run Xerographic Exerciser.
1330
495
530
1343
220
170
1351
495
430
1353
220
100
1355
2245
2550
1381
190
100
2.
3.
Record the Background Level. The Background Level should be below 4. If the
Background Level is above 4, the machine is running at an increased Toner Concentration (TC) which can be caused by low area coverage or low machine usage or by
a poor Mag or Donor Roll Contact or slow reacting Photoreceptor.
Perform the recommended repairs.
Toner Blow-Out is still present.
No - Return to Service Call Procedures and complete the service call.
Yes - Continue with this RAP.
Donor Roll Filming Check

1.
NVM location 780 is greater than 2600 and location 1273 is greater than 250.
Table 2 (Pre - 07.19.01.xxx) software

Current NVM
NVM Location Value
New
NVM Value
1222
49
44
1223
45
46.5
1229
86
87.5
45.5
46.5
11
Yes - Perform REP 09-13, Donor Roll Cleaning Procedure.
1230
No - Remove the Developer Housing from the machine. See Figure 1 and clean the
Donor Roll Shaft contact area with Scotch Brite, (43P74) or Pumice Paper, (43P46).
1231
10.5
1271
0.4
2.
Run Xerographic set-up. (must be run anytime properties of Developer Housing have
changed)
1281
42
3.
lower by 2 from
present value
(dont go below 39)
2.
Run Xerographic set-up.
3.
Yes - Continue with this RAP.
Image Quality
IQ-24
May 2003
3-50
V0.042
Yes - Escalate the service call to Field Engineering.
Clean Shaft
V0.042
May 2003
3-51
Image Quality
IQ-24
Image Quality
IQ-24
May 2003
3-52
V0.042
IQ Defect Samples Entry
IB-OB Bands
Purpose
Banding, IB-OB: Developer Donor Roll
The purpose of this section is to provide a collection of images that represent the types of
image quality defects that may occur. The defects are referenced and hotlinked from associated RAPs, and they are grouped here by defect type.
This defect was caused by a Developer Donor Roll with severe runout. The defect is a light
band running from IB-OB and separated by 42.6mm (40ppm) or 48.5mm (65ppm). Refer to the
IQ-13 Lines/Bands/Streaks RAP. Replace the Developer Housing.
NOTE: If you have trouble displaying these samples, change the number of colors that your
laptop will display to 256.
Defect Types
This area is grouped by category. Choose the defect type and go to the appropriate area:
IB-OB Bands
LE-TE Streaks/Bands
Scrogged Images
Non-Uniform Copies/prints
Smeared copies/prints
Spots/Dirt
Image Distortion
Toner Disturbance
Figure 1 Developer Donor Roll Runout
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May 2003
3-53
Image Quality
IQ Defect Samples Entry, IB-OB Bands
Banding, IB-OB: Developer Donor Roll
Banding, IB-OB: PR Belt Ground
This defect was caused by a Developer Donor Roll with slight runout. The defect is a light band
running from IB-OB and separated by 42.6mm (40ppm) or 48.5mm (65ppm). Refer to the IQ13 Lines/Bands/Streaks RAP. Replace the Developer Housing.
Four samples are shown here. This defect which appears as light bands IB-OB, is caused by a
poor PR Belt ground. It is usually intermittent and no pattern prevails. Refer to the IQ-13
Lines/Bands/Streaks RAP. Replace the XRU.
Figure 2 Developer Donor Roll Runout
Figure 3 P/R Belt Ground Problem
Image Quality
IB-OB Bands
May 2003
3-54
V0.042
V0.042
May 2003
3-55
Image Quality
IB-OB Bands
Banding, IB-OB: Developer Donor Roll Bias Intermittent

In addition to the IB-OB banding caused by bad high voltage contact to the donor roll, a diagonal pattern is also visible.
Figure 7 Developer Donor Roll Bias Intermittent
Image Quality
IB-OB Bands
May 2003
3-56
V0.042
Banding IB-OB: XRU, PR Ground
Banding IB-OB: Loss of Mag Roll Bias
Poor PR Belt Ground, low frequency. Here, the banding has no consistent pattern. Refer to the
IQ-13 Lines/Bands/Streaks RAP.
Image is washed out, also diagonal pattern appears.
Figure 9 Developer Mag Roll Bias Problem
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May 2003
3-57
Image Quality
IB-OB Bands
Band IB-OB: DADF
Bands IB-OB: High Frequency
Speed Change while document in CVT. Also known as Torn Image.
This is a sample of High Frequency Banding. Very narrowly spaced lines running IB-OB, usually repeating across the page. This particular sample was caused by a defective Xerographic
Module that had a high friction condition between the P/R Belt and the P/R Drive Module
backer bars which caused the belt to vibrate.
Figure 10 DADF Band
Figure 11 High Frequency Banding
Image Quality
IB-OB Bands
May 2003
3-58
V0.042
Band IB-OB: Dark Bands

This is a sample of dark bands known as "charge flashing". An interaction between the Charge
Scorotron and the P/R Belt. Either one or both may have failed. Replace the Xerographic Module PL 5.1A Item 1.
Figure 13 Dark Bands
Figure 12 Dark Band
V0.042
May 2003
3-59
Image Quality
IB-OB Bands
LE-TE Streaks/Bands
Streak, LE-TE: XRU, Cleaner problem
The narrow, streak which is a light streak through solid areas and is a dark streak through nonimaged areas here was caused by poor PR Belt cleaning. Refer to the IQ-13 Lines/Bands/
Streaks RAP.
Figure 14 Dark Band
Figure 1 Cleaner Streak
Image Quality
IB-OB Bands, LE-TE Streaks/Bands
May 2003
3-60
V0.042
Streak, LE-TE: XRU, Transfer Problem
Band, LE-TE: Developer Problem
This defect which is a dark streak through non-imaged areas was caused by a bad Transfer
Corotron. Note that is not a continuous image and not smeared which indicates that no contact
was involved (rule out Developer Housing and Cleaner problems). Refer to the IQ-13 Lines/
Bands/Streaks RAP.
Both of these defects were caused by something internal to the Developer Housing rubbing on
the donor roll. Refer to the IQ-13 Lines/Bands/Streaks RAP.
Figure 3 Donor Roll Rubbing

Figure 2 Transfer Streak
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May 2003
3-61
Image Quality
LE-TE Streaks/Bands
Short Horizontal Lines

This problem can be caused by several contributors. Use IQ-13, Lines Bands and Streaks
RAP.
Figure 4 Donor Roll Rubbing

Figure 5 Short Horizontal Lines
Image Quality
LE-TE Streaks/Bands
May 2003
3-62
V0.042
Bands, LE - TE: Dirty Charge Scorotron Problem
Scrogged Images
This defect was caused by a dirty or damaged Charge Scorotron. Clean or replace Charge
Scorotron.
Compressed Image
This sample is indicative of a situation where a compressed image was corrupted. Once corrupted, the data cannot be reconstructed, and an image that is unintelligible remains. The
image is compressed before it goes to the EPC Memory and the
Image Disk Drive and
decompressed on the Main Control PWB. Go to the IQ-3 Video Path RAP.
Figure 1 Scrogged Image
Figure 6 Dirty Charge Scorotron
V0.042
May 2003
3-63
Image Quality
LE-TE Streaks/Bands, Scrogged Images
No Sync Image
Broken Image
This defect resembles a loss of horizontal hold on an old television set. Loss of sync has
occurred. Go to the IQ-3 Video Path RAP.
In this defect, an recognizable image is visible, but it has been broken up and put together
incorrectly. The image has most likely made it through most of the image path correctly, but
deformed just before the CVT Dirt Streaks Label. Go to the IQ-3 Video Path RAP.
Figure 2 No Sync
Figure 3 Broken Image
Image Quality
Scrogged Images
May 2003
3-64
V0.042
Autoseg Defect
This defect is distinguished by only occurring within haltones on scanned images. It will not
appear on the IOT internal patterns. Go to the IQ-3 Video Path RAP.
Figure 5 Autoseg Defect
Figure 4 Autoseg Defect
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May 2003
3-65
Image Quality
Scrogged Images
Negative Image
EHR PWB Mismatch
Figure 6 Negative Image
Figure 7 EHR PWB Mismatch
Figure 6 looks similar to a "negative image", but all images aren't reversed. The white background is black, but some black images remain black. Go to the IQ-3 Video Path RAP.
Image Quality
Scrogged Images
Wavy image caused by incorrect EHR PWB in machine.
May 2003
3-66
V0.042
Figure 8 EHR PWB Mismatch

Figure 9 Bad ROS Video Cable
Pattern in halftones caused by incorrect EHR PWB.
V0.042
May 2003
3-67
Image Quality
Scrogged Images
Structured Background
Figure 11 Main Control PWB

Figures 9 and 10 are from the same machine. Figure 11 should have been a blank copy. Dark
bands of structured background was caused by a defective Main Control PWB.
Image Quality
Scrogged Images
May 2003
3-68
V0.042
Figure 12 ROS Video Cable
Figure 13 ROS Video Cable
Another type of structured background. No background at the trail edge side of images.
Caused by a defective ROS Video cable.
Bad ROS Video cable also caused this defect. Note that the black bars are lighter than usual
(normal at very top). Small horizontal lines form a diagonal pattern.
V0.042
May 2003
3-69
Image Quality
Scrogged Images
Non-Uniform Copies/Prints
Non-Uniform Halftones
Non Uniform copies/prints are best seen in halftones. The 106dpi 50% pattern will show this
defect. Figure 1 is a sample of a defective Developer Housing. In this case one of the augers
was not being driven. Use the IQ-5, Non-Uniform Prints RAP to diagnose the problem.
Figure 14 Bad ROS Video Cable
Figure 1 Non-Uniform
Image Quality
Scrogged Images, Non-Uniform Copies/Prints
May 2003
3-70
V0.042
Figure 2 is known as a "parking deletion". It is distinguished by being located near the trail
edge of the prints, and only on every other print. Replace the Xerographic Module PL 5.1A
Item 1.
Figure 3 is a sample of an intermittent bias connection on the Developer Housing mag roll.
Use the IQ-5, Non-Uniform Prints RAP to diagnose the problem.
Figure 3 Developer Mag BIas

Figure 2 Parking Deletion
V0.042
May 2003
3-71
Image Quality
Figure 4 appears as non-uniform or light bands IB-OB, is caused by a poor PR Belt ground. It
is usually intermittent and no pattern prevails. Refer to the IQ-13 Lines/Bands/Streaks RAP.
Replace the XRU.
Figure 5 Channel Banding
Channel Banding
Channel Banding is an IIT Defect and is distinguished by the distinct line separating the copy
into two halves. Switch the machine power off/on to force a scanner calibration for this defect.
Image Quality
May 2003
3-72
V0.042
Washed Out
Smeared Copies/Prints
This may appear as washed out on normal copies. This particular defect was due to a problem
with the Developer Mag roll. Could be diagnosed using the IQ-5, Non-Uniform Prints RAP.
Smeared/Dirty
Print is smeared/dirty. Occurs over entire page which distinguishes it from common paper path
induced smears which are usually localized. Image is still visible, though it is very light/almost
deleted. This defect was caused by a poor contact between the Developer HVPS and the
Developer Housing. This might occur if the Developer HVPS is removed/reinstalled with the
Developer Housing in place.
Figure 6 Washed Out
Figure 1 Dirty Image

V0.042
May 2003
3-73
Image Quality
Non-Uniform Copies/Prints, Smeared Copies/
Smudges/Smears
These four samples show an unusual defect, jumping Gap Arcing defect, sometimes referred
to a "Doppler Defect". These defects can occur in an image area or a non-image area. It is
unrelated to the image but can affect the image. The defect is random, but usually localized. It
will usually look like a smudge or fingerprint, but it may run in the lead edge to the trail edge
direction of the copy/print and have branches that fork off towards the top or bottom of the
copy/print. It also can appear as a long narrow smudge.
This defect is caused by small particles of debris passing between the inside of the photoreceptor belt and the development backer bar on the Photoreceptor Drive Module. Frequently
the debris is small flakes from the rubber LLF (Low Lateral Force) Rolls in the Photoreceptor
Drive Module. It also has been attributed to the Card Cage touching the Developer HVPS
heat sink. Use IQ-4, Signature Defects RAP to diagnose this problem.
Refer to any bulletins that pertain to this problem.
Figure 2 Jumping Gap Arcing
Image Quality
May 2003
3-74
V0.042
V0.042
May 2003
3-75
Image Quality
Image Quality
May 2003
3-76
V0.042
Figures 7, 8, and 9 are examples of Jumping Gap Air Breakdown. Similar to Jumping Gap Arcing, but related to altitude above sea level. Go to IQ-4
Figure 8 Jumping Gap Air Breakdown
V0.042
May 2003
3-77
Image Quality
Spots/Dirt
Donor Debris Arcing
This defect is caused by debris getting between the Donor Roll and the P/R Belt. Use the IQ4, Signature Defects RAP and troubleshoot Donor Debris Arcing.
Figure 1 Donor Debris Arcing
Image Quality
Smeared Copies/Prints, Spots/Dirt
May 2003
3-78
V0.042
Image Distortion
Document Glass screws too tight.
This defect (lines not straight) is caused by the Document Glass screws being too tight. To correct this problem, back off on the screws until the distortion problem is resolved.
Figure 2 Donor Debris Arcing
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May 2003
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Image Quality
Spots/Dirt, Image Distortion
Toner Disturbance
Toner Blow-Out
Toner Blow-Out is a form of toner disturbance that occurs between transfer and fusing. It usually shows up on parallel lines such as those in a table. Go to RAP IQ-24, Toner Blow-Out RAP.
Figure 1 Toner Blow-Out
Figure 1 Image Distortion
Image Quality
Image Distortion, Toner Disturbance
May 2003
3-80
V0.042
Introduction/Test Patterns
Introduction
This section of the Service Manual provides the required information for setting up and checking the machine at customers sites to evaluate image quality. The information is presented in
the following manner:
A description of all test patterns necessary.
A heading titled Procedure.
Two subheadings titled Prerequisite Procedures/Checks and Post Requisite Procedures/
Checks. The Prerequisite Procedures/Checks identifies procedures or checks if any,
which must be done first. The Post Requisite Procedures/Checks identifies procedures or
checks that are affected by the subject procedure.
The Procedure identifying how to check the image quality element. The required test pattern, if any, is also include here.
The Specification for the element. Several specification entries may be given for multiple
modes.
CAUTION
Use care when handling and storing the hard copy test pattern. Dirt and oil from hands will
change the appearance of the patches and consequently the accuracy of visual comparisons
between the copies/prints and the test pattern.
All image quality elements and specifications for the Xerox Document Centre 240/255/265/
460/470 are evaluated using the test patterns listed below. These are the only test patterns
authorized for evaluating image quality.
NOTE: Xerox Document Centre 240/255/265/460/470 Family image quality specifications
should be evaluated when using copy paper such as: 4024DP 20 lb. (70gsm) or equivalent.
Table 1 Hard Copy Test Patterns
Number
Name /Description /Function
82E13100
82E12191*
Copier Test Pattern (11")

*(82E12191 is no longer available)
82E13110
82E12320*
Copier Test Pattern (A4)

*(82E12320 is no longer available)
V0.042
May 2003
3-81
Image Quality
Side 1
Side 1 is the test pattern side. The following describes the features on the test pattern:
"A1" - 1.3 absolute density patch, Flag A1
"A2" - 1.3 absolute density patch, Flag A2
A3 - 1.3 absolute density patch, Flag A3
A4 - 1.3 absolute density patch, Flag A4
"B" - 1.3 absolute density patch, Flag B
"C" - 106 dots/in halftone at 45 , 0.42 absolute density, Flag C
"D1" - 133 dots/in halftone at 45, 0.33 absolute density, Flag D1
"D2" - 133 dots/in halftone at 45, 0.33 absolute density, Flag D2
"E1" -133 dots/in halftone at 45, 0.53 absolute density, Flag E1
"E2" -133 dots/in halftone at 45, 0.53 absolute density, Flag E2
"F" - IB-OB Band, solid contone, 0.81 absolute density, Flag F
"G" -LE-TE Band, solid contone, 0.81 absolute density, Flag G
"H1, H2, H3, H4" - Magnification Lines, Flag H1, Flag H2, Flag H3, Flag H4
"K1, K2, K3, K4" - Magnification Lines, Flag K1, Flag K2, Flag K3, Flag K4
"J1, J2" - Magnification lines DADF Mode, Flag J1, Flag J2
"R1" - Resolution Target, Flag R1
"Blue Text" - Blue copyability
Figure 1 Test Pattern Side 1
Image Quality
May 2003
3-82
V0.042
Side 2
Side 2 is a SIR (Standard Image Reference) pattern. It is used to evaluate copies of side 1 of
the pattern.
"M1" - Minimum density for 50% Step Wedge, Flag M1
"M2" - Nominal density for 50% Step Wedge, Flag M2
"M3" - Maximum density for 50% Step Wedge, Flag M3
"N1" - Minimum density for D1 and D2, Flag N1
"N2" - Nominal density for D1 and D2, Flag N2
"N3" - Maximum density for D1 and D2, Flag N3
"P1" - Minimum density for E1 and E2, Flag P1
"P2" - Nominal density for E1 and E2, Flag P2
"P3" - Maximum density for E1 and E2, Flag P3
"S" - Maximum level of reload for C, Flag S
"T" - Maximum level of reload for B, Flag T
"V" - Minimum level of solid area density for A1 and A2, Flag V
"W" - Spot size reference, Flag W
X" - Gray band reference, Flag X
X1" - Dark band defect reference, Flag X1
X2" - White line defect reference, Flag X2
X3" - Periodic banding defect reference, Flag X3
Y" - Gray band reference, Flag Y
Y1" - Periodic banding defect reference, Flag Y
Figure 2 Test Pattern Side 2
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May 2003
3-83
Image Quality
PWS Test Patterns
Table 2 PWS Test Patterns
The electronic test patterns are available on the PWS. These patterns do not reside on the
PWS, but are generated on the Main Control PWB upon request from the PWS. Enter PWS
Diagnostics, enter [Marking tab , Print Test Pattern]. The table that follows indicates the patterns that are available.
Name
Lines that run LE-TE
8 On 56 Off
This pattern produces lines parallel to

the process direction. The ROS is
switched on for 8 pixels and then off for
56. This is repeated for the width of a
page in the fast scan direction for each
scan line. For checking line quality,
smears.
Perpendicular
Lines
Line that run IB-OB

Name
Description /Function
Common/General
Blank Page
Manufacturing
0% Area coverage. Used for evaluating

background and background defects
such as spots and PR scratches. Also
residual image and cleaning failures.
10mm wide strips that run IB-OB of
alternating area coverage, 50%, 25%,
75%, and 100%. Used in manufacturing
for automated measurements.
Quadrille
Grid pattern, 4 on 60 off. Use for deletions, skew, jitter.
Registration
This is the same pattern used during

Registration setup routines, but with all
offsets switched off.
Step Wedge
17mm wide bands of varying area coverage running IB-OB. Starting at lead
edge, 0%, 100%. 93.75%, 87.5%, 75%,
50%, 25%, 12.5%, 6.25%, 0%. The
50% wedge is used for checking IOT
darkness.
25% Halftones
Light Density uniformity, deletions,

lines, bands, streaks
75 DPI
75 dots/in.
106 DPI
106 dots/in. - Use this pattern for evaluation
212 dots/in.
212 DPI Reserved for engineering investigations
50% Halftones
Uniformity, fuser defects, lines. bands,

streaks, smears
106 DPI
106 dots/in. - Use this pattern for evaluation
212 DPI
212 dots/in. - Reserved for engineering

investigations
424 DPI
424 dots/in. - This pattern should not be

used for normal IQ troubleshooting. It is
made available here for unique circumstances that may require engineering
investigations.
Image Quality
Parallel Lines
2 On 2 Off
Motion quality, wobble
2 On 30 Off
8 On 56 Off
Black Bands
Used for solid area reproducibility
1" On 1" Off
For checking fusing, stripper finger

marks, solid area, offsetting, cleaning
1" On 1" Off Black
For checking fusing, stripper finger

marks, solid area, offsetting, cleaning
1.75" Lead Edge
For checking fuser offsetting, cleaning

failure
IQ Tests
Sequences of test patterns
IQ Test 1 - 1" On 1" For checking P/R Belt. Belt is comOff followed by 1" pletely covered with image.
On 1" Off Black.
Repeated twice.
IQ Test 2 - 106dpi
50% halftone
repeated 4 times.
Uniformity over entire P/R Belt
For checking fuser offsetting, cleaning

IQ Test 3 - 1.75"
Lead Edge Black failure
band - repeated 15
times followed by 2
blank page
IQ Test 4 - 1" On 1" For checking ghosting
Off followed by
106dpi 50% halftone
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IQ Definitions

Name
PURPOSE
IQ Test 5 For checking overall IOT print quality

sequence as follows: four blank
pages, one 8 On
56 Off perpendicular lines, one 8 On
56 Off parallel
lines, one 2 on 30
off perpendicular
lines, one quadrille, four registration, one
manufacturing,
one step wedge
IQ Test 6 - Duplex
sequence as follows: Side one all
Quadrille, side 2
Four 106dpi 25%
halftone, Four
106dpi 50% halftone, four 1.75"
Lead Edge Black
band
Understanding the IQ Definitions used in these procedures is critical to correctly navigating

through them and correcting the problem. Listed below are the six basic IQ categories. Choose
the category which best fits the IQ defect, and then refer to the specific definitions to further
define the problem.
IQ Defect Definitions
For checking IOT Duplex IQ
Background Defects: Image or toner appears in an area which should be non-image.
Deletion Defects: Part or all of an image is missing.
Image Location Defects: Image that is incorrectly located on the print. (Also known as
Geometrics)
Image Density Defects: Images that have incorrect darkness.
Image Distortion Defects: Images that are distorted in some way.
Other Defects: Defects that don't fit the other categories.
Background Defects
Background: Randomly distributed toner particles in a non-image area.
Background Bands: A form of Localized Background.
Black Copies/ Prints: Prints which are solid black with no image visible within.
Black Segments: Segments or strips of the copies are black.
Border Bands: Dark bands near the edges of the prints.
Ghosting: A type of residual image.
Line/Streak: An unwanted line or streak in a image or non-image area. Refer to the Line/
Streak LE-TE Defect Sample Scrogged Images.
ESS Test Patterns
Localized Background: Background that occurs in a localized area.
There is a test pattern stored on the ESS that can be printed via [ESS/Network tab , ESS Test
Jobs]. Select [Test Pattern]. The usual job options are available for this job.
Offsetting: A cause of residual image.
Overall Background: Background that is present over the entire copy/print.
The ESS Test Pattern is an electronic version of the 82E12191 hard copy test pattern. The IIT
unique elements have been removed from the pattern (blue text, solids). For copy quality evaluation use the CSE Test Pattern from the Document Glass.
The only intended use for the ESS Test Pattern is for troubleshooting failures related to the
video path. Troubleshoot the video path by halfsplitting. Run copies from the Document Glass
and print from the ESS. Use the IQ Entry RAP in the EDOC.
The ESS Test Pattern should not be used to evaluate image quality (see IQ-2 RAP) and to
compare copier vs. printer.
V0.042
Spots: Unwanted spots of toner in a non-image area.
Deletion Defects
Blank Copies/Prints: No image on the copy/print.
Blank Segments: Segments or strips of the copies/prints are white (color of substrate).
Body Deletions: Deletions within the central area of the copy/print.
Comets: Deletions about 0.1mm in width and about 1 to 2mm in length that tail off in the
trail edge direction.
Debris Centered Deletion (DCD): A type of spot deletion caused by developer bead carry
out.
Deletions: Generally, missing toner in an image area.
Dotted Line Deletion: A line deletion that is not continuous and resembles a dotted line.
Edge Deletions: Deletions along or at any edge of the copy/print.
Hollow Characters: Text which does not appear to be filled in.
Line Deletion: A deletion that looks like a white line (color of substrate) in an image area.
Up to 3mm wide and anywhere from 5mm to the length of the paper long.
Spot Deletion: A small deletion in the shape of a spot.
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Image Quality
Introduction/Test Patterns , IQ Definitions
Trail Edge Deletion: A deletion that occurs near the trail edge of the copies/prints.
Oil on copies/prints:
Image Location Defects
Oil Streaks:
Deformed Image: Part of the image is incorrectly located on the copies/prints.
Poor Fusing: Toner that does not adhere correctly to the paper/substrate.
Magnification: The image is larger or smaller than it should be.
Wrinkles:
Misregistration: The image is not centered correctly on the page due to paper to image
timing mismatch.
Skew: The image is not parallel to the paper edges.
Shear: Two sides (LE and TE) of the image are not parallel to the paper edges. The
image is "parallelogrammed". Only a IIT defect.
Doppler Defect: A hard to categorize defect unique to the Document Centre 240/255/265.
May occur in an image area or a non-image area. It can be very limited and appear as a
small smear, or it may take on an unusual structure that covers much of the page. The
structure is usually a series of wide toner bands that branch out across the page. See the
Smudges, Smears section of Smeared Copies/Prints.
Geometrics: This term refers to the correct placement of the image on the page. Includes
registration, skew, and magnification.
Image Density Defects
Banding: Gray areas show a pattern of regularly spaced bands that extend from the
inboard to the outboard edge of the copy/print. Refer to IB-OB Bands for examples.
Dark image: Image density appears darker than it should.
Grainy Image: Uniform black or gray areas have a sandy-like appearance. Density variation over distances of 1-2mm or less.
Lines/Streaks/Bands in Image: Copy/Print has a variation of density that appears as one

or many lines/streaks, or bands.
Moire: Gray areas show a regular striped, plaid, or other pattern of density variation on a
scale of 1-2mm or greater.
Mottle: Black or gray areas that should be uniform and smooth have local density variations on a scale of 1-5mm.
Non-uniformity: Image density varies from one part of the copy/print to another.
Poor Solids: Images that should be black do not reproduce correctly.
Reload: A ghost of an image shows up 42-49mm towards the trail edge in solid areas or
halftones.
Image Distortion Defects
Blur: Images that are not clear, appear out of focus, not sharp.
Deformed Image: Gross defects where the image has been incorrectly reproduced.
background area.
Poor Resolution: Inability to distinguish fine details, usually fine lines.
Ragged Halftones: Gray areas have small-scale texture, line or herringbone appearance.
Ragged Lines: Lines that should be straight and smooth are ragged, or have bumpy or
ragged edges.
Smear: The toner in an image is disturbed and appears as a smear on the copies/prints.
Scrogged Image: A digital image defect. The digital data sent to the ROS an incorrect
Shear: Two sides (LE and TE) of the image are not parallel to the paper edges. The
image is "parallelogrammed". Only a IIT defect.
Other Defects
Embossing: Small raised areas or indentations on the copy/print paper.
Gloss Variations:
Image Quality
IQ Definitions
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IQ Specifications Entry
Background
IQ Specifications Links
Prerequisite Procedures/Checks
NOTE: All evaluations should be done with the copies on a flat surface with white paper underneath.
Image Density in spec
Post Requisite Procedures/Checks
Background
Spots
Registration, LE
Copier Background Procedure
Registration, Top to Bottom
Place clean blank white sheet of paper on the document glass.
Density
Deletions
Copier Background Specification
Uniformity
No objectionable background present
Toner Reload
Skew, LE
IOT Background Procedure
Resolution
Enter [Marking tab , Print Test Pattern], select [Marking] [Blank Page] [Start Job].
Magnification
None
IOT Background Specification

No objectionable background present
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May 2003
3-87
Image Quality
IQ Specifications Entry , Background
Spots
Registration, LE
Ensure that the Document Glass is clean
None
None
None
Copier Spots Procedure
Copier Registration Procedure
Black Spots - 10 copies of a clean blank page
Perform ADJ 14-2
White Spots - A clean print of 1" On 1" Off and 1" Off 1" On used as originals - 10 prints of each
Copier Registration Specification

All Sheets 1.8mm
IOT Spots Procedure

Black Spots - Enter [Marking tab , Print Test Pattern], select [Marking]. Make 10 prints of a
blank page.
IOT Registration Procedure
White Spots - Enter [Marking tab , Print Test Pattern], select [Marking]. Make 10 prints of 1" On
1" Off and 1" Off 1" On black bands.
IOT Registration Specification
Perform ADJ 8-1A
All Sheets 1.8mm
Copier/IOT Black Spots Specification

Less than 25 small (smaller than spot "W" represented on side 2 of test pattern) spots on any
of the10 copies/prints
No spots larger than 0.4mm
Copier/IOT White Spots Specification

Less than 36 small (smaller than spot "W" represented on side 2 of test pattern) spots on 9 of
10 copies/prints
Not more than 4 small (smaller than spot "W" represented on side 2 of test pattern) spot in a 1
square inch area
No spots larger than spot represented on side 2 of test pattern
Image Quality
Spots , Registration, LE
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Registration, Top to Bottom
Density
None
None
None
None
Copier Registration Procedure
Copier Density Procedure
Perform ADJ 14-2
Using test pattern 82E13100 (11") or 82E13110 (A4), place on the document glass. Make 5
copies.
Copier Registration Specification

Platen Mode - Side 1 - 1.5mm
Copier Density Specification
Platen Mode - Side 2 - 2.0mm
Use the 5th copy and compare the patch labeled "E1" to the patches labeled "P1", "P2", and
"P3" on the side 2 of the pattern. The E1 patch on the copy should be not darker than the "P3"
patch or lighter than the "P1" patch.
DADF Mode - Side 1 - 2.0mm
IOT Density Procedure
DADF Mode - Side 2 - 2.5mm
There are two methods:
IOT Registration Procedure

Perform ADJ 8-1B
1.
Enter [Marking tab , Print Test Pattern], select [Marking]. Make 5 prints of a [Step Wedge].
2.
(L18 or later software only) Enter [ESS/Network tab , ESS Test Jobs]. Select [Test Pattern]. Make 5 prints of test pattern.
IOT Density Specification
IOT Registration Specification
Use one of these depending on the method used above:
Side 1 - 1.5mm
1.
Compare the 50% band, which is the 5th band (start with darkest or look at the arrow that
points from the M2 patch to the schematic of the step wedge) on the IOT print to the
patches labeled "M1", "M2", and "M3" on the side 2 of the pattern. The 4th band (75%) on
the step wedge should be not darker than the "M3" patch or lighter than the "M1" patch.
2.
(L18 or later software) Use the 5th print and compare the patch labeled "E1" to the
patches labeled "P1", "P2", and "P3" on the side 2 of the hard copy pattern. The E1 patch
on the print should be not darker than the "P3" patch or lighter than the "P1" patch.
Side 2 - 2.0mm
NOTE: In software levels prior to L17.8.64 (5.07), up to 1.3mm additional misregistration is
allowed on print jobs due to an ESS software problem.
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May 2003
3-89
Image Quality
Registration, Top to Bottom , Density
Deletions
Uniformity
None
None
None
None
Deletions Procedure
Copier Uniformity Procedure
Any original. Ensure paper is fresh and within spec.
Make 5 copies of test pattern 82E13100 (11") or 82E13110 (A4) in standard mode, and 5 copies in Photo mode.
Deletions Specification
No loss of information. Some slight deletions can be expected within 12mm from an edge on
side 1, more on side 2 and slightly more pronounced. At higher temperatures and humidities,
the deletion performance will be degraded.
Copier Uniformity Specification

No objectionable variation in image density on any of the bands F or G, patches D1 and D2, E1
and E2 (use defect samples X1, X2, Y1,Y2, and Y3)
IOT Uniformity Procedure

Use one of these two methods:
1.
Enter [Marking tab , Print Test Pattern], select [Marking]. Make 5 prints of a 50% halftone
106dpi.
2.
(L18 or later software only) Enter [ESS/Network tab , ESS Test Jobs]. Select [Test Pattern]. Make 5 prints of test pattern.
IOT Uniformity Specification

Use one of these depending on method chose above:
Image Quality
Deletions , Uniformity
1.
No objectionable variation in image density
2.
(L18 or later software) No objectionable variation in image density on any of the bands F
or G, patches D1 and D2, E1 and E2 (use defect samples X1, X2, Y1,Y2, and Y3)
May 2003
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Toner Reload
Skew, LE
None
Registration
None
None
Copier Uniformity Procedure
Copier Skew Procedure
Make 5 copies of test pattern 82E13100 (11") or 82E13110 (A4) in standard mode.
DADF - Perform ADJ 05-1
Copier Uniformity Specification
Copier Skew Specification
Compare the copies of the "B" and "C" patches to the "S" and "T" patches on side 2 of the test
pattern. Ensure that the lightened area on the copy is no worse than the "S" and "T" patches.
1.6mm (8.5 x 11")

1.7mm (A4)

(L18 or later software only) Enter [ESS/Network tab , ESS Test Jobs]. Select [Test Pattern].
Make 5 prints of test pattern.
IOT Skew Procedure

Perform ADJ 8-2
IOT Skew Specification
(L18 or later software) Compare the prints of the "B" and "C" patches to the "S" and "T" patches
on side 2 of the hard copy test pattern. Ensure that the lightened area on the print is no worse
than the "S" and "T" patches.
1.2mm (8.5 x 11")
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1.2mm (A4)
May 2003
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Image Quality
Toner Reload , Skew, LE
Resolution
Magnification
None
None
None
None
Copier Resolution Procedure
IOT Horizontal Magnification Procedure
Make 5 copies of 82E13100 (11") or 82E13110 (A4)
Enter [Marking tab , Print Test Pattern], select [Marking]. Make 1 print of the Registration
test pattern.
Copier Resolution Specification
Using the last print of the Registration test pattern, lay the 82E13100 (11") or 82E13110
(A4) pattern on top.
Align the K1 mag line on the 82E13100 (11") or 82E13110 (A4) to the closest corresponding line on the registration pattern.
Compare and note the alignment of the H1 line with the closest corresponding line on the
registration pattern. (Each line is 0.5% difference from nominal mag.)
Perform the same procedure on the bottom edge of the pattern using the K2 and H2 mag
lines. Note the difference in mag from the nominal.
3.5 line pairs/inch should be clearly resolved and 4.3 line pairs/inch should be just resolved

(L18 or later software only) Enter [ESS/Network tab , ESS Test Jobs]. Select [Test Pattern].
Make 5 prints of test pattern.

(L18 or later software) 3.5 line pairs/inch should be clearly resolved and 4.3 line pairs/inch
should be just resolved
IOT Vertical Magnification Procedure
Enter [Marking tab , Print Test Pattern], select [Marking]. Make 1 print of the Registration
test pattern.
Using the last print of the Registration test pattern, lay the 82E13100 (11") or 82E13110
(A4) pattern on top.
Align the K3 mag line on the 82E13100 (11") or 82E13110 (A4) to a corresponding line on
the registration pattern.
Compare and note the alignment of the H3 line with the closest corresponding line on the
registration pattern. (Each line is 0.5% difference from nominal mag.)
Perform the same procedure on the left edge of the pattern using the K4 and H4 mag
lines. Note the difference in mag from the nominal.
IOT Horizontal Magnification Specification

less than or equal to 0.5%
IOT Vertical Magnification Specification

less than or equal to 0.5%
Copier Magnification Procedure
Image Quality
Resolution , Magnification
May 2003
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Platen Mode
1.
Place the 82E13100 (11") or 82E13110 (A4) on the document glass and make one
copy.
2.
Align the K1 mag line on the 82E13100 (11") or 82E13110 (A4) to the corresponding
line on the copy.
3.
Compare and note the alignment of the H1 line with the corresponding line on the
copy. (Each line is 0.5% difference from nominal mag.)
V0.042
4.
Perform the same procedure on the bottom edge of the pattern using the K2 and H2
mag lines. Note the difference in mag from the nominal.
5.
6.
line on the copy.
7.
8.
Perform the same procedure on the left edge of the pattern using the K4 and H4
9.
DADF Mode
1.
Run the 82E13100 (11") or 82E13110 (A4) through the DADF and make one copy.
2.
line on the copy.
3.
Compare and note the alignment of the J1 line with the H1 line on the copy. (Each
line is 0.5% difference from nominal mag.)
NOTE: A different mag is applied in DADF mode to avoid black border lines.
4.
Perform the same procedure on the bottom edge of the pattern using the K2 and J2
5.
6.
line on the copy.
7.
8.
Perform the same procedure on the left edge of the pattern using the K4 and H4
9.
Copier Magnification Specification

Platen mode Horizontal - 0.7%
Platen mode Vertical - 0.7%
DADF mode Horizontal - 1.0%
DADF mode Vertical - 0.7%
V0.042
May 2003
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Image Quality
Magnification
Image Quality
Magnification
May 2003
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4. Repairs and Adjustments

Component Locator Drawings
Component Locations .....................................................................................................
MFF Components ...........................................................................................................
MFF Electrical Components - Cross Section View .........................................................
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1. Standby Power
REP 01-1 Distribution PWB ............................................................................................
REP 01-2 AC Distribution Panel .....................................................................................
REP 01-3 Low Voltage Power Supply (LVPS) ................................................................
4-99
4-101
4-103
2. User Interface
REP 02-1 User Interface Assembly ................................................................................
REP 02-2 UI Processor PWB (With Tag #082 Only) ......................................................
REP 02-3 UI LCD Module (With Tag #082 Only) ............................................................
REP 02-4 UI Software Upload ........................................................................................
4-105
4-106
4-111
4-114

REP 03-1 SCAM PWB .................................................................................................... 4-117
REP 03-2 IPS1 Daughter PWB (240/255/265 Only) ....................................................... 4-119
REP 03-3 Accessory PWB .............................................................................................. 4-122
REP 03-4 Main Control PWB (Atlanta '96-to-'96 or Gold-to-Gold) (without Tag 077) .... 4-128
REP 03-5 Rotation SRAM SIMM (without Tag 077) ....................................................... 4-136
REP 03-6 EPC DRAM SIMM (without Tag 077) ............................................................. 4-137
REP 03-7 NVM RAM Chip (without Tag 077) ................................................................. 4-139
REP 03-8 Main Control PWB: Upgrade from Atlanta '96 (without Tag 015) to Atlanta Gold (Installing Tag 015).............................................................................................................. 4-145
REP 03-9 EPC SDRAM DIMM (With Tag 077 Only) ...................................................... 4-154
REP 03-10 Software/NVM Module (With Tag 077 Only) ................................................ 4-157
REP 03-11 Main Control PWB (Atlanta Platinum-to-Platinum) (With Tag 077 Only) ..... 4-163
REP 03-12 Electronic Hole Removal (EHR) PWB, 460/470 ........................................... 4-169
REP 03-13 Card Cage Riser PWB (460/470 Only)......................................................... 4-173

REP 04-1 Developer Drive Motor....................................................................................
REP 04-2 Fuser Drive Motor ...........................................................................................
REP 04-3 Developer Gear Bracket .................................................................................
REP 04-4 Decurler/OCT Drive Bracket ...........................................................................
REP 04-5 Decurler Drive Belt .........................................................................................
REP 04-6 Developer Drive Belt.......................................................................................
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4-182
4-185
4-187
4-189
4-190
REP 05-1 DADF Cleaning Procedure .............................................................................
REP 05-2 DADF Assembly .............................................................................................
REP 05-3 DADF Top Cover Assembly ...........................................................................
REP 05-4 DADF Feeder Assembly .................................................................................
REP 05-5 DADF Registration Deskew Assembly ...........................................................
REP 05-6 Document Input Tray Assembly .....................................................................
REP 05-7 DADF Exit Shaft .............................................................................................
REP 05-8 DADF Feed Motor ..........................................................................................
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4-194
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4-200
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4-213
4-218
REP 05-9 CVT Drive On Glass Kit ..................................................................................

REP 05-10 DADF Feed Roll Cartridge Release Lever Kit ..............................................
REP 05-11 DADF Exit Clutch..........................................................................................
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4-228
6. ROS Imaging
REP 06-1 ROS Assembly ...............................................................................................
REP 06-2 ROS Polygon Motor (With Tag #057 Only).....................................................
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4-234
7. Paper Supply
REP 07-1 Paper Feed Drives Plate.................................................................................
REP 07-2 Paper Tray Assembly .....................................................................................
REP 07-3 HCF/Bypass Tray Assembly...........................................................................
REP 07-4 Bypass Tray Assembly ...................................................................................
REP 07-5 HCF Elevator Motor ........................................................................................
REP 07-6 Bypass Input Tray...........................................................................................
REP 07-7 HCF Rear Cover .............................................................................................
REP 07-8 HCF Front Cover ............................................................................................
REP 07-9 HCF PWB .......................................................................................................
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4-244
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4-254
REP 08-1 Vertical Transport ...........................................................................................
REP 08-2 Registration Transport Assembly....................................................................
REP 08-3 HCF/Bypass Tray Feed Motor ........................................................................
REP 08-4 Bypass Tray Feeder .......................................................................................
REP 08-5 HCF Feeder ....................................................................................................
REP 08-6 HCF Paper Handling Baffle ............................................................................
REP 08-7 Registration Sensor (S2) ................................................................................
REP 08-8 Registration Clutch .........................................................................................
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4-258
4-267
4-270
4-274
4-277
4-279
9. Marking
REP 09-1 Xerographic Module........................................................................................
REP 09-2 Developer Housing .........................................................................................
REP 09-3 BTAC Sensor..................................................................................................
REP 09-4 Toner Dispenser .............................................................................................
REP 09-5 Photoreceptor Drive Module ...........................................................................
REP 09-6 Charge HVPS .................................................................................................
REP 09-7 Developer HVPS.............................................................................................
REP 09-8 Transfer/Detack HVPS ...................................................................................
REP 09-9 BTAC Sensor Cleaning Procedure .................................................................
REP 09-10 Developer Housing Support Rail ..................................................................
REP 09-11 Photoreceptor Drive Module Cleaning Procedure ........................................
REP 09-12 Developer HVPS Contacts Cleaning Procedure...........................................
REP 09-13 Donor Roll Cleaning Procedure ....................................................................
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4-301
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4-304
4-304

REP 10-1 Prefuser Transport (PFT)................................................................................
REP 10-2 Duplex Transport ............................................................................................
REP 10-3 Decurler or Exit Baffle.....................................................................................
REP 10-4 Inverter Drive Assembly, Exit Roll, or Feed/Reverse Roll ..............................
May 2003
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4-313
4-322
4-325
Repairs and Adjustments
12. Finishing
REP 12-1 Top Module Assembly ....................................................................................
REP 12-2 Stacker Drive Motor........................................................................................
REP 12-3 Finisher Service Tray Assembly .....................................................................
REP 12-4 Moving Stapler................................................................................................
REP 12-5 Fixed Stapler ..................................................................................................
REP 12-6 Nip 1 Drive Shaft ............................................................................................
REP 12-7 Nip 2 Drive Shaft ............................................................................................
REP 12-8 Finisher Transport Baffle ................................................................................
REP 12-9 Disk Baffle Assembly......................................................................................
REP 12-10 Disk Drive Motor ...........................................................................................
REP 12-11 Disk Shaft .....................................................................................................
REP 12-12 Finisher Assembly (Undocking the Finisher) ................................................
REP 12-13 Nip 1/2 Drive Belt..........................................................................................
REP 12-14 Nip 3/4 Drive Belt..........................................................................................
REP 12-15 Finisher Lubrication ......................................................................................
REP 12-16 Finisher Top Tray Back Wall ........................................................................
REP 12-17 Convenience Stapler Internal DC Harness...................................................
REP 12-18 Stapler Lead-In Baffle...................................................................................
REP 12-19 Convenience Stapler PWB ...........................................................................
REP 12-20 Stacker Tray Drive Belts ...............................................................................
REP 12-21 Stacker Tray Drive Belt Clamps ...................................................................
REP 12-22 Fixed-Stapler Safety Gate ............................................................................
REP 12-23 Moving-Stapler Safety Gate .........................................................................
REP 12-24 Tamper Cable...............................................................................................
REP 12.01.01 Main Tray Elevator Belt ...........................................................................
REP 12.01.02 Main Tray Offset Motor (M50)..................................................................
REP 12.01.03 Main Tray Offset Panel/Rails ...................................................................
REP 12.01.04 Main Tray Elevator Motor (M51) ..............................................................
REP 12.02.01 Booklet Maker Assembly .........................................................................
REP 12.02.02 Crease Blade ...........................................................................................
REP 12.02.03 Crease Rolls ............................................................................................
REP 12.02.04 Crease Roll Motor (M68) .........................................................................
REP 12.02.05 Crease Roll Gears ...................................................................................
REP 12.02.06 Crease Blade Motor (M67) ......................................................................
REP 12.02.07 Crease Blade Motor Encoder and Sensor (S70) .....................................
REP 12.02.08 Booklet Compiler Flapper ........................................................................
REP 12.02.09 Booklet Tamper Assembly .......................................................................
REP 12.02.10 Booklet Tamper Motor (M62)...................................................................
REP 12.02.11 Booklet Backstop Assembly ....................................................................
REP 12.02.12 Booklet Backstop Motor (M63) ................................................................
REP 12.02.13 Booklet Backstop Belt or Drive Belt .........................................................
REP 12.02.15 Booklet Rear Stapler................................................................................
REP 12.02.16 Booklet Front Stapler ...............................................................................
REP 12.03.01 Booklet Exit Sensor (S73)........................................................................
REP 12.04.01 Tri-Folder Assembly.................................................................................
REP 12.04.02 Tri-Folder Drive Belt.................................................................................
REP 12.05.01 Compiler Tamper Assembly ....................................................................
REP 12.05.02 Compiler Backstop Assembly ..................................................................
REP 12.05.03 Compiler Fingers Assembly .....................................................................
REP 12.05.04 Compiler Tamper Motor (M44) ................................................................
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4-419
4-420
4-421
4-424
4-427
4-428
4-429
4-431
4-432
4-434
4-435
REP 12.06.01 MFF Top Cover........................................................................................

REP 12.07.01 Eject Housing Assembly ..........................................................................
REP 12.07.02 Compiler Flapper Home Sensor (S40).....................................................
REP 12.07.03 Compiler Flappers....................................................................................
REP 12.07.04 Eject Shaft Drive Belt ...............................................................................
REP 12.08.01 MFF Control PWB....................................................................................
REP 12.10.01 Multi-Function Finisher Assembly (Undocking the MFF) .........................
REP 12.11.01 Upper Master Lock...................................................................................
REP 12.11.02 Lower Master Lock Assembly ..................................................................
REP 12.11.03 Nip 1, Nip 2 Outer Guide Assembly .........................................................
REP 12.12.01 Main Stapler Carriage Assembly .............................................................
REP 12.12.02 Main Stapler Position Motor (M43) ..........................................................
REP 12.12.03 Main Stapler.............................................................................................
REP 12.13.01 Buffer/Compiler Module Assembly...........................................................
REP 12.13.02 Nip 3 or 4 Drive Shaft...............................................................................
REP 12.13.03 Nip 5 Drive Shaft......................................................................................
REP 12.13.04 Nip 6/7 Outer Guide Assembly, Nip 6/7 Inner Guide ...............................
REP 12.13.06 Nip 8 Release Solenoid (L31) ..................................................................
REP 12.13.07 Nip 9 Clutch .............................................................................................
REP 12.13.08 Paper Path Nip Motor (M110) ..................................................................
REP 12.13.09 Buffer Nip Motor (M30) ............................................................................
REP 12.13.10 Buffer Entrance Nip Motor (M31) .............................................................
REP 12.13.11 Compiler Lower Eject Motor (M40) ..........................................................
REP 12.13.12 4-Bar Position Motor Assembly (M45) .....................................................
REP 12.13.13 4-Bar Exit Drive Assembly .......................................................................
REP 12.13.14 4-Bar Assembly........................................................................................
REP 12.13.16 Buffer Gate Solenoid (L33) or Trail Edge Clamp Solenoid (L30).............
REP 12.13.17 Top Tray Diverter Solenoid L40 ...............................................................
REP 12.13.18 Compile Belts...........................................................................................
REP 12.13.19 Buffer Module Entrance Sensor Bracket..................................................
REP 12.13.20 4-Bar Exit Drive Shaft ..............................................................................
REP 12.13.21 Compiler Entrance Sensor S46 ...............................................................
4-435
4-436
4-437
4-437
4-438
4-438
4-439
4-441
4-443
4-445
4-446
4-448
4-448
4-450
4-451
4-452
4-452
4-454
4-455
4-456
4-456
4-457
4-458
4-459
4-459
4-460
4-462
4-463
4-464
4-465
4-467
4-468
4-469
4-472
14. Scanning
REP 14-1 Image Module, Scanner Video Cable Kit........................................................
REP 14-2 Illumination Lamp Module...............................................................................
REP 14-3 Scanner Cleaning Procedure..........................................................................
REP 14-4 Document Glass Frame..................................................................................
REP 14-5 Scanner Top Frame........................................................................................
REP 14-6 Scanner Main Cover .......................................................................................
REP 14-7 Document Glass Pad......................................................................................
REP 14-8 Illumination Lamp Power Supply ....................................................................
REP 14-9 Scan Carriage Motor.......................................................................................
4-473
4-476
4-478
4-478
4-480
4-480
4-481
4-482
4-482
16 - ESS.
REP 16-1 ESS Disk Drive ............................................................................................... 4-485
REP 16-2 ESS PWB ....................................................................................................... 4-490
REP 16-3 ESS DRAM SIMM's (240/255/265 Only) ........................................................ 4-496
REP 16-4 Token Ring PWB or Image Processing Accelerator (IPA) PWB or 100 Mb Ethernet
PWB (240/255/265 Only) ................................................................................................ 4-501
May 2003
4-2
V0.042
REP 16-5 PCI Bus Adapter PWB (240/255/265 Only)...................................................

REP 16-6 Bykal Remote PWB (DT 65 / DP 65 Only) .....................................................
REP 16-7 ESS SDRAM DIMM(s) (460/470 Only)...........................................................
REP 16-8 Image Processing Accelerator (IPA) PWB, 460/470 ......................................
REP 16-9 Token Ring PWB, 460/470 .............................................................................
4-509
4-511
4-513
4-516
4-519

REP 19-1 Image Disk Drive ............................................................................................
4-521
ADJ 05-1 DADF Skew..................................................................................................... 4-527
ADJ 05-2 CVT Carriage Position Setup for Electronic Hole Removal (With Tag #296, Tag #080,
or Tag #285 Only) ........................................................................................................... 4-528
ADJ 05-3 DADF/Document Glass Cover Latch (460/470 with Tag 115 Only) ................ 4-530
ADJ 8-1 IOT Registration Setup Series .......................................................................... 4-533
ADJ 8-1A IOT Lead Edge Registration (Process Direction)............................................ 4-536
ADJ 8-1B IOT Top Edge Registration (IB-OB), Side 1.................................................... 4-537
ADJ 8-1C IOT Top Edge Registration (IB-OB), Side 2, Small Paper.............................. 4-539
ADJ 8-1D IOT Top Edge Registration (IB-OB), Side 2, Large Paper.............................. 4-541
ADJ 8-1E IOT Lead Edge Registration for Small Heavy Weight Paper (19.02 and Higher Software Only)....................................................................................................................... 4-542
ADJ 8-1F IOT Lead Edge Registration for Large Paper (19.02 and Higher Software Only) 4546
ADJ 8-1G IOT Lead Edge Registration for Large Heavy Weight Paper (19.02 and Higher Software Only)....................................................................................................................... 4-550
ADJ 8-2 IOT Skew (Registration Transport) ................................................................... 4-554
12. Finishing
ADJ 12-1 Tamping - Disk Finisher.................................................................................
ADJ 12-2 Tamper Position - Disk Finisher ....................................................................
ADJ 12.02.01 Crease Blade............................................................................................
ADJ 12.02.02 Booklet Stapler Anvils ..............................................................................
ADJ 12.02.03 Booklet Tamping ......................................................................................
ADJ 12.02.04 Booklet Staple Position ............................................................................
ADJ 12.02.05 Booklet Crease Position ...........................................................................
ADJ 12.02.06 Crease Roll Gate......................................................................................
ADJ 12.02.07 Booklet Maker Drawer Alignment .............................................................
ADJ 12.02.08 Booklet Compiling Position.......................................................................
ADJ 12.04.01 Tri-Fold First Crease Position...................................................................
ADJ 12.04.02 Tri-Fold Second Crease Position .............................................................
ADJ 12.05.01 Compiler Tamping ....................................................................................
ADJ 12.12.01 Main Stapler Alignment ............................................................................
ADJ 12.12.02 Main Stapler Staple Position ....................................................................
4-557
4-558
4-561
4-566
4-569
4-570
4-570
4-571
4-571
4-572
4-573
4-574
4-575
4-575
4-576
14. Scanning
ADJ 14-1 Image Module Set-Up .....................................................................................
ADJ 14-2 IIT Registration and Magnification...................................................................
V0.042
4-577
4-579
May 2003
4-3
May 2003
4-4
V0.042
Component Locations
Introduction
Locate the component in the left column of the Component Locator Table. Select the component name go to a specific component. Select the Figure Number to go to the figure in which
the component is located.
V0.042
May 2003
4-5
NOTE: To view components that are not a hotlink (green and underlined), select the Parts List
reference.
Component Locator Table

Table 1 Component Locator Table

Component Name
Figure Number
DADF Inverter Clutch
Figure 45
DADF Inverter Gate
Figure 27
DADF Main Cover
Figure 9
Component Name
Figure Number
DADF PWB
Figure 10
100Mb Ethernet PWB
Figure 54
DADF Paper Feed Roll Cartridge
PL 2.2 Item 4
3-Arm Sheet Separator
Figure 32
Accessory PWB
Figure 11
DADF Registration Deskew Assembly
Figure 35
AC Distribution Panel
Figure 18
DADF Registration Gate Sensor
Figure 10
Anti-Kickback Pad
Figure 9
DADF Registration Gate Solenoid
Figure 10
Area 2 Handle
Figure 7
DADF Static Eliminator
Figure 32
Area 3E
Figure 19
DADF Take Away Roll
Figure 26
Backlight
PL 1.1A Item 6
DADF Take Away Roll Idler
Figure 26
BTAC Sensor
Figure 1
DADF Top Cover
Figure 26
Bypass Tray Feeder
PL 4.2B Item 4
DADF Top Cover Assembly
Figure 26
Canard Wing
Figure 25
Decurler Cam Drive Belt (Tag 279 Decurler)
Figure 64
Card Cage
Figure 12
Decurler Cam Drive Motor (Tag 279 Decurler)
Figure 64
Charge HVPS
Figure 5
Decurler Gate Solenoid (Tag 279 Decurler)
Figure 64
Close Nip Solenoid
Figure 55
Decurler Home Sensor (Tag 279 Decurler)
Figure 64
Close Nip Solenoid Spring
Figure 55
Decurler Position Sensor (Tag 279 Decurler)
Figure 64
Close Nip Link
Figure 55
Decurler Drive Belt
Figure 6
UI Control Panel Assembly
PL 1.1A Item 1
Decurler/OCT Drive Bracket
Figure 6
Detack HVPS
Figure 5
CVT Drive on Glass Roll
Figure 27
Developer Collector
Figure 2
CVT/Reg Roll Drive Belt
Figure 10
Developer Collector Tube
Figure 28
CVT Skis
Figure 27
Developer Collector Sensor
PL 5.1B Item 9
NOTE: The DADF may have two CVT Skis, three

CVT Skis, or a single CVT Ski.
Developer Drive Belt
Figure 30
Developer Drive Motor
Figure 30
CVT Start of Scan Sensor
Figure 27
Developer Gear Bracket
Figure 30
Figure 10
Developer Housing
Figure 2
CVT Motor
Figure 10
Developer HVPS
Figure 5
CVT Motor Ground Wire
Figure 38
Developer HVPS Contact Springs
Figure 29
DADF Exit Clutch
Figure 45
Disk Baffle Assembly
Figure 20
DADF Exit/Invert Sensor
Figure 27
Disk Drive Gear
Figure 22
DADF Exit Roll
Figure 27
Disk Drive Motor
Figure 22
DADF Exit Roll Idler
Figure 32
Disk Fingers
Figure 21
DADF Exit Shaft
Figure 27
Disk Home Sensor
Figure 22
DADF Feeder Assembly
Figure 10
Disk Shaft
PL 8.3 Item 13
DADF Feed Clutch
Figure 45
Distribution PWB
Figure 18
DADF Paper Feed Roll Drive Coupling
Figure 8
Document Feeder Top Cover Sensor
Figure 10
DADF Feed Motor
PL 2.2 Item 7
Document Feeder Top Cover Sensor Actuator
Figure 26
DADF Interlock Switch
Figure 10
Document Input Tray
Figure 9
May 2003
4-6
V0.042
Component Name
Figure Number
Component Name
Figure Number
Document Input Tray Side Guides
Figure 9
Finisher Top Cover Door
Figure 20
Document Loaded Sensor
Figure 10
Figure 39
Document Output Tray
Figure 9
Finisher Upper Harness
Figure 23
Drive Gear (on Fuser Module)
Figure 58
Fixed Stapler
Figure 23
Document Restack Guide
Figure 32
Fixed - Stapler Safety Gate
Figure 25
Dual Idler
Figure 22
Front Bale Arm
Figure 21
Duplex Acceleration Nip
Figure 13
Front Stacker Tray Bracket
Figure 21
Duplex Gate (Inverter)
Figure 56
Fuse F3
Figure 16
Duplex Gate Solenoid
Figure 56
Fuser/Inverter Drawer
Figure 7
Duplex Transport
Figure 13
Fuser Drive Gear
Figure 50
Duplex Transport Belt
Figure 4
Fuser Drive Motor
Figure 6
Decurler
PL 6.1A Item 4
Fuser Fan
Figure 6
Fuser Jam Clearance Knob
Figure 7
Figure 7
Entrance Gate Solenoid (Inverter)
Figure 55
Fuser Module
EPC DRAM SIMMS
Figure 11
Guide Blade (Tag 279 Decurler)
Figure 64
EPC SRAM DIMM
Figure 53
Front Door Interlock Switch
Figure 2
Electronic Hole Removal PWB
Figure 11
HCF/Bypass Tray Feed Motor
Figure 31
ESS DRAM SIMMS
Figure 43
HCF Elevator Motor
Figure 31
ESS Hard Disk Drive
Figure 41
HCF Door Interlock Switch
Figure 40
ESS Hard Disk Drive Ribbon Cable
Figure 42
HCF/Duplex Baffle
Figure 61
ESS Hard Drive Power Cable
Figure 42
HCF Feeder
PL 4.2B Item 3
ESS LEDs
Figure 52
HCF PWB
Figure 31
ESS PWB
Figure 41
IIOC PWB A4A1 (in Inverter)
Figure 55
Exit Baffle
Figure 13
IIOC PWB A4A2 (in Inverter)
Figure 55
Exit Clutch Drive Belt
Figure 10
IIOC PWB A7A1 (Finisher)
Figure 37
Feed Clutch and Coupling (lower tray)
Figure 63
IIOC PWB A7A1 (IOT)
Figure 16
Feed Clutch and Coupling (upper tray)
Figure 63
IIOC PWB A7A2
Figure 16
Feed/Reverse Roll (Inverter)
Figure 56
IIOC PWB A7A3
Figure 16
Feed/Reverse Roll Idler (Inverter)
Figure 55
IIOC PWB A7A4
Figure 16
Feed/Reverse Roll Idler Spring
Figure 55
IIOC PWB A7A5
Figure 17
Figure 22
IIOC PWB A8A1
Figure 16
Finisher Diverter Gate
Figure 23
IIOC PWB A8A2
Figure 16
Finisher Diverter Gate Solenoid
Figure 24
IIOC PWB A8A3
Figure 16
Finisher Diverter Gate Solenoid Heat Cover
Figure 24
IIOC PWB A8A4
Figure 16
Finisher Entrance Sensor
Figure 39
IIOC PWB A8A5
Figure 17
Finisher Input Baffle
Figure 24
IIOC PWB W3A1
Figure 14
Finisher Interlock Switch
Figure 39
IIOC PWB W8A1
Figure 14
Finisher Interlock Switch Actuator
Figure 39
IIOC PWB W8A2
Figure 14
Finisher Set Separator
Figure 20
IIOC PWB W8A3
Figure 14
Finisher Top Tray
Figure 20
IIOC PWB W8A4
Figure 14
Finisher Top Cover
Figure 20
IIOC PWB W8A5
Figure 15
V0.042
May 2003
4-7
Component Name
Figure Number
Component Name
Figure Number
IIOC PWB W21A1
Figure 15
Nip 1/2 Drive Belt
Figure 22
IIOC PWB W25A1
Figure 14
Nip 2 Idlers
Figure 49
Image Disk Drive
Figure 12
Nip 1/2 Idler
Figure 22
Scanner Top Frame
PL 3.1 Item 4
Nip 3/4 Drive Belt
Figure 22
Input Tray Exit Sensor
Figure 10
Nip 3 Idlers
Figure 24
Input Tray Sensor 1
Figure 36
Nip 3/4 Idler
Figure 22
Input Tray Sensor 2
Figure 36
Nip 3 Drive Shaft
Figure 22
Instant OFF Switch
Figure 2
Nip 4 Drive Shaft
Figure 22
Inverter
Figure 13
Nip 4 Idlers
Figure 24
Inverter Entrance Gate
Figure 55
NOHAD Thermostat
PL 1.5 Item 5
Inverter Entrance Sensor
Figure 55
Nudger Solenoid
Figure 26
Inverter Exit Roll
Figure 56
OCT Tray (240/255/265/460DC)
PL 8.1 Item 8
Inverter Exit Roll Idler
Figure 55
OCT Assembly (240/255/265/460DC)
PL 8.1 Item 1
Inverter Exit Sensor
Figure 55
OCT Stacking Finger (240/255/265/460DC)
PL 8.1 Item 9
Inverter Drive Assembly
Figure 56
Figure 19
Inverter Drive Gear
Figure 55
Paper Tray
PL 4.1A Item 2
IPA PWB
Figure 51
Paper Feed Drive Belt
Figure 63
IPS1 Daughter Card
Figure 11
Paper Feed Motor (Tray 1/2)
Figure 17
Kicker
Figure 37
Paper Feed Motor (Tray 3/4)
Figure 17
Kicker Home Sensor
Figure 37
Pause Resume Switch
Figure 20
Left CVT Baffle
Figure 27
PFT Clip
Figure 2
Left CVT Roll
Figure 32
Photoreceptor Drive Module
Figure 4
Left CVT Roll Idler
Figure 32
Figure 30
Lower Guide - Tray 1
Figure 19
Power ON/OFF Switch
Figure 2
Figure 19
Prefuser Transport
Figure 13
Figure 19
Pressure Roll Stripper Fingers
Figure 60
Figure 19
Rear Bale Arm
Figure 21
LVPS
Figure 5
Registration Idler Rolls (Registration Transport)
Figure 61
LVPS Cooling Fan/Duct
Figure 3
Registration Roll (DADF)
Figure 35
Machine Resident Disk
Figure 15
Registration Roll Drive Gear (DADF)
Figure 45
Main Control PWB
Figure 11
Registration Roll Idler (DADF)
Figure 35
Moving Stapler
Figure 23
Registration Roll Shaft (DADF)
Figure 35
Moving Stapler drive gears
Figure 37
Registration Sensor
Figure 4
Moving - Stapler Safety Gate
Figure 25
Registration Transport Assembly
Figure 7
Moving Stapler Gear Rack
Figure 37
Retaining Ring
PL 7.1 Item 6
Mylar (Registration Transport)
Figure 61
Retard Bracket Spring
Figure 46
Moving Stapler Ball Slide
Figure 37
Retractable Registration Edge
Figure 20
Nip 1 Drive Rolls
Figure 24
Reversing Baffle
Figure 55
Nip 1 Drive Shaft
Figure 22
Reverse Drive Solenoid
Figure 56
Nip 1 Idlers
Figure 24
Reverse Drive Solenoid Spring
Figure 56
Nip 2 Drive Shaft
Figure 22
Right CVT Baffle
Figure 27
May 2003
4-8
V0.042
Component Name
Figure Number
Component Name
Right CVT Roll
Figure 34
Top Module Assembly
Figure 21
Right CVT Roll Idler
Figure 34
Tamper Motor
Figure 37
ROS
Figure 4
Tamper Motor Gear
Figure 37
ROS/Developer Cooling Fan Assembly
PL 9.1 Item 6
Token Ring PWB
Figure 44
Scan Carriage Motor
Figure 3
Top Tray Full Sensor
Figure 39
SCAM PWB
Figure 3
Top Tray Full Sensor Actuator
Figure 39
Service Tray Assembly
Figure 33
Top Tray Offset Drive Gear
Figure 24
Service AC Outlet
Figure 16
Top Tray Offset Motor
Figure 24
Shim (Fuser Module)
Figure 58
Top Tray Paper Path Sensor
Figure 39
Side Guide Sensor 1
Figure 36
Top Tray Static Eliminator
Figure 24
Side Guide Sensor 2
Figure 36
Transfer/Detack HVPS
Figure 5
Stack Height Sensor /Stack Too High Sensor
Figure 37
Transfer HVPS
Figure 5
Stack Height Sensor
Figure 48
Transport Drive Motor
Figure 22
Stack Too High Sensor
Figure 48
Tray 1 Elevator Motor
Figure 62
Stack Height Sensor actuator
Figure 48
Figure 62
Stacker Tray
Figure 20
Figure 62
Stacker Tray Drive Belt
Figure 21
Figure 62
Stacker Tray Drive Belt Clamp
Figure 21
Tray 1 Nudger Solenoid
Figure 62
Stacker Tray Front Bracket
Figure 47
Figure 62
Stacker Tray Full Sensor
Figure 47
Figure 62
Stacker Tray Full Sensor Actuator
Figure 47
Figure 62
Stacker Tray Drive Motor
Figure 22
Tray 1 Stack Height Sensor
Figure 19
Stacker Tray Drive Pulley
Figure 21
Figure 19
Stacker Tray Lower Limit Switch
Figure 47
Figure 19
Stacker Tray Upper Limit Switch
Figure 47
Figure 19
Stapler Access Door
Figure 20
Tray 1 Wait Station Sensor
Figure 17
Stapler Lead-In Baffle
Figure 25
Figure 17
Stapler Position Motor
Figure 23
Figure 17
Stapler Position Home Sensor
Figure 23
Figure 17
Static Eliminator
Figure 21
Tray 6 Paper Guide
Figure 40
Tamper Arm Gear Rack
Figure 37
Upper Guide - Tray 1
Figure 19
Tamper Button
Figure 20, Figure

21
Figure 19
Figure 19
Tamper Ball Slide
Figure 33
Figure 19
Tamper Arm
Figure 20
Vertical Transport
Figure 17
Tamper Capstan (Finishers withTAG F029)
Figure 57
Wait Station Sensor
Figure 17
Tamper Arm Drive Cable (Finishers withTAG

F029)
Figure 57
Xerographic Blower
Figure 15
Xerographic Module
Figure 2
Tamper Home Sensor
Figure 33
Toner Bottle Sensor
Figure 1
Toner Dispenser
Figure 1
V0.042
May 2003
4-9
Figure Number
Drawings
Toner Dispenser
BTAC Sensor
Toner Bottle Sensor
Figure 1 Toner Dispenser
May 2003
4-10
V0.042
PFT Clip
Instant OFF Switch
Xerographic
Module
Power ON/OFF
Switch
Front Door
Interlock Switch
Developer
Housing
Developer
Collector
Figure 2 Xerographic Module, Developer, and power switches
V0.042
May 2003
4-11
Scan Carriage Motor
SCAM PWB
Figure 3 SCAM PWB, LVPS Cooling Fan/Duct, Scan Carriage Motor
May 2003
4-12
V0.042
Registration Sensor
ROS
Figure 4 ROS, Photoreceptor Drive Module, Reg. Sensor, and Duplex Transport Belt
V0.042
May 2003
4-13
Detack HVPS
Transfer/Detack NOTE: Transfer/Detack HVPS

is one assembly. The Detack
HVPS
HVPS is left side, Transfer
HVPS is on the right side.
Transfer HVPS
Charge HVPS
Developer HVPS
LVPS
Figure 5 Power Supplies
May 2003
4-14
V0.042
Decurler Drive
Belt
Decurler/OCT
Drive Bracket
Fuser Drive
Motor
Fuser Fan
Figure 6 Fuser Drive Motor and Decurler Drive
V0.042
May 2003
4-15
Area 2 Handle
Fuser Module
Fuser Jam
Clearance
Knob
Registration Transport
Assembly
Fuser/Inverter
Drawer
Figure 7 Fuser Module, Fuser/Inverter Drawer, and Registration Transport
May 2003
4-16
V0.042
DADF Paper Feed Roll

Drive Coupling
Figure 8 DADF Paper Feed Roll Drive Coupling
V0.042
May 2003
4-17
DADF Main Cover

Document Input
Tray Side Guides
Anti-Kickback
Pad
Document Input
Tray
Figure 9 DADF
May 2003
4-18
V0.042
DADF Registration Gate Solenoid

Exit Clutch
Drive Belt
Document Feeder
Top Cover Sensor
Input Tray Exit
Sensor
DADF PWB
CVT Motor
CVT/Reg Roll
Drive Belt
Document
Loaded Sensor
DADF Feeder
Assembly
DADF Registration Gate Sensor
DADF Interlock
Switch
Figure 10 DADF Feed and Sensors
V0.042
May 2003
4-19
EPC DRAM
SIMMS
Electronic Hole Removal

PWB
(Not Shown)
IPS1 Daughter
Card
(Not Shown)
Main Control
PWB
Accessory PWB
May 2003
4-20
V0.042
Card Cage
Image Disk Drive
Figure 12 Image Disk Drive
V0.042
May 2003
4-21
Duplex Acceleration Nip

Prefuser Transport
Note: To view the

Duplex Acceleration
Roll, lower handle 3d.
Exit Baffle
Handle 3d
Duplex Transport
Inverter
Figure 13 PFT, Duplex, and Inverter
May 2003
4-22
V0.042
IIOC PWB W8A4
IIOC PWB W8A3

IIOC PWB W3A1
IIOC PWB W8A1
IIOC PWB W25A1
IIOC PWB W8A2
Figure 14 IIOC PWBs
V0.042
May 2003
4-23
IIOC PWB W8A5
IIOC PWB W21A1
Xerographic Blower
Figure 15 IIOC PWBs and MRD
May 2003
4-24
V0.042
IIOC PWB
A7A4
Tray 1/2 Paper Feed

Drives Plate
IIOC PWB
A7A3
IIOC PWB
A7A1
IIOC PWB
A7A2
Service AC
Outlet
IIOC PWB
A8A3
IIOC PWB
A8A4
Tray 3/4 Paper

Feed Drives Plate
IIOC PWB
A8A2
IIOC PWB
A8A1
Fuse F3
Figure 16 Paper Tray Electrical
V0.042
May 2003
4-25
Vertical Transport
IIOC PWB A7A5
Wait Station Sensor

Paper Feed Motor

(Tray 1/2)
IIOC PWB A8A5
Paper Feed Motor

(Tray 3/4)
Figure 17 Paper Feed Components
May 2003
4-26
V0.042
Distribution PWB
Figure 18 Distribution PWB and AC Distribution Panel
V0.042
May 2003
4-27

Tray 2 Stack
Height Sensor
Tray 1 Stack
Height Sensor
Area 3E
Tray 4 Stack
Height Sensor
Tray 3 Stack
Height Sensor
Figure 19 Paper Guides and Drives PLate
May 2003
4-28
V0.042
Finisher Top
Tray
Pause Resume
Switch
Finisher Top
Cover Door
Finisher Top
Cover

Tamper Arm
Disk Baffle Assembly
Tamper Button
Stacker Tray
Stapler Access Door
Finisher Rear Cover
Figure 20 Finisher Components
V0.042
May 2003
4-29
Static Eliminator
Top Module Assembly
Front Bale Arm
Disk Fingers
Tamper Button
Stacker Tray
Drive Pulley
Rear Bale Arm
Stacker Tray
Drive Belt Clamp
Front Stacker
Tray Bracket
Stacker Tray
Drive Belt
Figure 21 Finisher Components
May 2003
4-30
V0.042
Nip 3/4 Idler

Nip 4 Drive Shaft
Nip 3 Drive Shaft
Nip 2 Drive Shaft
Nip 3/4 Drive
Belt
Nip 1/2 Idler
Dual Idler
Nip 1 Drive Shaft
Nip 1/2 Drive

Belt
Disk Drive Motor

(pulley)
Disk Drive Gear
NOTE: The Transport Drive

Motor is mounted on the
inside of the Finisher
frame.
Disk Home Sensor
Stacker Tray
Drive Motor
Figure 22 Finisher Drives
V0.042
May 2003
4-31
Finisher Diverter
Gate
Finisher Upper
Harness
NOTE: The Finisher Diverter Gate is

part of the Finisher Transport Baffle
and is located under area 5b.
Fixed Stapler
Moving Stapler
Stapler Position
Home Sensor
Stapler Position
Motor
Figure 23 Finisher Staplers and Diverter Gate
May 2003
4-32
V0.042
Top Tray Offset

Motor
Top Tray Offset

Drive Gear
Finisher Diverter
Gate Solenoid
Heat Cover
Finisher Diverter
Gate Solenoid
(under heat cover)
Nip 4 Idlers
Top Tray Static

Eliminator
Finisher Transport
Baffle
Nip 1 Idlers
Nip 3 Idlers
Finisher Input
Baffle
Nip 1 Drive Rolls
Figure 24 Finisher Transport Baffle
V0.042
May 2003
4-33
Canard
Wing
Moving - Stapler
Safety Gate
Stapler Lead-In
Baffle
The Lead-In Baffle is part
of the Moving Stapler
Fixed - Stapler
Safety Gate
Figure 25 Fixed Stapler and Moving Stapler
May 2003
4-34
V0.042
Document Feeder
Top Cover Sensor
Actuator
DADF Top Cover

DADF Take Away
Roll Idler

(includes sensor)
DADF Take
Away Roll
Nudger Solenoid
Figure 26 DADF - Top View
V0.042
May 2003
4-35
CVT Skis
DADF Exit Shaft
Left CVT Baffle
CVT Drive on Glass

Roll
NOTE: The DADF

may have two CVT
Skis, three CVT
Skis, or a single
CVT Ski.
DADF Exit Roll
DADF Inverter
Gate
DADF Exit/Invert
Sensor
Right CVT Baffle
CVT Start of
Scan Sensor
Figure 27 DADF - Bottom View
May 2003
4-36
V0.042
Developer HVPS
Contact Springs
Figure 28 Developer Collector Tube
V0.042
Figure 29 Developer HVPS Contact Springs
May 2003
4-37
Developer Drive
Motor
Developer Drive
Belt
Photoreceptor
Drive Motor
Developer Gear
Bracket
Figure 30 Developer Drive Motor, Belt, and Bracket
May 2003
4-38
V0.042
HCF/Bypass
Tray Feed Motor
HCF Elevator
Motor
HCF PWB
Figure 31 HCF/Bypass Tray
V0.042
May 2003
4-39
DADF Exit Roll

Idler
3-Arm Sheet
Separator
DADF Static
Eliminator
Left CVT Roll

(see note below)
Document
Restack Guide
NOTE: The Left CVT Roll can be

viewed by lowering the Left CVT Baffle.
Left CVT Roll

Idler
Figure 32 DADF Components - Lower
May 2003
4-40
V0.042
Right CVT Roll
The Right CVT Roll can

be viewed by lowering the
Right CVT Baffle.
Right CVT Roll

Idler
Figure 34 Right CVT Roll and Right CVT Idler (CVT Skis removed)
Tamper Home
Sensor
Tamper Ball
Slide
Figure 33 Finisher Tamper Components
V0.042
May 2003
4-41
Registration Roll Idler
Registration Roll
(see note below)
DADF Registration Deskew

Assembly
Registration Roll Shaft

NOTE: The Registration Rolls are part of the DADF
Registration Deskew Assembly and contact the idlers
through cutouts in the DADF Reg Deskew Assembly.
Figure 35 Rear view of the DADF Registration Deskew Assembly.
May 2003
4-42
V0.042
Side Guide
Sensor 1
Input Tray
Sensor 2
Side Guide
Sensor 2
Input Tray Sensor 1
Figure 36 Document Input Tray - bottom view
V0.042
May 2003
4-43
Kicker Home Sensor
Kicker
Stack Height Sensor /

Moving Stapler
Ball Slide
Tamper Arm
Gear Rack
Stapler Position
Home Sensor
Tamper
Motor Gear
Moving Stapler
drive gears
Tamper Motor
Moving Stapler
Gear Rack
IIOC PWB A7A1
Figure 37 Service Tray Assembly - top view
May 2003
4-44
V0.042
CVT Motor
Ground Wire
Figure 38 CVT Motor Ground wire
V0.042
May 2003
4-45
Finisher Interlock
Switch Actuator

Top Tray Full Sensor
Top Tray Full

Sensor Actuator
Top Tray Paper

Path Sensor
Figure 39 Finisher Interlock Switch and Paper Path Sensors
May 2003
4-46
V0.042
Tray 6 Paper Guide

(one on each side of tray)
Figure 40 HCF
V0.042
May 2003
4-47
ESS PWB
ESS Hard Disk

Drive
Figure 41 ESS Components
May 2003
4-48
V0.042
ESS Hard Disk

Drive Ribbon
Cable
ESS Hard Drive

Power Cable
Figure 42 ESS Hard Disk Drive
V0.042
May 2003
4-49
ESS DRAM
SIMMS
(CARD CAGE)
(ESS PWB)
Figure 43 ESS PWB and DRAM SIMMS
May 2003
4-50
V0.042
Token Ring PWB
Figure 44 Token Ring PWB
V0.042
May 2003
4-51
DADF Feed
Clutch
DADF Inverter
Clutch
DADF Exit Clutch
Registration Roll
Drive Gear
Figure 45 DADF Feed Components
May 2003
4-52
V0.042
Retard Bracket
Spring
Stacker Tray Upper

Limit Switch
Stacker Tray Full

Sensor Actuator
Bottom view of the DADF

Feeder Assembly
Stacker Tray
Full Sensor
Stacker Tray Front

Bracket
Figure 46 DADF Retard Bracket Spring

Stacker Tray Lower
Limit Switch
Figure 47 Finisher Stacker Tray Position Sensors
V0.042
May 2003
4-53
Stack Too High

Sensor
Nip 2 Idlers
Stack Height
Sensor actuator
Stack Height
Sensor
Rear Bale
Arm
View of Disk Baffle Assembly removed from Finisher

Figure 48 Finisher Stack Height Sensing
Figure 49 Finisher Nip 2 Idlers
May 2003
4-54
V0.042
Fuser Drive Gear
Figure 50 Fuser Drive Gear
V0.042
May 2003
4-55
IPA PWB
Figure 51 IPA PWB
May 2003
4-56
V0.042
EHR PWB (Not Shown)
ESS LEDs
Figure 52 ESS LEDs
EPC SRAM DIMM
Figure 53 EHR PWB and EPC SRAM DIMM
V0.042
May 2003
4-57
100Mb Ethernet PWB
Figure 54 100Mb Ethernet PWB
May 2003
4-58
V0.042
Inverter Entrance Gate
Inverter Exit Roll Idler
Inverter Drive
Gear
Feed/Reverse
Roll Idler
Entrance Gate Solenoid

Reversing Baffle
Inverter Entrance
Sensor
IIOC PWB
A4A1
Close Nip
Link
Close Nip
Solenoid
Spring
Close Nip
Solenoid
IIOC PWB
A4A2
Feed/Reverse
Roll Idler
Spring
Figure 55 Inverter Entrance
V0.042
May 2003
4-59
Duplex Gate
Inverter Exit Roll
Inverter Drive
Assembly
Reverse Drive
Solenoid Spring
Reverse Drive
Solenoid
Feed/Reverse Roll
Figure 56 Inverter Exit
May 2003
4-60
V0.042
Tamper Arm
Drive Cable
Tamper Capstan
Figure 57 Capstan Driven Tamper (TAG F029)
V0.042
May 2003
4-61
Drive Gear
Shim
NOTE: Also referred to as Baffle Jack
Figure 58 Fuser Module - Drive Gear and Shim (Baffle Jack)
May 2003
4-62
V0.042
Figure 59 Fuser Module - Area 3b Open
V0.042
May 2003
4-63
Pressure Roll Stripper Fingers
Figure 60 Fuser Module - Pressure Roll Stripper Fingers
May 2003
4-64
V0.042
Duplex Transport
Vertical Transport
Registration Idler Rolls
HCF/Duplex Baffle
Mylar
Figure 61 Registration Transport Assembly
V0.042
May 2003
4-65
Figure 62 Paper Tray Elevator Motors and Nudger Solenoids
May 2003
4-66
V0.042
Feed Clutch and Coupling (upper tray)
Feed Clutch and Coupling (lower tray)
Figure 63 Paper Feed Drives Plate - Rear View
V0.042
May 2003
4-67
P5
P4
P3
Guide Blade
Decurler Position
Sensor
Decurler Gate
Solenoid
P137
Figure 64 Tag 279 Decurler Component Locations

May 2003
4-68
V0.042
MFF Components
MFF Component Table

Table 1 MFF Components
Name
Designator
Purpose
BSD
Location
12B.5
4 Bar Exit Motor
M41
Provides drive to Nip 10 and rotates the Compile Belts.
4 Bar Position Clutch
CL40
Keeps spring-loaded linkage of the 4 Bar Assembly in the lowered

12B.5
position. The clutch is de-energized to allow the linkage to move to the
upper position for jam clearance.
4 Bar Home Sensor
S45
Monitors the position of the 4-Bar Assembly. Indicates when the 4-Bar 12B.5
Assembly is in the home position.
4 Bar Position Motor
M45
Provides drive to raise and lower the 4-Bar Assembly to maintains a

12B.5
constant distance between the compiling components and the stack of
paper in the Compiler Tray.
Backstop Home Sensor
S64
Monitors the position of the Backstop in the Booklet Maker. Indicates 12B.9
when the Backstop is in the home (lowered) position.
Booklet BackStop Motor
M63
Lowers and raises the Backstop in the Booklet Maker.
12B.9
Booklet Compiler Tray Sensor
S61
Monitors booklets in the Booklet Compiler.
12B-9
Booklet Diverter Gate
N/A
Directs sheets to the Booklet Maker
12B.3
Booklet Diverter Gate Solenoid L60
Actuates the Booklet Diverter Gate to direct sheets to the Booklet

Maker.
12B.3
Booklet Entrance Sensor
S60
Monitors the movement of paper entering the Booklet Maker. Located 12B.9
just before Nip 20 in the Booklet Maker.
Booklet Exit Sensor
S73
Monitors the movement of paper exiting the Booklet Maker or Tri-Fold 12B.10
Assembly Located just before Nip 19 in the Tri-Fold Assembly.
Booklet Flapper
N/A
Guide sheets into the Booklet Maker
Booklet Flapper Solenoid
L61
When energized, drive from the booklet Paper Path Motor, M60, is pro- 12B.9
vided to rotate the Booklet Flapper. The flapper registers the lead
edge of the sheets against the backstop in the Booklet Maker.
Booklet Front Stapler
N/A
Applies staple to center of booklet
12B.8
Booklet Rear Stapler
N/A
Applies staple to center of booklet
12B.8
Booklet Paper Path Motor
M60
Provides drive to Nip 20 (Booklet Maker entrance nip) and the Flapper 12B.9
in the Booklet Maker.
Booklet Pullout PWB
N/A
Provides power and control signals to Booklet Maker components
12B.7, 12B.8,
12B.9,
Booklet Tamper Home Sensor
S63
Monitors the position of the tamper in the Booklet Maker. Indicates

when the Tamper is in the home position.
12B.7
Booklet Tamper Motor
M62
Provides drive to the Tamper in the Booklet Maker. Moves the Tamper 12B.7
Pads to the Letter tamping position or the A4 tamping position and
tamps the sheets as they enter the Booklet Maker.
Booklet Tray Belt Motor
M61
Provides drive to Booklet Tray Belts
Booklet Tray Full Sensor
S74
Monitors the quantity of booklets in the Booklet Output Tray. Indicates 12B.10
the Booklet Tray needs to be emptied when the Booklet Tray backstop
is in the raised position.
12B.9
12B.10
Buffer Entrance Nip Motor
M31
Provides drive to Nip 6, and Nip 7 in the Buffer Module.
12B.4
Buffer Gate
N/A
Directs the first sheet of a set into the buffer area.
12B.4
V0.042
May 2003
4-69
MFF Components

BSD
Location
Name
Designator
Purpose
Buffer Gate Solenoid
L33
Actuates the Buffer Gate to direct the first sheet of a set into the buffer 12B.4
area.
Buffer Nip Motor
M30
Provides drive to Nip 8, Nip 9 Clutch, Nip 12, and Nip 13.
12B.4
Buffer Module Entrance Sensor S20
Monitors the movement of paper entering the Buffer/Compiler Module. 12B.4

Located between Nip 6 and Nip 7.
Compile Belts
N/A
Assists the movement of sheets into the Compiler Tray
12B.5
Compiler Curl Guard Solenoid
L41
Lowers and raises the Curl Guard Fingers.
12B.5
Compiler Entrance Sensor
S46
Monitors the movement of paper entering the Compiler. Located

between Nip 9 and Nip 10.
12B.5
Compiler Fingers Motor
M47
Moves the Compiler Fingers to the compile position (extended) and to 12B.5
the eject position (retracted).
Compiler Fingers Home Sensor S90
Monitors the position of the Compiler Fingers.
12B.5
Exit Flapper Home Sensor
S40
Monitors the position of the Flapper in the compiler. Indicates when

the Flapper is in the home position.
12B.5
Compiler Flapper Motor
M47
Provides drive to rotate the Flapper in the Eject Housing. The Flapper 12B.5
aids in stacking of sheets as they are compiled.
Compiler Jam Sensor
S47
Monitors the presence of paper in the Compiler Tray.
12B.5
Compiler Lower Eject Motor
M40
Provides drive to Nip 11 to eject sets from the Compiler Tray.
12B.5
Compile Position Sensor
S51
Monitors the position of the Main Tray. Indicates when the Main Tray is 12B.6
in the compile position.
Compiler Tamper Home Sensor S44
Monitors the position of the tamper in the Compiler Tray. Indicates

Compiler Tamper Motor
Provides drive to the Tamper in the Compiler Tray. Moves the Tamper 12B.7
tamps the sheets as they enter the Compiler Tray.
M44
12B.7
Compiler Upper Eject Motor
M48
Provides drive to the Upper Compiler drive rolls in the Eject Housing.
12B.5
Cooling Fan
M111
Cools the MFF Entrance Baffle
12B.4
12B.6
Crash Bar Switch
SW53
Cuts power to the Main Tray Elevator Motor, M51, when actuated.
Crease Blade Home Sensor
S68
Monitors the position of the Crease Blade. Indicates when the Crease 12B.9
Blade is in the home (retracted) position.
Crease Blade Motor
M67
Provides drive to the Crease Blade.
Crease Blade Knob
N/A
Moves the Crease Blade for jam clearance
N/A
Crease Blade Motor Encoder
S70
Monitors the Crease Blade Motor M67
12B.9
Crease Exit Sensor
S72
Monitors the movement of booklets or sheets as the exit the Booklet

Maker and enter the Tri-Fold Assembly,
12B.10
Crease Nip Release Lever
N/A
Releases the Crease Roll nip for jam clearance
N/A
Crease Roll Gate
N/A
Prevents the curled edge of paper from entering the Crease Rolls
12B.9
Crease Roll Motor
M68
Provides drive to Nip 16 (crease Roll), Nip 17, Nip 18, and Nip 19.
12B.9
Crease Roll Motor Encoder
S71
Provides feedback to the MFF Control PWB from the Crease Roll
Motor, M68.
12B.9
Crease Roll Gate Home Sensor S67
Monitors the position of the Crease Roll Gate. Indicates when the
Crease Roll Gate is in the home (raised) position.
12B.9
MFF Components
12B.9
May 2003
4-70
V0.042

Name
Designator
Purpose
BSD
Location
Crease Roll Gate Motor
M66
Provides drive to raise and lower the Crease Roll Gate.
12B.9
Eject Housing Elevator Motor
M46
Provides drive to move the Eject Housing to the eject position (down)
and to the set compile position (up).
12B.5
Eject and Stapler PWB
N/A
Provides power and control signals to the Main Stapler and eject com- 12B.5, 12B.8
ponents
Eject Housing Home Sensor
S49
Monitors the position of the Eject Housing. Indicates when the housing is in the home position.
Frame/Booklet/Tri-Fold PWB
N/A
Provides power and control signals to Booklet Maker and Tri-Fold com- 12B.3, 12B.4,
ponents
12B.512B.61
2B.7, 12B.10
S110
Monitors the movement of paper as it enters the MFF. Located

between Nip 1 and Nip 2 in the MFF Entrance Baffle.
12B.3
Front BackStop Clamp Solenoid L63
Holds booklet in place for stapling and folding.
12B.9
SW01
Cuts +24 VDC to the MFF and send a 'Front Door open' signal to the 12B.2
MFF Control PWB, when the Front Door is open.
Front Staples Low Switch
SW62
Monitors staple supply in Booklet Front Stapler. Indicates when the

staple cartridge is low or is not installed.
12B.8
Front Stapler Head Switch
SW60
Monitors the position of the stapler head in the Booklet Front Stapler.
12B.8
Front Stapler Motor
M65
Provides drive to clinch and release the stapler head in the Booklet
Front Stapler.
12B.8
12B.1
12B.5
IOT/MFF Interface PWB
N/A
Interface between Main Control PWB in IOT and MFF Control PWB.
Main Staples Low Detected
S42
Monitors the staple supply in the Main Stapler. Indicates when the sta- 12B.8
ple cartridge is low.
Main Staples Ready Sensor
S92
Indicates when the staples in the Main Stapler are in the primed
(ready) position.
12B.8
Main Stapler Home Sensor
S41
Indicates when the stapler head in the Main Stapler is in the home
position.
12B.8
Main Stapler Position Motor
M43
Moves the Main Stapler to the rear position and to the front position for 12B.8
dual stapling of sets.
Main Tray Drive Belt - Front
Transfers drive from Main Tray Elevator Motor to the Main Tray
N/A
Main Tray Belt Clamp - Front
N/A
Secures Main Tray to Drive Belt
N/A
Main Tray Drive Belt - Rear
N/A
Transfers drive from Main Tray Elevator Motor to the Main Tray
N/A
Secures Main Tray to Drive Belt
N/A
Main Stapler Clinch Motor
M42
Provides drive to clinch and release the stapler head in the Main Stapler.
12B.8
Main Tray Elevator Motor

Encoder
S54
Provides feedback to the MFF Control PWB from the Main Tray Motor. 12B.6
Main Tray Full Sensor
S52
Monitors the position of the Main Tray. Indicates when the Main Tray
need to be emptied.
Main Tray Lower Limit Switch,

SW50
SW50
Cuts power to the Main Tray Motor if the Main Tray is lowered too far, 12B.6
preventing component damage.
Main Tray Elevator Motor, M51
M51
Raises and Lowers the Main Tray
12B.6
Main Tray Offset Motor
M50
Provides drive to offset the Main Tray
12B.6
Main Tray Belt Clamp - Rear
V0.042
May 2003
4-71
12B.6
MFF Components

Name
BSD
Location
Designator
Purpose
Main Tray Offset Sensor
S53
Monitors the position of the Main Tray (front to rear).
12B.6
Main Tray Upper Limit Switch,

SW51
SW51
Cuts power to the Main Tray Motor if the Main Tray is raised too far,
12B.6
MFF Control PWB
N/A
Monitors inputs and provides information to the four Drive PWBs.
All
Nip 1 Drive Rolls
N/A
Drives sheets to Buffer/Compiler Module or to Booklet Maker
12B.3
12B.3
Nip 2 Drive Rolls
N/A
Drives sheets to Buffer/Compiler Module or to Booklet Maker
Nip 1/2 Drive Belt
N/A
Transfers drive to Nip 1 Drive Shaft and Nip 2 Drive Shaft
N/A
Nip 1/2 Idler
N/A
Keeps the correct tension on the Nip 1/2 Drive Belt
N/A
Nip 6 Idlers
Provide nip force for Nip 6 Drive Rolls
12B.4
Nip 7 Idlers
12B.4
12B.4
Nip 8 Idlers
N/A
Nip 8 Release Solenoid
L31
Moves the Nip 8 Idlers to open Nip 8.
12B.4
Nip 9 Clutch
N/A
Provides drive from the Buffer Nip Motor to Nip 9.
12B.4
Nip 10 Drive Rolls
N/A
Transports sheets to the Compiler Tray
N/A
Nip 10 Drive Shaft
N/A
Transports sheets to the Compiler Tray
12B.5
Nip 12 Drive Rolls
N/A
Drives sheets to Top Tray
12B.4
Nip 12 Idlers
N/A
N/A
Nip 13 Drive Shaft
N/A
Drives sheets to Top Tray
12B.4
Nip 13 Idlers
N/A
N/A
Nip 17 Drive Rolls
N/A
Transports booklets to Booklet Output Tray
Nip 17 Idler Rolls
N/A
Nip 18 Drive Rolls
N/A
Transports booklets to Booklet Output Tray
Nip 18 Idler Rolls
N/A
Nip 20 Idlers
N/A
12B.9
Paper Path Nip Motor
M110
Provides drive to Input Nips 1, 2, 3, 4, and 5.
12B.3
Pause to Unload LED
LED51
Indicates the Pause to Unload Switch has been actuated.
12B.6
Pause to Unload Switch
SW52
This switch is allows the operator to pause the machine to unload sets 12B.6
from the Main Tray.
Rear Backstop Clamp Solenoid L64
12B.9
Rear Stapler Head Switch
SW61
Monitors the position of the stapler head in the Booklet Rear Stapler.
12B.8
Rear Stapler Motor
M64
Rear Stapler.
12B.8
Rear Staples Low Switch
SW63
Monitors staple supply in Booklet Rear Stapler. Indicates when the

staple cartridge is low or not installed.
12B.8
12B.5
Set Eject Sensor
S91
Monitors sets as they are ejected from the Compiler Tray.
Stapler Interlock Switch
SW04
Cuts power to the Main Stapler Clinch Motor, M42, when the Main Sta- 12B.8
pler is in the position for installing a new staple cartridge.
Staple Module Closed Sensor
S79
Indicates when the Booklet Maker Staple Module, Area 5d1, is closed. 12B.8
S43
Indicates when the Main Stapler Assembly is in the home position.
Top Cover Interlock Switch
SW120
Cuts power to MFF components when the Top Cover is open (raised). 12B.2
MFF Components
May 2003
4-72
12B.8
V0.042

BSD
Location
Name
Designator
Purpose
Top Tray 90% Full Sensor
S121
Monitors the paper in the Top Tray. Indicated when the Top Tray is
approximately 90% full.
12B.4
Actuates Top Tray 90% Full Sensor when Top Tray is 90% full
N/A
Top Tray 90% Full Sensor Actu- N/A

ator
Top Tray Exit Sensor
S120
Top Tray Diverter Gate
Monitors the paper as it enters the top tray.
12B.4
Directs sheets to either the Top Tray or to the Compiler Tray
12B.4
Top Tray Diverter Gate Solenoid L40
Actuates the Top Tray Diverter Gate
12B.4
Trail Edge Clamp Solenoid
L30
Holds trail edge of sheet in Buffer Module.
12B.4
Tri-Fold Curl Gate Solenoid
L81
Maintains the first fold of a tri-folded sheet in position.
12B.10
Tri-Fold Diverter Solenoid
L80
Actuates the Tri-Fold Diverter Gate
12B.10
Tri-Fold Drive Clutch
CL80
When energized, provides drive from Nip 17 to Tri-Fold nips.
12B.10
Tri-Fold Crease Rolls
N/A
Creates the second fold of tri-folded sheets.
12B.10
Tri-Fold Exit Nip Shaft
N/A
Provides drive to move tri-folded sheets to Nip 19.
12B.10
Tri-Fold Jam Sensor
S81
Indicates a jam in the Tri-fold area.
12B.10
Upper Eject Housing
N/A
Contains the Compiler Flapper and lowers to eject sheets into the
Main Tray
12B.5
Upper Pullout PWB
N/A
Provides power and control signals to Compiler and Buffer components
12B.3, 12B.4,
12B.5,
V0.042
May 2003
4-73
MFF Components
MFF Component Drawings

Top Tray 90% Full
Sensor Actuator
Nip 13 Idlers
Finisher Entrance
Sensor
Nip 12 Idlers
Front Door
Interlock Switch
Top Tray Exit

Sensor Actuator
Nip 13 Drive Rolls
Nip 1 Drive Rolls
Nip 2 Drive Rolls
Booklet Diverter
Gate Solenoid
Main Stapler
Figure 1 MFF Front View
MFF Components
May 2003
4-74
V0.042
Main Tray Belt

Clamp - Rear
Main Tray Upper

Limit Switch,
SW51
Main Tray Drive

Belt - Rear
Main Tray Elevator

Motor, M51
Main Tray Drive

Belt - Front
Main Tray Belt

Clamp - Front
Main Tray Lower
Limit Switch,
SW50
Figure 2 Main Tray Drive Components 1 of 2 (removed from MFF for clarity)
V0.042
May 2003
4-75
MFF Components
Compiler Lower
Eject Motor
Upper Eject
Housing
Nip 13 Drive Rolls
Top Cover Interlock

Switch
Nip 12 Drive Rolls
Nip 12 Idlers
Buffer Nip Motor
Nip 13 Drive Shaft
Nip 8 Drive Shaft

Nip 12 Drive Shaft
Figure 3 MFF Top View with cover removed
MFF Components
May 2003
4-76
V0.042
Nip 17 Idler Rolls
Nip 18 Idler Rolls

Main Tray Elevator
Belt - Rear
Main Tray Offset

Sensor
NOTE: The encoder

and sensor are
located inside the
motor housing
Crease Exit Sensor
Nip 17 Drive Rolls
Main Tray Elevator

Motor Encoder
Main Tray Elevator

Belt - Front
Nip 18 Drive Rolls
Figure 4 Tri-Fold Components and Main Tray Drive Components
V0.042
May 2003
4-77
MFF Components
Buffer Entrance
Nip Motor
Nip 8/9 Drive Belt
4 Bar Exit Motor
Nip x/x Drive Belt
4 Bar Position
Clutch
4 Bar Position
Motor
Figure 5 Buffer/Compiler Module - Rear View
MFF Components
May 2003
4-78
V0.042
4 Bar Exit Motor
Buffer Nip Motor
4 bar Position Motor
Compiler Lower
Eject Motor
Nip 1/2 Idler
Nip 1/2 Drive Belt
Figure 6 MFF Rear View
V0.042
May 2003
4-79
MFF Components
Main Tray Motor
Main Stapler Drive

Belt tensioner
Crease Roll
Gate Motor
Booklet
Flapper
Solenoid
IOT/MFF
Interface PWB
MFF LVPS
Main Tray
Lower Limit
Switch
LVPS Dirt Filter
Tri-Fold Drive Belt
Crease Roll Motor
MFF Components
May 2003
4-80
V0.042
Upper Pullout PWB
MFF Control PWB
Booklet Pullout PWB

Figure 8 MFF PWBs
V0.042
May 2003
4-81
MFF Components
Buffer Gate
Solenoid
Nip 7 Idlers
Buffer
Gate
Buffer Entrance
Motor
Paper Path Nip

Motor
Buffer Module
Entrance Sensor
Cooling Fan
Nip 6 Idlers
Figure 9 Buffer/Compiler Module Front Left
MFF Components
May 2003
4-82
V0.042
Compiler Curl Guard

Solenoid
Nip 8 Idlers
Top Tray
Diverter Gate
Nip 10 Drive Shaft
Compile Belts (2)
Set Eject Sensor
Compiler Curl Guard Fingers (6) Total
Nip 10 Drive Rolls
4 Bar Home Sensor
Figure 10 Buffer/Compiler Module - Front Right
V0.042
May 2003
4-83
MFF Components

Crease Blade
Knob
Upper Crease Roll
Crease Nip
Release Lever
Booklet Entrance
Sensor
Crease Roll Gate
Booklet Rear Stapler

Booklet Front Stapler
Figure 11 Booklet Maker - Front Right
MFF Components
May 2003
4-84
V0.042
Booklet Tamper
Nip 20 Idlers
Booklet Flapper
Booklet Flapper
Solenoid
Crease Blade Motor
Booklet Tamper Home

Sensor
Crease Blade Motor

Encoder
Crease Roll Motor

Encoder
Booklet Tamper
Motor
Crease Roll Motor
Crease Blade
Motor Encoder
Rear Backstop Clamp

Solenoid
Backstop Home
Sensor
Figure 12 Booklet Maker - Rear View
V0.042
May 2003
4-85
MFF Components
Booklet Entrance
Sensor
Crease Roll Gate

Home Sensor
Booklet Compiler
Tray Sensor
Front Stapler
Motor
Staple Module
Closed Sensor
Rear Stapler
Motor
Figure 13 Booklet Maker Rear Right View
MFF Components
May 2003
4-86
V0.042
Tri-Fold Diverter Gate
Tri-Fold Curl Gate

Solenoid
Tri-Fold Jam
Sensor
Figure 14 Tri-Folder Assembly - Rear View
V0.042
May 2003
4-87
MFF Components
Tri-Fold Crease Rolls
Tri-Fold Exit Nip Shaft
Figure 15 Tri-Folder Assembly - Front Right View
MFF Components
May 2003
4-88
V0.042
MFF Electrical Components - Cross Section View
MFF Electrical Component Table
Table 1 MFF Electrical Components

Name
Designator
Purpose
BSD
Location
12B.5
4 Bar Exit Motor
M41
Provides drive to Nip 10 and rotates the Compile Belts.
4 Bar Position Clutch
CL40
Keeps spring-loaded linkage of the 4 Bar Assembly in the lowered

12B.5
position. The clutch is de-energized to allow the linkage to move to the
upper position for jam clearance.
4 Bar Home Sensor
S45
Monitors the position of the 4-Bar Assembly. Indicates when the 4-Bar 12B.5
Assembly is in the home position.
4 Bar Position Motor
M45
Provides drive to raise and lower the 4-Bar Assembly to maintains a

12B.5
constant distance between the compiling components and the stack of
paper in the Compiler Tray.
S64
Monitors the position of the Backstop in the Booklet Maker. Indicates 12B.9
when the Backstop is in the home (lowered) position.
Booklet Backstop Motor
M63
Lowers and raises the Backstop in the Booklet Maker.
12B.9
S61
Monitors booklets in the Booklet Compiler.
12B-9
Booklet Diverter Gate Solenoid L60
Actuates the Booklet Diverter Gate to direct sheets to the Booklet

Maker.
12B.3
Booklet Entrance Sensor
S60
Monitors the movement of paper entering the Booklet Maker. Located 12B.9
just before Nip 20 in the Booklet Maker.
Booklet Exit Sensor
S73
Monitors the movement of paper exiting the Booklet Maker or Tri-Fold 12B.10
Assembly Located just before Nip 19 in the Tri-Fold Assembly.
Booklet Flapper Solenoid
L61
When energized, drive from the booklet Paper Path Motor, M60, is pro- 12B.9
vided to rotate the Booklet Flapper. The flapper registers the lead
edge of the sheets against the backstop in the Booklet Maker.
M60
Provides drive to Nip 20 (Booklet Maker entrance nip) and the Flapper 12B.9
in the Booklet Maker.
Booklet Pullout PWB
N/A
Provides power and control signals to Booklet Maker components
12B.7, 12B.8,
12B.9,
S63
Monitors the position of the tamper in the Booklet Maker. Indicates

12B.7
Booklet Tamper Motor
M62
Provides drive to the Tamper in the Booklet Maker. Moves the Tamper 12B.7
tamps the sheets as they enter the Booklet Maker.
Booklet Tray Belt Motor
M61
Provides drive to Booklet Tray Belts
Booklet Tray Full Sensor
S74
Monitors the quantity of booklets in the Booklet Output Tray. Indicates 12B.10
the Booklet Tray needs to be emptied when the Booklet Tray backstop
is in the raised position.
12B.10
Buffer Entrance Nip Motor
M31
Provides drive to Nip 6, and Nip 7 in the Buffer Module.
Buffer Gate Solenoid
L33
Actuates the Buffer Gate to direct the first sheet of a set into the buffer 12B.4
area.
Buffer Nip Motor
M30
Buffer Module Entrance Sensor S20
Provides drive to Nip 8, Nip 9 Clutch, Nip 12, and Nip 13.
12B.4
12B.4
Monitors the movement of paper entering the Buffer/Compiler Module. 12B.4

Located between Nip 6 and Nip 7.
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May 2003
4-89

Name
Designator
Purpose
BSD
Location
L41
Lowers and raises the Curl Guard Fingers.
12B.5
Compiler Entrance Sensor
S46
Monitors the movement of paper entering the Compiler. Located

between Nip 9 and Nip 10.
12B.5
Compiler Fingers Motor
M47
Moves the Compiler Fingers to the compile position (extended) and to 12B.5
the eject position (retracted).
Compiler Fingers Home Sensor S90
Monitors the position of the Compiler Fingers.
12B.5
Exit Flapper Home Sensor
S40
Monitors the position of the Flapper in the compiler. Indicates when

the Flapper is in the home position.
12B.5
Compiler Flapper Motor
M47
Provides drive to rotate the Flapper in the Eject Housing. The Flapper 12B.5
aids in stacking of sheets as they are compiled.
Compiler Jam Sensor
S47
Monitors the presence of paper in the Compiler Tray.
12B.5
Compiler Lower Eject Motor
M40
Provides drive to Nip 11 to eject sets from the Compiler Tray.
12B.5
Compiler Position Sensor

(receiver)
S51
Monitors the position of the Main Tray. Indicates when the Main Tray is 12B.6
Compile Position Sensor (trans- S51

mitter)
Monitors the position of the Main Tray. Indicates when the Main Tray is
Compiler Tamper Home Sensor S44
Monitors the position of the tamper in the Compiler Tray. Indicates

Compiler Tamper Motor
Provides drive to the Tamper in the Compiler Tray. Moves the Tamper 12B.7
tamps the sheets as they enter the Compiler Tray.
M44
12B.7
Compiler Upper Eject Motor
M48
Provides drive to the Upper Compiler drive rolls in the Eject Housing.
12B.5
Cooling Fan Motor
M111
Cools the MFF Entrance Baffle
12B.4
12B.6
Crash Bar Switch
SW53
Cuts power to the Main Tray Elevator Motor, M51, when actuated.
S68
Monitors the position of the Crease Blade. Indicates when the Crease 12B.9
Blade is in the home (retracted) position.
Crease Blade Motor
M67
Provides drive to the Crease Blade.
12B.9
Crease Blade Motor Encoder

Sensor
S70
Monitors the Crease Blade Motor M67
12B.9
Crease Roll Motor
M68
Provides drive to Nip 16 (crease Roll), Nip 17, Nip 18, and Nip 19.
12B.9

Sensor
S71
Provides feedback to the MFF Control PWB from the Crease Roll
Motor, M68.
12B.9
Crease Roll Gate Home Sensor S67
Monitors the position of the Crease Roll Gate. Indicates when the
Crease Roll Gate is in the home (raised) position.
12B.9
M66
Provides drive to raise and lower the Crease Roll Gate.
12B.9
Crease Exit Sensor
S72
Monitors the movement of booklets or sheets as the exit the Booklet

Maker and enter the Tri-Fold Assembly,
12B.10
Eject Housing Elevator Motor
M46
Provides drive to move the Eject Housing to the eject position (down)
and to the set compile position (up).
12B.5
N/A
Provides power and control signals to the Main Stapler and eject com- 12B.5, 12B.8
ponents
Eject Housing Home Sensor
S49
Monitors the position of the Eject Housing. Indicates when the housing is in the home position.
May 2003
4-90
12B.5
V0.042

BSD
Location
Name
Designator
Purpose
N/A
Provides power and control signals to Booklet Maker and Tri-Fold com- 12B.3, 12B.4,
ponents
12B.512B.61
2B.7, 12B.10
S110
Monitors the movement of paper as it enters the MFF. Located

between Nip 1 and Nip 2 in the MFF Entrance Baffle.
12B.3
front Door Interlock Switch
SW01
Front Backstop Clamp Solenoid L63
12B.9
SW01
Cuts +24 VDC to the MFF and send a 'Front Door open' signal to the 12B.2
MFF Control PWB, when the Front Door is open.
SW62
Monitors staple supply in Booklet Front Stapler. Indicates when the

staple cartridge is low or is not installed.
12B.8
SW60
Monitors the position of the stapler head in the Booklet Front Stapler.
12B.8
Front Stapler Motor
M65
Front Stapler.
12B.8
IOT/MFF Interface PWB
N/A
Interface between Main Control PWB in IOT and MFF Control PWB.
12B.1
Main Staples Low Detected

Sensor
S42
Monitors the staple supply in the Main Stapler. Indicates when the sta- 12B.8
ple cartridge is low.
S92
Indicates when the staples in the Main Stapler are in the primed
(ready) position.
12B.8
S41
Indicates when the stapler head in the Main Stapler is in the home
position.
12B.8
Main Stapler Position Motor
M43
Moves the Main Stapler to the rear position and to the front position for 12B.8
dual stapling of sets.
M42
Provides drive to clinch and release the stapler head in the Main Stapler.
12B.8
S52
Monitors the position of the Main Tray. Indicates when the Main Tray
need to be emptied.
12B.6
Main Tray Lower Limit Switch
SW50
Cuts power to the Main Tray Motor if the Main Tray is lowered too far, 12B.6
12B.2
M51
Raises and Lowers the Main Tray

Encoder
S54
Provides feedback to the MFF Control PWB from the Main Tray Motor. 12B.6
12B.6
M50
Provides drive to offset the Main Tray
12B.6
Main Tray Offset Sensor
S53
Monitors the position of the Main Tray (front to rear).
12B.6
Main Tray Upper Limit Switch
SW51
Cuts power to the Main Tray Motor if the Main Tray is raised too far,
12B.6
MFF Control PWB
N/A
Monitors inputs and provides information to the four Drive PWBs.
All
Nip 8 Release Solenoid
L31
Moves the Nip 8 Idlers to open Nip 8.
12B.4
Paper Path Nip Motor
M110
Provides drive to Input Nips 1, 2, 3, 4, and 5.
12B.3
Pause to Unload LED
LED51
Indicates the Pause to Unload Switch has been actuated.
12B.6
SW52
This switch is allows the operator to pause the machine to unload sets 12B.6
from the Main Tray.
V0.042
May 2003
4-91

Purpose
BSD
Location
Rear Backstop Clamp Solenoid L64
12B.9
SW61
Monitors the position of the stapler head in the Booklet Rear Stapler.
12B.8
Rear Stapler Motor
M64
Rear Stapler.
12B.8
SW63
Monitors staple supply in Booklet Rear Stapler. Indicates when the

staple cartridge is low or not installed.
12B.8
12B.5
Name
Designator
Set Eject Sensor
S91
Monitors sets as they are ejected from the Compiler Tray.
Stapler Interlock Switch
SW04
Cuts power to the Main Stapler Clinch Motor, M42, when the Main Sta- 12B.8
pler is in the position for installing a new staple cartridge.
S79
Indicates when the Booklet Maker Staple Module, Area 5d1, is closed. 12B.8
S43
Indicates when the Main Stapler Assembly is in the home position.
Top Cover Interlock Switch
SW120
Cuts power to MFF components when the Top Cover is open (raised). 12B.2
Top Tray 90% Full Sensor
S121
Monitors the paper in the Top Tray. Indicated when the Top Tray is
approximately 90% full.
12B.4
12B.8
S120
Monitors the paper as it enters the top tray.
12B.4
Top Tray Diverter Gate Solenoid
L40
Actuates the Top Tray Diverter Gate
12B.4
Trail Edge Clamp Solenoid
L30
Holds trail edge of sheet in Buffer Module.
12B.4
Tri-Fold Curl Gate Solenoid
L81
Maintains the first fold of a tri-folded sheet in position.
12B.10
L80
Actuates the Tri-Fold Diverter Gate
12B.10
Tri-Fold Drive Clutch
CL80
When energized, provides drive from Nip 17 to Tri-Fold nips.
12B.10
Tri-Fold Jam Sensor
S81
Indicates a jam in the Tri-fold area.
12B.10
Upper Pullout PWB
N/A
Provides power and control signals to Compiler and Buffer components
12B.3, 12B.4,
12B.5,
May 2003
4-92
V0.042
MFF Electrical Component Drawings

Crash Bar Switch
front Door Interlock Switch
Buffer Module
Entrance Sensor
Pause to Unload
LED
Compiler Jam
Sensor
Compiler Position
Sensor
Cooling Fan
Motor
(receiver)
Compiler Fingers
Home Sensor
Compiler Fingers
Motor

Main Staples Low Detected Sensor
Stapler Position
Home Sensor
Figure 1 Cross Section of MFF Front View - Buffer/Compiler, Main Tray, and Top Tray (1 of 2)
V0.042
May 2003
4-93
Top Cover Interlock

Switch
Top Tray 90%

Full Sensor
Paper Path Nip

Motor
Eject Housing
Elevator Motor
Compiler Flapper
Motor
Exit Flapper Home
Sensor
The Compiler Flapper
Motor and Exit Flapper
Home Sensor are
behind the Eject Housing Elevator Motor
Stapler Interlock
Switch
Finisher Entrance
Sensor
Set Eject
Sensor
4 Bar Home
Sensor
Main Tray Offset
Sensor
Compiler Entrance
Sensor
Main Tray Offset

Motor
Figure 2 Cross Section of MFF Front View - Buffer/Compiler, Main Tray, and Top Tray (2 of 2)
May 2003
4-94
V0.042
Crease Blade
Motor Encoder
Sensor
Booklet Entrance
Sensor
Crease Blade
Home Sensor
Booklet Exit Sensor
Crease Blade
Motor
Booklet Tray Full

Sensor
Booklet Tamper
Motor
Booklet Compiler
Tray Sensor
Booklet Backstop
Motor
Booklet Tray Belt

Motor
Front Stapler Motor
Front Backstop
Clamp Solenoid
Tri-Fold Jam Sensor
Crease Exit Sensor
Figure 3 Cross Section of MFF Front View - Booklet Maker, Tri-Folder, Booklet Maker Exit
V0.042
May 2003
4-95
Compiler Upper Eject

Motor
Compiler Lower
Eject Motor
4 Bar Exit Motor
Buffer Nip Motor
Buffer Gate
Solenoid
Main Tray Upper

Limit Switch
Trail Edge Clamp
Solenoid
Stapler Interlock
Switch
Buffer Entrance Nip
Motor
Eject Housing
Home Sensor
Compile Position
Sensor
Top Tray Diverter

Gate Solenoid
(Transmitter)
Nip 8 Release
Solenoid
Compiler Tamper
Home Sensor
Compiler Tamper
Motor
4 Bar Position
Motor
Main Stapler
Position Motor
4 Bar Position
Clutch
Main Tray Elevator

Motor
Main Tray Elevator

Motor Encoder
Compiler Curl
Guard Solenoid

Solenoid
Figure 4 Cross Section of MFF Rear View - Buffer/Compiler, Main Tray, and Top Tray
May 2003
4-96
V0.042
Main Tray Lower

Limit Switch
Crease Roll
Motor Encoder
Sensor
Tri-Fold Drive
Clutch
Crease Roll
Gate Motor
Crease Roll Gate

Home Sensor
Booklet Paper
Path Motor
Booklet Flapper
Solenoid
Booklet Tamper
Home Sensor
Staple Module
Closed Sensor
Backstop Home
Sensor
Located between
the Front and Rear
Backstop Clamp
Solenoids.
Crease Roll
Motor
Tri-Fold Curl Gate

Solenoid
Rear Stapler Motor
Rear Backstop
Clamp Solenoid
Tri-Fold Diverter
Solenoid
Figure 5 Cross Section of MFF Rear View - Booklet Maker, Tri-Folder, and Booklet Exit
V0.042
May 2003
4-97
May 2003
4-98
V0.042
REP 01-1 Distribution PWB

Parts List on PL 1.5
Removal
CAUTION
Certain components in this procedure are susceptible to damage from electrostatic discharge.
WARNING
1.
Switch off the machine power and disconnect the power cord.
2.
Remove all rear covers from the IOT.
3.
Swing out the Card Cage (one or two 1/4-turn T20 fasteners).
4.
Disconnect the connectors from the Distribution PWB (Figure 1).
5.
a.
Disconnect the connectors from J1, J2, J3, and J4.
b.
Disconnect the connectors from J5 (ribbon cable).
c.
Disconnect the connectors from J7, J8, and J10.
d.
Disconnect the connectors from J11 and J12.
e.
Disconnect the connectors from J13, J14, and J15.
Remove the Distribution PWB (Figure 2).
V0.042
May 2003
4-99
REP 01-1
J13
J2
J3
J1
J14
J4
J15
J5 (ribbon
cable)
J10
J11
J12
J8
J7
Figure 1 Connectors
REP 01-1
May 2003
4-100
V0.042
REP 01-2 AC Distribution Panel

Parts List on PL 1.2A
Removal
WARNING
1
Remove
the T20
screw (1).
1.
2.
Disconnect the power cord from the IOT.
3.
With TAG 300: Disconnect the HCF Heater Enable Harness from the AC Distribution Panel
(Figure 1).
Disconnect
J9 on the
Distribution
PWB from
J4 on the
LVPS.
Slide the Distribution

PWB to the
right.
With TAG 299: Disconnect the IOT Heater Power Supply connector P125 from the AC Distribution Panel.
4.
Remove the AC Distribution panel:

a.
Remove the T30 screws (2) securing the AC Distribution Panel.
b.
Disconnect connectors P92 and P48 from the AC Distribution Panel.
c.
Without TAG 105: If replacing the AC Distribution Panel with a new one, disconnect
P41 from the LVPS, and open the LVPS Cooling Fan/Duct (PL 9.1) and disconnect
the two in-line fastons P2 and P4.
Figure 2 Removal
With TAG 105: If replacing the AC Distribution Panel with a new one, disconnect
P41 from the LVPS, and open the LVPS Cooling Fan/Duct (PL 9.1) and disconnect
the three wires from the Flicker PWB.
Replacement
Align the Distribution PWB connector J9 with LVPS connector J4 carefully, ensuring all
pins are engaged and the connectors are not offset.
d.
Remove the AC Distribution Panel.
With TAG 300 or TAG 299: If replacing the AC Distribution Panel with a new one: Remove all
of the following components which are not present in the new panel, and install them in the new
panel (Figure 2):
a.
Heater Enable Harness (connector P6 to J1 on the Relay PWB, and J4 and J5 into
the panel case)
b.
AC Power Harness connector P8 to J3 on the Relay PWB, and FL1-1 and FL1-2 to
the Line Filter.
c.
Relay PWB, and standoffs (4)

NOTE: If the Relay PWB is not present in the new panel, you will need to remove a
jumper from P7 and connect P7 to J4 on the Relay PWB.
d.
V0.042
May 2003
4-101
Harness Clip for the AC Power Harness
REP 01-1, REP 01-2
Disconnect the HCF Heater

Enable Harness from the
REAR VIEW
Figure 1 HCF Heater Enable Harness

Figure 2 Heater Enabling Components
FL1-2
FL1-1
AC Power Harness P8/J3
Relay PWB and

Standoffs (4)
P7/J4
Replacement
CAUTION
Without TAG 105: If replacing the AC Distribution Panel with a new one, be sure to reconnect
the two in-line fastons P2 and P4 inside the LVPS Cooling Fan/Duct correctly: Connect the
blue wire to the blue wire and the brown wire to the brown wire.
Relay
With TAG 105: If replacing the AC Distribution Panel with a new one, be sure to reconnect the
wires to the Flicker PWB inside the LVPS Cooling Fan Duct correctly: Connect the brown wire
to J1, the violet wire to J2, and the blue wire to J3 on the Flicker PWB.
Harness Clip
J5
REP 01-2
J4
Heater
Enable
Harness
(P6/J1)
May 2003
4-102
V0.042
REP 01-3 Low Voltage Power Supply (LVPS)
NOTE: Leaving these two screws loose for now will make it easier to mate the Distribution PWB to the LVPS later.

Removal
WARNING
2.
Connect connector P41 to the LVPS on the left side (as viewed from the rear).
3.
Connect the connectors to J2, J3, J5, and J6 on the right side of the LVPS (as viewed
from the rear).
4.
Reposition the Distribution PWB (Figure 2).
5.
Tighten the LVPS mounting screws (2).
1.
2.
3.
Disengage the Distribution PWB from the LVPS(Figure 1).
NOTE: Figure 1 shows the Distribution PWB with the harnesses omitted for clarity. You
do not have to disconnect the harnesses from the Distribution PWB.
Reinstall the
screw here.
4.
Remove the LVPS:

a.
Disconnect connector P41 from the left side of the LVPS (as viewed from the rear).
b.
Disconnect the connectors from J2, J3, J5, and J6 on the right side of the LVPS (as
viewed from the rear).
c.
Remove the two T20 screws (one on each side) which secure the LVPS to the rear
machine frame.
d.
Tilt the LVPS outward, lift it out of its bottom mounts, and remove it.
Remove
the T20
screw.
Engage all
pins to the
LVPS connector J4.
Remove the
T20 screw.
Reinstall
the screw
here, holding the
PWB in
this position.
3
Slide the PWB
as far as possible to your left.
Figure 2 Reposition the Distribution PWB
3
Ensure that
all pins are
disengaged
from the
LVPS connector J4.
2
Slide the PWB
to your right.
Figure 1 Disengage the Distribution PWB
Replacement
1.
Position the LVPS and install the T20 screws (2) loosely.
V0.042
May 2003
4-103
REP 01-3
REP 01-3
May 2003
4-104
V0.042
REP 02-1 User Interface Assembly

Removal
Remove the plastic PWB

cover (snap-fit, not shown)
and disconnect the harness from J2 and J4.
CAUTION
If replacing the UI Assembly with a new one and the machine has any level of L0.15 software
(V1.1, 1.11, 1.12, 1.2, 1.21), then you must upgrade the machine software, using the latest
software upgrade kit, before performing this procedure. This procedure has you load software
onto the new UI (as required) to match the version of software currently on the machine, and
loading any level of L0.15 software onto a new UI may destroy the new UI.
2
Lift the
panel.
CAUTION
1.
If replacing the UI with a new one, determine the current software level in the machine
and obtain the appropriate Software Upgrade Kit:
CAUTION
Be sure to consult any bulletins which may have announced later software releases than
those listed in this version of EDOC.
a.
Identify the current software level on the machine by the highest software Tag number which is marked off on the IOT Change Tag Matrix (see Product Specifications :
Software Version Compatibility).
b.
Obtain the Software Upgrade Kit either for the level of software already in the
machine or for the next level higher
NOTE: The Software Upgrade Kit for each software release includes the files both
for that software release and for the previous release.
Remove T20 screws (2,

recessed).
WARNING
2.
Figure 1 Removal
Replacement
3.
Open the Front Door.
4.
Prepare to remove the User Interface Assembly (Figure 1).
5.
Remove the User Interface Assembly: Lift the rear out, disengaging the rear tabs.
6.
If replacing the User Interface Assembly with a new one, remove the bezel from the User
Interface Assembly. (The bezel provides the User Interface button labels, either in English
or in multinational symbols.)
NOTE: If the old UI has a SIMM attached that the new one does not have, do not transfer the
SIMM to the new UI. The SIMMs function is built into the new UI, and installing the SIMM on
the new UI will cause malfunctions.
1.
Install the User Interface Assembly in the reverse order of Removal.
2.
Reinstall the bezel (if removed earlier).

NOTE: This concludes the physical replacement of the UI. Continue only if replacing the
UI Assembly with a new one.
3.
4.
V0.042
May 2003
4-105
Reconnect the Power Cord and Switch on the machine power.

Check the software level on the new UI Assembly:
a.
Wait until 30 seconds have passed after switching on the machine power.
b.
Place the UI into Diagnostics mode: On the UI keypad, press and hold the [*] key
and the [Dial Pause] key (under the [*] key), and press the [#] key.
c.
Refer to the APPrevisionlevel on the UI display, and record the UI software version.
d.
Press the [0] key to take the UI out of Diagnostics mode.

REP 02-1
5.
If the new UI's software level does not match that already in the machine, or if the customer requires a non-default language set, perform a UI Software Upload (REP 02-4).
REP 02-2 UI Processor PWB (With Tag #082 Only)

Removal
NOTE: The UI Processor PWB is only replacable on a machine with TAG 082.
CAUTION
1.
If replacing the UI Processor PWB with a new one, determine the current software level in
the machine and obtain the appropriate Software Upgrade Kit:
CAUTION
a.
b.
Obtain the Software Upgrade Kit either for the level of software already in the
machine or for the next level higher
NOTE: The Software Upgrade Kit for each software release includes the files both
for that software release and for the previous release.
WARNING
REP 02-1, REP 02-2
2.
3.
Remove the User Interface Assembly (REP 02-1).
4.
Remove the Inverter PWB from the UI Processor PWB (Figure 1).
5.
Remove the UI Processor PWB (Figure 2).
May 2003
4-106
V0.042
3
Slide the Inverter PWB to
the right to disconnect
CN1, and remove the
Rotator PWB.
1
Disconnect CN2.
2
Remove the T10 screw.
Figure 1 Remove the Inverter PWB
V0.042
May 2003
4-107
REP 02-2
3
Remove the T10 screws
(4), and remove the UI
Processor PWB.
2
Slide the connector clip
out and disconnect the
ribbon cable from J3.
1
Slide the connector clip
out and disconnect the
Figure 2 Remove the Processor PWB
Replacement
1.
Install the UI Processor PWB (Figure 3).
2.
Reinstall the Inverter PWB (Figure 4).
3.
Reinstall the User Interface Assembly (REP 02-1).
b.
NOTE: This concludes the physical replacement of the UI Processor PWB. Continue only
if replacing the UI Processor PWB with a new one.
4.
Reconnect the Power Cord and Switch on the machine power.
5.
Check the software level on the new UI Processor PWB:

a.
6.
Place the UI into Diagnostics mode: On the UI keypad, press and hold the [*] key
and the [Dial Pause] key (under the [*] key), and press the [#] key.
c.
Refer to the APPrevisionlevel on the UI display, and record the UI software version.
d.
Press the [0] key to take the UI out of Diagnostics mode.
If the new UI Processor PWB's software level does not match that already in the
machine, or if the customer requires a non-default language set, perform a UI Software
Upload (REP 02-4).
Wait until 30 seconds have passed after switching on the machine power.
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2
Install the T10 screws (4).
3
Insert the ribbon cable
into (J3), and slide the
connector clip in. Ensure
that the ribbon cable is
connected securely.
4
Insert the ribbon cable
into (J1), and slide the
connector clip in. Ensure
that the ribbon cable is
connected securely.
1
Position the UI Processor
PWB onto the standoff,
pressing (J7) straight
down onto the connector
pins. USE CAUTION not
to bend the pins.
Figure 3 Install the Processor PWB
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REP 02-2
1
Slide the Inverter PWB to
the left to connect CN1,
and position the Rotator
PWB.
3
Connect CN2.
2
Install the T10 screw.
Figure 4 Install the Inverter PWB
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REP 02-3 UI LCD Module (With Tag #082 Only)

Removal
NOTE: The UI LCD Module is only replacable on a machine with TAG 082.
CAUTION
WARNING
1.
2.
3.
Remove the UI Processor PWB (REP 02-2).
4.
Remove the UI LCD Module (Figure 1).
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REP 02-3
UI Processor PWB
(removed)
Lift out the UI LCD Module.
Figure 1 Removal
Replacement
1.
Install the UI LCD Module (Figure 2).
2.
Reinstall the UI Processor PWB (REP 02-2).

NOTE: Remember to reinstall the Rotator PWB onto the UI Processor PWB (REP 02-2)
3.
Reinstall the User Interface Assembly (REP 02-1).
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UI Processor PWB
(removed)
Position the UI LCD Module.
Figure 2 Installation
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REP 02-3
REP 02-4 UI Software Upload
13. Select [OK].

14. Select [Upload].
UI Software Upload
If the software level of the new UI or new UI Processor PWB does not match the machine software level, or if the customer requires a non-default language set, upload to the UI the correct
software level and language set, using the appropriate Software Upgrade Kit. You may use
either the Software Upgrade Kit Instructions or the following UI Software Upload procedure:
1.
Place the UI in the Software Download Mode:

a.
If the machine power is on, switch off the machine power and wait at least 20 seconds.
b.
Press and hold the [C] and [#] buttons simultaneously, and switch on the machine
power. Wait ten seconds, then release the [C] and [#] buttons.
2.
Connect the PWS parallel cable to the parallel connector on the laptop and to the
machine parallel cable connection. Also, ensure the PWS serial cable is connected to the
serial connector on the laptop and the to the machine serial cable connection.
3.
In the Diagnostics Navigator, select the [Configuration] tab, then select [Software
Upgrade].
4.
The Choose Upgrade Type dialog box appears. Select [Manual].
5.
Under Platforms, select [UI].
6.
Select [Source], then select the CD ROM drive ([G:\]).
7.
Obtain the machine software CD-ROM from the Software Upgrade Kit.
8.
Read the following steps, up through and including inserting the EDOC CD-ROM back
into the PWS CD-ROM drive, and record those steps necessary to work from hardcopy
during the software upload process.
NOTE: The UI software upload will take at least 18 minutes. As long as the upload is progressing as described below, do not intervene until the third event has occurred, indicating the upload is complete.
15. After a few seconds you should begin to observe three stages in sequence:
a.
During approximately the first three minutes, the machine will go into quiescent
(quiet) state wherein the ROS stops spinning. The UI will show a horizontal gas
gauge display (a box with legs, like a rectangular centipede), which is empty during
this first stage. The Status window on the PWS will first display a message that it is
waiting for the machine to enter download mode. After approximately 60 seconds the
Percent Complete/Blocks Completed box at the bottom of the Software Upgrade
Wizard window starts to fill with an advancing blue bar, at which time the Status window on the PWS indicates that it is copying files to the Main Controller.
b.
Approximately three minutes after the start of file transfer, the machine UI display
begins to increment from left to right, then from bottom to top. (This UI display may
blink and restart several times during the upload -- this is normal.) A short time later,
the file transfer begins from the Main Control PWB (Atlanta) to the UI. The PWS Status window will display Transferring file to UI and Bank 1, then Bank 2, and so on,
up to Bank 5.
c.
When the upload has completed, the Platforms Upgraded window on the PWS displays User Interface Upgrade Complete. A short time later, the normal machine
sounds will resume (the ROS resumes spinning). The PWS may lose communications with the machine briefly and then reestablish communications.
NOTE: You will not have access to this EDOC procedure while the EDOC CD-ROM is
removed and the machine software CD-ROM is inserted into the PWS CD-ROM drive.
Again, you can use the Software Upgrade Kit Instructions instead.
9.
Remove the EDOC CD-ROM from the CD-ROM drive of the PWS and insert the Digital
Copier Software CD-ROM, included in the Software Upgrade Kit.
10. Open (double-click) the directory: [g:\inst\], then open the directory corresponding to the
machine's current software level.
11. Select the UI directory, then select the directory corresponding to the correct language
set.
NOTE: If a dialog box appears, warning of a Software Version Mismatch, select

[OK].
The Upgrade Wizard window disappears and the Diagnostics Navigator window
reappears.
16. Remove the machine software CD-ROM from the CD-ROM drive of the laptop and insert
the EDOC CD-ROM.
17. [Exit] Diagnostics Navigator.
18. Disconnect the parallel cable at both ends.
NOTE: The language sets are as follows:
19. Switch off the machine power using the red button inside the front door, and wait at least
20 seconds.
Language set 01: UK English, French, German, Dutch, Italian
20. Switch on the machine power.
Language set 02: UK English, Norwegian, Finnish, Swedish, Danish
21. Launch the Diagnostic Navigator.
Language set 03: UK English, Spanish, Italian, Portuguese, Greek
22. Verify the UI software version and language set:
Language set 04: UK English, Russian
a.
Language set 05 (for North America and South America): US English, Spanish,
South American Portuguese, French
In the Diagnostic Navigator, select the [Configuration] tab, then select [System,
Imaging, and IOT Configuration].
b.
Language set 07: Japanese, US English
In the System, Imaging, and IOT Configuration window, select the [Software] tab,
and verify that the software version shown for the [UI] matches the correct version for
the machine's software level, listed in Table 1 or in the Software Upgrade Kit Instructions.
Language set 08: Chinese, UK English
Language set 09: Korean, UK English
Language set 10: Czech, Polish, Hungarian, Romanian
12. Select the file spuXXXXX.sre, where XXXXX corresponds to the software version.
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c.
Press the [Language] button on the UI control panel, and verify that the desired languages are available.
Table 1 UI Software Versions

Release
UI Version
07.19.05.026
0.019.05.024
07.19.04.039
0.019.04.037
07.19.04.038
0.019.04.037
07.19.02.503
0.019.02.503
07.19.02.051
0.019.02.049
07.19.01.504
0.019.01.504
7.02 (L0.19.0.56)
0.019.00.056
7.01 (L0.19.0.28)
0.019.00.027
7.00 (L0.19.0.27)
0.019.00.027
6.08 (L0.18.6.07)
0.018.06.004
6.04 (L0.18.1.24)
0.018.01.025
6.03 (L0.18.1.24)
0.018.01.024
5.22 (L0.17.9.32)
0.017.09.032
5.18 (L0.17.8.67)
0.017.08.066
5.11 (L0.17.8.67)
0.017.08.066
5.08 (L0.17.8.65)
0.017.08.065
5.07 (L0.17.8.64)
0.017.08.063
5.06 (L0.17.8.12)
0.017.08.005
5.05 (L0.17.6)
0.017.06.005
5.03 (L0.17.5)
0.017.05.007
5.01 (L0.17.4)
0.017.04.010
5.00 (L0.17.3)
0.017.03.008
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REP 03-1 SCAM PWB

Removal
CAUTION
WARNING
1.
2.
Remove the Top Rear Cover from the IOT.
3.
Disconnect the connectors from the SCAM PWB (Figure 1).
4.
a.
Disconnect the connectors from J1, J2, and J3 along the top of the SCAM PWB.
b.
Disconnect the connectors from J4 and J5 along the right side of the SCAM PWB
(as viewed from the rear).
c.
Disconnect any connectors from J8, J7, and J6 along the bottom of the SCAM PWB.
d.
Disconnect any connectors from J10, J9, and J11 along the left side of the SCAM
PWB (as viewed from the rear).
Remove the SCAM PWB.

a.
Unsnap the SCAM PWB from the top supports (2).
b.
Lift the SCAM PWB from the bottom supports and remove it.
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REP 03-1
J1
J2
J3
J4
J10
J9
J11
J5
J8
J7
J6
Figure 1 Connectors
Replacement
REP 03-1
If replacing the SCAM PWB with a MSCAM PWB (160K72972 or higher), mark off TAG 108 on
the IOT Change/Tag Matrix (if not already marked off).
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REP 03-2 IPS1 Daughter PWB (240/255/265 Only)

Parts List on PL 1.4A (w/o Tag 077), PL 1.4B (with Tag 077)
Removal
WARNING
CAUTION
CAUTION
Do not install the Electronic Hole Removal PWB that is designed for an Atlanta Gold Main Control PWB onto an Atlanta Platinum Main Control PWB (with TAG 077 and TAG 296).
Do not install the Electronic Hole Removal PWB that is designed for an Atlanta Platinum Main
Control PWB onto an Atlanta Gold Main Control PWB (with TAG 015 and TAG 296, without
TAG 077).
Do not install the Autosegmentation PWB, which is designed for an Atlanta 96 Main Control
PWB only, onto an Atlanta Gold or Platinum Main Control PWB (with TAG 015 or TAG 077).
NOTE: The IPS1 Daughter PWB can be an Autosegmentation PWB (without TAG 015 only), or
an Electronic Hole Removal PWB (with TAG 015 and TAG 296, or with TAG 077 and TAG 296).
1.
2.
Remove the following from the IOT:
3.
a.
Top Rear Cover
b.
Left Rear Cover (on the right as viewed from the rear)
c.
Cardcage Cover
Remove the IPS1 Daughter PWB
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REP 03-2
Replacement
CAUTION
Be sure to position the upper left corner of the IPS1 PWB between the two Card Cage tabs
(Figure 1). Whereas the other three corners are each aligned by a standoff, the upper left corner of the PWB is aligned between the two Card Cage tabs.
CAUTION
Be sure to seat the daughter PWB connectors securely against the Main Control PWB by
pressing on the rear of the connectors (Figure 1).
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Press firmly in these two

locations to seat the IPS1
PWB connector.
Card Cage tabs (2)
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REP 03-2
REP 03-3 Accessory PWB

Parts List on PL 1.4A (w/o Tag 077), PL 1.4B (240/255/265 with Tag
077), PL 1.4C (460/470)
Removal
CAUTION
WARNING
1.
2.

a.
Top Rear Cover
b.
Left Rear Cover
c.
Right Rear Cover
3.
(240/255/265): Remove the rear (Main Control PWB side) Cardcage Cover
4.
(460/470): Remove the Main Card Cage Cover:

a.
Swing out the card cage (two T20 latches).
b.
Prepare to remove the Main Card Cage Cover (Figure 1).
c.
Remove the Main Card Cage Cover (Figure 2).
5.
Remove the Accessory PWB.
6.
XE (formerly RX) machines only: If replacing the Accessory PWB with a new one,
remove the Nationalization Chip from the old PWB, to be reused on the new PWB.
NOTE: DMO (formerly AO) 220V machines use the non-XE Accessory PWB.
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2
Disconnect the video cable from the card cage, and free
the video cable from its restraints on the fan housing.
1
Remove the video connector
cover (two T20 hex-head screws).
4
Disconnect the fan
connector.
3
Remove the T20 roundhead screw.
6
5
Remove the T20

hex-head screw.
Remove the T20 flat-head

screws (3). Repeat for the other
side of the card cage.
Figure 1 Prepare to Remove the Card Cage Cover
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REP 03-3
b.
Set the Accessory PWB Dip Switches correctly for the nationality of the machine
(see Product Specifications ).
2.
Install the Accessory PWB (Figure 3 for 240/255/265; Figure 4 for 460/470).
3.
Ensure that the Accessory PWB connector to the Main Control PWB is seated firmly (Figure 5 for 240/255/265; Figure 6 for 460/470).
Slide the cover out slightly, lift slightly,

and then slide it out the rest of the way.
1
Insert the PWB at an
angle.
Figure 2 Remove the Card Cage Cover
2
Pivot the PWB
inward.
Replacement
CAUTION
Be sure to seat the Accessory PWB connector securely against the Main Control PWB by
pressing on the rear of the connector.
1.
XE (formerly RX) machines only: If replacing the Accessory PWB with a new one, perform the following:
Figure 3 Installation -- 240/255/265
NOTE: DMO (formerly AO) 220V machines use the non-XE Accessory PWB.
a.
Reinstall the Nationalization Chip on the new PWB.
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Install the
PWB onto
the four
standoffs.
Figure 4 Installation -- 460/470
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REP 03-3
Press firmly in these two

locations to seat the Accessory PWB connector.
Figure 5 Seat the PWB -- 240/255/265
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Press firmly in
these two locations to seat
the Accessory
PWB connector.
Figure 6 Seat the PWB -- 460/470
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REP 03-3
REP 03-4 Main Control PWB (Atlanta '96-to-'96 or Gold-toGold) (without Tag 077)
Removal
WARNING
4.
NOTE: Use this procedure only if replacing an Atlanta96 or Atlanta Gold Main Control PWB
with the same type, i.e. (without TAG 015) if replacing an Atlanta '96 with another Atlanta '96 or
(with TAG 015) if replacing an Atlanta Gold with another Atlanta Gold. If replacing an Atlanta
'96 with an Atlanta Gold (upgrading to TAG 015), or if replacing an Atlanta 96 or Atlanta Gold
with an Atlanta Platinum (upgrading to TAG 077), you must order the appropriate Upgrade Kit
(PL 1.4A) and follow the instructions provided in that kit. If replacing an Atlanta Platinum (with
TAG 077) with another Atlanta Platinum, go to REP 03-11.
5.

a.
Top Rear Cover
b.
Left Rear Cover
c.
Right Rear Cover
d.
Connector Panel (lower center rear cover: remove four T20 screws)
Remove the Card Cage:

a.
b.
Disconnect the following connectors (at the Card Cage unless otherwise specified,
and freeing harnesses from cable clips as necessary):
CAUTION
Scanner video cable (remove cover first -- two T20 screws)
Fan connector P/J 98 (in-line)

ROS video cable
CAUTION
PWS cable (slide the clip down)
You must identify the current software level in the machine and on the new Main Control PWB,
and if the software levels are different then obtain the appropriate Software Upgrade Kit. If the
machine and new PWB software levels are different, software must be uploaded onto the new
PWB after the PWB replacement, to restore the machine operation.
NOTE: In all cases, this procedure has you restore the machine operation at the same level of
software as was already in the machine before the Main Control PWB replacement. You will
upload software onto the new PWB if necessary, to match the level of software already in the
machine; you will not upgrade or downgrade the machine software to match the software
level on the new PWB.
1.
2.
Determine the current software level in the machine and on the new Main Control PWB,
and obtain the appropriate Software Upgrade Kit if necessary.
Orange power harness -- disconnect at LVPS P42/J2 and P43/J3

Ground strap -- disconnect faston at IOT frame
6.
7.
c.
Unsnap and remove the fan/duct unit from the top of the Card Cage.
d.
Lift the Card Cage off of the hinge pins.
Remove the Card Cage covers.

a.
Front and rear covers: Loosen two T20 screws on top for each cover.
b.
Side connector plate (on the left side of the Card Cage as viewed from the rear, Main
Control PWB side: Loosen two T20 screws on top and two on the bottom)
Remove the following from the Main Control PWB:
CAUTION
a.
Accessory PWB (REP 03-3)
b.
(Without TAG 015) Auto Segmentation PWB (IPS1 Daughter PWB, REP 03-2)
c.
(With TAG 296) Electronic Hole Removal PWB (IPS1 Daughter PWB, REP 03-2)
a.
d.
Rotation SRAM SIMM (REP 03-5)
e.
EPC DRAM SIMMs (1 or 2) (REP 03-6).
b.
Identify the software level on the new Main Control PWB, by the labels on the Flash
chips near the lower right corner of the PWB (Figure 1 for Atlanta '96, or Figure 2 for
Atlanta Gold, TAG 015).
NOTE: You will reuse the NVM RAM Chip from the old PWB. However, leave the chip on
the old PWB for now, for safekeeping, until you are instructed later to transfer the chip to
the new PWB.
c.
If the new PWB's software level does not match that already in the machine, obtain
the Software Upgrade Kit for the level of software already in the machine.
If possible, save the NVM to Floppy (GP4), naming the file so as to identify the software
level (e.g. 1_0.nsf for Version 1.0).
NOTE: If an NVM download is not possible, inform the customer that any recent Tools
settings (entered since the last NVM download) will need to be reentered after the service
call.
3.
Ribbon cable (copper-shielded) -- disconnect at Distribution PWB J5
8.
Disconnect the connectors from the Main Control PWB (Figure 3).
CAUTION
Without TAG 015 only: If you are replacing an Atlanta '96 Main Control PWB with another
Atlanta '96, take care to save and reuse the mica washers on the two screws in the center of
the PWB.
9.
Remove the Main Control PWB (Figure 4).
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Atlanta '96:
Software level
printed on Flash
Chip label. Example shown: L0.15.3
Figure 1 Manufactured Software Level -- Atlanta 96
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REP 03-4
Atlanta Gold:
Software level printed on Flash Chip label.

Example shown: L0.15.3
Figure 2 Manufactured Software Level -- Atlanta Gold
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2
Remove metal cover
(two T20 screws) and
disconnect the connector from J14.
1
Disconnect Image Disk
4
(FX Only):
Disconnect
EPSV
3
Disconnect connectors from J6,
J7, and J13.
Figure 3 Connectors
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REP 03-4
3
Remove the PWB from
the standoffs and slide it
out of the Card Cage.
1
Remove the T20
screws (5).
2
Without TAG 015:
Remove the T20
screws (2).
Atlanta '96 Only:

mica washers (2)
(see CAUTION)
Figure 4 Screws
Replacement
NOTE: The new PWB may have a small metal EME shield on the ROS video connector,
and this shield may fall off easily. Ensure that this shield is in place when the new PWB is
installed.
CAUTION
This procedure assumes that the new Main Control PWB does not have an NVM RAM Chip
installed. If an NVM RAM Chip is presently installed on the new PWB, remove the chip (REP
03-7).
CAUTION
a.
Slide the PWB into the cardcage and position the right-edge connectors into the side
of the cardcage.
b.
Position the PWB onto the standoffs and reinstall the T20 screws (7 screws for
Atlanta 96, 5 screws for Atlanta Gold).
If the new PWB is an Atlanta Gold, be sure to set the jumper for the correct processing speed
according to the following step, to ensure that machine will function properly.
1.
(With TAG 015): Set the jumper on the new PWB for the correct processing speed (Figure 5).
NOTE: If this jumper is missing from the new PWB, you may reuse the jumper from the
old PWB.
2.
Install the Main Control PWB.
REP 03-4
CAUTION
Without TAG 015 only: When replacing an Atlanta '96 Main Control PWB with another
Atlanta '96, be sure to reinstall the mica washers on the two screws in the center of the PWB.
Otherwise, damage to the Main control PWB may result.
c.
Reconnect all connectors to the Main Control PWB.
3.
Reinstall all Card Cage covers except the rear, (Main Control PWB side) cover.
4.
Reinstall the following:
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CAUTION
c.
Select the file asy****.sre (where **** indicates the desired software level), and
select [OK].
d.
In the Software Upload window, select [Upload], and note the time at which you are
starting the upload.
e.
Wait until the upload is complete before proceeding:
Do not install the NVM RAM Chip until instructed to do so later.

a.
b.
5.
Reinstall the Card Cage in the reverse order of removal.
6.
(Without TAG 015): Reinstall the Auto Segmentation PWB (IPS1 Daughter PWB, REP
03-2)
7.
If you are certain that the new Main Control PWB has the same level software as was
already in the machine as determined earlier, skip the Manual IOT Software Upload and
go to Final Steps After the Main Control PWB Replacement, below.
CAUTION
Be sure to wait at least the length of time specified below, to ensure that the software
upload has time to complete.
After approximately ten minutes the PWS should indicate IOT Upgrade Complete , then you must wait at least 20 seconds longer.
If there is no feedback on the PWS indicating that the upload is complete (normal with some software releases), wait at least 15 minutes from the start of the
upload.
Manual IOT Software Upload

NOTE: This Manual IOT Software Upload section is only required if the new Main Control PWB
does not have the same level software as was already in the machine as determined earlier.
f.
CAUTION
g.
On the PWS, [Exit] Diagnostic Navigator and close the current session.
h.
Remove the machine software CD-ROM and insert the EDOC CD-ROM back into
the PWS CD-ROM drive.
Ensure that the front door is open and the interlock switch is not cheated.
CAUTION
10. Disconnect the parallel cable and connect the serial cable.
Ignore the machine UI during the manual software upload.
Final Steps After the Main Control PWB Replacement
1.
2.
Ensure that the PWS Diagnostics is set to the same software level as was already in the
machine. (If necessary, exit Session Manager and use the Multiple Version Handler to
switch versions.)
1.
Remove the NVM RAM Chip from the old Main Control PWB (REP 03-7).
2.
Install the NVM RAM Chip onto the new Main Control PWB. Perform only the Physical
Installation steps of REP 03-7 Replacement at this time, then return here.
3.
Connect the parallel cable (but not the serial cable -- disconnect the serial cable, if connected).
3.
Reinstall the Accessory PWB (REP 03-3).
4.
Open Diagnostic Navigator in Standalone mode.
5.
Select the [Configuration] tab, select [Software Upgrade], and select [Manual] (not Wizard), for the upgrade type.
4.
6.
In the Software Upgrade window, deselect [Automated Mode] (ensure that [Automated
Mode] is not selected).
7.
8.
Record the following step, up through and including inserting the EDOC CD-ROM
back into the PWS CD-ROM drive, to enable reading from hardcopy or Notepad during
the software upload process.
Record the entire next numbered step: Either write it down; or select the text in the
Browser, copy it (CTRL-C), open a blank Notepad text document, and paste the text
(CTRL-V) into the Notepad document. (In Notepad, select the Edit menu and select
Word Wrap to ensure that the text is easily readable.)
9.
CAUTION
NOTE: If the Auto Configuration detects that Remote Data Transfer has become disabled,
do not accept the configuration change. Instead, switch off the machine power and check
that the Accessory PWB is seated securely on the Main Control PWB.
NOTE: (With TAG 015): Accept an EPSV configuration error in all market regions except
FX.
5.
6.
Perform the software upload from the machine software CD-ROM:

a.
Remove the EDOC CD-ROM from the PWS CD-ROM drive and insert the machine
software CD-ROM.
b.
On the PWS, in the Software Upgrade window, select [Main Controller], select
[Source...], and navigate to the directory g:\inst\**_**\scs\ (where **_** indicates
the desired software level).
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If a Manual IOT Software Upload was performed, do the following:

a.
Reselect the previous session in Session Manager.
b.
Open Diagnostic Navigator in Local mode.
If a Manual IOT Software Upload was performed, verify the IOT checksums:
a.
Enter [Configuration tab , System, Imaging, and IOT Configuration].
b.
Select the [Software] tab
c.
Double-click on [SCS] to reveal the IOT checksums.
d.
Verify the checksums displayed against those listed in Product Specifications : IOT
Software Checksums , or in the Software Upgrade instructions if later than the software levels shown. If the checksums do not agree with those for the desired IOT
software level, go to 03-J Checksum Error RAP.
REP 03-4
NOTE: If the NVM appears to have been corrupted by the failed Main Control PWB, performing the Required Steps After NVM RAM Chip Replacement in (REP 03-7) may
restore the NVM to an operable state.
7.
If the NVM appears to have been corrupted by the failed Main Control PWB, perform the
Required Steps After NVM RAM Chip Replacement in (REP 03-7).
8.
Switch off the machine power, wait at least 20 seconds, and switch on the machine power.
9.
Reinstall the remaining components in the reverse order of removal.
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Set the jumper across pins 1 and 2 (F2 setting) for 65

ppm or 55 ppm. Set the jumper across pins 2 and 3
(F1 setting) for 40 ppm. Example shown: F1 (40
ppm).
Figure 5 55 ppm Jumper -- Atlanta Gold
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REP 03-4
REP 03-5 Rotation SRAM SIMM (without Tag 077)

Removal
CAUTION
WARNING
1.
2.
3.
a.
Top Rear Cover
b.
c.
Cardcage Cover
1
Gently press the
clips outward until
the SIMM tilts in
the socket.
Remove the Rotation SRAM SIMM (Figure 1).
2
Grasp the SIMM
by the edges.
3
Remove the
SIMM. Observe
the correct orientation for later installation.
Figure 1 Removal
REP 03-5
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REP 03-6 EPC DRAM SIMM (without Tag 077)
Replacement
CAUTION
Ensure that the SIMM is fully inserted, with both clips snapped into position. Applying power to
the machine with a SIMM partly-installed can destroy the SIMM or cause other machine damage.
Orient the SIMM with the notched corner downward when reinstalling it.

Removal
NOTE: If the customer wishes to upgrade their RAM, they must order the upgrade kit through
Sales and that kit includes CSE instructions for performing the upgrade. However, instructions
are included here to enable increasing RAM as a troubleshooting tool.
CAUTION
1.
If upgrading RAM: Place the machine into Manufacturing mode so that it will accept the
configuration change:
a.
Go to [Configuration tab , System, Imaging, and IOT Configuration].
b.
Select the [System] tab.
c.
Under Install Phase, pull down the menu and select [Manufacturing] (two places for
L0.17 or higher software).
d.
Select [Apply] and select [OK].
WARNING
2.
3.
a.
Top Rear Cover
b.
c.
Cardcage Cover
4.
If a SIMM is installed in the EPC DRAM 2 socket, remove the Rotation SRAM SIMM (REP
03-5) to gain clearance for removing and installing the EPC DRAM SIMM(s).
5.
Remove the EPC DRAM SIMM(s) (Figure 1).

a.
Remove the SIMM from the EPC DRAM 2 slot (if present).
b.
Remove the SIMM from the EPC DRAM 1 slot (if present).
NOTE: Either one or two EPC DRAM SIMMs can be installed. Figure 1 shows a SIMM in
the EPC DRAM 2 slot for clarity, which is the first SIMM to remove if there are two EPC
DRAM SIMMs. The same method is used for the SIMM in EPC DRAM 1 after the SIMM
is removed from EPC DRAM 2 (if present).
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REP 03-5, REP 03-6
Replacement
CAUTION
Ensure that the SIMM is fully inserted, with both clips snapped into position. Applying power to
the machine with a SIMM partly-installed can destroy the SIMM or cause other machine damage.
1
Gently press the
clips outward until
the SIMM tilts in
the socket.
1.
Install the EPC DRAM SIMM(s) in the reverse order of Removal, starting with the EPC
DRAM 1 slot. Orient each SIMM with the notched corner downward.
NOTE: A single SIMM will function the same in either slot, but EPC DRAM 1 is recommended.
2.
Install the remaining components in the reverse order of Removal.
3.
If upgrading RAM: Place the machine back into Install Complete mode.
a.
b.
c.
Under Install Phase, pull down the menu and select [Install Complete] (two places for
d.
e.
Switch off the machine power, wait 20 seconds, then switch on the machine power.
2
Grasp the SIMM
by the edges.
3
Remove the
SIMM. Observe
the correct orientation for later installation.
Figure 1 Removal
REP 03-6
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REP 03-7 NVM RAM Chip (without Tag 077)
NOTE: If replacing the NVM RAM Chip with a new one and an NVM download is not possible, inform the customer that any recent Tools settings (entered since the last NVM
download) will need to be reentered after the service call.

Removal
5.
CAUTION
Do not return as new, or reuse in any other machine, any NVM RAM Chip which has been
installed in any machine. Once the NVM RAM Chip is installed and the machine power
switched on, the chip is no longer new -- it is automatically initialized by the machine software and cannot be used again as a "virgin" chip.
WARNING
6.
CAUTION
a.
Top Rear Cover
b.
NOTE: If replacing the NVM RAM Chip with a new one, the NVM values must be restored from
the MRD afterward. However, all counters and Auditron information will be lost because, for
legal reasons, they cannot be copied as part of the NVM download or saved to the MRD. Also,
the machine serial number and time and date will be lost from machine memory and will need
to be reentered afterward using the PWS.
7.
NOTE: Windows '95 PWS, 55 ppm machine ONLY: You must have loaded PWS software
version L0.17.8.67 or higher, to use during this procedure (in addition to the version corresponding to the machine software). Otherwise, the PWS may be unable to communicate with
the machine after the NVM RAM Chip is installed, and you may be unable to restore machine
operation with the new chip installed.
NOTE: Passwords/Confirmation Codes Required: If replacing the NVM RAM Chip with a
new one on a non-FSMA service plan ("Sold" CRUs) machine, this procedure requires that a
protected NVM settings (Service Plan) be restored after replacing the NVM RAM Chip. The
PWS will be prompt you to obtain the necessary confirmation code for the Service Plan setting
during this procedure on a "Sold" machine. When prompted, contact Field Engineering to
obtain the confirmation code.
1.
Rear Cardcage Cover
d.
(With TAG 015): Accessory PWB (REP 03-3)
Remove the NVM RAM Chip.

CAUTION
(Without TAG 015): Note the position of the NVM Chip in the socket: The chip is biased
to the bottom of the socket so that pin 1 of the chip is in hole 3 of the socket.
a.
(Without TAG 015): See Figure 1.

CAUTION
(With TAG 015): Use only the correct NVM Replacement Tool for replacing the NVM
Chip. If you attempt to use any other tool such as a screwdriver, you will damage the
NVM Chip Socket and necessitate replacing the Main Control PWB. Also be sure to note
the orientation of the chip for correct reinstallation
b.
(With TAG 015): See Figure 2.
If possible, record all Billing Counter readings.

a.
Press the [Machine Status] hard button on the control panel.
b.
Select [Billing Counters] on the touch screen.
c.
Record all Billing Counter readings from the UI display.
d.
Select [Close].
2.
If possible, record any Auditron account information. If this is not possible, inform the customer that they will need to reenter this information after the service call.
3.
Check whether the machine is set for a "Sold (A)" Service Plan:
4.
c.
a.
In the Diagnostic Navigator window, select the [Configuration] tab.
b.
Select [CRU's].
c.
Select the [CRU Management] tab, and note the Service Plan setting. If the Service
Plan is set to "Sold (A)," then you will be instructed to obtain and enter a confirmation
code from Field Engineering later, in order to restore this setting.
d.
Select [Cancel].
level (e.g. 1_0.bnf for Version 1.0).
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REP 03-7
ATLANTA '96:
1
Disconnect this
connector to
gain clearance.
2
Remove the
NVM RAM Chip.
Figure 1 Removal -- Atlanta 96
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ATLANTA GOLD:
Remove the
NVM RAM Chip.
Figure 2 Removal -- Atlanta Gold
Replacement
CAUTION
(Without TAG 015): When installing the NVM chip, be careful not to bend the pins. Also
remember to install the NVM Chip in the position noted earlier: The chip must be at the bottom
of the socket so that pin 1 is in hole 3 of the socket (the top four holes are left empty).
CAUTION
(With TAG 015): Be sure to orient the NVM chip correctly, with the beveled (slanted) edge to
the right, even though the lettering on the chip may be upside down. Also, use the correct
technique for installing the chip, avoiding excessive force which can damage the chip and the
Main Control PWB.
1.
2.
Install the NVM RAM Chip

a.
(Without TAG 015): See Figure 4.
b.
(With TAG 015): See Figure 3.
If you are reinstalling the same NVM RAM Chip removed earlier, this procedure is now
complete.
Otherwise, continue.
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REP 03-7
ATLANTA GOLD:
Install the NVM RAM Chip with
this beveled edge to the right,
as viewed from the rear of the
IOT. (The bevel, or slanted
edge, is represented here by
diagonal lines).
Figure 3 Installation -- Atlanta Gold
Required Steps After NVM RAM Chip Replacement

NOTE: The remaining steps apply only if you are replacing the NVM RAM Chip with a new
(virgin) chip.
e.
When the [Switch to Version] button is grayed out, select [Exit].
f.
Open Session Manager or Case Server, and launch Diagnostic Navigator.

NOTE: The PWS may display a software version mismatch later. This mismatch will
not affect the tasks required in this procedure - select [OK] to dismiss the message.
CAUTION
CAUTION
Windows '95 PWS, 55 ppm machine ONLY: You must use PWS software version L0.17.6,
L0.17.8.66, or L0.18.1.13 or higher when first switching on the machine after replacing the
NVM RAM Chip. Otherwise, the PWS may be unable to communicate with the machine after
the 128K NVM RAM Chip is installed, and you may be unable to restore machine operation
with the new chip installed.
You must pull out the Xerographic Module and Fuser before switching on the machine power,
after replacing the NVM RAM Chip. Otherwise the machine may falsely declare the end-of-life
for either CRU, requiring that it be replaced.
2.
Pull out the Xerographic Module and Fuser.
1.
3.
Windows '95 PWS, 55 ppm machine ONLY: Switch the PWS Diagnostics to L0.17.6,
L0.17.8.66, or L0.18.1.13 or higher, using Multiple Version Handler:
a.
[Exit] Diagnostic Navigator, and close Session Manager or Case Server.
b.
Open the appropriate version of Multiple Version Handler.
c.
Under the heading "Available Versions, Install Paths," select PWS version L0.17.6,
L0.17.8.66, or L0.18.1.13 or higher.
d.
Select [Switch to Version].
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May 2003
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NOTE: When the machine power is switched on with a new (virgin) NVM RAM Chip
installed, it automatically switches from Install Complete phase to Manufacturing phase.
The PWS will therefore display a message indicating that installation is not complete.
Select [OK] to dismiss this message. The NVM upload, done later, will switch the machine
back to Install Complete phase.
CAUTION
Ignore any UI message to switch off the machine power during this phase of the upgrade. Do
not switch off the machine power until after restoring the NVM later, as directed in these
instructions. Until then, the Main Control PWB will not communicate with the UI, and the UI displays only the Document Centre screen with a series of dots at the top, followed by a false
message to switch off the machine power -- ignore this message.
CAUTION
Select [OK] to dismiss the PWS messages indicating that installation has not been completed,
but do not change the Install Phase at this time. When the machine was switched on with a
new (virgin) NVM RAM Chip installed, it defaulted to Manufacturing phase in order to temporarily accept the configuration mismatches associated with the other default NVM. The
machine will return to Install Complete phase when the NVM is restored later.
7.
b.
Open the appropriate version of Multiple Version Handler.
c.
Under the heading "Available Versions, Install Paths," select the PWS version corresponding to the machine software version.
d.
Select [Switch to Version].
e.
When the [Switch to Version] button is grayed out, select [Exit].
f.
Open Session Manager or Case Server and launch Diagnostics Navigator.
If this is a "Sold (A)" service plan machine: Contact Field Engineering and obtain the
confirmation code for Non-FSMA ("Sold" CRUs) service plan.
CAUTION
Select [OK] to dismiss the PWS messages indicating that installation has not been completed,
but do not change the Install Phase at this time.
8.
Non-FSMA ("Sold" CRUs) machine only: Restore the Service Plan setting to the
machine memory:
a.
Enter [Configuration tab , CRUs].
b.
Select the [CRU Management] tab.
c.
Under Service Plan, select [Sold (A)] from the pull-down menu.
CAUTION
d.
Do not proceed to enter information or restore NVM until the machine is ready, as indicated
below
In the Confirmation Code box that appears, enter the confirmation code obtained
from Field Engineering.
e.
Select [Apply].
4.
f.
Select [OK]. The machine will reset.
Observe the PWS attempting to establish communication with the machine as the
machine initializes the new NVM RAM Chip. The PWS will lose and then reestablish communication with the machine. Wait until the PWS-machine communication is stable (1-3
minutes after you switched on the machine power) before proceeding to the next step.
OR
If the PWS fails to establish stable communication with the machine after 3 minutes, or if it
displays a message, "Unable to read machine configuration," do the following: Switch off
the machine power, wait at least 20 seconds, and switch on the machine power. The PWS
should then establish stable communication with the machine, and you may proceed as
follows.
9.
Restore the machine NVM from the machine resident diskette file (GP4).
10. Reinsert the Xerographic Module and the Fuser.

11. Restore the Market Region and serial numbers to the machine memory, and reset the
machine time and date:
a.
b.
In the System tab, ensure that the Market Region is set correctly.
c.
Select [Apply]
d.
Select the [Serial Numbers] tab.

Enter the "System" (IOT) Serial Number and any options' serial numbers.
CAUTION
e.
You must reenter certain settings as follows, and then upload the NVM from the MRD, in order
to restore the machine operation.
f.
Select [Apply].
g.
Select the [Time] tab.
5.
Restore the Product Type:
h.
Enter the current time and date.
a.
i.
Select [Apply].
b.
In the System tab, ensure that the Product Type (40/55/65 ppm) are set correctly.
j.
EXCEPT:
12. Reset the Machine Administrator password back to the default (1111):
55 ppm machine only: Switch the Product Type to [65 ppm] and select [Apply] and
[OK] (the machine should reset - if not, switch the power off and on). Re-enter [System, Imaging, and IOT Configuration], and switch the Product type to [65 ppm] a second time. (This has to be done twice, to ensure that the 55 ppm setting takes full
effect).
6.
a.
Select the [Copier Sys] tab in Diagnostic Navigator.
b.
Select [Reset Administrator PIN].
c.
Select [Start], and answer [Yes] to the prompt.
d.
Select [Exit].
c.
Select [Apply]
13. [Exit] Diagnostic Navigator, and close Session Manager or Case Server.
d.
14. Switch off the machine power: Try the white On/Off switch first; then, only if the machine
does not respond at all within 3 minutes, use the red button.
Windows '95 PWS, 55 ppm machine ONLY: Switch the PWS Diagnostics version back
to correspond with the machine software version, using Multiple Version Handler:
a.
[Exit] Diagnostic Navigator, and close Session Manager or Case Server.
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15. Wait at least 20 seconds after the machine shuts down, and then switch on the machine
power. The machine should now cycle up normally, with the normal display on the UI.
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REP 03-7
16. Initialize the Auditron settings:

a.
Enter the Tools pathway on the UI.
b.
Select [Auditron and Access Administration] (if present), OR select [Access and
Accounting] and then [Internal Auditron Setup].
c.
Select [Auditron Initialization].
d.
Select [Initialize Auditron], and select [Confirm] (maybe twice) to accept the confirmation.
e.
Select [Close], then [Exit Tools].
ATLANTA '96:
NOTE: NVM RAM

Chip must be installed
with pin 1 in hole 3.
17. If possible, restore any Auditron account information.

18. When closing the call, be sure to report that the Billing Counters were reset (GP17).
19. If replacing the NVM RAM Chip as part of an Atlanta '96-to-Gold upgrade, return to
those instructions now.
2
Reconnect this connector to the Main
Control PWB.
1
Install the NVM RAM
Chip, with the bottom
pins in the bottom
holes of the socket.
Figure 4 Installation -- Atlanta 96
REP 03-7
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REP 03-8 Main Control PWB: Upgrade from Atlanta '96

(without Tag 015) to Atlanta Gold (Installing Tag 015)
NOTE: In all cases, this procedure has you restore the machine operation at the same level of
software as was already in the machine before the Main Control PWB replacement. You will
upload software onto the new PWB if necessary, to match the level of software already in the
level on the new PWB.

Removal
CAUTION
CAUTION
This procedure is provided here only as a backup to the Kit Installation Instructions provided in
the Atlanta '96 to Atlanta Gold Main Control PWB Upgrade Kit -- if possible, use those Kit
Installation Instructions instead. That kit includes parts which are required, in addition to the
Main Control PWB, when replacing an Atlanta '96 Main Control PWB with an Atlanta Gold.
CAUTION
Do not return as new, or reuse in any other machine, any NVM RAM Chip which has been
installed in any machine. Once the NVM RAM Chip is installed and the machine power
switched on, the chip is no longer new -- it is automatically initialized by the machine software and cannot be used again as a "virgin" chip.
NOTE: Use this procedure only if replacing an Atlanta '96 with an Atlanta Gold, upgrading to
TAG 015.
CAUTION
You must identify the current software level in the machine and on the new Main Control PWB,
and if the software levels are different then obtain the appropriate Software Upgrade Kit. If the
machine and new PWB software levels are different, software must be uploaded onto the new
PWB after the PWB replacement, to restore the machine operation.
NOTE: When replacing an Atlanta '96 with an Atlanta Gold Main Control PWB, you must also
replace the NVM RAM Chip with an Atlanta Gold style of NVM RAM Chip, included in this kit
(or see PL 1.4A).
1.
If replacing the Main Control PWB with the same type, i.e. (without TAG 015) if replacing
an Atlanta '96 with another Atlanta '96 or (with TAG 015) if replacing an Atlanta Gold with
another Atlanta Gold, go to REP 03-4.
Determine the current software level in the machine and on the new Main Control PWB,
and obtain the appropriate Software Upgrade Kit if necessary.
CAUTION
Kit Contents:
NVM Chip, Atlanta Gold, 32K
a.
Ferrites, Medium
Ferrite, Large
Software Version Compatibility ).
Tiewraps
b.
Ground Clip
Identify the software level on the new Main Control PWB, by the labels on the Flash
chips near the lower right corner of the PWB (Figure 1).
Backplane Shield
c.
F1/F2 Jumper (extra)
If the new PWB's software level does not match that already in the machine,
obtain the Software Upgrade Kit for the level of software already in the machine.
Installation Instructions
2.
level (e.g. 1_0.nsf for Version 1.0.
NOTE: If an NVM download is not possible, inform the customer that any recent Tools
settings (entered since the last NVM download) will need to be reentered after the service
call.
3.
WARNING
4.
5.

a.
Top Rear Cover
b.
Left Rear Cover
c.
Right Rear Cover
d.
Connector Panel (lower center rear cover: remove four T20 screws)

a.
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REP 03-8
b.
b.
7.
a.
ROS video cable
b.
Auto Segmentation PWB (IPS1 Daughter PWB, REP 03-2)
c.
d.
NOTE: You will not reuse the existing Auto Segmentation PWB (IPS1 Daughter PWB) or
NVM RAM Chip. The Atlanta Gold Main Control PWB requires a different NVM RAM Chip
and no Auto Segmentation PWB.

c.
d.
Remove the Card Cage covers.

a.
Remove the following from the Main Control PWB:
Orange power harness -- disconnect at LVPS P42/J2 and P43/J3
6.
Side connector plate (on the left side of the Card Cage as viewed from the rear,
Main Control PWB side: Loosen two T20 screws on top and two on the bottom)
Front and rear Card Cage covers: Loosen two T20 screws on top for each cover.
8.
Disconnect the connectors from the Main Control PWB (Figure 2).
9.
Remove the Main Control PWB (Figure 3).
Atlanta Gold:
Software level printed on Flash Chip label.

Example shown: L0.15.3
Figure 1 Manufactured Software Level -- Atlanta Gold
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V0.042
2
Remove metal cover
(two T20 screws) and
disconnect the connector from J14.
1
Disconnect Image Disk
4
(FX Only):
Disconnect
EPSV
3
Disconnect connectors from J6,
J7, and J13.
Figure 2 Connectors -- Atlanta 96
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May 2003
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REP 03-8
3
Remove the PWB from
the standoffs and slide it
out of the Card Cage.
1
Remove the T20
screws (5).
2
Without TAG 015:
Remove the T20
screws (2).
Atlanta '96 Only:

mica washers (2)
(see CAUTION)
Figure 3 Screws -- Atlanta 96
Replacement
NOTE: The new PWB may have a small metal EME shield on the ROS video connector,
and this shield may fall off easily. Ensure that this shield is in place when the new PWB is
installed.
CAUTION
This procedure assumes that the new Main Control PWB does not have an NVM RAM Chip
installed. If an NVM RAM Chip is presently installed on the new PWB, remove the chip (REP
03-7).
NOTE: When replacing an Atlanta '96 with an Atlanta Gold Main Control PWB, you may
need to extend the harness inside the Card Cage (cutting a tiewrap as necessary) to
reach the connectors along the bottom edge of the PWB.
CAUTION
Be sure to set the jumper on the new PWB for the correct processing speed according to the
following step, to ensure that machine will function properly.
a.
of the cardcage.
1.
Look for the jumper on the new Main Control PWB (Figure 4). If the jumper is missing,
use the extra jumper, provided in this kit, in the following step.
b.
Position the PWB onto the standoffs and reinstall the T20 screws (only 5 screws for
Atlanta Gold).
2.
Set the jumper on the new PWB for the correct processing speed (Figure 4).
c.
3.
Install the Main Control PWB.
REP 03-8
4.
Reinstall all Card Cage covers except the rear (Main Control PWB side) Card Cage
cover.
5.
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V0.042
CAUTION
Record the entire next numbered step: Either write it down; or select the text in the
Browser, copy it (CTRL-C), open a blank Notepad text document, and paste the text
(CTRL-V) into the Notepad document. (In Notepad, select the Edit menu and select
Word Wrap to ensure that the text is easily readable.)
Do not install the NVM RAM Chip until instructed to do so later.

CAUTION
Do not reinstall the Auto Segmentation PWB (IPS1 Daughter PWB). This daughter PWB
is not used with Atlanta Gold (its circuitry is incorporated into the Atlanta Gold), and will
cause errors at power-on if installed.
a.
b.
9.
6.
7.
Swing out the Card Cage and install the three ferrites, included in this kit, in the locations
shown (Figure 5).
8.
Prepare to install the Ground Clip and the Backplane Shield, by removing the following:
9.
a.
User Interface Assembly (REP 02-1)
b.
Scanner Main Cover (REP 14-6 )
c.
Scanner Rear Cover (three T20 screws)
Install the Ground Clip and the Backplane Shield, both provided in this kit (Figure 6).
Perform the software upload from the machine software CD-ROM:

a.
Remove the EDOC CD-ROM from the PWS CD-ROM drive and insert the machine
software CD-ROM.
b.
On the PWS, in the Software Upgrade window, select [Main Controller], select
[Source...], and navigate to the directory g:\inst\**_**\scs\ (where **_** indicates
the desired software level).
c.
Select the file asy****.sre (where **** indicates the desired software level), and
select [OK].
d.
In the Software Upload window, select [Upload], and note the time at which you are
starting the upload.
e.
Wait until the upload is complete before proceeding:
CAUTION
CAUTION
Be sure to reinstall the left rear Scanner mounting screw after installing the Ground Clip. This
screw is required to provide ground for the Ground Clip, and to secure the Scanner in place.
Be sure to wait at least the length of time specified below, to ensure that the software
upload has time to complete.
10. Reinstall the Scanner Main Cover and the User Interface Assembly.
After approximately ten minutes the PWS should indicate IOT Upgrade Complete , then you must wait at least 20 seconds longer.
11. If you are certain that the new Main Control PWB has the same level software as was
already in the machine as determined earlier, skip the Manual IOT Software Upload and
go to Final Steps After the Main Control PWB Replacement, below.
If there is no feedback on the PWS indicating that the upload is complete

(which is normal with some software releases), wait at least 15 minutes from
the start of the upload.
Manual IOT Software Upload

NOTE: This Manual IOT Software Upload section is only required if the new Main Control PWB
CAUTION
h.
Remove the machine software CD-ROM and insert the EDOC CD-ROM back into
the PWS CD-ROM drive.
CAUTION
1.
2.
Ensure that the PWS Diagnostics is set to the same software level as was already in the
machine. (If necessary, exit Session Manager and use the Multiple Version Handler to
switch versions.)
Connect the parallel cable (but not the serial cable -- disconnect the serial cable, if connected).
4.
Open Diagnostic Navigator in Standalone mode.
5.
Select the [Configuration] tab, select [Software Upgrade], and select [Manual] (not Wizard), for the upgrade type.
6.
In the Software Upgrade window, deselect [Automated Mode] (ensure that [Automated
Mode] is not selected).
7.
8.
Record the following step, up through and including inserting the EDOC CD-ROM
back into the PWS CD-ROM drive , to enable reading from hardcopy or Notepad during
the software upload process.
On the PWS, [Exit] Diagnostic Navigator and close the current session.
Final Steps After the Main Control PWB Replacement
Ignore the machine UI during the manual software upload.
V0.042
g.
10. Disconnect the parallel cable and connect the serial cable.
CAUTION
3.
f.
Avoid excessive force when installing the NVM RAM Chip. Otherwise, damage to the chip or
the Main Control PWB may result.
1.
Install the new NVM RAM Chip onto the new Main Control PWB. Perform only the
Physical Installation steps of REP 03-7 Replacement at this time, then return here.
2.
Reinstall the Accessory PWB (REP 03-3).
3.
Pull out the Xerographic Module and Fuser. Ignore the machine UI messages about
reseating the modules.
CAUTION
Be sure to pull out the Xerographic Module and Fuser before switching on the machine power,
after replacing the Main Control PWB and installing the NVM RAM Chip. Otherwise the
machine may falsely declare the end-of-life for either CRU, requiring that it be replaced.
4.
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Switch on the machine power and wait at least 20 seconds.
REP 03-8
NOTE: If the Auto Configuration detects that Remote Data Transfer has become disabled,
do not accept the configuration change. Instead, switch off the machine power and check
that the Accessory PWB is seated securely on the Main Control PWB.
TAG 015
TAG 018
13. Reinstall the remaining components in the reverse order of removal.
NOTE: Accept an EPSV configuration error in all market regions except FX.
CAUTION
5.
Reinsert the Xerographic Module and the Fuser.
6.
If a Manual IOT Software Upload was performed, do the following:
7.
a.
Reselect the previous session in Session Manager.
b.
Open Diagnostic Navigator in Local mode.
The PWS will display a message indicating that installation is not complete. Select [OK]
to dismiss this message.
CAUTION
Do not switch the machine to Install Complete mode at this time.

8.
If a Manual IOT Software Upload was performed, verify the IOT checksums:
a.
b.
Select the [Software] tab.
c.
Double-click on [SCS] to reveal the IOT checksums.

NOTE: The instructions included with the Software Upgrade Kit for Version 1.0
(L0.15.5) only provide the checksums for an Atlanta '96 PWB -- they do not include
the different IPS1 checksum for Atlanta Gold . Refer to Product Specifications :
IOT Software Checksums to verify the IOT checksums for that software level.
d.
9.
Verify the checksums displayed against those listed in Product Specifications : IOT
Software Checksums , or in the Software Upgrade instructions if later than the software levels shown. If the checksums do not agree with those for the desired IOT
software level, go to 03-J Checksum Error RAP.
Perform the Required Steps After NVM RAM Chip Replacement (REP 03-7).
CAUTION
Because a new NVM Chip has been installed, you must perform the Required Steps After
NVM RAM Chip Replacement in order to restore the machine operation.
10. Switch off the machine power, wait at least 20 seconds, and switch on the machine power.
11. The UI may display a configuration mismatch. If so, do the following to allow the machine
accept the configuration change:
a.
Switch the machine into Manufacturing mode (GP14 ).
b.
Switch off the machine power again, wait at least 20 seconds, then switch on the
machine power.
c.
Switch the machine back into Install Complete mode (GP14 ).

CAUTION
Be sure to switch the machine back into Install Complete mode. The machine must not
be left in Manufacturing mode, but there will be no message on the UI to remind you to
switch it back.
d.
Switch off the machine power again, wait at least 20 seconds, then switch on the
machine power.
12. Mark off the following Tags on the IOT Change Tag Matrix:
REP 03-8
May 2003
4-150
V0.042
Set the jumper across pins 1 and 2 (F2 setting) for 65

ppm or 55 ppm. Set the jumper across pins 2 and 3
(F1 setting) for 40 ppm. Example shown: F1 (40
ppm).
Figure 4 55 ppm Jumper -- Atlanta Gold
V0.042
May 2003
4-151
REP 03-8
1
Install one
medium ferrite on the
ROS Video
Cable, here.
VIEWED FROM THE LEFT SIDE (AS

VIEWED FROM THE REAR), WITH
THE CARD CAGE PIVOTED OUT
5
Roll the Scanner Video
Cable and carefully install
the large ferrite here.
Ensure that the cable is
not pinched (the ferrite can
move slightly).
4
Install one tiewrap
on the PWS Cable
here, no more than
60mm (2.25 in.)
from the connector
at the card cage.
2
Install one tiewrap on the
ROS Video Cable here, 100
+/- 10mm (4 +/- 0.4 in.)
away from the connector at
the card cage.
3
Install one medium
ferrite on the PWS
Cable, here.
Figure 5 Ferrites
REP 03-8
May 2003
4-152
V0.042
5
Reinstall the
Scanner Rear
Cover (three T20
screws).
4
Install the Backplane Shield onto
the inside of the
Scanner Rear
Cover.
Install the Ground Clip.
Remove the left rear

Scanner mounting screw
(T20).
Fully seat the

Ground Clip onto
the Scanner
frame here.
3
Reinstall the screw.
Figure 6 Install the Ground Clip and the Backplane Shield
V0.042
May 2003
4-153
REP 03-8
REP 03-9 EPC SDRAM DIMM (With Tag 077 Only)

Parts List on PL 1.4B (240/255/265), or PL 1.4C (460/470)
Removal
460/470
NOTE: If the customer wishes to upgrade their RAM, they must order the upgrade kit through
Sales and that kit includes CSE instructions for performing the upgrade. However, instructions
are included here to enable increasing RAM as a troubleshooting tool.
CAUTION
1.
If upgrading RAM: Place the machine into Manufacturing mode so that it will accept the
configuration change:
a.
b.
c.
Under Install Phase, pull down the menu and select [Manufacturing] (two places for
d.
Remove the
small access
cover (two T20
screws).
WARNING
2.
3.

a.
Top Rear Cover
b.
4.
5.
(460/470): Remove the small access panel from the Card Cage (Figure 1).
CAUTION
When pivoting the clips outward to remove the DIMM, be careful not to let the DIMM fall out
and become damaged.
6.
Remove the EPC SDRAM DIMM(s) (Figure 2 for 240/255/265, Figure 3 for 460/470).
NOTE: Either one or two EPC SDRAM DIMMs can be installed. Figure 2 and Figure 3
each shows a DIMM in the EPC SDRAM 1 slot. The same method is used for the DIMM
in EPC SDRAM 2.
REP 03-9
May 2003
4-154
Figure 1 Remove the Access Cover (460/470)
V0.042
240/255/265
460/470
Locate
the EPC
SDRAM
DIMM(s).
Locate
the EPC
SDRAM
DIMM(s).
2
Pivot the clips
(2) outward and
remove the
DIMM. (See
CAUTION.)
2
Pivot the clips
(2) outward and
remove the
DIMM. (See
CAUTION.)
Figure 3 Removal -- 460/470

Figure 2 Removal -- 240/255/265
V0.042
May 2003
4-155
REP 03-9
Replacement
240/255/265
CAUTION
Ensure that the DIMM is fully inserted, with both clips snapped into position. Applying power to
the machine with a DIMM partly-installed can destroy the DIMM or cause other machine damage.
1.
Install the EPC SDRAM DIMM(s) (Figure 4 for 240/255/265, or Figure 5 for 460/470).
NOTE: A single DIMM will function the same in either slot, but EPC SDRAM 1 is recommended.
2.
3.
If upgrading RAM: Place the machine back into Install Complete mode.
a.
b.
c.
Under Install Phase, pull down the menu and select [Install Complete] (two places for
d.
e.
1
Ensure the clips
are pivoted outward (2 places).
2
Align the DIMM
notches (2) with
the slot tabs, and
insert the DIMM
straight into the
slot.
3
Press the DIMM
straight into the
slot until both clips
are fully engaged.
REP 03-9
May 2003
4-156
V0.042
REP 03-10 Software/NVM Module (With Tag 077 Only)
460/470

Preparation for Replacing the Software/NVM Module with a New One
Ensure the clips

are pivoted outward (2 places).
NOTE: If removing and/or reinstalling the same module (not replacing it with a new one), go
directly to Removal or Replacement, as required.
CAUTION
Do not return as new, or reuse in any other machine, any Software/NVM Module that has
been installed in any machine. Once the Software/NVM Module is installed and the machine
power switched on, the module is no longer new -- the NVM is automatically initialized by the
machine software and cannot be used again as a "virgin" Software/NVM Module.
2
Align the DIMM
notches (2) with
the slot tabs, and
insert the DIMM
straight into the
slot.
NOTE: The NVM values must be restored from the MRD afterward. However, all counters and
Auditron information will be lost because, for legal reasons, they cannot be copied as part of
the NVM download or saved to the MRD. Also, the machine serial number and time and date
will be lost from machine memory and will need to be reentered afterward using the PWS.
NOTE: Confirmation Code Required: If performed on a non-FSMA service plan ("Sold"
CRUs) machine, this procedure requires that a protected NVM setting (Service Plan) be
restored after replacing the NVM RAM Chip. You will be required to obtain the necessary confirmation code for the Service Plan setting during this procedure on a "Sold" machine. This
confirmation code must be obtained from Field Engineering.
CAUTION
3
Press the DIMM
straight into the
slot until both clips
are fully engaged.
You must identify the current software level in the machine and on the new Software/NVM
Module, and if the software levels are different then obtain the appropriate Software
Upgrade Kit. If the machine and new module software levels are different, IOT software must
be uploaded onto the new module after the PWB replacement, to restore the machine operation.
CAUTION
Be sure to consult any bulletins which may have announced later software releases than those
listed in this version of EDOC.
NOTE: This procedure has you restore the machine operation at the same level of software as
was already in the machine before the Software/NVM Module replacement. You will upload
software onto the new module if necessary, to match the level of software already in the
level on the new module.
1.
2.
V0.042
May 2003
4-157
Determine the current software level in the machine and on the new Software/NVM Module, and obtain the appropriate Software Upgrade Kit if necessary.
a.
b.
Identify the software level on the new Software/NVM Module, by the label on the
Flash chips on the module (Figure 2).
c.
If the new module's software level does not match that already in the machine,
obtain the Software Upgrade Kit for the level of software already in the machine.
If possible, record all Billing Counter readings.
REP 03-9, REP 03-10
3.
If possible, record any Auditron account information. If this is not possible, inform the customer that they will need to reenter this information after the service call.
4.
level (e.g. 1_0.bnf for Version 1.0).
460/470
NOTE: If replacing the NVM RAM Chip with a new one and an NVM download is not possible, inform the customer that any recent Tools settings (entered since the last NVM
download) will need to be reentered after the service call.
Removal
CAUTION
Remove the
small access
cover (two T20
screws).
WARNING
1.
2.

a.
Top Rear Cover
b.
3.
4.
(460/470): Remove the small access panel from the Card Cage (Figure 1).
CAUTION
When pivoting the clips outward to remove the module, be careful not to let the module fall out
and become damaged.
5.
Remove the Software/NVM Module (Figure 3 for 240/255/265, or Figure 4 for 460/470).
Figure 1 Remove the Access Cover (460/470)
REP 03-10
May 2003
4-158
V0.042
240/255/265
1
Pivot the clips (2)
outward. (See
CAUTION.)
L0.17.8.64
software version
label
Figure 2 Manufactured Software Version
2
Pivot the
module to the
right and
remove the
module.
Figure 3 Removal -- 240/255/265
V0.042
May 2003
4-159
REP 03-10
Replacement
460/470
1.
Install the Software/NVM Module (Figure 5 for 240/255/265, or Figure 6 for 460/470).
2.
If you are reinstalling the same Software/NVM Module removed earlier, this procedure is
now complete.
Pivot the clips (2)

outward. (See
CAUTION.)
240/255/265
1
Orient the corner
notch at the top,
and align the
center notch with
the slot tab.
2
Pivot the
module to the
right and
remove the
module.
2
Insert the module,
angled to the right,
all the way into the
slot.
Figure 4 Removal -- 460/470
3
Pivot the module to
the left until both
clips are fully
engaged.
REP 03-10
May 2003
4-160
V0.042
NOTE: The machine power must be switched on, switched off after approximately one minute,
and then switched on a second time, in order for the new NVM RAM Chip to fully initialize.
460/470
1
Orient the corner
notch at the top,
and align the
center notch with
the slot tab.
2.
3.
Wait approximately one minute, then switch off the machine power.
4.
Wait approximately 20 seconds, then switch on the machine power again.

CAUTION
Ignore the UI message during this phase of the upgrade. The Main Control PWB will not communicate with the UI now, and the UI displays only the Document Centre screen with a series
of dots at the top, followed by a false message to switch off the machine power -- ignore this
message.
CAUTION
Select [OK] to dismiss the PWS messages indicating that installation has not been completed.
When the machine was switched on with a new (virgin) Software/NVM Module installed, it
defaulted to Manufacturing phase in order to temporarily accept the configuration mismatches
associated with the other default NVM.
2
Insert the module,
angled to the right,
all the way into the
slot.
CAUTION
Do not proceed to enter information or restore NVM until the machine is ready, as indicated
below
5.
3
Pivot the module to
the left until both
clips are fully
engaged.
Observe the PWS attempting to establish communication with the machine as the
machine initializes the new NVM RAM Chip on the Software/NVM Module and then the
machine resets automatically. When the machine resets automatically, the PWS will lose
and then reestablish communication with the machine. Wait until this automatic reset has
occurred and the PWS-machine communication is stable (1-3 minutes after you switched
on the machine power) before proceeding to the next step.
CAUTION
Keep the Front Door open, to prevent the machine from attempting an automatic xerographic
Setup until, the NVM has been restored later.
6.
Reinsert the Xerographic Module and the Fuser, but keep the Front Door open.
7.
Place the machine back into Install Complete mode and set the Product Type:
a.
b.
c.
Under both Install Phase (System) and Install Phase (Main Controller), pull down the
menu and select [Install Complete] (two places).
CAUTION
For a 55 ppm machine, you must toggle the Product Type setting off of 55 ppm, [Apply],
and back to 55 ppm, in order for the setting to take full effect.
Required Steps After Software/NVM Module Replacement
d.
For a 55 ppm machine: Switch the Product Type to 65 ppm, select [Apply], and
switch it back to 55 ppm.
NOTE: The remaining steps apply only if you are replacing the Software/NVM Module with
a new (virgin) module.
CAUTION
You must pull out the Xerographic Module and Fuser before switching on the machine power,
after replacing the Software/NVM Module. Otherwise, the machine may falsely declare the
end-of-life for either CRU, requiring that it be replaced.
1.
Ensure that the Product Type (40/55/65 ppm) is set correctly.
8.
Pull out the Xerographic Module and Fuser.
e.
f.
Restore the Market Region, System Configuration, Product Identifier (if present), and
serial numbers to the machine memory, and reset the machine time and date:
a.
b.
In the System tab:

i.
V0.042
May 2003
4-161
Ensure that the Market Region is set correctly.

REP 03-10
9.
ii.
Ensure that the System Configuration is set correctly.
iii.
460/470: Ensure that the Product Identifier is set correctly.
iv.
Select [Apply]
c.
Select the [Serial Numbers] tab.
d.
Enter the "System" (IOT) Serial Number and any options' serial numbers.
e.
Select [Apply].
f.
g.
Enter the current time and date.
h.
Select [Apply].
i.
6.
Reinstall the remaining components in the reverse order of removal.
Non-FSMA ("Sold" CRUs) machine only: Restore the Service Plan setting to the machine
memory:
a.
b.
Select the [CRU Management] tab.
c.
Under Service Plan, select [Sold (A)] from the pull-down menu.
d.
In the Confirmation Code box that appears, enter the confirmation code obtained
from Field Engineering.
e.
Select [Apply].
f.
10. If you are certain that the new Software/NVM Module has the same level software as was
already in the machine as determined earlier, skip the IOT Software Upload and go to
Final Steps After Software/NVM Module Replacement, below.
IOT Software Upload

CAUTION
NOTE: This IOT Software Upload section is only required if the new Software/NVM Module
Use the appropriate Software Upgrade kit to install the correct IOT software version. Use the
PWS Wizard software upload method, selecting only the Main Controller platform. Then, return
here.
Final Steps After Software/NVM Module Replacement

CAUTION
You must upload the NVM from the MRD, in order to restore the machine operation.
1.
2.
3.
Restore the machine NVM from the machine resident diskette file (GP4).
Reset the Machine Administrator password back to the default (1111):
a.
Select the [Copier Sys] tab in Diagnostic Navigator.
b.
Select [Reset Administrator PIN].
c.
Select [Start], and answer [Yes] to the prompt.
d.
Select [Exit].
If possible, restore any Auditron account information.
4.
When closing the call, be sure to report that the Billing Counters were reset (GP17).
5.
If replacing the Software/NVM Module as part of an Atlanta Gold-to-Platinum upgrade,

return to those instructions now.
REP 03-10
May 2003
4-162
V0.042
REP 03-11 Main Control PWB (Atlanta Platinum-toPlatinum) (With Tag 077 Only)
c.
6.

Removal
NOTE: Use this procedure only if replacing an Atlanta Platinum Main Control PWB (with TAG
077) with another Atlanta Platinum. If replacing an Atlanta '96 with an Atlanta Gold (upgrading
to TAG 015), or if replacing an Atlanta 96 or Atlanta Gold with an Atlanta Platinum (upgrading
to TAG 077), you must order the appropriate Upgrade Kit (PL 1.4A) and follow the instructions
provided in that kit. If replacing an Atlanta 96 (without TAG 015) with another Atlanta 96, or if
replacing an Atlanta Gold (with TAG 015, without TAG 077) with another Atlanta Gold, go to
REP 03-4.
If replacing the Main Control PWB with a new one, remove the following from the Main
Control PWB:
a.
Accessory PWB (REP 03-3) or filler plate.
b.
(240/255/265 with TAG 080): Electronic Hole Removal PWB (IPS1 Daughter PWB,
REP 03-2)
c.
(460/470 with TAG TBD): Electronic Hole Removal PWB (REP 03-12)
d.
EPC SDRAM DIMMs (1 or 2) (REP 03-9).
e.
Software/NVM Module (REP 03-10).
7.
(460/470): Remove the side connector plates from the card cage, and disconnect the distribution ribbon cable (Figure 3).
8.
Remove the Main Control PWB (Figure 4 for 240/255/265, or Figure 5 for 460/470).
CAUTION
a.
(240/255/265): Remove the small plate from the Card Cage (two T20 screws) and
disconnect the ribbon cable from the PWB.
b.
Disconnect the other connectors (2 or 3) from the PWB.
1.
c.
Remove the T20 screws securing the PWB (7 screws for 240/255265; 9 screws for
460/470).
d.
(240/255/265): Lift the PWB off of the standoffs and remove the PWB from the Card
Cage.
e.
(460/470): Remove the Main Control PWB. For ST, this requires lifting the PWB out
of its bottom edge connector on the Riser PWB.
WARNING
2.
3.

a.
Top Rear Cover
b.
Left Rear Cover
c.
Right Rear Cover
d.
(240/255/265): Connector Panel (lower center rear cover: remove four T20 screws)
(240/255/265): Remove the Card Cage:

a.
Swing out the Card Cage (one or two T20 latches).
b.
ROS video cable
Power harness -- disconnect at LVPS P42/J2 and P43/J3
4.
5.
c.
d.
(240/255/265): Remove the Card Cage covers.

a.
Front and rear covers: Loosen two T20 screws on top for each cover.
b.
Side connector plate (on the left side of the Card Cage as viewed from the rear, Main
Control PWB side: Loosen two T20 screws on top and two on the bottom)
(460/470): Remove the Main Card Cage Cover:

a.
b.
V0.042
May 2003
4-163
REP 03-11
460/470
2
1
4
Disconnect the fan
connector.
6
5
Remove the T20

hex-head screw.

REP 03-11
May 2003
4-164
V0.042
460/470
460/470

1
Remove the ROS/
PWS connector
plate (two thumb
screws).
2
Remove the connector cover (two
T20 hex-head
screws), and disconnect the distribution cable from the
Main Control PWB.
V0.042
Figure 3 Connector Plates
May 2003
4-165
REP 03-11
240/255/265
plate (two T20 screws)
T20
screws
(7)
ribbon cable
connectors (3)
Figure 4 Screws and Connectors -- 240/255/265
REP 03-11
May 2003
4-166
V0.042
460/470
T20
screws
(9)
NOTE: If this
machine has the
Removable Disk
Drive option ONLY:
This connector
should NOT be connected. The ribbon
cable should be
formed around the
PWB connector
when installing the
PWB, ensuring that
the cable connector
will not interfere with
the Main Card Cage
Cover installation.
Riser PWB
connectors (3)
Figure 5 Screws and Connectors -- 460/470
V0.042
May 2003
4-167
REP 03-11
Replacement
1.
2.
3.
240/255/265 ST/LP
(240/255/265): Install the Main Control PWB.

a.
of the cardcage.
b.
Position the PWB onto the standoffs and reinstall the T20 screws (7) loosely.
c.
LP/ST: Press on the Main Control PWB in the location shown, to seat the connectors
to the ESS PWB (Figure 6).
d.
Press where the

finger is shown
touching the PWB.
(460/470): Install the Main Control PWB (Figure 5).

a.
Position the PWB into the cardcage and position the right-edge connectors into the
side of the cardcage. For ST: Insert the PWBs bottom edge connector into the Riser
PWB. Align the 9 screw holes.
b.
Reinstall the T20 screws (9) loosely.
c.

a.
EPC SDRAM DIMMs (1 or 2) (REP 03-9).
b.
Software/NVM Module (REP 03-10)
c.
(240/255/265 with TAG 080) Electronic Hole Removal PWB (IPS1 Daughter PWB,
REP 03-2).
d.
(460/470 with TAG TBD): Electronic Hole Removal PWB (REP 03-12)
e.
Accessory PWB (REP 03-3).
4.
Reinstall all Card Cage covers and connector plate(s).
5.
Figure 6 Seat the PWB to the ESS PWB (240/255/265)
REP 03-11
May 2003
4-168
V0.042
REP 03-12 Electronic Hole Removal (EHR) PWB, 460/470

Parts List on PL 1.4C
Removal
CAUTION
WARNING
1.
2.
3.
a.
Top Rear Cover
b.
Left Rear Cover
c.
Right Rear Cover
Remove the Main Card Cage Cover:

a.
b.
c.

CAUTION
Hold the EHR PWB while releasing the clips, to prevent the PWB from falling and becoming
damaged.
4.
Remove the Electronic Hole Removal PWB (Figure 3).
V0.042
May 2003
4-169
REP 03-12
2
1
4
Disconnect the fan
connector.
6
5
Remove the T20

hex-head screw.

REP 03-12
May 2003
4-170
V0.042

V0.042
May 2003
4-171
REP 03-12
2
Pivot the EHR
PWB outward
from the Main
Control PWB,
and remove the
EHR WPB.
1
Press the two
clips outward.
Figure 3 Removal
Replacement
1.
Install the Electronic Hole Removal PWB (Figure 4).
REP 03-12
May 2003
4-172
V0.042
REP 03-13 Card Cage Riser PWB (460/470 Only)

Removal
CAUTION
1.
WARNING
2.
3.
1
Align the EHR PWB
notches with the slot
tabs, and insert the
EHR PWB all the way
into the slot at the
angle shown.
4.

a.
Top Rear Cover
b.
Left Rear Cover
c.
Right Rear Cover

a.
Swing out the Card Cage (two T20 latches).
b.
c.

a.
ROS video cable
Distribution ribbon cable (copper-shielded) -- disconnect at Distribution PWB J5
Power harness -- disconnect at LVPS P42/J2 and P43/J3
2
Pivot the EHR PWB to
the right, toward the
Main Control PWB,
until both clips are
fully engaged.
b.
5.
Remove the Main Control PWB (REP 03-11):
6.
(ST): Remove the following:
7.
a.
Image Processing Accelerator PWB, if present (REP 16-8).
b.
Token Ring PWB, if present (REP 16-9).
c.
ESS PWB (REP 16-2).
Remove the bottom access panel from the Card Cage (Figure 3).
8.
Disconnect the DC harness connector from the bottom of the Riser PWB (Figure 4).
9.
Remove the T20 screws (6) securing the Riser PWB (Figure 5).
10. Remove the Riser PWB (Figure 6).
V0.042
May 2003
4-173
REP 03-12, REP 03-13
2
1
4
Disconnect the fan
connector.
6
5
Remove the T20

hex-head screw.

REP 03-13
May 2003
4-174
V0.042

Remove the bottom

access panel (one T20
hex-head screw).
Figure 3 Remove the Bottom Access Panel
V0.042
May 2003
4-175
REP 03-13
Disconnect the DC harness

connector from the bottom of
the Riser PWB.
Figure 4 Disconnect the DC Harness
REP 03-13
May 2003
4-176
V0.042
screw
(hidden)
screws (2)
screws (3)
Replacement:
Install this corner
screw first.
Figure 5 Screws
V0.042
May 2003
4-177
REP 03-13
Use this notch for

clearance when
removing the
Riser PWB from
the Card Cage
chassis.
Figure 6 Removal
Replacement
When installing the Riser PWB, install the corner screw indicated, first, installing the
other screws to secure the PWB (Figure 5).
After installing the Riser PWB and all other components, set the System ID to Lakes for
the new Riser PWB (GP39 ).
REP 03-13
May 2003
4-178
V0.042
REP 04-1 Developer Drive Motor

Removal
WARNING
1.
2.
3.
Disconnect the motor from J4 on the SCAM PWB (Figure 1).

CAUTION
Do not rotate the developer drives while the Developer Housing is installed in the machine. If
the Mag Roll is rotated at less than the normal operating speed (1250 rpm), the developer
material can jam between the Mag Roll and the Donor Roll.
4.
5.
Remove the Developer Drive Motor (Figure 2 - shown with the SCAM PWB omitted for
clarity).
V0.042
May 2003
4-179
REP 04-1
J4 on the
SCAM PWB
Figure 1 Connector
REP 04-1
May 2003
4-180
V0.042
2.
Connect the motor to J4 on the SCAM PWB.
3.
Reinstall the Developer Drive Belt (REP 04-6).
4.
Reinstall the remaining components in the reverse of Removal.
5.
6.
Perform ADJ 8-1A IOT Lead Edge Registration.
Remove
the T20
screws
(4).
Insert the motor at an angle.
2
Remove
the
motor.
2
Rotate the flywheel left and right.
Figure 2 Removal
Replacement
CAUTION
Ensure that the Xerographic Module is in place before installing the Developer Drive Motor.
Removing the motor or other parts which bolt to the rear frame reduces the rigidity of the
frame. This can allow the Photoreceptor Drive Module to sag, deforming the rear frame, if the
Xerographic Module is not in place and supporting the front of the Photoreceptor Drive Module.
Installing the Developer Drive Motor will then 'lock in' the frame deformation.
1.
Install the Developer Drive Motor:

a.
(Figure 3): Insert the motor with the gears angled down under the Duplex Transport
gear. Rotate the motor flywheel left and right as you insert the motor -- you should
feel the motor gears engage the Registration Transport gear as the motor plate seats
against the rear IOT frame.
b.
Install one of the top two T20 screws loosely to hold the motor in place temporarily.
c.
From the front of the machine, use a flashlight to check visually that the motor gear
has engaged the Duplex Transport gear correctly (Figure 4). If not, remove the
motor and go back to step a.
d.
Install the remaining T20 screws (3) and tighten all four screws
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May 2003
4-181
REP 04-1
REP 04-2 Fuser Drive Motor

Removal
WARNING
1.
2.
Remove the Prefuser Transport (PFT) (REP 10-1).
3.
4.
Disconnect the motor from J2 on the SCAM PWB (Figure 1).
NOTE: (Without TAG 040): The machine may not have a Decurler Drive Belt. If not, then
ignore the following step.
5.
Detension and remove the Decurler Drive Belt (Figure 2).

CAUTION
Ensure that the Xerographic Module is in place while the Fuser Drive Motor is removed.
Removing the motor or other parts which bolt to the rear frame reduces the rigidity of the
6.
Remove the Fuser Drive Motor (Figure 3).
Ensure that the Developer Drive

Motor gear engages the Duplex
Transport gear as shown.
Figure 4 Gear Engagement
REP 04-1, REP 04-2
May 2003
4-182
V0.042
J2 on the
SCAM PWB
Figure 1 Connector
V0.042
May 2003
4-183
REP 04-2
1
Loosen the T20
screw 1/4 turn
only.
4
Remove the belt.
2
1
Move the idler pulley

up and hold it.
Remove the T20

screws (4).
Remove the
motor.
Retighten the
screw.
Figure 2 Belt Removal
Figure 3 Motor Removal
Replacement
CAUTION
Ensure that the Fuser Module is installed and the Fuser drawer is pushed in when installing the
Fuser Drive Motor. This ensures that the Fuser drive gears are aligned correctly when the
motor is secured in place.
1.
Install the motor and install the T20 screws (4) loosely.
CAUTION
Make sure that the motor bracket is rotated and held clockwise when tightening the screws.
This has been shown to reduce trail edge deletions on long sheets.
2.
Rotate and hold the motor bracket clockwise (as viewed from the rear), then tighten the
screws.
3.
Reconnect the motor to J2 on the SCAM PWB.
NOTE: (Without TAG 040): The machine may not have a Decurler Drive Belt. If not, then
ignore the following step.
REP 04-2
4.
5.
Retension the belt (Figure 4).
May 2003
4-184
V0.042
6.

Removal
1
Ensure the T20
screw is loosened 1/4 turn
only.
REP 04-3 Developer Gear Bracket
2
Rotate the motor
3-4 turns CCW
(arrow direction).
WARNING
1.
2.
3.
Remove the SCAM PWB (REP 03-1).

CAUTION
4.
Remove the SCAM PWB mounting bracket by removing the T20 screws (3).
5.

CAUTION
Ensure that the Xerographic Module is in place while the Developer Gear Bracket is removed.
Removing the bracket or other parts which bolt to the rear frame reduces the rigidity of the
6.
Remove the Developer Gear Bracket (Figure 1).
3
Retighten the
screw.
Figure 4 Belt Tensioning
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May 2003
4-185
REP 04-2, REP 04-3
2
Tighten the
T20 screws
(4; bottom 2
screws are
hidden).
1
Remove the
T20 screws
(4; bottom 2
screws are
hidden).
Snap the alignment arm onto the

Developer Housing shaft (setup
position).
Remove the gear

bracket.
Figure 1 Removal
Figure 2 Setting Up the Gear Spacing
Replacement
1.
Install the gear bracket and install the T20 screws (4) loosely.
2.
Set up the gear spacing (Figure 2).

CAUTION
Use the Developer Drive Alignment Arm as follows to set up the gear spacing, then be sure to
disengage the arm when finished. This will minimize gear noise.
3.
Disengage the Developer Drive Alignment Arm, leaving it in the operating position (Figure
3).
4.
5.
Reinstall the SCAM PWB mounting bracket, securing it with the T20 screws (3).
6.
Reinstall the SCAM PWB (REP 03-1).
REP 04-3
May 2003
4-186
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REP 04-4 Decurler/OCT Drive Bracket

Removal
WARNING
1.
2.
3.

CAUTION
Ensure that the Xerographic Module is in place while the Decurler/OCT Drive Bracket is
removed. Removing the bracket or other parts which bolt to the rear frame reduces the rigidity
of the frame. This can allow the Photoreceptor Drive Module to sag, deforming the rear frame,
if the Xerographic Module is not in place and supporting the front of the Photoreceptor Drive
Module.
4.
Remove the Decurler/OCT Drive Bracket (Figure 2).
1
Loosen the T20
screw 1/4 turn
only.
2
up and hold it.
Alignment arm in operating

position (disengaged)
Figure 3 Disengage the Alignment Arm
4
Remove the belt.
3
Retighten the
screw.
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May 2003
4-187
REP 04-3, REP 04-4
1
Ensure the T20
only.
1
Remove the T20
screws (2).
Remove the gear

bracket.
Retighten the
screw.
Figure 2 Bracket Removal
2
Rotate the motor
3-4 turns CCW
(arrow direction).
Replacement
1.
Install the gear bracket and secure it with the T20 screws (2).
2.
3.
REP 04-4
May 2003
4-188
V0.042
REP 04-5 Decurler Drive Belt

1

Removal
WARNING
1.
Ensure the T20

only.
2
Rotate the motor
3-4 turns CCW
(arrow direction).
2.
3.
Loosen the T20

screw 1/4 turn
only.

up and hold it.
3
Retighten the
screw.
Remove the belt.
Retighten the
screw.
Figure 1 Removal
Replacement
1.
2.
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May 2003
4-189
REP 04-5
REP 04-6 Developer Drive Belt
Replacement
CAUTION

Removal
Perform the following steps to prepare for tensioning the Developer Drive Belt. This will avoid
damage to the Developer Housing and ensure that the belt is tensioned properly for minimum
noise and wear.
WARNING
1.
1.
2.
Be sure to use the orange plastic cap, provided in the Hardware Kit and in the Developer Housing Kit, to cap the developer collector outlet after disconnecting the Developer Collector Tube.
This will minimize developer leakage and contamination of the machine.
CAUTION

CAUTION
2.
Prepare to slide the Developer Housing out partway (Figure 2).
3.
Slide the Developer Housing out approximately 4 in. (100mm).
4.
Install the Developer Drive Belt.
3.
5.
Tension the belt (Figure 3 - shown with the SCAM PWB omitted for clarity).
6.
Slide the Developer Housing back in.
Detension and remove the Developer Drive Belt (Figure 1 - shown with the SCAM PWB
omitted for clarity).
CAUTION
2
Move the
idler pulley
to the left
and hold it.
Be sure to reconnect the developer collection tube. Otherwise, developer material will spill
inside the machine during operation.
7.
Finish reinstalling the Developer Housing (Figure 4).
8.
3
Retighten the
screw.
4
Remove the
belt.
1
Loosen the T20 screw
1/4 turn only.
Figure 1 Removal
REP 04-6
May 2003
4-190
V0.042
Disconnect P50.
Ensure the
T20 screw
is loosened
1/4 turn
only.
2
Rotate the
motor 3-4
turns CW
(arrow direction).
3
Retighten
the screw.
2
Disconnect the developer collector tube and
cap the outlet on the
housing.
3
Remove the gold
T20 screw.
Figure 2 Developer Housing
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May 2003
4-191
REP 04-6
1
Connect P50.
2
Connect the
developer collector tube.
3
Install the gold
T20 screw.
Figure 4 Developer Housing (continued)
REP 04-6
May 2003
4-192
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REP 05-1 DADF Cleaning Procedure
15. Treat only the CVT Glass with Glass Cleaner 600T91872, in order to decrease the friction
of the glass.
Cleaning Materials
Cleaning Towel 600S4372 (soft, lint-free)
Platen Glass, Lens and Mirror Cleaner 43P81
Glass Cleaner 600T91872
Vacuum Cleaner
16. Lower the DADF.
Clean
WARNING
1.
CAUTION
Do not pour or spray fluid directly into the DADF. Do not use any abrasive cleaners to clean the
DADF. These actions will damage the machine.
CAUTION
Do not use yellow cloths or any oil or wax impregnated materials for the roll cleaning portion of
this procedure, as this will contaminate the feed rollers and cause feeding problems and
increased probability of image quality problems.
CAUTION
Do not force the towel into confined areas. Do not force parts open. These actions will damage the machine.
2.
3.
Remove the DADF Feed Roll Cartridge.
4.
Using a vacuum cleaner, or towel dampened with water, clean the following:
Feed Roll Cartridge cavity in the DADF
Baffle on the DADF Top Cover
All surfaces and rolls except the Drive-On-Glass Roll of the document transport,
including areas 6a and 6b.
5.
Reinstall the DADF Feed Roll Cartridge and close the DADF Top Cover.
6.
Raise the DADF.

CAUTION
Wiping the DOG Roll with cleaners or water may remove essential ingredients in the roll that
prevent noise from this roll.
7.
Using only a dry towel, clean the Drive-on-Glass Roll (DOG Roll).
8.
Moisten one end of a clean towel with Platen Glass, Lens and Mirror Cleaner.
9.
With a clean area of towel moistened with cleaning fluid, clean the glass area under the
DOG Roll, including the black ramp.
10. Lower the DADF.

11. Run one copy of 25 blank originals, 2-sided to 2-sided.
12. Raise the DADF.
13. Wipe the top side of the CVT platen glass and the manual platen glass. This will produce
a slight haze on the glass.
14. Use the dry end of the towel to remove all haze from the glass.
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May 2003
4-193
REP 05-1
REP 05-2 DADF Assembly

Parts List on PL 2.1B
Removal
WARNING
1.
2.
Remove the following.

a.
b.
Scanner Main Cover (REP 14-6 )
c.
Scanner Rear Cover PL 3.1
d.
All IOT rear covers
3.
Swing out the card cage (one 1/4-turn T20 or slotted fastener).
4.
Disconnect DADF Harness connector P12 from the Distribution PWB (Figure 1).
5.
Disconnect the ground faston connector, and extract the harness from the IOT.
6.
Remove the DADF Main Cover
7.
Raise the Document Handler, leaving the Document Glass Cover down.
8.
Keeping the Document Glass Cover Horizontal, lift it straight up and remove it from the
machine.
WARNING
The DADF is heavy and awkward to lift. Ensure that you have a firm, balanced grip on
the DADF before lifting it.
NOTE: You may wish to back out the DADF Skew Adjustment Screw to make it easier to
remove and install the DADF. Note the number of screw turns, to facilitate restoring the skew
adjustment later, if reinstalling the same DADF.
9.
Standing behind the machine, lift the DADF straight up and remove it at the rear, including
the counterbalance mechanism (Figure 2).
REP 05-2
May 2003
4-194
V0.042
P/J12 on the
Distribution
PWB
Figure 1 Connector
V0.042
May 2003
4-195
REP 05-2
Standing behind
the machine, lift
the DADF straight
up and remove it.
Figure 2 Removal
Replacement
NOTE: You may wish to back out the DADF Skew Adjustment Screw (if you have not already
done so) to make it easier to install the DADF.
1.
Install the DADF Assembly in the reverse order of Removal.
2.
If replacing the DADF Assembly with a new one, perform the following:
NOTE: If you are reinstalling the same DADF and you backed out the DADF Skew Adjustment
Screw before removing the DADF, turn the adjustment screw in again the same number of
turns before performing the DADF Skew adjustment.
a.
DADF Skew (ADJ 05-1).
b.
IIT Registration and Magnification setup (ADJ 14-2).
c.
Reset the Life Counter for the DADF Paper Feed Roll Cartridge (GP6).
d.
Before closing the call, be sure to save the NVM to Floppy (GP4).
REP 05-2
May 2003
4-196
V0.042
REP 05-3 DADF Top Cover Assembly

Removal
WARNING
1.
2.
3.
Remove the DADF Main Cover (four 1/4-turn slotted fasteners).
4.
Disconnect P4 from the DADF PWB (Figure 1).
5.
Remove the DADF Top Cover Assembly (Figure 2).
V0.042
May 2003
4-197
REP 05-3
P/J4 on the
DADF PWB
Figure 1 Connector
REP 05-3
May 2003
4-198
V0.042
3
Remove the DADF Top
Cover Assembly at the rear,
pulling the harness forward
through the rear hinge pin
hole.
2
Lift the DADF
Top Cover
Assembly at
the front.
1
Loosen the T20
screw and slide
the front hinge
pin toward the
rear.
Figure 2 Removal
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May 2003
4-199
REP 05-3
REP 05-4 DADF Feeder Assembly

Removal
WARNING
1.
2.
3.
4.
Raise the DADF.
5.
Remove the DADF Feeder Assembly.
WARNING
Perform the following steps with the DADF raised. Otherwise, the DADF can spring
up unexpectedly when its weight is reduced by the removal of parts, possibly causing machine damage or personal injury.
a.
b.
Loosen the bearing retainer screw and disconnect the ground wires (2) (Figure 2).
c.
Remove the T20 screws (3) securing the front and rear of the feeder assembly and
the bearing retainer, and remove the bearing retainer (Figure 3).
d.
Lift the DADF Feeder Assembly out carefully, noting the position of the spring underneath (Figure 4).
REP 05-4
May 2003
4-200
V0.042
P/J5 on the
DADF PWB
Figure 1 Connector
V0.042
May 2003
4-201
REP 05-4
ground wire
screw (T20)
ground wire
Figure 2 Ground Wires and Screw
REP 05-4
May 2003
4-202
V0.042
1
Remove the bearing retainer T20
screw, remove the bearing retainer,
and remove the rear T20 screw (hidden).
2
Remove the front
T20 screw.
Figure 3 Bearing Retainer and Screws
V0.042
May 2003
4-203
REP 05-4
spring
BOTTOM VIEW OF DADF

FEEDER ASSEMBLY
Figure 4 Spring
Replacement
1.
Position the DADF Feeder Assembly carefully, ensuring the correct positioning of the
spring underneath and the correct orientation of the clutch (Figure 4).
2.
Finish installing the DADF Feeder Assembly and the remaining components, in the
reverse order of Removal.
3.
If replacing the DADF Feeder Assembly with a new one, perform the following:
a.
Reset the Life Counter for the DADF Paper Feed Roll Cartridge (GP6).
b.
REP 05-4
May 2003
4-204
V0.042
Engage the clutch

tabs with the tab in
the DADF.
Figure 5 Anti-Rotation Tabs
V0.042
May 2003
4-205
REP 05-4
REP 05-5 DADF Registration Deskew Assembly

Removal
WARNING
1.
2.
Raise the DADF.
3.
WARNING
4.
5.

a.
DADF Main Cover (four 1/4-turn slotted fasteners)
b.
DADF Top Cover Assembly (REP 05-3)
c.
DADF Feeder Assembly (REP 05-4)
6.
Loosen the bearing retainer screw and disconnect the ground wire (Figure 2).
7.
Prepare to remove the DADF Registration Deskew Assembly (Figure 3).
8.
Remove the DADF Registration Deskew Assembly (Figure 4).
REP 05-5
May 2003
4-206
V0.042
P/J3 on the
DADF PWB
Figure 1 Connector
V0.042
May 2003
4-207
REP 05-5
screw (T20)
ground wire
3
Remove T20
screws (4).
Figure 2 Ground Wire and Screw
2
1
Slide the drive
belt off of the
pulley.
Remove the
bearing retainer
(one T20 screw).
Figure 3 Removal
REP 05-5
May 2003
4-208
V0.042
2
Lift the assembly
off partway.
Disconnect the
ground wire faston.
Press down on the right front corner of the DADF so that it contacts the Scanner
Main Cover, and hold it down while performing the next step:
c.
Tighten the four screws in the following sequence:

left rear
left front
Note how
this baffle is
positioned in
the slot of the
DADF.
b.
right front
right rear
d.
slot
Remove the spacer from under the left front corner of the DADF.
6.
Slide the drive belt onto the pulley of the registration deskew transport, ensuring that the
belt is positioned correctly on the other pulleys as well.
7.
Reinstall the bearing retainer, the ground wire, and the screw (T20).
4
Remove the
assembly.
Figure 4 Removal (continued)
Replacement
1.
Connect the ground wire faston at the right rear corner of the assembly.
2.
Position the assembly with its left baffle in the slot of the DADF, as noted during Removal.
3.
Install the T20 screws (4) loosely.
4.
Lower the DADF.
5.
Ensure that the Registration Deskew Assembly is mounted correctly (Figure 5):
a.
Place an approximate 3mm spacer (fold a sheet of paper to 3 +/- 0.5mm thick) under
the left front foot of the DADF frame.
V0.042
May 2003
4-209
REP 05-5
3
Tighten the T20
screws (4) IN
SEQUENCE:
3A
Tighten this
screw FIRST.
3B
Tighten
this screw
SECOND
3D
Tighten this
screw LAST.
3C
Tighten this
screw THIRD.
1
Place a 3mm
spacer under
this foot.
4
Remove the
spacer.
2
Press down on this corner
while performing step 3.
REP 05-5
May 2003
4-210
V0.042
REP 05-6 Document Input Tray Assembly

Removal
WARNING
1.
2.
3.
4.
Prepare to remove the Document Input Tray Assembly (Figure 1).
5.
Raise the DADF, leaving the Document Glass Cover down.
6.
Remove the Document Input Tray Assembly (Figure 2).
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May 2003
4-211
REP 05-6
Disconnect P6
from the DADF
PWB, noting the
correct harness
routing.
Disconnect the
ground wire faston.
Figure 1 Connectors
REP 05-6
May 2003
4-212
V0.042
REP 05-7 DADF Exit Shaft

Removal
Lift out the Document Input

Tray Assembly
and remove it.
WARNING
1.
2.
Raise the DADF.
3.
WARNING
4.
1
Remove the T20
screws (2).
5.
Figure 2 Removal

a.
DADF Main Cover (four 1/4-turn slotted fasteners)
b.
c.
Detension and remove the Exit Clutch drive belt (Figure 1).
6.
Loosen the bearing retainer screw and disconnect the ground wire (Figure 2).
7.
Prepare to remove the DADF Exit Shaft (Figure 3).
8.
Remove the DADF Exit Shaft (Figure 4).
Replacement
Remember the following:
Connect the ground wire faston.
Route the harness correctly, as noted during Removal, so that it is not pinched when the
DADF Main Cover is installed.
V0.042
May 2003
4-213
REP 05-6, REP 05-7
screw (T20)
ground wire
Figure 2 Ground Wire and Screw
1
Loosen the T20
screw (hidden),
move the idler
down and hold it,
then retighten
the screw.
Remove the belt

from the exit
shaft pulley.
REP 05-7
May 2003
4-214
V0.042
Loosen the T20

screws (2) and rotate
the retaining brackets
(2) out of the way.
Lift the shaft at

the rear.
2
Slide the shaft to
the rear, and
remove it from
the front support.
1
Disconnect the
clutch connectors (2).
Figure 3 Connectors, Retainers, and Screws
V0.042
Figure 4 Removal
May 2003
4-215
REP 05-7
Replacement
1.
Position the DADF Exit Shaft in the DADF (Figure 5).
2.
Reconnect the ground wire to the rear bearing retainer screw.
3.
Secure the shaft and connect the clutches (Figure 6).
4.
Reinstall and retension the Exit Clutch drive belt (Figure 7).
5.
2
Orient the two
clutches with
their antirotation
tabs downward.
Slide the front

end of the shaft
forward into the
front support.
3
Lower the rear end of the shaft into position with each of the two clutches' tabs
straddling the tab in the DADF so the
clutches will not rotate on the shaft.
REP 05-7
May 2003
4-216
V0.042
1
Rotate the retaining
brackets (2) into
position and tighten
the T20 screws (2).
2
Connect the clutch
connectors (2):
front clutch:
black and white
wires
Loosen the T20 screw

(hidden), turn the motor
3-4 turns CCW as
viewed from the rear,
then retighten the
screw.
rear clutch:
brown and red
wires
Figure 6 Installation (continued)
V0.042
Reposition the
belt on the exit
shaft pulley.
Figure 7 Belt Installation
May 2003
4-217
REP 05-7
REP 05-8 DADF Feed Motor

Removal
2
Remove the T20
screws (2).
WARNING
Lift the DADF

Feed Motor out
and remove it.
1.
2.
Raise the DADF.
3.
WARNING
4.
5.

a.
DADF Main Cover (four 1/4-turn fasteners)
b.
c.
d.
DADF Registration Deskew Assembly (REP 05-5)
e.
DADF Exit Shaft (REP 05-7)
Remove the DADF Feed Motor (Figure 1).

NOTE: Observe the routing of the motor harness, to aid in replacement: The harness is
routed through the CVT/Reg. Roll Drive Belt PL 2.3.
1
Disconnect P7
from the DADF
PWB. (See
NOTE.)
Figure 1 Removal
REP 05-8
May 2003
4-218
V0.042
REP 05-9 CVT Drive On Glass Kit
NOTE: The front ski (shorter) also has a 'foot' that must be positioned toward the
front and pointing to the right.

Single-ski and Three-ski kit instructions use vs. using this REP
Refer to Table 1.
If you are installing the Single-Ski Drive On Glass Kit in a machine that does not already have
the single ski (upgrading to TAG 075), follow the instructions provided in the kit to install all
parts provided in the kit and mark off TAG 075 on the IOT Change Tag Matrix. If you are installing the Single-Ski Drive On Glass Kit in a machine that does already have the single ski (with
TAG 075), the link and the belt provided in the kit are not required, and you may use this procedure.
b.
Remove the center ski (if present), while observing the correct orientation (Figure 3).
c.
Remove the rear CVT Ski, while observing the correct orientation (Figure 4).
NOTE: The rear ski (longer) also has a 'foot' that must be positioned toward the rear
and pointing to the right.
5.
Remove the CVT Drive On Glass Roll (Figure 5).
If you are installing the Three-Ski Drive On Glass Kit in a machine that does not already have
two or three skis, follow the instructions provided in the kit to install all parts provided in the kit.
If you are installing the Three-Ski Drive On Glass Kit in a machine that does already have two
or three skis, the link and the belt provided in the kit are not required, and you may use this procedure.
Table 1
Installing Singleski kit
Installing Threeski kit
Machine currently
has single ski-->
Use this REP. Link Use kit instrucand belt are not
tions and install all
required.
kit parts to convert
from one ski to
three skis.
Machine currently
has two or three
skis-->
Use kit instrucUse this REP. Link

tions and install all and belt are not
kit parts to convert required.
from two or three
skis to one ski.
Removal
WARNING
1.
2.
Raise the DADF.
3.
(With single ski): Remove the single CVT Ski, while observing the correct orientation (Figure 1)
NOTE: The ski has a 'foot' on each end that must be pointing to the right.
4.
(With two or three skis): Remove the CVT Skis:

a.
Remove the front CVT Ski, while observing the correct orientation (Figure 2).
V0.042
May 2003
4-219
REP 05-9
Figure 1 Single-Ski Removal
REP 05-9
May 2003
4-220
V0.042
1
Remove the front ski
and observe the
correct orientation.
Figure 2 Front Ski Removal
V0.042
May 2003
4-221
REP 05-9
Figure 3 Center Ski Removal
REP 05-9
May 2003
4-222
V0.042
1
Remove the rear ski
and observe the
correct orientation.
Figure 4 Rear Ski Removal
V0.042
May 2003
4-223
REP 05-9
3
Unsnap the shaft at
the front and the
rear, and slide it out
of the belt.
1
Slide the belt off of
the pulley.
2
Unhook the spring
(if present), taking
care not to lose the
end.
Figure 5 Shaft Removal
Replacement
If installing a new Drive On Glass Kit, first install the O-rings (if present) onto the shaft (Figure
6).
REP 05-9
May 2003
4-224
V0.042
NOTE: These O-rings reduce reflections from the polished shaft that can cause false sensor
readings. They are not used in the single-ski design (TAG 075).
1
Install the two O-rings
onto the shaft, in the
location shown.
Figure 6 O-RIngs
V0.042
May 2003
4-225
REP 05-9
REP 05-10 DADF Feed Roll Cartridge Release Lever Kit
2.

Removal
3.
4.
Remove the Feed Roll Cartridge Release Lever by unsnapping it in 2 places from the
frame of the DADF Feeder Assembly (Figure 1).
WARNING
1.
2
Release the snap by pushing it
toward the left.
1
Release the snap by prying it
toward the right.
3
Lift the lever off the frame of
the DADF Feeder Assembly.
Figure 1 Removal
REP 05-10
May 2003
4-226
V0.042
3.
Replacement
1.
Install the new Feed Roll Cartridge Release Lever, ensuring the yoke on the lever is over
the drive coupling (Figure 2).
2.
Reinstall the DADF Main Cover and close the DADF Top Cover.
Check the operation of the DADF Feeder Assembly by feeding at least one sheet of paper
through the DADF.
NOTE: A pen or other sharp instrument is required to disengage the DADF Paper Feed
Roll Cartridge when the new Feed Roll Cartridge Release Lever is installed. The CSE
has the option of instructing those customers who wish to replace the DADF Paper Feed
Roll Cartridge, how the new Feed Roll Cartridge Release Lever operates.
Yoke - on underside of
release lever
4
Snap the new lever onto the
DADF Feeder Assembly frame.
1
Move the new
release lever into
position on the DADF
Feeder Assembly
frame.
2
Ensure the yoke on the bottom of the release lever is
placed over the drive coupling
3
Press down here to
retract the solenoid.
Drive Coupling
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May 2003
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REP 05-10
REP 05-11 DADF Exit Clutch

Removal
NOTE: The procedure below requires the use of external retaining ring pliers 600T41402. If
you do not have this tool or an equivalent, do not use this procedure. Instead, remove the
DADF Exit Shaft (REP 05-7), and then either replace the DADF Exit Shaft (recommended) or
remove and replace the DADF Exit Clutch on the shaft (remove one e-ring to remove the clutch
from the shaft).
WARNING
1.
2
Remove the
belt from the
exit shaft pulley.
2.
Raise the DADF.
3.
WARNING
4.
5.
De-tension and remove the belt, and remove the e-ring (Figure 1).
6.
Remove the C-ring (using external retaining ring pliers 600T41402 or equivalent), and
remove the pulley part of the DADF Exit Clutch (Figure 2).
7.
Remove the electrical part of the clutch, observing the correct alignment to the anti-rotation tab for later installation (Figure 3).
REP 05-11
Remove the
e-ring.
1
Loosen the T20 screw (hidden),
move the idler down and hold it,
then retighten the screw.
May 2003
4-228
Figure 1 Detension the Belt
V0.042
2
Remove the
pulley part of
the clutch.
1
Remove the
C-ring.
Figure 2 Pulley Removal
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May 2003
4-229
REP 05-11
2
1
Remove the
electrical part
of the clutch.
Disconnect the
connector from
the clutch.
3
Observe the correct
alignment with the
anti-rotation tab.
Figure 3 Electrical Clutch Removal
Replacement
Be sure to align the clutch correctly with the anti-rotation tab, as observed during Removal
(Figure 3).
REP 05-11
May 2003
4-230
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REP 06-1 ROS Assembly

Removal
WARNING
1.
2.
Remove the following:

CAUTION
Lock the machine casters before removing the HCF (if present).
a.
b.
Any optional input device from the left side of the machine (Bypass Tray or HCF/
Bypass Tray)
Left Side Cover.
1
Disconnect P1
and P3 from the
ROS.
c.
Xerographic Module
d.
Developer Housing (REP 09-2)
e.
Paper Trays 1 and 2
f.
Developer Housing Support Rail (REP 09-10)
Disconnect the
ground faston
from the rear IOT
frame.
3.
Disconnect the electrical connectors at the rear of the ROS (Figure 1).
4.
Remove the ROS.

a.
Remove the T20 screw securing the bottom rear ROS mounting brackets together,
accessing from the front through the paper tray opening (Figure 2).
b.
Lift the front of the ROS and pull the ROS out the front of the machine.
VIEWED FROM THE LEFT

SIDE OF THE MACHINE
Figure 1 Connectors
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May 2003
4-231
REP 06-1
6.
Remove the T20

screw (1).
i.
Enter [NVM tab , NVM Tool], select the [Machine] pull-down menu and select
[Download].
ii.
After the NVM has downloaded, select Service = [Mark Service] and Module=[F1IOT 1,1] or [F2IOT 1,1].
iii.
After the screen refreshes, scroll down to location 723 and enter the imageFastScanReg value from the ROS label.
iv.
Scroll down to location 729 and enter the hallPeriodRef value from the ROS
label. If the value is rejected due to a range checking error, scroll down to location 1397 and enter the hallPeriodRef value there instead.
v.
Scroll down to location 793 and enter the exposureCalibration value from the
ROS label.
vi.
Exit NVM Tool in order to make the NVM changes effective.
b.
Enter [Marking tab , Xerographic Diagnostics], select the [Xerographic Routines] tab
and run the Set-Up.
c.
Perform ADJ 8-1A IOT Lead Edge Registration.
Figure 2 Screw
Replacement
1.
2.
If replacing the ROS with a new one, record the three values off of the label on the new
ROS before installing it (Figure 3):
a.
Record the imageFastScanReg number. Under the third barcode, it is the number
after the "L" (three digits).
b.
Record the hallPeriodRef number. Also under the second barcode, it is the number after the "H" (four, five, or six digits).
c.
Record the exposureCalibration number. Under the second barcode, it is the

number after the "E" and before the "H" (a zero, a decimal point, and four digits).
hallPeriodRef
exposure Calibration
imageFastScanReg
Position the ROS.

a.
Insert the rear locating pins of the ROS into the rear mounting bracket in the
machine (sandwich the two brackets together) (Figure 4).
b.
Lower the front locating pin into the front support hook.
c.
Install the T20 screw securing the bottom rear ROS mounting brackets together,
accessing from the front through the paper tray opening.
3.
Connect the electrical connectors at the rear of the ROS (Figure 5).
4.
Reinstall the remaining components in the reverse order of Removal.
VALUES SHOWN HERE

ARE EXAMPLES ONLY
Figure 3 ROS NVM Values on Label
CAUTION
Ensure that the ROS is not contacting any structural part of the machine (Developer Housing,
etc) which may transmit vibration to the ROS and cause image quality problems.
5.
If replacing the ROS with a new one, perform the following:

a.
Enter into NVM the exposureCalibration , hallPeriodRef , and imageFastScanReg values printed on the ROS barcode label as follows:
REP 06-1
May 2003
4-232
V0.042
mounting bracket
in the machine
2
Connect P1 and
P3 to the ROS.
ROS locating
pins
Connect the
ground faston at
the rear IOT
frame.
VIEWED FROM THE LEFT

SIDE OF THE MACHINE
Figure 5 Connectors
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May 2003
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REP 06-1
REP 06-2 ROS Polygon Motor (With Tag #057 Only)

Removal
CAUTION
Do not remove the Polygon Motor except to replace it with a new one. Due to the high risk of
contamination or damage to the Polygon Motor or other components inside the ROS, the ROS
must never be opened in any attempt at cleaning or any other service inside the ROS, except
when required to replace the Polygon Motor.
Remove the T20

screw and
remove the ROS
ground wire.
Remove the T20 screws (2).
NOTE: Only a machine with an aluminum ROS (TAG 057) has a replaceable ROS Polygon
Motor. Otherwise, you must replace the entire ROS for any Polygon Motor failure.
WARNING
1.
2.
CAUTION
3.
a.
Bypass Tray)
b.
Left Side Cover
c.
Xerographic Module
d.
e.
Paper Trays 1 and 2
Disconnect the
motor ground
wire faston from
the cover.
4
Remove the cover.
Figure 1 Cover Removal
f.
Developer Housing Support Rail (REP 09-10)
g.
ROS (REP 06-1)
Remove the top cover from the ROS (Figure 1).

CAUTION
Use extreme caution to avoid contamination or damage to the Polygon Motor and the inside of
the ROS. Minimize the length of time that ROS is open, prevent any dirt from contaminating
the Polygon Motor or the inside of the ROS, and do not touch the facets of the Polygon Mirror.
4.
Remove the Polygon Motor (Figure 2).
REP 06-2
May 2003
4-234
V0.042
Disconnect the Polygon Motor

connector from the PWB.
Lift out the Polygon Motor.
Insert the Polygon Motor in the

orientation
shown.
Position the ribbon cable

as shown, and connect the
Polygon Motor connector
to the PWB.
Remove the T20

screws (4; one is
hidden in this view).
Install the T20

screws (4; one is
hidden in this view).
Figure 2 Motor Removal
Figure 3 Motor Installation
Replacement
1.
Install the Polygon Motor into the ROS (Figure 3).
2.
Reinstall the top cover onto the ROS (Figure 4).
3.
Reinstall the remaining components in the reverse of removal.
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REP 06-2
Install the ROS

ground wire and
install the T20
screw.
4
Connect the
motor ground
wire faston to the
cover.
1
Position the cover.
Figure 4 Cover Installation
REP 06-2
May 2003
4-236
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REP 07-1 Paper Feed Drives Plate

Removal
Remove the T20

screw and pull
out the tray 1 left
rail.
WARNING
1.
2.
Remove the appropriate paper tray assemblies: either trays 1 and 2 or trays 3 and 4.
CAUTION
3.
Remove any optional input device from the left side of the machine (Bypass Tray or HCF/
Bypass Tray).
4.
Remove the Left Side Cover from the IOT.
5.
Disconnect the appropriate sensors and free the sensor wires from the cable clamps (Figure 1).
6.
Remove the appropriate slide rail/paper guide assemblies: either the trays 1 and 2 rails or
the trays 3 and 4 rails (one T20 screw each at the front frame, and pull out of the drives
plate at the rear). For trays 1 and 2 see Figure 2. For trays 3 and 4 see Figure 3.
7.
Remove the desired Paper Feed Drives Plate: either the trays 1 and 2 drives plate or the
trays 3 and 4 drives plate. For trays 1 and 2 see Figure 4. For trays 3 and 4 see Figure
5.
2
Repeat for the
tray 2 left rail.
1
Disconnect
these three
sensors if
removing
the trays 1
and 2 drives
plate.
Figure 2 Trays 1 and 2 Rails
OR
Disconnect
these two
sensors if
removing the
trays 3 and 4
drives plate.
2
Free the disconnected
sensors'
wires from
the cable
clamps.
Figure 1 Sensor Connectors
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REP 07-1
1
Remove the T20
screw and pull
out the tray 3 left
rail.
1
Disconnect
connector.
Remove T20
screws (4).
Repeat for the

tray 4 left rail.
Figure 3 Trays 3 and 4 Rails
REP 07-1
Figure 4 Trays 1 and 2 Removal
May 2003
4-238
V0.042
CAUTION
Be sure to dress the sensor harnesses correctly, out of the paper path, when reconnecting the
sensors on the slide rail/paper guide assemblies.
3.
Disconnect
connector.
For 65 ppm or
55 ppm
machines
ONLY, remove
this jumper.
(Leave it on for
40 ppm
machines.)
2
Remove T20
screws (4).
Figure 5 Trays 3 and 4 Removal
Replacement
CAUTION
Be sure to configure a new drives plate for 65 ppm or 55 ppm by removing the jumper from the
feed motor IIOC PWB on the drives plate, if required. However, do not remove the jumper for
a 40 ppm machine. If the drives plate is configured incorrectly, 08-105 jams will result.
NOTE: A new Paper Feed Drives Plate comes preconfigured for a 40 ppm machine, with a
jumper in place on the feed motor IIOC PWB. This jumper must be removed for a 65 ppm or 55
ppm machine, but must remain in place for a 40 ppm machine.
1.
2.
If replacing the Paper Feed Drives Plate with a new one in a 65 ppm or 55 ppm
machine only, configure the new drives plate for 65 ppm or 55 ppm by removing the
jumper from the feed motor IIOC PWB on the new drives plate (Figure 6).
Figure 6 Jumper
Align the drives plate's two locating pins with the holes in the machine frame, install the
four screws, and connect the connector. For trays 1 and 2 see Figure 7. For trays 3 and
4 see Figure 8.
V0.042
May 2003
4-239
REP 07-1
connector
connector
T20 screws (4)

T20 screws (4)
REAR VIEW
REAR VIEW
locating pins
locating pins
Figure 7 Trays 1 and 2 Installation
REP 07-1
Figure 8 Trays 3 and 4 Installation
May 2003
4-240
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REP 07-2 Paper Tray Assembly
REP 07-3 HCF/Bypass Tray Assembly

Removal

Removal
WARNING
1.
Pull out the desired Paper Tray until it stops.
2.
While gently pulling outward on the tray, insert the tip of a screwdriver into the opening in
the left rail and lift the latch until the tray slides farther out. Repeat on the right rail to
release the right latch, and remove the Paper Tray Assembly.
3.
If replacing the Paper Tray Assembly with a new one, do the following:
1.
2.
If the HCF/Bypass Tray is equipped with a Paper Heater, disconnect the heater power
cord from the IOT (Figure 1).
3.
If the HCF/Bypass Tray is equipped with a Paper Heater and you are replacing the HCF/
Bypass Tray Assembly with a new one, remove the Paper Heater and Heater Cover from
the HCF, for installation into the new HCF/Bypass Tray Assembly (Figure 2).
CAUTION
4.
Ensure that a Feed Roll Cartridge is installed in the Paper Tray before sliding the tray in. Damage can occur if the Paper Tray elevator raises without a Feed Roll Cartridge installed in the
tray.
Release the hand-operated 1/4-turn fastener at the rear of the HCF/Bypass Tray Assembly.
5.
Grasp the HCF/Bypass Tray Assembly by the rear hand-hold and by the top front, above
the number 5 -- do not grasp the Bypass Input Tray or the top cover.
a.
Remove the Feed Roll Cartridge from the old tray, to be reinstalled later onto the new
tray.
b.
Remove the tray number from the old tray, to be reinstalled later onto the new tray.
Replacement
CAUTION
If replacing the Paper Tray Assembly with a new one, perform the following:
Install the Feed Roll Cartridge, removed earlier from the old tray, onto the new tray.
Do not grasp the HCF/Bypass Tray Assembly by the top cover or by the Bypass Input Tray -these methods will cause damage. Grasp only in the areas specified below.
2.
Install the tray number, removed earlier from the old tray, onto the new tray.
6.
3.
Check/adjust IOT Top Edge Registration (IB-OB), Side 1, (ADJ 8-1B) for that tray only.
Carefully lift the assembly while gently pulling outward, until only the top two hooks disengage from the IOT frame.
7.
Rest the assembly against your body while disconnecting the electrical connector from
the IOT.
8.
Grasp the assembly in the same manner as above and lift carefully until the bottom two
hooks disengage from the IOT.
1.
NOTE: To run the machine with the HCF/Bypass Tray Assembly removed, you must
cheat the Input Devices Safety Interlock switch on the left side of the machine.
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May 2003
4-241
REP 07-2, REP 07-3
Disconnect the heater

power cord (if present)
from the IOT.
Figure 1 Heater Power Cord
REP 07-3
May 2003
4-242
V0.042
1
Remove the T20 screw and
pull out the Heater Power
Cord.
2
Remove the T20
screws (2), and
remove the
Paper Heater
and the Heater
Cover.
Figure 2 Heater Removal
Replacement
1.
Install the HCF/Bypass Tray Assembly in the reverse order of removal.
2.
If replacing the HCF/Bypass Tray Assembly with a new one, perform the following:
a.
Check/adjust IOT Top Edge Registration (IB-OB), Side 1, (ADJ 8-1B) for Trays 5 & 6.
b.
Reset the Life Counter for the Paper Feed Roll Cartridges in Trays 5 & 6 (GP6).
c.
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May 2003
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REP 07-3
REP 07-4 Bypass Tray Assembly
REP 07-5 HCF Elevator Motor

Removal

Removal
WARNING
WARNING
1.
1.
2.
Open the top cover of the Bypass Tray Assembly.
2.
Remove the HCF Rear Cover (REP 07-7).
3.
Release the hand-operated 1/4-turn fastener at the rear of the Bypass Tray Assembly.
3.
If replacing the Elevator Motor with a new one, perform the following:
4.
Unhook the rear of the Bypass Tray Assembly from the IOT.
5.
Support the rear of the Bypass Tray Assembly while disconnecting the electrical connector from the IOT.
Remove the HCF/Bypass Tray from the IOT (REP 07-3).
6.
Unhook the front of the Bypass Tray Assembly from the IOT.
Unroute the purple/grey load/run switch wires back from the front of the HCF, to
enable extracting them from the rear.
a.
Remove the HCF Front Cover (REP 07-8).
NOTE: To run the machine with the Bypass Tray Assembly removed, you must cheat the
Input Devices Safety Interlock switch on the left side of the machine.
Replacement
1.
Install the HCF/Bypass Tray Assembly in the reverse order of removal.
2.
If replacing the Bypass Tray Assembly with a new one, perform the following:
3.
a.
Check/adjust IOT Top Edge Registration (IB-OB), Side 1, (ADJ 8-1B) for Tray 5.
b.
Reset the Life Counter for the Paper Feed Roll Cartridge in Tray 5 (GP6).
b.
Remove the HCF/Bypass Tray Feed Motor (REP 08-3).
c.
Prepare to remove the Elevator Motor (Figure 1)

CAUTION
Removing the harness anchor from the HCF frame in the next step must only be done if
replacing the Elevator Motor with a new one. The harness anchor cannot be reused after
it has been removed.
NOTE: The purple and grey wires, extracted through the frame hole in the next step, are
only used for an uncovered HCF (if no Tray 6 door is present). Otherwise the purple and
grey wires are coiled and stored inside the frame hole.
d.
4.
REP 07-4, REP 07-5
For an uncovered HCF only (if no Tray 6 door present), do the following:
May 2003
4-244
Continue to prepare to remove the Elevator Motor (Figure 2)
Remove the HCF Elevator Motor (Figure 3).
V0.042
1
Remove the
switch plate.
2
Disconnect the
connectors from
J5 and J7 on the
PWB.
3
Disconnect the 2 ground wires (T20 screw).
Figure 1 Prepare for Removal
V0.042
May 2003
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REP 07-5
1
Free the Elevator Motor
harness from
the holders.
3
Extract the purple and grey
wires.
2
Remove the
harness
anchor from
the HCF
frame, cutting
as necessary.
Figure 2 Prepare for Removal (continued)
REP 07-5
May 2003
4-246
V0.042
1
Disconnect the
tray ground wire
faston.
3
While supporting the HCF tray,
slide the motor
off of the shaft.
2
Remove the K-clip and the thrust
washer, and save them for reuse.
Figure 3 Removal
Replacement
Ensure that the Elevator Motor harness is routed correctly (Figure 4).
For an uncovered HCF only (if no Tray 6 door is present): You must route the purple/
grey wire harness back through to the front, as noted earlier, to enable reconnecting the
load/run switch when reinstalling the HCF front cover.
V0.042
May 2003
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REP 07-5
Make sure that

the harness is
routed as
shown, so that
it will not bind
or snag as the
elevator raises
and lowers.
Figure 4 Harness Routing
REP 07-5
May 2003
4-248
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REP 07-6 Bypass Input Tray

Removal
1.
Open the HCF Door (or press the Elevator Button, if present) to lower Tray 6, if possible.
2.
WARNING
3.
4.
If you were unable to lower Tray 6 earlier, remove the Elevator Motor from the shaft (REP
07-5), and lower Tray 6.
5.
Disconnect the connector from J3 on the HCF PWB and free the harness from the holder
(Figure 1).
6.
Prepare to remove the Bypass Input Tray (Figure 2).
7.
Lift out the Bypass Input Tray, removing the front locating pin from its locating hole.
V0.042
May 2003
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REP 07-6
J3
Figure 1 Connector
REP 07-6
May 2003
4-250
V0.042
1
Remove the rear
T20 screw.
REP 07-7 HCF Rear Cover

Removal
1.
Remove the HCF Rear Cover (Figure 1).
2
Remove the bottom T20 screw
(hidden).
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May 2003
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REP 07-6, REP 07-7
1
Release the 1/4turn hand latch,
and slide it out.
5
Pull the cover off
here.
2
Release the slotted 1/4-turn fasteners (2).
Pull out on this

side of the cover.
Disengage the top cover

from the hinge pin.
Figure 1 Removal
REP 07-7
May 2003
4-252
V0.042
REP 07-8 HCF Front Cover

Removal
1.
Remove the HCF/Bypass Tray from the IOT (REP 07-3).
2.
Remove the HCF Front Cover (Figure 1).
2
3
Disengage the
top cover from
the hinge pin.
Pull out on this

side of the cover.
1
Remove the T20
screws (2).
4
Pull the cover off
here, and carefully remove it
partway.
6
Release the harness from the
hooks (2).
5
Disconnect the harness from the load/
run switch.
Figure 1 Removal
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May 2003
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REP 07-8
REP 07-9 HCF PWB

Removal
CAUTION
WARNING
Install the
jumper for a
HCF with a
Tray 6 Door.
1.
2.
3.
Remove the HCF PWB:

a.
Disconnect all connectors from the PWB.
b.
Release each of the standoffs (5), and remove the PWB.
Replacement
1.
If the HCF has a door on Tray 6, install the jumper, provided with the new PWB, onto the
new PWB (Figure 1).
If the HCF does not have a door on Tray 6, ensure that no jumper is installed on the
new PWB (Figure 1).
2.
Install the HCF PWB in the reverse of removal.
Ensure that no
jumper is
installed for a
HCF without a
Tray 6 Door.
Figure 1 Jumper
REP 07-9
May 2003
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V0.042
REP 08-1 Vertical Transport

Removal
1
Remove the top
T20 screws (2).
WARNING
1.
2.
Remove any optional input device from the left side of the machine (Bypass Tray or HCF/
Bypass Tray).
CAUTION
3.
Remove the Left Side Cover from the IOT.
4.
Remove the Vertical Transport.

a.
Remove the T20 screws (3) (Figure 1).
b.
Press the Vertical Transport downward to unclip the top corners from the Registration Transport.
c.
Tilt the top of the Vertical Transport outward from the left side of the IOT, lift the bottom out, and remove the Vertical Transport.
2
Remove the bottom T20 screw.
Figure 1 Removal
Replacement
1.
Position the Vertical Transport.

a.
Insert the bottom of the Vertical Transport, then tilt the top into the left side of the IOT.
b.
Position the Vertical Transport carefully to align with the Registration Transport, then
lift the Vertical Transport firmly, to clip the top corners into the Registration Transport.
NOTE: Ensure that the Vertical Transport and Registration Transport gears are
engaged before installing the screws.
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REP 08-1
c.
Install the T20 screws (3) securing the top corners of the Vertical Transport to the
Registration Transport.
d.
Install the T20 screw securing the bottom of the Vertical Transport to the frame.
2.
Reinstall the remaining parts in the reverse of Removal.
3.
If replacing the Vertical Transport with a new one, perform the following:
a.
Check/adjust top edge registration (IB-OB), side 1, for Trays 1 thru 4 (ADJ 8-1B).
b.
REP 08-2 Registration Transport Assembly

Removal
WARNING
1.
2.
3.
a.
Xerographic Module
b.
c.
Prefuser Transport (PFT) (REP 10-1)
d.
Duplex Transport (REP 10-2)
e.
Vertical Transport (REP 08-1)
Remove the Registration Transport (Figure 1).
2
Remove the
Registration
Transport.
1
Disconnect P82.
Figure 1 Removal
Replacement
1.
REP 08-1, REP 08-2
Position the Registration Transport.

a.
Engage the locating pin at the right rear with the hole in the mounting plate at the
rear machine frame (Figure 2).
b.
Hook the Registration Transport into the left IOT frame in two places.
2.
Connect P82 at the rear wall.
3.
May 2003
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V0.042
4.
a.
b.
c.
d.
e.
Xerographic Module
Remove the Top Rear Cover from the IOT and loosen and then retighten the T20 screw
securing the rear Registration Transport mounting plate. The mounting plate is shown in
Figure 2, and the screw is shown in Figure 3.
M1 Motor
NOTE: Loosening and retightening this screw will ensure free play of the Registration
Transport to seat fully to the rear when the Xerographic Module is installed. Otherwise, it
can interfere with the Xerographic Module installation and damage the Xerographic Module.
5.
rear mounting plate

screw
If replacing the Registration Transport with a new one, perform the following:
a.
Check/adjust lead edge registration (process direction) (ADJ 8-1A).
b.
Figure 3 Rear Mounting Plate Screw
rear mounting plate
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May 2003
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REP 08-2
REP 08-3 HCF/Bypass Tray Feed Motor

Removal
WARNING
1.
2.
3.
Disconnect the connector from J4 on the HCF PWB (Figure 1).
With TAG H002 only: Free the mylar shield at the bottom (Figure 2).
4.
Remove the HCF/ Bypass Tray Feed Motor (Figure 3).
REP 08-3
May 2003
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J4
Figure 1 Connector
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May 2003
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REP 08-3
mylar shield
(with Tag #H002
only)
WIth Tag #H002

only:
Remove the harnesses from this
clip, rotate the clip
to align with the slot
in the mylar shield,
and pull the bottom
of the shield off of
the clip.
Figure 2 Mylar Shield
REP 08-3
May 2003
4-260
V0.042
3
Remove the T20 screws
(3), and remove the
motor and the belt.
1
Remove and
save the spring.
2
Free the harness from
the cable clips attached
to the motor bracket and
move the harness to the
right as shown.
Figure 3 Removal
Replacement
6.
Route the harnesses as before.
7.
Test-feed from both Tray 5 and Tray 6. If gear noise occurs, check the Bypass feed gear
mesh (Figure 6).
8.
If the mylar shield is present on the new feed motor and was not on the old motor, mark
off TAG H002 on the HCF Tag Matrix.
May 2003
4-261
NOTE: A new version of the feed motor (TAG H002) has a mylar shield attached, which may
not have been present on the old feed motor. If this shield is present, you will be instructed
later to connect the bottom of the shield correctly, and to mark off TAG H002 on the HCF Tag
Matrix as required.
1.
Prepare to install the HCF/Bypass Tray Feed Motor (Figure 4).

NOTE: A new drive belt is provided with the new motor.
2.
Begin to install the HCF/Bypass Tray Feed Motor (Figure 5).
3.
Continue installing the HCF/Bypass Tray Feed Motor, setting the Bypass feed gear mesh
(Figure 6).
4.
Finish installing the HCF/Bypass Tray Feed Motor, setting the belt tension (Figure 7).
5.
Reconnect the connector to J4 on the HCF PWB (Figure 8).
With TAG H002, or if the mylar shield is present on the new feed motor:
mylar shield at the bottom (Figure 9).
V0.042
Connect the
REP 08-3
2
Move this bracket
to the left as
shown (stretching
the spring), and
tighten this screw.
Loosen the
T20 screws
(3).
Position the belt around

the HCF Feed Shaft
Pulley as shown.
1
Insert the motor
bracket behind
the harness as
shown.
3
Position the motor
bracket against the
HCF frame, aligning
the screw holes (3).
Position the belt

around the pulley and the
motor shaft as
shown.
Figure 4 Prepare for Installation
REP 08-3
May 2003
4-262
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1
Install the T20
screws (3)
loosely.
Tighten the screws in

the following order:
upper right first, upper
left second, lower right
last.
3
Ensure that the
bypass feed
gears mesh
properly.
2
Install the spring.
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May 2003
4-263
REP 08-3
1
Loosen this screw. (All 3
screws should now be loose.)
2
Rotate the motor
3-5 turns to allow
the belt to align.
3
Tighten the screws (3;
one is hidden).
REP 08-3
May 2003
4-264
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J4
Figure 8 Connector
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May 2003
4-265
REP 08-3
mylar shield,
present on new
Tag H002 feed
motor
WIth Tag #H002, or

if the new motor has
the mylar shield:
1
Remove the harnesses from this
clip (as required),
rotate the clip to
align with the slot
in the mylar shield,
and position the
shield slot all the
way onto the clip.
2
Rotate the clip
back to the orientation shown,
securing the bottom of the shield,
and reinsert the
harnesses.
Figure 9 Mylar Shield
REP 08-3
May 2003
4-266
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REP 08-4 Bypass Tray Feeder

Removal
1
Squeeze the
tabs together.
WARNING
1.
2.
If replacing the Bypass Tray Feeder with a new one, remove the Paper Feed Roll Cartridge from the Bypass Tray, to be reused in the new feeder.
3.

a.
HCF Rear Cover (REP 07-7).
b.
Bypass Input Tray (REP 07-6).
c.
HCF Top Cover (Figure 1).
4.
Disconnect the connector from J2 on the HCF PWB (Figure 2), and free the harness from
the cable clips.
5.
Remove the Bypass Tray Feeder (Figure 3).

NOTE: Save the bushing to reuse upon replacement.
3
2
Remove and
save the bushing.
Repeat for the

other side, and
remove the HCF
Top Cover.
Figure 1 HCF Top Cover Removal
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May 2003
4-267
REP 08-4
J2
Figure 2 Connector
REP 08-4
May 2003
4-268
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2
Remove the Bypass Tray
Feeder, disengaging the
locating/pivot pin at the
front.
1
Remove the T20
screw at the
rear. Save the
bushing.
Figure 3 Removal
Replacement
CAUTION
Do not overtighten the screw when installing the Bypass Tray Feeder. This will cause the pivot
bushing to bind when the Bypass Tray Feeder is raised and lowered with the opening and closing of the HCF Top Cover.
Remember to:
Reuse the bushing when installing the Bypass Tray Feeder.
Reconnect the connector to J2 on the HCF PWB.
If replacing the Bypass Tray Feeder with a new one, reinstall the Paper Feed Roll Cartridge in the Bypass Tray.
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May 2003
4-269
REP 08-4
REP 08-5 HCF Feeder

Removal
WARNING
1.
2.
If replacing the HCF Feeder with a new one, remove the Paper Feed Roll Cartridge from
the HCF, to be reused in the new feeder.
3.

a.
b.
c.
Bypass Tray Feeder (REP 08-4).
4.
Disconnect the connector from J6 on the HCF PWB (Figure 1), and free the harness from
the cable clips.
5.
Remove the HCF Feeder (Figure 2).
REP 08-5
May 2003
4-270
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J6 (hidden)
Figure 1 Connector
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May 2003
4-271
REP 08-5
1
2
Lift out the HCF Feeder,
removing the pulley from
inside the belt.
Figure 2 Removal
Replacement
1.
Install the HCF Feeder (Figure 3).
2.
Reconnect the connector to J6 on the HCF PWB.
3.
4.
If replacing the HCF Feeder with a new one, reinstall the Paper Feed Roll Cartridge in the
HCF.
REP 08-5
May 2003
4-272
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2
Position the HCF Feeder and
install the T20 screws (2).
1
Insert the HCF Feeder
pulley inside the belt.
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May 2003
4-273
REP 08-5
REP 08-6 HCF Paper Handling Baffle
3.

Removal
WARNING
1.
2.
Remove the Tray 6 Paper Feed Roll Cartridge.
4.
5.
6.

a.
b.
c.
Bypass Tray Feeder (REP 08-4).
d.
HCF Feeder (REP 08-5).
Release the locking tabs for the paper handling baffle (Figure 1).
Lift the baffle free of its mounts (Figure 2).
Tilt the baffle up and remove it (Figure 3).
2
Repeat for the
other locking tab.
1
Press in gently to
release the locking tab, and lift
the baffle slightly.
Figure 1 Locking Tabs
REP 08-6
May 2003
4-274
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Lift the baffle up evenly,

at least 10 mm, ensuring that it is free of its
mounts and loose
before the next step.
Figure 2 Removal
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May 2003
4-275
REP 08-6
1
Tilt the baffle up
approximately
90.
2
Lift the baffle out.
REP 08-6
May 2003
4-276
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REP 08-7 Registration Sensor (S2)
Replacement
CAUTION
Be careful, and take your time, when installing the new baffle. The plastic tabs on the baffle
can break if over-stressed.
1.

Removal
WARNING
Install the new paper handling baffle, provided in this kit, in the reverse of removal.
1.
2.
3.
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May 2003
4-277
a.
Xerographic Module
b.
c.
d.
e.
f.
Registration Transport (REP 08-2)
Remove the Registration Sensor:

a.
Remove the two T20 screws securing the sensor bracket to the Registration Transport (Figure 1).
b.
Lift the sensor bracket, disconnect the sensor connector, and remove the sensor
from the bracket (Figure 2)
REP 08-6, REP 08-7
sensor bracket
T20 bracket
screws (2)
sensor
connector
Figure 1 Bracket Screws
Figure 2 Removal
Replacement
REP 08-7
1.
Install the Registration Sensor onto the bracket and connect the connector (Figure 2).
2.
Position the bracket onto the Registration Transport and install the two screws loosely
(Figure 1).
3.
Push the bracket all the way to the left, and hold it while tightening the two T20 screws.
4.
May 2003
4-278
a.
b.
c.
d.

V0.042
e.
f.
Xerographic Module
REP 08-8 Registration Clutch

Push and hold the
bracket all the way
to the left before
tightening the
screws.

Removal
WARNING
1.
2.

a.
Xerographic Module
b.
c.
d.
e.
f.
Registration Transport Assembly (REP 08-2).
3.
Remove the Registration Gear/Clutch assembly from the Registration Transport (Figure
1).
4.
Remove the Registration Clutch Gear from the Registration Clutch (Figure 2).
Remove the T20 screws (2),

and remove the clutch bracket.
Disconnect the
clutch connector.
4
Remove the gear/
clutch assembly.
3
Remove the E-Ring.
Figure 1 Removing the Gear/Clutch Assembly
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May 2003
4-279
REP 08-7, REP 08-8
c.
Measure to the face of the clutch body that faces the gear: This distance should be
between 8.0 mm and 8.5 mm (between 0.33" and 0.35", or between 21/64" and 22/
64").
NOTE: As an additional check, the tip of a T8 Torx driver inserted in the gap
between the gear tab and the face of the clutch body should fit but not be able to
rotate.
clutch notch
gear tab
d.
If the setup for that gear tab is incorrect, move the gear tab in or out of the clutch
notch as appropriate and go back to step a. for that gear tab.
e.
Repeat steps a. through d. for the other two gear tabs, and again as required until all
three tabs are set up correctly.
3.
Check for and correct any noticeable wobble in the Registration Clutch Gear: Holding the
clutch body, roll the gear on a flat surface and observe whether the gear displays any
wobble in its rotation. If so, go back to step 2. and adjust the clutch/gear spacing to be
more even among the three gear tabs.
4.
gear tab
gap (see NOTE)
Measure to
face of clutch
body:
8.0 to 8.5 mm
Figure 2 Removing/Installing the Registration Clutch Gear
Replacement
CAUTION
Do not press the new gear all the way into the Registration Clutch. Follow the next three steps
to set up the gear/clutch spacing correctly and avoid binding.
1.
2.
scale end square

against gear face
(hidden)
scale flat against

side of clutch body
Start installing the new Registration Clutch Gear provided in this kit onto the Registration
Clutch (Figure 2):
a.
Place the gear on a flat surface with the tabs pointing up.
b.
Align the three clutch notches with the gear tabs, and press the clutch down a short
way onto the gear.
Figure 3 Setting Up the Clutch/Gear Spacing
Set up the spacing of the Registration Clutch Gear on the Registration Clutch (Figure 3):
a.
Place the scale flat against the side of the clutch body, adjacent to one of the gear
tabs.
b.
Slide the scale against the gear so that the end of the scale is square against the
recessed face of the gear.
REP 08-8
May 2003
4-280
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REP 09-1 Xerographic Module
REP 09-2 Developer Housing

Removal

Removal
WARNING
WARNING
1.
1.
CAUTION
2.
Keep the Xerographic Module covered with a black bag while it is out of the machine, to prevent light shock and image quality defects.
3.
Prepare to remove the Developer Housing (Figure 1).
2.
Remove the Xerographic Module according to the CRU instructions.
3.
Clean the Photoreceptor Drive Module (REP 09-11)
Be sure to use the orange plastic cap, provided in the Hardware Kit and in the Developer Housing Kit, to cap the developer collector outlet after disconnecting the Developer Collector Tube.
This will minimize developer leakage and contamination of the machine.
Replacement
CAUTION
4.
1.
Install the Xerographic Module according to the CRU instructions.
2.
3.
If you are replacing the Xerographic Module with a new one, the machine will automatically run a Xerographic Set-Up. Before closing the call, be sure to save the NVM to
Floppy (GP4).
Remove the Developer Housing.

NOTE: A drop cloth is provided in the Developer Housing Kit, to provide a surface on
which to place the housing while minimizing contamination of the customer's site.
CAUTION
Do not rotate the Developer Housing gears by hand. If the Mag Roll is rotated at less than
the normal operating speed (1250 rpm), the developer material can jam between the Mag
Roll and the Donor Roll.
a.
Supporting the front of the housing, slide it out until it stops.
b.
Lift the rear of the housing over the stop on the lower support rail, and remove the
Developer Housing.
NOTE: If not replacing the Developer Housing with a new one, this completes the Developer Housing removal.
Preparing the Old Developer Housing for Return

1.
2.
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May 2003
4-281
Remove the following items to be reinstalled onto the new housing:

a.
BTAC Sensor (REP 09-3).
b.
Toner Dispenser (REP 09-4).
Unpack the new housing, seal the old housing inside the plastic bag provided with the
new housing, and package the old housing in the packaging that the new housing came
in.
REP 09-1, REP 09-2
NOTE: If reinstalling the same Developer Housing removed earlier, skip down to
Replacement.
1
Disconnect P50.
CAUTION
Do not pour developer material on the Mag Roll or Donor Roll, near the developer collector
port, or within 25mm of the auger bearings (Figure 3).
5.
Carefully brush the material off of the center rib and any other surfaces where it may prevent the top cover from seating securely to the Developer Housing (Figure 4).
6.
Reinstall the top cover and secure it with the T10 screws (6) (Figure 2).
7.
Inspect the seating of the top cover to the Developer Housing for gaps or leaks, and adjust
as necessary.
CAUTION
Do not rotate the Developer Housing gears by hand. If the Mag Roll is rotated at less than the
normal operating speed (1250 rpm), the developer material can jam between the Mag Roll and
the Donor Roll.
8.
Return the empty developer material bottle in the package with the old Developer Housing.
9.
Reinstall the following items, removed earlier from the old housing, onto the new housing:
a.
Toner Dispenser (REP 09-4).
b.
BTAC Sensor (REP 09-3).
Replacement
1.
Disconnect the developer collector tube and

cap the outlet on the
housing
Lift the rear of the housing over the stop and align its center ribs with the center
groove on the lower support rail (Figure 5).
b.
Supporting the front of the housing, slide it all the way in.
NOTE: If the housing will not slide all the way in at first, you may need to rotate the
gears slightly at the rear of the Developer Housing, or lift the rear of the housing
slightly, in order for the housing gears to mesh with the drive gears in the IOT.
Remove the gold

T20 screw.
CAUTION
Figure 1 Removal
Preparing a New Developer Housing
2.
3.
4.
If replacing the Developer Housing with a new one, perform the following:
a.
Load the developer material into the new Developer Housing:
Set up the gear spacing (Figure 7 - shown with the SCAM PWB omitted for clarity).
CAUTION
1.
Place the new Developer Housing on a level surface.
2.
Remove the T10 screws (6) securing the top cover to the new Developer Housing (Figure
2).
3.
Lift the cover off carefully, taking care not to unseat the Mag Roll or the Donor Roll from
the Developer Housing.
4.
Carefully pour the developer material evenly over the two augers only, keeping the
material at least 25mm away from the auger bearings. Do not pour the material on the
Mag Roll or the Donor Roll, or near the developer collector port (Figure 3).
a.
REP 09-2
Position the Developer Housing in the machine.
May 2003
4-282
Use the Developer Drive Alignment Arm as follows to set up the gear spacing, then be
sure to disengage the arm when finished. This will minimize gear noise.
b.
Disengage the Developer Drive Alignment Arm, leaving it in the operating position
(Figure 8 - shown with the SCAM PWB omitted for clarity).
c.
Enter [Marking tab , Xerographic Diagnostics], select the [New Parts Setup] tab, and
run the [Developer Housing Install] Setup. Then, select the [Xerographic Routines]
tab and run the Xerographic Set-Up.
d.
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Carefully pour
the developer
material evenly
over the two
augers only.
Keep the material at least
25mm away from
the auger bearings and away
from the developer collector
port.
T10 screws (6)
Keep the material at least

25mm away from
the auger bearings.
recessed
Do not pour the

material on the
Mag Roll or the
Donor Roll.
Figure 2 Top Cover Screws
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Figure 3 Adding Developer Material
May 2003
4-283
REP 09-2
center rib
Figure 4 Center Rib
REP 09-2
May 2003
4-284
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center groove of
lower support rail
center ribs on
bottom of Developer Housing
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May 2003
4-285
REP 09-2
1
Connect P50.
1
Loosen the
T20 Develope
Gear Bracket
screws (4; bot
tom 2 screws
are hidden).
3
Retighten
the screws
(4).
2
Connect the developer collector tube.
Install the gold

T20 screw.
Snap the alignment arm onto the

Developer Housing shaft (setup
position).
REP 09-2
Figure 7 Setting the Gear Spacing
May 2003
4-286
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REP 09-3 BTAC Sensor

Removal
WARNING
1.
2.
a.
Xerographic Module.
b.
Developer Housing (REP 09-2).

CAUTION
Be careful in removing and installing the BTAC Sensor. Although it simply snaps into place, it
can break if not removed and installed correctly.
3.
Remove the BTAC Sensor (Figure 1).
1
Disconnect P5.
Alignment arm in operating
position (disengaged)
Figure 8 Disengage the Alignment Arm
2
Remove the sensor (snap-fit).
Figure 1 Connector
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May 2003
4-287
REP 09-2, REP 09-3
REP 09-4 Toner Dispenser
Replacement
CAUTION
Be careful in removing and installing the BTAC Sensor. Although it simply snaps into place, it
can break if not removed and installed correctly.
1.
Install the BTAC Sensor in the reverse order of removal.
2.
If replacing the BTAC Sensor with a new one, perform the following:
a.
b.
Enter [Marking tab , Xerographic Diagnostics], select the [Xerographic Routines]

tab, and run the Set-Up.

Removal
WARNING
1.
2.
a.
Xerographic Module.
b.
c.
Dry Ink Cartridge
3.
Prepare to remove the Toner Dispenser (Figure 1).
4.
Remove the Toner Dispenser (Figure 2).

a.
b.
Remove the Toner Dispenser.
1
Disconnect ground
fastons (1, 2 or 3)
from the BTAC
Sensor bracket.
2
Disconnect P5
from the BTAC
Sensor.
REP 09-3, REP 09-4
May 2003
4-288
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a.
b.
T10 screws (2)
2
If replacing the Toner Dispenser
with a new one: Remove the Bottle Empty Sensor, if present.*
1
Remove the
Toner Dispenser.
T10 screw (1)

T10 screw (1)
* Reinstall the Bottle Empty Sensor onto the new Toner Dispenser.
Figure 2 Removal
Replacement
1.
Install the Toner Dispenser in the reverse order of Removal.
2.
If replacing the Toner Dispenser with a new one, perform the following:
a.
Open the front door.
b.
c.
Enter [Marking tab , Xerographic Diagnostics], select the [New Parts Setup] tab, and
run the [Toner Dispenser Fill] routine.
NOTE: If the machine power was switched on with the font door closed, a low toner
fault will appear. If this occurs, open and close the front door, reenter [Marking tab ,
Xerographic Diagnostics], reselect the [New Parts Setup] tab, and rerun the [Toner
Dispenser Fill] routine.
d.
Close the front door (if open).
e.
Select the [Xerographic Routines] tab and run the Set-Up.
f.
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May 2003
4-289
REP 09-4
REP 09-5 Photoreceptor Drive Module

Removal
WARNING
1.
2.
Remove the Xerographic Module (REP 09-1).

NOTE: The replacement Photoreceptor Drive Module box contains two installation tools:
One on top, for use when removing the old module; and one on the new module, for use
when installing the new module. The installation tool takes the place of the Xerographic
Module and supports the Photoreceptor Drive Module while the Photoreceptor Drive
Module and surrounding modules are removed and installed. Both tools are then
returned along with the old module, in the new module's packaging.
CAUTION
Take care not to stress the front of the Photoreceptor Drive Module when it is in the machine
and the Xerographic Module is removed. Excessive deflection of the Photoreceptor Drive
Module, when not supported by the Xerographic Module or the installation tool, can adversely
affect the Photoreceptor Drive Module's critical alignment. This is true for the 'old' module
which is being removed as well as for the new module which is being installed, because (1) the
rear IOT frame can become bent and (2) the 'old' module must be returned for possible remanufacturing.
3.
Obtain the installation tool from inside the top of the new Photoreceptor Drive Module box
(Figure 1).
4.
Install the tool in place of the Xerographic Module.
5.
6.
a.
Bypass Tray).
b.
Left side cover and all rear covers.
c.
Vertical Transport (REP 08-1).
d.
e.
Fuser Module
f.
Prefuser Transport (REP 10-1).
g.
Developer Drive Motor (REP 04-1).
h.
Duplex Transport (REP 10-2).
i.
Registration Transport (REP 08-2).
Disconnect the Photoreceptor Drive Module harness from J3 on the SCAM PWB (Figure
2).
CAUTION
Be sure to capture the spring as instructed, when removing the Photoreceptor Drive Module.
Otherwise, this spring will fall into the paper trays area and may be difficult to retrieve.
7.
Remove the Photoreceptor Drive Module (Figure 3).

NOTE: The spring captured while removing the module must be kept and reused with the
new module, as instructed later.
REP 09-5
May 2003
4-290
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Figure 1 Installation Tool
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May 2003
4-291
REP 09-5
J3 on the SCAM PWB
Figure 2 Connector
REP 09-5
May 2003
4-292
V0.042
7.
Rotate the Xerographic Module locking handle down before installing the Developer
Housing (Figure 7).
8.
Reinstall the Developer Housing (REP 09-2).
9.
Remove the installation tool from the machine (Figure 8).
10. Reinstall the following:
Capture
the spring
during the
following
step.
Remove
long T20
screws
(2).
Xerographic Module (REP 09-1).
b.
Vertical Transport (REP 08-1).
c.
Left side cover and all rear covers.
d.
Any optional input device removed earlier from the left side of the machine (Bypass
Tray or HCF/Bypass Tray).
11. Enter [Marking tab , Xerographic Diagnostics], select the [Xerographic Routines] tab, and
run the Set-Up.
a.
12. Perform ADJ 8-1A IOT Lead Edge Registration.

13. Before closing the call, be sure to save the NVM to Floppy (GP4).
14. Package the old Photoreceptor Drive Module and the installation tools for return:
3
Pull the
module out
of the
machine.
a.
Rotate the handle to the unloaded position, and place the old Photoreceptor Drive
Module into the box correctly (Figure 9).
b.
Place the top foam block into the box correctly (Figure 10).
c.
Place the installation tool into the box correctly, nested into the top foam block (Figure 11).
d.
Insert the additional small foam block, to prevent the module from sliding end-to-end
(Figure 12).
e.
Close and seal the box for return.
Figure 3 Removal
Replacement
1.
Take the Photoreceptor Drive Module out of the box, with the other installation tool
attached (Figure 4).
2.
Begin to install the new Photoreceptor Drive Module (Figure 5).
3.
Continue installing the Photoreceptor Drive Module (Figure 6).
4.
Slide the module/tool the rest of the way in and install the long T20 screws (2) securing
the module to the rear frame.
NOTE: Leave the installation tool in the machine until instructed to remove it later.
5.
Connect the Photoreceptor Drive Module harness to J3 on the SCAM PWB (Figure 2).
6.

a.
b.
c.
Developer Drive Motor (REP 04-1)
d.
Prefuser Transport (REP 10-1)
e.
Fuser Module
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May 2003
4-293
REP 09-5
Carefully lift the module/

installation tool out of the
box.
Align the bottom of the installation

tool with the lower Xerographic
Module support rail.
Figure 4 Removal from the Box
REP 09-5
2
Slide the module
and tool halfway
into the machine.
May 2003
4-294
V0.042
2
Route
the harness
through
the rear
frame.
Rotate the
handle down.
1
Slide the
locating pin
through the
ROS
bracket, and
position the
spring captured earlier.
Figure 7 Rotate the Handle
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May 2003
4-295
REP 09-5
1
Rotate the handle to the
unloaded position.
Remove the installation tool.
2
Place the module in the box as
shown.
Figure 9 Packing the Module
Figure 8 Remove the Installation Tool
REP 09-5
May 2003
4-296
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Place the top foam block into the

box as shown.
Place the installation tool into the box as shown.
Figure 10 Packing the Module (continued)
Figure 11 Packing the Installation Tool
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May 2003
4-297
REP 09-5
1
Insert the foam
block as shown,
ensuring that it
misses the motor
PWB.
2
Slide the block
down until it is
flush with the top
of the large foam
block.
Figure 12 Inserting the Foam Block
REP 09-5
May 2003
4-298
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REP 09-6 Charge HVPS
REP 09-7 Developer HVPS

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
Pull out the Xerographic Module approximately 4 in. (100mm).
3.
Swing out the Card Cage (one 1/4-turn T20 or slotted fastener).
4.
Remove the Charge HVPS.
4.
a.
Disconnect P67 from the Charge HVPS
5.
Prepare to slide the Developer Housing out partway (Figure 1).
b.
Press down on the top hook to release it.
6.
Slide the Developer Housing out approximately 2 in. (50mm).
c.
Pivot the Charge HVPS down.
7.
Remove the Developer HVPS.
d.
Lift the Charge HVPS out at the bottom and remove it.
a.
Disconnect P64 from the Developer HVPS.
Replacement
b.
Lift the tab to release the top clip.
1.
Install the Charge HVPS and other components in the reverse order of Removal.
c.
Lift the Developer HVPS off of the hooks (4 places), and remove it.
2.
If replacing the Charge HVPS with a new one, perform the following:
a.

b.
1
Disconnect P50.
2
Disconnect the
Remove the gold

T20 screw.

V0.042
May 2003
4-299
REP 09-6, REP 09-7
Replacement
REP 09-8 Transfer/Detack HVPS
1.
Install the Developer HVPS in the reverse order of Removal.
2.
Slide the Developer Housing back in.
3.

Removal
WARNING
CAUTION
4.
5.
If replacing the Charge HVPS with a new one, perform the following:
a.

b.
1.
2.
3.
Pull out the Xerographic Module approximately 4 in. (100mm).
4.
Remove the Transfer/Detack HVPS.
1
Connect P50.
a.
Disconnect P65 and P66 from the Transfer/Detack HVPS.
b.
Remove the T20 screw (1) from the left side (as viewed from the rear) of the Transfer/Detack HVPS.
c.
Pivot the left side (as viewed from the rear) of the Transfer/Detack HVPS outward.
d.
Unhook the right side (as viewed from the rear) of Transfer/Detack HVPS (2 places),
and remove it.
2
Connect the
Install the gold

T20 screw.
REP 09-7, REP 09-8
May 2003
4-300
V0.042
REP 09-9 BTAC Sensor Cleaning Procedure
REP 09-10 Developer Housing Support Rail

Cleaning Materials

Removal
Cleaning Towels 600S4372 (soft, lint-free)
Water
WARNING
Clean
1.
WARNING
1.
2.
a.
b.
3.
2.
3.
a.
Xerographic Module.
b.
Prepare to remove the Developer Housing Support Rail:
Xerographic Module.
a.
Remove all rear covers.
b.
c.
Remove the T20 screw securing the rear of the support rail (Figure 1).
Clean the BTAC Sensor.

a.
Lightly dampen a cleaning cloth with water.
b.
Clean the BTAC Sensor with the damp cloth.
4.
Remove the Developer Housing Support Rail (Figure 2).
Remove
the T20
screw (1).
Figure 1 Rear Screw
V0.042
May 2003
4-301
REP 09-9, REP 09-10
1
Remove the Developer
Housing wire harness from
the restraint at the left rear
corner of the support rail.
Install the T20

screw.
2
Remove the T20
screw.
3
Slide the support rail forward
and lift it out.
Figure 2 Removal
Figure 3 Front Screw
Replacement
1.
Reinstall the Developer Housing Support Rail:

a.
Align and engage the rear locating tab with the slot in the rear IOT frame and the
front locating pins with the holes in the front IOT frame.
b.
Install the T20 screw securing the front of the support rail (Figure 3).
c.
Install the T20 screw securing the front of the support rail (Figure 3).
2.
Reinstall the T20 screw securing the rear of the support rail (Figure 4).
3.
Reinstall the remaining components in reverse order of Removal.
REP 09-10
May 2003
4-302
V0.042
REP 09-11 Photoreceptor Drive Module Cleaning

Procedure
Cleaning Materials
Install the
T20 screw
(1).
Film Remover 43P45
Vacuum Cleaner 600T01820
Brush 600T41901
Clean
WARNING
1.
2.
3.
4.
Clean the Photoreceptor Drive Module drive rolls as follows, using the vacuum cleaner
and brush, starting with one of the top rolls:
a.
Start at the rear end of the roll and clean toward the front end.
b.
Rotate the roll 90 and repeat, then rotate 90again and repeat (four times total per
roll).
Figure 4 Rear Screw
5.
c.
Repeat for the other top roll.
d.
Repeat for the bottom roll.
Clean the Photoreceptor Drive Module backer bars:

a.
Protect the ROS image path, ensuring that no fibers get in the ROS window, by placing a long (14 in., 17 in, or A3) piece of paper over the ROS window.
b.
To get better access to the developer backer bar, rotate the Xerographic Module
latch handle as if a Xerographic Module was installed.
c.
Clean all five of the backer bars in the Photoreceptor Drive Module using a lint-free
cloth (600S4372) and Film Remover (43P45).
NOTE: Ensure that the backer bars are clean and smooth after the cleaning. There
should be no tackiness felt.
V0.042
d.
Remove the paper from the ROS window.
e.
Rotate the Xerographic Module latch handle to the unlatched position.
6.
Reinstall the Developer Housing (REP 09-2).
7.
May 2003
4-303
REP 09-10, REP 09-11
REP 09-12 Developer HVPS Contacts Cleaning Procedure
REP 09-13 Donor Roll Cleaning Procedure

Cleaning Materials

Cleaning Materials
Rag
Scotch-brite scouring pad 43P74
One of the following cleaners:
Pumice Paper 43P46
USCO: Film Remover 43P45
Cleaning Cloth, damp
XE: Cleaner 8R90176
Cleaning Cloth, dry
Clean
Clean
WARNING
WARNING
1.
1.
2.
2.
3.
3.
Remove the Toner Dispenser from the Developer Housing (REP 09-4).
4.
Remove the Developer HVPS (REP 09-7).
5.
Pour some of the cleaner onto a rag, then use moderate pressure to clean the two high
voltage contact pads labeled J2 and J3 on the solder side of the HVPS by scrubbing for 5
seconds.
CAUTION
After removing the screws in the next step, do not remove the top cover from the Developer
Housing without first heeding the CAUTION and instructions that follow.
4.
Remove the T10 screws (6) securing the top cover to the Developer Housing (Figure 1).
CAUTION
NOTE: Do not use alternate methods for cleaning the contacts.
6.
Wipe the contacts dry.
You must hold down the Mag. Roll and lift the Developer Housing top cover at the rear (gears
end), in order to remove the top cover without unseating the Mag. Roll. If the Mag. Roll
becomes unseated, developer material may move under the Mag. Roll or under the bearings,
preventing the Mag. Roll and the top cover from re-seating correctly. This can result in toner/
developer leakage and image quality problems.
7.
Reinstall the Developer HVPS (REP 09-7).
5.
Hold down the Mag. Roll gear, carefully lift the Developer Housing top cover by the rear
(gears end), and remove the cover (Figure 2).
6.
Remove the Donor Roll from the Developer Housing (Figure 3).
WARNING
Any Film Remover on the contacts must be completely dry before the machine power is
switched on. Otherwise, a fire may result.
7.
Remove the outboard bearing from the Donor Roll (Figure 3).
8.
Using firm strokes with a Scotch-brite pad, clean the Donor Roll thoroughly.
NOTE: The Donor Roll has a ceramic coating and is difficult to damage.
9.
Wipe the Donor Roll clean with a damp cleaning cloth to remove residual contamination.
10. Wipe the Donor Roll with a dry cleaning cloth to remove all remaining moisture.
11. Using pumice paper, clean the carbon brush wear mark from the Donor Roll Shaft (Figure
4).
12. Reinstall the outboard bearing onto the Donor Roll.
13. Reinstall the Donor Roll, ensuring the following:
Each Donor Roller bearing's anti-rotation tab is engaged in the housing cutout (Figure 5).
The housing pin is in the seal cutout (Figure 5).
The gears mesh.
14. Reinstall the Developer Housing top cover and the T10 screws (6) (Figure 1).
15. Reinstall the Toner Dispenser onto the Developer Housing (REP 09-4).
16. Reinstall the Developer Housing (REP 09-2).
REP 09-12, REP 09-13
May 2003
4-304
V0.042
17. Enter [Marking tab , Xerographic Diagnostics], select the [Xerographic Routines] tab, and
run the Set-Up.
18. Before closing the call, be sure to save the NVM to Floppy (GP4).
Dev.
Housing
top cover
Donor
Roll
T10 screws (6)
Mag. Roll
recessed
Figure 2 Top Cover Removal
Figure 1 Top Cover Screws
V0.042
May 2003
4-305
REP 09-13
outboard bearing
1
Hold the Mag Roll gear down, and
lift the Donor Roll gear up and away
from the housing.
2
Lift the Donor Roll out of the
Developer Housing.
Figure 3 Donor Roll Removal
REP 09-13
May 2003
4-306
V0.042
carbon brush wear mark
DONOR ROLL SHOWN WITH

GEAR REMOVED, FOR CLARITY
Figure 4 Carbon Brush Wear Mark
V0.042
May 2003
4-307
REP 09-13
anti-rotation tab in housing cutout

(other bearing too)
MAG AND DONOR ROLLS

SHOWN WITH GEARS
REMOVED, FOR CLARITY
housing pin in seal cutout
Figure 5 Donor Roll Installation
REP 09-13
May 2003
4-308
V0.042
REP 10-1 Prefuser Transport (PFT)
2.

Removal
3.
Pull out the Fuser drawer.
4.
Remove the PFT Clip (Figure 1).
5.
Remove the PFT (Figure 2).
WARNING
1.
Remove the PFT

Clip.
Figure 1 Clip
V0.042
May 2003
4-309
REP 10-1
1
Disconnect
P94.
rear locating pin

PFT
gear
3
Pull the
PFT out of
the IOT
2
Unhook the
front PFT
locating pin
(up, right,
then down).
Figure 2 Removal
front locating pin
Replacement
1.
2.
Install the PFT.

a.
Insert the left rear locating pin into the locating hole and position the PFT gear on top
of the drive gear at the rear wall of the IOT cavity (Figure 3 and Figure 4).
b.
Connect P94 at the rear wall (Figure 5).
Install the PFT Clip (Figure 6).
WARNING
Be sure to reinstall the PFT Clip. The PFT Clip is required for safety, to prevent the PFT
from being removed accidentally.
3.
Push in the Fuser.
4.
5.
If replacing the PFT with a new one, perform the following:

a.
Check/adjust top edge registration (IB-OB), side 2, Small Paper (ADJ 8-1C).
b.
Check/adjust top edge registration (IB-OB), side 2, Large Paper (ADJ 8-1D).
c.
REP 10-1
May 2003
4-310
V0.042
drive
gear
locating hole
Connect
P94.
Figure 5 Connector
V0.042
May 2003
4-311
REP 10-1
Install the PFT

Clip.
Figure 6 Clip
REP 10-1
May 2003
4-312
V0.042
REP 10-2 Duplex Transport

Removal
Remove the T20

screw (1).
WARNING
1.
2.

a.
Bypass Tray)
b.
Left Side Cover
c.
d.
Xerographic Module
e.
3.
Remove the Area 4 Bracket (Figure 1).
4.
Disconnect the Duplex Module connectors (Figure 2):
Remove the
Area 4 Bracket.
Without TAG 014: 2 connectors

With TAG 014: 3 connectors
5.
Remove the baffle from the left side of the Duplex Transport:
Figure 1 Area 4 Bracket
NOTE: In the following step, lifting the Duplex Transport may provide more clearance for
removing and installing the baffle.
WARNING
Take care not to cut yourself on the top edge of the left frame opening in the next
step. This edge has not been deburred on frames built before June 8, 1998, and
may be sharp.
If the white fastener is present: follow the instructions in Figure 3.
If the white fastener is NOT present: follow the instructions in Figure 4.

6.
Disconnect
P97.
Unlatch the left front corner of the Duplex Transport (Figure 5).
7.
Disengage the spring hook at the right front corner of the Duplex Transport (Figure 6).
8.
Disengage the right front corner of the transport from the IOT frame (Figure 7).
9.
Pull the Duplex Transport straight out the front of the IOT.
1
Disconnect P74.
3
With Tag
#14: Disconnect third
connector.
Figure 2 Connectors
V0.042
May 2003
4-313
REP 10-2
IF THE WHITE FASTENER

IS PRESENT
1
Pull the
white fastener to
release
the baffle.
2
Lift the
Duplex
Transport.
3
Rotate and remove the baffle.
Figure 3 With the White Fastener
REP 10-2
May 2003
4-314
V0.042
IF THE WHITE FASTENER IS NOT PRESENT
1
Push this black
tab to the left
while pulling out
on the baffle, to
release the baffle.
2
Lift the Duplex
Transport.
3
Rotate and
remove the
baffle.
Figure 4 Without the White Fastener
V0.042
May 2003
4-315
REP 10-2
Pull the latch down and

unhook it from the Registration Transport.
Pivot the spring

hook to the left
and hold it for the
next step.
Figure 5 Left Front Latch
Figure 6 Right Front Latch
REP 10-2
May 2003
4-316
V0.042
4.
1
Move the right end
of the transport to
the right.
Position the right front corner of the transport (Figure 12).
5.
Engage the spring hook at the right front corner of the transport Figure 13).
6.
Connect the Duplex Transport connectors (Figure 14).

CAUTION
Do not connect the third connector (Figure 14) unless the machine has TAG 014. Without
TAG 014, a different connector carrying 24 Volts may be in the same location in the machine,
which will damage the Duplex Transport.
7.
8.
9.
Reinstall the Area 4 Bracket.

a.
Position the Area 4 Bracket in the machine, engaging the front and rear locating pins
(Figure 15).
b.
Install the T20 screw in front.

a.
b.
Xerographic Module
c.
If replacing the Duplex Transport with a new one, perform the following:
a.
Enter [Paper tab , IOT Paper Path Setup] and run [Duplex Feed Time] setup.
b.
Check/adjust top edge registration (IB-OB), side 2, Small Paper (ADJ 8-1C).
c.
Check/adjust top edge registration (IB-OB), side 2, Large Paper (ADJ 8-1D).
d.
2
Lift the transport locating tab out
of the T-slot in the IOT frame.
Figure 7 Right Front Corner
Duplex
Transport
left rear
locating
point
Replacement
1.
2.
Position the Duplex Transport.

a.
Insert the Duplex Transport straight into the front of the IOT.
b.
Ensure the right rear lower corner is resting on top of the IOT right frame flange.
c.
Engage the locating point on the Registration Transport at the left rear (Figure 8).
Install the baffle onto the left side of the Duplex Transport.
WARNING
Take care not to cut yourself on the top edge of the left frame opening in the next
step. This edge has not been deburred on frames built before June 8, 1998, and
may be sharp.
If the white fastener is present:
a.
Position the baffle, ensuring the rear locating tab is positioned correctly (Figure
9).
b.
Press the white fastener in place to secure the baffle in position.
Figure 8 Left Rear Locating Point
If the white fastener is NOT present: Install the baffle according to Figure 10.
3.
Secure the Duplex Transport at the left front (Figure 11).
V0.042
May 2003
4-317
REP 10-2
correct position
of locating tab
Duplex Transport left baffle
LEFT SIDE
OF IOT
Figure 9 Correct Baffle Position
REP 10-2
May 2003
4-318
V0.042
1
Insert the baffle between this
tab and the main body of the
Duplex Transport.
Slide the baffle

inward.
Push the baffle back until it clicks

into the latched position.
Figure 10 Without the White Fastener
V0.042
May 2003
4-319
REP 10-2
Latch the Duplex Transport to the

Registration Transport.
Hold the spring

hook as shown.
Figure 11 Left Front Latch
2
Lower the transport locating tab
into the T-slot in the IOT frame.
3
Move the right end
of the transport to
the left.
Figure 12 Right Front Corner
REP 10-2
May 2003
4-320
V0.042
2
Connect
P97.
1
Connect
P74.
3
With Tag
#14: Connect third
connector.
Pivot the spring

hook to the right
and into position
as shown.
Figure 14 Connectors
rear locating
pins
front locating
pins
Figure 13 Right Front Latch

INSIDE
IOT
rear locating
holes
Figure 15 Area 4 Baffle
V0.042
May 2003
4-321
REP 10-2
REP 10-3 Decurler or Exit Baffle

Removal
NOTE: A machine with an OCT uses an active Decurler (may have TAG 040), whereas a
machine with a Finisher usually uses either a disabled Decurler (with TAG 022) or an Exit Baffle.
WARNING
1.
2.
Remove the OCT, or undock the Finisher (REP 12-12) or MFF (REP 12.10.01).
3.
Remove the Decurler or Exit Baffle (Figure 1).
REP 10-3
May 2003
4-322
V0.042
NOTE: A Decurler is
shown here. An Exit
Baffle (Finisherequipped machine
only) has no gears,
rollers, or clutch.
2
Remove the T20
screws (2).
1
Decurler
machines only:
Disconnect the
connector.
3
Lift the Decurler
or Exit Baffle
straight up.
4
Pull the Decurler or Exit Baffle
straight out.
Figure 1 Removal
V0.042
May 2003
4-323
REP 10-3
Replacement
1.
Install the Decurler or Exit Baffle (Figure 2):

NOTE: Figure 2 shows a Decurler. An Exit Baffle (Finisher-equipped machines only)
installs the same as a Decurler, except that it has no gears to engage. An Exit Baffle or a
disabled Decurler (both in Finisher-equipped machines only) also do not use the harness
connector.
a.
Insert the bottom first, then pivot the top in and hook it to the IOT frame.
b.
Exit Baffle only: Install and tighten the T20 screws (2). Skip steps c - e.
c.
Decurler-equipped machines only: Connect the harness connector.
d.
Install the T20 screws (2) loosely, allow the decurler to hang freely, ensuring that the
Decurler and IOT gears mesh correctly.
e.
Hold the Decurler in position while tightening the screws.
Ensure that the

Decurler and IOT
gears mesh
properly before
tightening the
screws.
Finisher-equipped machines, with disabled Decurler (TAG 022) or Exit Baffle only:
Ensure that the jumper is installed on the Decurler harness in the IOT, and that the jumper/harness is positioned correctly:
NOTE: The jumper must be installed to complete the Decurler control circuit that is not
used with the disabled Decurler or Exit Baffle. Also, if the jumper/harness is positioned
incorrectly, it can interfere with the Fuser drawer closing.
a.
Pull out the Fuser drawer and remove the Fuser Module.
b.
Inside the IOT, ensure that the jumper is installed and is positioned correctly (Figure
3).
T20 screws (2)
connector (Decurler
machines only)
REP 10-3
May 2003
4-324
V0.042
REP 10-4 Inverter Drive Assembly, Exit Roll, or Feed/

Reverse Roll
The jumper/connector must be positioned as shown,
against the right side
frame wall of the IOT.

Removal
WARNING
1.
2.
Slide out the Inverter Drawer and remove the Fuser Module.
3.
Disconnect the Inverter Drawer connector from the IOT, and free the harness (two T20
screws).
4.
Remove the Inverter from the rails (four T20 screws).
5.
Separate the Inverter baffles from the Inverter frame (Figure 1).
6.
Separate the Inverter baffles from each other (Figure 2).
7.
Remove the two T20 screws securing the drives bracket to the Inverter, and remove the
ground lug. Some inverters will also have a spacer in the location indicated; if so, save the
spacer to reuse in Installation (Figure 3).
8.
Release the latch on the Exit Roll and begin to slide the shaft out of the roll (Figure 4).
9.
Release the latch on the Feed/Reverse Roll and begin to slide the shaft out of the roll, in
the same manner as for the Exit Roll (Figure 4).
10. Slide the Inverter Drive Assembly out just far enough to access the solenoid connector,
and disconnect the solenoid connector (Figure 5).
11. Slide the Inverter Drive Assembly out the rest of the way (Figure 6).
The jumper/connector
must not be positioned
away from the frame wall,
where it may interfere
with the Fuser drawer
closing.
12. If replacing the Exit Roll or the Feed/Reverse Roll, remove the desired roll (Figure 7).
Figure 3 Jumper/Harness Position
V0.042
May 2003
4-325
REP 10-3, REP 10-4
Figure 1 Inverter Drives Figure 1
REP 10-4
May 2003
4-326
V0.042
1
4
V0.042
May 2003
4-327
REP 10-4
1
Unlatch the Exit
Roll from the shaft.
T20 screw
T20 screw and ground lug
T20 screw and

ground lug
2
Begin to slide the
shaft out of the roll.
There may be a spacer here.

If so, save for re-use.
3
Repeat for the Feed/
Reverse Roll.
REP 10-4
May 2003
4-328
V0.042
1
Slide the drive
bracket out just far
enough to access the
solenoid connector.
2
Disconnect the
solenoid connector.
Slide the drive bracket out

the rest of the way.
V0.042
May 2003
4-329
REP 10-4
1
Slide the roll to the right.
2
Remove the roll out the
bottom of the baffle.
REP 10-4
May 2003
4-330
V0.042
REP 12-1 Top Module Assembly
3.

Removal
WARNING
1.
2.
Remove the following covers from the Finisher PL 8.2:

a.
Finisher Top Cover (disconnect the interlock switch)
b.
Upper Rear Cover
c.
Lower Rear Cover
d.
Upper Right Cover
e.
Lower Rear Right Cover
4.
Remove the nip 3/4 Drive Belt (Figure 1).
5.
Disconnect the necessary connectors (Figure 2).
6.
Remove the Top Module Assembly (Figure 3).
2
Move the idler up.
1
Loosen the T20
idler screw 1/4turn only.
4
Remove the belt.
3
Tighten the screw.

V0.042
May 2003
4-331
REP 12-1
Remove the T20

screws (4).
Disconnect the DC connector and the ground faston from the solenoid.
2
Disconnect the
connector from
J4 on the Finisher Controller
PWB.
2
Remove the Top
Module Assembly.
Figure 2 Connectors
Figure 3 Top Module Removal
Replacement
REP 12-1
May 2003
4-332
Remember to reconnect the interlock switch when reinstalling the Finisher Top Cover.
V0.042
REP 12-2 Stacker Drive Motor
REP 12-3 Finisher Service Tray Assembly

Removal

Removal
WARNING
1.
Press the Pause/Resume Switch to lower the Stacker Tray, and open the Stapler Access
Door.
2.
1.
2.
Remove the Lower Rear Cover from the Finisher PL 8.2.
WARNING
WARNING
personal injury.
3.
3.
Remove the Tamper Button (Figure 1).
4.
5.
If replacing the Service Tray Assembly with a new one, perform the following:
Remove the Stacker Drive Motor (Figure 1).
a.
Remove the Lower Left Rear Trim PL 8.2.

NOTE: This trim piece captures the Service Tray harness.
1
Disconnect the
motor connector.
CAUTION
Observe the correct harness routing carefully before removing the harness, to ensure a
correct replacement.
b.
6.
Disconnect the five connectors from the Finisher Controller PWB, and disconnect
the ground wire from the Stacker Drive Motor bracket (Figure 2).
Remove the main harness from the cable clamp on the Finisher main frame.
CAUTION
Support the Service Tray carefully when removing it -- it may fall out.
CAUTION
Take care not to allow the Stack Height Sensor/Stack Too High Sensor to become bent by contact with the Entrance Baffle when removing or installing the Service Tray (see Figure 3).
7.
Remove the Service Tray Assembly (Figure 3).
8.
If replacing the Service Tray Assembly with a new one, remove the following items to be
reinstalled on the new Service Tray Assembly:
a.
Set Separator PL 8.4
b.
Moving Stapler (REP 12-4)
c.
Fixed Stapler (REP 12-5)
3
2
Remove the T20
screws (2) and
the ground wire.
Remove Stacker Drive Motor,

while supporting the Stacker
Tray.
Figure 1 Removal
V0.042
May 2003
4-333
REP 12-2, REP 12-3
2
Pinch the hook-tabs
together and unsnap the
Tamper Button from the
Tamper Arm.
1
Remove the long
T20 screw (hidden).
Figure 1 Tamper Button Removal
REP 12-3
May 2003
4-334
V0.042
J1
J5, J6, J7, J8

ground wire to
Stacker Drive
Motor bracket
Figure 2 Connectors
V0.042
May 2003
4-335
REP 12-3
Replacement
1.
1
Remove the T20
Screws (2).
If replacing the Service Tray Assembly with a new one, install the following items removed
from the old Service Tray Assembly:
a.
b.
Moving Stapler (REP 12-4)
c.
Set Separator PL 8.4

CAUTION
Take care not to allow the Stack Height Sensor/Stack Too High Sensor to become bent by contact with the Entrance Baffle when removing or installing the Service Tray (see Figure 4).
2.
Be sure to install the Service Tray Assembly correctly (Figure 4).
3.
If replacing the Service Tray Assembly with a new one, perform the following:
a.
Check/adjust the Tamping (ADJ 12-1).
b.
Entrance
Baffle
Stack Height
Sensor/Stack
Too High Sensor
-- see CAUTION
2
Remove the Service Tray Assembly.
Figure 3 Service Tray Removal
REP 12-3
May 2003
4-336
V0.042
REP 12-4 Moving Stapler

Removal
2
Install the T20
Screws (2).
WARNING
1.
2.
3.
Remove the Service Tray Assembly (REP 12-3).
4.
Prepare to remove the Moving Stapler (Figure 1)

CAUTION
Carefully observe the correct harness routing before proceeding, to ensure a correct replacement.
5.
Remove the Moving Stapler (Figure 2)
Entrance
Baffle
Stack Height
Sensor/Stack
Too High Sensor
-- see CAUTION
1
Engage the two mounting
"forks" with the two mounting
pins in the Finisher.
V0.042
May 2003
4-337
REP 12-3, REP 12-4
Disconnect the connector.
BOTTOM
VIEW
2
Disconnect the
ground faston.
3
Unsnap the connector body from
the bracket.
4
Disconnect the
connector.
Figure 1 Connectors
3
Remove the Moving Stapler.
1
Cut the tie-wrap.
Figure 2 Removal
REP 12-4
May 2003
4-338
V0.042
Replacement
CAUTION
Route the harnesses carefully, as observed earlier, to ensure free movement of the Moving
Stapler and to avoid harness damage.
1.
Position the Moving Stapler (Figure 3).
2.
Install the remaining components in the reverse order of removal.
3.
If replacing the Moving Stapler with a new one, perform the following:
a.
Check/adjust the Tamping (ADJ 12-1).
b.

BOTTOM
VIEW
1
Insert the shaft
end into the rack
as shown.
V0.042
May 2003
4-339
REP 12-4
REP 12-5 Fixed Stapler

Removal
Disconnect the ground fastons (2), and remove the

stapler the rest of the way.
Disconnect the
connector
WARNING
1.
2.
3.
Remove the Fixed Stapler (Figure 1).
BOTTOM VIEW
Remove the T20

screws (3).
Pull the stapler

partway out.
Figure 1 Removal
REP 12-5
May 2003
4-340
V0.042

Removal
WARNING
1.
2.
3.

a.
Front Cover (disconnect the Pause/Resume Switch)
b.
Upper Rear Cover
c.
Lower Rear Cover
4.
Remove the nip 1/2 Drive Belt from the Nip 1 Drive Shaft Pulley (Figure 1).
5.
Remove the E-ring, the pulley, and the rear bushing from the Nip 1 Drive Shaft (Figure 2).
CAUTION
Observe the correct orientation of the pulley before removing it.

6.
Remove the front E-ring and bushing from the Nip 1 Drive shaft (Figure 3).
7.
Lift the Finisher Transport Baffle PL 8.3.
8.
Remove the Nip 1 Drive Shaft.
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May 2003
4-341
REP 12-6
2
Move the idler
down.
1
Loosen the T20
Tighten the screw.
4
Remove the belt
from the Nip 1
Drive Shaft Pulley.
REP 12-6
May 2003
4-342
V0.042
CAUTION
Observe the correct orientation of the pulley
before removing it.
Remove the Ering, the pulley,
and the rear bushing.
V0.042
May 2003
4-343
REP 12-6
Remove the front

E-ring and bushing.
Figure 3 Shaft Removal (continued)
Replacement
Remember to reconnect the Pause/Resume Switch when reinstalling the Finisher Front
Cover.
REP 12-6
May 2003
4-344
V0.042

Removal
WARNING
1.
2.
3.

a.
b.
Upper Rear Cover
c.
Lower Rear Cover
4.
5.
Remove the E-ring, the pulley, and the rear bushing from the Nip 2 Drive Shaft (Figure 2).
CAUTION
Observe the correct orientation of the pulley before removing it.

6.
Remove the front E-ring and bushing from the Nip 2 Drive shaft (Figure 3).
7.
Lift the Finisher Transport Baffle PL 8.3.
8.
Remove the Nip 2 Drive Shaft.
V0.042
May 2003
4-345
REP 12-7
2
Move the idler
down.
1
Loosen the T20
3
Tighten the screw.
4
Remove the belt.
REP 12-7
May 2003
4-346
V0.042
Remove the E-ring, the pulley, and

the rear bushing.
CAUTION
Observe the correct orientation of the pulley
before removing it.
V0.042
May 2003
4-347
REP 12-7
REP 12-8 Finisher Transport Baffle

Removal
Remove the front

E-ring and bushing.
WARNING
1.
2.
3.

a.
b.
Upper Rear Cover
c.
Lower Rear Cover
4.
Disconnect the necessary connectors (Figure 1).
5.
Remove the Transport Baffle (Figure 2).
Figure 3 Shaft Removal (continued)
Replacement
Cover.
REP 12-7, REP 12-8
May 2003
4-348
V0.042
1
Disconnect the DC connector and the ground faston from the solenoid.
Separate the
pivot arms and
remove the
Transport Baffle.
Remove the Kclips (2).
2
Lift the
Transport
Baffle.
3
Loosen the T20 screws (2)
securing the pivot arms.
Figure 2 Removal
Replacement
Figure 1 Connector
V0.042
May 2003
4-349
REP 12-8
REP 12-9 Disk Baffle Assembly

2

Removal
1.
Door.
2.
Pinch the hook-tabs

Tamper Arm.
WARNING
3.
Remove the Top Tray.
4.
5.

a.
b.
Upper Rear Cover
c.
Lower Rear Cover
d.
Lower Left Rear Trim

e.
6.
7.
f.
Upper Right Cover
g.
Remove the following from the Finisher:

a.
Nip 2 Drive Shaft (REP 12-7)
b.
Transport Baffle (REP 12-8)
c.
Tamper Button (Figure 1)
Remove the long

T20 screw (hidden).
Remove the Exit Baffle (Figure 2).
CAUTION
Do not set the Exit Baffle down with the Static Eliminator facing downward -- this can deform
the Static Eliminator bristles.
8.
Disconnect the two connectors from the Finisher Controller PWB (Figure 3).
CAUTION
Observe the correct harness routing before moving the harness.

9.
Remove the front mounting screws for the Disk Baffle (Figure 4).
10. Remove the rear mounting screws for the Disk Baffle (Figure 5).
11. Remove the Disk Baffle Assembly (Figure 6).
REP 12-9
May 2003
4-350
V0.042
1
Remove front
T20 screw.
2
Remove rear T20
screw.
3
Remove the Exit
Baffle.
Figure 2 Exit Baffle Removal
V0.042
May 2003
4-351
REP 12-9
J9
J3
Figure 3 Connectors
REP 12-9
May 2003
4-352
V0.042
Remove the T20

screws (2).
Remove the T20

screws (2).
Figure 4 Front Screws
V0.042
Figure 5 Rear Screws
May 2003
4-353
REP 12-9
Remove the Disk Baffle

Assembly.
Figure 6 Disk Baffle Removal
Replacement
CAUTION
Be sure to hold the Disk Baffle upward when tightening the screws securing the baffle. This
will help prevent the baffle from interfering with the Canard Wing during operation.
NOTE: If installing a new Disk Baffle Assembly, installing the screws may require more torque
than expected. This is normal, because the holes are not pre-threaded and the self-tapping
screws have to cut new threads in the new Disk Baffle holes.
Cover.
REP 12-9
May 2003
4-354
V0.042
REP 12-10 Disk Drive Motor
2.

Removal
3.
WARNING

a.
Upper Rear Cover
b.
Lower Rear Cover
Remove the Disk Drive Motor (Figure 1).
1.
Remove the T20

screws (2).
Remove the Disk

Drive Motor.
1
Disconnect the
motor connector.
Figure 1 Removal
V0.042
May 2003
4-355
REP 12-10
REP 12-11 Disk Shaft

Removal
Unsnap the
Tamper Button
from the Tamper
Arm.
WARNING
1.
2.
3.
4.
5.
a.
b.
Upper Rear Cover
c.
Lower Rear Cover
d.
e.
Upper Right Cover
f.

a.
b.
c.
d.
Disk Drive Motor (REP 12-10)
e.
Disk Drive Gear (Figure 2)

CAUTION
6.
Remove the rear Disk Baffle mounting screws and the rear Disk Shaft E-ring and bushing
(Figure 4).
7.
Remove the front Disk Baffle mounting screws and the front Disk Shaft E-ring and bushing (Figure 5)
8.
Remove the Disk Baffle Assembly (Figure 6).
9.
Remove the Disk Shaft.
REP 12-11
May 2003
4-356
Remove the long

T20 screw (hidden).
V0.042
Remove the E-ring

and remove the Disk
Drive Gear.
Figure 2 Gear Removal
V0.042
May 2003
4-357
REP 12-11
1
Remove front
T20 screw.
2
Remove rear T20
screw.
3
Remove the Exit
Baffle.
REP 12-11
May 2003
4-358
V0.042
1
Remove the T20
screws (2).
1
Remove the T20
screws (2).
NOTE: For
Disk Shaft
installation, the
spring (inside)
must be on top
of the bushing.
2
Remove the E-ring
and bushing.
Figure 4 Rear Screws, E-Ring and Bushing
V0.042
2
Remove the Ering and bushing.
Figure 5 Front Screws, E-Ring and Bushing
May 2003
4-359
REP 12-11
REP 12-12 Finisher Assembly (Undocking the Finisher)

Removal
Remove the Disk Baffle

Assembly.
WARNING
1.
2.
Remove the Lower Right Cover from the Finisher PL 8.2: Unlatch the two hand-operated
1/4-turn fasteners.
3.
Unlatch the slide-latch, located inside the Lower Right Cover: Loosen the thumbscrew or
T20 screw, slide the latch all the way out, and retighten the thumbscrew to prevent the
latch from sliding in accidentally.
4.
Ensure that the hitch-pins have been removed from the tops of the spring-loaded castors
(right two castors), to activate the spring-loading to aid in lifting the Finisher (next step).
5.
While preventing the bottom of the Finisher from moving away from the IOT, carefully lift
the Finisher just far enough to unhook only the top two docking hooks from the IOT,
and carefully pull outward on the top of the Finisher to unhook the top two hooks, leaving
the bottom two hooks engaged into the IOT.
WARNING
Use extreme care in performing the following three steps. If all four Finisher docking
hooks are unhooked from the IOT while the right castors' spring-loading is still active,
the Finisher will become extremely unstable. The top of the Finisher will then tend to tilt
to the left while the bottom rolls to the right, possibly resulting in the Finisher falling and
causing equipment damage or personal injury.
Figure 6 Disk Baffle Removal
6.
Deactivate the spring-loading of the two right castors: Press down with your foot on the
base of the Finisher to compress the springs and gain access to the pin holes, and insert
the two hitch-pins.
7.
Carefully tilt the top of the Finisher away from the IOT until the bottom two docking hooks
are disengaged, then carefully move the Finisher slightly away from the IOT and stand it
upright on its four castors.
Replacement
Cover.
WARNING
Do not attempt the following step (unhooking the bottom two docking hooks) without
first having performed the previous step (deactivating the spring-loading of the right
castors). (Refer to the WARNING above.)
8.
If you wish to operate the machine with the Finisher undocked from the IOT, insert an
interlock cheater into the interlock switch on the right side of the IOT.
9.
If you do not wish to operate the Finisher with it undocked, disconnect the Finisher connector from the IOT.
Replacement
NOTE: If you are installing the Finisher as part of an upgrade from an OCT, you must first order
a new Exit Baffle (PL 6.1A) and install it in place of the Decurler (see REP 10-3).
1.
Reconnect the Finisher Connector to the IOT (Figure 1).
2.
Install the Finisher in the reverse order of Removal.
3.
If replacing the Finisher Assembly with a new one, enter the new tamping value into NVM:
a.
REP 12-11, REP 12-12
May 2003
4-360
Enter [NVM tab , NVM Tool] and download the machine NVM.
V0.042
b.
Select Service: [Mark Service] and Module: [HighCapacityFinisher].
c.
Scroll (or Search) to location [0] (zero), [tamperHomeSetup], and change the value
to match the number printed on the label on the underside of the new Finisher's Top
Cover Door.
Figure 1 Connector
V0.042
May 2003
4-361
REP 12-12
2.

Removal
WARNING

a.
Upper Rear Cover
b.
Lower Rear Cover
3.
Remove the Nip 3/4 Drive Belt (REP 12-14).
4.
1.
2
Move the idler
down.
1
Loosen the T20
Tighten the screw.
4
Remove the belt.
Figure 1 Removal
REP 12-13
May 2003
4-362
V0.042
Replacement
1.
2.
Reinstall and tension the Nip 3/4 Drive Belt (REP 12-14).
Install and tension the Nip 1/2 Drive Belt (Figure 2).
2
Loosen the T20
idler screw 1/4turn only, allowing
the spring-loaded
idler to tension the
belt, then retighten
the screw.
1
Position the belt
as shown.
V0.042
May 2003
4-363
REP 12-13
2.

Removal
3.
WARNING

a.
Upper Rear Cover
b.
Lower Rear Cover
1.
2
Move the idler up.
1
Loosen the T20
4
Remove the belt.
3
Tighten the screw.
Figure 1 Removal
REP 12-14
May 2003
4-364
V0.042
Replacement
1.
Install and tension the Nip 3/4 Drive Belt (Figure 2).
2
Loosen the T20
idler screw 1/4-turn
only, allowing the
spring-loaded idler
to tension the belt,
then retighten the
screw.
1
Position the belt
as shown.
V0.042
May 2003
4-365
REP 12-14
REP 12-15 Finisher Lubrication

Lubrication Material
Lubricant, 70P81
Lubricate
WARNING
1.
2.
3.

a.
b.
Upper Rear Cover
c.
Lower Rear Cover
d.
Upper Right Cover
e.
4.
Remove the Nip 3/4 Idler and the Nip 1/2 Idler (Figure 1).
5.
Lubricate the shaft of the Nip 3/4 Idler.
6.
a.
Remove the roller from the idler shaft of the Nip 3/4 Idler.
b.
Grease the idler shaft using 70P81 lubricant.
c.
Reinstall the roller on the idler shaft.
Lubricate the shaft of the Nip 1/2 Idler.

a.
Remove the roller from the idler shaft of the Nip 1/2 Idler.
b.
Grease the idler shaft using 70P81 lubricant.
c.
Reinstall the roller on the idler shaft.
7.
Reinstall the Nip 3/4 Idler and the Nip 1/2 Idler (Figure 2).
8.
Tension the Nip 3/4 Drive Belt (Figure 3).
9.
Tension the Nip 1/2 Drive Belt (Figure 4).
REP 12-15
May 2003
4-366
V0.042
1
Disconnect the spring.
2
Remove the T20
idler screw.
Disconnect the
spring.
Remove the T20

idler screw.
Figure 1 Idlers Removal
V0.042
May 2003
4-367
REP 12-15
Reconnect the spring.
Reinstall the T20

idler screw. Do not
tighten the screw.
3
Reinstall the T20
idler screw. Do
not tighten the
screw.
4
Reconnect the
spring.
Figure 2 Idlers Installation
REP 12-15
May 2003
4-368
V0.042
2
Loosen the T20
idler screw 1/4-turn
only, allowing the
spring-loaded idler
to tension the belt,
then retighten the
screw.
1
Position the belt
as shown.
Figure 3 Nip 3/4 Belt Tensioning
V0.042
May 2003
4-369
REP 12-15
2
Loosen the T20
idler screw 1/4turn only, allowing
the spring-loaded
idler to tension the
belt, then retighten
the screw.
1
Position the belt
as shown.
Figure 4 Nip 1/2 Belt Tensioning
REP 12-15
May 2003
4-370
V0.042
REP 12-16 Finisher Top Tray Back Wall

Removal
WARNING
1.
2.
3.
Remove the Finisher Top Tray.
4.
Remove the Finisher Transport Baffle (REP 12-8).
5.
Remove the following covers from the Finisher PL 8.2.
6.
a.
Finisher Top Cover (disconnect the interlock switch).
b.
Finisher Top Gutter Cover.
Remove the 5a Baffle (two T20 screws) (PL 8.4).

NOTE: When removing the 5a Baffle, be careful not to damage or dislodge the actuator
for the Top Tray paper Path Sensor and the actuator for the Top Tray Full Sensor.
7.
Disconnect the offset link from the Top Tray Offset Drive Gear (large white gear) Figure 1.
V0.042
May 2003
4-371
REP 12-16
Disconnect the offset link

from the Top Tray Offset
Drive Gear.
Figure 1 Offset Link
REP 12-16
May 2003
4-372
V0.042
Replacement
REP 12-17 Convenience Stapler Internal DC Harness
1.

Removal
Reposition the Back Wall of the Finisher Top Tray.

a.
Ensure the flanges of the 2 upper guide rollers rest on the top surface of the upper
guides.
b.
Ensure the flanges of the 2 lower guide rollers rest on the top surface of the lower
guide rail.
NOTE: If any of the offset drive components for the Finisher Top Tray are damaged,
replace the Top Module Assembly (PL 8.3).
2.
Reinstall the offset link onto the Top Tray Offset Drive Gear.
3.
Reinstall the 5a Baffle.
1.
Disconnect the Convenience Stapler Harness from the back of the Convenience Stapler.
2.
Remove the bottom plate from the Convenience Stapler (Figure 1).
3.
Remove the Convenience Stapler batteries (if the stapler is the model with rechargeable
batteries) and remove the Convenience Stapler jack from the cover (Figure 2).
4.
Remove the Convenience Stapler Internal DC Harness (Figure 3).
1
Remove the screws (3).
NOTE: When reinstalling the 5a Baffle, be careful not to damage or dislodge the actuator
for the Top Tray paper Path Sensor and the actuator for the Top Tray Full Sensor.
4.
Reinstall the Finisher Top Gutter Cover.
5.
Reinstall the Finisher Top Cover (remember to reconnect the interlock switch).
6.
Reinstall the Finisher Transport Baffle.
7.
Reinstall the Finisher Top Tray.
2
Carefully separate the
bottom plate just enough
to access the connector
for the stapler.
3
Disconnect the stapler
connector from the
PWB.
Figure 1 Bottom Plate Removal
V0.042
May 2003
4-373
REP 12-16, REP 12-17
3
Disconnect the battery
connectors.
Remove the
batteries.
Remove the jack

from the cover.
1
Remove the nut and
set it aside. It will be
reused in Replacement.
Figure 2 Batteries and Jack Removal
REP 12-17
May 2003
4-374
V0.042
1
Disconnect the
connectors.
2
Remove the harness
Figure 3 Harness Removal
Replacement
1.
Install the new Convenience Stapler Internal DC Harness.
2.
Reinstall the Convenience Stapler batteries (staplers with rechargeable batteries).
3.
Install the jack using the nut removed earlier.
4.
Reconnect the stapler connector to the PWB.
5.
Reinstall the bottom plate.
6.
Reconnect the Convenience Stapler Harness to the Convenience Stapler.
7.
Check the operation of the Convenience Stapler by removing the Staple Cartridge and
closing the Convenience Stapler Cover. The red LED should be illuminated.
V0.042
May 2003
4-375
REP 12-17
REP 12-18 Stapler Lead-In Baffle

Removal
1.
Press the Pause/Resume Switch to lower the Stacker Tray.
WARNING
2.
3.
Open the Stapler Access door to gain access to the Moving Stapler.
4.
Remove the screws that secure the Lead-in Baffle to the Moving Stapler (Figure 1).
5.
Remove Lead-In Baffle (Figure 2).
Remove the 7 mm
screws.
Figure 1 Screws Removal
REP 12-18
May 2003
4-376
V0.042
1
Hold the Canard Wing and
the nickel plated registration
edge in the raised position.
2
Remove the Lead-In Baffle.
Figure 2 Removal
V0.042
May 2003
4-377
REP 12-18
Replacement
1.
Move the new Lead-In Baffle into position (Figure 3).
Push down and pull

toward you on the LeadIn Baffle and align the
holes in the baffle with
the holes in the bracket.
1
Hold the Canard Wing and
the nickel plated registration
edge in the raised position
Bracket
2
Install the 7 mm screws (2).
NOTE: Do not tighten at this
time.
2
Carefully move the new
Lead-In Baffle into position.
Figure 4 Screws Installation
Figure 3 Baffle Installation

2.
Install the mounting screws (Figure 4).
3.
Tighten the mounting screws (Figure 5).
REP 12-18
May 2003
4-378
V0.042
1
Push down and hold the Lead-In Baffle
against the white plastic block and outward.
Lead-In Baffle
NOTE: Ensure the front and the rear of the

Lead-In Baffle is making contact with the
white plastic block in the lower throat of the
Moving Stapler.
Top edge of the Stapler

Access Door.
2
Tighten the screws.
Figure 5 Screws Tightening

4.
Figure 6 Check for Interference
Close the Stapler Access Door. Ensure the Lead-In Baffle does not interfere with the top
of the Stapler Access Door when closing the door. When installed correctly, the Lead-In
Baffle should be flush with the top surface of the Stapler Access Door (Figure 6).
V0.042
5.
If the Lead-In Baffle interferes with the closing of the Stapler Access Door, or is not flush
with the top surface of the door, loosen the 2 mounting screws and repeat Step 3.
6.
If not already done, mark off Tag 031 on the Finisher Change Tag Matrix.
May 2003
4-379
REP 12-18
REP 12-19 Convenience Stapler PWB

Removal
1
CAUTION
Some Convenience Staplers will contain rechargeable batteries. Do not remove the batteries,
they will remain disconnected in the Convenience Stapler. The batteries will be correctly disposed of when the machine is returned for remanufacturing.
1.
Switch the Convenience Stapler power [Off].
2.
Disconnect the Convenience Stapler Harness from the back of the Convenience Stapler.
3.
4.
Remove the connectors from the Convenience Stapler PWB. (Figure 1).
3
Remove the stapler
connector from the
PWB.
2
Carefully separate the bottom plate just enough to
access the connector for
the stapler.
4
Remove the bottom plate
and disconnect the remaining connectors from the
PWB.
Figure 1 Removing the Connectors from the Convenience Stapler PWB.
REP 12-19
May 2003
4-380
V0.042
Replacement
REP 12-20 Stacker Tray Drive Belts
1.
Parts List on PL 8.3 and PL 8.5

Removal
WARNING
Install the Convenience Stapler PWB and reconnect the stapler connector P/J 3, and the
power connector, P/J 4.
NOTE: Note: The Convenience Stapler PWB does not contain the battery charging circuitry. The jacks J1 and J2 have been removed.
2.
Reinstall the bottom plate on the Convenience Stapler.
3.
Reinstall the Stapler Cartridge.
1.
4.
Reconnect the Convenience Stapler Harness.
2.
5.
Switch the Convenience Stapler power [On].
a.
Lower Rear Cover
NOTE: The customer cannot use the Convenience Stapler off-line. After installing the
Convenience Stapler PWB in a stapler that was previously battery operated, inform the
customer the Convenience Stapler will not operate unless it is connected to the machine.
b.
Front Cover
WARNING
personal injury.
3.
Remove the Stacker Drive Motor (REP 12-2).
4.
Remove both the front and the rear Stacker Drive Belt Clamps (REP 12-21).
5.
Remove the front Stacker Tray Drive Belt (Figure 1):
6.
V0.042
May 2003
4-381
a.
Remove the K-clip securing the top Stacker Drive Belt Pulley to the shaft, and slide
the pulley off of the shaft.
b.
Remove the Front Stacker Tray Drive Belt.
Remove the rear Stacker Tray Drive Belt (Figure 2):

a.
Remove the K-clip securing the top Stacker Drive Belt Pulley to the shaft, and slide
the pulley off of the shaft.
b.
Remove the rear Stacker Tray Drive Belt.
REP 12-19, REP 12-20
upper pulley
upper pulley
front Stacker Tray

Drive Belt.
rear Stacker Tray
Drive Belt.
Figure 1 Front Belt
Figure 2 Rear Belt
Replacement
REP 12-20
1.
Install the Stacker Tray Drive Belts and the upper pulleys and K-clips.
2.
Reinstall the Stacker Drive Motor (REP 12-2).
3.
Install the front and rear Stacker Tray Drive Belt Clamps, and level the Stacker Tray (REP
12-21).
May 2003
4-382
V0.042
REP 12-21 Stacker Tray Drive Belt Clamps
Parts List on PL 8.3 and PL 8.5

Removal
WARNING
Support the Stacker

Tray (see WARNING).
1.
2.

a.
Lower Rear Cover
b.
Front Cover
WARNING
If the Stacker Drive Motor was not already removed, support the Stacker Tray when
removing the Stacker Drive Belt Clamps, and then lower the tray gently. Otherwise, the
Stacker Tray will drop quickly, possibly causing damage or personal injury.
3.
Remove the Front Stacker Tray Drive Belt Clamp (Figure 1).
4.
Remove the rear Stacker Tray Drive Belt Clamp (Figure 2):
Remove the T20 screw.
Support the Stacker

Tray (see WARNING).
Remove the rear Stacker Tray

Drive Belt Clamp.
Figure 2 Rear Clamp Removal
Replacement
1.
Install the front and rear Stacker Tray Drive Belt Clamps and T20 screws.
2.
Install the remaining components in the reverse of removal.
3.
Reconnect the power cord and switch on the machine power.
4.
Perform the Stacker Tray Levelling Procedure, below
Stacker Tray Levelling Procedure

2
Remove the T20
screw.
3
Remove the front
Stacker Tray Drive
Belt Clamp.
1.
Remove any paper from the Stacker Tray and allow the Stacker Tray to raise to the home
position (all the way up, with no paper in the tray -- press the Pause/Resume Switch as
required).
2.
Observe whether the Stacker Tray is approximately level (parallel with the Stapler Access
Door).
3.
Figure 1 Front Clamp Removal
V0.042
If the Stacker Tray is approximately level, this procedure is complete
If the Stacker Tray is significantly unlevel, continue
Press the Pause/Resume Switch so that the Stacker Tray begins to lower, then open the
Finisher Top Cover Door to stop the Stacker Tray approximately 3 inches (75 mm) below
the home position.
4.
Switch off the machine power, and then close the Finisher Top Cover Door.
5.
May 2003
4-383
a.
Lower Rear Cover
b.
Front Cover
REP 12-21
6.
Count the number of teeth showing on the Stacker Tray Dive Belt between the Stacker
Tray Drive Belt Clamp and the bottom of the upper Stacker Drive Pulley in the front of the
Finisher (Figure 3).
7.
Count the number of teeth on the Stacker Tray Dive Belt between the Stacker Tray Drive
Belt Clamp and the bottom of the upper Stacker Drive Pulley in the rear of the Finisher
(Figure 4).
8.
If the number of teeth is the same in the previous two steps, the tray may be warped or
damaged. Repair or replace the Stacker Tray as required.
9.
If the number of teeth is not the same in the previous two steps, do the following:
a.
Support the Stacker Tray while performing the following steps.
b.
In the front of the Finisher, remove the T20 screw securing the Stacker Tray Drive
Belt Clamp, and disengage the clamp from the Stacker Tray support.
c.
Slide the belt out of the clamp, move it the required number of teeth up or down to
equal the position in the rear, and slide it back into the clamp.
d.
Reengage the clamp to the tray support and reinstall the T20 screw.
10. Recheck the number of teeth front an rear and readjust as required.
11. Switch on the machine power, allow the Stacker Tray to raise to the home position again,
and check the levelling again. If the Stacker Tray is still significantly unlevel, the tray
may be warped or damaged. Repair or replace the Stacker Tray as required
Stop counting
teeth here.
Start
counting
teeth
here.
Stop counting
teeth here.
Figure 4 Rear Clamp Installation
Start counting
teeth here.
Stacker Tray
support.
T20 screw.
front Stacker Tray

Drive Belt Clamp.
Figure 3 Front Clamp Installation
REP 12-21
May 2003
4-384
V0.042
REP 12-22 Fixed-Stapler Safety Gate

2

Removal
1.
Door.
2.
Pinch the hook-tabs

Tamper Arm.
WARNING
3.
4.
5.

a.
b.
Upper Rear Cover
c.
Lower Rear Cover
d.

e.
6.
f.
Upper Right Cover
g.
Lower Right Cover

a.
b.
c.
Remove the long

T20 screw (hidden).
CAUTION
7.
8.
9.
Dismount the Finisher Entrance Sensor from the Disk Baffle, to avoid damaging the sensor actuator during the rest of the procedure (Figure 3).
NOTE: You do not need to disconnect the connector from the sensor.
10. Remove the two screws (slotted 7mm) securing the Fixed-Stapler Safety Gate Solenoid to
the Disk Baffle (Figure 3).
11. Move the solenoid out of the way, and remove the gate actuator link (Figure 4).
12. Remove the two K-clips, and remove the right-hand gear (Figure 4).
13. Lift the gate to align the left-hand gears notch with the bracket for clearance, and remove
the left-hand gear (Figure 5).
14. Remove the Fixed-Stapler Safety Gate (Figure 5).
V0.042
May 2003
4-385
REP 12-22
1
Remove front
T20 screw.
2
Remove rear T20
screw.
3
Remove the Exit
Baffle.
REP 12-22
May 2003
4-386
V0.042
K-clips (2)
righthand
gear
solenoid
screws (2)
gate
actuator
link
solenoid
Figure 4 Link, K-Clips, and Right-Hand Gear
Finisher Entrance Sensor (dismounted)
Figure 3 Sensor and Solenoid Screws
V0.042
May 2003
4-387
REP 12-22
left-hand
gear
Install the right-hand

gear, aligning the two
notches on the gear
with the raised teeth
on the left-hand gear
and on the gate.
Fixed-Stapler
Safety Gate
notch
switch/solenoid
bracket
Install the left-hand gear, aligning the raised teeth

on the gear and on the gate.
Figure 5 Left-Hand Gear Removal
Figure 6 Gear Alignment
Replacement
Be sure to align the gears as shown in Figure 6.
Remember to reinstall the Finisher Entrance Sensor (Figure 3) before reinstalling the Disk
Baffle Assembly.
REP 12-22
May 2003
4-388
V0.042
REP 12-23 Moving-Stapler Safety Gate

2

Removal
1.
Door.
2.
Pinch the hook-tabs

Tamper Arm.
WARNING
3.
4.
5.

a.
b.
Upper Rear Cover
c.
Lower Rear Cover
d.

e.
6.
f.
Upper Right Cover
g.
Lower Right Cover

a.
b.
c.
Remove the long

T20 screw (hidden).
CAUTION
7.
8.
9.
Dismount the Finisher Entrance Sensor from the Disk Baffle, to avoid damaging the sensor actuator during the rest of the procedure (Figure 3).
NOTE: You do not need to disconnect the connector from the sensor.
10. Remove the two screws (slotted 7mm) securing the Moving-Stapler Safety Gate Solenoid
to the Disk Baffle (Figure 3).
11. Move the solenoid out of the way, and remove the gate actuator link (Figure 4).
12. Remove the two K-clips, and remove the right-hand gear (Figure 4).
13. Lift the gate to align the left-hand gears notch with the bracket for clearance, and remove
the left-hand gear (Figure 5).
14. Remove the Moving-Stapler Safety Gate (Figure 6).
NOTE: The foam washers, for noise reduction, are not present on older Finishers. If the
foam washers are present, be sure to keep them in place.
V0.042
May 2003
4-389
REP 12-23
1
Remove front
T20 screw.
2
Remove rear T20
screw.
3
Remove the Exit
Baffle.
REP 12-23
May 2003
4-390
V0.042
solenoid
screws (2)
K-clips (2)
right-hand
gear
gate
actuator
link
solenoid
Figure 4 Link, K-Clips, and Right-Hand Gear
Finisher Entrance Sensor (dismounted)
Figure 3 Sensor and Solenoid Screws
V0.042
May 2003
4-391
REP 12-23
Moving-Stapler
Safety Gate
left-hand
gear
notch
switch/solenoid
bracket
Figure 5 Left-Hand Gear Removal
REP 12-23
May 2003
4-392
V0.042
Lift the right-hand

end of the gate
over the frame, and
remove the gate.
Lift the left -hand

end of the gate
over the frame.
foam washers (2),

if present
Figure 6 Gate Removal
Replacement
Be sure to align the gears as shown in Figure 7.
Remember to reinstall the Finisher Entrance Sensor (Figure 3) before reinstalling the Disk
Baffle Assembly.
V0.042
May 2003
4-393
REP 12-23
REP 12-24 Tamper Cable

2
Install the righthand gear, aligning
the two notches on
the gear with the
raised teeth on the
left-hand gear and
on the gate.

Removal
WARNING
1.
2.
3.

CAUTION
DO NOT loosen the third screw on the tamper arm or rotate the arm position on the slide (Figure 1). The arm position on the slide has been set up at the factory for optimum tamping performance and should not be changed.
4.
Remove the Tamper Cable (Figure 1).

a.
Remove the cable clamp (one T20 screw and one T10 screw).
b.
Unhook the ball end of the cable from the tamper.
c.
Unhook the spring end of the cable from the tamper, and remove the cable.
Replacement
CAUTION
DO NOT loosen the third screw on the tamper arm or rotate the arm position on the slide (Figure 1). The arm position on the slide has been set up at the factory for optimum tamping performance and should not be changed.
1.
Install the left-hand gear, aligning the raised teeth

on the gear and on the gate.
Connect the spring end of the cable to the tamper, and route the cable to the right as
shown (Figure 2).
2.
Install the cable clamp and the screws (one T10 and one T20), but leave the screws loose
(Figure 2).
3.
Move the tamper all the way to the left (Figure 2).
Figure 7 Gear Alignment
4.
Route the cable around the right end of the tamper, and behind the capstan (Figure 3).
5.
Wind the cable counterclockwise around the capstan, from the bottom up, 2-1/2 times.
6.
Align the cable ball with the indent in the capstan. Rotate the capstan while letting the
cable slip on the capstan, until the ball aligns with the indent, and ensure that the ball is
seated in the indent (Figure 1).
7.
Route the ball end of the cable around the left end of the tamper, and hook the ball end
into the slot (Figure 1).
8.
Ensure the cable is wound correctly on the capstan (Figure 1):
9.
a.
With the tamper all the way to the left, the ball should be on the top cable-wind on the
capstan.
b.
Move the tamper to the right until the capstan has rotated one full turn. The ball
should now be on the middle cable-wind, with one wind above it and one wind below
it.
c.
If the cable is not wound correctly on the capstan or binds when the tamper is moved
right and left, go back to step 2 and repeat the procedure as required.
Tighten the cable clamp screws (one T10 and one T20) (Figure 1).
10. Move the tamper left and right several time and observe if the cable loosens. If so, loosen
and retighten the cable clamp screws (one T10 and one T20).
REP 12-23, REP 12-24
May 2003
4-394
V0.042
11. Reinstall the Service Tray Assembly (REP 12-3)
cable clamp
12. Redock the Finisher to the IOT (REP 12-12).
T20 screw
CAUTION: DO NOT
loosen this third
screw.
T10 screw
Installation: Cable should wind like this when

tamper is moved one capstan-turn to the right.
Installation: Cable should wind like this when

tamper is all the way to the left.
ball end of
cable in
slot
spring end of cable
cable ball seated in

capstan indent
Figure 1 Tamper Cable Figure 1
V0.042
May 2003
4-395
REP 12-24
CAUTION: DO NOT loosen this third screw.
T20 screw
cable clamp
T10 screw
CAUTION:
DO NOT
loosen this
third screw.
1
Route the cable
around the right
end of the
tamper.
spring
end of
cable
Route the cable

as shown.
2
Route the cable
behind the capstan.
Move the tamper all

the way to the left.
REP 12-24
May 2003
4-396
V0.042
REP 12.01.01 Main Tray Elevator Belt

Removal
WARNING
Remove the k-clip

and remove the top
pulley.
1.
2.
Remove the following MFF covers.

a.
Front Door
b.
Rear Cover
c.
Right Front
3
Remove the belt
form the belt clamp.
NOTE: When the Main Tray Elevator Motor is removed, the Main Tray will move to the
down position. This will take the load off the Elevator Belts and make them easier to
remove.
3.
Remove the Main Tray Elevator Motor (M51) (REP 12.01.04).
4.
Remove the Main Tray Elevator Belt, both sides are removed the same (Figure 1).
2
Remove the T20
screw.
1
Loosen the belt tensioner.
Figure 1 Removal of Main Tray Elevator Belt (front belt shown)
Replacement
V0.042
1.
Install in the reverse order of the removal.
2.
During the belt installation, make sure the placement of the belt holder is the same distance from the top pulley on both sides (Figure 2).
May 2003
4-397
REP 12.01.01
REP 12.01.02 Main Tray Offset Motor (M50)

Removal
WARNING
1.
2.
Remove the Offset Motor cover (Figure 1).
3.
Remove Offset Motor (M50) (Figure 2).
Adjust the tray level

by setting the number
of teeth between A
and B the same on
both sides.
Figure 2 Stacker Belt position to make tray level.
REP 12.01.01, REP 12.01.02
May 2003
4-398
V0.042
REAR VIEW
Offset Motor
(M50)
2
Remove two
T20 screws
(front screw
shown).
1
Remove two
7mm nuts.
Figure 1 Removal of Offset Motor cover
V0.042
May 2003
4-399
REP 12.01.02
Disconnect motor
(M50) connector.
Remove four T20

screws.
REP 12.01.03 Main Tray Offset Panel/Rails

Removal
WARNING
1.
2.
Remove the Main Tray (Figure 1).
3.
Remove the four (7mm) nuts that hold the Offset Panel to the MFF (Figure 2). and (Figure
3).
4.
Remove Rails from front panel.
3
Remove the Main Tray.
1
Disconnect
sensor (S53)
connector.
Figure 2 Removal of Offset Motor (M50)
Replacement
NOTE: The Offset Panel may have to be moved back and forth to allow proper alignment of
the Offset Cam and the Offset Panel.
1. Install in the reverse order of the removal.
1
Remove the
K-clip.
2
Remove the two T20 screws.
Figure 1 Removal of the Main Tray
REP 12.01.02, REP 12.01.03
May 2003
4-400
V0.042
REAR VIEW
Offset Motor
(M50)
Remove two
7mm nuts.
Figure 2 Offset Panel bottom rail nuts
V0.042
May 2003
4-401
REP 12.01.03
Main Compiler
front backstop
Top Rail
cam follower
slot
Offset Panel
Bottom Rail
Remove two
7mm nuts (front
nut shown).
Figure 4 Offset Panel and Rails
Figure 3 Offset Panel top rail nuts
Replacement
1.
2.
Install the Offset Panel so that the Offset Cam is properly located in the Cam Locator
Position (Figure 4).
a.
Locate the bottom rail studs first.
b.
Locate the top rail studs next.
c.
Install the top rail nuts (7mm), only finger tighten,
d.
With the rail studs located in the bottom holes, move the Offset Panel back and forth
until the cam is located properly in the cam locator position.
e.
Install the bottom rail nuts (7mm).
f.
Tighten the top and bottom rail nuts (7mm).
REP 12.01.03
May 2003
4-402
V0.042
REP 12.01.04 Main Tray Elevator Motor (M51)
REP 12.02.01 Booklet Maker Assembly

Removal

Removal
WARNING
WARNING
1.
2.
Remove the MFF Rear Cover.
CAUTION
CAUTION
Hold the tray from falling when removing the motor, to prevent damage to the lower limit switch.
3.
Remove the Main Tray Elevator Motor (M51) (Figure 1).
4
Slide the motor off of the
shaft (see CAUTION).
3
Remove the two T20
screws.
Be sure to loosen the drawer connector bracket screws before installing the Booklet Maker
Assembly, and retighten them afterward when the connectors are mated. Otherwise, the connectors may be misaligned, resulting in intermittent connections or connector damage.
1.
2.
Remove the MFF Front Door.
3.
Unlatch Area 5a and slide out the Booklet Maker drawer.
4.
Remove the rear screws (T10) from each Booklet Maker slide (left side: Figure 1; right
side: Figure 2).
5.
Remove the two front and one left-center slide screws (5.5 mm) (left side: Figure 1; right
side: Figure 2).
6.
Slide the Booklet Maker Drawer fully forward. The left side rail will disengage as shown in
7.
Standing on the right side of the Booklet Maker, grasp the front and rear handles, slide the
Booklet Maker forward slightly, and lift it off of the slides (Figure 3).
8.
Place the Booklet Maker on a flat surface (top of MFF or nearby table). The Booklet
Maker will need to be close enough to hook up the troubleshooting cable, (if required).
9.
Retract the drawer slides into the machine, to avoid a tripping hazard.
10. Loosen the four T20 drawer connector bracket screws on the back of the Booklet Maker
(Figure 5).
Remove the K-clip.
1
Disconnect the
two motor electrical connectors.
Figure 1 Removal of Stacker Motor (M51)
Replacement
1.
Raise the tray near the top before reinstalling the motor.
2.
V0.042
May 2003
4-403
REP 12.01.04, REP 12.02.01
front screw
(5.5 mm)
rear screw (T10): You must slide the

drawer to the position shown for the
access hole to align with the screw.
Figure 2 Right side Booklet Maker rail screws
rear screw (T10)

center screw
(5.5 mm)
front screw (5.5 mm)
Figure 1 Left side Booklet Maker rail screws
REP 12.02.01
May 2003
4-404
V0.042
RIGHT SIDE VIEW
rear
handle
front
handle
locator
slot
locator
stud
Figure 3 Booklet Maker handles
V0.042
Figure 4 Booklet Maker left side rail disengaged
May 2003
4-405
REP 12.02.01
6.
Install the front screw (5.5 mm) on each rail, and the left-center screw (5.5 mm).
7.
Install the rear screw (T10) on each slide (see Figure 2 for accessing the right rear screw
hole.
8.
Slide the Booklet Maker all the way back in and latch Area 5a.
9.
Tighten the four T20 drawer connector bracket screws on the MFF, through the rear of the
MFF.
10. Reinstall the remaining components in the reverse order of Removal.

11. If replacing the Booklet Maker with a new one, enter the NVM values from the label on the
Booklet Maker left frame or front frame.
a.
If the NVM label is not on the Booklet Maker left frame, remove the Booklet Maker
Front Cover:
i.
b.
Remove the Crease Blade Knob (5.5 mm screw, or clip -- do not lose the clip).
iii.
Remove the Crease Roll Release Lever (5.5 mm screw).
iv.
Remove the Booklet Maker Front Cover (four T20 screws).
Enter [NVM tab , NVM Tool], and download the machine NVM.
c.
Select Service: [Mark Service], and select Module: [MultiFunctionFinisher].
d.
Scroll or [Search] to the following locations, double-click on each one, enter the values indicated below, select [Write NVM] and select [OK]:
Loosen
four T20
screws.
Location 501 (BM Fold to Center): Enter the value for location 501 or NVM10
on the label.
Location 502 (BM Staple to Fold): Enter the value for location 502 or NVM11
on the label.
Location 503 (BM BM Tamper Stroke): Enter the value for location 503 or
NVM12 on the label.
Location 504 (Z-Fold First to LE): Enter the value for location 504 or NVM13
on the label.
Location 507 (BM Home to Compile): Enter the value for location 507 or
NVM19 on the label.
Figure 5 Booklet Maker Drawer Connector
NOTE: Ignore the value for NVM20 (if present) on the label. This value is not
used.
Replacement
CAUTION
Be sure to loosen the drawer connector bracket screws before installing the Booklet Maker
Assembly, and retighten them afterward when the connectors are mated. Otherwise, the connectors may be misaligned, resulting in intermittent connections or connector damage.
1.
Remove the Booklet Maker Front Handle (two slotted or 5.5 mm screws).
ii.
e.
Location 508 (C-Fold First to LE): Enter the value for location 508 or NVM21
on the label.
Exit NVM Tool.
Remove MFF rear cover.
2.
Swing open PWB panel (two T20 screws).
3.
Extend the Booklet Maker drawer rails fully.
4.
Standing on the right side of the Booklet Maker drawer, grasp the front and rear handles
and lift it onto the two posts on the right rail, positioning the Booklet Maker between the
rails (Figure 6).
5.
Engage the left side rail: Start the Booklet Maker's locator stud into the front of the rail's
locator slot, then gently slide the Booklet Maker in while holding the left rail all the way
out, until the left rear rail hook engages the Booklet Maker frame and the screw holes
align.
REP 12.02.01
May 2003
4-406
V0.042
REP 12.02.02 Crease Blade

Removal
Booklet Maker shown in

the raised position just
before positioning on the
posts.
WARNING
1.
Remove the Booklet Maker Assembly from the MFF (REP 12.02.01).
2.
Using the Crease Blade Knob, retract the Crease Blade to allow easy access to the four
mounting screws.
3.
Remove the Crease Blade (Figure 1).
posts
Figure 6 Booklet Maker right side rail posts
V0.042
May 2003
4-407
REP 12.02.01, REP 12.02.02
REP 12.02.03 Crease Rolls

Removal
2
Remove four 5.5 mm screws
and remove the Crease
Blade.
WARNING
1.
2.
3.
Remove the Booklet Maker Front Cover:

a.
b.
c.
d.
4.
Remove the Crease Roll Motor (REP 12.02.04).
5.
Remove the Crease Roll exit bracket (Figure 1).

a.
Remove the four T20 screws (two front and two rear).
CAUTION
Do not pivot the Crease Roll exit bracket downward when removing it. Pivoting it downward can dislodge the Crease Roll Bearings.
b.
Flex the Booklet Maker frame slightly to disengage the locating features, pull the
Crease Roll exit bracket out parallel (do not pivot it out), and remove it.
6.
Prepare to remove the Crease Rolls (Figure 2).
7.
Remove each Crease Roll from the Booklet Maker: Slide the roll rearward, disengage the
front end, slide the roll forward and remove it.
1
Remove two 5.5 mm screws
and disconnect the ground
wires.
Figure 1 Crease Blade removal
Replacement
CAUTION
When replacing or installing the stepper motors used in the MFF, make sure you use the spring
tensioning devises to assure for proper belt tension. Too much or too little tension will effect the
performance of the motors.
1.
Install the Crease Blade in the Reverse of Removal.

NOTE: Remember to re-secure the ground wires.
2.
If installing a new Crease Blade, perform the Crease Blade Adjustment (ADJ 12.02.01).
REP 12.02.02, REP 12.02.03
May 2003
4-408
V0.042
3
Remove the
snap rings
and bearings (front
and rear).
Upper Crease
Roll
Lower Crease
Roll
2
Remove the
bracket (front
and rear; two
T20 screws
each).
Crease
Roll Exit
Bracket
1
Remove the
spring (front
and rear).
Remove four T20 screws

(two each side)
Figure 1 Crease Roll Exit Bracket Removal
Figure 2 Crease Roll Removal (Viewed from the front)
Replacement
V0.042
1.
Install the top and bottom crease rolls.
2.
If the Crease Blade is suspected of causing the Crease Roll replacement then perform
the ADJ 12.02.01 Crease Blade Adjustment.
3.
Reinstall the Crease Roll Exit Bracket.
4.
Reinstall the Crease Roll Motor (REP 12.02.04).
5.
Complete the rest of the replacement in the reverse order of Removal.
May 2003
4-409
REP 12.02.03
REP 12.02.04 Crease Roll Motor (M68)
3.

Removal
4.
WARNING
1.
2.
Remove the rear Booklet Maker handle (Figure 1).

a.
Remove the plastic handle grip.
b.
Remove the three handle bracket screws.
Remove the Crease Roll Motor (Figure 2).

a.
Remove the Crease Roll Motor Encoder Sensor from the bracket (leave it connected
to the wiring harness).
b.
Disconnect the two Crease Roll Motor faston connectors.
c.
Remove the Crease Roll Motor Encoder Wheel/Coupler.
d.
Remove Crease Roll Motor.
e.
If replacing the motor with a new one, cut the tie-wraps.
1
Remove the
plastic rear
handle grip.
2
Remove the three T20
bracket mounting
screws.
Rear Handle Bracket
Figure 1 Booklet Maker rear handle removal
REP 12.02.04
May 2003
4-410
V0.042
REP 12.02.05 Crease Roll Gears

Removal
WARNING
1.
2.
3.
Remove the Crease Roll Motor (M68) (REP 12.02.04).
4.
Remove the Crease Rolls (REP 12.02.03).
5.
Remove the Crease Roll Drive and Idler gears.

a.
Remove the drive gears from each of the Crease Rolls.
b.
Remove the idler gears from the Booklet Maker frame (two E-rings and one link).
Remove the
sensor.
Slide the motor

off of the shaft
3
2
Remove the E-ring and
remove the encoder
wheel/coupling.
Disconnect the M68

electrical connectors.
Figure 2 Removal of Crease Roll Motor (M68)
V0.042
May 2003
4-411
REP 12.02.04, REP 12.02.05
REP 12.02.06 Crease Blade Motor (M67)

Removal
WARNING
1.
2.
3.

a.
b.
c.
d.
4.
Raise the Crease Roll Gate.
5.
Reinstall the Crease Blade Knob temporarily and fully extend the Crease Blade.
6.
Prepare to remove the Crease Blade Drive Shaft and Motor (Figure 1).
7.
a.
Remove the snap-rings and cams on both ends of the Crease Roll Drive Shaft.
b.
Remove the T20 retaining screw retaining the front shaft bearing.
Crease
Blade Cam
(snap ring)
bearing
retainer
Remove the Crease Blade Drive Shaft and Motor.

a.
Disconnect the Crease Blade Motor electrical connector and any tie-wraps.
b.
Support the Crease Blade Motor and Encoder and remove the Crease Blade Drive
Shaft toward the front of the Booklet Maker.
Figure 1 Crease Blade Drive Motor Shaft (Front bearing)
Replacement
NOTE: The Encoder/coupling is the same part used on the Crease Roll Drive Motor. The coupling portion is not used here and faces the motor during replacement.
1.
REP 12.02.06
May 2003
4-412
Install in the reverse order of Removal.
V0.042
REP 12.02.07 Crease Blade Motor Encoder and Sensor

(S70)
REP 12.02.08 Booklet Compiler Flapper

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
Remove the Booklet Compiler Flapper (Figure 1).
3.
Remove the Crease Blade Motor (M67) (REP 12.02.06). The shaft, Encoder Sensor
(S70) and Encoder come off with the motor.
1
Remove four
5.5 mm
screws.
2
Move the
assembly to
the right to
clear the
bearing, and
remove the
assembly.
3
Remove the flapper.
Figure 1 Booklet Compiler Flapper removal
Replacement
V0.042
1.
Install the Flapper Assembly in the Reverse of Removal.
2.
Rotate the Booklet Paper Path Drive Belt clockwise until the Booklet Flapper Solenoid
(L61) arm catches the clutch detente and stops the flappers (Figure 2).
May 2003
4-413
REP 12.02.07, REP 12.02.08
3.
Install the Flappers Assembly so that the Flappers stop outside the paper path with the
top paddle in a vertical position. Move the paddles one gear tooth at a time as required,
rotating towards your position (Figure 3).
Booklet Paper Path

Drive Belt
Flapper Solenoid/Clutch
Figure 2 Flapper clutch
REP 12.02.08
May 2003
4-414
V0.042
REP 12.02.09 Booklet Tamper Assembly

Removal
WARNING
CAUTION
Use caution when removing the Booklet Tamper Assembly, to avoid damaging the flag for the
Booklet Tamper Home Sensor (S63). The flag can easily be broken.
1.
2.
3.
Remove the Crease Blade (REP 12.02.02).
4.
Position the tampers near their outermost position, so that the edge of the Tamper Rack
Bracket (Figure 1: bracket) is located between the first and second teeth of the Front
Tamper Rack (Figure 1: front rack ).
5.
Remove Tamper Assembly (Figure 1).
6.
Separate the front or rear Tamper components as necessary (PL 8.43).
Flapper in the set position
Figure 3 Flapper paddle position
V0.042
May 2003
4-415
REP 12.02.08, REP 12.02.09
Tamper
Assembly
bracket
Remove six 5.5 mm screws.

Tamper Racks
front
rack
bracket
1
Disconnect M62 electrical
connector.
Remove the Booklet Tamper

Assembly.
Tamper Rack guide tabs
Figure 1 Tamper Assembly removal
Figure 2 Replacement of Tamper Racks
Replacement
NOTE: In case the tamper racks are removed from the assembly, each rack has a guide tab
built in to allow for proper assembly into the tamper rack guide.
1.
If the tamper racks were removed, start both tamper racks into the tamper rack guide
together from opposite sides, so they engage the Booklet Tamper Gear simultaneously to
ensure correct front and rear tamper alignment.
2.
Verify that each tamper rack is against the Tamper Assembly bracket (Figure 2).
3.
Replace the Assembly in the reverse order of the removal.
4.
Perform ADJ 12.02.03 Booklet Tamping.
REP 12.02.09
May 2003
4-416
V0.042
REP 12.02.10 Booklet Tamper Motor (M62)
Replacement

Removal
1.
Start both tamper racks into the tamper rack guide together from opposite sides, so they
engage the Booklet Tamper Gear simultaneously to ensure correct front and rear tamper
alignment.
WARNING
2.
3.
Perform ADJ 12.02.03 Booklet Tamping.
1.
2.
3.
Remove the Tamper Assembly (REP 12.02.09).
4.
Remove the Tamper Motor.

a.
Remove the four motor bracket screws (5.5 mm) and separate the motor from the
tamper rack guide (Figure 1).
b.
Remove the Booklet Tamper Gear (one E-ring) from the Booklet Tamper Motor.
four motor bracket screws

(5.5 mm) (one hidden)
Figure 1 Removal of Booklet Tamper Motor
V0.042
May 2003
4-417
REP 12.02.10
REP 12.02.11 Booklet Backstop Assembly

Removal
WARNING
1.
2.
3.
Prepare to remove the Booklet Backstop Assembly (Figure 1).
4.
2
Remove the
backstop slide
shaft support
bearing.
a.
Remove the two 5.5 mm screws.
b.
If replacing the Backstop Assembly with a new one, disconnect each of the Booklet
Backstop Solenoids' electrical connectors, at the opposite end of the harness from
solenoid.
Remove the Backstop Slide Shaft (Figure 2).
1
Remove two 5.5 mm screws.
Remove the backstop

slide shaft.
BOTTOM VIEW OF BOOKLET MAKER
Figure 2 Booklet Backstop Slide Shaft removal
two 5.5 mm screws

Booklet Backstop Solenoid
Figure 1 Preparing for Booklet Backstop removal
REP 12.02.11
May 2003
4-418
V0.042
REP 12.02.12 Booklet Backstop Motor (M63)
Replacement
CAUTION

Removal
tensioning devices to assure for proper belt tension. Too much or too little tension will effect the
WARNING
1.
2.
3.
Remove the Backstop Motor (M63) (Figure 1).
1.
4
Remove the
M63 motor.
5
Disconnect the
M63 electrical
connector.
3
Remove the
belt from the
motor pulley.
1
Remove the tension spring.
2
Remove four
5.5 mm
screws.
Figure 1 Booklet Backstop Motor
V0.042
May 2003
4-419
REP 12.02.12
REP 12.02.13 Booklet Backstop Belt or Drive Belt

Removal
WARNING
1.
2.
3.
If removing the Backstop Drive Belt only, loosen the two idler bracket screws (Figure 1),
then skip to step 9.
4.
Remove the Crease Blade (REP 12.02.02).
5.
Remove the Booklet Tamper Assembly (REP 12.02.09).
6.
Remove the Booklet Backstop Assembly from the belt (REP 12.02.11).
7.
Remove the Booklet Backstop idler bracket (Figure 1).

a.
Disconnect the tensioner links from the idler shaft (2 places).
b.
Remove the two 5.5 mm screws and remove the idler bracket.
8.
Remove the Booklet Backstop Belt from the idler shaft: Remove one E-ring from one end
of the shaft, slide the shaft over in the bracket, and remove the belt from the shaft.
9.
Remove the Booklet Backstop Motor (REP 12.02.12).
10. Remove the Booklet Backstop Belt or Drive Belt from the Booklet Backstop Drive Shaft:
Remove the E-ring from the inboard end of the shaft, slide the shaft forward, and remove
the belt from the shaft.
Figure 1 Booklet Backstop
REP 12.02.13
May 2003
4-420
V0.042
REP 12.02.15 Booklet Rear Stapler

Removal
WARNING
tensioner links
connected to the
idler shaft (2
places).
idler bracket
5.5 mm screws (2
places).
Figure 2 Preparing for Booklet Backstop belt removal
1.
2.
3.

a.
b.
c.
d.
4.
Remove the Rear Booklet Stapler cover (one 5.5 mm screw) (Figure 1).
5.
Remove the Stapler Latch Front Bushing (PL 8.44) (one K-clip).
6.
Open the Booklet Stapler Module (area 5b4).
7.
Remove the Stapler Module Closed Sensor (S79) (Figure 2).
8.
Close the Booklet Stapler Module (area 5b4).
9.
Remove the Stapler Latch Rear Bushing (Figure 3).
10. Open the Booklet Stapler Module (area 5b4).

11. Remove the two E-rings from the Stapler Latch Shaft (Figure 4).
12. Slide the Stapler Latch Shaft out the rear of the Booklet Maker, capturing the Stapler
Latch Cam (Figure 4) and the Stapler Latch Spring (Figure 3) at the same time.
13. Pivot the Booklet Stapler Module fully open.
14. Remove the Booklet Rear Stapler (Figure 5).
V0.042
May 2003
4-421
REP 12.02.13, REP 12.02.15
Stapler Module
Closed Sensor (S79)
Rear Booklet Stapler cover
Figure 1 Rear Booklet Stapler Cover removal
REP 12.02.15
Figure 2 Stapler Closed Sensor removal
May 2003
4-422
V0.042
Stapler Latch Cam

two E-rings
Stapler Latch Spring

Stapler Latch Rear
Bushing (one K-clip)
Figure 4 Stapler Latch Shaft removal
Figure 3 Stapler Latch Rear Bushing removal
V0.042
May 2003
4-423
REP 12.02.15
REP 12.02.16 Booklet Front Stapler

Removal
WARNING
Remove three 5.5 mm

screws and remove the Rear
Booklet Stapler.
1.
2.
3.

a.
b.
c.
d.
4.
Remove the front Booklet Stapler cover (one 5.5 mm screw) (Figure 1).
5.
Remove the Stapler Latch Front Bushing (PL 8.44) (one K-clip).
6.
7.
Remove the Stapler Module Closed Sensor (S79) (Figure 2).
8.
Close the Booklet Stapler Module (area 5b4).
9.
Remove the Stapler Latch Rear Bushing (Figure 3).
10. Open the Booklet Stapler Module (area 5b4).

11. Remove the two E-rings from the Stapler Latch Shaft (Figure 4).
12. Slide the Stapler Latch Shaft out the rear of the Booklet Maker, capturing the Stapler
Latch Cam (Figure 4) and the Stapler Latch Spring (Figure 3) at the same time.
13. Pivot the Booklet Stapler Module fully open.
14. Remove the Booklet Front Stapler (Figure 5).
Figure 5 Booklet Rear Stapler removal
Replacement
1.
2.
Adjust the Booklet Stapler Rear Anvil (ADJ 12.02.02).
REP 12.02.15, REP 12.02.16
May 2003
4-424
V0.042
Stapler Module
Closed Sensor (S79)
Front Booklet Stapler cover
Figure 1 Front Booklet Stapler Cover removal
V0.042
Figure 2 Stapler Closed Sensor removal
May 2003
4-425
REP 12.02.16
Stapler Latch Cam

two E-rings

Stapler Latch Rear
Bushing (one K-clip)
Figure 4 Stapler Latch Shaft removal
Figure 3 Stapler Latch Rear Bushing removal
REP 12.02.16
May 2003
4-426
V0.042
REP 12.03.01 Booklet Exit Sensor (S73)

Removal
WARNING
1.
2.
3.
Remove the Main Tray Offset Panel/Rails (REP 12.01.03).
4.
Remove the Booklet Exit Sensor (S73).
Remove three 5.5 mm

screws and remove the Front
Booklet Stapler.
Figure 5 Booklet Front Stapler removal
Replacement
1.
2.
Adjust the Booklet Stapler Front Anvil (ADJ 12.02.02).
V0.042
May 2003
4-427
REP 12.02.16, REP 12.03.01
REP 12.04.01 Tri-Folder Assembly

Removal
Tri-Folder
Drive Belt
on Clutch
(CL 80)
WARNING
1.
2.
3.
Remove the Booklet Exit front cover (three T20 screws).
4.
Remove the MFF rear cover.
5.
Swing out the PWB panel (two T20 screws).
6.
Prepare to remove the Tri-Folder Assembly (Figure 1).

a.
De-tension the Tri-Folder drive belt (T10 screw) and remove the belt from the pulleys.
NOTE: The belt is captured by the Booklet Exit drive assembly.
b.
7.
Disconnect the two solenoids' electrical connectors: Tri-Fold Diverter Gate Solenoid
(L80) and Tri-Fold Curl Gate Solenoid (L81).
Remove the Tri-Folder Assembly (Figure 2).

a.
Disconnect the Tri-Fold Jam Sensor (S81) electrical connector.
b.
Remove the four Tri-Folder mounting screws (T20, two front and two rear), and
remove the Tri-Folder Assembly out the front of the MFF.
Tri-Folder Drive
Belt tensioning
idler screw (T10)
Tri-Folder
Drive Belt on
Tri-Fold
crease roll
shafts
L80
L81
Figure 1 Tri-Folder rear
REP 12.04.01
May 2003
4-428
V0.042
REP 12.04.02 Tri-Folder Drive Belt

electrical
connector
S81

Removal
WARNING
1.
Remove the Booklet Exit front cover (three T20 screws).
2.
Remove the MFF rear cover.
3.
De-tension the Tri-Folder drive belt (T10 screw) and remove the belt from the pulleys (Figure 1).
NOTE: The belt is captured by the Booklet Exit drive assembly.
4.
If replacing the belt with a new one, remove the four T20 bracket screws and pull out the
Booklet Exit drive assembly, to free the belt (Figure 1)
four T20 screws (one hidden)
Figure 2 Tri-Folder left side / front
Replacement
1.
Install the Tri-Folder Assembly.
2.
Install and tension the Tri-Folder Drive Belt according to REP 12.04.02.
3.
Continue the replacement in the reverse order of Removal.
V0.042
May 2003
4-429
REP 12.04.01, REP 12.04.02
Tri-Folder
Drive Belt
on Clutch
(CL 80)
front Crease Spring
Tri-Fold Idler Roller
T20 bracket
screws (4).
Tri-Folder Drive
Belt tensioning
idler screw (T10)
Crease Rollers
Tri-Folder
Drive Belt on
Tri-Fold
crease roll
shafts
rear Crease Spring
Figure 2 Tri-Folder left side / front
Replacement
1.
Position the belt, and leave the tensioner screw loose (Figure 1).
2.
Remove both Tri-fold Crease Springs (front and rear) (Figure 1 and Figure 2).
3.
Raise the Tri-fold Idler Roller to prevent it from contacting the Crease Rollers while the
drive belt is being tensioned (Figure 2).
4.
Rotating the Tri-Folder Drive Clutch clockwise, ensure that the tensioning idler slides
freely, then tighten the idler bracket screw (T10) (Figure 1).
5.
Lower the Tri-fold Idler Roller, and reinstall the Tri-fold Crease Springs (front and rear)
(Figure 1 and Figure 2).
Figure 1 Tri-Folder rear
REP 12.04.02
May 2003
4-430
V0.042
REP 12.05.01 Compiler Tamper Assembly

Removal
1
Remove two T20
screws.
WARNING
1.
2.

a.
Front Door
b.
Rear Cover
c.
Top Cover
3.
Remove the Buffer/Compiler Module Assembly (REP 12.13.01).
4.
Move the Compiler Tray out of the way, and disconnect the Tamper Motor (M44) electrical
connector and ground wire (Figure 1).
5.
Remove the Compiler Tamper Assembly (Figure 2).
Disconnect the M44 motor

connector and ground wire.
Remove the
Tamper Assembly.
Figure 2 Removal of the Compiler Tamper Assembly
Remove two
T20 screws.
Replacement
CAUTION
1.

NOTE: Make sure the Tampers move freely back and forth when the tamper/backstop
cover is installed. If the cover is not installed correctly, it can cause the tampers to bind.
2.
Perform ADJ 12.05.01 Compiler Tamping.
2
Lift the tray off
and move it out
of the way.
Figure 1 Moving the CompilerTray
V0.042
May 2003
4-431
REP 12.05.01
REP 12.05.02 Compiler Backstop Assembly

Removal
WARNING
1.
2.

a.
Front Door
b.
Rear Cover
c.
Top Cover (REP 12.06.01)
d.
Right Front Cover
3.
Remove the Buffer/Compiler Module Assembly (REP 12.13.01).
4.
Move the Compiler Tray out of the way (Figure 1).
5.
Before removing the Compiler Backstop Assembly, take a look at the linkage and position
mechanism as the Main Stapler moves forward and back in the MFF. This will help during
the install or if the linkage comes apart.
6.
Remove the Compiler Backstop upper components (Figure 2 -- front shown; rear removes
the same).
7.
Remove the Compiler Backstop lower components (Figure 3 -- front shown; rear removes
the same).
REP 12.05.02
Remove two
T20 screws.
2
Lift the tray off
and move it out
of the way.
May 2003
4-432
Figure 1 Moving the Compiler Tray
V0.042
3
Slide the shaft to the rear,
lift, and remove the shaft
with the lower backstop
components attached.
2
Disconnect two
links.
1
Remove two
T10 screws.
Figure 2 Removal of upper portion of the Compiler Backstop Assembly (front shown)
1
Observe the position of the
springs and lower backstop components (front and rear).
2
Remove the K-clip.
Figure 3 Removal of Lower Compiler Backstop Assembly (front shown)
Replacement
V0.042
1.
Install in the reverse order of the removal. Ensure the spring and backstop lower components are located correctly as observed during Removal.
May 2003
4-433
REP 12.05.02
REP 12.05.03 Compiler Fingers Assembly

Removal
Remove the assembly.
WARNING
1.
2.
3.
Remove the Main Tray Offset Panel/Rails (REP 12.01.03).
4.
Remove the Compiler Fingers Assembly (Figure 2).
3
Remove the Main Tray.
3
Disconnect the M49

motor connector.
Disconnect the S91

sensor connector.
Figure 2 Removal of Compiler Fingers Assembly
Replacement
CAUTION
Ensure that the M49 Motor connector (Figure 2) is flat against the frame. Otherwise, the Main
Tray Offset Panel ribs may contact the connector during offsetting and damage the connector
and harness.
1
Remove the
K-clip.
2
Remove the two T20 screws.
Figure 1 Removal of the Main Tray
REP 12.05.03
May 2003
4-434
V0.042
REP 12.05.04 Compiler Tamper Motor (M44)
REP 12.06.01 MFF Top Cover

Removal

Removal
WARNING
WARNING
1.
2.
1.
a.
Front Door
2.
Remove the Top Cover (Figure 1)
b.
Rear Cover
c.
3.
Slide out the Buffer/Compiler Module.
4.
Remove the Compiler Tamper Motor (M44) (PL 8.54).

a.
Disconnect the M44 electrical connector and ground wire.
b.
Remove the two 5.5 mm motor screws.
c.
Remove the motor.
3
Remove the three
front T20 screws from
underneath.
NOTE: The tamper drive belt has no tensioner. The tensioner spring is for the tamper belt.
Replacement
1.
2.
Perform ADJ 12.05.01 Compiler Tamping.
4
Lift the cover and disconnect the Pause/
Resume Switch connector.
1
Remove the T20
screw and remove the
Top Tray.
Remove the three rear

T20 screws.
Figure 1 Removal of Top Cover
V0.042
May 2003
4-435
REP 12.05.04, REP 12.06.01
REP 12.07.01 Eject Housing Assembly

Removal
NOTE: Lowering the Eject Housing and the Main Tray as follows will allow room to remove the
Crash Bar.
1.
Eject Housing
stop bracket
Eject Housing
position screw
Crash Bar
Eject Housing harness connector
Enter [Copier Sys tab , Component Control], select Main Tray Elev Motor (Down), and
lower the Main tray all the way.
WARNING
2.
3.
Remove the MFF Top Cover (REP 12.06.01).
4.
Position the Eject Housing to approximately the middle of the gear racks.
The Eject Housing can be raised by grasping it and lifting. If the Eject Housing needs to
be lowered while power is off, turn the Eject Housing position screw clockwise to lower
the housing (Figure 1).
5.
Remove the Eject Housing stop bracket (one T20 screw) (Figure 1).
6.
Observe the correct positioning of the Crash Bar before removing it, then remove the
Crash Bar (Figure 1): Flex the Crash Bar to disengage the bottom pivot points, then pivot
the Crash Bar to disengage it at the top.
7.
If replacing the Eject Housing with a new one, cut the tie wraps and disconnect the Eject
Housing electrical harness from the housing (Figure 1).
8.
Lift and remove the Eject Housing Assembly (Figure 1).
Figure 1 Eject Housing
Replacement
1.
Position the Eject Housing, ensuring that the front and rear gears engage the gear racks
simultaneously.
2.
Install the Crash Bar:
3.
REP 12.07.01
May 2003
4-436
a.
Position the top front pivot pin into the Crash Bar Switch actuator.
b.
Position the top rear pivot pin.
c.
Flex the Crash Bar and position the two bottom pivot pins into their holes on the
Eject Housing.
Check that the Eject Housing is installed correctly and moves on the gear racks correctly.
Place two pieces of paper in the paper path under the front and rear of the Eject Housing,
and lower the Eject Housing by turning the position screw clockwise. When the housing
bottoms out, check that both the front and rear of the exit drive nip grip the paper. If not, lift
the housing to the top of the racks, recheck for even gear/rack engagement, and repeat
this step.
V0.042
REP 12.07.02 Compiler Flapper Home Sensor (S40)
REP 12.07.03 Compiler Flappers

Removal

Removal
Crash Bar.
1.
WARNING
2.
3.
Remove the top MFF Top Cover (REP 12.06.01).
4.
Remove the Eject Housing Assembly (REP 12.07.01).
5.
Pop off the Eject Housing Cover and Remove the Compiler Flapper Home Sensor (S40)
(PL 8.34).
V0.042
WARNING
1.
2.
Rotate the Flappers by hand to access the screws.
3.
Remove the Compiler Flappers: Remove the four 5.5 mm screws securing the two Flapper Bridges and remove the bridges and the flappers (PL 8.34)
May 2003
4-437
REP 12.07.02, REP 12.07.03
REP 12.07.04 Eject Shaft Drive Belt
REP 12.08.01 MFF Control PWB

Removal

Removal
Crash Bar.
1.
WARNING
2.
3.
Remove the top MFF cover.
4.
Remove the Eject Housing Assembly (REP 12.07.01).
5.
Remove the Eject Housing Cover (PL 8.34).
6.
Detension the Eject Shaft Drive Belt.
NOTE: Before disengaging the Compiler Upper Eject Shaft from the gear train, observe the
position of the Compiler Flappers. The gears will need to be reengaged in the same position as
before to ensure that the flappers and the Compiler Flapper Home Sensor flag are synchronized.
7.
CAUTION
WARNING
1.
2.
3.
Remove the MFF Control PWB:

a.
Dismount each of the four adjoining PWBs (T20 screws and standoffs) and disconnect them from the MFF Control PWB.
b.
Disconnect all connectors from the MFF Control PWB, and dismount and remove the
PWB (T20 screws and standoffs).
Replacement
1.
Install the PWB and the remaining components in the reverse of Removal.
2.
Ensure the MFF software version corresponds with the software version currently on the
machine:
Remove the rear (belt-side) E-ring from the Compiler Upper Eject Shaft, slide the shaft
forward, and remove the belt.
a.
Enter [System, Imaging, and IOT Configuration], [Software] tab.
b.
Refer to the Software Version Compatibility Table at the back of the Troubleshooting
section of the latest Software Upgrade Kit Installation Instructions.
c.
If necessary, use the appropriate Software Upgrade Kit to perform a Wizard software
upload, selecting only the Main Controller platform.
Replacement
As observed during Removal, align the Compiler Upper Eject Shaft gears so as to ensure that
the Compiler Flapper Home Sensor flag blocks the sensor when the flappers are fully out of the
paper path.
3.
Restore the MFF NVM:
Upload the MFF NVM from the Machine Resident Diskette (MRD) to the machine
(GP4 -- select Service: [Mark Service], Module: [MFF]).
Perform the following adjustments, and be sure to save the Machine NVM to the
MRD afterward (GP4):
OR
4.
REP 12.07.04, REP 12.08.01
May 2003
4-438
a.
b.
ADJ 12.12.01 Main Stapler Staple Position
c.
ADJ 12.02.03 Booklet Tamping
d.
ADJ 12.02.08 Booklet Compiling Position
e.
ADJ 12.02.05 Booklet Crease Position
f.
ADJ 12.02.04 Booklet Staple Position
g.
ADJ 12.04.01 Tri-Fold First Crease Position
Switch off the machine power, wait 20 seconds, and switch on the machine power.
V0.042
REP 12.10.01 Multi-Function Finisher Assembly

(Undocking the MFF)
Removal
WARNING
1.
2.
Open the MFF Front Door and remove the Left Front Cover (three T20 screws).
3.
Release the docking latches, and disconnect the MFF/IOT interface connector (Figure 1)
4.
Undock the MFF from the IOT.
V0.042
May 2003
4-439
REP 12.10.01
1
Disconnect the
MFF/IOT Interface
Connector.
2
Remove the two
T20 screws and
pivot the all the
way latches down.
FRONT
REAR
Figure 1 Undocking of MFF from machine
REP 12.10.01
May 2003
4-440
V0.042
REP 12.11.01 Upper Master Lock

Removal
WARNING
1.
2.
Undock the MFF from the IOT (REP 12.10.01).
3.
Slide out the Buffer/Compiler Module and Booklet Maker drawers
4.
5.
Disconnect the Master Lock Coupling (Figure 1).
6.
Remove two T20 screws securing the Upper Master Lock bracket (Figure 2).
7.
Remove Upper Master Lock (PL 8.37).
V0.042
May 2003
4-441
REP 12.11.01
Remove the two

small K-clips and
remove the two
pins.
Figure 1 Removal of Master Lock shaft coupling
REP 12.11.01
May 2003
4-442
V0.042
REP 12.11.02 Lower Master Lock Assembly

Removal
WARNING
1.
2.
Undock the MFF from the machine (REP 12.10.01).
3.
Slide out the Buffer/Compiler Module and Booklet Maker drawers
4.
5.
Remove the outer guide link shaft (Figure 1).
6.
Remove the Lower Master Lock (Figure 2).
Remove the two

T20 screws
accessed through
these holes
Figure 2 Removal of upper Master Lock bracket
Remove the two Erings and remove

the link shaft.
Figure 1 Removal of outer guide link shaft
V0.042
May 2003
4-443
REP 12.11.01, REP 12.11.02
1
Disconnect the
Master Lock Coupling: Remove the
two small K-clips
and remove the
two pins.
3
Remove the two
T20 screws and
remove the Lower
Master Lock.
2
Remove the three
T20 screws (one
on the side frame
not shown).
FRONT
REAR
Figure 2 Removal of the Lower Master Lock
REP 12.11.02
May 2003
4-444
V0.042
REP 12.11.03 Nip 1, Nip 2 Outer Guide Assembly

Removal
WARNING
1.
2.
Disconnect the MFF from the machine (REP 12.10.01).
3.
Remove the Nip 1, Nip 2 Outer Guide (Figure 1).
2
Remove the two flathead screws
and remove the outer guide.
1
Remove the two Erings and remove
the link shaft.
Figure 1 Removal of outer guide link shaft
V0.042
May 2003
4-445
REP 12.11.03
REP 12.12.01 Main Stapler Carriage Assembly
c.
Rear Cover
3.
Remove the Buffer/Compiler Module Assembly (REP 12.13.01) for easier access to the
Main Stapler Carriage Assembly.
4.
The flag for the Stapler Position Sensor (S43) is located on the underside of the stapler carriage. Use caution not to damage sensor flag during the Main Stapler removal.
Remove the Offset Motor cover (Figure 1) to access the Main Stapler electrical harness.
The harness is attached to the frame with tie wraps or twist ties. If replacing the carriage
with a new one, free the harness by cutting tie wraps as required.
5.
Remove the rear stapler belt tensioning mechanism (Figure 2).
WARNING
6.
Remove the front Main Stapler Carriage components indicated in Figure 3.

Removal
CAUTION
CAUTION
There is a bronze bearing that is captured by the Main Stapler Carriage Assembly and the
smaller support shaft runs through. As the shaft is pulled out the bearing will fall out.
1.
7.
Slide the Stapler fully forward.
2.
8.
Slide the carriage support shafts to the rear to disengage them at the front, then lift and
remove Main Stapler Carriage Assembly out the front of the MFF.
9.
If replacing the Main Stapler Carriage Assembly with a new one, remove the Main Stapler
from the carriage (REP 12.12.03).
a.
Front Door
b.
REAR VIEW
Offset Motor
(M50)
2
Remove two
T20 screws
(front screw
shown).
1
Remove two
7mm nuts.
Figure 1 Removal of Offset Motor cover
REP 12.12.01
May 2003
4-446
V0.042
NOTE:
The tensioning
mechanism
captures 5 teeth
of the belt.
Remove two
K-clips.
2
Disconnect the tensioning
mechanism from the MFF.
Remove one K-clip

and remove the pin.
Remove one T20 screw.
Figure 2 Removal of Main Stapler Belt Tensioning Mechanism
V0.042
Figure 3 Removal of Main Stapler shafts front K-clips and front belt support
May 2003
4-447
REP 12.12.01
REP 12.12.02 Main Stapler Position Motor (M43)
REP 12.12.03 Main Stapler

Removal

Removal
WARNING
WARNING
1.
1.
2.
Remove the Main Stapler Carriage Assembly (REP 12.12.01)
2.
3.
Remove the Main Stapler Position Motor.
3.
Slide the Main Stapler all the way back.
Replacement
4.
From the rear of the MFF, disconnect the stapler harness from the Stapler Cover.
1.
5.
Slide the Main Stapler fully forward.
2.
Perform ADJ 12.12.02 Main Stapler Staple Position.
6.
Remove Main Stapler Cover (one T10 screw).
7.
Disconnect Main Stapler electrical connections (Figure 1).
8.
Remove the Main Stapler (Figure 2).
REP 12.12.02, REP 12.12.03
May 2003
4-448
V0.042
Disconnect the two electrical connectors and the

ground wires.
Remove the Main Stapler.
1
Remove the three 7 mm
screws.
Figure 1 Disconnection of Main Stapler electrical connectors
Figure 2 Main Stapler Adjustment
Replacement
V0.042
1.
2.
Perform ADJ 12.12.01 Main Stapler Alignment.
May 2003
4-449
REP 12.12.03
REP 12.13.01 Buffer/Compiler Module Assembly

Removal
WARNING
1.
2.
Remove the MFF Front Door.
3.
4.
Slide out the Buffer/Compiler Module drawer.

NOTE: The Buffer/Compiler Module will tilt backward slightly after the front screws are
removed.
5.
Remove the four Buffer/Compiler Module rail screws: first the two T20 flathead screws
near the rear (one on each rail), and then the two 5.5 mm cross-head screws near the
front (one on each rail) (Figure 1).
CAUTION
Take extreme care not to damage any of the many connectors, motors, and solenoids on the
Buffer/Compiler Module when lifting, removing, and setting it down.
6.
Standing on the right side of the Buffer/Compiler Module with the module tilted back,
grasp the front handle, slide the module forward until it stops, grasp the rear handle (Figure 2) and lift it off of the slides.
7.
Carefully place the Buffer/Compiler Module Assembly on a flat surface.
8.
Retract the drawer slides into the machine, to avoid an injury hazard.
T20 flathead screw (one

on each rail)
5.5mm cross-head screw

(one on each rail)
Figure 1 Buffer/Compiler Module rail screws
REP 12.13.01
May 2003
4-450
V0.042
REP 12.13.02 Nip 3 or 4 Drive Shaft

Removal
WARNING
1.
2.
Remove the Buffer/Compiler Module Assembly from the MFF (REP 12.13.01).
3.
Remove the 3 or 4 drive belt/pulley and drive shaft (Figure 1).

Both shafts remove the
same. The Nip 3 shaft
steps are shown.
2
Remove
the drive
belt.
1
De-tension the drive
belt.
Buffer/Compiler Module
rear handle
Nip 4 shaft
5
Remove the K-clip
and the bearing
(hidden) and
remove the Nip 3
shaft.
Figure 2 Buffer/Compiler Module rear handle
3
Remove
the K-clip
and the pulley.
4
Remove the
bearing
retainer.
Figure 1 Removal of the 3 or 4 nip drive shaft

V0.042
May 2003
4-451
REP 12.13.01, REP 12.13.02
REP 12.13.04 Nip 6/7 Outer Guide Assembly, Nip 6/7 Inner
Guide

Removal

Removal
WARNING
WARNING
1.
2.
1.
3.
Remove the Nip 5 drive shaft (Figure 1).
2.
If removing the inner guide, remove the Nip 6/7 drive belt (Figure 1).
3.
Remove the Entrance Sensor (S20) Bracket (Figure 2).
4.
Remove the Nip 6/7 Outer Guide and/or the Nip 6/7 Inner Guide (Figure 3).
3
Remove the K-clip and the pulley.
4
Remove the bearing retainer (hidden).
Remove the K-clip and

bearing (hidden) and
remove the Nip 5 shaft.
If removing the Nip 6/7 Outer Guide only, pop only the outer guide off of the pivot
pins.
If removing the Nip 6/7 Inner Guide, pop both guides off of the pivot pins.
5.
If replacing the Nip 6/7 Outer Guide with a new one, remove the pulleys from the Nip 6
and 7 shafts (one E-ring each).
6.
If replacing the Nip 6/7 Inner Guide with a new one, remove the metal Nip 7 paper guide
(two T20 screws and one ground wire).
2
Move the rear
handle out of the
way (two T20
screws).
1
Loosen the idler
and remove the
drive belt.
Figure 1 Removal of Nip 5 drive shaft

REP 12.13.03, REP 12.13.04
May 2003
4-452
V0.042
Remove the E-rings

and pulleys and
remove the Nip 6/7
Drive Belt
Remove two T10 screws and

remove the S20 bracket
Figure 2 Removal of Entrance Sensor Bracket
Figure 1 Removal of Nip 6/7 Drive Belt
V0.042
May 2003
4-453
REP 12.13.04

Removal
WARNING
1.
2.
3.
Remove the Nip 8 drive shaft (Figure 1).
Remove the
bearing
retainer.
Remove the K-clip

and the pulley.
Pop the outer guide, and

the inner guide as
required, off of the pivot
pins.
Figure 3 Removal of the Nip 6/7 Outer and Inner Guides
Replacement
When installing the Entrance Sensor (S20) Bracket (Figure 2), before tightening the screws,
move the bracket toward the rear of the Buffer/Compiler Module until the sensor flag clears the
Nip 6/7 Inner Guide. After tightening the screws, open and close the Nip6/7 Outer Guide and
ensure that the flag clears teh cutout in the Nip 6/7 Inner Guide.
3
Remove the K-clip
and the bearing
(hidden).
4
Open the area
5b4 baffle and
remove the Nip 8
shaft.
Figure 1 Nip 8 Drive Shaft removal

REP 12.13.04, REP 12.13.05
May 2003
4-454
V0.042
REP 12.13.06 Nip 8 Release Solenoid (L31)

Removal
2
Disconnect the
solenoid arm.
WARNING
1.
2.
3.
Remove the 4-Bar Position Motor Assembly (M45) (REP 12.13.12).
4.
Remove the Nip 8 Release Solenoid (L31) (Figure 1).
3
Remove two
5.5mm screws (hidden) and remove
the Nip 8 Release
Solenoid.
1
Disconnect the L31
electrical connector.
Figure 1 Removal of the L31 Solenoid
V0.042
May 2003
4-455
REP 12.13.06
REP 12.13.07 Nip 9 Clutch
REP 12.13.08 Paper Path Nip Motor (M110)

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
Remove the Nip 9 Clutch (Figure 1).
3.
Disconnect the electrical connections and remove the fan/shroud assembly (Figure 1).
4.
Remove the M110 motor (Figure 2).
2
Remove the Nip 9
Drive Belt.
2
Remove one T20
screw.
3
Remove the K-clip
and remove the Nip
9 Clutch.
1
Disconnect the
motor and fan electrical connectors.
1
Loosen this T20
screw to loosen the
Nip 9 Drive Belt.
3
Slide the shroud
forward and lower it
to remove the fan/
shroud assembly.
Figure 1 Removal of fan/shroud assembly
Figure 1 Removal of the Nip 9 Clutch

REP 12.13.07, REP 12.13.08
May 2003
4-456
V0.042
REP 12.13.09 Buffer Nip Motor (M30)

Removal
1
Loosen the idler and
remove the drive belt.
WARNING
1.
2.
3.
4.
Remove the Buffer Nip Motor (M30) (PL 8.36).

a.
Disconnect the electrical connector and ground wire.
b.
Remove the two T20 screws securing the motor bracket to the MFF rear frame and
remove the motor.
Replacement
CAUTION
1.
3
Remove two 7mm
screws and remove
the motor.
Figure 2 Removal of M110 motor
Replacement
CAUTION
1.
V0.042
May 2003
4-457
REP 12.13.08, REP 12.13.09
REP 12.13.10 Buffer Entrance Nip Motor (M31)

Removal
2
Move the connector
bracket out of the way. The
blue connector may need
to be removed from the
bracket.
WARNING
1.
2.
3.
Remove Buffer/Compiler drawer connector bracket, to allow access to the M31 motor
(Figure 1).
4.
Remove the Buffer Entrance Nip Motor (M31) (PL 8.26).

a.
Disconnect the electrical connector and the ground wire.
b.
Remove the three T20 screws securing the motor bracket to the Buffer/Compiler
Module, and remove the motor part way.
c.
Disconnect the belt tensioner spring and remove the motor.
1
Remove the four
T20 screws
Figure 1 Removal of Buffer/Compiler Drawer Connector
Replacement
CAUTION
NOTE: When installing the Drawer Electrical Connector plate, make sure the holes in the plate
are properly located on the standoff shaft, before tightening the screws.
1.
REP 12.13.10
May 2003
4-458
V0.042
REP 12.13.11 Compiler Lower Eject Motor (M40)
REP 12.13.12 4-Bar Position Motor Assembly (M45)

Removal

Removal
WARNING
WARNING
1.
1.
2.
Slide out the Buffer/Compiler drawer.
2.
3.
4.
Remove the Compiler Lower Eject Motor (M40) (PL 8.55).
Don not lose the two support bearings during the motor removal.
CAUTION
a.
Disconnect the tension spring.
3.
b.
Disconnect the electrical connector.
c.
Remove the three T20 screws and remove the motor.
Remove the 4-Bar Position Motor Assembly (M45) (Figure 1)
Replacement
CAUTION
1.
V0.042
May 2003
4-459
REP 12.13.11, REP 12.13.12
REP 12.13.13 4-Bar Exit Drive Assembly
6
Remove the tension spring (hidden), then remove
the motor assembly.
5
Slide the motor
assembly part way
off of the shaft.

Removal
1
Disconnect the M45
WARNING
1.
2.
3.
Push down on the 4-Bar and remove the front two screws securing the Exit Drive Assembly (Figure 1).
4.
Disconnect the ground faston connector (Figure 1).
5.
Remove the rear three screws securing the Exit Drive Assembly (Figure 2).
CAUTION
Carefully note the correct harness routing before cutting any tie-wraps.
6.
If removing the Exit Drive Assembly completely (e.g. to replace the assembly with a new
one):
a.
Cut the three tie wraps on the 4-Bar (Figure 1).
b.
Cut the four tie wraps bundling the harnesses (Figure 2).
c.
Disconnect the three connectors for the Exit Drive Assembly (Figure 2).
Remove the E-ring

on the white gear.
d.
Note the orientation of the ground wires, then remove the screw securing the three
ground wires (Figure 2).
7.
Lower the front of the Exit Drive Assembly, carefully noting how the assembly fits on the 4Bar, then disengage it at the rear and remove it.
Remove one T20

screw.
3
Disconnect the
Figure 1 Removal of the M45 motor
Replacement
CAUTION
NOTE: Slide the motor assembly and white gear on at the same time. Remember to hook the
spring back on and to install the two bearings while installing the motor assembly.
1.
REP 12.13.12, REP 12.13.13
May 2003
4-460
V0.042
three tie-wraps
T20 screw
securing the
three ground
wires
four tie-wraps
sensor
connector
three T20 screws

securing the Exit
Drive Assembly
ground faston
motor connector
solenoid
connector
two T20 screws
Figure 1 Exit Drive Assembly front view
Figure 2 Exit Drive Assembly rear view
Replacement
CAUTION
tensioning devices to assure for proper belt tension. Too much or too little tension will effect the
1.
V0.042
May 2003
4-461
REP 12.13.13
REP 12.13.14 4-Bar Assembly

Removal
2 connectors
WARNING
1.
2.
3.
Remove the 4-Bar Exit Drive Assembly (REP 12.13.13).

CAUTION
Carefully note the correct harness routing before cutting any tie-wraps.
4.
If removing the 4-Bar Assembly completely (e.g. to replace the assembly with a new one):
a.
Cut the five tie wraps bundling the harnesses (Figure 1).
b.
Disconnect the two connectors for the 4-Bar Assembly (Figure 1).
5.
Remove the Nip 9 Drive Shaft (REP 12.13.15).
6.
Remove the 4-Bar Front Link (Figure 2).
7.
Remove the 4-Bar Assembly from the Rear Link (PL 8.28): Remove the T20 screw at the
outer pivot, and remove the 4-Bar Assembly from the Rear Link.
five tie-wraps
Figure 1 Exit Drive Assembly rear view
REP 12.13.14
May 2003
4-462
V0.042

3
Remove the 4-Bar

Front Link.
Disconnect the spring.

Removal
WARNING
1.
2.
3.
Remove the Buffer/Compiler Module Front Handle (two 5.5 mm screws) and remove the
Buffer/Compiler Module Front Cover (four 5.5mm screws).
4.
Remove the Nip 9 Clutch (REP 12.13.07).
5.
Remove the Nip 9 drive shaft (PL 8.28).

a.
Remove the font and rear E-rings and bearings.
b.
Slide the shaft rearward, flexing the baffle to allow the rollers to clear the baffle cutouts, and remove the front end of the shaft from the Buffer/Compiler Module frame,
then slide the shaft forward and remove the rear end of the shaft.
2
Remove the two
T20 screws.
Figure 2 Removal of 4-Bar Front Link
V0.042
May 2003
4-463
REP 12.13.14, REP 12.13.15
REP 12.13.16 Buffer Gate Solenoid (L33) or Trail Edge

Clamp Solenoid (L30)
Parts List on PL 8.26 (L30), PL 8.27 (L33)
Removal
WARNING
1.
2.
3.
Remove rear electrical wire guide (Figure 1).
4.
Prepare to remove Solenoid L30 or L33 (Figure 2).
5.
Remove L30 or L33.

a.
Remove the E-ring from the solenoid link arm.
b.
Remove the two T10 flathead screws securing the solenoid to the bracket.
Remove the two T10

screws and remove
the electrical guide.
Figure 1 Removal of rear electrical guide
REP 12.13.16
May 2003
4-464
V0.042
REP 12.13.17 Top Tray Diverter Solenoid L40

Removal
L33
WARNING
L30 (hidden)
1.
2.
3.
Remove rear electrical wire guide (Figure 1)
4.
Remove Solenoid L40 (Figure 2)
Remove the two T20

screws and remove
the L30/L33 solenoid
bracket.
Figure 2 Preparing for removal of L30 or L33 solenoid
V0.042
May 2003
4-465
REP 12.13.16, REP 12.13.17
1
Remove the E-ring
and disconnect the
solenoid link arm.
L40
Remove the two T10

screws and remove
the electrical guide.
2
Remove the two 5.5 mm
screws and remove the
solenoid.
Figure 1 Removal of rear electrical guide
REP 12.13.17
Figure 2 Removal of L40 Solenoid
May 2003
4-466
V0.042
REP 12.13.18 Compile Belts

Removal
WARNING
1.
Rear Belt Guard
Rear Compile Belt
2.
3.
Remove the 4-Bar Exit Drive Assembly part-way. Leave the Exit Drive harnesses attached
to the Buffer/Compiler Module, and do not not cut any tie-wraps (REP 12.13.13).
4.
Remove the Compile Belts (Figure 1):

a.
Remove either the front two or front four Curl Guard Fingers and Knuckles, as
required.
b.
Remove either one or two Belt Guards, as required (one screw each).
c.
Remove either one or two Compile Belts, as required, sliding the belt(s) off of the
front of the Exit Drive Assembly.
T20
screws
Front Compile Belt

Front Belt Guard
front four Curl Guard Fingers

and Knuckles
Figure 1 Removing the Compile Belts
V0.042
May 2003
4-467
REP 12.13.18
REP 12.13.19 Buffer Module Entrance Sensor Bracket

Replacement
When installing the Entrance Sensor Bracket (Figure 1), before tightening the screws, move
the bracket toward the rear of the Buffer/Compiler Module until the sensor flag clears the Nip 6/
7 Inner Guide. After tightening the screws, open and close the Nip6/7 Outer Guide and ensure
that the flag clears the cutout in the Nip 6/7 Inner Guide.
two T10 screws
Figure 1 Removal of Entrance Sensor Bracket
REP 12.13.19
May 2003
4-468
V0.042
REP 12.13.20 4-Bar Exit Drive Shaft
2.

Removal
3.
Remove the 4-Bar Exit Drive Assembly (REP 12.13.13).
4.
Remove the fingers, belt covers, and bearing (Figure 1).
WARNING
1.
2
Remove Compiler Belt
Covers (2).
3
Remove the middle
Curl Guard Bearing.
1
Remove Curl Guard
Knuckles and Fingers (6)
by pulling them off the
shaft.
Figure 1 Removing the Fingers, Belt Covers, and Bearing
V0.042
May 2003
4-469
REP 12.13.20
5.
Remove the motor/solenoid assembly, pulley, and bearing retainer (Figure 2).
1
2
Remove T20
screws (2).
Remove motor/solenoid
assembly and belt.
4
Remove the bearing
retainer.
3
Remove e-ring and pulley.
Figure 2 Removing the Motor/Solenoid Assembly, Pulley, and Bearing Retainer
REP 12.13.20
May 2003
4-470
V0.042
6.
Remove the Exit Drive Shaft (Figure 3).
1
Remove the T20
screw, then remove
the bearing retainer,
the antistatic brush,
and the ground wire.
2
Remove the bushing and the bearing.
4
Move the shaft towards
the rear to disengage it,
then remove the Exit
Drive Shaft.
3
Remove Compile Belts.
Figure 3 Removing the Exit Drive Shaft
Replacement
1.
2.
Ensure that the antistatic brush touches the shaft.
3.
Be careful not to damage the 4-Bar Home Sensor actuator.
4.
Ensure that the Compile Belts are positioned over the idlers on the small shaft.
V0.042
May 2003
4-471
REP 12.13.20
REP 12.13.21 Compiler Entrance Sensor S46

Removal
WARNING
1.
2.
3.
Remove the Compiler Entrance Sensor S46.
Replacement
CAUTION
Dress the harness leading to S46 properly back through the baffle in order to avoid pinched
wires. Ensure that the wires are not pinched when putting the Buffer/Compiler Module Assembly back together.
REP 12.13.21
May 2003
4-472
V0.042
REP 14-1 Image Module, Scanner Video Cable Kit

Removal
WARNING
1.
2.
3.
Remove the following components:
4.
a.
b.
Scanner Main Cover (REP 14-6)
c.
Scanner Top Frame with Document Glass Frame attached (REP 14-5)
d.
Illumination Lamp Module (REP 14-2)
Remove the Image Module.

a.
Remove the retainer clips (5) on the Video Cable and the Cable Cap (Figure 1).
b.
Remove the screw securing the connector cover on the Image Module, and disconnect the connector.
c.
Remove the Top Rear Cover and the lower left rear cover (covering the card cage) of
the IOT.
d.
Remove the cable cover at the top of the Main Control PWB.
e.
Disconnect the Video Cable from the Main Control PWB.
f.
Guide the Video Cable through the IOT/IIT interface and remove the cable from the
machine.
g.
Loosen the screws (4) securing the clamps to the scan carriage cables (Figure 2).
h.
Remove the scan carriage cables from the Image Module.
i.
Remove the Image Module.

CAUTION
With TAG 018: If replacing the Image Module Kit with a new one, be sure to remove the ferrite
from the old Scanner Video Cable, on top of the Card Cage, and reinstall the ferrite onto the
new Scanner VIdeo Cable in the same location. This ferrite is required for reducing electromagnetic emissions (EME), to meet regulatory requirements.
With TAG 018: If replacing the Image Module Kit with a new one, remove the ferrite from the
old Scanner Video Cable, on top of the Card Cage, and reinstall the ferrite onto the new Scanner VIdeo Cable in the same location.
V0.042
May 2003
4-473
REP 14-1
Remove the
Cable Cap
Remove the
retainer clips (5).
Figure 1 Retainer Clips and Cable Cap
REP 14-1
May 2003
4-474
V0.042
CAUTION
Make certain, when connecting the Video Cable connector at the Image Module, that it is not
caught under the lip of the module casting. If it is, it then flexes the PWB inside the module,
and indirectly flexes the Full Width Array underneath. This results in image distortion similar to
a lens streak (possibly white lines).
Loosen the rear T20 screws (2).
6.
Perform the Image Module Set-Up (ADJ 14-1).
7.
Move the Image Module to the left wall of the Scanner cavity and make sure that the
rounded bend in the cable just contacts the left wall. If the bend does not contact the wall,
or if there is excessive contact causing a bend in the cable between the Image Module
and the 180 degree light crease, readjust the 180 degree light crease so that the proper
conditions (bend below connector just contacting the left wall and no bends in the cable
between the Image Module and the 180 degree light crease) are met.
8.
Move the Image Module to the center position and check the 90 degree fold. If necessary,
readjust the position of the fold so that the cable run to the rear of the machine is centered
in the cutout.
9.
Once the conditions established in the above two steps are both met, flatten the 180 and
90 degree folds in their final position and install the five cable retainer clips.
10. Reinstall the Illumination Lamp Module (REP 14-2)

11. Check for contamination on the underside of the document glass including the Calibration
strip area. Clean if necessary following Scanner Cleaning Procedure (REP 14-3).
12. Reinstall the following components:
b.
c.
13. Reconnect the Video Cable to the Main Control PWB.
Loosen the
front T20
screws (2).
14. Reinstall the Cable Cover at the Main Control PWB, making sure that the cable is under
the wire mesh seal.
15. Route the Video Cable through the IOT following the route of the Video Cable that was
removed.
Figure 2 Screws
16. Reinstall the IOT rear covers.
Replacement
1.
a.
Using the old video cable as a guide for the location of folds and bends, lay the new cable
in place with the folds and bends lightly creased in the approximate location of the old
cable.
2.
Rotate the Scan Carriage capstan so that the Drive Cable tension springs are approximately 6 inches from the left end of the Scanner.
3.
Position the new Image Module so that the Drive Cable Tension springs are centered
between the Drive Cable clamps (Figure 3).
4.
Position the cables under the cable clamps (4) making sure that the cable at the left rear
clamp is positioned between the posts (Figure 3).
5.
Plug the Video Cable into the Image Module. Install the connector cover and secure with
the screw.
17. If replacing the Image Module with a new one, enter [IIT tab , Scanner Calibration] and
invoke a [Full] calibration.
18. If replacing the Image Module with a new one, perform the following:
a.
IIT Registration and Magnification setup (ADJ 14-2).
b.
NOTE: Ensure that the connector cover is installed in the correct orientation, otherwise it
could be installed upside-down.
V0.042
May 2003
4-475
REP 14-1
REP 14-2 Illumination Lamp Module

spring
post

Removal
WARNING
cable
post
1.
2.
3.
4.
5.
a.
b.
c.
Disconnect the lamp connector from the Lamp Power Supply.

a.
Remove the cover from the Lamp Power Supply.
b.
Remove the ribbon cable retainer clip.
c.
Lift the tabs on both ends of the connector to the Lamp Power Supply, and disconnect the connector.
Remove the Illumination Lamp Module from the Image Module (Figure 1).
REP 14-1, REP 14-2
May 2003
4-476
V0.042
c.
7.
1
Remove the T20
screws (2).
If replacing the Illumination Lamp Module with a new one, perform the following:
a.
Enter [IIT tab , Scanner Calibration] and run a [Full] calibration.
b.
Enter [IIT tab , Lamp Life Reset].
c.
Make several test copies. If significant background appears on the copies, burn in
the lamp by switching it on for 15 minutes in [Copier Sys tab , Component Control].
NOTE: Until the new lamp is burned-in, some background may appear on copies
for a short period after the new lamp is installed. A small amount of background will
probably disappear on its own, by the time the Scanner completes it first full calibration.
2
Remove the Illumination Lamp
Module from the
Image Module.
d.
Figure 1 Removal
Replacement
CAUTION
Do not fold or crease the ribbon cable of the Illumination Lamp Module. Although the old cable
may be creased, a new cable should not be.
1.
Using the screws (2) removed, install the Illumination Lamp Module. Make sure the Illumination Lamp Module is biased to the left against the screws before tightening them.
2.
Reconnect the Illumination Lamp Module cable to the Lamp Power Supply, making sure
that the cable is oriented properly.
3.
Reinstall the cable cap.
4.
Reinstall the cover on the Lamp Power Supply.
5.
Check for contamination on the underside of the document glass including the calibration
strip area. Clean the underside of the document glass if necessary, following Scanner
Cleaning Procedure (REP 14-3).
6.
Reinstall the following components:

a.
b.
V0.042
May 2003
4-477
REP 14-2
REP 14-3 Scanner Cleaning Procedure
REP 14-4 Document Glass Frame

Components to Inspect/Clean

Purpose
This procedure is to be used only when replacing the Document Glass due to breakage.
manual document glass (both sides)
CVT document glass (both sides)
calibration strip area on underside of document glass
reflector
lens
lamp aperture
1.
Document Glass Glide Buttons
2.
AGC tab
3.
Removal
WARNING
Cleaning Materials
Platen Glass, Lens and Mirror Cleaner 43P81
Clean
WARNING
a.
Remove the T20 screws (2) securing the rear of the Document Glass Frame (Figure
1).
b.
Lift the Document Glass Frame at the rear corners, using the finger notches (2) provided.
c.
Lift the Document Glass Frame, disengaging the front tabs (2) from the notches, and
remove the Document Glass Frame.
1.
2.
3.

a.
b.
c.
4.
Inspect the dust filter. If it is dirty, replace the NOHAD Filter Kit PL 9.1 Item 1.
5.
Moisten a clean towel with Platen Glass, Lens and Mirror Cleaner.
6.
Wipe the lens.
7.
Wipe the underside of the AGC tab.
8.
Wipe the reflector.
9.
Wipe the lamp aperture.
10. Wipe the tops of the white Document Glass Glide Buttons (3).
11. Turn the Document Glass Frame upside down.
12. With a clean area of towel moistened with Platen Glass, Lens and Mirror Cleaner, wipe
the underside (now showing) of the CVT document glass and the manual document
glass. Be sure to clean the glass area over the calibration strip.
13. Reinstall the following components:
a.
b.
c.
14. With a clean area of towel moistened with Platen Glass, Lens and Mirror Cleaner, wipe
the top side of the CVT document glass and the manual document glass.
15. Lower the Document Feeder.
REP 14-3, REP 14-4
May 2003
4-478
V0.042
CAUTION
If the Scanner Main Cover is in place when installing the Document Glass Frame, be careful to
hook the tabs under the Scanner Top Frame, not under just the cover. Otherwise, the Document Glass Frame will be too high at that corner, resulting in the scan carriage squeaking
against the Scanner Top Frame.
Remove the T20

screws (2).
4.
Start the screws by hand. If the holes do not align easily, do not attempt to start the
screws on an angle. Instead you can bias the Scanner Main Cover and Document Glass
Frame to align the holes as follows: Insert the tip of a flat blade screwdriver in the slot
between the Scanner Main Cover and Document Glass Frame at either the front or the
rear of the Document Glass Frame as appropriate, and gently turn the screwdriver until
the holes align, then carefully start the screws by hand.
5.
Once both screws are started threading by hand, then tighten them securely with a T20
Torx driver.
NOTE: With some new Document Glass Frames, you may hear a "crunch" or apparent
cracking sound when tightening the screws. This is not cause for alarm, but if this occurs
perform the following: Remove the Document Glass Frame as before and carefully
remove any small pieces of glass which may have chipped off of the corners (outside of
the scanning area), then reinstall the Document Glass Frame as before.
6.
If replacing the Document Glass Frame with a new one, perform the IIT Registration and
Magnification setup (ADJ 14-2).
May 2003
4-479
Figure 1 Screws
Replacement
CAUTION
Perform the installation as follows to ensure proper alignment of the Document Glass and to
avoid damage.
1.
Clean the Document Glass as necessary, according to the Scanner Cleaning Procedure
(REP 14-3).
2.
Hold the Document Glass Frame by the edges to keep the glass clean.
3.
Position the Document Glass Frame on the scanner carefully, starting with the front locating tabs and then lowering the rear into position.
V0.042
REP 14-4
REP 14-5 Scanner Top Frame
REP 14-6 Scanner Main Cover

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
3.
4.
Remove the Scanner Main Cover (REP 14-6).
4.
5.
Remove the Scanner Top Frame with Document Glass Frame attached
If a metal plate is present under the UI, covering the two 1/4-turn fasteners for the Scanner Main Cover, remove the metal plate (one T20 screw).
WARNING
Take care not to cut yourself on the edges of the Scanner Top Frame. These edges
can be sharp -- especially the inside edges.
a.
b.
Lift the Scanner Top Frame off of the scanner and remove it.
NOTE: This plate is installed in some machines to reduce electromagnetic emissions

(EME), to meet regulatory requirements.
5.
Replacement
1.
Orient the Scanner Top Frame with the caution labels facing forward and the locating
holes (2) at the rear, and position the holes over the locating pins on the scanner.
2.
Ensure that the white Document Glass Glide Buttons (3) on the scan carriage are not
caught under the Scanner Top Frame.
3.
Reinstall the T20 screws (4).
4.
Reinstall the remaining components in the reverse order of Removal.
Remove the Scanner Main Cover.

a.
Remove the snap-on ferrite from the user interface harness and feed the harness
down through the hole in the Scanner Main Cover.
b.
Release the two 1/4-turn slotted fasteners, lift the Scanner Main Cover at the front,
and slide it forward to release it at the rear.
Replacement
CAUTION
Be sure to pull the UI harness all the way through the hole in the Scanner Main Cover before
fastening the Scanner Main Cover 1/4-turn fasteners. Otherwise, the wires may be pinched
under the cover, causing machine malfunctions.
Remember to reinstall the ferrite on the user interface harness before installing the User Interface Assembly.
REP 14-5, REP 14-6
May 2003
4-480
V0.042
REP 14-7 Document Glass Pad
j.
Select [Apply] and [OK].

Replacement
k.
Switch OFF the machine power, wait approximately 20 seconds, and switch ON the
machine power.
l.
Enter [System, Imaging, and IOT Configuration] again.
1.
m.
Set both Install Phases to [Install Complete].
n.
Select [Apply] and [OK].
o.
Switch OFF the machine power, wait approximately 20 seconds, and switch ON the
machine power.
2.
Copy a blank sheet of paper from the Document Glass at 100% magnification with Auto
Paper not selected, and ensure that no black borders appear on the copy (perform ADJ
14-2 as required).
3.
If replacing an existing pad, peel off the old pad and remove any residual foam by hand.
4.
If installing the pad as part of a Document Glass Cover replacement, first install the Document Glass Cover and raise the cover.
5.
Peel the two protective strips off of the adhesive on the back of the new pad provided in
this kit. These are the two long white strips along the long edges of the pad only.
CAUTION
Take care not to adhere the pad to the cover prematurely or allow the adhesive to contact the
glass or other surfaces. The adhesive is exposed during the next few steps while the pad is
being positioned.
6.
Place the new pad on the Document Glass, with the adhesive side up and the cutout area
of the foam toward the right (nearest the Document Feeder.
7.
Ensure that the pad is registered on the glass, offset approximately 1mm from the left and
rear registration edges.
NOTE: Do not lower the cover yet.
8.
9.
Ensure the correct positioning of the pad:

a.
Make a copy of the pad, at 100% magnification with Auto Paper not selected.
b.
Check the copy for any black borders. If any black borders appear on the copy, move
the pad slightly to just eliminate any black borders (not all the way against the registration edges).
c.
Recheck/readjust as necessary.
Without moving the pad, carefully lower the Document Glass Cover onto the pad without
bending the cover, then press down evenly to adhere the pad to the cover.
10. If replacing a white pad with a gray pad or vice versa, program the machine to recognize
the change, as follows:
NOTE: If switching to a grey pad, this will allow automatic document size sensing with
theDocument Glass Cover down. If switching to a white pad, this will cause the machine
to prompt the customer to raise the Document Glass Cover as required for automatic document size sensing.
a.
Enter the Tools pathway on the machine UI.
b.
Select [More].
c.
Select [Configuration and Setup].
d.
[Close] the warning window.
e.
Select [Document Scanner Cover Color].
f.
Select [White] or [Grey], as appropriate.
g.
Select [Save] and [Exit Tools].
h.
Enter [System, Imaging, and IOT Configuration].
i.
Set both Install Phases to [Manufacturing].
V0.042
May 2003
4-481
REP 14-7
REP 14-8 Illumination Lamp Power Supply
REP 14-9 Scan Carriage Motor

Removal

Removal
WARNING
WARNING
It is extremely important to ensure that all power is removed from the machine before
servicing the Illumination Lamp Power Supply. Otherwise, severe machine damage and
possible personal injury could occur due to electrical arcing.
1.
1.
2.
Raise the Document Feeder, leaving the Document Glass Cover down.
2.
3.
3.
a.
460/470 only: DADF Main Cover (four 1/4-turn slotted fasteners).
a.
b.
Document Glass Cover (lift off at the rear)
b.
c.
c.
d.
4.
Remove the cover from the Lamp Power Supply.
4.
Remove the Scan Carriage Motor (Figure 1).
5.
Remove the lamp ribbon cable retainer clip next to the Lamp Power Supply.
5.
Save the spring to reuse with the new motor.
6.
Lift the tabs on both ends of the lamp connector to the Lamp Power Supply, and disconnect the connector.
7.
Disconnect the remaining connectors from the Lamp Power Supply.
8.
Remove the Illumination Lamp Power Supply:

a.
Lift the right side of the power supply PWB, and slide the PWB to the right.
b.
Lift the Lamp Power Supply out of the Scanner.
3
Remove the T20 screws (3)
and remove the motor.
1
Disconnect the
connector.
2
Lift the end of
the spring off of
the post.
Figure 1 Removal
REP 14-8, REP 14-9
May 2003
4-482
V0.042
Replacement
CAUTION
When installing the motor, do not tension the belt by grasping the motor cylinder -- grasp the
motor frame (bracket) instead. The motor shaft can bend, resulting a scanner malfunction.
1.
Position the Scan Carriage Motor and the ground clip in the Scanner (Figure 2).
2.
Tension the belt and connect the motor connector (Figure 3).
3.
If replacing the Scan Carriage Motor with a new one, perform the IIT Registration and
Magnification Setup (ADJ 14-2).
2
Position the
ground clip on
the motor as
shown.
3
Install the T20
screws (3), but
leave them 1/4
turn loose.
1
Position the
motor with the
shaft pulley
inside the belt
4
Hook the spring onto the post.
V0.042
May 2003
4-483
REP 14-9
2
Tighten the T20
screws (3).
3
Connect the connector.
1
Rotate the Capstan 3-4 turns to
allow the belt to "find home."
REP 14-9
May 2003
4-484
V0.042
REP 16-1 ESS Disk Drive

Parts List on PL 1.3A for 240/255/265, or PL 1.3C for 460/470
Removal
NOTE: Before beginning if replacing the ESS Disk Drive with a new one, obtain a configuration
report or other record of the Network Connectivity settings, or ask the System Administrator to
be available at the end of this procedure. When the drive is replaced, all customer network settings will be lost, and the ESS will be configured as if it was being booted for the first time in
manufacturing. All of the connectivity settings will be defaulted, all protocols will be disabled,
and all SA settings stored on the ESS will be defaulted (such as the Power-On config report
enable switch and the banner sheet enable switch). These settings will all need to be reentered
after the drive is replaced.
plastic screws (4
places)
WARNING
1.
2.
If the machine is equipped with the Removable Disk Drive Option (external cabinet
holding the disk drives in removable carriers):
a.
Remove the #1 carrier.
b.
Remove the Disk Drive from the carrier:

i.
Remove the top cover from the carrier.
ii.
Remove the four screws from the bottom of the carrier.
iii.
Lift the Disk Drive out of the carrier, and disconnect the power and data harnesses from the drive. Also remove any adapter used to connect the data cable
-- it may need to be reused.
iv.
Remove the four standoffs from the bottom of the drive -- they must be reused.
v.
This completes the removal. Go to Replacement.
3.
4.
240/255/265:
1.
Remove the front (non-Main-Control-PWB side) Card Cage cover (loosen or remove two
T20 screws on top).
2.
Swing out the Disk Support Bracket (one T20 latch).

CAUTION
Save and reuse the 4 plastic screws and 4 plastic spacers for mounting the ESS Disk.
3.
Dismount the ESS Disk (4 plastic screws), and save the plastic mounting hardware (Figure 1).
4.
Disconnect the power and data cables from the ESS Disk (Figure 2).
460/470:
1.
2.

a.
b.
Figure 1 Plastic Screws
Remove the ESS Disk Drive (Figure 5).
V0.042
May 2003
4-485
REP 16-1
ESS Disk
Data Cable
ESS Disk
Power Cable
Figure 2 Connectors
REP 16-1
May 2003
4-486
V0.042
2
1
4
Disconnect the fan
connector.
3
6
5
Remove the T20

hex-head screw.

V0.042
May 2003
4-487
REP 16-1
1
Disconnect the
power and data
cables from the ESS
Disk Drive (outer
drive).

2
Press and hold the
top clip upward and
the bottom clip
downward, and slide
the Disk Drive out.
Figure 5 ESS Disk Drive Removal
Replacement
REP 16-1
1.
holding the disk drives in removable carriers): Replace the disk drive in the reverse of
removal. This completes the replacement.
2.
460/470: If replacing the drive with a new one, remove the upper and lower mounting
plates from the old drive (two Phillips-head screws each), and install them onto the new
drive.
May 2003
4-488
V0.042
CAUTION
(240/255/265): Take care not to overtorque or cross-thread the plastic mounting screws -- they
can break if not used carefully.
3.
Install the ESS Disk Drive in the reverse order of removal (240/255/265: Reuse the plastic
mounting hardware).
4.
If replacing the ESS Disk Drive with a new one, you must load the level of ESS Software
to match the software level currently in the machine, using the Alternate Boot method in
the Software Upgrade Kit instructions.
5.
If replacing the ESS Disk Drive with a new one, restore the customers Network Connectivity settings, using the Machine Administrator Tools pathway on the UI. Obtain the correct settings from a previous Configuration Report or from the System Administrator, and
consult the System Administrator documentation as required to reenter the settings correctly. Lastly, print a final Configuration Report (in Tools: [System Settings]/[Configuration
Report]/[Print Configuration Report now]) and leave this sheet with the machine or with
the System Administrator.
V0.042
May 2003
4-489
REP 16-1
REP 16-2 ESS PWB

Parts List on PL 1.3A, or PL 1.3C for 460/470
Removal
screws (3)
CAUTION
Changing the ESS PWB results in a new MAC address for the built-in Ethernet interface.
Inform the SA that the new MAC address can be obtained from the Configuration Report, if
required.
WARNING
CAUTION
1.
2.
3.
240/255/265:
1.
T20 screws on top).
2.
3.
Remove the following optional items, if present: Image Processing Accelerator (IPA)
PWB, Token Ring PWB, or 100 Mb Ethernet PWB (REP 16-4 for any or all of these).
4.
5.
If replacing the ESS PWB with a new one, remove any of the following items, if present:
a.
All ESS DRAM SIMM's (REP 16-3).
b.
PCI-BUSS Adapter PWB (optional) (REP 16-5).
ESS Disk Drive

data connector
ESS Disk Drive

power connector
Prepare to remove the ESS PWB (Figure 1):

a.
Disconnect the following connectors from the ESS PWB:

ESS Disk Drive data connector
ESS Disk Drive power connector
ESS PWB power harness connector
b.
6.
screw
Remove the ESS PWB (Figure 2).
460/470
1.
2.

a.
b.
ESS PWB power

harness connector
Remove the following optional items, if present:

a.
Image Processing Accelerator (IPA) PWB (REP 16-8).
b.
Token Ring PWB (REP 16-9).
3.
If replacing the ESS PWB with a new one, remove the ESS SDRAM DIMM(s) from the
ESS PWB (REP 16-7).
4.
Remove the ESS PWB (Figure 5).
REP 16-2
May 2003
4-490
screws (3)
Figure 1 Connectors and Screws -- 240/255/265
V0.042
Release these
two white
standoffs and
remove the
ESS PWB.
Figure 2 PWB Removal -- 240/255/265
V0.042
May 2003
4-491
REP 16-2
2
1
4
Disconnect the fan
connector.
6
5
Remove the T20

hex-head screw.

REP 16-2
May 2003
4-492
V0.042

V0.042
May 2003
4-493
REP 16-2
2
Remove the
T10 hex-head
screws (3).
1
Remove the
filler bracket
(if present)
(one T20
hex-head
screw).
Riser PWB
3
Remove the T10
hex-head screw.
4
Lift the ESS PWB,
removing its bottom
edge connector from the
Riser PWB, and remove
the ESS PWB
Figure 5 PWB Removal -- 460/470
Replacement
3.
Finish installing the ESS PWB:

a.
Seat the PWB onto the two standoffs.
CAUTION
b.
Tighten the T20 screws (7).
Take care to align the ESS PWB as instructed below, before attempting to seat the back connectors to the Main Control PWB.
c.
Reconnect the following connectors to the ESS PWB:
240/255/265
1.
a.
b.
2.
ESS PWB power harness connector
Align the ESS PWB carefully (Figure 6):
ESS Disk Drive power connector
Position the ESS PWB part-way onto the two white standoffs (do not seat the PWB
all the way onto the standoffs yet).
ESS Disk Drive data connector

d.
Install the seven screws loosely.
Seat the ESS PWB back connectors to the Main Control PWB carefully (Figure 7).
REP 16-2
4.
May 2003
4-494
Double-check that the ESS-to-Main-Control-PWB back connectors are seated

securely.

V0.042
460/470
Reinstall all components in the reverse of Removal.
standoff
screws (4)
Press here, and

in the corresponding location on the Main
Control PWB at
the same time, to
seat the back
connectors
securely.
standoff
screws (3)
Figure 7 Installation (continued) -- 240/255/265

V0.042
May 2003
4-495
REP 16-2
REP 16-3 ESS DRAM SIMM's (240/255/265 Only)

Removal
NOTE: If the customer wishes to upgrade their ESS RAM, they must order the upgrade kit
through Sales and that kit includes CSE instructions for performing the upgrade. However,
instructions are included here to enable increasing ESS RAM as a troubleshooting tool.
WARNING
CAUTION
1.
2.
3.
4.
T20 screws on top).
5.
6.
Remove the ESS DRAM SIMM's, starting with the lowest SIMM:
NOTE: If increasing ESS RAM and not replacing a defective ESS DRAM SIMM, skip this
step, and leave the existing SIMMs in place.
a.
Unlatch the SIMM (Figure 1).
b.
Tilt the SIMM down and remove it (Figure 2).
c.
Repeat for the remaining SIMM's, working your way up.
REP 16-3
May 2003
4-496
V0.042
Press the two

spring latches outward to release the
SIMM.
Figure 1 Removal
V0.042
May 2003
4-497
REP 16-3
Tilt the SIMM down

and remove it.
REP 16-3
May 2003
4-498
V0.042
Replacement
1.
Install the ESS DRAM SIMM's, starting with the topmost SIMM:
NOTE: If increasing ESS RAM, install the additional SIMMs (either two 16MB or two
32MB SIMMs) in the bottom two slots.
a.
Insert the SIMM (Figure 3).
b.
Tilt the SIMM up into the latched position (Figure 4).
c.
Repeat for the remaining SIMM's, working your way down.
2.
3.
If increasing ESS RAM: When the machine power is switched on, the new configuration
will be detected. To check that the new configuration has been detected, print out a new
configuration report. In the Device Profile section of the report, the ESS RAM Size should
now reflect the total amount of ESS RAM (64MB or 96 MB).
Orient the SIMM with the

notched corner to the left.
Insert the SIMM at the

angle shown, all the
way into the slot.
NOTE
If increasing ESS RAM,
install the additional
SIMMs in the bottom 2
slots.
V0.042
May 2003
4-499
REP 16-3
Tilt the SIMM up

to the position
shown, ensuring
that both spring
latches engage.
REP 16-3
May 2003
4-500
V0.042
REP 16-4 Token Ring PWB or Image Processing

Accelerator (IPA) PWB or 100 Mb Ethernet PWB (240/255/
265 Only)
Removal
WARNING
CAUTION
1.
2.
Disconnect the Token Ring network cable (if present) from the IOT.
3.
4.
5.
T20 screws on top).
6.
7.
Remove the Token Ring PWB (Figure 1) or IPA PWB (Figure 2) or 100 Mb Ethernet PWB
(Figure 3).
V0.042
May 2003
4-501
REP 16-4
1
3
Remove the
Token Ring PWB
from the Card
Cage
2
Pull out on the left
end of the Token
Ring to disconnect it
from the PCI Bus
Adapter PWB.
Figure 1 Token Ring PWB Removal
REP 16-4
May 2003
4-502
V0.042
1
3
Remove the IPA
PWB from the
Card Cage
2
end of the IPA PWB
to disconnect it from
the PCI Bus Adapter
PWB.
Figure 2 IPA PWB Removal
V0.042
May 2003
4-503
REP 16-4
1
Remove the
screws (2).
3
Remove the 100 Mb
Ethernet PWB from
the Card Cage.
2
end of the 100 Mb
Ethernet PWB to
disconnect it from
the PCI Bus
Adapter PWB.
Figure 3 100Mb Ethernet PWB Removal
REP 16-4
May 2003
4-504
V0.042
Replacement
CAUTION
Ensure that the rubber gasket around the end of the Token Ring or IPA PWB or 100 Mb Ethernet PWB stays in position when inserting the PWB into the cutout.
1.
Install the Token Ring PWB, connecting J1 and J2 on the Token Ring PWB with J496A
and 496B on the PCI Bus Adapter PWB (Figure 4), or install the IPA PWB, connecting J1
and J2 on the IPA PWB with J495A and 495B on the PCI Bus Adapter PWB (Figure 5), or
install the 100 Mb Ethernet PWB, connecting J1 and J2 on the 100 Mb Ethernet PWB with
J497A and 497B on the PCI Bus Adapter PWB Figure 6.
NOTE: In order for the PWB to fit onto the connectors, the PWB must be worked far
enough into the knockout hole to align with the connectors properly.
2.
Reinstall the screws (2).
3.
V0.042
May 2003
4-505
REP 16-4
1
Insert the
right end of
the PWB
into the
middle cutout.
2
Align the hole
with the
locating pin.
3
Press on the
left side the
Token Ring
PWB to seat
the connectors.
Figure 4 Token Ring PWB Installation
REP 16-4
May 2003
4-506
V0.042
1
Insert the
right end of
the PWB
into the
lower cutout.
2
Align the hole
with the
locating pin.
3
Press on the
left side the
Token Ring
PWB to seat
the connectors.
Figure 5 IPA PWB Installation
V0.042
May 2003
4-507
REP 16-4
1
Insert the
right end of
the PWB
into the
upper cutout.
2
Align the hole
with the
locating pin.
3
Press on the
left side the 100
Mb Ethernet
PWB to seat
the connectors.
Figure 6 100Mb Ethernet PWB Installation
REP 16-4
May 2003
4-508
V0.042
REP 16-5 PCI Bus Adapter PWB (240/255/265 Only)

Removal
WARNING
CAUTION
1.
2.
3.
4.
T20 screws on top).
5.
Swing out the Disk Support Bracket (one 1/4-turn T20 fastener).
6.
Remove the Token Ring PWB and/or Image Processing Accelerator (IPA) PWB (REP 164).
7.
Remove the PCI Bus Adapter PWB, while noting the correct orientation (Figure 1).
V0.042
May 2003
4-509
REP 16-5
1
Remove the #1
phillips-head
screws (8).
2
Remove the
adapter PWB.
Figure 1 Removal
REP 16-5
May 2003
4-510
V0.042
Replacement
REP 16-6 Bykal Remote PWB (DT 65 / DP 65 Only)
1.
Orient the adapter PWB correctly, as observed when removing the PWB.
2.
Carefully align the two adapter PWB connectors with the corresponding connectors on
the ESS PWB, and seat the connectors securely.

Removal
3.
Reinstall the #1 phillips-head screws (8).
4.
WARNING
CAUTION
V0.042
1.
2.
Disconnect the server interface cable from the Bykal Remote PWB at the IOT Card Cage.
3.
4.
5.
T20 screws on top).
6.
7.
Remove the connector nuts from the Bykal Remote PWB connector (P12) on the outside
of the Card Cage (Figure 1).
8.
Remove the Bykal Remote PWB, while noting the correct orientation (Figure 2):
May 2003
4-511
a.
Disconnect connector P3 from J10 on the PWB.
b.
Remove the T20 screws (4) securing the Bykal Remote PWB.
c.
Carefully pull the PWB outward, disconnecting it from the Main Control PWB, then
move it to the left to remove it from the Card Cage cutout.
REP 16-5, REP 16-6
T20
screws
(4)
connector nuts
connector
nuts
removed
P3/J10
Figure 1 Connector Nuts
Figure 2 PWB Removal
Replacement
1.
Note the location of the two connectors on the back of the Bykal Remote PWB and the
two mating connectors on the back of the Main Control PWB (Figure 3).
CAUTION
Do not attempt to seat the Bykal Remote PWB connection to the Main Control PWB until
instructed to do so, after ensuring correct alignment. Otherwise, dame to both PWBs can
result.
2.
REP 16-6
Install the Bykal Remote PWB:

a.
Insert the edge connector into the Card Cage cutout (P12, as marked on the outside
of the Card Cage), then pivot the PWB in, but do not attempt to seat the connectors
to the Main Control PWB yet.
b.
Align the screws holes, and reinstall the T20 screws (4), loosely.
c.
Now seat the Bykal Remote PWB connection securely to the Main Control PWB.
d.
Tighten the screws, and double-check that the PWBs connectors are seated
securely together.
e.
Reconnect connector P3 to J10 on the Bykal Remote PWB.
3.
Reinstall the connector nuts (2) onto the Bykal Remote PWB connector (P12) on the outside of the Card Cage.
4.
May 2003
4-512
V0.042
REP 16-7 ESS SDRAM DIMM(s) (460/470 Only)
back of Main Control PWB

Removal
back of Bykal
Remote PWB
WARNING
CAUTION
1.
2.
3.
4.
5.
a.
b.
Remove the ESS SDRAM DIMM(s)(Figure 3).
V0.042
May 2003
4-513
REP 16-6, REP 16-7
2
1
4
Disconnect the fan
connector.
6
5
Remove the T20

hex-head screw.

REP 16-7
May 2003
4-514
V0.042

Press the clips outward (2

places), and remove the
DIMM.
Figure 3 DIMM Removal
Replacement
V0.042
1.
Install the ESS SDRAM DIMM(s)(Figure 4).
2.
May 2003
4-515
REP 16-7
REP 16-8 Image Processing Accelerator (IPA) PWB, 460/

470
Removal
WARNING
CAUTION
1.
2.
3.
4.
5.
a.
b.
Remove the IPA PWB (Figure 3).
Ensure the clips are pivoted outward

(2 places), align the DIMM notches
with the slot tabs, and insert the
DIMM straight into the slot until both
clips are fully engaged.
Figure 4 DIMM Installation
REP 16-7, REP 16-8
May 2003
4-516
V0.042
2
1
4
Disconnect the fan
connector.
3
6
5
Remove the T20

hex-head screw.

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May 2003
4-517
REP 16-8

1
Remove the T20
screw.
Riser PWB
2
Lift the IPA PWB, removing its
bottom edge connector from
the Riser PWB, and remove
the IPA PWB.
REP 16-8
May 2003
4-518
V0.042
REP 16-9 Token Ring PWB, 460/470
2.

Removal
3.
4.
WARNING
CAUTION
a.
b.
5.
Remove the IPA PWB, if present (REP 16-8).
6.
Remove the Token Ring PWB (Figure 3).
1.
2
1
4
Disconnect the fan
connector.
3
6
5
Remove the T20

hex-head screw.

V0.042
May 2003
4-519
REP 16-9

1
Remove the T20
screw.
2
Lift the Token Ring PWB,
removing its bottom edge connector from the Riser PWB,
and remove the Token RIng
PWB.
REP 16-9
Riser PWB
May 2003
4-520
V0.042
REP 19-1 Image Disk Drive

Parts List on PL 1.3A for 240/255/265, or PL 1.3C for 460/470
Removal
WARNING
plastic screws (4
places)
1.
2.
holding the disk drives in removable carriers):
a.
Remove the #2 carrier.
b.
Remove the Disk Drive from the carrier:

i.
Remove the top cover from the carrier.
ii.
Remove the four screws from the bottom of the carrier.
iii.
Lift the Disk Drive out of the carrier, and disconnect the power and data harnesses from the drive. Also remove any adapter used to connect the data cable
-- it may need to be reused.
iv.
Remove the four standoffs from the bottom of the drive -- they must be reused.
v.
This completes the removal. Go to Replacement.
3.
4.
240/255/265:
1.
T20 screws on top).
2.

CAUTION
Save and reuse the 4 plastic screws and 4 plastic spacers for mounting the Image Disk Drive.
3.
Dismount the Image Disk Drive (4 plastic screws), and save the plastic mounting hardware (Figure 1).
4.
Disconnect the power and data cables from the Image Disk Drive (Figure 2).
460/470:
1.
2.

a.
b.
Remove the Image Disk Drive (Figure 5).
Figure 1 Plastic Screws
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May 2003
4-521
REP 19-1
ESS Disk
Data Cable
ESS Disk
Power Cable
Figure 2 Connectors
REP 19-1
May 2003
4-522
V0.042
2
1
4
Disconnect the fan
connector.
3
6
5
Remove the T20

hex-head screw.

V0.042
May 2003
4-523
REP 19-1
2
Disconnect the
power and data
cables from the
Image Disk Drive
(inner drive).

3
Press and hold the
top clip upward and
the bottom clip
downward, and slide
the Disk Drive out.
1
ST: Disconnect the power and
data cables from the ESS Disk
Drive (outer drive).
Figure 5 Image Disk Drive Removal
Replacement
REP 19-1
1.
holding the disk drives in removable carriers): Replace the disk drive in the reverse of
removal. This completes the replacement.
2.
460/470: If replacing the drive with a new one, remove the upper and lower mounting
plates from the old drive (two Phillips-head screws each), and install them onto the new
drive.
May 2003
4-524
V0.042
CAUTION
(240/255/265): Take care not to overtorque or cross-thread the plastic mounting screws -- they
can break if not used carefully.
3.
Install the Image Disk Drive in the reverse order of removal (240/255/265: Reuse the plastic mounting hardware).
V0.042
May 2003
4-525
REP 19-1
REP 19-1
May 2003
4-526
V0.042
ADJ 05-1 DADF Skew

PURPOSE
4.
Select [OK] to dismiss the message box on the PWS.
5.
Recheck and readjust as necessary.
The purpose of this procedure is to check DADF skew semiautomatically using the IIT Skew
Check diagnostic routine, and as necessary to adjust it mechanically using the DADF skew
adjustment screw.
NOTE: Do not perform this procedure until after ensuring the skew on copies made from the
manual document glass is within specification.
DADF skew adjustment screw

(T20 Torx) (With TAG 115, this
screw is accessible through a
hole in the Rear Scanner Cover.
Perform this procedure when directed by a RAP or REP or after replacing any of the following
components:
DADF Registration Deskew Assembly
DADF Assembly
Scanner Assembly (RIS)
Preparation
1.
Enter [IIT tab , IIT Skew Check].
2.
Under [Select Type], select [DADF Document].
Check
1.
Load ten or more same-size blank sheets LEF in the Document Feeder.
2.
Select [Start], or select [Continue] if rechecking.
3.
Observe the skew check information on the PWS:

a.
If the Document Feeder skew is out of adjustment, a PWS message box will appear
indicating so, and indicating the number and direction of adjustment screw turns. If
so, perform the Adjustment.
b.
If the Results window indicates that the Document Feeder skew check passed, the
DADF skew is within specification.
4.
Select [Exit].
5.
If the Adjustment was performed, do the following:

a.
b.
Loosen the screw holding the Locator Pin, at the right front corner of the DADF (PL
2.1B Item 12).
c.
Align the Locator Pin to approximately center in the receiving hole in the Scanner
Top Frame (not just the Scanner Main Cover), and retighten the screw.
d.
Reinstall the DADF Main Cover.
e.
Reinstall the Scanner Rear Cover (three T20 screws).
f.
460/470 with TAG 115 only: Perform ADJ 05-3 DADF/Document Glass Cover
Latch.
Figure 1 Skew Adjustment Screw
Adjustment
1.
Raise the DADF.
2.
Without TAG 115: Remove the Scanner Rear Cover PL 3.1 (three T20 screws).
3.
19.04.xxx and higher software: Turn the DADF skew adjustment screw (Figure 1) in the
amount and direction indicated in the PWS message box during the check.
19.02.xxx and lower software: Turn the DADF skew adjustment screw (Figure 1) in half
the amount indicated in the PWS message box during the check, in the direction indicated
in the PWS message box during the check.
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May 2003
4-527
ADJ 05-1
ADJ 05-2 CVT Carriage Position Setup for Electronic Hole

Removal (With Tag #296, Tag #080, or Tag #285 Only)
g.
[Exit] NVM Tool, [Exit] Diagnostic Navigator, and end the session by selecting
another session in the Session Manager window. Answer [Yes] to the question: "Do
you wish to reset the machine?"
PURPOSE
7.
Go to Step 15.
The purpose of this procedure is to set up the CVT Carriage Position to ensure that the Electronic Hole Removal (EHR) feature functions as well as possible across the full range of common punched-hole patterns on originals. The EHR feature reduces the occurrence of the
punched holes on originals being reproduced as filled black circles on copies. Presence of the
EHR feature is identified by TAG 296 on machines with Atlanta Gold Main Control PWBs (with
TAG 015, without TAG 077), by TAG 080 on machines with Atlanta Platinum Main Control
PWBs (240/255/265 with TAG 077), and by TAG 285 on 460/470 machines.
8.
Decrease the CVT Carriage Location NVM value by 25 (Scan Service, Location 53):
Preparation:
Obtain EHR Test Pattern 82E12900 (punched test pattern, included in the EHR Kit)
Perform ADJ 05-1 DADF Skew.
a.
b.
From the NVM Tool menu bar, select [Machine], then [Download]. Answer [Yes] to
the question: "Initiate NVM download?"
c.
After the NVM downloads, select Service: [Scan Service].
d.
Scroll (or Search) to Location 53 (Cvt Carr Location).
e.
Subtract 25 from the current value in Location 53.
f.
Double-click and change the [Current Value] of Location 53 to the new value, then
select [Write NVM].
g.
Adjustment
CAUTION
Be sure to perform this setup exactly as instructed, even if all holes on the test pattern already
are removed from the copy. This will fine-tune the CVT Carriage Position to ensure the best latitude of hole removal.
9.
Go to Step 11.
10. Decrease the CVT Carriage Location NVM value by 75 (Scan Service, Location 53):
a.
b.
1.
Select Normal copy mode.
2.
If using metric copy paper: Select the next paper size wider than A4 (e.g. B4 or A3). Continue to use this size copy paper for the remainder of this procedure.
c.
NOTE: A4 paper is narrower than the 8.5 x 11-in. (216 x 279 mm) test pattern, and may
give false indications of hole removal.
d.
e.
Subtract 75 from the current value in Location 53.
f.
select [Write NVM].
g.
3.
Using the punched test pattern, make a copy from the Document Feeder with the test pattern fed LEF.
4.
If all holes #1 through #5 on the test pattern do appear as complete, solid black circles on
the copy made in step 3, go to step 10.
If not all holes #1 through #5 on the test pattern appear as complete, solid black circles on
the copy made in step 3. (none or only some do), continue with step 5.
11. Using the punched test pattern, make a copy from the Document Feeder with the test pattern fed LEF.
If holes #2 and #4 on the test pattern do appear as complete, solid black circles on the
copy made in step 3, continue with step 6.
12. If holes #2 and #4 on the test pattern do appear as complete, solid black circles on the
If holes #2 and #4 on the test pattern do not appear as complete, solid black circles on the
copy made in step 3, go to step 8.
5.
6.
Increase the CVT Carriage Location NVM value by 25 (Scan Service, Location 53):
13. Increase the CVT Carriage Location NVM value by 40 (Scan Service, Location 53):
a.
a.
b.
b.
c.
c.
d.
d.
e.
Add 25 to the current value in Location 53.
e.
f.
select [Write NVM].
f.
select [Write NVM].
ADJ 05-2
May 2003
4-528
V0.042
g.
14. Go to Step 23.

a.
b.
c.
d.
e.
f.
select [Write NVM].
g.
d.
e.
f.
select [Write NVM].
g.
24. If 1 or more of the holes #1 through #5 on the test pattern appear as complete, solid black
circles on the copy made in step 23, repeat steps 23 and 24 once, to ensure that the problem is not a one-time occurrence before proceeding. If 1 or more complete holes still
appear on the copy, continue with step 25.
If none of the holes #1 through #5 on the test pattern appear as complete, solid black circles on the copy made in step 23, go to Required Final Steps.
25. If this is the first time through this CVT Carriage setup process without success, continue
with step 26.
If this is the second time through this CVT Carriage setup process without success, go to
IQ-1 to troubleshoot the problem. After resolving the problem, return to this procedure and
go back to step 1.
26. Enter 5067 for the CVT Carriage Location NVM value (Scan Service, Location 53):
a.
b.
c.
d.
e.
Double-click and change the [Current Value] of Location 53 to 5067, then select
[Write NVM].
f.
a.
b.
c.
Required Final Steps
d.
1.
Perform ADJ 14-2 IIT Registration and Magnification.
e.
2.
f.
select [Write NVM].
Be sure to save the NVM to the Machine Resident Diskette (MRD) before closing the call
(GP4).
g.
May 2003
4-529
27. Go back to step 1.
21. Go to Step 23.

a.
b.
c.
V0.042
ADJ 05-2
ADJ 05-3 DADF/Document Glass Cover Latch (460/470

with Tag 115 Only)
Purpose
The purpose of this adjustment is to ensure smooth, reliable operation of the DADF/Document
Glass Cover Latch.
Check
Test the latch by opening the latch (separating the Document Glass Cover from the DADF) and
closing it. If the latch does not operate satisfactorily, perform the Adjustment.
Adjustment
1.
Unlatch the latch and separate the Document Glass Cover from the DADF.
2.
Remove the front bottom cover from the Document Glass Cover, exposing the latch
mounting screws (Figure 1).
3.
If the latch is misaligned, loosen the two T20 latch mounting screws, move the latch as
appropriate, and retighten the screws (Figure 1).
4.
If the latch engages too loosely or with too much effort, loosen the two screws securing
the striker (on the DADF), move the striker up or down as appropriate, and retighten the
screws (Figure 2).
5.
Recheck and readjust as required.
6.
When the adjustment is complete, reinstall the front bottom cover onto the Document
Glass Cover (two T20 screws).
latch screws
cover screws
Figure 1 Latch Adjustment
ADJ 05-3
May 2003
4-530
V0.042
striker screws
striker
Figure 2 Striker Adjustment
V0.042
May 2003
4-531
ADJ 05-3
ADJ 05-3
May 2003
4-532
V0.042
ADJ 8-1 IOT Registration Setup Series

PURPOSE
The purpose of this series of adjustments is to use the IOT Registration Setup diagnostic routine to adjust the image-to-paper alignment (registration).
NOTE: This IOT Registration Setup Series for 240/255/265/460/470 is significantly different
from the IOT Registration Setup Series for 480/490. If you need to check/adjust registration on
a 480/490 machine, switch to the 480/490 EDOC.
The complete IOT registration setup series consists of five to nine individual check/adjustments, depending how many paper supplies are present. Unless instructed to perform specific
procedures in this series, perform the entire series in sequence as instructed below.
V0.042
May 2003
4-533
ADJ 8-1
NOTE: In addition to the adjustments accomplished in the IOT Registration Setup routine, this
series also directs you to specific NVM locations which can be adjusted using NVM Tool. This
option enables you to optimize individual paper trays' side 2 registration, on large paper and
small paper separately.
15mm horizontal line

at top edge
test pattern number (position

may vary left-to-right)
NOTE: When [Offset] is selected in this routine, the test pattern image is automatically offset
5mm toward the lead edge and 5mm toward the top edge of the paper, to eliminate the need to
use a scale to measure registration. Figure 1 shows a correctly-registered print with the [Offset]
selected. This offset is reversed when [Offset] is deselected, or is automatically reversed upon
exiting the routine. Figure 2 shows a correctly-registered print with the [Offset] deselected.
(thin line represents edge

of paper)
Figure 1 Test Pattern, Offset
ADJ 8-1
May 2003
4-534
V0.042

2.
ADJ 8-1B IOT Top Edge Registration (IB-OB), Side 1
3.
ADJ 8-1C IOT Top Edge Registration (IB-OB), Side 2, Small Paper
4.
ADJ 8-1D IOT Top Edge Registration (IB-OB), Side 2, Large Paper
5.
ADJ 8-1E IOT Lead Edge Registration for Small Heavy Weight Paper (19.02 and Higher
Software Only)
6.
ADJ 8-1F IOT Lead Edge Registration for Large Paper (19.02 and Higher Software Only)
7.
ADJ 8-1G IOT Lead Edge Registration for Large Heavy Weight Paper (19.02 and Higher
Software Only)
May 2003
4-535
(thin line represents

edge of paper)
top edge
5.0mm
lead edge
5.0mm
Figure 2 Test Pattern, Not Offset

Go to the first procedure listed below to begin the setup series, or go to the desired procedure:
1.
ADJ 8-1A IOT Lead Edge Registration (Process Direction)
V0.042
ADJ 8-1
ADJ 8-1A IOT Lead Edge Registration (Process Direction)

PURPOSE

The purpose of this procedure is to use the IOT Registration Setup diagnostic routine to check/
adjust the IOT registration in the process direction (left-to-right on a LEF portrait page), as
measured at the lead edge. Registration in the process direction need only be set using one
paper tray, because one NVM location determines this registration for all trays.
components:
Developer Drive Motor (M1)
ROS
long
vertical line
at lead
edge
Preparation
1.
Load 8.5 x 11 in. or A4 paper LEF in Tray 1.
2.
Enter [Paper tab , System Registration Setup].
3.
Select the [IOT System Registration] tab and wait for the routine to receive the initial test
data.
4.
Select [Offset]
5.
Select [Tray 1].

NOTE: If there is a problem with Tray 1 which may affect lead edge registration, select
another tray and use that other tray consistently instead of Tray 1 when checking lead
edge registration.
6.
Under [Setups], select [x-reg].
7.
Under [Size], select [8.5 x 11] or [A4], as appropriate.
8.
Under [Paper Weight], select [Normal].
Check
1.
Select [Start Job]. Five prints will be made.

NOTE: When removing the prints from the output tray, be sure to note which is the lead
edge. The test pattern number "17" appears sideways at the top corner near the trail (left)
edge.
2.
Remove the prints from the output tray and hold one face-up, with the lead edge to the
right and the top (OB) edge at the top.
3.
Observe the long vertical line closest to the lead edge. Lead edge registration is within
specification if this line is as close as possible to the lead edge (less than one line width
away), but still visible. If no long vertical line appears between the lead edge and the
nearest "ladder" of short horizontal lines, the vertical line is too far to the right, off the
paper. Figure 1 shows a correctly-registered print with the [Offset] selected.
4.
If lead edge registration is not within specification, perform the Adjustment.
5.
If lead edge registration is within specification, [Exit] the routine to make any NVM
changes effective.
6.
7.
If you are performing the entire IOT Registration Setup Series, go to the next check in the
series: ADJ 8-1B IOT Top Edge Registration (IB-OB), Side 1.
ADJ 8-1A
May 2003
4-536
V0.042
Adjustment
ADJ 8-1B IOT Top Edge Registration (IB-OB), Side 1
1.
PURPOSE
Select the left- or right-arrow once for each 0.2mm (40 ppm machine) or 0.30mm (65 ppm
machine) of desired adjustment: With the test print face-up with the lead edge to the right
and the top (OB) edge at the top,
the left-arrow moves the image to the left, whereas
the right-arrow moves the image to the right.
2.
adjust the IOT registration in the inboard-outboard (IB-OB) direction (top-to-bottom) on side 1
of the print, as measured at the top edge of a LEF portrait page. Side 1 is either a simplex print
or the front side of a duplex print. Registration in the IB-OB direction for side 1 must be set
separately for each paper tray, because a separate NVM location determines this registration
for each tray. Depending on the number of trays present or suspect, this will require from one
to six separate check/adjustments for a complete setup.
components:
Vertical Transport: Check/adjust for trays 1 through 4.
Paper Tray Assembly: Check/adjust only for the tray replaced.
Bypass Tray or HCF/Bypass Tray feed components: Check/adjust only for Tray 5 or Tray
6, as appropriate.
Preparation
NOTE: This procedure assumes that the correct hallPeriodRef and imageFastScanReg values for the ROS have been entered into NVM, either in manufacturing or according to REP 061.
1.
Load 8.5 x 11 in. or A4 paper LEF in all the affected trays, ensuring that the side guides
are adjusted tight against the stack.
2.
3.
data.
4.
Select [Offset].
5.
Under [Setups], select [y-reg (Side One)].
6.
Check
1.
Select the first, next, or desired tray for which top edge registration is to be checked.
NOTE: Either select the specific tray for which top edge registration is suspect, or select
the next tray (if present) in the following sequence: Tray 1, Tray 2, Tray 3, Tray 4, Tray 5
(Bypass Tray), Tray 6 (HCF).
2.

NOTE: When removing the prints from the output tray, be sure to note which are the lead
and top (OB) edges. The number "17" appears sideways at the top, near trail (left) edge.
3.
V0.042
May 2003
4-537
Remove the prints from the output tray and hold one face up, with the lead edge to the
ADJ 8-1A, ADJ 8-1B
4.
Observe the 15mm horizontal lines closest to the top edge (the one line between the sideways number "17" and the top edge, for example). Top edge registration is within specification if the topmost line in each column is at the top of the paper. Figure 1 shows a
correctly-registered print with the [Offset] selected.

at top edge

NOTE: If the image is too high on the page, the line between the "17" and the top edge of
the image will be off the page (invisible). If the image is too low on the page, there will be
space visible between that line and the top edge of the paper.
5.
If top edge registration (side 1) is not within specification for the tray selected, perform the
Adjustment.
6.
If top edge registration (side 1) is within specification for the tray selected, repeat the
Check for the next of any remaining trays.
7.
If top edge registration (side 1) is within specification for all trays, [Exit] the routine to
make any NVM changes effective.
8.
9.
series: ADJ 8-1C IOT Top Edge Registration (IB-OB), Side 2, Small Paper.

of paper)
ADJ 8-1B
May 2003
4-538
V0.042
Adjustment
1.
Select the up- or down-arrow once for each 0.1mm of desired adjustment: With the test
print face-up with the lead edge to the right and the top (OB) edge at the top,
the up-arrow moves the image up (in the OB direction), whereas
the down-arrow moves the image down (in the IB direction).
NOTE: The change in the number displayed in the Position window in the routine may
seem opposite to the movement of the image. As you move the image up, the number
goes down, and vise verse.
2.
ADJ 8-1C IOT Top Edge Registration (IB-OB), Side 2, Small

Paper
PURPOSE
adjust the IOT registration in the inboard-outboard direction (top-to-bottom) on side 2 (back) of
a duplex print, as measured at the top edge of a 8.5 x 11 in. or A4 LEF portrait page. In the
setup routine, registration in the IB-OB direction for side 2 of small paper must only be set
using one paper tray, because this routine uses only one NVM location for this registration for
all trays. However, this procedure also directs you to specific NVM locations which can be
adjusted using NVM Tool. This option enables you to optimize individual paper trays' side 2
registration on small paper.
components:
Prefuser Transport (PFT)
Inverter
Duplex Transport
Preparation
NOTE: Side 1 must be checked/adjusted for Tray 1 before Side 2 can be checked.
1.
Ensure that the Duplex Feed Timing has been set up ([Paper tab , IOT Paper Path
Setup]).
2.
Load 8.5 x 11 in. or A4 paper LEF in Tray 1, ensuring that the side guides are adjusted
tight against the stack.
3.
4.
data.
5.
Select [Offset].
6.
Select [Tray 1].
7.
Under [Setups], under [y-reg (Side Two)], select [small paper].
8.
Check
1.

V0.042
2.
3.
Observe the 15mm horizontal lines closest to the top edge (the one line between the sideways number "17" and the top edge, for example). Top edge registration is within specification if the topmost line in each column is at the top of the paper. Figure 1 shows a
correctly-registered print with the [Offset] selected.
May 2003
4-539
ADJ 8-1B, ADJ 8-1C
4.
If top edge registration (side 2) for small paper is not within specification for Tray 1, perform the Adjustment.
5.
If top edge registration (side 2) for small paper is within specification for Tray 1, you may
then select other trays and check them also. However, do not adjust for other trays
within this routine.

at top edge

CAUTION
After checking/adjusting top edge registration (side 2) for small paper from Tray 1, do not adjust
for other trays within this routine, since this will then misadjust for tray 1. This routine affects
one NVM location which applies the adjustment to all trays equally. The NVM locations for
each tray may then be adjusted individually using NVM Tool, as specified later in this procedure.
6.
[Exit] the routine to make any NVM changes effective.
7.
If you wish to adjust top edge registration (side 2) for small paper for individual trays, do
the following:
a.
b.
Select Service: [Mark Service].
c.
Select Module: [F1IOT] or [F2IOT] for Trays 1-4, or [SMH] or [HCF] for Tray 5 or 6.
NOTE: The required change in the NVM value may seem opposite to the resulting movement
of the image. To move the image down (away from the top edge), the value must be
increased. To move the image up (toward the top edge), the value must be decreased.
d.
Scroll (or Search) for the location listed below for the desired tray, and change the
NVM value by 1 for each 0.1 mm of required adjustment:
Tray 1: Location 278
e.
Select another Module as required and change any other desired tray's NVM value
as above.
f.
Exit NVM Tool.
8.
9.
series: ADJ 8-1D IOT Top Edge Registration (IB-OB), Side 2, Large Paper.

of paper)
ADJ 8-1C
May 2003
4-540
V0.042
Adjustment
1.
The up-arrow moves the image up (in the OB direction), whereas
2.
ADJ 8-1D IOT Top Edge Registration (IB-OB), Side 2, Large

Paper
PURPOSE
adjust the IOT registration in the inboard-outboard direction (top-to-bottom) on side 2 (back) of
a duplex print, as measured at the top edge of an 11 x 17 in. or A3 page. In the setup routine,
registration in the IB-OB direction for side 2 of large paper must only be set using one paper
tray, because this routine uses only one NVM location for this registration for all trays. However, this procedure also directs you to specific NVM locations which can be adjusted using
NVM Tool. This option enables you to optimize individual paper trays' side 2 registration on
large paper.
components:
Prefuser Transport (PFT)
Inverter
Duplex Transport
Preparation
NOTE: Side 1 must be checked/adjusted for Tray 4 before Side 2 can be checked.
1.
Ensure that the Duplex Feed Timing has been set up ([Paper tab , IOT Paper Path
Setup]).
2.
Load 11 x 17 in. or A3 paper in Tray 4, ensuring that the side guides are adjusted tight
against the stack.
3.
4.
data.
5.
Select [Offset].
6.
Select [Tray 4].
7.
Under [Setups], under [y-reg (Side Two)], select [large paper].
8.
Under [Size], select [11 x 17] or [A3], as appropriate.
Check
1.

V0.042
2.
3.
Observe the 15mm horizontal lines closest to the top edge (the one line between the sideways number "17" and the top edge, for example). Top edge registration is within specification if the topmost line in each column is at the top of the paper.
May 2003
4-541
ADJ 8-1C, ADJ 8-1D
4.
If top edge registration (side 2) for large paper is within specification for Tray 4, you may
then select other trays and check them also. However, do not adjust for other trays
within this routine.
CAUTION
After checking/adjusting top edge registration (side 2) for large paper from Tray 4, do not adjust
for other trays within this routine, since this will then misadjust for tray 4. This routine affects
one NVM location which applies the adjustment to all trays equally. The NVM locations for
each tray may be then adjusted individually using NVM Tool, as specified later in this procedure.
5.
[Exit] the routine to make any NVM changes effective.
6.
If you wish to adjust top edge registration (side 2) for large paper for individual trays, do
the following:
a.
b.
c.
Select Module: [F1IOT] or [F2IOT] for Trays 1-4, or [SMH] or [HCF] for Tray 5.
NOTE: The required change in the NVM value may seem opposite to the resulting movement
of the image. To move the image down (away from the top edge), the value must be
increased. To move the image up (toward the top edge), the value must be decreased.
d.
ADJ 8-1E IOT Lead Edge Registration for Small Heavy

Weight Paper (19.02 and Higher Software Only)
Purpose
CAUTION
Use this procedure only if the customer insists on more precise lead-edge registration for the
specific heavy stock that they are running. Caution them that, because of wide variation in
heavy stocks feed properties, changing to a different heavy stock after this procedure is performed may result in another service call being required in order to re-adjust the heavy paper
lead-edge registration.
The purpose of this procedure is to check/adjust the IOT registration in the process direction on
small heavy weight paper (e.g. 110 lb. or 200 GSM, 8.5x11 or A4), as measured at the lead
edge. Heavy paper registration in the process direction need only be set using one paper tray,
because one NVM location determines this registration for all trays.
For machines with 19.02 software, the Check is performed using Print Test Pattern and the
Adjustment is performed using NVM Read/Write.
For machines with 19.03 and higher software, the IOT System Registration setup diagnostic
routine is used for both the Check and the Adjustment.
Scroll (or Search) for the location listed below for the desired tray, and change the
NVM value by 1 for each 0.1 mm of required adjustment:
e.
Select another Module as required and change any other desired tray's NVM value
as above.
f.
Exit NVM Tool.
7.
8.
If you are performing the entire IOT Registration Setup Series, this completes the series.
Adjustment
1.
The up-arrow moves the image up (in the OB direction), whereas
2.
ADJ 8-1D, ADJ 8-1E
May 2003
4-542
V0.042
NOTE: When [Offset] is selected in the IOT System Registration routine, the test pattern image
is automatically offset 5mm toward the lead edge and 5mm toward the top edge of the paper,
to eliminate the need to use a scale to measure registration. This offset is reversed when [Offset] is deselected, or is automatically reversed upon exiting the routine. Figure 1 shows a correctly-registered print with the [Offset] deselected.


edge of paper)
top edge
5.0mm
lead edge
5.0mm
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May 2003
4-543
ADJ 8-1E
FOR MACHINES WITH 19.02 SOFTWARE:
edge.
Preparation
Load the customers desired heavy weight paper in Tray 1.
2.
3.
Check
1.
2.
Under Select Pattern, select [Registration].
3.
Under Size, select [8.5 x 11] or [A4], as appropriate.
4.
Under Quantity, enter 5.
5.
Select [Start Job].
4.
6.
Select [Exit].
5.
7.
Inspect the lead edge registration on the copies as compared to Figure 2. If the lead edge
registration is unsatisfactory, perform the Adjustment.
changes effective.
6.
Adjustment
1.
Enter [NVM tab , NVM Read/Write].
2.
3.
Enter Location: 75 (IotSmHeavyRegClutchOn).
4.
Add to the Current Value to move the image right, or subtract to move the image left, 1 for
each 0.35 mm (75 ppm) or 0.42 mm (90 ppm) of desired movement, end enter the result
for the New Value.
5.
Select [Modify].
6.
Select [Exit].
7.
Recheck and Readjust as necessary.
FOR MACHINES WITH 19.03 OR HIGHER SOFTWARE:

Preparation
1.
Load the customers desired heavy weight paper in Tray 1.
2.
3.
data.
4.
Select [Offset]
5.
Select [Tray 1].

edge registration.
6.
7.
8.
Under [Paper Weight], select [Heavy].
Check
1.
ADJ 8-1E
May 2003
4-544
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Adjustment

1.
Select the left- or right-arrow once for each 0.35 mm (75 ppm) or 0.42 mm (90 ppm) of
desired adjustment: With the test print face-up with the lead edge to the right and the top
(OB) edge at the top,
2.
long
vertical line
at lead
edge
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May 2003
4-545
ADJ 8-1E
ADJ 8-1F IOT Lead Edge Registration for Large Paper

(19.02 and Higher Software Only)
Purpose
CAUTION
Use this procedure only if the customer insists on more precise lead-edge registration for the
specific large stock that they are running. Caution them that, because of wide variation in large
stocks feed properties, changing to a different large stock after this procedure is performed
may result in another service call being required in order to re-adjust the large paper lead-edge
registration.
large paper (e.g. 11 x 17 in. or A3, but not heavy weight), as measured at the lead edge.
Heavy paper registration in the process direction need only be set using one paper tray,
because one NVM location determines this registration for all trays.
ADJ 8-1F
May 2003
4-546
V0.042


edge of paper)
top edge
5.0mm
lead edge
5.0mm
V0.042
May 2003
4-547
ADJ 8-1F
FOR MACHINES WITH 19.02 SOFTWARE
edge.
Preparation
Load the customers desired large paper in Tray 1.
2.
3.
Check
1.
2.
3.
4.
5.
Select [Start Job].
4.
6.
Select [Exit].
5.
7.
changes effective.
6.
Adjustment
1.
2.
3.
Enter Location: 73 (IotLargeRegClutchOn).
4.
for the New Value.
5.
Select [Modify].
6.
Select [Exit].
7.
FOR MACHINES WITH 19.03 OR HIGHER SOFTWARE

Preparation
1.
Load the customers desired 11 x 17 in. or A3 paper in Tray 1.
2.
3.
data.
4.
Select [Offset]
5.
Select [Tray 1].

edge registration.
6.
7.
8.
Under [Paper Weight], select [Normal].
Check
1.
ADJ 8-1F
May 2003
4-548
V0.042
Adjustment

1.
2.
long
vertical line
at lead
edge
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May 2003
4-549
ADJ 8-1F
ADJ 8-1G IOT Lead Edge Registration for Large Heavy

Weight Paper (19.02 and Higher Software Only)
Purpose
large heavy weight Paper (e.g. 11 x 17 in. or A3,110 lb. or 200 GSM), as measured at the lead
edge. Large heavy paper registration in the process direction need only be set using one paper
tray, because one NVM location determines this registration for all trays.
ADJ 8-1G
May 2003
4-550
V0.042


edge of paper)
top edge
5.0mm
lead edge
5.0mm
V0.042
May 2003
4-551
ADJ 8-1G
FOR MACHINES WITH 19.02 SOFTWARE
edge.
Preparation
Load the customers desired large heavy weight paper in Tray 1.
2.
3.
Check
1.
2.
3.
4.
5.
Select [Start Job].
4.
6.
Select [Exit].
5.
7.
changes effective.
6.
Adjustment
1.
2.
3.
Enter Location: 74 (IotLrgHeavyRegClutchOn).
4.
for the New Value.
5.
Select [Modify].
6.
Select [Exit].
7.
FOR MACHINES WITH 19.03 OR HIGHER SOFTWARE

Preparation
1.
Load the customers desired 11 x 17 in. or A3 paper in Tray 1.
2.
3.
data.
4.
Select [Offset]
5.
Select [Tray 1].

edge registration.
6.
7.
8.
Under [Paper Weight], select [Heavy].
Check
1.
ADJ 8-1G
May 2003
4-552
V0.042
Adjustment

1.
2.
long
vertical line
at lead
edge
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May 2003
4-553
ADJ 8-1G
ADJ 8-2 IOT Skew (Registration Transport)
test pattern
number
PURPOSE
top edge
OB
The purpose of this procedure is to fine-tune the image-to-paper skew by varying the angle of
the Registration Transport in relation to the photoreceptor.
Perform this procedure only if directed here from 08-C Skewed Image RAP.
Preparation
1.
Load 8.5 x 11 in. or A4 paper LEF in the tray(s) in question.
2.
3.
Under [Select Pattern], under [Common/General], select [Registration].
4.
Check
1.
Select [Start Job].

NOTE: When removing the print from the output tray, be sure to note which are the lead
2.
Remove the print from the output tray and hold it face up, with the lead edge to the right
and the top (OB) edge at the top.
3.
Measure the lead edge registration at the IB (bottom) and OB (top) corners (Figure 1).
4.
Calculate the Skew:

a.
Subtract the OB measurement from the IB measurement:
b.
A positive Skew means the image is skewed CW on the paper (IB
c.
A negative Skew means the image is skewed CCW on the paper (OB
lead
edge
IB - OB = Skew
5.
Determine if the Adjustment should be performed, based on the following:

If the Skew is 1.5mm or more outside of the desired range, this Adjustment cannot
possibly correct the skew problem -- use the 08-C Skewed Image RAP to diagnose
the problem further.
If the Skew is less than 1.5mm outside of the desired range, perform the Adjustment.
6.
If the Skew is still outside of the desired range after trying the full range of this Adjustment, use the 08-C RAP to diagnose the problem further.
IB
Figure 1 Test Pattern
ADJ 8-2
May 2003
4-554
V0.042
Adjustment
1.
Determine the amount (number of increments) and direction (left or right) of the adjustment required:
a.
Divide the Skew by 0.3mm, then round off to the nearest whole number, to determine
the number of increments:
b.
If the Skew is positive, the adjustment will be to the left.
Skew / 0.3mm = # increments

If the Skew is negative, the adjustment will be to the right.
c.
Examples:
If Skew = - 1.0mm, adjustment = 3 increments to the right.
Registration
Transport
If Skew = + 0.6mm, adjustment = 2 increments to the left.

2.
Unlatch the Xerographic Module and remove it from the machine.
3.
Open the Registration Transport (lift the green handle).
4.
Perform the adjustment (Figure 2):
Skew
Adjustment
Lever
NOTE: The amount of adjustment from one Adjustment Position Hole to the next equals
one increment of adjustment. You may confirm the position of the Skew Adjustment Lever
by visually aligning the hole in the lever with the rear of one of the Adjustment Position
Holes. You may also confirm and hold the position by inserting a large (thick) paper clip
through the holes.
a.
b.
Loosen (do not remove) the Adjustment Locking Screw (T20).
c.
Rotate the Skew Adjustment Lever in the amount and direction of the desired adjustment.
d.
Tighten the screw, while holding the Skew Adjustment lever in the desired position.
FULL LEFT
1/2 LEFT
CENTER
1/2 RIGHT
FULL RIGHT
Observe the current position of the Skew Adjustment Lever.

NOTE: You may discover that the desired adjustment is not possible, if the current
position is already closer to the right or left end of the range than the amount of the
desired adjustment in that direction. If so, go to 08-C Skewed Image RAP to diagnose the skew problem further.
5.
Adjustment Position Holes:
Adjustment
Locking
Screw (T20)
Close the Registration Transport.
6.
Reinstall and latch the Xerographic Module.
7.
Figure 2 Registration Transport Skew Adjustment
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May 2003
4-555
ADJ 8-2
ADJ 8-2
May 2003
4-556
V0.042
ADJ 12-1 Tamping - Disk Finisher

Purpose
The purpose of this adjustment is to ensure that stapled sets are evenly tamped.
a.
Open the Finisher Top Cover Door and change the value on the NVM label (on the
underside of the door) to reflect the new value.
b.
components:
Moving Stapler
Tamper Home Sensor
Adjustment
1.
Enter [Finishing tab , Finisher Setup] (in Diagnostics Navigator: [Finishing] tab, [Finisher
Setup]).
2.
In the Finisher Adjustment window, select [Perform Tamper Position Adjustment] and
select [Start].
3.
In the setup welcome window, select [8.5 x 11] or [A4] as appropriate, and select [Next].
4.
Insert the long edge of the sheet of paper into the disk fingers, ensuring that the sheet is
all the way into the bottom of the fingers.
5.
Slide the sheet toward the front of the machine, keeping the sheet against the registration
edges, until it is biased against the retractable registration edge on the stapler.
6.
Select [Next] in the setup window on the PWS.
7.
Measure the tamping distance from the inboard (rear) edge of the sheet to the tamper.
NOTE: Measure to the plastic edge of the tamper face, not to the pad).
8.
Enter the measurement, to the nearest 0.5 mm, in the field indicated in the setup window
on the PWS, and select [Next].
9.
Select [Yes], and [OK] to confirm.
10. Remove the sheet of paper from the Finisher.

11. Exit Diagnostics.
12. Run some sets to check that the tamping is satisfactory. If not, do the following:
a.
Enter [Finishing tab , Finisher Setup] (in Diagnostics Navigator: [Finishing] tab, [Finisher Setup]) again.
b.
Select [Tamper Position Adjustment has already been performed and a slight modification is needed], and select [Start].
c.
Increase or decrease the tamping value in the field, or use the arrow buttons to move
tamper more or less toward the rear.
NOTE: Increasing the tamping value (moving the tamper toward the rear) results in
less tamping of the sets. Decreasing the tamping value (moving the tamper
toward the front) results in more tamping of the sets.
d.
Select [Modify].
e.
Select [Yes], and [OK] to confirm.
f.
Exit Diagnostics.
g.
Recheck/readjust as necessary.
13. If the tamping value was changed, do the following:
V0.042
May 2003
4-557
ADJ 12-1
ADJ 12-2 Tamper Position - Disk Finisher

Purpose
The purpose of this adjustment is to ensure the correct positioning of the Tamper. Incorrect
Tamper positioning can cause sheet-to-sheet registration problems within stapled sets.
Tamper Arm
Adjustment
1.
2.
Slide the Tamper Arm, by hand, to the set-up position. Ensure the locating features on the
Service Tray line up with the locating features on the Tamper Arm (Figure 1).
3.
Loosen the two T20 Tamper Arm mounting screws, rotate the Tamper Arm clockwise
within the locator tabs (underneath), then tighten the screws (Figure 2)
4.
Slide the Tamper Arm through it's full length of travel. The Tamper Arm should move the
full distance in both directions smoothly without binding (Figure 3). If not, repeat the previous step.
5.
Reinstall the Finisher Service Tray Assembly (REP 12-3).
6.
When reinstalling the Tamper Button, rotate the button slightly clockwise, then tighten the
screw (Figure 4).
7.
Position a sheet of heavy paper (e.g. 110 lb. or 200 gsm) to check the position of the
Tamper Arm and Tamper Button (Figure 5).
a.
Insert the long edge of the sheet of paper into the disk fingers, ensuring that the
sheet is all the way into the bottom of the fingers.
b.
Slide the sheet toward the rear of the machine, keeping the sheet against the registration edges, until it is biased against the Tamper Button.
8.
Check the Tamper position (Figure 5). If the Tamper is not in the correct position as
shown, return to step 6 to adjust the position of the Tamper Button.
9.
Perform ADJ 12-1 Tamping.
ADJ 12-2
May 2003
4-558
Figure 1 Set-up Postulation
V0.042
Tamper Arm
mounting
screws
Figure 2 Rotate the Arm
V0.042
Figure 3 Slide the Arm
May 2003
4-559
ADJ 12-2
The sheet should just touch the

tip of the one-way grass here.
The sheet should touch the base
of the one-way grass in the main
portion of the Tamper Button.
Figure 4 Rotate and Tighten the Tamper Button
Position a
test sheet.
Figure 5 Check the Tamper Position
ADJ 12-2
May 2003
4-560
V0.042
ADJ 12.02.01 Crease Blade
12. Rotate the Crease Blade Knob to cam the Crease Blade to its full extension (the green
arrow on the knob will be facing downward).
Purpose
The purpose of this procedure is to align and position the Crease Blade to ensure straight,
accurate booklet creasing.
Special Tools Required
13. Using a finger in each Crease Blade adjustment hole (Figure 7), move both ends of the
Crease Blade in until the blade stops against the setup tools on both sides.
14. Ensuring the Crease Blade remains in contact with the setup tools on both ends simultaneously, tighten the five accessible Crease Blade clamp screws (Figure 7).
15. Using the Crease Blade Knob, retract the Crease Blade.
Crease Blade Setup Tools (supplied with the MFF)
16. Tighten the five remaining Crease Blade clamp screws.

17. Remove both Crease Blade Setup Tools.
Adjustment
18. Reassemble and reinstall the Booklet Maker in the reverse of the removal and disassembly.
WARNING
1.
2.

a.
b.
c.
d.
3.
Reinstall the Crease Blade Knob and the Crease Roll Lever temporarily.
4.
Remove the Booklet Maker Rear Handle (Figure 1).
5.
Remove the Crease Roll Motor and the Rear Handle bracket, to access the rear screws
for the Crease Roll exit bracket (Figure 2).
6.
a.
Remove the Crease Roll Motor Encoder Sensor from the bracket (leave it connected
to the wiring harness).
b.
Remove the Crease Roll Motor Encoder Wheel/Coupler.
c.
Disconnect the two Crease Roll Motor electrical connectors.
d.
Slide the Crease Motor and the Rear Handle bracket off and move them aside (still
attached to the Crease Motor Encoder wiring harness).
Remove the Crease Roll Exit Bracket (Figure 3).

a.
Remove the four T20 screws (two front and two rear).
NOTE: Do not pivot the Crease Roll exit bracket downward when removing it. Pivoting it downward can dislodge the Crease Roll Bearings.
b.
Flex the Booklet Maker frame slightly to disengage the locating features, pull the
Crease Roll exit bracket out parallel (do not pivot it out), and remove it.
7.
Rotate the Crease Roll Release Lever CCW to release the Crease Roll nip.
8.
Rotate the Crease Roll Lever CW until the Upper Crease Roll just rests on the Lower
Crease Roll (Figure 4)
9.
Position both Crease Blade Setup Tools on the Crease Roll Shafts, on both ends of the
Crease Rolls (Figure 5).
10. Lift the Crease Roll Gate, and use the rear handle grip to hold gate in the up position (Figure 6).
11. Loosen all ten Crease Blade clamp screws (Figure 7).
V0.042
May 2003
4-561
ADJ 12.02.01
1
Remove the
plastic rear
handle grip.
2
Remove the three T20
bracket mounting
screws.
Rear Handle Bracket
Figure 1 Booklet Maker rear handle removal
ADJ 12.02.01
May 2003
4-562
V0.042
Remove the
sensor.
Slide the motor

off of the shaft
Crease
Roll Exit
Bracket
Remove four T20 screws

(two each side)
3
2
Remove the snap ring
and remove the encoder
wheel/coupling.
Disconnect the M68

electrical connectors.
Figure 3 Crease Roll Exit Bracket Removal
Figure 2 Removal of Crease Roll Motor (M68)
V0.042
May 2003
4-563
ADJ 12.02.01
Crease Roll shafts
CORRECT
(Crease Rolls
just touching)
INCORRECT
(Crease Roll nip
fully closed)
INCORRECT
(Crease Roll nip
fully open)
Rotate the Crease Roll Release Lever CW from the

full-open position until the Crease Rolls just touch.
Crease
Blade
Setup Tool
The outboard end of

the Crease Rolls is
shown. Position the
second tool on the
inboard end in the
same manner.
Figure 4 Setting the Crease Rolls for the Crease Blade Setup
Figure 5 Position of Crease Blade Setup Tool
ADJ 12.02.01
May 2003
4-564
V0.042
ten 5.5 mm screws
Rear handle grip, used to

hold the Crease Roll Gate up
Figure 6 Crease Gate in the up position
Crease Blade
adjustment holes
Figure 7 Crease Blade clamp screws and adjustment holes
V0.042
May 2003
4-565
ADJ 12.02.01
ADJ 12.02.02 Booklet Stapler Anvils

Purpose
The Purpose of this procedure is to align and position the Booklet Stapler Anvil to allow for
proper staple crimping.
Booklet Stapler Anvil Setup Tool (supplied with the MFF)
Drawer Extension Harness
CAUTION
14. Test the stapler for staple clinch quality:
3.
Remove the Booklet Tamper Assembly (REP 12.02.09).
4.
Remove the appropriate Booklet Stapler Cover (one 5.5 mm screw) (Figure 1).
Tighten the first screw firmly.
Ensure the machine power is switched off whenever connecting or disconnecting the Drawer
Extension Harness.
WARNING
2.
Tighten the second screw firmly.
c.
13. Cam the stapler back out and remove the setup tool.
Adjustment
1.
b.
5.
6.
Position the Anvil Setup Tool in the appropriate Booklet Stapler (Figure 2).
7.
Observe the alignment holes in the face of the Anvil (Figure 3). During the setup, these
holes must mate with the setup tools alignment pins (Figure 2).
a.
Connect the Booklet Maker to the MFF using the Drawer Extension Harness.
b.
Open the Booklet Maker Entrance Baffle (5d1 jam area), insert two sheets of 20 lb or
80 gsm paper into the booklet compiler area, and hold onto the sheets.
c.
Reconnect and switch on the machine power.
d.
Enter [Finishing tab, Finisher Tests, Booklet Maker tab], under Booklet Components,
select [Booklet Staplers], then select [Front Stapler] or [Rear Stapler] as appropriate
and make several staples, moving the paper after each to be sure to staple in a new
location.
e.
Switch off and disconnect the machine power and remove the Drawer Extension
Harness.
f.
Inspect the staples for clinch quality. If the clinch quality is unsatisfactory, repeat the
Adjustment as required.
15. Reinstall the remaining components in the reverse of removal.
CAUTION
Do not remove the Anvil Mylar Guide. The adhesive will not re-adhere properly if the guide is
reinstalled, and if the guide is dislodged it may become an obstruction. Also, if the guide is not
installed, the paper may stub on the Anvil or the baffles. In either case, booklet quality problems and 12-801 or 12-117 faults will result.
8.
9.
On the back of the Anvil, prepare the Anvil for the setup (Figure 4):
a.
Loosen the screws, then ensure the Anvil screws are just tight enough to hold the
Anvil in place, but loose enough to allow the Anvil to be moved by hand.
b.
As a starting point for the setup, position the Anvil so that both Anvil alignment
guides are centered in the openings.
Close the Booklet Stapler Module.
10. Rotating the stapler idler gear as shown in Figure 5, slowly cam the stapler in until the
setup tool contacts the Anvil. If the Anvil is nearly aligned, it may then self-align and its
alignment holes will engage the setup tools alignment pins. If not, carefully move the
Anvil by hand or with a narrow tool to align the holes with the pins.
NOTE: The alignment holes and pins are hidden at this point. Position the outer edges of
the Anvil so that it appears centered with respect to the stapler, and feel for the engagement of the alignment holes with the alignment pins.
11. Once the setup tools alignment pins engage the Anvils alignment holes, continue camming the stapler in until the setup tool is clamped firmly between the stapler and the Anvil.
12. Tighten the Anvil screws (Figure 4):
a.
Hold one screw firmly with your finger while tightening the other screw only partially,
to prevent the Anvil from rotating when the first screw is turned.
ADJ 12.02.02
May 2003
4-566
V0.042
2
Press the setup
tool firmly in place.
1
Insert the setup
tool into the throat
of the stapler as
shown.
alignment pins
Area 5b4 handle
Figure 2 Positioning the Anvil Setup Tool
Booklet Stapler
Covers
Figure 1 Booklet Stapler Cover removal
V0.042
May 2003
4-567
ADJ 12.02.02
Anvil alignment
guides
Anvil alignment
holes
Anvil screws (T20)
Figure 3 Anvil alignment holes
ADJ 12.02.02
Figure 4 Back of Anvil
May 2003
4-568
V0.042
ADJ 12.02.03 Booklet Tamping

Purpose
The Purpose of this procedure is to align and position the Booklet Tamper to allow for proper
tamping of the paper.
Check
Check the booklet tamping against Booklet Set Registration Specifications.
Adjustment
1.
2.
3.
[Search] to location "BM Tamper Stroke" and double-click on it.
4.
Enter a new value as appropriate: Increase the value to increase the tamping stroke, or
decrease the value to decrease the tamping stroke.
5.
Select [Write NVM] and select [OK].
6.
Exit NVM Tool.
7.
Figure 5 Camming the stapler in
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May 2003
4-569
ADJ 12.02.02, ADJ 12.02.03
ADJ 12.02.04 Booklet Staple Position
ADJ 12.02.05 Booklet Crease Position
Purpose
Purpose
The purpose of this procedure is to position the booklet staples and crease relative to the edge
of the sheet. Do not attempt use this procedure to align the staples to the crease -- instead use
ADJ 12.02.05 Booklet Crease Position to align the crease to the staples. For ease of performing this adjustment, ensure the crease and the staples are aligned to each other, using ADJ
12.02.05 Booklet Crease Position as required, before performing this procedure. Provided the
stapled-booklet crease and staple positions already coincide, this procedure may be used to
align the unstapled-booklet crease position relative to the edge of the sheet.
The purpose of this procedure is to position the booklet crease relative to the booklet staple
position. Do not attempt to use this procedure to align the crease relative to the edge of the
sheet directly, for either a stapled or an unstapled booklet. Instead, use this procedure as
required to align the crease to the staples of a stapled booklet, then use ADJ 12.02.04 Booklet
Staple Position as required to align the combined staple/crease position relative to the edge of
the sheet.
The Booklet Compiling, Stapling, and Folding series of adjustments must be performed in the
following sequence:
following sequence:
1.
ADJ 12.02.08 Booklet Compiling Position (BM Home to Compile NVM)
1.
2.
ADJ 12.02.05 Booklet Crease Position (BM Staple to Fold NVM)
2.
3.
ADJ 12.02.04 Booklet Staple Position (BM Fold to Center NVM)
3.
Check
Check
1.
Run a copy job of 3 stapled 4-sheet booklets.
1.
Run a copy job of 3 stapled 4-sheet booklets.
2.
Mark the booklets to indicate the top flap as they sit in the output tray.
2.
Mark the booklets to indicate the top flap as they sit in the output tray.
3.
3.
Observe the position of the trail edge of the top flap relative to the trail edge of the bottom
flap. The edges should align within 0.5 mm. If not, measure the distance between the
edges and perform the Adjustment.
Observe the position of the crease relative to the staples. The crease line should be positioned on the staples. If not, measure the distance from the crease to the staples and perform the Adjustment.
Adjustment
Adjustment
1.
1.
2.
2.
3.
[Search] to location "BM Staple to Fold" and double-click on it.
3.
[Search] to location "BM Fold to Center" and double-click on it.
4.
4.
Enter a new value as appropriate: Increase the value to lower the stapling and creasing
backstop positions and thus lengthen the lower flap of the booklet as it sits in the output
tray, or decrease the value to raise the stapling and creasing backstop positions and thus
lengthen the upper flap of the booklet as it sits in the output tray. An NVM change of 5 will
move the staple/crease position approximately 1.1 mm.
Enter a new value as appropriate: Increase the value to raise the creasing backstop
position and thus lengthen the upper flap of the booklet as it sits in the output tray (so the
staples are further toward the upper flap), or decrease the value to lower the creasing
backstop position and thus lengthen the lower flap of the booklet as it sits in the output
tray (so the staples are further toward the lower flap). An NVM change of 5 will move the
crease position approximately 0.6 mm.
5.
5.
6.
Exit NVM Tool.
6.
Exit NVM Tool.
7.
7.
ADJ 12.02.04, ADJ 12.02.05
May 2003
4-570
V0.042
ADJ 12.02.06 Crease Roll Gate
ADJ 12.02.07 Booklet Maker Drawer Alignment
Purpose
Purpose
The purpose of this procedure is to ensure correct alignment of the Crease Roll Gate so that
the Crease Roll Gate Home Sensor is actuated.
The purpose of this procedure is to align the Booklet Maker drawer so that it opens and closes
correctly and the drawer connector connects correctly.
Check
Check
1.
Enter [Finishing tab, Finisher Tests, Booklet Maker tab].
2.
Select Booklet Components: [Folding/Creasing].
Observe the alignment mark on the Booklet Maker front frame and the corresponding mark on
the MFF front frame (Figure 1). If the marks do not align, perform the Adjustment.
3.
Select Roll Gate: [Start].
4.
Observe the Crease Roll Gate Home Sensor window: It should display, "Blocked
Unblocked Blocked." If not, perform the Adjustment.
Adjustment
WARNING
1.
Open the MFF Front Door, Open Area 5a, and slide out the Booklet Maker drawer.
2.

a.
b.
c.
d.
3.
Remove the Crease Roll Gate Front Gear (one E-ring).
4.
Slide the Crease Roll Gate all the way up and hold it, ensuring that both the front and rear
ends of the gate are fully at the top of their travel.
5.
While holding the Crease Roll Gate up, reinstall the Crease Roll Gate Front Gear (one Ering).
6.
Recheck and readjust as required.
mark on MFF
frame
mark on Booklet
Maker frame
Figure 1 Booklet Maker drawer alignment marks
Adjustment
WARNING
1.
V0.042
May 2003
4-571
Loosen the three T20 screws securing the MFF right side rail to the MFF (Figure 2)
ADJ 12.02.06, ADJ 12.02.07
2.
Realign the drawer and tighten the screws.
3.
ADJ 12.02.08 Booklet Compiling Position

Purpose
The purpose of this procedure is to adjust the Booklet Backstop compiling position as a basis
for the booklet stapling and folding positions.
following sequence:
1.
2.
3.
Check
1.
Open the MFF Front Door and insert the Interlock Cheater.
2.
Enter [Copier Sys tab , Component Control], and select the [Finisher] tab.
3.
Under Outputs, select [Booklet Backstop Motor (Letter)] or [Booklet Backstop Motor
(A4)], depending whether 8.5 x 11 in. or A4 paper is available, respectively.
4.
Select [Output On]. The Booklet Backstop will begin to move up to the compiling position
and back down to the home position repeatedly.
5.
When the Booklet Backstop is up in the compiling position, remove the Interlock Cheater
to stop the backstop in the compiling position.
6.
Slide out the Booklet Maker and open the Booklet Maker Entrance Baffle (5d1 jam area).
7.
Insert a sheet of 8.5 x 11 in. or A4 paper (the same size as selected in 3) SEF into the
booklet compiler area, ensuring that the bottom edge rests on the Booklet Backstop and
the top edge is flat against the inside of the Booklet Entrance Right Baffle (Figure 1).
8.
Observe the position of the top edge of the sheet relative to the compiling position scale
(Figure 1). The top edge of the sheet should align with the 0 (zero) mark on the A scale,
within one scale mark (1.5 mm). If not, perform the Adjustment.
three T20 screws

(one hidden)
Figure 2 Booklet Maker drawer alignment screws
ADJ 12.02.07, ADJ 12.02.08
May 2003
4-572
V0.042
ADJ 12.04.01 Tri-Fold First Crease Position

Purpose
compiling position
scale (A)
Booklet Entrance
Right Baffle
The purpose of this procedure is to adjust the position of the first crease on a Tri-Fold output
(Z- or C-configuration fold). The first-crease distance on a Z-configuration fold is the distance
from the Top edge of the sheet to the crease that is closest to the bottom edge of the sheet.
The first-crease distance on a C-configuration fold is the distance from the bottom edge of the
sheet to the crease that is closest to the bottom edge of the sheet (i.e. the length of the inside
flap).
Check
Check the first fold length against the Tri-Fold Specifications.
Adjustment
1.
2.
3.
For Z-configuration fold, [Search] to location "Z-Fold First to LE" and double-click on it.
4.
Enter a new value as appropriate:
For C-configuration fold, [Search] to location "C-Fold First to LE" and double-click on it.
a.
Multiply by 8.8 the desired change in the first-crease distance in millimeters, and
then round off to the nearest whole number. The result is the amount of required
NVM change.
b.
For Z-configuration fold, increasing the NVM value will increase the first-fold distance and decreasing the NVM value will decrease the first-fold distance.
For C-configuration fold, decreasing the NVM value will increase the first-fold distance and increasing the NVM value will decrease the first-fold distance.
5.
6.
Exit NVM Tool.
7.
Figure 1 Compiling Position Scale
Adjustment
1.
2.
3.
[Search] to location BM Home to Compile and double-click on it.
4.
Enter a new value as appropriate: Increase the value to raise the compiling backstop
position, or decrease the value to lower the compiling backstop position. An NVM change
of 5 will move the staple/crease position approximately 0.6 mm.
5.
6.
Exit NVM Tool.
7.
V0.042
May 2003
4-573
ADJ 12.02.08, ADJ 12.04.01
ADJ 12.04.02 Tri-Fold Second Crease Position

Purpose
The purpose of this procedure is to adjust the position of the second crease on a Tri-Fold output (Z- or C-configuration fold), relative to the first crease position (i.e. the length of the middle
panel).
adjustment screw
(T20)
Check
Check the second fold length against the Tri-Fold Specifications.
Adjustment
WARNING
1.
Remove the Booklet Maker Exit front cover (three T20 screws).
2.
Adjust the Tri-Folder Backstop position (Figure 1)
3.
a.
Loosen the adjustment screw (T20).
b.
Move the backstop up to decrease the second fold length, or down to increase the
second fold length. Each graduated mark represents a change of approximately one
millimeter.
c.
Tighten the adjustment screw.
typical setting for

A4 paper

NOTE: If wrinkling, double folding, or overlapping occurs, the second fold length may
need to be increased.
4.
typical setting for

8.5 x 11 inch paper
Figure 1 Tri-Folder Backstop position adjustment
Reinstall the Booklet Maker Exit front cover.
ADJ 12.04.02
May 2003
4-574
V0.042
ADJ 12.12.01 Main Stapler Alignment
Purpose
Purpose
The Purpose of this procedure is to align and position the Compiler Tamper to allow for proper
paper tamping.
The Purpose of this procedure is to align and position the Main Stapler relative to the Compiler
Backstop to allow for proper stapling.
Check
Check the Compiler Tamping against Set Registration Specifications - Stapled Sets and/or
Stack Specifications - Stapled and Unstapled Sets.
One sheet of 11x17 inch or A3 paper
Preparation
Adjustment
WARNING
1.
2.
3.
[Search] to location "Main Tamper Stroke" and double-click on it.
4.
Enter a new value as appropriate: Increase the value to increase the tamping stroke, or
decrease the value to decrease the tamping stroke.
1.
Pull the Main Stapler fully forward.
2.
Fold the piece of 11 x 17 inch (A3) paper lengthwise, so that it is 3 to 4 inches wide. Leave
one edge exposed, this will be used as a straight edge.
5.
6.
Exit NVM Tool.
Check
7.
1.
Place the paper so that the straight edge touches both Compiler Backstops and lays
across the Main Stapler stapling area (Figure 1).
2.
Observe the straight edge of the paper: The Main Stapler's backstops, and the retractable Compiler Backstops should align. The alignment of the Main Stapler backstop and
the Compiler Backstop should be within +/- 0.5 mm.
Compiler backstops
straight edge touching at

three points (+/- 0.5 mm).
Main Stapler
Figure 1 Main Stapler to Compiler Backstop check

V0.042
May 2003
4-575
ADJ 12.05.01, ADJ 12.12.01
Adjustment
ADJ 12.12.02 Main Stapler Staple Position
1.
Loosen the three Main Stapler screws (7mm), move the Stapler in the direction required,
and tighten the three screws (Figure 2).
Purpose
2.
The Purpose of this procedure is to position the Main Stapler staple relative to the top edge of
the sheet.
Prerequisite
Ensure that the Main Stapler Carriage Assembly is installed correctly and the belt is tensioned
correctly (REP 12.12.01), before performing this procedure.
Check
Check the staple position against the Staple Position Specifications - Main Stapler.
Adjustment
1.
2.
3.
[Search] to location "Staple to Top Edge" and double-click on it.
4.
Enter a new value as appropriate: Increase the value to move the staple closer to the
top edge of the sheet, or decrease the value to move the staple farther from the top edge
of the sheet. An NVM change of 3 will move the staple approximately 1 mm.
5.
6.
Exit NVM Tool.
7.
2
Move the stapler up or down
and tighten the screws.
1
Loosen three 7 mm screws.
Figure 2 Main Stapler Adjustment
ADJ 12.12.01, ADJ 12.12.02
May 2003
4-576
V0.042
ADJ 14-1 Image Module Set-Up

PURPOSE
The purpose of this adjustment is to ensure that the Image Module is properly positioned on
the Scan Carriage Cables
components:
Image Module
Check
WARNING
1.
2.
3.

a.
Document Glass Frame (REP 6-4)
b.
c.
d.
Scanner Top Frame (REP 6-5)
4.
Rotate the scan carriage capstan to move the Image Module to the left wall of the Scanner cavity. Both stops on the Image Module should contact the ribs on the left wall of the
Scanner Cavity (Figure 1). If not, perform the Adjustment.
5.
Reinstall the following components:

a.
Scanner Top Frame (REP 6-5)
b.
c.
d.
Document Glass Frame (REP 6-4)
V0.042
May 2003
4-577
ADJ 14-1
stop
rib
stop
rib
Figure 1 Image Module Set-up
ADJ 14-1
May 2003
4-578
V0.042
Adjustment
ADJ 14-2 IIT Registration and Magnification
1.
Rotate the scan carriage capstan pulley so that the Image Module is approximately 6
inches (150mm) from the left wall of the Scanner cavity.
PURPOSE
2.
Loosen the two front cable clamp screws (T20), plus the right rear cable clamp screw.
3.
Slide the Image Module against the ribs on the left wall of the Scanner cavity.
4.
If the cable tension springs are not centered between the cable clamps, do the following:
5.
6.
a.
Loosen the left rear cable clamp screw.
b.
While holding the Image Module gently against the ribs, rotate the capstan to center
the springs between the clamps.
c.
The purpose of this adjustment is to use the IIT registration and magnification setup diagnostic
routine to adjust the IIT registration and magnification semiautomatically.
components:
CVT Motor
Document Glass Frame
Retighten the left rear screw, making sure that the cable coming off the pulley is
straight both horizontally and vertically.
Image Module
Scan Carriage Motor
Hold the Image Module gently against the ribs making sure that both stops on the Image
Module make contact with the ribs.
Tighten the left front cable clamp making sure that the cable coming off the capstan pulley
is straight both horizontally and vertically.
7.
Tighten the remaining two cable clamps.
8.
Rotate the capstan to move the Image Module to the center position and then return it to
the left wall. Check that both stops on the Image Module contact the ribs. If not, repeat
the Adjustment and recheck/readjust as necessary.
Preparation
CAUTION
Clean the Document Glass thoroughly before starting the setup. The glass must be completely
clean in order for the setup to function correctly.
Clean the glass thoroughly, according to the Scanner Cleaning Procedure (REP 14-3).
Adjustment
1.
2.
Select the [IIT System Registration] tab.

NOTE: If the setup fails or produces repetitive error messages, exit and restart the setup
and proceed carefully.
NOTE: Follow the instructions in the routine carefully in regards to positioning the paper
on the Document Glass. Failure to approximately center the paper when instructed to do
so may cause a message instructing to rotate the paper. If this occurs, exit and restart
the setup and proceed carefully.
Follow the instructions in the routine and below for the six steps in the semiautomatic
setup:
CAUTION
When opening the document glass cover, take care not to disconnect the PWS serial
cable, since this can damage the connector.
V0.042
a.
Measuring a sheet of paper: After reading the initial set of instructions in the routine,
select [Start] and follow the next set of instructions.
b.
Setting top edge document glass registration
c.
Setting document glass magnification
d.
Setting document glass default lead edge registration
e.
Setting CVT magnification
f.
Setting CVT default registration (lead edge and center)
3.
After the setup completes, run test copies and check for any obvious errors in registration
or magnification. If any occur, restart the setup as explained above and proceed carefully.
4.
[Exit] the setup routine.
May 2003
4-579
ADJ 14-1, ADJ 14-2
5.
With V3.00 (L0.17.1) or later software, this procedure is now complete. With any earlier
software, continue.
6.
7.
Select Service: [Scan Service].
8.
Scroll (or Search) to Location [40], [CVT Velocity Corr] and check the value in that location:
9.
a.
If the value is not between -40 and +40, assume the setup failed. Repeat the Adjustment and proceed carefully
b.
If the value is between -40 and +40, proceed to the next step.
17. [Exit] NVM Tool (select [Exit] in the [File] menu), [Exit] the Diagnostic Navigator, and close
the session.
Double-click on Location [40] and change the value to adjust CVT magnification:
For a 40 ppm machine, subtract 9 from the [Current Value], enter that new value in
[Current Value] and select [Write NVM].
For a 65 ppm or 55 ppm machine, subtract 5 from the [Current Value], enter that
new value in [Current Value] and select [Write NVM].
NOTE: Examples for a 65 ppm or 55 ppm machine: If the NVM value was +20, the new
value after subtracting 5 would be +15. If the NVM value was +2, the new value after subtracting 5 would be -3. If the NVM value was -10, the new value after subtracting 5 would
be -15. The important thing to remember is subtracting the fixed value from a negative
number always results in a number which is MORE NEGATIVE. (For example, -15 is
MORE NEGATIVE than -10.)
10. Scroll (or Search) to Location [41], [Carr Velocity Corr] and check the value in that location:
a.
If the value is not between -20 and +20, assume the setup failed. Repeat the Adjustment and proceed carefully
b.
If the value is between -20 and +20, proceed to the next step.
11. Select Service: [Image Processing Service].

12. Scroll (or Search) to Location [4], [CVT Center] and check the value in that location:
a.
If the value is not between 2300 and 2700, assume the setup failed. Repeat the
Adjustment and proceed carefully
b.
If the value is between 2300 and 2700, proceed to the next step.
13. Scroll (or Search) to Location [5], [CVT Slow Scan Registration] and check the value in
that location:
a.
b.
14. Scroll (or Search) to Location [6], [Platen Fast Scan Registration] and check the value in
that location:
a.
b.
15. Scroll (or Search) to Location [7], [Platen Slow Scan Registration] and check the value in
that location:
a.
If the value is not between 50 and 200, assume the setup failed. Repeat the Adjustment and proceed carefully
b.
16. Be sure to save the NVM to Floppy (GP4), either now or before closing the call.
ADJ 14-2
May 2003
4-580
V0.042
5. Parts List
Overview
Introduction .....................................................................................................................
Subsystem Information ...................................................................................................
Symbology ......................................................................................................................
5-3
5-4
5-5
Parts Lists
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-17
5-18
DADF
PL 2.1A DADF (1 of 5) ....................................................................................................
PL 2.1B DADF (2 of 5) ....................................................................................................
PL 2.2 DADF (3 of 5).......................................................................................................
PL 2.3 DADF (4 of 5).......................................................................................................
PL 2.4 DADF (5 of 5).......................................................................................................
5-19
5-20
5-21
5-22
5-23
Imaging
PL 3.1 Document Glass, Scanner (1 of 2) ......................................................................
PL 3.2 Document Glass, Scanner (2 of 2) ......................................................................
5-24
5-25
Paper Supply and Feeding

PL 4.1A Paper Trays And Transports (1 of 3).................................................................
PL 4.1B Paper Trays And Transports (2 of 3).................................................................
PL 4.1C Paper Trays And Transports (3 of 3).................................................................
PL 4.2A HCF/Bypass Tray Components (1 of 2) ............................................................
PL 4.2B HCF/Bypass Tray Components (2 of 2) ............................................................
PL 4.3 Bypass Tray Components ...................................................................................
5-26
5-27
5-28
5-29
5-30
5-31
Xerographics
PL 5.1A Xerographic Components (1 of 2) .....................................................................
PL 5.1B Xerographic Components (2 of 2) .....................................................................
PL 5.2 ROS .....................................................................................................................
5-32
5-33
5-34
Print Transportation and Fusing

PL 6.1A Print Transports (1 of 4) ....................................................................................
PL 6.1B Print Transports (2 of 4) ....................................................................................
PL 6.1C Print Transports (3 of 4) ....................................................................................
V0.042
5-38
5-39
5-40
5-41
5-42
Drives, Covers and Frames
Electrical
PL 1.1A Electrical Components (1 of 12) ........................................................................
PL 1.1B Electrical Components (2 of 12) ........................................................................
PL 1.2A Electrical Components (3 of 12) ........................................................................
PL 1.2B Electrical Components (4 of 12) ........................................................................
PL 1.3A Electrical - 240/255/265 (5 of 12) ......................................................................
PL 1.3B Electrical - 240/255/265 (6 of 12) ......................................................................
PL 1.3C Electrical - 460/470 (7 of 12) .............................................................................
PL 1.4A Electrical - Atlanta Gold 240/255/265 W/Out Tag 077 (8 of 12) .......................
PL 1.4B Electrical - Atlanta Platinum 240/255/265 W/Tag 077 (9 of 12) ........................
PL 1.4C Electrical - Atlanta Platinum 460/470 (360 NLX) (10 of 12) ..............................
PL 1.5 Electrical Components (11 of 12) ........................................................................
PL 1.6 Electrical Components (12 of 12) ........................................................................
PL 6.1D Print Transports (4 of 4) ....................................................................................

PL 6.2A Fusing (1 of 3) ...................................................................................................
PL 6.2B Fusing (2 of 3) ...................................................................................................
PL 6.2C Fusing (3 of 3) (Inverter Repair Kit)...................................................................
PL 6.3 Inverter.................................................................................................................
5-35
5-36
5-37
PL 7.1 Drives, Covers And Frames (1 of 4) ....................................................................

5-43
5-44
5-45
5-46
OCT/Convenience Stapler
PL 8.1 OCT/Convenience Stapler ...................................................................................
5-47
Finisher
PL 8.2 Finisher Covers....................................................................................................
PL 8.3 Finisher Components (1 of 5) ..............................................................................
5-48
5-49
5-50
5-51
5-52
5-53
Multi Function Finisher (MFF)

PL 8.20 MFF Covers .......................................................................................................
PL 8.21 MFF Components ..............................................................................................
PL 8.22A MFF Electrical (1 of 3) .....................................................................................
PL 8.22B MFF Electrical (2 of 3) .....................................................................................
PL 8.22C MFF Electrical (3 of 3) .....................................................................................
PL 8.23 MFF Buffer/Compiler Module Assembly (1 of 9)................................................
PL 8.32 MFF Main Stapler (1 of 2) ..................................................................................
PL 8.33 MFF Main Stapler (2 of 2) ..................................................................................
PL 8.34 MFF Eject Housing Assembly............................................................................
PL 8.35 MFF Top Tray Cover Assembly .........................................................................
PL 8.36 MFF Top Tray Assembly....................................................................................
PL 8.37 MFF Master Lock ...............................................................................................
PL 8.38 MFF Booklet Maker (1 of 10) .............................................................................
May 2003
5-1
5-54
5-55
5-56
5-57
5-58
5-59
5-60
5-61
5-62
5-63
5-64
5-65
5-66
5-67
5-68
5-69
5-70
5-71
5-72
5-73
5-74
5-75
5-76
5-77
Parts List

PL 8.47 MFF Booklet Maker (10 of 10) ...........................................................................
PL 8.48 MFF Booklet Maker Exit Assembly (1 of 3) .......................................................
PL 8.51 MFF Tri-folder Assembly ...................................................................................
PL 8.52 MFF Booklet Maker Exit Tray Assembly............................................................
PL 8.53 MFF Main Tray Assembly (1 of 2) .....................................................................
PL 8.54 MFF Main Tray Assembly (2 of 2) .....................................................................
PL 8.55 MFF Compiler/Tamper.......................................................................................
5-78
5-79
5-80
5-81
5-82
5-83
5-84
5-85
5-86
5-87
5-88
5-89
5-90
5-91
Noise/Ozone/Heat/Air/Dirt (NOHAD)
PL 9.1 Machine Cooling & Filters....................................................................................
5-92
Common Hardware
Common Hardware .........................................................................................................
Parts List
5-93
May 2003
5-2
V0.042
Introduction
Other Information
Overview
Abbreviations
The Parts List section identifies all part numbers and the corresponding location of all spared
subsystem components.
Abbreviations are used in the parts lists and the exploded view illustrations to provide
information in a limited amount of space. The following abbreviations are used in this manual:
Table 1 Definitions
Organization
Abbreviation
Parts Lists
Each item number in the part number listing corresponds to an item number in the related
illustration. All the parts in a given subsystem of the machine will be located in the same
illustration or in a series of associated illustrations.
Electrical Connectors and Fasteners
Meaning
A3
297 x 420 Millimeters
A4
A5
AD
Auto Duplex
AWG
American Wire Gauge
DT65/DP65
DocuTech 65 DocuPrint 65
EMI
Electro Magnetic Induction
Common Hardware
GB
Giga Byte
The common hardware is listed in alphabetical order by the letter or letters used to identify
each item in the part number listing and in the illustrations. Dimensions are in millimeters
unless otherwise identified.
KB
Kilo Byte
MB
Mega Byte
MM
Millimeters
MOD
Magneto Optical Drive
This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used
in the machine. A part number listing of the connectors is included.
Part Number Index

This index lists all the spared parts in the machine in numerical order. Each number is followed
by a reference to the parts list on which the part may be found.
MFF
MultiFunction Finisher
NOHAD
Noise Ozone Heat Air Dirt
PL
Part List
P/O
Part of
R/E
Reduction/Enlargement
REF:
Refer to
SCSI
Small Computer Systems Interface
W/
With
W/O
Without
Table 2 Operating Companies
Operating Companies
Abbreviation
Meaning
AO
Americas Operations
USMG
United States Marketing Operations
USO
United States Operations
XCL
Xerox Canada Limited
XE
Xerox Europe
Symbology
Symbology used in the Parts List section is identified in the Symbology section.
V0.042
May 2003
5-3
Parts List
Introduction
Service Procedure Referencing
Subsystem Information
If a part or assembly has an associated repair or adjustment procedure, the procedure number
will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)
Use of the Term "Assembly"

The term "assembly" will be used for items in the part number listing that include other itemized
parts in the part number listing. When the word "assembly is found in the part number listing,
there will be a corresponding item number on the illustrations followed by a bracket and a
listing of the contents of the assembly.
Brackets
A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The
item number of the assembly or kit precedes the bracket; the item numbers of the piece parts
follow the bracket.
Tag
The notation "W/Tag" in the parts description indicates that the part configuration has been
updated. Check the change Tag index in the General Information section of the Service Data
for the name and purpose of the modification.
In some cases, a part or assembly may be spared in two versions: with the Tag and without the
Tag. In those cases, use whichever part is appropriate for the configuration of the machine on
which the part is to be installed. If the machine does not have a particular Tag and the only
replacement part available is listed as "W/Tag," install the Tag kit or all of the piece parts. The
Change Tag Index tells you which kit or piece parts you need.
Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate
number on the Tag matrix.
Parts List
Introduction, Subsystem Information
May 2003
5-4
V0.042
Symbology
A Tag number within a circle pointing to an item number shows that the part has been changed
by the tag number within the circle (Figure 1). Information on the modification is in the Change
Tag Index.
A Tag number within a circle having a shaded bar and pointing to an item number shows that
the configuration of the part shown is the configuration before the part was changed by the Tag
number within the circle (Figure 2).
Figure 2 Without Tag Symbol

Figure 1 With Tag Symbol
V0.042
May 2003
5-5
Parts List
Symbology
A tag number within a circle with no apex shows that the entire drawing has been changed by
the tag number within the circle (Figure 3). Information on the modification is in the Change Tag
Index.
A tag number within a circle with no apex and having a shaded bar shows that the entire
drawing was the configuration before being changed by the tag number within the circle (Figure
4).
Figure 3 Entire Drawing With Tag Symbol
Figure 4 Entire Drawing Without Tag Symbol
Parts List
Symbology
May 2003
5-6
V0.042
PL 1.1A Electrical Components (1 of

12)
Item
1
Part
101K41803
101K41815
101K42937
101K42947
101K42901
101K42912
2
3
110E07000
110E08780
5
6
7
110K13360
110K08682
123E01301
891E27421
891E33411
891E34811
891E34821
892E26900
892E08790
892E08760
892E27860
892E07570
892E08770
892E07560
892E07540
892E07550
892E27870
892E08780
048E51441
048E51461
048E59840
048E59850
048E59830
048E51451
048E51490
048E51471
10
Description
UI Control Panel Assembly (NASG)
(240/255/265) (W/TAG 082, TAG 089,
TAG 095, TAG 099) (REP 02-1)
UI Control Panel Assembly (XE) (240
ST) (255/265) (W/TAG 082, TAG 089,
TAG 095, TAG 099) (REP 02-1)
(460/470) (W/TAG 115, TAG 129, TAG
133, TAG 140) (REP 02-1)
UI Control Panel Assembly (XE)
(460/470) (W/TAG 115, TAG 129, TAG
133, TAG 140) (REP 02-1)
(460/470) (W/TAG 102) (W/O TAG 115)
(REP 02-1)
UI Control Panel Assembly (XE)
(460/470) (W/TAG 102) (W/O TAG 115)
(REP 02-1)
Instant OFF Switch
Front Door Interlock Switch (W/TAG
011)
Power ON/OFF Switch (W/TAG 115)
Power ON/OFF Switch (W/O TAG 115)
UI Control Panel (P/O PL 1.1A Item 1)
Backlight (240/255/265) (W/O TAG 082)
UI Keypad Overlay (NASG)
(240/255/265)
UI Keypad Overlay (XE) (240/255/265)
UI Keypad Overlay (Spanish) (NASG)
(240/255/265)
UI Keypad Overlay (Portuguese)
(NASG) (DC/ST)
UI Keypad Overlay (French) (NASG)
(240/255/265)
(NASG) (460/470) (W/O TAG 115)
UI Keypad Overlay (English) (NASG)
(460/470) (W/O TAG 115)
(460/470) (W/O TAG 115)
(NASG) (460/470) (W/TAG 115)
UI Keypad Overlay MN (460/470) (W/O
TAG 115)
(460/470) (W/TAG 115)
UI Keypad Overlay (English) (NASG)
(460/470) (W/TAG 115)
UI Keypad Overlay MN (460/470)
(W/TAG 115)
(460/470) (W/TAG 115)
(460/470) (W/O TAG 115)
Logo (NASG) (240DC)
Logo (240ST)
Logo (255DC)
Logo (255LP)
Logo (255 ST)
Logo (265 DC)
Logo (265 LP)
Logo (265 ST)
UI Processor PWB (P/O PL 1.1A Item 1)
(W/TAG 082) (REP 02-2)
UI LCD Module (P/O PL 1.1A Item 1)
(W/TAG 082) (REP 02-3)
V0.042
May 2003
5-7
Parts List
PL 1.1A
PL 1.1B Electrical Components (2 of

12)
Item
Part
Description
1
2
3
4
5
6
7
8
101K40981
600K75280
600K75270
162K51610
Removable Disk Drive Assembly

Dual Drive Enclosure
ESS Carrier Kit
IOT Carrier Kit
ESS Carrier (P/O PL 1.1B Item 3)
IOT Carrier (P/O PL 1.1B Item 4)
Removable Disk Drive Cable
ESS Hard Disk Drive (P/O PL 1.1B
Item 3)
Image Disk Drive (P/O PL 1.1B
Item 4)
Parts List
PL 1.1B
May 2003
5-8
V0.042
PL 1.2A Electrical Components (3 of

12)
Item
Part
Description
101K40501
101K42660
101K40491
101K40511
117E17820
117K22761
098S04470
098S04469
3
4
105K26690
117K18429
5
6
105K13095
105K24861
7
8
105K18311
117K28610
117K25305
9
10
11
12
117K22913
098S04279
105K24881
162K68110
13
606K07440
AC Distribution Panel (NASG)

(240) (W/TAG 053) (REP 01-2)
AC Distribution Panel (XE) (240
ST) (255/265) (DT65) (460/470)
(W/TAG 105) (REP 01-2)
AC Distribution Panel (NASG)
(255/265) (DT65) (460/470)
(W/TAG 053) (REP 01-2)
AC Distribution Panel (XE) (240 ST,
255/265, DT65, 460/470) (W/TAG
053) (W/O TAG 105) (REP 01-2)
Power Cord (15A) (NASG) (240)
Power Cord (20A) (NASG)
(255/265) (DT65) (460/470)
AC Adapter Kit (30A to 20A)
(208VAC) (NASG)
AC Adapter Kit (30/25A to 10A)
(220-240VAC) (XE)
LVPS (REP 01-3)
Raster Output Scanner Video
Cable
Charge HVPS (PS2) (REP 09-6)
Transfer/Detack HVPS (PS4) (REP
09-8)
Developer HVPS (REP 09-7)
Portable Work Station Cable
(Printer) (255/265 LP) (DT65)
Portable WorkStation Cable
(240/255/265 DC/ST) (W/TAG 104)
Distribution Cable
CRUM Bypass Enablement Kit
Flicker Control PWB
Flicker Control DC Harness
(W/TAG 105)
Flicker Solution Kit (W/TAG 105)
NOTE: Includes Jumper to enable Portable Workstation AC

Outlet Kit
V0.042
May 2003
5-9
Parts List
PL 1.2A
PL 1.2B Electrical Components (4 of

12)
Item
Part
Description
160K39551
162K23144
162K29610
162K22642
162K22651
105K17930
8
9
708W03501
600K76080
10
600K76050
600K76060
HCF Heater PWB (W/TAG 299,

TAG 300)
HCF Heater Enable Harness
(W/TAG 300)
HCF Paper Heater Harness
(W/TAG 300)
Part of AC Distribution Panel (REF:
PL 1.2A Item 1)
Heater Enable Harness (W/TAG
299, TAG 300)
AC Power Harness (W/TAG 299,
TAG 300)
IOT Paper Heater LVPS (XE)
(W/TAG 299)
Fuse (.5A slo blo) (W/TAG 300)
IOT Paper Heater Kit (XE) (W/TAG
299)
HCF Paper Heater Kit (NASG)
(W/TAG 300)
HCF Paper Heater Kit (XE) (W/TAG
300)
Parts List
PL 1.2B
May 2003
5-10
V0.042
PL 1.3A Electrical - 240/255/265 (5 of

12)
Item
Part
Description
160K40901
2
3
600K88170
162K37912
162K56780
162K28521
162K37930
162K21913
9
10
11
003E40760
ESS PWB (240 ST/255/265

ST/LP) (REP 16-2)
Disk Support Bracket (Not Spared)
Common ESS/Image Hard Disk
Drive Kit (NOTE: This kit contains
only one disk drive that can replace
either the Image Disk Drive or the
ESS Disk Drive) (W/TAG 091)
ESS Disk Drive / Image Disk Drive
(P/O PL 1.3A Item 3) (REP 16-1
REP 19-1)
Card Cage Harness (LV)
(240/255/265) (W/TAG 051)
Card Cage Harness (LV) (DT65)
(W/TAG 051)
Image Disk Cable
(240/255/265/DT65)
ESS Hard Disk Drive Power Cable
(240 ST/255/265 ST/LP)
ESS Hard Disk Drive Cable (240
ST/255/265 ST/LP)
Card Cage Chassis (Not Spared)
Pin Hinge
Card Cage Rear Cover (Not
Spared)
V0.042
May 2003
5-11
Parts List
PL 1.3A
PL 1.3B Electrical - 240/255/265 (6 of

12)
Item
Part
Description
1
2
733W03696
733W03678
3
4
160K30190
160K37510
160K39411
160K54540
160K50230
8
9
162K44890
162K59700
Part of ESS PWB (REF: PL 1.3A)

ESS DRAM SIMM (32MB) (QTY 2)
(ST/LP) (REP 16-3)
ESS DRAM SIMM (16MB) (QTY 2)
(REP 16-3)
PCI Bus Adapter PWB (REP 16-5)
Image Processing Accelerator
PWB (NOTE: 160K30190 is a
prerequisite to installing 4, 5, and 6)
(REP 16-4)
Token Ring PWB (ST/LP) (NOTE:
160K30190 is a prerequisite to
installing 4, 5, and 6) (REP 16-4)
100mb Ethernet PWB (NOTE:
160K30190 is a prerequisite to
installing 4, 5, and 6) (REP 16-4)
Bykal Remote PWB (DT65) (REP
16-6)
Token Ring Adapter Cable
100mb Ethernet Adapter Cable
Parts List
PL 1.3B
May 2003
5-12
V0.042
PL 1.3C Electrical - 460/470 (7 of 12)

Item
Part
Description
160K88962
733W14691
604K00370
600K88170
121E17800
160K73490
160K73110
113K02860
8
9
10
11
162K58940
162K58950
162K58970
962K03340
162K58961
12
13
162K58980
133E59650
14
15
030K68351
16
17
18
ESS PWB (W/TAG 122, TAG 139,

TAG 141) (REP 16-2)
ESS DRAM DIMM (64MB)
(460/470) (REP 16-7)
ESS/Image Common Hard Disk
Drive Kit (9.1 GB) (460/470 ST)
(NOTE: This kit contains only one
disk drive that can replace either
the ESS Disk Drive or the Image
Disk Drive) (W/TAG 103)
Common ESS/Image Hard Disk
Drive Kit (4.5 GB) (NOTE: This kit
contains only one disk drive that
can replace either the Image Disk
Drive or the ESS Disk Drive)
(W/TAG 091) (W/O TAG 103, TAG
122)
ESS Disk Drive (REP 16-1), Image
Disk Drive (REP 19-1) (P/O PL
1.3C Item 3)
ESS System Hard Disk Drive (ST)
(W/TAG 122) (REP 16-1)
Token Ring PWB W/Adapter
(Optional) (ST) (REP 16-9)
Image Process Accelerator PWB
W/Adapter (Optional) (460/470 ST)
(REP 16-8)
Disk Adapter (68 to 50 Pin)
(460/470)
Card Cage harness (LV) (460/470)
Disk Power Harness (460/470 DC)
Disk Power Harness (460/470 ST)
ESS Disk Drive Cable (460/470 ST)
(W/TAG 122)
ESS Disk Drive Cable (460/470 ST)
(W/O TAG 122)
Image Disk Drive Cable (460/470)
SDRAM DIMM (32MB) (Optional)
(REP 16-7)
RDD Adapter Bracket (460/470)
Image Disk Lower Rail (Not
Spared)
ESS Disk Upper Rail (Not Spared)
ESS Disk Lower Rail (Not Spared)
Image Disk Upper Rail (Not
Spared)
V0.042
May 2003
5-13
Parts List
PL 1.3C
PL 1.4A Electrical - Atlanta Gold

240/255/265 W/Out Tag 077 (8 of 12)
Item
1
Part
160K39309
600K81900
2
3
117K28232
160K37503
160K08504
160K09002
733W05744
133E50060
117K28272
152S05901
152S05903
152S05906
152S05907
152S05909
152S05910
152S05911
152S05912
152S05913
733W06562
733W06557
10
11
160K59430
12
606K07132
Parts List
PL 1.4A
Description
Main Control PWB (Gold) (240/255/265)
(NOTE: Machines W/O TAG 015 order
Item 1 and Kit 606K06710) (W/TAG 065,
TAG 073, TAG 074, TAG 089) (W/O TAG
077) (REP 03-4)
Platinum Upgrade Kit (Use if 160K39309
is not available) (W/TAG 095)
PCI Link Cable (DT65)
Auto Segmentation PWB (IPSI Daughter
PWB) (Not Spared) (W/O TAG 015, TAG
042) (REP 03-2)
Accessory PWB (NASG) (REP 03-3)
Rotation SRAM SIMM (240/255/265)
(DT65) (REP 03-5)
EPC DRAM SIMM (16MB) (REP 03-6)
EPC DRAM SIMM (32MB)
(240/255/265) (W/O TAG 077) (REP
03-6)
Sixth Sense Phone Cord (ACO/NASG)
Sixth Sense Phone Cord (French)
Sixth Sense Phone Cord (Dutch)
Sixth Sense Phone Cord
(Norwegian/Finnish)
Sixth Sense Phone Cord (Swedish)
Sixth Sense Phone Cord (Danish)
Sixth Sense Phone Cord (Russian)
Sixth Sense Phone Cord (Swiss)
Sixth Sense Phone Cord (Belgian)
Sixth Sense Phone Cord (Austrian)
NVM RAM Chip (32KB) (240/255/265)
(W/TAG 015) (W/O TAG 077) (REP
03-7)
NVM RAM Chip (128KB) (240/255/265)
(W/TAG 036)
Connector (Low Profile Gold) (Not
Spared)
Card Cage Front Cover (Not Spared)
Electronic Hole Removal PWB (DC)
(W/TAG 296)
Electronic Hole Removal Kit (W/TAG
296)
May 2003
5-14
V0.042
PL 1.4B Electrical - Atlanta Platinum

240/255/265 W/Tag 077 (9 of 12)
Item
Part
Description
160K65433
2
3
117K28232
160K64610
160K37503
160K08504
133E59650
160K60133
117K28272
606K07290
Main Control PWB (Platinum)

(240/255/265 DC/ST) (W/TAG 077,
TAG 097) (REP 03-11)
PCI Link Cable (DT65)
(240/255/265 DC/ST) (W/TAG 080)
(REP 03-2)
Accessory PWB (NASG) (REP
03-3)
EPC SDRAM DIMM (32MB)
(240/255/265) (DT65) (W/TAG 077)
(REP 03-9)
Software/NVM Module
(240/255/265) (W/TAG 077, TAG
089, TAG 095) (REP 03-10)
Sixth Sense Phone Cord
(ACO/NASG)
Card Cage Front Cover (Not
Spared)
Electronic Hole Removal Kit
(NOTE: 600K75950 CVT Dirt
Reduction Kit is a prerequisite to
installing 606K07290) (W/TAG 075,
TAG 080)
V0.042
May 2003
5-15
Parts List
PL 1.4B
PL 1.4C Electrical - Atlanta Platinum

460/470 (360 NLX) (10 of 12)
Item
Part
Description
160K80762
160K71892
160K37503
160K08504
606K07431
160K72401
160K65342
160K73838
160K73336
133E59650
133E61830
10
Main Control PWB (Platinum

NLX860) (460/470) (W/TAG 131)
(REP 03-11)
Main Control PWB (Platinum
NLX360) (460/470) (W/O TAG 131)
(REP 03-11)
Accessory PWB (NASG) (REP
03-3)
(REF: PL 2.4 Item 7) (460/470)
(NOTE: Must install W/Tag 075
CVT Drive on Glass Kit) (W/TAG
285) (REP 03-12)
Riser PWB (460/470 ST) (W/TAG
122) (REP 03-13)
Riser PWB (460/470 ST) (W/O TAG
122) (REP 03-13)
NLX860 Software/NVM Module
(460/470) (W/TAG 131, TAG 135)
(REP 03-10)
NLX360 Software/NVM Module
(460/470) (W/TAG 102,129) (W/O
TAG 131) (REP 03-10)
EPC SDRAM DIMM (32MB) (REP
03-9)
SDRAM DIMM (128 MB Upgrade)
(Optional)
Main Card Cage Cover (Not
Spared) (460/470)
Card Cage Chassis (Not Spared)
(460/470)
Card Cage Distribution Cable (Not
Spared) (460/470)
Support Bracket (Not Spared)
(460/470)
Parts List
PL 1.4C
May 2003
5-16
V0.042
PL 1.5 Electrical Components (11 of

12)
Item
Part
Description
1
2
162K29434
3
4
162K14268
110E07780
5
6
160K72974
7
8
9
10
11
12
13
14
160K43300
162K38220
162K39001
162K38982
162K40850
103K01030
604K04261
604K04250
15
604K05690
16
Convenience Stapler Harness

2 Input IIOC PWB (P/O PL 1.5 Item
13)
IIOC Harness (BUS 1)
Input/Output Devices Safety
Interlock
NOHAD Thermostat
SCAM PWB (W/TAG 108) (REP
03-1)
Distribution PWB (REP 01-1)
ROS Power Harness
IIOC Harness (BUS 1)
IIOC Harness (BUS 0 ES)
IIOC Harness (255/460 Only)
Jumper (255/460 Only)
2-Input IIOC PWBs Kit (Contains 3)
Convenience Stapler Power
Harness Kit (Contains 3) (W/TAG
112)
DADF Counterbalance Ground Kit
(W/TAG 119)
DADF Ground Harness (P/O PL 1.5
Item 15)
V0.042
May 2003
5-17
Parts List
PL 1.5
PL 1.6 Electrical Components (12 of

12)
Item
Part
Description
2
3
4
5
6
7
8
160K28652
162K07274
162K14282
113K02047
113E16841
600K75681
10
11
12
13
14
708W04001
160K54102
127K40900
130E06980

13) (Contains 3)
4 Input IIOC PWB
Decurler IIOC Harness
Decurler Harness
AC Drawer Connector
DC Drawer Connector
Inverter IIOC Harness
Portable Workstation AC Outlet Kit
(NOTE: 600T02145 (NASG) AC
Adapter Cord is required to use the
Service Outlet)
AC Service Outlet (P/O PL 1.6 Item
8)
Safety Label 115V (P/O PL 1.6
Item 8)
Fuse (1A Slo Blo)
Drives Plate IIOC PWB
Tray Feed Motor
Tray Stack Height Sensor
Parts List
PL 1.6
May 2003
5-18
V0.042
PL 2.1A DADF (1 of 5)
Item
Part
Description
022S06755
022S06688
048K53292
802K41360
050K44913
050K53570
130K53461
050K39506
004K00914
004K01192
9
10
031E08720
019K04352
11
12
011E07631
13
14
15
125E02181
600K89640
16
17
DADF Assembly (W/TAG 115)

(REP 05-2,ADJ 14-2)
DADF (W/O TAG 115) (REP
05-2,ADJ 14-2)
DADF Main Cover (W/O TAG 115)
DADF Main Cover (W/TAG 115)
Document Input Tray Assembly
(W/O TAG 115) (REP 05-6)
Document Input Tray Assembly
(W/TAG 115) (REP 05-6)
Document Input Tray Top (P/O PL
2.1A Item 3)
Input Tray Sensor 1, 2 (Q11) (Q12),
Side Guide Sensor 1, 2 (Q7) (Q6)
(240/255/265 DC/ST)
Document Input Tray Bottom (P/O
PL 2.1A Item 3)
Document Glass Cover/Document
Output Tray (order item 8 also)
Document Glass Pad (white) (REP
14-7)
Document Glass Pad (grey) (REP
14-7)
Document Restack Guide (DC/ST)
Anti-kickback Pad (DC/ST)
(W/TAG 020)
Document Glass Cover Latch
Magnet Plate (Top) (P/O PL 2.1A
Item 7)
Bottom Plate (P/O PL 2.1A Item 7)
Static Eliminator
Document Input Tray Side Guides
Kit
Side Guide - Rear (P/O PL 2.1A
Item 15)
Side Guide - Front (P/O PL 2.1A
Item 15)
V0.042
May 2003
5-19
Parts List
PL 2.1A
PL 2.1B DADF (2 of 5)
Item
Part
Description
048K53378
130E06851
130E10610
001K56397
8
9
606K06880
10
11
12
13
14
006E42535
003K10012
130E02271
15
16
17
18
019E27452
031K05390
19
604K16900
Part of DADF Assembly (REF: PL

2.1A Item 1) (REP 05-2,ADJ 14-2)
(W/TAG 037) (REP 05-3)
Input Tray Exit Sensor (Q1) DADF
Registration Gate Sensor (Q2)
(ADJ 14-2)
CVT Start of Scan Sensor (Q3)
(ADJ 14-2)
Take Away Roll Idler Baffle (P/O
PL 2.1B Item 2)
DADF Top Cover (P/O PL 2.1B
Item 2)
DADF Registration Deskew
Assembly (W/TAG 078) (REP
05-5)
Registration Deskew Transport
(P/O PL 2.1B Item 6)
DADF Frame (P/O PL 2.1B Item 1)
DADF Deflector Fingers (5/Kit)
(optional) (W/TAG 037)
DADF Top Cover Hinge Pin
DADF Handle Assembly
Locator Pin (P/O PL 2.1B Item 1)
CVT Spacer Arm (P/O PL 2.4 Item
7)
Drive On Glass Roll Drive Belt
(P/O PL 2.4 Item 7)
Clip
Drive On Glass Roll Tensioner
Locator Pin Support Bracket (P/O
PL 2.1B Item 1)
Counterbalance Hinge Kit
Parts List
PL 2.1B
May 2003
5-20
V0.042
PL 2.2 DADF (3 of 5)
Item
Part
Description
022K56016
3
4
108R00149
108R00151
130K53461
7
8
015K27374
9
10
006K17191
11
12
130E06851
600K76000
13
121E10383
14
15
16
17
18
19

2.1A Item 1)
DADF Feeder Assembly (W/TAG
048) (REP 05-4)
DADF Feeder (P/O PL 2.2 Item 2)
(NASG)
DADF Feed Roll Cartridge (XE)
Feed Roll Cartridge Release Lever
(P/O PL 2.2 Item 2,PL 2.2 Item 12)
Document Loaded Sensor (Q5)
Document Feeder Top Cover
Sensor (Q9) (NOTE:Actuator for
Q9 P/O PL 2.1B Item 5)
DADF Feed Motor (REP 05-8)
Document Loaded Sensor Actuator
(P/O PL 2.2 Item 2)
DADF Exit Shaft (REP 05-7)
DADF Feed Nip Spring (P/O PL
2.2 Item 2)
DADF Exit/Invert Sensor (Q4)
Feed Roll Cartridge Release Lever
Kit (REP 05-10)
DADF Exit Clutch (60T) (REP
05-11)
Inverter Clutch (P/O PL 2.2 Item 9)
Shaft (P/O PL 2.2 Item 9)
DADF Feed Clutch/Shaft (P/O PL
2.2 Item 2)
Flywheel (P/O PL 2.2 Item 2)
DADF Paper Feed Roll Drive
Coupling (P/O PL 2.2 Item 2)
Spring (P/O PL 2.2 Item 2)
V0.042
May 2003
5-21
Parts List
PL 2.2
Item
Part
Description
2
3
162K11386
4
5
6
7
160K44432
423W02349
423W01349
606K07220
10
11
606K06890
12
13
14
604K04490
15

2.1A Item 1)
DADF Harness (W/TAG 119)
CVT Motor (P/O PL 2.3 Item 14)
(ADJ 14-2)
DADF PWB
Exit Clutch Drive Belt
DADF CVT Motor Grounding Kit
(W/TAG 084)
Shield (P/O PL 2.3 Item 7,PL 2.3
Item 14)
Ground Bracket (P/O PL 2.3 Item
7)
Retainer (P/O PL 2.3 Item 7)
DADF Shafts Grounding Kit
(W/TAG 039)
Ground Wire (P/O PL 2.3 Item 11)
Ground Tab (P/O PL 2.3 Item 11)
CVT Motor/Scan Carriage Motor Kit
(NOTE: Machines W/O Tag 084,
order and install CVT Motor
Grounding Kit 606K07220 (except
for the shield, use the shield
supplied with 606K04490))
Bearing Retainer (P/O PL 2.3 Item
1)
Parts List
PL 2.3
May 2003
5-22
V0.042
Item
Part
Description
5
6
7
055K24065
055K24075
600K67893
604K08490

2.1A Item 1)
Retainer Clip (Item C in
600K57931) (P/O PL 2.4 Item 1)
CVT Drive ON Glass Roll (P/O PL
2.4 Item 1,PL 2.4 Item 7)
CVT Ski (P/O PL 2.4 Item 1,PL 2.4
Item 7)
Left CVT Baffle
Right CVT Baffle
CVT Drive ON Glass Kit (REF: PL
1.4C Item 3) (NOTE: Must install
with 606K07431 Electronic Hole
Removal PWB) (W/TAG 016, TAG
060, TAG 075, TAG 296) (REP
05-9)
CVT Drive on Glass Kit (3 ski
design)
V0.042
May 2003
5-23
Parts List
PL 2.4
PL 3.1 Document Glass, Scanner (1 of

2)
Item
Part
Description
062S02384
062S02389
062S02385
048K36825
802K22690
002E62856
802E20820
801K00301
017K03361
017K01747
001K58228
600K75950
7
8
Scanner Assembly (RIS) (240)

(255/265/460/470) (W/TAG 115)
(255/265/460/470) (W/O TAG 115)
Scanner Main Cover (W/O TAG
115) (REP 14-6)
Scanner Main Cover (W/TAG 115)
(REP 14-6)
Scanner Rear Cover (W/O TAG
115)
Scanner Rear Cover (W/TAG 115)
Scanner Top Frame (P/O PL 3.1
Item 1) (REP 14-5)
Document Glass Frame (460/470)
(NOTE: 017K03361 is an alternate
part) (W/O TAG 115) (REP
14-4,ADJ 14-2)
Document Glass Frame (Alternate
to 801k00301) (460/470) (W/TAG
115) (REP 14-4,ADJ 14-2)
Document Glass Frame (Primer 1K58228 is the alternate part.)
(W/TAG 076) (REP 14-4,ADJ 14-2)
Document Glass Frame (NASG)
(NOTE: Alternate to 17K01747)
CVT Dirt Reduction Kit (NOTE:
There are six labels and strips per
kit, use one each per machine )
(W/TAG 076)
Viewing Label (P/O PL 3.1 Item 6)
CVT Dirt Streaks Label (34mm)
(P/O PL 3.1 Item 6)
CVT Dirt Streaks Label (32mm)
(REF: PL 1.4A Item 12) (W/TAG
076)
Parts List
PL 3.1
May 2003
5-24
V0.042
PL 3.2 Document Glass, Scanner (2 of

2)
Item
Part
Description
600K54633
600K54643
2
3
003E27481
4
5
117K18438
105K17072
122K01635
9
10
11
12
130K53461
162K37971
604K13050
13
14
15
604K04490
16
Image Module, Scanner Video

Cable Kit (240) (W/TAG 018) (REP
14-1,ADJ 14-1 ADJ 14-2)
Image Module, Scanner Video
Cable Kit (255/265/460/470 Only)
(W/TAG 018) (REP 14-1,ADJ 14-1
ADJ 14-2)
Glass Glide
Image Module (P/O PL 3.1 Item 1,
PL 3.2 Item 1) (240/265) (REP
14-1,ADJ 14-1 ADJ 14-2)
Scanner Video Cable
Illumination Lamp Power Supply
(REP 14-8)
Scan Carriage Motor (P/O PL 3.2
Item 15, PL 3.1 Item 1)
Illumination Lamp Module (REP
14-2)
Lamp Power Supply Cover (P/O PL
3.1 Item 1)
SOS Sensor (ADJ 14-2)
Scanner IOT Harness
Scan Carriage Cable kit
Scan Carriage Cable - Rear (short)
(P/O PL 3.2 Item 11)
Scan Carriage Cable - Front (long)
Cable Pulley (P/O PL 3.2 Item 11)
CVT Motor/Scan Carriage Motor Kit
(REP 14-9,ADJ 14-2)
Ground Clip (P/O PL 3.2 Item 15)
V0.042
May 2003
5-25
Parts List
PL 3.2
PL 4.1A Paper Trays And Transports

(1 of 3)
Item
1
Part
050K35159
050K53000
050K46211
2
3
108R00148
108R00150
007K12921
5
6
7
055K25741
055K23983
022K51135
022K50958
802E19480
048K53341
10
11
12
13
14
001K58033
096E62511
096E62521
096E62531
096E62501
600K89760
130K53452
15
16
17
18
103K01210
038E16214
022K53414
606K07030
19
20
21
22
038K10882
23
24
038K13120
109R00658
038E15922
038E22950
Parts List
PL 4.1A
Description
Paper Tray Assembly (460/470) (W/O
TAG 115) (REP 07-2,ADJ 8-1B)
Paper Tray Assembly (240/255/265)
(W/O TAG 115) (REP 07-2,ADJ
8-1B)
Paper Tray Assembly (460/470)
(W/TAG 115) (REP 07-2,ADJ 8-1B)
Paper Tray (P/O PL 4.1A Item 1)
Paper Feed Roll Cartridge (NASG)
Paper Feed Roll Cartridge (XE)
Paper Feed Drives Plate (NOTE: This
part is preconfigured for a 40 PPM
machine. A jumper must be removed
from this part for it to function correctly in
a 65 PPM machine) (REP 07-1)
Lower Guide (W/TAG 002, TAG 066)
Upper Guide Assembly (W/TAG 066)
Vertical Transport (REP 08-1,ADJ
8-1B)
Registration Transport Assembly (REP
08-2,ADJ 8-1A)
Paper Tray Front Cover (W/TAG 115)
Paper Tray Front Cover (W/O TAG
115)
Paper Tray Rail (Left and Right)
Paper Tray 1 Label (W/O TAG 115)
Paper Tray Slide KIt (2 slides/kit)
Wait Station Sensor
Upper Guide (P/O PL 4.1A Item 6,PL
4.1A Item 20)
IOT Paper Heater (XE) (W/TAG 299)
Duplex Guide
Paper Tray Feed Head
2/4 Hole Paper Feed Guide Kit (W/TAG
066)
Lower/Upper Guide Assembly (P/O PL
4.1A Item 20)
Lower/Upper Guide (P/O PL 4.1A Item
18)
Paper Tray Slide (P/O PL 4.1A Item
1,PL 4.1A Item 22)
Front Side Guide (240/255/265
DT/DP65)
Front Side Guide (460/470)
Tabs Tray Insert Kit
Rear Side Guide (blue)
Rear Side Guide (green) (460/470)
May 2003
5-26
V0.042
PL 4.1B Paper Trays And Transports

(2 of 3)
Item
Part
Description
2
3
4
5
130E07610
604K03950
604K04180
7
8
9
10
604K03960
11
12
13
14
121E16950
15
16
Part of Registration Transport

(REF: PL 4.1A Item 8)
Registration Sensor (S2)
Registration Transport Handle Kit
Handle (P/O PL 4.1B Item 3)
Wire Form Latch (P/O PL 4.1B Item
3)
Mylar Registration Kit (5 Guides /
kit)
Registration Transport Gear Kit
Clutch Gear (P/O PL 4.1B Item 7)
Idler Gear (P/O PL 4.1B Item 7)
Pre-Registration Gear (P/O PL
4.1B Item 7)
50T Idler Gear (P/O PL 4.1B Item
7)
Entrance Gear (P/O PL 4.1B Item
7)
Registration Clutch (REP 08-8)
Clutch Bracket (P/O PL 4.1B Item
1)
Latch Pin (P/O PL 4.1B Item 1)
Sensor Bracket (P/O PL 4.1B Item
1)
V0.042
May 2003
5-27
Parts List
PL 4.1B
PL 4.1C Paper Trays And Transports

(3 of 3)
Item
Part
Description
606K06921
5
6
7
600K89530
P/O Paper Tray Assembly (REF:

PL 4.1A Item 1)
Small Paper Size Sensing Kit
(W/TAG 063)
Switch Actuator (P/O PL 4.1C Item
2)
Small Paper Actuator (P/O PL
4.1C Item 2)
Actuator Link (P/O PL 4.1C Item 1)
Paper Tray Gear Kit
Gear Coupling 16T (P/O PL 4.1C
Item 6)
Segment Gear 42T (P/O PL 4.1C
Item 6)
Tray Locator Pin (P/O PL 4.1C Item
1)
Parts List
PL 4.1C
May 2003
5-28
V0.042
PL 4.2A HCF/Bypass Tray

Components (1 of 2)
Item
Part
Description
059K29130
022K57980
802K21630
802K21620
3
4
5
6
026K01260
110E07780
048K74071
048K57030
7
8
9
048E43630
050P02096
103K01130
103K01120
10
11
12
048K72722
13
048K74061
HCF/Bypass Tray Assembly

(W/Front Door - H4D) (NOTE: E2Y
is a HCF W/O Front Door. H4D is a
HCF W/Front Door) (W/TAG 115)
(REP 07-3)
HCF/Bypass Tray Assembly (W/O
Front Door - E2Y) (NOTE: E2Y is a
HCF W/O Front Door. H4D is a
HCF W/Front Door) (REP 07-3)
HCF L4L Unit (W/O TAG 115)
HCF Front Cover Assembly
(W/Front Door) (W/TAG 115)
HCF Front Cover Assembly
(W/Front Door) (W/O TAG 115)
Stud
HCF Top Cover (W/TAG H003)
HCF Front Cover (W/O Front Door)
(REP 07-8)
HCF Rear Cover (REP 07-7)
Retainer
HCF Paper Heater (NASG)
(W/TAG 300)
HCF Paper Heater (XE) (W/TAG
300)
HCF Front Cover (P/O PL 4.2A
Item 2)
HCF Front Door
HCF Rear Panel (P/O PL 4.2A Item
13)
HCF Rear Cover Assembly (REP
07-7)
V0.042
May 2003
5-29
Parts List
PL 4.2A
PL 4.2B HCF/Bypass Tray

Components (2 of 2)
Item
1
Part
055E43601
022K64440
022K79371
5
6
108R00148
108R00150
050K46440
050K34966
007K12600
127K41132
10
160K45082
600K70770
11
600K75870
12
13
030K67141
809E30770
14
15
16
17
18
19
20
606K06911
606K07181
21
Parts List
PL 4.2B
Description
Part of HCF/Bypass Tray Assembly
(REF: PL 4.2A Item 1)
HCF Paper Handling Baffle (W/TAG
H006 W/O TAG H004)
HCF Feeder (W/TAG H005, TAG H006)
(REP 08-5)
Bypass Tray Feeder (W/TAG H005,
TAG H006) (REP 08-4)
Bushing (P/O PL 4.2B Item 1)
Bypass Input Tray (W/TAG 115) (REP
07-6)
Bypass Input Tray (W/O TAG 115) (REP
07-6)
HCF Bypass Tray Feed Motor (Includes
Belt) (NOTE: W/O Tag H009 must also
replace Item 10 and mark off Tag H009)
(W/TAG H002, TAG H009) (REP 08-3)
HCF Elevator Motor Assembly (W/TAG
115) (REP 07-5)
HCF PWB (H4D) (W/Jumper) (460/470)
(NOTE: E2Y is a HCF W/O Front Door.
H4D is a HCF W/Front Door) (REP 07-9)
HCF PWB (E2Y) (W/Jumper) (NOTE:
E2Y is a HCF W/O Front Door. H4D is a
HCF W/Front Door) (REP 07-9)
HCF Feed Improvement Kit (W/TAG
079, TAG H007)
Retard Bracket (W/TAG H007)
HCF Feed Spring, Nominal Force
(NOTE: For use with normal to heavyweight papers) (W/TAG H007)
HCF Feed Spring, Low Force (P/O PL
4.2B Item 20) (W/TAG H112)
Drive Actuator (P/O PL 4.2B Item 3,PL
4.2B Item 11)
Lift Actuator (P/O PL 4.2B Item 3,PL
4.2B Item 11)
Solenoid (P/O PL 4.2B Item 3,PL 4.2B
Item 11)
Solenoid Bracket (P/O PL 4.2B Item 3)
HCF Feeder Cover (P/O PL 4.2B Item
3)
HCF 4 Hole Kit (W/TAG H004)
HCF Feed Improvement Kit ((NOTE:
This kit is for light weight paper only and
may reduce Feed Roll Cartridge life.)
(W/TAG H112)
Torsion Shaft (P/O PL 4.2B Item 4)
May 2003
5-30
V0.042
PL 4.3 Bypass Tray Components

Item
Part
Description
059K28900
022K57990
3
4
5
108R00148
108R00150
048E47050
026K01260
050P02096
Bypass Tray Assembly (W/TAG

115) (REP 07-4)
SMH Assembly (W/O TAG 115)
(REP 07-4,ADJ 14-2)
Bypass Top Cover
Stud
Bypass Front Cover (P/O PL 4.3
Item 1)
Bypass Rear Cover (P/O PL 4.3
Item 1)
Retainer
V0.042
May 2003
5-31
Parts List
PL 4.3
PL 5.1A Xerographic Components (1

of 2)
Item
Part
Description
113R00621
113R00623
113R00620
113R00622
113R00624
064K01550
4
5
025E03096
606K06950
Xerographic Module (NASG)

(FSMA) (REP 09-1 REP 09-11)
Xerographic Module (XE) (FSMA)
(REP 09-1 REP 09-11)
Xerographic Module (EP) (NASG)
(Sold) (Not Spared) (REP 09-1
REP 09-11)
Xerographic Module (NASG) (Sold)
(REP 09-1 REP 09-11)
Xerographic Module (XE) (Sold)
(REP 09-1 REP 09-11)
Xerographic Module (ACO) (Sold)
(REP 09-1 REP 09-11)
(W/TAG 028) (REP 09-5,ADJ 8-1A)
Photoreceptor Module (P/O PL
5.1A Item 2)
Developer Backer Bar
Developer Backer Spring (P/O PL
5.1A Item 2)
Developer Backer Shaft (P/O PL
5.1A Item 2)
Imager Backer Belt Guide Kit
(W/TAG 047)
Parts List
PL 5.1A
May 2003
5-32
V0.042
PL 5.1B Xerographic Components (2

of 2)
Item
1
Part
604K00702
604K00712
3
4
130K54161
094K04442
6
7
8
053K03600
093K03411
093K02922
9
10
130K59510
11
12
13
606K07240
14
15
16
600K88070
17
18
19
20
21
22
600K88840
604K00171
604K00620
23
24
25
26
27
604K13680
28
29
Description
Developer Housing Kit (REP 09-2)
Developer Housing High Altitude Kit
Developer Housing Support Rail (Not
Spared) (REP 09-10)
BTAC Sensor (REP 09-3)
Dry Ink Dispenser (W/O Low Toner Bottle Sensor) (DC/ST) (REP 09-4)
Dry Ink Dispenser (W/Low Toner Bottle
Sensor) (DT65), (LP only) (Not Spared)
(Order the Toner Bottle Sensor - Item 20
and the Dry Ink Dispenser W/O the Sensor - Item 4))
Developer Housing (P/O PL 5.1B Item
1)
Dry Ink Cartridge (Not Spared)
Developer Collector Bottle (NASG)
(240/255/265/DT65/460/470)
Developer Collector Bottle (XE)
(240/255/265/DT65/460/470)
Bottle of Developer Material (P/O PL
5.1B Item 18)
Developer Housing Trickle Cap (P/O PL
5.1B Item 1)
High Altitude Gear Kit (W/TAG 292)
Donor Roll Gear (P/O PL 5.1B Item 1,PL
5.1B Item 12)
Donor/Magnet Roll Gear (P/O PL 5.1B
Item 1,PL 5.1B Item 12)
Magnet Roll Drive Gear 32/29T (P/O PL
5.1B Item 1,PL 5.1B Item 27)
Developer Housing Top Cover Kit
(W/TAG 088)
Developer Housing Top Cover (P/O PL
5.1B Item 16)
Developer Material Replacement Kit
Donor Roll Kit
Toner Bottle Sensor
Donor Roll (P/O PL 5.1B Item 19)
Donor Roll Bearing (P/O PL 5.1B Item
19) (2 Places)
Donor Roll Contact (P/O PL 5.1B Item
19)
Donor Roll Seal Inboard (P/O PL 5.1B
Donor Roll Seal Outboard (P/O PL 5.1B
Item 1)
BTAC Mounting Bracket (P/O PL 5.1B
Item 1)
Developer Balanced Sump Gears
(W/TAG 278)
Pickup Auger Gear (70/49T) (P/O PL
5.1B Item 27)
Mix Auger Gear (63T) (P/O PL 5.1B Item
27)
V0.042
May 2003
5-33
Parts List
PL 5.1B
PL 5.2 ROS
Item
Part
Description
1
2
600K75400
062K08922
062K09261
ROS (P/O PL 5.2 Item 3)

Polygon Motor Kit (NOTE: Can
only be used on machines with Tag
057 (Aluminum ROS) (W/TAG 057)
(REP 06-2)
ROS Assembly (Aluminum) (240)
(W/TAG 057) (REP 06-1,ADJ 8-1A)
ROS Assembly (Aluminum)
(255/265, 460/470) (W/TAG 057)
(REP 06-1,ADJ 8-1A)
Parts List
PL 5.2
May 2003
5-34
V0.042
PL 6.1A Print Transports (1 of 4)

Item
Part
Description
022K70283
022K78683
600K70692
3
4
019E40980
022K59526
5
6
300K63850
600K75203
103K01140
103K01340
9
10
809E45820
11
12
012E07562
600K87870
13
14
121E14391
15
Prefuser Transport (W/TAG 034,

TAG 093) (REP 10-1,ADJ 8-1C
ADJ 8-1D)
Duplex Transport (W/TAG 005)
(REP 10-2,ADJ 8-1C ADJ 8-1D)
Light Weight Paper Duplex Kit
(W/TAG 298) (REP 10-2,ADJ 8-1C
ADJ 8-1D)
PFT Clip (W/TAG 032)
Enabled Decurler (NOTE: For use
with OCT) (W/TAG 040) (REP 10-3)
Exit Baffle Kit (W/TAG 083, TAG
085 W/O TAG 040) (REP 10-3)
Jumper (W/O TAG 123)
Jumper (NOTE: Use if previously
installed Tag 279 Decurler is
removed) (W/TAG 123)
Exit Baffle (P/O PL 6.1A Item 6)
(W/TAG 083, TAG 085)
Xerographic Module Guide
Preregistration Gate Solenoid
Spring
Preregistration Gate Link
Exit Baffle Bracket Kit (W/TAG
085)
Exit Baffle Bracket (P/O PL 6.1A
Item 12)
Preregistration Gate Solenoid (High
Force)
Solenoid Plunger (P/O PL 6.1A
Item 14)
V0.042
May 2003
5-35
Parts List
PL 6.1A
PL 6.1B Print Transports (2 of 4)

Item
Part
Description
2
3
4
121E16940
007E52380
8
9
055K32600
10
11
12
13
14
15
16
17
18
809E13571
023E14361
19
20
21
22
604K03980
604K03990
015K26032
23
059K29800
Part of Duplex Transport (REF: PL

6.1A Item 2)
Duplex Wait Clutch
Helical Drive Gear 42T
Bearing (P/O PL 6.1B Item 1,PL
6.1B Item 21)
Duplex TEER Mirror (P/O PL 6.1B
Duplex TEER LED Array (P/O PL
Duplex TEER Window (P/O PL
HCF/Duplex Baffle
Duplex Transport Left Front Cover
(P/O PL 6.1B Item 1)
Duplex TEER Sensor (P/O PL 6.1B
Duplex TEER Sensor Cover (P/O
PL 6.1B Item 1)
Duplex Frame (P/O PL 6.1B Item 1)
Duplex TEER LED Cover (P/O PL
6.1B Item 1)
TAR Roller (P/O PL 6.1B Item 1)
Spring, Extension
Shaft
Right Drive Plate (P/O PL 6.1B Item
1)
TEER Mirror and Window Kit
Duplex TEER PWB Kit
Left Drive Plate Assembly
Duplex Drive Plate (P/O PL 6.1B
Right Drive Plate Assembly Roller
(23a), Left Drive Plate Assembl;y
Roller (23b)
Parts List
PL 6.1B
May 2003
5-36
V0.042
PL 6.1C Print Transports (3 of 4)

Item
Part
Description
2
3
4
5
6
7
8
9
10
022K37486
Part of Prefuser Transport (REF:

PL 6.1A Item 1)
Drive Roll Assembly
Idler Shaft (P/O PL 6.1C Item 1)
Drive Belt (P/O PL 6.1C Item 1)
Drive Roll
Gear (P/O PL 6.1C Item 2)
Control Ring (P/O PL 6.1C Item 2)
Bearing (P/O PL 6.1C Item 2)
Bushing 6mm (P/O PL 6.1C Item 1)
Bottom Plate (P/O PL 6.1C Item 1)
V0.042
May 2003
5-37
Parts List
PL 6.1C
PL 6.1D Print Transports (4 of 4)

Item
Part
Description
604K13441
2
3
130K53461
121E14401
Exit Decurler Kit (460/470) (W/TAG

279)
Decurler (P/O PL 6.1D Item 1)
Decurler Position Sensor (3a),
Decurler Home Sensor (3b)
(W/TAG 279)
Decurler Gate Solenoid (low force)
(W/TAG 279)
Decurler Wiring Harness (P/O PL
6.1D Item 1)
Parts List
PL 6.1D
May 2003
5-38
V0.042
PL 6.2A Fusing (1 of 3)
Item
Part
Description
109R00330
109R00334
109R00328
109R00332
109R00345
109R00341
109R00343
109R00339
109R00347
109R00329
109R00333
109R00344
109R00340
109R00346
109R00327
109R00331
109R00342
109R00338
050K52934
3
4
5
010E03825
010E03935
003E38990
Fuser Module (NASG) (255/265)

(FSMA)
Fuser Module (XE) (255/265)
(FSMA)
Fuser Module (NASG) (240)
(FSMA)
Fuser Module (XE) (240) (FSMA)
Fuser Module (115V) (ACO)
(255/265) (FSMA)
(255/265) (FSMA)
Fuser Module (115V) (ACO) (240)
(FSMA)
(FSMA)
(Sold)
(Sold)
Fuser Module (XE) (255/265)
(Sold)
(255/265) (Sold)
(255/265) (Sold)
Fuser Module (NASG) (240) (Sold)
Fuser Module (NASG/XCL) (240)
(Sold)
Fuser Module (XE) (240) (Sold)
(Sold)
(Sold)
Inverter Assembly (NOTE:
Machines withoutTag 035 use
605K09100 Fuser Safety Kit)
(W/TAG 004, TAG 035, TAG 072,
TAG 128) (ADJ 8-1C ADJ 8-1D)
Slide (L)
Slide (R)
Fuser/Inverter Drawer Latch
V0.042
May 2003
5-39
Parts List
PL 6.2A
PL 6.2B Fusing (2 of 3)
Item
Part
Description
2
3
4
5
108K00711
113E16831
130K65890
6
7
604K00181
604K18150
10
019K03399
019K05410
11
604K05601
604K18160
Part of Fuser Module (REF: PL

6.1A Item 1)
DC Thermal Fuse (GP 42)
Fuser Module DC Connector
DC Thermistor (GP 42)
CRUM (P/O PL 6.2B Item 1,PL
6.2B Item 7)
Top Cover (P/O PL 6.2B Item 1)
Fuser Web Repair Kit (NASG)
(NOTE 1: When ordering
604K00181, also order 604K00200
Return Label Kit) (NOTE 2: For
model 240, also order Item 11)
Fuser Web Repair Kit (XE)
Maintenance Label (P/O PL 6.2B
Item 7)
Web (P/O PL 6.2B Item 1,PL 6.2B
Item 7)
Stripper Assembly (GP 42)
Stripper Assembly (GP 42)
(Alternate)
Fuser CRUM Kit (NASG)
Fuser CRUM Kit (XE)
Parts List
PL 6.2B
May 2003
5-40
V0.042
PL 6.2C Fusing (3 of 3) (Inverter

Repair Kit)
Item
Part
Description
2
3
4
600K87920
7
8
9
10
11
12
13
14
15
809E45820
007E37431
007K08262
007K08272
Part of Inverter Assembly (REF: PL

6.2A Item 2)
Inverter Repair Kit (W/TAG 085)
Retainer Nut (P/O PL 6.2C Item 2)
Inverter Bracket (P/O PL 6.2C Item
2)
Part of Inverter Drive Assembly
(REF: PL 6.3 Item 17)
Reverse Drive Frame (P/O PL 6.2C
Item 5)
Yoke (P/O PL 6.2C Item 5)
Reverse Drive Solenoid (P/O PL
6.2C Item 5)
Solenoid Spring
Inverter Drive Gear (30T)
Pin (P/O PL 6.2C Item 5)
Gear (24/35T)
Gear (24T)
Clutch/Gear (P/O PL 6.2C Item 5)
Ground Lug (P/O PL 6.2C Item 1)
V0.042
May 2003
5-41
Parts List
PL 6.2C
PL 6.3 Inverter
Item
Part
Description
3
4
160K59672
130E06851
059K29800
9
10
121E14391
11
12
13
14
022K51950
15
16
17
18
009E67421
005K04227
19
20
21
22
23
24
25
26
604K00241
604K00250
809E13571
809E12211
121E14401
27
Part of Inverter Assembly (REF: PL

6.2A Item 2)
Close Nip Link (P/O PL 6.3 Item
1,PL 6.3 Item 22)
Inverter IIOC PWB
Reversing Baffle (P/O PL 6.3 Item
1,PL 6.3 Item 22)
Inverter Entrance Baffle Frame
(P/O PL 6.3 Item 1)
Inverter Entrance Sensor (S4),
Inverter Exit Sensor (S5)
Inverter Exit Roll, Feed/Reverse
Roll (ADJ 10-1)
Inverter Exit Baffle Frame (P/O PL
6.3 Item 1)
IIOC PWB (P/O PL 6.3 Item 1)
Close Nip Solenoid (L2) (High
Force)
Close Nip Solenoid Spring (Not
Spared)
Duplex Gate (P/O PL 6.3 Item 21)
Inverter Entrance Gate (P/O PL 6.3
Item 21)
Inverter Exit Roll Idler,
Feed/Reverse Roll Idler
Idler Spring
IIOC Cover (P/O PL 6.3 Item 1)
Inverter Drive Assembly
Reversing Baffle Bearing (P/O PL
6.3 Item 1,PL 6.3 Item 22) (2
places)
Outboard Gate Bearing (P/O PL 6.3
Item 1,PL 6.3 Item 21) (2 places)
Inboard Gate Bearing (P/O PL 6.3
Item 1,PL 6.3 Item 21) (2 places)
Inverter Gate Kit
Reversing Baffle Kit
Reverse Idler Roll Spring
Spring
Cover (P/O PL 6.3 Item 1)
Entrance Gate Solenoid (L3),
Duplex Gate Solenoid (L4), (Low
Force)
Solenoid Cover (P/O PL 6.3 Item 1)
Parts List
PL 6.3
May 2003
5-42
V0.042
PL 7.1 Drives, Covers And Frames (1

of 4)
Item
1
Part
604K17010
604K12840
068K07634
068K07054
068K16354
068K16366
068K20040
423W00548
423W00448
423W00248
9
10
600K67481
11
12
13
14
15
16
600K71820
17
Description
(255/265/460/470) (W/TAG 006,
TAG 055, TAG 071) (REP 04-1,ADJ
8-1A)
Developer Drive Motor (240)
(W/TAG 006, TAG 055, TAG 281)
(REP 04-1,ADJ 8-1A)
Developer Gear Bracket (240)
(REP 04-3)
Developer Gear Bracket (255/265)
(DT65) (460/470) (REP 04-3)
Fuser Drive Motor (240) (W/TAG
056) (REP 04-2)
Fuser Drive Motor (255/265)
(DT65) (460/470) (W/TAG 056)
(REP 04-2)
Decurler/OCT Drive Bracket
(240/255/265) (DT65) (W/TAG 030)
(W/O TAG 090) (REP 04-4)
Fuser Drive Gear (P/O PL 7.1 Item
15)
Retaining Ring (P/O PL 7.1 Item
15)
Decurler Drive Belt (120T)
(240/255/265) (DT65) (NOTE: Not
required for machines with Tag 083,
Exit Baffle) (W/O TAG 090) (REP
04-5)
Developer Drive Belt (6mm) (161T)
(240 W/Tag 281, 255/265/460/470)
(REP 04-6)
Developer Drive Belt (6mm) (163T)
(240) (W/O TAG 281) (REP 04-6)
Developer Drive Motor Gear Kit
Gear (P/O PL 7.1 Item 9) (50T
Plastic Gear. To obtain the metal
gear order the Developer Drive
Motor)
Gear (P/O PL 7.1 Item 9) (60T)
Retaining Ring (P/O PL 7.1 Item 9)
Gear (41T) (P/O PL 7.1 Item 9)
Gear (P/O PL 7.1 Item 9) (31T)
Fuser Drive Gear Kit
Decurler Drive Gear (P/O PL 7.1
Item 3)
Decurler Drive Belt Tensioner (P/O
PL 7.1 Item 3)
NOTE:
NOTE:
V0.042
May 2003
5-43
Parts List
PL 7.1

of 4)
Item
Part
Description
802K21841
048K17716
2
3
4
5
6
003E30593
029E19172
003E54460
048E03664
8
9
10
048K17726
021E07180
017K01972
11
017K01982
12
13
014E26262
050P02096
Front Door (240/255/265) (DT65)

(460/470) (W/TAG 115)
Front Door (240/255/265) (DT65)
(460/470) (W/O TAG 115)
Front Door Insert (Not Spared)
Hinge
Pivot Pin
Magnet
Left Side Cover (P/O PL 7.2 Item
8)
Left Side Cover Upper Knockout
(240/255/460)
Left Side Cover Assembly
Left Side Cover Lower Knockout
Non-swivel Casters (NOTE: When
replacing item 10, Caster
Replacement Tool 600T02062 is
required)
Swivel Casters (NOTE: When
replacing item 11, Caster
Replacement Tool 600T02062 is
required)
Pivot Block
Retainer
Parts List
PL 7.2
May 2003
5-44
V0.042

of 4)
Item
Part
Description
048K17743
802K01070
048K17732
802K01060
048E10243
802E01240
048E10253
802E01250
048K42873
802K21010
802K21250
048K32362
802K01050
Top Rear Cover (240/255/265)

(DT65) (460/470) (W/O TAG 115)
Top Rear Cover (240/255/265)
(DT65) (460/470) (W/TAG 115)
Right Rear Cover (240/255/265)
(DT65) 460/470) (W/O TAG 115)
Right Rear Cover (240/255/265)
(DT65) 460/470) (W/TAG 115)
Rear Left Side Cover
(240/255/265) (DT65) (460/470)
(W/O TAG 115)
(240/255/265) (DT65) (460/470)
(W/TAG 115)
Rear Right Side Cover
(240/255/265) (DT65) (460/470)
(W/O TAG 115)
(240/255/265) (DT65) (460/470)
(W/TAG 115)
Connector Panel (240/255/265)
(DT65)
Connector Panel (460/470) (W/O
TAG 115)
Connector Panel (460/470) (W/TAG
115)
Left Rear Cover (240/255/265)
(DT65) (460/470) (W/O TAG 115)
Left Rear Cover (240/255/265)
(DT65) (460/470) (W/TAG 115)
V0.042
May 2003
5-45
Parts List
PL 7.3

of 4)
Item
Part
Description
1
2
3
4
5
048K73840
802K07380
048E59750
030K62730
6
7
8
9
10
030K68490
003E41720
098K87320
606K07310
Top Cover (255/265 LP) (DT65)

UI False Cover (DT65)
Monitor Support Cover (DT65)
Logo Badge
Accessory Shelf (DT65) (W/O TAG
115)
DT Shelf Assembly (W/TAG 115)
Touch Latch (255/265 LP) (DT65)
Paper Tray (REF: PL 4.1A Item 1)
Tabs Tray Kit
Monitor Foot Kit (3 feet/kit)
Monitor
Parts List
PL 7.4
May 2003
5-46
V0.042
PL 8.1 OCT/Convenience Stapler

Item
Part
Description
1
2
3
4
5
6
022K59060
162K07645
160K31522
029K01629
048E26154
8
9
10
11
12
13
801K12100
030K62720
050K40040
019K04330
048K57900
029E27200
162K16722
14
15
160K32371
Offsetting Catch Tray Assembly

OCT IIOC Harness (BUS 2)
OCT IIOC PWB
Convenience Stapler Assembly
Convenience Stapler Top Cover
Convenience Stapler Housing (P/O
PL 8.1 Item 4)
Accessory Shelf (W/TAG 115)
Accessory Shelf (W/O TAG 115)
OCT Tray
OCT Stacking Finger
OCT Lower Cover
Bezel (Not Spared)
OCT Stacking Finger Pin
Convenience Stapler Internal DC
Harness (REP 12-17)
Stapler (P/O PL 8.1 Item 4)
Convenience Stapler PWB (REP
12-19)
V0.042
May 2003
5-47
Parts List
PL 8.1
PL 8.2 Finisher Covers

Item
1
Part
802E01230
048E28420
802E20270
048E28472
050E17851
4
5
6
050E11366
050E21640
048K56873
048E28482
802E01220
048E28440
802E01200
048E28400
802E52950
802E01210
9
10
11
12
048E28391
802E52960
017K02252
017K02240
048E28461
802K21370
802K21390
13
14
15
802K54880
048E31071
048E41730
038K12760
038K11682
16
050K50733
050K44940
17
18
19
20
21
22
23
24
050K41760
160K32240
110E08350
110E04251
604K12850
Description
Lower Rear Cover (W/TAG 115 or NF3)
Lower Rear Cover (W/O TAG 115)
Lower Rear Right Cover (W/TAG 115 or
NF3)
Lower Rear Right Cover (W/O TAG 115)
Finisher Top Tray (green) (W/TAG 115 or
NF3)
Finisher Top Tray (white) (W/O TAG 115)
Finisher Top Tray (dark gray)
Lower Right Cover
Upper Right Cover
Upper Rear Cover (W/TAG 115 or NF3)
Upper Rear Cover (W/O TAG 115)
Finisher Top Cover (green) (W/TAG 115
or NF3)
Finisher Top Cover (W/O TAG 115)
Finisher Top Cover (white)
Finisher Top Cover Door (green) (W/TAG
115 or NF3)
Finisher Top Cover Door (W/O TAG 115)
Finisher Top Cover Door (white)
Right Casters
Left Casters
Top Gutter Cover
Front Cover Assembly (green) (W/TAG
115 or NF3)
Front Cover Assembly (blue) (W/O TAG
115)
Front Cover Assembly (gray)
Upper Left Rear Trim
Tamper Button (W/TAG 115 or NF3)
(W/TAG F023,)
Tamper Button (W/O TAG F023, TAG
115)
Stacker Tray (PE1) (NOTE: W/TAG 115
or NF3. Product Code PE1 indicates
Smart Tray Finisher, W/Tag F024)
Stacker Tray (W/TAG F027 W/O TAG
115)
Stacker Tray (W/O TAG F027, TAG 115)
Safety Guard (Not Spared)
Pause/Resume Switch
Stacker Tray Rear Upper Limit Switch
Switch Mounting Bracket (Not Spared)
Leaf Spring (Not Spared)
Interlock Switch
Front Cover (P/O PL 8.2 Item 12)
Thin Stapled Sets Tray Kit
NOTE: NF3 denotes Smart Tray Finisher
Parts List
PL 8.2
May 2003
5-48
V0.042
PL 8.3 Finisher Components (1 of 5)

Item
1
Part
801K06632
2
3
4
5
6
7
023E16920
030K57626
130K53461
007E37183
030K71300
019E35692
019E38020
023E23220
9
10
11
12
020E23532
023E23810
038K11727
048K72737
13
14
15
16
130K66330
160K44456
960K10060
17
18
413W29457
19
20
21
600K88761
22
23
606K07360
24
25
26
055E39672
27
28
055E39681
29
30
604K04100
31
32
33
34
600K89781
Description
Top Module Assembly (W/TAG F033)
(REP 12-1)
Nip 3/4 Drive Belt (REP 12-14)
Stacker Drive Motor (REP 12-2)
Disk Home Sensor (Q2)
Disk Drive Gear (72T)
Disk Drive Motor (REP 12-10)
Stacker Tray Drive Belt Clamp (rear)
(When replacing Item 7, (rear), you must
also replace PL8.5 Item 7 (front)) (W/O
TAG F027, TAG 115) (REP 12-21)
Stacker Tray Drive Belt Clamp (rear)
(W/TAG 115 or NF3. When replacing
Item 7 (rear), you must also replace
PL8.5 Item 7 (front)) (W/TAG F027)
(REP 12-21)
Stacker Tray Drive Belt (rear) (When
replacing Item 8 (rear), you must also
replace PL8.5 Item 8 (front)) (REP
12-20)
Nip 1/2 Drive Belt (REP 12-13)
Finisher Transport Baffle (REP 12-8)
Disk Baffle Assembly (NOTE: Includes
Safety Gate Solenoids) (W/TAG F009,
TAG F014, TAG F017, TAG F028) (REP
12-9)
Disk Shaft (Reference Item 31) (REP
12-11)
Disk Baffle (P/O PL 8.3 Item 12)
Finisher Entrance Sensor (Q1)
Finisher Controller PWB (W/TAG F007,
TAG F026) (W/O TAG 115)
Finisher Controller PWB (W/TAG 115 or
NF3) (W/TAG 115)
Top Module Frame (P/O PL 8.3 Item 1)
Nip3 Drive Shaft Bearing (2), Nip4 Drive
Shaft Bearing (2), Disk Shaft Bearing (2)
Nip3 Drive Shaft Gear (P/O PL 8.3 Item
1)
Nip4 Drive Shaft Gear (P/O PL 8.3 Item
1)
Top Tray Backwall Kit (W/TAG F033)
(REP 12-16)
Static Eliminator Kit (W/TAG F112)
Static Eliminator Power Supply (P/O PL
8.3 Item 22)
Static Eliminator Harness (P/O PL 8.3
Item 22)
Exit Baffle (P/O PL 8.3 Item 22)
Moving - Stapler Safety Gate (REP
12-23)
Fixed - Stapler Safety Gate (REP 12-22)
Disk Finger (P/O PL 8.3 Item 31) (4
Places)
Torsion Spring (P/O PL 8.3 Item 31) (4
Places)
Transport Baffle Idler Kit (Contains 2
Idler Rolls)
Disk Fingers Kit
Idler Spring (P/O PL 8.3 Item 30)
Idler Roller (P/O PL 8.3 Item 30)
Idler Shaft (P/O PL 8.3 Item 30)
V0.042
May 2003
5-49
Parts List
PL 8.3

Item
Part
Description
130K53461
006K14606
3
4
130K66330
5
6
7
8
9
10
11
12
055K25130
019E35701
125E02322
125E02524
012E07473
007K12110
413W49457
Top Tray Offset Sensor (Q10), Top

Tray Full Sensor (Q11) (ADJ 12-1)
Nip1 Drive Shaft (REP 12-6), Nip2
Drive Shaft (REP 12-7)
Top Tray Paper Path Sensor (Q12)
Finisher Upper Harness (P/O PL
8.3 Item 1)
Safety Guard
Top Tray Full Sensor Actuator
Top Tray Static Eliminator
Static Eliminator
5a Baffle (REF: PL 8.3 Item 1)
Offset Drive Link
Offset Gear Assembly
Nip1 Drive Shaft Bearing (2), Nip2
Drive Shaft Bearing (2)
Parts List
PL 8.4
May 2003
5-50
V0.042

Item
1
Part
050K50765
050K53921
014K04099
014K07830
015K56074
015K36814
015K57493
130K53461
5
6
7
110E08350
110E05870
019E38020
023E23220
9
10
020E23532
130E08200
11
12
802K41941
048K73404
110E07350
13
014K08031
14
15
127K24432
091K13030
16
17
18
19
606K07390
604K03760
20
21
22
23
809E53490
Description
Service Tray Assembly (460/470)
(W/TAG 115 or NF3) (REP
12-3,ADJ 12-1)
Service Tray Assembly (W/O TAG
115) (REP 12-3,ADJ 12-1)
Fixed Stapler (6UP) (W/TAG 115)
(REP 12-5)
Moving Stapler (W/TAG 115 or
NF3) (REP 12-4,ADJ 12-1)
Moving Stapler (W/O TAG 115)
(REP 12-4,ADJ 12-1)
Moving Stapler (REP 12-4,ADJ
12-1)
(Q4), Kicker Home Sensor (Q5),
Stacker Tray Full Sensor (Q8),
Tamper Home Sensor (Q3) (ADJ
12-1)
Stacker Tray Drive Belt Clamp
(front) (When replacing Item 7
(front), you must also replace PL8.3
Item 7 (rear)) (W/TAG F027)
Stacker Tray Drive Belt (front)
(When replacing Item 8 (front), you
must also replace PL8.3 Item 8
(rear))
Stack Height Sensor (Q16), Stack
Too High Sensor (Q15)
Stapler Access Door (W/TAG F040)
Stapler Access Door (6UP)
Stapler Access Door Interlock
Switch
Finisher Set Separator (W/Tag 115
or NF3, Tag F041) (NOTE: 6UP
models W/O Tag 115 order Item 19,
604K03760)
Stapler Lead In Baffle (W/TAG 031)
(REP 12-18)
Front Bail Arm (P/O PL 8.5 Item 18)
Rear Bail Arm (P/O PL 8.5 Item 18)
Bail Arm Kit (W/TAG F111)
Finisher Set Separator Kit (W/O
TAG 115)
Tray (REF: PL 8.2 Item 16)
Adhesive Film (P/O PL 8.5 Item 19)
Bail Arm Spring (2 places)
Stapler Frame (Not Spared)
V0.042
May 2003
5-51
Parts List
PL 8.5

Item
Part
Description
1
2
3
600K75260
6
7
Finisher Noise Reduction Pad Kit

Exit Baffle Pad (P/O PL 8.6 Item 1)
Rear Frame Pad (P/O PL 8.6 Item
1)
Top Stiffener Pad (P/O PL 8.6 Item
1)
Rear Stiffener Pad (P/O PL 8.6
Item 1)
Exit Baffle (P/O PL 8.3 Item 1)
13) (Contains 3)
Parts List
PL 8.6
May 2003
5-52
V0.042

Item
1
Part
Description
606K07472
Paper Cooling and Stacking Fan Kit

(W/TAG F109)
V0.042
May 2003
5-53
Parts List
PL 8.7
PL 8.20 MFF Covers

Item
Part
Description
1
2
3
802K41832
802K60741
802K60960
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
050K54461
802E43330
802E43630
802E44890
802K61260
802E43291
802E43310
802E43300
029E19172
017K03880
050K54751
004K07010
120E08322
19
20
Front Door
Rear Cover
Top Cover Assembly (REP
12.06.01)
Top Tray (P/O PL 8.20 Item 16)
Top Tray Extension (P/O PL 8.20
Item 16)
Main Tray Assembly
Right Booklet Exit Cover (FEC)
Right Side Lower Cover (EVW)
Right Front Cover
Left Front Cover
Upper Left Cover
Front Door Hinge Pin
Top Cover (P/O PL 8.20 Item 3)
Caster
Top Output Tray
Left Cover Gasket
Actuator
Spring (Not Spared)
Actuator Cover (Not Spared)
Parts List
PL 8.20
May 2003
5-54
V0.042
PL 8.21 MFF Components

Item
Part
Description
801K13361
801K13351
038K15104
038K15234
802K55273
050K55070
Booklet Maker Assembly ((NOTE:

Booklet Maker is for Professional
(FEC) configuration Finishers))
(REP 12.02.01)
Booklet Maker Exit Assembly
((NOTE: Booklet Maker Exit
Assembly is for Professional (FEC)
configuration Finishers)) (REP
12.02.01)
Tri-folder Assembly (NOTE:
Tri-folder Assembly is for
Professional (FEC) configuration
Finishers)) (W/TAG M020) (REP
12.04.01,ADJ 12.04.02)
Buffer / Compiler Module Assembly
(W/TAG M007, TAG M016) (REP
12.13.01)
Main Stapler and Carriage
Assembly (REP 12.12.01)
Eject Housing Assembly (REP
12.07.01)
Top Tray Exit Cover Assembly
V0.042
May 2003
5-55
Parts List
PL 8.21
PL 8.22A MFF Electrical (1 of 3)

Item
Part
Description
960K11071
2
3
4
5
6
160K96882
160K96871
160K96891
160K96901
160K79522
7
8
9
10
105K26501
053K04310
498K03530
MFF Control PWB (W/TAG M009,

TAG M028) (REP 12.08.01)
Upper Pullout PWB
Booklet Pullout PWB
Frame / Booklet / Trifold PWB
IOT / MFF Interface PWB (W/TAG
M002)
MFF LVPS (W/TAG M021)
MFF PWB Panel
LVPS Dirt Filter
MFF Power Cord (NASG - US)
(470) (DT/DP 65)
Parts List
PL 8.22A
May 2003
5-56
V0.042
PL 8.22B MFF Electrical (2 of 3)

Item
1
2
Part
Description
962K12433
962K12414
Booklet Maker Harness

MFF Main harness
V0.042
May 2003
5-57
Parts List
PL 8.22B
PL 8.22C MFF Electrical (3 of 3)

Item
1
2
3
4
Part
Description
962K10830
962K12480
962K16512
962K01751
IOT/MFF Harness
Interface PWB Harness
AC Power Harness
DC Power Harness
Parts List
PL 8.22C
May 2003
5-58
V0.042
PL 8.23 MFF Buffer/Compiler Module

Assembly (1 of 9)
Item
Part
Description
2
3
038K15021
5
6
809E45700
809E43940
10
11
12
13
14
022K79591
038K15031
023E23660
15
020E38410
16
17
18
19
020E30340
007E70240
802K60941
20
21
22
23
24
25
26
809E43970
022K79901
010K03430
010K03443
013E81150
413W30854
Part of Buffer / Compiler Module

Assembly (REF: PL 8.21 Item 4)
Nip 4 Outer Guide Assembly
Area 5b4 Shaft (P/O PL 8.23 Item
2)
Are 5b4 Handle (P/O PL 8.23 Item
2)
Area 5b4 Spring
Area 5b4 Rear Latch (P/O PL 8.23
Item 2)
Area 5b4 Front Latch (P/O PL 8.23
Item 2)
Nip 3 Idler Rolls (8a), Nip 4 Idler
Rolls (8b) (P/O PL 8.23 Item 2)
Nip 3 Idler Spring (9a), Nip 4 Idler
Spring (9b)
Nip 4 Outer Guide (P/O PL 8.23
Item 2)
Nip 4 Drive Shaft (REP 12.13.02)
Nip 3/4 Drive Belt
Item 1)
Nip 3 Pulley (15a), Nip 4 Pulley
(15b)
Nip 3/4 Belt Idler
Alignment Gear (Nip3, Nip 4, Nip 5)
Buffer / Compiler Front Cover
Buffer / Compiler Handle (5b) (P/O
PL 8.23 Item 1)
Belt Idler Spring
Pin (P/O PL 8.23 Item 1)
Left Rail
Right Rail
Bearing (8MM)
Bearing
V0.042
May 2003
5-59
Parts List
PL 8.23

Assembly (2 of 9)
Item
Part
Description
2
3
038K15041
5
6
809E45700
9
10
809E43940
11
12
022K79901
13
013E81150

Area 5b1 Shaft (P/O PL 8.24 Item
2)
Area 5b1 Handle (P/O PL 8.24 Item
2)
Area 5b1 Spring
Area 5b1 Rear Latch (P/O PL 8.24
Item 2)
Area 5b1 Front Latch (P/O PL 8.24
Item 2)
Nip 5 Idler Rolls (P/O PL 8.24 Item
2)
Nip 5 Idler Spring
Item 2)
Nip 5 Inner Guide (P/O PL 8.24
Item 1)
Bearing (8MM)
Parts List
PL 8.24
May 2003
5-60
V0.042

Assembly (3 of 9)
Item
Part
Description
127K41170
4
5
6
7
8
9
10
11
020E38890
809E48380
020E38410
023E23670
962K16794
127E10300

Paper Path Nip Motor (M110) (Nips
1-5) (REP 12.13.08)
Nip 5 Drive Gear (P/O PL 8.25 Item
1)
Nip 5 Belt Idler
Nip 5 Belt Idler Spring
Nip 5 Drive Belt Pulley
Nip 5 Drive Belt
Buffer / Compiler Harness
Shroud (P/O PL 8.25 Item 1)
Cooling Fan (M111)
Grill
V0.042
May 2003
5-61
Parts List
PL 8.25

Assembly (4 of 9)
Item
Part
Description
038K15313
809E44840
130K67591
9
10
11
038K15011
019E51501
12
13
120E92240
127K43170
14
121K33540
15
16
17
18
19
20
21
22
23
24
25
023E23640
023E23650
020E38850
020E38860
125E00430
809E45560
962K16822
013E81150

Nip 6/7 Outer Guide Assembly
(REP 12.13.04)
Nip 6/7 Outer Guide (P/O PL 8.26
Item 2)
2)
Nip 6 Idler Spring (5a), Nip 7 Idler
Spring (5b)
2)
Buffer Module Entrance Sensor
(S20)
Entrance Sensor (S20) Bracket
(P/O PL 8.26 Item 1) (REP
12.13.19)
Nip 6/7 Inner Guide (REP 12.13.04)
Trail Edge Clamp
Nip 7 Paper Guide (P/O PL 8.26
Item 1)
Wire Clip
Buffer Entrance Nip Motor (M31)
(Nip 6 and Nip 7) (REP 12.13.10)
Trail Edge Clamp Solenoid (L30)
(REP 12.13.16)
Nip 6/7 Drive Belt
Nip 7 Belt
Nip 6/7 Pulley
Nip 7 Pulley
Nip 6/7 Shafts Ground Brush
Connector Block (Not Spared)
Connector (Not Spared)
Return Spring
Retaining Ring
Sensor Harness
Bearing (8MM)
Parts List
PL 8.26
May 2003
5-62
V0.042

Assembly (5 of 9)
Item
Part
Description
2
3
4
5
6
038K15060
830E89700
038E30041
050E20600
121K33530
7
8
050E21880
121K33210
10
11
011E13890
12
13
120E23211
14
15
809E44280
121K33201
16
17
18
19
20
21
22
23
059K34580
809E43961
013P90359
055E52400

Baffles 5 and 6 Bracket
Buffer Guide (W/TAG M016)
Buffer Gate
Buffer Gate Solenoid (L33) (REP
12.13.16)
Spacer (P/O PL 8.27 Item 1)
Top Tray Diverter Gate (W/TAG
M016)
Top Tray Diverter Gate Solenoid
Assembly (L40) (REP 12.13.17)
Diverter Gate Lever
Nip 8 Lifter Shaft (P/O PL 8.27 Item
2)
Nip 8 Lifter
2)
Nip 8 High Force Spring
Nip 8 Release Solenoid (L31) (REP
12.13.06)
Nip 8 Release Lever (P/O PL 8.27
Item 1)
Item 2)
Bearing
Solenoid (P/O PL 8.27 Item 9)
Solenoid Spring
Bearing (4MM)
Lead-in Baffle
V0.042
May 2003
5-63
Parts List
PL 8.27

Assembly (6 of 9)
Item
Part
Description
3
4
5
6
7
8
9
029E37880
012E13030
022E25820
008E07030
809E44490
028E15120
10
11
12
029E38410
059K34410
13
14
15
16
020K12630
023E23630
17
18
19
20
125E00430
809E48140
012K05740
413W30854

4-Bar Assembly (P/O PL 8.28 Item
1) (W/TAG M010) (REP 12.13.14)
4-Bar Front Pivot
4-Bar Front Link
4-Bar Cam Roller
4-Bar Elevate Cam (2 places)
4-Bar Elevate Spring - Front
Retainer Washer
4-Bar Rear Link (P/O PL 8.28 Item
19)
Rear Link Pivot Plate (P/O PL 8.28
Item 19)
4-Bar Rear Pivot
Nip 9 Drive Shaft (P/O PL 8.28 Item
1) (REP 12.13.15)
Nip 9 Clutch (REP 12.13.07)
Nip 9 Drive Belt
4-Bar Torsion Spring (P/O PL 8.28
Item 19)
Nip 9 Drive Shaft Ground Brush
4-Bar Elevate Spring - Rear
4-Bar Rear Link Assembly
Bearing
Parts List
PL 8.28
May 2003
5-64
V0.042

Assembly (7 of 9)
Item
Part
Description
3
4
130E09710
125K03860
130K67572
809E44280
10
11
12
13
14
15
16
809E44261
019E61611
17
18
19
20
055K33993
21
22
23
24
25
26
27
28
125E00430
962K16810
801K13960
Part of 4-Bar Assembly (REF: PL

8.28 Item 2)
Compiler Entrance Top Cover (P/O
PL 8.29 Item 1)
Compiler Jam Sensor (S47)
Compiler Jam Sensor Guard (P/O
PL 8.29 Item 1)
Anti-Static Brush (P/O PL 8.29 Item
1)
Compiler Entrance Sensor (S46)
(REP 12.13.21)
1)
Nip 9 Idler Rolls Spring (P/O PL
8.29 Item 1)
Nip 9 Idler Rolls Bracket (P/O PL
8.29 Item 1)
Area 5b3 Spring (P/O PL 8.29 Item
1)
Area 5b3 Handle (P/O PL 8.29 Item
1)
4-Bar Front Latch (P/O PL 8.29
Item 1)
4-Bar Rear Latch (P/O PL 8.29 Item
1)
Spring
Exit Drive (P/O PL 8.29 Item 1)
Restack Finger (2 places) (P/O PL
8.29 Item 1)
Shaft (P/O PL 8.29 Item 1)
4-Bar Upper Lead-in Baffle
Assembly
Ground Brush
Sensor Harness
Exit Bridge Assembly
Exit Bridge (P/O PL 8.29 Item 24)
4-Bar Pivot (P/O PL 8.29 Item 1)
Cable Clip (P/O PL 8.29 Item 1)
Lead-in Baffle (P/O PL 8.29 Item
20)
V0.042
May 2003
5-65
Parts List
PL 8.29

Assembly (8 of 9)
Item
Part
Description
127K43528
604K16871
604K13380
121K33651
9
10
023E24630
11
12
13
130K67894
059K34600
Part of 4-Bar Assembly (REF: PL

8.28 Item 2)
4-Bar Exit Drive Assembly (W/TAG
M008, TAG M013, TAG M022)
(REP 12.13.13)
4-Bar Exit Drive (P/O PL 8.30 Item
2)
Compile Belt Kit (4/kit) (REP
12.13.18)
Compiler Curl Guard Finger Kit (6
Fingers/Knuckles per kit)
Curl Guard Finger (P/O PL 8.30
Item 2,PL 8.30 Item 5)
Curl Guard Knuckle (P/O PL 8.30
(L41) (W/TAG M012)
Compile Belt
Compile Belt Cover - Front (P/O PL
8.30 Item 2)
Compile Belt Cover - Rear (P/O PL
8.30 Item 2)
4-Bar Home Sensor (S45)
Exit Roll Shaft
Parts List
PL 8.30
May 2003
5-66
V0.042

Assembly (9 of 9)
Item
Part
Description
127K43510
5
6
007E74120
007E73700

4-Bar Position Motor Assembly
(M45) (REP 12.13.12)
4-Bar Position Motor (M45) (P/O PL
8.31 Item 2)
4-Bar Elevate Drive Plate (P/O PL
8.31 Item 2)
4-Bar Elevate Drive Gear
4-Bar Elevate Gear
V0.042
May 2003
5-67
Parts List
PL 8.31
PL 8.32 MFF Main Stapler (1 of 2)

Item
Part
Description
127K43790
2
3
029K03830
4
5
6
802K61900
962K12401
7
8
9
10
013E21560
11
12
13
14
038E28620
830E78861
15
16
038E29251
008R12912
Main Stapler Carriage Assembly

(NOTE: Includes Main Stapler
Position Motor (M43)) (REP
12.12.01,ADJ 12.12.02)
Carriage (P/O PL 8.32 Item 1)
Main Stapler Assembly (REP
12.12.03,ADJ 12.12.01)
Stapler Cover
Stapler Power Harness
Stapler Drive Belt Tensioner (P/O
PL 8.32 Item 1)
Annular Headed Pin (Not Spared)
Bearing
Anti-Rotation Shaft (Not Spared)
Stapler Transport Shaft (Not
Spared)
Main Stapler (P/O PL 8.32 Item 3)
Stapler Lower Guide Throat
Stapler Backstop
Stapler Position Drive Belt (P/O PL
8.32 Item 1)
Stapler Upper Guide Throat
Main Stapler Cartridge
Parts List
PL 8.32
May 2003
5-68
V0.042
PL 8.33 MFF Main Stapler (2 of 2)

Item
Part
Description
2
3
4
5
022E25830
013E23100
019E55801
107E22570
Part of Main Stapler Carriage

Asembly (REF: PL 8.32 Item 1)
Kickarms Roller
Stapler Bearing
Bearing Retainer
Idler Pin Support Bracket (P/O PL
8.33 Item 1)
(S43)
V0.042
May 2003
5-69
Parts List
PL 8.33
PL 8.34 MFF Eject Housing Assembly

Item
Part
Description
2
3
604K13400
107E22570
8
9
013E81150
10
11
12
13
14
809E43970
962K01671
125K03840
15
16
17
18
19
20
21
110E13561
007E70260
802K55640
110E13810
22
23
Part of Eject Housing Assembly

Eject Housing (P/O PL 8.34 Item 1)
Compiler Upper Eject Drive Shaft
Compiler Flapper Eject Kit (4 per
kit) (REP 12.07.03)
Eject Housing Cover (P/O PL 8.34
Item 1)
Eject Flapper Home Sensor (S49),
Compiler Flapper Home Sensor
(S40) (REP 12.07.02)
Eject Shaft Drive Belt (P/O PL 8.34
Item 1) (REP 12.07.04)
Bearing (8MM)
Compiler Flapper Drive Gear (P/O
PL 8.34 Item 1)
Compiler Flapper Drive Shaft (P/O
PL 8.34 Item 1)
Tension Spring
Eject Housing Harness
Eject Housing Anti-Static Brush
Anti Static Brush Cover (P/O PL
8.34 Item 1)
Stapler Interlock Switch (SW04)
Eject Housing Gear Rack (2 places)
Crash Bar Kit
Crash Bar Switch (SW53)
Extension Spring (Not Spared)
Support Bracket (Not Spared)
Flapper Bridge (2 places) (P/O PL
8.34 Item 1)
Crash Bar (P/O PL 8.34 Item 17)
Bearing (2 Places) (P/O PL 8.34
Item 17)
Parts List
PL 8.34
May 2003
5-70
V0.042
PL 8.35 MFF Top Tray Cover

Assembly
Item
Part
Description
107E22600
5
6
7
8
9
10
120E23130
125K03472
11
12
Part of Top Tray Exit Cover

Top Tray Exit Sensor (S120), Top
Tray 90% Full Sensor (S121)
Top Tray Exit Sensor Actuator (Not
Spared)
Top Tray Exit Sensor Actuator Clip
Top Tray 90% Full Sensor Actuator
Top Tray Anti-Static Brush
Top Tray Cover (Not Spared)
Inner Baffle (P/O PL 8.35 Item 1)
Top Tray harness (Not Spared)
Full Sensor Actuator Clip (Not
Spared)
Nip Idler Bracket (Not Spared)
Nip 12 Idler (12a), Nip 13 Idler
(12b) (P/O PL 8.35 Item 1)
V0.042
May 2003
5-71
Parts List
PL 8.35
PL 8.36 MFF Top Tray Assembly

Item
Part
Description
1
2
3
4
5
6
110E08780
055K33842
020E30340
110E08000
8
9
10
11
12
127K43180
13
14
005E13460
15
16
809E45530
17
Front Door Interlock Switch (SW01)

Top Tray Trim Cover (Not Spared)
Top Tray Lower Baffle Assembly
Nip 12/13 Drive Belt Idler
Top Tray Interlock Switch
Pause to Unload Switch (SW52)
Pause to Unload Button (P/O PL
8.20 Item 3)
LED Retainer (P/O PL 8.20 Item 3)
Top Tray Belt Cover (Not Spared)
Top Tray Lower Baffle (P/O PL 8.36
Item 3)
Nip 8/12 Drive Belt
Buffer Nip Motor (M30) (Nips 8, 9,
12, 13) (REP 12.13.09)
Drive Belt Tensioner Spring
Nip 12/13 Drive Coupling (14a), Nip
8/9 Drive Coupling (14b)
Coupler Spring
Buffer Nip Motor Bracket (Not
Spared)
Pulley (22T) (Not Spared)
Parts List
PL 8.36
May 2003
5-72
V0.042
PL 8.37 MFF Master Lock

Item
Part
Description
120K02702
2
3
4
120K02690
038K15222
6
7
8
809E53000
050E21870
050E20590
9
10
130K67572
121K33461
11
011E13720
12
13
14
013P90359
125E00430
604K18550
15
16
17
18
023E23440
005E13460
809E45530
020E38410
19
20
21
22
23
24
25
26
27
28
29
020E30340
809E44450
120E23160
809E43950
120E23420
413W30854
Lower Masterlock (EVW) (REP

12.11.02)
Lower Masterlock (FEC) (REP
12.11.02)
Upper Masterlock (REP 12.11.01)
Masterlock Coupling (Not Spared)
Nip 1/2 Outer Guide Assembly
(REP 12.11.03)
Nip 1/2 Outer Guide (P/O PL 8.37
Item 4)
Nip 1 (6a), Nip 2 (6b) Spring
Nip 1/2 Inner Guide (Not Spared)
Booklet Diverter Gate (W/TAG
M017)
Booklet Diverter Gate (W/O TAG
M017)
Finisher Entrance Sensor (S110)
Booklet Diverter Gate Solenoid
(L60)
Booklet Diverter Gate Solenoid
Lever
Bushing
Ground Brush
Nip 1/2 Drive Shaft Kit (W/TAG
M027)
Nip 1/2 Drive Belt
Coupler
Coupler Spring
Nip 1 Pulley (18a), Nip 2 Pulley
(18b), Nip 1/2 Drive Belt Pulley
(18c)
Belt Idler (MEXICO)
Belt Tension Spring
Nip 6/7 Front Pressure Arm
Pressure Arm Spring
Pressure Arm Pin (Not Spared)
Nip 6/7 Rear Pressure Arm
Bushing Retainer
Bracket (Not Spared)
Shaft (Not Spared)
Pins (Not Spared) (2)
Bearing
V0.042
May 2003
5-73
Parts List
PL 8.37
PL 8.38 MFF Booklet Maker (1 of 10)

Item
Part
Description
2
3
4
5
6
010K03472
010K03443
802K60951
10
107E22600
Part of Booklet Maker Assembly

Booklet Maker (P/O PL 8.38 Item 1)
Left Rail
Right Rail (ADJ 12.02.07)
Front Cover (GFEC)
Booklet Maker Front Handle (P/O
PL 8.38 Item 1)
Crease Roll Release Lever (P/O PL
8.38 Item 1)
Crease Blade Knob (P/O PL 8.38
Item 1)
Booklet Maker Stapler Assembly
(S79)
Parts List
PL 8.38
May 2003
5-74
V0.042

Item
Part
Description
055K34090
4
5
6
7
006K28660
130K67602
125K03831
8
9
020E39990
013E12610

Booklet Maker Entrance Baffle
Assembly
Booklet Tamper Assembly (P/O PL
8.39 Item 1) (REP 12.02.09)
Nip 20 Drive Shaft
Booklet Entrance Sensor (S60)
Anti-Static Brush
Booklet Maker Entrance Guide
Nip 20 Drive Pulley
Bearing (6MM)
V0.042
May 2003
5-75
Parts List
PL 8.39

Item
Part
Description
127K44330
3
4
5
6
023E24580
121K33271
022K78851
7
8
809E31200
9
10
11
013E12610
020E39990
12
13
14
15
16
17
962K12444
604K17660

Booklet Paper Path Motor (M60)
(W/TAG M015)
Booklet Paper Path Drive Belt
Booklet Flapper Solenoid (L61)
Booklet Paper Path Drive Belt
Tensioner (W/TAG M015)
Tensioner Spring
Booklet Flapper Solenoid Bracket
Bearing (6MM)
Nip 20 Drive Pulley (W/TAG M015)
Nip Release Lever (P/O PL 8.40
Item 1)
Crease Nip Spring (P/O PL 8.40
Item 1)
Inner Nip Release Link (P/O PL
8.40 Item 1)
Outer Nip Release Link (P/O PL
8.40 Item 1)
Nip Release Shaft (P/O PL 8.40
Item 1)
Harness
Booklet Paper Path Motor (M60)
Upgrade Kit (W/TAG M015)
Parts List
PL 8.40
May 2003
5-76
V0.042

Item
Part
Description
4
5
022E26670
059K30860
013E12610
10
11
12
007E69030
13
121K33310

Part of Booklet Maker Entrance
Baffle Assembly (REF: PL 8.39
Item 2)
Booklet Maker Entrance Baffle (P/O
PL 8.41 Item 2)
Nip 20 Idler roller (4 places)
Nip 20 Idler Shaft (P/O PL 8.41
Item 2)
Nip 20 Idler Spring (P/O PL 8.41
Item 2)
Booklet Compiler Shaft (P/O PL
8.41 Item 1)
Booklet Compiler Flapper (REP
12.02.08)
Flapper Bearing (9a) (2 places),
Compiler Shaft Bearing (9b) (3
places)
Compiler Idler Gear (P/O PL 8.41
Item 1)
Compiler Shaft Gear
Flapper Bracket (P/O PL 8.41 Item
1)
Magnet (2 places)
V0.042
May 2003
5-77
Parts List
PL 8.41

Item
Part
Description
3
4
5
012E13020
809E25100
8
9
802K54312
10
11
121K33432
12
13
006K28670
023E23300
14
15
127K43770
16
17
809E48440
023E23140
18
19
20
21
22
107E22600
125K03593
604K13370

Booklet Compiler Left Baffle (P/O
PL 8.42 Item 1)
Backstop Link
Backstop Link Spring
Booklet Backstop Idler Shaft (P/O
PL 8.42 Item 1,PL 8.42 Item 21)
Backstop Tensioner Link (2 places)
Booklet Backstop Idler Bracket
Booklet Backstop (REP 12.02.11)
Booklet Backstop Slide Shaft (P/O
PL 8.42 Item 1)
Booklet Backstop Slide Shaft
Support (P/O PL 8.42 Item 1)
Front Backstop Clamp Solenoid
(L63), Rear Backstop Clamp
Solenoid (L64) (W/TAG M003, TAG
M023)
Booklet Backstop Drive Shaft
Backstop Drive Belt (REP
12.02.13)
Booklet Backstop Drive Belt Pulley
(P/O PL 8.42 Item 1,PL 8.42 Item
21)
Booklet Backstop Motor (M63)
(REP 12.02.12)
Tensioning Spring
Booklet Backstop Belt (REP
12.02.13)
Anvil Baffle Brush
Anvil Baffle (P/O PL 8.42 Item 1)
Backstop Pulley Kit
Bearing
Parts List
PL 8.42
May 2003
5-78
V0.042

Item
Part
Description
007K13180
007K13190
10
11
12
127K43330
13
14
007E69040
15
107E22600

Front Tamper Assembly (REP
12.02.09,ADJ 12.02.03)
Rear Tamper Assembly (REP
12.02.09,ADJ 12.02.03)
Front Tamper Slider (P/O PL 8.43
Item 2)
Rear Tamper Slider (P/O PL 8.43
Item 3)
Tamper Slider Spring (P/O PL 8.43
Front Tamper rack (P/O PL 8.43
Item 2)
Rear Tamper Rack (P/O PL 8.43
Item 3)
Tamper Guide Plate (P/O PL 8.43
Item 1)
Front Tamper Finger (P/O PL 8.43
Item 1)
Rear Tamper Finger (P/O PL 8.43
Item 1)
Booklet Tamper Motor (M62) (REP
12.02.01)
Booklet Tamper Gear
Tamper Rack Guide (P/O PL 8.43
Item 1)
(S63)
V0.042
May 2003
5-79
Parts List
PL 8.43

Item
Part
Description
4
5
6
7
8
9
020E38512
809E44010
016E17731
809E48830
008E06850
130K67640
10
029K03232
11
12
802E42770
13
14
15
055E51870

Booklet Stapler Bracket (P/O PL
8.44 Item 1)
Stapler Latch Shaft (P/O PL 8.44
Item 1)
Stapler Latch Front Bushing
Stapler Latch Rear Bushing
Stapler Bracket Return Spring
Stapler Latch Cam
(S61)
Booklet Maker Front Stapler (REP
12.02.16, ADJ 12.02.02), Booklet
Maker Rear Stapler (REP
12.02.15,ADJ 12.02.02)
Stapler Cover
Anvil Plate Shim (P/O PL 8.44 Item
1) (ADJ 12.02.02)
Anvil (P/O PL 8.44 Item 1) (ADJ
12.02.02)
Anvil Pad (P/O PL 8.44 Item 1)
(ADJ 12.02.02)
Anvil Mylar Guide
Parts List
PL 8.44
May 2003
5-80
V0.042

Item
Part
Description
015K62191
3
4
127K43600
7
8
413W30654
107E22600
10
014E47460
11
12
13
14
032E19330
15
16
17
18
013E81150
012E12730
008E06840
19

Crease Blade (W/TAG M024) (REP
12.02.02,ADJ 12.02.01)
Blade (P/O PL 8.45 Item 2)
Crease Blade Upper Support (P/O
PL 8.45 Item 2)
Crease Blade Lower Support (P/O
PL 8.45 Item 2)
Crease Blade Motor (M67) (REP
12.02.06)
Crease Blade Bearing
Crease Blade Bearing Retainer
Crease Blade Home Sensor (S68)
(9a), Crease Blade Motor Encoder
Sensor (S70) (9b) (REP 12.02.07)
Crease Blade Motor Encoder (REP
12.02.07)
Crease Blade Shaft (P/O PL 8.45
Item 1)
Crease Blade Gear (P/O PL 8.45
Item 1)
Blade Return Shaft (P/O PL 8.45
Item 1)
Crease Blade Support Guide (4
places)
Bearing (8MM) (4 places)
Crease Blade Link
Crease Blade Cam
Bracket (P/O PL 8.45 Item 1)
Blade Return Shaft Bearing (P/O
PL 8.45 Item 1)
V0.042
May 2003
5-81
Parts List
PL 8.45

Item
Part
Description
2
3
4
006K26093
006K26103
9
10
809E42861
11
127K43610
12
13
014E47460
107E22600
14
15
16
413W31054
17
18
604K13200

Lower Crease Roll (REP 12.02.03)
Upper Crease Roll (REP 12.02.03)
Crease Roll Gear (P/O PL 8.46
Item 18) (REP 12.02.05)
Crease Roll Idler Gear (P/O PL
8.46 Item 18) (REP 12.02.05)
Crease Roll Idler Gear Link (P/O PL
8.46 Item 1)
Crease Roll Front Lever (P/O PL
8.46 Item 1)
Crease Roll Rear Lever (P/O PL
8.46 Item 1)
Crease Roll Nip Spring (2 places)
1)
Crease Roll Motor (M68) (REP
12.02.04)
Crease Roll Motor Encoder Sensor
(S71)
Booklet Maker Rear Handle (P/O
PL 8.46 Item 1)
Crease Roll Bearing
Crease Roll Exit Bracket (P/O PL
8.46 Item 1)
Anti-Static Brush (P/O PL 8.46 Item
1)
Booklet Maker Crease Roll Gear Kit
(REP 12.02.05)
Parts List
PL 8.46
May 2003
5-82
V0.042

Item
Part
Description
2
3
050E20330
020E38700
020E38080
007E68951
007E69081
007E69070
10
11
127K43020
107E22600
12

Crease Roll Gate (ADJ 12.02.06)
Crease Roll Gate Front Guide (ADJ
12.02.06)
Crease Roll Gate Rear Guide (ADJ
12.02.06)
Crease Roll Gate Drive Shaft (P/O
PL 8.47 Item 1)
Crease Roll Gate Shaft (P/O PL
8.47 Item 1)
Crease Roll Gate Rack (2 places)
(ADJ 12.02.06)
Crease Roll Gate Front Gear (2
places) (ADJ 12.02.06)
Crease Roll Gate Rear Gear (ADJ
12.02.06)
Crease Roll Gate Motor (M66)
Crease Roll Gate Home Sensor
(S67)
Bushing (P/O PL 8.47 Item 1)
V0.042
May 2003
5-83
Parts List
PL 8.47
PL 8.48 MFF Booklet Maker Exit

Assembly (1 of 3)
Item
Part
Description
055K33861
059K30880
5
6
7
8
802K53670
802E52460
Booklet Maker Exit Baffle Assembly

(FEC)
Upper Booklet Exit Baffle (P/O PL
8.48 Item 1)
Nip 17 Idler Rolls (3a), Nip 18 Idler
Rolls (3b)
Nip 17 Idler Spring (4a), Nip 18
Idler Spring (4b) (P/O PL 8.48 Item
1)
Hinge Pin (Not Spared)
Bail Arm
Bail Arm Cover
Booklet Maker Exit Front Cover
(Not Spared)
Parts List
PL 8.48
May 2003
5-84
V0.042

Assembly (2 of 3)
Item
Part
Description
3
4
013E81150
5
6
7
8
9
10
11
809E44810
130K67562
962K12493
120E92240
809E44030
12
13
14
125K03531
15
130K67551
16
17
059K30880
18
19
20
21
22
23
050E20621
24
25
Part of Booklet Maker Exit

Booklet Maker Exit Frame (P/O PL
8.49 Item 1)
Bearing (8MM)
Nip 19 Idler Spring (P/O PL 8.49
Item 1)
Tri-Fold Diverter Spring (2 places)
Crease Exit Sensor (S72)
Tri-Fold Exit Harness
Wire Clamp (4 places)
Nip 19 Idler Spring
Nip 19 Idler (P/O PL 8.49 Item 1)
Lower Exit Baffle (P/O PL 8.49 Item
1)
Lower Exit Baffle Return Spring
Booklet Maker Exit Static Brush
Booklet Maker Exit Upper Baffle
Booklet Exit Sensor (S73) (REP
12.03.01)
Nip 19 Idler Rolls
1)
Nip 19 Drive Shaft (P/O PL 8.49
Item 1)
Tri-Fold Exit Drive Shaft (P/O PL
8.49 Item 1)
Item 1)
Item 1)
Tri-Fold Diverter Gate
Nip 17 Drive Gear (P/O PL 8.49
Item 1)
Item 1)
Item 1)
V0.042
May 2003
5-85
Parts List
PL 8.49

Assembly (3 of 3)
Item
Part
Description
2
3
005K11381
4
5
6
7
023E23290
023E23370
809E48380
Part of Booklet Maker Exit

Booklet Exit Drive Assembly
Booklet Exit Drive Bracket (P/O PL
8.50 Item 2)
Gear 40T (P/O PL 8.50 Item 2)
Tri-folder Drive Belt (REP 12.04.02)
Nip 19 Belt
Nip 19 Belt Tensioner (P/O PL 8.50
Item 1)
Nip 19 Belt Tensioner Spring
Parts List
PL 8.50
May 2003
5-86
V0.042
PL 8.51 MFF Tri-folder Assembly

Item
Part
Description
121K33471
3
4
121K33491
020E38480
5
6
7
8
9
809E44040
130E03991
011E13832
604K17650
Tri-folder Assembly (FEC) (REF:

PL 8.21 Item 3)
Tri-fold Diverter Gate Solenoid
(L80)
Tri-fold Curl Gate Solenoid (L81)
Tri-fold Crease Drive Pulley (2
places)
Tri-fold Crease Spring (2 places)
Tri-fold Jam Sensor (S81)
Tri-fold Diverter Gate Solenoid Link
Tri-fold Backstop Kit (W/TAG M018)
Spacer (P/O PL 8.51 Item 8)
V0.042
May 2003
5-87
Parts List
PL 8.51
PL 8.52 MFF Booklet Maker Exit Tray

Assembly
Item
Part
Description
050K54562
2
3
4
5
6
7
8
9
10
11
050E20850
107E22600
127K43321
007E69000
013E12610
12
604K13210
13
14
15
Booklet Tray Assembly (FEC)

((NOTE: Booklet Tray Assembly is
for Professional (FEC)
Configuration Finishers))
Booklet Tray (P/O PL 8.52 Item 1)
Tray Extension
Booklet Tray Full Sensor (S74)
Booklet Tray Belt Motor (M61)
Drive Belt Gear 50T/Pulley 24T
Bearing (6MM) (6 places)
Bottom Cover (P/O PL 8.52 Item 1)
Pulley (P/O PL 8.52 Item 1)
Drive Belt (P/O PL 8.52 Item 1)
Booklet Transport Belt (P/O PL
8.52 Item 1)
Booklet Tray Full Sensor Actuator
Kit
Booklet Tray Full Sensor Actuator
(P/O PL 8.52 Item 12)
Actuator Spring (P/O PL 8.52 Item
12)
Bracket (P/O PL 8.52 Item 1)
Parts List
PL 8.52
May 2003
5-88
V0.042
PL 8.53 MFF Main Tray Assembly (1 of

2)
Item
Part
Description
023E23270
3
4
5
6
7
8
020E23532
020E31100
022E25810
130K67620
802E52701
9
10
11
802E52370
802E52360
12
13
14
15
010K03481
019E62280
Part of Main Tray Assembly (REF:

PL 8.20 Item 6)
Main Tray Elevator Belt - Front
(REP 12.01.01)
Belt Drive Pulley - Front
Belt Idler Pulley - Front (2 places)
Belt Idler Roller - Front
Compile Position Sensor (S51)
Spring (Not Spared)
Main Tray Offset Panel (REP
12.01.03)
Front Inner Cover
Rear Inner Cover
2K Stacker Main Tray (P/O PL 8.53
Item 1)
Main Tray Support (P/O PL 8.53
Item 1)
Slide (2 places)
LED Housing (Not Spared)
Belt Clamp - Front
V0.042
May 2003
5-89
Parts List
PL 8.53
PL 8.54 MFF Main Tray Assembly (2 of

2)
Item
Part
Description
023E23270
2
3
4
5
020E23532
020E31100
022E25810
110E13590
107E22570
127K40980
127K40990
9
10
11
12
13
14
15
008E06950
010K03481
130K56430
16
17
019E62280
Main Tray Elevator Belt - Rear

(REP 12.01.01)
Belt Drive Pulley - Rear
Belt Idler Pulley - Rear (2 places)
Belt Idler Roller - Rear
Main Tray Upper Limit Switch (5a)
(SW51), Main Tray Lower Limit
Switch (5b) (SW50)
Main Tray Full Sensor (6a) (S52),
Main Tray Offset Sensor (6b) (S53)
Main Tray Elevator Motor (M51)
(REP 12.01.04)
Main Tray Offset Motor (M50) (REP
12.01.02)
Offset Cam
Slide (2 places)
Spring (Not Spared)
Compile Position Sensor LED
Cover (Not Spared)
LED Housing (Not Spared)
Elevator Motor Bracket (Not
Spared)
Offset Motor Bracket (Not Spared)
Belt Clamp - Rear (NOTE: Flag on
clamp actuates Main Tray Full
Sensor)
Parts List
PL 8.54
May 2003
5-90
V0.042
PL 8.55 MFF Compiler/Tamper

Item
Part
Description
604K13391
4
5
6
7
8
038K15072
038K15082
019K06163
10
11
12
809E44450
019K06283
13
14
107E22570
15
050E22290
16
17
18
130E09710
962K17381
127K41820
19
20
023E23720
21
22
022K79570
23
24
25
019E52521
962K12471
Compile Backstop Kit (REP

12.05.02)
Front Backstop Kick Arm (P/O PL
8.55 Item 1)
Rear Backstop Kick Arm (P/O PL
8.55 Item 1)
Backstop Link (P/O PL 8.55 Item 1)
Backstop Spring (P/O PL 8.55 Item
1)
Front Backstop (REP 12.05.02)
Rear Backstop (REP 12.05.02)
Main Stapler Anti-Rotation Shaft
(Not Spared)
Compiler Tamper Assembly
(W/TAG M014) (REP 12.05.01)
Compiler Tamper (P/O PL 8.55 Item
9)
Tamper Belt Tension Spring
Compiler Fingers Assembly (REP
12.05.03)
Compiler Fingers Motor (M49) (P/O
PL 8.55 Item 12)
Compiler Fingers Home Sensor
(14a) (S90), Compiler Tamper
Home Sensor (14b) (S44)
Compiler Tray (W/TAG M001, TAG
M029)
Set Eject Sensor (S91)
Set Eject Harness
Compiler Lower Eject Motor (M40)
(REP 12.13.11)
Nip 11 Drive Belt
Nip 11 Drive Belt Tension Spring
(Not Spared)
Nip 11 Drive Shaft
Lower Eject Motor Mounting
Bracket (Not Spared)
Lower Eject Motor Pulley (Not
Spared)
Compiler Fingers
Sensor Harness
V0.042
May 2003
5-91
Parts List
PL 8.55
PL 9.1 Machine Cooling & Filters

Item
Part
Description
1
2
600K54550
054K06045
3
4
5
6
054K10564
054K02803
054K03333
8
9
10
11
12
13
127K25820
127E09711
053E04182
053E06671
NOHAD Filter Kit

(240/255/265/DT65)
PWB Cooling Fan/Duct
Ozone Filter (P/O PL 9.1 Item 1)
Fuser Fan/Duct
ROS/Developer Cooling Fan
(255/265/DT65/460/470)
ROS/Developer Filter (P/O PL 9.1
Item 1,PL 9.1 Item 6) (265)
Cooling Fan (P/O PL 9.1 Item 6)
Scanner Dust Filter (P/O PL 9.1
Item 1)
Scanner Cooling Fan
Xerographic Blower
Fuser Dirt Filter
LVPS Cooling Fan Filter
Parts List
PL 9.1
May 2003
5-92
V0.042
Common Hardware
Item
Part
Description
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
AN
AO
AP
AR
AS
AT
AU
AV
AW
AX
BB
CC
DD
EE
600K57932
Hardware Repair Kit

Plastite Screw
Baffle Clip (019E27452)
Machine Screw (113W40763)
Plastite Screw, Tap (M4 x 8 Lg) (153W72153)
Plastite Screw (M4 x 12 Lg) (153W72353)
Sheet Metal Screw (158W01599)
K Clip, Large (354W01055)
K Clip, Small (354W00555)
1/4 Turn Fastener (459W02355)
1/4 Turn Fastener, blue (429W16355)
1/4 Turn Retainer (429W20155)
1/4 Turn Receptacle (429W31355)
Washer (M4 x 12) (112W26463)
Machine Screw (M6 x 16) (158W40161)
Plastite Screw (M4.5 x 12 oversized) (153W02699)
Developer Cap (021E08190)
K-clip
K-Clip, Medium (354W00855)
1/4 Turn Fastener, white (429W26355)
Retaining Ring
MFF Hardware Kit
K Clip (354W00355)
Bushing (6MM) (013E12610)
Hex Head Screw (153W72253)
Retaining Ring (354W71253)
Screw (153W23652)
Screw (158W27655)
Bushing (013E90840)
Bushing (413W29357)
Bushing (413W39457)
Washer (251W16755)
Machine Screw
Screw (M3 x 8) (153W61153)
V0.042
FF
GG
HH
JJ
KK
LL
MM
NN
PP
RR
SS
TT
UU
VV
WW
XX
YY
ZZ
May 2003
5-93

Machine Screw (M3 X 8 Torx) (113W30763)
Machine Screw, flat (M4 X 8 Torx) (102W13356)
Plastite Screw (M4X12) (153W62353)
K Clip (354W00655)
Machine Screw (M4) (113W45963)
Thread Forming Screw (158W20464)
Bearing (013E10832)
Bearing (013E12220)
Registration Gear Bearing (013E10812)
Hex Head Screw (M3 x 8 Torx) (153W71153)
Screw (158W35457)
Bushing (8MM) (413W29457)
Parts List
Common Hardware
Parts List
Common Hardware
May 2003
5-94
V0.042
6. General Procedures and Information

Copier/Printer Procedures
GP1 Connecting the PWS to the Machine .....................................................................
GP2 Using the Molex Connector Probing Tool ..............................................................
GP4 Saving NVM to or Restoring NVM from Diskette ....................................................
GP5 ESD Field Service Kit Usage .................................................................................
GP6 Life Counter Reset ..................................................................................................
GP7 CSE Bypass in Diagnostic Mode ...........................................................................
GP8 Paper Grain Direction ............................................................................................
GP9 Equivalent Weights of Paper...................................................................................
GP10 Paper Performance Guide ...................................................................................
GP12 Moving the Machine for Service...........................................................................
GP13 Converting Paper Trays for 12 x 18 Inch Paper...................................................
GP14 Switching Machine Installation Phases ................................................................
GP15 Installing Third-party Auditron ..............................................................................
GP17 Copy/Print Meters .................................................................................................
GP18 Resetting Auditron Administrator Access Code ...................................................
GP19 Customer Business Unit Dust-off (Category A) ...................................................
GP20 Resetting Power Saver (Energy Saver) ...............................................................
GP21 Placing the UI into Software Download Mode......................................................
GP22 Connecting the PWS to the ESS Serial Port........................................................
GP23 Accessing the ESS Alternate Boot Menus...........................................................
GP24 ESS Command Line Diagnostics (255/265 PowerPC Only)................................
GP25 ESS Commands ..................................................................................................
GP26 Setting Greenwich Mean Time Offset (GMT Offset) ............................................
GP27 Downgrading a ST Machine to a DC Machine.....................................................
GP28 Software Upload Failures.....................................................................................
GP29 Document Feeder Size Sensing Setup ................................................................
GP30 Programming the Finisher for Thin Stapled Sets .................................................
GP31 Changing the AC Line Frequency and Line Voltage............................................
GP32 Clearing the Machine Network Settings...............................................................
GP33 Special Setups for Kinkos Machines ....................................................................
GP34 Entering Software Options Password ...................................................................
GP35 Running the ESS Memory Test ...........................................................................
GP36 Retrieving ESS Logs............................................................................................
GP37 Accessing ESS Diagnostic Menu (460/470 - Intel ESS) ......................................
GP38 Getting POST Results (460/470 - Intel ESS) .......................................................
GP39 Changing the Alt-Boot System ID (460/470 - Intel ESS)......................................
GP40 Initializing Xerographic NVM .................................................................................
GP41 Measuring the Height of the Paper Buckle ...........................................................
GP42 CSE Fuser Rebuild/Return Process .....................................................................
GP43 Enabling Auto Version Handler / Using Master Uninstaller...................................
GP44 DADF Ground Checkout ......................................................................................
GP45 Upgrade Kits Sequence ........................................................................................
GP46 460/470 Software Upgrade Tool Usage................................................................
GP47 Saving and Restoring Scan to File Templates (460/470 Only) .............................
GP48 Tabs Creation .......................................................................................................
GP49 Exit Decurler (460/470 Only).................................................................................
V0.042
6-3
6-3
6-4
6-4
6-5
6-6
6-6
6-7
6-9
6-10
6-11
6-16
6-17
6-17
6-18
6-19
6-21
6-21
6-22
6-22
6-24
6-25
6-25
6-26
6-27
6-28
6-29
6-29
6-30
6-30
6-31
6-31
6-32
6-33
6-33
6-34
6-34
6-35
6-36
6-44
6-45
6-50
6-51
6-55
6-57
6-58
GP50 Image Overwrite Security (460/470 Only) .............................................................

GP51 MFF Installation.....................................................................................................
GP52 Tri-Fold Setup for 8.5 x 11-inch or A4 Paper ........................................................
GP53 OCT to Disk Finisher Conversion..........................................................................
6-59
6-60
6-61
6-65
PWS Diagnostics
NVM ...............................................................................................................................
Paper ..............................................................................................................................
IIT ...................................................................................................................................
Self Tests .......................................................................................................................
Configuration ..................................................................................................................
Copier Sys ......................................................................................................................
Faults/Counters ..............................................................................................................
Finishing .........................................................................................................................
Marking ...........................................................................................................................
ESS/Network ..................................................................................................................
ESS Alternate Boot Tool .................................................................................................
6-67
6-68
6-71
6-74
6-77
6-79
6-81
6-82
6-84
6-85
6-87
General Information / Specifications

Product Specifications ....................................................................................................
General Service Notes ...................................................................................................
Supplemental Tools and Supplies ..................................................................................
6-89
6-115
6-125
Change Tag Information

Change Tag Introduction.................................................................................................
6-129
IOT Tags
Finisher Tags
HCF Tags
MFF TAGS
Glossary of Terms
Glossary of Terms ..........................................................................................................
May 2003
6-1
6-173
General Procedures
General Procedures
May 2003
6-2
V0.042
GP1 Connecting the PWS to the Machine
GP2 Using the Molex Connector Probing Tool
Purpose
Purpose
The purpose of this procedure is to connect the PWS to the machine to enable correct communication between the two devices.
The purpose of this procedure is to provide the correct procedure for use of the molex connector probing tool.
GP2 Using the Molex Connector Probing Tool

On-Site PWS Connection
1.
Ensure the machine is connected to a correct power source and the machine main power
is switched on.
2.
Switch on the PWS power.
3.
Connect the serial cable between the PWS serial port and the serial port connector on top
of the machine.
4.
Start PWS Lock. Enter correct PWS Lock password.
5.
Open Diagnostic Navigator.
6.
Ensure the correct Comm port is selected when the connection selection window
appears.
1.
Snap the tool over the pin to be measured. Figure 1
2.
Clip the meter lead on to the connector tool.
Figure 1 Using the Molex Connector Probing Tool
V0.042
May 2003
6-3
General Procedures
GP1 , GP2
GP4 Saving NVM to or Restoring NVM from Diskette
GP5 ESD Field Service Kit Usage
Purpose
Purpose
The purpose of this procedure is explain how to save or restore the machine NVM on the
machine resident diskette (MRD).
The purpose of the ESD (Electrostatic Discharge) Field Service Kit is to preserve the inherent
reliability and quality of electronic components handled by Field Service personnel. The kit
should be used whenever handling circuit boards and any ESD sensitive components. To prevent further damage, use the kit when handling the circuit boards being returned for repair.
Saving NVM to Diskette, Using NVM Tool

1.
Enter PWS diagnostics.
2.
Download the machine NVM to the PWS as follows:

a.
Select [NVM] and then [NVM Tool].
b.
In NVM Tool, select [Machine] [Download] [Yes].
ESD Field Service Kit Usage

1.
2.
Assemble the kit.
CAUTION
You must ensure that Service is set to [All]. Otherwise, only the NVM locations in the service
displayed will be saved to the floppy.
3.
Ensure that Service is set to [All].
4.
Ensure the machine resident diskette is in the floppy drive of the PWS.
5.
Select [File] [Save As].

NOTE: When saving NVM, the filename should reflect the current machine software level.
Example: 1_10.bnf (for L1.10 a.k.a. L0.15.6 software). It is recommended to remove
any down-rev filenames to avoid filling up the diskette with multiple nvm files.
6.
Select Drive A:
7.
Select [OK]
8.
Upon completion select [File], [Exit] to return to the Diagnostic Navigator.
3.
a.
Place the static dissipative work surface mat on a flat surface.
b.
Connect the snap end of the grounding cord to the snap on the static dissipative
work surface mat, and the plug end to the metal frame on the machine.
c.
Connect the large snap end of the coiled cord to the top snap on the grounding cord.
d.
Connect the small snap end of the coiled cord to the snap on the adjustable cloth
wrist strap or the ESD digital wrist-watch.
e.
Place the adjustable cloth wrist strap or ESD digital wrist-watch snugly on your wrist.
Circuit boards and ESD sensitive components can now be handled without causing any
ESD related damage. Place any of these components which are removed from the
machine on the static dissipative work surface.
Restoring NVM from Diskette

1.
Launch Diagnostic Navigator.
2.
Ensure the machine resident diskette is in the floppy drive of the PWS.
3.
Restore the machine NVM to the PWS as follows:

a.
Select [NVM] and then [NVM Tool].
b.
In NVM Tool, select [File] [Open].
c.
In the Drives: box, select Drive [A:]
d.
In the File Type box, select [All Files *.*]. This will cause all files on the disk (including those with .BNF extensions) to be displayed.
NOTE: Files containing a .BNF extension are given a default filename at call-close.
The default file name is NVM_XXX.BNF. (Where, XXX is a variable number that is
automatically incremented from the last call. A higher number indicates a more
recent call.)
e.
View the list and click on the desired filename. The filename will appear in the File
name box. Select [OK].
f.
Select [Machine] [Upload] [Yes] to upload the file to the machine. When the message NVM Successfully Written appears, select [OK].
4.
Upon completion select [File], [Exit] to return to the Diagnostic Navigator.
5.
Switch the machine power Off, then On in order for the NVM changes to take effect.
For more help on this routine, go to [NVM tab , NVM Tool], and click on Help.
General Procedures
GP4, GP5
May 2003
6-4
V0.042
GP6 Life Counter Reset
For Document Feeder Paper Feed Roll Cartridge replacement do the following:
Purpose
This procedure outlines the process for resetting the Life Counters for the Paper Feed Roll
Cartridges.
Life Counter Reset using PWS

CRUs
Perform the following steps to reset the counters, then select the link to CRUs:
1.
With the Feeder Replacement window displayed on the Touch Screen, open the Document Feeder Top Cover, replace the DADF Paper Feed Roll Cartridge, then close the
Document Feeder Top Cover.
2.
The Touch Screen will display a window requesting confirmation of replacement of the
DADF Paper Feed Roll Cartridge. Select Confirm .
3.
Select Close to exit the Feeder Replacement window.
4.
Select Exit Tools .
For Tray 5 and or Tray 6 Paper Feed Roll Cartridge replacement do the following:
1.
In CRUs, select [CRU Information].
2.
In the CRU Information window, highlight the appropriate Paper Feed Roll Cartridge from
the list.
3.
Select [Replace].
4.
A popup window will display the message Do you want to reset the counters for this
feed roll? Select [Yes].
5.
6.
1.
With the Feeder Replacement window displayed on the Touch Screen, open the HCF Top
Cover, replace the Paper Feed Roll Cartridge, then close the HCF Top Cover.
2.
Tray 5 Paper Feed Roll Cartridge, the Tray 6 Paper Feed Roll Cartridge, or the replacement of the Paper Feed Roll Cartridges in Tray 5 and Tray 6. Select the appropriate
choice.
In the CRUs window, select [Apply] and then [OK].
3.
After resetting the appropriate counter, exit PWS Diagnostics.
4.
Select Exit Tools .
For Tray 1 , Tray 2, Tray 3, or Tray 4 Paper Feed Roll Cartridge replacement do the following:
NOHAD Filters
1.
With the Feeder Replacement window displayed on the Touch Screen, pull out the Tray,
replace the Paper Feed Roll Cartridge, then push in the Tray.
2.
Paper Feed Roll Cartridge in the Tray, and confirmation the paper in the Tray was
changed. Select the appropriate responses.
3.
4.
Select Exit Tools .
Perform the following steps to reset the counters, then select the link to Counters Display:
1.
In Counters Display, select [Diagnostic Data].
2.
In the Diagnostic Data window, highlight NOHAD Filter Life (ID 15) from the list.
3.
Select [Reset].
4.
A popup window will display the message

counters? Select [Yes].
5.
After resetting the NOHAD Filters counter, exit PWS Diagnostics.
Are you sure you want to clear the
Enter [Faults/Counters tab , Counters Display].
Life Counter Reset using machine UI

Do the following when Auditron is disabled:
1.
Ensure the machine is not in diagnostics mode.
2.
Press the Access button on the keypad to enter the login screen.
3.
Enter the password using the keypad, then select Enter on the Touch Screen.
4.
Select Go to Tools.
5.
On the Touch Screen, select More , Supplies Management , and Feed Roll Cartridge
Replacement .
Do the following when Auditron is enabled:

1.
Ensure the machine is not in diagnostics mode.
2.
Enter the programming pathway to get the login screen.
3.
Enter the password, then select Enter
4.
Select Go to Tools .
5.
On the Touch Screen, select More , Supplies Management , and Feed Roll Cartridge
Replacement .
V0.042
May 2003
6-5
General Procedures
GP6
GP7 CSE Bypass in Diagnostic Mode
GP8 Paper Grain Direction
Purpose
Purpose
The purpose of this procedure is to document how to activate the Start print button on the
User Interface (UI) Control Panel when in diagnostic mode.
The purpose of this procedure is to determine the direction of the grain in any paper stock
Procedure
Procedure
1.
Select the [Access] button on the UI Control Panel.
2.
Enter the appropriate password (0925482).
During the paper making process, the majority of the paper fibers align themselves parallel with
one another, and it is this parallel alignment of fibers which is called the "grain" of the paper.
Depending on how the paper is cut to the finished size, it will either be "grain long" (the grain is
parallel to the long edge), or "grain short" (the grain is parallel to the short edge).
3.
The Start print button is now active in diagnostics mode.
4.
When diagnostic mode is exited, a message will appear on the machine UI Display, asking whether the machine should be reset. Answer [YES].
NOTE: If the machine is not reset, the Start print button will not be active for 10 minutes
after diagnostics is exited.
To determine the direction of the grain in a sheet of paper, crease the paper and observe the
creased edge. Paper creases easily and smoothly parallel to the grain, while creases across
the grain tend to have a rough or ragged appearance. Refer to Figure 1 for illustrations of both
types of creases.
Figure 1 Creasing Paper to Find Grain Direction
General Procedures
GP7 , GP8
May 2003
6-6
V0.042
GP9 Equivalent Weights of Paper

Purpose
The purpose of this procedure is to describe different types of paper stock, and provide a chart
to compare the weights of those paper stocks.
Paper Weight and Substance Information

Paper weight or substance is based on the weight of a ream of 500 sheets of the paper stock at
a specific uncut size. Table 1 shows the uncut ream sizes used to determine paper weights for
common papers used in USCO. In other Op Co's (such as RX and FX), the uncut ream sizes
are different and are specified in millimeters.
Table 1 Uncut Ream Sizes
Paper Type
Uncut Ream Size (Inches)
Xerographic Bond
17 x 22
Offset
25 x 38
Cover
20 x 26
Index
25.5 x 30.5
The weight and substance of the uncut reams of papers are used together to establish the
paper specification, such as 20 lb Bond, or 110 lb Index. In other Op Co's (such as RX and
FX), the paper specifications are stated in grams per square meter (gsm), such as 80gsm
Bond.
It is important to understand the different compositions of the papers themselves, along with
different uncut ream sizes, results in a marked inconsistency of weight designations. For
example, 20 lb Xerographic Bond is approximately equal to 50 lb Offset paper.
Figure 1 was developed to help identify equivalent weights of different paper stocks. It shows
a scale for each type of paper listed in Table 1, and the scales are marked so the indicated
weights are relative to the gsm scale at the top of the chart. Drawing a vertical line on the chart
identifies the equivalent weights of several paper stocks, determined by where the vertical line
intersects each scale.
V0.042
May 2003
6-7
General Procedures
GP9
Figure 1 Equivalent Weights of Paper
General Procedures
GP9
May 2003
6-8
V0.042
GP10 Paper Performance Guide
Table 2 Tray 5 (Bypass Tray)

Excellent
Purpose
Good
Fair
Not Recommended
Mylar Reinforced
(LEF)
The purpose of this procedure is to provide information on which paper trays provide the best
performance for various size and stock papers.
Procedure
Table 3 Tray 6 (HCF)
Choose the appropriate tray/duplex.
Excellent
Good
Fair
Not Recommended
Table 1 Trays 1-4
Less than 20 lbs
Transparencies
Tab Stock
Table 2 Tray 5
20-24 lbs (75-90

gsm)
Table 3 Tray 6
2, 3, 4, 5, 7 hole
drilled
Greater than 24 lbs
Labels (LEF)
GBC (LEF)
Table 4 Duplex
Letterhead
Never Tear
greater than 32 lbs
Labels (SEF)
Pre-printed forms
Other copiers output
Mylar Reinforced
Quality Carbonless
Envelopes
Table 1 Trays 1-4

Excellent
Good
Fair
Not Recommended
Table 4 Automatic Duplex
8.5 x 11 (A4)
Other standard sizes Non-Standard Sizes Envelopes
11 x 17 (A3)
Less than 20 lbs
Labels (LEF)
GBC (LEF)
Excellent
Good
Fair
20-24 lbs (75-90

gsm)
Greater than 24 lbs
Carbonless
Removable strip
transparencies
(SEF)
Letterhead
GBC (SEF)
11 x 17 or A3
Transparencies
Pre-printed forms
Greater than 32 lbs
Carbonless
2, 3, 4, 5, 7 hole
drilled
Other copiers output Mylar Reinforces

(LEF)
Mylar Reinforces
(SEF)
Output from other

copiers
High Quality Carbonless
Quality Carbonless
Tab Stock
Pre-printed forms
Never Tear
Paper Backed
Transparencies (LEF
bound edge trailing)
Letterhead
GBC (SEF)
Labels (SEF)
Quality Recycle
Transparencies
Not Recommended
Labels (LEF)
Envelopes
Table 2 Tray 5 (Bypass Tray)

Excellent
Good
8.5 x 11 (A4)
Other standard sizes Tab Stock (SEF)
Fair
Tab Stock (LEF)
Not Recommended
11 x 17 (A3)
Less than 20 lbs
Envelopes
GBC (LEF)
20-24 lbs (75-90

gsm)
Greater than 24 lbs
Carbonless
Paper Backed
Transparencies (LEF
bound edge trailing)
2, 3, 4, 5, 7 hole
drilled
Other copiers output Mylar Reinforced

(SEF)
High Quality Carbonless
Quality Carbonless
Window Stock
Pre-printed forms
Never Tear
Drafting Film
Letterhead
GBC (SEF)
Labels (SEF)
Labels (LEF)
V0.042
May 2003
6-9
General Procedures
GP10
GP12 Moving the Machine for Service
3.
Check the rear of the machine is at the desired distance from the wall (5 inches or 127mm
is the minimum). If not, repeat the [Moving the Machine Out from the Wall] and the [Moving the Machine Back into Operating Position] procedures to try to steer the machine to
the desired rear clearance.
4.
Once the desired rear clearance is gained, grasp the top corners of the IOT (or Finisher)
at either the left or right end of the machine as required and push the machine end-to-end
to the desired left-to-right position.
5.
Lock the right casters on the IOT.
Purpose
The purpose of this procedure is to use a safe method to move the machine to gain access to
the rear for service. The specified method is required in order to avoid personal injury and
machine damage, and to accommodate the fact that only the right casters of the IOT pivot (the
left IOT casters are fixed in a left/right orientation).
NOTE: In this procedure, it is assumed the machine's operating position is with a wall or other
barrier behind it, with approximately the recommended minimum 5 inches (127 mm) clearance
at the rear. This barrier is referred to here as the wall.
WARNING
Whenever possible, push forward, away from the front of your body (not sideways) to
move the machine. This method uses your body's strongest muscles, minimizing the
risk of personal injury.
WARNING
Any time the machine must be moved in the end-to-end direction (left-to-right or rightto-left) on carpet, it is recommended that you get help from a second person. The force
required for this task can exceed the recommended maximum for a single person.
Moving the Machine Out from the Wall

1.
Unlock the right casters on the IOT.
2.
Facing the right end of the machine, grasp the IOT or the Finisher by the top right corner
(not the DADF).
CAUTION
Do not push on the Document Feeder to move the machine. Pushing on the Document Feeder
can misalign it or cause other damage.
3.
Carefully push the machine to your left, pivoting the right end away from the wall, until it is
far enough from the wall to allow you to step behind the machine.
4.
5.
Step behind the machine and, with your back braced against the wall, continue pushing
the right end of the machine away from the wall until the required service clearance is
gained.
Moving the Machine Back into Operating Position

WARNING
Any time the machine must be moved in the end-to-end direction (left-to-right or rightto-left) on carpet, it is recommended that you get help from a second person. The force
required for this task can exceed the recommended maximum for a single person.
NOTE: This procedure assumes the machine is now positioned at an angle or perpendicular to
the wall, with the left end closest to the wall.
1.
Grasping the top corners of the IOT (or Finisher) at either the left or right end of the
machine as required, push the machine end-to-end to position the left rear corner of the
IOT approximately 5 inches (127 mm) from the wall, or at the customer's desired position
for the rear of the machine.
2.
Push on the front of the machine at the right end to pivot the machine back parallel with
the wall.
General Procedures
GP12
May 2003
6-10
V0.042
GP13 Converting Paper Trays for 12 x 18 Inch Paper

Purpose
The purpose is to convert a Paper Tray (any of Trays 1-4) to feed 12 x 18 inch paper at the customer's request, or to convert it back from 12 x 18 inch to normal operation (accepting up to 11
x 17 inch or A4 paper). The conversion to 12 x 18 inch involves removing the length guide,
which the customer must store until such time as they wish to have the tray converted back to
normal operation.
4.
Turn the tray upside-down.
5.
Remove the screw from the location shown, mate the lever with the bottom of the length
guide, and reinstall the screw into the bottom of the guide (Figure 4).
6.
Ensure the length guide and the lever (size-sensing mechanism) operate smoothly.
7.
Reinstall the Paper Tray Assembly.
8.
NOTE: Though the machine can feed paper as large as 12 x 18, the largest image the scanner can scan is 11.7 x 17.
Do the following on the machine UI:

a.
Dismiss any tray information message which may appear.
b.
Enter the Tools pathway. (Press the [Access] key and enter the customers Tools
password, or log into the Auditron screen if present and select [Tools Pathway].)
c.
Converting a Paper Tray for 12 x 18 Inch Paper
d.
Select [Stock Settings].
1.
Remove the Paper Tray Assembly which is to be converted.
e.
2.
Adjust the length guide out to 17 inch (full-right position).
Select the tray which you are converting back from 12 x 18 inch and select [Change
Stock Size]
3.
Turn the tray upside-down.
4.
Remove the screw from the bottom of the length guide, and reinstall it in the location
shown (Figure 1).
h.
Select [Tray Settings].
5.
Remove the length guide from the paper tray (Figure 2)
i.
NOTE: After removing the length guide, give it to the customer and inform them they must
keep the guide if they ever wish to convert the tray back to normal operation.
Select the tray which you are converting back from 12 x 18 inch and select [Change
Description].
j.
Select [Fully Adjustable].
k.
Select [Save], select [Close], and select [Exit Tools].
6.
7.
f.
Select 8.5 x 11 inch LEF paper, then select [Save] and select [Close].
g.
Select [Paper Settings].
Reinstall the Paper Tray Assembly.

Do the following on the machine UI:
a.
Answer [Confirm] to any tray information message which may appear.
b.
Enter the Tools pathway. (Press the [Access] key and enter the customers Tools
password, or log into the Auditron screen if present and select [Tools Pathway].)
c.
d.
Select [Paper Settings].
e.
Select [Tray Settings].
f.
Select the tray which you are converting to 12 x 18 inch and select [Change Description].
g.
Select [Dedicated].
h.
Select [Save], and select [Close]
i.
Select [Measurements], ensure that [Units] is set to inches (not mm), and select
[Close].
j.
Select [Stock Settings].
k.
Select the tray which you are converting to 12 x 18 inch and select [Change Stock
Size].
l.
Select [Custom Size] and enter [12.0] for the width (cross-process direction) and
enter [18.0] for the length (process direction).
m.
Select [Save], select [Close], and select [Exit Tools].
Converting a Paper Tray Back from 12 x 18 Inch to Normal

1.
Obtain the length guide (removed from the paper tray when it was converted to 12 x 18
inch) from the customer.
2.
Remove the Paper Tray Assembly which is to be converted back from 12 x 18 inch.
3.
Install the length guide into the paper tray (Figure 3)
V0.042
May 2003
6-11
General Procedures
GP13
1
Remove the T20
screw from the
bottom of the
length guide.
3
Reinstall
the screw
here to
secure the
lever in this
position.
2
Pivot the lever to
align this hole with
the hole in the bottom of the tray.
Figure 1 Move the Screw
General Procedures
GP13
May 2003
6-12
V0.042
1
Press the
release button.
2
Lift, rotate, and
remove the
guide.
Figure 2 Remove the Guide
V0.042
May 2003
6-13
General Procedures
GP13
1
Insert the guide
as shown.
3
Ensure the
guide is under
tabs as shown.
2
Rotate the guide
into position.
Figure 3 Install the Guide
General Procedures
GP13
May 2003
6-14
V0.042
3
Install the screw
and tighten until
it stops.
1
Remove the
T20 screw.
2
Pivot the lever as necessary and
insure the boss on the bottom of
the paper guide is inserted through
the slot in the lever.
Figure 4 Move the Screw
V0.042
May 2003
6-15
General Procedures
GP13
GP14 Switching Machine Installation Phases
8.
Purpose
The purpose is to switch the machine's Installation Phase (Install Phase, or mode) from the
normal Install Complete phase to a different phase, and/or switch to Install Complete phase
from another phase. The possible Install Phases are as follows:
Manufacturing phase is used in manufacturing or whenever the card cage configuration

is changed in the field (e.g. memory upgrade). When in Manufacturing Install Phase, the
machine will accept any change to the card cage configuration and not declare configuration mismatch errors.
Either answer [Yes] to resetting the machine or switch off the machine power after exiting
Diagnostics.
Switching the Machine to Install Complete

NOTE: If the machine was in Customer Install phase and the Installation Wizard was completed, the machine should have then switched to Install Complete phase automatically.
1.
Launch Diagnostic Navigator
2.
Select [Configuration].
3.
Select [System, Imaging and IOT Configuration].
Fic phase is only used in manufacturing or during VALO operation -- it is not to be used by
Field Service personnel.
4.
Select [System].
5.
Under [Install Phase], pull down the menu and select [Install Complete].
Customer Install phase is the state in which the machine is delivered to the customer.
Upon the first power-up by the customer or by delivery personnel, the full Installation Wizard sequence of UI screens leads the installer through an initial IOT setup for the customers configuration and location. Upon completion of the Installation Wizard, the
machine transitions automatically to Install Complete phase.
6.
7.
[Exit] Diagnostic Navigator and close the current session to take the machine out of Diagnostics.
Customer Setup phase is the state to which the machine transitions automatically if the
operator accepts a detected configuration change displayed on the UI, if the new configuration requires a setup (e.g. Trays 5 and 6 top edge registration if a HCF/Bypass Tray is
added). A sequence of UI screens (a subset of the Installation Wizard screens) leads the
operator through the necessary setup. Upon completion of the setup, the machine transitions automatically to Install Complete phase.
NOTE: Answer [No] to downloading NVM.

NOTE: The machine must now be reset or powered off in order for the selected installation phase to take effect.
8.
Diagnostics.
Install Complete phase is the normal, operating state of the machine.
The following procedure is used, for example:
to switch the machine to Customer Install phase to have it go through the Installation Wizard,
to switch the machine from Customer Install phase to Install Complete phase if the Installation Wizard cannot be completed, or
Switching the Machine from Install Complete to Another Installation

Phase
1.
Launch Diagnostic Navigator
2.
3.
4.
Select [System].
5.
Under [Install Phase], pull down the menu and select the desired phase, such as [Customer Install] .
NOTE: For 3.0 (L0.17.1) or later software, be sure to set both the [Install Phase (System)]
and the [Install Phase (Main Controller)].
6.
7.
General Procedures
GP14
May 2003
6-16
V0.042
GP15 Installing Third-party Auditron
GP17 Copy/Print Meters
Purpose
Purpose
The purpose of this procedure is to provide a means to allow connection of a third-party device
to the machine.
There are eight copy/print meters (Billing Counters) in this machine. The copy/print meters
available in the Counters area are listed in Table 1.
Perform the following to connect to an external device:
Each meter display can be individually enabled or disabled by changing a bit in NVM.
Machines are shipped from manufacturing with only meter C13 enabled, but the customer can
request the other meters be enabled. Changing the NVM bit(s) can occur on-site by a CSE.
See Meters Display Enable/Disable Procedure.
1.
2.
Connect the device to the machine by following the instructions provided with the device.
The Foreign Interface connector P7/J6 is located in the recessed area at the rear of the
machine.
3.
When the device is correctly connected, switch the power on.
4.
At the UI, select [Tools].
5.
In the Tools section, go to [Tools Screen 2] and select [Auditron Administration].
6.
Select [Authentication mode].
7.
If the Billing Counters are reset for any reason (e.g. the NVM RAM Chip or Software/NVM
Module is replaced, or all machine variable NVM is initialized), you must report the meters
being reset according to Meters Reset Reporting Procedure.
Table 1 Copy/Print Meters
Select [External Auditron] to enable communications between the machine and the external device.
Meter
#
Meter Name
NVM Service
C13
Total Printed Images [Copy Service]

Displayable*
C1
All marked copy

Images 1
[Copy Service]
C10
Copy 11x17 A3
Sheets Displayable
[Copy Service]
C7
Copy Duplex Sheets [Copy Service]

Displayable
C4
Copy Sheets Displayable 2
[Copy Service]
NOTE: Sheets and images removed during jam clearance actions or sheets and images
purged after jam clearance are not included.
NOTE: Meter C13 is always enabled. This appears in NVM Tool as Copy Marked Images Displayable.
Compound images (e.g., N-up, annotated images, merged images) will count as a single
image
Events associated with a service call will be included in these counters
Composite Feature selection resulting in two separate outputs will be counted in each
appropriate counter.
The print meters available in the ESS Counters area are listed in Table 2.
Table 2 ESS Print Meters
NOTE: 1 Known blank pages are not counted as images (e.g., blank transparency dividers,
odd last sheets of 1-2 sided copy jobs, etc.
Meter Name
NVM Service
NOTE: 2 Blank sheets and banner sheets will be included in these counts
Total Marked Print

Images
[Print Service]
Total Large Print

Sheets
[Print Service]
Total Duplex Print

Sheets
[Print Service]
Total Print Sheets
[Print Service]
V0.042
May 2003
6-17
General Procedures
GP15 , GP17
GP18 Resetting Auditron Administrator Access Code
Table 2 ESS Print Meters

Meter Name
NVM Service
Purpose
Total S2F Xfers to

net for FAX
[xfer Service]
Total S2F Xfers to

net
[xfer Service]
If the Auditron Administrator access code number (PIN) has been corrupted or the Administrator cannot remember the previously set access code, the default PIN can be set from the PWS
until a new code can be entered by the Administrator. The purpose of this procedure is to reset
the Auditron Administrator access code to the default setting. The default PIN is 1111 .
NOTE: Resetting the Auditron Administrator access code to the default setting will not change
or remove any previously entered customer account PIN numbers.
Meters Display Enable/Disable Procedure

Use the following procedure to enable/disable the copy/print meters on the copier/IOT.
Procedure
1.
From Diagnostic Navigator, select [Faults/Counters tab , Counters Display].
2.
Select [Billing Display Setup].
3.
To add a billing meter to the display, in the Display column, click the No box at the appropriate line.
1.
From the PWS, launch the Diagnostic Navigator. Select [Local]. After a short wait, the
Diagnostic Navigator window will be displayed.
4.
The box will change to Yes and will be Xed to show it is selected.
2.
Select [Copier Sys tab , Reset Administrator PIN].
5.
To remove a copy/print meter from the display, click the Yes box at the appropriate line.
The box will change to No and will be not be Xed.
3.
From the Reset Administrator PIN window, select [Start].
4.
Answer [Yes] to the question: This will reset the Auditron Administrator PIN to the
default value. Are you sure? .
5.
Select [Exit] to return to the Diagnostic Navigator screen.
6.
Exit the Diagnostic Navigator.
6.
Repeat step 4 (if necessary) and step 5 for each meter to be enabled/disabled.
7.
Exit the counters routine.
Perform the following procedure to reset the Auditron Administrator Access Code:
To enable/disable print meters on the ESS:

1.
From Diagnostic Navigator, select the [Faults/Counters] tab and select [ESS Counters
Display].
2.
Select [Billing Display Setup].
3.
To add a billing meter to the display, in the Display column, click the No box at the appropriate line.
4.
The box will change to Yes and will be Xed to show it is selected.
5.
To remove a copy/print meter from the display, click the Yes box at the appropriate line.
The box will change to No and will be not be Xed.
6.
Repeat step 4 (if necessary) and step 5 for each meter to be enabled/disabled.
7.
Exit the counters routine.
Meters Reset Reporting Procedure

CSEs need to call in meter reads when a service call results in a meter reset. Be prepared to
report the 9-digit machine serial number, the meter read date, and the old and new meter
reads
NASG: To report the Billing Meters reset, call into one of the Customer Business Centers:
Chicago CBC: 1-888-771-5225 (7 AM - 7 PM Central Time). Choose option 4 - (For all

other administrative inquiries).
St. Petersburg CBC: 1-888-435-6333 (8 AM - 8 PM Eastern Time). Choose option 4 - (If

you have questions regarding your invoice or account).
Dallas CBC: 1-888-339-7887 (7 AM - 6 PM Central Time). Choose option 4 - (If you

have questions regarding your invoice or account).
General Procedures
GP17, GP18
May 2003
6-18
V0.042
GP19 Customer Business Unit Dust-off (Category A)

Purpose
The purpose of this procedure is to prepare the Document Centre 240/255/265 DC, ST, or LP
for re-deployment to another customer site within the Customer Business Unit (CBU) and, at
the same time, maintain the reliability of a new installation.
2.
Inspect all of the systems covers, trays, front door, panels, labels, and bezels. Replace
any that are damaged or missing.
3.
Inspect the PWS serial and parallel ports on the machine for damage or bent pins.
Replace the PWS Cable (PL 1.2A) as required.
4.
Clean the Platen Glass and other Scanner components per REP 14-3.
5.
Clean the BTAC Sensor per REP 09-9.
The system may only be used as a demo or for a customer satisfaction replacement (like-forlike).
6.
Clean the Photoreceptor Drive Module per REP 09-11.
7.
Clean the Upper and Lower Paper Guides and sensors, and the Vertical Transport rollers
(PL 4.1A ).
A system is defined herein as including the following:
8.
Clean any paper dust from Paper Tray Wait Station Sensor (S1), Registration Sensor (S2)
on the Registration Transport Assembly (PL 4.1A) and Prefuser Sensor (S3) on the Prefuser Transport (PL 6.1A).
Clean the sensors in the Inverter (S4 and S5).
Table 1 System Definitions

265 DC and ST
265 LP
240/255 DC
9.
IOT
IOT
IOT
10. Inspect all filters and replace if necessary.
HCF
HCF
HCF or Bypass Tray or no

input device
11. Inspect the Developer Housing for damage or leaking developer. Replace the Developer
Housing PL 5.1B as necessary.
Finisher
Finisher
OCT or Finisher
12. On the PWS, enter the Diagnostic Navigator and select the [Faults / Counters] tab, and
then [Faults]. Check the last 40 faults and the fault counter. Perform any necessary service action.
Shelf
--
Shelf (optional)
Stapler
--
Stapler (optional)
13. Install all mandatory system retrofits (found in manual and electronic format). Check the
Change/Tag Matrixes of the IOT and the input/output devices for all the appropriate tags.
If necessary, obtain and install the most current tags to bring the system up to the correct
tag level.
The System must also meet the following criteria to qualify for CBU Dust-off (Category A):
No non-repairable damage (frame, water, fire, ect.)
Must have a meter indication of less than 250,000 prints
14. Check for skew and perform the ADJ 05-1 DADF Skew adjustment procedure, if necessary.
Must meet a minimum build configuration (IOT Serial Number can be no lower than 2UP074008 (265 DC) (serial number for ST, LP, 240 and 255 are TBD).
IOT CRUs
Must be kept as the original system
1.
Inspect the Dry Ink Cartridge. Install a new Dry Ink Cartridge PL 5.1B if it is less than 1/3
full.
NOTE: Any system that does not meet the above criteria must flow through Category B
(extended dust-off process at the XCC) or Category C (returned for re-manufacturing at the
Focus Factory Site).
2.
Inspect the Developer Collector Bottle. Install a new Developer Collector Bottle PL 5.1B if
it is more than 2/3 full.
3.
Brush off the mylar strip on the Xerographic Module.
The following is an overview of the tasks that will be performed during CBU dust-off:
4.
On the machine UI, press the [Machine Status] key and then select the [Supplies] tab on
the touch screen.
5.
Check the indication for the Xerographic Module (PL 5.1A Item 1). Replace the module if
the indication is over 25,000 copies.
6.
Check the indication for the Fuser Module (PL 6.2A ). Replace the module if the indication
is over 125,000 copies.
Troubleshoot and repair any fault codes or other problems as necessary.
Upgrade the system with the most current version software.
Install all mandatory system retrofits (found in manual and electronic format).
Install upgrades per the customer order.
Follow standard Call Close procedures: Run a matrix of copies. Record the metereadings. Record the call and state what was done to the system.
Inspection and Cleaning Procedures

1.
Order replacements for any of the following loose items that are missing:
power cord
phone cord
Nationalization Kit (order through PUBS ordering system)
Documentation Holder (for the back of a DC or ST).
V0.042
DADF
1.
Clean the DADF (REP 05-1).
2.
Replace the DADF Paper Feed Roll Cartridge (PL 2.2), and reset the life counter (GP6).
3.
Inspect the Document Restack Guide (PL 2.1A Item 9) for damage, and replace as necessary.
Bypass Tray, HCF/Bypass Tray, and Paper Trays

1.
Replace the Bypass Tray and HCF Paper Feed Roll Cartridges (PL 4.2B Item 6 or PL 4.3
Item 2) and all Paper Tray Paper Feed Roll Cartridges (PL 4.1A Item 3). Be sure to reset
the life counters (GP6).
May 2003
6-19
General Procedures
GP19
2.
Inspect all paper trays for damage. Replace the Paper Tray(s) PL 4.1A as necessary.
In LO17 SW, when performing a Dust Off, the NVM values that cause a full wizard to be run when Uninstall phase is set to Customer Install are not reset,
resulting in the Tray 5/6 registration setups not being run.
To ensure the wizard will prompt the correct setups, reset the NVM values to 0
as indicated in Table 2.
Finisher
1.
Inspect the Service Tray Assembly (PL 8.4) and Top Module Assembly (PL 8.3) for damage. Replace as necessary.
2.
Inspect the docking hooks for damage.
3.
Inspect the Staple Cartridges. Hold the cartridge up to the light. If it is less than half full,
replace the cartridge.
OCT
1.
Inspect the OCT Stacking Fingers (PL 8.4) for damage, and replace as necessary.
2.
Inspect the OCT mounting hooks for damage.
Accessory Shelf
1.
Inspect the Accessory Shelf (PL 8.1) for damage. Replace as necessary.
2.
Make sure the latching pin is extended.
Convenience Stapler
1.
Inspect the Convenience Stapler (PL 8.1) for damage. Replace as necessary.
2.
Inspect the Staple Cartridge. Hold the cartridge up to the light. If it is less than half full,
replace the cartridge.
ST or LP
1.
Reset the Network Configuration Settings to the factory defaults:

a.
In Diagnostic Navigator, select the [Configuration] tab.
b.
Select [Network Configuration Initialization].
c.
Select [Start].
Table 2 NVM Values

Name
Service
Module
Location
Value
Machine Phone
Number Setup
DC Platform Manager
None
28
ModuleHasBeenSetup
Mark
F2IOT/F1IOT
96
ModuleHasBeenSetup
Mark
HCF with Covers
96
ModuleHasBeenSetup
Mark
High Cap Finisher
96
ModuleHasBeenSetup
Mark
SMH
96
5.
Ensure the Convenience Stapler Power Cord is stored correctly.
6.
Clean the system with Formula A cleaner.
NOTE: System packaging and delivery will be determined by the carrier's relocation process.
2.
Ensure a Configuration Report will print out. Troubleshoot and repair as necessary.
3.
Install any ESS options per customer order.
4.
Install any mandatory ESS retrofits. Check the Change/Tag Matrixes of the IOT for all the
appropriate tags. If necessary, obtain and install the most current tags to bring the ESS
up to the correct tag level.
Preparation for Installation

1.
Run test copies and evaluate the image quality. If image quality does not meet specifications, go to the IQ-1, IQ Entry RAP.
2.
Perform procedure ADJ 8-1 IOT Registration Setup Series.
3.
Perform procedure ADJ 14-2 IIT Registration and Magnification.
4.
Perform the following to reset the install wizard for customer install:
a.
From the PWS, launch the Diagnostic Navigator. Select [Local]. After a short wait,
the Diagnostic Navigator window will be displayed.
b.
Select [Configuration], and then [System, Imaging and IOT Configuration]. Click on
[Install Phase].
c.
To enable Customer Install, select [Customer Install] or [Customer Setup]. To disable Customer Install, select [Install Complete].
d.
Select [OK] to return to the Diagnostic Navigator screen.
e.
If the machine has a version of LO17 installed, perform the following (if any other
version LO15, LO18, go to the next step):
General Procedures
GP19
May 2003
6-20
V0.042
GP20 Resetting Power Saver (Energy Saver)
GP21 Placing the UI into Software Download Mode
Purpose
Purpose
These machines comply with the federal guidelines for energy conservation. Part of that compliance involves an automatic control to cut back on electrical power consumption during periods of inactivity.
The purpose of this procedure is to place the User Interface into a state in which it will accept a
software download (upload, from the PWS' perspective). This is required whenever uploading
software to the UI as part of a UI replacement, but is not normally required for a full system
software upgrade. However, this procedure can be used when the UI fails to respond during a
software upgrade, such as if the parallel cable is not connected securely.
Procedure
There are two stages of Power Saver available: Low Power Mode and Off.
Procedure
If the machine is inactive for a pre-determined amount of time, it will automatically enter
Low Power Mode, which switches off some outputs of the LVPS and lights the Power
Saver indicator on the UI.
1.
2.
Ensure the parallel and serial cables are connected securely to both the PWS and the
machine.
If the machine remains inactive for an additional pre-determined amount of time, it is automatically switched completely off.
3.
Press and hold the C and # buttons simultaneously, and switch on the machine power.
Wait approximately ten seconds, then release the C and # buttons.
NOTE: During Low Power Mode, power is delivered to the Main Control PWB and the UI in
order to maintain the ability to sense when the customer uses the UI, or actuates an interlock
switch. This action causes the machine to automatically go into Standby Mode. However,
because the Fuser cools when the machine is in Low Power Mode, the first job after a Power
Saver interval will be delayed until the Fuser warms up.
The UI should now respond normally, as described in the software upgrade instructions or the
UI replacement procedure REP 02-1. If not, repeat the above procedure.
The time intervals for both Power Saver modes are to be adjusted by the customer only,
using the User Interface. Refer the customer to the Reference Guide, Power Saver Administration, for the instructions for changing the Power Saver settings.
The default settings and adjustment ranges for each machine version are shown in Table 1.
KEY: LPM = Low Power Mode
Table 1 Power Saver Adjustment Intervals
Machine Time Until
Entering LPM
(minutes)
Warm-up
(LPM to
Standby)
(seconds)
Time From
LPM to Off
(minutes)
DC 240
Default; 15
Range; 15 - 225
less than 30 Default; 15

Range; 0 - 15
DC 255
Default; 15
Range; 15 - 120

Range; 0 - 120
DC 265
Default; 15
Range; 15 - 120

Range; 0 - 120
DT65/
DP65
Default; 15
Range; 15 - 120

Range; 0 - 120
V0.042
May 2003
6-21
General Procedures
GP20 , GP21
GP22 Connecting the PWS to the ESS Serial Port
GP23 Accessing the ESS Alternate Boot Menus
Purpose
Purpose
The purpose of this procedure is to connect the PWS to the ESS Serial port and enable correct
communication between the two for the purpose of monitoring the boot process or to access
the operating system to perform maintenance activities.
The purpose of this procedure is to access the ESS Alternate Boot menu for maintenance
activities.
Initial Actions
Initial Actions
The following is required:
The PWS must be connected to the ESS using GP22 Procedure.
PWS Serial Cable 600T2058
The machine software CD-ROM must be in the PWS CD-ROM drive.
Null Modem Adaptor 600T2073 (240/255/265)
Null Modem Adaptor 113E40060 (460/470/480)
GP23 On-Site Procedure (255/265 - PowerPC ESS)
Connect the Null Modem adaptor to the PWS Serial Cable.
1.
On the PWS, launch the Alternate Boot Tool.
2.
When the Alternate Boot Tool opens click the Upload Forth Code button in the Alternate
Boot dialog to open the Windows terminal emulator with the correct communication settings.
GP22 On-Site Procedure (240/255/265 - PowerPC ESS)

1.
If not already done, create a Windows HyperTerminal file for reading the ESS TTY data. If
done, go to step 2.
a.
In Windows, select the [Start] button, then [Programs]. Select the Accessories Program Group.
b.
Select HyperTerminal.
c.
After HyperTerminal has started, the New Connection dialog will request that you
choose a name for the profile you are creating. Choose something that will allow
you to remember it, such as DC265.
d.
In the Connect using pull-down window, select [Direct to COM 1], then OK.
e.
In the Port Settings box, change the Baud Rate to 9600, Data Bits should be 8, Stop
Bits=1, Parity=None, Flow Control=Xon/Xoff, and then OK
f.
The file just saved should be opened whenever the PWS needs to be connected to
the ESS Serial port.
2.
Open the saved HyperTerminal file.
3.
Connect the serial cable between the PWS serial port and the ESS Serial Port Connector.
Use the Null Modem adaptor with the standard PWS Serial cable.
4.
To record ESS information as it occurs (recommended), do the following:

In the HyperTerminal program, select [Transfer], then [Capture Text]. Select a location and a file name for the text file.
NOTE: While using the Terminal Program, it may be necessary to use the scroll bars at
the side of the window to view some of the system responses.
3.
NOTE: The software versions have the following directory structures:

17.6 SW = 05_05
17.8.12 SW = 05_06
17.8.63 SW = 05_07
It is important to select the correct software version to ensure correct completion of this
procedure.
4.
Position the mouse cursor inside the Terminal program window and click once to bring
that application to the front. Power the machine on and observe the activity in the window.
5.
When the ESS system has started and is about to run self-test, hit any key to interrupt the
test.
6.
When the message appears, Type any key to interrupt self-test, hit any
key to interrupt the test. A screen menu (Main) will appear. Use the arrow keys to select
Administrative Options (you may need to scroll to see the whole menu) and press
[ENTER]. In the next menu displayed (again you may need to scroll to see it), select
Invoke the Command Line Prompt and press [ENTER].
7.
At the ok, type setenv load-base 0xF00000 [ENTER]. You should see the message: load-base= 15728640
Click [Start] to start the capture process.

5.
6.
Observe the ESS boot on the PWS screen or on the captured text file set-up above.
When the Select Software Version window appears, select the version the machine is
running, then select [OK].
GP22 On-Site Procedure (460/470/480 - Intel ESS)

1.
8.
Type: dl [ENTER] You should see the message: Ready for download.
then
2.
Start the Alternate Boot Tool.
9.
Connect the PWS parallel port to the ESS parallel port.
3.
4.
Observe the ESS boot on the PWS screen.
10. In the Terminal window select the Transfers menu, then select the Send Text File option.
The Send Text File dialog will open, at the bottom of the dialog use the drop list menu to
list ALL FILES and find the altboot.fth on the Lakes Software CD-ROM. NOTE the path to
this file is normally [CDROM_drive_letter] / inst / [software_version] / ESS / diskimage /
altboot.fth. Once the file is selected, click the [OK] button to download it to the ESS.
General Procedures
GP22 , GP23
May 2003
6-22
Send file
V0.042
NOTE: Ensure the machine software CD-ROM is in the PWS CD-ROM Drive, and the
ESS Parallel cable is connected between the PWS and the ESS.
Unless there are any checksum errors, the screen should read:
START PARALLEL DOWNLOAD NOW
If there are any errors, the program will abort and it will be necessary to repeat the procedure starting at step 4.
11. Use your mouse and click once on the Alternate Boot dialog to bring it to the front, select
the Upload System Kernel button. The status textbox will read Please select file to
upload. Press the Browse button to locate the file on the Lakes Software CD-ROM. This
file is typically named ekpXXXXX.sre, where XXXXX is the Lakes software version. Consult your release documentation and/or software install instructions for details.
12. After the file is selected, the status message should read ESS Upgrade can begin. Press
the Upload button. You may wish to minimize all windows except the Alternate Boot dialog and Terminal window for the duration of the download.
13. You will see text messages going by in the Terminal window and after about 1.5 minutes,
the transfer will complete and the kernel will load and display the following menu:
5.
The Select Software Version dialog window will appear. In most cases the present software version should be selected. The available versions that are on the CD are listed in
the lower section of the window. The actual install path is near the top. If the default version is not correct, click the Browse button to navigate to another version.
6.
The Parallel Boot Code - Intel Platform dialog window will appear. In the Filename area,
the parallel bot code path and filename should appear and will be format like PBCV2P71.
BIN. Click [Upload]
7.
The Parallel / Serial menu will be displayed. Select 2) Download Lynx Mini-Kernel.
The version follows this format: 90_11 = L19.0.11
8.
@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
DCS 240/265 Alternate Boot v2.2 - compatible from 19.0 onward
DCS 240/265 Alternate Boot v1.5 - compatible from 17.0 onward
(C) 1996, 1997, 1998, 1999 Xerox Corporation
(C) 1996, 1997, 1998 Xerox Corporation
@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
1) Repair (Recreate) ESS SCSI Disk Partitions
1) Repair (Recreate) ESS SCSI Disk Partitions
2) Display SCSI Disk Partition Information
2) Display SCSI Disk Partition Information
3) Verify ESS Software
3) Format ESS SCSI disk (Low level)
4) Reset ESS configuration to defaults
3) Verify ESS Software
5) Install ESS software via network (FTP)
4) Reset ESS configuration to defaults
6) Install ESS software via network (NFS)
5) Install ESS software via network (FTP)
7) Install ESS software via parallel port
6) Install ESS software via network (NFS)
8) Format
7) Install ESS software via parallel port

8) Format
ESS
The kernel will load and display the following menu:

@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@
ESS
SCSI disk (Low Level)- [Seagate Only]
b) Boot SCSI disk
SCSI disk (Low Level)- [Seagate Only]
q) Quit
b) Boot SCSI disk

q) Quit
14. Click once on the Upload System Kernel window to bring it to the front then on the Exit
button to close it.
GP23 On-Site Procedure (460/470/480 - Intel ESS)

The Intel based ESS has different menus and options. This procedure documents how to
access and load the mini-kernel, which is equivalent to the GP23 procedure for the old ESS.
1.
2.
3.
After approximately 30 seconds, a message will appear in the terminal window, Press
any key to access Alternate Boot Menu . When this message appears, press
any key on the PWS keyboard.
4.
The Alternate Boot Menu will appear. Ensure the System ID is Lakes. If the System ID is
Hodaka, go to , GP39 , Changing the System ID and return here.
Select 3) Parallel / Serial Boot.
NOTE: Do not press the Enter key.
V0.042
May 2003
6-23
General Procedures
GP23
GP24 ESS Command Line Diagnostics (255/265 PowerPC

Only)
Purpose
test /memory
type test /memory [Enter] - tests the integrity of the ESS memory. Ok prompt is returned
if test passes. A failure will be indicated by a message. This test has little value. It won't catch
all memory failures.
The purpose of this procedure is to access the ESS command line and identify the available
diagnostics. These diagnostics are part of the Open Firmware which is resident on the ESS
PWB. They can be used to help verify correct operation of the ESS PWB and communications
to the network. These are only available on 255/265 machines with the PowerPC based ESS.
type probe-scsi [Enter] - identifies devices attached to the SCSI bus. An ok prompt without any information about the hard disk would indicate a failure.
Initial Actions
watch net
The machine software CD-ROM must be available.
type watch net [Enter] - checks the network connection. A series of . . . . . . . . . . . . indicates packets are being received from the network. X indicates bad packets. No information
indicates a connection problem.
GP24 On-Site Procedure

1.
2.
When the Alternate Boot Tool opens click the Upload Forth Code button in the Alternate
Boot dialog. When the Select Software Version dialog opens, select [OK] to open the
Windows terminal emulator with the correct communication settings.
probe-scsi
To restart the ESS when complete, type boot
NOTE: If you get an error message the Terminal program can't find the file, clear the error
message by clicking [OK], then use the File menu Open command to browse for the altrboot.trm file to set up the correct terminal profile.
3.
4.
When the ESS system has started and is about to run self-test, hit any key to interrupt the
test. A screen menu will appear. Use the arrow keys to select Administrative Options
(you may need to scroll to see the whole menu) and press [ENTER]. In the next menu
displayed (again you may need to scroll to see it), select Invoke the Command Line
Prompt and press [ENTER].
5.
The ok prompt is now available (you may need to scroll to see this).
test net
type test net [Enter] - checks that data can be received and verified via internal loopback.
If pass, the ok prompt will return. If it fails, a message will be displayed indicating a failure.
test /nvram
type test /nvram [Enter] - tests the integrity of the ESS nvram. Ok prompt is returned if
test passes. A failure will be indicated by a message
Memory Test
type showstack [Enter], after the ok prompt appears, type 10000 1D905C0 mem-bitstest [Enter] - tests the integrity of the ESS memory. Ok prompt followed by a 0 is returned if
test passes. A failure will be indicated by a memory address indicating the location of the failure.
General Procedures
GP24
May 2003
6-24
V0.042
GP25 ESS Commands
GP26 Setting Greenwich Mean Time Offset (GMT Offset)
Purpose
Purpose
The purpose of this procedure is to document special commands that are available in the ESS
terminal window.
The purpose of this procedure is to set the Greenwich Mean Time Offset (GMT Offset) correctly in the machines memory. The GMT Offset is the difference between the machines local
time and the time in Greenwich, England (called Greenwich Mean Time, or Zulu time).
Combined with the local time and date which are also set in the machines memory, the
machine has a complete time setting which is based on a global standard.

The following commands can be used whenever the ESS user prompt is displayed:
shutdown
Procedure
type shutdown [Enter] - Shuts the system down
1.
2.
Select the [Configuration] tab.
startess
3.
type startess [Enter] - Starts the DC240/255/265 ESS
4.
5.
Under [GMT Offset], pull down the menu and select the correct number for the machines
time zone (Table 1).
stopess
type stopess [Enter] - Stops the DC240/255/265 ESS
info
6.
7.
type info [Enter] - Displays system information

ps
type ps [Enter] - Lists the currently running processes

8.
Diagnostics.
Table 1 GMT Offsets
GMT
Offset
V0.042
Time Zone, Cities, or Areas
-12
Eniwetok
-11
Samoa
-10
Hawaii
-9
Alaska
-8
Pacific United States (PST), Vancouver
-7
Mountain United States (MST)
-6
Belize, Central United States (CST), Houston, Mexico City
-5
Eastern United States (EST), Lima, Montreal
-4
Antigua, Atlantic, Grenada
-3
Brazilia, Buenos Aries
-2
Mid-Atlantic
-1
Cape Verdes
Greenwich Mean Time (GMT), Dakar, Dublin, London, Reykjavik
+1
Algiers, Berlin, Danderyd, Madrid, Milano, Paris, Rome, Vienna
+2
Cairo, Damascus, Holargos, Israel
+3
Kuwait, Moscow, Qatar, Riyadh
May 2003
6-25
General Procedures
GP25 , GP26
Table 1 GMT Offsets

GMT
Offset
Time Zone, Cities, or Areas
+4
Abu Dhabi, Muscat
+5
Islamabad, Karachi
+6
Almaty, Dhaka
+7
Bangkok, Jakarta
+8
Beijing, Hong Kong, Singapore
+9
Osaka, Tokyo
+10
Brisbane, Guam, Melbourne, Sydney
+11
Magadan, Soloman Is.
+12
Auckland, Fiji, Wellington
GP27 Downgrading a ST Machine to a DC Machine

Purpose
The purpose of this procedure is to remove a NCFT or Beta Trial DC-to-ST upgrade, downgrading it from a ST copier-printer back to a DC copier. This procedure is only to be used upon
notification from Sales that a downgrade is required. This procedure can only be performed
after the release of Version 5.03 or higher software.
Procedure
Before Visiting the Customer Site
1.
Call ahead to the customer to schedule the downgrade. Confirm the System Administrator has removed the ST from the network and notified all users the machine is no longer
available for print jobs.
2.
Order the DC Front Door Insert (logo) and UI logo (PL 7.2), and bring them when visiting
the customer site.
3.
Bring the Version 5.03 or higher Software Upgrade Kit and associated required items to
bring listed in that kits instructions, when visiting the customer site.
At the Customer Site

1.
Verify the machine software version is 5.03 or higher. If not, upgrade the software,
excluding the ESS software.
2.
Using the PWS, change the Install Phases and the System Configuration as follows:
a.
b.
Select the [Configuration] tab.
c.
d.
e.
Under [Install Phase (System)] and [Install Phase (Main Controller)], pull down each
menu and select [Customer Install].
f.
Under [System Configuration], pull down the menu and select [Digital Copier].
g.
h.
[Exit] Diagnostic Navigator and close the current session to take the machine out of
Diagnostics.
General Procedures
GP26 , GP27
3.
Switch off the machine power and disconnect the Power Cord.
4.
Remove the following items:

a.
ESS Disk Drive (REP 16-1) and its power and data cables.
b.
ESS PWB (REP 16-2).
c.
Network Cable.
d.
ST Front Door Insert (logo) and UI Logo.
5.
Install the DC Front Door Insert (logo) and UI Logo.
6.
Reconnect the Power Cord, and switch on the machine power.
7.
Complete the Installation Wizard procedure as instructed on the UI screen, as a DC

copier.
8.
Place a note on the machine stating that it is now a copier only. Ensure the Machine
Administrator understands the change, and that they will reinforce with the users the
machine is now a copier only.
May 2003
6-26
V0.042
9.
Close the call (e.g. on FWSS) as a XI (Xerox Initiated -- not charged to the customer), and
revise the service records to reflect the machine is now a DC copier.
10. Materials removed should be returned by your normal parts return process.
GP28 Software Upload Failures

Purpose
The purpose of this procedure is to identify known causes of software upload failures, and suggest remedies for those causes.
Procedure
CAUTION
Before troubleshooting a software upload failure, ensure you have carefully followed the appropriate Machine Software Upgrade Procedure in the Software Kit Installation Instructions.
Each version of the Machine Software Upgrade Procedure identifies potential causes of software upload failures unique to that version of software, and the corrective action(s) to take
when those failures occur.
If the Machine Software Upgrade Procedure has been carefully followed, and the cause of the
software upload failure still has not been identified, read through the items in the following list
to determine if any of the causes listed here apply to your PWS or the DC265-family product
being upgraded.
1.
Running the PWS on battery power.

Running the PWS on battery power causes it to go into power saver mode after periods of
keyboard/mouse inactivity.
Remedy: Connect the PWS to a reliable source of AC power before starting the software
download process.
2.
Printer drivers may be loaded on the PWS.

Printer drivers use the parallel port as does the software upload process. When printer
drivers are loaded on the PWS, they can cause contention problems for the parallel port
which results in an interrupted flow of data through that port.
Remedy: If printer drivers are loaded on the PWS, remove them, then try the software
upload process again.
3.
The response time of the PWS CD drive may be too slow for the system to tolerate.
Remedy: If there is room on the C:\ drive, copy the contents of the machine software CD
to the C:\ drive and install the software from that location.
4.
Electrical noise can enter the system through the parallel cable(s). Complicating this
problem is the inability of the Main Control PWBs without Tag 015 (also called "Atlanta 96"
PWBs) to correctly filter high levels of noise.
Remedies:
V0.042
a.
Ensure the parallel cable(s) are firmly seated into their connectors, and are placed
away from sources of electrical noise (i.e., power supplies, monitors, and motors).
b.
Use shorter parallel cables.
The recommended IOT parallel cable is now 600T2155 (6' long) instead of
600T2065 (the original 10' cable). (This cable is used on all machines.)
The recommended ESS parallel cable is now 600T2037 (6' long) instead of
600T2066 (the original 10' cable). (This cable is used only on DCS 265/255/
240 ST/LP machines.)
5.
Main Control PWBs without Tag 015 (also called "Atlanta 96" PWBs) do not correctly filter high levels of electrical noise.
May 2003
6-27
General Procedures
GP27 , GP28
6.
Remedy: If you have implemented all items on this list and still experience repeated software upload failures on machines without Tag 015, upgrade the machine to a newer version of Main Control PWB to reduce the susceptibility to electrical noise. The newer
versions of Main Control PWBs are also called "Atlanta Gold" PWBs, and the Tag numbers associated with those PWBs are 015, 042, 052, and 065. You will get the latest
available version when you order the part number in the EDOC.
GP29 Document Feeder Size Sensing Setup
Problem uploading ESS Software after replacing ESS Hard Disk Drive.
Document Feeder Size Sensing
Remedy: Some ESS Hard Disk Drives manufactured by Quantum, with part numbers
121E15370, were shipped with 3 jumpers installed instead of one.
NOTE: This procedure can be performed by either the Key Operator or by the CSE.
Refer to Figure 1. Verify there is only one jumper on the connector and it is installed
Do the following:
1.
Load the document in the Document Input Tray.
If the connector has additional jumpers, remove them.
2.
Ensure the Document Input Tray Side Guides are touching the paper and the document is
3.
Enter Tools.
4.
In Tools, select System Settings , More ,and Document Scanner Size Sensing .
5.
In the Document Scanner Size Sensing screen, check the scrolling list of document sizes.
6.
If there is a size that matches the document loaded in the Document Input Tray, select the
appropriate size on the Touch Screen, then select the Save button. Exit Tools.
7.
In order for the DADF to sense the document correctly, remove the document from the
Document Input Tray then load the document in the Document Input Tray.
8.
If there is a not a size that matches the document loaded in the Document Input Tray, do
the following:
Purpose
The purpose of this procedure is setup the Document Feeder to sense standard and custom
document sizes.
a.
Select Custom Size on the Touch Screen.
b.
Press the X dimension button on the Touch Screen.
c.
Enter the X dimension size of the document in millimeters using the Keypad, then
press the X dimension button.
d.
Select the Save button on the Touch Screen. Exit Tools.
e.
In order for the DADF to sense the document correctly, remove the document from
the Document Input Tray then load the document in the Document Input Tray.
If a custom size cannot be entered via Tools, the DADF NVM may have become corrupted. Go
to Resetting the Document Feeder NVM to initialize the DADF NVM and setup the IIT Registration and Magnification.
Resetting the Document Feeder NVM

Do the following:
Figure 1 Jumpers
7.
Problem uploading ESS Software

Remedy: There could be a problem with ESS Memory. Run the ESS Memory test from
the Alternate Boot Tool. Check for failures and replace if indicated.
General Procedures
GP28 , GP29
1.
Enter [NVM tab , IOT Variable NVM Initialization]. Select [DADF], then select [Start].
2.
When the DADF NVM initialization is complete, select [Exit].
3.
4.
Perform ADJ 14-2 IIT Registration and Magnification.
5.
Return to Document Feeder Size Sensing.
May 2003
6-28
V0.042
GP30 Programming the Finisher for Thin Stapled Sets
GP31 Changing the AC Line Frequency and Line Voltage
Purpose
Purpose
The purpose of this procedure is to change the following:
The number of sheets the machine will consider as a thin set.
The purpose of this procedure is to change the machine AC line frequency to match the line
frequency of the source of AC power.
The number of thin stapled sets that will be produced before the machine will automatically pause.
Procedure
What will happen after the machine pauses; it will either automatically resume or remain
paused (for machines without a Finisher Empty Sensor in the Stacker Tray)
Procedure
CAUTION
Only attempt to change the Line Frequency and Line Voltage when the AC supply is KNOWN
to be different from the present settings.
Do the following to change the Line Frequency:
NOTE: This procedure can be performed by either the Key Operator or by the CSE.
1.
Do the following:
2.
In the [System] tab, find the Line Frequency section in the lower center of the window.
1.
Enter Tools.
3.
Click on the pull down arrow. Select the appropriate Line Frequency.
2.
In Tools, select System Settings.
4.
Click OK if done.
For DC machines, select More, and Output Options.
To change the Line Voltage,
For ST machines select, More ,More, and Output Options
1.
3.
Select Thin Stapled Sets.
2.
In the [System] tab, find the Line Voltage section in the lower right of the window.
4.
Set the [Number of sheets in a Thin Stapled Set] to a number between 5 and 20.
3.
Click on the pull down arrow. Select the appropriate Line Voltage.
5.
Set the [Number of Thin Stapled Sets before Finisher unload] to a number between 20
and 1000
4.
Click OK when done.
NOTE: Setting the number to a value greater than 30 may result in, poor stacking, misstapled sets, or poor set registration.
6.
Set [After the printer pauses to unload Thin Set] to one of the following options (machines
without a Finisher Empty Sensor):
Restart after one minute.
Do not restart after one minute.
NOTE: The following may occur in machines with software versions earlier than LO.17.6
(5.05): A Finisher Unload Message can come up at anytime for the customer, if the Finisher
Tray has not moved during any of the jobs. For example, if the customer runs 29 small jobs that
don't cause the trays to step down, and then someone comes up to run a 5 set job, the unload
message will be displayed after the first set goes into the finisher. The machine will not complete the final 4 sets of the job until the 1 minute timer times out, or the customer uses the finisher tray pause button to cycle the tray down/up, or the finisher tray moves up, depending on
the size of the set. If the customer is running a large number of thin sets, the problem can occur
only for the first unload message. After the first unload message, the next unload message will
be 30 sets later (or at whatever value it is set in TOOLS.)
V0.042
May 2003
6-29
General Procedures
GP30 , GP31
GP32 Clearing the Machine Network Settings
GP33 Special Setups for Kinkos Machines
Purpose
Purpose
The purpose of this procedure is to clear the machine network settings. This procedure can be
used when a machine is being removed from an account or when the customers network is
reconfigured such that the machine would need to be reinstalled on the network.
Kinko's wants the following two features enabled when their machines are installed.
1.
The copy count signal going to the Foreign Interface Connector must be programmed to
"double-count" when copies are made on large size papers. (Large size papers are
defined as greater than 380mm (15") long.)
Do the following to clear the network settings:
2.
The "Incomplete Scan" timer must be changed to 1 minute.
1.
In Diagnostics Navigator, select the [Configuration] tab and select [Network Configuration
Initialization].
These features can be enabled by the CSE on DC265 copiers with L0.17.5 (V5.03) software
and higher.
2.
Select [Start].
Procedure
Procedure
Ensure the following features are enabled on all Kinko's machines.
a.
Double-count billing of large copies to the Foreign Interface Connector

1.
Connect the PWS and start a session.
2.
Launch the Diagnostic navigator and select: [NVM], [NVM Tool], [Machine], [Download].
3.
Select Service: [Foreign Interface Service].
4.
Go to Location "0".
5.
Change the Value to "1".
6.
When this feature is enabled, the Foreign Interface Connector will receive 1 pulse for
each copy made on paper that has a dimension of less than 380mm, and 2 pulses for
each copy made on paper that has a dimension of 380mm or more.
NOTE: Enabling this option DOES NOT change the normal Xerox billing for the product.
b.
"Incomplete Scan" timer is set to one (1) minute.

1.
Access the Tools pathway on the User Interface.
2.
Select: [Go To Tools], [System Settings], [Timers], [Incomplete Scan].
3.
Change the timer to 1 minute.
Changing this timer minimizes the job carry-over problem when a user walks away with
only a portion of his or her job completed.
General Procedures
GP32 , GP33
May 2003
6-30
V0.042
GP34 Entering Software Options Password
GP35 Running the ESS Memory Test
Purpose
Purpose
To enable a new software option, a password must be entered. This password is generated
real-time on the PWS.
The purpose of this procedure is to provide the procedure for running the ESS Memory Test.
The ESS Memory Test is available only with L18 or later software.
Procedure
Initial Actions
When installing or removing a software option using the PWS, a screen will appear indicating
that a password is required. While connected to a machine, a machine unique identifier is
used to generate a real-time password.
The machine software CD-ROM must be in the PWS CD-ROM drive.
To enter the password, perform the following:
GP35 On-Site Procedure (255/265 - PowerPC ESS Only)
1.
Note the unique machine identifier on the first screen. This will be used later.
1.
2.
Select [Decode MUI].
2.
3.
A password window will appear. Type xerox 1998
When the Alternate Boot Tool opens click the ESS Memory Test button in the Alternate
Boot dialog to open the Windows terminal emulator with the correct communication settings.
4.
Select [OK].
5.
Another window will appear. In the Machine Unique Identifier field, enter the number that
appeared on the first screen.
6.
Select [Generate Password].
7.
A password will appear in the Password field. Type the Password in the password field
on the first screen.
8.
Select [Next]. The install of the software option will continue.
3.
4.
When the message appears, Type any key to interrupt self-test, hit any key
to interrupt the test (do two times). A screen menu (Main) will appear. Use the arrow
keys to select Administrative Options (you may need to scroll to see the whole menu) and
press [ENTER]. In the next menu displayed (again you may need to scroll to see it),
select Invoke the Command Line Prompt and press [ENTER].
5.
At the ok setenv load-base 0xF00000 [ENTER]. You should see the message:
load-base= 15728640
6.
Type: dl [ENTER] You should see the message: Ready for download.
then type ^D
7.
Connect the PWS parallel port to the ESS parallel port.
8.
In the Terminal window select the Transfers menu, then select the Send Text File option.
The Send Text File dialog will open. Navigate to the Lakes Software CD-ROM. NOTE the
path to this file is normally [CDROM_drive_letter] / inst / [software_version] / ESS / diskimage / ess_mem_test.txt. Once the file is selected, click the [OK] button to download it to
the ESS.
9.
As the test runs, you will see messages indicating total memory detected, how long the
test should take to complete, and a Test Successful message and an ok prompt when
complete.
Send file
10. If there are errors, you will see an indication of where the problem was detected.
GP-35 On-Site Procedure (460/470/480 - Intel ESS Only)

The Intel based ESS has different menus and options. This procedure documents how to
access and load the mini-kernel, which is equivalent to the GP23 procedure for the old ESS.
V0.042
1.
2.
May 2003
6-31
General Procedures
GP34, GP35
3.
4.
GP36 Retrieving ESS Logs
The Alternate Boot Menu will appear. Select 3) Parallel / Serial Boot.
The purpose of this procedure is to provide a method for retrieving ESS logs for submission to
engineering the purpose of investigating software problems.

5.
Purpose

1.
2.
Under the ESS Log Type section, select [Debug Log}.
3.
Select [Get Log File].
4.
After several minutes, a FTP Status Monitor window will appear while the file is transfering.
5.
6.
the parallel boot code path and filename should appear and will be format like
PBCV2P71. BIN. Click [Upload]
When complete, a DCS40-65 PWS Message Box will appear with the message Compressed debug log saved as c:\xrxdata\cases\xxxxxxxx\debug.log. The xxxxxxxx varies
depending on the case number.
6.
The file can be saved to a floppy and sent to Field Engineering.
7.
The Parallel / Serial menu will be displayed. Select 1) Display Diagnostic Menu.
8.
In the Diagnostic Menu, select 1) Test Memory
9.
As the test runs, you will see memory locations scroll on the screen as they are checked,
and a Memory Test Pass message and an ok prompt when complete.
10. If there are errors, you will see an indication of where the problem was detected.
General Procedures
GP35 , GP36
May 2003
6-32
V0.042
GP37 Accessing ESS Diagnostic Menu (460/470 - Intel

ESS)
GP38 Getting POST Results (460/470 - Intel ESS)
Purpose
The purpose of this procedure is to provide a method for retrieving ESS Power On Self Test
results.
Purpose
The purpose of this procedure is to provide a method for accessing the ESS Diagnostic Menu.

1.
2.
3.
4.
1.
2.
3.
4.
5.
6.

5.
ESS Parallel cable is connected between the PWS and the ESS (240/255/265) or Riser
PWB (460/470).
7.
8.
1) Test Memory
9.
2) Test Lakes NVRAM
10. In the Diagnostic Menu, select 5) Read POST Results

6.
7.
8.
The following menu will appear:
Diagnostic Menu
3) Test IEEE 1284 Parallel Port

4) Test Hodaka Serial Port
5) Read POST Results
6) Download Diagnostic Test
7) Exit Diagnostic Menu
V0.042
May 2003
6-33
General Procedures
GP37 , GP38
GP39 Changing the Alt-Boot System ID (460/470 - Intel

ESS)
GP40 Initializing Xerographic NVM
Purpose
Initializing the Xerographic NVM will reset those settings to their default values, providing a
new baseline from which to set up the Xerographic processes. This is sometimes done after
new software is installed which has changed the default values.
Purpose
The purpose of this procedure is to provide a method to change the Alt-Boot system ID from
Hodaka to Lakes.
Procedure

1.
2.
3.
4.
5.
6.
If the ESS has version 2.9 or higher BIOS and the System ID has not yet been set, a window will appear briefly, allowing you to select the System ID. If so, type L for Lakes and
skip to step 8.
Otherwise, when the Alternate Boot Menu appears, select 4) Change System ID.
7.
In the System Types menu, select 1) Lakes System
8.
In the Alt-Boot menu, select 5) Reboot System . The System ID should now be Lakes.
Perform the following to initialize the Xerographic NVM:

1.
Open the front door of the machine to prevent an automatic Xerographic Setup, and leave
it open.
2.
Enter [NVM tab , IOT Variable NVM Initialization].
3.
When the message Do you wish to download NVM appears, select [No].
4.
Select the Category : [Xerographics] and select [Start]. Select [Yes] to the confirmation to
continue.
5.
Select [OK] to dismiss the notification to power off and power on the machine, but do not
power off and on the machine at this time.
NOTE: The machine will be powered off/on later.
6.
Select [Exit].
7.
Now that Xerographic NVM has been reinitialized, the ROS values need to be re-entered.
Observe the bar code label on the ROS.
a.
From under the third bar code, record the three digits that appear after the letter L
(this is the imageFastScanReg).
b.
From under the second bar code, record the four or five digits that appear after the
letter H (this is the hallPeriodRef).
c.
From under the second bar code, record the number (a zero, decimal point, and four
digits) that appears between the letter E and the leter H (this is the exposureCalibration).
8.
Enter [NVM tab , NVM Tool]. Select the [Machine] menu, then [Download].
9.
Select [Yes] to initiate download.
10. When download completes, select Service: [Mark Service].

11. Scroll or search to location 723 (imageFastScanReg). Double click and change the value
to the number recorded above.
12. Scroll or search to location 729 (hallPeriodRefGB). Double click and change the value to
the number recorded above. If the value is rejected by range checking, scroll or Search to
location 1397 (hallPeriodRefFA) and enter the value there instead.
13. Scroll or search to location 793 (exposureCalibration). Double click and change the value
to the number recorded above.
14. If this is a High Altitude machine (with Tag 297 and above 4000ft (1200m): Scroll or
search to location 841 (machineAltitude). Double click and change the value to the altitude, in feet, at which the machine is installed.
NOTE: To covert meters to feet, multiply by 3.
15. Scroll or search to location 870 (openLoopEnabled). Double click and change the value
to the number to 0 (zero).
16. Make any remaining Xerographic NVM changes per any applicable bulletins.
General Procedures
GP39 , GP40
May 2003
6-34
V0.042
17. Exit the NVM Tool.

18. Switch off the machine power, wait 20 seconds, then switch on the machine power.
19. Perform a Xerographic Setup.
a.
Enter [Marking tab , Xerographic Diagnostics].
b.
Close the machine front door.
GP41 Measuring the Height of the Paper Buckle

Purpose
The purpose of this procedure is to provide a method to measure the buckle height of the
paper as it is stalled at the Registration nip.
c.
Select [Setup], then [Start].
d.
When complete, exit Xerographic Diagnostics.
1.
Open the IOT front Door
2.
Cheat the Front Door Interlock Switch.
3.
Program a job to run 10 prints.
4.
Measure the height of the paper buckle for all 10 sheets. Measure from the surface of the
Registration Transport to the top of the buckle (see Figure 1).
5.
The buckle height measurement for all 10 sheets of paper should be between 20 mm and
30 mm and should be relatively consistent for all 10 sheets.
20. Exit the Diagnostic Navigator.
The Buckle Height

should be
between 20mm
and 30 mm when
measured here.
Figure 1 Measuring the Buckle Height
V0.042
May 2003
6-35
General Procedures
GP40, GP41
GP42 CSE Fuser Rebuild/Return Process

Purpose
The purpose of this procedure is the implementation of the DC255/265/460/470 Fuser Maintenance Procedure and sparing of lower level parts to permit Fuser rebuild by the CSE.
5.
Ensure the Fuser Return label is removed from all Fuser Module cartons.
Inspect and rebuild or return the Fuser Module by following the attached procedure (Fuser
Inspection.pdf) and using the newly spared parts listed below as required. This Fuser inspection and rebuild procedure can also be found in the Fuser Web Repair Kit listed below.
If the Fuser Module can be rebuilt, leave the newly rebuilt Fuser Module in the machine.
Repackage the good Fuser Module from the machine and put it back into the customer's
stock.
NASG - If the Fuser Module cannot be rebuilt, return the Fuser Module using the UPS
Label or Canadian Post Label from the Fuser Return Label Kit.
XE - If the Fuser Module cannot be rebuilt, return the Fuser Module using the local return
process.
The following parts are now spares (PL 6.2B):
If ANY such damage exists, the Fuser Module cannot be rebuilt in the field.
Go to step 27 and return the Fuser Module as a failed part.
If NO such damage exists, continue.
With the Stripper door still open, check whether the Web is more than half used: The
Web take-up roll is the very bottom roller in the Fuser Module. A new Web will have
wrapped only a few times around the take-up roll, leaving about an inch (25 mm) of space
above the bottom Fuser Module frame. A completely used Web will have taken up nearly
all of that space, nearly contacting the bottom Fuser Module frame.
If the Web is more than half used, take note that you will need to replace the Web
assembly AND the CRUM as described later.
NOTE: One purpose of the CRUM is to monitor Web consumption and to signal the customer to replace the Web before the Web expires.
6.
With the Stripper door still open, inspect for any damage to the Stripper assembly
(broken or missing fingers, springs, baffles etc.).
If the Stripper assembly is damaged, take note that you will need to replace the Stripper
assembly as described later.
7.
Test for continuity of the Fuser Lamp circuit, using the AC connector on the rear of
the Fuser Module (Figure 3):
DC Fuse
DC Thermistor
Fuser Module DC Connector
If there is no continuity across the outside terminals of the AC connector, do the following:
Stripper Assembly
a.
Fuser Return Label kit (NASG Only)
Ensure the Fuser Lamp is connected. Remove the Fuser handle (two E-rings) and
the Fuser top cover (four hook tabs) to access the Fuser Lamp.
Fuser Web Repair Kit
b.
Check again for continuity.
Check for continuity across the outside terminals of the AC connector.

1.
If the Fuser Lamp is connected and there is still no continuity across the outside terminals of the AC connector, the Fuser Module cannot be rebuilt in the field. Go to step 27
and return the Fuser Module as a failed part.
Record the Fuser CRUM image count:

a.
Press the [Machine Status] button on the UI, and select the [Supplies] tab.
b.
Read and record the Fuser Image Count.
If there is continuity across the outside terminals of the AC connector, continue.

8.
WARNING
Test the DC Thermal Fuse, using the large black DC connector at the rear of the Fuser
Module (Figure 3):
The machine power must be switched off and the power cord disconnected, to avoid the
electrical hazard of personal injury or machine damage.
Measure the resistance across pins 7 and 8 (the third and fourth pins from the top).
The resistance should read zero (+.5) Ohms.
2.
If the resistance across pins 7 and 8 is greater than 5 Ohms, take note that you will
need to replace the DC Thermal Fuse as described later.
WARNING
Allow the Fuser to cool sufficiently to avoid burning yourself while working on the
Fuser.
3.
4.
9.
Test the DC Thermistor, using the large black DC connector at the rear of the Fuser
Module (Figure 3):
Remove the Fuser Module from the machine.
a.
Set the Ohmmeter to the DC 200K Ohm range or 400K with a Fluke Meter.
Check the Fuser Module for irreparable damage:
b.
Measure the resistance across pins 9 and 10 (the top two pins).
Ensure the Inverter/Fuser latch hook is not broken off at the right rear of the
Fuser Module (Figure 1).
At a very cold temperature, a good DC Thermistor can read up to 80.5 K

Ohms.
b.
Unlatch and pivot the Stripper door out (open Area 3c) (Figure 2).
c.
Inspect the Heat Roller and Pressure Roller while turning the green jam clearance
knob on the front of the Fuser Module.
At room temperature, the DC Thermistor resistance should read approximately 10.5 K Ohms.
At operating temperature (hot), a good DC Thermistor can read down to 1.3

K Ohms.
a.
Look for damage to the roller surfaces, or the gears. Turn the green jam clearance
knob and check for binding of the fuser rollers' bearings.
General Procedures
GP42
May 2003
6-36
V0.042
If the resistance across pins 9 and 10 is not within specification as described

above, take note that you will need to replace the DC Thermistor, as described
later.
If the Stripper assembly already failed the inspection in step 6, skip to step 10 .
CAUTION
Observe the correct harness routing before and while removing the DC Thermistor and the DC
Thermal Fuse.
15. Remove both the DC Thermistor and the DC Thermal Fuse:
a.
If the Stripper assembly date is in the range 6/99 - 9/99, take note that you will need
to replace the Stripper assembly as described later.
Free the DC Thermistor harness from the harness restraints, while observing the
correct harness routing.
b.
If the Stripper assembly date is earlier than 6/99 or later than 9/99, and the Stripper
assembly is not damaged, you will NOT need to replace the Stripper assembly.
Insert a narrow tool such as a small screwdriver as shown to release the hook tab
(hidden), and slide the DC Thermistor out (Figure 9).
c.
Dismount the DC Thermal Fuse in the same manner as the Thermistor, while
observing how both the Fuse harness and the Thermistor harness are routed and
restrained around the Fuse mounting (Figure 10)
Check the date on the Stripper assembly (if not damaged) (Figure 4):
If the DC Thermal Fuse already failed the electrical test in step 8, skip to step 12.
Check the Fuser manufacturing date above the 126KXXXXX part number on the
Fuser Module bar code label, to help determine if the DC Thermal Fuse must be
replaced (Figure 5):
If the Fuser manufacturing date is EARLIER THAN Nov. '99, take note that you will
need to replace the DC Thermal Fuse as described later.
16. Using a new DC Thermal Fuse and/or a new DC Thermistor as determined earlier,
install the DC Thermal Fuse and DC Thermistor in the reverse of removal, carefully
routing and restraining the harnesses as before.
17. If the Web is NOT more than half used (as determined in step 5), go to step 19.
If the web is more than half used (as determined in step 5), continue.
CAUTION
If the Fuser Module has PASSED ALL of the checks above, go to step 23.
If the Stripper assembly, the Web assembly and CRUM, the DC Thermal Fuse, and/or the
DC Thermistor must be replaced (as determined in steps 5 through 9), continue and
replace the required component(s).
10. If the Stripper assembly must be replaced (as determined in step 6), replace the
Stripper assembly: Unlatch and pivot the Stripper assembly out (open Area 3c), remove
the E-ring from the rear pivot pin, and remove the Stripper assembly. Install the new Stripper assembly in the reverse of removal.
Be sure to install the CRUM in the correct position in the main DC connector - it is physically possible to install it in the wrong position.
18. Remove the CRUM from the main DC connector and replace it with the new CRUM
provided in the Fuser Web kit. Ensure the CRUM is in the correct position in the DC
connector (Figure 11).
NOTE: Be sure to install the CRUM in the correct position in the main DC connector - it is
physically possible to install it in the wrong position.
CAUTION
11. If the Web, the DC Thermistor, and the DC Thermal Fuse are ALL okay (as determined in steps 5, 8, and 9), go to step 23.
Be sure to reconnect the DC Thermal Fuse and the DC Thermistor in the correct locations
in the main DC connector - it is physically possible to connect them in reversed positions.
If these connectors are reversed, a 10-301 fault will result.
12. Remove the Web assembly:
a.
Lay the Fuser Module on its right side (left side up).
b.
Insert the tip of a small screwdriver or needle-nose pliers into each latch and slide it
inward (Figure 6).
c.
Lift and pivot the Web assembly out and remove it (Figure 7).
19. Reconnect the DC Thermal Fuse connector (orange wires) into the pins 7 and 8
position in the main DC connector (Figure 8).
NOTE: Be sure to reconnect the DC Thermal Fuse and the DC Thermistor in the correct
locations in the main DC connector - it is physically possible to connect them in reversed
positions. If these connectors are reversed, a 10-301 fault will result.
13. Remove the main DC connector, with the CRUM, from the Fuser Module (Figure 8):
a.
Press each of the two locking tabs to release the connector as shown.
b.
Pull the connector out carefully while pivoting it as required to clear the CRUM past
the connector opening in the Fuser Module frame.
c.
Disconnect the DC Thermal Fuse connector and the DC Thermistor connector from
the main DC connector, and remove the main DC connector from the Fuser Module.
14. If the Thermal DC Fuse and DC Thermistor are okay (as determined in steps 8 and 9)
and only the Web and CRUM need to be replaced (as determined in step 5), go to step
18.
If the DC Thermistor AND/OR the DC Thermal Fuse need(s) to be replaced (as determined in steps 8 and 9), continue.
20. Reconnect the DC Thermistor connector (black wires) into the pins 9 and 10 position in the main DC connector (Figure 8).
21. Reposition the main DC connector into the Fuser Module in the reverse of removal.
Be sure that it "clicks" into position.
CAUTION
If installing a new Web assembly in the next step, be sure you have also installed a new
CRUM (step 18).
If re-installing the same Web assembly removed earlier, be sure you still have the same
CRUM installed (NOT replaced it with a new one in step 18).
22. Install the Web assembly:
V0.042
May 2003
6-37
If the Web is NOT more than half used as determined earlier, reinstall the same
Web assembly.
General Procedures
GP42
If the Web IS more than half used as determined earlier, install the new Web
assembly provided in the Fuser Web kit.
a.
Ensure the aligning hook on the rear (non-gears) end of the Web assembly engages
the pin in the Fuser Module (Figure 12).
b.
Insert the Web assembly, keeping the front (gears) end parallel with the rear end,
and pivot it into position in the reverse of removal.
c.
Engage the two latches outward in the reverse of removal, securing the Web assembly in place.
Pressure Roller (hidden)
23. Fill out the Fuser Maintenance Label provided in the Fuser Web kit: Include the date,
the Fuser Module Image Count recorded at the beginning of this procedure, and the parts
used.
24. Attach the Fuser Maintenance Label to the front of the Fuser Module, to the lower
left of the green knob (Figure 13).
25. Reinstall the Fuser Module and switch on the machine power.
26. Test the Fuser: Make 50 prints and look for any print quality defects that indicate Fuser
problems. If any appear, continue to troubleshoot and repair or return the Fuser Module.
Heat Roller
27. If returning the Fuser Module, repackage the Fuser Module in the original box or the
box from the new Fuser Module if possible, attach the correct Return Label to the box.
Web take-up roll
(hidden)
Web
Figure 2 Stripper Door Open
Inverter/Fuser
latch hook
Figure 1 Inverter/Fuser Latch Hook
General Procedures
GP42
May 2003
6-38
V0.042
AC connector
DC connector
Figure 3 Fuser Module AC and DC Connectors
year in center;
arrow points to
month
Figure 4 Stripper Assembly Date
V0.042
May 2003
6-39
General Procedures
GP42
date, above
126KXXXXX
part number
latches (2)
Figure 5 DC Thermal Fuse Date on Barcode
General Procedures
GP42
Figure 6 Releasing the Web Assembly Latches
May 2003
6-40
V0.042
DC Thermistor
connector
(black wires)
DC connector
locking tabs (2)
Figure 7 Removing the Web Assembly

CRUM
DC Thermal
Fuse connector
(orange wires)
Figure 8 Removing the Main DC Connector
V0.042
May 2003
6-41
General Procedures
GP42
tool
tool
DC Thermal Fuse
DC Thermistor
DC Thermistor
(already dismounted)
Figure 9 Dismounting the DC Thermistor
General Procedures
GP42
Figure 10 Removing the DC Thermal Fuse
May 2003
6-42
V0.042
Figure 11 Replacing the CRUM
V0.042
Figure 12 Installing the Web Assembly
May 2003
6-43
General Procedures
GP42
GP43 Enabling Auto Version Handler / Using Master

Uninstaller
Purpose
The new "Auto Version Handler" Feature is disabled by default after installation of PWS
L19.01.019 software. The PWS L19.01.019 installation application places the default setting
for Auto Version Handler to off (1).
Procedure
Do the following to enable the Auto Version Handler feature:
1.
Launch C:\Xerox\PWS_D32\PREFTOOL\preftool32.exe
2.
Highlight "Full disable Auto Version Functionality"
3.
Select [Modify], change value to zero (0). Select [OK] to save,
4.
Select [OK] to Exit the Preftool32 application.
Using Master Uninstaller

Purpose
Fuser Maintenance Label
Figure 13 Fuser Maintenance Label Location
General Procedures
GP42 , GP43
The old Multiple Version Handler has been changed so that after installation of PWS
L19.02.04x software, you cannot delete versions manually and are directed to use the new
Master Uninstaller.
Procedure
Instead of using Multiple Version Handlers Delete Version function to remove an old version
of PWS Diagnostics, use the Master Uninstaller as follows:
1.
Select the [Start] menu.
2.
Select [Programs].
3.
Select [Xerox Applications].
4.
Select [DCS40-65 DCMA Master Uninstaller].
5.
Follow the instructions in the Master Uninstaller window.
May 2003
6-44
V0.042
GP44 DADF Ground Checkout

Purpose
The purpose of this procedure is to check the grounding on the DADF.
Incorrect grounding of the DADF and/or the Scanner Frame may result in lost outputs on the
LVPS (+5 VDC, +12 VDC, -12 VDC, +36VDC, +24 VDC), due to a blown IIOC chip on the
DADF PWB. Fault codes may include one or more of the following: 05-331, 09-370, 09-372,
09-374 09-376, 09-354, 10-354, 14-325, 14-335, 14-345/347. Troubleshooting reveals a blown
DADF PWB but machines may be experiencing repeat DADF PWB failures.

1.
2.
Connect the black meter lead to the IIT ground braid (Figure 1).
3.
Set the Fluke Meter to Ohms, and the Range to the 4M Ohms - remove from Auto Range
(Set the DMM to 200k Range). A good meter reading is less than .100 M Ohms (100,000
Ohms).
4.
Check between the IIT ground braid and the 7 areas indicated in (Figure 2).
5.
Check for continuity between the IIT ground braid and the Static Eliminator (Figure 3).
6.
Check for continuity between the IIT ground braid and the Scanner Frame (Figure 4).
7.
If you exceed the 100,000 Ohm limit on any of the test points, initially rotate the shaft and
check again. If the check is still high follow the ground path back to the IOT frame to see
at what point you loose ground. The Retaining Tab connection is a common weak link for
the ground path. Disassemble/Reassemble of the components may be required.
V0.042
May 2003
6-45
General Procedures
GP44
Connect the black

meter lead to the
IIT ground braid.
Figure 1 Rear view of IOT and Scanner
General Procedures
GP44
May 2003
6-46
V0.042
Check #4 DADF Feed Shaft
Check #3 Take
Away Roll Shaft
NOTE: This component is Document

Centre 480/4xx Only.
Check #5 Inverter/
Exit Shaft
Check #2 Registration
Roll Shaft
Check #1 Right
CVT Roll Shaft
Check #7 Feed Motor spindle/gear
Check #6 CVT Motor Bracket
Figure 2 DADF Drive Shaft Ground Checks
V0.042
May 2003
6-47
General Procedures
GP44
Figure 3 Checking the Static Eliminator Ground
General Procedures
GP44
May 2003
6-48
V0.042
Place the red meter lead

here. The Scanner Frame
can be accessed through
in the opening for the
DADF Pin.
Figure 4 Check the Scanner Frame Ground
V0.042
May 2003
6-49
General Procedures
GP44
GP45 Upgrade Kits Sequence
Ensure the machine is at the latest applicable Software Release Level.
Purpose
The purpose of this procedure is ensure the upgrade kits are installed in the correct sequence.
Follow L0.18 Enablement (650K12083) instructions if present.
Follow 07.19.02.xxx or Higher Enablement (301K06900) instructions if present.
Upgrade the machine to the latest level software:
Procedure
1.
Conversions
Do you have one of these conversion kits (Identified by Product code on the Box) delivered at the site?
If the machine is 460/470 and 07.19.02.xxx or Higher Enablement (301K06900)

is present, install latest software 07.19.02.xxx or higher, as appropriate.
If the machine is 480/490, install latest software 07.19.02.xxx or higher, as

appropriate.
DH1 Document Centre 240/255 DC to ST, 240/255265 DC to ST (Kit #2)
VE5 Document Centre 255/265 to 460/470 ST (Card Cage)
VE8 Document Centre 255/265 to 460/470 ST (logos and covers)
VE9 Document Centre 255/265 to 460/470 DADF Upgrade
VE7 Document Centre 460/470 DC to ST
Install all network hardware option kits
CNR Document Centre 460/470/480 DC to ST
FVD Document Centre 490 DC to ST
If you have T8R (PCI-BUS Adaptor 240/255/265), F1D (100Mb Ethernet PWB 240/
255/265), F4D (IPA PWB 240/255/265), F0D (Token Ring 240/255/265), install T8R
first
If you have both UD6 (Token Ring PWB, 460/470/480/490 ST) and UD7 (IPA PWB,
460/470/480/490 ST), install UD6 first.
If you have UD6 or UD7, install the individual kit by itself
Proceed to Step 6.
6.
Perform the procedure in the conversion kit(s):

a.
Install the hardware kit T7V, DH1, VE5, VE7, CNR, or FVD
Network Hardware Options
b.
Install the DADF Upgrade Kit VE9, if present.
c.
Install the logos and covers kit VE8, if present.
d.
Proceed to Step 3.
Proceed to step 7.
7.
Software Option Kits

Install the following kit or kits, if present at the customer site:
ESS/Main Controller RAM Upgrades

Do you have one of the following kits at the customer site:
Network Scanning Option Enablement Kits:
650K12094 for Document Centre 240/255/265 ST (NASG)
301K03081 for Document Centre 460/470/480/490 ST (NASG)
650S32300 for Document Centre 240/255/265 ST, 460/470/480/490 ST (XE)
LAN Fax Option Enablement Kits:
F7D or F8D - for Document Centre 265 ST
300K87044 for Document Centre 240/255/265 ST, 460/470/480/490 ST
F2C - for Document Centre 265 without TAG 077
604S03500 for Document Centre 240/255/265 ST, 460/470/480/490 ST (XE)
98K81990 - ESS PWB / Main Control PWB DRAM Upgrade
Network Accounting (Job Based Accounting) Option Enablement Kits:
Yes - Go to Step 4.
301K00790 for Document Centre 240/255/265 ST/LP (NASG)
No - Go to step 5.
300K87034 for Document Centre 460/470/480/490 ST (NASG)
Install the RAM upgrade kits as follows:
604S03600 for Document Centre 240/255/265 ST/LP, 460/470/480/490 ST

(XE)
F7D or F8D - for Document Centre 265 ST. Install this kit on the ESS PWB.
F2C for Document Centre 265 without TAG 077. Install this kit on the Main Control
PWB
98K81990
If machine is a Document Centre 265DC/ST, install this kit on the Main Control
PWB.
If machine is a Document Centre 460/470/480/490 DC/ST, install this kit on the

ESS PWB.
Proceed to Step 5.
5.
If the machine is 240/255/265 with L0.18.xx.xx software, install software

L0.18.6.07
NOTE: You must perform the entire conversion procedure before proceeding to Step
3.
4.
T7V Document Centre 240/255265 DC to ST (Kit #1)
No - Go to Step 3.
3.
If the machine is 240/255/265 and L0.18 Enablement (650K12083) is present,

install software L0.18.6.07
Yes - Go to Step 2.
2.
General Procedures
301K06070 for Document Centre 460/470/480/490
NOTE: If the instructions cannot be found but you know the customer wants the options
enabled, ensure the hardware and memory are installed, then go to GP34 for instructions
on how to enable the option(s).
Proceed to Step 8.
8.
Customer and System Administrator Documentation, and Client Software

Hand off the Customer and SA Documentation and Client Software kits to the Customer.
Software Upgrades
GP45
Scan to E-Mail Option Enablement Kits:
May 2003
6-50
V0.042
GP46 460/470 Software Upgrade Tool Usage
CAUTION
Purpose
The purpose of this procedure is to determine whether a particular 460/470 ST machines
requires the Software Upgrade Tool 600T02212 in order to upgrade Main Controller software,
and to ensure the tool is used correctly.
NOTE: This is only necessary on a 460/470 ST machine with a 360 Atlanta Main Control PWB.
NOTE: Disregard the workarounds provided in the original Bulletin #428.
When installing software onto a 460/470 ST machine with a Main Control (Atlanta) PWB that
has part number 160K73622 through 160K7362X or part number 160K71891 through
160K7189X * without using the Software Upgrade Tool, the Main Controller software upload
will fail during the "Writing Flash Memory" stage at 57, 58 or 59 Blocks complete. The PWS
then displays a "Supload 32" window, with a message "Checksum Error on Machine Code" in
it. (* NOTE: Main Control PWB's labeled with part numbers 160K73622 through 160K7362X
were installed in the factory, whereas Main Control PWB's with part numbers 160K71891
through 160K7189X were installed as field spares.) Also at that time, there is no PWS communication with the machine and the Software/NVM Module cannot be saved by using the "Installing Main Controller Software Only: Forced Upload Method", described in the software upgrade
kit instructions. You must replace the Software/NVM Module.
3.
CAUTION
DO NOT attempt to pre-install the capacitor into the Connector Cap and install the cap and
capacitor onto the Debug connector at the same time!!! The capacitor legs will not align with
the connector correctly, and will contact the wrong connector positions!!!
4.
Obtain one of the capacitors provided in this kit. Remove the capacitor from the strip by
cutting the capacitor leads adjacent to the tape to separate the capacitor from the tape
Figure 4. Do not pull the leads out of the tape, because the tape residue on the leads can
impair electrical contact, resulting in a software upload failure.
5.
Form the legs of the capacitor so that they align with the two guide holes in the Connector
Cap, and insert the capacitor legs all the way into the guide holes until they make contact
with the Debug connector.
NOTE: The Connector Cap is designed to guide the capacitor legs into positions 51 and
60 on the Debug connector.
6.
The root cause of the problem is noise affecting a clock signal. This is only a problem on 460/
470 ST machines that have a 160K7362X or 160K7189X Main Control PWB in them. It is not
related to software levels or market region. It only affects the loading of the Main Control PWB
software, at any level.
Before installing software to the Main Controller on a 460/470 ST machine, determine if the
Main Control (Atlanta) PWB in the machine is a 160K7362X or 160K7189X PWB as follows:
Remove the card cage access panel (Figure 1) and identify which chip is installed in the
location indicated in Figure 2 on the Main Control PWB. You will need to look down and to
the left through the access opening with a flashlight.
2.
If the chip indicated in Figure 2 is marked "Bengal 2", the Main Control PWB is a
160K7362X or 160K7189X PWB and you must use the 460/470 Software Upgrade Tool
kit 600T02212, and follow the instructions in that kit or the procedure below.
3.
If the chip indicated in Figure 2 is marked "Bengal" (not Bengal 2), the Main Control PWB
is not a 160K7362X or 160K7189X PWB, therefore install the software normally.
Switch ON the machine power, and begin the Machine Software Upgrade Procedure in
the Software Upgrade kit instructions.
If the Main Controller software upload fails during the "Writing Flash Memory" stage at 5759 Blocks complete with a Supload 32 error message "Checksum Error on Machine
Code", do the following: (1) Switch OFF the machine power. (2) Double-check the Software Upgrade Tool is installed correctly. (3) Force-upload the PRE-UPGRADE LEVEL of
software back onto the Main Control PWB: Perform "Installing Main Controller Software
Only: Forced-Upload Method" in the Software Upgrade Kit instructions' Troubleshooting
section. (4) Re-attempt the Wizard upload to the Main Controller: Perform "Installing Main
Controller Software Only: PWS Wizard Method " in the Software Upgrade Kit instructions'
Troubleshooting section. (5) Go to "Required Actions After PWS Wizard-Method Software
Upload" in the Software Upgrade Kit instructions and proceed from there.
Determining if the Software Upgrade Tool is required
1.
Install one plastic Connector Cap, provided in the kit, onto the Debug connector on the
Main Control PWB (Figure 3).
7.
After completing the software upload, switch OFF the machine power and remove the
capacitor and the Connector Cap.
May 2003
6-51
General Procedures
Using the Software Upgrade Tool

From the Software Upgrade Tool Kit, one plastic Connector Cap and one capacitor are
installed in the machine before the software upload and are removed afterward. The Connector
Cap and the capacitor may then be reused for subsequent uploads, until worn out. An extra
Connector Cap and extra capacitors are provided in the kit to replace worn out or lost ones.
WARNING
1.
Switch OFF the Machine power and disconnect the power cord.
2.
Remove the card cage access panel (Figure 1).
V0.042
GP46
access panel (two

T20 screws)
Figure 1 Access Panel
General Procedures
GP46
May 2003
6-52
V0.042
SHOWN WITH THE MAIN

CARD CAGE COVER
REMOVED FOR CLARITY
Look at this chip.

If it is marked "Bengal 2",
the PWB is 160k73622 or
or 160K7189X and
requires tool for software
upgrade.
Figure 2 Bengal 2 or Bengal Chip
V0.042
May 2003
6-53
General Procedures
GP46
Debug connector
Cut the legs here.
Figure 4 Removing the Capacitor from the Strip
Figure 3 Debug Connector
General Procedures
GP46
May 2003
6-54
V0.042
GP47 Saving and Restoring Scan to File Templates (460/

470 Only)
CAUTION
The PWS software version selected must be 19.02.xxx, even if the machine software version is
older (19.0.xxx or L19.01.xxx). Ignore the PWS Software Mismatch message when you launch
Diagnostic Navigator. DO NOT check the "auto switch to match machine software" box.
Purpose
The purpose of this procedure is to save copies of Scan to File templates created through CentreWare and the machine's embedded HTTP (Web) server, and restore them on the machine
after an Alternate Boot procedure is performed to reload ESS software.
4.
Select the [ESS/Network] tab in Diagnostic Navigator.
5.
Select [ESS Terminal Window].
6.
Under "Scan Templates," select [Save].
Prerequisites
7.
Insert the MRD or other floppy disk into the PWS floppy disk drive.
8.
Select [OK] in the MRD message box on the PWS. FTP Status Monitor window is opened
and the templates will be retrieved from the ESS and saved on the floppy disk in a file
named "s2ftempl.out." Wait until you see the message, "Operation Completed. Scan to
File Templates have been saved to the MRD."
9.
Select [OK] in the message box.
The PWS must be at 19.02.049 or higher SW version.
The MRD or other floppy disk will be used to save the Scan to File templates. Ensure the
MRD diskette is available. If not, a floppy disk is needed to continue with the following
procedure.
Procedure for Saving Scan to File Templates

1.
Obtain the Default Repository and Template Pool settings:
11. Continue with the software install instructions.
NOTE: The log-in password is not displayed in the Default Repository settings or the
Template Pool settings on the machine UI. The customer's System Administrator (SA) will
have to re-enter the password later, if one is required
Procedure for Restoring Scan to File Templates
2.
3.
10. Select [OK] to close the ESS Terminal Window.
DC480/490: Print a configuration report from the machine UI. (The SA will re-create
the Default Repository from the configuration report at the end of the restore procedure.):
This procedure is used to restore the Scan to File templates from the "s2ftempl.out" file, saved
on the MRD or other floppy, onto the machine after an Alternate Boot procedure has been performed.
NOTE: Ensure that Remote Testing Access for Network Controller is enabled as instructed
above in the Procedure for Saving Scan to File Templates.
a.
b.
Select [System Settings] and select [Configuration Report].
1.
c.
Select [Print Configuration Report now], and wait for the report to print out.
2.
d.
Select [Cancel], and [Exit Tools].
Ensure the Scan to File option has been re-enabled using the Software Option Wizard,
then reboot all three platforms. When the machine has fully rebooted, exit the Software
Option Wizard. (This should already have been done as part of the Software Upgrade
procedure "Required Final Steps.")
3.
Select the [ESS/Network] tab in Diagnostic Navigator.
4.
Select [ESS Terminal Window].
DC460/470: Record the Default Repository and Template Pool settings manually in
Tools on the machine UI. (Those settings will be re-entered by the SA at the end of
the restore procedure.):
a.
b.
Select [More], select [More] again, and select the [Network Scanning] tab.
c.
Select [Scan Repository Settings].
d.
Record all of the Repository settings
e.
For IP and IPX if available: Select [Template Pool Settings] and record the settings.
f.
Select [Cancel], and [Exit Tools]
Enable Remote Testing Access for Network Controller:

a.
b.
5.
Under "Scan Templates," select [Restore].
6.
Insert the MRD or other floppy disk containing the file "s2ftempl.out" into the PWS floppy
disk drive.
7.
Select [OK] in the MRD message box on the PWS. The FTP Status monitor is opened
and the file will be transferred from the PWS to the ESS. Wait until you see the message,
"Operation Completed. Scan to File Templates have been restored from the MRD."
8.
Select [OK] in the message box.
9.
Select [OK] to close the Terminal window.
Select [More].
10. In the ESS/Network tab, ensure the [Banner, Error, and Confirmation Sheets] radio button
is selected so the Scan to File confirmation sheet is enabled.
c.
11. [Exit] Diagnostic Navigator.
d.
Select [More].
12. Take the machine out of Diagnostics mode:
e.
Select [Remote Testing Access for Network Controller].
f.
Select [Enable] to enable Remote Testing Access for Network Controller.
g.
Select [Save], and [Exit Tools].
V0.042
May 2003
6-55
a.
Close the current case by right-clicking another case and selecting [Set as Active
Case].
b.
Answer [No] to the dialog box asking if you want to download NVM.
c.
Select [Exit Diagnostics].
d.
Answer [No] to the dialog box asking if you want to reset the machine.
General Procedures
GP47
13. Disable the Network Service Access Control feature using Tools on the UI:
a.
b.
Select [More], select [More] again, and select [Service Access Control].
c.
Select the [Network Authenticated Access] button, so the button is now de-selected.
d.
Select [Next]
e.
14. Have the SA re-enter the machine's Default Repository setup and Template Pool setup as
required:
For 19.02.xxx machines:

The SA may use the Web Browser to re-enter the machine's setups. They will also
need to enter the log-in passwords, if required.
In an IPX environment, the SA will re-enter the machine's setups via CentreWare.
For 19.0.xxx or 19.01.xxx machines: The SA may use the Tools pathway on the
machine UI, they may access the machine's web page using a web browser, or they
may use CentreWare Scanning Services software. They will also need to enter the
log-in passwords, if required.
15. Update the template list on the machine UI:
For 19.02.xxx machines: On the machine UI, select the [Network Scanning] tab,
then select [Update Template List]. The original list of templates should appear in the
template list.
For 19.0.xxx or 19.01.xxx machines: On the machine UI, select the [Network
Scanning] tab, then select [More Scan Features], then select [Update Template List].
The original list of templates should appear in the template list.
16. Disable Remote Testing Access for Network Controller:

a.
b.
Select [More].
c.
d.
Select [More].
e.
Select [Remote Testing Access for Network Controller].
f.
Select [Disable] to disable Remote Testing Access for Network Controller.
g.
17. Have the SA check to ensure the Scan to File is working before you leave the account.
General Procedures
GP47
May 2003
6-56
V0.042
GP48 Tabs Creation
NOTE: When using Paper Tray 5, you must use reverse order tab stock.
Purpose
The purpose is to provide a procedure for creating tabs.
Xerox mylar tabs are recommended as they provide excellent quality and are a
firmer tab, which can mean more reliable tab printing.
Load the correct number of tabs in sequence. For example, if you need 6 tabs and
are using a bank of 5 tabs, you will have to add the 6th tab to the bank and eliminate
the next 4 tabs from the stack.
Load tab stock in Paper Trays 2, 3 or 4 when using the Tab Tray Insert or load stock
in Paper Tray 5.
Do not use the Print To Edge option as this may create a black line at the top of the
tab.
Introduction
Some companies have a need to create index tabs to separate and organize information in
reports, handbooks, etc. Xerox provides the Tab Creation solution for companies with occasional requirements for Tab Creation. Document Centre Tab Creation allows you to copy on 9 x
11-inch223 x 297mm, blank tabs, on an as needed basis, using the Xerox Document Centre
490/480/470/460 DC/ST models. This solution provides a special Tab Tray Insert for use in
Paper Trays 2, 3, or 4. The Tab Tray Insert allows the Document Centre to hold a box of tab
stock. Tab Creation includes the Tab Tray Insert and step by step instructions on how to load
blank index tab stock in the Document Centre to produce printed tab output. A minimum
amount of tab stock can be loaded in Paper Tray 5 without the Tab Tray Insert.
Print only on the tab, not the tab body.
Output must be directed to the top tray.
You cannot print on both sides of the tab. The solution is for one-sided output only.
The registration of the image on the tabs may vary depending on the Document
Centre system that you are using. You may have to adjust the image shift or tab
matrix to achieve correct registration on your system.
Automatic job recovery is not available when copying or printing on tab stock.
Tab printing may not provide the same image quality and/or paper handling performance as plain paper.
How Tab creation works:
Tab Creation works similarly to the way you copy or print documents on special stock
using the Document Centre 490/480/470/460 DC/ST models. Refer to the Reference
Guide (Paper & Stock chapter) that accompanied your Document Centre. Programming
the Document Centre and installing the Tab Tray Insert in Paper Trays 2, 3, or 4 are the
key actions required when using the Tab Creation solution.
You can enable tab creation on the Document Centre by installing a special Tab Tray
Insert in Paper Trays 2, 3 or 4. Tab stock can be loaded in Paper Tray 5 if you do not have
the Tab Tray Insert. When using the Tab Tray Insert from Paper Trays 2, 3, or 4, the Document Centre User Interface will prompt you to confirm media settings. When using Paper
Tray 5, you need to set the paper size to 9 x 11-inch (223 x 297mm). Tab Master documents can then be placed in the Document Feeder. Make selections for Output destination and Image Adjustments using the User Interface touch screen as outlined in the Tab
Creation Instructions. You must manually collate the completed tabs within your copied or
printed sets.
Procedure
Making Tabs
1.
NOTE: If using punched stock, ensure that the punched side is in the feeding edge position.
When using the Tab Tray Insert
Depending on the tab stock type, you might have to manually order the tab stock before
making specific programming selections to ensure successful tab creation. It is important
to note that the Tab Creation solution does not provide job recovery. In other words, if the
tab stock jams or misfeeds in the Document Centre, you will need to clear the jam, replenish and re-order the tabs, and then you must rerun the job. The Document Centre system
will not automatically re-order the tabs or resume the job.
Copying or printing on tabs should be an occasional application, rather than a mainstream

application frequently done on the Document Centre. For rigorous tab copying or printing,
contact Xerox either through your local representative or through the Xerox Welcome
Center for other product solutions that better meet your needs.
2.
Please familiarize yourself with the following information to ensure successful tab creation
on the Document Centre.
Straight Collated tabs such as 5-bank white or color mylar tabs are recommended.
Xerox tab stock is recommended for the best performance (i.e. order number
3R4417 white; 3R5709 clear).
V0.042
a.
Install the Tab Tray Insert into Paper Tray 2, 3 or 4 only.
b.
Place the tab stock in the Tab Tray Insert. Adjust the paper guide-post to accommodate the tab stock size.
c.
Make sure the straight edge side of the tab stock is on the feeding edge and the tab
side of the stock is on the trailing edge. The top tab must be toward the rear of the
machine. The bottom tab must be toward the front of the machine.
When using Paper Tray 5 (Bypass Tray)
What you should know before you begin:
Load tab stock using the Tab Tray Insert or use Paper Tray 5
3.
May 2003
6-57
a.
Place the tab stock with the tab end facing away from the machine. Adjust the paper
guides to accommodate the tab stock size.
b.
Make sure that the top tab in the sequence is toward the rear of the machine and the
bottom tab is toward the front of the machine.
Confirm media settings for 9 x 11-inch paper

a.
The Document Centre will ask you to confirm paper size of the tray selected. If the
size is not 9 x 11-inch, change the setting to 9-inches for the short edge of the paper
and 11-inches for the long edge of the paper.
b.
Select Confirm.
Place tab masters in Document Feeder
General Procedures
GP48
Place the tab masters document or tab originals into the Document Feeder with the
tabs on the trailing edge in a left to right sequence. The imaged side of the tab original should be face up in the Document Feeder.
4.
Select the following options from the Document Centre User Interface:
a.
Go to the Image Adjustment tab; select the Image Shift button.
Purpose
The purpose is to provide a procedure for setting the amount of decurling performed when the
UI button, Max Decurler Enabled, is selected.
b.
On the Image Shift screen, select Margin Shift.
c.
On the Margin Shift screen, use the left horizontal arrow key to shift the margin 0.5
inches to the left.
d.
Select Save.
For more information about the Exit Decurler, go to Print Transportaion, Exit Decurler in the
Principles of Operation section of this manual.
The Exit Decurler requires IOT software level 07.09.04.XXX or higher .
NOTE: Margin Shift settings may vary depending on your tab and font. Validate this
setting by printing a sample tab to ensure the image is correctly positioned on the tab
before running the full tab job.
5.
GP49 Exit Decurler (460/470 Only)
Make the following output selections from the Document Centre User Interface
a.
Go to the Basic Copying Tab. Under Output options, select Top Tray - Collated;
under Paper Supply options, select Paper Tray 2, 3, or 4 if using the Tab Tray Insert
or select Paper Tray 5.
b.
Using the number keypad, select the number of tab sets that you are making. Then
press Start.
Introduction
Decurler operation is selectable through SA tools. In tools select [System settings], [More],
then select [Decurler Settings]. The decurler feature screen has three UI soft buttons to select
operation as follows:
NOTE: On a 460/470 machine there is no E-Sensor. The machine operation is the same
as when AutoDecurling Disabled is selected.
Creating Tab Masters

Use the following Xerox web site to create three-position, five-position, or eight-position
tab masters: http://www2.xerox.com/go/xrx/supplies/SuppA.jsp?oid=19864&sub=1.
Auto Decurler Disabled - Make the Disabled selection to turn the machines automatic
decurling capability off. Decurling will be set to minimum.
If you do not have access to the internet, use the following process to create a template
document with one tab on each 8.5 x 11-inch (A4) page. The spacing of the tabs will vary
depending on the font size that you use. As a rule of thumb, the tabs are spaced about 2
inches apart. You will have to experiment with the creation of the tabs in the document to
make sure that they correspond to the appropriate tab that will be printed.
Max Decurler Enabled - Select Maximum to allow the machine to maximize the output
copy decurling capability.
When you have completed the document, you should have one tab on each page of the
document. For example, if you will be using five tabs, you should have a document with
five pages, and tab data imaged on each page.
Procedure
Saving Tab Creation Settings

Refer to the Reference Guide (Making Copies chapter) that accompanied your Document
Centre for details on how to use the following advanced copy features.
Stored Programming is helpful to save commonly used selections or combinations of
selections. Select the Job Assembly Tab then select Stored Programming. For example,
you can save Tab Creation settings such as image shift, media setting of 9 x 11-inch (223
x 297mm), and selection of a Paper Tray for feeding the tabs. Use the Recall Programming option to retrieve the tab creations settings.
NOTE: The amount of decurling performed when Max Decurler Enabled is selected can
be adjusted by the CSE via NVM, as explained in this procedure.
1.
2.
Answer [Yes] to the question: Initiate NVM Download?
4.
After the NVM loads, select [Mark Service].
5.
Change the amount of decurling for Simplex jobs and or Duplex jobs:
6.
Inserting Tabs
2.
General Procedures
GP48, GP49
a.
For Simplex mode, scroll or search for location 1164 (decManualSimplex).
b.
For Duplex mode, scroll or search for location 1165 (decManualDuplex).
Change the current value by:

a.
Position the cursor over the appropriate row and double-click.
b.
Type the new value in the [Current Value] field using these options:
c.
Use the Build Job feature to insert colored stock into the documents to identify tabs location during copying.
Manually remove the colored sheet markers and insert the tabs.
Enter [NVM tab , NVM Tool], then select [Machine] [Download].
3.
Build Job allows you to combine multiple, individually programmed job segments from
either the Document Centre Glass or the Document Feeder into a single copy job. You
can use the Build Job feature when creating the document and insert colored stock into
the document where a tab belongs. Once the sets are created, you can then replace the
colored stock with the respective tab.
1.
Auto Decurler Enabled - Select Auto Decurler Enabled to allow a 480/490 machine to
automatically minimize curl on output copies, based on the humidity level sensed by the
E-Sensor. This is the default selection.
1 = Low Decurling
2 = Medium Decurling
3 = Maximum Decurling
After the new value is entered, select [Write NVM].
7.
8.
Switch the machine power Off/On for changes to take effect.
May 2003
6-58
V0.042
GP50 Image Overwrite Security (460/470 Only)
NOTE: This version of the Network Controller Image Overwrite Enablement software is
under evaluation for National Information Assurance Partners/Common Criteria certification. Customers interested in complying with this certification must disable HTTP after the
Network Controller (ESS) disk overwrite has been enabled. Customers who do not
require compliance with this certification can leave HTTP enabled. HTTP must be reenabled before the ESS disk overwrite can be disabled. (To enable/disable HTTP: (1)
Enter the Tools pathway on the UI, select [Connectivity and Network Setup], [Network
Setup], [TCP/IP Options]. (2) Ensure TCP/IP is enabled: Select [TCP/IP Settings], [Protocol and Media], [Enable], [Save], [Close]. (3) Select [HTTP/IPP], [Enable] or [Disable],
[Save], [Close], [Exit Tools].) Customers interested in complying with this certification
must also disable Network Scanning and Job Based Accounting, and any network protocols that are defaulted off must stay off.
Purpose
The purpose of this procedure is to enable the Image Overwrite Security Option, to support
certain governmental and other accounts' security policies requiring the ability to cleanse all
image/job data from all hard disks.
Before this option can be enabled, the customer must order this option through Xerox sales
and receive the Image Overwrite Security Kit.
Prerequisite
The machine and the PWS must have 19.04.xxx or higher software.
Procedure
1.
Enter Diagnostic Navigator, [NVM] tab, open [NVM Tool], and download NVM from the
machine.
2.
Select Service: [System Management Service].
3.
Scroll or [Search] to location 96 (declassify system enable - options enablement).
4.
Set the NVM value to 1 to enable the Image Disk overwrite.
5.
Close NVM Tool, [Exit] Diagnostic Navigator, and take the machine out of Diagnostics
mode.
6.
Switch OFF the machine power, wait approximately 20 seconds, and switch the machine
power back ON. (The machine must be reset in order for this NVM change to take effect.)
7.
Provide the CD-ROM, the Customer Letter, the "Quick Install Card," and the Image Overwrite Security Introduction to the Customer/SA.
8.
Inform the customer/SA:
9.
a.
You (the CSE) have enabled the Image Overwrite Security option on the Document
Centre's Main hard disk drive (the only hard disk drive on a Digital Copier or DT/DP
IOT).
b.
ST: Action is required on the SA's part to enable the feature on the Document Centre's Network hard disk drive. The necessary instructions are provided on the Quick
Install Card, and the necessary files are contained on the CD-ROM.
c.
The instructions for using the Image Overwrite Security feature (once enabled) are
contained in the Image Overwrite Security Introduction.
Enabling/Disabling ESS (Network Controller) Disk Overwrite (ST Only):

To enable or disable the Image Overwrite Security feature for the ESS Disk, the Customer/SA
must send the appropriate instruction file, provided on the CD-ROM (provided in the Image
Overwrite Security Kit), to the machine:
overwrite
feature,
the
SA
sends
the
file
Troubleshooting a Image Overwrite Security problem:
feature,
the
SA
sends
the
file
How the Image Overwrite Security feature is used:
Mark off Tag #280 on the IOT Change Tag Matrix.
To enable the ESS disk

enable_disk_overwrite.dlm.
overwrite
If the ESS Image Overwrite Security feature must be disabled temporarily for Service purposes and re-enabled afterward, the CSE can have the customer/SA send the disable
file and later the enable file again. In case the customer/SA's CD-ROM is unavailable, the
above files are also available to the CSE on the 19.04.xxx or higher machine software
CD-ROM in the following directory (where XX_XXX is the specific software release number): 7_19_XX_XXX\ESS\DiskOverwrite\ .
Additional Information
To disable the ESS disk

disable_disk_overwrite.dlm.
ESS (Network Controller) Disk Overwrite:

Once enabled by the DLM file, the ESS Image Overwrite Security feature is invoked automatically each time the machine is powered up, and any other time the ESS resets. The
ESS disk overwrite process adds up to 22 minutes (but typically less) to the usual ESS
initialization. (Normal ESS initialization takes up to five-minutes, plus the ESS disk overwrite time of up to 22 minutes equals up to 27 minutes total from power-up before the
ESS becomes available). During the ESS initialization/disk overwrite, the UI continues to
display the usual Network Controller is initializing message. The customer can use the
machine to make copies during this time. The customer must wait until after the ESS initialization/disk overwrite completes before invoking the Main Image Disk Overwrite as
described below. After the ESS Disk overwrite process is completed, the ESS will generate a SUCCESS or FAILURE report sheet to indicate the overwrite success or failure,
respectively.
Image (Main) Disk Overwrite:
Once enabled by the NVM setting, the Image Disk overwrite feature can be invoked at
any time by the following manual procedure on the UI: Press the [Access] key, type
*33OVERWRITE on the keypad (*33683797483), and select [Enter] on the touch screen.
The Image Disk overwrite process takes up to 27 minutes (but typically less), during
which the machine is unavailable and the UI displays the Diagnostics are active message and a pop-up window that reads Please wait. In the case of a power loss during
the Image Disk overwrite process, the overwrite process will not restart automatically at
the next power-up; it must be re-invoked manually on the UI as described above. After the
Image Disk overwrite process is completed, the customer may verify its success or failure
as follows: Press the [Machine Status] button on the UI, select the [Faults] tab, select
[Error Log], and look for any 19-300, 19-301, 19-302, or 19-304 faults having occurred
during the overwrite process.
the appropriate RAP to troubleshoot the problem.
If a 19-300 , 19-301 , or 19-302 fault occurs during Image (Main) Disk overwrite, go to
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General Procedures
GP50
If a 19-304 fault occurs during Image (Main) Disk overwrite, go to the 03-338 RAP to troubleshoot the problem.
NOTE: It is left to the customer's discretion to determine how to handle a disk overwrite
failure. This allows the customer to follow the government or company standards during a
failure (e.g. if required by their policy, the customer may have the CSE replace the drive
with a new one and give the old drive to the customer to be destroyed). Otherwise, the
customer may elect to continue to use the Document Centre as is.
If a PWS session is opened while the Main Image Disk overwrite is in progress and an
intrusive diagnostic routine is attempted, the routine will be rejected with the message,
Failed to Enter Routine: Not in Diag Mode. NO further diagnostic routines or customer
jobs can be run until the system is powered off and on.
During the Main Image Disk overwrite operation, the white power off button will be
ignored.
If SW Verify is run on a system with the ESS Image Overwrite feature enabled, it will fail
with a bad checksum for start_Lakes. This is expected. Please run SW verify before the
ESS Image Overwrite Security software is enabled.
If ESS software is loaded on a system that has ESS Image Overwrite enabled, it will be
disabled after the upgrade. This is because ESS software has the feature disabled as
default. ESS Image Overwrite will need to be re-enabled after ESS software is loaded.
General Procedures
GP50, GP51
GP51 MFF Installation

Purpose
The purpose of this procedure is to install the Multifunction Finisher (MFF), either as part of a
new machine installation or as an upgrade of an existing machine from the Disk Finisher configuration.
Prerequisite
The machine must have 19.05.xxx or higher software.
Procedure
Refer to the Delivery/Removal Carrier MFF Installation Manual, stored as a PDF file mff drc
instructions.pdf on the EDOC CD-ROM, in the directory installation_manual.
May 2003
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V0.042
GP52 Tri-Fold Setup for 8.5 x 11-inch or A4 Paper
a.
Run C-configuration and Z-configuration Tri-fold jobs with 20 lb. / 80 gsm or equivalent weight paper.
Purpose
b.
If the customer uses A4 paper and TAG M011 is not marked off on the MFF Change Tag
Matrix, follow the Tri-fold Setup Procedure for A4 Paper, and mark off Tag #011 on the MFF
Change Tag Matrix.
As the output exits the finisher and stacks onto the Booklet Tray, label the top pane
as a reference for each job as shown in Figure 2.
c.
Open the Tri-fold sheets, measure the fold lengths indicated in Figure 3, and compare them to the specifications in Figure 3. Use "TOP" as a reference, labeled from
the previous step. If any dimensions are incorrect, adjust the fold lengths as follows.
If the customer uses 8.5x11-inch paper, follow the Tri-fold Setup Procedure for 8.5 x 11 Inch
Paper.
d.
To adjust the middle fold (second crease) length, refer to step 1.
e.
Adjusting C-configuration first crease position (dimension C):
NOTE: If the customer requires Tri-Fold output using both 8.5x11-inch and A4 paper, the TriFolding must be set up for A4 paper. The customer will then experience unequal fold lengths
on 8.5x11-inch paper, but this compromise is necessary in order to avoid A4 paper wrinkling,
double folding, overlapping, or jamming in the Tri-Folder.
Tri-Fold Setup Procedure for 8.5 x 11-inch Paper

NOTE: This procedure assumes an 8.5 x 11-inch paper length of 279 mm.
NOTE: Setting fold lengths for 8.5x11-inch paper will affect the fold lengths for A4-sized paper
and vice versa.
1.
Compare dimension C from the output to that in Figure 3 and determine the
length the output dimension is off by and whether it must be increased or
decreased. For example, if the output measured is 89.5 mm, the fold length is
off by 1.5 mm (91 mm - 89.5 mm), and must be increased.
ii.
Take the length that the output is off by in millimeters and multiply it by 8.8 to
determine the NVM adjustment. (In the example, 1.5 mm multiplied by 8.8 is
13).
iii.
Follow step 2. section a and b.
iv.
[Search] to location "C-Fold First to LE".
v.
To increase dimension C, subtract the value obtained in step ii. from the current
value and enter the result as a new value. (In the example, if the current value
is +26, change the value to +13.
vi.
To decrease dimension C, add the value obtained in step ii. to the current value
and enter the result as a new value. (For another example, if dimension C is
92.5 mm (must be decreased by 1.5 mm, i.e. 13 in NVM) and the current NVM
value is +26, change the value to +39.
vii.
Run more C-fold jobs to verify the change.
Adjust the middle fold (second crease) length mechanically on the Trifolder module (Figure 1):
a.
Remove the Booklet Maker Exit cover (three T20 or 5.5 mm screws).
b.
c.
Adjust the Trifolder Backstop position by setting the tab as shown.
d.
NOTE: The position shown is a starting point. To verify the middle fold (second crease)
length, run Tri-fold jobs and measure the output as in step 3. Each graduation in Figure 1
indicates approximately 1 mm of adjustment. To increase the middle fold length, lower the
backstop tab; to decrease the middle fold length, raise the backstop tab.
NOTE: If wrinkling, double folding, or overlapping occurs, the middle fold may have to be
increased.
2.
i.
Adjust the outer fold (first crease) lengths in NVM:

a.
b.
c.
d.
Enter Diagnostics Navigator, [NVM] tab, [NVM tool], and download the machine
NVM.
f.
Adjusting Z-fold first crease position (dimension Z):

i.
Compare dimension Z from the output to that in Figure 3 and determine the
decreased. For example, if the output measured is 184 mm, the fold length is
off by 1.0 mm (185 mm - 184 mm), and must be increased.
ii.
Take the length that the output is off by in millimeters and multiply it by 8.8 to
determine the NVM adjustment. (In the example, 1.0 mm multiplied by 8.8 is 9).
iii.
iv.
[Search] to location "Z-Fold First to LE".
v.
To increase dimension Z, add the value obtained in step ii. to the current value
and enter the result as a new value. (In the example, if the current value is -96,
change the value to -87).
vi.
To decrease dimension Z, subtract the value obtained in step ii. from the current value and enter the result as a new value. (For another example, if dimension Z is 186 (must be decreased by 1.0 mm, i.e. 9 in NVM) and the current
value is -96, change the value to -105).
vii.
Run more Z-fold jobs to verify the change.
Set the Z configuration NVM value:

i.
ii.
Change the value to -96).
Set the C configuration NVM value:

i.
ii.
Change the value to +26).
NOTE: Each of these NVM settings is a starting point. To verify the outer fold (first
crease) lengths, run Tri-fold jobs and inspect the output as in step 3.
3.
Run Trifold jobs and inspect the output:
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General Procedures
GP52
Tri-Fold Setup Procedure for A4 Paper

NOTE: This procedure assumes an A4 paper length of 297mm.
NOTE: Setting fold lengths for A4 paper will affect the fold lengths for 8.5 x 11-inch paper and
vice versa
1.
Adjust the middle fold (second crease) length mechanically on the Tri-folder module (Figure 1):
a.
Remove the Booklet Maker Exit Front Cover (three T20 or 5.5 mm screws).
b.
c.
Adjust the Tri-folder Backstop position by setting the tab as shown.
d.

f.
NOTE: The position shown is a starting point. To verify the middle fold (second crease)
length, run Tri-fold jobs and measure the output as in step 3. Each graduation in Figure 1
indicates approximately 1 mm of adjustment. To increase the middle fold length, lower the
backstop tab; to decrease the middle fold length, raise the backstop tab.
2.
ii.
Take the length that the output is off by and multiply it by 8.8 to determine the
NVM adjustment. (In the example, 1.0 mm multiplied by 8.8 is 9).
iii.
iv.
v.
To increase dimension C, subtract the value obtained in step ii. from the current
value and enter the result as a new value. (In the example, if the current value
is +4, change the value to -5.)
vi.
To decrease dimension C, add the value obtained in step ii. to the current value
and enter the result as a new value. (For another example, if dimension C is 98
mm (must be decreased by 1 mm, i.e. 9 in NVM) and the current value is +4,
change the value to +13.)
vii.
Run more C-configuration Tri-fold jobs to verify the change.
Adjusting Z-configuration first crease position (dimension Z):

i.
NOTE: If wrinkling, double folding, or overlapping occurs, the middle fold may need to be
increased.
Compare dimension Z from the output to that in Figure 4 and determine the
decreased. For example, if the output measured is 196 mm, then the fold length
is off by 1.0 mm (197 mm - 196 mm), and must be increased.
ii.
Take the length that the output is off by and multiply it by 8.8 to determine the
NVM adjustment. (In the example, 1.0 mm multiplied by 8.8 is 9.)
Adjust the outer fold (first crease) lengths in NVM:
iii.
Follow step 2 . section a and b.
a.
iv.
v.
To increase dimension Z, add the value obtained in step ii. to the current value
and enter the result as a new value. (In the example, if the current value is -26,
change the value to +17.)
vi.
To decrease dimension Z, subtract the value obtained in step ii. from the current value and enter the result as a new value. (For another example, if dimension Z is 198 (must be decreased by 1.0 mm, i.e. 9 in NVM) and the current
value is -26, change the value to -35.)
vii.
Run more Z-configuration Tri-fold jobs to verify the change.
b.
c.
d.
Enter Diagnostics Navigator, [NVM] tab, [NVM tool], and download the machine
NVM.
Set the Z configuration NVM value:
i.
ii.
Set the value to -26.
Set the C configuration NVM value:

i.
ii.
Set the value to +4.
4.
Mark off Tag # 011 on the MFF Change Tag Matrix.
NOTE: Each of these NVM settings is a starting point. To verify the outer fold (first crease)
lengths, run Tri-fold jobs and inspect the output as in step 3.
3.
Run Tri-fold jobs and inspect the output:

a.
Run C-configuration and Z-configuration Tri-fold jobs with 20 lb. / 80 gsm or equivalent weight paper.
b.
As the output exits the finisher and stacks onto the Booklet Tray, label the top pane
as a reference for each job as indicated in Figure 2.
c.
Open the Tri-fold sheets, measure the fold lengths indicated in Figure 4, and compare them to the specifications in Figure 4. Use "TOP" as a reference, labeled from
the previous step. If any dimensions are incorrect, adjust the fold lengths as follows.
d.
To adjust the middle fold (second crease) length, refer to step 1.
e.
Adjusting C-configuration first crease position (dimension C):

i.
Compare dimension C from the output to that in Figure 4 and determine the
decreased. For example, if the output measured is 96 mm, the fold length is off
by 1 mm (97 mm - 96 mm), and must be increased.
General Procedures
GP52
May 2003
6-62
V0.042
adjustment screw
(T20)
TOP
TOP
Finisher
Finisher
typical setting for

8.5 x 11 inch paper
Booklet Tray
typical setting for
A4 paper
C-configuration
Figure 1 Tri-Folder Backstop position adjustment
V0.042
Booklet Tray
Z-configuration
Figure 2 Tri-Fold Output in Booklet Tray
May 2003
6-63
General Procedures
GP52
TOP
Middle
Fold
94 mm
TOP
Z
185 mm
(91 mm + 94 mm)
C
91 mm
TOP
C-configuration
Middle
Fold
94 mm
Middle
Fold
100 mm
91 mm
C
97 mm
Figure 3 Tri-Fold Dimensions for 8.5x11-inch (279 mm length) paper
General Procedures
GP52
Z
197mm
(97mm + 100 mm)
TOP
C-configuration
Z-configuration
Middle
Fold
100 mm
97 mm
Z-configuration
Figure 4 Tri-Fold Dimensions for A4 (297 mm length) paper
May 2003
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V0.042
GP53 OCT to Disk Finisher Conversion

Purpose
The purpose of this procedure is to upgrade a machine from Offsetting Catch Tray (OCT) to
Disk Finisher Configuration.
Procedure
1.
Order and install the Exit Baffle Kit (PL 6.1A).
2.
Dock the Finisher to the IOT (REP 12-12).
3.
Switch on the machine power and accept the configuration change displayed on the UI.
4.
Machine Software Version 19.04.xxx and Higher Only: Set the Exit Decurler Configuration NVM value:
a.
b.
c.
Scroll or [Search] to location 529 (Exit Decurler Config Type).
d.
Double-click on the Value, change the Current Value to 0 (zero), and select [Write
NVM], and [OK].
e.
Close NVM Tool.
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General Procedures
GP53
General Procedures
GP53
May 2003
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V0.042
NVM
CAUTION
You must ensure that Service is set to [All]. Otherwise, only the NVM locations in the service displayed will be saved to the floppy.
IOT Variable NVM Initialization

Purpose
The purpose of IOT Variable NVM Initialization is to reset the nominal value for all machine
variable NVM locations within a specified service or module.
a.
Ensure that Service is set to [All].
b.
Ensure that the diskette is in the floppy drive of the PWS.
c.
Select [File] [Save As].
NOTE: In this procedure, any references to SMH are to be interpreted to mean Bypass Tray.
NOTE: When saving NVM, the filename should reflect the current machine software
level. Example: 1_10.bnf (for L1.10 a.k.a. L0.15.6 software). It is recommended to
remove any down-rev filenames to avoid filling up the diskette with multiple nvm
files.
Procedure
CAUTION
Running this routine will reset several NVM locations to default settings. This may affect some
setup procedures, and cause fault codes in some instances. If a bulletin that required NVM
changes had been previously implemented since the last software upgrade, the bulletin may
need to be reapplied.
1.
3.
Select Category
High Capacity Disk Finisher
d.
Select Drive A:
e.
Select [OK]
To change an NVM value:

a.
Double-click the row which contains the location or NVM name to be changed.
b.
Another dialog box appears (Edit NVM Value). The fields which appeared in the
table are also located here. The current value is the only editable field.
c.
When changed, [Write NVM] will save the new value. [Set Nominal] will set the current value to its nominal value.
Paper Path
Xerographics
Paper Registration
SMH / HCF
d.
[Undo] will undo the last change.
Scanner
e.
[Close] will close the (Edit NVM Value) box.
DADF
4.
To upload the active NVM file to the machine: Select [Machine] [Upload].
Image Processing
5.
To upload a saved NVM file to the machine:
An individual category can be selected, or multiple categories can be selected by holding

down the shift key when selecting with the left mouse button. All categories can be
selected by using the [Select All] button.
2.
Select [Start] to begin the routine. Selecting [Exit] will exit the routine. Standard Status
and Results windows are available for indication on routine progress.
For more help on this routine, go to [NVM tab , IOT Variable NVM Initialization], and click on
Help.
Select [File] [Open].
c.
A (File Open) dialog window will appear. NVM Data files have a.nsf extension.
Locate the desired NVM file to be restored (uploaded).
d.
Select [OK].
For more help on this routine, go to [NVM tab , NVM Tool], and click on Help.
Purpose
Purpose
The NVM Tool will enable the capability to download machine NVM to the PWS, save the NVM
to a file, restore NVM from a file, and to read or modify NVM values.
Procedures
2.
Close any open NVM files.
b.
ESS Variable NVM Initialization
NVM Tool
1.
a.
The purpose of this routine is to initialize the NVM values stored on the ESS PWB.
For more help on this routine, go to [NVM tab , ESS Variable NVM Initialization], and click on
Help.
To download NVM to the PWS:
Backup ESS NVM
a.
Select [Machine] [Download]. A status bar will appear indicating the progress of the
download.
Purpose
b.
When the download is complete, a window will appear with a table view of machine
NVM. Once the download is complete, the following actions may be performed:
The purpose of this routine is to back up the Network information stored on the ESS.
For more help on this routine, go to [NVM tab , Backup ESS NVM], and click on Help.
To save the NVM to the Machine Resident Diskette or other floppy diskette:
Restore ESS NVM

Purpose
The purpose of this routine is to restore previously backed-up Network information to the ESS.
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General Procedures
NVM
For more help on this routine, go to [NVM tab , Restore ESS NVM], and click on Help.
Paper
System Registration Setup
Purpose
This routine will allow the user to adjust the IOT and IIT System, image-to-paper registration.
IOT System Registration Setup
Refer to the following adjustment procedures for IOT Registration setup instructions:
ADJ 8-1, IOT Registration Setup Series, including:
ADJ 8-1A, IOT Lead Edge Registration (Process Direction)
ADJ 8-1B, IOT Top Edge Registration (IB - OB), Side 1
ADJ 8-1C, IOT Top Edge Registration (IB - OB), Side 2, Small Paper
ADJ 8-1D, IOT Top Edge Registration (IB - OB), Side 2, Large Paper
ADJ 8-1E, IOT Lead Edge Registration for Small Heavy Weight Paper (19.02 and Higher
Software Only)
ADJ 8-1F, IOT Lead Edge Registration for Large Paper (19.02 and Higher Software Only)
ADJ 8-1G, IOT Lead Edge Registration for Large Heavy Weight Paper (19.02 and Higher
Software Only)
The IOT System Registration Setup screen offers the following selections and information:
Setups: There are three types of Setups offered: x-reg, y-reg (Side 1), or y-reg (Side 2).
Tray Selection: This is used to select the desired tray.
Size: There are two standard paper sizes that may be selected for the specified tray:
8.5x11-20# or A4-75gsm.
Offset: When selected, an optional 5 mm offset is applied.
Paper Weight (19.03 and Higher Software Only): This is used to select Normal or Heavy
paper.
Setup Status: Indicates the current setup status.
Setup Information: Displays special instructions for the current setup.
Directional Buttons: The directional buttons (shown as arrows) allow the directional
adjustment of the selected registration. The x-reg setup allows left and right directional
adjustments. The y-reg setup (Sides 1 & 2) allows up and down directional adjustments.
The current position of the registration is indicated in the Setup Status window.
Starting the Setup: Selecting [Start Job] will save the current position of the selected registration and start a five page registration test pattern job. Once the setup has been
started, the text on the Start Job button will change to Stop Job. Selecting the Stop Job
button will interrupt the setup process. Upon completion (either by selecting the Stop Job
button or by allowing the setup to continue to completion), the Stop Job button text will
change back to Start Job.
IIT System Registration Setup

Refer to adjustment procedure ADJ 14-2 for IIT Registration setup instructions.
The IIT System Registration Setup screen offers the following selections and information:
General Procedures
NVM , Paper
Information: Displays a description of the current setup.
Instructions: Displays special instructions for the current setup.
Status: Indicates the current status of the setup.
Results: Lists the results of the setup which have already completed.
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V0.042
Starting the Setup: Selecting [Start] will start the next step of the setup.
Procedure
For more help on this routine, go to [Paper tab , System Registration Setup], and click on Help.
IOT Paper Path Setup
NOTE: If a Jam occurs during the running of this routine, stop collecting data beyond and
including the jam and clear all jams in the required areas. Repeat the test when requested.
1.
Purpose
The IOT Paper Path Setup routine allows the CSE to set the nominal buckle-height value for
Duplex Feed Time, Paper Width, and SMH (Bypass Tray) Feed-time.
2.
Select [Paper]
3.
Procedure
Select [IOT Paper Path Timing]. The IOT Paper Path Timing screen will be displayed.
Select the following:
1.
a.
Tray - Paper Tray to be tested (Choices are Trays 1, 2, 3, 4, SMH (Bypass Tray), or
HCF)
2.
Select [Paper].
b.
3.
Select [IOT Paper Path Setup]. The IOT Paper Path Setup screen is displayed.
Interval - Time interval for which test results will be displayed as follows (The default
is ALL):
4.
Select the desired setup from the choices listed in the [Setups] box:
5.
All - Displays all intervals
a.
Duplex Feed Time Setup - sets the duplex buckle to its nominal value. This setup is
run whenever the Registration Transport or Duplex Transport is replaced.
b.
(This feature is not yet available) Paper Width Setup - enables the ON LINE consistency check of the paper passing over the Registration Sensor. This setup is run
whenever the Registration Transport is replaced.
c.
SMH (Bypass Tray) Feed Time Setup - sets the Bypass Tray buckle to its nominal
value.
TE@S1 - With a sheet of paper stopped at the Wait Station Sensor, this test
measures the time interval from Feed Clutch on, to Trail Edge at Wait Station
Sensor.
TO S2 - Total time (lead edge to trail edge) the sheet is at the Registration Sensor.
TO S3 - Total time (lead edge to trail edge) the sheet is at the Prefuser Sensor.
TO S4 - Total time (lead edge to trail edge) the sheet is at the Inverter Entrance
Sensor.
Select the desired paper size from the [Size] box (8.5x11 or A4)
TE@S4 - LE@S5 - Time interval between the Trail Edge at the Inverter
Entrance Sensor and the Lead Edge at the Inverter Exit Sensor (inverted
mode).
NOTE: If the correct sized paper is not loaded in the selected tray, a message is displayed to load the correct sized paper.
(This feature is not yet available) If the desired setup includes label stock, perforated
stock, or envelopes, the SMH (Bypass Tray) buckle can be set to a value of 10 mm less
than nominal. This will optimize the buckle height for this feature. Click on the [Adjust
SMH Buckle] box to enable this feature.
S5 Inv - Dup - Total time (lead edge to trail edge) the sheet is over the Inverter
Exit Sensor going to the Duplex Transport (inverted mode).
7.
Select [Start Job]. The [Start Job] button text will change to [Stop Job]. Select it again to
stop the job, or wait for a [Job Complete] status indication.
S5 Byp - Exit - Total time (lead edge to trail edge) the sheet is over the Inverter
Exit Sensor going to the Decurler (non-inverted mode).
8.
Status and related information are displayed in their respective boxes on the screen.
9.
Upon completion of the job, select [Start Job] to repeat the routine, or select [Exit] to
return to the Diagnostic Navigator.
6.
S5 Inv - Exit - Total time (lead edge to trail edge) the sheet is over the Inverter
Exit Sensor going to the Decurler (inverted mode).
c.
4.
For more information on this routine, go to [Paper tab , IOT Paper Path Setup], and click on
Help.
Plex - single-sided or double-sided jobs (choices are Simplex or Duplex. Default is

Simplex.)
Select [Start Job].

Status Window
The status window shows the status of the current routine. This allows the routine's
progress to be continually monitored.
IOT Paper Path Timing
Results Window
Purpose
This routine allows the CSE to monitor critical timing values within the paper path. It also
allows access to timing information from machine memory and the monitoring of critical timing
events, both remotely and on site.
The results window displays the test results for the selected interval. To view the
results in a table format, select [Table]. When finished reviewing the data, select
[Exit] to return to the IOT Paper Path Timing screen.
5.
Select [Exit] to return to Diagnostic Navigator.
For more help on this routine, go to [Paper tab , IOT Paper Path Timing], and click on Help.
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General Procedures
Paper
Fuser Drives Test
This checks the alignment of the LED sensor array. A 10-726 will be displayed if this test
fails.
Purpose
The purpose of this routine is to provide a means to run the Fuser Drives test from the PWS.
This test will display Machine Status, Diagnostic Status, and any existing or encountered faults.
Sequential Read Test

This tests each LED sequentially and checks for a response from the sensor array.
Group 2 Tests
NOTE: A machine without a Decurler will always fail this test.
1.
2.
Select the [Paper] tab.
3.
Select the [Fuser Drives Test] icon. The Fuser Drives Test screen is displayed.
Sensor Monitor Test

Similar to Component Control. If paper is moved by the sensor, a bar graph on the screen
will indicate the position of the paper as it is moved by the sensor.
Procedure
Print Test
This test will dynamically check the sensor in run mode. Duplex prints will be made using
the registration test pattern. The number of prints and paper tray are selectable from the
PWS.
NOTE: The [Start Test] and [Exit] buttons displayed in the Fuser Drives Test screen are
shown in two different states; Enabled (dark outline, black text) and Disabled (light outline, gray text). The button cannot be selected when disabled.
4.
When the [Start Test] button becomes enabled, click on it to start the routine. At this time,
the [Start Test] button changes to disabled and the [Exit] button changes to enabled.
NOTE: Selecting the [Exit] button before the test is completed, will cause a test-inprogress warning to be displayed. The option is given to cancel or exit.
5.
At the completion of the test, the results are displayed in the [Results] box. Passed or
Failed is displayed in the [Status] box. In the event of a failure, specific faults are also displayed in the [Status] box.
6.
Click [Exit] to return to the Diagnostic Navigator screen.
For more help on this routine, go to [Paper tab , Fuser Drives Test], and click on Help.
TEER Diagnostics (L18 and Later Software Only)

Purpose
The purpose of this routine is to test the TEER Sensor for correct operation.
Group 1 Tests
Five tests are available in Group 1. They can be selected individually or all at once using the
Select All button.
NOTE: If the Diagnostic Navigator is started when the machine is in the Power Saver mode,
the Duplex TEER Diagnostic Test routine will not operate. The Main Controller PWB must be
reset. In Diagnostic Navigator, select [Self Tests], then select [Reset Platforms]. In the Reset
Platform(s) dialog box, select the Main Controller checkbox, then select [Start].
Communications Test
This test will determine if the sensor is communicating with the Main Control PWB. If not,
a 10-720 fault will be displayed.
Blank Calibration Test

If this test fails, there may be a problem with the LED, or too much stray light. A 10-722
fault will be displayed if this test fails.
Intensity Calibration Test
Position Calibration Test
The LEDs intensity is checked in this test. If it fails, a 10-724 will be displayed.
General Procedures
Paper
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IIT
DADF Clutch/Solenoid Tests
Scanner Calibration
Purpose
Purpose
The purpose of the Scanner Calibration routine is to perform a Full Calibration or a Partial Calibration.
The purpose of the DADF Clutch/Solenoid Tests is to test the electrical and mechanical operation of the following Document Feeder Components:
The DADF Exit Clutch
The DADF Inverter Clutch
The DADF Feed Clutch
The DADF Nudger Solenoid
Procedure
The DADF Registration Gate Solenoid
1.
When the Status window displays the message [Ready], select [Full] or [Partial], then
select [Start].
The following tests are available for selection:
IIOC Turnaround
2.
While the test is running, [Calibrating] will be displayed in the Status window. The text
will flash until the test is complete. The [Start] button will be disabled until the test is completed.
The Exit Clutch and Inverter Clutch Test checks the mechanical operation of the Exit
Clutch and the Inverter Clutch
3.
When the calibration test is complete, the Status window will display the message [Complete].
Feed Clutch Nudger Solenoid Test checks the mechanical operation of the DADF Feed
Clutch and the DADF Nudger Solenoid.
4.
Observe the Results window. The message [White Lamp On calibration passed/failed]
and or [Black Lamp Off calibration passed/failed], will be displayed. Associated fault
code(s) for the failed component(s) will be displayed in the Faults window.
The DADF Registration Gate Solenoid Test checks the mechanical operation of the
DADF Registration Gate Solenoid.
Full Calibration will invoke the same routine performed at power up, which includes lamp
on (white) and lamp off (black) tests.
Partial Calibration will perform a lamp off (black) test only.
For more help on this routine, go to [IIT tab , Scanner Calibration], and click on Help.
IIT Motor Tests

Purpose
The purpose of the IIT Motor Tests are to test the following:
Procedures
To perform the IIOC Turnaround Test, do the following:
1.
When the Status window displays the message [Ready], select [IIOC Turnaround] then
select [Start Test].
2.
When all the components have been tested, the Status window will display the message
[IIOC Turnaround completed].
3.
Observe the Results window. A passed or failed message for each component tested
will be displayed. Associated fault code(s) for the failed component(s) will be displayed in
the Faults window.
The operation of the Scan Carriage Motor
The operation of the DADF Feed Motor
The operation of the DADF CVT Motor
To perform the Exit Clutch and Inverter Clutch Test, do the following:
The CVT Drive Belts (Exit Clutch Drive Belt)
1.
The CVT and Scanner (RIS) Motor common feedback signal
When the Status window displays the message [Ready], select [Exit Clutch and Inverter
Clutch] then select [Start Test].
2.
When the Exit Clutch and Inverter Clutch have been tested, the Status window will display the message [Exit Clutch and Inverter Clutch completed].
3.
The Results window will display a passed or failed message for the Exit Clutch and for
the Inverter Clutch. Associated fault code(s) for the failed component(s) will be displayed
in the Faults window.
Each motor is tested by energizing the motor and checking for encoder feedback. If no
encoder feedback is measured, the test result for that motor will be [failed].
The Exit Clutch Drive Belt is tested by energizing the DADF Feed Motor, the DADF Exit Clutch,
and the DADF Inverter Clutch and then checking for encoder feedback from the CVT Motor.
To perform the Feed Clutch and Nudger Solenoid Test, do the following:
Procedure
1.
When the Status window displays the message [Ready], select [Feed Clutch Nudger
Solenoid] then select [Start Test].
When the Motors and the CVT Drive Belts have been tested, the Status window will display the message [Tests complete].
2.
When the Feed Clutch and the Nudger Solenoid have been tested, the Status window
will display the message [Feed Clutch Nudger Solenoid completed].
Observe the Results window. A passed or failed message for each of the IIT Motors and
for the CVT belts will be displayed. If the CVT and Scanner (RIS) Motor common feedback signal is missing, the message [CVT and RIS motor common feedback leg failed]
will be displayed. Associated fault code(s) for the failed component(s) will be displayed in
the Faults window.
3.
Observe the Results window. A passed or failed message for the Feed Clutch and for
the Nudger Solenoid will be displayed. Associated fault code(s) for the failed component(s) will be displayed in the Faults window.
1.
When the Status window displays the message [Ready], select [Start Test].
2.
3.
For more help on this routine, go to [IIT tab , IIT Motor Tests], and click on Help.
V0.042
To perform the DADF Registration Gate Solenoid Test, do the following:

1.
When the Status window displays the message [Ready], select [DADF Registration
Gate Solenoid].
2.
Follow the instructions in the Information window, then select [Start Test].
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General Procedures
IIT
3.
When the DADF Registration Gate Solenoid Test has been tested, the Status window
will display the message [DADF Registration Gate Solenoid completed].
4.
Observe the Results window. A series of passed or failed messages (one for each document fed) for the Registration gate will be displayed.
5.
Associated fault code(s) for a failed DADF Registration Gate, will be displayed in the
Faults window.
Jam Time is the time in milliseconds, if exceeded for a particular timing interval, a
jam will be declared.
6.
To view data for a particular sensor, scroll to that sensor in the Display Selection Window.
7.
To view the same timing data for the sensor in a histogram format, select Histogram.
For more help on this routine, go to [IIT tab , DADF Document Timing Test], and click on Help.
For more help on this routine, go to [IIT tab , DADF Clutch / Solenoid Tests], and click on Help.
DADF Sensor Tests
DADF Document Timing
Purpose
Purpose
The purpose of DADF Document Timing is to feed documents through the DADF document
path at full speed and measure the following feed times:
Lead Edge at Q1 (Input Tray Exit Sensor) - the time measured between when the DADF
Feed Motor was energized to when the LE of the document arrives at the Input Tray Exit
Sensor.
Lead Edge at Q2 (DADF Reg. Gate Sensor) - the time measured between the LE of the
document arriving at the Input Tray Exit Sensor to when the LE of the document arrives at
the DADF Reg. Gate Sensor.
Lead Edge at Q3 (CVT Start of Scan Sensor) - the time measured between when the LE
of the document arrived at the DADF Reg. Gate Sensor to when the LE of the document
arrives at the CVT Start of Scan Sensor.
The purpose of DADF Sensor Tests is to determine whether or not actuation of the DADF Document Path Sensors, the Document Input Tray Sensors, the Document Feeder Top Cover Sensor, and the DADF Interlock Switch, is sensed by the control logic.
The following tests are available for selection in the Test Selection window.
DADF Top Cover Sensor Test
DADF Interlock Test
DADF Input Tray Guides Test
DADF Input Tray Sensors Test
DADF Document Path Sensors Test
Procedure
Lead Edge at Q4 (DADF Exit/Invert Sensor) - the time measured between when the LE of
the document arrived at the CVT Start of Scan Sensor to when the LE of the document
arrives at the DADF Exit/Invert Sensor.
1.
Scroll to and select a test in the Test Selection window.
2.
Select [Start], then follow the instructions displayed in the Instructions window.
Time Over Q2 (DADF Reg. Gate Sensor) - the time measured between when the LE of
the document arrived at the DADF Reg. Gate Sensor to when the LE of the document
leaves the DADF Reg. Gate Sensor.
3.
Time Over Q3 (CVT Start of Scan Sensor) - the time measured between when the LE of
the document arrived at the CVT Start of Scan Sensor to when the LE of the document
leaves the CVT Start of Scan Sensor.
View the results of the DADF Sensor Tests in the Results window. If the control logic
detected the actuation of the sensors/switch, the question mark to the left of the sensors/
switch name will be replaced by a check mark.
4.
If you want to retest a particular sensor or switch, select [Clear Results], then run the test
again.
Time Over Q4 (DADF Exit/Invert Sensor) - the time measured between when the LE of
the document arrived at the DADF Exit/Invert Sensor to when the LE of the document
leaves the DADF Exit/Invert Sensor.
NOTE: For Test 5, follow the instructions before pressing [Start].
For more help on this routine, go to [IIT tab , DADF Sensor Tests], and click on Help.
Scanner Lamp Profile
Procedure
Purpose
1.
After placing the correct paper in the Document Input Tray as directed by the instructions,
select [Start].
The purpose of the Scanner Lamp Profile diagnostic routine is to provide selections for the following tests:
2.
A popup window will display the message [Please place documents in the Document
Feeder]. Select [OK] to start the test.
Lamp Off test - this test measures the response of the Image Module when the Illumination Lamp is off.
3.
When all the documents have been fed, the Status Window will display the message
[Test Complete], and a graph will display the timing data for Lead Edge At Q1 (Input Tray
Exit Sensor).
Lamp On test - this test measures the response of the Image Module when the Illumination Lamp is on in order to check the Illumination Lamp output for uniformity.
4.
The individual document feeds are displayed on the X axis with their corresponding times
in milliseconds displayed on the Y axis
1.
5.
To the right of the graph, the following times are displayed:
2.
Select a Refresh Rate of 2 to 10 seconds, then select [Start].
3.
After the test is successfully started, the Status window will display the message [Test in
progress]. The [Start] button changes to a [Stop] button. The test runs until the [Stop] button is selected.
Low is the low limit time, in milliseconds, for a particular timing interval
Procedure
High is the high limit time, in milliseconds, for a particular timing interval
Nominal is the nominal time, in milliseconds, for a particular timing interval
General Procedures
IIT
May 2003
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When the Status window displays the message [Ready], select [Lamp Off] or [Lamp
On].
V0.042
4.
While the test is running, [Calibrating] will be displayed in the Status window. The text
will flash until the test is complete. The [Start] button will be disabled until the test is completed.
4.
Observe the Results window. The message [AGC tab passed] or [AGC tab failed], will
be displayed.
5.
Associated fault code(s) for the failed test will be displayed in the Faults window.
5.
When the test is stopped, the Status window will display the message [Stopped].
To perform the Carriage Parking Test, do the following:
6.
Test data will be displayed on a graph in the Results window.
1.
7.
Test data is displayed using Gray Level (Y-axis) and Cluster Number (X-axis). The lamp
has been divided into 20 Clusters, with Cluster 1 at the rear of the machine and Cluster 20
at the front of the machine. Each cluster is divided into 8 pixels from which a gray level
data point is obtained, representing the 8 pixels/cluster.
When the Status window displays the message [Ready], select [Carriage Parking], then
select [Start].
2.
While the test is running, the Status window will display the message [Test started...
please wait], then the message [Test in progress...]
3.
When the Carriage Parking Test is completed, the Status will display the message
[Complete]
4.
Observe the Results window.

parked.], will be displayed.
5.
8.
9.
In the Lamp Off test, the black line indicates the maximum value for the clusters, and the
bright green line is the test data or Image Module response. The test passes if the data
(green line) is flat and does not exceed the maximum value.
In the Lamp On test, the black lines indicate the minimum and maximum values and the
gray line represents the nominal value for the clusters. The bright green line is the test
data or Image Module response. The test passes if the data (green line) is flat and falls
between the minimum and maximum value.
NOTE: Once the Scan Carriage is parked, the machine must be powered off immediately
for the Scan Carriage to remain in the correct position for shipping. If more than 10 seconds elapse, the Scan Carriage will return to the unparked position.
10. To view any faults that may have occurred during the test, select [Faults].
For more help on this routine, go to [IIT tab , Scanner Lamp Profile], and click on Help.
The message [Carriage parking...] and [Carriage
To perform the Scan Carriage Test, do the following:

1.
When the Status window displays the message [Ready], select [Scan Carriage], then
select [Start].
Purpose
2.
The purpose of the Scanner Tests diagnostic routine is to provide selections for the following
Scanner tests.
3.
When the Scan Carriage Test is completed, the Status will display the message [Complete]
Scanner Tests
Lamp Operation - this test determines whether or not the Illumination Lamp is functioning.
AGC Tab - this test checks for a dirty or missing AGC Tab.
4.
Carriage Parking - this routine moves the Scan Carriage to the correct position for shipping.
Observe the Results window. The message [PSOS sensor and drives passed] or
[PSOS sensor and drives failed], will be displayed.
5.
Scan Carriage - this test checks the mechanical drives for the Scan Carriage and the
operation of the PSOS Sensor.
For more help on this routine, go to [IIT tab , Scanner Tests], and click on Help.
Procedures
IIT Skew Check
To perform the Lamp Operation Test, do the following:
Purpose
1.
When the Status window displays the message [Ready], select [Lamp Operation], then
select [Start].
The purpose of the IIT Skew Check diagnostic routine is to provide selections for the following
IIT Skew Checks
2.
DADF Document - this routine is used to measure the skew of the Document Feeder in
relation to the Scanner. The information is used to adjust DADF Skew.
3.
When the Lamp Operation Test is completed, the Status will display the message [Complete]
4.
Observe the Results window. The message [Lamp on passed] or [Lamp on failed], will
be displayed.
Image Module (not yet implemented) - this routine is used to measure the skew of the
Image Module in relation to the Scanner frame. The information is used to adjust Image
Module Skew.
Procedure
5.
To perform the DADF Document Skew Check, do the following:
To perform the AGC Tab Test, do the following:
1.
When the Status window displays the message [Ready], select [DADF Document].
1.
When the Status window displays the message [Ready], select [AGC Tab], then select
[Start].
2.
Load paper in the Document Input Tray as directed to by the text in the Instructions
window.
2.
please wait], then the message [Test in progress...
3.
While the DADF Document Skew Check is running, the Status window will display the
message [#X is XX mrad] as each sheet is fed through the Document Feeder.
3.
When the AGC Tab Test is completed, the Status will display the message [Complete]
4.
When the DADF Document Skew Check is completed, observe the Results window.
The average skew will be displayed in mrad (milliradians).
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General Procedures
V0.042
IIT
5.
Associated fault code(s) for the failed DADF Document Skew Check will be displayed in
the Faults window.
For more help on this routine, go to [IIT tab , IIT Skew Check], and click on Help.
Self Tests
Video and Controls POST
Purpose
Lamp Life Reset

Purpose
The purpose of the Lamp Life Reset diagnostic routine is to reset the Lamp Usage Counter to
zero when the Illumination Lamp is replaced.
The Video & Controls Power On Self Test (POST) routines consist of low level initialization and
validation exercises to verify the Main Control, RCM, SCAM, HP or SP, and attached peripheral integrity or to detect a malfunction. This test automatically will take place at system startup or it can be enabled by a service representative via the PWS either on site or remotely.
Procedure
Procedure
1.
When the Status window displays the message [Ready], select [Start].
2.
A popup window will display the message [Has the lamp been changed?]. Select [Yes]. If
[No] is selected a popup window with the message [Please change the lamp and run
again].
3.
If [Yes] is selected, a popup window will display the message [Has the Scanner been calibrated?].
4.
If the Scanner Calibration routine has been performed, do the following:
1.
2.
Select [Self Tests]
3.
The Video and Controls POST screen contains four tabs:
Select [Yes].
a.
Power On Self Test Results (default) - This is the initial screen displayed. It displays the results from the last power on self test. The results can be re-read by
selecting [Refresh].
b.
Main Controller Tests (1) -These are Main Control PWB tests, including:
DRAM Test
Select [Start] to zero the Lamp Usage Counter.
Flash ROM Test
The Results window will display the message [New reset value stored: 0, when the
counter has been set to zero.
5.
NVM Test
Options Present Test
If the Scanner Calibration routine has been not been performed, do the following
EPC Memory Test
Select [No]. This will launch the Scanner Calibration routine
Rotation Memory Test
In the Scanner Calibration routine, select [Full], then select [Start].
PBus Test
After the routine is completed, select [Exit] to return to the Lamp Life Reset routine.
On-board SCSI Test
In the Lamp Life Reset routine, select [Start], to zero the Lamp Usage Counter. The
Results window will display the message [New reset value stored: 0], when the
counter has been set to zero.
6.
c.
Main Controller Tests (2) - These are more Main Control PWB tests, including:
IPS1 RAM Test
Any associated fault code(s) declared during the Lamp Life Reset will be displayed in the
Faults window.
IP ASIC Test
SCVM RAM Test
For more help on this routine, go to [IIT tab , Lamp Life Reset], and click on Help.
SCVM ROM Test

SCVM Loop Test
d.
Ping Tests - These test send a message which requires a response from the tested
item. Ping test can be performed on the following:
User Interface
Image Processing
IIT
4.
General Procedures
IIT , Self Tests
Select the tab for the desired test and perform the following procedure:
a.
Select the desired test checkbox(es) from the list provided at the left side of the
screen.
b.
c.
Upon completion, the pass/fail results will be displayed next to the test name. Any
faults encountered and the associated fault codes are displayed in the Faults window.
5.
Repeat this procedure to run any other tests desired.
6.
Select [EXIT] to return to the Diagnostic Navigator.
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V0.042
For more help on this routine, go to [Self Tests tab , Video and Controls POST], and click on
Help.
Video Path Diagnostics
To perform the SCVM Digital Test A/B, do the following:

NOTE: The SCVM DIgital Test should not be run on LP machines. The test will fail because
the SCVM function is not enabled on LP machines.
Purpose
NOTE: This test is not available on machines with TAG 077 Main Control PWB.
The purpose of the Video Path Diagnostics routine is to provide selections for the following
video tests.
1.
When the Status window displays the message [Ready], select [SVCM Digital Test A/B],
then select [Start].
EPC Memory Test
2.
VCM + IPS1 Loop Test
While the test is running, the Status window will display the message [Video Test in
Progress].
IPS1 Daughter Card Test
3.
When the SVCM Digital Test A/B is completed, the results will be [Passed] or [Failed].
SCVM Digital Test A/B (Atlanta Gold Main Control PWB with TAG 015 Only)
4.
ESS / Atlanta Test
To perform the ESS / Atlanta Test, do the following:
IPA Daughter Card Test (L18 Only)
1.
When the Status window displays the message [Ready], select [ESS / ATLANTA Test],
2.
Progress].
Procedure
To perform the EPC Memory Test, do the following:
1.
When the Status window displays the message [Ready], select [EPC Memory Walking
Test] then select [Start].
3.
When the ESS / ATLANTA Test is completed, the results will be [Passed] or [Failed].
2.
A popup window will display the message [Memory test will take more than 15 minutes.
Do you want to continue?]. Select [Yes] to start the test.
4.
3.
The test results will be [Passed] or [Failed]. If the test fails, the status area will display the
SIMM socket number and the memory location where the failure occurred. The total
amount of memory tested, out of the total memory available, will be displayed in the MB
Tested window.
1.
When the Status window displays the message [Ready], select [IPA Daughter Card
Test], then select [Start].
2.
Progress].
4.
To perform the IPA Daughter Card Test, do the following:
3.
When the IPA Daughter Card Test is completed, the results will be [Passed] or [Failed].
To perform the VCM + IPS1 Loop Test, do the following:
4.
1.
When the Status window displays the message [Ready], select [VCM IPS1 Loop Test],
For more help on this routine, go to [Self Tests tab , Video Path Diagnostics], and click on
Help.
2.
Progress].
3.
When the VCM IPS1 Loop Test is completed, the results will be [Passed] or [Failed].
Purpose
4.
The purpose is to provide an automated method to test the functionality of the IIOC Busses
and IIOC PWB's. It also tests the electrical condition of the output components which are controlled by the IIOC PWB's.
To perform the IPS1 Daughter Card Test, do the following:

NOTE: The IPS1 Bypass Daughter Card Test will be available for selection if a Daughter Card
is installed and the VCM IPS1 Loop Test fails. The test will not be available if the machine
does not have a Daughter Card installed, or the VCM IPS1 Loop Test passes.
1.
When the Status window displays the message [Ready], select [IPS1 Bypass Daughter
Card Test] then select [Start].
2.
Progress].
3.
When the IPS1 Bypass Daughter Card Test is completed, the results will be [Passed] or
[Failed].
4.
V0.042
IIOC Controller Tests
NOTE: Input components are not checked with this routine.

The IIOC Controller Tests are divided into three sections:
IIOC Self Tests
IIOC Buss (Chain) Controller Tests
Serial Controller Tests
Following are descriptions of the three sections.
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General Procedures
Self Tests
IIOC Self Tests
8.
The IIOC Self Tests are the most-used tests in the RAPs. There are two tests which can be
run: Type 1 and Type 2.
Serial Controller Tests
The Type 1 test checks for the presence of the working voltage (typically +24VDC) from
the IIOC PWB through an output component (such as a clutch or solenoid or motor), and
back to the IIOC PWB. If the test fails, it means the voltage is not sensed: therefore there
is an open circuit in the wiring or the load, or there is a short circuit to DC COM.
The Type 2 test checks for the working voltage (typically +24VDC) to go to 0 VDC when
the output component is momentarily switched on. If the test fails, it means the voltage
did not go to 0 VDC, therefore there is either a short circuit across the load or the IIOC
PWB is defective. (A short circuit across the load provides maximum current flow through
the circuit and the IIOC PWB cannot gate the entire current flow to DC COM.)
1.
2.
Select [Self Tests].
3.
Select [IIOC Controller Tests].
4.
Select [Serial Controller Tests].
5.
Select the individual tests desired from the checkboxes in the Diagnostic Turn Around
boxer select [Select All] to run all available tests.
6.
Select [Start].
7.
When the test completes, the pass/fail result are displayed in the Test Status box adjacent
to the test name. Any faults encountered during the test are displayed in the Faults box.
8.
There are limitations on the usefulness of the IIOC Self Tests.
Input components are not checked. There is no way to predict the state of an input device
(such as a sensor or switch), so the test results would be unpredictable. The only diagnostic routine which can reliably test all input components is Component Control.
The Type 2 test is not functional for the IIT. Due to the quickness of the Type 2 test, and
communication delays between the IIT and the Main Control PWB, IIT Type 2 tests usually give erroneous failure indications. Using Component Control is the only reliable way
to test the full functionality of IIT components.
1.
2.
3.
Select [IIOC Controller Tests]. The IIOC Controller Tests screen is displayed. This screen
contains three tabs; IIOC Self Tests, IIOC Bus Controller Tests, and Serial Controller
Tests. The default tab is IIOC Self Tests.
4.
box, or select [Select All] to run all available tests.
5.
Select the desired Test Type.
6.
Select [Start].
7.
8.
For more help on this routine, go to [Self Tests tab , IIOC Controller Tests], and click on Help.
IIOC Chain Controller Tests

The IIOC Buss (Chain) Controller Tests perform an internal turnaround test on the Buss Interface Controllers on the Main Control PWB.
1.
2.
3.
Select [IIOC Controller Tests].
4.
Select [IIOC Bus Controller Tests].
5.
box, or select [Select All] to run all available tests.
6.
Select [Start].
7.
General Procedures
Self Tests
May 2003
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V0.042
Configuration
Current Mode
Power Saver Enabled
Machine Configuration and Tag Matrix
Power Off Enabled
Purpose
The purpose of this routine is to provide a means for the CSE to access the electronic tag information and enter, store and retrieve hardware upgrade information contained in the machine's
Non-Volatile Memory (NVM).
If the machine configuration is changed between service calls the CSE will be instructed to
load the tag matrix information, using the PWS during the current service call entry.
Procedure
1.
2.
3.
Select [Machine Configuration and Tag Matrix].
4.
Select [Tag Matrix].
5.
Move the cursor to, and click on the appropriate module.
7.
Select [Set Tags].
b.
Select [Add Tag].
c.
Enter the tag number and tag description in the appropriate fields.
d.
Select [OK].
e.
Select [Exit] when completed.
Billing Meter
Transfer Blade
Decurler
Duplex Decurler
Appearance Tuning
Fuser Type - indicates the type of fuser roll (hard roll, soft roll)
Paper Trays
External Feeders - indicates what external feeders are installed (HCF, SMH, none)
To enter a new tag into the matrix, perform the following:

a.
Resettable Meter
Number of Internal Paper Trays - indicates the number of internal trays in the IOT
The PWS will list the current tag number and tag description for the selected module. The
PWS also will match the NVM location and NVM value to the description of the tag.
6.
Power Off Timeout
Tray Attributes - brings up the Paper Tray Configuration window that indicates the size,
weight, color, and type of paper stock in each tray
Finishing Devices - Indicates the type of output device for each position (Basic Disk Finisher, High Capacity Finisher, Mail box 20 Bin, OCT)
Detected Configuration - indicates the detected configuration based on the most recent
power-on sequence.
System Serial Number
Finisher Serial Number
HCF/Bypass Serial Number
Software
Indicates the software level for each platform.
To delete an existing tag, perform the following:

a.
Select [Set Tags].
Platform
b.
Click on the tag to be removed. The tag entry will become highlighted.
c.
Select [Delete Tag]. The PWS will ask [Are you sure you want to delete this tag?].
Select [Yes].
d.
Platform Configuration
IOT
IIT
UI
For more help on this routine, go to [Machine Configuration and Tag Matrix], and click on Help.
ESS
Accessory Card
System, Imaging, and IOT Configuration
Purpose
The purpose of this routine is to view and change various machine configuration parameters.
Platform Options
Foreign Interface
Time
System
System Time - to view or change the system time on the machine.
System Date - to view or change the system date on the machine.
Time Display Format - toggle between 12 hour and 24 hour format for system time
machine.
GMT Offset (Hours) - to view or change the offset from Greenwich Mean Time on the
machine.
Install Phase
Customer Install
Customer Setup
Install Complete
Customer Service Number
Auto Configuration
Power Saver
V0.042
For more help on this routine, go to [System, Imaging, and IOT Configuration], and click on
Help.
May 2003
6-77
General Procedures
Configuration
Paper Tray Configuration
Procedure
Purpose
1.
The Paper Tray Configuration routine is intended to provide the CSE with a means to view and
modify attributes of all paper trays in the system.The initial screen is read only, and contains a
sub-set of the total information available on the tray(s).
2.
3.
Select [CRUs]. The CRUs screen will open. This screen contains three tabs, allowing the
CSE to view or modify the CRU configuration:
Module -Displays a descriptive identification for the tray or feeder. (Tray 1, Tray 2, HCF
etc.)
a.
CRU Information; lists all CRUs registered in the machine. Selecting a specific CRU
from the list and clicking on the [Details] button will cause additional information
about the specific CRU to be displayed.
Id -Displays the logical identification number of the tray or feeder.
Length -Displays the length designation of the media in the tray or feeder.
4.
After the desired modifications are made, select [Apply] to initiate changes.
Width -Displays the width designation of the media in the tray or feeder.
5.
Select [OK] to return to the Diagnostic Navigator screen.
Weight -Displays the weight designation of the media in the tray or feeder.
For more help on this routine, go to [Configuration tab , CRUs], and click on Help.
Color -Displays the color setting of the media in the tray or feeder.
Type -Displays the type of the media in the tray or feeder.
Version Information
Purpose
Procedure
The purpose is to verify the current Diagnostics software level selected on the PWS.
NOTE: It is not necessary to reset the machine to initiate changes.
Procedure
1.
2.
Select [Paper Tray Configuration]. The Paper Tray Configuration screen is displayed.
3.
Double-click the row containing the tray to which the desired configuration changes are to
be made. The Modify Attributes - Tray screen for the specified tray is displayed. Changes
can now be made to the length, width, weight, type, media color, and media type configuration settings.
2.
Select [Version Information] on the [Configuration] tab.
3.
The [Version Information] screen is displayed. (This screen is a display-only screen. No

entries are allowed.)
4.
Select [OK] to return to the Diagnostic Navigator.
4.
Select [Apply] to enable changes. Select [Cancel] to ignore changes and return to the
Paper Tray Configuration screen.
Network Configuration
5.
Whenever the Modify Attributes - Tray screen is closed with the [Apply] button, the Paper
Tray configurations are automatically re-read.
6.
If the operation fails while modifying a tray attribute, an error message will be displayed.
7.
Select [Close] to exit the routine and return to Diagnostic Navigator.
1.
Purpose
Network Configuration is used to verify the network configuration data stored on the ESS. You
may run this utility after a UI configuration was performed to check what was entered at the UI
with what was stored as well as other troubleshooting functions.
For more help on this routine, go to [Configuration tab , Paper Tray Configuration], and click on
Help.
For more help on this routine, go to [Configuration tab , Network Configuration], and click on
Help.
Software Upgrade
Network Configuration Initialization
Purpose
Purpose
This feature offers the user the ability to upgrade the machine software configuration.
Network Configuration Initialization is used to initialize the network configuration data stored on
the ESS.
CAUTION
Due to the variances in procedures for upgrading specific software, explicit upgrade instructions are supplied in the applicable Software Upgrade Kit. It is important to follow the step-bystep procedures exactly as instructed.
For more help on this routine, go to [Network Configuration Initialization], and click on Help.
CRUs
Purpose
Purpose
Software Option Wizard is used to manage the installation and enablement of machine
optional features.
The purpose of this routine is to allow the CSE to view or modify configuration of the system
CRUs.
Software Option Wizard (L18 Software Only)
Procedure
General Procedures
Configuration
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Software Options and Status

V0.042
Scan to File
LAN Fax
Job Accounting
Copier Sys
Communication Tests
Purpose
Action
The purpose of this test is to check the communication between various electrical components
in the machine.
Install
Remove
Enable
Procedure
Disable
There are several communication tests which can be run.
To install or remove an option using the PWS, a password needs to be entered.
The CRUM test checks the ability of the Main Control PWB to communication with the
CRUMs in the Fuser Module and the Xerographic module.
The LCN test detects if the LCN UART passes or fails an external turnaround test. This
test verifies all components up to the isolation transformer on the accessory PWB.
If there is a failure on the Reset Line, the Main Control PWB reports a communication failure. The SCB test distinguishes between a Comm failure or a Reset failure. The SCB
test has three elements. 1) Communication Test 1 tests the communication between the
Main Control PWB and the SCAM PWB. 2) Communication Test 2 tests the communication between the Main Control PWB and the RCM and DSSF. 3) The Reset Test continuously toggles the Pitch Reset line between '1' and '0' for 12 second intervals.
The UI test checks the ability of the Main Control PWB to communication with the UI.
To enter the password, perform the following:

1.
Note the unique machine identifier on the first screen. This will be used later.
2.
Select [Decode MUI].
3.
A password window will appear. Type xerox 1998
4.
Select [OK].
5.
Another window will appear. In the Machine Unique Identifier field, enter the number
that appeared on the first screen.
6.
Select [Generate Password].
7.
A password will appear in the Password field. Type the Password in the password
field on the first screen.
8.
For more help on this routine, go to [Copier Sys tab , Communications Test], and click on Help.
Select [Next]. The install of the software option will continue.
For more help on this routine, go to [Configuration tab , Software Option Wizard], and
click on Help.
Component Control
Purpose
The purpose of this routine is to allow most input components and output components to be
checked for electrical and mechanical function.
With this test, input components can be switched on or off, and output components can be
switched on steady, cycled on and off, or switched off steady. In addition, various input and
output selections can be added together (stacked), giving a wide range of functionality to this
diagnostic routine.
For more help on this routine, go to [Copier Sys tab , Component Control], and click on Help.
Control Panel Diagnostics

Purpose
The purpose is to provide a Reset (soft boot) function for the User Interface, and report specific
information about the UI.
The test interrogates the User Interface software, and the following results are reported: Platform Version; Runtime Version; Checksum.
For more help on this routine, go to [Copier Sys tab , Control Panel Diagnostics], and click on
Help.
Status
Purpose
The purpose of this routine is to provide a means to view the current machine status.
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General Procedures
Configuration , Copier Sys
Procedure
Displays any faults encountered while performing the SCSI bus polling process.
1.
Model
2.
Select [Copier Sys] tab, [Status] icon. The Status screen will appear, displaying the following:
Disk SIze
Date
Manufacturer
3.
a.
System Status
b.
Completed
c.
Current Status List
d.
Last 40 Faults
Displays the dive model number as reported during the polling process.
Displays drive size in megabytes.
Displays the SCSI BIOS date of the device
Displays the drive manufacturer
To exit, click on the box at the upper right-hand corner of the Status screen and select
[Close] from the pop-up menu.
SCSI Firmware Release
For more help on this routine, go to Diagnostics Navigator, select the [Copier Sys] tab, select
[System Status], and click on Help.
Revision Level
Reset Administrator PIN
Firmware release number

Current revision level of the SCSI Firmware
Image DIsk Format
Purpose
Perform the following to format the Image DIsk:
The purpose is to provide a means to reset the administrator PIN. If the Auditron Administrator
access code number (PIN) has been corrupted or the Administrator cannot remember the previously set access code, the default PIN can be set from the PWS until a new code can be
entered by the Administrator. The purpose of this procedure is to reset the Auditron Administrator access code to the default setting. The default PIN is 1111.
1.
Procedure
1.
2.
Select [Copier Sys tab , Reset Administrator PIN].
3.
From the Reset Administrator PIN window, select [Start].
4.
Answer [Yes] to the question: This will reset the Auditron Administrator PIN to the
default value. Are you sure? .
5.
6.
For more help on this routine, go to [Copier Sys tab , Reset Administrator PIN], and click on
Help.
Image Disk Format

Purpose
The purpose is to have the ability to re-format the Image Disk Drive in cases where the disk
may become corrupted.
Verify that the Status indicates Ready.
2.
Press [Start].
3.
The Image Disk will begin to format. The progress indicator will display the percentage complete as the disk is formatted. Depending on the size of the disk, this may
take up to 20 minutes.
4.
When the status indicates complete, select [Exit].
Bad Block Report

This allows the user to review a bad block table or create a new one. SCSI drives build
this table automatically when formatted.
Status
Faults
Bad Block Information

Displays the total number of bad blocks on the device. These bad blocks will be displayed as Cylinder, Head, and Track.
To create a new Bad Block Report, perform the following:

1.
Select [Current Bad Block Report].
2.
Select [Start].
3.
The Image Disk will be queried to get the bad block information and will be displayed
at the bottom right corner of the window.
4.
The SCSI Faults button can be selected to get a list of SCSI faults.
5.
When complete, select [Exit].
Procedure
The following tabs are available in this routine:
Image Disk Describe
Status
When first invoked, message will indicate that it is executing while it polls the SCSI
bus for devices. When finished it will indicate complete.
Faults
General Procedures
Copier Sys
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V0.042
Faults/Counters
Counters Display
Faults
Purpose
Purpose
The Faults dialog is intended to provide a single location to view key fault and fault counter
data from the machine. There are two selections available for selection in the Faults screen,
Last 40 Faults and Fault Counters.
Procedure
The Last 40 Faults is the default selection in the Faults screen. The faults are sorted by time
with the most recent fault at the top of the list. The display is updated when the dialog is first
brought up or when the Refresh button is selected. The following information is displayed for
each fault:
The Faults dialog is intended to provide a single location to view key counter data provided by
the machine. To facilitate navigation through the large number of counters, the data is divided
into several tabs. Each of the tabs listed below provide some additional filtering of the data:
The Diagnostic Data tab displays the service related counters that are use to calculate
the Mean Events Between Jams for all XX-1XX faults.
The Billing tab displays the counters used to track paper usage for billing purposes.
These counters are not modifiable by the CSE.
The Billing Display Setup tab provides a means by which the CSE can enable or disable
the local UI capability of displaying a particular counter.
Procedure
Fault Name - a brief description of the failure
The Fault Code (chain, link, and extension)
In Diagnostic Data, the display is updated when the dialog is first brought up. The following
information is displayed:
Time (faults will be time stamped when they occur)
Id - the counter ID
Copy Count
Counter Name - a brief description of the counter
For paper jams, an asterisk will precede the fault name. To view the paper size that was being
used when a jam occurred, double click on the fault name. This information for Document
Feeder jams will be available in a future software release.
In Fault Counters, the display is updated when the dialog is first brought up or when the
Refresh button is selected. The following information is displayed:
Service ID - the service name (Mark Service, Scan Service, etc.).
Value - the number of times the counter has been incremented since the Diagnostic Data
counters were reset
The following two options are used to filter the large number of Diagnostic Data counters:
Filter By To display the counters for a particular service (Mark, Scan, etc. or All), a
combo box with a list of all valid services is provided. By selecting a service in the Filter
By combo box, only the counters for the selected service will be displayed.
Display Counters with Zero Value To display only the counters that have a non-zero
value, click the Display Counters with Zero Value check box (the default is to show all
counters).
Id - the counter ID
Code - The chain, link, and extension of the fault code associated with the counter
Value - the number of times the counter has been incremented since the counters were
reset
The following will facilitate navigation through the large number of fault counters:
In Billing, the display is updated when the dialog is first brought up. The following information
is displayed:
Filter By Chain To display the counters for a particular chain, a combo box with a list of
all valid chains is provided. By selecting a chain in the Filter By Chain combo box, only the
counters for the selected chain will be displayed.
Id - the counter ID
Service ID - the service name (Mark Service, Scan Service, etc.).
Display Counters with Zero Value To display only the counters that have a non-zero
value, click the Display Counters with Zero Value check box (the default is to show all
counters).
Value - the number of times the counter has been incremented.
The Rates button is used to view more information about a jam counter (XX-1XX faults).
Select the fault counter, then select the Rates button. A dialog box will display jam
counter information, events counter information, and mean events between jams.
The Sort button, when selected, will sort all the fault counters in the list by chain and
then by link.
For more help on this routine, go to [Faults/Counters tab , Faults], and click on Help.
To display the counters for a particular service (Mark, Scan, etc. or All), a Filter By combo box
with a list of all valid services is provided. By selecting a service in the Filter By combo box,
only the counters for the selected service will be displayed.
In Billing Display Setup, the following information is displayed:
Id - the counter ID
Service ID - the service name (Mark, Scan, etc.).
Display - shows the display for each counter as either enabled (the Yes checkbox
selected), or disabled (the Yes checkbox not selected)
By clicking on the Yes checkbox, the display of each counter at the local UI, can either be
enabled (the Yes checkbox selected), or disabled (the Yes checkbox not selected). A command to change the counter display is sent when the machine is reset at the close of the service call.
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General Procedures
Faults/Counters
For more help on this routine, go to [Faults/Counters tab , Counters Display], and click on
Help.
Finishing
Stack Height/Elevator Diagnostic Test
Purpose
The purpose of the Stack Height/Elevator Diagnostic Test is to provide selections for a Single
Cycle Test or a Continuous Cycle Test.
The Single Cycle Test energizes the Stacker Tray Drive Motor to drive the Stacker Tray
down until it reaches the Stacker Tray Full Sensor. After reaching the Stacker Tray Full
Sensor the Stacker Tray is driven up until it actuates the Stack Height Sensor. When the
Stack Height Sensor is actuated, the Stacker Tray Drive motor is deenergized and the test
is complete. The time it takes the Stacker Tray to drive down to the Stacker Tray Full Sensor and then back up to actuate the Stack Height Sensor is shown in the Results window.
The Continuous Cycle Test energizes the Stacker Tray Drive Motor to drive the Stacker
Tray down until it reaches the Stacker Tray Full Sensor. After reaching the Stacker Tray
Full Sensor the Stacker Tray is driven up until it actuates the Stack Height Sensor. When
the Stack Height Sensor is actuated, the Stacker Tray Drive motor is energized in the
reverse direction to begin another cycle. This will continue until the [Stop] button is
selected. The time it takes the Stacker Tray to drive down to the Stacker Tray Full Sensor
and then back up to actuate the Stack Height Sensor for each cycle is shown in the
Results window.
Procedures
To perform the Stack Height / Elevator (Single Cycle) Test, do the following:
1.
When the Status window displays the message [Ready], select [Single Cycle], then
select [Start].
2.
When the [Start] button is selected, a popup dialog box will display the message [Please
remove all paper from Stacker Tray prior to starting test.].
3.
Ensure all paper is removed from the Stacker Tray, then select [OK] to close the dialog
box.
4.
Select [Continue] to start the test. The Status window will display the message [Started].
5.
When the test is complete, observe the Results window. The following information will
be displayed:
a.
6.
[Test passed] or [Test failed]
b.
The time in milliseconds the Stacker Tray took to make one complete cycle
c.
The maximum allowable time in milliseconds for the Stacker Tray to make one complete cycle
Associated fault code(s) for the failed component(s) will be displayed in the Faults window.
To perform the Stack Height / Elevator (Continuous Cycle) Test, do the following:
General Procedures
Faults/Counters , Finishing
1.
When the Status window displays the message [Ready], select [Continuous Cycle], then
select [Start].
2.
When the [Start] button is selected, a popup dialog box will display the message [Please
remove all paper from Stacker Tray prior to starting test.].
3.
Ensure all paper is removed from the Stacker Tray, then select [OK] to close the dialog
box.
4.
Select [Continue] to start the test. The Status window will display the message [Started].
The test will continue to run until the [Stop] button is selected.
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5.
6.
After selecting [Stop] to stop the test, observe the Results window. The following information will be displayed for each complete cycle of the Stacker Tray:
Procedure
To Run the Main Tray Offset / Position Test, do the following:
[Test passed] or [Test failed]
1.
On test entry, the system will read and display the Sensor State.
The time in milliseconds the Stacker Tray took to make one complete cycle
2.
Select Single or Continuous test
The maximum allowable time in milliseconds for the Stacker Tray to make one complete cycle
3.
If using Continuous test, select Mode 1 (2 position) or Mode 2 (4 position).
Associated fault code(s) for the failed component(s) will be displayed in the Faults window.
4.
Select Start. Tray will move to Home position.
5.
When Home is complete, Start button will change to Continue.
6.
Select Continue to begin positioning.
For more help on this routine, go to [Finishing tab, Finisher Tests], and click on Help.
Finisher Setup (Tamping)
7.
If using Single Step mode, the tray will stop at the next position.
8.
If using Continuous mode, tray will continue stepping until Stop is selected.
For more help on this routine, go to [Finishing tab, Finisher Tests], and click on Help.
Purpose
The purpose of the Finisher Setup Diagnostic Routine is to adjust tamping to ensure that stapled sets are evenly tamped
The Perform Tamper Position Adjustment selection leads to a series of screens that
semiautomatically check and adjust the tamping to the machine specification.
The Tamper Position Adjustment has already been performed and a slight modification is needed selection allows a direct change to the tamping value, for fine tuning.
Procedures
See ADJ 12-1 for the procedure for using this diagnostic routine.
For more help on this routine, go to [Finishing tab , Finisher Setup] (in Diagnostic Navigator:
[Finishing] tab, [Finisher Setup]), and click on Help.
Main Tray Offset / Position

Purpose
The Main Tray Offset / Position test provides a means to exercise the Smart Tray finisher
through all four offset positions. Observations of reliability, vibration and noise can be made
while the tray is moving.
Test Types:
Single Step:
Steps the tray to the next position when Continue is selected. Position sequence is A to
B, B to C, C to D, D to A and repeats.
Continuous Cycle:
Steps the tray continuously when Continue is selected. The tray pauses for .5 seconds at
each position. The tray stops when Stop is selected.
Mode 1 steps the tray through positions A and B and repeats.
Mode 2 steps the tray through the sequence A to D, D to B, B to C, C to A and

repeats.
Tray Home Position:

At the start of the Single or Continuous test, selecting Start will cause the tray to move
to the Home position (position A). After arriving at Home, the button will change from
Start to Continue.
Sensor Monitor:
The state of the Position Sensor will be monitored at all times except while continuous
mode is running.
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General Procedures
Finishing
Marking
IQ Test #2
IQ Test #3
Print Test Pattern
IQ Test #4
Purpose
IQ Test #5
To provide a means to print out known images to help setup, verify, and troubleshoot image
quality.
IQ Test #6
f.
Perpendicular Lines
Procedure
2 On 2 Off
1.
2 On 30 Off
Enter Print Test Pattern

a.
From the EDOC, select the highlighted text [Print Test Pattern].
b.
The PWS software will start and the Print Test Pattern dialog window will be displayed.
c.
From Session Manager, select [Diags] [Marking] [Pattern].
8 On 56 Off
1" Off 1" On
1.75" Lead Edge
3.
Select the job parameters.

Four paper size options are available in the Size sub-window.
Select the appropriate test pattern. The left side of the window is the Select Pattern subwindow.
8.5" x 11"
11" x 17"
Seven categories of patterns are available, each with one or more options. The Pattern
Preview button near the bottom of the window allows a thumbnail preview of the test pattern. The test pattern categories are:
a.
A3
A4
Common/General
One-sided (Simplex) or two-sided (Duplex) selections are available in the Plex subwindow.
Blank Page - Used for viewing background defects

Manufacturing - Used during the manufacturing process
The quantity of test patterns to be printed can be selected by typing in the quantity in
the Quantity field. The up/down arrows may also be used to change the quantity. A
maximum of 999 can be entered.
Quadrille - A series of X on and X off parallel and perpendicular lines

Registration - Used for checking registration and skew performance
Step wedge - A series of 1 inch bars running IB to OB, starting with 0%, 100%,
then decreasing in 12.5% steps across the page
b.
4.
Select job options

The following options are available:
Orientation
25% Halftones
Face Up (Default)
75 DPI
Face Down
106 DPI
Collation
CAUTION
Collated (Default)
Do not use the 212 DPI pattern to make image quality evaluations. This is a stress
document and will be not be defect free on most machines.
Uncollated
212 DPI - Reserved for engineering investigations only

c.
Labeling/Page Numbering
50% Halftones
Checkbox On/Off (Default is On)
106 DPI
5.
Select [Start Job] to initiate the Test Pattern job.
When the job starts, a Status window appears. Included is a System Status, Completed, Current Status List, and Last 40 Faults dialog boxes. The Fault History button will place the fault history in the Last 40 Faults box.
CAUTION
Do not use the 212 DPI or 424 DPI patterns to make image quality evaluations.
These are stress documents and will be not be defect free on most machines.
d.
Parallel Lines
8 On 56 Off
e.
Image Quality Tests

IQ Test #1
General Procedures
Marking
Black Bands
1" On 1" Off
NOTE: The routine can be exited at any time before the Start Test button is selected, by
selected Exit.
2.
g.
For more help on this routine, go to [Marking tab , Print Test Pattern], and click on Help.
Xerographics Diagnostics
Purpose
The purpose of Xerographic Diagnostics, is to provide tools to assist in setting up, troubleshooting, and repairing the Xerographics in the machine.
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Procedure
1.
Upon entering Xerographic Diagnostics, three folder tabs appear at the top of the window.
Xerographics Routines is the default window. The following selections are available:
Xerographics Routines
New Parts Setup
1.
Exerciser
b.
The Exerciser is used to diagnose failures in the Xerographics system. Select [Start]
to run the routine.
Status, Results, and Faults windows are available.
Set-Up
3.
a.
The Set-Up routine adjusts the process control parameters for optimum Image Quality.
b.
Status, Results, and Faults windows are available.
Detack Power Supply

The High Voltage Power Supply Tests are similar to the Component Control Test.
The Power Supply selected is set to a pre-determined output, so that a known voltage can be measured at the Power Supply test points. When one of the supplies is
activated, the expected voltage levels for each of the signals is displayed. They are
NOT ACTUAL measured voltages. The voltages are meant to be measured with a
DMM as directed by the Service Documentation.
CAUTION
Select the ESS Log Type

Select Debug Logging:
Enable
Purpose
The ESS Online/Offline dialog is used to change the state of the ESS connection to the IOT.
This can be used to stop ESS communication with the IOT during service so no print jobs will
be processed.
Procedure
New Parts Setup

Toner Dispenser Fill
The Toner Dispenser Fill routine is used whenever the Toner Dispenser is
replaced.
CAUTION
Do not run this routine unless a new Toner Dispenser has been installed. Running it
on an existing Toner Dispenser will damage the Toner Dispenser.
b.
Follow the instructions in the REP 09-4 Toner Dispenser.
2.
Enter ESS Online/Offline:

a.
From the EDOC, select the highlighted text [ESS Online/Offline].
b.
The PWS software will start and the ESS Online/Offline dialog window will be displayed.
c.
From the Table of Contents, select [DCS40-65 Diagnostics]. In Diagnostic Navigator,

select [ESS/Network] [ESS Online/Offline].
Select [Start] to switch the ESS from offline to online, or vise verse.
For more help on this routine, go to [ESS/Network tab , ESS Online/Offline], and click on Help.
ESS Software Verification

Purpose
Developer Housing Install

i.
Select [Get Log File...] to initiate the ESS Log.
ESS Online/Offline
Select [Start] to activate the routine.
ii.

select [ESS/Network] [ESS Logs].
3.
1.
This routine does not time out. Select [Stop] when the measurements are complete.
i.
The PWS software will start and the ESS Logs dialog window will be displayed.
c.
For more help on this routine, go to [ESS/Network tab , ESS Logs], and click on Help.
Transfer Power Supply
a.
From the EDOC, select the highlighted text [ESS Logs].
b.
When the job starts, a Status window appears...
Development Power Supply
4.
a.
2.
4.
Charge Power Supply
b.
Enter ESS Logs:
Disable
Power Supply Tests
a.
Purpose
Procedure
Xerographic Routines
a.
ESS Logs
ESS Logs are useful for troubleshooting as well as event tracking.
Power Supply Tests

2.
ESS/Network
The Developer Housing Install routine is used whenever the Developer Housing is replaced.
The ESS Software verification routine tests the software for the ESS. In case of a missing file
or directory, you have invalid permissions, a bad check sum, or the ESS process is not running, you will have the option to fix the problem or abort the routine.
CAUTION
Do not run this routine unless a new Developer Housing has been installed. Running it on an existing Developer Housing will damage the Developer Housing.
ii.
For more help on this routine, go to [ESS/Network, ESS Software Verification Tool], and click
on Help.
Follow the instructions in the REP 09-2 Developer Housing.
For more help on this routine, go to [Marking tab , Xerographic Diagnostics], and click on Help.
V0.042
May 2003
6-85
General Procedures
Marking , ESS/Network
ESS Test Jobs
Shutdown
Purpose
Errors and Warnings
To provide a means to print out either a configuration report; or known images to help setup,
verify, and troubleshoot ESS/Network image quality problems.
All
3.
Retrieve From
ESS
Procedure
1.
2.
File
Enter ESS Test Jobs:
4.
a.
From the EDOC, select the highlighted text [ESS Test Jobs].
b.
The PWS software will start and the ESS Test Jobs dialog window will be displayed.
c.

select [ESS/Network] [ESS Test Jobs].
Select the tab for the desired job type:

Power On/Demo (Configuration Set)
Last X
Time
5.
Retrieve - Starts the log retrieval process.
6.
Print Report - prints the log
7.
Save - Saves the log
For more help on this routine, go to [ESS/Network tab , ESS Error Log], and click on Help.
Test Pattern (in L18, prints 82E12191 style pattern)
3.
Retrieve By - Select the method how the log will be sorted.
NOTE: The routine can be exited at any time before the Start Job button is selected, by
selected Exit.
Get Network Data
Select the appropriate job parameters.
This routine will invoke an ESS network test that verifies network connection information for the
selected protocol.
Two job parameter types are available, each with two or more options.
Size Four paper size options are available in the Size sub-window.
Purpose
Procedure
8.5" x 11"
1.
11" x 17"
A3
A4
Composition Selects the appropriate
Enter Get Network Data:

a.
From the EDOC, select the highlighted text [Get Network Connectivity Data].
b.
The PWS software will start and the Get Network Data dialog window will be displayed.
c.

select [ESS/Network] [Get Network Data].
PS
HP-PCL
NOTE: In HP-PCL, there will be a slight edge deletion.
4.
2.
Select the Protocol
3.
Select [Start] to initiate the Get Network Data test.

When the job starts, a Status window appears...
Select [Start Job] to initiate the ESS Print job.

When the job starts, the Job Status window provides information on the progress of the
job.
For more help on this routine, go to [ESS/Network tab , ESS Test Jobs], and click on Help.
For more help on this routine, go to [ESS/Network tab , Get Network Data], and click on Help.
Echo Test
Purpose
ESS Error Log
This routine will invoke an ESS network test using the protocol selected.
Purpose
Procedure
The purpose of the ESS Error log is to display the log of all ESS errors on the PWS.
1.
Procedure
1.
2.
Enter ESS Error Log:

a.
From the EDOC, select the highlighted text [ESS Error Log].
b.
The PWS software will start and the ESS Error Log dialog window will be displayed.
c.

select [ESS/Network] [ESS Error Log].
Select the log type.
General Procedures
ESS/Network
Enter Echo Test:

a.
From the EDOC, select the highlighted text [Echo Test].
b.
The PWS software will start and the Echo Test dialog window will be displayed.
c.

select [ESS/Network] [Echo Test].
2.
Select the desired protocol to be tested. Only protocols that are enabled are selectable.
Others will be grayed out.
3.
Select [Start] to initiate the Echo Test.
For more help on this routine, go to [ESS/Network tab , Echo Test], and click on Help.
May 2003
6-86
V0.042
Banner, Error, and Confirmation Sheets
ESS Alternate Boot Tool
Purpose
Purpose
This routine is used to review or modify the printing of Banner, Error, and Confirmation sheets
for Scan and FAX functions.
Procedure
1.
Enter Banner, Error, and Confirmation Sheets:
The ESS Alternate Boot Tool is a separate application and is not part of the Diagnostic Navigator. The Alternate Boot Tool is used to help diagnose and repair certain ESS memory, hard
disk, and/or software problems.
For more information, launch the Alternate Boot Tool and select Help.
a.
From the EDOC, select the highlighted text [Banner, Error, and Confirmation
Sheets].
Procedure
b.
The PWS software will start and the Banner, Error, and Confirmation Sheets dialog
window will be displayed.
For the detailed procedure for using the Alternate Boot Tool for loading ESS Software, refer to
the appropriate release of Software Upgrade Kit Installation Instructions.
c.

select [ESS/Network] [Banner, Error, and Confirmation Sheets].
ESS Memory Test (L18 and L19 Only)
2.
Select one or more of the check boxes.
3.
Select the radio buttons to make selections for Scan to File Confirmation Sheets and Lan
Fax Confirmation Sheets.
4.
Select [Apply] to change the settings.
Allows a thorough test of ESS memory to be started from the PWS with one button click. If
there is a failure in memory, a message will indicate which SIMM is faulty. For detailed information on running this test go to the GP35 Running the ESS Memory Test.
For more help on this routine, go to [Banner,Error and Confirmation Sheets], and click on Help.
ESS Terminal Window

Purpose
This feature will allow access to Document Centre ESS command prompt while connected with
the Diagnostic Navigator. This tool will be available through either the PWS port on the IOT or
the RDT modem. This test will provide the ability to monitor the performance of the Lakes ESS
and to quickly isolate printer malfunctions that cannot be diagnosed with the ESS and network
tools provided.
Procedure
1.
2.
ESS Terminal Window:

a.
From the EDOC, select the highlighted text [ESS/Network tab, ESS Terminal Window].
b.
The PWS software will start and the ESS Terminal Window will be displayed.
c.

select [ESS/Network] [ESS Terminal Window].
Select [OK] or [Cancel] to close the window.
For more help on this routine, go to [ESS/Network tab , ESS Terminal Window], and click on
Help.
V0.042
May 2003
6-87
General Procedures
ESS/Network ,
General Procedures
ESS/Network ,
May 2003
6-88
V0.042
Product Specifications
Table 2 460/470 IOT Product Codes

Product Code
Market Region
IOT Type
NE1
ESG/DMO-E/
FXAP
65 ppm ST 220V
Product Codes
Select area of interest:
NE4
NASG/DMO-W
55 ppm DC 110V
240/255/265 IOT Product Codes Table 1
NE5
55 ppm DC 220V
460/470 IOT Product Codes Table 2
ESG/DMO-E/
FXAP
Input Devices Product Codes Table 3
Output Devices Product Codes Table 4
Additional Product Codes Table 5
NE8
NASG/DMO-W
55 ppm ST 110V
NE9
ESG/DMO-E/
FXAP
55 ppm ST 220V
Table 3 Input Device Product Codes
Table 1 240/255/265 IOT Product Codes

Product Code
Market Region
IOT Type
E2C
NASG/DMO-W
40 ppm DC 110V
E1D
ESG/DMO-E
40 ppm DC 220V
1UP
NASG/DMO-W
40 ppm ST 110V
E2D
ESG/DMO-E
40 ppm ST 220V
E0E
FX
40 ppm ST 100V
Product Code
Description
E3Y
Bypass Tray
H4D
HCF w/Bypass Tray (with HCF door)

Table 4 Output Device Product Codes
Product Code
Description
Offset Catch Tray
2UP
NASG/DMO-W
65 ppm DC 110V
H2F
E6D
ESG/DMO-E/
FXAP
65 ppm DC 220V
6UP
Finisher
NF3
Disk Finisher with Smart Tray
DCE
Smart Tray Finisher with Turbo staplers
EVW
MultiFunction Finisher - Standard
E5E
KFX
65 ppm DC 220V
E4E
FX
65 ppm DC 100V
E6E
TFX
65 ppm DC 100V
E5C
NASG/DMO-W
65 ppm LP 110V
E5D
ESG/DMO-E
65 ppm LP 220V
H6E
NASG/DMO-W
DocuTech 65 110V
H7E
ESG/DMO-E
DocuTech 65 220V
3UP
NASG/DMO-W
65 ppm ST 110V
E8D
ESG/DMO-E
65 ppm ST 220V
R4F
NASG/DMO-W
55 ppm DC 110V
R6F
ESG/DMO-E
55 ppm DC 220V
Product Code
Description
T6C
NASG/DMO-W
55 ppm LP 110V
T7C
ESG/DMO-E
55 ppm LP 220V
E4Y
Accessory Shelf
R5F
NASG/XCL/ACO
55 ppm ST 110V
T6W
DT Accessory Shelf
R7F
ESG/DMO-E
55 ppm ST 220V
Table 2 460/470 IOT Product Codes
NOTE: Document Centre 470 with

19.05.xxx or later software only.
FEC
MultiFunction Finisher - Professional

NOTE: Available on Document Centre
470 with 19.05.xxx or later software.
Table 5 Additional Product Codes
E6Y
Convenience Stapler
F2C
IOT 128KB NVM RAM
F5C
16MB Incremental EPC DRAM
F4C
32MB Incremental EPC DRAM
F7D
PPC ESS RAM 32MB Upgrade
Product Code
Market Region
IOT Type
ND8
NASG/DMO-W
65 ppm DC 110V
F8D
PPC ESS RAM 32MB Upgrade
ND9
ESG/DMO-E/
FXAP
65 ppm DC 220V
F4D
IPA PWB, PPC ESS
NE0
NASG/DMO-W
65 ppm ST 110V
F0D
Token Ring PWB, PPC ESS
V0.042
May 2003
6-89
General Procedures
Table 5 Additional Product Codes

Product Code
Description
F1D
100 Mb Ethernet PWB
T8R
PPC ESS Spacer PWB (PCI BUSS

Adapter)
T7V
2xx DC-to-ST Conversion Kit #1
DH1
2xx DC-to-ST Conversion Kit #2
T6V
2xx LP-to-ST Conversion Kit
W3T
240 ST Logo Kit
W4T
255 ST Logo Kit
W5T
265 ST Logo Kit
FD6
Removable Disk Drives (RDD) Kit
UV9
RDD NLX Supplemental Kit
FD7
Image Disk & Carrier
FD8
ESS Disk & Carrier
H0H
Platen Pad Kit -- Grey
H5E
Platen Pad Kit -- White
L2H
Sixth Sense Phone Cord, WH
F9C
Accessory PWB, 460/470 WH
F9D
Accessory PWB, 460/470 EH
UD7
IPA PWB, Intel ESS
UD6
Token Ring PWB, Intel ESS
VE5
460/470 Conversion Kit (Card Cage)
VE7
460/470 DC-to-ST Conversion Kit
VE8
460/470 ST Logos & Covers Kit
VE9
460/470 Conversion DADF Kit
General Procedures
May 2003
6-90
V0.042
Table 6 Capabilities
Physical Characteristics
Dimensions (W x D x H):
Feature
Capabilities
w/ OCT and no input device: 1194 x 711 x 1142 mm
w/ OCT and Bypass Tray or HCF/Bypass Tray: 1549 x 711 x 1142 mm
Maximum sheets
per set:
50 sheets of 20lb (80 gsm) paper

or
w/ Finisher and no input device: 1397 x 711 x 1142 mm
w/ Finisher and Bypass Tray or HCF/Bypass Tray: 1753 x 711 x 1142 mm
48 sheets of 20lb (80 gsm) paper

with two 110lb covers
Weight:
IOT (DC, ST): 388 lbs. (176kg)
IOT (LP, DT65/DP65): 327 lbs. (148kg)
Bypass Tray: 8 lbs. (4kg)
HCF/Bypass Tray: 38 lbs. (17kg)
OCT: 7 lbs. (3kg)
Finisher: 92 lbs. (43kg)
Convenience Stapler: 10 lbs. (5kg)
Accessory Shelf: 10 lbs. (5kg)
Finisher Top Tray:
250 Sheets 20lb (80 gsm) paper
Manual:
Convenience Stapler
Copying Services
Point Floor Loading (full ST system):
Left IOT Casters (each): 140 lbs. (63.6kg)
Right IOT Casters (each): 156 lbs (70.9kg)
Capabilities
Refer to Table 6 for a listing of the capabilities available for the various features.
Feature
Capabilities
Scanning
Document Feeder: Duplex Automatic Document Feeder
(DADF); 50 sheets (240/255/265) or 75
sheets (460/470) / 1-N processing with
top feed 40/65 scans per minute
Type:
Platen and CVT (Constant Velocity

Transport) with DADF
Optics:
Butted silicon full width array
25-400% R/E, Anamorphic R/E
Image Rotation 90 & 180 degrees
Image Shift
Concurrent scanning and printing
Program and Scan ahead
Settable contention management
Auto R/E
Auto Registration
Auto Center
Auto Paper Selection
Auto Tray Switching
Auto Signatures
Bound Document Copying
Proof Set
Store/Recall Job Programming
Accounting Services
Auditron on Copier configuration
User Interface
Printing and
Copying
Rated Speed simplex
Finishing
Offsetting Catch
Tray:
250 Sheets, 20lb (80 gsm) paper
Finisher Stacker
Tray:
(Unstapled)
2000 Sheets, 20lb (80 gsm) paper
Finisher Stacker
Tray:
(Stapled)
50 sets @ 2 to 10 sheets* per set
8.5 x 11" or A4 at 40/55/65 ppm
8.5 x 14" or B4 at 20/27/32 ppm
11 x 17" or A3 at 20/27/32 ppm
Duplex Trayless; all sizes except A6

Copy sets - scan once / print many with
1-N processing
Print Sets Document printing with 1- N
processing
* = 20lb (80 gsm) paper
Automatic Electronic Collation - 16MB

up to 64MB EPC RAM, 1GB up to 4GB
Hard Disk.
Collation
V0.042
May 2003
6-91
General Procedures
Feature
Capabilities
Feature
6 trays with total capacity of 5,350

sheets
Copy / Print Quality
Tray capacities based on 20lb /

80gsm paper
Settable attributes for size, type,

color
Smallest: Statement 5.5 x 8.5" A5

(A6 in bypass)
Largest: 11 x 17" / A3 plus 12 x

18"
Paper Supply
Quantity
Sizes
Capabilities
MultiFunction Finisher Specifications

MFF Main Tray and Top Tray Paper Specifications
Table 7 Standard Paper Sizes

Paper Size
Orientation
Name
Inches (W x L)
MM (W x L)
A6 (1, 2)
4.13 x 5.83
5 x 7 (1)
5x7
Output Tray
SEF
Dim. (mm)
105 x 148
105
127 x 177.8
127
B6 JIS (1)
5.06 x 7.17
128.5 x 182
A5 (2)
5.38 x 8.27
148 x 210
LEF
Stapled Edge
X
X
Top Tray
128.5
210
Staple
Main Tray Landscape Portrait
Dual
+
+
A5
5.38 x 8.27
148 x 210
148
Statement
8.5 x 5.5
216 x 140
140
B5 JIS
7.17 x 10.12
182 x 257
257
B5 JIS
7.17 x 10.12
182 x 257
182
Executive
7.25 x 10.12
184 x 267
267
Executive
7.25 x 10.12
184 x 267
184
16K (Taiwan)
7.64 x 10.51
194 x 267
16K (Taiwan)
7.64 x 10.51
194 x 267
8 x 10
8 x 10
203 x 254
8 x 10
8 x 10
203 x 254
Letter
8.5 x 11
216 x 279
Letter
8.5 x 11
216 x 279
Letter Cover
9 x 11
229 x 279
Letter Cover
9 x 11
229 x 279
A4
8.27 x 11.69
210 x 297
A4
8.27 x 11.69
210 x 297
A4 Cover
8.78 x 11.69
223 x 297
A4 Cover
8.78 x 11.69
223 x 297
Spanish (RX)
8.46 x 12.4
215 x 315
215
Foolscap (RX)
8.15 x 13
215 x 330
215
General Procedures
X
X
X
X
X
267
194
254
203
279
216
279
X
X
X
X
X
X
X
X
May 2003
6-92
229
297
210
297
223
V0.042
Table 7 Standard Paper Sizes

Paper Size
Orientation
Output Tray
Staple
Name
Inches (W x L)
MM (W x L)
220 x 330
8.66 x 13
220 x 330
Legal
8.5 x 14
216 x 356
216
B4 (JIS)
10.12 x 14.33
257 x 364
257
8K (Taiwan)
10.51 x 15.2
267 x 388
267
A3
11.69 x 16.54
297 x 420
297
Ledger
11 x 17
279 x 432
279
12 x 18
12 x 18
305 x 457
305
Labels
Transparency
LEF
Stapled Edge
X
8.5 x 11
Transparency (A4) 8.27 x 11.69
SEF
Dim. (mm)
Top Tray
Main Tray Landscape Portrait
Dual
220
not recommended
216 x 279
279
210 x 297
297
NOTE: + Indicates availability of tray and stapling options for paper size. Papers must be 4 in.
(102 mm) to 12 in. (305mm) in the cross process direction.
NOTE: 1 SEF only, IOT paper handling limitation is process direction 5.83 in. (148 mm) to 18
in. (457.2mm)
NOTE: 2 Simplex only - IOT paper handling limitations due to Inverter paper path.
V0.042
May 2003
6-93
General Procedures
Booklet Maker Paper Sizes

Table 8 Booklet Maker Paper Sizes
Name
Inches (W x L)
MM (W x L)
Orientation
A4
8.27 x 11.69
210 x 297
SEF, LEF**
Letter
8.5 x 11
216 x 279
SEF, LEF**
Foolscap
8.15 x 13
215 x 330
SEF
Legal
8.5 x 14
216 x 356
SEF
Ledger
11 x 17
279 x 432
SEF
A3
11.69 x 16.54
297 x 420
SEF
NOTE: Booklet Maker (Folded and Stapled) - 15 sheets or less of 80 gsm (20lbs) or equivalent
thickness e.g. 12 sheets of 80 gsm (20lbs) with one cover of 200 gsm.
NOTE: Booklets (Folded only) - 5 sheets or less of 80gsm (20lbs) or equivalent thickness.
NOTE: ** A4 LEF and 8.5 x 11" LEF is for Banner sheets only
General Procedures
May 2003
6-94
V0.042
Booklet Maker Exit Tray Capacity
Stack Specifications - Stapled and Unstapled Sets
Table 9 Booklet Output Tray capacity

Sheets per Booklet
Number of booklets with tray

extension raised
Number of booklets with tray

extension lowered
11 - 15
12
unlimited
6 - 10
20
unlimited
1-5
30
unlimited
Stack Quality - The maximum X and Y scatter as measured in Figure 1, is 25.0 mm or less.
Within Set Registration (unstapled sets) - Measure dimension X and Y as shown in Figure 2.
Refer to Table 10 for within unstapled set registration specifications.
X scatter
Nth sheet
(>50)
1st sheet
Y scatter
Maximum Scatter
Maximum Y scatter measured at offset

position A and offset position B.
Figure 1 Stack Quality Specifications

Table 10 Within Unstapled Set Registration Specifications
Tray
Paper
Main Tray
8.5 x 11 in (A4)
20 lb. (80 gsm)
95% of Sets
X
V0.042
4.0 mm.
Y
13.0 mm.
Main Tray
All zones all papers
6.0 mm.
20.0 mm.
Top Tray
8.5 x 11 in (A4)
20 lb. (80 gsm)
undefined
40.0 mm.
Top Tray
All zones all papers
undefined
undefined
May 2003
6-95
General Procedures
Staple Position Specifications - Main Stapler

For single staple portrait and single staple landscape sets, refer to Figure 3 for the specifications
Top View (Main Tray and Top Tray)

Total Set
For dual stapled sets, the distance of the staple from the edge of the set is indicated in Figure
3. The other staple position specifications are dependent upon paper size. Measure dimension X and dimension Y (Figure 3) and refer to Table 11.
Table 11 Booklet Dual Staple Position for standard Paper Sizes
Paper
Dimension
Paper Type and Size
Total Set
Name
Y Scatter
X Scatter
X Scatter
Inches (W x L)
Stapled Edge
LEF
SEF
B5
7.17 x 10.12
182 x 257
8 x 10
8 x 10
203 x 254
8 x 10 - SEF
8 x 10
203 x 254
Letter
8.5 x 11
216 x 279
Letter - SEF
8.5 x 11
216 x 279
Letter Cover
9 x 11
229 x 279
Letter Cover
9 x 11
229 x 279
114.5 mm. 57.25 mm.
Letter Tab
9 x 11
229 x 279
139.5 mm. 69.75 mm.
A4
8.27 x 11.69
210 x 297
A4 - SEF
8.27 x 11.69
210 x 297
A4 Cover
8.78 x 11.69
223 x 297
128.5 mm. 64.25 mm.
101.5 mm. 50.75 mm.
127 mm.
63.50 mm.
139.5 mm. 69.75 mm.

X
105 mm.
54.0 mm.
139.5 mm. 69.75 mm.
148.5 mm. 74.25 mm.

X
105.0 mm. 52.50 mm.

148.5 mm. 74.25 mm.
A4 Cover - SEF
8.78 x 11.69
223 x 297
111.5 mm. 55.75 mm.
A4 Tab/Cover
8.78 x 11.69
223 x 297
148.5 mm. 74.25 mm.
Spanish (RX)
8.46 x 12.4
215 x 315
107.5 mm. 53.75 mm.
Foolscap (RX)
8.15 x 13
215 x 330
107.5 mm. 53.75 mm.
Legal
8.5 x 14
216 x 356
108.0 mm. 54.00 mm.
B4 (JIS)
10.12 x 14.33
257 x 364
129.5 mm. 64.75 mm.
252 x 358
126 mm.
SB4 (FX)
Side view of sheets in tray
MM (W x L)
Orientation
63.00 mm.
A3
11.69 x 16.54
297 x 420
148.5 mm. 74.25 mm.
Ledger
11 x 17
279 x 432
139.5 mm. 69.75 mm.
12 x 18
12 x 18
305 x 457
150.5 mm. 75.25 mm.
Figure 2 Within Set Registration Unstapled sets
General Procedures
May 2003
6-96
V0.042
6.0 mm +/- 2.0 mm
6.0 mm +/- 2.0 mm
6.0 mm +/- 2.0 mm
Single Staple Portrait
Single Staple Landscape
6.0 mm +/- 2.0 mm
X
Center of Staple
Center of Staple
Dual Staple
Figure 3 Staple Positions
V0.042
May 2003
6-97
General Procedures
Set Registration Specifications - Stapled Sets
Staple Quality Specifications
Take two measurements as follows:
Refer to Figure 5 for staple quality specifications.
For single stapled sets measure dimension X and Y at the stapled corner (refer to Figure
4).
For dual stapled sets measure dimension X and Y at the worst stapled corner (refer to
Figure 4).
0.4 mm
(max)
0 mm
(min.)
Refer to Table 12 for stapled in-set registration specifications.

Table 12 Stapled In-Set Registration Specifications
95% of Sets
Paper Weight
99.7% of Sets
100% of Sets
Leg ends must be more

than 0 mm from crown ends.
Stapled In-Set Registration - Single Staple

20 lb. (80 gsm)
1.5 mm.
1.5 mm.
3.0 mm.
3.0 mm.
6.0 mm.
6.0 mm.
All zones all paper 3.0 mm.
3.0 mm.
6.0 mm.
6.0 mm.
8.0 mm.
8.0 mm.
Leg ends must be flush to

sheet within 0.4 mm.
1.5 mm
(max)
13.5 mm
Stapled In-Set Registration - Dual Staple

20 lb. (80 gsm)
2.0 mm.
2.0 mm.
3.0 mm.
3.0 mm.
6.0 mm.
6.0 mm.
All zones all paper 3.0 mm.
3.0 mm.
6.0 mm.
6.0 mm.
8.0 mm.
8.0 mm.
1.5 mm
(max)
Crown Length
Legs must be parallel to each

other within 1.5 mm
Figure 5 Staple Quality Specifications

X
For dual stapled sets take measurements X and Y at the stapled corner that shows the worst in-set registration.
Figure 4 In-Set Registration for stapled sets
General Procedures
May 2003
6-98
V0.042
Booklet Staple Specifications
Booklet Fold Quality Specifications
Measure the booklet staple position at X1, X2, X3, and X4 (refer to Figure 6). Refer to Table 13
for staple location specifications.
Take 3 measurements as indicated on Figure 7.
NOTE: The measurement for X4 (distance between staple position and fold line) is 0mm - 1.5
mm for all paper sizes
X - measured at any point along the booklet
Z1 - measured on the inside sheet of the booklet.
Z2 - measured on the inside sheet of the booklet.
Calculate Y
If Z1 is greater than Z2, subtract Z2 from Z1 (Y=Z1-Z2)
If Z2 is greater than Z1, subtract Z1 from Z2 (Y=Z2-Z1)
Refer to Table 14 for booklet fold quality specifications.
X3
Table 14 Booklet Fold Quality Specifications
X1
X4
Dimensions are based on

a four sheet (16 page)
booklet
Fold Line
X2
Paper size 8.5 x 11 in. (A4)

95% of
Booklets
Paper Size 11 x 17 in. (A3)
99.7%
ofBooklets
95% of
Booklets
99.7%
ofBooklets
X at ambient conditions.
30.0 mm
35.0 mm
22.0 mm
Y B zone
1.0 mm
2.5 mm
1.2 mm
25.0 mm
3.1 mm
Y All zones all paper
1.5 mm
3.0 mm
1.8 mm
3.6 mm
Figure 6 Where to Make Staple Position Measurements

Table 13 Staple Position Specifications for Booklets
Paper Type
X1
X2
X3
A4 - SEF
40 mm +/-2.0 mm
120 mm +/-2.0 mm
Letter - SEF
43 mm +/-2.0 mm
120 mm +/-2.0 mm
139.5 mm +/-1.5 mm
Foolscap - SEF
42 mm +/-2.0 mm
120 mm +/-2.0 mm
115 mm +/-1.5 mm
Fold Line
148.5 mm +/-1.5 mm
Legal - SEF
43 mm +/-2.0 mm
120 mm +/-2.0 mm
178 mm +/-1.5 mm
Ledger - SEF
83.5 mm +/-2.0 mm
120 mm +/-2.0 mm
210 mm +/-1.5 mm
A3 - SEF
74.7 mm +/-2.0 mm
120 mm +/-2.0 mm
216 mm +/-1.5 mm
Z1
Z2
If Z1 > Z2, then Y= Z1 - Z2

If Z2 > Z1, then Y= Z2 - Z1
Figure 7 Booklet Fold Quality Measurements
V0.042
May 2003
6-99
General Procedures
Booklet Set Registration Specifications

Measure the booklet lead edge registration and top to bottom registration as follows.
For booklet top to bottom edge registration specification, measure dimension X with the
booklet opened as in Figure 8.
For booklet lead edge registration specification, measure dimension Y with the booklet
opened as in Figure 9.
Refer to Table 15 for booklet registration specifications.

Table 15 Booklet Registration Specifications
8.5 x 11, 11 x 17 in., and 8.5 x 14 in
95% of Booklets
99.7% of Booklets
Top to bottom registration X

B Zone 20 lb. (80 gsm) paper
1.0 mm
2.0 mm
Lead edge registration Y

B Zone 20 lb. (80 gsm) paper
1.0 mm
2.0 mm
Top to bottom registration X

All zones all paper
2.0 mm
3.0 mm
Lead edge registration Y

All zones all paper
2.0 mm
3.0 mm
Figure 9 Booklet Lead Edge Registration

Tri-Fold Specifications
The Tri- Folder is capable of folding A4/8.5 x 11 size papers (see Figure 10) in one of 2 customer selectable fold configurations, either a C-shape fold or a Z-shape fold. The machine will
be factory-set to fold 8.5 x 11 size paper, and then adjusted for folding A4 size paper as part of
machine setup / installation. The folded sheets are single sheets only and are stacked on the
same Output Tray as Booklets. Shown in Figure 10 is the image side and top pane for both C
shaped and Z shaped fold configuration of Trifold output as well as the direction the output
flows out of finisher and onto the Output Tray.
X
Figure 8 Booklet Top to Bottom Registration
General Procedures
May 2003
6-100
V0.042
C Configuration
Direction of Output
Side 1 Image
(inside)
Z Configuration
Side 1 Image
Direction of Output
Figure 10 Tri-Fold Configurations
V0.042
May 2003
6-101
General Procedures
The following are the fold specifications for tri-folded documents:
Applies to 80 gsm or equivalent paper, ambient conditions
Tri-Folded sheet A4 or 8.5 x 11" must fit into a DL (European standard) sized envelope
and a #10 standard envelope and meet the skew specification as shown in Figure 11.
Folded sheet will not have double folds or creases to any section of the document.
Center section of tri-folded sheet must be greater than either side section to avoid overlapping.
Specifications in Figure 12 Tri-Fold Z Configuration, and Figure 13 Tri-Fold C Configurationapply at centerline of page.
Specifications apply for nominal cut-sheet dimensions shown in Table 16.
With the Booklet Tray Stop in the up position, tri-folded sheets should be stacked such
that they are on top of each other or staggered with out being captured within another trifolded sheet and remain on the tray.
Table 16 Tri-Fold Paper Sizes and Weights
Paper Type and Size
Orientation
Name
Inches (W x L)
Weights
(gsm)
MM (W x L)
Letter
8.5 x 11
216 x 279
LEF
60-90
A4
8.27 x 11.69
210 x 297
LEF
60-90
General Procedures
May 2003
6-102
V0.042
DL size (European) = 110 mm

Envelope
#10 size = 4.125 in (104 mm)
DL size (European) = 210 mm
#10 size = 9.5 in (241mm)
+ / - 1.5 mm
+ / - 1.5 mm
Fold Skew
Figure 11 Fold Skew
V0.042
May 2003
6-103
General Procedures
Top
Finisher
Booklet Tray
8.5 x 11 in. Tri-Fold Specification

188.0 mm +/- 2.0 mm
A4 Tri-Fold Specification
200.0 mm +/- 2.0 mm
Top
Center Line
Top
Not Specified
Not Specified
103.0 mm +/- 2.0 mm
97.0 mm +/- 2.0 mm
Figure 12 Tri-Fold Z Configuration
General Procedures
May 2003
6-104
V0.042
Top
Finisher
Booklet Tray
8.5 x 11 in. Tri-Fold Specification
A4 Tri-Fold Specification
Top
Top
Center Line
Not Specified
Not Specified
91.0 mm +/- 2.0 mm
97.0 mm +/- 2.0 mm
97.0 mm +/- 2.0 mm
103.0 mm +/- 2.0 mm
Figure 13 Tri-Fold C Configuration
V0.042
May 2003
6-105
General Procedures
Paper Curl Specification
Paper curl specification - 12 mm height maximun, any edge, any corner. Refer to Figure 14
for measuring the amount of curl.
Letter Cover LEF (11 x 9 in. or 279 x 229mm)
Legal SEF (8.5 x 14 in. or 216 x 356mm)
JIS B4 SEF (10.12 x 14.33 in. or 247 x 364mm)
Ledger 11 x 17 in. or 297 x 420mm
NOTE: Under certain environmental conditions and job modes, paper stack(s) may have to be
inverted to achieve the above specification.
Letter Cover SEF (9 x 11 in. or 229 x 279mm)
A3 SEF (11.69 x 16.54 in. or 297 x 420mm)
A5 SEF 148 x 210mm
A5 LEF 210 x 148mm
A4 Cover SEF 8.78 x 11.69 in. or 223 x 297mm
A4 Cover LEF 11.69 x 8.78 in. or 297 x 223mm
Executive SEF 7.25 x 10.5 in. or 184 x 267mm
Executive LEF 10.5 x 7.25 in. or 267 x 184mm
12.0 mm
Table 17 Tray Size Capabilities

US Size
Metric
Trays 1-4 Tray 5

Tray 6
(Bypass) (HCF)
8 to 18 in. in feed
direction, 5.5 to 12
in. in cross feed
direction
5.5 to 18 in. in feed

direction, 4.13 to 12
in. in the cross feed
direction
6.7 to 18 in. in the

feed direction, 4.13
to 12 in. in the cross
feed direction
Figure 14 Paper Curl Specification
Paper Specifications
Stock Sizes
5.5 x 8.5 in. SEF
140 x 216mm SEF
8.5 x 5.5 in. LEF
216 x 140mm LEF
7.17 x 10.12 in. SEF B5 JIS SEF 182 x

257mm
Letter SEF 8.5 x 11

in.
216 x 279mm SEF
Letter LEF 8.5 x 11

in.
279 x 216mm
Letter Cover SEF 9

x 11 in.
229 x 279mm
8 x 10 in. SEF
254 x 203mm SEF
8 x 10 in. LEF
203 x 254mm LEF
5.5 x 8.5 in. or 140 x 216mm SEF
B5 JIS SEF (7.17 x 10.12 in. or 182 x 257mm)
B5 JIS LEF (10.12 x 7.17 in. or 257 x 182mm)
8 x 10 in. or 254 x 203mm SEF
8 x 10 in. or 203 x 254mm LEF
A4 SEF (8.27 x 11.69 in. or 210 x 297mm)
A4 LEF (11.69 x 8.27 in. or 297 x 210mm)
Letter SEF (8.5 x 11 in. or 216 x 279mm)
Letter LEF (8.5 x 11 in. or 279 x 216mm)
General Procedures
11.69 x 8.27 in. LEF A4 LEF 297 x

210mm
The following is a list of acceptable stock sizes:

5.5 x 8.5 in. or 216 x 140mm LEF
x
x
10.12 x 7.17 in. SEF B5 JIS LEF 257 x

182mm
x
x
Refer to Table 17 for a listing of the tray size capabilities for the various types of paper.
Duplex
8.27 x 11.69 in. SEF A4 SEF 210 x

297mm
May 2003
6-106
V0.042
Table 17 Tray Size Capabilities
Table 18 Output Device Capabilities
US Size
Metric
Trays 1-4 Tray 5

Tray 6
(Bypass) (HCF)
Letter Cover LEF 11

x 9 in.
279 x 229mm
Legal SEF 8.5 x 14

in.
216 x 356mm
10.12 x 14.33 in.

SEF
JIS B4 SEF 247 x

364mm
Ledger 11 x 17 in.
297 x 420mm
11.69 x 16.54 in.
A3 SEF 297 x
420mm
A5 SEF 148 x
210mm
Duplex
Paper
Size
Designation (US)
Size
(Metric)
LEF
A5
5.83x8.27
148x210
A5
5.83x8.27
148x210
Statement
5.5x8.5
140x216
Statement
5.5x8.5
140x216
B5 - JIS
7.17x10.12
182x257
B5 - JIS
7.17x10.12
182x257
Executive
7.25x10.5
184x267
Executive
7.25x10.5
184x267
16 K Taiwan
7.64 x 10.51 194x267
16 K Taiwan
7.64 x 10.51 194x267

8x10
203x254
A5 LEF 210 x
148mm
8.78 x 11.69 in.
A4 Cover SEF 223 x

297mm
8x10
8x10
8x10
203x254
11.69 x 8.78 in.
A4 Cover LEF 297 x x

223mm
Letter
8.5x11
216x279
Letter
8.5x11
216x279
Executive SEF 7.25

x 10.5 in.
184 x 267mm
Ltr Cover
9x11
229x279
Executive LEF 10.5

x 7.25 in. or
267 x 184mm
Output Device Capabilities

Table 18 contains a list of the allowable paper sizes for the various output devices.
KEY:
X
X
X
X
229x279
229x279
A4
8.27x11.69
210x297
A4
8.27x11.69
210x297
A4 Cover
8.78x11.69
223x297
223x297
223x297
Spanish -RX 8.46x12.4
X
X
X
X
Dual
O
Dual
Dual
X
X
O
O
X
X
O
O
Finishe Smart
r Top
Tray
Tray
Staplin
g
9x11
8.78x11.69
OO
X
9x11
8.78x11.69
OO
Ltr Tab
A4 Tab
Finishe OCT
Tray
r
Stacker
Tray
Ltr Cover
A4 Cover
SEF
Dual
Dual
215x315
O
O
Dual
Dual
Dual
0 = stacking only, no stapling
Foolscap-RX 8.5x13
215x330
00 = face-up reverse collated copy
220x330
8.66x13
220x330
Legal
8.5x14
216X356
Portrait,
Dual
Dual
NOTES:
1 - No Duplex or Inversion
2 - LEF only
3 - SMH recommended (SMH = Bypass Tray)
Table 18 Output Device Capabilities
Paper
Size
Designation (US)
Size
(Metric)
LEF
SEF
Finishe OCT
r
Tray
Stacker
Tray
Finishe Smart
r Top
Tray
Tray
Staplin
g
A6
4.13x5.83
105x148
5x7
5x7
127x177.8
B6 - JIS
5.06x7.17
128.5x182
V0.042
B4 -JIS
10.12x14.33 257x364
8K Taiwan
10.51x15.28 267x388
A3
11.69x16.54 297x420
Ledger
11x17
279x432
12 x18
12x18
305x457
notes 2 and
3
notes 2 and X
3
Envelopes
Labels
May 2003
6-107
General Procedures
Stock Weights
The machine can accept stock weights from 16 to 110 pound bond or 56 to 203 gsm. However, for optimal performance, use 20 to 24 pound or 75 to 90 gsm paper and avoid lower
weight stock.
Special Stocks
Pre-printed Forms and Letterheads: Pre-printed stock performs the same as other stock of
the same size and weight (follow tray labels for loading orientation). Embossed letterheads
may degrade paper handling, and may show image deletions near the embossed area on
either side of the sheet.
Pre-drilled Stock: Pre-drilled stock (standard hole patterns) perform the same as other stock
of the same size and weight (follow tray labels for loading orientation).
Perforated Stock: Perforated stock (e.g. GBC-brand, with rectangular holes the full length of
the edge) should be fed with the perforations parallel to the feed direction, preferably at the
rear of the tray.
General Procedures
May 2003
6-108
V0.042
Installation Space Requirements

IOT with Disk Finisher - The minimum space requirements are shown in Figure 15. Dimensions A, B, and C vary with the options included and are listed in Table 19.
IOT with MultiFunction Finisher - The minimum space requirements are shown in Figure 16.
Dimensions A, B, and C vary with the options included and are listed in Table 20.
NOTE: US and Canada only: If installed in a hallway or exit route, allow 44 in. (1118mm)
more in front to meet fire code requirements.
Output Device
Shelf
Top View
Input Device
FRONT
(See
NOTE)
Minimum height of
ceiling or overhang: 78 in. (1981
mm) above floor
(See NOTE)
Figure 15 Minimum Space Requirements

Table 19 Space for Input/Output Devices (OCT and Disk Finisher)
Input Device
Output Device
None
OCT
13 in. (330 mm)
27 in. (686 mm)
70 in. (1778 mm)
Bypass Tray or HCF/

Bypass Tray
OCT
29 in. (737 mm)
27 in. (686 mm)
86 in. (2184 mm)
None
Finisher
13 in. (330 mm)
43 in. (1092 mm)
86 in. (2184 mm)
Bypass Tray or HCF/

Bypass Tray
Finisher
29 in. (737 mm)
43 in. (1092 mm)
102 in. (2591 mm)
V0.042
May 2003
6-109
General Procedures
Phone Cord 14ft. (4.25m)
Power Cord 10 ft. (3m)
5 in.
(127 mm)
28 in (711 mm)
69 in.
(1752 mm)
10 in.
(254 mm)
36 in.
(914 mm)
26 in
(660mm)
17 3/4 in.
(451 mm)
General Procedures
May 2003
6-110
V0.042
Figure 16 Minimum Space Requirements (with MultiFunction Finisher)

Table 20 Space for Input/Output Devices (MultiFunction Finisher)
Input Device
Output Device
HCF/Bypass Tray
MFF - Professional
15 in. (381 mm)
14 in. (356 mm)
109 in. (2769 mm)
80 in. (2032 mm)
HCF/Bypass Tray
MFF - Standard
15 in. (381 mm)
12 in. (305 mm)
107 in. (2718 mm)
80 in. (2032 mm)
Electrical Power Requirements
DC Voltage Tolerances
Refer to Table 21 for a listing of the electrical power requirements for the machine. A MFF
requires an additional power source the same as that required for the IOT (15.0 A in NASG).
The DC voltage tolerances specified are listed in Table 22.

Table 22 DC Voltage Tolerances
Table 21 Electrical Power Requirements

Market Region 40 ppm Machine
75 ppm Machine
Voltage
+36 VDC
34.2 to 37.8 VDC

22.8 to 25.2 VDC
NASG
115 11.5 VAC, 15.0 A*, 60Hz
115 11.5 VAC, 20.0 A*, 60Hz
+24 VDC
XE
200 20 VAC, 10.0 A 50 Hz

220 22 VAC, 10.0 A 50 Hz
230 23 VAC, 10.0 A 50 Hz
240 24 VAC, 10.0 A 50 Hz
200 20 VAC, 10.0 A

220 22 VAC, 10.0 A
230 23 VAC, 10.0 A
240 24 VAC, 10.0 A
+5 VDC
5.05 to 5.25 VDC
+12 VDC
+11.4 to + 12.6 VDC
-12 VDC
-11.4 to - 12.6 VDC
50 Hz
50 Hz
50 Hz
50 Hz
*NASG Only: A 55 ppm or 65 ppm machine requires a 20 A outlet, whereas a 40 ppm machine
may use either a 15 A or a 20 A outlet. An MFF may use either a 15 A or a 20 A outlet. A 15 A
outlet and a 20 A outlet are illustrated below.
15 A
Environmental Data
Environmental specifications are as follows:
Temperature Range: 50 - 90 degrees F (10 - 32 degrees C)
Humidity: 15 - 90%
Noise:
With Disk Finisher: 40 dBA (Standby), 55 dBA (Operating), 58 dBA (Impulse)
With MFF: 55 dBA (Standby), 81 dBA (Operating), 89 dBA (Impulse)
Accessory PWB DIP Switch Settings

In Table 23, [0] indicates the corresponding position is off (open). A [1] indicates the corresponding position is on [closed]. The four positions in each dip switch are listed left-to-right
(positions 1, 2, 3, and 4).
Table 23 Accessory PWB DIP Switch Settings
20 A
The MFF accepts from 85 VAC to 264 VAC, 50 Hz or 60 Hz.
V0.042
Country
Switch
SW1
Switch
SW2
Switch
SW3
Austria
0010
1111
0011
Belgium
1011
0100
0011
China*
0000
1111
0011
Czech Republic
1110
0100
0011
Denmark
0000
1111
0011
Finland
0000
1100
0011
France
0000
0011
0011
Germany
1100
1100
0101
Greece
1000
1100
0011
May 2003
6-111
General Procedures
Table 23 Accessory PWB DIP Switch Settings

Country
Switch
SW1
Switch
SW2
Switch
SW3
Hungary*
0010
1111
0011
Ireland
1000
1111
0011
Italy
0100
1111
0011
Morocco
0000
0011
0011
Netherlands
0000
1111
0011
Norway
0000
0100
0011
Poland
0110
1111
0011
Portugal
0000
0111
0011
Romania
1100
1100
0101
Russia
0010
1111
0011
Spain
0000
1111
0011
Sweden
0000
1111
0011
Switzerland
0010
1111
0101
Turkey
0010
1111
0011
United Kingdom
0000
1111
0011
* Settings unconfirmed for these countries.
General Procedures
May 2003
6-112
V0.042
Software Version Compatibility
Future Software Releases
Table 24 lists the machine System Software versions released as of the time of this publication.
For each system-level software version listed, the corresponding software versions for the specific platforms within the system are given, including PWS and EDOC versions.
This space is reserved to attach bulletins announcing any future software releases before the
next EDOC revision.
Table 24 Software Version Compatibility

Release Date
Tag #
Release
Main Controller /
MFF
UI
ESS
PWS Diagnostics
EDOC
Aug. 2002
136 / M009
07.19.05.026
19.05.026 / 12.20
19.05.024
19.05.021
19.05.025
v0.040 or v0.041
April 2002
135
07.19.04.039
19.04.039
19.04.037
19.04.034
19.04.037
v0.040
March 2002
133
07.19.04.038
19.04.038
19.04.037
19.04.034
19.04.037
v0.040
Sept. 2001
129
07.19.02.503
19.02.503
19.02.503
19.02.503
19.02.503
v0.040
July 2001
125
07.19.02.051
19.02.051
19.02.049
19.02.050
19.02.050
v0.039 or v0.040
May, 2001
124
7.19.01.504
07.19.01.504
07.19.01.504
07.19.01.502
07.19.01.503
v0.038A or v0.039
April, 2001
113
7.19.01.503
07.19.01.503
07.19.01.502
07.19.01.502
07.19.01.503
v0.038A or v0.039
Oct. 2000
111
7.02
L0.19.0.52
L0.19.0.56
L0.19.0.56
L0.19.0.26
v0.038A or v0.039
June, 2000
102
7.01
L0.19.0.28
L0.19.0.27
L0.19.0.28
L0.19.0.26
v0.038A
May, 2000
101
7.00
L0.19.0.27
L0.19.0.27
L0.19.0.26
L0.19.0.26
v0.038A
June, 2000
099
6.08
L0.18.6.07
L0.18.6.04
L0.18.6.05
L0.18.6.06
v0.038
March, 2000
287
5.22
L0.17.9.32
L0.17.9.32
L0.17.9.32
L0.17.9.21
v0.038
December, 1999
095
6.04
L0.18.1.26
L0.18.1.25
L0.18.1.24
L0.18.5.19
v0.038
December, 1999
288
5.18
L0.17.9.28
L0.17.8.66
L0.17.8.63
L0.17.9.21
v0.038
November, 1999
094
6.03
L0.18.1.24
L0.18.1.24
L0.18.1.24
L0.18.1.23
v0.038
September, 1999
089
5.11
L0.17.8.67
L0.17.8.66
L0.17.8.63
L0.17.8.67
v0.037 or v0.038
July, 1999
087
5.08
L0.17.8.65
L0.17.8.65
L0.17.8.63
L0.17.8.64
v0.036 or v0.037
June, 1999
086
5.07
L0.17.8.64
L0.17.8.63
L0.17.8.63
L0.17.8.64
v0.036 or v0.037
April, 1999
293
5.06
L0.17.8.11
L0.17.8.05
L0.17.8.12
L0.17.8.06
v0.036 or v0.037
January, 1999
074
5.05
L0.17.6.08
L0.17.6.05
L0.17.6.08
L0.17.6.04
v0.036 or v0.037
November, 1998
073
5.03
L0.17.5.08
L0.17.5.07
L0.17.5.08
L0.17.5.06
v0.035 or v0.036
September, 1998
070
5.01
L0.17.4.10
L0.17.4.10
L0.17.4.10
L0.17.4.10
v0.035 or v0.036
August, 1998
None
1.31
L0.15.8.02
L0.15.8.01
NA
L0.15.8.01
v0.034 or v0.035
June, 1998
061
1.30
L0.15.8.01
L0.15.8.01
NA
L0.15.8.01
v0.034 or v0.035
April, 1998
041
1.21
L0.15.7.19
L0.15.7.15
NA
L0.15.7.17
v0.034
December 1997
029
1.12
L0.15.6.16
L0.15.6.15
NA
L0.15.6.15
v0.033
October 1997
019
1.11
L0.15.6.14
L0.15.6.15
NA
L0.15.6.15
v0.033
September 1997
021
1.1
L0.15.6.14
L0.15.6.14
NA
L0.15.6.14 or
L0.15.6.15
v0.032 or v0.033
IOT Software Checksums
listed in the table for the expected software level.
Table 25 (for pre-860 Atlanta Main Control PWB) and Table 26 (for pre-860 Atlanta Main Control PWB) list the IOT (Main Control PWB) Checksums for software versions released as of the
time of this publication. To view the checksums of the software currently installed in the Main
Control PWB, enter [System, Imaging, and IOT Configuration], select the [Software] tab, and
double-click on [SCS]. You can then compare the machine's IOT (SCS) Checksums to those
V0.042
May 2003
6-113
General Procedures
Table 25 Software Levels and Checksums (Pre-860 Atlanta Main Control PWB)
Boot Sector
IPS1 (Atlanta '96)

(w/o TAG 015)
IPS1 (Atlanta Gold w/

TAG 015) / Platinum
w/TAG 077)
IIT
Run Time
Application
Boot Loader
07.19.05.026
07.82.16
D8965B85
66EE547
263AE3D2
N/A
1C0E4D6B
07.19.04.039
07.81.06
4A543F83
66EE547
263AE3D2
N/A
1C0E4D6B
26E3CB91
07.19.04.038
07.81.06
4A2C90C2
66EE547
263AE3D2
N/A
1C0E4D6B
26E3CB91
07.19.02.503
07.80.06
32E2A409
66EE547
263AE3D2
N/A
1C0E4D6B
26E3CB91
07.19.02.051
07.80.06
332DF896
66EE547
263AE3D2
N/A
1C0E4D6B
26E3CB91
26E3CB91
26DC6B31
07.19.01.504
07.78.08
27D789BD
66EE547
26474106
N/A
1B776E3B
07.19.01.503
07.78.07
24BB4A2F
66EE547
26474106
N/A
1B776E3B
26E3CB91
L0.19.0.56 (V7.02) 07.76.03
B9CD2640
66EE547
2582C494
N/A
154501B7
26E3CB91
L0.19.0.28 (V7.01) 07.76.02
B24FD7AC
66EE547
257264F0
N/A
1545418B
26E3CB91
L0.19.0.27 (V7.00) 07.76.02
B18489BE
66EE547
257264F0
N/A
1545418B
26E3CB91
L0.18.6.07 (V6.08) 07.73.42
77C9022
66AC67D
254719D8
N/A
1545418B
26CB69B6
L0.17.9.32 (V5.22) 07.72.15
F277C173
66B0553
23ED9B6D
N/A
14FC1F16
26C8FEEA
L0.18.1.26 (V6.04) 07.73.21
8CE34112
66AC67D
2503AE67
N/A
1504AC70
26CB69B6
L0.17.9.28 (V5.18) 07.72.15
F14A9B91
66B0553
23ED9B6D
N/A
14EA0367
26C8FEEA
L0.18.1.24 (V6.03) 07.73.21
72A3940D
66AC67D
2503AE67
N/A
1504AC70
26D3174D
L0.17.8.67 (V5.11) 07.72.15
EBF625C8
66B0553
23ED9B6D
N/A
14EA0367
26D0AC81
L0.17.8.65 (V5.08) 07.72.15
ECA26151
66B0553
23ED9B6D
N/A
14EA0367
26D0AC81
L0.17.8.64 (V5.07) 07.72.15
ECA26420
66B0553
23ED9B6D
N/A
14EA0367
26D55F1F
L0.17.8.12 (V5.06) 07.72.11
C3050D9E
66B0553
239E13FC
N/A
136A53AF
26DE4045
L0.17.6 (V5.05)
07.72.04
F28A7EC1
5F339A7
220C4776
13F270E6
13698027
26835E69
L0.17.5 (V5.03)
07.72.02
E577D9C1
5F339A7
211B9E85
13F270E6
13698027
2682D038
L0.17.4 (V5.01)
7.71.02
B300B46C
5F339A7
211B9E02
NA
1364C2BB
2682D038
L0.15.8.01 (V1.30) 7.65.42
64DF52ED
39A28B6
19000125
13DCCF22
1343E5FD
2682C837
L0.15.7 (V1.21)
7.65.42
5FE6B6DE
39A28B6
19000125
13DCCF22
1343E5FD
2682C837
L0.15.6.16 (V1.12) 7.65.37
35E23F3C
39A28B6
1878D8A1
135E37D0
12E24420
265FAAB5
L0.15.6.15 (V1.11
or V1.1)
350949D6
39A28B6
1878D8A1
135E37D0
12E24420
265FAAB5
7.65.37
Table 26 Software Levels and Checksums (860 Atlanta Main Control PWB)
Run Time
Application
Boot Loader
Boot Sector
IPS1
IIT
07.19.05.026
07.82.16
EC648248
1E63403
1C0E4D6B
26180815 or
26DC6B31 or
26C5B429
07.19.04.039
07.81.06
D35D9447
1E63403
1C0E4D6B
260E76CB or
26E3CB91 or
26E33424
07.19.04.038
07.81.06
D6ED5A14
1E63403
1C0E4D6B
260E76CB or
26E3CB91 or
26E33424
General Procedures
May 2003
6-114
V0.042
General Service Notes

General Service Notes Entry
7.19.02.503
Software Change Highlights
7.19.02.503 SOFTWARE HIGHLIGHTS
Bulletins
Supports Scan to E-mail feature on 460/470/480
Software Change Highlights
Supports Smart Tray Disk Finisher on 460/470
7.19.05.026
Reduces Light Prints and Toner Blow-Out (TBO) image quality problems on 480/490.
7.19.04.039
7.19.04.038
7.19.02.503
07.19.02.051
07.19.01.504
07.19.01.503
L0.19.0.56 (V7.02)
L0.19.0.28 (V7.01)
L0.19.0.27 (V7.00)
L0.18.6.07 (V6.08)
07.19.02.051
DC 460/470 Refresh version
07.19.01.504
Same as 07.19.01.503, except for changes to support 480/490.
L0.17.9.32 (V5.22)
L0.18.1.26 (V6.04) and L0.17.9.28 (V5.18)
07.19.01.503
L0.18.1.24 (V6.03)
L0.17.8.67 (V5.11)
L0.17.8.65 (V5.08)
Mandatory for 480 DC/ST (NASG); situational for 460/470 DC/ST (NASG) and 460/470/
480 DC/ST (XE) to correct one of the problems listed below:
L0.17.8.64 (V5.07)
L0.17.8.12 (V5.06)
Intermittent 08-115.06, 08-101.06, 08-105.06 faults when the machine is left on for long
periods of time. (Refer to Bulletin #423.)
L0.17.6.08 (V5.05)
L0.17.5.08 SOFTWARE UPGRADE ISSUES
480 only (07.19.01.020 software): 08-101.06 and 08-115.06 faults after 100 - 150K cycles
on the HCF feeder CRU due to incorrect HCF CRU Life Factor. (Refer to Bulletin #421.)
L0.17.5.08 (V5.03)
UI "Blue Screen"
7.19.05.026
MFF Launch Version. Includes MFF software version 12.20.
"Dots of Death": UI only displays only a series of dots and the machine does not cycle up.
Gray band on Scan-to-File images
Cover inserted in middle of Build Job when front and back covers selected and more than
256 images
Installation Wizard fails to complete, resulting in aborted installs.
L0.19.0.56 (V7.02)
7.19.04.039
L0.19.0.56 (V7.02) SOFTWARE HIGHLIGHTS
Same as 19.04.038, but contains a correction for one NVM default. Mark Service location
35 (hcfAquire), if initialized in 19.04.038, would cause misfeeds (08-101.06 faults) and
false Tray 6 out of paper statuses.
CAUTION: DO NOT install this software on 240/255/265 machines.
L0.19.0.56 (V7.02) software has been cut into XE Manufacturing only for the 460/470
products.
L0.19.0.56 (V7.02) software is required for the Flicker solution (TAG 105).
7.19.04.038
L0.19.0.28 (V7.01)
Supports Image Overwrite Security feature
(Text from Bulletin 398)
Supports new Cost-down UI (Manufacturing cut-in only)
V0.042
May 2003
6-115
General Procedures
Upgrade your PWS with the following software, which are included in the L0.19.0.27
(V7.00) kit *:
L0.19.0.28 (V7.01) software has been cut into Manufacturing for the 460/470 products.
a.
Version L0.19.0.26 (V7.00) Diagnostic software.
All CSEs servicing the new 460/470 machines are being sent the L0.19.0.28 (V7.01) kit
630K11661 (301K03480 for Service Agents)
b.
Auditron Report 3.0 software, if not already installed.
1.
*CAUTION: Your PWS must have the 8.0 or higher ("Next Generation") base software installed before installing V7.00 PWS Diagnostics or servicing the 460/470
products.
Upon receiving the V7.01 Software Upgrade Kit, do the following:

1.
(V7.01) kit *:
Version L0.19.0.26 (V7.00/7.01) Diagnostic software (if not already installed

from the L0.19.0.27 (V7.00) kit).
Auditron Report 3.0 software (if not already installed).
2.
* NOTES:
*CAUTION: Your PWS must have the 8.0 or higher ("Next Generation") base software installed before installing V7.00/7.01 PWS Diagnostics or servicing the 460/
470 products.
2.
Use the enclosed L0.19.0.28 (V7.01) machine software to upgrade any 460/470
machine currently running L0.19.0.27 (V7.00) software, if required to correct the following problems in L0.19.0.27 (V7.00):
03-331 faults (Atlanta resets) when the System Administrator enters Network
Configuration settings
False "Network Controller not available" messages
Use the PWS to service the new 460/470 machines, but no machine upgrades to
this software level should be required.*
Be sure to perform the Supplemental Training: "460/470 Differences" on the

EDOC v0.038A CD-ROM (provided separately), before servicing any 460/470
machines.
If the customer keeps both a Xerographic Module and a Fuser Module on site,
be sure to reduce the Reorder Message Trigger to the minimum setting of one
day, and set the Reorder Method to "Customer" as follows:
Enter the UI Tools pathway, select [More] (if required), then [Supplies Management], then [Warning Message Notices]. Select [Time to Reorder], decrease the
value to 1, and select [Save]. Then, select [Replacement Method], select [Customer Replaced], and select [Save].
This will help to reduce wasted module life, and the associated service cost, as
much as possible.
CAUTION: Follow the Software Upgrade Kit instructions carefully.

* NOTES:
Be sure to perform the Supplemental Training: "460/470 Differences" on the EDOC

v0.038A CD-ROM (provided separately), before servicing any 460/470 machines.
If the customer keeps both a Xerographic Module and a Fuser Module on site, be
sure to reduce the Reorder Message Trigger to the minimum setting of one day, and
set the Reorder Method to "Customer" as follows:
L0.18.6.07 (V6.08)
A major source of excessive service cost on all machines in the field to date is wasted
Xerographic and Fuser Module life. Customers are changing modules while significant life
remains - thousands of copies in many cases - because the UI messages that prompt
customer replacement are displayed prematurely. This latest software calculates the
Xerographic and Fuser Module usage rate much more accurately, timing the replacement
messages as closely as possible to the module's actual end-of-life.
Currently U.S. Only: Sixth Sense (RDT) Callout for billing may be enabled, on a machine
that is already enabled for Sixth Sense and is connected to an active phone line. The
Software Upgrade Kit instructions will direct you when and how to set up RDT Callout on
U.S. Sixth Sense machines.
Enter the UI Tools pathway, select [More] (if required), then [Supplies Management],
then [Warning Message Notices]. Select [Time to Reorder], decrease the value to 1,
and select [Save]. Then, select [Replacement Method], select [Customer Replaced],
and select [Save].
much as possible.
L0.19.0.27 (V7.00)
L0.18.6.07 (V6.08) SOFTWARE CAVEATS
All CSEs in Europe servicing the new 460/470 products are being supplied the L0.19.0.27
(V7.00) software kit by their NTS or local management.
The L0.19.0.27 (V7.00) software kit is available for order by any U.S. CSEs who are
required to service the 460/470 demo machines. The kit part number to order is
630K11660 for CSEs (301K03219 for Service Agents).
General Procedures
The ESS Software Verification diagnostic tool does not work in L0.18.6.06 (V6.08) Diagnostics software. DO NOT USE THE ESS SOFTWARE VERIFICATION (or "ESS Software Verify") tool in this software version.
Other Information from bulletin:
May 2003
6-116
MANDATORY
The following two MANDATORY new versions of software are being released for Document Centre 240/255/265 to address the above two problems:
L0.18.6.07 (V6.08) (Tag #099), releasing now: MANDATORY for the following
machines:
V0.042
All machines that are already at L0.18.xx (V6.03 or V6.04) software
All Digital Copiers

All ST/LP machines being upgraded from L0.17 to L0.18 to enable any of the
customer-ordered options of Network Scanning, Faxing, or Accounting.
L0.17.9.32 (V5.22) (Tag #287), released March, 2000: MANDATORY for All ST and
LP machines that are not already at L0.18.xx (V6.03 or V6.04) software that will NOT
receive the new features of Network Scanning, Network Faxing, or Network
Accounting. Exception: Machines that already have at least 64 MB ESS RAM may
be upgraded from L0.17 to L0.18.6.07 (V6.08) instead (see above), depending upon
direction from your NTS or local management.
NOTE: Unlike upgrading to L0.17.9.32 (V5.22), which only causes machines

with extended internal Auditron (128 KB of NVM RAM) to lose internal Audition
data, upgrading to L0.18.6.07 (V6.08) causes all L0.17 internal Auditron
machines (whether 32 KB or 128 KB of NVM RAM) to lose internal Audition
data.
NOTE: The reason for not upgrading all ST/LP's from L0.17 to L0.18.6 is that an ESS
RAM upgrade to at least 64 MB would be required, which costs approximately $200 US
per machine. Machines with L0.17 software that already have at least 64 MB ESS RAM
may be upgraded to L0.18.6.07 (V6.08) instead of L0.17.9.32 (V5.22), depending upon
Upgrading the machine from L0.17 to L0.18.6.07 (V6.08) software will DELETE
any Internal Auditron account information. If a machine with L0.17 software has
any Internal Auditron accounts, you must use the Auditron Report Software to
save the Internal Auditron account information before the software upgrade and
to restore it afterward.
Before performing the software upgrade, disable any external Auditron device,
and then re-enable it after the software upload.
Follow the Software Upgrade Kit instructions carefully.
L0.17.9.32 (V5.22)
1.
2.
(V6.08) kit:
Versions L0.18.6.06 (V6.08) Diagnostic software.
Auditron Report 3.0 software, if not already installed.
PWS DLL Patch, only if required to correct the DLL problem in L0.18.1.25 PWS
Diagnostics that caused PWS lock-ups (see Bulletin #386).
Upgrade * to L0.18.6.07 (V6.08) EVERY machine already at L0.18.xx (V6.03 or

V6.04) software and EVERY DC machine.
Additionally: ST/LP machines at L0.17 that already have at least 64 MB ESS RAM
may be also be upgraded to L0.18.6.07 (V6.08), depending upon direction from your
NTS or local management.
* IMPORTANT:
Set the PWS Diagnostics version to correspond with the CURRENT machine
software version, for the NVM download and save to MRD, before the software
upgrade. (NOTE: This also applies to upgrades to all other software versions).
ST/LP: Do not attempt to use PWS Wizard method to upgrade the ESS to
L0.18.6.07 (V6.08) software -- use the Alternate Boot method instead, according to the instructions. The PWS Software Upgrade Wizard does not work for
the ESS in this software version.
A major source of excessive service cost on all machines in the field to date is wasted
Xerographic and Fuser Module life. Customers are changing modules while significant life
remains - thousands of copies in many cases - because the UI messages that prompt
customer replacement are displayed prematurely. This latest software calculates the
Xerographic and Fuser Module usage rate much more accurately, timing the replacement
messages as closely as possible to the module's actual end-of-life.
The following two MANDATORY new versions of software are being released for Document Centre 240/255/265 to address the above two problems:
L0.17.9.32 (V5.22) (Tag #287), releasing now: MANDATORY for All ST and LP
machines that are not already at L0.18.xx (V6.03 or V6.04) software that will NOT
receive the new features of Network Scanning, Network Faxing, or Network
Accounting. Exception: In Europe only, machines that already have at least 64 MB
ESS RAM may be upgraded to L0.18.6 instead (when available), depending upon
L0.18.6, expected late April 2000: MANDATORY for the following machines:
All machines that are already at L0.18.xx (V6.03 or V6.04) software
If the customer keeps both a Xerographic Module and a Fuser Module on site,
be sure to reduce the Reorder Message Trigger to the minimum setting of one
day, and set the Reorder Method to "Customer" as follows:
Enter the UI Tools pathway, select [More] (if required), then [Supplies Management], then [Warning Message Notices]. Select [Time to Reorder], decrease the
value to 1, and select [Save]. Then, select [Replacement Method], select [Customer Replaced], and select [Save].
much as possible.
All Digital Copiers

All ST/LP machines being upgraded from L0.17 to L0.18 to enable any of the
customer-ordered options of Network Scanning, Faxing, or Accounting.
NOTE: The reason for not upgrading all ST/LP's from L0.17 to L0.18.6 is that an
ESS RAM upgrade to at least 64 MB would be required, which costs approximately
$200 US per machine.

1.
Upgrade your PWS with the following software, all of which are included in the
L0.17.9.32 (V5.22) kit:
Versions L0.17.9.21 (V5.22) Diagnostic software.
Versions L0.18.5.19 (V6.06) Diagnostic software. *
Auditron Report 3.0 software.
V0.042
May 2003
6-117
General Procedures
2.
*NOTE: Use L0.18.5.19 PWS Diagnostics software for servicing machines at

L0.18.1.26 (V6.04), as well as early machines at L0.18.6. Installing this version
of PWS Diagnostics will correct or avoid the DLL problem in L0.18.1.25 PWS
Diagnostics that caused PWS lock-ups (see Bulletin #386).
L0.18.1.26 (V6.04) and L0.17.9.28 (V5.18)
Upgrade * to L0.17.9.32 (V5.22) EVERY ST/LP machine NOT already at

L0.18.xx (V6.03 or V6.04) software, for which the customer has NOT ordered
the new options of Network Scanning, Network Faxing, and/or Network
Accounting. (Exception: In Europe only, machines that already have at least 64
MB ESS RAM may be upgraded to L0.18.6 instead (when available), depending upon direction from your NTS or local management.)
Changes the lube stripe frequency and patch size, and enables planned future Xerographic Module hardware improvements, all of which will increase Xerographic Module
life by up to 30%, resulting in significantly lower Xerox service costs.
Reduces the occurrence of a particular print quality defect characterized by a multitude of

fine lines running the length of the page in the process direction ("bar code" defect).
For Customers receiving L0.18 software for the first time, the introduction of this software
supports the launch of the new features: Network Scanning, Network Faxing, and Network Accounting. Fully enabling these features requires additional hardware and enablement kits. The enablement kits are either pre-installed in each new L0.18 machine
ordered with these options, or are shipped separately to the customer, based on their
Sales order.
With L0.18.1.26 (V6.04) software and with a Finisher, the default output tray for copy
mode is the Stacker Tray. However, upgrading to L0.18.1.26 (V6.04) software will not
change this setting automatically:
IMPORTANT:
a.

L0.18.1.26 (V6.04) AND L0.17.9.28 (V5.18) SOFTWARE HIGHLIGHTS
If the customer keeps both a Xerographic Module and a Fuser Module on

site, be sure to reduce the Reorder Message Trigger to the minimum setting - one day, as follows:
Enter the UI Tools pathway, select [More], then [Supplies Management],
then [Warning Message Notices]. Select [Time to Reorder], and decrease
the value to 1. (Ignore the UI text, "3-25 Days.") Select [Save], and [Exit
Tools].
This will help to reduce wasted module life, and the associated service
cost, as much as possible.
b.
c.
It is CRITICAL to switch the machine power off and back on after this software upgrade, for the intended IIT changes to take effect. A complete
restart of the machine logic is required in order to move the new software
code to the SCVM chip.
Unlike with L0.18.1.24 (V6.03) software, upgrading from L0.17 to L0.18.1.26 (V6.04)
software will not change the default copy output from the Stacker Tray to the Top
Tray.
If upgrading from L0.18.1.24 (V6.03) to L0.18.1.26 (V6.04) software and the customer has not changed the default from the Top Tray to the Stacker Tray, this setting
is not changed back to the Stacker Tray automatically. The customer can still change
the default tray back to the Stacker Tray if they so choose, by using Customer Tools
on the UI.
The L0.18.1.26 (V6.04) kit contains a PWS Software "Album" CD-ROM, which contains
the following software:
L0.18.1.25 (V6.04) Diagnostic Software
L0.18.5.19 (V6.06) Diagnostic Software *
Auditron Report 3.0 Software
d.
e.
Upgrading the machine to L0.17.9.32 (V5.22) software will DELETE any

extended Internal Auditron account information. If the machine has any
Internal Auditron accounts and has 128K of NVM RAM (Tag #036, or Tag
#077 Atlanta Platinum Main Control PWB), you must use the Auditron
Report Software to save the Internal Auditron account information before
the software upgrade and to restore it afterward.
Before performing the software upgrade, disable any external Auditron

device, and then re-enable it after the software upload.
The L0.17.9.32 (V5.22) kit contains a PWS Software "Album" CD-ROM, which contains the following software:

Auditron Report 3.0 Software
The L0.17.9.28 (V5.18) kit contains no PWS software CD-ROM. You must use the
L0.18.1.26 (V6.04) kit to install L0.17.9.21 (V5.18) Diagnostic software onto the PWS.
All support for L0.15 software on Digital Copiers is being phased out as of 1 January
2000.
L0.17.9.28 (V5.18) UPGRADE NOTES:
*NOTE: Use L0.18.5.19 PWS Diagnostics software for servicing machines at

L0.18.1.26 (V6.04), as well as early machines at L0.18.6. Installing this version of
PWS Diagnostics will correct or avoid the DLL problem in L0.18.1.25 PWS Diagnostics that caused PWS lock-ups (see Bulletin #386).
General Procedures
May 2003
6-118
1.
Upgrading the machine to L0.17.9.28 (V5.18) software will DELETE any extended
Internal Auditron account information. If the machine has any Internal Auditron
accounts and has 128K of NVM RAM (Tag #036 or Tag #077), you must use the
Auditron Report Software to save the Internal Auditron account information before
the software upgrade and to restore it afterward.
V0.042
2.
The ESS software has not changed since V5.07 (the ESS software is still
L0.17.8.63), so you may de-select the ESS platform in the Software Upgrade Wizard
if upgrading from L0.17.8.64 (V5.07) or higher. This will save time and avoid the
unnecessary risk of a ESS software upload failure.
3.
It is CRITICAL to switch the machine power off and back on after this software
upgrade, for the intended IIT changes to take effect. A complete restart of the
machine logic is required in order to move the new software code to the SCVM chip.
L0.18.1.24 (V6.03) software is released for Document Centre 240/255/265 to support the
limited worldwide launch of L0.18 software and its new options of Network Scanning, Network Faxing, and Network Accounting.
4.
Before performing the software upgrade, disable any external Auditron device, and
then re-enable it after the software upload.
The tag number for L0.18.1.24 (V6.03) software is Tag 094.
IMPORTANT NOTE:
5.
At this time, L0.18.1.24 software should be installed ONLY on machines where the customer has ordered any of the new options of Network Scanning, Network Faxing, and/or
Network Accounting.
L0.18.1.26 (V6.04) UPGRADE NOTES:

1.
It is strongly recommended that you perform the Supplemental Training contained in

EDOC V0.038, to learn about the new Network Scanning, Faxing, and Accounting
options, before upgrading or servicing a machine with these options.
2.
The customer/SA must use CentreWare 5.1 or higher, in order for their clients to utilize L0.18.1.26 (V6.04) machine software fully, and to avoid problems of incompatibility between the new machine software and earlier versions of CentreWare.
3.
The new CentreWare is included with the option enablement kits delivered to all new
L0.18 customers, and can be downloaded from www.centreware.com when available.
4.
If any Document Centre 220/230/332/340 machine is used by the same clients as

the DC 240/255/265, make sure the DC 220/230/332/340 CSE is aware that CentreWare 5.1 will be installed on these clients. The DC 220/230/332/340 must be
upgraded as follows in order for scanning to function correctly for clients with CentreWare 5.1 or higher:
DC220/230: SMP V1.08 or higher.
DC332/340: SMP V1.0 or higher.
Therefore, until further notice, DO NOT upgrade any machine from L0.17 to L0.18 unless
you are dispatched to enable the software and new option(s) PER CUSTOMER SALES
ORDER. Then, be sure to follow the instructions in the option enablement kits (delivered
to the customer's site) before installing the new machine software.
L0.17.8.67 (V5.11)
The Xerographic Exerciser now operates correctly with an Atlanta Platinum Main Control
PWB (TAG 077).
The toner concentration NVM Values are now correct for machines at altitudes below
4000 ft. (1200 m).
5.
Before performing the software upgrade, disable any external Auditron device, then
re-enable it after the software upload.
The problem of large single-sided jobs sometimes resulting in 08-105.06 faults and
sheets being misdirected into the duplex paper path, has been fixed.
6.
The problem of 8.5 x 13 in. (216 x 330 mm) documents in the DADF causing 03-338 Main
Controller crashes ("Atlanta resets"), has been fixed.
The 32-bit (Windows '95) PWS software is now able to re-establish communication with a
55 ppm machine after the NVM RAM Chip is replaced.
L0.18.1.24 (V6.03)
NOTE: There is no 16-bit (Windows for Workgroups) version of L0.17.8.67 PWS software. The 16-bit PWS operating system is no longer being supported.
With L0.18.1.24 software, and with a Finisher, the default output tray for copy mode is
now the Top Tray. Customers can change the default tray back to the Stacker Tray if they
so choose, by using Customer Tools on the UI.
For Customers receiving L0.18 software for the first time, the introduction of this software
supports the launch of the new features: Network Scanning, Network Faxing, and Network Accounting. Fully enabling these features requires additional hardware and enablement kits, which are either pre-installed in each new L0.18 machine or shipped separately
to the customer, based on their Sales order.
After the machine is upgraded to L0.18.1 or higher software, the customer's System
Administrator can perform subsequent software upgrades via their network from a client
PC. Availability of these subsequent software upgrades will be communicated directly to
the customer by e-mail.
Existing L0.18 customers (Customer Field Test Phases 1 and 2) will benefit from the final
"hardening" improvements over Customer Field Test software L0.18.1.22 (V6.02).
V0.042
May 2003
6-119
The UI message to order a new Xerographic or Fuser Module appears a shorter time in
advance of the CRU end-of-life (the default number of days has been decreased), reducing premature CRU replacements. Upgrading to the new software will overwrite the current setting with this new Reorder Message Trigger value:
For NASG Market Region machines: the default has changed from 5 days to 4 days.
For XE, XCL, and DMO Market Region machines: the default has changed from 5
days to 3 days.
General Procedures
NOTE:
If your country, Customer Business Unit, or a specific account requires a longer

warning period before the machine shuts down requiring a new CRU, the CSE can
increase this number of days (Reorder Message Trigger) from the default value
listed above, up to 25 days. However, You are strongly advised to keep the value as
low as possible, to minimize lost output from the CRU's and the associated costs.
Some known exceptions to the default setting are as follows:
When using the Serif PagePlus application, some graphic images would not print. With
this new release, these images will print correctly.
When printing in booklet format onto 11x17-inch paper, some pages would not format correctly, causing blank pages in the booklet. These jobs should now print correctly.
The machine would not connect in a Cabletron SecureFast switched ethernet environment. These problems have been addressed in this release.
Postscript resources could not be stored onto the hard disk of the machine, preventing the
resource from being recalled for future use. This release has corrected this problem.
Sweden: 10 days
Norway, Finland, Italy: 5 days
PWS FIXES:
To change the Reorder Message Trigger setting (number of days before CRU endof-life when the Reorder message appears):
HCF Interlock name changed in Component Control, so as not to mislead and cause
incorrect parts replacement.
1.
Enter [Configuration tab , CRUs] and select the [CRU Messages] tab.
2.
Double-click in the "Reorder Message Trigger" field, and change the value as
required.
NETBIOS had been displayed as available for Echo Test and unavailable for Get Network
Data. This is now fixed.
Additional Highlights:
3.
Select [Apply], and select [OK].
ST/LP: A new version of CentreWare, 4.1 SP2, is available to operate with this new
machine software. The customer can download the new CentreWare from www.centreware.com.
The IOT now must cycle up and down 5 times (was 3 times) without delivering sheets,
before the job is automatically deleted.
L0.17.8.65 (V5.08)
This software is identical to L0.17.8.64 (V5.07) software, except that it now supports the
Atlanta Platinum Main Control PWB (with TAG 077) in addition to the Atlanta Gold Main Control
PWB (with TAG 015, without TAG 077).
L0.17.8.64 (V5.07)
B) SOFTWARE UPGRADE CAVEATS

NOTE: "High altitude" in the following paragraphs is defined as elevations of 4000 feet (1200
meters) or more above sea level.
In order to enable the xerographic fixes included in this software, you must initialize the
xerographic NVM and reenter the three ROS NVM values. For High Altitude machines
(with TAG 297), you must also set the machineAltitude NVM value for the machine's location. Follow the software upgrade kit instructions carefully to ensure the correct NVM
changes are made.
For a High Altitude machine (with TAG 297, or being upgraded to Tag #297 Developer
Housing): You must ensure the TAG 292 Developer Housing Gears are installed at the
same time that L0.17.8.64 (V5.07) software is installed. Either install the new High Altitude Developer Housing Kit that includes the Tag #292 gears, or install the Tag #292
Gears for High Altitude Developer Housing Kit in combination with the earlier High Altitude Developer Housing, when upgrading to this new software level. These two Tag #292
kits will be announced in a separate communication.
A) L0.17.8.64 (V5.07) SOFTWARE HIGHLIGHTS

XEROGRAPHIC FIXES (requires Xerographic NVM to be reinitialized - refer to CAVEATS list,
below):
Worm-like image quality defects (Jumping-Gap Arcing, and Air Breakdown), occurring primarily at high altitudes, have been addressed. High Altitude (TAG 297) machines must
have new Developer Housing Gears (TAG 292) installed concurrently with this software refer to CAVEATS.
Problems have been addressed that led to frequent xerographic setups at all altitudes.
These setups would interrupt the job in progress and could take as long as 10 minutes to
complete. Setups were associated with 09- series xerographic faults.
NOTE: After this software is installed, manipulating the "special eleven" NVM values
(TAG 294, described in Bulletin 347) for these Xerographic problems no longer applies.
The software automatically adjusts Xerographic settings, including those for the specified
altitude for a High Altitude machine.
DO NOT ATTEMPT TO LOAD L0.17.8.64 (V5.07) OR HIGHER SOFTWARE ON A

MACHINE WITH AN ATLANTA '96 MAIN CONTROL PWB (without TAG 015). Loading
this software will destroy an Atlanta '96 Main Control PWB. Any Atlanta '96 machine that
requires this software must first be retrofitted to a Tag #015 or higher Main Control PWB
(Atlanta Gold or Atlanta Platinum), using the correct retrofit kit (PL 1.4).
You must ensure the PWS Diagnostics version is set to L0.15 for the software upgrade
from L0.15 to L0.17.8.64 (V5.07). Follow the software upgrade kit instructions carefully to
ensure that you are using the correct PWS software version.
You must disable and disconnect any external Auditron device before beginning the software upgrade to L0.17.8.64 (V5.07). Follow the software upgrade kit instructions carefully
to ensure the external Auditron device is disable/disconnected and reconnected/reenabled at the appropriate times.
ESS IMPROVEMENTS:
The PCL interpreter is improved, for formatting on XE machines.
Large job handling is further improved. Some jobs of 15,000 pages and more would hang
as scheduling and generate 03-338 faults.
A thin line would sometimes print near a graphic in a PostScript job. Improvements have
been made to help eliminate this problem.
General Procedures
May 2003
6-120
V0.042
19-407 or 19-408 faults are declared with some middle function jobs. When the job
requires a 270 degree rotation and the rotation is broken into a 90 degree rotation and a
180 degree rotation because tumble duplex is selected and SE document handler feed
onto LE output is selected on a system with a 1 GB (slower) Image Disk. Upgrade the
customer with the 2 GB Image Disk (PL 1.3A) to alleviate this problem.
Refer to the Release Notes, included in the V5.07 software kit, for information on additional caveats (known problems) with L0.17.8.64 (V5.07) software.
Refer to the Release Notes, included in the V5.06 software kit, for information on additional caveats (known problems) with L0.17.8.12 (V5.06) software.
L0.17.8.12 (V5.06)
A) MACHINE PROBLEMS CORRECTED BY L0.17.8.12 (V5.06) SOFTWARE
The system may crash during a very large print job (>1000 pages); for example: when out
of paper, when tray switching is required, or when a jam occurs.
If the system crashes during a very large print job (>1000 pages), after rebooting it then
may then restart the job at page 1, or may cancel printing the job (incorrect job recovery).
A thin line appears across the page near graphics in PostScript jobs.
The system crashes when source routing is enabled in very large Token Ring network
environments.
The date format on the banner page cannot be changed.
The system crashes when attempting to print high resolution embedded TIFF images.
The printer reports a duplicate IP address.
The system operates erratically with reduction settings below 50%.
When many jobs are printed, jobs remain in the NT spool.
The printer cannot connect on the SecureFast VLAN NT network.
Several PCL printing problems, including:

- PageMaker jobs sent through PCL drivers from Windows '95 clients.
- MS Word document with Courier New or certain other True Type font, sent through PCL
drivers: not all characters will print.
- The ESS crashes (03-331 fault) when a PCL job is deleted at the machine UI while the
job is formatting.
- The Main Control PWB crashes if the banner sheet is enabled in the PCL print driver but
disabled at the machine.
B) SOFTWARE UPGRADE CAVEATS
DO NOT ATTEMPT TO LOAD L0.17.8.12 (V5.06) OR HIGHER SOFTWARE ON A

MACHINE WITH AN ATLANTA '96 MAIN CONTROL PWB (without Tag #015). Loading
this or higher software will destroy an Atlanta '96 Main Control PWB. Any Atlanta '96
machine that requires L0.17.8.12 (V5.06) or higher software must first be retrofitted to a
Tag #015 Main Control PWB, using the correct retrofit kit (PL 1.4).
from L0.15 to L0.17.8.12 (V5.06). Follow the software upgrade kit instructions carefully to
You must disable and disconnect any external Auditron device before beginning the software upgrade to L0.17.8.12 (V5.06). Follow the software upgrade kit instructions carefully
to ensure the external Auditron device is disable/disconnected and reconnected/reenabled at the appropriate times.
V0.042
May 2003
6-121
General Procedures
L0.17.6.08 (V5.05)

A) CHANGES FROM L0.17.5.08 (V5.03)
You must disable and disconnect any external Auditron device before beginning the software upgrade to L0.17.6 (V5.05). Follow the software upgrade kit instructions carefully to
ensure the external Auditron device is disable/disconnected and reconnected/re-enabled
at the appropriate times.
ESS Caveats
Customer Safety: L0.17.5 (V5.03) and higher software improves the finisher operation to
prevent the remote chance the customer can have their hand pinched above the Stacker
Tray when removing stacks of prints.
CSE Safety: ST/LP: The problem of the machine continuing to print after entering diagnostics has been corrected with L0.17.5 (V5.03) and higher software. The CSE will no
longer need to ensure the front door interlock circuit is opened (door open, no cheater) in
order to prevent the machine from continuing to print after entering diagnostic mode.
However, it is still good safety practice, before entering diagnostics, to allow the job that is
currently marking to run to completion and delete any jobs displayed on the UI.
This machine software release takes full advantage of the new CentreWare release, version 4.1 SP1, which the customer can download from the CentreWare web site (www.centreware.com).
Several enhancements have been incorporated to improve overall reliability and reduce
the occurrence of paper and document jams.
Finisher Unload Message: When a small number of thin stapled sets are run and
removed, the thin set counter now correctly reports the number of sets, and the machine
does not declare the finisher is full with less then the required numbers of sets.
The problem of Second Side Registration NVM resetting to "0" during I/O configuration
has been corrected. When a configuration mismatch occurs (for example, when reattaching an external feeder or output device), the two duplex side 2 registration NVMs (locations 8 and 65 in Mark Service) would be set to 0. This caused the side 2 top edge
registration (IB-OB) to be incorrect.
A number of different system reset/crash situations were corrected, including for low EPC
memory mode with memory sweep
The Echo Test and the Get Network Data test, performed on the machine UI, only function
intermittently.
You must disable and disconnect any external Auditron device before beginning the software upgrade to L0.17.6 (V5.05). Follow the software upgrade kit instructions carefully to
ensure the external Auditron device is disable/disconnected and reconnected/re-enabled
at the appropriate times.
The system will sometimes crash on large PCL jobs, resulting in a 03-331 fault for ESS,
or a 03-338 fault for the Main Control PWB.
The Configuration Report incorrectly reports the IPX frametype to be 802.2 when Token
Ring is selected as the NetWare physical media. The frametype in use is actually Token
Ring and it is displayed correctly in the UI Tools in Network Setup.
The only method to set the AppleTalk zone name to use the default zone on the network
is to use the [Default All] button on the UI Tools in Network Setup. There is no '*' character available to set the zone name to this directly.
Occasionally, a job will remain "Scheduling" in the queue indefinitely. If this occurs, delete
the job from the queue, switch the machine power off using the white button, and switch it
back on.
Requesting a new Configuration Report via the PWS will occasionally cause the ESS to
crash, requiring a power-off/power-on to recover. Workaround: Request a Configuration
Report via UI Tools instead.
Other Caveats
The NOHAD filter counter cannot be reset via the PWS.
If the Machine Administrator PIN number is changed at the machine UI, the machine must
be reset before the change will take effect. Until the machine is reset, remote applications
such as CentreWare Internet Services and CentreWare Network and Administration Services cannot authorize operations using the new PIN.
ESS Improvements
The problem of the printer not responding to the network when in low power mode has
been corrected.
Web UI reliability has been optimized.
The Xerox logo prints correctly.
The UI displays the maximum number of connections for NetBEUI correctly.
AppleTalk reliability is improved.
The Postscript Interpreter has improvements to address problems with particular True
Type fonts printing incorrectly.
B) L0.17.6 (V5.05) SOFTWARE TOP CAVEATS

Software Upgrade Caveats
from L0.15 to L0.17.6 (V5.05). Follow the software upgrade kit instructions carefully to
General Procedures
May 2003
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V0.042
L0.17.5.08 SOFTWARE UPGRADE ISSUES
5.

The following issues have been identified as problems with the L0.17.5 software upgrade. Following each issue is a status of that issue.
1.
Software upgrade instructions are not being followed completely, resulting in numerous
calls to Field Engineering.
STATUS: The upgrade instructions have been simplified, and then verified in a field test.
2.
3.
STATUS: This problem is driven by not having the Finisher Interlock correctly seated. Use
the following procedure to recover:a) Switch Off the machine power.b) Correctly re-mount
the Finisher, ensuring the interlock is actuated correctly.c) Switch On the machine
power.d) Continue the Install Wizard.e) Reset the second side registration when done.
Second side NVM resets to "0" during I/O configuration. This means that anytime the I/O
configuration of the machine is changed, side 2 NVM will be reset to "0", resulting in the
Side 2 Top Edge Registration being out of spec.
STATUS: This problem will be fixed with the L0.17.6 software release. Until then, there is
no easy workaround for this problem. You can expect to see an increase in UM's from rigger installs. Also, anytime an I/O device is removed and reconfigured during troubleshooting, the CSE must reset the Side 2 Top Edge Registration. In the interim, in order to
prevent a recall, verify the Side 2 Top Edge Registration is in spec before leaving the
account.
UI lockup during Wizard: When the disk finisher is not mounted correctly and its interlock
is not seated correctly during the Install/Wizard, the message "Ensure the input and output devices are installed correctly, or call for service" will appear on the local UI. If the
Rigger proceeds with the Install Wizard without following the below recovery procedure,
the Install Wizard will continue until the System Install is complete, the UI will reset and
not advance past the opening "Document Centre" frame. If the Rigger then Power-Off/
Power-On the machine without following the below recovery procedure the local UI will
not advance past the "Document Center" opening screen.
6.
22-303.05 is a new fault code without a description or RAP in EDOC v0.036. This new
fault code was generated to fix a problem in L0.15.8 software where the machine just
hangs up. The conditions that cause this fault fall into the following categories:
A Finisher Unload Message can come up at anytime for the customer, if the Finisher Tray
has not moved during any of the jobs. For example, if the customer runs 29 small jobs
that don't cause the trays to step down, and then someone comes up to run a 5 set job,
the unload message will be displayed after the first set goes into the finisher. The machine
will not complete the final 4 sets of the job until the 1 minute timer times out, or the customer uses the finisher tray pause button to cycle the tray down/up, or the finisher tray
moves up, depending on the size of the set. If the customer is running a large number of
thin sets, the problem can occur only for the first unload message. After the first unload
message, the next unload message will be 30 sets later (or at whatever value it is set in
TOOLS.)
a) The inferred document size is wrong.
STATUS: This problem will be fixed in L0.17.6 software.
b) The stack of originals contains at least one original that is at least 2 inches smaller than
the others, and the user did not select "Mixed Size Originals".
c) The DADF feeds multiple originals in a 'shingle' feed (or multiple feed) condition, or
feeds the originals too slowly in the CVT region, or does not feed at all.
The above conditions will cause the following:- A 22-303.05 fault to be declared,- The job
is automatically deleted by the system, and- A pop-up on the UI stating "The job was
deleted because a document was larger than expected. Try flattening the document and
either rescan it through the Document Feeder or scan it from the Document Glass". The
message on this pop-up can be confusing to the operator and CSE, since there are many
other causes of this fault in addition to folded originals.
STATUS: Refer to Bulletin # 334 for more information about this fault.
4.
Atlanta 96 Main Control PWB Related S/W Upgrade Failures: This upgrade is hardware
and process related. Atlanta 96 is susceptible to noise problems, and the Atlanta Gold
PWB was introduced to address these problems.
STATUS: The new upgrade instructions mention that you might experience problems
when upgrading Atlanta 96 PWB's. At this time, it is recommended that you do not
upgrade Atlanta'96 PWB's. If you need to upgrade an Atlanta 96 PWB, and experience
problems with the upgrade, install an Atlanta Gold PWB and then perform the software
upgrade. There will be more information available in another bulletin that will be sent out
shortly.
V0.042
May 2003
6-123
General Procedures
L0.17.5.08 (V5.03)
The product configuration now includes GMT Offset (Greenwich Mean Time Offset),
which is the difference between the machine's local standard time and the standard time
in Greenwich, England. This value is set during the Installation Wizard, and can also be
set in Diagnostic Navigator ([Configuration] tab, [System, Imaging and IOT Configuration],
[Time] tab. The correct GMT Offset settings for all time zones are listed in the customer
Installation and Start-Up Guide, and also in GP26 of EDOC V0.036 (expected November
1998).
DCS40-65 Diagnostics software now includes a 32-bit version, for use only with the Windows '95 PWS (when Windows '95 PWS becomes available). The 32-bit version may be
installed in combination with existing 16-bit versions, but version switching then requires
using two different Multiple Version Handlers (the existing 16-bit Multiple Version Handler
plus a new 32-bit Multiple Version Handler). Once all machines that you service are at
L0.17.4 (V5.01) or higher, you may then delete all 16-bit versions (using the [Delete Version] function in the 16-bit Multiple Version Handler), and install all 32-bit versions. This
will then eliminate the need for the 16-bit Multiple Version Handler.
When upgrading a ST or LP machine from L0.17.4 (V5.01) to L0.17.5 (V5.03) software,

the Software Upgrade Wizard may now be used to install software onto the UI, ESS, and
Main Controller together automatically. The Alternate Boot method of installing ESS software is no longer required in the normal, full upgrade, but is still needed for correcting
some ESS software problems.

A) CHANGES FROM L0.17.4 (V5.01) OR LOWER
The software improves the finisher operation to prevent the remote chance the customer
can have their hand pinched above the Stacker Tray when removing stacks of prints.
Resolved 03-370 cycle-up/down and 08-105 jams due to cruse control.
"Out of Memory" Machine internal memory is better managed, reducing "Out of Memory"
errors and improving the ability to handle a large number of jobs or a large copy count.
L0.17.5 (V5.03) may also be used on ST/LP machines to resolve "Out of Memory".
The problem of the machine continues to print after entering diagnostics, (CSE Safety)
has been corrected with this software. The CSE will no longer need to ensure the front
door interlock circuit is opened (door open, no cheater) in order to prevent the machine
from continuing to print after entering diagnostic mode. However, it is still good safety
practice, before entering diagnostics, to allow the job that is currently marking to run to
completion and delete any jobs displayed on the UI.
Consecutive 19-403 faults requiring power-off/power-on for lack of memory are now limited to two, after which the customer is asked to delete the job. (This is a temporary partial fix to reduce PO/PO's until the root cause is found.)
The Job Interrupt feature has been improved, allowing users to interrupt a job that is
being processed rather than having to wait until it is completed. All copier features are
available to the interrupt users.
The possibility of seeing the process control patch printed on the front edge of the sheet
has been eliminated.
DADF skew control performance is improved over L0.15.
Finisher setups are improved over L0.15.
Finisher stapled sets operability is improved over L0.15, including UI messages to help in
handling of odd size papers.
Finisher registration and stacking performance is improved over L0.15.
Finisher operability of the pause/unload feature is improved over L0.15.
Scan-no-print problems are reduced from L0.15.
Build Job capability is increased and partial job segment recovery is improved over L0.15.
Large side-2 misregistration is now easier to correct.
The customer may now request to have a specific internal tray (1-4) set as the default tray
from which to feed banner sheets. This is set in Diagnostic Navigator as follows:
1.
Select [NVM] tab.
2.
Select [NVM Tool].
3.
Select [Machine] menu, [Download].
4.
5.
Scroll or [Search] to Location 524 ("MSDefaultAuxiliaryTray").
6.
Change the value (nominal=0) to a number from 1-4, corresponding to the desired
tray.
7.
Exit NVM Tool ([File] menu, [Exit]).
General Procedures
B) L0.17.5 (V5.03) SOFTWARE TOP CAVEATS
This software release is not accompanied by a new CentreWare release. ST and LP customers must receive the next release of machine software (L0.17.6, expected in January
1999) in order to receive a new CentreWare release.
If a diagnostic session is started without the serial cable connected, wait until the "Maximum Retransmits exceeded" message disappears (ten seconds after it appears) before
connecting the cable. Otherwise, an "Error Opening Session" message will appear and
you will need to restart the session.
When upgrading a Digital Copier from L0.15 to V5.03 (L0.17.5) software, the PWS Diagnostics version must first be set to L0.15 for the NVM backup and the software upgrade,
and later switched to L0.17.5 after the Main Controller has been upgraded to L0.17.5.
Follow the software upgrade kit instructions carefully to ensure that you are using the correct PWS software version.
The Novell or IPX Network Connectivity Test available in Tools still can give misleading
results as follows:
- False fail: The primary file server will not be discovered if it is more than one hop away.
- False pass: If the primary server is discovered, then the UI will indicate the device is
connected to the queue even though it may not be logged into the server.
May 2003
6-124
The network diagnostic test still may fail with the following message "The test cannot be
completed." If this occurs, reboot the machine and attempt to run the test again.
V0.042
Supplemental Tools and Supplies

Supplemental Tools and Supplies Entry
The tables supplied within this section list the various tools, supplies and consumables
required for this machine. The tables and the specified topics are as follows:
Electrical Tools - Table 2
Multinational Tools - Table 3
MultiFunction Finisher Tools - Table 4.
Machine Consumables - Table 5
Cleaning and Lubrication Materials - Table 6
V0.042
May 2003
6-125
General Procedures
Tools
Table 3 Multinational Tools

Table 1 PWS Accessories
Tool Number
Description
600T01824
Flashlight
600T41300
Torx Driver (handle and Torx bits)
Part Number
Description
600T02037
ESS Parallel Cable
600T01988
Nutdriver, 5.5mm
600T02029
Digital PhoneAdapter
600T91616
Interlock Cheater
600T80325
Lap LinkCable
600T40903
Pliers, Diagonal Cutters
600T02040
Cable Lock
600T40902
Pliers, Needle Nose
600T02155
IOT Parallel Cable
600T40906
Pliers, Universal Crimping
600T02046
Phone Cable (25 ft.)
600T41502
Rule, 6 Inch
600T02058
Serial Cable
600T40210
Screwdriver, Stubby
Inverter (12 vdc to 115 vac)
600T01903
Soft Pouch
300K63850
MRD Diskette w/case
600T01820
Vacuum Cleaner
600T02063
Parts Audit Scanner
600T01832
Vacuum Filters
600T02047
Power Cable, AC Extension (15 ft.)
82E12191
Test Pattern, Copy Quality (8.5 x 11)
600T02145
Power Cord Adapter (NASG only)
82E12320
Test Pattern, Copy Quality (A4)
600T91926
Power Cord Adapter (UK only)
82P01187
Test Pattern, Document Damage
600T91927
Power Cord Adapter (Europe)
600T02161
Configuration Information Tool (ProCfg)
600T91928
Power Cord Adapter (Denmark only)
600T41402
Pliers, External Retaining Ring, 45 deg
600T91929
Power Cord Adapter (Czech. only)
600T02073
Null Modem Adapter, 240/255/265

(male/female)
113E40060
600K75681
Null Modem Adapter, 460/470 (female/

female)
PWS AC Outlet Kit
Table 4 MultiFunction Finisher Tools

Tool Number
600T01921
7 mm Nut Driver
600T02034
5.5 Open-end Wrench
600T02223
Drawer Extension Harness. Enables

troubleshooting of Buffer/Compiler
Module and Booklet Maker module.
600T02232
Booklet Maker Adjustment Tools

Supplied with every MFF - CSE is not
required to carry.
Contains:
Table 2 Electrical Tools

Tool Number
Description
600T02020
DMM, Fluke
600T42001
ESD Kit
600T41620
IDC Tool
600T02030
Meter Leads
600T02059
NVM Replacement Tool
600T02039
Test Probe, Molex Mini Fit
600T01831
Test Probe, Molex SL
600T02079
Molex Pin Extractor
600T02127
Foreign Interface Test Tool
Description
1 Stapler Anvil Adjustment Tool
2 Blade Adjustment Tools
499T00355
# 2 Phillips Head Screwdriver
None
Castor Leveling Tool.

Supplied with every MFF - CSE is not
required to carry.
Table 3 Multinational Tools

Tool Number
Description
600T02043
Flat-blade Bits for Torx Driver
600T41901
Brush
600T02062
Castor Replacement Tool
General Procedures
May 2003
6-126
V0.042
Machine Consumables
Table 5 Consumables
Table 5 Consumables
Description
Part Number
Market Region
Other
Fuser Module 55/

65ppm 200v
109R341
ACO
Non-Sold
Description
Part Number
Market Region
Other
Xerographic Module
113R131
NASG/XCL
Sold
Fuser Module
40ppm 200v
109R331
XE
Sold
Xerographic Module
113R132
NASG/XCL
Non-Sold
Fuser Module
40ppm 200v
109R332
XE
Non-Sold
Xerographic Module
113R133
XE
Sold
Fuser Module 55/

65ppm 200v
109R333
XE
Sold
Xerographic Module
113R134
XE
Non-Sold
Fuser Module 55/

65ppm 200v
109R334
XE
Non-Sold
Xerographic Module
113R266
FX Domestic/APO Sold
Fuser Module
65ppm 100v
109R336
Xerographic Module
113R174
ACO
Sold
Fuser Module
65ppm 200v
109R337
FX APO
Xerographic Module
113R175
ACO
Non-Sold
Paper Feed Roll

Cartridge
108R148
NASG/XCL
Xerographic Module
113R290
Paper Feed Roll

Cartridge
108R150
XE/ACO
Dry Ink Cartridge
6R01007
NASG/XCL
2 Pack
6R01006
NASG/XCL
6 Pack
DADF Paper Feed 108R149

Roll Cartridge
NASG/XCL
Dry Ink Cartridge

Dry Ink Cartridge
6R90321
XE
6 Pack
XE/ACO
Fuser Module
40ppm 115v
109R327
NASG/XCL
Sold
DADF Paper Feed 108R151

Roll Cartridge
109R328
NASG/XCL
Non-Sold
Disk Finisher Sta- 108R00053

ple Cartridge
All
Fuser Module
40ppm 115v
All
Non-Sold
Fuser Module 55/

65ppm 115v
109R329
NASG/XCL
Sold
Developer Material Replacement

Kit
Fuser Module 55/

65ppm 115v
109R330
NASG/XCL
Non-Sold
MFF Main Stapler 8R12912

Loaded Cartridge
All
1 Pack
Fuser Module
40ppm 115v
109R342
ACO
Sold
MFF Main Stapler

Cartridge Refill
8R12898
All
3 Pack
Fuser Module
40ppm 115v
109R343
ACO
Non-Sold
MFF Booklet Staple Cartridge
8R12897
All
8 Pack
Fuser Module 55/

65ppm 115v
109R344
ACO
Sold
Fuser Module 55/

65ppm 115v
109R345
ACO
Non-Sold
Fuser Module
40ppm 200v
109R338
ACO
Sold
Fuser Module
40ppm 200v
109R339
ACO
Non-Sold
Fuser Module 55/

65ppm 200v
109R340
ACO
V0.042
Sold
600K88840
Sold
Cleaning and Lubrication Materials

CAUTION
The contacts on connectors used in this machine are gold-plated. Do not use contact cleaner
on these connectors. The use of any type of contact cleaner could cause intermittent problems
due to the chemical residue left by the cleaner.
Table 6 Cleaning and Lubrication Materials
Part Number
Description
43P81
Lens and Mirror Cleaner
600T91872
Silicone Glass Treatment
May 2003
6-127
General Procedures
Table 6 Cleaning and Lubrication Materials

Part Number
Description
43P48
Formula A Cleaner
43P45
Film Remover
8R90176
Cleaner (XE equivalent for Film

Remover)
600S4372
Cleaning Cloth
43P46
Pumice Paper
43P74
Scotch-brite scouring pad
70P81
Lubricant, plastic-to-plastic or plasticto-metal
70P87
Lubricant, metal-to-metal
General Procedures
May 2003
6-128
V0.042
Change Tag Introduction

Purpose
Each modification to the system is assigned a unique tag number. This section of the service
documentation contains a listing and brief description of all change tags. It also references the
diagnostic routine used to access and enter, store and retrieve hardware upgrade information
contained in the machine's Non-Volatile Memory (NVM).
Change tags listed in this section are arranged according to the applicable machine subsystem. The subsystem to which the tag pertains is identified by the tag prefix letter (i.e.; tag F051 applies to the Finisher). The various subsystem prefixes are:
No prefix - IOT Tags
F - Finisher Tags
H - High Capacity Feeder (HCF) Tags
M - Multi-Function Finisher (MFF) Tags
If the machine configuration is changed between service calls, the CSE will be instructed to
load the tag matrix information during the current service call entry. For more information or to
view the tag placement/removal procedures refer to [Configuration tab , Machine Configuration
and Tag Matrix].
Procedure
Information included within each tag is as follows:
Tag Number - Lists the control number for the tag.
Classification Codes - Lists the Classification Codes as follows:

M (Mandatory) - Any modification which must be installed because of safety issues
or important operational differences.
S (Situational) - Any modification which is installed only in specific situations and is
not cut in Manufacturing.
O (Optional) - Any modification which is installed as a special customer option and
is not needed to repair or retrofit the machine.
R (Repair) - Any modification which is installed in order to repair a component.
N (Not installed in the field) - Any modification which is installed only in Manufacturing and cannot be installed in the field.
Use - Lists the multinational operating markets affected by the modification.
Manufacturing Serial Number - Lists the first serial number of the factory built machines
with the modification installed.
Name - Lists the name of the part or modification.
Purpose - Gives a brief description of the modification.
Kit Number - Lists the part number of the kit required to install the modification.
Reference - Lists the Parts List where the kit or modification part can be found.
The term N/A anywhere in the tag information identifies anything that is Not Applicable or Not
Available.
V0.042
May 2003
6-129
General Procedures
General Procedures
May 2003
6-130
V0.042
TAG:
001
TAG:
004
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
PURPOSE:
Replacement Paper Feed Drives Plate (P/N 7K09043)
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Replacement Inverter (P/N 50K34391)
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 4.1A
REFERENCE:
PL 6.2A
TAG:
002
TAG:
005
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
Lower Paper Guide
PURPOSE:
Replacement Lower Paper Guide (P/N 55E37323)
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Replacement Duplex Transport (P/N 22K50980)
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 4.1A
REFERENCE:
PL 6.1A
TAG:
003
TAG:
006
CLASS:
CLASS:
USE:
all markets
USE:
all markets
NAME:
N/A
PURPOSE:
Replacement Developer Collector Sensor (P/N 130K54515)
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Replacement Developer Drive Motor (F1 P/N 15K30321) (F2 P/N 15K30331)
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 5.1B
REFERENCE:
PL 7.1
May 2003
6-131
N/A
KIT NUMBER:
V0.042
N/A
Duplex Transport
KIT NUMBER:
MFG SERIAL NUMBERS:
N/A
Inverter
General Procedures
TAG:
007
TAG:
010
CLASS:
CLASS:
USE:
USCO, UK, FX
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
User Interface Assembly and version 1.0 (L0.15.5) software
PURPOSE:
NAME:
Replacement User Interface Assembly (P/N 101K32221 US, 101K32231 UK,

101K32241 FX) and version 1.0 (L0.15.5) software (P/N 635K04610). Superseded by TAG 021.
KIT NUMBER:
N/A
REFERENCE:
PL 1.1A
TAG:
008
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
USE:
N/A
2UP57698, E6D88173
Add new Decurler (P/N 22K59520) to meet curl specs.
KIT NUMBER:
N/A
REFERENCE:
PL 6.1A
Not assigned.
KIT NUMBER:
REFERENCE:
TAG:
011
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
Dual Decurler
PURPOSE:
PURPOSE:
NAME:
PURPOSE:
Change to new LVPS and gold-contact Front Door Interlock Switch.
KIT NUMBER:
N/A
REFERENCE:
PL 1.1A, PL 1.2A
TAG:
012
M
USE:
all markets
TAG:
009
CLASS:
CLASS:
MFG SERIAL NUMBERS:
USE:
MFG SERIAL NUMBERS:
NAME:
PURPOSE:
NAME:
N/A
Low Voltage Power Supply Output Resistor (CANCELLED)
PURPOSE:
Not assigned.
KIT NUMBER:
REFERENCE:
N/A
Low Voltage Power Supply (Venray)
KIT NUMBER:
5 Ohm resistor added between the LVPS and the SCAM PWB for 36V output
surge protection. (Surge current from LVPS causes 09-370, 372, 374, and 376
faults.) NOTE: This tag is needed only on machines without Tag 011. The Tag
011 LVPS has this resistor built-in. Superseded by TAG 011.
N/A
REFERENCE:
General Procedures
May 2003
6-132
V0.042
TAG:
013
TAG:
016
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
Donor Roll/ Photoreceptor Gap
PURPOSE:
NAME:
New Donor Roll bearings (in Developer Housing) changed to improve gap. Was
causing 09-338, 318 faults.
PURPOSE:
Change CVT Skis, P/O CVT Drive On Glass Kit to correct the problem of image
bands on halftone originals in DADF mode. Superseded by TAG 060.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 5.1B
REFERENCE:
PL 2.4
TAG:
014
TAG:
017
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
Top Edge Electronic Registration (TEER) Sensor (P/O Duplex Transport)
PURPOSE:
NAME:
A sensor is added to the Duplex Transport to detect the outboard edge of each
sheet in order to improve Top Edge Registration. Requires version 1.1 or higher
software.
KIT NUMBER:
N/A
REFERENCE:
PL 6.1A
PURPOSE:
The TEER Sensor in the Duplex Transport was changed to improve top edge
registration on A4 paper.
KIT NUMBER:
N/A
REFERENCE:
PL 6.1A
018
CLASS:
USE:
all markets
all markets
MFG SERIAL NUMBERS:
015
CLASS:
USE:
MFG SERIAL NUMBERS:
N/A
Atlanta Gold Main Control PWB
PURPOSE:
NAME:
N/A
Top Edge Electronic Registration (P/O Duplex Transport) for A4 paper.
TAG:
TAG:
NAME:
N/A
N/A
CVT backup guides (Skis)
N/A
Atlanta Gold Main Control PWB EME Fix
PURPOSE:
Replace Atlanta 95/96 Main Control PWB with Atlanta Gold Main Control
PWB. ALSO REQUIRES TAG 018.
Reduce Main Control PWBA noise (EME) with Atlanta Gold. This kit, which is
required in addition to the PWB when replacing Atlanta '96 with Atlanta Gold,
also includes the NVM RAM Chip.
KIT NUMBER:
N/A
KIT NUMBER:
606K06710
REFERENCE:
PL 1.4A
REFERENCE:
PL 1.4A, PL 3.1 , PL 3.2
V0.042
May 2003
6-133
General Procedures
TAG:
019
TAG:
022
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
Version 1.11 (L0.15.6.15) Software
PURPOSE:
NAME:
Fix User Interface language problem in version 1.1 (L0.15.6.14) software (see
TAG 021). This kit also includes improved PWS software. Supersedes TAG
021. Superseded by TAG 029.
PURPOSE:
Preset curl level for FInisher-equipped machines by locking the decurler at one
setting and disconnecting it from software control. Corrects curl control problems causing finishing problems. Superseded by Exit Baffle (no TAG).
KIT NUMBER:
N/A
KIT NUMBER:
600K67670
REFERENCE:
N/A
REFERENCE:
PL 6.1A
TAG:
020
TAG:
023
CLASS:
CLASS:
USE:
all markets
USE:
FX only
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
DADF Anti-Kickback Pad
PURPOSE:
NAME:
New Anti-Kickback Pad to correct excessive kick-back of the last sheet in the
DADF input tray.
PURPOSE:
Software Upgrade to Version 1.20 (L0.15.7.14) for FX machines only. Supersedes TAG 019 and TAG 021. Superseded by TAG 029.
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 2.1A
REFERENCE:
N/A
TAG:
021
TAG:
024
CLASS:
CLASS:
USE:
all markets
USE:
all markets
NAME:
N/A
MFG SERIAL NUMBERS:
Version 1.1 (L0.15.6.14) Software.
PURPOSE:
NAME:
Software Upgrade (from L0.15.5 to L0.15.6.14), enables Top Edge Electronic

Registration (TAG 014). Supersedes TAG 007. Superseded by TAG 019.
PURPOSE:
Physical changes to the machine to reduce EME. These are factory-only

changes.
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
REFERENCE:
N/A
May 2003
6-134
N/A
EME Changes
KIT NUMBER:
General Procedures
N/A
Version 1.20 (L0.15.7.14) Software-- FX only
KIT NUMBER:
MFG SERIAL NUMBERS:
N/A
Decurler Disconnection
V0.042
TAG:
025
TAG:
028
CLASS:
CLASS:
USE:
FX only
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
Size Sensing
PURPOSE:
MFG SERIAL NUMBERS:

NAME:
N/A
PURPOSE:
EME changes to the Photoreceptor Drives Module (P/N 64K01222 and higher).
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
REFERENCE:
PL 5.1A
TAG:
026
TAG:
029
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
DADF CVT Motor Ground Wire
PURPOSE:
Install a ground wire on the CVT Motor to correct CVT Motor encoder faults.
Superseded by TAG 084.
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
027
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
N/A
Decurler Drive Pulley Change
PURPOSE:
KIT NUMBER:
Change a pulley on the Decurler Drive Bracket. Found to have undesired

effects -- superseded by TAG 030.
N/A
REFERENCE:
V0.042
NAME:
Software Upgrade to Version 1.12 (L0.15.6.16) to correct Foreign Interface

problem with external Auditron devices. Supersedes TAG 019. Superseded by
TAG 041.
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
030
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
N/A
Removal of Tag 027
PURPOSE:
Undo TAG 027 by changing to a new Decurler Drive Bracket.
KIT NUMBER:
N/A
REFERENCE:
PL 7.1
May 2003
6-135
2UP059719,E6D883836,E8D898003,E2C020053,E10858028+
Version 1.12 (L0.15.6.16) Software.
PURPOSE:
NAME:
2UP058491, E6D883657
Photoreceptor Drives Module ESD Changes
General Procedures
TAG:
031
TAG:
034
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
EME Changes (not required)
PURPOSE:
Physical changes to the machine to reduce EME. These are factory-only

changes.
KIT NUMBER:
N/A
REFERENCE:
PL 8.5
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Prevent cutting injury.
KIT NUMBER:
N/A
REFERENCE:
PL 6.1A
035
CLASS:
USE:
all markets
all markets
MFG SERIAL NUMBERS:
032
CLASS:
USE:
MFG SERIAL NUMBERS:
N/A
Prefuser Transport (PFT) Safety Clip
PURPOSE:
Prevent accidental PFT removal.
KIT NUMBER:
605K09091
REFERENCE:
PL 6.1A
TAG:
033
CLASS:
NAME:
PURPOSE:
Prevent accidental Fuser removal.
KIT NUMBER:
605K09100
REFERENCE:
PL 6.2A
TAG:
036
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
NAME:
NAME:
PURPOSE:
Increase NVM RAM, increasing number of possible Auditron accounts from 500
to 1800.
KIT NUMBER:
KIT NUMBER:
N/A
REFERENCE:
REFERENCE:
PL 1.4A
May 2003
6-136
N/A
128K NVM RAM Chip
PURPOSE:
General Procedures
N/A
Fuser Safety Retainer
USE:
Not assigned
N/A
Safety: File Prefuser Transport (PFT) Sharp Corners
TAG:
TAG:
NAME:
N/A
V0.042
TAG:
037
TAG:
040
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
2UP060926, E6D884209
MFG SERIAL NUMBERS:
DADF Deflector Fingers
PURPOSE:
NAME:
Install mylar fingers onto the Takeaway Roll Idler Baffle to limit jams of curled
originals.
KIT NUMBER:
N/A
REFERENCE:
PL 2.1B
PURPOSE:
Controllable curl level for OCT-equipped machines: The decurler is connected

electrically and controlled by software through an IIOC. Supersedes TAG 022
when installed.
KIT NUMBER:
N/A
REFERENCE:
PL 6.1A
TAG:
038
CLASS:
TAG:
041
XL only
CLASS:
USE:
all markets
USE:
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
CISPR B Changes
PURPOSE:
NAME:
Meet CISPR B certification requirements
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
039
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
DADF Shafts Grounding
PURPOSE:
Reduce occurrence of 19-404 DVMA time-out faults. Superseded by TAG 048.
KIT NUMBER:
N/A
REFERENCE:
PL 2.3
V0.042
Software Upgrade to Version 1.21 (L0.15.7.19); supersedes TAG 019, TAG

021, and TAG 029. Superseded by TAG 061.
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
042
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
New Atlanta Gold Main Control PWB
PURPOSE:
NVM socket fix and Ultra SCSI enablement. Superseded by TAG 052.
KIT NUMBER:
N/A
REFERENCE:
PL 1.4A
May 2003
6-137
N/A
PURPOSE:
N/A
N/A
Enabled Decurler
General Procedures
TAG:
043
TAG:
046
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
NAME:
Enable feeding of small (e.g. 5.5 x 8.5 in.) paper from Trays 1-4. Superseded
by TAG 063.
KIT NUMBER:
606K06921
REFERENCE:
PL 4.1A
PURPOSE:
Switch Change on Paper Feed Drives Plate
KIT NUMBER:
N/A
REFERENCE:
PL 4.1A
047
CLASS:
USE:
all markets
all markets -- DC only
MFG SERIAL NUMBERS:
044
CLASS:
USE:
MFG SERIAL NUMBERS:
2UP060926, E6D884209
NAME:
Image Disk Alternative Power Harness
PURPOSE:
KIT NUMBER:
605K09180
REFERENCE:
PL 1.3B
TAG:
045
CLASS:
USE:
all markets
606K06950
REFERENCE:
PL 5.1A
TAG:
048
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
N/A
N/A
New DADF Feeder Assembly
PURPOSE:
NVM Change for DADF
PURPOSE:
Limit Photoreceptor Belt snagging when Xerographic Module is removed.
KIT NUMBER:
NAME:
2UP060926, E6D884209
Photoreceptor Drive Module Clip
PURPOSE:
Correct the "degraded mode" problem which can occur when coming out of
Power Saver. Supplies power to the Image Disk from the ESS PWB connector
on the low voltage harness, instead of from the Main Control PWB. Superseded
by TAG 051.
N/A
Switch Change on Paper Feed Drives Plate
TAG:
TAG:
NAME:
MFG SERIAL NUMBERS:
Trays 1-4 Small Paper Size Sensing
PURPOSE:
NAME:
N/A
Improve document feeding performance. Supersedes TAG 039.
KIT NUMBER:
605K09220
REFERENCE:
PL 2.2
NVM Change for DADF
KIT NUMBER:
N/A
REFERENCE:
N/A
General Procedures
May 2003
6-138
V0.042
TAG:
049
TAG:
052
CLASS:
CLASS:
USE:
FX only
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
NAME:
NAME:
Size Sensing Enablement
PURPOSE:
PURPOSE:
Enables Loading ESS software via Main Control PWB. Supersedes TAG 042.
Superseded by TAG 065.
KIT NUMBER:
REFERENCE:
TAG:
050
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
Inspect AC Distribution Panel for loose terminals on Relay K2, and mark off
Tag. (Replace AC Distribution Panel if relay terminals are loose.)
KIT NUMBER:
N/A
REFERENCE:
PL 1.2A
TAG:
051
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
N/A
REFERENCE:
PL 1.4A
TAG:
053
CLASS:
USE:
all markets
NAME:
N/A
Enables ESS PWB power while maintaining "degraded mode" fix. Supersedes
TAG 044
Replace AC Distribution Panel with one containing new relay. Required for AC
convenience outlet for PWS.
KIT NUMBER:
N/A
REFERENCE:
PL 1.2A
TAG:
054
CLASS:
USE:
FX only
MFG SERIAL NUMBERS:

NAME:
N/A
PURPOSE:
REFERENCE:
PL 1.3A
KIT NUMBER:
N/A
REFERENCE:
N/A
May 2003
6-139
N/A
L0.15.7.20 Software (FX only)
KIT NUMBER:
V0.042
2UP071585, 3UP060357, E5C045145, H6E015147,

R4F036970, R5F020001
New Relay on AC Distribution Panel
PURPOSE:
ST/LP Card Cage Low Voltage Power Harness
PURPOSE:
KIT NUMBER:
MFG SERIAL NUMBERS:
AC Distribution Panel Inspection for Loose Relay Terminals.
PURPOSE:
NAME:
2UP060926, E6D884209
N/A
New Atlanta Gold
N/A
General Procedures
TAG:
055
TAG:
058
CLASS:
CLASS:
USE:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
NAME:
NAME:
New Developer Drive Motor
PURPOSE:
KIT NUMBER:
N/A
REFERENCE:
PL 7.1
TAG:
056
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
2UP060800 - 2UP061999
PURPOSE:
Extend Developer Housing life span from approximately 500k prints to machine
end-of-life.
KIT NUMBER:
600K68112 and higher
REFERENCE:
PL 5.1B
TAG:
059
CLASS:
USE:
all markets -- Prelaunch ST and LP machine only
MFG SERIAL NUMBERS:
Fuser Drive Motor

Replace defective Fuser Drive Motor which will otherwise fail 1-2 months after
installation.
NAME:
PURPOSE:
Software Upgrade to Version 3.02 (L0.17.1.23). Superseded by TAG 067.
See Bulletin #287
KIT NUMBER:
635K04741
REFERENCE:
PL 7.1
REFERENCE:
N/A
TAG:
057
TAG:
060
CLASS:
CLASS:
USE:
all markets
USE:
NAME:
N/A
Aluminum ROS
PURPOSE:
Improve ROS performance. Includes replaceable Polygon Motor.
MFG SERIAL NUMBERS:

NAME:
3-Ski CVT Drive On Glass
PURPOSE:
Improved document handling. Supersedes TAG 016. Superseded by TAG 075.
KIT NUMBER:
N/A
KIT NUMBER:
600K67892
REFERENCE:
PL 5.2
REFERENCE:
PL 2.4
General Procedures
N/A
KIT NUMBER:
MFG SERIAL NUMBERS:
N/A
Longer-life Developer Housing
May 2003
6-140
V0.042
TAG:
061
TAG:
064
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
PURPOSE:
NAME:
Software Upgrade to Version 1.30 (L0.15.8.01); supersedes TAG 041. Superseded by TAG 073.
KIT NUMBER:
N/A
REFERENCE:
N/A
PURPOSE:
Replace Image Disk Drive with new, larger capacity drive
KIT NUMBER:
N/A
REFERENCE:
PL 1.3A
065
CLASS:
USE:
all markets
all markets
MFG SERIAL NUMBERS:
062
CLASS:
USE:
MFG SERIAL NUMBERS:
N/A
NAME:
Touch-screen Defects Fix
PURPOSE:
PURPOSE:
ST/LP only: SCVM Chip change prevents Scanner faults at power-up if host is
connected to ESS parallel port. Supersedes TAG 052.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 1.1A
REFERENCE:
PL 1.4A
TAG:
063
TAG:
066
CLASS:
CLASS:
USE:
all markets
USE:
all markets
NAME:
N/A
MFG SERIAL NUMBERS:
Trays 1-4 Small and A4 size sensing
PURPOSE:
NAME:
New Paper Tray Switch Actuators to enable small and A4 size sensing. Supersedes TAG 043.
PURPOSE:
Misfeed sensor location changed on trays 1-4 Upper Guides. Avoids 08-115
faults with 2- or 4-hole paper.
606K06921
KIT NUMBER:
606K07030
REFERENCE:
PL 4.1C
REFERENCE:
PL 4.1A
May 2003
6-141
N/A
A4 4-hole and 8.5 x 14 2-hole paper Enablement
KIT NUMBER:
V0.042
N/A
New Main Control PWB for Parallel-Port Printing
Touch-screen Defects Fix
MFG SERIAL NUMBERS:
2UP065838, E4E020482
2.0 Gb Image Hard Drive
TAG:
TAG:
NAME:
N/A
General Procedures
TAG:
067
TAG:
070
CLASS:
CLASS:
USE:
all markets -- Prelaunch ST and LP machine only
USE:
all markets -- ST and LP machines only
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
PURPOSE:
NAME:
Software Upgrade to Version 3.03 (L0.17.1.25). Supersedes TAG 059. Superseded by TAG 068.
N/A
Version 5.01 (L0.17.4.10) Software (ST/LP-Launch Software Version)
PURPOSE:
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
REFERENCE:
N/A
TAG:
068
TAG:
071
CLASS:
CLASS:
USE:
all markets -- Prelaunch ST and LP machines only
USE:
all markets -- ST, LP, and DT65 machines only
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
PURPOSE:
NAME:
KIT NUMBER:
N/A
REFERENCE:
N/A
PURPOSE:
KIT NUMBER:
N/A
REFERENCE:
PL 7.1
TAG:
072
CLASS:
USE:
all markets
TAG:
069
CLASS:
USE:
FX only
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:

NAME:
LVPS change
PURPOSE:
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
General Procedures
N/A
NAME:
N/A
Inverter Change
PURPOSE:
Inverter change, to support possible future change.
KIT NUMBER:
N/A
REFERENCE:
PL 6.2A
May 2003
6-142
N/A
V0.042
TAG:
073
TAG:
076
CLASS:
CLASS:
USE:
all markets
USE:
all markets -- DC and ST only
MFG SERIAL NUMBERS:
NAME:
MFG SERIAL NUMBERS:
PURPOSE:
NAME:
Software Upgrade to Version 5.03 (L0.17.5.08). Supersedes TAG 061 and TAG
070. Superseded by TAG 074.
KIT NUMBER:
635K06782
REFERENCE:
PL 1.4A
TAG:
074
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
NAME:
2UP075303, 1UP040042, 3UP061265, E2D867002,

E5C045241, E5D943259, E8D898528, H6E015359,
H7E030273, R5F020001, R7F025087, T6C015001,
T7C025137
1UP040123, 2UP077428, 3UP062596, E2C022440,

E5C045296, E8C944200, E2D867002, E5D943259,
E8D898696, R4F037857, R5F020001, R6F016043,
R7F025087, T6C015001, T7C025137
635K06784
REFERENCE:
PL 1.4A
The Viewing Label facilitates cleaning the CVT Document Glass, and the Dirt/
Streaks Label reduces the amount of dirt transferred from the document to the
CVT Glass and causing streaks on copies. Each kit contains 6 of each label,
sufficient for 6 machines.
KIT NUMBER:
600K75950
REFERENCE:
PL 3.1
TAG:
077
CLASS:
USE:
all markets
NAME:
KIT NUMBER:
CVT Viewing and Dirt Labels
PURPOSE:
MFG SERIAL NUMBERS:
PURPOSE:
Cost Reduction vs. Atlanta Gold
KIT NUMBER:
600K81900
REFERENCE:
PL 1.4A , PL 1.4B
TAG:
078
CLASS:
USE:
All markets
075
CLASS:
USE:
all markets -- DC and ST only
MFG SERIAL NUMBERS:
NAME:
N/A
NAME:
Single-Ski Drive-On-Glass Roll Kit
PURPOSE:
KIT NUMBER:
600K67893
REFERENCE:
PL 2.4, PL 1.4B
V0.042
Eliminate creasing of 16 lb. documents in DADF reg. rolls.
KIT NUMBER:
N/A
REFERENCE:
PL 2.1B
May 2003
6-143
N/A
DADF 16 lb. Document Handling
PURPOSE:
Single-Ski Drive-On-Glass Roll Kit. Required for Electronic Hole Removal TAG
296, TAG 080, or TAG 285). Supersedes TAG 060.
1UP041007, 3UP068320, E5C045296, R5F021729,

T6C015065, R4F039888, 2UP082005, E2C023092
Atlanta Platinum Main Control PWB
PURPOSE:
TAG:
MFG SERIAL NUMBERS:
1UP040523, 2UP079194, 3UP064444, E2C021689,

E5C045296, R4F038382, R5F020473, R6F0106043,
R7F025088, T6C015064, T7C025137, E2D867002,
E5D943260, E8D898701
General Procedures
TAG:
079
TAG:
082
CLASS:
CLASS:
USE:
all markets -- HCF-equipped machines only
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
NVM Change for HCF Feed Improvement
PURPOSE:
NAME:
Change HCF stack height NVM, as part of HCF feed performance improvement. 600K75870 also installs TAG H007; 606K07180 also installs TAG H112
PURPOSE:
Cost-down User Interface Assembly, in which the UI Processor PWB and UI

LCD Module are spared, but the Backlight is not spared.
KIT NUMBER:
600K75870; 606K07180
KIT NUMBER:
TBD
REFERENCE:
PL 4.2B
REFERENCE:
PL 1.1A
TAG:
080
TAG:
083
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
Electronic Hole Removal (EHR) for Atlanta Platinum Main Control PWB
PURPOSE:
Eliminate black dots when copying drilled/punched originals with Document

Glass Cover raised. This Non-Saber EHR PWB for Atlanta Platinum (TAG
077) is not interchangeable with the TAG 296 Saber EHR PWB for Atlanta
Gold. Also includes Single-Ski CVT Drive-On-Glass Roll (TAG 075).
KIT NUMBER:
N/A
REFERENCE:
PL 1.4B
TAG:
081
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
NAME:
N/A
1UP040649, 2UP079599, 3UP065324 and 065237 up,

E2C021979, E5C045296, R4F038589, R5F020505,
R6F0106043, R7F025088, T6C015064, T7C025137,
E2D867002, E5D943260, E8D898701
NAME:
Improved UI flash RAM. New UI Assembly may not be loaded with software
lower than L0.17.5 (V5.03, TAG 073).
KIT NUMBER:
N/A
Replaces Disabled Decurler for Finisher-equipped machines. Supersedes TAG

022. Superseded by TAG 085. Initial cut-in of Exit Baffle (600K75200) was not
tagged.
KIT NUMBER:
600K75201
REFERENCE:
PL 6.1A
TAG:
084
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
REFERENCE:
PL 1.1A
General Procedures
NAME:
1UP040523, 2UP079194, 3UP064444, E2C021689,

E5C045296, R4F038382, R5F020473, R6F0106043,
R7F025088, T6C015064, T7C025137, E2D867002,
E5D943260, E8D898701
CVT Motor Grounding
PURPOSE:
Eliminate electrostatic buildup that causes 05-370 faults and magnification

problems without a fault code. Supersedes TAG 026.
KIT NUMBER:
606K07220
REFERENCE:
PL 2.3
May 2003
6-144
1UP040523, 2UP079194, 3UP064444, E2C021689,

E5C045296, R4F038382, R5F020473, R6F0106043,
R7F025088, T6C015064, T7C025137, E2D867002,
E5D943260, E8D898701
Exit Baffle
PURPOSE:
UI Change
PURPOSE:
N/A
UI Cost-down
V0.042
TAG:
085
TAG:
088
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:
NAME:
1UP040808, 2UP080819, 3UP066316, E2C022128,

E5C045296, R4F038787, R5F020748, R6F016043,
R7F025088, T6C015065, T7C025137, E0C030006,
E8C944200, E2D867002, E5D943260, E8D898701,
H6E016006, H7E030294
600K75202
REFERENCE:
PL 6.1A, PL 6.2C
TAG:
086
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
630K10941
REFERENCE:
N/A
TAG:
087
CLASS:
USE:
all markets
PL 5.1B
TAG:
089
CLASS:
USE:
all markets
KIT NUMBER:
630K10943
REFERENCE:
PL 1.1A, PL 1.4A, PL 1.4B
TAG:
090
CLASS:
USE:
all markets
NAME:

Software Upgrade to Version 5.08 (L0.17.8.65). Identical to Version 5.07
(L0.17.8.64) software (TAG 086), except supports Atlanta Platinum PWB (TAG
077). Supersedes TAG 086. Superseded by TAG 089.
KIT NUMBER:
630K10942
REFERENCE:
N/A
V0.042
Cost-down. In machines equipped with Exit Baffles (for use with Finishers)
instead of Decurlers, the Decurler Drive Bracket and Decurler Drive Belt are not
required.
KIT NUMBER:
N/A
REFERENCE:
PL 7.1
May 2003
6-145
N/A
Decurler Drives Elimination
PURPOSE:
1UP040829, 2UP080819, 3UP066404, E2C022707,

E5C045296, R4F039125, R5F020781
1UP041007, 3UP068320, E5C045296, R5F021729,

T6C015065, R4F039888, 2UP082005, E2C023092
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
PURPOSE:
600K88070
REFERENCE:
PURPOSE:
Software Upgrade to Version 5.07 (L0.17.8.64). High Altitude machines (with

TAG 297) also require new High Altitude Developer Housing or Gears (TAG
292). Supersedes TAG 293 and TAG 074. Superseded by TAG 087.
KIT NUMBER:
KIT NUMBER:
NAME:
PURPOSE:
Fix incorrect magnetic seal orientation, that was one of many causes of pencilline-like smears.
MFG SERIAL NUMBERS:

1UP040829, 2UP080819, 3UP066404, E2C022707,
E5C045296, R4F039125, R5F020781
1UP041007, 2UP082005, 3UP068584, E2C023092,

E5C045296, R4F039888, R5F021729, T6C015064,
T7C025137, H6E016719, H7E030294
Developer Housing Top Cover Magnetic Seal Orientation
PURPOSE:
Eliminate the problem of the entrance baffle coming loose in jam clearance,
and interfering with the Inverter Drawer. Supersedes TAG 083.
KIT NUMBER:
NAME:
NAME:
Improved Exit Baffle
PURPOSE:
NAME:
MFG SERIAL NUMBERS:
General Procedures
TAG:
091
TAG:
094
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
1UP041280, 3UP073654, E5C045296, R5F024473,

H6E017314
NAME:
Common Hard Disk Drive (4.5 GB)
PURPOSE:
600K88170
REFERENCE:
PL 1.3A, PL 1.3C
TAG:
092
CLASS:
USE:
all markets -- DT65/DP65 only
KIT NUMBER:
630K11383
REFERENCE:
N/A
TAG:
095
CLASS:
USE:
all markets
NAME:
H6E016802, H7E030294
Rubber feet reduce monitor slipping.
KIT NUMBER:
N/A
REFERENCE:
N/A
Software Upgrade to Version 6.04 (L0.18.1.26). Refer to Bulletin #382. Superseded by TAG 099 .
KIT NUMBER:
630K11384
REFERENCE:
PL 1.1A, PL 1.4A, PL 1.4B
TAG:
096
CLASS:
USE:
all markets
TAG:
093
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:

NAME:
1UP041073, 2UP082252, 3UP069190, E2C023101,

E5C045296, R4F039888, R5F022057, H6E016777
NAME:
PURPOSE:
Screw added, plus center tab height changed to reduce the bow of the bottom
plate.
KIT NUMBER:
N/A
REFERENCE:
PL 6.1A
General Procedures
Not yet assigned.
KIT NUMBER:
N/A
REFERENCE:
N/A
May 2003
6-146
N/A
N/A
PURPOSE:
PFT Noise Reduction and 10-101 Fault Fix
1UP-041238, 2UP-083613, 3UP-072398, E2C-023390,

E5C-054296, R4F-040838, R5F-024026
PURPOSE:
Monitor Feet
PURPOSE:
Software Upgrade to Version 6.03 (L0.18.1.24). Refer to Bulletin #373. Superseded by TAG 095.
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
N/A
PURPOSE:
4.5 GB Common Hard Disk Drive installed in the Image Disk location. When
this Tag is present, the same drive can be installed in either the Image Disk
location or the ESS location, provided the correct jumper is removed for the
ESS Disk Drive per the kit instructions.
KIT NUMBER:
NAME:
MFG SERIAL NUMBERS:
V0.042
TAG:
097
TAG:
100
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
Image Quality Fix for EHR
PURPOSE:
NAME:
New Main Control PWB to resolve image quality problem when Electronic Hole
Removal (EHR) is enabled (TAG 080).
KIT NUMBER:
N/A
REFERENCE:
N/A
PURPOSE:
Paper Tray Slides Repair Kit
KIT NUMBER:
600K89760
REFERENCE:
PL 4.1A
101
CLASS:
USE:
all markets
all markets
MFG SERIAL NUMBERS:
098
CLASS:
USE:
MFG SERIAL NUMBERS:
H6E017455, H7E030294
NAME:
Version 5.14 (L0.17.9.28) Software for DT65/DP65 Only
PURPOSE:
N/A
REFERENCE:
N/A
PURPOSE:
Version 7.00 (L0.19.0.27) Software to support ESG Launch of 460/470 plus

NASG demo 460/470 machines. Refer to Bulletin #395. Superseded by TAG
102.
KIT NUMBER:
630K11660
REFERENCE:
N/A
TAG:
099
CLASS:
TAG:
102
all markets
CLASS:
USE:
all markets
USE:
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
Version 6.08 (L0.18.6.07) Software (Service Maintenance Pack release)
PURPOSE:
Software Upgrade to Version 6.08 (L0.18.6.07). Refer to Bulletin #396. Supersedes TAG 095.
KIT NUMBER:
635K09281
REFERENCE:
N/A
NAME:
Version 7.01 (L0.19.0.28) Software to support Worldwide Launch of 460/470.

Refer to Bulletin #398. Supersedes TAG 101.
KIT NUMBER:
630K11661
REFERENCE:
PL 1.4C
May 2003
6-147
NE0000660, 679, 706, 786, 832, 843; NE4000588, 595,

608, 609, 611- 613, 615, 617- 619, 622, 624, 626-628, 630633, 636, 637, 639, 642; ND8000659, 670, 672, 686, 690,
701, 702, 713, 719, 741, 760, 761; NE8000548, 637, 641,
645, 648-661, 664, 665, 666, 672, 674, 675, 677-694
PURPOSE:
V0.042
N/A
Version 5.14 (L0.17.9.28) Software for DT65/DP65 Only
KIT NUMBER:
N/A
Paper Tray Slides Repair Kit
TAG:
TAG:
NAME:
N/A
General Procedures
TAG:
103
TAG:
108
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
MW9-000586, NE4-001248, H6E-018170, MY0-001079,

NE8-002113, ND8-001235, NE0-003456
NAME:
Common Hard Disk Drive (9.1 GB)
PURPOSE:
N/A
REFERENCE:
PL 1.3A, PL 1.3C
TAG:
104
CLASS:
USE:
all markets
N/A
REFERENCE:
PL 1.5
TAG:
111
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
N/A
Eliminate interference between PWS Cable and 480 Document Glass Cover/
Document Output Tray, while maintaining cable commonality with 240/255/265/
460/470.
KIT NUMBER:
N/A
REFERENCE:
PL 1.2A
Version 7.02 (L0.19.0.56) Software to support Anti-Flicker solution in XE (see

TAG 105).
KIT NUMBER:
630K12050
REFERENCE:
N/A
TAG:
112
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
TAG:
105
NAME:
CLASS:
PURPOSE:
USE:
XE
MFG SERIAL NUMBERS:

NAME:
N/A
Anti-Flicker Circuitry
PURPOSE:
N/A
PURPOSE:
PWS Cable Change
PURPOSE:
New SCAM PWB. Supports Anti-Flicker solution in XE (see TAG 105).
KIT NUMBER:
NAME:
N/A
MSCAM PWB
PURPOSE:
9.1 GB Common Hard Disk Drive installed in the Image Disk location. For
replacing either the Image Disk Drive or the ESS Disk Drive upon failure.
Replaces 50-pin 4.5 GB HDD (with 68 to 50-pin adapter) with a 68-pin 9.1 GB
HDD (with pre assembled 68 to 68-pin terminator). For NLX card cages only.
KIT NUMBER:
NAME:
MFG SERIAL NUMBERS:
N/A
Convenience Stapler Power Harness

Bypass the IIOC circuit to eliminate the Convenience Stapler as a cause of
IIOC failures.
KIT NUMBER:
604K04250
REFERENCE:
PL 1.5
To reduce customer complaints of flickering lights due to peak/inrush current on

the line service when the Fuser cycles. Requires MSCAM PWB (TAG 108) and
minimum L0.19.0.56 software (TAG 111).
KIT NUMBER:
606K07440
REFERENCE:
PL 1.2A
General Procedures
May 2003
6-148
V0.042
TAG:
113
TAG:
119
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
Version 07.19.01.503 Software
PURPOSE:
Issues the 07.19.01.503 software to the 460/470 and enables Smart Tray (NF3)
Finisher to run on a 460/470.
DADF Counterbalance Grounding
PURPOSE:
Adds ground wires and ground clips to IOT interface harness for counterbalance grounding to address ESD problem in DADF.
KIT NUMBER:
604K04250
KIT NUMBER:
604K0xxxx
REFERENCE:
N/A
REFERENCE:
N/A
TAG:
114
TAG:
120
CLASS:
CLASS:
USE:
NASG
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
Right Side Output Finishing Device Interlock Removed (in Manufacturing)
PURPOSE:
Output Finishing Device Interlock is removed in Manufacturing in order to

decrease aborted installs due to suspect switch actuation. Does not apply to
460 DC, due to safety need for interlock with offset catch tray installed.
KIT NUMBER:
N/A
REFERENCE:
PL 1.5
I/O Devices Safety Interlock Removed (in Manufacturing)
PURPOSE:
Removes the left side (HCF) interlock in Manufacturing and inserts an inline
splice in its place to address high abort rates.
KIT NUMBER:
N/A
REFERENCE:
N/A
122
CLASS:
USE:
All
all markets
MFG SERIAL NUMBERS:
115
CLASS:
USE:
MFG SERIAL NUMBERS:
N/A
PURPOSE:
Covers Upgraded for 460/470
PURPOSE:
Identifies cutin of sixth-generation covers for the 460/470 product refresh.
KIT NUMBER:
N/A
REFERENCE:
PL 1.1A, PL 2.1A, PL 3.1, PL 4.1A, PL 4.2A, PL 4.2B, PL 4.3, PL 7.2, PL

7.3, PL 7.4, PL 8.1, PL 8.2, PL 8.3, PL 8.5
V0.042
N/A
NAME:
TAG:
TAG:
NAME:
N/A
N/A
NAME:
KIT NUMBER:
N/A
PARTS LIST ON:
N/A
May 2003
6-149
N/A
IDE ESS Disk Drive requires different data cable and Riser PWB, and BIOS
v2.91 or higher on the ESS PWB. Upgrading to this configuration is not currently supported. Replace Tag 122 parts with Tag 122 parts only, and replace
non-Tag 122 parts with non-Tag 122 parts only.
General Procedures
TAG:
123
TAG:
128
CLASS:
CLASS:
USE:
All
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
Decurler Interface Harness
PURPOSE:
New interface harness accommodates new decurler that can be used with a
MFF on 470/480/490.
KIT NUMBER:
N/A
REFERENCE:
PL 6.1A
MFG SERIAL NUMBERS:

PURPOSE:
KIT NUMBER:
PARTS LIST ON:
PL 6.2A
TAG:
129
CLASS:
USE:
all markets
TAG:
124
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
N/A

Issues the 07.19.02.503 software to the 460/470/480/490.
PURPOSE:
PURPOSE:
Issues the 07.19.01.504 software to the 470.
KIT NUMBER:
N/A
REFERENCE:
N/A
N/A
REFERENCE:
N/A
TAG:
131
CLASS:
USE:
all markets
TAG:
125
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
N/A
NAME:
PURPOSE:
KIT NUMBER:
N/A
REFERENCE:
N/A
General Procedures
N/A
NAME:
NAME:
KIT NUMBER:
N/A
Inverter with metallized Mylar grounding strip and new harness to prevent IIOC
failures due to static discharge.
PURPOSE:
The 330 processor chip on 360 and 860 NLX Main PWBA has gone EOL. Manufacturing will cut-in 860 NLX 331 as the replacement. Field will continue to use
current config on machines w/o this tag due to software and hardware dependencies and reman efforts.
KIT NUMBER:
N/A
PARTS LIST ON:
N/A
May 2003
6-150
V0.042
TAG:
133
TAG:
140
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:
N/A
MFG SERIAL NUMBERS:
NAME:
NAME:
PURPOSE:
PURPOSE:
This tag was issued to reduce parts inventory.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
REFERENCE:
PL 1.1A
TAG:
135
TAG:
141
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:
N/A
MFG SERIAL NUMBERS:
NAME:
NAME:
PURPOSE:
PURPOSE:
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
139
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
N/A
Intel Flash U6H1 is no longer available and has been replaced with AMD part
with new Bios..
KIT NUMBER:
N/A
REFERENCE:
PL 1.3C
TAG:
278
CLASS:
USE:
all markets
New ESS PWB
MFG SERIAL NUMBERS:
PURPOSE:
Intel Flash U6H1 is no longer available and has been replaced with AMD part
with new Bios.
NAME:
N/A
REFERENCE:
PL 1.3C
V0.042
N/A
ESS PWB
NAME:
KIT NUMBER:
N/A
UI Costdown Part
N/A
Developer Balanced Sump Gears Kit
PURPOSE:
The purpose of this kit is to balance the sump mass in the developer housing.
The modification consisting of a change of three gears will help copy quality
issues in the field.
KIT NUMBER:
604K13680, 604K702
REFERENCE:
PL 5.1B
May 2003
6-151
General Procedures
TAG:
279
TAG:
284
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
Decurler Kit
PURPOSE:
NAME:
Decurler kit is designed to remove the curl from paper as it exits the IOT. It
works with the Disk Finisher and the MultiFunction Finisher on Document Centre 460/470.
KIT NUMBER:
604K13440
REFERENCE:
PL 6.1D
PURPOSE:
Fixes problem with secure prints spontaneously reprinting 2-3 days after job
submitted. Refer to Bulletin #424.
KIT NUMBER:
630K12150
REFERENCE:
N/A
TAG:
285
CLASS:
USE:
all markets
TAG:
281
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:

NAME:
NAME:
Developer Drive Motor (M1) for DC240
PURPOSE:
604K12840
REFERENCE:
PL 7.1
TAG:
283
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
N/A
606K0xxxx
REFERENCE:
N/A
General Procedures
PL 1.4C
TAG:
286
CLASS:
USE:
all markets
Not yet assigned.
KIT NUMBER:
N/A
REFERENCE:
N/A
May 2003
6-152
N/A
N/A
PURPOSE:
Applies two shims and a stronger nudger roll spring to each of the four paper
drawers. Shims will fix paper side guides in position for specific widths and
NVM values will be adjusted to optimize feed performance.
KIT NUMBER:
606K07430
REFERENCE:
MFG SERIAL NUMBERS:
Heavyweight Paper Feed Kit
PURPOSE:
Situational retrofit to enable Electronic black Hole Removal on the 460/470

product. Requires TAG 075 single-ski Drive-On-Glass Rolls.
KIT NUMBER:
NAME:
N/A
Electronic Hole Removal (EHR) for 460/470/480/490
PURPOSE:
The 40 ppm unique motor is no longer available. The new spare is a DC 265
motor that has been geared down for 40 ppm, and is provided in a kit along with
the required new Developer Drive Belt.
KIT NUMBER:
NAME:
N/A
N/A
SPAR Release Identified (L0.17.9.34)
V0.042
TAG:
287
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Software Upgrade to Version 5.22 (L0.17.9.32). Refer to Bulletin #387. Supersedes TAG 288.
KIT NUMBER:
630K10945
REFERENCE:
N/A
TAG:
288
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
Software Upgrade to Version 5.18 (L0.17.9.28). Refer to Bulletin #382. Supersedes TAG 089. Superseded by TAG 287 .
KIT NUMBER:
630K10944
REFERENCE:
N/A
TAG:
289
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
Not yet assigned.
KIT NUMBER:
N/A
REFERENCE:
N/A
May 2003
6-153
N/A
N/A
PURPOSE:
V0.042
N/A
PURPOSE:
NAME:
N/A
General Procedures
TAG:
290
TAG:
293
CLASS:
CLASS:
USE:
N/A
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
N/A
PURPOSE:
NAME:
Not yet assigned.
KIT NUMBER:
N/A
REFERENCE:
N/A
291
CLASS:
USE:
all markets -- Customer Field Test Only
MFG SERIAL NUMBERS:
N/A
REFERENCE:
N/A
TAG:
292
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
KIT NUMBER:
REFERENCE:
630K10940
REFERENCE:
N/A
TAG:
294
CLASS:
USE:
all markets
N/A
Speed up Donor Roll on High Altitude Developer Housing only (with TAG 297).
Requires minimum Software Version 5.07 (L0.17.8.64, TAG 086).
Reduce 09-318 faults and frequent image quality set-ups. Part of High Altitude
Kit (TAG 297). Not used when L0.17.8.64 (V5.07, TAG 064) software is
installed.
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
295
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
KIT NUMBER:
N/A
PL 5.1B
REFERENCE:
N/A
May 2003
6-154
N/A
TBD
Gears only: 606K07240. High Altitude Developer Housing Kit:

600K71993.
General Procedures
N/A
"Special Eleven" Xerographic NVM Changes
PURPOSE:
New High Altitude Developer Housing Gears
PURPOSE:
KIT NUMBER:
NAME:
Software Upgrade to Version 6.01 or 6.02 (L0.18.1.19 and L0.18.1.22) -- for

Customer Field Test ONLY.
KIT NUMBER:
Software Upgrade to Version 5.06 (L0.17.8.12). For specific SPAR problems

only. Refer to Bulletin #351. Superseded by TAG 086.
MFG SERIAL NUMBERS:
Version 6.01 and 6.02 (L0.18.1.19 and L0.18.1.22) Software
PURPOSE:
NAME:
N/A
N/A
PURPOSE:
TAG:
NAME:
MFG SERIAL NUMBERS:
TBD
V0.042
TAG:
296
TAG:
299
CLASS:
CLASS:
USE:
USCO only
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
Electronic Hole Removal (EHR) for Atlanta Gold Main Control PWB
PURPOSE:
KIT NUMBER:
606K07132
PL 1.4A, PL 2.4
TAG:
297
CLASS:
USE:
all markets
PURPOSE:
Adds a paper heater for the IOT paper trays. (Also includes components
required to modify the circuitry inside the AC Distribution Panel, if needed.)
KIT NUMBER:
600K76070 (100/120V), 600K76080 (220-240V)
REFERENCE:
PL 1.2B, PL 4.1A
TAG:
300
CLASS:
USE:
all markets
NAME:
High Altitude Air Breakdown Fix
PURPOSE:
Resolve Air Breakdown IQ defects at high altitudes (above 4000 ft. or 1300 m).
Requires minimum L0.17.8.64 (V5.07, TAG 086) or higher software and TAG
292 Gears for Developer Housing. (Kit includes Developer Housing with TAG
292 gears.)
KIT NUMBER:
600K71993
REFERENCE:
PL 5.1B
TAG:
298
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
N/A
HCF Paper Heater Power Outlet
PURPOSE:
N/A
N/A
IOT Paper Heater
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
NAME:
NAME:
Eliminate black dots when copying drilled/punched originals with Document

Glass Cover raised. This Saber EHR PWB for Atlanta Gold (with TAG 015,
without TAG 077) is not interchangeable with the TAG 080 Non-Saber EHR
PWB for Atlanta Platinum. Requires Three-Ski CVT Drive-On-Glass Roll (TAG
060).
REFERENCE:
NAME:
MFG SERIAL NUMBERS:
Adds circuitry to the IOT to provide power for the optional HCF Paper Heater.
(Also includes components required to modify the circuitry inside the AC Distribution Panel, if needed.)
KIT NUMBER:
600K76050 (120V), 600K76060 (220-240V)
REFERENCE:
PL 1.2B, PL 4.2A
N/A
Duplex Transport for Lightweight Paper
PURPOSE:
Enhanced Duplex Transport performance when using lightweight papers
KIT NUMBER:
600K70690
REFERENCE:
PL 6.1A
V0.042
May 2003
6-155
General Procedures
General Procedures
May 2003
6-156
V0.042
TAG:
F001
TAG:
F004
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
S/N 6UP147100
Stacker Tray Drive Belt (100 Teeth)
PURPOSE:
Eliminate Transport Drive Motor stalling.
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Change Set Separator spring and finger to correct sticking.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 8.3 and PL 8.5
REFERENCE:
PL 8.5
TAG:
F002
TAG:
F005
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
Finisher Controller PWB Mounting
PURPOSE:
New Finisher Controller PWB (P/N 160K44451 and higher) with redesigned
mounting bracket.
KIT NUMBER:
N/A
REFERENCE:
PL 8.3
TAG:
F003
CLASS:
USE:
all markets
NAME:
S/N 6UP147213
Set Separator
PURPOSE:
Change Set Separator arm to correct its coming loose.
KIT NUMBER:
N/A
REFERENCE:
PL 8.5
TAG:
F006
CLASS:
MFG SERIAL NUMBERS:

S/N 6UP147100
Safety Guard
PURPOSE:
MFG SERIAL NUMBERS:
USE:
MFG SERIAL NUMBERS:

NAME:
S/N 6UP147100
S/N 6UP147213
Set Separator
New Safety Guard for Stapler (P/N 55E39660)
KIT NUMBER:
N/A
REFERENCE:
N/A
V0.042
NAME:
PURPOSE:
Not yet assigned
KIT NUMBER:
REFERENCE:
May 2003
6-157
General Procedures
TAG:
F007
TAG:
F010
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
Firmware on Finisher Controller PWB
PURPOSE:
Change to eliminate erroneous 12-310 faults.
KIT NUMBER:
N/A
REFERENCE:
PL 8.3
TAG:
F008
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
S/N 6UP147525
S/N 6UP147213
Firmware on Finisher Controller PWB
PURPOSE:
Change to eliminate incorrect profile for first sheet of dual stapled set.
MFG SERIAL NUMBERS:

NAME:
S/N 6UP148073
Tamper Button
PURPOSE:
Install redesigned Tamper Button (P/N 38K11682) for better stacking of 11 x 17

or A3 paper.
KIT NUMBER:
N/A
REFERENCE:
PL 8.2
TAG:
F011
CLASS:
USE:
MFG SERIAL NUMBERS:
NAME:
KIT NUMBER:
N/A
PURPOSE:
REFERENCE:
PL 8.3
KIT NUMBER:
Not yet assigned.
REFERENCE:
TAG:
F009
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
S/N 6UP147590
Safety Guard
PURPOSE:
Change spring on Safety Guard, P/O Disc Baffle Assembly (P/N 48K72253).
KIT NUMBER:
N/A
REFERENCE:
PL 8.3
General Procedures
TAG:
F012
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Install new Service Tray Assembly (P/N 50K40281) to reduce Tamper Motor
noise.
KIT NUMBER:
N/A
REFERENCE:
PL 8.5
May 2003
6-158
S/N 6UP147598
V0.042
TAG:
F013
TAG:
F016
CLASS:
CLASS:
USE:
All
USE:
All
MFG SERIAL NUMBERS:

NAME:
S\N 6UP152492
MFG SERIAL NUMBERS:
Catch Tray Offsetting Fix
PURPOSE:
NAME:
Rework spring to correct pin popping out when offsetting full tray of large paper.
PURPOSE:
New Bales and Cushions (ramps) in Service Tray, to soften Disk Finger "snap."
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 8.4
REFERENCE:
PL 8.5
TAG:
F014
TAG:
F017
CLASS:
CLASS:
USE:
All
USE:
All
MFG SERIAL NUMBERS:

NAME:
S/N 6UP148368
MFG SERIAL NUMBERS:
Safety Gate Performance Improvement
PURPOSE:
NAME:
Replace Disk Baffle Assembly to Improve Safety Gate Performance. Requires

TAG F017 Moving Stapler.
S/N 6UP150301
Disk Finger Noise Fix
S/N 6UP150282
Moving Stapler: Crumple Fix
PURPOSE:
New Moving Stapler in Service Tray, to reduce crumpling of lightweight paper

as it enters the Disk Fingers.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 8.3 and PL 8.5
REFERENCE:
PL 8.3 and PL 8.5
TAG:
F015
TAG:
F018
CLASS:
CLASS:
USE:
N/A
USE:
FX
MFG SERIAL NUMBERS:

NAME:
N/A
Not yet assigned.
PURPOSE:
N/A
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Add harness for FX requirement.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
REFERENCE:
N/A
V0.042
May 2003
6-159
S/N 6UP150282
Harness
General Procedures
TAG:
F019
TAG:
F022
CLASS:
CLASS:
USE:
FX
USE:
FX only
MFG SERIAL NUMBERS:

NAME:
S/N 6UP150282
Harness Dressing
PURPOSE:
MFG SERIAL NUMBERS:

NAME:
Dress harnesses away from drive components.
PURPOSE:
Eliminate trail edge hang-up causing misregistration.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
REFERENCE:
N/A
TAG:
F020
TAG:
F023
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
Harness
PURPOSE:
N/A
REFERENCE:
N/A
TAG:
F021
CLASS:
USE:
FX only
MFG SERIAL NUMBERS:
N/A
Moveable Stapler Reg. Edge Spring
PURPOSE:
MFG SERIAL NUMBERS:

NAME:
EME Fix (part not spared)
KIT NUMBER:
NAME:
S/N 6UP147213
Add Spring to Moving Stapler Reg. Edge.
Limit misregistration of large sheet sets. Frame change required, making old
parts obsolete.
KIT NUMBER:
N/A
REFERENCE:
PL 8.2
TAG:
F024
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
N/A
PURPOSE:
REFERENCE:
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
May 2003
6-160
S/N 6UP155563
Reduced EMC Emissions
KIT NUMBER:
General Procedures
S/N 6UP150301
Larger Tamper Button
PURPOSE:
NAME:
N/A
Exit baffle mylar strip
Reduced EMC Emissions
V0.042
TAG:
F025
TAG:
F028
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
Improved Noise Reduction Ramp
PURPOSE:
New Ramp in Service Tray, Eliminates interference with new Tamper.
KIT NUMBER:
N/A
REFERENCE:
PL 8.5
TAG:
F026
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
S/N 6UP204514
PURPOSE:
EME requirements for network product.
KIT NUMBER:
N/A
REFERENCE:
PL 8.3
TAG:
F027
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
S/N 6UP154860
NAME:
S/N 6UP206480
Includes wiring for new Finisher Empty Sensor.
KIT NUMBER:
N/A
REFERENCE:
PL 8.2, PL 8.3, and PL 8.5
V0.042
6UP209078
Disk Baffle Noise Fix
PURPOSE:
Noise reduction foam added to Disk Baffle (48K72732). Requires TAG F017
Moving Stapler (15K36811).
KIT NUMBER:
N/A
REFERENCE:
PL 8.3 and PL 8.5
TAG:
F029
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
Reduce Finisher noise by changing to capstan-driven Tamper in Service Tray

Assembly .
KIT NUMBER:
N/A
REFERENCE:
PL 8.5
TAG:
F030
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
Stacker Tray Elevator Safety Improvement
PURPOSE:
Added second switch (110E08350) and harness (not spared), to reduce risk of
operators hand being wedged between stack and Disk Baffle as Stacker Tray
raises.
KIT NUMBER:
N/A
REFERENCE:
PL 8.2.
May 2003
6-161
N/A
Final Finisher Noise Fix: Capstan-Driven Tamper
PURPOSE:
Stacker Tray IIOC Harness
PURPOSE:
MFG SERIAL NUMBERS:
General Procedures
TAG:
F031
TAG:
F034
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
6UP-749381
MFG SERIAL NUMBERS:
Stapler Lead-In Baffle Improvement
PURPOSE:
NAME:
Stapler Lead-In Baffle changed, to avoid interference with the Moving Stapler
staple cartridge that was causing poor stapling.
PURPOSE:
Improved IOT/Finisher interface. Reduced 12-101 and 12-107 jams. Weights

vs. magnets for easier jam clearance. Idler rollers retained more securely.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 8.5
REFERENCE:
PL 8.3
TAG:
F032
TAG:
F036
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
6UP-757751
Top Tray Sensor (Q12) Bracket Change
PURPOSE:
Bend bracket to reposition sensor, to fix 12-107 jams.
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Material removed from actuator bracket to eliminate interference.
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
REFERENCE:
N/A
TAG:
F033
TAG:
F037
CLASS:
CLASS:
USE:
all markets
USE:
all markets
NAME:
6UP-774056
Top Tray Capacity Increase
PURPOSE:
New Top Tray Back Wall, increases Top Tray capacity to 250 sheets
KIT NUMBER:
600K88760
REFERENCE:
PL 8.3
General Procedures
MFG SERIAL NUMBERS:

NAME:
N/A
Improved Disk Shaft return after safety switch actuation.
PURPOSE:
Spacer added between switch and frame, to reduce interference to Disk Shaft
return.
KIT NUMBER:
N/A
REFERENCE:
N/A
May 2003
6-162
6UP-795815, NF3-008089
Improved stapler door switch actuation
KIT NUMBER:
MFG SERIAL NUMBERS:
6UP-783330
Transport Baffle Improvements
V0.042
TAG:
F040
TAG:
F110
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
N/A
MFG SERIAL NUMBERS:
Stapler Access Door.
PURPOSE:
NAME:
New door assembly improves set registration.
PURPOSE:
Reduce irregular stacking due to sticky sheets.
KIT NUMBER:
N/A
KIT NUMBER:
606K07470
REFERENCE:
PL 8.5
REFERENCE:
N/A
TAG:
F042
TAG:
F111
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:
N/A
MFG SERIAL NUMBERS:
NAME:
Stacker Tray
NAME:
PURPOSE:
New Stacker Tray reduces part breakage in the field.
PURPOSE:
Different Bail Arms, to increase the possible number of small stapled sets.
N/A
KIT NUMBER:
606K07390
REFERENCE:
PL 8.2
REFERENCE:
PL 8.5
TAG:
F109
TAG:
F112
CLASS:
CLASS:
USE:
all markets
USE:
all markets
NAME:
N/A
MFG SERIAL NUMBERS:
Finisher Paper Cooling Kit
PURPOSE:
NAME:
PURPOSE:
KIT NUMBER:
606K07360
This kit cannot be installed with TAG F112 Active Static Eliminator.
REFERENCE:
PL 8.3
606K07472
REFERENCE:
N/A
V0.042
May 2003
6-163
N/A
Active Static Eliminator
To cool sheets exiting from the Finisher, in order to reduce in-set registration
problems due to sticky sheets. This kit also ensures sheets do not go over the
disk fingers.
KIT NUMBER:
N/A
Small Stapled Sets Performance Improvement
KIT NUMBER:
MFG SERIAL NUMBERS:
N/A
Paper Cooling
To reduce static electricity on prints that are output to the Stacker Tray, in dry
conditions where the standard brush (passive) static eliminator is not sufficient.
General Procedures
General Procedures
May 2003
6-164
V0.042
TAG:
H001
TAG:
H004
CLASS:
CLASS:
USE:
all markets
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
NAME:
New HCF PWB (160K43481) ensures a 6-ream stack will not overload the
motor design.
KIT NUMBER:
N/A
REFERENCE:
PL 4.2B
PURPOSE:
Improves A4 4-hole Paper Handling.
KIT NUMBER:
606K06911
REFERENCE:
PL 4.2B
H005
CLASS:
USE:
all markets
all markets
MFG SERIAL NUMBERS:
H002
CLASS:
USE:
MFG SERIAL NUMBERS:
S/N H4D234816
NAME:
HCF/Bypass Tray Harness Deflector Shield
PURPOSE:
KIT NUMBER:
N/A
REFERENCE:
PL 4.2B
TAG:
H003
CLASS:
USE:
N/A
N/A
REFERENCE:
PL 4.2B
TAG:
H006
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
N/A
Not yet assigned.
PURPOSE:
A new HCF Paper Feeder to improve paper feeding performance. Install HCF
Feeder Assembly 22K53319 or higher plus TAG H007 kit, and mark off HCF
Tags 5 & 7.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 4.2A
V0.042
NAME:
S/N H4D513847
Retard Bracket/Paper Handling Baffle/Feeder (Manufacturing only)
PURPOSE:
Manufacturing only
KIT NUMBER:
N/A
REFERENCE:
PL 4.2B
May 2003
6-165
S/N 8UP-175775, H4D235413
Tray 6 Feeder Kit
PURPOSE:
Adds a mylar shield to the HCF/Bypass Tray Feed Motor (7K10011). The shield
guides the HCF Elevator Motor harness so it does not catch on the Feed Motor
bracket as The HCF Tray is lowered which results in an open interlock condition.
S/N H4D237786
A4 4-hole Paper Handling Upgrade
TAG:
TAG:
NAME:
MFG SERIAL NUMBERS:
HCF PWB
PURPOSE:
NAME:
S/N H4D229421
General Procedures
TAG:
H007
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
HCF Feed Performance Improvement. Kit also installs TAG 079.
KIT NUMBER:
600K75870
REFERENCE:
PL 4.2B
TAG:
H009
CLASS:
USE:
NASG, XE
MFG SERIAL NUMBERS:

NAME:
N/A
HCF Bypass Tray Feed Motor and HCF PWB
PURPOSE:
When motor is replaced, it requires a new HCF PWB on a pre-Tag H009 HCF
due to firmware requirements. PWB can be replaced by itself.
KIT NUMBER:
604K04540
REFERENCE:
N/A
TAG:
H112
CLASS:
USE:
all markets
MFG SERIAL NUMBERS:

NAME:
H4D-52234
HCF Feed Performance Improvement
N/A
HCF Lightweight Paper Feed Performance Improvement
PURPOSE:
HCF Feed Performance Improvement for lightweight paper only. Will reduce
Feed Roll Cartridge life to approximately 40,000 feeds. Kit also installs TAG
079.
KIT NUMBER:
606K07180
REFERENCE:
PL 4.2B
General Procedures
May 2003
6-166
V0.042
TAG:
M001
TAG:
M004
CLASS:
CLASS:
USE:
All markets
USE:
All markets
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:
Compiler Tray
PURPOSE:
The new tray raises the position of the Set Eject Sensor, S91 allowing the sensor to detect darker tones, reducing the number of 12-128 faults.
KIT NUMBER:
N/A
REFERENCE:
PL 8.55
NAME:
Not used.
PURPOSE:
Not used.
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
M005
CLASS:
USE:
All markets
All markets
MFG SERIAL NUMBERS:
TAG:
M002
CLASS:
USE:
MFG SERIAL NUMBERS:

NAME:
FEC 015588, EVW 000503
FEC 015603 & UP, EVW 000503 & UP
Improved IOT/MFF Interface PWB
PURPOSE:
4-Bar Exit Drive Assembly baffle.
PURPOSE:
New baffle added to 4-Bar Exit Drive Assembly to prevent the Compile Belt
from adhering to baffle.
KIT NUMBER:
N/A
KIT NUMBER:
N/A
REFERENCE:
PL 8.22A
REFERENCE:
N/A
TAG:
M003
TAG:
M006
CLASS:
CLASS:
USE:
All markets
USE:
All markets
NAME:
FEC 015515, 015521, 015523 & UP, EVW 000503 & UP
MFG SERIAL NUMBERS:
Booklet Backstop Clamp Solenoid spring retaining.
PURPOSE:
Booklet Backstop Clamp Solenoid spring retaining.
KIT NUMBER:
N/A
REFERENCE:
N/A
V0.042
FEC 015525 & UP, EVW 000503 & UP
NAME:
ESD protection.
MFG SERIAL NUMBERS:
N/A
FEC015529, 015532, 015535015537 & UP, EVW 000501 &

UP
NAME:
Curl Guard short-term fix
PURPOSE:
Warpage of the curl guard enables belts to catch and cause 12-118's as well as
making the Critical Parameter of exit shaft to compile height vary. A tywrap was
added to prevent warpage.
KIT NUMBER:
N/A
REFERENCE:
N/A
May 2003
6-167
General Procedures
TAG:
M007
TAG:
M010
CLASS:
CLASS:
USE:
All markets
USE:
All markets
MFG SERIAL NUMBERS:
FEC 015598 & UP, EVW 000503 & UP
MFG SERIAL NUMBERS:
FEC 015588 & UP, EVW 000503 & UP
NAME:
TAG M008 enablement.
NAME:
Improved 4-Bar upper baffle assembly cover screw bosses
PURPOSE:
Removes material from Buffer/Compiler Module to enable addition of a bearing

in the 4-Bar Exit Drive Assembly (TAG M008).
PURPOSE:
The screw bosses that secure the upper baffle top cover of the 4-Bar
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
M008
CLASS:
USE:
All markets
Assembly and the Nip 9 idler roll crack, allowing the upper baffle assembly
to fail and causing 12-118 compiler entry jams. Installing a new 4-Bar Assembly with this Tag introduces improved screw bosses.
KIT NUMBER:
N/A
REFERENCE:
PL 8.28
TAG:
M011
CLASS:
NAME:
Curl Guard long-term fix
USE:
All markets
PURPOSE:
Add a bearing and related hardware to 4-Bar Exit Drive Assembly to prevent
curlguard from warping.
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
M009
CLASS:
USE:
All markets
MFG SERIAL NUMBERS:
FEC 015620 & UP, EVW 000528 & UP
NAME:
PURPOSE:
All
For customers who use A4 paper, this setup produces even folds in TriFold jobs.
KIT NUMBER:
N/A
REFERENCE:
GP52
TAG:
M012
CLASS:
R
All markets
NAME:
MFF Version 12.20 Software
USE:
PURPOSE:
MFF Version 12.20 Software, part of IOT Software 07.19.05.026 for MFF
launch
MFG SERIAL NUMBERS:
KIT NUMBER:
N/A
REFERENCE:
N/A
General Procedures
N/A
Tri-Fold Setup for A4 paper.
FEC 015588 & UP, EVW 000503 & UP
NAME:
Curl Guard Solenoid clip fix
PURPOSE:
Prevents the Curl Guard Solenoid clip from becoming deformed and falling off
when the solenoid gets hot (during very long single-staple jobs) causing extremenly poor compiling.
KIT NUMBER:
N/A
REFERENCE:
PL 8.30
May 2003
6-168
V0.042
TAG:
M013
TAG:
M016
CLASS:
CLASS:
USE:
All markets
USE:
All markets
MFG SERIAL NUMBERS:
N/A
MFG SERIAL NUMBERS:
NAME:
S45 flag 3-hole paper hang-up fix
NAME:
PURPOSE:
Corrects a problem with the middle hole of 3 hole paper catching on the 4-Bar
Position Sensor (S45) flag, causing 12-239 and/or misresgistered sets.
PURPOSE:
KIT NUMBER:
N/A
REFERENCE:
N/A
TBD
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
M017
CLASS:
USE:
All markets
All markets
MFG SERIAL NUMBERS:
TAG:
M014
CLASS:
USE:
MFG SERIAL NUMBERS:
FEC 015691 & UP, EVW 000583 & UP
NAME:
TBD
TBD
NAME:
Tamper slide drive belt clip fix
PURPOSE:
PURPOSE:
Clip on tamper slide drive belt can interfere with the Compile Fingers, causing
12-240 faults.
KIT NUMBER:
N/A
REFERENCE:
N/A
KIT NUMBER:
N/A
REFERENCE:
N/A
TAG:
M018
R
USE:
All markets
TAG:
M015
CLASS:
CLASS:
USE:
All markets
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
N/A
NAME:
M60 speed-up (harmonic noise fix)
PURPOSE:
Increase speed of Booklet Paper Path Motor (M60) to prevent low frequency
vibrations which cause a humming sound.
KIT NUMBER:
604K17660
REFERENCE:
PL 8.40
V0.042
N/A
TBD
N/A
None. Field-installed only.
NAME:
Tri-Folder Skew Shim Kit
PURPOSE:
Tri-Fold skew occurs when the Tri-Folder backstop bends/sags since the
inboard side is not supported. This field tag is for a kit that will shim the IB side
of the backstop to minimize and control skew. Superseded by TAG M020.
KIT NUMBER:
604K17650
REFERENCE:
PL 8.51
May 2003
6-169
General Procedures
TAG:
M019
TAG:
M022
CLASS:
CLASS:
USE:
All markets
USE:
All markets
MFG SERIAL NUMBERS:
N/A
MFG SERIAL NUMBERS:
NAME:
New Elevator Belt Clamp with shorter sensor flag.
NAME:
PURPOSE:
Decreased tray travel to 2000 to 2100 sheets for 11 inch, 20 lb. paper results in
tray capacity for A4, 80 gsm being marginal. This change removes 5 mm from
the Main Tray Full Sensor (S52) flag feature of the belt clamp. This increases
tray travel enough to satisfy the A4, 80 gsm requirement of 2000 sheets.
IMPORTANT: The TAG M019 belt clamp spared part should not be used in a
pre-TAG M019 machine.
PURPOSE:
KIT NUMBER:
N/A
REFERENCE:
PL 8.53, PL 8.54
TAG:
M020
CLASS:
USE:
All markets
MFG SERIAL NUMBERS:
Tri-Folder Skew Long-Term Fix

Tri-Folder skew occurs when the backstop bends/sags since the inboard side is
not supported. This field tag replaces the Tri-Folder Assembly with a new one
that has a fully supported backstop. The backstop must then be adjusted
inboard as well as outboard whenever the Tri-Fold second crease is adjusted.
N/A
PL 8.21
PL 8.30
TAG:
M023
CLASS:
USE:
All markets
New Backstop Solenoid 121K33502 has repositioned cable ties to reduce

strain on the solenoid harness.
KIT NUMBER:
N/A
REFERENCE:
PL 8.42
TAG:
M024
CLASS:
USE:
All markets
MFG SERIAL NUMBERS:
TAG:
M021
NAME:
CLASS:
PURPOSE:
USE:
All markets
MFG SERIAL NUMBERS:
N/A
NAME:
LVPS Shuts-Down when MFF Front Door is open for more than 5 Minutes.
PURPOSE:
LVPS shuts down when MFF front door is open for over 5 minutes. A UI message finisher door open will not change even if the front door is closed. Communication faults will result during this condition. The LVPS will recover only
after POPO manually or automatically with Atlanta reset or power save.
KIT NUMBER:
N/A
REFERENCE:
PL 8.22A
General Procedures
N/A
New Crease Blade issued.

New Crease Blade 015K62191 has feature on the blade to allow tip tp nip CP
to be set to 10.4.
KIT NUMBER:
N/A
REFERENCE:
PL 8.45
May 2003
6-170
FEC-016033 & UP
New Backstop Solenoid prevents premature failure.
PURPOSE:
N/A
PURPOSE:
REFERENCE:
604K16871
REFERENCE:
MFG SERIAL NUMBERS:
NAME:
KIT NUMBER:
These new Compiler Belts fix a condition where the belts stick to the drive pulley and bind in the curl guard. The new belts also fix the problem of poor inset
registration caused by tacky belt surfaces.
KIT NUMBER:
NAME:
EVW-001294 & Up, FEC-016232 & UP
New Compiler Belts fix sticking condition.
V0.042
TAG:
M027
CLASS:
USE:
All markets
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
New Drive Shaft for Nip 1 and 2 replaces 022K79721. New shaft has 6mm
outside diameter to prevent breakage.
KIT NUMBER:
604K18550
REFERENCE:
PL 8.37
TAG:
M028
CLASS:
USE:
All markets
MFG SERIAL NUMBERS:

NAME:
N/A
Software Version Update
PURPOSE:
New MFF software cut-in for manufacturing. New version 12.53 replaces
12.20.
KIT NUMBER:
N/A
REFERENCE:
PL 8.22A
TAG:
M029
CLASS:
USE:
All markets
MFG SERIAL NUMBERS:

NAME:
N/A
Drive Shaft Kit.
N/A
Chrome Compiler Tray.
PURPOSE:
New tray prevents registration problems due to static build up when running
stapled set.
KIT NUMBER:
N/A
REFERENCE:
PL 8.55
V0.042
May 2003
6-171
General Procedures
General Procedures
May 2003
6-172
V0.042
Glossary of Terms
Table 1 Glossary of Terms
Table 1 contains the terms and phrases that are used throughout the Service Documentation.
Term
Description
CVT
Constant Velocity Transport
CW
Clockwise (right-hand rotation)
Term
Description
DADF
Duplex Automatic Document Feeder
A3
Paper size 11.69 x 16.54 inches (297 x

420 millimeters)
DSS
Density Sample Sensor. The Density Sensor.
A4
Paper size 8.27 x 11.69 inches (210 x 297

millimeters)
Decurler
Device used to remove curl from the print

after passing the Fuser.
A4 Cover

millimeters)
Detack
Corotron
A5

millimeters)
Device that neutralizes the electrostatic

charge on a print, so that it can be stripped
from the Photoreceptor.
DIAG NAV
Diagnostic Navigator
ACT
Advanced Customer Training, teaches

customers to perform some of the service
that is normally performed by a Xerox Service Representative.
DIP Switch
Dual In-line Package switch
DMM
Digital Multimeter
Dog Ear
A condition when the corner or corners of

the paper are curled or folded.
DPI
Dots Per Inch
DRAM
Dynamic Random Access Memory
EDOC
Electronic Documentation
ELOG
Electronic Service-Log, an electronic tool

used to track machine service history.
Atlanta PWB
Main Control PWB
Auditron
Electronic counters for tracking customer

usage of the machine.
B4
Paper size 10.12 x 14.33 inches (247 x

364 millimeters)
B5

millimeters)
EME
Electromagnetic Emissions
BBS
Bulletin Board System, Electronic Bulletins

can be downloaded to the machine via this
system.
EPC
Electronic Pre-collation (memory)
EPROM
Bit
Binary digit (1 or 0), representing an electrical state.
Erasable Programmable Read-Only Memory. A ROM that can be erased and then
programmed again with new software.
ESD
BSD
Block Schematic Diagram
BUS
An electrical connection that allows data

flow in two directions at the same time.
Electrostatic Discharge. A transfer of

charge between bodies at different electrostatic potential. Could be damaging to
sensitive devices.
CBU
Customer Business Unit
ESS
Electronic subsystem
CCW
Counterclockwise (left-hand rotation)
Executive
CD
Circuit Diagram

millimeters)
CD-ROM
Compact Disk, Read Only Memory
FAX
Charge
Scorotron
Device which places the charge on the

photoreceptor.
Facsimile Product, the conversion of

paper media to electronic impulses that
are transmitted over phone lines and then
re-compiled at the receive end.
CPM
Copies Per Minute
FIC
Final Integration Configuration
CQ
Copy Quality, refers to characteristics that

are xerographic and/or cosmetic related.
FSMA
Full Service Maintenance Agreement
FWA
Full Width Array
CRU
Customer Replaceable Unit
FWA/VBB
Full Width Array/Video Buffer Board
CRUM
Customer Replaceable Unit Monitor, individual CRU usage monitor (internal to

each CRU)
FX
Fuji Xerox
GSM
Grams per Square Meter
HCF
High Capacity Feeder
CSE
Customer Service Engineer
V0.042
May 2003
6-173
General Procedures
Glossary of Terms

Term
Description
Term
Description
HVPS
High Voltage Power Supply
OEM
Original Equipment Manufacturer
Hz
Hertz, cycles per second
OPCO
Operating Company
IB
Inboard; the side of the paper path closer

to the rear of the machine; toward the
inside of the machine.
P/N
Part Number
P/R
(See Photoreceptor)
PBX system
Private Branch Exchange (Telephone)

system
PFT
Pre Fuser Transport
IIOC
Integrated Input Output Controller
IIT
Integrated Input Terminal/ -or- Image Input

Terminal
Install Wizard
Automated software routine, used to facilitate customer and/or rigger installations.
IOT
Image Output Terminal
IPS1
Input Image Processing Module
IQ defects
Image Quality defects (see CQ)
ISDN
Photoreceptor Device which charges, exposes, develops,

and transfers images
PIN
Personal Identification Number
Pixel
Individual illuminated element on a video

screen.
Integrated Services Digital Network
Document
Glass
Surface, on which an original document is

placed for scanning.
IVCM
Integrated Video and Control Module
PO/PO
Power Off/Power On
LAN
Local Area Network
POST
Power On Self Test
LCD
Liquid Crystal Display
PPM
Prints Per Minute
LE
Lead Edge
PROM
Programmable Read Only Memory
LED
Light Emitting Diode
PS
PostScript
Ledger
Paper size 11x 17 inches (297 x 420 millimeters)
PTC
Pre-Transfer Corotron (reduces TBO)
PWB(A)
Printed Wiring Board (Assembly)
LEF
Long Edge Feed; Portrait orientation
PWPM
Pulse Width and Position Modulated
Legal
Paper size 8.5 x 14 inches (216 x 356 millimeters)
PWS
Portable Workstation (CSE laptop computer)
Letter
Paper size 8.5 x 11 inches (216 x 279 millimeters)
R/E
RAM
Random Access Memory. A digital memory circuit from which information can be
accessed or where software information
can be stored.
Letter Cover
Paper size 9 x 11 inches (229 x 279 millimeters)
LVPS
Low Voltage Power Supply
MFF
RAP
Repair Analysis Procedure
Moire
Unwanted pattern caused by the interaction of two halftone frequencies
RCM
ROS Control Module
RDT
Remote Data Transfer
Machine Resident Diskette, 3.5 inch floppy

diskette stored inside the machine, to the
right of the Fuser. Used to store NVM
(backup) and ELOG files.
RIS
Raster Input Scanner
ROM
NOHAD
Noise, Ozone, Heat, and Dirt
Read Only Memory. A digital memory circuit that is designed to contain permanent
software information.
NVM
Non-Volatile Memory. A Random Access

Memory device (RAM)
ROS
Raster Output Scanner (name given to

laser unit which exposes the photoreceptor, producing the latent image)
OB
Outboard; the side of the paper path closer

to the front of the machine; toward the outside of the machine.
RS422
TBD
RX
Rank Xerox (Obsolete term. See XL)
SA
System Administrator
SCAM PWB
Servo Control Analog Module
MRD
OCT
Offsetting Catch Tray
General Procedures
Glossary of Terms
May 2003
6-174
V0.042

Term
Description
SCB
Serial Command Bus/ Serial Communications Bus
SCSI
Small Computer Systems Interface
SCVM
Scanner Control & Video Module
SEF
Short Edge Feed; Landscape orientation
SELV
Safety Extra Low Voltage
SIMM
Serial In-line Memory Module
Skew
Angular error between the xerographic

image and the copy paper, measured at
the lead edge.
SMH
Special Material Handler (Any reference to

SMH = Bypass Tray)
T and M
Time and Materials service plan
Tag Matrix
Hardware upgrade information
TBD
To Be Determined (or Disclosed)
TBO
Toner Blow-Out (IQ defect reduced by

PTC)
TE
Trail Edge, also, in some instances TE

refers to the top edge of a print.
TEER Sensor
Top Edge Electronic Registration Sensor
TOC
Table Of Contents
UI
User Interface
UM
Unscheduled Maintenance
USCO
United States Customer Operations
VAC
Voltage Alternating Current
VBB
Video Buffer Board
VCM
Video and Control Module
VDC
Voltage Direct Current
Welcome Cen- Customer service, trouble-call phone-in

tre
access center.
Wirenet
Schematic diagram, showing the distribution of all AC and DC voltages, DC Return

voltages, and the IIOC SID/SOD/CLK signals used throughout the machine.
XL
Xerox Limited (formerly RX, or Rank

Xerox)
x-reg
Lead edge registration; registration in the

process direction
y-reg
Top edge registration; registration in the

cross-process direction
V0.042
May 2003
6-175
General Procedures
Glossary of Terms
General Procedures
Glossary of Terms
May 2003
6-176
V0.042
7. Wiring Data
Plug/Jack Locations
Plug / Jack Index.............................................................................................................
Plug / Jack Locations ......................................................................................................
MFF Plug Jack Locations ................................................................................................
PWB Drawings ................................................................................................................
IIOC PWB Locations .......................................................................................................
7-3
7-6
7-27
7-32
7-39
Wirenets
Wirenet Drawings ............................................................................................................
MFF Wirenet Drawings ...................................................................................................
V0.042
7-55
7-111
May 2003
7-1
Wiring Data
Wiring Data
May 2003
7-2
V0.042
Plug / Jack Index
Table 1 Plug Jack Index
Locate the source Plug/Jack in the left column of the Index. Select P/J to go to a specific P/J.
Select -+Figure to go to the figure in which the P/J is located.
PJ
Description
Figure
J45
LVPS - Illumination Lamp

Power Supply and Covenience Stapler in-line connector (Tag 112)
Figure 21
J49
Fuser AC
Figure 3
J59
LVPS Cooling Fan
Figure 20
Figure 3

PJ
Description
Figure
A14P1/J80
Decurler IIOC
Figure 4
A1B1P1/J3
SCAM PWB - P/R Drive

Motor
Figure 8
J69
Finisher SCB and IIOC
A7P1/J75
Drive Plate - Trays 1 and 2
Figure 4
J81
Inverter IIOC
Figure 3
A8P1/J79
Drive Plate - Trays 3 and 4
Figure 4
J87A
Figure 21
B1P1/J4
SCAM PWB - Developer

Drive Motor
Figure 8
Covenience Stapler power

(Tag 112)
J105
HCF Tray Heater AC
Figure 20
J110
HCF Tray Heater AC
Figure 20
J9/J4
Distribution PWB / LVPS
Figure 1
J16/P9
Main Control PWB - ROS

Video
Figure 2
P/J1
Distribution PWB - Bus 0 (ES Figure 1

On) IIOC
B2P1/J2
SCAM PWB - Fuser Drive

Motor
Figure 8
B2P1/J7
DADFPWB
Figure 6
B4P1/W8A3
IIOC PWB W8A3
Figure 14
B5P1/W3A1
IIOC PWB W3A1
Figure 14
Charge Grid
Xerographic Module Charge Grid
Figure 3
Charge
Scorotron
Xerographic Module Charge Scorotron
Figure 3
Detack
XRU - Detack
Figure 3
Fuse
Tray Heater fuse
HCF Elevator HCF Elevator Motor Ground

Motor Ground
Figure 20
Figure 5
P/R Ground
XRU - Photoreceptor Ground Figure 3
Transfer
XRU - Transfer
Figure 3
J1
Moving Stapler
Figure 11
J1
Tray Heater - Relay PWB
Figure 20
J2
Fixed Stapler
Figure 11
J2
Developer - Donor Roll Bias
Figure 3
J3
Developer - Mag Roll Bias
Figure 3
J3
Tray Heater Relay PWB AC
Figure 20
J4
IOT Paper Tray Heater AC
Figure 20
J5
HCF Paper Tray Heater AC
Figure 20
J5
Main Control PWB - Scanner Figure 2

Video
J7
SCAM PWB - Flicker Control Figure 8
J7
ESS PWB - ESS Hard Disk

Drive Ribbon Cable
Figure 16
J9
Main Control PWB
Figure 2
J15
Finisher power and communications
Figure 12
V0.042
P/J1
Finisher Communications
Figure 10
P/J1
DADFPWB
Figure 6
P/J2
Distribution PWB - SCAM

PWB
Figure 1
P/J2
Disk Home Sensor, Transport Figure 10

Drive Motor, and Disk Motor
P/J2
DADFPWB
P/J3
Distribution PWB - Bus 0 (ES Figure 1

Off) IIOC
P/J3
Safety Gate Solenoids and

P/J3
DADFPWB
Figure 6
P/J4
Distribution PWB - DF/SCB
Figure 1
P/J4
Finisher Top Tray components
Figure 10
P/J4
DADFPWB
Figure 6
P/J5
Distribution PWB - Main Con- Figure 1

trol PWB
P/J5
Tamper Motor, Tamper Home Figure 10

Sensor, and Stack Height
Sensors
P/J5
Accessory PWB - PFPLCN
Figure 2
P/J5
DADFPWB
Figure 6
May 2003
7-3
Figure 6
Figure 10
Wiring Data
Plug / Jack Index
PJ
Description
PJ
Description
Figure
P/J6
Figure 10
Stapler Position Motor,
Retractable Reg. Edge Solenoid, Stapler Position Home
Sensor, and Kicker Home
Sensor
Figure
P/J121
IOT Paper Tray Heater Heater AC
Figure 20
P/J123
IOT Paper Tray Heater Humidity Sensor PWB
Figure 20
P/J6
DADF PWB
Figure 6
P1
Stacker Tray Drive Motor
Figure 10
P/J7
Distribution PWB - Bus 1

IIOC
Figure 1
P2
Image Disk Drive Power
Figure 17
P2
Figure 18
P/J7
Moving Stapler components

and Fixed Stapler components
Figure 10
Stacker Tray Lower Limit

Switch
P2
Stapler Position Motor
Figure 13
P2
Toner Bottle Sensor
Figure 9
P/J7
HCF Elevator Motor
Figure 5
P2
Dual Decurler
Figure 19
P/J8
Distribution PWB
Figure 1
P3
Stacker Tray Upper Limit

Switch
Figure 18
P4
Disk Drive Motor
Figure 10
P4
Tamper Motor
Figure 11
P4
Stacker Tray Full Sensor
Figure 18
P5
Pause/Resume Switch
Figure 18
P5
Figure 20
P6
Relay PWB - Tray Heater AC Figure 20
P/J8
IIOC Bus 2
Figure 10
P/J8
Sensor
Figure 5
P/J9
Safety Gate Interlock

Switches
Figure 10
Stacker Tray Drive Motor,

Finisher Interlock Switch,
Stapler Access Door Interlock Switch, Stacker Tray
Upper and Lower Limit
Switches
Figure 10
P/J10
Distribution PWB - ROS
Figure 1
P/J11

IIOC
Figure 1
P/J10
P/J11
Stacker Tray Full Sensor and Figure 10

Pause Resume Switch
Disk Home Sensor
P8
Relay PWB - Tray Heater AC Figure 20

input
Figure 10
P9
Kicker Motor
P10
Input Tray Sensor 2
Figure 11
Figure 7
P11
Input Tray Sensor 1
Figure 7
P12
Side Guide Sensor 1
Figure 7
P13
Side Guide Sensor 2
Figure 7
P14
DADFPWB
Figure 6
Figure 6
P/J12

IIOC (DADF)
P/J12
Stacker Tray Offset Motor

Figure 10
and Stacker Tray Offset Sensor
P15
DADF Registration Gate

Sensor
P16
DADFPWB
Figure 6
P/J13
Distribution PWB - Interlock
Figure 1
P17
DADF Nudger Solenoid
Figure 6
P/J14
Distribution PWB - CRUM
Figure 1
P18
P/J15
Distribution PWB - Scanner
Figure 1
Document Feeder Top Cover Figure 6

Sensor
P/J15
Main Control PWB - PWS
Figure 2
P19
DADFPWB
Figure 6
P/J50
Developer Housing
Figure 9
P20
DADFPWB
Figure 6
P/J55
Figure 3
P21
DADFPWB
Figure 6
P/J74
Preregistration Solenoid
Figure 3
P22
Figure 6
P/J87
Convenience Stapler IDC

connector
Figure 8
P23
DADF Exit/Invert Sensor
Figure 7
P24
CVT Start of Scan Sensor
Figure 7
TEER Sensor
Figure 3
P25
Input Tray Exit Sensor
Figure 6
P41
LVPS - Input Power
Figure 1
P/J116
Wiring Data
Plug / Jack Index
Figure 1
P6
May 2003
7-4
V0.042
PJ
Description
Figure
PJ
Description
P48
AC Distribution Module - to
Power On Switch
Figure 1
P3/J2
ESS PWB Power
Figure 16
P3/J5
HCF Sensors
Figure 5

Power Supply and Covenience Stapler in-line connector (Tag 112)
Figure 21
P4/J3
Accessory PWB - RDT
Figure 2
P8/J3
Accessory PWB - ICVM Exp. Figure 2

Card

Power Supply and Covenience Stapler (Tag 112)
Figure 21
P7/J6
Accessory PWB - Foreign

Interface
Figure 2
P17/A7A5
IIOC PWB A7A5
Figure 9
P60
Xerographic Module - DC
Figure 3
P17/A8A5
IIOC PWB A8A5
Figure 9
P61
Fuser DC
Figure 3
P20/J10
Figure 8
P69
Finisher power and communications
Figure 12
SCAM PWB - Transfer/

Detack PS
P72
ROS Power Cable
Figure 9
P77
Duplex Decurler
Figure 3
P87
Covenience Stapler power

(Tag 112)
Figure 21
P89
ROS Video Cable
Figure 9
P92
AC Distribution Module - Low Figure 1

voltage to relays
P45
P45A
P21/J1
SCAM PWB +36 VDC Input
Figure 8
P25/J5
SCAM PWB - BTAC Sensor
Figure 8
P26/J6
SCAM PWB - Distribution

PWB
Figure 8
P28/J8
SCAM PWB - LVM
Figure 8
P29/J9
SCAM PWB - Developer Bias Figure 8

HVPS
P31/J11
SCAM PWB - Fuser SSR
Figure 8
P42/J2
LVPS
Figure 1
P43/J3
LVPS to Main Control PWB
Figure 1
P45/J5
LVPS +24 VDC to Scanner
Figure 1
P46/J6
LVPS +36 VDC to SCAM

PWB
Figure 1
P105
P109
Convenience Stapler connec- Figure 8

tor
P125
IOT Paper Tray Heater AC
Figure 20
P1/J2
SMH Feed Head
Figure 5
P1/J3
Bypass Tray (Tray 5) Sensors
Figure 5
P51/W8A2
IIOC PWB W8A2
Figure 15
P52/W8A1
IIOC PWB W8A1
Figure 15
ESS Hard Disk Drive Power

(w/o Tag 44)
Figure 16
P53/W8A1
IIOC PWB W8A1
Figure 15
P57/W8A3
IIOC PWB W8A3
Figure 14
P1/J6
Main Control PWB
Figure 2
P58/W8A4
IIOC PWB W8A4
Figure 14
P1/J6
HCF Feed Head
Figure 5
P62/W3A1
IIOC PWB W3A1
Figure 14
P1/J8
HCF PWB
Figure 5
P64/J301
Developer Bias HVPS
Figure 1
P1/J8
DADFPWB
Figure 6
P65/J1
Transfer/DetackPS
Figure 8
P1/J13
Main Control PWB - Distribu- Figure 2

tion PWB
P66/J1
Transfer/DetackPS
Figure 8
P67/JI
Charge HVPS
Figure 2
P1/J84
IIOC Bus 1 fromIOT
Figure 5
P73/W8A4
IIOC PWB W8A4
Figure 14
P2/J1
Tray 6 Fuel Gauge Sensor
Figure 5
P83/W3A1
IIOC PWB W3A1
Figure 14
P2/J1
HCF PWB - IIOC Bus 1
Figure 5
P87/J14
P2/J1
ESS Hard Disk Drive Power
Figure 17
Main Control PWB - Distribu- Figure 2

tion PWB
P2/J1
HCF/Bypass Tray Feed

Motor
Figure 5
P93/W8A3
IIOC PWB W8A3
Figure 14
P94/W8A5
IIOC PWB W8A5
Figure 3
P2/J7
Main Control PWB
Figure 2
P97/W8A5
IIOC PWB W8A5
Figure 3
P3/J2
Accessory PWB - RS232
Figure 2
P100/W8A2
IIOC PWB W8A2
Figure 15
P1/J5
Figure 20
Figure
V0.042
May 2003
7-5
Wiring Data
Plug / Jack Index
Plug / Jack Locations

PJ
Description
Figure
S4
Left Side Intlk Switch
Figure 8
S5
Right Side Intlk Switch
Figure 8
S6P1/W8A4
IIOC PWB W8A4
Figure 14
Wiring Data
Plug / Jack Index, Plug / Jack Locations
May 2003
7-6
V0.042
AC Distribution Module, LVPS, and Distribution PWB
P/J15
P/J14
P/J2
P/J13
P/J1
P64/J301
P41
P48
P/J3
P92
P/J4
P/J10
P46/J6
P45/J5
P/J5
P/J12
P/J11
J9/J4
P43/J3
P42/J2
P/J12
P/J8
P/J7
Figure 1 AC Dist. Panel, LVPS, and Dist. PWB
V0.042
May 2003
7-7
Wiring Data
Main Control PWB and Charge PS
J5
J16/P9
P67/JI
J9
P/J15
P87/J14
P8/J3
P7/J6
P5/J4
P3/J2
P1/J13
P2/J7
P4/J3
P1/J6
Figure 2 Main Control PWB and Charge PS
Wiring Data
May 2003
7-8
V0.042
Developer, P/R, PFT, Fuser, and Inverter Connectors
Transfer
Detack
P/R Ground
P/J74
P94/W8A5
P97/W8A5
J49
P61
P/J55
J3
J2
Charge Grid
Charge Scorotron
P60
P77
P/J116
J81
J69
Figure 3 IOT Paper Path
V0.042
May 2003
7-9
Wiring Data
Paper Tray Drive Plates
A14P1/J80
A7P1/J75
A8P1/J79
Figure 4 Paper Tray Drive Plates
Wiring Data
May 2003
7-10
V0.042
P1/J84
P1/J8
P1/J3
P1/J4
P1/J2
P1/J6
P/J8
P3/J5
P2/J1
P2/J1
P/J7
HCF Elevator
Motor Ground
Figure 5 HCF
V0.042
May 2003
7-11
Wiring Data
DADF Top View

P14
P/J2
P/J1
P16
P21
P18
P15
P20
P25
P1/J8
P/J6
P/J5
P/J3
P/J4
B2P1/
P19
P17
P22
(located under solenoid)
Figure 6 DADF Top View
Wiring Data
May 2003
7-12
V0.042
DADF Bottom View
P12
P24
P10
P11
P13
P23
Figure 7 DADF Bottom View
V0.042
May 2003
7-13
Wiring Data
SCAM PWB, Detack/Transfer PS, and Interlocks
P65/J1
P21/J1
P66/J1
B2P1/J2
A1B1P1/J3
B1P1/J4
P109
P/J87
S4
P20/J10
P25/J5
S5
P29/J9
P31/J11
P28/J8
J7
P26/J6
Figure 8 SCAM PWB, Detack/Transfer PS
Wiring Data
May 2003
7-14
V0.042
ROS, Tray Feed Motors, and Developer
P72
P/J50
P89
P2
P17/A7A5
P17/A8A5
Figure 9 ROS, Tray Feed Motors, and Developer
V0.042
May 2003
7-15
Wiring Data
P1
P4
P/J2
P/J3
P/J4
P/J5
P/J1
P/J6
P/J12
P/J7
P/J11
P/J8
P/J10
P/J9
P6
Figure 10 Finisher - Rear View
Wiring Data
May 2003
7-16
V0.042
Finisher - Service Tray
P9
J1
P4
J2
Figure 11 Finisher - Service Tray
V0.042
May 2003
7-17
Wiring Data
Finisher/IOT Connector
Stapler Position Motor Connector
P2
P69
J15
View of the Finisher undocked from the IOT
Stapler Position
Motor
Figure 12 Finisher/IOT Connector
Wiring Data
Figure 13 Stapler Position Motor Connector
May 2003
7-18
V0.042
W8A4, W8A3, and W3A1 IIOC PWBs
P58/W8A4
B4P1/W8A3
P57/W8A3
P73/W8A4
P93/W8A3
S6P1/W8A4
B5P1/
W3A1
P62/W3A1
P83/W3A1
Figure 14 IIOC PWBs
V0.042
May 2003
7-19
Wiring Data
W8A2, and W8A1 IIOC PWBs
P51/W8A2
P52/W8A1
P100/W8A2
P53/W8A1
Figure 15 IIOC PWBs
Wiring Data
May 2003
7-20
V0.042
ESS PWB
J7
P3/J2
P1/J5
Figure 16 ESS PWB
V0.042
May 2003
7-21
Wiring Data
ESS Hard Disk Drive and Image Disk Drive
P2
P2/J1
Figure 17 ESS and Image Hard Drives
Wiring Data
May 2003
7-22
V0.042
Finisher Front
P3
P5
P4
P2
Figure 18 Finisher Front
V0.042
May 2003
7-23
Wiring Data
Decurler
P2
Figure 19 Decurler
Wiring Data
May 2003
7-24
V0.042
IOT Paper Tray Heater and HCF Tray Heater
P/J123
J59
P/J121
P125 Connects to J4
J110
P5 Connects to J5
P105
J105
J3
P8
Fuse
P6
J4
J1
J5
Figure 20 IOT Paper Tray and HCF Tray Heater
V0.042
May 2003
7-25
Wiring Data
Tag 112 Convenience Stapler Harness

J87A
P87
P45A
J45
P45
Figure 21 Tag 112 Convenience Stapler Harness
Wiring Data
May 2003
7-26
V0.042
MFF Plug Jack Locations

P/J118
P-EJT
Plug Jack Drawings

P144
P/J141
P145
P/J111
P/J126
P145B

V0.042
May 2003
7-27
Wiring Data
P-STPWB/J-STPWA
P/J92
P573
P/J567
P/J578
P/J565
P/J577
P1
P41
P/J35
P1 (LVPS)
P3
P-STLG/J-STLG
P2
P54
REC 2
REC 1
P/J439
P/J411
P/J256
P/J257
P666
P666A
P666B
P999
P903
Wiring Data
May 2003
7-28
V0.042
P411
P203
P201
P202
P403
P101
P103
P102
P410
P401
P404
P402
P406
P405
P407
P408
P400
P409
P6
P302
P4
P5
P2
P1
P301
P303
Figure 3 MFF PWBs
V0.042
May 2003
7-29
Wiring Data
P55
P-EJT-JP
P142
J-EJT-JP
Figure 4 MFF - Top View with cover removed

Wiring Data
May 2003
7-30
V0.042
P563
P605
P562
Figure 5 Booklet Maker Staplers

V0.042
May 2003
7-31
Wiring Data
PWB Drawings
Index
Go to the appropriate PWB Drawing:
Main Control PWB Figure 1.
Distribution PWB Figure 2.
SCAM PWB Figure 3.
HCF PWB Figure 4.
DADF PWB Figure 5.
Finisher Controller PWB Figure 6.
Wiring Data
PWB Drawings
May 2003
7-32
V0.042
PWB Drawings
V0.042
May 2003
7-33
Wiring Data
PWB Drawings
Figure 2 Distribution PWB
Wiring Data
PWB Drawings
May 2003
7-34
V0.042
Figure 3 SCAM PWB
V0.042
May 2003
7-35
Wiring Data
PWB Drawings
Figure 4 HCF PWB
Wiring Data
PWB Drawings
May 2003
7-36
V0.042
Figure 5 DADF PWB
V0.042
May 2003
7-37
Wiring Data
PWB Drawings
Figure 6 Finisher Controller PWB
Wiring Data
PWB Drawings
May 2003
7-38
V0.042
IIOC PWB Locations

Index
IIOC PWBs - IOT Rear View (Top)
IIOC PWBs - IOT Rear View (Lower)
IIOC PWBs - Inverter
IIOC PWBs - Paper Tray Drives Plate (Tray 1/Tray 2)
IIOC PWB - Finisher
V0.042
May 2003
7-39
Wiring Data
IIOC PWB Locations
IIOC PWBs - Duplex, PFT, and Decurler

Table 1 IIOC PWBs - Duplex, PFT, and Decurler
IIOC
W8A5
W21A1
Plug/Jack
Input/Output Description
J1/P97
Duplex Exit Sensor
J2/P97
Duplex Wait Clutch
J3/P94
PreFuser Transport Sensor (S3)
J4/P94
PreFuser Transport Fan
J4/P1
6.8k Ohm Resistor or Decurler
Wiring Data
IIOC PWB Locations
May 2003
7-40
V0.042
Figure 1 IIOC PWBs - Duplex and PFT
V0.042
May 2003
7-41
Wiring Data
IIOC PWB Locations

Table 2 IIOC PWBs - IOT Rear View (Top)
IIOC
W3A1
W8A3
W8A4
W25A1
Plug/Jack
J1/P62
J2/B5P1
ROS Developer Cooling Fan
J3/P83
Registration Sensor (S4)
J4/P83
Registration Clutch
J1/P57
IOT Interlocks Closed Signal
J2/B4P1
xerographic Blower Motor (CRU Blower)
J3/P119
Document Glass Cover Position Sensor
J4/P93
Pre-Charge Erase lamp
J2/P58
Card Cage and LVPS Cooling Fan
J3/PS6P1
NOHAD Thermostat
J4/P73
Duplex PreRegistration Solenoid
J2
Jumper - 6.8k Ohm Resistor (DC 255 Only)
Wiring Data
IIOC PWB Locations
May 2003
7-42
V0.042
DC 255 ONLY
Figure 2 IIOC PWBs - IOT Rear View (Top)
V0.042
May 2003
7-43
Wiring Data
IIOC PWB Locations
IIOC PWBs - IOT Rear View (Lower)

Table 3 IIOC PWBs - IOT Rear View (Lower)
IIOC
W8A1
W8A2
Plug/Jack
J1/P52
Low Toner Sensor
J2/P52
Toner Bottle Motor
J3/P53
J4/P53
Fuser Power Relay
J1/P51
Toner Bottle Sesnor
J2/P51
Toner Dispenser Motor
J3/P100
Power ON/OFF Switch (white)
J4/P100
Fuser Fan
Wiring Data
IIOC PWB Locations
May 2003
7-44
V0.042
Figure 3 IIOC PWBs - IOT Rear View (Lower)
V0.042
May 2003
7-45
Wiring Data
IIOC PWB Locations
IIOC PWBs - Inverter

Table 4 Inverter IIOC PWBs
IIOC
A4A1
A4A2
Plug/Jack
J2/P7
Inverter Reverse Drive Solenoid
J4/P9
Inverter Close Nip Solenoid
J1/P1
Inverter Entrance Sensor (S4)
J2/P1
Inverter Entrance Gate Solenoid
J3/P3
Inverter Exit Sensor (S5)
J4/P3
Wiring Data
IIOC PWB Locations
May 2003
7-46
V0.042
NOTE: The IIOC PWBs in

the Inverter are located
under plastic covers.
Figure 4 Inverter IIOC PWBs
V0.042
May 2003
7-47
Wiring Data
IIOC PWB Locations

Table 5 Paper Tray Drives Plate IIOC PWBs (Tray 1 / Tray 2)
IIOC
A7A1
Plug/Jack
J1&J2/P1
Lower Tray Size Sensing Switches
J3&J3/P2
A7A2
J1&J2/P1
Upper Tray Size Sensing Switches
J3&J3/P2
A7A3
A7A4
A7A5
J2/P2
Upper Tray Size Elevator Motor
J4/P4
Lower Tray Size Elevator Motor
J1/P15
Lower Tray Stack Height Sensor
J2/P13
Lower Tray Nudger Solenoid
J3/P11
Upper Tray Stack Height Sensor
J4/P9
Upper Tray Nudger Solenoid
J1&J2/P17
Tray 1/ Tray 2 Wait Station Sensor
J3/B3P1
Tray 1/ Tray 2 Feed Motor
Wiring Data
IIOC PWB Locations
May 2003
7-48
V0.042
Figure 5 Paper Tray Drives Plate (Tray 1 / Tray 2)
V0.042
May 2003
7-49
Wiring Data
IIOC PWB Locations

Table 6 Paper Tray Drives Plate IIOC PWBs (Tray 3 / Tray 4)
IIOC
A8A1
Plug/Jack
J1&J2/P1
Lower Tray Size Sensing Switches
J3&J3/P2
A8A2
J1&J2/P1
Upper Tray Size Sensing Switches
J3&J3/P2
A8A3
A8A4
A8A5
J2/P2
Upper Tray Size Elevator Motor
J4/P4
Lower Tray Size Elevator Motor
J1/P15
Lower Tray Stack Height Sensor
J2/P13
Lower Tray Nudger Solenoid
J3/P11
Upper Tray Stack Height Sensor
J4/P9
Upper Tray Nudger Solenoid
J1&J2/P17
Tray 3 / Tray 4 Wait Station Sensor
J3/B3P1
Tray 3 / Tray 4 Feed Motor
Wiring Data
IIOC PWB Locations
May 2003
7-50
V0.042
Figure 6 Paper Tray Drives Plate (Tray 3 / Tray 4)
V0.042
May 2003
7-51
Wiring Data
IIOC PWB Locations
IIOC PWB - Finisher

Table 7 Finisher IIOC PWB
IIOC
Plug/Jack
A7A1
J1/P13
Finisher Empty Sensor
Wiring Data
IIOC PWB Locations
May 2003
7-52
V0.042
Figure 7 Finisher IIOC PWB
V0.042
May 2003
7-53
Wiring Data
IIOC PWB Locations
Wiring Data
IIOC PWB Locations
May 2003
7-54
V0.042
Wirenet Drawings
Introduction
The wirenet drawings in this section show the distribution of all AC and DC voltages, DC
Return voltages, and the IIOC SID/SOD/CLK signals used throughout the Document Centre
240/255/265/460/470 and DocuTech65/DocuPrint65 machines. The wirenet drawings are
designed to interface with the Circuit Diagrams and the RAPs. If a voltage is missing from the
circuit diagram, or you are directed to the wirenet drawings from a RAP, locate the component
that is missing the voltage and follow the circuit back to the source of the voltage or return voltage.
Index
Figure 1 AC Distribution 60HzSheet 1 of 2
Figure 2 AC Distribution 60Hz Sheet 2 of 2
Figure 3 ACN Distribution 60HzSheet 1 of 2
Figure 4 ACN Distribution 60Hz Sheet 2 of 2
Figure 9 +5 VDC Distribution (240/255/265DC) 1 of 4
Figure 10 +5 VDC Distribution (255/265ST) 2 of 4
Figure 11 +5 VDC Distribution (240/255/265) 3 of 4
Figure 13 DC COM (5 V RET) Distribution (240/255/265 DC) 1 of 4
Figure 14 DC COM (5 V RET) Distribution (255/265 ST) 2 of 4
Figure 15 DC COM (5 V RET) Distribution (240/255/265) 3 of 4
Figure 17 +5 VDC Distribution (460/470DC) 1 of 4
Figure 18 +5 VDC Distribution (460/470 ST) 2 of 4
Figure 19 +5 VDC Distribution (460/470) 3 of 4
Figure 21 DC COM (5 V RET) Distribution (460/470 DC) 1 of 4
Figure 23 DC COM (5 V RET) Distribution (460/470) 3 of 4
Figure 29 +24 VDC Distribution 1 of 10
V0.042
Figure 39 DC COM (24 V RET) Without Tag F 027 Distribution 1A of 5
Figure 40 DC COM (24 V RET) Distribution (With Tag F027) 1B of 5
Figure 41 DC COM (24 V RET) Distribution 2 of 5
Figure 45 +36 VDC Distribution (240/255/265)
Figure 46 DC COM (36 V RET) Distribution (240/255/265)
Figure 47 +36 VDC Distribution (460/470)
Figure 48 DC COM (36 V RET) Distribution
Figure 49 IIOC Bus 0 SID/SOD/CLK Distribution 1 of 2
Figure 54 IIOC Bus 2 and Bus 4 SID/SOD/CLK Distribution (Without Tag F027) 1 of 2
Figure 55 IIOC Bus 2 and Bus 4 SID/SOD/CLK Distribution (With Tag F027) 2 of 2
May 2003
7-55
Wiring Data
Wirenet Drawings
Drawings
Wiring Data
Wirenet Drawings
May 2003
7-56
V0.042
V0.042
May 2003
7-57
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-58
V0.042
V0.042
May 2003
7-59
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-60
V0.042
V0.042
May 2003
7-61
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-62
V0.042
V0.042
May 2003
7-63
Wiring Data
Wirenet Drawings
Figure 9 +5 VDC Distribution (240/255/265DC) 1 of 4
Wiring Data
Wirenet Drawings
May 2003
7-64
V0.042
Figure 10 +5 VDC Distribution (255/265ST) 2 of 4
V0.042
May 2003
7-65
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-66
V0.042
V0.042
May 2003
7-67
Wiring Data
Wirenet Drawings
Figure 13 DC COM (5 V RET) Distribution (240/255/265 DC) 1 of 4
Wiring Data
Wirenet Drawings
May 2003
7-68
V0.042
V0.042
May 2003
7-69
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-70
V0.042
V0.042
May 2003
7-71
Wiring Data
Wirenet Drawings
Figure 17 +5 VDC Distribution (460/470DC) 1 of 4
Wiring Data
Wirenet Drawings
May 2003
7-72
V0.042
Figure 18 +5 VDC Distribution (460/470 ST) 2 of 4
V0.042
May 2003
7-73
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-74
V0.042
NOTE: Some Document Centre 460/470

machines built in June 2000 will have this harness (from P/J4 on the distribution PWB to
J95).
V0.042
May 2003
7-75
Wiring Data
Wirenet Drawings
Figure 21 DC COM (5 V RET) Distribution (460/470 DC) 1 of 4
Wiring Data
Wirenet Drawings
May 2003
7-76
V0.042
V0.042
May 2003
7-77
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-78
V0.042
NOTE: Some Document Centre 460/470

machines built in June 2000 will have this
harness (from P/J4 on the distribution
PWB to J95).
V0.042
May 2003
7-79
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-80
V0.042
V0.042
May 2003
7-81
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-82
V0.042
V0.042
May 2003
7-83
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-84
V0.042
V0.042
May 2003
7-85
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-86
V0.042
V0.042
May 2003
7-87
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-88
V0.042
V0.042
May 2003
7-89
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-90
V0.042
Figure 36 +24 VDC Distribution (Without Tag F027) 8 of 10
V0.042
May 2003
7-91
Wiring Data
Wirenet Drawings
Figure 37 +24 VDC Distribution (With Tag F027) 9 of 10
Wiring Data
Wirenet Drawings
May 2003
7-92
V0.042
V0.042
May 2003
7-93
Wiring Data
Wirenet Drawings
Figure 39 DC COM (24 V RET) Without Tag F 027 Distribution 1A of 5
Wiring Data
Wirenet Drawings
May 2003
7-94
V0.042
Figure 40 DC COM (24 V RET) Distribution (With Tag F027) 1B of 5
V0.042
May 2003
7-95
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-96
V0.042
V0.042
May 2003
7-97
Wiring Data
Wirenet Drawings
Figure 43 DC COM (24 V RET)T Distribution 4 of 5
Wiring Data
Wirenet Drawings
May 2003
7-98
V0.042
V0.042
May 2003
7-99
Wiring Data
Wirenet Drawings
Figure 45 +36 VDC Distribution (240/255/265)
Wiring Data
Wirenet Drawings
May 2003
7-100
V0.042
Figure 46 DC COM (36 V RET) Distribution (240/255/265)
V0.042
May 2003
7-101
Wiring Data
Wirenet Drawings
Figure 47 +36 VDC Distribution (460/470)
Wiring Data
Wirenet Drawings
May 2003
7-102
V0.042
Figure 48 DC COM (36 V RET) Distribution
V0.042
May 2003
7-103
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-104
V0.042
V0.042
May 2003
7-105
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
7-106
V0.042
V0.042
May 2003
7-107
Wiring Data
Wirenet Drawings
Wiring Data
Wirenet Drawings
May 2003
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Figure 54 IIOC Bus 2 and Bus 4 SID/SOD/CLK Distribution (Without Tag F027) 1 of 2
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Wiring Data
Wirenet Drawings
Figure 55 IIOC Bus 2 and Bus 4 SID/SOD/CLK Distribution (With Tag F027) 2 of 2
Wiring Data
Wirenet Drawings
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MFF Wirenet Drawings

Introduction
The wirenet drawings in this section show the distribution of all DC voltages and DC Return
voltages used throughout the MultiFunction Finisher. The wirenet drawings are designed to
interface with the Circuit Diagrams and the RAPs. If a voltage is missing from the circuit diagram, or you are directed to the wirenet drawings from a RAP, locate the component that is
missing the voltage and follow the circuit back to the source of the voltage or return voltage.
Index
Figure 1 +5 VDC MFF Wirenet Sheet 1 of 4
Figure 5 DC COM (5V RET) MFF Wirenet Sheet 1 of 4
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MFF Drawings
Wiring Data
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Wiring Data
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MFFWirenetFig6a
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Wiring Data
Wiring Data
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Wiring Data
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10. Principles of Operation

Machine Overview...........................................................................................................
Standby Power ................................................................................................................
User Interface..................................................................................................................
Machine Run Control and IIOC .......................................................................................
Start Power .....................................................................................................................
Document Transportation................................................................................................
Imaging (Scanning - Chain 14 & ROS-Chain 6)..............................................................
Paper Supply...................................................................................................................
Paper Transportation ......................................................................................................
Marking ...........................................................................................................................
Fusing and Copy Transportation.....................................................................................
NOHAD ...........................................................................................................................
Finishing..........................................................................................................................
ESS (Chain 16) and Connectivity (Chain 18) ..................................................................
460/470 ESS ...................................................................................................................
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10-139
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Principles of Operation
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Machine Overview
Introduction
The Document Centre 240/255/265 consists of a family of products, such as, copiers, printers,
faxes, and multifunction devices. It is designed to provide multiple functionality as one system.
The entire system can provide digital copying, fax, LAN printing and host printing capabilities at
a speed of 40 pages per minute for DC240, 55 pages per minute for DC255 or 65 pages per
minute for DC265.
Document Centre 240/255/265 Product Configuration

The Document Centre 240/255/265 products are designed as combinations of modular platforms that share a common interface design. This provides system flexibility and the ability to
develop new functions efficiently without redesigning the entire product.
The basic configuration includes electronic image editing, a document feeder, and 4 paper
drawers. Additional functionality can be added with the following options (Figure 1):
High Capacity Feeder (HCF)
Bypass Tray
Finisher
Convenience Stapler
Bypass Tray
Convenience Stapler
Finisher
DADF
IOT
High Capacity
Feeder (HCF)
Figure 1 Document Centre 240/255/265
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Machine Overview
Principles of Operation Overview
User Interface (Chain 2)
Principles of Operation is written on a BSD chain by chain basis. This is done because the
Block Schematic Diagrams (BSDs) form a good outline for describing machine operation.
The User Interface (Figure 3) is a soft control-panel consisting of a display unit, plastic overlays, key caps, indicators, and the electronics associated with these components.
Standby Power (Chain 1)
User Interface (Chain 2)
Machine Run Control (Chain 3)
The purpose of the User Interface is to provide communication between the user and Machine
Run Control. The User Interface transmits operator commands to Machine Run Control, and
displays messages and graphics in response to commands from Machine Run Control.
Start Power and Drives (Chain 4)
Document Transportation (Chain 5)
Imaging (Chain 6 - actually Chain 14 but covered under Chain 6)
Paper Supply (Chain 7)
Paper Transportation (Chain 8)
Marking - Xerographics (Chain 9)
Fusing and Copy Transportation (Chain 10)
Finishing (Chain 12)
User Interface
Standby Power (Chain 1)

Standby Power includes the AC power distribution, DC power distribution, and the electrical
interlock system.
The purpose of Standby Power is to filter the AC power input, generate various levels of DC
voltages, and distribute the AC and DC voltages at required power levels to the various subsystems.
Figure 2 User Interface
Machine Overview
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Machine Run Control (Chain 3)
Start Power and Drives (Chain 4)
Machine Run Control is the electronics and software that controls the operating cycle of the
machine. Machine Run Control receives status information from all subsystems within the
machine and controls the operation of the subsystems. Machine Run Control provides the following major functions:
Start Power provides mechanical drive to various subsystems at required speeds and torque
levels.
Implementation of operator commands and the determination of feedback to the operator.
Determination of prescans and other subsystem setup requirements, and issuing commands or switching on/off components to accomplish them.
Provide the timing information and sequence instructions to all subsystems during run.
Monitor faults and provide job recovery.
Provide the cycle down commands to all subsystems.
Start Power (Figure 4) consists of two Main Drive Motors, (the Developer Drive Motor, the
Fuser Drive Motor) and the main gear train. These components supply drive to the main copier
subassemblies responsible for paper transport and imaging. Several other subassemblies,
such as the Document Feeder the Paper Trays and the Bypass Tray / High Capacity Feeder,
contain their own drive motors and systems that operate independent of the main drive system.

Fuser Drive Motor
Figure 3 Drives
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Machine Overview
Document Transportation (Chain 5)
Imaging Chain 6
The Document Feeder (DADF) (Figure 6) feeds one or two-sided documents from a positioned
stack, registers the document on the CVT (Constant Velocity Transport) platen for scanning,
and then removes the document and transports it to the Exit Tray.
The Document Feeder can automatically feed up to 50 documents (up to 75 documents on
Document Centre 460/470), one at a time, across the scanner. The documents can range in
size from 5.5 x 8.5 (A5) to 11 x 17 (A3). The lengths of documents within one set can vary a
maximum of 2 mm.
NOTE: Imaging includes Chain 6 and Chain 14.

Imaging includes both the input and output scanning operations, as well as the exposing operation of the Photoreceptor:
The scanner scans the document, and the Video Buffer Board combines the optical
image for each scan line into an electrical, analog voltage data.
The SCVM (Scanning Control and Video Module) portion of the Main Control PWB converts the analog video data into digital data.
IPS1area of the Main Control PWB processes the digital data and creates a histogram to
analyze the scanned image and make necessary corrections. It also can perform several
image rendering functions, such as the application of filters, screens, thresholds and error
diffusion.
IPS2 area of the Main Control PWB fine tunes the pixel data and generates laser output
signals which are sent to the ROS Control Module
The RCM (ROS Control Module) converts the laser output signals into rasterized light
pulses for each scan line. It then controls the laser so each line is exposed on the photoconductor, creating an electrostatic image pattern representing the processed video data.
Document Feeder
Figure 4 Document Feeder (DADF)
Machine Overview
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Paper Supply (Chain 7)
Paper Transportation (Chain 8)
Paper Supply provides paper or other copy material such as transparencies to a ready-to-feed
position.
The Paper Transportation (Figure 9) moves paper or other copy material from the selected
paper supply source, positions the material correctly in the Registration Assembly, and sends
the material to the Transfer Assembly to accept the image from the photoreceptor.
The Paper Supply (Figure 7) consists of four Paper Trays. An optional Bypass Tray / High
Capacity Feeder is available to increase the paper supply capacity and to feed special materials such as transparencies and thick paper.
Photoreceptor
Bypass Tray
(Tray 5)
Registration
Transport
Figure 6 Cross Section of the IOT Paper Path

High Capacity
Feeder Tray
(Tray 6)
Paper Trays 1
through 4
Figure 5 Paper Trays
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Machine Overview
Marking - Xerographics (Chain 9)

The Marking (Xerographic) module (Figure 10) provides the following functions:
Charges the photoreceptor so it can be exposed with the document image data to create
a latent electrostatic image on the photoreceptor.
Develops the latent electrostatic image with a process that deposits toner on the charged
image areas.
Transfers the developed image from the photoreceptor to the paper or other copy material. The transport of the material through this area is also included.
Strips the unfused copy from the Photoreceptor so it can be transported to the fusing station.
Cleans the residual toner from the photoreceptor to prepare for the next charging cycle.
Xerographic Module
Machine Overview
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Fusing and Copy Transportation (Chain 10)

Fusing and Copy Transportation receives the unfused copy, fuses the image to the copy material, and transports the copy to either the output device or the duplex path.
The Fuser Module (Figure 12) uses a combination of heat and pressure to fuse the copy.
Fuser Module
Figure 8 Fuser Module
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Machine Overview
Finishing (Chain 12)

Offsetting Catch Tray (OCT)
Finisher
The Offsetting Catch Tray (OCT) (Figure 14) will support printer operation at both 40 and 65
ppm and stack up to 250 sheets of 75gsm paper. It will accommodate paper sizes from A6
(SEF) to 12" x 18" in the weight range of 56 gsm to 203 gsm. Output is stacked face down in
the tray and alternate sets may be offset from one another by 30 mm to provide set separation.
Finisher
Top Tray
Offsetting
Catch Tray
Finisher
Main Tray
IOT
Figure 10 IOT with Finisher
ESS (Chain 16) and Connectivity (Chain 18)

ESS - Chain 16
The ESS (Electronic Subsystem) Hardware platform provides an Ethernet PCI Controller with
RJ45 connectivity for the Document Centre 240/255/265 LP/ST. Based on a PowerPC Microprocessor, the ESS performs many essential functions for the system.
Figure 9 IOT with Offsetting Catch Tray (OCT)
Connectivity - Chain 18
Finisher
The Finisher (Figure 15) is an output device that receives the fused copies and prepares them
for delivery to the operator.
A network interface is a device which allows the machine to communicate on the network. The
Document Centre 240/255/265 ST/LP can be equipped with several different network interfaces to allow it to be connected to various types of networks
The Finisher offers dual stapling capabilities and two output trays. The Main Tray, can accept a
capacity of 2000 sheets, while the other, the Finisher Top Tray, can accept 250 sheets. The
Main Tray and the Offsetting Top Tray offsets the sets so they are separated.
460/470 ESS
The finisher can finish the completed sets by either stapling them or offsetting unstapled sets.
The finished sets are then delivered to an output tray for stacking or offsetting.
64 Mb DIMM (Dual In-line Memory Module) Expandable to 128 Mb
9.1 GB, 7200 RPM Wide SCSI-2 System Hard Disk Drive
System BIOS now resides on the motherboard
Integrated 10/100 Mbps Ethernet Interface Category 5 cable (or better) is required
Runs on LynxOS a UNIX based operating system
A maximum of three Finishers can be connected to one machine, with a separate bypass
transport connecting any Mailbox Finisher to another Finisher or to another finishing device.
Machine Overview
The 460/470 ESS includes:
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A 433MHz Intel Celeron processor
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Standby Power
Overview
The Standby Power subsystem receives and distributes AC electrical power, and generates
and distributes DC electrical power. This subsystem also contains interlock circuits to monitor
the IOT Front Door and the input and output devices attached to the machine.
Power On/Off Switch

(Hidden from view)
Power Switches
The Power On/Off Switch is located on the right side of the machine (Figure 1). This switch is
white in color and is a two-position rocker switch. Pushing the switch actuator towards the rear
switches the power on. Pushing the switch actuator towards the front initiates a controlled
shutdown of the machine.
The Instant Off Switch is located behind the IOT Front Door (Figure 1). This switch is red in
color and is a single-position rocker switch. Actuating this switch results in an immediate
power-off condition of the machine.
NOTE: Using the Instant Off Switch has no detrimental effect on a digital copier, but its use on
printers is discouraged. The ESS needs to be shut down in a controlled sequence, and using
this switch does not allow that sequence to occur.
NOTE: IOT Shown with Front

Door open for clarity.
Instant Off
Switch
Figure 1 Power Switches
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Standby Power
AC Power
All AC wiring (except the two wires to the Power On/Off Switch) is located at the rear of the
machine. The AC components are the AC Distribution Panel, the Power On/Off Switch, the
Low Voltage Power Supply (LVPS), and the heater rod in the Fuser Module.
DC Power
All DC power is generated by the Low Voltage Power Supply (LVPS) (Figure 3). The LVPS is
designed to operate satisfactorily within the ranges of 85 to 264 VAC, and 47 to 83 Hz. Therefore, only one LVPS is needed to meet the operating requirements of all OpCos, world-wide.
The LVPS produces five different DC voltages. Those voltages, their distribution from the
LVPS, and their uses are shown in Table 1.
Table 1 LVPS Output Voltages
J4
J6
LVPS
J2, J3
(Distribution J5 (SCAM J7 EPSV
Connector (Card Cage)
PWB)
(IIT) PWB) (FX Only)
+5.15 VDC
Used for .....

Logic Voltage
+12 VDC
Logic Voltage
-12 VDC
Logic Voltage
+24 VDC
+36 VDC
X
X
IIOC, interlocks, cooling

fans
Drive Motors (Chain 4)
and High Voltage Power
Supplies (Chain 9)
Low Voltage
Power Supply
Grounds
The ground wire of the AC Input Power Cord is attached to the metal case of the AC Distribution Module.
Distribution PWB
The DC Common (DC Com) return lines for all voltages are connected to a common electrical
bus in the LVPS. The metal case of the LVPS is also connected to that common electrical bus.
An electrical connection between the LVPS and the AC Distribution Module completes the
grounding circuit for the DC Common circuits.
Figure 2 Low Voltage Power Supply and Distribution PWB
Distribution PWB
Power Saver Mode

The DC265 product family employs several power saver modes, depending on the specific
machine model.
Copiers have two power saver modes: a Low Power Mode, and Power Off.
Printers have three power saver modes: Low Power Mode 1, Low Power Mode 2, and
Power Off.
The Distribution Board PWB (Figure 3) plugs in directly to the LVPS. (Wire harnesses distribute
the power from the LVPS to the Card Cage, the IIT, and the SCAM PWB.) DC power is distributed from the Distribution PWB to most other components in the machine, including the IIOC
buses.
The purpose of the power saver modes is to automatically shut down specific outputs of the
LVPS (up to and including complete power off) during periods of inactivity.
Refer to GP20 for a complete explanation of the power saver Modes.
Standby Power
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Interlocks
The LVPS outputs of +5.15 VDC and +/-12 VDC are continuously supplied to the Distribution
PWB and the Card Cage whenever power is switched on (and the machine is not in a power
saver mode.) However, the LVPS outputs of 24 VDC and 36 VDC are controlled by interlocks.
The IOT Front Door Interlock Switch has two separate circuits.
One circuit is used by itself to provide a logic signal to the software to inhibit machine
function when the IOT Front Door is opened.
The other circuit is used in series with the left and right side interlock switches to interrupt
the +36 VDC output of the LVPS if either the IOT Front Door is opened, or an input device
or output device is not securely attached to the IOT.
Power Supplies
The Distribution Board supplies +36 VDC to several high voltage power supplies in the
machine. These power supplies are covered in more detail in the information provided for the
Chain to which the specific power supply is applicable.
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Standby Power
Standby Power
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User Interface
Overview
The User Interface (Figure 1) contains a touch-sensitive LCD display, a hard button panel (a
key panel), and several LED indicators.
The touch-sensitive LCD display and the key panel allow the user to communicate with
the machine software.
The machine provides feedback to the user by displaying various messages in the LCD
display, and by lighting the LEDs.
Feature
Buttons
Touch Screen
Pathway
buttons
Keypad
Figure 1 User Interface
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User Interface
Liquid Crystal Display Module (LCDM)
Pathways PWB
The LCDM (Figure 2) is a black and white display, providing up to 16 gray scales at a 640 x
240 pixel resolution. It consists of a touch screen, backlit by a cold cathode fluorescent lamp.
The Pathways PWB (part of the UI assembly) includes 6 switches, 6 LEDs, 6 resistors and a
harness that connects the board to the UI Processor PWB. The switches and LEDs on this
board provide the signals that control different pathways on the Liquid Crystal Display.
The LCDM communicates between the user and the machine control two ways. Light emitting
diodes (LEDs) indicate machine and feature status, while switches activated by keycaps are
used to identify customer selections.
The LEDs and switches are mounted to two PWBs, which are controlled by UI Processor
PWB. This PWB communicates directly with the main machine controls via the Main Control
PWB.
Core PWB
The Core PWB (part of the UI assembly) includes 28 switches, 13 LEDs, 13 resistors and a
harness that connect the board to the Processor PWB. The switches and LEDS on this board
provide controls for the UI system, such as the numeric keypad, start, stop, etc.
Liquid Crystal Display Module

(Touch Screen)
Figure 2 Liquid Crystal Display
Inverter Module
The Inverter module (part of the UI assembly) controls the intensity of the CCFL backlight. The
processor board sends 5 VDC input signals to the inverter, which converts the signals to the
voltage needed to obtain that level from the CCFL. The Processor PWB can also send a signal
to reduce the brightness or shut off the CCFL lamp to increase the life of the CCFL lamp.
User Interface
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Machine Run Control and IIOC

Overview
The copier uses data communication methods to control its operation. Controls are initiated at
the UI PWB and sent via a Serial Command Bus (SCB) to the Main Control PWB. The Main
Control PWB then distributes the control signals to machine components via two power harnesses, two ribbon cables and two video cables.
One CPU (Central Processor Unit) provides real time control in the system. This CPU controls
the system management software, machine control and video control. Inputs and outputs are
controlled by IIOCs (Integrated Input Output Connector). A Serial Command Bus (SCB) is
used to communicate between the CPU and remote boards that require real time control
(SCAM, RCM). Point-to-point serial UART (Universal Asynchronous Receiver / Transmitter)
channels are used to communicate with the scanner and UI.
The Electronic SubSystem (ESS) can also receive control signals via a network. The ESS is
the network client interface that decomposes PostScript and HP PCL5e print languages and
sends the print request to the copier.
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Card Cage
The card cage contains all the machine control and video modules used by the machine. There
are four modules combined into one functional board called the Main Control PWB:
Low Cost Processing Module (LCPM).
Integrated Video and Control Module (IVCM).
Input Image Processing Module (IPS1 and IPS2).
Scanner Control and Video Module (SCVM).
iIPS1 Daughter PWB
The card cage is mounted to the back of the machine with hinges. This design allows the card
cage to swing open if access is needed to the components located on the machine side of the
card cage.
The power and control signals are distributed from the card cage to machine components via
two power harnesses, two ribbon cables and two video cables. +24 DC power is controlled by
IIOCs. Go to topic IIOC for more information.
Main Control PWB

The Main Control PWB (Figure 1) is the main video and control board for the machine. It is
actually a combination of 4 boards, which are described individually on the following pages.
The purpose of the Main Control PWB is to receive analog video data via the Video Buffer
Board, process the data, and output PWPM (Pulse Width and Pulse Modulated) video data to
the laser diode drivers. The video data is output over 2 data lines to the RCM (ROS Control
Module).
Accessory PWB
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Low Cost Processing Module (LCPM)

The LCPM area of the Main Control PWB provides the main system control for the machine.
The LCPM accomplishes this using two types of communication:
It communicates with the IIOCs by sending control signals and receiving signals from the
devices.
It communicates with the User Interface through a Serial Command Bus (SCB).
Input Image Processing Module (IPS1)

The IPS1 (Image Processing) area of the Main Control PWB provides image processing functions such as reduction, enlargement, edge enhancement, TRC (Tone Reproduction curve)
correction, resolution conversion, segmentation, screening and error diffusion. It also provides
the image registration functions for the scanner.
The IPS1 includes a microcontroller that assists the image processing ASICs (Application Specific Integrated Circuit).
Integrated Video and Control Module (IVCM)

The IVCM provides video control, output image processing and ROS beam PWPM (Pulse
Width Pulse Modulation) functions.
The IVCM receives video signals from the scanner via the SCVM module. It then compresses
and decompresses the video data so it represents 600x600x2 images. If merging or rotating
features are required, the IVCM manipulates the video data to provide the desired result. The
IVCM then transmits pulse signals that modulate the dual laser beams in the ROS. These
pulse signals, called pulse width and position modulated (PWPM) data, are generated by the
IPS2 area of the Main Control PWB and ROS electronics resident in this module
The IVCM also provides line buffering for the dual beam lasers in the ROS, patch generation,
pixel density counting, image registration, compact dot growth and other ROS interface functions.
Scanner Control and Video Module (SCVM)

The SCVM (part of the Main Control PWB) controls the scanner operations and provides a
video circuit for image data from the Full Width Array.
Scanner operations
The SCVM uses a microcontroller to control the operation of scanner components and
servo control for the scanner. It also processes and controls the scanner calibration process.
Video circuit.
The video circuit of the SCVM receives image data from the Full Width Array via the Video
Buffer Board. It then adjusts the video data for the needed analog offset and gain correction as determined by UI selections.
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The Servo Control and Analog Module (SCAM)

The Servo Control and Analog Module (SCAM) (Figure 2) is a remote (stand alone) PWB that
controls the servo motor for the photoconductor and the two servo motors for the main drive
motors (Developer Drive Motor and Fuser Drive Motor). This PWB contains 2 microcontrollers
that communicate over the Serial Command Bus to the Main Control PWB.
The SCAM board also performs read/write operations for the fuser circuit. It updates and polls
analog I/Os for the fuser control algorithm. This algorithm then uses a PWM (Pulse Width Modulation) to turn on the fuser lamps, power supplies, fuser temperature circuit, xerographics, etc.
SCAM PWB
Figure 2 SCAM PWB
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Power Up Self-Test
IIOC
The LCPM and SCVM portions of the Main Control PWB run self-tests of the RAM, FLASH,
NVM and other resources on the PWB at power-up.
IIOC (Integrated Input/Output in a connector) is a low intelligence IC Driver in a single integrated circuit is integrated into a connector. IIOC is the Integrated Input/Output Control bus. It
is a multiplexing communication bus. It provides the ability to accommodate a large amount of
I/O while minimizing the amount of physical wires. This bus has 5 wires, 24V, 24V RET, Clock,
SID, and SOD. The clock supplies a +15 VDC reset pulse followed by 32 +5 VDC pulses, then
a +15 VDC reset pulse to start the cycle over. SID and SOD are + 5 VDC logic level lines for
the input and output respectively. This connector is attached to a five wire BUS that includes
time division multiplexed signals and power.
The IIOC modules are tested using two methods:
an internal turnaround test which tests the channel controller ASIC.
an external turnaround which tests the IIOC modules, harnesses and inputs/outputs of
electrical components.
Communication Channels
The Main Control PWB communicates over several channels; the UI, SCAM, and RCM (Ros
Control Module). These channels use Universal Asynchronous Receive Transmit circuits or
busses (UARTs) to communicate with the CPU on the Main Control PWB. (MCB).
Image Disk Drive

The Image Disk Drive (Figure 4) is a hard disk that stores submitted jobs after they are processed by IIT and the Main Control PWB. The disk provides hundreds of megabytes of temporary storage. The IOT then retrieves the image data from the Image Disk when the copier is
ready to create the next print. This configuration allows the IOT to make multiple copies of the
document without requiring the DADF to feed documents multiple times.
IIOC Logic and signals

Each IIOC BUS has five wires. These five wires contact the IIOC PWB via pins in the IIOC
Module. The wires carry the following signals:
Serial Input Data (SID) to the module. This can be programmed to provide from 8 to 32
Inputs/Outputs.
Serial Output Data (SOD) from the module. The number of data bits is determined by the
SID.
Synchronous Clock and Frame Pulse signal (CLK). Operation is limited to between
25KHz and 100KHz. The reset pulse is +15 VDC with the clock at +5 VDC.
+ 24 VDC. Current is limited to 8A per IIOC BUS.
DC COM
There are four IIOC BUS Controllers on the Main Control PWB
Image
Disk Drive
Figure 3 Image Disk Drive
BUS 0 Controller.
An 03-800 fault code indicates a failure of the Bus 0 Controller Chip on the Main
Control PWB.
An 03-340 indicates the system cannot communicate with IIOC Bus 0. All other IIOC
Buses are functional. This indicates there may be a short circuit in the BUS 0 IIOC
harness.
BUS 1 Controller.
Control PWB.
An 03-341 indicates the system cannot communicate with IIOC Bus 1. All other IIOC
harness.
BUS 2 Controller.
Control PWB.
An 03-342indicates the system cannot communicate with IIOC Bus 2. All other IIOC
harness.
BUS 4 Controller DADF IIOC. Failure of the BUS 4 Controller will generate a 05-331 fault
The signals IIOC BUS x output (SID), IIOC BUS Clock (CLK), and IIOC BUS Reset are generated by the BUS Controllers on the Main Controller PWB and sent to the Distribution PWB.
The Distribution PWB provides the +24 VDC and DC COM for each IIOC BUS, distributes the
SID and CLK signals to each BUS, and passes the Serial Output Data (SOD) from the BUS
back to the BUS Controllers.
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2 Bit, 3 Bit, and 4 Bit Mode
Each IIOC Module consists of the IIOC Housing, the IIOC PWB, and the Input/Output Connectors (Figure 8). The IIOC Module is connected to the IIOC harness via IDC connectors on the
bottom of the IIOC Housing.
In 2 Bit Mode, data is sent over the SID line to:
Enable two high current drivers to drive two outputs (solenoid, clutch, motor).
Enable two inputs (sensor, switch).
IIOC Addressing and Configuration
The input state data is sent back via the SOD line to the Main Control PWB.
Within Bus 0, 1 and 2, each IIOC PWB is uniquely controlled by the matrix of pins which touch
the PWB from the IIOC Housing (Figure 9).
Enable one low current driver to drive one output (LED, SSR).
Enable one input (sensor, switch).
The five large pins in the IIOC Housing make the connection between the IIOC harness
and the IIOC PWB. All five large pins must touch the IIOC PWB.
The seven small pins in the IIOC Housing are the programming pins (Table 1):
The input state data is sent back via the SOD line to the Main Control PWB.
A IIOC in 2 Bit mode has Pin 1 and Pin 2 up (both pins contacting the IIOC PWB)
A IIOC in 3 Bit mode has Pin 1 or Pin 2 up (one pin contacting the IIOC PWB)
Enable two low current drivers to drive two low current output (LED, SSR).
Pin 2 and Pin 3 configure the IIOC for 2 Bit Mode, 3 Bit Mode, or 4 Bit Mode.
A IIOC in 4 Bit mode has Pin 1 and Pin 2 down (both pins not contacting the IIOC
PWB)
See Figure 5 for a layout of a 2 input / 2 output IIOC in 2 Bit, 3 Bit and 4 Bit mode.
Each IIOC module has a unique address, determined by which programming pins (4,
5, 6, and 7) are bent down into the IIOC Housing and DO NOT touch the IIOC PWB.
4 Input and 4 Output Modules

The IIOC Chip used in the 4 Input and 4 Output IIOC Module is the same chip used for the 2
Input / 2 Output IIOC Module. The difference between the 4 Input and 4 Output IIOC Modules
and the 2 Input / 2 Output IIOC Module is the components on the IIOC PWB.
Table 1 IIOC Programming Pins

Pin
PWB Contact
Purpose
Gnd
Logic Ground
C2
Configuration (2, 3 or 4 bit mode)
C1
Configuration (2, 3 or 4 bit mode)
A4
Address on BUS
A3
Address on BUS
A 4 Output IIOC Module is used for motors that require breaking or are required to run in the
forward and reverse direction. This type of IIOC Module is used for the Tray 1/2 Feed Motor,
the Tray 3/4 Feed Motor, and the HCF/Bypass Tray Feed Motor.
A2
Address on BUS
A1
Address on BUS
See Figure 6 for a layout of a 4 Input IIOC and a 4 Output IIOC.
Go to Table 2 to view the specific Module # and Pin # combinations for BUS 0
A 4 Input IIOC Module is used for IIOC Module A7A1 (size sensing for Paper Tray 1), IIOC
Module A7A2 (size sensing for Paper Tray 2), IIOC Module A8A1 (size sensing for Paper Tray
3), and IIOC Module A8A2 (size sensing for Paper Tray 4),
Table 2 IIOC Housing Pin Connections BUS 0
IIOC Hardware
There are four IIOC BUS harnesses (the DADF IIOC BUS does not have a dedicated harness).
IIOC BUS 0 is split into IIOC BUS 0 (ES) and IIOC BUS 0. Each IIOC BUS originates at the
Distribution PWB and consists of one or more IIOC Modules. Figure 7 is an example of a typical IIOC harness.
IIOC BUS 0 (ES) - IOT Front Door, Toner Bottle, Toner Dispenser, Xerographic components, Fuser Fan, Card Cage Cooling Fan, LVPS Cooling Fan, NOHAD Thermostat,
Duplex Transport.
Module
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
A7A1 (Paper Tray Drives Plate)
W8A1 (IOT rear)
W8A2 (IOT rear)
W8A3 (IOT rear)
W8A4 (IOT rear)
W8A5 (IOT rear)
W20A1 (FX Only)
W25A1 (55 ppm only)
NOTE: Components on this BUS are energized when the machine is in the Energy Saver
mode.
IIOC BUS 0 - Tray 1/2 Drives Plate.
IIOC BUS 1 - Tray 3/4 Drives Plate, Registration Transport, Inverter, HCF PWB, ROS/
Developer Cooling Fan.
IIOC BUS 2 - Finisher.
IIOC BUS 4 - DADF. The DADF IIOC PWBs are mounted directly to the DADF PWB
May 2003
10-22
V0.042
Go to Table 3 to view the specific Module # and Pin # combinations for BUS 1.
Module
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
A4A1 (Inverter)
A4A2 (Inverter)
A14A1
W3A1 (IOT rear)
W21A1
Improved harness manufacturing cost and quality (fewer wires/more automation, reduces
final line debug time, smaller wire bundles to assemble).
Improved field reliability (improved fault protection and detection).
Improved field cost (reduced time to diagnose and repair, reduced unit cost of spared
assemblies).
IIOCs provides fault isolation in the field via diagnostic turnaround tests. These tests can:
Identify the IIOC module that is failing.
Identify the BUS that is failing.
Detect if an output load is not connected (high current output)
Detect if an input load is not connected (if the load is energized in the standby state)
IIOC Diagnostics
There are two types of IIOC Turnaround tests used to diagnose IIOC failures of individual IIOC
Modules:
[Self Tests tab , IIOC Controller Tests], [Type 1] - A Type 1 test failure indicates the energizing voltage through an output component was not sensed by the IIOC PWB. Check
the output components and the associated wiring for an open circuit or a short circuit to
DC COM. If there is no problem with the wiring, the IIOC PWB most likely has failed.
[Self Tests tab , IIOC Controller Tests], [Type 2] - A Type 2 test failure indicates the energizing voltage through the output component was not gated to zero by the IIOC PWB.
load. If there is not a short circuit across the load, the IIOC PWB most likely has failed
Go to Table 4 to view the specific Module # and Pin # combinations for BUS 2.
Module
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
A7A1 (Finisher)
W1A1 (OCT)
There are two tests used to diagnose IIOC Controller failures
[Self Tests tab , IIOC Controller Tests], [IIOC Chain Controller Tests], [Main Controller].
This diagnostic routine tests the BUS 0 Controller, BUS 1 Controller and BUS 2 Controller
on the Main Controller PWB.
[Self Tests tab , IIOC Controller Tests], [Serial Controller Tests], [IIT]. This diagnostic routine tests the BUS 4 Controller on the Main Controller PWB.
IIOC Module features and functions

Each IIOC PWB has the following:
Input sensor/switch interface
Two +5VDC power supplies for driving sensors or external low power logic.
Two low current drivers (50ma)
Two high current drivers (1A, 0.5A)
Built in diagnostic I/O turnaround test
Built in fail safe features
WDT (watch dog timer) - detects whether or not the reset/framing pulse is being
received, the clock is being detected, and the chip logic is generating address detection
TCO (thermal cutout) - protects the chip from excessive temperatures such as those
caused by excessive loads.
SCP (short circuit protection) this is provided for the four output drivers as well as the
SOD driver and the +5 VDC output driver.
Why use IIOC?

IIOCs were used for the following reasons
Reduced wire harness cost (minimizes number and size of connectors, minimizes PWB
to component wiring, minimizes power supply to PWB wiring).
Reduced electronics cost (reduced power supply requirements, enables lower EME, minimizes spare I/O requirements).
V0.042
May 2003
10-23
Figure 4 2 Input/2 Output IIOC 2, 3, and 4 Bit Mode
May 2003
10-24
V0.042
Figure 5 4 Input IIOC and 4 Output IIOC
V0.042
May 2003
10-25
IIOC Harness
SID
SOD
CLK
+24 VDC
DC COM
Micro
Switch
DC Motor
Solenoid
Sensor
IIOC
Module
Solenoid
LED
DC Motor
IIOC
Module
Push Button
Switch
Figure 6 Typical IIOC Harness
May 2003
10-26
V0.042
Chip
IIOC PWB
I/O Connector
These pins connect the IIOC harness
to the IIOC PWB.
IIOC Harness
Large Pins (5)
IIOC Housing
IDC Connector
Small Pins (7)

The IIOC module address is determined
by the position of these pins.
Figure 7 IIOC Module components
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May 2003
10-27
Figure 8 IIOC Housing Pins
May 2003
10-28
V0.042
Start Power
Developer Drive
Motor
Introduction
The Start Power starts the machine operation after the Start button is pressed. The Mechanical
power for this chain consists of the Developer Drive Motor, the Fuser Drive Motor and the
related Drive Control circuits which provide machine timing.
Fuser Drive Motor and Developer Drive Motor Power

The following voltages and control signals are supplied to the Fuser Drive Motor and the Developer Drive Motor by the Servo Control and Analog Module (SCAM) PWB:
+36 VDC
ENABLE
+5 VDC (ES)
5V RET (DC COM)
ENABLE
Pulse Width Modulation (PWM)
The Low Voltage Power Supply (LVPS) supplies +36 VDC and 36V RET (DC COM) directly to
the Servo Control and Analog Module (SCAM) PWB. When the Front Door Interlock Switch,
the Left Side Interlock Switch, and the Right Side Interlock Switch are closed, the signal, IOT
Interlocks Closed (H) +24 VDC is sent to the LVPS. This signal enables the generation of +36
VDC.
NOTE: TAG 114 is a 460/470 manufacturing tag that removes the Right Side Interlock Switch
and inserts an inline splice in its place.
TAG 120 is a 460/470 manufacturing tag that removes the Left Side Interlock Switch and
inserts an inline splice in its place.
Fuser Drive
Motor
SCAM PWB
Figure 1 SCAM PWB Developer Drive Motor and Fuser Drive Motor
The +5 VDC (ES) and 5V RET (DC COM) are supplied to the SCAM PWB by the LVPS via the
Distribution PWB. The ENABLE signal and the PWM signal for the drive motors are generated
by the SCAM PWB.
See Figure 1 for the location of the SCAM PWB, the Developer Drive Motor, and the Fuser
Drive Motor
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May 2003
10-29
Start Power
Mechanical Power Overview

Developer
Drive
Motor
The mechanical power of the machine is provided by two main drive motors, the Developer
Drive Motor and the Fuser Drive Motor. These motors supply drive to the main gear train,
which drives the following paper transport and imaging subassemblies.
The Developer Drive Motor supplies drive to components on the left side of the machine:
Vertical Transport
Duplex Transport
Developer Housing.
The remaining subassemblies contain separate motors and drive systems that operate independent of the main drive motors and gears. These subassemblies include the Document
Feeder, the Paper Trays, the Bypass/High Capacity Feeder (Bypass / HCF) and the Photoreceptor Drives.
Developer
Drive Belt
Figure 3 illustrates the Developer Drive Motor and drive components.

Refer to Figure 5 (40 PPM IOT) or Figure 6 (55/65 PPM IOT) for a schematic of the drives subsystem.
Developer
Gear Bracket
Figure 2 Developer Drive Motor and Drive Components
Start Power
May 2003
10-30
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Fuser Drive Motor

The Fuser Drive Motor supplies drive to components on the right side of the machine:
Decurler
Pre-Fuser Transport (PFT)
Inverter
Exit Rollers
Fuser Assembly
Decurler
Drive Belt
Fuser Drive Motor
Figure 4 illustrates the Fuser Drive Motor and drive components.

Refer to Figure 5 (40 PPM IOT) or Figure 6 (55/65 PPM IOT) for a schematic of the drives subsystem.
Decurler/OCT Drive
Bracket
Figure 3 Fuser Drive Motor and Drive Components
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May 2003
10-31
Start Power
Decurler/OCT
Drive Belt
Duplex
Module
Pre Fuser
Transport
Decurler/OCT
Drives
Photoreceptor
Drive Module
Fuser
Preregistration
Transport
Fuser Drive Motor
Cleaner
Photoreceptor
Drive Motor
Driven sub system gears

Developer Module
Drive Motor Gears

Drive Motor output to driven
sub system gears
Figure 4 Drives Schematic for 40 PPM IOT

Start Power
May 2003
10-32
V0.042
Decurler/OCT
Drive Belt
Duplex
Module
Pre Fuser
Transport
Decurler/OCT
Drives
Photoreceptor
Drive Module
Fuser
Preregistration
Transport
Fuser Drive Motor
Cleaner
Photoreceptor
Drive Motor
Driven sub system gears

Developer Module
Drive Motor Gears

Drive Motor output to driven
sub system gears
Figure 5 Drives Schematic for 55/65 PPM IOT

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May 2003
10-33
Start Power
Motor Control and Fault Declaration

Motor PWM and Duty Cycle
The Developer Drive Motor, the Fuser Drive Motor, and the Photoreceptor Drive Motor are controlled via Pulse Width Modulation (PWM). The motor control circuitry varies the amount of
time current is supplied to the motor during each cycle. This Motor On portion of the cycle is
the pulse. The greater the motor on time, the greater the width of the pulse. The proportion of
the cycle when current is supplied to the motor is the duty cycle. If current is supplied to the
motor for half of the cycle, this is a 50% duty cycle. The graph in Figure 7 illustrates a 75% duty
cycle.
1 cycle
When a motor on signal is received from the Main Control PWB, the motor runs in the open
loop mode for 45 ms. At this time the duty cycle is 100% and feedback from the motor encoder
is not monitored. After 45 ms., the motor continues to increase in speed until it reaches a
steady velocity. During this time, the motor speed is monitored via feedback from the motor
encoder but fault declaration is disabled. Once the motor reaches the desired velocity, it runs
in the closed loop mode.
As the velocity of the motor increases, the motor encoder frequency increases. When the control circuitry monitoring the encoder feedback detects a predetermined encoder frequency, current to the motor is switched off. As the motor velocity begins to decrease, encoder frequency
decreases. When the control circuitry monitoring the encoder feedback detects a drop in
encoder frequency, current to the motor is switched on.
Motor Off
Voltage
Motor On
If the load on the motor increases, the motor on time (% duty cycle) is increased to maintain
the motor at a constant velocity.
Time
Under normal conditions the% duty cycle is as follows:
Developer Drive Motor 80% - 85%
Fuser Drive Motor 70% - 75%
Photoreceptor Drive Motor 60% - 65%
Start Print cycle

When the Start Print cycle begins, the motors are energized in the following order:
1.
2.
3.
Fuser Drive Motor
If all three motors were energized at the same time, the current demand would exceed the
capacity of the Low Voltage Power Supply, causing it to shut down.
Start Power
May 2003
10-34
Figure 6 Motor PWM Signal Duty Cycle
V0.042
Motor Speed
Diagnostics and troubleshooting:
The nominal velocity of the motors is as follows:
Diag Nav.\Paper\Fuser Drive Test:

This test utilizes the Decurler Home sensor to verify the drive train from the Fuser Drive
Motor to the decurler. Presence of the decurler clutch is first provided through IIOC. The
Fuser Drive Motor is energized and then the decurler clutch is energized while monitoring
the decurler home sensor - appropriate messages are then displayed via the PWS.
40 PPM machines
Photoreceptor Drive Motor 703.4 rpm
Developer Drive Motor 1222.3 rpm
Fuser Drive Motor PWM 1218.15 rpm
Diag.Nav.\Copier Sys\Component Control\IOT Paper Path\Outputs:
55 and 65 PPM machines
Photoreceptor Drive Motor 1143 rpm
Developer Drive Motor 1986.2 rpm
Fuser Drive Motor PWM 1979.5 rpm
Developer Drive Motor: Provides a quick test of Developer Drive Motor.

Fuser Drive Motor: Provides a quick test of Fuser Drive Motor.
Photoreceptor Drive Motor: Provides a quick test of Photoreceptor Drive Motor.
Motor velocity is adjusted based upon a pre-set ROS rpm timing parameter hallPeriodRef.
The NVM value for hallPeriodRef and the NVM value MotorVelocityAdjustment are used to
ensure the Photoreceptor belt is at the correct speed. The Developer Drive Motor speed and
the Fuser Drive Motor speed must be adjusted proportionally to the speed of the Photoreceptor
Drive Motor.
Tips:
CAUTION
Motor Saturation Faults

If the% duty cycle is 97% for greater than 500 ms, the fuse located on the motor PWB will blow.
To avoid blowing the fuse, which would result in replacement of the motor, a saturation fault is
declared and the machine is shut down. The faults declared are:
Developer Drive Motor PWM saturation fault 04-202
Photoreceptor Drive Motor PWM saturation fault 04-206
Fuser Drive Motor PWM saturation fault 04-211
Motor Hardware Faults

If the encoder feedback is missing, or the encoder feedback is incorrect, a motor system hardware fault is declared and the machine is shut down. The faults declared are:
Developer Drive Motor PWM motion system hardware fault 04-201
Photoreceptor Drive Motor PWM motion system hardware fault 04-205
Fuser Drive Motor PWM motion system hardware fault 04-206
To correctly tension Developer Drive Motor or Fuser Drive Motor, you must follow the procedures exactly as written. Performing belt tensioning with the developer housing
engaged can cause a bound developer housing since an excessive amount of material
will be deposited on the developer rolls when turned at a low rate of speed. Should this
occur - you will need to replace the developer housing
CAUTION
A saturation fault is usually an indicator there is a binding of a component driven by the motor.
CAUTION
You should never unplug servo motors while the power is on (even if the interlock is
open). Since 5VDC is always at the motor, you may damage the motor unless the power
is off. Typically a damaged motor will appear bound up or the encoder will no longer function.
The approved lubricant for plastic gears and plastic to metal contact areas is 70P81 - Dow
#44. Other lubricants may cause deterioration of the plastic.
The fuser motor runs approximately 30 seconds every 20 minutes. This is normal and is
necessary since the fuser nip never releases. Without this, the pressure roll and fuser
rolls could fuse together.
Gradual load increases (i.e. contaminated idlers- etc.) will cause saturation type faults
whereas hard load faults (i.e. bound drives) will generally result in encoder faults.
A motion system hardware fault is usually an indicator the motor has stalled or voltage to the
motor has been interrupted.
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May 2003
10-35
Start Power
Start Power
May 2003
10-36
V0.042
Document Transportation
Document Input
Tray Side Guides
Overview
The Document Feeder feeds one or two-sided documents from a positioned stack, moves the
document across the scanner and then transports the document into the Document Output
Tray. The Document Feeder can automatically feed up to 50 documents (up to 75 documents
for Document Centre 460/470), one at a time, across the scanner. The documents can range in
size from 5.5 x 8.5 (A5) to 11 x 17 (A3). The lengths of documents within one set can vary by
a maximum of 2 mm.
The Document Feeder (Figure 1) can feed either one-sided or two-sided originals. When twosided originals are copied, the front (top) side is copied first. The originals are then turned over
and returned to the platen for scanning of the back side. The originals are then turned over a
second time so they return to their original orientation. The original is then exited to the Document Output Tray.
Document
Input Tray
All scanning is accomplished using a 1 to N sequence. This means that the first page fed and
scanned is the first page copied
Figure 1 Document Feeder (DADF)
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May 2003
10-37
DADF Electrical Power

The Low Voltage Power Supply supplies +5 VDC and +24 VDC through the Distribution Board
to the DADF PWB. IIOCs on the DADF PWB then control the output of power to all the components in the Document Feeder (Figure 2).
DADF PWB
Figure 2 DADF PWB
May 2003
10-38
V0.042
DADF Sensors and Interlocks

DADF Top Cover Sensor
When the DADF Top Cover is closed, the Document Feeder Top Cover Sensor Actuator (Figure 3), blocks the Document Feeder Top Cover Sensor (Figure 4). This sends a lo signal to
IIOC 2 on the DADF PWB. This signal indicates a ready condition and allows power to be supplied to the Feed and CVT Motors. If the actuator does not block the sensor, a hi signal is generated indicating the Cover is opened. This removes power to the motors and generates a 05325 error code if the condition occurs during the copy cycle.
When the Document Feeder is closed, a magnet located in the Scanner Main Cover actuates
the reed switch in the DADF Interlock Switch (Figure 5). This sends a low signal to IIOC 2 on
the DADF PWB. This signal indicates a ready condition and allows power to be supplied to the
Feed and CVT Motors. If the switch is not actuated, a high signal is generated indicating the
Document Feeder is raised. This removes power to the motors and generates a 05-310 error
code if the condition occurs during the copy cycle.
Document Feeder
Top Cover Sensor
Document Feeder Top

Cover Sensor Actuator
DADF Interlock
Switch
Figure 4 DADF Interlocks
Figure 3 Document Feeder Top Cover Sensor Actuator
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May 2003
10-39
Document Feeding
Document Feed Components
The Retard and Feed Rolls separate the top sheet from the document input stack, and feed it
into the paper path. The document is then transported to the CVT Platen by the Takeaway
Rolls, Registration Rolls and Pre-CVT Rolls. While the document is transported, it is detected
by several sensors. A Registration Gate also aligns the document at the Registration Rolls.
The CVT Rolls drive the document at a constant velocity across the CVT Platen, where the
image is scanned. Then, the Exit Rolls transport the document into the Output Tray.
Figure 5 shows the relative positions of the document feed components. These components
are discussed in more detail on the following pages.
During duplex operation, the operation is slightly different. After the first side is scanned and
the document begins to exit into the Output Tray, the Exit Rolls reverse rotation. This causes
the document to invert and return through the paper path so the second side can be scanned.
Finally, the document is inverted again to return it to the original orientation, and sent through
the paper path a third time. This time, no scanning occurs and the document exits into the Document Output Tray in its original orientation.
Document
Loaded Sensor
Input Tray Exit

Sensor
Registration Gate
Sensor
Paper Feed
Roll Cartridge
Document Output
Tray
DADF Exit/Invert
Sensor
CVT Start of Scan

Sensor
DADF Inverter Gate
Figure 5 Cross Section of the DADF Document Path
May 2003
10-40
V0.042
Document Feeder Drive

Two 24 VDC servo motors provide the drive for all Document Feeder components; the Feed
Motor and the CVT (Constant Velocity Transport) Motor (Figure 6). The circuits for these
motors are interlocked via the signal from the DADF Top Cover Sensor.
DADF Feed
Motor
DADF Feed Motor

The DADF Feed Motor supplies direct drive to the feed Roll / takeaway Roll. The Feed Motor
operates on 24 VDC.
A helical gear drive system provides a 1:4 drive ratio from the motor. When the Feed Clutch
CL2 energizes, drive is also supplied to the Feed and Nudger Rolls.
This motor also drives the exit/inverter Roll. One of two electromechanical clutches, the
Inverter Clutch or Exit Clutch, engages the motor to provide either forward or reverse motion to
the exit/inverter Roll. The change in direction is accomplished using a gear set, and does not
require motor reversal. The Exit Clutch provides motion to drive document out of the feeder;
the Inverter Clutch reverses the rolls direction and drives document back into the feed path.
Constant Velocity Transport (CVT) Motor

CVT Motor supplies drive to the mechanical components in the Constant Velocity Transport
(Figure 6). The CVT Motor operates on 24 VDC. One timing belt transfers the drive from the
CVT Motor to 3 Rolls; the Registration, Pre-CVT and Post-CVT Rolls. A separate belt for the
exit/inverter Roll receives direct drive from the CVT motor. When an original needs to be
inverted during the duplex mode, the electromechanical Exit Clutch deactuates to disengage
the exit/inverter Roll from the CVT motor. The Inverter Clutch is then engaged and applies
drive through the Feed Motor.
CVT Motor
Figure 6 CVT Motor and DADF Feed Motor
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May 2003
10-41
Document Size Sensing

The size of the document in the document feeder is determined by the status of 4 Input Tray
sensors. (Refer to Figure 7 and Figure 8.) The matrix created by the condition of the side guide
switches and direction sensors allows the copier to predict an accurate document size. An
NVM adjustment is available to customize these settings for special customer needs.
Actuator for
Input Tray
Sensor 2
Document Input
Tray Side Guides
Two side guide sensors determine the front to back size of the document. The sensors detect a
flag mounted to the bottom of each movable guide. As the guide moves, the flag blocks and
unblocks the sensors. The feeder uses the signals from both Side Guide Sensors to determine
the front to back paper size.
The state of the two Input Tray sensors, Input Tray Sensor 1 and Input Tray Sensor 2, is controlled by 2 actuators located in the Document Input Tray (Figure 7). These sensors determine
the size of the document in the process direction. If document is placed on top of an actuator,
the actuator depresses and the state of the sensor changes. The document may actuate none,
one or both of the actuators. The combined state of both sensors and the NVM setting determines the process direction size of the paper.
Actuator for
Input Tray
Sensor 1
Figure 7 Input Tray Sensor Actuators and Document Input Tray Side Guides
May 2003
10-42
V0.042
NOTE: These sizes are present in the paper handling matrix but are not comprehended here:
5x7, B6 (128x182mm), 12x18
Input Tray Sensor 2
Side Guide Sensor 1
Table 1 Document Size Sensing Combinations
Side Guide Sensor 2
Input Tray Sensor 1
Figure 8 Document Input Tray Sensors

The Document Feeder assumes a paper size depending upon the combined signals from the
Side Guide Sensors and the Input Tray Sensors. Table 1 shows the default sizes for various
sensor states.
Input Tray
Sensors (Slow
Scan)
Possible paper
Size
Side Guide
Sensors (Fast
Width Length
Scan)
(mm) (mm)
(Fast (Slow Sensor Sensor
Scan) Scan) 1
2
A5 (SEF)
5.5x8.5 (SEF)
148
140
210
216
hi
hi
hi
hi
6x9 (SEF)
B5 ISO (SEF)
B5 (SEF)
7.25x10.5 (SEF)
152
176
182
184
229
250
257
267
lo*
lo*
lo
lo
hi
hi
hi
hi
8.5x5.5 (LEF)
A5 (LEF)
216
210
140
148
hi
hi
hi
hi
8x10 (SEF)
8x10.5 (SEF)
8.27x10.63 (SEF)
8.46x10.7 (SEF)
8.46x10.83 (SEF)
8.5x11 (SEF)
9x11 (SEF)
9x12 (SEF)
A4 (SEF)
8.46x12.4 (SEF)
203
203
210
215
215
216
229
229
210
215
254
267
270
273
275
279
279
305
297
315
lo
lo
lo
lo
lo
lo
lo
lo
lo
lo
hi
hi
hi
hi
hi
hi
hi
hi
hi
hi
8x13
8.27x13
8.5x13
8.5x14
203
210
216
216
330
330
330
356
lo
lo
lo
lo
lo
lo
lo
lo
B5 ISO (LEF)
B5 (LEF)
10x8 (LEF)
10.5x7.25 (LEF)
10.5x8 (LEF)
11x8.5 (LEF)
250
257
254
267
267
279
176
182
203
184
203
216
hi
hi
hi
hi
hi
hi
hi
hi
hi
hi
hi
hi
11x9 (LEF)
279
229
hi
hi
SB4 (SEF)
B4ISO (SEF)
B4 (SEF)
11x17 (SEF)
252
250
257
279
358
353
364
432
lo
lo
lo
lo
lo
lo
lo
lo
A4 (LEF)
297
420
hi
hi
A3 (SEF)
297
420
lo
lo
hi
lo
lo
hi
hi
hi
lo
lo
Factory Default
Size by OPCO
Sensor Sensor
1
2
USCO XCL XL FX
*These will detect only if the paper zone is set to a special size.
V0.042
May 2003
10-43
Document Position Sensing

There are sensors located throughout the feed path to detect the position of the document. The
signals from these sensors initiate operations within the Document Feeder, and also perform
jam detection.
Input Tray Exit

Sensor
A description of each sensor and its function follows:
Document Loaded Sensor. See Figure 9.

This sensor indicates when a document is present in the Document Feeder, and when the
last sheet has been fed. When the sensor is blocked, the signal indicates that a document
is in the Document Feeder. When the sensor changes state and is no longer blocked, the
machine assumes the last sheet of the set has been fed.
Input Tray Exit Sensor. See Figure 9.

This sensor detects the leading edge of the document after it has been fed. This signal is
used to detect jams, to deenergize the Nudger Solenoid, to deenergize the Feed Clutch,
and during the duplex mode, it deenergizes the Inverter Clutch.
DADF Registration Gate Sensor. See Figure 9.

This sensor detects the leading and trailing edges of the document at the registration
area. The resulting signal is used to detect jams and multifeeds between the Input Tray
Exit Sensor and the DADF Registration Gate Sensor, and to deenergize the Gate Solenoid so the document can continue through the feed path.
CVT Start of Scan Sensor. See Figure 10.

This sensor detects both the leading edge and trailing edge of the document at the CVT.
The leading edge signal detects jams between the registration area and the CVT. It also
initiates the sequence to establish the SLOW scan registration.
DADF Exit/Inverter Sensor. See Figure 10.

This sensor detects both the leading edge and trailing edge of the document at the exit
nip. The leading edge signal detects jams between the CVT and the exit nip.
Document Loaded
Sensor
DADF Registration
Gate Sensor
Figure 9 Upper Document Path Sensors
May 2003
10-44
V0.042
DADF Exit/Invert
Sensor
CVT Start of
Scan Sensor
Figure 10 Lower Document Path Sensors
V0.042
May 2003
10-45
Document Feeding
When the Document Feeder (Figure 11) is ready to begin the feed cycle, the Nudger Solenoid
and DADF Feed Clutch energize:
The Nudger Solenoid moves the Nudger Roll against the stack of documents and unlocks
the Input Gate, so that it moves out of the way (Figure 12).
The DADF Feed Clutch engages and the DADF Feed Motor energizes. This supplies
drive to the Feed Roll which transfers drive to the Nudger Roll gear train.
A semi-active Retard Roll provides the nip for the Feed Roll. The Retard Roll contains a wrapspring slip clutch, which develops slip torque as documents feed. When a single sheet is in the
nip, the motion of the Drive Roll drives the Retard Roll in the feeding direction. When two
sheets are fed into the nip, however, the torsion spring unwinds, causing the Retard Roll to
reverse direction and push the lower sheet back towards the stack (Figure 12).
The Feed Clutch serves as a drive coupling and is only engaged at zero velocity. The
clutch disengages when the document arrives at the Input Tray Exit Sensor.
DADF Feed Clutch
Input Tray Exit

Sensor
Feed Roll
Nudger Roll
DADF Inverter
Clutch
DADF Exit
Clutch
Retard Roll
Figure 12 DADF Paper Feed Roll Cartridge Components
Nudger Solenoid
Figure 11 Document Feed Components
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The Feed Roll drives the document until it reaches the Takeaway Rolls and the Input Tray Exit
Sensor detects the leading edge of the document. Refer to Figure 13. The following will occur:
The Nudger Solenoid deenergizes, which cause the Nudger Roll to release and the Input
Gate to lower. This prevents more paper from feeding.
The Registration Gate Solenoid energizes, lowering the Registration Gate into the paper
path at the Registration Rolls.
After a short timing window, the Feed Clutch deenergizes, removing drive from the Feed
Rolls.
Takeaway
Roll Idler
Input Tray
Exit Sensor
Now, the Takeaway Rolls have full control of the document and drive it to the Registration
Gate. When the leading edge reaches the Registration Gate Sensor (Figure 14), two things
occur:
A timing window begins while the document registers against the gate to remove skew by
producing a buckle in the document. When the timing window expires, the Registration
Gate Solenoid deenergizes to raise the gate. The registered document can now continue
moving through the feed path.
The Exit Clutch energizes, providing forward drive to the DADF Exit Rolls. The DADF Exit
Rolls receive drive from a dedicated belt driven by the CVT Motor.
Takeaway
Roll
DADF Exit
Rolls
Figure 13 Cross Section View of a Document at the Input Tray Exit Sensor
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DADF Registration
Gate
Registration
Gate Sensor
Registration
Roll
Figure 14 Cross Section View of a Document at the DADF Registration Gate
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Document Transport During Scanning
Document Exit
The document continues until the lead edge is detected at the CVT Start of Scan Sensor (Figure 15). This signal starts the scanning operation. The CVT Motor drives the Right-CVT Roll,
which transports the document to the CVT Drive-on Glass Roll, which rotates above the Image
Module for scanning. The document continues to the Left-CVT Rolls. Since the rolls driving
the document are controlled by the same timing belt and the CVT servo motor, the velocity of
the paper is constant.
During a one-sided copy job, the Left-CVT Roll transports the document past a passive
diverter, causing the DADF Inverter Gate to move up. After the document passes, the DADF
Inverter Gate drops down. The document then continues past the DADF Exit/Inverter Sensor to
the DADF Exit Rolls and into the Document Output Tray (Figure 16). The signal from the DADF
Exit/Inverter Sensor is used for jam detection purposes only during the simplex operation.
CVT Drive on
Glass Roll
DADF
Exit Roll
Right CVT
Roll
Left CVT
Roll
DADF Exit/
Invert Sensor
CVT Start of
Scan Sensor
DADF Inverter Gate
Figure 16 Cross Section View of a Document at Document Exit

Figure 15 Cross Section View of a Document at the CVT Start of Scan Sensor
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Inverting for Second-Side Feeding

The Document Feeder Inverter functions only when copying a two-sided document. The cycle
is the same as a simplex job, except the Inverter path turns the document over and returns it to
the feed path.
After the first side of the document is scanned, the Left-CVT Roll transports the document past
the DADF Inverter Gate, past the Exit/Inverter Sensor to the DADF Exit Rolls. When the DADF
Exit/Inverter Sensor detects the trail edge of the document, the CVT Motor deenergizes. This
stops the document at a point between the DADF Inverter Gate and the DADF Exit Rolls (Figure 17).
Now, the invert operation begins. The Exit Clutch deenergizes, uncoupling the DADF Exit Roll
from the CVT Motor. The Inverter Clutch energizes, applying reverse drive from the gear train
of the Feed Motor. This causes the DADF Exit Rolls to reverse rotation and transport the document back to the DADF Inverter Gate. The DADF Inverter Gate, which is now in the down position, diverts the document into the inverter path until it reaches the Takeaway Rolls (Figure 18).
The document continues through the normal feeder path.
After the second side is scanned, the document re-enters the invert path and makes a third
pass through the document feeder. This time, however, the image is not scanned and the document exits into the Document Output Tray in its original orientation.
DADF Exit Roll
DADF Exit Roll
Takeaway Roll
Document
Output Tray
DADF Exit/Inverter
Sensor
DADF Inverter Gate
DADF Exit/Inverter
Sensor
Figure 18 Cross Section View of an Inverted Document
Figure 17 Cross Section View of a Document in the Invert Position
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DADF Inverter Gate
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Diagnostics and Troubleshooting:

Diag. Nav.\Copier System\Component Control\DADF-Scanner
Component Control is useful in determining if an input (i.e. sensor or switch) or an output

(i.e. servo or solenoid) is functioning. Component control allows multiple actuations for
troubleshooting intermittences.
Diag. Nav.\IIT\DADF Clutch and Solenoid Tests:
IIOC Turnaround Test: Used to test the electrical integrity of the Feed Clutch, Exit Clutch,
Inverter Clutch, Reg. Gate Sol., and Nudger Solenoid.
Exit Clutch and Inverter Clutch: This tests utilizes drive from the Feed motor and encoder
feedback from the CVT motor to test the Exit and Inverter Clutches and the related drive
belts.
Feed Clutch and Nudger Solenoid: This tests utilizes drive from the Feed motor and
encoder feedback from the feed motor to detect load conditions when the Feed Clutch or
the Nudger Solenoid is engaged.
DADF Registration Gate Solenoid: This test should be used after first passing the electrical test in the IIOC test. This test will only catch gross mechanical failures of the Registration gate
Diag. Nav.\IIT\DADF Timing:
This routine will display a graphic representation of time. The available graphs are as
listed below. Min., Max and nominal times should be available in later versions of PWS
software.
LE @ Q1,Q2,Q3 or Q4
Time over Q2,Q3 or Q4
All
Diag. Nav.\IIT\DADF Sensor Tests
This test provides a one time only test until the screen is reset. This can be used for a
quick test of the sensors, but component control - with numerous actuations possible,
should be used for troubleshooting most sensor problems, particularly intermittences.
Note that many of the sensors can be interchanged with another sensor, of the same part
number, for troubleshooting purposes.
Diag. Nav.\Paper\System Reg. Setup.\IIT System Registration
This routine is used to set IIT magnification and CVT speed (thereby setting CVT magnification in the slow scan direction). The first portion of this test tells the machine the location of the platen surround and attains a precise measurement of the piece of paper. The
second portion of this test utilizes that same sheet of paper and paper of the same size, to
set CVT speed (therefore magnification).
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Imaging (Scanning - Chain 14 & ROS-Chain 6)

Overview
A copy is produced by sensing the image on the original document and then converting the
video (or analog) data into digital data. The digital information is then used to expose the photoreceptor. This process involves two sub-assemblies; IIT (Input Image Terminal) and the ROS
(Raster Output Scanner).
The Image Module is responsible for illuminating, scanning, projecting and sensing the image.
The ROS is responsible for exposing the digital image on the photoreceptor. This section
describes the operation of both subsystems.
Scanner (Chain 14)

The Scanner creates the image input for the copier by digitizing the analog image that exists
on the original document. The scanner is capable of reading a maximum image size of 297 mm
x 432 mm (11.69 x 17 in.).
The Scanner operates in three different modes, depending on the copier operation:
In the Document Feeder mode, the Image Module remains in one fixed position while the
Constant Velocity Transport (CVT) in the Document Feeder transports the document over
the platen.
In the Manual Platen mode, the document remains in a fixed position on the platen, while
the Image Module moves across the platen.
In the Calibration mode, the Image Module movement is controlled by the copier. During
this mode, values such as the Start of Scan (SOS) positions are determined.
Frame
Scanner Components
The Scanner consists of five subsystems: (Figure 1)
Image Module Optics - illuminates and focuses the image onto the Full Width Array.
Full Width Array - acquires the image information and sends it to the Video Buffer
Boards (VBB) video/control circuits.
Video Buffer Board Control Circuitry - receives analog image data from the Full Width
Array and converts it into digital image data.
Frame - Supports all the scanner components
Drive - (not shown in Figure 1) moves the Image Module when needed
Image Module
Optics
Each of these subsystems is described in more detail on the following pages.
Video Buffer
Board
Full Width
Array
Figure 1 Image Module Components
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Image Module Optics

The Image Module optics illuminate the document on the platen and convert the information to
an optical image. It then projects this optical image onto the Full Width Array. This is accomplished through an illumination system and a projection system.
Illumination System
The Optics uses a fluorescent lamp, lamp heater jacket and reflector to illuminate the document on the platen (Figure 2 ). The Lamp Power Supply is located at the base of the Scanner
and supplies the power to the lamp and heater.
Lamp, Heater and Reflector
The lamp is a T5-size, mercury-filled, heated-filament fluorescent lamp approximately 440
mm long. An aperture in the lamp directs the light onto the platen. A reflector, mounted to
the opposite side of the Image Module, captures escaping light and redirects it back to the
platen.
Since the lamp must provide uniform illumination at all times, a heater jacket surrounds
the lamp to help maintain the lamp at a constant temperature when the lamp is both on
and off. This stabilizes the video output over both long and short term lamp intensity fluctuations.
Both the lamp and the heater jacket receive power from the Lamp Power Supply.
Reflector
Lamp Power Supply
Lamp
Figure 2 Illumination Components
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Lamp Power Supply

The Lamp Power Supply (Figure 3) receives two +24 VDC inputs from the LVPS. One input
supplies power to the lamp, while the other supplies power to the heater jacket.
The lamp power circuit is enabled by a signal from the MCB PWB. The heater output is controlled by voltage, which varies depending on pre-determined setpoints based on the resistance of the heater.
Lamp Power Supply
Figure 3 Lamp Power Supply
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Projection System
The projection system uses a platen and a lens to focus the document image on the full width
array.
Lens
The lens is self-focusing and contains a two-row, full-width, gradient-index array, with a
surface of 482 mm (Figure 4). The lens magnification is not affected by changes in height
above the platen (however, focus is affected). This feature provides equal magnification of
flat and raised objects (like books). During the scanning process, the lens magnifies the
image very slightly and projects it onto the full width array.
Lens
Figure 4 Lens
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Full Width Array

The full width array subsystem includes the sensors which receive the projected image, a Full
Width Array circuit board which transmits the sensor signals, and a Video Buffer Board which
combines the sensor signals into one video signal for each pixel line (Figure 5).
40-Pin Connectors
Image Sensors
The image sensors are contained within 20 chips mounted end to end on the ceramic circuit
board. Each chip covers 400 pixels per inch. This provides a total of 4,960 pixels on an imaging
surface of 315 mm (12.4 in.). The sensors on each chip are approximately 1/400 in. square
(this is why the scanner scans at 400 X 600 instead of 600 X 600).
A glass filter covers the full width array so the projected image is focused directly on the sensors.
Full Width Array Circuit Board
Each chip communicates via its own channel to the Full Width Array circuit board. This ceramic
board transforms the originals image into an electronic, analog signal that is transmitted over
two, 40-pin connectors to the Video Buffer Board. The chips send pixel data for one scan line
at a time.
Glass Filter
Image
Sensor
Pixel 1
Full Width Array Circuit

Board (ceramic)
Figure 5 Full Width Array
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Video Buffer Board (VBB)

The Video Buffer Board (Figure 6) receives the pixel signals from the 20 channels of the Full
Width Array circuit board, and combines these signals into one analog video signal for the
entire scan line. The VBB then sends this data to the Scanner Control and Video Module
(SCVM) which is part of the Main Control PWB).
The Video Buffer Board is located beneath the Full Width Array in the Image Module.
Video Buffer Board
Figure 6 Video Buffer Board
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Video Control Circuitry

Both the video and control electronics are provided by the Scanner Control and Video Module
(SCVM). This PWB is part of the Main Controller Board, and is connected via one shielded harness to the Video Buffer Board.
Video Electronics
The video electronics receive the analog images from the Video Buffer Board and amplify,
sample and hold, calibrate and convert the data into 8-bit, digital image data. This image
data describes a 600 dpi image.
The SCVM transmits the 8-bit image data to the IPS1. The IPS1, which is also part of the
Main Controller Board, then generates image processing signals and transmits them to
the ROS.
Control Electronics
The control electronics provide signals that move the Image Module, regulate the illumination, calibrate the video circuits, and control the Document Feeder. They also generate
timing signals, such as the start of image, scanner ready, etc.
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Frame
The scanner frame (Figure 7) is an enclosed unit that mounts the scanner components and
provides the mechanical interface to the copier. It also sets up and maintains the optical alignment and focus, ensures correct registration of the Image Module (IM) to the document, prevents stray light / contamination from reaching the image sensors and positions the IM
correctly against the platen.
Spacers
Position and Movement of the Scanner Frame

The movement and position of the Image Module is controlled by spring-loaded wheel assemblies on the bottom of the scanner frame. The wheels move along rails molded in the scanner
frame. When the IM must move across the platen, the spring-loading action of the wheels
ensures that the wheels remain within the rails. It also pushes the Image Module upward,
causing three plastic buttons on the top of the Image Module to push against the bottom of the
platen. This creates a constant spacing between the platen and the Image Module and
ensures correct optical alignment and focus (Figure 8).
Twin drive cables attached near the ends of the IM help control skew.
When the Image Module moves to the left, it actuates the Start of Scan (SOS) sensor at the
rear of the scanner. This actuation identifies the location of the Image Module during the platen
scan mode and is used to position the Image Module for the CVT mode - by counting the number of encoder pulses away from the SOS sensor.
Capstan
Scan Carriage Motor
Illumination
Lamp Module
Image Module
Start of Scan
(SOS) Sensor
Drive Cables
(wire cable)
Figure 7 Scanner Frame Components
Figure 8 Spacers
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AGC Patch
The Image Module (IM) includes an Automatic Gain Control (AGC) tab on the IM above the last
outboard pixel of the full width array. This white reference patch provides a signal reference for
the video control system.
Scan Carriage
Motor
The video control system monitors the signals generated by the last pixel as it scans the AGC
tab during a normal scan operation. It then averages the last 16 signals, and compares the
average to a reference value to determine any changes in illumination. If a change is detected,
the video control system adjusts the gain of the video signal to maintain a uniform output signal
level.
Calibration Strip
A white calibration strip is located at the left side of the platen, under the platen bezel. This strip
stretches from the front to the back of the bezel, providing a scannable area for the full width of
the Image Module Array.
The calibration strip provides a uniform reference for the video control system, which uses it to
calibrate the video data. Calibration is necessary because tolerance variations in the scanner
may result in different video data. The calibration procedure scans the calibration strip, compares the signals to the reference values, and then calculates a calibration value to ensure
consistent video data.
Scanner Drive
The Scanner includes only one motor, the Scan Carriage Motor. This motor is controlled by a
driver which receives input from the SCVM portion of the Main Control PWB to coordinate
motor operation with the scan operation (Figure 9).
The motor uses a belt and pulleys to transfers drive to the capstan. The capstan then uses two
wire-cables and a system of pulleys to move the Image Module.
The operation of the Scan Carriage motor varies, depending on the required scan mode. See
the following pages for a detailed description of the Scan Carriage motor operation for each
scan mode.
Wire Cables
Timing Belt
Capstan and Pulley
Figure 9 Scanner Drive
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Scanning Operations
Analog Image data is collected, converted into digital data and sent to the ROS for imaging.
At the end of the cycle, the scanner lamp deenergizes. The Image Module remains in the
CVT position.
Power-Up
When the main power is turned on, the scanner initializes its components and prepares for
scanning. This process requires that the following operations occur:
Warm-Up
Power is supplied to the lamp heater and fan. The Scan Carriage motor energizes and
moves the Image Module to a position between the CVT position and the left edge of the
CVT platen. (This position, called the lamp warm up location, prevents the lamp illumination from being visible during the power-up sequence). The lamp profile software checks
for lamp stability as it reaches the desired operating temperature.
The normal scanning speed is 40 or 65, A4 or 8 1/2 x 11 in. documents per minute, depending
upon the model. The scanning speed can vary, however, if enlargement of the document is
required, see the following table for the approximate changes in scan speed based on reduction or enlargement requirements.
Table 1 Document Feeder Scan Mode Speeds
Power-Up Self Test
Requirements
Scan Speed
The copier performs the appropriate self tests.
25 - 100%
full speed
Calibration
101 - 200%
half speed
The scanner enters the calibration mode. During this process, the Scan Carriage motor
moves the Image Module to the calibration strip, the lamp illuminates and a video image
of the white calibration strip is projected onto the full width array. The video control electronics analyze these signals and calculate pixel offset and gain values. At the end of the
calibration, the Scan Carriage motor moves the IM to the CVT position at the right edge of
the scanners travel.
Self Test
The copier runs several self tests to check the scanner readiness. These checks include
the movement of the Image Module, the operation of the Start of Scan (SOS) sensor,
etcetera.
Ready
The lamp and the Scan Carriage motor deenergize. The Image Module remains at the
CVT position unless the DADF is raised off the platen. This action initiates a preparation
for a manual platen job. The Image Module moves to the left of the manual platen and
awaits a start scan request.
Document Feeder Mode

In the document feeder mode, the Image Module remains fixed in the CVT position, while the
Constant Velocity Transport of the Document Feeder moves the documents at a fixed velocity
over the CVT platen.
The following events occur during the Document Feeder mode:
The cycle begins when documents are present in the Document Feeder, and the Document Feeder is closed.
At the START print signal, the scanner lamp energizes.

In most cases, no Image Module movement is required at the beginning of the cycle. If
the scanner has just completed a manual mode scan and the START print signal energizes, the Scan Carriage motor energizes and moves the Image Module to the CVT position.
The Constant Velocity Transport of the Document Feeder moves the document over the
Image Module.
Electronic edge detection signals tell the full width array when to start and stop collecting
image data from good quality, white border documents. For other documents, the software calculates the expected arrival and departure time based on the Input Tray switch
settings and the width detected by the CVT sensor.
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Manual Scan Mode
Calibration Mode
In the manual scan mode, the Image Module moves while the original remains in a fixed position on the platen. This mode handles scanning of books, oversize originals and fragile documents. The manual scan mode is initiated when the Document Feeder is opened.
In the calibration mode, the Image Module moves back and forth under the calibration strip
while the lamp cycles on and off. The video control circuitry then compares the signals to a reference, and calculates a calibration correction value. This process compensates for tolerance
variations within the scanners components.
The following events occur during the manual scan mode:
The cycle begins when the Document Feeder is opened.
The Image Module moves from the default CVT position to the platen start-of scan-position at the left edge of the manual platen. During this operation, called retrace, the Scan
Carriage motor energizes and moves the Image Module slowly at first, and then at full
velocity until the Image Module activates the Start of Scan (SOS) sensor.
The Scan Carriage motor ramps down to stop the Image Module, and then reverses
direction.
At the START print signal, the scanner lamp energizes and the Scan Carriage motor
ramps up until the Image Module reaches scan velocity. This must occur before the Image
Module deactivates the SOS sensor.
IPS1(part of MCB) uses the change in SOS state and the carriage position to determine
when to start and stop the collection of image data.
Image data is collected, converted into digital data and sent to the ROS for imaging.
Scanning begins at the upper, left corner of the platen and covers the same area as the
paper in the selected tray.
The Image Module continues moving at the scan velocity until the scan is complete.
The motor ramps down to stop the Image Module, then reverses direction.
The retrace function is repeated to return the Image Module (IM) to the platen start-ofscan (SOS) position.
Additional manual scans will start from the platen start-of scan position. If a START print
signal is not received within a predetermined time (about 90seconds), the Scan Carriage
motor returns the IM to the CVT position.
The normal scanning speed is 40 or 65, A4 or 8 1/2 x 11 in. documents per minute, depending
upon the model. The scanning speed can vary, however, if enlargement of the document is
required. See the following table for the approximate changes in scan speed based on reduction or enlargement requirements.
Table 2 Manual Scan Mode Speeds
Requirements
The calibration mode is automatically initiated during the power-up sequence of the copier.
Calibration is also performed at predetermined time intervals when the copier is running. If the
time interval expires during a job, the copier waits until the job is complete before entering the
calibration mode. The operator or service representative can also initiate the calibration mode
when needed.
Calibration Sequence
The following events occur during the calibration mode:
The Image Module begins in the CVT position. Before calibration can start, the Image
Module must move to the calibration strip located to the left of the SOS sensor. This operation is similar to the retrace operation in the manual scanning mode, except the Image
Module does not stop when it reaches the SOS sensor.
The Scan Carriage motor energizes and moves the Image Module slowly at first, and then
at full velocity until the Image Module activates the Start of Scan (SOS) sensor.
The Scan Carriage motor reduces the speed of the Image Module and moves it slowly
until it reaches the calibration strip.
The Scan Carriage motor oscillates to move the Image Module back and forth while the
lamp is cycled on and off. This continues until all the calibration data is collected.
The oscillation allows the video control circuitry to calculate the calibration correction values while it collects data from the calibration strip. It also ensures that random samples
are considered during the calibration.
When calibration is complete, the Scan Carriage motor moves the Image Module back to
the CVT position.
Since the full calibration procedure is time-consuming, both a full and partial calibration are
used to calibrate the machine during operation. The calibration sequence is the same for both
processes, but the partial calibration does not calculate all the algorithms. Instead, it performs
a fast, incremental calibration algorithm.
Scan Speed
25 - 100%
full speed
101 - 200%
half speed
201 - 400%
quarter speed
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Image Processing
The IPS1(part of the Main Control PWB) receives 8-bit digital image data from the scanners
SCVM (also part of the Main Control PWB), which describes an image at a resolution of
400x600x8. IPS1 processes this information and provides image sensing, image rendering
and image registration functions. The image sensing and image registration functions support
the scanning process. The image rendering function manipulates the image data before it
sends it to be output.
Image sensing
IPS1 determines the beginning and end of the scanned image. This process differs if the
Image Module is in the Document Feeder (CVT) or the manual Platen Scan mode.
Document Feeder Mode

In the Document Feeder Mode, IPS1 begins by creating a histogram of the incoming scanner
data. IPS1 analyzes the histogram to locate the scanned image and determine the background
level of the leading edge. It then centers the image and deletes black edges. The lead-edge
background level is used to set the gain and offset of the video data to remove any grayness of
the paper and / or to compensate for colored background originals.
Platen Scan Mode

In the manual Platen Scan Mode, IPS1 also creates a histogram of the incoming scanner data.
IPS1 analyzes the histogram to locate the lightest and the darkest information on the page. It
then uses this information to adjust the gain and offset to stretch the Tone Reproduction Curve
(TRC) of the copy output or suppress the background, depending on the mode selected by the
customer.
Image Rendering
When IPS1 processes the image data, it can perform several image rendering functions, such
as the application of filters, screens, thresholds and error diffusion.
If auto-segmentation is active (it is in auto/defaults), each pixel of the data is automatically considered part of a continuous tone, black or white, edge, or halftone, and decisions are made as
to how to reproduce each pixel. Halftone threshold frequencies can be programmed in lines
per inch for each type image. IPS1 then applies the appropriate threshold to the image data.
IPS1 can also process an image using two dimensional filtering, two dimensional scaling, TRC
modification, image suppression and halftoning. The halftoning is applied through the application of thresholding, screening or error diffusion methods. Error diffusion is frequently used with
hard screens to increase the flexibility and effectiveness of halftoning an image.
IPS1 then processes the scanned images to create the desired copy resolution. If desired, the
processed image can be rotated or annotated.
Once the images are processed, they are compressed and stored in the Electronic Pre-Collation memory (EPC).
When the photoreceptor is ready for the next image, IPS1 decompresses the image data and
sends it to IPS2 (also on MCB). IPS2 fine-tunes the pixel data and generates laser output signals, which it sends to the ROS Control Module. See Figure 10 for an overview of the image
process flow.
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8
Input
Scanner
2
90Degree Rotate/
Annotate/ Merge
IPS-1
2
Compress
Image
Disk
2
EPC DRAM
2
MCB
Decompress
IPS-2
ROS/IOT Engine
Output
Copy
Figure 10 Image Processing Flow
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Raster Output Scanner (ROS) Chain 6
Diagnostics and Troubleshooting (Chain 6 and Chain 14)
The image is output using a Raster Output Scanner (ROS). The ROS converts the 8-bit electronic image data from the Main Control PWB into rasterized light pulses for each scan line.
The laser then exposes the photoreceptor. The laser light intensities are controlled continuously to provide consistent print quality.
Four LEDs are located on the IIT Lamp Power Supply. These provide a quick visual reference
for troubleshooting. The function of each LED is printed on the PWB and are explained here.
Starting from left to right (from the front), the first LED is ENBL and should be lit when the lamp
enable signal is present (when the Lamp is on). The second LED is the 24VLMP and is lit when
power is available to the Lamp. The third LED is 24VHTR and is on whenever 24V is available
to the Lamp Heater. The fourth LED is HTR and is lit whenever the Lamp Heater is on.
The ROS consists of the following main components and the hardware to mount them:
Base containing 4 optical power elements and 2 flat mirrors
Motor Polygon Assembly (MPA)
Collimator Assembly that includes a Dual Laser Diode and a lens
ROS Control Module PWB that the Motor Polygon Driver (MPD)
Start of Scan Detector
Diag. Nav.\IIT \ Scanner Calibration: This routine allows the forcing of a full or partial calibration.
Diag. Nav.\IIT \ IIT Motor Tests: This routine allows testing of the Scan Carriage
Mot.,CVT motor, Feed Motor and CVT belts via driven encoders. NOTE: Motors operate
at their slowest speed, since this is where most failures will occur.
ROS Control Module
Diag. Nav.\IIT\DADF Clutch and Solenoid Tests: (covered in Chapter 5)
The ROS Control Module (RCM) is a PWB that contains a microprocessor and software stored
in ROM. These electronic components control the speed of the Motor Polygon, the laser output, the system synchronization and the communications over the Serial Command Bus
(SCB).
Diag. Nav.\IIT\DADF Sensor Test: (covered in Chapter 5)
Diag. Nav.\IIT \ Scanner Lamp Profile: This routine provides a graphic display of the Illumination lamps light output (with limits shown); with lamp off or on.
NOTE: The initial displayed screen may show a ramp at the end - this should be ignored
on the first read.
ROS Motor Control

When the copier has completed self-test and warm-up, the ROS initializes the Motor Polygon
Assembly. The software tests the operation of the MPA and then applies power to bring the
MPA up to speed. The speed of the MPA is measured by the internal Hall effect sensors.
EPC Memory Walking Test: Test takes approximately 19 minutes. This test forces
bits (1s and 0s) through the digital image path and compares them before and after
the transition. Can detect faulty SIMM or memory chips
Dual Laser Diode Control
VCM _IPS1 Loop Test: This is almost instantaneous. This tests ASICs,IPS1,and
VCM data paths on the Main Control PWB.
Once the MPA is up to speed, the RCM supplies power to the two lasers. An internal photodiode provides feedback to the RCM so the RCM can set the laser levels to previously established calibration points.
IPS1 bypass daughter card test: Used only if VCM and IPS1 loop test fails and the
machine has a daughter card. Since new Main Control PWBs dont have daughter
cards - this test is not presently available.
When the lasers reach their operating output, the MPA and lasers operate so feedback loops
and timing can be set. The timing is set when one of the laser beams is detected by the ROS
SOS. This signal synchronizes the MPA and times the laser level feedback. The RCM sends
the synchronization and laser level data over the video cable to the Video Control Module
(VCM).
When the ROS software determines that the MPA and both lasers are at their operating levels,
the RCM sends a READY TO PRINT signal over the Serial Command Bus to the main controller board.
SCVM Digital Test: This test is almost instantaneous and tests the SCVM portion of
ESS Main Controller test: A known image on the ESS is sent to the EPC memory on
the Main Control PWB and then sent back to the ESS. NOTE: Not available as of DC
launch - Printers only
AGC Tab: Approximately 30 second test which includes a scan. This looks at and
calibrates to the AGC tab. Verifies presence and cleanliness of the AGC tab.
Carriage Parking: Quickly moves IM off home and then return IM to home.
Scan Carriage: Turns lamp on and provides approximately 1/3 of a scan to verify
motor, cables and SOS operation.
Diag. Nav.\IIT \ Scanner Tests:

Lamp Operation: Provides a quick on and off of the lamp
When an image is ready, the VCM sends video and pixel clock data to the RCM. The RCM
uses this data to modulate the current supplied to each laser and change the output intensity of
each laser to correspond with the VCM data.
Diag. Nav.\IIT \ Video Path Diagnostics:
May 2003
10-64
Diag. Nav.\IIT \ IIT Skew Check: This check monitors the edge of originals as they are
fed through the DADF and determines the average skew and then displays the appropriate action to correct the skew. i.e. turn the adjustment screw 1/4 turn clockwise.
V0.042
Diag.Nav.\IIT \ Lamp Life Reset: This allows a means for the CSE to notify the machine
that the lamp has been changed. If Lamp Life is reset without changing the lamp, Image
Quality problems may occur (generally digital background). If an old MRD is reloaded,
the IOT may believe the lamp is much newer than it actually is and again, digital background may occur.
NOTE: Keeping the MRD current is very important!
Diag.Nav.\Self Tests\Video and Controls POST:

POSTS: Power on Self Tests - This test checks the Main control PWB (MCB) DRAM,
MCB Flash, SCSI on Board, NVM integrity, EPC Memory, Rotation SIMMS, PBus,
Image Processing RAM, Image Processing ASICs, IIT RAM and IIT ROM.
MAIN CONTROL TESTS (1): This test checks the DRAM, Flash ROM, NVM,
Options present, EPC Memory, Rotation Memory Test, Pbus, and On Board SCSI.
MAIN CONTROL TESTS (2): This test checks the IPS1 RAM, IPASICs, SCVM
RAM, SCVM ROM, and SCVM Loop,
PING TESTS: This test provides a ping check of the UI, Image Processing, IIT, and
ESS (with NP product).
Differences in IIT DC240 versus DC 255 DC260

DC240 and DC255, DC265 IITs have different size capstans to provide the appropriate speed.
The DC255,DC265 Image Module has a Vbb PWB which utilizes two video lines of output
whereas the DC240 has only one video line (but the identical Vbb). There could be only one IIT
(with different capstans), however there are two, mainly due to projected costs savings.
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May 2003
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Paper Supply
Paper Trays
Overview
The Paper Supply consists of four Paper Trays (Figure 3). Trays 1 thorough 4 are supplied with
all machines, while Trays 5 (Bypass) and 6 (HCF) are optional. Trays 1 thorough 4 are
accessed through the front of the machine. Access to the Trays is not inhibited during operation.
The Paper Supply for this copier consists of up to four Paper Trays, and an optional High
Capacity Feed Tray/ Bypass Tray (Figure 1).
This chapter describes the Paper Supply System up to the point where the paper or other copy
material is ready to feed.
Bypass Tray
(Tray 5)
The Trays accommodate sheet sizes of 133mm(5.5) to 305mm (12) in a cross-feed direction,
and 203 mm (8) to 457 mm (18) in a feed direction. Each Tray holds 550 sheets of paper. The
recommended paper weight is 20-lb/80 gsm stock. Pre-formatted paper (i.e. three hole punch)
is loaded face up, with the bind-edge to the right
Paper Trays
1 through 4
High Capacity Tray
(Tray 6)
Figure 1 Paper Trays
Figure 2 IOT Paper Tray
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Paper Supply
Paper Size Sensing

Each Tray includes four switch actuators that are used to monitor the size of the paper.
Switches on the Drives Plate are activated by a notched switch plate and width actuators
located on the back of each tray (Figure 4). A different notch configuration exists for each size
paper, causing different combinations of switches to actuate when the tray is closed. Machine
Run Control determines the size of the paper based on the combination of actuated Switches.
See Table 1. No switches actuated indicates a tray opened condition.
The switch plate is connected to the Side Guides. When the operator moves the guides to fit
the paper on the tray, the Switch Plates change position. Two length actuators in the tray actuate when paper is placed on the tray. The position of the switch plate combined with the
depressed length actuators causes the tray to actuate different switch combinations when the
tray is closed.
Table 1 Paper Size Switch Status

Size - mm
Switch State
No. Paper/Description
Feed Direction
Cross-Feed Direction A
Tray Out
N/A
N/A
D
0
8.5 x 11
216
279
8.5 x 11
279
216
A4
210
297
A4
297
210
8 x 10
203
254
8 x 10
254
203
A4 Covers
223
297
A4 Covers
297
223
9 x 11
229
279
10
9 x 11
279
229
11
A5
210
148
12
5.5 x 8.5
216
140
13
8.5 x 14
356
216
14
A3
420
297
15
11 x 17
432
279
Switch Plate and

Length Actuators
Figure 3 Tray Sensing Actuators
Paper Supply
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Stack Position
The position of the paper stack is determined by the status of the Stack Height Sensor after the
Nudger Solenoid energizes. The Nudger Solenoid is linked to a shaft containing the Nudger
Roll and the Actuator. As the solenoid retracts, the nudger lowers and the Actuator moves (Figure 5.
If the Stack Height Sensor is uncovered, the elevator motor energizes to move the stack
up. As the paper stack pushes against the Nudger Roll, the Nudger Roll and shaft move
upward. This causes the Actuator at the back of the shaft to move also, blocking the sensor (located on the Drives Plate). The machine uses the signal from the Stack Height Sensor to deenergize the elevator motor.
If the Stack Height Sensor is covered, the Nudger Solenoid retracts so the Actuator just
uncovers the Stack Height Sensor.
Paper Feed
Roll Cartridge
Nudger Solenoid
Actuator
Stack Height Sensor
Figure 4 Stack Height Sensing
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May 2003
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Paper Supply
High Capacity Feeder and Bypass Tray

The High Capacity Feeder/ Bypass Tray is located on the outside of the machine to the left of
the Registration subsystem.
The HCF/Bypass Tray includes two feeder assemblies; one for the High Capacity Feeder
(HCF) and one for the Bypass Tray. Figure 6 illustrates the HCF/Bypass Tray Assembly. The
Bypass Tray can also be installed separately, as a stand-alone item. Figure 8 illustrates the
stand-alone version
Bypass Tray
Assembly
Bypass Tray
Feeder
Figure 6 Bypass Tray Stand-alone (Tray 5)
High Capacity
Feeder
HCF/Bypass
Tray Feeder
Figure 5 HCF/Bypass - Tray 5 and Tray 6
Paper Supply
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High Capacity Feeder

The High Capacity Feeder is located to the left of the machine, and provides a 6th paper supply. The HCF is discussed in detail later in the Paper Transportation section.
Bypass Tray
The Bypass Tray is generally used for feeding transparencies and thick paper. It can also be
used for material which is not currently supplied in any of the Paper Trays.
Side
Guides
The Bypass Tray has a semi-active Friction Retard Feeder with a shared Drive Motor. An
Acquisition Roll Lift Mechanism energizes a Solenoid, which drops the roll onto the stack of
materials. When the Solenoid is deenergized, the roll lifts out of contact with the stack.
A Paper Present Sensor detects whether or not material is loaded. The quantity of material in
the Bypass Tray is not measured. A Sensor does, however detect if the material exceeds 9
inches in the feed direction.
The Bypass Tray has a 50-sheet capacity and handles sheet sizes ranging from 102 mm(4) to
305mm (12) in the cross-feed direction, and 140mm (8.5) to 457mm (18) in the feed direction. The Side Guides, which are positioned by the operator, detect the size of the paper. Preformatted paper is loaded face down, with the bind-edge to the left (i.e. three hole punch).
Paper Size
Sensor
Paper Present
Sensor
Figure 7 Bypass Tray (Tray 5) Sensors
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Paper Supply
Paper Supply
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Paper Transportation
Overview
This section describes the transportation of paper from the Paper Trays or Bypass Tray to the
Registration Assembly. This process includes the acquisition, staging, feeding and registering
of the paper so the paper is ready for imaging.
The Paper Transportation function, shown below in Figure 1, includes the following subassemblies:
Feed Roll Cartridge Assemblies in the four Paper Trays
High Capacity Feed Tray
Vertical Transport Assembly
Registration Assembly
Vertical Transport
Paper Tray Feed

Roll Cartridges
Figure 1 Paper Transportation
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Feeder Assemblies (Paper Feed Roll Cartridge)

The paper transportation process begins at the Paper Feed Roll Cartridge (Figure 2). Each
Paper Tray includes its own Paper Feed Roll Cartridge. Although these Feeder Assemblies are
identical, the timing of the feeding operation is slightly different because the length of the path
to the Registration Assembly is different from each Paper Tray
The clutches move freely in opposite directions. When the Feeder Motor rotates in a clockwise
direction, a belt engages the top clutch and drive is transferred to the feedhead coupling in the
top Paper Tray. When the motor reverses direction, the bottom clutch engages, transferring
drive to the feedhead coupling in the bottom Paper Tray. Drive is then transferred to the drive
shaft and Feed Roll in the Paper Feed Roll Cartridge.
The Paper Feed Roll Cartridge performs several functions;
The Feeder Motor energizes at the beginning of the copy cycle.
Separates the top sheet from the rest of the stack
Prevents multiple-sheet feeds
Feeds the paper to the staging, or waiting area
Drives the paper into the paper path
Feed Clutch and Coupling for

upper tray (Tray 1 or Tray 3)

Feed Motor
These functions, as well as the drive that supports them, are discussed in detail on the following pages.
Nudger Roll
Feed Roll
Feed Clutch and Coupling for

lower tray (Tray 2 or Tray 4)
Figure 3 Paper Tray Drives Plate
Retard Roll
Figure 2 Tray 1 Through Tray 4 Paper Feed Roll Cartridge

Drive
The Paper Feed Roll Cartridges in a paper supply are driven by the same 24 VDC, servo-controlled motor. The Motor accomplishes this by reversing direction and switching between two
mechanical clutches. The clutches then transfer drive to the Paper Feed Roll Cartridge via a
Feedhead Coupling. All Feeder drive components are located on the Drives Plate (Figure 3),
which is on the rear inside wall of the IOT.
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Paper Feeding
The feeding operation is basically the same for all paper fed using the Paper Feed Roll Cartridge. There is, however, a slight difference between the feeding of the first sheet of a job, and
the subsequent sheets of the same job. This section describes both sequences.
Nudger Roll in the
paper feed position
Feeding the First Sheet

The feeding of paper is controlled by the Nudger Solenoid, which is linked mechanically to
the Nudger Roll (Figure 4). The solenoid energizes once the Feed Roll is up to speed.
This causes the Nudger Roll to lower onto the top of the paper stack and contact the Feed
Roll.
The Feed Roll transfers drive to the Nudger Roll, causing it to push the top sheet toward
the nip created by the Feed Roll and the Retard Roll. When the sheet of paper reaches
the nip, the Nudger Solenoid deenergizes to lift the Nudger Roll. This reduces the friction
on the paper stack and helps prevents more than one sheet from feeding. The Feed Roll
then transports the paper out of the feeder assembly to the Wait Station Sensor.
Vertical
Transport Nip
Nudger Roll in
the reset position
Wait Station
Feed Roll
Nudger Roll
Figure 5 Nudger Roll Positions

Feeding Subsequent Sheets
If more than one sheet is needed for a job, the feeding sequence changes slightly. This creates
a gap between sheets so the sensors can detect the leading and trailing edges of the sheets.
When the first sheet exits the Feed Roll, the Nudger Solenoid energizes and the Nudger Roll
acquires the next sheet of paper. This operation is the same as the acquisition of paper for the
first sheet. The solenoid and the feeder motor, however, deenergize when the lead edge of the
paper is approximately 70 mm from the drive nip. This stops the paper and creates a gap
between sheets.
When the trail edge of the previous sheet is detected at the Wait Station Sensor, the feeder
motor energizes and the Feed Roll drives the acquired sheet to the Wait Station Sensor. The
sequence continues as described for the first sheet.
Retard Roll
Wait Station Sensor
Nudger Solenoid
Figure 4 Acquisition Area
Feeding the last sheet
When the Wait Station Sensor detects the leading edge of the paper, the feeder motor
deenergizes and the paper stops moving. The paper remains at this waiting area until the
feed command is issued. The amount of waiting time varies between paper trays,
because the distance from each wait station to the photoconductor is different. Figure 5
illustrates the acquisition and rest positions of the Nudger Roll.
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At the end of the job, the Nudger Solenoid does not energize after the last sheet exits the drive
nip. This allows the operator to open the paper tray between jobs because paper is not sitting
at the wait station.
May 2003
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Paper Detection
Retard Roll Operation
In the paper path, reflective sensors are used to detect the presence of paper. A reflective sensor measures the amount of reflectivity at a specific point in the copier. The presence and
absence of paper is determined by a change in the status of this sensor:
The Retard Roll pushes back the sheets under the top sheet of the stack so only the top sheet
is fed. A semi-active Retard Roll provides this function in the Paper Feed Roll Cartridge. The
Retard Roll, which receives drive through contact with the Feed Roll, also provides the nip for
the Feed Roll (Figure 6)
When no paper is present, no light is reflected back to the sensor causing a lo signal.
When paper is present, light is reflected back to the sensor causing a hi signal.
While the Retard Roll rotates to drive the top sheet, a wrap-spring clutch within the roll accumulates tension. This tension creates a reverse torque that causes the roll to periodically
reverse direction for a moment. This action kicks the sheets under the top sheet back into the
paper tray
Feed Roll
Paper feed
direction
Retard Roll
Figure 6 Retard Roll Operation
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The HCF/Bypass Tray includes two Feed Roll Cartridges; one for the High Capacity Feeder
(Tray 6) and one for the Bypass Tray (Tray 5). The Bypass Tray (Tray 5) can also be installed
separately, as a stand-alone item.
Tray 5 Feed
Clutch
Tray 6 Feed
Clutch
Drives
The Feed Roll Cartridges function similarly to the ones in the paper trays; they separate
the top sheet from the rest of the stack, feed the paper to the wait station and drive the
paper into the paper path. These functions, as well as the drive that supports them, are
discussed in detail on the following pages.
The HCF/Bypass Tray contains one 24 VDC motor that provides drive for both Feeder
Assemblies (Figure 7). The motor accomplishes this by reversing direction and switching
between two mechanical clutches. The clutches then transfer drive to the Feeder Assemblies via a Feedhead Coupling.
HCF/Bypass
Tray Feed
Motor
Feeder Motor and Clutches

The clutches (Figure 7) move freely in opposite directions. When the Feed Motor rotates
in a clockwise direction, a belt engages the top clutch and drive is transferred to the feedhead coupling in the Bypass Tray. When the motor reverses direction, the bottom clutch
engages, transferring drive to the feedhead coupling in the HCF Tray. Drive is then transferred to the drive shaft and Feed Roll in the Feed Roll Cartridge.
The Feeder Motor is controlled by the Servo Control Board and IIOCs. When the HCF/
Bypass Tray is selected by the operator, the Feed Motor energizes at the beginning of the
copy cycle.
HCF PWB
HCF Elevator Motor
Figure 7 HCF/Bypass Tray Drive
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Stand-alone Bypass Tray Drive
Interlocks
The stand-alone Bypass Tray (Figure 8) uses a slightly different drive system, that includes
only a motor. The Bypass Tray Feed Motor transfers drive in one direction only via a gear set to
a one-way clutch to the drive shaft. The one-way clutch provides easy jam clearance. The
motor is controlled by a control board located at the rear of the Bypass Tray Assembly, not an
IIOC.
The HCF/Bypass Tray has two interlocks that cause the removal of 24 VDC from the HCF/
Bypass Tray.
The Bypass interlock prevents opening the Bypass during operation. If the Bypass is
opened, the interlock switch actuator arm breaks the signal at the interlock sensor. This
change in state causes logic control to remove 24 VDC from the Bypass Tray.
The HCF generates a similar signal if the height of the elevator or paper is too high. The
elevator or paper will actuate a crossbar at the top of the HCF cavity. When the crossbar
pivots, an actuator arm moves up, breaking the signal at the interlock sensor. This change
in state causes logic control to remove 24 VDC from the HCF/Bypass Tray (Figure 9)
The Bypass Tray Stand-alone does not include an interlock switch. Instead, the operator
pushes a button to open the cover, which signals that the Bypass Tray is open and not
ready for operation.
Clutch
Switch
Actuator
Gear set
HCF Interlock Switch

Bypass Tray
Feed Motor
Figure 9 HCF Interlock Switch
Figure 8 Bypass Tray Drive
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HCF/Bypass Tray Paper Feeding

The feeding operation is basically the same for the HCF/Bypass Tray and stand-alone Bypass
Tray as it is for the Paper Trays. The only difference is the sheet exits directly into the Registration Assembly, and not into the Vertical Transport as it is with trays 1 through 4. Figure 10 illustrates the feed path for the Bypass Tray and HCF.
Registration
Transport
Bypass Tray Paper
Feed Roll Cartridge
Bypass Tray
HCF Paper
Feed Roll
Cartridge
HCF
Vertical
Transport
Figure 10 Bypass Tray and HCF Feed Paper Path

NOTE: The process of acquiring the first sheet, feeding subsequent sheets, feeding the last
sheet and retard roll operation is as previously explained and applies to all Paper Feed Roll
Cartridges.
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HCF Paper Level Detection

Stack height detection for the HCF is similar to the process used in the paper trays. If the
acquisition actuator blocks the sensor, the stack height is correct. If the sensor is unblocked,
logic control energizes the elevator motor (Figure 11) to raise the stack. The elevator motor is a
brush motor, which receives control signals via the Servo Motor Control Board and IIOC.
The elevator motor adjusts the duration of motor-on time, depending on the position of the elevator and the amount of paper in the stack. The motor and a connected beam sensor move up
and down an encoder strip. The beam sensor identifies every transition on the encoder strip as
a step. When the paper stack breaks the sensor, and the motor deenergizes, logic control can
determine the amount of paper in the stack by calculating the number of steps travelled by the
motor. Now the motor can compensate accordingly for the weight of paper on the stack.
Encoder
Strip
HCF Elevator Motor
Beam Sensor
Figure 11 HCF Paper Detection and Stack Height
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Bypass Tray Paper Level Detection

The Bypass Tray uses the Paper Present Sensor and two guides to align the paper. The Paper
Present Sensor actuates when paper is inserted. When the paper supply is depleted, the
Switch Actuator deactuates. The maximum fill line on the Rear Side Guide identifies the maximum amount of paper that can be loaded in the Bypass Tray. This fill line represents a stack of
50 sheets of 20 lb. paper.
The Bypass Tray includes 2 Length Sensors and one Width Sensor to determine the size of
material in the tray (Figure 12). The rib on the Rear Side Guide actuates the Length Sensors
as the rear guide moves, identifying the length of the paper. The Width Sensor determines if
the material is less than or greater than 9. The various combinations of these 3 signals help
logic control determine the approximate size of the material.
Length Sensors
Rear Side Guide
Paper Present Sensor

Width Sensor
Figure 12 Bypass Tray Paper Detection
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Vertical Transport
The Vertical Transport Assembly consists of a baffle device, several sensors and drive Rolls
(Figure 13 and Figure 14).
The purpose of the Vertical Transport Assembly is to transport the paper from the wait station
of the Paper Trays to the Registration Assembly. It does not transport materials from the HCF/
Bypass Tray.
For a short time, both the feeder Feed Roll and the vertical transport Rolls drive the paper
at the same time. Since these Rolls are controlled by different motors, they may not be
driving the paper at the same speed. A pivoting baffle in the baffle area compensates for
these differences in speeds:
If the main drive motor is faster than the feeder motor, the baffle pivots to create a
shorter paper path.
If the main drive motor is slower than the feeder motor, the baffle pivots to provide
room for the paper to buckle slightly
The feeder motor deenergizes when the trailing edge of the paper clears the Wait Station
Sensor. Now, only the vertical transport Rolls drive the paper to the registration Rolls.
Vertical Nip
Rolls
Baffle
area
Vertical
Transport
Paper Feed Roll

Cartridge
Tray 1
Wait Station
Sensor
Tray 2
Wait Station
Sensor
Tray 3
Wait Station
Sensor
Tray 4
Wait Station
Sensor
Wait Station Sensor
Figure 14 Vertical Transport Wait Station Area (Typical)
Figure 13 Vertical Transport

Vertical Transport Drive
The Vertical Transport Assembly is driven directly by the Developer Drive Motor.
Operation
When the feed command is issued, feeder drive motor energizes, causing the feeder
Feed Roll to drive the sheet of paper through a baffle area to the vertical nip Rolls (Figure
14).
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The purpose of the Registration Assembly is to receive the sheet of copy material from either
the Vertical Transport or the HCF/Bypass Tray, remove any skew, and register the sheet so it
aligns correctly with the image on the photoconductor. The Registration Transport (Figure 15)
then feeds the sheet at the correct time to receive the image. The Registration Transport components are shown in Figure 16.
Preregistration Roll
Registration Roll
Vertical Transport
Figure 16 Cross section of the Registration Transport
Figure 15 Registration Transport
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May 2003
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Drive
The Registration Assembly receives drive from the Developer Drive Motor, via a series of
gears.
From Duplex
Transport
Preregistration Nip Loading/Unloading Mechanism

The paper is transported through the Registration Transport Assembly by the Preregistration
Nip Rolls. These rolls apply a nip force when transporting and registering the paper, but
remove the nip force when the sheet is fed out of the Registration Assembly. This is accomplished by the Preregistration Nip Loading/Unloading Mechanism. This mechanism applies
and removes force to the nip Rolls as needed during the registration operation.
The mechanism consists of a solenoid linked to the Preregistration Drive Roll. When the solenoid energizes, the link moves the Preregistration Nip Roll so it contacts the Preregistration
Drive Roll. The drive roll transfers drive, creating a nip load of 1.75 lb.
Preregistration
Nip Roll
Registration Roll
From HCF/
Bypass Tray
The solenoid energizes after the previous sheet has passed the nip, and before the next sheet
arrives.
The Registration Transport consists of: (Figure 17)
Registration Roll
Drive/Nip Rolls
Registration Clutch
Registration Drive Shaft
Registration Sensor
Pre-transfer baffles
Vertical Transport
Preregistration
Drive Roll
Registration
Sensor
Figure 17 Registration Transport Components
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Operation of the Registration Transport
The function of the Registration Transport is to receive the sheet of copy material from any of
the paper supply sources, deskew the sheet, and register the sheet prior to feeding it to the
Photoreceptor Transfer Area (Figure 18).
Paper Registration Area

Transfer Area
When paper arrives at the Registration Roll, it is traveling at 305 mm per second. The paper
presses against the stalled Registration Roll and forms a buckle for the purpose of deskewing.
Sheets are transported at a speed of 302.5mm per second through the Assembly by Drive/Idler
Rolls (Figure 19).
A Clutch on the Registration Drive Shaft engages the Registration Roll and drives the sheet to
the Photoreceptor Transfer Area. This process occurs at a specified time interval that ensures
lead-edge registration to the PITCH RESET image after deskew.
A Registration Sensor detects early or late sheet arrival, jams, and Registration Clutch deactuation when the sheet leaves the Registration Assembly. Clutch engagement is synchronized to
the appropriate PITCH RESET signal and arrival of a sheet at the Registration Sensor. Isolated
Pre-Transfer Baffles flatten and guide the sheet to the Transfer Zone.
From Duplex
Transport
Paper
Buckle
Registration Roll
From HCF/
Bypass Tray
Vertical Transport
Preregistration
Nip Roll
Registration
Sensor
Figure 19 Registration Transport Operation
Figure 18 Registration Transport and Transfer Area
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Marking
Detack
Xerographics overview
The primary functions of the xerographic module are to:
Provide a charged Photoreceptor which can then be exposed with the document image
data to create a latent electrostatic image on the Photoreceptor
Develop the latent electrostatic image with a process that deposits toner on the image
areas
Transfer the developed image from the Photoreceptor to paper or other copy material
Strip and move the unfused copy from the Transfer Station so that it can be transported to
the fusing station
Clean the residual toner from the Photoreceptor in preparation for the next charging cycle
Erase
Transfer
Clean
This chapter describes the electrical and mechanical components that perform these functions,
the Process Controls which control the functions to obtain the desired level of image quality,
and the Diagnostics available for troubleshooting and adjustments.
The major sections of this chapter are:
Development
Photoreceptor
Charging
Development
Transfer
Photoreceptor cleaning
Charge
ROS
Figure 1 illustrates these main areas.
Figure 1 Xerographic Functions

The marking process in this product is called a black writing system or Discharge Area Development (DAD), as opposed to the more standard white writing system. In a black writing system the areas which will represent the image on the charged Photoreceptor are exposed,
rather than the background areas.
The Charge Scorotron puts a negative electrostatic charge on the Photoreceptor surface. A
latent electrostatic image of the document is formed by exposing the image area with a laser
beam (ROS). The areas that represent images to be developed are discharged to a very low
electrostatic potential (approximately 70 Vdc) while the background areas, which are not
exposed, retain their high negative charge (approximately 500 Vdc). As the latent image
passes through the development zone, the toner, which is negative, is repelled by the background areas and is attracted to the image areas which are more positive than the toner particles
In most cases, the symptoms that result from failures in the xerographic process areas of the
copier will be different than those which are observed in the more standard white writing system. For instance, if the ROS fails so that there is no exposure, blank copies will result. In a
write-white system, this would result in a dark dusting. When troubleshooting xerographic problems in this copier, it will be important for the Service Representative to remember that this is a
write-black system
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Marking
Charging
Charge Scorotron
The Charge Scorotron (Figure 2), located within the Xerographic Module, provides a uniform
charge level to the Photoreceptor in preparation for imaging. Unlike the Corotron, the
Scorotron uses a Grid to regulate the voltage applied to the photoreceptor.
The Charge HVPS (Figure 3) supplies -6000 Vdc (-6 kV) to the Charge Scorotron Pins and a
nominal bias voltage of 550 Vdc to the Grid.
Charge HVPS
The Pins emit current, while the grid absorbs 80% of the current and applies a charge to the
photoreceptor. There should be no voltage difference between the grid and the photoreceptor.
These similar voltages prevent current from being attracted to the photoreceptor. The grid bias
voltage is controlled by process control algorithms, and is adjusted as necessary.
The Scorotron plugs directly into the Power Supply, and transfers power via a conductive strip.
Figure 3 Charge HVPS

Charge
Scorotron
Figure 2 Charge Scorotron
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Development
Toner Supply
The primary function of the development system is to apply toner to the electrostatic image on
the Photoreceptor. Because this is a Discharged Area Development (DAD) process, the electrostatic image on the Photoreceptor is negative. The lesser negatively charged areas of the
Photoreceptor develop into the visible image. The fully charged areas of the Photoreceptor
remain clear of toner.
The purpose of the Toner Supply is to deliver toner from the Toner Cartridge to the Developer
Assembly as required by process controls (Figure 5).
The Hybrid Jumping Development (HJD) design uses a conductive magnetic brush to load
toner onto a Donor Roll. Image development occurs by attracting toner from the AC-biased
Donor Roll onto the Photoreceptor
Toner is dispensed into the outboard end of the Auger #1 channel, where it is mixed with the
developer material. The developer is then transported to the inboard end of the housing,
where it flows into Auger #2 via a cut-out between the channels. As the developer in Auger #2
moves toward the front of the machine, it is attracted to the Mag Roll. The attracted developer
is picked up and trimmed at the same time. The rotation of the Mag Roll transports the developer to the nip area between the Mag Roll and the Donor Roll, where a solid coverage of toner
is deposited onto the Donor Roll. The rotation of the Donor Roll transports toner to the Photoreceptor development region where it is jumped onto the latent image on the photoreceptor
using an AC bias.
Toner Cartridge
The Toner Cartridge Unit is located above the Developer Housing. The cartridge slowly rotates,
which causes the toner material to move through the Cartridge. At the end of the Cartridge is a
Paddle Wheel that scoops up the material and dumps it onto the Extracting Auger. The Extracting Auger transports the toner to the Dispenser Sump. The Developer Auger them delivers
replenisher from the Sump to the Developer at the required rate.
The Toner Cartridge is cylindrical with a spiral rib molded in the side. It holds 2.4 liters of toner
and carrier, which equals approximately a 20,000 copy capacity when running an average 6%
coverage area. It is loaded horizontally in the guides above the developer. The cartridge is
pushed on to the Extracting Auger. There are seals between the Cartridge and the Extracting
Auger that prevent leakage of toner.
A trickle system is used to replenish the Sump. When utilizing this scheme, a small amount of
carrier is included with the toner in the Toner Cartridge. The trickle system usually eliminates
the need for a Service Representative to change the developer, since new carrier is added to
the Sump whenever toner is required. An overflow system maintains a constant developer volume in the Sump. The developer flows out of the housing and falls down a tube into a storage
container called a Developer Collector. There is a 3-pin Sensor that detects whether the bottle
is full or missing. When the output signal on the Trickle Bottle Sensor is Low, the bottle is not
full. When the signal is High, the bottle is either full or not in the machine.
It should be noted that there is a single configuration of developer housing for all of the Document Centre 240/255/265 DC/LP/ST machines. However, there is a unique developer housing
for machines that are installed at an altitude of 4000ft/1200m or higher. This high altitude
developer housing differs from the standard developer housing in the following ways:
The high altitude developer housing is spaced .001 closer to the photoreceptor than a
standard housing
The high altitude housing has a donor roll with a tighter tolerance on its runout
The high altitude housing has a donor roll that rotates 30% faster
Whenever a high altitude housing is present, there is an NVM value that must be set to indicate
what the local altitude is. Machines that have had the High Altitude Kit installed at VALO are
set to 6000ft. This should be changed as necessary to match the local altitude.
NOTE: The NVM value must be set using the altitude in feet. If the altitude is known in meters,
multiply by 3 to get an equivalent value in feet.
High altitude developer housings should only be installed on machines that are 4000ft/1200m
or higher, otherwise Image Quality will be degraded.
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Low Toner Sensor

(hidden)
Toner
Car-
Donor Roll
Auger #1
Auger #2
Developer
Housing
Figure 4 Developer Housing/Toner Cartridge

Low Toner Monitoring
The earliest warning of an impending empty Toner Cartridge comes from an optical Toner Bottle Sensor. When the Sensor looks through the Toner Bottle and sees low toner, a message is
displayed indicating that approximately 3,000 copies remain. (This applies to FX machines
only.)
When the Low Toner Sensor reads less than 2.5V, a 24 Vdc Motor energizes the Toner Cartridge and the Extracting Auger. The Motor stays on until the Low Toner Sensor is cleared. If
the sensor has not cleared after 80 seconds, a Low Dry Ink message is displayed. The customer can run approximately 900 additional copies before an Add Dry Ink message is displayed
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Transfer
Transfer Corotron
The purpose of the Transfer system is to:
The Transfer Corotron (Figure 7), located within the Xerographic Module, places a high positive charge on the paper as it passes beneath it. This charge causes the negatively charged
toner to transfer from the photoreceptor to the paper. To maintain copy quality, the power supply adjusts the transfer coronode current continuously in response to the load (paper, transparencies, environmental zone, and other factors).
bring the copy material into contact with the Photoreceptor
transfer the toner image from the Photoreceptor to the copy material
remove the copy material, with its image, from the Photoreceptor Detack function.
In the digital copier, a Pretransfer Guide (Figure 6) directs the paper onto the photoreceptor.
The transfer corotron (Figure 7) then places a charge on the paper as it passes beneath the
corotron.
Transfer Corotron
Pretransfer Guide
Figure 6 Transfer Corotron
Figure 5 Transfer
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Paper Stripping
After transfer of the toner image, the copy material must be removed from the photoreceptor.
This function, called paper stripping, is accomplished by the Stripper Roll and the Detack
Corotron. The Stripper Roll is 25.25 mm in diameter.
Detack Corotron
The Detack Corotron, located within the Xerographic Module (Figure 8), is a single-array pin
device. The shield of the Corotron is grounded. The Detack Corotron is located at the top of the
Stripper Roll, 25.5mm after the Transfer Corotron. A lace cover prevents the paper from getting
caught in the Corotron.
Detack Corotron
Stripper
Roll
Figure 7 Detack Corotron
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Photoreceptor Cleaning
Cleaning Operation
The Cleaner Assembly (Figure 9) performs the following specific operations:
NOTE: All components in the Cleaning Assembly are completely contained within the Xerographic Module.
removes untransferred toner from the Photoreceptor
transports the waste toner and other debris to a waste container
Once the image has been transferred and the paper is returned to the paper path, residual
toner remains on the photoreceptor. The Cleaner Assembly removes this toner and prepares
the photoreceptor for another image cycle.
The Cleaner Assembly includes the Blade Assembly, Cleaning Blade, Brush Assembly, Flicker
Bar Assembly, Drive Assembly, Seal Assemblies, and a Waste Toner Container. There is no
sensor in the Cleaner Assembly.
Cleaning Brush
Lamp
Once the toner and particles are removed from the photoreceptor, a Lamp erases the voltage remaining on the photoreceptor. This function attempts to achieve a uniform 0 Vdc on
the photoreceptor before it begins a new cycle. The Lamp consists of red LEDs that are
powered continuously by 24 Vdc from the Low Voltage Power Supply (LVPS).
Cleaning Blade
The residual toner is scraped off the Photoreceptor by a Cleaning Blade made of urethane rubber. The angle of the blade to the Photoreceptor surface has been selected to
provide effective cleaning and no filming. The blade is always against the Photoreceptor
and is not retracted as it is in some products. The Blade contains a pivot mechanism,
which allows for some deflection, and compensates for location tolerance between the
photoreceptor and cleaner. If the Cleaner is not completely parallel to the photoreceptor,
the blade will pivot to provide the correct angle.
The end of the blade is also spring-loaded so it applies constant pressure to the photoreceptor. A lever and torsion spring combination causes a retractor lever to move, releasing
the spring-loaded tension of the blade. The blade can then be removed.
Cleaning Brush
The scraped off toner is picked up by the Cleaning Brush, which is driven by the Photoreceptor (P/R) motor. The Flicker Bar Assembly then dislodges the toner and fibers in the
Cleaning Brush, causing them to fall into the Chute and Waste Toner Container located
under the Cleaner. The waste container can hold approximately 1900 gm of waste toner.
The Cleaner Assembly is totally isolated by seals on three sides and the cleaning blade.
This prevents the release of airborne toner into the copier. The entrance seal is a polyurethane flap, and the two side seals at the end of the blade are polypropylene fiber brushes.
Low Area Coverage Copy Runs
If a long run occurs with low area coverage, the photoreceptor can become too clean, creating friction between the photoreceptor and blade. To prevent this situation, the copier
creates a toner band in the inter-document zone once every 4 copies.
Waste Toner
Container
Figure 8 Cleaning Components
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Process Controls
Control patch calibration - sets the sensitivity of the actuators
Overview
Electrostatic Convergence - adjusts all the actuators to obtain correct density of the
patches
A closed-loop process control system is utilized to maintain excellent and consistent image
quality as the environment changes and as the machine components age. The term, closed loop, indicates that image quality is constantly being checked as the machine runs, and that
information is fed back to the system to determine what adjustments need to be made.
The factors that can cause variation in image quality and create a need for continuous adjustment are:
The amount of time it takes for the Xerographic Setup to complete varies, depending on the
machine condition. It can take as little as a couple of minutes to as long as 20 minutes. 40ppm
machines will take longer than 65ppm machines. If the machine cannot setup due to some
machine problem, a fault code will occur and will be logged. The machine will still be available
to the customer.
Toner and Developer variability
Run Time Image Quality Control
Ambient temperature and relative humidity
Photoreceptor photosensitivity characteristics
Photoreceptor to Developer Donor Roll gap
Document area coverage and toner usage
ROS Output
During normal run, image quality is being monitored. Before every job, the BTAC Sensor is calibrated. Also, once every revolution of the photoreceptor, three process control patches are
created in the inter-document zone and measured by the BTAC. At every job cycle-out, a toner
control patch is made. These patches are not transferred to the paper, they occur between
pages. Based on the measurements of these patches, the process controls will make adjustments to optimize image quality and maintain the correct toner concentration of the developer.
Part life
Altitude
Process control patches of differing densities are generated by the system. All measurements
of these patches are made by the BTAC (Black Toner Area Coverage) Sensor. Sophisticated
software routines then adjust the various xerographic settings (actuators) based on those measurements.
There are two basic modes for process controls: Setup Mode (Xerographic Setup) and Runtime Image Quality Control.
The toner dispensing is controlled by an IIOC device which signals the Developer Dispense
Motor to energize or not energize based on the need. The need is determined by the continual
monitoring of the patches, but also by counting the number of pixels being processed by the
image processing systems.
Also, if the customer is unhappy with the machine image quality, a setup can be initiated by the
customer via the UI Tools menu.
Setup Mode (Xerographic Setup)

Xerographic Setup is an automated process where Xerographic settings are adjusted until
image quality specifications are met. It is more thorough than the run time control and ensures
a nominal starting point. Whenever the copier is energized or when it comes back from Power
Saver mode, if it has been over 24 hours since copies were made, patches are checked. If they
are not within a specified range, the machine automatically enters into Xerographic Setup.
Xerographic Setup also needs to be performed whenever the Xerographic Module, Developer
Housing, or the ROS are replaced. It will be run automatically when the Xerographic Module is
replaced, because the machine will sense the new CRUM. When the Developer Housing or the
ROS is replaced, it must be run by invoking the routine from the PWS. The repair procedure in
the Service Manual will indicate this.
In the event certain xerographic faults occur, the machine will run a xerographic setup at the
completion of the current job. This setup is the same as a standard setup (see below), except
that the exposure setup part of the routine is omitted. This will shorten the setup by approximately 2 minutes.
Xerographic setup can be divided into five stages:
Xerographic Exerciser - calibrates BTAC, checks for hardware failures
Toner Concentration setup - adjusts the toner concentration to a nominal range
Exposure setup - sets the correct output for the ROS
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BTAC (Black Toner Area Coverage) Sensor

The BTAC Sensor is an electro-optic infrared reflective sensor for use in black toner copiers.
The sensor provides an output signal that indicates the amount of reflection off a Photoreceptor. The sensor is calibrated against the readings measured on a clean photoreceptor belt. The
BTAC Sensor readings are based on relative reflectance (RR). The relative reflectance off a
clean photoreceptor is 1, and the reflectance off a 100% coverage black patch would be 0. Figure 10 shows the location of the BTAC Sensor.
Transfer/
Detack HVPS
Charge
HVPS
Developer
HVPS
BTAC Sensor
Figure 10 Xerographic Power Supplies
Charge HVPS
The Charge HVPS uses interlocked 36 VDC and supplies current for the Charge Scorotron
pins and a voltage to bias the Charge Scorotron grid. The output of the supply is enabled by a
digital signal from the SCAM PWB. The bias to the grid is also controlled by an analog output
of the SCAM PWB, based on requirements of the Process Control system.
In the event of an overcurrent or overvoltage condition is sensed by the supply, the HVPS will
shut down and a signal is sent to the SCAM PWB and a fault is declared.
Figure 9 BTAC Sensor Location

Xerographic Power Supplies
There are three xerographic power supplies used on this product (Figure 11). These are
explained in detail as follows.
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Transfer/Detack HVPS
New Parts Setup
The Transfer/Detack HVPS is a single field replaceable unit, but consists of two separate
PWBs. The Transfer HVPS uses interlocked 36 VDC to produce current for the Transfer
Corotron wire. The output of the supply is enabled by a digital signal from the SCAM PWB and
the level is fixed, but different for 40ppm machines. A digital signal from the SCAM PWB is sent
to the Transfer HVPS on 40ppm machines to set the correct level.
New Parts Setup is only used when certain xerographic components are replaced. The Toner
Dispense Fill routine ensures that the toner pipeline is full before the process controls try to
adjust the image density. The Developer Housing install ensures that new developer material is
conditioned correctly before the process controls attempt to setup the xerographics.
The Detack HVPS also uses interlocked 36 VDC to produce an AC voltage superimposed on a
DC bias for the Detack Corotron pins. The output of the supply is enabled by a digital signal
from the SCAM PWB.
In the event of an overcurrent or overvoltage condition is sensed by either supplies, the HVPS
will shut down and a signal is sent to the SCAM PWB and a fault is declared
Developer HVPS
The Developer HVPS uses interlocked 36 VDC and produces two outputs to bias the Developer Mag Roll and Donor Roll. The Donor Roll output consists of an AC bias superimposed on
a DC bias. The Mag Roll output also consists of an AC bias superimposed on a DC bias, which
is in turn, superimposed onto the Donor Roll bias.
Both outputs are enabled by a digital signal from the SCAM PWB. Three analog outputs from
the SCAM PWB control the Donor and Mag DC levels and the Donor AC amplitude. These levels are determined by the process controls system.
In the event of an overcurrent condition due to a short from the Donor to ground, mag to
ground, or Donor to Mag, the HVPS will shut down and a signal is sent to the SCAM PWB and
a fault will be declared.
Diagnostics
Xerographic Exerciser
The Xerographic Exerciser is an automated diagnostic tool that can help determine the cause
of xerographic problems. The Exerciser runs a series of tests where xerographic parameters
are manipulated, and by using the BTAC Sensor, analyzing the response of the control
patches. Based on these results, the Exerciser will display a pass or fail message, with recommended parts to replace. The routine will complete within 2 minutes.
The Xerographic Exerciser is not effective for all xerographic problems. The BTAC Sensor is
fixed and only views a narrow area of the image, it can only diagnose a limited number of
image quality defects. The analysis of the data also depends on an active xerographic fault
code. In addition, the Exerciser cannot diagnose some xerographic fault codes. Because of
this, the routine should only be run when directed to by the RAPs.
Power Supply Tests
The Power Supply Tests are similar to Component Control. They allow the Charge, Developer,
and the Transfer/Detack HVPSs to be energized so that measurements can be made with the
Digital Multimeter.
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Fusing and Copy Transportation
Prefuser
Transport
Duplex Transport
Overview
This section presents the details of the Prefuser Transport, Fuser Module, Inverter, Dual
Decurler, and Duplex Transport. The Prefuser Transport moves the stripped, unfused copies
from the photoreceptor to the Fuser Module. The Fuser Module permanently bonds the toner
image into the copy paper by means of heat and pressure.
Diverter
Gate
After a sheet of paper has been imaged and fused, it will exit the product or be directed by the
Inverter to the Duplex Transport to be imaged again. When the paper is imaged only on one
side, it will exit the product either face up or face down. When the paper is to be imaged again,
it will be directed to the Duplex Transport to be copied on the reverse side of the paper.
To
Decurler
Fusing and Copy Transportation Consists of (Figure 1):
Prefuser Transport
Fuser Module
Inverter
Dual Decurler
Duplex Transport
Inverter
Fuser Module
Figure 1 Cross Section of Fusing and Copy Transportation Components.
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Prefuser Transport
The Prefuser Transport (Figure 2) acquires the lead edge of the stripped, unfused sheet from
the Photoreceptor. It then transports the sheet to the Fuser by Transfer Belts. The Transfer
Belts operate at slightly higher than process speed, which forms a buckle on the paper as it
enters the Fuser.
Gear (Driven by
the Fuser Motor)
Belt (1 of 4)
The Prefuser Transport is located after the detack corotron in the paper path. The left side of
the transport actually contacts the detack corotron. The front of the transport rests on top of the
fuser at the front of the transport.
The Prefuser Transport consists of 4 belts that rotate around a vacuum plenum, idler shaft and
drive shaft. The drive shaft connects to a gear at the back of the transport, which is driven
directly by the Fuser Drive Motor.
A reflective sensor (PFT Sensor) is located in the center of the plenum. This sensor generates
timing signals used for jam detection purposes.
PFT Sensor
Drive Shaft
Figure 2 Prefuser Transport - Bottom View
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The transport also includes a 24 VDC, 11 watt blower that draws air out of the plenum, pulling
the paper against the belts with vacuum. This blower operates continuously while the copier is
powered on. The blower is grounded via a ground strip or brush located at the rear of the transport (Figure 3).
Diagnostics and Troubleshooting the Prefuser Transport

Component Control Input - PFT Sensor
Checks the operation of the PFT Sensor S3
Component Control output - PFT Fan
Allows testing of the PFT Fan
Troubleshooting Tip: A loss of PFT ground may result in jams and/or image disturbance.
Ground Strip
Prefuser
Transport Fan
Figure 3 Prefuser Transport - Top View
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Fuser Module
The Fuser Assembly (Figure 4) receives paper from the prefuser transport and applies heat
and pressure to permanently adhere the toned image to the paper.
The paper is guided by an entrance baffle into the nip of the fuser roll and pressure roll. The
pressure roll is a soft roll, located on top of the harder fuser roll. The two rolls, which contact
each other continuously, are held in position by 2 compression springs. The nip created by the
two rolls is expected to be 5.6mm 0.3 mm (DC265) or 5.2mm + 0.3mm (DC240) at the center
of the rolls. The nip at each end of the roll should within 0.4 mm of each other. All fuser components are spared as part of the Fuser Customer Replaceable Unit.
The fuser roll receives drive from a gear set driven by the Fuser Drive Motor and transfers the
drive to the pressure roll. The fuser roll also contains a quartz-halogen lamp that heats the
fuser roll to a temperature of approximately 375 degrees Fahrenheit. A thermistor and 2 nonresettable thermal fuses protect the copier from over-temperature conditions. These are discussed in more detail in the heating and temperature control discussion later in this section.
Static is dissipated in the fuser assembly by a non-contacting static brush, which is grounded
through the ground circuit. The fuser roll is grounded through the core and the bearings to the
frame.
Baffle
The fuser roll assembly also includes an oil-impregnated web that cleans toner from the fuser
roll while supplying the fuser roll with a small amount of oil. The web is driven through gear
reduction from the fuser drive gears. At this time the web is not replaceable separately but may
be as fuser life improves.
As the fused paper exits the rolls, a set of strippers separate the paper from the fuser roll and
direct it into the paper path. These strippers prevent the paper from wrapping around the fuser
roll.
CRUM values
The end of life of the Fuser Module is monitored by a CRUM (Customer Replaceable Unit Monitor) for approximately 250,000 copies (this may change as improvements are made to the
fuser). Fuser life, however, will vary depending upon the types of jobs run. Since the fuser components are turning during print and therefore web is being used, life will vary. If a Customer
ran only 1 original for each copy and let the machine fully cycle between jobs, the web life may
be as low as 80K copies.
Functions of components and subassemblies
The Fuser Assembly performs the following significant functions. Each of these functions is
discussed in detail on the following pages.
Mechanical drive of the rolls
Heating and temperature control of the rolls
Supplying of Fuser Release Agent to the Fuser Roll
Web cleaning of the Fuser Roll (uses both sides)
Mechanical drive of the rolls

The Fuser Drive Motor provides mechanical drive to the Fuser. Two compression springs on
the pressure roll apply a constant rate of nip-force to the fuser roll.
Pressure
Roll
A knob, located at the front of the Fuser Assembly, can be manually turned to drive the gear
set which drives the fuser roll and web. The purpose of this knob is to aid in jam clearance. The
knob, which can be turned in either direction, can rotate the fuser and pressure rolls and the
Fuser Drive Motor.
Fuser Heat Roll
Figure 4 Cross Section of PFT and Fuser Module
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Heating and Temperature control of the rolls
Supplying Fuser release agent to the Fuse Roll
A quartz-halogen lamp inside the Fuser Roll supplies the heat for the fusing process. Power is
provided to the lamp via connector strips instead of wires. The lamps power duty cycle is governed by a software feedback loop which uses a DC Thermistor to sense the surface temperature of the Fuser Roll. Temperature of the Lamp is controlled by logic control and protected
from a destructive overheat by an AC Thermal Fuse.
The Fuser Roll is lubricated with fuser oil, which acts as a release agent to prevent toner from
sticking to the roll. An oil-impregnated Web moves across the surface of the Roll to lubricate it.
The web is driven by gears within the Fuser CRU. The web is unique in that both sides of the
web are used to clean the fuser roll.
The thermistor contains a 5-volt, negative-temperature coefficient resistor. As the temperature increases, the resistance decreases. The signals are sent to the SCAM Board and
through an A/D (Analog to Digital) Converter. Logic control then reads the value and
adjusts the normal temperature. If the Thermistor senses an over-temperature condition,
the Lamp is automatically turned OFF. Both the range of change and the actual temperature are monitored by logic control.
Cleaning the Fuser Roll
An AC thermal fuse, which is non-resettable, is located 2 mm from the Fuser Roll. If this
fuse melts, the AC circuit opens, signalling an overtemperature condition and protecting
the machine from a damaging overheat.
As the fuser matures, it may be necessary to make the web assembly a separately spared
module. This has been planned and may be available in the future, but is not at this date.
For backup overtemperature protection, the Fuser Assembly also includes an OPP (Outside
Paper Path) fuse that touches the fuser roll outside the paper path. This non-resettable thermal
fuse is wired in series with the coil of the relay. If the thermal fuse circuit opens, the relay
removes all power to the machine.
Logic control monitors the warm-up rate. Operational temperature is 375 degrees F. If the correct temperature is not achieved within a specified time, Fuser fault 10-301 occurs and the system does not become operational. After the temperature reaches 350 degrees F during warmup, the rolls rotate until the correct temperature is reached.
The Standby temperature ranges between 350 - 400 degrees F. To maintain this temperature,
logic control energizes and deenergizes the Fuser. Power is conserved during Standby, which
means that some time to get back to a Ready temperature may be required.
There are several possible failures which can occur in the temperature control system. Table 1
shows the fault codes utilized to indicate these failures.
Table 1 Fuser Fault Codes
Fault Code
10-300
Condition
Fuser Thermistor circuit is open.
10-301
Fuser failed to warm up.
10-302
Fuser under temperature.
10-303
Fuser over temperature.
10-350
Fuser Module CRU Connector is open.
10-352
Incorrect Fuser CRU is installed.
10-354
Fuser CRU CRUM is missing.
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The fuser assembly includes a web cleaning system to remove toner that has adhered to the
Fuser Roll during the fusing process. Since this web is driven by gear reduction from the fuser
roll drive, it moves constantly from a supply roll to a take-up roller. The web is part of the Fuser
Assembly CRU, and is expected to last the life of the Fuser CRU assembly.
Diagnostics and Troubleshooting: Fuser

Via the Diagnostic Navigator - Component Control:
Fuser Drive Motor: Tests Fuser motor, drive belt and decurler clutch by utilizing the clutch
position to verify the motor and drives
Fuser Power Relay: Tests the Fuser Power Relay
Fuser Fan: Used to test the basic operation of the fan
Tips:
The thermistor is used to tell software if the fuser is installed. If the thermistor opens or you
have a defective SCAM PWB - causing an incorrect thermistor sense, the machine may think
the fuser is not installed
DC240 and the DC255/DC265 fusers are not interchangeable, they have different nips, fuser
rods, CRUMs, and operating temperatures.
There are no field adjustments in the fuser and none should be attempted. There is no accurate way to test nip pressure in the field
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Inverter
Diagnostics and troubleshooting: Inverter
The Inverter (Figure 5) moves paper from the Fuser to either the Decurler or to the Duplex
Transport through two decision gates:
Diag.Nav.\Copier Sys\Component Control\IOT Paper Path\Inputs:
Inverter Gate
Duplex Gate
Inverter Entrance Sensor

The Inverter Gate is controlled by the Inverter Gate Solenoid, which is powered by 24VDC.
When energized, this Solenoid diverts sheets to the Reversing Nip Rollers and on to the
Inverter Exit Rollers.
Inverter Close Nip Solenoid
The Reversing Nip Rollers are energized by the Inverter Nip Close Solenoid, which is 24VDC.
When this nip is closed, the forward drive of the Inverter is engaged. When the trail edge of the
sheet reaches the stop position, the reverse drive of the Inverter is engaged. This drives the
sheet out to the Exit Nip Rollers. The Inverter Reverse Solenoid is 24VDC.
Inverter Gate Control Solenoid
Inverter Duplex gate solenoid

Inverter Reverse Drive Solenoid
The Duplex Gate is controlled by the Duplex Gate Solenoid. When energized, this Solenoid
diverts sheets to the Duplex Transport.
The Inverter Entrance Sensor and Exit Sensor start timing windows for both the gates and the
reversing mechanism. These sensors operate on 5VDC.
Inverter Entrance
Sensor
Duplex Gate
Dual Decurler
Inverter Exit Rolls
Inverter
Gate
Reverse Nip Rolls

Figure 5 Inverter Paper Path
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Decurler
Diagnostics and Troubleshooting
The Decurler transports paper from the Duplex Decision Gate to the IOT exit. It forms a
mechanical bend in a direction opposite to the expected curl of an incoming sheet. Decurler
activation is an option offered on the KEY OP screen, assuming the decurler is enabled
(plugged in).
Decurler Cam Clutch
Decurler Clutch Reset
The Decurler provides two decurling positions, depending upon the output path of the sheet.
This is necessary because paper enters the Offsetting Catch Tray (OCT), Disk Finisher Top
Tray or Mailbox in a different orientation than paper entering the Disk Finisher Main Tray
(i.e.;Mailbox/Finisher Top Tray - image down, Finisher Main Tray - image up).
Dog Ears: If it is suspected that the dog ears are coming from the Decurler, remove the
entrance baffle from the Decurler and rerun - if dog ears are no longer present - replace the
Decurler assembly. If the dog ears persist, the cause probably lies elsewhere.
Troubleshooting Tips:
The Decurler consists of two sets of nip rollers. The first set of nip rollers on the entrance side
of the Decurler control the decurling of paper exiting the IOT oriented image down. The second
set of nip rollers on the exit side of the Decurler control the decurling of paper exiting into the
Disk Finisher Main Tray.
Each set of nip rollers contains one small nip roller (hard), which, when engaged, applies pressure to a larger roller (soft). This pressure creates a reverse-curl that straightens the paper.
The movement of the smaller rollers is controlled by a software-controlled clutch. The software
detects the KEY OP screen selections, the number of inversions used in the paper path, and
the normal setting area coverage to set the Decurler. The Decurler can switch positions during
a job if these parameters change.
The clutch has 3 positions:
home position (minimized roll engagement)
OCT/Mailbox/Disk Finisher Top Tray exit (first set of rolls engaged)
Disk Finisher Main Tray exit (second set of rolls engaged)
When the clutch engages, it turns a cam shaft, which opens or closes the appropriate roll pair.
The Decurler receives drive via a belt from the Fuser Drive Motor.
On the input side of the Decurler, an entrance baffle applies pressure against the inverter to
prevent a gap between the Inverter and Decurler. The Decurler also includes a passive static
brush at the exit of the Decurler to remove any static before the paper exits into the output
device.
The Customer can change the operation of the decurler via the Customer tools, by selecting
the Machine Tests and Humidity Adjustment buttons. Choices are High, Normal and Low
decurling depending upon output device, paper, and humidity. Generally, for a Disk Finisher the
Low setting is appropriate. The High setting is needed for the OCT. The High setting is the only
setting that causes the Decurler to act on duplex sheets.
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Duplex Transport
The Duplex Transport (Figure 6) transports the sheets from the Inverter back to the Registration Nip so the side 2 image can be transferred to the second side. The Acceleration Zone,
which is beyond the Inverter, accelerates the paper to expedite its arrival at the Registration
Nip.
The transport belt receives the sheets from the Acceleration Nip and delivers them to the
Retiming Nip.
TEER Sensor
Transport Belt
Acceleration Zone
Retiming Nip
Duplex Top Edge Electronic Registration System

A Duplex Top Edge Electronic Registration (TEER) system has been developed which uses an
optical sensor in the Duplex Transport to detect the exact top edge position of a sheet when it
stops at the Retiming Nip. The TEER software then modifies the ROS Start Of Scan timing in
order to shift the image on the photoreceptor to match the position of the sheet.
The TEER sensor is physically located near the Retiming Nip in the top left-hand side of the
Duplex Transport. The sensor consists of an array of LEDs, an array of photo sensors, and two
PWBs containing various control and processing circuits.
As a sheet moves through the Duplex Transport, it stops briefly at the Retiming Nip. When this
occurs, two LEDs in the sensor (first one, and then another) are lit at two predetermined locations on the LED array. (The specific LED locations are determined by the paper size.) Sensors
detect the shadow cast by the edge of the paper. The exact paper edge location is then determined by splitting the difference between the two sensor measurements.
The Retiming Nip then feeds the sheet toward Registration at the required time, depending on
the particular job. The feeding of the sheet is synchronized with images on the Photoreceptor
by the Top Edge Electronic Registration Sensor.
Acceleration Nip
Figure 6 Duplex paper path

Diagnostics and troubleshooting: Duplex Transport
Diag.Nav.\Copier Sys\Component Control\IOT Paper Path\Outputs
Duplex Decurler:.....
Duplex Wait Clutch......
May 2003
10-104
V0.042
Exit Decurler
The Exit Decurler (or TAG 279 Decurler) subsystem transports media from the Inverter exit nip
to the IOT exit. Its primary function is to apply a mechanical bending in the process direction
opposite to the curl direction of an incoming sheet. The direction and degree of bending can
be either, automatically selected and adjusted based on several variables, which are monitored
by machine software, or manually controlled.
As shown in Table 2 , the number of Decurler Position Sensor transitions sets cam position
after the Home sensor is actuated. The result is an amount of decurler nip roll penetration in
the upper or lower decurler paper path as shown.
Decurler operation is selectable through SA tools. In tools select [System settings], [More],
then select [Decurler Settings]. The decurler feature screen has three UI soft buttons to select
operation as follows:
Auto Decurler Enabled - Select Auto Decurler Enabled to allow the machine to automatically minimize curl on output copies. This is the default selection.
Auto Decurler Disabled - Make the Disabled selection to turn the machines decurling
capability off.
Max Decurler Enabled - Select Maximum to allow the machine to maximize the output
copy decurling capability.
NOTE: The amount of decurling performed when Max Decurler Enabled is selected can
be adjusted by the CSE via NVM.
The Document Centre 480 and 490 machines contain an Environmental Sensor (E-Sensor) to
monitor the amount of water present in the air which, when enabled allows all selections
above. If the E-Sensor is not enabled, automatic decurler settings are disabled.
The mechanism uses a solenoid-actuated gate to direct sheets into an upper or lower paper
path to apply the correct direction of post process bending. A five-position cam creates a nip
between a foam roll and the drive rolls with a precise penetration level thus creating the necessary reverse bending as the sheets pass through. Regardless of which paper path is selected,
the five cam settings correspond to a "Home" position where both upper and lower nips remain
open, a low penetration position for each nip and a high penetration position for each nip. A
+24 VDC motor (Decurler Cam Drive Motor), pulsing on and off in 7 msec intervals in one
direction only drives the cam. All cam position changes are initiated during the sheet's inter
document gap. The decurler nips are driven at constant speed by the Decurler Drive Belt.
This belt is driven by a gear on Main Drive Motor 2 and transfers drive to the Decurler Drive
Shaft on the IOT frame.
If the number of inversions is 1 the Decurler Gate Solenoid will be On and the sheets
will be directed to the lower paper path of the Decurler.
NOTE: The Low settings at cam position 2 and 4 are used when the High penetration is
required in the opposing path. Cam positions 2 or 4 are not used to achieve Low settings
because they consume more electrical power.
Table 2 Decurler Nip Roll Operation
Amount of
Upper Path Nip
Penetration
Amount of
Lower Path Nip
Penetration
Cam Position
Home Sensor
Position
Sensor
Home
Actuated
Actuated
Open
Open
De-actuated
Actuated + 1
transition
Medium
Low
De-actuated
Actuated + 2
transitions
High
Low
De-actuated
Actuated + 3
transitions
Low
Medium
De-actuated
Actuated +4
transitions
Low
High
Table 3 is used when the [Auto Decurler Enabled] button is selected on the UI. It shows the
four variables (Simplex/Duplex, Grains of Water, LEF/SEF, and # of inversions) that determine
the cam position required to achieve the appropriate Decurler nip setting automatically. If
"grains of water" input is not received, the Decurler defaults to "Manual OFF".
Figure 7 shows the Decurler and its major components.

A 10-706 fault will be declared if:
The machine software does not sense the expected sensor transitions from the Decurler
Home Sensor and the Decurler Position Sensor within 1000 msec of sending a move
command.
The value in NVM, [Mark Service] location 529, Exit Decurler Config Type is not set to 2
A 10-357 or a 10-358 Decurler Configuration Mismatch fault will be declared if the value in
NVM, [Mark Service] location 529, Exit Decurler Config Type is not set to 2 when an Exit
The operation of the Decurler Gate Solenoid is determined by the number of times a sheet has
been inverted.
If the number of inversions is 0 or 2, the Decurler Gate Solenoid will be Off and the
sheets will be directed to the upper paper path of the Decurler.
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May 2003
10-105
Table 3 Automatic Decurler Variables (used when Auto Decurler Enabled is selected)
Copy
Mode
Sheet
Orientation
Rel Humidity
(grains of water)
Number of
Inversions
Decurler Cam
Position - Disk Decurler Cam
Finisher
Position - MFF
Nip
Penetration
Level
Simplex
LEF
Less than 40
Low
Less than 40
Low
40 to 80
Med
Simplex
Duplex
Duplex
SEF
LEF
SEF
40 to 80
Med
Greater than 80
High
Greater than 80
High
Less than 60
Low
Less than 60
Low
60 to 100
Med
60 to 100
Med
Greater than 100
High
Greater than 100
High
N/A
Low
N/A
Low
N/A
Low
N/A
Low
Table 4 is used when the [Auto Decurler Disabled] or the [Max Decurler Enabled] button is
selected on the User Interface. It shows the Decurler Cam position and the Decurler Nip penetration levels achieved in the manual mode
May 2003
10-106
V0.042
Table 4 Manual Decurler Variables (used when Max Decurler Enabled is selected)
Copy
Mode
Simplex
Duplex
Decurler Control
Setting
Decurler
Number of Cam
Inversions Position
NVM value for

Maximum
(see note below)
Nip
Penetration
Level
Nip
Penetration
Amount
Auto Decurler Disabled 0
N/A
Low
0.2 mm
N/A
Low
0.2 mm
Max Decurler Enabled
Low
0.2 mm
Med
0.5 mm
High
0.8 mm
Low
0.2 mm
Med
0.5 mm
High
0.8 mm
N/A
Low
0.2 mm
N/A
Low
0.2 mm
Low
0.2 mm
Med
0.5 mm
High
0.8 mm
Low
0.2 mm
Med
0.5 mm
High
0.8 mm
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May 2003
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NOTE: To adjust the Decurler nip penetration when Maximum decurling is selected on the UI,
in NVM Tool, select [Mark Service]. To adjust the amount of nip penetration for Simplex mode,
modify the value in location 1164. To adjust the amount of nip penetration for Duplex mode,
modify the value in location 1165.
Decurler
Home
Sensor
Decurler
Position
Sensor
Decurler
Cam
Drive Belt
Decurler
Gate
Solenoid
Decurler Cam Drive
Motor
(not Shown)
May 2003
10-108
V0.042
NOHAD
Fuser Fan Filter
Overview
The Noise, Ozone, Heat, and Dirt (NOHAD) system consists of:
Xerographic Blower Assembly and Dirt Filter
Fuser Fan Duct Assembly
ROS/Developer NOHAD Duct Assembly
NOHAD Thermostat
Fuser Fan Duct Assembly

The Fuser Fan Duct provides the means to remove heat and wastes from around the Fuser
area, including ozone, exhausted from the Xerographic Blower. It includes a 120mm Fuser
Fan and a duct. Located in the duct, is a Fuser Fan Filter (Figure 1) composed of a Fuser Dirt
Filter and an Ozone Filter.
The Fuser Dirt Filter PL 9.1 Item 12, is now spared separately to enable replacing the filter
without ordering the entire NOHAD Filter Kit.
Fuser Drive Motor
Figure 1 Fuser Fan Filter

The Fan is 24VDC. It is duty-cycle controlled, depending on the machine state. The Fan automatically deenergizes when the Fuser Module or Xerographic Module is removed.
Xerographic Blower and Dirt Filter

The purpose of the Xerographic Blower (Figure 2) is to draw air, dirt and wastes into the Xerographic Dirt Filter. The filter is located in a duct in the Xerographic Module and is therefore
replaced whenever the Xerographic Module is replaced.
The Blower is +24 VDC. It is mounted to the back plate of the Frame and discharges along the
inside of that plate toward the Fuser Fan. As a safety precaution, when the Xerographic Module is removed, the Xerographic Blower is deenergized.
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NOHAD
ROS/Developer Cooling Fan

The ROS/Developer Cooling Fan Assembly (DC 265 only) consists of a 120mm Fan and the
ROS/Developer Filter.
The ROS/Developer Cooling Fan is 24V, 0.31A, and is duty-cycle controlled, depending upon
machine state. It removes heated air and dirt from around the Developer Housing and the
ROS.
Replacement of the NOHAD Filter Kit, which contains the Scanner Dust Filter, the Fuser Fan
Filter, and the ROS/Developer Filter is required every 2 million impressions. The Xerographic
Dirt Filter is changed automatically with the Xerographic Module.
NOHAD Thermostat
Xerographic Blower
Figure 2 Xerographic Blower
NOHAD
The NOHAD Thermostat is a normally closed temperature sensitive reed switch on 5VDC. It is
read at regular intervals in Standby, Power Save #1, and Run modes. When a consecutive
number of positive readings are detected, a high temperature fault occurs. The number of
faults are counted and recorded in fault registers. When 255 faults are recorded, the counting
stops and service is required.
When component control is first entered, all the Fans are deenergized except the PWB Cooling
Fan and the LVPS Cooling Fan. These fans not affected by component control. The other
Fans are energized to full speed operation when a code is entered. All Fans and the Blower go
to the appropriate duty cycle when the component control is exited.
May 2003
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Finishing
20 sets for sets containing 26 to 50 sheets
This tray can only handle paper that is 8 inches or more in the cross-process direction.
This tray has an optional offset function.
Overview
Finishing is accomplished by either the Offsetting Catch Tray, or an attached Finisher device.
These are discussed in more detail in the following paragraphs.
Finisher Top Tray - The Finisher Top Tray has a 250-sheet capacity. In addition to being
used as another output destination, this tray can be used as a sample, purge, or FAX output. Sheets enter the tray with the bound edge trailing, with the possible exception of
purged sheets. This tray can handle all paper sizes and is the only output location for
paper sizes smaller than 8 inches in the cross-process direction. This tray has an optional
offset function.
Offsetting Catch Tray (OCT)

The Offsetting Catch Tray (OCT) (Figure 1) will support printer operation at both 40 and 65
ppm and stack up to 250 sheets of 75gsm paper. It will accommodate paper sizes from A6
(SEF) to 12" x 18" in the weight range of 56 gsm to 203 gsm. Output is stacked face down in
the tray and alternate sets may be offset from one another by 30 mm to provide set separation.
Finisher Top Paper Path
Offsetting
Catch Tray
Top Tray
Paper Path
from IOT
Disk
Stacker Tray
Finisher Main Paper Path
IOT
Figure 2 IOT Exit and Finisher Paper Paths

There are two staplers (one fixed, one moving) that accommodate sets of from 2 to 50 sheets
of paper to be stapled, depending on the weight of the paper. The operator determines one of
three staple options:
Figure 1 IOT with Offsetting Catch Tray (OCT)

Finisher
The Finisher stacks and staples copies. It can operate at two speeds, either 40ppm or 65ppm.
It handles paper sizes from A6 through 12x18 and paper weights of 56gsm to 203 gsm. Sheets
enter the tray with the bound edge leading.
no staple
single staple
dual staple
The Finisher has two output trays; the Stacker Tray and the Finisher Top Tray (Figure 2).
Stacker Tray - This tray is the main output tray and has an 2000-sheet (unstapled) capacity. Stapled-set capacities are as follows:
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Finishing
Finisher Operation
The height of the elevator is controlled by the position of the bale, which rests on the stack during part of the disk rotation cycle. If the stack is too high a sensor becomes blocked and a signal is sent to the elevator motor to drive down. The elevator drives down until the sensor is
clear and then stops. There is no elevator height adjustment while sets are being compiled,
stapled or ejected. An elevator upper and lower limit switch stops the elevator in the event the
tray is driven too high or too low. A tray full sensor indicates when the elevator tray is filled to
maximum capacity.
Paper Transport
The Paper Transport Assembly receives paper from the IOT exit and transports them to an output tray. The main paper path is a straight-through path that consists of two drive nips. There is
a lower baffle that guides paper through this path. On the basic Disk Finisher there is also an
upper baffle that guides the paper. The High Capacity Disk Finisher does not have this upper
baffle on the main paper path.
The High Capacity Disk Finisher has a second paper path with a solenoid-operated gate. The
gate is normally open allowing paper to travel the straight path to the disks. When the gate
closes the paper travels to the top path. An upper and lower paper baffle guide the paper
through this path. The Q12 Sensor for the top paper path is in the lower baffle.
The Finisher paper transport is powered by the Transport Drive Motor, a +24 VDC stepper
motor. Power is distributed to all of the drive nips by pulleys, drive belts and gears.
The paper transport operates at two distinct speeds:
302.3mm/sec for the 265 DC/LP
186mm/sec for the 240 DC/LP
The Paper Transport subsystem receives sheets from the IOT exit and transports these sheets
to an output tray.
Finisher paper path sensors
The debounce strategy for the Finisher Entrance Sensor or the Top Tray Paper Path Sensor is
as follows: from a LE there is a lockout equal to {(PW-15mm)/velocity}ms before looking for a
TE & from a TE there is a lockout equal to 50ms before looking for the next LE.
Finishing
May 2003
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V0.042
Finisher Power and Interlocks
Power to the Moving Stapler is not available if the Moving Stapler Safety Gate (Figure 4)
is not in position. When the Safety Gate is in the down position, the gate actuates the
Moving Stapler Interlock Switch providing power to the Moving Stapler Motor.
Power to the Finisher is affected by the state of the following interlock switches (Figure 3).
Fixed Stapler Interlock Switch
Power to the Finisher is removed whenever this interlock is not actuated. Safety during
jam clearance is the main reason for this switch. All Finisher inputs and outputs are turned
off. All Finisher functions are delayed by 100 ms after the Finisher Interlock Switch is
actuated.
Power to the Fixed Stapler is not available if the Fixed Stapler Safety Gate (Figure 4) is
not in position. When the Safety Gate is in the down position, the gate actuates the Fixed
Stapler Interlock Switch, providing power to the Fixed Stapler Motor.

Power to move the Stacker Tray downward is removed whenever the lower limit switch is
actuated. This prevents damage to the Stacker Tray drives should the Stacker Tray Full
Sensor fail.
Power to move the Stacker Tray upward is removed, and the Disk Motor is turned off
whenever the Stacker Tray Upper Limit Switch is actuated. The Disk Shaft floats in its
bearings and is lifted off the switch actuator if something is pinched between the top of the
stack or the Stacker Tray surface and one of the Disks.
Finisher
Interlock
Switch
(Hidden)
Moving Stapler
Safety Gate
Fixed Stapler
Safety Gate
Stacker Tray
Upper Limit
Switch
Figure 4 Stapler Safety Gates

Stapler Access Door Interlock Switch
Power to the Finisher, except for top tray functions, is removed if this interlock switch is
not actuated,. This signifies the Stapler Access Door is not closed. To protect the operator, the staplers and the Stacker Tray Drive Motor cannot function
Stacker Tray
Lower Limit
Switch
Figure 3 Finisher Interlock Switches

Moving Stapler Interlock Switch
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May 2003
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Finishing
The main paper path (Figure 6) is a straight through path. It consists of the Nip 1 Drive Rolls
and idlers, and the Nip 2 Drive Rolls and idlers. The nips are formed by 20 mm diameter elastomeric rolls and 20 mm diameter plastic idlers supported by leaf springs. The Nip 1 Drive Roll
and idlers are located 63 mm from the IOT frame and 51.5 mm from the outer finisher frame.
The Nip 2 Drive Rolls and idlers are located 72.7 mm downstream and are adjacent to the
Disks. A lower baffle guides paper through this path. The baffle also supports and locates the
Finisher Entrance Sensor. The sensor actuation point is located at 12.1 mm from Nip 1 for LE
actuation and is located at 27.6 mm from Nip 1 for TE actuation
The Main Paper Path drives consists of the following components (Figure 5):
The Transport Drive Motor
The Nip 1 / 2 Drive Belt (2-sided belt)
The Nip 1 / 2 Idler (spring tensioned)
The Nip 1 Drive Shaft and Nip 1 Drive Rolls
The Finisher Entrance Sensor (Figure 6)
The Disk Drive Motor and the Disk Drive Gear
The Disk Home Sensor
The Disk Shaft (not shown)

Nip 1
Nip 2 Drive Shaft
Nip 2
Disk Fingers
Nip 1 / 2 Idler
Paper Path
from IOT
Disk
Nip 1 / 2 Drive Belt

Finisher Entrance
Sensor
Nip 1 Drive Shaft
Disk Drive Motor

(Inside Frame)
Disk Drive Gear
Stacker Tray
Disk Home
Sensor
Figure 6 Finisher Main Paper Path
Figure 5 Finisher Main Paper Path Components
Finishing
May 2003
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V0.042
Finisher Top Paper Path

The Finisher Top Paper Path drives consists of the following components (Figure 7):
The Transport Drive Motor
The Nip 1 / 2 Drive Belt (2-sided belt)
The Nip 3 / 4 Drive Belt
The Finisher Diverter Gate and the Finisher Diverter Gate Solenoid (Figure 8)
The Top Tray Paper Path Sensor (Figure 8)
The Finisher has a second paper path (Figure 8). This path has a solenoid operated Diverter
Gate. The gate is normally open allowing paper to travel the main paper path to the Disks. The
gate closes to allow paper to travel to the top path. The Finisher Diverter Gate Solenoid is
energized when the first sheet of the job sent to the top tray is 44mm before the gate or 44mm
after the IOT frame. It is turned off when the LE of the first sheet of the next main paper path
job is 44mm before the gate or 44mm after the IOT frame or when the last sheet of the last set
is at the Top Tray Paper Path Sensor. The top paper path also has two drive nips; Nip 3 and
Nip 4. Nip 3 is 122.7 mm downstream from Nip 1 and 97.7 mm from the Finisher Diverter Gate.
The nip configuration is the same as Nip 1. Nip 4 is 113 mm further downstream and is the exit
nip for the Finisher Top Tray. The exit nip is a corrugating nip. It consists of a 20 mm diameter
elastomeric roll with corrugating ridges. Common plastic idlers of 20 mm diameter are also
used. This top paper path has an upper paper baffle to guide the paper. This baffle pivots for
jam clearance access. A lower baffle also helps guide the paper through this path. Top Tray
Paper Path Sensor, is located in the lower baffle. The paper transport is powered by The
Transport Drive Motor. Pulleys and drive belts are used to distribute power to all of the nips. A
two sided belt is used to ensure that the nip adjacent to the disk rotates in the correct direction.
Nip 3 / 4 Idler
Nip 4 Drive Shaft
Top Tray Paper

Path Sensor
Nip 4
Top Tray
Full Sensor
Nip 3 Drive Shaft

Nip 3
Top Tray
Nip 1 / 2 Idler
Paper Path
from IOT
Nip 2 Drive Shaft

Nip 1 Drive Shaft
Nip 1
Diverter Gate

(Inside Frame)
Figure 8 Finisher Top Paper Path

Figure 7 Finisher Top Paper Path Components
Paper Path Drive

The Transport Drive Motor is turned on when the previous drive (post fuser motor) is turned on.
It is turned off when the drive is turned off and/or paper in the Finisher paper path clears the
Finisher Entrance Sensor or the Top Tray Paper Path Sensor.
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May 2003
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Finishing
Disk Loading and Disk Drives

The Disk Loading and Drive Assembly consists of two disks, which provide drive friction to the
paper during inversion and registration, and side shift friction during tamping, the Disk Drive
Shaft and Home Flats, which place disks in the home position, the Disk Drive Motor, which provides the power, gears which transmit motor power to the disk shaft, and the Disk Home Sensor, which detects when disks are in the home position.
Disk Drive Shaft
The Disk Drive Motor operates at two speeds.
For 65ppm:302.3mm/sec
For 40ppm:186mm/sec
Disk Drive Motor
It operates whenever the Finisher is initialized at start-up. The Motor moves the disks into
home position for the start of a print cycle. It also initializes when the copier is deenergized to
clear any sheet in the disk fingers and to allow easier jam clearance.
Disk Drive Gear
Once a print cycle has been initiated, paper enters the stationary disks and is driven to the end
of the disk finger slot.
Disk Home
Sensor
The disks receive pages from the paper transport and invert them during delivery to the lead
edge registration position. Support is provided by the disks to these pages during the tamping
operation. Motion of the bale bars is controlled via pins in the rotating disks and a cam profile in
the bale bar arm
The Disk mechanism consists of the following (Figure 9):
Two (2) Disks (not shown) which provide drive friction to the paper during inversion and
registration, and side shift friction during tamping. The disks have two fingers 180 degrees
apart.
Disk Drive Shaft and home flags which positions disks in the home position. There are
two home positions 180 degrees apart. The home position is 15.7mm of disk travel from
actuation of the Disk Home Sensor.
Disk Drive Motor which provides power.
Disk Drive Gear which transmits motor power to the disk shaft
The Disk Home Sensor which detects when disks are in the home position
Figure 9 Disk Finisher Components

Motor to Disk speed ratio is 4:1. The Disk diameter is 125mm. This corresponds to a disk surface displacement to motor step ratio of 0.49mm/step
The Disk Drive Motor is turned ON whenever the Finisher is Initialized at Power Up and moves
the disks to the home position for the start of a print cycle. The disk should also be initialized at
paper path shut downs to clear any sheet in the Disk Fingers and to allow easier jam clearance.
Once a print cycle has been initiated, paper enters the stationary disks and is driven to the end
of the disk finger slot. The disk will be driven through a specific timing profile based on the
sheet size and the process speed.
Timing profile for 65 ppm and sheets less than 229mm
When the LE of the sheet is at the Finisher Entrance Sensor plus 629ms, the Disk Motor turns
on. It accelerates to process speed (302.3mm/s) within 25ms (6.1mm). It continues at process
speed for 346ms (104.7mm) until the sheet reaches the registration edge. At this point, the
Disk Motor stays at the process speed for 99ms (30mm). It then must accelerate and return to
the Disk home position within 118ms, which is a disk travel distance of 55.4mm. This return to
home profile must travel the first 16mm within 32ms to get past the collision point of the sheet
and the disk finger and then travel the remaining 39.4mm and stop within 86ms. The Disk
Motor stays off until the next LE at the Finisher Entrance Sensor plus 629ms.
Finishing
May 2003
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V0.042
Timing profile for 65 ppm and sheet greater than or equal to 229mm
on. It accelerates to (186.0mm/s) within 5ms (1mm). It continues at 186.0mm/s for 590ms
(109.8mm) until the sheet reaches the registration edge and then continues for an additional
15mm and then stops. It turns on again at TE at Finisher Entrance Sensor plus 399ms for
sheets greater than 320mm. It must then accelerate and travel 71.8mm in 170ms max. and
stop at home. The Disk Motor stays off until the next LE at the Finisher Entrance Sensor plus
629ms. For greater than or equal to 229 sheets, less than or equal to 320mm, after the disk
stops. It turns on again when the LE is at the Finisher Entrance Sensor plus 1280 +240ms.
Timing profile for 40 ppm and sheet less than 229mm
on. It accelerates to process speed (186mm/s) within 5ms (1mm). It continues at process
speed for 590ms (109.8mm) until the sheet reaches the registration edge. At this point, the
disk motor stays at process speed for 161ms (30mm). It then must accelerate and return to the
disk home position within 250ms, which is a disk travel distance of 55.4mm. This return to
home profile must travel the first 16mm within 110ms to get past the collision point of the sheet
and the disk finger and then travel the remaining 39.4mm and stop within 140ms. The motor
stays off until the LE of the next sheet is at the Finisher Entrance Sensor plus 1031ms.
Timing profile for 40 ppm and sheets greater than or equal to 229mm
on. It accelerates to process speed (186mm/s) within 5ms (1mm). It continues at process
speed for 300ms and then stops within 10ms, to create a 25mm buckle in the sheet, which
takes 135ms. It then accelerates to process speed within 5ms (1mm) and continues for 285ms
until the sheet reaches the registration edge and then continues at process speed for 40ms
and then stops within 10ms. It turns on again at TE at the Finisher Entrance Sensor plus
515ms for sheets greater than 272mm. It must then accelerate and travel 71.8mm in 170ms
max and stop at home. The motor stays off until the LE of the next sheet is at the Finisher
Entrance Sensor plus 1031ms. For 229 greater than or equal to sheets less than or equal to
272mm, after the disk stops, it turns on again at LE at Finisher Entrance Sensor plus 1820 +
240ms.
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Finishing
Tamping
Overview
The Tamper mechanism aligns the copies for stapling. This mechanism is attached to the moving stapler frame. It consists of the Tamper Arm which contacts the edge of the paper, the
Tamper Motor, which is a stepper motor that provides power and motion to the Tamper Arm,
and the Tamper Home Sensor, which detects when the Tamper Arm is in the home position.
The Tamper Motor drives the Tamper Assembly to the home position prior to the start of a print
cycle. Home position of the Tamper is when the Tamper Home Sensor is blocked. The Tamper
is then moved to a second home position for each stapled set.
The Tamper mechanism translates sheets in the cross process direction to achieve side edge
registration for stapling and stacking. It works in conjunction with a retractable side registration
edge. This mechanism is attached to the moving stapler frame. It will be discussed later. For
single stapling and stacking, the tamping distance is 25mm. For dual stapling, the tamp distance varies with paper size and is based on the second staple position. The second staple
head is fixed
The Tamper mechanism consists of the following (Figure 10):
The Tamper is moved to a second home position for each stacked or stapled set. This position
is equal to paper edge location based on paper width minus 11mm. The Tamper is moved
350ms after the first sheet of the set reaches Finisher Entrance Sensor.
Home position is defined by the position of the Tamper face and is located 166.4mm from the
nominal center line of the paper path. Second home position for 12 or 304.8mm wide paper is
3mm away from home.
NOTE: In the following formulas, Q1 = Finisher Entrance Sensor.
The second home position can be calculated as:
DSecondHome=((304.8-PaperWidth) divided by 2 + 3) + NVM (tol. adjustment) for all
other sizes. If a second home position is calculated to be less than -3mm, then the move
should be limited to -3mm. This is the mechanical limits of the hardware
The maximum time to move between the furthest homes (53.8mm) is 280ms. The motor step
to linear displacement ratio is 200 steps=56.54mm or 0.2827 mm/step.
Also the maximum allowable homing time is 800ms.
Tamper Start Timing and Duration
Tamper Arm which contacts the edge of the page
Tamper Motor which is a stepper motor provides power and motion to the Tamper Arm
Tamper Home Sensor which detects when the Tamper Arm is in the home position
The Tamper has been moved to its second home position. The Tamper Motor is turned on for
each sheet of the set just before it reaches the registration edge.
For sheets less than 229mm in process direction: The on time is at LE at Q1 plus t5 -15ms 40ms with t5=(((x2+(128.2)+(110.8-6.1))/0.3023) +5ms+25ms) for 65ppm or LE at Q1 plus
945ms and at LE at Q1 + t5=(((x2+(128.2)+(110.8-1.0))/0.1860) +16ms+5ms) for 40ppm or LE
at Q1 +1626ms.
Tamper Motor
For 229mm less than or equal to sheet less than or equal to 320mm (65ppm): The on time is at
LE at Q1 plus 1280ms.
For 229mm less than or equal to sheet less than or equal to 272mm (40ppm): The on time is at
LE at Q1 + 1820ms.
For sheets greater than 320mm in process direction (65ppm): The on time is at TE at Q1+t4
with t4=(x2+6)/vel or TE at Q1+169ms.
Tamper
Arm
Tamper
Arm
Sensor
Figure 10 Tamper Mechanism Components

Tamper Home positioning
The Tamper Drive Motor is turned ON whenever the Finisher is initialized and moves the
Tamper to the home position prior to the start of a print cycle. Home position of the Tamper is
when the Tamper Home Sensor is blocked plus 0.85mm (3 steps)
Finishing
For sheets greater than 272mm (40ppm): The on time is at TE at Q1 + 275ms.

The relationship for tamp duration is: For sheets greater than 229mm-120ms (+0-10) Sheets
greater than or equal to 229mm-The tamp duration time varies with tamp distance. The Tamper
always moves 25mm in 120ms. The tamper velocity profile is trapezoidal. It accelerates to a
max velocity and then decelerates to a stop in 120ms. The time increase is proportional to the
increase in tamp distance beyond 25mm. The maximum tamp time is 240ms.
Tamping in Single Staple Mode
In single-staple mode, the Tamper is in the second home position. The Tamper Motor is energized for each sheet of the set just before it reaches the registration edge.The Tamper travels
from the second home position to the registration point, then returns to the second home position to await the next sheet. The distance to tamp from the second home position for single staple mode is always equal to 22mm.
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The Tamper travels 25mm from the second home position to the registration point. It then
returns to the second home, until the next sheets arrival.The distance for tamping from the
second home position is given by the equation: DSingle = 25 mm
Tamping in Dual Staple Mode
In the dual staple mode, the Tamper is in the second home position. The Tamper Motor is energized for each sheet of the set at the same times as in the single staple mode. The tamper
function in this mode is to register sheets at the fixed stapler position. The distance to tamp
from the second home position for dual staple mode is equal to the distance of the stapler position to the second home position minus one fourth of the paper width.
After the Tamper has been moved to its second home position, the Tamper Motor is turned on
for each sheet of the set at the same times as in the single staple mode. The difference is the
tamper stroke.
The tamper function in this mode is to register sheets at the fixed stapler position. The centerline of the fixed stapler position is 132.9mm from the tamper home position. The staple position
for dual stapling is given as the PaperWidth/4 from the paper edges. The tamper stroke for any
paper size can be calculated.
The distance for tamping from the second home position is given by the equation: DDual =
((132.9 - (DSecondHome-NVM)) - 1/4PW)for all paper sizes except >279.4mm.
Simply stated the distance to tamp from second home for dual staple position is equal to the
distance of the stapler position to the second home minus one fourth of the paper width. The
maximum tamping distance is 47.4mm.
The maximum tamper position away from tamper home is about 82mm, and the furthest forward retractable side reg edge registration position is the position for dual staple registration of
11 or 279.4mm paper. To enable handling dual staple registration for paper sizes >279.4mm,
the retractable side reg edge is set at the 279.4mm position. This position is used when tamping sheets >279.4mm.
Therefore tamping for paper sizes >279.4mm varies by the following. TAMPING FOR DUAL
STAPLING MODE FOR SHEETS - 279.4mm<PW<=304.8mm: DDual* = [((342.45- (DSecondHome-NVM)) - PW)]mm.
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Finishing
Stapling
Stapler
Staple Positioning
Cassette-style Staplers are provided in the machine. This type stapler holds 5000 pre-cut staples in each cassette. The staples are driven up through the sets and clinched on the top of the
stack. The staple cartridges are identical whether used in the finisher or the Convenience Stapler.
There are two staplers in the Finisher (Figure 11): the Moving Stapler and the Fixed Stapler.
The Moving Stapler must be adjusted for positioning and registration. The Fixed Stapler is stationary and requires no positioning or registration adjustment.
Two Staple Motors provide the power to open and close the stapler jaws which drive, form, and
clinch the staples. The Moving Stapler Home Sensor and Fixed Stapler Home Sensor ensure
that the stapler has completed a stapling cycle and is ready to accept more copies. Two Staple
Present Sensors detect either that the cassette is low on staples, or if the cassette is present in
the machine.
Moving Stapler
The Single Staple cycle is initiated after the last sheet has travelled through the disks and the
disk mechanism is in the home position. The Staple Motor is deenergized when the Moving
Staple Home Sensor is blocked, indicating that the cycle is complete.
The Dual Staple cycle is initiated after the last sheet has travelled through the disks and the
disk is in the home position. The cycle is enabled when the Safety Switch is activated, indicating the safety gate for the Fixed Stapler is in place. The Stapler Motor is deenergized when the
Fixed Stapler Home Sensor is blocked, indicating the cycle is complete.
Both staplers are equipped with safety gates (Figure 12) to protect the customer from injury.
Fixed Stapler
Moving Stapler
Home Sensor
Figure 11 Stapler Locations

The Moving Stapler mechanism consists of the following:
Stepper Motor, which provides power to the stapler
Gear Train
Rack and Slide Mechanism
Stapler Home Sensor
Moving Stapler
Safety Gate
Fixed Stapler
Safety Gate
The Stapler Mechanism goes to home position when the machine is energized. Home position
is at the single staple position for a 12-inch sheet. The stapler moves to the correct staple position based on the paper size and stapling mode.
Figure 12 Stapler Safety Gates

Finishing
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Registration Edge
The Registration Edge mechanism provides a lead edge registration position for compiling sets
as well as ejecting sets. It consists of a Registration Edge (Figure 14), which establishes the
lead registration edge for incoming sheets, and the Registration Edge Solenoid (Figure 13),
which drives the Registration Edge between the compile position and the eject position.
Retractable Registration
Edge Solenoid
Retractable
Registration
Edge
Figure 14 Retractable Registration Edge Location
Figure 13 Retractable Registration Edge Solenoid Location
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Finishing
Set Ejection
Completed single-sheets, stapled and unstapled sets are ejected into the Stacker Tray by the
Kicker.
The Kicker consists of the following (Figure 15):
Kicker, which is parked behind the lead registration edge for incoming sheets and moves
(kicks) the sheets or sets into the Stacker Tray.
Kicker Motor, drives the Kicker between the compile position and the eject position.
Kicker Home Sensor, detects when the Kicker is in the home position.
Kicker Home Sensor
Kicker Drive
Motor
Kicker
Figure 15 Kicker Components

At the power up, the Kicker is initialized and moves to the compile position. The Kicker Motor
is energized until the Kicker Home Sensor goes from unblocked to blocked, at which time the
motor is turned off immediately.
For the stack mode, the eject cycle is started after the last sheet of a set has been delivered to
the compiler and 270ms after the Disk Shaft has returned to the home position. For single staple and dual stapled sets, the eject cycle starts 320 ms after the Moving Stapler cycle began.
The Kicker pushes the set into the Stacker Tray in a maximum of 230 ms from when the Kicker
Motor is turned on. The Kicker Motor continues to run until the Eject Home Sensor becomes
blocked.
To maintain set integrity in the Stacker Tray, the Kicker does not move to the eject position in
less than 160 ms.
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Stacker Tray Drives and Stack Height Sensing

The height of the Stacker Tray is controlled by the Stack Too High and Stack Height Sensors,
the Stacker Tray Drive Motor, and the Stacker Tray Full Sensor. Component locations are
shown in Figure 16, Figure 17, and Figure 18. Stack Too High and Stack Height Sensor operation is shown in Figure 19.
Stacker Tray
Drive Motor

Stack Height Sensor
Figure 16 Stack Height Sensors
Figure 17 Stacker Tray Drive Motor
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Finishing
Stacker Tray
Full Sensor
Figure 18 Stacker Tray Sensors
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Stack Height Sensing Operation

Upon initialization, the tray drives check the appropriate sensors to ensure that the stacker tray
is in the correct position to accept sheets. (Figure 19)

Flag
Table 1 shows the possible conditions and appropriate actions when the sensors are checked.
Table 1 Stack Height Tray Sensor Conditions
Tray Full
Sensor
Stack Too
High Sensor
Stack Height
Sensor
Blocked
Blocked
Stack Height
Sensor
Status
Action
Blocked
Tray Too
High
Energize Stacker Tray Drive Motor

until the Stack Too High Sensor is
unblocked
Unblocked
Blocked
Correct
None
Stack Height
Unblocked
Unblocked
Tray Too
Low
Blocked
Tray Full
Rear Bale Arm
Finished Copies
Energize Stacker Tray Drive Motor

until the Stack Height Sensor and
Stack Too High Sensor are
blocked. Stop, then deenergize
the Stacker Tray Drive Motor until
the Stack Too High Sensor is
unblocked.
Pivot Point
Stacker Tray
Send Tray Full Status. Do not

accept any jobs to the Main Tray
Upon entering Standby, the sensors are checked to ensure the tray is at the correct position for
accepting sheets for stapled or unstapled sets. (The Flag blocks the Stack Height Sensor and
the Stack Too High Sensor and the Tray Full Sensor are unblocked.)
The machine goes to run mode. In the stapled sets mode, 2 to 50 sheets are compiled in the
stapler throat. The Stack Too High Sensor and Stack Height Sensor are checked to determine
if the stacker tray should be driven down. If both sensors are blocked by the Flag, the Stacker
Tray Drive Motor energizes and lowers the tray, causing the Rear Bale Arm to pivot until the
Stack Too High Sensor is unblocked. This cycle must be completed before another copy
comes through.
Figure 19 Stack Too High and Stack Height Sensor Operation
Document Centre 460/470 Smart Tray Finisher

The following are improvements in the Document Centre Smart Tray Finisher.
A Top Tray capacity of 250 sheets (200 sheets for 5.5 in x 8.5 in (A5) paper).
A Main (Stacker) Tray capacity of 100 thin stapled sets.
Increased number of stapling options.
Portrait Staple Mode 8.5 x 14 in (SEF)
Dual Staple Mode B4 (SEF)
The unstapled sets mode operates the same way except that when there is more than 25 copies in the stacked sets, they are compiled and ejected onto the stack in segments.
Dual Staple Mode 8.5 in x 14 in (SEF)
Dual Staple Mode 9 in x 11 in (SEF)
When the Tray Full Sensor and the blocked Stack Height Sensor determine that the tray is
almost full, the copier delivers all sets that are currently in progress. At this point there is room
for 56 more sheets in the tray. Up to that many sheets will be output to the Finisher if not in stapler mode.
Dual Staple Mode A4 (SEF)
Dual Staple Mode 8 in x 10 in (LEF)
Dual Staple Mode B5 (LEF)
Dual Staple Mode A5 (LEF)
In stapler mode, any small sets, up to 50 sheets, are printed and stapled, but no additional sets
are directed to the Finisher.
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Service Tray Improvements.
Capstan Driven Tamper - reduced noise
Redesigned Set Separator

Finishing
Collapsible Kicker - allows staple positioning for landscape dual staple
Finisher Transport Baffle Improvements.
For 8.5 x 11" SEF and 8.5 x 14" Portrait Staple Mode, all 4 offsetting positions are used (Refer
to Figure 21):
Nip1/Nip 3 Idler cover
The tray moves from Position A or Position B to Position D to compile the first set.
Magnets replaced by weights
The tray then moves outboard to Position B where the set is stapled and ejected.
Top Tray
For the next set, the tray moves to Position C to compile the set.
The customer has the option to select where unstapled copy and print sets will be sent by
default. They may either be sent to the Top Tray or the Main Tray of the Finisher. Because of
this customer option, the Top Tray has been redesigned to reliably stack up to 250 copies. The
capacity is slightly less, 200 sheets, for 8.5 in x 5.5 in (A5) paper.
The tray then moves outboard to Position A where the set is stapled and ejected
The output (the completed, stapled sets) in this mode are placed in Position A and Position B as are all other sets following the above sequence.
When this mode is complete the tray will resume its normal operation using only Position
A and Position B for offsetting.
To change the default location for unstapled sets, enter [Tools]. In Tools, select [System Settings], [More], [More] to get to Screen 3 of 3. In Screen 3, select [Output Options], then select
[Output Location].
Main Tray Thin Stapled Set Capacity
The Stacker Tray has been redesigned to provide greater staple relief than the Document
Centre 255/265 Finisher. A magnet has been incorporated into the tray that ensures the stapled corner of single-stapled sets are at or below the level of the rest of the set. This increases
to 100 sets the maximum number of thin stapled sets the Stacker Tray can reliably stack.
To change the settings for thin stapled sets, enter [Tools]. In Tools, select [System Settings],
[More], [More] to get to Screen 3 of 3. In Screen 3, select [Output Options], then select [Thin
Stapled Sets].
Main Tray Offset / Position Diagnostic routine

The 4 test types are:
Single Step: Steps the tray to the next position when [Continue] is selected. Position
sequence is A to B, B to C, C to D, D to A and repeats.
Continuous Cycle: Steps the tray continuously when [Continue] is selected. The tray
pauses for .5 seconds at each position. The tray stops when Stop is selected.
There are 2 settings that can be changed by the customer:

repeats.
Number of sheets in Thin Stapled Set. This can be 5 to 20 sheets.
Number of Thin Sets before Finisher Tray unload. This can be 20 to 1000 sets. The
maximum recommended is 100. If greater than 100 is selected, set registration problems
may occur.
Tray Home Position: At the start of the Single or Continuous test, selecting [Start] will
cause the tray to move to the Home position (position A). After arriving at Home, the button will change from [Start] to [Continue].
Sensor Monitor: The state of the Stacker Tray Offset Sensor will be monitored at all
times except while continuous mode is running.
Stacker Tray Offsetting

The Offset Home Sensor detects a flag attached to the tray. There are 3 slots in the flag. This
provides 4 positions for the Main Tray.
How to Run the Main Tray Offset / Position Test

1.
On test entry, the system will read and display the state of the Stacker Tray Offset Sensor.
Position A - Home (Outboard)
2.
Select [Single] or [Continuous] test
Position B - 22mm from home
3.
If using Continuous test, select [Mode 1] (2 position) or [Mode 2] (4 position).
Position C - 40.8mm from home
4.
Select [Start]. Stacker Tray will move to the Home position.
Position D - 62.8mm from home
5.
When Home is complete, [Start] button will change to [Continue].
For all jobs except 8.5 x 11" SEF and 8.5 x 14" Portrait Staple Mode, only 2 positions, A and B,
are used (Refer to Figure 20):
6.
Select [Continue] to begin positioning.
7.
8.
If using Continuous mode, tray will continue stepping until [Stop] is selected.
If the tray is in Position A at the start of the job, the Offset Motor is energized to move the
tray to Position B where the first set is compiled/stapled then ejected. The tray then
moves to Position A for the next job. The tray offsets between Position A and Position B
for successive jobs.
To run this test, in Diagnostic Navigator, select [Finisher], [Finisher Tests], [Main Tray/Offset
Position].
If the tray is in Position B at the start of the job, the Offset Motor is energized to move the
tray to Position A where the first set is compiled/stapled then ejected. The tray then
moves to Position B for the next job. The tray offsets between Position A and Position B
Finishing
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Figure 21 8.5 x 11" SEF and 8.5 x 14" Portrait Staple Mode
Figure 20 All jobs except 8.5 x 11" SEF and 8.5 x 14" Portrait Staple Mode
Service Tray
In the Capstan Driven Tamper, the gear on the Tamper Motor and the gear rack on the Tamper
Arm have been replaced by the Tamper Capstan and the Tamper Arm Drive Cable. This was
done to reduce the noise generated during Tamper initialization and Tamper operation. The
Tamper operation is the same as the operation of the gear driven Tamper.
The Finisher Set Separator has been redesigned to improve set-to-set registration.
The Kicker now has a Collapsible Kicker Arm that enables the Moving Stapler a greater range
of movement. This was needed for the correct placement of staples when dual stapling on
landscape (SEF) sets and single stapling on landscape (SEF) sets.
The Canard Wing is now mounted to the Retractable Registration Edge. The Canard Wing is
raised during the portrait staple mode reducing the possibility of the stapled set being misregistered.
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Finishing
Capstan Driven Tamper
Tamper Arm
Drive Cable
Tamper
Capstan
Tamper Motor
Figure 22 Finisher Service Tray - rear view
Finishing
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Canard Wing
A cover for the Nip 1 idlers and Nip 3 Idlers has been added to prevent the idlers from becoming dislodged during jam clearance. When a Finisher Transport Baffle is ordered, it will have
this new cover.
The magnets that secured the Finisher Transport Baffle in the correct position against the Exit
Baffle have been removed. The Finisher Transport Baffle is now held in the correct position by
weights that are located just to the left of the Area 5 handle.

Collapsible Kicker Arm
Figure 23 Set Separator and Collapsible Kicker
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Finishing
Finishing
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ESS (Chain 16) and Connectivity (Chain 18)
Overview
Windows 95/98
The ESS (Electronic Subsystem) Hardware platform provides an Ethernet PCI Controller with
RJ45 connectivity for the Document Centre 240/255/265 LP/ST. Based on a PowerPC Microprocessor, the ESS performs many essential functions for the system.
Supported Network Interfaces
A network interface is a device which allows the machine to communicate on the network.
TheDocument Centre 240/255/265 ST/LP can be equipped with several different network interfaces to allow it to be connected to various types of networks. Here is a list of supported network interfaces for the DocumentCentre 240/255/265 ST/LP:
The use of CentreWare in this environment requires the Novell Client software to
perform printer discovery
Peer to Peer printing using NetBEUI protocol and TCP/IP protocol
TCP/IP (lpr) printing using Microsoft TCP/IP stack and a third party software such as
NIPRINT
The use of CentreWare in this environment requires the Novell Client 32 software to
Windows NT 4.0 Workstation
Ethernet 10BaseT (built-in on the ESS PWB) 10 Megabits/second with twisted pair wires
through the RJ45 connector (10Base2 cabling can be used with external transceiver/
adapter) (10Base5 cabling can be used with external transceiver/adapter)
Peer to Peer printing using NetBEUI protocol and TCP/IP protocol
TCP/IP (lpr) printing using Microsoft TCP/IP stack
The use of CentreWare in this environment requires the Novell Client 32 software to
Macintosh OS 7.1/7.5/8.0
Token Ring (with add-on PWB) 4 Megabits/second or 16 Megabits/second through an

RJ45 connector
PPD
EtherTalk/TokenTalk Print Server
UNIX Operating Systems
Ethernet 100BaseT (with add-on PWB available and L18 software) 100 Megabits/second
through RJ45 connector (Category 5 cabling required)
Solaris 2.x (or greater, with print driver support)
Supported Network Operating Systems
SunOS 4.x (or greater, with print driver support)
A Network Operating System (NOS), is software that controls the operation of the network and
manages everything that happens over the network. The NOS resides on a central file server
or servers. Customers use many kinds of network operating systems and the Document Centre 240/255/265 supports a large variety of NOSs. A protocol is an agreed-upon standard format for transmitting data between two devices. Many network devices can transmit data using
more than one protocol.
HP-UX Version 9.0 (or greater, with native tools support ONLY)
IBM AIX (with native tools support ONLY)
Here are the Network Operating Systems and protocols supported by the Document Centre
240/255/265:
NetWare 3.1x (IPX protocol)
NetWare 4.1x (IPX protocol)
Microsoft Networking (NetBEUI protocol, TCP/IP protocol)
UNIX Networking (TCP/IP protocol)
AppleTalk (EtherTalk and TokenTalk physical layer protocols)
OS/2 Networking (TCP/IP protocol, NetBEUI protocol)
Banyan VINES (VINES IP protocol)
Ultrix (with native tools support ONLY)
Santa Cruz Operations UNIX (with native tools support ONLY)
IBM OS/2
OS/2 Warp 3 Peer to Peer printing using NetBEUI protocol and TCP/IP protocol
OS/2 Warp 4 Peer to Peer printing using NetBEUI protocol and TCP/IP protocol
Supported PDLs
Multiple Page Description Languages (PDLs) are supported by the ESS. The ESS is capable
of rendering jobs which may be composed of documents defined in one or more of the supported PDLs. An automatic emulation sensing capability allows the interpreter to interpret and
rasterize each document within a job. The ESS comes standard with PCL5E interpreter and
an Adobe PostScript Level 2 decomposer. Support for PostScript Level 3 and PCL6 is
planned for L18 software.
Image Quality
Supported Client Operating Systems

The Document Centre 240/255/265 ST/LP provides drivers in support of a variety of popular
client (workstation) operating systems. The following list outlines the client operating systems
that are supported and the protocols by which these client operating systems can send jobs
across the network to the Document Centre 240/255/265 ST/LP.
Windows 3.11 Windows For Workgroups
The available resolution modes for Postscript printing are (Fast Scan dpi x Slow Scan dpi x bits
per pixel) 600x600x1, 600x600x2, 1200x1200x1 and 1800x1800x1. PCL printing is a
600x600x1 dpi. PCL images at lower resolutions are converted by the print driver software.
Increasing the resolution will consume more EPC (Electronic Pre-collation) memory storage
per page. The performance (speed) of image decomposition is better at lower resolution. The
default resolution mode is 600x600x2 for Postscript and 600x600x1 for PCL. PCL images are
often chosen because they are faster to create.
Peer to Peer printing using NetBEUI protocol and TCP/IP protocol (TCP/IP not
included with Windows 3.11. Requires third party software)
Concurrency
TCP/IP (lpr) printing requires third party Winsock stack and lpr utility
The ESS is capable of performing the following operations concurrently:
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Receiving jobs from the network
ESS (Chain 16) and Connectivity (Chain 18
Spooling jobs to the internal disk
Decomposing a job
Transferring an image to the IOT Main Control PWB
Scanning and printing simultaneously
The ESS is a computer platform based on a MPC603e microprocessor at an internal

speed of 100 Mhz. The chosen operating system is the Lynx Real-Time Systems (Lynx
OS) operating systems. The ESS PWB uses the Eagle chip for memory control and
DRAM refresh. The DRAM interface is connected to four 72 pin SIMM sockets (Figure 2).
Performance
The Lakes ESS is capable of decomposing PCL5E jobs and PostScript jobs at the rated speed
of 65/55/40 pages per minute (ppm).
Embedded Internet Server
An embedded Internet server is standard as part of the Document Centre 240/255/265 ST/LP
product. It is intended to provide features such as submission of print ready files, device status,
queue listings, and paper tray contents. Through the use of any industry standard browser
(Netscape 3.0 or greater, Internet Explorer 3.0 or greater), both system administrators and
standard users will be able to access information from and input data to the ST/LP via the web
browser. The URL for the device is its IP number used for addressing the machine over the
HTTP and TCP/IP protocols.
Because the Eagle chip uses a 64 bit memory interface, SIMMS must always be installed
in multiples of two. The ESS senses the type and speed of installed SIMMS and will configure the chip for the user installed size and speed of memory automatically.
NVRAM
The Non-Volatile RAM (NVRAM) provides 4KB of NVRAM for storage and configuration
information. This is provided through a device which combines the RAM with a battery
and a real-time clock. The NVRAM contains among other things, information about the
PWB serial number and information needed by the ROM at boot time.
Real-Time Clock (RTC)
The real-time clock is a portion of the NVRAM component. It supplies a battery backed
clock which continuously stores and updates the current time, even when the system
power is removed.
Storage
ESS Hardware
Random Access Memory (RAM)
The ESS hardware provides a single PWB (the ESS PWB, Figure 1) which includes processor,
memory, and expansion capability.
The base ESS configuration reserves 16MB of RAM for a frame buffer. The additional 16 MB is used for everything else.
Hard Disk
(Figure 1) The standard configuration supports an internal SCSI-2 hard disk referred
to as fast SCSI. At various stages of development, the size has changed. Some
machines may still have a 1GB disk drive, newer machines are being built with a
2GB Quantum drive. The disk is partitioned into four partitions as follows:
/dev/sd0a
ESS PWB
/dev/sd0b
/dev/sd0c
/dev/sd0d
where a is the boot partition, b is the root partition, c is the usr partition, and d is the
tmp partition.
IOT Interface
The IOT interface consists of a dual backside IEEE P1386 type connector which connects
the PCI bus to the Main Control PWB.
Expansion Capability
Expansion is accomplished via the PCI Bus Extender PWB (Figure 3). Two IEEE P1386
type connectors on the front of the ESS PWB connect to the PCI Bus Extender PWB
which allows attaching up to three daughter boards.
Connectivity
ESS Hard Disk Drive
The ESS is designed to provide simultaneous operation of multiple connectivity interfaces.

Several network interfaces will be supported within and across a customer network. This
is accomplished through the use of the base configuration in combination with possible
additional connectivity interfaces.
Figure 1 ESS PWB and ESS Hard Disk Drive
The base configuration consists of three connectivity ports: one serial port (TTY port), a
P1284 Parallel port and a 10BaseT Ethernet interface. There are presently no plans to
provide an internal bidirectional driver to support the ESS parallel port.
Processor
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The base platform has one built in 10MBps Ethernet interface for connectivity with a host
in peer-to-peer and client/server networks applications. The interface conforms to IEEE
802.3 standard. An RJ45 connector is provided to enable interconnection with UTP category 5 wiring. A shielded RJ45 cable is shipped with printer and must be used for EME
compliance.
TokenRing is supported as an option to the base platform via a PCI TokenRing card
mounted on the PCI Bus Extender PWB (Figure 3). It provides two ring speeds: 4 and 16
mbps. The Token Ring driver provides the user with the ability to read the Token Ring
MAC address only when the device is connected to a ring. Token Ring will also allow the
user to set the Token Ring MAC address, ring speed and the routing type.
Token Ring PWB
In the future ( L18 ), Fast Ethernet will be supported as an option to the base platform.
PCI Bus Extender

PWB
ESS DRAM
SIMMs (standard configuration shown,
two slots
empty)
Operating System
SESS Applications Software
SESS is an acronym for Strategic ESS. SESS was developed to have common ESS
architecture for the Document Centre products. SESS software is based on Smart technology. The Scalable Multifunction Microkernel Architecture Technology (Smart) consists
of a fully-integrated set of software components that have been optimized for quality and
market needs. The basic Microkernel supports Networking and Multifunctional facilities.
There are four major software subsystems in the Smart Microkernel:
Connectivity Services (CS) subsystem provides LAN client/server and peer to peer
connections, printing protocols, various protocol stacks, and their diagnostics.
Figure 2 ESS DRAM
Document Management (DM) subsystem is responsible for document queuing,

spooling, and scheduling and document recovery.
System Controller (SC) subsystem supports the main control, disk i/o, administration and synchronization of the overall system platform.
Document Processing (DP) subsystem supports various documents processing
such as PDL decomposition and imaging.
Network DLMs
The Dynamic Loadable Modules (DLMs) are run-time loadable software applications supported by the SMart Microkernel for extensibility. DLMs can be developed to add new
connectivity and extended diagnostics. These include the various network protocol drivers.
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The Smart system supports multiple protocols stacks at the connectivity level. Each
Smart Dynamic Loadable Module (DLM) protocol stack is found in the /tmp/dlms directory.
Lakes Applications Software
APPLETALK
Booting
The AppleTalk protocols are implemented by the stacks as LynxOS streams. Two
programs must be executed in order to support printing. They are appletalkd and
atalk_pap processes. The appletalkd program is required to maintain the stack and
to support the protocol. The atalk_pap program must be executed in order to support printing. In general, these programs will be started automatically by the System
Controller if the dlm is enabled.
If printer fails to receive AppleTalk print jobs, make sure that the appletalkd and
atalk_pap processes are running by executing the command ps -ax at the tty operating system prompt.
When Lakes is powered on, control is immediately assumed by the Open Boot
PROM (OBP). The boot process is controlled by a number of configuration variables.
The configuration variables are stored in the system NVRAM. These variables determine the start-up machine configuration. NVRAM configuration variables can be
viewed using this command printenv and can be changed using the setenv
command before the operating system is booted. Next the countdown automatic
selftest boot process are shown. The OBP goes out to disk then loads and starts the
kernel lynx.os. The kernel starts up the initial master process which is responsible to
get the name of the startup script
(/bin/rc) to run.
BANYAN VINES
On Lakes, /bin/rc performs the following tasks:
This Smart System provides support for the Banyan Vines protocols over Ethernet in
the LynxOS kernel. The vpsd and vps programs must be executed in order to support Banyan. Vpsd program maintains the Protocol stack and vps provides Banyan
Protocol Module capability. In general these programs will be started automatically
by System Control if the dlm is enabled.
1.
It performs a filesystem check for each filesystem
2.
It runs /etc/rc.custom1 to perform pre-network initialization
If printer fails to receive Banyan jobs, make sure that the vpsd and vps processes
are running by executing the command ps-ax at the tty operating system prompt.
NETBIOS
This system provides support for NetBIOS/NetBEUI over Ethernet or Token Ring
and Netbios over IP over Ethernet in the LynxOS kernel. The llcd, netbiosd, and
netbios_print programs must be executed in order to support Netbeui over Ethernet
or Token Ring. The netbios_print program must be executed in order to support Netbios over IP over Ethernet. These programs will be started automatically by System
Control if the dlm is enabled.
If printer fails to receive NetBIOS jobs, make sure that the llcd, netbiosd,
netbios_print are running by executing the command ps-ax at the tty operating system prompt.
NOVELL
The SMart provides support Novell IPX/SPX protocols over Ethernet and Token Ring
in the LynxOS kernel. These protocols are enabled by the npsd program. The
release also provides Novell Pserver capability via the nps4 program. The programs
npsd and nps4 must be running in order to support the Novell PServer on the Microkernel. Generally these programs will be started automatically by System Control if
the dlm is enabled. Novell supports three distinct CSMA/CD frame types (802.3,
802.2, Ethernet_II) and may operate over Ethernet or Token Ring (802.5).
The npsd and nps4 processes must be running in order for the printer to function
properly on a Novell Network. They can be checked by executing the ps-ax command at the tty operating system prompt.
HTTP
The SMart system provides support for the Hyper Text Transfer Protocol (HTTP).
The http process must be running in order to support HTTP. In General, this program
will be started by System Control if the dlm is enabled.
The embedded http server supports any client tool that uses HTTP 1.0 ( Need
frames support and client Netscape Navigator 4.0, Microsoft Explorer 4.0). The http
process can be checked by executing the ps-ax command at the tty operating system prompt.
May 2003
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3.
It runs /net/rc.network to perform network initialization
4.
It runs rc.custom2 to perform post-network initialization
The amount of configuration information that needs to be stored on Lakes exceeds

the capacity of NVRAM, and the Lynx OS cannot address the NVRAM chip, so some
configuration information and all operating system information must be stored in files
on the disk. In particular, the network connectivity files (in /etc and /etc/ nvram).
Lakes uses a SMC Driver (Shared Memory Communication Driver) that allows data
to be accessed and transferred between the ESS and Atlanta.
System Initialization
System initialization occurs at power up and at an ESS reset. On system initialization, System Control checks a system configuration file to determine what processes
to initiate. A communication synchronization procedure between the ESS Platform
and the Main Control PWB System Manager occurs on power on and after either
platform has been reset. The System Control (SC) process starts the ESS Platform
Manager service. This service is responsible to check for the existence of the Main
Control PWB Platform and notify the Main PWB that the ESS Platform is available.
The ESS Platform is considered to be available when all the Lakes ESS applications
are ready for operation.
Error Reporting
All errors within the ESS software are reported to the Error Handling service for logging and handling. All ESS error logs are maintained and stored on the ESS Hard
Disk. The ESS error logs may be accessed via the PWS or local UI.
Error Recovery
The ESS fault list provides the recovery action to be initiated for each error. The
recovery actions for each error internal to the ESS are selected from the ESS Fault
Table in the EDOC :
Warm reset: A warm reset resets an individual ESS process and then performs
the process start-up handshaking procedure.
Cold Reset: A cold reset stops all ESS processes and then performs the system start-up procedure, restarting all applications.
V0.042
System Shutdown: A system shutdown is performed when a cold reset has

failed and/or is unable to re-synchronize the system. All ESS processes are
stopped and then the system halts.
Refer to Figure 4.
1.
The client submits a print job to the 240/255/265 using the print drivers installed on the
clint workstation.
Power Saver Modes
2.
In power saver modes, the ESS maintains the capability to receive and store jobs submitted by network clients. When a condition to exit power saver mode has occurred, for
example, when a print operation is requested from a network client, the ESS will send a
message to the IOT Main Control PWB (Atlanta) to exit power saver mode.
The job is received by the Protocol Module which forwards the job to the connectivity core
(DCH Connectivity Services) and the Document Manager (DM).
3.
The Document Manager spools the incoming job on the ESS Hard Disk.
4.
The print job is decomposed in the ESS and transferred to the Image Frame Store.
5.
The image is then transferred to the IOT Main Control PWB where it is processed similarly to all other images in the IOT.
ESS Job Flow
Figure 4 ESS Job Flow
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ESS and Network Diagnostics

There are two types of diagnostics available, ESS On-Board diagnostics and tests that are
available through the PWS.
For AppleTalk, since a router must be present, the driver is opened and checked for
existence of RTMP (Router Table Maintenance Protocol) which is normally broadcast by all AppleTalk routers every 30 seconds.
For Banyan Vines, the system sends a Vine IP echo to broadcast.
ESS On-Board Diagnostics
For NetBIOS, a request to register a name is sent to the naming registration service.
ESS On-Board diagnostics are included as part of the firmware on the ESS PWB or are part of
the operating system. ESS On-Board diagnostics contains those routines that can only be
executed when the system is powering up and/or before the operating system is loaded. To
view the results of these diagnostics, one must access the serial port on the ESS. The base
ESS Platform supports manual diagnostics in off-line mode. In this mode, the ESS does not
accept job submissions from the network.
Get Network Data
Power On Self Tests (POST)

These tests are executed during normal start-up. The following are the tests that occur on
POST:
Memory Tests (DRAM, NVRAM)
Ethernet Network Interface Controller
Parallel/Serial Interface
SCSI Controller
Async/Sync Serial Chip Test
Real Time Clock (RTC)
Get Network Data is very similar to the Echo test in its look and how it functions. It has
more capabilities for error messages in the results window and in a log file.
Get Network Data can be initiated from the machine UI. The log files will not be available
at the UI.
Get Network Data is not fully implemented in L17 software. Only IPX (Novell) and TCP/IP
(Unix) are functional. Even if other protocols are enabled, they will remain grayed out.
Do not confuse this behavior with Echo Test. In Echo Test, if these are grayed out, It is
because they are not enabled or configured properly.
Test Behavior -TCP/IP
The ESS collects data from all responding IP routers and lpd hosts in the local subnet. When the data is collected, a TFTP window will pop-up while data is transferring to the PWS.
When complete, a message will appear in the Results window indicating that the
selected protocol is present.
When the View Log button is selected, the following information is available in the
text file that is displayed:
MACHINE CONFIGURATION
Command Line Diagnostics
Host Name
Several useful diagnostic routines are available from the Command Line Interface, such as:
IP Address
watch-net
Net Mask
probe-scsi
Broadcast address
test net ilpbk
Default Gateway
test /nvram
Interface
showstack
Configured List Size
test /memory
Responders
More information on these tests is located in GP24 , ESS Command Line Diagnostics.
All devices discovered will be listed, along with their IP address, MAC address, and
Subnet Mask.
PWS Diagnostics
This is accomplished by sending an icmp echo (ping) request to the local broadcast
and then looking at the ARP (Address Resolution Protocol) table. For every entry in
the list, the machine sends a directed request asking for the subnet mask.
The following diagnostic routines are available in the PWS Diagnostic Navigator, in the ESS/
Network tab (except for Network Configuration). All are available directly connected to the
machine or through a RDT connection.
Echo Test
Echo Test verifies that the ESS can communicate with the network. It is also available on
the machine UI in the Tools pathway. The test is implemented differently, depending upon
the Network protocol:
For IPX (Novell), first the system sends out a Get Nearest Server request. At least
one local server must have Get Nearest Server enabled. Once a connection is
established, an IPX Diagnostic Inquiry is made to broadcast.
For TCP/IP, the system sends an ICMP Echo request to broadcast.
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This is a convenient way to check for the subnet mask if a systems administrator is
not available.
If data is missing, that host does not support the standard IP mask request.
Currently, (L17 SW) the host names are only available if a DHCP and DNS server
are available.
V0.042
For TCP/IP, an IP ping packet is sent to the broadcast address for which the machine is
configured. If no response is indicated, always ensure that the broadcast address is correct. In TCP/IP, the following scenarios will result in the following messages to be displayed:
If no other hosts or routers respond - TCP/IP protocol not found. Please check
printer network connections.
If at least one TCP/IP device responds - TCP/IP protocol present.
Test Pattern - The test pattern job has options for paper size and the PDL (Composition) type. This option can be useful if unusual IQ defects are occurring. It tests a
known good image through the PDL interpreter on the ESS. If for some reason the
known good image won't render properly, the ESS Software Verification routine can
be run to verify the integrity of the ESS software.
Verify ESS Software

This tool appears to be very simple, but it is a very powerful and useful tool. It is possible
because of a "manifest" file on the ESS that describes all ESS files and directories.
Repair is possible because a copy of the ESS Software is stored on a secondary (alternate) partition on the ESS Hard Disk Drive. This area of the disk is not usually read from
or written to, so the integrity of this partition is maintained.
Test Behavior - IPX (Novell)

After running the test, view the log file when the test completes.
The following information is available in the log file:
Number of servers that responded
Server number (only a reference number)
When the test is started, the routine will do various comparison checks between the
primary ESS Software partition and the manifest file. It will look for all directories,
and replace any missing ones. Any files that are known to be static, that is, never
changing, are checked and replaced if necessary. It also checks file permissions.
Dynamic files that are corrupt or missing, will be replaced with the same file with
default values. Created files that are missing or corrupted will result in a message
that the ESS must be rebooted. Created files include those that hold network configuration data.
If errors are found on the primary partition, one of two things will occur. A message
will be displayed that files were repaired, or if the damage is extensive, a message
will be displayed indicating that the ESS Software should be reloaded. The use of
this tool is described in the 16-C ESS Software Verification RAP.
Server Name
Port ID (if discovered over Ethernet, Token Ring, Fast Ethernet)
Server Network Operating System (version)
NDS Enabled
Number of Hops (always 1 in L17 SW)
Internal Network Number
Attached Network Number (s)
Only two messages are presently implemented in Get Network Data for Novell in L17 software. A server did respond, or no server responded. In L18 software, the following scenarios will result in the following messages to be displayed:
If no servers or routers respond - No servers responding. Please check printer network connections.
If the file server name defined in the ESS configuration is not found - Novell queue
server {server name} could not be located.
If the ESS is not attached to the file server - Lakes device not attached to server
{server name}.
If the ESS is attached to the server, but not attached to the print queue - Lakes
device not attached to queue {print queue name}.
If the ESS successfully connected to the defined Novell file server and print queue Lakes device is attached to queue {print queue name} on server {server name}.
NOTE: Currently (L17.5 software), this test will only work on a local network. It can
not go out beyond a router. If the printer is printing from a server across a router, the
test will fail.
NOTE: As of this writing, there were several error messages that came up when running this routine that should not. Bulletin 299 identifies some of them. Others that
indicate that file filename.off are missing are also incorrect. After running Verify ESS
Software, network configuration should be rechecked.
The results can be saved by selecting the Save Results button.
ESS Logs and Error Log

Error Log
The ESS stores the last 500 errors in a log file. The Select Log option allows you to display only Shutdown faults, or only errors and warnings, or all errors.
The logs can be retrieved real time from the ESS or from a stored file. The file can also
be saved or printed.
ESS Test Jobs
By default, retrieve by Last X is selected. This retrieves faults in order. If there are any
faults logged, it will come back with a Get Error Log Entries window. This details how
many faults are in the log. (The exact number retrieved can be set by changing the number of entries to retrieve field, but it defaults to 40 to be consistent with the IOT).
There are two types of test jobs available from the ESS Test Jobs area, the Power On/
Demo and Test Pattern.
For each line retrieved, you can select a row and the name of the fault will appear in the
description window.
Also, errors can be retrieved by time. If you wanted to retrieve errors that occurred on a
particular day, select Time. You will be given options on sorting by time and date range.
Power On/Demo - The Power On/Demo job will print the previous configuration
report, which is generated at every graceful power-down. If you prefer, a new one
will be created if Generate New Configuration Report is selected. This will take
slightly longer.
If you look at the Configuration Report, the first section is labeled Report Profile.
The Report Profile Date and Time is for when the data was gathered. If Generate
New Configuration Report was not selected, this date and time will be of the last
graceful power-down.
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ESS Logs
This routine is most helpful to software developers, but may help you understand intermittent failures.
There are 6 different logs available. They are described as follows:
State/Process Log - Any state changes of software processes are logged here.
Event Log - Any "interesting" event is logged in this log.
Shutdown Fault Log - Information about shutdown faults that have occurred.
Error/Warning Log - Information about any errors or warnings that have occurred.
Completed Job Log - All completed jobs.
Debug Log - All of the above logs compressed into one log.
Logging can be disabled. This may be necessary in some rare cases since enabling logging can have a negative impact on ESS performance. This should not be expected
under normal circumstances. Logging should be left at default setting unless you are
requested by Field Engineering to change them.
ESS Online/Offline
When the PWS is connected to the machine, the machine enters diagnostic mode and
automatically puts the ESS offline. This is done to ensure that the machine will not start
up while it is being serviced. ESS Online/Offline provides a means for a Service Engineer
to prints jobs when in diagnostics.
NOTE: The machine will print any other jobs that are in the queue before the priority job.
You must remember to put the machine Offline to continue servicing.
Network Configuration
Network Configuration is available in the Configuration Tab in the Diagnostic Navigator.
The network configuration that is stored on the ESS can be displayed on the PWS.
Select View to display the Network Configuration. It also provides a means for a Service
Engineer to change network configuration values.
If, for some reason, the Configuration Report cannot be run, the same information is available on the Network Configuration routine.
A pop-up window appears called Edit ESS Configuration Values. Here you can change
the values for many of the configuration settings. When a value is changed, click on Write
Value, and the setting will be changed. This routine can be run remotely via RDT. Mistakes in configuration settings can be corrected this way
May 2003
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V0.042
460/470 ESS
ESS General Description
The ESS includes:
A 433MHz Intel Celeron processor
64 Mb DIMM (Dual In-line Memory Module) Expandable to 128 Mb
9.1 GB, 7200 RPM Wide SCSI-2 System Hard Disk Drive
System BIOS now resides on the motherboard
Integrated 10/100 Mbps Ethernet Interface Category 5 cable (or better) is required
Runs on LynxOS a UNIX based operating system
ESS Components and Locations

The ESS has the following replaceable components:
ESS PWB (Printer Wiring Board) or motherboard.
ESS Hard Disk Drive
ESS Software
ESS DRAM DIMM
Token Ring is available as a plug-in card.
An IPA PWB plug-in card is required for Network Scanning.

NOTE: (Note: The IPA PWB and the Token Ring PWB are physically different from their
PowerPC ESS versions.)
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460/470 ESS
NOTE: All of the ESS components are located in the Card Cage at the rear of the printer/copier
(Figure 1). The Card Cage also contains the Main Control Board (MCB).
Image Hard
Drive
ESS DRAM
DIMM
433MHz Intel
Celeron
ESS Hard
Drive
SCSI-2 Hard
Drive Controller Interface
ESS PWB
(motherboard)
ESS PWB
Interface
Diagnostic
LEDs
Token Ring
PWB PCI Slot
Parallel Port
IPA PWB PCI
Slot
Card Cage Riser

PWB
Figure 1 Card Cage / ESS PWB

Card Cage Riser PWB
The Riser PWB provides:
NOTE: The MCB PWB (Alanta Platinum 860NLX) was redesigned to accommodate the new
ESS and Card Cage design. The MCB PWB connects to the Riser PWB using a standard PCI
connector. The ESS PWB is connected to the MCB PWB through its mounting position. A connector on the back of the ESS PWB is mated to a connector on the back of the Main Control
PWB.
NOTE: A Card Cage Riser exists only if an ESS exists.
460/470 ESS
PCI Bus for
Main Control PWB
ESS
IPA PWB
Token Ring PWB
Parallel Port (IEE 1284)
ESS Hard Drive Controller (SCSI-2)
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V0.042
Diagnostic LEDs (Refer to Table 1)
/dev/sd0c (usr partition)
Voltage regulation and distribution (Refer to Table 2)
/dev/sd0d (tmp partition)
ESS Ports
Table 1 Diagnostic LEDs
ESS provides several ports for communication.

LEDS
Status
Monitor
CR1
Flashing - Activity
LAN
CR2
Green
pwr
Serial Port - Connect the PWS for boot sequence monitoring.
SCSI Port - Not presently used
Ethernet Network Port - RJ45 type connector
USB - Not presently used
Parallel Port - Used during software upgrades (Can also be used for Parallel printing.)
CR3
Off (Green during power up)
SCSI
CR4
Light Green
PMG
Token Ring PWB
CR7
Red
+12v
CR8
Off
-12v
Token Ring is supported with an optional Token Ring PWB card. The card mounts into the PCI
bus slot on the Riser PWB in the ESS assembly.
CR9
Red
3.3v (CPU)
CR10
Red
5v
NOTE: A special adapter cable is not required with this card. Instead, an RJ45 port on the end
of the card will accept the customers Un-shielded Twisted Pair cable directly.
Table 3 Token Ring LAN Connector LEDs
Table 2 Voltage regulation and

distribution
Test Hole
Voltage
TH1
3.3v
TH2
+5v
TH3
+12v
TH4
-12v
TH5
-5v
TH6
gnd
TH7
gnd
TH8
gnd
TH9
gnd
LED Color
LED State
Green
Off
Indicates
Not inserted into the Token Ring
Green
On
Working - receiving tokens
Red
On (Steady State)
Passed the Lobe Media Test and is transmitting
Red
On (Pulsing)
Attempting Lobe Media Test - when light is out

test has failed
NOTE: The Red and Green LEDs on steady together signify the machine has joined the Token
Ring and is sending and receiving on the ring. If the machine does not print at this point, then
the machine is mostly likely not configured correctly for the customers protocol(s).
IPA PWB (Network Scanning)
Network Scanning is supported with an optional IPA PWB card. The card mounts into the PCI
bus slot on the Riser PWB in the ESS assembly. It also requires 96MB ESS Memory
NCP (Netware) and TCP/IP are supported on Ethernet or Token Ring.
NOTE: Faxing is supported with an IPA PWB.
Alternate Boot Overview

Alternate Boot (AltBoot)
ESS Hard Disk Drive
The Alternate Boot is used to diagnose ESS problems and to load ESS software.
The standard configuration is an internal SCSI-2, referred to as fast SCSI. The disk is partitioned into four partitions as follows:
/dev/sd0a (boot partition)
/dev/sd0b (root partition)
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460/470 ESS
NOTE: The Alternate Boot Utility should be used when the ESS is down or unavailable with
Diagnostics Navigator and/or the PWS Wizard.
Use the following procedure to connect the PWS to the ESS.

1.
Power off the Printer/Copier.
CAUTION
2.
Connect the serial cable to the Null Modem adaptor.
When loading software the Alternate Boot Utility will delete all Scanning templates and FAX
Repository settings residing on the ESS.
3.
Connect the serial cable and Null Modem adaptor between the PWS serial port and the
ESS Serial Port Connector.
Connecting the PWS to the ESS

You must connect the PWS to the ESS with the following instructions to use AltBoot.
NOTE: See General Procedures (GP22 - Connecting the PWS to the ESS Serial Port, as
required.
The following equipment is required to connect the PWS to the ESS on the DC460/470
An example of an Boot Sequence
PWS Serial Cable 600T2058
Null Modem Adaptor 113E40060
Table 4 is an example of n ESS Boot sequence. The left column is the text of the boot
sequence (the line numbers are for reference only. and do not appear in the boot sequence.).
The right column of the table describes the boot sequence.
NOTE: Note: The Null Modem for the DC240/255/265 cannot be used.
Table 4 ESS Boot sequence
Boot sequence
Description
1. Intel BALI 440BX User Flash Firmware

2. ================================
3. ALTERNATE BOOT Ver 2.7
4. ================================
5. System ID => LAKES RevC+
6. Bios ID => 4B4LZ0XA.86A.0012.P05.9911101047
7. uP Speed => 0366 MHz
8. ================================
Lines 1-8
Whats happening here:
System Information
-BIOS Version
-BIOS ID
-CPU Speed
-Post
-Loads BIOS
Critical checks:
-Ensure the system ID is set to Lakes.
-If there is no info here then you want to
check the 5V on the Riser PWB or
reseat the ESS PWB or replaced the
Riser PWB
9. Press Any Key For AltBoot Menu

10. Xerox LynxOS Preboot 3.0.1 build 110298-G created Tue Mar 07
03:09:52 EST 2000
11. Copyright (C) 1987-1997 Lynx Real-Time Systems, Inc.
12. Usage:
13. To Default Boot from SCSI Drive 0, Partition B (will default boot in
10 sec)
14. Enter
15. To ALT Boot from SCSI Drive 0, Partition A (for sec image loading)
16. A
17. Command? <b s0b /lynx.os>
18. Default: Booting Multi-user!
19. Loading.../loaded
20. LynxOS 386/486/Pentium PC-AT Version 3.0.1
21. Copyright 1987-1998 Lynx Real-Time Systems Inc.
22. All rights reserved.
460/470 ESS
Lines 9-22
-The ESS is trying to boot to partition
B and load the LynxOS.
Critical checks:
-If the boot sequence stops here, then
you would repair the partition using Alt
Boot.
-If the boot fails after the repair partition
then reload S/W.
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V0.042

Boot sequence
Description
23. LynxOS (x86) created Wed Mar 22 14:15:09 EST 2000

24. Copyright 1993 Xerox Corporation Version ROM
25. Running fsck on [/dev/sd810.0b], Please Wait ...
26. fsck: /dev/sd810.0b: Filesystem Ok!
27. Running fsck on [/dev/sd810.0c], Please Wait ...
28. fsck: /dev/sd810.0c: Filesystem Ok!
29. Running fsck on [/dev/sd810.0d], Please Wait ...
30. fsck: /dev/sd810.0d: Filesystem Ok!
Lines 23-30
- The LYNX OS has taken over the boot
up and a File System check is being
performed on all partition.
31. Dynamically installing clpar @ 0x4000...

32. Creating clparInfo device...
33. Making file system node for clpar: major=21 minor=32...
34. rc.custom1 is allowing the pci_enet DLM to install the i82559 Enet
Driver!
35. Begin cleanup...
36. ...cleanup finished.
37. drinstall -c ./eltDriver
38. ./eltDriver installed on driver id 30
39. generate ./elt.info
40. devinstall -c 30 ./elt.info
41. ELT-LTP Version 2 installed. Compiled Feb 23 2000 14:30:14
42. Software revision 2.2
43. elt.info0 installed on device id 33
44. mknod /dev/elt0 c 21 33 0666
45. drinstall -c ./eltNR
46. ./eltNR installed on driver id 31
47. generate ./eltnr.info
48. devinstall -c 31 ./eltnr.info
49. ELT-LNP Version 2 installed. Compiled Feb 23 2000 14:30:19
50. Software revision 2.2
Lines 31-50
-Loading the elt Driver for ESS to
Atlanta PWB communication,
V0.042
Critical checks:
- If the boot up sequence stops or if any
error messages appear in this section,
(lines 23- 30), (bad block on partition
). Run S/W verify using Alt Boot.
- Format HDD (Seagate and reload
SW), or suspect a bad HDD.
Critical checks:
-Suspect bad S/W and run S/W verify
using Alt Boot to fix.
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460/470 ESS

Boot sequence
Description
51. eltnr.info0 installed on device id 34

52. mknod /dev/eltNR0 c 21 34 0666
53. drinstall -c ./smcDriver
54. ./smcDriver installed on driver id 32
55. generate ./smcInfo
56. devinstall -c 32 ./smcInfo
57. PCI Bus NPLI Driver
58. Atlanta GOLD Configured.
59. **********************************************************
60. ** Atlanta to ESS connection Test
**
61. **
**
62. ** PPPP AAA SSSS SSSS EEEEEEE DDDD
**
63. ** P
P A A S
S
E
D
DD **
65. ** PPPP A A SS
SS
EEE
D
D **
66. ** P
AAAAA SS
SS
E
D
D **
67. ** P
A
A
S
S
E
D
D **
68. ** P
A
A
S
S
E
D
DD **
69. ** P
A
A SSSS SSSS EEEEEEE DDDDD
**
70. **
**
71. **********************************************************
72. Software revision 2.10 Compiled Feb 23 2000 14:30:01
73. Pinned memory size = 9961472 bytes
74. smcInfo0 installed on device id 35
75. mknod /dev/smcDriver c 21 35 0666
76. 84 eltDaemon started
Lines 51-77
- SCM driver is being loaded for ESS to
IOT communication.
- Loopback check for ESS PWB to
Atlanta PWB communication, (lines 59
to 77).
460/470 ESS
Critical checks:
- Connection between the Atlanta PWB
and ESS PWB.
-If SMC Driver cannot load, run SW
verify using Alt Boot.
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Boot sequence
Description
78. Removing IPA devices ...

79. IPA devices cleaned.
80. Removing IPA drivers ...
81. IPA drivers cleaned.
82. Removing /dev/ipa
83. ... clean up finished
84. create ipaInfoFile ...
85. Trying Dynamically installing ipa Driver IPA2...
86. IPA Placid Board not found.
87. devinstall: ipaInfoFile: Device doesn't exist
88. IPA2 board not found
90. Removing IPA devices ...
91. IPA devices cleaned.
92. Removing IPA drivers ...
93. Removing Driver 33 ipa2Drv94. IPA drivers cleaned.
95. ... clean up finished
96. create ipaInfoFile ...
97. Trying Dynamically installing ipa Driver IPA...
98. Board/Device name
= IPA-CE (Keuka)
99. XPCI Device/Vendor ID, Slot = 001710C5 14
100. Allocated PhysAddr, VirtAddr = FEBF8000 DDFE7000
101. PAL,AHA,PM22,XPCI Reg.BaseAddr = DDFEA400 DDFEA800
DDFEAC00 DDFEB000
102. Driver System Thread ID
= 20
103. VirtAddr of dma_chain1..3
= E054D000 E055D000 E056D000
104. PM2 Clock Speed
= 2X (4826)
105. PM2 RAM Speed
= Fast
106. Max DMA Pages, Max Image size = 4096 Pages, 16MB
107. Last PutBack: ESSar23069. Compiled Feb 23 2000 14:30:31
108. IPA Driver ready...
109. ipaInfoFile0 c 36 0
110. ipaDrv is installed.
111. ---------------------------------------112. i82559 driver
113. Version 0.009
114. ----------------------------------------
Lines 78-114
- Checking the PCI slots on the
Riser PWB for the IPA PWB.
- The IPA Driver is being loaded.
- Checking the RAM allocation for
scanning.
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Critical checks:
- Reseat the IPA PWB.
- Replace the IPA PWB
- Replace the Riser PWB
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Boot sequence
Description
115. BAD DEST PORT 111...dropping msg

116. Installing pro0 Ethernet Interface!
117. Token Ring card found at slotNumber 16
118. Setting ring speed to 16 Mbits/Sec
119. Token Ring LLC/MAC Microcode:
120. (C)1983-89,90-98 Texas Instruments
121. (C)1983,4,5,6 IBM Corp
122. Assigned Hardware address = 00:00:aa:59:15:87
123. Factory Hardware address = 00:00:aa:59:15:87
127. routeType = NON ROUTING maxRouteNodes = 1500
128. Token Ring driver installed. Compiled Feb 9 2000 10:28:53
130. Installing tring Tokenring Interface!
131. inetd started
Lines 115-131
- Checking for the Token Ring PWB.
- Loading the Token Ring driver.
132. Setting Timezone: -300 mins

133. Tue Jul 11 09:49:19 EST 2000
134. /net/unfsio started
135. /etc/rpcbind started
136. /etc/lftpd started
137. /etc/termWinServer started...
138. 'start_lakes' is beginning
139. --- Creating FrameBuffer --140. --- FrameBuffer Creation Successful --141. Collecting ESS files into /tmp/saveLogs/
save_071100_09:49...done
142. Cleaning /tmp directory...done
143. Cleanup of IPC queues... done
144. Removing leftover semaphores...done
145. Starting up System Control process
146. ...... The ESS is intializing and starting required processes.
147. ...... Please wait for system to become 'OPERATIONAL'.
Lines 132-147
- Log files are being saved.
- Start NFS services, WINs loads
- Load app (Start Lakes)
148. 'start_lakes' is complete

149. /usr/smart/bin/startLakesProcess /usr/smart/bin/start_lakes
started
150. Done with /bin/rc
151. user name:Removing Lakes IPC queues (except SC)... done
152. add net default: gateway 13.175.184.1
Line 152
Default gateway
460/470 ESS
Critical checks:
- Reseat the Token Ring PWB.
- Ensure that drop cable is good.
Driver will not load if we cannot insert
to the Ring (Phantom Current).
- Replace the Token Ring PWB.
- Replace the Riser PWB.
Lines 124-126
Trying to establish communication
between ESS/MCB
Critical checks:
- If boot fails here then reset NVRAM.
- Perform GoldenDisk
Reload ESS S/W.
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Boot sequence
Description
153. ****************************************************************
154. ***************** ESS System is 'OPERATIONAL' ********
155. ****************************************************************
156. ****************************************************************
157. **** ESS System 'SYNCHRONIZED' with SYSTEM MANAGER
****
158. ****************************************************************
159. ****************************************************************
160. ************* DIGITAL COPIER PLATFORM 'AVAILABLE'
*************
161. ****************************************************************
162. ****************************************************************
163. ******************* UI PLATFORM 'AVAILABLE' *******************
164. ****************************************************************
165. ds: ds_delete_obj() got out of range object handle 0, tid = 27
Lines 153- 165

What's happening here:
The message, ESS System is 'OPERATIONAL', means that the ESS is completely initialized and is operational. If
this message is not displayed, ESS
failed to initialize correctly.
Thi message, ESS System 'SYNCHRONIZED' with SYSTEM MANAGER, means the Atlanta System
Manager is available and the ESS Platform Manager was able to sync to the
System Manager. If this message is not
displayed, either the System Manager
is not communicating or RPC is not
working.
The message, DIGITAL COPIER PLATFORM 'AVAILABLE', means that the
Atlanta DC (Digital Copier) Platform is
available and has synchronized with
the Atlanta System Manager. After this
message is received the ESS Platform
will begin cross-platform registration of
services.
The message, UI PLATFORM 'AVAILABLE', indicates that the UI Platform is
available and has synchronized with
the Atlanta System Manager. If this
message is not displayed UI is not
communicating with System Manager.
ESS Software Loading/Upgrading
Contents
ESS Software Loading/Upgrading
Help Button
Loading/Upgrading is accomplished by using:
ESS Logs
The PWS Wizard - See Kit Installation Instructions Part 3 of. 4. The serial and parallel
ports on top of the printer/copier are required for the Wizard.
ESS Online/Offline
Software Verification
The Alternate Boot Method Kit - See Kit Installation Instructions Part 4 of 4. The ESS
serial port and the ESS parallel port are used for this procedure.
ESS Test Jobs
ESS Error Log
ESS PWS Diagnostics Navigator (ESS/Network)
Get Network Data
PWS Diagnostics Navigator (ESS/Network)
Echo Test
A brief of each function available on the ESS/Network tab.
Banner, Error and Configuration Sheets
ESS Terminal Window
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Help Button
Echo Test
The help button when selected will give you information about the PWS window you are in. If it
is a test or a procedure, it will tell you how to perform the test or procedure.
For Novell, the system sends out a Get Nearest Server request. At least one server must have
Get Nearest Server enabled. Once a connection is established, an IPX Diagnostic Inquiry is
made to broadcast.
ESS Logs
For TCP/IP, the system sends an ICMP Echo request to broadcast.
State/Process Log - Any state changes of software processes are logged here
Event Log - Any interesting event is logged in this log.
Shutdown Fault Log - Information about shutdown faults that have occurred. File name is
(Sdfault.log)
Error/Warning Log - Information about any errors or warnings that have occurred. File
name is (Errwarn.log)
Completed Job Log - All completed jobs. File name is (compljob.log)
Debug Log - All of the above logs compressed into one log
For AppleTalk, since a router must be present, the driver is opened and checked for existence
of RTMP (Router Table Maintenance Protocol) which is normally broadcast by all AppleTalk
routers every 30 seconds.
For Banyan Vines, the system sends a Vine IP echo to server.
For NetBIOS, a request to register a name is sent to the naming registration service.
NOTE: A request may be made by Field Engineering to obtain a Debug Log from a machine
that is experiencing intermittent ESS boot-up, Network connection, or another online related
problem(s). The Debug Log is accessed by opening the ESS/Network tab and then, pressing
ESS Logs icon. There will be a list of items that can be selected. The Debug Log is one of
them, and is usually the only file that needs to be retrieved and e-mailed to Field Engineering.
Do not forward any logs without first contacting a Document Centre Products Network Field
Engineer.
If some protocols are grayed out, it is because they are not enabled or configured correctly.
Online/Offline
ESS Terminal Window
The Online/Offline diagnostic switch is used to change the state of the ESS connection of the
IOT.
This feature will allow access to ESS command prompt while connected with the Diagnostic
Navigator. This tool will be available through either the PWS port on the IOT or the RDT
modem. This feature is password protected. To use this feature, the Remote Testing Access for
Network Controller on the local UI should enabled.
Software Verification Tool

The ESS software verification routine tests the software for the ESS. If a file is missing, a directory is missing, you have invalid permissions, there is a bad checksum, or the ESS process is
not running, you will have the option to fix the problem or abort the routine.
Banner Error and Configuration Sheet

The network configuration that is stored on the ESS can be displayed on the PWS. If the
machine cannot print the configuration report, the configuration information is available using
this routine. You can change configuration values with this routine and it can be done via RDT.
This tool can be used to:
Retrieve log files
Check process status
ESS Test Jobs
Review network statistics (arp cache, host table, route table, subnet mask, etc.)
Allows print of:
Remove corrupt jobs from spool directory
Previous Configuration reports
Start or Stop routing, telnet or ftp function
New Configuration reports
Edit script files
Internal test patterns
Replace corrupted files remotely
ESS Error Logs
Start or stop logging remotely
These instructions allow you to view error messages and warnings issued during system operation, or you can view any error or shutdown events that occurred during system operation.
Review log files
Get Network Data
From the diagnostics Navigator menu:
The Get Network Data is very similar to the Echo test in its look and how it functions. It has
more capabilities for error messages in the results window and in a log file.
CONFIGURATION:
Examples of two messages are: A Server did respond or No server responded.
Additional Troubleshooting
ESS Network Configuration is used to verify the network configuration data stored on the ESS.
You may run this utility after a UI configuration was performed to check what was entered at
the UI with what was stored as well as other troubleshooting functions.
NVM:
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Network Configuration Initialization clears the ESS network information and restores it to
the default conditions.
ESS Variable NVM Initialization - Set NVM variables to default.
Interpreter Profile - contains information as it relates to Printer Job Language (PJL) settings such as the Language Description and version. It also displays the resolution and
available memory
Language Description:PostScript
Language Level:3
Dust-off ESS NVM Initialization - ESS billing initialized, ESS system usage initialized, ESS
fault counters initialized, ESS diagnostic counters initialized, ESS SAKO settings initialized,
and All ESS dust-off nvm has been initialized.
Language Version:3010
Default Orientation:portrait
Default X-Orientation:600
Restore ESS NVM - This function is used to Restore the Network information stored on the
ESS.
Default Y-Orientation:600
Fault/Counters:
Current Y-Orientation:600
ESS Counters Display - The ESS Counters dialog is intended to provide a single location to
view key counter data. To facilitate navigation through the large number of counters, the data is
divided into several tabs. The default is Display All counter information.
Language Description:PCL
Configuration Report
Default Orientation:portrait
Current X-Resolution:600
Interpreter Memory:6500000
Language Level:6
Language Version:6
Default X-Orientation:600
Configuration Report
Default Y-Orientation:600
The printing of the configuration report confirms that the ESS has successfully booted.
Current X-Resolution:600
Current Y-Orientation:600
The configuration report fields:
Device Profile - Shows specific information that pertains to the system that includes the
machine software versions, disk size, total memory installed, and the status of the IPA
PWB.
Device Name:
Device Serial Number:
NE0000504
ESS Software Version:
0.19.0.26.2
0. 19.0.27
IOT Software Version:
used=276MB/total=4340MB
ESS RAM Size:
96MB
EPC Memory Size:
0. 19.0.28
ESS Disk Size:
32MB
Xerox Service Number:

IPA Card:
DC470
UI Software Version:
Interpreter Memory:6500000
Report Profile - Date and Time that the report was printed
1-800-821-2797
Ethernet Profile - displays the physical hardware address for the printer. The Speed
determines if the printer is connected to a 10MBPS or a 100 MBPS network segment. The
default setting AUTO
Ethernet Card:
pci card
MAC Address:
00:90:27:eb:c0:bf
Speed:
auto
Token Ring Profile - Protocol Interfaces (TCP/IP, NetWare, etc) can only be configured
for Token Ring if the Token Ring Option has been installed. The MAC Address is the physical hardware address of the Token Ring card and will be displayed ONLY if physically
connected to a Token Ring Network. Otherwise, the MAC Address will appear as all 0s
The Network Administrator sets the Speed or it can remain set for Auto. Source Routing is
set for networks with multiple Rings where routing is a requirement.
Token Ring Card: pci card
available
MAC Address: 00:00:aa:59:15:87
Printer Setup - Banner Sheet setting and default output handling
Speed: auto
Banner Sheet Enabled:enabled
Source Routing: disabled
Document Defaults:
Size:x= 216mm, y= 279mm
TCP/IP
Type:System-Default
TCP/IP Enabled - determines if TCP/IP will be used
Color: Unspecified
Host Name - identifies the printer to users if the IP address and printer name is listed
in the Hosts file
Sides:1
IP Address - is a UNIQUE number assigned by a Network Administrator
Plex:simplex
Broadcast Address - determines what network segment the printer broadcasts its
services on
Copy Count:1
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Subnet Mask- determines what network segment the printer is on. The Network
Administrator sets it
NDS Tree:-
Default Gateway - necessary in a routed network
IPX Frame Type:ethernet_II
Interface - determines how the machine is connected to the network over TCP/IP
(Ethernet or Token Ring).
Poll Interval:
Automatic Addressing - allows the printer to obtain its TCP/IP configuration from a
DHCP, RARP, or BOOTP Server. DHCP is the default setting.
SAP Rate:60
Line Printer Daemon (LPD) - is used with TCP/IP Printing. It can be Disabled, however, if it is disabled then the printer WILL NOT accept print jobs from workstations or
servers that submit print jobs using the LPR protocol.
NDS Context:-
Interface:ethernet
Primary File Server:FS1
AppleTalk - can be Enabled or Disabled

AppleTalk Name - can be changed to identify the printer to users on the network
LPD Port Number - can be changed to meet the network requirements and should
be provided/changed by the System Administrator ONLY.
AppleTalk Zone - determines what network segment (zone) the printer is installed on
Port 9100 - is used to support Microsoft Windows 2000 TCP/IP printing.
AppleTalk Phase - determines what type of AppleTalk network the machine is connected to
TCP / IP Enabled:enabled
Printer Type - cannot be changed
Host Name:DC470
AppleTalk Interface - determines how the printer is connected to the network
IP Address:13.175.184.193
AppleTalk Enabled:disabled
Broadcast Address:13.175.187.255
AppleTalk Name: DCNS470
Subnet Mask:255.255.252.0
AppleTalk Zone:*
Default Gateway:13.175.184.1
AppleTalk Phase:2
Interface:ethernet
Printer Type:LaserWriter
AppleTalk Interface:ethernet
Automatic Addressing:DHCP
LPD Enabled:enabled
Apple Talk Setting
HTTP Settings
LPD Port Number:515
HTTTP Port Enabled - can be enabled or disabled
Port 9100 Enabled:enabled
Port Number - is not editable
Netware Settings
Maximum Connections - how many users can be connected simultaneously
Netware Enabled - turns the protocol OFF or On (Enabled or Disabled)
Print Server - The name given to the printer by the System Administrator. This will
see when the printer is logged onto the network. The Print Server pulls the print jobs
from the NetWare Print Queue
NDS Tree - name is used with NetWare 4.x, does not apply to NetWare 3.x.
NDS Context - determines where in the NDS Tree the Print Server object reside.
IPX Frame Type - determines which Frame Type to use when communicating with
the Novell Server. Choices are 802.2, 802.3, Ethernet_II, or 802.5 (Token Ring
only).
Banyan Enabled - enables or disables Banyan Vines
Poll Interval - determines how often the printer will poll the NetWare Print Queue for
jobs.
User Name and Print Service name - parameters setup by the Network Administrator that allows users to print to the printer
Interface - determines how the machine is connected to the network (Ethernet or

Token Ring).
Interface - determines how the printer is connected to the network
SAP Rate - determines how often the Print Server will advertise itself on the network.
User Name:
Primary File Server - is used with NetWare 3.x and 4.x (Bindery). Up to four Primary
File Servers can be configured
Print Service Name: Byn@SC265@XEROX
NOTE: The Embedded web server allows access to users as well as a network
administrator to modify specific device settings as well as submit jobs to be printed
via the internet
HTTP Port Enabled:enabled
Port Number:80
Max Connections:32
Banyan Vines -
Banyan Enabled:
Interface:
enabled
CALEB@DC265@XEROX
ethernet
NetBIOS
Netware Enabled:enabled
NetBIOS Enabled - enables or disables NetBIOS
Print Server Name:LINCOLN_PS
Host Name - identifies the printer on the network
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Workgroup - identifies what group of network resources the printer belongs in. Workgroup and Domain are synonymous in the Microsoft Networking Model
Number of Connections - limits how many workstations can be connected to the

printer at any given time
Connection Timeout - determines when the connection is dropped
Interface - determines how the printer is connected to the network
Media Type:standard
Media Color:white
Media Size:x=216mm, y=279mm
Media Name:MediumInTray_2
Media Type:standard
Media Color:white
NetBIOS Enabled:enabled
Host Name:LINCOLN
Printer Name:270ST
Media Type:standard
Workgroup:LAB
Media Color:white
Number Connections:30
Connection Timeout:100
Interface:IP/Ethernet
Media Type:standard
Parallel Port Settings - allows communications as well as printing via the Parallel Port on
the ESS ONLY
Media Color:white
Parallel Port Enabled:disabled

Timeout:10sec
Media Trays - show the specific details about the paper trays that are installed on the
system
Power PC vs. Intel

Power PC vs. Intel
This section is to info you of the difference between the DC240/255/265 ST and the DC460/
470 ST products. These products have different ESS as seen in Table 5. This table highlights
some of them major differences and the follow text show some of them.
Media Trays:
Table 5 Power PC vs. Intel
Intel
Power PC
ESS LEDs used for activity and connection (Link)
None
10/100 auto switching
100MB card mounts on spacer PWB
Alt Boot S/W load using the Parallel Boot Code
Uses Alt boot fth file
L19.xx (7.0)
L18.xx and L17.xx (6.xx and 5.xx)
Riser PWB needed with ESS
Spacer PWB needed for Options
Card Cage is different
Card Cage is different
IPA / Token Ring PCI cards are different mount in

Riser PWB slots.
IPA, TR and 100MB mount on Spacer PWB
Hard Drives are Ultra SCSI
Hard Drives are SCSI 2
DIMMs 128MB
DIMMs 128MB
Celeron CPU
Power PC 100Mzh
White Null Modem (113E40060)
Black Null Modem
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Table 5 Power PC vs. Intel

Intel
Power PC
Atl Boot Menus are different
Atl Boot Menus are different
None
Low Level Diagnostic
Technical Overview
General Description
The ESS (Electronic Subsystem) is the portion of the machine that provides network connectivity and print job processing functions. The ESS is also known as the Embedded Print Controller.
The ESS is built around a 100MHz Power PC 603E processor and the basic configuration
includes:
2 GB SCSI Hard Disk Drive
32 MB of DRAM Memory
10BaseT Ethernet Interface
The ESS runs on a PowerPC version of the LynxOS operating system, which is based on
UNIX. The ESS is a standalone computer. If power was supplied, the ESS could boot and run
the operating system without being connected to Document Centre 265 at all.
ESS Components and Locations
The ESS has very few components. The following are the only replaceable parts:
ESS PWB
ESS Hard Disk Drive
ESS DRAM SIMM
ESS Hard Disk Drive Power Cable
ESS Hard Disk Drive Cable
ESS Software
All of the ESS components are located in the Card Cage at the rear of the machine (Refer to
Figure 2).
ESS PWB
The Main Control PWB is located facing the outside of the machine. The ESS faces the inside
of the machine and can only be accessed if the card cage is open. The ESS PWB is connected to the Main Control PWB through its mounting position. A connector on the back of the
ESS PWB is mated to a connector on the back of the Main Control PWB.
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Card Cage
ESS PWB
Figure 2 ESS PWB
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ESS Hard Disk Drive

Also located in the Card Cage is the ESS Hard Disk Drive. This drive is located on the same
panel as the Image Disk Drive. (Refer to Figure 3)
ESS Hard Disk Drive

Cable
ESS Hard Disk

Power Cable
Figure 3 ESS Hard Disk Drive
The cables for the Hard Disk Drive connect at the back of the drive. A 50 pin ribbon cable
transfers data to/from the ESS PWB and a 4 pin power connector supplies +5 VDC, +12 VDC,
-12 VDC, and ground. (Refer to Figure 3).
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ESS DRAM SIMMs

The ESS DRAM SIMMs are located at the top right corner of the ESS PWB. Two 16MB
SIMMs are standard (32MB total), with an option of 32MB additional (64MB total). (Refer to
Figure 4).
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ESS DRAM SIMMs
Optional
Slots
Figure 4 ESS DRAM SIMMs
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ESS Ports
Parallel Port
(IEEE)1284
The ESS has several ports for communication. (Refer to Figure 5 )
Serial Port - This is where the PWS can be connected to and monitor the ESS using a terminal window.
Parallel Port - Used during software upgrades
Ethernet Network Port - RJ45 type connector for 10BaseT twisted pair ethernet
SCSI Port - Not presently used
Token Ring (Optional) - Used for Token Ring networks. RJ45 connects to the Token Ring
PWB with an adaptor cable
100BaseT (optional, post-launch)
Token
Ring (Not
shown)
Serial Port (RS223C)
Ethernet Network
Port (RJ45)
SCSI Port
Figure 5 ESS Ports

Monitoring the ESS POST (Power On Self Test) and Boot Process
Normally, as the ESS is booting, appropriate messages are relayed to the UI through the Main
Control PWB. These give the users information on when the printer is online and ready to
accept jobs.
If there is a problem with the ESS, communication with the Main Control PWB is often interrupted, and no status is available on the UI, other than communication is not occurring.
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Also, PWS diagnostics (covered in Module 8) is not effective, since the PWS interface is with
the Main Control PWB and needs communication with the ESS to function.
In this case, the PWS must be connected directly to the ESS serial port to monitor the boot process or run diagnostic commands. To connect to the ESS, a PWS serial cable 600T2058 and
a Null Modem Adapter 600T2073 are required. The complete procedure is included in the
EDOC, General Procedures, GP22 Connecting the PWS to the ESS Serial Port. Refer to it at
this time.
Once connected to the ESS, when the machine is switched on, text will scroll by on the PWS
screen as the ESS goes through its POST (Power On Self-Test) and boot process.
The ESS POST/Boot process can be broken down into five phases:
1.
Configuration Reporting
2.
Resource Testing
3.
Loading the LynxOS Operating System
4.
ESS to IOT Communications
5.
Display Operational Banners
Power PC Option Kits

Introduction
Several kits are available as part of optional features that some customers may require or
request. Each kit has instructions included, so we wont describe how to install them, just what
there purpose is.
DC to ST Upgrade
This kit contains all the parts and instructions to upgrade a digital copier to a full system (ST).
This will be a very popular kit as customers upgrade the earlier machines.
There is presently one version of this kit. In the future, there may be are two versions of this
kit. The present kit includes a new card cage. The new card cage is complete including a
newer version Main Control PWB that is required for an ST upgrade. The new card cage
comes complete (except for an Accessory PWB) so that all of the components do not have to
be individually reassembled.
The UI software must be upgraded to the level of software that the Main Control PWB and ESS
are at. Also, any other options can be installed during the upgrade. All of this information is
included in the instructions packed with the kit.
The second kit which may be available in the future, would be for newer machines. It includes
an ESS PWB, ESS Hard Drive, and cables to add an ESS to an existing card cage that already
contains the correct Main Control PWB.
PCI Bus Extender PWB

The PCI Bus Extender PWB (Figure 6) is required to add either a Token Ring PWB or an
Image Processor Accelerator PWB. This allows these PWBs to connect to the ESS PWB.
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PCI Bus Extender PWB
Figure 6 PCI Bus Extender PWB
Token Ring PWB

The Token Ring PWB (Figure 7) allows the machine to connect to a Token Ring network. The
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PWB mounts to the PCI Bus Extender PWB, and includes an adapter cable to interface with a
RJ45 connector.
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Token Ring PWB
Image Processing Accelerator PWB

The Image Processing Accelerator PWB (Figure 8) is required for the Scan-to-File function (a
future feature). It performs the intense image processing that is required to store scanned jobs
out to the network.
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Image Processing
Accelerator PWB
Figure 8 Image Processing Accelerator PWB
32MB and 64MB DRAM Upgrade Kits

Two memory upgrade kits are available. One adds two 16MB SIMMS (32MB), the other adds
two 32MB SIMMS (64MB). The added memory improves ESS performance in processing print
jobs. (Refer to Figure 9).
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Spare SIMM Slots
Figure 9 Spare SIMM Slots
Module summary
A Digital Copier (DC machine) can be upgraded to a full system (ST) machine in the field.
There are two versions of the DC to ST upgrade kit depending on the age of the machine.
The PCI Bus Extender Kit is required before installing a Token Ring PWB or an Image Processing Accelerator PWB.
460/470 ESS
May 2003
10-162
V0.042
11. Supplemental Training

L0.18.xx Software Highlights
L0.18.xx (Version 6.x) Differences Update Overview .....................................................
What You Need to Know About the L018/Ver.6 Options ................................................
Major Features ................................................................................................................
Diagnostics......................................................................................................................
Check Your Knowledge...................................................................................................
Glossary ..........................................................................................................................
More Information .............................................................................................................
Answers to Checkpoint Questions ..................................................................................
11-3
11-4
11-5
11-10
11-11
11-12
11-13
11-14
Document Centre 460/470 Differences

Document Centre 460/470 Differences Update ..............................................................
What You Need to Know About the 460/470 ..................................................................
Card Cage Changes .......................................................................................................
Diagnostics......................................................................................................................
Check Your Knowledge...................................................................................................
Answers to Checkpoint Questions ..................................................................................
11-15
11-16
11-16
11-20
11-21
11-22
Smart Tray Finisher Differences

Smart Tray Finisher.........................................................................................................
11-23
19.02 Software Highlights

19.02 Software Highlights ...............................................................................................
V0.042
11-29
May 2003
11-1
Supplemental Training
May 2003
11-2
V0.042
L0.18.xx (Version 6.x) Differences Update Overview
Drivers
Purpose
HP-UX, IBM-AIX
custom PCL
The purpose of this differences module is to familiarize you with the changes that have come
about with the release of L0.18.xx/Ver.6 software, especially as it relates to the servicing of the
machine.
Driver Features
Major driver changes
New Features Overview
Delay print - Delay printing until a specified time
Accounting field
Customer Solutions
Customer Software Upgrades
The following are the major new features available in L18 software:
Once L18 software is installed, the customer will have the ability to upgrade the machine software.
Network Scanning
allows a walk-up user to scan an original, and send it off to a server, to e-mail, or to
an application on a workstation
LAN Fax
Allows walk-up user to send outgoing Fax
receives incoming Fax and prints as a print job or
routes incoming Fax to a network user workstation
Job Based Accounting
Keeps track of copy, print, scan and Fax usage
TIFF Printing
TIFF Interpreter that allows direct printing of TIFF files
Connectivity Additions
100Mb Ethernet capability with option card (also known as Fast Ethernet)
Enhanced support for PrinterMap
Windows 2000 compatibility
Device administration and install via Internet Services
PDL Support
Support for Adobe PostScript 3
Support for PCL 6
176 Fonts including Hero Symbol
Internet
Device Management - adds management of printer through the World Wide Web.
V0.042
May 2003
11-3
L0.18.xx (Version 6.x) Differences Update Overview
What You Need to Know About the L018/Ver.6 Options

Introduction
The L18 software enables use of the scanning, faxing, network accounting and 100 Mb Ethernet options which are for sale to the customer. If a customer orders one or more of the options
with a new machine, the option or options are installed at the factory and you have no activity.
If a customer orders one or more of the options for a machine already in use, they will be sent
a kit for each option. The kits require your assistance. The customer will hold the kit or kits until
your arrival.
Optional Kits
Before enabling any of these options you must assure that the machine has L18 software
installed.
NOTE: The kits marked below with an asterisk may already be installed depending on which
options the machine already has. For example, the PCI Bus Adapter PWB kit is required to
enable both the scan and fax options. So, for example, if a machine already has the fax option
installed, you will not have to install that kit when enabling the scan option.
2.
Install the 128K NVM RAM Chip kit (tag 036), unless the machine has an Atlanta
Platinum Main Control PWN, (tag 077).
3.
Open the Network Accounting Option enablement kit envelope and follow the
instructions to enable Network Accounting. This includes using the PWS to enter a
password that enables the option.
4.
Give the customer letter to the System Administrator.
5.
Give the customer software and documentation kits to the System Administrator.
6.
Emphasize to the System Administrator the importance of following the documentation to install the necessary software to enable Network Accounting.
100Mb Ethernet Option

1.
Install the PCI Bus Adapter PWB kit.*
2.
Install the 100Mb Ethernet PWB Kit.
3.
Notify the customer's System Administrator that 100Mb Ethernet is enabled. They
may have To change a network setting to make it functional.
Then do the following:
Network Scanning Option

1.
Open the scanning kit.
2.
3.
Install the Image processor Accelerator (IPA) PWB kit.*
4.
Install ESS DRAM upgrade kit to expand the memory to 96MB.*
5.
Open the Network Scanning Option enablement kit envelope and follow the instructions to enable scanning. This includes using the PWS to enter a password that
enables the option.
6.
7.
8.
Emphasize to the System Administrator the importance of following the documentation to install the necessary software to enable scanning.
Lan Fax Option

1.
Open the LanFax kit.
2.
3.
Install the Image processor Accelerator (IPA) PWB kit.*
4.
Install ESS DRAM upgrade kit to expand the memory to 96MB.*
5.
Open the LanFax Option enablement kit envelope and follow the instructions to
enable LanFax. This includes using the PWS to enter a password that enables the
option.
6.
7.
8.
Emphasize to the System Administrator the importance of following the documentation to install the necessary software to enable LanFax.
Network Accounting Option

1.
Open the Network Accounting kit.
May 2003
11-4
V0.042
Major Features
Documents can be stored to a server. Locations are determined as part of the system
administrators configuration process. Electronic documents are sent via an FTP connection over TCP/IP or IPX to a server. There, the documents can be accessed by users
using Windows/Netware tools.
Network Scanning
Network Scanning is an optional feature that must be purchased by the customer.
For more information about scanning features, go to More on Network Scanning.
Once the scan feature is purchased, it must be ensured that the machine hardware meets the
requirements of Network Scanning before enabling it in the software.
System Requirements
ST machine (can be installed on a DC machine if DC to ST upgrade is performed

first)
96MB ESS DRAM
IPA PWB (Image Processing Accelerator) installed on ESS
The additional ESS memory (ESS DRAM SIMMS) and IPA PWB are available as
Optional Kits. Their respective kit numbers are shown in Table 1:
Table 1 Optional Kits
Kit Name
Kit Number
IPA PWB
98S03002
ESS 32MB ESS

DRAM Upgrade
98S03005
ESS 64MB ESS

DRAM Upgrade
98S03006
Installation
Once the Network Scanning option is purchased and the hardware requirements are met,
the option must be enabled in software. It must be enabled via the PWS by the service
engineer. A password must be entered using a code obtained from the UI and then entering it into the PWS for the installation to be completed. See GP34, Entering Software
Options Password for more detail.
On the PWS, it can be enabled using [Configuration tab , Software Option Wizard]. It can
also be disabled or removed using this routine.
No additional software is necessary (assuming L18 SW already installed). Network Scanning software is loaded during boot-up using a DLM (Dynamically Loadable Module). To
ensure the functionality of Network Scanning, during ESS boot, the system is checked for
the correct amount of ESS DRAM, the existence of an IPA PWB on the ESS, and that
Network Scanning is enabled before the Network Scanning DLM is loaded. A fault code
will be declared if the required hardware is not detected.
Configuration
Configuration is usually performed by the customer or customers system administrator.
Network Scanning can be configured at the machine User Interface or remotely using the
CentreWare Network Scanning Admin Wizard.
Document Storage
V0.042
May 2003
11-5
Major Features
Scan to Network Server
Scan to PC
Visioneer PaperPort
Scansoft TextBridge
240ST/255ST/265ST
Scan to E-Mail
Lotus Notes
Microsoft Exchange
FTP via TCP/IP

NCP via IPX/SPX
Novell, NT, UNIX

Scan to Application
Scan to Optika eCentre
Scan to Xerox DocuShare
Scan to Documentum
CentreWare Software
- Scan Administration Wizard
- Scan Template Utility
- Document Management Agents (2)
Lakes Hardware
- IPA PWB
- 96MB ESS DRAM
Figure 1 Network Scanning Services
LAN Fax
System Requirements
LAN Fax ix also an optional feature that must be purchased by the customer. It uses the same
basic functionality as network scanning and therefore has the same hardware requirements.
Additionally, Xerox is partnering with RightFAX to enable this feature.

first)
96MB ESS DRAM
IPA PWB (Image Processing Accelerator) installed on ESS
For more information about LAN Fax features, go to More Information About LAN Fax
The customer will be required to have a RightFAX server, but the servicing of the server will not
be the responsibility of Xerox. Essentially, the LAN Fax image path is the same as Network
Scanning, except for the final destination of the file.
Major Features
May 2003
11-6
V0.042
The additional ESS memory (ESS DRAM SIMMS) and IPA PWB are available as
Optional Kits. Their respective kit numbers are shown below:
Table 2 Optional Kits
Kit Name
Kit Number
IPA PWB
98S03002
ESS 32MB ESS

DRAM Upgrade
98S03005
ESS 64MB ESS

DRAM Upgrade
98S03006
Once the LAN Fax option is purchased and the hardware requirements are met, the
option must be enabled in software. Presently, it must be enabled via the PWS by the
service engineer. A password must be entered for it to be completed successfully. The
password is generated in real-time on the PWS. See GP34, Entering Software Options
Password for more detail.
No additional software is necessary (assuming L18 SW already installed). LAN Fax software is loaded during boot-up using a DLM (Dynamically Loadable Module). During
boot, the system is checked for the correct amount of ESS DRAM, the existence of an IPA
PWB on the ESS, and that LAN Fax is enabled before the Network Scanning DLM is
loaded.
Additional Requirements
Configuration
A server must be available to temporarily store Fax documents before they are transferred to the RightFax server.

LAN Fax can be configured at the machine User Interface. More information is available
in the Document Centre Network Installation and Troubleshooting Guide (available on this
CD-ROM in PDF format).
Installation
Transmission report as a print job
Server based RightFAX

Repository
1. Program Job
2. Scan document
RightFAX Server
- Converts to CCITT GIV
- Transmits document
TIFF File with
RightFAX Agent retrieves TIFF
FAX instructions
Reads FAX instruction
Outgoing FAX
Transmission
NETWORK
Figure 2 FAX - Outbound Hard Copy Flow
V0.042
May 2003
11-7
Major Features
Treated as standard
incoming print job
RightFAX Server
Incoming FAX
Transmission
Sent to Document Centre over network as a PCL Print Job
Figure 3 FAX - Inbound Flow
Job Based Accounting
Job Based Accounting is an additional feature available to the customer for purchase. It gives
the customer the ability to control access to the machine and keep track of accounting information on a per job basis. It works on copy jobs, print jobs, FAX jobs, and Network Scanning
jobs.
Partnering with Xerox for the Job Based Accounting solution is Equitrac. Equitrac is supplying
the server and software to manage the information.
System Requirements
Machine Hardware Requirements

first)
TAG 036, 128K NVM RAM Chip is required on the Main Control PWB
No additional software is necessary (assuming L18 SW already installed).

Configuration
TCP/IP must be available on the customers network and enabled on the machine. All
walk-up jobs and print jobs will require the user to input a user name and password.
Equitrac System 4 Office Trac
Job Based Accounting requires a server that is running the Equitrac System 4 software. System 4 provides an effective and manageable tool for controlling and/or monitoring office
expenses. System 4 is primarily a tool for organizing, storing, and managing all System 4
account and transaction information. This information consists of user codes, account codes,
and transactions performed (e.g., photocopy, fax, etc.).
Installation
The System 4 application provides many powerful features, including:
Once the Job Based Accounting option is purchased and the hardware requirements are
met, the option must be enabled in software. Presently, it must be enabled via the PWS
by the service engineer. A password must be entered for it to be completed successfully.
The password is generated in real-time on the PWS. See GP34, Entering Software
Options Password for more detail.
Ability to customize flexible costing formulas using the System 4 Cost Definitions Form.
Ability to generate fully customized reports (in quick view, summary or detail format) using
the System 4 Report Builder.
Ability to export and import all types of data.
Ability to view logs of all system activity, including imports, exports, transactions, and
tasks.
Major Features
May 2003
11-8
V0.042
Ability to automatically schedule many system activities, using the System 4 Transaction
Interface Manager (TIM) module, including automatic report generation and automatic
backup operations.
Ability to view the status of all components of the control system, using the System Information Manager, including all local and remote systems, sites, and units.
Ability to operate concurrently with other operations; the system can print reports or transmit data while continuing to collect and store information from active terminals.
Ability to communicate over both LANs and WANs to support remote terminals and systems.
TCP/IP
Ethernet/Token Ring
Print
Job Accounting Information (HTTP)
Copy
Fax
Scan
Win 95/98/NT
Mac 7.x, 8.x
Web UI
Customers PC
Equitrac Accounting
Database Server
Figure 4 Job Based Accounting
Customer Upgrade of Machine Software on Connected Machines
What this means to you
ST or LP machines manufactured with version 6 software or those that have been upgraded to
version 6 are enabled for customer installation of machine software upgrades. Future software
upgrades will be made available to the customer on a CD or from a Xerox website. Instructions
for the customer upgrade will be provided with the software.
First, it will save you time. Be sure your customers are aware of this feature. Next, it may result
in a service call if the customer has problems. If you take a service call for a customer software
upgrade problem you may want to discuss the problem with the System Administrator and
watch them as they try an upgrade. If the problem isn't evident then you have the option of
upgrading software with the PWS, as usual.
The Process
The customer's System or Network Administrator either puts the software upgrade CD in their
PC or downloads the upgrade file from the web. They then open the CentreWare Internet Services home page via a browser using the machine web address (the IP address). Then, following the instructions provided with the software, the administrator sends the software file to the
machine. The upload takes 7 to 10 minutes. The machine will then automatically enter the software upgrade mode and upgrade its machine software. This takes about 45 minutes. The procedure can be repeated on another machine as soon as the software file is uploaded to the
first machine. One does not have to wait for each machine to upgrade itself before sending the
upgrade file to the next machine.
V0.042
You will continue to receive software upgrade kits that enable you to upgrade machine software using the PWS.
May 2003
11-9
Major Features
Diagnostics
EDOC Updates for L18
Diagnostics Changes
In support of L18 software, the EDOC has been updated to include new and updated RAPs,
repairs, parts lists and other procedures.
L18 software has brought some new diagnostic features and some changes to existing diagnostic routines.
Listed below are some of the diagnostic changes that are available in L18 software:
Software Option Wizard

This new routine is provided to enable and manage the new optional features available in
L18 software. For more information go to Software Option Wizard (L18 Software Only) in
General Procedures.
Highlights of the L18 EDOC changes:
Service Call Procedures SCP-04 Corrective Actions RAP updated to include Network
Scanning and LAN Fax problems.
New RAPs added to Chain 16 (ESS)
16-781.19 Not Enough Memory available for Network Scanning
16-785.19 IPA PWB Missing or failed with Network Scanning enabled
To view the routine, select [Configuration tab , Software Option Wizard].
16-786.19 IPA PWB Missing or failed with LAN Fax enabled
TEER Diagnostics
16-787.19 Not Enough Memory available for LAN Fax
16-B ESS Boot RAP updated to include ESS Memory Test and new ESS Software verify
from ESS Alt-Boot menu.
18-A Network Entry RAP updated to include 100Mb Ethernet, improved Token Ring
checkout using added checks in Echo Test, and also utilizing the new ESS Memory Test.
ESS Memory Tests
18-K Updated to include new ESS Memory Test.
The ESS Memory Test is a new tool, launched from within the Alternate Boot Tool. It creates a TTY window to the ESS and runs extensive tests of the ESS DRAM. For more
information go to ESS Memory Test (L18 in General Procedures.
18-L Network Scanning/Fax RAP added.
Diagnostics section of General Procedures updated to include new and changed diagnostic routines.
Go to the 16-B ESS Boot RAP and observe how the ESS Memory Test is being used.
Use the Back button on the browser to return here when done.
Repairs have been updated to show IPA PWB and 100Mb Ethernet PWB, REP 16-4
IQ-2 IQ Checkout RAP has been updated to utilize the new electronic test pattern for LP
machines.
IQ Specifications have been updated to include running the Test Pattern from within ESS
Test Jobs for checking IOT Specifications when appropriate.
TEER Diagnostics adds a series of tests designed to help diagnose TEER Sensor failures. For more information go to TEER Diagnostics (L18 Software Only) in General Procedures.
To view the routine, select [Paper tab, TEER Diagnostic].
ESS Terminal WIndow

The ESS Terminal Window allows a terminal window to the ESS to be opened during any
normal PWS diagnostic session, including remote. This routine requires a password and
is intended for use by Field Engineering.
Echo Test
For L18, additional features have been added. Token Ring and PCI Ethernet (100Mb
Ethernet PWB) have been added to the list of protocols. This will test the functionality of
the optional Network Interface cards.
To view the routine, select [ESS/Network tab , Echo Test].
Go to the 18-A Network Entry RAP and observe how the Echo Test is being used. Use
the Back button on the browser to return here when done.
ESS Software Verify

This routine has been available from the PWS in L17 software, but in instances where a
problem with the ESS software did not allow the ESS to boot completely and establish
communication to the Main Control PWB. Communication with the ESS from IOT/PWS
was not possible. In L18, this tool is available through the ESS Alternate Boot menu. For
more information, go to GP23 ESS Alternate Boot Menu.
Go to the 16-B ESS Boot RAP and observe how the ESS Memory Test is being used.
Use the Back button on the browser to return here when done.
ESS Test Jobs

The Test Pattern job option of ESS Test Jobs includes an electronic version of the
82E12191 (11) or 82E12320 (A4). This improves IQ diagnostics especially on LP
machines where there was no all around pattern available. It also allows direct comparison to images copied using the scanner and image processing systems vs. one sent
directly from the ESS to the IOT.
May 2003
11-10
V0.042
Check Your Knowledge
Question 7
Checkpoint Questions
Any customer can upgrade their DC265 machine software (Think before answering).
Question 1
a.
True
b.
False
How much ESS RAM is required for Network Scanning to be installed?

a.
32MB
b.
64MB
c.
96MB
d.
128MB
Answer available at Checkpoint Answers.

Question 8
Customers must have Internet Services available to upgrade machine software.
a.
True
b.
False
Question 2
Which ESS option PWB is required for Network Scanning?
Question 9
a.
IPA PWB
b.
Token Ring PWB
A procedure for entering the Software Options password exists in the EDOC.
c.
100Mb Ethernet PWB
a.
True
b.
False

Question 3
Question 10
The machine hardware requirements for LAN Fax are the same as Network Scanning.
a.
True
You will need to order kits to enable any option.
b.
False
a.
True
b.
False

Question 4
Question 11
Job Based Accounting requires 128MB of ESS RAM.
a.
True
b.
False
Every time a customer orders one of the options enabled by L018 software, you will be called
to install it. (Think about this one).
a.
True
b.
False
Question 5
You no longer need machine software upgrade kits.

a.
True
b.
False

Question 6
You must provide machine upgrade software to customers.
a.
True
b.
False
V0.042
May 2003
11-11
Glossary
Scan Template Utility
CSMA/CD
A CentreWare tool designed to help with creating Scan Templates.
Carrier Sense Multiple Access/Collision Detection.
Template
DLM
See Scan Template
Dynamically Loadable Module
TIFF
Document Management Agents
Tagged Image File Format. A widely used raster graphics file format.
Part of CentreWare. Enables Scan to Desktop and Scan to E-Mail.
Transmission Report
Ethernet
A report generated at the completion of a Fax transmission.
IEEE 802.3 LAN Standard that uses the CSMA/CD access method and transmits at 10Mbps.
Fast Ethernet
Also known as 100BaseT. Allows transmission rates ten times faster than 10BaseT.
FTP
File Transfer Protocol. A standard method for transferring files from computer to computer.
HP-UX
Hewlett-Packards version of Unix
IBM-AIX
IBMs version of Unix
LAN
Local Area Network
PCL
Printer Control Language. A command language originally for the HP LaserJet printers.
PDL
Page Description Language. A high level language for defining printer output.
PrinterMap
PrinterMap is a desktop application that provides enterprise printer management with a proactive, single view topology map to manage multiple vendors printers
Scan Administration Wizard

A CentreWare tool designed to simplify the task of setting up network scanning.
Scan Template
A template contains preprogramming applied by a user to a particular job. Templates are similar to Stored Jobs.
Glossary
May 2003
11-12
V0.042
More Information
Scan to Application
Scan to Application allows users to integrate network scanning with third-party offerings
such as Lotus Notes/ Domino.doc, Optika eCentre, Adobe Capture and CTI Documentum.
More on Network Scanning

The Document Centre 255/265 ST, with CentreWare Network Scanning Services 5.1, provides
scanning solutions that help customers capture and utilize knowledge, an important asset in
todays business environment.
The Optika eCentre solution was developed specifically for CentreWare Network Scanning services. It is another simple link into an integrated workflow and document management application. Optika eCentre provides a digital document repository for scanned
documents. An Optika eCentre agent resides on the server, looks for scanned images in
the repository and links them into Optika eMedia and FPMulti software.
When customers scan a hard copy document, they create an electronic file, which when saved
onto the network increases its value exponentially in terms of document management, file
sharing, re-use and re-purposing.
The Document Centre Adobe Capture solution, Scan to PDF via Adobe Capture, is targeted at all enterprises that have a need to capture documents as PDF files on an ongoing basis. The Adobe Capture client watches the repository on the NT server and
automatically processes the files placed at the server by the Document Centre.
CentreWare Network Scanning Services gives Xerox customers a powerful tool in transitioning
documents from the hard copy to digital formats.
Scan to Network Server
Using the Scanning Feature
Sharing the knowledge becomes an easy exercise when documents are scanned to your
customers network server. Putting documents on a permanent network location enables
users to manually retrieve the documents to their desktop for OCRing, editing, incorporating into other documents and distributing to other workgroups. Documents placed on the
network server can be made private, shared with other users in a specific workgroup or
made accessible to anyone with access rights to the server.
To create a scanned file, the user loads a document or documents in the Document
Feeder and presses the Network Scanning button on the UI Display. They select a template on the UI that tells the machine how to process the scan and where to send it. Templates can be created or modified as necessary.
Scan to Desktop
More Information About LAN Fax

A Document Centre 240/255/265/460/470 ST with the Fax option can scan documents and
send them as faxes or receive faxes that have been sent from another fax location.
Users can scan documents to their desktops directly into Visioneer PaperPort software.
By dragging and dropping the image file into compatible word processing, spreadsheet or
presentation programs (such as MS Word, Excel or PowerPoint), image files are automatically OCRd via TextBridge Pro 98, thus creating a document that can now be edited.
CentreWare Scanning to Desktop includes Scan Admin Wizard for setting up network
scanning, Template Utility for creating scan templates, Document Management Agent for
automatically monitoring and managing scan job processing, VisioneerPaperPort for
retrieving and manipulating scanned documents and TextBridge Pro98 for OCRing
scanned documents.
At the desktop, users can tap into a huge range of simplicity and functionality offered
through Visioneer PaperPort. The PaperPort application can be linked with over 185 different applications, including MS Word, MS Excel, Novell InForms, OmniForm, Adobe
PhotoDeluxe, Lotus Notes Mail, Quicken, Ami Pro and WordPerfect. This means that
almost anyone within the customers organization can have valuable access to the information they need.
Outgoing Fax
To send a fax the user loads a document or documents in the document feeder, uses the
keypad to dial in one or more numbers, selects the resolution to be transmitted and
presses START. If multiple documents are to be sent, the user must indicate whether
they are one or two sided. The document or documents are fed through the document
feeder and scanned. The resulting TIFF file along with the phone number is then
retrieved by what is known as an agent (a software routine on one of the customers servers). The server then forwards the file and phone number to a RightFax server. The
RightFax server converts the file for phone transmission and sends it to the appropriate
phone number. The RightFax server sends a transmission report to the Document Centre
for printing or display on the UI.
Incoming Fax
Incoming Faxes are received by the RightFax server and are either sent to the Document
Centre as a PCL print job or are distributed directly to end-user workstations.
CentreWare Network Scanning Services with DocuShare 2.0 provides users with the
capability to seamlessly store scanned documents from the Visioneer PaperPort desktop.
This means users can easily scan documents on the Document Centre and drag and drop
them using PaperPort to store them in DocuShare directly from the PaperPort desktop.
With this solution, the scanned documents, now on a users Intranet, can be easily shared
without going through a webmaster.
Scan to E-Mail
The Scan to E-mail function enables users to scan documents and deliver them directly to
the desktop of anyone with an E-mail address. The Scan to E-mail service supports standard E-mail applications, including MS Mail, Lotus Notes, MS Exchange and is compliant
with the widely adopted MAPI protocol. MAPI is defined as MAIL API a programming
interface that enables an application to send and receive mail over the Microsoft Mail
messaging system.
V0.042
May 2003
11-13
More Information
Answers to Checkpoint Questions

Checkpoint Answers
Question 1
c. 96MB
Question 2
a. IPA PWB
Question 3
a. True
Question 4
b. False
Question 5
b. False
Question 6
b. False
Question 7
b. False
Question 8
a. True
Question 9
a. True - GP34
Question 10
b. False Question 11
b. False - You will not be called if the customer orders the option when they order a new
machine.
Answers
May 2003
11-14
V0.042
Document Centre 460/470 Differences Update

Purpose
The purpose of this differences module is to familiarize you with the changes that have come
about with the release of the Document Centre 460/470, especially as it relates to the servicing
of the machine.
Reverse Image
Mirror Image
System Administrator Tools Enhancements
Disable Electronic Hole Removal (Customer Tools, System Settings, Screen 3 of 3)
Enable offset on or off within a job
Drivers PostScript Level 3 and PCL 5e
460/470 Overview
Accounting added to Windows 2000 GPD/PPD
The 460/470 is a significant upgrade to the Lakes family in terms of printing performance. The
Intel based ESS is the most significant change in the system. The 460/470 will be available as
both a Digital Copier (460 and 470 DC) and a Networked System (460 and 470ST). There will
not be a stand-alone Laser Printer (LP) model available. Both the DC and ST models will be
available at launch. As with other Document Centre products, a 460 and 470 DC can be
upgraded to a 460 or 470 ST.
Support for MAC OS 9.x Postscript Custom
Added DEC Alpha Drivers
Windows Secure Print Only Drivers
The 460/470 will have the highest performance in the Document Center family. As a family,
copy jobs print with a resolution of 600 x 600 x 8. Network print jobs have a base resolution of
600 x 600, with other resolutions available. The ST Models support Ethernet, Token Ring and
various network protocols such as TCP/IP, Novell, AppleTalk, Banyon Vines, Windows and NT.
All ST products offer multiple scanning solutions, Network FAX with RightFax and Network
Accounting with EquiTrac. Each ST comes with an embedded HTTP (Internet) server and
Xerox CentreWare Software.
IOT / ESS
Finisher Output Tray selection
NT PCL watermark / Booklet / N-up /Fit-to-oage
Windows 95/98 Postscript Booklet
PCL custom paper size
Print count to 9,999 (PostScript only)
Driver install enhancments - Retain driver settings after upgrade (Windows 95/98
PS3)
Network Connectivity
Token Ring SNAP
Support for Snap-ins in Net Management Tools:
IETF compliance (MIB-II) (Management Information Block)
The following are the major changes:
Drivers Features
ESS - New SMart Controller with Intel Processor
CA Unicentre
Faster job processing (RIP speeds)
HP Openview
Improved Tagged Image File Format (TIFF) printing performance
Tivoli
Card Cage
Microsoft Management Console Snap-In
WINS Support
The Card Cage has been redesigned to accept the new ESS PWB and Main Control
PWB.
New ESS PWB
New Main Control PWB (Atlanta Platinum 360NLX)
Addition of Card Cage Riser PWB
UI
Covers
Color change to a blue haze
LPR Print Queue Name
LPR Port Number
Internet
Network Scanning
Internet Printing Protocol (IPP) Support (v1.0)

Scan to PC Desktop: Deluxe Edition
PaperPort 6.5 Deluxe for Workgroups
IOT Lower Rear Panels
TextBridge 9.0 Business Edition
DADF
Increase paper guides height / 75 sheet capacity
Paper guides color change
L19 / Version 7.0 Software / New Features
Support for new ESS and Main Control PWB
New Copy Features:
User selectable Output Tray
Copy quantity up to 9,999
V0.042
Scan to Microsoft Exchange Public Folders
User Improvements - Improved template selection (easier scroll), UI responsiveness
Finisher
Top Tray now has 250 sheet capacity .
May 2003
11-15
What You Need to Know About the 460/470
Card Cage Changes
Service Information
Intel Based ESS
The Document Centre 460/470 is in many ways the same as a 240/255/265. The most significant change is the redesign of the Card Cage and the changes in the ESS Hardware.
The new ESS is designed around an Intel motherboard with a Celeron 366MHz processor. A 64MB DIMM is standard. The BIOS resides on the ESS motherboard. The motherboard interfaces to a Riser PWB, which provides a PCI Interface, MCB Interface, SCSI
Hard Drive Controller, and voltage regulation.
Here are the ten most important things a Customer Service Engineer needs to know about servicing a 460/470:
1.
There is a performance gain in printing due to the new ESS, there is no performance gain
in the 460/470 Digital Copier.
The new ESS uses the same operating system as before (Lynx), but the Alternate Boot
tool has changed.
2.
A new Null Modem Adaptor (113E40060) is required to service the ESS. The Intel ESS
has a serial port with the opposite gender from what the PowerPC ESS used.
10Mb and 100Mb ethernet capability are built on to the ESS PWB. Token Ring is available with a plug-in card. An IPA PWB is still a required option for Network Scanning.
3.
255 and 265 DC and STs can be converted to a 460/470 in the field.
The RJ45 Ethernet Connector on the ESS PWB has link lights that indicate network activity as well as speed (10Mb or 100Mb) (see Diagnostics).
4.
460/470 machines must run L19 or later software.
5.
100Mb ethernet capability is built-in to the Intel ESS PWB.
The IPA PWB and the Token Ring PWB are physically different from their PowerPC ESS
versions.
6.
The same EDOC is used to service the 240/255/265/460/470. The EDOC is configurable,
or the differences will be noted within the procedure.
Card Cage Riser PWB
7.
The 460 runs at 55ppm, and the 470 runs at 65ppm.
Voltage regulation and distribution
8.
The customer has the ability to disable Electronic Hole Removal, if in some rare cases,
data is being deleted.
PCI Bus for
9.
Use the Link Lights on the ESS PWB Ethernet connector to help troubleshoot connectivity
problems.
The Riser PWB contains the following functions:
Main Control PWB

ESS
IPA PWB
10. Any repair procedures involving components within the card cage have changed.
Token Ring PWB
Card Cage
May 2003
11-16
Parallel Port
Diagnostic LEDs
ESS Hard Drive Controller
V0.042
ESS DRAM
DIMM
ESS PWB
Slots Token
Ring PWB
and IPA
PWB
Card Cage Riser

PWB
Figure 1 ESS PWB

More information on the new ESS can be found in the Principles of Operation, ESS and Connectivity - Chain 16 & Chain 18.
Main Control PWB (Atlanta Platinum 360NLX)

This PWB was redesigned to accomodate the new ESS and Card Cage design. The Main
Control PWB now connects to the Riser PWB using a standard PCI edge connector. Electronic
Hole Removal was changed from a daughter card, to a SIMM type module built on to the PWB.
Access to the software and NVM modules is now through a small cover on the Card Cage.
V0.042
May 2003
11-17
Card Cage
Accessory PWB
EHR PWB
EPC SDRAM
Card Cage
The Card Cage has physically changed somewhat. There is now an outer cover that slides
over an inner support frame where the PWBs are mounted. Refer to REP 03-11 for details .
Card Cage
May 2003
11-18
V0.042
Upgrade kits are available that include all the required hardware and software to replace the
existing ESS with the Intel-based ESS. Three different kits will be available to cover the following upgrade scenarios:
NVM Module Access
Cover
An existing 255DC or 265DC can be upgraded to a 460ST or 470ST with purchase and
installation of a DC to ST Upgrade Kit.
An existing 255ST or 265ST can be upgraded to a 460ST or 470ST with the purchase
and installation of a ST to ST Upgrade Kit.
An existing 460DC or 470DC can be upgraded to a 460ST or 470ST with the purchase
and installation of a DC to ST Upgrade Kit.
Note that no upgrades are available for the following:
240DC or 240ST - There is no 4xx series 40ppm machine.
255LP or 265LP - There is no 4xx series LP machine.
255DC or 265DC to a 460DC or 470DC - There is no performance advantage in the

460DC or 470DC.
Figure 3 Card Cage
New Features
The 460/470 ST and L19 software include the Network Scanning, LAN Fax, and Job Based
Accounting features that were part of the L18 software upgrade. These features are a very
important component to the 460/470 products. If you have not yet read the L18 Differences
Update, you should do that now. It can be found here: L018/Version 6.x Differences Update
Overview.
Upgrading to a 460/470
In order to support Xerox committment to the modular, upgradable Document Centre platform,
several upgrade paths are available.
V0.042
May 2003
11-19
Card Cage
Diagnostics
Highlights of the EDOC changes:
Global Browser Variables have been renamed and moved out of the Introduction. They
now are called Browser Configuration Variables and appear at the front of the EDOC.
The Browser Configuration Variables now contain a new item called Product Identifier.
This is new in L19 software and identifies the type of machine. In L19.1 software it is
planned that this will be automatically configured when connected to a machine. In L19.0,
it must be set manually by clicking on a machine type.
16-B ESS Boot RAP has been re-written for the 460/470.
18-A Network Entry RAP revised for 460/470
GP22 , Connecting to the ESS Serial Port has been re-written for the 460/470.
GP23 , Accessing the Alternate Boot Menu has been re-written for 460/470
Some diagnostic tests that were part of the firmware in the old ESS are no longer available (watchnet, testnet)
GP35 , ESS Memory Test has been re-written for the 460/470.
GP37 , Accessing the ESS Diagnostic Menu is new for the 460/470.
The RJ45 Ethernet Connector on the ESS PWB has link lights that indicate network activity as well as speed (10Mb or 100Mb).
GP38 , Accessing ESS POST Results is new for the 460/470.
PL 1.3C has been added for the new ESS
PL 1.4C has been added for the new Atlanta Platinum 360 NLX Main Control PWB
Principles of Operation for the ESS and Connectivity - Chain 16 & Chain 18 has been
updated to include the 460/470.
Diagnostics Changes
The 460/470 and L19 software did not bring about drastic changes in diagnostics. The one
area that was affected is the ESS Alternate Boot Tool.
Listed below are some of the changes that are evident in the 460/470:
Procedures for running ESS Alternate Boot Tool have changed. Refer to GP23 .
ESS POST results are no longer seen during ESS boot. Results are stored and accessed
through a diagnostics menu using Alternate Boot. See GP38 .
To connect to the ESS Serial port requires a different type null modem connector (gender
change).
The ESS will auto-configure to the highest speed (can be set manually in Connectivity and Network Setup)
There are green and amber LEDs on the connector indicate the following LAN conditions
Table 1 RJ-45 LAN Connector LEDs
LED Color
LED State
Indicates
Green
Off
10Mb/sec speed
selected
Green
On
100Mb/sec speed
selected
Amber
Off
LAN link is not

established
Amber
On (Steady State)
LAN link established
Amber
On (Brighter and
pulsing)
The ESS is communicating with

another device on
the LAN
Procedure for Running ESS Memory Test has changed. See GP35 .
EDOC Updates for the 460/470

In support of the 460/470, the EDOC has been updated to include new and updated RAPs,
repairs, parts lists and other procedures.
Click on the links below to view the new or revised procedures.
Diagnostics
May 2003
11-20
V0.042

Checkpoint Questions
Question 1
The DADF sheet capacity is now ____ sheets?
c.
45/55 ppm.
d.
55/65 ppm

Question 7
a.
40
What is the most significant improvement in the 460/470?
b.
50
a.
UI Color change
c.
75
b.
75 Sheet DADF Capacity
d.
100
c.
A printing performance gain enabled by the Intel ESS.
d.
Faster copying speeds

Question 2
100Mb ethernet capability is available with an add-on PWB.

Question 8
a.
True
What new tool is necessary to service the 460/470?
b.
False
a.
A new style null modem adaptor
b.
Fluke Network Analyzer

Question 3
A 265DC can be upgraded to a 470ST in the field.
a.
True
b.
False

Question 4
c.
Celeron Ionizer
d.
Photon Counter

Question 9
What version of software does the 460/470 have?
a.
L18.2 / v6.8
b.
L19.0 / v7.0
The IPA PWB is no longer needed for Network Scanning in the 460/470..
c.
Any 240/255/265 release
a.
True
d.
L24 / v12
b.
False

Question 5
What is the purpose of the Link Lights on the ESS PWB?
a.
They look impressive in the dark.
b.
They indicate network activity and speed (10Mb or 100Mb) at the ethernet port.
c.
They verify Token Ring operation.
d.
To keep the Link illuminated

Question 6
What are the speeds of the 460/470?
a.
60/70 ppm
b.
46/47 ppm
V0.042
Question 10
What would you do if customer complained about deletions on certain documents copied from
DADF in the area where hole punches might be?
a.
Replace Xerographic Module
b.
Clean the CVT Glass
c.
Show customer how to disable Electronic Hole Removal in Customer Tools, System Settings
d.
Tell customer to rotate the document and cough

Question 11
What change was made to the DADF?
a.
Sped up to 120 ppm
b.
New retard roll material
May 2003
11-21
c.
Capacity increased to 75 sheets
d.
Trimmed 4 inches off the top
Answers to Checkpoint Questions

Checkpoint Answers
Question 1
c. 75 Sheets
Question 2
b. false
Question 3
a. true
Question 4
b. false
Question 5
b. Indicates network activity and speed at ethernet port
Question 6
d. 55/65 ppm
Question 7
c. A printing performance gain enabled by the Intel ESS
Question 8
a. New style null modem adaptor
Question 9
b. L19.0 / v7.0
Question 10
c. Show customer how to disable Electronic Hole Removal in Customer Tools
Question 11
c. Capacity increased to 75 sheets
Check Your Knowledge, Answers to Checkpoint
May 2003
11-22
V0.042
Smart Tray Finisher
To change the settings for thin stapled sets, enter [Tools]. In Tools, select [System Settings],
[More], [More] to get to Screen 3 of 3. In Screen 3, select [Output Options], then select [Thin
Stapled Sets].
Finisher Improvements
The following are improvements in the Document Centre 460/470 Smart Tray Finisher.
There are 2 settings that can be changed by the customer:
NOTE: A Smart Tray is identified by the product code NF3.

NOTE: A Smart Tray requires the installation of 19.01.503 software or higher.
A Top Tray capacity of 250 sheets (200 sheets for 5.5 in x 8.5 in (A5) paper).
A Main (Stacker) Tray capacity of 100 thin stapled sets.
Increased number of stapling options.
Portrait Staple Mode 8.5 x 14 in (SEF)
Dual Staple Mode A4 (SEF)
Dual Staple Mode 8 in x 10 in (LEF)
Dual Staple Mode B5 (LEF)
Dual Staple Mode A5 (LEF)

Capstan Driven Tamper - reduced noise
Redesigned Set Separator
Collapsible Kicker - allows staple positioning for landscape dual staple
Number of sheets in Thin Stapled Set. This can be 5 to 20 sheets.

Number of Thin Sets before Finisher Tray unload. This can be 20 to 1000 sets. The
maximum recommended is 100. If greater than 100 is selected, set registration problems
may occur.
Stacker Tray Offsetting

The Offset Home Sensor detects a flag attached to the tray. There are 3 slots in the flag. This
provides 4 positions for the Main Tray.
Position A - Home (Outboard)
Position B - 22mm from home
Position C - 40.8mm from home
Position D - 62.8mm from home
For all jobs except 8.5 x 11" SEF and 8.5 x 14" Portrait Staple Mode, only 2 positions, A and B,
are used (Refer to Figure 1):
Service Tray Improvements.
If the tray is in Position A at the start of the job, the Offset Motor is energized to move the
tray to Position B where the first set is compiled/stapled then ejected. The tray then
moves to Position A for the next job. The tray offsets between Position A and Position B
If the tray is in Position B at the start of the job, the Offset Motor is energized to move the
tray to Position A where the first set is compiled/stapled then ejected. The tray then
moves to Position B for the next job. The tray offsets between Position A and Position B
Finisher Transport Baffle Improvements.
For 8.5 x 11" SEF and 8.5 x 14" Portrait Staple Mode, all 4 offsetting positions are used (Refer
to Figure 2):
Nip1/Nip 3 Idler cover
The tray moves from Position A or Position B to Position D to compile the first set.
Magnets replaced by weights
The tray then moves outboard to Position B where the set is stapled and ejected.
Top Tray
For the next set, the tray moves to Position C to compile the set.
The customer has the option to select where unstapled copy and print sets will be sent by
default. They may either be sent to the Top Tray or the Main Tray of the Finisher. Because of
this customer option, the Top Tray has been redesigned to reliably stack up to 250 copies. The
capacity is slightly less, 200 sheets, for 8.5 in x 5.5 in (A5) paper.
The tray then moves outboard to Position A where the set is stapled and ejected
The output (the completed, stapled sets) in this mode are placed in Position A and Position B as are all other sets following the above sequence.
When this mode is complete the tray will resume its normal operation using only Position
A and Position B for offsetting.
To change the default location for unstapled sets, enter [Tools]. In Tools, select [System Settings], [More], [More] to get to Screen 3 of 3. In Screen 3, select [Output Options], then select
[Output Location].
Main Tray Thin Stapled Set Capacity

The Stacker Tray has been redesigned to provide greater staple relief than the Document
Centre 240/255/265 Finisher. A magnet has been incorporated into the tray that ensures the
stapled corner of single-stapled sets are at or below the level of the rest of the set. This
increases to 100 sets the maximum number of thin stapled sets the Stacker Tray can reliably
stack.
Main Tray Offset / Position Diagnostic routine

The 4 test types are:
Single Step: Steps the tray to the next position when [Continue] is selected. Position
sequence is A to B, B to C, C to D, D to A and repeats.
Continuous Cycle: Steps the tray continuously when [Continue] is selected. The tray
pauses for .5 seconds at each position. The tray stops when Stop is selected.
V0.042
May 2003
11-23

Smart Tray Finisher

repeats.
Tray Home Position: At the start of the Single or Continuous test, selecting [Start] will
cause the tray to move to the Home position (position A). After arriving at Home, the button will change from [Start] to [Continue].
Sensor Monitor: The state of the Stacker Tray Offset Sensor will be monitored at all
times except while continuous mode is running.
How to Run the Main Tray Offset / Position Test

1.
On test entry, the system will read and display the state of the Stacker Tray Offset Sensor.
2.
Select [Single] or [Continuous] test
3.
If using Continuous test, select [Mode 1] (2 position) or [Mode 2] (4 position).
4.
Select [Start]. Stacker Tray will move to the Home position.
5.
When Home is complete, [Start] button will change to [Continue].
6.
Select [Continue] to begin positioning.
7.
8.
If using Continuous mode, tray will continue stepping until [Stop] is selected.
To run this test, in Diagnostic Navigator, select [Finisher], [Finisher Tests], [Main Tray/Offset
Position].
Figure 1 All jobs except 8.5 x 11" SEF and 8.5 x 14" Portrait Staple Mode
Smart Tray Finisher
May 2003
11-24
V0.042
Figure 2 8.5 x 11" SEF and 8.5 x 14" Portrait Staple Mode
Service Tray
In the Capstan Driven Tamper, the gear on the Tamper Motor and the gear rack on the Tamper
Arm have been replaced by the Tamper Arm Drive Cable and the Tamper Capstan. This was
done to reduce the noise generated during Tamper initialization and Tamper operation. The
Tamper operation is the same as the operation of the gear driven Tamper.
The Finisher Set Separator has been redesigned to improve set-to-set registration.
The Kicker now has a Collapsible Kicker Arm that enables the Moving Stapler a greater range
of movement. This was needed for the correct placement of staples when dual stapling on
landscape (SEF) sets and single stapling on landscape (SEF) sets.
The Canard Wing is now mounted to the Retractable Registration Edge. The Canard Wing is
raised during the portrait staple mode reducing the posibility of the stapled set being misregistered.
V0.042
May 2003
11-25
Smart Tray Finisher
Capstan Driven Tamper
Tamper Arm
Drive Cable
Tamper
Capstan
Tamper Motor
Figure 3 Finisher Service Tray - rear view
Smart Tray Finisher
May 2003
11-26
V0.042

Canard Wing
A cover for the Nip 1 idlers and Nip 3 Idlers has been added to prevent the idlers from becoming dislodged during jam clearance. This change has also been incorporated into the Document Centre 240/255/265/460/470. When a Finisher Transport Baffle is ordered, it will have
this new cover.
The magnets that secured the Finisher Transport Baffle in the correct position against the Exit
Baffle have been removed. The Finisher Transport Baffle is now held in the correct position by
weights that are located just to the left of the Area 5 handle.
Document Centre DCE Finisher

NOTE: DCE is the product code for the common 460/470/480/490 Smart Tray Finisher.
The key differences between the NF3 Finisher and the DCE Finisher are:
The Finisher Controller PWB firmware has been changed to support the 90 PPM timing
algorith and the two Turbo staplers.
Turbo configuration Moving Stapler . The stapler has a faster cycle time, enabling it to
operate with 90 PPM machines.
Turbo configuration Fixed Stapler. The stapler has a faster cycle time, enabling it to operate with 90 PPM machines.
In late 2001, the DCE Finisher will be available for use on Document Centre 460/470 machines
that have been upgraded to 07.19.02.0xx software.

Collapsible Kicker Arm
Figure 4 Set Separator and Collapsible Kicker
V0.042
May 2003
11-27
Smart Tray Finisher
Smart Tray Finisher
May 2003
11-28
V0.042

The 19.02 software upgrade enhances the Network Scanning option and adds other features.
For additional information, refer to the Document Centre Reference Guide or CentreWareTM
Getting Started with Network Services booklet in the customer literature folder of your documentation CD.
Added Network Scanning Functionality

The 19.02 software provides the following functionality, if the Document Centre already has
Network Scanning Services installed:
Walk-up e-mail addressing at the Document Centre user interface.
The ability to scan directly to the mail server via Simple Mail Transfer Protocol (SMTP).
This eliminates the need for Centre Ware Scanning Distribution Service.
The ability to look up e-mail addresses in global or public address lists via Lightweight
Directory Access Protocol (LDAP).
User Authentication, which optionally enables the Document Centre to require user login
in order to access the Network Scanning, E-mail, and Fax functions.
The ability to create Data Management Fields inside individual scan templates.
The ability to add up to 4 altemate scan repositories.
The ability to scan ahead multiple jobs.
Other Features
Enhancements to CentreWareTM Print Services/Scan Services/ Admin Services.
User-defined font downloading.
Extended compliance with industry networking standards.
Copy feature enhancements:
Build Job:
sample last segment
delete/re-scan last segment
Scan to file:
scan direct to PDF
edge/border erase
Smart-tray finisher:
stack up to 100 small sets
legal/landscape top-left stapling
V0.042
May 2003
11-29
May 2003
11-30
V0.042

DocumentCentre 240 - 255 - 265 - 460 - 470 - DT65 - DP65 (SM, PC)

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Document Centre 240/255/265/460/470 DT65/DP65

About This Documentation

Service Documentation Sections

The Document Centre 240/255/265/460/470 DT65/DP65 Service Documentation is part of the

The Document Centre 240/255/265/460/470 DT65DP65 Service Documentation is the primary

The Document Centre 240/255/265/460/470 DT65/DP65 documentation contains information

Section 1 Service Call Procedures

Section 2 Status Indicator Repair Analysis Procedures

Service Documentation Revisions

Section 3 Image Quality Repair Analysis Procedures

How To Use This Documentation

Section 5: PARTS LIST

Section 7: WIRING DATA

Section 3: IMAGE QUALITY RAPs

Wirenet drawings of power distribution networks in the machine.

Section 10: PRINCIPLES OF OPERATION

115 VAC 60Hz

103.5 to 126.5 VAC

200 VAC 50Hz

180 to 220 VAC

220 VAC 50Hz

198 to 242 VAC

230 VAC 50Hz

207 to 253 VAC

240 VAC 50Hz

216 to 264 VAC

+5.05 VDC TO +5.25 VDC

+11.4 VDC TO +12.6 VDC

Table 1 Voltage Measurement and Specifications

-11.4 VDC TO -12.6 VDC

+22.8VDC TO +25.2 VDC

+34.2 VDC TO +37.8 VDC

Logic Voltage Levels

Table 2 Logic Levels

H= +3.00 TO +5.25 VDC, L=

H= +23.37 TO +27.06 VDC,

Test Point, Test Hole, Test Stake

DC Voltage Measurements in RAPs

There is +5 VDC from TP7 to TP68.

Another example of a statement found in a RAP might be:

There is -15 VDC from TP21 to TP33.

Example 2). Check the Bottle Sensor (FX Only)

Terminology and Symbols

Additional Product Safety Information

Warning, Cautions, and Notes

Electrostatic Discharge (ESD) Field Service Kit

Example 1). Tag xx: PWB . . .

Example 2) PWB (Tag xx) . . .

is used to show a Tag change has modified an area of the terminal.

points to the location to install, to gain access to, or to release an object.

How to use this documentation

DANGER: Mettre la machine sur Arrt et dbrancher le cble d'alimentation de la prise

09-338 Electrostatic Setup Convergence Failure

Improper operation may result in injury to a person.

Additional Product Safety Information

DANGER: Mettre la machine sur Arrt et dbrancher le cble d'alimentation de la prise

Status Indicator RAPs

12-115 LE Late to the Top Tray Exit Sensor RAP

12-232 Eject Housing Home Fault RAP

12-117 TE Late to the Finisher Entrance Sensor RAP

DANGER: Faire attention en excutant ces tests. Les sous-ensembles du module de

12-233 Stapler Transport Home Fault RAP