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THE DOCUMENT COMPANY 
XEROX 



DocuColor 1632/2240 Service 
Manual 

Prelaunch CSE Training/Review 




701 PXXXXX 
June 17, 2002 



/fc^ 



CAUTION 

Certain components in the DocuColor 1632/2240 are 
susceptible to damage from electrostatic discharge. 
Observe all ESD procedures to avoid component 
damage. 



Prepared by: 

Xerox Corporation 

Global Knowledge & Language Services 

800 Phillips Road Bldg. 845-1 7S 

Webster, New York 14580-9791 

USA 



©2002 by Xerox Corporation. All rights reserved. Copyright protection 
claimed includes all forms and matters of copyrightable material and infor- 
mation now allowed by statutory or judicial law or hereinafter granted, 
including without limitation, material generated from the software programs 
that are displayed on the screen such as styles, templates, icons, screen 
displays, looks, etc. 

***XEROX DocuLock Protect Until Forever*** 
XEROX/E The Document Company/^ the stylized X and the identifying 
product names and numbers herein are trademarks of XEROX CORPORA- 
TION. Other company trademarks are also acknowledged. 

NOTICE 

While every care has been taken in the preparation of this manual, no liabil- 
ity will be accepted by Xerox Corporation arising out of any inaccuracies or 
omissions. 

NOTICE 
All service documentation is supplied to Xerox external customers for infor- 
mational purposes only. Xerox service documentation is intended for use by 
certified product trained service personnel only. Xerox does not warrant or 
represent that such documentation is complete, nor does Xerox represent 
or warrant that it will notify or provide to such customer any future changes 
to this documentation. Customer performed service of equipment, or mod- 
ules, components or parts of such equipment may affect the warranty 
offered by Xerox with respect to such equipment. You should consult the 
applicable warranty for its terms regarding customer or third party provided 
service. If the customer services such equipment, modules, components or 
parts thereof, the customer releases Xerox from any and all liability for the 
customer actions, and the customer agrees to indemnify, defend and hold 
Xerox harmless from any third party claims which arise directly or indirectly 
from such service. 



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 inter- 
ference 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 cor- 
rect the interference. 

DANGER: Cet Equipement g En Ere, utilise et peut Emettre des frEquences radio, et, s'il 
n'est pas installEet utilisEselon les recommandations du manuel d'instructions, peut 
causer des interfErences aux communications radio. II a EtEtestEet jugEconforme aux 
limites des systEmes de catEgorie A, conformEment $ la partie 15 de I'alinEa J des rEgle- 
ments FCC, Etablis pour protEger contre de telles interfErences pendant le fonctionne- 
ment en milieu commercial. Dans une zone rEsidentielle, il peut causer des 
interfErences; dans ce cas, I'utilisateur devra corriger le problEme $ ses propres frais. 

WARNING 

This machine contains an invisible laser. There is no visual indication that the laser 
beam is present. During servicing, the machine is a Class 3B product because of the 
invisible laser, the laser beam could cause eye damage if looked at directly. Service pro- 
cedures must be followed exactly as written without change. The service representative 
must observe the established local laser safety precautions when servicing the 
machine. Do not place tools with a reflective surface into the ROS opening. Do not look 
in the area of the ROS window if the power is On and the laser is energized. 
DANGER: L'Equipement contient un faisceau laser invisible et aucune indication visible 
signale la prEsence du faisceau laser. De ce fait le produit est classE 3B pour tout ce qui 
concerne la maintenance. L'exposition directe des yeux au faisceau laser peut entradker 
des lEsions visuelles. Les procedures de maintenance doivent I tre rEalisEes sans 
aucun changement comme indiquEdans la documentation. Le reprEsentant Xerox lors 
d'interventions sur I'Equipement doit respecter les consignes de sEcuritE locales con- 
cernant les faisceaux laser. Ne pas placer d'objet rEflEchissant dans la zone du ROS 
quand il est ouvert. Ne pas regarder dans la zone du ROS lorsque la machine est sous 
tension et que le laser est en fonctionnement. 



Introduction 



About this Manual 

Organization 

How to Use this Documentation. 
Symbology and Nomenclature ... 
Translated Warnings 



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Introduction 



Introduction 6/02 Prelaunch Training/Review 

2 DC1 632/2240 



About this Manual 

This Service Manual is part of the multinational documentation system for DocuColor 1632/ 
2240 copier/printers. The Service Documentation is used in order to diagnose machine mal- 
functions, adjust components and has information which is used to maintain the product in 
superior operating condition. It is the controlling publication for a service call. Information on its 
use is found in the Introduction of the Service Documentation. 

This manual contains information that applies to NASG and ESG copiers. 

Service Manual Revision 

The Service Manual will be updated as the machine changes or as problem areas are identi- 
fied. 



Organization 



This Service Manual is divided into seven sections. The titles of the sections and a description 
of the information contained in each section are contained in the following paragraphs: 

Section 1 Service Call Procedures 

This section contains procedures that determine what actions are to be taken during a service 
call on the machine and in what sequence they are to be completed. This is the entry level for 
all service calls. 

Section 2 Status Indicator RAPs 

This section contains the diagnostic aids for troubleshooting the Fault Code and non-Fault 
Code related faults (with the exception of copy quality problems). 

Section 3 Image Quality 

This section contains the diagnostic aids for troubleshooting any copy quality problems, as well 
as copy quality specifications and copy defect samples. 

Section 4 Repairs/ Adjustments 

This section contains all the Adjustments and Repair procedures. 

Repairs 

Repairs include procedures for removal and replacement of parts which have the following 
special conditions: 

When there is a personnel or machine safety issue. 

When removal or replacement cannot be determined from the exploded view of the 

Parts List. 

When there is a cleaning or a lubricating activity associated with the procedure. 

When the part requires an adjustment after replacement. 

When a special tool is required for removal or replacement. 
Use the repair procedures for the correct order of removal and replacement, for warnings, cau- 
tions, and notes. 



Adjustments 

Adjustments include procedures for adjusting the parts that must be within specification for the 
correct operation of the system. 

Use the adjustment procedures for the correct sequence of operation for specifications, warn- 
ings, cautions and notes. 

Section 5: Parts Lists 

This section contains the Printer/Copier Parts List. 

Section 6: General Procedures/Information 

This section contains General Procedures, Diagnostic Programs, and Copier Information. 

Section 7: Wiring Data 

This section contains drawings, lists of plug/jack locations, and diagrams of the power distribu- 
tion wire networks in the machine. Individual wire networks are shown in the Circuit Diagrams 
contained in Section 2. This section also contains the Block Schematic Diagrams. 

How to Use this Documentation 

The Service Call Procedures in Section 1 describe the sequence of activities used during the 
service call. The call must be entered using these procedures. 

Use of the Circuit Diagrams 

Circuit Diagrams (CDs) are included in Sections 2 (Status Indicator RAPs) and 3 (Image Qual- 
ity RAPs) of the Service Manual. All wirenets, with the exception of power distribution wirenets, 
are shown on the CDs. Power distribution wirenets are shown in Section 7 (Wiring Data) of the 
Service Manual. The power distribution wirenets on the CDs will end at the terminal board for 
the power being distributed. Find the wirenet for that power and locate the terminal board on 
the wirenet. Use the wirenet to troubleshoot any power distribution wiring not shown on the 
CD. 

Use of the Block Schematic Diagrams 

Block Schematic Diagrams (BSDs) are included in Section 7 (Wiring Data) of the Service Man- 
ual. The BSDs show the functional relationship of the electrical circuitry to any mechanical, or 
non-mechanical, inputs or outputs throughout the machine. Inputs and outputs such as motor 
drive, mechanical linkages, operator actions, and air flow are shown. The BSDs will provide an 
overall view of how the entire subsystem works. 

It should be noted that the BSDs no longer contain an Input Power Block referring to Chain 1. It 
will be necessary to refer to the Wirenets in order to trace a wire back to its source. 

Symbology and Nomenclature 

The following reference symbols are used throughout the documentation. 



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Introduction 



Warnings, Cautions, and Notes 

Warnings, Cautions, and Notes will be found throughout the Service Documentation. The 
words WARNING or CAUTION may be listed on an illustration when the specific component 
associated with the potential hazard is pointed out; however, the message of the WARNING or 
CAUTION is always located in the text. Their definitions are as follows: 

WARNING 

A Warning is used whenever an operating or maintenance procedure, a practice, condi- 
tion, or statement, if not strictly observed, could result in personal injury. 

CAUTION 

A Caution is used whenever an operating or maintenance procedure, a practice, condition, or 
statement, if not strictly observed, could result in damage to the equipment. 

NOTE: A Note is used whenever it is necessary to highlight an operating or maintenance pro- 
cedure, practice, condition, or statement. 

Machine Safety Icons 

The following safety icons are displayed on the machine: 



CAUTION 

The use of controls or adjustments other than those specified in the Laser Safety Training Pro- 
gram may result in an exposure to dangerous laser radiation. 
For additional information, review the Laser Safety Training program. 

An arrow points to the location to install, to gain access to, or to release an object. 



* 



Figure 2 Customer Access Label 

This symbol indicates that a surface can be hot. Use caution when reaching in the machine to 
avoid touching the hot surfaces. 



WARNING 

This machine contains an invisible laser. There is no visual indication that the laser 
beam is present. During servicing, the machine is a Class 3B product because of the 
invisible laser, the laser beam could cause eye damage if looked at directly. Service pro- 
cedures must be followed exactly as written without change. The service representative 
must observe the established local laser safety precautions when servicing the 
machine. Do not place tools with a reflective surface in the area of the ROS opening. Do 
not look in the area of the ROS window if the power is On and the laser is energized. 
The following symbol and statement appear on a label in the machine. The symbol by 
itself, or the symbol and the statement may also appear in the service documentation 
and in the training program. When this symbol appears, the service representative is 
warned that conditions exist that could result in exposure to the laser beam. 

WARNING 

Do not try to bypass any laser interlocks for any reason. Permanent eye damage could 
result if the laser is accidentally directed into your eye. 



Figure 1 Laser Hazard Symbol 



Laser Hazard Statement 



DANGER INVISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO 
BEAM. 



Figure 3 Heated Surface Label 

Danger label indicates where electrical currents exist when the machine is closed and operat- 
ing. Use caution when reaching in the machine. 



A 



Figure 4 Shock Hazard Label 

These symbols indicate components that may be damaged by Electrostatic Discharge (ESD). 



^A <k 



Figure 5 ESD warning Label 



0700002A-RAP 



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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 ESD Field Service Kit 
Usage in the General Procedures section of the Service Documentation. 

Illustration Symbols 

Figure 6 shows symbols and conventions that are commonly used in illustrations. 



REFERENCE SYMBOLOGY 

Test data, notes, adjustments, and parts lists are 
supportive to the BSD and RAP information. This 
supportive data is referenced, using the symbols 
shown in the following paragraphs: 



TEST DATA 



NOTES 



<D 



ADJUSTMENTS 



PARTS LISTS 

PL2-XX 



This symbol appears on the BSD 
whenever a test data reference is 
necessary in order to verify the 
presence of a signal. 



This symbol is used to refer to notes. 
The notes normally appear on the 
same page. 



This symbol refers to adjustments on 
the Service Data Section. 



TEST POINTS 

TP1 



X- 



This symbol is used to identify a test 
point/test hole available for 
measuring a signal. 



BSD GRAPHICS 



^ 



[ x-xxx ] 



[ x-xxx ] [ x-xxx ] 



This symbol refers to a parts list on 
the Service Data Section. 
PL indicates that this is a parts list 
reference and, in this example, the 
exploded view drawing is on Parts 
List 2-XX. Parts list reference appear 
on the BSDs next to all replaceable 
parts shown on the diagram. 



A\ This symbol indicates the 

continuation of a signal line in a 



K 



■4 



vertical direction. 



This symbol indicates the 
continuation of a signal line in a 
horizontal direction. 

This symbol indicates the direction 
of signal flow. 



[ x-xxx/x-xxx ; 



-4^ — This symbol indicates a feedback 
signal. 



JtTL 



This symbol is used to show a twisted 
pair of wires. 



r<n 



This symbol placed above a signal 
name on a BSD indicates the input or 
output component control code for 
that signal. 

This symbol placed above a signal 
name on a BSD indicates that two 
component control codes ( an output 
and an input ) are required to check 
that signal. 



This symbol placed above a signal 
name on a BSD indicates component 
control codes for two components, 
in this example, two Paper Trays. 
The left hand code is for Paper Tray 
1, and the right hand code is for 
Paper Tray 2. 

Fault Codes Indicator 
shown on BSD. 



The Flag symbol indicates a reference 
point into a Circuit Diagram from a RAP. 

Instructions will be given to check for 
an open circuit, a short circuit, 

or an intermittent condition 



Figure 6 Illustration Symbols 



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Introduction 



Signal Nomenclature 

Refer to Figure 7 for an example of Signal Nomenclature used in Circuit Diagrams and BSDs. 



FEED CLUTCH ON ( L I *2< VDC 



LOGIC STATE 
WHEN SIGNAL 
IS AVAILABLE 



LOGIC VOLTAGE 

WHEN SIGNAL 

IS AT HIGH STATE 



SOME SIGNALS MAT BE IN THE I H J 
STATE WHEN THEY ARE AVAILABLE 



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: 

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. 
Another example of a statement found in a RAP might be: 
There is -15 VDC from TP21 to TP33. 



INTERLOCK SENSOR LED ( _TL. > 



SIGNAL NAME 



INDICATES THAT 
THE SIGNAL IS 
PULSED INFORMATION 



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. 



Figure 7 Signal Nomenclature 
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 volt- 
age should be made with respect to the adjacent return or ACN wire. 

Table 1 Voltage Measurement and Specifications 



VOLTAGE 


SPECIFICATION 


INPUT POWER 220 V 


198 VAC TO 242 VAC 


INPUT POWER 100 V 


90 VAC TO 135 VAC 


INPUT POWER 120 V 


90 VAC TO 135 VAC 


+5 VDC 


+4.75 VDC TO +5.25 VDC 


+24 VDC 


+23.37 VDC TO +27.06 VDC 



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 Logic Levels 



VOLTAGE 


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 



Introduction 



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Translated Warnings 



Prelaunch Training/Review g^ 2 Introduction 

DC1 632/2240 vii 



Introduction 

Symbology and Nomenclature 

WARNING 

A Warning is used whenever an operating or maintenance procedure, a practice, condi- 
tion, or statement, if not strictly observed, could result in personal injury. 
DANGER: Une note DANGER est utilisEe $ chaque fois qu'une procEdure de mainte- 
nance ou qu'une manipulation prEsente un risque de blessure si elle n'a pas EtEstricte- 
ment observEe. 

WARNING 

This machine contains an invisible laser. There is no visual indication that the laser 
beam is present. During servicing, the machine is a Class 3B product because of the 
invisible laser, the laser beam could cause eye damage if looked at directly. Service pro- 
cedures must be followed exactly as written without change. The service representative 
must observe the established local laser safety precautions when servicing the 
machine. Do not place tools with a reflective surface in the area of the ROS opening. Do 
not look in the area of the ROS window if the power is On and the laser is energized. 
DANGER: L'Equipement contient un faisceau laser invisible et aucune indication visible 
signale la prEsence du faisceau laser. De ce fait le produit est classE3B pour tout ce qui 
concerne la maintenance. L'exposition directe des yeux au faisceau laser peut entraffier 
des lEsions visuelles. Les procedures de maintenance doivent Itre rEalisEes sans 
aucun changement comme indiquE dans la documentation. Le reprEsentant Xerox lors 
d'interventions sur I'Equipement doit respecter les consignes de sEcuritE locales con- 
cernant les faisceaux laser. Ne pas placer d'objet rEflEchissant dans la zone du ROS 
quand il est ouvert. Ne pas regarder dans la zone du ROS lorsque la machine est sous 
tension et que le laser est en fonctionnement. 

The following symbol and statement appear on a label in the machine. The symbol by 
itself, or the symbol and the statement may also appear in the service documentation 
and in the training program. When this symbol appears, the service representative is 
warned that conditions exist that could result in exposure to the laser beam. 
DANGER: Les symboles et instructions suivants sont indiquEs sur des Etiquettes dans 
la machine et sont identifiEs dans la documentation technique et dans le manuel de for- 
mation. Quand ces symboles s'affichent le reprEsentant Xerox est prEvenu des risques 
encourus concernant une exposition au rayon laser. 

WARNING 

Do not try to bypass any laser interlocks for any reason. Permanent eye damage could 
result if the laser is accidentally directed into your eye. 

DANGER: Ne pas essayer de shunter les contacts laser pour quelques raisons que ce 
soit. Si le faisceau laser est dirigEaccidentellement vers les yeux il peut en rEsulter des 
lEsions oculaires permanentes. 

3 Image Quality 

IQ6 IOT Background RAP 

WARNING 
HIGH VOLTAGE! 
DANGER: HAUTE TENSION! 

Exercise care when making the voltage check in the following steps. 
DANGER: Soyez extrl mement vigilant lorsque vous effectuez les tests de tension au 
cours des Etapes qui suivent. 



IQ21 Developer Bias RAP 

WARNING 
HIGH VOLTAGE! 
DANGER: HAUTE TENSION! 

Exercise caution when performing the voltage checks in this procedure. 
DANGER: Soyez extrl mement vigilant lorsque vous effectuez les tests de tension au 
cours de cette procEdure. 

4 Repairs and Adjustments 
Electrical 

REP 1.1 3.3/5 V LVPS Bracket 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP1.2MCU PWB 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 1.3 ESS Chassis 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 1.4 3.3 V LVPS or 5 V LVPS 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 1.5 24 V LVPS 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 



Introduction 



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DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 1.6 T5 T7 HVPS Chassis 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 1 .7 T5 or T7 High Voltage Power Supplies 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 1.8 l/F (Interface) PWB 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 1.9 24 VLVPS Bracket 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 1.10 HVPS T6 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 1.11 AC Drive PWB 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 



the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 1.12 ESS PWB 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 1.13 ESSNVMPWB 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

Main Drives 

REP 4.1 Main Drive Motor Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 4.2 IBT Motor 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 4.3 Developer Drive Motor 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 4.4 Drum Motor Assembly 



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WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

Document Handler 

REP 5.1 DADF 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.2 Registration Gate Solenoid 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.3 Left/Right Counterbalance 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.4 DADF Control PWB 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.5 Feed Motor Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 



REP 5.6 Nudger Roll 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.7 Feed Roll Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.8 Lower Chute Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.9 Retard Roll 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.10 Set Gate Solenoid Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.11 Registration Sensor 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 



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d'alimentation branchE. 

REP 5.12 Size Sensors 1/2 (Rear/Front) 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.13 DADF Belt Motor Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.14 Duplex Sensor 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.15 Registration Pinch Roll 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.16 Exit Motor Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.17 Document Transport 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 



activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 5.18 Rear Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 5.19 Platen Belt 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

WARNING 

Switch off the power and disconnect power cord. 

DANGER: Mettre la machine sur Arrl t et dEbrancher le cordon d'alimentation. 

Imaging 

REP 6.1 ROS 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 6.2 Platen Glass 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 6.3 NT Top Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 



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REP 6.11 Carriage Cables 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 6.12 Carriage Motor 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 6.13 Exposure Lamp 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 6.14 Lamp Wire Harness 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

Paper Trays 

REP 7.1 Tray 5 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 7.2 Tray 5 Feed Roll 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 



activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 7.3 Tray 1 Feeder 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 7.4 Tray 1 Feed/Lift Motor 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 7.5 Tray 1 Paper Size Sensor 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 7.6 Tray 3 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 7.7 Tray 4 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 7.8 Tray 1 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 



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DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 7.9 Tray 2 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 7.10 Tray 2 Feeder 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 7.11 Tray 3 Feeder 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 7.12 Tray 4 Feeder 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

Paper Feed and Registration 

REP 8.1 Left Cover Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 8.2 Duplex Chute 

WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 8.3 Duplex Transport Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 8.5 Inverter Transport 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 8.6 Registration Transport Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 8.7 Exit Transport Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

Xerographic 

REP 9.1 Drum Cartridge 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.2 ROS Shutter Motor 



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Introduction 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.3 Waste Toner Cartridge Cover 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.9 Developer Housing 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.4 Waste Toner Cartridge 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.10 Developer 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.5 Full Toner Sensor 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.11 Toner Dispenser Base Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.6 Inner Cover 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.12 IBT Steering Drive Assembly 



WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 
REP 9.7 Toner Dispenser 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.13 Agitator Motor Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 9.8 Plate Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 9.14 MOB Sensor Assembly 



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WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.15 IBT Belt Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.21 Left Lift Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.16 IBT Cleaner Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.22 Transfer Belt 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.17 Auger Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.23 1st BTR Roll 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.18 Lever 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.24 2nd BTR Roll 



WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 
REP 9.19 Left Hinge/Right Hinge 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 9.26 ATC Sensor 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 9.20 Right Lift Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

Fuser 



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REP 10.1 Fuser 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

WARNING 

Personal injury may result from grasping hot areas of Fuser Module. If a hot Fuser Mod- 
ule must be removed, grasp Fuser Module by black plastic frame component, shown in 
figure (Figure 1). 

DANGER: Des blessures peuvent rEsulter si les zones chaudes du module de four sont 
touchEes. Si un module de four chaud doit I tre enlevE, le saisir par I'EIEment en plas- 
tique noir du b, ti, montrEsur la figure (Figure 1). 

WARNING 

If machine was making copies within 30 minutes, Fuser Module is hot. Grasp Fuser 
Module using Grip Rings. 

DANGER: Si moins de 30 minutes se sont EcoulEes depuis le dernier tirage de copies, le 
module de four est chaud. Saisir ce module par les demi-cercles en plastique noir. 

REP 10.2 Fuser Fan 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

WARNING 

Personal injury may result from grasping hot areas of Fuser Module. If a hot Fuser Mod- 
ule must be removed, grasp Fuser Module by black plastic frame component, shown in 
figure (Figure 1). 

DANGER: Des blessures peuvent rEsulter si les zones chaudes du module de four sont 
touchEes. Si un module de four chaud doit I tre enlevE, le saisir par I'EIEment en plas- 
tique noir du b, ti, montrEsur la figure (Figure 1). 
REP 10.3 Main/Sub Heater Rod 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

Finisher 

REP 12.1 H Transport Assembly 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.2 H Transport Belt 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.3 Entrance Sensor 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.5 Stack Height Sensor Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.6 Eject Roll Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.7 Decurler Roll Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 12.8 Finisher Drive Motor 



Introduction 



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WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.9 Belt 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.15 Paddle Gear Shaft 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.10 Rail 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.16 Finisher PWB 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.11 Stapler Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.12 Compiler Tray Assembly 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 
REP 12.13 Stacker Motor Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

REP 12.14 Front Elevator Bracket 



WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 12.18 Cam Bracket Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

Covers 

REP 14.1 Top Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.2 Rear Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 



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Introduction 



REP 14.3 Right Cover 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.4 Rear Left Middle Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.5 Rear Left Upper Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.6 Left Lower Cover Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.7 Cover Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.8 Fuser Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 



d'alimentation branchE. 

REP 14.9 Rear Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.10 Inner Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.11 Left Cover Assembly 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

REP 14.12 Lower Cover 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

DADF 

ADJ 5.2 DADF Counterbalance 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Electriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

ADJ 5.3 DADF Parallelism 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 



Introduction 



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DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

ADJ 5.4 Document Transport Height 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 

Scanner 

ADJ 6.1 Full/Half Rate Carriage 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 

the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 

activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 

d'alimentation branchE. 

Xerographic/Registration 

ADJ 9.6 Color Registration (dC685) 

WARNING 

To avoid exposure to laser light, reinstall the Waste Cartridge before attempting to 

recheck the adjustment. 

DANGER: Pour Eviter toute exposition au rayon laser, rEinstaller la cartouche de toner 

usagEavant de re-vErifier le rEglage. 

Finisher 

ADJ 12.1 Finisher Alignment 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

DANGER: Afin d'Eviter des blessures ou des chocs Bectriques, ne pas effectuer des 
activitEs de maintenance ou de rEglage avec I'Equipement sur Marche ou avec le cordon 
d'alimentation branchE. 



Prelaunch Training/Review g^ 2 Introduction 

DC1 632/2240 xix 



Introduction 6/02 Prelaunch Training/Review 

xx DC1 632/2240 



1 Service Call Procedures 



Service Call Procedures 1-3 

Initial Actions 1-4 

Call Flow 1-5 

Detailed Maintenance Activities (HFSI) 1-6 

Cleaning Procedures 1-7 

Final Actions 1-7 



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Service Call Procedures 



Service Call Procedures g/Q 2 Prelaunch Training/Review 

1-2 DC1 632/2240 



Service Call Procedures 

Service Strategy 

The service strategy for the DocuColor 1632/2240 Copier/Printer is to perform any High Fre- 
quency Service Item (HFSI) actions before attempting to repair any problems. Some problems 
will be corrected by this strategy without the need to diagnose them. The Repair Analysis Pro- 
cedures (RAPs) will be used for any remaining problems. 

Problems that occur in the Basic Printer mode will be repaired before problems that occur 
when using the accessories. 

Image Quality problems should be repaired after all other problems are repaired. 

Service Call Procedures 

The Service Call Procedures are a guide for performing any service on this machine. The 
procedures are designed to be used with the Service Manual. Perform each step in order. 

Initial Actions 

The Initial Actions gather information about the condition of the machine and the problem that 
caused the service call. 

Call Flow 

Call Flow summarizes the sequence of the Service Call Procedures. 

Detailed Maintenance Activities 

This section provides the information needed to perform the DC135 High Frequency Service 
Item (HFSI) actions. 

Cleaning Procedures 

The cleaning procedures list what needs to be cleaned at each service call. 

Final Actions 

The Final Actions will test the copier/printer and return it to the customer. Administrative activi- 
ties are also performed in the Final Actions. 



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Service Call Procedures 

Service Call Procedures 



1. 



Initial Actions 
Purpose 

The purpose of the Initial Action section of the Service Call Procedures is to determine the rea- 
son for the service call and to identify and organize the actions which must be performed. 

Procedure 

Gather the information about the service call and the condition of the copier/printer. 

a. Question the operator(s). Ask about the location of most recent paper jams. Ask 
about the image quality and the copier/printer performance in general, including any 
unusual sounds or other indications. 

After informing the customer, disconnect the machine from the customeris network. 
Check that the power cords are in good condition, correctly plugged in the power 
source, and free from any defects that would be a safety hazard. Repair or replace 
the power cords as required. Check that the circuit breakers are not tripped. 
Inspect any rejected copies. Inquire as to, or otherwise determine, the paper quality 
and weight. The specified paper for optimum image quality with this machine is TBD. 
Look for any damage to the copies, oil marks, image quality defects, or other indica- 
tions of a problem. 
Record the billing meter readings. 

Enter the Diagnostics Mode. Go to the TBD RAP if the Diagnostic Mode can not be 
entered. Return here after repairing the Diagnostics entry problem. 



2. 



4. 



b. 



d. 



NOTE: If a fault code is displayed while performing a diagnostics procedure, go to 
that fault code RAP and repair the fault. Return to Diagnostics and continue with the 
dC procedure that you were performing. 

g. Go to dC135 and determine what HSFI action is required based on the customer 
output volume. Refer to the Detailed Maintenance Activities section for the detailed 
HSFI information. Record any items that require action, 
h. Select the History File. Display and record the information in the Fail History, Jam 
History, Fail Counter, and Jam Counter. Classify this information into categories: 
Information that is related to the problem that caused the service call. 
Information that is related to secondary problems. 

Information that does not require action, such as a single occurrence of a prob- 
lem, 
i. Check the Service Log for any recent activities that are related to the problem that 

caused the service call or any secondary problem. 
Perform any required HSFI activities identified above. Refer to the Detailed Maintenance 
Activities section. 

Exit diagnostics. Try to duplicate the problem by running the same jobs that the customer 
was running. 

Go to Call Flow. 



Service Call Procedures 

Initial Actions 



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Call Flow 

This procedure should be performed at every service call. 

Initial Actions 

Ask the operator about the problem. If the problem appears to be related to operator error, or 
an attempt to perform a job outside of the machine specifications, assist the customer in learn- 
ing the correct procedure. 

Procedure 

Does the Ul display correctly? 

Y N 
The machine is completely dead (no cooling fans running, no indicator lamps on) 

Y N 

Go to the OF 2-1 RAP to repair the Ul display error. 

Go to the OF 1-2 RAP. 

The reported problem occurs in Print Mode ONLY. 

Y N 

Place the Color Test Pattern on the Document Glass. Make a copy from each paper tray. 
The Copier/Printer can copy from all trays. 

Y N 

NOTE: Not all fault codes can be displayed on the Ul. Connect the PWS and launch 
the diagnostic tool to ensure that any fault code is displayed. Some codes will 
appear only the Last 40 Faults list. 

A fault code is displayed. 
Y N 

Go to the GP 4 Intermittent Problem RAP. 

Go to the RAP for the displayed fault. 



Place two originals into the DADF and program a duplex job. The Copier/Printer can 
copy from the DADF 
Y N 

A fault code is displayed. 
Y N 

Check the DADF Document Sensors for debris or damage. Check the docu- 
ment mechanical drives and Feed Rolls for contamination, wear, damage, or 
binding. 

Go to the RAP for the displayed fault code. 

Check the image quality in the BASIC COPIER MODE: 
i Select a tray that is loaded with 11 X 17 or A3 paper, 
i Select the following parameters: 

h Output Color to Auto 

h Original Type to Photo and Text Halftone 

h Reduce/Enlarge Auto 



n Lighter/Darker to Auto Contrast 

h Sharpness to Normal 

h Preset Color Balance Normal 

h Color Shift to Normal 

h Color Saturation to Normal 

h Copy Position to No Shift 

h Variable Color Balance Normal 
i Run four copies of the Color Test Pattern. 
The Image Quality of the copies produced is acceptable. 
Y N 

Go to the IQ1 RAP. 



Go to Final Actions. 

The problem occurs in all print jobs. 

Y N 

If the problem is specific to a single application or group of applications, ensure that cur- 
rent drivers are loaded. If the problem persists, escalate the call to the Customer Support 
Center. 

Go to GP 1 (Network Printing Simulation) and send a print job. An acceptable print is pro- 
duced. 

Y N 

i verify machine settings 

i reload system software? 

i replace the ESS PWB (PL 13.1). 

The problem is in the customer network or the setup. Ask the customeris system administrator 

to verify the configuration. 

Check network settings. 

When resolved, go to Final Actions. 



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Service Call Procedures 

Call Flow 



Detailed Maintenance Activities (HFSI) 

Procedure 

1 . Clean the ADC Sensor on every call. 

2. Enter Diagnostics and select dC135. 



Perform the Service Actions in Table 1 for any High Frequency Service Item (HFSI) 
counters that are over threshold or approaching the threshold. Using the customer's out- 
put volume numbers (high, medium, or low volume), evaluate which HFSI actions should 
be accomplished now to avoid an additional service call in the near future. 
Refer to Cleaning Procedures for detailed cleaning instructions. 



Table 1 



Counter 


Name 


Threshold 


Service Action to be performed 


006-802 


NT Scan 

No. of Scan (Including pre-scan) after HFSI 

Counter Cleared 





No action required - counter only 


005-805 


Document Feed 

No. of DADF Feed after HFSI Counter 

Cleared. 





No action required - counter only 


954-801 


IBT Belt Unit 


480K 

increments by 1 for letter size 
or smaller; by 2 for longer 
than letter size 


Replace of the IBT Belt Unit 
Warning at478.5K 


954-802 


2nd BTR Unit 


150K 


Replacement of the 2nd BTR Unit 
Warning at 98. 5K 


954-803 


IBT Belt CLN Assy 


100K 


Replacement of the IBT Belt Cleaner 
Warning at 98. 5K 


954-804 


Fuser 


10000000 

Area conversion with 

A4L=100 


Usage of Fuser CRU equivalent to A4L conversion 
Warning at 9000000 


954-806 


Tray 1 Feed counter 


300000 


Replace the Roll Kit (PL 2.5). 


954-807 


Tray 5 Feed counter 


300000 


Replace the Feed Roll Assembly and Retard Pad (PL 2.14). 


954-808 


Tray 2 Feed counter 


300000 


Replace the Roll Kit (PL 16.8). 


954-809 


Tray 3 Feed counter 


300000 


Replace the Roll Kit (PL 16.10). 


954-810 


Tray 4 Feed counter 


300000 


Replace the Roll Kit (PL 16.12). 



Service Call Procedures 

Detailed Maintenance Activities 



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Cleaning Procedures 
Purpose 

The purpose is to provide cleaning procedures to be performed at every call. 

Procedure 

CAUTION 

Do not use any solvents unless directed to do so by the Service Manual. 
General Cleaning 

Use a dry lint free cloth or a lint free cloth moistened with water for all cleaning unless directed 
otherwise by the Service Manual. Wipe with a dry lint free cloth if a moistened cloth is used. 

1 . Feed Components (Rolls and Pads) 

Follow the General Cleaning procedure above. 

2. ROS Windows 

Use the cleaning wand to clean the ROS windows (follow the procedure in the User 
Guide). 

3. Toner Dispense Units 
Vacuum the Toner Dispense units. 

4. Jam Sensors 

Clean the sensors with a dry cotton swab. 

5. IBT Cleaning 

Check the Transfer Belt surface and wipe with a dry lint free cloth. If the surface is exces- 
sively dirty, replace the Transfer Belt (PL 5.3). 

6. Fuser Components (best cleaned when hot). 
Wipe with a lint free cloth. 

7. Scanner 

a. Switch off the power and allow the Exposure Lamp to cool off. 

b. Using the optical Cleaning Cloth, clean the front and rear of the Document Glass, 
Document Cover, White Reference Strip, Reflector, and Mirror. 

c. Clean the Exposure Lamp with a clean cloth and Film Remover. 

d. Clean the Lens with Lens and Mirror Cleaner and lint free cloth. 

8. ADF 

Check the paper path for debris or damage. Clean the rolls with a clean cloth and Film 
Remover as required. 

9. Finisher 

Check the paper path for debris or damage. Clean the Finisher with a dry lint free cloth. 



Final Actions 
Purpose 

The intent of this procedure is to be used as a guide to follow at the end of every service call. 

Procedure 

1. Ensure that the exterior of the copier/printer and the adjacent area are clean. Use a dry 
cloth or a cloth moistened with water to clean the copier/printer. Do not use solvents. 

2. Check the supply of consumables. Ensure that an adequate supply of consumables is 
available according to local operating procedures. 

3. Conduct any operator training that is needed. Ensure that the operator understands that 
the Automatic Gradation Adjustment procedure in the Operator Manual should be used to 
adjust the colors. 

4. Complete the Service Log. 

5. Perform the following steps to make a copy of the Demonstration Original for the Cus- 
tomer: 

a. Load Tray 1 with 8.5 x 11 inch (A4) or 11 x 17 inch paper. 

b. Place the Color Test Pattern on the glass with the short edge of the test pattern reg- 
istered to the left edge of the glass. Select Tray 1 and make a single copy. 

c. Print out the Machine Settings page. 

d. Present the copies to the customer. 

6. Reconnect the machine to the customer network. Verify function. 

7. Issue copy credits as needed. 

8. Discuss the service call with the customer to ensure that the customer understands what 
has been done and is satisfied with the results of the service call. 



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Service Call Procedures 

Cleaning Procedures, Final Actions 



Service Call Procedures g/Q 2 Prelaunch Training/Review 

Cleaning Procedures, Final Actions 1-8 DCI632/2240 



2 Status Indicator RAPs 



Chain 1 

1-300 RAP. 
1-301 RAP. 
1-302 RAP. 
1-303 RAP. 
1-306 RAP. 



Chain 3 

3-317 NT Software Failure 

3-318 NT Software Failure 

3-319 NT Video Driver Failure 

3-320 IIT-ESS Communication Failure 1 ... 
3-321 IIT-ESS Communication Failure 2 ... 
3-322 IIT-ESS Communication Failure 3 ... 
3-323 IIT-ESS Communication Failure 4 ... 
3-324 IIT-ESS Communication Failure 5 ... 
3-325 IIT-ESS Communication Failure 6 ... 
3-326 IIT-ESS Communication Failure 7 ... 
3-327 IIT-ESS Communication Failure 8 ... 
3-328 IIT-ESS Communication Failure 9 ... 
3-329 IIT-ESS Communication Failure 10 . 
3-330 IIT-ESS Communication Failure 11 . 
3-331 IIT-ESS Communication Failure 12 
3-332 IIT-ESS Communication Failure 13 . 
3-333 IIT-ESS Communication Failure 14 
3-334 IIT-ESS Communication Failure 15 . 
3-335 IIT-ESS Communication Failure 16 . 
3-336 IIT-ESS Communication Failure 17 . 



3-340 IOT-ESS Communication Fai 
3-341 IOT-ESS Communication Fai 
3-342 IOT-ESS Communication Fai 
3-343 IOT-ESS Communication Fai 
3-345 IOT-ESS Communication Fai 
3-346 IOT-ESS Communication Fai 
3-347 IOT-ESS Communication Fai 
3-348 IOT-ESS Communication Fai 
3-349 IOT-ESS Communication Fai 
3-350 IOT-ESS Communication Fail 
3-351 IOT-ESS Communication Fail 
3-352 IOT-ESS Communication Fail 
3-353 IOT-ESS Communication Fail 
3-354 IOT-ESS Communication Fail 
3-355 IOT-ESS Communication Fail 
3-356 IOT-ESS Communication Fail 
3-357 IOT-ESS Communication Fail 
3-358 IOT-ESS Communication Fai 
3-359 IOT-ESS Communication Fail 



lure 1.... 

I 2 

lure 3.... 
lure 4.... 
lure 5.... 
lure 6.... 
lure 1 .... 
lure 8.... 
lure 9.... 
lure 10.. 
lure 11 .. 
lure 12.. 
lure 13.. 
lure 14.. 
lure 15.. 
lure 16.. 
lure 17.. 
lure 1.... 
lure 19.. 



3-360 IOT-ESS Initialization Failure 2-34 

2-9 3-364 DMA Transfer Failure 2-35 

2-10 3-370 Marker Code Detect Failure 2-35 

2-11 3-747 Print Instruction Failure 2-36 

2-12 3-750 Insufficient Number of Document Pages 2-36 

2-13 3-761 Tray Select Error 2-37 

3-941 Insufficient Page Memory 2-37 

3-942 Document Size Error 2-38 

2 " 15 3-946 Tray 1 Not In Position 2-38 

2 " 15 3-947 Tray 2 Not In Position 2-39 

2 " 16 3-948 Tray 3 Not In Position 2-39 

2 " 16 3-949 Tray 4 Not In Position 2-40 

2 " 17 3-950 Tray 1 No Paper 2-40 

2 " 17 3-951 Tray 2 No Paper 2-41 

2 " 18 3-952 Tray 3 No Paper 2-41 

2 " 18 3-953 Tray 4 No Paper 2-42 

2 " 19 3-954 Tray 5 Empty 2-42 

2 " 19 3-958 Tray 5 Paper Size Mismatch 2-43 

2-20 3-959 Tray 1 Paper Size Mismatch 2-43 

2-20 3-960 Tray 2 Paper Size Mismatch 2-44 

2 " 21 3-961 Tray 3 Paper Size Mismatch 2-44 

2 - 21 3-962 Tray4 Paper Size Mismatch 2-45 

2 " 22 3-965 No Paper 2-45 

2-22 3-971 Magnification 2-46 

2 " 23 3-972 Over Number of Document Pages Stored 2-46 

2-23 3-980 Stapler Position Error 2-47 

2 " 2 4 3-985 Tray 5 Pause Check 2-47 

2 " 24 3-986 Print Completion Error 2-48 

2-25 

2-25 Chain 4 

2-26 4-340 IOT RAM 2-49 

2-26 4-341 IOT Logic 2-50 

2-27 4-342 Flash ROM Motion 2-50 

2-27 4-343 IOT Flash ROM Read Write 2-51 

2-28 4-344 IOT Micro Pitch 2-51 

2-28 4-345 MCU HVPS Communication 2-52 

2-29 4-346 IBT Home Sensor 2-52 

2-29 4-347 IBT Belt Edge 2-53 

2-30 4-348 IBT Belt Edge 2-54 

2-30 4-349 Marking Software Logic 2-55 

2-31 4-358 ESS IOT Communication 2-55 

2-31 4-361 Drum Motor 2-56 

2-32 4-362 IOT NVM Read Write 2-57 

2-32 4-371 IOT Controller Timing Failure 2-57 

2-33 4-363 K Drum Motor 2-58 

2-33 4-414 IBT Belt Cleaner 2-59 

2-34 4-415 2nd BTR Unit 2-59 

4-417 1st BTR Unit 2-60 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-1 



Status Indicator RAPs 



4-420 1st BTR Unit 2-60 

4-421 IBT Belt Cleaner Life End 2-61 

4-605 IOT NVM Corrupt 2-61 

4-640 Belt Tracking 2-62 

4-641 Belt Edge 2-62 

4-642 Belt Edge 2-63 

4-650 IOT Cycle Down Time Out 2-63 

4-908 2nd BTR Unit Life End 2-64 

Chain 5 

5-110 Registration Sensor On 2-65 

5-111 Registration Sensor Off 2-66 

5-112 Registration Sensor Inversion 2-68 

5-113 Registration Sensor Inversion 2-69 

5-115 Exit Sensor On 2-70 

5-116 Exit Sensor Off 2-71 

5-195 Document Size Mismatch 2-72 

5-274 Original Size Sensor 2-73 

5-275 DADF Ram Failure 2-74 

5-301 Top Cover Interlock Open 2-75 

5-900 Document Sensor Timing 2-76 

5-901 Power On Document Present 2-77 

5-902 Power On Registration Sensor 2-78 

5-903 Power On Exit Sensor 2-79 

5-904 Power On Duplex Sensor 2-80 

5-940 Document Removed During Start 2-81 

5-941 Document Miscount 2-82 

Chain 6 

6-277 IISS DADF Communication 2-83 

6-312 NT Memory Hot Line 2-84 

6-340 IISS RAM TEST ERROR 2-84 

6-345 IISSEEPROM 2-85 

6-355 IPS Fan 2-86 

6-360 Carriage Position 2-87 

6-361 Scan Registration Sensor 2-88 

6-371 Exposure Lamp 2-89 

6-372 ROS Polygon Motor 2-90 

6-380 ROS SOS Y Length 2-91 

6-381 ROS SOS Length Fail M 2-92 

6-382 ROS SOS C Length 2-92 

6-383 ROS SOS K Length 2-93 

6-385 ROS ASIC 2-93 

6-389 Carriage Over Run Right 2-94 

6-390 Carriage Over Run Left 2-95 

6-391 Scan Initialize Motor Driver 2-96 

Chain 7 

7-104 Tray 1 Feed Out Sensor 2-97 

7-105 Tray 1 Misfeed 2-98 

7-110Tray2Misfeed 2-100 

7-1 15 Tray 3 Misfeed 2-102 



7-1 19 Tray 4 Misfeed 2-104 

7-122 Tray 4 Opened 2-106 

7-250 Tray Communication 2-107 

7-252 Out Module Logic 2-108 

7-270 Tray 1 Paper Size Sensor 2-108 

7-271 Tray 2 Paper Size Sensor 2-109 

7-274 Tray 5 Paper Size Sensor 2-109 

7-276 Tray 3 Paper Size Sensor 2-110 

7-277 Tray 4 Paper Size Sensor 2-110 

7-281 Tray 1 Lift 2-111 

7-282 Tray 2 Lift 2-112 

7-291 Tray 3 Lift 2-113 

7-293 Tray 4 Lift 2-114 

7-397 All Trays Lift Sensors 2-115 

7-930 Tray 1 Paper Size Mismatch 2-116 

7-931 Tray 2 Paper Size Mismatch 2-117 

7-932 Tray 3 Paper Size Mismatch 2-117 

7-933 Tray 4 Paper Size Mismatch 2-118 

7-935 Job Continue Not Available 2-118 

7-954 SMH Size Mismatch (Slow Scan Direction) 2-119 

7-959 Tray 5 Paper Mismatch 1 2-119 

7-960 Tray 5 Paper Mismatch 2 2-120 

7-969 Full Paper Stack 2-120 

Chain 8 

8-151 Tray 3 Take Away Sensor On 2-121 

8-1 52 Tray 4 Take Away Sensor On 2-122 

8-164 POB Sensor 2-123 

8-175 Registration Sensor On Jam Tray 5 2-124 

8-176 Registration Sensor On Jam Tray 1-4 2-125 

8-180 Registration Sensor On Duplex 2-126 

8-181 Registration Sensor On Wait Sensor 2-127 

8-184 Registration Sensor Off 2-129 

8-620 Regicon Temp Sensor 2-130 

8-622 Regicon Data Overflow (A1 Patch X) 2-131 

8-623 Regicon Data Overflow (A2 Patch Y) 2-131 

8-624 Regicon Data Overflow (Patch Magnification) 2-132 

8-625 Regicon Sample Block (A1 Patch-rear) 2-132 

8-626 Regicon Sample Block (A1 Patch-front) 2-133 

8-627 Regicon Sample Lateral (A1 Patch-rear) 2-133 

8-628 Regicon Sample Lateral (A1 Patch-front) 2-134 

8-629 Regicon Skew (Patch Y) 2-134 

8-630 Regicon Skew (Patch M) 2-135 

8-631 Regicon Skew (Patch K) 2-135 

8-900 Static Jam 2-136 

Chain 9 

9-342 2nd BTR Contact 2-137 

9-343 2nd BTR Retract 2-138 

9-348 1st BTR Contact 2-139 

9-349 1st BTR Retract 2-140 

9-350 IBT Home Sensor 2-141 



Status Indicator RAPs 



6/02 
2-2 



Prelaunch Training/Review 
DC1 632/2240 



9-351 Drive Logic 2-142 

9-358 Full Toner Sensor 2-143 

9-360 Yellow Drum Cartridge Communication 2-143 

9-361 Magenta Drum Cartridge Communication 2-144 

9-362 Cyan Drum Cartridge Communication 2-144 

9-363 Black Drum Cartridge Communication 2-145 

9-380 ATC Sensor (Y) 2-145 

9-381 ATC Sensor (M) 2-146 

9-382 ATC Sensor (C) 2-146 

9-383 ATC Sensor (K) 2-147 

9-390 New Toner Cartridge (K) 2-147 

9-391 New Toner Cartridge (C) 2-148 

9-392 New Toner Cartridge (M) 2-148 

9-393 New Toner Cartridge (Y) 2-149 

9-408 Waste Toner Cartridge Near Full 2-149 

9-410 Toner Cartridge (Y) Near Empty 2-150 

9-411 Toner Cartridge (M) Near Empty 2-151 

9-412 Toner Cartridge (C) Near Empty 2-152 

9-413 Toner Cartridge (K) Near Empty 2-153 

9-428 Change Drum Cartridge (K) Soon 2-153 

9-429 Change Drum Cartridge (Y) Soon 2-154 

9-430 Change Drum Cartridge (M) Soon 2-154 

9-431 Change Drum Cartridge (C) Soon 2-155 

9-654 ADC Sensor 2-155 

9-660 Environment Sensor Temperature 2-157 

9-661 Environment Sensor Humidity 2-158 

9-670 New Toner Cartridge (K) Detected 2-159 

9-671 New Toner Cartridge (C) Detected 2-159 

9-672 New Toner Cartridge (M) Detected 2-160 

9-673 New Toner Cartridge (Y) Detected 2-160 

9-684 ADC Shutter 2-161 

9-910 Drum (Y) Type Mismatch 2-162 

9-911 Drum (M) Type Mismatch 2-162 

9-912 Drum (C) Type Mismatch 2-163 

9-913 Drum (K) Type Mismatch 2-163 

9-920 Toner Cartridge (Y) Empty 2-164 

9-921 Toner Cartridge (M) Empty 2-165 

9-922 Toner Cartridge (C) Empty 2-166 

9-923 Toner Cartridge (K) Empty 2-167 

9-924 Waste Toner Cartridge Full 2-168 

9-925 Waste Toner Cartridge Not Set 2-168 

9-926 Drum Cartridge (K) End Of Life 2-169 

9-927 Change Drum Cartridge (C) End Of Life 2-169 

9-928 Drum Cartridge (M) End Of Life 2-170 

9-929 Drum Cartridge (Y) End Of Life 2-170 

9-930 Black Drum Cartridge Not Detected 2-171 

9-931 Cyan Drum Cartridge Not Detected 2-171 

9-932 Magenta Drum Cartridge Not Detected 2-172 

9-933 Yellow Drum Cartridge Not Detected 2-172 

Chain 10 

10-105 Face Up Exit Sensor On 2-173 



10-106 Face Up Exit Sensor Off 2-175 

10-110 Fuser Exit Switch On (Face Down/duplex) 2-175 

10-111 Fuser Exit Switch Off (Face Down) 2-177 

10-125 Duplex Wait Sensor On 2-178 

10-348 Main Heater Over Heat 2-180 

10-349 Front Thermistor Open 2-182 

10-350 Sub Heater Over Heat 2-183 

10-351 Rear Thermistor Open 2-184 

10-352 Main Heater Warm Up 2-185 

10-353 Main Heater On Time 2-187 

10-354 Sub Heater Warm Up 2-189 

10-356 Sub Heater On Time 2-190 

10-398 Fan Lock 2-192 

10-420 Fuser Near End Of Life 2-194 

10-421 Fuser End Of Life 2-194 

Chain 12 

12-100 H Transport Entrance Sensor On 2-195 

12-102 H Transport Entrance Sensor Off 2-197 

12-104 H Transport Exit Sensor On 2-198 

12-106 H Transport Exit Sensor Off 2-199 

12-120 Compiler Entrance Sensor On 2-200 

12-122 Compiler Entrance Sensor Off 2-201 

12-170 Set Eject 2-202 

12-241 Staple Move Sensor On 2-203 

12-242 Staple Move Sensor Off 2-204 

12-244 Staple Home Sensor 2-205 

12-252 Front Tamper 2-207 

12-253 Rear Tamper 2-209 

12-254 Stacker Tray 2-211 

12-255 Stacker Tray Upper Limit 2-213 

12-256 Staple Front Corner Sensor On 2-215 

12-257 Staple Front Corner Sensor Off 2-217 

12-260 Eject Clamp Home Sensor On 2-219 

12-262 Eject Clamp Home Sensor Off 2-221 

12-267 Decurler 2-223 

12-281 Set Clamp 2-225 

12-301 Top Cover Interlock 2-227 

12-302 Front Door Interlock Open 2-228 

12-303 H Transport Interlock Open 2-229 

12-305 Docking Interlock Open 2-230 

12-350 Finisher Communication 2-232 

12-399 Staple Mode Logic 2-233 

12-901 Power On H Transport Entrance Sensor 2-234 

12-902 Power On H Transport Exit Sensor 2-235 

12-903 Power On Compiler Entrance Sensor 2-236 

12-904 Power On Compiler Paper Sensor 2-237 

12-910 Staple Feed Ready 2-238 

12-91 1 Stacker Lower Safety Warning 2-240 

12-914 Stacker Tray Staple Set 2-241 

12-916 Stapling 2-242 

12-960 Stacker Tray Full Stack 2-244 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-3 



Status Indicator RAPs 



12-961 Mix Full Stack 2-246 

12-965 Staple Near Empty 2-248 

12-966 Scratch Sheet Compile 2-249 

12-969 IOT Top Tray Full 2-250 

Chain 15 

15-362 X Hard Failure 2-251 

15-367 X PIO Failure 2-251 

15-370X PIO Initialization Failure 1 2-252 

15-371 X PIO Initialization Failure 2 2-252 

15-372 X PIO Initialization Failure 3 2-253 

15-375 X PIO Before Scan Failure 2-253 

15-376 X PIO Non-match Failure 1 2-254 

15-377 X PIO Non-match Failure 2 2-254 

15-380 CCDAGC 2-255 

15-381 CCDAGC 2-255 

15-382 CCDAGC 2-256 

15-383 CCDAGC 2-256 

15-384 CCDAGC 2-257 

15-385 CCDAGC 2-257 

15-790 X Detail Failure 2-258 

Chain 16 

16-311 Scanner 2-259 

16-315 NT Interface 2-259 

16-316 Page Memory 2-260 

16-317 Page Memory 2-260 

16-318 Optional Page Memory 2-261 

16-450 SMB Host Name 2-261 

16-452 IP Address Duplicated 2-262 

16-453 IP Address Acquisition 2-262 

16-454 Dynamic DNS Update 2-263 

16-460 Full Status Detected 2-263 

16-590 Read Error (Partition A) 2-264 

16-591 Read Error (Partition B) 2-264 

16-592 Read Error (Partition C) 2-265 

16-593 Read Error (Partition D) 2-265 

16-594 Read Error (Partition E) 2-266 

16-595 Read Error (Partition H) 2-266 

16-701 PLW Memory 2-267 

16-702 PLW Memory 2-267 

16-703 Email To Invalid Box 2-268 

16-704 Security Box 2-268 

16-705 Security Storage without HD 2-269 

16-706 Maximum User Number 2-269 

16-709 PLW Command 2-270 

16-716 Spool TIFF Data 2-270 

16-721 Other Errors 2-271 

16-726 Decomposer Auto Judgement 2-271 

16-728 TIFF Data 2-272 

16-729 TIFF Data 2-272 

16-730 ART Command 2-273 



16-731 


16-735 


16-737 


16-739 


16-740 


16-741 


16-742 


16-743 


16-744 


16-745 


16-748 


16-749 


16-757 


16-758 


16-759 


16-760 


16-761 


16-762 


16-763 


16-764 


16-765 


16-766 


16-767 


16-768 


16-769 


16-770 


16-771 


16-772 


16-773 


16-774 


16-775 


16-776 


16-777 


16-778 


16-779 


16-780 


16-781 


16-782 


16-783 


16-784 


16-785 


16-786 


16-787 


16-788 


16-793 


16-950 


16-951 


16-952 


16-953 


16-954 


16-958 


16-959 


6/02 


2-4 



TIFF Data 2-273 

Job Template 2-274 

Server Read 2-274 

Job Template Path 2-275 

Job Template Login 2-275 

Job Template Connection 2-276 

HDFile 2-276 

Job Template Installation 2-277 

Job Template Address 2-277 

Job Template Definition 2-278 

HDFull 2-278 

XJCL Syntax 2-279 

Auditron User 2-279 

Auditron Function 2-280 

Auditron Limit 2-280 

Decomposer 2-281 

FIFO 2-281 

Decomposer 2-282 

Patch 2-282 

Server Transmission 2-283 

Server Storage 2-283 

Server Storage 2-284 

Mailbox 2-284 

Mail From Command 2-285 

DSN Unsupported 2-285 

Template Processing 2-286 

Scan Data Repository 2-286 

Scan Data Repository 2-287 

IP Address 2-287 

HD Compression 2-288 

HD Capacity 2-288 

Image Conversion 2-289 

HD Access 2-289 

HD Capacity 2-290 

Scan Image Conversion 2-290 

HD Access 2-291 

Scan Server 2-291 

Scan Server Login 2-292 

Server Path 2-292 

Server Write 2-293 

Server HDFull 2-293 

HD Scan Write 2-294 

Job Template Syntax 2-294 

Mailbox to PC 2-295 

MF I/O HD Full 2-295 

Tray 1 Empty 2-296 

Tray 2 Empty 2-296 

Tray 3 Empty 2-297 

Tray 4 Empty 2-297 

Tray 5 Empty 2-298 

Tray 5 Size 2-298 

Tray 1 Size 2-299 



Status Indicator RAPs 



Prelaunch Training/Review 
DC1 632/2240 



16-960 Tray 2 Size 2-299 

16-961 Tray 3 Size 2-300 

16-962 Tray 4 Size 2-300 

16-965 ATS/APS No Paper 2-301 

16-966 ATS/APS No Destination 2-301 

16-981 Full HD 2-302 

16-982 FullHD 2-302 

Chain 102 

102-200 Receive Buffer Overflow 2-303 

102-201 Send Buffer Overflow 2-303 

102-202 Request Queue Full 2-304 

102-203 Send Request Queue Full Debug 2-304 

102-204 SIO Parameter 2-305 

102-205 SIO Command 2-305 

102-206 SIO Status 2-306 

102-207 Communication Manager Target 2-306 

102-208 Communication Manager Command 2-307 

102-209 EVM Returns Wrong Value 2-307 

102-310 Send Queue Full 2-308 

102-311 Receive Queue Full 2-308 

102-312 EVM Uses Wrong API 2-309 

102-313 AS Uses Wrong API 2-309 

102-314 Wait Event Time Out 2-310 

102-315 CTS Internal 2-310 

102-316 Send Request Queue Full SIO 2-311 

102-317 Receive Message Queue Full 2-311 

102-318 Receive Finish Queue Full 2-312 

102-319 Send with No ACK 2-312 

102-320 Polling 2-313 

102-321 Send Message 2-313 

102-322 Target 2-314 

102-323 Address 2-314 

102-324 Size 2-315 

102-325 Object Creation 2-315 

102-326 Memory Overflow 2-316 

102-327 Button Overflow 2-316 

102-328 Ul Internal with Out of Area 2-317 

102-329 Ul Internal with Invalid Coordinates 2-317 

102-330 Interface with Invalid Parameter LCD 2-318 

102-331 Ul Internal with Invalid LED Request 2-318 

102-332 Interface with Invalid Parameter CP 2-319 

102-333 Interface with Impossible Communication 2-319 

102-334 Interface with Receiving Error Key Code 2-320 

102-335 Interface with Receiving Invalid Coordinates 2-320 

102-336 Interface DM - ACD Drv. I/F 2-321 

102-337 Frame Data Error with Invalid Data Type 2-321 

102-338 Frame Data Error Offset Address Out of Scope 2-322 

102-339 Display Request Code Invalid 2-322 

102-340 Interface GUAM - DM l/F 2-323 

102-341 Event Queue Full 2-323 

102-342 Event Queue Empty 2-324 



102-343 Invalid Class 2-324 

102-344 Invalid Type 2-325 

102-345 Timer Queue Full 2-325 

102-346 Invalid Timer Number 2-326 

102-347 Undefined Trap 2-326 

102-348 Command Access Exception 2-327 

102-349 Invalid Command 2-327 

102-350 Privilege Command 2-328 

102-351 No FPU Exception 2-328 

102-352 Address Misalign 2-329 

102-353 Data Access Exception 2-329 

102-354 Tag Overflow 2-330 

102-355 No Co Processor Exception 2-330 

102-356 Short of Area 2-331 

102-357 Cancel Wait Status 2-331 

102-358 Time Out 2-332 

102-359 Queue Overflow 2-332 

102-360 Context 2-333 

102-361 Object 2-333 

102-362 No Object 2-334 

102-363 Invalid ID 2-334 

102-364 Parameter 2-335 

102-365 Reserve Attribute 2-335 

102-366 Reserve Function Code 2-336 

102-367 Unsupported Function 2-336 

102-368 Short of Ul Memory 2-337 

102-369 Invalid Interface Value 2-337 

102-370 Interface Length 2-338 

102-371 Interface Parameter 2-338 

102-372 Interface Sequence 2-339 

102-373 Channel 2-339 

102-374 Invalid User Job ID 2-340 

102-375 Internal Resource 2-340 

102-376 Internal Memory 2-341 

102-377 Ul Timer 2-341 

102-378 Interface Format 2-342 

102-379 Dispatch 2-342 

102-380 Copy Interface 2-343 

102-382 Scanner Interface 2-343 

102-383 Report Interface 2-344 

102-384 Server Access 2-344 

102-385 Service Object Overflow 2-345 

102-386 Invalid Service Object 2-345 

102-387 Invalid Service Object Attribute 2-346 

102-388 Attribute 2-346 

102-389 Argument 2-347 

102-390 Job Parameter 2-347 

102-391 Job Actual Parameter 2-348 

102-392 Auditron 2-348 

102-393 EP 2-349 

102-394 File Access 2-349 

102-395 NVM 2-350 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-5 



Status Indicator RAPs 



102-396 FF 2-350 

102-397 MGR 2-351 

102-398 Delay Release Queue Full 2-351 

102-399 Internal 2-352 

Chain 103 

103-203 Machine Code Failure 2-353 

103-204 Serial Number Failure 2-353 

103-207 All Machine Codes Mismatch 2-354 

103-208 All Serial Numbers Mismatch 2-354 

103-320 EEPROM Failure 2-355 

103-321 Backup SRAM Failure 2-355 

103-330 ESS ROM DIMM #3 Check Failure 2-356 

103-331 ESS ROM DIMM #1 Not Found 2-356 

103-332 ESS Standard ROM Error 2-357 

103-333 ASIC Failure (Panther-t) 2-357 

103-334 Standard Post Script Font ROM Error 2-358 

103-335 Post Script Font ROM Not Found 2-358 

103-336 ESS RAM DIMM #3 W/r Check Failure 2-359 

103-337 ESS Standard RAM Error 2-359 

103-338 Same Post Script Font ROMiS Found 2-360 

103-339 ROM DIMM Of Another Product Found 2-360 

103-372 IOT Sc Soft Failure 2-361 

103-701 Changed Output Bin: Side To Center 2-361 

103-702 Changed Output Bin: Finisher To Center 2-362 

Chain 116 

116-200 MainPWBAIC 2-363 

116-201 HD 2-363 

116-206 Timer 2-364 

116-207 Ethernet Board 2-364 

116-209 ESS PS-1 ROM Check 2-365 

116-310 ESS PS-2 ROM Check 2-365 

116-311 ESS Font ROM DIMM #3 Check 2-366 

116-314 Ethernet Address 2-366 

116-315 ESS RAM DIMM #1 W/R Check 2-367 

116-316 ESS RAM DIMM #2 W/R Check 2-367 

116-317 Standard ROM DIMM Check 2-368 

116-318 Option ROM DIMM Check 2-368 

116-319 Serial 2-369 

116-320 STREAMZSoft 2-369 

116-321 System Soft 2-370 

116-323 ESS NVRAM W/R Check 2-370 

116-324 Exception Error 2-371 

116-325 Communication Error 2-371 

116-326 ESS ROM DIMM #1 Flash 2-372 

116-327 ESS ROM DIMM #2 Flash 2-372 

116-328 L2 Cache 2-373 

116-329 Serial l/F Soft 2-373 

116-330 HD File System 2-374 

116-332 Invalid Log Info 2-374 

116-333 LocalTalk Soft 2-375 



116-335 MFIOHD 2-375 

116-336 RedirectorHD 2-376 

116-337 Template HD Write Error 2-376 

116-340 Short of Memory 2-377 

116-341 ROM DIMMs Mismatch 2-377 

116-342 JT Monitor 2-378 

116-344 MFIO 2-378 

116-345 Token Ring Board 2-379 

116-346 Formatter 2-379 

116-348 Redirecter 2-380 

116-349 SIF on Calling Pflite Function 2-380 

116-350 AppleTalk Soft 2-381 

116-351 EtherTalk Soft 2-381 

116-352 NetWare Soft 2-382 

116-353 IpdSoft 2-382 

116-355 SNMP Agent Soft 2-383 

116-356 EWSSoft 2-383 

116-357 PS Soft 2-384 

116-358 Salutation Soft 2-384 

116-359 PLWSoft 2-385 

116-360 SMBSoft 2-385 

116-361 Spool Fatal HD 2-386 

116-365 Spool Fatal 2-386 

116-366 Report Generator Soft 2-387 

116-367 Parallel l/F Soft 2-387 

116-368 Dump Print 2-388 

116-370 XJCL 2-388 

116-372 P-Formatter 2-389 

116-373 Dynamic DNS Soft 2-389 

116-374 Auto Switch 2-390 

116-375 l-Formatter 2-390 

116-376 Port 9100 Software 2-391 

116-377 Video DMA 2-391 

116-378 MCRSoft 2-392 

116-379 MCCSoft 2-392 

116-380 MF Ul ContSoft 2-393 

116-381 Data Link Layer Error between Cont and Ul 

Panel 2-393 

116-382 Panel Application Layer Command Error on Ul 2-394 

116-388 No HD that Should Be 2-394 

116-389 No Add-On RAM that Should Be 2-395 

116-390 Standard ROM and NVM Version Mismatch 2-395 

116-395 USB Soft 2-396 

116-396 Mail IO Soft 2-396 

116-398 IPPSoft 2-397 

116-399 JMESoft 2-397 

116-701 Execute forced separation of two sides 2-398 

116-702 Perform printing by using a substitution font 2-398 

116-703 PS Interpret error 2-399 

116-710 HP-GL spool file overflows 2-399 

116-711 PLW form synthesis error 2-400 

116-712 Insufficient PLW form capacity 2-400 



Status Indicator RAPs 



6/02 
2-6 



Prelaunch Training/Review 
DC1 632/2240 



1 16-714 A HP-GL command error was detected 2-401 

116-715 PLWform registry error 2-401 

116-718 PLWform synthesis error 2-402 

1 16-737 Insufficient ART user defined area 2-402 

116-738 Form synthesis error 2-403 

1 16-739 Insufficient form/logo capacity 2-403 

116-740 Value Calculation Error 2-404 

116-741 Form registry error 2-404 

116-742 Logo registry error 2-405 

116-743 Form/logo size overflow 2-405 

116-745 Art Command Error 2-406 

116-746 Form synthesis error 2-406 

116-747 White page detected 2-407 

116-748 White page detected 2-407 

1 16-780 Attached document failure of email to XXX 2-408 

116-790 Printed without the stapler 2-408 

Other Faults 

OF 1-1 +3.5 VDC 2-409 

OF1-2+5VDC 2-410 

OF 1-4 AC Power 2-411 

OF 2-1 Dark /Blank Display 2-412 

OF 99-1 Reflective Sensor 2-413 

OF 99-2 Transmissive Sensor 2-414 

OF 99-3 Switch 2-415 

OF 99-4 Solenoid / Clutch Open 2-416 

OF 99-5 Solenoid / Clutch Shorted 2-417 

OF 99-6 Motor Open 2-418 

OF 99-7 Motor On 2-419 

OF 99-8 Nip / Release Solenoid Open 2-420 



Prelaunch Training/Review g^ 2 Status Indicator RAPs 

DC1 632/2240 2-7 



Status Indicator RAPs 6/02 Prelaunch Training/Review 

2-8 DC1 632/2240 



1-300 RAP 

Left Cover is open. 

Procedure 

Enter dC330 [001-301] and press Start. Open and close Left Cover. Display changes state. 
Y N 

Measure the voltage between +24 LVPS J502-1 and GND(-). +24 VDC measured. 

Y N 

Replace LVPS (PL 9.1). 



Disconnect p/j 172 from Left Cover Interlock Switch. Check resistance between A1 and 
B1 when switch is actuated. Resistance is less than 3 ohms. 

Y N 
Replace Left Cover Interlock Switch (PL 2.10). 

Reinstall switch. Close the Left Cover. Measure the voltage at J535-A1 on the l/F PWB. 
+24 VDC measured. 

Y N 
Repair the open circuit between the +24 VDC LVPS and the l/F PWB. 

Replace the l/F PWB (PL 9.1). 

If the problem continues, replace the MCU PWB (PL 13.1). 



Check installation of Cover/Actuator. 



+24VDC 




LEFT COVER 


LVPS 




INTERLOCK 


PL9.1 




SWITCH 
PL2. 


h~ 


J502 J172 

A 

ORN 


1 -oV E 



J172 



ORN 



DC330 [1-301] 

LEFT COVER INTERLOCK 

CLOSED (H) +24VDC J535 



l/F PWB 
PL9.1 



MCU PWB 

PL13.1 

3.3VDC 



P/J4105 



BLU 



BLU 



CONTROL 
LOGIC 



-J TO FRONT INTERLOCK SWITCH 



Figure 1 Left Cover Interlock Switch CD 



T701006A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-9 



Status Indicator RAPs 

1-300 



1-301 RAP 

Left Lower Cover is open 

Procedure 

Enter dC330 [001-302] and press Start. Open Left Lower Cover. Actuate Left Lower Cover 
Interlock Switch with screwdriver. Display changes state. 
Y N 

Go to General Transmissive Sensor RAP and repair LH Lower Cover Interlock Switch (PL 

2.3). 

Check Actuator and Left Lower Cover installation. 



MCU PWB 
PL13.1 



47 



J407 DC COM 



i YEL 



"L +5 



-B14h 



+5VDC 



CONTROL 
LOGIC 



— *— B13 1 - 



YEL 



LH LOWER COVER 
INTERLOCK SWITCH 
PL2.3 



lJ)S(g 



T701005A-CAR 



Figure 1 LH Lower Cover Interlock Switch CD 



■ LH Lower Cover 
Interlock Switch 




0102054A-CAR 



Figure 2 Component Location 



Status Indicator RAPs 

1-301 



6/02 
2-10 



Prelaunch Training/Review 
DC1 632/2240 



1-302 RAP 

Front Cover or is open 

Initial Actions 

Check the operation of the Actuator and the switch. 

Procedure 

Open the Front Cover. Cheat the Front Cover Interlock Switch. 001-302 is cleared. 
Y N 

+24VDC is measured between the l/F PWB [531-1 (+) and GND (-). 
Y N 

+24VDC is measured between the Front Cover Interlock Switch J171-B1 (+) and 
GND (-). 
Y N 

24VDC is measured between the Front Cover Interlock Switch J171-A1 (+) 
and GND (-). 
Y N 

Repair the open circuit between the Left Cover Interlock Switch J172-B1 
and the Front Interlock Switch J171-A1. 

Replace the Front Cover Interlock Switch. 



+24VDC is measured between the RH Cover Interlock Switch J173-B1 (+) and 
GND (-). 
Y N 

+24VDC is measured between the RH Cover Interlock Switch J173-A1 (+) 
and GND (-). 
Y N 

Repair the open circuit between the Front Cover Interlock Switch J171-B1 
and the RH Cover Interlock Switch J173-A1. 

Replace the RH Cover Interlock Switch. 

Check the wire for an open circuit between the RH Cover Interlock Switch J173-B1 

and the Interlock Relay PWB J569-2. 

Check the wire for an open circuit between the Interlock Relay PWB J569-1 and the I/ 

FPWBJ531-1. 



Replace the l/F PWB (PL 9.1). 

If the problem continues, replace the MCU PWB (PL 13.1). 

Check installation of Cover/Actuator. 



^ TO l/F PWB J535-A1 



+24VDCFROM LEFT COVER 
INTERLOCK SWITCH J172-BH QRN 




I— Vv\— 



DC330 [1-300] 
FRONT INTERLOCK/ 
RH COVER 
INTERLOCK 
J569 CLOSED (H) +24 VDC J531 



l/F PWB 
PL9.1 



MCU PWB 

PL13.1 

3.3VDC 



P/J4105 



ORN 



ORN 



CONTROL 
LOGIC 



T701000A-CAR 



Figure 1 Front Cover / Right Cover Interlock CD 




Front Cover 
Interlock Switch 



Figure 2 Front Cover Interlock Switch Location 




Figure 3 Left Cover Interlock Switch Location 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-11 



Status Indicator RAPs 

1-302 



1-303 RAP 

HCF Left Door is open. 

Procedure 

Enter dC330 [001-304] and press Start. Actuate Tray Module LH Cover Interlock Switch with a 
screwdriver. Display changes state. 
Y N 

Check voltage between Tray Module PWB j554-3(+) and GND(-). +24 VDC is mea- 
sured. 
Y N 

Check the wires from the Tray Module PWB J554-3 to Tray Module L/H Cover Inter- 
lock Switch FS813 for damage. If the wires are good, replace Tray Module L/H 
Cover Interlock Switch (PL 15.10). 

Replace Tray Module PWB (PL15.9). 

Check Cover Actuator and Cover installation. 



TRAY MODULE PWB 
PL16.15 



DC COM 



CONTROL 
LOGIC 



DC COM 



J554 FS812 


TRAY MODULE LH 
COVER INTERLOCK 
SWITCH 
PL16.13 


FS813 


| BLU BLU 




BLU 


| TRAY MODULE LH 
! COVER INTERLOCK 
i SWITCH CLOSED 
! (H) +24 VDC 







T701007A-CAR 



Figure 1 Tray Module LH Cover Interlock Switch Cd 



Status Indicator RAPs 

1-303 



6/02 
2-12 



Prelaunch Training/Review 
DC1 632/2240 



1-306 RAP 

Duplex Door is open. 

Procedure 

Enter dC330 [008-300] and press Start. Open Duplex Transport. Actuate Duplex Cover Inter- 
lock Switch with a screwdriver. Display changes state. 
Y N 

Deactuate Duplex Cover Interlock Switch. Check voltage on the Drawer Connector 
between J626-A6 (+) and GND(-). +5 VDC is measured. 
Y N 

Check voltage between MCU PWB J406-A9 and GND(-). +5 VDC is measured. 
Y N 

Replace MCU PWB (PL13.1). 

Repair the open circuit between the MCU PWB J406-A9 and Drawer Connector 
between J626-A6 

Check the wires between Drawer Connector between J626-A6 and Duplex PWB J540-1 . If 
the wires are good, replace the Duplex Cover Interlock Switch. 

Check Cover Actuator and Cover installation. If there is no problem, replace MCU PWB 
(PL13.1) 





DOUBLE DRAWER 






J540 J136 


DUPLEX 
COVER 
INTERLOCK 
SWITCH 






J538 


DUPLEX 

PWB 

PL12.2 

IT 

DC COM 


J136 






i VIO VIO 




MCU PWB 
PL13.1 


J406 

9 

YEL 


YEL 


















^VDC 


P640 


— 


P640 J626 




J626 




CONTROL 
LOGIC 














YEL 






















T701008A-CAR 



Figure 1 Duplex Cover Interlock Switch 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-13 



Status Indicator RAPs 

1-306 



Status Indicator RAPs 6/02 Prelaunch Training/Review 

1-306 2-14 DC1 632/2240 



3-317 NT Software Failure 

Configuration mismatch 

Procedure 

Change the position of the document sensor. The problem is corrected. 
Y N 

Rewrite the NVM values. 

Return to Service Call Procedures. 



3-318 NT Software Failure 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the ESS PWB connectors. If the 
check is OK, replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-15 



Status Indicator RAPs 

3-317,3-318 



3-319 NT Video Driver Failure 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the ESS PWB connectors. If the 
check is OK, replace the ESS PWB (PL 1 3.1 ). 

Return to Service Call Procedures. 



3-320 NT-ESS Communication Failure 1 

Controller received check code error. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the IIT/IPS PWB (PL 18.3). 

Return to Service Call Procedures. 



Status Indicator RAPs 

3-319 , 3-320 



6/02 
2-16 



Prelaunch Training/Review 
DC1 632/2240 



3-321 NT-ESS Communication Failure 2 3-322 NT-ESS Communication Failure 3 

Controller received check code error. Controller received check code error. 

Procedure Procedure 

Switch the power off then on. The problem is corrected. Switch the power off then on. The problem is corrected. 

Y N Y N 



Reinstall the software. If the problem continues, check the I IT/IPS PWB connectors. If the 
check is OK, replace the I IT/I PS PWB (PL 18.3). 



Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the NT/IPS PWB (PL 18.3). 



Return to Service Call Procedures. Return to Service Call Procedures. 



Prelaunch Training/Review g^2 Status Indicator RAPs 

DC1 632/2240 2-17 3-321,3-322 



3-323 NT-ESS Communication Failure 4 3-324 NT-ESS Communication Failure 5 

Controller received check code error. Controller received check code error. 

Procedure Procedure 

Switch the power off then on. The problem is corrected. Switch the power off then on. The problem is corrected. 

Y N Y N 



Reinstall the software. If the problem continues, check the I IT/IPS PWB connectors. If the 
check is OK, replace the I IT/I PS PWB (PL 18.3). 



Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the NT/IPS PWB (PL 18.3). 



Return to Service Call Procedures. Return to Service Call Procedures. 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

3-323, 3-324 2-1 8 dci 632/2240 



3-325 NT-ESS Communication Failure 6 3-326 NT-ESS Communication Failure 7 

Controller received check code error. Controller received check code error. 

Procedure Procedure 

Switch the power off then on. The problem is corrected. Switch the power off then on. The problem is corrected. 

Y N Y N 



Reinstall the software. If the problem continues, check the I IT/IPS PWB connectors. If the 
check is OK, replace the I IT/I PS PWB (PL 18.3). 



Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the NT/IPS PWB (PL 18.3). 



Return to Service Call Procedures. Return to Service Call Procedures. 



Prelaunch Training/Review g^2 Status Indicator RAPs 

DC1 632/2240 2-19 3-325, 3-326 



3-327 NT-ESS Communication Failure 8 3-328 NT-ESS Communication Failure 9 

Controller received check code error. Controller received check code error. 

Procedure Procedure 

Switch the power off then on. The problem is corrected. Switch the power off then on. The problem is corrected. 

Y N Y N 



Reinstall the software. If the problem continues, check the I IT/IPS PWB connectors. If the 
check is OK, replace the I IT/I PS PWB (PL 18.3). 



Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the NT/IPS PWB (PL 18.3). 



Return to Service Call Procedures. Return to Service Call Procedures. 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

3-327, 3-328 2-20 dci 632/2240 



3-329 NT-ESS Communication Failure 10 3-330 NT-ESS Communication Failure 11 

Controller received check code error. Controller received check code error. 

Procedure Procedure 

Switch the power off then on. The problem is corrected. Switch the power off then on. The problem is corrected. 

Y N Y N 



Reinstall the software. If the problem continues, check the I IT/IPS PWB connectors. If the 
check is OK, replace the I IT/I PS PWB (PL 18.3). 



Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the NT/IPS PWB (PL 18.3). 



Return to Service Call Procedures. Return to Service Call Procedures. 



Prelaunch Training/Review g^ 2 Status Indicator RAPs 

DC1 632/2240 2-21 3-329, 3-330 



3-331 NT-ESS Communication Failure 12 3-332 NT-ESS Communication Failure 13 

Controller received check code error. Controller received check code error. 

Procedure Procedure 

Switch the power off then on. The problem is corrected. Switch the power off then on. The problem is corrected. 

Y N Y N 



Reinstall the software. If the problem continues, check the I IT/IPS PWB connectors. If the 
check is OK, replace the I IT/I PS PWB (PL 18.3). 



Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the NT/IPS PWB (PL 18.3). 



Return to Service Call Procedures. Return to Service Call Procedures. 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

3-331,3-332 2-22 dci 632/2240 



3-333 NT-ESS Communication Failure 14 3-334 NT-ESS Communication Failure 15 

Controller received check code error. Controller received check code error. 

Procedure Procedure 

Switch the power off then on. The problem is corrected. Switch the power off then on. The problem is corrected. 

Y N Y N 



Reinstall the software. If the problem continues, check the I IT/IPS PWB connectors. If the 
check is OK, replace the I IT/I PS PWB (PL 18.3). 



Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the NT/IPS PWB (PL 18.3). 



Return to Service Call Procedures. Return to Service Call Procedures. 



Prelaunch Training/Review g^ 2 Status Indicator RAPs 

DC1 632/2240 2-23 3-333, 3-334 



3-335 NT-ESS Communication Failure 16 3-336 NT-ESS Communication Failure 17 

Controller received check code error. Controller received check code error. 

Procedure Procedure 

Switch the power off then on. The problem is corrected. Switch the power off then on. The problem is corrected. 

Y N Y N 



Reinstall the software. If the problem continues, check the I IT/IPS PWB connectors. If the 
check is OK, replace the I IT/I PS PWB (PL 18.3). 



Reinstall the software. If the problem continues, check the NT/IPS PWB connectors. If the 
check is OK, replace the NT/IPS PWB (PL 18.3). 



Return to Service Call Procedures. Return to Service Call Procedures. 



Status Indicator RAPs g /02 Prelaunch Training/Review 

3-335, 3-336 2-24 dci 632/2240 



3-340 IOT-ESS Communication Failure 1 

Controller received check code error. 



3-341 IOT-ESS Communication Fail 2 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-25 



Status Indicator RAPs 

3-340, 3-341 



3-342 IOT-ESS Communication Failure 3 

Controller received check code error. 



3-343 IOT-ESS Communication Failure 4 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

3-342, 3-343 



6/02 
2-26 



Prelaunch Training/Review 
DC1 632/2240 



3-345 IOT-ESS Communication Failure 5 

Controller received check code error. 



3-346 IOT-ESS Communication Failure 6 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-27 



Status Indicator RAPs 

3-345, 3-346 



3-347 IOT-ESS Communication Failure 7 

Controller received check code error. 



3-348 IOT-ESS Communication Failure 8 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

3-347, 3-348 



6/02 
2-28 



Prelaunch Training/Review 
DC1 632/2240 



3-349 IOT-ESS Communication Failure 9 

Controller received check code error. 



3-350 IOT-ESS Communication Failure 10 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-29 



Status Indicator RAPs 

3-349, 3-350 



3-351 IOT-ESS Communication Failure 11 

Controller received check code error. 



3-352 IOT-ESS Communication Failure 12 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

3-351,3-352 



6/02 
2-30 



Prelaunch Training/Review 
DC1 632/2240 



3-353 IOT-ESS Communication Failure 13 

Controller received check code error. 



3-354 IOT-ESS Communication Failure 14 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-31 



Status Indicator RAPs 

3-353, 3-354 



3-355 IOT-ESS Communication Failure 15 

Controller received check code error. 



3-356 IOT-ESS Communication Failure 16 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

3-355, 3-356 



6/02 
2-32 



Prelaunch Training/Review 
DC1 632/2240 



3-357 IOT-ESS Communication Failure 17 

Controller received check code error. 



3-358 IOT-ESS Communication Failure 1 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-33 



Status Indicator RAPs 

3-357, 3-358 



3-359 IOT-ESS Communication Failure 19 

Controller received check code error. 



3-360 IOT-ESS Initialization Failure 

Controller received check code error. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Reinstall the software. If the problem continues, check the MCU PWB connectors. If the 
check is OK, replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

3-359 , 3-360 



6/02 
2-34 



Prelaunch Training/Review 
DC1 632/2240 



3-364 DMA Transfer Failure 

Compression/extraction did not complete. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Replace the RAM (PL1 3.1) then the HDD. If the problem continues, replace the ESS PWB 
(PL 13.1). 

Return to Service Call Procedures. 



3-370 Marker Code Detect Failure 

The end code cannot be found in the compressed data. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Replace the RAM (PL13.1) then the HDD. If the problem continues, replace the ESS PWB 
(PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-35 



Status Indicator RAPs 

3-364, 3-370 



3-747 Print Instruction Failure 

The print parameter is incorrect. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Change the print parameter and print again. 

Return to Service Call Procedures. 



3-750 Insufficient Number of Document Pages 

Insufficient number of pages programed when making a book. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Set the number of document pages to the maximum count. 

Return to Service Call Procedures. 



Status Indicator RAPs 

3-747, 3-750 



6/02 
2-36 



Prelaunch Training/Review 
DC1 632/2240 



3-761 Tray Select Error 

The paper sizes are different than the tray that will be selected by the APS. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Select an appropriate tray. 

Return to Service Call Procedures. 



3-941 Insufficient Page Memory 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Perform the operation again. 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-37 



Status Indicator RAPs 

3-761,3-941 



3-942 Document Size Error 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Perform the operation again. 

Return to Service Call Procedures. 



3-946 Tray 1 Not In Position 

Tray 1 not in ready position. 

Initial Actions 

i Check that the paper size setting is correct. 

i Check the Paper Size Sensor for obstructions or damage. 

Procedure 

Ensure Tray 1 is closed. The voltage measured at P/J536-B9 on the l/F PWB corresponds 
to the paper size in the table. 
Y N 

There is +3.3VDC measured at P/J536-B10. 
Y N 

Check the connection between the l/F PWB and the MCU PWB. If the check is OK, 
replace the l/F PWB (PL 9.1). If the problem continues, replace the MCU PWB (PL 
13.1) 

Check the wires and connectors. If the check is OK, replace the Tray 1 Paper Size Sensor 
(PL 2.1). 

Check the connection between l/F PWB and MCU PWB. If the check is OK, replace the MCU 
PWB (PL 13.1). 



I/F PWB 
PL9.1 



+3.3VDC 
J536 J115 • 
■ B10 , , 1 



TRAY 1 PAPER SIZE SENSOR 
PL2.1 




T707012A-CAR 



Figure 1 Tray 1 Paper Size Sensor 



Status Indicator RAPs 

3-942, 3-946 



6/02 
2-38 



Prelaunch Training/Review 
DC1 632/2240 



3-947 Tray 2 Not In Position 

Tray 2 not in ready position. 

Initial Actions 

i Check that the paper size setting is correct. 

i Check the Paper Size Sensor for obstructions or damage. 

Procedure 

Ensure Tray 2 is closed. The voltage measured at P/J546-8 on the Tray Module PWB (PL 
16.15) corresponds to the paper size in the table. 
Y N 

There is +5VDC measured at P/J546-9 on the Tray Module PWB (PL 16.15) 
Y N 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB 
(PL 16.15) 

Check the wires and connectors. If the check is OK, replace the Tray 2 Paper Size Sensor 
(PL 16.1). 

Check the wires and connectors, If the check is OK, replace the Tray Module PWB (PL 16.15). 
If the problem continues, replace the Tray 2 Paper Size Sensor (PL 16.1). 



3-948 Tray 3 Not In Position 

Tray 3 not in ready position. 

Initial Actions 

i Check that the paper size setting is correct. 

i Check the Paper Size Sensor for obstructions or damage. 

Procedure 

Ensure Tray 3 is closed. The voltage measured at P/J548-11 on the Tray Module PWB (PL 
16.15) corresponds to the paper size in the table. 
Y N 

There is +5VDC measured at P/J548-12 on the Tray Module PWB (PL 16.15) 
Y N 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB 
(PL 16.15) 

Check the wires and connectors. If the check is OK, replace the Tray 3 Paper Size Sensor 
(PL 16.1). 

Check the wires and connectors, If the check is OK, replace the Tray Module PWB (PL 16.15). 
If the problem continues, replace the Tray 3 Paper Size Sensor (PL 16.1). 




TRAY 2 PAPER 
SIZE SENSOR 
SENSED SIGNAL 



TRAY MODULE PWB 
PL16.15 

+5VDC 




VA 














Figure 1 Tray 3 Paper Size Sensor 



T707015A-CAR 



T707013A-CAR 



Figure 1 Tray 2 Paper Size Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-39 



Status Indicator RAPs 

3-947, 3-948 



3-949 Tray 4 Not In Position 

Tray 4 not in ready position. 



3-950 Tray 1 No Paper 

No paper in Tray 1 



Initial Actions 

i Check that the paper size setting is correct. 

i Check the Paper Size Sensor for obstructions or damage. 

Procedure 

Ensure Tray 4 is closed. The voltage measured at P/J548-5 on the Tray Module PWB (PL 
16.15) corresponds to the paper size in the table. 
Y N 

There is +5VDC measured at P/J548-6 on the Tray Module PWB (PL 16.15) 
Y N 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB 
(PL 16.15) 

Check the wires and connectors. If the check is OK, replace the Tray 2 Paper Size Sensor 
(PL 16.1). 

Check the wires and connectors, If the check is OK, replace the Tray Module PWB (PL 16.15). 
If the problem continues, replace the Tray 4 Paper Size Sensor (PL 16.1). 



TRAY 

MODULE PWB 
PL16.15 



J548 +5VDCJ824 



■5VDC 



TRAY 4 PAPER 
SIZE SENSOR 
SENSED SIGNAL 




Procedure 

Enter dC330 [007-120] and press Start. Actuate Tray 1 No Paper Sensor. The display 

changes state. 
Y N 

Go to OF 99-2 Transmissive Sensor RAP, repair Tray 1 No Paper Sensor (PL 2.4). 

Replace MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



+3.3VDC 



CONTROL 
LOGIC 



l£ 



l/F PWB 
PL9.1 

DC COM 



A7 



DOUBLE 
PLUG 

J532 DC COM P617 ' ' J617 J106 



TRAY 1 NO PAPER 

SENSOR 

PL2.4 



£~~ A9 ^BLU 



+5VDC 



P/J410 
94 — 



DC330 [7-120] 
TRAY 1 NO PAPER 
SENSOR SENSED 
(H) +3.3VDC 



GRY 



J 5 



| BLU L_^ - 

Figure 1 Tray 1 No Paper Sensor CD 



lJ)S(g 



J106 
YEL 



T707007A-CAR 



T707016A-CAR 



Figure 1 Tray 4 Paper Size Sensor 



Status Indicator RAPs 

3-949, 3-950 



6/02 
2-40 



Prelaunch Training/Review 
DC1 632/2240 



3-951 Tray 2 No Paper 

No paper in Tray 2 



3-952 Tray 3 No Paper 

No paper in Tray 3 



Procedure 

Enter dC330 [007-121] and press Start. Actuate Tray 2 No Paper Sensor. Display changes 

state. 

Y N 

Go to OF 99-2 Transmissive Sensor RAP, repair Tray 2 No Paper Sensor (PL 15.3, PL 

16.7). 

Replace MCU PWB (PL 13.1). 



Procedure 

Enter dC330 [007-122] and press Start. Actuate Tray 3 No Paper Sensor. Display changes 

state. 

Y N 

Go to OF 99-2 Transmissive Sensor RAP, repair Tray 3 No Paper Sensor (PL 15.5, PL 

16.9). 

Replace MCU PWB (PL 13.1). 




DOUBLE 
PLUG 

J547 DC COM P670 J670 J815 

1 6—7 

VIO 



TRAY 2 NO PAPER 

SENSOR 

PL16.7 



+5VDC 



GRY 

DC330 [7-121] 
TRAY 2 NO PAPER 
SENSOR SENSED 
(H) +5VDC 



4 — 9 



GRY 



YEL 



I I 

Figure 1 Tray 2 No Paper Sensor CD 



lJ)S(g 



J815 
YEL 



T707009A-CAR 




DOUBLE 
PLUG 

J549 DC COM P872 J872 J818 



TRAY 3 NO PAPER 

SENSOR 

PL16.9 



DC330 [7-122] 
TRAY 3 NO PAPER 
SENSOR SENSED 
(H) +5VDC 



6 — 7 



GRY 



YEL 



I I 



Figure 1 Tray 3 No Paper Sensor 



|(£>*d : 



J818 
YEL 



T707011A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-41 



Status Indicator RAPs 

3-951,3-952 



3-953 Tray 4 No Paper 

No paper in Tray 4. 



3-954 Tray 5 Empty 

Tray 5 is empty. 



Procedure 

Enter dC330 [007-123] and press Start. Actuate Tray 4 No Paper Sensor. Display changes 

state. 

Y N 

Go to OF 99-2 Transmissive Sensor RAP, repair Tray 4 No Paper Sensor (PL 15.7, PL 
16.1). 

Replace MCU PWB (PL 13.1). 



Procedure 

Enter dC330 [007-125] and press Start. Actuate the Tray 5 No Paper Sensor. Display 
changes state. 
Y N 

Go to OF 99-2 Transmissive Sensor RAP, repair the Tray 5 No Paper Sensor (PL 2.13). 

Replace l/F PWB (PL 9.1). If the problem continues, replace the MCU PWB (PL 13.1). 



TRAY MODULE 

PWB 

PL16.15 



47 



■A7 r 



J549 DC COM P674 



DOUBLE 
PLUG 
I 1 

6 — 7 



J674 J823 



+5VDC 



-A9k 



! +5VDC 



-14-9 



CONTROL 
LOGIC 



iGRY 

J DC330 [7-123] j I I 

' TRAY 4 NO PAPER SENSOR i I 

Ag | SENSED (H) +5VDC j 5 _ 



GRY 



TRAY 4 NO PAPER 

SENSOR 

PL16.11 



lJ)S(g 



YEL 



I I 

Figure 1 Tray 4 No Paper Sensor CD 



T707005A-CAR 



MCU PWB 
PL13.1 



+3.3VDC 



CONTROL 
LOGIC 



li 



l/F PWB 
PL9.1 



DOUBLE 
PLUG 

J532 DC COM P61° ' ' 

I B8 i 1 3 — 6 

J3 |YEL 

DC COM ! 



J610 J103 



B10 



+5VDC 



+5VDC 



P/J410 
37 — 



YEL 

! DC330 [7-125] 
I TRAY 4 NO PAPER 
| SENSOR SENSED 
i (H) +3.3VDC 



1 — 



GRY 



TRAY 5 NO PAPER 

SENSOR 

PL2.13 



|(£>*d : 



YEL 



J 2 - 7 
I I 



YEL 



Figure 1 Tray 5 No Paper Sensor CD 



T708006A-CAR 



Status Indicator RAPs 

3-953, 3-954 



6/02 
2-42 



Prelaunch Training/Review 
DC1 632/2240 



3-958 Tray 5 Paper Size Mismatch 

The paper in the Tray 5 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 5. 
Y N 

Load the correct size paper and return to Service Call Procedures. 

Go to RAP 7-954. 



3-959 Tray 1 Paper Size Mismatch 

The paper in Tray 1 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 1 . 
Y N 

Load the correct size paper and return to Service Call Procedures. 



Go to RAP 7-955. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-43 



Status Indicator RAPs 

3-958, 3-959 



3-960 Tray 2 Paper Size Mismatch 

The paper in Tray 2 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 2. 
Y N 

Load the correct size paper and return to Service Call Procedures. 

Goto RAP 7-271. 



3-961 Tray 3 Paper Size Mismatch 

The paper in Tray 3 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 3. 
Y N 

Load the correct size paper and return to Service Call Procedures. 



Go to RAP 7-276. 



Status Indicator RAPs 

3-960, 3-961 



6/02 
2-44 



Prelaunch Training/Review 
DC1 632/2240 



3-962 Tray 4 Paper Size Mismatch 

The paper in Tray 4 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 4. 
Y N 

Load the correct size paper and return to Service Call Procedures. 

Go to RAP 7-277. 



3-965 No Paper 

The paper does not match the paper size selected. 

Procedure 

The correct size paper is loaded. 
Y N 

Load the correct size paper and return to Service Call Procedures. 

Go to the appropriate paper size sensor RAP. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-45 



Status Indicator RAPs 

3-962, 3-965 



3-971 Magnification 

Incompatible Magnification 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Change parameters and rerun job. 



3-972 Over Number of Document Pages Stored 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Set the number of document pages to the maximum count. 

Return to Service Call Procedures. 



Status Indicator RAPs 

3-971,3-972 



6/02 
2-46 



Prelaunch Training/Review 
DC1 632/2240 



3-980 Stapler Position Error 

The Stapler is not available at the specified position. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Re-set the parameters. 

Return to Service Call Procedures. 



3-985 Tray 5 Pause Check 

The SMH tray jamed. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Go to RAP 7-794. 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-47 



Status Indicator RAPs 

3-980, 3-985 



3-986 Print Completion Error 

The number of spooled pages does not match the output. 

Procedure 

Switch the power off then on. The problem is corrected. 
Y N 

Count the number of prints to ensure job integrity. 

Return to Service Call Procedures. 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

3-986 2-48 DC1 632/2240 



4-340 IOT RAM 

MCU PWB RAM test failed. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 

If the problem continues, replace the MCU NVM PWB (PL 13.1). 



Prelaunch Training/Review g^ 2 Status Indicator RAPs 

DC1 632/2240 2-49 4-340 



4-341 IOT Logic 

Operation failure of an MCU PWB operation. 

Initial Actions 

Re-installation the software. 

Procedure 

CH3.1A, CH3.6A 

Connect black meter lead to ground or machine frame. There is +5VDC measured at J401- 

B20 

Y N 

There is +5VDC measured at J568-5 
Y N 

There is +5VDC measured at J568-1 
Y N 

Repair the wire between FS534 and J568-2. 

Replace ROS Assembly (PL 3.1). 

Check for an open circuit between J568-5 the p400-9. 
If the circuit is OK, replace the MCU PWB (PL 13.1). 

Replace MCU PWB (PL 13.1). 

If the problem continues, replace ROS Assembly (PL 3.1). 



4-342 Flash ROM Motion 

Motion failure of Flash ROM 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace ROM PWB (PL13.1) 



Status Indicator RAPs 

4-341,4-342 



6/02 
2-50 



Prelaunch Training/Review 
DC1 632/2240 



4-343 IOT Flash ROM Read Write 

There is a FLASH ROM operation failure. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 



4-344 IOT Micro Pitch 

The MICRO PIT did not occur within the specified time. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-51 



Status Indicator RAPs 

4-343, 4-344 



4-345 MCU HVPS Communication 

Communication error between MCU PWB and HVPS Control PWB 

Procedure 

BSD:CH3.1BCH3.6A 

Between MCU PWB j406-B1(+) and GND(-). +5 VDC is measured. 

Y N 
Between MCU PWB J406-B1(+) and GND(-). +3.3 VDC is measured. 
Y N 

Check frame short between MCU PWB J406-B1 and HVPS Control PWB J574-9. If 
the check is good, replace MCU PWB (PL 13.1). 

Check for wire breakage and bad connection between MCU PWB J406-B1and HVPS 
Control PWB J574-9. 

Turn the power OFF. Measure resistance of following. 
Between HVPS CONTROL PWB J574-7 and MCU PWB J406-B3 

Between HVPS CONTROL PWB J574-6 and MCU PWB J406-B4. 10 ohms or less is mea- 
sured. 

Y N 
Repair wire breakage and bad connection. 

10 ohms or less is measured between HVPS Control PWB J574-8 and MCU PWB J406-B2. 

Y N 

Repair wire breakage and bad connection. 

Replace MCU PWB (PL 13.1). If this does not solve the problem, replace HVPS Control PWB 
(PL 9.1). 



4-346 IBT Home Sensor 

IBT Home Sensor does not detect Belt Home signal. 

Procedure 

BSD:CH9.19CH9.31A 

If the IBT was just serviced, verify the installation is correct (REP 9.15). 

If any Developer Housings were just serviced, verify installation is correct (REP 9.9). 

If a Finisher status code occurred just before the 4-346 in fault history, go to the RAP for the 

Finisher status code. 

Check the Belt Home Marker. A Belt Home Marker is present. 

Y N 
Replace IBT Belt (PL 5.3). 

Block Belt Home Sensor with paper. Enter dC330 [004-100] and press Start. Display indi- 
cates Hi. 

Y N 
Between l/F PWB J533-A13(+) and GND(-). +5 VDC is measured. 

Y N 
Between l/F PWB J533-A9(+) J533-A12(-). +5 VDC is measured. 
Y N 

Replace MCU PWB (PL 13.1). 

Check for wire breakage and bad connection between IBT Home Sensor J121 and I/ 
F PWB J533. If the check is good, replace IBT Home Sensor (PL 5.4). 

Replace MCU PWB (PL 13.1). 

If the problem continues, replace l/F PWB (PL 9.1). 

Reinstall IBT Assembly (REP 9.15). Enter dC330 [004-002] and press Start. IBT Motor ener- 
gizes. 

Y N 
Between l/F PWB j551-3(+) and GND(-). +24 VDC is measured. 

Y N 
By following Ch7 Wire Network, check +24VDC circuit up to l/F PWB J551-3 



Between IBT MOTOR j208-3(+) and GND(-). +24 VDC is measured. 

Y N 

Check wire breakage and bad connection between IBT MOTOR J208-3 and l/FPWB 
J551-3. 

Check wire breakage and bad connection between IBT MOTOR J208 and l/FPWB J551. 
There are broken wires or bad connections. 

Y N 
Replace IBT MOTOR (PL 1.1). 

Repair broken wire and bad connection. 



Replace MCU PWB (PL 13.1). 

If the problem continues, replace l/FPWB (PL 9.1). 



Status Indicator RAPs 

4-345, 4-346 



6/02 
2-52 



Prelaunch Training/Review 
DC1 632/2240 



4-347 IBT Belt Edge 

IBT belt edge not in position. 

Procedure 

BSD:CH9.19CH9.31A 

Check if actuator for IBT Edge Sensor touches belt edge. IBT Edge Sensor touches belt 

edge. 

Y N 

Check actuator installation. 

Turn the power ON. Between l/F PWB J533-A11(+) and GND(-). Between +3 VDC and +1 
VDC is measured. 

Y N 

Between l/F PWB J533-A9(+) J533-A1 0(-). +5 VDC is measured. 

Y N 

Close FRONT door. If voltage between J533-A9(+) J533-A10(-) is less than +5VDC, 
replace MCU PWB (PL 13.1). 

Between l/F PWB j533-A11(+) and GND(-). +5 VDC is measured. 

Y N 
Between l/F PWB J533-A11(+) and GND(-). VDC is measured. 
Y N 

Check wire breakage and bad connection between l/F PWB J533 and IBT- 

EDGESENSORJ119. 

If the check is good, replace IBT Edge Sensor (PL 5.4). 

If the problem continues, replace MCU PWB (PL 13.1). 

Check wire breakage and bad connection between l/F PWBJ533-A11 and IBTEDGE 
SENSORJ119-2. 

Replace IBT EDGE SENSOR (PL5.4) 

between l/F PWB j550-5(+) and GND(-). +24 VDC is measured. 

Y N 

By following Wire Network, check +24VDC circuit up to l/F PWB J550-5. 

Remove IBT Assembly. Enter dC330 [004-001] and energize the Steering Motor. Steering 
Motor energized. 

Y N 
Check wire breakage and bad connection between l/F PWB J550 and IBT STEERING 
MOTOR J207. There are broken wires or bad connections. 

Y N 
Replace MCU PWB (PL 13.1). If the problem continues, replace l/F PWB (PL 9.1), 
and IBT Steering Motor (PL 1.3). 

Repair broken wire and bad connection. 

Check IBT Belt installation (REP 9.22). If the check is good, replace MCU PWB (PL 13.1). 



Prelaunch Training/Review g^ 2 Status Indicator RAPs 

DC1 632/2240 2-53 4-347 



4-348 IBT Belt Edge 

IBT Belt Edge not detected. 

Procedure 

BSD:CH9.19CH9.31A 

Check if actuator for IBT Edge Sensor touches belt edge. IBT Edge Sensor touches belt 

edge. 

Y N 

Check actuator installation. 

Turn the power ON. Between l/F PWB J533-A11(+) and GND(-). Between +3 VDC and 1 
VDC is measured. 

Y N 
Between l/F PWB J533-A9(+) J533-A10(-). +5 VDC is measured. 
Y N 

Close FRONT door. If voltage between J533-A9(+) J533-A10(-) is less than +5VDC, 
replace MCU PWB (PL 13.1). 



Between l/F PWB j533-A11(+) and GND(-). +5 VDC is measured. 
Y N 

Between l/F PWB J533-A11(+) and GND(-). VDC is measured. 

Y N 

Check wire breakage and bad connection between l/F PWB j533and IBT Edge 

Sensorj119. 

If the check is good, replace IBT Edge Sensor (PL 5.4). 

If the problem continues, replace MCU PWB (PL 13.1). 

Check wire breakage and bad connection between l/F PWB J533-A11 and IBT Edge 
Sensorj119-2. 

Replace IBT Edge Sensor (PL 5.4). 



Between l/F PWB j550-5(+) and GND(-). +24 VDC is measured. 

Y N 

Following Wire Network, check +24VDC circuit up to l/F PWB J550-5. 

Remove IBT Assembly. Enter dC330 [004-001] and energize the Steering Motor. Steering 
Motor energized. 

Y N 
Check wire breakage and bad connection between l/F PWB J550 and IBT Steering Motor 
J207. There are broken wires or bad connections. 
Y N 

Replace MCU PWB (PL 13.1). If the problem continues, replace l/F PWB (PL 9.1), 
and IBT Steering Motor (PL 1.3). 

Repair broken wire and bad connection. 

Check IBT Belt installation (REP 9.22). If the check is good, replace MCU PWB (PL 13.1). 



Status Indicator RAPs 

4-348 



6/02 
2-54 



Prelaunch Training/Review 
DC1 632/2240 



4-349 Marking Software Logic 

Control Logic detected a fatal failure in the Marking software. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Again, switch the power off then on. Run the job again. 



4-358 ESS IOT Communication 

Communication failure between the ESS and IOT. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Check the MCU PWB and ESS PWB connectors. 

If the problem continues, re-install the software. 

If the problem continues, replace the MCU PWB (PL 13.1). 

If the problem continues, replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-55 



Status Indicator RAPs 

4-349, 4-358 



4-361 Drum Motor 

Drum Motor failure. 

Procedure 

BSD:CH9.1 CH9.31A 

Remove Y/M/C/K Drum Assembly. Enter dC330 [004-003] and press Start. Drum Motor 

energizes and drives rotate 

Y N 

Between Drum Motor j210-4(+) and GND(-). +5 VDC is measured. 

Y N 

By following Wire Network, check +5VDC circuit to Drum Motor J210-4. 



Between Drum Motor j210-6(+) and GND(-). +24 VDC is measured. 

Y N 

By following Wire Network, check +24VDC circuit to Drum Motor J21 0-6. 

Between Drum Motor J21 0-1 (+) and GND(-). Ensure dC330 [004-003] is entered and 
press Start. VDC is measured. 

Y N 
Between l/F PWB J535-B5(+) and GND(-). Ensure dC330 [004-003] is entered and 
press Start. VDC is measured. 

Y N 
Check for wire breakage and bad connection between Drum Motor J210-1 to l/F 
PWB J535-B5. If the check is good, replace MCU PWB? (PL 1 3. 1 ). 

Check for wire breakage and bad connection between Drum Motor J21 0-1 to l/FPWB 
J535-B5. 

Between Drum Motor j210-2(+) and GND(-). Ensure dC330 [004-003] is entered and 
press Start. VDC is measured. 

Y N 
Between l/F PWB J535-B3(+) and GND(-). Ensure dC330 [004-003] is entered and 
press Start. VDC is measured. 

Y N 
Check for wire breakage and bad connection between Drum Motor J21 0-2 and 
l/F PWB J535-B3. If the check is good, replace l/F PWB (PL 9.1). 

Check for wire breakage and bad connection between Drum Motor J210-2 and l/F 
PWBJ535-B3. 

Between Drum Motor j210-3(+) and GND(-). Ensure dC330 [004-003] is entered and 
press Start. Frequency is between 1KHz and 1.3 KHz. 

Y N 
Between l/F PWB J535-B2(+) and GND(-). Ensure dC330 [004-003] is entered and 
press Start. Frequency is between 1 KHz and 1 .3 KHz. 

Y N 
Check frame short between Drum Motor J210-3 and l/FPWB J535-B2. If the 
check is good, replace l/F PWB? (PL 9.1). 

Check for wire breakage and bad connection between Drum Motor J210-3? and l/F 
PWBJ535-B2. 





A B 

Replace Drum Motor (REP 4.4) (PL 1 . 1 ). 

Between l/F PWB J535-B1(+) and GND(-). Ensure dC330 [004-003] is entered and press 
Start. +5 VDC is measured. 

Y N 
Replace l/F PWB (PL 9.1). 

Between Drum Motor j210-8(+) and GND(-). Ensure dC330 [004-003] is entered and press 
Start. +5 VDC is measured. 

Y N 
Check for wire breakage and bad connection between l/F PWB J535-B1 and Drum Motor 
J210-8. 

Replace Drum Motor (PL 1.1). 



Status Indicator RAPs 

4-361 



6/02 
2-56 



Prelaunch Training/Review 
DC1 632/2240 



4-362 IOT NVM Read Write 

Read Write at the MCU PWB NVM R/W. 



4-371 IOT Controller Timing Failure 

There is a communication failure between the ESS and IOT. 



Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Check the connection between the MCU PWB and the MCU NVM PWB. 

If the problem continues, replace the MCU PWB (PL 13.1). 

If the problem continues, replace the MCU NVM PWB (PL 13.1). 



Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Check the MCU PWB and ESS PWB connectors. 

If the problem continues, re-install software. 

If the problem continues, replace the MCU PWB (PL 13.1). 

If the problem continues, replace the ESS PWB (PL 13.1) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-57 



Status Indicator RAPs 

4-362, 4-371 



4-363 K Drum Motor 

Drum Motor K failure 

Procedure 

BSD:CH9.2CH9.31A 

Remove K DRUM. Enter dC330 [004-006] and press Start. Drum Motor K energizes. 

Y N 

Between Drum Motor Kj235-4(+) and GND(-). +5 VDC is measured. 

Y N 

Following Wire Network, check +5VDC circuit to Drum Motor K J235-4. 



Between Drum Motor Kj235-2(+) and GND(-). +24 VDC is measured. 

Y N 

Following Ch7 Wire Network, check +24VDC circuit to Drum Motor KJ235-2. 

Between Drum Motor K j235-5(+) and GND(-). Ensure dC330 [004-006] is entered and 
press Start. VDC is measured. 

Y N 
Between l/F PWB J534-A11(+) and GND(-). Ensure dC330 [004-006] is entered and 
press Start. VDC is measured. 

Y N 
Check connection between MCU PWB and l/F PWB P410/J410. 
If the check is good, replace MCU PWB (PL 13.1). 
If the problem continues, replace l/F PWB (PL 9.1). 

Check wire breakage and bad connection between l/F PWB J534-A11 and Drum 
Motor K J235-5 

Between Drum Motor K j235-8(+) and GND(-). Ensure dC330 [004-006] is entered and 
press Start. Frequency is between 1 KHz and 1 .3 KHz. 

Y N 
Between l/F PWB J534-A8 and GND (-). Frequency is between 1KHz and 1.3 
KHz. 

Y N 
Check connection between MCU PWB and l/F PWB p410/j410. 
If the check is good, replace MCU PWB (PL 13.1). 
If the problem continues, replace the l/F PWB (PL 9.1). 

Check wire breakage and bad connection between l/F PWB J534-A8 and Drum 
Motor K J235-8. 

Between l/F PWB J534-A10 and Drum Motor KJ235-6 
between l/F PWB J534-A9 and Drum Motor KJ235-7 
If the check is good, replace Drum Motor K (PL 1.1). 



Between l/F PWB J534-A7(+) and GND(-). Enter dC330 [004-006] and press Start. 
Y N 

Check connector between MCU PWB and l/F PWB p410/j410. If the check is good, 

replace MCU PWB (PL 13.1). 

If the problem continues, replace the l/F PWB (PL 9.1). 



Between Drum Motor K j235-9(+) and GND(-). Ensure dC330 [004-006] is entered and press 
Start. +5 VDC is measured 
Y N 

Check wire breakage and bad connection between Drum Motor K J235-9 and l/FPWB 

J534-A7. 

Check if there is load on K DRUM. If the check is good, replace Drum Motor K (PL 1.1). 



Status Indicator RAPs 

4-363 



6/02 
2-58 



Prelaunch Training/Review 
DC1 632/2240 



4-414 IBT Belt Cleaner 

IBT Belt Cleaner near end of life. 

Procedure 

Replace the Cleaner Assembly. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 

If the problem continues, replace the MCU NVM PWB (PL 13.1) 



4-415 2nd BTR Unit 

It is time to replace the 2nd BTR UNIT. 

Procedure 

Replace the 2nd BTR Unit. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 

If the problem continues, replace the MCU NVM PWB (PL 13.1) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-59 



Status Indicator RAPs 

4-414,4-415 



4-417 1st BTR Unit 

IBT Belt Unit near end of life. 



4-420 1st BTR Unit 

IBT Belt Unit end of life. 



Procedure 

Replace the IBT Belt Unit. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1) 

If the problem continues, replace the MCU NVM PWB (PL 13.1) 



Procedure 

Replace the 1st IBT Belt Unit The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 

If the problem continues, replace the MCU NVM PWB (PL 13.1). 



Status Indicator RAPs 

4-417, 4-420 



6/02 
2-60 



Prelaunch Training/Review 
DC1 632/2240 



4-421 IBT Belt Cleaner Life End 

IBT Belt Cleaner Assembly end of life. 

Procedure 

Replace the IBT Belt Cleaner Assembly. The problem continues. 
Y N 

Return to Service Call Procedures. 

If the problem continues, replace the MCU PWB (PL 13.1). 

If the problem continues, replace the MCU NVM PWB (PL 13.1). 



4-605 IOT NVM Corrupt 

The system detected that the NVM of the IOT is empty. 

Procedure 

Turn the power OFF/ON. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 

If the problem continues, replace the MCU NVM PWB (PL 13.1) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-61 



Status Indicator RAPs 

4-421,4-605 



4-640 Belt Tracking 

IBT tracking failure 

Procedure 

BSD:CH9.19CH9.31A 

Check if actuator for IBT Edge Sensor touches belt edge. IBT Edge Sensor touches belt 

edge. 

Y N 

Check actuator installation. 

Turn the power ON. Between l/F PWB J533-A11(+) and GND(-). Between +3 VDC and 1 
VDC is measured. 

Y N 
Between l/F PWB J533-A9(+) J533-A10(-). +5 VDC is measured. 
Y N 

Check +5VDC circuit to l/F PWB J533-A9. 



Between l/F PWB j533-A11(+) and GND(-). +5 VDC is measured. 
Y N 

Between l/F PWB j533-A11(+) and GND(-). VDC is measured. 

Y N 

Check wire breakage and bad connection between l/F PWB j533and IBT Edge 

Sensorj119. 

If the check is good, replace IBT Edge Sensor (PL 5.4). 

If the problem continues, replace MCU PWB (PL 13.1). 

Check wire breakage and bad connection between l/F PWB J533-A11 and IBT Edge 
Sensorj119-2. 

Replace IBT Edge Sensor (PL 5.4). 



Between l/F PWB J530-A9(+) and GND(-). +24 VDC is measured. 

Y N 

Following Wire Network, check +24VDC circuit up to l/F PWB J530-A9. 

Remove IBT Assembly (REP 9.15). Enter dC330 [004-001] and press Start. IBT Steering 
Motor energizes. 

Y N 
Check wire breakage and bad connection between l/F PWB J550 and IBT Steering Motor 
J207. There are broken wires or bad connections. 
Y N 

Replace MCU PWB (PL 13.1). 

If the problem continues, replace l/F PWB (PL 9.1). 

If the problem continues, replace IBT Steering Motor (PL 1.3). 

Repair broken wire and bad connection. 

Check IBT Belt installation (REP 9.22). If the check is good, replace MCU PWB (PL 13.1). 



4-641 Belt Edge 

IBT belt edge not detected. 

Procedure 

BSD:CH9.19CH9.31A 

Check if actuator for IBT Edge Sensor touches belt edge. IBT Edge Sensor touches belt 

edge. 

Y N 

Check actuator installation. 

Turn the power ON. Between l/F PWB J533-A11 (+) and GND(-). Between +3 VDC and 1 
VDC is measured. 

Y N 

Between l/F PWB J533-A9(+) J533-A10(-). +5 VDC is measured. 
Y N 

Close FRONT door. If voltage between J533-A9(+) J533-A10(-) is less than +5VDC, 
replace MCU PWB (PL 13.1). 



Between l/F PWB J533-A11(+) and GND(-). +5 VDC is measured. 
Y N 

Between l/F PWB J533-A11(+) and GND(-). VDC is measured. 

Y N 

Check wire breakage and bad connection between l/F PWB j533and IBT Edge 

Sensor J119. 

If the check is good, replace IBT Edge Sensor (PL 5.4). 

If the problem continues, replace MCU PWB (PL 13.1). 

Check wire breakage and bad connection between l/F PWB J533-A11 and IBT Edge 
Sensor j1 19-2. 

Replace IBT Edge Sensor (PL 5.4). 



Between l/F PWB J530-A9(+) and GND(-). +24 VDC is measured. 

Y N 

Following Wire Network, check +24VDC circuit up to l/F PWB J530-A9 

Remove IBT Assembly (REP 9.15). Enter dC330 [004-001] and press Start. IBT Steering 
Motor energizes. 

Y N 
Check wire breakage and bad connection between l/F PWB J550 and IBT Steering Motor 
J207. There are broken wires or bad connections. 
Y N 

Replace MCU PWB (PL 13.1). 

If the problem continues, replace l/F PWB (PL 9.1). 

If the problem continues, replace IBT Steering Motor (PL 1.3). 

Repair broken wire and bad connection. 

Check IBT Belt installation (REP 9.22). If the check is good, replace MCU PWB (PL 13.1). 



Status Indicator RAPs 

4-640, 4-641 



6/02 
2-62 



Prelaunch Training/Review 
DC1 632/2240 



4-642 Belt Edge 

IBT belt edge not in position. 

Procedure 

BSD:CH9.19CH9.31A 

Check if actuator for IBT Edge Sensor touches belt edge. IBT Edge Sensor touches belt 

edge. 

Y N 

Check actuator installation. 

Turn the power ON. Between l/F PWB J533-A11(+) and GND(-). Between +3 VDC and 1 
VDC is measured. 

Y N 
Between l/F PWB J533-A9(+) J533-A10(-). +5 VDC is measured. 
Y N 

Close FRONT door. If voltage between J533-A9(+) J533-A10(-) is less than +5VDC, 
replace MCU PWB (PL 13.1). 



Between l/F PWB j533-A11(+) and GND(-). +5 VDC is measured. 
Y N 

Between l/F PWB J533-A11(+) and GND(-). VDC is measured. 

Y N 

Check wire breakage and bad connection between l/F PWB j533and IBT Edge 

Sensorj119. 

If the check is good, replace IBT Edge Sensor (PL 5.4). 

If the problem continues, replace MCU PWB (PL 13.1). 

Check wire breakage and bad connection between l/F PWB J533-A11 and IBT Edge 
Sensorj119-2. 

Replace IBT Edge Sensor (PL 5.4). 



Between l/F PWB J530-A9(+) and GND(-). +24 VDC is measured. 

Y N 

Following Wire Network, check +24VDC circuit up to l/F PWB J530-A9 

Remove IBT Assembly (REP 9.15). Enter dC330 [004-001] and press Start. IBT Steering 
Motor energizes. 

Y N 
Check wire breakage and bad connection between l/F PWB J550 and IBT Steering Motor 
J207. There are broken wires or bad connections. 
Y N 

Replace MCU PWB (PL 13.1). 

If the problem continues, replace l/F PWB (PL 9.1). 

If the problem continues, replace IBT Steering Motor (PL 1.3). 

Repair broken wire and bad connection. 

Check IBT Belt installation (REP 9.22). If the check is good, replace MCU PWB (PL 13.1). 



4-650 IOT Cycle Down Time Out 

Incorrect print processing continued for 2 minutes. 

Procedure 

Check the wire between the ESS PWB and the MCU PWB for a poor contact. The problem 

continues. 

Y N 

Return to Service Call Procedures. 

Replace the ESS PWB (PL 13.1) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-63 



Status Indicator RAPs 

4-642, 4-650 



4-908 2nd BTR Unit Life End 

2nd BTR Unit end of life. 

Procedure 

Replace the 2nd BTR UNIT. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 

If the problem continues, replace the MCU NVM PWB (PL 13.1). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

4-908 2-64 DC1 632/2240 



5-110 Registration Sensor On 

Registration Sensor did not detect a document after the Feed Motor energized. 

Initial Actions 

i Ensure document path is clear. 

i Ensure Feed and Nudger Rolls are free of contamination and wear (PL 20.4). 

Procedure 

Feed a document and observe the Feed Rolls and prefeed action. The Feed Rolls move 
down. 

Y N 

Remove following: 

i Front Cover (PL 20.1). 

i Entrance Tray (PL 20.1). 

T Document Feed Lower Chute (REP 5.8). 

Check Set Gate Solenoid linkage. If the linkage is good, check the circuit of the Set Gate 

Solenoid (Figure 1). 

Clear the jam and feed a document. The Document prefeeds into the DADF. 

Y N 

Remove Rear Cover (REP 5.18). Check Fuse F3 on DADF Control PWB (Figure 4). 
Fuse is good. 
Y N 

Check the +24 VDC wires on the Feed Motor (Figure 2) for a short circuit to frame. 

If the wires are good, replace the Feed Motor (PL 20.4). 

Also replace the DADF Control PWB (PL 20.3) if a fuse is not available. 

Access the Feed Rolls (REP 5.7). Check the Feed Roll Drives. Repair as required (PL 
20.4). If the drives are good, check the circuit of the Feed Motor (Figure 2). 

Check the circuit of the Registration Sensor (Figure 3). 



DADF CONTROL PWB 
PL20.3 



CONTROL 
LOGIC 



ttr 



DC330 [5-012] 
SET GATE CLOSED 
J598 (L) +24 VDC J591 



-C~' 



+24 VDC 

L*C BLU 

DC COM 



BLU 



ORN DC330 [5-011] 

SET GATE OPEN 
(L) +24 VDC 




DADF CONTROL PWB 
PL20.3 



CONTROL 
LOGIC 



DC COM 
DC COM 

-^ 

DC COM 



DC330 [5-040] 
FEED MOTOR ON 
J600 +24VDC PULSED P588 



DC330 [5-040] 
FEED MOTOR ON 
+24VDC PULSED 



DC330 [5-040] 
FEED MOTOR ON 
+24VDC PULSED 



DC330 [5-040] 
FEED MOTOR ON 
+24VDC PULSED 





FEED MOTOR 
PL20.4 




\ 




Y 




(mot) 




T 




/ 







T705001A-CARR 



Figure 2 Feed Motor CD 



DADF CONTROL 

PWB 

PL20.3 



DC COM 



J599 DC COM 



J591 



+5 VDC 



iGRY 



^Onr i" I P" DC33 °[ 5 - 11 °] 

+5 VDC £ i DOCUMENT SENSED 

1 ] (L)+5VDC 



H 1 



CONTROL 
LOGIC 



YEL 



J580 


REGISTRATION 

SENSOR 

PL20.5 




iVIO i "* T 






si, 






g>r 


J580 


IGRY 

i 














YEL 








T705002A-CAR 



Figure 3 Registration Sensor CD 



Figure 1 Set Gate Solenoid CD 



F2 




P599 


P551 




P550 






Is 

□ CD 












11 


Ro") 

ao 
Ho 












B| 


1 F3 

P598 fuse 








F1 
fuse 




B| 



Figure 4 DADF Control PWB 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-65 



Status Indicator RAPs 

5-110 



5-111 Registration Sensor Off 



The document did not deactuate the Registration Sensor after the DADF Belt Motor energized. 

Initial Actions 

Ensure document path is clear. 

Procedure 

Feed a document and observe the Platen Belt. The Platen Belt rotates. 

Y N 

Remove Rear Cover (REP 5.18). 

Check drive components for DADF Belt Motor (PL 20.6). 

Check the Fuse F1 on the DADF Control PWB (Figure 3). 

If no problems are found, check the circuit of the DADF Belt Motor (Figure 1 ) (PL 20.6). 

Remove the following: 

i Front Cover (PL 20.1). 

i Document Transport (REP 5.17). 

Check the Registration Rolls and Registration Pinch Rolls for drive or contamination problems 

(PL 20.8). 

Reinstall the Document Transport. Feed a document and observe the ends of the Registration 

Rolls and Registration Pinch Rolls. The ends of the rolls rotate. 

Y N 
There is a drives problem. Repair as required (PL 20.6) (PL 20.8). Ensure the Registra- 
tion Pinch Roll Springs are in position (REP 5.15). 

There is a blockage problem. Remove the Registration Rolls (REP 5.15). Ensure the docu- 
ment path is free of obstruction. 



DADF CONTROL PWB 
PL20.3 



CONTROL 
LOGIC 



DC COM 
DC COM 

-^ 

DC COM 



DC330 [5-055] (FWD) [5-056] (RVS) 
DADF BELT MOTOR ON 
J595 +24 VDC PULSED 


DADF BELT 

MOTOR 

PL20.6 


J DC330 [5-055] (FWD) [5-056] (RVS) 
i DADF BELT MOTOR ON 
! +24 VDC PULSED 


\ 


! DC330 [5-055] (FWD) [5-056] (RVS) 
i DADF BELT MOTOR ON 
! +24 VDC PULSED 


Y 


' DC330 [5-055] (FWD) [5-056] (RVS) 
! DADF BELT MOTOR ON 
! +24 VDC PULSED 


(mot) 


! +24 VDC 
| INTERLOCKED 


T 


! +24 VDC 

INTERLOCKED 


/ 








DC330 [5-301] 
DADF INTERLOCK 
SWITCH CLOSED 
J594 (H) +24 VDC F1 



ORN 



ORN 



DADF 

INTERLOCK 
SWITCH 
PL20.3 



ORN 



Figure 1 DADF Belt Motor CD 



ORN 
T705003A-CARR 



CONTROL 
LOGIC 



DADF CONTROL PWB 
PL20.3 



VtT 



DC330 [5-075] 
REGISTRATION GATE 
SOLENOID ON 
J598 (L) +24 VDC J591 



BLU 



£~ I 0RG 
+24VDC 



+24VDC 



ORG 



REGISTRATION 
GATE 
SOLENOID 
PL20.2 



Figure 2 Registration Gate Solenoid CD 



T705006A-CAR 



Status Indicator RAPs 

5-111 



6/02 
2-66 



Prelaunch Training/Review 
DC1 632/2240 



F2 




P599 


P551 


P550 






Is 

□ CD 










11 


ACT) 

ao 
Ho 










B| 


1 F3 

P598 fuse 








F1 
fuse 


B| 



Figure 3 DADF Control PWB 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-67 



Status Indicator RAPs 

5-111 



5-112 Registration Sensor Inversion 

The document does not actuate the DADF Registration Sensor after the Belt Motor energized 
for document inversion. 

Procedure 

Select 1 to 1 and make a copy. The document exist the DADF. 

Y N 

Go to the RAP for the displayed status code. 

Enter dC330 [005-119] and press Start. Actuate the Duplex Sensor. The display changes. 

Y N 
Check the circuit of the Duplex Sensor (Figure 1 ). 

Enter dC330 [005-075] and press Start. The Registration Gate Solenoid energizes. 

Y N 

Check the circuit of the Registration Gate Solenoid (Figure 2). 

Check Following: 

i The Platen Belt for contamination, wear and a rotation failure 

i The Platen Belt for an improper tension 

i The DADF Registration Gate Solenoid for a return failure 



F2 
B-d fuse 

Is 

□ CD 




P599 


P551 


P550 


Is 




RCD 

ao 
Ho 










Bs 


1 F3 

P598 fuse 








F1 
fuse 


Bs 



Figure 3 DADF Control PWB 




J599 DC COM J591 J769 



VIO 



+5VDC 



i 15 



H 13 



GRY GRY 

i DC330 [5-119] I 

| DUPLEX DOC SENSED! 

| (L) + 5VDC ' 

14 '— 1 14 L 



VIO 



3 — 1 



P769 J765 



DUPLEX SENSOR 
PL20.7 



1 — 3 ■ 



GRY 



YEL 



■ 2 — 2 ■ 



lJ)S(g 



T705009A-CAR 



Figure 1 Duplex Sensor CD 



DADF CONTROL PWB 
PL20.3 



CONTROL 
LOGIC 



H^ 



DC330 [5-075] 
REGISTRATION GATE 
SOLENOID ON 
J598 (L)+24VDC J591 



BLU 



DC COM 

£~ | ORG 
+24VDC 



REGISTRATION 
GATE 
SOLENOID 
PL20.2 



T705006A-CAR 



Figure 2 Registration Gate Solenoid CD 



Status Indicator RAPs 

5-112 



6/02 
2-68 



Prelaunch Training/Review 
DC1 632/2240 



5-113 Registration Sensor Inversion 

The document does not deactuate the DADF Registration Sensor after the Belt Motor ener- 
gized for document inversion. 

Procedure 

Check the following in dC330. 

i [5-110] Registration Sensor 

i [5-056] DADF Belt Motor 

i [5-075] Registration Gate Solenoid 

The components are good. 

Y N 

Go to the appropriate circuit and check the component. 

Check the following: 

i The NO. 1/NO. 2 Duplex ROLL for contamination, wear and a rotation failure 

i The Duplex Roll Drive for a mechanical load 

i The Duplex Chute for deformation 

i The Registration Roll for a transportation failure due to contamination, paper chip, wear 

etc. 
i Document Transport Height (ADJ 5.4). 
T The wire between the DADF Registration Sensor and the DADF Control PWB for an open 

circuit or poor contact 
i The DADF Control PWB for failure (PL 20.3) 



DADF CONTROL PWB 
PL20.3 



CONTROL 
LOGIC 



H^ 



DC330 [5-075] 
REGISTRATION GATE 
SOLENOID ON 
J598 (L)+24VDC 



BLU 



DC COM 

£~ | ORG 
+24VDC 



J591 



REGISTRATION 
GATE 
SOLENOID 
PL20.2 



Figure 1 Registration Gate Solenoid CD 



T705006A-CAR 



F2 




P599 


P551 


P550 






Is 

□ CD 










11 


RCD 

ao 
Ho 










B| 


1 F3 

P598 fuse 








F1 
fuse 


B| 



Figure 2 DADF Control PWB 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-69 



Status Indicator RAPs 

5-113 



5-115 Exit Sensor On 

The DADF Exit Sensor does not detect a document after the DADF Exit Motor energized at 
document replacement/output. 

Procedure 

Check the following in dC330: 
i [5-115] DADF Exit Sensor 
i [5-081] DADF Exit Motor 
The components are good. 
Y N 

Go to the appropriate circuit and check the component. 

Check the following: 

i The Platen Belt for contamination, wear, tear and a rotation failure 

T The NO. 1-4 Belt Pinch RolLs for a rotation failure. 

i The Platen Belt for an improper tension. 

T The Platen Glass for contamination, a foreign substance and a high friction coefficient 

i Document Transport Height (ADJ 5.4). 

T The DADF Exit Sensor for an improper installation. 

T The DADF Control PWB for a failure (PL 20.3). 

i The Exit Lower Chute for correct installation. 



DADF CONTROL 

PWB 

PL20.3 



47 



J599 DC COM 




+5VDC 



DC330 [5-115] 
DOCUMENT SENSED 
(L) +5 VDC 



DADF EXIT SENSOR 
PL20.9 



YEL 



l£_iii i^n 



T705011A-CAR 



Figure 1 DADF Exit Sensor CD 



F2 




P599 


P551 


P550 






Is 

□ CD 










11 


RCD 

ao 
Ho 










B| 


1 F3 

P598 fuse 








F1 
fuse 


B| 



Figure 2 DADF Control PWB 



Status Indicator RAPs 

5-115 



6/02 
2-70 



Prelaunch Training/Review 
DC1 632/2240 



5-116 Exit Sensor Off 

The document does not deactuate the DADF Exit Sensor after the DADF Exit Sensor actuated. 

Procedure 

Check the following in dC330: 

i [5-115] DADF Exit Sensor 

i [5-081] DADF Exit Motor (Check Fuse F2 on DADF PWB) 

The components are good. 

Y N 

Go to the appropriate circuit and check the component 

Check the following: 

i The Exit Roll for contamination, wear and a rotation failure 

i The Exit Upper/lower Chute for deformation 

i The Eliminator for deformation 

i The Exit Roll Drive Belt for disengagement and damage 

i The DADF Control PWB for failure (PL 20.3). 



DADF CONTROL PWB 
PL20.3 



CONTROL 
LOGIC 



DC COM 
DC COM 

-^ 

DC COM 



+24VDC 



DC330 [5-081] 
EXIT MOTOR ON 
J596 +24 VDC PULSED 


DADF EXIT 

MOTOR 

PL20.9 


J DC330 [5-081] 
i EXIT MOTOR ON 
1 +24 VDC PULSED 


\ 


" DC330 [5-081] 
i EXIT MOTOR ON 
! +24 VDC PULSED 


Y 


> DC330 [5-081] 
! EXIT MOTOR ON 
| +24 VDC PULSED 


(mot) 


| +24 VDC 


T 


' +24 VDC 


/ 








J599 DC COM 



+5 VDC 



GRY 

i DC330 [5-115] 

| DOCUMENT SENSED 

] (L) +5 VDC 



GRY 



DADF EXIT SENSOR 
PL20.9 



lJ)S(g 



J589 



YEL 



T705011A-CAR 



Figure 1 DADF Exit Sensor CD 



Figure 2 Exit Motor CD 



T705012A-CAR 



F2 




P599 


P551 


P550 






Is 

□ CD 










11 


RCD 

ao 
Ho 










B| 


1 F3 

P598 fuse 








F1 
fuse 


B| 



Figure 3 DADF Control PWB 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-71 



Status Indicator RAPs 

5-116 



5-195 Document Size Mismatch 

Different sized documents are detected in the NO MIX mode. 

Procedure 

Check the following in dC330: 

i [5-150] DADF Size Sensor 1 (Front) 

i [5-151] DADF Size Sensor 2 (Rear) 

The components are good. 

Y N 

Go to the appropriate circuit and check the component. 

Check the following: 

i The SIZE SENSOR for correct installation 

i Multiple feed due to an improper retard pressure 

i DADF document skew 

i Document for damage, out of specification and an improper loading 

i The DADF Control PWB for failure (PL 20.3). 

i Different document size (such as Mixed documents) 



F2 
B-d fuse 

Is 

□ CD 




P599 


P551 


P550 


Is 




RCD 

ao 
Ho 










Bs 


1 F3 

P598 fuse 








F1 
fuse 


Bs 



Figure 3 DADF Control PWB 




J599 DC COM 



VIO 



YEL 



+5VDC 



DC330 [5-151] 
SIZE SENSED 
(L) +5 VDC 



J591 J583 



SIZE SENSOR 2 

FRONT 

PL20.5 



-110 



VIO 



YEL 



j<pp3 



YEL 



T705008A-CAR 



Figure 1 Size Sensor 2 Front CD 




J599 DC COM 



VIO 



GRY 



+5 VDC 



DC330 [5-150] 
SIZE SENSED 
(L) +5 VDC 



J591 J582 
1 9 



SIZE SENSOR 1 

REAR 

PL20.5 



H 7 



VIO 



GRY 



l£JII \^\ 



T705007A-CAR 



Figure 2 Size Sensor 1 Rear CD 



Status Indicator RAPs 

5-195 



6/02 
2-72 



Prelaunch Training/Review 
DC1 632/2240 



5-274 Original Size Sensor 



At power on, the DADF Registration Sensor turns OFF, and the DADF Size Sensor 1 or the 
DADF Size Sensor 2 turns ON when the document is loaded. (Size Sensor detection failure) 

Procedure 

Enter [5-150] and press Start, press Start, actuate sensor. The display changes? 

Y N 
Remove DADF Entrance Tray (PL 20.1). Remove the DADF Size Sensor 1 J582 (REP 
5.12). The display changes 

Y N 
Disconnect J599 on the DADF Control PWB. Measure the resistance between the 
pin J599-8 and the frame. Resistance 3 Ohm or less. 

Y N 
Replace DADF Control PWB (PL 20.3). 

Check wire between DADF Size Sensor 1 J582-2 and DADF Control PWB J599-8 for 
a short circuit to frame. 

Replace DADF Size Sensor 1 (PL 20.5). 

Enter dC330 [005-151] and press Start. H is displayed. 

Y N 
Remove the DADF Entrance Tray (PL 20.1). Remove the DADF Size Sensor 2 J583. 
The display changes. 

Y N 
Disconnect J599 on the DADF Control PWB. Measure the resistance between J599- 
11 and frame. The resistance 3 Ohm or less. 

Y N 
Replace DADF Control PWB (PL 20.3). 

Check the wire between the DADF Size Sensor 1 J583-2 and the DADF Control 
PWB J599-11 for a short circuit to the frame. 

Replace DADF Size Sensor 2 (PL 20.5). 

Replace DADF Control PWB (PL 20.3). 



DADF CONTROL 

PWB 

PL20.3 



47 



J599 DC COM 



J591 




+5VDC 



GRY 



-110 



DC330 [5-151] 
SIZE SENSED 
(L) +5 VDC 



J583 


SIZE SENSOR 2 

FRONT 

PL20.5 




VIO I 


*t 


>© : 


J583 
YF.L 


GRY 
















YEL 






T705008A-CAR 



Figure 2 Size Sensor 2 Front CD 



F2 
refuse 

Is 

□ CD 




P599 


P551 




P550 


dm 




Ro") 

Ho 












Bs 

4^. 


1 F3 

P598 fuse 








F1 
fuse 




Bs 



Figure 3 DADF Control PWB 




J599 DC COM 



+5 VDC 



GRY 



DC330 [5-150] 
SIZE SENSED 
(L) +5 VDC 



J591 



SIZE SENSOR 1 

REAR 

PL20.5 



GRY 



Figure 1 Size Sensor 1 Rear CD 



!$fp3 



J582 



T705007A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-73 



Status Indicator RAPs 

5-274 



5-275 DADF Ram Failure 

RAM failure of the DADF PWB. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the DADF Control PWB (PL 20.3). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

5-275 2-74 DC1 632/2240 



5-301 Top Cover Interlock Open 

The Top Cover is open. 

Procedure 

Manually actuate DADF Top Cover Interlock Switch (front/rear) at the same time. 
cleared. 



5-301 is 



N 



+5VDC is mea- 



Remove DADF Rear Cover (REP 5.18). Close the DADF Top Cover. 
sured between the DADF Control PWB J599-17 (+) and GND (-). 
Y N 

+5VDC is measured between the DADF Control PWB J599-22 (+) and GND (-). 

Y N 

Replace the DADF Control PWB (PL 20.3). 



Cheat Pin J590-1 and Pin 2 of the DADF Top Cover Rear Interlock Switch. 5-301 is 

cleared. 

Y N 

Check the wire between the Top Cover Rear Interlock Switch J590-1 and the 
DADF Control PWB J599-22, and the wire between the Top Cover Rear Inter- 
lock Switch J690-2 and the DADF Control PWB J599-21 for an open circuit or 
poor contact. 

Replace the DADF Top Cover Rear Interlock Switch. (PL 20.2). 



Cheat Pin J585-1 and Pin 2 of the DADF Top Cover Front Interlock Switch. 0VDC is 
measured between the DADF Control PWB J599-17 (+) and GND (-). 
Y N 

Check the wire between the Top Cover Front Interlock Switch J585-1 and the DADF 
Control PWB J599-17, and the wire between the Top Cover Front Interlock Switch 
J585-2 and the DADF Control PWB J599-16 for an open circuit or poor contact. 



Replace the DADF Top Cover Front Interlock Switch. (PL20.2) 

Mismatching of the DADF Top Cover. 

Check the actuator for breakage and bending, and the TOP COVER for correct installation. 



DADF 
CONTROL 
PWB 
PL20.3 



DOUBLE 
PLUG 



DC COM 
+5VDC 



CONTROL 
LOGIC 



VIO 



J590 I I P590 
■ 2 — 1 



VIO 



- 22 l 
| YEL 



DC330 [5-301] 
TOP COVER INTERLOCK 
SWITCH REAR CLOSED 
(L) +5 VDC 



TOP COVER 
INTERLOCK 
SWITCH (REAR) 
PL20.2 



YEL 



T705005A-CAR 



Figure 2 Top Cover Interlock Switch (rear) 



F2 




P599 


P551 




P550 






Is 

□ CD 












11 


Ro") 

ao 
Ho 












B| 


1 F3 

P598 fuse 








F1 
fuse 




B| 



Figure 3 DADF Control PWB 



DADF 
CONTROL 
PWB 
PL20.3 



DOUBLE 
PLUG 



J599 



DC COM 
+5VDC 



CONTROL 
LOGIC 



DC330 [5-301] 

TOP COVER INTERLOCK 

SWITCH FRONT CLOSED 

(LJ+5VDC 



TOP COVER 
INTERLOCK 
SWITCH (FRONT) 
PL20.2 



Figure 1 Top Cover Interlock Switch (front) 




T705004A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-75 



Status Indicator RAPs 

5-301 



5-900 Document Sensor Timing 

A timing error occurred between document sensing and the opening of a DADF Interlock. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the DADF Control PWB (PL 20.3). 



Status Indicator RAPs 6/02 Prelaunch Training/Review 

5-900 2-76 DC1 632/2240 



5-901 Power On Document Present 

The Document Sensor detects a document at Power On. 

Procedure 

Check the following in dC330. 

i [5-102] DADF Document Sensor 

The component is good. 

Y N 

Go to the appropriate circuit and check the component. 

Check that the voltage at the customer outlet is in specification and does not drop during 
machine start. 



DADF CONTROL 

PWB 

PL20.3 



47 



J599 DC COM J591 
6 rrr^ 1 6 




+5VDC 



J581 



H 4 



DC330 [5-102] ! 

DOCUMENT SENSED | 
(L) +5 VDC ' 



GRY GRY 



DOCUMENT SENSOR 
PL20.5 


j <p=*Ksi , 



YEL 



YEL 



T705010A-CAR 



Figure 1 Document Sensor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-77 



Status Indicator RAPs 

5-901 



5-902 Power On Registration Sensor 

At Power On, the Registration Sensor detected a document when the Top Cover/platen Inter- 
lock was closed. 

Procedure 

Check the following in dC330. 
i [5-110] Registration Sensor 
The component is good. 
Y N 

Go to the appropriate circuit and check the component. 

Check that the voltage at the customer outlet is in specification and does not drop during 
machine start. 




J599 DC COM 



J580 



REGISTRATION 

SENSOR 

PL20.5 



VIO 



+5VDC 



H 1 



GRY GRY 

i DC330 [5-110] . 

| DOCUMENT SENSED | 
I (L) + 5VDC j 

9 — ' 2 L 



VIO 



l£JII \^\ 



YEL 



T705002A-CAR 



Figure 1 Registration Sensor CD 



Status Indicator RAPs 

5-902 



6/02 
2-78 



Prelaunch Training/Review 
DC1 632/2240 



5-903 Power On Exit Sensor 

At Power On, the DADF Exit Sensor detected a document when the Top Cover/platen Interlock 
was closed. 

Procedure 

Check the following in dC330. 
i [5-115] DADF Exit Sensor 

The component is good. 
Y N 

Go to the appropriate circuit and check the component. 

Check that the voltage at the customer outlet is in specification and does not drop during 
machine start. 



DADF CONTROL 

PWB 

PL20.3 



47 



J599 DC COM 




+5VDC 



GRY 

i DC330 [5-115] 

| DOCUMENT SENSED 

] (L) +5 VDC 



GRY 



DADF EXIT SENSOR 
PL20.9 



lJ)S(g 



YEL 



Figure 1 Exit Sensor CD 



J589 



T705011A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-79 



Status Indicator RAPs 

5-903 



5-904 Power On Duplex Sensor 



At Power On, the DADF Duplex Sensor detected a document when the Top Cover/platen Inter- 
lock was closed. 

Procedure 

Check the following in dC330. 

T [5-1 1 9] DADF Duplex Sensor 

The component is good. 
Y N 

Go to the appropriate circuit and check the component. 

Check that the voltage at the customer outlet is in specification and does not drop during 
machine start. 



DADF CONTROL 

PWB 

PL20.3 



47 



+5VDC 



CONTROL 
LOGIC 



J599 DC COM J591 J769 



iVIO 



■ 13 r- 



+5VDC 



i 15 



H 13 



GRY GRY 

I i DC330 [5-119] ! 

| DUPLEX DOC SENSED! 

1 | (L) + 5VDC J 

■ 14 T^r ' 14 L 



VIO 



3 — 1 



P769 J765 



DUPLEX SENSOR 
PL20.7 



1 — 3 ■ 



GRY 



YEL 



. 2 — 2 ■ 



Figure 1 Duplex Sensor CD 



lJ)S(g 



T705009A-CAR 



Status Indicator RAPs 

5-904 



6/02 
2-80 



Prelaunch Training/Review 
DC1 632/2240 



5-940 Document Removed During Start 

Control Logic detected that the document was removed immediately after the DADF started. 

Procedure 

Rerun job. 5-940 is declared again. 
Y N 

Return to Service Call Procedures. 

Replace the DADF Control PWB (PL 20.3). 



Prelaunch Training/Review g^ 2 Status Indicator RAPs 

DC1 632/2240 2-81 5-940 



5-941 Document Miscount 

Document miscount. 

Procedure 

Rerun job. 5-941 is declared again. 
Y N 

Return to Service Call Procedures. 

Replace the DADF Control PWB (PL 20.3). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

5-941 2-82 DC1 632/2240 



6-277 IISS DADF Communication 

Communication cannot be established between the IIT/IPS and the DADF Control PWB. 

Procedure 

Turn on the power. The CR4 on the DADF Control PWB illuminates. 

Y N 
+5VDC is measured between the DADF Control PWB J550-6 (+) and GND (-)■ 
Y N 

Check the +5VDC circuit to the DADF Control PWB J550-6 by referring to Chapter 7 
Wiring Data (DADF+5VDC) 

Replace the DADF Control PWB (PL 20.3). 

Turn off the power. Check conductivity of the following: 

Between IIT/IPS PWB J725-20 and DADF Control PWB j755-a1 

Between IIT/IPS PWB J725-19 and DADF Control PWB J551-a2 

Between IIT/IPS PWB J725-18 and DADF Control PWB J551-a3 

Between IIT/IPS PWB J725-17 and DADF Control PWB J551-a4 
The resistance is 1 Ohm or less for all wires. 

Y N 
Check wires with more than 1 Ohm for an open circuit or poor contact. 

Replace the following parts: 

DADF Control PWB (PL 20.3) 
IIT/IPS PWB (PL 18.3) 



IIT/IPS PWB 
PL18.3 



CONTROL 
LOGIC 




IIT/IPS TO DADF 

COMMUNICATION 

J725 LINE J750 



DOUBLE 
PLUG 



DC COM 
DC COM 



DC COM 



H^ 



YEL 



DC330[05-300] 
DADF 0PEN(L)+5VDC 



_ DC330[05-201] 
[06-091] 

DOCUMENT EXCHANGE 
(D+5VDC 



DADF RESET(H)+5VDC 



A2 — A2 



A6 — A6 



Figure 1 NT DADF Communication CD 



P750 


<^> 


J551 


i X 




XI 














! X 




X! 










<j 





DADF CONTROL PWB 
PL20.3 




CONTROL 
LOGIC 

$> 

CKCR2 



^F CRC 



T706000A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-83 



Status Indicator RAPs 

6-277 



6-312 NT Memory Hot Line 

The system detected an open circuit in the I IT Memory Hot Line. 

Procedure 

Check connections at I IT/IPS PWB. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the NT/IPS PWB (PL 18.3). 



6-340 IISS RAM TEST ERROR 

At power on, the system detected a NT/IPS PWB RAM test error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 



Replace the NT/IPS PWB (PL 18.3). 



Status Indicator RAPs 

6-312,6-340 



6/02 
2-84 



Prelaunch Training/Review 
DC1 632/2240 



6-345 IISS EEPROM 

i The NVM value cannot be written at the NT/IPS PWB Write. 
T A communication failure with the EEPROM was detected. 

Procedure 

Check connections at I IT/IPS PWB. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the NT/IPS PWB (PL 18.3). 



Prelaunch Training/Review g^ 2 Status Indicator RAPs 

DC1 632/2240 2-85 6-345 



6-355 IPS Fan 

IPS Fan failure. 

Procedure 

Enter dC330 [006-014] and press Start. The IPS FAN energizes. 
Y N 

+24VDC is measured between the NT/IPS PWB J725-2 (+) and GND (-) 

Y N 

Visually check the F6 Fuse on the I IT/IPS PWB. The Fuse is open. 
Y N 

Turn OFF the power. Disconnect the NT LVPS J702 and turn the power ON. 
+24VDC is measured between the NT LVPS J702-1 (+) and GND (-) 
Y N 

Check the power (ACH) to the NT LVPS. If no problems are found, 
replace the NT LVPS (PL 18.4) 

Check for a short circuit by referring to Chapter 7 Wiring Data ( IIT+24VDC) 

Replace the NT/IPS PWB (PL 18.3) 



Enter dC330 [006-014] and press Start. +24VDC is measured between the NT/IPS 
PWB j722-b8 (+) and GND (-). 
Y N 

Replace the NT/IPS PWB (PL 18.3) 

Turn the power OFF. Check the conductivity of the following. If no problems are found, 
replace the IPS FAN (PL 18.4) 

Between the IIT/IPS PWB j722-b8 and the IPS FAN J738-1 

Between the IIT/IPS PWB j722-b9 and the IPS FAN J738-2 

Between the IIT/IPS PWB j722-b10 and the IPS FAN J738-3 

Between the IIT/IPS PWB j722-b11 and the IPS FAN J738-4 



+5VDC is measured at the IIT/IPS j722-b10 
Y N 

Replace the IIT/IPS PWB (PL 18.3) 

Replace the IPS FAN (PL 18.4) 



IIT/IPS PWB 
PL18.3 



CONTROL 
LOGIC 



^ 



DC COM 

3.3 VDC 



DOUBLE 
PLUG 



DC330[006-014] 

IPS FAN HI-SPEED . . 

J722 (H)+24VDC P73S I I 



ORN 



P738 ' ' J738 

4 — 1 



DC330[006-004] 
IPS FAN SLOW 



B10L- 



DC330 [006-281] 
FAN FAIL 
(H) +3.3 VDC 



« 12 - 3 I «- 

I I 



IPS FAN 
PL18.4 



T706001A-CAR 



Figure 1 IPS Fan CD 



Status Indicator RAPs 

6-355 



6/02 
2-86 



Prelaunch Training/Review 
DC1 632/2240 



6-360 Carriage Position 

The CRG Position error was detected. 

Procedure 

BSD6.3BSD6.12A 

Turn off the power. Remove the Platen Glass. 

Manually move the Full Rate Carriage. The Carriage moves easily. 

Y N 
Clear the Carriage Cable distortion, stranding, damage and foreign substance on the 
CARRIAGE RAIL etc., causing the load. 

Turn on the power. Enter dC330 [006-21 2] and press Start. 

Manually move the Full Rate Carriage and turn the NT Registration Sensor ON/OFF. The 

display changes. 

Y N 
Repair the NT Registration Sensor using Generic Transmissive Sensor RAP. 

Enter dC330 [006-005] (Scan) or [06-006] (Return) and press Start. The Carriage Motor 
energizes 

Y N 
+24VDC is measured between the NT/IPS PWB J725-2 (+) and GND (-) 
Y N 

Visually check the F6 Fuse on the I IT/IPS PWB. The Fuse is open. 
Y N 

Turn OFF the power. Disconnect the NT LVPS J702 and turn the power ON. 
+24VDC is measured between the NT LVPS J702-1 (+) and GND (-) . 
Y N 

Check the power (ACH) to the NT LVPS. If no problems are found, 
replace the NT LVPS (PL 18.4) 

Check for a short circuit by referring to Chapter 7 Wiring Data ( IIT+24VDC) 

Replace the NT/IPS PWB (PL 18.3) 



When dC330 [006-005] (Scan) or [006-006] (Return) is ON, +24VDC is measured 
between the Carriage Motor p739-1 (+) and GND (-) 
Y N 

In the same Diagnostic, +24VDC is measured between the NT/IPS PWB J725-1 

(+) and GND (-). 

Y N 

Replace the NT/IPS PWB (PL 18.3) 

Check the wire between the NT/IPS PWB J725-1-6 and the Carriage Motor p739-1-6 
for an open circuit or poor contact. 

Check the wire between the I IT/I PS PWB J725 and the Carriage Motor p739-5 for an open 

circuit or poor contact. 

If no problems are found, replace the Carriage Motor (PL 18.5. 

If the problem continues, replace the NT/IPS PWB (PL 18.3). 



T The Carriage Motor BELT for damage, loosening and disengagement 
T The Carriage Capstan Shaft/pulley for wear, distortion and chips 
T Full Rate/Half Rate Carriage Position Adjustment (ADJ ) 
If no problems are found, replace the I IT/IPS PWB (PL 18.3). 



Check the following: 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-87 



Status Indicator RAPs 

6-360 



6-361 Scan Registration Sensor 

Registration Sensor failure at CRG INIT 

Procedure 

BSD6.4BSD6.12A 

Turn off the power. Remove the Platen Glass. Manually move the Full Rate Carriage. The 

Carriage moves easily. 

Y N 
Clear the Carriage Cable distortion, stranding, damage and foreign substance on the Car- 
riage Rail etc., causing the load. 

Turn on the power. Enter dC330 [006-212] and press Start. Manually move the Full Rate Car- 
riage and turn the NT Registration Sensor ON/OFF. The display changes 

Y N 
Repair the NT Registration Sensor using Generic Transmissive Sensor RAR 

Enter dC330 [006-005] (Scan) or [06-006] (Return) and press Start. The Carriage Motor 
energizes. 

Y N 
+24VDC is measured between the NT/IPS PWB J725-2 (+) and GND (-). 
Y N 

Visually check the F6 Fuse on the I IT/IPS PWB. The Fuse is open. 
Y N 

Turn OFF the power. Disconnect the NT LVPS J702 and turn the power ON. 
+24VDC is measured between the NT LVPS J702-1 (+) and GND (-). 
Y N 

Check the power (ACH) to the NT LVPS. If no problems are found, 
replace the NT LVPS (PL 18.4) 

Check for a short circuit by referring to Chapter 7 Wiring Data ( IIT+24VDC) 

Replace the NT/IPS PWB (PL 18.3) 



When dC330 [006-005] (Scan) or [006-006] (Return) is ON, +24VDC is measured 
between the Carriage Motor p739-1 (+) and GND (-). 
Y N 

In the same Diagnostic, +24VDC is measured between the NT/IPS PWB J725-1 

(+) and GND (-). 

Y N 

Replace the NT/IPS PWB (PL 18.3). 

Check the wire between the NT/IPS PWB J725-1-6 and the Carriage Motor p739-1-6 
for an open circuit or poor contact. 

Check the wire between the I IT/I PS PWB J725 and the Carriage Motor p739-5 for an open 

circuit or poor contact. 

If no problems are found, replace the Carriage Motor (PL 18.5). 

If the problem continues, replace the NT/IPS PWB (PL 18.3). 



Check the following: 

i The Carriage Motor BELT for damage, loosening and disengagement 



i The CARRIAGE CAPSTAN SHAFT/PULLEY for wear, distortion and chips 
i Full Rate/Half Rate Carriage Position Adjustment (ADJ ) 
If no problems are found, replace the NT/IPS PWB (PL 18.3). 



Status Indicator RAPs 

6-361 



6/02 
2-88 



Prelaunch Training/Review 
DC1 632/2240 



6-371 Exposure Lamp 

Open circuit of the Lamp was detected. 

Procedure 

BSD6.2BSD6.12A 

Enter dC330 [006-002]. Press Start. The Exposure Lamp illuminates. 

Y N 

Switch off the power. Remove the following Platen Glass and the IPS Cover. Switch 

on the power. 

There is +24VDC between J720-2 (+) on the IIT/IPS PWB and GND (-). 

Y N 

Remove the DADF and the NT Top Cover. There is +24VDC between J 702-1 on 
the NT LVPS (+) and GND (-). 
Y N 

Switch off the power. Disconnect J 702 from the NT LVPS. Switch on the 
power. There is +24VDC between the NT LVPS P 502-1 (+) and GND (-). 
Y N 

Check for I IT LVPS On signal from ESS 

Check the input power (ACH) to the NT LVPS. 

If no problems are found, replace the I IT" LVPS (PL 18.4) 

Check for a short circuit. Refer to the IIT+24VDC wirenet 

Check the wires from J 702 on the I IT LVPS to J 720 on the IIT/IPS PWB for an open 
or short circuit. 



There is +24VDC from J 724-3 on the IIT/IPS PWB to GND. 

Y N 
There is +24VDC from J 724-1 to J 724-4 on the IIT/IPS PWB. 
Y N 

Replace the IIT/IPS PWB (PL 18.3) 

Replace the following parts: 

Lamp Wire Harness (PL 18.6) 
Lamp Ballast PWB (PL 18.6) 
IIT/IPS PWB (PL 18.3) 

Enter dC 330 [006-002]. Press Start. The voltage at J 724-3 drops to approximately 
7.5 VDC. 

Y N 

Replace the IIT/IPS PWB (PL 18.3) 

Replace the following parts: 
Exposure Lamp (PL 18.6) 
Lamp Wire Harness (PL 18.6) 
Lamp Ballast PWB (PL 18.6) 



i The White Reference Board on the reverse side of the Platen Glass for excessive con- 
tamination 
T The optical light path for contamination 

If no problems are found, replace the Lens Kit (PL 1 8.4) (REP 6.4) (ADJ 9.6). 
If the problem continues, replace the IIT/IPS PWB (PL 18.3). 
If the Exposure Lamp is not brightly lit, replace the Exposure Lamp (PL 18.6). 
If the problem continues, replace the Lamp Ballast PWB (PL 18.6). 



Check the following: 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-89 



Status Indicator RAPs 

6-371 



6-372 ROS Polygon Motor 

ROS Motor failure. 

Procedure 

BSD 6.9 BSD 6.1 

Enter dC330 [006-031]. +3.3VDC is measured between the MCU PWB J402-3 (+) and GND 

(-) 

Y N 

Check the wire between the ROS ASSY Relay Connector J51 8-4 and the MCU PWB J402- 
3 for an open circuit. 

+24VDC is measured between the MCU PWB J402-6 (+) and GND (-). 
N 

+24VDC is measured between the MCU PWB J402-6 (+) and GND (-) 
Y N 

Check the +24VDC circuit to the MCU MF PWB J402-6 by referring to Chapter 7 Wir- 
ing Data ( +24V) 

Check the wire between the MCU PWB J402-6 and the ROS ASSY Relay Connector J51 8- 
1 for an open circuit. 

Enter dC330 [006-031]. 0VDC is measured between the MCU PWB J402-4 (+) and GND (-) 

Y N 

Check the wire between the MCU PWB J402-4 and the ROS ASSY Relay Connector J51 8- 
3 for an open circuit. If no problems are found, replace the PWB (PL 13.1) 

Check the wire between the MCU PWB J402-4 and the ROS ASSY Relay Connector J51 8-3 for 
an open circuit. 

Enter dC330 [006-031]. The frequency between the MCU PWB J402-4 (+) and GND (-) 2 
KHz to 2.5 KHz. 

Y N 
Check the wire between the MCU PWB J402-2 and the ROS ASSY Relay Connector J51 8- 
5 for an open circuit. If no problems are found, replace the PWB (PL 13.1) 

Check the wire between the MCU PWB J402-2 and the ROS ASSY Relay Connector J51 8-5 for 
an open circuit. 

Check the wiring status of the Harness in the ROS ASSY. If no problems are found, replace 
the ROS ASSY (PL 3.1) 



Status Indicator RAPs 

6-372 



6/02 
2-90 



Prelaunch Training/Review 
DC1 632/2240 



6-380 ROS SOS Y Length 

The interval of the ROS SOS (Y) signals exceeds the specified value. 

Procedure 

BSD 6.5 BSD 6.1 

+5VDC is measured between the MCU PWB J401-b20 (+) and GND (-) 

Y N 

Replace the MCU PWB (PL 13.1) 

Check the wire between the SOS PWB (Y) J51 6-1 and the MCU PWB J401 for an open circuit. 
Check the wire between the LD Drive (Y) J529 and the MCU PWB J401 for an open circuit. 
If no problems are found, replace the ROS Assembly (PL 3.1). 
If the problem continues, replace the MCU PWB (PL 13.1). 



Prelaunch Training/Review g^ 2 Status Indicator RAPs 

DC1 632/2240 2-91 6-380 



6-381 ROS SOS Length Fail M 6-382 ROS SOS C Length 

The interval of the ROS SOS (M) signals exceeds the specified value. The interval of the ROS SOS (C) signals exceeds the specified value. 

Procedure Procedure 

BSD 6.6 BSD 6.1 BSD 6.7 BSD 6.1 

Check the voltage between J401-b20 (+) and GND (-) on MCU PWB. +5VDC is measured +5VDC is measured between the MCU PWB j401-b20 (+) and GND (-). 

between the MCU PWB j401-b20 (+) and GND (-). Y N 

Y N Replace the MCU PWB (PL 13.1) 

Replace the MCU PWB (PL 13.1) 

Check the wire between the SOS PWB (C) J514-1 and the MCU PWB J401 for an open circuit. 

Check the wire between the SOS PWB (M) J517-1 and the MCU PWBJ401 for an open circuit. Check the wire between the LD Drive CJ527 and the MCU PWBJ401 for an open circuit. 

Check the wire between the LD Drive M J528 and the MCU PWB J401 for an open circuit. If no problems are found, replace the ROS Assembly (PL 3.1). 

If no problems are found, replace the ROS Assembly (PL 3.1). If the problem continues, replace the MCU PWB (PL 13.1). 
If the problem continues, replace the MCU PWB (PL 13.1). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

6-381,6-382 2-92 dci 632/2240 



6-383 ROS SOS K Length 

The interval of the ROS SOS (K) signals exceeds the specified value. 

Procedure 

BSD 6.8 BSD 6.1 

Check the voltage between the MCU PWB J401-b20 (+) and GND (-). +5VDC is measured. 

Y N 

Replace the MCU PWB (PL 13.1) 

Check the wire between the SOS PWB (K) J51 5-1 and the MCU PWB J401 for an open circuit. 
Check the wire between the LD Drive K J526 and the MCU PWB J401 for an open circuit. 
If no problems are found, replace the ROS Assembly (PL 3.1). 
If the problem continues, replace the MCU PWB (PL 13.1). 



6-385 ROS ASIC 

Operation failure of the ROS ASIC in the MCU PWB. 

Procedure 

BSD 6.5 BSD 6.1 

Switch power off then on. The problem continues. 

Y N 

Return to Service Call Procedures. 

Replace the MCU PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-93 



Status Indicator RAPs 

6-383, 6-385 



6-389 Carriage Over Run Right 

The carriage has overrun at the Scan End. 

Procedure 

BSD6.4BSD6.12A 

Turn off the power. Remove the Platen Glass. Manually move the Full Rate Carriage. The 

Carriage moves easily. 

Y N 
Clear the Carriage Cable distortion, stranding, damage and foreign substance on the 
CARRIAGE RAIL etc., causing the load. 

Turn on the power. Enter dC330 [006-212] and press Start. Manually move the Full Rate Car- 
riage and turn the IIT Registration Sensor ON/OFF. The display changes. 

Y N 
Repair the IIT Registration Sensor using Generic Transmissive Sensor RAP. 

Enter dC330 [006-005] (Scan) or [06-006] (Return) and press Start. The Carriage Motor 
energizes. 

Y N 
+24VDC is measured between the NT/IPS PWB J725-2 (+) and GND (-). 
Y N 

Visually check the F6 Fuse on the I IT/IPS PWB. The fuse is open. 
Y N 

Turn OFF the power. Disconnect the IIT LVPS J702 and turn the power ON. 
+24VDC is measured between the IIT LVPS J702-1 (+) and GND (-). 
Y N 

Check the power (ACH) to the IIT LVPS. If no problems are found, 
replace the IIT LVPS (PL 18.4) 

Check for a short circuit by referring to Chapter 7 Wiring Data ( IIT+24VDC) 

Replace the NT/IPS PWB (PL 18.3) 



When dC330 [006-005] (Scan) or [006-006] (Return) is ON, +24VDC is measured 
between the Carriage Motor p739-1 (+) and GND (-). 
Y N 

In the same Diagnostic, +24VDC is measured between the NT/IPS PWB J725-1 

(+) and GND (-). 

Y N 

Replace the NT/IPS PWB (PL 18.3) 

Check the wire between the NT/IPS PWB J725-1-6 and the Carriage Motor p739-1-6 
for an open circuit or poor contact. 

Check the wire between the I IT/I PS PWB J725 and the Carriage Motor p739-5 for an open 

circuit or poor contact. 

If no problems are found, replace the Carriage Motor (PL 18.5). 

If the problem continues, replace the NT/IPS PWB (PL 18.3). 



Check the following: 

i The Carriage Motor BELT for damage, slackening and disengagement. 



i The CARRIAGE CAPSTAN SHAFT/PULLEY for wear, distortion and chips 
i Full Rate/Half Rate Carriage Position Adjustment (ADJ) 
If no problems are found, replace the NT/IPS PWB (PL 18.3). 



Status Indicator RAPs 

6-389 



6/02 
2-94 



Prelaunch Training/Review 
DC1 632/2240 



6-390 Carriage Over Run Left 

The CRG has overrun at the Home End. 

Procedure 

BSD6.4BSD6.12A 

Turn off the power. Remove the Platen Glass. 

Manually move the Full Rate Carriage. The Carriage moves easily. 

Y N 
Clear the Carriage Cable distortion, stranding, damage and foreign substance on the 
CARRIAGE RAIL etc., causing the load. 

Turn on the power. Enter dC330 [006-212] and press Start. 

Manually move the Full Rate Carriage and turn the NT Registration Sensor ON/OFF. The 

display changes. 

Y N 
Repair the NT Registration Sensor using Generic Transmissive Sensor RAP. 

Enter dC330 [006-005] (Scan) or [06-006] (Return) and press Start. The Carriage Motor 
energizes. 

Y N 
+24VDC is measured between the NT/IPS PWB J725-2 (+) and GND (-). 
Y N 

Visually check the F6 Fuse on the I IT/IPS PWB. The Fuse is open. 
Y N 

Turn OFF the power. Disconnect the NT LVPS J702 and turn the power ON. 
+24VDC is measured between the NT LVPS J702-1 (+) and GND (-). 
Y N 

Check the power (ACH) to the NT LVPS. If no problems are found, 
replace the NT LVPS (PL 18.4) 

Check for a short circuit by referring to Chapter 7 Wiring Data ( IIT+24VDC) 

Replace the NT/IPS PWB (PL 18.3) 



When dC330 [006-005] (Scan) or [006-006] (Return) is ON, +24VDC measured 
between the Carriage Motor p739-1 (+) and GND (-) 
Y N 

In the same diagnostic, +24VDC is measured between the NT/IPS PWB J725-1 

(+) and GND (-). 

Y N 

Replace the NT/IPS PWB (PL 18.3) 

Check the wire between the NT/IPS PWB J725-1-6 and the Carriage Motor p739-1-6 
for an open circuit or poor contact. 

Check the wire between the I IT/I PS PWB J725 and the Carriage Motor p739-5 for an open 

circuit or poor contact. 

If no problems are found, replace the Carriage Motor (PL 18.5). 

If the problem continues, replace the NT/IPS PWB (PL 18.3). 



i The Carriage Motor BELT for damage, loosening and disengagement 
i The CARRIAGE CAPSTAN SHAFT/PULLEY for wear, distortion and chips 
i Full Rate/Half Rate Carriage Position Adjustment (ADJ) 
If no problems are found, replace the I IT/IPS PWB (PL 18.3). 



Check the following: 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-95 



Status Indicator RAPs 

6-390 



6-391 Scan Initialize Motor Driver 

The Carriage Motor error was detected after the initialization was started. 

Procedure 

BSD 6.4 BSD 6.1 

Turn off the power. Remove the following covers: 

i TOP COVER 

T NT REAR COVER 

Measure conductivity of the following: 

Between the Carriage Motor p739-6 and the NT/IPS PWB J725-6 
Between the Carriage Motor p739-6 and the NT/IPS PWB J725-5 
Between the Carriage Motor p739-4 and the NT/IPS PWB J725-4 
Between the Carriage Motor p739-3 and the NT/IPS PWB J725-3 
Between the Carriage Motor p739-2 and the NT/IPS PWB J725-2 
Between the Carriage Motor p739-1 and the NT/IPS PWB J725-1 

The resistance is 1 Ohm or less for all wires. 

Y N 

Check wires with more than 1 Ohm for an open circuit or poor contact. 

Replace the Carriage Motor (PL 18.5). 

If the problem continues, replace the I IT/I PS PWB (PL 18.3) 



Status Indicator RAPs 

6-391 



6/02 
2-96 



Prelaunch Training/Review 
DC1 632/2240 



7-104 Tray 1 Feed Out Sensor 

The Tray 1 Feed Out Sensor does not detect paper after feeding from Tray 1 . 

Initial Actions 

i Check condition and specification of paper in Tray 1 . 

i Check the paper path for obstructions. 

i Check for wear and clean the Tray 1 Feeder Roll, Take Away Roll and the Nudger Roll. 

Procedure 

Enter dC330 [008-100] and press Start. Block and unblock Tray 1 Feed Out Sensor (PL2.3). 
The display changes. 

Y N 
Go to OF 99-2 Transmissive Sensor RAR 

Enter dC330 [008-106] and press Start. Block and unblock the Take Away Sensor (PL 16.6). 
The display changes. 

Y N 
Go to OF 99-2 Transmissive Sensor RAP. 

Enter dC330 [008-029] then dC330 [008-036] and press Start. The Take Away Motor 1 ener- 
gizes (PL 15.9). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Replace the Tray Module PWB (PL 16.15). 



TRAY MODULE 

PWB 

PL16.15 



47~ 

DC COM 



-B5r 



DOUBLE 
PLUG 

P623 I I J623 J150 
1 3 — 1 



47" 

+5VDC 



-B7^ 



+5VDC 



CONTROL 
LOGIC 



YEL 
DC330 [8-100] 
TRAY 1 FEEDOUT SENSOR 
SENSED (H) +5VDC 



] 1 — 3 



VIO 



TRAY 1 FEED OUT 

SENSOR 

PL16.5 



!<Pp3 



YEL 



J 2 — 2 
I I 



YEL 



J150 
YEL 



TRAY MODULE 

PWB 

PL16.15 



J546 



DC COM 



P840 



47 



47 

+5VDC 



- 12 h 



+5VDC 



DOUBLE 
PLUG 

I 1 

3 — 1 



J840 J830 



CONTROL 
LOGIC 



GRY 

DC330 [8-106] 
TAKE AWAY SENSOR 



GRY 



TAKE AWAY SENSOR 
PL16.6 



!$fp3 



YEL 



CONTROL 
LOGIC 



T708005A-CAR 



TRAY MODULE PWB 
PL16.15 



DC COM 
DC COM 



+24VDC 
TM INTLK 

DC COM 

ST 



I I 

Figure 2 Takeaway Sensor CD 



DOUBLE 
DC330 [8-029 - 036] PLUG 

TAKEAWAY MOTOR 1 i 1 

J552 ON 24V PULSED P826 ' _ J 



6 — 2 



I YEL 


DC330 [8-029 - 036] | 
TAKEAWAY MOTOR 1 1 ] 
ON 24V PULSED i 


jYEL 


+24VDC TM INTLK ] 


JVIO 


+24VDC TM INTLK ] 


]VIO 


DC330 [8-029 - 036] j 
TAKEAWAY MOTOR 1 i 
ON 24V PULSED ! 


lYEL 


DC330 [8-029 - 036] | 
TAKEAWAY MOTOR 1 | 
ON 24V PULSED ' 



DC COM 



4 — 4 



3 — 5 



2 — 6 
I I 



T708002A-CAR 



J826 


TAKEAWAY 
MOTOR 1 
PL16.15 




\ 




\ 




(mot) 




J 




I 







T708000A-CAR 



Figure 1 Tray 1 Feed Out Sensor CD 



Figure 3 Takeaway Motor 1 CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-97 



Status Indicator RAPs 

7-104 



7-105 Tray 1 Misfeed 

The Tray 1 Feed Out Sensor does not detect paper after feeding from Tray 1 . 

Initial Actions 

i Check condition and specification of paper in Tray 1 . 

i Check the paper path for obstructions. 

i Check for wear and clean the Tray 1 Feed Roll, Take Away Roll and the Nudger Roll. 

Procedure 

Enter dC330 [008-100] and press Start. Block and unblock the Tray 1 Feed Out Sensor (PL 
2.3). The display changes. 

Y N 
Go to OF 99-2 Transmissive Sensor RAP. 

Enter dC330 [008-001] and press Start. The Tray 1 Feed/Lift motor energizes (PL 2.4). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [008-029] then dC330 [008-036] and press Start. The Take Away Motor 1 ener- 
gizes PL 15.9). 

Y N 

Go to the OF 99-6 Motor Open RAP. 

Replace the l/FPWB PL 9.1. 

If the problem continues, replace the MCU PWB (PL 13.1). 




DOUBLE 
PLUG 

P623 I I J623 J150 
1 3 — 1 



+5VDC 



YEL 
DC330 [8-100] 
TRAY 1 FEEDOUT SENSOR 
SENSED (H) +5VDC 



n — 3 



VIO 



TRAY 1 FEED OUT 

SENSOR 

PL16.5 



!<Pp3 



YEL 



J 2 — 2 
I I 



YEL 



J150 
YEL 



CONTROL 
LOGIC 



l/F PWB 
PL9.1 



DC COM 



DC330 [8-001] (FEED) D0U BLE 

DC330 [8-002] (LIFT) PLUG 

TRAY 1 FEED/LIFT i 1 

J532 MOTOR ON 24V PULSED P617^ ' J617 J205 

A6n— T 



A5 



DC330 [8-001] (FEED) 
DC330 [8-002] (LIFT) 
TRAY 1 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



-A4- 



+24VDC TM INTLK 



-A3 



+24VDC TM INTLK 



+24VDC 
TM INTLK 



DC COM 



VIO 



DC330 [8-001] (FEED) 
DC330 [8-002] (LIFT) 
TRAY 1 FEED/LIFT 
MOTOR ON 24V PULSED 



DC330 [8-001] (FEED) 
DC330 [8-002] (LIFT) 
TRAY 1 FEED/LIFT 
MOTOR ON 24V PULSED 





" iBLU i 


8 — 




' |BLU i 


9 — 




|ORN | 


— 




' ;orn i 








|BLU ; 



YEL 



Figure 2 Tray 1 Feed/Lift Motor CD 



L_^ BLU L 



T707003A-CAR 



T708005A-CAR 



Figure 1 Tray 1 Feed out Sensor CD 



Status Indicator RAPs 

7-105 



6/02 
2-98 



Prelaunch Training/Review 
DC1 632/2240 



TRAY MODULE PWB 
PL16.15 



CONTROL 
LOGIC 



DC COM 
DC COM 



+24VDC 
TM INTLK 

DC COM 

St' 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
J552 ON 24V PULSED 



YEL 



YEL 



YEL 



YEL 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 1 
ON 24V PULSED 



+24VDC TM INTLK 



+24VDC TM INTLK 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
ON 24V PULSED 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
ON 24V PULSED 



DOUBLE 
PLUG 

P826 I I 

7 — 1 



6 — 2 



2 — 6 
I I 



J826 


TAKEAWAY 
MOTOR 1 
PL16.15 




\ 




\ 




(mot) 




J 




I 







Figure 3 Takeaway Motor 1 CD 



T708000A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-99 



Status Indicator RAPs 

7-105 



7-110 Tray 2 Misfeed 

The Take Away Sensor does not detect paper after feeding from Tray 2. 

Initial Actions 

i Check condition and specification of paper in Tray 2. 

i Check the paper path for obstructions. 

i Check for wear and clean the Tray 2 Feeder Roll, Take Away Roll and the Nudger Roll. 

Procedure 

Enter dC330 [008-106] and press Start. Block and unblock the Take Away Sensor (PL 16.6). 
The display changes. 

Y N 
Go to OF 99-2 Transmissive Sensor RAR 

Enter dC330 [008-003] and press Start. The Tray 2 Feed/Lift motor energizes (PL 15.3). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [008-029] then dC330 [008-036] and press Start. The Take Away Motor 1 ener- 
gizes (PL 15.9). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB (PL 16.15). 




J546 DCC0M P840 3 



DOUBLE 

PLUG 

I 1 



VIO 



+5VDC 



1 J840 J830 
1 i , 3 



TAKE AWAY SENSOR 
PL16.6 



GRY 
| DC330 [8-106] 

TAKE AWAY SENSOR 



VIO 



GRY 






YEL 



I I 

Figure 1 Takeaway Sensor CD 



T708002A-CAR 



TRAY MODULE PWB 
PL16.15 



CONTROL 
LOGIC 



DC COM 

St 



DC330 [8-003] (FEED) DOUBLE 

DC330 [8-003] (LIFT) PLUG 

TRAY 2 FEED/LIFT i 1 

J547 MOTOR ON 24V PULSED p67 ° 1 



J670 J827 



YEL 



DC330 [8-003] (FEED) 
DC330 [8-003] (LIFT) 
TRAY 2 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



+24VDC TM INTLK 



+24VDC TM INTLK 



+24VDC 
TM INTLK 

DC COM 



VIO 



DC330 [8-003] (FEED) 
DC330 [8-003] (LIFT) 
TRAY 2 FEED/LIFT 
MOTOR ON 24V PULSED 



DC330 [8-003] (FEED) 
DC330 [8-003] (LIFT) 
TRAY 2 FEED/LIFT 
MOTOR ON 24V PULSED 



10— 3 



YEL 



12— 1 
I I 



BLU 



ORN 



BLU 



Figure 2 Tray 2 Feed/Lift Motor CD 



T707000A-CAR 



Status Indicator RAPs 

7-110 



6/02 
2-100 



Prelaunch Training/Review 
DC1 632/2240 



TRAY MODULE PWB 
PL16.15 



CONTROL 
LOGIC 



DC COM 
DC COM 



+24VDC 
TM INTLK 

DC COM 

St' 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
J552 ON 24V PULSED 



YEL 



YEL 



YEL 



YEL 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 1 
ON 24V PULSED 



+24VDC TM INTLK 



+24VDC TM INTLK 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
ON 24V PULSED 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
ON 24V PULSED 



DOUBLE 
PLUG 

P826 I I 

7 — 1 



6 — 2 



2 — 6 
I I 



J826 


TAKEAWAY 
MOTOR 1 
PL16.15 




\ 




\ 




(mot) 




J 




I 







Figure 3 Takeaway Motor 1 CD 



T708000A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-101 



Status Indicator RAPs 

7-110 



7-115 Tray 3 Misfeed 

The Take Away Sensor does not detect paper after feeding from Tray 3. 

Initial Actions 

i Check condition and specification of paper in Tray 3. 

i Check the paper path for obstructions. 

i Check for wear and clean the Tray 3 Feeder Roll, Take Away Roll and the Nudger Roll. 

Procedure 

Enter dC330 [008-102] and press Start. Block and unblock the Tray 3 Feed Out Sensor (PL 
1 5.10). The display changes. 

Y N 
Go to OF 99-2 Transmissive Sensor RAR 

Enter dC330 [008-005] and press Start. The Tray 3 Feed/Lift motor energizes (PL 15.6). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [008-029] and press Start. The Take Away Motor 1 energizes (PL 15.9). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB (PL 16.15). 




J548 



DC COM 



DOUBLE 
PLUG 

P841 I I J841 J821 
3 — 1 rrr^ 



+5VDC 



GRY 

DC330 [8-102] I 

TRAY 3 FEED OUT SENSOR | 
SENSED (H) +5VDC 

YEL 



3 (■ 



GRY 



TRAY 3 FEEDOUT 
SENSOR SENSED 
PL16.6 



lJ)S(g 



2 — 2 L- 

L_^ V 



J821 



TRAY MODULE PWB 
PL16.15 



CONTROL 
LOGIC 



DC COM 

St 



DC330 [8-005] (FEED) 
DC330 [8-006] (LIFT) 

TRAY 3 FEED/LIFT i 1 

•J549 MOTOR ON 24V PULSED P672 ' ' J672 J828 

B6i " 



DOUBLE 
PLUG 



B5 



YEL 



DC330 [8-005] (FEED) 
DC330 [8-006] (LIFT) 
TRAY 3 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



B4r 



+24VDC TM INTLK 



■B3 



+24VDC TM INTLK 



+24VDC 
TM INTLK 

DC COM 



B2 



Bl 



VIO 



DC330 [8-005] (FEED) 
DC330 [8-006] (LIFT) 
TRAY 3 FEED/LIFT 
MOTOR ON 24V PULSED 



DC330 [8-005] (FEED) 
DC330 [8-006] (LIFT) 
TRAY 3 FEED/LIFT 
MOTOR ON 24V PULSED 





" iblu ; 


8 — 




] |BLU ; 


9 — 




|ORN ! 


lO- 




' ;orn i 


ll — 




|BLU ; 



YEL 



I I 



BLU 



Figure 2 Tray 3 Feed/Lift Motor CD 



T707001A-CAR 



T708003A-CAR 



Figure 1 Tray 3 Feedout Sensor CD 



Status Indicator RAPs 

7-115 



6/02 
2-102 



Prelaunch Training/Review 
DC1 632/2240 



TRAY MODULE PWB 
PL16.15 



CONTROL 
LOGIC 



DC COM 
DC COM 



+24VDC 
TM INTLK 

DC COM 

St' 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
J552 ON 24V PULSED 



YEL 



YEL 



YEL 



YEL 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 1 
ON 24V PULSED 



+24VDC TM INTLK 



+24VDC TM INTLK 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
ON 24V PULSED 



DC330 [8-029 - 036] 
TAKEAWAY MOTOR 1 
ON 24V PULSED 



DOUBLE 
PLUG 

P826 I I 

7 — 1 



6 — 2 



2 — 6 
I I 



J826 


TAKEAWAY 
MOTOR 1 
PL16.15 




\ 




\ 




(mot) 




J 




I 







Figure 3 Takeaway Motor 1 CD 



T708000A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-103 



Status Indicator RAPs 

7-115 



7-119 Tray 4 Misfeed 

The Feed Out Sensor does not detect paper after feeding from Tray 4. 

Initial Actions 

i Check condition and specification of paper in Tray 4. 

i Check the paper path for obstructions. 

i Check for wear and clean the Tray 4 Feeder Roll, Take Away Roll and the Nudger Roll. 

Procedure 

Enter dC330 [008-103] and press Start. Block and unblock the Tray 4 Feed out Sensor (PL 
16.5). The display changes. 

Y N 
Go to OF 99-2 Transmissive Sensor RAR 

Enter dC330 [008-007] and press Start. The Tray 4 Feed/Lift motor energizes (PL 15.7). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [008-029] and press Start. The Take Away Motor 2 energizes (PL 16.15). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB (PL 16.15). 



TRAY MODULE 

PWB 

PL16.15 



47 



+5VDC 



CONTROL 
LOGIC 



J548 



DC COM 



DOUBLE 
PLUG 

P842 I I J842 J825 
1 3 — 1 



3 ^ 



+5VDC 



GRY 
DC330 [8-103] 
TRAY 3 FEEDOUT SENSOR 
SENSED (H) +5VDC 



^ 1 



VIO 



GRY 



TRAY 4 FEED OUT 

SENSOR 

PL16.5 



lJ)S(g 



YEL 



J 2 — 2 
I I 



TRAY MODULE PWB 
PL16.15 



CONTROL 
LOGIC 



DC COM 
DC COM 



DC330 [8-007] (FEED) D0UBLE 

DC330 [8-008] (LIFT) PLUG 

TRAY 4 FEED/LIFT i 1 

•J549 MOTOR ON 24V PULSED P"4 ' ' J674 J829 

A6 i 



A5 



YEL 



DC330 [8-007] (FEED) 
DC330 [8-008] (LIFT) 
TRAY 4 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



-A4- 



+24VDC TM INTLK 



-A3 



+24VDC TM INTLK 



+24VDC 
TM INTLK 

DC COM 



A2 



Al 



VIO 



DC330 [8-007] (FEED) 
DC330 [8-008] (LIFT) 
TRAY 4 FEED/LIFT 
MOTOR ON 24V PULSED 



DC330 [8-007] (FEED) 
DC330 [8-008] (LIFT) 
TRAY 4 FEED/LIFT 
MOTOR ON 24V PULSED 





" iblu ; 


8 — 




] |BLU ; 


9 — 




|ORN ! 


lO- 




' ;orn i 


ll — 




|BLU ; 



YEL 



I I 



BLU 



Figure 2 Tray 4 Feed/Lift Motor CD 



T707002A-CAR 



T708004A-CAR 



Figure 1 Tray 4 Feedout Sensor CD 



Status Indicator RAPs 

7-119 



6/02 
2-104 



Prelaunch Training/Review 
DC1 632/2240 



TRAY MODULE PWB 
PL16.15 



CONTROL 
LOGIC 



DC COM 
DC COM 



+24VDC 
TM INTLK 

DC COM 

St 



J553 


DC330 [8-047 - 048] 
TAKEAWAY MOTOR 2 
ON 24V PULSED 


TAKEAWAY 
MOTOR 2 
PL16.15 


iYEL 


DC330 [8-047 - 048] 
TAKEAWAY MOTOR 2 
ON 24V PULSED 


\ 


]YEL 


+24VDC TM INTLK 


\ 


|VIO 


+24VDC TM INTLK 


(mot) 


]VIO 


DC330 [8-047 - 048] 
TAKEAWAY MOTOR 2 
ON 24V PULSED 


J 


iYEL 


DC330 [8-047 - 048] 
TAKEAWAY MOTOR 2 
ON 24V PULSED 


I 


YEL 







T708001A-CAR 



Figure 3 Takeaway Motor 2 CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-105 



Status Indicator RAPs 

7-119 



7-122 Tray 4 Opened 



The Tray 4 Feed Out Sensor detected paper when Tray 4 is pulled out and pushed in during a 
print. 



Initial Actions 

i Check condition and specification of paper in Tray 4. 

i Check the paper path for obstructions and clean the Tray 4 Feed out Sensor. 

i Check the Tray 4 mechanical operation. 

Procedure 

Enter dC330 [008-103] and press Start. Block and unblock the Tray 4 Feed out Sensor (PL 
16.5). The display changes. 
Y N 

Go to OF 99-2 Transmissive Sensor RAP. 

Check the machine Shutdown History Report. If there is a history of this failure, replace the 

Tray 4 Feed Out Sensor (PL 16.5). 

If the problem continues, replace the Tray Module PWB (PL 16.15). 




vio 



+5VDC 



P842 



DOUBLE 
PLUG 
I 1 



TRAY 4 FEED OUT 

SENSOR 

PL16.5 



-i 3 



1 



GRY 
DC330 [8-103] 
TRAY 3 FEEDOUT SENSOR 
SENSED (H) +5VDC 



^ 1 



VIO 



GRY 



l£JII \^] 



YEL 



J 2 — 2 
I I 



T708004A-CAR 



Figure 1 Tray 4 Feedout Sensor CD 



Status Indicator RAPs 

7-122 



6/02 
2-106 



Prelaunch Training/Review 
DC1 632/2240 



7-250 Tray Communication 

Communication fault between Tray Module PWB and MCU PWB. 

Procedure 

There is +5 VDC measured at P/J541-9 on the Tray Module PWB (PL 15.9). 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 13.1). 
If the problem continues, replace the l/F PWB (PL 13.1) 
A 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
— i 79 i — 



MCU To Tray 

Module Comm. 

5 Line F 




BLU 
TRAY CLOCK * 



BLU 
TRAY CLOCK - 



DOUBLE 

1 — 1 - 



CAUTION 

ESS PWB and MCU PWB cannot be replaced at the same time. 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB (PL 15.9). 

If the problem continues, replace the MCU PWB (PL 13.1). 

If the problem continues, replace the ESS PWB (PL13.1). 



TRAY MODULE PWB 
PL15.9/16.15 
+5VDC 

K YEL 



T707017A-CAR 



Figure 1 Tray Communication 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-107 



Status Indicator RAPs 

7-250 



7-252 Out Module Logic 

Incorrect software data was detected. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Reinstall the software. 

If the problem continues, replace the MCU PWB (PL 13.1). 



7-270 Tray 1 Paper Size Sensor 

An abnormal AD value was detected by the Tray 1 Paper Size Sensor. 

Initial Actions 

Ensure that the Paper Guide Tab makes contact with the sensor. 

Procedure 

Ensure that Tray 1 is fully seated. The voltages measured at P/J536-B9 on the l/F PWB cor- 
responds with the table on BSD 7.1 
Y N 

There is 3.3VDC measured between P/J115-1 and 3 on the Paper Size Sensor. 
Y N 

Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9.1). 
If the problem continues replace the MCU PWB (PL 13.1). 

Replace the Tray 1 Paper Size Sensor (PL 2.1). 

Replace the l/F PWB (PL 9.1). 

If the problem continues replace the MCU PWB (PL 13.1). 



I/F PWB 
PL9.1 



+3.3VDC 
J536 J115 • 
■ B10 , , 1 



TRAY 1 PAPER SIZE SENSOR 
PL2.1 




T707012A-CAR 



Figure 1 Tray 1 Paper Size Sensor 



Status Indicator RAPs 

7-252, 7-270 



6/02 
2-108 



Prelaunch Training/Review 
DC1 632/2240 



7-271 Tray 2 Paper Size Sensor 

An abnormal AD value was detected by the Tray 2 Paper Size Sensor. 



7-274 Tray 5 Paper Size Sensor 

An abnormal AD value was detected by the MSI Paper Size Sensor. 



Initial Actions 

Ensure that the Paper Guide Tab makes contact with the sensor. 



Initial Actions 

Check the connectors between the Tray 5 Paper Size Sensor and the l/F PWB 



Procedure 

Ensure that Tray 2 is fully seated. The voltages measured at P/J546-8 on the Tray Module 
PWB corresponds with the table on BSD 7.2 
Y N 

There is +5VDC measured between P/J816-1 and 3 on the Tray 2 Paper Size Sensor. 
Y N 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB 
(PL 16.15). 

Replace the Tray 2 Paper Size Sensor (PL 16.1). 

Replace the Tray Module PWB (PL 16.15). 




TRAY 2 PAPER 
SIZE SENSOR 
SENSED SIGNAL 



TRAY MODULE PWB 
PL16.15 

+5VDC 

















T707013A-CAR 



Procedure 

Enter dC140 [007-100] and press Start. Move the Tray 5 Paper Size Sensor (PL 2.15). The 
AD value changed. 
Y N 

There is 3.3VDC measured at P/J265-3 on the Tray 5 Paper Size Sensor. 

Y N 

Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9. 1 ) 



Enter dC140 [007-100] and press Start. Move the Tray 5 Paper Size Sensor (PL 2.15). 
The voltage at P/J265-2 changes. 
Y N 

Check the wires and connectors. If the check is OK, replace the Tray 5 Paper Size 
Sensor (PL 2.15). 



Replace the MCU PWB (PL 13.1). 

If the problem continues, replace the l/F PWB (PL 9.1). 

Replace the MCU PWB (PL 13.1). 

If the problem continues, replace the l/F PWB (PL 9.1). 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 

+3.3VDC 



JT 

DC COM 



1 J532 +3 3VDC P61 

B3 , , 8 — 1 



DOUBLE 
PI UG 
I I J610 



DOUBLE 



P/J410 
- 34 — 



DC1 40 [007-100] 
MSI PAPER SIZE 
SENSOR 
SENSED SIGNAL 



J265 

3 — 1 



P265 


PAPER 
SIZE 
SENSOR 
PL2.15 

























YEL 



T707014A-CAR 



Figure 1 Tray 2 Paper Size Sensor 



Figure 1 Tray 2 Paper Size Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-109 



Status Indicator RAPs 

7-271,7-274 



7-276 Tray 3 Paper Size Sensor 

An abnormal AD value was detected by the Tray 3 Paper Size Sensor. 

Initial Actions 

Ensure that the Paper Guide Tab makes contact with the sensor. 

Procedure 

Ensure that Tray 3 is fully seated. The voltages measured at P/J548-11 on the Tray Module 
PWB corresponds with the table on BSD 7.4 
Y N 

There is +5VDC measured between P/J820-1 and 3 on the Tray 3 Paper Size Sensor 
(PL 16.1). 
Y N 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB 
(PL 16.15). 

Replace the Tray 3 Paper Size Sensor (PL 16.1). 

Replace the Tray Module PWB (PL 16.15). 



7-277 Tray 4 Paper Size Sensor 

An abnormal AD value was detected by the Tray 4 Paper Size Sensor. 

Initial Actions 

Ensure that the Paper Guide Tab makes contact with the sensor. 

Procedure 

Ensure that Tray 4 is fully seated. The voltages measured at P/J548-5 on the Tray Module 
PWB corresponds with the table on BSD 7.6 
Y N 

There is +5VDC measured between P/J824-1 and 3 on the Tray 4 Paper Size Sensor 
(PL 16.1). 
Y N 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB 
(PL 16.15). 

Replace the Tray 4 Paper Size Sensor (PL 16.1). 

Replace the Tray Module PWB (PL 16.15). 



TRAY 

MODULE PWB 
PL16.15 



J548 +5VDC J820 



J. 



TRAY 3 PAPER 
SIZE SENSOR 
SENSED SIGNAL 




T707015A-CAR 




T707016A-CAR 



Figure 1 Tray 3 Paper Size Sensor 



Figure 1 Tray 3 Paper Size Sensor 



Status Indicator RAPs 

7-276, 7-277 



6/02 
2-110 



Prelaunch Training/Review 
DC1 632/2240 



7-281 Tray 1 Lift 

The Tray 1 Level Sensor does not detect tray lift. 

Initial Actions 

Check drive of the following: 

i Manually turn the gear at rear of the TRAY 1 to check that the Bottom Plate moves up and 

down smoothly, 
i Gently push Tray 1 in to check the drive transmission is firmly engaged. 

Procedure 

Enter dC330 [008-002] and press Start. The Tray 1 Feed/Lift motor energizes (PL2.4). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [007-1 1 6] and press Start. Open and close Tray 1 . The display changes. 

Y N 

Check the wires and connectors. 

If the check is OK, replace the Tray 1 Level Sensor (PL 2.4). 

If the problem continues, replace the Tray Module PWB (PL 16.15). 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB (PL 16.15). 



CONTROL 
LOGIC 



l/F PWB 
PL9.1 



DC COM 



DC330 [8-001] (FEED) D0U BLE 

DC330 [8-002] (LIFT) PLUG 

TRAY 1 FEED/LIFT i 1 

J532 MOTOR ON 24V PULSED P617^ ' J617 J205 

A6n— T 



A5 



YEL 



-A4- 



-A3 



+24VDC 
TM INTLK 



DC COM 



VIO 



YEL 



DC330 [8-001] (FEED) 
DC330 [8-002] (LIFT) 
TRAY 1 FEED/LIFT 
MOTOR ON 24V PULSED 



+24VDC TM INTLK 



+24VDC TM INTLK 



DC330 [8-001] (FEED) 
DC330 [8-002] (LIFT) 
TRAY 1 FEED/LIFT 
MOTOR ON 24V PULSED 



DC330 [8-001] (FEED) 
DC330 [8-002] (LIFT) 
TRAY 1 FEED/LIFT 
MOTOR ON 24V PULSED 





" iBLU i 


8 — 




' |BLU i 


9 — 




|ORN | 


— 




' ;orn i 








|BLU ; 



L_^ BLU L 



T707003A-CAR 



MCU PWB 
PL13.1 



Figure 1 Tray 1 Lift/Feed Motor CD 



CONTROL 
LOGIC 



KJ.3VUI 



l/F PWB 
PL9.1 

DC COM 

+5VDC 



A10 



A12 



DOUBLE 
PLUG 

J532 DC COM P617 ' ' J617 J10 



P/J410 
93 — 



+5VDC 



- A11 L 



BLU 

DC330 [7-116] 
TRAY 1 LEVEL 
SENSOR SENSED 
(H) +3.3VDC 



3—10 



1 —12 



GRY 



BLU 



J 2 — 11 L- 
I I 



YEL 



TRAY 1 LEVEL SENSOR 
PL2.4 



lJ)S(g 



Figure 2 Tray 1 Level Sensor CD 



YEL 



T707006A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-111 



Status Indicator RAPs 

7-281 



7-282 Tray 2 Lift 

The Tray 2 Level Sensor does detect tray lift. 

Initial Actions 

Check drive of the following: 

i Manually turn the gear at rear of the Tray 2 to check that the Bottom Plate moves up and 

down smoothly, 
i Gently push Tray 2 in to check the drive transmission is firmly engaged. 

Procedure 

Enter dC330 [008-004] and press Start. The Tray 2 Feed/Lift motor energizes (PL16.7). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [007-117] and press Start. Open and close Tray 2. The display changes. 

Y N 

Check the wires and connectors. If the check is OK, replace the Tray 2 Level Sensor PL 

16.7. 

If the problem continues, replace the Tray Module PWB (PL 16.15). 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB (PL 16.15). 



TRAY 

MODULE 

PWB 

PL16.15 I 10 



DOUBLE 
PLUG 




J547 DC COM P670 J670 J815 

3—10 



VIO 



+5VDC 



GRY 

DC330 [7-117] 
TRAY 1 LEVEL 
SENSOR SENSED 
(H) +5VDC 

YEL 



1 —12 



I I 



GRY 



TRAY 2 LEVEL SENSOR 
PL16.7 



|(£>*d : 



J815 
YEL 



T707008A-CAR 



Figure 2 Tray 2 Level Sensor CD 



CONTROL 
LOGIC 



TRAY MODULE PWB 
PL16.15 



DC COM 

St 



DC330 [8-003] (FEED) DOUBLE 

DC330 [8-003] (LIFT) PLUG 

TRAY 2 FEED/LIFT i 1 

J547 MOTOR ON 24V PULSED p67 ° 1 



J670 J827 



YEL 



DC330 [8-003] (FEED) 
DC330 [8-003] (LIFT) 
TRAY 2 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



+24VDC TM INTLK 



+24VDC TM INTLK 



+24VDC 
TM INTLK 

DC COM 



VIO 



DC330 [8-003] (FEED) 
DC330 [8-003] (LIFT) 
TRAY 2 FEED/LIFT 
MOTOR ON 24V PULSED 



DC330 [8-003] (FEED) 
DC330 [8-003] (LIFT) 
TRAY 2 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



10— 3 



12— 1 
I I 



BLU 



ORN 



BLU 



T707000A-CAR 



Figure 1 Tray 2 Lift/Feed Motor CD 



Status Indicator RAPs 

7-282 



6/02 
2-112 



Prelaunch Training/Review 
DC1 632/2240 



7-291 Tray 3 Lift 

The Tray 3 Level Sensor does detect tray lift. 

Initial Actions 

i Manually turn the gear at rear of the TRAY 3 to check that the Bottom Plate moves up and 

down smoothly, 
i Gently push Tray 3 in to check the drive transmission is firmly engaged. 

Procedure 

Enter dC330 [008-006] and press Start. The Tray 3 Feed/Lift motor energizes (PL 16.9). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [007-118] and press Start. Open and close Tray 3. The display changes. 

Y N 

Check the wires and connectors. If the check is OK, replace the Tray 3 Level Sensor PL 

16.7. 

If the problem continues, replace the Tray Module PWB (PL 16.15). 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB (PL 16.15). 




DOUBLE 
PLUG 



J549 DC COM P872 J872 J819 



VIO 



+5VDC 



GRY 

DC330 [7-118] 
TRAY 3 LEVEL 
SENSOR SENSED 
(H) +5VDC 

YEL 



3—10 



1 —12 



I I 



GRY 



TRAY 3 LEVEL SENSOR 
PL16.9 



|(£>*d : 



J819 
YEL 



T707010A-CAR 



Figure 2 Tray 3 Level Sensor CD 



CONTROL 
LOGIC 



TRAY MODULE PWB 
PL16.15 



DC COM 

St 



B6 



B5 



DC330 [8-005] (FEED) 
DC330 [8-006] (LIFT) 

TRAY 3 FEED/LIFT i 1 

•J549 MOTOR ON 24V PULSED P672 ' ' J672 J828 



DOUBLE 
PLUG 



YEL 



DC330 [8-005] (FEED) 
DC330 [8-006] (LIFT) 
TRAY 3 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



■B4- 



+24VDC TM INTLK 



■B3- 



+24VDC TM INTLK 



+24VDC 
TM INTLK 

"£- 

DC COM 

-%- 

DC COM 



B2 



Bl 



DC330 [8-005] (FEED) 
DC330 [8-006] (LIFT) 
TRAY 3 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



DC330 [8-005] (FEED) 
DC330 [8-006] (LIFT) 
TRAY 3 FEED/LIFT 
MOTOR ON 24V PULSED 





" IBLU i 


8 — 




3 |BLU ! 


9 — 




|ORN | 


— 




' |ORN | 








'BLU ; 



I I 



T707001A-CAR 



Figure 1 Tray 3 Lift/Feed Motor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-113 



Status Indicator RAPs 

7-291 



7-293 Tray 4 Lift 

The Tray 4 Level Sensor does detect tray lift. 

Initial Actions 

Check drive of the following: 

i Manually turn the gear at rear of the TRAY 4 to check that the Bottom Plate moves up and 

down smoothly, 
i Gently push Tray 4 in to check the drive transmission is firmly engaged. 

Procedure 

Enter dC330 [008-008] and press Start. The Tray 4 Feed/Lift motor energizes (PL 16.11). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [007-119] and press Start. Open and close Tray 4. The display changes. 

Y N 

Check the wires and connectors. If the check is OK, replace the Tray 4 Level Sensor (PL 

16.7). 

If the problem continues, replace the Tray Module PWB (PL 16.15). 

Check the wires and connectors. If the check is OK, replace the Tray Module PWB (PL 16.15). 



TRAY MODULE 

PWB 

PL16.15 



J549 



DC COM 



47 



DOUBLE 
PLUG 

P674 ' ' J674 J822 
, 3 — 10 



iVIO 



■A12J- 



! +5VDC 




GRY 



H 1 — 12 l 



DC330 [7-119] 
TRAY 4 LEVEL SENSOR 
SENSED (H) +5VDC 



GRY 



TRAY 4 LEVEL SENSOR 
PL16.11 



|(£>*d : 



' 2 — 11 • 
I I 



Figure 2 Tray 4 Level Sensor CD 



T707004A-CAR 



CONTROL 
LOGIC 



TRAY MODULE PWB 
PL16.15 



DC COM 

St 



DC330 [8-007] (FEED) D0UBLE 

DC330 [8-008] (LIFT) PLUG 

TRAY 4 FEED/LIFT i 1 

•J549 MOTOR ON 24V PULSED P"4 ' ' J674 J829 

A6r 



A5 



YEL 



DC330 [8-007] (FEED) 
DC330 [8-008] (LIFT) 
TRAY 4 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 



-A4- 



+24VDC TM INTLK 



-A3 



+24VDC TM INTLK 



+24VDC 
TM INTLK 

"£- 

DC COM 

St 



A2 



Al 



VIO 



DC330 [8-007] (FEED) 
DC330 [8-008] (LIFT) 
TRAY 4 FEED/LIFT 
MOTOR ON 24V PULSED 



DC330 [8-007] (FEED) 
DC330 [8-008] (LIFT) 
TRAY 4 FEED/LIFT 
MOTOR ON 24V PULSED 



YEL 





" iblu ; 


8 — 




3 |BLU ! 


9 — 




|ORN ! 


— 




' |ORN J 








|BLU ; 



I I 



BLU 



T707002A-CAR 



Figure 1 Tray 4 Lift/Feed Motor CD 



Status Indicator RAPs 

7-293 



6/02 
2-114 



Prelaunch Training/Review 
DC1 632/2240 



7-397 All Trays Lift Sensors 

All the Tray Level Sensors did not energize. 

Procedure 

Check the dC122 Shutdown History. 007-281, 007-282, 007-283, 007-284, 007-291, or 007- 
293 fault has occurred. 
Y N 

Replace the following in sequence: 

i Tray Module PWB (PL 15.9) (PL 16.15) 

i MCU PWB (PL 13.1) (TRAY 1 only) 

Go to the appropriate RAP. 



Prelaunch Training/Review g^2 Status Indicator RAPs 

DC1 632/2240 2-115 7-397 



7-930 Tray 1 Paper Size Mismatch 

The paper in Tray 1 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 1 . 
Y N 

Load the correct size paper. 

Go to (RAP7-270). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

7-930 2-116 DC1 632/2240 



7-931 Tray 2 Paper Size Mismatch 

The paper in Tray 2 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 2. 
Y N 

Ensure Paper Guides are correctly adjusted. 

Load the correct size paper. 

Goto(RAP7-271). 



7-932 Tray 3 Paper Size Mismatch 

The paper in Tray 3 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 3. 
Y N 

Ensure Paper Guides are correctly adjusted. 

Load the correct size paper. 

Go to (RAP7-276). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-117 



Status Indicator RAPs 

7-931,7-932 



7-933 Tray 4 Paper Size Mismatch 

The paper in Tray 4 does not match the paper size selected. 

Procedure 

The correct size paper is loaded in Tray 4. 
Y N 

Ensure Paper Guides are correctly adjusted. 

Load the correct size paper. 

Go to (RAP7-277). 



7-935 Job Continue Not Available 

Automatic Tray switching cannot be continued because a tray was not programed. 

Procedure 

Program the appropriate tray. The problem continues. 
Y N 

Return to Service Call Procedures. 

Refer to the User Guide information for Auto Tray Switching. 



Status Indicator RAPs 

7-933, 7-935 



6/02 
2-118 



Prelaunch Training/Review 
DC1 632/2240 



7-954 SMH Size Mismatch (Slow Scan Direction) 

The paper in the slow scan direction is shorter than the specified paper size. 

Procedure 

The correct size paper is loaded in the SMH. 
Y N 

Load the correct size paper. 

Replace the Registration Sensor. (PL 2.6). 



7-959 Tray 5 Paper Mismatch 1 

Other than dedicated stock is detected by the OHP sensor. 

Initial Actions 

Ensure that dedicated stock is used. 

Check that the transparencies are oriented correctly. 

Check for obstructions and clean the OHP Sensor. 

Procedure 

Enter dC330 [008-110] and press Start. Block the OHP Sensor R using plain paper (PL 2.6). 
The display changes. 
Y N 

Go to OF 99-1 Reflective Sensor RAP. 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 13.1). 




T708007A-CAR 



Figure 1 The OHP Sensor R 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-119 



Status Indicator RAPs 

7-954, 7-959 



7-960 Tray 5 Paper Mismatch 2 



A different paper type or transparency was detected when plain/heavyweight paper was spec- 
ified. 

Initial Actions 

i Check that the loaded paper type matches the Ul selection, 
i Check the OHP sensor area for foreign substances 

Procedure 

Enter dC330 8-110. Block the OHP Sensor R using plain paper. The display changes. 
Y N 

Go to RAP OF 99-1 Reflective Sensor RAP. 

Replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 

DC COM 

r B 

+5VDC 



YEL 
+5VDC 



DOUBLE 

11— 1 



OHP SENSOR R 
J155 IPL2.6 



^ 




* * 



DC330 [008-1 10] 
OHP SENSOR R 
SENSED (L) +5VDC 



U 



T708007A-CAR 



Figure 1 The OHP Sensor R 



7-969 Full Paper Stack 

The Full Paper Stack Sensor detects that Face Down Tray is full. 

Initial Actions 

Check the Full Paper Stack Sensor for obstructions and actuator operation. 

Procedure 

Enter dC330 [010-102] and press Start. Move the Full Paper Stack Sensor (PL 10.2) actuator 
up and down. The display changes. 
Y N 

Go to OF 99-2 Transmissive Sensor RAP. 

Check the connectors and wires. If the check is OK, replace the MCU PWB (13.1). 
If the problem continues, replace the l/F PWB (PL 9.1). 



MCU PWB 
PL13.1 



J532DCCOM P611 



DOUBLE 



FULL PAPER STACK 

SENSOR 

"L2.10/2.11 



DC COM 
+5VDC 



P/J410 
— 41 B16- 



YEL 
+5VDC 



©: 



YEL 



GRY 



DC330 [010-102] 
FULL PAPER 
STACK SENSOR 
SENSED fLI +3.3VDC 



YEL 



T707018A-CAR 



Figure 1 The Full Paper Stack Sensor 



Status Indicator RAPs 

7-960, 7-969 



6/02 
2-120 



Prelaunch Training/Review 
DC1 632/2240 



8-151 Tray 3 Take Away Sensor On 

The Take Away Sensor does not detect paper fed from Tray 3. 

Initial Actions 

I Check condition and specification of paper in Tray 3. 
i Check the paper path and sensor area for obstructions. 

i Check for wear and clean the Tray2 and Tray3 Feeder Roll, Take Away Roll and the 
Nudger Roll. 

Procedure 

Enter dC330 [008-102] and press Start. Block and unblock the Take Away Sensor (PL 16.6). 
The display changes state. 

Y N 
Go to OF 99-2 Transmissive Sensor RAR 

Enter dC330 [008-029. The Take Away Motor 1 energizes. 

Y N 

Go to OF 99-6 Motor Open RAP. 

Replace the Tray Module PWB (PL 16.15). 



TRAY MODULE 

PWB 

PL16.15 



DC COM 

+5VDC 
+5VDC 



J546 DC COM P840 
! vio 



DC330 [008-106] 
TAKE AWAY SENSOR; 
SENSED (H) +5VDC 



r^ 



TAKE AWAY SENSOR 



J840 J830 IPL16.6 



VIO 




T708012A-CAR 



Figure 1 The Take Away Sensor 



TRAY MODULE PWB 
PL16.15 



DOUBLE 
TAKE AWAY MOTOR 1 f L UG 
ON 24V CLOCK P826 ' I j 82 6 



+24VDC 
TM INTLK 



YEL 



TAKE AWAY MOTOR 1 
ON 24V CLOCK 



YEL 
+24VDC TM INTLK 



VIO 
+24VDC TM INTLK 



TAKE AWAY MOTOR 1 
ON 24V CLOCK 



TAKE AWAY MOTOR 1 
ON 24V CLOCK 



TAKE AWAY 
MOTOR 1 
PL16.15 



708O13A-CAR 



Figure 2 The Take Away Motor 1 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-121 



Status Indicator RAPs 

8-151 



8-152 Tray 4 Take Away Sensor On 

The Take Away Sensor does not detect paper fed from Tray 4. 

Initial Actions 

I Check condition and specification of paper in Tray 4. 

i Check the paper path and sensor area for obstructions. 

i Check for wear and clean the Tray 4 Feeder Roll, Take Away Roll and the Nudger Roll. 

Procedure 

Enter dC330 [008-102] and press Start. Block and unblock the Block and unblock the Take 
Away Sensor (PL 16.6). The display changes state. 

Y N 
Go to OF 99-2 Transmissive Sensor RAR 

Enter dC330 [008-029] and press Start. The Take Away Motor 1 PL 16.15 energizes. 

Y N 

Go to OF 99-6 Motor Open RAR 

Enter dC330 [008-047] and press Start. The Take Away Motor 2 (PL 16.15) energizes. 

Y N 

Go to OF 99-6 Motor Open RAR 

Replace the Tray Module PWB (PL 16.15). 



TRAY MODULE PWB 
PL16.15 



+24VDC 
TM INTLK 



DOUBLE 
TAKE AWAY MOTOR 1 f L UG 
ON 24V CLOCK P826 ' I j 82 6 



YEL 



TAKE AWAY MOTOR 1 
ON 24V CLOCK 



YEL 
+24VDC TM INTLK 



VIO 
+24VDC TM INTLK 



TAKE AWAY MOTOR 1 
ON 24V CLOCK 



TAKE AWAY MOTOR 1 
ON 24V CLOCK 



Figure 2 The Take Away Motor 1 



TAKE AWAY 
MOTOR 1 
PL16.15 



708O13A-CAR 



TRAY MODULE 

PWB 

PL16.15 



J. 
DC COM 

+5VDC 
+5VDC 



J546 DC COM P840 
! vio 



DC330 [008-106] 
TAKE AWAY SENSOR; 
SENSED (H) +5VDC 

YEL 



r^ 



TAKE AWAY SENSOR 



J840 J830 IPL16.6 



VIO 



®=*!=» 



T708012A-CAR 



Figure 1 The Take Away Sensor 



TRAY MODULE PWB 
PL16.15 






(/ 






// 


"^ 


6 






DC COM 


5 






DC COM 


4 






+24 
TM If 




3 


VDC 
-ITLK 






r£- 


2 






DC COM 








4^ 


1 






DC COM 


l 



TAKE AWAY MOTOR 2 
ON 24V CLOCK 



TAKE AWAY MOTOR 2 
ON 24V CLOCK 



+24VDC TM INTLK 



+24VDC TM INTLK 



TAKE AWAY MOTOR 2 
ON 24V CLOCK 



TAKE AWAY MOTOR 2 
ON 24V CLOCK 



TAKE AWAY 
MOTOR 2 
PL16.15 



T708014A-CAR 



Figure 3 The Take Away Motor 2 



Status Indicator RAPs 

8-152 



6/02 
2-122 



Prelaunch Training/Review 
DC1 632/2240 



8-164 POB Sensor 

The POB Sensor did not detect paper after the Registration Clutch Energized. 

Initial Actions 

i Check condition and specification of the paper supply. 

i Check for paper on the IBT. 

i Check for obstructions in the paper feed path 

i Clean the POB Sensor. 

i Check the 2nd BTR transmission gears for breakage 

i Clean the Registration Roll and check for damage or ware. 

Procedure 

NOTE: Cheat the Left Cover Interlock. 

Enter dC330 [009-201] and press Start. Block and unblock the POB Sensor (PL 2.9). The dis- 
play changes state. 

Y N 
Go to OF 99-1 Reflective Sensor RAP. 

Enter dC330 [008-037] and press Start. The Registration Clutch energizes (PL 2.6). 

Y N 

Go to OF 99-4 Solenoid/Clutch Open RAP. 

In sequence enter the following: dC330 [009-051] then dC330 [009-052] and press Start. The 
2BTR contacts and retracts. 

Y N 

Go to RAP 9-342 for a contact failure or go to 9-343 for a retract failure. 

Check the wires and connectors. If the check is OK, replace the ESS PWB (PL 13.1) 



TRAY 

MODULE 

PWB 

PL16.15 I 10 



DOUBLE 
PLUG 




J547 DC COM P670 J670 J815 

3—10 



VIO 



+5VDC 



GRY 

DC330 [7-117] 
TRAY 1 LEVEL 
SENSOR SENSED 
(H) +5VDC 

YEL 



1 —12 



I I 



GRY 



TRAY 2 LEVEL SENSOR 
PL16.7 



|(£>*d : 



J815 
YEL 



T707008A-CAR 



Figure 2 Registration Clutch CD 



MCU PWB 
PL13.1 



+3.3VDC 



CONTROL 
LOGIC 



if.' 



l/F PWB 
PL9.1 



DOUBLE 
PLUG 



POB SENSOR 
J533 nnmy P612 I I J612 J121 I PL2 - 9 



DC COM 



6 — 10 



XT 1 

+5VDC 
P/J410 



VIO 



+5VDC 



H 4 — 12 L. 



DC330 [9-201] 
POB SENSOR 
SENSED (L) +3.3VDC 



YEL 



J 5 11 • 

I I 



YEL 



@Jnvy 



•»* 



YEL 



T709000A-CAR 



Figure 1 POB Sensor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-123 



Status Indicator RAPs 

8-164 



8-175 Registration Sensor On Jam Tray 5 

The Registration Sensor does not detect paper fed from the MSI. 

Initial Actions 

i Check condition and specification of the paper supply. 

i Check for obstructions in the paper feed path 

T Clean the MSI Feed Roll and check for ware. 

i Clean the Take Away Roll and check for ware. 

i Check the drive transmissions for damage or ware. 

Procedure 

Enter dC330 [009-104] and press Start. Block and unblock the Registration Sensor (PL 2.6). 
The display changes state. 

Y N 
Go to OF 99-1 Reflective Sensor RAP. 

Enter dC330 [007-003] and press Start. The Tray 5 Feed Solenoid energizes (PL 2.14). 

Y N 

Go to OF 99-4 Solenoid/Clutch Open RAP. 

Check the wires and connectors. If the check is OK, replace the ESS PWB (PL 1 3.1 ). 



MCU PWB 
PL13.1 

DC COM 
+5VDC 



J407 DC COM P620 



DOUBLE 
PJJJS, 



J620 J1G 



REGI SENSOR 
PL2.6 



YEL 
+5VDC 



YEL 



VIO 



DC330 [008-104] 
REGI SENSOR 
SENSED (L) +3.3VDC 



T708009A-CAR 



Figure 1 The Registration Sensor 



MCU PWB l/F PWB 
PL13.1 I PL9.1 
P/J410 
36 B7 



DC330 [007-003] 

TRAY 5 FEED SOLENOID 

ON (L) +24VDC DOUBLE 



PI I IG PI I in 

10 I I J610 poiq I ' 



+24VDC 



YEL 
+24VDC 



P219 I ' J219 
1 — 2 , 



TRAY 5 
FEED 
SOLENOID 
PL2.14 



T708010A-CAR 



Figure 2 The Tray 5 Feed Solenoid 



Status Indicator RAPs 

8-175 



6/02 
2-124 



Prelaunch Training/Review 
DC1 632/2240 



8-176 Registration Sensor On Jam Tray 1-4 

The Registration Sensor does not detect paper fed from each Tray. 

Initial Actions 

i Check condition and specification of the paper supply. 

i Check for obstructions in the paper feed path 

i Clean the Take Away Roll and check for ware. 

i Check the drive transmissions for damage or ware. 

Procedure 

Enter dC330 [008-104] and press Start. Block and unblock the Registration Sensor. The dis- 
play changes state. 

Y N 
Go to OF 99-1 Reflective Sensor RAP. 

Enter dC330 [008-038] and press Start. The Take Away Clutch energizes (PL 1.2). 

Y N 

Go to OF 99-4 Solenoid/Clutch Open RAP. 

Check the wires and connectors. If the check is OK, replace the ESS PWB (PL 1 3.1 ). 



MCU PWB 
PL13.1 

DC COM 
+5VDC 



J407 DC COM P620 



DOUBLE 
PJJJS, 



J620 J1Q 



REGI SENSOR 
PL2.6 



YEL 
+5VDC 



YEL 



VIO 



DC330 [008-104] 
REGI SENSOR 
SENSED (L) +3.3VDC 



T708009A-CAR 



Figure 1 The Registration Sensor 



MCU PWB l/F PWB 
PL13.1 I PL9.1 
P/J410 
92 A15 



+24VDC 



DC330 [008-038] (400ms) Dl . , r 

TAKE AWAY CLUTCH ,„, f L U S 

J532 0N (|_) +24VDC ^221 ' i 



BLU 



TAKE AWAY 

CLUTCH 

PL1.2 



T708011A-CAR 



Figure 2 The Take Away Clutch 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-125 



Status Indicator RAPs 

8-176 



8-180 Registration Sensor On Duplex 

The Registration Sensor does not detect paper after a duplex feed. 

Initial Actions 

i Check condition and specification of the paper supply. 

i Check for obstructions in the paper feed path. 

i Clean the Exit Roll, Transport Roll, Wait Roll and check for ware. 

i Check the drive transmissions for damage or ware. 

Procedure 

Enter dC330 [008-104] and press Start. Block and unblock the Registration Sensor (PL 2.6). 
The display changes state. 

Y N 
Go to OF 99-1 Reflective Sensor RAP. 

Enter dC330 [008-112] and press Start. The Duplex Motor energizes (PL 12.2). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [008-043] and press Start. The Inverter Reverse Clutch energizes (PL 11.2). 

Y N 

Go to OF 99-4 Solenoid/Clutch Open RAP. 
A 



Enter dC330 [008-046] and press Start. The Duplex Gate Solenoid energizes (PL 11.2). 
Y N 

Go to OF 99-4 Solenoid/Clutch Open RAP. 

Check the wires and connectors. If the check is OK, replace the Duplex PWB (PL 12.2). 



MCU PWB 
PL13.1 

DC COM 
+5VDC 



J407 DC COM P620 



DOUBLE 
PJJJS, 



J620 J1C 



REGI SENSOR 
PL2.6 



YEL 
+5VDC 



VIO 



DC330 [008-104] 
REGI SENSOR 
SENSED (L) +3.3VDC 



YEL 



T708009A-CAR 



Figure 1 The Registration Sensor 



MCU PWB 
PL13.1 



^ A1 ° 



£Hr 



DC330 [008-009 - 01 2] dm^ 

DUPLEX MOTOR l K L U ^ l 

ON (L) +5VDC P640 ' ' J640 

5 — 7 



YEL 




DC330 [008-009 - 
DUPLEX MOTOR 
REF CLOCK 


012] 


YEL 




DC330 [008-009 -012] 
DUPLEX MOTOR 
HIGH SPEED (L) +5VDC 



DRAWER 

CONNECTOR 

P626 ' I J626 

1 B5 — A5 , 



DUPLEX PWB 
PL12.2 
+5VDC 



St 



DC COM 



DUPLEX MOTOR 
J539 ON 24V CLOCK 


DUPLEX 
MOTOR 
PL12.2 


DUPLEX MOTOR 
ON 24V CLOCK 


\ 


+24VDC 


\ 


+24VDC 


(mot) 


DUPLEX MOTOR 
ON 24V CLOCK 


I 


DUPLEX MOTOR 
ON 24V CLOCK 


I 







Figure 2 The Duplex Motor 



T708015A-CAR 



Status Indicator RAPs 

8-180 



6/02 
2-126 



Prelaunch Training/Review 
DC1 632/2240 



MCU PWB 
PL13.1 



DOUBLE DOUBLE 

PI I IP PI I in. 



+24VDC 



DC330 [008-043] (400ms) 

inverter reverse 
clutch on (l) +24vdc 

blu 

+24VDC 

1 

BLU 



INVERTER 
REVERSE 
CLUTCH 
PL11.2 



4 -10 B4 — A4 i 4 

l I BLU I I BLU 



3 -11 B3 — A3 - 



U 0RN U 



T708016A-CAR 



MCU PWB 
PL13.1 



Figure 3 The Inverter Reverse Clutch 



PLUG CONNECTOR D0UB| _, 



„„ P251 ' ' J251 
A2 — B2 -^7777- 1 — 2 , 



DCC °" A7 +24VDC \_\_ 



BLU , , BLU 
A1 — B1 



ORN 



ORN 



Figure 4 The Duplex Gate Solenoid 



DUPLEX GATE 

SOLENOID 

PL11.2 



T708017A-CAR 



8-181 Registration Sensor On Wait Sensor 

The Registration Sensor does not detect paper after the Duplex Wait Sensor was energized. 

Initial Actions 

Check condition and specification of the paper supply. 
Check for obstructions in the paper feed path. 
Clean the Take Away Roll and check for ware. 
Check the drive transmissions for damage or ware. 

Procedure 

Enter dC330 [008-104] and press Start. Block and unblock the Registration Sensor (PL 2.6). 
The display changes state. 

Y N 
Go to OF 99-1 Reflective Sensor RAP. 

Enter dC330 [009-105] and press Start. Block and unblock the Duplex Wait Sensor (PL 12.2). 
The display changes state. 

Y N 
Go to OF 99-2 Transmissive Sensor RAP. 

Enter dC330 [008-112] and press Start. The Duplex Motor energizes (PL 12.2). 

Y N 

Go to the Motor Does Not Energize Failure RAP. 

Check the wires and connectors. If the check is OK, replace the Duplex PWB(PL 1 2.2). 



MCU PWB 
PL13.1 

DC COM 
+5VDC 



J407 DC COM P620 



YEL 
+5VDC 



YEL 



JOUBL 
PJJJS, 
3 — S 

1 — 1 


E 
J620 J109 


REGI SENSOR 
PL2.6 




1 


vio ; " 


r-fT 2 


J109 






GRY 


^ 


9f 


DC330 [008-104] 
REGI SENSOR 
SENSED (L) +3.3VDC 




YEL 









T708009A-CAR 



Figure 1 The Registration Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-127 



Status Indicator RAPs 

8-180,8-181 



DRAWER DOUBLE DC330 [008-1 05] 

CONNECTOR PIUG DUPLEX WAIT SENSOR 

F \ Pfi?fi .IR40 F^H p 640 SENSED (H) +5VDC J4| 




MCU PWB 
PL13.1 



DC330 [008-300] 
DUPLEX COVER 
INTERLOCK SWITCH 
CLOSED (L) +3.3VDC 



YEL 



T708018A-CAR 



Figure 2 The Duplex Wait Sensor 



MCU PWB 
PL13.1 



/?H^ A10 



VX^- 



DC330 [008-009 - 01 2] dm^ 

DUPLEX MOTOR | K L U ^ I 

ON (L) +5VDC P640 ' ' 

5 — 7 



J640 P626 



DRAWER 
CONNECTOR 



J626 J538 



DUPLEX PWB 
PL12.2 
+5VDC 



YEL 




DC330 [008-009 - 
DUPLEX MOTOR 
REF CLOCK 


012] 


YEL 




DC330 [008-009 -012] 
DUPLEX MOTOR 
HIGH SPEED (L) +5VDC 



H^ 



DC COM 



DUPLEX MOTOR 
J539 ON 24V CLOCK 


DUPLEX 
MOTOR 
PL12.2 


DUPLEX MOTOR 
ON 24V CLOCK 


\ 


+24VDC 


\ 


+24VDC 


(mot) 


DUPLEX MOTOR 
ON 24V CLOCK 


I 


DUPLEX MOTOR 
ON 24V CLOCK 


I 







Figure 3 The Duplex Motor 



T708015A-CAR 



Status Indicator RAPs 

8-181 



6/02 
2-128 



Prelaunch Training/Review 
DC1 632/2240 



8-184 Registration Sensor Off 

The Fuser Exit Switch did not detect paper after the Registration Clutch was energized. 



Initial Actions 

i Check condition and specification of the paper supply, 

i Check for obstructions in the paper feed path, 

i Check the Fuser Belt and the Heat Roll for damage or ware, 

i Clean the Registration Roll and check for ware or damage. 

I Check the drive transmissions for damage or ware. 

Procedure 

Enter dC330 [010-101] and press Start. Actuate and de-actuate the Fuser Exit Switch PL 2.8. 
The display changes state. 

Y N 
Go to the of 99-3 Switch RAP. 

Enter dC330 [008-037] and press Start. The Registration Clutch energizes (PL 2.6). 

Y N 

Go to OF 99-4 Solenoid/Clutch Open RAP. 

In sequence enter the following: dC330 [009-051] then dC330 [009-052] and press Start. The 
2nd BTR Retract Motor energizes (PL 2.9). 

Y N 

Go to RAP 9-342 for a contact failure or go to 9-343 for a retract failure. 

Check the wires and connectors. If the check is OK, replace the Duplex PWB (PL 12.2). 



MCU PWB 
PL13.1 



CONTROL 
LOGIC 



+3.3VDC 

P/J410 



l/F PWB 
PL9.1 



DC COM 



DOUBLE 
PLUG 

J533 DC COM P612 ' ' J612 P113 

BHr-r: 7 — 9 



YEL 



DC330 [10-101] 
FUSER EXIT SWITCH 
SENSED (H) +3.3VDC 




DOUBLE 
PLUG 

1 ! J113 


FUSER EXIT 

SWITCH 

PL2.8 








v2_i_V 




I MAGNET | 







YEL | | YEL 



Figure 1 Fuser Exit Switch CD 



T710002A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-129 



Status Indicator RAPs 

8-184 



8-620 Regicon Temp Sensor 

Environment Sensor not in range. 

Procedure 

NOTE: Machine operation continues. Status Code not displayed on ill. Status Code logged in 
History. 

Turn the power off. Disconnect the Environment Sensor (PL 1.3). 
Measure the resistance between the following: 
i l/F PWB P/J536-B4 and P/J255-1 
i l/F PWB P/J536-B2 and P/J255-3 



i l/F PWB P/J536-B1 and P/J255-4 

The Resistance is 1 ohm or less. 

Y N 

Check the wires and connectors. If the check is OK, replace the replace MCU PWB (PL 
13.1). 

Measure resistance between P/J255-3 and P/J255-4 on Environment Sensor. 6k ohms to 20k 
ohms is measured. 

Y N 

Replace Environment Sensor (PL 1.3). 

Replace MCU PWB (PL 13.1). If problem continues, replace ESS PWB (PL 13.1). 



I/F PWB | 

PL9.1 B4 

I 
+5VDC 



DOUBLE 
PLUG 



+5VDC P619 



r 

DC COM 



B2 



YEL 
DC COM 



ENVIRONMENT 

SENSOR 

PL1.3 






ENVIRONMENT 




1 - 


I TEMP. I 


- 4 








3 - 


I HUMIDITY I 


- 2 















DOUBLE 
PLUG 



J255 J619 



DC140 [009-256] 
ENVIRONMENT 
SENSOR 
P619 TEMP. SIGNAL 



DC1 40 [009-257] YtL 

ENVIRONMENT 

SENSOR HUMIDITY SIGNAL 



Figure 1 The Environmental Sensor 



l/F 


MCU 




PWB 


PWB 




PL9.1 


PL13.1 




P/J41 U 


/ / 




B1 — ^51H 


/< 




I : I : 

B3 '- 53 '— 

I I 




V/ 



T708019A-CAR 



Status Indicator RAPs 

8-620 



6/02 
2-130 



Prelaunch Training/Review 
DC1 632/2240 



8-622 Regicon Data Overflow (A1 Patch X) 

At A1 patch detection, the XSO correction setting value for either Y, M, C, or K exceeds the set- 
ting range (NVM value to 472). 

NOTE: Status Code not displayed on ill. Machine operation continues. 

Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



8-623 Regicon Data Overflow (A2 Patch Y) 

At A2 patch detection, the YSO correction setting value of either Y, M, C, or K exceeds the set- 
ting range (NVM value to 474). 

NOTE: Status Code not displayed on ill. Machine operation continues. 

Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-131 



Status Indicator RAPs 

8-622, 8-623 



8-624 Regicon Data Overflow (Patch Magnification) 

MAG Adjusted Set Point of operation results for each of Y,M,C exceeded the set range (NVM 
value: 0-1432). 

NOTE: Status Code not displayed on ill. Machine operation continues. 

Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Go to ADJ 9.6 Color Registration dC685. 



8-625 Regicon Sample Block (A1 Patch-rear) 

At A1 (IN) patch detection, the number of the sample blocks does not reach the specified num- 
ber. 

NOTE: Status Code not displayed on ill. Machine operation continues. 

Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



Status Indicator RAPs 

8-624, 8-625 



6/02 
2-132 



Prelaunch Training/Review 
DC1 632/2240 



8-626 Regicon Sample Block (A1 Patch-front) 

At A1 (OUT) patch detection, the number of the sample blocks does not reach the specified 
number. 

NOTE: Status Code not displayed on ill. Machine operation continues. 

Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



8-627 Regicon Sample Lateral (A1 Patch-rear) 

At A1 (IN) patch detection, the Fast Scan scan position of CYAN color that is the standard for 
the rest is incorrect. (Against the MOB SENSOR, the center position of the CYAN pattern is 
shifted by ±500|im or more.) 

NOTE: Status Code not displayed on ill. Machine operation continues. 

Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-133 



Status Indicator RAPs 

8-626, 8-627 



8-628 Regicon Sample Lateral (A1 Patch-front) 

At A1 (OUT) patch detection, the scan position of CYAN color that is the standard for the rest is 
incorrect. (Against the MOB SENSOR, the center position of the CYAN pattern is shifted by 
±500|im or more.? 

NOTE: Status Code not displayed on ill. Machine operation continues. 

Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



8-629 Regicon Skew (Patch Y) 

During A1 Patch detection, skew deviation for Y exceeded tolerance. 

NOTE: Machine operation continues. Status Code not displayed on ill. Status Code logged in 
History. 

Initial Actions 

Clean MOB Sensor. 

Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



Status Indicator RAPs 

8-628, 8-629 



6/02 
2-134 



Prelaunch Training/Review 
DC1 632/2240 



8-630 Regicon Skew (Patch M) 

During A1 Patch detection, skew deviation for M exceeded tolerance. 

NOTE: Machine operation continues. Status Code not displayed on lit. Status Code logged in 
History. 

Initial Actions 

Clean MOB Sensor. 



8-631 Regicon Skew (Patch K) 

During A1 Patch detection, skew deviation for K exceeded tolerance. 

NOTE: Machine operation continues. Status Code not displayed on ill. Status Code logged in 
History. 

Initial Actions 

Clean MOB Sensor. 



Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



Procedure 

Check the IBT Belt and Drum for a scratch or contamination. The check is OK. 
Y N 

Replace as required. 

Perform DC685 Color Registration (ADJ 9.6). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-135 



Status Indicator RAPs 

8-630, 8-631 



8-900 Static Jam 

When the machine power is turned off then on before a paper path fault is cleared, an 8-900 
fault will be displayed. A voltage drop or interruption can also cause this fault. 

Initial Actions 

i Check the entire paper path for paper or obstructions. 

i Clean all the paper path sensors. 

i Check the Fault History for the last paper path fault. Go to that paper path fault RAP. 

Procedure 

In sequence, enter the following dC330 codes: 

Block and unblock each sensor 

i 8-100 Tray 1 Mis-feed, (7-105). 

i 8-106 Tray 2 Mis-feed, (7-110). 

i 8-102 Tray 3 Mis-feed, (7-115). 

i 8-103 Tray 4 Mis-feed, (7-119). 

i 8-104 Registration Sensor, (8-175). 

i 9-201 POB On Jam, (8-164) 

The display for each code changes. 
Y N 

Go to the appropriate paper path fault RAR 

Check the machine input voltage, if the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

8-900 



6/02 
2-136 



Prelaunch Training/Review 
DC1 632/2240 



9-342 2nd BTR Contact 

The 2nd BTR did not reach the contact position. 

Initial Actions 

i Clean the 2nd BTR Retract Sensor and check for damage, 
i Check the 2nd BTR transmission gears for breakage. 

Procedure 

In sequence, enter the following: dC330 [009-051] then dC330 [009-052], The 2nd BTR con- 
tacts and retracts. 
Y N 

Go to OF 99-6 Motor Open RAR 

Go to OF 99-2 Transmissive Sensor RAP. 



MCU PWB 
PL13.1 



DOUBLE 



l/F PWB DC COM p| [)n 

PL9.1 I J533 P612 I " J612 J140 
B18 , , 3-13 



2ND BTR RETRACT 

SENSOR 

PL2.9 



r' 

DC COM 
+5VDC 



YEL 
+5VDC 



VIO 



CDS 



YEL 



DC330 [009-200] 
2ND BTR 

RETRACT SENSOR 
SENSED (L) 
+3.3VDC 



T709005A-CAR 




DC330 [009-051] (CONTACT) nnilRI F 

DC330 [009-052] (RETRACT) □, i ,A 

2ND BTR RETRACT MOTOR l K L U ^ l 

J533 ON +24VDC CLOCK P612 ' ' 



Figure 1 2ND BTR Retract Sensor 



r^ 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 



+24VDC INTLK 



+24VDC INTLK 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 



J216 


2ND BTR 
RETRACT 
MOTOR 
PL2.9 




\ 




1 




(mot) 




T 




j 







T709004A-CAR 



Figure 2 2ND BTR Retract Motor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-137 



Status Indicator RAPs 

9-342 



9-343 2nd BTR Retract 

The 2nd BTR did not reach the retract position. 

Initial Actions 

i Clean the 2nd BTR Retract Sensor and check for damage, 
i Check the 2nd BTR transmission gears for breakage. 

Procedure 

In sequence, enter the following: dC330 [009-051] then dC330 [009-052]. The 2BTR contacts 
and retracts. 
Y N 

Go to OF 99-6 Motor Open RAR 

Go to OF 99-2 Transmissive Sensor RAP. 



MCU PWB 
PL13.1 



DOUBLE 



l/F PWB DC COM p| [)n 

PL9.1 I J533 P612 I " J612 J140 
B18 , , 3-13 



2ND BTR RETRACT 

SENSOR 

PL2.9 



r' 

DC COM 
+5VDC 



YEL 
+5VDC 



VIO 



CDS 



YEL 



DC330 [009-200] 
2ND BTR 

RETRACT SENSOR 
SENSED (L) 
+3.3VDC 



T709005A-CAR 




DC330 [009-051] (CONTACT) nnilRI F 

DC330 [009-052] (RETRACT) □, i ,A 

2ND BTR RETRACT MOTOR l K L U ^ l 

J533 ON +24VDC CLOCK P612 ' ' 



Figure 1 2ND BTR Retract Sensor 



r^ 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 



+24VDC INTLK 



+24VDC INTLK 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 



J216 


2ND BTR 
RETRACT 
MOTOR 
PL2.9 




\ 




1 




(mot) 




I 




j 







T709004A-CAR 



Figure 2 2ND BTR Retract Motor 



Status Indicator RAPs 

9-343 



6/02 
2-138 



Prelaunch Training/Review 
DC1 632/2240 



9-348 1st BTR Contact 

The 1st BTR did not reach the contact position. 

Initial Actions 

i Clean the 1st BTR Retract Sensor and check for damage 
i Check the 1st BTR transmission gears for breakage 



Procedure 

In sequence, enter the following: dC330 [009-054] then dC330 [009-055]. The 1st BTR con- 
tacts and retracts. 
Y N 

Go to OF 99-6 Motor Open RAR 

Go to OF 99-2 Transmissive Sensor RAR 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



?P/J410 
74- 



P/J410 
— 71 — 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



DOUBLE DOUBLE 

PLUG PLUG 

P639 | | J639 P605 I I J605 

B6 — A6 



1ST BTR RETRACT 

SENSOR 

PL5.4 



DC330 [004-014] BLU 
1ST BTR RETRACT SENSOR 
POWER ON(H)+5VDC 



DC330[009-203] 
1ST BTR RETRACT 
SENSOR 
CONTACTfH1+3.3VDC 




» )--t * 



GRY L 



BLU 



u 



u 



T709007A-CAR 



Figure 1 1ST BTR Retract Sensor 




DC330 [009-054] CONTACT 
DC330 [009-055] RETRACT 
1ST BTR MOTOR 
J533 ON +24VDC CLOCK 



DOUBLE 
PLUG 



DOUBLE 
PLUG 



DOUBLE 
PLUG 



J639 P605 



J605 J237 



BLU DC330 [009-054] CONTACT 
DC330 [009-055] RETRACT 
1ST BTR MOTOR 
ON +24VDC CLOCK 



BLU DC330 [009-054] CONTACT 
DC330 [009-055] RETRACT 
1ST BTR MOTOR 
ON +24VDC CLOCK 



BLU DC330 [009-054] CONTACT 
DC330 [009-055] RETRACT 
1ST BTR MOTOR 
ON +24VDC CLOCK 



BLU 



+24VDC INTLK 



P237 


1ST BTR 
RETRACT 
MOTOR 
PL5.4 


BLU 


\ 


BLU 




BLU 




BLU 


/ 


BLU 





T709006A-CAR 



Figure 2 1ST BTR Retract Motor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-139 



Status Indicator RAPs 

9-348 



9-349 1st BTR Retract 

The 1st BTR did not reach the retract position. 

Initial Actions 

i Clean the 1 st BTR Retract Sensor and check for damage 
i Check the 1st BTR transmission gears for breakage 



Procedure 

In sequence, enter the following: dC330 [009-054] then dC330 [009-055]. The 1st BTR con- 
tacts and retracts. 
Y N 

Go to OF 99-6 Motor Open RAR 

Go to OF 99-2 Transmissive Sensor RAP. 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



?P/J410 
74- 



P/J410 
— 71 — 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



DOUBLE DOUBLE 

PLUG PLUG 

P639 | | J639 P605 I I J605 

B6 — A6 



1ST BTR RETRACT 

SENSOR 

PL5.4 



DC330 [004-014] BLU 
1ST BTR RETRACT SENSOR 
POWER ON(H)+5VDC 



DC330[009-203] 
1ST BTR RETRACT 
SENSOR 
CONTACTfH1+3.3VDC 




'i)--n--t 



GRY L 



BLU 



u 



u 



T709007A-CAR 



Figure 1 1ST BTR Retract Sensor 




DC330 [009-054] CONTACT 
DC330 [009-055] RETRACT 
1ST BTR MOTOR 
J533 ON +24VDC CLOCK 



DOUBLE 
PLUG 



DOUBLE 
PLUG 



DOUBLE 
PLUG 



J639 P605 



BLU DC330 [009-054] CONTACT 
DC330 [009-055] RETRACT 
1ST BTR MOTOR 
ON +24VDC CLOCK 



BLU DC330 [009-054] CONTACT 
DC330 [009-055] RETRACT 
1ST BTR MOTOR 
ON +24VDC CLOCK 



BLU DC330 [009-054] CONTACT 
DC330 [009-055] RETRACT 
1ST BTR MOTOR 
ON +24VDC CLOCK 



BLU 



+24VDC INTLK 



P237 


1ST BTR 
RETRACT 
MOTOR 
PL5.4 


BLU 


\ 


BLU 




BLU 




BLU 


/ 


BLU 





T709006A-CAR 



Figure 2 1ST BTR Retract Motor 



Status Indicator RAPs 

9-349 



6/02 
2-140 



Prelaunch Training/Review 
DC1 632/2240 



9-350 IBT Home Sensor 

The IBT Home Sensor detected the IBT position strip before the IBT Belt made a complete rev- 
olution. 

Initial Actions 

i Clean the IBT Home Sensor and check for damage 
i Check the IBT drives for damage. 

Procedure 

Enter dC330 [004-002]. The IBT Motor energizes. 
Y N 

Go to OF 99-6 Motor Open RAP. 
A 



Enter dC330 [004-414] then enter dC330 [004-002]. The display changes state. 

Y N 

Go to OF 99-2 Transmissive Sensor RAP. 

Enter dc330 [004-100] then enter dC330 [004-002]. The display changes state. 

Y N 

Check the wires and connectors. If the check is OK, replace the IBT Home Sensor (PL 
5.4). 

Replace the l/F PWB (PL 9.1). If the problem continues, replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



l/F PWB 

PL9 1 ' J533 DC COM 

■A12, 



P/J410 
74 - 



P/J410 
- 72 - 



DC COM 



BLU \ 
DC330[004-014] 
IBT SENSOR POWER 
ON (H) +5VDC 



n 



DRAWER 
CONNECTOR 



DNNECTC 



IBT HOME SENSOR 
J605 J121 IPL5.4 



BLU 



DC330 [004-100] 
IBT HOME SENSOR 
SENSED (H) +5VDC 



3^>(gr 



** 



T709008A-CAR 



Figure 1 IBT Home Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-141 



Status Indicator RAPs 

9-350 



9-351 Drive Logic 

The IBT Edge Sensor detected that the IBT Belt is not tracking correctly. 

Initial Actions 

i Check the IBT Edge Sensor for damage. Ensure that the actuator is touching the edge of 

the belt, 
i Check the IBT steering drives for damage. 

Procedure 

Switch on the power. There is +1VDC to +3VDC from P/J 533-A11 to GND. 
Y N 

There is +5VDC measured between P/J533-A10 and P/J533-A9 on the l/F PWB. 

Y N 

Replace the MCU PWB (PL 13.1). 



There is +5VDC from P/J 533-A11 on the l/F PWB to GND. 
Y N 

Check the connectors and wires. If the check is OK, replace the IBT Edge Sensor 
(PL 5.4). If the problem continues, replace the MCU PWB (PL 13.1). 



Replace the IBT Sensor (PL 5.4). 

Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9.1). If the prob- 
lem continues, replace the MCU PWB (PL 13.1). 



MCU 
PL13 



PWB 
1 



l/F PWB 
PL9.1 
P/J410 



90,— 



DC COM 



S- 



DC330 [004-001] 
DC330 [004-005] 
IBT STEERING MOTOR 
ON +24VDC CLOCK 



DOUBLE 



+24VDC 
INTLK 



BLU 

DC330 [004-001] 
DC330 [004-005] 
IBT STEERING MOTOR 
ON +74VDC CLOCK 



P207 

5 — 1 



BLU 
DC330 [004-001] 
DC330 [004-005] 
IBT STEERING MOTOR 
ON +24VDC CLOCK 



BLU 
DC330 [004-001] 
DC330 [004-005] 
IBT STEERING MOTOR 
ON +24VDC CLOCK 



BLU 



+24VDC INTLK 



Figure 1 IBT Steering Motor 



J207 


IBT 

STEERING 
MOTOR 
PL1.3 




\ 












/ 







T709010A-CAR 



MCU PWB 
PL13.1 



-*- 



l/F PWB 
PL9.1 



P/J410 
74 - 



JVUV 

1 



P/J410 
— 15 — 



DC COM 



IT 

DC COM 



CONNEC 



DC330[004-014] 

IBT SENSOR POWER.. 

ON (H) +5VDC h 



r^ 



J639 P605! 



OR 
J605 



DC1 40 [004-100] 
IBT EDGE SENSOR 
SENSED SIGNAL 



GRY 



IBT EDGE SENSOR 
PL5.4 



VIO 

DC330[004-014] 

IBT SENSOR POWER 

ON (H) +5VDC 



® 



-n 



GRY 



- A4 — B4 - 



Figure 2 IBT Edge Sensor 




T709009A-CAR 



Status Indicator RAPs 

9-351 



6/02 
2-142 



Prelaunch Training/Review 
DC1 632/2240 



9-358 Full Toner Sensor 

The Full Toner Sensor detects a full toner condition. 



9-360 Yellow Drum Cartridge Communication 

A communication failure with the Yellow Drum Cartridge was detected. 



Initial Actions 

i Ensure that the Waste Toner Cartridge is not full. 

i Check the sensor for toner contamination and foreign substances. 

Procedure 

Remove the Full Toner Sensor from the bottle. Enter dC330 [009-150]. Block and unblock the 
Full Toner Sensor (PL 4.1). The display changes state. 
Y N 

Go to OF 99-2 Transmissive Sensor RAP. 

Replace the MCU PWB. (PL 13.1) 



MCU PWB 
PL13.1 

DC COM 

-r B 

+5VDC 
+3.3VDC 



J407 DC COM J614 



DOUBLE 



P614 J133 



FULL TONER 

SENSOR 

PL4.1 



YEL 
+5VDC 



YEL 



DC330 [009-150] 
FULL TONER SENSOR 
SENSED (H) +3.3VDC 



®- 



t t 



T709010A-CAR 



Figure 1 The Full Toner Sensor 



Initial Actions 

Check that the Yellow Drum Cartridge is seated correctly. 

Procedure 

Enter dC330 [009-151 Drum (Y) Data]. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the Yellow Drum Cartridge 
(refer to Section 6, Machine Consumables). 

Replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



+3.3VDI 



DC330 [009-035] 
DRUM (Y) POWER 
ON (H) +3.3VDC 



DOUBLE 



-^ 



JT 

DC COM 



JT 



YEL 






DRUM (Y) 
+3.3VDC CLOCK 


YEL 






DC330 [009-151] 
DRUM (Y) DATA 


YEL 




DC COM 


YEL 






DC330 [009-035] 
DRUM (M) POWER 
ON (H) +3.3VDC 


YEL 






DRUM (M) 
+3.3VDC CLOCK 


YEL 






DC330 [009-152] 

DRUM (M) DATA 


YEL 


DC COM 



3—7 
I I 

4—6 



5 - 


- 5 


YEL 












YEL 


7 - 
I 


- 3 

I 




YEL 


8 - 


- 2 




VIO 



w 



DRUM (Y) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




I 







DRUM (M) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




I 







T709012A-CAR 



Figure 1 Drum Y Communication 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-143 



Status Indicator RAPs 

9-358, 9-360 



9-361 Magenta Drum Cartridge Communication 

A communication failure with Magenta Drum Cartridge was detected. 



9-362 Cyan Drum Cartridge Communication 

A communication failure with the Cyan Drum Cartridge was detected. 



Initial Actions 

Check that the Magenta Drum Cartridge is seated correctly. 



Initial Actions 

Check that the Cyan Drum Cartridge is seated correctly. 



Procedure 

Enter dC330 [009-1 52, Drum (M) Data]. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the Magenta Drum Cartridge 
(refer to Section 6, Machine Consumables). 

Replace the MCU PWB. (PL 13.1). 



Procedure 

Enter dC330 [009-154, Drum (C) Data]. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the Cyan Drum Cartridge 
(refer to Section 6, Machine Consumables). 

Replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



+3.3VDI 



-^ 



DC330 [009-035] 
DRUM (Y) POWER 
ON (H) +3.3VDC 



DOUBLE 



DC COM 



JT 



YEL 






DRUM (Y) 
+3.3VDC CLOCK 


YEL 






DC330 [009-151] 
DRUM (Y) DATA 


YEL 




DC COM 


YEL 






DC330 [009-035] 
DRUM (M) POWER 
ON (H) +3.3VDC 


YEL 






DRUM (M) 
+3.3VDC CLOCK 


YEL 






DC330 [009-152] 

DRUM (M) DATA 


YEL 


DC COM 



3—7 
I I 

4—6 



5 - 


- 5 


YEL 












YEL 


7 - 
I 


- 3 

I 




YEL 


8 - 


- 2 




VIO 



yIT 



DRUM (Y) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




| 







DRUM (M) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




| 







MCU PWB 
PL13.1 



DC330 [009-035] m , , R , F 

DRUM (K) POWER □, , ,~ 

ON (H) +3.3VDC 1 1| 



P624 



DC COM 



DC COM 



BLU 



DRUM (K) 
+3.3VDC CLOCK 



DC330 [009-154] 
DRUM (K) DATA 



BLU 
DC COM 



DC330 [009-035] 
DRUM (C) POWER 
ON (H) +3.3VDC 



DRUM (C) 
+3.3VDC CIOCK 



DC330 [009-153] 

DRUM (C) DATA 



BLU 
DC COM 



J624 J151 



3 — 7 
I I 

4 — 6 



DRUM (K) 
PL4.1 


4 

3 

2 

I 

1 


CRUM 


I 





DRUM (C) 
PL4.1 



T709012A-CAR 



T709013A-CAR 



Figure 1 Drum M Communication 



Figure 1 Drum C Communication 



Status Indicator RAPs 

9-361,9-362 



6/02 
2-144 



Prelaunch Training/Review 
DC1 632/2240 



9-363 Black Drum Cartridge Communication 

A communication failure with the Black Drum Cartridge was detected. 



9-380 ATC Sensor (Y) 

The ATC Sensor (Y) detects a low TC (toner concentration). 



Initial Actions 

Check that the Black Drum Cartridge is seated correctly. 

Procedure 

Enter dC330 [009-154, Drum (K) Data]. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the Black Drum Cartridge 
(refer to Section 6, Machine Consumables). 

Replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



DC330 [009-035] m , , R , F 

DRUM (K) POWER □, , ,~ 

ON (H) +3.3VDC 1 1| 



P624 



DC COM 



DC COM 



BLU 



DRUM (K) 
+3.3VDC CLOCK 



DC330 [009-154] 
DRUM (K) DATA 



BLU 
DC COM 



DC330 [009-035] 
DRUM (C) POWER 
ON (H) +3.3VDC 



DRUM (C) 
+3.3VDC CIOCK 



DC330 [009-153] 

DRUM (C) DATA 



BLU 
DC COM 



J624 J151 



DRUM (K) 
PL4.1 



3 — 7 
I I 

4 — 6 



Figure 1 Drum K Communication 



DRUM (C) 
PL4.1 



T709013A-CAR 



Initial Actions 

i Check that Toner/Developer is present. 

i Check the ATC Sensor (Y) for contamination. Ensure that the sensor is seated correctly. 

Procedure 

NOTE: To clear this fault, enter dC1 31 and set the value of NVM location 752-110 to 0. 

Record the value in NVM location 752-324, then set the value to 1 . Perform ADJ 9.3. After the 
measurement has completed, restore the value. The ATC Sensor (Y) fail judgement is OK. 
Y N 

Check the connector P/J 129. If the check is OK, replace the ATC Sensor (Y) (PL 6.2). 

If the problem continues, replace the MCU PWB (PL 13.1). 



After checking that no failures are detected during normal operation, go to call close out. 

DOUBLE 
J405 DC COM P129 



MCU PWB 
PL13.1 



DC COM 



B12 



B14 



YEL 



DC330[009-080] 

ATC SENSOR POWER 

ON (HH5VDC 



DC1 40 [009-100] 
ATC SENSOR (Y) 
SENSED SIGNAL 



n 

3 1 



J129 



Figure 1 ATC Sensor CD 



ATC SENSOR (Y) 
PL6.2 



T709014A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-145 



Status Indicator RAPs 

9-363, 9-380 



9-381 ATC Sensor (M) 

The ATC Sensor (M) detects a low TC (toner concentration) 



9-382 ATC Sensor (C) 

The ATC Sensor (C) detects a low TC (toner concentration) 



Initial Actions 

i Check that Toner/Developer is present. 

T Check the ATC Sensor (M) for contamination. Ensure that the sensor is seated correctly. 

Procedure 



Initial Actions 

i Check that Toner/Developer is present. 

i Check the ATC Sensor (C) for contamination. Ensure that the sensor is seated correctly. 

Procedure 



NOTE: To clear this fault, enter dC 131 and set the value of NVM location 752-110 to 0. 

Record the value in NVM location 752-324, then set the value to 1 . Perform ADJ 9.3. After the 
measurement has completed, restore the value. The ATC Sensor (M) fail judgement is OK. 
Y N 

Check the connector P/J130. If the check is OK, replace the ATC Sensor (M) (PL 6.2). If 

the problem continues, replace the MCU PWB (PL 13.1). 

After checking that no failures are detected during normal operation, go to call close out. 



NOTE: To clear this fault, enter dC131 and set the value of NVM location 752-110 to 0. 

Record the value in NVM location 752-324, then set the value to 1 . Perform ADJ 9.3. After the 
measurement has completed, restore the value. The ATC Sensor (C) fail judgement is OK. 
Y N 

Check the connector P/J131. If the check is OK, replace the ATC Sensor (C) (PL 6.2). If 

the problem continues, replace the MCU PWB (PL 13.1). 

After checking that no failures are detected during normal operation, go to call close out. 



MCU PWB 
PL13.1 



J405 DC COM 



DC COM 



I.I405 
-B10 



■ H 



DC330[009-080] 

ATC SENSOR POWER 

ON (H)+5VDC 



DC140 [009-101] 
ATC SENSOR (M) 
SENSED SIGNAL 





ATC SENSOR (M) 
PL6.2 




J130 




// 






| 






: 










i 








; 







T709015A-CAR 




J405 



BLU 



DC COM 



PI UG 
P131 | | J13 



BLU DC330[009-080] 

ATC SENSOR POWER! 
ON (HJ+5VDC 



DC1 40 [009-102] 
ATC SENSOR (C) 
SENSED SIGNAL 



u 



ATC SENSOR (C) 
PL6.2 



BLU 
T709016A-CAR 



Figure 1 ATC Sensor M 



Figure 1 ATC Sensor C 



Status Indicator RAPs 

9-381,9-382 



6/02 
2-146 



Prelaunch Training/Review 
DC1 632/2240 



9-383 ATC Sensor (K) 

The ATC Sensor (K) detects an insufficient amount of developer material 

Initial Actions 

i Check that Toner/Developer is present. 

i Check the ATC Sensor (K) for contamination. Ensure that the sensor is seated correctly. 

Procedure 

NOTE: To clear this fault, enter dC131 and set the value of NVM location 752-110 to 0. 

Record the value in NVM location 752-324, then set the value to 1 . Perform ADJ 9.3. After the 
measurement has completed, restore the value. The ATC Sensor (K) Fail judgement is OK. 
Y N 

Check the connector P/J132 If the check is OK, replace the ATC Sensor (K) (PL 6.2). If 

the problem continues, replace the MCU PWB (PL 13.1). 

After checking that no failures are detected during normal operation, go to call close out. 



MCU PWB 
PL13.1 



J405 DC COM 



^WUDLC 

PI UG 

| J13 



DC COM 



DC330[009-080] 

ATC SENSOR POWER 

ON (HJ+5VDC 



DC140 [009-103] 
ATC SENSOR (K) 
SENSED SIGNAL 



ATC 

SENSOR (K) 
PL6.2 



BLU 
T709017A-CAR 



9-390 New Toner Cartridge (K) 

The New Cartridge Detect Switch (K) was not engaged to reset the Accumulative Dispense 
time NVM value to when a new cartridge was installed. 

Initial Actions 

i Re-install the Toner Cartridge ensuring that the Dispense Motor and the Toner Cartridge 

is engaged, 
i Check that the New/Old Detection Switch (metal part) at the rear of the Toner Cartridge is 

raised. If the New/Old Detection Switch is not raised, lift it up, then set NVM location 752- 

686 (Accumulative Dispense Time Value K) to 0. 
i Check that the Dispense Motor is operating; check dC330 [009-004, Dispense Motor (K)]. 

Procedure 

Disconnect P/J405 from the MCU PWB. The fault has cleared. 

Y N 

Replace the MCU PWB. (PL 13.1) 

Remove the Toner Cartridge K and check the Dispense Motor Assembly for ware or damage. 
Disconnect FS186/187 at both edges of the New Cartridge Detect Switch (K). 
Check continuity at both edges of the New Cartridge Detect Switch (K). There is continuity 
when the Switch is not engaged. 

Y N 
Check the wire between the connector J405-A1 8 and the New Cartridge Detect Switch (K) 
FS187 for a short circuit to the frame. 

Replace the New Cartridge Detect Switch (K). (PL 16.1) 



Figure 1 ATC Sensor K 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-147 



Status Indicator RAPs 

9-383, 9-390 



9-391 New Toner Cartridge (C) 

The New Cartridge Detect Switch (C) was not engaged to reset the Accumulative Dispense 
time NVM value to when a new cartridge was installed. 



9-392 New Toner Cartridge (M) 

When a new Toner Cartridge was installed, the level of the New Cartridge Detect Switch (M) 
remained L when it should be changed to H by the Dispenser Motor drive. 



Initial Actions 

i Re-install the Toner Cartridge ensuring that the Dispense Motor and the Toner Cartridge 

is engaged, 
i Check that the New/Old Detection Switch (metal part) at the rear of the Toner Cartridge is 

raised. If the New/Old Detection Switch is not raised, lift it up, then set the value of NVM 

location 752-685 (Accumulative Dispense Time Value C) to 0. 
i Check that the Dispense Motor is operating; check dC330 [009-003, Dispense Motor (C)]. 

Procedure 

Disconnect P/J504 from the MCU PWB. The fault has cleared. 

Y N 

Replace the MCU PWB. (PL 13.1) 

Remove the Toner Cartridge C and check the Dispense Motor Assembly for ware or damage. 
Disconnect FS185/185 at both edges of the New Cartridge Detect Switch (C). 
Check continuity at both edges of the New Cartridge Detect Switch (C). There is continuity 
when the Switch is not engaged. 

Y N 
Check the wire between the connector J405-A17 and the New Cartridge Detect Switch 
(C) FS185 for a short circuit to the frame. 

Replace the New Cartridge Detect Switch (C) (PL 6.1). 



Initial Actions 

i Re-install the Toner Cartridge ensuring that the Dispense Motor and the Toner Cartridge 

is engaged, 
i Check that the New/Old Detection Switch (metal part) at the rear of the Toner Cartridge is 

raised. If the New/Old Detection Switch is not raised, lift it up, then set the value of NVM 

location 752-684 (Accumulative Dispense Time Value M) to 0. 
i Check that the Dispense Motor is operating; check dC330 [009-002, Dispense Motor (M)]. 

Procedure 

Disconnect P/J405 from the MCU PWB. The fault has cleared. 

Y N 

Replace the MCU PWB. (PL 13.1) 

Remove the Toner Cartridge M and check the Dispense Motor Assembly for ware or damage. 
Disconnect FS182/183 at both edges of the New Cartridge Detect Switch (M). 
Check continuity at both edges of the New Cartridge Detect Switch (M). There is continuity 
when the Switch is not engaged. 

Y N 
Check the wire between the connector J405-B16 and the New Cartridge Detect Switch 
(M) FS183 for a short circuit to the frame. 

Replace the New Cartridge Detect Switch (M) (PL 6.1). 




o — o o — o — 



DC330 [009-103] 

NEW CARTRIDGE DETECT 

SWITCH (C) 

NEW DETECT(L)+3.3VDC 



T709019A-CAR 



Figure 1 New Cartridge Detect Switch (C) 



MCU PWB 
PL13.1 



DOUBLE 
PLUG 



JT 

DC COM 



J405 P163 
B15 — , 4 



NEW 

CARTRIDGE 
DETECT 
SWITCH (M) 
PL6.1 




DC330 [009-102] 

NEW CARTRIDGE DETECT 

SWITCH (M) 

NEW DETECT(L)+3.3VDC 



YEL 



T709020A-CAR 



Figure 1 New Cartridge Detect Switch (M) 



Status Indicator RAPs 

9-391,9-392 



6/02 
2-148 



Prelaunch Training/Review 
DC1 632/2240 



9-393 New Toner Cartridge (Y) 

When a new Toner Cartridge was installed, the level of the New Cartridge Detect Switch (Y) 
remained L when it should be changed to H by the Dispense Motor drive. 

Initial Actions 

i Re-install the Toner Cartridge ensuring that the Dispense Motor and the Toner Cartridge 

is engaged, 
i Check that the New/Old Detection Switch (metal part) at the rear of the Toner Cartridge is 

raised. If the New/Old Detection Switch is not raised, lift it up, then set the value of NVM 

location 752-683 (Accumulative Dispense Time Value Y) to 0. 
i Check that the Dispense Motor is operating; check dC330 [009-001 , Dispense Motor (C)]. 

Procedure 

Disconnect P/J405 from the MCU PWB. The fault has cleared. 

Y N 

Replace the MCU PWB. (PL 13.1) 

Remove the Toner Cartridge Y and check the Dispense Motor Assembly for ware or damage. 
Disconnect FS180/181 at both edges of the New Cartridge Detect Switch (Y). 
Check continuity at both edges of the New Cartridge Detect Switch (Y). There is continuity 
when the Switch is not engaged. 

Y N 
Check the wire between the connector J405-B18 and the New Cartridge Detect Switch 
(Y) FS181 for a short circuit to the frame. 

Replace the New Cartridge Detect Switch (Y) (PL 6.1). 



MCU PWB 
PL13.1 



DOUBLE 
PLUG 



^fYEL 



J405 P163 



NEW 

CARTRIDGE 
DETECT 
SWITCH (Y) 
PL6.1 



O— o o ft 



DC330 [009-101] 

NEW CARTRIDGE DETECT 

SWITCH (Y) 

NEW DETECT(L)+3.3VDC 



YEL 



T709021A-CAR 



Figure 1 New Cartridge Detect Switch (Y) 



9-408 Waste Toner Cartridge Near Full 

The Waste Toner Cartridge is nearly full. 

Initial Actions 

Replace the Waste Toner Cartridge. Check the Full Toner Sensor for contaminants. 

Procedure 

Enter dC330 [009-150. Actuate and de-actuate the Full Toner Sensor (PL 4.1). The display 
changes state. 
Y N 

Go to OF 99-2 Transmissive Sensor RAP. 

Replace the MCU PWB. (PL 13.1) 



MCU PWB 
PL13.1 



J407 DC COM J614 



DC COM 
+5VDC 



YEL 



DC330 [009-150] 
FULL TONER SENSOR 
SENSED (H) +3.3VDC 



DOUBLE 



1 _ 3 



P614 J133 



FULL TONER 

SENSOR 

PL4.1 



@f>(2i. 



YEL 



T709022A-CAR 



Figure 1 Full Toner Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-149 



Status Indicator RAPs 

9-393, 9-408 



9-410 Toner Cartridge (Y) Near Empty 

The Yellow Toner Cartridge is nearly empty/empty. 

NOTE: Continuous running of high density prints can temporarily deplete the toner supply. 

Initial Actions 

i Ensure that there is toner and the toner is evenly distributed in the cartridge (Y). 
i Check the ATC Sensor (Y) for blockage or contaminants. 

T Check the drive system from the Developer Drive Motor to the Developer Housing (Y) for 
damage. 

Procedure 

Enter dC330 [009-001]. The Toner Dispense Motor (Y) energizes (PL 6.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [009-014]. The Developer Motor energizes (PL 1.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Check ADJ 9.3. The ATC Sensor (Y) fail judgement is OK. 

Y N 

Go to the 9-380, ATC Sensor Failure RAP. 

After checking that no failures are detected during normal operation, go to call closeout. 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



+24VDC 
INTLK 

r f 

DC COM 



DC COM 



DC330 [009-014] (5s) 
DEVE MOTOR ._,_ 
ON (L) +5VDC • il il 



DC330 [009-014] (5s) 
DEVE MOTOR 
HIGH SPEED (L) +5VDC 



BLU 
+24VDC INTLK 



ORN 

DC COM 



VIO 



DEVE MOTOR 




PL1.1 








SERVO 


1 


CONTROL 




2 




3^) 


5 




y* 


6 

7 






I 





T709027A-CAR 



Figure 2 The Developer Motor 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
17 



+24VDC 
INTLK 



DC330 [009-001] (5s) 
TONER DISPENSE 
MOTOR (Y) 
ON (L) +24VDC 



BLU 
+24VDC INTLK 



BLU 



TONER 
DISPENSE 
MOTOR (Y) 
PL6.1 

IDS) 



T709023A-CAR 



Figure 1 Toner Dispenser Motor Y 



Status Indicator RAPs 

9-410 



6/02 
2-150 



Prelaunch Training/Review 
DC1 632/2240 



9-411 Toner Cartridge (M) Near Empty 

The Yellow Toner Cartridge is nearly empty. 

NOTE: Continuous running of high density prints can temporarily deplete the toner supply. 

Initial Actions 

i Ensure that there is toner and the toner is evenly distributed in the cartridge (M). 
i Check the ATC Sensor (M) for blockage or contaminants. 

T Check the drive system from the Developer Drive Motor to the Developer Housing (M) for 
damage. 

Procedure 

Enter dC330 [009-002]. The Toner Dispense Motor (M) energizes (PL 6.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [009-014]. The Developer Motor energizes (PL 1.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Perform ADJ 9.3. The ATC Sensor (M) fail judgement is OK. 

Y N 

Go the 9-382 ATC Sensor Failure (M) RAP. 

After checking that no failures are detected during normal operation, go to call closeout. 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
48 i — 



DC330 [009-014] (5s) 
J534 DEVE MOTOR 
A6 J3J4 ON (L) +5VDC J ~ oi 



+24VDC 
INTLK 

r f 

DC COM 



xr f 

DC COM 
+5VDC 



BLU 

DC330 [009-014] (5s) 
DEVE MOTOR 
HIGH SPEED (L) +5VDC 



BLU 
+24VDC INTLK 



ORN 

DC COM 



VIO 



DEVE MOTOR 




PL1.1 








SERVO 


1 


CONTROL 




2 




3^) 


5 




y* 


8 

7 






I 





T709027A-CAR 



Figure 2 The Developer Motor 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 h-^ 
77 -\£— 
DC COM 



DC330 [009-002 (5s) 
TONER DISPENSE 
MOTOR (M) 
J533 ON (L) +24VDC 



XT 

+24VDC 
INTLK 



BLU 
+24VDC INTLK 



TONER 
DISPENSE 
MOTOR (M) 
PL6.1 



| jg) 



T709024A-CAR 



Figure 1 Toner Dispense Motor M 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-151 



Status Indicator RAPs 

9-411 



9-412 Toner Cartridge (C) Near Empty 

The Cyan Toner Cartridge is nearly empty/empty. 

NOTE: Continuous running of high density prints can temporarily deplete the toner supply. 

Initial Actions 

i Ensure that there is toner and the toner is evenly distributed in the cartridge (C). 
i Check the ATC Sensor (C) for blockage or contaminants. 

T Check the drive system from the Developer Drive Motor to the Developer Housing (C) for 
damage. 

Procedure 

Enter dC330 [009-003]. The Toner Dispense Motor (C) energizes (PL 6.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [009-014]. The Developer Motor energizes (PL 1.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Perform ADJ 9.3. The ATC Sensor (C) fail judgement is OK. 

Y N 

Go the 9-383, ATC Sensor Failure (C) RAP. 

After checking that no failures are detected during normal operation, go to call closeout. 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
48 i — 



DC330 [009-014] (5s) 
J534 DEVE MOTOR 
A6 J3J4 ON (L) +5VDC J ~ oi 



+24VDC 
INTLK 

r f 

DC COM 



DC COM 
+5VDC 



BLU 

DC330 [009-014] (5s) 
DEVE MOTOR 
HIGH SPEED (L) +5VDC 



BLU 
+24VDC INTLK 



ORN 

DC COM 



VIO 



DEVE MOTOR 




PL1.1 








SERVO 


1 


CONTROL 




2 




3^) 


5 




y* 


8 

7 






I 





T709027A-CAR 



Figure 2 The Developer Motor 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
76 



X" 

+24VDC 
INTLK 



DC330 [009-003 (5s) 
TONER DISPENSE 
MOTOR (C) l99q 

ON (L) +24VDC 



BLU 
+24VDC INTLK 



BLU 



Figure 1 Toner Dispense Motor C 



TONER 
DISPENSE 
MOTOR (C) 
PL6.1 



T709025A-CAR 



Status Indicator RAPs 

9-412 



6/02 
2-152 



Prelaunch Training/Review 
DC1 632/2240 



9-413 Toner Cartridge (K) Near Empty 

The Black Toner Cartridge is nearly empty. 



9-428 Change Drum Cartridge (K) Soon 

The Drum Cartridge (K) needs to be replaced soon/reached end of life. 



NOTE: Continuous running of high density prints can temporally deplete the toner supply. 

Initial Actions 

i Ensure that there is toner and the toner is evenly distributed in the cartridge (K). 
i Check the ATC Sensor (K) for blockage or contaminants. 

i Check the drive system from the Main Drive Motor to the Developer Housing (K) for dam- 
age. 

Procedure 

Enter dC330 [009-004]. The Toner Dispense Motor (K) energizes (PL 6.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330. Stack the codes [004-004, Main Motor] and [009-013, Dev. Clutch (K)]. The 
Black Developer Assy, energizes (PL 1.1). 

Y N 

Go to OF 99-6 Motor Open RAP (refer to BSD 4.1 and BSD 9.13 for circuit). 

Check ADJ 9.3. The ATC Sensor (K) fail judgement is OK. 

Y N 

Go the 9-383, ATC Sensor Failure (K) RAP. 

After checking that no failures are detected during normal operation, go to call closeout. 



Procedure 

Replace the Black Drum Cartridge (refer to Section 6, Machine Consumables). The problem 
is corrected. 
Y N 

Replace the MCU PWB (PL 13.1). 

Return to Service Call Procedures. 



MCU PWB 
PL13.1 



-t 



l/F PWB 
PL9.1 



P/J410 
— 75 



+24VDC 
INTLK 



DC330 [009-004 (5s) 
TONER DISPENSE 
MOTOR (K) J230 

ON (L) +24VDC 



BLU 
+24VDC INTLK 



Figure 1 Toner Dispense Motor K 



TONER 
DISPENSE 
MOTOR (K) 
PL6.1 

l (mot) 



T709026A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-153 



Status Indicator RAPs 

9-413,9-428 



9-429 Change Drum Cartridge (Y) Soon 

The Drum Cartridge (Y) needs to be replaced soon. 

Procedure 

Replace the Yellow Drum Cartridge (refer to Section 6, Machine Consumables). The problem 
is corrected. 
Y N 

Replace the MCU PWB. (PL 13.1). 

Return to Service Call Procedures. 



9-430 Change Drum Cartridge (M) Soon 

The Drum Cartridge (M) needs to be replaced soon. 

Procedure 

Replace the Magenta Drum Cartridge (refer to Section 6, Machine Consumables). The prob- 
lem is corrected. 
Y N 

Replace the MCU PWB. (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

9-429, 9-430 



6/02 
2-154 



Prelaunch Training/Review 
DC1 632/2240 



9-431 Change Drum Cartridge (C) Soon 

The Drum Cartridge (C) needs to be replaced soon. 

Procedure 

Replace the Cyan Drum Cartridge (refer to Section 6, Machine Consumables). The problem 
is corrected. 
Y N 

Replace the MCU PWB. (PL 13.1). 

Return to Service Call Procedures. 



9-654 ADC Sensor 

The machine logic detected an ADC Sensor operation failure. 

Procedure 

Check ADJ 9.4. The fail judgement of the ADC Sensor is OK. 
Y N 

There is +5VDC from P/J 536-A13 on the l/F PWB to GND. 

Y N 
Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9.1). If 
the problem continues replace the MCU PWB (PL 13.1). 

Enter dC330 [009-078. The ADC Shutter Solenoid energized (PL 1.3). 

Y N 

Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9.1). If 
the problem continues replace the MCU PWB (PL 13.1). 

Enter dC330 [009-078. There is 0VDC from P/J 536-A8 on the l/F PWB to GND. 

Y N 
Check the wires and connectors. If the check is OK, replace the l/F PWB PL 9.1. If 
the problem continues replace the MCU PWB (PL 13.1). 

Enter dC330 [009-079. The voltage from P/J 536-A6 to GND changed to 0VDC momen- 
tarily. 

Y N 
Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9.1). If 
the problem continues replace the MCU PWB (PL 13.1). 

Check the wires and connectors. If the check is OK, replace the, replace the ADC Sensor 
Assembly (PL 1.3). 

After checking that no failures are detected during normal operation, go to call closeout. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-155 



Status Indicator RAPs 

9-431,9-654 




DC330 [009-076] 
ADC SENSOR LED 2 
J536 ON (L) +5VDC 



DOUBLE 
PLUG 



BLU 

DC330 [009-077] 
ADC SENSOR LED 1 
ON (L) +5VDC 



P602 ' ' J602 J144 

4 — 5 



BLU 
+5VDC 



BLU 
DC COM 



BLU 
DC330 [009-078] (100ms) 
ADC SENSOR SOLENOID 
NIP (L) +24VDC 



BLU 
+24VDC 



BLU 
DC330 [009-079] (100ms) 
ADC SENSOR SOLENOID 
RELEASE (L) +24VDC 



BLU 



ADC SENSOR 
PL1.3 



LED 2 



LED1 



DOUBLE DC1 40 [009-250] 

PLUG ADC SENSOR 

SENSED SIGNAL 



J144 J602 ' ' P602 
7 — 2 



1 I 

if 




T709028A-CAR 



Figure 1 The ADC Sensor 



Status Indicator RAPs 

9-654 



6/02 
2-156 



Prelaunch Training/Review 
DC1 632/2240 



9-660 Environment Sensor Temperature 

An incorrect value was detected by the Environment Sensor (Temperature). 

Procedure 

There is 1 Ohm or less measured between the Environment Sensor P255-3 and P255-4 



Y N 

Replace the Environment Sensor (PL 1 .3). 

Replace the l/F PWB (PL 9.1) and MCU PWB (PL 13.1) in sequence. 



DOUBLE 
PLUG 



l/F PWB | 

PL9.1 B4 

I 
+5VDC 



+5VDC P619 



r 

DC COM 



B2 



YEL 
DC COM 



ENVIRONMENT 

SENSOR 

PL1.3 






ENVIRONMENT 




1 - 


I TEMP. I 


- 4 








3 - 


I HUMIDITY I 


- 2 















DOUBLE 
PLUG 



J255 J619 



DC140 [009-256] 
ENVIRONMENT 
SENSOR 
P619 TEMP. SIGNAL 



DC1 40 [009-257] YtL 

ENVIRONMENT 

SENSOR HUMIDITY SIGNAL 



l/F 

PWB 

PL9.1 


MCU 
PWB 
PL13.1 


P/J41 U 
B1 r 51r 

I i I i 
B3 '- 53 '— 


/// 


I 







T709029A-CAR 



Figure 1 The Environment Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-157 



Status Indicator RAPs 

9-660 



9-661 Environment Sensor Humidity 

An incorrect value was detected by the Environment Sensor (Humidity). 

Procedure 

There is +0.4VDC to +17VDC from P/J 536-B3 on the l/F PWB to GND. 
Y N 

There is +5VDC from P/J 536-B4 on the l/F PWB to GND. 



Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 

Check for an open circuit and poor contact if the check is OK replace the Environment 
Sensor (PL1. 3). 



Replace the l/F PWB (PL 9.1). If the problem continues, replace the MCU PWB (PL 13.1). 



I/F PWB | 

PL9.1 B4 

I 

+5VDC | 
DC COM 



DOUBLE 
PLUG 



J536 +5VDC P619 ' ' J619 J255 

1 — 4 



YEL 
DC COM 



ENVIRONMENT 

SENSOR 

PL1.3 






ENVIRONMENT 




1 - 


I TEMP. I 


- 4 








3 - 


I HUMIDITY I 


- 2 















DOUBLE DC1 40 [009-256] 

PLUG ENVIRONMENT 

I 1 SENSOR 

J255 J619 ' ' P619 TEMP. SIGNAL 

1 — 4 



YEL 



DC1 40 [009-257] YtL 

ENVIRONMENT 

SENSOR HUMIDITY SIGNAL 




T709029A-CAR 



Figure 1 The Environment Sensor 



Status Indicator RAPs 

9-661 



6/02 
2-158 



Prelaunch Training/Review 
DC1 632/2240 



9-670 New Toner Cartridge (K) Detected 

The machine logic detected that the Toner Cartridge has been replaced. This is a message 
fault only. 



9-671 New Toner Cartridge (C) Detected 

The machine logic detected that the Toner Cartridge has been replaced. This is a message 
fault only. 



Procedure 

Switch the power off, then on. The message fault clears. 
Y N 

Go to the 9-390 RAP. 

Return to Service Call Procedures. 



Procedure 

Switch the power off, then on. The message fault clears. 
Y N 

Go to the 9-391 RAP. 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-159 



Status Indicator RAPs 

9-670, 9-671 



9-672 New Toner Cartridge (M) Detected 

The machine logic detected that the Toner Cartridge has been replaced. This is a message 
fault only. 



9-673 New Toner Cartridge (Y) Detected 

The machine logic detected that the Toner Cartridge has been replaced. This is a message fault 
only. 



Procedure 

Switch the power off, then on. The message fault clears. 
Y N 

Go to the 9-392 RAP. 

Return to Service Call Procedures. 



Procedure 

Switch the power off, then on. The message fault clears. 
Y N 

Go to the 9-393 RAP. 

Return to Service Call Procedures. 



Status Indicator RAPs 

9-672, 9-673 



6/02 
2-160 



Prelaunch Training/Review 
DC1 632/2240 



9-684 ADC Shutter 

The machine logic detected an ADC Shutter operation failure. 

Procedure 

BSD 9.16, 9.31D 

Enter dC330 [009-078]. The ADC Shutter Solenoid energized. 

Y N 

There is +24VDC from P/J 536-A7 on the l/F PWB to GND. 
Y N 

Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9.1). If 
the problem continues, replace the ADC Sensor (PL 1.3). 

Enter dC330 [009-078]. There is 0VDC from P/J536-A8 on the l/F PWB to GND. 



Y N 

Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9.1). If 
the problem continues, replace the MCU PWB (PL 13.1). If the problem continues, 
replace the ADC Sensor (PL 1 .3). 

Enter dC330 [009-079]. The voltage from P/J 536-A6 on the l/F PWB to GND changed to 
0VDC momentarily. 

Y N 
Check the wires and connectors. If the check is OK, replace the l/F PWB (PL 9.1). If 
the problem continues, replace the MCU PWB (PL 13.1). If the problem continues, 
replace the ADC Sensor (PL 1 .3). 



Check the wires and connectors. If the check is OK, replace the ADC Sensor (PL 1 .3). 
After checking that no failures are detected during normal operation, go to call closeout. 




DC330 [009-076] 

ADC SENSOR LED 2 

J536 ON (L) +5VDC P602 



DOUBLE 
PLUG 



ADC SENSOR 
PL1.3 



BLU 
DC330 [009-077] 
ADC SENSOR LED 1 
ON (L) +5VDC 



BLU 
+5VDC 



BLU 
DC COM 



BLU 
DC330 [009-078] (100ms) 
ADC SENSOR SOLENOID 
NIP (L) +24VDC 



BLU 
+24VDC 



BLU 
DC330 [009-079] (100ms) 
ADC SENSOR SOLENOID 
RELEASE (L) +24VDC 



BLU 



-@ 



t®l 




1 I 

"J 



T709028A-CAR 



Figure 1 The ADC Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-161 



Status Indicator RAPs 

9-684 



9-910 Drum (Y) Type Mismatch 

Drum Type Mismatch 



9-911 Drum (M) Type Mismatch 

Drum Type Mismatch 



Initial Actions 

Ensure that the correct drum type is installed. 



Initial Actions 

Ensure that the correct drum type is installed. 



Procedure 

Enter dC330 [009-151, Drum (Y) Data]. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the Yellow Drum Cartridge 
(refer to Section 6, Machine Consumables). 

Replace the MCU PWB. (PL 13.1). 



Procedure 

Enter dC330 [009-152 (Drum (M) Data]. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the Magenta Drum Cartridge 
(refer to Section 6, Machine Consumables). 

Replace the MCU PWB. (PL 13.1). 



MCU PWB 
PL13.1 



+3.3VDI 



-^ 



DC330 [009-035] 
DRUM (Y) POWER 
ON (H) +3.3VDC 



DOUBLE 



DC COM 



JT 



YEL 






DRUM (Y) 
+3.3VDC CLOCK 


YEL 






DC330 [009-151] 
DRUM (Y) DATA 


YEL 




DC COM 


YEL 






DC330 [009-035] 
DRUM (M) POWER 
ON (H) +3.3VDC 


YEL 






DRUM (M) 
+3.3VDC CLOCK 


YEL 






DC330 [009-152] 

DRUM (M) DATA 


YEL 


DC COM 



3—7 
I I 

4—6 



5 - 


- 5 


YEL 












YEL 


7 - 
I 


- 3 

I 




YEL 


8 - 


- 2 




VIO 



yIT 



DRUM (Y) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




| 







DRUM (M) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




| 







T709012A-CAR 



MCU PWB 
PL13.1 



+3.3VDI 



DC330 [009-035] 
DRUM (Y) POWER 
ON (H) +3.3VDC 



DOUBLE 



-^ 



JT 

DC COM 



JT 



YEL 






DRUM (Y) 
+3.3VDC CLOCK 


YEL 






DC330 [009-151] 
DRUM (Y) DATA 


YEL 




DC COM 


YEL 






DC330 [009-035] 
DRUM (M) POWER 
ON (H) +3.3VDC 


YEL 






DRUM (M) 
+3.3VDC CLOCK 


YEL 






DC330 [009-152] 

DRUM (M) DATA 


YEL 


DC COM 



3—7 
I I 

4—6 



5 - 


- 5 


YEL 












YEL 


7 - 
I 


- 3 

I 




YEL 


8 - 


- 2 




VIO 



w 



DRUM (Y) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




I 







DRUM (M) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




I 







T709012A-CAR 



Figure 1 Drum Y Communication 



Figure 1 Drum M Communication 



Status Indicator RAPs 

9-910,9-911 



6/02 
2-162 



Prelaunch Training/Review 
DC1 632/2240 



9-912 Drum (C) Type Mismatch 

Drum Type Mismatch 



9-913 Drum (K) Type Mismatch 

Drum Type Mismatch 



Initial Actions 

Ensure that the correct drum type is installed. 



Initial Actions 

Ensure that the correct drum type is installed. 



Procedure 

Enter dC330 [009-153 (Drum (C) Data]. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the Cyan Drum Cartridge 
(refer to Section 6, Machine Consumables). 

Replace the MCU PWB. (PL 13.1) 



Procedure 

Enter dC330 [009-154 (Drum (K) Data. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the Black Drum Cartridge 
(refer to Section 6, Machine Consumables). 

Replace the MCU PWB. (PL 13.1) 



MCU PWB 
PL13.1 



DC330 [009-035] m , , R , F 

DRUM (K) POWER □, ,7,7 

ON (H) +3.3VDC 1 1| 



P624 



DC COM 



DC COM 



BLU 



DRUM (K) 
+3.3VDC CLOCK 



DC330 [009-154] 
DRUM (K) DATA 



BLU 
DC COM 



DC330 [009-035] 
DRUM (C) POWER 
ON (H) +3.3VDC 



DRUM (C) 
+3.3VDC CIOCK 



DC330 [009-153] 

DRUM (C) DATA 



BLU 
DC COM 



J624 J151 



DRUM (K) 
PL4.1 



3 — 7 
I I 

4 — 6 



DRUM (C) 
PL4.1 



T709013A-CAR 



MCU PWB 
PL13.1 



DC330 [009-035] m , , R , F 

DRUM (K) POWER □, ,7,7 

ON (H) +3.3VDC 1 1| 



P624 



DC COM 



DC COM 



BLU 



DRUM (K) 
+3.3VDC CLOCK 



DC330 [009-154] 
DRUM (K) DATA 



BLU 
DC COM 



DC330 [009-035] 
DRUM (C) POWER 
ON (H) +3.3VDC 



DRUM (C) 
+3.3VDC CIOCK 



DC330 [009-153] 

DRUM (C) DATA 



BLU 
DC COM 



J624 J151 



3 — 7 
I I 

4 — 6 



DRUM (K) 
PL4.1 


4 

3 

2 

I 

1 


CRUM 


I 





DRUM (C) 
PL4.1 



T709013A-CAR 



Figure 1 Drum C Communication 



Figure 1 Drum C Communication 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-163 



Status Indicator RAPs 

9-912,9-913 



9-920 Toner Cartridge (Y) Empty 

The Yellow Toner Cartridge is empty. 

NOTE: Continuous running of high density prints can temporarily deplete the toner supply. 

Initial Actions 

i Ensure that there is toner and the toner is evenly distributed in the cartridge (Y). 
i Check the ATC Sensor (Y) for blockage or contaminants. 

T Check the drive system from the Developer Drive Motor to the Developer Housing (Y) for 
damage. 

Procedure 

Enter dC330 [009-001]. The Toner Dispense Motor (Y) energizes (PL 6.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [009-014]. The Developer Motor energizes (PL 1.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Check ADJ 9.3. The ATC Sensor (Y) fail judgement is OK (PL 6.2). 

Y N 

Go the 9-380 ATC Sensor Failure (Y) RAP. 

After checking that no failures are detected during normal operation, go to call closeout. 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
48 i — 



DC330 [009-014] (5s) 
J534 DEVE MOTOR 
A6 J3J4 ON (L) +5VDC J ~ oi 



+24VDC 
INTLK 

r f 

DC COM 



DC COM 
+5VDC 



BLU 

DC330 [009-014] (5s) 
DEVE MOTOR 
HIGH SPEED (L) +5VDC 



BLU 
+24VDC INTLK 



ORN 

DC COM 



VIO 



DEVE MOTOR 




PL1.1 








SERVO 


1 


CONTROL 




2 




3^) 


5 




y* 


8 

7 






I 





T709027A-CAR 



Figure 2 The Developer Motor 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
17 



I" 
+24VDC 
INTLK 



DC330 [009-001] (5s) 
TONER DISPENSE 
MOTOR (Y) 
ON (L) +24VDC 



BLU 
+24VDC INTLK 



BLU 



TONER 
DISPENSE 
MOTOR (Y) 
PL6.1 

IDS) 



T709023A-CAR 



Figure 1 Toner Dispense Motor Y 



Status Indicator RAPs 

9-920 



6/02 
2-164 



Prelaunch Training/Review 
DC1 632/2240 



9-921 Toner Cartridge (M) Empty 

The Yellow Toner Cartridge is empty. 

NOTE: Continuous running of high density prints can temporarily deplete the toner supply. 

Initial Actions 

i Ensure that there is toner and the toner is evenly distributed in the cartridge (M). 
i Check the ATC Sensor (M) for blockage or contaminants. 

T Check the drive system from the Developer Drive Motor to the Developer Housing (M) for 
damage. 

Procedure 

Enter dC330 [009-002]. The Toner Dispense Motor (M) energizes (PL 6.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [009-014]. The Developer Motor energizes (PL.1.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Check ADJ 9.3. The ATC Sensor (M) fail judgement is OK. 

Y N 

Go the 9-382 ATC Sensor Failure (M) RAP. 

After checking that no failures are detected during normal operation, go to call closeout. 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
48 i — 



DC330 [009-014] (5s) 
J534 DEVE MOTOR 
A6 J3J4 ON (L) +5VDC J ~ oi 



+24VDC 
INTLK 

r f 

DC COM 



xr f 

DC COM 
+5VDC 



BLU 

DC330 [009-014] (5s) 
DEVE MOTOR 
HIGH SPEED (L) +5VDC 



BLU 
+24VDC INTLK 



ORN 

DC COM 



VIO 



DEVE MOTOR 




PL1.1 








SERVO 


1 


CONTROL 




2 




3^) 


5 




y* 


8 

7 






I 





T709027A-CAR 



Figure 2 The Developer Motor 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 h-^ 
77 -\£— 
DC COM 



DC330 [009-002 (5s) 
TONER DISPENSE 
MOTOR (M) 
J533 ON (L) +24VDC 



XT 

+24VDC 
INTLK 



BLU 
+24VDC INTLK 



TONER 
DISPENSE 
MOTOR (M) 
PL6.1 



| jg) 



T709024A-CAR 



Figure 1 Toner Dispense Motor M 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-165 



Status Indicator RAPs 

9-921 



9-922 Toner Cartridge (C) Empty 

The Cyan Toner Cartridge is empty. 

NOTE: Continuous running of high density prints can temporally deplete the toner supply. 

Initial Actions 

i Ensure that there is toner and the toner is evenly distributed in the cartridge (C). 
i Check the ATC Sensor (C) for blockage or contaminants. 

T Check the drive system from the Developer Drive Motor to the Developer Housing (C) for 
damage. 

Procedure 

Enter dC330 [009-003]. The Toner Dispense Motor (C) energizes (PL 6.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330 [009-014]. The Developer Motor energizes (PL.1.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Check ADJ 9.3. The ATC Sensor (C) fail judgement is OK. 

Y N 

Go the 9-383, ATC Sensor Failure (C) RAP. 

After checking that no failures are detected during normal operation, go to call closeout. 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
48 i — 



DC330 [009-014] (5s) 
J534 DEVE MOTOR 
A6 J3J4 ON (L) +5VDC J ~ oi 



+24VDC 
INTLK 

r f 

DC COM 



DC COM 
+5VDC 



BLU 

DC330 [009-014] (5s) 
DEVE MOTOR 
HIGH SPEED (L) +5VDC 



BLU 
+24VDC INTLK 



ORN 

DC COM 



VIO 



DEVE MOTOR 




PL1.1 








SERVO 


1 


CONTROL 




2 




3^) 


5 




y* 


8 

7 






I 





T709027A-CAR 



Figure 2 The Developer Motor 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
76 



X" 

+24VDC 
INTLK 



DC330 [009-003 (5s) 
TONER DISPENSE 
MOTOR (C) l99q 

ON (L) +24VDC 



BLU 
+24VDC INTLK 



BLU 



Figure 1 Toner Dispense Motor C 



TONER 
DISPENSE 
MOTOR (C) 
PL6.1 



T709025A-CAR 



Status Indicator RAPs 

9-922 



6/02 
2-166 



Prelaunch Training/Review 
DC1 632/2240 



9-923 Toner Cartridge (K) Empty 

The Black Toner Cartridge is empty. 

NOTE: Continuous running of high density prints can temporally deplete the toner supply. 

Initial Actions 

i Ensure that there is toner and the toner is evenly distributed in the cartridge (K). 
i Check the ATC Sensor (K) for blockage or contaminants. 

i Check the drive system from the Main Drive Motor to the Developer Housing (K) for dam- 
age. 

Procedure 

Enter dC330 [009-004]. The Toner Dispense Motor (K) energizes (PL 6.1). 

Y N 

Go to OF 99-6 Motor Open RAP. 

Enter dC330. Stack the codes [004-004, Main Motor] and [009-013, Dev, Clutch (K)]. The 
Black Developer Assy, energizes (PL 1.1). 

Y N 

Go to OF 99-6 Motor Open RAP (refer to BSD 4.1 and BSD 9.13 for circuit). 

Check ADJ 9.3. The ATC Sensor (K) fail judgement is OK (PL 6.2). 

Y N 

Go the 9-383 ATC Sensor Failure (K) RAP. 

After checking that no failures are detected during normal operation, go to call closeout. 



MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
48 i — 



DC330 [009-014] (5s) 
J534 DEVE MOTOR 
A6 J3J4 ON (L) +5VDC J ~ oi 



+24VDC 
INTLK 

r f 

DC COM 



DC COM 
+5VDC 



BLU 

DC330 [009-014] (5s) 
DEVE MOTOR 
HIGH SPEED (L) +5VDC 



BLU 
+24VDC INTLK 



ORN 

DC COM 



VIO 



DEVE MOTOR 




PL1.1 








SERVO 


1 


CONTROL 




2 




3^) 


5 




y* 


8 

7 






I 





T709027A-CAR 



Figure 2 The Developer Motor 



MCU PWB 
PL13.1 



-t 



l/F PWB 
PL9.1 



P/J410 
— 75 



+24VDC 
INTLK 



DC330 [009-004 (5s) 
TONER DISPENSE 
MOTOR (K) J230 

ON (L) +24VDC 



BLU 
+24VDC INTLK 



TONER 
DISPENSE 
MOTOR (K) 
PL6.1 

l (mot) 



T709026A-CAR 



Figure 1 Toner Dispense Motor K 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-167 



Status Indicator RAPs 

9-923 



9-924 Waste Toner Cartridge Full 

The Waste Toner Cartridge is full. 



9-925 Waste Toner Cartridge Not Set 

The Waste Toner Cartridge was not installed correctly 



Initial Actions 

Replace the Waste Toner Cartridge. Check the Full Toner Sensor for contaminants. 



Initial Actions 

Ensure that the Waste Toner Cartridge is installed correctly. 



Procedure 

Enter dC330 [009-150]. Actuate and de-actuate the Full Toner Sensor (PL 4.1) The display 
changes state. 
Y N 

Go to the OF 99-2 Transmissive Sensor RAP. 

Replace the MCU PWB. (PL 13.1) 



MCU PWB 
PL13.1 



_ J407 DC COM J614 



DOUBLE 



P614 J133 



FULL TONER 

SENSOR 

PL4.1 



DC COM 
+5VDC 



YEL 



DC330 [009-150] 
FULL TONER SENSOR 
SENSED (H) +3.3VDC 



1 _ 3 



©fXSl 



YEL 



T709022A-CAR 



Figure 1 Full Toner Sensor 



Procedure 

There is +5VDC from P/J 535-A3 on the l/F PWB to GND. 
Y N 

There is +5VDC measured at FS135 on the Waste Toner Cartridge Interlock Switch. 

Y N 

Check the +5VDC circuit to the Waste Toner Cartridge Interlock Switch FS135. 



There is +5VDC measured at FS143 on the Waste Toner Cartridge Interlock Switch. 
Y N 

Replace the Waste Toner Cartridge Interlock Switch (PL 4.1) 

Check the wire between the Waste Toner Cartridge Interlock Switch FS134 and the l/F 
PWB P/J535-A3 for an open circuit or poor contact. 



Check the connector P/J410 between the l/F PWB and the MCU PWB. If no problems are 

found, replace the MCU PWB. (PL 13.1) 

If the problem persists, replace the l/F PWB. (PL 9.1) 



+5VDC Low 

Voltage 

Power 

Supply 

PL9.1 



J511 FS135 
2 +5VDC 



WASTE 

TONER 

BOTTLE 

INTERLOCK 

SWITCH 

PL4.1 



</o — 0- 



WASTE TONER 

BOTTLE INTERLOCK 

CLOSED (H) +5VDC 

S134 J535 



l/F PWB 
PL9.1 



MCU PWB 
PL13.1 



. A3 



3.3VDC 
P/J410 <■ 



T709030A-CAR 



Figure 1 The Waste Toner Bottle Interlock Switch 



Status Indicator RAPs 

9-924, 9-925 



6/02 
2-168 



Prelaunch Training/Review 
DC1 632/2240 



9-926 Drum Cartridge (K) End Of Life 

The Drum Cartridge (K) needs to be replaced. 

Procedure 

Replace the Black Drum Cartridge (refer to Section 6, Machine Consumables). The problem 
is corrected. 
Y N 

Replace the MCU PWB. (PL 13.1). 

Return to Service Call Procedures. 



9-927 Change Drum Cartridge (C) End Of Life 

The Drum Cartridge (C) needs to be replaced. 

Procedure 

Replace the Cyan Drum Cartridge (refer to Section 6, Machine Consumables). The problem 
is corrected. 
Y N 

Replace the MCU PWB. (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-169 



Status Indicator RAPs 

9-926, 9-927 



9-928 Drum Cartridge (M) End Of Life 

The Drum Cartridge (M) needs to be replaced. 

Procedure 

Replace the Magenta Drum Cartridge (refer to Section 6, Machine Consumables). The prob- 
lem is corrected. 
Y N 

Replace the MCU PWB. (PL 13.1). 

Return to Service Call Procedures. 



9-929 Drum Cartridge (Y) End Of Life 

The Drum Cartridge (Y) needs to be replaced. 

Procedure 

Replace the Yellow Drum Cartridge (refer to Section 6, Machine Consumables). The problem 
is corrected. 
Y N 

Replace the MCU PWB. (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

9-928, 9-929 



6/02 
2-170 



Prelaunch Training/Review 
DC1 632/2240 



9-930 Black Drum Cartridge Not Detected 

The machine logic detected that Black Drum Cartridge is not installed. 



9-931 Cyan Drum Cartridge Not Detected 

The machine logic detected that Cyan Drum Cartridge is not installed. 



Initial Actions 

i Ensure Black Drum Cartridge is installed correctly, 
i Switch the power off, then on. 

Procedure 

Swap Black Drum Cartridge with Drum (Y), (C) or (M). The problem is corrected. 
Y N 

Check that P/J-405 on the MCU PWB and P/J-622 are connected and the wires for an 
open or short. If the check is OK, replace the MCU PWB (PL 1 3. 1 ). If the problem contin- 
ues, replace the ESS PWB (PL 13.1). 

Replace the defective Drum Cartridge (refer to Section 6, Machine Consumables). 



Initial Actions 

i' Ensure Cyan Drum Cartridge is installed correctly, 
i Switch the power off, then on. 

Procedure 

Swap Cyan Drum Cartridge with Drum (Y), (K) or (M). The problem is corrected. 
Y N 

Check that P/J-405 on the MCU PWB and P/J-622 are connected and the wires for an 
open or short. If the check is OK, replace the MCU PWB (PL 13.1). If the problem contin- 
ues, replace the ESS PWB (PL 13.1). 

Replace the defective Drum Cartridge (refer to Section 6, Machine Consumables). 



MCU PWB 
PL13.1 



DC330 [009-035] m , , R , F 

DRUM (K) POWER □, ,7,7 

ON (H) +3.3VDC 1 1| 



P624 



DC COM 



DC COM 



BLU 



DRUM (K) 
+3.3VDC CLOCK 



DC330 [009-154] 
DRUM (K) DATA 



BLU 
DC COM 



DC330 [009-035] 
DRUM (C) POWER 
ON (H) +3.3VDC 



DRUM (C) 
+3.3VDC CIOCK 



DC330 [009-153] 

DRUM (C) DATA 



BLU 
DC COM 



J624 J151 



DRUM (K) 
PL4.1 



DRUM (C) 
PL4.1 



T709013A-CAR 



MCU PWB 
PL13.1 



DC330 [009-035] m , , R , F 

DRUM (K) POWER □, ,7,7 

ON (H) +3.3VDC 1 1| 



P624 



DC COM 



DC COM 



BLU 



DRUM (K) 
+3.3VDC CLOCK 



DC330 [009-154] 
DRUM (K) DATA 



BLU 
DC COM 



DC330 [009-035] 
DRUM (C) POWER 
ON (H) +3.3VDC 



DRUM (C) 
+3.3VDC CIOCK 



DC330 [009-153] 

DRUM (C) DATA 



BLU 
DC COM 



J624 J151 



DRUM (K) 
PL4.1 


4 

3 

2 

I 

1 


CRUM 


I 





DRUM (C) 
PL4.1 



T709013A-CAR 



Figure 1 Drum C Communication 



Figure 1 Drum C Communication 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-171 



Status Indicator RAPs 

9-930, 9-931 



9-932 Magenta Drum Cartridge Not Detected 

The machine logic detected that Magenta Drum Cartridge is not installed. 



9-933 Yellow Drum Cartridge Not Detected 

The machine logic detected that the Yellow Drum Cartridge is not installed. 



Initial Actions 

i Ensure Magenta Drum Cartridge is installed correctly, 
i Switch the power off, then on. 

Procedure 

Swap Magenta Drum Cartridge with Drum (Y), (C) or K). The problem is corrected. 
Y N 

Check that P/J-405 on the MCU PWB and P/J-624 are connected and the wires for an 
open or short. If the check is OK, replace the MCU PWB (PL 1 3. 1 ). If the problem contin- 
ues, replace the ESS PWB (PL 13.1). 

Replace the defective Drum Cartridge (refer to Section 6, Machine Consumables). 



Initial Actions 

i Ensure Yellow Drum Cartridge is installed correctly, 
i Switch the power off, then on. 

Procedure 

Swap Yellow Drum Cartridge with Drum (K), (C) or (M). The problem is corrected. 
Y N 

Check that P/J-405 on the MCU PWB and P/J-624 are connected and the wires for an 
open or short. If the check is OK, replace the MCU PWB (PL 13.1). If the problem contin- 
ues, replace the ESS PWB (PL 13.1). 

Replace the defective Drum Cartridge (refer to Section 6, Machine Consumables). 



MCU PWB 
PL13.1 



+3.3VDI 



DC330 [009-035] 
DRUM (Y) POWER 
ON (H) +3.3VDC 



DOUBLE 



DC COM 



"^ 



JT 



YEL 






DRUM (Y) 
+3.3VDC CLOCK 


YEL 






DC330 [009-151] 
DRUM (Y) DATA 


YEL 




DC COM 


YEL 






DC330 [009-035] 
DRUM (M) POWER 
ON (H) +3.3VDC 


YEL 






DRUM (M) 
+3.3VDC CLOCK 


YEL 






DC330 [009-152] 

DRUM (M) DATA 


YEL 


DC COM 



5 - 


- 5 


YEL 












YEL 


7 - 
I 


- 3 

I 




YEL 


8 - 


- 2 




VIO 



yIT 



DRUM (Y) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




| 







DRUM (M) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




[ 







MCU PWB 
PL13.1 



+3.3VDI 

St 



DC330 [009-035] 
DRUM (Y) POWER 
ON (H) +3.3VDC 



DOUBLE 



-^ 



JT 

DC COM 



JT 



YEL 






DRUM (Y) 
+3.3VDC CLOCK 


YEL 






DC330 [009-151] 
DRUM (Y) DATA 


YEL 




DC COM 


YEL 






DC330 [009-035] 
DRUM (M) POWER 
ON (H) +3.3VDC 


YEL 






DRUM (M) 
+3.3VDC CLOCK 


YEL 






DC330 [009-152] 

DRUM (M) DATA 


YEL 


DC COM 



5 - 


- 5 


YEL 












YEL 


7 - 
I 


- 3 

I 




YEL 


8 - 


- 2 




VIO 



w 



DRUM (Y) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




I 







DRUM (M) 
PL4.1 




4 

3 

2 

I 

1 


CRUM 




I 







T709012A-CAR 



T709012A-CAR 



Figure 1 Drum M Communication 



Figure 1 Drum Y Communication 



Status Indicator RAPs 

9-932, 9-933 



6/02 
2-172 



Prelaunch Training/Review 
DC1 632/2240 



10-105 Face Up Exit Sensor On 

The Face Up Exit Sensor did not energize. 

Initial Actions 

i Check condition and specification of the paper supply. 

i Check for obstructions in the paper feed path. 

i Clean the Exit Roll and check for wear. 

T Check the drive transmissions for damage or wear. 

Procedure 

Enter dC330 [01 0-1 03] and press Start. Block and unblock the Face Up Exit Sensor (PL 1 1 .2). 
The display changes state. 

Y N 
Go to OF 99-2 Transmissive Sensor RAP. 

Enter dC330 [010-101] and press Start. Actuate and de-actuate the Fuser Exit Switch (PL 
2.8). The display changes state. 

Y N 
Go to OF 99-3 Switch RAP. 

Enter dC330 [008-046] and press Start. The Duplex Gate Solenoid energizes (PL 11.2). 



Y N 

Go to the OF 99-4 Solenoid/Clutch RAP. 

Enter dC330 [008-045] and press Start. The Exit Gate Solenoid energizes (PL 11.2). 

Y N 

Go to OF 99-4 Solenoid/Clutch RAP. 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 13.1). 



DRAWER 

CONNECTOR 

J613 P633 I I J633 J102 




FACE UP EXIT 

SENSOR 

D L11.2 



®£ 



t-t 



DC330 [010-103] 
FACE UP EXIT 
SENSOR 
SENSED (H) +3.3VDC 



T710010A-CAR 



Figure 1 The Face Up Exit Sensor CD 



MCU PWB 
PL13.1 



DC330 [008-045] (200ms) 

EXIT GATE SOLENOID 

ON (L) +24VDC P613 

J407 



DOUBLE 



J613 P633 



DRAWER 
CONNECTOR 



DOUBLE 



BLU 



+24VDC 



J215 


EXIT GATE 
SOLENOID 
PL11.2 




A. 

r 















T710005A-CAR 



Figure 2 The Exit Gate Solenoid CD 




DC330 [008-037] (400ms) ™ 

REGI CLUTCH f L utj i 

P620 I I j 620 J231 



ON (L) +24VDC 



REGI 

CLUTCH 

PL2.6 



YEL 
+24VDC 



YEL 



BLU 



T710006A-CAR 



Figure 3 The Registration Clutch CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-173 



Status Indicator RAPs 

10-105 




DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
J533 ON +24VDC CLOCK 



YEL 



+24VDC INTLK 



+24VDC INTLK 



YEL 



r^ 



r^ 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



J216 


2ND BTR 
RETRACT 
MOTOR 
PL2.9 




\ 




1 




(mot) 




I 




j 







T709004A-CAR 



Figure 4 The 2ND BTR Retract Motor CD 



Status Indicator RAPs 

10-105 



6/02 
2-174 



Prelaunch Training/Review 
DC1 632/2240 



10-106 Face Up Exit Sensor Off 

The Face Up Exit Sensor did not de-energize. 



10-110 Fuser Exit Switch On (Face Down/duplex) 

The Fuser Exit Switch did not energize. 



Initial Actions 

i Check condition and specification of the paper supply. 

i Check for obstructions in the paper feed path. 

i Clean the Fuser Exit Roll and check for wear. 

T Check the drive transmissions for damage or wear. 

Procedure 

Enter dC330 [01 0-1 03] and press Start. Block and unblock the Face Up Exit Sensor (PL 1 1 .2). 
The display changes state. 
Y N 

Go to OF 99-2 Transmissive Sensor RAP. 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 13.1). 



DOUBLE 



DRAWER 

CONNECTOR 

J613 P633 ' ' J633 J102 




FACE UP EXIT 

SENSOR 

D L11.2 



®=*i : * 



DC330 [010-103] 
FACE UP EXIT 
SENSOR 
SENSED fl-n +3.3VDC 



T710010A-CAR 



Figure 1 The Face Up Exit Sensor CD 



Initial Actions 

Check condition and specification of the paper supply. 
Check for obstructions in the paper feed path. 
Clean the Fuser Exit Roll and check for wear. 
Check the drive transmissions for damage or wear. 

Procedure 

Check the Fuser Stripper Fingers and Fuser Roll for dirt build up, wear or damage. The 
check is OK. 

Y N 

Clean or replace the Fuser Assembly (PL 7.1 ). 

Enter dC330 [010-101] and press Start. Actuate and de-actuate the Fuser Exit Switch (PL 
2.8). The display changes state. 

Y N 

Go to OF 99-3 Switch RAP. 

Enter dC330 [008-045] and press Start. The Exit Gate Solenoid energizes (PL 11.2). 

Y N 

Go to OF 99-4 Solenoid/Clutch RAP] and press Start. 

Enter dC330 [008-037] and press Start. The Registration Clutch energizes (PL 2.6). 

Y N 

Go to OF 99-4 Solenoid/Clutch RAP. 

In sequence enter the following: dC330 [9-051] then dC330 [9-052] and press Start. The 2nd 
BTR Retract Motor contacts and retracts (PL 2.9). 

Y N 

Go to RAP 9-342 for a contact failure or go to 9-343 for a retract failure. 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



CONTROL 
LOGIC 



+3.3VDC 

P/J410 



l/F PWB 
PL9.1 

DC COM 



J533 DC COM P612 

h 

i YEL 



-B13' 



DC330 [10-101] 
FUSER EXIT SWITCH 
SENSED (H) +3.3VDC 

YEL 



Figure 1 Fuser Exit Switch CD 




T710002A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-175 



Status Indicator RAPs 

10-106,10-110 



MCU PWB 
PL13.1 



DC330 [008-045] (200ms) 

EXIT GATE SOLENOID 

ON (L) +24VDC P613 

J407 



DOUBLE 



DRAWER 

CONNECTOR 

;33 r I iR 



DOUBLE 



BLU 



+24VDC 



J215 


EXIT GATE 
SOLENOID 
PL11.2 




A. 

r 















T710005A-CAR 



Figure 2 Exit Gate Solenoid CD 




DC330 [008-037] (400ms) 
REGI CLUTCH 
ON (L) +24VDC 



YEL 
+24VDC 



YEL 



DOUBLE 



P620 ' _ I j 620 J231 



REGI 

CLUTCH 

PL2.6 



T710006A-CAR 



Figure 3 Registration Clutch CD 




DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
J533 ON +24VDC CLOCK 



r^ 



r^ 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 



+24VDC INTLK 



+24VDC INTLK 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 
DC330 [009-051] (CONTACT) 
DC330 [009-052] (RETRACT) 
2ND BTR RETRACT MOTOR 
ON +24VDC CLOCK 



YEL 



J216 


2ND BTR 
RETRACT 
MOTOR 
PL2.9 




\ 




1 




(mot) 




j 




/ 







T709004A-CAR 



Figure 4 2ND BTR Retract Motor 



Status Indicator RAPs 

10-110 



6/02 
2-176 



Prelaunch Training/Review 
DC1 632/2240 



10-111 Fuser Exit Switch Off (Face Down) 

The Fuser Exit Switch did not de-energize. 

Initial Actions 

i Check condition and specification of the paper supply. 

i Check for obstructions in the paper feed path. 

i Clean the Fuser Exit Roll and check for wear. 

i Check the drive transmissions for damage or wear. 

Procedure 

Check the Fuser Stripper Fingers and Fuser Roll for dirt build up, wear or damage. The 
check is OK. 

Y N 

Clean or replace the Fuser Assembly (PL 7.1). 

Enter dC330 [010-101] and press Start. Actuate and de-actuate the Fuser Exit Switch (PL 
2.8). The display changes state. 

Y N 

Go to OF 99-3 Switch RAP. 



Enter dC330 [008-045] and press Start. The Exit Gate Solenoid energizes (PL 11.2). 
Y N 

Go to OF 99-4 Solenoid/Clutch RAP. 

The switch and solenoid are operating correctly. If the problem continues, check the wires and 
connectors. If the check is OK, replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



CONTROL 
LOGIC 



+3.3VDC 

P/J410 



l/F PWB 
PL9.1 

DC COM 



J533 DC COM P612 

h 

i YEL 



DC330 [10-101] 

fuser exit switch 
sensed (h) +3.3vdc 

yel 




T710002A-CAR 



Figure 1 Fuser Exit Switch CD 



MCU PWB 
PL13.1 



DC330 [008-045] (200ms) 

EXIT GATE SOLENOID 

ON (L) +24VDC P613 



r^ 



DRAWER 
CONNECTOR 
33 I I .Ifi 



DOUBLE 
P^ 



BLU 
+24VDC 



BLU 



+24VDC 



J215 


EXIT GATE 
SOLENOID 
PL11.2 




r 















T710005A-CAR 



Figure 2 Exit Gate Solenoid CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-177 



Status Indicator RAPs 

10-111 



10-125 Duplex Wait Sensor On 

The Duplex Wait Sensor did not energize 

Initial Actions 

I Check condition and specification of paper in Tray 2. 

i Check the paper path for obstructions. 

i Check for wear and clean the Duplex Drive Rolls. 

i Check the exit transmission gears for breakage and wear. 

Procedure 

Enter dC330 [008-105] and press Start. Block and unblock the Duplex Wait Sensor (PL 12.2). 
The display changes state. 
Y N 

Go to OF 99-1 Reflective Sensor RAP. 

Enter dC330 [008-003] and press Start. The Duplex Motor energizes (PL 12.2). 



Y N 

Go to OF 99-6 Motor RAP. 

Enter dC330 [008-046] and press Start. The Duplex Gate Solenoid energizes. 

Y N 

Go to OF 99-4 Solenoid/Clutch RAP. 

Enter dC330 [008-042] and press Start. The Inverter Forward Clutch Energizes. 

Y N 

Go to OF 99-4 Solenoid/Clutch RAP. 

Enter dC330 [008-043] and press Start. The Inverter Reverse Clutch Energizes. 

Y N 

Go to OF 99-4 Solenoid/Clutch RAP. 

The circuits are operating correctly, re-check the Drawer connector and the duplex mechanical 
drives. If the problem continues, check the wires and connectors. If the check is OK, replace 
theMCUPWB(PL13.1). 



DUPLEX 

PWB 

PL12.2 

DC COM 

JT 

+5VDC 



DC COM 



J540 DC COM J135 



DUPLEX WAIT 

SENSOR 

PL12.2 



VIO 
+5VDC 



GRY 



© 



<gl 



J135 J540 



DUPLEX 

PWB 

PL12.2 



DUPLEX COVER 
INTERLOCK 
SWITCH 
PL12.2 



-1- 



DRAWER DOUBLE DC330 [008-1 05] 

CONNECTOR PI UG DUPLEX WAIT SENSOR 

J538 J626 I * P626 J640 ' I P640 SENSED ( H ) +5VDC J4 gg 

A7— B7, -5 7-, ,A8- 



MCU PWB 
PL13.1 





YEL 



DC330 [008-300] 
DUPLEX COVER 
INTERLOCK SWITCH 
CLOSED (L) +3.3VDC 



YEL 



T708018A-CAR 



Figure 1 Duplex Wait Sensor CD 



Status Indicator RAPs 

10-125 



6/02 
2-178 



Prelaunch Training/Review 
DC1 632/2240 



MCU PWB 
PL13.1 



-[^A10 



^ 



DC330 [008-009 - 01 2] du^ 

DUPLEX MOTOR | K L U ^ I 

ON (L) +5VDC P640 ' ' 

5 — 7 



J640 P626 



DRAWER 
CONNECTOR 



J626 J538 



DUPLEX PWB 
PL12.2 
+5VDC 



YEL 




DC330 [008-009 - 
DUPLEX MOTOR 
REF CLOCK 


012] 


YEL 




DC330 [008-009 -012] 
DUPLEX MOTOR 
HIGH SPEED (L) +5VDC 



H^ 



DC COM 



DUPLEX MOTOR 
J539 ON 24V CLOCK 


DUPLEX 
MOTOR 
PL12.2 


DUPLEX MOTOR 
ON 24V CLOCK 


\ 


+24VDC 


\ 


+24VDC 


(mot) 


DUPLEX MOTOR 
ON 24V CLOCK 


1 


DUPLEX MOTOR 
ON 24V CLOCK 


1 







Figure 2 Duplex Motor CD 



T708015A-CAR 



MCU PWB 
PL13.1 



PLUG CONMECTOR D0UB| _, 



„„ P251 ' ' J251 
A2 — B2 -^7777- 1 — 2 , 



DCC °" A7 +24VDC ;_^ 



BLU | | BLU 
A1 — B1 



ORN 



ORN 



DUPLEX GATE 

SOLENOID 

PL11.2 



T708017A-CAR 



Figure 3 Duplex Exit Gate Solenoid 



MCU PWB 
PL13.1 



?r%~ 



DC330 [008-042] (400ms) 
INVERTER FORWARD 
CLUTCH ON (L) +24VDC 

DOUBLE 



+24VDC 



L 



J407 X P613 



l r s \ 



BLU 
+24VDC 



DRAWER 

CONNECTOR 

533 r 1 j 6 ; 

B6 — A6 



BLU 



J217 


INVERTER 
FORWARD 
CLUTCH 
PL11.2 




r 















T710011A-CAR 



Figure 4 Inverter Forward Clutch CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-179 



Status Indicator RAPs 

10-125 



MCU PWB 
PL13.1 



DOUBLE DOUBLE 

PI I in PI I in. 



+24VDC 



DC330 [008-043] (400ms) 

inverter reverse 
clutch on (l) +24vdc 

blu 

+24VDC 

1 

BLU 



INVERTER 
REVERSE 
CLUTCH 
PL11.2 



4 -10 B4 — A4 i 4 

l I BLU I I BLU 



3 -11 B3 — A3 - 



U 0RN U 



T708016A-CAR 



Figure 5 Inverter Reverse Clutch CD 



10-348 Main Heater Over Heat 

The Front Thermistor detected an overheat condition. 

Procedure 

NOTE: To clear this fault, re-set the value ofdC131 [744-003] to "0". 

Turn off the power, remove the Fuser Assembly, and allow it to cool down. 
Measure the resistance between P/J600-4 and P/J600-6 on the Fuser Assembly. 
The resistance is between 30 and 190 K Oh mis. 

Y N 
Check the Front Thermistor for an open circuit and poor contact. If the check is OK, 
replace the Sensor Assembly (PL 7.2). 

Reinstall the Fuser Assembly, turn the power ON. Enter dC140 [010-100] and press Start. The 
display value is between 678 and 699. 

Y N 

Turn the power off. Check for an open or poor connection between P/J404-12 and P/J404- 
11 on the MCU PWB PL 13.1. If the check is OK, replace the MCU PWB (PL 13.1). 

There is +3.4VDC measured at P/J404-5 on the MCU PWB. 

Y N 

Replace the MCU PWB (PL 13.1). 

Check the wires and connectors. If the check is OK, replace the AC Drive PWB (PL 9.2). 



MCU PWB 
PL13.1 

4T 12 

DC COM 


CONTROL 
LOGIC 


- 11 


JT 13 

DC COM 


CONTROL 
LOGIC 


- 14 
1 



J404 DC COM P641 



DOUBLE 
PLUG 
I 1 



J641 J600 P600 P21 



DOUBLE 
PLUG 

1 I I , 



BLU 

DC140 [10-100] 
FRONT THERMISTOR 
SENSED SIGNAL 



BLU 



DC140 [10-101] 
REAR THERMISTOR 
SENSED SIGNAL 

BLU 



VIO 



YEL 



- 2 5 ■ 

I I YEL 



2 — 1 
I I 



DOUBLE 
PLUG 

I I J212 

,1—2 



YEL 



Figure 1 Fuser Front and Rear Thermistor CD 



SENSOR 

ASSEMBLY 

PL7.2 



FRONT 
THERMISTOR 



SENSOR 

ASSEMBLY 

PL7.2 



REAR 
THERMISTOR 



T710000A-CAR 



Status Indicator RAPs 

10-125,10-348 



6/02 
2-180 



Prelaunch Training/Review 
DC1 632/2240 



MCU PWE 
PL13.1 




CONTROL 
LOGIC 


+5VDC 
DC COM 

If 

+5VDC 
DC COM I 




A. i 

+24VDC 



MAIN 
HEATER 
ON 
J404 (H)+5VDC J590 



YEL 



SUB 

HEATER 

ON 

(H) +5VDC 



FUSER RELAY 
ON (L) +24VDC 



YEL 




I " 



T710001A-CAR 



Figure 2 Fuser Main Heater and Sub Heater CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-181 



Status Indicator RAPs 

10-348 



10-349 Front Thermistor Open 

The machine logic detected an open circuit in the Front Thermistor. 

Procedure 

Turn off the power, remove the Fuser Assembly, and allow it to cool down. 
Measure the resistance between P/J600-4 and P/J600-6 on the Fuser Assembly. The resis- 
tance is between 30 and 190 K Ohmis. 

Y N 
Check the Front Thermistor for an open circuit and poor contact. If no problems are found, 
replace the Sensor Assembly (PL 7.1). 

Reinstall the Fuser Assembly, turn the power on, enter dC140 [010-101] and press Start. The 
display value is between 900 and 1000. 

Y N 

Turn the power off. Check for an open or poor connection between P/J404-12on the MCU 
PWB and P/J600-4 on the Fuser Assembly. If the check is OK, replace the MCU PWB (PL 
13.1). 

Replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



4T 



12 r 



J404 DC COM P641 



DOUBLE 
PLUG 
I 1 



J641 J600 P600 P21 



DOUBLE 
PLUG 

1 I I . 



DC COM 



CONTROL 
LOGIC -11 



BLU 

] DC140 [10-100] 

i FRONTTHERMISTOR 

! SENSED SIGNAL 



BLU 



l 13- 



DC COM 



DC COM 



CONTROL 
LOGIC - 14 



DC140 [10-101] 
REAR THERMISTOR 
SENSED SIGNAL 



VIO 



YEL 



VIO 



VIO 



2 — 1 
I I 



DOUBLE 
PLUG 

P212 ' ' J212 

1 — 2 



H 



YEL 



2 — 1 
I I 



I I 

Figure 1 Fuser Front and Rear Thermistor CD 



SENSOR 

ASSEMBLY 

PL7.2 



FRONT 
THERMISTOR 



SENSOR 

ASSEMBLY 

PL7.2 



REAR 
THERMISTOR 



T710000A-CAR 



Status Indicator RAPs 

10-349 



6/02 
2-182 



Prelaunch Training/Review 
DC1 632/2240 



10-350 Sub Heater Over Heat 

The Rear Thermistor detected an over heat condition. 

Procedure 

NOTE: To clear this fault, re-set the value ofdC131 [744-003] to "0". 

Turn off the power, remove the Fuser Assembly and allow it to cool down. 
Measure the resistance between P/J600-7 and P/J600-9 on the Fuser Assembly. 
The resistance is between 30 and 190 K Ohmis. 

Y N 
Check the Rear Thermistor for an open circuit and poor contact. If the check is OK, 
replace the Sensor Assembly (PL 7.2). 

Reinstall the Fuser Assembly, turn the power ON. Enter dC140 [010-101] and press Start. The 
display value is between 676 and 699. 

Y N 

Turn the power off. Check for an open or poor connection between P/J404-14 and P/J404- 
13ontheMCUPWB(PL13.1). If the check is OK, replace the MCU PWB (PL 13.1). 

There is +3.4VDC measured at P/J404-7 on the MCU PWB (PL 13.1). 

Y N 

Replace the MCU PWB (PL 13.1). 



Check the wires and connectors. If the check is OK, replace the AC Drive PWB (PL 9.2). 



MCU PWB 
PL13.1 

4T 12 

DC COM 


CONTROL 
LOGIC 


- 11 


JT 13 

DC COM 


CONTROL 
LOGIC 


- 14 
1 



J404 DC COM P641 



DOUBLE 
PLUG 
I 1 



J641 J600 P600 P21 



DOUBLE 
PLUG 

1 I I , 



BLU 

DC140 [10-100] 
FRONT THERMISTOR 
SENSED SIGNAL 



BLU 



DC140 [10-101] 
REAR THERMISTOR 
SENSED SIGNAL 

BLU 



VIO 



YEL 



2 — 1 
I I 



DOUBLE 
PLUG 

I I J212 

,1—2 



- 2 5 ■ 

I I YEL 



YEL 



2 — 1 
I I 



SENSOR 

ASSEMBLY 

PL7.2 



FRONT 
THERMISTOR 



SENSOR 

ASSEMBLY 

PL7.2 



REAR 
THERMISTOR 



T710000A-CAR 



Figure 1 Fuser Front and Rear Thermistor CD 



MCU PWE 
PL13.1 




CONTROL 
LOGIC 


+5VDC 
DC COM 

If 

+5VDC 

-%- 

DC COM I 




+24VDC 



MAIN 
HEATER 
ON 
J404 (H)+5VDC J590 



YEL 



DC COM 



YEL 



SUB 

HEATER 

ON 

(H) +5VDC 



YEL 



FUSER RELAY 
ON (L) +24VDC 



YEL 



+24VDC 




T710001A-CAR 



Figure 2 Fuser Main Heater and Sub Heater CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-183 



Status Indicator RAPs 

10-350 



10-351 Rear Thermistor Open 

The machine logic detected an open circuit in the Rear Thermistor. 

Procedure 

Turn off the power, remove the Fuser Assembly and allow it to cool down. 
Measure the resistance between P/J600-7 and P/J600-9 on the Fuser Assembly. The resis- 
tance is between 30 and 190 K Ohmis. 

Y N 
Check the Rear Thermistor for an open circuit and poor contact. If the check is OK, 
replace the Sensor Assembly (PL 7.2). 

Reinstall the Fuser Assembly, turn the power on, enter dC140 [010-101] and press Start. The 
display is between 678 and 699. 

Y N 

Turn the power off. Check for an open or poor connection between P/J404-1 3 on the MCU 
PWB and P/J600-7on the Fuser Assembly. If the check is OK, replace the MCU PWB (PL 
13.1). 

Replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



4T 



12 r 



J404 DC COM P641 



DOUBLE 
PLUG 
I 1 



J641 J600 P600 P21 



DOUBLE 
PLUG 

1 I I . 



DC COM 



CONTROL 
LOGIC -11 



BLU 

] DC140 [10-100] 

i FRONTTHERMISTOR 

! SENSED SIGNAL 



BLU 



l 13- 



DC COM 



DC COM 



CONTROL 
LOGIC - 14 



DC140 [10-101] 
REAR THERMISTOR 
SENSED SIGNAL 



VIO 



YEL 



VIO 



VIO 



2 — 1 
I I 



DOUBLE 
PLUG 

P212 ' ' J212 

1 — 2 



H 



YEL 



2 — 1 
I I 



I I 

Figure 1 Fuser Front and Rear Thermistor CD 



SENSOR 

ASSEMBLY 

PL7.2 



FRONT 
THERMISTOR 



SENSOR 

ASSEMBLY 

PL7.2 



REAR 
THERMISTOR 



T710000A-CAR 



Status Indicator RAPs 

10-351 



6/02 
2-184 



Prelaunch Training/Review 
DC1 632/2240 



10-352 Main Heater Warm Up 

The temperature did not reach the READY temperature within the specified time. 

Procedure 

Turn off the power, remove the Fuser Assembly, and allow it to cool down. 
Measure the resistance between P/J600-4 and P/J600-6 on the Fuser Assembly. 
The resistance is between 30 and 190 K Ohmis. 

Y N 
Check the Front Thermistor for an open circuit and poor contact. If the check is OK, 
replace the Sensor Assembly (PL 7.2). 

Measure the resistance between P/J600-3 and P/J600-12 on the Fuser Assembly. The resis- 
tance is 20 Ohmis or less. 

Y N 

Replace the Fuser Assembly (PL 7.1). 

Reinstall the Fuser Assembly, turn the power on, enter dC140 [010-100] and press Start. The 
display is between 678 and 699. 

Y N 

Turn the power off. Check for an open or poor connection between P/J404-12 on the MCU 
PWB and P/J600-6 on the Fuser Assembly. If the check is OK, replace the MCU PWB (PL 
13.1). 

There is Line Voltage measured at FS41 on the AC Drive PWB (PL 9.2). 

Y N 
There is +5VDC measured at P/J590-5 on the AC Drive PWB (PL 9.2). 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 



There is +24VDC measured at P/J590-1 on the AC Drive PWB (PL 9.2). 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 



Replace the AC Drive PWB (PL 9.2). 
Check the wires and connectors. If the check is OK, replace the Fuser Assembly (PL 7. 1 ). 



MCU PWB 
PL13.1 

4T 12 

DC COM 


CONTROL 
LOGIC 


- 11 


JT 13 

DC COM 


CONTROL 
LOGIC 


- 14 
1 



J404 DC COM P641 



BLU 

DC140 [10-100] 
FRONT THERMISTOR 
SENSED SIGNAL 



BLU 



DC140 [10-101] 
REAR THERMISTOR 
SENSED SIGNAL 

BLU 



DOUBLE 
PLUG 

I 1 

4 — 3 



J641 J600 P600 P211 



VIO 



YEL 



DOUBLE 
PLUG 

I 1 

1 — 2 



2 — 1 
I I 



J211 



DOUBLE 
PLUG 

I I J212 

,1—2 



- 2 5 ■ 

I I YEL 



YEL 



2 — 1 
I I 



Figure 1 Fuser Front and Rear Thermistor CD 



SENSOR 

ASSEMBLY 

PL7.2 



FRONT 
THERMISTOR 



SENSOR 

ASSEMBLY 

PL7.2 



REAR 
THERMISTOR 



T710000A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-185 



Status Indicator RAPs 

10-352 



MCU PWE 
PL13.1 




CONTROL 
LOGIC 


+5VDC 
DC COM 

If 

+5VDC 
DC COM I 




A. i 

+24VDC 



MAIN 
HEATER 
ON 
J404 (H)+5VDC J590 



YEL 



SUB 

HEATER 

ON 

(H) +5VDC 



FUSER RELAY 
ON (L) +24VDC 



YEL 




I " 



T710001A-CAR 



Figure 2 Fuser Main Heater and Sub Heater CD 



Status Indicator RAPs 

10-352 



6/02 
2-186 



Prelaunch Training/Review 
DC1 632/2240 



10-353 Main Heater On Time 

The Main Heater remained on for more than the specified time. 

Procedure 

Turn off the power, remove the Fuser Assembly, and allow it to cool down. 
Measure the resistance between P/J600-4 and P/J600-6 on the Fuser Assembly. 
The resistance is between 30 and 190 K Ohmis. 

Y N 
Check the Front Thermistor for an open circuit and poor contact. If the check is OK, 
replace the Sensor Assembly (PL 7.2). 

Measure the resistance between P/J600-3 and P/J60012 on the Fuser Assembly. The resis- 
tance is 20 Ohmis or less. 

Y N 

Replace the Fuser Assembly (PL 7.2). 

Reinstall the Fuser Assembly, turn the power on, enter dC140 [010-100]. The display is 
between 676 and 699. 

Y N 

Turn the power off. Check for an open or poor connection between P/J404-12 on the MCU 
PWB and P/J600-6 on the Fuser Assembly. If the check is OK, replace the MCU PWB (PL 
13.1). 

There is Line Voltage measured at FS41 on the AC Drive PWB (PL 9.2). 

Y N 
There is +5VDC measured at P/J590-5 on the AC Drive PWB (PL 9.2). 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 



There is +24VDC measured at P/J590-1 on the AC Drive PWB PL 9.2. 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 



Replace the AC Drive PWB (PL 9.2). 
Check the wires and connectors. If the check is OK, replace the Fuser Assembly (PL 7. 1 ). 



MCU PWB 
PL13.1 

4T 12 

DC COM 


CONTROL 
LOGIC 


- 11 


JT 13 

DC COM 


CONTROL 
LOGIC 


- 14 
1 



J404 DC COM P641 



BLU 

DC140 [10-100] 
FRONT THERMISTOR 
SENSED SIGNAL 



BLU 



DC140 [10-101] 
REAR THERMISTOR 
SENSED SIGNAL 

BLU 



DOUBLE 
PLUG 

I 1 

4 — 3 



J641 J600 P600 P211 



VIO 



YEL 



DOUBLE 
PLUG 

I 1 

1 — 2 



2 — 1 
I I 



J211 



DOUBLE 
PLUG 

I I J212 

,1—2 



- 2 5 ■ 

I I YEL 



YEL 



2 — 1 
I I 



Figure 1 Fuser Front and Rear Thermistor CD 



SENSOR 

ASSEMBLY 

PL7.2 



FRONT 
THERMISTOR 



SENSOR 

ASSEMBLY 

PL7.2 



REAR 
THERMISTOR 



T710000A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-187 



Status Indicator RAPs 

10-353 



MCU PWE 
PL13.1 




CONTROL 
LOGIC 


+5VDC 
DC COM 

If 

+5VDC 
DC COM I 




A. i 

+24VDC 



MAIN 
HEATER 
ON 
J404 (H)+5VDC J590 



YEL 



SUB 

HEATER 

ON 

(H) +5VDC 



FUSER RELAY 
ON (L) +24VDC 



YEL 




I " 



T710001A-CAR 



Figure 2 Fuser Main Heater and Sub Heater CD 



Status Indicator RAPs 

10-353 



6/02 
2-188 



Prelaunch Training/Review 
DC1 632/2240 



10-354 Sub Heater Warm Up 

The temperature did not reach the READY temperature. 

Procedure 

NOTE: To clear this fault, re-set the value of 
dC1 31 -744-003 to "0". 

Turn off the power, remove the Fuser Assembly, and allow it to cool down. Measure the resis- 
tance between P/J600-4 and P/J600-6 on the Fuser Assembly. The resistance is between 30 
and 190 KOhmis. 

Y N 
Check the Front Thermistor for an open circuit and poor contact. If the check is OK, 
replace the Sensor Assembly (PL 7.2). 

Reinstall the Fuser Assembly, turn the power ON. Enter dC140 [010-100]. The display value 
is between 678 and 699. 

Y N 

Turn the power off. Check for an open or poor connection between P/J404-1 2 and P/J404- 
HontheMCU PWBPL13.1. If the check is OK, replace the MCU PWB (PL 13.1). 

There is +3.4VDC measured at P/J404-5 on the MCU PWB. 

Y N 

Replace the MCU PWB (PL 13.1). 

A 



Check the wires and connectors. If the check is OK, replace the AC Drive PWB (PL 9.2). 



MCU PWB 
PL13.1 

4T 12 

DC COM 


CONTROL 
LOGIC 


- 11 


JT 13 

DC COM 


CONTROL 
LOGIC 


- 14 
1 



J404 DC COM P641 



BLU 

DC140 [10-100] 
FRONT THERMISTOR 
SENSED SIGNAL 



BLU 



DC140 [10-101] 
REAR THERMISTOR 
SENSED SIGNAL 

BLU 



DOUBLE 
PLUG 

I 1 

4 — 3 



J641 J600 P600 P211 



VIO 



YEL 



DOUBLE 
PLUG 

I 1 

1 — 2 



2 — 1 
I I 



J211 



DOUBLE 
PLUG 

I I J212 

,1—2 



- 2 5 ■ 

I I YEL 



YEL 



2 — 1 
I I 



Figure 1 Fuser Front and Rear Thermistor CD 



SENSOR 

ASSEMBLY 

PL7.2 



FRONT 
THERMISTOR 



SENSOR 

ASSEMBLY 

PL7.2 



REAR 
THERMISTOR 



T710000A-CAR 



MCU PWE 
PL13.1 




CONTROL 
LOGIC 


+5VDC 
DC COM 

If 

+5VDC 
DC COM I 




a. ; 

+24VDC 



MAIN 
HEATER 
ON 
J404 (H)+5VDC J590 



YEL 



SUB 

HEATER 

ON 

(H) +5VDC 



YEL 



FUSER RELAY 
ON (L) +24VDC 



YEL 



+24VDC 




T710001A-CAR 



Figure 2 Fuser Main Heater and Sub Heater CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-189 



Status Indicator RAPs 

10-354 



10-356 Sub Heater On Time 

The Sub Heater remained on for more than the specified time. 

Procedure 

Turn off the power, remove the Fuser Assembly, and allow it to cool down. 
Measure the resistance between P/J600-7 and P/J600-9 on the Fuser Assembly. The resis- 
tance is between 30 and 190 K Ohmi's. 

Y N 
Check the Rear Thermistor for an open circuit and poor contact. If the check is OK, 
replace the Sensor Assembly (PL 7.2). 

Measure the resistance between P/J600-3 and P/J600-12 on the Fuser Assembly. The resis- 
tance is 20 Ohmis or less. 

Y N 

Replace the Fuser Assembly (PL 7.1). 

Reinstall the Fuser Assembly, turn the power on, enter dC140 [010-101]. The display is 
between 678 and 699. 

Y N 

Turn the power off. Check for an open or poor connection between P/J404-1 3 on the MCU 
PWB and P/J600-7 on the Fuser Assembly. If the check is OK, replace the MCU PWB (PL 
13.1). 

There is Line Voltage measured at FS47 on the AC Drive PWB (PL 9.2). 

Y N 
There is +5VDC measured at P/J590-3 on the AC Drive PWB (PL 9.2). 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 



There is +24VDC measured at P/J590-1 on the AC Drive PWB (PL 9.2) 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 



Replace the AC Drive PWB (PL 9.2). 
Check the wires and connectors. If the check is OK, replace the Fuser Assembly (PL 7.1). 



MCU PWB 
PL13.1 

4T 12 

DC COM 


CONTROL 
LOGIC 


- 11 


JT 13 

DC COM 


CONTROL 
LOGIC 


- 14 
1 



J404 DC COM P641 



BLU 

DC140 [10-100] 
FRONT THERMISTOR 
SENSED SIGNAL 



BLU 



DC140 [10-101] 
REAR THERMISTOR 
SENSED SIGNAL 

BLU 



DOUBLE 
PLUG 

I 1 

4 — 3 



J641 J600 P600 P211 



VIO 



YEL 



DOUBLE 
PLUG 

I 1 

1 — 2 



2 — 1 
I I 



J211 



DOUBLE 
PLUG 

I I J212 

,1—2 



- 2 5 ■ 

I I YEL 



YEL 



2 — 1 
I I 



Figure 1 Fuser Front and Rear Thermistor CD 



SENSOR 

ASSEMBLY 

PL7.2 



FRONT 
THERMISTOR 



SENSOR 

ASSEMBLY 

PL7.2 



REAR 
THERMISTOR 



T710000A-CAR 



Status Indicator RAPs 

10-356 



6/02 
2-190 



Prelaunch Training/Review 
DC1 632/2240 



MCU PWE 
PL13.1 




CONTROL 
LOGIC 


+5VDC 
DC COM 

If 

+5VDC 
DC COM I 




A. i 

+24VDC 



MAIN 
HEATER 
ON 
J404 (H)+5VDC J590 



YEL 



SUB 

HEATER 

ON 

(H) +5VDC 



FUSER RELAY 
ON (L) +24VDC 



YEL 




I " 



T710001A-CAR 



Figure 2 Fuser Main Heater and Sub Heater CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-191 



Status Indicator RAPs 

10-356 



10-398 Fan Lock 

The machine logic detected a failure of the Fuser Fan, LVPS Fan or the Rear Fan. 

Procedure 

Enter dC330 [004-050]. The Fuser Fan revolves at high speed. 
Y N 

There is +24VDC measured at J222-4. 

Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 



With dC330 [004-050] entered, stack dC330 [004-200] and press Start. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 

13.1). 

Replace the Fuser Fan (PL 8.1). 



The Rear Fan revolves at high speed (PL 8.1). 
Y N 

There is +24VDC measured at J552-1 . 

Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). If the problem continues replace the l/F PWB (PL 9.1). 



With dC330 [004-050] entered, stack dC330 [004-200] and press Start. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 

13.1). 

Replace the Rear Fan (PL 8.1). 



The LVPS Fan revolves at high speed (PL 9.1). 
Y N 

There is +24VDC measured at J214-4. 

Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 
13.1). 



With dC330 [004-050] entered, stack dC330 [004-200] and press Start. The display is H. 
Y N 

Check the wires and connectors. If the check is OK, replace the MCU PWB (PL 

13.1). 



Replace the LVPS Fan (PL 9.1). 
The Fans are operating correctly. If the problem continues replace the MCU PWB (PL 13.1). 



MCU PWB 
PL13.1 



DC330 [004-050] ™ 

FUSER FAN HIGH l K L U ^ l 

J407 SPEED (L) +24VDC J222 ' ' P222 



+24VDC 
DC COM 



BLU 



DC330 [004-200] 
FUSER FAN 
LOCKED (H) +3.3VDC 



3 — 2 



BLU 




T710007A-CAR 



Figure 1 The Fuser Fan CD 




MCU PWB 
PL13.1 



l/F PWB 
PL9.1 



P/J410 
62, — 



DC330 [004-050] 
REAR FAN HIGH 
SPEED (L) +24VDC 



-24VDC 
DC COM 



DC330[004-200] 
REAR FAN 
LOCKED(H)+3.3VDC 




T710009A-CAR 



Figure 2 The Rear Fan CD 



Status Indicator RAPs 

10-398 



6/02 
2-192 



Prelaunch Training/Review 
DC1 632/2240 



MCU PWB 
PL13.1 



DC330 [004-050] 
LVPS FAN HIGH 
J407 SPEED (L) +24VDC J214 I ' P214 

B12, „,,, r 3-2 



+24VDC 
DC COM 



? 



DC330 [004-200] 

LVPS FAN 

LOCKED (H) +3.3VDC 



BLU 




T710008A-CAR 



Figure 3 The LPVS Fan CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-193 



Status Indicator RAPs 

10-398 



10-420 Fuser Near End Of Life 

Replace the Fuser Assembly in X copies. 

Procedure 

The Fuser Assembly was replaced. 

Y N 

Replace the Fuser Assembly (PL 7.2) 

Run the dC135 [954-804]. The initial value is 0. 

Y N 

Replace the MCU PWB (PL 13.1). 

Ensure that the LIFE setting value is 100K, turn power OFF/ON. 
If the problem continues, replace the MCU PWB (PL 13.1). 



10-421 Fuser End Of Life 

Fuser at end of life. 

Procedure 

The Fuser Assembly was replaced. 

Y N 

Replace the Fuser Assembly (PL 7.2). 

Run the dC135 [954-804]. The initial value is 0. 

Y N 

Replace the MCU PWB (PL 13.1). 

Ensure that the LIFE setting value is 100K, turn power OFF/ON. 
If the problem continues, replace the MCU PWB (PL 13.1). 



Status Indicator RAPs 

10-420,10-421 



6/02 
2-194 



Prelaunch Training/Review 
DC1 632/2240 



12-100 H Transport Entrance Sensor On 

The H Transport Entrance Sensor does not detect paper within the specific time after the Reg- 
istration Clutch (in IOT) actuated. 

Procedure 

Enter dC330 [012-001] and press Start. The Finisher Drive Motor energizes. 

Y N 

Press Stop. Repair the drives as required (PL 17.7) for mechanical problems. If the 
drives are mechanically good, check the circuit of the Finisher Drive Motor (Figure 4). +5 
VDC is measured between J846-3 on the Finisher PWB and Finisher PWB Chassis 

(-)■ 
Y N 

Check the wire between J846-3 on the Finisher PWB and J879-1 on the Finisher 

Drive Motor PWB. 

If the wire is good, replace the Finisher Drive Motor (PL 17.7). 



Press Start and check the voltage between J846-3 on the Finisher PWB and Finisher 
PWB Chassis (-). Less than +1 VDC is measured. 

Y N 
Replace the Finisher PWB (PL 17.3). 

Check the voltage between J846-7 and -5 on the Finisher PWB and Finisher PWB Chas- 
sis (-). +24 VDC is measured. 

Y N 
Replace the Finisher PWB (PL 17.3). 

Check the resistance between J846-11 and -9 on the Finisher PWB and Finisher PWB 
Chassis (-). Less than 10 ohms is measured. 

Y N 
Replace the Finisher PWB (PL 17.3). 

Replace the Finisher Drive Motor (PL 17.3). 



Enter dC330 [012-103] and press Start. Actuate and deactuate the H Transport Entrance Sen- 
sor. The display changes. 

Y N 
Repair the sensor as required (PL 17.4) for mechanical problems. If the sensor is 
mechanically good, check the circuit of the H Transport Entrance Sensor (Figure 2). 

Enter dC330 [012-060 or 061] and press Start. The gate changes position. 

Y N 

Repair the gate as required (PL 17.4) for mechanical problems. If the gate linkage is 
mechanically good, check the circuit of the Gate In Solenoid (Figure 3). 

Check the following: 

i Paper path failure for burr and foreign substance. 

T H-Transport Belt for contamination, wear and a drive failure 

i Sensor Actuator for breakage 



Entrance 
Sensor 



Gate In 
Solenoid 




0102032A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



■ A5 



J845 DC COM J 861 ,, J859A 

[vio 



-"L +| 



■B5b 



+5 VDC 



CONTROL 
LOGIC 



5 VDC | i DC330 [12-103] 

PAPER SENSED 
(H) +5 VDC 



— *— A4 1 

, YEL 




YEL 



■2 — 5 



T712013A-CAR 



Figure 2 H Transport Entrance Sensor CD 



FINISHER PWB 


PL17.13 


INTERLOCKED^ 


+24 VDC >] 


CONTROL 


r^ 


LOGIC 


4> B1 




-I 

DC COM 




-5-- 






INTERLOCKED J* 


+24 VDC r 



DC330 [12-060] 
PAPER TO FINISHER 
J845 (H) +24 VDC J881 



DOUBLE 
PLUG 



DC330 [12-061] 

PAPER TO TOP TRAY 

(H) +24 VDC l~ 



2 — 2 



GATE IN 

SOLENOID 

PL17.4 



T712008A-CAR 



Figure 3 Gate In Solenoid CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-195 



Status Indicator RAPs 

12-100 



FINISHER PWB 
PL17.13 



CONTROL 
LOGIC 



DC COM 



DC330 [12-001] 
FINISHER DRIVE 
MOTOR ON 
P846 (L)+5VDC 



J879 



FINISHER 
DRIVE 
MOTOR 
PL17.7 



+5VDC 



INTERLOCKED 
+24VDC 



JT 



Iyel 


DC330 [12-001] ! 
FINISHER DRIVE MOTOR i 
BRAKE ON (L) +5 VDC | 


! YEL 


INTERLOCKED ! 
+24 VDC | 


lORN 


INTERLOCKED ! 
+24 VDC | 


lORN 


DC COM ; 


! VIO 


DC COM | 



+5 VDC 



CONTROL 
LOGIC 




T712010A-CAR 



Figure 4 Finisher Drive Motor CD 



P848 



CN2 



P849 

"| i i i i i i i Q 






1 nmn P852 
/\ An 1 1 1 1 1 1 1 a j 1nn4 1 1fl 



Figure 5 Finisher PWB 



T712036A-CAR 



Status Indicator RAPs 

12-100 



6/02 
2-196 



Prelaunch Training/Review 
DC1 632/2240 



12-102 H Transport Entrance Sensor Off 

Paper did not deactuate the H Transport Entrance Sensor. 

Procedure 

Open the H Transport. Check H Transport Belts, H Transport Belt Drive Rolls, and Guides on 
H Transport Cover for installation or damage problems. The components are good. 

Y N 
Repair as required (PL 17.3, PL 17.4). 

Rerun the job. The problem continues. 

Y N 

Return to Service Call Procedures. 

Replace the H Transport Entrance Sensor for intermittent operation (PL 17.4). 
NOTE: If the sensor fails H, 12-901 is declared after power is switched on. 



Entrance 
Sensor 




0102032A-CAR 



Figure 1 Component Location 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-197 



Status Indicator RAPs 

12-102 



12-104 H Transport Exit Sensor On 

The H Transport Exit Sensor did not detect paper within the specific time after the H Transport 
Entrance Sensor has detected the paper. (The specified time differs depending on the paper 
size.) 

Procedure 

Enter dC330 [012-104] and press Start. Actuate and deactuate the H Transport Exit Sensor. 

The display changes. 

Y N 

Repair the sensor as required (PL 17.4) for mechanical problems. If the sensor is 
mechanically good, check the circuit of the H Transport Exit Sensor (Figure 2). 

Check H Transport Belts, H Transport Belt Drive Rolls, and Guides on H Transport Cover for 
installation or damage problems. Repair as required (PL 17.3, PL 17.4). 



Entrance 
Sensor 



Interlock 
Sensor 




P848 



CN2 



P849 

"| i i i i i i i Q 



/\ a q 1 1 1 1 1 1 1 ft j 1 cm 4 1 muni ! 

ft1 ^P850 A1 P851 P843 



Figure 3 Finisher PWB 



13 

3 H 



T712036A-CAR 



0102032A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



DOUBLE 
PLUG 



47 



■ B6 



J845 DC COM J8 61 _ J858A 

VIO 



EXIT 

SENSOR 

PL17.4 



DC COM 



+5VDC 



'-L. +: 



+5VDC 



,._„ , ,GRY 

■5VDC | i DC330 [12-104] 



CONTROL 
LOGIC 



a 



B7 1 - 



PAPER SENSED 
(H) +5 VDC 



VIO 



GRY 



J 7 4 



1 — 3 ■ 



2 — 2 ■ 



VIO 



GRY 



j<fiSSl: 



T712012A-CAR 



Figure 2 H Transport Exit Sensor CD 



Status Indicator RAPs 

12-104 



6/02 
2-198 



Prelaunch Training/Review 
DC1 632/2240 



12-106 H Transport Exit Sensor Off 

Paper did not deactuate the H Transport Exit Sensor. 

Procedure 

Enter dC330 [012-217] and press Start. Actuate and deactuate the Decurler Cam Home Sen- 
sor. The display changes. 

Y N 
Check the circuit of the Decurler Cam Home Sensor (Figure 2). 

Enter dC330 [012-070] and press Start. The Decurler Cam Clutch energizes. 

Y N 

Check the circuit of the Decurler Cam Clutch (Figure 3). 

Check the following: 

i Paper path failure for burr and foreign substance. 

i H Transport Belt Drive Roll for contamination, wear and a drive failure 

i Drive Transmission Gear from the Finisher Drive Motor for wear and breakage 

i H Transport and Finisher for a docking failure 

i Decurler Roll/pinch Roll for a drive failure 

i Compiler Entrance Roll for a drive failure 



Decurler 
Clutch 




Decurler 
Cam 
Home 
Sensor 



0102033A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



J849 DC COM 



HOME 

SENSOR 

PL17.8 



ivio 



"L +5 



3 I- 



GRY 



GRY 



|(£>*d : 



J884 



+5VDC 



CONTROL 
LOGIC 



a 



T712001A-CAR 



Figure 2 Decurler Cam Home Sensor CD 



FINISHER PWB 
PL17.13 



CONTROL 
LOGIC 



fe~ 



DC330 [12-070-071] 
DECURLER CAM CLUTCH 
J846 ON(L)+24VDC 



DC COM 

I W" 1 

J~ RT5 



BLU 



BLU 



INTERLOCKED 
+24VDC 



RT5 
INTERLOCKED 
+24VDC 



ORN 



ORN 



DOUBLE 
PLUG 



2 — 2 



1 — 1 
I I 





DECURLER 




CAM CLUTCH 


P880 


PL17.7 




~\ 








r 















T712014A-CAR 



Figure 3 Decurler Cam Clutch CD 



A12r 



P849 

"| i i i i i i i Q 



3 B1 2 C 



1 mm p852 
. , q Rrffn , , 1nn4 1 10 



T712036A-CAR 



Figure 4 Finisher PWB 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-199 



Status Indicator RAPs 

12-106 



12-120 Compiler Entrance Sensor On 

The Compiler Entrance Sensor did not detect paper. 

Procedure 

Enter dC330 [012-101] and press Start. Actuate and deactuate the Complier Entrance Sen- 
sor. The display changes. 
Y N 

Check the circuit of the Complier Entrance Sensor (Figure 2). 

Check the following: 

i Complier Entrance Sensor Actuator for breakage and bending 

i Paper path failure for burr and foreign substance. 

T Decurler Roll/pinch Roll for a drive failure 

i Drive Transmission Gear from the Finisher Drive Motor for wear and breakage 



P848 



CN2 



P849 

"| i i i i i i i Q 



a B1 2™™14 



1 amn P852 

.". 1 o r rrrrn A , inn4 1 in 

A1 ^P850 A1 P851 P843 



6cm4 



T712036A-CAR 



Decurler Clutch. 



Compiler 
Entrance 
Sensor 




Home 
Sensor 



Figure 3 Finisher PWB 



0102033A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



J850 DC COM 



4~ 

DC COM 

~ +5 VDC 
+5VDC 



iVIO 



VIO 



DOUBLE 
PLUG 



J870B I I J870A J867 

3 — 4 



B9 !■ 



+5 VDC 



VIO 



CONTROL 
LOGIC 



iX, 



GRY DC330 [12-101] GRY 

COMPILER ENTRANCE 
PAPER SENSED 
(H) +5 VDC 



COMPILER ENTRANCE 

SENSOR 

PL17.12 



j<fiS<5l: 



YEL 



YEL 



2 — 5 ■ 



YEL 



T712015A-CAR 



Figure 2 Compiler Entrance Sensor CD 



Status Indicator RAPs 

12-120 



6/02 
2-200 



Prelaunch Training/Review 
DC1 632/2240 



12-122 Compiler Entrance Sensor Off 

Paper does not deactuate the Compiler Entrance Sensor. 

Procedure 

Make a copy and observe paper in the Compiler Tray. The copy enters the Compiler Tray. 
Y N 

There is a drives problem. Check the following: 

i The paper path failure for burr and foreign substance. 

i The Drive Transmission Gear from the Finisher Drive Motor for wear and breakage 

i The Decurler Roll/pinch Roll for a drive failure 

T The Compiler Entrance Roll for a drive failure 

Repair the sensor as required (PL 17.4) for mechanical problems. If the sensor is mechani- 
cally good, replace the Compiler Entrance Sensor. 



Decurler Clutch. 



Compiler 
Entrance 
Sensor 




Home 
Sensor 



0102033A-CAR 



Figure 1 Component Location 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-201 



Status Indicator RAPs 

12-122 



12-170 Set Eject 

The Compiler Paper Sensor did not deactuate after the Eject Motor energized. 

Procedure 

Enter dC330 [012-102] and press Start. Actuate and deactuate the Compiler Paper Sensor. 

The display changes. 

Y N 

Repair the sensor as required (PL 17.10) for mechanical problems. If the sensor is 
mechanically good, check the circuit of the Compiler Paper Sensor (Figure 2). 

Check the following: 

i Eject Roll for contamination, wear and a drive failure 

i Drive Transmission Gear from the Eject Motor for wear and breakage 

i Eject Clamp for an up and down movement failure 

i Stacker Tray for foreign substance 



P848 



CN2 



P849 

"| i i i i i i i Q 



B8 B1 



ft An 1 1 1 1 1 1 1 a j 1cm 4 1 1fl 

A1 ^P850 A1 P851 P843 



Figure 3 Finisher PWB 



13 

3 H 



6cm4 



T712036A-CAR 



Compiler 

Paper 

Sensor 




0102034A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



J848 DC COM 



COMPILER PAPER 

SENSOR 

PL17.10 



XT 

DC COM 



iVIO 



VIO 



A, +! 



■ A6k 



+5VDC 



,._„ , ,GRY , , GRY 

■5VDC | , DC330 [12-102] 



CONTROL 
LOGIC 



, b YEL 



COMPILED PAPER 
(H) +5 VDC 



j<pp3 



J875 
YEL 



T712004A-CAR 



Figure 2 Compiler Paper Sensor CD 



Status Indicator RAPs 

12-170 



6/02 
2-202 



Prelaunch Training/Review 
DC1 632/2240 



12-241 Staple Move Sensor On 



i The Staple Move Sensor did not turn on within 2sec after the system has started to move 
to the Staple Position and the Staple Move Sensor has turned off. 

i The Staple Move Sensor did not turn on after the move to the Staple Position has com- 
pleted. 

Procedure 

The Staple Head move smoothly without any load. 

Y N 

Remove the cause of Staple Head not moving, such as rail breakage, drag, and gnawed 
gear. 

Cheat the Front Cover Interlock Switch. Enter dC330 [012-224] and press Start. Actuate the 
Staple Move Sensor with paper. The display changes. 

Y N 
Repair the Staple Move Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-081] (front direction) or [12-083] (rear direction) and press Start. The Sta- 
ple Move Motor energized. 

Y N 
+24 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis 

(-)■ 
Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Stapler Move Motor p/j for an open 

circuit or poor contact. 

If no problems are found, replace the Stapler Assembly (PL 17.9). 

If the problem continues, replace the Finisher PWB (PL 17.13). 



Replace the Finisher PWB (PL 17.13). 



Staple Front 
Corner Sensor 




Staple Move Sensor 



0102035A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



J852 DC COM 



J885 



STAPLE MOVE 

SENSOR 

PL17.9 



iVIO 



'-L +: 



+5 VDC 



■5 VDC | i GRY DC330 [12-225] GRY 



|(£>*d : 



CONTROL 
LOGIC 



\l\ 



STAPLE MOVE 
(H) +5 VDC 



T712016A-CAR 



Figure 2 Stapler Move Sensor CD 



P848 



CN2 



P849 

"| i i i i i i i Q 



13 
a B"i 2 cmifl 14 



1 nmn P852 

A jq rrrrrn » * icm4 1 in 



Figure 3 Finisher PWB 



T712036A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-203 



Status Indicator RAPs 

12-241 



12-242 Staple Move Sensor Off 



i The Staple Move Sensor did not turn off within 500ms after the move to the Staple Posi- 
tion has started. 

i The Staple Move Sensor turned off after Staple Position has been fixed. 

i The Staple Move Sensor did not turn off within 500ms after it has turned on when paper 
passed through the 1st position of the DUAL STAPLE at moving to the Rear Staple Posi- 
tion. 

Procedure 

Open the Finisher Front Cover. Turn the Stapler Assembly manually. 

Y N 

Remove the cause of Staple Head not moving, such as rail breakage, drag, and gnawed 
gear. 

Cheat the Front Cover Interlock Switch. 

Enter dC330 [12-224] and press Start. Actuate the Staple Move Sensor with paper. The dis- 
play changes. 

Y N 
Repair the Staple Move Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-081] (front direction) or [12-083] (rear direction )and press Start. The Sta- 
ple Move Motor energized. 

Y N 
+24 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis 

(-)■ 
Y N 

Replace the Finisher PWB (PL 17.13) 

Check the wire between the Finisher PWB p/j and the Stapler Move Motor p/j for an open 

circuit or poor contact. 

If no problems are found, replace the Stapler Move Motor (PL 17.9). 

If the problem continues, replace the Finisher PWB (PL 17.13) 

Replace the Finisher PWB (PL 17.13) 



FINISHER PWB 
PL17.13 



47 



J852 DC COM 



J885 



STAPLE MOVE 

SENSOR 

PL17.9 



iVIO 



'-L +: 



+5 VDC 



■5 VDC | i GRY DC330 [12-225] GRY 



|(£>*d : 



CONTROL 
LOGIC 



\l\ 



STAPLE MOVE 
(H) +5 VDC 



T712016A-CAR 



Figure 2 Stapler Move Sensor CD 



P848 



CN2 



P849 

"| i i i i i i i Q 



13 
a B"i 2 cmifl 14 



1 nmn P852 

A jq rrrrrn » * icm4 1 in 



Figure 3 Finisher PWB 



T712036A-CAR 



Staple Front 
Corner Sensor 




Staple Move Sensor 

Figure 1 Component Location 



0102035A-CAR 



Status Indicator RAPs 

12-242 



6/02 
2-204 



Prelaunch Training/Review 
DC1 632/2240 



12-244 Staple Home Sensor 

The Staple Head Home Sensor never turn on within 200ms after the STAPLER MOTOR 
started to revolve backward (open). 

Procedure 

Enter dC330 [012-207] and press Start. Turn the Staple Head Home Sensor on/off using 
paper. The display changes. 
Y N 

+5 VDC is measured between the Stapler Assembly p/j (+) and Finisher PWB Chas- 
sis (-). 
Y N 

+5 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chas- 
sis (-). 
Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Stapler Assembly p/j for an 
open circuit or poor contact. 



Turn the Staple Motor Gear manually in order not to interrupt the SENSOR. +5 VDC is 
measured between the Finisher PWB p/j (+) and Finisher PWB Chassis (-). 

Y N 
Switch off the power. 
Pull out the on the Finisher PWB. 

Turn on the power. +5 VDC is measured between the Finisher PWB p/j (+) and 
Finisher PWB Chassis (-). 

Y N 
Replace the Finisher PWB (PL 17.13). 

Check the circuit between the p/j and the Stapler Assembly p/j for short circuit. 

Block the sensor. VDC is measured between the Finisher PWB p/j (+) and Finisher 
PWB Chassis (-). 

Y N 
VDC is measured between the Stapler Assembly p/j (+) and Finisher PWB 
Chassis (-). 

Y N 
Replace the Stapler Assembly (PL 17.9). 

Check the wire between the Stapler Assembly p/j and the Finisher PWB p/j for an 
open circuit or poor contact. 

Replace the Finisher PWB (PL 17.13). 



Enter dC330 [012-020] (CLOSE). The STAPLE MOTOR energizes. 
Y N 

With [12-020] running +24 VDC is measured between the Finisher PWB p/j (+) and 

Finisher PWB Chassis (-). 

Y N 

Replace the Finisher PWB (PL 17.13). 

— B 



A B 

Check conductivity of the following: 

Between the Finisher PWB p/j ~ Stapler Assembly p/j 
Between the Finisher PWB p/j ~ Stapler Assembly p/j 
Between the Finisher PWB p/j ~ Stapler Assembly p/j 

i' Between the Finisher PWB p/j ~ Stapler Assembly p/j 

If no problems are found, replace the Stapler Assembly (PL 17.9). 

If the problem continues, replace the Finisher PWB (PL 17.13). 



Replace the Finisher PWB (PL 17.13). 



Staple Front 
Corner Sensor 




Staple Move Sensor 

Figure 1 Component Location 



0102035A-CAR 



FINISHER PWB 
PL17.13 



47 



J852 DC COM 



STAPLER ASSEMBLY 
PL17.9 



"L +5 



+5 VDC 



CONTROL 
LOGIC 



li 



YEL 



YEL 



DC330 [12-207] 
STAPLE HOME 
(L) +5 VDC 



STAPLE HEAD 
HOME SENSOR 



jgfjg-- 



T712020A-CAR 



Figure 2 Staple Head Home Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-205 



Status Indicator RAPs 

12-244 



FINISHER PWB 
PL17.13 



DC COM 




T712037A-CAR 



Figure 3 Stapler Assembly Logic Power CD 



A12r 



,A1 



, P845 , 



P849 

"| i i i i i i i Q 



3 B1 2™14 



1 nam P852 

A1 ^P850 A1 P851 P843 



3 tttl 1 
J P844' 



Figure 4 Finisher PWB 



T712036A-CAR 



Status Indicator RAPs 

12-244 



6/02 
2-206 



Prelaunch Training/Review 
DC1 632/2240 



12-252 Front Tamper 



i With the Front Tamper Home Sensor off the Front Tamper Home Sensor did not turn on 
within 800ms after move to the Front Tamper Home position has begun. 

i With the Front Tamper Home Sensor on The Front Tamper Sensor did not turn off when 
the Front Tamper Home Sensor is deactuating. 

Procedure 

Enter dC330 [012-091] (front) or [12-094] (rear) and press Start. The Front Tamper Guide 
moves. 

Y N 
The Front Tamper Motor energized. 
Y N 

+24 VDC is measured between J848-B7 or B9 or B10 or B12 on the Finisher 
PWB and Finisher PWB Chassis (-). 
Y N 

+24 VDC is measured between J848-B8 or B11 on the Finisher PWB p/j (+) 

and Finisher PWB Chassis (-). 

Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Front Tamper Motor p/j 

for a short circuit, open circuit, or poor contact. 

If the wires and connections are good, replace the Front Tamper Motor (PL 

17.10). 

Replace the Finisher PWB (PL 17.13). 

Check the tamper mechanism for load or drive transmission failure (gear wear or break- 
age.). 

Enter dC330 [012-216] and press Start. 

Move the Front Tamper manually and turn the Front Tamper Home Sensor on/off. The display 

changes. 

Y N 
Check the Front Tamper Home Sensor using the Generic Transmissive Sensor RAP. 

Replace the Finisher PWB (PL 17.13). 



Front Compiler Front Tamper Motor 

Tamper Paper Connection 

Home Sensor 
Sensor 




Rear Tamper 
Rear Tamper Motor Home Sensor 
Connection 



0102034A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



J848 DC COM 



J876 



FRONT TAMPER 
HOME SENSOR 
PL17.10 



ivio 



'-L +: 



- A3k 



+5 VDC 



GRY 

■5 VDC | i DC330 [12-216] 



GRY 



|(£>*d : 



J876 



CONTROL 
LOGIC 



a 



A2 '■ 



FRONT TAMPER HOME 
(H) +5 VDC 



T712005A-CAR 



Figure 2 Front Tamper Home Sensor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-207 



Status Indicator RAPs 



FINISHER PWB 
PL17.13 



CONTROL 
LOGIC 



DC COM I 
DC COM 
DC COM 



DC330 [12-091 -096] 
FRONT TAMPER MOTOR 
J848 ON +24VDC PULSED J877B 



-B11 



+24VDC 
INTERLOCKED 



RED DC330 [12-091 -096] 

FRONT TAMPER MOTOR 
ON+24VDC PULSED 



RED DC330 [12-091 -096] 

FRONT TAMPER MOTOR 
ON +24VDC PULSED 



RED DC330 [12-091 -096] 

FRONT TAMPER MOTOR 
ON +24VDC PULSED 



RED 



+24VDC 
INTERLOCKED 



+24VDC 
INTERLOCKED 



ORN 



J877A 


FRONT 
TAMPER 
MOTOR 
PL17.10 




\ 




Y 




(mot) 




T 




/ 







T712006A-CAR 



Figure 3 Front Tamper Motor CD 



P848 



CN2 



P849 

"| i i i i i i i Q 






1 nmn P852 
/\ An 1 1 1 1 1 1 1 a j 1nn4 1 1fl 



T712036A-CAR 



Figure 4 Finisher PWB 



Status Indicator RAPs 



6/02 
2-208 



Prelaunch Training/Review 
DC1 632/2240 



12-253 Rear Tamper 



i With the Rear Tamper Home Sensor off The Rear Tamper Home Sensor did not turn on 
within 800ms after move to the Rear Tamper Home position has begun. 

i With the Rear Tamper Home Sensor on: The Rear Tamper Home Sensor did not turn off 
when the Rear Tamper Home Sensor is deactuating. 

Procedure 

Enter dC330 [012-010] (front) or [12-013] (rear) and press Start. The Rear Tamper Guide 
energizes. 

Y N 
The Rear Tamper Motor energizes. 
Y N 

+24 VDC is measured between J848-B1 or B3 or B4 or B6 on the Finisher PWB 
and Finisher PWB Chassis (-). 
Y N 

+24 VDC is measured between J848-B2 or B5 on the Finisher PWB and 

Finisher PWB Chassis (-). 

Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Rear Tamper Motor p/j 

for a short circuit, open circuit, or poor contact. 

If the wires and connections are good, replace the Front Tamper Motor (PL 

17.10). 

Replace the Finisher PWB (PL 17.13). 

Check the tamper mechanism for load or drive transmission failure (gear wear or break- 
age). 

Enter dC330 [012-212] and press Start. Move the Rear Tamper manually and turn the Rear 
Tamper Home Sensor on/off. The display changes. 

Y N 
Check the Rear Tamper Home Sensor using the Generic Transmissive Sensor RAP. 

Replace the Finisher PWB (PL 17.13). 



FINISHER PWB 
PL17.13 



47 



■ A7 



J848 DC COM 



J874 



REAR TAMPER 
HOME SENSOR 
PL17.10 



VIO 



'-L +: 



■ A9k 



+5 VDC 



GRY 

■5 VDC | i DC330 [12-212] 



GRY 



|(£>*d : 



CONTROL 
LOGIC 



a 



A8 '■ 



REAR TAMPER HOME 
(H) +5 VDC 



Figure 2 Rear Tamper Home Sensor CD 



FINISHER PWB 
PL17.13 



CONTROL 
LOGIC 



DC COM I 
DC COM 
DC COM | 



DC330 [12-010 -015] 
REAR TAMPER MOTOR 
J848 ON +24 VDC PULSED J878B 



DOUBLE 
PLUG 



DC COM 



RT4: 



+24 VDC 
INTERLOCKED 



RED DC330 [12-010 -015] 
REAR TAMPER MOTOR 
ON +24 VDC PULSED 



RED DC330 [12-010 -015] 
REAR TAMPER MOTOR 
ON +24 VDC PULSED 



RED DC330 [12-010 -015] 
REAR TAMPER MOTOR 
ON +24 VDC PULSED 



RED 



+24 VDC 
INTERLOCKED 



ORN 



+24 VDC 
INTERLOCKED 



Figure 3 Rear Tamper Motor CD 



T712003A-CAR 



J878A 


REAR 
TAMPER 
MOTOR 
PL17.10 




\ 




Y 




(mot) 




T 




/ 







T712007A-CAR 



Front 
Tamper 
Home 
Sensor 



Compiler 

Paper 

Sensor 



Front Tamper Motor 
Connection 




Rear Tamper 
Rear Tamper Motor Home Sensor 
Connection 



0102034A-CAR 



Figure 1 Component Location 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-209 



Status Indicator RAPs 

12-253 



P848 



CN2 



P849 

"| i i i i i i i Q 



Bin 

A12? 



□ B12 

~ A1 






P851 P843 



T712036A-CAR 



Figure 4 Finisher PWB 



Status Indicator RAPs 

12-253 



6/02 
2-210 



Prelaunch Training/Review 
DC1 632/2240 



1 2-254 Stacker Tray 



i The Stack Height Sensor did not detect that the tray went down within 500ms after the 

Stacker Tray lowered at initialization, 
i The Stack Height Sensor did not detect that the tray went up within 5sec after the Stacker 

Tray lifted up. 

Procedure 

Check the Stack Height Sensor Actuator for disengagement, bending, and breakage. 

Enter dC330 [012-201] and press Start. Manually turn the Stack Height Sensor Actuator to turn 

the Stack Height Sensor on/off. The display changes. 

Y N 
Check the Stack Height Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-050] (up) or [12-051] (down) and press Start. The Stacker Tray moves. 

Y N 
Stacker Motor energized. 
Y N 

With [12-050] (up) running. +24VDC is measured between the Finisher PWB p/j 
(+) and Finisher PWB Chassis (-). 
Y N 

Replace the Finisher PWB (PL 17.13). 



With [12-050] (up) running. +24 VDC is measured between the Stacker Motor p/j 
(+) and Finisher PWB Chassis (-). 

Y N 

Check the wire between the Finisher PWB p/j and the Stacker Motor p/j for an 
open circuit or poor contact. 

With [12-050] (up) running +24 VDC is measured between the Stacker Motor p/j 
(+) and Finisher PWB Chassis (-). 

Y N 

Replace the Stacker Motor (PL 17.11). 

Check the wire between the Finisher PWB p/j and the Stacker Motor p/j for an open 

circuit or poor contact. 

If no problems are found, replace the Stacker Motor (PL 17.11). 

If the problem continues, replace the Finisher PWB (PL 17.13). 



Check the following: 

i The Stacker Motor Gear for wear and damage 

i The Stacker Tray for dragging and improper installation 

i The Stacker Elevator Belt/rack/gear for wear and damage 

Remove the other mechanical causes of the Stacker Tray not operating. 

Replace the Finisher PWB (PL 17.13). 



Stack 

Height 

Sensor 




Stacker 
Motor 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



J850 DC COM 



4T~ 

DC COM 



i VIO 



DOUBLE 
PLUG 



J870B I I J870A J868 

■ 6 — 1 



STACK HEIGHT 

SENSOR 

PL17.6 



VIO 



■Bel- 



ts VDC 



VIO 



-<■ +5 VDC I ! GRY DC330 [12-200] GRY 

+5 VDC ~C I ! STACK HEIGHT SENSED 



4 — 3 ■ 



CONTROL 
LOGIC 



-*-B5'- 



(H) +5 VDC 



j<pp3 



YEL 



T712027A-CAR 



Figure 2 Stack Height Sensor 



FINISHER PWB 
PL17.13 

+24 VDC 
INTERLOCKED 



CONTROL 
LOGIC 



+24 VDC 
INTERLOCKED 




DC330 [12-050] 
STACKER UP 
J847 (H) +24 VDC 



DC330 [12-051] 
STACKER DOWN 
(H) +24 VDC 




T712029A-CAR 



Figure 3 Stacker Motor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-211 



Status Indicator RAPs 

12-254 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 4 Finisher PWB 



Status Indicator RAPs 

12-254 



6/02 
2-212 



Prelaunch Training/Review 
DC1 632/2240 



12-255 Stacker Tray Upper Limit 



i The system detected that the Stacker Tray Upper Limit Sensor was turned on after the 
Stacker Tray had begun lifting up. 

i The system detected that the Stacker Tray Upper Limit Sensor remained on when lower- 
ing down of the Stacker Tray has completed. 

Procedure 

Enter dC330 [012-202] and press Start. Actuate the Upper Limit Sensor. The display 

changes. 

Y N 

Check the Upper Limit Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-201] and press Start. Actuate the Stack Height Sensor. The display 

changes. 

Y N 

Check the Stack Height Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-051] (down) on and press Start. The Stacker Tray moves. 

Y N 
Stacker Motor energized. 

Y N 
With [12-050] (down) running +24 VDC is measured between the Finisher PWB 
p/j (+) and Finisher PWB Chassis (-). 

Y N 
Replace the Finisher PWB (PL 17.13). 

Check conductivity of the following: 

T Between the Finisher PWB p/j and the Stacker Motor p/j 
T Between the Finisher PWB p/j and the Stacker Motor p/j 
If no problems are found, replace the Stacker Motor (PL 17.11). 
If the problem continues, replace the Finisher PWB (PL 17.13). 

Check the following: 

i The Stacker Motor Gear for wear and damage 

i The Stacker Tray for dragging and improper installation 

i The Stacker Elevator Belt/rack/gear for wear and damage 

Remove the other mechanical causes of the Stacker Tray not operating. 

Enter dC330 [012-050] (up) and press Start. The Stacker Tray ascends. 

Y N 
Stacker Motor energized. 

Y N 
With [12-050] (up) running +24 VDC is measured between the Finisher PWB p/j 
(+) and Finisher PWB Chassis (-). 

Y N 
Replace the Finisher PWB (PL 17.13). 

Check conductivity of the following: 

T Between the Finisher PWB p/j and the Stacker Motor p/j 

i Between the Finisher PWB p/j and the Stacker Motor p/j 





If no problems are found, replace the Stacker Motor (PL 17.11). 
If the problem continues, replace the Finisher PWB (PL 17.13). 

Check the following: 

i The Stacker Motor Gear for wear and damage 

T The Stacker Tray for dragging and improper installation 

i The Stacker Elevator Belt/rack/gear for wear and damage 

Remove the other mechanical causes of the Stacker Tray not operating. 



Replace the Finisher PWB (PL 17.13). 



Upper 

Limit 

Sensor 



Stack A 
Sensor 



Stack B 
Sensor 



Stack 

Height 

Sensor 




Stacker 
Motor 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



J850 DC COM 



ST 

DC COM 

~ +5 VDC 
+5VDC 



VIO 



A12I- 



+5VDC 



CONTROL 
LOGIC 



it 1 ' 

— *— A11 1 - 



DC330 [12-202] 
UPPER LIMIT SENSED 
(H) +5 VDC 



GRY 



UPPER LIMIT SENSOR 
PL17.11 



j<fiS<5l: 



J862 



T712030A-CAR 



Figure 2 Upper Limit Sensor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-213 



Status Indicator RAPs 

12-255 



FINISHER PWB 
PL17.13 



47 



■ B4 



J850 DC COM 



i VIO 



DOUBLE 
PLUG 



J870B I I J870A J868 
6 — 1 1 



STACK HEIGHT 

SENSOR 

PL17.6 



- B6 I— 



-<■ +5VDC I ! GRY DC330 [12-200] GRY 

+5VDC ~C I ! STACK HEIGHT SENSED 



4 — 3 ■ 



CONTROL 
LOGIC 



li. 



(H) +5 VDC 



|(£>*d : 



YEL 



T712027A-CAR 



Figure 3 Stack Height Sensor 



FINISHER PWB 
PL17.13 

+24 VDC 
INTERLOCKED 



CONTROL 
LOGIC 



+24 VDC 
INTERLOCKED 




DC330 [12-050] 
STACKER UP 
J847 (H) +24 VDC 



DC330 [12-051] 
STACKER DOWN 
(H) +24 VDC 




T712029A-CAR 



Figure 4 Stacker Motor CD 



A12r 



,A1 



P849 

"| i i i i i i i Q 



3 B1 2™14 



1 nnm p852 
njQ^^H nj 1nn4 1 10 



Figure 5 Finisher PWB 



T712036A-CAR 



Status Indicator RAPs 

12-255 



6/02 
2-214 



Prelaunch Training/Review 
DC1 632/2240 



12-256 Staple Front Corner Sensor On 

i The Stapler Front Corner Sensor does not turn on within 2sec after starting to move to 

Front Corner, 
i The Stapler Front Corner Sensor remained on when starting to move to Front Corner. 

Procedure 

Open the Finisher Front Cover. Turn the Stapler Assembly manually. The Staple Head 
moves smoothly without any load. 

Y N 

Repair the cause of Staple Head not moving, such as rail breakage, drag, or damaged 
gear. 

Enter dC330 [012-225] and press Start. Actuate the Staple Front Corner Sensor on/off. The 
display changes. 

Y N 
Check the Staple Front Corner Sensor using the Generic Transmissive Sensor RAP. 

Cheat the Front Cover Interlock Switch. 

Enter dC330 [012-081] (front direction) or [12-083] (rear direction) and press Start. STAPLE 

MOVE MOTOR energized. 

Y N 
+24 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis 

(-)■ 
Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Stapler Move Motor p/j for an open 

circuit or poor contact. 

If no problems are found, replace the Stapler Move Motor (PL 17.9). 

If the problem continues, replace the Finisher PWB (PL 17.13). 

Replace the Finisher PWB (PL 17.13). 



Staple Front 
Corner Sensor 




Staple Move Sensor 



0102035A-CAR 



FINISHER PWB 
PL17.13 



47 



A1 



J850 DC COM 



'-L +: 



■ A3k 



+5 VDC 



CONTROL 
LOGIC 



,._„ , ,GRY , , GRY 

■5 VDC | i DC330 [12-225] 

STAPLE AT FRONT CORNER 

(H) +5 VDC 



STAPLE FRONT CORNER 

SENSOR 

PL17.9 



|(£>*d : 



ii, 



Figure 2 Stapler Front Corner Sensor CD 



FINISHER PWB 
PL17.13 



CONTROL 
LOGIC 



DC COM 
DC COM 
DC COM 



DC330 [12-080 -083] 

STAPLE MOVE 

ON +24 VDC PULSED 



DC COM 



RT4: 



+24 VDC 
INTERLOCKED 



DC330 [12-080 -083] 

STAPLE MOVE 

ON +24 VDC PULSED 



DC330 [12-080 -083] 

STAPLE MOVE 

ON +24 VDC PULSED 



YEL 



DC330 [12-080 -083] 

STAPLE MOVE 

ON +24 VDC PULSED 



YEL 



+24 VDC 
INTERLOCKED 



ORN 



+24 VDC 
INTERLOCKED 



Figure 3 Stapler Move Motor CD 



T712017A-CAR 





STAPLE 
MOVE 
MOTOR 
PL17.9 




\ 




Y 




(mot) 




T 




/ 







T712018A-CAR 



Figure 1 Component Location 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-215 



Status Indicator RAPs 

12-256 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 4 Finisher PWB 



Status Indicator RAPs 

12-256 



6/02 
2-216 



Prelaunch Training/Review 
DC1 632/2240 



12-257 Staple Front Corner Sensor Off 

i The Staple Front Corner Sensor does not turn off after the move from Front Corner has 

completed, 
i The Staple Front Corner Sensor does not turn off within 200ms after starting to move from 

Front Corner. 

Procedure 

Open the Finisher Front Cover. Turn the Stapler Assembly manually. The Staple Head 
moves smoothly without any load. 

Y N 

Remove the cause of Staple Head not moving, such as rail breakage, drag, and gear 
damage. 

Enter dC330 [012-225] and press Start. Actuate the Staple Front Corner Sensor. The dis- 
play changes. 

Y N 
Check the Staple Front Corner Sensor using the Generic Transmissive Sensor RAP. 

Cheat the Front Cover Interlock Switch. 

Enter dC330 [012-081] (front) or [12-083] (rear) and press Start. The Staple Move Motor 

energized 

Y N 
+24 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis 

(-)■ 
Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Stapler Move Motor p/j for an open 

circuit or poor contact. 

If no problems are found, replace the Stapler Move Motor (PL 17.9). 

If the problem continues, replace the Finisher PWB (PL 17.13). 

Replace the Finisher PWB (PL 17.13). 



Staple Front 
Corner Sensor 




Staple Move Sensor 

Figure 1 Component Location 



0102035A-CAR 



FINISHER PWB 
PL17.13 



47 



A1 



J850 DC COM 



'-L +: 



■ A3k 



+5 VDC 



CONTROL 
LOGIC 



,._„ , ,GRY , , GRY 

■5 VDC | i DC330 [12-225] 

STAPLE AT FRONT CORNER 

(H) +5 VDC 



STAPLE FRONT CORNER 

SENSOR 

PL17.9 



|(£>*d : 



ii, 



Figure 2 Stapler Front Corner Sensor CD 



FINISHER PWB 
PL17.13 



CONTROL 
LOGIC 



DC COM 
DC COM 
DC COM 



DC330 [12-080 -083] 

STAPLE MOVE 

ON +24 VDC PULSED 



DC COM 



RT4: 



+24 VDC 
INTERLOCKED 



DC330 [12-080 -083] 

STAPLE MOVE 

ON +24 VDC PULSED 



DC330 [12-080 -083] 

STAPLE MOVE 

ON +24 VDC PULSED 



YEL 



DC330 [12-080 -083] 

STAPLE MOVE 

ON +24 VDC PULSED 



YEL 



+24 VDC 
INTERLOCKED 



ORN 



+24 VDC 
INTERLOCKED 



Figure 3 Stapler Move Motor CD 



T712017A-CAR 





STAPLE 
MOVE 
MOTOR 
PL17.9 




\ 




Y 




(mot) 




T 




/ 







T712018A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-217 



Status Indicator RAPs 

12-257 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 4 Finisher PWB 



Status Indicator RAPs 

12-257 



6/02 
2-218 



Prelaunch Training/Review 
DC1 632/2240 



12-260 Eject Clamp Home Sensor On 

The Eject Clamp Home Sensor does not turn on after the Eject Clamp up started. 

Procedure 

Remove the Eject Clamp Home Sensor bracket. (Leave the Connector plugged in) 

Enter dC330 [012-210] and press Start. Actuate the Eject Clamp Home Sensor with a sheet of 

paper. The display changes. 

Y N 
Check the Eject Clamp Home Sensor using the Generic Transmissive Sensor RAP. 

Restore the Sensor to the original state. 

Enter dC330 [012-034] and press Start. Eject Clamp moves up. 

Y N 
Eject Motor energized. 
Y N 

+24 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB 
Chassis (-). 
Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Eject Motor p/j for an open cir- 
cuit or poor contact. 

If no problems are found, replace the Eject Motor (PL 17.8). 
If the problem continues, replace the Finisher PWB (PL 17.13). 

Remove the other mechanical causes of the Eject Clamp not operating, such as wear or 
damage of the Gear, Belt, and Eject Cam. 

Replace the Finisher PWB (PL 17.13). 




FINISHER PWB 
PL17.13 


J849 


DC COM 


J883 


HOME SENSOR 
PL17.8 




-I 

DC COM 


ivio 

i 


+5 VDC 


VIO i " T 






Si, 






#f< 


J883 



YF.L 




IGRY 

i 

] 


DC330 [12-210] 
EJECT HOME 
(L) +5 VDC 


GRY 






+5 VDC 


r 












CONTROL 
LOGIC 






YEL 












T712026A-CAR 



Figure 2 Eject Clamp Home Sensor 



FINISHER PWB 
PL17.13 




CONTROL 
LOGIC 


DC COM 
DC COM 
DC COM 




DC COM 


RT4> 

INTERLOCKED 
+24 VDC 


12 



J846 



DC330 [12-030-034] 
EJECT MOTOR ON 
+24 VDC PULSED 



I YEL 


DC330 [12-030-034] \ 




EJECT MOTOR ON i 




+24 VDC PULSED i 


! YEL 


DC330 [12-030-034] ! 




EJECT MOTOR ON i 




+24 VDC PULSED | 


! YEL 


DC330 [12-030-034] ' 




EJECT MOTOR ON , 




+24 VDC PULSED j 


! YEL 






INTERLOCKED | 




+24 VDC ; 


lORN 






INTERLOCKED ] 




+24 VDC ; 



Figure 3 Eject Motor CD 




T712023A-CAR 



0102037A-CAR 



Figure 1 Component Location 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-219 



Status Indicator RAPs 

12-260 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 4 Finisher PWB 



Status Indicator RAPs 

12-260 



6/02 
2-220 



Prelaunch Training/Review 
DC1 632/2240 



12-262 Eject Clamp Home Sensor Off 

The Eject Clamp Home Sensor does not turn off within 200ms after the Eject Clamp DOWN 
has started. 

Procedure 

Remove the Eject Clamp Home Sensor bracket. (Leave the Connector plugged in) 

Enter dC330 [012-210] and press Start. Actuate the Eject Clamp Home Sensor with a sheet of 

paper. The display changes. 

Y N 
Check the Eject Clamp Home Sensor using the Generic Transmissive Sensor RAP. 

Restore the Sensor to the original state. 

Enter dC330 [012-032] and press Start. Elect Clamp moves down. 

Y N 
The Eject Motor energized. 
Y N 

+24 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB 
Chassis (-). 
Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Eject Motor p/j for an open cir- 
cuit or poor contact. 

If no problems are found, replace the Eject Motor (PL 17.8). 
If the problem continues, replace the Finisher PWB (PL 17.13). 

Remove the other mechanical causes of the Eject Clamp not operating, such as wear or 
damage of the Gear, Belt, and Eject Cam. 

Replace the Finisher PWB (PL 17.13). 




FINISHER PWB 
PL17.13 


J849 


DC COM 


J883 


HOME SENSOR 
PL17.8 




-I 

DC COM 


ivio 

i 


+5 VDC 


VIO i " T 






Si, 






#f< 


J883 



YF.L 




IGRY 

i 

] 


DC330 [12-210] 
EJECT HOME 
(L) +5 VDC 


GRY 






+5 VDC 


r 












CONTROL 
LOGIC 






YEL 












T712026A-CAR 



Figure 2 Eject Clamp Home Sensor 



FINISHER PWB 
PL17.13 




CONTROL 
LOGIC 


DC COM 
DC COM 
DC COM 




DC COM 


RT4> 

INTERLOCKED 
+24 VDC 


12 



J846 



DC330 [12-030-034] 
EJECT MOTOR ON 
+24 VDC PULSED 



I YEL 


DC330 [12-030-034] \ 




EJECT MOTOR ON i 




+24 VDC PULSED i 


! YEL 


DC330 [12-030-034] ! 




EJECT MOTOR ON i 




+24 VDC PULSED | 


! YEL 


DC330 [12-030-034] ' 




EJECT MOTOR ON , 




+24 VDC PULSED j 


! YEL 






INTERLOCKED | 




+24 VDC ; 


lORN 






INTERLOCKED ] 




+24 VDC ; 



Figure 3 Eject Motor CD 




T712023A-CAR 



0102037A-CAR 



Figure 1 Component Location 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-221 



Status Indicator RAPs 

12-262 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 4 Finisher PWB 



Status Indicator RAPs 

12-262 



6/02 
2-222 



Prelaunch Training/Review 
DC1 632/2240 



12-267 Decurler 

The Decurler Cam Home Sensor did not actuate after the Decurler Cam Clutch energized. 

Procedure 

Open H Transport Cover and cheat the H Transport Cover Interlock Sensor (Figure 1). The H 
Transport Belts rotate. 

Y N 

Go to the 12-100 RAP. 

Enter dC330 [012-217] and press Start. Rotate the Actuator and turn the Decurler Cam Home 
Sensor on/off. The display changes. 

Y N 
Check the Decurler Cam Home Sensor using the Generic Transmissive Sensor RAR 

Enter dC330 [012-070] and press Start. The Decurler Cam Clutch energized. 

Y N 

Check the Decurler Cam Clutch using the Solenoid/Clutch Open RAP. 

Enter dC330 [012-071] and press Start. The Decurler Cam rotates. 

Y N 

Check the following: 

i The Decurler Cam Clutch for slippage 

i The Driver Gear for wear, a drive failure, and breakage 

i The belt for disengagement, breakage, and improper tension 

Remove the other mechanical causes of the Decurler Cam not operating. 

Replace the Finisher PWB (PL 17.13). 



Interlock 
Sensor 




0102032A-CAR 



Figure 1 Component Location 



Decurler Cam Clutc 



Compiler 
Entrance 
Sensor 




Decurler 
Cam 
Home 
Sensor 



0102033A-CAR 



Figure 2 Component Location 



FINISHER PWB 
PL17.13 



47 



-"L. +5 VDC 
+5VDC 



J849 DC COM 



HOME 

SENSOR 

PL17.8 



ivio 



3 h 



+5 VDC 



i d)fp*(d 2 *» 



CONTROL 
LOGIC 



ii 



YEL 



T712001A-CAR 



Figure 3 Decurler Cam Home Sensor CD 



FINISHER PWB 
PL17.13 



CONTROL 
LOGIC 



\§r 



DC330 [12-070-071] 
DECURLER CAM CLUTCH 
J846 ON (L) +24 VDC 



DC COM 

i W- 1 

J~ RT5 



BLU 



INTERLOCKED 
+24 VDC 



RT5 
INTERLOCKED 
+24 VDC 



ORN 



ORN 



DOUBLE 
PLUG 



1 — 1 
I I 





DECURLER 




CAM CLUTCH 


P880 


PL17.7 




~\ 








r 















T712014A-CAR 



Figure 4 Decurler Cam Clutch CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-223 



Status Indicator RAPs 

12-267 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 5 Finisher PWB 



Status Indicator RAPs 

12-267 



6/02 
2-224 



Prelaunch Training/Review 
DC1 632/2240 



12-281 Set Clamp 

The Set Clamp Home Sensor does not turn on within 200ms after the Set Clamp has started 
operation. 

Procedure 

Enter dC330 [012-211] and press Start. Rotate the Actuator and turn the Set Clamp Home 
Sensor on/off. The display changes. 

Y N 
Check the Set Clamp Home Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-040] and press Start. The Set Clamp Solenoid energized. 

Y N 

Check the Set Clamp Solenoid using the Generic Solenoid/Clutch Open RAR 

Enter [12-034] and press Start to energize Eject Clamp up or [12-032] to lower the Eject 

Clamp. 

Enter dC330 [012-041] and press Start. Has the Set Clamp rotated. 

Y N 
Enter dC330 [012-030] and press Start. The Eject Motor energized. 
Y N 

+24 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB 
Chassis (-). 
Y N 

Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Eject Motor p/j for an open cir- 
cuit or poor contact. 

If no problems are found, replace the Eject Motor (PL 17.8). 
If the problem continues, replace the Finisher PWB (PL 17.13). 

Check the following: 

i Eject Roll for wear and a drive failure (PL 17.8). 

i Eject Shaft for wear and a drive failure (PL 1 7.8). 

T Each Driver Gear for wear, a drive failure, and breakage (PL 17.8). 

i Belt for disengagement, breakage, and improper tension (PL 17.8). 

Replace the Finisher PWB (PL 17.13). 



Eject Clamp Home Sensor 




Set 
Clamp 
Home 
Sensor 



Set 

Clamp 

Solenoid 



0102037A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



J849 DC COM 



J882 



HOME SENSOR 
PL17.8 



iVIO 



'"L +: 



9 h 



+5 VDC 



■5 VDC | i GRY DC330 [12-211] GRY 



i d)fp*(d 2 *» 



CONTROL 
LOGIC 



vt 



CLAMP HOME 
(L) +5 VDC 



YEL 



T712025A-CAR 



Figure 2 Set Clamp Home Sensor 



FINISHER PWB 
PL17.13 



CONTROL 
LOGIC 



fe- 



RT5 
INTERLOCKED 
+24 VDC 



DC330 [12-040-041] 


J873B 


UOUBLb 
PLUG 


SETC 
SOLEI* 
PL17.8 


_AM 
OID 


P 


SET CLAMP SOLENOID 
J848 ON (L) +24 VDC 


J873A 




i BLU 

! INTERLOCKED 

! +24 VDC 


BLU | 


1 li 


V 

r 






ORN 


ORN 

















T712024A-CAR 



Figure 3 Set Clamp Solenoid 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-225 



Status Indicator RAPs 

12-281 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 4 Finisher PWB 



Status Indicator RAPs 

12-281 



6/02 
2-226 



Prelaunch Training/Review 
DC1 632/2240 



12-301 Top Cover Interlock 

The Top Cover Interlock is open. 

Procedure 

Cheat the Top Cover Interlock Switch. 12-301 is cleared. 
Y N 

+5 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis (- 

)■ 

Y N 

Replace the Finisher PWB (PL 17.13). 



+5 VDC is measured between the Top Cover Interlock Switch p/j (+) and Finisher 
PWB Chassis (-). 

Y N 

Check the wire between the Top Cover Interlock Switch p/j and the Finisher PWB p/j 
for an open circuit or poor contact. 

+5 VDC is measured between the Top Cover Interlock Switch p/j (+) and Finisher 
PWB Chassis (-)■ 

Y N 

Replace the Top Cover Interlock Switch (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Top Cover Interlock Switch p/j for 
an open circuit or poor contact. 



There is misalignment between the Top Cover and the Top Cover Interlock Switch. 

Check the Top Cover for correct installation and the actuator for breakage or bending (PL 

17.6). 



Top Cover 

Interlock 

Switch 



Front Door 

Interlock 

Switch 




Docking 
Interlock 
Sensor 



0102030A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



J851 



J890 



DC COM 
+5VDC 



CONTROL 
LOGIC 



TOP COVER 
INTERLOCK 
SWITCH 
PL17.13 

2B V 



YEL 



DC330 [12-301] 

TOP COVER INTERLOCK 

SWITCH CLOSED 

(L) +5 VDC 



YEL 



T712033A-CAR 



Figure 2 Top Cover Interlock Switch CD 



A12r 



P849 

"| i i i i i i i Q 



B1 
A12 



P85(T 



1 mm p852 
° B12 1mi4 1d 



Figure 3 Finisher PWB 



T712036A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-227 



Status Indicator RAPs 

12-301 



12-302 Front Door Interlock Open 

The Front Door Interlock is open. 

Procedure 

Cheat the Front Door Interlock Switch. Has the display of 012-302 been cleared. 
Y N 

+5 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis (- 

)■ 

Y N 

Replace the Finisher PWB (PL 17.13). 



+5 VDC is measured between the Front Door Interlock Switch p/j (+) and Finisher 
PWB Chassis (-). 

Y N 

Check the wire between the Front Door Interlock Switch p/j and the Finisher PWB p/ 
j for an open circuit or poor contact. 

+5 VDC is measured between the Front Door Interlock Switch p/j (+) and Finisher 
PWB Chassis (-)■ 

Y N 

Replace the Front Door Interlock Switch (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Front Door Interlock Switch p/j for 
an open circuit or poor contact. 



Mismatching between the Front Door and the Front Door Interlock Switch. 

Check the Front Door and Front Cover for improper installation, the Actuator for breakage and 

bending, and the Magnet for improper mounting. 



Top Cover 

Interlock 

Switch 



Front Door 

Interlock 

Switch 




Docking 
Interlock 
Sensor 



0102030A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



J851 



J890 



FRONTDOOR 
INTERLOCK 
SWITCH 
PL17.13 

2B 



DC COM 
+5VDC 



CONTROL 
LOGIC 



■oVc 



YEL 



3 ' 
j YEL 



DC330 [12-300] 

FRONT DOOR INTERLOCK 

SWITCH CLOSED 

(L) +5 VDC 



T712034A-CAR 



Figure 2 Front Door Interlock Switch CD 



A12r 



P849 

"| i i i i i i i Q 



3 B1 j™.^ 



B1 
A12 



P850 A 



1 mm p852 
° B12 1im4 1d 



Figure 3 Finisher PWB 



T712036A-CAR 



Status Indicator RAPs 

12-302 



6/02 
2-228 



Prelaunch Training/Review 
DC1 632/2240 



12-303 H Transport Interlock Open 

The H Transport Interlock Sensor detected open. 

Procedure 

Block the H Transport Interlock Sensor with a sheet of paper. Has the display of 012-303 
been cleared. 
Y N 

+5 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis (- 

)■ 

Y N 

Replace the Finisher PWB (PL 17.13). 

+5 VDC is measured between the H Transport Interlock Sensor p/j (+) and Finisher 
PWB Chassis (-). 

Y N 

Check the wire between the H Transport Interlock Sensor p/j and the Finisher PWB 
p/j for an open circuit or poor contact. 

+5 VDC is measured between the H Transport Interlock Sensor p/j (+) and 3 (-)■ 

Y N 

Check the wire between the Finisher PWB p/j and the H Transport Interlock Sensor 
p/j and between the Finisher PWB p/j and H Transport Interlock Sensor p/j for an 
open circuit or poor contact. 
If no problems are found, replace the Finisher PWB (PL 17.13). 

Replace the H Transport Interlock Sensor (PL 17.4). 

Mismatching between the H Transport Cover and the H Transport Interlock Sensor. 

Check the H Transport Cover for improper installation, the Actuator for breakage and bending, 

and the Magnet for improper mounting. 



FINISHER PWB 
PL17.13 



47 



J845 DC COM 



J861 



J853 



INTERLOCK 

SENSOR 

PL17.4 



"L +5 



■ A1k 



+5 VDC 



-I 13 



GRY 

-5 VDC I i DC330 [12-3051 

+5 VDC *£■ | i INTERLOCK CLOSED 

CONTROL [_£_ A2 i vw^VDC I 14 L 

LOGIC 



VIO VIO 



GRY GRY 



Figure 2 H Transport Interlock Sensor CD 



P848 



CN2 



P849 

"| i i i i i i i Q 



a B1 2™™14 



1 mm p852 
n . q Hrffn . , 1nn4 1nxnn10 



lJ)S(g 



T712011A-CAR 



T712036A-CAR 



Interlock 
Sensor 




Figure 3 Finisher PWB 



0102032A-CAR 



Figure 1 Component Location 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-229 



Status Indicator RAPs 

12-303 



12-305 Docking Interlock Open 

The Docking Interlock is open. 

Procedure 

Block the Docking Interlock Sensor with a sheet of paper. Has the display of 012-305 been 

cleared. 

Y N 

+5 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis (- 

)■ 

Y N 

Replace the Finisher PWB (PL 17.13). 

+5 VDC is measured between the Docking Interlock Sensor p/j (+) and Finisher 
PWB Chassis (-). 

Y N 

Check the wire between the Docking Interlock Sensor p/j and the Finisher PWB p/j 
for an open circuit or poor contact. 

+5 VDC is measured between the Docking Interlock Sensor p/j (+) and 3 (-). 

Y N 

Check the wire between the Finisher PWB p/j and the Docking Interlock Sensor p/j 
and between the Finisher PWB p/j and Docking Interlock Sensor p/j for an open cir- 
cuit or poor contact. If no problems are found, replace the Finisher PWB (PL 17.13). 

Replace the Docking Interlock Sensor (PL 17.13). 

Mismatching between the Actuator and the Docking Interlock Sensor. Check the Sensor for 
improper installation, the Actuator for breakage and bending, and the Finisher and the Main 
Processor for the docking failure. 



Top Cover 

Interlock 

Switch 



Front Door 

Interlock 

Switch 




FINISHER PWB 
PL17.13 



Figure 1 Component Location 



Docking 
Interlock 
Sensor 
(rear) 



0102030A-CAR 



47 



-B10: 



J850 DC COM 



VIO 



-B12k 



JT^..~~"." iGRY 



GRY 



DOCKING INTERLOCK 

SENSOR 

PL17.13 



|(£>*d : 



J866 



+5 VDC 



CONTROL 
LOGIC 



— *— B11 1 - 



T712001A-CAR 



Figure 2 Docking Interlock Sensor CD 



Status Indicator RAPs 

12-305 



6/02 
2-230 



Prelaunch Training/Review 
DC1 632/2240 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 3 Finisher PWB 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-231 



Status Indicator RAPs 

12-305 



12-350 Finisher Communication 

Communication cannot be established between the MCU PWB and the Finisher PWB. 

Procedure 

Switch the power off then on. CR7 on the Finisher PWB is lit. 

Y N 
+24 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chassis 

(-)■ 
Y N 

Check the +24VDC circuit to the Finisher PWB p/j by referring to Chapter 7 Wiring 
Data( Finisher +24VDC-1) 

Replace the Finisher PWB (PL 17.13). 

Switch off the power. 

Check conductivity of the following: 

(Including the l/F) 

i Between the MCU PWB p/j and the Finisher PWB p/j 

i Between the MCU PWB p/j and the Finisher PWB p/j 

i Between the MCU PWB p/j and the Finisher PWB p/j 

i Between the MCU PWB p/j and the Finisher PWB p/j 

Is the resistance 1 Ohm or less for all wires. 

Y N 
Check wires with more than 1 Ohm for an open circuit or poor contact. 

Replace the following parts: 
i Finisher PWB (PL 17.13). 
i MCU PWB (PL 13.1). 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 



P850 HI P851 P843 



13 
B 14 



Figure 1 Finisher PWB 



T712036A-CAR 



Status Indicator RAPs 

12-350 



6/02 
2-232 



Prelaunch Training/Review 
DC1 632/2240 



12-399 Staple Mode Logic 

A paper size and staple mode that cannot be specified were specified. 

Procedure 

Reprogram job. 



Prelaunch Training/Review g^2 Status Indicator RAPs 

DC1 632/2240 2-233 12-399 



12-901 Power On H Transport Entrance Sensor 

The H Transport Entrance Sensor detected a paper at power on, when all the interlock were 
closed, or at initialization. 

Procedure 

Check the following: 

i The Actuator for return failure 

i Enter dC330 [012-103] and press Start. Check only the signal wire of the sensor. 

i Check that the power voltage at the customer site does not drop. 



Entrance 
Sensor 




P848 



CN2 



P849 

"| i i i i i i i Q 



a B1 2 ™™14 



1 amn P852 
iin^ffl i\j 1nn4 1 1H 

A1 ^P850 A1 P851 P843 



Figure 3 Finisher PWB 



6cm4 



T712036A-CAR 



0102032A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



DOUBLE 
PLUG 



47 



• A5 



J845 DC COM J861 J859A 



VIO 



i 11 



*"L +; 



■B5k 



+5VDC 



CONTROL 
LOGIC 



■5VDC | i DC330 [12-103] 

PAPER SENSED 
(H) +5 VDC 



H 5 



iX, 



VIO 



3 — 4 ■ 



J859B J854 



ENTRANCE 

SENSOR 

PL17.4 



-tU-t 



YEL 



YEL 



2 — 5 ■ 



<Si,_ 



YEL 



T712013A-CAR 



Figure 2 H Transport Entrance Sensor CD 



Status Indicator RAPs 

12-901 



6/02 
2-234 



Prelaunch Training/Review 
DC1 632/2240 



12-902 Power On H Transport Exit Sensor 

The H Transport Exit Sensor detected a paper at power on, when all the INTERLOCK were 
closed, or at initialization. 

Procedure 

Check the following: 

i The Actuator for return failure 

i Enter dC330 [012-104] and press Start. Check only the signal wire of the sensor. 

i Check that the power voltage at the customer site does not drop. 



Exit 
Sensor 




P848 



CN2 



P849 

"| i i i i i i i Q 



a B1 2 ™™14 



1 amn P852 
iin^ffl i\j 1nn4 1 1H 

A1 ^P850 A1 P851 P843 



Figure 3 Finisher PWB 



6cm4 



T712036A-CAR 



0102032A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



DOUBLE 
PLUG 



47 



J845 DC COM J8 61 „ J858A 

[vio 



"L +; 



+5VDC 



cwn „ , .GRY 

■5VDC | i DC330 [12-104] 



CONTROL 
LOGIC 



a 



B7 1 - 



PAPER SENSED 
(H) +5 VDC 



VIO 



3 — 1 



J858B J856 



EXIT 

SENSOR 

PL17.4 



GRY 



1 — 3 ■ 



GRY 



J 7 ^ 



2 — 2 ■ 



|(£>*d : 



J856 



T712012A-CAR 



Figure 2 H Transport Sensor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-235 



Status Indicator RAPs 

12-902 



12-903 Power On Compiler Entrance Sensor 

The Compiler Entrance Sensor detected a paper at power on, when all the INTERLOCK were 
closed, or at initialization. 

Procedure 

Check the following: 

i The Actuator for return failure 

i Enter dC330 [012-101] and press Start. Check only the signal wire of the sensor. 

i Check that the power voltage at the customer site does not drop. 



Compiler 

Entrance 

Sensor 

Decurler 

Home 

Sensor 




P848 



CN2 



P849 

"| i i i i i i i Q 



B8 B1 



ft An 1 1 1 1 1 1 1 a j 1cm 4 1 1fl 

A1 ^P850 A1 P851 P843 



Figure 3 Finisher PWB 



13 



6cm4 



T712036A-CAR 



0102033A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



• B7 



J850 DC COM 



VIO 



"L. +5 



■ B9 I- 



+5VDC 



CONTROL 
LOGIC 



a, 



DOUBLE 
PLUG 



J870B I I J870A J867 
7^ 3 — 4 



+5VDC 



iGRY DC330 [12-101] GRY 

COMPILER ENTRANCE 
PAPER SENSED 
(H) +5 VDC 



1 — 6 ■ 



GRY 



COMPILER ENTRANCE 

SENSOR 

PL17.12 



|(£>*d : 



2 — 5 ■ 



J867 



T712015A-CAR 



Figure 2 Compiler Entrance Sensor CD 



Status Indicator RAPs 

12-903 



6/02 
2-236 



Prelaunch Training/Review 
DC1 632/2240 



12-904 Power On Compiler Paper Sensor 

i The Compiler Paper Sensor continues to detect paper when the paper was output auto- 
matically due to the power on initialization. 

i The Compiler Paper Sensor detected paper with no history of paper output to the Com- 
piler Tray when all the interlocks were closed. 

Procedure 

Check the following: 

i The Actuator for return failure 

i Enter dC330 [012-102] and press Start. Check only the signal wire of the sensor. 

i Check that the power voltage at the customer site does not drop. 

i Replace Finisher PWB (PL 17.13). 



Compiler 

Paper 

Sensor 




P848 



CN2 



P849 

"| i i i i i i i Q 



/\ a q 1 1 1 1 1 1 1 ft j 1 cm 4 1 muni ! 

ft1 ^P850 A1 P851 P843 



Figure 3 Finisher PWB 



13 

3 H 



T712036A-CAR 



0102034A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



■ A4 



J848 DC COM 



VIO 



--L, +! 



■ A6k 



+5VDC 



J875 



,._„ , ,GRY , , GRY 

■5VDC | , DC330 [12-102] 



COMPILER PAPER 

SENSOR 

PL17.10 


I* 


1 


>©, 



CONTROL 
LOGIC 



, b YEL 



COMPILED PAPER 
(H) +5 VDC 



T712004A-CAR 



Figure 2 Compiler Paper Sensor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-237 



Status Indicator RAPs 

12-904 



12-910 Staple Feed Ready 



i At the staple preparation operation at initialization, the Staple Ready Sensor does not go 

to ready (L) status after 13 times of stapling operation, 
i The Stapler Ready Sensor is turned off (H) just before the Staple. 

Procedure 

Remove the Stapler Assembly with a connector connected. Enter dC330 [012-209] and press 
Start. Actuate the Staple Ready Sensor. The display changes. 

Y N 
+5 VDC is measured between the Stapler Assembly p/j (+) and Finisher PWB Chas- 
sis (-). 

Y N 
+5 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB Chas- 
sis (-). 

Y N 
Replace the Finisher PWB (PL 17.13). 

Check the wire between the Finisher PWB p/j and the Stapler Assembly p/j for an 
open circuit or poor contact. 

Pull out the cartridge. +5 VDC is measured between the Finisher PWB p/j (+) and Fin- 
isher PWB Chassis (-). 

Y N 
Switch off the power. 
Pull out the on the Finisher PWB. 

Turn on the power. +5 VDC is measured between the Finisher PWB P852-3 (+) 
and Finisher PWB Chassis (-). 

Y N 
Replace the Finisher PWB (PL 17.13). 

Check the circuit between the p/j and the Stapler Assembly p/j for short circuit. 

Load the cartridge. VDC is measured between the Finisher PWB p/j (+) and Fin- 
isher PWB Chassis (-). 

Y N 
VDC is measured between the Stapler Assembly p/j (+) and Finisher PWB 
Chassis (-). 

Y N 
Replace the Stapler Assembly (PL 17.9). 

Check the wire between the Stapler Assembly p/j and the Finisher PWB p/j for an 
open circuit or poor contact. 

Replace the Finisher PWB (PL 17.13). 

Restore the Staple Head to the original status and cheat the Front Interlock Switch. 
Enter dC330 [012-020] and press Start. The STAPLE MOTOR energizes. 

Y N 
With [12-020] running +24 VDC is measured between the Finisher PWB p/j (+) and 
Finisher PWB Chassis (-). 



Y N 

Replace the Finisher PWB (PL 17.13). 

Check conductivity of the following: 
i Between the Finisher PWB p/j ~ Stapler Assembly p/j 
i Between the Finisher PWB p/j ~ Stapler Assembly p/j 
i Between the Finisher PWB p/j ~ Stapler Assembly p/j 
i Between the Finisher PWB p/j ~ Stapler Assembly p/j 

If no problems are found, replace the Stapler Assembly (PL 17.9). 
If the problem continues, replace the Finisher PWB (PL 17.13). 



Switch off the power. 

Remove the Stapler Assembly from the Finisher. 

Turn the Staple Motor Gear manually. The staple needles fed. 

Y N 

Replace the Stapler Assembly (PL 17.9). 

Replace the Finisher PWB (PL 17.13). 



FINISHER PWB 
PL17.13 



DC COM 

~ +5 VDC 
+5 VDC 



CONTROL 
LOGIC 



ii 



YEL 



YEL 



YEL 



J852 DC COM 



STAPLER ASSEMBLY 
PL17.9 



+5 VDC 



DC330 [12-209] 
STAPLE READY 
(L) +5 VDC 



YEL 



STAPLE READY SENSOR 



jlgfJg-- 



YEL 



T712021A-CAR 



Figure 1 Staple Ready Sensor CD 



Status Indicator RAPs 

12-910 



6/02 
2-238 



Prelaunch Training/Review 
DC1 632/2240 



FINISHER PWB 
PL17.13 

INTERLOCKED^ 
+24VDC 



DC330 [12-020] CLOSE (H) +24 VDC 
J847 DC330 [12-021] OPEN (L) +24 VDC 



STAPLER 

ASSEMBLY 

PL17.9 



CONTROL 
LOGIC 



INTERLOCKED ■, 
+24 VDC 



ORN 


DC330 [12-020] CLOSE (H) +24 VDC 
DC330 [12-021] OPEN (L) +24 VDC 


ORN 


ORN 


DC330 [12-020] CLOSE (L) +24 VDC 
DC330 [12-021] OPEN (H) +24 VDC 


ORN 


BLU 


DC330 [12-020] CLOSE (L) +24 VDC 
DC330 [12-021] OPEN (H) +24 VDC 


BLU 



BLU 



BLU 



Figure 2 Staple Motor CD 



P848 



CN2 



P849 

"| i i i i i i i Q 






1 nmn P852 
/\ An 1 1 1 1 1 1 1 a j 1cm 4 1 1fl 



Figure 3 Finisher PWB 



T712036A-CAR 



T712019A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-239 



Status Indicator RAPs 

12-910 



12-911 Stacker Lower Safety Warning 

The Height Alignment was not successful within 250ms during Tray lowering while stacking. 

Procedure 

Check the following: 

This Fault Code is an operation message. No need for servicing If the display of 012-911 has 

not been cleared after removing paper in the Stacker Tray, check the following: 

i The Actuators of the Stack Height Sensor for dragging and return failure. 

T Enter dC330 [012-201] and press Start. Check the circuit of the Sensor. 



Stack 

Height 

Sensor 




Stacker 
Motor 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 



P850 HI P851 P843 



Figure 3 Finisher PWB 



13 



T712036A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



J850 DC COM 



-U 



i VIO 



DC COM 



■ B6 h 



+5VDC 



-<■ +5VDC I ! GRY DC330 [12-200] 



CONTROL 
LOGIC 



+5VDC 



DOUBLE 
PLUG 



J870B I I J870A J868 

■ 6 — 1 



STACK HEIGHT 

SENSOR 

PL17.6 



VIO 



■ 4 — 3 ■ 



YEL 



STACK HEIGHT SENSED 
(H) +5 VDC 



YEL 



5 — 2 ■ 



VIO 



GRY 



j<fiS<5l: 



T712027A-CAR 



Figure 2 Stack Height Sensor 



Status Indicator RAPs 

12-911 



6/02 
2-240 



Prelaunch Training/Review 
DC1 632/2240 



12-914 Stacker Tray Staple Set 



The STAPLE SET count of the Stacker Tray exceeded 50 sets at the Staple Set Eject opera- 
tion. 

Procedure 

Check the following: 

This Fault Code is an operation message. No need for servicing If the display of 012-914 has 

not been cleared after removing the Staple Set, check the following: 

T The Actuators of the Stack Paper Sensor for dragging and return failure. 

i Enter dC330 [012-200] and press Start. Check the circuit of the Sensor. 



Stack 

Height 

Sensor 




Stacker 
Motor 



P848 



CN2 



P849 

"| i i i i i i i Q 



B8 B1 



ft An 1 1 1 1 1 1 1 a j 1cm 4 1 1fl 

A1 ^P850 A1 P851 P843 



Figure 3 Finisher PWB 



13 



6cm4 



T712036A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



J850 DC COM 



i VIO 



DOUBLE 
PLUG 



J871B ' ' J871A J869 
■3 — 1 



PAPER STACK SENSOR 
PL17.11 



VIO 



'"L +; 



-B3|- 



+5VDC 



■5VDC | ! GRY DC330 [12-200] 



1 — 3 ■ 



CONTROL 
LOGIC 



ii. 



PAPER STACK SENSED 
(H) +5 VDC 



GRY 



i (i)fE*d 2 « 
1 JJ|| r 



T712028A-CAR 



Figure 2 Stack Paper Sensor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-241 



Status Indicator RAPs 

12-914 



12-916 Stapling 

The Staple Head Home Sensor turned on by the open operation while the Sensor failed to turn 
on (stapling was not available due to an error) after the Staple Head began to close. 

Procedure 

Enter dC330 [012-020] and press Start. The STAPLE MOTOR energizes. 

Y N 

Check conductivity of the following: 

i Between the Finisher PWB p/j and the Staple Head p/j 

T Between the Finisher PWB p/j and the Staple Head p/j 

7 Between the Finisher PWB p/j and the Staple Head p/j 

i Between the Finisher PWB p/j and the Staple Head p/j 

Is the resistance 1 Ohm or less for all wires. 

Y N 

Check wires with more than 1 Ohm for an open circuit or poor contact. 

Replace the Stapler Assembly (PL 17.9). 

If the problem continues, replace the Finisher PWB (PL 17.13). 

Replace the Staple Head. Leave the Connector plugged in. 

Turn the gear of the Staple Motor manually to make the Actuator interrupt the Staple Head 
Home Sensor. +5 VDC is measured between the Finisher PWB p/j (+) and Finisher PWB 
Chassis (-). 

Y N 
Replace the Finisher PWB (PL 17.13). 

+5 VDC is measured between the Staple Head p/j (+) and Finisher PWB Chassis (-)■ 

Y N 

Check the wire between the Staple Head p/j and the Finisher PWB p/j for an open circuit 
or poor contact. 

Check conductivity of the following: 

i Between the Finisher PWB p/j and the Staple Head p/j 
7 Between the Finisher PWB p/j and the Staple Head p/j 
Is the resistance 1 Ohm or less for both wires. 

Y N 

Check wires with more than 1 Ohm for an open circuit or poor contact. 

Replace the Stapler Assembly (PL 17.9). 

If the problem continues, replace the Finisher PWB (PL 17.13). 



FINISHER PWB 
PL17.13 

INTERLOCKED^ 
+24 VDC 



CONTROL 
LOGIC 



INTERLOCKED , 
+24 VDC 



J847 


DC330 [12-020] CLOSE (H) +24 VDC 
DC330 [12-021] OPEN (L) +24 VDC 


J887 


ORN 


DC330 [12-020] CLOSE (H) +24 VDC 
DC330 [12-021] OPEN (L) +24 VDC 


ORN 


ORN 


DC330 [12-020] CLOSE (L) +24 VDC 
DC330 [12-021] OPEN (H) +24 VDC 


ORN 


BLU 


DC330 [12-020] CLOSE (L) +24 VDC 
DC330 [12-021] OPEN (H) +24 VDC 


BLU 



STAPLER 

ASSEMBLY 

PL17.9 



FINISHER PWB 
PL17.13 



DC COM 

~ +5 VDC 
+5 VDC 



CONTROL 
LOGIC 



ii 



YEL 



YEL 



YEL 



BLU 



BLU 



T712019A-CAR 



Figure 1 Stapler Motor CD 



J852 DC COM 



STAPLER ASSEMBLY 
PL17.9 



YEL 



+5 VDC 



DC330 [12-207] 
STAPLE HOME 
(L) +5 VDC 



YEL 



STAPLE HEAD 
HOME SENSOR 



Jf^sL 



YEL 



T712020A-CAR 



Figure 2 Staple Head Home Sensor 



Status Indicator RAPs 

12-916 



6/02 
2-242 



Prelaunch Training/Review 
DC1 632/2240 



P848 



CN2 



P849 

"| i i i i i i i Q 



B1 B12 

A12™A1 






P850 HI P851 P843 



T712036A-CAR 



Figure 3 Finisher PWB 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-243 



Status Indicator RAPs 

12-916 



12-960 Stacker Tray Full Stack 



i The system detected Small Size Paper full during the Stacker Tray Height Adjustment 

operation during lowering, 
i The system detected Small Size Paper full during the Stacker Tray Height Adjustment 

operation (during lowering down) when the Big Size Paper is ejected, 
i The Big Size Paper was ejected while the system already detected Big Size Paper FULL 

(HALF). 

Procedure 

Remove the Finisher Front Cover. 

Enter dC330 [012-204] and press Start. Actuate the Stack A Sensor with a sheet of paper. 

The display changes. 

Y N 
Check the Stack A Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-205] and press Start. Actuate the Stack B Sensor with a sheet of paper. 
The display changes. 

Y N 
Check the Stack B Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-200] and press Start. Actuate the Actuator of the Stack Paper Sensor. The 
display changes. 

Y N 
Check the PAPER SENSOR using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-050] (up) or [12-051] (down) and press Start. The Stacker Tray moves. 

Y N 
The Stacker Motor energizes. 
Y N 

With [12-050] (up) running +24 VDC is measured between the Finisher PWB p/j 
(+) and Finisher PWB Chassis (-). 
Y N 

Replace the Finisher PWB (PL 17.13). 



With [12-050] (up) running +24 VDC is measured between the Stacker Motor p/j 
(+) and Finisher PWB Chassis (-). 

Y N 

Check the wire between the Finisher PWB p/j and the Stacker Motor p/j for an 
open circuit or poor contact. 

With [12-050] (up) running +24 VDC is measured between the Stacker Motor p/j 
(+) and Finisher PWB Chassis (-). 

Y N 

Replace the Stacker Motor (PL 17.9). 

Check the wire between the Finisher PWB p/j and the Stacker Motor p/j for an open 

circuit or poor contact. 

If no problems are found, replace the Finisher PWB (PL 17.13). 

If the problem continues, replace the Stacker Motor (PL 17.11). 



i The Stacker Motor Gear for wear and damage 

i The Stacker Tray for dragging and improper installation 

i The Stacker Elevator Belt/rack/gear for wear and damage 

Remove the other mechanical causes of the Stacker Tray not operating. 

Replace the Finisher PWB (PL 17.13). 



Upper 

Limit 

Sensor 



Stack A 
Sensor 



Stack B 
Sensor 




Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



J850 DC COM 



i VIO 



~ +5 VDC 
+5 VDC 



A9|- 



+5 VDC 



CONTROL 
LOGIC 



iX, 



DC330 [12-204] 
STACK A SENSED 
(H) +5 VDC 



GRY 



STACK A SENSOR 
PL17.11 


j <p=*Ksi , 



T712031A-CAR 



Figure 2 Stack A Sensor CD 



Check the following: 



Status Indicator RAPs 

12-960 



6/02 
2-244 



Prelaunch Training/Review 
DC1 632/2240 



FINISHER PWB 
PL17.13 



47 



■ A4 



J850 DC COM 



STACK B SENSOR 
PL17.11 



i VIO 



"L +5 



- A6 h 



iGRY 



+5VDC 



CONTROL 
LOGIC 



—J- A5 1 

i YEL 



DC330 [12-205] GRY 
STACK B SENSED 
(H) +5 VDC 



!$fp3 



J864 
YEL 



T712032A-CAR 



Figure 3 Stack B Sensor CD 



FINISHER PWB 
PL17.13 

+24 VDC 
INTERLOCKED 



CONTROL 
LOGIC 



+24 VDC 
INTERLOCKED 




DC330 [12-050] 
STACKER UP 
J847 (H) +24 VDC 



DC330 [12-051] 
STACKER DOWN 
(H) +24 VDC 




T712029A-CAR 



Figure 4 Stacker Motor CD 



A12r 



,A1 



P849 

"| i i i i i i i Q 



3 B1 2™14 



1 nnm p852 
iijq^^H /.j 1nn4 1 10 



Figure 5 Finisher PWB 



T712036A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-245 



Status Indicator RAPs 

12-960 



12-961 Mix Full Stack 



i Compared to the maximum paper size that was loaded at the previous job, the paper size 

(either feed direction or width direction) of the next job is bigger, 
i Staple mode has been changed while the width of the maximum paper size that was 

loaded at the previous job is less than 279.4mm. 
i The maximum paper size that was loaded at the previous job is "unknown". 

Procedure 

Remove the Finisher Front Cover. 

Enter dC330 [012-204] and press Start. Actuate the Stack A Sensor with a sheet of paper. 

The display changes. 

Y N 
Check the Stack A Sensor using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-205] and press Start. Actuate the Stack B Sensor with a sheet of paper. 
The display changes. 

Y N 
Check the Stack B Sensor using the Generic Transmissive Sensor RAR 

Enter dC330 [012-200] and press Start. Actuate the Actuator of the Stack Paper Sensor. The 
display changes. 

Y N 
Check the Paper SensoR using the Generic Transmissive Sensor RAP. 

Enter dC330 [012-050] (up) or [12-051] (down) and press Start. The Stacker Tray moves. 

Y N 
The Stacker Motor energizes. 
Y N 

With [12-050] (up) running +24 VDC is measured between the Finisher PWB p/j 
(+) and Finisher PWB Chassis (-). 
Y N 

Replace the Finisher PWB (PL 17.13). 



With [12-050] (up) running +24 VDC is measured between the Stacker Motor p/j 
(+) and Finisher PWB Chassis (-). 

Y N 

Check the wire between the Finisher PWB p/j and the Stacker Motor p/j for an 
open circuit or poor contact. 

With [12-050] (up) running +24 VDC is measured between the Stacker Motor p/j 
(+) and Finisher PWB Chassis (-). 

Y N 

Replace the Stacker Motor (PL 17.11). 

Check the wire between the Finisher PWB p/j and the Stacker Motor p/j for an open 

circuit or poor contact. 

If no problems are found, replace the Finisher PWB (PL 17.13). 

If the problem continues, replace the Stacker Motor (PL 17.11). 



Check the following: 

Remove the other mechanical causes of the Stacker Tray not operating. 



i The Stacker Motor Gear for wear and damage 

i The Stacker Tray for dragging and improper installation 

i The Stacker Elevator Belt/rack/gear for wear and damage 

Replace the Finisher PWB (PL 17.13). 



Upper 

Limit 

Sensor 



Stack A 
Sensor 



Stack B 
Sensor 




Stack 
Paper 
Sensor 



Stacker 
Motor 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



J850 DC COM 



i VIO 



~ +5 VDC 
+5 VDC 



A9|- 



+5 VDC 



CONTROL 
LOGIC 



iX, 



DC330 [12-204] 
STACK A SENSED 
(H) +5 VDC 



GRY 



STACK A SENSOR 
PL17.11 


j <p*p(gi , 



T712031A-CAR 



Figure 2 Stack A Sensor CD 



Status Indicator RAPs 

12-961 



6/02 
2-246 



Prelaunch Training/Review 
DC1 632/2240 



FINISHER PWB 
PL17.13 



47 



■ A4 



J850 DC COM 



STACK B SENSOR 
PL17.11 



i VIO 



"L +5 



- A6 h 



iGRY 



+5VDC 



CONTROL 
LOGIC 



—J- A5 1 

i YEL 



DC330 [12-205] GRY 
STACK B SENSED 
(H) +5 VDC 



Figure 3 Stack B Sensor CD 



!$fp3 



J864 
YEL 



T712032A-CAR 



P848 



CN2 



P849 

"| i i i i i i i Q 



a B1 2™™14 



1 amn P852 

A1 ^P850 A1 P851 P843 



6cm4 



T712036A-CAR 



FINISHER PWB 
PL17.13 



47 



J850 DC COM 



i VIO 



DOUBLE 
PLUG 



J871B ' ' J871A J869 
■3 — 1 



PAPER STACK SENSOR 
PL17.11 



VIO 



"L +; 



-B3|- 



+5 VDC 



■5 VDC | ! GRY DC330 [12-200] 



1 — 3 ■ 



CONTROL 
LOGIC 



ii, 



PAPER STACK SENSED 
(H) +5 VDC 



GRY 



1 JJ|| ^ yel 



T712028A-CAR 



Figure 6 Finisher PWB 



Figure 4 Stack Paper Sensor CD 



FINISHER PWB 
PL17.13 



+24 VDC 
INTERLOCKED 



CONTROL 
LOGIC 



+24 VDC 
INTERLOCKED' 




DC330 [12-050] 
STACKER UP 
J847 (H) +24 VDC 



DC330 [12-051] 
STACKER DOWN 
(H) +24 VDC 



DOUBLE 
PLUG 



2-2 



1 - 1 



P889 



STACKER 

MOTOR 

PL17.11 




T712029A-CAR 



Figure 5 Stacker Motor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-247 



Status Indicator RAPs 

12-961 



12-965 Staple Near Empty 



i The Low Staple Switch detected Low Staple at Power On and Interlock Close, 
i The Low Staple Switch detected Low Staple at Staple Head Close. 

Procedure 

Install a new Staple Cartridge loaded with staples. +5VDC measured between the Finisher 
PWB p/j (+) and Finisher PWB Chassis (-). 

Y N 

Replace the Finisher PWB (PL 17.13). 

+5VDC measured between the Stapler Assembly p/j (+) and Finisher PWB Chassis (-). 

Y N 

Check the wire between the Stapler Assembly p/j and the Finisher PWB p/j for an open 
circuit or poor contact. 

Check the wire between the Stapler Assembly p/j and the Finisher PWB p/j and between the 
Stapler Assembly p/j and Finisher PWB p/j for an open circuit or poor contact. 
If no problems are found, replace the Stapler Assembly (PL 17.9). 
If the problem continues, replace the Finisher PWB (PL 17.13). 



P848 



CN2 



P849 

"| i i i i i i i Q 



/\ a q 1 1 1 1 1 1 1 ft j 1 cm 4 1 muni ! 

ft1 ^P850 A1 P851 P843 



Figure 2 Finisher PWB 



13 

3 H 



T712036A-CAR 





DC COM 


J886 


STAPLER ASSEMBLY 
PL17.9 












LOW STAPLE SENSOR 




FINISHER PWB 
PL17.13 


J852 




-L i ! YEL 

DC COM j 
' i 


+5VDC 


YEL | 


— I 


JL 




^J 




> 


1 


»03 


J886 








A, + wnr ,' |YEL 


DC330 [12-208] 
LOW STAPLE 
(H) +5 VDC 


YEL 




+5VDC 


f l 












CONTROL 
LOGIC 


J- 


i 






' YEL 












T712022A-CAR 



Figure 1 Low Staple Sensor CD 



Status Indicator RAPs 

12-965 



6/02 
2-248 



Prelaunch Training/Review 
DC1 632/2240 



12-966 Scratch Sheet Compile 

An abnormal paper (SCRATCH SHEET) is output to the COMPILER. 

Procedure 

This Fault Code is an operator message. No service required 



Prelaunch Training/Review g/02 Status Indicator RAPs 

DC1 632/2240 2-249 12-966 



12-969 IOT Top Tray Full 

The Top Tray Full Sensor has detected FULL status for 10 sec continuously. 

Procedure 

Enter dC330 [012-215] and press Start. Move paper near the Top Tray Full Sensor, then away 
from it. The display changes. 
Y N 

Check the Top Tray Full Sensor using the Generic Reflective Sensor RAP. 

Check the sensor for improper installation. If no problems are found, replace the Finisher PWB 
(PL 17.13). 



Top Tray Fu 
Sensor 




A19 P848 ai 

MIZ AI 



CN2 



P849 

"| i i i i i i i Q 



a B1 2™™14 



1 amn P852 

.". 1 o r rrrrn A , inn4 1 in 

A1 ^P850 A1 P851 P843 



Figure 3 Finisher PWB 



6 m 4 
3 tttl 1 
J P844' 



T712036A-CAR 



0102031A-CAR 



Figure 1 Component Location 



FINISHER PWB 
PL17.13 



47 



■ A5 



J845 DC COM J861 J859A 



VIO 



i 11 



- A6k 



+5VDC 



rtD ' nov 

+5VDC I i DC330 [12-215] 

+5VDC •<- i TOP TRAY FULL 

> I ! (L)+5VDC 



H 10 



CONTROL 
LOGIC 



YEL 



J859A 




J859B J855 


TOP TRAY FULL 
SENSOR 
PL17 4 




— 






I VIO 


VIOi 


' JL 




^J 






— 




& 


1 


>© : 


J855 

yEI 


IGRY 


GRY 




i 


— 












YEL 








T712009/ 


-CAR 



Figure 2 Top Tray Full Sensor CD 



Status Indicator RAPs 

12-969 



6/02 
2-250 



Prelaunch Training/Review 
DC1 632/2240 



15-362 X Hard Failure 

Communication Failure. 



15-367 XPIO Failure 

Communication Failure. 



Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Check the connectors on the NT/IPS PWB (PL 18.3). If the check ia OK, replace the NT/IPS 
PWB(PL18.3). 



Procedure 

Switch the power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Check the connectors on the NT/IPS PWB (PL 18.3). If the check ia OK, replace the NT/IPS 
PWB (PL 18.3). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-251 



Status Indicator RAPs 

15-362, 15-367 



15-370 X PIO Initialization Failure 1 15-371 X PIO Initialization Failure 2 

Communication Failure. Communication Failure. 

Procedure Procedure 

Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. 

Y N Y N 



Return to Service Call Procedures. 



Return to Service Call Procedures. 



Check the connectors on the NT/IPS PWB (PL 18.3) and the ESS PWB (PL 13.1). If the check Check the connectors on the NT/IPS PWB (PL 18.3) and the ESS PWB (PL 13.1). If the check 
iaOK, replace the ESS PWB (PL 13.1). If the problem continues, replace the NT/IPS PWB (PL ia OK, replace the ESS PWB (PL 13.1). If the problem continues, replace the NT/IPS PWB (PL 
18.3). 18.3). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

15-370,15-371 2-252 DC1 632/2240 



15-372 X PIO Initialization Failure 3 15-375 X PIO Before Scan Failure 

Communication Failure. Communication Failure. 

Procedure Procedure 

Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. 

Y N Y N 



Return to Service Call Procedures. 



Return to Service Call Procedures. 



Check the connectors on the NT/IPS PWB (PL 18.3) and the ESS PWB (PL 13.1). If the check Check the connectors on the NT/IPS PWB (PL 18.3) and the ESS PWB (PL 13.1). If the check 
iaOK, replace the ESS PWB (PL 13.1). If the problem continues, replace the NT/IPS PWB (PL ia OK, replace the ESS PWB (PL 13.1). If the problem continues, replace the NT/IPS PWB (PL 
18.3). 18.3). 



Prelaunch Training/Review g^2 Status Indicator RAPs 

DC1 632/2240 2-253 15-372, 15-375 



15-376 X PIO Non-match Failure 1 15-377 X PIO Non-match Failure 2 

Communication Failure. Communication Failure. 

Procedure Procedure 

Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. 

Y N Y N 



Return to Service Call Procedures. 



Return to Service Call Procedures. 



Check the connectors on the NT/IPS PWB (PL 18.3) and the ESS PWB (PL 13.1). If the check Check the connectors on the NT/IPS PWB (PL 18.3) and the ESS PWB (PL 13.1). If the check 
iaOK, replace the ESS PWB (PL 13.1). If the problem continues, replace the NT/IPS PWB (PL ia OK, replace the ESS PWB (PL 13.1). If the problem continues, replace the NT/IPS PWB (PL 
18.3). 18.3). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

15-376,15-377 2-254 dci 632/2240 



15-380 CCDAGC 

Automatic Gain Control (AGC) for CCD Channel 1 red failed. 

Initial Actions 

i Verify that Platen Glass is installed correctly, 
i Verify that NVM 715-400 = 1 

Procedure 

NOTE: Refer the BSD 6. 1, 6.2 and 6. 7 as required. 

Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. 

Y N 

Go to the 6-371 Exposure Lamp RAP. 

The Exposure Lamp illumination is bright and steady. 

Y N 

Go to p/j722 and p/j724 on BSD 6.1 and check the wires for an open or short circuit. 
Verify that J742 on the Lamp Ballast PWB and p/j724 on the IIT/IPS PWB are seated. 
If the wires and connectors are good, replace the Exposure Lamp (PL 18.6). 
If the problem continues, replace the Lamp Ballast PWB (PL 18.6). 
If the problem continues, replace the IIT/IPS PWB (PL 18.3). 

Remove the Platen Glass (REP 6.2). The white reference strip on the bottom of the 
Platen Glass is clean and undamaged. 

Y N 

Clean the white reference strip or replace the Platen Glass (PL 18.3). 

Go to p/j721 on BSD 6.2 and check the flat cable on the IIT/IPS PWB and J741 on the CCD 

PWB for damage. Reseat the flat cable. 

If the problem continues, replace the Lens Kit (PL 18.4). 

If the problem continues, replace the IIT/IPS PWB (PL 18.3). 



15-381 CCDAGC 

Automatic Gain Control (AGC) for CCD Channel 2 red failed. 

Initial Actions 

i Verify that Platen Glass is installed correctly, 
i Verify that NVM 71 5-400 = 1 

Procedure 

NOTE: Refer the BSD 6. 1, 6.2 and 6. 7 as required. 

Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. 

Y N 

Go to the 6-371 Exposure Lamp RAP. 

The Exposure Lamp illumination is bright and steady. 

Y N 

Go to p/j722 and p/j724 on BSD 6.1 and check the wires for an open or short circuit. 
Verify that J742 on the Lamp Ballast PWB and p/j724 on the IIT/IPS PWB are seated. 
If the wires and connectors are good, replace the Exposure Lamp (PL 18.6). 
If the problem continues, replace the Lamp Ballast PWB (PL 18.6). 
If the problem continues, replace the IIT/IPS PWB (PL 18.3). 

Remove the Platen Glass (REP 6.2). The white reference strip on the bottom of the 
Platen Glass is clean and undamaged. 

Y N 

Clean the white reference strip or replace the Platen Glass (PL 18.3). 

Go to p/j721 on BSD 6.2 and check the flat cable on the IIT/IPS PWB and J741 on the CCD 

PWB for damage. Reseat the flat cable. 

If the problem continues, replace the Lens Kit (PL 18.4). 

If the problem continues, replace the IIT/IPS PWB (PL 18.3). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-255 



Status Indicator RAPs 

15-380, 15-381 



15-382 CCDAGC 

Automatic Gain Control (AGC) for CCD Channel 3 green failed. 

Initial Actions 

i Verify that Platen Glass is installed correctly, 
i Verify that NVM 715-400 = 1 

Procedure 

NOTE: Refer the BSD 6. 1, 6.2 and 6. 7 as required. 

Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. 

Y N 

Go to the 6-371 Exposure Lamp RAP. 

The Exposure Lamp illumination is bright and steady. 

Y N 

Go to p/j722 and p/j724 on BSD 6.1 and check the wires for an open or short circuit. 
Verify that J742 on the Lamp Ballast PWB and p/j724 on the IIT/IPS PWB are seated. 
If the wires and connectors are good, replace the Exposure Lamp (PL 18.6). 
If the problem continues, replace the Lamp Ballast PWB (PL 18.6). 
If the problem continues, replace the NT Driver PWB (PL 18.3). 

Remove the Platen Glass (REP 6.2). The white reference strip on the bottom of the 
Platen Glass is clean and undamaged. 

Y N 

Clean the white reference strip or replace the Platen Glass (PL 18.3). 

Go to p/j721 on BSD 6.2 and check the flat cable on the IIT/IPS PWB and J741 on the CCD 

PWB for damage. Reseat the flat cable. 

If the problem continues, replace the Lens Kit (PL 18.4). 

If the problem continues, replace the IIT/IPS PWB (PL 18.3). 



15-383 CCD AGC 

Automatic Gain Control (AGC) for CCD Channel 4 green failed. 

Initial Actions 

i Verify that Platen Glass is installed correctly, 
i Verify that NVM 71 5-400 = 1 

Procedure 

NOTE: Refer the BSD 6. 1, 6.2 and 6. 7 as required. 

Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. 

Y N 

Go to the 6-371 Exposure Lamp RAP. 

The Exposure Lamp illumination is bright and steady. 

Y N 

Go to p/j722 and p/j724 on BSD 6.1 and check the wires for an open or short circuit. 
Verify that J742 on the Lamp Ballast PWB and p/j724 on the IIT/IPS PWB are seated. 
If the wires and connectors are good, replace the Exposure Lamp (PL 18.6). 
If the problem continues, replace the Lamp Ballast PWB (PL 18.6). 
If the problem continues, replace the I IT Driver PWB (PL 18.3). 

Remove the Platen Glass (REP 6.2). The white reference strip on the bottom of the 
Platen Glass is clean and undamaged. 

Y N 

Clean the white reference strip or replace the Platen Glass (PL 18.3). 

Go to p/j721 on BSD 6.2 and check the flat cable on the IIT/IPS PWB and J741 on the CCD 

PWB for damage. Reseat the flat cable. 

If the problem continues, replace the Lens Kit (PL 18.4). 

If the problem continues, replace the IIT/IPS PWB (PL 18.3). 



Status Indicator RAPs 

15-382,15-383 



6/02 
2-256 



Prelaunch Training/Review 
DC1 632/2240 



15-384 CCDAGC 

Automatic Gain Control (AGC) for CCD Channel 5 blue failed. 

Initial Actions 

i Verify that Platen Glass is installed correctly, 
i Verify that NVM 715-400 = 1 

Procedure 

NOTE: Refer the BSD 6. 1, 6.2 and 6. 7 as required. 

Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. 

Y N 

Go to the 6-371 Exposure Lamp RAP. 

The Exposure Lamp illumination is bright and steady. 

Y N 

Go to p/j722 and p/j724 on BSD 6.1 and check the wires for an open or short circuit. 
Verify that J742 on the Lamp Ballast PWB and p/j724 on the IIT/IPS PWB are seated. 
If the wires and connectors are good, replace the Exposure Lamp (PL 18.6). 
If the problem continues, replace the Lamp Ballast PWB (PL 18.6). 
If the problem continues, replace the NT Driver PWB (PL 18.3). 

Remove the Platen Glass (REP 6.2). The white reference strip on the bottom of the 
Platen Glass is clean and undamaged. 

Y N 

Clean the white reference strip or replace the Platen Glass (PL 18.3). 

Go to p/j721 on BSD 6.2 and check the flat cable on the IIT/IPS PWB and J741 on the CCD 

PWB for damage. Reseat the flat cable. 

If the problem continues, replace the Lens Kit (PL 18.4). 

If the problem continues, replace the IIT/IPS PWB (PL 18.3). 



15-385 CCD AGC 

Automatic Gain Control (AGC) for CCD Channel 6 blue failed. 

Initial Actions 

i Verify that Platen Glass is installed correctly, 
i Verify that NVM 71 5-400 = 1 

Procedure 

NOTE: Refer the BSD 6. 1, 6.2 and 6. 7 as required. 

Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. 

Y N 

Go to the 6-371 Exposure Lamp RAP. 

The Exposure Lamp illumination is bright and steady. 

Y N 

Go to p/j722 and p/j724 on BSD 6.1 and check the wires for an open or short circuit. 
Verify that J742 on the Lamp Ballast PWB and p/j724 on the IIT/IPS PWB are seated. 
If the wires and connectors are good, replace the Exposure Lamp (PL 18.6). 
If the problem continues, replace the Lamp Ballast PWB (PL 18.6). 
If the problem continues, replace the I IT Driver PWB (PL 18.3). 

Remove the Platen Glass (REP 6.2). The white reference strip on the bottom of the 
Platen Glass is clean and undamaged. 

Y N 

Clean the white reference strip or replace the Platen Glass (PL 18.3). 

Go to p/j721 on BSD 6.2 and check the flat cable on the IIT/IPS PWB and J741 on the CCD 

PWB for damage. Reseat the flat cable. 

If the problem continues, replace the Lens Kit (PL 18.4). 

If the problem continues, replace the IIT/IPS PWB (PL 18.3). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-257 



Status Indicator RAPs 

15-384, 15-385 



15-790 X Detail Failure 

Communication Failure. 

Procedure 

Switch the power off then on. The problem continues. 
Y N 

Check the connectors on the NT/IPS PWB (PL 18.3). If the check ia OK, replace the NT/ 
IPS PWB (PL 18.3). 

Return to Service Call Procedures. 



Status Indicator RAPs 

15-790 



6/02 
2-258 



Prelaunch Training/Review 
DC1 632/2240 



16-311 Scanner 

Scanner not detected during power up. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check connections between Scanner and IOT. Service as required (PL 18.3) (PL 18.4). 



16-315 NT Interface 

NT interface error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pivot down T5 T6 HVPS (REP 1 .6) to access l/F PWB. 
Check that connections on l/F PWB are secure. 
If problem continues, replace l/F PWB (PL 9.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-259 



Status Indicator RAPs 

16-311,16-315 



16-316 Page Memory 

Page memory not detected. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check installation of Page Memory of the Scanner. 



16-317 Page Memory 

Page Memory error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the Page Memory of the Scanner. 



Status Indicator RAPs 

16-316,16-317 



6/02 
2-260 



Prelaunch Training/Review 
DC1 632/2240 



16-318 Optional Page Memory 

Optional page memory error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace optional Page Memory of the Scanner. 



16-450 SMB Host Name 

PC of the same host name is duplicated on a network. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Change the host name. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-261 



Status Indicator RAPs 

16-450 



16-452 IP Address Duplicated 

PC of the same IP address exists on a network. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Change the IP address. 



16-453 IP Address Acquisition 

The IP address failed to be granted from the DHCP server. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set the IP address. 



Status Indicator RAPs 

16-452,16-453 



6/02 
2-262 



Prelaunch Training/Review 
DC1 632/2240 



16-454 Dynamic DNS Update 

Dynamic DNS update failed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on 



16-460 Full Status Detected 

Full Status Detected at HD Access. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-263 



Status Indicator RAPs 

16-454,16-460 



16-590 Read Error (Partition A) 

A verify error occurred in the HD partition A at PC-Diag operation from PWS. 



16-591 Read Error (Partition B) 

A verify error occurred in the HD partition B at PC-Diag operation from PWS. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set up the HD partition A and perform the verify test again. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set up the HD partition B and perform the verify test again. 



Status Indicator RAPs 

16-590,16-591 



6/02 
2-264 



Prelaunch Training/Review 
DC1 632/2240 



16-592 Read Error (Partition C) 

A verify error occurred in the HD partition C at PC-Diag operation from PWS. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Set up the HD partition C and perform the verify test again. 



16-593 Read Error (Partition D) 

A verify error occurred in the HD partition D at PC-Diag operation from PWS. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set up the HD partition D and perform the verify test again. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-265 



Status Indicator RAPs 

16-592,16-593 



16-594 Read Error (Partition E) 

A verify error occurred in the HD partition E at PC-Diag operation from PWS. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set up the HD partition E and perform the verify test again. 



16-595 Read Error (Partition H) 

A verify error occurred in the HD partition H at PC-Diag operation from PWS. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set up the HD partition H and perform the verify test again. 



Status Indicator RAPs 

16-594,16-595 



6/02 
2-266 



Prelaunch Training/Review 
DC1 632/2240 



16-701 PLW Memory 

An insufficient memory is detected while using the ART EX. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Decrease the resolution. 

NOTE: Decreasing the resolution may have affect of reducing the PLW memory. 



16-702 PLW Memory 

System detected insufficient buffer for the print page that cannot be compressed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Decrease the resolution. 

NOTE: Decreasing the resolution may have affect of reducing the PL W memory. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-267 



Status Indicator RAPs 

16-701,16-702 



16-703 Email To Invalid Box 

System detected an unopened or invalid Mailbox and aborted a job when receiving an Email. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Open the appropriate Mailbox. 
Send an Email to a valid Mailbox. 



16-704 Security Box 

The system detected that a Mailbox was full (it exceeded the maximum number of documents 
per Box) and aborted a job. Full status was detected at HD access and a job was aborted. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Delete unwanted documents and retry the job. 



Status Indicator RAPs 

16-703,16-704 



6/02 
2-268 



Prelaunch Training/Review 
DC1 632/2240 



16-705 Security Storage without HD 

Registry for Secure Print has failed because Security Storage cannot be done due to no HD 
available. 



16-706 Maximum User Number 

The system detected that a job exceeded the maximum number of users for Secure and Proof 
Prints and aborted the job. Full status was detected at HD access and a job was aborted. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check whether the HD is installed. 

If the problem has occurred at installation, check whether the operations for Secure Print are 

correct. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Delete unwanted documents/users and retry printing. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-269 



Status Indicator RAPs 

16-705,16-706 



16-709 PLW Command 

An ART EX Command error has occurred during PLW processing. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Cancel the job and execute the command again. 



16-716 Spool TIFF Data 

Unable to spool TIFF files because disk capacity is exceeded. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Install the HD or increase the capacity of the HD. 



Status Indicator RAPs 

16-709,16-716 



6/02 
2-270 



Prelaunch Training/Review 
DC1 632/2240 



16-721 Other Errors 

An error occurred during printing that is not defined. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Run the same job again to check the error status and ask Support G for help. 



16-726 Decomposer Auto Judgement 

Cannot switch decomposer; a print Language auto judgement error occurred. 
Auto Judgement Error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Fix and select the Decomposer from the Operation Panel or with a command. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-271 



Status Indicator RAPs 

16-721,16-726 



16-728 TIFF Data 

The data contains a Tag that is not set in the Image File Expansion Library. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Delete the unsupported Tag from the data and retry printing, etc. 



16-729 TIFF Data 

The specified settings exceed the upper limit of the valid number of colors and pixels. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Correct the valid range, etc. 



Status Indicator RAPs 

16-728,16-729 



6/02 
2-272 



Prelaunch Training/Review 
DC1 632/2240 



16-730 ART Command 

ART IV Command Invalid. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Delete the unsupported command from the data and retry printing. 



16-731 TIFF Data 

Invalid TIFF Data. The TIFF data is broken or cut halfway. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Resend the data, etc. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-273 



Status Indicator RAPs 

16-730,16-731 



16-735 Job Template 

The system tried to output the Job Template List while the Job Template was being updated. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Run the job again after the Job Template update has completed. 



1 6-737 Server Read 

Read error from the Job Template Pool Server 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check that "Authorization to read" is established for the storage destination server directory set 
as resource. 



Status Indicator RAPs 

16-735,16-737 



6/02 
2-274 



Prelaunch Training/Review 
DC1 632/2240 



16-739 Job Template Path 

The specified path of the Job Template Pool Server cannot be found. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set the resource of the storage destination path from a client PC on the CentreWare. 



16-740 Job Template Login 

Job Template Server Login Error. Cannot log in to the Job Template Pool Server. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set the log-in name and password in the Job Template file storage destination. 

From some other PC connected to the network, check that you can log in with the above 

account. 

Set the log-in name and password as a resource from the CentreWare client PC. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-275 



Status Indicator RAPs 

16-739,16-740 



16-741 Job Template Connection 16-742 HD File 

Cannot connect to the Job Template Pool Server. File system was full when the Job Template was stored into the local HD. 

Procedure Procedure 

Switch power off then on. The problem continues. Switch power off then on. The problem continues. 

Y N Y N 



Return to service call procedures. 



Return to service call procedures. 



Connect the cable from the M/C to a network correctly. Because the scanned images may exceed HD capacity, rerun the job. 

From the destination server, check that you can identify the M/C with "ping". If the problem continues, Initialize the HD. 

Perform the "ping" test on the destination server from . If the problem continues, replace the HD (PL 13.1). 

From a client PC to check that the FTP connection to the destination server is possible. 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

16-741,16-742 2-276 dci 632/2240 



16-743 Job Template Installation 

Job template pool server installation error or job template pool server setting failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set the Spool Server related parameters again. 



16-744 Job Template Address 

The Job Template Pool Server address cannot be solved (Response to the DNS library error) 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the connection to the DNS. Check that the Job Template Pool Server domain name is 
the one that has been registered in the DNS. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-277 



Status Indicator RAPs 

16-743,16-744 



16-745 Job Template Definition 

The Job Template Pool Server address cannot be solved (The DNS address is not set) 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set the DNS address. Or set the Job Template Pool Server address by the IP address. 



16-748 HDFull 

Full status was detected at HD access and a job was aborted. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Retry printing after making more space of the HD capacity. 



Status Indicator RAPs 

16-745,16-748 



6/02 
2-278 



Prelaunch Training/Review 
DC1 632/2240 



16-749 XJCL Syntax 

Syntax error of the JCL command was detected. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Correct the command. 



16-757 Auditron User 

Invalid Auditron User 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set a correct account and retry. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-279 



Status Indicator RAPs 

16-749,16-757 



16-758 Auditron Function 

An auditron function is disabled. 



16-759 Auditron Limit 

Auditron reached limit. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Consult the account administrator to add a right. 

Set the new function that is allowed for that account and retry. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Consult the account administrator to set the number of copies, etc. 



Status Indicator RAPs 

16-758,16-759 



6/02 
2-280 



Prelaunch Training/Review 
DC1 632/2240 



16-760 Decomposer 

Error during decompose processing. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Resend the job. The execution environment/data check are required if the problem persists. 



16-761 FIFO 

Image Enlargement Error, FIFO EMPTY Error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Print in fast print mode. 

If problem continues, use print guarantee mode. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-281 



Status Indicator RAPs 

16-760,16-761 



16-762 Decomposer 

The print language is not installed or an unsupported function (print language, print utility, etc.) 
was required. The Decomposer specified with PJL or Auto SW is not installed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Fix and select the Decomposer from the Operation Panel or with a command. 



16-763 Patch 

Original patch does not exist. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Place the Auto Gradation Correction Chart correctly. 



Status Indicator RAPs 

16-762,16-763 



6/02 
2-282 



Prelaunch Training/Review 
DC1 632/2240 



16-764 Server Transmission 

SMTP Server Connection Error, result code: 421/451 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Retrieve emails in the Server HD. Restart the SMTP service. 



16-765 Server Storage 

SMTP Server HD Full, Result code: 452 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Retrieve emails in the Server HD. Rearrange the server capacity. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-283 



Status Indicator RAPs 

16-764,16-765 



16-766 Server Storage 

SMTP Server File System has a problem, result code: 552. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Contact the SMTP Server administrator. Rearrange the server capacity limit. 



16-767 Mailbox 

Mailbox not found, or no access. Email destination address Incorrect, result code: 550/551 . 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the destination of the email. 



Status Indicator RAPs 

16-766,16-767 



6/02 
2-284 



Prelaunch Training/Review 
DC1 632/2240 



16-768 Mail From Command 

Mail From Command, Sending Address Incorrect, Login Error. 



16-769 DSN Unsupported 

SMTP Server Not Applicable to DSN 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the settings of the self-email address. Check whether it is a valid email address in the 
domain. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Enable the ESMTP function of nearest SMTP Server. Or disable the Sending/Receiving Confir- 
mation function when sending an email. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-285 



Status Indicator RAPs 

16-768,16-769 



16-770 Template Processing 

The system aborted a job due to insufficient HD capacity at Job Template processing. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Create free space for the HD capacity. 



16-771 Scan Data Repository 

The Scanned Data Repository Address cannot be solved. DNS Address is not set. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set the DNS address. Or set the Scan Data Repository address by the IP address. 



Status Indicator RAPs 

16-770,16-771 



6/02 
2-286 



Prelaunch Training/Review 
DC1 632/2240 



1 6-772 Scan Data Repository 

The Scan Data Repository address cannot be solved (Response to the DNS library error) 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the connection to the DNS. Or check that the Scanned Data Repository domain name is 
the one that has been registered in the DNS. 



16-773 IP Address 

Self-machine IP address invalid, DHCP Lease Expired. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the DHCP environment. Set the fixed IP address for the self-machine. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-287 



Status Indicator RAPs 

16-772,16-773 



16-774 HD Compression 

HD Full at Compression type conversion 

HD Full has occurred when the S-Formatter did the compression type conversion of the JBIG 
compressed images into the MH system (partition #1). 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Create free space for the HD capacity and retry. 



16-775 HD Capacity 

Image Conversion Error. Insufficient HD capacity is detected during image conversion process 
by S-Formatter. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Create free space for the HD capacity and retry. 



Status Indicator RAPs 

16-774,16-775 



6/02 
2-288 



Prelaunch Training/Review 
DC1 632/2240 



16-776 Image Conversion 16-777 HD Access 

An error has occurred due to other causes than HD Access during image conversion process The HD Access Error has occurred during image conversion process by S-Formatter. 
by S-Formatter. 

Procedure 

Procedure Switch power off then on. The problem continues. 

Switch power off then on. The problem continues. Y N 



Y N 

Return to service call procedures. 

Perform the operation again. 



Return to service call procedures. 
Replace the HD (PL 13.1) and perform the operation again. 



Prelaunch Training/Review g/02 Status Indicator RAPs 

DCI632/2240 2289 16-776 Image Conversion, 1 6-777 



16-778 HD Capacity 



The insufficient HD capacity was detected during scanned image conversion process by l-For- 
matter. 



16-779 Scan Image Conversion 

An error has occurred due to other causes than HD Access during scanned image conversion 
process by l-Formatter. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Create free space of the HD capacity and retry scanning. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on and perform the operation again. 



Status Indicator RAPs 

16-778,16-779 



6/02 
2-290 



Prelaunch Training/Review 
DC1 632/2240 



16-780 HD Access 

The HD Access Error has occurred during scanned image conversion process by l-Formatter. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the HD (PL 13.1) and retry scanning. 



16-781 Scan Server 

Net Connection Error during Scanning. Connection to the Server cannot be established during 
Scan to Server file transfer operation. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set "Sub-net Mask" and "Gateway" of the main processor correctly. 

From the destination server, check that you can identify the M/C with "ping". 

From a Windows95 or UNIX machine to check that the FTP connection to the destination 

server is possible. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-291 



Status Indicator RAPs 

16-780,16-781 



16-782 Scan Server Login 



Server Login Error during Scanning. Cannot log in to the Server during Scan to Server file 
transfer operation. 



1 6-783 Server Path 

Server Path Error at Scanning. The specified path cannot be found at Scan to Server file 
transfer operation. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set the log-in name and password in the destination server. 

Make correct settings for the attributes of the Job Template file. 

From a client PC, set the same account as the above as a resource in CW. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Make correct settings for the attributes of the Job Template file. 



Status Indicator RAPs 

16-782,16-783 



6/02 
2-292 



Prelaunch Training/Review 
DC1 632/2240 



16-784 Server Write 

Write Error at Scanning. The Server cannot be written to at the Scan to Server file transfer. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check that there is "Write Authorization:" in the server directory. 
Create free space on the server disk. 



16-785 Server HD Full 

Server File Full at Scanning. The Server File System became full during the Scan to Server 
file transfer. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check that there is "Write Authorization" in the server directory. 
Create free space on the server disk. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-293 



Status Indicator RAPs 

16-784,16-785 



16-786 HD Scan Write 16-787 Job Template Syntax 

Internal HD Write Error at Scanning. A temporary file cannot be written to the internal HD at This is a syntax error in the Job Template during Scan to Server operation and limited to the 
the Scan to Server file transfer. following cases (because of Redirector detection): Server IP Address Incorrect (IP Syntax 

Error) 

Procedure 

Switch power off then on. The problem continues. HrocedU re 

Y N Switch power off then on. The problem continues. 

Return to service call procedures. Y N 

Return to service call procedures. 
HD may be filled with print jobs. Allow time and retry. 

If the problem continues, format the HD. Check the contents of the attributes (string RepositoryName) in the Job Template file. 
If the problem continues, replace the HD (PL 13.1). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

16-786,16-787 2-294 dci 632/2240 



16-788 Mailbox to PC 

Retrieval Failed at Scan to PC (via Web Browser. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Improve the connection status to a network. 
Check for problem such as duplicated IP addresses. 



16-793 MF I/O HD Full 

MFIO HD Full 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Insufficient Area of Hard Disk (MF I/O). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-295 



Status Indicator RAPs 

16-788,16-793 MF I/O HD 



16-950 Tray 1 Empty 

Tray 1 Empty 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Add paper. 



16-951 Tray 2 Empty 

Tray 2 Empty 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Add paper. 



Status Indicator RAPs 

16-950,16-951 



6/02 
2-296 



Prelaunch Training/Review 
DC1 632/2240 



16-952 Tray 3 Empty 

Tray 3 Empty 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Add paper. 



16-953 Tray 4 Empty 

Tray 4 Empty 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Add paper. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-297 



Status Indicator RAPs 

16-952,16-953 



16-954 Tray 5 Empty 

Tray 5 Empty 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Add paper. 



16-958 Tray 5 Size 

Tray 5 Size Mismatch 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Load proper paper in the tray. 



Status Indicator RAPs 

16-954,16-958 



6/02 
2-298 



Prelaunch Training/Review 
DC1 632/2240 



16-959 Tray 1 Size 

Tray 1 Size Mismatch 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Load proper paper in the tray. 



16-960 Tray 2 Size 

Size Mismatch Tray 2 Size Mismatch 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Load proper paper in the tray. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-299 



Status Indicator RAPs 

16-959,16-960 



16-961 Tray 3 Size 

Tray 3 Size Mismatch 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Load proper paper in the tray. 



16-962 Tray 4 Size 

Tray 4 Size Mismatch 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Load proper paper in the tray. 



Status Indicator RAPs 

16-961,16-962 



6/02 
2-300 



Prelaunch Training/Review 
DC1 632/2240 



16-965 ATS/APS No Paper 

APS/ATS NG No Paper. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Add paper. 



16-966 ATS/APS No Destination 

ATS/APS No Destination, other than No Paper. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Change the settings and replace the Trays. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-301 



Status Indicator RAPs 

16-965,16-966 



16-981 Full HD 

Full status was detected at HD access. Full status was not cleared even during waiting for tim- 
ing. One or more pages are already stored. 



16-982 FullHD 

Full status was detected at HD access. Full status was not cleared even during waiting for tim- 
ing. No pages can be stored. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Service actions depend on the operation specifications. 

Again, switch power off then on. 

If the problem continues, reload software. 

If the problem continues, replace the HD (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. 



Status Indicator RAPs 

16-981,16-982 



6/02 
2-302 



Prelaunch Training/Review 
DC1 632/2240 



102-200 Receive Buffer Overflow 

The data received from the Controller exceeded the buffer amount of the destination in the 
Panel. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the ESS PWB (PL 13.1) 



102-201 Send Buffer Overflow 

The data to be sent from the Panel exceeded the buffer amount of the destination in the Panel. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the ESS PWB (PL 13.1) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-303 



Status Indicator RAPs 

102-200, 102-201 



102-202 Request Queue Full 



The event that requires more than the processing capability for the request arising in the Panel 
has occurred. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the ESS PWB (PL 13.1) 



102-203 Send Request Queue Full Debug 

Data cannot be sent from the Panel to the Controller. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the ESS PWB (PL 13.1) 



Status Indicator RAPs 

102-202, 102-203 



6/02 
2-304 



Prelaunch Training/Review 
DC1 632/2240 



102-204 SIO Parameter 

Serial communication failure. Incorrect message size at SIO receiving request, or incorrect 
Mailbox ID when a message is sent. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-205 SIO Command 

Serial communication failure. A command error has occurred at SIO receiving request. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-305 



Status Indicator RAPs 

102-204, 102-205 



102-206 SIO Status 

Serial communication failure. A header status error of the RX packet or a message status error 
of the RX packet has occurred. 



102-207 Communication Manager Target 

Serial communication failure. Incorrect Mailbox value on the cm_send_msg statement, or the 
target is not SYS when receiving from SIO. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-206, 102-207 



6/02 
2-306 



Prelaunch Training/Review 
DC1 632/2240 



102-208 Communication Manager Command 

Serial communication failure. A command error has occurred when receiving from SIO. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Perform re-installation of the software. 



102-209 EVM Returns Wrong Value 

Return value error from EVM. Panel-SW failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-307 



Status Indicator RAPs 

102-208, 102-209 



102-310 Send Queue Full 

Over the upper limit of the processing capability to send data from the Panel to the Controller. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-311 Receive Queue Full 

The data received from the Controller exceeded the upper limit of the processing capability in 
the Panel. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-310,102-311 



6/02 
2-308 



Prelaunch Training/Review 
DC1 632/2240 



102-312 EVM Uses Wrong API 

Illegal use of API by EVM. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-313 AS Uses Wrong API 

Illegal use of API by AS 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-309 



Status Indicator RAPs 

102-312,102-313 



102-314 Wait Event Time Out 

Time-Out of the event waiting timer. The response message from the Controller was not noti- 
fied for a specified time. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-315 CTS Internal 

CTS Internal Error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-314, 102-315 



6/02 
2-310 



Prelaunch Training/Review 
DC1 632/2240 



102-316 Send Request Queue Full SIO 

Over the upper limit of the processing capability to send data from the Panel to the Controller. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-317 Receive Message Queue Full 

The data received from the Controller exceeded the upper limit of the processing capability in 
the Panel. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-311 



Status Indicator RAPs 

102-316,102-317 



102-318 Receive Finish Queue Full 

The data received from the Controller exceeded the upper limit of the processing capability in 
the Panel. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-319 Send with No ACK 

Serial communication failure. Sending failure, ACK was not returned. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-318, 102-319 



6/02 
2-312 



Prelaunch Training/Review 
DC1 632/2240 



102-320 Polling 

Serial communication failure. Communication failure (polling error) 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-321 Send Message 

Serial communication failure. Sending message error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-313 



Status Indicator RAPs 

102-320, 102-321 



102-322 Target 

Serial communication failure. Target error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-323 Address 

Serial communication failure. Address error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-322, 102-323 



6/02 
2-314 



Prelaunch Training/Review 
DC1 632/2240 



102-324 Size 

Serial communication failure. Size error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-325 Object Creation 



Object creation error. The specified object failed to be created due to a setting or specifying 
error on gm_create. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-315 



Status Indicator RAPs 

102-324, 102-325 



102-326 Memory Overflow 

Memory overflow. The memory in the GUAM exceeded the upper limit. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Expand the memory in the GUAM. 

If the problem continues, perform re-installation of the software. 



102-327 Button Overflow 

Button overflow. The memory for the (synchronous display) button in the GUAM exceeded the 
upper limit. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Expand the memory for the button in the GUAM. 

If the problem continues, perform re-installation of the software. 



Status Indicator RAPs 

102-326, 102-327 



6/02 
2-316 



Prelaunch Training/Review 
DC1 632/2240 



102-328 Ul Internal with Out of Area 

l/F failure in the Ul. The coordination value out of the area of the displayed screen was 
detected (W x H = 640 x 240) 



102-329 Ul Internal with Invalid Coordinates 

l/F failure in the Ul. The coordination value that cannot be displayed was detected (X = 4 times 
number position) 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. 

If the problem continues, perform re-installation of the software. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. 

If the problem continues, perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-317 



Status Indicator RAPs 

102-328, 102-329 



102-330 Interface with Invalid Parameter LCD 

Interface failure. Incorrect parameter was detected at the Drv. I/F between the DM and LCD. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. 

If the problem continues, perform re-installation of the software. 



102-331 Ul Internal with Invalid LED Request 

l/F failure in the Ul. The request for lighting up an incorrect LED was received. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. 

If the problem continues, perform re-installation of the software. 



Status Indicator RAPs 

102-330, 102-331 



6/02 
2-318 



Prelaunch Training/Review 
DC1 632/2240 



102-332 Interface with Invalid Parameter CP 

Interface failure. Incorrect parameter was detected at the Drv. I/F between the DM and CP. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. 

If the problem continues, perform re-installation of the software. 



102-333 Interface with Impossible Communication 

Interface failure. Impossible communication with the Control Panel was detected. H/W con- 
nection failure in the Panel, or the internal connection was unable to be detected correctly. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-319 



Status Indicator RAPs 

102-332, 102-333 



102-334 Interface with Receiving Error Key Code 

Interface failure. Invalid Key Code was received from the Control Panel. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Repair/adjust the Control Panel (PL 18.2) 



102-335 Interface with Receiving Invalid Coordinates 

Interface failure. Invalid coordination value was received from the Control Panel with a param- 
eter. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Repair/adjust the Control Panel (PL 18.2) 



Status Indicator RAPs 

102-334, 102-335 



6/02 
2-320 



Prelaunch Training/Review 
DC1 632/2240 



102-336 Interface DM - ACD Drv. I/F 

Interface failure. Incorrect parameter was detected at the Drv. I/F between the DM and ACD. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. 

If the problem continues, perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-337 Frame Data Error with Invalid Data Type 

Invalid frame data was detected. The incorrect value of the Data Type detected by Frame ID 
was detected. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. 

If the problem continues, perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-321 



Status Indicator RAPs 

102-336, 102-337 



102-338 Frame Data Error Offset Address Out of Scope 

Invalid frame data was detected. The Offset Address out of range was extracted from the 
Frame ID. 



102-339 Display Request Code Invalid 

Text Code failure. The system detected that the Code requested to be displayed was incor- 
rect. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. Replace the Control Panel (PL 18.2) 
If the problem continues, perform re-installation of the software. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. Replace the Control Panel (PL 18.2) 
If the problem continues, perform re-installation of the software. 



Status Indicator RAPs 

102-338, 102-339 



6/02 
2-322 



Prelaunch Training/Review 
DC1 632/2240 



102-340 Interface GUAM - DM l/F 

Interface failure. Incorrect parameter was detected at the l/F between the GUAM and DM. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Check the D-RAM and ROM. Replace the Control Panel (PL 18.2) 
If the problem continues, perform re-installation of the software. 



102-341 Event Queue Full 

Event queue full 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-323 



Status Indicator RAPs 

102-340, 102-341 



102-342 Event Queue Empty 

Event queue empty 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-343 Invalid Class 

Invalid class 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Status Indicator RAPs 

102-342, 102-343 



6/02 
2-324 



Prelaunch Training/Review 
DC1 632/2240 



102-344 Invalid Type 

Invalid type 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-345 Timer Queue Full 

Timer queue full 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-325 



Status Indicator RAPs 

102-344, 102-345 



102-346 Invalid Timer Number 

Invalid timer number 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-347 Undefined Trap 

Undefined trap 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Status Indicator RAPs 

102-346, 102-347 



6/02 
2-326 



Prelaunch Training/Review 
DC1 632/2240 



102-348 Command Access Exception 

Exceptional command access 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-349 Invalid Command 

Illegal command 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-327 



Status Indicator RAPs 

102-348, 102-349 



102-350 Privilege Command 

Privilege command 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-351 No FPU Exception 

Exceptional FPU non-existence 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Status Indicator RAPs 

102-350, 102-351 



6/02 
2-328 



Prelaunch Training/Review 
DC1 632/2240 



102-352 Address Misalign 

Address mis-alignment 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-353 Data Access Exception 

Exceptional data access 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-329 



Status Indicator RAPs 

102-352, 102-353 



102-354 Tag Overflow 

Tag overflow 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-355 No Co Processor Exception 

Exceptional Co Processor non-existence 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Status Indicator RAPs 

102-354, 102-355 



6/02 
2-330 



Prelaunch Training/Review 
DC1 632/2240 



102-356 Short of Area 

Insufficient area 



102-357 Cancel Wait Status 

Forced cancellation of the wait status 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-331 



Status Indicator RAPs 

102-356, 102-357 



102-358 Time Out 

Time-Out 



102-359 Queue Overflow 

Queue overflow 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Switch power off then on. 



Status Indicator RAPs 

102-358, 102-359 



6/02 
2-332 



Prelaunch Training/Review 
DC1 632/2240 



102-360 Context 

Context error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-361 Object 

Object error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-333 



Status Indicator RAPs 

102-360, 102-361 



102-362 No Object 

Object non-existence 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-363 Invalid ID 

Incorrect ID 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Status Indicator RAPs 

102-362, 102-363 



6/02 
2-334 



Prelaunch Training/Review 
DC1 632/2240 



102-364 Parameter 

Parameter error 



102-365 Reserve Attribute 

Reserve attribute 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-335 



Status Indicator RAPs 

102-364, 102-365 



102-366 Reserve Function Code 

Code number for reserve function 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-367 Unsupported Function 

Unsupported function 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Status Indicator RAPs 

102-366, 102-367 



6/02 
2-336 



Prelaunch Training/Review 
DC1 632/2240 



102-368 Short of Ul Memory 

Insufficient memory, or connection failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



102-369 Invalid Interface Value 

Invalid interface value. Panel-SW failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-337 



Status Indicator RAPs 

102-368, 102-369 



102-370 Interface Length 

Interface length failure. The parameter notified from the Controller was incorrect. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-371 Interface Parameter 

Interface parameter failure. The parameter notified from the Controller was incorrect. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-370, 102-371 



6/02 
2-338 



Prelaunch Training/Review 
DC1 632/2240 



102-372 Interface Sequence 

Interface sequence failure. The initial command from the Controller was not notified for a 
specified time. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-373 Channel 

Channel failure. The channel notified from the Controller was incorrect. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-339 



Status Indicator RAPs 

102-372, 102-373 



102-374 Invalid User Job ID 

Incorrect User Job ID. The Job ID parameter notified from the Controller was incorrect. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-375 Internal Resource 

Internal resource failure. Panel-SW failure. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-374, 102-375 



6/02 
2-340 



Prelaunch Training/Review 
DC1 632/2240 



102-376 Internal Memory 

Internal memory failure. Panel-SW failure. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-377 Ul Timer 

Timer failure. Panel-SW failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-341 



Status Indicator RAPs 

102-376, 102-377 



102-378 Interface Format 

Interface format failure. The data format notified from the Controller was incorrect. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-379 Dispatch 

Dispatch failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-378, 102-379 



6/02 
2-342 



Prelaunch Training/Review 
DC1 632/2240 



102-380 Copy Interface 

Copy interface failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-382 Scanner Interface 

Scanner interface failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-343 



Status Indicator RAPs 

102-380, 102-382 



102-383 Report Interface 

Report interface failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-384 Server Access 

Server access failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-383, 102-384 



6/02 
2-344 



Prelaunch Training/Review 
DC1 632/2240 



102-385 Service Object Overflow 

Service object overflow 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-386 Invalid Service Object 

Invalid service object 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-345 



Status Indicator RAPs 

102-385, 102-386 



102-387 Invalid Service Object Attribute 

Invalid service object attribute 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Perform re-installation of the software. 



102-388 Attribute 

Attribute Error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-387, 102-388 



6/02 
2-346 



Prelaunch Training/Review 
DC1 632/2240 



102-389 Argument 

Argument Error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-390 Job Parameter 

Job parameter argument error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-347 



Status Indicator RAPs 

102-389, 102-390 



102-391 Job Actual Parameter 

Job execution argument error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. 



102-392 Auditron 

Invalid Auditron 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-391,102-392 



6/02 
2-348 



Prelaunch Training/Review 
DC1 632/2240 



102-393 EP 

Software failure 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-394 File Access 

Invalid file access 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-349 



Status Indicator RAPs 

102-393, 102-394 



102-395 NVM 

NVM failure 



102-396 FF 

FF error 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



Status Indicator RAPs 

102-395, 102-396 



6/02 
2-350 



Prelaunch Training/Review 
DC1 632/2240 



102-397 MGR 

MGR error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 



102-398 Delay Release Queue Full 

Delay release queue full. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-351 



Status Indicator RAPs 

102-397, 102-398 



102-399 Internal 

Internal error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the software. 

If the problem continues, replace the Control Panel (PL 18.2) 



Status Indicator RAPs 

102-399 



6/02 
2-352 



Prelaunch Training/Review 
DC1 632/2240 



103-203 Machine Code Failure 

Product Number Failure (Not initialized). 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

CAUTION 

ESS PWB and MCU PWB cannot be replaced at the same time. 

Replace the ESS PWB (PL 13.1). 

If the problem continues, replace the MCU PWB (PL 13.1) 

Return to Service Call Procedures. 



103-204 Serial Number Failure 

Serial Number Failure (Not initialized). 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

CAUTION 

ESS PWB and MCU PWB cannot be replaced at the same time. 

Replace the ESS PWB (PL 13.1). 

If the problem continues, replace the MCU PWB (PL 13.1) 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-353 



Status Indicator RAPs 

103-203, 103-204 



103-207 All Machine Codes Mismatch 

At least one of the three Product codes are mismatched. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

CAUTION 

ESS PWB and MCU PWB cannot be replaced at the same time. 

Replace the ESS PWB (PL 13.1). 

If the problem continues, replace the MCU PWB (PL 13.1) 

Return to Service Call Procedures. 



103-208 All Serial Numbers Mismatch 

At least one of the three Serial Numbers are mismatched. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Go to (GP 10). 

Return to Service Call Procedures. 



Status Indicator RAPs 

103-207, 103-208 



6/02 
2-354 



Prelaunch Training/Review 
DC1 632/2240 



103-320 EEPROM Failure 

A write error has occurred in the SEEPROM on the ESS PWB. 



103-321 Backup SRAM Failure 

A write error has occurred in the NVM on the ESS PWB. 



Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-355 



Status Indicator RAPs 

103-320, 103-321 



103-330 ESS ROM DIMM #3 Check Failure 

An ESS ROM DIMM #3 check failure was detected. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Remove and replace the ESS ROM DIMM #3. 

If the problem continues, replace the ESS ROM DIMM #3 



Return to Service Call Procedures. 



103-331 ESS ROM DIMM #1 Not Found 

The system detected that the ESS ROM DIMM #1 was not installed. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Remove and replace the ESS ROM DIMM #1. 

If the problem continues, replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

103-330, 103-331 



6/02 
2-356 



Prelaunch Training/Review 
DC1 632/2240 



103-332 ESS Standard ROM Error 

An error was detected in the ESS built-in standard ROM. 



103-333 ASIC Failure (Panther-t) 

An error was detected in the Panther. 



Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Remove and replace the ESS built-in standard ROM. 

If the problem continues, replace the ESS built-in standard ROM. 

Return to Service Call Procedures. 



Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-357 



Status Indicator RAPs 

103-332, 103-333 



103-334 Standard Post Script Font ROM Error 

An error was detected in the standard built-in Post Script Font ROM. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Replace the Post Script Font ROM (PL 13.1). 

Return to Service Call Procedures. 



103-335 Post Script Font ROM Not Found 

Post Script Font ROM installation was detected. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Replace the Post Script Font ROM (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

103-334, 103-335 



6/02 
2-358 



Prelaunch Training/Review 
DC1 632/2240 



103-336 ESS RAM DIMM #3 W/r Check Failure 

A failure was detected during Read/Write Check of the ESS RAM DIMM #3. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Remove and replace the ESS RAM DIMM #3. 

If the problem continues, replace the ESS ROM DIMM #3 

Return to Service Call Procedures. 



103-337 ESS Standard RAM Error 

An error was detected in the ESS built-in standard RAM. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-359 



Status Indicator RAPs 

103-336, 103-337 



103-338 Same Post Script Font ROMiS Found 

The system detected that the same Post Script Font ROM was installed. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Install the appropriate Post Script Font ROM. 

If the problem continues, replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



103-339 ROM DIMM Of Another Product Found 

The system detected that the ROM DIMM for another machine was installed. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Install the appropriate ROM DIMM. 

If the problem continues, replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



Status Indicator RAPs 

103-338, 103-339 



6/02 
2-360 



Prelaunch Training/Review 
DC1 632/2240 



103-372 IOT Sc Soft Failure 

IOT Controller software failure was detected. 

Procedure 

Turn the power OFF/ON. The fault is cleared. 
Y N 

Reinstall the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 

Return to Service Call Procedures. 



103-701 Changed Output Bin: Side To Center 

The output tray was changed (Side Tray to Center Output Tray). 

Procedure 

No action required. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-361 



Status Indicator RAPs 

103-372, 103-701 



103-702 Changed Output Bin: Finisher To Center 

The output tray was changed (Finisher Tray to Center Output Tray). 

Procedure 

No action required. 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

103-702 2-362 DC1 632/2240 



116-200 Main PWBA IC 

An error was detected in the IC in the ESS PWB. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



116-201 HD 

The HD was not booted due to a HD error detected on booting 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Run the HD Diag (DC355). 

If the problem continues, replace the HD (PL 13.1) 

If the problem continues, replace the ESS PWB (PL 13.1) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-363 



Status Indicator RAPs 

116-200,116-201 



116-206 Timer 

A timer error was detected. 

Procedure 

Replace the ESS PWB (PL 13.1). 



116-207 Ethernet Board 

A timer error was detected in the Ethernet board. 

Procedure 

This code is not supposed to occur. 



Status Indicator RAPs 

116-206,116-207 



6/02 
2-364 



Prelaunch Training/Review 
DC1 632/2240 



116-209 ESSPS-1 ROM Check 

A failure was detected when the ESS PS-1 ROM was checked. 



116-310 ESS PS-2 ROM Check 

A failure was detected when the ESS PS-2 ROM was checked. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the PS-1 ROM (PL 13.1). 

If the problem continues, replace PS-1 ROM (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the PS-2 ROM (PL 13.1). 

If the problem continues, replace PS-2 ROM (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-365 



Status Indicator RAPs 

116-209,116-310 



116-311 ESS Font ROM DIMM #3 Check 

A failure was detected when the ESS FONT ROM DIMM #3 was checked. 



116-314 Ethernet Address 

A Ethernet error was detected. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the ESS FONT ROM DIMM #3. 

If the problem continues, replace the ESS FONT ROM DIMM #3. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Switch power off then on. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-311,116-314 



6/02 
2-366 



Prelaunch Training/Review 
DC1 632/2240 



116-315 ESS RAM DIMM #1 W/R Check 

A failure was detected during W/R of the ESS RAM DIMM #1 . 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the ESS RAM DIMM #1 . 

If the problem continues, replace the ESS RAM DIMM #1. 



116-316 ESS RAM DIMM #2 W/R Check 

A failure was detected during W/R of the ESS RAM DIMM #2. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the ESS RAM DIMM #2. 

If the problem continues, replace the ESS RAM DIMM #2. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-367 



Status Indicator RAPs 

116-315,116-316 



116-317 Standard ROM DIMM Check 

An error was detected when the standard ROM DIMM was checked. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the standard ROM DIMM. 

If the problem continues, replace the standard ROM DIMM. 



116-318 Option ROM DIMM Check 

An error was detected when the optional ROM DIMM was checked. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the optional ROM DIMM. 

If the problem continues, replace the optional ROM DIMM. 



Status Indicator RAPs 

116-317,116-318 



6/02 
2-368 



Prelaunch Training/Review 
DC1 632/2240 



116-319 Serial 

There is no serial board at the serial board initialization failure. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Reinstall the serial board. 



116-320 STREAMZSoft 

Fatal error of the STREAMZ. Due to an error during the software processing, the subsequent 
processes cannot be performed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-369 



Status Indicator RAPs 

116-319,116-320 



116-321 SystemSoft 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



116-323 ESS NVRAM W/R Check 

An error was detected at the W/R check of the NVM in the ESS PWB. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-321,116-323 



6/02 
2-370 



Prelaunch Training/Review 
DC1 632/2240 



116-324 Exception Error 

CPU exceptional error. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to Service Call Procedures. 

Replace the ESS PWB (PL 13.1). 



116-325 Communication Error 

+24 VDC enabled Communications failure. 

Procedure 

+24 VDC power is failed. Status Code 102-319 is displayed after 116-325 is displayed. 

Y N 

Preliminary information not available. 

+24V LVPS is failed. Perform following: 

Remove Rear Cover (REP 14.2). 

Remove cover from +24V LVPS (PL 9.1). 

Disconnect P502 on +24V LVPS (Figure 1). 
Check that power is switched off. Measure resistance of fuse on +24V LVPS. Resistance is 1 
ohm or less. 

Y N 
Replace +24V LVPS (PL 9.1). 

Switch on the power. Measure the AC voltage between the white and black wires in P2 on the 
+24 VDC. 110 or 220 VAC is measured. 

Y N 
Go to the AC Power RAP. 

Connect the black meter lead to DC COM or frame. Measure DC voltage at P505 on the +24 V 
LVPS (Figure 1). Voltages are measured as shown. 

Y N 
There is a problem with the +24 VDC enable circuit. Go to the +24 VDC Enable RAP. 

Measure the DC voltage at P502 on the +24V LVPS (Figure 1). Voltages are measured as 
shown. 

Y N 

Replace the 24V LVPS (PL 9.1 ). 

There is a short circuit in +24 VDC distribution. Go to the +24 VDC Short Circuit RAP. 



+24 VDC RET 
Vio (all on top) 




+24 VDC 
Orn (al 



+24V, 0V, +3.5V, +5V 

T701001A-CAR 



Figure 1 P502, P505 on +24V LVPS 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-371 



Status Indicator RAPs 

116-324,116-325 



116-326 ESS ROM DIMM #1 Flash 

A failure was detected in the ESS ROM DIMM #1 Flash. 



116-327 ESS ROM DIMM #2 Flash 

A failure was detected in the ESS ROM DIMM #2 Flash. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the ESS ROM DIMM #1 . 

If the problem continues, replace the ESS ROM DIMM #1. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Pull out and insert the ESS ROM DIMM #2. 

If the problem continues, replace the ESS ROM DIMM #2. 



Status Indicator RAPs 

116-326,116-327 



6/02 
2-372 



Prelaunch Training/Review 
DC1 632/2240 



116-328 L2 Cache 

A L2 Cache failure was detected. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



116-329 Serial l/F Soft 

The system call error related to the serial l/F was detected. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch the power off then on. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-373 



Status Indicator RAPs 

116-328,116-329 



116-330 HD File System 

The system detected that the an error has occurred or the HD was not formatted during HD 
check at power on. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Run the HD Diag (DC355). 

If the problem continues, replace the HD (PL 13.1). 

If the problem continues, replace the ESS PWB (PL 13.1). 



116-332 Invalid Log Info 

A failure related to log was detected. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

After removing the HD and switching power off then on. Install the HD again and turn the 

power on. 

If the problem continues, run the HD Diag (DC355). 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-330,116-332 



6/02 
2-374 



Prelaunch Training/Review 
DC1 632/2240 



116-333 LocalTalk Soft 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



116-335 MFIOHD 

HD failure to be detected by MFIO 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set up the HD. 

If the problem continues, replace the HD (PL 13.1). 

If the problem continues, replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-375 



Status Indicator RAPs 

116-333,116-335 



116-336 Red i rector HD 

HD failure to be detected by Redirector 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set up the HD. 

If the problem continues, replace the HD (PL 13.1). 

If the problem continues, replace the ESS PWB (PL 13.1). 



116-337 Template HD Write Error 

<Write error in obtaining JT> 

An error has occurred when the Job Template was stored in the local HD. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Set up the HD. 

If the problem continues, replace the HD (PL 13.1). 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-336,116-337 



6/02 
2-376 



Prelaunch Training/Review 
DC1 632/2240 



116-340 Short of Memory 

When the system detected that the memory was insufficient. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Add memory 

Pull out PostScript option. 



116-341 ROM DIMMs Mismatch 

several invalid ROM DIMM versions that are installed The combination of the installed ROM 
DIMMs is invalid for use at the same time. When installing multiple ROM DIMMs, it is neces- 
sary to match the major version with the minor version. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace PS-1 and PS-2 ROM. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-377 



Status Indicator RAPs 

116-340,116-341 



116-342 JT Monitor 

Fatal errors to be detected by the JT monitor 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



116-344 MFIO 

Fatal errors to be detected by MFIO 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-342,116-344 



6/02 
2-378 



Prelaunch Training/Review 
DC1 632/2240 



116-345 Token Ring Board 

Token Ring Control IC Access error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. Return to service call procedures. 



116-346 Formatter 

Fatal errors to be detected by the Formatter were detected. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-379 



Status Indicator RAPs 

116-345,116-346 



116-348 Redirecter 

Fatal errors to be detected by Redirecter 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



116-349 SIF on Calling Pflite Function 

An error has occurred when calling the Pflite function with SIR 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-348,116-349 



6/02 
2-380 



Prelaunch Training/Review 
DC1 632/2240 



116-350 AppleTalk Soft 

Overall fatal errors of the AppleTalk 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



116-351 EtherTalk Soft 

Fatal error related to the EtherTalk 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-381 



Status Indicator RAPs 

116-350,116-351 



116-352 NetWare Soft 

Fatal error related to the NetWare 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



116-353 IpdSoft 

Fatal error related to the Ipd 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-352,116-353 



6/02 
2-382 



Prelaunch Training/Review 
DC1 632/2240 



116-355 SNMP Agent Soft 

Fatal error related to the SNMP Agent 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



116-356 EWSSoft 

Fatal error related to the EWS 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-383 



Status Indicator RAPs 

116-355,116-356 



116-357 PS Soft 

PS Fatal System Error 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



116-358 Salutation Soft 

Fatal error related to the Salutation 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-357,116-358 



6/02 
2-384 



Prelaunch Training/Review 
DC1 632/2240 



116-359 PLWSoft 

Fatal error in PLW 



116-360 SMBSoft 

Fatal error related to the SMB 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-385 



Status Indicator RAPs 

116-359,116-360 



116-361 Spool Fatal HD 

Fatal error of the SPL HD 



116-365 Spool Fatal 

Fatal error of the SPL 



The spoolCont detected an error at HD access. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Run the HD Diag (DC355). 
Replace the HD (PL 13.1). 
If the problem continues, replace the ESS PWB (PL 13.1). 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-361,116-365 



6/02 
2-386 



Prelaunch Training/Review 
DC1 632/2240 



116-366 Report Generator Soft 

An operation failure of the Report Generator 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



116-367 Parallel l/F Soft 

Overall fatal errors of the Parallel 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-387 



Status Indicator RAPs 

116-366,116-367 



116-368 Dump Print 

Fatal error of DumpPrint 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



116-370 XJCL 

Fatal error of XJCL 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-368,116-370 



6/02 
2-388 



Prelaunch Training/Review 
DC1 632/2240 



116-372 P-Formatter 

Fatal error of P-Formatter 



116-373 Dynamic DNS Soft 

Fatal error related to DDNS 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-389 



Status Indicator RAPs 

116-372,116-373 



116-374 Auto Switch 116-375 l-Formatter 

Fatal error of Auto SW 

Due to an error during the software processing, the subsequent processes cannot be per- Procedure 
formed. 



Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 



Procedure 

Switch power off then on. The problem continues. 

Y N Replace the ESS PWB (PL 13.1). 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 6/n2 Prelaunch Training/Review 

116-374,116-375 2-390 dci 632/2240 



1 1 6-376 Port 91 00 Software 

[Detection Conditions] Port 9100 Software Fail 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. 



116-377 Video DMA 

[Detection Conditions] Video DMA failure was detected. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-391 



Status Indicator RAPs 

116-376,116-377 



116-378 MCRSoft 

Fatal error of MCR (Mail Contents Requester) 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. 



116-379 MCCSoft 

Fatal error of MCC (Mail Contents Creator) 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Switch power off then on. 



Status Indicator RAPs 

116-378,116-379 



6/02 
2-392 



Prelaunch Training/Review 
DC1 632/2240 



116-380 MFUIContSoft 

Fatal error of MF Ul cont 

Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



116-381 Data Link Layer Error between Cont and Ul 
Panel 

Controller - MF Ul panel: Communication error on the Data Link layer 

At the communication between the ESS and Panel, the ESS detected an initialization error of 
SCOPE, a message sending error, or retrieve error of the received data. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS or Panel software. 

If the problem continues, replace the ESS PWB (PL 13.1). 

If the problem continues, replace the Control Panel (PL 18.2). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-393 



Status Indicator RAPs 

116-380,116-381 



116-382 Panel Application Layer Command Error on Ul 

Controller - MF Ul panel: Command error at the application level 

A necessary parameter was not sent from the Panel, an length error was detected in a variable 
parameter, or the confirmation message was not returned for a specified time after the request 
message had been sent to the Panel. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



116-388 No HD that Should Be 

The necessary HD was not installed. 

Though the system has the configuration requiring the installation of the HD (with Fax), it 
detected that the HD was not installed. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Install the HD. 



Status Indicator RAPs 

116-382,116-388 



6/02 
2-394 



Prelaunch Training/Review 
DC1 632/2240 



116-389 No Add-On RAM that Should Be 116-390 Standard ROM and NVM Version Mismatch 

The necessary expansion RAM was not installed. A mismatch of the versions between the standard ROM and NVM was detected. 

Though the system has the configuration requiring the installation of the expansion RAM (with Procedure 

the HD), it detected that the expansion RAM was not installed. o..,:*„i, r „« n, -ru„ .„n™ „„„.;„..„„ 

' r Switch power off then on. The problem continues. 

Y N 



Procedure 



Return to service call procedures. 



Switch power off then on. The problem continues. 

Y N Initialize the NVM by following the instructions on the LCD display. 

Return to service call procedures. (When the NVM is not to be initialized, use the standard ROM whose version is applicable.) 

Install the expansion RAM. 



Prelaunch Training/Review g /n2 Status Indicator RAPs 

DC1 632/2240 2-395 1 1 6-389, 1 1 6-390 



116-395 USB Soft 

Fatal error related to USB 



116-396 Mail IO Soft 

Fatal error related to Mail IO 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Status Indicator RAPs 

116-395,116-396 



6/02 
2-396 



Prelaunch Training/Review 
DC1 632/2240 



116-398 IPPSoft 

Fatal error related to IPP 



116-399 JMESoft 

Fatal error related to JME 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Due to an error during the software processing, the subsequent processes cannot be per- 
formed. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Perform re-installation of the ESS software. 

If the problem continues, replace the ESS PWB (PL 13.1). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-397 



Status Indicator RAPs 

116-398,116-399 



116-701 Execute forced separation of two sides 

Due to insufficient memory, 2-Sided print is impossible. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Expand the memory or install the HD if the HD is not installed. 



116-702 Perform printing by using a substitution font 

[Detection Conditions] Printed with a substitution font. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. 



Status Indicator RAPs 

116-701,116-702 



6/02 
2-398 



Prelaunch Training/Review 
DC1 632/2240 



116-703 PS Interpret error 

An error has occurred in language analysis 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Correct the job data. 



116-710 HP-GL spool file overflows 

[Detection Conditions] HP-GL/2 memory overflow 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Increase the HP-GL spool size. Or install the HD. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-399 



Status Indicator RAPs 

116-703,116-710 



1 1 6-71 1 PLW form synthesis error 

Synthesis is impossible because the size/orientation of the PLW form's drawing is different 
from that of the paper. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Select the paper with the size and orientation of the registered form. 



116-712 Insufficient PLW form capacity 

The PLW form/logo data cannot be registered because of the insufficient RAM or Hard Disk 
space. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Use the Operation Panel to check the registered forms/logos, and delete unnecessary ones. 
Or increase the allocated capacity of the RAM disk. 



Status Indicator RAPs 

116-711,116-712 



6/02 
2-400 



Prelaunch Training/Review 
DC1 632/2240 



116-714 A HP-GL command error was detected 

[Detection Conditions] HP-GL/2 command error 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Correct or remove the data in the print data that causes the error. 



116-715 PLW form registry error 

The PLW form data cannot be registered because of the restriction of the number of forms. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Use the Operation Panel to check the registered forms, and delete unnecessary ones. Or 
delete unnecessary forms. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-401 



Status Indicator RAPs 

116-714,116-715 



116-718 PLW form synthesis error 

The specified form is not registered. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Use a registered form, or register a necessary form. 



116-737 Insufficient ART user defined area 

The user defined data (external characters, patterns, etc.) cannot be registered because of 
insufficient RAM capacity. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Delete registered user defined data. Or increase the allocated capacity of the RAM. 



Status Indicator RAPs 

116-718,116-737 



6/02 
2-402 



Prelaunch Training/Review 
DC1 632/2240 



116-738 Form synthesis error 

Synthesis is impossible because the size/orientation of the form's drawing is different from that 
of the paper. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Select the paper with the size and orientation of the registered form. 



116-739 Insufficient form/logo capacity 

The form/logo data cannot be registered because of the insufficient RAM or Hard Disk space. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Use the Operation Panel to check the registered forms, and delete unnecessary ones. Or 
increase the allocated capacity of the RAM disk. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-403 



Status Indicator RAPs 

116-738,116-739 



116-740 Value Calculation Error 

The number calculated in the interpreter exceeded the limit value. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Remove the data that exceeds the limit value of the printer from the print data. 



116-741 Form registry error 

The form data cannot be registered because of the restriction of the number of forms. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Use the Operation Panel to check the registered forms, and delete unnecessary ones. Or 
delete unnecessary forms. 



Status Indicator RAPs 

116-740,116-741 



6/02 
2-404 



Prelaunch Training/Review 
DC1 632/2240 



116-742 Logo registry error 

The logo data cannot be registered because of the restriction of the number of logos. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Use the Operation Panel utility to check the registered logos, and delete unnecessary ones. Or 
delete unnecessary logos with the Print command. 



116-743 Form/logo size overflow 

The received data (forms/logos) indicating that forms/logos cannot be registered (due to insuf- 
ficient area) exceeded the registered buffer size. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Increase the form registry area size from the Operation Panel. Or install the HD. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-405 



Status Indicator RAPs 

116-742,116-743 



116-745 Art Command Error 

The decomposer checks the syntax error and excess of each limit value at decomposing. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Correct the command. 

Change the ART command where an error has occurred. 



116-746 Form synthesis error 

The specified form is not registered. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Use a registered form, or register a necessary form. 



Status Indicator RAPs 

116-745,116-746 



6/02 
2-406 



Prelaunch Training/Review 
DC1 632/2240 



116-747 White page detected 

After subtracting the paper margin from the valid coordinate area, the result of the calculation 
will be negative. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. No actions required. 



116-748 White page detected 

[Detection Conditions] There is no drawing data in the page data. 

Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Again, switch power off then on. No actions required 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-407 



Status Indicator RAPs 

116-747,116-748 



116-780 Attached document failure of email to XXX 



116-790 Printed without the stapler 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Attached document failure of email to XXX 
No actions required. 



Procedure 

Switch power off then on. The problem continues. 
Y N 

Return to service call procedures. 

Printed without the stapler 
No actions required. 



Status Indicator RAPs 

116-780,116-790 



6/02 
2-408 



Prelaunch Training/Review 
DC1 632/2240 



OF 1-1 +3.5 VDC 

+3.5 VDC failure. 

Procedure 

Perform following: 

i Remove Rear Cover (REP 14.2). 

i Tilt out HVPS Chassis (REP 1 .6). 

Check that power is switched off. Measure resistance of fuse on +3.5V LVPS (Figure 1). 

Resistance is 1 ohm or less. 

Y N 
Replace +3.5V LVPS (PL 9.1). 

Switch on the power. Measure the AC voltage between the white and black wires in p15 on the 
+3.5V LVPS (Figure 1). 110 or 220 VAC is measured. 

Y N 
Go to the AC Power RAP. 

Connect the black meter lead to DC COM or frame. Measure DC voltage at p510 on the +3.5 

Y LVPS (Figure 1). Voltages are measured as shown. 

Y N 
Replace the 3.5V LVPS (PL 9.1). 

There is a short circuit in +3.5 VDC distribution. Go to the +3.5 VDC Short Circuit RAP. 



/ 

+3.5 
VDC 
Gry 



X 



+3.5 
VDC 
RET 
Vio 



Black White 
Wire Wire 



rrrrn ; 



T701003A-CAR 

Figure 1 P15, P510 on +3.5V LVPS 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-409 



Status Indicator RAPs 

OF 1-1 



OF1-2+5VDC 

+5 VDC failure. 

Procedure 

Perform following: 

i Remove Rear Cover (REP 14.2). 

i Tilt out HVPS Chassis (REP 1 .6). 

Check that power is switched off. Measure resistance of fuse on +5V LVPS (Figure 1). 

Resistance is 1 ohm or less. 

Y N 
Replace +5V LVPS (PL 9.1). 

Switch on the power. Measure the AC voltage between the black and white wires in P16 on 
the +5V LVPS (Figure 1). 110 or 220 VAC is measured. 

Y N 
Go to the AC Power RAP. 

Measure the DC voltage at P511 on the +5V LVPS (Figure 1). Voltages are measured as 
shown. 

Y N 
Replace the +5V LVPS (PL 9.1). 

There is a short circuit in +5 VDC distribution. Go to the +5 VDC Short Circuit RAP. 



+5VDC Vio (all) 
Orn (3) 



fuse 



rrrm ? 



T701002A-CAR 

Figure 1 P16, P511 on +5V LVPS 



Status Indicator RAPs 

OF 1-2 



6/02 
2-410 



Prelaunch Training/Review 
DC1 632/2240 



OF 1-4 AC Power 

AC Power Failure 

Initial Actions 

Check Circuit Breaker. 

Procedure 

110/220/240 VAC is measured between the Noise Filter PWB FS75 (+) and FS74 (-). 

Y N 
110/220/240 VAC is measured between the Circuit Breaker J72-1 (+) and J72-1 (-)■ 
Y N 

Disconnect power cord from power outlet. The voltage of the power outlet is 110/ 
220/240 VAC. 
Y N 

Inform customer power is not available. 

Check the Power Cord for an open circuit. If no problems are found, replace the Cir- 
cuit Breaker (PL 9.2). 

Check wire between Circuit Breaker J72 and Noise Filter PWB for an open circuit and poor 
contact. 

110/220/240 VAC is measured between the Noise Filter PWB fs77 (+) and fs76 (-). 

Y N 

If the Circuit Protector on the Noise Filter PWB is tripped, reset it. If it is not tripped, 
replace the Noise Filter PWB (PL 9.2). 

110/220/240 VAC is measured between the Main Power Switch FS57 (+) and Noise Filter 
PWB fs76 (-). 

Y N 

Check the wire between the MAIN POWER Switch and the NOISE FILTER PWB for an 
open circuit and poor contact. 

110/220/240 VAC is measured between the Main Power Switch FS69 (+) and Noise Filter 
PWB fs76 (-). 

Y N 

Replace the Main Power Switch (PL 9.2). 

100 (FX), 110 (TFX) or 220-240 (AP) VAC is measured between the AC Drive PWB fs40 (+) 
and the fs39 (-)? 

Y N 

Check the wire between the AC DRIVE PWB and the Main Power Switch for an open cir- 
cuit and poor contact. 

100 (FX), 110 (TFX) or 220-240 (AP) VAC is measured between the AC drive PWB J43-9 (+) 
and the J43-1 (-). 

Y N 

Replace the AC Drive PWB (PL 9.2). 

Check the AC circuit distribution by referring to Chapter 7 Wiring Data. 



Prelaunch Training/Review g/02 Status Indicator RAPs 

DC1 632/2240 2-411 OF 1-4 



OF 2-1 Dark / Blank Display 

Ul Display is dark or no text or graphics are visible. 

Procedure 

NOTE: If a Status Code is displayed, go to status code RAP . 

Switch off the power. Listen to the cooling fans at the rear of the machine and switch on the 
power. Cooling fans are audible either momentarily or continuously. 
Y N 

There is a +5 VDC failure. Go to the +5 VDC RAP. 

There is a +3.5 VDC failure. Go to the +3.5 VDC RAP 



Status Indicator RAPs 

OF 2-1 



6/02 
2-412 



Prelaunch Training/Review 
DC1 632/2240 



OF 99-1 Reflective Sensor 

Procedure 

Enter DC330[XXXX-XXX]. Block the Sensor with a blank sheet of paper. The display 

changed. 

Y N 

There is +5VDC measured between the sensor Pin 2 (+) and GND (-). 
Y N 

Check the wire between the sensor Pin 2 and the PWB Pin 8 for an open circuit or a 
poor contact. If the check is OK, replace the PWB 



There is +5VDC measured between the sensor Pin 1 (+) and Pin 3. 
Y N 

There is +5VDC measured between the PWB Pin 4 (+) and Pin 5. 

Y N 

Replace the PWB. 

Check the wire between the PWB Pin 4 and the sensor Pin 1 and between the PWB 
Pin 5 and the sensor Pin 3 for an open circuit or a poor contact. 

Replace the sensor. 



Remove the blank sheet of paper from the sensor. The display changed. 
Y N 

Remove the sensor connector. The display changed. 
Y N 

Check for a short circuit between the sensor Pin 2 and the PWB Pin 8. 
If the check is OK, replace the PWB. 



Replace the sensor. 
Replace the sensor. 



PWB 

PL 



+3.3VDC 



CONTROL 
LOGIC 



i 



PWB 
PL 



DC COM 

XT 

+5VDC 



DOUBLE 
PLUG 
I 1 



H — 



-J 7—6 
I I 



SENSOR 
PL 



@Jnvy 



•»* 



T799001A-CAR 



Figure 1 Reflective Sensor CD 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-413 



Status Indicator RAPs 

OF 99-1 



OF 99-2 Transmissive Sensor 

Procedure 

Enter DC330 [XXX-XXX]. Block the Sensor. The display changed. 

Y N 
Remove the sensor connector. The display changed. 

Y N 

Check a short circuit between the sensor Pin 2 and the PWB Pin 8. If the check is 
OK, replace the PWB. 

Replace the sensor. 

Unblock the sensor. The display changed. 

Y N 
There is +5VDC measured between the sensor Pin 2 (+) and GND (-). 

Y N 

Check the wire between the sensor Pin 2 and the PWB Pin 8 for an open circuit or a 
poor contact. If the check is OK replace the PWB 

There is +5VDC measured between the sensor Pin 1 (+) and Pin 3 (-). 

Y N 

Check the wire between the PWB Pin 4 and the sensor Pin 1 and between the PWB 
Pin 5 and the sensor Pin 3 for an open circuit and poor contact. If the check is OK, 
replace the PWB. 

Replace the sensor. 

Replace the sensor. 




DC COM 



+5VDC 



DOUBLE 
PLUG 
I 1 



H — 



-J 7 - 6 
I I 



SENSOR 
PL 




1 


1 



YEL 



T799000A-CAR 



Figure 1 Transmissive Sensor CD 



Status Indicator RAPs 

OF 99-2 



6/02 
2-414 



Prelaunch Training/Review 
DC1 632/2240 



OF 99-3 Switch 
Procedure 

Enter DC330 [XXX-XXX]. Actuate the switch. The display changed. 
Y N 

There is +5VDC measured between Pin 2(+) of the Switch and GND(-). 
Y N 

Check the wire between the switch Pin 2 and the PWB Pin 3 for an open circuit and 

poor contact. If the check is OK, replace the PWB. 



There is +5VDC measured between Pin 1(+) of the Switch and GND(-). 
Y N 

Replace the switch. 

Check the wire between the PWB Pin 4 and the switch Pin 1 for an open circuit and poor 
contact. If the check is OK, replace the PWB. 



De-actuate the switch. The display changed. 
Y N 

Remove the connector on the switch. The display changed. 

Y N 

Check for a short between the switch Pin 2 and the PWB Pin 3. If the check is OK, 
replace the PWB. 

Replace the switch. 

Replace the switch. 









DC COM 






SWITCH 

PL 




PWB 
PL 


PWB 

PL 

DC COM 


PWB 

OR 

PLUG 

! 





_ 




+3.5/5 VDC 








CONTROL 
LOGIC 


^ 3 






Figure 1 2003 
















T799002A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-415 



Status Indicator RAPs 

OF 99-3 



OF 99-4 Solenoid / Clutch Open 
Procedure 

NOTE: Before performing this RAP, ensure that there is no mechanical problem for the sole- 
noid and clutch. 

Enter DC330 [XXX-XXX]. There is +24VDC measured between the PWB Pin 3 (+) and GND 

(-)■ 
Y N 

There is +24VDC measured between Pin 2(+) of the Solenoid/Clutch and GND(-). 
Y N 

There is +24VDC measured between Pin 1(+) of the Solenoid/Clutch and GND(-). 
Y N 

Check the wire between the PWB Pin 4 and the solenoid/clutch Pin 1 for an 
open circuit and poor contact. If the check is OK, replace the PWB 

Replace the solenoid/clutch. 

Check the wire for a short between the PWB Pin 3 and the solenoid/clutch Pin 2 for an 
open circuit or poor contact. 

Replace the PWB. 



PWB 

PL 




CONTROL 
LOGIC 


St- 




DC COM I 

r I 

+24VDC | 



+24VDC 



PWB 

OR 

PLUG 



I I 



Figure 1 Solenoid/Clutch CD 



SOLENOID/ 

CLUTCH 

PL 



T799003A-CAR 



Status Indicator RAPs 

OF 99-4 



6/02 
2-416 



Prelaunch Training/Review 
DC1 632/2240 



OF 99-5 Solenoid / Clutch Shorted 
Procedure 

Turn off the power. 

Remove the PWB connector. There is 10 Ohmis or less measured between the connector 

Pin 3 and the frame. 

Y N 

Replace the PWB. 

Check for a short circuit to frame of the circuit between PWB Pin 3 and the solenoid/clutch Pin 

2. 

If the check is OK, replace the solenoid/clutch. 



PWB 

PL 




CONTROL 
LOGIC 


^' 




DC COM I 

r I 

+24VDC | 



PWB 

OR 

PLUG 



I I 



Figure 1 Solenoid/Clutch CD 



SOLENOID/ 

CLUTCH 

PL 



T799003A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
2-417 



Status Indicator RAPs 

OF 99-5 



OF 99-6 Motor Open 

Procedure 

NOTE: Before performing this RAP, ensure that the motor is not locked or loaded 

Enter the DC330 [XXX-XXX]. 

There is +24VDC measured between Pin 3(+) of the PWB and GND(-). 

Y N 

There is +24VDC measured between the Motor Pin 2(+) of the Motor and GND(-). 
Y N 

There is +24VDC measured between the Motor Pin 1(+) of the Motor and GND(-). 
Y N 

There is +24VDC measured between the PWB Pin 4(+) of the PWB and GND(- 

)■ 

Y N 

Replace the PWB. 

Check the wire between the PWB Pin 4 and the Motor Pin 1 for an open circuit 
or poor contact. 

Replace the motor. 

Check the wire between the PWB Pin 3 and the MTOTR Pin 2 for an open circuit or poor 
contact. 

Replace the PWB. 



Status Indicator RAPs 

OF 99-6 



6/02 
2-418 



Prelaunch Training/Review 
DC1 632/2240 



OF 99-7 Motor On 
Procedure 

Turn off the power. Remove the PWB connector. There is 10 Ohmi's or less measured 
between the connector Pin 3 and the frame. 
Y N 

Replace the PWB. 

Check the wire between the connector Pin 3 and the motor Pin 2 for a short circuit. 
If the check is OK, replace the motor. 



Prelaunch Training/Review g^2 Status Indicator RAPs 

DC1 632/2240 2-419 OF 99-7 



OF 99-8 Nip / Release Solenoid Open 
Procedure 

NOTE: Before performing this RAP, ensure that there is no (mechanical) operation failure for 
the solenoid. 

There is +24VDC measured between the Nip/Release Solenoid Pin 1 (+) and GND (-). 

Y N 
There is +24VDC measured between the PWB Pin 5 (+) and GND(-). 

Y N 

Check +24VDC inputs on the PWB. If the check is OK, replace the PWB. 

Check the wire between the PWB Pin 5 and the Nip/Release Solenoid Pin 1 for an open 
circuit or poor contact. 

Enter DC330 [XXX-XXX]. There is +24VDC measured between the PWB Pin 4 (+) and 
GND(-). 

Y N 
There is +24VDC measured between the Nip/Release Solenoid Pin 3 (+) and GND (- 

)■ 

Y N 
Replace the Nip/Release Solenoid. 

Check the wire between the PWB Pin 4 and the Nip/Release Solenoid Pin 3 for an open 
circuit and poor contact. 

Follow the following when the RELEASE caused a problem. 

Go to the DC330 [XXX-XXX]. There is +24VDC measured between the PWB Pin 6 (+) and 

GND(-). 

Y N 
There is +24VDC measured between the Nip/Release Solenoid Pin 2 (+) and GND (-) 

Y N 
Replace the Nip/Release Solenoid. 

Check the wire between the PWB Pin 6 and the Nip/Release Solenoid Pin 2 for an open 
circuit or poor contact. 

Replace the PWB. 



Status Indicator RAPs 

OF 99-8 



6/02 
2-420 



Prelaunch Training/Review 
DC1 632/2240 



3 Image Quality 



IQ1 IOT Image Quality Entry RAP 3-3 

IQ2 NT Image Quality Entry RAP 3-4 

IQ3 Low Image Density RAP 3-5 

IQ4 Wrinkled Image RAP 3-5 

IQ5 Residual Image (Ghosting) RAP 3-6 

IQ6 IOT Background RAP 3-8 

IQ7 Deletions RAP 3-8 

IQ8 Color-to-Color Misregistration RAP 3-10 

IQ9 Skew/Misregistration RAP 3-10 

IQ12 Process Direction Bands, Streaks, and Smears RAP 3-11 

IQ13 Unfused Copy RAP 3-12 

IQ14 Repeating Bands, Streaks, Spots, and Smears RAP 3-12 

IQ15 Mottle RAP 3-13 

IQ16 Spots RAP 3-13 

IQ20 1st BTR Checkout RAP 3-14 

IQ21 Developer Bias RAP 3-16 

IQ22 2nd BTR Checkout RAP 3-18 

IQ23 BCR Checkout RAP 3-20 

Image Quality Specifications 3-21 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-1 



Image Quality 



Image Quality 6/02 Prelaunch Training/Review 

3-2 DC1 632/2240 



IQ1 IOT Image Quality Entry RAP 



The purpose of this RAP is to serve as the entrance vehicle into the Image Quality RAPs sec- 
tion. All Image Quality RAPs must be accessed through this RAP. 

The RAP will have you evaluate the copies made during the Call Flow procedure for image 
quality defects. It will refer you to the Image Quality Analysis RAPs, the Image Quality Defect 
section in order to diagnose and repair any image quality problems. 



Initial Actions 

Check for the presence of the defect in Copy mode and in Print mode. If the problem occurs in 
Copy mode only, go to the IQ2 RAP. 

Procedure 

Go to Table 1. Compare the prints for any of the listed defects. Perform the corrective action 
that is listed. 



Table 1 Image Quality Defects 



Defect 


Description 


Corrective Action 


Background 

See Defect Sample . 


Undesirable toner deposits on the copy or print. The toner deposits can be localized or may cover the entire copy or print. Depend- 
ing on the density of the background, it is referred to as low, medium, high, or very high background. It may occur in all colors, sin- 
gle colors, or any combination of single colors. 


Go to the I Q6 RAP 


Color Misregistration 
See Defect Sample . 


Multi-colored images that should be superimposed are offset. This offset may be in the process direction or perpendicular to pro- 
cess direction. 


Go to the I Q8 RAP 


Deletions 
Debris-Centered 

See Defect Sample . 

Nonuniform Streak 

See Defect Sample . 


The undesirable absence of toner from the copy or print. This defect can show as white, light, or untrue colored areas on the copy 

or print. The most common example is a deletion caused by the itentingT of paper from mishandling or moisture, or by dents or 

defects in the Transfer Belt. 

T Debris-Centered: Deletions in the areas surrounding toner agglomerates. 

T Nonuniform Streak: A deletion in the form of a single streak that runs from the lead edge to the trail edge of the copy. 


Go to the I Q7 RAP 


High Frequency Bands 
See Defect Sample . 


Repeating interval bands that are most noticeable in low density (20-30%) halftone areas of the copy. These bands run perpendic- 
ular to process direction. 


GotothelQ14 RAP 


Irregular Streak in Process Direc- 
tion 
See Defect Sample . 


Streaks: Usually medium-width streaks of (or shifts in) color most noticeable in low density 20-30%) halftone areas of the copy. 
A deletion in the form of a single streak that runs from the lead edge to the trail edge of the copy. 


GotothelQ12 RAP 


Low Image Density 


A condition that results when too little toner of a single color or combination of colors is developed on the copy or print. This results 
in lighter copies or prints for the single-color toner or the color that results from the combination of color toners. 


Go to the I Q3 RAP 


Misregistration/Skew 


The position and/or alignment of the image relative to the top edge and side edge of the paper is not within specification. 


Go to the I Q9 RAP 


Missing Colors 


One or more of the primary colors are missing from the image. 




Mottle 

See Defect Sample . 


Areas of solid, or high density coverage that are reproduced with a surface that resembles marble. 


GotothelQ15 RAP 


Regular (repeating) Bands, 
Streaks, or Smears 


A defect that repeats at an interval from14 to 264 mm, is most noticeable in low density (20-30%) halftone areas of the copy, and 

runs perpendicular to process direction. 

Lines and bands are generally uniform in shape from one end to the other. 

Streaks are generally shorter than lines and are of nonuniform width along their length. They may have a more ragged or fuzzy 

appearance than lines. 


GotothelQ14 RAP 


Residual Image 


A toner image that remains on the photoreceptor or Transfer Belt after cleaning. The next image is placed on top of the residual 
image and both images are transferred to the next copy. 


Go to the I Q5 RAP 


Spots 


Generally circular in shape, these defects can be caused by an absence of toner in a desired area, or a deposit of toner in an 
undesired area 


Go to the IQ16 RAP 


Unfused prints 


Image can be rubbed off with little or no pressure 


Go to the IQ13 RAP 


Wrinkled Image 

See Defect Sample . 




Go to the IQ4 RAP 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-3 



Image Quality 

IQ1 



IQ2 NT Image Quality Entry RAP 



This RAP is for troubleshooting I IT (Scanner/ADF) problems only. Before proceeding, verify 
that the defect is present in Copy mode only. If the defect is present in Print mode, go to the 
IQ1 RAP. 



Initial Actions 

Clean the Lens, the top and bottom surface of the Platen Glass, and all Mirrors with Lens and 
Mirror Cleaner and a soft, lint-free cloth. 

Procedure 

Compare the defective copies with the descriptions listed in Table 1. Perform the corrective 
action listed for that defect. 



Table 1 



Defect 


Corrective Action 


Background 


Clean the Platen Belt. 
Calibrate the NT (ADJ 9.7). 


Blurred or Streaked Copy 


Ensure that the Platen Glass is installed correctly. 
Check/adjust the carriage alignment (ADJ 6.1). 


R/E error 


Check/adjust NT magnification (ADJ 9.12). 


Deletions 


Clean the Lens, the top and bottom surface of the Platen Glass, and all Mirrors with Lens and Mirror Cleaner and a soft, lint-free cloth. 
If the problem persists, replace the Lens Kit (PL 18.4). 


Misregistration/Skew 


Go to the IQ9 RAP. 


Moire 

Patterns in the image areas of the print that have the 
appearance of a screen or grid overlaying the 
image. The pattern may be uniform or nonuniform in 
area or shape. 


i Switch between photo modes to determine which mode minimizes the defect. 

i Decrease the Sharpness level. 

i Reduce or enlarge the copy slightly. 

i Rotate the original on the platen by 90 degrees. 


Newton Rings 

Repetitive, irregular-shaped marks that occur when 

making copies of glossy photographs. These marks 

are most noticeable in large low-density or highlight 

areas. 


Clean the Document Glass 

Place a transparency between the document and the glass 



Image Quality 

IQ2 



6/02 
3-4 



Prelaunch Training/Review 
DC1 632/2240 



IQ3 Low Image Density RAP 



This RAP troubleshoots the causes of output images showing image density lower than speci- 
fication 

Initial Actions 

i Clean the ROS windows 

i Replace the paper in use with fresh, dry paper of the correct specification 

i Determine if the Drum Cartridge or any of the Toner Cartridges are approaching end-of- 

life. Replace if necessary, 
i Perform the Automatic Gradation procedure (refer to the User Guide). If this does not 

resolve the problem, continue with this RAP. 



IQ4 Wrinkled Image RAP 

Initial Actions 
Procedure 

TBD 



Procedure 

Go to dC612. Print Test pattern??????. The defect involves a single color. 

Y N 

Go to dC61 2. Print Test pattern??????. Open the Front Door in the middle of the print job 
(approximately 7 seconds after selecting Start.). There is a good toner image on the 
Transfer Belt. 
Y N 

Go to the IQ21 RAP to check the Developer Bias. If this does not resolve the prob- 
lem, go to the IQ20 RAP to check the 1st BTR bias. 

If the problem continues, check the ROS for contamination of the windows or mis- 
alignment. 

Check the 2nd BTR for damage or incorrect installation. Go to the IQ22 RAP to check the 
Backup Roll bias. If the problem continues, replace 2nd BTR Assembly (PL 7.1). If this 
does not resolve the problem, replace the Transfer Belt (PL 5.3). 

Swap the affected Drum Cartridge with an adjacent unit. Print Test Pattern???. The defect 
moved to the new color. 

Y N 

Go to the IQ21 RAP to check the Developer Bias. If this does not resolve the problem, go 
to the IQ20 RAP to check the 1st BTR bias. If the problem continues, replace the Devel- 
oper for the affected color (PL 6.2). If this does not resolve the problem, replace the ATC 
Sensor for the affected color (PL 6.2). 

Replace the Drum Cartridge (see Machine Consumables in Section 6). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-5 



Image Quality 

IQ3, IQ4 



IQ5 Residual Image (Ghosting) RAP 

Initial Actions 

i Check the end-of-life counter for the Drum Cartridge. If the unit is at or near end-of-life, 
replace the Drum Cartridge (see Machine Consumables in Section 6). 

NOTE: Some ghosting on transparencies is unavoidable. 

i If the problem occurs only with certain types of media, ensure that the media in use is 
within specification, and that the customer is aware of correct operation of print driver. 

i If the distance between the intended image and the residual image has a fixed rate of rep- 
etition, go to the IQ14 RAP. Return to this procedure if the problem persists. 

Procedure 

The problem is with a single primary color 

Y N 

Remove the Fuser. Examine the Heat Roll and Pressure Roll for evidence of toner offset- 
ting. There is Toner adhering to the Heat Roll. 
Y N 

Check for a residual image on the Transfer Belt. Repair or replace the IBT Cleaner 

(PL 5.3) as required. 

Check the 2nd BTR for contamination. Clean/replace as required 

Clean the Heat Roll. If the problem persists, replace the Fuser (PL 7.1). 

Check the Erase Lamp for the affected color: 

i Enter dC330 [009-045] (C, Y, or M), or [009-042] (K), as appropriate. 

i Remove the Drum cartridge for the affected color. 

i check for light along the mounting rail left side 

The Erase lamp is lit. 

Y N 
Go to Flag 1 (C), Flag 2 (Y), Flag 3 (M), or Flag 4 (K). Check for an open circuit. If the 
wires are OK, replace the Erase Lamp (PL 4.2) for the affected color. If the problem per- 
sists, Replace the MCU PWB (PL 13.1). 

Go to the IQ21 RAP. Check for a short circuit in the Developer bias circuit of the affected color. 



Image Quality 

IQ5 



6/02 
3-6 



Prelaunch Training/Review 
DC1 632/2240 




[009-045] 

LAMP(CYM)ON 
J403 ( L ) +24VDC 



+24VDC 



<n 



DOUBLE 
PLUG 



J225 I I P225 

1 — 2 



2 — 1 
I I 









I \ 2 


J403 


[009-045] 

LAMP (GYM) ON 
(L) +24VDC 


v J223 


lYEL 










+24VDC 


v ! 



DOUBLE 
PLUG 

I I P223 

1 — 2 



[009-045] 

LAMP (GYM) ON 
J403 (L) +24VDC 



+24VDC 



2 — 1 
I I 



DOUBLE 
PLUG 



J224 I I P224 

1 — 2 



J403 



[009-042] 

LAMP (K) ON 
(L) +24VDC 



+24VDC 



2 — 1 
I I 



DOUBLE 
PLUG 



J226 I I P226 

1 — 2 



2 — 1 
I I 



ERASE LAMP 

(C) 

PL4.2 



(^ 



* 



* 



ERASE LAMP 

(Y) 

PL4.2 



ft) 



* 



** 



ERASE LAMP 

(M) 

PL4.2 






ERASE LAMP 

(K) 

PL4.2 



d? 



(D" 



ERASE LAMP (MOUNTED ON CHANNEL) 




T-730000-A-CAR 



Figure 1 IQ5 RAP Circuit Diagram 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-7 



Image Quality 

IQ5 



IQ6 IOT Background RAP 

Initial Actions 

NOTE: Some background is unavoidable on certain media, such as heavyweight paper and 
transparencies. Ensure that the customer selects the correct settings on the Ul and print driver. 

Perform Max Setup (ADJ 9.1). If this does not resolve the problem, continue with this RAP. 

Procedure 

The problem is Single Color Background. 
Y N 

Examine the face of the ADC Sensor. The ADC Sensor is clean. 
Y N 

Go to the 9-684 RAP to troubleshoot the ADC Sensor Solenoid. 



Examine the Transfer Belt for excessive dirt, damage, or uncleaned toner. The Belt is 
clean. 

Y N 
Check the Belt Cleaner for damage or wear. Clean or replace as required. 

WARNING 

HIGH VOLTAGE! 

Exercise care when making the voltage check in the following steps. 

Enter dC140 [09-026]. Measure the voltage from P/J 580, pins 1 , 3, 5, and 7. The volt- 
age is approximately -540 VDC on all pins. 

Y N 

Go to the IQ21 RAP to troubleshoot the Developer bias circuit. 

Replace the Transfer Belt (PL 5.3). If this does not resolve the problem, replace the 2nd 
BTR (PL 2.8). If the problem persists, replace the MCU PWB (PL 13.1). 



The background is very high and even density, and covers the entire sheet (no edge 

erase. 

Y N 

Check the following: 

T Check the end-of-life counter for the Toner Cartridge and Drum Cartridge for the 
affected color. Replace if at or near end-of-life (see Machine Consumables in Sec- 
tion 6). 

i If the problem continues, examine the Developer Housing for the affected color. 
Check for toner bridging, uneven brush, or loose High Voltage terminals. Clean, 
repair, or replace as required (PL 6.2). 

Go to the IQ23 RAP. 



IQ7 Deletions RAP 

Initial Actions 

Reload the machine with fresh, dry paper of the correct specifications. If the problem occurs 
when using heavyweight paper, ensure that the correct selections are being made on the print 
driver. If the problem is not resolved, continue with this RAP. 

NOTE: Small white deletions with a sharp edge are usually caused by Fuser offsetting. Go to 
the IQ16 Spots RAP. 

Procedure 

The problem is debris-centered deletions (small-area deletions surrounding a dark 

speck). 

Y N 

Enter dC61 2. Print a copy of the 20% coverage pattern for each color. The defect is 
present for all colors. 
Y N 

Make several prints of the Test Page (?????). The defect is present in approxi- 
mately the same location on all letter-size prints. 
Y N 

Remove the Drum cartridge for the affected color. Check for light from the 
Erase Lamp along the mounting rail left side The Erase lamp is lit. 
Y N 

Examine the surface of the Drum Cartridge. Check for dents, scratches, or 
contamination such as fingerprints, etc. The drum is free from damage. 
Y N 

Clean or replace the Drum Cartridge as required (see Machine Con- 
sumables in Section 6). 



Switch the affected Drum Cartridge with an adjacent unit. The problem 
moves with the cartridge. 
Y N 

Go to the IQ20 RAP and check Flags 1 through 3 for a loose, cor- 
roded, or damaged connection. 
Replace the Developer (PL 6.2) for the affected color. 

Replace the Drum Cartridge (see Machine Consumables in Section 6). 



Go to Flag 1 (C), Flag 2 (Y), Flag 3 (M), or Flag 4 (K). Check for a short circuit. 
If the wires are OK, replace the Erase Lamp for the affected color. If the prob- 
lem persists, Replace the MCU PWB (PL 13.1). 

Remove the ROS. Examine the ROS windows for dirt or damage. Clean or replace 
as required PL 3.1). 



Check the Transfer Belt (PL 5.3) for dirt, damage, or contamination. Clean/replace as 

required. 

Check the 2nd BTR (PL 2.8) for damage or wear. Clean or replace if required. 

Examine the spot in the center of the DCD. Replace the Developer (PL 6.2) and Toner Car- 
tridge for the affected color. If the problem persists, replace the Developer Housing for the 
affected color (PL 6.2). 



Image Quality 

IQ6, IQ7 



6/02 
3-8 



Prelaunch Training/Review 
DC1 632/2240 




[009-045] 

LAMP(CYM)ON 
J403 ( L ) +24VDC 



+24VDC 



<n 



DOUBLE 
PLUG 

J225 I I P225 

1 — 2 









I \ 2 


J403 


[009-045] 

LAMP (GYM) ON 
(L) +24VDC 


v J223 


lYEL 










+24VDC 


^' ! 



2 — 1 
I I 



DOUBLE 
PLUG 



I I P223 

1 — 2 



[009-045] 

LAMP (GYM) ON 
J403 (L) +24VDC 



+24VDC 



2 — 1 
I I 



DOUBLE 
PLUG 



J224 I I P224 

1 — 2 



J403 



[009-042] 

LAMP (K) ON 
(L) +24VDC 



+24VDC 



2 — 1 
I I 



DOUBLE 
PLUG 



J226 I I P226 

1 — 2 



2 — 1 
I I 



ERASE LAMP 

(C) 

PL4.2 



* 



& 



ERASE LAMP 

(Y) 

PL4.2 



'x 



<if 



ERASE LAMP 

(M) 

PL4.2 






ERASE LAMP 

(K) 

PL4.2 



d? 



(D" 



ERASE LAMP (MOUNTED ON CHANNEL) 




T-730000-A-CAR 



Figure 1 IQ7 RAP Circuit Diagram 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-9 



Image Quality 

IQ7 



IQ8 Color-to-Color Misregistration RAP 

Initial Actions 

Adjust the color registration (ADJ 9.6). If the problem remains, continue with this procedure 

Procedure 

The problem involves a single color. 
Y N 

Check that the ROS is securely mounted and that the ROS window is not dirty or dam- 
aged. If the problem persists, replace the ROS (PL 3.1). 

Check the mounting of the Developer Housing for the affected color. Ensure that it is installed 
correctly and that it is free from damage. Repair or replace as required (PL 6.2). 



IQ9 Skew/Misregistration RAP 

This RAP is used when Skew, System Registration, or Magnification are out of specification. 
For Color-to-Color-Misregistration, go to the IQ8 RAP. 

Initial Actions 

Load some new, dry 24 lb. 11X17/A3 Xerox COLOR Xpressions (NASG), or 90 GSM Colortech 
+ (ESG) into each paper tray (use 8.5X11/A4 in Tray 1). Make 3 full color copies from each 
paper tray. Mark the appropriate paper tray on these copies. 

Procedure 

The problem is still present when using the proper paper. 

Y N 

Explain to the customer that new, dry, 24 lb. Xerox COLOR Xpressions (NASG), or 90 
GSM Colortech + (ESG) paper is the specified paper for use in the DocuColor 1632/2240. 

The problem occurs only in the Printer Mode 

Y N 
The defect occurs when the document is manually registered on the platen glass. 
Y N 

Ensure that the Document Transport Belt is clean. Check the Document Handler 
Adjustments (ADJ 5.1 through ADJ 5.7). If the problem continues, check the DADF 
drive rolls and pinch rolls for wear or glossing. 



The problem is Skew 
Y N 

The problem is Misregistration 

Y N 

Adjust the I IT" Vertical/Horizontal Magnification (ADJ 9.12) and the IOT Lead 
Edge/Side Edge Registration (ADJ 9.9). 



Enter dC612. Select Pattern????. Misregistration is present on the copy 

Y N 

Adjust the IOT Lead Edge/Side Edge Registration (ADJ 9.9), then the NT Lead 
Edge and Side Edge Registration (ADJ 9.10 and ADJ 9.11). 

The defect occurred on copies from all five paper trays. 

Y N 

Check the IOT Lead Edge/Side Edge Registration (ADJ 9.9) for that tray. 
Check the feeder for the affected tray for wear, slipping, damage, or contami- 
nation. 

i Tray 1 Feeder (PL 2.4) 
i Tray 2 Feeder (PL 16.7) 
i Tray 3 Feeder (PL 16.9) 
i Tray4 Feeder(PL 16.11) 
i Tray 5 Feed Assembly (PL 2.14) 

Registration varies from copy to copy. 

Y N 

Go to ADJ 9.9, Lead/Side Edge Adjustment. 



Image Quality 

IQ8, IQ9 



6/02 
3-10 



Prelaunch Training/Review 
DC1 632/2240 



B C 

Check the components in the Registration Transport Assembly (PL 2.6) for wear, 
slipping, damage, or contamination. Clean/replace as required 

The defect occurred on copies from all five paper trays. 
Y N 

Check the components in the Registration Transport Assembly (PL 2.6) for wear, 
slipping, damage, or contamination. Clean/replace as required 

Check the IOT Lead Edge/Side Edge Registration (ADJ 9.9) for that tray. 
Check the feeder for the affected tray for wear, slipping, damage, or contamination, 
i Tray 1 Feeder (PL 2.4) 
i Tray 2 Feeder (PL 16.7) 
T Tray 3 Feeder (PL 16.9) 
i Tray 4 Feeder (PL 16.11) 
i Tray 5 Feed Assembly (PL 2.14) 



TBD. 



IQ12 Process Direction Bands, Streaks, and Smears RAP 

Procedure 

NOTE: The repetition rate for Transfer Belt defects varies considerably, depending on paper 
size and mode of operation. The defect may appear as frequently as every 3rd sheet, or may 
only occur every 14 sheets. 

The defect occurs in approximately the same position on multiple prints. 

Y N 

If the defect occurs intermittently, examine the Developer Housings for evidence of toner 
clumping. If clumping is found, replace the Developer (PL 6.2). if this does not resolve the 
problem 

The defect is a full-width (LE - TE) process direction deletion. 

Y N 

Remove the Fuser Assembly. Examine the Heat Roll for damage or contamination. Clean 
or replace as required (PL 7.1). 

If the Fuser is OK, check the Developer Housing (PL 6.2). Repair or replace as required. 
If the problem remains, replace the ROS (PL 3.1 ). 

If the problem is related to a single color, replace the Drum Cartridge (see Machine Con- 
sumables in Section 6). 

Enter dC612. Select Test Pattern 20% coverage pattern for all colors. The defect is present 
for all colors. 

Y N 

i Check the ROS window for damage or contamination. Clean or replace as required, 
i Check Drum Cartridge for affected color. Check for damage or contamination to the 

BCR. 
i Go to the IQ20 RAP to check the 1 st BTR bias circuit for the affected color 
i Replace the Developer (PL 6.2) for the affected color. Check the housing for damage 

or toner clumping. 

Remove the IBT Cleaner (PL 5.3). Inspect the cleaning blade and Mylar seal for damage. 
Clean or replace as required. 

If the IBT Cleaner is OK, check the Transfer Belt (PL 5.3) for damage or contamination. Ensure 
that there is no debris or loose wiring, etc. in contact with the belt. Clean or replace as required. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-11 



Image Quality 

IQ9, IQ12 



IQ13 Unfused Copy RAP 

Initial Actions 

Replace the paper in use with fresh, dry paper of the correct specification. 

Ensure that the media being used matches the settings on the Ul screen or print driver. Using 
the next heavier setting may resolve the problem. 

If the Key Operator/Administrator has configured certain trays for a specific type of media, 
ensure that the specified media is actually loaded in those trays. 

Procedure 

Check the following: 

i Check the Sensor Assembly (PL 7.2) for contamination or incorrect mounting. Clean, 
repair, or replace as required. 

i Check the Fuser (PL 7.1) for damage, toner offsetting, paper wrap, or incorrect installa- 
tion. Clean or replace as required. 



IQ14 Repeating Bands, Streaks, Spots, and Smears RAP 

Procedure 

Measure the distance between the repeating defects. Locate the distance on the table below. 
Perform the indicated repair actions 

Table 1 Repeating Defects 



Repetition 
spacing 


Component(s) 


Repair Actions 


<4 mm. 


High Frequency Band- 
ing 


Replace the ROS 


28.3 mm. 


Developer Mag Roll 


Check Developer roll bias for floating or shorting out. 
Replace Developer Housing (PL 6.2) if required. 


44 mm. 


Drum Cartridge 


Replace the Drum Cartridge (see Machine Consum- 
ables in Section 6). 


84 mm. 


Fuser Heat Roll 


Remove the Fuser Assembly. Check the Heat Roll for 
damage (nicks, wear, or cuts) or contamination. Clean 
or replace as required (PL 7.1). 


88 mm. 


BTR 2 Backup Roll 
BTR 2 Roll 


Check the 2nd BTR Assembly for damage or contami- 
nation. Clean, repair or replace as required (PL 2.8). 
Replace the Transfer Belt (PL 5.3). 


94 mm. 


Drum Cartridge 
Fuser 


Single Color - Replace the Drum Cartridge (see 
Machine Consumables in Section 6). 
All Colors - Remove the Fuser Assembly. Check the 
Heat Roll for damage (nicks, wear, or cuts) or contami- 
nation. Clean or replace as required (PL 7.1). 



Image Quality 

IQ13, IQ14 



6/02 
3-12 



Prelaunch Training/Review 
DC1 632/2240 



IQ15 Mottle RAP 

This RAP troubleshoots the causes of output images showing image density that varies from 
inboard to outboard edges, or randomly throughout the print. 

Initial Actions 

i Replace the paper in use with fresh, dry paper of the correct specification. Ensure that the 

loaded media matches the Ul or print driver settings, 
i Determine if the Drum Cartridge or any of the Toner Cartridges are approaching end-of- 

life. Replace if necessary, 
i Perform Max Setup (ADJ 9.1). If this does not resolve the problem, continue with this 

RAP. 

Procedure 

Make a print of the Test Page (??????). The defect involves a single color. 

Y N 
Make a print of the Test Page. Open the Front Door when the lead edge of the print 
begins to protrude from the Fuser Exit nip. Open the Fuser and examine the partially- 
fused sheet. The defect is present in both the fused and unfused portion of the 
sheet. 

Y N 
Clean or replace the Fuser (PL 7.1). 

Enter dC612. Make a print of Test Pattern???. As the print is being processed, open the 
Front Door. Examine the image on the Transfer Belt. The image on the belt has accept- 
able density. 

Y N 
Replace the Transfer Belt (PL 5.3). 

Go to the IQ22 RAP to check 2nd BTR Backup Roll bias/contacts. 

Clean/replace the 2nd BTR Assembly (PL 7.1). 

If the problem continues, replace the Transfer Belt (PL 5.3). 

Switch Drum Cartridges. The problem moves with the cartridge. 

Y N 

Check the following: 

i Clean the HV contact for the developer in question. 
T Replace the Toner Cartridge if not done previously. 

i Replace the Developer (PL 6.2). Examine the housing for damage, wear, or contam- 
ination. If the problem persists, replace the ATC Sensor (PL 6.2). 

Replace the Drum Cartridge (see Machine Consumables in Section 6). 



IQ16 Spots RAP 

Initial Actions 

Ensure that the paper in use is fresh, dry, and within specification for weight and quality. 

Check print driver and copier control panel settings to ensure the media is being un in the 
proper mode. 

Compare the spots against the samples in the Image Quality Defects supplement. If the defect 
matches the Debris Centered Deletions sample, go to the IQ9 RAP. 

Procedure 

The defect occurs in Copy mode only. 
Y N 

The spots occur at a fixed interval on each print. 
Y N 

The spots occur in the same location on every letter size print. 
Y N 

NOTE: The repetition rate for Transfer Belt defects varies considerably, 
depending on paper size and mode of operation. The defect may appear as fre- 
quently as every 3rd sheet, or may only occur every 14 sheets. 

The defect occurs in approximately the same position on multiple prints. 
Y N 

The problem is Fuser offset. 
Y N 

CAUTION 
Do not use a vacuum cleaner or any solvents in the following step. 
Damage to the Belt Cleaner will result. 

Remove the Belt Cleaner (REP 9.16). Carefully clean the cleaning 
blade and the Mylar shield with a soft brush or a lint free cloth. Brush 
away any accumulation of toner on the foam seal and the outside 
surfaces. Wipe the surface of the Transfer Belt with a lint free cloth. 
If the problem continues, replace the Belt Cleaner (PL 7.1). 

Check the Fuser for dirt, damage, or toner buildup. Clean or replace as 
required (PL 7.1). 

Check the Transfer Belt (PL 5.3) for dirt or damage. Clean or replace as 
required. 

Check the Drum Cartridge for dirt or damage. Clean or replace as required ((see 
Machine Consumables in Section 6). 

Go to the IQ14 RAP. 

Ensure that the original is free from the defect. 
Clean the Platen Glass and Lens. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-13 



Image Quality 

IQ15, IQ16 



IQ20 1st BTR Checkout RAP 

Procedure 



TBD - refer to Figure 1 . 



Image Quality 6/02 Prelaunch Training/Review 

IQ20 3-14 DC1 632/2240 



DC140 [009-200] 
1STBTR(Y) MONITOR 



HVPS T5 
PL9.1 



HVPS CONTROL 

PWB 

PL9.1 



DC140 [009-201] 
1STBTR(M) MONITOR 



-»- 



-»- 



DC140 [009-202] 
1STBTR(C) MONITOR 



-»- 



DC140 [009-203] 
1STBTR(K) MONITOR 



-»- 



l/F PWB 
PL9.1 



DC COM 



+24VDC 
INTLK 



ORN 



1STBTR(Y) p/J570 
MONITOR 

2 t— 



HVPS 

T5 

PL9.1 



1STBTR(M) 
MONITOR 



1STBTR(C) 
MONITOR 



1STBTR(K) 
MONITOR 



ANALOG GND 



P/J571 
-,21r- 



-B12 

I 
-B11 
I 



ORN 
J535 



r^ 



F 1 ^ 




/7\ 1STBTR(K) 

J501 \1/ REMOTE ,, J575 


YEL 

/7\ 1STBTR(C) 
W REMOTE ,, 


YEL 

/7\ 1STBTR(M) 
\_/ REMOTE ,, 


YEL 

/7\ 1STBTR(Y) 
\_/ REMOTE ,, 


YEL 

ANALOG GND 



HVPS T6 
PL9.1 



+24VDC 
INTLK 



VIO 



A 



1STBTR 

POWER 

CONTROL 



1STBTR(C) HV 



1STBTR(Y)HV ,, 



1STBTR(M)HV ,, 



1STBTR(K)HV ,, 



>^- 



-»- 



-»- 



-»- 



-»■ 



DC COM 



-«- 



-«- 



-«- 



-«- 



1> DC140 [009-051] ENABLES 1ST BTR 
FOR ALL COLORS. 



<n 



+24VDC 
INTLK 



DC140 [009-203] 
1ST BTR (K) MONITOR 



DC140 [009-202] 
1ST BTR (C) MONITOR 



DC140 [009-201] 
1ST BTR (M) MONITOR 



DC140 [009-200] 
1ST BTR (Y) MONITOR 



-«- 



-«- 



-«- 



-«- 



<2> 




DRUM CART 



T730004A-CAR 



Figure 1 IQ20 RAP Circuit diagram 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-15 



Image Quality 

IQ20 



IQ21 Developer Bias RAP 

Procedure 

WARNING 

HIGH VOLTAGE! 

Exercise caution when performing the voltage checks in this procedure. 

Enter dC140 [09-026]. Check the voltage at P/J 580 for the affected color(s). There should be 
approximately 370 VAC and -540 VDC (+/- 10%) present. The voltages are within range. 
Y N 

There is +24 VDC from J 501 pin 13 to J 501 pin 10 on the HVPS T5 PWB. 
Y N 

There is +24 VDC from J 553 pin 2 to J 553 pin 4 on the l/F PWB 
Y N 

Go the +24 VDC Wirenets to troubleshoot this problem. 

Go to Flag 2. Check for an open circuit 

Check that the HVPS Control PWB is seated correctly. If the problem continues, replace 
the HVPS T5 PWB (PL 9.1). 

Go to Flag 1 . Check for an open circuit or a short circuit to ground. Check P/J 580 and the HV 
terminals on the Developer Housing(s). for damage or loose connections. If the checks are 
good, return the RAP from which you came. 



Image Quality 

IQ21 



6/02 
3-16 



Prelaunch Training/Review 
DC1 632/2240 



I/F PWB 
PL9.1 



:COM I 




DC COM 



DC COM 



+24VDC 
INTLK 



VIO 

DC COM 


. | 


VIO 

+ 24VDC INTLK 


. i 


ORN 

+ 24VDC INTLK 




ORN 





DC COM 



13 I +24VC 



24VDC 
INTLK 







V-l_l 
J580 ir DEV. BIAS(Y) . 


DEV. BIAS (M) 


DEV. BIAS (C) 


DEV. BIAS (K) 




T-730001-A-CAR 



Figure 1 IQ21 RAP Circuit Diagram 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-17 



Image Quality 

IQ21 



IQ22 2nd BTR Checkout RAP 

Procedure 



TBD - refer to Figure 1 . 



Image Quality 6/02 Prelaunch Training/Review 

IQ22 3-18 DC1 632/2240 



MCU PWB 
PL13.1 



2ND BTR SELECT 
TRANSFER: (L) +5VDC 

CLEAN: (H) +5VDC J574 



l/F PWB 
PL9.1 



DC COM 



n: 





. 


DC COM 


, 


+24VDC INTLK 


, 


+24VDC INTLK 


, 





Figure 1 IQ22 RAP Circuit Diagram 



T730005A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-19 



Image Quality 

IQ22 



IQ23 BCR Checkout RAP 

Procedure 

The problem is very high single-color background 
Y N 

TBD 
A 




DC330 [009-038] 

BCR (K) DC CHANGE 
(L)+5VDC 



DC330 [009-038] 

BCR (K) AC CHANGE 
(L)+5VDC 



Kn 



l/F PWB 1 
PL9.1 I 


DC COM 


I 
3 

I 


+24VDC 
INTLK 


I 
1 

I 




Go to Flag 3. Check the wires associated with the problem color for an open circuit. If the wires 
are OK., check the HV outputs at P 581 for open circuits or loose contacts. If the problem per- 
sists, replace the Drum Cartridge for the affected color (see Machine Consumables in Section 
6). 
If this does not resolve the problem, replace the HVPS T7 PWB (PL 9.1 ). 



<n 



HVPS T7 
PL9.1 



AC 

FREQUENCY/ 

DUTY 

CONTROL 



2 




3 


A 


4 




5 


BCR 

POWER 

CONTROL 


6 




8 




9 





J581 BCR (K) POWER 



BCR (C) POWER 



BCR (M) POWER 



BCR (Y) POWER 




~1 
DC COM 



~1 
+24VDC 
INTLK 



T730003 A-CAR 



Figure 1 IQ23 RAP Circuit Diagram 



Image Quality 

IQ23 



6/02 
3-20 



Prelaunch Training/Review 
DC1 632/2240 



Image Quality Specifications 

The following steps are used to set up the machine for the purpose of making test pattern cop- 
ies to judge output image color density, balance, and registration. 

1 . Set the following Customer Mode Settings to the positions listed: 

a. Output Color - Full Color 

b. Original Type - Photo & Text / Halftone 

c. Lighter/Darker - Auto Contrast 

d. Variable Color Balance - Normal 

e. Color Saturation - Normal 

f. Sharpness - Normal 

2. Place the Color Test Pattern on the platen. Load 11TX17 or A3 paper into Tray 1 . Make 
a copy of the test pattern. 

3. Compare the copy to the test pattern. Refer to Figure 2 and Table 1 for this evaluation. 

Table 1 Color Specifications Check Locations 



AREA 
(Fig. 1) 


Check for the Following Results 


A 


Text Reproduction. Each of the seven sentences in this area are fully repro- 
duced with no missing letters or portions of letters. The sentences are repro- 
duced in Black, Cyan, Magenta, Yellow, Red, Green and Blue. 


B 


Color Registration. The patterns in location B should be properly registered to 
provide Black, Red, Green and Blue lines. 


C 


Front to Rear Density. The density of both the low density and high density 
bands should be uniform from front to rear. This can be tested by folding the 
copy in the center and comparing the front side of the copy to the rear side of 
the copy at location C. Both the high density and low density locations should 
exhibit even front to rear density. 


D 


Color Gradation. This area should exhibit a decreasing density of each of the 
colors from 100% density to 5% density. In a properly adjusted machine, the 
10% patches should be visible and the 5% patches should be barely visible or 
not visible on the test pattern copy (except for the bottom row). 


E 


Routine Color. Location E represents three general tests for the machine to 

reproduce colors common to customer originals. 

Location A is a general skin tone test. 

Location B represents the color of grass or other common foliage. 

Location C represents the color of the sky. 


F 


Photo Gradation. Location F is not used for any copy quality evaluation on 
this product. 


G 


NT Calibration Patches. These patches are scanned for NT Calibration during 
the DC945 NT Calibration portion of Max Setup. 


H 


100 Lines/Inch Image. A Moire defect will show on this image. Moire on a 100 
Line/Inch image is within specification. 


I 


175 Lines/Inch Image. This image is used to test for Moire. Depending on the 
degree of the defect, moire seen on this image should be considered out of 
specification. 



Registration and border deletions are checked using the Step Scales on the Geometric Test 
Pattern, an example of which is shown in Figure 1. All of the scales are 20mm in height, and 
are made up of four 5mm steps. Step 1 will be described as at the top of the Step Scale, and 
Step 4 will be described as at the bottom. 




20mm 



Bottom 

Figure 1 Step Scales 

Each Step Scale is positioned for a particular paper size and orientation. Table 2 indicates the 
appropriate Step Scales to use for the various paper sizes, orientations and measurement 
locations. 

Table 2 Geometric Checkout - Step Scale Data. 



Paper 
Size 


Orientation 


To check: 


Step Scales to use (refer to Figure 2) 


11x17 


SEF 


Lead Edge 
Side Edge 
Trail Edge 


LE1 through LE3 

SE1 through SE4 (top); SE5 and SE8 (bottom) 

TE3 


A3 


SEF 


Lead Edge 
Side Edge 
Trail Edge 


LE 1 through LE3 

SE1 through SE4 (top); SE6 and SE7 (bottom) 

TE4 


8.5x11 


SEF 


Lead Edge 
Side Edge 
Trail Edge 


LE 1 and LE2 

SE1 through SE3 (top); SE9 (bottom) 

TE5 


A4 


LSEF 


Lead Edge 
Side Edge 
Trail Edge 


LE 1 and LE2 

SE1 through SE3 (top); SE10 (bottom) 

TE6 


8.5x11 


LEF 


Lead Edge 
Side Edge 
Trail Edge 


LE1 through SE3 

SE1 and 2 (bottom) SE6 and SE7 (top) 

TE2 


A4 


LEF 


Lead Edge 
Side Edge 
Trail Edge 


LE1 through SE3 

SE5 (top); SE1 and SE2 (bottom) 

TE1 



1 . Set the following Customer Mode Settings to the positions listed: 
T Output Color - Full Color 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-21 



Image Quality 

Image Quality Specifications 



i Original Type - Photo & Text / Halftone 

i Lighter/Darker - Auto Contrast 

i Color Saturation - Normal 

i Variable Color Balance - Normal 

i Sharpness - Normal 

Place Test Pattern 82E8220 on the platen and 24# Xerox Color Xpressions 11X17 

(USCO), or 90 GSM Colotech A3 (XL) paper in Tray 1 . Make a copy of the test pattern. 

Follow the directions in Table 3 to determine if the machine registration is within specifica- 



Table 3 Test Pattern Image Data Locations for Geometric Specifications 



tion. 



Table 3 Test Pattern Image Data Locations for Geometric Specifications 



GEOMETRIC 
AREA 


CHECK PERFORMED 


Magnification 


Locate the 300mm line running from near LE1 to the trail edge of the 1.8 Ip 
ladder. Locate the 200mm line running from near LE1 to near LE3. Make a 
copy. The measurements should be:, 
i Left to Right.: 300mm ±1 .8mm 
i Front to Rear: 200mm ±1 .2mm 


Resolution 


Observing the targets on the test pattern copy at locations R1 through R8, the 
line pairs specified below are clearly visible for the magnification value indi- 
cated: 

i 70%: 3.0 Ip/mm 
'i 1 00% through 400%: 4.3 Ip/mm 


Lead Edge 
Registration 


Measure from the lead edge of the paper to the top of Step 3 on the LE2 Step 
Scale. The measurement should be: 

i Trays 1 through 4: 10mm ±1 .5mm (±1 .9mm for 2nd side of duplex job) 
i Tray 5: 10mm ±2. 2mm 


Side Edge 
Registration 


Measure from the side edge of the paper to the top of Step 3 on the SE2 and 
SE3 Step Scales. The distance should be within the following tolerance: 
i Trays 1 through 4: 10mm ±2. 0mm (±2.4mm for 2nd side of duplex job) 
i Tray 5: 10mm ±2.4mm 


Lead Edge 
Skew 


For skew from front to rear, the distance from the lead edge of the paper to the 
targets at LE1 and LE3 are measured. The measurements must match each 
other to within the tolerance below. 

i Trays 1 through 4: within ±1 .5mm (±2. 0mm for 2nd side of duplex job) 
i Tray 5: within ±2. 0mm 


Side Edge 
Skew 


For skew from left to right, the distance from the side edge of the paper to the 
targets at SE1 and SE4 are measured. They must match each other to within 
the tolerance below: 

i Trays 1 through 4: within ±3. 0mm (±4. 0mm for 2nd side of duplex job) 
i Tray 5: within ±4. 0mm 


Line Density 


This parameter is measured on the two 0.7G Text Blocks on the test pattern 
copy. The machine should reproduce all of the characters shown in the block 
on the output copy. 


Solid Repro- 
duction 


This specifies the desired standard for reproduction of solid gray images at 1 .0 
K. The 1.0 K blocks on the output copy should reproduce with minimal mottle 
or graininess. 



GEOMETRIC 
AREA 



Low Contrast 
Reproduction 



ROS Borders 
(Image Loss) 



CHECK PERFORMED 



This specifies the desired standard for reproduction of low density images. 
The machine should reproduce all of the text in the 0.2 G Text Blocks on the 
output copy. 



Measure from the lead edge of the paper at LE2, the side edge of the paper at 
SE2 and SE7, and the trail edge at TE4, to the top edge of the step scales in 
those locations. The measurements should conform to the following specifica- 
tions: 

i Lead Edge 4mm ± 1 mm 
i Side Edges 2 mm ± 1 mm 
i Trail Edge 2 mm ± 1 mm 



Image Quality 

Image Quality Specifications 



6/02 
3-22 



Prelaunch Training/Review 
DC1 632/2240 



m 



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Figure 2 Color and Geometric Test Patterns 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
3-23 



Image Quality 

Image Quality Specifications 



Image Quality 6/02 Prelaunch Training/Review 

Image Quality Specifications 3-24 Dc-1632/2240 



REPAIRS 

Electrical 

REP 1.1 3.3/5 V LVPS Bracket 4-3 

REP 1.2 MCU PWB 4-3 

REP 1.3 ESS Chassis 4-4 

REP 1 .4 3.3 V LVPS or 5 V LVPS 4-4 

REP 1.5 24 V LVPS 4-5 

REP 1.6 T5 T7 HVPS Chassis 4-5 

REP 1.7 T5 orT7 High Voltage Power Supplies 4-6 

REP 1.8 l/F (Interface) PWB 4-6 

REP 1.9 24 V LVPS Bracket 4-7 

REP 1.10 HVPS T6 4-8 

REP 1.11 AC Drive PWB 4-8 

REP 1.12 ESS PWB 4-9 

REP 1.13 ESS NVM PWB 4-11 

Main Drives 

REP 4.1 Main Drive Motor Assembly 4-13 

REP 4.2 IBT Motor 4-14 

REP 4.3 Developer Drive Motor 4-14 

REP 4.4 Drum Motor Assembly 4-15 

Document Handler 

REP 5.1 DADF 4-17 

REP 5.2 Registration Gate Solenoid 4-18 

REP 5.3 Left/Right Counterbalance 4-19 

REP 5.4 DADF Control PWB 4-21 

REP 5.5 Feed Motor Assembly 4-22 

REP 5.6 Nudger Roll 4-23 

REP 5.7 Feed Roll Assembly 4-24 

REP 5.8 Lower Chute Assembly 4-25 

REP 5.9 Retard Roll 4-26 

REP 5.10 Set Gate Solenoid Assembly 4-27 

REP 5.11 Registration Sensor 4-29 

REP 5.12 Size Sensors 1/2 (Rear/Front) 4-30 

REP 5.13 DADF Belt Motor Assembly 4-31 

REP 5.14 Duplex Sensor 4-32 

REP 5.15 Registration Pinch Roll 4-33 

REP 5.16 Exit Motor Assembly 4-35 

REP 5.17 Document Transport 4-36 

REP 5.18 Rear Cover 4-37 

REP 5.19 Platen Belt 4-38 

Imaging 

REP 6.1 ROS 4-41 

REP 6.2 Platen Glass 4-42 

REP 6.3 IITTop Cover 4-43 



4 Repairs & Adjustments 

REP 6.4 Lens Kit 4-43 

REP 6.11 Carriage Cables 4-44 

REP 6.12 Carriage Motor 4-49 

REP 6.13 Exposure Lamp 4-50 

REP 6.14 Lamp Wire Harness 4-51 

Paper Trays 

REP 7.1 Tray 5 4-53 

REP 7.2 Tray 5 Feed Roll 4-54 

REP 7.3 Tray 1 Feeder 4-55 

REP 7.4 Tray 1 Feed/Lift Motor 4-55 

REP 7.5 Tray 1 Paper Size Sensor 4-56 

REP 7.6 Tray 3 4-56 

REP 7.7 Tray 4 4-57 

REP 7.8 Tray 1 4-57 

REP 7.9 Tray 2 4-58 

REP 7.10 Tray 2 Feeder 4-59 

REP 7.11 Tray 3 Feeder 4-60 

REP 7.12 Tray 4 Feeder 4-61 

Paper Feed and Registration 

REP 8.1 Left Cover Assembly 4-63 

REP 8.2 Duplex Chute 4-65 

REP 8.3 Duplex Transport Assembly 4-66 

REP 8.5 Inverter Transport 4-66 

REP 8.6 Registration Transport Assembly 4-67 

REP 8.7 Exit Transport Assembly 4-68 

Xerographic 

REP 9.1 Drum Cartridge 4-69 

REP 9.2 ROS Shutter Motor 4-69 

REP 9.3 Waste Toner Cartridge Cover 4-70 

REP 9.4 Waste Toner Cartridge 4-70 

REP 9.5 Full Toner Sensor 4-71 

REP 9.6 Inner Cover 4-71 

REP 9.7 Toner Dispenser 4-72 

REP 9.8 Plate Assembly 4-73 

REP 9.9 Developer Housing 4-75 

REP 9.10 Developer 4-76 

REP 9.11 Toner Dispenser Base Assembly 4-77 

REP 9.12 IBT Steering Drive Assembly 4-78 

REP 9.13 Agitator Motor Assembly 4-78 

REP 9.14 MOB Sensor Assembly 4-79 

REP 9.15 IBT Belt Assembly 4-79 

REP 9.16 IBT Cleaner Assembly 4-80 

REP 9.1 7 Auger Assembly 4-80 

REP 9.18 Lever 4-81 

REP 9.19 Left Hinge/Right Hinge 4-81 



Prelaunch Training/Review 
DC1 632/2240 



6/02 

4-1 



Repairs and Adjustments 



REP 9.20 Right Lift Assembly 4-82 

REP 9.21 Left Lift Assembly 4-83 

REP 9.22 Transfer Belt 4-84 

REP 9.23 1st BTR Roll 4-90 

REP 9.24 2nd BTR Roll 4-90 

REP 9.26 ATC Sensor 4-91 

REP 9.27 Retract Shaft 4-93 

Fuser 

REP 10.1 Fuser 4-95 

REP 10.2 Fuser Fan 4-95 

REP 10.3 Main/Sub Heater Rod 4-96 

Finisher 

REP 12.1 H Transport Assembly 4-99 

REP 12.2 H Transport Belt 4-100 

REP 12.3 Entrance Sensor 4-103 

REP 12.4 Finisher 4-104 

REP 12.5 Stack Height Sensor Assembly 4-105 

REP 12.6 Eject Roll Assembly 4-106 

REP 12.7 DecurlerRoll 4-110 

REP 12.8 Finisher Drive Motor 4-111 

REP 12.9 Belt 4-112 

REP 12.10 Rail 4-115 

REP 12.11 Stapler Assembly 4-120 

REP 12.12 Compiler Tray Assembly 4-122 

REP 12.13 Stacker Motor Assembly 4-126 

REP 12.14 Front Elevator Bracket 4-128 

REP 12.15 Paddle Gear Shaft 4-131 

REP 12.16 Finisher PWB 4-133 

REP 12.17 Entrance Upper Cover 4-135 

REP 12.18 Cam Bracket Assembly 4-136 

REP 12.19 Finisher Rack Assembly 4-139 

REP 12.20 Lowering Stacker Tray 4-141 

Covers 

REP 14.1 Top Cover 4-143 

REP 14.2 Rear Cover 4-144 

REP 14.3 Right Cover 4-144 

REP 14.4 Rear Left Middle Cover 4-145 

REP 14.5 Rear Left Upper Cover 4-145 

REP 14.6 Left Lower Cover Assembly 4-146 

REP 14.7 Cover Assembly 4-146 

REP 14.8 Fuser Cover 4-147 

REP 14.9 Rear Cover 4-148 

REP 14.10 Inner Cover 4-148 

REP 14.11 Left Cover Assembly 4-149 

REP 14.12 Lower Cover 4-149 



ADJUSTMENTS 

DADF 

ADJ 5.1 DADF Side Registration 4-151 

ADJ 5.2 DADF Counterbalance 4-153 

ADJ 5.3 DADF Parallelism 4-154 

ADJ 5.4 Document Transport Height 4-155 

ADJ 5.5 DADF Top Registration 4-157 

ADJ 5.6 DADF Document Detection 4-159 

ADJ 5.7 DADF Non-standard Document Custom Registration 4-160 

Scanner 

ADJ 6.1 Full/Half Rate Carriage 4-161 

Xerographic/Registration 

ADJ 9.1 Max Setup 4-165 

ADJ 9.2 ATC Sensor Setup (dC921) 4-165 

ADJ 9.3 TRC Control/Toner Density Setup (dC922) 4-166 

ADJ 9.4 ADC Output Check (dC934) 4-166 

ADJ 9.5 TRC Adjust (dC924) 4-167 

ADJ 9.6 Color Registration (dC685) 4-168 

ADJ 9.7 NT Calibration (dC945) 4-170 

ADJ 9.8 Hard Disk Diagnostics/Setup (dC355) 4-170 

ADJ 9.9 IOT Registration Series (dC1 29) 4-171 

ADJ 9.10 NT Lead Edge Registration 4-173 

ADJ 9.11 NT Side Edge Registration 4-174 

ADJ 9.12 IIT Vertical/Horizontal Magnification 4-175 

ADJ 9.13 Ul Display Calibration 4-178 

ADJ 9.14 Inboard/Outboard Density 4-179 

Finisher 

ADJ 12.1 Finisher Alignment 4-185 



Repairs and Adjustments 



6/02 
4-2 



Prelaunch Training/Review 
DC1 632/2240 



REP 1.1 3.3/5 V LVPS Bracket 

Parts List on PL 9.1 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

CAUTION 
PWBis can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid 
component damage. 

1 . Remove Rear Cover (REP 14.2). 

2. Remove High Voltage Power Supply Chassis (REP 1 .6). 

3. Release 6 harness clips. 

4. Remove 3.3/5 VDC Power Supply Chassis (Figure 1). 

a. Disconnect Harness P/Jis (4). 

b. Loosen Lower Screws (2). 

c. Remove upper Screws (2) and remove 3.3/5 VDC Power Supply Chassis. 



REP1.2MCUPWB 
Parts List on PL 13.1 
Removal 

1 . If a new PWB will be installed, record NVM values for new PWB 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

2. Remove Right Cover (REP 14.3). 

3. Remove Top Cover (REP 14.1). 

4. Remove Rear Cover (REP 14.2). 

CAUTION 
PWBis can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid 
component damage. 

5. Remove ESS Chassis (REP 1 .3). 

6. Remove Screws and remove MCU PWB from ESS Chassis. 



Harness P/Jis 



Upper 
Screw 



3.3 VDC 
LVPS 



Lower 
Screw 




Upper 
Screw 



5 VDC 
LVPS 



Lower 
Screw 



Harness P/Jis 



0102018A-CAR 



Figure 1 Removing 3.3/5 VDC Power Supply Chassis 



Prelaunch Training/Review 
DC1 632/2240 



6/02 

4-3 



Repairs and Adjustments 

REP 1.1, REP 1.2 



REP 1.3 ESS Chassis 

Parts List on PL 13.1 
Removal 

1 . If a new PWB will be installed, record NVM values for new PWB. 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

2. Remove Right Cover (REP 14.3). 

3. Remove Top Cover (REP 14.1). 

4. Remove Rear Cover (REP 14.2). 

CAUTION 
PWBis can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid 
component damage. 

5. Remove ESS PWB (REP 1 . 1 2). 

6. Remove ESS Chassis (Figure 1). 

a. Push Harness Clips (2) down out of Chassis holes 

b. Disconnect Harness P/Jis (6). 

c. Disconnect Harness P/Jis (2). 

d. Disconnect Switch from Chassis. 

e. Loosen Screws (2) at front and remove Screws (2) at rear of machine. 

f. Lift outer end of Chassis to disconnect Hidden Connector and then remove Chassis. 



Screws (2) 



Harness 
Clii 



Screw 



Hidden 

Connector 

Switch 

Screw 

Harness 
P/Jis (2) 




Harness 
P/Jis (6) 



Figure 1 Removing ESS Chassis 



Replacement 



NOTE: If the ESS PWB will be replaced with anew ESS PWB, discard the MAC ROM from the 
new ESS PWB and install the MAC ROM removed from the old ESS PWB. 



REP 1 .4 3.3 V LVPS or 5 V LVPS 

Parts List on PL 9.1 
Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

CAUTION 

PWBis can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid 
component damage. 

1. Remove Rear Cover (REP 14.2). 

2. Remove High Voltage Power Supply Chassis (REP 1 .6). 

3. Remove appropriate LVPS (Figure 1). 

a. Disconnect appropriate Harness P/Jis (2). 

b. Remove appropriate Screws (4) and remove LVPS. 

Harness P/Jis 



Screws 



Screws (2) 



3.3 VDC 
LVPS 



Screws (2) -as 




Harness P/Jis 



Figure 1 Removing LVPS 



0102018A-CAR 



Repairs and Adjustments 

REP 1.3, REP 1.4 



6/02 
4-4 



Prelaunch Training/Review 
DC1 632/2240 



REP1.5 24VLVPS 

Parts List on PL 9.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 14.2). 

CAUTION 
PWBis can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid 
component damage. 

2. Remove 24 V LVPS (Figure 1 ). 

a. Disconnect Harness P/Jis (3). 

CAUTION 
5 screws with red marks secure LVPS to heat sink. Do not remove them. 

b. Loosen Screws (2) and remove LVPS. 



Screw 



Harness 
P/Jis (2) 




Harness 
P/J 



Screw 
Figure 1 Removing 24 VDC Power Supply 



REP 1.6 T5 T7 HVPS Chassis 

Parts List on PL 9.1 
Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

CAUTION 

HVPS can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid 
component damage. 

1. Remove Rear Cover (REP 14.2). 

2. Remove High Voltage Power Supply Chassis (Figure 1 ). 

a. Loosen screw and disconnect Ground Wire. 

b. Disconnect Harness P/Jis (2). Do not disconnect Soldered Connection 

c. Disconnect High Voltage P/J (1). 

d. Disconnect High Voltage P/Jis (2). 

e. Remove Screws (3). 

f. Pivot HVPS down and engage stop strap with frame tab (not shown in figure). 

g. Disconnect High Voltage P/J (1) at bottom (not shown in figure). 



Ground 
Wire 



High 
Voltage 




Screws (3) 
Figure 1 Removing High Voltage Power Supply 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-5 



Repairs and Adjustments 

REP 1.5, REP 1.6 



REP 1.7 T5 or T7 High Voltage Power Supplies 

Parts List on PL 9.1 

Removal 

1 . Perform NVRAM Save. 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

2. Remove Rear Cover (REP 14.2). 

CAUTION 

PWBis can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid 
component damage. 

3. Remove High Voltage Power Supply Chassis (REP 1 .6). 

4. Remove High Voltage Power Supplies from Chassis. 

i T5 HVPS (Detack/2nd BTR) is power supply toward machine rear. 

T T7 HVPS (Developer Bias and Charge) is power supply toward machine front. 



REP 1.8 l/F (Interface) PWB 
Parts List on PL 9.1 
Removal 

1 . Perform NVRAM Save. 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

2. Remove Right Cover (REP 14.3). 

3. Remove Top Cover (REP 14.1). 

4. Remove Rear Cover (REP 14.2). 

5. Pivot down T5 T7 HVPS Chassis (REP 1 .6). 

CAUTION 
PWBis can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid 
component damage. 

6. Remove ESS Chassis (REP 1 .3). 

7. Remove Main PWB Interface PWB (Figure 1 ). 

a. Loosen Screws (2). 

b. Lift Main PWB Interface PWB until Harness P/Jis (11) can be disconnected. 

c. Remove Main PWB Interface PWB from chassis 



Screws (2) 




Harness xm 

P/Jis (11) l ~ 



Figure 1 Removing Interface PWB 



Repairs and Adjustments 

REP 1.7, REP 1.8 



6/02 
4-6 



Prelaunch Training/Review 
DC1 632/2240 



Replacement 

Ensure Screws (2) are positioned in slots as shown before tightening Screws (2) (Figure 2). 



Screws (2) 



Slot 




Slot 



Figure 2 Installing Interface PWB 



REP 1.9 24 V LVPS Bracket 

Parts List on PL 9.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Rear Cover (REP 14.2). 

2. Remove Upper Rear Left Cover (REP 14.4). 

3. Remove 24 V LVPS (REP 1 .5). 

4. Remove 24 VDC LVPS Chassis (Figure 1 ). 

a. Remove Top Screw. 

b. Remove upper harnesses from Harness Clips (2). 

c. Disconnect Fan P/J and remove harness from Harness Clip. 

d. Loosen Screws (4). 

e. Remove 24 VDC LVPS Chassis. 



Harness 
Clips 




Screws (2) 

Figure 1 Removing 24 VDC LVPS Bracket Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-7 



Repairs and Adjustments 

REP 1.8, REP 1.9 



REP 1.10 HVPST6 

Parts List on PL 9.1 
Removal 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 14.2). 

2. Remove 24 V LVPS (REP 1 .5). 

3. Remove 24 VDC LVPS Chassis (REP 1 .9). 

4. Remove HVPST6 (Figure 1). 

a. Disconnect P/Jis (4). 

b. Disconnect Harness P/Jis (2). 

c. Remove Screws (2) and remove High Voltage Power Supply with chassis. 

d. Remove High Voltage Power Supply from chassis. 



"IstBTR 
P/Jis (4) 




Harness 
P/Jis (2) 



Screws 



0102019A-CAR 



Figure 1 Removing HVPS T6 



REP 1.11 AC Drive PWB 

Parts List on PL 9.2 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Rear Cover (REP 14.2). 

2. Remove 24 V LVPS (REP 1 .5). 

3. Remove 24 VDC LVPS Chassis (REP 1 .9). 

4. Remove HVPS T6 (REP 1 . 1 0). 

5. Remove AC Drive PWB (Figure 1 ). 

a. Remove Screws (2) and Bracket. 

b. Carefully observe position of wiring harnesses and AC Wires for later reinstallation 

c. Disconnect AC Harness P/Jis (3) and AC Wires (6). 

d. Disconnect DC Harness P/Jis (2). 

e. Release harness from Harness Clip. 

f. Remove Mounting Screws (3) 

g. Disengage rear clip (not shown) and remove AC Drive PWB. 



Harness 
Clip 



Mounting 
Screw 



P46 



AC Har- 
ness P/Jis 
(3) and 
AC wires 
(6) 



P43 
White 



Mounting' 
Screw 




DC Har- 
ness P/Jis 



ounting 
Screw 



Screws (2) 

and 

Bracket 



Figure 1 Removing AC Drive PWB 



Repairs and Adjustments 

REP 1.10, REP 1.11 



6/02 

4-8 



Prelaunch Training/Review 
DC1 632/2240 



Replacement 

CAUTION 

Ensure White connector P43 and Blue connector is P42. 
to ensure correct connection. 



Other connectors are different sizes 



REP 1.12 ESSPWB 

Parts List on PL 13.1 
Removal 

WARNING 

To avoid personal Injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

CAUTION 

The ESS PWB has a lithium battery. Dispose of the used battery following the manufacturers' 
instructions after replacing. Do not throw it away at customer's site. 

1 . Remove Right Cover (REP 14.3). 

2. Remove Top Cover (REP 14.1). 

3. Remove Rear Cover (REP 14.2). 

4. Remove ESS Top Cover (PL 13.1). 

CAUTION 
Protect Hard Drive Harness. Hard Drive is mounted to ESS Top Cover. Hard Drive har- 
ness remains connected to ESS PWB while removing ESS Top Cover. 

a. Remove screws (11) from ESS Top Cover. 

b. Lift ESS Top Cover and place it upside down on Toner Cartridges. 

c. Disconnect Hard Drive harness from ESS PWB. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 

4-9 



Repairs and Adjustments 

REP 1.11, REP 1.12 



NOTE: 5 mm tool may be required. 
5. Remove ESS PWB (Figure 1). 

4 

o Remove ESS 

Firmware 
Remove EPR0 MS 

Postscript 
Font ROM 




9 

Disconnect 
Fan P/J 



10 

Remove Screws (9) and 
remove ESS PWB 

Figure 1 Removing ESS PWB 



8 

Remove 
jacks from 
plate 



0102021A-CAR 



Repairs and Adjustments 

REP 1.12 



6/02 
4-10 



Prelaunch Training/Review 
DC1 632/2240 



REP 1.13 ESSNVMPWB 

Parts List on PL 13.1 
Removal 

1. Download ESS NVM values to machine floppy. If download is not possible, most recent 
NVM values will be downloaded during replacement step 3. 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

2. Remove Right Cover (REP 14.3). 

3. Remove Top Cover (REP 14.1). 

4. Remove Rear Cover (REP 14.2). 

5. Remove ESS Top Cover (PL 13.1). 

CAUTION 
Protect Hard Drive Harness. Hard Drive is mounted to ESS Top Cover. Hard Drive har- 
ness remains connected to ESS PWB while removing ESS Top Cover. 

a. Remove screws (11) from ESS Top Cover. 

b. Lift ESS Top Cover and place it upside down on Toner Cartridges. 



CAUTION 

The ESS PWB has a lithium battery. Dispose of the used battery following the manufacturers' 
instructions after replacing. Do not throw it away at customer's site. 
6. Remove the ESS NVM PWB (Figure 1 ). 

ESS NVM 

PWB 




0102022A-CAR 



Figure 1 Removing the ESS NVM PWB 



Replacement 



1. Connect the PSW and enter DC132. 

2. Match the Billing, following the steps of DC1 32. 

3. Enter all the NVM values described in the NVM List that comes with the machine or down- 
load NVM values from machine floppy. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-11 



Repairs and Adjustments 

REP 1.13 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

REP 1.13 4-12 DC1 632/2240 



REP 4.1 Main Drive Motor Assembly 

Parts List on PL 1.1 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1. 
2. 
3. 
4. 
5. 
6. 
7. 



Remove Fuser Module (REP 10.1). 
Remove Tray 5 (REP 7.1). 
Remove Rear Cover (REP 14.2). 
Remove 24 V LVPS (REP 1 .5). 
Remove 24 VDC LVPS Chassis (REP 1.9). 
Remove Developer High Voltage Power Supply (REP 1.10). 
Remove AC Drive PWB (REP 1.11). 
8. Remove Main Drive Motor Assembly (Figure 1 ). 

a. Carefully observe position of wiring harnesses for later reinstallation 

b. Disconnect Harness P/Jis (5). 

c. Disconnect Harness P/Jis (3). 

d. Remove harness from Harness Clips (3). 

e. Disconnect HV Wire. 

NOTE: In next step, do not remove small round head screws that appear to secure Main Drive 
Motor Assembly to machine. 



Harness 
P/Jis (3) 



f. 



Remove Screws (5) and remove Main Drive Motor Assembly. 




.Harness Clips (3) 
(2 not shown) 

Figure 1 Removing Main Drive Motor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-13 



Repairs and Adjustments 

REP 4.1 



REP 4.2 IBT Motor 

Parts List on PL 1.1 
Removal 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 14.2). 

2. Pivot down High Voltage Power Supply Chassis (REP 1 .6). 

3. Remove Photoreceptor Module Drive Motor. 

a. Disconnect Cooling Fan P/J. 

b. Remove screws (2) and remove Cooling Fan. 

c. Disconnect Photoreceptor Module Drive Motor P/J. 

d. Remove Photoreceptor Module Drive Motor screws (3) and remove Photoreceptor 
Module Drive Motor. 



Cooling Fan 




Photoreceptor. 
Module Drive 3 
Motor 



Figure 1 Removing Photoreceptor Module Drive Motor 



REP 4.3 Developer Drive Motor 

Parts List on PL 1.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Rear Cover (REP 14.2). 

2. Remove High Voltage Power Supply Chassis (REP 1 .6). 

NOTE: Step 3 can be omitted if Low Voltage Power Supply P/Jis are disconnected before per- 
forming step 4. 

3. Remove 3.3 VDC and 5 VDC Low Voltage Power Supply (REP 1 .4). 

4. Remove Chassis for 3.3 VDC and 5 VDC Low Voltage Power Supply. 

a. Release harnesses from harness clips (3). 

b. Remove screws (4) and remove Chassis. 

5. Remove Developer Drive Module (Figure 1). 

a. Disconnect P/J. 

b. Remove harness from Harness Clip. 

c. Remove Screws (2) and remove Developer Drive Module. 




Screw Harness Clip 
Figure 1 Removing Developer Drive Module 



Repairs and Adjustments 

REP 4.2, REP 4.3 



6/02 
4-14 



Prelaunch Training/Review 
DC1 632/2240 



REP 4.4 Drum Motor Assembly 

Parts List on PL 1.1 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Right Cover (REP 14.3). 

2. Remove Top Cover (REP 14.1). 

3. Remove Rear Cover (REP 14.2). 

CAUTION 
Machine problems will result from careless harness routing during reassembly. Carefully 
observe position of wiring harnesses for later reinstallation. 

NOTE: Step 6 can be omitted if Low Voltage Power Supply P/Jis are disconnected before per- 
forming step 7. 

4. Remove 24 V LVPS (REP 1 .5). 

5. Remove 24 VDC LVPS Chassis (REP 1 .9). 

6. Remove Control Chassis (REP 1 .3). 

7. Remove High Voltage Power Supply Chassis (REP 1 .6). 

NOTE: In next step, do not disconnect P/Jis. 

8. Loosen Interface PWB chassis mounting screws (2) and move chassis up (REP 1.8). 

9. Remove Photoreceptor Module Drive Motor (REP 4.2). 

10. Remove Developer High Voltage Power Supply (REP 1.10). 

1 1 . Remove 3.3/5 VDC Power Supply Chassis (REP 1.1). 

12. Remove Print Cartridge Drive Module (Figure 1). 

a. Release harness from Harness Clips (3) 

b. Remove screws (2) to release Connector from frame. 

c. Disconnect P/J. 

d. Remove Screws (8) and remove Print Cartridge Drive Module. 



Harness 
Clips (3) 




Con- , - 

nector P/J Screws < 8 > 

Figure 1 Removing Print Cartridge Drive Module 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-15 



Repairs and Adjustments 

REP 4.4 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

REP 4.4 4-16 DC1632/2240 



REP 5.1 DADF 

Parts List on PL 20.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1 . Disconnect connector (Figure 1 ). 



Remove Screws (2) and remove DADF (Figure 2). 



Connector 





0101002A-CAR 



Figure 2 Removing DADF 



Replacement 



0101001A-CAR 



Check DADF Side Registration (ADJ 5.1). 
Check DADF Top Registration (ADJ 5.5). 



Figure 1 Disconnecting Connector 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-17 



Repairs and Adjustments 

REP 5.1 



REP 5.2 Registration Gate Solenoid 

Parts List on PL 20.2 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Front Cover (PL 20. 1 ). 

2. Remove Registration Gate Solenoid (Figure 1). 

a. Disconnect connector. 

b. Release clamps (2) and remove wire. 

c. Loosen screws (2). 

d. Remove Registration Gate Solenoid. 



Connector 



Screws (2) 




Clamps (2) 



0101003A-CAR 



Figure 1 Removing Registration Gate Solenoid 



Repairs and Adjustments 

REP 5.2 



6/02 
4-18 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.3 Left/Right Counterbalance 

Parts List on PL 20.3 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1. 
2. 
3. 



Remove Right Counterbalance (Figure 2). 

a. Remove Terminals (2). 

b. Remove Screws (4). 

c. Remove Right Counterbalance. 

d. Mark counterbalance as Right. 



4. 



Remove DADF (REP 5.1). 

Remove Rear Cover (REP 5.18). 

To remove Left Counterbalance, go to step 4. 

To remove Right Counterbalance, go to step 5. 

Remove Left Counter Balance (Figure 1). 

a. Remove Screws (4). 

b. Remove Left Counterbalance. 

c. Mark counterbalance as Left. 




Screws (4) 




Terminals (2) 



Screws (4) 



0101005A-CAR 



Figure 2 Removing Right Counterbalance 



0101004A-CAR 



Figure 1 Removing Left Counterbalance 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-19 



Repairs and Adjustments 

REP 5.3 



Replacement 

1 . If new counterbalances are installed, position as shown (Figure 3). 

If counterbalances are reinstalled, install according to marks made in steps 4c or 5d. 



Left Counterbal- 
ance \ 



h 



S 



-or 



t 



Right Counter- 
'alance 






Figure 3 Install Left/Right Counterbalance 



0101006A-CAR 



Repairs and Adjustments 

REP 5.3 



6/02 
4-20 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.4 DADF Control PWB 

Parts List on PL PL 20.3 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Rear Cover (REP 5.18). 

2. Remove DADF Control PWB (Figurel ). 

a. Disconnect connectors (7). 

b. Remove DADF Control PWB from PWB supports (3). 



Supports (2) 



Connectors 




Support (1) 



01 01 007 A CAR 



Figure 1 Removing DADF Control PWB 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-21 



Repairs and Adjustments 

REP 5.4 



REP 5.5 Feed Motor Assembly 

Parts List on PL 20.4 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 5. 1 8). 

2. Remove Feed Motor Assembly (Figure 1). 

a. Disconnect connector. 

b. Release clamps (3) and remove harness. 

c. Loosen Screws (2). 

d. Remove Feed Motor Assembly. 



Connector 



Clamps (3) 




Screws (2) 



0101008A-CAR 



Figure 1 Removing Feed Motor Assembly 



Repairs and Adjustments 

REP 5.5 



6/02 
4-22 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.6 Nudger Roll 

Parts List on PL 20.4 
Removal 



Remove Nudger Rolls (Figure 2). 

a. Remove Clips (2). 

b. Remove Nudger Rolls (2). 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . To install new Nudger Rolls, go to Feed Roll Assembly (REP 5.7) at this time and replace 
the Nudger Rolls and Feed Rolls as an assembly. Otherwise, continue below. 

2. Open DADF Top Cover and remove Inner Cover (Figure 1 ). 

a. Open Top Cover. 

b. Loosen screws (2). 

c. Remove Inner Cover. 





Screws 
(2) 



101011 A-CAR 

Figure 2 Remove Nudger Rolls 

Replacement 

NOTE: Nudger Rolls rotate freely in direction of document movement. 

NOTE: After replacing Nudger Roll, reset HFSI counter. Enter dC135 HFSI Counters Diag. 
Screen (NVM 005-80). 

NOTE: Replace Feed Roll Assembly (REP 5. 7). 



0101010A-CAR 



Figure 1 Removing Inner Cover 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-23 



Repairs and Adjustments 

REP 5.6 



REP 5.7 Feed Roll Assembly 

Parts List on PL 20.4 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1 . Open Top Cover and remove Inner Cover (Figure 1 ). 

a. Open Top Cover. 

b. Loosen screws (2). 

c. Remove Inner Cover. 



Inner 
Cover 




Screws 
(2) 



Remove Feed Roll Assembly (Figure 2). 

a. Remove clip. 

b. Slide bearing. 

c. Remove Feed Roll Assembly. 




Bearing 



0101010A-CAR 



Figure 1 Removing Inner Cover 



0101013A-CAR 

Figure 2 Removing Feed Roll Assembly 

Replacement 

NOTE: Feed Rolls rotate freely in direction of document movement. 

NOTE: After replacing Feed Roll, reset HFSI counter. Enter dC135 HFSI Counters Diag. 
Screen (NVM 005-805). 

NOTE: Feed Rolls and Nudger Rolls are replaced at same time. 



Repairs and Adjustments 

REP 5.7 



6/02 
4-24 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.8 Lower Chute Assembly 

Parts List on PL 20.5 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Top Cover. 

2. Remove following: 

a. Front Cover (PL 20.1). 

b. Entrance Tray (PL 20.1). 

3. Remove Lower Chute Assembly (Figure 1 ). 

a. Open Document Feed Upper Chute. 

b. Loosen screws (2). 

c. Remove Lower Chute Assembly. 



Screws (2) 



Document Feeder Upper Chute 



Top Cover 




0101015A-CAR 



Figure 1 Removing Lower Chute Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-25 



Repairs and Adjustments 

REP 5.8 



REP 5.9 Retard Roll 

Parts List on PL 20.5 
Removal 



Replacement 

CAUTION 

While replacing Retard Roll, make sure that Retard Roll Plastic Guide is in correct position. 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 



1. 
2. 



3. 

4. 



Open Top Cover. 
Remove following: 

a. Front Cover (PL 20.1). 

b. Entrance Tray (PL 20.1). 

Remove Lower Chute Assembly (REP 5.8). 
Remove Retard Roll (Figure 1). 



Remove Sprin 

3 

Remove Clip. 



Remove Shaft 




1 

Make note of 
position of 
plastic guide 



5 

Remove 
Bracket 



Remove Shaft 
and Retard Roll 



Figure 1 Removing Retard Roll 



Repairs and Adjustments 

REP 5.9 



6/02 
4-26 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.10 Set Gate Solenoid Assembly 

Parts List on PL 20.5 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 



Replacement 

1. Engage pin with slot (Figure 2). 



1. 


Open Top Cover. 


2. 


Remove following: 




a. Front Cover (PL 20.1). 




b. Entrance Tray (PL 20.1). 


3. 


Remove Lower Chute Assembly (REP 5.8). 


4. 


Remove Set Gate Solenoid Assembly (Figure 1). 



Make note of pin 
engagement 



Disconnect 





0101018A-CAR 



Figure 2 Engaging Pin with Slot 



Release clamp 
and remove wire 



Loosen screws 
(2) and remove 
solenoid 



0101017A-CAR 



Figure 1 Removing Set Gate Solenoid Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-27 



Repairs and Adjustments 

REP 5.10 



2. Install Set Gate Solenoid Assembly (Figure 3) 



Move Solenoid as 
shown and tighten 
Screws (2) 



Position Solenoid 
on Screws 




Connect and secure 
harness in clip 



0101019A-CAR 



Figure 3 Installing Set Gate Solenoid Assembly 



Repairs and Adjustments 

REP 5.10 



6/02 
4-28 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.11 Registration Sensor 

Parts List on PL 20.5 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Top Cover. 

2. Remove following: 

a. Front Cover (PL 20.1). 

b. Entrance Tray (PL 20.1). 

3. Remove Lower Chute Assembly (REP 5.8). 

4. Disconnect P/J580 and remove Registration Sensor (Figure 1). 



2 

Remove 
Registration 
Sensor and 
disconnect 



Replacement 

1. When installing Registration Sensor align holes with bumps and tighten screw (Figure 2). 





0101021A-CAR 



Figure 2 Installing Registration Sensor 



0101020A-CAR 



Figure 1 Removing Registration Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-29 



Repairs and Adjustments 

REP 5.11 



REP 5.12 Size Sensors 1/2 (Rear/Front) 

Parts List on PL 20.5 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 



1. 


Open Top Cover. 




2. 


Remove following: 

a. Front Cover (PL 20.1). 

b. Entrance Tray (PL 20.1). 




3. 


Remove Lower Chute Assembly (REP 5.8). 




4. 


Remove Set Gate Solenoid Assembly (REP 5.10). 




5. 


Remove Size Sensors 1/2 (front/rear) (Figure 1). 






1 2 


3 




Remove Disconnect plugs 


Remove screws (2) and 




screws (2) 


sensors 




0101022A-CAR 



Figure 1 Removing Size Sensors 1/2 



Repairs and Adjustments 

REP 5.12 



6/02 
4-30 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.13 DADF Belt Motor Assembly 

Parts List on PL 20.6 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Rear Cover (REP 5.18). 

2. Remove DADF Belt Motor Assembly (Figure 2). 



Replacement 

NOTE: Align motor bracket with marks on frame before tightening screws. 



Mark position of motor bracket on frame 
near all four mounting screws 




4 

Remove 
Belt from 
motor pulley 
and remove 
motor 



01 01 024 A CAR 



Figure 1 Removing DADF Belt Motor Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-31 



Repairs and Adjustments 

REP 5.13 



REP 5.14 Duplex Sensor 

Parts List on PL 20.7 
Removal 



WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove following: 

a. Front Cover (PL 20.1) 

b. Rear Cover (REP 5.18) 

c. Top Cover (PL 20.2) 

2. Loosen screws (2) and remove Feed Motor from mounting (REP 5.5). 

3. Remove Duplex Sensor (Figure 1). 

a. Remove screws (2). 

b. Lift Duplex Chute to disengage lower mounts. 

c. Lift rear end of Duplex Chute so that Duplex Sensor is visible. Harness remains 
connected. 

d. Remove screw and remove Duplex Sensor. 



Screws 




Lower Mounts 



Figure 1 Removing Duplex Sensor 



0101026A-CAR 



Repairs and Adjustments 

REP 5.14 



6/02 
4-32 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.15 Registration Pinch Roll 

Parts List on PL 20.8 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

NOTE: Do not damage or scratch surface of Registration Pinch Roll. (Scratches may cause 
skewing.) 

1. Remove following: 

a. Front Cover (PL 20.1) 

b. Rear Cover (REP 5.18). 

c. Registration Gate Solenoid (REP 5.2). 

2. Remove Gate (Figure 1). 



3 

Remove 
Screws (2) 



2 

Remove 
screws (4) 




01 01 029 A CAR 



Figure 1 Removing Gate 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-33 



Repairs and Adjustments 

REP 5.15 



3. Remove Gate (Figure 2). 



4. Remove Registration Pinch Roll (Figure 3). 



3 

Remove 
Screws (2 



Close DADF 




CAUTION 

Plastic edge on 
Gate is fragile 



Remove Gate while 
containing Springs 



Observe position 
of Springs 



Remove C 
Clip, shorter 
Spring, and 
Bearing 



01 01 030 A CAR 




Remove Regis- 
tration Pinch Roll 



01 01 031 A CAR 



Figure 2 Removing Gate 



Figure 3 Removing Registration Pinch Roll 



Repairs and Adjustments 

REP 5.15 



6/02 
4-34 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.16 Exit Motor Assembly 

Parts List on PL 20.9 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Rear Cover (REP 5.18). 

2. Remove Exit Motor Assembly (Figure 1). 

a. Disconnect connector. 

b. Release clamps (2) and remove wire. 

c. Loosen screws (2). 

d. Remove belt. 

e. Remove Exit Motor Assembly. 



Replacement 

NOTE: Belt should be tight but not stretched before tightening motor mounting screws (Figure 
2). 



Release wires 
from Clamps 



1 

Disconnect 



3 

Loosen 
Screws (2) 





0101033A-CAR 



Figure 2 Tightening Exit Motor Assembly Mounting Screws 



4 

Remove 
Exit Motor 
Assembly 
and Belt 



0101032A-CAR 



Figure 1 Removing Exit Motor Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-35 



Repairs and Adjustments 

REP 5.16 



REP 5.17 Document Transport 

Parts List on PL 20.10 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Front Cover (PL 20. 1 ). 

2. Remove Document Transport (Figure 1). 

a. Loosen screws (3). 

CAUTION 
Document Handler rises quickly after lowering when Document Transport is removed. 

b. Support bottom of Document Transport and remove it by pulling up and off mounting 
screws. 




0101034A-CAR 



Figure 1 Removing Document Transport 



Repairs and Adjustments 

REP 5.17 



6/02 
4-36 



Prelaunch Training/Review 
DC1 632/2240 



REP 5.18 Rear Cover 

Parts List on PL 20.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

CAUTION 
LED harness breakage occurs if Rear Cover is removed without disconnecting LED plug 
1. Loosen Screws (3) and remove Rear Cover enough to disconnect LED harness from 
DADF Control PWB. 



Prelaunch Training/Review 6/n2 Repairs and Adjustments 

DC1 632/2240 4-37 REP 5.18 



REP 5.19 Platen Belt 

Parts List on PL 20.10 
Removal 



Replacement 

NOTE: Lock shaft support by matching hole with frame's detent (Figure 3). 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

NOTE: After replacing Platen Belt, reset HFSI counter. Enter DC135 HFSI Counters Diag. 
Screen (NVM 005-805). 

WARNING 

Switch off the power and disconnect power cord. 

1. Remove Front Cover (PL 20.1). 

2. Remove Document Transport (REP 5.17). 

3. Remove Platen Belt (Figure 2). 

a. Loosen screws (2). 

b. Move shaft support in direction of arrow. 

c. Remove Platen Belt. 





0101036A-CAR 



Figure 2 Lock shaft support 



0101035A-CAR 



Figure 1 Removing Platen Belt 



Repairs and Adjustments 

REP 5.19 



6/02 
4-38 



Prelaunch Training/Review 
DC1 632/2240 



NOTE: Make sure that both sides of Platen Belt are correctly set in pulley (Figure 4). 





CORRECT 



INCORRECT 



0101037A-CAR 



Figure 3 Install Platen Belt 

1 . Connect power cord and switch on power. 

2. Enter DC330 [5-055]. Press START button and press the Stop button in 15 seconds. 
Check the belt position. If the belt has moved to either side, 

3. Rotate Platen Belt for 15 seconds. Press STOP button. Check the Belt position. If the belt 
moved to either side, check the installation of the Shaft Supports. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-39 



Repairs and Adjustments 

REP 5.19 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

REP 5.19 4-40 DC1 632/2240 



REP 6.1 ROS 

Parts List on PL 3.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Right Cover (REP 14.3). 

2. Remove Rear Cover (REP 14.2). 

CAUTION 
Image quality defects result if covers on ROS cleaning openings are removed. 

3. Remove ROS (Figure 1). 

a. Carefully observe position of wiring harness for later reinstallation. 

b. Remove Harness from Harness Clips. 

c. Disconnect Harness P/Jis (2). 

d. Remove Screws (2). 

e. Pull out ROS to remove it. 



Screws (2) 



P/Jis 




Harness Clips * "-1 n' 

Figure 1 Removing ROS 



Replacement 

After machine reassembly perform following: 

1. DC956 Belt Edge. 

2. DC685 Color Registration Control (ADJ 9.6). 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-41 



Repairs and Adjustments 

REP 6.1 



REP 6.2 Platen Glass 

Parts List on PL 18.3 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open DADF. 

2. Remove Platen Glass (Figure 1). 



1 

Remove 
screws (2) 



Replacement 

NOTE: Press Platen Glass in direction of arrow A; Press Right Side Plate in direction of arrow 
B (Figure 2). 





0101053A-CAR 



Figure 2 Positioning Platen Glass 



0101052A-CAR 



Figure 1 Removing Platen Glass 



Repairs and Adjustments 

REP 6.2 



6/02 
4-42 



Prelaunch Training/Review 
DC1 632/2240 



REP 6.3 NT Top Cover 

Removal 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove DADF (REP 5.1). 

2. Remove Screws (2) from top front of NT Top Cover. 

3. Loosen Screws (2) under Control Panel, each end. 

4. Remove Screw from rear of I IT Top Cover, left side. 

5. Remove Document Output Tray. 

6. Remove Document Output Tray support bracket Screws (4) and Brackets (2). 

7. Lift NT Top Cover to access harness connectors (2). Disconnect P/Jis and remove NT Top 
Cover. 



REP 6.4 Lens Kit 

Parts List on PL 18.4 
Removal 

1 . Remove Platen Glass (REP 6.2). 

CAUTION 
In the following, do not remove any red screws. 

2. Remove the Lens/CCD Chassis (Figure 1 ). 

a. Mark the position of the APS Sensor bracket. 

b. Remove the Screw (1 ) and the APS Sensor with bracket. 

c. Remove Lens Cover Screws (6) and Lens Cover. 

d. Disconnect CCD Connector (not shown). 

e. Remove Lens/CCD Chassis Screws (4) and remove Lens/CCD Chassis. 



Lens Cover 
Screws (3) 



Lens Cover 
Screws (3) 



Lens/CCD 
Chassis 
Screws (2) 




Lens/CCD 
Chassis 
Screws (2) 



APS Sen- 
sor Bracket 
and Screw 



Figure 1 Removing Lens Cover 

Replacement 

NOTE: Align APS Sensor with marks made in step 2a before tightning screw. 
NOTE: Perform DC945 1 IT Calibration (ADJ 9.7). 



01 02047 A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-43 



Repairs and Adjustments 

REP 6.3, REP 6.4 



REP 6.11 Carriage Cables 

Parts List on PL 18.5 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

NOTE: This page describes how to remove Rear Carriage Cable. 

NOTE: Do not replace both cables at same time. Remove front and rear cables separately. 

1. Remove DADF (REP 5.1). 

2. Remove Platen Glass (REP 6.1). 

3. Remove IIT Top Cover (REP 6.3). 

4. DADF machines: Remove registration gate and plate (Figure 1). 

a. 1 . Remove screws (2). 

b. 2. Remove Registration Gate. 

c. 3. Remove screws (2). 

d. 4. Remove plate. 



6. Move Half Rate Carriage so that position of Carriage Cable Ball on Capstan is one of fol- 
lowing: (Figure 2). 

i Two Carriage Cable Rolls in front and rear. 
T Carriage Cable Ball is directly above. 





0101063A-CAR 



Figure 2 Positioning Half Rate Carriage 



0101062A-CAR 



Figure 1 Removing Registration Gate and Plate 



5. Remove Full Rate Carriage from IIT Frame (REP 6.14). Keep lamp wire harness connec- 
tor connected. 



Repairs and Adjustments 

REP 6.11 



6/02 
4-44 



Prelaunch Training/Review 
DC1 632/2240 



Remove Carriage Cable (Figure 3). 

a. Remove spring. 

b. Separate spring and cable. 

c. Pull out ball from hole. 

d. Remove cable. 



Replacement 

1 . Wind Carriage Cable into pulley (Figure 4). 

a. Insert Carriage Cable Ball into groove of pulley. 





0101065A-CAR 



Figure 4 Winding Carriage Cable 



0101064A-CAR 



Figure 3 Removing Carriage Cable 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-45 



Repairs and Adjustments 

REP 6.11 



b. Wind cable (spring hook side) onto pulley for 2.5 turns. Tape and lock cable (on 
spring hook) on frame (Figure 5). 



c. Wind cable (ball side) onto pulley for 2.4 turns. Tape and lock cable wound on pulley 
(Figure 6). 





0101066A-CAR 



Figure 5 Locking Cable 



0101067A-CAR 



Figure 6 Locking Cable 



Repairs and Adjustments 

REP 6.11 



6/02 
4-46 



Prelaunch Training/Review 
DC1 632/2240 



d. Check orientation of ends and number of carriage cable windings (front/rear) (Figure 
7). Reconfigure as required. 



Install Carriage Cable (ball side) (Figure 8). 

a. Hook cable to pulley (from bottom to top). 

b. Hook cable to large pulley in Half Rate Carriage (from top to bottom). 

c. Insert ball into frame hole. 



(£>* 




©=» 





0101068A-CAR 



Figure 7 Carriage Cable Windings 



0101069A-CAR 



Figure 8 Installing Carriage Cable (ball side) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-47 



Repairs and Adjustments 

REP 6.11 



Install Carriage Cable (spring hook side) (Figure 9). 

a. Hook cable to pulley (from bottom to top). 

b. Hook cable to small pulley in Half Rate Carriage (from bottom to top). 

c. Hook cable to stud (from bottom to top). 

d. Install spring on cable (spring hook side). 

e. Hook spring onto frame. 



4. Remove tape from cable. 

5. Install Full Rate Carriage in NT Frame. 

6. Adjust positions of Full Rate/Half Rate Carriages (ADJ 6.1). 

7. Manually move Full Rate Carriage to make sure it moves smoothly. 

8. Install remaining parts. 




0101070A-CAR 



Figure 9 Installing Carriage Cable (spring hook side) 



Repairs and Adjustments 

REP 6.11 



6/02 
4-48 



Prelaunch Training/Review 
DC1 632/2240 



REP 6.12 Carriage Motor 

Parts List on PL 18.5 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove DADF (REP 5.1). 

2. Remove Platen Glass (REP 6.2). 

3. Remove IIT Top Cover (REP 6.3). 

4. Remove Carriage Motor (Figure 1). 

a. Release clamps (2). 

b. Disconnect connector. 

c. Remove screws (3). 

d. Remove spring. 

e. Remove Carriage Motor. 




0101071A-CAR 



Figure 1 Removing Carriage Motor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-49 



Repairs and Adjustments 

REP 6.12 



REP 6.13 Exposure Lamp 

Parts List on PL 18.6 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

CAUTION 
Avoid touching exposure lamp with your bare hands during removal or installation. Oil from 
your hands will contaminate surface of lamp. 

1. Open DADF (REP 5.1). 

2. Remove Platen Glass (REP 6.2). 

3. Move Full Rate Carriage to frame notch. 

4. Remove Exposure Lamp (Figure 1). 

a. Disconnect connector. 

b. Remove screw. 

c. Remove Exposure Lamp. 




0101072A-CAR 



Figure 1 Removing Exposure Lamp 



Repairs and Adjustments 

REP 6.13 



6/02 
4-50 



Prelaunch Training/Review 
DC1 632/2240 



REP 6.14 Lamp Wire Harness 

Parts List on PL 18.6 

Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove DADF (REP 5.1). 

2. Remove Platen Glass (REP 6.2). 

3. Remove IIT Top Cover (REP 6.3). 

4. Disconnect Lamp Wire Harness connector and release Clamp Hook (Figure 1). 

a. Disconnect connector. 

b. Release clamp. 

c. Remove clamp. 

d. Release hook. 



Remove Full Rate Carriage (Figure 2). 

a. Remove screws (2). 

b. Remove Full Rate Carriage. 





0101074A-CAR 



Figure 2 Removing Full Rate Carriage 



0101073A-CAR 



Figure 1 Disconnecting Lamp Wire Harness 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-51 



Repairs and Adjustments 

REP 6.14 



6. Remove Lamp Wire Harness from Full Rate Carriage (Figure 3). 

a. Flip Full Rate Carriage. 

b. Remove screw. 

c. Remove guide. 

d. Disconnect connector. 

e. Remove Lamp Wire Harness. 




0101075A-CAR 



Figure 3 Removing Lamp Wire Harness 

Replacement 

NOTE: After reinstalling parts, adjust positions of Full Rate/Half Rate Carriages (ADJ 6. 1). 



Repairs and Adjustments 

REP 6.14 



6/02 
4-52 



Prelaunch Training/Review 
DC1 632/2240 



REP 7.1 Tray 5 

Parts List on PL 2.2 
Removal 



Install Tray 5. 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 14.2). 

2. Remove Power Switch Cover (REP 14.6). 

3. Remove Upper Rear Left Cover (REP 14.4). 

4. Close Left Door Transport. 

5. Remove Tray 5 (Figure 1). 

a. Observe position of harness for later reinstallation. 

b. Disconnect Tray 5 connector. 

c. Disconnect harness Clip from frame. 

d. Remove Screws (2). 

e. Pull out Tray 5 while applying a small amount of lifting force to right side. 



Harness 




Screws (2) 



Figure 1 Removing Tray 5 

Replacement 

CAUTION 

Duplex Paper Guide must be in up position before installing Tray 5. 

1. Open Left Door Transport. Pivot and hold Duplex Paper Guide against Left Door Trans- 
port and then close Left Door Transport. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-53 



Repairs and Adjustments 

REP 7.1 



REP 7.2 Tray 5 Feed Roll 

Parts List on PL 2.14 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 14.2). 

2. Remove Power Switch Cover (REP 14.6). 

3. Remove Upper Rear Left Cover (REP 14.4). 

4. Close Left Door Transport. 

5. Remove Tray 5 (REP 7.1). 

6. Remove Chute (Figure 1). 

a. Remove Screws (3). 

b. Lift to remove Chute. 





Lock Roll 



Feed 
Roll 



Locking 
Tab 



Figure 2 Removing Feed Roll 



Replacement 

Ensure Arrow is positioned as shown (Figure 3). 



Chute 



Figure 1 Removing Chute 

Remove Feed Roll (Figure 2). 

a. Release Locking Tab from groove on shaft and slide Lock Roll away from Feed Roll. 

b. Slide Feed Roll to disengage drive pin and remove Feed Roll. 




Arrow 



Figure 3 Installing Feed Roll 



Repairs and Adjustments 

REP 7.2 



6/02 
4-54 



Prelaunch Training/Review 
DC1 632/2240 



REP 7.3 Tray 1 Feeder 

Parts List on PL 2.3 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Pull out Tray 1 to paper loading position. 

2. Open Tray 1 Left Door. 

3. Remove Tray 1 Feeder (Figure 1). 



Disconnect 
Harness 




2 

Remove 
Screws (2) 



3 

Remove 
Feeder 

Figure 1 Removing Tray 1 Feeder 



REP 7.4 Tray 1 Feed/Lift Motor 

Parts List on PL 2.4 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Pull out Tray 1 to paper loading position. 

2. Open Tray 1 Left Door. 

3. Remove Tray 1 Feeder (REP 7.3). 

4. Remove Tray 1 Feed Motor (Figure 1). 

Remove Screws 
(2) and motor 




Figure 1 Removing Tray 1 Feed Motor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-55 



Repairs and Adjustments 

REP 7.3, REP 7.4 



REP 7.5 Tray 1 Paper Size Sensor 

Parts List on PL 2.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 14.2). 

2. Remove High Voltage Power Supply Chassis (REP 1 .6). 

NOTE: Step 3 can be omitted if Low Voltage Power Supply P/Jis are disconnected before per- 
forming step 4. 



Remove 3.3 VDC and 5 VDC Low Voltage Power Supply (REP 1 .4). 
Remove Chassis for 3.3 VDC and 5 VDC Low Voltage Power Supply. 

a. Release harnesses from harness clips (3). 

b. Remove screws (4) and remove Chassis. 
Remove Developer Drive Module (REP 4.3). 
Remove Tray 1 Paper Size Switch (Figure 1). 

a. Disconnect P/J. 

b. Remove Screws (2) and remove Tray 1 Paper Size Switch. 




Screws (2) 
Figure 1 Removing Tray Paper Size Switch 



REP 7.6 Tray 3 

Parts List on PL 16.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Open HCF Left Door. 

2. Remove Tray 3 (Figure 1). 

a. Pull out Tray 3. 

b. Remove Screw. 

c. Pivot bottom of Tray Lock away from Tray 3 and pull out Tray 3 to remove it. 



Screw 



Bottom of 
Tray Lock 




Figure 1 Removing Tray 3 



Repairs and Adjustments 

REP 7.5, REP 7.6 



6/02 
4-56 



Prelaunch Training/Review 
DC1 632/2240 



REP 7.7 Tray 4 
Parts List on PL 16.1 
Removal 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Pull out Tray 4. 

2. Remove Tray 4 (Figure 1 ). 

a. Pull out Tray 4. 

b. Remove Transport Screws (2). 

c. Remove Tray Lock Screws (2). 

d. Remove Tray Lock. 

e. Pull out Tray 4 to remove it. 



REP 7.8 Tray 1 

Parts List on PL 2.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Pull out Tray 1. 

2. Lift end of tray to disengage lock on rail (not visible) and remove tray. 



Transport 




Tray Lock" 
Figure 1 Removing Tray 4 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-57 



Repairs and Adjustments 

REP 7.7, REP 7.8 



REP 7.9 Tray 2 

Parts List on PL 16.2 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Pull out Tray 2. 

2. Lift end of tray to disengage lock on rail (not visible) and remove tray. 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

REP 7.9 4-58 DC1632/2240 



REP 7.10 Tray 2 Feeder 

Parts List on 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Pull out Tray 2. 

2. Remove the Left Lower Cover. (PL 16.16) 

3. Remove the Tray 2 Feeder (Figure 1 ). 



2 

Release 
Wire Har- 
ness from 
Clamp and 
disconnect 
P/J 




1 

Loosen 
Screw and 
move 
Bracket 



3 

Remove 
Screws (2) 
and Feeder 



Figure 1 Removing the Tray 2 Feeder 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-59 



Repairs and Adjustments 

REP 7.10 



REP 7.11 Tray 3 Feeder 

Parts List on 
Removal 



6. Remove the Tray 3 Feeder from mounting bracket (Figure 2). 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Tray 2. 

2. Pull out Tray 3 and Tray 4. 

3. Open the Left Cover. 

4. Remove the Lower Chute. 

5. Remove the Tray 3 Feeder Assembly (Figure 1 ). 



Remove the 
Screws (2) 
and Bracket 



Release Wire 
Harness and 
disconnect P/J 



3 

Loosen 
Screw (1) 





0102025A-CAR 

Figure 2 Removing Tray 3 Feeder from Bracket 



1 

Remove 
Screws (2) 



Remove Screws 
(2) and Tray 3 
Feeder Assembly 



0102024A-CAR 



Figure 1 Removing the Tray 3 Feeder Assembly 



Repairs and Adjustments 

REP 7.11 



6/02 
4-60 



Prelaunch Training/Review 
DC1 632/2240 



REP 7.12 Tray 4 Feeder 

Parts List on 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove the Tray 2. 

2. Pull out the Tray 3/4. 

3. Remove the Stud Bracket (Figure 1). 



4. Remove the Tray 4 Feeder Assembly (Figure 2). 




0102026A-CAR 




Figure 1 Removing Stud Bracket 



Remove Screw and 
Feeder Assembly 



Figure 2 Removing the Tray 4 Feeder Assembly 



0102027A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-61 



Repairs and Adjustments 

REP 7.12 



5. Remove the Tray 4 Feeder Guides (Figure 3). 



6. Remove Brackets from Tray 4 Feeder Assembly (Figure 4). 



Remove Screws (2) 
and Upper Guide 



Remove Screws 
and Lower Guide 




Remove Screw 
and Bracket 



1 

Remove 
Screws (2) 
and Bracket 




0102028A-CAR 



Figure 3 Removing the Guides 



Remove Screw 
and Bracket 



Figure 4 Removing the Brackets 



0102029A-CAR 



Repairs and Adjustments 

REP 7.12 



6/02 
4-62 



Prelaunch Training/Review 
DC1 632/2240 



REP 8.1 Left Cover Assembly 

Parts List on PL 2.9 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1. 
2. 
3. 
4. 
5. 
6. 
7. 



Remove Rear Cover (REP 14.2). 

Remove Power Switch Cover (REP 14.6). 

Remove Upper Rear Left Cover (REP 14.4). 

Close Left Cover Assembly. 

Remove Tray 5 (REP 7.1). 

Remove Fuser Front Cover (REP 14.8). 

Disconnect Electrical Connectors (3) (Figure 1). 




Move Harnesses 
into this space 



Remove Screw 
and Cover 



Figure 1 Disconnecting Electrical Connectors (3) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-63 



Repairs and Adjustments 

REP 8.1 



8. Remove Left Cover Assembly (Figure 2). 



Remove Clip and 
disconnect Stop 




CAUTION 

Before closing Left Cover Assembly to connect harness, hold up black plastic Duplex Baffle 
while closing transport. 



Marks on 

Motion 

Damper 



Stop Pin 



Hinge 
Pin 



Support Left Cover 
Assembly while per- 
form steps 3 and 4 















4 ^V 


•*,% 




Lower Left Cover Assembly and then 


*9 




lift to disengage hinges and remove it 










Figure 2 Removing Left Cover Assembly 



Figure 3 Aligning Marks on Motion Damper 



Replacement 

Install Left Cover Assembly on hinge pins, manually align marks on Motion Damper, then tip 
up transport to engage Motion Damper gears and connect stop arm on Stop Pin (Figure 3). 



Repairs and Adjustments 

REP 8.1 



6/02 
4-64 



Prelaunch Training/Review 
DC1 632/2240 



REP 8.2 Duplex Chute 

Parts List on PL 2.8 
Removal 



CAUTION 

Before closing Left Cover Assembly to connect harness, hold up black plastic Duplex Baffle 
while closing transport. 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 14.2). 

2. Remove Power Switch Cover (REP 14.6). 

3. Remove Upper Rear Left Cover (REP 14.4). 

4. Close Left Cover Assembly. 

5. Remove Tray 5 (REP 7.1). 

6. Open and close Left Cover Assembly to allow Duplex Paper Guide to swing down. 

7. Swing Duplex Paper Guide back and forth while carefully pushing Duplex Paper Guide 
toward rear. Key in front hinge pin will enter hinge pin slot and front hinge pin will disen- 
gage hinge pin hole. Move Duplex Paper Guide toward front to disengage rear hinge pin. 

Replacement 

Install Left Cover Assembly on hinge pins, manually align marks on Motion Damper, then tip 
up transport to engage Motion Damper gears and connect stop arm on Stop Pin (Figure 3). 



Marks on 

Motion 

Damper 



Stop Pin 



Hinge 
Pin 




Figure 1 Aligning Marks on Motion Damper 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-65 



Repairs and Adjustments 

REP 8.2 



REP 8.3 Duplex Transport Assembly 

Parts List on PL 2.7 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Duplex Transport Assembly (Figure 1 ). 

a. Remove Clip and Left Upper Cover. 

b. Loosen Screws and remove Duplex Transport Assembly. 



Left Upper 
Cover 




Screws 
(2) 



Figure 1 Removing Duplex Transport Assembly 



Replacement 



REP 8.5 Inverter Transport 

Parts List on PL 11.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Left Cover Assembly. 

2. Remove Inverter Transport (Figure 1). 

a. Remove E-rings (2), Bearings (2), and Transport Shaft. 

b. Remove Screws (2). 

c. Remove Inverter Transport. 



Screw E-Ring and 
(1) Bearing 




Inverter 
Transport 



E-Ring and 
Bearing 

Figure 1 Removing Inverter Transport 



Repairs and Adjustments 

REP 8.3, REP 8.5 



6/02 
4-66 



Prelaunch Training/Review 
DC1 632/2240 



REP 8.6 Registration Transport Assembly 

Parts List on PL 2.6 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. 
2. 
3. 
4. 
5. 
6. 
7. 



Replacement 

NOTE: bearing is equipped with two Anti-rotation Tabs. If one breaks during removal, install 
bearing so other tab is employed. 

NOTE: Check that ground spring is pressing against Bronze bushing after installing it. 



Remove Rear Cover (REP 14.2). 

Remove Power Switch Cover (REP 14.6). 

Remove Upper Rear Left Cover (REP 14.4). 

Close Left Cover Assembly. 

Remove Tray 5 (REP 7.1). 

Remove Left Cover Assembly (REP 8.1). 

Remove Registration Transport Assembly (Figure 1). 

a. Observe position of harness for later reinstallation. 

b. Remove Screws (2). 

c. Pivot top of Registration Transport out and disconnect Harness. 

d. Lift to remove Registration Transport. 



Harness 




Screws (2) 



Figure 1 Removing Registration Transport Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-67 



Repairs and Adjustments 

REP 8.6 



REP 8.7 Exit Transport Assembly 

Parts List on PL 2.10 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. 
2. 
3. 

4. 
5. 



Open Front Cover. 

Remove Fuser Front Cover (REP 14.8). 
Remove Rear Cover (REP 14.2). 
Remove Power Switch Cover (REP 14.5). 
Remove Exit Transport (Figure 1 ). 

a. Disconnect P/Jis (2). 

b. Remove Screws (3) 

c. Rotate Exit Transport slightly to disengage Tab and then lift to remove Exit Trans- 
port. 



Screws (3) 




Figure 1 Removing Exit Transport 



Repairs and Adjustments 

REP 8.7 



6/02 
4-68 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.1 Drum Cartridge 

Parts List on PL 4.1 
Removal 



WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Drum Cartridge. 

a. Open Left Cover Assembly. 

b. Open Front Cover. 

c. Actuate orange release and pull out Drum Cartridge. 

CAUTION 
Drum Cartridge photoreceptor damage is likely if Drum Cartridge is handled carelessly. 
This results in image quality defects. Use caution when Drum Cartridge is removed from 
machine. 

d. Place Drum Cartridge in a black bag. 



REP 9.2 ROS Shutter Motor 

Parts List on PL 8.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Rear Cover (REP 14.2). 

2. Remove Power Switch Cover (REP 14.6). 

3. Remove Upper Rear Left Cover (REP 14.4). 

4. Close Left Cover Assembly. 

5. Remove MSI Tray (REP 7.1). 

6. Remove Left Cover Assembly (REP 8.1). 

7. Remove Registration Transport (REP 8.6). 

8. Remove Shutter Actuator(Figure 1). 



u 



c & 



1 

Disconnect 




Figure 1 Removing Shutter Actuator 



Replacement 

Ensure solenoid arm engages 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-69 



Repairs and Adjustments 

REP 9.1, REP 9.2 



REP 9.3 Waste Toner Cartridge Cover 

Parts List on PL 4.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Waste Cartridge Cover (Figure 1). 

a. Open Waste Cartridge Cover. 

b. Remove Screw. 

c. Remove Waste Toner Cartridge Cover. 



REP 9.4 Waste Toner Cartridge 

Parts List on PL 4.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Waste Cartridge (Figure 1 ). 

a. Open Waste Cartridge Cover. 

b. Release Lever and move half way down. 

c. Pull out to remove Waste Cartridge. 



Waste 

Cartridge 

Cover 




Screw 



Figure 1 Removing Waste Toner Cartridge Cover 



Waste 

Cartridge 

Cover 




Waste 
Cartridge 



Figure 1 Removing Waste Cartridge 



Repairs and Adjustments 

REP 9.3, REP 9.4 



6/02 
4-70 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.5 Full Toner Sensor 

Parts List on PL 4.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Waste Cartridge (REP 9.4). 

3. Remove Waste Cartridge Cover (REP 9.3). 

4. Access Waste Cartridge Full Sensor (Figure 1). 

a. Lift Left End slightly and pull left to disengage Mounting Tabs. 

b. Rotate Sensor Support and remove. Left End harness connection limits movement. 



Connected 
Harness 




Sensor 

Support Mounting Tabs 

Figure 1 Accessing Waste Cartridge Full Sensor 

Remove Waste Cartridge Full Sensor (Figure 2). 

a. Push against Sensor Head while releasing Locking Tabs. 

b. Disconnect sensor from harness. 



REP 9.6 Inner Cover 

Parts List on PL 10.2 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Open Left Cover Assembly. 

3. Remove Y, M, C, K, Drum. 

4. Remove Fuser Front Cover (REP 14.8). 

5. Release and move Xerographic Release Lever half way down. 

6. Remove Dispenser Assembly Cover (Figure 1 ). 

a. Remove Screws (4). 

b. Remove Dispenser Assembly Cover. 




Screws (4) 



Figure 1 Removing Toner Transport Cover 



Locking 
Tabs 



Waste Car- 
tridge Full 
Sensor 




Sensor 
Head 



Figure 2 Removing Waste Cartridge Full Sensor 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-71 



Repairs and Adjustments 

REP 9.5, REP 9.6 



REP 9.7 Toner Dispenser 

Parts List on PL 6.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Fuser Front Cover (REP 14.8). 

3. Release and move Xerographic Release Lever half way down. 

4. Remove Dispenser Assembly Cover (REP 9.6). 

5. Remove Drum Cartridges as required. 

CAUTION 
Y must be removed first followed in order by M, C, then K. They must be reinstalled in reverse 
order of removal, which is install K, C, M, and then Y. 

6. Prepare to remove Toner Transport (Figure 1). 

a. Carefully pull out Toner Outlet Door while holding Housing back to shut off toner out- 
let. 



CAUTION 

Connection Tube may separate from upper or lower housing. 

Agitator may disconnect if flex coupling is compressed enough so agitator hits inside bot- 
tom of lower housing 

b. Pull out Upper and Lower Housings together while ensuring flexible Connection 
Tube remains connected. 



Upper 
Housing 



Toner 
Outlet 
Door 



Housing 





Screw 



Lower 
Housing 



Figure 2 Removing Toner Transport 



Figure 1 Closing Toner Outlet 



7. Remove Toner Transport (Figure 2). 
a. Remove Screw, 



Repairs and Adjustments 

REP 9.7 



6/02 
4-72 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.8 Plate Assembly 

Parts List on PL 4.2 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Front Cover (REP 14.7). 

2. Remove Drum Cartridges. 

3. Remove Waste Cartridge (REP 9.4). 

4. Remove Waste Cartridge Cover (REP 9.3). 

5. Remove Fuser Front Cover (REP 14.8). 

6. Release and move Xerographic Release Lever half way down. 

7. Remove Dispenser Assembly Cover (REP 9.6). 

8. Remove all Dispenser Assemblies (REP 9.7). 

CAUTION 
Note position of harnesses. Correct harness routing is required for assembly. 

NOTE: In next step, do not remove sensor. 

9. Remove housing for Waste Cartridge Full Sensor (REP 9.5). 



10. Disconnect Developer Housing Plugs, 4 large and 4 small (small not shown). 

Position wires straight out from machine. Wires remain stationary while removing Plate 
Assembly (Figure 1). 




Developer 
Housing Plugs 
(4 Large) 



Figure 1 Disconnecting Developer Housing Plugs 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-73 



Repairs and Adjustments 

REP 9.8 



11. Disconnect Developer Housing Harnesses (Figure 2). 

a. Open Harness Clip and remove harness from Clip. 

b. Disconnect Harness P/Jis (3). 

c. Remove Screw from Inner Left Harness Cover and remove cover. 

d. Remove Developer Housing Harnesses from additional harness clips (not shown, 
under Harness Cover). 



12. Remove Plate Assembly (Figure 3). 

a. Remove Screws (6). 

b. Pull Plate Assembly toward front to remove it. Ensure harnesses are cared for. 



Harness 
P/Jis (3) 



Harness 
Clip 



Inner Left 

Harness 

Cover 





Figure 3 Removing Plate Assembly 



Screw 



m^br 



Figure 2 Disconnecting Developer Harnesses 



Repairs and Adjustments 

REP 9.8 



6/02 
4-74 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.9 Developer Housing 

Parts List on PL 6.2 
Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 

2 
3 
4 
5 
6 
7 



Remove Front Cover (REP 14.7). 

Remove Drum Cartridges. 

Remove Waste Cartridge (REP 9.4). 

Remove Waste Cartridge Cover (REP 9.3). 

Remove Fuser Front Cover (REP 14.8). 

Move Xerographic Release Lever up to a mid position. 

Remove Dispenser Assembly Cover (REP 9.6). 

8. Remove all Dispenser Assemblies (REP 9.7). 

NOTE: In next step, do not remove sensor. 

9. Remove housing for Waste Cartridge Full Sensor (REP 9.5). 

NOTE: In next step, it may not be necessary to disconnect harnesses for Plate Assembly (PL 
4.2) to remove a developer housing. 

10. Remove Plate Assembly (REP 9.8). 

CAUTION 
IBT belt damage results when Developer Housing is removed carelessly. 

11. Remove Developer Housing (Figure 1). 




Replacement 

NOTE: If installing a new Developer Housing, go to step 1. If reinstalling existing developer 
housing, go to 5. 

1. Install new Developer (REP 9.10) as required. 

2. Remove ATC Sensor Setup Data Tag from new Developer Housing. On tag, highlight K, 
C, M, or Y as required for color of developer housing. Tag will be installed during machine 
reassembly. 

CAUTION 
Image quality defects occur when ATC Sensor Data is mishandled in dC921. 

3. During machine assembly, install ATC Sensor Setup Data Tag as shown (Figure 2). 




Tag with K 
highlighted 

Tag 

2 ' '"•'"'"•'"'-'-" highlighted 

Position Tag in correct location 



Tag with Y 
highlighted 



Raise Xerographic 
Release Lever 

0102045A-CAR 



Figure 2 Installing ATC Sensor Setup Data Tag 

4. Perform dC921 ATC Sensor Setup (ADJ 9.2). 

5. While reinstalling Developer Housing ensure pin at rear of Developer Housing engages 
hole in rear frame of machine. 



Figure 1 Removing Developer Housing 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-75 



Repairs and Adjustments 

REP 9.9 



REP 9.10 Developer 

Parts List on PL 6.2 
Removal 



Release tabs and 
remove Cover 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Front Cover (REP 14.7). 

2. Remove Drum Cartridges. 

3. Remove Waste Cartridge (REP 9.4). 

4. Remove Waste Cartridge Cover (REP 9.3). 

5. Remove Fuser Front Cover (REP 14.8). 

6. Release and move Xerographic Release Lever half way down. 

7. Remove Dispenser Assembly Cover (REP 9.6). 

8. Remove all Dispenser Assemblies (REP 9.7). 

NOTE: In next step, do not remove sensor. 

9. Remove housing for Waste Cartridge Full Sensor (REP 9.5). 

NOTE: In next step, it may not be necessary to disconnect harnesses for Plate Assembly (PL 
4.2) to remove a developer housing. 

1 0. Remove Plate Assembly (REP 9.8). 

11. Remove Developer Housing (REP 9.9). 

12. Remove Developer. (Figure 1). 

a. Carefully observe position of wiring harness for later reinstallation. 




Place Drop Cloth 



Figure 2 Removing Housing Cover 

c. Rotate Drive Gear to remove Developer (Figure 3). 

Drive Gear. 





Figure 3 Removing Developer 



Replacement 

1. Rotate Drive Gear while installing new Developer (Figure 4). 



Position of 
Harness 



Figure 1 Observing position of Harness 

b. Remove Housing Cover (Figure 2). 



Repairs and Adjustments 

REP 9.10 



6/02 
4-76 



Prelaunch Training/Review 
DC1 632/2240 




Figure 4 Installing Developer 

2. Install Developer Housing. 

a. Ensure pin at rear of Developer Housing engages hole in rear frame of machine. 

b. Reassemble machine. 

c. Adjust ATC Sensor (ADJ). 



REP 9.11 Toner Dispenser Base Assembly 

Parts List on PL 6.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Drum Cartridges. 

3. Remove Fuser Front Cover (REP 14.8). 

4. Release and move Xerographic Release Lever half way down. 

5. Remove Dispenser Assembly Cover (REP 9.6). 

6. Remove all Dispenser Assemblies (REP 9.7). 

7. Remove Top Cover (REP 14.1). 

8. Remove Right Cover (REP 14.3). 

9. Remove Toner Dispense Module (Figure 1). 

a. Remove Screws (2). 

b. Carefully observe position of wiring harness for later reinstallation 

c. Disconnect motor connectors (4). 

d. Lift to remove Toner Dispense Module. 



Screws (2) 



Harness 




Figure 1 Removing Toner Dispense Module 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-77 



Repairs and Adjustments 

REP 9.10, REP 9.11 



REP 9.12 IBT Steering Drive Assembly 

Parts List on PL 1.3 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. 
2. 
3. 

4. 
5. 



Open Front Cover. 

Remove Fuser Front Cover (REP 14.8). 

Release and move Xerographic Release Lever halfway down. 

Remove Dispenser Assembly Cover (REP 9.6). 

Remove Steering Drive Motor (Figure 1). 

a. Disconnect Motor P/J. 

b. Remove Screws (3). 

c. Pull out to remove using care to avoid damage to steering gear. 



REP 9.13 Agitator Motor Assembly 

Parts List on PL 4.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Waste Cartridge (REP 9.4). 

3. Remove Fuser Front Cover (REP 14.8). 

4. Release and move Xerographic Release Lever half way down. 

5. Remove Dispenser Assembly Cover (REP 9.6). 

6. Remove Waste Toner Agitator (Figure 1 ). 

a. Disconnect P/J. 

b. Remove Screws (2) and remove Waste Toner Agitator. 



Motor P/J 



Screws (3) 





Screw 



Figure 1 Removing Waste Toner Agitator 



Figure 1 Removing Steering Drive Motor 



Repairs and Adjustments 

REP 9.12, REP 9.13 



6/02 
4-78 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.14 MOB Sensor Assembly 

Parts List on PL 1.3 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. 
2. 
3. 

4. 
5. 
6. 
7. 



Open Front Cover. 

Remove Waste Cartridge (REP 9.4). 

Remove Fuser Front Cover (REP 14.8). 

Release and move Xerographic Release Lever halfway down. 

Remove Dispenser Assembly Cover (REP 9.6). 

Remove Waste Toner Agitator (REP 9.13). 

Remove MOB Sensor Assembly (Figure 1). 

a. Open Harness Clip and remove harness from Clip. 

b. Remove Screw and remove Inner Left Harness Cover. 

c. Disconnect Harness P/Jis (3) 

d. Remove MOB Sensor Assembly Harnesses (violet) from additional harness clips 
(not shown). 

e. Remove MOB Sensor Assembly Screw and pull out to remove MOB Sensor Assem- 
bly. Xerographic Release Lever must be down as shown. 



Harness 
P/Jis (3) 

Belt Mark 

Sensor 

Screw 



Harness Clip 



Screw 




Inner Left 

Harness 

Cover 



Xerographic 

Release 

Lever 



Figure 1 Removing MOB Sensor Assembly 



REP 9.15 IBT Belt Assembly 

Parts List on PL 5.2 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Release and move Xerographic Release Lever down. 

3. Open Right Side Door. 

4. Remove IBT Belt Assembly (Figure 1). 

a. Lift to release Slide Lock. 

b. Pull out IBT Unit to remove it. Use Handle to transport IBT Unit. 

c. Protect IBT Belt Assembly from direct light. 



Slide 
Lock 1 



Handle 




Figure 1 Removing IBT Belt Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-79 



Repairs and Adjustments 

REP 9.14, REP 9.15 



REP 9.16 IBT Cleaner Assembly 

Parts List on PL 5.3 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Release and move Xerographic Release Lever down. 

3. Remove Right Cover (REP 14.3). 

4. Remove IBT Belt Assembly just enough to access Belt Cleaner (REP 9.15). 

CAUTION 
In next step, toner may spill out of Belt Cleaner if cleaner is handled carelessly. 

5. Remove Screws and remove Belt Cleaner (Figure 2). 




Figure 1 Removing IBT Cleaner Assembly 

Replacement 

Ensure both rear locating pins engage holes in IBT Belt Assembly frame during installation of 
IBT Cleaner Assembly. 



REP 9.17 Auger Assembly 

Parts List on PL 5.2 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Waste Cartridge (REP 9.4). 

3. Release and move Xerographic Release Lever down. 

4. Remove Right Cover (REP 14.3). 

5. Remove Belt Module (REP 9.1 5). 

6. Move Xerographic Release Lever to up position. 

7. Remove Waste Toner Agitator (Figure 1 ). 

a. Remove Screws (2). 

b. Move Waste Auger toward Bearing to disengage Cutout from Bearing. 

c. Remove Waste Auger. 



Screws (2) 



Bearing 




Figure 1 Removing Waste Toner Agitator 

Replacement 

Move Xerographic Release Lever to down position before reinstalling Belt Module. 



Repairs and Adjustments 

REP 9.16, REP 9.17 



6/02 
4-80 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.18 Lever 

Parts List on PL 5.1 
Removal 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 



1. 
2. 
3. 
4. 
5. 
6. 
7. 



10. 



Open Front Cover. 

Remove Fuser Front Cover (REP 14.8). 

Remove Waste Cartridge (REP 9.4). 

Remove Waste Cartridge Cover (REP 9.3). 

Remove Inner Left Harness Cover (REP 14.10). 

Release and move Xerographic Release Lever down. 

Remove Drum Cartridges. 

Remove Right Cover (REP 14.3). 

Remove Belt Module (REP 9.15). 

Remove Xerographic Release Lever (Figure 1). 

a. Remove Screw, Washer, and Hinge Pin. 

b. Remove E-Ring and Hinge Pin. 

c. Remove Xerographic Release Lever. 



REP 9.19 Left Hinge/Right Hinge 

Parts List on PL 5.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Fuser Front Cover (REP 14.8). 

3. Remove Waste Cartridge (REP 9.4). 

4. Remove Waste Cartridge Cover (REP 9.3). 

5. Remove Inner Left Harness Cover (REP 14.10). 

6. Release and move Xerographic Release Lever down. 

7. Remove Drum Cartridges. 

8. Remove Right Cover (REP 14.3). 

9. Remove Belt Module (REP 9.1 5). 

10. Remove Xerographic Release Lever (REP 9.18). 

11. Remove Xerographic Release Lever Brackets (Figure 1). 

a. Remove Screws (2) and remove Bracket. 

b. Remove Screws (2) and remove Bracket. 



Screw, Washer, 
Hinge Pin 




E-Ring, 
Hinge Pin 

Figure 1 Removing Xerographic Release Lever 

Replacement 

Move Xerographic Release Lever to down position before reinstalling Belt Module. 




Figure 1 Removing Xerographic Release Lever 

Replacement 

Move Xerographic Release Lever to down position before reinstalling Belt Module. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-81 



Repairs and Adjustments 

REP 9.18, REP 9.19 



REP 9.20 Right Lift Assembly 

Parts List on PL 5.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. 
2. 
3. 
4. 
5. 
6. 
7. 



d. Remove Lower Screws (2). 

e. Remove Right Xerographic Lift. 



10. 
11. 



Open Front Cover. 

Remove Fuser Front Cover (REP 14.8). 

Remove Waste Cartridge (REP 9.4). 

Remove Waste Cartridge Cover (REP 9.3). 

Remove Inner Left Harness Cover (REP 14.10). 

Release and move Xerographic Release Lever down. 

Remove Drum Cartridges. 

Remove Right Cover (REP 14.3). 

Remove Belt Module (REP 9.15). 

Remove Xerographic Release Lever (REP 9.18). 

Remove Lift Bracket (Figure 1). 

a. Remove E-Rings (2) and Washers (2). 

b. Remove Screws (4) and remove Lift Bracket. 

c. Remove Bearings (2) and Washers (2). 




Lift Secondary 
Position Screw 




Lower Screws (2) 
Figure 2 Removing Right Xerographic Lift 

Replacement 

Move Xerographic Release Lever to down position before reinstalling Belt Module. 



Washer 



Bearing 



Screws (4) 



Figure 1 Removing Lift Bracket 



12. Remove Right Xerographic Lift (Figure 2). 

a. Remove Auger Mounting Screws (2). 

b. Remove Lift Position Screw. 

c. Remove Secondary Position Screw. 



Repairs and Adjustments 

REP 9.20 



6/02 
4-82 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.21 Left Lift Assembly 

Parts List on PL 5.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. 
2. 
3. 
4. 
5. 
6. 
7. 



b. Remove Screws (4). 

c. Remove Left Xerographic Lift and maintain orientation to ensure Bearings (2) and 



Open Front Cover. 

Remove Fuser Front Cover (REP 14.8). 

Remove Waste Cartridge (REP 9.4). 

Remove Waste Cartridge Cover (REP 9.3). 

Remove Inner Left Harness Cover (REP 14.10). 

Release and move Xerographic Release Lever down. 

Remove Drum Cartridges. 

8. Remove Right Cover (REP 14.3). 

9. Remove Belt Module (REP 9. 1 5). 

10. Remove Xerographic Release Lever (REP 9.18). 

1 1 . Remove Rear Cover (REP 1 4.2). 

12. Remove Power Switch Cover (REP 14.6). 

13. Remove Upper Rear Left Cover (REP 14.4). 

14. Close Left Cover Assembly. 

15. Remove MSI Tray (REP 7.1). 

1 6. Remove Left Cover Assembly (REP 8.1). 

17. Optional for improved visibility: Remove Fuser Module (REP 10.1). 

18. Remove Registration Transport (REP 8.6). 

1 9. Remove Dispenser Assembly Cover (REP 9.6). 

20. Remove Waste Toner Agitator (REP 9.13). 

21 . Remove Belt Mark Sensor (REP 9.14). 

22. Remove Left Xerographic Release Lever Bracket (REP 9.19). 

23. Remove Front Cover (REP 14.7). 

24. Remove K and C Toner Cartridges. 

25. Remove K and C Dispenser Assembly (REP 9.7). 

NOTE: In next step, do not remove sensor from housing 

26. Remove housing for Waste Cartridge Full Sensor (REP 9.5). 

NOTE: In next step, it may not be necessary to disconnect harnesses for Plate Assembly (PL 
4.2) to remove a developer housing. 

27. Remove Plate Assembly (REP 9.8). 

28. Remove K and C Developer Housing (REP 9.9). 

29. Remove Left Xerographic Lift (Figure 1). 

NOTE: In next step, use a magnet to capture E-Ring and Washer while removing them. 

a. From inside Developer Housing cavity, remove E-Ring and Washer from each end of 
Left Xerographic Lift. 



Washers (2) do not fall off posts 
Screws (2) 



Bearing Washer 



Washer 




E-Ring 



Screws (2) 



Figure 1 Removing Left Xerographic Lift 

Replacement 

1. Install Lift. 

a. Position Lift in frame. 

b. Raise or lower xerographic frame as required and push in or pull out Lift actuator as 



required to engage lift bearings with slots in xerographic frame. 
Install front top screw, then front bottom screw, then rear screws (2). 
Install washers (2) and e-rings (2). 



c. 
d. 
Assemble remaining machine components. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-83 



Repairs and Adjustments 

REP 9.21 



REP 9.22 Transfer Belt 

Parts List on PL 5.3 
Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

CAUTION 

Cover Transfer Belt in a black bag. 

NOTE: Keep your hand off Transfer Belt. 

1. Remove IBT Belt Assembly (REP 9.15). 

2. Remove IBT Cleaner Assembly (REP 9.16). 

3. Remove Stand Plate (Figure 1). 

a. Remove Screw (2). 

b. Remove Stand Plate in direction of arrow. 



4. Remove Handle (Figure 2). 




0102006A-CAR 




Figure 2 Removing Handle 

5. Remove screws on both sides (Figure 3). 



0102005A-CAR 




Figure 1 Removing Stand Plate 



0102007A-CAR 



Figure 3 Removing Screws (both sides) 



Repairs and Adjustments 

REP 9.22 



6/02 
4-84 



Prelaunch Training/Review 
DC1 632/2240 



6. Position Latch (Figure 4) 

a. Remove Screw. 

b. Remove Latch. 

c. Fix Latch. 



7. Install Stand Plate (Figure 5) 
a. Install Plate. 





0102009A-CAR 



Figure 5 Installing Stand Plate 



Figure 4 Positioning Latch 



0102008A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-85 



Repairs and Adjustments 

REP 9.22 



8. Place Stand Plate below and stand IBT Belt Assembly. 

9. Relax tension of Belt on both sides (Figure 6) 

a. Push up Bracket. 

b. Push up Lever and hang Pin on Hole. 




10. Remove Bracket (Figure 7) 

a. Remove Screw (2). 

b. Remove Bracket. 

c. Remove Screw (3). 

d. Remove Bracket. 




0102010A-CAR 



Figure 6 Relaxing Belt Tension 



0102011A-CAR 



Figure 7 Removing Bracket 



Repairs and Adjustments 

REP 9.22 



6/02 
4-86 



Prelaunch Training/Review 
DC1 632/2240 



11. Pull out BUR ROLL Housing from Hole below and move it in arrow direction (Figure 8) 

a. Pull Housing. 

b. Turn Housing to move it. 




0102012A-CAR 



Figure 8 Pulling Out BUR Roll Housing 

12. Remove Transfer Belt (Figure 9) 




0102013A-CAR 



Figure 9 Removing Transfer Belt 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-87 



Repairs and Adjustments 

REP 9.22 



Replacement 

1 . Install Transfer Belt with Reflector at rear (Figure 1 0). 



2. After installing Transfer Belt, move it to center of IBT Frame (exposed parts of IBT Drive 
Roll are same at In and Out sides) (Figure 11). 



Front 




Reflector 



Rear 



0102014A-CAR 



Drive Roll 

OyUO OOO 

O " OO 




Outside 



Transfer Belt 



Inside 



0102015A-CAR 



Figure 11 Positioning Transfer Belt 



Figure 10 Installing Transfer Belt 



Repairs and Adjustments 

REP 9.22 



6/02 
4-88 



Prelaunch Training/Review 
DC1 632/2240 



3. If Transfer Belt is skewed or wrinkled, perform following steps: (Figure 12) 

a. Relax tension of Belt. 

b. Rotate Gear in arrow direction and move Transfer Belt. 




0102016A-CAR 



Figure 12 Re-positioning Transfer Belt 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-89 



Repairs and Adjustments 

REP 9.22 



REP 9.23 1st BTR Roll 

Parts List on PL 5.4 
Removal 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Release and move Xerographic Release Lever down. 

3. Open Right Side Door. 

4. Remove IBT Assembly (REP 9.15). 

5. Remove Transfer Belt (REP 9.22). 

6. Remove 1 st BTR Roll (Figure 1 ). 




2 

Remove' 
Support and 
1st BTR Roll 

NOTE: Front 
axle is long- 
est 



Front 
Axle 



REP 9.24 2nd BTR Roll 

Parts List on PL 2.8 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove 2nd BTR (Figure 1 ). 

a. Open Left Cover Assembly. 

b. Remove Screws (4). 

c. Remove 2nd BTR with Support Brackets 



Screws (2) 



Support 
Bracket 




/ 

Transfer Roll 
Assembly 



Support 
Bracket 



Figure 1 Removing 2nd BTR 



0102020A-CAR 



Figure 1 Removing 1st BTR Roll 



Repairs and Adjustments 

REP 9.23, REP 9.24 



6/02 
4-90 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.26 ATC Sensor 

Parts List on PL 6.2 
Removal 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Front Cover (REP 14.7). 

2. Remove Drum Cartridges. 

3. Remove Waste Cartridge (REP 9.4). 

4. Remove Waste Cartridge Cover (REP 9.3). 

5. Remove Fuser Front Cover (REP 14.8). 

6. Release and move Xerographic Release Lever half way down. 

7. Remove Dispenser Assembly Cover (REP 9.6). 

8. Remove all Dispenser Assemblies (REP 9.7). 

NOTE: In next step, do not remove sensor. 

9. Remove housing for Waste Cartridge Full Sensor (REP 9.5). 

NOTE: In next step, it may not be necessary to disconnect harnesses for Plate Assembly (PL 
4.2) to remove a developer housing. 

1 0. Remove Plate Assembly (REP 9.8). 

11. Remove Developer Housing (REP 9.9). 

12. Release Harness from Harness Clips (Figure 1). 



13. Remove ATC Sensor (Figure 2). 



1 

Lift Lock, 
and move 
end away 
from Tab 




Remove Seal 
from under 
Sensor 

0102044A-CAR 



Figure 2 Removing ATC Sensor 



Release Tab and 
remove wires 



1 

Carefully notice posi- 
tion of wires 




Lift Tab and remove wires 



Figure 1 Removing Harness form Clips 



0102043A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-91 



Repairs and Adjustments 

REP 9.26 



Replacement 

NOTE: Remove ATC Sensor Setup Data Tag from new sensor. On tag, highlight K, C, M, or Y 
as required for color of developer housing. Raise Xerographic Release Lever and install Tag in 
position shown (Figure 3). 



Tag with K 
highlighted 




Tag witl 
highlighted 



highlighted 



Tag with Y 
highlighted 



Position Tag in correct location 

Figure 3 Installing ATC Sensor Setup Data Tag 
NOTE: Perform dC921 ATC Sensor Setup (ADJ 9.2). 



Raise Xerographic 
Release Lever 

0102045A-CAR 



Repairs and Adjustments 

REP 9.26 



6/02 
4-92 



Prelaunch Training/Review 
DC1 632/2240 



REP 9.27 Retract Shaft 

Parts List on PL 5.4 
Replacement 

NOTE: Cam and Flag must be aligned as shown, both on the same side (Figure 1). 



Incorrect 
Alignment 




Correct 
Alignment 

0102046A-CAR 

Figure 1 Cam and Flag Alignment 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-93 



Repairs and Adjustments 

REP 9.27 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

REP 9.27 4-94 DC1 632/2240 



REP 10.1 Fuser 

Parts List on PL 7.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

WARNING 

Personal injury may result from grasping hot areas of Fuser Module. If a hot Fuser Mod- 
ule must be removed, grasp Fuser Module by black plastic frame component, shown in 
figure (Figure 1). 

CAUTION 

Damage to work surface may result if a hot Fuser Module is removed and positioned on an 
unprotected work surface. Place a hot fuser on ten sheets of paper. 

1 . Open Left Cover Assembly. 

2. Remove Fuser Module (Figure 1). 

a. Loosen Screws (2). (PL 1.1) 

WARNING 

If machine was making copies within 30 minutes, Fuser Module is hot. Grasp 
Fuser Module using Grip Rings. 

b. Use Grip Rings to pull Fuser Module out. 



REP 10.2 Fuser Fan 

Parts List on PL 8.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

WARNING 

Personal injury may result from grasping hot areas of Fuser Module. If a hot Fuser Mod- 
ule must be removed, grasp Fuser Module by black plastic frame component, shown in 
figure (Figure 1). 

CAUTION 

Damage to work surface may result if a hot Fuser Module is removed and positioned on an 
unprotected work surface. Place a hot fuser on ten sheets of paper. 

1 . Open Front Cover. 

2. Remove Right Cover (REP 14.3). 

3. Remove Top Cover (REP 14.1). 

4. Remove Rear Cover (REP 14.2). 

5. Remove Fuser Cooling Fan (Figure 1). 

a. Disconnect P/J. 

b. Remove Screws (2) and lift to remove Fuser Cooling Fan. 




Screws (2) 



ScreWS < 2 > 0^ 

Figure 1 Removing Fuser Module 




Figure 1 Removing Fuser Cooling Fan 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-95 



Repairs and Adjustments 

REP 10.1, REP 10.2 



REP 10.3 Main/Sub Heater Rod 

Parts List on PL 7.2 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove the Fuser Assembly (REP 10.1). 

2. Remove the following parts: 

i Front Cover (REP 14.7) 
T Handle (PL 7.2) 
i Rear Cover (PL 7.2) 
i Handle (PL 7.2) 

3. Disconnect P/Jis (2) at rear of Fuser (Figure 1). 



4. Prepare Fuser at front (Figure 2). 




Disconnect 
P/Jis (2) 




Remove Screw 
and Heat Rod 
Support 



0102041A-CAR 



Figure 2 Preparing Fuser at Front 



Disconnect 
P/Jis (2) 



0102040A-CAR 

Figure 1 Disconnecting Connectors 



Repairs and Adjustments 

REP 10.3 



6/02 
4-96 



Prelaunch Training/Review 
DC1 632/2240 



5. Remove Heater Rods (Figure 3). 




Remove 

Heater 

Rods 



0102042A-CAR 



Figure 3 Removing Heater Rods 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-97 



Repairs and Adjustments 

REP 10.3 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

REP 10.3 4-98 DC1 632/2240 



REP 12.1 H Transport Assembly 

Parts List on PL 17.1 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1. Disconnect P/J (Figure 1). 



2. Disengage Hook (2) from the Stud on both sides and remove H Transport Assembly (Fig- 
ure 2). 




Figure 1 Disconnecting P/J 



0101090A-CAR 




0101091A-CAR 



Figure 2 Removing H Transport 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-99 



Repairs and Adjustments 

REP 12.1 



REP 12.2 H Transport Belt 

Parts List on PL 17.4 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove the H Transport Assembly (REP 12.1). 

2. Remove the following parts: 

a. H Transport Front Cover (PL 1 7.3) 

b. H Transport Rear Cover (PL 1 7.3) 

c. Stop (PL 17.3) 

3. Remove the H Transport Cover (Figure 1). 



1 

Remove 
Screw (2) 



4. Remove the Gate In Solenoid Assembly (Figure 2). 



Disconnect Wires 
as required 





2 

Remove 
Screws (2) 



Remove Sole- 
noid Assembly 



0101093A-CAR 
Figure 2 Removing the Gate In Solenoid Assembly 



0101092A-CAR 



Figure 1 Removing the H Transport Cover 



Repairs and Adjustments 

REP 12.2 



6/02 
4-100 



Prelaunch Training/Review 
DC1 632/2240 



5. Remove the Entrance Upper Cover (Figure 3) 



6. Remove the input H Transport Roll (Figure 4). 



1 

Remove 
Screws (4) 



2 

Remove 
Entrance 
Upper Cover 




0101094A-CAR 



2 

Remove H 

Transport 

Roll 




Remove Clips (2) 
and Bearings (2) 

0101095A-CAR 



Figure 3 Removing the Entrance Upper Cover 



Figure 4 Removing the H Transport Roll 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-101 



Repairs and Adjustments 

REP 12.2 



7. Remove the output H Transport Roll (Figure 5). 



Remove the H 
Transport Belts 



1 

Remove 
Clip and 
Bearing 




3 

Remove H 

Transport 

Roll 




2 

Remove 
Clip, Pulley, 
and Bearing 



0101096A-CAR 



Figure 5 Removing the H Transport Roll 



Repairs and Adjustments 

REP 12.2 



6/02 
4-102 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.3 Entrance Sensor 

Parts List on PL 17.4 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove the H Transport Assembly (REP 12.1). 

2. Remove the following: 

a. H Transport Front Cover (PL 1 7.3) 

b. H Transport Rear Cover (PL 1 7.3) 

c. Stop (PL 17.3) 

3. Remove the Entrance Upper Cover (REP 12.17). 

4. Remove the Cover (Figure 1). 

a. Push up the hook (2). 

b. Remove the Cover, while moving it in the arrow direction. 



5. Remove the H Transport Entrance Sensor and Top Tray Full Sensor (Figure 2). 



Top Tray Fu 
Sensor 



Entrance 
Sensor 





Disconnect 
and Remove 
Sensors 



0101099A-CAR 
Figure 2 Removing Entrance Sensor and Top Tray Full Sensor 



0101098A-CAR 



Figure 1 Removing the Cover 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-103 



Repairs and Adjustments 

REP 12.3 



REP 12.4 Finisher 

Parts List on PL 17.5 
Removal 

CAUTION 

Make sure to have two people to operate since the Finisher Unit weighs more than 16Kg. 
When one person operates, detach the unit following the Steps after making it weigh less than 
16 Kg. Take extreme care to avoid lower back injury. 

1. Separate NT and IOT. 

2. Remove the following parts: 

a. H Transport Assembly (REP 12.2) 

b. H Transport Front Cover (PL 1 7.3) 

c. H Transport Rear Cover (PL 1 7.3) 

d. Stacker Tray (PL 17.1) 

e. Right Lower Cover (PL 1 7.5) 

3. Remove the Thumbscrews (2) (Figure 1). 



4. Lift the Finisher from the Rack (Figure 2). 




3 

Lift to 

Remove 

Finisher 



Push Finisher 
away from 
Rack to disen- 
gage Finisher 



0101100A-CAR 




0101101A-CAR 
Figure 2 Removing Finisher from Rack 



Figure 1 Removing Thumbscrews 



Repairs and Adjustments 

REP 12.4 



6/02 
4-104 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.5 Stack Height Sensor Assembly 

Parts List on PL 17.6 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1 . Remove the Links from the Top Cover Assembly (Figure 1 ). 



Open Top Covei 



Remove 3 

Screws Remove 

(2) on L i nks on 

both both side: 
sides 



2. Remove the Stack Height Sensor Assembly (Figure 2). 




Remove the Screw 



2 

Disconnect 
P/J and 
remove 




0101103A-CAR 



Figure 2 Removing Stack Height Sensor Assembly 



0101102A-CAR 



Figure 1 Removing Links from Top Cover Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-105 



Repairs and Adjustments 

REP 12.5 



REP 12.6 Eject Roll Assembly 

Parts List on PL 17.6 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1 . Remove the following parts: 

a. Rear Cover (PL 17.5) 

b. Stacker Tray (PL 17.1) 

c. Right Cover (PL 17.5) 

d. Front Cover (PL 17.5) 
Remove the Bracket (Figure 1). 



1 

Remove 
Screws (4) 



3. Disconnect P/J (Figure 2). 



2 

Remove 
Plate 



2. 





0101105A-CAR 



Figure 2 Disconnecting P/J 



2 

Remove 
Bracket 



0101104A-CAR 



Figure 1 Remove the Bracket 



Repairs and Adjustments 

REP 12.6 



6/02 
4-106 



Prelaunch Training/Review 
DC1 632/2240 



4. Remove the Thumbscrews (2) (Figure 3). 



5. Remove the Tray Guide (Figure 4). 




0101100A-CAR 



Figure 3 Removing Thumbscrews 



Remove 
Screws (4) 



Remove Cabl' 
from Cover and 
remove Cover 




0101107A-CAR 



Figure 4 Removing Tray Guide 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-107 



Repairs and Adjustments 

REP 12.6 



6. Remove the Sensor (Figure 5). 



7. Remove Eject Roll (Figure 6). 



Disconnect harness 
and remove Sensor 




2 

Remove 
Collar — 
and Gea 



0101108A-CAR 



Figure 5 Remove Sensor 




Disconnect Hook (2) from EjecfN 
Shaft and remove Eject Roll 



3 

Remove 

Clip and 

Bearing 

from 

both 

ends 



0101109A-CAR 



Figure 6 Removing Eject Roll 



Repairs and Adjustments 

REP 12.6 



6/02 
4-108 



Prelaunch Training/Review 
DC1 632/2240 



8. Remove Eject Shaft (Figure 7). 




3 

Remove 
Eject Shaft 



Figure 7 Removing Eject Shaft 



2 

Remove 
Clip Bear- 
ing on both 
sides 



0101110A-CAR 



Replacement 

NOTE: When replacing Feed Roll or Eject Shaft, replace them simultaneously. 

NOTE: When installing the Clutch, ensure to insert the Stop into Clutch grooves (Figure 8). 




0101111A-CAR 



Figure 8 Inserting Stop into Clutch Grooves 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-109 



Repairs and Adjustments 

REP 12.6 



REP 12.7 DecurlerRoll 

Parts List on PL 17.7 
Removal 



3. Remove the Decurler Roll (Figure 2). 



1 



WARNING 



Remove Clip 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove the following parts: 

a. Front Cover (PL 17.5) 

b. Rear Cover (PL 17.5) 

c. Top Cover (PL 17.5) 

2. Remove the Arm (Figure 1). 




2 


1 


Remove 


Remove 


Clip and 


Clip and 


Arm 


Gear 





3 

Remove 
Decurler Roll 



0101113A-CAR 



Figure 2 Removing the Decurler Roll 



0101112A-CAR 



Figure 1 Removing the Arm 



Repairs and Adjustments 

REP 12.7 



6/02 
4-110 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.8 Finisher Drive Motor 

Parts List on PL 17.7 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove the Rear Cover (PL 17.14). 

2. Remove the Finisher Drive Motor (Figure 1 ). 



1 

Remove Screws 
(4) and Finisher 
Drive Motor 




Disconnect P/J 

Figure 1 Removing the Finisher Drive Motor 

Replacement 

NOTE: Hang the Belt to the Guide when installing the Drive Motor. 



0101114A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-111 



Repairs and Adjustments 

REP 12.8 



REP 12.9 Belt 

Parts List on PL 17.7 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove the Rear Cover (PL 17.5) 

2. Rotate the Actuator (Figure 1 ). 



3. Release Harnesses (Figure 2). 



Remove Clamp 
from Frame 



Remove wires from 
Clip 



2 

Rotate 
Cam 1/4 

revolution 



Release Sole^ 
noid Pawl 




Disconnec 
P/Jis (3) 



Removewires 
from Clip 




0101116A-CAR 



Figure 2 Releasing Harnesses 



0101115A-CAR 



Figure 1 Rotate the Actuator 



Repairs and Adjustments 

REP 12.9 



6/02 
4-112 



Prelaunch Training/Review 
DC1 632/2240 



4. Remove the Cam Bracket Assembly (Figure 3). 

a. Remove the Screws (4). 

b. Remove the Cam Bracket Assembly. 



1 

Remove 
Screws (4) 



5. Remove the Belt (Figure 4). 




2 

Remove 
Cam Bracket 
Assembly 



0101117A-CAR 



Remove 
Clips, 
Pulleys, 
and Belt 




Figure 4 Removing the Belt 



0101118A-CAR 



Figure 3 Removing the Cam Bracket Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-113 



Repairs and Adjustments 

REP 12.9 



Replacement 

NOTE: During assembly, refer to Figure 5. 



Raise Top 
Cover to raise 
Roller while, 
performing 
step 2 



NOTE: During assembly, refer to Figure 6. 




2 

Align Axle 
with Hole 




Rotate Cam so 
Pawl engages 
Slot 



0101111A-CAR 



0101119A-CAR 



Figure 6 Engaging Pawl with Slot 



Figure 5 Inserting Axle of Cam Bracket Assembly into Hole 



Repairs and Adjustments 

REP 12.9 



6/02 
4-114 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.10 Rail 

Parts List on PL 17.9 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove the following: 

a. Front Cover (PL 17.5) 

b. Rear Cover (PL 17.5) 

2. Remove Harness from Stapler (Figure 1). 



4 

Disconnect 
Harness 
from Motor 
and remove 
Harness 
from Guide 



Disconnect Sta- 
pler P/J is (2) 



3. Remove Stapler Assembly (Figure 2). 



Remove 
Screws (2), 
Ground Wire 
(1) and Stapler 





0101130A-CAR 



Figure 2 Removing Stapler Assembly 



Disconnect 
Sensor 



Disconnect 
Harness Clip 
from Frame 

0101129A-CAR 



Figure 1 Removing Harness from Stapler 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-115 



Repairs and Adjustments 

REP 12.10 



4. Remove the PWB Cover (Figure 3). 



5. Move the PWB Chassis down (Figure 4). 



Remove Screws (10) 
and Cover 




Figure 3 Removing the PWB Cover 



1 

Disconnect 
P848 and 
remove from 
Guide 



4 

Remove 
Screws (2) 
and allow 
PWB Chas 
sis to hang 
down 



0101121A-CAR 




Disconnect 
P849 and 
P846 and 
remove from 
Guide 



Loosen Screw 



0101123A-CAR 



Figure 4 Moving PWB Chassis Down 



Repairs and Adjustments 

REP 12.10 



6/02 
4-116 



Prelaunch Training/Review 
DC1 632/2240 



6. Remove Rear Rail Mounting Screws (2) (Figure 5). 



7. Remove Front Rail Mounting Screws (2) (Figure 6). 



Remove 
Screws (2) 




0101124A-CAR 




Disconnect 
P/J 



Remove Screws (2) 



0101125A-CAR 



Figure 5 Removing Rear Rail Mounting Screws (2) 



Figure 6 Removing Front Rail Mounting Screw 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-117 



Repairs and Adjustments 

REP 12.10 



8. Remove the Rail Assembly (Figure 7). 



9. Remove the Carriage Assembly (Figure 8). 




0101126A-CAR 




0101127A-CAR 



Figure 7 Removing Rail Assembly 



Figure 8 Removing the Carriage Assembly 



Repairs and Adjustments 

REP 12.10 



6/02 
4-118 



Prelaunch Training/Review 
DC1 632/2240 



10. Remove Screws (5) and remove Rail (Figure 9). 



Screws (5) 




0101128A-CAR 



Figure 9 Removing Rail 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-119 



Repairs and Adjustments 

REP 12.10 



REP 12.11 Stapler Assembly 

Parts List on PL 17.9 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open the Front Cover. 

2. Disconnect Stapler P/Jis (2) (Figure 1). 



Disconnect Sta- 
pler P/J is (2) 



3. Remove the Stapler Assembly (Figure 2). 




Remove 
Screws (2), 
Ground Wire 
(1) and Stapler 




0101130A-CAR 



Figure 2 Removing Stapler Assembly 



0101129A-CAR 



Figure 1 Disconnecting P/Jis 



Repairs and Adjustments 

REP 12.11 



6/02 
4-120 



Prelaunch Training/Review 
DC1 632/2240 



Replacement 

NOTE: Insert Stapler Assembly Tab into Slot (Figure 3). 



Slot 




0101131A-CAR 



Figure 3 Inserting Tab into Slot 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-121 



Repairs and Adjustments 

REP 12.11 



REP 12.12 Compiler Tray Assembly 

Parts List on PL 17.10 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1 . Remove the following parts: 

a. Rear Cover (PL 17.5) 

b. Stacker Tray (PL 17.1) 

c. Right Cover (PL 17.5) 

d. Front Cover (PL 17.5) 
Remove the Bracket (Figure 1). 



1 

Remove 
Screws (4) 



3. Disconnect P/J (Figure 2). 



2 

Remove 
Plate 



2. 





0101105A-CAR 



Figure 2 Disconnecting P/J 



2 

Remove 
Bracket 



0101104A-CAR 



Figure 1 Remove the Bracket 



Repairs and Adjustments 

REP 12.12 



6/02 
4-122 



Prelaunch Training/Review 
DC1 632/2240 



4. Remove Thumbscrews (2) (Figure 3). 



5. Remove the Tray Guide (Figure 4). 




0101100A-CAR 



Figure 3 Removing Thumbscrews (2) 



Remove 
Screws (4) 



Remove Cabl' 
from Cover and 
remove Cover 




0101107A-CAR 



Figure 4 Removing Tray Guide 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-123 



Repairs and Adjustments 

REP 12.12 



6. Release Compiler Tray Harness (Figure 5). 



7. Remove the Screw on the Inboard side (Figure 6). 



Disconnect and' 
remove form 
Guide 



Move harnesses 
back through 
frame 




Screw 



Disconnect from 
Finisher PWB and 
remove from Guide 



0101132A-CAR 




0101133A-CAR 



Figure 5 Releasing Compiler Tray Harness 



Figure 6 Removing Screw on Inboard Side 



Repairs and Adjustments 

REP 12.12 



6/02 
4-124 



Prelaunch Training/Review 
DC1 632/2240 



8. Remove the Compiler Tray Assembly (Figure 7). 




0101133A-CAR 



Figure 7 Removing Compiler Tray Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-125 



Repairs and Adjustments 

REP 12.12 



REP 12.13 Stacker Motor Assembly 

Parts List on PL 17.11 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove the Rear Cover (PL 17.5) 

2. Hold Stacker Tray and move Gear to lower the Stack Tray (Figure 1 ). 



3. Remove the screws on PWB Chassis (Figure 2). 





Figure 2 Removing Screws on PWB Chassis 



1 

Loosen 
Screw 



Remove 
Screws (2) 

0101135A-CAR 



0101134A-CAR 



Figure 1 Moving Gear to Lower Stack Tray 



Repairs and Adjustments 

REP 12.13 



6/02 
4-126 



Prelaunch Training/Review 
DC1 632/2240 



4. Remove the Stacker Motor Assembly (Figure 3). 

a. Remove the screws (3) while sliding the PWB Chassis upward. 

b. Slide the Gear. 

c. Remove the Stacker Motor Assembly. 



3 

Move 
Gear an 
Remove 
Stacker 
Motor 
Discon- 
nect P/J 



Lift PWB Chassis 
and Remove 
Screws (2) 




2 

Remove 

Screw 

(1) 



0101136A-CAR 



Figure 3 Removing Stacker Motor Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-127 



Repairs and Adjustments 

REP 12.13 



REP 12.14 Front Elevator Bracket 

Parts List on PL 17.11 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1 . Remove the following parts: 

a. Rear Cover (PL 17.5) 

b. Stacker Tray (PL 17.1) 

c. Right Cover (PL 17.5) 

d. Front Cover (PL 17.5) 
Remove the Bracket (Figure 1). 



1 

Remove 
Screws (4) 



3. Disconnect P/J (Figure 2). 



2 

Remove 
Plate 



2. 





0101105A-CAR 



Figure 2 Disconnecting P/J 



2 

Remove 
Bracket 



0101104A-CAR 



Figure 1 Remove the Bracket 



Repairs and Adjustments 

REP 12.14 



6/02 
4-128 



Prelaunch Training/Review 
DC1 632/2240 



4. Remove the Thumbscrews (2) (Figure 3). 



5. Remove the Tray Guide (Figure 4). 




0101100A-CAR 



Figure 3 Removing Thumbscrews 



Remove 
Screws (4) 



Remove Cabl' 
from Cover and 
remove Cover 




0101107A-CAR 



Figure 4 Removing Tray Guide 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-129 



Repairs and Adjustments 

REP 12.14 



6. Move PWB Chassis (Figure 5). 



7. Remove Front Elevator Bracket (Figure 6). 



1 

Release 
Wires from 
Clamp, 



4 

Move PWB 
Chassis 




Figure 5 Moving PWB Chassis 




Figure 6 Removing Elevator Belt Assembly 



Remove 
Screws (3) 
and Elevator 
Belt Assembly 



0101138A-CAR 



0101137A-CAR 



Repairs and Adjustments 

REP 12.14 



6/02 
4-130 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.15 Paddle Gear Shaft 

Parts List on PL 17.12 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove the following parts: 

a. Stapler Assembly (REP 12.11). 

b. Rear Cover (PL 17.5). 

2. Remove the Cam Bracket Assembly (REP 12.18). 

3. Remove the Bearing (Figure 1 ). 



4. Remove Screw on Paddle Gear Shaft (Figure 2). 



Remove 
Clip, GearT 
and Bearing 





0101140A-CAR 



Figure 2 Removing Screw on Paddle Gear Shaft 



0101139A-CAR 



Figure 1 Removing Bearing 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-131 



Repairs and Adjustments 

REP 12.15 



5. Remove the Paddle Gear Shaft (Figure 3). 




0101141A-CAR 



Figure 3 Removing Paddle Gear Shaft 



Repairs and Adjustments 

REP 12.15 



6/02 
4-132 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.16 Finisher PWB 

Parts List on PL 17.13 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (PL 17.5). 

2. Remove the PWB Cover (Figure 1 ). 



Remove 

Screws 

(10) 



3. Disconnect P/Jis (Figure 2). 




Disconnect 
P/Jis(10) 




2 

Remove 
Wire Har- 
ness from 
Guides (4) 



mr 



0101120A-CAR 



Figure 2 Disconnecting P/Jis 



Figure 1 Removing PWB Cover 



0101121A-CAR 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-133 



Repairs and Adjustments 

REP 12.16 



4. Remove the Finisher PWB (Figure 3). 




Figure 3 Removing Finisher PWB 

Replacement 

NOTE: When installing, keep the Core (Figure 2) inside the PWB Box. 



Remove 
Screws (6) 
and PWB 



0101106A-CAR 



Repairs and Adjustments 

REP 12.16 



6/02 
4-134 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.17 Entrance Upper Cover 

Parts List on PL 17.3 
Removal 

1. Remove the H Transport Assembly (REP 12.1). 

2. Remove the following: 

a. H Transport Front Cover (PL 1 7.3) 

b. H Transport Rear Cover (PL 1 7.3) 

c. Stop (PL 17.3) 

3. Remove the H Transport Cover (Figure 1). 



1 

Remove 
Screw (2) 




0101092A-CAR 



Figure 1 Removing the H Transport Cover 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-135 



Repairs and Adjustments 

REP 12.17 



REP 12.18 Cam Bracket Assembly 

Parts List on PL 17.8 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove the Rear Cover (PL 17.5) 

2. Rotate the Actuator (Figure 1 ). 



3. Release Harnesses (Figure 2). 



Remove Clamp 
from Frame 



Remove wires from 
Clip 



2 

Rotate 
Cam 1/4 

revolution 



Release Sole^ 
noid Pawl 




Disconnec 
P/Jis (3) 



Removewires 
from Clip 




0101116A-CAR 



Figure 2 Releasing Harnesses 



0101115A-CAR 



Figure 1 Rotate the Actuator 



Repairs and Adjustments 

REP 12.18 



6/02 
4-136 



Prelaunch Training/Review 
DC1 632/2240 



4. Remove the Cam Bracket Assembly (Figure 3). 

a. Remove the Screws (4). 

b. Remove the Cam Bracket Assembly. 



Replacement 

NOTE: During assembly, refer to Figure 4. 



1 

Remove 
Screws (4) 




2 

Remove 
Cam Bracket 
Assembly 



Raise Top 
Cover to raise 
Roller while, 
performing 
step 2 



0101117A-CAR 




2 

Align Axle 
with Hole 



0101119A-CAR 



Figure 3 Removing the Cam Bracket Assembly 



Figure 4 Inserting Axle of Cam Bracket Assembly into Hole 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-137 



Repairs and Adjustments 

REP 12.18 



NOTE: During assembly, refer to Figure 5. 




Rotate Cam so 
Pawl engages 
Slot 



0101111A-CAR 



Figure 5 Engaging Pawl with Slot 



Repairs and Adjustments 

REP 12.18 



6/02 
4-138 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.19 Finisher Rack Assembly 

Parts List on PL 17.1 
Removal 

1 . Remove Finisher (REP 1 2.4). 

2. Loosen Feet (Figure 1 ). 



3. Remove Bottom Plate (Figure 2). 




Loosen Feet 



0102050A-CAR 




0102051A-CAR 



Figure 2 Removing Bottom Plate 



Figure 1 Loosening Feet 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-139 



Repairs and Adjustments 

REP 12.19 



4. Remove Rear Rack (Figure 3). 



Remove Front Rack (Figure 4). 




2 

Lift to 

Remove 

Rack 



0102052A-CAR 



2 

Lift to 

Remove 

Rack 




Figure 3 Removing Rear Rack 



0102049A-CAR 



Figure 4 Removing Front Rack 



Repairs and Adjustments 

REP 12.19 



6/02 
4-140 



Prelaunch Training/Review 
DC1 632/2240 



REP 12.20 Lowering Stacker Tray 

Parts List on PL 17.1 
Purpose 

If the need arises to lower the Stacker Tray quickly or without power applied perform following: 

1 . Remove Finisher Rear Cover (PL 1 7.5). 

2. While holding the Stacker Tray, move the gear outward and the Stacker Tray is released 
(Figure 1). 




0101134A-CAR 



Figure 1 Moving Gear to Lower Stack Tray 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-141 



Repairs and Adjustments 

REP 12.20 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

REP 12.20 4-142 DC1 632/2240 



REP 14.1 Top Cover 

Parts List on PL 10.2 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Finisher H Transport (REP 12.1). 

2. Remove Finisher (REP 12.4). 

3. Remove Front and Rear Brackets (Figure 1). 



Remove Finisher Rack Assembly (REP 12.19). 
Remove Gate Cover (Figure 2). 




Release 

Clips (2) 

and 

Remove 

Gate 

Cover 




Figure 2 Removing Gate Cover 



Remove Right Cover (REP 14.3). 
Remove Top Cover (Figure 3). 

a. Open Front Cover. 

b. Remove Screws (3). 

c. Remove Top Cover. 



Figure 1 Removing Brackets 



Remove Thumbscrews (2) 
and Brackets 



0102053A-CAR 




Screws (3) 



inK^^ /V."—- 1 ^ d 0102017A-CAR 

Figure 3 Removing Top Cover 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-143 



Repairs and Adjustments 

REP 14.1 



REP 14.2 Rear Cover 

Parts List on PL 10.3 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1 . Remove Rear Cover (Figure 1 ). 

a. If optional feeder is installed, open Harness Cover and disconnect Harnesses 

b. Remove Screws (4). 

c. Remove Rear Cover. 



REP 14.3 Right Cover 

Parts List on PL 10.1 
Removal 



WARNING 




To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Right Cover (Figure 1). 

a. Open Right Door. 

b. Remove Screws (3). 

c. Push cover down, or allow cover to drop slightly to release Hidden Tabs, then pull 
cover away and remove it. 



Hidden Tabs 



Rear 
Cover 



Screws (4) 
Harness Cover 

Harnesses 



Figure 1 Removing Rear Cover 




Figure 1 Removing Right Cover 



Repairs and Adjustments 

REP 14.2, REP 14.3 



6/02 
4-144 



Prelaunch Training/Review 
DC1 632/2240 



REP 14.4 Rear Left Middle Cover 

Parts List on PL 10.3 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Rear Cover (REP 14.2). 

2. Open Left Cover Assembly. 

3. Remove Power Switch Cover (REP 14.5). 

4. Remove Upper Rear Left Cover (Figure 1). 

a. Remove Screw (1 ). 

b. Lift slightly to disengage hidden tab and remove Upper Rear Left Cover. 



REP 14.5 Rear Left Upper Cover 

Parts List on PL 10.3 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Rear Cover (REP 14.2). 

2. Open Left Cover Assembly. 

3. Remove Power Switch Cover (Figure 1). 

a. Remove Screw (1). 

b. Push end of cover in direction shown to release Hidden Tabs (2). 

c. Pull up to release Hidden Tab (1 ) and remove Power Switch Cover. 




Figure 1 Removing Upper Rear Left Cover 



Hidden 
Tabs (2) 



Sere 




Figure 1 Removing Power Switch Cover 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-145 



Repairs and Adjustments 

REP 14.4, REP 14.5 



REP 14.6 Left Lower Cover Assembly 

Parts List on PL 2.3 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 
1 . Remove Lower Left Cover (Figure ). 

a. Open Left Lower Cover Assembly. 

b. Carefully observe position of wiring harness for later reinstallation. 

c. Disconnect harness connector and remove harness from harness guide. 

d. Use flat tipped screwdriver to pry out Pivot Lock. 

e. Remove Pivot Pin Sleeve. 

f. Remove Lower Left Cover. 



REP 14.7 Cover Assembly 

Parts List on PL 10.1 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Front Cover. 

a. Open Tray 1 approximately 100 mm for possible cover support. 

b. Open Front Cover. 

c. Remove screw to disconnect Support Strap from cover. 

d. Repeat c for other strap. 

e. Remove screws (2) on Hinge Pin Locks and remove hinge pin locks. 

f. Remove Front Cover. 



Pivot 




S7700-123 

Figure 1 Removing Left Lower Cover Assembly 



Replacement 



NOTE: Partially install Pivot Sleeve. Then install Left Lower Cover Assembly and push in Pivot 
Sleeve. 



Repairs and Adjustments 

REP 14.6, REP 14.7 



6/02 
4-146 



Prelaunch Training/Review 
DC1 632/2240 




REP 14.8 Fuser Cover 

Parts List on PL 10.2 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Fuser Cover (Figure ). 

a. Remove Screws (2). 

b. Move cover up to release Hidden Tabs (3) and pull out to remove cover. 



Hidden 
Tabs 




Figure 1 Removing Fuser Cover 



Figure 1 Removing Front Cover 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-147 



Repairs and Adjustments 

REP 14.7, REP 14.8 



REP 14.9 Rear Cover 

Parts List on PL 16.16 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Thumbscrews (4). 

2. Remove Screws (4) and remove Lower Rear Cover. 



REP 14.10 Inner Cover 

Parts List on PL 8.1 
Removal 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Open Front Cover. 

2. Remove Fuser Front Cover (REP 14.8). 

3. Remove Waste Cartridge Cover (REP 9.3). 

4. Remove Inner Cover (Figure 1). 

a. Open Harness Clip and remove harness from Clip. 

b. Remove Screw and remove Harness Cover. 



Harness Clip 



Screw 

Inner 
Cover 




Figure 1 Removing Inner Cover 



Repairs and Adjustments 

REP 14.9, REP 14.10 



6/02 
4-148 



Prelaunch Training/Review 
DC1 632/2240 



REP 14.11 Left Cover Assembly 

Parts List on PL 16.13 
Removal 

WARNING 
To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Lower Cover (REP 14.12). 

2. Remove Left Cover Assembly (Figure 1 ). 

a. Remove Screws (2) and Straps (2) from frame. 

b. Remove Screw (1 ) and Pivot Support and remove Left Cover Assembly. 



REP 14.12 Lower Cover 

Parts List on PL 16.16 

Removal 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Remove Lower Cover (Figure 1 ). 

a. Remove Screws (4). 

b. Open Left Cover Assembly. 

c. Remove Lower Cover. 




1 

Remove 
Screws (2) 




Left Cover 
Assembly 



Screws (2) 



Figure 1 Removing Lower Cover 



Figure 1 Removing Left Cover Assembly 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-149 



Repairs and Adjustments 

REP 14.11, REP 14.12 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

REP 14.11, REP 14.12 4-150 DCI632/2240 



ADJ 5.1 DADF Side Registration 

Purpose 

Align image scanned from document with left side edge of paper. 



Check 

1 . Make two copies from the Platen Glass to be used as DADF originals. 

a. Register Test Chart 82E8220 on Platen with side edge metrics SE1 through SE4 
against rear registration guide. 

b. Select the following: 
i 1 to 1 sided 

i A3 or 11 x 17 Paper Supply 
i 100% Reduce/Enlarge 
i 2 Copies 

c. Press Start and write DADF Original 1 on first copy and DADF Original 2 on second 
copy. 

2. Verify side edge registration of DADF Originals. 

a. On DADF Original 2 measure and record the distance between the side edge and 
the reference line and write A next to this measurement (Figure 1). 

b. Check that A is 10.0 ±0. 5mm. If A is 10.0 ±0.5 mm, go to step 3. 

If A is not 10.0 ±0.5 mm, check both of the following and then return to the beginning 

of this procedure. 

i. DC129 IOT Lead Edge/Side Edge Registration (ADJ 9.9). 

ii. NT Side Edge Registration (ADJ 9.11) 



i 1 to 1 -sided 

i A3 or 11 x 17 Paper Supply 

i 100% Reduce/Enlarge 

i 2 Copies 

Press Start and discard the first copy. 

On side 1 of copy 2 measure and record the distance between the side edge and the 

reference line and write B next to this measurement (Figure 2). 



Paper 

Feed 

Direction 



T 




A I 

.. •#■■( 

| imfi ^ | 


A_ A 

flifli 

-■■ . 
■■ 



0102001A-CAR 



Figure 2 Checking Side Edge Registration of DADF 



Paper sf- 
Feed 


Manually 
labeled 2 


Direction 1 






A I 

Kill I II 

| imfi ^ i 

TI 


i A 

■ ■ 

■ ■ 

*=4= 

■1 1 lllglll 


H 



0102000A-CAR 

Figure 1 Verifying Side Edge Registration of DADF Originals 

Check DADF Side Edge Registration for Side 1. 

a. Load both DADF Originals in DADF, 1 on top, with side edge metrics SE1 through 
SE4 against rear registration guide. Check that side guide touches documents. 

b. Select the following: 



e. Compare B to A. B must be within ±1.1 mm of A. 

If the difference between B and A is greater than 1.1 mm, go to step 1 of the adjust- 
ment. 
Otherwise go to step 4. 

Check DADF Side Edge Registration for Side 2. 

a. Make a 2-sided test pattern. 

i. Load DADF originals 1 and 2 face up, 1 on top, with side edge metrics toward 

rear of DADF. 
ii. Select 1 to 2-sided and press Start to make the 2-sided test pattern 

b. Make test copies. 

i. Load 2-sided test pattern with side 1 edge metrics up and toward rear of DADF. 
ii. Select the following: 

T 2 to 1 sided 

i A3 or 11 x 17 Paper Supply 

i 100% Reduce/Enlarge 

i 1 Copy 
iii. Press the Start button. 

c. Check that side edge metrics are same distance from edge of paper for both copies. 
If the difference is greater than ±1.1 mm, go to step 2 of the adjustment. 
Otherwise DADF Side Registration is good. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-151 



Repairs and Adjustments 

ADJ 5.1 



Adjustment 

1 . Adjust Side 1 DADF Side Registration. 

a. Enter NVM Rear/Write (DC131) [715-015]. 

NOTE: Increasing value moves side edge metrics SE1 through SE4 toward edge. 

b. If B is more than A, increase the NVM value (15 = approx. 1 mm). 
If B is less than A, decrease the NVM value (15 = approx. 1 mm). 

c. Check results of adjustment and adjust if required. 

2. Adjust Side 2 DADF Side Registration. 

a. Enter NVM Rear/Write (DC1 31) [715-128]. 

NOTE: Increasing value moves side edge metrics SE1 through SE4 toward edge. 

b. If copy 2 edge metric is farther away from edge than copy 1 , increase the NVM value 
(15 = approx. 1 mm). 

If copy 2 edge metric is closer to edge than copy 1, decrease the NVM value (15 = 
approx. 1 mm). 

c. Check results of adjustment and adjust as required. 

NOTE: 2 to 2-sided or 2 to 1 -sided must be selected to view a change in [715- 128]. 
[715-128] produces no change in 1 to 2-sided copying. 

NOTE: Total lead edge deviation for DADF is ±1.6mm. Total lead edge deviation for lit is ±0.5 
mm. This leaves ±1.1 mm for DADF when a copy paper test pattern is made for use in DADF. 



Repairs and Adjustments 

ADJ 5.1 



6/02 
4-152 



Prelaunch Training/Review 
DC1 632/2240 



ADJ 5.2 DADF Counterbalance 

Purpose 

Correct DADF opening and closing action. 

Check 

1 . Check DADF opening and closing action. 

a. Raise DADF and check that it remains in fully raised position. 

b. Check that the DADF closes from a height of 100 ±50mm by its own weight without 
excessive noise (Figure 1). 




100 mm +/- 50 mm 



0101000A-CAR 



Figure 1 Checking DADF Height 



Adjustment 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

CAUTION 

When removing the Rear Cover, disconnect LED Connector on DADF PWB. 

1. Remove the Rear Cover. (REP 5.18) 

2. Adjust the Left Counterbalance (Figure 2). 

NOTE: Rotate in A direction for stronger spring pressure 
Rotate in B direction for weaker spring pressure 

a. Loosen the nut. 

b. Rotate the Set Screw for the adjustment. 

c. Tighten the nut. 




0101039A-CAR 



Figure 2 Adjusting Left Counterbalance 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-153 



Repairs and Adjustments 

ADJ 5.2 



ADJ5.3 DADF Parallelism 
Purpose 

Enable parallel Document placement and image scan. 

Check 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1. Remove Front Cover. (PL 20.1) 

2. Remove Entrance Tray. (PL 20.1) 

3. Remove the Document Transport. (REP 5.17 ) 

4. Check DADF Parallelism. 

a. Manually hold down the DADF. 

b. Check that the distance between the DADF Rear Frame and the Rear Registration 
Edge is 20 ±1 mm (Figure 1). 

c. Perform the same check at the left end of the DADF. 

If 20 ±1 mm is not measured in each check, or the measurements are different, go to 

the adjustment. 

Otherwise DADF Parallelism is good. 



DADF Rear Frame 




///////////////////// ///////// /// ////// 


20 mm ' 










1. II 






\ 

Rear Regis- 
tration Edge 






Right End 
of DADF 



0101040A-CAR 



Adjustment 

CAUTION 

The DADF Parallelism must be made within ±1mm of the specified range. 

CAUTION 
When removing the Rear Cover, disconnect LED Connector on DADF PWB. 

1. Remove Rear Cover (REP 5.18). 

2. Adjust DADF Parallelism (Figure 2). 



1 

Loosen 
Screws (4) 



Adjust Screw 



DADF Move 
to Front 




4 

Tighten 
Screws (6) 



2 

Loosen 
Screws (2) 



0101041A-CAR 



Figure 2 Adjusting DADF Parallelism 



3. Adjust Left Counterbalance if required. 

4. Repeat the check. 



Figure 1 Checking DADF Parallelism 



Repairs and Adjustments 

ADJ 5.3 



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ADJ 5.4 Document Transport Height 
Purpose 

Enable document feed at the correct speed and free of skew. 

Check 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

Remove Front Cover (PL 20.1 ). 

Entrance Tray (PL 20.1). 

Check Document Transport Height (Figure 1). 

a. At left end of Document Transport, check that there is 24.5 ±0.3 mm between top of 
Document Transport Frame and Top of Rear Registration Edge. 

b. At Right end of Document Transport, check that there is 24.5 ±0.3 mm between top 
of Document Transport Frame and Top of Rear Registration Edge. 

c. If there is more or less than specified, perform the adjustment on the counterbalance 
for the side that is not in specification. Adjust both counterbalances if required. 
Otherwise, Document Transport Height is good. 



Adjustment 

CAUTION 

When removing the Rear Cover, disconnect LED Connector on DADF PWB. 

1. Remove Rear Cover (REP 5.18). 

2. Raise DADF and loosen the Screws (2) (Figure 2). 



1. 
2. 
3. 



Document Transport Frame 



Top of 
Rear Reg- 
istration 
Edge 



Left End of Document Transport 





0101043A-CAR 



Figure 2 Loosening Screws 



Right End of 
Document 
■ Transport 



0101042A-CAR 



Figure 1 Checking Document Transport Height 



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Repairs and Adjustments 

ADJ 5.4 



3. Adjust Document Transport Height (Figure 3). 



I 



Lower DADF 



Raise Docu- 
ment Trans- 
port Frame 




3 

Raise 
DADF 



Screws 



0101044A-CAR 



Figure 3 Adjusting Document Transport Height 



4. Repeat check. 



Repairs and Adjustments 

ADJ 5.4 



6/02 
4-156 



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ADJ 5.5 DADF Top Registration 

Purpose 

Align image scanned from document with top edge of paper. 

Check 

1 . Make two DADF originals. 

a. Register Test Chart 82E8220 on Platen with lead edge metrics LE1 through LE3 
against left registration guide. 

b. Select the following: 
i 1 to 1 sided 

i A4 or 8.5 x 11 Long Edge Feed Paper Supply 
i 100% Reduce/Enlarge 
i 2 Copies 

c. Press Start and write DADF Original 1 on first copy and DADF Original 2 on second 
copy. 

2. Verify top edge registration of DADF Originals. 

a. On copy 2 measure and record the distance between the top edge and the reference 
line and write A next to this measurement (Figure 1 ). 

b. Check that A is 10.0 ±0.5 mm. If A is 10.0 ±0.5 mm, go to step 3. 

If A is not 10.0 ±0.5 mm, check both of the following and then return to the beginning 

of this procedure. 

i. DC129 IOT Lead Edge/Side Edge Registration (ADJ 9.9). 

ii. NT Side Edge Registration (ADJ 9.11) 



Top Edge 
of Copy 




Manually 1= 

labeled 2 0102002A-CAR 

Figure 1 Verifying Top Edge Registration of DADF Originals 



Check DADF Top Edge Registration for Side 1 . 

a. Load both DADF Originals in DADF, 1 on top, with top edge metrics LE1 through 
LE3 toward right. 

b. Select the following: 
i 1 to 1 -sided 

i A4 or 8.5 x 11 Long Edge Feed Paper Supply 
i 100% Reduce/Enlarge 
i 2 Copies 

c. Press Start and discard the first copy. 

d. On side 1 of copy 2 measure and record the distance between the top edge and the 
reference line and write B next to this measurement (Figure 2). 



Top Edge 
of Copy 




Paper 

Feed 

Direction 



A ij 


L A 

niiiii B ^ 

% '"" >■ 

J llllJlHI | 


imfi ■ ■ | 
| inifiiii ^ | 

. " ~-- T i 



0102002A-CAR 

Figure 2 Checking Top Edge Registration of DADF 

e. Compare A to B. B must be within ±1.1 mm of A. 

If the difference between A and B is greater than 1 mm, go to step 1 of the adjust- 
ment. 
Otherwise go to step 4. 

Check DADF Side Edge Registration for Side 2. 

a. Make a 2-sided test pattern. 

i. Load DADF originals 1 and 2 face up, 1 on top, with top edge metrics toward 

right, 
ii. Select 1 to 2-sided and press Start to make the 2-sided test pattern 

b. Make test copies. 

i. Load 2-sided test pattern with side 1 edge metrics up and toward right of DADF. 
ii. Select the following: 

i 2 to 1 sided and press Start. 

i A4 or 8.5 x 11 Long Edge Feed Paper Supply 

i 100% Reduce/Enlarge 



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Repairs and Adjustments 

ADJ 5.5 



i 1 Copy 
iii. Press the Start button. 

Check that top edge metrics are same distance from edge of paper for both copies. 
If the difference is greater than 1 mm, go to step 2 of the adjustment. 
Otherwise DADF Side Registration is good. 



Adjustment 

1 . Adjust Side 1 DADF Side Registration. 

a. Enter NVM Rear/Write (DC1 31) [710-005]. 

NOTE: Increasing value moves lead edge metrics LE1 through LE3 toward edge. 

b. If B is more than A, increase the NVM value (5 = approx. 1 mm). 
If B is less than A, decrease the NVM value (5 = approx. 1 mm). 

c. Check results of adjustment and adjust if required. 

2. Adjust Side 2 DADF Side Registration. 

a. Enter following NVM Rear/Write (DC131) 
[710-025] for B5 SEF or smaller 

[710-026] for B5 LEF, A4 SEF/LEF, 8.5x11 SEF/LEF 
[710-027] for 8.5x14, B4, A3, 11x17 

NOTE: Decreasing value moves lead edge metrics LE1 through LE3 toward edge. 

b. If copy 2 edge metric is farther away from edge than copy 1, decrease the NVM 
value ( 5 = approx. 1 mm). 

If copy 2 edge metric is closer to edge than copy 1, increase the NVM value (5 = 
approx. 1 mm). 

c. Check results of adjustment and adjust as required. 

NOTE: 2 to 2-sided or 2 to 1 -sided must be selected to view A change in [710-02X]. 
[71 0-02X\ produces no change in 1 to 2-sided copying. 

NOTE: Total lead edge deviation for DADF is ±1.6 mm. Total lead edge deviation for lit is ±0.5 
mm. This leaves ±1.1 mm for DADF when a copy paper test pattern is made for use in DADF. 



Repairs and Adjustments 

ADJ 5.5 



6/02 
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ADJ 5.6 DADF Document Detection 
Purpose 

Preliminary-Enable document size sensing. 

Check 

dC927 Size Detection Automatic Correction 

Perform this adjustment when the following operation is conducted: 



Restrictions to Note> 

i Once this process has started, it cannot be stopped (interrupted) half-way until it com- 
pletes irrespective of success or failure. 

i This process does not allow the fourth sheet onwards to be pulled in when documents of 
four or more sheets are set in the DADF. 

NOTE: If the result is NG after the adjustment, perform the process again. 



i Replacing of the DADF ASSY. 

i When an error is detected after replacing Registration Roll, Feed Roll, and Retard Roll. 

i When an error is found on the size detection. 

Scan three sheets of document continuously in the DADF. Comparing the Slow Scan length 

detected in the DADF with the standard value, correct the NVM data automatically. The NVM 

data subject to the correction is "Document Slow Scan size correction value in Non CVT Mode" 

(Chain Link No. 71 0-003). 

Documents for scanning differ depending on each market as below. 

FX, XE/AP: A4LEF (Slow scan length accuracy (210.0mm ±0.7mm)) 
XC: 8.5"x11"LEF (Slow scan length accuracy (215.9mm ±0.7mm)) 

Adjustment 

1. Enter dC 527. 

2. Set three documents to be transported in the DADF. 
'Document sizes to be transported differ depending on each market. 

FX, XE/AP: A4LEF (Slow scan length accuracy (210.0mm ±0.7mm)) 
XC: 8.5"x11"LEF (Slow scan length accuracy (215.9mm ±0.7mm)) 

3. When the [Enter] button is pressed, DADF starts pulling in the document and calculate the 
correction value. At this point, the [Entering] message appears. 

4. The corresponding NVM data is updated and PSW screen indicates that the process has 
been completed 

Or, if this process becomes NG, the NVM data is not updated and the message telling that 
NG has occurred appears on the screen. 

5. Pressing the [Exit] button completes the servicing. 
Specification on Result Confirmation 

The following result can be checked in the NVM Read after the process completes. 

Table 1 



Chain-Link 


Indicated Data Name 


Remarks 


710-003 


Document slow scan size 


Setup Range=144~256 




correction value in Non 


(Equivalent to ±56 Step 




CVT Mode 


[±10mm] <- Left 0.18mm/ 

Step) 

Initial value: 200 (But the 

factory adjustment value is 

set as the initial value.) 



Prelaunch Training/Review 
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6/02 
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Repairs and Adjustments 

ADJ 5.6 



ADJ 5.7 DADF Non-standard Document Custom 
Registration 

Purpose 

Preliminary-Document sizes other than DADF detectable document size (non-standard size) 
are registered and transported as standard document size. Hence, special document sizes 
specified by a user can be transported. 

Check 

Document size detection is performed based on custom-registered data and the DADF pro- 
cess is performed by making the specified document sizes as scanning size. Only one cus- 
tom-registration is available. If the registered data is valid, document size detection is 
performed, placing priority over the existing detection table. 

Preparation: 

1 . Borrow the non-standard document to be custom- registered from the customer. 

2. Check which direction (LEF or SEF) the customer wants to run in. 

3. Check which paper size and direction the customer wants to make copies of. 

4. Check the length of Fast Scan direction (X) and Slow Scan direction (Y) in Scale etc. of 
the borrowed document accurately and write them down. 

Adjustment 

1 . Enter the Ul Diag and change the NVM Read/Write. 

2. Set the following NVM Data to be custom-registered detection. 

NOTE: Set Fast Scan direction max. value - Fast Scan direction min. value are 200 or 
below, (within 20mm) 

NOTE: Set slow scan direction max. value - slow scan direction min. value are 200 or 
below, (within 20mm) 

NOTE: The following sizes cannot be entered in order to prevent mis-detection of the size 
sensor. 

i Fast Scan direction Max.:21 90-2290 

i Fast Scan direction Min. :28 1 0-29 1 

For the X and Y obtained at Preparation: 

i Set the 710-024 data to 1 . (Have the custom-registration valid.) 

i Store (X+10) x 10 in the 710-018 data. (Set the Fast Scan direction Max. value) 

i Store (X-10) x 10 in the 710-019 data. (Set the Fast Scan direction Min. value) 

i Store (Y+10) x 10 in the 710-020 data. (Set the Slow scan direction Max. value) 

i Store (Y-10) x 10 in the 710-021 data. (Set the Slow scan direction Min. value) 

i Enter the 710-022 data. (Select the paper size that the customer specifies from the 

table below, and enter it.) 
i Enter the 710-023 data. (Select the paper direction that the customer specifies from 

the table below, and enter it.) 

Enter the 710-023 data. (Select the paper direction that the customer specifies from 

the table below, and enter it.) 



Enter the 710-023 data. (Select the paper direction that the customer specifies from 

the table below, and enter it.) 

The following are information regarding the NVM entered above. 

Table 1 



Chain-Link 


Indicated Data Name 


Remarks 


710-018 


Fast Scan direction Max. 


Setup Range=1 297-3070 




value Notel) 


Set by 0.1mm (initial 
value=2970) 


710-019 


Fast Scan direction Min. 


Setup Range=1 297-3070 




value Notel) 


Set by 0.1mm (initial 
value=2970) 


710-020 


Slow Scan direction Max. 


Setup Range=1 297-441 8 




value Note2) 


Set by 0.1mm (initial 
value=2100) 


710-021 


Slow Scan direction Min. 


Setup Range=1 297-441 8 




value Note2) 


Set by 0.1mm (initial 
value=2100) 


710-022 


Specified paper code for cus- 


03: 5.5x8.5 




tom-registration 


0.4: A5 

05: B5 

08: A4 

09:8x10 

10:8.5x11 

11; 8.5x12.4 

12:8.5x13 

13:8.5x14 

14: B4 

15: A3 

16: 11x17 

1 7: 8K (267x388mm) 

20: ILLEGAL SIZE (Initial 

Value=08) 


710-023 


Feed direction of document 


0: LEF, 1:SEF (Initial 




size 


Value=0) 



3. Check the settings of the NVM Data again. 

4. Set the document that was custom-registered for the size detection table in the DADF and 
feed it. -> Check that the document size is detected as specified. 

NOTE: Be careful with scan data image missing since the non-standard document size is 
handled as standard document size. 



Repairs and Adjustments 

ADJ 5.7 



6/02 
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Scanner 



ADJ 6.1 Full/Half Rate Carriage 

Purpose 

Establish Full Rate and Half Rate Carriage position. 



Align Half Rate Carriage with Rail Hole (Figure 2). 

a. Manually move Full Rate Carriage away from home position approximately 105 mm 
while observing Rail Tool Hole to align with Carriage Tool Hole in Half Rate Carriage. 



Check 



WARNING 



To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

NOTE: The Half Rate Carriage is checked, and adjusted if required by repositioning a pulley. 
Then the Full Rate Carriage is checked, and adjusted if required by repositioning the carriage 
on the cable. 

1 . Remove Platen Glass (REP 6.2). 

2. Remove Alignment Tools (2) from Storage (Figure 1). 

Remove Screws 
(2) and Tools (2) 



Front of Scanner 



Rail Hole for 
Alignment Tool 



Carriage Hole 
for Alignment 
Tool 





0101047A-CAR 



Figure 2 Aligning Half Rate Carriage with Rail Hole 



Figure 1 Removing Tools 



0101046A-CAR 



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Repairs and Adjustments 

ADJ 6.1 



4. Install Alignment Tool in front end of Half Rate Carriage (Figure 3). 




Check that tool will install in other end of carriage. 

If the tool installs, go to step 6. 

If tool does not install, loosen the Set Screw (2) and turn the pulley to align the tool holes 

with each other (Figure 4). 



0101048A-CAR 

Figure 3 Installing Alignment Tool in Front End of Half Rate Carriage 




0101049A-CAR 



Figure 4 Loosening the Set Screw (2) 



Repairs and Adjustments 

ADJ 6.1 



6/02 
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6. Check that Alignment Tool can be installed through frame into alignment hole in Full Rate 
Carriage (Figure 5). 

If Alignment Tool fits through frame hole into Full Rate Carriage Alignment Hole, perform 
the same check at the rear of the carriage. 
If the rear of the carriage is aligned, the check is good. 
If the rear of the carriage is not aligned, go to the adjustment. 

If Alignment Tool does not fit through frame hole into Full Rate Carriage Alignment Hole, 
go to the adjustment. 



Adjustment 

NOTE: Front of Full Rate Carriage shown. Adjustment steps are same for rear of Full Rate 
Carriage. 

1 . Adjust Full Rate Carriage (Figure 6). 

a. Loosen Screw. 

b. Move carriage so that Alignment Tool will drop into Alignment Holes. 

c. Tighten Screw. 




Screw 



Alignment 
Holes 




0101050A-CAR 



0101051A-CAR 



Figure 5 Checking Alignment Tool in Full Rate Carriage 



Figure 6 Adjust Full Rate Carriage 



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6/02 
4-163 



Repairs and Adjustments 

ADJ 6.1 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

AD J 6.1 4-164 DC1 632/2240 



ADJ 9.1 Max Setup 

Purpose 

To conduct a check of the machine and set it up so that excellent copy quality can be consis- 
tently obtained by stabilizing the development potential and copy density. 

Adjustment 

Max Setup consists of 5 separate adjustments that should be performed in the following 
sequence: 

1 . ADJ 9.7, NT Calibration (dC945) 

NOTE: Perform ADJ 9.2 only when replacing the ATC Sensor or Developer Housing. 

2. ADJ 9.2, ATC Sensor Setup (dC921 ) 

3. ADJ 9.3, TRC Control/Toner Density Setup (dC922) 

4. ADJ 9.4, ADC Output (dC934) 

NOTE: Perform ADJ 9.5 only when the customer requests. 

5. ADJ 9.5, Manual TRC Adjust (dC924) 



ADJ 9.2 ATC Sensor Setup (dC921) 
Purpose 

NOTE: This procedure should only be performed when the ATC Sensor or Developer Housing 
has been replaced, or when there is reason to believe that the calibration values in NVM are 
incorrect. 

To set the calibration values [ATC Correction Coefficient], [ATC Correction Offset] in NVM to 
calibrate the new ATC Sensor. 

Adjustment 

1 . Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic 
Mode using the PWS). 

2. Under the Adjustments tab, select Max Setup. 

3. Select the TC/ATC Sensor Setup tab. 

4. Locate the ATC Sensor calibration code on the ATC Sensor. This is the 3-digit number in 
the 3rd line of text on the label (it will always start with a zero). 

5. Enter the last 2 digits of this code into the appropriate column of the first row. 

6. Select the Read button. 

7. Proceed to ADJ 9.3, TRC Control/Toner Density Setup (dC922) 



Prelaunch Training/Review 
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6/02 
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Repairs and Adjustments 

ADJ 9.1, ADJ 9.2 



ADJ 9.3 TRC Control/Toner Density Setup (dC922) 
Purpose 

To check the output of ATC Sensor and to determine if TC Control performed normally. 
Allows manual adjustment of TC if control is not functioning. 

Check 

1 . Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic 
Mode using the PWS). 

2. Under the Adjustments tab, select Max Setup. 

3. Select the TRC Control tab. 

4. Load letter size paper (8.5 x 11 or A4) into Tray 1 . 

5. Select the Start button. The machine will read the output of the ATC Sensor and display 
the results in the row labeled ATC Mean Detected Value. If the routine is unable to read 
the ATC Sensor correctly, this fact will be displayed in the row labeled ATC Sensor Fail 
Determination. 

6. If the row labeled ATC Sensor Fail Determination displays OK for all colors, continue 
with the check. If any color is not OK, go to the appropriate RAP (9-380 for yellow, 9-381 
for magenta, 09-382 for cyan, or 9-383 for black) to fix the problem before continuing with 
this procedure. 

7. Compare the data in the row labeled ATC Mean Detected Value with the data in the row 
labeled ATC Control Environment Correction Standard. If the measured value for any 
color is more than 50 bits higher or lower than the target (correction standard) value, per- 
form the Adjustment. 

8. If the Check is OK, proceed to ADJ 9.4, ADC Output Check. 

Adjustment 

The Tone Judge window in the upper right portion of the screen shows the result of the ATC 
Sensor read. Perform the following steps to adjust the toner density. 

1. Select Run. The control logic will automatically tone up or tone down each color per the 
display. 

2. When the tone up/down cycle is complete, select Start to re-run the check. 

NOTE: It is not necessary to repeat the tone up/down procedure until the match is exact. 

3. Repeat steps 2 and 3 until the ATC Mean Detected Value is within 50 bits of the ATC 
Control Environment Correction Standard for all colors. 

4. Proceed to ADJ 9.4, ADC Output Check. 



ADJ 9.4 ADC Output Check (dC934) 
Purpose 

i To check the following functions 

i ADC (2 gradation) patch for Potential Control on the IBT 

i ADC Sensor output 

i Laser Diode light output 

Check 

1 . Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic 
Mode using the PWS). 

2. Under the Adjustments tab, select Max Setup. 

3. Select the ADC AGC Setup tab. 

4. Select the Start button. The machine will read the output of the ADC Sensor, The Laser 
Diode, and Developer bias, and display the results on the screen. 

5. Check for unsatisfactory results: 

T If a fault code is declared, go to the RAP for that code. Resolve the problem, then 
repeat the Check. 

i If ADC Shutter Fail is NG go to the 9-654 RAP and troubleshoot the shutter sole- 
noid circuits 

T If ADC Sensor Fail is NG go to the 9-654 RAP and troubleshoot the sensor circuits. 



Repairs and Adjustments 

ADJ 9.3, ADJ 9.4 



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ADJ 9.5 TRC Adjust (dC924) 
Purpose 

CAUTION 

Perform this adjustment only to correct a strong customer complaint. Altering the setpoints will 
affect both Print and Copy modes. Also, there is quite a bit of overlap among the low, medium, 
and high densities. For these reasons, it is recommended that this procedure not be used 
unless absolutely necessary. 

To adjust image quality (TRC) to meet the user's preference, by increasing or decreasing the 
center value of gradation correction for each (YMCK) color, in low density, medium density, and 
high density ranges. 

Adjustment 

1 . Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic 
Mode using the PWS). 

2. Under the Adjustments tab, select Max Setup. 

3. Select the TRC Adjust tab. 

4. Type in the desired value; the default is 128, and the range is from to 255. the results 
on the screen. 

5. Select Save. 

6. Perform a Temporary Call Closeout, then switch the machine power off then on 

7. Make 2 prints or copies; the changes are not implemented until the 2nd print is made. 

8. Repeat steps 4 through 7 until the customer is satisfied with the image quality. 



Prelaunch Training/Review 6/n2 Repairs and Adjustments 

DC1632/2240 4-167 ADJ 9.5 



ADJ 9.6 Color Registration (dC685) 
Purpose 

To establish correct horizontal and vertical positioning of the four primary color images 

The procedure consists of the following steps, which must be performed in the listed sequence: 

1 . Belt Edge Learn - to align the Transfer Belt positioning system. 

2. Fine Skew Setup - automatically performs horizontal and vertical alignment, and reports 
any skew in the various images caused by ROS misalignment. This skew must be cor- 
rected through manual adjustment 

3. IN/OUT Setup - automatically performs magnification adjustment so that scan lines are 
the same length for all four colors. Also checks for skew. 

4. Center Setup - Aligns the midpoints of scan lines for all colors, for magnification balance. 
There is also a Rough Skew Setup for cases where the skew is outside the measurement 
parameters of the Fine Skew test. 

This procedure is required if any of the following occur: 

i ROS removal 

i NVM Initialization 

i An Image Quality RAP directed performance of this procedure. 

Check 

NOTE: Excessive toner on the Transfer Belt will prevent completion of the adjustment. Make 
sure that there are no Image Quality problems, and that the IBT Cleaner is functioning cor- 
rectly. Resolve any Image Quality problems before attempting this adjustment. 

1 . Open the Front door and cheat the interlock. 

2. Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic 
Mode using the PWS). 

3. Under the Adjustments tab, select RegiCon. 

Set the Belt Edge Alignment 



1. 
2. 
3. 

4. 



Select the Belt Edge Learn Mode tab. 

Select the Edge Learn Mode button. 

Select Start. 

If Edge Learn fails, check: 

T Installation of IBT Belt Assembly (REP 9.15). 

i Installation of IBT Edge Sensor (PL 5.4). 

i Installation of IBT Home Sensor (PL 5.4). 

Perform Edge Learn again. If it fails, replace the IBT Edge Sensor (PL 5.4). 

If it fails again, replace IBT Home Sensor (PL 5.4). 

When Edge Learn is successful, select the RegiCon Setup Cycle (dC685) tab. 



Check the Fine Skew Setup 

1 . Select the Skew (Fine) Setup button. 

2. Select Start. 



3. Check the Judgement window. If NG is displayed, perform the Rough Skew Setup then 
repeat the Fine Skew check. 

4. If OK is displayed in the Judgement window, check the Skew Correction row in the 
Skew Values window. If a value greater than 1 is displayed for any color, perform the 
Adjustment, then perform the IN/OUT Setup check. 

Check the IN/OUT Setup 

1 . Select the IN/OUT Setup button. 

2. Select Start 

3. Check the Judgement window. If NG is displayed, perform the Adjustment, then perform 
the Center Registration check 

4. If IN/OUT Setup is OK, check the Center Registration. 

Check the Center Registration 

1 . Remove the Waste Toner Cartridge. 

2. Move MOB sensor to the center position (Figure 1 ). 



2 

Remove 
Cleaning 
Tool from 
Front Cover. 



1 

Remove 
Screw 




Pull out MOB 
Sensor slightly 
with needle nose 
pliers (pliers not 
shown). 
Hook end of 
Cleaning Tool to 
MOB Sensor. 



NOTE: 
Stop Tab 



Push in MOB Sensor until sensor stops. 
Tool will be positioned as shown (Stop Tab 
on tool should be flush with frame). 



0104910-A-CAR 



Figure 1 Moving MOB Sensor to Center Position 



Reinstall the Waste Toner Cartridge. 



Repairs and Adjustments 

ADJ 9.6 



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4. Select the Center Setup button. 

5. Select Start. 

CAUTION 

Make sure not to hook the wiring harness when moving the MOB Sensor. 

6. If Center Setup is OK, dC685 is complete. Use the Cleaning Tool to pull the MOB Sensor 
back to the original position, and fasten the screw. 

If Center Setup fails, ensure MOB Sensor is positioned to the rear. Go back to step 1 of 
the Center check. 

Check the Rough Skew Setup 

1 . Select the Skew (Rough) Setup button. 

2. Select Start. 

3. Check the Judgement window. If NG is displayed, there is a problem with the ROS, the 
IBT Assembly, or the MOB Sensor. 

4. If OK is displayed in the Judgement window, check the Skew Correction row in the 
Skew Values window. If a value greater than 1 is displayed for any color, perform the 
Adjustment, then repeat the Fine Skew Setup check. 

Adjustment 

1. In the Skew Values window, record the value for each color in the Skew Correction 
row. This is the required number of rotations of the adjustment screw. 

WARNING 

To avoid exposure to laser light, reinstall the Waste Cartridge before attempting to 
recheck the adjustment. 

2. Remove the Waste Toner Cartridge (REP 9.4). 

3. For each color, rotate the appropriate (CYMK) adjustment screw (Figure 2) in + (CW), or - 
(CCW) direction the number of clicks recorded in step 1 . 




0104911-A-CAR 
Figure 2 Adjusting Skew 

4. Reinstall Waste Toner Cartridge (REP 9.4). 



Check IOT Lead Edge/Side Edge (ADJ 9.9) after performing this adjustment. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-169 



Repairs and Adjustments 

ADJ 9.6 



ADJ 9.7 NT Calibration (dC945) 
Purpose 

i To calculate and set up the White Reference Correction Coefficient. 

i To correct the IIT sensitivity dispersion (CCD Calibration). 

i Adjust the light axis correction data when replacing the Lens unit. 



Adjustment 

1. Clean the Optics: 

a. Switch off the power and allow the Exposure Lamp to cool off. 

b. Using the optical Cleaning Cloth, clean the front and rear of the Document Glass, 
Document Cover, White Reference Strip, Reflector, and Mirror. 

c. Clean the Exposure Lamp with a clean cloth and Film Remover. 

d. Clean the Lens with Lens and Mirror Cleaner and lint free cloth. 

2. Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic 
Mode using the PWS). 

3. Under the Adjustments tab, select Max Setup. 

4. Select the IIT Calibration tab. 

5. Select the White Reference Adjustment button. 

6. Press Start. 

7. Follow the instructions on the PWS screen, then select OK. 

8. Select the Read button. 

9. The setup values are displayed on the White Reference Setup Value screen. 

10. When White Reference setup is done, select the CCD Calibration button. 

11. Press Start. 

12. Follow the instructions on the screen, then select OK. 

13. The obtained data is displayed in the b* Calibration Coefficients window. 

14. Select [Close] to return to the Color Image Quality Adjustment screen. 

NOTE: Do not select Optical Axis Calibration unless replacing the Lens Kit (PL 18.4). Refer to 
REP 6.4. 



ADJ 9.8 Hard Disk Diagnostics/Setup (dC355) 
Purpose 

CAUTION 

This procedure does not work as described in the current tool; the spec is being rewritten. 

This description is an attempt to document the new spec. DO NOT USE. 

To perform the diagnostics in the hard disk and setup (initialization) of each partition. 

NOTE: Perform this procedure only after the customer's approval is obtained. Check what 
kind of data are stored in each partition according to the list below since some partitions store 
fonts etc. that the customer has installed. 

NOTE: Setup function is only available from customer's mode or Ul-Diag mode in Partition A. 

Adjustment 

1 . Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic 
Mode using the PWS). 

2. Under the Diagnostics tab, select System Test. 

3. Select the Hard Disk Diag. Program tab. 

4. Select the appropriate Partition (see Table 1 .) 





Table 1 Partition Content 




Display of appropriate 
hard disk column 


Size 

(GB) 


Stored information and usages 


MP All 


All 


All the items in Partition 1-6 


MP Partition 1 (a) 


2.0 


Font, Form/Logo, SMB Folder (Config. txt, 
Job Template 


driver), 


MP Partition 2 (b) 


2.0 


Printing range 


MP Partition 3 (c) 


1.2 


Scan, Report, Mailbox, Security - Print 


MP Partition 4 (d) 


2.0 


PLD, Others 


MP Partition 5 (e) 


2.0 


Copying range 


MP Partition 6 (f) 


0.5 


Spool Cont Control Information, Log 



5. Select the Diag Type (see Table 2). 



Table 2 



Work Item 


Details 


Setup 


Initialize the file system. It is required when the management data 
of the file system corrupts and when read errors occur. 


Hard Disk Test 
Read Verify) 


Perform the Read verify diagnostics of all the sectors in designated 
partitions. Sector numbers where a read error is occurring will 
appear. 


Troubleshooting 


Perform the hard disk ROM check and controller diagnostics. 


Trouble Prediction 


Perform the SMART (Self-monitoring analysis and reporting tech- 
nology) to predict latent troubles on the hard disk. 



Press Start. 



Repairs and Adjustments 

ADJ 9.7, ADJ 9.8 



6/02 
4-170 



Prelaunch Training/Review 
DC1 632/2240 



ADJ 9.9 IOT Registration Series (dC129) 
Purpose 

The purpose is to adjust the position of the printed image on the page. This is done by chang- 
ing the value in the appropriate NVM location in dC129. This controls where the ROS writes 
the image. 

Introduction 

This series consists of 4 procedures: 

Lead Edge Registration (Trays 1-4) 

Side Edge Registration (Trays 1-5) 

Duplex (Side 2) Registration 

Lead Edge Registration for Tray 5 
All procedures must be checked. 

Lead Edge Registration (Paper Trays 1 - 4) 
Purpose 

To correctly set the lead edge of the image in relation to the edge of the paper. There is one 
lead edge setting for Trays 1-4. 

Check 

1 . Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic 
Mode using the PWS). Select dC129 from the DC Quick menu 

2. Load Tray 1 with the largest paper used by the customer. 

3. Select ALL in the Lead Edge column. 

4. Press the Start button on the screen. As the prints are made, mark each to indicate the 
lead edge. 

5. Take the third pattern that was printed and measure from the lead edge to point eM on Fig- 
ure 1 (the intersection of the 7th line from the left edge and the first line from the lead 
edge). 



SIDE 
EDGE 









LEAD EDGE 
\ 


















































''A 
























































E 


B1 




















\ 
























\ 










































































B2 




























































































































































































































































n-irupn-i-A- 


~AR 



Figure 1 Measurement points 

6. If the measured value is not 21 .6mm±0.5, perform the Adjustment. 

Adjustment 

1. Use the Right and Left Arrow buttons to move the image toward or away from the lead 
edge of the paper. Each click on the button moves the image 0.25mm. The cumulative 
amount of shift is indicated in the Lead Reg. box. 

2. After adjusting the registration, click Set Adjust Value. 



NOTE: Changes made to the NVM 
machine exits Diagnostic Mode. 



for LE registration are not implemented unless the 



3. Go to the Service Exit tab and select Temporary Closeout. 

4. After the machine reboots and is ready to copy, reconnect the PWS. 

5. Select Start. 

6. Repeat the check/adjustment until the specifications are met. 

7. Select Save [LR] to save the new NVM settings. 

8. Proceed to Side Edge Registration for Paper Trays 1 - 5. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-171 



Repairs and Adjustments 

ADJ 9.9 



Side Edge Registration for Paper Trays 1 - 5 
Purpose 

NOTE: Each Paper Tray has a separate setting for side edge registration. 

To correctly position the side edge of the image in relation to the outboard edge of the paper. 

Check 

1. Check that paper is loaded in all trays, and that the paper guides are adjusted correctly. 
For Tray 1 and Tray 2, use 1 1 x 1 7 in. or A3 paper if available. 

2. Select Tray 1 in the Side Edge column. 

3. Press the Start button on the screen. As the prints are made, mark each to indicate the 
lead edge. 

NOTE: Print All prints from each tray in numerical sequence from Tray 1 through Tray 6 
(HCF - if installed). Make sure to keep the sheets in the correct sequence. 

4. Take the third pattern that was printed and measure the following: perform the Adjust- 
ment for that tray. 

For paper larger than letter size: from the intersection between the 1st line from the 

left top edge and the 10th line from the lead edge of the paper (point B2i on Figure 

1). 

For paper letter size (A4/8.5 x 11) or smaller: from the intersection between the 1st 

line from the left top edge and the 5th line from the lead edge of the paper (point SS1 i 

on Figure 1). 

5. If the measured value is not 21 .6mm±0.5, perform the Adjustment. 

6. If the measurement is within specifications, repeat the Check for Trays 2-5. Perform the 
Adjustment for any tray that is not within specifications. 

7. If all trays are within specifications, proceed to Duplex (Side 2) Registration. 

Adjustment 

1 . Select the paper tray to be adjusted from the Side Edge column. 

2. Use the Up and Down Arrow buttons to move the image toward or away from the out- 
board edge of the paper. Each click on the button moves the image 0.21 mm. The cumu- 
lative amount of shift is indicated in the Side Reg. box. 
After adjusting the registration, click Set Adjust Value. 
Select Start. 

Repeat the check/adjustment until the specifications are met. 
Select Save [SR] to save the new NVM settings. 
Repeat steps 1 through 6 for each tray that requires adjustment. 
Proceed to Duplex (Side 2) Registration. 



3. 
4. 
5. 
6. 
7. 



Duplex (Side 2) Registration 
Purpose 

The purpose of this procedure is to correctly position the lead edge and side edge of the image 
in relation to the edge of the paper. 

Check 

1 . Ensure that Paper Tray 1 contains paper and that the paper guides are adjusted correctly. 
If available, load the tray with 11 x 17 in. or A3 paper. 

2. Select Duplex (Side 2) in the Lead Edge column. 

NOTE: Side 2 will be face down in the output tray. 

3. Press the Start button on the screen. As the prints are made, mark each to indicate the 
lead edge. 

4. Check Lead Edge: 

Check the Side 2 Lead Edge Registration (Figure 1). If the measured value is not 
21.6mm±0.5, perform the Adjustment. 

5. Check Side Edge: 

Check the Side Edge Registration (Figure 1). If the measured value is not 21.6mm±0.5, 
perform the Adjustment. 

Adjustment 

Duplex Lead Edge: 

1. Use the Right and Left Arrow buttons to move the image toward or away from the lead 
edge of the paper. Each click on the button moves the image 0.25mm. The cumulative 
amount of shift is indicated in the Lead Reg. box. 

2. After adjusting the registration, click Set Adjust Value. 



NOTE: Changes made to the NVM 
machine exits Diagnostic Mode. 



for LE registration are not implemented unless the 



3. Go to the Service Exit tab and select Temporary Closeout. 

4. After the machine reboots and is ready to copy, reconnect the PWS 

5. Select Start. 

6. Repeat the check/adjustment until the specifications are met. 

7. Select Save [LR] to save the new NVM settings. 
Duplex Side Edge: 

1 . Select Duplex (Side 2) in the Side Edge column 

2. Use the Up and Down Arrow buttons to move the image toward or away from the out- 
board edge of the paper. Each click on the button moves the image 0.21 mm. The cumula- 
tive amount of shift is indicated in the Side Reg. box. 

3. After adjusting the registration, click Set Adjust Value. 

4. Select Start. 

5. Repeat the check/adjustment until the specifications are met. 

6. Select Save [SR] to save the new NVM settings. 



Repairs and Adjustments 

ADJ 9.9 



6/02 
4-172 



Prelaunch Training/Review 
DC1 632/2240 



Lead Edge Registration for Tray 5 (MSI) 
Purpose 

NOTE: There are three settings for Tray 5 Lead Edge; one for standard weight paper, one for 
heavyweight stock, and one for extra-heavyweight stock. 

To correctly set the lead edge of the image in relation to the edge of the paper. 

Check 

1 . Load Tray 5 with the largest standard weight paper used by the customer. 

2. Select Tray 5 (MSI) in the Lead Edge column. 

3. Press the Start button on the screen. As the prints are made, mark each to indicate the 
lead edge. 

4. Take the third pattern that was printed and measure from the lead edge to point eM on Fig- 
ure 1 (the intersection of the 7th line from the left edge and the first line from the lead 
edge). 

5. If the measured value is not 21 ,6mm±0.5, perform the Adjustment. 

6. If the customer uses heavyweight or extra-heavyweight stock, load Tray 5 with the stock. 
Select Tray 5 (HW) or Tray 5 (XHW), as appropriate. Repeat the check. 

Adjustment 

1. Use the Right and Left Arrow buttons to move the image toward or away from the lead 
edge of the paper. Each click on the button moves the image 0.25mm. The cumulative 
amount of shift is indicated in the Lead Reg. box. 

2. After adjusting the registration, click Set Adjust Value. 

NOTE: Changes made to the NVM for LE registration are not implemented unless the machine 
exits Diagnostic Mode. 

3. Go to the Service Exit tab and select Temporary Closeout. 

4. After the machine reboots and is ready to copy, reconnect the PWS. 

5. Select Start. 

6. Repeat the check/adjustment until the specifications are met. 

7. Select Save [LR] to save the new NVM settings. 



ADJ 9.10 NT Lead Edge Registration 
Purpose 

To adjust the NT scan timing in the Slow Scan direction and to correct the copy position. 

Check 

CAUTION 

Perform this adjustment only if absolutely required; the IIT Lead Edge Registration affects the 
precision of the document size detection. 

NOTE: Before performing this procedure, make sure that the IOT Lead Edge Registration is 
correct. Refer to ADJ 9.9, IOT Side/Lead Edge Registration. 

1 . Place the Geometric Test Pattern on the Platen Glass correctly and make a copy with the 
following settings: 

i Copy Mode: Black 

T Paper Size: 11 x 17 in or A3 

T Magnification: 100% 

T No. of Copies: 2 

2. On the 2nd copy, check that the distance from the lead edge to the top of Step 3 on the 
LE2 scale is 10.0mm +/- 2.1mm (Figure 1). 



Lead Edge 



1 



Lead Edge 



10.0mm 
+/- 2.1mm 





ill 



■ : *Si 



ill n %mi ip I 

Figure 1 Checking IIT Side Registration 

3. If the value is not within the specified range, Perform the Adjustment: 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-173 



Repairs and Adjustments 

ADJ 9.9, ADJ 9.10 



Adjustment 



1. Enter dC131 [715-301]. 

2. Change the value: 

i Each bit represents 0.036 mm 

i Increase the value to move the image toward the lead edge. 

I Decrease the value to move the image away from the lead edge. 



AD J 9.11 NT Side Edge Registration 
Purpose 

To adjust the NT scan timing in the Fast Scan direction and to correct the copy position. 

Check 

CAUTION 

Perform this adjustment only if absolutely required; the IIT Lead Edge Registration affects the 
precision of the document size detection. 

NOTE: Before performing this procedure, make sure that the IOT Side Edge Registration is 
correct. (Refer to ADJ 9.9, IOT Side/Lead Edge Registration.) 

1. Load 11 x 17 in. or A3 paper into Tray 2. 

2. Place the Geometric Test Pattern on the Platen Glass correctly and make a copy with the 
following settings: 

i Copy Mode: Black 
T Paper Tray: Tray 2 
T Magnification: 100% 
i No. of Copies: 2 

3. On the 2nd copy, check that the distance from the lead edge to the top of Step 3 on the 
SE2 and SE3 scales is 1 0.0mm +/- 1 .6mm (Figure 1 ). 



Lead Edge 




Figure 1 Checking IIT Side Edge Registration 



Repairs and Adjustments 

ADJ 9.10, ADJ 9.11 



6/02 
4-174 



Prelaunch Training/Review 
DC1 632/2240 



4. If the value is not within the specified range, perform the Adjustment: 

Adjustment 
Purpose 

1. Enter dC131 [715-014]. 

2. Change the value: 

i Each bit represents 0.036 mm 

i Increase the value to move the image toward the edge. 

i Decrease the value to move the image away from the edge. 



ADJ 9.12 NT Vertical/Horizontal Magnification 
Purpose 

To correct the horizontal (fast scan)/vertical (slow scan) magnification ratio for a 100% copy. 

Check 

CAUTION 

Perform this procedure only if absolutely required; changing IIT magnification may adversely 
affect resolution due to ASIC shift, and may cause a color shift. 

NOTE: Before performing this procedure, make sure that the IOT horizontal/vertical magnifica- 
tion ratios are correct. 

1. Place the Geometric Test Pattern on the Platen Glass and make a copy using the follow- 
ing copy mode settings: 

i Copy Mode: Black 

i Document Type: Text/Photo 

i Paper: 11 x17in. or A3 

T Magnification: 100% 

i No. of Copies: 2 

2. Check the 2nd copy for the following: 

3. Check horizontal magnification (Figure 1): 

Measure the 200mm line running from near LE1 to near LE3. If the dimension is not 
200mm ±1mm, perform the Adjustment. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-175 



Repairs and Adjustments 

ADJ 9.11, ADJ 9.12 



Lead Edge 



200mm 
+/-1mm 



L 

i9i 



liQI 



1'i 
f 



IIIIIIIIIIIIIIIIII 



A 



*§! 



r.as^'T^'-.* 



■ft 



T ! *" 












iiihiiiiiiiiiiii 



(0 



Figure 1 Checking Horizontal Magnification 



Repairs and Adjustments 

ADJ9.12 



6/02 
4-176 



Prelaunch Training/Review 
DC1 632/2240 



4. Check vertical magnification (Figure 2): 

Measure the 300mm line running from near LE1 to the trail edge of the 1.8lp ladder. If the 
dimension is not 300mm ±1.5mm, perform the Adjustment. 



i Lead Edge 







i , 


i 

300mm 
1.5mm 


i 

+/- ■*<* 










■■#i 
f 




iiiiiiiiuimmH 













1 



^«i 


■ 


■ I 


- : s : ; ; =l 


S; '1 


; r|M. 


•1* 


;■# 


■ 


*^^N 




1 


... 


■ 

! 


!■ 


m 


lllllllllllllll 


:;i,i ■ 


■ 


lw 




— 


ft;T 





Figure 2 Checking Vertical Magnification 



Adjustment 



2. 



Horizontal Magnification Adjustment 

i Enter dC1 31 [715-234] 

i Each bit represents 0.1% change: 

Increase the value to lengthen the line 
Decrease the value to shorten the line 

Vertical Magnification Adjustment 

i Enter dC131 [715-302] 

T Each bit represents 0.1% change: 

Increase the value to lengthen the line 
Decrease the value to shorten the line 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-177 



Repairs and Adjustments 

AD J 9.12 



ADJ 9.13 Ul Display Calibration 

Purpose 

Adjust the display by making the buttons on the display correspond to the Touch Panel, so that 
users can correctly select the content indicated on the display. 

Perform this adjustment when Ul PWB or the Control Panel are replaced. 

Adjustment 

NOTE: Use the touch pen for the adjustment as it is installed in the Ul Control Panel of the 
machine. A tapered substitute can be replaced if the pen has been lost. In this case, care 
should be taken not to have the Ul surface scratched. 

1 . Switch off the power and remove the Control Panel Cover. 

2. Remove the Touch Pen (Figure 1 ). 



Pen 








P1 


P2 P3 


P4 
P7 


P5 P6 
P8 P9 







Figure 2 Calibration Screen 1 

In numeric sequence (P 1 to P 9), touch the intersections of the vertical and horizontal 
lines with the touch pen. A message is displayed on the screen after each touch. 
After pressing down all the buttons, the machine will calculate the deviation and the cor- 
rection value on the coordinates. This automatic calculation takes about 0.1 second. 
Calibration Screen 2 will be displayed (Figure 3). 

Apply the adjusting pen to each of the four line intersections. A black square should 
appear at the point of contact, and a beep should sound. 
T If four beeps are heard, adjustment is OK. 
T If you donit hear four beeps, repeat the adjustment from step 3. 



0104902-A-CAR 



Figure 3 Adjustment Screen #2 

7. Switch off the power. Restore the pen to its original place and reinstall the Control Panel 
Cover. 



Figure 1 Accessing the Touch Pen 

3. Switch on the power while simultaneously holding down the numerical keys 0, 1, and 3 
on the Control Panel. 
Calibration Screen 1 will be displayed (Figure 2). 



Repairs and Adjustments 

ADJ 9.13 



6/02 
4-178 



Prelaunch Training/Review 
DC1 632/2240 



ADJ 9.14 Inboard/Outboard Density 
Purpose 

To perform the ROS In/Out light quantity correction with this adjustment, when IN/Out densities 
are different but the parameters other than ROS light quantity judges that all is normal. 

Adjustment 

1. Enter dC612. 

2. Select the Test Pattern in the modes as shown below and print out the test pattern, 
i Pattern name: Binary highlight PG LUT: C-TRA On IOT ON 

(Pattern No 13??? 25?) 
i Color Mode: 4C 
i Cin (%): 20% 
i Number of prints: 1 
i Tray: Tray 1/A4LEF 
i Resolution: Not specified 
T Binary ED screen 
i Print: single mode 

3. Select the pattern that has the same inclination on the four check points in the test pattern 
from the 20 patterns below. 

Write down the Pattern number. (Vertical axis shows density, and horizontal axis shows 
width direction in the pattern) 



1 




2 












1 




2 




1 




2 




1 




2 





3 4 

3~ 4 

3 4 

3 4 



0104903-A-CAR 



Figure 1 Check Point 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-179 



Repairs and Adjustments 

ADJ 9.14 



o 



o 



1 



3 4 



No 



o 



0104904-A-CAR 
Figure 2 Standard Pattern: Pattern 
'Group 1: when the patterns become darker along the rear> (Fig. 3) 




No 

4 
3 
2 
1 



3 4 



0104905-A-CAR 

Figure 3 Group 1 

<Group 2: when the patterns become darker along the front> (Fig. 4) 



Repairs and Adjustments 

ADJ9.14 



6/02 
4-180 



Prelaunch Training/Review 
DC1 632/2240 



No 




o 



o 



3 4 

0104906-A-CAR 



Figure 4 Group 2 
Group 3: when the patterns are dark/light for only both edges. (Fig. 5) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-181 



Repairs and Adjustments 

AD J 9.14 



o 



V 



No 



12 3 4 



O 



O 



: = 5 

12 3 4 



No 

10 



o 



o 



No 



12 3 4 



11 



<h 



^> 



12 3 4 



No 

12 



Figure 5 Group 3 



0104907-A-CAR 



Repairs and Adjustments 

ADJ9.14 



6/02 
4-182 



Prelaunch Training/Review 
DC1 632/2240 



<Group 4: when the patterns are dark only in the center areas> (Fig. 6) 



o 



o 




3 4 

0104908-A-CAR 

Figure 6 Group 4 

=Group 5: when the patterns are light only in the center areas> (Fig. 7) 




0104909-A-CAR 



Figure 7 Group 5 



Select a pattern and change the following NVM corresponding to the pattern. 

NOTE: Do NOT use the value other than the recommended values below as the NVM 
value. 

The In/Out density adjustment is available by changing the 6 NVM below. 
Table 1 



Chain/Link no. 


NVM names 


[753-801] 


Legible Adjustment (Yellow) 


[753-802] 


Legible Adjustment (Magenta) 


[753-803] 


Legible Adjustment (Cyan) 


[753-804] 


Legible Adjustment (Black) 


[753-805] 


InOut Pattern setting (Yellow) 


[753-806] 


InOut Pattern setting (Magenta) 


[753-807] 


InOut Pattern setting (Cyan) 


[753-808] 


InOut Pattern setting (Black) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-183 



Repairs and Adjustments 

AD J 9.14 



Table 2 Pattern No. 0-9 



Pattern # 
NVM 





1 


2 


3 


4 


5 


6 


7 


8 


9 


[753-801] 


1024 


973 


922 


870 


819 


1024 


1024 


1024 


1024 


922 


[753-802] 


1024 


973 


922 


870 


819 


1024 


1024 


1024 


1024 


922 


[753-803] 


1024 


1024 


1024 


1024 


1024 


973 


922 


870 


819 


1024 


[753-804] 


1024 


1024 


1024 


1024 


1024 


973 


922 


870 


819 


1024 


[753-805] 





1 


2 


3 


4 


5 


6 


7 


8 


9 


[753-806] 





1 


2 


3 


4 


5 


6 


7 


8 


9 


[753-807] 





1 


2 


3 


4 


5 


6 


7 


8 


9 


[753-808] 





1 


2 


3 


4 


5 


6 


7 


8 


9 


Table 3 Pattern No. 1 0-9 


Pattern # 
NVM 


10 


11 


12 


13 


14 


15 


16 


17 


18 


19 


[753-801] 


1024 


922 


1024 


1024 


1024 


1024 


1024 


973 


922 


870 


[753-802] 


1024 


922 


1024 


1024 


1024 


1024 


1024 


973 


922 


870 


[753-803] 


922 


1024 


922 


1024 


1024 


1024 


1024 


973 


922 


870 


[753-804] 


922 


1024 


922 


1024 


1024 


1024 


1024 


973 


922 


870 


[753-805] 


10 


11 


12 


13 


14 


15 


16 


17 


18 


19 


[753-806] 


10 


11 


12 


13 


14 


15 


16 


17 


18 


19 


[753-807] 


10 


11 


12 


13 


14 


15 


16 


17 


18 


19 


[753-808] 


10 


11 


12 


13 


14 


15 


16 


17 


18 


19 



5. 
6. 
7. 



Reference Information 

The correct light quantity value in ROS is normally 1024. If the value is decreased by 5%, 

the light quantity decreases too. 

Hence, entering the 5 stages of light quantity correction value by 5% is possible as below. 

1024: Correct ROS Light Quantity Value 

973: Light quantity value of 5% down 

922: Light quantity value of 10% down 

870: Light quantity value of 15% down 

919: Light quantity value of 20% down 

Take test patterns again with the Step 2 mode after changing. 

Repeat Steps 3-5 until the density distribution that the client requests can be obtained. 

Check the condition using the customer's samples. (Or ask the customer to print out the 

sample from the same file and check the density on it.) 



NOTE: Be careful in servicing because tone jump trouble may occur if the adjustment is cor- 
rected drastically. The tone jump is a noticeable difference in the midstream of gradations 
when the gradations etc. are printed out. 

NOTE: When copying, borrow the document or sample that the clients has complained about. 
(To show the adjustment result after the adjustment) 



Repairs and Adjustments 

ADJ9.14 



6/02 
4-184 



Prelaunch Training/Review 
DC1 632/2240 



ADJ 12.1 Finisher Alignment 

Purpose 

Align IOT copy output with entrance to Finisher H Transport. 

Adjustment 

WARNING 

To avoid personal injury or shock, do not perform repair or adjustment activities with 
the power switch on or electrical power applied to the machine. 

1 . Ensure H Transport is set correctly (Figure 1) and (Figure 2). 




Figure 1 H Transport Clearance 



H Transport Gate 




Figure 2 H Transport Gate Clearance 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
4-185 



Repairs and Adjustments 

ADJ 12.1 



Repairs and Adjustments 6/02 Prelaunch Training/Review 

ADJ 12.1 4-186 DC1632/2240 



5 Parts List 



Overview 

Introduction 5-3 

Subsystem Information 5-4 

Symbology 5-5 

Parts Lists 

Drives 

PL 1.1 Drive Unit 5-7 

PL 1.2 Main Drive Motor Assembly 5-8 

PL 1.3 IBT Steering Motor and MOB Sensor 5-9 

Paper Transportation 

PL 2.1 Tray 1: 1 of 2 5-10 

PL 2.2 Tray 1 : 2 of 2 5-11 

PL 2.3 Tray 1 Feeder and Left Lower Cover Assembly 5-12 

PL2.4Tray 1 Feeder: 1 of 2 5-13 

PL 2.5 Tray 1 Feeder: 2 of 2 5-14 

PL 2.6 Registration Transport 5-15 

PL 2.7 Left Cover Unit 5-16 

PL 2.8 Left Cover Assembly: 1 of 2 5-17 

PL 2.9 Left Cover Assembly: 2 of 2 5-18 

PL 2.10 Exit Transport Assembly 5-19 

PL 2.11 Exit Transport Assembly (OCT) 5-20 

PL 2.12 Tray 5: 1 of 2 5-21 

PL 2.13 Tray 5: 2 of 2 5-22 

PL 2.14 Tray 5 Feed Assembly 5-23 

PL 2.15 Tray Assembly 5-24 

ROS 

PL 3.1 ROS Assembly 5-25 

Xerographies 

PL 4.1 Xerographic Module: 1 of 2 5-26 

PL 4.2 Xerographic Module: 2 of 2 5-27 

Transfer 

PL 5.1 Lift Unit 5-28 

PL 5.2 IBT Unit 5-29 

PL 5.3 IBT Belt Assembly 5-30 

PL 5.4 IBT Frame Assembly: 1 of 2 5-31 

PL 5.5 IBT Frame Assembly: 2 of 2 5-32 

PL 5.6 IBT Elevator 5-33 

Development 

PL 6.1 Developer Unit: 1 of 2 5-34 

PL 6.2 Developer Unit: 2 of 2 5-35 

Fuser 

PL 7.1 Fuser Assembly: 1 of 2 5-36 



PL 7.2 Fuser Assembly: 2 of 2 5-37 

Air System 

PL 8.1 Air System 5-38 

Electrical Components 

PL 9.1 Electrical Components: 1 of 3 5-39 

PL9.2 Electrical Components: 2 of 3 5-40 

PL 9.3 Electrical Components: 3 of 3 5-41 

Covers 

PL 10.1 Front Cover 5-42 

PL 10.2 Top Covers and Inner Covers 5-43 

PL 10.3 Rear Cover 5-44 

Inverter 

PL 11.1 Inverter Transport: 1 of 2 5-45 

PL 11.2 Inverter Transport: 2 of 2 5-46 

Duplex Transport 

PL 12.1 Duplex Transport Assembly: 1 of 2 5-47 

PL 12.2 Duplex Transport Assembly: 2 of 2 5-48 

ESS 

PL 13.1 ESS 5-49 

Tray Module - TT 

PL 16.1 Tray 2/3/4 Assembly 5-50 

PL 16.2 Tray 2 5-51 

PL 16.3 Tray 3 5-52 

PL 16.4 Tray 4 5-53 

PL 16.5 Paper Feeder: 1 of 2 5-54 

PL 16.6 Paper Feeder: 2 of 2 5-55 

PL 16.7Tray2 Feeder: 1 of 2 5-56 

PL 16.8 Tray 2 Feeder: 2 of 2 5-57 

PL 16.9 Tray 3 Feeder: 1 of 2 5-58 

PL 16.10 Tray 3 Feeder: 2 of 2 5-59 

PL 16.11 Tray4 Feeder: 1 of 2 5-60 

PL 16.12 Tray 4 Feeder: 2 of 2 5-61 

PL 16.13 Left Cover Assembly 5-62 

PL 16. 14 Tray 3/4 Lift Gear Assembly 5-63 

PL 16.15 Electrical Components and Casters 5-64 

PL 16.16 Covers 5-65 

Finisher 

PL 17.1 Finisher 5-66 

PL 17.2 Gate Assembly 5-67 

PL 17.3 H-Transport Assembly: 1 of 2 5-68 

PL 17.4 H-Transport Assembly: 2 of 2 5-69 

PL 17.5 Covers 5-70 



Prelaunch Training/Review 
DC1 632/2240 



6/02 

5-1 



Parts List 



PL 17.6 Top Cover and Eject Roll 5-71 

PL 17.7 Paper Transportation: 1 of 2 5-72 

PL 17.8 Paper Transportation: 2 of 2 5-73 

PL 17.9 Stapler Unit 5-74 

PL 17.10 Compiler Tray Assembly 5-75 

PL 17.11 Elevator 5-76 

PL 17.12 Exit Assembly 5-77 

PL 17.13 Electrical Components 5-78 

PL 17.14 Rack Assembly 5-79 

NT 

PL 18.2 Control Panel 5-80 

PL 18.3 Platen Glass 5-81 

PL 18.4 CCD PWB, Sensor 5-82 

PL 18.5 Carriage Cable/ Motor 5-83 

PL 18.6 Full/Half Rate Carriage 5-84 

Rack 

PL 19.1 Rack 5-85 

DADF 

PL 20.1 Front/Rear Cover, Entrance Tray 5-86 

PL 20.2 Top Cover, Registration Gate Solenoid 5-87 

PL 20.3 Counterbalance, DADF Control PWB 5-88 

PL 20.4 Document Feed Chute (Upper), Feed Motor 5-89 

PL 20.5 Document Feed Chute (Lower) 5-90 

PL 20.6 DADF Belt Motor, Duplex Roll 5-91 

PL 20.7 Duplex Chute 5-92 

PL 20.8 Registration Roll 5-93 

PL 20.9 Exit Motor/Chute 5-94 

PL 20.10 Document Transport, Platen Belt 5-95 

PL 20.1 1 Platen Glass, Registration Gate, Exit Tray 5-96 

Common Hardware 

Common Hardware 5-97 

Part Number Index 5-98 



Parts List 



6/02 
5-2 



Prelaunch Training/Review 
DC1 632/2240 



Introduction 

Overview 

The Parts List section identifies all part numbers and the corresponding location of all spared 
subsystem components. 

Organization 

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 

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. 

Common Hardware 

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 millimetres 
unless otherwise identified. 

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. 



Other Information 

Abbreviations 

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 



Abbreviation 


Meaning 


A3 


297 x 594 Millimetres 


A4 


210 x297 Millimetres 


A5 


148x210 Millimetres 


AD 


Auto Duplex 


AWG 


American Wire Gauge 


EMI 


Electro Magnetic Induction 


GB 


Gigabyte 


KB 


Kilobyte 


MB 


Megabyte 


MM 


Millimetres 


MOD 


Magneto Optical Drive 


NOHAD 


Noise Ozone Heat Air Dirt 


PL 


Parts 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 


Abbreviation 


Meaning 


AO 


Americas Operations 


NASG - US 


North American Solutions Group - US 


NASG 

Canada 


North American Solutions Group - 
Canada 


XE 


Xerox Europe 



Symbology 

Symbology used in the Parts List section is identified in the Symbology section. 

Service Procedure Referencing 

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) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-3 



Parts List 

Introduction 



Subsystem Information 

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 

Subsystem Information 



6/02 

5-4 



Prelaunch Training/Review 
DC1 632/2240 



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). 



W7PI 
(A29WIJI) 








Z004 


A 


8 50 


PL 


M 


1 






Z005 


A 


850 


PL 


M 


1 



Figure 2 Without Tag Symbol 



Figure 1 With Tag Symbol 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-5 



Parts List 

Symbology 



A tag number within a circle with no apex shows that the entire drawing has been changed by A tag number within a circle with no apex and having a shaded bar shows that the entire 
the tag number within the circle (Figure 3). Information on the modification is in the Change Tag drawing was the configuration before being changed by the tag number within the circle 
Index. (Figure 4). 



© 







roo6 


A 


850 


PL 


M 


1 







2 007 


A 


850 


PL 


M 


1 



Figure 3 Entire Drawing With Tag Symbol 



Figure 4 Entire Drawing Without Tag Symbol 



Parts List 

Symbology 



6/02 
5-6 



Prelaunch Training/Review 
DC1 632/2240 



PL 1.1 Drive Unit 



Item 


Part 


1 


007K85750 


2 


- 


3 


- 


4 


007K87110 


5 


- 


6 


- 


7 


007K86400 



9 


- 


10 


- 


11 


- 


12 


- 


13 


- 


14 


007K86920 


15 


007K87220 


16 


- 


17 


- 



Description 

Drum Motor Assembly (REP 4.4) 
Drum Motor (P/O PL 1 .1 Item 1 ) 
Gear Bracket (P/O PL 1 .1 Item 1) 
IBT Motor Assembly (REP 4.2) 
IBT Motor (P/O PL 1.1 Item 4) 
Gear Bracket (P/O PL 1 .1 Item 4) 
Developer Drive Motor Assembly 
(REP 4.3) 

Developer Drive Motor (P/O PL 1 .1 
Item 7) 

Gear (47/38T) (P/O PL 1 .1 Item 7) 
Gear (51/25T) (P/O PL 1 .1 Item 7) 
Gear (P/O PL 1.1 Item 7) (76T) 
Clamp (P/O PL 1.1 Item 7) 
Edge Saddle (P/O PL 1.1 Item 7) 
Main Drive Motor Assembly (REP 
4.1) 

Developer Gear 

Drum Motor (K) (P/O PL 1 .1 Item 1 ) 
Screw (P/O PL 1.1 Item 1) 




J0mf50101 



Prelaunch Training/Review 
DC1 632/2240 



6/02 

5-7 



Parts List 

PL 1.1 



PL 1.2 Main Drive Motor Assembly 


Item Part 


Description 


1 


Friction Clutch (Not Spared) 


2 


Shaft (Not Spared) 


3 


Gear (32T) (Not Spared) 


4 


Gear (28T) (Not Spared) 


5 


Bearing (Not Spared) 


6 


Shaft (Not Spared) 


7 


Gear (20T) (Not Spared) 


8 121K22470 Takeaway Clutch 


9 


Bearing (Not Spared) 


10 


Shaft (Not Spared) 


11 


Gear (39T) (Not Spared) 


12 


Bearing (Not Spared) 


13 121K23270 Developer K Clutch 


14 


Gear (69/27T) (Not Spared) 


15 


Gear (23T) (Not Spared) 


16 


Gear (28/22T) (Not Spared) 


17 


Gear (45/30T) (Not Spared) 


18 


Gear (41/21T) (Not Spared) 


19 


Gear (24/20T) (Not Spared) 


20 


Gear (19T) (Not Spared) 


21 


Gear(18T) (Not Spared) 


22 


Gear (73/23T) (Not Spared) 


23 


Spring (Not Spared) 


24 


Tension Bracket (Not Spared) 


25 


Bracket (Not Spared) 


26 


Pulley (Not Spared) 


27 


Screw (Not Spared) 


28 


Main Motor (Not Spared) 


29 


Belt (Not Spared) 


30 


Clamp (Not Spared) 


31 


Clamp (Not Spared) 


32 


Connector (Not Spared) 


33 


Pulley (Not Spared) 



PL1.2 




32d/2Pcs.: 



31 (1/2Pcs.) 



J0mf50102 



Parts List 

PL 1.2 



6/02 
5-8 



Prelaunch Training/Review 
DC1 632/2240 



PL 1.3 IBT Steering Motor and MOB 
Sensor 



Item 


Part Description 


1 


007K85580 IBT Steering Motor Assembly (REP 




9.12) 


2 


IBT Steering Motor (P/O PL 1 .3 




Item 1) 


3 


Plate (P/O PL 1 .3 Item 1 ) 


4 


130K60865 MOB Sensor Assembly (REP 




9.14.ADJ9.6) 


5 


MOB Sensor (P/O PL 1 .3 Item 4) 


6 


- Environment Sensor (P/O PL 1.3 




Item 4) 


7 


Wire Harness (P/O PL 1 .3 Item 4) 


8 


Cover (P/O PL 1 .3 Item 4) 


9 


ADC Sensor (P/O PL 1 .3 Item 4) 


10 


Shutter (P/O PL 1 .3 Item 4) 


11 


Spring (P/O PL 1 .3 Item 4) 


12 


Link (P/O PL 1.3 Item 4) 


13 


Spacer (P/O PL 1 .3 Item 4) 


14 


MOB Bracket (P/O PL 1 .3 Item 4) 


15 


Slide (P/O PL 1 .3 Item 4) 



PL1.3 
1 {2,3 
4 { 5-15 




/ 7 



J0mf50103 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-9 



Parts List 

PL 1.3 



PL 2.1 Tray 1 : 1 of 2 



Item 


Part 


Description 


1 


003E23672 


Stop 


2 


014E42850 


Spacer 


3 


110K08541 


Tray 1 Paper Size Sensor (REP 
7.5) 


4 


050K48170 


Tray 1 (REP 7.8) 


5 


- 


Cover (Not Spared) 


6 


892E41110 


Label (1) 


7 


- 


Bracket (Not Spared) 



PL2.1 




20/2Pcs.) 



4(PL2.2) 



j0mf50201 



Parts List 

PL 2.1 



6/02 
5-10 



Prelaunch Training/Review 
DC1 632/2240 



PL 2.2 Tray 1 : 2 of 2 



Item 


Part 


Description 


1 


892E13310 


Instruction Label 


3 


- 


Max Label (Not Spared) 


4 


- 


Tray (Not Spared) 


5 


- 


Side Guide (Not Spared) 


6 


- 


End Guide (Not Spared) 


7 


- 


Link (Not Spared) 


8 


- 


Stop (Not Spared) 


9 


- 


Spring (Not Spared) 


10 


- 


Pad (Not Spared) 



PL2.2 




J0mf50202 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-11 



Parts List 

PL 2.2 



PL 2.3 Tray 1 Feeder and Left Lower 
Cover Assembly 



Item 


Part 


1 


059K15573 


2 


802K13193 



4 


- 


5 


- 


6 


- 


7 


- 


8 


- 


9 


- 


10 


- 


11 


130K60851 


12 


- 


13 


- 


14 


- 


15 


130E82190 


16 


- 


17 


029E31600 



Description 

Tray 1 Feeder (REP 7.3) 

Left Lower Cover Assembly (REP 

14.6) 

Left Lower Cover (P/O PL 2.3 Item 

2) 

Pinch Roll (P/O PL 2.3 Item 2) 

Bracket (P/O PL 2.3 Item 2) 

Spring (P/O PL 2.3 Item 2) 

Pinch Roll (P/O PL 2.3 Item 2) 

Bearing (P/O PL 2.3 Item 2) 

Bearing (P/O PL 2.3 Item 2) 

Bearing (P/O PL 2.3 Item 2) 

Tray 1 Feedout Sensor 

Wire Harness (P/O PL 2.3 Item 2) 

Ground Plate (P/O PL 2.3 Item 2) 

Magnet (P/O PL 2.3 Item 2) 

LH Lower Cover Interlock Switch 

Bracket (Not Spared) 

Rivet 




J0mf50203 



Parts List 

PL 2.3 



6/02 
5-12 



Prelaunch Training/Review 
DC1 632/2240 



PL 2.4 Tray 1 Feeder: 1 of 2 



Item 


Part 


Description 


1 


127K23230 


Tray 1 Feed/Lift Motor (REP 7.4) 


2 


- 


Bracket (Not Spared) 


3 


005K83081 


One-way Clutch 


4 


007K85730 


One-way Gear 


5 


- 


Gear(13T) (Not Spared) 


6 


- 


Bearing (Not Spared) 


7 


- 


Shaft (Not Spared) 


8 


- 


Front Frame (Not Spared) 


9 


- 


Upper Frame (Not Spared) 


10 


- 


Front Chute (Not Spared) 


11 


- 


Actuator (Not Spared) 


12 


130E82190 


Tray 1 Level / No Paper Sensor 


13 


- 


Wire Harness (Not Spared) 


14 


- 


Support (Not Spared) 


15 


- 


Gear(15T) (Not Spared) 



PL2.4 




J0mf50204 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-13 



Parts List 

PL 2.4 



PL 2.5 Tray 1 Feeder: 2 of 2 



Item 


Part Description 


1 


Spring (Not Spared) 


2 


600K78460 Roll Kit (3 Rolls/Kit) 


3 


005K05890 One-way Clutch 


4 


Gear (Not Spared) 


5 


Shaft (Not Spared) 


6 


Chute (Not Spared) 


7 


Spring (Not Spared) 


8 


Friction Clutch (Not Spared) 


9 


Support (Not Spared) 


11 


Spacer (Not Spared) 


12 


Gear (31T) (Not Spared) 


13 


Support (Not Spared) 


14 


Bearing (Not Spared) 


15 


Gear (Not Spared) 


16 


Support (Not Spared) 


17 


Screw (Not Spared) 


18 


Bearing (Not Spared) 


19 


Gear (35T) (Not Spared) 


20 


Spring (Not Spared) 


21 


Lever (Not Spared) 


22 


Holder (Not Spared) 



PL2.5 




J0mf50205 



Parts List 

PL 2.5 



6/02 
5-14 



Prelaunch Training/Review 
DC1 632/2240 



PL 2.6 Registration Transport 



Item 


Part 


Description 




1 


059K24661 


Registration Transport Assembly 








(REP 8.6) 


PL2.6 


2 
3 


— 


Bearing (P/O PL 2.6 Item 1 ) 
Bearing (P/O PL 2.6 Item 1) 


1 {2-16 


4 


- 


Takeaway Roll (P/O PL 2.6 Item 1) 




5 


- 


Gear (22T) (P/O PL 2.6 Item 1) 




6 


- 


Paper Guide (P/O PL 2.6 Item 1) 




7 


- 


Registration Chute (P/O PL 2.6 








Item 1) 


7 


8 


121K22220 


Registration Clutch 


9 


- 


Bearing (P/O PL 2.6 Item 1) 




10 


- 


Ground Plate (P/O PL 2.6 Item 1) 




11 


- 


Registration Roll (P/O PL 2.6 Item 

1 \ 




12 


130E82650 


Registration Sensor 


s — 4" 


13 


- 


Screw (P/O PL 2.6 Item 1) 




14 


160K46290 


OHP Sensor 




15 


— 


Registration Support (P/O PL 2.6 
Item 1) 




16 


- 


Wire Harness (P/O PL 2.6 Item 1 ) 




17 




Ground Plate (Not Spared) 






J0mf50206 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-15 



Parts List 

PL 2.6 



PL 2.7 Left Cover Unit 



Item 


Part 


Description 


1 


007E64740 


Damper Gear (11 /23T) 


2 


- 


Stud (Not Spared) 


3 


004E11831 


Damper (White) 


4 


- 


Left Upper Cover (Not Spared) 


5 


802K45490 


Left Cover Assembly 


6 


- 


Left Cover (P/O PL 2.7 Item 5) 


7 


- 


Screw (Not Spared) 


8 


- 


Label (P/O PL 2.7 Item 5) 


9 


- 


Cover (P/O PL 2.7 Item 5) 


10 


- 


Left Cover (Not Spared) 



6 (PL2.8) 




J0mf50207 



Parts List 

PL 2.7 



6/02 
5-16 



Prelaunch Training/Review 
DC1 632/2240 



PL 2.8 Left Cover Assembly: 1 of 2 



Item 


Part 


Description 


1 


054K2241 


Registration Chute 


2 


- 


Holder (Not Spared) 


3 


604K07070 


2nd BTR (REP 8.1) 


4 


809E29620 


Spring 


5 


015K48381 


Support 


6 


054E16330 


Exit Chute 


7 


007E62630 


Gear (22T) 


8 


059K15611 


Exit Roll 


9 


007E75201 


Gear 


10 


- 


Bearing (Not Spared) 


11 


- 


Holder (Not Spared) 


12 


110K10650 


Fuser Exit Switch 


13 


- 


Holder (Not Spared) 


14 


054K16130 


Duplex Chute (REP 8.2) 


15 


- 


Stop (Not Spared) 


16 


- 


Left Cover (Not Spared) 



PL2.8 




J0mf50208 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-17 



Parts List 

PL 2.8 



PL 2.9 Left Cover Assembly: 2 of 2 



Item 


Part 


1 


- 


2 


007K85522 


3 


127K29511 


4 


130E82190 


5 


- 


6 


130E84300 


7 


- 


8 


- 


9 


- 


10 


802K27073 


11 


- 


12 


- 


13 


- 


14 


- 


15 


- 


16 


- 


17 


007K86931 



Description 

Bearing (Not Spared) 

Gear 

2nd BTR Retract Motor 

2nd BTR Retract Sensor 

Bracket (Not Spared) 

POB Sensor 

Bracket (Not Spared) 

Spring (Not Spared) 

Bracket (Not Spared) 

Left Cover Assembly (REP 8.1) 

Left Cover (P/O PL 2.9 Item 10) 

Lever (P/O PL 2.9 Item 10) 

Bracket (P/O PL 2.9 Item 10) 

Gear (21T) (P/O PL 2.9 Item 10) 

Connector Assembly 

Spring (P/O PL 2.9 Item 10) 

Damper Gear (45T) 



PL2.9 
10(11-14,16,17 




J0mf50209 



Parts List 

PL 2.9 



6/02 
5-18 



Prelaunch Training/Review 
DC1 632/2240 



PL 2.10 Exit Transport Assembly 



Item 


Part Description 


1 


Exit Transport (Not Spared) 


2 


Exit Transport Cover (Not Spared) 


3 


Bearing (Not Spared) 


4 


Gear (20T) (Not Spared) 


5 


Exit Roll (Not Spared) 


6 


Actuator (Not Spared) 


7 


Bracket (Not Spared) 


8 


1 30E821 90 Full Paper Stack Sensor 


9 


Latch (Not Spared) 


10 


Spring (Not Spared) 


11 


Pinch Roll (Not Spared) 


12 


Pinch Roll (Not Spared) 


13 


LH Cover Interlock Switch (Not 




Spared) 


14 


Bracket (Not Spared) 


15 


Static Eliminator (Not Spared) 


16 


Wire Harness (Not Spared) 


17 


Front Bracket (Not Spared) 


18 


Frame (Not Spared) 




J0mf50210 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-19 



Parts List 

PL 2.10 



PL 2.11 Exit Transport Assembly 
(OCT) 

Description 

Exit Transport Assembly (REP 8.7) 
Exit Transport Cover (Part of Item 

1) 

Bearing (Part of Item 1) 

Pin (Part of Item 1) 

Exit Roll (Part of Item 1) 

Actuator 

Bracket (Part of Item 1) 

Full Paper Stack Sensor 

Latch (Part of Item 1 ) 

Spring (Part of Item 1) 

Pinch Roll (Part of Item 1) 

Pinch Roll (Part of Item 1) 

LH Cover Interlock Switch (Part of 

Item 1) 

Bracket (Part of Item 1) 

Static Eliminator (Part of Item 1 ) 

Offset Motor (Part of Item 1 ) 

Wire Harness (Part of Item 1) 

Screw (Part of Item 1 ) 

Front Bracket (Part of Item 1) 

Frame (Part of Item 1) 



Item 


Part 


1 


059K24690 


2 


- 


3 


_ 


4 


- 


5 


- 


6 


120E18160 


7 


- 


8 


130E82190 


9 


- 


10 


- 


11 


- 


12 


- 


13 


- 


14 


_ 


15 


- 


16 


- 


17 


- 


18 


- 


19 


- 


20 


- 



PL2.11 x 

1 { 2-20 




J0mf50211 



Parts List 

PL 2.11 



6/02 
5-20 



Prelaunch Training/Review 
DC1 632/2240 



PL 2.12 Tray 5:1 of 2 

Item Part Description 

1 059K24801 Tray 5 (REP 7.1) 



PL2.12 




J0mf50212 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-21 



Parts List 

PL 2.12 



PL 2.13 Tray 5: 2 of 2 



Item 


Part 


1 


- 


2 


- 


3 


- 


4 


- 


5 


050K48181 


6 


- 


7 


120E11971 


8 


130E82190 


9 


- 


10 


- 


11 


- 


12 


- 


13 


- 


14 


- 


15 


- 


16 


- 


17 


- 


18 


- 


19 


- 


20 


- 



Description 

Spring (Not Spared) 

Bracket (Not Spared) 

Gear (Not Spared) 

Spring (Not Spared) 

Tray 5 Assembly 

Upper Frame (Not Spared) 

Actuator 

Tray 5 No Paper Sensor 

Pinch Roll Assembly (Not Spared) 

Spring (Not Spared) 

Pinch Roll 1/2 (Not Spared) 

Pinch Roll 3 (Not Spared) 

Guide (Not Spared) 

Shaft (Not Spared) 

Spring (Not Spared) 

Spacer (Not Spared) 

Pinch Roll 3 (Not Spared) 

Pinch Roll 2 (Not Spared) 

Chute (Not Spared) 

Tray 5 Feed Assembly (Not 

Spared) 



PL2.13 

9(10,11,13,14,16 
12(13-17 
18 { 1 1.13—16 




20 (PL2.14) 



5 (PL2.15) 



J0mf50213 



Parts List 

PL 2.13 



6/02 
5-22 



Prelaunch Training/Review 
DC1 632/2240 



PL 2.14 Tray 5 


Feed Assembly 


Item 


Part 


Description 


1 


038E23560 


Paper Guide 


2 


- 


Takeaway Roll (Not Spared) 


3 


- 


Bearing (Not Spared) 


4 


- 


Gear (Not Spared) 


5 


- 


Pick-up Gear (Not Spared) 


6 


- 


Cam Gear (Not Spared) 


7 


- 


Stop Lever (Not Spared) 


8 


- 


Gear Lever (Not Spared) 


9 


121E87830 


Tray 5 Feed Solenoid 


10 


- 


Screw (Not Spared) 


11 


- 


Spring (Not Spared) 


12 


- 


Ground Plate (Not Spared) 


13 


- 


Spring (Not Spared) 


14 


059K24020 


Feed Roll Assembly 


15 


059K24010 


Feed Roll (REP 7.2) 


16 


- 


Cam (P/O PL 2.14 Item 14) 


17 


- 


Cam (P/O PL 2.14 Item 14) 


18 


- 


Shaft (P/O PL 2.14 Item 14) 


19 


019K97130 


Retard Pad 


20 


- 


Spring (Not Spared) 


21 


- 


Bottom Plate (Not Spared) 


22 


- 


Spring (Not Spared) 


23 


- 


Lower Frame (Not Spared) 


24 


- 


Spring (Not Spared) 



PL2.14 
14(15-18 




J0mf50214 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-23 



Parts List 

PL 2.14 



PL 2.15 Tray Assembly 

Item Part Description 

1 - Lower Tray (Not Spared) 

2 - Cover (Not Spared) 

3 - Paper Size Sensor (Not Spared) 

4 - Side Guide (Not Spared) 

5 - Attention Label (Not Spared) 

6 - Instruction Label (Not Spared) 

7 - Label (Not Spared) 

8 - Label (Not Spared) 

9 - Max Label (Not Spared) 

10 - Registration Guide (Not Spared) 

11 - Holder (Not Spared) 

12 - Tray (Not Spared) 

13 - Spring (Not Spared) 

14 - Link (Not Spared) 



PL2.15 




J0mf50215 



Parts List 

PL 2.15 



6/02 
5-24 



Prelaunch Training/Review 
DC1 632/2240 



PL 3.1 ROS Assembly 



Item 


Part 


Description 


1 


- 


Bracket (Not Spared) 


2 


062K10881 


ROS (REP 6.1, ADJ 9.6) 


3 


- 


Seal Glass (Y) (Not Spared) 


4 


- 


Seal Glass (M) (Not Spared) 


5 


- 


Seal Glass (C) (Not Spared) 


6 


- 


Seal Glass (K) (Not Spared) 



PL3.1 




J0mf50301 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-25 



Parts List 

PL 3.1 



PL 4.1 Xerographic Module: 1 of 2 



Item 


Part 


Description 






1 


802K47090 


Waste Toner Cartridge Cover (REP 
9.3) 


PL4.1 


2 


— 


Waste Toner Cartridge (Not 
Spared) (REP 9.4) 


3 


{4-6,11,12 


3 

4 


003K86121 


Sensor Holder Assembly 
Lever (P/O PL 4.1 Item 3) 


8 


{9,10,13,14 


5 


— 


Waste Toner Cartridge Interlock 
Switch (P/O PL 4.1 Item 3) 






6 


- 


Holder (P/O PL 4.1 Item 3) 






7 


— 


Drum Cartridge (Not Spared) (REP 
9.1) 






8 


127K29242 


Agitator Motor Assembly (REP 
9.13) 




,0 ^7 


9 


- 


Bracket (P/O PL 4.1 Item 8) 




13-Jt 


10 


- 


Agitator Motor (P/O PL 4.1 Item 8) 




11 


130E91010 


Full Toner Sensor (REP 9.5) 




^^ i 


12 


- 


Wire Harness (P/O PL 4.1 Item 3) 






13 


- 


Damper (P/O PL 4.1 Item 8) 






14 


- 


Screw (P/O PL 4.1 Item 8) 








J0mf50401 



Parts List 

PL 4.1 



6/02 
5-26 



Prelaunch Training/Review 
DC1 632/2240 



PL 4.2 Xerographic Module: 2 of 2 



Item 


Part 


1 


015K52320 


2 


- 


3 


- 


4 


- 


5 


- 


6 


122K93330 


7 


122K93340 



Description 

Plate Assembly (REP 9.8) 
Wire Harness (P/O PL 4.2 Item 1 ) 
Xero PLate (P/O PL 4.2 Item 1) 
Block (M, C, K) (P/O PL 4.2 Item 1 ) 
Block (Y) (P/O PL 4.2 Item 1) 
Erase Lamp w/Rail (Y, M, C) 
Erase Lamp w/Rail (K) 
Bracket (Not Spared) 
Screw (Not Spared) 



PL4.2 
1 {2-5 




J0mf50402 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-27 



Parts List 

PL 4.2 



PL 5.1 Lift Unit 



Item 


Part 


Description 


1 


001K70542 


Left Lift Assembly (REP 9.21) 


2 


001K70551 


Right Lift Assembly (REP 9.20) 


3 


- 


Bearing (Not Spared) 


4 


- 


Washer (Not Spared) 


5 


- 


Plate (Not Spared) 


6 


003K12680 


Latch Assembly 


7 


003E52290 


Left Hinge (REP 9.19) 


8 


003E52300 


Right Hinge (REP 9.19) 


9 


006E71740 


Shaft 


10 


011K94970 


Lever Assembly 


11 


— 


Lever (P/O PL 5.1 Item 10) (REP 
9.18) 


12 


- 


Bearing (P/O PL 5.1 Item 10) 


13 


- 


Left Cap (P/O PL 5.1 Item 10) 


14 


- 


Right Cap (P/O PL 5.1 Item 10) 


15 


- 


Grip (P/O PL 5.1 Item 10) 


16 


- 


Label (Not Spared) 



PL5.1 
10 {11-15 




J0mf50501 



Parts List 

PL 5.1 



6/02 
5-28 



Prelaunch Training/Review 
DC1 632/2240 



PL 5.2 IBT Unit 



Item 


Part 


Description 




1 


604K07050 


IBT Belt Assembly (REP 9.15.ADJ 








9.6) 


PL5.2 


2 


003K12650 


Removal Support 




3 


- 


Bearing (Not Spared) 




4 


007E61910 


Gear(14T) 


1 {9, 10 


5 


007E61890 


Gear(18T) 




6 


- 


Shaft (Not Spared) 




7 


802K12950 


Auger Assembly (REP 9.17) 




8 


- 


Screw (Not Spared) 




9 


- 


IBT Belt Assembly (P/O PL 5.2 Item 

1 \ 




10 


604K07060 


') 

IBT Belt Cleaner Assembly 





9 (PL5.3) 




J0mf50502 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-29 



Parts List 

PL 5.2 



PL 5.3 IBT Belt Assembly 



Item 


Part 


1 


- 


2 


_ 


3 


- 


4 


- 


5 


- 


6 


- 


7 


064K91451 


8 


- 


9 


- 


10 


- 


11 


- 


12 


- 


13 


- 


14 


- 


15 


059K23150 


16 


- 


17 


- 


18 


013E18980 


19 


- 



Description 

IBT Belt Cleaner Assembly (P/O PL 
5.2 Item 1) (REP 9.16) 
Blade (P/O PL 5.3 Item 1) 
Seal (P/O PL 5.3 Item 1) 
Screw (P/O PL 5.3 Item 1) 
Spring (P/O PL 5.3 Item 1) 
Housing (P/O PL 5.3 Item 1) 
Transfer Belt (ADJ 9.6) 
Support (P/O PL 5.2 Item 9) 
IBT Frame (P/O PL 5.2 Item 9) 
Right Handle (P/O PL 5.2 Item 9) 
Left Handle (P/O PL 5.2 Item 9) 
Bracket (P/O PL 5.2 Item 9) 
Housing (P/O PL 5.2 Item 9) 
Housing (P/O PL 5.2 Item 9) 
Backup Roll 

Bearing (P/O PL 5.2 Item 9) 
Pre Roll (P/O PL 5.2 Item 9) 
Bearing 
Screw (P/O PL 5.2 Item 1) 



PL5.3 
1 (2-6 




J0mf50503 



Parts List 

PL 5.3 



6/02 
5-30 



Prelaunch Training/Review 
DC1 632/2240 



PL 5.4 IBT Frame Assembly: 1 of 2 



Item 

1 

2 


Part 


130E84270 


3 


- 


4 


- 


5 


130K60830 


6 


162K56020 


7 


- 


8 


162K61090 


9 


- 


10 


- 


11 


- 


12 


019K98200 


13 


059K21260 


14 


019K98190 


15 


127K33950 


16 


130E82190 


17 


- 


18 


- 


19 


019K97550 


20 


019K97540 



Description 

Frame (Not Spared) 

IBT Home Sensor (ADJ 9.6) 

Spring (Not Spared) 

Clamp (Not Spared) 

IBT Edge Sensor (ADJ 9.6) 

Connector (C, K) 

Connector (Not Spared) 

Connector (Y, M) 

Screw (Not Spared) 

Rear Frame (Not Spared) 

Connector (Not Spared) 

Front Holder 

IstBTR Roll 

Rear Holder 

Retract Motor 

Retract Sensor 

Worm Gear (Not Spared) 

Retract Shaft (Not Spared) 

Front Holder 

Rear Holder 



PL5.4 




13 (1/4Pcs.) 



J0mf50504 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-31 



Parts List 

PL 5.4 



PL 5.5 IBT Frame Assembly: 2 of 2 

Item Part Description 

1 - Handle (Not Spared) 

2 - Spring (Not Spared) 

3 - Gear (Not Spared) 

4 - Plate (Not Spared) 

5 - Gear (Not Spared) 

6 - Bracket (Not Spared) 

7 - Top Roll (Not Spared) 

8 - Front Bracket (Not Spared) 

9 - Bearing (Not Spared) 

10 - Bearing (Not Spared) 

11 - Roll (Not Spared) 

12 - Roll (Not Spared) 

13 - Rear Bracket (Not Spared) 

14 - Collar (Not Spared) 

1 5 - Latch (Not Spared) 

16 - Bracket (Not Spared) 

17 - Roll (Not Spared) 



PL5.5 




BA ^M 

BA T 9 
10 



J0mf50505 



Parts List 

PL 5.5 



6/02 
5-32 



Prelaunch Training/Review 
DC1 632/2240 



PL 5.6 IBT Elevator 



Item 

1 

2 
3 

4 



Part 

809E26330 
01 5K49480 
015K49310 



Description 

Spring 

Rear Plunger 
Front Plunger 
Frame (Not Spared) 



PL5.6 




J0mf50506 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-33 



Parts List 

PL 5.6 



PL 6.1 Developer Unit: 1 of 2 



Item 


Part 


1 


802K45910 


2 


- 


3 


802K45920 


4 


- 


5 


802K45930 


6 


- 


7 


802K45940 


8 


- 


9 


802K33090 



10 



I I 
12 


127K33930 


13 


127K33940 


14 


- 


15 


116K90810 



Description 

Toner Dispenser (Y) (REP 9.7) 
Toner Cartridge (Not Spared) 
Toner Dispenser (M) (REP 9.7) 
Toner Cartridge (Not Spared) 
Toner Dispenser (C) (REP 9.7) 
Toner Cartridge (Not Spared) 
Toner Dispenser (K) (REP 9.7) 
Toner Cartridge (Not Spared) 
Toner Dispenser Base Assembly 
(REP 9.11) 

Toner Dispenser Base (P/O PL 6.1 
Item 9) 

Gear (P/O PL 6.1 Item 9) 
Toner Dispenser Motor (Y, M, C) 
Toner Dispenser Motor (K) 
Shaft (P/O PL 6.1 Item 9) 
New Cartridge Detect Switch 



PL6.1 
9(10-15 



12 (1/3Pcs.) 




Parts List 

PL 6.1 



6/02 
5-34 



Prelaunch Training/Review 
DC1 632/2240 



PL 6.2 Developer Unit: 2 of 2 



Item 


Part 


Description 




1 


802K28891 


Developer Housing (Y, M, K, C) 


PL6.2 






(REP9.9.ADJ9.1) 


2 


- 


Developer Housing (P/O PL 6.2 


1 {2-4 






Item 1) 


3 


130K63000 


ATC Sensor (Y, M, K, C) (ADJ 9.1) 




4 


035E65010 


Seal 




5 


604K07520 


Developer (K) (REP 9.10.ADJ 9.1) 




6 


604K07490 


Developer (Y) (REP 9.1 0.ADJ 9.1) 




7 


604K07500 


Developer (M) (REP 9.10.ADJ 9.1) 




8 


604K07510 


Developer (C) (REP 9.1 0.ADJ 9.1 ) 






J0mf50602 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-35 



Parts List 

PL 6.2 



PL 7.1 Fuser Assembly: 1 of 2 

Item Part Description 

1 126K14890 Fuser (220V) (REP 10.1) 

126K13940 Fuser (120V) (REP 10.1) 



PL7.1 




J0mr50701 



Parts List 

PL 7.1 



6/02 
5-36 



Prelaunch Training/Review 
DC1 632/2240 



PL 7.2 Fuser Assembly: 2 of 2 



Item 


Part 


Description 


1 


- 


Front Cover (Not Spared) 


2 


- 


Rear Cover (Not Spared) 


3 


- 


Front Lamp Bracket (Not Spared) 


4 


126K13950 


Main Heater Rod (110V) 


- 


126K13980 


Main Heater Rod (220V) 


5 


126K13990 


Sup Heater Rod (220V) 


- 


126K13960 


Sup Heater Rod (110V) 


6 


- 


Exit Chute (Not Spared) 


7 


- 


Cap (Not Spared) 


8 


- 


Handle (Not Spared) 


9 


- 


Upper Cover (Not Spared) 


10 


- 


Lower Cover (Not Spared) 


11 


130K61020 


Sensor Assembly 


12 


- 


Fuser (Not Spared) 



PL7.2 




J0mf50702 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-37 



Parts List 

PL 7.2 



PL 8.1 Air 


System 


Item 


Part 




Description 


1 


127K32730 


ROS Shutter Motor (REP 9.2) 


2 


- 




Link (Not Spared) 


3 


- 




Spring (Not Spared) 


4 


— 




Inner Cover (Not Spared) (REP 
14.10) 


5 


- 




Duct (Not Spared) 


6 


127K29340 


FuserFan (REP 10.2) 


7 


- 




Duct (Not Spared) 


8 


127K36640 


ROS Fan 



PL8.1 




jOmf 50801 



Parts List 

PL 8.1 



6/02 
5-38 



Prelaunch Training/Review 
DC1 632/2240 



PL 9.1 Electrical Components: 1 of 3 



Item 


Part 


1 


105K18771 


2 


105E09980 


3 


- 


4 


105E11130 


- 


105E09810 


5 


105E09820 


- 


105E09830 


6 


160K76802 


7 


- 


8 


— 


9 


105E09760 


- 


105K18641 


10 


- 


11 


127K29330 


12 


- 


13 


- 


14 


105E09970 


15 


- 


16 


- 


17 


103E27220 


- 


104E93610 


18 


160K84400 


19 


- 


20 


160K87730 



Description 

HVPS (T5) (REP 1.6 REP 1.7) 

HVPS (T7) (REP 1.6 REP 1.7) 

LVPS Bracket (Not Spared) (REP 

1.1) 

3.3V LVPS (110V) (REP 1.4) 

3.3V LVPS (220V) (REP 1.4) 

5V LVPS (110V) (REP 1.4) 

5V LVPS (220V) (REP 1.4) 

Interface PWB (REP 1.8) 

LVPS Bracket (Not Spared) (REP 

1.9) 

Screw (Not Spared) 

24V LVPS (220V) (REP 1 .5) 

24V LVPS (110V) (REP 1.5) 

Bracket (Not Spared) (REP 1.9) 

LVPS Fan 

Screw (Not Spared) 

HVPS Control PWB (P/O PL 9.1 

Item 1) 

HVPS (T6) (REP 1.10) 

Connector Chassis (Not Spared) 

T5/T7 HVPS Chassis (P/O PL 9.1 

Item 1) 

Resistor (220V) 

Choke Coil (110V) 

Fuser Noise Filter 

Plate (Not Spared) 

Interlock Relay PWB 




J0mf50901 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-39 



Parts List 

PL 9.1 



PL 9.2 Electrical Components: 2 of 3 



Item 


Part 


1 


101K38980 


- 


101K38810 


2 


_ 


3 


160K84820 


- 


160K76770 


4 


- 


5 


160K84800 


- 


160K76760 


6 


908W01200 


7 


962K08820 


8 


- 


9 


- 


10 


- 


11 


- 


12 


- 


13 


074K94320 


14 


917W00723 


- 


117E94370 


15 


162K69330 


16 


- 


17 


- 


18 


160K77201 



Description 

AC Power Chassis Assembly 

(220V) 

AC Power Chassis Assembly 

(110V) 

Bracket (P/O PL 9.2 Item 1) 

AC Drive PWB (220V) (REP 1.11) 

AC Drive PWB (110V) (REP 1.11) 

Clamp (P/O PL 9.2 Item 1) 

Noise Filter PWB (220V) 

Noise Filter PWB (110V) 

GFI Breaker 

Wire Harness 

Wire Harness (P/O PL 9.2 Item 1 ) 

Wire Harness (P/O PL 9.2 Item 1 ) 

Wire Harness (P/O PL 9.2 Item 1 ) 

Screw (P/O PL 9.2 Item 1) 

Wire Harness (P/O PL 9.2 Item 1 ) 

Outlet Panel 

Power Cord (110V) 

Power Cord (220V) 

Wire Harness 

Wire Harness (P/O PL 9.2 Item 1 ) 

AC Power Chassis (P/O PL 9.2 

Item 1) 

Delay PWB 



PL9.2 

1 {2-12, 15-18 




J0mf50902 



Parts List 

PL 9.2 



6/02 
5-40 



Prelaunch Training/Review 
DC1 632/2240 



PL 9.3 Electrical Components: 3 of 3 



Item 


Part 


Description 


1 


014K81604 


Developer Block 


2 


162K62110 


Wire Harness 


3 


162K55941 


Wire Harness (Y, M) 


4 


162K55971 


Wire Harness (C, K) 


5 


162K56000 


2nd Wire Harness 


6 


113K82310 


DTS Connector 


7 


162K56031 


DTS Wire Harness 


8 


962K09800 


DC Wire Harness 



PL9.3 




J0mf50903 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-41 



Parts List 

PL 9.3 



PL 10.1 Front Cover 



Item 


Part 


Description 


1 


891E75951 


Logo Plate 


2 


892E78280 


Name Plate (1 6/32) 


- 


892E78290 


Name Plate (22/40) 


3 


802K46050 


Front Cover Assembly (REP 1 4.7) 


4 


- 


Front Cover (P/O PL 10.1 Item 3) 


5 


- 


Magnet (P/O PL 10.1 Item 3) 


6 


- 


Strip (P/O PL 10.1 Item 3) 


7 


042K91990 


Rod Cleaner Assembly 


8 


- 


Rod Cleaner (P/O PL 10.1 Item 7) 


9 


- 


Cleaner Base (P/O PL 10.1 Item 7) 


10 


110E94770 


Front Interlock Switch, Right 
Interlock Switch 


11 


- 


Label (P/O PL 10.1 Item 3) 


12 


802K46060 


Right Cover (REP 14.3) 


13 


- 


Hinge (Not Spared) 




J0mf51001 



Parts List 

PL 10.1 



6/02 
5-42 



Prelaunch Training/Review 
DC1 632/2240 



PL 10.2 Top Covers and Inner Covers 



Item 


Part 


1 


802K29610 


2 


- 


3 


- 


4 


802E12400 


5 


- 


6 


110K11211 


7 


802E12430 


8 


802K45710 


9 


012K94260 



Description 

Top Cover Assembly (REP 14.1) 

Top Cover (P/O PL 10.2 Item 1) 

Stop(P/0 PL 10.2 Item 1) 

Connector Cover 

Panel (P/O PL 10.2 Item 1) 

Main Power Switch 

Fuser Cover (REP 14.8) 

Inner Cover (REP 9.6) 

Link 




J0mf51002 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-43 



Parts List 

PL 10.2 



PL 10.3 Rear Cover 



Item 


Part 


Description 




1 

2 


802E 12480 


Data Plate (Not Spared) 
Blind Cover 


PL10.3 


3 

4 


802K28110 


Rear Cover Assembly 

Rear Cover (P/O PL 1 0.3 Item 3) 

(REP 14.2) 


3 {4,5 


5 


802E 12490 


Blind Cover 




6 

7 

8 
9 


802E12500 
802E27860 


Rear Left Middle Cover (REP 14.4) 

Rear Left Lower Cover (Not 

Spared) 

Front Left Cover (Not Spared) 

Rear Left Upper Cover (REP 14.5) 





rf^ 




r^l/Y 



J0mf51003 



Parts List 

PL 10.3 



6/02 
5-44 



Prelaunch Training/Review 
DC1 632/2240 



PL 11.1 Inverter Transport: 1 of 2 



Item 


Part 


1 


059K16742 


2 


- 


3 


- 


4 


- 


5 


- 



Description 

Inverter Transport (REP 8.5) 
Face-up Tray (Not Spared) 
Cover (Not Spared) 
Front Cover (Not Spared) 
Rear Cover (Not Spared) 



PL11.1 




KPL11.2) 



J0mf51101 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-45 



Parts List 

PL 11.1 



PL 11.2 Inverter 


Item 


Part 


1 


- 


2 


015K45802 


3 


- 


4 


- 


5 


121K23560 


6 


- 


7 


- 


8 


- 


9 


121K82870 


10 


- 


11 


- 


12 


- 


13 


054K17241 


14 


054K17252 


15 


130K93230 


16 


059K16750 


17 


- 


18 


- 


19 


- 


20 


- 


21 


- 


22 


- 


23 


- 


24 


- 


25 


- 


26 


- 


27 


- 


28 


- 


29 


121K22860 


30 


- 


31 


- 


32 


- 


33 


- 


34 


121K22870 


35 


011E10711 


36 


- 


37 


- 



Transport: 2 of 2 

Description 

Cover (Not Spared) 

Clutch Assembly 

Wire Harness (Not Spared) 

Bracket (Not Spared) 

Duplex Gate Solenoid 

Link (Not Spared) 

Bracket (Not Spared) 

Bracket (Not Spared) 

Exit Gate Solenoid 

Link (Not Spared) 

Spring (Not Spared) 

Spring (Not Spared) 

Inverter Chute Assembly 

Exit Gate 

Face-up Sensor 

Roll 

Pinch Roll Assembly (Not Spared) 

Bearing (Not Spared) 

Bearing (Not Spared) 

Bracket (Not Spared) 

Holder (Not Spared) 

Upper Chute (P/O PL 11 .2 Item 1 3) 

Lower Chute (P/O PL 1 1 .2 Item 1 3) 

Duplex Gate (P/O PL 11 .2 Item 13) 

Bracket (P/O PL 11.2 Item 2) 

Gear (P/O PL 11.2 Item 2) 

Gear (P/O PL 11.2 Item 2) 

Spacer (P/O PL 11.2 Item 2) 

Forward Clutch 

Gear (23T) (P/O PL 1 1 .2 Item 2) 

Bearing (P/O PL 11.2 Item 2) 

Shaft (P/O PL 11.2 Item 2) 

Gear (23T) (P/O PL 11.2 Item 2) 

Reverse Clutch 

Interlock Actuator 

Plunger (P/O PL 11.2 Item 5) 

Linear Solenoid (P/O PL 11 .2 Item 

5) 



PL11.2 
2 { 25-35 
13(22-24 

5(36,37 




J0mf51102 



Parts List 

PL 11.2 



6/02 
5-46 



Prelaunch Training/Review 
DC1 632/2240 



PL 12.1 Duplex Transport Assembly: 
1 of 2 

Description 

Duplex Transport Upper Cover (Not 

Spared) 

Duplex Transport Assembly (REP 

8.3) 

One-way Pulley (P/O PL 12.1 Item 

2) 

Bearing (P/O PL 12.1 Item 2) 

Bearing (P/O PL 12.1 Item 2) 

Duplex Transport Roll 

Handle (P/O PL 12.1 Item 2) 

Lower Cover (P/O PL 12.1 Item 2) 

Screw (P/O PL 12.1 Item 2) 

Nylon Washer (P/O PL 12.1 Item 2) 

Cover (P/O PL 12.1 Item 2) 

Spring (P/O PL 12.1 Item 2) 

Duplex Transport (P/O PL 12.1 

Item 2) 

Label (P/O PL 12.1 Item 2) 

Wire Harness (Not Spared) 

Bracket (Not Spared) 

Screw (Not Spared) 



Item 

1 


Part 


2 


059K18714 


3 


- 


4 


_ 


5 


- 


6 


059K23960 


7 


- 


8 


- 


9 


- 


10 


- 


11 


- 


12 


- 


13 


- 


14 


_ 


15 


- 


16 


- 


17 


- 




J0mf51201 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-47 



Parts List 

PL 12.1 



PL 12.2 Duplex Transport Assembly: 
2 of 2 



Item 


Part 


Description 


1 


- 


Spring (Not Spared) 


2 


022K33920 


Pinch Roll 


3 


- 


Cover (Not Spared) 


4 


160K66860 


Duplex Transport PWB 


5 


- 


Wire Harness (Not Spared) 


6 


- 


Bracket (Not Spared) 


7 


130K61250 


Duplex Transport Wait Sensor 


8 


- 


Spring (Not Spared) 


9 


059K23980 


Pinch Roll 


10 


127K29930 


Duplex Transport Motor 


11 


- 


Pulley (20/21T) (Not Spared) 


12 


- 


Pulley (16T) (Not Spared) 


13 


- 


Screw (Not Spared) 


14 


- 


Belt (Not Spared) 


15 


- 


Bearing (Not Spared) 


16 


059K23970 


Wait Roll 


17 


- 


Cover (Not Spared) 


18 


- 


Interlock Switch (Not Spared) 


19 


- 


Inner Chute (Not Spared) 


20 


- 


Outer Chute (Not Spared) 


21 


- 


Belt (Not Spared) 



PL12.2 




J0mf51202 



Parts List 

PL 12.2 



6/02 
5-48 



Prelaunch Training/Review 
DC1 632/2240 



PL 13.1 ESS 



Item 

1 

2 
3 
4 
5 
6 
7 



10 
11 
12 
13 
14 
15 
16 
17 
18 
19 
20 
21 
22 
23 

24 
25 
26 
27 
28 
29 
30 



Part 

160K74231 
160K90840 



537K62680 
133K22400 
160K82222 



121K27751 
962K08641 



538K94570 
160K76650 
537K61180 
127K32920 
537K62670 
133K21100 
133K21200 



Description 

ESS PWB 

MCU PWB (REP 1.2) 

Rear Panel (Not Spared) 

DIMM Cover (Not Spared) 

Top Cover (Not Spared) 

PS-2 ROM 

SDRAM 256MB 

ESS NVM PWB 

ESS Chassis (Not Spared) (REP 

1.3) 

Seal (Not Spared) 

Screw (Not Spared) 

Support (Not Spared) 

Cover (Not Spared) 

HDD (ADJ9.8) 

HDD Harness Assembly 

Bracket (Not Spared) 

Screw (Not Spared) 

Font ROM 

MCU NVM PWB 

MAC ROM 

ESS Fan 

PS-1 ROM 

SDRAM 64MB 

SDRAM 128MB 

Screw (Not Spared) 

Screw (Not Spared) 

Blind Panel (Not Spared) 

Blind Panel (Not Spared) 

Option Panel (Not Spared) 

Screw (Not Spared) 

Fan Guard (Not Spared) 




J0mf51 301 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-49 



Parts List 

PL 13.1 



PL 16.1 Tray 2/3/4 Assembly 



Item 


Part 


Description 


1 


891E49060 


Label (Tray 2) 


2 


050K48170 


Tray 2 (REP 7.9) 


3 


003E23672 


Stop 


4 


014E42850 


Spacer 


5 


- 


Tray 3 Stop (Not Spared) 


6 


- 


Tray 4 Stop (Not Spared) 


7 


050K43130 


Tray 3 (REP 7.6) 


8 


050K43120 


Tray 4 (REP 7.7) 


9 


110K08541 


Tray 2 Paper Size Switch 


10 


110K10880 


Tray 3/4 Paper Size Switch 


11 


059E95930 


Roll 


12 


- 


Shaft (Not Spared) 


13 


- 


Bracket (Not Spared) 


14 


- 


Roll (Not Spared) 


15 


- 


Shaft (Not Spared) 


16 


- 


Max Label (Not Spared) 


17 


891E49510 


Label (Tray 3) 


18 


891E49520 


Label (Tray 4) 


19 


892E28491 


Label 


20 


- 


Instruction Label (Not Spared) 



PL16.1 



2CPL16.2) 




7 (PL16.3) 



J0mf51601 



Parts List 

PL 16.1 



6/02 
5-50 



Prelaunch Training/Review 
DC1 632/2240 



PL 16.2 Tray 2 



Item 


Part 


Description 


1 


892E74500 


Instruction Label 


2 


- 


Pad (Not Spared) 


3 


- 


Max Label (Not Spared) 


4 


- 


Tray (Not Spared) 


5 


- 


Side Guide (Not Spared) 


6 


- 


End Guide (Not Spared) 


7 


- 


Link (Not Spared) 


8 


- 


Stop (Not Spared) 


9 


- 


Spring (Not Spared) 



PL16.2 




J0mf51602 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-51 



Parts List 

PL 16.2 



PL 16.3 Tray 3 



Item 


Part 


Description 


1 


802E23990 


Tray 3 Cover 


2 


- 


Pulley (Not Spared) 


3 


- 


Lift Shaft (Not Spared) 


4 


- 


Bearing (Not Spared) 


5 


- 


Pulley (Not Spared) 


6 


- 


Pulley (Not Spared) 


7 


- 


Cable Guide (Not Spared) 


8 


020E93120 


Tray Cable 


9 


- 


Cable Guide (Not Spared) 


10 


- 


Bottom Plate (Not Spared) 


11 


- 


Pad (Not Spared) 


12 


- 


Side Guide (Not Spared) 


13 


- 


Knob (Not Spared) 


14 


- 


Knob (Not Spared) 


15 


009E26970 


Spring 


16 


- 


Frame (Not Spared) 


17 


- 


Bracket (Not Spared) 


18 


- 


Spacer (Not Spared) 


19 


- 


Spacer (Not Spared) 


20 


- 


Bracket (Not Spared) 


21 


- 


Brake (Not Spared) 


22 


- 


Latch (Not Spared) 


23 


- 


Actuator (Not Spared) 



PL16.3 




19(1/4Pcs.) 



J0mf51603 



Parts List 

PL 16.3 



6/02 
5-52 



Prelaunch Training/Review 
DC1 632/2240 



PL 16.4 Tray 4 



Item 


Part 


Description 


1 


802E23980 


Tray 4 Cover 


2 


- 


Tray Front Frame (Not Spared) 


3 


- 


Lift Shaft (Not Spared) 


4 


- 


Lift Gear (Not Spared) 


5 


- 


Bearing (Not Spared) 


6 


- 


Brake (Not Spared) 


7 


- 


Pulley (Not Spared) 


8 


- 


Cable Guide (Not Spared) 


9 


012E10070 


Tray Cable 


10 


- 


Bottom Plate (Not Spared) 


11 


- 


Pad (Not Spared) 


12 


- 


Side Guide (Not Spared) 


13 


- 


Knob (Not Spared) 


14 


- 


Knob (Not Spared) 


15 


009E26970 


Spring 


16 


- 


Tray Frame (Not Spared) 


17 


- 


Bracket (Not Spared) 


18 


- 


Latch (Not Spared) 


19 


- 


Actuator (Not Spared) 


20 


- 


Shaft (Not Spared) 


21 


059E95920 


Roll 



PL16.4 




J0mf51604 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-53 



Parts List 

PL 16.4 



PL 16.5 Paper 


Item 


Part 


1 


- 


2 


- 


3 


- 


4 


059K21790 


5 


- 


6 


- 


7 


- 


8 


- 


9 


- 


10 


- 


11 


- 


12 


- 


13 


- 


14 


- 


15 


- 


16 


059K18283 


17 


- 


18 


- 


19 


130E82650 


20 


054E18540 


21 


054E18530 


22 


- 



Feeder: 1 of 2 

Description 

Spacer (Not Spared) 

Guide (Not Spared) 

Stop (Not Spared) 

Tray 4 Transport Assembly 

Upper Chute (P/O PL 16.5 Item 4) 

Takeaway Roll (P/O PL 16.5 Item 4) 

Bearing (P/O PL 16.5 Item 4) 

Cover (P/O PL 16.5 Item 4) 

Pinch Roll (P/O PL 16.5 Item 4) 

Bearing (P/O PL 16.5 Item 4) 

Spring (P/O PL 16.5 Item 4) 

Spacer (P/O PL 16.5 Item 4) 

Spacer (P/O PL 16.5 Item 4) 

Lower Chute (P/O PL 16.5 Item 4) 

Bracket (Not Spared) 

Tray 4 Feeder 

Bracket (Not Spared) 

Bracket (Not Spared) 

Tray 4 Feedout Sensor 

Upper Chute 

Lower Chute 

Bracket (Not Spared) 




LQ>^M 17 ■" ^v 

6 l (PL16.11.PL16.12) 



J0mf51605 



Parts List 

PL 16.5 



6/02 
5-54 



Prelaunch Training/Review 
DC1 632/2240 



PL 16.6 Paper Feeder: 2 of 2 



Item 


Part 


Description 


1 


059K18900 


Takeaway Roll 


2 


- 


Bearing (Not Spared) 


3 


- 


Chute (Not Spared) 


4 


- 


Cover (Not Spared) 


5 


130K61510 


Takeaway Sensor 


6 


162K62810 


Wire Harness 


7 


059K15573 


Tray 2 Feeder 


8 


054K18270 


Chute Assembly 


9 


- 


Actuator (P/O PL 16.6 Item 8) 


10 


130E81600 


Tray 3 Feedout Sensor 


11 


- 


Wire Harness (P/O PL 16.6 Item 


12 


- 


Chute (P/O PL 16.6 Item 8) 


13 


054E18520 


Lower Chute 


14 


- 


Bracket (Not Spared) 


15 


- 


Tray 3 Feeder (Not Spared) 



PL16.6 
8(9-12 




15 

(PL16.9.PL16.10) 



J0mf51606 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-55 



Parts List 

PL 16.6 



PL 16.7 Tray 2 Feeder: 1 of 2 



Item 


Part 


Description 


1 


127K23230 


Tray 2 Feed/Lift Motor 


2 


- 


Bracket (Not Spared) 


3 


005K83081 


One-way Clutch 


4 


007K85730 


One-way Gear 


5 


- 


Gear(13T) (Not Spared) 


6 


- 


Bearing (Not Spared) 


7 


- 


Shaft (Not Spared) 


8 


- 


Front Frame (Not Spared) 


9 


- 


Upper Frame (Not Spared) 


10 


- 


Front Chute (Not Spared) 


11 


- 


Actuator (Not Spared) 


12 


130E82190 


Tray 2 Level Sensor 


13 


- 


Wire Harness (Not Spared) 


14 


- 


Support (Not Spared) 


15 


- 


Gear (29T) (Not Spared) 



PL16.7 




J0mf51607 



Parts List 

PL 16.7 



6/02 
5-56 



Prelaunch Training/Review 
DC1 632/2240 



PL 16.8 Tray 2 Feeder: 2 of 2 



Item 


Part Description 


1 


Spring (Not Spared) 


2 


600K78460 Roll Kit (3 Rolls/Kit) 


3 


005K05890 One-way Clutch 


4 


Gear (Not Spared) 


5 


Shaft (Not Spared) 


6 


Chute (Not Spared) 


7 


Spring (Not Spared) 


8 


Friction Clutch (Not Spared) 


9 


Support (Not Spared) 


10 


Holder (Not Spared) 


11 


Spacer (Not Spared) 


12 


Gear (31T) (Not Spared) 


13 


Support (Not Spared) 


14 


Bearing (Not Spared) 


15 


Gear (Not Spared) 


16 


Support (Not Spared) 


17 


Screw (Not Spared) 


18 


Bearing (Not Spared) 


19 


Gear (35T) (Not Spared) 


20 


Spring (Not Spared) 


21 


Lever (Not Spared) 



PL16.8 




J0mf51608 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-57 



Parts List 

PL 16.8 



PL 16.9 Tray 3 Feeder: 1 of 2 



Item 


Part 


Description 


1 


127K23230 


Tray 3 Feed/Lift Motor 


2 


- 


Bracket (Not Spared) 


3 


005K83081 


One-way Clutch 


4 


007K85730 


One-way Gear 


5 


- 


Gear(13T) (Not Spared) 


6 


- 


Bearing (Not Spared) 


7 


- 


Shaft (Not Spared) 


8 


- 


Front Frame (Not Spared) 


9 


- 


Upper Frame (Not Spared) 


10 


- 


Front Chute (Not Spared) 


11 


- 


Actuator (Not Spared) 


12 


130E82190 


Tray 3 Level/No Paper Sensor 


13 


- 


Wire Harness (Not Spared) 


14 


- 


Support (Not Spared) 


15 


- 


Gear (29T) (Not Spared) 



PL16.9 




J0mf51609 



Parts List 

PL 16.9 



6/02 
5-58 



Prelaunch Training/Review 
DC1 632/2240 



PL 16.10 Tray 3 Feeder: 2 of 2 



Item 


Part Description 


1 


Spring (Not Spared) 


2 


600K78460 Roll Kit (3 Rolls/Kit) 


3 


005K05890 One-way Clutch 


4 


Gear (Not Spared) 


5 


Shaft (Not Spared) 


6 


Chute (Not Spared) 


7 


Spring (Not Spared) 


8 


Friction Clutch (Not Spared) 


9 


Support (Not Spared) 


10 


Holder (Not Spared) 


11 


Spacer (Not Spared) 


12 


Gear (31T) (Not Spared) 


13 


Support (Not Spared) 


14 


Bearing (Not Spared) 


15 


Gear (Not Spared) 


16 


Support (Not Spared) 


17 


Screw (Not Spared) 


18 


Bearing (Not Spared) 


19 


Gear (35T) (Not Spared) 


20 


Spring (Not Spared) 


21 


Lever (Not Spared) 



PL16.10 




J0mf51610 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-59 



Parts List 

PL 16.10 



PL 16.11 Tray 4 Feeder: 1 of 2 



Item 


Part 


Description 


1 


127K23230 


Tray 4 Feed/Lift Motor 


2 


- 


Bracket (Not Spared) 


3 


005K83081 


One-way Clutch 


4 


007K85730 


One-way Gear 


5 


- 


Gear(13T) (Not Spared) 


6 


- 


Bearing (Not Spared) 


7 


- 


Shaft (Not Spared) 


8 


- 


Front Frame (Not Spared) 


9 


- 


Upper Frame (Not Spared) 


10 


- 


Front Chute (Not Spared) 


11 


- 


Actuator (Not Spared) 


12 


130E82190 


Tray 4 Level/No Paper Sensor 


13 


162K56590 


Wire Harness 


14 


- 


Support (Not Spared) 


15 


- 


Gear (29T) (Not Spared) 



PL16.11 




j0mf51611 



Parts List 

PL 16.11 



6/02 
5-60 



Prelaunch Training/Review 
DC1 632/2240 



PL 16.12 Tray 4 Feeder: 2 of 2 



Item 


Part Description 


1 


Spring (Not Spared) 


2 


600K78460 Roll Kit (3 Rolls/Kit) 


3 


005K05890 One-way Clutch 


4 


Gear (Not Spared) 


5 


Shaft (Not Spared) 


6 


Chute (Not Spared) 


7 


Spring (Not Spared) 


8 


Friction Clutch (Not Spared) 


9 


Support (Not Spared) 


10 


Holder (Not Spared) 


11 


Spacer (Not Spared) 


12 


Gear (31T) (Not Spared) 


13 


Support (Not Spared) 


14 


Bearing (Not Spared) 


15 


Gear (Not Spared) 


16 


Support (Not Spared) 


17 


Screw (Not Spared) 


18 


Bearing (Not Spared) 


19 


Gear (35T) (Not Spared) 


20 


Spring (Not Spared) 


21 


Lever (Not Spared) 



PL16.12 




J0mf51612 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-61 



Parts List 

PL 16.12 



PL 16.13 Left Cover Assembly 



Item 


Part 


1 


802K25731 


2 


003E53700 


3 


003E53710 


4 


011 E1 0800 


5 


- 


6 


- 


7 


- 


8 


- 


9 


- 


10 


- 


11 


- 


12 


- 


13 


809E28960 


14 


- 


15 


809E28980 


16 


- 


17 


01 5K49470 


18 


- 



Description 

Left Cover Assembly (REP 14.11) 

Shaft 

Hook 

Handle 

Left Cover (P/O PL 16.13 Item 1) 

Support (P/O PL 16.13 Item 1) 

Chute (P/O PL 16.13 Item 1) 

Actuator (P/O PL 16.13 Item 1) 

Spring (P/O PL 16.13 Item 1) 

Bearing (P/O PL 16.13 Item 1) 

Bearing (P/O PL 16.13 Item 1) 

Pinch Roll (P/O PL 16.13 Item 1) 

Spring 

Bracket (P/O PL 16.13 Item 1) 

Spring 

Bracket (P/O PL 16.13 Item 1) 

Interlock Switch 

Bracket (Not Spared) 



PL16.13 
1 (2-16 




J0mf51613 



Parts List 

PL 16.13 



6/02 
5-62 



Prelaunch Training/Review 
DC1 632/2240 



PL 16.14 Tray 3/4 Lift Gear Assembly 



Item 


Part 


Description 


1 


- 


Transport Guide 


2 


01 5K49460 


Gear Assembly (Tray 3) 


3 


01 5K49450 


Gear Assembly (Tray 4) 


4 


007E66080 


Lift Gear 


5 


011K96790 


Coupling 


6 


- 


Bearing 



PL16.14 




J0mf51614 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-63 



Parts List 

PL 16.14 



PL 16.15 Electrical Components and 
Casters 



Item 


Part 


Description 


1 


007E66060 


Gear (23/46T) 


2 


007E66070 


Gear (46T) 


3 


007E66050 


Gear (33T) 


4 


127K31840 


Takeaway Motor 2 


5 


127K36020 


Takeaway Motor 1 


6 


- 


Left Coupling (Not Spared) 


7 


- 


Right Coupling (Not Spared) 


8 


- 


Foot (Not Spared) 


9 


017K92350 


Caster 


10 


017K92360 


Caster 


11 


- 


Bracket (Not Spared) 


12 


160K85980 


Tray Module PWB 



PL16.15 




J0mf51615 



Parts List 

PL 16.15 



6/02 
5-64 



Prelaunch Training/Review 
DC1 632/2240 



PL 16.16 Covers 


Item Part 


Description 


1 


Right Cover (Not Spared) 


2 802E23950 


Front Upper Cover 


3 802E23960 


Front Lower Cover 


4 802K36580 


Rear Cover (REP 14.9) 


5 802E23930 


Left Lower Cover (REP 14.12) 



PL16.16 




J0mf51616 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-65 



Parts List 

PL 16.16 



PL 17.1 Finisher 



Item 


Part 


Description 


1 


802K36650 


Gate Assembly 


2 


801K02480 


H-Transport Assembly (REP 12.1) 


3 


- 


Stapler Finisher (Not Spared) 


4 


003K12090 


Thumbscrew 


5 


— 


Rack Assembly (Not Spared) (REP 

12.19) 


6 


- 


Right Cover (Not Spared) 


7 


— 


Stacker Tray (Not Spared) (REP 
12.20) 


8 


026E93560 


Screw 


9 


- 


Bracket (Not Spared) 


10 


- 


Front Bracket (Not Spared) 


11 


- 


Stud Screw (Not Spared) 


12 


- 


Rear Bracket (Not Spared) 



PL17.1 



2 (PL17.3.PL17.4) 




40/2Pcs.) 



j0mf51 701 



Parts List 

PL 17.1 



6/02 
5-66 



Prelaunch Training/Review 
DC1 632/2240 



PL 17.2 Gate Assembly 



Item 


Part Description 


1 


Gate Cover (Not Spared) 


2 


Bearing (Not Spared) 


3 


Chute (Not Spared) 


4 


In Gate (Not Spared) 


5 


In Gate Lever (Not Spared) 


6 


Gate Bracket (Not Spared) 


7 


Link Assembly (Not Spared) 


8 


Lever Assembly (Not Spared) 


9 


Lever (Not Spared) 


10 


Spring (Not Spared) 


11 


Gate Link (Not Spared) 


12 


120E20700 Actuator 


13 


Bearing (Not Spared) 


14 


Spring (Not Spared) 


15 


Exit Chute (Not Spared) 



PL17.2 




2 J0mf51702 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-67 



Parts List 

PL 17.2 



PL 17.3 H-Transport Assembly: 1 of 2 



Item 


Part 


Description 


1 


802K28600 


H-Transport Cover Assembly 


2 


— 


H-Transport Cover (P/O PL 1 7.3 
Item 1) 


3 


- 


Screw (P/O PL 17.3 Item 1) 


4 


121E91450 


Magnet 


5 


- 


Guide (P/O PL 17.3 Item 1) 


6 


- 


Roll (P/O PL 17.3 Item 1) 


7 


- 


Spring Plate (P/O PL 17.3 Item 1) 


8 


- 


Stop (Not Spared) 


9 


802K28590 


Entrance Upper Cover Assembly 


10 


— 


Entrance Upper Cover (P/O PL 
17.3 Item 9) 


11 


- 


Roll (P/O PL 17.3 Item 9) 


12 


- 


Spring Plate (P/O PL 17.3 Item 9) 


13 


- 


Roll (Not Spared) 


14 


- 


Front Cover (Not Spared) 


15 


- 


Upper Rear Cover (Not Spared) 


16 


- 


Rear Cover (Not Spared) 


17 


- 


Exit Guide (Not Spared) 


18 


- 


Stop (Not Spared) 


19 


- 


Support (Not Spared) 



PL17.3 

1 { 2-7 

9J10-12 




Parts List 

PL 17.3 



6/02 
5-68 



Prelaunch Training/Review 
DC1 632/2240 



PL 17.4 H-Transport Assembly: 2 of 2 


Item 


Part 


Description 


1 


- 


H-Transport Roll (In) (Not Spared) 


2 


- 


H-Transport Roll (Out) (Not Spared) 


3 


023E20020 


H-Transport Belt (REP 12.2) 


4 


- 


Roll (Not Spared) 


5 


- 


Support (Not Spared) 


6 


- 


Bearing (Not Spared) 


7 


802E30150 


Harness Guide 


8 


802E30140 


Cover 


9 


130K93360 


Entrance Sensor (REP 12.3) 


10 


130E82970 


Top Tray Full Sensor 


11 


130K62360 


Exit Sensor 


12 


802K28580 


Gate In Solenoid Assembly 


13 


- 


Gate In Solenoid (P/O PL 1 7.4 Item 

12) 

Spring (P/O PL 17.4 Item 12) 


14 


- 


15 


- 


Link (P/O PL 17.4 Item 12) 


16 


- 


Cover (P/O PL 17.4 Item 12) 


17 


- 


Ground Wire (P/O PL 17.4 Item 12) 


18 


162K69070 


Wire Harness 


19 


162K69060 


Wire Harness 


20 


- 


Bearing (Not Spared) 


21 


007E67850 


Gear (37T) 


22 


007E67860 


Gear (30T) 


23 


007E67870 


Gear (26T) 


24 


130E82540 


Interlock Sensor 


25 


- 


Bracket (Not Spared) 


26 


038E24650 


Paper Guide 


27 


022E88210 


Roll 


28 


- 


Bracket (Not Spared) 


29 


- 


Frame (Not Spared) 


30 


- 


Bracket (Not Spared) 


31 


- 


Screw (Not Spared) 




j0mf51 704 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-69 



Parts List 

PL 17.4 



PL 17.5 Covers 



Item 


Part 


Description 


1 


802E28560 


Front Cover 


2 


802E28520 


Rear Cover 


3 


802E28530 


Top Cover 


4 


802E28540 


Left Cover 


5 


802E28550 


Front Cover Door 


6 


802E28570 


Left Panel 


7 


- 


Hinge (Not Spared) 


8 


121E88470 


Magnet 



PL17.5 




J0mf51705 



Parts List 

PL 17.5 



6/02 
5-70 



Prelaunch Training/Review 
DC1 632/2240 



PL 17.6 Top Cover and Eject Roll 

Item Part 

1 802K28570 



2 
3 

4 

5 

6 

7 

8 

9 

10 
11 

12 
13 
14 
15 
16 
17 
18 
19 
20 
21 
22 
23 
24 
25 
26 
27 
28 



830E81670 



022K62610 



130K61920 



130E82530 



120E20970 
005E16220 
005E16510 
007E67760 

007K86910 
013E20240 

006K21730 



Description 

Top Cover 

Arm (Not Spared) 

Bearing (Not Spared) 

Bracket (Not Spared) 

Spring (Not Spared) 

Support 

Bracket (Not Spared) 

Shaft (Not Spared) 

Eject Pinch Roll 

Eject Chute (Not Spared) 

Stack Height Sensor Assembly 

(REP 12.5) 

Actuator (P/O PL 17.6 Item 11) 

Bracket (P/O PL 17.6 Item 11) 

Stack Height Sensor 

Shaft (Not Spared) 

Link (Not Spared) 

Actuator 

Clutch 

Collar 

Gear (28Z) 

Eject Roll (P/O PL 17.6 Item 25) 

Gear (20T) 

Bearing 

Eject Shaft (P/O PL 17.6 Item 25) 

Eject Roll Assembly (REP 12.6) 

Link (Not Spared) 

Static Eliminator (Not Spared) 

Collar (Not Spared) 




BA 
J0mf51706 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-71 



Parts List 

PL 17.6 



PL 17.7 Paper Transportation: 1 of 2 



Item 


Part 


Description 


1 


120E20690 


Actuator 


2 


121K24610 


Decurler Cam Clutch 


3 


008E94070 


Cam 


4 


- 


Shaft (Not Spared) 


5 


- 


Bearing (Not Spared) 


6 


031E94030 


Arm 


7 


059K20210 


Decurler Roll (REP 12.7) 


8 


007E67740 


Gear (40Z/20T) 


9 


007E67750 


Gear (40Z) 


10 


007E72090 


Gear(18Z/21T) 


11 


- 


Shaft (Not Spared) 


12 


- 


Bearing (Not Spared) 


13 


007E67730 


Gear (23Z/52T) 


14 


023E20160 


Belt (REP 12.9) 


15 


423W29655 


Belt 


16 


127K32840 


Finisher Drive Motor (REP 12.8) 


17 


- 


Bracket (Not Spared) 



PL17.7 




J0mf51707 



Parts List 

PL 17.7 



6/02 
5-72 



Prelaunch Training/Review 
DC1 632/2240 



PL 17.8 Paper Transportation: 2 of 2 



Item 


Part 


Description 


1 


015K52280 


Cam Bracket Assembly 


2 


020E34970 


Pulley 


3 


007E67780 


Gear(15Z) 


4 


423W28054 


Belt 


5 


007E67810 


Gear (30Z) 


6 


- 


Collar (P/O PL 17.8 Item 1) 


7 


007E67790 


Gear Pulley 


8 


127K32870 


Eject Motor 


9 


007E67800 


Cam Gear 


10 


007E67770 


Gear (42Z/27Z) 


11 


121K24620 


Set Clamp Solenoid 


12 


- 


Bracket (P/O PL 17.8 Item 1 


13 


- 


Wire Harness (Not Spared) 


14 


130E82540 


Home Sensor 


15 


- 


Plate (Not Spared) 


16 


- 


Stop (P/O PL 17.8 Item 1) 


17 


- 


Spring (Not Spared) 


18 


- 


Bracket (Not Spared) 



PL17.8 

1 {2- 12, 14, 16 




j0mf51 708 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-73 



Parts List 

PL 17.8 



PL 17 


.9 Stapler 


Unit 


Item 


Part 


Description 


1 


041 K94260 


Carriage Assembly 


2 


- 


Bracket (P/O PL 17.9 Item 1) 


3 


127K32860 


Staple Move Motor 


4 


- 


Gear (P/O PL 17.9 Item 1) 


5 


130E82530 


Staple Sensor 


6 


- 


Roll (P/O PL 17.9 Item 1) 


7 


— 


Staple Front Corner Sensor (Not 
Spared) 


8 


- 


Plate (Not Spared) 


9 


001E59600 


Rail (REP 12.10) 


10 


029K91990 


Stapler Assembly (REP 12.11) 


11 


- 


Stapler (P/O PL 17.9 Item 10) 


12 


- 


Cartridge (P/O PL 17.9 Item 10) 


13 


- 


Bracket (Not Spared) 


14 


962K07440 


Stapler Harness 




Parts List 

PL 17.9 



6/02 
5-74 



Prelaunch Training/Review 
DC1 632/2240 



PL 17.10 Compiler Tray Assembly 



Item 


Part 


1 


050K43880 


2 


127K32850 


3 


- 


4 


130E82530 


5 


- 


6 


- 


7 


- 


8 


- 


9 


- 


10 


130E82540 


11 


- 


12 


038E24410 


13 


809E33600 


14 


- 



15 



Description 

Compiler Tray Assembly (REP 

12.12) 

Front/Rear Tamper Motor 

Plate (P/O PL 17.10 Item 1) 

Front/Rear Tamper Home Sensor 

Rack (P/O PL 17.10 Item 1) 

Actuator (P/O PL 17.10 Item 1) 

Tamper (P/O PL 17.10 Item 1) 

Finger (P/O PL 17.10 Item 1) 

Spring (P/O PL 17.10 Item 1) 

Compiler Paper Sensor 

Actuator (P/O PL 17.10 Item 1) 

Paper Guide 

Spring 

Wire Harness (P/O PL 17.10 Item 

1) 

End Guide (P/O PL 17.10 Item 1) 



PL17.10 
1 {2-15 




J0mf51710 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-75 



Parts List 

PL 17.10 



PL 17.11 Elevator 



Item 


Part 


Description 


1 


127K33420 


Stacker Motor Assembly (REP 
12.13) 


2 


015K50680 


Front Elevator Bracket (REP 1J 


3 


019E50340 


Clamp 


4 


- 


Bearing (Not Spared) 


5 


007E67830 


Rear Gear 


6 


- 


Actuator (Not Spared) 


7 


007E67840 


Front Gear 


8 


- 


Bracket (Not Spared) 


9 


007E67820 


Rack 


10 


- 


Tray Guide (Not Spared) 


11 


015K51640 


Paper Stack Sensor Assembly 


12 


130E82530 


Sensor 


13 


- 


Actuator (P/O PL 17.11 Item 11 


14 


- 


Bracket (P/O PL 17.11 Item 11) 


15 


- 


Spring (P/O PL 17.11 Item 11) 


16 


- 


Cover (P/O PL 17.11 Item 11) 


17 


- 


Bracket (Not Spared) 


18 


- 


Sensor (Not Spared) 


19 


- 


Bracket (Not Spared) 


20 


- 


Pin (Not Spared) 


21 


- 


Bearing (Not Spared) 


22 


- 


Shaft (Not Spared) 


23 


- 


Rivet (Not Spared) 



PL17.11 
11 {12-16 




j0mf51711 



Parts List 

PL 17.11 



6/02 
5-76 



Prelaunch Training/Review 
DC1 632/2240 



PL 17.12 Exit Assembly 


Item 


Part 


Description 


1 


007E72080 


Gear (48Z) 


2 


- 


Bearing (Not Spared) 


3 


006K21720 


Exit Shaft 


4 


- 


Collar (Not Spared) 


5 


007E72070 


Gear(32Z/18T) 


6 


- 


Bearing (Not Spared) 


7 


006K21970 


Paddle Gear Shaft (REP 12.15) 


8 


013E20250 


Paddle Bearing 


9 


- 


Lower Exit Chute (Not Spared) 


10 


022K65880 


Pinch Roll 


11 


- 


Pinch Roll (Not Spared) 


12 


- 


Pinch Roll (Not Spared) 


13 


- 


Upper Exit Chute (Not Spared) 


14 


130K94740 


Compiler Entrance Sensor 


15 


- 


Spring Plate (Not Spared) 


16 


- 


Bracket (Not Spared) 


17 


105E11320 


Static Eliminator 



PL17.12 




J0mf51712 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-77 



Parts List 

PL 17.12 



PL 17.13 Electrical Components 



Item 


Part 


Description 


1 

2 


160K76660 


PWB Cover (Not Spared) 
Finisher PWB (REP 12.16) 


3 


537K64070 


ROM 


4 
5 


962K10120 


PWB Bracket (Not Spared) 
DC Harness 


6 


962K10130 


Cable 


7 


110E97990 


Top Cover/Front Door Interlock 
Switch 


8 
9 

10 
11 


130E82530 


Docking Interlock Switch 
Spring Plate (Not Spared) 
Bracket (Not Spared) 
Plate (Not Spared) 



PL17.13 




J0mf51713 



Parts List 

PL 17.13 



6/02 
5-78 



Prelaunch Training/Review 
DC1 632/2240 



PL 17.14 Rack 


Item 


Part 


1 


802K36660 


2 


- 


3 


003K12090 


4 


- 


5 


- 


6 


- 


7 


- 


8 


001E60050 


9 


017E94660 


10 


- 


11 


802K36670 


12 


- 


13 


- 


14 


- 


15 


015E77040 



Assembly 



Description 

Front Rack Assembly 

Front Cover (P/O PL 1 7.1 4 Item 1 ) 

Knob Screw 

Screw (P/O PL 17.14 Item 1,PL 

17.14 Item 11) 

Bracket (P/O PL 1 7.1 4 Item 1 ,PL 

17.14 Item 11) 

Stop (P/O PL 17.14 Item 1,PL 

17.14 Item 11) 

Spring Plate (P/O PL 17.14 Item 

1,PL 17.14 Item 11) 

Rail 

Foot 

Front Rack (P/O PL 17.14 Item 1) 

Rear Rack Assembly 

Rear Cover (P/O PL 17.14 Item 11) 

Rear Rack (P/O PL 17.14 Item 11) 

Bracket (P/O PL 17.14 Item 11) 

Bottom Plate 



PL17.14 
1 {2-10 
11 {3-9,12-14 




J0mf51714 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-79 



Parts List 

PL 17.14 



PL 18.2 Control Panel 



Item 


Part 


Description 


1 


802K46022 


Control Panel Assembly 


2 


— 


Control Panel Housing (P/O PL 
18.2 Item 1) 


3 


- 


Panel Housing (P/O PL 18.2 Item 

1 \ 


4 


123K94020 


') 
Display 


5 


110K11100 


Touch Panel (ADJ 9.13) 


6 


160K75800 


VR PWB (ADJ 9.13) 


7 


- 


Screw (P/O PL 18.2 Item 1) 


8 


- 


Right Panel (P/O PL 18.2 Item 1) 


9 


- 


Center Panel (P/O PL 18.2 Item 1 


10 


802E32860 


One-touch Panel 


11 


160K77367 


Ul PWB Assembly (ADJ 9.13) 


12 


— 


Ul PWB Base (P/O PL 18.2 Item 
1,PL 18.2 Item 11) 


13 


- 


ROM (P/O PL 18.2 Item 11) 


14 


- 


ROM (P/O PL 18.2 Item 11) 


15 


- 


Bracket (P/O PL 18.2 Item 1) 


16 


- 


Plate (P/O PL 18.2 Item 1) 


17 


- 


Adjust Pen (P/O PL 18.2 Item 1) 


18 


- 


Bracket (P/O PL 18.2 Item 1) 



PL18.2 



I {2-18 
2(3-6,17,18 

II {12-14 




J0mf51802 



Parts List 

PL 18.2 



6/02 
5-80 



Prelaunch Training/Review 
DC1 632/2240 



PL 18.3 Platen Glass 


Item Part 


Description 


1 


Right Side Plate (Not Spared) 


2 090K92820 


Platen Glass (REP 6.2) 


3 050K43070 


Registration Gate 


4 


IPS Cover (Not Spared) 


5 


Screw (Not Spared) 


6 068E10210 


Platen Glass Support 


7 160K66429 


ITT/IPS PWB 


8 117E20840 


Cable 




J0mf51803 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-81 



Parts List 

PL 18.3 



PL 18.4 CCD PWB, Sensor 



Item 


Part 


Description 


1 


127K33160 


IPS Fan 


2 


- 


Bracket (Not Spared) 


3 


130K62000 


NT Registration Sensor 


4 


- 


Bracket (Not Spared) 


5 


110K08471 


Platen Open Switch 


6 


130K62580 


Platen Angle Sensor Assembly 


7 


107E08680 


Platen Angle Sensor 


8 


- 


Bracket (P/O PL 18.4 Item 6) 


9 


- 


Support (P/O PL 18.4 Item 6) 


10 


- 


Actuator (P/O PL 18.4 Item 6) 


11 


009E55450 


Spring 


12 


604K05330 


Lens Kit (Kit contains CCD PWB 
and Lens Assembly) (REP 6.4) 
(ADJ 9.7) 


13 


117K30960 


CCD Flat Cable 


14 


- 


Lens Cover (Not Spared) 


15 


- 


APS Sensor (Not Spared) 


16 


- 


Bracket (Not Spared) 


17 


- 


Screw (Not Spared) 


18 


962K05910 


AC Harness (220V) 


- 


962K05900 


AC Harness (120V) 


19 


105E10480 


NT LVPS (100V) 


- 


105E10650 


NT LVPS (220V) 


20 


019E49830 


Clamp 


21 


- 


Plate (Not Spared) 




J0mf51804 



Parts List 

PL 18.4 



6/02 
5-82 



Prelaunch Training/Review 
DC1 632/2240 



PL 18.5 Carriage Cable/ Motor 


Item 


Part 


Description 


1 


063E94040 


Tape 


2 


- 


Frame (Not Spared) 


3 


020E99590 


Pulley 


4 


012K94110 


Front Carriage Cable (REP 6.11 


5 


012K94120 


Rear Carriage Cable (REP 6.11 


6 


063E94050 


Tape 


7 


020E32740 


Timing Pulley 


8 


023E19300 


Belt 


9 


- 


Capstan Shaft (Not Spared) 


10 


020E25090 


Capstan Pulley 


11 


413W10950 


Bearing 


12 


009E62830 


Spring 


13 


017E92060 


Foot 


14 


- 


Pulley (Not Spared) 


15 


- 


Stop Bracket (Not Spared) 


16 


127K32140 


Carriage Motor (REP 6.12) 



PL18.5 




J0mf51805 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-83 



Parts List 

PL 18.5 



PL 18.6 Full/Half Rate Carriage 


Item 


Part 


Description 


1 


- 


Harness Guard (Not Spared) 


2 


041 K94050 


Full-Rate Carriage Assembly (ADJ 
6.1) 


3 


— 


Full-Rate Carriage (P/O PL 18.6 
Item 2) 


4 


117E19780 


Lamp Wire Harness (REP 6.1 4) 


5 


- 


No 1 Motor (P/O PL 18.6 Item 2) 


6 


062E10040 


No 1 Mirror 


7 


019E50400 


Clip 


8 


118E12090 


Insulator 


9 


122E92030 


Exposure Lamp (REP 6.13) 


10 


105E10510 


Lamp Ballast PWB 


11 


- 


Pad (P/O PL 18.6 Item 2) 


12 


041K94271 


Half-Rate Carriage Assembly (ADJ 

6.1) 


13 


062K10730 


No 2 and No 3 Mirror 


14 


— 


No 2, No 3 Mirror (P/O PL 1 8.6 Item 
2.PL18.6 Item 13) 


15 


— 


Damper (P/O PL 18.6 Item 2, PL 
18.6 Item 13) 


16 


- 


Single Clip (P/O PL 18.6 Item 12) 


17 


809E09110 


Clip 


18 


— 


Half-Rate Carriage (P/O PL 18.6 
Item 12) 


19 


- 


Shaft (P/O PL 18.6 Item 12) 


20 


004E06560 


Damper Bearing 


21 


- 


Pulley (P/O PL 18.6 Item 12) 


22 


020K94970 


Pulley 


23 


- 


Harness Pulley (P/O PL 18.6 Item 
1?1 


24 


019E49470 


Pad 



PL18.6 



BA^^^__^21 




J0mf51806 



Parts List 

PL 18.6 



6/02 
5-84 



Prelaunch Training/Review 
DC1 632/2240 



PL 19.1 Rack 

Part 



Item 
1 

2 
3 

4 



017E94710 
017E94730 
017E94700 



Description 

Rack (Not Spared) 
Swivel Caster 
Stationary Caster 
Foot 



PL19.1 




(2PLACES) 



J0mf51901 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-85 



Parts List 

PL 19.1 



PL 20.1 Front/Rear Cover, Entrance 
Tray 

Description 

Rear Cover Assembly (REP 5.18) 

Rear Cover (P/O PL 20.1 Item 1 ) 

LED PWB 

Wire Harness (P/O PL 20.1 Item 1) 

Label (Display) 

Entrance Tray Assembly 

Entrance Tray (P/O PL 20.1 Item 6) 

Plate (P/O PL 20.1 Item 6) 

Spring Plate 

Document Guide 

Front Cover 

Label (Not Spared) 

Size Label 

Clamp (Not Spared) 



Item 


Part 


1 


048K76180 


2 


- 


3 


140K60480 


4 


- 


5 


891E65180 


6 


050K36410 


7 


- 


8 


- 


9 


009E26870 


10 


032K93800 


11 


048E64200 


12 


- 


13 


891E65210 


14 


- 



1 {2-5 
6 { 7-10 




J0mf52001 



Parts List 

PL 20.1 



6/02 
5-86 



Prelaunch Training/Review 
DC1 632/2240 



PL 20.2 Top Cover, Registration Gate 
Solenoid 



Item 


Part 


1 


054K13621 


2 


- 


3 


015E48890 


4 


809E11130 


5 


059K11880 


6 


015E48900 


7 


110K07850 


8 


- 


9 


- 


10 


121K93870 


11 


- 


12 


110K07870 


13 


121K22710 


14 


_ 


15 


- 


16 


- 


17 


019E93510 


18 


- 



Description 

Top Cover Assembly 

Top Cover (P/O PL 20.2 Item 1) 

Front Magnet Plate 

Spring 

Pinch Roll 

Front Magnet Plate 

Top Cover Interlock Switch (Rear) 

Bracket (Not Spared) 

Screw (Not Spared) 

Magnet 

Bracket (Not Spared) 

Top Cover Interlock Switch (Front) 

Registration Gate Solenoid 

Assembly (REP 5.2) 

Bracket (P/O PL 20.2 Item 13) 

Registration Gate Solenoid (P/O PL 

20.2 Item 13) 

Registration Arm (P/O PL 20.2 Item 

13) 

Push Rivet 

Label (Not Spared) 



PL20.2 



1 {2-6 
13(14-16 "g 




5(1/4Pcs.) 



4(1/2Pcs.) 



J0mf52002 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-87 



Parts List 

PL 20.2 



PL 20.3 Counterbalance, DADF 
Control PWB 



Item 


Part 


Description 


1 


003K91881 


Thumbscrew 


2 


036K91431 


Right Counterbalance (REP 5.3) 


3 


— 


Counterbalance (P/O PL 20.3 Item 
2) (ADJ 5.2 ADJ 5.3 ADJ 5.4) 


4 


— 


DADF Interlock Switch (P/O PL 
20.3 Item 2) 


5 


- 


Screw (P/O PL 20.3 Item 2) 


6 


- 


Screw (Not Spared) 


7 


- 


Wire Harness (Not Spared) 


8 


036K91420 


Left Counterbalance (REP 5.3.ADJ 
5.2 ADJ 5.3 ADJ 5.4) 


9 


- 


PWB Support (Not Spared) 


10 


- 


PWB Support (Not Spared) 


11 


- 


Screw (Not Spared) 


12 


- 


Safety Bracket (Not Spared) 


13 


- 


PWB Support (Not Spared) 


14 


160K83080 


DADF Control PWB Assembly 
(W/ROM) (REP 5.4) 


15 


- 


ROM (P/O PL 20.3 Item 14) 


16 


— 


DADF Control PWB (P/O PL 20.3 
Item 14) 


17 


162K64340 


Wire Harness 



PL20.3 




J0mf52003 



Parts List 

PL 20.3 



6/02 
5-88 



Prelaunch Training/Review 
DC1 632/2240 



PL 20.4 Document Feed Chute 
(Upper), Feed Motor 



Item 


Part 


Description 


1 


054K13600 


Document Feed Upper Chute 
Assembly 


2 


059K11840 


Feed Roll Assembly 


3 


- 


Upper Baffle (P/O PL 20.4 Item 1) 


4 


- 


Drive Shaft (P/O PL 20.4 Item 1) 


5 


- 


Gear (P/O PL 20.4 Item 1) 


6 


013E92760 


Bearing 


7 


- 


Gear (P/O PL 20.4 Item 1) 


8 


600K90370 


Roll Kit (2 Rolls/Kit) (REP 5.6 REP 
5.7) 


9 


012E09750 


Link 


10 


413W77359 


Bearing 


11 


— 


Gear (P/O PL 20.4 Item 1 ,PL 20.4 
Item 2) 


12 


— 


Gear (P/O PL 20.4 Item 1 ,PL 20.4 
Item 2) 


13 


— 


Feed Shaft (P/O PL 20.4 Item 1 ,PL 
20.4 Item 2) 


14 


— 


Nudger Shaft (P/O PL 20.4 Item 
1, PL 20.4 Item 2) 


15 


— 


Gear (P/O PL 20.4 Item 1 ,PL 20.4 
Item 2) 


16 


— 


Housing (P/O PL 20.4 Item 1 ,PL 
20.4 Item 2) 


17 


802K08320 


Inner Cover Assembly 


18 


- 


Inner Cover (P/O PL 20.4 Item 1 7) 


19 


- 


Pad (P/O PL 20.4 Item 17) 


20 


- 


Pulley (Not Spared) 


21 


023E20000 


Belt 


22 


- 


Bearing (Not Spared) 


23 


127K32680 


Feed Motor Assembly (REP 5.5) 


24 


- 


Feed Motor (P/O PL 20.4 Item 23) 


25 


— 


Motor Bracket (P/O PL 20.4 Item 
23) 


26 


- 


Damper (P/O PL 20.4 Item 23) 


27 


- 


Pulley (P/O PL 20.4 Item 23) 


28 


- 


Screw (Not Spared) 



PL20.4 




J0mf52004 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-89 



Parts List 

PL 20.4 



PL 20.5 Document Feed Chute 
(Lower) 

Description 

Lower Chute Assembly (REP 5.8) 

Lower Chute (P/O PL 20.5 Item 1) 

Spring (P/O PL 20.5 Item 1) 

Retard Roll (REP 5.9) 

Spring Plate (P/O PL 20.5 Item 1 ) 

Arm (P/O PL 20.5 Item 1) 

Guard 

Arm Shaft (P/O PL 20.5 Item 1) 

Retard Shaft (P/O PL 20.5 Item 1 ) 

Set Gate (Not Spared) 

Document Sensor, Registration 

Sensor (REP 5.11) 

Set Gate Solenoid Assembly (REP 

5.10) 

Bracket (P/O PL 20.5 Item 12) 

Set Gate Solenoid (P/O PL 20.5 

Item 12) 

Spring (P/O PL 20.5 Item 12) 

Bracket (Not Spared) 

Size Sensor 1 (Rear), Size Sensor 

2 (Front) (REP 5.12) 

Bracket (Not Spared) 



Item 


Part 


1 


054K18780 


2 


- 


3 


- 


4 


059K19720 


5 


- 


6 


- 


7 


055K19260 


8 


- 


9 


- 


10 


- 


11 


130K60600 


12 


121K22690 


13 


_ 


14 


- 


15 


_ 


16 


- 


17 


130E80890 



PL20.5 




r\ J0mf52005 



Parts List 

PL 20.5 



6/02 
5-90 



Prelaunch Training/Review 
DC1 632/2240 



PL 20.6 DADF 

Item Part 

1 127K32690 



9 

10 
11 
12 
13 
14 
15 
16 
17 
18 
19 



007K86700 
023E19990 



023E20010 
020E21050 

020K91230 
022K37080 
022K37070 
023E12230 



Belt Motor, Duplex Roll 

Description 

DADF Belt Motor Assembly (REP 

5.13) 

DADF Belt Motor (P/O PL 20.6 Item 

1) 

Damper (P/O PL 20.6 Item 1) 

Bracket (P/O PL 20.6 Item 1) 

Pulley (P/O PL 20.6 Item 1) 

Screw (Not Spared) 

Gear Pulley 

Belt 

Spacer (Not Spared) 

Tension Roll (Not Spared) 

Spacer (Not Spared) 

Tension Roll (Not Spared) 

Belt 

Pulley 

Bearing (Not Spared) 

Pulley 

Upper Duplex Roll 

Lower Duplex Roll 

Belt 




J0mf52006 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-91 



Parts List 

PL 20.6 



PL 20.7 Duplex Chute 



Item 


Part 


1 


- 


2 


- 


3 


130K60600 


4 


050K46690 


5 


- 


6 


- 


7 


054K18790 


8 


- 


9 


- 


10 


121E90640 



Description 

Duplex Chute (Not Spared) 

Wire Harness (Not Spared) 

Duplex Sensor (REP 5.14) 

Gate 

Screw (Not Spared) 

Screw (Not Spared) 

Lower Chute Assembly 

Lower Chute (P/O PL 20.7 Item 7) 

Pinch Roll (P/O PL 20.7 Item 7) 

Open Switch Magnet 



PL20.7 




7 {8-10 



J0mf52007 



Parts List 

PL 20.7 



6/02 
5-92 



Prelaunch Training/Review 
DC1 632/2240 



PL 20.8 Registration Roll 



Item 


Part 


Description 


1 


- 


Spacer (Not Spared) 


2 


007K81120 


Gear Pulley 


3 


- 


Bearing (Not Spared) 


4 


059K19750 


Registration Roll 


5 


012E09760 


Link 


6 


809E04210 


Rear Spring 


7 


005E80250 


Clip 


8 


013E94561 


Bearing 


9 


008E90941 


Rear Cam 


10 


012E91960 


Link 


11 


022K38040 


Registration Pinch Roll (REP 5.15) 


12 


008E90931 


Front Cam 


13 


809E04220 


Front Spring 


14 


009E28570 


Spring 


15 


050K46690 


Gate 


16 


009E28560 


Spring 



PL20.8 



PL20.6 




J0mf52008 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-93 



Parts List 

PL 20.8 



PL 20.9 Exit Motor/Chute 



Item 


Part 


Description 


1 


127K32640 


Exit Motor Assembly (REP 5.16) 


2 


- 


Exit Motor (P/O PL 20.9 Item 1 ) 


3 


- 


Pulley (P/O PL 20.9 Item 1) 


4 


- 


Damper (P/O PL 20.9 Item 1) 


5 


- 


Bracket (P/O PL 20.9 Item 1 ) 


6 


- 


Spacer (Not Spared) 


7 


023E20000 


Belt 


8 


020E93230 


Pulley 


9 


- 


Bearing (Not Spared) 


10 


059K11860 


Exit Roll 


11 


130K60600 


DADF Exit Sensor 


12 


- 


Bracket (Not Spared) 


13 


- 


Plate (P/O PL 20.9 Item 17) 


14 


105E06910 


Static Eliminator 


15 


- 


Exit Upper Chute (Not Spared) 


16 


055K26060 


Document Guard 


17 


054K13081 


Lower Exit Chute 


18 


- 


Exit Lower Chute (P/O PL 20.9 Item 

17) 

Sensor Pad (P/O PL 20.9 Item 17) 


19 


- 


20 


059K11821 


Pinch Roll 



PL20.9 

1 {2-5 

17 {13, 18-20 




Parts List 

PL 20.9 



6/02 
5-94 



Prelaunch Training/Review 
DC1 632/2240 



PL 20.10 Document Transport, Platen 
Belt 



Item 

1 

2 
3 

4 

5 

6 

7 

8 

9 

10 
11 
12 
13 
14 
15 
16 
17 



Part 



007E66340 

013E80970 
049E91070 
022K3971 
023E15690 



Description 

Document Transport (Not Spared) 

(REP 5.17) 

Static Eliminator (Not Spared) 

Gear 

Collar (Not Spared) 

Bearing 

Tension Plate 

Idler Roll 

Platen Belt (REP 5.19) 

Drive Roll (Not Spared) 

Belt Guide (Not Spared) 

Belt Guide (Not Spared) 

Transport Frame (Not Spared) 

Deflector (Not Spared) 

Pinch Roll (Not Spared) 

Pinch Roll (Not Spared) 

Pinch Roll (Not Spared) 

Damper (Not Spared) 



PL20.10 




J0mf52010 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-95 



Parts List 

PL 20.10 



PL 20.11 Platen Glass, Registration 


Gate, Exit Tray 




Item Part 


Description 


1 090K92820 


Platen Glass (REP 6.2) 


2 050K43070 


Registration Gate 


3 015K83700 


Plate 


4 673K51382 


Exit Tray 


5 003E43840 


Thumbscrew 


6 830E17490 


Bracket 


7 050E88440 


Wing Tray 



PL20.11 




J0mf5201 1 



Parts List 

PL 20.11 



6/02 
5-96 



Prelaunch Training/Review 
DC1 632/2240 



Common Hardware 



Item 


Part 


Description 


A 


112W27651 


Screw 


M3x6) 


B 


112W27659 


Screw 


M3x6) 


C 


112W27851 


Screw 


M3x8) 


D 


112W28451 


Screw 


M3x14) 


E 


113W20457 


Screw 


M3x4) 


F 


113W20651 


Screw 


M3x6) 


G 


113W20857 


Screw 


M3x8) 


H 


113W21057 


Screw 


M3x10) 


J 


113W21657 


Screw 


M3x16) 


K 


113W27451 


Screw 


M3x4) 


L 


113W27551 


Screw 


M3x5) 


M 


113W27651 


Screw 


M3x6) 


N 


113W27851 


Screw 


M3x8) 


P 


113W28051 


Screw 


M3x10) 


Q 


113W28851 


Screw 


M3x20) 


R 


153W17655 


Thread 


-forming Screw (M3x6) 


S 


153W17855 


Thread 


-forming Screw (M3x8) 


T 


153W18055 


Thread 


-forming Screw (M3x10) 


U 


153W27855 


Thread 


-forming Screw (M3x8) 


V 


158W27655 


Screw 


M3x6) 


w 


1 58W27663 


Screw 


M3x6) 


X 


1 58W27855 


Screw 


M3x8) 


Y 


1 58W27863 


Screw 


M3x8) 


z 


1 58W28255 


Screw 


m3x12) 


AA 


158W35855 


Screw 


M4x8) 


AB 


220W21250 


Flange Nut (M3) 


AC 


251W24251 


Washe 


(4) 


AD 


251W24450 


Washe 


(4) 


AE 


252W24250 


Nylon Washer (4) 


AF 


252W26450 


Nylon Washer (5) 


AG 


252W27350 


Nylon Washer (6) 


AH 


252W27450 


Nylon Washer (6) 


AJ 


252W29450 


Nylon Washer (8) 


AK 


271W16050 


Dowel Pin (2x1 0) 


AL 


271W28250 


Dowel 


3 in (3x12) 


AM 


271W28650 


Dowel 


3 in(3x16) 


AN 


271W28950 


Dowel 


=>in (3x22) 


AP 


271W36850 


Dowel 


=>in (4x20) 


AQ 


285W15651 


Spring 


Pin (2x6) 


AR 


285W15851 


Spring 


Pin (2x8) 


AS 


285W16251 


Spring 


Pin (2x12) 


AT 


285W28051 


Spring 


Pin (3x10) 


AU 


285W28251 


Spring 


Pin (3x12) 


AV 


285W28651 


Spring 


Pin (3x16) 


AW 


354W15251 


E-Clip 


2) 


AX 


354W19251 


E-Clip 


2.5) 


AY 


354W21251 


E-Clip 


3) 


AZ 


354W21254 


K-Clip 


3) 


BA 


354W24251 


E-Clip 


4) 



BB 354W24254 K-Clip (4) 

BC 354W26251 E-Clip (5) 

BD 354W27251 E-Clip (6) 

BE 354W27254 K-Clip (6) 

BF 354W29251 E-Clip (8) 

BG 113W20657 Screw (M3x6) 

BH 113W16051 Screw (M2x10) 

BJ 158W45055 Screw (M5x10) 

BK 158W36355 Screw(M4x12) 

BL 251W24451 Washer (4) 

BM 113W20557 Screw (M3x5) 

BN 113W15851 Screw 

BP 113W28056 Screw (M3x10) 

BQ 113W28251 Screw(M3x12) 

BR 113W28256 Screw(M3x12) 

BS 153W27650 Thread-forming Screw (M3x6) 

BT 153W27850 Thread-forming Screw (M3x8) 

BU 252W27250 Nylon Washer (6) 

BV 252W29350 Nylon Washer (8) 

BW 285W29151 Spring Pin (3x25) 

BX 158W35655 Screw (M4x6) 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
5-97 



Parts List 

Common Hardware 



Part Number Index 



Table 1 Part Number Index 



Table 1 Part Number Index 



Part Number 


Part List 


001E59600 


PL 17.9 


001E60050 


PL 17.14 


001K70542 


PL 5.1 


001K70551 


PL 5.1 


003K12090 


PL 17.1 




PL 17.14 


003K12650 


PL 5.2 


003K12680 


PL 5.1 


003E23672 


PL 16.1 




PL 2.1 


003E43840 


PL 20.11 


003E52290 


PL 5.1 


003E52300 


PL 5.1 


003E53700 


PL 16.13 


003E53710 


PL 16.13 


003K86121 


PL 4.1 


003K91881 


PL 20.3 


004E06560 


PL 18.6 


004E11831 


PL 2.7 


005K05890 


PL 16.10 




PL 16.8 




PL 2.5 




PL 16.12 


005E16220 


PL 17.6 


005E16510 


PL 17.6 


005E80250 


PL 20.8 


005K83081 


PL 16.11 




PL 16.7 




PL 16.9 




PL 2.4 


006K21720 


PL 17.12 


006K21730 


PL 17.6 


006K21970 


PL 17.12 


006E71740 


PL 5.1 


007E61890 


PL 5.2 


007E61910 


PL 5.2 


007E62630 


PL 2.8 


007E64740 


PL 2.7 


007E66050 


PL 16.15 



Part Number 


Part List 


007E66060 


PL 16.15 


007E66070 


PL 16.15 


007E66080 


PL 16.14 


007E66340 


PL 20.10 


007E67730 


PL 17.7 


007E67740 


PL 17.7 


007E67750 


PL 17.7 


007E67760 


PL 17.6 


007E67770 


PL 17.8 


007E67780 


PL 17.8 


007E67790 


PL 17.8 


007E67800 


PL 17.8 


007E67810 


PL 17.8 


007E67820 


PL 17.11 


007E67830 


PL 17.11 


007E67840 


PL 17.11 


007E67850 


PL 17.4 


007E67860 


PL 17.4 


007E67870 


PL 17.4 


007E72070 


PL 17.12 


007E72080 


PL 17.12 


007E72090 


PL 17.7 


007E75201 


PL 2.8 


007K81120 


PL 20.8 


007K85522 


PL 2.9 


007K85580 


PL 1.3 


007K85730 


PL 16.11 




PL 2.4 




PL 16.9 




PL 16.7 


007K85750 


PL 1.1 


007K86400 


PL 1.1 


007K86700 


PL 20.6 


007K86910 


PL 17.6 


007K86920 


PL 1.1 


007K86931 


PL 2.9 


007K87110 


PL 1.1 


007K87220 


PL 1.1 


008E90931 


PL 20.8 


008E90941 


PL 20.8 


008E94070 


PL 17.7 



Parts List 

Part Number Index 



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Table 1 Part Number Index 



Table 1 Part Number Index 



Part Number 


Part List 


009E26870 


PL 20.1 


009E26970 


PL 16.3 




PL 16.4 


009E28560 


PL 20.8 


009E28570 


PL 20.8 


009E55450 


PL 18.4 


009E62830 


PL 18.5 


011 E1 0711 


PL 11.2 


011 E1 0800 


PL 16.13 


011K94970 


PL 5.1 


011K96790 


PL 16.14 


012E09750 


PL 20.4 


012E09760 


PL 20.8 


012E10070 


PL 16.4 


012E91960 


PL 20.8 


012K94110 


PL 18.5 


012K94120 


PL 18.5 


012K94260 


PL 10.2 


013E18980 


PL 5.3 


013E20240 


PL 17.6 


013E20250 


PL 17.12 


013E80970 


PL 20.10 


013E92760 


PL 20.4 


013E94561 


PL 20.8 


014E42850 


PL 16.1 




PL 2.1 


014K81604 


PL 9.3 


015K45802 


PL 11.2 


015K48381 


PL 2.8 


015E48890 


PL 20.2 


015E48900 


PL 20.2 


015K49310 


PL 5.6 


015K49450 


PL 16.14 


015K49460 


PL 16.14 


015K49470 


PL 16.13 


015K49480 


PL 5.6 


015K50680 


PL 17.11 


015K51640 


PL 17.11 


015K52280 


PL 17.8 


015K52320 


PL 4.2 


015E77040 


PL 17.14 



Part Number 


Part List 


015K83700 


PL 20.11 


017E92060 


PL 18.5 


017K92350 


PL 16.15 


017K92360 


PL 16.15 


017E94660 


PL 17.14 


017E94700 


PL 19.1 


017E94710 


PL 19.1 


017E94730 


PL 19.1 


019E49470 


PL 18.6 


019E49830 


PL 18.4 


019E50340 


PL 17.11 


019E50400 


PL 18.6 


019E93510 


PL 20.2 


019K97130 


PL 2.14 


019K97540 


PL 5.4 


019K97550 


PL 5.4 


019K98190 


PL 5.4 


019K98200 


PL 5.4 


020E21050 


PL 20.6 


020E25090 


PL 18.5 


020E32740 


PL 18.5 


020E34970 


PL 17.8 


020K91230 


PL 20.6 


020E93120 


PL 16.3 


020E93230 


PL 20.9 


020K94970 


PL 18.6 


020E99590 


PL 18.5 


022K33920 


PL 12.2 


022K37070 


PL 20.6 


022K37080 


PL 20.6 


022K38040 


PL 20.8 


022K39710 


PL 20.10 


022K62610 


PL 17.6 


022K65880 


PL 17.12 


022E88210 


PL 17.4 


023E12230 


PL 20.6 


023E15690 


PL 20.10 


023E19300 


PL 18.5 


023E19990 


PL 20.6 


023E20000 


PL 20.4 




PL 20.9 



Prelaunch Training/Review 
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Parts List 

Part Number Index 



Table 1 Part Number Index 



Table 1 Part Number Index 



Part Number 


Part List 


023E20010 


PL 20.6 


023E20020 


PL 17.4 


023E20160 


PL 17.7 


026E93560 


PL 17.1 


029E31600 


PL 2.3 


029K91990 


PL 17.9 


031E94030 


PL 17.7 


032K93800 


PL 20.1 


035E65010 


PL 6.2 


036K91420 


PL 20.3 


036K91431 


PL 20.3 


038E23560 


PL 2.14 


038E24410 


PL 17.10 


038E24650 


PL 17.4 


041K94050 


PL 18.6 


041 K94260 


PL 17.9 


041 K94271 


PL 18.6 


042K91990 


PL 10.1 


048E64200 


PL 20.1 


048K76180 


PL 20.1 


049E91070 


PL 20.10 


050K36410 


PL 20.1 


050K43070 


PL 18.3 




PL 20.11 


050K43120 


PL 16.1 


050K43130 


PL 16.1 


050K43880 


PL 17.10 


050K46690 


PL 20.7 




PL 20.8 


050K48170 


PL 16.1 




PL 2.1 


050K48181 


PL 2.13 


050E88440 


PL 20.11 


054K13081 


PL 20.9 


054K13600 


PL 20.4 


054K13621 


PL 20.2 


054K16130 


PL 2.8 


054E16330 


PL 2.8 


054K17241 


PL 11.2 


054K17252 


PL 11.2 


054K18270 


PL 16.6 



Part Number 


Part List 


054E18520 


PL 16.6 


054E18530 


PL 16.5 


054E18540 


PL 16.5 


054K18780 


PL 20.5 


054K18790 


PL 20.7 


054K2241 


PL 2.8 


055K19260 


PL 20.5 


055K26060 


PL 20.9 


059K11821 


PL 20.9 


059K11840 


PL 20.4 


059K11860 


PL 20.9 


059K11880 


PL 20.2 


059K15573 


PL 16.6 




PL 2.3 


059K15611 


PL 2.8 


059K16742 


PL 11.1 


059K16750 


PL 11.2 


059K18283 


PL 16.5 


059K18714 


PL 12.1 


059K18900 


PL 16.6 


059K19720 


PL 20.5 


059K19750 


PL 20.8 


059K20210 


PL 17.7 


059K21260 


PL 5.4 


059K21790 


PL 16.5 


059K23150 


PL 5.3 


059K23960 


PL 12.1 


059K23970 


PL 12.2 


059K23980 


PL 12.2 


059K24010 


PL 2.14 


059K24020 


PL 2.14 


059K24661 


PL 2.6 


059K24690 


PL 2.11 


059K24801 


PL 2.12 


059E95920 


PL 16.4 


059E95930 


PL 16.1 


062E10040 


PL 18.6 


062K10730 


PL 18.6 


062K10881 


PL 3.1 


063E94040 


PL 18.5 


063E94050 


PL 18.5 



Parts List 

Part Number Index 



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Table 1 Part Number Index 



Table 1 Part Number Index 



Part Number 


Part List 


064K91451 


PL 5.3 


068E10210 


PL 18.3 


074K94320 


PL 9.2 


090K92820 


PL 18.3 




PL 20.11 


101 K38810 


PL 9.2 


101K38980 


PL 9.2 


103E27220 


PL 9.1 


104E93610 


PL 9.1 


105E06910 


PL 20.9 


105E09760 


PL 9.1 


105E09810 


PL 9.1 


105E09820 


PL 9.1 


105E09830 


PL 9.1 


105E09970 


PL 9.1 


105E09980 


PL 9.1 


105E10480 


PL 18.4 


105E10510 


PL 18.6 


105E10650 


PL 18.4 


105E11130 


PL 9.1 


105E11320 


PL 17.12 


105K18641 


PL 9.1 


105K18771 


PL 9.1 


107E08680 


PL 18.4 


110K07850 


PL 20.2 


110K07870 


PL 20.2 


110K08471 


PL 18.4 


110K08541 


PL 16.1 




PL 2.1 


110K10650 


PL 2.8 


110K10880 


PL 16.1 


110K11100 


PL 18.2 


110K11211 


PL 10.2 


110E94770 


PL 10.1 


110E97990 


PL 17.13 


113K82310 


PL 9.3 


116K90810 


PL 6.1 


117E19780 


PL 18.6 


117E20840 


PL 18.3 


117K30960 


PL 18.4 


117E94370 


PL 9.2 



Part Number 


Part List 


118E12090 


PL 18.6 


120E11971 


PL 2.13 


120E18160 


PL 2.11 


120E20690 


PL 17.7 


120E20700 


PL 17.2 


120E20970 


PL 17.6 


121K22220 


PL 2.6 


121K22470 


PL 1.2 


121K22690 


PL 20.5 


121K22710 


PL 20.2 


121K22860 


PL 11.2 


121K22870 


PL 11.2 


121K23270 


PL 1.2 


121K23560 


PL 11.2 


121K24610 


PL 17.7 


121K24620 


PL 17.8 


121K27751 


PL 13.1 


121K82870 


PL 11.2 


121E87830 


PL 2.14 


121E88470 


PL 17.5 


121E90640 


PL 20.7 


121E91450 


PL 17.3 


121K93870 


PL 20.2 


122E92030 


PL 18.6 


122K93330 


PL 4.2 


122K93340 


PL 4.2 


123K94020 


PL 18.2 


126K13940 


PL 7.1 


126K13950 


PL 7.2 


126K13960 


PL 7.2 


126K13980 


PL 7.2 


126K13990 


PL 7.2 


126K14890 


PL 7.1 


127K23230 


PL 16.11 




PL 16.9 




PL 2.4 




PL 16.7 


127K29242 


PL 4.1 


127K29330 


PL 9.1 


127K29340 


PL 8.1 


127K29511 


PL 2.9 



Prelaunch Training/Review 
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Parts List 

Part Number Index 



Table 1 Part Number Index 



Table 1 Part Number Index 



Part Number 


Part List 


127K29930 


PL 12.2 


127K31840 


PL 16.15 


127K32140 


PL 18.5 


127K32640 


PL 20.9 


127K32680 


PL 20.4 


127K32690 


PL 20.6 


127K32730 


PL 8.1 


127K32840 


PL 17.7 


127K32850 


PL 17.10 


127K32860 


PL 17.9 


127K32870 


PL 17.8 


127K32920 


PL 13.1 


127K33160 


PL 18.4 


127K33420 


PL 17.11 


127K33930 


PL 6.1 


127K33940 


PL 6.1 


127K33950 


PL 5.4 


127K36020 


PL 16.15 


127K36640 


PL 8.1 


130K60600 


PL 20.5 




PL 20.9 




PL 20.7 


130K60830 


PL 5.4 


130K60851 


PL 2.3 


130K60865 


PL 1.3 


130K61020 


PL 7.2 


130K61250 


PL 12.2 


130K61510 


PL 16.6 


130K61920 


PL 17.6 


130K62000 


PL 18.4 


130K62360 


PL 17.4 


130K62580 


PL 18.4 


130K63000 


PL 6.2 


130E80890 


PL 20.5 


130E81600 


PL 16.6 


130E82190 


PL 16.11 




PL 2.3 




PL 2.9 




PL 5.4 




PL 2.4 




PL 2.13 



Part Number 


Part List 




PL 16.9 




PL 16.7 




PL 2.11 




PL 2.10 


130E82530 


PL 17.10 




PL 17.6 




PL 17.9 




PL 17.11 




PL 17.13 


130E82540 


PL 17.10 




PL 17.8 




PL 17.4 


130E82650 


PL 16.5 




PL 2.6 


130E82970 


PL 17.4 


130E84270 


PL 5.4 


130E84300 


PL 2.9 


130E91010 


PL 4.1 


130K93230 


PL 11.2 


130K93360 


PL 17.4 


130K94740 


PL 17.12 


133K21100 


PL 13.1 


133K21200 


PL 13.1 


133K22400 


PL 13.1 


140K60480 


PL 20.1 


160K46290 


PL 2.6 


160K66429 


PL 18.3 


160K66860 


PL 12.2 


160K74231 


PL 13.1 


160K75800 


PL 18.2 


160K76650 


PL 13.1 


160K76660 


PL 17.13 


160K76760 


PL 9.2 


160K76770 


PL 9.2 


160K76802 


PL 9.1 


160K77201 


PL 9.2 


160K77367 


PL 18.2 


160K82222 


PL 13.1 


160K83080 


PL 20.3 


160K84400 


PL 9.1 


160K84800 


PL 9.2 



Parts List 

Part Number Index 



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Table 1 Part Number Index 



Table 1 Part Number Index 



Part Number 


Part List 


160K84820 


PL 9.2 


160K85980 


PL 16.15 


160K87730 


PL 9.1 


160K90840 


PL 13.1 


1 62K55941 


PL 9.3 


162K55971 


PL 9.3 


162K56000 


PL 9.3 


162K56020 


PL 5.4 


162K56031 


PL 9.3 


162K56590 


PL 16.11 


162K61090 


PL 5.4 


162K62110 


PL 9.3 


162K62810 


PL 16.6 


1 62K64340 


PL 20.3 


162K69060 


PL 17.4 


162K69070 


PL 17.4 


1 62K69330 


PL 9.2 


413W10950 


PL 18.5 


413W77359 


PL 20.4 


423W28054 


PL 17.8 


423W29655 


PL 17.7 


537K61180 


PL 13.1 


537K62670 


PL 13.1 


537K62680 


PL 13.1 


537K64070 


PL 17.13 


538K94570 


PL 13.1 


600K78460 


PL 16.10 




PL 2.5 




PL 16.8 




PL 16.12 


600K90370 


PL 20.4 


604K05330 


PL 18.4 


604K07050 


PL 5.2 


604K07060 


PL 5.2 


604K07070 


PL 2.8 


604K07490 


PL 6.2 


604K07500 


PL 6.2 


604K07510 


PL 6.2 


604K07520 


PL 6.2 


673K51382 


PL 20.11 


801K02480 


PL 17.1 



Part Number 


Part List 


802K08320 


PL 20.4 


802E12400 


PL 10.2 


802E12430 


PL 10.2 


802E12480 


PL 10.3 


802E12490 


PL 10.3 


802E12500 


PL 10.3 


802K12950 


PL 5.2 


802K13193 


PL 2.3 


802E23930 


PL 16.16 


802E23950 


PL 16.16 


802E23960 


PL 16.16 


802E23980 


PL 16.4 


802E23990 


PL 16.3 


802K25731 


PL 16.13 


802K27073 


PL 2.9 


802E27860 


PL 10.3 


802K28110 


PL 10.3 


802E28520 


PL 17.5 


802E28530 


PL 17.5 


802E28540 


PL 17.5 


802E28550 


PL 17.5 


802E28560 


PL 17.5 


802E28570 


PL 17.5 


802K28570 


PL 17.6 


802K28580 


PL 17.4 


802K28590 


PL 17.3 


802K28600 


PL 17.3 


802K28891 


PL 6.2 


802K29610 


PL 10.2 


802E30140 


PL 17.4 


802E30150 


PL 17.4 


802E32860 


PL 18.2 


802K33090 


PL 6.1 


802K36580 


PL 16.16 


802K36650 


PL 17.1 


802K36660 


PL 17.14 


802K36670 


PL 17.14 


802K45490 


PL 2.7 


802K45710 


PL 10.2 


802K45910 


PL 6.1 


802K45920 


PL 6.1 



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Parts List 

Part Number Index 



Table 1 Part Number Index 



Part Number 


Part List 


802K45930 


PL 6.1 


802K45940 


PL 6.1 


802K46022 


PL 18.2 


802K46050 


PL 10.1 


802K46060 


PL 10.1 


802K47090 


PL 4.1 


809E04210 


PL 20.8 


809E04220 


PL 20.8 


809E09110 


PL 18.6 


809E11130 


PL 20.2 


809E26330 


PL 5.6 


809E28960 


PL 16.13 


809E28980 


PL 16.13 


809E29620 


PL 2.8 


809E33600 


PL 17.10 


830E17490 


PL 20.11 


830E81670 


PL 17.6 


891 E49060 


PL 16.1 


891E49510 


PL 16.1 


891 E49520 


PL 16.1 


891E65180 


PL 20.1 


891E65210 


PL 20.1 


891E75951 


PL 10.1 


892E13310 


PL 2.2 


892E28491 


PL 16.1 


892E41110 


PL 2.1 


892E74500 


PL 16.2 


892E78280 


PL 10.1 


892E78290 


PL 10.1 


908W01200 


PL 9.2 


917W00723 


PL 9.2 


962K05900 


PL 18.4 


962K05910 


PL 18.4 


962K07440 


PL 17.9 


962K08641 


PL 13.1 


962K08820 


PL 9.2 


962K09800 


PL 9.3 


962K10120 


PL 17.13 


962K10130 


PL 17.13 



Parts List 

Part Number Index 



6/02 
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6 General Procedures & Information 



Diagnostics 

Entering Diagnostic Mode using the PWS 6-3 

Ul Diagnostic Mode 6-4 

DC Quick (CODE Number LIST) 6-5 

dC100 Service Entry 6-6 

dC118 Jam Counter 6-7 

dC120 Fail Counter 6-7 

dC122 Shutdown History 6-8 

dC129 System Registration Setup 6-8 

dC131 NVM Read/Write 6-9 

dC131 NVM Tables 6-10 

dC132 Serial Number/Billing Meter Synchronization 6-67 

dC135 HFSI Counters 6-67 

dC140 Analog Monitor 6-68 

dC188 Exiting from Service Mode 6-68 

dC301 NVM Initialization 6-69 

dC305 Ul Component Check 6-70 

dC330 Component Control 6-70 

dC351 NVM Background Processing 6-77 

dC355 Hard Disk Diagnostic Program 6-78 

dC371 Configuration Page 6-78 

dC612 Color Test Pattern Print 6-79 

dC685 Color Registration 6-83 

dC921 TC/ATC Sensor Setup 6-83 

dC922 TRC Control 6-84 

dC924 TRC Adjust 6-84 

dC929 Max Setup 6-85 

dC934 ADC/AGC Setup 6-85 

dC945 NT Calibration 6-86 

dC956 Belt Edge Learn Mode 6-86 

General Procedures 

GP 1 Network Printing Simulation 6-87 

GP 4 Intermittent Problem RAP 6-87 

GP 10 Replacing Billing PWBs 6-88 

GP 12 Printing Reports 6-89 

General Information 

Space Requirements 6-91 

Paper Specifications 6-92 

Product Specs 6-92 

Power Requirements 6-93 

Environmental Data and Requirements 6-93 

Tools and Supplies 

Common Tools 6-95 

Product Tools and Test Patterns 6-95 

Cleaning Materials 6-96 

Machine Consumables 6-96 

Glossary of Terms 6-97 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
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General Procedures and Information 



General Procedures and Information 



6/02 
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Prelaunch Training/Review 
DC1 632/2240 



Entering Diagnostic Mode using the PWS 

Procedure 

The following procedure describe how to enter the Diagnostics Mode with the PWS. 

1 . Inform the customer that the machine will be undergoing service and will not be available. 
(Copy jobs and local print jobs will be stopped). 

2. Disconnect the machine from the customer network. 

3. Connect the Portable Work Station (PWS) to the machine (Figure 1). 




01 04900 A-CAR 



Loosen screw and rotate 
plate 



Remove cover and con- 
nect PWS power cord 



Connect serial 
cable 



Figure 1 Connecting the PWS 

Switch on the PWS. 

Make sure the machine is not copying or printing. The machine Ul should display Ready 

to Copy when there are no pending jobs. 

At the PWS, enter the GSNLock Password and select OK. 

From the Start menu in the lower left corner, select Programs\Xerox Applications\DC 

1632 PWS Tools. 



NOTE: The PWS cannot connect to the machine if it is in Power Save mode. Ensure that the 
machine indicates Ready to Copy before launching the PWS Tools. 

8. The Diagnostics Tool screen will display. 

a. Select Use Local DB from the Diagnostics Tool screen. The PWS Diagnostic 
Service Entry Window displays. 

b. While the machine is connected to the PWS, the machine Ul will display the mes- 
sage, Connecting to the Machine. 

9. When the tool starts obtaining machine data, that data is displayed on the Service Entry 
Screen. When the system has obtained the machine data, it displays Complete at the 
upper left corner of the Service Entry Screen. 

The data listed in Table 1 will be displayed. 

Table 1 Machine Data displayed at Service Entry 



Heading 


Contents 


Description 


Machine Data 


Product Code 


Displays a code allocated to 
each machine to identify the 
machine. 


Serial Number 


Displays a 6-digit number (0- 
9) allocated to each machine 
type to identify the machine. 


Total Copies 


Displays the total number of 
copies/prints 


Copies Since Last Call 


Displays the total number of 
copies/prints since the last 
CSE visit (complete closeout). 


Software Version 


Displays current IOT S/W Ver- 
sion 


Non-Zero Jams 


ID, Description, Occurrences 


Displays the Jams that have 
occurred since the last com- 
plete closeout. 


HFSI Requiring Replacement 


ID, Description, Threshold, 
Count. 


Displays the component(s) 
(HFSI) that has exceeded the 
life Threshold). 


Faults in Progress (Current 
Faults) 


ID, Description, Primary 


Displays current (active) faults 
in the machine. 



10. If communication is lost between the PWS and the machine, click Reconnect from the 
main file menu. 

11. To exit the Diagnostic Mode: 

a. Select the Service Exit Tab. 

b. Click on the appropriate close-out buttons: 
i Complete Closeout 

i Temporary Closeout 

c. After the PWS has disconnected from the machine, select Exit PWS to close the 
tool. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-3 



General Procedures and Information 

Entering Diagnostic Mode using the PWS 



Ul Diagnostic Mode 

Diagnostic routines are mainly instructed/executed through the PWS. The Ul Diagnostic mode 
tis provided for simple tasks that do not require connection with the PWS. 

Procedure 

Access the Ul Diagnostic mode by following the procedures below. 

Entering the Ul Diagnostic mode 

1 . At the Control Panel, press and hold the key for 5 seconds, then press the Start button 
while still pressing the key. 

The CE Mode - Password Entry screen will appear. 

2. Enter the Access Number (6789) and press Confirm. 

The colors on the display will be reversed to indicate that the mode has changed to the Ul 
Diagnostic mode. 
Accessing Diagnostic routines 

1 . Press the Access button on the Control Panel 

2. Press the System Settings button on the display 

3. Press the Common Settings button on the display 

4. Press the Diagnostics button on the display 

5. The following dC routines can be accessed from the Ul screen 

a. DC301 NVM Initialization 

- Select the subsystem to be initialized and press the Start button on the display. 
Refer to dC301 for details. 

b. DC355 Hard Disk Initialization 

- Only Partition A can be initialized. For full initialization, refer to ADJ 9.8. 

c. DC1 31 NVM Read/Write 

- follow the instructions on the screen. If one or more NVM locations is changed, the 
machine will reboot upon exit. Refer to dC1 31 for details. 

Printing Service Reports 

1. 

2. 

3. 
4. 
5. 
6. 



Exiting Ul Diagnostic mode 

CAUTION 

Ensure that the machine is not inadvertently left in Ul Diagnostic Mode. 

There are three ways to exit from the Ul Diagnostic mode. 

T Switch the power off and on. 

T perform the following: 

h Press Close to exit any of the service screens that were opened, 
h When the System Settings screen is displayed, press Exit 

h When the reversed-color Copy Mode screen is displayed, press the Start button 
while the key is pressed. 

T If the Restart button is displayed in the screen, pressing the button will restart the opera- 
tion and exit from the mode. 



To access Service reports, follow the Entering the Ul Diagnostic mode procedure. 

After entering the Access Number, press the Machine Status button on the Control 

Panel. 

Select the Billing Meter/Print Reports tab on the display. 

Press the Print Reports/List button. 

Press the CE button 

The following reports can be printed. 

a. Debug Log 

b. HFSI Report 

c. Jam Report 

d. Shutdown Report 

e. Fail Report 



General Procedures and Information 

Ul Diagnostic Mode 



6/02 
6-4 



Prelaunch Training/Review 
DC1 632/2240 



DC Quick (CODE Number LIST) 

Once in the Service Mode, dC Routines can be selected by dC Number or by selecting the 
appropriate tabs starting at the Service Entry Screen. 

Procedure 

1 . Enter the Diagnostic Mode. Refer to Entering Diagnostic Mode using the PWS. 

2. Using the DC Quick pull-down menu (upper-right side of Diagnostics Service Entry 
Screen), select the desired dC routine. 

Table 1 is a complete list of dC Routines that are available from the DC Quick pull-down 
menu. 

Table 1 dC Routines 



Table 1 dC Routines 



dC Number 


Name 


Description 


100 


Service Entry Screen 


1 . Displays the Service Routine Tabs. 

2. Lists Active Faults 

3. Lists the item names of the HFSIs 
that exceeded life expectancy. 

4. Lists the jams that have occurred 
since the last Call Closeout. 

5. Displays IOT S/W Version. 


118 


Jam Counter 


Displays the following: Number of jam 
events since the last Complete Closeout 
(performed in Service Exit) to the current 
Number of jams. 


120 


Fail Counters 


Displays the following: Number of Fault 
events after the last Complete Closeout 
(performed in Service Exit) to the current 
copy count. 


122 


Shut-down History 


1 . Displays the history in three catego- 
ries: Document Jam, Paper Jam and 
Other Fault. 

2. Displays the most recent 40 Faults 
(without categorizing) 


129 


Automatic Setting: Adjust Sys- 
tem Registration 


The IOT lead registration and side regis- 
tration are matched. 


131 


NVM access: Read/Write 
NVM 


You can reference or set/change the NVM 
data. 


132 


Set Machine Serial Number. 
Read Billing Meter Information 


If you have replaced the PWB that has a 
Machine Serial Number, check the PWB 
and set the Machine Serial Number. 
Reads Billing Meter Information for the fol- 
lowing: 

i MCU PWB 
T ESS PWB 
T ESS NVM PWB 



dC Number 


Name 


Description 


135 


Service Data 
HFSI Counter 


Displays the regular part replacement life 
expectancy (threshold) and current value 
(usage). You can change the replacement 
life expectancy to a preset value in the 
PWS database and reset the current 
value. 


140 


Component Check: Analog 
Monitor 


Monitor the analog values of the sensors 
(A/D conversion) while operating the com- 
ponents (e.g., C.C). You can temporarily 
change the output value. 


188 


Service Mode Exit Screen 


Displays the requirements for exit from the 
Service Mode. 


301 


NVM access: NVM initializa- 
tion 


Initiates NVM Data initialization 


305 


System Test: Component 
Operation Check Ul Compo- 
nent Check 


Checks the Ul Screen and Component 
Panel Button operation. 


330 


Component Check: Compo- 
nent Control 


Displays the instructions and results of the 
Input Component Check and Output Com- 
ponent Check 

1 . You can monitor each Input Compo- 
nent or check the operation of each 
Output Component. 

2. You can simultaneously check multi- 
ple Input Components and Output 
Components up to 11 total. 


351 


NVM Background Processing 


1 . Saves and restores values of all 
NVM in PWS dC131 database. 

NOTE: Background Read must com- 
plete prior to saving. 

2. Start and Stop background NVM 
Read. 

3. Saves/restores machine settings. 
Saves NVM values listed: 

4. Resets all HFSI. 


355 


HDD Diagnostics 


Perform maintenance on HDD. 


361 


NVM access: Save/Restore 
NVM 


Saves the machine NVM data in the PWS. 
Restores the machine NVM data (stored 
in the PWS) back to the machine. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-5 



General Procedures and Information 



DC Quick 



Table 1 dC Routines 



dC Number 


Name 


Description 


371 


Configuration Page 


Allows viewing of current software version 
and Market Place setting, Machine Con- 
figuration, Output Device(s), Accessories, 
Tray 1 Paper Size setting, Feature Con- 
fig., and Input Device. 
These settings can be changed to align 
with the machine configuration. 


612 


Color Test Pattern Print 


1 . Outputs a test pattern to identify a 
copy quality problem. 

2. Generates a test pattern from the 
Pattern Generator in the machine. 


685 


Reg icon 


Color Registration/Skew setup 


921 


ATC Calibration 


Enter ATC Sensor Calibration code into 
NVM. 


922 


TRC Control/Toner Density 
Adjustment 


Measure the grayscale patch by the ADC 
sensor. Make the LUT for IOT TRC cor- 
rection. 


924 


TRC Adjustment 


Manually fine adjust each color (low/mid/ 
high density) in PG 


934 


ADC/AGC Setup 


Execute automatic adjustment of the ADC 
Sensor Gain. 


945 


NT calibration 


1 . Calculate and set the white reference 
compensation coefficient. 

2. Correct the NT sensitivity variation. 


956 


Belt Edge Learn 


Set up the Belt Edge Sensor. 



dC100 Service Entry 



When entering Diagnostics, this routine allows you to view faults in progress, Non-Zero Jams 
and HFSI items requiring replacement. Service entry allows you to view product information, 
such as: 

i Product Code 

i Machine Serial Number 

i Total Copies 

i Copies since Last Call 

i IOT Software Version 

Procedure 

1 . Enter the Diagnostic Mode. Refer to Entering Diagnostic Mode using the PWS. 

2. Check the HFSI Requiring Replacement. 

3. Check the Non-Zero Jams. Jams that have occurred since the last service exit with the 
Complete Closeout option selected. Check for any Jams that have a high number of 
occurrences. 

4. Check the Faults In Progress. If any faults in progress are displayed, troubleshoot 
accordingly. 

5. Select the Refresh button to have the PWS request and receive the latest information on 
Total Copies, Copies Since Last Call, Non-Zero Jams or HFSI Requiring Replacement. 



General Procedures and Information 

DC Quick, dC1 00 



6/02 
6-6 



Prelaunch Training/Review 
DC1 632/2240 



dC118 Jam Counter 

Purpose 

Displays the number of occurrences of Jams from time of previous Complete Closeout on ser- 
vice exit until present. 

NOTE: This procedure does not count jams detected while in the Service Mode. 

Procedure 

1 . Enter the Diagnostic Mode. Refer to Entering Diagnostic Mode using the PWS. 

2. Select Maintenance on the Service Entry Screen. 

3. Select the Jam Counters (dC 118). 

4. The screen displays all jam-related fault codes, and the number of times that the fault has 
occurred since the last time the Complete Closeout option was selected when exiting 
Diagnostic Mode. 

5. The following subsets of data are selectable: 
i All Jams 

- This is the default. All jam-related faults are listed 
i DADF Jams 

- Selecting this tab lists only the DADF jam codes, 
i Paper Jams 

- Selecting this tab lists only the paper supply and paper feeding jam codes, 
i Non-Zero Jams 

- Selecting this tab lists only those jam codes that have had at least one occurrence 
since the last time the Complete Closeout option was selected. 



dC120 Fail Counter 
Purpose 

Displays the number of occurrences of each fault since the last Service Exit with the Complete 
Closeout option selected. 

NOTE: 

i The machine does not count the faults detected while in the Service Mode, 
i The machine does not count interlock open detected faults while the Main Processor is 
stopped. 

Procedure 

1 . Enter the Diagnostic Mode. Refer to Entering Diagnostic Mode using the PWS. 

2. Select Maintenance on the Service Entry Screen. 

3. Select the Fail Counters (dC120) tab. 

4. The screen displays all fault codes that have occurred since the last time the Complete 
Closeout option was selected when exiting Diagnostic Mode. 

The codes are listed in ascending order; to list in descending order, click on ID in the table 

header. 

If machine data was previously saved to diskette, and Diagnostic Mode was entered 

with the Read From Diskettes option selected, the previous fault history #Occurrence 

will display in the P1 column. If this same procedure was performed previously, the fault 

history #Occurrence will display in P2, then P3, up to columns P7. 

5. The following subsets of data are selectable: 
i All Faults 

i DADF Faults 
T System faults 
T Xero Faults 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-7 



General Procedures and Information 

dC118, dC120 



dC122 Shutdown History 
Purpose 

To display the Last 40 Faults (History). 



NOTE: 

1. fault detected while in Service Mode are not counted. 

2. An Interlock open while the machine is stopped is not counted. 

3. If multiple faults occurred in the machine, the primary fault is recorded. 

Procedure 



1. 

2. 
3. 

4. 



6. 



Enter the Diagnostic Mode. Refer to Entering Diagnostic Mode using the PWS. 
Select the Diagnostics Tab. 
Select the Shutdown Hist (dC122) tab. 

The system displays the faults that occurred in Customer Mode since the last service call 
closeout, up to a maximum of 40 faults. 

The information in the lower right corner of the screen (Input, Original, Paper, Tray, Out- 
put) reflects the fault highlighted in the Table. 
The following subsets of data are available: 
i Last 40 Faults History (default screen). 

- displays the 40 newest faults and lists copy count when each occurred, 
i Last 40 Faults Occurrences 

- displays the 40 newest faults and lists the number of occurrences, 
i DADF Jams 

- displays the 40 newest DADF jams and lists copy count when each occurred, 
i Paper Jams 

- displays the 40 newest paper jams and lists copy count when each occurred, 
i Fail 

- displays the 40 newest non-jam faults and lists copy count when each occurred. 
To clear the shutdown history, select Complete Closeout in the Service Mode Exit 
screen (dC188). Exiting from the Service Mode clears all data in the Shut-Down History. 



dC129 System Registration Setup 
Purpose 



Performs the Lead Registration and Side Registration adjustments by looking at the output of 
the built-in Test Pattern. 

NOTE: For details on the dC129 System Registration adjustment, see ADJ 9.9 IOT Registra- 
tion Series (dC129). 



General Procedures and Information 

dC122, dC129 



6/02 
6-8 



Prelaunch Training/Review 
DC1 632/2240 



dC131 NVM Read/Write 
Purpose 

Reads, sets or changes the NVM data. 

Procedure 

Module Selection 

1 . Enter the Diagnostic Mode. Refer to Entering Diagnostic Mode using the PWS. 

2. Select Adjustments in the Service Entry Screen. 

3. The system displays one of the Read/Write Screens. dC131 NVM Read/Write is the 
default screen. 

4. Select a Sub-System from the Vertical Left Tab List. The default tab is All. 

Table 1 Module Selection 



a. If the input value is valid (within the range), the system writes the new NVM value in 
the NVM location in the machine. 

b. If the input value is invalid, the system displays the following message in the infor- 
mation screen, The given NVM value is out of range. NVM was not changed. 

c. If the NVM cannot be changed (Write protected NVM), the system displays the fol- 
lowing message, The specified NVM is read only. 

When the system writes the new value in the specified NVM code, the value is updated in 
the New box and reduces the count in the Changed Tab. 



Module item 


Chain number allocation 


All 


700 - 999 


U I/Tools 


700, 720 


IISS 


715 


Config/System 


719,740 


Xfer 


746 


RegiCon 


760 


PHM 


742 


DADF 


710 


Xero 


751 


Drives / Output 


741,764 


ProCon 


752 


Developer 


762 


Fuser 


744 


Other 


755, 769 


Errors (number of errors) 


Displays and NVM outside of the ranges listed in the 
PWS database. 


Changed (number pending change) 


Displays any with new value entered in the New col- 
umn, but not written yet. 



Reading NVM 

1 . Select an ID from the Sub-System Table, then click Read NVM, or double click on the line 

ID and the value will be read in the Value column. 

The Range Check column will fill in. 
Writing NVM 

1 . To change a value, enter a new value in the New column and press Enter. 

2. When a new value is entered, the Changed tab will turn green. The number in parenthe- 
ses count the number of pending NVM values. Clicking this tab will show a list of all the 
changed values. These locations can be written individually or as a block from this tab, or 
can be canceled. 

3. Select Write NVM. 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-9 



General Procedures and Information 

dC131 



dC131 NVM Tables 

700-xxx ESS Configuration NVM List 



Table 1 Chain 700 



Chain-Link 


Name 


Default 


Range 


Description 


700-006 


Configuration 


" 


0x00-0x08 


[P, SP, CSP, CFSP] Set up at factory production. It allocates bits in the following P(rinter), F(ax), C(opy), S(can). 
P = 0x01, F = 0x02, C = 0x04, S = 0x08. 


700-073 


Page Memory Size 




64*1024*102 
4-256*1024* 
1024 


bytes (Auto Setting) 


700-075 


ART User Buffer Size 


32KB 


32*1024-204 
8*1024 


32KB-2048KB (32KB interval) 


700-076 


PostScript Buffer Size 




8*1024*1024 
-32*1024*10 
24 


Color machine = [8 MB-32 MB] B/W machine = [4.5 MB-32 MB] (0.25 MB interval) 


700-078 


Form Buffer Size 


128KB 


128*1024-20 
48*1024 


128KB-2048KB 


700-080 


HPGL/Auto Layout Buffer Size 


64KB 


64*1024-512 
0*1024 


64 KB-5120 KB (32 KB interval) 


700-081 


Parallel Buffer Size 


64KB 


- 


64 KB-1 MB (32 KB interval) 


700-082 


TBD 


256KB 


64*1024-1*1 
024*1024 


64 KB-1 MB (32 KB interval) 


700-083 


Lpd Buffer Size 


256KB 


64*1024-1*1 
024*1024 


64 KB-1 MB (32 KB interval) 


700-084 


NetWare Buffer Size 


256KB 


64*1024-1*1 
024*1024 


64 KB-1 MB (32 KB interval) 


700-085 


AppleTalk Buffer Size 


256KB 


- 


64 KB-1 MB (32 KB interval) 


700-086 


SMB Buffer Size 


256KB 


64*1024-1*1 
024*1024 


64 KB-1 MB (32 KB interval) 


700-087 


IPP Buffer Size 


256KB 


64*1024-1*1 
024*1024 


64 KB-1 MB (32 KB interval) 


700-088 


Salutation Buffer Size 


256KB 


- 


64 KB-1 MB (32 KB interval) 


700-089 


HDD Status 


- 


-2-0 


= Yes, -1 = Error, -2 = No (Auto Detect) 


700-120 


Time Zone 


540 


- 


Displays the Time difference from GMT. E.g. Japan = 540, Hawaii = -600 


700-124 


Auto Clear Timer 


1min 


0-240 


MF = 0, 1-4 = [Disable (0), 1~4min] (in increments of 1min) P = 0, 1-30 = [Disable (0), 1~30min] (in incre- 
ments of 1min) 


700-125 


Job Cancel Timer 


10min 


0-5940 


0= Disable 240-5940= 4~99min (in increments of 1min) 


700-126 


Operating Timer 


10sec 


0-240 


0= Disable 1-240 = [1~240sec] (in increments of 1 sec) 


700-127 


Job End Timer 


6sec 


0-240 


0= Disable 1-240 = [1~240sec] (in increments of 1 sec) 


700-128 


Scanning Timer 


4sec 


1-20 


1-20= [1~20sec(1 sec unit) 


700-129 


LowPower Mode Timer 


15 


6-240 


6-240 = [6~240min (in increments of 1min)] 


700-130 


Sleep Mode Timer 


60min 


15-240 


15-240 = [15~240min (in increments of 1min)] 


700-131 


Sleep Mode Available 


1 


[Setup 
Range] = 


= Disable, 1 = Enable 





General Procedures and Information 



6/02 
6-10 



Prelaunch Training/Review 
DC1 632/2240 



Table 1 Chain 700 



Chain-Link 


Name 


Default 


Range 


Description 


700-132 


Operation Panel OK Beep 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-133 


Operation Panel NG Beep 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-134 


Job Complete Beep with Copy 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-135 


Job Complete Beep without Copy 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-136 


Abnormal Warning Beep 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-137 


Job Incomplete Beep 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-138 


Ready Beep 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-139 


Toner Empty Warning Beep 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-140 


Bell Tone 


2 


0-3 


= Off, 1 = Low volume, 2 = Medium volume, 3 = High volume 


700-141 


Line Monitor Tone 


2 


0-3 


1 = Low volume, 2 = Medium volume, 3 = High volume 


700-144 


Auto Log Print Flag 





0-1 


0= OFF 1 = ON 


700-145 


Report Duplex Print 





0-1 


0= OFF 1 = ON 


700-146 


Mail Box Receive Report 


ON 


0-1 


0= OFF 1 = ON 


700-147 


Protocol Monitor Output Control 





0-2 


0= When instructed 1= When error occurs 2= When normal 


700-151 


Transmission Report on Error Output 
Control 


1 


0-2 


[0=OFF, 1=ON, 2=Outputat normal] 


700-152 


User Abort Transmission Report Output 
Control 





0-1 


0= Do not output 1= Output 


700-153 


TBD 





0-1 


= Do not register 1 = Register 


700-164 


Language 


Japanese 


[Setup 
Range] 1 


1 = Japanese, 2 = English, 3 = French, 4 = German, 5 = Italian, 6 = Spanish, 7 = Portuguese, 8 = Russian, 
9 = Chinese, 10 = Korean, 11 = Thai, 12 = Vietnamese, 13 = Taiwanese 


700-165 


Country Code 


0=Undefined 




0=Undefined, 840 =USA, 124=Canada, 076=Brazil, 3=Latin America -> Cannot be assigned 826=UK, 
276=Germany, 380=ltaly, 250=France, 724=Spain, 528=Holland, 756=Swiss, 752=Sweden, 056=Belgium, 
040=Austria, 620=Portugal, 246=Finland, 208=Denmark 


700-166 


Territory 


- 


[Setup 
Range] = 


1=FX, 2=XC, 3=XE, 4=AP 


700-169 


Print Priority 


48 


18-48 


48= Priority (low), 38 = Priority 1 , 28 = Priority 2, 18 = Priority 3 (high), Default = Priority (48) 


700-170 


Copy Priority 


Priority 1 (38) 


18-48 


48= Priority (low), 38 = Priority 1 , 28 = Priority 2, 18 = Priority 3 (high), Default = Priority (38) 


700-171 


KO Tools Entry Password 


NULL 


- 


ASCII 'O'-'g'. 4 -12 digits. 


700-172 


TBD 


- 


- 


"6789" Fixed value 


700-175 


Transaction Report Display point 





0-1 


0= Displays lead edge in 40 digits 1= Displays rear edge in 40 digits 


700-197 


Max. Job Numbers 


60002>90 


90-3000 


Set up 90 (min.)~3000 (max.) in increments of 1. 02>30~3000 


700-198 


TBD 


1 


0-1 


1 = Permit, = Prohibits 


700-207 


TBD 


- 


- 


= Not valid, 1 = Valid 


700-301 


SEEPROM Serial* (1st digit) 


- 


- 


Alphanumerics (ASCII) 


700-302 


SEEPROM Serial* (2nd digit) 


- 


- 


Alphanumerics (ASCII) 


700-303 


SEEPROM Serial* (3rd digit) 


- 


- 


Alphanumerics (ASCII) 


700-304 


SEEPROM Serial* (4th digit) 


- 


- 


Alphanumerics (ASCII) 


700-305 


SEEPROM Serial* (5th digit) 


- 


- 


Alphanumerics (ASCII) 


700-306 


SEEPROM Serial* (6th digit) 


- 


- 


Alphanumerics (ASCII) 


700-307 


SEEPROM Serial* (7th digit) 


- 


- 


Alphanumerics (ASCII) 


700-308 


SEEPROM Serial* (8th digit) 


- 


- 


Alphanumerics (ASCII) 





Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-11 



General Procedures and Information 



Table 1 Chain 700 



Chain-Link 


Name 


Default 


Range 


Description 


700-309 


SEEPROM Serial# (9th digit) 


- 


- 


Alphanumerics (ASCII) 


700-310 


SEEPROM Serial# (10th digit) 


- 


- 


Alphanumerics (ASCII) 


700-311 


Battery Backup SRAM Serial # (1st 
digit) 


" 


" 


Alphanumerics (ASCII) 


700-312 


Battery Backup SRAM Serial # (2nd 
digit) 


~ 


~ 


Alphanumerics (ASCII) 


700-313 


Battery Backup SRAM Serial # (3rd 
digit) 


" 


" 


Alphanumerics (ASCII) 


700-314 


Battery Backup SRAM Serial # (4th 
digit) 


" 


" 


Alphanumerics (ASCII) 


700-315 


Battery Backup SRAM Serial # (5th 
digit) 


~ 


~ 


Alphanumerics (ASCII) 


700-316 


Battery Backup SRAM Serial # (6th 
digit) 


" 


" 


Alphanumerics (ASCII) 


700-317 


Battery Backup SRAM Serial # (7th 
digit) 


" 


" 


Alphanumerics (ASCII) 


700-318 


Battery Backup SRAM Serial # (8th 
digit) 


~ 


~ 


Alphanumerics (ASCII) 


700-319 


Battery Backup SRAM Serial # (9th 
digit) 


" 


" 


Alphanumerics (ASCII) 


700-320 


Battery Backup SRAM Serial # (10th 
digit) 


" 


" 


Alphanumerics (ASCII) 


700-321 


SEEPROM Product # (1st digit) 


- 


- 


Alphanumeric (ASCII) 


700-322 


SEEPROM Product # (2nd digit) 


- 


- 


Alphanumeric (ASCII) 


700-323 


SEEPROM Product # (3rd digit) 


- 


- 


Alphanumeric (ASCII) 


700-324 


SEEPROM Product #(4th digit) 


- 


- 


Alphanumeric (ASCII) 


700-325 


Battery Backup SRAM Product # (1st 
digit) 


~ 


~ 


Alphanumeric (ASCII) 


700-326 


Battery Backup SRAM Product # (2nd 
digit) 


" 


" 


Alphanumeric (ASCII) 


700-327 


Battery Backup SRAM Product # (3rd 
digit) 


" 


" 


Alphanumeric (ASCII) 


700-328 


Battery Backup SRAM Product # (4th 
digit) 


~ 


~ 


Alphanumeric (ASCII) 


700-329 


SEEPROM Product Code (1st digit) 


- 


- 


Alphanumerics (ASCII) 


700-330 


SSEEPROM Product Code (2nd digit) 


- 


- 


Alphanumerics (ASCII) 


700-331 


SEEPROM Product Code (3rd digit) 


- 


- 


Alphanumerics (ASCII) 


700-332 


SEEPROM Product Code (4th digit) 


- 


- 


Alphanumerics (ASCII) 


700-333 


SEEPROM Product Code (5th digit) 


- 


- 


Alphanumerics (ASCII) 


700-334 


SEEPROM Product Code (6th digit) 


- 


- 


Alphanumerics (ASCII) 


700-335 


SEEPROM Product Code (7th digit) 


- 


- 


Alphanumerics (ASCII) 


700-336 


SEEPROM Product Code (8th digit) 


- 


- 


Alphanumerics (ASCII) 





General Procedures and Information 



6/02 
6-12 



Prelaunch Training/Review 
DC1 632/2240 



Table 1 Chain 700 



Chain-Link 


Name 


Default 


Range 


Description 


700-337 


Configuration (info. On SEEPROM) 


" 


" 


[P, SP, CSP, CFSP (C)] Set at factory. It allocates bits in the following into P(rinter), F(ax), C(opy), S(can) 
respectively and display it in that disjunction. P = 0x01 , F = 0x02, C = 0x04, S = 0x08 


700-338 


Territory (SEEPROM) 


- 


1-4 


1=FX, 2=XC, 3=XE, 4=AP 


700-339 


IOT ROM Major version 


- 


- 


(Auto Setting) 


700-340 


IOT ROM Minor version 


- 


- 


(Auto Setting) 


700-341 


IOT ROM Revision version 


- 


- 


(Auto Setting) 


700-342 


Sys Main ROM Major 


- 


- 


(Auto Setting) 


700-343 


Sys Main ROM Minor 


- 


- 


(Auto Setting) 


700-344 


Sys Main ROM Revision 


- 


- 


(Auto Setting) 


700-348 


I IT ROM Major 


- 


- 


(Auto Setting) 


700-349 


IIT ROM Minor 


- 


- 


(Auto Setting) 


700-350 


I IT ROM Revision 


- 


- 


(Auto Setting) 


700-351 


DADF ROM Major 


- 


- 


(Auto Setting) 


700-352 


DADF ROM Minor 


- 


- 


(Auto Setting) 


700-353 


DADF ROM Revision 


- 


- 


(Auto Setting) 


700-354 


Ul Frame ROM Major 


- 


- 


(Auto Setting) 


700-355 


Ul Frame ROM Minor 


- 


- 


(Auto Setting) 


700-356 


Ul Frame ROM Revision 


- 


- 


(Auto Setting) 


700-357 


Ul control ROM Major 


- 


- 


(Auto Setting) 


700-358 


Ul control ROM Minor 


- 


- 


(Auto Setting) 


700-359 


Ul control ROM Revision 


- 


- 


(Auto Setting) 


700-360 


Product Code (1st digit) 


- 


- 


Alphanumerics (ASCII) 


700-361 


Product Code (2nd digit) 


- 


- 


Alphanumerics (ASCII) 


700-362 


Product Code (3rd digit) 


- 


- 


Alphanumerics (ASCII) 


700-363 


Product Code (4th digit) 


- 


- 


Alphanumerics (ASCII) 


700-364 


Product Code (5th digit) 


- 


- 


Alphanumerics (ASCII) 


700-365 


Product Code (6th digit) 


- 


- 


Alphanumerics (ASCII) 


700-366 


Product Code (7th digit) 


- 


- 


Alphanumerics (ASCII) 


700-367 


Product Code (8th digit) 


- 


- 


Alphanumerics (ASCII) 


700-368 


Lpd Buffer Size (Memory Spool) 


1MB 

(1*1024*1024 

) 


512*1024-32 
*1 024*1 024 


Memory Spool = [512 KB-32 MB] (256 KB interval) 



710-xxx DADF NVM List 



Table 2 Chain 710 



Chain-Link 


Name 


Default 


Range 


Description 


710-001 


ADF Fail Bypass 





0-1 


= Bypass ON 1 = Bypass OFF 


710-002 


JAM Bypass 





0-1 


= Bypass ON 1 = Bypass OFF 


710-005 


Regi Sensor Off to Belt Motor Slow- 
down Step (Non CVT Mode) 


250 


217-283 


No. of Steps after the Regi Sensor turned Off and until the Belt Motor started to reduce speed in the Non CVT 
Mode. Lead Regi Adjustment Value = 5 +/-5mm 





Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-13 



General Procedures and Information 



Table 2 Chain 710 



Chain-Link 


Name 


Default 


Range 


Description 


710-006 


DupMode RegiSensor On to Belt Mot. 
Slowdown Step (Non CVT Mode) 


44 


19-69 


[Description] = No. of Steps after the Regi Sensor turned On and until the Belt Motor started to reduce speed in 
the Non CVT Mode (Reverse & Reverse Output Loop) Regi Roll Loop Adjustment Value at Reverse & Reverse 
Output = 4 +/-5mm 


710-012 


8.5x1 1"LEF Threshold 


2093 


1993-2193 


Threshold to separated the size detection of 8.5x1 1"LEF and 8x10"LEF. 


710-013 


B5SEF/8x10"SEF Switching 





0-1 


0= B5SEF(FX/XE/AP), 1 = 8x10"SEF(XC) 


710-014 


11x15"SEF/8K Switching (for AP mar- 
ket) 





0-1 


11x15"SEF, 1 = 8K 


710-018 


FS MAX value 


2970 


1297-3070 


For customized registration of DADF Document Size Detection Decurler 


710-019 


FS MIN value 


2970 


1297-3070 


For customized registration of DADF Document Size Detection Decurler 


710-020 


SS MAX value 


2100 


1297-4418 


For customized registration of DADF Document Size Detection Decurler 


710-021 


SS MIN value 


2100 


1297-4418 


For customized registration of DADF Document Size Detection Decurler 


710-022 


Document Size 


8 


3-20 


For customized registration of DADF Document Size Detection Decurler 


710-023 


Document Process Direction 





0-1 


For customized registration of DADF Document Size Detection Decurler 


710-024 


DADF Doc Size Detection Table 





0-1 


For customized registration of DADF Document Size Detection Decurler 


710-025 


S Size Side2 Lead Regi Adjust 


250 


217-283 


Side 2 Lead Regi Correction Value of S Size document. Unit = Step (S Size = 131.7mm~158.0mm in Slow 
Scan Direction) 


710-026 


M Size Side2 Lead Regi Adjust 


250 


217-283 


Side 2 Lead Regi Correction Value of M Size document. Unit = Step (M Size = 158.1mm~245.9mm in Slow 
Scan Direction) 


710-027 


L Size Side2 Lead Regi Adjust 


250 


217-283 


Side 2 Lead Regi Correction Value of L Size document. Unit = Step (L Size = 246.0mm~460.0mm in Slow Scan 
Direction) 


710-800 


ADF Static Jam Count Total (No Sensor 
Sensed Jam) 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-801 


ADF Static Jam Count Since Reset (No 
Sensor) 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-802 


ADF Document Input Sensor Static 
Jam Count Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-803 


ADF Doclnput SNR Static Jam Count 
Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-804 


ADF Registration Sensor Static Jam 
Count Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-805 


ADF Regi Sensor Static Jam Count 
Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-806 


ADF Exit Sensor Static Jam Count Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-807 


ADF Exit Sensor Static Jam Count 
Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-808 


ADF Duplex Sensor Static Jam Count 
Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-809 


ADF Duplex Sensor Static Jam Count 
Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-810 


ADF Regi SNR On Nonlnvert Dynamic- 
Jam Count Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-811 


ADF Regi SNR On Dynamic Jam Count 
Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 





General Procedures and Information 



6/02 
6-14 



Prelaunch Training/Review 
DC1 632/2240 



Table 2 Chain 710 



Chain-Link 


Name 


Default 


Range 


Description 


710-812 


ADF RegiSNR Off Nonlnvert Dynamic- 
Jam Count Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-813 


ADF Regi SNR Off Dynamic Jam Count 
Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-814 


ADF Regi SNR On Dynamic Jam Count 
Total (invert) 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-815 


ADF RegiSNROn DynamicJamCount 
Since Reset (invert) 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-816 


ADF Regi SNR Off Dynamic Jam Count 
Total (invert) 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-817 


ADF RegiSNROffDynamicJamCount 
Since Reset (invert) 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-818 


ADF Exit Sensor On Dynamic Jam 
Count Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-819 


ADF Exit Sensor On Dynamic Jam 
Count Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-820 


ADF Exit Sensor Off Dynamic Jam 
Count Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-821 


ADF Exit Sensor Off DynamicJam 
Count Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-822 


Size Mismatch Jam Count Total 





0-65535 


Cumulative Jam Counter (Write not permitted) 


710-823 


Size Mismatch Jam Count Since Reset 





0-65535 


Cumulative Jam Counter at the previous clearing (Write not permitted) 


710-900 


Feed Life Count (upper digits) 


36 


0-65535 


Feed Count Replacement Life (Upper digits) (Write not permitted) 


710-901 


Feed Life Count (lower digits) 


40704 


0-65535 


Feed Count Replacement Life (Lower digits) (Write not permitted) 



715-xxxllTNVMList 



Table 3 Chain 715 



Chain-Link 


Name 


Default 


Range 


Description 


715-001 


PrelPS Fail Bypass 





0-1 


= Fail Bypass is not available, 1 = Fail Bypass is available 


715-004 


ACS Detection Level 


2 


0-4 


Level (judged from Black and White )~Level 4 (judged from Color) 


715-014 


PRadjF 


120 


0-240 


Fast Scan Direction Regi Correction Value (Dot) Adjustment at factory. VLSS=PROMVLSS+PRadjF -120 - 
Shift Amount 


715-015 


DADF FS Offset 


71 


0-150 


Fast Scan Offset Value (Dot) when DADF is used. VLSS=PROMVLSS+PRadjF -120 +DADF Offset- Shift 
Amount, Adjustment at factory. (DUP Side can be used too) 


715-016 


Side Registration Shift (-) 





0-256 


For VLSS=PROMVLSS+PRadjF - 120 - Shift Amount and (Dot) Regi adjustments. 


715-017 


COSAC FS1x5 Filter 





0-1 


= OFF, 1 = ON (Moire reduction) 


715-018 


COSAC Special Feature (Setting range 
isTBD) 





0-2047 


bit -> = Normal, 1 = LSWIDE LineSync Active large width bit 1 -> = Normal, 1 = AGOC Cancel, Manual 
Setup from NVM-AGCP, AOCP. bit 2 -> = Normal, 1 = Forward revolution output (ONPF=0) 


715-051 


AOCerr 





0-255 


No. of times the AOC flow has ended in an abnormal way. 


715-080 


Pshad(1) 


148 


115-255 


Red W-Ref Correction Coefficient Adjustment at factory. 


715-081 


Pshad (2) 


158 


115-255 


Green W-Ref Correction Coefficient Adjustment at factory. 


715-082 


Pshad (3) 


165 


115-255 


Blue W-Ref Correction Coefficient Adjustment at factory. 





Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-15 



General Procedures and Information 



Table 3 Chain 715 



Chain-Link 


Name 


Default 


Range 


Description 


715-083 


Pshad (4) 


65 


0-127 


Red W-Ref Correction Coefficient P Paper Adjustment at factory. 


715-084 


Pshad (5) 


72 


0-127 


Green W-Ref Correction Coefficient P Paper Adjustment at factory. 


715-085 


Pshad (6) 


69 


0-127 


Blue W-Ref Correction Coefficient P Paper Adjustment at factory. 


715-113 


A6/Postcard Detection 





0-1 


= A6 Document, 1 = Postcard Document (XC = Postcard, 1 = A6) 


715-114 


A4S/8.5in Detection 1 





0-1 


= A4 Fixed (Other than XC), Letter Fixed (XC), 1 = Can be changed by Area Switching 2 


715-115 


A4S/8.5in Detection 2 


3 


0-6 


= 210mm(A4S)~6 = 216mm(8.5") 


715-116 


Original detection table for special 
paper 





0-2 


= Do not use special table 1 = A Series (A4L when APS is Off, and A3S when APS is On) 2 = Inch Series 
(Letter LEF when APS is Off, and 11x17" when APS is On) 


715-128 


DADF FS Offset (side 2) 


71 


01-50 


Fast Scan Offset value (Dot) on IPS at DADF DUP Side 2. VLSS=PROMVLSS+PRadjF - 50 +DADF Offset Side 
2 Adjustment at factory. 


715-138 


Document Size Detection 





0-1 


= Detection by 4 Registers, 1 = Detection by 3 Registers (Contamination Countermeasure) 


715-139 


B5/8x10" Detection 





0-1 


B5/8x10" Switching (Default = B5 Detection, 1 = 8x10" Detection) 


715-140 


8K Detection 





0-1 


8K detection specification (Default = Do not detect, 1 = Detect) 


715-141 


8.5x1378.5x14" Detection 





0-1 


8.5x1378.5x14" Detection Switching Specification in AP/XE markets. 


715-142 


NutAngleF 


990 


0-1980 


Front NUT Revolution Angle (990-1980 = Right revolution angle, 0-990 = Left revolution angle) 


715-143 


NutAngleR 


990 


0-1980 


Rear NUT Revolution Angle (990-1980 = Right revolution angle, 0-990 = Left revolution angle) 


715-200 


External Area of FS Sampling 


255 


0-511 


Speed Priority AE/Fast Scan direction undetected area 


715-204 


Maximum Sampling Value of Back- 
ground color 


90 


0-255 


Speed Priority AE/Sampling Upper Limit/BMAX 


715-205 


Initial Background color Value 





0-255 


Speed Priority AE/Background level initial value/INIT 


715-208 


Line to Fix Variation 


48 


0-255 


Speed Priority AE/Slow Scan variation fixed position/NCON 


715-212 


Background Color Suppression mode 
forBW 


2 


0-2 


Speed Priority AE/Suppression Mode Setup in B/W = Register, 1 = Fixed, 2 = Vary 


715-213 


Background Color Suppression mode 
for Color 





0-2 


Speed Priority AE/Suppression Mode Setup in Color = Register, 1 = Fixed, 2 = Vary 


715-214 


Undercolor Data for BW 





0-255 


Speed Priority AE/Fixed background color data in B/W Register Mode 


715-215 


Undercolor Data for Color 





0-255 


Speed Priority AE/Fixed background color data in Color Register Mode 


715-218 


Gamma Data for BW 


1 


0-2 


AE GAMMA Data in B/W mode = GMD=2, 1 = GMD=3, 2 = GMD=5 


715-219 


Gamma Data for Color 


1 


0-2 


AE GAMMA Data in Color mode = GMD=2, 1 = GMD=3, 2 = GMD=5 


715-220 


Color Balance Default = Y/Low density 


4 


0-8 


Default Color Balance Adjustment Level Y Color Low density 


715-221 


Color Balance Default = Y/Medium 
density 


4 


0-8 


Default Color Balance Adjustment Level Y Color Medium density 


715-222 


Color Balance Default = Y/High density 


4 


0-8 


Default Color Balance Adjustment Level Y Color High density 


715-223 


Color Balance Default = M/Low density 


4 


0-8 


Default Color Balance Adjustment Level M Color Low density 


715-224 


Color Balance Default = M/Medium 
density 


4 


0-8 


Default Color Balance Adjustment Level M Color Medium density 


715-225 


Color Balance Default = M/High den- 
sity 


4 


0-8 


Default Color Balance Adjustment Level M Color High density 


715-226 


Color Balance Default = C/Low density 


4 


0-8 


Default Color Balance Adjustment Level C Color Low density 


715-227 


Color Balance Default = C/Medium 
density 


4 


0-8 


Default Color Balance Adjustment Level C Color Medium density 


715-228 


Color Balance Default = C/High density 


4 


0-8 


Default Color Balance Adjustment Level C Color High density 





General Procedures and Information 



6/02 
6-16 



Prelaunch Training/Review 
DC1 632/2240 



Table 3 Chain 715 



Chain-Link 


Name 


Default 


Range 


Description 


715-229 


Color Balance Default = K/Low density 


4 


0-8 


Default Color Balance Adjustment Level K Color Low density 


715-230 


Color Balance Default = K/Medium 
density 


4 


0-8 


Default Color Balance Adjustment Level K Color Medium density 


715-231 


Color Balance Default = K/high density 


4 


0-8 


Default Color Balance Adjustment Level K Color High density 


715-232 


Photo reproduction level 


1 


0-2 


= Above Text, 1 = Normal, 2 = Above Photo 


715-233 


Text/Photo separation level 


2 


0-4 


= Above Text, 1 = Slightly above text, 2 = Normal, 3 = Slightly above photo, 4 = Above Photo 


715-234 


FS Magnification Adjustment 


50 


0-100 


Magnification fine adjustment in Fast Scan direction. Specified in units between range of 0-100. The value indi- 
cates the magnification adjustment with 0= -5%, 50= 0% and 100= 5% at ±5% (0.1% unit) (Adjustment at fac- 
tory.) 


715-237 


Normal Density Text (BW Copy) 


128 


0-256 


B/W COPY Text Normal Density Adjustment 


715-238 


High Density Text (BW Copy) 


128 


0-256 


B/W COPY Text Darker 3 Density Adjustment 


715-239 


Normal Density Text (Scan) 


128 


0-256 


Scan Text Normal Density Adjustment 


715-240 


High Density Text (Scan) 


128 


0-256 


Scan Text Darker 3 Density Adjustment 


715-241 


SS Not Detect Area for Platen model 
(Real Time AE) 


38 


0-65535 


Slow Scan Non-detection area Setup value at Real Time AE for platen model. 


715-242 


SS Not Detect Area for DADF model 
DADF mode (Real Time AE) 


38 


0-65535 


Slow Scan Non-detection area Setup value at Real Time AE for DADF model platen job. 


715-243 


SS Not Detect Area for DADF model 
Platen mode (Real Time AE) 


38 


0-65535 


Slow Scan Non-detection area Setup value at Real Time AE for DADF model DADF job. 


715-244 


B/W-Offset for Text/Image Platen mode 
(Real Time AE) 


10 


0-255 


For AE OFFSET data Platen text/photo in B/W model 


715-245 


B/W-Offset for Text Platen mode (Real 
Time AE) 


10 


0-255 


For AE OFFSET data Platen text in B/W model 


715-246 


B/W-Offset for Map Platen mode (Real 
Time AE) 


10 


0-255 


For AE OFFSET data Platen map in B/W model 


715-247 


B/W-Offset for Text/Image DADF Single 
Side mode (Real Time AE) 


13 


0-255 


For AE OFFSET data DADF Single Side Document text/photo in B/W model 


715-248 


B/W-Offset for Text DADF Single Side 
mode(Real Time AE) 


15 


0-255 


For AE OFFSET data DADF Single Side Document text in B/W model 


715-249 


B/W-Offset for Map DADF Single Side 
mode Real Time AE) 


13 


0-255 


For AE OFFSET data DADF Single Side Document map in B/W model 


715-250 


B/W-Offset for Text/Image DADF 
Duplex Side mode (Real Time AE) 


17 


0-255 


For AE OFFSET data DADF Duplex Side Document text/photo in B/W model 


715-251 


B/W-Offset for Text DADF Duplex Side 
mode (Real Time AE) 


17 


0-255 


For AE OFFSET data DADF Duplex Side Document text in B/W model 


715-252 


B/W-Offset for Map DADF Duplex Side 
mode (Real Time AE) 


17 


0-255 


For AE OFFSET data DADF Duplex Side Document map in B/W model 


715-253 


Color-Offset for Text/Image Platen 
mode (Real Time AE) 


15 


0-255 


For AE OFFSET data Platen text/photo in Color model 


715-254 


Color-Offset for Text Platen mode (Real 
Time AE) 


15 


0-255 


For AE OFFSET data Platen text in Color model 


715-255 


Color-Offset for Text Platen mode (Real 
Time AE) 


15 


0-255 


For AE OFFSET data Platen map in Color model 





Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-17 



General Procedures and Information 



Table 3 Chain 715 



Chain-Link 


Name 


Default 


Range 


Description 


715-256 


Color-Offset for Text/Image DADF Sin- 
gle Side mode (Real Time AE) 


17 


0-255 


For AE OFFSET data DADF Single Side Document text/photo in Color model 


715-257 


Color-Offset for Text DADF Single Side 
mode (Real Time AE) 


18 


0-255 


For AE OFFSET data DADF Single Side Document text in Color model 


715-258 


Color-Offset for Map DADF Single Side 
mode (Real Time AE) 


17 


0-255 


For AE OFFSET data DADF Single Side Document map in Color model 


715-259 


Color-Offset for Text/Image DADF 
Duplex Side mode (Real Time AE) 


17 


0-255 


For AE OFFSET data DADF Duplex Side Document text/photo in Color model 


715-260 


Color-Offset for Text DADF Duplex Side 
mode (Real Time AE) 


18 


0-255 


For AE OFFSET data DADF Duplex Side Document text in Color model 


715-261 


Color-Offset for Map DADF Duplex 
Side mode (Real Time AE) 


17 


0-255 


For AE OFFSET data DADF Duplex Side Document map in Color model 


715-300 


I IT Fail Bypass 





0-1 


= Fail Bypass is not available, 1 = Fail Bypass is available 


715-301 


SS Registration Adjustment 


100 


16-184 


Slow Scan Direction Regi Correction Value (0.036mm/step) Adjustment at factory. 


715-302 


SS Magnification Adjustment 


50 


44-56 


Slow Scan direction Magnification Correction Value (0.1%/step) Adjustment at factory. 


715-400 


Platen/ADF 





0-1 


= Platen model 1 = ADF model Adjustment at factory. 


715-401 


AGOC Timing 


15 


0-29 


Time between Power ON/Energy Saver recovery and AGOC (min.) (0 = Timer not available) 


715-800 


IIISS/ADF Communication Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-801 


IISS/ADF Communication Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-802 


MISS RAM CHECK Failure Count Over- 
all Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-803 


IISS RAM CHECK Failure Count Since 
Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-804 


EEPROM Failure Count Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-805 


EEPROM Failure Count Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-806 


Fan Failure Count Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-807 


Fan Failure Count Since Reset 





0-065535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-808 


Scan Carriage Position Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-809 


Scan Carriage Position Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-810 


Scan CRG Init Regi SNR Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-811 


Scan CRG Init Regi Sensor Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-812 


PrelPS (X) Recognition Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-813 


PrelPS (X) Recognition Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-814 


Lamp Failure Count Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-815 


Lamp Failure Count Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 





General Procedures and Information 



6/02 
6-18 



Prelaunch Training/Review 
DC1 632/2240 



Table 3 Chain 715 



Chain-Link 


Name 


Default 


Range 


Description 


715-816 


CRG Over Run Fail Count Overall Total 
(Scan End) 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-817 


CRG Over Run Fail Count Since Reset 
(Scan End) 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-818 


CRG Over Run Fail Count Overall Total 
(Home End) 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-819 


CRG Over Run Fail Count Since Reset 
(Home End) 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-820 


CRG INIT Motor Driver Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-821 


CRG INIT Motor Driver Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-822 


Platen AGC Channel 1 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-823 


Platen AGC Channel 1 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-824 


Platen AGC Channel 2 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-825 


Platen AGC Channel 2 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-826 


Platen AGC Channel 3 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-827 


Platen AGC Channel 3 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-828 


Platen AGC Channel 4 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-829 


Platen AGC Channel 4 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-830 


Platen AGC Channel 5 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-831 


Platen AGC Channel 5 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-832 


Platen AGC Channel 6 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-833 


Platen AGC Channel 6 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-834 


Platen AOC Channel 1 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-835 


Platen AOC Channel 1 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-836 


Platen AOC Channel 2 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-837 


Platen AOC Channel 2 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 





Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-19 



General Procedures and Information 



Table 3 Chain 715 



Chain-Link 


Name 


Default 


Range 


Description 


715-838 


Platen AOC Channel 3 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-839 


Platen AOC Channel 3 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-840 


Platen AOC Channel 4 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-841 


Platen AOC Channel 4 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-842 


Platen AOC Channel 5 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-843 


Platen AOC Channel 5 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-844 


Platen AOC Channel 6 Fail Count 
Overall Total 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-845 


Platen AOC Channel 6 Fail Count 
Since Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-854 


Original Size Sensor Failure Total 
Count 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-855 


Original Size Sensor Failures Since 
Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-856 


NT Memory Hot Line Failure Total 
Count 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-857 


NT Memory Hot Line Failures Since 
Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-858 


DADF RAM CHECK Failure Total 
Count 





0-65535 


Cumulative Fail Counter (Write not permitted) 


715-859 


DADF RAM CHECK Failures Since 
Reset 





0-65535 


Cumulative Fail Counter at the previous clearing (Write not permitted) 


715-900 


Scan Life Count (upper digits) 


36 


0-65535 


Scan Count Replacement Life (Upper Level) (Write not permitted) 


715-901 


Scan Life Count (lower digits) 


40704 


0-65535 


Scan Count Replacement Life (Lower Level) (Write not permitted) 



719--xxx IIT/DADF Software NVM List 



Table 4 Chain 719 



Chain-Link 


Name 


Default 


Range 


Description 


719-001 


Version No. (Upper level) 





0-65535 


Indicates the IISS Version No. 


719-002 


Market Information 





0-3 


FX=0,AP=1,XC=2, XE=3 


719-003 


A4/Letter 


1 


0-3 


Basic unit of document size. For A4 = bit0=1 , letter = bit=1 'Checking of range is not performed. 


719-004 


ADF Version No. 





0-65535 


Indicates the ADF Version No. 


719-005 


IISS Major Version 





0-65535 


IISS Major Version No. 


719-006 


IISS Minor Version 





0-65535 


IISS Minor Version No. 


719-007 


IISS Revision Version 





0-65535 


IISS Revision Version No. 


719-008 


IISS Patch Version 





0-65535 


IISS Patch Version No. 





General Procedures and Information 



6/02 
6-20 



Prelaunch Training/Review 
DC1 632/2240 



Table 4 Chain 719 



Chain-Link 


Name 


Default 


Range 


Description 


719-010 


ADF Major Version 





0-65535 


ADF Major Version No. 


719-011 


ADF Minor Version 





0-65535 


ADF Minor Version No. 


719-012 


ADF Revision Version 





0-65535 


ADF Revision Version No. 


719-013 


ADF Patch Version 





0-65535 


ADF Patch Version No. 



720-xxx ESS Meter/Counter NVM List 



Table 5 Chain 720 



Chain-Link 


Name 


Default 


Range 


Description 


720-002 


Billing 


PFV BILL- 
ING TYPE1 


1-6 


1= Billing1,2= Billing2, 3 = Billing3, 4 = Billing4, 5 = Billing5, 6 = Billing6 


720-003 


Master Print-Full Color 


- 


0-1999999 


0-1,999,999 


720-004 


Master Print-Colorl 


- 


0-1999999 


0-1,999,999 


720-005 


Master Print-Color2 


- 


0-1999999 


0-1,999,999 


720-006 


Master Print-B&W 


- 


0-1999999 


0-1,999,999 


720-012 


Backupl Print-Full Color 


- 


0-1999999 


0-1,999,999 


720-013 


Backupl Print-Colorl 


- 


0-1999999 


0-1,999,999 


720-014 


Backupl Print-Color2 


- 


0-1999999 


0-1,999,999 


720-015 


Backupl Print-B&W 


- 


0-1999999 


0-1,999,999 


720-040 


[PSW Display] Group 





0-999999999 
999 


0-999999999999 (0 means not set up) 


720-041 


TBD 





0-999999999 
999 


0-999999999999 (0 means not set up) 


720-042 


TBD 





0-3 


= FreeAccess, 1 = Color Only, 2 = B&W Only, 3 = Cannot be used 


720-043 


TBD 





0-3 


= FreeAccess, 1 = Color Only, 2 = B&W Only, 3 = Cannot be used 


720-044 


Group C Mode to use 





0-3 


= FreeAccess, 1 = Color Only, 2 = B&W Only, 3 = Cannot be used 



740-xxx IOT Manager NVM List 



Table 6 Chain 740 



Chain-Link 


Name 


Default 


Range 


Description 


740-024 


RegiCon Request Flag 





0-255 


= Performed, 1 = Not performed 


740-025 


Edge Check Request Flag 





0-255 


= Performed, 1 = Not performed 


740-026 


ProCon Request Flag 





0-255 


= Performed, 1 = Not performed 



Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-21 



General Procedures and Information 



741--xxx Drive NVM List 



Table 7 Chain 741 



Chain-Link 


Name 


Default 


Range 


Description 


741-054 


NVM_PR_MOT_HIGH_PULSE (PR 
(Drum) Motor Speed Fine Adjustment 
(Standard) 


23 


0-40 


Performs fine adjustment of Drum Speed at Standard Speed. Increases the Drum Speed by +1 (approx. 0.05%) 
with respect to the initial value. Decreases the Drum Speed by -1 (approx. 0.05%). 


741-055 


NVM_PR_MOT_LOW_PULSE (PR 
(Drum) Motor Speed Fine Adjustment 
(Heavy Weight /Transparency) 


23 


0-40 


Fine adjusts the Drum Speed at half speed. Increases the Drum Speed by +1 (approx. 0.05%) with respect to 
the initial value. Decreases the Drum Speed by -1 (approx. 0.05%). 


741-056 


Belt Home Fail Too Long Counter 





0-3 


It is necessary to reset the No. of Occurrence of Belt Home Fail Too Long to 3. 


741-057 


NoPaperRun Mode SW 





0-2 


= Normal NoPaperRun 1 = MainMotor Stop 2 = Main/Dev. Motor Stop 


741-068 


NVM_PR_MOT_DOUBLE_PULSE (PR 
(Drum) Motor Speed Fine Adjustment 
(Double Speed) 


22 


0-40 


Fine adjusts the Drum Speed at double speed. Increases the Drum Speed by +1 (approx. 0.05%) with respect 
to the initial value. Decreases the Drum Speed by -1 (approx. 0.05%). 



742-xxx Paper Handling NVM List 



Table 8 Chain 742 



Chain-Link 


Name 


Default 


Range 


Description 


742-001 


Invert Clutch CW Off Timing 


82 


0-163 

(1bit= 2.4462ms) 


Paper inversion position adjustment (P Speed) default=2300ms 


742-002 


Invert Clutch CW Off Timing (MF-1) 


106 


0-259 

(1bit= 1.31136ms) 


Paper inversion position adjustment (Double Speed) 


742-006 


RegiLoopLengthAjust (Tray Standard 
Paper) 


41 


0-81 

(1bit= 2.4462ms) 


Regi Loop Length Adjustment (P Speed) for Standard Paper from Tray. Default=260ms 


742-007 


RegiLoopLengthAjust (Tray Standard 
Paper) (MF) 


41 


0-81 

(1bit= 1.31136ms) 


Regi Loop Length Adjustment (Double Speed) for Standard Paper from Tray 


742-009 


RegiLoopLengthAjust (Tray 5 Standard 
Paper) 


41 


0-81 


Regi Loop Length Adjustment (P Speed) for Standard Paper from Tray 5 (1bit= 2.4462ms) 


742-011 


RegiLoopLengthAjust (Tray 5 Standard 
Paper) (MF) 


41 


0-81 

(1bit= 1.322ms) 


Regi Loop Length Adjustment (Double Speed) for Standard Paper from MSI 


742-013 


RegiLoopLengthAjust (Tray 5 Heavy2 
Paper) 


41 


0-81 

(1bit= 4.8924ms) 


Regi Loop Length Adjustment (Half Speed) for Heavy Weight Paper from MSI. Default=221ms 


742-014 


RegiLoopLengthAjust (DUP) (2sheets 
of paper) 


41 


0-81 

(1bit= 2.4462ms) 


Regi Loop Length Adjustment (P Speed) from Dup (Feeding length Letter-LEF and Shorter) Default=157ms 


742-015 


RegiLoopLengthAjust (DUP) (MF) 


76 


0-152 

(1bit= 1.31136ms) 


Regi Loop Length Adjustment (Double Speed) from Dup 


742-016 


T/A Clutch On Timing (From Regi Start) 


20 


8-32 

(1bit= 2.4462ms) 


Synchronize adjustment to be same as Regi Clutch at Regi Start (-30~30ms) Default=0ms 


742-017 


Dup On Timing (From Regi Start) 


20 


0-40 

(1bit= 2.4462ms) 


Synchronize adjustment to be same as Regi Clutch at Regi Start (P Speed). Default=373ms 


742-018 


Full Stack Paper Sensing Condition 


2 


1~12(1bit=5sec) 


Full Stack Detection Condition (5~60sec). 


742-019 


Full Stack Paper Cancel Condition 


1 


1~30(1bit= 1sec) 


Full Stack Cancel Condition (1~30sec) 


742-020 


Feed Start Timing (MSI) 


41 


0~82(1bit= 
2.4462ms) 


Feed Start Timing Adjustment from Pitch (P Speed) (850-1 050ms). Default=950ms 





General Procedures and Information 



6/02 
6-22 



Prelaunch Training/Review 
DC1 632/2240 



Table 8 Chain 742 



Chain-Link 


Name 


Default 


Range 


Description 


742-021 


Feed Start Timing (MSI) (MF) 


150 


0-300 (1bit= 
1.31136ms) 


Feed Start Timing Adjustment from Pitch (Double Speed) (100~500ms) 


742-022 


Feed Motor Off Timing 


10 


0-35 
(1bit= 10ms) 


Feed Motor Off Timing Adjustment from T/A Nip 


742-023 


Regi Clutch Off Timing 


41 


0-81 

(1bit= 2.4462ms) 


Adjusts the time between the paper rear edge has passes the Regi Sensor and the Regi Clutch Turns Off (P 
Speed) (90~290ms). Default=190ms 


742-024 


Regi Clutch Off Timing (MF) 


76 


0-152 

(1bit= 1.31136ms) 


Adjusts the time between the paper rear edge has passes the Regi Sensor and the Regi Clutch Turns Off (Dou- 
ble Speed) 


742-025 


ADJUST SIDE REGI (ALL) 


25 


0-50 

(1bit= 0.211mm) 


Side Regi Adjustment (ALL, Offset value) 


742-026 


ADJUST SIDE REGI (MSI) 


20 


0-50 

(1bit= 0.211mm) 


Side Regi Adjustment (MSI) 


742-027 


ADJUST SIDE REGI (Dup) 


22 


0-50 
(1bit= 0.211mm) 


Side Regi Adjustment (Dup) 


742-028 


ADJUST LEAD REGI (ALL) 


20 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (ALL, Offset value) 


742-029 


ADJUST LEAD REGI (Tray) 


12 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (P Speed) from Tray 


742-030 


ADJUST LEAD REGI (Tray) 


20 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (Double Speed) from Tray 


742-031 


ADJUST LEAD REGI (MSI) (Standard 
Paper) 


11 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (P Speed) Standard Paper from Tray 5 


742-032 


ADJUST LEAD REGI (MSI) (Standard 
Paper) 


20 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (Double Speed) Standard Paper from MSI 


742-033 


ADJUST LEAD REGI (MSI) (Heavyl) 


20 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (P Speed) Heavy Weight Paper 1 from Tray 5 


742-034 


ADJUST LEAD REGI (MSI) (Heavy2) 


20 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (Half Speed) Heavy Weight Paper 2 from Tray 5 


742-035 


ADJUST LEAD REGI (MSI) (Heavy 
Paperl) 


20 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (Half Speed) Heavy Weight Paper 1 from Tray 5 


742-036 


ADJUST LEAD REGI (MSI) (Heavy 
Paper2) 


20 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (Half Speed) Heavy Weight Paper 2 from Tray 5 


742-037 


ADJUST LEAD REGI (Dup) 


11 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (P Speed) (Side2) 


742-038 


ADJUST LEAD REGI (Dup) 


20 


0-40 

(1bit= 0.2544mm) 


Lead Regi Adjustment (Double Speed) (Side2) 


742-039 


Jam Bypass 





0-255 


= Normal Mode 255 = Jam Bypass 


742-040 


OCT Start Timing (Offset) 


42 


0-202 

(1bit= 2.4462ms) 


OCT (Offset) Start Timing Adjustment (P Speed) 


742-041 


OCT Start Timing (Offset) 


42 


0-202 

(1bit= 1.31136ms) 


OCT (Offset) Start Timing Adjustment (Double Speed) 


742-046 


Face Up Tray Condition 





0-1 


Face Up Tray Present = No 1 = Yes 


742-047 


OCT Start Timing (Home) 


17 


0-112 

(1bit= 2.4462ms) 


OCT (Home) Start Timing Adjustment (P Speed) 





Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-23 



General Procedures and Information 



Table 8 Chain 742 



Chain-Link 


Name 


Default 


Range 


Description 


742-048 


OHP Sheet Sensing Condition 


1 


0-1 


Transparency Detection 1 = Detect = Does not detect 


742-049 


Tray 5 Side Guide Min Data 


972 


927-1017 
(1bit= 1mm) 


Saves the Tray 5 Size Detection Min Value 


742-050 


Tray 5 Side Guide Max Data 


52 


7~97(1bit= 1mm) 


Saves the Tray 5 Size Detection Max Value 


742-051 


FEED START TIMING 1Tray 


82 
(450ms) 


0-163 

(1bit= 2.4462ms) 


Adjusts the time between Pitch (Standard Signal IOT) and FEED Starts (250~650ms). 


742-052 


FEED START TIMING 1Tray 


82 


0-163 

(1bit= 1.31136ms) 




742-053 


ADJUST SIDE REGI 1Tray 


22 


0-50 

(1bit= 0.211mm) 


SIDE REGI Adjustment for each TRAY 


742-054 


PAPER THE REST 1Tray 





0-4000 


Saves the Cumulative LIFT UP Time from TRAY insertion (For remaining detection calculation as=A). 


742-055 


PRE T/A START TIMING 3TM-1 


74 


0-115 

(1bit= 2.4462ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (303~803ms) 


742-056 


PRE T/A START TIMING 3TM-2 


74 


0-115 
(1bit= 2.4462ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (365~865ms) 


742-057 


PRE T/A START TIMING 3TM-3 


74 


0-115 

(1bit= 2.4462ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (429~929ms) 


742-058 


PRE T/A START TIMING TTM-1 


10 


0-16 

(1bit= 2.4462ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) 


742-059 


PRE T/A START TIMING TTM-2 


74 


0-115 

(1bit= 2.4462ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (457~957ms) 


742-060 


PRE T/A START TIMING TTM-3 


74 


0-115 

(1bit= 2.4462ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (431 -931 ms) 


742-061 


PRE T/A START TIMING 1TM-1 


102 


0-204 

(1bit= 2.4462ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (303~803ms). Default=553ms 


742-062 


ADJUST PRE FEED POSITION 3TM-1 





0-40 
(1bit= 10ms) 


Adjust the Time between the FEED OUT SNR ON and the FEED MOT OFF (0~400ms). 


742-063 


ADJUST PRE FEED POSITION 3TM-2 





0-40 
(1bit= 10ms) 


Adjust the Time between the FEED OUT SNR ON and the FEED MOT OFF (0~400ms). 


742-064 


ADJUST PRE FEED POSITION 3TM-3 





0-40 
(1bit= 10ms) 


Adjust the Time between the FEED OUT SNR ON and the FEED MOT OFF (0~400ms). 


742-065 


ADJUST PRE FEED POSITION TTM-1 





0-40 
(1bit= 10ms) 


Adjust the Time between the FEED OUT SNR ON and the FEED MOT OFF (0~400ms). 


742-066 


ADJUST PRE FEED POSITION TTM-2 





0-40 
(1bit= 10ms) 


Adjust the Time between the FEED OUT SNR ON and the FEED MOT OFF (0~400ms). 


742-067 


ADJUST PRE FEED POSITION TTM-3 


37 


10-50 
(1bit= 10ms) 


Adjust the Time between the FEED OUT SNR ON and the FEED MOT OFF (100~500ms). Default=370ms 


742-068 


ADJUST PRE FEED POSITION 1TM-1 





0-40 
(1bit= 10ms) 


Adjust the Time between the FEED OUT SNR ON and the FEED MOT OFF (0~400ms). 


742-069 


MAIN FEED START TIMING 3TM-1 


20 


0-44 
(1bit= 10ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (330~830ms). 


742-070 


MAIN FEED START TIMING 3TM-2 


20 


0-44 
(1bit= 10ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (570-1 070ms). 





General Procedures and Information 



6/02 
6-24 



Prelaunch Training/Review 
DC1 632/2240 



Table 8 Chain 742 



Chain-Link 


Name 


Default 


Range 


Description 


742-071 


MAIN FEED START TIMING 3TM-3 


20 


0-44 
(1bit= 10ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (810~1310ms). 


742-072 


MAIN FEED START TIMING TTM-1 


20 


0-44 
(1bit= 10ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (330~830ms). 


742-073 


MAIN FEED START TIMING TTM-2 


20 


0-44 
(1bit= 10ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (780-1 280ms). 


742-074 


MAIN FEED START TIMING TTM-3 


20 


0-44 
(1bit= 10ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (1410~1910ms). 


742-075 


MAIN FEED START TIMING 1TM-1 


25 


0-50 
(1bit= 10ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (330~830ms).Default=580ms 


742-076 


ADJUST SIDE REGI2Tray 


20 


0-50 

(1bit= 0.211mm) 


SIDE REGI adjustment of 2TRAY 


742-077 


ADJUST SIDE REGI3Tray 


20 


0-50 
(1bit= 0.211mm) 


SIDE REGI adjustment of 3TRAY 


742-078 


ADJUST SIDE REGI4Tray 


20 


0-50 

(1bit= 0.211mm) 


SIDE REGI adjustment of 4TRAY 


742-079 


ADJUST SIDE REGI TrayModuleAII 


25 


0-50 

(1bit= 0.211mm) 


SIDE REGI adjustment of 2, 3, 4TRAY (Batch adjustment) 


742-080 


PAPER THE REST 3TM-1 





0-4000 


Saves the Cumulative LIFT UP Time from TRAY insertion (For remaining detection calculation as=A). 


742-081 


PAPER THE REST 3TM-2 





0-4000 


Saves the Cumulative LIFT UP Time from TRAY insertion (For remaining detection calculation as=A). 


742-082 


PAPER THE REST 3TM-3 





0-4000 


Saves the Cumulative LIFT UP Time from TRAY insertion (For remaining detection calculation as=A). 


742-083 


PAPER THE REST TTM-1 





0-4000 


Saves the Cumulative LIFT UP Time from TRAY insertion (For remaining detection calculation as=A). 


742-084 


PAPER THE REST TTM-2 





0-12000 


Saves the Cumulative LIFT UP Time from TRAY insertion (For remaining detection calculation as=A). 


742-085 


PAPER THE REST TTM-3 





0-15000 


Saves the Cumulative LIFT UP Time from TRAY insertion (For remaining detection calculation as=A). 


742-086 


PAPER THE REST 1TM-1 





0-4000 


Saves the Cumulative LIFT UP Time from TRAY insertion (For remaining detection calculation as=A). 


742-087 


OCT Condition 


1 


0-1 


= Not available, 1 = Available 


742-088 


Dup On Timing (From Regi Start) 


20 


0-40 

(1bit= 1.31136ms) 


Synchronize adjustment to be same as the Regi Clutch at Regi Start (Double Speed) 


742-089 


OCT Start Timing (Home) 


17 


0-112 

(1bit= 1.31136ms) 


OCT (Home) Start Timing Adjustment (Double Speed) 


742-093 


PRE T/A START TIMING 3TM-1 


139 


0-215 

(1bit= 1.31136ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (303~803ms) 


742-094 


PRE T/A START TIMING 3TM-2 


139 


0-215 

(1bit= 1.31136ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (365~865ms) 


742-095 


PRE T/A START TIMING 3TM-3 


139 


0-215 

(1bit= 1.31136ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (429~929ms) 


742-096 


PRE T/A START TIMING TTM-2 


139 


0-215 

(1bit= 1.31136ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (457~957ms) 


742-097 


PRE T/A START TIMING TTM-3 


139 


0-215 

(1bit= 1.31136ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (431 -931 ms) 


742-098 


MAIN FEED START TIMING 3TM-1 


38 


0-83 

(1bit= 1.31136ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (330~830ms). 


742-099 


MAIN FEED START TIMING 3TM-2 


38 


0-83 

(1bit= 1.31136ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (570-1 070ms). 





Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-25 



General Procedures and Information 



Table 8 Chain 742 



Chain-Link 


Name 


Default 


Range 


Description 


742-100 


MAIN FEED START TIMING 3TM-3 


38 


0-83 

(1bit= 1.31136ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (810~1310ms). 


742-101 


MAIN FEED START TIMING TTM-2 


38 


0-83 

(1bit= 1.31136ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (780-1 280ms). 


742-102 


MAIN FEED START TIMING TTM-3 


38 


0-83 

(1bit= 1.31136ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (1410~1910ms). 


742-103 


Select A/B or INCH (SMH Auto Detect) 





0-1 


= A/B series, 1 = Inch series 


742-104 


Select 2ndBTR Cleaning (SMH Auto 
Detect) 


1 


0-1 


= No, 1 = Yes 


742-105 


RegiLoopLengthAjust (DUP) (a sheet of 
paper) 


41 


0-81 

(1bit= 2.4462ms) 


Lead Regi Length Adjustment (P Speed) from Dup (Feeding Length Letter-LEF and longer)Default=157ms 


742-106 


PRE T/A START TIMING 3TM-1 (Half) 


37 


0-58 

(1bit= 4.8924ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (303~803ms) 


742-107 


PRE T/A START TIMING 3TM-2 (Half) 


37 


0-58 

(1bit= 4.8924ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (365~865ms) 


742-108 


PRE T/A START TIMING 3TM-3 (Half) 


37 


0-58 

(1bit= 4.8924ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (429~929ms) 


742-109 


PRE T/A START TIMING TTM-2 (Half) 


37 


0-58 

(1bit= 4.8924ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (457~957ms) 


742-110 


PRE T/A START TIMING TTM-3 (Half) 


37 


0-58 

(1bit= 4.8924ms) 


Adjusts the Time between PRE T/A Starts and Standard Signal (IOT) (431 -931 ms) 


742-111 


MAIN FEED START TIMING 3TM-1 
(Half) 


10 


0-22 

(1bit= 4.8924ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (330~830ms). 


742-112 


MAIN FEED START TIMING 3TM-2 
(Half) 


10 


0-22 

(1bit= 4.8924ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (570-1 070ms). 


742-113 


MAIN FEED START TIMING 3TM-3 
(Half) 


10 


0-22 

(1bit= 4.8924ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (810~1310ms). 


742-114 


MAIN FEED START TIMING TTM-2 
(Half) 


10 


0-22 

(1bit= 4.8924ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (780-1 280ms). 


742-115 


MAIN FEED START TIMING TTM-3 
(Half) 


10 


0-22 

(1bit= 4.8924ms) 


Adjust the Time between the MAIN FEED Starts and the PRE T/A (1410~1910ms). 



744-xxx User NVM List 



Table 9 Chain 744 



Chain-Link 


Name 


Default 


Range 


Description 


744-001 


STS-1 CONT TEMP in Low PWR Mode 


80 


0-160 

(1 bit=1 deg. C) 


Main-Lamp temperature control in Low-Power Mode. Setting the default as Degrees Celsius is same as 
Fuser-Off. It is necessary for high temperature for recovery Time Claim. 


744-002 


STS-2 CONT TEMP in Low PWR Mode 


80 


0-160 

(1 bit=1 deg. C) 


Sub-Lamp temperature control in Low-Power Mode. Setting the default as Degrees Celsius is same as Fuser- 
Off. It is necessary for high temperature for recovery Time Claim. 


744-003 


UM status by High Temperature Error 
Detection 





0-2 


(Normal) or 1 (STS-1 High Temperature Error Detection) or 2 (STS-2 High Temperature Error Detection). UM 
Status occurs when either STS-1 or STS-2 High Temperature Error Detection is detected. Once this occurs, UM 
cannot be canceled unless this NVM value is changed to by entering the Diag Mode in the Interlock-Open sta- 
tus of the M/C-Front Cover. 



General Procedures and Information 



6/02 
6-26 



Prelaunch Training/Review 
DC1 632/2240 



Table 9 Chain 744 



Chain-Link 


Name 


Default 


Range 


Description 


744-004 


STS-2 High-TEMP-Not-Ready TEMP 


220 


150-250 

(1 bit=1 deg.C) 


Once the STS-2 reaches High Temperature Not-Ready Temperature, the Fuser is moved to sagging status. 
This is because when continuous Run is performed for A5SEF and below, Temperature Distribution Control 
would fail. 


744-005 


STS-1 Ready Temperature 


150 


100-150 

(1 bit=1 deg.C) 


For an appropriate distribution of [Ready to copy] Temperature. 


744-006 


STS-2 Ready Temperature 


127 


100-150 

(1 bit=1 deg.C) 


For an appropriate distribution of [Ready to copy] Temperature. 


744-007 


STS-1 Stand-by Temperature 


160 


100-200 

(1 bit=1 deg.C) 


For an appropriate distribution of Standby Temperature. 


744-008 


STS-2 Stand-by Temperature 


160 


100-200 

(1 bit=1 deg.C) 


For an appropriate distribution of Standby Temperature. 


744-051 


Environment Temperature Correction 


3 


0-5 


Environment dependent correction coefficient for level of fusing. Temperature AD value shift amount when the 
environment temperature varies 1 Degrees Celsius from 20 Degrees Celsius. Corrects the target temperature 
of Ready temperature/Standby temperature/RUN. Both STS-1 and STS-2 have the same temperature. Cor- 
rects between 10-20 Degrees Celsius. Correction is not performed outside this range. = No 1 = 0.2 
Degrees Celsius/Environment Temperature (Maximum 2 Degrees Celsius) 2 = 0.4 Degrees Celsius/Environ- 
ment Temperature (Maximum 4 Degrees Celsius) 3 = 0.6 Degrees Celsius/Environment Temperature (Maxi- 
mum 6 Degrees Celsius) 4 = 0.8 Degrees Celsius/Environment Temperature (Maximum 8 Degrees Celsius) 5 = 
1.0 Degrees Celsius/Environment Temperature (Maximum 10 Degrees Celsius) 


744-052 


STS-1 Low TEMP Not-Ready TEMP 


125 


100-150 

(1 bit=1 deg.C) 


Once the STS-1 reaches Low Temperature Not-Ready Temperature, the Fuser is moved to sagging status to 
avoid poor fusing. 


744-053 


STS-2 Low TEMP Not-Ready TEMP 


125 


100-150 

(1 bit=1 deg.C) 


Once the STS-2 reaches Low Temperature Not-Ready Temperature, the Fuser is moved to sagging status to 
avoid poor fusing. 


744-054 


HFSI Counter Index 





0-5 


For HFSI Counter Symmetry 


744-085 


Plain Paper S Setting Temperature 


5 


0-5 


= Light Weight paper (55~63gsm) 1 = Plain paper (64~70gsm) 2 = Plain paper (71~80gsm) 3 = Bond 
(81~89gsm)4= Bond (90~98gsm) 5 = Bond (99-1 05gsm) 


744-196 


Plain Paper S Setting Temperature 


2 


0-2 


= Lightweight paper (55~63gsm) 1 = Plain paper (64~80gsm) 2 = Bond (81~105gsm) 


744-197 


104 OHP Pitch Adjustment Value 





0-10 

(1 count=1 pitch) 


OHP Blocking Measures; It prevents OHP Blocking by lowering the PPM with increase of Pitch. A4LEF = 
PPM=66/(4+NVM value) A4SEF = PPM=66/(5+NMV value) 


744-198 


52 OHP Pitch Adjustment Value 


1 


0-10 

(1 count=1 pitch) 


OHP Blocking Measures; It prevents OHP Blocking by lowering the PPM with increase of Pitch. A4LEF = 
PPM=33/(3+NVM value) A4SEF = PPM=33/(4+NVM value) 



746-xxx Zero Transfer NVM List 



Table 10 Chain 746 



Chain-Link 


Name 


Default 


Range 


Description 


746-006 


2nd Resistance detection calculation 
results 


245 


102-921 
(1bit= -4.888V) 


Measures the resistance of the Secondary Transfer part composed of 2nd BTR and Backup Roll at printable - 
1000V and display the voltage at Secondary Transfer corresponding that resistance. Secondary Transfer Volt- 
age=245x-4.888=-1200V (Display range = 500V— 4500V) 


746-007 


Final output value (Voltage value) 


17 


0-1023 

(1bit= 1MOhm) 


Measures and displays the resistance of the Secondary Transfer part composed of 2nd BTR and Backup Roll at 
printable -1000V (Display range = 0-1023M Ohm) 


746-009 


Calculation results of Absolute Humidity 


9 


0-200 


Displays the absolute humidity calculated from the relative humidity and relative temperature. (Absolute Humid- 
ity=(5.375-0.077*Temperature+0.027*Temperature2)*Humidity/100) 





Prelaunch Training/Review 
DC1 632/2240 



6/02 
6-27 



General Procedures and Information 



Table 10 Chain 746 



Chain-Link 


Name 


Default 


Range 


Description 


746-012 


2nd Output 


368 


0-921 

(1bit= -4.888V) 


For Component Control (0— 4500V) 


746-013 


DTS Output 


818 


0-818 

(1bit= -3.666V) 


For Component Control (0— 3000V) 


746-017 


Resistance detection calculation results 
Y 


51 


31-255 ( 
1bit=0.196uA) 


Displays the output current corresponding to the resistance of the Primary Transfer part calculated from the volt- 
age measured at fixed current (10 uA) in Y Color 1ST BTR. 


746-018 


Resistance detection calculation results 
M 


51 


31-255 
(1bit=0.196uA) 


Displays the output current corresponding to the resistance of the Primary Transfer part calculated from the volt- 
age measured at fixed current (10 uA) in M Color 1ST BTR. 


746-019 


Resistance detection calculation results 
C 


51 


31-255 
(1bit=0.196uA) 


Displays the output current corresponding to the resistance of the Primary Transfer part calculated from the volt- 
age measured at fixed current (10 uA) in C Color 1ST BTR. 


746-020 


Resistance detection calculation results 
K 


102 


25-459 
(1bit=0.196uA) 


Displays the output current corresponding to the resistance of the Primary Transfer part calculated from the volt- 
age measured at fixed current (10 uA) in K Color 1 ST BTR. 


746-021 


1ST BTR Output Remote Normal- 
speed Y 


86 


0-200 
(1bit=1%) 


For primary transfer output adjustment of Y Color at FC1 04mmsec. Displays the multiplication value in primary 
transfer current of 746-017. ex., At 100 = Primary Transfer Current=14 uAx1.0=10 uA; At 150 = Primary Trans- 
fer Current=14 uAx1.5=21 uA 


746-022 


1ST BTR Output Remote Normal- 
speed M 


86 


0-200 
(1bit=1%) 


For primary transfer output adjustment of M Color at FC104mmsec. Displays the multiplication value in primary 
transfer current of 746-018. ex., At 100 = Primary Transfer Current=14 uAx1.0=10 uA; At 150 = Primary Trans- 
fer Current=14 uAx1.5=21 uA 


746-023 


1ST BTR Output Remote Normal- 
speed C 


86 


0-200 (1bit= 1%) 


For primary transfer output adjustment of C Color at FC104mmsec. Displays the multiplication value in primary 
transfer current of 746-019. ex., At 100 = Primary Transfer Current=14 uAx1.0=10 uA; At 150 = Primary Trans- 
fer Current=14 uAx1.5=21 uA 


746-024 


1ST BTR Output Remote Normal- 
speed K 


86 


0-200 (1bit= 1%) 


For primary transfer output adjustment of K Color at FC104mmsec. Displays the multiplication value in primary 
transfer current of 746-020. ex., At 100 = Primary Transfer Current=14 uAx1.0=10 uA; At 150 = Primary Trans- 
fer Current=14 uAx1.5=